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O2 %
0
Furn Outlet AH Inlet AH Outlet ID outlet
210 MW 210 MW 500 MW 210 MW
4. Boiler Air Ingress
• Cold air leaks into the boiler from openings in the furnace
and convective pass and through open observation doors.
• Some of the boiler leakage air aids the combustion
process; some air that leaks into the boiler in the low
temperature zones causes only a dilution of the flue gas.
• This portion of air appears as a difference in O2 level
between the furnace exit and oxygen analysers at
economizer exit. Actual oxygen in the furnace could be
much less.
• Also, boiler casing and ducting air ingress affects ID fans’
power consumption and margins in a major way.
Air Ingress Points – Furnace Roof , Expansion
joints, Air heaters, Ducts, ESP Hoppers, Peep
Holes, Manholes, Furnace Bottom
Air-in-
leakage
Furnace
Outlet
Zirconia
O2 Probe
Expansion Joints
AH ESP
Seal
Lkg
Air Ingress Calculations
Air ingress quantification is done with the same formulae as those
used for calculation of AH leakage
= 4.84 kg / kg of coal
Step – 2 Find theoretical CO2 %
Moles of C
% CO2 at theoretical condition =
( CO2 )t Moles of N2 + Moles of C
Where,
4.84 x 77/100 0.016
Moles of N2 = + = 0.1332
28 28
0.0347
( CO2 )t =
0.1332 + 0.0347
= 20.67
Step – 3 To find Excess air
supplied
= 7900 x [20.67 – 14 ]
= 47.44 %
Step – 4 to find actual mass of air supplied
= {1 + 47.44/100} x 4.84
= 7.562 kg / kg of coal
Step – 6 to find all losses
L1 = 7.89 %
2. % Heat loss due to formation = 9 x H2 x {584 + Cp (Tf – Ta )}
of water from H2 in fuel (L2) x 100
GCV of fuel
M x {584 + Cp ( Tf – Ta )}
3. % Heat loss due to moisture in = X 100
fuel (L3) GCV of fuel
L3 = 5.91 %
AAS x humidity x Cp x (Tf – Ta ) x 100
4. % Heat loss due to moisture in =
air (L4) GCV of fuel
%CO x %C 5744
5. % Heat loss due to partial = x x 100
conversion of C to CO (L5) % CO + (% CO2)a GCV of fuel
L5 = 2.58 %
6. Heat loss due to radiation and = 0.548 x [ (343/55.55)4 – (304/55.55)4] + 1.957 x
convection (L6)
(343 - 304)1.25 x sq.rt of [(196.85 x 3.5 + 68.9) /
68.9]
= 633.3 w/m2
= 633.3 x 0.86
= 544.64 kCal / m2
Total radiation and convection = 544.64 x 90
loss per hour
= 49017.6 kCal
% radiation and convection loss = 49017.6 x 100
3501 x 5591.17
L6 = 0.25 %
7. % Heat loss due to unburnt in fly ash
= 100-22.24
= 77.76 %