RAJARAMBAPU COLLEGE OF SUGAR TECHNOLOGY,

ISLAMPUR
ONE DAY WORKSHOP ON BOE Exam 2024
TOPICS COVERED
1. FUEL AND THEIR PROPERTIES
2. COMBUSTION OF FUEL
3. DRAUGHT SYSTEM
4. STEAM
5. EQUIVALENT EVAPORATION AND BOILER
EFFICIENCY
6. STEAM COSTING

PRESENTED BY – SHRI. SUDHIR S. PATIL

Ex. Managing Director,
 TYPES OF FUELS & THERE PROPERTIES
Types of Fuels
There are mainly three types of fuels
1) Solid Fuels- Coal, Wood, Bagasse etc.
2) Liquid Fuels- Furnace Oil, L.D.O, LSHS etc.
3) Gaseous Fuels- Natural Gas, Methen,Ethane etc.
 Types Of Coals
1) Lignite Coal-
It contains high percentage of moisture i.e. upto 30-45%,but
can be dried just by exposing to air. It is hardly contains 6 % moisture when
dried. Due to this it can be used as fuel in pulverized form. It’s calorific value
ranging from 4450 to 5450 Kcal/Kg.
2) Bituminous Coal-
It is most popular form of coal used for all purpose. It has low
moisture contain. The ash contain may very from 6 to 12% and fusion temp. of
ash usually 1093oC.
Sub-Bituminous coal is similar to Lignite. It contains 50% less
moisture than Lignite. It also contains less ash then Lignite, but it has no
cacking power. Sub Bituminous coal is intermediate between Anthracite &
Bituminous coal in properties & widely used in thermal power plants. It has
low percentage of moisture , Ash , Sulphur & Volatile matters. Its calorific
value is high. It contains 90 to 93% Carbon,10 to 20% Volatile matters & 2to
4% Oxygen. It is used on moving gate as well as Pulverized form.
3) Anthracite Coal- It contains high percentage of Carbon &
volatile matter is below 8%. It has zero cacking power. It burns
only at high temp. and does not fuses or soften. The
pulverization of Anthracite is very difficult and costly, therefore
it is used only on forced draft grate.

GVC Of Various Coals

The Gross Calorific Values of various types of coals is as follows

Coal Type Gross Calorific Value

Kcal/Kg
Lignite 4500
Bituminous 3500
Sub-Bituminous 4000
Indian 4000
Indonesian 5500
South Africa 6000
 Proximate & Ultimate Analysis of Coal
The common test which are used to find the commercial
value to find the commercial value of coal are Proximate & Ultimate
analysis
Proximate Analysis -
The proximate analysis of coal gives the composition of coal
in respect of moisture, volatile matter, Ash & Carbon. The
constituents given by proximate analysis mostly decide the adoption
of coal and design of power plant Coal Handling, Ash handling,
Combustion & Dust removal System.
The Proximate analysis of various coals in percentage is as
follows
Parameter Indian Coal Indonesian Coal South Africa
Coal
Moisture 5.98 9.43 8.5
Ash 38.63 13.99 17
Volatile Matter 20.70 29.79 23.28
Fixed Carbon 34.69 46.79 51.22
Ultimate Analysis -
The proximate analysis does not gives any ideas about the
suitability of coal for purpose of heating. It is also not possible to find
out the calorific value of coal with the help of proximate analysis.
To find chemical analysis of coal like Carbon, Hydrogen,
Oxygen, Nitrogen, Sulphur & Ash etc. Ultimate Analysis of coal is
generally used.
The Ultimate Analysis of various coal are as follows

Parameters Indian Coal Indonesian Coal

Moisture 5.98 9.43
Mineral Matter(1.1 X Ash) 38.63 13.99
Carbon 41.11 58.96
Hydrogen 2.76 4.16
Nitrogen 1.22 1.02
Sulphur 0.41 0.56
Oxygen 9.89 11.88
Liquid Fuels
All the commercially used liquid fuels are
furnished by petroleum & its products. The petroleum
or Crude oil consist of 83 to 87% Carbon,10 to 14%
Hydrogen & various percentage of Sulphur, Nitrogen,
Oxygen & metallic derivatives of vanadium
The fuel used for industrial and domestic
purpose are obtained by refining the crude oil. There
are specially produced products like Gasoline, Fuel Oil
etc. produced. The typical fractions from light to heavy
oil are Naphtha, Gasoline, Kerosene & Gas Oil. The
remaining are heavy fuel oil which is used from steam
generation. Furnace Oil & LSHS( Low Sulphur Heavy
Stock) oil is commonly used for steam generation.
Advantages Of Liquid Fuels
The liquid fuels is used in thermal power plants to
generate steam instead of coal as it is offers many
advantages over coal is as follows
1) Excess Air required for complete combustion is less as
uniform mixing of fuel & air is possible
2) The storage & Handling is much more easy compared with
coal
3) The change in load can be meet easily and rapidly
4) There is no problem of Ash disposal due to very low ash
contain
5) The system is very clean
6) The operational labour required is less and therefore overheads
are considerably less
 Low Sulphur Heavy Stock(LSHS)Oil
This is an indigenous products having very low sulphur about
1.2% by weight. At 60oC solidifies and between 70.75oC its viscosity is
pumpables. LSHS is clean oil but it’s lubricating property is very poor
and hence wear & tear of pump gear is more. As LSHS is waxy, steam
tracing lines are to be provided in all seasons, so that oil can flow in
pipes easily. LSHS is slightly cheaper than furnace oil. It’s calorific
value is 10,700 kcal/kg.
Physical & Chemical Properties of LSHS
The following are physical & Chemical properties of LSHS
1) It should be solid at room temp. & melts when heated.
2) Its calorific value is 10,600 kcal/Kg
3) It’s poor point is 57oC
4) It’s flash point is 85oC
5) It has low sulphur contain i.e.1% & ash 0.05%
6) It’s price is lower than furnace oil.
 Advantages & Disadvantages of LSHS
Advantages of LSHS
1) As it contains low sulphur, Exit flue gas temp. can be lower &
hence get more heat recovery
2) As preheat temp. is less than furnace oil. Therefore initial
heating is lower than furnace oil
3) Loss due to spillages can be recovered because it becomes solids
at room temp. & does not flow into drain.
4) Calorific value is slightly more than furnace oil i.e.10,600
Kcal/Kg.
5) The flue gas outlet temp. through chimney is lowered, thus
efficiency of boiler increased.
Disadvantages of LSHS
6) Handling is more difficult as it is solid at room temp.
7) If tanks are used for storage, the tank must be steam jacketed &
steam coils must be given from inside for melting it, thus storage
cost is more.
Compression Between LSHS,Furnace Oil & LDO
Parameter LSHS Furnace Oil L.D.O
Sulphur by Wt. Max.0.5% Max. 4% Max.1.8%
Water Contain by Wt. 1% 1% 0.25%
Sediment by Wt. Max.0.25% Max.0.25% Max.0.1%
Ash by Wt. Max.0.10% Max.0.010% Max.0.02%
Flash Point oC 93 66 66
Pour Point oC 72 20 18
GVC Kcal/Kg 10,600 10,500 10,700
Sp. Gravity 0.88 to 0.98 0.89 to 0.95 0.85 to 0.87
 Gaseous Fuels
The natural is commonly used for steam
generation plant. It has composed mainly of Hydro Carbons such as
Methane(CH4) & Ethane(C2H6) with small amount of Carbon
Dioxide, Oxygen, Nitrogen & some times Hydrogen Sulphide. The
following are typical analysis of Natural gas
Methane – 80.2%; Ethane-17.3%; N2-2.3% & O2-0.2%
The natural gas is colourless ,odorless & non
poisonous. It’s calorific values lies between 6000 to 12500 Kcal/M 3
according to Methane contain in gas.
The gaseous fuels have all advantages of oil fuels
expect case of storage. The major disadvantage of using natural
gas as fuel is that the power plant must be located near natural
gas field, otherwise transportation cost is more.
 COMBUSTION OF FUELS
Requirements for Complete Combustion of Fuels.
For complete combustion of fuels following requirements should
be necessary
 For good operation practice of boiler excess air should be as minimum
as possible with casing no smoke nuisance
 The minimum CO2 must result with no oxygen in flue gas
 There should be proper control of primary & secondary air is necessary
 The moisture in fuel quenches fire, so keep moisture in fuel as
minimum as possible.
 There should be no air leakage in furnace wall, because of air leakage
surrounding cold air enters in furnace & they should be quenches the
fire & complete combustion is not takes place.
 The draft is furnace is kept ideal
 The exit flue gas temp. of gases should be lowest without causing low
temp. corrosion on cold end side.
 Use high ash fusion fuel because when use low ash fusion temp. fuel, it
blocks the holes of grate when burned.
 When pulverized coal, liquid & gaseous fuels used, kept fuel air
mixture as ideal.
Role of Primary, Secondary & Tertiary Air in Combustion.

