Paper 4 Set B

SUPPLEMENTARY

Note to Evaluator: Please give marks for the steps & logic. A mistake in value in initial step
would lead to subsequent steps getting wrong values. Consider 75% marks, if step is right.
16th NATIONAL CERTIFICATION EXAMINATION
FOR
ENERGY MANAGERS & ENERGY AUDITORS September, 2015
PAPER 4:Energy Performance Assessment for Equipment and Utility Systems
Date: 20.09.2015

Timings: 14:00-16:00 HRS

Duration: 2 HRS

Max. Marks: 100

General instructions:
o
o
o
o
o

Please check that this question paper contains 7 printed pages

Please check that this question paper contains 16 questions
The question paper is divided into three sections
All questions in all three sections are compulsory
All parts of a question should be answered at one place

Section - I:

BRIEF QUESTIONS

Marks: 10 x 1 = 10

(i) Answer all Ten questions

(ii) Each question carries One mark
S-1
Ans

In low load region, current measurements are not a right indicator of motor loading.
Why?
PF will be low.

S-2

Due to gradual choking of AHU filter, AHU fan power decreased. Why?

Ans

Due to increased resistance, the air flow decreased.

S-3

Why are water-cooled condensers more efficient than air-cooled condensers for
refrigeration applications?
In water cooled condensers, the cooling water temperature can be bought below dry
bulb temperature

Ans

S-4

The dry bulb and wet bulb temperatures of air entering an air washer are 35 and 28
0
C respectively. If the saturation efficiency is 90%, calculate the air temperature
leaving the air washer.

Ans

90% = 35 -Tout
35-28

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Bureau of Energy Efficiency

SUPPLEMENTARY

Paper 4 Set B

Tout = 28.7oC
S-5
Ans

For a process requiring indirect heating to 200 oC, thermic fluid is preferred to steam
as a heat carrier. Why?
Because for steam to be heated to high temperatures, the pressure required will be
very high.

S-6

If the condenser back pressure is 82 mm Hg, calculate the condenser vacuum.

if the atmospheric pressure is 745 mmHg.

Ans

Condenser vacuum, mmHg = (Atmospheric pressure, mmHg - Condenser back

pressure, mmHg)
= (745 - 82) = 663 mmHg.

S-7

A direct driven centrifugal fan delivers more air after replacing its standard motor drive
with an energy efficient motor. Why?
Since motor slip is reduced, speed increases and hence fan flow increases.
Between a natural gas fired boiler and oil fired boiler which will have a higher
percentage of hydrogen loss in flue gas? Why ?
Gas fired boiler. Because the hydrogen percentage is more in natural gas compared
to oil.
Why cant a boiler in normal operating conditions deliver its rated capacity?
Because boiler are rated from and at 100 oC.
If the heat rate of a power plant is 1967 kCal/kWh, what is the efficiency of power
plant?

Ans
S-8
Ans
S-9
Ans
S-10
Ans

860/1967 x 100 = 43.7%

. End of Section - I .
Section - II:

SHORT NUMERICAL QUESTIONS

Marks: 2 x 5 = 10

(i) Answer all Two questions

(ii) Each question carries Five marks
L-1

The gross heat rate of a thermal power plant is 2550 kcal/kWh and its net
heat rate is 2833.33 kcal/kWh. The plant is targeting to improve the net heat
rate by 50 kcal/kWh through reduction in auxiliary power consumption. What
will be its % auxiliary power consumption with the above improvement and
incremental reduction in auxiliary power consumption.

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Bureau of Energy Efficiency

SUPPLEMENTARY

Paper 4 Set B

Solution:
Existing case:
Gross heat rate = 2550 kcal/kWh, Net heat rate: 2833.33 kcal/kwh
% Auxiliary power consumption in the existing case
= [ I (2550/2833.33)] x 100
= 10
---- 2 marks
Improved case:
Net heat rate = 2833.33 50.00 = 2783.33 kcal/kwh
% Auxiliary power consumption in the improved case
= [ I (2550/2783.33)] x 100
= 8.38
---- 2 marks
Incremental reduction in Auxiliary power consumption
= 10 -8.38
= 1.62%
L-2

