World Academy of Science, Engineering and Technology

International Journal of Industrial and Manufacturing Engineering

Vol:6, No:3, 2012

Calculating the Efficiency of Steam Boilers

Based on Its Most Effecting Factors: A Case
Study
Nabil M. Muhaisen, Rajab Abdullah Hokoma

Abstract—This paper is concerned with calculating boiler The heating balance method (used for calculating the boiler
efficiency as one of the most important types of performance efficiency) is considered as the most important method in
measurements in any steam power plant. That has a key role in many calculations of boilers efficiency [3], [4]. The heating
Digital Open Science Index, Industrial and Manufacturing Engineering Vol:6, No:3, 2012 waset.org/Publication/15720

determining the overall effectiveness of the whole system within the

power station. For this calculation, a Visual-Basic program was
balance of boilers is usually limited by the maximum thermal
developed, and a steam power plant known as El-Khmus power value of fuel (HHV) which includes six parts. One of them is
plant, Libya was selected as a case study. The calculation of the absorbing energy water, whereas the other five parts represents
boiler efficiency was applied by using heating balance method. The indicators related to the boilers, usually due to incomplete
findings showed how the maximum heat energy which produced burning, and increasing the temperature of let-out gaze [2],
from the boiler increases the boiler efficiency through increasing the [5].
temperature of the feed water, and decreasing the exhaust
temperature along with humidity levels of the of fuel used within the
boiler. II. COMMON ENERGY LOSSES IN HEATING BALANCE METHOD
The common losses in energy while using the heating
Keywords—Boiler, Calculation, Efficiency, Performance. Steam balance method are cited as below [2]:
• Energy absorbed by water feed, expressed
I. INTRODUCTION mathematically as E1=[Ms(hs-hw)+Mrh(hro-hri)]/mf
•
T HIS recent era complied many areas of research and
industry to work towards improving their operations.
Loss energy in dry exhaust gases, expressed as E2 = [
Mg. Cpg (Tg- Ta)]/Mf
Among of these operations are developing the electric energy • Loss of energy in exhaust gases due to humidity level
operations which indeed play a key role for updating and in fuel, as E3=Mw[Cpw (100-Ta) +2285+ Cpfuel(Tg-100)]
improving this area of industry and research. In general, many • Loss of energy attributed to incomplete combustion
methods are well-known and being used within this area for (CO), expressed as E4= (Pwco/Pwgass) . Mg. Cvco
producing the electric energy, among of them is using steam • Loss from rays and uncountable loss, expressed as E5
generation stations. Boilers are considered to be as the key part = Εf -∑ Ei
in any generation station as it is the place where the fuel is • Loss of energy in exhaust gases attributed to the
used for producing the needed amount of heat [1]. This fact water vapor for med by combustion of the hydrogen in the fuel
arises the importance of knowing the efficiency levels of the which can be expressed as 2H2 +O2 → 2H2O
boilers within any electrical generation station. The efficiency
levels of the boiler can be known as the percentage between The heating balance method (used for calculating the boiler
the used amount of heat to generate the steam and the amount efficiency) is considered as the most important method in
of heat produced by burning of the used fuel [1], [2].In many calculations of boilers efficiency [3], [4]. The heating
balance of boilers is usually limited by the maximum thermal
general, there are many methods being used for calculating the
value of fuel (HHV) which includes six parts. One of them is
boiler efficiency levels, direct methods, indirect ones, and a
absorbing energy feed water, whereas the other five parts
method known as heating balance. For this research, the
represents indicators related to the boilers, usually due to
heating balance method was the selected method to be used for incomplete burning, and increasing the temperature of let-out
the required calculations as it provides a general insight for the gaze [2], [5].
changes of the heating energy levels in the boiler, making
these calculations much more clear and easy to present.
III. EXPERIMENTAL STUDY
Mr. Nabil M. Muhaisen is with the Mechanical Engineering Department, The experimental study took place at El-Khmus Steam
High Institute for Training, Zliten-Libya, e-mail: n_m 203@yahoo.com, Power Plant, Libya, and will be concerned on the changes of
+218-91-4585397 the boiler efficiency levels, along with the effect of different
Dr. Rajab Abdullah Hokoma, is with the Mechanical & Industrial
Engineering Department, Faculty of Engineering, University of Tripoli, factors that can be changed in the boiler such as temperature of
Libya, e-mail: rhokoma@triopoliuniv.edu.ly, +218-91-8228415 water feed , temperature of exhaust gases, level of humidity in

