RECIPROCAL COMPRESSORS APPLICATIONS Pneumatic hand tools Drills Paint spraying Mining Blast furnaces Lifts rams and

ms and pneumatic conveyors

FAD: Actual volume of air delivered by an air compressor is reduced to either NTP or STP conditions or intake conditions. () inlet of compressor = ()outlet of compressor *V1/RT1 =P2*V2/R*T2 = Pf*Vf/TF(neglecting Vc) Pf ,Vf , Tf are free sir conditions & Vf will be FAD. For convenience Pf=101.325kPa Tf=288k If Vc is taken into account Pf*Vf/Tf =P1(V1-V4)/T1= P2(V2-V3)/T2

P in bar Roots 1 to 3 bar

M3/min v .14 to 1400

applications Scavenging,supercharging of ic engines

Rotary vane

1 to 8.5

150

Hinge vane compressor,expander used a integrated supercharges to active throttle(ISCAT)

FOOD,CHEMICAL,PETROCHEMICAL,REFINING,STEEL INDUSTRIES

Screw

1 to 3.2

3-1000

Single stage reciprocating

1 to 46.87

0.1

Higher pressure and low discharge

Centrifugal

11 to 3.2

60-190

Aircraft unit turbo propeller

APPLICATIONS OF VARIOUS TYPES OF COMPRESSORS COMPRESSORS DISCHARGE PRESSURE(MPa) 69 DISCHARGE VOLUME( /min) 170-830 APPLICATIONS

Centrifugal compressor

Continuous duty functions as ventilation fans ,air movers ,cooling units on turbo charges and supercharges

Axial flow compressor

830-2300

Jet engines ,air conditioning systems in aircraft and in bleed air Oil refineries ,gas pipelines ,chemical plants and refrigeration power plants

Reciprocating compressor

180

780

Roots blower

0.6 to 1

100 -120

Pneumatic conveying of bulk materials ,pressurized aeration of basins in sewage treatment plants ,High vacuum boosters

Rotary vane compressor

1.3

35

Vacuum pump and air motor Super chargers ,vacuum pumps

Screw compressor

8.3

45

GOOGLE SEARCH Applications of various compressors Discharge pressure of various compressors Discharge volume of various compressors

Air compressor
Importance Industry applications Brief working principle Construction details Work supplied without clearance volume Efficiencies Work supplied with clearance volume Volumetric efficiency

Some basic formulas WORK DONE PROCESS P,v,t relation

(p2v2-p1v1)/n-1 Wd=p(v2-v1) Wd=p1v1 ln(p2/p1) Wd=(p2v2-p1v1)/-1 Wd=v(p)

polytrophic isobaric isothermal Rev adiabatic/isentropic isochoric

Pvn=c v/t=c Pv=c pv=c P/T=C

Work supplied to compressor without

4-1 Suction

constant pressure

1-2 compression polytropic 2-3 discharge W=( =( = (1/n-1 + 1) ( = n/n-1 ( = n/n-1* ( = = n/n-1* / ( ) ) - 1) ( ) ) ) constant pressure ( ) ( )

/n-1) + /n-1) +

(( ) ( )
( )

= n/n-1*mR (( ) = n/n-1*mR ( ( ) Also, ( ) ( ) ( )

( )

or

( )

Comparison of work supplied among three processes

1-2 isothermal process (PV =C) 1-3 polytropic process 1-3 reversible adiabatic process 1-2 isothermal process: ( ) 1-3 polytropic *n/n-1 (( ) 1-4 adiabatic */-1 (( ) =
( ) ( )

( ) (since PV = C)

-1)

-1)
( )

( )/ n/n-1 (( )

-1)

= n/n-1 (( )

-1)/ /-1 (( )

-1)

= IP/SP, SP-IP = Fr.P.

