Sample problem 1.

(Boiler/steam generator)

A steam boiler on a test generates 885,000 lbs of steam in a 4-hour period. The
average steam pressure is 400 psia, the average steam temperature is 700°F, and the
average temperature of the feedwater supplied to the boiler is 280°F. If the boiler
efficiency for the period is 82.5%, and if the coal has a heating value of 13,850 Btu/lb as
fired, find the average amount of coal burned, in short tons per hour.(1 ST = 2000 lbs).

Given.

ms = 885,000 lbs in 4 hours

ps = 400 psia
ts = 700°F
tf = 280°F
eb = 82.5%
Qh = 13,850 Btu/lb

Requirement:

Coal burned, in ST/hr

Solution:

eb = ms(hs-hf)/Qh x mf

where:
hs = 1362.7 Btu/lb @ 400 psia and 700°F
hf = 249 .1 Btu/lb @ 280°F
ms = 885,000 lbs/4 hours = 221,250 lbs/hr

0.825 = [(221,250 lbs/hr) (1362.7-249.1) Btu/lb]/[mf (13,850 Btu/lb)]

mf = 21,563 lb/hr
mf = 10.78 short tons/hr

Answer:

mf = 10.78 short tons/hr

Sample problem 2.

A boiler operating at 11 kg/cm 2 is required to generate a minimum of 50,000

kg/hr of saturated steam. Feedwater enters the boiler at 80°C. The furnace is
designed to fire coal at an average rate of 4,800 kg/hr and boiler efficiency 85%.
Compute the developed boiler horsepower.
I. Given:

boiler pressure, p = 11 kg/cm2

ms = 50,000 kg/hr
mf = 4,800 kg/hr
eb = 85%
feedwater temp., tfw = 80°C

II. Requirement:

Developed boiler hp

III. Solution:

Dev. Boiler hp = ms(hs – hf)/35322

At 11 kg/cm2 (1.0971 MPa);

hs = hg = 2781 kJ/kg
At 80°C;
hf = 334.91 kJ/kg

Dev. Boiler hp = 50,000 kg/hr (2781 – 334.91) kJ/kg/35,322 kJ/hp.hr

Dev. Boiler hp = 3,462.56 hp

IV. Answer:

Dev. Boiler hp = 3462.56 hp

Sample problem 3.

A water tube boiler evaporated 5.05 kg of water per second from a feedwater
temperature at 104.44°C to steam at 1241.1 kPa and quality of 0.97; weight of coal fired
per second, 0.57 kg; HHV of coal as fired, 11,800 Btu/lb. Determine the rate of heat
absorption, in kJ/s, the boiler horsepower, and the efficiency of steam generating unit.
I.Given:

A water-tube boiler
ms = 5.05 kg/s
ps = 1241.1 kPa
x = 0.97
tfw = 104.44°C
mf = 0.57 kg/s
HHV = 27,450 kJ/kg

II. Requirements:

Q, boiler hp, eb

III. Solution:

At 104.44°C;
hf = 437.78 kJ/kg
At 1241.1 kPa;
hf = 805.29 kJ/kg
hfg = 1980.6 kJ/kg
h2 = hf + xhfg
h2 = 805.29 + 0.97(1980.6)
h2 = 2726.5 kJ/kg

Heat absorbed by the boiler, Q

Q = ms(h2 – h1)
Q = 5.05 kg/s(2726.5 – 437.78)kJ/kg
Q = 11,558 kJ/s

Dev. Boiler horsepower,

Dev. Boiler hp = msΔh/35,322
= [5.05kg/s(2726.5–437.28)kJ/kgx3600s/hr]/35,322 kJ/hp.hr
= 1,178 hp

Boiler efficiency, eb

eb = ms(h2 – h1)/mfxQh = 11,558 kJ/s/0.57 kg/s x 27,450 kJ/kg

eb = 0.7387 = 73.87%

IV. Answers:
 Q = 11,558 kJ/s
Dev. boiler hp = 1,178 hp
eb = 73.87%

Sample problem 4.

A waste heat-recovery boiler produces 4.8 MPa (dry saturated) steam from
104°C feedwater. The boiler receives energy from 5 kg/s of 954°C dry air. . After
passing through the waste- heat boiler, the temperature has been reduced to 343°C.
How much steam, in kg, is produced per second (At 4.8 MPa, dry and saturated, h =
2796.0 kJ/kg)?

I. Given:
Waste-heat recovery boiler

ps = 4.8 MPa; h = 2796.0 kJ/kg

tfw = 104°C
tai = 954°C
tao = 343°C
ma = 5 kg/s

II. Requirement:

Steam produced ms, kg/s

III. Solution:

Heat released by air = Heat absorbed by water

Qa = Qw
maCpaΔta = ms(hs – hf)

At 4.8 MPa, dry and saturated;

hs = hg = 2796 kJ/kg
hf = h @ 104°C or
= Cp x t = 4.187 kJ/kg°C (104°C)
hf = 435.45 kJ/kg

(5 kg/s)(1 kJ/kg°C)(954-343)C° = ms (2796-435.45)kJ/kg

ms = 1.29 kg/s
 IV. Answer:
ms = 1.29 kg/s

Sample problem 5.

A steam-generating plant consisting of a boiler, an economizer and a

superheater generates superheated steam at a rate of 50 tons per hour. Feedwater
enters the economizer at 5 MPa and 120°C. Steam leaves the superheater at 4.5 MPa
and 320°C. If the coal has a heating value of 30,000 kJ/kg, calculate the number of tons
of coal fired per hour for a gross efficiency of 85%.