Ans

---- 1 mark
In a counter current heat exchanger, the hot stream enters at 80C and leaves at
50C. On the other hand, the cold stream enters at 20C and leaves the heat
exchanger at 50C. Determine the heat transferred in Kcal/hour if the area is 30 m 2
and overall heat transfer coefficient is 800 W/m 2 K.
For counter-current type:
LMTD = (80-50) (50-20)
ln(80-50/50-20)
= 30 - 30
ln (30/30)
=0
--- 1.5 marks

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Bureau of Energy Efficiency

SUPPLEMENTARY

Paper 4 Set B

In this case LMTD is the same as the temperature difference on each end of the
heat exchanger (terminal temperature difference).
Hence LMTD = 20oC for counter-current flow.
--- 1.5 marks

Heat transfer = (800 /1000) x 30 x 30 x 860 = 6,19,200 kcal/hr

--- 2 marks

. End of Section - II .
Section - III:

LONG NUMERICAL QUESTIONS

Marks: 4 x 20 = 80

(i) Answer all Four questions

(ii) Each question carries Twenty marks
N-1

A gas engine-based trigeneration plant operates in two modes:

Power and heating mode (10 hours per day) :
Pel= 650 kW of electricity and 975 kg/h of steam with enthalpy addition of 530 kcal/kg of
steam
EUFheat = 0.85
Power and cooling mode (14 hours per day) :
Pel = 650 kW of electricity and chilling load of 256 TR for absorption chillers
EUFcool = 0.73

Calorific value of natural gas = 8500 kcal/Sm3

Average operating days/year = 330
Alternator efficiency = 0.95
The energy loss in the flue gas and that in the cooling water is same as engine power output
and other losses are negligible

Find out the following:

(1)
(2)
(3)
(4)

Plant average energy utilization factor

The useful energy produced daily by the trigeneration plant in MTOE
The daily plant natural gas requirements based on average energy utilization factor
The plant proposes to install a 60 TR hot water driven Vapour absorption chiller with a
COP of 0.5 using waste heat from jacket cooling water. Check if it is feasible with
supporting calculations.

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Bureau of Energy Efficiency

Paper 4 Set B

SUPPLEMENTARY

Ans

PEle
QHeat
QCool

=
=
=
=
=

650 KW
975 x 530
516750 kcal/h
256 x 3024
774144 kcal/h

(0.85 x 10 + 0.73 x 14)/24

0.78

.(3 marks)
(650 x 860 x 24 + 516750 x 10 + 774144 x 14)

=
=
=

13416000 + 5167500 + 10838016

29421516 kcal/day
29421516/107

2.94

=
=
=
=

29421516 / 0.78
37719892 kcal/day
37719892 / 8500
4438 Sm3/day

.(2 marks)
Plant average energy utilization
factor

Total daily useful energy production of

the plant

The useful energy produced daily

by trigeneration plant in MTOE/day

.(4 marks)
Input heat
Natural gas requirements

N-2

.(4 marks)
4) Justification for a 60 TR Vapour Absorption chiller from waste heat of the jacket
cooling water
Heat required for operating 60 TR at
= 60 x 3024/0.5
COP of 0.5
= 362880 Kcal/hr
.(2 marks)
650 /0.95
Power output of the engine
=
684.2 KW
.(2 marks)
= 684.2 x 860
Heat in the jacket cooling water
= 588412 kcal/hr
.(2 marks)
Since the heat requirement (362880 kcal/hr) is much less than heat available (588412
kcal/hr) the proposal is feasible.
.(1 mark)
3
An engineering industry has a compressor of capacity 2500 m /h in operation. Free air delivery
test of the compressor was carried out by filling the receiver. The test and other data are given
below.
Receiver capacity
Interconnecting pipe

: 9 m3
: 1 m3

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Bureau of Energy Efficiency

Paper 4 Set B

SUPPLEMENTARY

Ans

Atmospheric pressure
Initial pressure in receiver
Inlet air pressure to compressor
Final pressure
Time taken to fill the receiver
Inlet air temperature
Air temperature in the receiver

: 1.03 kg/cm2a
: 1.0 kg/cm2a
1.0 kg/cm2a
: 5 kg/cm2a
: 3 minutes (180 seconds)
: 30 oC
: 40 oC

Motor rpm (D1)

Motor pulley diameter (N1)
Compressor rpm (D2)
Compressor Pulley diameter (N2)
Average duration of loading
Average duration of unloading
Power consumption during loading
Power consumption during unloading
Cost of energy

: 1440
: 300mm
: 650 rpm
: 600 mm
: 40 minutes in an hour
: 20 minutes in an hour
: 150 kW
: 45 kW
: Rs. 5.00 per kWh

A:

What is the operating free air delivery of the compressor?