Primary Air -
Air which flows through the bed or below furnace, which
controls the rate of burning of fuels is called Primary Air
Secondary Air -
Air supplied over the fire to react with unburned gases
called Secondary Air
Tertiary Air -
Air for combustion supplied to a furnace to supplement
the primary & secondary air is called Tertiary Air.
 Causes of Bad Combustion & Measures Required to Avoid It.
There are many causes of bad combustion & measures required to
avoid them is as follows -
1) When we are use multi fuels, they requires various percentage of
excess air. When there is insufficient air supply, combustion is
incomplete, so to avoid them supply sufficient air.
2) When there is inadequate furnace volume, there is bad
combustion. So adequate proper furnace volume
3) Inefficient installation is cause of bad combustion, so for
complete combustion correct efficient installation
4) Poor automation is cause of bad combustion, correct the good
atomization for complete combustion
5) The poor mixture of fuel volatiles & air is also cause of bed
combustion, correct the air fuel mixture
6) The entrance of air in furnace at wrong place is cause of bad
combustion, enter the air at correct position
7) The cooling of unconsumed gases below there ignition temp. is also
cause of bad combustion
8) The unconsumed oil striking on cooling surface & presence of
impurities in oil fuel is also cause of bad combustion.

Delayed Combustion -
Continuation of combustion beyond the furnace is called
Delay or Late combustion.
 Methods To Minimize Excess Air
Due to use of high excess air, the heat loss through
flue gas is more. To avoid this, the following are the methods to
minimize excess air in boiler.
1) Operate the furnace at correct air fuel ratio.
2) Do not supply more excess air to furnace.
3) Control the draught ideal.
4) Prevent the air leakage in boiler.
5) When rate of steam generation is low or fuel combustion
rate of steam is minimum, supply minimum air from forced and
secondary air fan.
6) Do not furnace doors is open in operation because cold air
enter in furnace.
7) Control or Fine tune up the F.D. fan speed on oxygen % in
flue gas.
 PROBLEMS ON COMBUSTION
Atomic Weights -
Hydrogen- H=1; Carbon-C=12; Oxygen-o=16
Nitrogen-N=14 & Sulphur-S=32
Combustion Reactions -
Combustion of Carbon -
C+O2=CO2 - Complete Combustion
12 +(2*16) = 44
Oxygen Required for complete Combustion = 32/12=8/3
Combustion of Hydrogen -
2H2+O2=2H2O - Complete Combustion
(2*2) + (2+16)= 36
Oxygen Required for complete combustion of Hydrogen = 32/4=8
Combustion of Sulphur -
S+O2= SO2 - Complete Combustion
32+32=64
Oxygen Required for Complete combustion of Sulphur =32/32=1
Theoretical Oxygen Required for 1Kg Fuel -
Theoretical Oxygen Required= (8/3*Xc+8*XH+1*Xs-Xo) Kg
Where,
Xc- Weight of Carbon in Fuel in Kg
XH- Weight of Hydrogen in Fuel in Kg
Xs- Weight of Sulphur in Fuel in Kg
Xo- Weight of Oxygen in Fuel in Kg
Now, we know Oxygen in air is 23%
Actual Air Required for Complete Combustion= (Oxygen Required*100)/23
Combustion Products
Total Combustion Products=Ma+1 Kg
Where, Ma= Mass of Air Supplied per Kg of fuel.
CO2 =11/3* Weight of Carbon in Fuel Kg
CO = 7/3*Weight of Carbon in Fuel Kg
H2O = 9* Weight of Hydrogen in Fuel Kg
SO2 =2*Weight of Sulphur in Fuel Kg
Formula's OR Chemical Detonation of Fuel

Fuel Detonation
Methane CH4
Ethane C2H6
Propane C3H8
Butane C4H10
Rentane C5H12
Hexane C6H14
Hentane C7H16
Octane(Petrol) C8H18
Hexadecane(Diesel) C9H34
 PROBLEMS
1) What is stiochmetric Air fuel ratio. Calculate stiochmetric air fuel
ratio of Ethylene(C2H4)(Marks-6; Feb.2019)
Stiochmetric Air Fuel Ratio -
It is minimum mass of air required for complete
combustion of one Kg fuel.
Given Fuel, Ethylene= C2H4
By Atomic Weight,
C2+H4=C2H4
(2*12)+(4*1)=C2H4
24+4 = 28 Kg
Weight of Carbon = C=24/28=0.857 Kg
Weight of Hydrogen = H= 4/28 = 0.16 Kg
Now in one kg Ethylene 0.857 Kg Carbon & 0.16 Kg Hydrogen is
contain.
Theoretical Oxygen Required = (8/3Xc+8XH)
= 2.66*0.857 + 8*0.16
= 2.279+1.28
= 3.559 Kg
Now in Air 23% is Oxygen.
Theoretical Air Required = Theoretical Oxygen Req.*100/23
= 3.559*100/23
= 15.47 Kg

