Energy Balance Analysis of A

Steam Generator

BY
P M V Subbarao
Associate Professor
Mechanical Engineering Department
I I T Delhi

A Criteria for performance Rating ……..

 First Law for SG:Steady State Steady Flow


Q CV W CV
 
m water m steam

m fuel
   
m air Q
m fluegas  m ash  m uc

 
m water  m steam
    
m fuel  m air  m fluegas  m ash  muc

Q CV   min   h  V 2  gz  in   m out   h  V 2  gz  out  W CV

   

in out
 First Law Analysis of Furnace:SSSF

Wfans
Qsteam
m fuel
  

m air Qloss
m fluegas  m ash  m uc

     
m fuel  m PA  m SA  m fluegas  m ash  m uc

Q steam  Q loss  m PA   h  V  gz  PA  m SA   h  V  gz  SA  m fuel   h  V 2  gz  fuel

    
2 2

 m fluegas   h  V  gz  fluegas  m Ash   h  V  gz  Ash  muc   h  V  gz  uc  W fans

   
2 2 2
 Some Valid Assumptions

• The role of a furnace is to promote combustion and generate high

enthalpy (Temperature) gas products.
• Not for accelerating or decelerating the fluid. ⇒ Vi = Ve
• Not for lifting or dropping the fluid. ⇒ Zi = Ze

• There is some amount of heat transferred to boiling water.

• The loss to the ambient should be minimum.

 First Law Analysis of Furnace:SSSF

Wfans
Qsteam
m fuel
  

m air Qloss
m fluegas  m ash  m uc

     
m fuel  m PA  m SA  m fluegas  m ash  m uc
    
Q steam  Q loss  m PA  hPA  m SA  hSA  m fuel  h fuel
   
 m fluegas  h fluegas  m Ash  hAsh  mUC  hUC  W fans
 Direct Method of SG Performance Analysis
• Energy balance:
• Fuel Energy = Steam Enthalpy + Losses.

Steam Enthalpy
Efficiency of Steam Generator 
Fuel Energy  Energy Credits

• Measurements:
– Steam Flow Rate
– Steam properties
– Fuel flow rate.
• Difficulties:
• Measurement of steam flow rate.
• Measurement of fuel flow rate.
• Errors in measurements.
 Performance Testing of SG

Air Flow Rate

Dry Flue gas Analysis

Ex. Gas Flow Rate

 Indirect Method of SG Performance Analysis

• For every 100 kg of Coal.

 Y K
C x H y S z Ok   4.76  X   Z   AIR
 4 2
 Moisture in Air

 P  CO2  Q  H 2O  R  SO2  T  N 2

 UO2  V  CO  W  C  Ash
But A gas analyzer measures dry volume percentages of individual
gases.
 Output of A Gas Analyzer
• Total Dry Exhaust gases: P +R + T + U + V kmols.
• Volume of gases is directly proportional to number of
moles.
• Volume fraction = mole fraction.
• Volume fraction of CO2 : x1

Number of moles of CO 2
x1  100
Total number of moles of dry gas

p
x1   100
p  R  T U V
 Output of A Gas Analyzer
• Volume fraction of CO2 : x1 = P * 100 /(P +R + T + U + V)
• Volume fraction of CO : x2= V * 100 /(P +R + T + U + V)
• Volume fraction of SO2 : x3= R * 100 /(P +R + T + U + V)
• Volume fraction of O2 : x4= U * 100 /(P +R + T + U + V)
• Volume fraction of N2 : x5= T * 100 /(P +R + T + U + V)

• These are dry gas volume fractions.

• Emission measurement devices indicate only Dry gas volume
fractions.
• Measurements:
• Volume flow rate of air.
• Volume flow rate of exhaust.
• Dry exhaust gas analysis.
• x1 +x2 +x3 + x4 + x5 = 100 or 1
• Ultimate analysis of coal.
• Combustible solid refuse.

nCXHYSZOK +n 4.76 (X+Y/4+Z-K/2) AIR +

Moisture in Air + Ash
→
x1 CO2 +x6 H2O +x3 SO2 + x5 N2 + x4 O2 + x2 CO + x7 C +
Ash
 Stoichiometry for 100 kmols of Exhaust Gas

nCXHYSZOK +n 4.76 (X+Y/4+Z-K/2) AIR + Moisture in Air + Ash & Moisture
in fuel → x1 CO2 +x6 H2O +x3 SO2 + x5 N2 + x4 O2 + x2 CO + x7 C + Ash
•x1, x2,x3, x4 &x5 : These are dry volume fractions or percentages.
•Conservation species:
•Conservation of Carbon: nX = x1+x2+x7
•Conservation of Hydrogen: nY = 2 x6
•Conservation of Oxygen : nK + 2 n (X+Y/4+Z-K/2) = 2x1 +x2 +2x3 +2x4+x6
•Conservation of Nitrogen:  n 3.76 (X+Y/4+Z-K/2) = x5
•Conservation of Sulfur: nZ = x3
 nCXHYSZOK +n 4.76 (X+Y/4+Z-K/2) AIR + Moisture in
Air + Ash & Moisture in fuel → x1 CO2 +x6 H2O +x3 SO2 +
x5 N2 + x4 O2 + x2 CO + x7 C + Ash
• Re arranging the terms (Divide throughout by n):
CXHYSZOK + 4.76 (X+Y/4+Z-K/2) AIR + Moisture in Air +
Ash & Moisture in fuel → (x1 /n)CO2 +(x6/n) H2O +(x3/n)
SO2 + (x5/n) N2 + (x4/n) O2 + (x2/n) CO + (x7/n) C
+ Ash

CXHYSZOK + 4.76 (X+Y/4+Z-K/2) AIR + Moisture in Air +

Ash Moisture in fuel
→ P CO2 +Q H2O +R SO2 + T N2 + U O2 + V CO + W C +
Ash
 Specific Flue Gas Analysis

• For each kilogram of fuel:

• Air :  4.76 (X+Y/2+Z-K/2) * 29.9 /100kg.
• CO2 : P * 44/100 kg.
• CO : V * 28/100 kg.
• Oxygen in exhaust : 32 * U/100 kg.
• Unburned carbon: 12*12/100 kg.
 Various Energy Losses in A SG

• Heat loss from furnace surface.