B:

Evaluate the cost of energy per day (24hrs operation).

C:

The Plant was interested in reducing the unloading time of the compressor by reducing
the pulley diameter of the motor. Evaluate the speed of the compressor required for a
cycle of 10 minutes unloading and 50 minutes loading and accordingly evaluate the
diameter of the pulley of the motor.

D:

Estimate the hourly power consumption and energy savings after replacement of the
pulley and payback period. Consider the cost of pulley and belts is Rs 40,000 and
operating hours of the compressor is 8000 in a year. (consider that the power
consumption was 120 kW during loading and 35 kW during unloading)

A.

Operating free air delivery of the compressor, Q

P2 P1 V
Nm3 / Minute
P0
T

Applying for temperature correction factor (273 + t1) / (273 + t2), Operating free air delivery
is:
Q1 = 5 1.0 x 10 x (273 + 30)
1.03
3 (273 + 40)
= 12.95 m3/hr x 0.968
= 12.5 Nm3/min
= 750 Nm3/hr.
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Bureau of Energy Efficiency

Paper 4 Set B

SUPPLEMENTARY

---- 5 marks
B.

Cost of energy per day

Average power consumption per hour = (150 x 40) + (45 x 20)
(40 + 20)
= 115 kW.
Average energy consumption per day = 115 x 24
= 2760 kWh.
Cost of energy per day = 2760 x 5 = Rs. 13,800 per day.
---- 5 marks

C.

Speed of compressor and Pulley diameter of motor

(for 10 minutes unloading and 50 minutes loading)
Air flow rate Q2= (750 x 50) + (0 x 10)
60
= 625 m3/hr.

( Q1 / Q2) compressor= (RPM 1 / RPM 2) compressor

750 / 625 = 650 / RPM2
RPM2 = 542 rpm.
(RPM1 / RPM2)Compressor = (D1/D2 )Motor
650/542=300/ D2
D2 = 250 mm.
(or) (Q1 / Q2) compressor = (D 1 / D 2)Motor
750 / 625 = 300 / D2
D2 = 250 mm.

Reduced motor pulley diameter = 250 mm

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Bureau of Energy Efficiency

Paper 4 Set B

SUPPLEMENTARY

Reduced speed of the compressor = 542 rpm

---- 5 marks
D.

Energy Savings and Payback period (after replacement of pulley)

Average power consumption per hour = (120 x 50) + (35 x 10)
(50 + 10)
= 105.8 kW.
Power Savings = 115 105.8 = 9.2 kW.
Annual energy savings = 9.2 x 8000 = 73600 kWh/year.
Annual cost savings = 73600 x 5 = Rs. 3,68,000/year.
Payback Period = 40,000 / 3,68,000 = 1.3 months.
---- 5 marks

N-3

Chilled water is circulated through the evaporator of a vapor compression chiller and
the outlet chilled water temperature is 7 oC. The evaporator is maintained at 2.5 oC.
Terminal Temperature Difference (TTD) on the chilled water inlet side is 5 oC higher
than chilled water outlet side.
Other given data:

Overall heat transfer coefficient of the evaporator 542.42 kcal/hr m2oC

Area of the evaporator 250 m2
Efficiency of the compressor motor is 88%
Condenser heat load is 20% more than the evaporator cooling load.

Calculate
a.
b.
c.
d.
e.

LMTD of the evaporator

Refrigeration load or evaporator cooling load in tonne refrigeration(TR)
C.O.P. of the chiller
Compressor input kW/TR
Indicate the operating parameters and the calculated values in a simple
schematic diagram
f. Find out the energy savings if the chilled water supply to one of the process
heat exchanger with a heat load of 90,000 kcal/hr operating for 8000 hrs in a
year is eliminated by process modification

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Bureau of Energy Efficiency

Paper 4 Set B

SUPPLEMENTARY

Solution
a.

T2 = To - TE = 7 2.5 = 4.5oC
T1 = T2+ 5 = 4.5 + 5 = 9.5oC
T1 = Ti - TE = 9.5oC

Ti = 9.5 + 2.5 = 12oC

Ti To = 12 7 = 5oC
LMTD of evaporator =

T1 - T2
-------------ln 9.5 / 4.5

= 6.69 oC
---- 4 marks

b.

