Boiler Efficiency Calculation.xls 4c40q
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RELIANCE JAMNAGAR RPCTEFH - SHEET-1 of 5 PROCEDURE FOR CALCULATION OF THERMAL EFFICIENCY OF FIRED HEATERS THERMAL EFFICIENCY OF FIRED HEATER ENUMERATED BELOW IS BASED ON API 560 Definitions: Thermal efficiency is defined as total heat absorbed divided by the total heat input. Total heat absorbed is equal to the total heat input minus the total heat losses. Total heat input is equal to the sum of the net heat of combustion of the fuel ( LHV ) and the sum of sensible heat of the air, fuel and atomising medium to the system. In case of steam Air Preaheating, it also includes heat input in steam for such purpose. Total heat losses are equal to the sum of radiation heat loss and stack heat loss. Radiation heat loss is a defined percentage of the net heat of combustion of the fuel Stack heat loss is the total sensible heat of the flue gas components at the temperature of flue gas when it leaves the last heat exchange surface. Sensible heat correction is the sensible heat differential at test temperature when compared with a datum temperature of 60deg. F ( 16deg C ) for air, fuel, and the atomising medium. { for steam as an atomising medium, the datum enthalpy is 1087.7 Btu / l EFFICIENCY = (TOTAL HEAT INPUT - TOTAL HEAT LOSSES ) / ( TOTAL HEAT INPUT ) * 100 Further details on the same are given in the API, a copy of which is being sent along with this communication.
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 2 of 5 PROCEDURE TO USE THE WORKSHEET The following steps to be followed while using the worksheet. 1. Go to Tools ---> Options ----> Calculation; Select iteration. Input Maximum iterations 100 and Maximum Change 0.001. Select Manual calculation 2. Fuel Oil and Fule Gas composition to be entered in "FUEL_DETAILS" sheet. Also enter LHV of Fuel Oil in the same sheet. 3. If O2 composition of stack is available on wet basis pl. use "EFF_CALCULATION_WET_BASIS" sheet, if it is available on dry basis then use "EFF_CALCULATION_DRY_BASIS" sheet. 4. Input data in column "C" only in sheets "EFF_CALCULATION_WET_BASIS" or "EFF_CALCULATION_WET_BASIS" 5. After entering all the input data, Press F9 OR SAVE the file to refresh calculations.
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 3 of 5 FUEL COMPOSITION INPUT SHEET Fuel Oil Fuel Composition C= H= LHV (Kcal/kg)
wt%
87.00% 13.00% 10000
Fuel Gas Component
Composition
Nitrogen
6.10%
28
0
0.0000
0.0000
H2O
0.00%
18
0
0.0000
0.0000
0
H2S
0.00%
34
0
0.0000
0.0000
123810
NH3
0.00%
17
0
0.0000
0.0000
67744
CO2
0.60%
44
0
0.0060
0.0000
0
Hydrogen
23.80%
2
0.119
0.0000
0.2380
57796
methane
36.60%
16
0.732
0.3660
0.7320
191760
ethylene
10.20%
28
0.306
0.2040
0.2040
316190
ethane
18.10%
30
0.6335
0.3620
0.5430
341260
propane
1.80%
44
0.09
0.0540
0.0720
488520
propylene
0.00%
42
0
0.0000
0.0000
460430
iC4
0.00%
58
0
0.0000
0.0000
633040
iC4=
0.00%
56
0
0.0000
0.0000
603350
nC4=
0.00%
56
0
0.0000
0.0000
607370
nC4
0.90%
58
0.0585
0.0360
0.0450
635040
cis-2-C4=
0.00%
56
0
0.0000
0.0000
605730
trans-2-C4=
0.00%
56
0
0.0000
0.0000
604730
iC5
0.00%
72
0
0.0000
0.0000
780130
nC5
0.00%
72
0
0.0000
0.0000
782050
0.00%
68
0
0.0000
0.0000
468290
C6+
0.00%
78
0
0.0000
0.0000
928950
17.90
1.94
1.03
1.83
MW
O2 req. (Kgmol/hr)
CO2 gen (Kgmol/hr)
H2O gen (Kgmol/hr)
LHV
(Kcal/kgmol)
98.10%
0
10750 Kcal/kg
Note: Please input your data in "B" Column only Rest all data is calculated by Excel.