Therefore Stoichometric Air Fuel Ratio for Ethylene = 15.47:1

2) Steam boiler used pulverized coal in furnace. The ultimate analysis of
coal by mass received as follows
C-78%; H2-3%;S-1%;Ash-10%;Moisture-55;
Excess air supplied 30%.Calculate
i)The mass of air supplied
ii)The mass of gaseous products formed per Kg of coal burnt
(Marks-6;March2018)
Given Data,
Carbon-C=78%=0.78 Kg; Hydrogen-H2-3 % = 0.03kg,
Oxygen- O2=3.1%=0.03kg. Sulphur=S=1%=0.01kg,
Ash=10%=0.1kg., Moisture-5%=0.05kg.
Excess Air Supplied = 30%=0.3
Now,
Oxygen req. for combustion = {8/3Xc + 8XH+Xs – Xo]
= 8/3x0.78+8x0.03+0.01-0.03
= 2.07+0.24+0.01-0.03
= 2.32-0.03 = 2.29Kg.
Excess theoretical oxygen supply = 2.29x0.3= 0.687kg.
Total theoretical oxygen supply – 2.29+0.687=2.977kg.
Now assume 23% oxygen in air
Mass of Air supplied = (2.977x100)/23 = 12.94kg/kg of coal.
Combustion product –
CO2 = 11/3 x C = 11/3 x 0.78 = 2.86kg.
H2O = 9xH = 9 x 0.03 = 0.27kg.
O2 = = Excess air Oxygen = 0.687 kg.
SO2 = 2 x S = 2 x 0.01 = 0.02kg.
Ash = 10% = 0.1Kg.
Free Moisture = 5 % = 0.05 kg.
N2 = Air supplied x Nitrogen contains
= 12.94 x 0.77 = 9.963 kg.

Total mass of gaseous product =2.86+0.27+0.687+0.02+0.1+0.05+9.963

= 13.950kg.
3. The composition of sample of coal is given below –
C-90% , H2 – 3.5%, O2 – 3% , N2- 1% & S= 0.5% & remaining is ash
Determine
i)Theoretical weight of air required for combustion of 1kg fuel.
ii) The composition of dry product of combustion by volume if 50%
Excess air supplied (Marks – 6, March 2018)
Given,
- Carbon= 90% = 0.9kg, Hydrogen=H 2 = 3.5%= 0.035kg, Oxygen = O2=3% =
0.03kg., Nitrogen=N2 = 1%=0.01kg, Sulphur=S=0.005kg Remaining ash
- Ash = (1-(0.9+0.035+0.03+0.001+0.005))
- = 1-0.971 =0.029kg.
i) Theoretical oxygen req. for combustion=[8/3Xc+8XH+1Xs-Xo]
= [8/3x0.9+8x0.035+1x0.005-0.03]
= 2.394+0.28+0.005-0.03]
= 2.679-0.03 = 2.649kg.
 Now 23% oxygen is in air
Theoretical weight of air for combustion = (2.649x100)/23
=
11.52kg/kg of fuel.
ii) When 50% Excess air is supplied –
Excess oxygen supplied = 2.649x 0.5 = 1.324kg.
Total oxygen supplied = 2.649+1.324 = 3.973kg.
Weight of air supplied for combustion = (3.973x100)/23 = 17.27kg.
Dry combustion products
CO2 = 11/3 x C = 11/3 x 0.9 = 3.66 x 0.9 = 3.30kg.
H2O = 9xH = 9x0.035 = 0.315kg.
SO2 = 2xS = 2x 0.005 = 0.010kg.
O2 = Excess Oxygen supplied = 1.324kg.
N2 = Air supplied x N2 contain = 17.27 x 0.77 = 13.297kg.
Ash = 0.029kg.

Total Dry combustion product =3.30+0.315+0.01+1.324+13.297+0.029

= 18.275kg.
Now
Specific volume of flue gas @ NTP = 0.735M3/Kg.
Specific volume of CO2 @ NTP = 0.505M3/kg.
Specific volume of Water vapour @ NTP = 0.001M3/kg.
Specific volume of O2 @ NTP = 0.7M3/kg.
Specific volume of SO2 @ NTP = 0.0011M3/kg.
Specific volume of N2 @ NTP = 0.8M3/kg.
Volume of Gases -
Volume of Dry gas = 18.275 x 0.735 = 13.43M3
Volume of CO2 = 3.30 x 0.505 = 1.666 M3
Volume of vapour = 0.315 x 0.001 = 0.000315
M3
Volume of Oxygen = 1.324 x 0.7 = 0.9268 M3
Volume of SO2 = 0.010 x 0.0011 = 0.00001M3
Volume of Nitrogen = 13.297 x 0.8 = 10.637M3
 Volumetric % of Combustion Products

CO2 = (1.666/13.43) x 100 = 12.40%

H2O = (0.000315 x 100) / 13.43 = 0.0023%
O2 = (0.9268 x100) / 13.43 =
6.90%
SO2 = ( 0.00001 x 100)/ 13.43 = 0.0007 %
N2 = (10.637 x 100) / 13.43 =
79.20%
 PROBLEM ON EMISSION

1. A power boiler consumes 350 Ton of coal per hour. Sulphur percentage
as per ultimate analysis of coal is 1.0%. Calculate quantity of sulphur
dioxide per day from boiler.
( Marks – 6 Feb.- 2017)

Given –
Coal consumption per Hour – 350 MT
Sulphur contain – 1.0%
Coal burning per day = 24 x 350 = 8400 MT
Sulphur weight in coal burning per day = (8400 x 1)/100 = 84 MT
Sulphur dioxide generated per day = 2 x weight of Sulphur
= 2 x 84
= 168 MT/Day.
2. Efficiency of a 250TPH, 80Kg/cm2, 500 OC boiler is 82% coal having GVC
3400 Kcal/kg & 46% ash is used in boiler. Calculate number of trucks
required per day to remove total ash generated when boiler is operated at
full load. Consider feed water temp. 135OC & net loading capacity of truck
is 10MT
(Marks – 6, Feb.- 2017)
Given –
Steam generated capacity – 250 TPH = 250000 Kg/Hr.
Working Pressure – 80 kg/Cm2, Steam temperature – 500OC,
Feed water Temp. – 135OC, Boiler efficiency – 82%,
Coal GVC – 3400 Kcal/Kg., Ash % - 46%,
Net loading capacity of truck – 10MT.
Now from Steam Table –
Enthalpy of Steam @ 80 Kg/Cm2 pressure & 500OC Temp=