Refrigeration load or evaporator heat load

Heat load

= U(kcal/hr m2 C) x A (m2) x LMTD oC

= 542.42 x 250 x 6.69
= 9,07,197.45 kcal/hr

Refrigeration load

= 9,07,197.45/3024
= 300 TR
---- 4 marks

c.

Condenser heat load =

300 x 1.2 = 360 TR

d.

Compressor input (heat energy) equivalent = 360 300 = 60 TR

COP = 300 / 60 = 5
Electrical input power to compressor motor
Input KW for compressor = 60 x 3024 / 860 = 210.98
Compressor chiller KW / TR

= 210.98 / 300 = 0.703

---- 4 marks

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Bureau of Energy Efficiency

SUPPLEMENTARY

Paper 4 Set B

e.

Schematic of the Vapor Compression Water Chiler indicating the operating parameters
and the calculated values

---- 4 marks
f.

Reduction in chiller load = 90,000.00 kcal/hr

Reduction in refrigeration load = (90000.00) / 3024 = 29.76 TR
Compressor input power is 0.703kw/TR, motor efficiency is 88%
Saving in electrical energy = (29.76 x 0.703) / 0.88 = 23.774 KW
Annual energy savings = 23.774 x 8000 = 1,90,192.00 kwh

---- 4 marks
N-4

Answer ANY ONE OF THE FOLLOWING among A, B, C and D

A)

A steam power plant consisting of high pressure Turbine(HP Turbine) and low pressure
Turbine(LP Turbine) is operating on Reheat cycle(schematic of power plant is

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SUPPLEMENTARY

Paper 4 Set B

represented below).Steam from Boiler at a pressure of 150 bar(a) and a temperature of

5500C expands through the HP Turbine. The exhaust steam from HP Turbine is
reheatedin a Reheater at a constant pressure of 40 bar (a) to 550 0C and then expanded
through LP Turbine. The exhaust steam from LP Turbine is condensed in a condenser
at a pressure of 0.1 bar (a).The isentropic efficiency of HP Turbine and LP Turbine is
same and is 90%. Generator efficiency is 95%
The other data of the power plant is as given below:
Main steam flow rate
: 228 TPH
Enthalpy of main steam
: 3450 KJ/kg
Enthalpy of feed water
: 990.3KJ/kg
Isentropic Enthalpy of cold reheat steam : 3050 KJ/kg
Enthalpy of hot reheat steam : 3560 KJ/kg
Condenser pressure and temperature : 0.1 bar(a) and 45.80C
Isentropic enthalpy of LP Turbine exhaust steam : 2300 KJ/kg
Enthalpy of dry saturated steam at 0.1 bar(a) and 45.8 0C : 2584.9KJ/kg
Enthalpy of water at 0.1 bar(a) and 45.8 0C:191.9 KJ/kg

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Paper 4 Set B

SUPPLEMENTARY

Based on the above data calculate the following parameters

(a) Power developed by the Generator
(b) Turbine heat rate
(c) Turbine cycle efficiency
(d)Dryness fraction of LP Turbine Exhaust steam
(e) Specific steam consumption of turbine cycle.
Ans

SOLUTION:
(a) Power developed by the Generator: Turbine output x Generator efficiency--------(1)
Turbine out put = Q1 (H1 h2) + Q2(H3 h4)/860 MW -----------------(2)
Where, Q1=main steam flow rate =228 TPH
H1=main steam enthalpy=3450 KJ/Kg
h2=actual enthalpy at HP Turbine outlet= cold reheat enthalpy
Q2=steam flow through reheater=228TPH
H3=enthalpy of hot reheat steam=3560 KJ/kg
h4= actual enthalpy of LP turbine exhaust steam=?
---- 1 mark
HP Turbine isentropic efficiency= Actual enthalpy drop/isentropic enthalpy drop
0.9= (H1- h2)/(H1-h2is) , h2is=isentropic enthalpy of cold reheat steam=3050KJ/kg
0.9= (3450 h2)/(34503050)
h2= 3090KJ/kg
---- 3 marks
LP Turbine isentropic efficiency= (H3h4)/(H3h4is), h4is=isentropic enthalpy of LP
Turbine Exhaust steam=2300KJ/kg
0.9=( 3560-h4)/(35602300)
h4= 2426 KJ/kg
---- 3 marks
Substituting the values in equation-2,we get
Turbine output = 228(34503090) + 228(35602426)/860 =75.73MW
Generator output= 75.73 x 0.95= 71.5 MW
---- 3 marks
(b) Turbine heat rate=Q1 (H1hfw) +Q2(H3h2)/Generator output =KJ/kwhr---------(3)
hfw=enthalpy of feed water=990.3KJ/kg
Substituting the values in the above equation-3, we get

