Efficiency of BoilersCDNA07279ENC_001

Commission of the European Communities

energy

THE IDENTIFICATION OF A FAST ACCURATE METHOD

OF MEASURING THE OVERALL EFFICIENCY OF INDUSTRIAL BOILERS

Report EUR 7279 EN

Blow-up from microfiche original

Commission of the European Communities

energy

THE IDENTIFICATION OF A FAST ACCURATE METHOD

OF MEASURING THE OVERALL EFFICIENCY OF INDUSTRIAL BOILERS

M. Foley THE INSTITUTE FOR INDUSTRIAL RESEARCH AND STANDARDS

BALLYMUN ROAD, DUBLIN 9, IRELAND

Contract No 588-78 EE EIR

FINAL REPORT

Directorate-General for Research, Science and Education

1981 EUR 7279 EN

Published by th« COMMISSION OF THE EUROPEAN COMMUNITIES

Directorate-General Information Mark·! and Innovation

Bâtiment Jean Monnet LUXEMBOURG

LEGAL NOTICE Neither the Commission of the European Communities nor any person

acting on behalf of the Commission is responsible for the use which might be made of the following information

ECSC-EEC-EAEC, Brussels-Luxembourg

T A B L E O F C O N T E N T S

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S hooi no J j ]

PAGE

SUMMARY 1

INTRODUCTION 2

MEASUREMENT TECHNIQUES 5

STEAM WETNESS 7

SAMPLING TECHNIQUES 9

COMPILING RESULTS 12

INSTRUMENTATION 15

CLASSIFICATION OF TESTS 16

ACCURACY OF RESULTS 16

TEST RESULTS 18

COMPARISON RESULTS 21

CONCLUSIONS 30

CALCULATIONS AND RESULTS 34

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Sheet no. / -î -Î \

SYMBOLS AND ABBREVIATIONS

Mass

Temperature

Flow Rate

Pressure

Carbon Dioxide

Oxygen

Carbon monoxide

Sulphur dioxide

Ni trogen

Carbon

Sulphur

Hydrogen

Dryness fraction

Latent heat

Heat content(enthalpy)

Overall ef f ic iency (d i rect test)

Energy content of f lue gases

Specific heat (content pressure)

Radiation loss

Combustion ef f ic iency

Thermal ef f ic iency

Calor i f ic value

Abbreviation Symbol

m

T

Q

ρ

C02

0 2

CO

so2

Ν 2

C

s

H

X

L

h

Nn

r

nc

η

C ,

Engineering Division

Industrial Engineering Department.

An Institiuid Taiçjhde 1 lonscail agus Caighdean

Institute for Industrial Research and Standards

ShlN'l tun l lol 111 Ballymun Road. Dublin 9, Ireland Telephone (01) 370101 Telegrams "Research. Dubln Telex 5449

I Confidential Report

Client 11 t ie

Commission of the European Communities Directorate - General for Research, Science λ Education

XI1 - Β - 4 Rue de la Loi 200 B-1049 Brussels

BELGIUM

The Ident i f i ca t ion of a fas t , accurate method of measurinn the overal l e f f ic iency of Industr ial Boi lers.

Contract No. 5R8.78.7EE FIR

—

—

R.P«.,.. E/G/129/IR-DK

F*.,» R33/43/1

Dal· received

Copie· lo

Order no./ref.

Report by

Approved by

Dale

'A Ì

TYU-0

''UJ '

</

j

Conditions

1 I his Ht-poft '-.hiii nnl be used lor purposes ol advertising, publicity or litigation without the consent ot In« ()irm:tor Gem* al of the Insolute φν·*η in win.ini

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to the· contrary h.ivp tteen nolihed hy lhe scitdet

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appointed hy the Hoard or any officer ot servant of the Institute by reason ol. or arising out ol. the carrying out of any research inveshq.ition. tosi or analysis m ai ■ ooi

ance with lhe Industrial Research and Standards Act. 1961 or the publication of the results thereof in the name of lhe Institute

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Sheet no

SUMMARY:

The requirement of the project is to design a fast, accurate method of measuring the overall thermal efficiency of Industrial Boilers.

Overall Thermal Efficiency is a measurement of boiler efficiency which includes the effects of load factor and varying load conditions over a given test period. The recommended method of measuring overall efficiency is based on measurements made on combustion efficiency and fuel input at regular intervals over a daily period.

Test results show that Fyrite and Dwyer combustion test equipment present both a fast and accurate method of determining combustion efficiency.

It is estimated that losses of the order of 10 % - 15 % are incurred due to operation at low load factors resulting in poor overall thermal efficiencies. Assuming that the loss could be halved by effective monitoring of overall thermal efficiency and consequent remedial action taken, then a saving of 8 % in fuel consumption would occur.

The aim of the research is to develop a technique of measuring overall thermal efficiency of industrial boilers based on one of the following methods:

(a) Standard Direct, according to VDI/DIN 1942 (1956). (b) Standard Indirect, according to VDI/DIN 1942 (1956). (c) Bacharach Fyrite combustion test kit (Indirect). (d) Dwyer combustion test (Indirect).

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Sheet no J>

INTRODUCTION.

In Ireland the majority of industr ial boi lers are in the range ¿MW-10MW and are f i r ed with fuel o i l . In general the range of industry involved is of insu f f i c ien t size to support f a c i l i t i e s for the measurement of ef f ic iency. In the bo i le r eff ic iency test ing service offered to I r i sh Industry two pr incipal thermal ef f ic iency determination techniques were used, namely the direct and the indi rect techniques.

The pr incipal factors involved in evaluating the ef f ic iency performance uf industr ia l boi lers are:

(ß) Stack losses. This is the largest single loss and is dependant on the quantity and the temperature of the flue gas.

(b) Radiation losses. This is due to surface heat losses and is a constant for a given boi 1er.

(c) Blowdown losses. This is incurred because of the necessity to maintain a safe level of concentration of solids in boiler water.

(d) Loading losses. Loading losses are caused by a bo i le r standing by on pressure and by running at low load factor. The greatest loss associated with loading lo^s is the standby loss.

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Sheet no. 3 .

Efficiency Measurement Techniques.

Indirect Techniques:-

This technique is based on the evaluation of stack loss which depends on

(a)% COp in flue gas. (b) Temperature of flue gas.

Both these parameters may be conveniently collected on site during a boiler test. % Stack loss may then be found from tables. Radiation loss can be found from charts knowing boiler surface area and temperature.

Thermal Efficiency = 100% - % Stack Loss - % Radiation loss.

Direct Techniques:-This technique involves the measurement of potential heat input to the boiler and the useful heat output. The following measurements are required:

(a) Fuel flow rate. (b) Steam generation Rate. (c) Feedwater temperature. (d) Steam temperature and pressure. (e) Steam wetness.

From th is data the overall thermal ef f ic iency may be calculated.

The aim of this project is to develop a re la t ive ly fas t , accurate technique of determining the overall ef f ic iency of industr ia l boi lers in the range of load JMW to 10MW. In attempting to achieve th is aim an assessment of the di rect and indi rect methods was undertaken. Each of the methods has i t s advantages and disadvantages. The indi rect technique is easy to apply and gives re la t i ve ly rapid results but only

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gives a measure of thermal eff ic iency at a par t icu lar load at a part icular time. The direct method has the advantage of giv ing an ostiniate of overall thermal eff ic iency but is not easy to apply to small industry. This is because of the necessity to i ns ta l l meters in the feedwater and o i l supply l ines. Considerable time and expense involved would be in con f l i c t with the requirement of rapid tes t ing .

Capac i t y

11.6 MW

10 MW

ΰ,.3 MW

6.6 MW

b.O MW

0.8 MW

Energy Conservation

No. E/G/129/IR-DK

Test

Pressure

1380kN/m2

1380kN/m2

1380kN/m2

1380kN/m2

1380kN/m2

690kN/m2

Boi lers

Pro jec t

remperature

195°C

195°C

195°C

195°C

195°C

165°C

Burner System

Rotary Cup.

Rotary Cup.

Pressure j e t .

Pressure j e t .

Rotary cup.

Pressure j e t .

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Sho-t no. 5 .

MEASUREMENT TECHNIQUES:-Four measurement techniques were used on each test bo i le r .

(a) Standard Direct, according to VDI/DIN 1942 (1956) (b) Standard Ind i rect , according to VDI/DIN 1942 (1956) (c) Bacharach Fyr i te combustion tes t . (d) Dryer combustion test .

(a) Standard di reet.

(5)

Referring to the above diagram representation of the bo i le r the points for flow measurement are as indicated 1 , 2, 3, 4, 5.

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Slier, no. 6 ,

Subscr ip t r e fe rs t o

po in ts i n d i c a t e d on

diagram.

The fo l l ow ing readings were recorded: -

( i ) Oi l meter f low read ing. Q-,

( i i ) O i l meter re tu rn reading. Q.

( i i i ) O i l f low temperature. T_

( i v ) Water f low reading. Q.

(v) Water temperature. T.

( v i ) B o i l e r steam pressure. P~

( v i i ) Ambient temperature. T.

( v i i i ) S t e a m Wetness.

Oi l temperature and water temperature i s cont inuous ly recorded using

thermocouples inse r ted i n t o pockets in the o i l f low and water l i n e s .

An accurate measurement of b o i l e r pressure is obta ined by i n s t a l l i n g

a spec ia l t e s t Burdeon pressure gauge on the b o i l e r s h e l l . O i l f low

and water f low are measured using flowmeters o f the i n t e g r a t i n g t ype .

I t should be ensured tha t these instruments are of a r e l i a b l e design

and show no a l t e r a t i o n in c a l i b r a t i o n when checked before and a f t e r

the t e s t . The water l eve l i n the b o i l e r should be the same at the

f i n i s h as a t the s t a r t of the t e s t . In the case o f b o i l e r blowdown

i t should be ensured tha t no blowdown takes place f o r the du ra t i on

of the t e s t . Where t h i s is not poss ib le the n e t t loss should be

est imated as accurate ly as poss ib le .

Duration of t e s t : -

ihe recommended per iod i s s i x hours f o r the d i r e c t t e s t and fou r hours

' o r the i n d i r e c t t e s t , f o r each o f the load stages t o be t e s t e d ,

ü i r ec t tes ts f o r t h i s p ro j ec t were c a r r i e d out f o r a per iod of four

iiours at each load s e t t i n g .

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Sheet no. / .

Intervals between Readings:-

Intervals between readings should be arranged to cover fluctuations in measured values with sufficient accuracy. All measured values associated with the direct test (values (i) - (vii)) above were carried out at ten minute intervals.

Steam Wetness Measurement:-

The measurement of quality of steam using conventional calorimetrie methods has always presented difficulties because of inevitable changes in steam temperature during the measurement process. Moreover, certain types of calorimeters rely on the separation of liquid water from the steam, which is often far from complete and depends upon test conditions. The separation process is carried out in a separating calorimeter. After passing through the separating calorimeter the comparatively dry steam flows to the throttling calorimeter where the former is throttled after passing through a small orifice. The heat content of the steam remains the same but steam, now at a lower pressure after throttling, is superheated. The temperature of the superheated steam, as well as its pressure are now measured. The steam pressure in the separating calorimeter is also noted and also the volume of separated water. The volume of condensate from the throttling calorimeter is noted. With a knowledge of the above quantity the steam dryness fraction can be calculated.

Steam Sampl ing: -

In general moisture entrained in wet steam flowing in a pipe w i l l not be uniformly d is t r ibuted over the cross-sectional area of the pipe. In addition to th is uneven d is t r ibu t ion of entrained moisture, water

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S tion t no. Q

ay a c t u a l l y separate out of the steam and run along the pipe w a l l s .

