DESIGN OF BOILER

hassan ali

IRFAN KHAN 2015167

IJAZ AKBAR 2015162
M. HASSSAN 2015270
Abstract
A 2 TPH boiler is designed according to the specific details provided in the
problem statement. Suitable assumptions were made for the variables which were left to
the student’s choice and design requirements. Standard methods were followed to
design an efficient boiler. Cost analysis and environmental protection measures were
observed during the process.

Introduction

Steam boiler is a container in which water is heated to produce steam of

desired temperature .Heat is supplied to the boiler by burning fuel and water get heated,
evaporate and desired temperature is achieved . Steam boilers are used in many
industries, steam power plants and engines.
Design of steam boiler depends upon its service, target temperature,
production of steam and some other factors .Efficiency of boiler depends upon its
design and the fuel used .It has many types based on efficiency ,quantity of production
of steam and fuel used .Environmental protection, cost analysis and net profit that can
be obtained from the steam produced are other factors that are observed while
designing a boiler.
The aim of this project is to design a boiler of 2 TPH that can increase the
temperature of steam to 184C and maintain pressure in the range of 0.7-2.5 MPa.
Efficiencies, cost analysis and environmental protection measurements were taken into
account while accomplishing this task.

Types of Boilers
With respect to drought

Boiler design use both induce fan draught and forced fan draught so it is a balanced fan
draught boiler.
With respect to coal

Pulverized Fuel Boiler

Most coal-fired power station boilers use pulverized coal, and many of the
larger industrial fire-tube boilers also use this pulverized fuel. This
technology is well developed, and there are thousands of units around the
world, accounting for well over 90% of coal-fired capacity.
The coal is ground (pulverised) to a fine powder, so that less than 2% is
+300 micro metre (μm) and 70-75% is below 75 microns, for a bituminous
coal. It should be noted that too fine a powder is wasteful of grinding mill
power. On the other hand, too coarse a powder does not burn completely in
the combustion chamber and results in higher unburnt losses.

Methodology
 Dimensions of cylindrical boiler are calculated at first.,Boiler was
designed in such a way that its size does not be over sized because fuel bills will be
excessive and not undersize so it may not generate enough heat. Boiler is assumed to
be working for 5 hours in a day .Volume is calculated . Air to fuel ratio is measured than
boiler effecieny by direct and indirect method is measured. Combustion effecieny was
measured assuming the amount of partially burned carbon monoxide.Thermal efficiency
was measured using enthalpies of water and steam. Content of flue gases was also
measured.

Concept Diagram

Boiler Efficiency

Boiler efficiency is a combined result of efficiencies of different components of a boiler. A

boiler has many sub systems whose efficiency affects the overall boiler efficiency.
Couple of efficiencies which finally decide the boiler efficiency are-

1. Combustion efficiency
2. Thermal efficiency

Apart from these efficiencies, there are some other losses which also play a role while
deciding the boiler efficiency and hence need to be considered while calculating the
boiler efficiency.
Combustion Efficiency

The combustion efficiency of a boiler is the indication of burner’s ability to burn fuel. The
two parameters which determine the burner efficiency are unburnt fuel quantities in
exhaust and excess oxygen levels in the exhaust. As the amount of excess air is
increased, the quantity of unburnt fuel in the exhaust decreases. This results in lowering
the unburnt fuel losses but elevating the enthalpy losses. Hence, it is quite important to
maintain a balance between enthalpy losses and un burnt losses. Combustion efficiency
also varies with the fuel being burnt. Combustion efficiency is higher for liquid and
gaseous fuels than for solid fuels.

Formula for combustion efficiency :

CO 2
CE= *100
CO2 +CO

Combustional efficiency depends upon conversion of fuel into carbon dioxide, while in
flue gases percent of co2 was measured and theoretically all carbon converts to co2. In
real cases fuel is not fully burned and some carbon convert into carbon monoxide if we
know the percentage of carbon monoxide we can find thermal effecieny.

Let CO=5g in 100g

Co2=40 g in 100g

Than CE=89%

In real cases it can go up to 86%.

