Universal Robina Corporation

Universal Robina Sugar Milling Company

Manjuyod, Negros Oriental

The Mill and Boiler

By:
Rommel LitoNepalar
JaypeeTimanuno
Richard Mark Zamora

To:
Engr. Dennis Cafe
Manager
Mill and Boiler Department
URSUMCO
Mill and Boiler Department

Objectives:
To mill canes and maximize juice extraction at the
right time in accordance to costumers satisfaction
To supply enough bagasse to boilers for efficient
operation
To generate steam required for smooth flow of the
operation
To execute organizational goal conforming to
manufacturing plan and quality plan

MILLING
The extraction of juice from Cane constitutes the first stage of the entire process of
cane sugar manufacture wherein the object of separation of juice from the fibrous
portion of the cane is accomplish by employing heavy machinery. It begins by
dumping of canes at the dumping station. Before dumping, canes are weighed to
serve as method for payment to growers. Canes are arranged by batch in the
dumping area. Then, the canes are being conveyed by the feeding carrier. The
speed of the carrier is being controlled by an operator in the tower. It has a leveller
which levels the cane and a kicker. Theleveller rotates in a direction opposite to the
direction of the feeding carrier while the kicker rotates opposite in the direction of
the leveller. Afterwards, the cane moves to the cane carrier which carries the cane
to the shredder. As the cane move towards the shredder, it passes through levellers
and cutters. The cane first passes through the first cane leveller. Then the cane
passes through the two cutters which cuts the cane into smaller pieces, with
different clearance and the number of blades. Cane cutter number has twice the
number of blades as the first cutter. Then the cane moves to the kicker which kicks
the cane to the shredder.

Note:
(a)The sugarcane plant is essentially composed of two types of fiber, the
interior soft pith which `holds sugar rich juice and the outer portion known as
rind, containing juice with high impurities.
(b)The feeding carrier and the cane carrier are an apron type conveyor.

Parameters

Feeding Carrier
Motor Speed:
Power:
Reduction:

1185 rpm
132 kw
1:121.382

Cane Carrier
Speed:

10 m/ min

Leveller (Feeding Carrier)

Motor Speed:
Power:
Reduction:

1770 rpm
55 kw
1:43.192

Kicker (Feeding Carrier)

Motor Speed:
Power:
Reduction:

1770 rpm
55 kw
1:43.192

Leveller #1 (Cane Carrier)

Motor Speed:
Power:
Reduction:

1770 rpm
55 kw
1:43.192

Cane Cutter # 1 (motor driven)

Motor Speed:
Power:
Knife Quality:
Clearance:
Pitch/number:

595 rpm
450 kw
hard facing build-up om knife edge
(19mm T x 210mm W x 483mm L)
(250-300)mm
From tip of the knife to cane carrier slats
28 pieces

Cane Cutter #2 (turbine driven)

Turbine speed:
Reduction:
Knife quality:

4000 rpm
1:7:52
Hard facing build-up on knife edge
(19mm T x 210mm W x 613mm L)
Clearance
(40-60) mm
From tip of the knife to cane carrier slats
Pitch/ number:
56 pieces
Turbine Steam Supply Pressure: 182 kgf/cm2
Turbine Chest Pressure:
6-13 kgf/cm2
Turbine exhaust Pressure:
1.5 kgf/cm2
Oil Lubrication Supply pressure:
0.5-2 kgf/cm2
Bearing Temperature:
not more than 75C
Oil Temperature:
not more than 60C
Water Temperature :
not more than 55C

Leveller #2 (Cane Carrier)

Motor Speed:
Power:
Reduction:

The Iron Separator

1750 rpm
22 kw
1:32

Iron separators are installed in the mill to separate metals which goes together with
the canes. It is really important to separate metals because it may damage the mill
rollers and most especially interrupt the operation. The efficiency of these
separators in removing iron pieces and thus avoiding damage to processing
equipment is 80-90%. The commonest objects are: pieces of knife-blades, bolts and
nuts. Pieces of cast iron or special steel are the most dangerous. Whether it is
detected in time or not such incidents are expensive.
The Shredder
The shredder is essentially a hammer mill adapted to the function of sugarcane
pulverising. It composed of 88 swing type hammers arranged into 11 rows. Each
row has 8 hammers which revolves on pivot. As the name indicates, the equipment
shreds or tears the cane to pieces or pulverises it into long fluffy material which in
effect increases the extraction of the mill. Shredder is always preceded by usual
two sets of cutters and levellers which cut the cane prior to feeding the shredder.
Cane Shredder
Hammer Quality
No. of Hammer
Cutting Bar Quality
Number of Cutting Bars
Clearance: inlet
Discharge
Turbine average speed
Steam supply Pressure
Chest Pressure
Exhaust Pressure
Oil Lubrication supply pressure
Bearing Temperature
Oil temperature
Water temperature

Hard facing build up

88 pcs.
Carbon steel with hard facing build up
7 lengths
(30-40)mm
(45-55)mm
3500 rpm
182 kgf/cm2
7-14 kgf/cm2
1.5 kgf/cm2
0.5-2 kgf/cm2
not more than 75C
not more than 60C
not more than 55C

Shredded Cane Elevator is the responsible for the delivering shredded cane to the
1st mill. The shredded cane drops to a chute, namely Donnely chute, named after
the inventor. Then itis fed to two pusher rolls followed by three roller mills forming a
mill train in which the subsequent mills perform the function of extracting the
juice.The pusher rolls are connected by a chain in the top mill roller and bottom mill
roller. The three mill rollers that are responsible for the extraction: top roller, feed
roller and discharge roller. The rollers have V shaped grooves, on the periphery of
the shell, distributed over the entire length. The grooves serve two-fold purpose:

(1) To provide passage for juice extracted on compression

(2) To disintegrate the bagasse to facilitate juice extraction
The pure juice of the 1st mill is collected by the mixed juice tank and is pumped to
the rotary screen filter. The rotary screen filter, filters the bagasse that mixed with
the juice. After the 1st mill, the bagasse is transported to the 2 nd mil by an
intermediate carrier. An intermediate carrier is a rake type of conveyor as well as
the shredded cane elevator. The bagasse drops to a chute, passed to the pusher
roll and the mill rollers. Same goes with the 3 rd, 4th, and 5thmill.The juice that is
collected by the 5th mill will be pump to the 4 thmill, the 4th mill to the 3rdmill and the
3rdmill to the 2ndmill. the mixed juice of the 2 nd mill will be pumped to the rotary
screen filter together with the pure juice of the 1 st mill. the bagasse that is filtered
by the screen filter will be conveyed by a screw conveyor to the intermediate carrier
of the 2nd mill. The bagasse that exits the 5th mill will be carried by the main bagasse
elevator. The final bagasse will be used by the boilers as fuels.

The bagasse that exits the 5 th mill must not be wet to avoid low steam
pressure.

Mill

Openings

1
2
3
4
5

Feed
roller
to
top roller
80 mm
95 mm
90 mm
75 mm
60 mm

Discharge
roller to top
roller
40 mm
45 mm
40 mm
35 mm
34 mm

Standard

Mill

Standard Mill Openings

URSUMCO Milling operations can process an average of 8000 tons of cane per
day

Mill # 1
Input Speed: 4521 rpm max
High Speed reduction: 1: 37.64
Output Speed: 120.105 rpm
1st low speed reduction: 1: 4.385
Output Speed: 27.39

Mill # 2, 3, 4, 5
Input Speed: 4463 rpm max
High Speed reduction: 1: 27.05
Output Speed:165 rpm
low speed reduction: 1: 24.94
Output Speed: 6.61

