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PREDICTING AND TESTING INCINERATOR BOILER EFFICIENCY. A PROPOSED SHORT FORM METHOD IN

LINE WITH THE ASME TEST CODE PTC 33

GEORG STABENOW Consultant to UOP, Inc.

Stroudsburg, Pennsylvania

ABSTRACT

Solid waste as a heterogeneous fuel demands a careful analysis for a realistic performance and efficiency prediction. A uniform method of determining combustion data for a given fuel composition is necessary so that an agency requesting bid offerings from competing vendors will be assured to receive realistic performance data subinittals from vendors for direct comparison of the potential energy recovery.

This paper presents an analytical short form procedure to predict the performance as well as testing of the solid waste incinerator-boiler for energy recovery in line with the newly approved ASME Test OJde PTC-33 by the input-output method as indicated under Section 1, "Object and Scope," Par. 1.6.1.

INTRODUCTION

Municipalities throughout the country are faced with the never ending problem of how to dispose of the continuously increasing quantity of solid waste. Landfill areas are less available and disposal at far distant locations is becoming more costly as a result of the recent increases in both fuel and transportation charges.

Solid waste incineration, especially with energy recovery, accordingly becomes progressively more attractive to a wide range of communities, from large cities to towns with less than 20,000 inhabitants. Municipal authorities, however are reluctant

to prepare and release specifications, unless they can be assured that the contracted-for acquisition will also be capable of demonstrating, not alone a long term reliability, but also fully proven performance in compliance with the original intent of the Request for Proposals.

PERFORMANCE TEST GUARANTEE

A specifying authority should request each approved bidder to submit an anticipated continuous full load performance calculation which will permit a realistic evaluation and which shall also become the basis for a performance test demonstration to prove compliance with capacity, efficiency and ecological as well as environmental regulations. To enable a purchaser, as well as a bidder to prepare his own calculations for evaluation or for conducting performance tests, data sheets have been developed to permit a systematic analysis of the anticipated efficiency.

In accordance with Method One, the input-output method as outlined in the new ANSI/ASME Performance Test Code PTC-33, "Large Incinera· , tors" under Section 1, Object and Scope Par. 1.6.1. The ASME Power Test Code PTC 4.1, "Steam Generating Units," contains test form data sheets for Abbreviated Efficiency Tests. However, due to the fact that Solid Waste is a heterogeneous'fuel and varies widely in its composition, it is not feasible to apply these forms in their present state to determine the efficiency of large incinerators with waterwall boilers for steam generation.

301

SHORT FORM TEST REPORT

This paper is prepared especially as a guide to cover short form performance tests for large refuse burning incinerators with waterwall boilers. For this purpose, short form test report data sheets have been prepared which will enable a specifying engineer to establish design criteria and parameters for a realistic evaluation of anticipated performance guarantees and at the same time to have uniform test data sheets available for actual performance tests.

Solid waste or refuse becomes the fuel in this case and the word, "refuse," in the PTC 4.1 short form test report becomes "residue" in the incinerator code. Fuel data for solid waste, which generally require a proximate and ultimate analysis cannot be selected from standard fuel tables such as are available for nearly all types of fossil fuel but must be derived from typical test samples over a wide variety of heating values. Table 1 shows such a grouping of typical American Solid Waste Compositions from which one example has been selected to show a calculation procedure.

CALCULATION PROCEDURE

The following data sheets are designed to be filled in by the engineer who will be in charge of

the efficiency test or who desires to prepare anticipated incinerator performance data.

For clarification, a typical example is shown for a 600 ton/day (545 tid) unit in which the performance data are in italics. As fuel, "as fired" or as fed to the furnace, an average solid waste composition of 4500 Btu/lb (10,500 kJ/kg) has been selected from Table 1 and applied in Chart 1 with the assumption that an analysis of the average residue sample will reveal a combustible content of 5.0 percent.

