Biology for Computer Engineers Course Handout.pptx
Boiler Efficiency.pptx
1. B O I L E R E F F I C I E N C Y C A L C U L A T I O N
M E A S U R E M E N T O F E X C E S S A I R
B E S T P R A C T I S E S F O R B O I L E R O P E R A T I O N
Boiler
2. BOILER EFFICIENCY
Boiler efficiency is the percentage of heat input
that is effectively utilized to generate steam.
3. Why performance evaluation is important?
The performance parameter of boiler reduces with
time due to poor combustion, heat transfer surface
fouling and poor operation and maintenance. Even
for new boilers, reasons such as fuel quality, water
quality can result in poor boiler performance.
Boiler efficiency tests help us to find out the
deviations from the best efficiency and target
problem area for corrective actions.
4. Direct Method Indirect Method
Also known as input-output
method.
Parameters to be monitored:
Quantity of steam generated per
hour.
Quantity of fuel used per hour.
The working pressure &
superheat temperature.
The feed water temperature.
The spray water temperature.
Gross calorific value of the fuel
(GCV in kcal/kg)
Also known as heat loss method.
Reference standard: ASME PTC-
4.
Data required for calculation:
Ultimate analysis of fuel.
% of O2 & CO2 in flue gas.
Flue gas temperature.
Ambient temperature & humidity
of air.
GCV of fuel.
Percentage of combustible in ash.
Methods of assessing Boiler Efficiency
6. Advantages Disadvantages
Plant people can
evaluate quickly the
efficiency of boiler.
Requires few
parameters for
computation.
New few instruments
for monitoring.
Does not give clues to
operator the reason for
deviation w.r.t. design
efficiency, if any
Does not calculate
various losses
accountable for various
efficiency levels.
Direct Method
8. Dry Gas Loss (Controllable)
This is the heat carried away by flue gas at AH outlet.
It’s a function of flue gas quantity and the temperature difference
between air heater exit flue gas temperature and FD fan inlet air
temperature
Sensible heat of flue gas (Sh)= Mass of dry flue gas* Sp. Heat*
(Tfg-Tair)
Mass of dry flue gas = ( C+S/2.67-U)/12 Co2
Dry flue gas loss % = (Sh /GCV of fuel) * 100
9. Reduction in Dry Gas Loss
Factors affecting furnace Heat transfer include
Furnace wall condition
Combustion Heat release rate,
Emissivity,
Absorptivity and thermal conductivity of deposits
ash dust loading,
Pulverised fuel fineness
Mill combination (Top, Middle, Bottom),
Air regime for combustion etc.
10. Reduction in Dry Gas Loss
Operation at optimum excess air – Hi O2 ~ Hi DFG
Cleanliness of boiler surfaces – Dirty tubes ~ Hi EGT
Cleaning of air heater surfaces and proper heating elements.
Reduction of tempering air to mill.
Reduction in air ingress.
Representative measurements.
Typically 20~22°C increase in exit gas temperature ~ 1% reduction in
boiler efficiency.
11. Unburnt Carbon loss
The amount of unburnt is a measure of combustion process in
general and mills/burners in particular.
Loss due to Unburnt Carbon:
= U*Cvc*100/GCV of Coal
CVc – CV of carbon 8077.8 kcal/kg
U = Carbon in ash/kg of coal = Ash/100* (C/(100-C)
12. Influencing factors- Unburnt Carbon Loss
Type of mills and firing system
Furnace size
Coal FC/VM ratio, coal reactivity
Burners design/ condition
PF fineness ( Pulverizer problems)
Insufficient excess air in combustion zone
Burner balance / worn orifices
Primary air flow / pressures
13. CO Loss ( Controllable)
Ideally, average CO at gooseneck after combustion completion
should be below 100 ppm and no single value over 200 ppm
C + O2 = CO2 + 80084 kcal/kg of Carbon
2C + O2 = 2CO + 2430 kcal/kg of Carbon
(We lose 5654 kcal for each kg of CO formed)
14. Loss due to moisture
Includes loss due to inherent & surface moisture in fuel,
moisture loss due to combustion of H2 in fuel & loss due
to moisture in combustion air.
Fuel H2 loss: On combustion H2 in fuel reacts with O2 to
form water. This water evaporates & gets superheated
and is a loss.
Fuel & air moisture loss: This loss is due to evaporation
and heating of inherent and surface moisture present in
fuel and air.
Total moisture loss = (9H + M) * Sw / GCV
Sw – Sensible heat of water vapour
= 1.88*( Tgo- 25)+ 2442 + 4.2*( 25- Trai)
15. Other losses
Sensible heat loss of ash
Bottom ash hopper Eco hopper
AH hopper ESP hopper
Radiation loss through Bottom Ash Hopper
Coal mill reject loss
Radiation Loss
Actual radiation and convection losses are difficult to assess
because of particular emissivity of various surfaces.
17. Pre requisites Measurements
Sootblowing completed atleast
one hour before starting the test.
SCAPH isolated
All FW heaters are in service,
with normal level & normal
cascading
No mill changeover/oil guns
CBD/IBD isolated.
Bottom hopper deashing after
completion of test.
Auxiliary steam isolated/defined.
Flue gas composition at APH
outlet.
Flue gas temperature at APH
inlet/outlet.
Coal sample for proximate
analysis & GCV.
Bottom ash & Flyash samples.
PA/SA temp at APH inlet/outlet.
Dry/Wet bulb temperature.
Control room parameters.
All measurements/sampling to be
done simultaneously.
Boiler Tests
18. Measurement of Excess air
Importance of Excess Air:
With insufficient air available for complete combustion
process, some of the fuel is left unburnt, resulting in
inefficiency and undesirable emissions.
In actual practice, some amount of excess air above and
beyond stoichiometric requirements is needed for complete
combustion of fuel.
Measurement of excess air is important because excess oxygen
not consumed during combustion passes through boiler,
absorbs otherwise useful heat and is carried away in the form
of a stack loss.
21. Excess air recommendations
Recommended excess air levels at full boiler load:
For natural gas ……………….. 10-20%
For fuel oil ……………….. 10-20%
For pulverized coal ………….. 20-25%
For stocker coal ……………….. 35-40%
23. Constituent Measured Advantages Disadvantages
Carbon dioxide only One instrument Can not determine on
which side of
stoichiometric
combustion is occurring
Oxygen only One instrument If sub-stoichiometric,
extent of incomplete
combustion is measured.
Oxygen and Carbon
Dioxide
Defines entire
combustion range ( if O2
& CO2 measured
separately)
CO2 not usually used to
measure incomplete
combustion.
Oxygen and Carbon
monoxide
Defines entire
combustion
CO is preferred method
of sensing incomplete
combustion.
24. Factors affecting Boiler Performance
Periodic cleaning of boiler
Periodical sootblowing
Proper water treatment program and blowdown control
Draft control
Excess air control
Percentage loading of boiler
Steam generation pressure and temperature
Boiler insulation
Quality of fuel
Primary airflow
Mill fineness
Mill outlet temperature
Air ingress