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Performance Indices & Assessment AH Performance Enhancement Options Calculation of Boiler Efficiency - Sample Calculations
Air Heaters
Boiler efficiency and APC deteriorate with Air Heater performance degradation from O/H to O/H. The symptoms include Lower fan margins (ID amperes 95 to 135A) Lower gas exit temperatures due to high AH leakage Increased flue gas volume - affects ESP performance Boiler operation at less than optimum excess air - Specially in units where in ID fans are running at maximum loading
AH Performance Monitoring
O2 & CO2 in FG at AH Inlet O2 & CO2 in FG at AH Outlet Temperature of gas entering / leaving air heater Temperature of air entering / leaving air heater Diff. Pressure across AH on air & gas side
Air leakage occurring at the hot end of the air heater affects its thermal and hydraulic performance while cold end leakage increases fans loading.
Entrained Leakage due to entrapped air between the heating elements (depends on speed of rotation & volume of rotor air space)
HOT END
AXIAL SEAL
COLD END
HOT INTERMEDIATE
SEALS ARRANGEMENT
Leakage Assessment
Leakage assessment must be done by a grid survey using a portable gas analyser. Calculation of leakage using CO2 values is preferred because of higher absolute values and lower errors. Method of determination of O2 or CO2 should be the same at inlet and outlet - wet or dry (Orsat) Single point O2 measurement feedback using orsat is on dry basis while zirconia measurement is on wet basis. Leakage assessment is impacted by air ingress from expansion joints upstream of measurement sections.
CO2 measurement is preferred due to high absolute values; In case of any measurement errors, the resultant influence on leakage calculation is small.
Tgas out (no leakage) = The temperature at which the gas would have left the air heater if there were no AH leakage = AL * Cpa * (Tgas out - Tair in) + Tgas out Cpg * 100
Say AH leakage 17.1%, Gas In Temp 333.5 C, Gas Out Temp 133.8 C, Air In Temp 36.1 C Tgasnl = 17.1 * (133.8 36.1) + 133.8 = 150.5 C 100
X Ratio
Ratio of heat capacity of air passing through the air heater to the heat capacity of flue gas passing through the air heater. = Wair out * Cpa Wgas in * Cpg Tgas in - Tgas out (no leakage) Tair out - Tair in
Say AH leakage 17.1%, Gas In Temp 333.5 C, Gas Out Temp 133.8 C , Air In Temp 36.1 C, Air Out Temp 288 C X ratio = (333.5 150.5) / (288 36.1) = 0.73
X-Ratio depends on
moisture in coal, air infiltration, air & gas mass flow rates leakage from the setting specific heats of air & flue gas X-ratio does not provide a measure of thermal performance of the air heater, but is a measure of the operating conditions. A low X-ratio indicates either excessive gas weight through the air heater or that air flow is bypassing the air heater. A lower than design X-ratio leads to a higher than design gas outlet temperature & can be used as an indication of excessive tempering air to the mills or excessive boiler setting infiltration.
5 4
S3
3
S1
Probe
Grid sampling is needed for correct assessment of gas temperature & composition at AH outlet due to stratification in flue gas
C Probes
S1
Air Heaters
Thermocouples for flue gas temperatures at AH inlet as well as exit are generally clustered on one side. A grid survey is needed for representative values. Exit gas temperatures need to be corrected to a reference ambient and to no leakage conditions for comparison. Thermocouples for SA temperature measurement at AH outlet are mounted too close to air heaters and need to be relocated downstream to avoid duct stratification. Additional mill or changes in coal quality change thermal performance of a tri-sector air heater in a very major way; performance evaluation is difficult.
Its worthwhile to re-look at all the instrumentation around Air heaters for air temperatures / Flue gas composition & temperature measurement. The unit operation, equipment efficiency assessments and maintenance decisions are based on the same.
High air temp rise Low gas temp drop High AH leakages Low X-ratio
Unit 2 A B 222 217 166 155 15.4 16.9 182 195 0.67 0.61 50.2 45.4 Unit 3 A B 219 222 155 158 16.5 18.4 185 188 0.62 0.61 47.9 47.5
Unit 1 Design PGT A B Air Temp Rise C 230 228 228 221 Gas Temp Drop C 200 185 165 162 Leakage % 8.8 6.6 15.9 16.6 Gas Out Temp (NL) C 146.8 164.5 190 188 X ratio % 0.83 0.73 0.64 0.64 Gas Side Efficiency % 62.6 56.1 49.1 49.1
Increased air flows ~ better heat recovery across Air Heaters Constraint ID fan margins - reduction in AH leakage boiler casing air-in-leakage gas ducts air ingress
After
Double Sealing
Rotor modifications
Before Typical 24 sector rotor design
Minimum Basket
Boiler Efficiency
Boiler Efficiency can be determined by a) Direct method or Input / Output method b) Indirect method or Loss method
Direct Method
Steam
Efficiency =
Boiler Efficiency =
Steam flow rate x (steam enthalpy feed water enthalpy) x 100 Fuel firing rate x Gross calorific value
Water
Boiler Efficiency
Direct method or Input / Output method measures the heat absorbed by water & steam & compares it with the total energy input based on HHV of fuel. Direct method is based on fuel flow, GCV, steam flow pressure & temperature measurements. For coal fired boilers, its difficult to accurately measure coal flow and heating value on real time basis. Another problem with direct method is that the extent and nature of the individual components losses is not quantified.