Effect of clearance of work of compression:

*n/n-1 (( ) (

-1) ( )

*n/n-1 (( ) -1) if

-1)

)*n/n-1 (( ) *n/n-1 (( )
( )

is negligible

-1)
( )

Also, Also, *

*n/n-1 (( ) / -1 (( )
(

-1) -1) * / -1 (( )
( )

-1)

Clearance ratio C = Also, C = 3% to 12% of Thus the effect of clearance is to reduce the volume of air actually sucked in working cycle

Two stage air compressor with inter cooling and without clearance volume: Wc=n/n-1*p1v1((p2/p1)n-1/n-1) +n/n-1*p2p3((p3/p2)n-1/n-1) P1V1=P2V2= Perfect intercooling to T1 Wc=n/n-1*p1v1((p2/p1)n-1/n + (p3/p2)n-1/n-2 dwc/dP2=0 for minimum work

(1/p1)n-1/n- p3n-1/n/p22(n-1/n)=0

P2=(p1p3)0.5

Wc=n/n-1*p1v1((p3/p1)n-1/2n+(p3/p1)n-1/2n-2

Wc= (2n/n-1 v1 (p3/p1)n-1/2n-1)p1 For N-stages, Similarly Wc= (Nn/n-1) *p1v1 (pN+1/p1)n-1/Nn-1

Wc= (Nn/n-1)maRT1((pL/pS)n-1/n-1)

VOLUMETRIC EFFICIENCY

= Actual volume of air intake per cycle/volume of Air which could theoretically fill the swept volume under optimum condition

vol=Va/VS=V1-V4/VS

=(VS+CVS)-CVS(P2/P1)1/n/Vs

vo=1+c- CVS(P2/P1)1/n

=1-C(V1/V2-1)

T2/T1 =( V1/V2)N-1= (p2/p1)n-1/n

PROBLEMS: 1) Air is to be isentropically compressed at the rate of 1 m3/s from 1 bar and 200 c to 10 bar, Find the work of compressor and the volumetric efficiency. If the clearance volume is 4% of stroke volume for all the cylinders for the following causes 1) single stage 2) two stage 3) Three stage compression Given: Free air delivered = 1.2 /s

Assume =1.2 kg/ 1. Work done =/-1 mR (( ) -1) -1)

= 1.4/0.4 * 1.2 * 0.287 * 293 *( = 328.71 kw = 1(( ) -1) -1)

= 1 0.04 ( = 83.28%

2. Intermediate pressure = W=2*/-1*maRT1((P2/P1)/-1-1) =2*1.4/0.4*1.2*0.287 * 293 *( =274.92 kw =1-0.04(3.161/1.4-1) =94.9% -1)

P 2= = =2.15 Bar WC=3*1,4/0.4*1.2*.287*293*(2.15).4/1.4-1) =259 Kw =1-0.04*(2.151/1.4-1) =97.09%

2.A single stage single acting reciprocating air compressor with 0.3 m bore and 0.4 m stroke runs at 400 rpm.the suction pressure is 1 bar at 300k and the elivery preure is 5 bar.Find the power required to run it if compression is thermal,compression follows the Pv 1.3=constant nd compression and reversible adiabatic.Alao find the isothermal efficiency Volume of air compressed per min= d2/4*1*N =3.14/4*0.302*0.4*400 =11.31 m3/min Given: d-=0.3 m l=0.4 m N=400rpm P1=1 bar T1=300k P2= 5bar Isothermal compression work=P1V1ln(P2/P1)=1*105*11.31/60*ln(5/1) = 30337.0 W. Polytropic compression work= *n/n-1 (( )
( )

-1)

=1*105*11.31/60*(1.3/1.3-1)((5/1).3/1.3-1) =36.74 kw

Isothermal efficiency=isotherml work/actual work)*100=30.34/36.74)*100 =82.58% Isentropic work of compression= * /-1*((P2/P1)/-1-1)

=1*105*11.31/60*(1.4/1.4-1)((5/1).4/1.4-1) =38.52 kw =36.74/38.52)*100=78.76% =actual work/adiabatic work done

3. A double acting two stage compressor delivers air at 25 bar. The pressure and temperature of air at the beginning of compression in L.P. cylinder are 1 bar and 20 degree Celsius . the temperature of air coming out from an intercooler between two stages is 40 degree Celsius and the pressure is 7 bar. The diameter and stroke of L.P cylinder are 60 cm and 80 cm and N = 100 rpm. The vol = 80%. Find the power of the electric motor required to drive the compressor assuming mech = 85% Given: Pd = 25 bar, P1 = 1 bar , T1 = 20+273 = 293 k, T3 = 313 k , P2 = 7 bar D = 60 cm, l = 80 cm ,N = 100 rpm , vol = 80%, mech = 85% PVn = C, n = 1.35