2nd low speed reduction: 1:4.1

Output: 6.68
Speed Input, Output and Reduction for Mill Turbines
The input speed above are the maximum speed of the turbine. The current speeds
that are used in the mills are the following: 2700 rpm (mill 1), 3800 rpm (mill 2),
3400 rpm (mill 3), 3900 (mill 4), and 3200rpm (mill 5). The governor is an auxiliary
part of the mill turbine which regulates the speed of the turbine. The shaft of the
turbine is coupled in the speed reduction. Speed reduction is a series of gears of
different diameter.
Parameters
Mill 1
Turbine Supply 18
2
Pressure
kg/cm2
Turbine

320
Temperature
5 oC
Turbine Speed
26003000 rpm
Turbine
Chest 5-7
Pressure
kgf/cm2
Exhaust
1.5
Pressure
kgf/cm2
max
Top
Roller 2700 psi
Hydraulic
max
Pressure
Mill
Roller
Condition
Groove Depth
65 mm
Pitch
64 mm
Extraction
77%
Milling Rate
360
tons/hr
max
Maceration
None (dry)

Oil lubrication
Pressure
Bearing
Temperature
Oil
Temperature

0.5-2.0
kgf/cm2
75oC max
60 oC max

Mill 2
18

Mill 3

2 18

kg/cm2
320

Mill 4

2 18

kg/cm2

320

Mill 5

2 18

kg/cm2
5 320

kg/cm2

320

5 oC

5 oC
4000 rpm
max
5-7
kgf/cm2
1.5
kgf/cm2
max
2700 psi
max

C
4000 rpm
max
7-12
kgf/cm2
1.5
kgf/cm2
max
2700
psi
max

5 oC
4400 rpm
max
7-10
kgf/cm2
1.5
kgf/cm2
max
2700 psi
max

65 mm
64 mm
85%
360
tons/hr
max
Multiple
compoun
d
maceratio
n
0.5-2
kgf/cm2
75oC max

65 mm
64 mm
90%
360
tons/hr
max
Multiple
compound
maceratio
n

65 mm
64 mm
93.50%
360
tons/hr
max
Multiple
compoun
d
maceratio
n
0.5-2
kgf/cm2
75oC max

65 mm
64 mm
95.80%
360
tons/hr
max

60 oC max

60 oC max

60
max

0.5-2
kgf/cm2
75oC max

C 60 oC max

4400 rpm max

8-15 kgf/cm2
1.5
max

kgf/cm2

2700 psi max

Multiple
compound
maceration
(40-70 C)
0.5-2 kgf/cm2
75oC max

Water
Temperature

55 oC max

o
55
C 55 oC max
max
Mill Parameter

55 oC max

55 oC max

START-UP OPERATING PROCEDURE (milling section)

1.
2.
3.
4.
5.
6.
7.
8.
9.

Start motor of cane carrier .

Turn on the cane carrier kicker.
Switch on the AVR of the cane carrier, push ON of speed controller panel.
Turn the speed regulator of the cane carrier at rate speed 0-10m.
Call the feeding carrier operator to start feeding canes.
Inform the boiler control panel operator to start the bagasse elevator.
Observe the thickness of the cane at cane carrier through ammeter.
Swtich on the SCE when cutted cane reaches shredder.
Switch ON screw conveyor and rotary screen as soon as shredded canes
enter the mill.
10.Swtich ON IC no. 1 when bagasses starts to came out of the mill no. 1 and
switch ON juice pump no. 1.
11.And the switch ON screened juice pump.
12.Switch ON IC NO.2 when bagasse starts to came out of mill No. 2.
13.Switch ON juice pump no. 3.
14.Switch ON IC no. 3 as soon as bagasse came out from mill no. 3.
15.Switch ON juice pump no. 5.
16.Switch ON IC no. 4 as soon as bagasse come out from mill 4.
17.Switch ON juice pump no.7.
18.Signal the boiler panel operator that bagasse is now in the bagasse elevator
19.Inform the juice pan tender to open the maceration and the hot water
maceration and the sprayer.
20.Switch ON interlock equipments.