hs = 813.39 Kcal/kg.
Enthalpy of Feed Water @ 135OC temp = hf = 135.83 Kcal/kg.
 We know
Steam generation(H-h)
Boiler Efficiency = ----------------------------- x 100
Coal firing x GVC
250000 (813.39 – 135.83)
0.82 = -----------------------------
Coal firing x 3400
Coal firing = (250000 x 677.56)/(3400x0.82) = 60756.81
kg/hr.
Coal firing per Hour = 60756.81 kg/Hr. = 60.756 MT/Hr.
Coal fired per day = 24 x 60.756 = 1458.24 MT/Day
Ash Generated per day = 1458.24 x 0.46 = 670.790 MT/Day
No. of Trucks req. per day = (ash Generated per day / Net loading of Truck)
= 670.790 / 10 = 67.07
= 67 Nos. of Trucks.
3. A boiler plant has ESP of 99% Efficiency & flue gas scrubber for removal of
Sulphur dioxide with 80% Efficiency. It operates at Efficiency of 85% at fill load.
In which bottom ash share is 20%. Calculate the Sulphur dioxide & particulate
emission through the stack per day ?
GVC of coal – 4000 Kcal/kg., Steam generation – 480 Kg/Min., Working Pressure –
45 Kg/cm2, Steam temp.- 410OC , Feed water Temp.- 105OC
Ash % in Coal- 35% & sulphure % - 0.5 % ( Marks – 5, Feb.- 2019)
Given Data –
Steam Consumption = ms = 480 Kg/min = 28800 Kg/Hr.
Steam Pressure–45Kg/Cm2, steam Temp.-410OC, Feed water Temp.- 105OC
GVC of Coal – 4000 Kcal/Kg, Boiler efficiency – 85%, ESP efficiency – 99 %
Scrubber Efficiency – 80%, ash % coal – 35%,Sulphur % = 0.5%,
Bottom Ash% - 20%
Now from steam table –
Enthalpy of Steam @ 45 Kg/Cm2 pressure & 410OC Temp.

hs= 772.56 Kcal/kg.

Enthalpy of Feed Water @ 105OC temp = hf = 105 Kcal/kg.
 Ms(hs-hf)
Boiler Efficiency = ---------------------
Coal firing x GVC
Coal firing per Hour = ((28800(772.56-105))/(0.85x4000)
=
(28800x667.56)/3400
= 5654.62kg/hr.
Coal fired/Hr. = 5654.62Kg/Hr = 5.655 kg/Hr.
Coal fired per day = 24 x 5.655 = 135.7 MT/Day.
Now
Ash production per day = 135.7 x 0.35 = 47.495 MT/day.
Total sulphur fired per day = 135.7 x 0.005 = 0.6785 MT/Day.
Bottom ash Quantity = 47.495 x 0.20 = 9.499 MT/Day
Fly ash quantity = 47.495 – 9.499 = 37.996 MT/Day
Sulphur dioxide Generated per day = 2 x Weight of Sulphur

= 2 x 0.678 = 1.357 MT/Day.

We Know
ESP Efficiency = Ash Collected / Ash Input
Ash Collected = 0.99x37.996 = 37.61 MT/Day
Particulate Emission through stack = 37.996 – 37.61 = 0.3799MT/Day.
Scrubber Efficiency – SO2 Collected / SO2 inlet quantity
SO2 collected per day = 0.8 x 1.357 = 1.085 MT/Day
SO2 Emission through stack = 1.357 – 1.085= 0.272 MT/Day.
4. Calculate SO2 emission in Tons/Annum of height of chimney 90M which is suitable
for coal fired boilers. Data is given as follows –
i) No. of boilers connected to chimney – 2 Nos.( one boiler with coal another
with F.O.)
ii) Sulphur contain in coal & FO- 1.2 & 3.5% respectively.
iii) Coal consumption – 40MT/Day & Furnace oil consumption – 10 MT/Day.
iv) Running Hrs. of each boiler – 8160 hrs. (Marks – 6 , Feb.- 2019)
Given Data –
No. of working boilers – 2 Nos. (One on coal & another on furnace oil)
Sulphur contain in coal – 1.2 %, Sulphur contain in F.O. – 35%
Coal Consumption – 40MT/Day, Furnace oil Consumption – 10MT/day.
Running Hrs. of each boiler/Annum – 8160 Hrs.
Now,
Sulphur burning in coal boiler/Day = (40 x 1.2)/100
= 0.48MT/Day=
0.02MT/Hr.
Sulphur Burning in FO Boiler/Day = (10x3.5)/100 = 0.35MT/Day
After burning of sulphur production of SO2 gas is as follows
SO2 gas production in coal fired boiler = 2 x 0.02= 0.04 MT/Hr.
SO2 gas production in F.O. Fired boiler = 2 x 0.0145 = 0.0291 MT/Hr.
Now,
SO2 Emission from coal fired Boiler = 8160x0.04 = 326.4 MT/Annum.
SO2 Emission from F.O. fired Boiler = 8160 x 0.0291 = 237.45
MT/Annum.

Total SO2 emission from Chimney/Annum = 326.4 + 237.45 = 563.856 MT.

 Draught System
Draught
Draught is the pressure difference which is necessary to draw the required
quantity of air for combustion & to remove the flue gases out of the
system.
In boiler there are mainly two types of draughts.
1. Natural Draught
2. Artificial Draught i) Forced Draught
ii) Induced Draught
iii)Balance Draught.
3. Natural Draught –
The draught which is obtained by the tall chimney is called
natural draught. The draught is obtained on natural circulation of air,
there is no artificial unit is used to produce draught.
2. Artificial Draught –
The draught which is produced by the artificial unit such as fans is
called artificial draught. This types of draught system meets every types
i) Forced Draught –
In this types the fan is placed at near the boiler grate. It takes air
from atmosphere & passes through air heater from air heater this
pressurized air flows below the grate. This draught is very economical for
combustion of fuel.
ii) Induced Draught –
In this type, the fan is placed at near the base of chimney. The
fan is known as induced fan & draught produced by this fan is known as
induced draught. It sucks the flue gases from boiler and deliver to the
chimney.
iii) Balanced Draught –
The combination of both forced and induced draught fan, the
draught produced is called as balanced draught. This draught is measured
in furnace zone & its value is ranging from -5 to +5 mm of WC.
 Problems on Natural Draught

1. Density of air at NTP = 1/Specific Volume of air @ NTP in Kg/M 3

2. Mass Density of air at Ambient Temperature –
ƍa = ƍaNTP (T1/Ta) Kg/M3
Where T1 = 0OC = 273OK
Ta = Ambient air temp in OK
3. Mass Density of flue gas at exhaust gas temp.
ƍg = ƍgNTP (T1/Tg) Kg/M3
Where ƍgNTP = Density of the flue gas at NTP
T1 = 0OC = 273OK Tg = Flue gas Temp in
K
O