'he ch ie f d i f f i c u l t y encountered in es t imat ing steam q u a l i t y using

ι a l o r i i ne t r i c methods is to ensure t h a t the sample of steam taken i s

epresenta t ive o f the main steam f l ow . The pipe connect ing the probe

o the ca lo r imeter should be as shor t as poss ib le and the sampling

ubo, connecting p ipe , valve and ca lo r imete r should be f u l l y and

■ff< c t i v e l y i nsu la ted . In p rac t i ca l t e s t cases, however, due to the

team l i n e d i s t r i b u t i o n system, sampling had to be c a r r i e d out i n a

o r i z c n t a l l i n e about J meter from the b o i l e r o u t l e t .

.'jam Wetness Measurements using Conduct iv i t y Analysis o f Water Samples.

"■'. the beginning of the t e s t samples o f the b o i l e r water and o f the

teedwater should be taken. During the t e s t steam should be generated

v. α uni form ra te and b o i l e r water maintained at a constant l e v e l ,

iiowdown should not be c a r r i e d out dur ing the t e s t . At the end o f the

e:'.·!:, which lasts f o r one hour, f u r t h e r samples o f the b o i l e r water and

¡todwater should be taken and the amount o f steam generated dur ing the

•••ιod determined. From a knowledge o f these q u a n t i t i e s the % moisture

... i i tent of the steam can be determined.

ιi r

t u r e content % = 300W

s χ t

( r i - r ^ ) 350 r?

T r T T T 7 5 r 7 T +

( r , + 2 . 5 r 9 ) 1

Actual weight of water in boiler as steaming in tonnes,

Steaming Rate during test in tonnes/hr.

Duration of t. st.

1 otal dissolved solids at beginning of test (ppm)

i ota¡ dissolved solids at end of test (ppm)

Averaqe total dissolved solids in feedwater (ppm).

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S lient no y .

(b) Standard Indirect, according to VDI/DIN 1942 (1956).

This test is carried out with an Orsat apparatus flue gas analyser, which depends on the absorption of C0„, 0. and CO as the basis for measurement of exhaust gas composition. A sample of exhaust gas is drawn into a measuring burette. The change in volume after a particular constituent has been absorbed is the partial volume of that constituent in the original exhaust gas sample.

Sampling Techniques:-

The ideal sample accurately represents the mean composition of the total gas passing along the flue at the time of sampling. In practice the following difficulties occur:-

(a) Variation in composition of gas across section of flue. Normally the larger the flue and the lower the gas velocity, the greater is the possibility of varying composition occurring.

(b) Air-inleakage will also give rise to variation in composition of the sample because air may exist as a stream adjacent to the wall of the flue.

(c) Changes in composition during sampling. (i) Further combustion within sampling probe when sampling is

carried out close to the combustion chamber, (ii) Chemical reaction between sample and the material of sampling

system, (iii) Condensation.

Condensed water is likely to dissolve small quantities of soluble gasses in the sample.

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She«! no | Q t

Bearing in mind fac to rs ( a ) , (b) and (c) the sampling method used

is i l lust ratec i below.

A X

7

X

8

X

9

C

X 1

X 2

X 3

X 4

X 5

X 6

D

Χ

10

χ

11

X Β

12

ACB0 is a cross section of the flue. AB and CD are two diameters of the circular cross section which intersect at right angles. The sampling points for the determination of C0„ and 0? of the flue gas by the Orsat method are indicated 1 to 12. Twelve samples are taken, the time between each sample is twenty minutes. 0 'X level is also checked using a "Servomex" 0? Analyser. Sampling at a constant rate is carried out at each of the points 1 - 12 and a 0Λ result is obtained for each point. These measurements are averaged over the twelve points:-

A R1 + R2 + •+ R12/l2,

The sampling probe of the "Seromex" Analyser is now placed at one of (.he points 1 - 12 such that the difference between A and the 0Λ

reading at that point, is a minimum. This enables a check to be made 'in the Q.}% as obtained by the Orsat Flue Gas Analyser.

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(c) Fyrite Combustion Test Kit.

This method gives a direct indication of % C0„ in the flue gas. A sample of the gas is absorbed by potassium hydroxide and the resulting increase in volume determines C0„ level. Flue gas temperature measurements corresponding to each C0? reading are also recorded. Since dry flue gas loss is a function of t C0„ and flue gas temperature, the heat loss in the dry flue gas can be read from relevant tables.

(d) Dwyer Combustion Test Kit.

This method is based on exactly the same principle as the Fyrite Combustion Test. Measurements of % C0„ and flue gas temperature are made at twenty minute intervals, and the dry flue gas losses are obtained from charts as before.

Both the Fyrite and Dwyer measurements are accompanied by an estimate of Smoke Number. Excessive Smoke is evidence of incomplete combustion of fuel so that in general the amount of heat lost with incomplete burning of fuel will be small with light smoke, and this fuel waste will increase as the smoke density increases. An estimate of smoke density is made using a pump in which smoke laden flue gas are drawn through a small area of filter paper. A comparison is made between the resultant smoke stain on the filter paper and the cTosest colour on a standard graduated smoke scale, and the result obtained is known as the smoke number. Maximum combustion efficiency is obtained by

(a) C0~% as high as possible. (b) Smoke number as low as possible.

METHOD OF COMPILING RESULTS:-

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Efficiency determination by direct method:-Uata recorded during direct test ewery 20 minutes :-( a ) T i me (b) Temperature (Ambiant) tA (c) Oil meter flow reading Qf (d) Oil meter flow temperature T0

(e) Oil meter return flow (f) Boiler pressure (g) Feedwater temperature (h) Feedwater flow

R

'FW

(°C) (gallons) (°C) (gallons) (bar) (°C) (gallons)

Calculation of feedwater flow rate and fuel oil flowrate. Initial oil flow reading = Qfi Final oil flow reading = Qff Initial oil return reading = Qri Final Oil return reading = Qrf Therefore, Actual oil flow during test = (Qff - Qfi) gallons

Actual oil return during test = (Qrf - Qri) gallons. Using correction factors K f and K for flow and return meters, Q o - Actual oil flow = Kf(Qff - Q f i ) - Kr(Qrf - Qri) gallons Q can be found in kgm/sec knowing the density of oil at temperature T 0 and the duration of the test in sees. A similar result is calculated for the feedwater flow using initial and final readings. The actual flow is calculated using specific gravity correction at feedwater temperature L,·

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13.

2.

Calculation of Energy in Steam.

Boiler pressure (p) and assuming saturated steam with dryness

fraction X then enthalpy of the steam can be found from:

Hs = h+ XL (KJ/KG)

h = sensible heat in steam at temperature corresponding to satura

tion pressure P, from steam tables.

L = Latent heat at boiler pressure Ρ in the steam.

Heat in feedwater HW(KJ/KG) can be calculated using the seasible

heat in water =4.2 KJ/ KG°C multiplied by feedwater temperature

(TW)

The overall efficiencyNo

ND= QFW(

HS

Hw) / Q0(Calorific Value of oil + H0)

QpN = Feedwater flow rate (Kg/sec)

Q0 = Fuel oil flow rate (Kg/sec)

Calorific value of fuel oil (KJ/Kgm)

HQ = Fuel oil enthalpy (KJ/Kgm) at temperature T 0

Efficiency Determination using Indirect Method.

(Orsat Flue Gas Analysis)

(a) Analysis of flue gas (Orsat apparatus)

(b) Analysis of fuel.

(a) yields % CO2, O2» CO, N2, etc. in flue gas

(b) yields % C, H, S, in fuel

co2 (kg)

Kg fuel

S_Q2(kg)

KG~TuTL

0 (kg)

KQ fuel

(%C in fuel)

(%S in fuel)

(kg.Dry h lue Gas

X (Molecular wt. CO2) (a)

(atomic wt. c)

X (Molecular wt. SO2)

(atomic wt. S)

X (kg Dry Flue Gas)

(b)

(c) — k g füêl

= Excess O2 (kg) / kg fuel. Theoretical O2 = ( 8/3 C + 8H + S 0) kg/kg fuel

Air consists of O2/N2 = 23/77

So N2 (kg) can be calculated using (theoretical + exess) O2 (kg)

KG FUEL FgTüel (d)

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Sheet no. 1 4 .

Adding (a), (b), (c), (d). Total products of combustion by mass (dry) = (C02 + S02 + 0 2 + N2) kg/kg fuel. The energy lost to the flue gasses is equivalent to the increase in enthalpy of the gasses:-

Qg= H 2 - Hi = cp (T2 - η ) Therefore, energy carried away by dry products/kg fuel burned

= mg cp (t f l u e - t a t m o s p h e r e) where mg = mass of dry products formed per kg of fuel burned

cp = mean specific heat capacity of dry products. *flue = t e m P e r a t u r e °f exhaust gas at chimney base atmos. = temperature of atmosphere in boiler house.

% loss = mg cp (tflue - tatmos.) (kj . kg fuel) calorific value of fuel kg" fuel " kj

Combustion efficiency = 100% - % heat loss in flue gas.

Fyrite and Dwyer combustion test kits. Measurements taken :-(a) % C02 in flue gas (b) Temperature of the flue gas (c) Smoke member to ensure complete combustion. A standard table gives % stack loss corresponding to % COo in the flue gas for a wide range of flue gas temperatures. Combustion efficiency is calculated as in the tests using Orsat apparatus; Combustion ffficiency = 100% - % heat loss in flue gas.

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Sheet no. 1 5 .

CLASSIFICATION OF TEST INSTRUMENTATION USED ON BOILERS RATED AT

0.8 mw, 6.6 mw, 5 mw, 10 mw, 11.6 mw.

INSTRUMENT MEASUREMENT

"Orsat" apparatus Gas Analyster

"Fyrite" gas analyster

"Dwyer" gas analyster

"Bacharach" spot smoke tester

Bundenberg standard test pressure

gauge.

"Crane" oil meter (20 mm)

(Series 11)

"Tyler" Watermeters (Type 61)

(50 mm and 80 mm)

Thermocouple temperature

measurement.

Dobbie M Innés separating and

throttling steam calorimeter

"Nalfloe conductivity meter

Concentration of 0«, C0? and CO in flue gas

samples.

Concentration of C0? in flue gas samples.

Concentration of C0„ in flue gas samples.

Density of smoke emmission in flue gases.

Records steam pressure.

Suitable for heavy fuel oil flow measuremeti

min

max

min

max

flow

flow

flow

flow

14 litres/hour 3

1.55 m /hour

50 mm 80 mm

137 456

10450 22730

(litres/hour)

Flue gas temperature

Feedwater temperature

Oil flow temperature

Ambient temperature

Steam quality

In practical tests carried out using both the "Nalfloe" conductivity

meter and the "Dobbie McInnes" separating and throttling calorimeter

steam quality measurements proved to be erratic and inconsistent.

This was due to steam sampling difficulties as has already been explained.

In calculations performed on Direct (DIN) test results steam dryness fraction of

95% was assumed in all cases.

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Sheet no. 16 .

CLASSIFICATION OF TESTS ON BOILERS RATED AT 0.8 mw, 6.6 mw, 5 mw, 8.3 mw, 10 mw, 11.6 mw.

'!irect test VDI/DIN 1942 (1956)

HR. 100% 60% 30% 0% HR. 100% 60% 30% 0%

!ndirect test VDI/DIN 1942 (1956)

1 hr 100% 60% 30% ì hr 100% 60% 30%

y ri te Combustion Test

·. hr 100% 60% 30% 1 hr 100% 60% 30%

v.yer Combustion Test

4 hr 100% 60% 30% " hr 100% 60% 30%

refers to the percentage of rate load at which test was performed. " nr, 1 hr refers to test duration.

ACCURACY OF RESULTS MEASUREMENT

Ui! volume Water volume Radiation losses Halorific value of oil intimate analysis of oil

INSTRUMENT Calibrated meter Calibrated meter Thermocouples Bomb calorimeter Spectrograph

ACCURACY 2.0% 2.0% 0.5% 0.5% 1.0%

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n- ι R/33/43/1

s ,,,, 17.

