Formula Discussion

Direct Efficiency

This method calculates boiler efficiency by using the basic efficiency formula-

η = (Energy output)/(Energy input) × 100

In order to calculate boiler efficiency by this method, we divide the total energy output of
a boiler by total energy input given to the boiler, multiplied by hundred.

Calculation of direct efficiency-

Q× ( H−h ) ×100
E=
q × GCV

Where,

Q = Quantity of steam generated (kg/hr)

H = Enthalpy of steam (Kcal/kg)

H = Enthalpy of water (kcal/kg)

GCV = Gross calorific value of the fuel.

Example Questions and Answers

1.

Analyse the diagram given below and answer the question.

Data

Enthalpy of steam (dry & saturated) at 10 kg/cm2 (g) pressure: 665 kcal/kg

Furnace oil consumption: 600 litres

Specific gravity of furnace oil: 0.89

Calorific value of FO (GCV): 9650 kcal/kg

i. Calculate the boiler efficiency by direct method?

ii. Calculate the water temperature in the condensate tank?
iii. Estimate the fuel loss due to drop in feed water temperature

Ans.

i. Evaluation of boiler efficiency: By direct method

Q× ( H−h ) ×100
Boiler efficiency (%) :
q × GCV

Q = Quantity of steam generation per hour : 7000 kg/h

q = Quantity of fuel used per hour : 600 x 0.89 = 534 kg/h

GCV = Gross calorific value of the fuel : 9650 kcal/kg

H = Enthalpy of steam (kcal/kg) : 665 kcal/kg

h = Enthalpy of feed water : 42 kcal/kg

 7000× ( 665−75 ) ×100
Boiler efficiency (η) :
534 × 9650

: 84.6 %

ii. Feed water temperature at condensate tank :

5000× 1× 94+2000 × 1× 28
=75.1℃
7000× 1

Feed water temperature at boiler entrance : 42 °C

iii. To estimate the fuel loss quantity, due to feed water temperature drop:

7000× ( 665−75 )
Fuel consumption at 75°C feed water temperature =
0.846 × 9650
: 505.9 kg/h

FO (litre) : 505.9/0.89 = 568.4 litre

Furnace oil loss quantity : 600 – 568.4

: 31.6 litre/h
2.

The measured parameters of paper industry boiler is given below:

Fuel analysis Ash content in fuel : 8.63%

Moisture in coal : 31.6%

Carbon content : 41.65%

Hydrogen content : 2.0413%

Nitrogen content : 1.6%

Oxygen content : 14.48%

GCV of coal : 3501 kcal/kg

Useful data

Theoretical air requirement : 4.84 kg/kg of coal

Theoretical CO2% : 20.67%

Specific heat of air : 0.24 kcal/kg °C

Ambient air temp : 30 °C

Boiler efficiency : 82%

Coal consumption/per hr : 12 TPH

i. Estimate the heat loss due to air infiltration.

ii. Estimate heat loss quantity as percentage of fuel input
Ans.

i. Estimation of heat loss:

O2 % × 100
Excess air percentage level =
21−O 2 %

3× 100
=
21−3

3× 100
At boiler outlet = = 16.66 %
21−3

9 ×100
At ID fan = = 75 %
21−9

Actual air infiltration quantity in the duct =

[( 1+
75
100) ] [(
× 4.84 − 1+
16.66
100 )
× 4.84
]
= 8.47 – 5.65

= 2.82 kg/kg of coal

Infiltration air quantity = 2.82 x 12000

= 33,840 kg/h

Heat loss due to infiltrated air : 33840 x 0.24 x (135-30)

: 852768 kcal/h

Heat loss as equivalent to fuel quantity (as coal) : 852768/3501 : 243.6 kg/h

243.6
Heat loss as percentage of input fuel : ×100
12000
= 2.03 %
Indirect Method

Indirect efficiency is also known as heat loss efficiency calculation method. In this
method, efficiency calculation is done by subtracting heat loss fraction from 100.
Standard is ASME PTC-4-1 issued for calculating boiler efficiency by indirect
method. The standards do not include blow down loss in the efficiency determination
process.

Boiler indirect Efficiency = 100 – (i +ii + iii + iv + v + vi + vii)

Where,

i. Percentage heat loss due to dry flue gas

ii. Percentage heat loss due to evaporation of water formed due to H2 in fuel

 iii. Percentage heat loss due to evaporation of moisture present in fuel

iv. Percentage heat loss due to moisture present in air.

v. Percentage heat loss due to unburnt in fly ash

vi. Percentage heat loss due to unburnt in bottom ash

vii. Percentage heat loss due to radiation and other unaccounted loss

Stepwise Calculation of boiler indirect efficiency:-

Step-1 Data Collection

Following Data needs to be collected :-

Ultimate analysis of fuel (H2, O2, S, C, moisture content (M), ash content)

Percentage of Oxygen or CO2 in the flue gas

 Flue gas temperature in °C (Tf)

Ambient temperature in °C (Ta) & humidity of air in kg/kg of dry air

GCV of fuel in kCal/kg (GCV)

Percentage combustible in ash (in case of solid fuels)

GCV of ash in kCal/kg (in case of solid fuels)

