B O I L E R E F F I C I E N C Y T E S T J A M E S R I V E R N A H E O L A A L A B A M A N A H E O L A A L A B A M A 2 1 A p r i l 2 0 1 1 B O I L E R NO. NO. 1 E N G R: B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER NAHEOLA ALABAMA TEST RUN NO. PAGE 1 Date: 21 April 2011 BOILER NO.: NO. 1 Eng.: METERED STEAM RATED CAPACITY: 300,000 lb/Hr FLOW DURING TEST: 265,800 lb/Hr DRUM PRESSURE: 890 PSIG DRUM TEMPERATURE: 533 F STEAM PRESSURE: 850 PSIG STEAM TEPERATURE: 825 F FEEDWATER TEMP.: 315 F L Fuel Source: I Fuel unit 100lb, solid or liquid fuels N 100 moles, gaseous fuels E Fuel anal. as fired (AF), % by wt. or vol a 10,000.00 lb/Hr. COAL 15,300.00 lb/Hr. BARK C 69.67 C 32.04 H2 4.74 H2 3.48 S 3.18 S 0.06 O2 7.13 O2 22.68 b N2 1.54 N2 0.06 CO2 CO2 H2O 4.74 H20 40.00 ASH 9.00 ASH 1.68 100.00 100.00 12,500 Btu/lb 5,400 Btu/lb 38,000.00 lb/Hr. BARK C 30.66 H2 3.32 S 0.06 O2 21.70 b N2 0.06 CO2 H2O 40.00 ASH 4.20 100.00 5,177 Btu/lb B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER NAHEOLA ALABAMA TEST RUN NO. PAGE 2 Date: 21 April 2011 BOILER NO.: NO. 1 Eng.: FLUE GAS ORSAT ANALYSIS CO2 14.37 O2 5.52 CO 0.00 N2 80.12 % c Wet flue gas O2 5.40 Dry Flue Gas Excess Air (E.A.) assigned or by orsat 35 % d Lines f,g,h, for gaseous fuels e Wt. fuel unit =(moles each X mol. wt.)lb f Mol. wt of fuel=line f/100 g Density of fuel @ 80 F & 30 in.=line g/394 h Fuel heat value, Btu/lb 6,388 Btu/lb i Combustible in refuse, %'C' j Carbon unburned, lb/100lb fuel =% ash in fuel X %'C'/100-%'C' k Exit temp of flue gas, t2 445 F l Dry bulb (ambient) temp, t1 80 F m Wet bulb temp 65 F n Rel humid,(pyschrometric chart) 60.% o B, barometric pressure, in. Hg 29.92 p Sat. press. H2O at amb temp. in. Hg 1.04 q A, press. H2O in air, lines (o X q), in. Hg. 0.62 r B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER NAHEOLA ALABAMA TEST RUN NO. PAGE 3 Date: 21 April 2011 BOILER NO.: NO. 1 Eng.: Flue Gas (F. G.) Composition Fuel, O2, and Air per Unit of Fuel Moles per Fuel Unit (AF) Moles L Per Mol. Fuel O2 O2 I Fuel Fuel wt con- Mul- Moles CO2 N Constituent Unit, Divi- stit- ti- Theo + O2 N2 H2O CO E lb sor uent plier Reqd SO2 1 C to CO2 37.15 12 3.1 1 3.1 3.1 2 C to CO 0.00 12 0.0 .5 0.0 0.0 3 CO to CO2 0.00 28 0.0 .5 0.0 0.0 4 C unburned 0.00 12 0.0 line k 5 H2 3.58 2 1.8 .5 0.9 1.8 6 S 0.55 32 0.0 1 0.0 0.0 7 O2 19.64 32 0.6 1 -.6 8 N2 0.29 28 0.0 0 0.0 9 CO2 0.00 44 0.0 0 0.0 10 H20 34.43 18 1.9 0 1.9 11 ASH 4.35 12 Sum 99.99 7.44 3.40 O2 and Air, Moles for Total Air=135 % (See line d Page 1) 13 O2(theo) reqd= O2, line 12 3.40 14 O2(excess)=T.A.-100/100 X O2, line 12 1.19 1.2 15 O2(Total) Supplied= Lines 13+14 4.58 16 N2 Suplied= 3.76 X O2, Line 15 17.23 17.2 17 Air(dry) Supplied= O2+N2 21.82 18 H2O in Air= moles dry air X A/B-A 0.46 0.5 19 Air(wet) Supplied= lines 17+18 22.28 20 Flue gas constituents= lines 1 to 18 'Tot.' 3 1 17 4 0.0 20a Total Wet Flue Gas Dry Flue Gas 25.71 21.55 21 *Note - for air at 80 F and 60% relative humidity, A/B-A= 0.0212 (standard) B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER NAHEOLA ALABAMA TEST RUN NO. PAGE 4 Date: 21 