Solution: I.P = n/n-1 maR(T1((P2/P1)n-1/n -1)+ T2((P3/P2)n-1/n -1) Ma = P1V1/RT = 1*105*3.14*0.62*0.8*0.8*100*2/4*287*293*60 Ma = 0.7174 kg/s I.P = 1.35/0.35 * 0.7174* 287 * (293(70.35/1.35-1)+313(25/7)0.35/1.35-1)) I.P = 249.9 kw B.P = I.P/ mech =249.9/0.85 =294 kw

MULTI STAGE RECIPROCATING AIR COMPRESSOR Compression of air to high pressure in one stage has many disadvantages, Less volumetric efficiency Higher work of compression Leakage past the piston Ineffective cooling of the air Robust construction of the cylinder(to withstand delivery pressure)

Hence, multistage compression is necessary for efficient compression with higher volumetric efficiency. In multistage compression, the air can be cooled perfectly at intermediate pressures resulting in same power required to drive the compressor, than compared to a single stage compressor of same delivery pressure and flow rate. The mechanical balance of the machine is also better in multistage compression due to phasing out of operation in stages.

TWO STAGE AIR COMPRESSOR WITH INTERCOOLER The arrangement of a two stage compressor is given in the figure below. Air is sucked into the low pressure cylinder and compressed into intermediate pressure. This compound air at higher temperature from l.p cylinder flows into a air-cooler. In the inter cooler the air is cooled to its initial temperature, In the high pressure cylinder, the air is then compressed to the final delivery tube. The compressed air from the H.P cylinder is also passed through an after cooler sometimes to send cooled air to the reservoir n avoid the reservoir to the store hot air. The inter cooler and after coolers are simple heat exchangers. The coolant may be water or any other fluid which passes through the tubes secured between the two end plates and the air circulates over the through a system of baffles. Baffles are provided to ensure intimate contact between the tubes and the air in long path. The indicator diagram for low pressure and high pressure cylinders. Suction to the low pressure stage is represented by 7-1 and this is followed by a compression process from pressure p1 to p21 following the polytropic flow PvN=c.

Thus the air is then discharged from the low pressure cylinder to the inter cooler where it is cooled at constant pressure condition 2, to the initial temperature T .From the inter cooler the air is sucked into the high pressure cylinder followed by a compression process from p2-p3 following the law Pv=c. Finally the air I discharged at p3 to the receiver. Total compression work done on air is, Wc = n/n-1 * P1 V1 ((P2/P1)n-1/n-1)+n/n-1 * P2 V2 ((P3/P2)n-1/n-1) assuming the same value for the index of compression n and assuming that the intercooler is perfect ,that is the air is cooled in the inter cooler to original temperature, T 1 and there is no pressure drop in the intercooler we have, P1V1=P2V2 (isothermal condition) P2=P1

Wc

= n/n-1 P1 V1 ((P2/P1)n-1/n + (P3/P2)n-1/n-2)

As P1 and P3 are fixed , the only variable pressure for minimum work done is P 2. dW/dP2 = 0 (for minimum work) n/n-1 P1 V1 ((1/P1)n-1/n (n-1/n)P2-1/n- P3n-1/n(n-1/n)P21/n-2) =0 (1/P1)n-1/n P3n-1/n/P22(n-1/n) = 0 Or (1/P1)n-1/n = (P3/P22)n-1/n i.e 1/P1 = P3/P22 P22 = P1P3 P2 = Wc Wc = n/n-1 P1 V1 ((P3/P1)n-1/2n + (P3/P1)n-1/2n-2) = 2 n/n-1 P1 V1 ((P3/P1)n-1/2n-1)

For N number of stages , the pressure ratio will be P2/P1 = P3/P2 = P4/P3 = P5/P4 = . . . . . . . = PN+1/PN And minimum work done for all stages will be, Wc = N n/n-1 P1 V1 ((P3/P1)n-1/Nn-1)

The following assumptions are used for the minimum work required to compress the air , in multi stage compressor . 1. The air is cooled to the initial temperature after each stage of compression. 2. The pressure ratio in each stage is same . 3. Work done in all stages is equal if the same index of compression is used.

