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Pr drop for ID>152 Delta P = 89.254 x 10^6 x {1 + (91.44/ID) } F^2 x V x TEL / ID^5
Friction
Tube ID inch Di mm
Factor
Darcy friction factor(FF) no 12.7 0.028
Flow(F) lb/h 19.05 0.025
Equivalent length(EL) ft 25.4 0.023
38.1 0.021
Specific volume(SP.V) cft/lb 50.8 0.02
Pressure drop psi 63.5 0.018
76.2 0.018
101.6 0.017
127 0.016
203.2 0.014
254 0.013
No off
length metre
ID
entry no 20
exit no 40
squeeze bend no 75
180 bend no 50
90 short rad bend (R<3d) no 32
90 std radius ( r = 3d) no 26
90 long rad bend ( R>3d) no 20
45 short rad bend ( r<3d) no 15
45 long rad bend ( R >3d) no 12
reducer no 120
expander no 100
Tee - entering run no 60
Tee- entering branch no 90
Generally 5 – 10 deg C drop is expected in main
steam line.
Selection and proper application of insulation is
important to ensure not much temperature is
dropped across the steam piping.
Stepped over insulation and sagged insulation are
causes for temperature drop.
HP turbine exhaust pressure – IP turbine inlet pressure
(100 – MAFR)
AS FIRED GCV = x GCVADB
(100 – MADB)
MAFR - Moisture as fired (To be done by plant
lab).
MADB - Moisture air dried basis
GCVADB - GCV air dried basis (from Lab report)
DIFFERENCE BETWEEN AIR DRIED
BASIS GCV & AS RECEIVED GCV
(100 – MAR)
AS RECD GCV = x GCVADB
(100 – MADB)
MAR - Moisture as recd (To be done by plant lab).
MADB - Moisture air dried basis
GCVADB - GCV air dried basis (from Lab report)
As fired GCV is used for boiler efficiency
calculation.
As sampled basis is used for paying the
vendor.
Air dried basis / bone dry basis is used for
knowing the trend of GCV.
Efficiency
Efficiency
y = Heat liberated by
y Fuel – Losses
Heat liberated by fuel
Loss 1-
1-Heat lost through unburned carbon particles
in the ash removed from the boiler
Depending
D di upon the
th combustion
b ti mechanism
h i th
the
unburned carbon particles are found in the ash.
The fuel size, the combustor design, fuel moisture
/ fixed carbon / ash / volatile matter govern this
loss.
Measured as LOI ( loss on ignition
g or GCV of ash))
LOI is the weight loss of the ash sample when
reburning is done at lab furnace.
Loss 1:
1: Heat lost through unburned carbon particles in
boiler
bo e ash
as
As fired moisture
moist re is a key
ke parameter in this loss
Manipulation of H2 content can vary the loss
Since the heat lost through the flue gas through
air moisture are separately estimated, the left
out components is the heat through the dry flue
gas.
Byy designing
g g the boiler for low exit g gas
temperature the loss can be kept minimum.
Further the lower the excess air percentage,
Further, percentage
the loss will be lower.
Loss 6: Radiation heat lost to surrounding
Fuel fed
Fuel fed kg/h = 100
Moisture fed in limestone kg/h = 1.8
Dry Lime stone fed kg/h = 15
Fraction of CaCo3 in limestone kg/kg = 0.75
F ti
Fraction of MgCo3 in limestone
f M C 3 i li t k /k
kg/kg = 0 15
0.15
Inerts in limestone kg/kg = 0.4
GCV of fuel kcal/kg = 7900
Heat loss due to calcination of CaCo3 & Kcal/kg of fuel = ( 15 / 100 ) x ( 0.75 x 436.6) + (0.15 x 284.8)
MgCO3
= 55.5255
Sulfur content in fuel kg/kg = 0.007
% SOX capture
% p % = 80
Heat gain from sulfation reaction kcal/kg of fuel fired = 0.007 x ( 80 / 100 ) x 3620.48
= 20.27
Sensible heat addition to limestone
Sensible heat addition to limestone Kcal/kg = ( 15 / 100 ) x 0 24 x 100
( 15 / 100 ) x 0.24 x 100
Kcal/kg = 3.6
Moisture heat loss = (M / F )x [595.4+(Cp1 x Te) ‐Ta] x 100 / GCV
= 10.61
Efficiency loss due to limestone feeding % = 100*(55.5255 + 3.6 + 10.61 ‐ 20.27 )/7900
= 0.63
Fuel Firing Rate
LOSS 1: HEAT LOST THROUGH UNBURNED CARBON
PARTICLES IN THE ASH
PARTICLES IN THE ASH
In AFBC
Bed temperature should be minimum 850 deg C.C
Shallow bed leads to high elutriation loss.
Denser bed leads to high elutriation loss.
TIP FOR PF
In PF boiler
High PA leads to more loss.
loss
Unbalance in fuel piping leads to unburnt loss of
carbon.
b
Too less O2 leads to poor combustion.
TIP FOR TRAVELING GRATE
In travagrate boiler
The
e main
a factor
acto iss tthee fuel
ue moisture.
o stu e CClosed
osed ssheds
eds to p
prevent
e e t
rainwater entry into fuel storage yard would keep the loss
minimum.
Solar drying of fuel would help in achieving overall economy.
Flue gas drying is being adopted in the case of bagasse.
LOSS 4: HEAT LOST THROUGH HEATING UP
ATMOSPHERIC MOISTURE
ATMOSPHERIC MOISTURE
As explained earlier,
earlier the loss is because of the
moisture in ambient.
One has to ensure the air is not drawn from closed
rooms where the air is saturated with water vapor
such as paper mills,
mills or near cooling tower.
tower
LOSS 5: RADIATION HEAT LOST TO SURROUNDING
LOSS 5: RADIATION HEAT LOST TO SURROUNDING
Some boiler companies maintain that the insulation of
airbox & valves are not their practice.
LOSS 6: HEAT LOST THROUGH THE DRY FLUE GAS AT THE
END OF HEAT RECOVERY DEVICE OF BOILER
END OF HEAT RECOVERY DEVICE OF BOILER
Allowing
All i high
hi h exhaust
h temperature with
i h choked
h k d air
i heater,
h
fouled economizer leads to poor efficiency of the boiler.
deposits.
deposits
Honey combing of ash accumulations is seen in agro waste
fired boilers.
BLOW DOWN
Mixing
Mi i twot different
diff t fuels
f l affects
ff t the
th combustion
b ti to t some
extent. Manually rpm regulation is not practical when the
GCV varies
aries due
d e to improper fuel
f el mix.
mi
This is the trend of O2, steam flow, steam pressure & fuel feeder rpm (feeder no 6 & feeder no 1) in 90 TPH
boiler. The cyclic pattern of O2 to repeat within a short span of 3 minutes. This cycle comes short because the
feeder rpm is increased by 66% over the lowest rpm by the combustion control. When two feeders are on
auto the net fuel flow variation is 22%. This fuel addition when dumped in two locations in the compartments
may lead to poor combustion. Reducing the gain would help to remove such a cycle.
LOI feed back to boiler operators –in an hour after the shift
commences