For every 0.5% increase of Hydrogen in bagasse, boiler efficiency decreases by 0.8–1% and vice versa.For every 100 kcal/kg increase in bagasse GCV, boiler efficiency increases by 1.2% and vice versa.For every 5% increase in excess air for bagasse, boiler efficiency decreases by 0.18% and vice versa.For every 1% increase in bagasse moisture, boiler efficiency reduces by 0.27% and vice versa.Fuel handling power consumption = Total plant auxiliary consumption X 4%.Turbine auxiliary power consumption = Total plant auxiliary consumption X 10–12%.
Boiler feed pumps power consumption = Total plant auxiliary consumption X 35–38%.Boiler fans power consumption = Total plant auxiliary consumption X 35–38%.Mass of flue gas generated = Mass of air per kg of fuel to be burned + 1.A travelling grate Boiler ID fans (2 Nos) capacity (m3/sec.) with 25% extra margin = Boiler Capacity(TPH) X 95%.Ex: A 100 TPH boiler has two ID fans of each capacity =100 X 95/(100 X 2) = 47.5 m3/sec.A travelling grate Boiler ID fans motor rated capacity in KW = Boiler capacity TPH X 200%.Ex: A boiler of capacity 75 TPH requires ID fan motor of rated KW = 75 X 200/100 = 150 KW each.Flue gas Pressure drop in ESP 25 to 30 mmwc.Pressure drop in Economiser coils 0.5 to 1 kg/cm2.Feed water velocity in Economiser coils 0.6 to 1 meter/sec.Boiler drum hold up capacity is 2–4 minutes at MCR operation.Drum man hole door size 410 mm X 310 mm (Elliptical).Boiler CBD water flow is 0.8 to 2% of steam generating capacity of the boiler.Boiler start up vent steam blow capacity 30–35% of boiler MCR on full open condition.Safety valves pop up pressure = Operating pressure X 106–107%.Ex: A boiler operating pressure of 110 kg/cm2 has safety valve set at 110 X 106/100 =116.6 kg/cm2.All boiler safety valves (super heater and drum safety valves) relieving capacity at full open condition= Boiler MCR X 125–130%.Drum safety valve (1 no.) relieving capacity at full open condition in TPH = Boiler MCR X 46–48%.Super heater safety valve relieving capacity at full open condition in TPH = Boiler MCR X 36–38%.Ex: 125 TPH Boiler has SH safety valve of relieving capacity = (125 X 36/100) = 45 TPH.Deaerator steam venting capacity = Deaeration capacity X 0.1%.of open tubes in steam drum for water recirculation = 30–31% of total no. Boiler flue gas ducting size (M2) = Boiler capacity in TPH/15.Boiler heating surface (M2) = Boiler capacity in kg/hr/(17–18).Ex: 115 TPH boiler will have heating surface = (115 X 1000/17 or 18) = 6390 to 6750 M2 (Appx.).
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