Step-2 Find Theoretical air qty and Actual mass of air supplied

Theoretical air requirement= [(11.6 × C) + {34.8 × (H 2 – O2/8)} + (4.35 × S)]/100

kg/kg of fuel

Excess Air supplied (EA) = O2% / (21-O2%) X 100

Actual mass of air supplied/ kg of fuel (AAS) = {1 + EA/100} × theoretical air

Step-3 Calculate different percentage loss

i Percentage heat loss due to dry flue gas

= m × Cp × (Tf – Ta) ×100 / GCV

Where, m = mass of dry flue gas in kg/kg of fuel, C p = Specific heat of flue gas (0.23
kCal/kg °C), Tf = Flue gas temp Deg C, T a = Ambient air Temp Deg C, GCV = GCV
of fuel

ii. Percentage heat loss due to evaporation of water formed due to H2 in fuel

= 9 × H2 × [584 + Cp × (Tf-Ta)] × 100 / GCV

Where, H2 – kg of H2 in 1 kg of fuel Cp – Specific heat of superheated steam (0.45

kCal/kg °C), Tf = Flue gas temp Deg C, T a = Ambient air Temp Deg C, GCV = GCV
of fuel

 iii. Percentage heat loss due to evaporation of moisture present in fuel

= M × [584 + Cp × (Tf - Ta)] × 100 / GCV

Where, M – kg of moisture in 1kg of fuel, C p – Specific heat of superheated steam

(0.45 kCal/kg)°C 584 is the latent heat corresponding to the partial pressure of water
vapour. Tf = Flue gas temp Deg C, T a = Ambient air Temp Deg C, GCV = GCV of
fuel

iv. Percentage heat loss due to moisture present in air.

= AAS × humidity Factor × Cp × (Tf - Ta) × 100 / GCV

Where, AAS = Actual air supplied, Tf = Flue gas temp Deg C, Ta = Ambient air Temp
Deg C, GCV = GCV of fuel

v. Percentage heat loss due to unburnt in fly ash

= Total ash collected per Kg of Fuel Burnt ×GCV of Fly Ash × 100 / GCV of Fuel

vi. Percentage heat loss due to unburnt in bottom ash

= Total ash collected per Kg of Fuel Burnt ×GCV of bottom Ash × 100 / GCV of fuel

vii. Percentage heat loss due to radiation and other unaccounted loss

The actual radiation and convection losses are difficult to assess because of
particular emissivity of various surfaces and shape of boiler, air flow pattern etc. In
generally it can be assumed between 1% to 2% for smaller boilers and 0.2% to 1 %
for higher size boilers of about 500MW.

Step-4 Calculate indirect boiler efficiency

Boiler indirect Efficiency = 100 – (i +ii + iii + iv + v + vi + vii)

Example Question and Answer

1. Estimate the boiler efficiency by indirect method for the following data.

Type of fuel fired = Paddy husk

Paddy Husk composition: Moisture = 10.79%

Mineral Matter = 16.73%

Carbon = 33.95%

Hydrogen = 5.01%

Nitrogen = 0.91%

Sulphur = 0.09%

Oxygen = 32.52%

GCV (Kcal/kg) = 3568

Cost of Paddy Husk = RM 1100 / MT

Ambient DBT = 32°C

Boiler parameters on Paddy

Husk Flue gas temperature = 190 °C

CO2 in flue gas = 12 %

The losses other than exhaust loss = 28%

 Ans.

Step – 1 Boiler Efficiency Calculation for Paddy Husk

Find theoretical air requirement

a) Theoretical air required for complete combustion

= { ( ( ))}
( 11.6× ∁ ) × 34.8 × H−
O2
8
+(4.35 × S)

100

{ (
( 11.6× 33.95 ) × 34.8 × 5.01−
8 )) }
( 32.52 +(4.35 ×0.09)

100
= 4.27 kg / kg of paddy husk

Find theoretical CO2 %

Moles of C
% CO2 at theoretical condition (CO2)t =
Moles of N 2+ Moles of C + Moles of S

Moles of N2 =
4.27 × ( 100
77
) + ( 0.00091
28 )
28
= 0.1178
 0.3395
12
% CO2 at theoretical condition (CO2)t =
0.1178+ (
0.3395
12
+ )(
0.0009
32 )
Max theoretical (CO2)t = 19.36 %

To find Excess Air supplied

Actual CO2 measured in flue gas = 12.0 %

b) % Excess air supplied = 7900 ׿ ¿

= 60.09 %

To find actual mass of air supplied

c) Actual mass of air supplied = {1 + EA/100} x theoretical air

= {1 + 60.09/100} x 4.27

= 6.83 kg/kg of coal

To find actual mass of dry flue gas

0.3395× 44 6.83 ×77 ( 6.83−4.27 ) ×23

Mass of dry flue gas = + 0.0091+ +
12 100 100

= 7.11 kg / kg of coal

m×C p × ( T f −T a )
% Heat loss in dry flue gas (L1) = ×100
GCV of fuel
7.11× 0.23× ( 190−32 )
= ×100
3568
L1 = 7.24 %

Losses other than exhaust loss = 28 %

Total losses = 35.24% Boiler efficiency = 100 – 35.24

= 64.76 %