CO« meter

Exhaust gas temp.

Meter and Recorder 3.0 %

Thermocouple 0.5 %

The accuracy of results obtained on Indirect tests:

(1) Direct method based on VDI/DIN code (?) Indirect method based on Fyrite and Dwyer kits (3) Direct method based on VDI/DIN code

n.% n.5 3.9'

Four hour tests were performed for comparison and evaluation of results obtained from Direct (DIN), Indirect (DIN), Fyrite and Dwyer test method' Λ similar procedure was adopted using results obtained from one hour tests from which an estimate of overall thermal efficiency was obtained.

Continuation stieet

T E S T R E S U L T S

BOILER RATED LOAD 5 MW

Report,el. R / 3 3 / 4 3 / 1

Sheet no 1 P>,

Ï h r

9.9 ,6.93 •7.35

4 hr

81.72 74.98 74.60

1 hr

74.84

1 hr

81.35 75.69 77.22

4 hr

82.70 76.17 76.04

1 hr

82.85 76.47 79.22

4 hr

82.00 73.36 76.09

1 hr

81.70 74.87 78.34

Surface losses = 2% of rated capacity at full load.

BOILER MIED LOAD - 8.3 MW

hr

1.53 2.19 0.63

4hr

79.88 77.22 78.42

1 rrr

84.71

1 hr

79.28 77.85 78.16

4 hr

81.40 78.67 79.54

1 hr

82.70 80.07 80.34

4 hr

79.70 78.47 78.04

1 hr

79.33 77. n 78.b7

Surface ¡usses = ?t of rated capacity at full load

^ U i l t l l l U d U U I I S l i t t i

-oad

100%

150%

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Sheet no 1 9 .

RATED CAPACITY OF BOILER UNDER TEST =0.8 MW.

4 hr Test (DIN) Direct Indirect 4 hr

80.86

81.42

4hr

79.13

77.00

1 hr Test (DIN) I Fyrite Direct Indirect 1 hr 1 hr

81.88 79.74

76.43

4 hr 1 hr

81.80 81.30

78.96 80.06

Surface losses = 3.22% of rated capacity at full load.

Dwyer

4 hr 1 hr ,

80.48 80.9/:

J

78.06 77. Pò1:

RATED CAPACITY OF BOILER UNDER TEST - 10 MW

100%

60%

j 30%

4 hr

75.46

86.50

77.09

4 hr

81.80

78.18

68.06

1 hr

81.52

1 hr

81. 70

78.81

68.34

4 hr

84.46

78.77

68.79

1 hr

83.46

80.27

4 hr

82.66

78.02

64.54

Ih r

80. i', t

75. 3ί',

Surface losses = 2.54% of rated capacity at full load.

Continuation sheet

Repo,, rei R / 3 3 / 4 3 / 1

S,lee, no. 2 0 .

T E S T R E S U L T S

i 4hr

i 95.11

Ì 98.56

101.10

4 hr

81.03

72.84

71.09

BOILER

1 hr

83.31

RATED LOAL"

1 hr

81.24

73.51

71.84

6.6 MW

4 hr

82.13

74.64

73.48

1 hr

82.70

76.09

73.27

4 hr

81.43

73.34

71.47

1 hr

81.45

72.94

72.27

Surface losses = 2.8% of rated capacity at f u l l load.

Surface losses = 2% òf rated capacity at f u l l load.

¡ 4 hr

1

82.38

79.96

82.55

4 hr

81.28

79.95

76.23

BOILER RATED LOAD

1 hr

84.02

1 hr

76.86

76.14

79.84

= 11.6 MW

4 hr

82.40

80.92

78.44

1 hr

78.50

78.07

81.54

ι 4 hr

82.30

80.92

77.34

1 hr

76.50

77.07

80.04

Lôniinuaiion sneei

Repo,, ref. R / 3 3 / 4 3 / 1

Sheet no. 21.

COMPARISON OF RESULTS USING DIN INDIRECT Vs 'FYRITE', 'DWYER' CO, MEASURES AND DIN DIRECT DETERMINATION.

BOILER RATING MW

0.8

5.0

6.6

8.3

10.0

11.6

LOAD %

100

50

100

60

30

100

60

30

100

60

30

100

60

30

DETERMINED USING ORSAT APPARATUS DIN INDIRECT

79.13

77.00

81.72

74.98

74.60

81.03

72.84

71.09

79.88

77.22

78.42

81.80

78.18

68.06

81.28

79.75

76.23

DIFFERENCE DETERMINE!

'FYRITE'

+ 2.67

+ 1.96

+ 0.98

+ 1.19

+ 1.44

+ 1.10

+ 1.80

+ 2.38

+ 1.52

+ 1.45

+ 1.12

+ 2.66

+ 0.59

+ 0.73

+ 1.12

+ 1.17

+ 2.21

" FROM EFFICIENCY AS 1 BY DIN INDIRECT

'DWYER'

+ 1.35

+ 1.06

+ 0.28

- 1.62

+ 1.49

+ .40

+ 0.50

+ 0.38

- 0.18

+ 1.25

- 0.38

+ 0.86

- 0.16

- 3.52

+ 1.02

+ 1.17

+ 1.11

DIRECT (DIN) DETERMINATION

+ 1.73

+ 4.42

- 1.82

+ 1.95

+ 2.75

+ 14.08

+ 25.72

+ 30.01

+ 1.65

+ 4.97

- 1.79

- 6.34

+ 8.23

+ 9.03

+ 1.1

+ 0.21

+ 6.32

NO-LOAD SURFACE LOSSES-% OF RATING

3.22

2.0

2.8

2.0

2.54

2.0

Continuation sheet

Report ref. R / 3 3 / 4 3 / 1

Sheet no. CC .

COMPARISON OF RESULTS OBTAINED BY VARIOUS TEST METHODS

Examination of the table shows that agreement of better than two percentage points between Indirect, 'Fyrite' and 'Dwyer' tests was obtained 85% of the time.

On the other hand comparison between Direct and Indirect (DIN) shows that agreement of better than two percentage points occurred only 41% of the time.

Since the results obtained from Indirect (DIN) method conform to DIN specifications of accuracy (+ 0.96%) it can be concluded that the 'Fyrite' and 'Dwyer' methods are quite accurate. The results of 'Fyrite' and 'Dwyer' tests showed better agreement by a factor of two over tests performed by the Direct method, when compared to the Indirect (DIN) test results. Sources of errors in the Direct tests would be most evident in the case of flow meter measurements and in particular steam wetness due to the problems in steam sampling as already described. Overall it may be concluded that the accuracy and reliability of results obtained by the Direct test method is suspect under normal boilerhouse test conditions.

continuation sneet

Report ref R / 3 3 / 4 3 / 1

Sheet no 23.

In a document by the EEC commission en t i t l ed "Code of good practice for the performance test ing of a heat generator for space heating and the production of domestic hot water at a time of i ns ta l l a t i on in a non-industrial bu i ld ing" , (RUE-B No. 85 Apr i l 1979) the commission states that operating ef f ic iency w i l l be calculated on s i te by the indirect method since th is method w i l l reduce the duration and the cost of the test . The direct test method is recommended for laboratory use only.

Assessment of d i rect and indi rect ef f ic iency measurement techniques.

(a) Instrumentation and measurement. A direct test requires measurement of oil flow, water flow, steam temperature, pressure, etc. Each meter involved in these measurements has its own percentage accuracy tolerance, so that the cumulative error in the final result will be significant. On the other hand, using the Fyrite or Dwyer Gas Analysers only two measurements are required for the resulting combustion efficiency with an accuracy superior to all measurements taken in the direct test.

(b) Duration and cost of efficiency measurement.

The indirect test method requires less labour both for installing the equipment and actual execution of the test. Taking into consideration the reduced outlay on equipment makes a strong case in favour of the indirect method of testing.

(c) Using the indirect method an indication can be obtained of burner combustion performance and boiler internal condition.

The C0? analysis will indicate whether unnecessary excess air levels are being used. The flue temperature if excessive may indicate fouling of heat transfer surfaces and this can be checked by measuring smoke number.

Continuation sheet

Report rei R / 3 3 / 4 3 / 1

Sheet no. 2 4 .

Recommendation based on the above analysis taking the EEC document (RUE - Β No. 5 Apri l 1979) in to consideration would strongly favour the ind i rect tes t method preferably using the combustion test k i t measurement technique.

Continuat ion sheet

Repo..,ef R / 3 3 / 4 3 / 1

Sheet no 2 5 .

ESTIMATION OF RADIATION LOSS:-

Estimation of radiation loss must be determined according to E.E.C. commission document - RUE -B No. 85 which states that the radiation loss can be measured by a choice of methods.

METHOD (a) Radiation loss to be estimated by standard curves supplied by the manufacturer.

METHOD (b) Radiation loss to be estimated on the basis of the measured surface temperature of the casing when the casing is divided up into sufficiently small segments to ensure that the temperature variation in simple segments are not too great. The surface area of the segment and its temperature should be recorded. The total loss can be tibtained by addition of losses from individual segments -

RT = A-,Wi+AoW2+... where W = 5.72 X 10'* ( V - T ' The value of the temperature indicated by the instrument shall be that of a black surface radiating corresponding energy Ti ( K)

T = temperature of ambient air ( K)

η W/M'

Continuation sheet

Repor,,ef. R / 3 3 / 4 3 / 1

Sheet no. 26 .

Overal l Thermal E f f i c i ency (DIN)

84.71

83.31

74.84

84.02

81.52

81.88 1

Estimates o f ove ra l l I n d i r e c t t e s t s .

I n d i r e c t (DIN)

78.55

77.70

79.36

77.35

78.66

79.03

e f f i c i ency

F y r i t e

81.30

79.45

80.78

79.11

82.01

81.03

' based on

Dwyer.

78.56

77.74

79.58

77.64

78.37

80.16

I B o i l e r | Rating (MW)

8.3

6.6

5.0

11.6

10.0

0.8

Tests carried out over varying load ranges (100% - 60% -30%)

Estimates of overall thermal ef f ic iency based on Indirect tests show reasonable agreement with d i rect measurements only in the case of a bo i ler rated at 0.8 MW. A comparison may be made with the indirect (DIN) simi lar to that performed with f ixed loading conditions.

Indi reet

! 78.55

' 77.70

! 79.36

I 77.35

78.66

7Q.03

F y r i t e

+ 2.75

+ 1.75

+ 1.42

+ 1.76

f 3.35

+ 2.00

Dwyer

+ 0.01

+ 0.04

+ 0.22

+ 0.29

- 0.29

+ 1.13

D i rec t

+ 6.16

+ 5.61

- 4.52

+ 6.67

+ 2.86

+ 2.85

Load (MW)

8.3

6.6

5.0

11.6

10.0

0.8

Continuation sneet

Rettori rel. R / 3 3 / 4 3 / 1

ShofM no. C. f .

Examination of the above table shows that agreement of better than two percentage points between Indirect, Fyrite and Dwyer tests was obtained 75% of the time. Comparison of overall direct results to Indirect shows that none of the results gave agreement better than two percentage points over a range of six boilers. To obtain an overall assessment of the results a comparison was made between the combined Indirect, Fyrite and Dwyer, and the Direct test. It was found that in only 16% of the cases was agreement better than two percentage points obtained. In general it may be concluded that the Indirect test methods gave more acceptable results than those achieved during direct test methods. It appears that the direct method as applied to varying load conditions is subject to similar wide variations over Indirect test results. Similar results have been obtained comparing Direct and Indirect test results under fixed load conditions.

Continuation shoot

Repo,,,el. R / 3 3 / 4 3 / 1

Sheet no. 28.

Variation of efficiency with load and its effect on overall thermal efficiency.

