Total water evaporated, 153,543 pounds.
Per cent of moisture in steam, 0.5 per cent.
Heat value per pound of dry coal, 13,516.
Heat value per pound of combustible, 15,359.
The factor of evaporation for such a set of conditions is 1.0834. The actual evaporation corrected for moisture in the steam is 152,775 and the equivalent evaporation from and at 212 degrees is, therefore, 165,516 pounds.
The total dry fuel will be 17,500 .97 = 16,975, and the evaporation per pound of dry fuel from and at 212 degrees will be 165,516 16,975 = 9.75 pounds. The heat absorbed per pound of dry fuel will, therefore, be 9.75 970.4 = 9461 B. t. u. Hence, the efficiency by (31) will be 9461 13,516 = 70.0 per cent. The total combustible burned will be 16,975 - 2396 = 14,579, and the evaporation from and at 212 degrees per pound of combustible will be 165,516 14,579 = 11.35 pounds. Hence, the efficiency based on combustible from (32) will be (11.35 97.04) 15,359 = 71.79.[**should be 71.71]
For approximate results, a chart may be used to take the place of a computation of efficiency. Fig. 39 shows such a chart based on the evaporation per pound of dry fuel and the heat value per pound of dry fuel, from which efficiencies may be read directly to within one-half of one per cent. It is used as follows: From the intersection of the horizontal line, representing the evaporation per pound of fuel, with the vertical line, representing the heat value per pound, the efficiency is read directly from the diagonal scale of efficiencies. This chart may also be used for efficiency based upon combustible when the evaporation from and at 212 degrees and the heat values are both given in terms of combustible.
[Graph: Evaporation from and at 212 per Pound of Dry Fuel against B.T.U. per Pound of Dry Fuel
Fig. 39. Efficiency Chart. Calculated from Marks and Davis Tables
Diagonal Lines Represent Per Cent Efficiency]
Boiler efficiencies will vary over a wide range, depending on a great variety of factors and conditions. The highest efficiencies that have been secured with coal are in the neighborhood of 82 per cent and from that point efficiencies are found all the way down to below 50 per cent.
Table 59[57] of tests of Babc.o.c.k & Wilc.o.x boilers under varying conditions of fuel and operation will give an idea of what may be obtained with proper operating conditions.
The difference between the efficiency secured in any boiler trial and the perfect efficiency, 100 per cent, includes the losses, some of which are unavoidable in the present state of the art, arising in the conversion of the heat energy of the coal to the heat energy in the steam. These losses may be cla.s.sified as follows:
1st. Loss due to fuel dropped through the grate.
2nd. Loss due to unburned fuel which is carried by the draft, as small particles, beyond the bridge wall into the setting or up the stack.
3rd. Loss due to the utilization of a portion of the heat in heating the moisture contained in the fuel from the temperature of the atmosphere to 212 degrees; to evaporate it at that temperature and to superheat the steam thus formed to the temperature of the flue gases. This steam, of course, is first heated to the temperature of the furnace but as it gives up a portion of this heat in pa.s.sing through the boiler, the superheating to the temperature of the exit gases is the correct degree to be considered.
4th. Loss due to the water formed and by the burning of the hydrogen in the fuel which must be evaporated and superheated as in item 3.
5th. Loss due to the superheating of the moisture in the air supplied from the atmospheric temperature to the temperature of the flue gases.
6th. Loss due to the heating of the dry products of combustion to the temperature of the flue gases.
7th. Loss due to the incomplete combustion of the fuel when the carbon is not completely consumed but burns to CO instead of CO_{2}. The CO pa.s.ses out of the stack unburned as a volatile gas capable of further combustion.
8th. Loss due to radiation of heat from the boiler and furnace settings.
Obviously a very elaborate test would have to be made were all of the above items to be determined accurately. In ordinary practice it has become customary to summarize these losses as follows, the methods of computing the losses being given in each instance by a typical example:
(A) Loss due to the heating of moisture in the fuel from the atmospheric temperature to 212 degrees, evaporate it at that temperature and superheat it to the temperature of the flue gases. This in reality is the total heat above the temperature of the air in the boiler room, in one pound of superheated steam at atmospheric pressure at the temperature of the flue gases, multiplied by the percentage of moisture in the fuel. As the total heat above the temperature of the air would have to be computed in each instance, this loss is best expressed by:
Loss in B. t. u. per pound = W(212-t+970.4+.47(T-212)) (33)
Where W = per cent of moisture in coal, t = the temperature of air in the boiler room, T = temperature of the flue gases, .47 = the specific heat of superheated steam at the atmospheric pressure and at the flue gas temperature, (212-t) = B. t. u. necessary to heat one pound of water from the temperature of the boiler room to 212 degrees, 970.4 = B. t. u. necessary to evaporate one pound of water at 212 degrees to steam at atmospheric pressure, .47(T-212) = B. t. u. necessary to superheat one pound of steam at atmospheric pressure from 212 degrees to temperature T.
