PROBLEM I

A waste heat recovery boiler is being considered to recover 50% of heat from
the exhaust of a diesel engine. Other data are as follows:

Fuel: C12H23

Excess air: 30%

Air conditions: 1 atm pressure, 28C

Fuel conditions: 102 kPa pressure and 26C

Exhaust gas temperature: 400C

Specific heat of gases: 0.255 kcal/kg- C

Brake thermal efficiency: 35%

Temperature of jacket water (used as boiler feedwater): 70C

Steam generated: 300 kPa, dry and saturated

Mass of steam generated: 450 kg/hr

Boiler efficiency: 65%

Generator efficiency: 95%

Determine:

a. The actual air-fuel ratio

b. The volumetric analysis of dry flue gas (in %)
c. The dew point temperature of water in the product (C)
d. The amount of fuel supplied (in kg/hr)
e. The overall thermal efficiency (in %)

Solution:
a. The actual air-fuel ratio
From actual combustion equation
Fuel + air product of combustion
C12H23 + (1.3)aO2 + (1.3)3.76aN2bCO2 + cH2O + 0.3aO2 +
(1.3)3.76aN2
Balancing:
Carbon: 12 = b; b = 12 moles
Hydrogen: 23 = 2c; c = 11.5 moles
Oxygen: 2(1.3)a = 2b + c + 2(0.3)a ; a = 17.75 moles

Then,
C12H23 + 23.075 O2 + 86.762N212 CO2 + 11.5 H2O + 5.325 O2 +
86.762 N2

A m air N MW air
Actual = = air
F mfuel N Fuel MW Fuel
Where,
Nair = 23.075 + 86.762 = 109.837 moles
MWair = 28.97 kg air/mol air
Nfuel = 1 mole
MWfuel = (12 x 12) + (23 x 1)
MWfuel = 167 kg fuel / mol fuel

A 109.837(28.97)
Actual =
F 1(167)

A kg air
Actual =19.054
F kg fuel

b. Volumetric Analysis of dry flue gas (in %)

From the actual combustion equation for dry flue gas,
NTdg = 12 + 5.325 + 86.762 = 104.087 moles

N CO 12 mol C O2
CO 2= x 100 =
2
x 100 =11.529 %C O2
N Tdg 104.087 mol flue gas

NO 5.325 mol O 2
O 2= 2
x 100 = x 100 =5.116 O2
N Tdg 104.087 mol flue gas
 NN 86.762mol N 2
N 2= 2
x 100 = x 100 =83.355 N 2
N Tdg 104.087 mol flue gas

c. The dew point temperature of water in the product (C)

t dp=t sat @ P H O 2

NH
PH O =P flue gas
2 ( 2

N Flue gas
O
)
where ,
N H O =11.5 moles
2

N Flue gas=115.587 moles

Using PT = 101.325 kpa

11.5
PH O =101.325 kPa
2 ( 115.587 )=10.081kPa
t dp=t sat at 10.081kPa

t dp=45.96

d. The amount of fuel supplied (in kg/hr)

ms( hs hfw )
bo Q3 p

Q3 p=0.50 ( Q 3 )

ms( hs hfw )
bo
0.50Q 3

where;
hs = hg @ 300 kPa = 2725.30 kj/kg
hf = hf @ 70C = 292.96 kj/kg
ms = 450 kg/hr

450(2725.3292.96)
0.65 0.50Q3
 kJ
Q3=3 367 855.4
hr
kJ
Q3=935.5154
sec
Btu
Qh=13 500 C+60 890 H ,
lb
Ultimate analysis of fuel:
12 mol C 12 kg C 144 kg C mol fuel kg C
Carbon: x = x =0.86228
mol fuel mol C mol fuel 167 kg fuel kg fuel

23 mol H 1kg H 23 kg H mol fuel kg H

Hydrogen: x = x =0.13772
mol fuel mol H mol fuel 167 kg fuel kg fuel

Qh=[ 13 500 ( 0.86228 ) +60 890(0.13772) ] x 2.326275 kJ/kg

kJ
Qh=46 587.264
kg
Q3 a=m d g c p g ( t gt f )

Q3 b=mv ( 1066+0.5 t g t f ) 2.326275 ,kJ / kg t g >575

t g=400 =752
t f =70 =158

Q3=Q3 a +Q3 b
Q3=mdg c pg ( t g t f ) +mv ( 1066+0.5 t gt f ) (2.326275)
mdg=mwg mv

mwg = ( FA +1)=( 19.054+1) m = (20.054 ) (m )

f f

mv =( 9 H 2 ) ( mf )=( 9 )( 0.13772 ) ( mf ) =( 1.239 ) ( mf )

