SRI SAI PUMPS AND ENERGY SYSTEMS (P) LTD

Administrative Office: House No. 5/11, Ist Main Road, A-1, Raja Colony,Trichy-620001
Email: marketin@saienergy.com, web site: www.saienergy.com Phone: 0431 - 4040085

Date: 10.12.2014

To
M/s.DALMIA CEMENT BHARAT LIMITED
Dalmiapuram,
Trichy – 621 651.

Kind Attn: Mr.A.L.Nachiappan / Senior General Manager

Sub: Submission of Establishing 100% Petcoke firing performance study report

-Reg.
Dear Sir,

We thank you very much for placing order on us for Establishing 100% Petcoke firing
at your 1 x 27 MW Captive Power plant at Ariyalur. Based on our trial run and Lab
analysis report received, we are submitting the detailed performance report
(Volume-II) for your kind reference.

We hope the same is in line with your requirement.

We assure our best services in the years to come.

Thanking you,

Yours faithfully,
For SRI SAI PUMPS AND ENERGY SYSTEMS (P) LTD

P.Thangaraju
Director
0 93451 87085
 ESTABLISHING 100 %PET COKE FIRING

PERFORMANCE REPORT

at
DALMIA CEMENT (B) LTD
1 X 27 MW CAPTIVE POWER PLANT
ARIALUR, TAMILNADU

Volume -II

August, 2014
 

Study conducted by
 

SRI SAI PUMPS AND ENERGY SYSTEMS (P) LTD

No. 5/11, Ist Main Road, A-1, Raja Colony, Cantonment, Trichy-620001.
Email: info@saienergy.com  web site: www.saienergy.com
Introduction
M/s. Dalmia Cement Bharat Limited has awarded a contract for trials at their 1 X 120 TPH CFBC Boiler to
assess the capability of firing pet coke on a full 100% capacity. Accordingly a team of five members from M/s.
SPEL, Tiruchirapalli reached site on 22.07.2014 and met Mr. Nandakumar (Sr.Manager/CPP) and discussed the
procedure and action plan for pet coke firing in the CFBC Boiler which is designed for 100 % Lignite firing.
The modality and action plan was readily accepted and it was decided to start pet coke firing from the next day
itself. The test was conducted for next 20days and the details of tests and observations were already submitted
to M/s Dalmia Cements (Bharat) Ltd. vide volume-I dated 19.08.14.
Subsequent to the same, the sample analyses were obtained for fuel and ash and the thermal efficiency
calculations were made. The same is attached in this volume-II for records.

Plant Details

1 x 27 MW Captive Power Plant

Plant Details Boiler 1 x 125 TPH CFBC Boiler
Turbine 1 x 27 MW
Place Ariyalur, Tamilnadu.

Customer Name M/s. Dalmia Cement Bharat Ltd.

Boiler Make M/s. ISGEC Heavy Engineering Ltd.

Boiler Type CFBC Boiler

Designed Fuel Lignite, Indian coal and Imported coal

Boiler Thermal Efficiency Calculation:

Boiler PG test
calculation
Project : M/s Dalmia Cements LTD - Ariyalur Annexure -1

DATE OF TEST 07.08.14

100% TMCR
SL.NO DURATION ----
TEST -1
LOAD 22 MW
 ENTHALPHY CALCULATIONS

1 DRY AIR

Hk=(C0+C1*Tk+C2*Tk^2+C3*Tk^3+C4*Tk^4+C5*Tk^5)*2323.7,Tk IN K

C0 -0.1310658X10^3

C1 +0.458130X10^0

C2 -0.107503X10^(-3)

C3 +0.1778848X10^(-6)

C4 -0.9248664X10^(-10)

C5 +0.1682031X10^(-13)

T °C 196.00

Tk K 469.15

HkDRY AIR J/kg 173056.63

T °C 37.00

Tk K 310.15

Hk DRY GAS J/kg 12040.78

2 WATER VAPOUR

Hk=(C0+C1*Tk+C2*Tk^2+C3*Tk^3+C4*Tk^4+C5*Tk^5)*2323.7,Tk IN K

C0 -0.2394034X10^3

C1 +0.8274589X10^0

C2 -0.1797539X10^(-3)

C3 +0.3934614X10^(-6)

C4 -0.2415873X10^(-9)

C5 +0.6069264X10^(-13)
 T °C 196.00

Tk K 469.15

HWV J/kg 324248.36

T °C 37.00

Tk K 310.15

HWV J/kg 22352.34

3 DRY FLUE GAS

Hk=(C0+C1*Tk+C2*Tk^2+C3*Tk^3+C4*Tk^4+C5*Tk^5)*2323.7,Tk IN K

C0 -0.1231899X10^3

C1 +0.4065568X10^0

C2 0.5795050X10^(-5)

C3 +0.6331121X10^(-7)

C4 -0.2924434X10^(-10)

C5 +0.2491009X10^(-14)

T °C 149.00

Tk K 422.15

Hk DRY FG J/kg 123942.49

ENTHALPHY CALCULATIONS

4 RESIDUE

Hk=(C0+C1*Tk+C2*Tk^2+C3*Tk^3+C4*Tk^4+C5*Tk^5)*2323.7,Tk IN K

C0 -0.3230338X10^2

C1 -0.2431404X10^0
 C2 +0.1787701X10^(-2)

C3 -0.2598230X10^(-5)

C4 +0.2054892X10^(-8)

C5 -0.6366886X10^(-12)