April 2011 BOILER NO.: NO. 1 Eng.: a1 Air(dry) supplied/unit fuel= moles air, line 17X29, (mol. wt air) 632.04 lb b1 H2O in air supplied/unit fuel= moles H2O, line 18X18, (mol. wt H2O) 8.33 lb c1 Wet air supplied/unit fuel=lines a1+b1 640.38 lb Line c1/100 (solid or liquid fuels) 6.40 lb d1 Wet air supplied/lb of fuel Line c1/line f for gaseous fuels e1 Flue gas constituent and mol. wt. CO2+SO2 O2 N2 H2O CO 44 64 32 28 18 28 f1 Wet F.G.,% by vol= 100Xline 20/line 20a(wet) 12.04 0.07 4.62 67.07 16.21 0.00 g1 Dry F.G.,% by vol= 100Xline 20/line 20a(dry) 14.37 0.08 5.52 80.04 0.00 h1 Wt each constituent= line 20Xmol. wt of each, lb 136.24 1.11 38.03 483.0 75.08 0.00 i1 Total wt F.G.= sum(h1 wet) & sum(h1 dry) Wet wt 733.47 lb Dry wt 658.38 lb Wet wt. line i1/100, solid & liquid fuels 7.33 lb j1 Wet flue gas/lb fuel Wet wt. line i1/line f, gaseous fuels Dry wt. line i1/100, solid & liquid fuels 6.58 lb k1 Dry flue gas/lb fuel Dry wt. line i1/line f, gaseous fuels l1 Molecular wt of wet flue gas= Wet wt, line i1/wet moles, line 20a 28.53 m1 Molecular wt of dry flue gas= dry wt, line i1/dry moles, line 20a 30.56 n1 Density of wet flue gas= line l1/394 (at 80 F & 30 in. Hg.) .0724 lb/ft3 o1 Density of dry flue gas= line m1/394 (at 80 F & 30 in. Hg.) .0776 lb/ft3 p1 SO2 in flue gas 1,509.0197 ppm q1 Lb. SO2 per Million Btu 1.7327 B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER NAHEOLA ALABAMA TEST RUN NO. PAGE 5 Date: 21 April 2011 BOILER NO.: NO. 1 Eng.: Determination of flue gas and combustible losses in Btu per fuel unit (AF) 22 Flue gas constituents CO2+SO2 O2 N2 H2O CO Total 23 Mcp, mean, t2 to t1 10.7 11.2 7.47 7.06 8.40 7.14 24 In dry gas= moles each line 20 X Mcp X(t1-t2) 12,070 70 3,241 44,457 59,839 25 In H2O in air= H2O, line 18 X Mcp X (t2-t1) 1,419 1,419 26 In sens heat, H2O in fuel= moles, lines (5+10) X Mcp X (t2-t1) 11,362 11,362 27 In latent heat, H2O in fuel- moles, lines (5+10) X 1040 X 18 69,344 69,344 28 Total in wet flue gas 141,963 29 Due to carbon in refuse= line k X 14,000 30 Due to unburned CO in flue gas= moles C to CO X 12 X 9,750 31 Total flue gas losses + unburned combustible=line 28+29+30 TOTAL 141,963 32 Heat value of fuel unit= 100 X line i for solid or liquid fuels 638,777 and 394 X line i X 100, for gaseous fuels 33 Heat losses due to dry gas 9.37 34 Heat loss from combustion of H2 6.11 35 Heat loss due to moisture in fuel 6.52 36 Heat loss due to moisture in air 0.22 37 Loss due to carbon in refuse 38 Loss due to unburned CO in flue gas 39 Combustion Efficiency 77.78 40 Unaccounted losses 1.00 41 Radiant heat loss ( 4 water walls) 0.37 42 Continuous blowdown loss ( 6 %) 1.56 43 Boiler Efficiency 74.85 ID Fan Capacity required= 177,037.6410 CFM @ 445 F 464,285.6600 LBS/HOUR FLUE GAS for 63,300 pounds of COAL & BARK & BARK FD FAN CAPACITY REQUIRED= 90,799.7660 CFM @ 80 F 405,358.0300 LBS AIR/HOUR SUPPLIED for 63,300 pounds of COAL & BARK; & BARK ACTUAL STEAM PRODUCED= 268,986.0000 lb/Hr. per 63,300 pound(s) of COAL & BARK & BARK & BARK burned per hour Btu INPUT #1 COAL= 30.9 % #2 BARK= 20.4 % #3 BARK= 48.7 % nesjr