Q3=( mwg m v ) ( c pg ) ( t gt f ) +mv ( 1066 +0.5 t gt f ) (2.326275)

( mf ) ( 20.0541.239 ) ( c pg )( t gt f ) + ( mf ) ( 1.239 ) ( 1066+0.5 t gt f ) ( 2.326275 )

 ( mf ) ( 18.815 ) ( c pg ) ( t gt f ) + ( mf ) ( 1.239 ) ( 1066+0.5 t gt f ) (2.326275 )
substituting the values :
kJ kcal 4.187 kJ
935.5154
s (
=( m f ) ( 18.815 ) 0.255
kg
x
1 kcal )
( 400 70 )+ ( mf ) ( 1.239 ) ( 1066+0.5 ( 752 )1

kJ kJ kJ
935.5154
s (
=m f 6629.203
kg )
+mf ( 3700.815 )
kg
kg 3600 s
mf =0.09056 x
s 1 hr
kg
mf =326.016
hr

e. The overall thermal efficiency (in %)

G .O
tho =
mf ( HV )
B.P
thb =
mf HV
B . P=( thb ) ( m f HV )

kg kJ
(
B . P=( 0.35 ) 326.016
hr )(
46587.264
kg )
kJ
B . P=5315867.711
hr

G. O=gen ( B . P )

kJ
(
G. O= ( 0.95 ) 5315867.711
hr )
kJ
G. O=5 050 074.326
hr
Thus,
kJ
5 050 074.326
hr
tho = x 100
326.016 kg kJ
( hr )(
46 587.264
kg )
 tho =33.25

PROBLEM II
A certain boiler under test gives the following:
Steam is delivered at 2.0 MPa and 280 C
Feedwater temperature is 70 C
Water fed to boiler is 60,000 kg/hr
Boiler efficiency is 85%
The ultimate analysis of the coal, % by weight:
C = 77.37 % N2 = 1.83 % A = 4.39 %
H2 = 5.43 % S = 1.22 % O2 = 9.76 %
Dry flue gas analysis: 12.0 % CO2; 0.94 %CO; 6.06 % O2; 81.0 % N2
Room temperature is 30 C
Percent excess air is 30 %
Stack gas temperature is 330 C
Specific heat of stack gas is 1.026 kJ/kgC

Determine:
a. The developed boiler horsepower (in bo. hp)
b. The amount of coal fired in the boiler (in kg/hr)
c. The amount of refuse removed from the ashpit (in kg/hr)
d. The heat loss due to evaporating and superheating moisture in fuel
and moisture formed by combustion of hydrogen (in kJ/sec)
e. The heat carried away by dry flue gases or combustion dry products
(in kJ/sec)

Solutiion:

a. Finding boiler horsepower

 ms ( h shf )
Bo . hp=
kJ /hr
35322
Bo . hp

Where:
h s=h @2.0 MPa280
kJ
h s=2975.084
kg
h f =h f @70
h f =292.96 kJ /kg

Then,

60 000 kg /hr ( 2975.084292.96 ) kJ /kg

Bo . hp=
kJ / hr
35322
Bo . hp

Bo . hp=4556.0116 Bo . hp

b. The amount of coal fired in the boiler

ms ( h shf )
bo . =
mf ( HV )

O
HV =33 820C +144212 H ( 8 )
+9304 S

0.0976
(
HV =33 820 ( 0.7737 ) +144212 0.0543
8 )
+ 9304 ( 0.0122 )

HV =32351.368 kJ /kg

60 000 kg /hr ( 2975.084292.96 ) kJ /kg

0.85=
mf ( 32 351.368 kJ /kg )

kg
mf =5852.1915
hr
c. The amount of refuse removed from the ashpit (in kg/hr)
Finding c:
N2
A
actual =3.03 c '
F (
CO2 +CO )
A A
actual =theo. ( 1+e )
F F
Where:

A O
theo.
F (
=11.5 C+ 34.5 H +4.31 S
8 )
A 0.0976
theo.
F (
=11.5 ( 0.7737 ) +34.5 0.0543
8 )
+ 4.31 ( 0.0122 )

A kg air
theo. =10.4
F kg fuel

A
actual =10.4 ( 1+0.30 ) =13.52
F

Then,

N2
actual
A
F
=3.03 c ' (
CO2 +CO )
13.52=3.03 c ' ( 12+810.94 )
c ' =0.7128

c ' =ccu
0.7128=0.7737cu

kg c
c u=0.0609
kg fuel
 kg
c u=0.0609 ( 5852.1915 )=356.4
hr

c u=m Rm ash

kg
356.4 =m R0.0439(5852.1915)
hr

kg
mR =613.311
hr

d. The heat loss due to evaporating and superheating moisture in fuel and
moisture formed by combustion of hydrogen

