DESIGN OF A DUMPING GRATE LOW PRESSURE BOILER

FOR SUGARCANE BAGGASSE

COURSE TITLE:
Combustion Reaction Engineering
COURSE CODE:
EE-313
SUBMITTED BY:
Abdullah Maqbool
EN-20E-14
SUBMITTED TO:
Dr. Syed Sheraz Dawood
SUBMITTED ON:
9th Jan,2023

___________________________________________________________________________

INSTITUTE OF ENERGY AND ENVIRONMENTAL ENGINEERING

UNIVERSITY OF THE PUNJAB, LAHORE PAKISTAN
 CONTENTS
ANALYSIS...........................................................................................................................................3
LOW-PRESSURE BOILER..................................................................................................................3
CALORIFIC VALUE........................................................................................................................4
DIFFERENT FUELS HAVE DIFFERENT COMPOSITION. BEING ON DIIFERENT
COMPOSITIONS WE USE FOLLOWING FORMULA TO CALCULATE MASS OF AIR..........4
MASS OF FLUE GASES..................................................................................................................4
FUEL REQUIRED TO GENERATE STEAM PER HOUR.............................................................5
Combustion Chamber Volume..........................................................................................................5
VOLUME OF GASES......................................................................................................................5
TEMPERATURE OF FLUE GASES................................................................................................5
SPECIFIC HEAT OF FLUE GASES................................................................................................6
HEAT CARRIED BY EACH FLUE GAS COMPONENT...............................................................6
ESTIMATION OF FURNACE TEMPERATURE............................................................................6
ADIABATIC FLAME TEMPERATURE.........................................................................................7
VOLUME OF GASES......................................................................................................................7
CAPACITY OF FEED WATER TANK...........................................................................................7
HEIGHT OF CHIMNEY...................................................................................................................8
BOILER HORSE POWER................................................................................................................8
ELECTRICITY.................................................................................................................................8
BOILER EFFICIENCY.....................................................................................................................9
TOTAL HEAT SUPPLIED BY BAGASSE..................................................................................9
POWER OF FANS REQUIRED.......................................................................................................9
AIR HEATER.................................................................................................................................10
CALCULATIONS...........................................................................................................................10
ECONOMIZER...............................................................................................................................11

ANALYSIS
ULTIMATE ANALYSIS
ELEMENTS COMPOSITION
 %

Carbon 35.4

Hydrogen 6.5

Oxygen 46

Nitrogen 0.18

Sulphur 0.23

90.31

PROXIMATE ANALYSIS
COMPONENTS COMPOSITION
%

Fixed Carbon 11.82

Volatile Matter 8.79

Ash 2.91

Moisture 48.03

Sugar Content 3

LOW-PRESSURE BOILER
 Steam Pressure = 25.6 bar

 Steam Temperature = 370oC

BASIS = 57 Ton Steam = 1,14,000 lb./hr

Per Hour

CALORIFIC VALUE
GROSS CALORIFIC VALUE NET CALORIFIC VALUE
AS GIVEN
9 × H 2 %+ M
NCV = GCV - 540 ( )
=2181 kcal/kg 1000
 =9125 kj/kg =1862.508 kcal/kg
=3923.044 BTU/lb. = 7792.733472 KJ/kg
= 3350.27234393809BTU/lb.
Where
 M = % Moisture Content in Baggasse = 48.03
https://www.energypurse.com/calorific-value-of-fuel-and-its-calculation/
DIFFERENT FUELS HAVE DIFFERENT COMPOSITION. BEING ON DIIFERENT
COMPOSITIONS WE USE FOLLOWING FORMULA TO CALCULATE MASS OF
AIR
mass air = ( 2.9978 k h−0.3747 k 0 + 0.3747 k s +k c ) × 11.445

where;
kh = Percentage Hydrogen in Fuel
kO = Percentage Oxygen in Fuel
kS = Percentage Sulphur in Fuel
kC = Percentage Carbon in Fuel
So;

mair = ( 2.9978 ×0.065−0.3747 ×0.46+ 0.3747 ×0.0023+0.35 ) ×11.445

mair = 4.27 kg
MASS OF FLUE GASES
mass flue=( 2.9978 k h−0.3747 k 0 + 0.3747 k s +k c ) × 11.445+(1−k ash )

where;
kh = Percentage of Hydrogen in Fuel
kO = Percentage of Oxygen in Fuel
kS = Percentage of Sulphur in Fuel
kC = Percentage of Carbon in Fuel
Kash = Percentage of Ash in Fuel

mass flue= ( 2.9978 ×0.065−0.3747 ×0.46+ 0.3747 ×0.0023+0.46 ) × 11.445+(1-0.0291)