4. Draught = hw = H x g x (ƍa – ƍg)

Where, draught = hw = in pascal (N/m2)
H = Height of chimney in meter
g = Specific gravity = 9.81 Kg/M 3
ƍa = Density of air at temp (Ta) OK
ƍg = density of flue gas at temp. (Tg) OK
1. A Boiler chimney produces a draught of 15mm of WC & handle a flue gas
at a temp. of 220OC. Estimate the height of chimney for an ambient
temp. of 20OC.
Specific volume of air at NTP = 0.775 M3/Kg.
Density of flue gas at NTP = 1.35 Kg/M3
Given –
Draught = hw= 15mm WC = 15 x9.81 = 147.15 N/M2
Ambient Air Temp = Ta = 20OC = 20 + 273 = 293 OK
Flue gas Temp. = Tg = 220OC = 220 + 273 = 473 OK
Specific Volume of air at NTP = Va = 0.775 M3/Kg.
Density of Flue gas at NTP = ƍgNTP = 1.35 Kg/M3
Now,
Density of air NTP = ƍa NTP = (1/Va) = (1/0.775) = 1.29 Kg/M3
Mass Density of Air @ 20OC
ƍa = ƍa NTP (T1/Ta)
= 1.29 (273/293) = 1.29 x
3
Mass Density of flue gas @ 220OC
ƍg = ƍg NTP (T1/Tg)
= 1.35(273/493) = 1.35 x 0.55 = 0.747 Kg/M3
We Know,
Draught = H x g (ƍa-ƍg)
147.15 = H x 9.81 (1.20 – 0.747)
147.15 = H x 9.81 x 0.453
147.15 = 4.44 H
H = 147.15/4.44 = 33.11 i.e 33 Meter

Height of Chimney = H = 33 Meter.

Problem No. 2
Find the draught produced in mm of water by a chimney of 40 Meter height &
discharging 20Kg of flue gas per kg of fuel burned in the combustion chamber. The
temp. of flue gases and ambient air are 270OC & 23OC respectively. Assuming the
dia. of chimney is 1.5M & 30% theoretical draught is loss in friction. Find the mass
of flue gas passing through the chimney per Minute.
Given –
Height of chimney = H = 40 Meter, Dia. Of Chimney = D = 1.5 Meter.
Ambient air Temp.= Ta =23OC = 23+273 = 296OK
Flue gas Temp. = Tg = 270 OC = 270 + 273 = 543OK
Mass of flue gas = Ma+1 = 20 Kg/Kg of fuel.
Mass of Air = Ma =19Kg/Kg of fuel.
30% draught loss in the friction
We Know –
Draught = 353H {(1/Ta) – (Ma+1)/(Ma x Tg)}
= 353 x 40 {(1/296)-(20 / (19 x 543)}
= 353 x 40 {(1/296) – (20/10317)}
= 353 x 40 (3.37 x 10-3 ) – (1.938 x 10 -3)
-3
30% draught is lost in friction i.e. 70% draught is available for velocity of gas
Draught used for velocity of gas = hw=0.7 x 20.33 = 14.23 mm WC
We know
Mass flow of flue gas/Min.= A x V x hw
where, A = Cross sectional Area of chimney
v = Volume of flue gas in M3
hw = Draught available for velocity.
Now,
Cross sectional Area of Chimney = 0.7856 X D2
= 0.7856
X (1.5)2 = 1.77 M2
Volume of Flue Gas = (0.773 X Ma x M)Ta/273
=(0.773X19X1)296/273
= 0.773X19X1X1.084
= 15.92 M3
Mass Flow of Flue Gas/Min. = A X V X hw
= 1.77 X 15.92 X
14.23
= 401 M3/Min.

Draught Produced by Chimney = hw = 20.33 mm of WC

Flue gas passing through chimney/Min = 401 M3/Min
 Problems on Artificial Draught
Volume Delivered by Fan per Min
W X Ma Ta or Tg
Vaf or Vai= --------------- x ----------
ƍa or ƍg T1
Where, W = Fuel buring in Kg/Min.
Ma = Air Supplied per Kg of Fuel in Kg
ƍa = Density of Air at NTP = 1.29 Kg/M 3 when F.D.fan used
ƍa = Density of flue gas at NTP = 1.35 Kg/M 3 when I.D.Fan used.
Ta = Ambient air Temp in OK
T1 = 0OC = 273OK
Tg = Temp. of flue gas in OK
BHP of Fan = ( hw/4500 x ƞ) x Vaf or Vai
where,
hw = Draught produced by fan in mm WC.
ƞ = Efficiency of Fan
Vaf = Volume of air delivered by fan M 3/min.
1. A forced draught fan operates at an efficiency of 80% and handle air at 20OC in
boiler house. Estimate the power required to drive the fan to maintain a draught of a
8cm of water. Air supplied per kg. of coal is 18Kg. Coal consumption –
2500 Kg/Hr., Density of air at NTP = 1.29Kg/M3
Given –
Draught = hw = 8cm of WC = 80 mm of WC
Ambient air temp. = Ta = 20OC = 20+273=293OK
Coal consumption = W = 2500Kg/hr. = 41.66 Kg/min.
Air supplied per Kg of coal = Ma = 18 Kg.
Efficiency of fan = ƞ = 80% = 0.80
Density of air at NTP = ƍa = 1.29Kg/M3
We Know
Volume of air Delivered = Vaf = (WxMa)/ ƍa x (Ta/T1)
= (41.66 x18)/1.29 x (293/273)
= 581.39 x 1.073 = 623.99 M3/Min
Now
BHP of Prime mover = (hwxVaf)/(4500 x ƞ)
= (80x623.99)/(4500 x 0.80) = 49919.07/3600
= 13.86BHP.
 Steam

There are mainly two types of steam.