SHUT DOWN PROCEDURE (milling section)

1. Switch off the interlock of equipments.
2. Empty first the cane carrier before stopping and switch off the drive motor at
the control panel.
3. Switch off the cane kicker.

4. Switch off the maceration and empty the all mills of residual bagasse and
inform the boiler operator.
5. Switch off the ff. juice pumps ,mixed juice pumps ,rotary screen ,screw
conveyor and the intermediate carriers.
6. Inform to the feed water turbine tender to stop stop the steam supply for
mills and shredder.

The Boiler or Steam Generator

The remaining fibrous solids, called bagasse are burned for fuel in the steam boilers.
These boilers produce high-pressure steam. A boiler is a device for heating water or
generating steam above atmospheric pressure. All boilers consist of a separate
compartment where the fuel is burned, and a compartment where water can be
evaporated into steam.
Classifications of boiler:
Fire Tube Boiler- a steam boiler in which ho gaseous products of combustion
pass through tubes surrounded by boiler water
Water Tube Boiler- a steam boiler in which water circulates within tubes and
heat is applied from outside the tubes to generate steam.

Essential elements of boiler:

In starting a

turbine
(1) Water
(2) Air
(3) Fuel
lubrication oil
(4) Fire

Check for:
(a)cooling water (b)
(c) fuel(steam)

In the plant, there are three water tube type of boiler. URSUMCO boilers are
Pneumatic Spreader with Damping Grate type of boiler. Boilers 1 and 2 have the
same capacity while boiler 3 has larger capacity.
Boiler Parameters
Boiler 1 and 2
Product
1.0High Pressure Steam
1.1Temperature
1.2Pressure
1.3Capacity
2.0Make up Steam
2.1Temperature
2.2Exhaust Pressure
Process
1.0H.P Steam
1.1Exhaust pressure
1.2Feed water pump delivery
pressure
1.3Lift pump delivery pressure
1.4Feed Water Temperature
1.5Boiler Drum level
1.6Deaerator water level
1.7Boiler gas outlet
1.8AH gas outlet
1.9AH air outlet
1.10 PFDF air outlet
1.11 Furnace chamber
1.12 IDF Gas inlet
1.13 IDF turbines 1 and 2
1.13.1Bearing Temp.
1.13.2Cooling Water temp.
1.14
1.15

Bagasse fuel
Boiler water treatment

32525C
182 kgf/cm2
60 tons/hr max
122 C
1.5 kgf/cm2

1.5 kgf/cm2
36 kgf/cm2 max
0.6 kgf/cm2 max.
9510 C
050 mm
50mm average level
27525C
21030C
15525mm HO
15050mm HO
020mm HO
-100to -150mm HO
Not more than 80C
Not more than 55C
56% bagasse moisture max
Refer to boiler water treatment
Boiler 3

Product
1.0High Pressure Steam
1.1Temperature
1.2Pressure
1.3 Capacity
2.0 Bleed Steam
2.1Pressure setting

34020C
26 4 kgf/cm2
80 tons/hr max
182 kgf/cm2

Process
2.0H.P Steam
2.1Boiler water level
Boiler drum level
Feed water pump delivery
pressure
Feed water treatment
Deaerator level
Deaerating steam pressure
2.2Combustion temperature
Boiler gas outlet
AH gas outlet
2.3combustion draft
DC air outlet
BO air outlet
Furnace chamber

Normal 75mm
42 kgf/cm2 max
Refer to boiler water guidelines
100 mm setting level
0.5 kgf/cm2 setting pressure
17525C
180 to 250C
-5 to 10mm HO
+5 to 30mm HO
0 to 20 mm HO
56% bagasse moisture max
100% maximum opening