T °C 149.00

Tk K 422.15

Hr J/kg 104330.43

T °C 37.00

Tk K 310.15

Hr J/kg 9112.67

5 COAL

Hcoal=MFrFc*HFc+MFrVm1*HVm1+MFrVm2*HVm2+MFrWF*HW+MFrAsF

MFrFc=mass fraction of fixed carbon, kg/kg coal as fired 0.85

MfrAsF=mass fraction of ash , kg/kg coal as fired 0.01

MfrWF=mass fraction of water(moisture), kg/kg coal as fired 0.04

MfrVm=mass fraction of volatile matter, kg/kg coal as fired 0.10

MfrVmCr=mass fraction of volatile matter on a dry and kg/kg
ash free basis, Coal ,dry -ash free
kg/kg fuel dry -ash
MfrVmCr=MFrVm/(1-MFrAsF-MFrWF), 0.10
free
MfrVm1=mass fraction of primary volatile matter. kg/kg coal as fired

MfrVm2=mass fraction of secondry volatile matter. kg/kg coal as fired

if MfrVmCr is greater than 0.10 ,then

 MfrVm2=0.10*(1-MfrAsF-MfrWF) 0.09

MfrVm1=MFrVm-MFrVm2 0.00

if MFrVmCr is less than 0.10 ,then

MfrVm2=MfrVm 0.10

MfrVm1=0 0.00

Ta Ambient temp,°C 36.88

Tf Ambient temp,°F 98.38

Hfc=(0.152*T+1.95*10^(-4)*T^2-12.860)*2323.7 ,J/kg J/kg 9252.63

Hvm1=(0.38*T+2.25*10^(-4)*T^2-30.594)*2323.7,J/kg J/kg 20843.10

Hvm2=(0.70*T+1.70*10^(-4)*T^2-54.908)*2323.7,J/kg J/kg 36264.36

Hrs=(0.17*T+0.80*10^(-4)*T^2-13.564)*2323.7,J/kg J/kg 9145.23

HW=(T-77)*2323.7,J/kg J/kg 49690.00

Hcoal J/kg 13313.43

8 Steam /water at partial pr of 1 psia

Enthalpy of steam/water at 1 psia(j/kg)

Hst=(0.4329Tf+3.958E-5 Tf^2+1062.2)*2323.7 , Tf in
°F
T °C 149.00

Tf °F 300.20

Hst J/kg 2778502.77

UNBURNED CARBON ,REDIDUE & SORBENT CALCULATIONS

[1] Ash in fuel % 1.40

Coal GCV Kcal/kg 8110.00

[2] Coal GCV 33955.79

KJ/kg
[3] Fuel mass flow rate T/hr 9.50

[4]

[5a] Furnace a bottom(FB)

[6a] Unburnt carbon (FB) % 1.63

[7a] Residue distribution(FB) % 20.00

[8a] Unburnt carbon in FB Kg/100 kg of ash 0.33

[8a]=[6a]*[7a]/100

[5b] Air preheater ash(APHA)

[6b] Unburnt carbon (APHA) % 2.18

[7b] Residue distribution(APHA) % 5.00

[8b] Unburnt carbon in (APHA) Kg/100 kg of ash 0.11

[8b]=[6b]*[7b]/100

[5c] ECO Ash (ECOA)

[6c] Unburned carbon (ECOA) % 3.16

[7c] Residue distribution(ECOA) % 5.00

[8c] Unburnt carbon in (ECOA) Kg/100 kg of ash 0.16

[5d] Fly ash (FA)

[6d] Unburnt carbon (FA) % 5.24

[7d] Residue distribution(FA) % 70.00

[8d] Unburnt carbon in (FA) Kg/100 kg of ash 3.67

[8c]=[6c]*[7c]/100

[9f] Total unburnt carbon Kg/100 kg of ash 4.26

9f=8a+8b+8c

1 Fuel flow T/hr 9.50

2 Sorbent flow T/hr 2.30

3 Sorbent / Fuel ratio kg/kg 0.24

10(c)=10(b)/10(a)

4 Carbon in residue % 4.26

5 CO2 in residue % 0.00

6 Moisture in air kg/kg Dry air 0.03

7 So2 Flue gas ppm 2800.00

8 O2 flue gas % 4.90

15 Fuel ultimate analysis

[15a] Carbon % mass 84.03

[15b] Unburnt carbon in ash % mass 0.69

[15c] Carbon burnt % mass 83.34

[15c]=[15]a-[15]b

[15d] Sulphur % mass 5.67

[15e] Hydrogen % mass 3.54

[15f] Moisture in air % mass 3.70

[15g] Vapour Moisture % mass 0.00

[15h] Nitrogen % mass 1.04

[15i] Oxygen % mass 0.62

[15j] Ash % mass 1.40

UNBURNED CARBON ,RESIDUE & SORBENT CALCULATIONS

Theoretical air

Theoretical air of carbon kg of air/kg of carbon 11.51

kg of air /100 kg of
[16c] Theoretical air of carbon 959.24
coal
[16c]=[15c]*Tc

Theoretical air for sulphur kg of air/kg of sulphur 4.31

kg of air /100 kg of
[16d] Theoretical air for sulphur 24.44
coal
[16d]=[15d]*Ts
kg of air/kg of
Theoretical air for hydrogen 34.29
hydrogen
kg of air /100 kg of
[16e] Theoretical air for hydrogen 121.39
coal
[16e]=[15e]*Th

Theoretical air for oxygen kg of air/kg of oxygen -4.32

kg of air /100 kg of
[16i] Theoretical air for oxygen -2.68
coal
kg of air /100 kg of
Theoretical air for fuel 1102.39
coal
Ta=[16c]+[16d]+[16e]+[16i]

