B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER MARATHON CANADA TEST RUN NO. PAGE 1 Date: 20 April 2011 BOILER NO.: NO. 5 Eng.: METERED STEAM RATED CAPACITY: 150,000 lb/Hr FLOW DURING TEST: 152,000 lb/Hr DRUM PRESSURE: 684 PSIG DRUM TEMPERATURE: 503 F STEAM PRESSURE: 607 PSIG STEAM TEPERATURE: 679 F FEEDWATER TEMP.: 250 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 10,691.00 lb/Hr. OIL C 85.53 H2 10.33 S 3.50 O2 0.50 b N2 0.14 CO2 H2O ASH 100.00 18,242 Btu/lb DRY FLUE GAS ORSAT ANALYSIS CO2 14.48 O2 2.19 CO 0.00 N2 83.11 c Wet flue gas CO2 12.60 O2 1.91 CO 0.00 N2 72.33 Excess air (E.A.) assigned or by orsat 11 % 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 18,242 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 375 F l Dry bulb (ambient) temp, t1 100 F m Wet bulb temp 84 F n Rel humid,(pyschrometric chart) 61.% o B, barometric pressure, in. Hg 29.26 p Sat. press. H2O at amb temp. in. Hg 1.94 q A, press. H2O in air, lines (o X q), in. Hg. 1.18 r B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER MARATHON CANADA TEST RUN NO. PAGE 2 Date: 20 April 2011 BOILER NO.: NO. 5 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 85.53 12 7.1 1 7.1 7.1 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 10.33 2 5.2 .5 2.6 5.2 6 S 3.50 32 0.0 1 0.1 0.1 7 O2 0.50 32 0.0 1 -.0 8 N2 0.14 28 0.0 0 0.0 9 CO2 0.00 44 0.0 0 0.0 10 H20 0.00 18 0.0 0 0.0 11 ASH 0.00 12 Sum 100.00 12.42 9.80 O2 and Air, Moles for Total Air=111 % (See line d Page 1) 13 O2(theo) reqd= O2, line 12 9.80 14 O2(excess)=T.A.-100/100 X O2, line 12 1.08 1.1 15 O2(Total) Supplied= Lines 13+14 10.88 16 N2 Suplied= 3.76 X O2, Line 15 40.92 40.9 17 Air(dry) Supplied= O2+N2 51.80 18 H2O in Air= moles dry air X A/B-A 2.17 2.2 19 Air(wet) Supplied= lines 17+18 53.97 20 Flue gas constituents= lines 1 to 18 'Tot.' 7 1 41 7 0.0 20a Total Wet Flue Gas Dry Flue Gas 56.58 49.24 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 MARATHON CANADA TEST RUN NO. PAGE 3 Date: 20 April 2011 BOILER NO.: NO. 5 Eng.: a1 Air(dry) supplied/unit fuel= moles air, line 17X29, (mol. wt air) 1,500.62 lb b1 H2O in air supplied/unit fuel= moles H2O, line 18X18, (mol. wt H2O) 39.17 lb c1 Wet air supplied/unit fuel=lines a1+b1 1,539.79 lb Line c1/100 (solid or liquid fuels) 15.40 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) 12.60 0.19 1.91 72.33 12.97 0.00 g1 Dry F.G.,% by vol= 100Xline 20/line 20a(dry) 14.48 0.22 2.19 83.11 0.00 h1 Wt each constituent= line 20Xmol. wt of each, lb 313.68 7.01 34.51 1146.2 132.24 0.00 i1 Total wt F.G.= sum(h1 wet) & sum(h1 dry) Wet wt 1,633.67 lb Dry wt 1,501.42 lb Wet wt. line i1/100, solid & liquid fuels 16.34 lb j1 Wet flue gas/lb fuel Wet wt. line i1/line f, gaseous fuels Dry wt. line i1/100, solid & liquid fuels 15.01 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 28.88 m1 Molecular wt of dry flue gas= dry wt, line i1/dry moles, line 20a 30.49 n1 Density of wet flue gas= line l1/394 (at 80 F & 30 in. Hg.) .0733 lb/ft3 o1 Density of dry flue gas= line m1/394 (at 80 F & 30 in. Hg.) .0774 lb/ft3 p1 SO2 in flue gas 4,288.8604 ppm q1 Lb. SO2 per Million Btu 3.8409 B O I L E R E F F I C I E N C Y T E S T Plant: JAMES RIVER MARATHON CANADA TEST RUN NO. PAGE 4 Date: 20 April 2011 BOILER NO.: NO. 5 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 10.4 10.9 7.37 7.02 8.31 7.08 24 In dry gas= moles each line 20 X Mcp X(t1-t2) 20,377 328 2,187 78,981 101,873 25 In H2O in air= H2O, line 18 X Mcp X (t2-t1) 4,966 4,966 26 In sens heat, H2O in fuel= moles, lines (5+10) X Mcp X (t2-t1) 11,798 11,798 27 In latent heat, H2O in fuel- moles, ines (5+10) X 1040 X 18 96,689 96,689 28 Total in wet flue gas 215,326 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 215,326 32 Heat value of fuel unit= 100 X line i for solid or liquid fuels 1,824,200 and 394 X line i X 100, for gaseous fuels 33 Heat losses due to dry gas 5.58 34 Heat loss from combustion of H2 5.95 35 Heat loss due to moisture in fuel 36 Heat loss due to moisture in air 0.27 37 Loss due to carbon in refuse 38 Loss due to unburned CO in flue gas 39 Combustion Efficiency 88.20 40 Unaccounted losses 1.00 41 Radiant heat loss ( 4 water walls) 0.39 42 Continuous blowdown loss ( 0.00%) 0.00 43 Boiler Efficiency 86.81 ID Fan Capacity required= 61,715.6330 CFM @ 375 F 174,655.1560 LBS/HOUR FLUE GAS for 10,691 pounds of OIL FD FAN CAPACITY REQUIRED= 38,879.9260 CFM @ 100 F 164,619.0940 LbS/HOUR AIR SUPPLIED for 10,691 pounds of OIL ACTUAL STEAM PRODUCED= 151,294.0620 lb/Hr. per 10,691 pound(s) of OIL burned per hour nesjr F