/

Virin)

c,. Lo at!

HEAT BALANCE FOR A BOILER 50 100

Useful heat External heat loss + Flue gas heat loss = Energy input.

(a) External heat losses. Operation at full load ensures that the external heat losses expressed as a percentage of the heat input will be relatively smalli (less than 2% normally). The overall thermal efficiency of a boiler which is operated at full load for long periods will approach the maximum thermal efficiency attainable for that boiler. Operation at part load or low load for long periods means that the external losses expressed as a percentage of boiler output are more significant than as in the case of full load operation. As a result overall thermal efficiency will be considerably reduced.

(b) Flue Gas Losses Test results show that as the boiler load is reduced from 100% to 30%, a corresponding reduction in flue gas temperature occurs. At loads above 60% rating capacity, the decrease in flue gas loss tends to compensate for the percentage increase in external loss (A - B, Fig. (a) above). At loads below 60% boiler rating, the increase in percentage external loss more than offsets the gain in efficiency due to reduction in the temperature of the flue gas.

·."■' - ' ," . ' ' · rl? v i · ' · " . . ■ · F . '

Continuation sheet

Report,.! R / 3 3 / 4 3 / 1

Sheet no 29.

The combination of these losses means that at loads greater than

60% boiler rating (A - B, Fig. (a) the efficiency remains fairly

constant but dropping rapidly with reduction in load below 60%

CA - C - D, Fig. (a).

IDLING LOSSES

During burner idle periods, heat loss will occur due to cool air

passing through the boiler and becoming heated by brickwork, steam

generating tubes, etc., In order to maintain steam pressure during

standby periods, the boiler must be intermittenly fired to balance heat

lost during idle periods.

Cootinuation sheet

Repor, ref R / 3 3 / 4 3 / 1

Sheet no. 30,

C O N C L U S I O N S

Extensive tests were carried out on six indust r ia l boi lers (0.8 MW to 11 MW) using four ef f ic iency measurement techniques:-

(a) Standard Direct. (b) Standard Indi rect . (c) Bacharach Fyr i te . (d) Dwyer.

Results indicated that the accuracy and reliability of the results obtained by the Direct test method is not acceptable and that this method should be reserved for laboratory use only.

The ind i rec t measurement techniques were preferred to the d i rec t technique since:-

(a) Direct tests require measurements of o i l , water f low, steam wetness, temperature, pressure etc. Fyr i te and Dwyer combustion tests require measurements of C02% and temperature only to determine combustion ef f ic iency.

(b) Less time, labour and cost are evident in carrying out ef f ic iency measurements based on ind i rec t methods.

(c) Referring to EEC document RUE-B No. 5 1979 and the test results obtained, i t may be concluded that the ind i rec t ef f ic iency test method preferably using the combustion test k i t fpeasurernent technique is to be strongly favoured.

The proposed method to measure the overal l e f f ic iency of industr ia l boi lers is based on measurements of combustion ef f ic iency and fuel imput at regular intervals over a da i ly period. (See procedural manual fo r de ta i l s ) .

Continuat ion shoot

Report rel R / 3 3 / 4 3 / 1

Sheet no 31 ·

Overall Thermal Efficiency = h. + h« + H + H. + H0 + o c

(Mass of steam produced at load L.) χ (Total heat of steam - heat in feed water)

(Mass of fuel oil flow at load L. ) χ (Calorific value of oil)

Energy input required to balance heat losses from boiler during standby periods.

Thermal Efficiency (Load = L.) is n.

Hi

But η. ~ nci - ri

nci Combustion efficiency using indirect efficiency measurement technique

r i = % Radiation loss

Ί = ( n c i - r i > H i

So overall thermal efficiency = (nci " V ^ + i nc 2 " Γ2 ) Η2 + H« + H, + H9 + ο Ζ

Continuation sheet

Repor, ref R / 3 3 / 4 3 / 1

Sheet no. OC ·

¡he overall thermal eff ic iency depends one-

fa) N Combustion ef f ic iency, which may be estimated using the

indi rect method ( i . e . Fyrite or Dwyer test k i t s ) .

(b) r Radiation loss can be estimated from manufacturers data or from independent test data.

(c) H Energy consumed in the fuel which can be calculated by measuring the amount of fuel used (flowmeter readings) over a given period.

Assuming that the interval between measurements of N and H is a c 6t - (tp - t·,) = ( t^ - t ? ) = e tc . , the table below gives the measurements necessary to evaluate overall e f f ic iency.

Time t , t 0 t_ t I ¿ 3 n

% Load Ln L0 L.. L l c 3 n

Combustion Eff iciency n ·, n „ n 0 n J cl c2 c3 en

i".:dss flow of fuel m, m„ m, m 1 2 3 n

Where ( t - t . ) = Period over which overall e f f ic iency is to be evaluated.

Continuation sheet

Report ref R / 3 3 / 4 3 / 1

Sheet no 3 3 .

Overall efficiency can now be calculated for period (t - t,) according to the formula as proposed where

H. = m. χ (Calorific value of fuel) ι ι v ' N . = Combustion efficiency at load L. (%)

Radiation loss (%) at load L.

Advantages of the proposed method of measuring overall efficiency:

(a) Proposed method depends on the measurement of combustion efficiency which can be carried out quickly accurately and at low cost using the 'Fyrite'or 'Dwyer' combustion test kits .

(b) Proposed method eliminates measurements associated with steam and feed water flow.

(i) Steam dryness fraction is extremely difficult to measure with an acceptable degree of accuracy. By eliminating this measurement a signigicant improvement in accuracy over results using the direct measurement technique is achieved.

(ii) Steam flow rate measured under test conditions is liable to errors of + 2%. Proposed method eliminates this error from the overall efficiency figure.

DIRECT TEST

Cont inuat ion shoot

Repor, ref R / 3 3 / 4 3 / 1

Sheet no. 3 4 .

Boiler Rating Load Duration of Test

Average fuel flow Average feedwater

Boiler pressure Enthalpy of steam

flow

Enthalpy of feedwater

Eff iciency




flow


F f f i r i p n r v

5 MW

100 %

4 hr

7.73 kg/min 108.10 kg/min

10.90 bar 2680.6 kJ/kg

352.8 kJ/kg

1 3 · 9 * (2 3 2 8) χ 100 = 79.9 % 40735

5 MW 60 % 4 hr

3.665 kg / min 49.309 kg/min

10.94 bar 2681 kJ/kg

351 kJ/kg

49.309 χ 2330 χ 100 = 76.9

3.665 40735

DIRECT TEST

Report r ef R/33/43/1

Sher;t no. 3 5 .

Bo i l e r Rating

Load

Duration o f Test

Average fuel f low

Average feedwater f low

Bo i l e r pressure

Enthalpy of steam


E f f i c i ency

5 MW

30 t

4 hr

2.A3 kg/min 32.515 kg / min

in .«7 bar 2680.5 kJ/kg

325.5 kJ

32.515 2355 χ 100 = 77.35 % 2.43 40735

Bo i le r Rating

Load

Duration of Test

5 MW Overall test 3 hours

Average fuel flow Average feedwater flow

4,70 kg/min 60.99 ka/min


10.76 bar 2fiR0.5 k.l/kn

Enthalpy of feedwater 331. R U / k q

E f f i c i ency ™ i x Z25LZ x 100 __1RMt 4.70 40735

Continuation sheet

II,,pon rel.

INDIRECT TEST (DIN)

Boiler Rating Load Durat ion of Test

Γ lue Gas Analysis

C0? 13.325

0 o 2.9

N9 83.775

5 MW 100 % 4 l ir

Fuel Analysis C 84.1 % H 11.3 %

ς 3.87 % Stoichiometric Products of Combustion

C0? 3.078 kq SO, 0.(1774 k q N., ]0.f60 k(|

R/33/43/1 36.

% by mass of Products of Combustion

co., io. 38

c

N„ 3.06

77.548

kq of Carbon Kq Dry I lue Cas kg o(_ ()ry_ f lue Gas

kq Fuel 0.0528 Exces-;, π Total mass of N„ Mass of CO., Mass of SO., Products of Combustion = Flue gas loss

0.1038 χ 12/44 0.0528 kg 0.841 15.928 kq

0.487 12.300

kg of Op/kg of fuel kg of N?/kg of fuel

3.078 kg of CO^/kg of fuel 0.0774 kg of SO^/kg of fuel 15.04 kg DFG/kg of fuel 1.01 χ 15,°4 χ (244-20) = R RR ,„

40735

ι .untimi,itu m shoe)

Report,el R / 3 3 / 4 3 / 1

She«l no .j / .

INDIRFCT TEST (DIN)


flue Gas Analysis CO, 0, N,

6.9

11.4

HI.7 7 Stoichiometric Products of Combustion

5 MW 60 % 4 hr

Fuel C H S

Analysis PI .4

11.3

3.R7

f,0?

SO t

N„

3.078

0.0774

10.669 ?


CO., m . 27

kg Kg kg_

°2 N2

of Carbon Dry Flue Gas of Dry riue kg Fuel

Excess Op Total mass of IN

Ma; Ma:

;s of C0 ?

is of S0 o

12. 77.

Gas

2

34 30

- 0.1027 χ 12/44 = 0.028 kq

0.841 0.028

Products of Combustion

Flue gas loss

= 30.03 kg

3.706 kg of 02/kg of fuel

23.069 kg of N2/kg of fuel

3.078 kg of C02/kg of fuel

0.0774 kg of S02/kg of fuel

29.03 kg DFG/kg of fuel 20.03 χ 1.01 _x (217.00-21.04)

40735 14.47

Continuation sheet


Flue Gas Analysis C02 8.1

0 2 9.78

N2 82.12

INDIRECT TEST (DIN)

: 5 MW : 30 %

4 hr

Repor, ,ef. R/33/43/1

Sheet no. 3 8 .

Fuel Analysis C

H

S Stoichiometric Products of Combustion

co2

S0? N2

3. 0 10.

% by mass of Products

co2

°2 N2

kg of Carbon Kg Dry Flue Gas kg of Dry Flue Gas

kg Fuel

Excess 0?

Total mass of N2

Mass of C02

Mass of SOp

12 10. 77

=

078

0774

669

of Combustion

00 54 46

0.12 χ 12/44 = 0

°· 8 4 1 « 25.718 0.0327

2.710 19.743

3.078

0.0774 Products of Combustion = 25.609

Flue gas loss = 1.01 χ 25

84.1

3.87

11.30

.0327

kg

kg of 02/kg of fuel kg of N2/kg of fuel

kg of C02/kg of fuel

kg of S02/kg of fuel

kg DFG/kg of fuel

.609 χ (204-22.5) .. }} ς9 r

40735

continuation sheet

n""°·"" R/33/43/1

Sliei'l no 3 9 .

INDIRECT TEST (DIN)


Flue Gas Analysis

CO,

0,

13.3

3.6

83.10

5 MW Overal l (100 %) 1 hr

Fuel Analys is C «4.1

H

S

3.87

11.30

Stoichiometric Products of Combustion

CO 2

N 2

3.078

10.669


co2 19.33

02 3.80

N2 76.87

kg of Carbon Kg Dry Flue Gas =

kg of Dry Flue Gas kg Fuel

Excess 02

Total mass of Np

Mass of C0p

Mass of S0p


Flue gas loss :

0.1933 χ 12/44 = 0.0527

0.841 0.0527

= 15.

0.606 12.698

3.078

0.0774

16.45

06

kg of Op/kg of fuel kg of Np/kg of fuel



kg DFG/kg of fuel

16.45 χ 1.01 χ (246-20) 4Π735

9.22 %

Continuation sheet

Repo,, ref. R/33/43/1

40. Sheet no.

INDIRECT TEST (DIN)

Boiler Rating

Load

Duration of Test

Flue Gas Analysis

C02 7.50

02 10.80

Np 81.70

Stoichiometric

co2

so2

Np

: 5 MW : 60 % : 1 hr

; Fuel Analysis

C 84.1

H 3.87

S 11.30


3.078

0.0774

10.669


C0p

°2

Np

kg of Carbon

Kg Dry Flue Gas

11.13

11.66

77.20

0 ~

kg of Dry Flue Gas 0

kg Fuel 0

Excess 0o

Total mass of N?