2.4Bagasse fuel
3.0Bleed Steam
PRV opening

Bagasse Flow
The figure above indicates how bagasse and ash are being conveyed. From the 5 th
mill, the bagasse is conveyed by the main bagasse elevator to the main bagasse
carrier. The main bagasse carrier has the upper and lower portion. The lower
portion carries the bagasse from the main bagasse elevator and distributes the
bagasse to the boilers. The excess bagasse drops in the shutter and is carried to
the surplus bagasse conveyor. The surplus conveyor has shutter which connects to
the return bagasse elevator. The surplus bagasse conveyor connects to the
travelling belt conveyor. The travelling belt conveyor conveys the bagasse to the
bagasse warehouse. As the name implies, it is where the excess bagasse is stored.
The stored bagasse will be used if the milling operation stops. Backfeeding is the
feeding of bagasse in the return bagasse elevator using heavy equipment like
payloader.

Boiler
maximum capacity )

Fuel

Consumption

30 tons/hr

30 tons/hr

40 tons/hr

(based

on

Ash Flow
Ash and unburned bagasse drops and collected in the deashing conveyor during
deashing. Deashing is done in the 1 st hour and every after four hours of the shift. It
is done periodically to minimize the bagasse that goes with the ash in deashing.
Deashing is done by the fireman. The fireman releases the lever to open and close
the damping grate. The ashman make sure that no metal or stone is being carried
by the conveyor. Metals or stones may clog in the conveyor. Ashes that are
accumulated in the air preheater drops into the air preheater conveyor. Ashes that
are being carried by the flow of smoke to the chimney are being trap by the ash
trap and then drops in the dust conveyor. The ash and unburned bagasse that
drops in the deashing conveyor, air pre-heater conveyor, and dust conveyor are
conveyed into a conveyor that is common of this three conveyors and is called ash
removal conveyor and is directed to the ash bin. Ash truck collects the ash in the
ash bin.

Uses of Steam
In sugar mills steam is used for both power generation and as source of heat in
process operation. Some of the fundamental properties of steam which govern its
use for generation of power and for heating as well as boiling in process are:
(1) High pressure and temperatures of steam are desirable for generating power.
(2) Low pressure steam is required in process operation.
High pressure steam from boilers is fed to prime movers for some units like mill
turbines as well as to the power house turbines. And the exhaust from these prime
movers is utilised for process operations. The steam that is being generated goes
to the high pressure header(HPH) and the HPH is responsible for the distribution of
steam. The exhaust steam that is produced by the turbines in the mills and power
house will go to the low pressure header and will be utilized in the process.
Boiler Feed Water
The source of water for steam for steam generation in the boilers is mostly the
condensate from the heat exchangers in the process and the condensate is derived
from condensed vapour obtain from juice boiling in the evaporators and water from
steam condensed in the heat exchangers . The condensate tank pumps water to
the day tank. The day tank provides water supply in the boiler when there is no
operation. If the mill operation starts, the deaerator tank will supply water in the
boiler. A deaerator is a device that is widely used for the removal of oxygen and
other dissolved gases from the feedwater to steam-generating boilers. Exhaust
steam enters the deaerator and heats up the water to 110C. The water from the
deaerator is being pumped to the boiler by a feedwater pump.
Before entering the steam drum, the water enters an economizer. An economizer is
a feedwater preheating device which utilizes the heat of the flue gas. Economizers
are usually made of cast iron and their function is essentially to heat the feedwater
and not to boil. When the water exits the economizer, water temperature is now
170C. Then it enters the steam drum. It collects the steam generated in the boiler.
It must be half filled with water.
The mud drum is located below the steam drum where impurities settle. The steam
drum and mud drum is connected by the generating tubes The superheater isa
bank of tubes suitably located in the path of hot gases and connected to the boiler
drum.
Air Flow in theBoiler
Air is one of the essential part of a boiler. Without air the rate of combustion is
slow. In the boiler, the force draft fan collects fresh air and carries it to the air
preheater. Air preheater heats up fresh air and supplies it to three tubes: bagasse
distribution fan(BDF), secondary force draft fan(SFDF) and undergrate fan. The BDF

