CPP BOILER TURBINE

86 816 82.5 815 0.9 688

45000 510 43554 505 3624.161 204
GLAND
Power Generation 10.2 MW
LP HEATER SEALING
Specific Steam Consumption 4.27 kg/Kw
Intraps and drains 200 Kg/hr 0.01 710
Soot Blowing Steam 1000 kg/hr PRDS Not in line
DEARATOR EXTRACTION 200 250
Steam to Process 54 Kg/hr
Difference 796 kg/hr HP HEATER
16 722.938
17 695 5331.848 297
54 250 17 665 EJECTOR
3400 211.483 PRDS
CARCASS APH 12.5 700
14 684 250 250
2400 225

14 684 Oil Steam Other Steam

1000 225 Heaters Usage
4 695
2400 220 3 509.929 3 509.929 0.75 531.734
232.5742 143.207 300 143.207 247.8188 111.422
CPP
INLINE BOILER TANKER HEATING DEAERATOR
19 668.42 PRDS 4.5kg/cm2 3.5 677
4524.093 211.483 2492.92 200 2.5 513.308
605.7446 138.507 3 509.929 4 667
14 668 20 143.207 1064.015 170
1085.472 200 3.5 677 2 517.029
365.5835 190
CARCASS MIXER 175.4639 133.235
Additive Tank
2.5 513.308
545.7353 138.507
INLINE BOILER
DEAERATOR Tank Farm
MOLASSES TANK
3 509.929 TREAD MIXER
21.45703 143.207

# Latent heat of steam is taken for all steam heaters except HP, LP heater,Dearators
#Steam to APH sootblowing is considered as 1000kg/hr
#Steam from CPP boiler is taken as 45000kg/hr according to the flow meter reading
 Molases T
3 kg/cm2

Mixer Tr
2.5 kg/cm2
Additive tank Steam
2.5 kg/cm2
Inline Boiler Steam Mixer Car
2.5 kg/cm2
19 Kg/cm2
211.483 Deg C Steam to Inline bo
4524.093 kg/hr 3.5 kg/cm2

PRODUCTION Steam to CPP

4 kg/cm2
Tankers he
0.75 kg/cm2
Additive tank Steam
3 kg/cm2
Oil Heaters (
3 kg/cm2
Tank Hea
2 kg/cm2

Soot Blowing
14 kg/cm2

Steam from CPP

17 kg/cm2
Ejector 12.5 kg/cm2, 250 d

Gland steam 0.10 kg/cm2

Boiler
Output Turbine 83kg/cm2, 510 De
45 TPH CPP Extraction
HP Heater: 16 kg/cm2, 297
LP Heater: 0.9 kg/cm2, 204

Steam traps/ drains - 0.2 t

 Molases Tank
143 Deg C 21.457 kg/hr

Mixer Tread
139 Deg C 546 kg/hr
Additive tank Steam Flow 3 kg/cm2
138 Deg C 20 kg/hr
Mixer Carcass
139 Deg C 606 kg/hr

Steam to Inline boiler Dearator # Soot blowing steam is considered as 1000kg/hr

190 Deg C 366 kg/hr # Other usage includes steam trap, ESD steam, Lab usage, Atomizing steam
Steam to CPP dearator
170 Deg C 1064 kg/hr
Tankers heating
111 Deg C 248 kg/hr
Additive tank Steam Flow 3 kg/cm2
150 Deg C 300 kg/hr
Oil Heaters (Tread)
143 Deg C 233 kg/hr
Tank Heating
133 Deg C 175 kg/hr

Soot Blowing System

225 Deg C 1000 kg/hr

Steam from CPP to Process

225 Deg C 54 kg/hr
ector 12.5 kg/cm2, 250 deg C, 0.25 TPH

land steam 0.10 kg/cm2 , 200 Deg C, 0.2 TPH

urbine 83kg/cm2, 510 Deg C, 43.5 Tons

xtraction
P Heater: 16 kg/cm2, 297 deg C, 5.739 TPH
P Heater: 0.9 kg/cm2, 204 deg C, 3.686 TPH

eam traps/ drains - 0.2 tons

eam, Lab usage, Atomizing steam traps
 Inline Boiler
Inile boiler gas inlet 490 Deg C
Gas oultel temp 260 Deg C
Average Air flow 6250 Nm3/hr
No of Reactor 4 Nos
Air Gas ratio 1.85 - Assumptions ,constant
1)Air gas ratio is consid
Density of Gas 0.92 kg/Nm3 2)Speciific heat of smo
Gas flow 42550 kg/hr 3)Boiler steam generati
Specific heat 0.282 kcal/kg DegC 4)Molasses steam cons
5)Considered latent he
Available heat in boiler 2759793 Kcal/hr 6)Additive tank steam
Steam Pressure 19 Deg C 7)Other usage includes
Steam temperature 211.483 kg/cm2 8)Remaining steam is c
Feed water Inlet 95 Deg C
Enthalphy of steam 668.42 kcal/kg
Enthalphy difference 573.42 kcal/kg
Steam flow 4812.86491577 kg/hr
Steam flow @ 94% boiler efficiency 4524.09302082 kg/hr