Mass of C0p

Mass of S0p

=

=

Products of Combustion =

Flue gas loss *

.1113 χ 12/44 = 0.0303

•ñ41

= 27.755 kq .0303

3.236 kg of 02/kg of fuel




?7.89 kg DFG/kg of fuel

1.01 χ 27.89 χ 199

— — = 13.76 40735

^ U l I n i i U Ü i H J I i J I I U C I

INDIRECT TEST (FYRITE AND DWYER)

Report ref.

R/33/43/1 Sheet no. 4 1 .

BOILER RATING LOAD

DURATION OF TEST

5 MW

100 %

4 hr ( F y r i t e )

% C0„ 14.60 %

STACK TEMP

AMBIENT TEMP 2470C 20°c

EFFICIENCY 84.70 %

BOILER RATING LOAD

DURATION OF TEST

5 MW

100 %

4 hr (Dwyer)

% CO, 14.30 %

STACK TEMP

AMBIENT TEMP ?*7°C

EFFICIENCY 84.00 %

Continuation sheet


Hopori rel.

R/33/43/1 Sheet no. 4 2 .

BOILER RATING LOAD DURATION OF TEST

5 MW 60 % 4 h4 (Fyrite)

% co 2

STACK TEMP AMBIENT TEMP

7.7 %

22 7 ^ 2 2 ^

EFFICIENCY 79.50 %


5 MW 60 % 4 hr (Dwyer)

% c o 2


7.18 %

?27^

EFFICIENCY 76.49 %

v ' J I I I I U j U l t O H J I I C ' U l


Report ref.

R/33/43/1 Sheet no 4 3 .

BOILER RATING LOAD

DURATION OF TEST

5 MW 30 % 4 hr (Fyr i te )

% CO, 8 . 6 %

STACK TEMP

AMBIENT TEMP

EFFICIENCY

Λ o 203 C

2 2^:

82.70 %

BOILER RATING LOAD

DURATION OF TEST

5 MW

30 %

4 hr (Dwyer)

% CO, 7 .9 %

STACK TEMP

AMBIENT TEMP

o ?m r

EFFICIENCY 82 .75 %

Continuation sheet


Repon ref. R/33/43/1 44.


5 MW 100 % 1 hr (Fyrite)

% CO, 14.3 %


?4?°C 20°C

EFFICIENCY 84.85 %


5 MW 100 % 1 hr (Dwyer)

% CO, 13.3 %


243°C

EFFICIENCY 83.70 %

Continuation sheet


H " | m i l I

R/33/43/1 •.ι,,,,·,,.,, 45.


5 MW 60 % 1 hr (Fyrite)

% CO, 7.3 %


217°f 20 °C

EFFICIENCY 79.80 %


5 MW 60 % 1 hr (Dwyer)

% CO, 7.4 %


?17°C

EFFICIENCY 78.20 %

Cont inuat ion sheet

[»DIRECT TEST (FYRITE AND DWYER)

»«port ,·■!

R/33/43/1

.... 46.

' • r . ' l . n RAI !Γ<-

LOAD

DURATION OF TES!

'"■ MW

30 '/.

1 hr ( F y r i t e )

% ro„

:;TACI< lb MP

AMBIENT TEMP

11.5 %

o i°? r

o po r

TflCUNCY 85.875

WiLEf' ·'·■"■'' ÍN''

LOAD

pi T f T ' nh\ Ç,·- ~

; , C O p

STAC!; TEMP

AMD 1 El1·'f TEMP

I ' i r (Dwyer)

I I . 20 ?

o

1°2 <

6R°F

¿»'1CÏENCY 85 . Of! ;,

continuation sneet

DIRECT TEST

Heportrel R / 3 3 / 4 3 / 1

Sheet no. 47 .

Boiler Rating

Load

Duration of Test


Boiler pressure Enthalpy o f steam


Efficiency

8.3 MW 100 %

4 hr

8.948 kg/min

124.627 kg/min

11.103 bar

2681 kJ/kg

290 kJ/kg

13.928 χ 2391 χ 100 81 .53 40848





Efficiency

: :

*

:

:

:

8.3 MW

60 % 4 hr

7.074 kg/min 100.914 kg/min

10.88 bar 2681 kJ/kg

327.6 kd/kq

14.265 χ 2353.4 χ 100 = 82.10 % 40845


DIRECT TEST

Report,el. R / 3 3 / 4 3 / 1

Sheet no. " u .




Enthalpy of feedwater :

Eff iciency :

8.3 MW 30 % 4 hr


11 bar 2681 kJ/kg

344 kJ/kg

13.396 χ 2337 χ 100 = = 76.63 40856

Boiler Rating Load Durat ion o f Test

8.3 MW

o v e r a l l t e s t

3 hr

Average fue l f low

Average feedwater f low

7.027 kq/min

103.15 kg/min

Bo i le r pressure

Enthalpy of steam

11.25 bar

2685.8 kJ/kg

Enthalpy of feedwater 327.6 kJ/kg

E f f i c i e n c y 14.679 χ 2357.2 40845

χ 100 = 84.71 %

Repor, ,e, R / 3 3 / 4 3 / 1

Sheet no "-* ·

INDIRECT TEST (DIN)


Flue Gas

COp

°2

Np

Analysis

9.95

7.37

82.68

8.3 MW

100 %

4 hr

Fuel Analysis

C 84.1

H

S


C02 3.078 kg

SOp 0.0774 kg

N. 10.64 kg


11.3

3.87

COp

Op

Np

kg of Carbon

Kg Dry Flue Gas

14

7

77

kg of Dry Flue Gas

kg Fuel

Excess Op

Total mass of N,

Mass of C02

Mass of S02

ι

65

.89

.46


Flue gas loss ■

0.1465 χ 12/44 = 0.0399 kg

0.841

0.0399

21.07 kg

1.662

16.21

3.078

0.0774

kg of Op/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

1.01 χ 21.03 χ 209.34 . l n 0

40735


Repor, rei R / 3 3 / 4 3 / 1

Sheiit no 5 0 .


Flue Ga

COp

°2

Np

s Analysis

Ç.566

9.100

82.334

INDIRECT TEST (DIN)

8.3 MW 60 % 4 hr

Fuel Analysis

C 84.1

H

S

11.3

3.87


COp 3.078

SO, 0.0774

10.64


COp

°2

N2

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue

kg Fuel

Excess Op

Total mass of f

Mass of COp

Mass of S0o

12.

9.

77.

Gas

'2

67

80

53

- 0.1267 χ 12/44 = 0.0345

0.841

0.0345 24.37 kg


Flue gas loss =

2.389

18.64

3.078

0.0774

24.18

1.01 χ

kg of Op/kg of fuel

kg of Np/kg of fuel

kg of COp/kg of fuel


kg DFG/kg of fuel

24.18 χ 203 _ 1? 17

40735

Continuat ion shoot

Report ref R/33/43/1

Sheet no. 5 1



02 4.133

N„ 83.357

INDIRECT TEST (DIN)

8.3 MW 30 % 4 hr

Fuel Analysis C 84.1

H 11.3

S 3.87


CO, SO,

3.078 kg

0.0794 kg

10.64


C02 18.21

Op 4.38

Np 77.41

kg of Carbon Kg Dry Flue Gas = ° · 1 8 2 1

kg of Dry Flue Gas . 0.841 kg Fuel 0.04966

Excess Op = Total mass of N2 =

Mass of C02

Mass of S0p


Flue gas loss =

χ 12/44

= 16.935 kg

0.74 kg of 02/kg of fuel 13.123 kg of N?/kg of fuel



17.0204 kg DFG/kg of fuel

1.01 χ 17.204 χ 182.5 . 7 7 r

40735

Continuation sheet

Report ref. R/33/43/1 52.

INDIRECT TEST (DIN)


Flue Gas COp

°2 Np

Analysis 9.7 %

7.4 %

82.9 %

8.3 MW 100 % 1 hr

Fuel C H S

Analysis 84.1

11.3

3.97


C02 3.078 kg

SOp 0.0774 kg

No 10.64


COp 14.3

Op 7.93 Np 77.76


kg Fuel

Excess Op Total mass of Np

Mass of COp

Mass of SOp


Flue gas loss =

0.143

0.841 0.039

= =

=

=

=

χ 12/44 = 0.039

= 21.564

1.71 kg of 02/kg of fuel 16.36 kg of N2/kg of fuel




1.01 χ 21.23 χ 218.6 . Ί1 çrj v 40735

• ·· Mi.... ■ M


Flue Gas Analysis

C02 8.86

02 8.93

N2 82.21

Report ref R / 3 3 / 4 3 / 1

Sheet no. Do.

INDIRECT TEST (DIN)

: 8.3 MW : 60 % : 1 hr

: Fuel Analysis

C 84.1

Η 11.3

S 3.87


co2

so2

N2

3.078

0.0794

10.64


COp

°2 Np

kg of Carbon

Kg Dry Flue Gas

13.09

9.597

10.64

0.1309 χ 12/44 = 0.0357

kg of Dry Flue Gas 0.841 _ 2 3 ς ς ?

kg Fuel 0.0357

Excess Op Total mass of N2

Mass of C02

Mass of S02




Products of Combustion = 23.624 kg DFG/kg of fuel

Flue gas loss = 1.01 χ 23.624 χ (197) . u ^Λ γ

40735

Continuation sheet

Repor,,.f. R / 3 3 / 4 3 / 1

Sheet no. 54.

INDIRECT TEST (DIN)


Flue Gas Analysis COp 12.000

Op 4.700

N2 83.300


8.3 MW Overall 1 hr

(30%)

Fuel Analysis C H

S

84.1

11.3

3.87

C02 3.078

SO, 0.0794

10.64


COp

°2 N2

kg of Carbon Kg Dry Flue Ga< kg of Dry Flue

kg Fuel

Excess Op

17.53

4.99

77.48

Gas

Total mass of Np

Mass of COp

Mass of S0o

0.1753 χ 12/44 = 0.0473 kg

0.R41 0.0473

17.78 kq


Flue gas loss =

0.887 13.61

3.078

0.0794

17.654

kg of Op/kg of fuel kg of N2/kg of fuel


kg of SOp/kg of fuel

kg DFG/kg of fuel 1.01 χ 17.654 χ 182

40735 = 7.06 %

Continuation sheet

0 ¿Ktofjit 'íÊÊÊ^ÊÊÊÊáêííÚ^


Repor, iel R/33/43/1

Sheet no. 5 5 .

BOILER RATING

LOAD

DURATION OF TEST

8.3 MW

100 %

4 hr (Fyrite)

% CO, 10.5

STACK TEMP

AMBIENT TEMP

?32°C

22 τ·

EFFICIENCY 83.40

BOILER RATING

LOAD

DURATION OF TEST

8.3 MW

100 %

4 hr (Dwyer)

% CO, 10.7

STACK TEMP

AMBIENT TEMP

231 °C

EFFICIENCY 81.70 %

Continuation sheet


Repor, ref. R/33/43/1

Sheet no. 5 6 ,


8.3 MW 60 % 4 hr (Fyrite)

% CO, 9.3


221 °C 20.5°C

EFFICIENCY 82 %


8.3 MW 60 % 1 hr (Dwyer)

% c o 2


9.2

2 2 1 ^

EFFICIENCY 81.8 %

Continuation sheet


Repor, rol R/33/43/1

Sheet no. 5 7 .