Problems: 1. An air compressor takes in air at 1 bar and 20 degree Celsius and compresses it according to law PV1.2 = constant. It is then delivered to a receiver at a constant pressure of 10 bar . R = 0.287 kJ/kg.k. Determine : 1. Temperature at the end of compression 2. Work done and heat transferred during compression per kg of air

Solution: In fig T1 = 20 + 273 = 293, P1 = 1 bar , P2 = 10 bar Law of compression : PV1.2 = constant , R = 0.287 kJ/kg.k. 1.temperature at the end of compression, For compression process 1-2, we have T2/T1 = (P2/P1)n-1/n =(P2/P1)1.2-1/1.2 = 1.468 T2 = T1 * 1.468 = 430k 2.Work done and heat transferred during compression per kg of air Work done W = mRT1 n/n-1 ((P2/P1)n-1/n -1) = 1*0.287 * 293 * (1.2/1.2-1)(101.2-1/1.2 -1)

= 236.13 kJ/kg of air Heat transferred Q = W +U

= P1V1 P2V2/n-1 + Cv(T2-T1) =mR(T1-T2)/n-1 + Cv(T2- T1) = (T2-T1)(Cv-R/n-1) = (430 293 )(0.78 0.287 / 1.2 -1) Q = -98.23 kJ/kg Negative sign indicates heat rejection 2.following data relate to a performance test of a single acting 14cm * 10cm reciprocating compressor Suction pressure = 1 bar Suction temperature = 20C Discharge pressure = 6 bar Discharge temperature = 180C Speed of compressor = 1200 rpm Shaft power = 6.25 kw Mass of air delivered = 1.7 kg/min Calculate the following, The actual volumetric efficiency, the indicated power, the isothermal efficiency, the mechanical efficiency, the overall isothermal efficiency. Solution: Given: P1 = 1 bar

T1 = 20+273 = 293k P2 = 6 bar T2 = 180+273 = 453k. N= = 1200 rpm Pshaft = 6.25 kw Ma = 1.7 kg/min Displacement volume, Vd = /4 *D2*L*N (for single acting compressor)

= /4 * (14/100)2 * 10/100 *1200 = 1.8373 m3/min. F.A.D = mRT1/P1 = 1.7 * 0.287 *1000 * 293/1*105 = 1.4295 m3/min vol = F.A.D/Vd * 100 = 1.4295/1.8473 * 100 = 77.38% The indicated power (I.P): T2/T1 = (P2/P1)n-1/n or n-1/n = ln(T2/T1)/ln(P2/P1) 1/n = 1- ln(453/293)/ln(6/1) n= 1.32 hence , index of compression , n = 1.32 indicated power = n/n-1 mRT1 ((P2/P1)n-1/n - 1) = 1.32-1/1.32 * 1.7/60 * 0.287 * 293 ((6/1)1.32-1/1.32 -1) = 5.346 kw

The isothermal efficiency, iso: Isothermal power = mRT1 *ln(P2/P1) = 1.7/60 *0.287*293 ln(6/1) = 4.269 kw iso = 4.269/5.346 *100 = 79.85% The mechanical efficiency, mech: mech =indicated power / shaft power * 100 = 5.346/6.25 * 100 =85.5% The overall isothermal efficiency, overall: overall = isothermal power / shaft power * 100 = 4.269 / 6.25 * 100 = 68.3% 3. A single stage double acting compressor has free air delivery of 14 m 3/min measured at 1.013 bar and 15C. the pressure and temperature in the cylinder during induction are 0.95 bar and 32 C. the delivery pressure is 7 bar and index of compression and expansion , n= 1.3. the clearance volume is 5% of the swept volume. Calculate Indicated power required, Volumetric efficiency.

