Calculation of Oil fired Process Heater Efficiency by INDIRECT Method

Input Data

GUW 01

GUW 01

GUW 01

Barauni
Boiler

GUW 01

A: Fuel Composition
Carbon
Hydrogen
Nitrogen
Oxygen
Sulphur
Moisture
Ash

B. GCV of Fuel

Kcal/Kg

% wt
87
12
0
0
0.7
0.2
0.1
100

% wt
87
12
0
0
0.7
0.2
0.1
100

% wt
87
12
0
0
0.7
0.2
0.1
100

% wt
87
12
0
0
0.4
0.5
0.1
100

% wt
86.5
12
0
0
0.8
0.5
0.2
100

10400

10400

10400

10400

10400

C. Input data for Radiation and Convection Losses

Fuel Firing rate
Kg/hour
Surface Temperature C
Surface Area
Sq Meter
Humidity, kg/kg of dry air
Wind speed
mtr / sec

1250
75
357
0.025
1.5

1250
75
357
0.025
1.5

1250
75
357
0.025
1.5

1250
65
357
0.025
1.5

3700
75
714
0.025
1.5

D. Flue gas Analysis

% CO2 in flue gas actual
% O2 in flue gas
% CO in flue gas
Specific heat of flue gas
Flue gas Temp
C
Ambient Temp
C
N2 % wt in air
O2 % wt in air

10.8
5
0.005
0.23
170
30
77
23

10.8
5
0.005
0.23
150
30
77
23

12
3.5
0.005
0.23
150
30
77
23

10.8
5
0.005
0.23
150
30
77
23

10.8
5
0.005
0.23
170
30
77
23

14.30

14.30

14.30

14.29

14.24

31.25

31.25

20.00

31.25

31.25

18.77

18.77

17.16

18.75

18.70

3.19

3.19

3.19

Or assumed

Solution

I. Theoretical Air Requirement

Kg of air / Kg of fuel
II. Excess Air Supplied (%)
III. Actual Air Supplied
Kg of air / Kg of fuel
IV. Mass of Dry Flue Gas per kg of fuel
Mass of CO2
Kg

3.19 3.171667

Mass of N2 in fuel
Kg
Mass of N2 in Actual airKg
suppled
Mass of O2 in flue gas Kg
Mass of SO2
Kg
Total

0
14.45
1.028
0.014
18.68

0
14.45
1.028
0.014
18.68

0
13.21
0.658
0.014
17.07

0
14.44
1.027
0.008
18.66

0
14.40
1.024
0.016
18.61

L1 : % Heat Loss in dry flue gas

5.78

4.96

4.53

4.95

5.76

L2 : Heat loss due to evaoration

of water formed due to H2
content in fuel

6.72

6.63

6.63

6.63

6.72

L3 : % Heat loss due to moisture in fuel

0.01

0.01

0.01

0.03

0.03

L4 : % Heat Loss due to moisture in air

0.28

0.24

0.22

0.24

0.28

L5. Heat loss due to partial combustion

(Formation of CO)
L6 : Raiation & Convection Loss

0.02

0.02

0.02

0.02

0.02

2.09

2.09

2.09

1.53

1.41

Radiation heat loss

Surface Temp o K
Ambient Temp o K
Convection Heat Loss
Raiation & Convection Loss

W/m2
358.95
358.95
358.95
266.04
358.95
Ts
348
348
348
338
348
Ta
303
303
303
303
303
W/m2
524.39
524.39
524.39
383.02
524.39
W/m2
883.34
883.34
883.34
649.06
883.34
Kcal/m2
759.674111 759.6741 759.6741 558.1928 759.6741
Kcal /Hour 271203.657 271203.7 271203.7 199274.8 542407.3

Total Lossess

14.91

13.95

13.50

13.41

14.23

85.09

86.05

86.50

86.59

85.77

Utilised Heat
Heat Input excluding latent heat loss
Efficiency

85.09
93.28
91.22

86.05
93.37
92.16

86.50
93.37
92.64

86.59
93.37
92.74

85.77
93.28
91.95

Efficiency = (100 - Losses)

Efficiency Based on NCV

= 0.87 * (44/12) + 18.77 * 0.77 + 0.007 * 2 + (18.77 14.30) * 0.23

3.19

14.4529
0.014
1.0281
18.685

3.19
14.45
0.014
1.028
18.682

Barauni
Boiler

Barauni
Boiler

Barauni
Boiler

PDRP
INDMAX

% wt
86.5
12
0
0
0.8
0.5
0.2
100

% wt
86.5
12
0
0
0.8
0.5
0.2
100

% wt
86.5
12
0
0
0.8
0.5
0.2
100

% wt
89.57
10.18
0
0
0.25
0
0
100

10400

10400

10400

10400

3700
75
714
0.025
1.5

3700
75
714
0.025
1.5

3700
75
714
0.025
1.5

3700
75
714
0.025
1.5

10.8
4
0.005
0.23
160
30
77
23

10.8
3
0.005
0.23
150
30
77
23

10.8
3
0.005
0.23
140
30
77
23

12
3.5
0.005
0.23
199
30
77
23

14.24

14.24

14.24

13.94

23.53

16.67

16.67

20.00

17.60

16.62

16.62

16.73

3.171667 3.171667 3.171667

3.284233

0
13.55
0.771
0.016
17.51

0
12.80
0.546
0.016
16.53

0
12.80
0.546
0.016
16.53

0
12.88
0.641
0.005
16.81

5.03

4.39

4.02

6.28

6.67

6.63

6.58

5.81

0.03

0.03

0.03

0.00

0.25

0.22

0.20

0.31

0.02

0.02

0.02

0.02

1.41

1.41

1.41

1.41

358.95
358.95
358.95
348
348
348
303
303
303
524.39
524.39
524.39
883.34
883.34
883.34
759.6741 759.6741 759.6741
542407.3 542407.3 542407.3

358.95
348
303
524.39
883.34
759.6741
542407.3

13.42

12.69

12.26

13.84

86.58

87.31

87.74

86.16

86.58
93.33
92.77

87.31
93.37
93.50

87.74
93.42
93.92

86.16
94.19
91.48