Contract No.

5795 – BALCO

TYPICAL METHOD OF CALCULATION

GROSS THERMAL EFFICIENCY AND HEAT BALANCE

BASED ON GROSS CALORIFIC VALUE OF FUEL
BY HEAT LOSS METHOD
(BS 2885:1974)

Note - Where symbols have been given in BS 2885:1974, these symbols have
been used below. Additional "non-standard symbols have been used
where no equivalent has been given in the Standard.

SYMBOLS

FUEL

Gross calorific value kJ/kg H1

Proximate analysis (by weight)

Moisture % E x 100
Volatile matter % V x 100
Fixed carbon % F x 100
Ash % Z x 100

Ultimate analysis (by weight)

Moisture % E x 100
Carbon % C x 100
Hydrogen % H x 100
Sulphur % S x 100
Nitrogen % N x 100
Oxygen % O x 100
Ash % Z x 100

Calorific value of carbon kJ/kg H3 (33820 KJ/Kg)

Calorific value of CO kJ/kg H4
PERFORMANCE DATA

Carbon dioxide in fuel gas at airheater outlet % 1

Oxygen in fuel gas airheater outlet % 4
Carbon monoxide in fuel gas at airheater outlet % 2

Temperature
0
Air at F.D fan intake C t12
0
Flue gas at airheater outlet C t16

Food water flow kg/s W1

Spray water flow kg/s W7

Combustible matter in fly ash % i3

Quantity of fly ash Kg/s D3
Combustible matter in coarse (bottom) ash % i1
Quantity of coarse (bottom) ash Kg/s D1

DERIVED DATA

Weight of combustion air per kg of fuel kg/kg Wa

Weight of moisture in combustion air per Kg Kg/kg K2
Enthalpy of steam at superheater outlet kJ/kg h2
Enthalpy of feed water at economiser inlet kJ/kg h1
Enthalpy of spray water to attemperator kJ/kg h7
Boiler heat output kJ/s h
Weight of carbon in residues per kg fuel kg/kg CR **
Weight of carbon in flue gas per kg fuel kg/kg Cg
Weight of carbon equivalent of sulphur in
Flue gas per kg of fuel kg/kg Cs
Weight of fuel fired kg/s C1

Note – Weight of combustion air obtained from fuel analysis and flue gas analysis and
weight of moisture in combustion air obtained from tables.

Method of determining fuel weight is given later.

** This figure should correspond to unburnt loss used in the heat account.
Heat losses

Heat Percentage
loss loss
kJ %

Heat lost to sensible heat in fly ash P7 P’7

Heat lost to carbon monoxide in flue gas P2 P’ 2

Heat lost to sensible heat in dry flue gas P5 + P4 P’5 + P’4

Heat lost to moisture in combustion air P6 P’ 6

Heat lost to combustible matter in ash P1 P’1

Total heat losses P P’

Gross thermal efficiency % B

CALCULATIONS

Boiler Heat output = W 1 x (h2 – h1) + W7 x (h2 – h7) kJ/s

Heat balance

Heat lost due to sensible heat in dry flue gas

Weight of carbon in flue gas per kg of fuel Cg = C x 100 - CR kg

100
Weight of carbon equivalent of sulphur in flue per
kg of fuel Cs = S x 100 kg **
2.67 x 100

**This item only applies if gas

analysis is carried out by
Orsat apparatus..

Weight of carbon plus carbon equivalent of

sulphur in flue gas per kg of fuel Cg + C S kg

Heat lost to dry flue gas per kg of fuel

P3 = (Cg + CB) x 100 x _1 x 30.6 x ( t16 – t12 ) kj

12 1 + 2

PERCENTAGE HEAT LOSS TO DRY FLUE GAS P3 = P3 X 100 %

H1

Heat lost due to moisture and hydrogen in fuel and moisture formed in combustion

Total moisture in flue gas per kg of fuel = (E x 100) + 8.937 x (H x 100) – (E + 8.937H) kg
100 100

Heat lost per kg of moisture in flue gas = 1.88 x (t16 – 25) + 2442 + 4.2 x (25 – t12) kj

Heat lost due to moisture in flue gas per

Kg of fuel =P5 + P4 = (E +8.937H) x [ 1.88 x (t16 – 25) + 2442 + 4.2 x (25 – t12)] kg