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Paper 4 Set B

SUPPLEMENTARY

Turbine heat rate = 228 (3450990.3) + 228(35603090)/71.5

= 9342 KJ/kWhr
---- 3 marks
(C) Turbine cycle efficiency= 860/Turbine heat rate
=860/9342=38.5%
---- (2 marks)

(d)Dryness fraction of steam at 0.1 bar(a) and 45.80C

Actual enthalpy of LP Exhaust steam= enthalpy of water + dryness fraction of steam x
L.H of vaporisation of steam
2426 = 191.9+ dryness fraction of steam x (2584.9191.9)
Dryness fraction of steam= 93.35%
---- (3 marks)

(e) Specific steam consumption of cycle = Steam flow/generator output

= 228/71.5 = 3.19 tons/MWhr
---- (2 marks)
or
B)

Stenter operations in a textile process were significantly improved to reduce inlet

moisture of from 60% to 55% in wet cloth while maintaining the same outlet moisture of
7% in the dried cloth . The Stenter was operated at 80 meters/min in both the cases.
The dried cloth weighs 0.1 kg /meter . Further steps were taken to improve the efficiency
of the fuel oil fired thermic fluid from 80% to 82%, which was supplying heat energy
from to the dryer. The other data and particulars are,
Latent heat of water evoprated = 540kcal/kg,
Inlet temperature of wetcloth = 28oC ,
Outlet temperature of dried cloth = 80 oC,
Dryer efficiency = 50% ,
G.C.V of fuel oil = 10,300.00 kcal/kg,
Yearly operation of the stenter = 7000 hours
Find out the % reduction in Dryer heat load ,
Estimate the overall yearly fuel savings in tonnes by reducing moisture and efficiency
improvement compared to the initial case. Assume only energy for moisture evaporation
only for dryer heat load

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Bureau of Energy Efficiency

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Paper 4 Set B

SUPPLEMENTARY

Ans

Solution:
Initial case: inlet moisture, 60%, outlet moisture 7%, dryer efficiency
50%,thermic fluid heater efficiency 80%
Output of stenter

=
=

80 mts/min x 0.1 x 60
480 Kg/hr.

Moisture in the dried output cloth = 7%

= 480 X (1 0.07)
= 446.4 Kg/hr.

Wt of bone- dry cloth

i.e. W

---- (1.5 mark)

mo = moisture in outlet cloth= (480 446.4) /446.4

= 0.0753 Kg./Kg.bone-dry cloth
---- (1 mark)

Inlet moisture
Wt of inlet cloth

= 60%
= 446.4 / (1 0.60) = 1116.00 Kg/hr.

mi

= moisture in inlet cloth

= (1160.0 - 446.4) 446.4 = 1.5 Kg/Kg bone- dry

cloth
---- (1 mark)

28oC
80oC

Inlet temperature of cloth Tin

Final temperature of clothTout

=
=

Heat load on the dryer

w x (mi mo) X [(T out Tin) + 540] Kcal/hr.

Heat load on the dryer

=
=

446.4 (1.5 0.0753) X [(80 28) + 540]

3,76,503.76 Kcal/hr
---- (3 marks)

Efficiency of the dryer is50%, Efficiency of the thermic fluid heater is 80%
Fuel oil consumption in the thermic fluid heater
=3,76503.76/( 0.5x 0.8x10300) = 91.40 kg/hr
---- (2.5 marks)

Improve case: inlet moisture, 55%, outlet moisture 7%, dryer efficiency
50%,thermic fluid heater efficiency 82%
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Paper 4 Set B

SUPPLEMENTARY

Inlet moisture
Wt of inlet cloth

= 55%
= 446.4 / (1 0.55) = 992.00 Kg./hr.
mi

= moisture in inlet cloth

= (992-446.4) 446.4 = 1.22 Kg/Kg bone-dry cloth
---- (1.5 marks)

Heat load on the dryer

w x (mi mo) X [(T out Tin) + 540] Kcal/hr.