= 5.18 kg
The present approach is applicable for all carbon-based fuels, especially biomass, fossil fuels
and fuel mixtures for co-combustion. Also, new formulation is given for average universal
gas constant of combustion products. The researchers, designers and engineers working in the
area of combustion or boiler

REFERENCE
 Coskun, C., Oktay, Z. U. H. A. L., & İlten, N. (2009). A new approach for simplifying the
calculation of flue gas specific heat and specific exergy value depending on fuel
composition. Energy, 34(11), 1898 1902.

FUEL REQUIRED TO GENERATE STEAM PER HOUR

steam mass ×(h g−hf )
Fuel Required =
GCV
57 ×(2801−640.81)
=
9125
= 13.5 ton/hr.
= 27000lb./hr.

REFERENCE
M. J. B. Kabeyi and O. A. Olanrewaju, "Preliminary Design of a Bagasse Based Firm Power Plant for a
Sugar Factory," 2021 Southern African Universities Power Engineering Conference/Robotics and
Mechatronics/Pattern Recognition Association of South Africa (SAUPEC/RobMech/PRASA), Potchefstroom,
South Africa, 2021, pp. 1-9, doi: 10.1109/SAUPEC/RobMech/PRASA52254.2021.9377242.
Combustion Chamber Volume
B×N
 V=
28,000
Where;
V = combustion chamber volume, in cu.ft.
B = weight of bagasse burned, in lb./h
N = N.C.V. of the bagasse, in B.Th.U./lb.
27000× 2801.243
=
28,000

= 2701.2 cu. ft.

= 76.5 m3(cu. meter)
VOLUME OF GASES
Vg = 71.3(1 — w) m + 9.17w+ 10.75
With w = 0.48 and m = 1.7:
Vg = 71.3 X (1-0.48) X 1.7 + 9.17 x 0.48 + 10.75
Vg= 81.8171 cu.ft./lb. bagasse
Vg = 2.31 m3
TEMPERATURE OF FLUE GASES
T
Vf = 0.773×ma× f
32
 81.8171× 32
Tf =
0.773 × 5.7
Tf =594oF
Tf = 312oC
SPECIFIC HEAT OF FLUE GASES
Cpc
CpFlue=
ac +b n+C h + d s

Where;
Cpc =0.203 Btu/lb. °F

0.203
CpFlue=
ac +b n+C h + d s
0.203
CpFlue=
0.2498+0.63660 .1196+0.0029
CpFlue= 0.20121 Btu/lb. °F
CpFlue= 0.836 KJ/kg oC
NOTE:(Reported value is 0.3 in hugot)

HEAT CARRIED BY EACH FLUE GAS COMPONENT

FLUE GAS FORMULA VALUE
COMPONEN
T
BTU/lb.
N2 QN = 4.42(1 — w) m x 0.250t 580.23

O2 QO = 1.33(1 — w) (m — 1) X 0.218t 62.6897

H2O QW = [0.585(1 — w) + w] 0.499t 232.4416
CO2 QC = 0.603(1 — w) x 0.215t 40.045

ESTIMATION OF FURNACE TEMPERATURE

The furnace temperature is measured with the aid of pyrometers or Seger cones. It may also
be estimated by eye with a certain degree of accuracy, particularly if the observer has trained
himself to compare his estimates with pyrometer readings. The color of the furnace is more
brilliant as the temperature increases.