As indicated in Chart No. 1, the combustible content in the residue varies from case to case and should be determined by individual sampling. The resulting "as burned" composition is shown in Chart 2 and permits the systematic stoichiometric -

flue gas analysis of the Products of Combustion in Chart 3. F lue gas analyses at various excess air rates resulting from possible air inftltration between the furnace and boiler outlet can now be determined in Chart 4. In the sample calculation a 95 percent excess air rate at the boiler outlet was selected for mass burning. Normally the excess air rate may vary anywhere from 40-120 percent depending on the refuse burning method selected, whether combined with other fossil fuel, suspension ruing or mass burning. The last section in Chart 4 permits to evaluate the hypothetical gas composition at 12.0 percent CO2 which can be used to correct for par-

TABLE 1. HEATING VALUES, COMPOSITION AND ANALYSIS OF TYPICAL AMERICAN SOLID WASTE

HEATING VALUES

High Heating Value (HHV) Btu/1b 3,500 4,000 4,500 5,000 5,500 6,000 6,500

High Heating Value (HHV) kJ/kg 8,141 9,304 10,467 11,630 12,793 13,956 15,119

Lower Heating Value (LHV) Btullb 2,892 3,407 3,922 4,433 4,912 5,409 5,893

Lower Heating Value (LHV) kJ/kg 6,727 7,924 9,122 10,311 11,425 12,581 13,708

COMPOSITION OF SOLID WASTE

Ash & Inert8 WT % 23.70 22.30 21. 00 20.00 16.20 14.00 11. 50

Moisture WT % 32.00 27.20 22.40 17.50 16.00 13.00 11.00

Combustible Matter WT % 44.30 50.50 56.60 62.50 67.80 73.00 77.50

Total WT % 100.00 100.00 100.00 100.00 100.00 100.00 100.00

COMPOSITION OF THE COMBUSTIBLE MATTER

Cellulose WT % 92.5 91. 8 91. 0 90.0 87.5 85.0 82.0

Albumen WT % 4.3 4 . 7 5.1 5.5 6.9 8.0 9.0

Grease, Fats & 011 WT % 2.1 2. 2 2.3 2 . 5 3.0 3.5 4.5

Plastics WT % 1.1 1.3 1.6 2.0 2.6 3.5 4 . 5

Total WT % 100.0 100.0 100.0 100.0 100.0 100.0 100.0

ANALYSIS OF THE COMBUSTIBLE MATTER

Carbon WT % 20.07 22.92 25.74 28.51 31.13 33.77 36.25 Hydrogen WT % 2. 84 3.24 3.64 4.04 4.43 4.81 5.18 Oxygen WT % 20.87 23.70 26.43 28.99 30.96 32.78 34.05 Nitrogen WT % 0.39 0.48 0.58 0.67 0.87 7. 06 7.25

Chlorine WT % 0.08 0.11 0.16 0.21 0.30 0.44 0.60

Sulfur WT % 0.02 0.02 0.02 0.03 0.04 0.05 0.06 Phosphorous WT % 0.02 0.02 0.02 0.03 0.04 0.05 0.06

'Fluorine WT % 0.01 0.01 0.01 0.02 0.03 0.04 0.05 Summary of Combus t ib Ie Matter WT % 44.30 50.50 56.60 62.50 67.80 73.00 77.50

Hydrogen in Combustible Matter 000%) WT % 6.40 6.42 6.44 6.46 6.52 6.59 6.68

302

CHART 1 ENERGY RECOVERY FROM SOLID WASTE

TEST FORM FOR ABBREVIATED EFFICIENCY TEST

FUEL ANALYSIS & CALCULATIONS -INCINERATOR BOILER TEST PROJECT LOCATION OWNER, OF PLANT I NC I NERA TOR NO. TEST NO. OBJECTIVE OF TEST DURATION CONDUCTED BY RATED CAPACITY 600 ton/day 544 tonne dav'BURNING RATE5DOOO Ib/h 22 6.Jl..6 HEATING VALUE (HHV) 4.500 Btu/lb' ( 10.467 � J/kg) R.A,TED HEAT INPUT 225.0 X 10bBtu/h (237.3976 106 kJ/h INCINERATOR BOILER MAKE & TYPE WELDED WATERWALL -STOKER MAKE & TYPE MASS BURNING SOLID \�ASTE, TYPE & SIZE AS FIRED RESIDENTIAL & COMMERCIA� - A g .lfE.f:.E.