Dry product
 Molecular mass of carbon ,Mc Mol/kg of carbon 12.01

[17c] Dry product carbon burnt Mol/100 kg of coal 6.94

[17c]=[15c]/Mc

Molecular mass of sulphur ,Ms Mol/kg of sulphur 32.07

[17d] Dry product sulphur burnt Mol/100 kg of coal 0.18

[17d]=[15d]/Ms

Molecular mass of nitrogen ,Mn Mol/kg of nitrogen 28.01

[17h] Dry product nitrogen burnt Mol/100 kg of coal 0.04

[17h]=[15h]/Mn

[17] Total Dry product

[17]=[17c]+[17d]+[17h] Mol/100 kg of coal 7.15

Wet product

Molecular mass of hydrogen Mol/kg of hydrogen 2.02

[18e] Wet product due to hydrogen Mol/100 kg of coal 1.76

[18e]=[15e]/Mh

Molecular mass of water Mol/kg of moisture 18.02

[18f] Wet product due to moisture Mol/100 kg of coal 0.21

[18f]=[15f]/Mm

Molecular mass of water vapour Mol/kg of moisture v 18.02

[18g] Wet product due to moisture vapour Mol/100 kg of coal 0.00

[18g]=[15g]/Mmv
[18] Total wet product Mol/100 kg of coal 1.96

[18]=[18e]+[18f]+[18g]

[20] Sorbent product

[20a] caco3 % mass 80.00

[20b] ca(OH)2 % mass 0.00

[20c] mgco3 % mass 1.50

[20d] Mg(OH)2 % mass 0.00

[20e] H2O % mass 5.00

[20f] INERT % mass 13.50

[22I] Total ca Mol/100 kg sorb 1.09

[25I] CO2 produced Kg/100 kg sorb 35.96

[26I] H2O produced Kg/100 kg sorb 5.78

UNBURNED CARBON ,RESIDUE & SORBENT CALCULATIONS

Sulphur capture Dry basis

30 Moisture in air kg/kg of dry air 0.00

31 Additional moisture 0.00

32 Products combustion of fuel mol/100 kg of fuel 7.15

33 H2O sorb 0.08

34 CO2 sorb 0.20

3X25I/44.01

35 (0.7905+[30])x[16]/28.963 30.09
36 Summation [31] thru [35] 37.52

37 1.0-(1.0+[30])x[8]/20.95 0.77

38 (0.7905+[30])2.387-1 0.89

39 [7b]x[36]/[17D]/[37] 77.54

40 [38]x[7B]/[37] 0.32

45 Sulphur capture kg/kg sulphur 0.22

(100-39)/(100+40)

47 SO3 formed kg/100 kg of fuel 3.17

45x17dx80.064

48 Spent sorbent kg/100 kg of fuel 17.27

[47]+(100-[25I]-[26I]X[3]

49 Unburned carbon kg/100 kg of fuel 0.83

([48]+[15J])x[4]/(100-[4])

50 Residue rate kg/100 kg of fuel 19.50

[49]+[48]+[15J]

51 Calcination kg/kg of Caco3 1.00

1-[50]x0.0227/[20A]/[3]

52 Ca/s ratio mol ca /mol s 1.50

[3]x[22I]x32.0646/[15D]

60 Reference temperature °C 25.00

60a Enthalpy of water kJ/kg 104.67

61 Sorbent temperature °C 36.88

61a Enthalpy of sorbent J/kg 10280

T °C 36.88

Tf °F 98.38
MfrH2OSb=mass fraction of water in sorbent, kg/kg of
kg/kg 0.01
sorbent
Hcc=0.179T+0.1128E-3T2-14.45 Btu/lbm 4.25

Hsb=((1-MFrH2OSb)Hcc+MfrH2OSb(T-77))*2323.7 J/kg 10280

62 Avg exit gas tem °C 149.00

63 Enthalpy of steam J/kg 2778503

64 HHV of fuel kj/kg 33956

losses

65 Water from sorbent J/hr 368197542.0

[2]x[26]x([62A]-[60A])x10

Calcination / Dehydration

71 caco3 J/hr 3278880000

[20a] x 1x [2] x 1782 x10000

72 ca(OH)2 J/hr 0.00

[20b] x 1.0x [2] x 1480 x10000

73 mgco3 J/hr 52336500

[20c] x 1.0x [2] x 1517 x10000

74 Mg(OH)2 J/hr 0.00

[20d] x 1.0x [2] x 1455 x10000

 77 Summation J/hr 3331216500

UNBURNED CARBON ,RESIDUE & SORBENT CALCULATIONS

Credits

80 Sulfation % 0.59

3740.55x[45]x[15d]/[63]

85 sensible heat from sorbent J/hr 23643513

[2]x[61a]x1000

[11] Unburnt carbon Kg/100 kg of coal 0.83

From 49

[20] Total residue Kg/100 kg of coal 19.50

From 50

[21] Total residue T/hr 1.85

[21]=([20]/100)*[3]

[22] Total residue kg/1000kj 0.01

[21]=[20]/100*[2]*1000

[23] Sensible heat in residue

[23a] Furnace

Residue temperature °C 980.0

[24a] Residue temperature °F 1796.0

[25a] Residue quantity Kg/10^3 kj 0.00

[25a]=[22]*[7a]/100

[26a] Residue enthalpy J/kg 1071926

 [26a]=2323.7*(0.16*[24a]+1.09*10^(-4)*([24a])^2-2.843*10^(-8)*([24a])^3-
12.95
[27a] Loss percentage % 0.12

[27a]=[26a]*[25a]*100/1000000

[23b] Air preheater

Residue temperature °C 149.00

[24b] Residue temperature °F 300.20

[25b] Residue quantity Kg/10^3 KJ 0.00029

[25b]=[22]*[7b]/100

[26b] Residue enthalpy J/kg 102559

[26b]=2323.7*(0.16*[24b]+1.09*10^(-4)*([24b])^2-2.843*10^(-8)*([24b])^3-
12.95
[27b] Loss percentage % 0.0029