Thermal Efficiency

The thermal efficiency of a boiler specifies the effectiveness of the heat exchanger of
the boiler which actually transfers the heat energy from fireside to water side. Thermal
efficiency is badly affected by scale formation/soot formation on the boiler tubes.

Formula for thermal efficiency :

∩t =1- Qout / Q¿

T 1 =184 Ć
 h g =2781.4KJ/kg

T 2 =80 Ć

hf =335.02KJ/kg

Q¿ = ht 1 −ht 3

=2781.4-104.83

Q¿ =2676.57kJ/kg

Qout = ht 2−ht 3

=335.02-104.83

Qout =230.19KJ/kg

∩t =1-230.19/2676.57

∩t =91.31%

Direct and Indirect Boiler Efficiency

The overall boiler efficiency depends on many more parameters apart from combustion
and thermal efficiencies. These other parameters include ON-OFF losses, radiation
losses, convection losses, blow down losses etc. In actual practice, two methods are
commonly used to find out boiler efficiency, namely direct method and indirect method
of efficiency calculation.

Direct efficiency

This method calculates boiler efficiency by using the basic efficiency formula-
η=(Energy output)/(Energy input) X 100
In order to calculate boiler efficiency by this method, we divide the total energy output of
a boiler by total energy input given to the boiler, multiplied by hundred.

Calculation of direct efficiency-

E= [Q (H-h)/q*GCV]*100

Where,
Q= Quantity of steam generated (kg/hr)
H= Enthalpy of steam (Kcal/kg)
h= Enthalpy of water (kcal/kg)
GCV= Gross calorific value of the fuel.

ṁ=Q=1814.37KG/hr=2000kg/hr

H=2780KJ/Kg=664.6

h=104.83=25.06

q=3164.76kg/hr

E= Q(H-h)/q*GCV

q=m c p ∆T

=(0.7)*(4.2)*(184-25)

= 467.46

E=20000[(664.6-25.06)/(467.46*3347.036)]

E=81.75%

Indirect Efficiency
The indirect efficiency of a boiler is calculated by finding out the individual losses taking
place in a boiler and then subtracting the sum from 100%. This method involves finding
out the magnitudes of all the measurable losses taking place in a boiler by separate
measurements. All these losses are added and subtracted from 100% to find out the
final efficiency. Blow down valve is kept closed during the procedure. This method
should be implemented as per the norms provided in BS845 standards. The losses
calculated include stack losses, radiation losses, blowdown losses etc.

Flue Gas Temperature (Tf) = (55+25)°C

Ambient Temperature (Ta) = 25°C
% Heat Loss in Dry Flue Gas

(L1) = (m ×Cp×(Tf-Ta))/(GCV OF FUEL ) X 100

= (7.54 ×0.23 ×(80-25))/3347.036 X100
L1 = 2.84%
% Heat loss due to formation
of water from h2 in fuel (L2) = (9 ×H2×{584+Cp (Tf-Ta})/(GCV OF FUEL ) X 100
=(9 ×0.02041 ×{584+0.45 (80-25))/3347.036 X 100
L2 = 3.34 %

% Heat Loss Due To Moisture in Fuel (L3) = (M ×{584+Cp (Tf-Ta)})/(GCV OF FUEL )

X 100
= (0.316 ×{ 584+0.45 (80-25)})/3347.036 X100
L3 = 5.74 %
% Heat Loss Due To Moisture in Air = (AAS ×HUMIDITY ×Cp ×(Tf-Ta))/(GCV OF
FUEL ) X 100
= (7.13 ×0.0204 ×0.45 ×(80-25))/3347.036 X 100
L4 = 0.1%
% Heat Loss Due To Partial Conversion of C to Co
= %CO X C X 5744
%CO + CO2% GCV OF FUEL