ITEM II

1

lA

2

3

4

5 £> 7 8

9

3

10

1 1

4

12

5

13

SOLID WASTE FUEL DATA I SOLID WASTE AS RECEIVED (SEE TABLE til)

2 Btu/lb HEATING VALUE (HHV) 4.500 (kJ /kg 10.467 )

HHV ASH & MOISTURE FREE Btu/lb 7.951 (kJ/kg 18,493 ) SOLID WASTE COMPOS IT I ON

WT FRACTION Ib/lb (kg/kg)

MOISTURE 0.224

COMBUSTIBLE MATTER 0.566

ASH & INERTS 0.210

TOTAL 1.000

ANALYSIS OF COMBUSTIBLE MATTER (AS RECEIVED)

CARBON 0.2574

HYDROGEN 0.0364

OXYGEN 0.2643

NITROGEN 0.0058

SULFUR 0.0021

TOTAL COMBUSTIBLE 0.5660

ANALYSIS OF DRY RESIDUE

COMBUSTIBLE IN RESIDUE SAMPLE % 5.0

DRY RESIDlJE INCL. UNBURNED C -- ITEM #4 X 100

100- ITEM # 10 0.2210

DRY RESIDUE ( = ASH + INERTS) 0.2100

UNBURNED CARBON IN RESIDUE 0.0110

TOTAL CARBON 0.2574

ACTUAL CARBON BURNED 0.2464

NOTE: 1 ambien� temp. 80°

F (26.7°

C) at 29.92" Hg (760mm Hg)

2 for HHV & LHV determination by Boje Formula see Chart 9 . - -

303

kg

'PD

h)

ITEM �

13

6

7

8

9

11

2

15

16

17

18

1 9

20

21

22

23

24

25

26

27

28

2 9


TEST FORM FOR ABBREVIATED EFF1CIENCY TEST

SOLID WASTE AS BURNED

CARBON AS BURNED

HYDROGEN

OXYGEN

NITROGEN

SULFUR

RESIDUE

MOISTURE

TOTAL CENTER THESE VALUES ON PAGE 3)

CO2

02

CO

N2 BY DIFFERENCE

EXCESS AIR

TOTAL DRY PRODUCTS BASED ON FUEL RATE

GAS TEMP. LVG

AIR TEMP. ENT'G AIR HEATER

COMBUSTION AIR

TOTAL DRY AIR REQ'D BASED ON ON FUEL RATE

DRY BULB TEMPERATURE

RELATIVE HUMIDITY

MOISTURE IN AIR

AMBIENT AIR TEMPERATURE

AIR TEMP. FOR COMBUSTION IF CONDITIONS TO BE CORRECTED TO GUARANTEE

FUEL TEMPERATURE

304

,

WT FRACTION Ib/lb (kg/kg)

0.2464

0.0364

0.2643

0.00 5 8

0.0021

0.2210

0.2240

1.0000

THEOR. AIR AT BLR OUTLET 20.25 % VOL 10.37 % VOL

o . - % VOL 10.19 % VOL

o . - % VOL 0. - % VOL

79.75 % VO L 79.44 % VOL

o . - % VOL 95 % VOL

3.1805 Ib/lb 5.9779 kg/kg -

380 ° F

80 ° F

2.9508 Ib/lb

80 ° F

50

0.013 Ib air Ib

80 of •

210 of

80 of

193 °c

27 °C -....!:....!.�-

5.754 kg/kg

__ ::...2:.....7_0 C

50 %

0.013 � kg

27 °c

99 °c

27 ° C ---=---

air

ITEM FUEL AS

NO.

13 C

6 H

7 I °

!

8 N

9 S

11 RESIDUE

2 MOISTURE

I:

ArR

BURNED

WEIGHT FRACTION

Ib/lb (kg/kg)

0.2464

0.0364

0.2643

0.0058

0.0021

0.2210

0.2240 I I

1. 000

I

CHART 3 STOICHIOMETRIC FLUE GAS ANA L YSI�

02 REQ'D

FACTOR

X 2.664

X 7.937

X 0.998

I: 02

� 0. 2315

& AIR

+.6564

+.2889

-.2643

+.0021

O�

2.9508 1 I

CO2 + S02 H2O

FACTOR FACTOR

X 3.664 0.9028

X 8.937 0.3253 ---

X 1. 998 0.0042

0.2240

I:C02 0.9070 I: H2O 0.5493

ENTER APPR OPR IAT E VA LUES ON CHAR T 4

305

N2

FACTOR

0.0058 ---

0.7685 2.2677 X.AIR

I: N2 2.2735

I

CHART 4 FLUE GAS COMPOSITION

THEOR ET ICAL AIR (0 % EXCESS AIR = ITEM �19)

ITEM GAS FUEL 1fT FRACTION % ORY % DR Y PRODUC TS - ITEM \ -

CCW'ONENT Ib/lb (kg/kg) PRODUCTS 0.2 5 X M:lL.IfT . � VOL.