i) Saturated or Wet Steam –
Saturated steam is pure steam in direct contact with the liquid
water from which it was generated & at a temp. of water at existing
pressure. Its dryness fraction is about 0.5. It is used for process only.
ii) Superheated Steam –
Superheated steam is pure steam having dryness fraction 0.98 that
means there is no water contain in steam. It is used for power generation.
Degree of Superheat –
The temp. raised above saturated temp. of steam then the
difference between superheated steam temp. is called Degree of
Superheat.
Properties of Steam –
Specific Volume of Steam = V = Vf + x Vg
Where Vf = Specific Volume of feed Water
X = Dryness fraction of Steam
Vg = Specific Volume of Evaporation
 Total Enthalpy = H = hf + Xhfg
Where, hf = Enthalpy of Feed Water
X = Dryness fraction of steam
hfg = Enthalpy of Evaporation
Density of steam = ƍ = 1 / Specific volume of Steam
1) Calculate the enthalpy, specific volume & density of steam at a pressure of 40
kg/cm2 and dryness fraction of 0.9.
Given Data –
Pressure – 40kg/cm2, Dryness fraction of Steam – 0.9
From steam table, @ 40kg/cm2 pressure
Enthalpy of feed water = hf = 258.37 Kcal/kg.
Enthalpy of Evaporation = hfg = 411.65 Kcal/kg.
Specific volume of Water = Vf = 0.001249 M3/kg.
Specific Volume of evaporation = Vfg = 0.051061 M 3/kg.
We Know
Enthalpy of steam = H = hf + (X x hfg)
= 258.37 + (0.9 x 411.65)
= 258.37 + 370.48 = 628.85 Kcal/kg.
Specific Volume of steam = V = Vf + XVfg
=
0.001249 + (0.9 x 0.051061)
=
0.001249 + 0.04595 = 0.0472 M3/kg.
Now,
Density of Steam = 1 / Specific Volume of Steam
= 1 / 0.0472 =
21.18 kg/M3
At pressure 40 Kg/cm2 & Dryness Fraction 0.9
i) Enthalpy of Steam = H =628.85 Kcal/kg.
ii) Specific Volume of Steam = V = 0.0472 M3/kg.
iii) Density of Steam = ƍ = 21.18 Kg/M3.
2. Determine the dryness fraction of sample of steam weighing 4.7Kg. If
total heat of sample is 11000 KJ & Steam pressure 5 Kg/cm 2
Given Data –
Pressure – 5 Kg/cm2, Mass of Steam = M = 4.7Kg.
Total heat of sample = Enthalpy =H = 11000 KJ = 11000/4.18 =
2631.57Kcal/kg.
Now from steam table @ 5Kg/cm2 pressure
Specific enthalpy of Feed Water = hg = 153.11 Kcal/kg.
Specific Enthalpy of Evaporation = hfg = 504.16 Kcal/kg.
We Know –
Enthalpy = H = M(hg + Xhfg)
2631.57 =4.7 (153.11 + X x 504.16)
2631.57 = 4.7(657.27 x)
2631.57 = 3089.18 x
X = 2631.57 / 3089.18 = 0.85
Dryness fraction of Steam = 0.85
 Equivalent Evaporation & Boiler Efficiency
Factor of Evaporation –
Ratio of heat required to convert the water into steam to
equivalent heat required to convert 100OC water into 100OC steam is
called Factor of Evaporation. Heat required by one kg of feed water at
100OC and 1 atmospheric pressure for its conversion into dry and
saturated steam at 100OC & 1 Atmospheric pressure is 540Kcal or 2257 KJ
Factor of Eavaporation = (H-h)/540 or (H-h) / 2257
Where, H = Enthalpy of steam in Kcal/kg.
h = Enthalpy of Feed water in Kcal/kg.
Equivalent Evaporation –
It is defined as the amount of Water evaporated or steam
generated per unit time during conversion of feed water at 100OC into
dryness & saturated steam at 100OC.
Equivalent Eavaporation = Ms(H-h)/540
Where, Ms = Mass of steam in Kg/hr.
Actual specific Evaporation or Ratio of Evaporation –
It is ratio of actual steam generation to actual fuel consumption.
Rate of Evaporation or
Steam generated per Hour
Actual Specific Evaporation = -----------------------------------------------------------
Fuel
consumption per Hour
Boiler Efficiency –
It is the ratio of heat output to heat input in Boiler.
Boiler Efficiency = Ms(H-h) / W x GCV
Where
Ms = Mass of steam generated in Kg.
H = Enthalpy of Steam in Kcal/kg.
h = Enthalpy of feed water in Kcal/kg.
W = Fuel consumption in Kg.
GCV = Gross Calorific Value in Kcal/Kg.
i) Following observation were made on boiler plant during one hour performance test.
Steam pressure – 20 Bar Absolute, Steam Temp – 260 OC,
Steam Generated – 37500Kg., Temp of Feed Water entering Economiser – 15 OC,
Temp of Feed Water leaving Economiser – 90 OC, Fuel used – 4400Kg, Energy of combustion
of fuel – 30000 KJ/kg, Cp for Superheated steam – 2.1KJ/Kg. Calculate – i) Equivalent
Evaporation per kg of fuel. ii) Thermal Efficiency of Plant. iii) Percentage heat of fuel
utilised by economiser (Marks –
6, March 2018)
Given –
Steam pressure – 20 Bar Absolute,
Steam Temp – 260OC, Steam Generated = Ms= 37500Kg.,
Temp of Feed Water entering Economiser = 15 OC,
Temp of Feed Water leaving Economiser = 90 OC,
Fuel used = W= 4400Kg,
Energy of combustion of fuel = CV= 30000 KJ/kg,
Specific heat of Superheated steam = Cp = 2.1KJ/Kg. OK = 2.1KJ/Kg OC
At 20 Bar absolute pressure saturated temp of steam = T (sat) = 212.38 OC
At 20 bar absolute pressure enthalpy of steam = H =2798.38KJ/Kg.
Enthalpy of feed Water @ 15 OC at inlet of Economiser = hei= 62.9837KJ/Kg.
Enthalpy of Superheated steam = H
H = Enthalpy of Saturated Steam + Sp. Heat of steam (T sup – T sat)
= 2798.38 +(2.1 x (260 – 212.38))
= 2798.38 + (2.1 x 47.62)
= 2798.38 + 100 = 2898.38 KJ/Kg.
Equivalent Evaporation = Ms(H-h)/2257, = 37500(2898.38 – 376.968) / 2257
= (37500 x 2521.412)/2257, =94552950/2257
= 41893.19 kg.
Boiler Efficiency = Ms(H-h) / (W x GCV)
= 37500(2898.38 – 376.968) / (4000 x 30000)
= (37500 x 2521.412) / 132000000
= 94552950 / 132000000 = 0.7163 = 71.63%
Boiler Thermal Efficiency = 71.63%
Now,
Heat gained by Feed water in Economiser =
= Enthalpy @ Eco. outlet – Enthalpy@ Eco. Inlet
= (376.968 – 62.9837) = 313.98 KJ/Kg.
% of heat utilised by Economiser = Ms x Heat gained in Eco. / (W x GCV)
= (37500 x 313.98) / (4400 x 30000)
= 11774411.25 /132000000 = 0.0892 = 8.92%
% of heat of fuel utilised by Economiser = 8.92%
2. Following reading are taken during the test of a boiler for one hour.
Steam Generated 5000Kg. Coal burnt – 800 Kg. CV of coal – 5600 Kcal/Kg.,
Dryness fraction of steam entering the super heater – 0.92, Rated pressure of
Boiler – 25Kg/Cm2, Feed Water temp – 105OC, Temp. of steam leaving the super
heater – 310OC. Determine
i) Equivalent Evaporation per kg of fuel with & without super heater.
ii) Thermal Efficiency of boiler without super heater & with super heater.
iii) Amount of Heat supplied by super heater per Hr. (Marks -6 Feb.-2019)
Given Data –
Steam Generated = Ms = 5000Kg. Coal burnt =W= 800 Kg/Hr.
CV of coal=CV=5600 Kcal/Kg.,
Dryness fraction of steam entering the super heater = X = 0.92,
Rated pressure of Boiler – 25Kg/Cm 2,
Feed Water temp – 105OC,
Temp. of steam leaving the super heater – 310 OC.
Now from Steam Table –
Enthalpy of Feed water @ 105OC temp = h = 105.3 Kcal/kg.
Enthalpy of Evaporation @25Kg/cm2 pressure = hgf = 670.399Kcal/kg.
2 O
Enthalpy of steam entering the superheater = hg + Xhgf
= 105.3 + [0.92 x 670.399]
= 105.3+616.76 =721.76Kcal/kg.
Now,
Equivalent Evaporation –
i) Equivalent Evaporation without SH =Ms (H-h)/540=5000(721.76-105.3)/540
= (5000 x 616.46) / 540
= 3082300/540
= 5707.96 Kg/hr.
ii) Equivalent Evaporation with SH = =Ms (H-h)/540=5000(725.4-105.3)/540
= (5000 x 620.1) / 540
= 3100500/540
= 5741.66 Kg/hr.
Thermal Efficiency of Boiler –
i) Thermal Efficiency of Boiler without SH =Ms (H-h)/(W x CV)
=5000(721.76-105.3)/(800 x5600)
= 3082300 / 4480000
= 0.6880
= 68.80 %
ii) Thermal Efficiency of Boiler with SH =Ms (H-h)/(W x CV)
=5000(725.40-105.3)/(800
x5600)
= 3100500 / 4480000
= 0.6920
= 69.20 %
Amount of Heat Supplied by SH = Ms (Hs – H sat)
= 5000 (725.4 – 721.76)
= 5000 x 3.64
= 18200 Kcal / Hr.
Results –
1. Equivalent Evaporation without Super heater = 5707.96 Kg/Hr.
2. Equivalent Evaporation with Super heater = 5741.66 Kg/Hr.
3. Thermal Efficiency of Boiler without Superheater = 68.80 %
4. Thermal Efficiency of Boiler with Superheater = 69.20%
5. Amount of heat supplied by super heater = 18200 Kcal/Hr.
3. A boiler generates 6.5Ton of steam per ton of coal fired. Steam generation is at
18 Kg/cm2 pressure. Boiler feed water temp. is 110 OC at the downstream of
the deareator. Boiler Efficiency 75%, Factor of evaporation – 1.15, Cp of steam –
0.55 Kcal/kg OC, Determine –
i) Temp. of Steam (ii) Degree of superheat if any (iii) CV of coal.