Heat load on the dryer

=
=

446.4 (1.22 0.0753) X [(80 28) + 540]

3,02508.00 Kcal/hr
---- (3 marks)

Efficiency of the dryer is50%, Efficiency of the thermic fluid heater is 82%
Fuel oil consumption in the thermic fluid heater in impoved case
=3,02,508.00/( 0.5x 0.82x10300) = 71.63 kg/hr
---- (2.5 marks)

% reduction in dryer load due to reduction inlet moisture

( 3,76,504-3,02,508)x 100
= ----------------------------------------( 3,76,504)
= 19.65%
---- (2 marks)

Saving in fuel oil consumption in improved case

= 91.4- 71.63
= 19.77 kg/hr
Yearly fuel oil savings

=19.77x7000 x1/1000
=138.39 tonnes
---- (2 marks)
or

C)

In a steel industry, the composition of blast furnace gas by volume is as follows

CO 27%, H2 - 2%, CO2 11%, N2 - 60%.

i)
ii)
iii)
iv)

Calculate the stoichiometric air for combustion

Calculate the gross calorific value of gas in kcal/Nm 3
Calculate the net calorific value of gas in kcal/Nm3
If 3,00,000 Nm3/hr of gas is available and is to be co-fired in a coal fired boiler. How much

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Paper 4 Set B

SUPPLEMENTARY

coal it can replace if the GCV of coal is 4300 kcal/kg.

Ans

(i) Stoichiometric air for combustion:

C + O2 ------ CO2 + 8,084 kcal/kg Carbon
2C + O2 ------ 2 CO + 2,430 kcal/kg Carbon

Available in Book-2

H2 + O2 -------H2O + 28,922 kcal/kg Hydrogen

CO + O2 -------CO2 + 5,654 kcal/kg Carbon
---- (2 marks)
1 mole CO + 0.5 mole O2 ------ 1 mole CO2 + 5654 kCal/kg
For 27% CO, O2 required is (0.5/1) x 0.27 = 0.135 O 2
---- (2 marks)
1 mole H2 + 0.5 mole O2 ------ 1 mole H2O + 28922 Kcal/kg
For 2 % of H2, O2 required is (0.5/1) x 0.02 = 0.01 O2
---- (2 marks)
Total stoichiometric oxygen required = 0.135 + 0.01 = 0.145 O2
Stoichiometric air required = 100 x 0.145 = 0.690 m3 air / m3 blast furnace gas
21
---- (3 marks)
(ii) Gross calorific value of gas:
1 kg mole of any gas at STP occupies 22.4 m3 of volume.
---- (1 mark)
Therefore,
((5654 x 12) / 22.4) x 0.27 = 817,83 kCal/m3 (molecular weight of Carbon = 12)
---- (2 marks)
((28922 x 2) / 22.4) x 0.02 = 51.64 kCal/m3 (molecular weight of Hydrogen = 2)
---- (2 marks)
Gross Calorific Value = 817.83 + 51.64 = 869.5 kcal/m3
---- (1 mark)
(iii) Replacement of coal by blast furnace gas:
Gross calorific value of coal = 4300 kcal/kg (given)
Blast furnace gas available = 3,00,000 m3/hr (given)
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Paper 4 Set B

SUPPLEMENTARY

Heat content available from gas

= 3,00,000 m3/hr x 869.5 kcal/m3

= 2608.5 x 105 kcal/hr
---- (2.5 marks)

If X is the coal quantity to be replaced, then

4300 kcal/kg x X = 2608.5 x 10 5 kcal/hr
X = 60663 kg/hr of coal can be replaced by gas of 3,00,000 m3/hr.
---- (2.5 marks)
or
D)

As an energy auditor, auditing a cement plant, it is essential to assess the specific coal
consumption for the production of the clinker. With the following data available, calculate the
specific coal consumption (kgCoal/ KgClinker).
S.No Parameter