Q3 b=9 H 2 ( 1066+0.5 t gt f ) ( 2.326275 )

kg H 5852.1915 kg coal
(
Q3 b=9 0.0543
kg coal
x
hr )
( 1066+ 0.5 ( 626 )88 ) ( 2.326275 )

kJ 1 hr
Q3 b=8 589 109.98 x
hr 3600 s
Q3 b=2 385.864 kJ / sec
e. The heat carried away by dry flue gases or combustion dry products

Q3 a=mdg c pdg ( t gt a )

mdg=19.425 c ' =19.425 ( 0.7128 )

kg c kg coal 1hr
mdg=13.846 x 5852.1915 x
kg coal hr 3600 s

mdg=22.508 kg /s

Q3 a=22.508 kg /s ( 1.026 kJ /kg )( 33030 )

Q3 a=6 927.9624 kJ /s
PROBLEM III
The percentage volumetric composition of a natural gas is as follows:
CH4 = 60 % C2H6 = 37.5 %
N2 = 2.0 % CO2 = 0.5 %
The volume flow rate of fuel-gas supplied to the furnace is 20 m 3 per min and
30 % excess air is required for complete combustion. Air at 1 atm pressure and 29C
is used for combustion. The exhaust gas temperature is 340 C and has a specific
heat of 0.256 kcal/kgC. If the conditions of fuel-gas are 105 kPa and 27C.
Determine:
a. The actual air-fuel ratio
b. The volumetric analysis of dry flue gas (in %)
c. The percent of carbon and hydrogen in the fuel on a mass basis
d. The heat loss due to evaporating and superheating moisture formed by
combustion of hydrogen (in kJ/sec)
e. The heat carried away by dry flue gases or combustion dry products (in
kJ/sec)

Solution:
Given:
Volumetric analysis:
CH4 = 60 % C2H6 = 37.5 %
N2 = 2.0 % CO2 = 0.5 %
3
Vf = 20 m /min
e = 30 %
ta = 29 C ; Pa = 101.325 kPa
tg = 340 C
cp = 0.256 kcal/kgC x kj/kcal = 1.072 kJ/kgC
tfuel = 27 C
Pfuel = 105 kPa

a. Actual air-fuel ratio

Fuel + air product of combustion
0.6 CH 4 +0.375 C2 H 6 +0.02 N 2+ 0.005CO 2 +0.3 a O 2+ 3 ( 3.76 a N 2) bC O 2 +c H 2 O+0.3 a O2 +1.3 ( 3.

Balancing:

Carbon: 0.6 + 2(0.375) + 0.005 = b ; b = 1.355 moles

Hydrogen: 4(0.6) + 6(0.375) = 2c ; c = 2.325 moles

Nitrogen: 2(0.02) + 2(1.3)(3.76)(a) = 1.3(3.75)a + 2(0.002)

Oxygen: 2(1.3)a + 2(0.005) = 2b + c + 2(0.3)a ; a = 2.5125 moles

Actual combustion equation:

 0.6 C H 4 + 0.375C 2 H 6 + 0.02 N 2 +0.005 C O2 +3.267 O2+12.284 N 2 1.355C O2 +2.325 H 2 O+12.284

MW fuel =0.6 ( 16 ) +0.375 ( 30 ) +0.02 ( 28 ) +0.005 ( 44 )

kg fuel
MW fuel =21.63
mol fuel

N air =3.267+12.284=15.551

Then,

A mair
Actual =
F mfuel

A 15.551( 28.97)
Actual =
F 1(21.63)

A kg air
Actual =20.828
F kg fuel

b. Volumetric Analysis of dry flue gas

N Tdg=1.355+ 0.754+12.304=14.413 moles

1.355 mol C O 2
%C O2= x 100
14.413 mol flue gas
%C O2=9.401 C O2

0.754 mol O 2
O 2= x 100
14.413 mol flue gas

O2=5.23 O2

12.304 mol N 2
N 2= x 100
14.413 mol flue gas
N 2=85.367 N 2

c. Percent Carbon and Hydrogen

 0.6 (12 ) +0.375 ( 24 ) +0.005 ( 12 )
Carbon: x 100 =75.173
21.63

0.6 ( 4 )+ 0.375 ( 6 )
Hydrogen: x 100 =21.498
21.63

d. Q3 b=?