Given:

Free air delivery = 14 m3 / min (measured at 1.013 bar and 15 C) Induction pressure, P1 = 0.95 bar, Induction temperature, T1 = 32+273 = 305 k Delivery pressure , P2 = 7 bar Index of compression and expansion, n= 1.3

Clearance volume Vc = 0.05Vs Solution: Indicated power:

Mass delivered per minute, m= PV/RT = 1.013*105*14/0.287*288*103 = 17.16 kg/min T2/T1 = (P2/P1)n-1/n T2 = T1(P2/P1)n-1/n = 305 * (7/0.95)1.3-1/1.3 =483.5 k Indicated power = 3809.4/60 = 63.49 kw Volumetric efficiency: V4/V3 = (P3/P4)1/n = (P2/P1)1/1.3 = (7/0.95)1/1.3 = 4.65 V4 = 4.65*V3 =4.65*0.05*Vs =0.233Vs

V1 V4 = V1 0.233Vs = 1.05Vs 0.233Vs = 0.817Vs m = PV/RT = P1(V1 V4)/RT1 F.A.D/cycle, v. = (V1- V4)TP1/T1P (where P1 and T1 are the suction conditions) V= 0.817Vs*288*0.95/305*1.013 = 0.723Vs Volumetric efficiency, vol = V/Vs = 0.723 Vs/Vs = 72.3%

4. Air at 103 kpa and 27 C is drawn into reciprocating , two stage L.P cylinder of a air compressor and is isentropically compressed to 700 kpa. The air is then cooled at constant pressure 37 C in an inter cooler and is then again compressed isentropically to 4 MPa in the H.P cylinder and is delivered at this pressure . determine the power required to run the compressor if it has to deliver 30 m 3 of air per hour measured at inlet conditions. Given: Pressure of intake air (L.P. cylinder) , P1 = 103 KPa Temperature of intake air, T1 = 27 + 293 = 300 k Pressure of air entering H.P. cylinder , P2 = 700 KPa Temperature of air entering H.P. cylinder, T2 = 37 + 273 = 310 k

Pressure of air after compression in H.P cylinder , P3 = 4 MPa Volume of air delivered = 30 m3/h

Solution: Power required to run the compressor: Mass of air compressed , m = (103*105)*30/(0.287*1000*300) 35.89 kg/h For the compression process 1- 2 , we have T2/T1 = (P2/P1)-1/ = (700/103)0.4/1.4 =1.7289 T2 = 300 * 1.7289 = 518.7 k Similarly for the compression process 2-3 , we have T3/T2=(P3/P2)-1/=(4000/700)1.4-1/1.4 =1.645 T3= 310* 1.645=510.1 K Work reqiuredto run the compressor, W=/-1*(m*R(T2-T1)+m*R(T3-T2)) = /-1*(m*R((T2-T1)+(T3-T5))) =(1.4/1.4-1)*35.89/3600*0.287((518.7-300)+(510.7-310)) =4.194 K

24.8 C) A free air delivered by a single srage double acting reciprocating compressor,measured at 1 bar and 150 c of free air,is 16 m3/min.Apressure and temperature of air inside the cylinder duing suction are 0.96 bar and 30 0c respectively and delivery pressure is 6 bar.The compressor has a clearance of 4 % of the swept volume and the mean piston speed is limitd to 300 m/min.Determine 1) The power input to the compressor if mechanical eddiciency is 90% and the compression efficiency is 85%. 2) Stroke and bore if the compressor runs at 500 rpm. Take index of compression and expansion as 1.4 Given: F.A.D=16 m3/min(measured at 1 Bar and 150c) P1=0.96 bar T1=303 K n= 1.3,V3=VC=0.04 VS P2=6 Bar 1)Piston input to compressor Mass flow rate of compressor M=pv/RT=1*105*16/287*288=19.36 Kg/min