[27b]=[26b]*[25b]*100/1000000

[23d] Fly ash

Residue temperature °C 149.00

[24d] Residue temperature °F 300.20

[25d] Residue quantity Kg/10^3 KJ 0.00

[25d]=[22]*[7d]/100

[26d] Residue enthalpy J/kg 102559

[26d]=2323.7*(0.16*[24d]+1.09*10^(-4)*([24d])^2-2.843*10^(-8)*([24d])^3-
12.95
[27d] Loss percentage % 0.041

[27d]=[26d]*[25d]*100/1000000

[28] Total sensible loss due to residue % 0.17

 [28]=[27a]+[27b]+[27c]+[27d]

UNIT OUTPUT CALCULATIONS

1 Feed water flow T/hr 103.30

2 Feed water temp °C 215.00

3 Feed water pressure, abs kg/cm2,abs 127.00

4 Feed water specific enthalpy Kcal/kg 220.70

5 Feed water specific enthalpy KJ/kg 924.06

6 Feed water enthalpy KJ/hr 95455402

7 SH spray flow T/hr 4.20

8 SH spray temp °C 215.00

9 SH spray pressure ,abs kg/cm2,abs 127.00

10 SH spray specific enthalpy Kcal/kg 247.34

11 SH spray specific enthalpy KJ/kg 1035.59

12 SH spray enthalpy KJ/hr 4349472

13 Main steam flow T/hr 107.50

14 Main steam temp °C 533.80

15 Main steam pressure ,abs kg/cm2,abs 108.80

16 Main steam specific enthalpy Kcal/kg 824.99

17 Main steam specific enthalpy KJ/kg 3454.16

18 Main steam enthalpy KJ/hr 371321899

 37 Total unit output KJ/hr 271517025

COMBUSTION CALCULATION

[1] HHV of fuel,as fired KJ/kg 33956

[2] UBC – unburnt carbon Kg/100 kg of coal 0.83

[3] Fuel flow T/hr 9.50

[5] Output KJ/hr 271517025

[6] Fuel efficiency estimated % 90.25

[7] Moisture in air kg/kg of dry air 0.03

[9] Dry bulb temp °C 36.88

[10] Wet bulb temp °C 26.69

[11] Relative humidity % 51.00

Additional moisture

[12] Atomising steam kg/hr 0.0

[12a] Soot blowing steam kg/hr 0.0

[12] Summation of additional moisture kg/hr 0.0

12=12a+12b

[13] Additional moisture Kg/100 kg of coal 0.0

[13]=[12]*100/[4a]/1000

[14] Additional moisture Kg/KJ 0.0

[14]=[13]/[1]/100

[15] Gas temp leaving air heater °C 149.00

[16] Air temp entering air heater °C 37.00

[17] O2 entering air heater % 4.90

[18] O2 leaving air heater % 4.90

Sorbent data(enter 0 if sorbent not used)

[20] Sorbent rate kg/hr 2300.00

[21] CO2 from sorbent Kg/100 kg sorbent 35.96

[22] H2O from sorbent Kg/100 kg sorbent 5.78

[23] Sulfur capture kg/kg of sulphur 0.22

[24] Spent sorbent kg/100 kg of fuel 17.27

[25] Sorb/fuel ratio 1 kg sorbent/kg fuel 0.24

[25]=[20]/[3]/1000

[30] Fuel ultimate analysis

[30a] Carbon % mass 84.03

[30b] Unburned carbon in ash % mass 0.83

[30c] Carbon burnt % mass 83.20

[30c]=[30]a-[30]b

[30d] Sulphur % mass 5.67

[30e] Hydrogen % mass 3.54

[30f] Moisture % mass 3.70

[30g] Vapour Moisture % mass 0.00

[30h] Nitrogen % mass 1.04

[30i] Oxygen % mass 0.62

[30j] Ash % mass 1.40

[30k] Volatile matter % mass 9.50

[30l] Fixed carbon % mass 85.10

Theoretical air

Theoretical air for carbon kg of air / kg of carbon 11.51

kg of air /100 kg of
[31c] Theoretical air for carbon 957.62
coal
[31c]=[30c]*Tc
kg of air / kg of
Theoretical air for sulphur 4.31
sulphur
kg of air /100 kg of
[31d] Theoretical air for sulphur 24.44
coal
[31d]=[30d]*Ts
kg of air / kg of
Theoretical air for hydrogen 34.29
hydrogen
kg of air /100 kg of
[31e] Theoretical air for hydrogen 121.39
coal
[31e]=[30e]*Th
kg of air / kg of
Theoretical air for oxygen -4.32
oxygen
kg of air /100 kg of
[31i] Theoretical air for oxygen -2.68
coal
Theoretical air for fuel
kg of air /100 kg of
Ta=[31c]+[31d]+[31e]+[31i] 1100.77
coal
[31] Theoretical air for fuel mol/100 kg of coal 38.00

[31]=Ta/28.966

Dry product

Molecular mass of carbon ,Mc mol/kg of carbon 12.01

[32c] Dry product carbon burnt Mol/100 kg of coal 6.93

[32c]=[30c]/Mc

Molecular mass of sulphur ,Ms mol/kg of sulphur 32.07

[32d] Dry product sulphur burnt Mol/100 kg of coal 0.18

[32d]=[30d]/Ms

Molecular mass of nitrogen ,Mn mol/kg of nitrogen 28.01

[32h] Dry product nitrogen burnt Mol/100 kg of coal 0.04

[32h]=[30h]/Mn

[32] Total Dry product

[32]=[32c]+[32d]+[32h] Mol/100 kg of coal 7.14

Wet product

Molecular mass of hydrogen mol/kg of hydrogen 2.02

[33e] Wet product due to hydrogen mol/100 kg of coal 1.76

[32h]=[30h]/Mh

Molecular mass of water mol/kg of moisture 18.02

[33f] Wet product due to moisture mol/100 kg of coal 0.21

[33f]=[30f]/Mm

Molecular mass of water vapour mol/kg of moisture v 18.02

[33g] Wet product due to moisture vapour mol/100 kg of coal 0.000000

[33g]=[30g/Mmv

[33] Total wet product mol/100 kg of coal 1.96

 [33]=[33e]+[33f]+[33g]