= (0.55 ×0.4165)/(0.55+14) X 5744/3347.036 X 100

L5 = 2.70%
Heat Loss Due To Radiation and Convection
= 0.548 X [(Ts/55.55)4-(Ta/55.55)4] + 1.957 X (Ts-Ta) 1.25 X
SQRT OF [(196.85 Vm + 68.9)/68.9]
Where
Vm = wind velocity in m/s
Ts = Surface Temperature (K)
Ta = Ambient Temperature (K)
Surface area of boiler = 32.31m2
= O.548 [(353/55.55)4- (303/55.55)4] + 1.957 X (353-
303)1.25√((196.85×3.5+68.9))/68.9)
=1271.48 w/m2
=1271.48 X 0.86
=1093.47 Kcal /m2
TOTAL RADIATION AND CONVECTION LOSS PER HOUR
= 1093.47 X 32.31.
= 35330.01 Kcal
% RADIATION AND CONVECTION LOSS = (35330.01 ×100)/(3500 ×450)
L6= 2.24%

Heat loss due to unburnt in fly ash

% ash in coal = 8.63
ratio of bottom ash to fly ash = 90:10
Gcv of fly ash = 452.5 kcal/kg
Amount of fly ash in 1 kg of coal = fly ash % x amount of ash in 1 kg of coal
Total ash %
0.1 x 0.0863
= 0.00863 kg
Heat loss in fly ash = 0.00863 X 452.5
= 3.905 kcal/kg OF COAL
% Heat loss in fly ash = heat loss in fly ash / GCV of coal = 3.905 X 100/3500
L7= 0.11%
% Heat loss due to unburnt in bottom ash
GCV of bottom ash = 800 kcal / kg
Amount of bottom ash in 1 kg of coal = 0.9X 0.0863
= 0.077 kg
Heat loss in bottom ash = 0.077 X 800
= 62.136 kcal / kg OF COAL
% Heat loss in bottom ash = 62.136 X 100 / 3500
L7 =1.77%
BOILER EFFICIENCY BY INDIRECT METHOD
=100-(L1 + L2 + L3 +L4 +L5 +L6 +L7 +L8)
=100-(2.84+3.34+5.74+0.1+2.70+2.24+0.11+1.77)
=81.16%

Comparison of direct and indirect efficiency-

Both the methods of finding out boiler efficiency mentioned above have some
advantages and some disadvantages associated with them. The greatest advantage of
indirect method is that it also speaks about the sources of losses. By finding out indirect
efficiency, one can come to know where the losses are increased and can be reduced.
On the other hand, direct efficiency values are closer to reality as compared to indirect
efficiency on account of uncovered losses such as radiation losses, ON-OFF losses etc.
But direct efficiency can only tell us about the magnitude of overall loss. No information
about individual losses and their magnitudes is conveyed from direct efficiency
calculation. There always exists some difference in the values of direct and indirect
efficiencies. Indirect efficiency is measured at a particular time whereas direct efficiency
is measured over a period of time and hence, losses on account of fluctuating loads,
boiler on-off etc. are also taken into consideration.

Fuel Analysis (in %)

Ash Content in Fuel = 8.63, Moisture in Coal = 31.65, Carbon Content = 41.65,
Hydrogen Content= 2.0413, Nitrogen Content = 1.6, Oxygen Content = 14.48, GCV of
Coal = 3500 Kcal/Kg Flue Gas Temperature = 180°C, Ambient Temperature = 30°C,
Percentage of O2 and Co2 in Flue Gas = 11 & 14,
THE CHEMICAL REACTION ARE
C + O2 ------------------------ CO2
2H2 + O2 -------------------2H2O
S + O2 -------------------- SO2
C + O2 ---------------------CO2
12 + 32 ---------------------- 44
12 kg of carbon requires 32 kg of oxygen to form 44 kg of carbon dioxide. Therefore 1
kg of carbon requires 32/ 12 kg i,e2.67 kg of oxygen
41.65 kg C + (41.65 X 2.67) kg O2 ---------------------------- 152.85 kg CO2
2H2 + O2 ------------------------------- 2H2O
4 + 32 ------------------------------- 36
4 kg of hydrogen requires 32 kg of oxygen to form 36 kg of water. Therefore 1 kg of
hydrogen requires 32/ 4 kg i,e 8 kg of oxygen