To fin T2 using the relation, T2/T1=(P2/P1)n-1/n T2=T1(P2/P1)1.3-1/1.3=462.4 K Power input to the compressor=(n/n-1 m*R(T2-T1))*1/mech*comp =((1.3-1/1.3)* 19.36*.287*(462.4-303)*1/0.9*0.5 =5016.9 kJ/min=83.6 kj/s 2)stroke (L) and bore (D) Piston speed =2LN 300 =2*L*500 L= 0.3 m or 300 mm F..A.D=(3.14*D2L*2N*vd.for double acting air compressor------(1) To find vol proceed as follows V4/V3=(P3/P4)1/N=(P2/P1)1/3=(6/0.96)1/3=4.094 V4=4.094*V3=4.094*0.04VS=0.1637 VS V1-V4= V1-0.1637 VS=1.04 VS-0.1637 VS=0.8763 VS m= pv/RT =P1(V1-V4)/RT1 V=(V1-V4) T/T1*P1/P

Where P1 and T1 are suction conditions V= 0.8763 Vs * 288/303* 0.96 = 0.799Vs vol = V/Vs = 0.799Vs/Vs = 0.799 substituting the values in (1), we get 16 = /4 * D2 *0.3 * 2* 500 *0.799 D = (16*4 / * 0.2 * 500 * 0.799)1/2 = 0.29m or 290 mm 24.22) in a single acting two stage reciprocating compressor 4.5 kg of air per min are compressed from 1.013 bar Solution: Amount of air compressed m = 4.5 kg/min Suction conditions, Ps = 1.013 bar, Ts = 15 + 273 = 288 k Pressure ratio Pd/Ps = 9 Also Pi/Ps = Pd/Pi .

Compression expansion index , n = 1.3 Clearance volume in each stage = 5% swept volume Speed of the compressor , N = 300 rpm 1) Indicted power : Pi/Ps = Pd/Pi Pi2 = Ps / Pd = Ps * 9Ps = 9*Ps2 Pi = 3Ps i.e. Pi/Ps = 3

Now using the equation , Ti/Ts = (Pi/Ps)n-1/n = 31.3-1/1.3 Ti = Ts * 31.3-1/1.3 = 288*31.3-1/1.3 = 371 k Now as n,m and temperature difference are the same for both stages the the work done in each stage is the same . Total work required per min = 2* n/n-1*mR* (Ti Ts) = 2 *1.3/1.3-1 * 4.5 *0.287 (371 288) = 929 kj/min Indicated power = 929/60 = 1.8 kw 2) The cylinder swept volume requied: The mass indicated per cycle m=4.5/300 0.015 kg/cycle The mass is passed through each stage in turn For the L.P. pressure cylinder V1 -V4 = mRTs/Ps = 0.015 * 287 *288/ 1.013 * 105 = 0.0122 m3 / cycle.

vol = V1 V4 / Vs = 1+k k*(Pi/Ps)1/n = 1+0.05 0.05 * 31/1.3 = 0.934 Vs = V1 V4/vol = 0.0122/0.934 = 0.0131 m3/ cycle Swept volume of L.P. cylinder Vs(L.P.)= 0.0131 m3 For the high pressure stage , a mass of 0.015 kg/ cycle is drawn in at 15 o c and a pressure of Pi = 3*1.013 = 3.039 bar Volume drawn in = 0.015 * 287 * 288 / 3.039*105 = 0.00408 m3/cycle vol = 1+k-k(Pd/Pi)1/n and since Vc/Vs = k is the same as for the low pressure stage and also Pd/Pi = Pi/Ps then vol is 0.934 as above swept volume of H.P. stage , Vs(H.P.) = 0.00408 / 0.934 = 0.004367 m3 it may be noted that the clearance ratio k = Vc/Vs is the same in each cylinder , and the suction temperatures are the same since intercooling is complete , therefore the swept volumes are in the ratio of the suction pressures, Vs(H.P.) = VL.P/3 = 0.0131/3 = 0.000437 m3

BOILER: Boilers are also known as steam generators. In boilers , the heat energy produced during the combustion of fuel is transferred to water for generating steam Classification: 1. Fire tube boiler 2. Water tube boiler Fire tube boiler: The hot gases produced during fuel combustion passes through the tubes which are surrounded by water Eg: Cochran, lancashire boilers. Water tube boiler: Water flows through the tube which are surrounded by hot flue gases. Eg: bab cock and Wilcox, laMont boilers.