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 4 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON WET BASIS) CALCULATED DATA WITH DIAGRAM AIR INPUT
OUTPUT
1
FO Firing rate (Kg/hr)
3496
Fired Duty (MMKcal/hr)
35.0
2
FG Firing rate (Kg/hr)
0
Sencible Heat Input ex FO (MMKcal/hr)
Heat Input ex Pilot Gas (MMKcal/hr)
0.15 0.11 0.01 0.00
RADIATION LOSS
200.0 30 60.0%
Total Heat Input (MMKcal/hr)
35.2
Qr (MMKcal/hr) =
0.026 1.50% 31.0
1. Through Flue Gas (MMKcal/hr) 2. Through Radiation Loss (MMKcal/hr)
2.93 0.52
Total
3.5
Total Heat Absorbed (MMKcal/hr)
31.79
Heat Input ex Atomising Steam (MMKcal/hr) Heat Input ex Steam Air Preheating (MMKcal/hr)
3
Mol. % O2 in Flue Gas (Wet Basis)
4
Stack Temp. (oC)
5 6
Ambient Temp. (oC) Relative Humidity of Air
7
Moles Water Vap./ Moles Dry Air
8
Radiation loss (percent of heat released)
9
Air inlet temp. after steam heater
10
Atomizing Steam flow (TPH)
11 12
Pilot Gas flow (kg/hr)
13
Fuel Oil Sp. Heat. (Kcal/kg/0K)
14
Enthalpy of Atomising Steam (Kcal/kg)
2.60
, av., (Air) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
6.96 7.94
STACK
Steam APH
O2 =
0.52
Total Loss
M (Kgmol/hr) (Dry)
2032.7
H2O (V) (Kgmol/hr)
52.8
Enthalpy of air (MMKcal/hr)
0.01
N2 =
31.0
Fuel Oil Inlet Temp. ( C)
1.8 0.0 120 0.48 673
Thermal Efficiency ( h ) =
90.20%
Excess Air Used =
16.3%
Flue Gas Composition
Mole %
CO2 =
11.02%
O2 = N2 = H2O =
2.60% 69.84% 16.53%
H2O
200.0
Mol% 11.02% 2.60%
Kgmol/hr 253.5 59.8
69.84% 16.53% 100.00%
1605.8 380.1 2299.1
Stack
Combustion APH
Heat Loss through Stack
PROCESS FLUID IN
o
CO2 =
FIRED HEATER
1. Through Dry Flue Gas (kcal/hr)
2400145
2. Through Water Vap. (kca/hr)
527734
Total (MMKcal/hr)
2.93
, av., (CO2) (Kca/0K,Kgmole) , av., (O2) (Kca/0K,Kgmole)
9.75 7.19 6.99 8.17
, av., (N2) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
PROCESS FLUID OUT Fuel Gas Heat Supplied ex Fuel Gas (MMKcal/hr)
0.00
FUEL OIL C= H= M (kg/hr) = Cal. Value (Kcal/kg) Heat Supplied ex Fuel Oil (MMKcal/hr)
wt%
Kg/hr
87.00% 13.00% 3496.00 10000 34.96
3041.5 454.5
AIR
Note: 1. Please input your data in "C" Column only 2. Ambient Temp. use as datum temp. for simplification of calculation
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 5 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON DRY BASIS) CALCULATED DATA WITH DIAGRAM AIR INPUT
OUTPUT
1
FO Firing rate (Kg/hr)
4000
Fired Duty (MMKcal/hr)
104.5
2
FG Firing rate (Kg/hr)
6000
Sencible Heat Input ex FO (MMKcal/hr)
Heat Input ex Pilot Gas (MMKcal/hr)
0.08 0.16 3.47 0.23
RADIATION LOSS
184.0 30 60.0%
Total Heat Input (MMKcal/hr)