Value

1. Reference temperature

20OC

2. Barometric pressure

10329 mmWC

3. Density of the Pre-heater at NTP

1.436kg/m3

4. Density of Air

1.293Kg/m3

5. Pitot Tube Constant

0.85

6. Clinker production rate

4127 TPD

7. Static Pressure of the gas at Pre-heater gas in the pre-heater duct

640mmWC

8. Dynamic pressure of the pre-heater gas in the duct

15.8mmWC

9. Temperature of the Pre-heater gas

320OC

10. Specific heat of the Pre-heater gas

0.247kCal/kg 0C

11. Area of the Pre-heater Duct

8.5 m2

12. Temperature of the exit clinker

128OC

13. Specific heat of the clinker

0.193 kCal/kg 0C

14. Static Pressure of the Cooler Exhaust gas in the duct

42mmWC

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Paper 4 Set B

SUPPLEMENTARY

Ans

15. Dynamic pressure of the Cooler Exhaust gas in the duct

15.5mmWC

16. Temperature of the Cooler Exhaust gas gas

290

17. Specific heat of the Cooler Exhaust gas

0.247kCal/kg 0C

18. Area of the Cooler exhaust duct

7.1m2

19. Heat of Formation of Clinker

405 Kcal/KgClinker

20. All other heat loss except heat loss through Pre-heater gas,
exiting clinker and cooler exhaust gases
21. All heat inputs except heat due to Combustion of fuel (Coal)

84.3 Kcal/Kg Clinker

22. GCV of the Coal

6200Kcal/Kg

29 Kcal/Kg Clinker

Heat Lost along with the Exiting pre-heater gases:

QPH Gas = mphgas Cpphgas (tephgas-tr)
mphgas = VphgasX Phgas
Vphgas = vph gas X A

Corrected density of the pre-heater gas:

10329 640
273
= 1.436

Phgas
10334
273 320
= 0.6198 kg/ m3

Velocity (v)

=Pt (2g(Pdynamic)avg / Phgas) m/sec

2 9.81 15.8

0.85

19.0 m/sec

0.6198

m/sec

VPH gas = 19.0m3/s X 8.5 m2

= 161.5 m3/sec
= 5,81,400m3/hr
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Bureau of Energy Efficiency

18

Paper 4 Set B

SUPPLEMENTARY

Mph gas

= 581400 m3/hr X 0.6198 kg/m3

= 3,60,351/72 Kg/hr

mphgas = 3,60,351 kg/hr / 1,71,958 kg/hr =2.095Kgph gas/ Kg clinker

QPH Gas = 2.095 X 0.247 X (320 -20)
= 155.24Kcal/KgClinker
----- 7 marks

Heat Lost along with the Exiting Hot Clinker:

QHot clinker
= mclinker Cpclinker ( tclinker- tr)
= 1 x 0.193 x (128 20),
= 20.84 kCal/kgClinker
---- 2 marks
Heat Lost along with the Exiting Cooler Exhaust gases:
QCooler Exhaust Gas
= mCooler Exhaust Gas CpCooler Exhaust Gas (tCooler Exhaust Gas-tr)
mCooler Exhaust Gas
= VCooler Exhaust Gas X Cooler Exhaust Gas
VCooler Exhaust Gas
= vCooler Exhaust Gas X A
Corrected density of the pre-heater gas:
10329 42
273

Cooler Exhaust gas = 1.293

10334
273 290
= 0.624 kg/ m3

Velocity (v)

= Pt (2g(Pdynamic)avg / Cooler Exhausts) m/sec

= 0.85

2 9.81 15.5
0.624

m/sec

= 18.76 m/sec
VcoolerExhaustgas = 18.76m/s X 7.1 m2
= 133.196 m3/sec
= 4,79,505m3/hr

McoolerExhaustgas = 479505 m3/hr X 0.624 kg/m3

= 2,99,211 Kg/hr
mcoolerExhaustgas = 2,99,211 kg/hr / 1,71,958 kg/hr =1.74 KgcoolerExhaustgas/ Kg clinker
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Bureau of Energy Efficiency

19

Paper 4 Set B

SUPPLEMENTARY

QcoolerExhaustgas

= 1.74 X 0.244 X (290 -20)

= 114.63Kcal/KgClinker
------- 7 marks

Heat Input = Heat output

Heat Inputcoal + Heat inputothers
Heatothers

= HeatClikerfrmtn+ HeatPH gas + HeatCliker+ Heatcooler exhaust gas gas +

GCVcoalX m coal + 29 = 405 + 155.24 + 20.84 +114.63 + 84.3

mcoal

= 751 / 6200
= 0.121 Kgcoal/Kgclinker
------- 4 marks

-------- End of Section - III ---------

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Bureau of Energy Efficiency

20