blows the bagasse into the furnace equally. The SFDF aids the burning of bagasse
by blowing hot air in the furnace. The undergrate fan blow air under the furnace.
The smoke(flue gas) produced in the combustion will be absorb by the induced
draft fan(IDF). After the IDF, the flue gas discharged to the atmosphere by the
chimney.
The Safety Valve
Safety valves are installed in the boiler which automatically releases the steam
incase of over pressure. Boiler 1 and 2 has 4 safety valves (3 for the steam drum, 1
for superheater) and boiler 3 has 3 safety valves (2 for steam drum , 1
superheater). Each safety has different settings and the valve settings are as
follows:
Boiler 1
SV1: 24.2
SV2: 23.6
SV3: 24.3
SHV:23.5

Boiler 2
SV1:24.9
SV2: 23.8
SV3: 24.2
SHV:23.6

Boiler 3
SV1:34.5
SV2: 35.2
SHV:34.0

(all units are in kgf/cm2)

Boiler Water Treatment

It is necessary for the water in the boiler be treated to achieve great steam
production at a lower cost. Another reason is that the water has chemical elements
it that must be controlled to limit and eliminate the formation of scaling, corrosion
and entrainment in the boiler.
Scaling may cause low heat transfer at the point of deposits. Some of the more
common scale forming constituents are silica, iron, oil, hardness and sugar.
Corrosion causes development of weak spots which could lead to failure. Corrosion
may be due to chloride, iron, sugar, oil and dissolved gases such as oxygen.
Entrainment is often caused by variety f soluble and suspended solids.
Chemicals were put in the high pressure and low pressure chemical injection tank to
control the formation of the chemical elements that is carried by the water to the
boiler.

Dosing points
Low Pressure Line
Chemical Tank
High Pressure Line

Boilers 1 and 2
Chemical Dillution
Diclean B-901 = 2.1 kg
Oxynon S-340FG = 2.4 kg
Dillute to 200 L water
Caustic Soda = 2kg

Boiler 3
Chemical Dillution
Diclean B-901 = 1.4 kg
Oxynon S-340FG = 1.6 kg
Dillute to 200 L water
Caustic Soda = 2kg

Chemical Tank

Diclean B-562 = 900g

Dillute to 200 L water

Diclean B-562 = 900g

Dillute to 200 L water

The figure above indicates the chemicals and the dosage required. Dosage will vary
depending on the result after the test has been done by the Q.A. in the water
sample. the turbine tender gets water sample from the feedwater, continuous
blowdown of the three boilers. Below is the table indicating the boiler water
treatment control parameters.

Parameter
pH
Electrical
Conductivity
P-alkalinity
M-alkalinity
Total
Hardness
Calcium
Hardness
Silica
Residual
Sulfite
Phosphate
Ion
Chloride Ion
Total Iron
Sugar
Presence

Units
S/cm

Feed
8-9.5
-

Boiler 1 & 2
10.5-11.5
3000

Boiler 3
10-11
1000

mg CaCO3/L
mg CaCO3/L
mg CaCO3/L

500 max
600 max
0

120 max
150 max
0

mg CaCO3/L

mg SiO2/L
mg/L

10-20

50 max
5-10

mg PO4-3/L

20-40

5-10

mg Cl-/L
mg Fe/L
-

0.1 max

150 max
Absolutely negative

100 max
-

How to fire a boiler?

To fire a boiler, there are preparatory measures that needs to be considered:
(1)Man power
(2)Operating abilities
(3)Sufficient water in the drum
(4)Fuel
(5)Fans are in good condition
(6)Base fire

If you have all of the stated above, you are ready to fire boiler. Coordinate
with the process, power house, mill and refinery that you are ready to fire a
boiler. If the boiler has too much water, open the blowdown valve. Open also
the superheater drain to release the water residue in the superheater. Open
the induced draft fan. Open the force draft fan, secondary force draft fan
and bagasse distribution fan. Open the boiler feeders. Turn on the feedwater
pump.