COLOUR SCALE OF TEMPERATURE

Color o
C F
o

Dazzling white 1,500 2,700

Welding heat 1400 2500
White 1300 2400
 Straw yellow 1200 2200
Pale yellow 1150 2100
Golden yellow 1100 2000
Orange 1050 1900
Light cherry red 1000 1800
Cherry red 900 1650
Incipient cherry red 800 1500
Dark red 650 1200

ADIABATIC FLAME TEMPERATURE

The combustion temperature T prevailing in the bagasse furnace is readily calculated from
the fact that the heat developed in the combustion is recovered in the gases passing from the
furnace to the boiler.
Since the calorific value and all the heat quantities are expressed with reference to a basic
temperature of 25°C, it is necessary to take into account the heat already stored in the fuel
and in the combustion air, at an ambient temperature of t degrees.

NCV
Tadb= +25 oC
mt × C p
 NCV= net calorific value of fuel in kJ/kg
 mt = 6.6 kg
 Cp = specific heat of flue gases

7792.733472
Tadb= +25oC
6.6 × 0.836

Tadb=1437.341oC
https://gala.gre.ac.uk/id/eprint/12214/1/Doc-0566.pdf

VOLUME OF GASES
Vg = 71.3(1 — w) m + 9.17w+ 10.75
With w = 0.48 and m = 1.7:
Vg = 71.3 X (1-0.48) X 1.5 + 9.17 x 0.48 + 10.75
Vg= 80.119 cu.ft./lb. bagasse
Vg = 2.26 m3
CAPACITY OF FEED WATER TANK
c = 22C
c = capacity of the feed water tank, in imperial gallons
C = crushing rate of the factory, in t.c.h.
A factory of 1800 ton/hr. bagasse. should therefore have a feed tank of 39600 gallons’
capacity.

HEIGHT OF CHIMNEY

2×d
H= p ( 1 − b )
a
Ta Tc
2× 0.7
H= 1 1.05
14.69×( − )
459+77 459+594
H= 109.73ft
H= 33.45m
VELOCITY OF FLUE GASES
V= √(2gh)
IF H= 109.73 ft., g= 32.174 ft./s2
Then
V= 84.0292 ft./s
V= 33.445704 m/s
BOILER HORSE POWER
Steam generated Pound per hour
BHP=
34.5
 1,14,000
BHP =
34.5
BHP = 3304.3478
ELECTRICITY
3304.3478
KW =
0.10
3304.3478
KW =
0.10
KW = 33043.4783
https://www.rasmech.com/blog/boiler-formulas-and-other-useful-calculations/
BOILER EFFICIENCY
TOTAL HEAT SUPPLIED BY BAGASSE
0.50
Q= t(1-w) (1.4 m+ −0.12¿
1−w
 T= Flue stack temperature=312oC
 W=moisture =0.48
 Ratio of weight of actual air required for combustion to weight theoretically
necessary. Its value depends on the type of furnace used. For spreader stoker furnace,
the excess air required is 70 % of the theoretical air required. Its value is taken as 1.7.
So
0.50
Q= 312(1-0.48) (1.4 ×1.7 + −0.12 ¿
1−0.48
Q= 521.478 kcal/kg.
The quantity of remaining heat transferred to steam is given by the expression. (Hugot,
1986).
Mv = (4250 – 4850w - Q) α β γ
Where
α = Co-efficient representing heat loss due to un-burnt solids. For spreader stroker furnaces,
its normal value is taken as 0.975.
β = Co-efficient to account for heat losses by radiation. This value varies from 0.95 to 0.99
for more or less efficient lagging. Its value is taken as 0.97.
γ = Co-efficient of incomplete combustion. Its value is taken as 0.95.
Mv = Heat transferred to steam per pound of bagasse in kcal/kg
Substituting the values of w, s, q, α, β & γ
Mv = [4250-(4850 x 0.48) -521.478] x 0.975 x 0.97 x 0.95
= (4250- 2328-521.478) x 0.898
= 1400.522 x 0.898
= 1257.668 kcal/kg
Boiler efficiency = Mv / N.C.V
Boiler efficiency = 1257.668 / 1862.508
= 67%
POWER OF FANS REQUIRED
B × D ×(460+ t)
P=
435
 D= Draught
 t= gas temperature at suction in oF
 B= fuel rate
13.5× 2(460+594 )
P=
435
P= 65.421 h.p
AIR HEATER
We are given with given data:
 Crushing rate of factory = 250 ton/hr. = 500000 lb./hr.
 Weight of baggase = 661 lb./ton cane
 Moisture = 0.48
 Excess air used 70% m = 1.7
 Temperature of gases leaving the boiler = 594oF
 Temperature of ambient air = 100oC = 212 oF
 Temperature of hot air required = 152 oC = 305oC
CALCULATIONS
Volume of Gases
Pg.= 5.75(1-w) m+1
Pg.= 5.75(1-0.48) 1.7+1
Pg.= 6.083 lb./lb. bagasse
Total Volume of Gases
Pg. = 6.083×661×250
Pg.=1005215lb./hr.
Volume of air
Pa= 5.75(1-w) m
Pa= 5.75(1-0.48) 1.7
Pa= 5.083 lb. /lb. bagasse
Total Volume of air
= 5.083×661×250
= 839965.75 lb./hr.
a × P ×C
r=
p ×c
0.93× 1005215× 0.2
r=
29,273 × 0.24
r = 26.6
TEMPEARTURE OF FLUE GASES LEAVING THE AIR HEATER
t−¿
T=To -
r
257−212
T=594 -
26.6
T=592oF
SURFACE AREA
a × P ×C T −¿
S= ×2.3 log
K (r −1) ¿−t
T= flue gas leaving temperature =592oF
to= temperature of ambient air =212 oF
T0= flue gas entering temperature = 594 oF
t=temperature of air required = 305 oF
0.90 ×1005215 ×0.2 592−212
S= ×2.3 × ln ⁡( )
2(26.6−1) 594−305
S= 985.63 sq. ft.
S= 91.56802332 m2

