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Boiler Efficiency

This document analyzes the boiler efficiency and cost savings opportunities at a Coca-Cola plant. It details the ultimate and flue gas analysis, calculates the current boiler efficiency to be 81.5775784%, and identifies heat losses from dry flue gas (L1), fuel evaporation (L2), and humidity (L4) as making up most of the inefficiency. Reducing L1 and L2 through measures like an economizer and improved ignition could increase efficiency by 10% and save 940 kg of fuel per hour.

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82 views4 pages

Boiler Efficiency

This document analyzes the boiler efficiency and cost savings opportunities at a Coca-Cola plant. It details the ultimate and flue gas analysis, calculates the current boiler efficiency to be 81.5775784%, and identifies heat losses from dry flue gas (L1), fuel evaporation (L2), and humidity (L4) as making up most of the inefficiency. Reducing L1 and L2 through measures like an economizer and improved ignition could increase efficiency by 10% and save 940 kg of fuel per hour.

Uploaded by

Computer Maintainance Hardware and software
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COCA-COLA COMPANY BOILER EFFICIENCY COST ANALYSIS

Ultimate analysis
Carbon 85.63
Hydrogen 13.5
Nitrogen o.12
Oxygen 0.2
Sulphur 0.55
GCV value of fuel 10869.025kCal/kg
Fuel firing rate 9408kg/hr
Boiler surface temperature 60oC
Surface area of the boiler 54.081m2
Humidity 0.025kg/kg of dry air
Wind speed 1m/s
Flue gas analysis
Flue gas temperature 180 oC
Ambient temperature 30 oC
CO2 of flue gas in % 12.2
O2 of flue gas in % 3.03
A) Efficiency

a) Theoretical air required =

= [(11.6 x 85.63) + [{34.8 x (13.5 – 0.2/8)}


+ (4.35 x 0.55)] / 100
= 14.646305 kg/kg of oil
b) Excess Air supplied (EA) = (O2 x 100) / (21 – O2)
= (3.03 x 100) / (21 – 3.03)
= 16.86144%
c) Actual mass of air supplied/ kg = {1 + EA/100} x theoretical air
of fuel (AAS)
= {1 + 16.86144%} x 14.646305 kg/kg of oil
= 17.11588
Mass of dry flue gas = Mass of (CO2 + SO2 + N2 + O2) in flue gas + N2
in air we are supplying
Mass= 0.8563*44/12 + (0.0055*64)/32 + 0.0012
+0.002 + AA*0.77
Mass of dry flue gas = 16.3332 kg/kg of oil
Heat loss in dry flue gas
L1=m*Cp*(Tf-Ta)*100/GCV
L1=10.81885%
Heat loss due to evaporation of water in the
fuel
9*H2(584+(Tf -Ta)*Cp)*100
L2=7.3331%
Heat loss due to humidity of air (0.025kg/kg of
dry air)
AA*humidity*Cp*(Tf-Ta)*100/GCV
L4=0.2704716%
…
81.5775784%
….
As per my calculation L3, L5, L6, L7, L8 are
almost negligeable losses
B) Fuel cost

From this we can analyze that the 98 percent lose is accumulated in L1 and L2, if we reduce L1 and L2
the machine will become 99 percent efficient, but lets reduce the value of L1 and L2

L1 and L3 can be reduced by using an economizer for preheating a feed water and that of combustion
air

An increase

CIP program for the boiler internal system( what it enhances/ removes the solid particles or scale
formed.

L2 can be reduced by using an electricity ignition and resistor fire continuous supply

…..

Aim

Enhancing boiler efficiency by 10%

….
Since the cost of the fuel consumed is the amount in liter of fuel multiplied by the unit liter fuel.

9408kg/hr.

Simply this is the cost in terms of kg of fuel in hours production

Current applicable fuel per hour(output)

9408kg/hrs.*81.5775784%=7674.818576kg/hrs.

Ambition after improvement


9408kg/hrs.*( 81.5775784%+10)=8615.618576kg/hr.
The amount of fuel saved after our project will be
(8615.618576kg/hr.- 7674.818576kg/hrs.)= 940kg/hr.

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