[Ill.u.s.tration: Portion of 15,000 Horse-power Installation of Babc.o.c.k & Wilc.o.x Boilers, Equipped with Babc.o.c.k & Wilc.o.x Chain Grate Stokers at the Northumberland, Pa., Plant of the Atlas Portland Cement Co. This Company Operates a Total of 24,000 Horse Power of Babc.o.c.k & Wilc.o.x Boilers in its Various Plants]
(B) Loss due to heat carried away in the steam produced by the burning of the hydrogen component of the fuel. In burning, one pound of hydrogen unites with 8 pounds of oxygen to form 9 pounds of steam. Following the reasoning of item (A), therefore, this loss will be:
Loss in B. t. u. per pound = 9H((212-t)+970.4+.47(T-212)) (34)
where H = the percentage by weight of hydrogen.
This item is frequently considered as a part of the unaccounted for loss, where an ultimate a.n.a.lysis of the fuel is not given.
(C) Loss due to heat carried away by dry chimney gases. This is dependent upon the weight of gas per pound of coal which may be determined by formula (16), page 158.
Loss in B. t. u. per pound = (T-t).24W.
Where T and t have values as in (33),
.24 = specific heat of chimney gases,
W = weight of dry chimney gas per pound of coal.
(D) Loss due to incomplete combustion of the carbon content of the fuel, that is, the burning of the carbon to CO instead of CO_{2}.
10,150 CO Loss in B. t. u. per pound = C--------- (35) CO_{2}+CO
C = per cent of carbon in coal by ultimate a.n.a.lysis,
CO and CO_{2} = per cent of CO and CO_{2} by volume from flue gas a.n.a.lysis.
10,150 = the number of heat units generated by burning to CO_{2} one pound of carbon contained in carbon monoxide.
(E) Loss due to unconsumed carbon in the ash (it being usually a.s.sumed that all the combustible in the ash is carbon).
Loss in B. t. u. per pound = per cent C per cent ash B. t. u. per pound of combustible in the ash (usually taken as 14,600 B. t. u.) (36)
The loss incurred in this way is, directly, the carbon in the ash in percentage terms of the total dry coal fired, multiplied by the heat value of carbon.
To compute this item, which is of great importance in comparing the relative performances of different designs of grates, an a.n.a.lysis of the ash must be available.
The other losses, namely, items 2, 5 and 8 of the first cla.s.sification, are ordinarily grouped under one item, as unaccounted for losses, and are obviously the difference between 100 per cent and the sum of the heat utilized and the losses accounted for as given above. Item 5, or the loss due to the moisture in the air, may be readily computed, the moisture being determined from wet and dry bulb thermometer readings, but it is usually disregarded as it is relatively small, averaging, say, one-fifth to one-half of one per cent. Lack of data may, of course, make it necessary to include certain items of the second and ordinary cla.s.sification in this unaccounted for group.
TABLE 57
DATA FROM WHICH HEAT BALANCE (TABLE 58) IS COMPUTED
+------------------------------------------------------+ |+----------------------------------------------------+| ||Steam Pressure by Gauge, Pounds | 192 || ||Temperature of Feed, Degrees Fahrenheit | 180 || ||Degrees of Superheat, Degrees Fahrenheit |115.2|| ||Temperature of Boiler Room, Degrees Fahrenheit| 81 || ||Temperature of Exit Gases, Degrees Fahrenheit | 480 || ||Weight of Coal Used per Hour, Pounds | 5714|| ||Moisture, Per Cent | 1.83|| ||Dry Coal Per Hour, Pounds | 5609|| ||Ash and Refuse per Hour, Pounds | 561|| ||Ash and Refuse (of Dry Coal), Per Cent |10.00|| ||Actual Evaporation per Hour, Pounds |57036|| || .- C, Per Cent |78.57|| || | H, Per Cent | 5.60|| ||Ultimate | O, Per Cent | 7.02|| ||a.n.a.lysis -+ N, Per Cent | 1.11|| ||Dry Coal | Ash, Per Cent | 6.52|| || "- Sulphur, Per Cent | 1.18|| ||Heat Value per Pound Dry Coal, B. t. u. |14225|| ||Heat Value per Pound Combustible, B. t. u. |15217|| ||Combustible in Ash by a.n.a.lysis, Per Cent | 17.9|| || .- CO_{2}, Per Cent |14.33|| ||Flue Gas -+ O, Per Cent | 4.54|| ||a.n.a.lysis | CO, Per Cent | 0.11|| || "- N, Per Cent |81.02|| |+----------------------------------------------+-----+| +------------------------------------------------------+
A schedule of the losses as outlined, requires an evaporative test of the boiler, an a.n.a.lysis of the flue gases, an ultimate a.n.a.lysis of the fuel, and either an ultimate or proximate a.n.a.lysis of the ash. As the amount of unaccounted for losses forms a basis on which to judge the accuracy of a test, such a schedule is called a "heat balance".
A heat balance is best ill.u.s.trated by an example: a.s.sume the data as given in Table 57 to be secured in an actual boiler test.
From this data the factor of evaporation is 1.1514 and the evaporation per hour from and at 212 degrees is 65,671 pounds. Hence the evaporation from and at 212 degrees per pound of dry coal is 65,6715609 = 11.71 pounds. The efficiency of boiler, furnace and grate is:
(11.71970.4)14,225 = 79.88 per cent.