(Marks - 6 Feb. 2017.)

Given Data –
Boiler generates 6.5 Ton of steam per ton of coal = Ms = 6.5MT = 6500Kg.
Boiler Pressure – 18 Kg/cm2, Feed Water temp.- 110 OC
Boiler Efficiency – 75 %, Factor of Evaporation – 1.15
Specific Heat of Steam = Cp = 0.55 Kcal/Kg OC
From Steam table –
Enthalpy of Feed water @ 110OC = h = 110.37 Kcal/Kg.
Now
Factor of Evaporation = H-h / 540
H = (1.15 x 540) + 110.37, = 621 +
110.37
Enthalpy of Steam = H = 731.37 Kcal/Kg.
From Steam table @ 18Kg/cm2 pressure
Enthalpy of Evaporation = hfg = 669.10 Kcal/kg.
Saturated steam Temp = T(sat) = 208.9OC
Enthalpy of Steam = Enthalpy of Evaporation + Cp ( T sup – T sat)
731.37 = 669.10 + 0.55 ( T sup – 208.9)
731.37 = 669.10 + 0.55 Tsup – 114.89
731.37 = 554.2 + 0.55 Tsup
Temp. of Superheated steam = (731.37 – 554.20)/0.55 =
= 177.16 / 0.55
= 322 OC
Boiler Efficiency = Ms (H-h)/(W x CV)
CV = Ms (H-h)/(W x Boiler Efficiency)
CV = 6500(721.37-110.3)/(0.75 x 1 )
= 4036955 / 0.75 x 1000
= 4036955 / 750
= 5382 kcal/kg
i) Temp. of Super heated steam = Tsup = 322OC
ii) Degree of Super heat = (Tsup – Tsat) = (322 – 208.9) = 113.1
 Problems of Steam Costing
1. Find out the efficiency of the furnace oil fired boiler by direct method
with the given data. Type of Boiler. Furnace oil Fired. Quantity of steam
(dry) generated 5 TPH, steam Pressure – 10Kg/cm2, steam Temp.- 180OC,
quantity of oil consumed – 0.35, Feed water Temp.- 75OC, GCV of Furnace
oil – 10400 Kcal/kg.
i) Enthalpy of saturated steam at 10Kg.cm2 – 665Kcal/kg, Enthalpy of feed
water – 75 Kcal/kg.
ii) The above furnace oil fired boiler was converted to coconut shell firing.
Determine the boiler efficiency by direct method after conversion, GCV of
coconut shell fuel is 4565 Kcal/kg. quantity of coconut shell for same steam
demand & pressure 850 kg/hr.
iii) The cost of fuel & operating hour of boiler given below –
Operating Hours/Year – 5000 Hr. Cost of Furnace oil – Rs. 40000/MT
Cost of Coconut shell – Rs. 5000/MT.
Find out the annual cost saving due to fuel substitution in above
boiler.
(Marks – 6 Feb. 2015)
Given Data –
Steam generation=Ms=5TPH = 5000 Kg.Hr, steam Pressure – 10 Kg/cm 2,
Steam Temp. – 180OC, Furnace oil Consumption – 0.35TPH = 350Kg/hr.,
Furnace oil GCV = 10400 Kcal/kg.
Enthalpy of Feed water @ 75OC = h= 75 Kcal/kg
Enthalpy of Steam @ 10 kg/cm2 pressure & 180OC temp. = H =665
Kcal/Kg.
Coconut shell consumption = 850 Kg/Hr.,
Coconut shell GCV = 4565 Kcal/kg.
Yearly operating Hours – 5000 Hrs., Cost of Furnace oil = Rs. 40000 / MT
Cost of Coconut Shell = Rs. 5000 / MT.
i) Efficiency of Boiler when furnace oil used.
Boiler efficiency = Ms(H-h) / fuel firing x CV
= 5000 (665 – 590) / 350 x 10400
= 5000 x 590 / 3640000
= 2950000 / 3540000 = 81.04 %
Boiler Efficiency When furnace oil used = 81.04%
ii) Boiler Efficiency = Ms(H-h) / fuel firing x GCV
= 5000 (665 – 75) / 850 x 4565
= 2950000 / 3880250 = 0.7602
Boiler Efficiency when Coconut shell is used = 76.02%
iii) Annual Cost saving
Cost of furnace oil / year = 5000 x 40,000 x 0.35
= Rs.
7,00,00,000/-
Cost of coconut shell /Year = 5000 x 5,000 x 0.850
= Rs.
2,12,50,000 / -
Annual cost saving after fuel substitution =
= 7,00,00,000 –
2,12,50,000
= Rs. 4,87,50,000 / -
2. An coal fired boiler is generating 20T/Hr. steam & operates for 8400
Hrs/Years The TDS in Boiler feed Water was reduced from 500ppm to 200
ppm. The maximum permissible limit of TDS in boiler is 3000ppm & make
water 12% temp. of blowdown water is 178OC & boiler feed water temp. is
47OC. GCV of coal is 5500 Kcal/Kg. & efficiency of Boiler is 78%. Calculate the
saving in coal per annum due to reduction in blowdown.