ECONOMIZER
In the sugar factory, the boiler feed water is generally at a temperature of about 190°F. Now,
the saturation temperature at which the water should be fed into the boiler to be transformed
into steam varies, according to the pressure used, between 327°F (85 p.s.i.) and 455°F (427
p.s.i.). There is thus a large margin of temperature to be made up in the boiler. This margin
means that a substantial proportion of the total heat has to be supplied to the water before
evaporation proper commences.

α × P ×C T 0−t
S= × ln
K (1−r ) T −t 0

Where;
M = quantity of heat transmitted by the economizer in B.Th./h
a = coefficient < 1, generally between 0.90 and 0.95; frequently 0.93
P = weight of gas passing through the economizer, in lb./h
C = specific heat of the gases
 To = temperature of gases entering the economizer, in °F
T = temperature of gases leaving the economiser, in °F
p = weight of water to be heated, in lb./h
c = specific heat of the water = 1
to = temperature of water entering the economiser, in °F
t = temperature of water leaving the economiser, in °F
k = heat transfer coefficient for the economiser in B.Th./sq./h/°F, generally between
1.5 and 3, according to the degree of cleanness of the exterior of the tubes, the
velocity
of the water in the tubes and of the gases around the tubes, and the temperature of the
gases. As a mean value, we may take 2.
S = heating surface of the economiser, in sq. ft.
r = ratio:

Volume of Gases
Pg.= 5.75(1-w) m+1
Pg.= 5.75(1-0.48) 1.7+1
Pg.= 6.083 lb./lb. bagasse
Total Volume of Gases
Pg. = 6.083×661×250
Pg.=1005215lb./hr.
Volume of air
Pa= 5.75(1-w) m
Pa= 5.75(1-0.48) 1.7
Pa= 5.083 lb. /lb. bagasse
Total Volume of air
= 5.083×661×250
= 839965.75 lb./hr.
Value of r
t−¿
r=
¿−T
257−212
r=
581−329
r= 0.17
Surface Area Calculation
 a × P ×C T −¿
S= ×2.3 log
K (r −1) ¿−t
Where;
T=flue gas entering temperature=594oF=312.2 oC
to= feed temperature required =125oC =257 oF
To= flue gas leaving temperature = 165oC=329 oF
t= temperature of feed water = 100oC=212 oF
0.90 ×1005215 ×0.2 594−257
S= ×2.3 × ln ⁡( )
2(1−0.17) 329−212
S=115181.79 sq. ft.
S= 10700.738 m2