Boiler Calculation
For Boiler 1 and 2
Rated Boiler Horsepower
HS( m2)
Rated Boiler Horsepower=
0.91
Where:

HS=Heating Surfacem 2=1,708 m 2

Solution:

Rated Boiler Horsepower=

1708 m2
0.91

Rated Boiler Horsepower=1,876.923077 hp

Solving for Develop Boiler Horsepower

Given:
0

t s=340 C Ps =20
t f =110 0 C ms=60,000

340 C , and @

kg f
cm

kg
hr
21.03322

kg 0.101325 MPa
=2.06 MPa
cm2 1.03322 kg
2
cm

From Steam Tables, table 3 (Superheated)

2.05
2.06
2.1

3113.5
hs
3112.4

By interpolation;

h s=3113.28

kJ
kg

From Steam Tables, table 1 (saturated), @

Develop Boiler Horsepower=

Where:

1 BHp=35322

1100 C ;

h f =461.30

kJ
kg

m s ( hshf )
35322

kJ
hr

( 60,000 kghr )( 3,113.28 kJkg 461.3 kJkg )

35322

kJ
hr

Develop Boiler Horsepower=4504.807202 hp

Solving for Percent Rating

Percent Rating is the ratio of the develop boiler horsepower to the rated boiler
horsepower.

Percent Rating=

Develop Boiler Hp
100
Rated Boiler Hp

4,504.807202hp
100
1,876.923077 hp

Percent Rating=240.0102198

Solving for ASME Evaporation Units

ASME Evaporation Units is the heat output of the boiler or the rate at which heat is
transferred.

ASME Evaporation Units=m s ( h sh f )

60,000

kg
kJ
kJ
3,113.28 461.3
hr
kg
kg

ASME Evaporation Units=159,118,800

kJ
hr

Solving for Factor of Evaporation, (FE)

Factor of Evaporation is the actual heat absorption per kilogram of steam generated
divided by 2257 (hfg from and at 1000C)

FE=

hs hf
2257
kJ
kJ
461.3
kg
kg
=1.175002215
kJ
2257
kg

3,113.28
FE=

Solving for Equivalent Evaporation

Equivalent Evaporation is the product of the rate of evaporation of steam and factor
of evaporation.

Equivalent Evaporation=m s FE
60,000

kg
1.175002215
hr

Equivalent Evaporation=70,500.1329

kg
hr

Solving for Actual Specific Evaporation (ASE) or Boiler Economy

Actual Specific Evaporation (ASE) or Boiler Economy is the ratio of the mass of
steam to the mass of fuel.

m
Boiler economy= s =
mf

kg
hr
=2
kg
30,000
hr
60,000

Solving for Equivalent Specific Evaporation

Equivalent Specific Evaporation is the product of boiler economy and factor of
evaporation.

Equivalent Specific Evaporation=Boiler economy FE

2 1.175002215

Equivalent Specific Evaporation=2.35000443

Solving for Boiler Efficiency

e bo=

m s ( hshf )
mf Qh

100

Where:

ms=mass of steam
h s=enthalpy of steam
h f =enthalpy of feedwater
mf =mass of fuel
Qh=fuel heating value
ms=60,000

kg
hr

h s=h @2.06 MPa ,@ 3400 C ( table 3 )=3,113.28

h f =h @110 0 C ( table 1 )=461.3

kJ
kg

kg
kg
hr of bagasse
mf =60,000 of steam
hr
kg
2,000 of steam
hr
1,000

mf =30,000

kg
of bagasse
hr

kJ
kg

Qh=3,300

Btu 2.205lb 4.187 kJ 0.252 kcal

lb
1 kg
1 kcal
Btu

Qh=7,677.609786

e bo=

kJ
kg

ms ( hshf )
100
mf Qh

( 60,000 kghr )( 3,113.28 kJkg 461.3 kJkg ) 100

(30,000 kghr )(7,677.609786 kJkg )
e bo=69.08

For Boiler 3
Rated Boiler Horsepower
2

Rated Boiler Horsepower=

HS ( m )
0.91

Where:

HS=Heating Surfacem 2=2,200 m 2

Solution:

Rated Boiler Horsepower=

2,200 m 2
0.91

Rated Bioler Horsepower=2,417.58 hp

Solving for Develop Boiler Horsepower
Given:

t s=360 C Ps =30
t f =110 0 C ms=80,000

340 C , and @

kg f
cm 2

kg
hr
31.03322

kg 0.101325 MPa
=3.04 MPa
cm 2 1.03322 kg
2
cm

From Steam Tables, table 3 (Superheated)

3.0
3.04
3.05
By interpolation;

h s=3,137.9

kJ
kg

From Steam Tables, table 1 (saturated) @

Develop Boiler Horsepower=

Where:

1 BHp=35322

3,138.7
hs
3,137.7

110 C ;

h f =461.30

kJ
kg

m s ( hshf )
35322

kJ
hr

( 80,000 kghr )( 3,137.9 kJkg 461.3 kJkg )

35322

kJ
hr

Develop Boiler Horsepower=6062.171 hp

Solving for Percent Rating

Percent Rating is the ratio of the develop boiler horsepower to the rated boiler
horsepower.

Percent Rating=

Develop Boiler Hp
100
Rated Boiler Hp

6,062.171 hp
100
2,417.58 hp

Percent Rating=250.7536876

Solving for ASME Evaporation Units

ASME Evaporation Units is the heat output of the boiler or the rate at which heat is
transferred.

ASME Evaporation Units=m s ( h sh f )

80,000

kg
kJ
kJ
3,137.9 461.3
hr
kg
kg

ASME Evaporation Units=214,128,000

kJ
hr

Solving for Factor of Evaporation, (FE)

Factor of Evaporation is the actual heat absorption per kilogram of steam generated
divided by 2257 (hfg from and at 1000C)

FE=

hs hf
2257
kJ
kJ
461.3
kg
kg
=1.185910501
kJ
2257
kg

3,137.9
FE=

Solving for Equivalent Evaporation

Equivalent Evaporation is the product of the rate of evaporation of steam and factor
of evaporation.

Equivalent Evaporation=m s FE

 80,000

kg
1.185910501
hr

Equivalent Evaporation=94,872.84005

kg
hr

Solving for Actual Specific Evaporation (ASE) or Boiler Economy

Actual Specific Evaporation (ASE) or Boiler Economy is the ratio of the mass of
steam to the mass of fuel.

m
Boiler economy= s =
mf

kg
hr
=2
kg
40,000
hr
80,000

Solving for Equivalent Specific Evaporation

Equivalent Specific Evaporation is the product of boiler economy and factor of
evaporation.

Equivalent Specific Evaporation=Boiler economy FE

2 1.185910501
Equivalent Specific Evaporation=2.371821002

Solving for Boiler Efficiency

e bo=

ms ( hshf )
100
mf Qh

Where:

ms=mass of steam
h s=enthalpy of steam
h f =enthalpy of feedwater
mf =mass of fuel
Qh=fuel heating value

ms=80,000

kg
hr

h s=h @3.04 MPa ,@3600 C ( table 3 ) =3137.9

h f =h @110 0 C ( table 1 )=461.3

kJ
kg

kJ
kg

kg
kg
hr of bagasse
mf =80,000 of steam
hr
kg
2,000 of steam
hr
1,000

mf =40,000
Qh=3,300

kg
of bagass e
hr

Btu 2.205lb 4.187 kJ 0.252 kcal

lb
1 kg
1 kcal
Btu

Qh=7,677.609786

kJ
kg

kg
kJ
kJ
80,000 )(3,137.9 461.3 )
(
hr
kg
kg
e =
100
kg
kJ
( 40,000 hr )(7,677.609786 kg )
bo

e bo =69.72

CONDENSATE
LINE