TCPL – 1X 63.75 MW POWER PLANT.
GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 1 of 7
Unit heat rate
1. INTRODUCTION
Unit heat rate of a thermal power plant is a measure of the efficiency of operations
and the performance of main equipments. Calculation of unit heat rate at regular intervals
enables us to pinpoint problem and take remedial actions for deviation from the design. The
procedure for calculating the unit heat rate is explained in this document
UNIT HEAT RATE:
Heat rate is defined as the quantity of heat supplied to generate one unit of
electricity. The unit of heat rate is KCAL/KWhr
TURBINE HEAT RATE:
Turbine heat rate is defined as the heat input to the turbine to generate one unit of
electricity
BOILER EFFICIENCY
Boiler efficiency is the ratio of heat added to the feed water in the boiler to that of heat input
to the boiler from the fuel
Unit heat rate =turbine heat rate /boiler efficiency
2. BOILER EFFICIENCY
Boiler efficiency is defined as the heat added to the working fluid expressed as a
percentage of heat in the fuel being burnt. Boiler looses heat only because it would be
extremely difficult and not a paying proposition to recover it all
The boiler efficiency can be calculated by two methods
[Link] method
[Link] method
The widely used method for determining boiler efficiency is the losses method. The reason
is that the percentage of error in measurements do not make significant change in
efficiency and also we can know proportion of various losses.
The various losses in the boiler are
(a) Dry flue gas loss
(b) Wet flue gas loss
(c) Unburnt gas loss
(d) Combustible in ash loss
(e) Radiation and unaccounted loss
(a)Dry flue gas loss
This is a major loss in the boiler and it is happening due to heat lost in the dry
component of the gases as these are discharged from the chimney at a temperature
considerably higher than that of the atmospheric temperature. The carbon and sulphur
present in the fuel produces the dry components. As the percentage of sulphur is low it can
be ignored. Now carbon can burn to CO2,[Link] of combustion contain
CO2,CO,N2&[Link] of this O2&N2 are from the air being supplied for combustion.
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 2 of 7
The dry flue gas loss depends upon two factors
(1) Excess air
(2) Flue gas exit temperature
EXCESS AIR
Excess air is the air being supplied in addition to the theoretical air for complete
combustion. The excess air is required because only with the theoretical air, all the O2
molecules will not react with the fuel particles in the given time and will result in poor
combustion. If the quantity of excess air increases, the heat being carried away in the
stack will be more as the N2, which constitutes 79% by volume of the air, being inert
only carries away heat.
FLUE GAS EXIT TEMPERATURE.
This should be kept as low as possible from the point of view of efficiency. Very
low flue gas exit temperature cannot be maintained as it will lead to corrosion at APH as
well as the downstream ducts, ESP etc.,because of flue gas temperature coming close
to acid dew point. Therefore, we have to maintain an optimum gas exit temperature.
(b)WET FLUE GAS LOSS
This results from the heat carried away by the steam in the flue gas. The source of
steam is the moisture being present in the fuel and moisture formed due to combustion
of hydrogen in the fuel
The moisture in the fuel is to be heated to raise it to its boiling temperature, and
then finally super heated to leave the boiler at the same temperature of the flue gas.
The heat lost is by means of the heat required to raise from the initial temperature to the
final temperature.
(c)UNBURNT GAS LOSS(OR)PARTIAL COMBUSTION LOSS
This loss is due to the presence of CO in the flue gas due to incomplete
combustion. The heat released when C burns to CO is only 1/3 of heat that would have
released when C burns to [Link] insufficient level of O2 is present in the furnace it will
lead to incomplete combustion. This can be prevented by thorough mixing of O2 with
the fuel and also by supplying some excess air.
(d) UNBURNT IN ASH LOSS(OR)CARBON IN ASH LOSS
This loss is due to the presence of unburnt carbon particles in bottom ash and
flyash. This is because the fuel that is present in ash is not completely burnt and also
has heat value, which is not utilised. This loss depends upon the fineness of p.f, excess
air, and the combustion process. This loss will be less if p.f fineness is increased.
However a limit is reached where extra cost of grinding is more than the reduction in
losses.
The optimum fineness of p.f. fuel is 70% through 200 mesh.