COMBUSTION CALCULATION

Moisture from fuel

Moisture from hydrogen kg m/ kg hydrogen 8.94

[34e] Moisture from hydrogen kg m/ kJ 0.0000093

[34e]=[30e]*Wh/1/100

Moisture from fuel kg m/ kg moisture 1.00

[34f] Moisture from fuel kg m/ kJ 0.0000011

[34f]=[30f]*Wf/1/100

Moisture from moisture vapour kg m/ kg moisture v 1.00

[34g] Moisture from moisture vapour kg m/ kJ 0.0000000

[34g]=[30g]*Wg/1/100

Total moisture from fuel kg m/ kJ 0.00001041

[34]=[34e]+[34f]+[34g]

[40] CO2 from sorb kg/100 kg of fuel 8.71

[21]x[25]

[41] H2O from sorb kg/100 kg of fuel 1.40

[22]x[25]

[42] SO2 from sorb kg/100 kg of fuel 0.04

[32D]x[23]

[43] Dry prod comb kg/100 kg of fuel 7.30

 [32]x[40]/44.01-[42]

[44] Wet prod comb kg/100 kg of fuel 9.34

[33]x[41]/18.016+[43]

[46] Theoretical air corrected Kg/100 kg of coal 1103.51

[46]=Ta+2.16*[30d]*[23]

[47] Theoretical air for fuel Kg/100 kg of coal 38.10

[47]=[46]/28.966

[48] Theoretical air Kg/KJ 0.000325

[48]=[47]/[1]/100

[48] Wet gas from fuel Kg/KJ 0.000028

[49]=(100-[30j]-[30b]-[30d]*[23])/[1]/100

Air heater inlet

[52i] O2 entering air heater % 4.90

COMBUSTION CALCULATION

Flue gas analysis, AH inlet,Mol/100 kg of fuel

[53i] Moisture in air kg/kg of air 0.04

[53i]=[7]*1.608

[54dryi] Dry combustion products Mol/100 kg of coal 7.30

[54weti
Wet combustion products Mol/100 kg of coal 9.34
]]
[55i] Additional moisture Mol/100 kg of coal 0.00

[55i]=[12]/18.015

[56i] Theoretical air Mol/100 kg of coal 30.12

[56i]=[47]*(0.7905+[53i])

[57i] Summation Mol/100 kg of coal 37.41

[57i]=[54i]+[55i]+[56i]

[58i] [58i]=20.95-[52i]*(1+[53i]) 16.05

[60i] Excess air % 29.98

[60i]=100*[52i]*[57i]/[47]/[58i]

[69i] Dry air Kg/kJ 0.0004224

[69i]=(1+[60i]/100)*[48]

[70i] Wet gas from fuel Kg/kJ 0.0000284

[70i]=[49]

[72i] Moisture in air Kg/kJ 0.0000109

[72i]=[69i]*[7]

[74i] Additional moisture Kg/kJ 0.0

[75i] Total wet gas Kg/kJ 0.000462

[75i]=[69i]+[70i]+[72i]+[74i]

[76i] H2O in wet gas Kg/kJ 0.0000214

[76i]=[34]+[72i]+[74i]

[77i] Dry gas Kg/kJ 0.0004404

[77i]=[75i]-[76i]

[78i] H2O in wet gas % 4.62

[78i]=[76i]/[75i]*100
 Air heater outlet

[52o] O2 leaving air heater % 4.90

COMBUSTION CALCULATION

Flue gas analysis, AH outlet,Mol/100 kg of fuel

[53o] Moisture in air kg/kg of air 0.04

[53o]=[7]*1.608
[54dryo
Dry combustion products Mol/100 kg of coal 7.30
]
[54weto
Wet combustion products Mol/100 kg of coal 9.34
]]
[55o] Additional moisture Mol/100 kg of coal 0.00

[55o]=[12]/18.015

[56o] Theoretical air Mol/100 kg of coal 30.12

[56o]=[47]*(0.7905+[53o])

[57o] Summation Mol/100 kg of coal 37.41

[57o]=[54o]+[55o]+[56o]

[58o] [58o]=20.95-[52o]*(1+[53o]) 16.05

[60o] Excess air % 29.98

[60o]=100*[52o]*[57o]/[47]/[58o]

[69o] Dry air Kg/kJ 0.0004224

[69o]=(1+[60o]/100)*[48]

[70o] Wet gas from fuel Kg/kJ 0.0000284

[70o]=[49]

[72o] Moisture in air Kg/kJ 0.0000109

 [72o]=[69o]*[7]

[74o] Additional moisture Kg/kJ 0.0

[75o] Total wet gas Kg/kJ 0.0004618

[75o]=[69o+[70o]+[72o]+[74o]

[76o] H2O in wet gas Kg/kJ 0.0000214

[76o]=[34]+[72o]+[74o]

[77o] Dry gas Kg/kJ 0.0004404

[77o]=[75o]-[76o]

[78o] H2O in wet gas % 4.62

[78o]=[76o]/[75o]*100

[82] Infiltration % gas entering % 0.000

Gas temp leaving air heater °C 149.000

Air temp entering air heater °C 37.000

Enthalpy of air leaving air heater KJ/kg 173.057

Enthalpy of air entering air heater KJ/kg 12.041

Cpg KJ/kg k 1.010

Corrected flue gas temperature °C 149.00

[88]=[83]+([82]/100*([85]-[86])/[87])