2.0413 kg H2 + (2.0413 X 8) kg O2 ------------------------ 18.37 kg H2O

S + O2 ------------------------------------ SO2
32 + 32 ------------------------------------ 64
32 kg of sulphur requires 32 kg of oxygen to form 64 kg of sulphur dioxide. Therefore 1
kg of sulphur require 32/32 kg i,e, 1 kg of oxygen .
0 kg S + (0 X 1) kg O2 ------------------------------------------ 0 kg OF SO2
Total Oxygen Required
(111.20 + 16.33 + 0) = 127.53 kg
Oxygen already present in 100 kg fuel = 14.28 kg (from ultimate analysis)
Additional oxygen required = 127.53 – 14.28 = 113.25kg
Therefore quantity of dry air required = 113.25/0.23 = 492.39 kg OF AIR
(Air Contains 23 % Oxygen By Wt.)

Air/Fuel Ratio
Theoretical air required = 492.39/100
= 4.9239 kg OF AIR /kg OF FUEL

Theoretical CO2 % present in exhaust gases

% CO2 at Theoretical Condition = MOLES OF C
MOLES OF N2 + MOLES OF C

% CO2 at Theoretical Condition = MOLES OF C

MOLES OF N2 + MOLES OF C

Moles of N2 = WT. OF N2 IN THEORITICAL AIR + WT. OF N2 IN FUEL

MOL. WT. OF N2 MOL. WT. OF N2

Moles of N2 = (4.91 ×7.7)/28 +0.016/28 = 0.1356

Where Moles of C = (WT.OF C IN FUEL )/(MOL.WT OF C)

= 0.4165/12
= 0.0347
(CO2)t = 0.0347/(0.1332+0.0347)
(CO2)t = 20.37%

Excess air present in exhaust gases

Actual Co2 measured in flue gas = 14%
% Excess air supplied (EA) = 7900 X [( CO2%)t – (CO2%)a]
(CO2%)a X[100 – (CO2%)t]

= (7900 ×[20.37-14])/(14 ×[100-20.37])

= 45.17%

Actual mass of air supplied for combustion

Actual mass of air supplied = [1+ EA/100] X theoretical air
= [1+ 45.17/100] X 4.91
= 7.13 kg of air/kg OF COAL
Actual mass of dry flue gas
Mass of dry flue gas = MASS OF CO2 + MASS OF N2 CONTENT IN THE FUEL +
MASS OF N2
IN THE COMBUSTION AIR SUPPLIED + MASS OF OXYGEN IN FLUE GAS
Mass of dry flue gas = (0.4165 ×44)/12 +0.016+ (7.13 ×77)/100+((7.13-4.9))/100X23
= 7.54 kg/kg OF COAL

Total cost of Boiler

Chimney and Burning chamber = 15,000 and 10,000

Air preheater=15,000

Economizer=10,000

Boiler=20,000

Pipes and tubes=15,000

Water supply= 5000

Miscellaneous=10,000
 Fuel =12000

Ash disposal = 15000

Total cost=127000 rupees

Return on investment :

We assume that boiler will work for 5 hours a day ;

Electricity generated = [ (5*365)h/year *230.19*5t/h]/0.97

=2.16 MWh/year

Annual Return= 2.16MWh/year* (10.997)*(30)

= 285042.24 ruppes

Profit :

The profit that we get by designing this boiler :

Profit = Return – Cost

= 285042.24 – 127000

= 158042 rupees

Conclusion:
 Steam boiler with efficiency of 81.75% is designed to achieve 184C and 0.7-
2.5Mpa. coal is used as a fuel. It is burned in excess of oxygen to provide heat to the boiler
chamber . water is heated to 184 C (steam) and flues gases leave the chimney at 55 C stack
temperature . Before that air pre –heater and economizer are installed to increase the
efficiency . Boiler , thermal and combustion efficiencies are calculated as 91.37 % , 89 % and
respectively . the whole design process was done ; observing environment safely measures
investment omn return and cost analysis .