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 3 of 7
Causes of high carbon in ash are
a) Coarse grinding of p.f. in the mill.
b)Improper classifier setting.
c)Improper roller setting
d)Insufficient turbulence for proper mixing of fuel and air
e)Improper operation of secondary air dampers and fuel air dampers
(e)RADIATION AND UNACCOUNTED LOSSES
Unaccounted losses include heat being carried away by the ash in bottom ash and dry
ash, Heat loss in bottom hopper seal water, loss from boiler casing to surrounding, losses
due to unburnt volatile matter and loss due to moisture in combustion air
Radiation loss depends upon the effectiveness of boiler casing insulation. As a
percentage, this loss varies with the size of the unit ,because surface area of casing is
proportionately lower for a larger unit than a small unit .Normally for a unit of 100MW size
this loss would be around 1.2% and unaccounted losses are around 0.3%
Unit heat rate calculation procedure
BOILER EFFICIENCY
The following data is required for calculating boiler efficiency.
Ultimate analysis
If the Ultimate analysis values are readily available it can be directly used. Otherwise it may
be calculated using one of the following methods.
(1)Gebhardt’s formula
(2)Parr’s formula
(3)the modified Seyler chart
(4)Simplified Seyler Dulong formula.
In this document the Parr’s formula has been adopted to deduce ultimate analysis from
proximate analysis
Parr’s formula
FC =fixed carbon %
M =moisture % in coal
A =ash % in coal
VM =volatile matter %
S =sulphur % in coal
GCV=gross calorific value of coal in KJ/Kg
UCF=un burnt carbon % in flyash
UCB=un burnt carbon % in bottom ash
T1 =ambient temperature in deg c
T2 =flue gas exit temperature at APH in deg c
CO2 =carbon dioxide % in flue gas at APH outlet
CO =carbon monoxide % in flue gas at APH exit
Boiler efficiency calculation requires carbon and hydrogen % in coal, which is given by
ultimate analysis of coal. Ultimate analysis of coal can be deduced using Parr formulae.
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 4 of 7
Ultimate analysis of using Parr formulae:
Z =mineral matter content of fuel burnt in %
=M+1.1A+0.1S
VP =volatile content in %
=100(VM-0.1A-0.1S)/(100-Z)
GCVp =calorific value in KJ/Kg
=100*GCV/(100-Z)
Cp =carbon content (mineral matter free) in %
=(1.5782*GCVp/1000)-0.2226Vp+37.69
Hp =Hydrogen content (mineral matter free) in %
=(0.1707*GCVp/1000)+0.0663Vp –2.92
C =carbon content in coal in %
=(1-0.01Z)(Cp+0.05A-0.5S)
H =hydrogen content in coal in %
=(1-0.01Z)(Hp+0.01A-0.015S)
All the boiler losses are calculated on GCV basis i.e, as a % of GCV
CB=carbon in bottom ash=0.2*(UCB/100)*(A/100) Kg/Kg of coal
CF=carbon in fly ash =0.8*(UCF/100)*(A/100) Kg/Kg of coal
a) DRY FLUE GAS LOSS:
Dry flue gas = [(C/100)+(S/267)-CB-CF]*[100/12(CO2+CO)] Kg mol/kg fuel
Kilogram molecular specific heat of flue gases = 30.6KJ/Kg mol deg K
Dry flue gas losses = dry flue gas *Kilogram molecular [Link] *(T2-T1) KJ/Kg of fuel.
=[(C/100)+(S/267)-CB-CF]*[100/12(CO2+CO)]*30.6*(T2-T1) KJ/Kg fuel
= [(C/100)+(S/267)-CB-CF]*[100/12(CO2+CO)]*30.6*(T2-T1)]*100/GCV %
b) WET FLUE GAS LOSS:
1 Kg of hydrogen produces 9 Kg of moisture
mass of moisture =( M+9H)/100
Wet flue gas loss =[(M+9H)/100]*[1.88(T2-25)+2442+4.2(25-T1) KJ/Kg fuel
=[(M+9H)/100]*[1.88(T2-25)+2442+4.2(25-T1)]*100/GCV %
Where, sp heat of steam =1.88KJ/Kg deg K
[Link] of water = 4.2 KJ/Kg deg K
Latent heat of evaporation of water at 25 deg c saturation temperature=2442KJ/Kg
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 5 of 7
c) UNBURNT GAS LOSS:
Weight of carbon burnt = (C/100)+(S/267)-CB-CF
calorific value of burning carbon in CO to CO2 = 23717 KJ/Kg
unburnt gas loss= [CO/(CO2+CO)]*[(C/100)+(S/267)-CB-CF]*23717 KJ/kg
=[CO/(CO2+CO)]*[(C/100)+(S/267)-CB-CF]*23717*100/GCV %
d) COMBUSTIBLE IN ASH LOSS
Calorific value of carbon = 33820 KJ/Kg
combustible in ash loss=(CB+CF)*33820 KJ/Kg fuel
=(CB+CF)* 33820*100/GCV %
e) RADIATION AND UNACCOUNTED LOSSES:
Assumed to be 1.5% for an outdoor boiler of 100MW
Boiler efficiency = 100-sum of all losses
100-[(a)+(b)+(c)+(d)+(e)]
3. TURBINE HEAT RATE:
The following data is required for calculating turbine heat rate
M =main steam flow inT/hr
T =main steam temperature in deg c
P =main steam pressure in Kg/[Link](abs)
Ms =spray water flow in T/hr
Mst =spray water temperature in deg c
Msp=spray water pressure in Kg/[Link](abs)
Fwt=feed water temperature at economizer inlet in deg c
Fwp=feed water pressure at economizer inlet in KG/[Link](abs)
LOAD=unit load in MW
Unit load is calculated from the difference in energy meter readings taken at the beginning
and the end of the performance test period
H1=specific enthalpy of steam in Kcal/KG at turbine inlet at pressure P and temperature T
H2=specific enthalpy of feed water in Kcal/Kg at economizer inlet at pressure Fwp and
temperature Fwt
H3=specific enthalpy of spray water in Kcal/Kg at pressure Msp and temperature Mst
Turbine heat rate=[M(H1-H2)+Ms(H2-H3)]/P Kcal /Kwhr
Design boiler efficiency is 87%
Design turbine heat rate is 2420 Kcal/Kwhr
Unit heat rate =turbine heat rate /boiler efficiency
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 6 of 7
Readings should be taken when the unit is running at full load and also stable. Readings to
be taken for thirty minutes at 10 min interval. The average of these readings to be used for
calculation
[Link] OF INSTRUMENTS:
The accuracy of unit heat rate calculation depends upon the accuracy of
instruments. The following instruments may, therefore, be calibrated at least once in a year.
Ambient temperature
Flue gas exit temperature at APH
Main steam flow
Main steam temperature
Main steam pressure
Spray water flow
Spray water temperature (BFP discharge temp)
Spray water pressure (BFP discharge pressure)
Feed water temperature at economizer
Feed water pressure at economizer inlet
MW Transducer
Energy meter
[Link] TO STANDARD FUEL:
It is common to compare the results of boiler efficiency with that of previous test
results. For eg.,it is common to compare the test results with those obtained with standard
fuel. Such comparisons cannot be made directly because it is almost certain that the fuel
composition will have changed. There fore corrections must be made to obtain the results
that would have resulted had a standard fuel been burnt.
The correction formula is shown below
The subscripts ‘s’ and ‘c’ refers to standard and current fuel respectively.
Correction for moisture and hydrogen
WFGs=WFGc+i[{Ms+9Hs/Qs}-{Mc+9Hc/Qc}]
Where
WFG=wet flue gas loss%
i =heat loss by moisture in flue gas in kJ/kg
=[1.88(T2-25)+2442+4.2(25-T1)] KJ/Kg
M =moisture % in fuel
H =hydrogen % in fuel
Q =calorific value GCVv
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TCPL – 1X 63.75 MW POWER PLANT. GUMMIDIPOONDI
[Link]: LMI /OPR/24 Date of issue: 18/02/06 Rev: 0 Page 7 of 7
Correction for unburned carbon loss:
C in As =Cin Ac [{As*Qc}/{Ac*Qs}]+v
Where
C in A =combustible in ash loss%
A=ash content % in fuel
V=zero,unless,volatile matter of either fuel is less than 17%
If volatile matter content of either fuel is less than 17 %:
V=0.013[As/Ac*Qc/Qs]*K, where K=exp(0.225*Cs/Hs)-exp(0.225*Cc/Hc)
The dry flue gas loss is given by
DFGs=DFGc({CVc/CVs})*({Ces/Cec})
Where
CVc =calorific value of current fuel in kJ/Kg
CVs =calorific value of standard fuel in KJ/Kg
Ce =equivalent carbon in the fuel
Ce =[C-CinAs{GCV/33820}+0.375s}]%
The ultimate analysis values of the standard fuel are given below.
VM =21.3%
FC =27.1%
M =3.9%
ASH =47.7%
H =2.86%
S =2.95%
GCV =3800kcal/kg
From the above corrected boiler efficiency can be calculated and corrected unit heat rate
can also be calculated.
[Link]
The Engineer(O&E) shall be responsible for calculating unit heat rate as per the procedure
described in this document.
[Link]
Any review of this document shall be with the approval of The Works Manager.
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