8.3 MW

30 % 4 hr (Fyr i te )

% C0r 12.79

STACK TEMP

AMBIENT TEMP

201 °C

240C

EFFICIENCY 86.2 %


8.3 MW 30 % 4 hr (Dwyer)

% co 2


12.0

202°C

EFFICIENCY 84.70 %


Continuation sheet


Sheet no. D O .


8.3 MW 100 % 1 hr (Fyrite)

% CO, 11.0


232°C 20°C

EFFICIENCY 84.70 %


% co 2


8.3 100

1

10.

232

MW % hr

33

°C

(Dwyer)

EFFICIENCY 81.33 %


continuation sheet

Report ref. R/33/43/1

Sheet no. 5 9 .



% COp


9.2 %

o 227 C o 20 C

EFFICIENCY 83.4 %


8.3 MW 60 % 1 hr (Dwyer)

% co 2


0.6 o 227 C

EFFICIENCY 80.P, %


Repor, ref.

R/33/43/1 Shoe, no. 6 0 .

BOILER RATING

LOAD

DURATION OF TEST

8 . 3 MW

3 0 %

1 hour (Fyr i te)

% CO, 12 .33 %

STACK TEMP

AMBIENT TEMP 1°7°C

2<">°C

EFFICIENCY 8 7 %

BOILER RATING

LOAD

DURATION OF TEST

: fi. : 3f

: 1

3 MW

) %

hour

% CO, 12.3 %


. o in«; c

EFFICIENCY 85.33 %

I WfåffiØk.

DIRECT TEST

• W e i R/33/43/1

Sheet no. 6 1 .

Boiler Rating

Load

Duration of Test

Average fuel flow

Average feedwater flow

Boiler pressure

Enthalpy of steam


Efficiency

0.8 MW

50 %

4 hr

0.3632 kg/min

4.835 kg/min

8.07 bar

2677 kJ/kg

125.35 kJ/kg

13.312 χ 2551.65

Boiler Rating

Load

Duration of Test

Average fuel flow


Boiler pressure

Enthalpy of steam


Efficiency

:

•

:

•

44718

0.8 MW

100 %

4 hr

1.0894 kg/min

14.178 kg/min

7.53 bar

2669.7 kJ/kg

77.5 kJ/kg

13.014 χ 2592.2

= 81.42 %

41718 = 80.86 %

DIRECT TEST

Continuation sheet

Rîref R /33 /43 /1

62,


0.8 MW Overall load tes t 2 hr


0.7316 kg/min 9.935 kg/min


7.34 bar 2662.5 kJ/kg

Enthalpy of feedwater 147 kJ/kg

Eff iciency 13.580 χ 2515.5 41718

81.88





Efficiency

Continuation sheet

Repo,!,cl. R / 3 3 / 4 3 / 1

63.

INDIRECT TEST (DIN)

Boiler Rating Load

Duration of Test

Flue Gas Analysis

COp 12.24

0.8 MW 100 % 4 hr

Fuel Analysis

C 85.6

Op 4.0 H 13.7

Np 83.76 S 0.6


C02 3.138 kg

S02 0.012 kg

Np 11.20 kg


CO, 17.88

4.25

77.87

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas

kg Fuel

Excess 0 2

Total mass of N2

Mass of C02

Mass of S0o

0.1788 χ 12/44 = 0.0487

0.856 = 17.55

0.0487

" 0.744

■ 13.665

' 3.138

■ 0.012

Products of Combustion = 17.559

kg of 02/kg of fuel

kg of N2/kg of fuel


kg of SOp/kg of fuel

kg DFG/kg of fuel

Flue gas loss = 17.559 χ 1.01 χ 230.5

41718 = 9 .8 %

Continuation shoot

Repor,,ef. R/33/43/1

INDIRECT TEST (DIN)



Op' 7.275

Np 83.025

Stoichiometric Products

COp 3.138

SOp 0.012

Np 11.20

Sheet no. O H .

: 0.8 MW : 50 %

4 hr

Fuel Analysis C

1 H S

of Combustion


COp 14.30

Op 7.80

Np 77.90

kg of Carbon Kg Dry Flue Gas kg of Dry Flue Gas .

kg Fuel


Mass of COp

Mass of SOp


Flue gas loss =

0.143 χ 12/44

0.855 21

0.039

1.709 16.85

3.138 -

0.012

21.71

21.71 χ 1

85.5

13.7

0.6

= 0.039

92

kg of 02/kg of fuel kg of Np/kg of fuel



kg DFG/kg of fuel

01 χ 172.25 „ 9 > 0 5 %

41718

vôiuiiiuaiion sneet



02 3.97

N2 83.97

INDIRECT TEST (DIN)


co2 3.138

: 0.8 MW : 100 %

1 hr

Fuel C Η S

of Combustion

kg

Report ref.

Sheet no.

Analysis 85.5

13.7

0.6

R/3 65.

S02 0.012 kg

Np 11.20 kg


CO, 12.06 χ 44 3.97 χ 32 83.97 χ 28

= 530.64

= 127.04

= 2351.16


kg Fuel

Excess 02

Total mass of Np

Mass of C02

Mass of SOp


Flue gas loss «

3008.84

0.1764 χ 12/44

0.855 χ 44 0.1764 χ 12

- 0.75 * 13.71

« 3.14

« 0.012

- 17.612

17.64 %

4.22 %

78.14 % 100.00 %

= 17.77




kg DFG/kg of fuel

1.01 χ 17.612 χ 215 41718

= 9.16 %

Continuation sheet

fy M -*■'■ :· ,iy(ÄC'!


Flue Gas Analysis

COp 9.9

0 2 7.1

N2 83.0

INDIRECT TEST (DIN)

■

0.8 MW 50 % 1 hr

Fuel

c

H

S


co2 3.138 kg

Sheet no

Analysis

85.5

13.7

0.6

Repor, ref R/33/43/1

66.

SOp 0.012 kg

Np 11.20 kg


COp 9.9

Op 7.1

Np 83.0

kg of Carbon .

Kg Dry Flue Gas

kg of Dry Flue Gas

kg Fuel

Excess Ù2

Total mass of N2

Mass of C02

Mass of SOp

X

X

X


Flue gas loss =

44 = 435.6

32 = 227.2

28 = 2324.0

2986.8

0.1458 χ 12/44

0.855 χ 44

0.1458 χ 12

1.636

16.677

3.138

0.012

21.463

1.01 χ 21

14.48 %

7.61 %

77.81 %

100.00 %

21.50

kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

.463 χ 183 5 5 -

41718


Continuation sheet

Report ref.

R/33/43/1 Sheet no. 6 7 .

BOILER RATING

LOAD

DURATION OF TEST

0.8 Mw

100 %

4 hr (Fyrite)

% CO 2

STACK TEMP

AMBIENT TEMP

12.125 %

230OC

2Ρ°Γ.

EFFICIENCY 84.3 %

BOILER RATING

LOAD

DURATION OF TEST

0.8 MW

100 %

4 hr (Dwyer)

* co2

STACK TEMP

AMBIENT TEMP

12.98 %

?30°C

EFFICIENCY 83.7 *

í¿.'*

Continuation sheet


R u"° ■ R/33/43/1

Shod no O n ,

BOILER RATING

LOAD

DURATION OF TEST

% C0„

0.8 MW

5o %

4 hr (Fyrite)

9.2 %

STACK TEMP

AMBIENT TEMP

167°C

20°r

EFFICIENCY 85.4 %

BOILER RATING

LOAD

DURATION OF TEST

% c o 2

STACK TEMP

AMBIENT TEMP

0.8 MW

50 %

4 hr (Dwyer)

8.65 %

160 <C

EFFICIENCY 84.5 %


Continuation sheet

Repor, ici R/33/43/1

Shec, no 6 9 .


% COp


0.8 MW 100 % 1 hr (Fyrite)

12.25 %

2280C 15.5°C

EFFICIENCY 84.52 %


0.8 MW 100 % 1 hr (Dwyer)

% co 2


13.025 %

236°C

EFFICIENCY 84.18 %

¡ffltäj

Continuation sheet


Report ref.

Sheet no.

R/33/43/1 70.


0.8 WM 50 % 1 hr (Fyrite)

% CO, 10.0 %


183°C 20°C

EFFICIENCY 86.5 %


% c o 2


0.8 MW 50 % 1 hr (Dwyer)

9.6 %

1P9°C

EFFICIENCY 83.7 %

V A I I I I I I I U i U I O I I S U C C I

DIRECT TEST


71




flow


Efficiency




flow

6.6 MW 60 % 4 hr

5.058 kg/min 78.489 kg/min

15.84 bar 2697 kJ/kg

201 kJ/kg

78.489 χ 2496 5.058 χ 39296

6.6 MW 30 % 4 hr


15.91 bar 2697 kJ/kg

98.56 %

Enthalpy of feedwater 113 kJ/kg

Efficiency 48.738 χ 2584 3.17 392Q6 101 .1 %


DIRECT TEST

Repor, ref. R / 3 3 / 4 3 / 1

Sheet no. 72 .


6.6 MW 100 % 4 hr




Efficiency

9.619 kg/min 147.21 kg/min

15.83 bar 2698 kJ/kg

255.8 kJ/kg

15.304 χ 2442.2 39296

= 95.11 %


6.6 Mw Overall test load 3 hrs




Efficiency


15.84 bar 2697 kJ/kg

257.5 kJ/kg

13.42 χ 2439.5 39296

= 83.31

INDIRECT TEST (DIN)

L-oniinuation sheet

Repor, ref R/33/43/1

Shout no. ' J .


Flue Gas Analysis CO, 0,

12.2

4.6

83.2

6.6 MW 100 % 4 hr Fuel Analysis C 84.80

H 11.20

Np 83.2 S 4.0


CO, SO,

3.11

0.08

10.56


COp Op N2

kg of Carbon Kg Dry Flue Ga; kg of Dry Flue

kg Fuel

Excess Op Total mass of 1 Mass of C09

Mass of S0o!

17 81 4.88

77

Gas

h

31

-~ 0.1781 χ 12/44 = 0.04857

0.848 0.04860 = 17.449


Flue gas lcks =

0.85 kg of Op/kg of fuel





1.01 χ 17.42 χ 210.5 39296 9.42 %

Continuation sheet

INDIRECT TEST (DIN)


6.6 MW 60 % 4 hr

Repor, ,ef. R/33/43/T

She»! no. 74.

Flue Gas Analysis : COp 6.9

Op 11.6 H

Np 81.5 S Stoichiometric Products of Combustion


11.2

4.0

CO, SO,

3.11

0.08

10.56

t by mass of Products of Combustion

CO, 10.269

12.554

77.178

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas kg Fuel 0.028

Excess Op = Total mass of N? =

Mass of COp

Mass of SOp =


Flue gas loss =

0.10267 χ 12/44 = 0.028

0.848 = 30.285




30.27 kg DFG/kg of fuel 1.01 χ 30.27 χ 204

39296 15.87

t-uiiiiiiuaiiuii sneer.

INDIRECT TEST (DIN) I



02 10.4

Np 81.8

: 6.6 : 30 %

4 hr

Report ,e. R/33/43/1

Sheet no 75.

MW

: Fuel Analysis C H S


COp 3.11

SOp 0.08 Np 10.56


COp 11.57

Op " -22 Np 77.21


kg Fuel

Excess Op = Total mass of Np =

Mass of C02

Mass of S02


Flue gas loss =

84.8

11.2 4.0

.

0.1157 χ 12/44 = 0.03155

0.848 0.0315

3.02 20.67

3.11 0.08 26.88 1.01 χ 26

= 26.874


kg of C02/kg of fuel kg of S02/kg of fuel kg DFG/kg of fuel

.88 X 187.5 _ η 9 ας o/

39296

Continuation shoot

INDIRECT TEST (DIN)



Op 4.5

Np 83.3

: 6.6 MW : 100 %

1 hour

Report ref R / 3 3 / 4 3 / 1

Sheet no. 7 6 .