108.4
Qr (MMKcal/hr) =
0.026 2.50% 109.0
1. Through Flue Gas (MMKcal/hr) 2. Through Radiation Loss (MMKcal/hr)
7.79 2.61
Total
10.4
Total Heat Absorbed (MMKcal/hr)
98.0
Heat Input ex Atomising Steam (MMKcal/hr) Heat Input ex Steam Air Preheating (MMKcal/hr)
3
Mol. % O2 in Flue Gas (Wet Basis)
4
Stack Temp. (oC)
5 6
Ambient Temp. (oC) Relative Humidity of Air
7
Moles Water Vap./ Moles Dry Air
8
Radiation loss (percent of heat released)
9
Air inlet temp. after steam heater
10
Atomizing Steam flow (TPH)
11 12
Pilot Gas flow (kg/hr)
13
Fuel Oil Sp. Heat. (Kcal/kg/0K)
14
Enthalpy of Atomising Steam (Kcal/kg)
3.68
, av., (Air) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
7.01 8.05
STACK
Steam APH
O2 =
2.61
Total Loss
M (Kgmol/hr) (Dry)
6084.2
H2O (V) (Kgmol/hr)
158.2
Enthalpy of air (MMKcal/hr)
3.47
N2 =
109.0
Fuel Oil Inlet Temp. ( C)
2.2 21.1 70 0.48 683
Thermal Efficiency ( h ) =
90.4%
Excess Air Used =
19.4%
Flue Gas Composition
Mole %
CO2 =
11.23%
O2 = N2 = H2O =
3.68% 85.09% 0.00%
Mol% 11.23% 3.68%
Kgmol/hr 634.5 207.9
85.09% 100.00%
4806.5 5648.9 1155.0
H2O
184.0
Stack
Combustion APH
Heat Loss through Stack
PROCESS FLUID IN
o
CO2 =
FIRED HEATER
1. Through Dry Flue Gas (kcal/hr)
6339413
2. Through Water Vap. (kca/hr)
1448942
Total (MMKcal/hr)
7.79
, av., (CO2) (Kca/0K,Kgmole) , av., (O2) (Kca/0K,Kgmole)
9.69 7.17 6.97 8.15
, av., (N2) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
PROCESS FLUID OUT Fuel Gas Heat Supplied ex Fuel Gas (MMKcal/hr)
64.50
FUEL OIL C= H= M (kg/hr) = Cal. Value (Kcal/kg) Heat Supplied ex Fuel Oil (MMKcal/hr)
wt%
Kg/hr
87.00% 13.00% 4000.00 10000 40.00
3480.0 520.0
AIR
Note: 1. Please input your data in "C" Column only 2. Ambient Temp. use as datum temp. for simplification of calculation
Confidential - Property of Reliance
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 2 of 5 PROCEDURE TO USE THE WORKSHEET The following steps to be followed while using the worksheet. 1. Go to Tools ---> Options ----> Calculation; Select iteration. Input Maximum iterations 100 and Maximum Change 0.001. Select Manual calculation 2. Fuel Oil and Fule Gas composition to be entered in "FUEL_DETAILS" sheet. Also enter LHV of Fuel Oil in the same sheet. 3. If O2 composition of stack is available on wet basis pl. use "EFF_CALCULATION_WET_BASIS" sheet, if it is available on dry basis then use "EFF_CALCULATION_DRY_BASIS" sheet. 4. Input data in column "C" only in sheets "EFF_CALCULATION_WET_BASIS" or "EFF_CALCULATION_WET_BASIS" 5. After entering all the input data, Press F9 OR SAVE the file to refresh calculations.