I.Given:

msh = 50 tons/hr
psh = 4.5 MPa
tsh = 320°C
tfw = 120°C
pfw = 5 MPa
HHVc = 30,000 kJ/kg
eb = 85%

II. Requirement:

Coal fired, tons/hr

III. Solution:
eb = ms(hsh – hf)/mf x HHV

At 4.5 MPa and 320°C; - superheated steam

hs = hsh = 3000.6 kJ/kg

At 5 MPa and 120°C; - compressed liquid

hf = 507.09 kJ/kg

0.85 = 50 tons/hr (3000.6 – 507.09)kJ/kg/mf x 30,000 kJ/kg

mf = 4.889 tons/hr

IV. Answer:
mf = 4.889 tons/hr
Sample problem 6.
 Coal has the following ultimate analysis by weight:

C = 70.5% H2 = 4.5% O2 = 6.0% Moisture = 4%

S = 3.0% Ash = 11% N2 = 1.0%

A stocker-fired boiler of 175,000 kg/hr steaming capacity uses this coal as fuel.
Calculate the volume of air, in m 3/hr, with air at 60°F and 14.7 psia pressure if boiler
efficiency is 70%, excess air, e = 30% and FE = 1.10.

Sample Problem 7. - Boiler Heat Balance

The ff. data were obtained from a boiler test. Heat absorbed by the boiler, 74.8%
of the Higher Heating Value, HHV, of the fuel, as fired.
Analysis of coal as fired, percentage by weight:
C – 62%
H – 4%
N2 – 1%
O2 – 8%
S – 2%
moisture – 8%
ash – 15%
HHV = 11,800 Btu/lb

Flue gas analysis:

CO2 – 13%
CO – 1%
O2 – 5%
N2 – 81%

Temperature of air and fuel entering the furnace, 74°F; temperature of the flue
gas, 452°F; temperature of steam in the boiler, 360°F; percentage of saturation of air
entering the furnace, 70%; coal fired per hour, 2000 lb; refuse per hour, 420 lb; and
unburned carbon in the refuse, 18%. Barometer, 29.92 in. Hg. Calculate and tabulate
complete heat balance per pound of coal, as fired.

I. Given:
(as above)

II. Requirement:

Calculate and tabulate heat balance

 III. Solution:

Weight of carbon appearing in the flue gas, C 1

C1 = [(mfCf – mrCr)]/(mf x 100%) – actual carbon burned/consumed

per pound of coal
C1 = [(2000 lb)(62%) – (420 lb)(18%)]/[(2000 lb)(100%)]
C1 = 0.5822 lb C/lb coal

Weight of dry chimney gases, mdg

mdg = (mg x C1)
mdg = [(4CO2 + O2 + 700)/3(CO2 + CO)]C1
where:
CO2, O2 – dry gases as determined from Orsat Flue-
Gas Analyzer
700 – Orsat constant
mdg = [(4(13%)+5%+700)/3(13% + 1%)]lb dg/lb C(0.5822)lb C/lb
coal
mdg = 10.494 lb/lb coal

Weight of dry air supplied, maa

maa = mdg – C1 + 8(H – O/8)

= 10.494 lb/lbcoal –0.5822 lb C/lb coal+8(0.04 –
0.08/8)lb/lbcoal
maa = 10.15 lb/lb coal

1.) Heat absorbed by the boiler, H1

H1 = ms(h” – h’)/mf
H1 = 0.748(11,800 Btu/lb) = 8826 Btu
H1/HHV x 100%= 74.80%

2.) Heat loss due to moisture in the fuel, H2

H2 = mm(h” – h’)
H2 = 0.08 lbm/lbcoal(1265.9 – 42.03)Btu/lb = 98 Btu
H2/HHV x 100%= 0.83%

3.) Heat loss due to water from combustion of hydrogen, H 3

H3 = 9Hg ((h” – h’)
H3 = 9(0.04)lb/lb coal(1265.9 – 42.03)Btu/lb = 440 Btu
H3/HHV x 100% = 3.73 %
 4.) Heat loss due to moisture in air supplied, H4
H4 = mv x 0.46(tg – ta)
H4 = 0.70(0.01815 lbH2O/lbda) (10.15 lbda)(0.46 Btu/lb.R)(452F-74F)
H4 = 23 Btu
H4/HHV x 100%= 0.18%

5.) Heat loss due to dry chimney gases, H5

H5 = mdgCp(tg – ta)
H5 = 10.494lb/lbcoal (0.24 Btu/lb°R) (452°F – 74°F) = 952 Btu
H5/HHV x 100% = 8.07%

6. Heat loss due to unburned gaseous combustible/incomplete

combustion, H6
H6 = [CO/(CO2 + CO)] x 10160 x C1
H6 = [1%/(13%+1%)] lbC/lbdgx10160 Btu/lbC x 0.5822 lbC/lbcoal = 423
Btu
H6/HHV x 100%= 3.59%

7.) Heat loss due to unconsumed combustible in the refuse, H 7

H7 = 14540 x mr x cr/mf
H7 = 14540 Btu/lbC(420)(0.18)lbC/2000lbcoal = 550 Btu
H7/HHV x 100%= 4.66%

8.) Heat loss due to unconsumed hydrogen, hydrocarbons, radiation,

unaccounted-for losses, H8, by difference

H8 = HHV – (H1 + H2 + H3 + H4 + H5 + H6 + H7)

H8 = 11800 Btu– (8826+98+440+23+952+423+550 ) Btu
H8 = 488 Btu
H8/HHV x 100%= 4.14%
Htotal = H1+H2+H3+H4+H5+H6+H7+H8 =11,800 Btu
(H1+H2+H3+H4+H5+H6+H7+H8)Btu/HHV Btu x 100% = 100%