: Fuel Analysis C H S


COp 3.11

SOp 0.08

Np 10.56


COp 12.2

Op 4.5 Np 83.3


kg Fuel


Mass of C02

Mass of SOp


Flue gas loss =

χ 44 = 536. χ 32 = 144

χ 28 = 2332. 3013.

17.8 χ 12/44

0.848 χ 44 0.173 χ 12

0.84 13.37

3.11

0.08

17.40

17.40 χ 1.01

8

4 2

kg kg kg kg

84.8

11.2

4.0

17.8 %

4.8 %

77.4 % 100.0 %

17.47

of Op/kg of fuel of Np/kg of fuel

of C02/kg of fuel

of S02/kg of fuel

kg DFG/kg of fuel χ 2 0 2 = 9.03 %

39296

^ U i i U i i U d l i U I I à i i t t í i

Ref tor t rel.

Sheet no

INDIRECT TEST (DIN]

Boiler Rating

Load

Duration of Test

Flue Ga

co2

°2

N2

s Analysis

6.9

11.3

81.8


:

:

6.6 MW 60 % 1 hour

of Combustion

Fuel

C

H

S

Analysis

84.8

11.2

4.0

CO,

SO,

3.11

0.08

10.56


CO,

N,

6.9 χ

11.3 χ

81.8 χ

44

32

28

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas _

kg Fuel

Excess 02

Total mass of N2

Mass of C02

Mass of S0„

= 303.6

= 361.6

= 2290.4

2955.6

0.1028 χ 12/44

0.848 χ 44

0.1028 χ 12

3.70

22.94

3.11

0.08

10.28 %

12.23 %

77.49 %

100.00 %

= 30.24

R/33/43/1

77.


Flue gas loss *

kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

1.01 χ 29.83 χ 195.5

39295 = 14.99 %

Continuation sheet

INDIRECT TEST (DIN)


Flue Gas Analysis

COp 8.1 %

Op 10.0 %

Np 81.9 %

6.6 MW 30 % 1 hour

Report rei. R / 3 3 / 4 3 / 1

Sheet no. 78.

Fuel Analysis C 84.8 %

H

S

11.2 %

4.0 %


CO, SO,

3.11

0.08

10.56


COp 8.1 χ 44

Op 10.0 χ 32

HL 81.9 χ 28

0.12 χ 12/44

0.848 χ 44 0.12 χ 12

2.79 19.91

3.10

0.08

25.89

356.4

320

2293.2 2969.6


kg Fuel

Excess Op

Total mass of Np

Mass of COp

Mass of SOp


Flue gas loss =

12.00 %

10.78 %

77.22 % 100.00 %

25.91




kg DFG/kg of fuel

1.01 χ 25.89 χ 180 39296

11.98 %


Report ref. R/33/43/1 Sheet no 7 9 .


6.6 MW 100 % 4 hr (Fyrite)

% COp


12.2 %

230.5°C 17.5°C

EFFICIENCY 84.93 %


20 χ 10° lbs/hr 100 % 4 hr (Dwyer)

% co 2

STACK TtMr AMBIENT TEMP

12.5%

79Λ0Γ

EFFICIENCY 84.23%

Continuation sheet



Sheet no. ß Q #



% CO, 7.4 %


211 °C 14°C

EFFICIENCY 79.3 %


6.6 MW 60 % 4 hr (Dwyer)

% CO, 6.9


211 °C

EFFICIENCY 78.0 %


uoniinuaiion sneet

Repon ruf.

R/33/43/1 Sheet no n i .



% C0?


8 . 9 %

200°C i7°r.

EFFICIENCY 82.8 %


6.6 MW 30 % 4 hour (Dwyer)

% CO, 7.7%


o 199 C

EFFICIENCY 80.8 %


Continuation sheet

Repo"re' R/33/43/1 Sheet no. O c .


6.6 MW 100 % 1 hr (Fyrite)

% c o 2


EFFICIENCY

12.8 %

2.31 °C

12.9°C

85.5 %

BOILER RATING

LOAD

DURATION OF TEST

6.6 MW 100 % 1 hr (Dwyer)

% COp


12.5 %

?23°C

EFFICIENCY 84.25 %


vôniinuation sneet

,hpw"-· R/33/43/1 Sheet no. 8 3 .

1


6.6 MW 60 % 1 hour (Fyrite)

% CO, 7.5 %

v_


EFFICIENCY

2?90C 9.8°C

80.75 %

L BOILER RATING LOAD DURATION OF TEST

6.6 MW 60 % 1 hr (Dwyer)

* C 02


7.0 %

216°C

EFFICIENCY 77.6 %


Continuation sheet

Report ref. R/33/43/1 Sheelno. 8 4 .


% COo


8.0


EFFICIENCY

9.30C

82.6 %


6.6 MW 30 % 1 hr (Dwyer)

* co2


8.1

2m oc

EFFICIENCY 81.6 %

DIRECT TEST

Repor,,ef. R / 3 3 / 4 3 / 1

Sheet no. 85 .





Efficiency

11.6 MW 100 % 4 hr

14.594 kg/min 203.78

10.80 2679.25

275.9

13.963 χ

kg/mi n

bar kJ/kg

kJ/kg

2403.35 χ 100 82.38 % 40735

L





Efficiency

: 11.6 MW : 60 %

4 hr

: 13.154 kg/min 183.46 kg/m1n

10.8 bar : 2679.25 kJ/kg

349.6 kJ/kg

13.947 χ 2329.65 40735

χ 100 = 79 .76 %

Continuation sheet

DIRECT TEST

Repor, ref. R /33 /43 /1

Sheet no. 86 .


11.6 MW 30 % 4 hr


5.596 kg/min 79.917 kg/min


10.35 bar 2678.3 kJ/kg

Enthalpy of feedwater 323.4 kJ/kg

Efficiency 1 4 · 2 8 x 2 3 5 4 · 9 χ 100 = 82.55 % 40735


11.6 MW Overall 3 hr


11.53 kg/min 168.839 kg/min


10.23 bar 2678 kJ/kg

Enthalpy of feedwater 340.2 kvl/kg

Efficiency 14.64 χ 2337.8 40735

χ 100 = 84.02 %

Continuation sheet

_

INDIRECT TEST (DIN)



. Op 3.84

Np 83.535


C02 3.08

: 11.6 MW : 100 % : 4 hr

Fue' C H S

of Combustion

S02 0.0774

Np 10.65


COp 18.41

Op 4.07

Np 77.52

kg of Carbon „ n cl r . = 0.1841 χ 12/44 = Kg Dry Flue Gas

Repor, ,e. R/33/43/1

Sheet no. 8 7 .

1 Analysis 84 11.3

3.87

0.0502

kg of Dry Flue Gas . 0.84 _ 1C 7<? kQ kg Fuel 0.0502


Mass of C02

Mass of SOp


Flue gas loss =

= 0.673 = 12.903

» 3.08

= 0.0774

= 16..733

1.01 χ 16.733

kg of 02/kg kg of N2/kg

kg of C02/kg

kg of S02/kg

kg DFG/kg of χ 224.04

3f fuel 3f fuel

of fuel

of fuel

fuel

9.29 % 40735

Continuation sheet

^ I Î ^ | | ^ % ^ |

Ropon rel R / 3 3 / 4 3 / 1

88. Sheet no.

INDIRECT TEST (DIN)


Flue Gas Analysis

COp 11.216

Op 5.65

Np 83.134


COp 3.08

SOp 0.0774

Np 10.65

: 11.6 MW ; 60 %

: 4 hr

Fuel Analysis

C

H

S

of Combustion


COp 16.43

Op 6.02

Np 77.54

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas

kg Fuel

Excess Op

Total mass of Np

Mass of COp

Mass of SOp


Flue gas loss =

0.1643 χ 12/44

84.0

11.3

3.87

= 0.04480

0 , 8 4 = 18.746 kq

0.0448

1.128

14.428

3.08

0.0774

18.713

1.01 χ 18 1

kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

.713 χ 210.5 o 7ç <y

40735

Continuation sheet

Report ref.

Sheet no.

R/33/43/1

89.



02 8.20

N2 82.36


C02 3.08 S02 0.0774

of

: 11.6 MW : 30 %

4 hr

Fuel Analysi C 84.0

H 11.3

S 3.87

Combustion

17.16


CO,

N.

13.92

8.79

77.29

kg of Carbon Kg Dry Flue Gas kg of Dry Flue Gas _

kg Fuel

Excess 02

Total mass of N2

Mass of C02

Mass of S02


Flue gas loss »

0.1392 χ 12/44 = 0.03796

0.84 0.03796

= 22.126

1.945 kg of 02/kg of fuel 17.160 kg of N2/kg of fuel




1.01 x 22.26 χ 180.2 40735

= 9.94 %

Continuation sheet

INDIRECT TEST (DIN)


Flue Gas Analysis

COo

Wj¡$É

Repor,,.f. R / 3 3 / 4 3 / 1

Shee, no. 90.

0,

6.5

12.0

81.5

11.6 MW 100 % 1 hour

Fuel

C

H

S

Analysis

8Λ.1

11.3

3.87

%

%

%


COp 3.08 kg

SO, 0.0774 kg

Np 10.65 kg


COp 65 x 44 = 286

0 12.0 χ 32 = 384

N 81.5 χ 28 = 2282

2952

9.69 %

13.01 %

77.30 %

100.00 %

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas

kg Fuel

Excess Op

Total mass of Np

Mass of COp

Mass of S0„


Flue gas loss =

0.0969 χ 12/44

0.841 χ 44

0,0969 χ 12

= 31.82

3.083

20.97

3.08

0.0774

27.210

kg of Op/kg of fuel

kg of Np/kg of fuel



kg DFG/kg of fuel

1.01 χ 27.21 χ 214

40735

14.43 %

INDIRECT TEST (DIN)


Flue Gas Analysis

11.6 MW 60 % 1 hour


Sheet no. 91

CO, 7.8 % Fuel Analysis C 84.1 %

Op 10.9 %

Np 81.3% H

S Stoichiometric Products of Combustion

11.3 % 3.87 %

CO, SO,

3.08

0.0774

Np 10.650


COp 7.80 χ

0 2 10.90 χ

N2 81.30 χ


kg Fuel

Excess 0 2

Total mass of N„ Mass of COp Mass of SOp Products of Combustion

Flue gas loss =

44 = 343.2 32 = 348.8

28 = 2276.4 2968.4

0.1156 χ 12/44

0.841 χ 44 0.1156 χ 12

3.13

21.14 3.08

0.0774 27.43

11.56

11.75

76.6 100.00 %

= 26.67 kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel 1.01 χ 27.43 χ 203

40735 13.81 %

Continuation sheet


Flue Gas Analysi

C02 13.6 %

Op 2.7 %

Np 83.7 %

INDIRECT TEST (DIN)

: 11.6 MW : 30 %

: 1 hr

s :


COp

SOp

Np

3.08

0.0774

10.65


COp 13.

Op 2.

N9 83.

kg of Carbon

Kg Dry Flue Gas

6 χ 44 = 598.4

7 χ 32 = 86.4

7 χ 28 = 2343.6

3028.4

0.1976 χ 12/44

kg of Dry Flue Gas . 0.841 χ 44

kg Fuel 0.1976 χ 12

Excess (¡2

Total mass of N2

Mass of C02

Mass of SOp

0.44

12.14

3.08

0.077


Flue gas loss = 1.01 χ 15.74 χ

■ue'

C

H

S

15

178

Repor,,ef. R / 3 3 / 4 3 / 1

Sheet no. 92 ·

Analysis

84.1 %

11.3 %

3.87 %

19.76 %

2.85 %

77.39 %

100.00 %

.605

kg of Op/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

■ = 6.Q4%

40735


Continuation sheet


Sheet no. 9 3 .