• Unburned carbon losses.
• Incomplete combustion losses.
• Loss due to hot ash.
• Loss due to moisture in air.
• Loss due to moisture in fuel.
• Loss due to combustion generated moisture.
• Dry Exhaust Gas Losses.
 •Loss due to moisture in air.
Heat gained by boiling water •Loss due to moisture in fuel.
40% •Loss due to combustion
Fuel Energy generated moisture.

100% •Dry Exhaust Gas Losses

Hot gas •~ 4.5%

Flue gas

•Heat loss from furnace surface.

Heat gained by
•Unburned carbon losses. superheater & reheater
•Incomplete combustion losses. 40%

•Loss due to hot ash.

Heat gained by economizer &
air preheater
12%
 Energy Credits

• Chemical Energy in the fuel.

• Energy credit supplied by sensible heat in entering air (recycling of
energy).
• Energy credit supplied by sensible heat in the fuel(Recycling of
energy).
• Energy credit supplied by auxiliary drives.
 Furnace Energy Balance
• First Law for Furnace in SSSF Mode (in molar form):
    
Q steam  Q loss  n PA  hPA  n SA  hSA  n fuel  h fuel
   
 n fluegas  h fluegas  n Ash  hAsh  nUC  hUC  W fans

Wfans
Qsteam
n fuel

n fluegas
n air Qfans
 Dry Exhaust Gas Losses

• As gasses are leaving at temperature higher than ambient

temperature.
• For 100 kg of fuel.
• QDEGL =  n fluegas hfluegas

• QDEGL = n CO2 hCO2 + n CO hCO + n O2 hO2 + n N2 hN2 + n SO2 hSO2 kJ.

• QDEGL = P hCO2 + R hSO2 + T hN2 + U hO2 + V hCO kJ.

• Alternate method:
• Total number of moles of dry exhaust gas nex.gas = P+R+T+U+V
• QDEGL = nex. Gas Cp,exgas (Tex.gas - Tatm)
• Cp.exgas = 30.6 kJ/kmol. K
• Typical value of DEGL ~ 4.5%
 Accurate Calculation of Gas Enthalpy

• For any gas

dh  c p dT

SGexit Texit

h   dh   c
ambient Tamb
p (T )dT
 Properties of Gases
2 3
T  T   T 
c p  C0  C1  C2    C3   kJ / kgK
1000  1000   1000 
Gas C0 C1 C2 C3

Air 1.05 -0.365 0.85 -0.39

Methane 1.2 3.25 0.75 -0.71
CO2 0.45 1.67 -1.27 0.39
Steam 1.79 0.107 0.586 -0.20
O2 0.88 -0.0001 0.54 -0.33
N2 1.11 -0.48 0.96 -0.42
 Unburned carbon losses.

• For 100 kg of fuel

• QUCL = W * MC * Calorific Value of Carbon : kJ

• QUCL = W * 12 * 33820 kJ.

 Incomplete combustion losses

• For 100 kg of fuel:

• QICL = V * MCO * CV of CO. kJ.

• QICL = V * 28 * 23717 kJ.

 Loss due to moisture in Combustion air

• For 100 kg of fuel:

• QMCAL =  4.76 (X+Y/2+Z-K/2) * 29.9 *  * Csteam * (Tg – 25) kJ

• Where  is absolute or specific humidity : kg of moisture per kg of

dry air.
• Csteam is the specific heat of steam at constant pressure.
• Tg is the temperature of exhaust gas.
 Losses due to moisture in fuel & combustion generated
moisture.

• For 100 kg of fuel:

• QML = ( M +9* Y) {2442 + Csteam * (Tg – 25) } kJ.

• M is the moisture content in the fuel, %.

• Y is the combustible hydrogen atoms in the fuel.

 Loss due to hot ash or Slag

• For 100 kg of fuel

• QASL = A * Cp,ash * Tash

• Where Cp.ash, is the specific heat of ash, 0.5 – 0.6 kJ/kg K.

• Tash is the temperature of the ash or slag.

• Tash = Varies from 300 to 800 oC

 Heat loss from furnace surface

• Loss due to Surface Radiation and Convection.

• QRCL = As ( hs) (Tsurface - Tamb) kW

• As = Total surface area, m2

• hs = Surface heat transfer coefficient.

• For 100 kg of fuel:

• Rate of heat loss/fuel flow rate * 100

Off Design Performance
 % HEAT LOSS IN BOILER

6 FUEL MOIST LOSS

%LOSS

4 HYDROGRN LOSS
2 DRY FLUE LOSS

0
1 2 3 4
 TYPICAL ACTUAL BOILER
EFFICIENCY VS DESIGN EFFICIENCY

88
87
86
85 ACTUAL BOILER
EFFICIENCY
84
DESIGN BOILER
83 EFFICIENCY
82
1 2
%BOILER 3
EFFICIENCY 4