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 World Academy of Science, Engineering and Technology
International Journal of Industrial and Manufacturing Engineering
Vol:6, No:3, 2012

the fuel. A computer program (visual basic) was developed for TABLE III
VALUE OF (EF% , ET , EE1 , E1 , HW) WITH TEMPERATURE CHANGE TO THE
this purpose to calculate the changes in the efficiency levels of FEED WATER (TW)
the boiler. Table I presents some constants being used to run Tw Hw E1 EE1 ET
the developed computer program [4], [7]. Whereas, Table II, EF%
Cº KJ/Kg KJ/Kg KJ/Kg KJ/Kg
shows the readings that being taken as the maximum load 230 990.12 37218.98 0.0234375 37219.02 0.9258463
being used within the steam power plant [3], [6].
235 1013.62 36917.84 301.1563 37520.16 0.9333372

TABLE I 240 1037.32 36614.15 604.8477 37823.85 0.9408917

CONSTANTS NEEDED TO RUN THE COMPUTER PROGRAM
Type of Constant Symbol Constant 245 1061.23 36307.77 911.2305 38130.23 0.9485132

Enthalpy of steam outlet of boiler hs 3445 KJ/KG 250 1085.36 35998.57 1220.434 38439.43 0.9562048
Enthalpy of steam inlet to reheat hri 3075 KJ/KG
255 1109.73 35686.29 1532.715 38751.71 0.963973
Enthalpy of steam outlet of reheat hro 3555 KJ/KG
260 1134.37 35370.55 1848.453 39067.45 0.9718272
Enthalpy of feed water hw 999.12 KJ/KG
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TABLE II The change of the thermal energy loses along with the
READINGS FROM EL-KHUMS STEAM POWER PLANT
values of thermal gains when decreasing the temperature of the
Parameter Symbol Value(Unit)
exhaust gases are all shown in Table IV, whereas the changes
Temperature of feed in inlet of E3, EE3, ET, and EF% with changing the humidity value
Tw 230 Cº
economizer
(W) are all shown in Table V.
Mass flow feed water ratio mw 375000 Kg/hr TABLE IV
The mass of the used fuel mf 29264.75 Kg/hr VALUES OF (E2, EE2, ET, AND EF%) WITH TEMPERATURE OF EXHAUST
GASES
Flow ratio of steam outlet of super
Ms 351300 Kg/hr Tg E2 KJ/Kg EE2 KJ/Kg ET KJ/Kg EF%
heater
160 2167.053 -4.49992 37219 0.925845
Specific heat of fuel Cp.f 2.3 KJ/Kg.Kº 7
155 2089.659 77.77143 37296.77 0.927780
Thermal value of fuel HHV 40200 KJ/Kg 3
150 2010.264 155.5474 37374.55 0.929715
Humidity level in fuel Mw 3.3% 1
145 1934.869 233.3233 37452.32 0.931649
Mass of combustion gases per kg/fuel Mg 14.21 Kg/Kgfuel 9
140 1857.474 311.0992 37530.1 0.933584
Average temp. for exhaust gases Tg 165 Cº 5
135 1780.08 388.8751 37607.88 0.935519
Average temperature for air 3
Ta 25 Cº 130 1702.685 466.651 37685.65 0.937454
surrounding the boiler
Specific heat for exhaust gases Cpg 1.0893 KJ/Kg.Kº
TABLE V
Flow ratio of steam outlet of reheat Mrh 300000 Kg/hr SHOWS THE VALUES OF E3, EE3, ET, AND EF% WITH CHANGING THE
HUMIDITY (W)
Temp. of steam outlet of superheat Ts 540 Cº
W E3 EE3 ET EF %
Temperature of steam outlet of reheat Tro 540 Cº 0.03 87.0928 2.717196 37221.72 0.9259134
Temperature of steam inlet to reheat Tri 330 Cº 2
0.03 84.37115 5.438853 37224.44 0.9259810
1
Pressure of steam outlet of reheat Pso 28.1 bar 0.03 18.6495 8.160502 37227.16 0.9260488
Pressure of steam upon out of boiler Pro 131 bar 0.02 87.92785 10.88215 37229.88 0.9261165
9
0.02 67.2062 13.6038 37232.61 0.9261842
Quality of thermal capacity water Cpw 4.18 KJ/Kg.Kº
8
0.02 37.48455 16.32545 37253.32 0.9262518
Quality of thermal capacity to air Cpa 1.005 KJ/Kg.Kº 7
0.02 70.7629 19.0471 37238.05 0.9263196
6
IV. RESULTS AND DISCUSSION
To discuss these findings, Figures from 1 to 5, represents
Key results are shown in Table III, values of EF % , ET,
the changes realized due to changing the temperature of the
EE1 , E1 and hw all being taken and being presented the
feed water. The temperature of output exhaust gases, the fuel
changes of the temperature of feed water (Tw), enthalpy to
humidity levels are all clearly shown on the same figures. The
feed water (hw), The quantity of thermal energy (E1), The
figures also show how the factors affect these changes due to
value of thermal gain energy (thermal acquirement energy)
the thermal gain (EE) along with the efficiency of the boiler
(EE1), the value of total thermal energy that used in the steam
(EF%).
boiler (ET), and thermal specific to the boiler (EF%).