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 3 of 5 FUEL COMPOSITION INPUT SHEET Fuel Oil Fuel Composition C= H= LHV (Kcal/kg)
wt%
87.00% 13.00% 10000
Fuel Gas Component
Composition
Nitrogen
6.10%
28
0
0.0000
0.0000
H2O
0.00%
18
0
0.0000
0.0000
0
H2S
0.00%
34
0
0.0000
0.0000
123810
NH3
0.00%
17
0
0.0000
0.0000
67744
CO2
0.60%
44
0
0.0060
0.0000
0
Hydrogen
23.80%
2
0.119
0.0000
0.2380
57796
methane
36.60%
16
0.732
0.3660
0.7320
191760
ethylene
10.20%
28
0.306
0.2040
0.2040
316190
ethane
18.10%
30
0.6335
0.3620
0.5430
341260
propane
1.80%
44
0.09
0.0540
0.0720
488520
propylene
0.00%
42
0
0.0000
0.0000
460430
iC4
0.00%
58
0
0.0000
0.0000
633040
iC4=
0.00%
56
0
0.0000
0.0000
603350
nC4=
0.00%
56
0
0.0000
0.0000
607370
nC4
0.90%
58
0.0585
0.0360
0.0450
635040
cis-2-C4=
0.00%
56
0
0.0000
0.0000
605730
trans-2-C4=
0.00%
56
0
0.0000
0.0000
604730
iC5
0.00%
72
0
0.0000
0.0000
780130
nC5
0.00%
72
0
0.0000
0.0000
782050
0.00%
68
0
0.0000
0.0000
468290
C6+
0.00%
78
0
0.0000
0.0000
928950
17.90
1.94
1.03
1.83
MW
O2 req. (Kgmol/hr)
CO2 gen (Kgmol/hr)
H2O gen (Kgmol/hr)
LHV
(Kcal/kgmol)
98.10%
0
10750 Kcal/kg
Note: Please input your data in "B" Column only Rest all data is calculated by Excel.
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 4 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON WET BASIS) CALCULATED DATA WITH DIAGRAM AIR INPUT
OUTPUT
1
FO Firing rate (Kg/hr)
3496
Fired Duty (MMKcal/hr)
35.0
2
FG Firing rate (Kg/hr)
0
Sencible Heat Input ex FO (MMKcal/hr)
Heat Input ex Pilot Gas (MMKcal/hr)
0.15 0.11 0.01 0.00
RADIATION LOSS
200.0 30 60.0%
Total Heat Input (MMKcal/hr)
35.2
Qr (MMKcal/hr) =
0.026 1.50% 31.0
1. Through Flue Gas (MMKcal/hr) 2. Through Radiation Loss (MMKcal/hr)
2.93 0.52
Total
3.5
Total Heat Absorbed (MMKcal/hr)
31.79
Heat Input ex Atomising Steam (MMKcal/hr) Heat Input ex Steam Air Preheating (MMKcal/hr)
3
Mol. % O2 in Flue Gas (Wet Basis)
4
Stack Temp. (oC)
5 6
Ambient Temp. (oC) Relative Humidity of Air
7
Moles Water Vap./ Moles Dry Air
8
Radiation loss (percent of heat released)
9
Air inlet temp. after steam heater
10
Atomizing Steam flow (TPH)
11 12
Pilot Gas flow (kg/hr)
13
Fuel Oil Sp. Heat. (Kcal/kg/0K)
14
Enthalpy of Atomising Steam (Kcal/kg)
2.60
, av., (Air) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
6.96 7.94
STACK
Steam APH
O2 =
0.52
Total Loss
M (Kgmol/hr) (Dry)
2032.7
H2O (V) (Kgmol/hr)
52.8
Enthalpy of air (MMKcal/hr)
0.01
N2 =
31.0
Fuel Oil Inlet Temp. ( C)
1.8 0.0 120 0.48 673
Thermal Efficiency ( h ) =
90.20%
Excess Air Used =
16.3%
Flue Gas Composition
Mole %
CO2 =
11.02%
O2 = N2 = H2O =
2.60% 69.84% 16.53%
H2O
200.0
Mol% 11.02% 2.60%
Kgmol/hr 253.5 59.8
69.84% 16.53% 100.00%
1605.8 380.1 2299.1
Stack
Combustion APH
Heat Loss through Stack
PROCESS FLUID IN
o
CO2 =
FIRED HEATER
1. Through Dry Flue Gas (kcal/hr)