Molases Tank
Tank capacity (4 tank) 16500 ltrs
Tank capacity for 75% 12375 ltrs/day
Initial Temp 40 Deg C
Final Temp 60 Deg C
Specific heat of molases 0.51 kcal/kg DegC
Density of molases 1.1 kg/m3
Heat Required 138847.5 kcal/day
Steam pressure 3 kg/cm2
Steam temperature 143.207 Deg C
Latent heat of Steam 509.929 Kcal/kg
Considering 10Kcal loss per lit in tank 123750 Kcal/kg
Tank Heat loss 262597.5 kcal/hr
Molases Steam Flow 21.457031273 kg/hr

Other usage *Atomizing Steam, ESD line steam

Steam pressure 3 kg/cm2
Steam temperature 143.207 Deg C
Steam Latent Heat 509.929 Kcal/kg
Additive tank Steam Flow 3 kg/cm2 300 kg/hr

Additive tank
Steam pressure 3 kg/cm2
Steam temperature 143.207 Deg C
Steam Latent Heat 509.929 Kcal/kg
Additive tank Steam Flow 3 kg/cm2 20 kg/hr

Mixer Tread
CB mass flow rate 115 TPD
CB mass flow rate 4791.66666667 kg/hr water
CB inlet temp 80 Deg C 32 deg
CB o/l temp 95 Deg C
Specific Heat of CB 0.3079 kcal/kg DegC
Heat in CB 22130.3125 Kcal/hr
Water Inlet temperature 35 Deg C Mixer
water flow 4791.66666667 Kg/hr
Heat carried by water 258000 Kcal/hr
Total Heat 280130.3125 Kcal/hr
Steam Pressure 2.5 kg/cm2 CB
Steam Temp 138.507 Deg C 95 deg
Latent heat of steam 513.308 kcal/kg
545.735333367 Kg/hr

Mixer Carcass
CB mass flow rate 130 TPD
CB mass flow rate 5416.66666667 Kg/hr
CB inlet temp 80 Deg C
CB O/l temp 95 Deg C
Heat in CB 25016.875 Kcal/hr
Water Inlet temperature 35 Deg C
water flow 5416.66666667 kg/hr *considering 50% moisture
Heat required by water heater 135416.666667 Kcal/hr
Heat carried by water 150500 Kcal/hr
Total Heat 310933.541667 Kcal/hr
Steam Pressure 2.5 kg/cm2
Steam Temp 138.507 Deg C
Latent heat of steam 513.308 Kcal/kg
Steam flow in Mixer 605.744585447 kg/hr

Steam to Inline boiler Dearator

Dearator inlet temp 40 Deg C
Dearator outlet temp 95 Deg C
Water flow 4500 kg/hr
Heat required 247500 Kcal/hr
Steam pressure 3.5 kg/cm2
Steam temp 190 Deg C
Steam Enthalphy 677 Kcal/kg
Steam flow 365.583456425 kg/hr

Steam to CPP dearator

Dearator inlet temp 100 Deg C
Dearator outlet temp 125 Deg C
Water flow 39668.1517325 kg/hr
Total Heat required 709697.705194 kcal/hr
Steam pressure 4 kg/cm2
Steam temp 170 Deg C
Enthalphy of Steam at 3.5 kg/cm2 667 kcal/kg
Steam Flow 1064.01455052 kg/hr

Tankers heating
Specific heat of oil 0.32943423251 kcal/kg DegC
Total oil inlet 480000 kg/day
Total outlet 450000 kg/day
Oil inlet temp 40 Deg C
Oil outlet temp 60 Deg C
Steam Pressure 0.75 kg/cm2
Steam temperature 111.422 Deg C
Latent heat of steam 531.734 Kcal/kg
Tankers Heating 3162568.63213 kcal/day
Tank heating 247.818821075 kg/hr *Assuming total oil is heated and

Tank Heating
Tank height 1175 1170 1175 1175
Tank outer circumference 3833 3813 3816 3820
Dia 1220.7006369 1214.3312101911 1215.287 1216.561
Tank insulation thickness 11 8.1 7.5 8
Total Dia 1242.7006369 1230.5312101911 1230.287 1232.561
Outer surface area 1460173.2484 1439721.5159236 1445587 1448259
Surface area of the tank 146.01732484 143.97215159236 144.5587 144.8259
Tank outer surface temp 43 43 43 43
Amphient temp 35 35 35 35
Heat loss per m2 in surface area 83.2 83.2 83.2 83.2
Total heat loss in the surface of the tank 12148.641427 11978.483012484 12027.28 12049.51
Steam pressure 2 kg/cm2
Steam Temperature 133.235 Deg C
Latent Heat of steam 517.029 kcal/kg
Total Steam 175.46387745 kg/hr *Heat required to maintain the ta

Oil Heaters (Tread)