11.6 MW 100 % 4 hr (Fyrite)

% CO, 13.65


?4?Oc 19°C

EFFICIENCY 84.4 %


% co 2


11.6 MW 100 %

4 hr (Dwyer)

13.3 %

237 °C

EFFICIENCY R4.3 %


Continuation sheet

Repon rol.

R/33/43/1 Sheet no. ^" *


11.6 MW 60 % 4 hr (Fyrite)

% CO, 12.15


232 nC 19 °C

EFFICIENCY 84.25 %


% c o 2


11.6 60 % 4 hr

11.70

231 °C

MW

(Dwyer)

Ύ

EFFICIENCY 84.25 %

Continuation sheet


Report ref.

Sheet no.

R/33/43/1 95.

BOILER RATING LOAD

DURATION OF TEST

% co 2


11.6 MW 30 % 4 hr (Fyrite)

10.8

194°C 17°C

EFFICIENCY 8 5 . 1 %

BOILER RATING LOAD

DURATION OF TEST

% CO 2

11.6 MW 30 % 4 hr (Dwyer)

9.7 %


188°C

EFFICIENCY 84.0 %

#SÉ W?&0^


Continuation sheet

Report ref. ^ 3 3 ^ 3 ^

Sheet no. 9 ^ ·


11.6 MW 100 % 1 hr (Fyrite)

% CO, 7.8 %


2310c 10°C

EFFICIENCY 80.5 %


11.6 MW 100 % 1 hr (Dwyer)

% CO, 8.4


230°C 10°C

EFFICIENCY 78.5 %

continuation sheet


"~"*· R/33/43/1 Sheet no " 7 .


11.6 MW 60 % 1 hr (Fyrite)

* CO,


?.31°C 11°C

EFFICIENCY 81.4 %


11.6 MW 60 % 1 hr (Dwyer)

% co 2


8.23

225°C

EFFICIENCY 80.Λ %


Continuation sheet

Reportr... R / 3 3 / 4 3 / 1

Sheet no. 9 8 .


11.6 MW 30 % 1 hr (Fyrite)

% CO, 14.67


198°C n°c

EFFICIENCY 88.2 %


11.6 MW 30 % 1 hr (Dwyer)

% CO, 1Λ.6


ln3°C 11°C

EFFICIENCY 86.7 %

Continuation sheet

DIRECT TEST

Report,... R /33 /43/1

Sheet no 9 9 .


Average fuel flow




Efficiency





Efficiency

: :

:

'

'·

•

:

•

: •

:

:

10 MW.

100%.

4 hr.

859.56 kg/hr.

11146.32 kg/hr.

9.95 bar. 2681 kJ/Kg.

309.54 kJ/kg.

12.967 X 2372 X 100 = 75.46%

40758

10 MW

60% 4 hr.

459.54 kg/hr. 6904.54 kg/hr.

10.77 bar. 2682 kJ/kg.

334 kJ/kg.

15.025 X 2348 = 86.5% 40770

Continuation sheet

DIRECT TEST

Repo,,™.. R/33/43/1

Sheet no. 1 OO .





Efficiency

: :

; :

:

:

10 MW. 30% 4 hr.

268.11. 3565.09 kg/hr

10.5 bar. 2676 kJ/kg.

313 kJ/kg.

13.29 X 2363 77.09% 40753





Efficiency

Continuation shoot


Report,... ( ^ 3 3 / 4 3 / !

Sheet no. 101 .

INDIRECT TEST (DIN)

: 10 MW : 100* : 4 hr.

Flue Gas Analysis : Fuel Analysis

C02 12.67

o2 3.4ß

N2 83.85

C 84.1

H 11.3

S 3.87


co2

so2

N 2

3.086

0.0794

10.64


co2

°2 N ,

kg of Carbon

Kg Dry Flue Gas

18.48

3.69

77.80

= 0.1848 Χ 12 = 0.0504

kg of Dry Flue Gas _ 0.841 = 16.686

k9

F u e l 0.0504

Excess Op

Total mass of Np

Mass of C02

Mass of SOp

= 0.581 kg of 02/kg of fuel

»12.58 kg of N2/kg of fuel

« 3.086 kg of C02/kg of fuel

« 0.0774 kg of S02/kg of fuel

Products of Combustion ·■ 16.3244 kg DFG/kg of fuel

Flue gas loss ■ 21.2854 X 1.01 X 195.7 = 10.35%

40637

INDIRECT TEST (DIN)

Continuation sheet

Repor,,... R/33/43/1

Sheet no. 102.


10 MW 60% 4 hr.


0o 8.0


H 11.3 S 3.87


CO,

so.

3.086

0.0794

16.40


COp

°2 Np

kg of Carbon Kg Dry Flue Gas

14.29

8.56

77.1

=

kg of Dry Flue Gas kg Fuel


Mass of COp

Mass of SOp


Flue gas loss * 21

0.1429 X

0.841 = Ö.Ö3Ö96

= 1.72 = 16.40

= 3.086

= 0.0794

= 21.2854

.2854 X 1.

12 Vi

= 0.03896

21.586 kg.

01 X




kg DFG/kg of fuel

195.7 = 10.35%

40637

INDIRECT TEST (DIN)

Continuation sheet

Repon,*. R /33 /43 /1

Sheet no. 103.

Boiler Rating Load

Duration of Test

10 MW. 30%. 4 hr.

>.. Flue Gas Analysis

CO,

o.

5.3

12.9

81.7

Fuel Analysis

C 84.1

H 11.3

S 3.87


C02 3.086

SO, 0.0794

10.64


C02 7.94

Op 14.10

Np 77.9

CO 0.095 kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas .

kg Fuel

Excess Op

Total mass of Np

Mass of COp

Mass of S02


Flue gas loss *

0.0794 X 12 + 44

0.841 = 38 Ö.Ö22Ö5

=

=

■

c

B

4.92

27.116

3.086

0.0794

35.20

35.20 X 1.01 )

0.00095 X 12 = 0.02205 2S

14 kg.

kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

( 185.73 = 16.24%

40637

Continuation sheet

INDIRECT TEST (DIN)

Boiler Rating 10 MW Load : 100% Duration of Test : 1 hour

Flue Gas Analysis : 1

COp 12.7%

Op 4.4%

Np 82.9%


COp 3.086 kg

SOp 0.0794 kg

Np 10.61 kg


CO 12.7 X 44 = 558.8

0 4.4 X 32 = 140.8

N 82.9 X 28 = 2321.2

kg of Carbon n . i M y 1 ?

Kg Dry Flue Gas 44

kg of Dry Flue Gas . 0.841 X 44

kg Fuel 0.185 X 12

Excess Op «» 0.7767

Total mass of N£ ■ 13.21

Mass of C02 » 3.086

Mass of S02 « 0.079


Flue gas loss » 1.01 X 17

Repon r*. R / 3 3 / 4 3 / 1

Sheet no. 1 04 .

:uel Analysis

C

Η

S

16

.15

84.1

11.3

3.87

18.50%

4.66%

76.84%

.67 kg.

kg of 02/kg of fuel

kg of N2/kg of fuel



kg DFG/kg of fuel

X 211 = 9JD%

40637

Continuation sheet

INDIRECT TEST (DIN)

Boiler Rating . 10 MW n.°a . - : 60* Duration of Test : l hr. Flue Gas Analysis

C02 10.0* 02 7.4* N2 82.6*

Stoichiometric Products of rnmhncf ,·

Report ref.

Sheet no

R/33/43/1

105.


H 11.3

S 3.87

on

C02 3.086 Kg

S02 0.0794 Kg.

N2 10.61 Kg.


C02 10 X 440

02 7.4 X 32 = 236.8

Np 82.6 X 28 = 2312.8 ?989.6

kg of Carbon

Kg Dry Flue Gas

kg of Dry Flue Gas _

kg Fuel

Excess 0 2

Total mass of N2

Mass of C0 2

Mass of S02

Products of Combustion Flue gas loss *

0.1472 X 12 π

0.841 X 44 Ί2 X 0.1472

= 1.659 . 16.164

3.086

- 0.079

> 20.988

14.72

7.92

77.36 lTJOü*

= 20.949




kg DFG/kg of fuel

1.01 X 20.988 X 107 40637

= 10.27*

Continuation sheet

Report ref.

Sheet no.

R/33/43/1 106.

INDIRECT TEST (DIN)

Boiler Rating . ]Q m Load . 3Q^ Duration of Test \ ι nr#


02 15.0

Np 80.9

Stoichiometric Products of Cnmh..c»,·


H 11.3

S 3.87

on CO 3.086

S09 0.0794

30.61


C02 4.1 X 44 - 180.4

0 2 15.0 X 32 = 480.0

Np 80.9 X 28 = 2265.2 2925.6 kg of Carbon

Kg Dry Flue Gas kg of Dry Flue Gas _

kg Fuel Excess Op

Total mass of N2

Mass of C02

Mass of S02


Flue gas loss =

0.0616 X 12 J*

0.841 X 44 0.0616 X 12 = 8.21

= 38.11

« 3.086

= 0.0794

* 49.487

49.487 X 1.01 χ 40637

6.16*

16.41%

77.43% 100.00%

50.06




kg DFG/kg of fuel

183 22.51*

. r ' ■· · f-,,ηι,ιτι»'»' 'P'Wiï.-'Tn «-.r/w

..;...■ ^î^..... . i i - - . . . . . ι . . . trattai ÉM — in »*■—IMIIlillÉltl- |-|flÉtl "ι ' " MÉMH --■'■' Ί ι -■■■- ■


Repon ref.

R/33/43/1

She., no. 1 07 .

BOILER RATING

LOAD

DURATION OF TEST

10 MW

100*

4 hr (Fyr i te )

* CO, 13.65

STACK TEMP

AMBIENT TEMP

2 9 Ο Ο Λ

21°C

EFFICIENCY 87 .0*

BOILER RATING

LOAD

DURATION OF TEST

10 MW

100%

4 hr (Dwyer)

* CO, 14.37%

STACK TEMP

AMBIENT TEMP

219°C

21°C

EFFICIENCY 85 .2 *

Sfå«!8p


Continuation sheet

Report rei. R / 3 3 / 4 3 / 1

Sheet no. 1 0 8 .


10 MW 60% 4 hr (Fyrite)

*CO, 9.75*


EFFICIENCY


i 209°C : 19°C

: 83.0*

10 MW : 60* : 4 hr (Dwyer)

* CO, 9.5


'Q7°C 19°C

EFFICIENCY 82.25*


Continuation sheet

R β p o r t r · , R/33/43/1 Sheet no. 1 0 9 .


10 MW 30% 4 hr (Fyrite)

* CO, : 5.3


: 199°C : 1°°C

EFFICIENCY 77.25


10 MW 30* 4 hr (Dwyer)

* CO 2 4.6


190°C 19°C

EFFICIENCY 73.0*


Continuation sheet

Report ηΛ. R / 3 3 / 4 3 / 1

Sheet no. 110.


10 MW 100* 1 hr (Fyrite)

* CO, 12.5*


221°C 10°C

EFFICIENCY 86*


10 MW 30* 1 hr (Dwyer)

* co2


11.46*

221 °C

EFFICIENCY 83.4*

Continuation sheet


Report r...

R/33/43/1 Sheet no. 1 1 .

BOILER RATING

LOAD

DURATION OF TEST

10 MW

60%

1 hr (Fyrite)

* CO, 9.9*

STACK TEMP

AMBIENT TEMP

212°C

10°C

EFFICIENCY 84.5%

BOILER RATING

LOAD

DURATION OF TEST

10 MW

60*

1 hr (Dwyer)

* CO, 8.83*

STACK TEMP

AMBIENT TEMP

210°C

EFFICIENCY 79.61*

· ■ _

CDNA07279ENC

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