2400145
2. Through Water Vap. (kca/hr)
527734
Total (MMKcal/hr)
2.93
, av., (CO2) (Kca/0K,Kgmole) , av., (O2) (Kca/0K,Kgmole)
9.75 7.19 6.99 8.17
, av., (N2) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
PROCESS FLUID OUT Fuel Gas Heat Supplied ex Fuel Gas (MMKcal/hr)
0.00
FUEL OIL C= H= M (kg/hr) = Cal. Value (Kcal/kg) Heat Supplied ex Fuel Oil (MMKcal/hr)
wt%
Kg/hr
87.00% 13.00% 3496.00 10000 34.96
3041.5 454.5
AIR
Note: 1. Please input your data in "C" Column only 2. Ambient Temp. use as datum temp. for simplification of calculation
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 5 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON DRY BASIS) CALCULATED DATA WITH DIAGRAM AIR INPUT
OUTPUT
1
FO Firing rate (Kg/hr)
4000
Fired Duty (MMKcal/hr)
104.5
2
FG Firing rate (Kg/hr)
6000
Sencible Heat Input ex FO (MMKcal/hr)
Heat Input ex Pilot Gas (MMKcal/hr)
0.08 0.16 3.47 0.23
RADIATION LOSS
184.0 30 60.0%
Total Heat Input (MMKcal/hr)
108.4
Qr (MMKcal/hr) =
0.026 2.50% 109.0
1. Through Flue Gas (MMKcal/hr) 2. Through Radiation Loss (MMKcal/hr)
7.79 2.61
Total
10.4
Total Heat Absorbed (MMKcal/hr)
98.0
Heat Input ex Atomising Steam (MMKcal/hr) Heat Input ex Steam Air Preheating (MMKcal/hr)
3
Mol. % O2 in Flue Gas (Wet Basis)
4
Stack Temp. (oC)
5 6
Ambient Temp. (oC) Relative Humidity of Air
7
Moles Water Vap./ Moles Dry Air
8
Radiation loss (percent of heat released)
9
Air inlet temp. after steam heater
10
Atomizing Steam flow (TPH)
11 12
Pilot Gas flow (kg/hr)
13
Fuel Oil Sp. Heat. (Kcal/kg/0K)
14
Enthalpy of Atomising Steam (Kcal/kg)
3.68
, av., (Air) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
7.01 8.05
STACK
Steam APH
O2 =
2.61
Total Loss
M (Kgmol/hr) (Dry)
6084.2
H2O (V) (Kgmol/hr)
158.2
Enthalpy of air (MMKcal/hr)
3.47
N2 =
109.0
Fuel Oil Inlet Temp. ( C)
2.2 21.1 70 0.48 683
Thermal Efficiency ( h ) =
90.4%
Excess Air Used =
19.4%
Flue Gas Composition
Mole %
CO2 =
11.23%
O2 = N2 = H2O =
3.68% 85.09% 0.00%
Mol% 11.23% 3.68%
Kgmol/hr 634.5 207.9
85.09% 100.00%
4806.5 5648.9 1155.0
H2O
184.0
Stack
Combustion APH
Heat Loss through Stack
PROCESS FLUID IN
o
CO2 =
FIRED HEATER
1. Through Dry Flue Gas (kcal/hr)
6339413
2. Through Water Vap. (kca/hr)
1448942
Total (MMKcal/hr)
7.79
, av., (CO2) (Kca/0K,Kgmole) , av., (O2) (Kca/0K,Kgmole)
9.69 7.17 6.97 8.15
, av., (N2) (Kca/0K,Kgmole) , av., (H2O) (Kca/0K,Kgmole)
PROCESS FLUID OUT Fuel Gas Heat Supplied ex Fuel Gas (MMKcal/hr)
64.50
FUEL OIL C= H= M (kg/hr) = Cal. Value (Kcal/kg) Heat Supplied ex Fuel Oil (MMKcal/hr)
wt%
Kg/hr
87.00% 13.00% 4000.00 10000 40.00
3480.0 520.0
AIR
Note: 1. Please input your data in "C" Column only 2. Ambient Temp. use as datum temp. for simplification of calculation
Confidential - Property of Reliance
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