(Marks – 6 Mar. 2018.)

Given Data –
Steam Generation = Ms = 20T/Hr = 20000 Kg/Hr.,
Operating Hr. /Year = 8400
TDS of Feed Water – 500ppm, Reduced TDS of Feed Water – 200ppm.
Permissible limit of TDS in Boiler – 3000ppm.
Make up water % - 12 %, GCV of Coal – 5400 Kcal/kg.,
Boiler Efficiency – 78%
Blowdown Water Temp – 178OC, Boiler Feed Water Temp.- 47OC
% of Blowdown=(TDS of Feed Water/Permissible TDS in Boiler)Make up Water
%
% of Blowdown @ 500 TDS = (500/3000) x 0.12 x 100
= 0.166 x 0.12 x 100 = 0.02
= 2.0 %
% of Blowdown @ 200 TDS = (200/3000) x 0.12 x 100
= 0.066 x 0.12 x 100 = 0.008
= 0.8 %
Water loss through blow down -
@ 500ppm TDS = 20000 x 0.02 = 400 Kg/hr.
@ 200ppm TDS = 20000 x 0.008 = 160 Kg/hr.
Total Steam generation –
@ 500ppm TDS = 20000 + 400 = 20400 Kg/hr.
@ 200ppm TDS = 20000 + 160 = 20160 Kg/hr.
From steam Table
Enthalpy of blow down water @ 178OC = H = 180.46 Kcal/kg.
Enthalpy of Boiler feed water @ 47OC = h = 47 Kcal/kg.
Now,
Boiler efficiency = (Ms (H-h) / Fuel firing x GCV)
Fuel firing = Ms(H-h) / Boiler Efficiency x GCV
Coal firing @ 500 TDS = 20400(180.46 – 47) / 0.78 x 5500
= (20400 x 133.38) / 4290
= 2720944.19 / 4290 =
634.25 Kg.
= 0.634 MT/Hr.
Coal firing @ 200 TDS = 20160(180.46 – 47) / 0.78 x 5500
= (20160 x 133.38) / 4290
= 2688940.8/ 4290 =
626.79 Kg.
= 0.627 MT/Hr.
Coal required per year –
Coal required per year @ 500ppm TDS = 0.634 x 8400 = 5325.6MT
Coal required per year @ 200ppm TDS = 0.627 x 8400 = 5260.8 MT.
Due to reduction in TDS coal saving per year = 5325.6 –5266.8 =58.8 MT.
3. Work out cost benefit analysis for coal v/s. Natural Gas
Coal fired boiler details- Boiler operating pressure(sat) is 25Kg/cm 2 &
Feed water temp. is 105OC,
Efficiency of coal fired Boiler – 75%, SF ratio – 5.6
Landed cost of coal – Rs. 4500 / MT
Power consumption for coal preparation – 2.85 Kwh/MT.
Auxiliary power consumption = 15 Kwh/MT,
Chemical cost = Rs. 3.2/MT.
Efficiency of Natural gas fired boiler – 90%,
Cost of NG = Rs. 900/Mmbtu.
GCV of Ng = 9500 Kcal/ SCM, 1 Mmbtu = 25.2 SCM.
Auxilliary power consumption = 4Kwh/MT
Chemical Cost – Rs. 3.2 / MT (Marks- 6 Feb.-
2019)
Given Data –
Boiler operating pressure(sat) is 25Kg/cm2 &
Feed water temp. is 105OC,
Efficiency of coal fired Boiler – 75%,
Steam Fuel ratio – 5.6 so steam generation = 5.6MT/MT of coal

= 5600 Kg/Hr.

Landed cost of coal – Rs. 4500 / MT

Power consumption for coal preparation – 2.85 Kwh/MT
Auxiliary power consumption = 15 Kwh/MT
Chemical cost = Rs. 3.2/MT., Efficiency of Natural gas fired boiler –
90%,
Cost of NG = Rs. 900/Mmbtu =900/ 25.2 = Rs.35.71 / SCM,
GCV of NG = 9500 Kcal/ SCM,
Now,
Assume gross calorific value of coal = 5500 Kcal/kg.
Power Rate – Rs. 5 / Kwh
Natural gas fired boiler has same steam generation capacity as coal fired
boiler.
From Steam Table –
Enthalpy of steam @ 25Kg/cm2 (sat) = H = 670.39 Kcal/kg.
Enthalpy of Feed water @ 105OC = h = 105.31 Kcal/kg.
Boiler Efficiency = Ms(H-h) / Fuel firing x GCV
Coal firing / Hr. = Ms(H-h) / Boiler Efficiency x GCV
= 5600(670.39 – 105.31) / 0.75 x 5500
= 5600 x 565.07 / 0.75 x 5500
= 3164424.95 / 4125 = 767.13 Kg. = 0.767
MT/Hr.
Power required for coal preparation = 2.85 x 0.767 = 2.18 Kwh
Cost of coal = 0.767 x 4500 =
3451.5
Power cost for coal preparation = 2.18 x 5 = 10.9
 Chemical cost = 5.6 x 3.2 = 17.92
Cost of steam generation for coal fired boiler = Rs. 3900.32 /MT
Now, 1SCM = 0.86 kg.
Natural gas fired/hr. = M(H-h)/Boiler Efficiency x GCV
= 5600 (670.39 – 105.31) / (0.9
x 9500 x 0.86)
= 5600 x 565.07 / 0.9 x 8161
= 3164424.95 / 7344.9 = 430 Kg.
Natural Gas fired/Hr. = 430Kg = 430 / 0.86 = 501 SCM.
Cost of natural gas = 501 x 35.71 =
17890.71
Auxiliary power cost = 4 x 5.6 x 5 = 112
Chemical cost = 5.6 x 5 = 28
The total cost of steam generation for NG = 17890.71 + 112 + 28

= Rs.18030.71 /MT
Thus the cost of steam generation of coal fired boiler is less than Natural gas
THANK YOU