EFFICIENCY CALCULATION

[1] Reference air temperature °C 25.00

[1a] Enthalpy of water KJ/kg 104.67

 [1a]=[1]*4.1868

[2] Average air entering temperature °C 37.00

[2a] Enthalpy of dry air KJ/kg 12.04

[2b] Enthalpy of water vapour KJ/kg 22.35

[3] Average gas exit temperature, no leakage °C 149.00

[3a] Enthalpy of dry gas KJ/kg 123.94

[3b] Enthalpy of water vapour KJ/kg 22.35

[3c] Enthalpy of steam KJ/kg 2778.50

[4] Fuel temperature °C 36.88

[4a] Enthalpy of fuel KJ/kg 13.31

[10] Dry air weight KJ/kg 0.000422

[11] Dry gas weight KJ/kg 0.000440

[12] Water from H2 KJ/kg 0.000009

[13] Water from H2O KJ/kg 0.000001

[14] Water from H2O vap KJ/kg 0.000000

[15] Moisture in air KJ/kg 0.025900

[16] Moisture in air KJ/kg 0.000010

[17] Fuel rate T/hr 9.500

[18] Unburnt carbon % 0.831

[19] HHV KJ/kg 33956

[30] Unit output KJ/hr 271517025

[31] Auxiliary equipment power KJ/hr 0.00

Loss in

[40] Dry gas loss % 5.46

[40]=[11]*[3a]*100

[41] Water from H2 fuel % 2.49

[41]=[12]*([3c]-[1a])*100

[42] Water from H2O fuel % 0.29

[42]=[13]*([3c]-[1a])

[43] Water from H2O fuel vap % 0.0

[43]=[14]*[3b]*100

[44] Moisture in air % 0.02

[44]=[16]*[3b]*100

[45] Unburnt carbon % 0.83

[45]=[18]*8054*4.1868/[19]

[46] Sensible heat of residue % 0.17

EFFICIENCY CALCULATION

[85a] CO in flue gas % 0.0

[85a]=CO at AH in /10000*28.01*4347/HHV of
coal*((C burnt%/1201+sulphur%
/3206.4+N2%/2801.3)+Ta/100/28.96

[85b] Pulverizer rejects % 0.0

[85b]=Mill reject*calorific value of rejects/total coal
flow/HHV of coal*100
[85N] Loss due to Nox formation
Nox at AH inlet/10000*total dry
product/100*89850/HHV of coal
Quantity of Nox dry basis % 0.0

No.of moles of dry gas Mol/kg of coal 0.0

[54] Summation of losses % 9.26

[54]=[40]+[41]+[42]+[43]+[44]+[45]+[46]+[85a]+[85b]
+[85N]

Other losses

[85rl] Heat loss due to surface radiation and convection % 1.0

[85rs] Heat loss due to surface radiation and convection KJ/hr 2715170

[85rs]=[85rl]*[30]

Projected area of hopper opening(15.250x1.143M2)

Equi.Heat flux through furnace hopper opening KJ/m2hr 0.0

[85ra] Heat loss due to ash pit radiation KJ/hr 0.0

[85r] Total radiation loss KJ/hr 0.0

[85r]=[85rs]*[85ra] % 0.0

[76] Sorbent calcination /dehydration KJ/hr 3331217

[77] Water from sorbent KJ/hr 368198

[78] Total loss KJ/hr 6414584

Heat credits

[63 Entering dry air % 0.51

 [63]=[10]*[2a]*100

[64] Moisture in air % 0.022

[64]=[16]*[2b]*100

[65] Sensible heat in fuel % 0.04

[65]=[4a]/[19]*100

[88] Sulfation % 0.59

[75] Summation of heat cerdits % 1.16

[75]=[63]+[64]+[65]+[88]

[66] Auxiliary equipment KJ/hr 0.00

[95] sensible heat from sorbent KJ/hr 23644

[80] Fuel efficiency % 89.78

[80]=(100-[54]+[75])*total unit output /(total unit output
+[78]-[95])
[81] Input from fuel KJ/hr 308542074

[81]=unit output / estimated efficiency *100

 

Conclusion:

The following are the observations of SPEL’s team during Pet coke firing and the same are submitted for
further action by M/s Dalmia Cements Bharat limited.

1. The boiler is suitable for Pet coke firing.

2. Pet coke firing is normal and no major problems were experienced.
3. Lime feeding system should be made feasible for feeding uniformly throughout the bed. SPEL can
offer modifications for proper lime feeding system.
4. Bed conditions and combustion were better than lignite.
5. Bed height can be maintained at the present level (700 mm) to maintain bed temperatures. However,
this can be optimized after uniform lime feeding and checking the Thermocouple locations during
shut down.
6. SO2 analyser is not reliable and hence the same shall be checked.
7. O2 could be maintained between 4.5 to 6.5% at higher loads.
8. Steam temperatures and gas temperatures were normal.
9. DESH control valve passing problem is to be checked.
10. Main drag chain feeder fuel conveying is to be checked for uniform pet coke conveying.
11. Fuel efficiency obtained is 89.78% with Petcoke firing.
 SRI SAI PUMPS AND ENERGY SYSTEMS (P) LTD 
M/s DALMIA BOILER LOG SHEET 