PERCENTAGE HEAT LOSS TO MOISTURE IN FLUE GAS

P’5+P’4 = P’5+P’4 X 100 %
H1

Heat lost due to combustible matter in ash

Combustible matter in coarse ash = D1 x i1 Kg/s

100
Heat lost due to combustible matter in coarse ash = D1 x i1 x H3 %
C1 x H 1

Suitably ,

Heat lost due to combustible matter in fly ash = D3 x i3 x H3 %

C1 x H1

Total Heat loss due to combustible matter in ash, P’ 1 = H3 [(D1i1) + (D3 i3)] %
C1 x H1

Heat lost due to moisture in combustion air

Water content of combustion air per kg of fuel = Wa x K2 Kg/kg

Heat lost due to moisture in combustion air

Per kg of fuel P6 = Wa x k2 x 1.88 x (t16 – t12) KJ/kg

Percentage heat loss to moisture in combustion air P’ 6 = P6 x 100 %

H1

Heat lost due to sensible heat in fly ash

Quantity of fly ash per kg fuel fired = D3 Kg/kg

C1
Average specific heat of fly ash at exit temp. = 0.67 kJ/kg 0K

Heat lost due to sensible heat in fly ash P7 = [ D3 x 0.67 x (t16 – t12) ] kJ/kg
C1

Percentage heat loss due to sensible heat in fly ash P’7 = P7 x 100 %
H1

Heat loss due to CO in flue gas

CO content in flue gas at AH exit = 2 % Vol.

CO2 content in flue gas at AH exit = 3 % Vol.
Carbon content in fuel = C x 100 %
Sulpher content in fuel = S x 100 %
Combustible content in coarse ash = i1 %
Combustible content in fly ash = i3 %
Quantity of coarse ash = D1 kg/s
Quantity of fly ash = D3 kg/s
Quantity of fuel fired = C1 kg/s

Combustible content per unit mass of fuel = (i3 + D3) + (i1 x D1) kg/kg
100C1 100C1

Calorific Value of CO = H4 kJ/kg

CO in flue gas per unit mass of fuel = 72 [C + S + 100 - (i3 x D3) – (i1D1)]
3(1 +2 ) 267 100C1 100C1

= L (say) kg/kg

Heat loss due to unburnt CO in flue gas, P2 = L x H4 kJ/kg

Percentage heat loss due to CO in flue gas, P’ 2 = [P2 x 100] %
H1

Summary of Heat Balance (based on GCV of fuel)

Heat loss due to sensible heat in fly ash % P’7

Heat loss due to sensible heat in dry flue gas % P’3
Heat loss due to moisture and hydrogen in fuel and % P’4 + P’5
moisture formed in combustion
Heat loss due to moisture in combustion air % P’6
Heat loss due to CO in flue gas % P’2
Heat loss due to un-burnt carbon in ashes, dust and
grits % P’1
Heat loss due to sensible heat in coarse ash % 0.38 (fixed)
Heat loss due to radiation, convection & un-accounted % 0.30 (fixed)
Total heat losses % P (sum of all
Above losses)
Gross thermal efficiency (by difference) % B = (100-P)

Derivation of Fuel Weight

Compute preliminary heat balance as follows :-

From measurements, calculate the following losses :-

Sensible heat in fly ash % P’7

Dry gas loss % P’3
Moisture and hydrogen loss % P’4+P’5
Moisture in combn. Air loss % P6
CO loss % P’2
Unburnt carbon loss % P’1

Fixed losses
Sensible heat in coarse ash loss % 0.38
Radiation and unaccounted loss % 0.30

1st estimate – total losses % P

1st estimate of efficiency 100 – P % B1

Calculation of some losses involves the use of the weight of fuel fired (C 1). Therefore,
initially these must be estimated and precise calculation carried out by a process of
iteration as follows :
1st estimate of fuel weight C1i = h . x 100 kg/s
B1 x H1

Recalculate the losses using fuel weight c1I and insert the revised values in the heat
balance, thus deriving a revised efficiency B2

2nd estimate of fuel weight C1.f = h . x 100 kg/s

B2 x H1

Repeat the calculations until two consecutive coal weights are the same and
consequently the efficiency remains constant in the heat balance. The number of
repeat calculation necessary is dependent on estimated values chosen to insert in the
preliminary heat balance.