Specific heat of oil 0.32943423251 kcal/kg DegC
Total oil inlet 288000 kg/day
Oil inlet temp 60 Deg C
Oil outlet temp 90 Deg C
Steam Pressure 3 kg/cm2
Steam temperature 143.207 Deg C
Latent heat of steam 509.929 Kcal/kg
Tankers Heating 2846311.76892 kcal/day
Tank heating 232.574189162 kg/hr
 Assumptions ,constants and approximation:
1)Air gas ratio is considered as 1.85
2)Speciific heat of smoke is taken as 0.282kcal/kg Deg C to match the boiler steam generation
3)Boiler steam generation as per water consumption falls around 4.5TPH
4)Molasses steam consumption based on the tank volume
5)Considered latent heat of steam for all application of heating except direct steam heating
6)Additive tank steam consumption is measured by measuring the quantity of condensate
7)Other usage includes usage of steam for ESD steam, Lab, Hygiene center, traps
8)Remaining steam is considered as soot blowing steam in carcass APH

ng Steam, ESD line steam & traps, Steam to lab, Steam to hygiene center

Steam
CB 4kg/cm2,
133 deg
 4kg/cm2,
80 deg 133 deg

Mixer

Condensate
133

ing 50% moisture

g total oil is heated and stored in the tank

1000 1000 1099 1099 cm

3820 3822 3773 3773 cm
1216.5605 1217.197 1201.592 1201.5923567 cm
8 8.3 0.6 0.6 cm
1232.5605 1233.797 1202.792 1202.7923567 cm
1232561 1233797 1321869 1321868.8 cm2
123.25605 123.3797 132.1869 132.18688 m2
43 43 43 43 Deg C
35 35 35 35 Deg C
83.2 83.2 83.2 83.2 kcal/m2
10254.903 10265.19 10997.95 10997.948416 Kcal/kg

uired to maintain the tank temperature in 65 Deg C

Boiler Steam Flow 45000 kg/hr
Turbine steam flow 43500 kg/hr
Steam to Ejector 250 kg/hr
Gland sealing 200 kg/hr
Steam Trap and drains 200 kg/hr
Calibration Error 850 kg/hr

HP heater
Water Flow 45000 Kg/hr
Water Inlet temp 125 Deg C
Water outlet temp 191.7 Deg C
Steam Temperature 297 Deg C
Steam Pressure 16 kg/cm2
Steam Enthalphy 722.938 kcal/kg
Steam condensate temperature 160 Deg C
Steam Flow 5331.848267482 kg/hr

LP heater
Water Flow 45000 Kg/hr
Water Inlet temp 52 Deg C
Water outlet temp 100 Deg C
Steam Temperature 204 Deg C
Steam Pressure 0.9 kg/cm2
Steam Enthalphy 688 kcal/kg
Steam condensate temperature 92 Deg C
Steam Flow 3624.161073826 kg/hr

Deareator
Dearator inlet temp 100 Deg C
Dearator outlet temp 125 Deg C
Feed water flow 45000 kg/hr *45000 kg/hr is considered (Actual 46000kg/h
Water flow 39668.15173252 kg/hr * Total inflow includes HP heater drain
Mixing of water from HP heater drain 107.1091310233 Deg C
Total Heat required 709697.7051939 kcal/hr
Steam pressure 4 kg/cm2
Steam temp 170 Deg C
Enthalphy of Steam at 3.5 kg/cm2 667 kcal/kg
Steam Flow 1064.014550516 kg/hr

#Data is based on 10.2 MW with closed second extraction

idered (Actual 46000kg/hr includes dearator steam)
es HP heater drain
Saturation Steam Table
Pressure Sat Temp Latent Heat Sp Enthalphy
0 99.97 539.069 639.16
0.5 111.422 531.734 643.388
1.0 120.115 525.998 646.465
1.5 127.205 521.201 648.879
2.0 133.235 517.029 650.86
2.5 138.507 513.308 652.533
3.0 143.207 509.929 653.976
3.5 147.46 506.82 655.241
4.0 151.351 503.929 656.362
4.5 154.944 501.219 657.366
5.0 158.286 498.273 658.273
5.5 161.414 496.238 659.096
6.0 164.357 493.927 659.848
6.5 167.138 491.716 660.538
7.0 169.777 489.595 661.173
7.5 172.288 487.552 661.761
8.0 174.686 485.581 662.305
8.5 176.981 483.674 662.812
9.0 179.183 481.826 663.283
9.5 181.3 480.031 663.723
10.0 183.339 478.286 664.134
10.5 185.307 476.586 664.518
11.0 187.209 474.927 664.879
11.5 189.05 473.308 665.217
12.0 190.834 471.725 665.534
12.5 192.565 470.175 665.833
13.0 194.247 468.658 666.113
13.5 195.883 467.169 666.377
14.0 197.4766 465.709 666.625
14.5 199.027 464.275 666.858
15.0 200.54 462.866 667.077
15.5 202.017 461.48 667.284
16.0 203.46 460.116 667.478
16.5 204.869 458.774 667.661
17.0 206.248 457.451 667.832
17.5 207.598 456.148 667.994
18.0 208.919 454.862 668.145
18.5 210.214 453.594 668.287
19.0 211.483 452.342 668.42
19.5 212.728 451.106 668.544
20.0 213.95 449.886 668.66