DATE:      07.08.14  7:00  8:00  9:00  10:00  11:00  12:00  13:00  14:00  15:00  16:00  17:00  18:00  Avg 
S.N
Parameters  Unit 
O                           
1  Load  MW  24.00  24  24  25  24.5  24.8  24.7  24  24.1  24.5  24.3  24.5  24.4 
2  Drum pressure  kg/cm²  118  120  120  120  117  120  120  119  117  119  120  117  118.9 
3  Steam flow  TPH  107  107  109  111  109  107  107  105  106  107  108  107  107.5 
4  Main steam line pressure  kg/cm²  108  108  110  110  107  110  110  109  107  109  110  107  108.8 
5  Main steam line temperature  °C  525  532  531  536  536  532  532  534  534  538  539  536  533.8 
6  Feed water flow  TPH  102  109  100  100  99  107  107  106  106  104  106  100  103.8 
Feed control valve opening 
7  %  81  76  74  78  80  79  79  63  69  62  67  69  73.1 
position 
8  Deareator pressure  kg/cm²  9.1  8.9  9.5  9.2  9.1  9  9  8.9  9  8.9  8.9  9  9.0 
9  Deareator temperature  °C  176  176  177  177  177  177  177  176  175  176  176  177  176.4 
10  BFP Discharge pressure  kg/cm²  127  128  129  129  125  129  129  127  125.5  126  128  126  127.4 
11  HP Heater inlet temperatue  °C  176  175  176  176  177  177  177  175  176  175  176  176  176.0 
12  HP Heater outlet temperatue  °C  216  215  216  217  217  216  216  215  218  216  216  216  216.2 
13  Economiser inlet temperature  °C  216  215  216  217  217  217  217  214  215  215  216  218  216.1 
14  Economiser outlet temperature  °C  279  285  276  275  274  273  273  273  273  273  274  273  275.1 
Drum / Steam cooled wall inlet 
15  °C  343  345  346  344  343  345  345  344  343  348  345  344  344.6 
temperature °C 
Primary superheater inlet 
16  °C  343  345  346  344  343  345  345  344  343  345  345  344  344.3 
temperature 
17  PSH O/L  temp.  (before DSH‐1)  °C  425  427  422  419  419  418  418  419  419  413  414  412  418.8 
18  DSH ‐1 Flow  TPH  3.5  5.3  5.7  4.1  4.6  3.9  3.9  3.6  4.3  3.4  4.2  4.1  4.2 
19  Spray control valve opening  %  61  74  75  65  68  64  64  64  66  62  67  68  66.5 
Radiant SH I/L Temp   (After 
20  °C  396  385  386  388  385  387  387  388  388  384  382  382  386.5 
DSH‐1) 
 Radiant O/L Temp (Before DSH‐
21  °C  474  459  463  466  466  465  465  470  471  463  463  464  465.8 
2) 
22  DSH ‐2 Flow  TPH  0  1.4  2.3  1.6  1.5  1.1  1.1  1.1  1.1  1.2  1.3  1.2  1.2 
23  Spray control valve opening  %  0  27  43  30  30  18  18  17  17  22  22  22  22.2 
24  FSH I/L Temp.  (After DSH‐2)  %  460  445  441  447  448  452  452  456  455  447  447  446  449.7 
26  Drum level  %  48  48  48  48  48  49  49  48  48  48  48  48  48.2 
AIR PROFILE 
27  PA  APH I/L Temp.  °C  48  48  48  51  52  53  54  54  55  55  55  53  52.2 
28  PA APH O/L Temp.  °C  208  212  212  196  197  158  199  191  198  195  195  194  196.3 
29  SA APH inlet Temp  °C  35  34  34  36  38  38  29  40  41  40  40  39  37.0 
30  SA APH outlet temp  °C  210  213  203  198  198  200  201  148  197  196  195  193  196.0 

Drag Chain FEEDERS 
31  Drag Chain Feeder‐1  rpm  245  244  237  235  245  246  240  242  242  252  250  252  244.2 
34  Drag Chain Feeder‐4  rpm  256  258  252  251  255  248  242  239  239  248  250  251  249.1 
BED TEMPERATURE 
35  Bed temperature ‐1  °C  966  959  959  969  954  948  962  972  970  982  979  989  967.4 
36  Bed temperature ‐2  °C  911  899  900  895  889  888  906  914  917  930  933  933  909.6 
37  Bed temperature ‐3  °C  1006  1009  1019  1032  1031  1031  1017  1021  1020  1023  1021  1021  1020.9 
38  Bed temperature ‐4  °C  1030  1028  1035  1052  1048  1049  1034  1041  1038  1039  1031  1038  1038.6 
39  Bed temperature ‐5  °C  765  764  767  773  774  775  773  770  770  770  769  770  770.0 

FLUE GAS TEMPERATURE 
47  Cyclone I/L Temp  °C  852  864  871  862  864  864  854  852  858  867  869  863  861.7 
48  Down leg Temp  °C  921  927  938  933  931  931  920  913  923  930  938  927  927.7 
49  Cyclone o/l temp  °C  820  827  836  823  830  829  817  811  816  821  826  819  822.9 
50  FHS I/L Temp  °C  746  715  740  731  740  742  729  720  723  712  717  709  727.0 
51  PSH I/L Temp  °C  638  580  536  548  554  564  563  557  559  517  519  516  554.3 
52  Eco I/L Temp  °C  384  390  377  374  373  375  375  361  360  357  353  352  369.3 
53  APH I/L Temp  °C  302  298  269  270  270  274  274  270  270  264  263  262  273.8 
54  ESP I/L Temp  °C  153  160  149  142  142  145  146  144  144  141  140  139  145.4 
55  Esp O/L Temp  °C  142  141  143  132  131  133  134  133  133  133  131  129  134.6 
Bed Ash cooler 3rd comp ash 
56  °C  51  51  50  53  55  55  61  55  60  55  55  54  54.6 
temp 