La Mont boiler:

Type : water tube boiler

Working: The water is circulated by afeed pump. The water first passes through the economizer . economizer is used to heat the feed water before the gasses passes through the chimney. The feed water then reaches the drum . from the storage drum, the circulation pump takes the water to the evaporater.from the evaporator , the steam gets separated and then forced through superheater.

Boiler accessories: 1. Economizer:

Economizer transfers the excess heat in the flue gasses to the feed water. Economizer helps to improve the boilers efficiency. 2. Super heater: Super heater is used to increase the temperature of saturate steam without raising the pressure. It is placed in the path of flue gasses. 3. Safety valves: Safety valves are used to prevent the explosion of the boiler due to high internal pressure. The function of safety valve is to release the pressure when it exceeds the danger level. 4. Steam stop valve: Steam stop valve is used to To control the flow rate of steam from boiler To shut off steam flow completely if required

5. Blow off cock: The function of blow off cock is

 To empty the boiler To remove mud and scale at the bottom of the boiler 6. Feed check valve: Feed check valve is used to regulate the supply of water pumped into the boiler 7. Fusible plug: Fusible plug is used to put off the fire in boiler when the water level in the boiler falls below unsafe limit. Performance of boiler: Boiler performance is measured by its evaporative capacity

Equivalent evaporation = total heat required to evaporate feed water at 100 0c at normal atm/2257 E is always more than 1 for all boilers E=mw(h-hw)/2257 mw=mass of feed water evaporated/kg of coal h=steam enthalpy hw=enthalpy of feed water latent heat=2257kj/kg (h-hw)/2257=evaporation factor

Boiler efficiency=heat used to produce steam/heat generated in the furnace =ms(h-hw)/mf*cv

ms = mass of the steam mf = mass of the fuel cv = calorific value of the fuel kj/kg heat balance: 1) Heat loss in the dry flue gases = mg * cpg (Tg Ta) Mg = mass of the dry flue gas Cpg = specific heat capacity of the flue gas Tg = temperature of the flue gas leaving chimney Ta = temperature of the air 2) Heat lost to conversion of water present in the fuel to the steam = mw(hs hw) = mw(hg + cp(Ts-T) hw) =mw(2676+ cp(Ts-100) hw) Ts = temperature of the superheated steam Hg = 2676kj/kg at 1.013 bar T = temperature of boiler = 100oc

3) Heat lost to the water formed by the combustion of hydrogen /kg of the fuel into steam=9H2(2676+ cp(Ts-100) hw) 4) Heat lost to the unburnt carbon = mc * cv

mc = mass of the carbon 5) Heat lost to incomplete combustion of carbon to carbon monoxide due to inefficient air supply = mco (combustion heat of co2 combustion heat of co) mco = mass of the carbon monoxide 6) Heat lost to radiation = heat supplied (heat to steam + all heat losses)

Problem: In the boiler 300kg of coal with a calorific value of 30000kj/kg is used to evaporate 1800kg of water to steam at 12 bar. Dryness fraction of steam is 0.98. and the feed water temperature is 40oc. find the equivalent evaporation and boiler efficiency.

Given: Mass of the coal mf = 300kg

c.v. of the coal = 30000kj/kg pressure = 12bar temperature = 40o c dryness fraction x = 0.98 to find: 1. Equivalent evaporation 2. Efficiency of the boiler Solution: From the steam table At 12 bar , hf = 798.4 kj/kg Hfg =1984.3 kj/kg Hg = 2782.7 kj/kg h=hf+x*hfg =798.4 + 0.98*1984.3 h=2745.3kj/kg (h=enthalpy of steam) Hw = cp.Tw =4.18 *40 =167.2 kj/kg hw=enthalpy of water

mass of water evaporated per kg of coal mw = ms/mf = 1800/300 = 6 kg/kg of coal

equivalent evaporation: E = mw *(h- hw)/2257 = 6(2745.3 167.2)/2257 E = 6.85 kg/kg of coal Efficiency of the boiler: = ms(h hw)/mf * c = 1800(2745.3 167.2)/300*30000 = 0.5156 =51.6% Solution: 1) equivalent evaporation = 6.85 kg/kg of coal 2)boiler efficiency =s 51.6%