Boiler Efficiency
Indirect method or Loss method For utility boilers efficiency is generally calculated by heat loss method wherein the component losses are calculated and subtracted from 100. Boiler Efficiency = 100 - Losses in %
Indirect Method
1. Dry Flue gas loss 2. H2 loss 3. Moisture in fuel 4. Moisture in air 5. CO loss
Steam
6. Radiation
Fuel + Air
Boiler
Flue gas
Water
The unit of heat input is the higher heating value per kg of fuel. Heat losses from various sources are summed & expressed per kg of fuel fired.
Boiler Efficiency
Commonly used standards for boiler performance testing are ASME PTC 4 (1998) BS 2885 (1974) IS: 8753: 1977 DIN standards
Boiler Losses Typical values Dry Gas Loss 5.21 Unburnt Loss 0.63 Hydrogen Loss 4.22 Moisture in Fuel Loss 2.00 Moisture in Air Loss 0.19 Carbon Monoxide Loss 0.11 Radiation/Unaccounted Loss 1.00 Boiler Efficiency 86.63
This is the heat carried away by flue gas at AH outlet Its a function of flue gas quantity and the temperature difference between air heater exit gas temperature and FD fan inlet air temperature Typically 20 C increase in exit gas temperature ~ 1% reduction in boiler efficiency.
U =
= Ash 100
Moisture Loss
Fuel Hydrogen Loss This loss is due to combustion of H present in fuel. H is burnt and converted in water, which gets evaporated. Fuel Moisture Loss This loss is due to evaporation and heating of inherent and surface moisture present in fuel. (Can be reduced by judicious sprays in coal yards)
Other Losses
1. Sensible Heat Loss of ash Bottom Ash Hoppers Eco Hoppers AH Hoppers ESP hoppers (~0.5-0.6 %)
Sensible Heat Loss (%) = (X / GCV) *100 X = [{Ash * Pflyash * C pash * (T go - T rai)} + {Ash * Pahash * C pash * (T go - T rai)} + {Ash * Peash * C pash * (T gi -T rai )} + {Ash * Pba * C pash * (T ba - T rai )}]
Other Losses
2. Radiation Loss through Bottom Ash Hopper
Coal Flow Rate 135 Tons/Hr GCV of Coal 3300 Kcal/Kg Eqv. Heat Flux thro Bottom opening 27090 Kcal/hr/m2 Bottom opening area of S-Panel 15.85 m2
Radiation Loss through Bottom Ash Hopper = [H BOTTOM * A S-PANEL *100 ] / [Coal Flow * GCV * 1000] = 0.096 %
Other Losses
3. Coal Mill Reject Loss Coal Flow Coal Mill Rejects GCV of Coal CV of Rejects Mill Outlet Temp Tmillout Reference Temperature Trai Specific Heat of Rejects CpREJECT 135 T/hr 200 kg/hr 3300 kcal/Kg 900 kcal/Kg 90 C 30 C 0.16 kcal/Kg/C
Loss due to Mill Rejects = X / (Coal Flow * GCV * 1000) X = [Rejects * (CVREJECT + CpREJECT (Tmillout Trai))* 100 ] = (0.0408 %)
Other Losses
4. Radiation Loss Actual radiation and convection losses are difficult to assess because of particular emissivity of various surfaces.
HEAT CREDIT
Heat Credit due to Coal Mill Power = [MP * 859.86 * 100] / [Coal Flow * GCV * 1000] Coal Flow Rate Coal FLOW Tons/Hr Total Coal Mill Power MP kWh GCV of Coal Kcal/Kg
Computations
Two Excel spreadsheets for determination of Boiler and Air Heater performance indices are being provided with this presentation. These also include methodology for correcting these indices for deviation in coal quality and ambient temperature from design. The operating equipment performance should be corrected for boundary conditions before comparison with design parameters.
THANKS