International Scholarly and Scientific Research & Innovation 6(3) 2012 555
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International Journal of Industrial and Manufacturing Engineering
Vol:6, No:3, 2012

E 1 K J /K g E 2 K J /K g

230 235 160 155 150

240 245
250 255 145 140 135
260
130

Fig. 1 effect of temperature of the feed water (Tw C°) on E1,EE1,ET

Fig. 3 shows the effect of temperatures of exhaust gases (Tg C°) on
Digital Open Science Index, Industrial and Manufacturing Engineering Vol:6, No:3, 2012 waset.org/Publication/15720

E2, EE2, ET
When discussing Figure 1, the increase in the temperature of
feed water (Tw), a decrease of the value of thermal energy can
Figure 4, represents the effect of the temperature of exhaust
be seen with the change of the feed water to the superheat
gases on the efficiency of boiler, whereas Figure V, points to
steam (E1). The thermal gain (EE1) will be increased (see
the changes being realized to ET, EE3, E3 with humidity
Table III). When E1 decreases, EE1 will increase. The value
levels of the used fuel.
of 37219 represents the value of the energy supplied to the
feed water when (Tw)=230 Cº, and consequently the value of
the total thermal energy that used in steam boiler (ET)will
increase too .

0.94
0.935
260 0.93
255 0.925 E f %
0.92
250 Ef % 130
145140135
245 160155150
240 Ef %
235 Fig. 4, shows the effect of exhaust gases temperature (Tg C°) on EF
230
Table IV, also shows that when the level of humidity is
0.9 0.95 1
3.3%, it can be seen that E3=87.0928KJ/Kg,
Fig. 2 effect of temperature of the feed water ( Tw C°) on EF% EE=2.717196KJ/Kg, showing that if the humidity decreases to
2.6%, E3 decreases to 70.7629KJ/Kg. EE3 is also increases
Figure 2, shows increasing values of efficiency levels (ET) to19.0471KJ/Kg and ET increases as well. According to the
of the boiler with increasing of Tw, whereas Figure III design standards, it can be noticed that increasing the value of
represents the change of ET, EE2, E2 values with decreasing ET can be seen when increasing the temperature of the feed
the temperature of the exhaust gases. It shows that when the water due to decreases in exhaust gases as shown on Figure 5.
temperature of exhaust gases around the surrounding area
increases, the lost of thermal energy will increase as well, and
vice versa. A decrease in E2 values was noticed with the
exhaust gases, means an increases in EE2 (thermal gain
energy) and increases in ET (the total thermal energy).