Q3 b=9 H 2 ( 1066+0.5 t gt f ) ( 2.326275 ) kJ /kg , since t g >575

kg H
(
Q3 b=9 0.21498
kg Fuel )
x mf ( 1066+0.5 t gt f ) ( 2.326275 )

For mf:
Pf V f
mf =
Rf T f

Where;
R 8.3143 kJ
Rf = = =0.384
MW 21.63 kg

m 3 1min m3
V f =20 x =0.333
min 60 sec sec

Then,

(105 )( 0.333 )
mf =
0.384 (300.15 )
kg
mf =0.303
sec

kgH kg fuel kJ
(
Q3 b=9 0.21498
kg fuel
x 0.303
sec )
[ 1066+0.5 ( 644 )80.6 ](2.326275)
kg

kJ
Q3 b=1783
sec
e. Q3 a=?
Q3 a=mdg c pdg ( t gt a )
mdg=mw mv
mw =mair +mfuel

mw =mfuel ( AF + 1)
mw =0.303 ( 20.828+1 )
kg
mw =6.614
sec

kg H 0.303 kg fuel
(
mv =9 H 2=9 0.21498
kg fuel
x
sec )
kg H
mv =0.586
sec
mdg=6.6140.586
kg
mdg=6.028
sec

kg kJ
Q3 a=6.028
sec (
1.072
kg )
( 34029 )

kg
Q3 a=2009.447
sec
PROBLEM IV

The following coal has the following ultimate analysis by weight:

C=70.5% H2=4.5% O2=6.0% M=4%

S=3.0% A=11% N2=1.0%

A water tube boiler of 175000 kg/hr steaming capacity uses the above coal as fuel. The
boiler efficiency is 70% and the factor of evaporation is 1.2. the air supplied to the boiler is at
1atm and 27C with 30% excess air. The feedwater enters the boiler at 5 MPa and 120C and th
steam leaves at the same pressure. If the boiler percent rating is 200%, calculate:

a) The developed boiler horsepower (in bo.hp)

b) The rated boiler horsepower (in bo.hp)
c) The boiler heating surface (in m2)
d) The volume of air (in m3/min)
e) The temperature of the superheated steam leaving the boiler (in C)
f) The equivalent specific evaporation (in kgsteam/ kgfuel)

Solution:

hf=h @ 5MPa and 120C =507.09 kJ/kg

2257(FE)=hs- hfw

hs- hfw= 2257(1.2)=2708.4 kJ/kg

a.) Developed Bo.hp = ms(hs-hf)/35322

kg
175,000 ( 3151.12507.09 ) kJ /kg
hr
= kJ
hr
35322
Bo . hp
175000(2708.4)
= 35322
 Developed Bo.hp = 13418.55 Bo.hp

b.) Rated boiler hp

Dev . Bo. hp
Percent Rating = Rated Bo. hp

Rated boiler hp = 13418.549/ 2.0 = 6,709.2745 Bo.hp

c.) Hs=?

H.S= Rated Bo.hp x 0.91

H.S= 6709.2745 x 0.91

H.S= 6105.44 m2

d.) Va= maRTa/Pa

FE= (hs-hf)/2257

1.2 = (hs-492.72)/2257

hs=3215.49 kJ/kg

theo A/F =11.5C +34.5(H O/8)+ 4.31 S

theo A/F =11.5(0.705) +34.5(0.045 0.06/8)+ 4.31(0.03)

theo A/F =9.531 kg air/kg fuel

actual A/F = theo A/F (1+e)

actual A/F = 9.531 (1+0.3)

actual A/F = 12.39 kg air/kg fuel

From Dylongs Formula

HV=33820H+144212(H- O/8)+9304 S

HV=33820(0.705)+144212(0.045- 0.06/8)+9304 (0.03)

 HV=29,530.17 kJ/kg

ms ( hshf ) 175,000 ( 2708.4 )

BO= ( mf ( HV ) ;0.7 = mf ( 29530.17 )

mf =23,929.09252 kg/hr x (1hr/3600s)

mf=6.3692 kg/sec

then;

ma=(A/F) (mf) =12.39(6.3692)

ma=78.9144 kg/sec

Va=( 78.9144)(0.287)(300.15)/(101.3250

Va=67.09 m3/sec =4,025.4 m3/min

a.) ths = t @ 5MPa and 3151.12 kJ/kg

From steam table: @ 5MPa

h t

3145.9 380

3151.12 t

3171.0 390

t=408.2116 C

b.) eq. Sp. Evap. = (ms/ mf) x F.E

=(175,000/23,929.09252) (1.2)

eq. Sp. Evap. =8.776 kg steam/kg fuel