HEAT BALANCE - BOILER

UNIT - 5

Prabir Basu

Output Efficiency Input

Heat losses 1 fuel heat input + heat credits

Heat distribution in a power plant

HEAT FLOW IN A BOILER

Heat given to steam in a boiler

Heat delivered to water = m (Hsteam Hfeed)

where Hsteam = Enthalpy of superheated steam (kJ/kg) Hfeed = Enthalpy of feed water (kJ/kg) m = amount of water produced from all sources

HEAT BALANCE

HEAT INPUT = HEAT UTILIZATION +LOSSES Q = Q1+ Q2+ Q3+ Q4+ Q5+ Q6 Q = Available heat of fuel Q1= Heat utilized by steam and water Q2 = heat lost through stack gas Q3= Incomplete combustion (CO,CH4 H2 ) Q4 = Unburned carbon Q5 = Loss from boiler surfaces Q6 = sensible heat in ash

Components of Heat Input, Q

Lower heating value (LHV) Sensible heat of fuel (CfTf) Sensible heat of air [ Hb- Ha)] Heat of fuel atomizing steam [Gas(Has-2500)]

HEAT LOSS COMPONENTS

Flue gas loss, Q2= [(IgQ4/Q)] Incomplete combustion of gas, Q3= [Vg(126 CO+108H2+358CH4)x(1 Q4/Q)] Heat loss due to unburned carbon, Q4 = 32866(GbaCba+GfaCfa) Heat loss due to surface radiation & convection, Q5=Fs(hc+hr)(Tsb-T0)

CONVECTION-RADIATION LOSS (Q5)

Other losses

Moisture in sorbents = LqXmHg kJ/kg Calcination losses = LqXcaco31183 kJ/kg Moisture loss in fuels = mfHg kJ/kg Moisture loss in air = Af Xair Hg kJ/kg Loss in hydrogen burning = 9H Hg kJ/kg Sulfation credit = 15141 so2S kJ/kg Unburnt carbon loss in ash = 32790 XcWa Dry flue gas = Wg Hg

HEAT BALANCE (PC & CFB) - I

ITEM
Moisture in limestone Calcination Sulfation Unburnt C Dry flue gas Fuel H2O H2O from H2

PC %

CFB % GOOD 0.06

1.02 -1.6 0.5 5.57 1.03 4.19

CFB % WORST 0.1

1.69 -1.69 2 5.6 1.03 4.19

0.25 5.28 1.03 4.16

HEAT BALANCE (PC & CFB)-ii

ITEM Surface loss H2O in air PC 0.03 0.13 CFB 0.3 0.14 0.09 CFB 0.8 0.14 0.76

Ash sensible heat 0.03 Bottom ash 0.05

Fan & Mill credit

TOTAL LOSS

-.45
10.81

-.075
10.55

-0.40
14.31

LOSSES FROM A CFB BOILER

Component Cyclone loop seal Loss (kW) 482 Area (m2) 1241 Surface temp.( C) 89

Combustor Drum & piping PA Duct Air heater Conv. Pass & SA duct

394 173 134 111 47

1804 1355 1610 1408 537

43 67 56 51 58

Heat losses (from CFB Boiler-Basu)

Calcination loss Feed rate of CaCO 1830 100 CaCO3 Fuel feed rate HHV Feed rate of MgCO 1183 100 MgCO3 (6.3)
3
3

(6.2)

Fuel feed rate

sor

HHV

Sulfation credit

S 15141 100 HHV

c

(6.5)

Unburnt carbon loss Dry flue gas loss =

Wa

32790 100 , HHV

f

(6.6)

Ma

100

HHV

(6.7)

Hf is difference in enthalpy of steam at flue gas temperature and that of water at ambient condition

Losses

Moisture loss from fuel

Hf is difference in enthalpy of steam at flue gas temperature and that of water at ambient condn

= (Mf Hf 100)/HHV

From air = (Ma Xm Hf 100)/HHV From hydrogen burning = 9HxHf x100/HHV FD fan credit = - (Power consumed)/(Mc HHV) Sensible heat in ash =

[Ash] xb( Tba-T0)+(1-xb)(Tfa-T0)

Problem

A boiler fires 250 kg pure Methane per hour using dry air with 20% excess air. Higher heating value is 54865 kJ/kg Find the volumetric capacity of the combustion air fan and induced draft fan for the boiler if the air handled by these fans are at 27 C and 127 C respectively Find the efficiency of the boiler assuming complete combustion neglecting air preheating, surface heat loss 1%

Problem II

Nova Scotia Power Corporation is considering cofiring in their Trenton plant (150 Mwe) which fires coal. The co-firing unit is an external hot gas generator capable of generating 3 MWth heat. This hot gas will be fed into the boiler. This unit will have surface heat loss as per the worst case scenario in a CFB boiler. Using required data from sources Find the reduction in CO2 emission Savings in fuel cost Effect on thermal efficiency of the main boiler

Fuel
Fuel HHV (Dry basis) Moisture Volatiles C H O N S Cl Ash Unit MJ/kg Wt% Wt% DAF Coal 24.65 7 66 56.59 4.21 5.69 0.9 4.99 0.4 20.6 Waste wood 20.14 14.2 79.1 49 5.9 40.7 2.5 0.05 0.03 1.9

Price (C$ per ton wet fuel)

Waste wood - $7/ton +$10/ton/100 km Whole tree chip - $45/ ton delivered Moisture = 45-55% Heating value 8200-8500 BTU/dry lb fuel Price of imported coal in Point Tupper $35$65 (av.$50/ton) Heat rate: 7400 kJ/kWh Ca/S ratio = 2.0 for 90% capture