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 World Academy of Science, Engineering and Technology
International Journal of Industrial and Manufacturing Engineering
Vol:6, No:3, 2012

100 [7] Bindra & Rajab Hokoma (2003), Automobile Pollution Control
Strategies: Some Case Studies, Workshop on Energy & Environment,
90
Tripoli, Libya
80
70
60
E3
50
KJ/Kg
40 EE Dr. Rajab Abdullah Hokoma began his career in Industrial Engineering
30 KJ/Kg in 1990, after his graduation from Industrial Engineering, Garyounis
University, Libya, he received his MSc in Enterprise Management at Warsaw
20
University of Technology, Poland. In 2007 Mr. Hokoma was awarded his
10 PhD in the area of Manufacturing and Quality Planning and Control from The
0 University of Bradford, England (UK). Presently, his duties and research at
0.032 0.031 0.03 0.029 0.028 0.027 0.026 Tripoli University (main university in Libya) are in the area of Manufacturing
and Quality Planning and Control, JIT, MRPII, TQM, Supply Chain
Fig. 5 shows the effect of W% on E3, EE3 Management, Maintenance Planning, Operations Management, Pollution
Control, Risk Management and Strategy. His non-lecturing duties include
V. CONCLUSIONS among others, (acting as) the consultant and advisor for manufacturing and
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quality planning and control and liaison with Industry and Education. Dr.
The findings of this research clearly show the changes of HOKOMA published more than 40 reviewed papers in National &
efficiency levels that related to the steam boilers. The International Conferences and Journals within the scope of his interested area.
efficiency levels were based on the changes of the temperature Nabil M. Y. Muhaisen, received his B.Sc. from Belarusian National
of the used feed water for the boilers along with the changes of Technical University, (Belarus) on 1985 and his MSc degree from the same
the temperature of the exhaust gases. The humidity levels of university two years after. both in the area of Automotive Engineering.
Recently, he is member of the academic Staff of High Institute for Training
the used fuel within the boiler are also being considered. This (Zliten, Libya). His lecturing duties are in the area of Engines, Power-
research has also indicated that the efficiency of the steam Stations, Power Systems, and Material & Engineering Applications.
power plant will increase and showing higher level of
effectiveness when applying good and more reliable working
conditions.
Herewith, some recommendation points:
• An economical and more detailed feasibility studies
should be conducted to arise the potential benefits of
increasing the efficiency of the boilers and heat ness
• Conducting an investigation studies for other steam
power plants within the same area, and then after
making comparisons between both findings in order
to be more aware of all the working conditions and
environments within more power plants.
• Future studies may include some more effective
factors that affecting the boiler efficiency such as
boiler pressure and input air to the fuel room.
• Future studies should also include quality factors of
the used fuel within the steam power plants in order
to improve the efficiency of the boilers within the
electrical power stations.

REFERENCES
[1] Ahmad Miolhat Salam, Energy and Defend Sources, El-Ahram Centre,
Egypt, 2001
[2] Abrahain Salim Munsour, Guidance of Consume Occupation of Energy
Boiler Steam, Dar Elretab Eljamia, 1999
[3] Library Guidance for El-khmus Boiler Steam, 2005
[4] Ramadan Ahmed Mohmoud & Monshat Elmaarif, Principals and
Applying Steam, 2000
[5] Bindra & Rajab Hokoma (2004), Challenges & Opportunities of
Automobile Pollution Control in Developing Countries, Proceedings of
the International Conference on Industrial and Commercial Use of
Energy Conference 2004, Western Cape, South Africa, pp-197-202
[6] Bindra & Rajab Hokoma (2004), Challenges & Opportunities of
Automobile Pollution Control in Developing Countries, Proceedings of
the International Conference on World Renewable Energy Congress VIII
(WREC VIII), Denver, Colorado, USA

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