GAS SIDE PRESSURE DROP 
73  Combustor Draft  mmWc  ‐18  ‐9.3  ‐16  ‐1.2  ‐7.2  ‐18  ‐15  ‐15  ‐20  ‐12  ‐16  ‐14  ‐13.5 
74  Cyclone o/l Draft  mmWc  ‐57  ‐40  ‐54  ‐37  ‐35  ‐43  ‐45  ‐47  ‐44  ‐51  ‐44  ‐44  ‐45.1 
75  FHS I/L Draft  mmWc  ‐70  ‐48  ‐70  ‐62  ‐52  ‐57  ‐56  ‐57  ‐54  ‐71  ‐57  ‐58  ‐59.3 
76  PSH I/L Draft  mmWc  ‐74  ‐54  ‐73  ‐67  ‐55  ‐58  ‐60  ‐61  ‐55  ‐73  ‐63  ‐61  ‐62.8 
77  Eco I/L Draft  mmWc  ‐88  ‐65  ‐89  ‐97  ‐78  ‐76  ‐81  ‐68  ‐73  ‐91  ‐77  ‐86  ‐80.8 
78  APH I/L Draft  mmWc  ‐107  ‐113  ‐113  ‐117  ‐106  ‐98  ‐96  ‐88  ‐98  ‐105  ‐95  ‐106  ‐103.5 
79  Esp I/L Draft  mmWc  ‐170  ‐188  ‐181  ‐177  ‐171  ‐163  ‐163  ‐153  ‐103  ‐165  ‐161  ‐168  ‐163.6 
80  Esp O/L Draft  mmWc  ‐205  ‐237  ‐217  ‐205  ‐200  ‐191  ‐195  ‐184  ‐191  ‐204  ‐191  ‐196  ‐201.3 
81  ID fan I/L  mmWc  ‐205  ‐237  ‐221  ‐205  ‐200  ‐191  ‐195  ‐184  ‐191  ‐204  ‐191  ‐196  ‐201.7 
83  Down leg Top Draft  mmWc  411  405  414  401  385  389  376  376  398  387  391  399  394.3 
84  Down leg bottom Draft  mmWc  345  363  360  344  344  336  327  319  351  357  350  364  346.7 
85  O2 level in flue gas  %  5.2  5.3  5  4.6  4.8  4.6  5.2  4.9  4.6  4.6  4.5  4.9  4.9 

ID fan ‐1 
333/3 367/ 355/35 329/3 325/3 310/2 324/3 291/3 312/2 346/3 333/3 307/3
86  ID FAN load  Amps 
17  343  3  16  07  98  14  30  92  38  21  32   
517/5 570/ 540/54 494/5 490/4 487/4 485/4 483/4 478/4 505/5 495/4 490/4
87  Motor speed  rpm 
22  575  4  00  94  94  91  91  86  03  94  96   
SA FAN 
1103
1103/ 1102/1 1029/ 1029/ 1029/ 1029/ 1030/ 1030/ 1030/ 1031/ 1044/
88  SA FAN speed  rpm  /110
1107  106  1032  1033  1033  1032  1031  1032  1030  1033  1033   
7 
 130/1 130/ 132/13 120/1 119/1 118/1 120/1 120/1 119/1 117/1 118/1 123/1
89  SA FAN load  Amps 
34  134  4  21  21  20  20  22  20  18  19  17   
90  SA suction damper opening  %  100  100  100  100  100  100  100  100  100  100  100  100  100.0 
91  SA fan O/L pressure  mmWc  662  663  661  568  564  563  563  556  558  558  560  569  587.1 
92  SA pr. At AH I/L  mmWc  662  663  661  568  564  563  563  556  558  558  560  569  587.1 
93  SA pr. At AH O/L  mmWc  565  565  566  484  480  481  479  474  474  476  473  486  500.3 
94  SA Header pr  mmWC  662  663  660  564  565  563  561  558  560  559  556  571  586.8 
mmWC 
95  SA Air Flow 
m3/hr  58  58  58  54  53  54  54  53  53  53  56  55  54.9 
PA FAN 
1410/ 141/ 1411/  1411/ 1411/ 1428/ 1411/ 1411/ 1410/ 1410/ 144/1 1412/
97  PA Fan speed  rpm 
1377  1375  1373  1347  1352  1361  1362  1361  1361  1361  361  1361   
400/  400/ 391/  401/  395/  424/  398/  395/  411/  373/  389/4 401/ 
98  PA FAN load  Amps 
412  421.  403  387  408  394  411  406  381  392  12  402   
99  PA Suction Damper opening  %  100  100  100  100  100  100  100  100  100  100  100  100  100.0 
100  PA fan O/L pressure  mmWc  1799  1803  1816  1765  1778  1796  1771  1761  1750  1750  1756  1768  1776.1 
101  PA pressure at AHR I/L  mmWc  1800  1803  1816  1765  1778  1796  1771  1761  1750  1750  1756  1768  1776.2 
102  PA pressure at AHR O/L  mmWc  1745  1724  1729  1678  1707  1712  1686  1668  1670  1670  1674  1684  1695.6 
103  PA Header pr  mmWC 
mmWC  . 
104  PA Air Flow 
m3/hr  88  89  87  84  87  88  85  86  84  84  84  86  86.0 
105  Bed pr1  mmWc  740  733  727  711  756  750  678  736  708  708  704  760  725.9 
106  Bed pr 2  mmWc  587  649  649  667  679  667  670  634  644  644  650  670  650.8 
1706
1694/ 1706/1 1659/ 1691/ 1692/ 1666/ 1654/ 1643/ 1643/ 1645/ 1664/
107  Air Box pressure mmWC  mmWc  /170
1700  706  1655  1688  1695  1664  1655  1649  1649  1649  1666   
6 
Seal pot blower O/L pressure 
108  mmWc  3931  3962  3942  3879  3854  3855  3909  3854  3864  3864  3894  3877  3890.4 
mmWC 

109  SPM analyser  24  25  215  23  23  25  25  25  24  24  25.9  24  40.2 
110  Sox  ppm  546  293  546  546  547  546  546  546  546  546  546  546  525.0 
111  Nox  ppm  36  17  407  13.8  13.8  8.8  24  29  12  37  23.9  24.6  53.9 
112  CO  ppm  15  10  9.5  16  16  5.1  6.4  23.5  4.4  15.4  13.3  18.6  12.8