CO2 0.9070 28.52 11. 0 2.5927 I 5 20.25

°2 1 6

N2 2.2735 71.48 7 . 0 10.2114 18 79.75

� 20 E DRY PROD. 3.1805 100.00 12.8041 100.00

�60 H2O 0.6543

� WET PROD. 3.8348

*23 E DRY AIR 2.9508

AT FUR NACE OUTLET ( \ EXCESS AIR - ITEM H9) -

CO2 11. 0 15

O2 8.0 16

N2 7.0 18

*20 E DRY PROD.

*60 H2O

E WET PROD.

�23 E DRY AIR

AT BOILER, ECONOMIZER, AIR HEATER, OUTLET ( 95 \ EXCESS AIR = ITEM *19) ,

CO2 0.9070 15.17 11.0 1.3791 15 10.37

°2 0.6489 10.85 8.0 1.3563 16 10.19

N2 4.4220 73.98 7 .0 10.5686 18 79.44

*20 E DRY PROD. 5.9779 100.00 13.3040 1700.00

*60 H2O 0.6543

6.6322 .

E WET PROD.

*23 1: DRY AIR 5.7540

AT 12 .0 \ CO2 ( \ EXCESS AIR - ITEM *19) -

CO2 11.0 15

°2 8.0 16

N2 7.0 18

*20 E DRY PROD.

*60 H2O

E WET PROD.

*23 E DRY AIR

306

ticulate emissions as found during an actual performance test. In this case, only the boiler outlet gas composition is calculated.

4. Moisture content in the combustion air.

The summation of these values (se� Chart 5 and 8; Item No. 60) can now be entered in Chart 4 to permit calculation of the total Wet Products of Combustion.

To permit an accurate flue gas analysis and its specific heat it is important to determine the moisture content resulting from:

1. Evaporation of the moisture in the "as received" solid waste.

2. Generation of moisture due to burning of hydrogen in the fuel.

The next step is to determine the overall efficiency as outlined in Chart 6 for which the values to be entered have been established in the previously mentioned charts.

3. Flashed off vapor resulting from quenching

of residue when leaving the furnace.

The difference between the calculated and guaranteed efficiencies are the ''unaccounted for losses

and manufacturers margin" which are generally

ITEM �


T EST F O RM F O R ABBREVIAT ED EFFICIENCY TEST

HEAT LOSSES IN RESIDUE A N D FROM QUENCH VAPOR BASED O N AS FIRED FUE L

3& DRY RESIDUE

A

B

C

o

DRY RESIDUE INCL. UNBURN ED CARB O N (ITEM 1 1)

RESIDUE TEMPERATURE L EAVING FURNACE

RESIDUE TEMPERAT URE AFTER Q UE NCH

TEMPERATURE DIFFERENCE

S PECIFIC HEAT OF DRY RESIDUE

HEAT L OSS IN DRY RESIDUE ( A X B x C )

0. 2210 1b/1b n ��7n kg/k g

700 0 F

° ." I _ ... 2 .... 1.J.1.0 - ,.-

490 ° F

371 ° C o

99 C

2, o C -

0.25 Btu/lb F 1.0468 kJ/kg C 27.07 Btu/lb 62.96 kJ/kg

3& MOISTURE IN RESIDUE

E

F

G

H

MOISTURE C O N TENT IN RESIDUE

TEMPERATURE OF RESIDUE LEAVING QUE NCH

TEMPERATURE OF W ATER EN TERING Q UENCH

TEMPERATURE DIFFERENCE - fit

MOISTURE IN RESIDUE .- ITEM 11 100 - E

HEAT L OSS IN MOISTURE = fit X F

X E

T OTA L RESIDUE HEAT L OSSES - 360 + 36G

15 % 210 OF

80 ° F .

130 ° F

0. 0391b/ lb

5.070 Btu/lb

32.140 Btu/lb

15 % 99 °c 27 ° C

72 ° C

0.039 k g/ k g

0. 7862 kJ/kg

63.7462 kJ/kg

3& QUENCH V A P O R

J L ATEN T HEAT OF VAPOR AT ATMOSPHERIC PRESSURE 9 7 0 .4 Btu/lb 2J257.15 kJ/kg

K QUANTITY OF VAPOR FLASHED = 9. 0.0279 Ib/lb 0.0279 kg/kg

L

M

N

P

J TEMPERATURE OF QUENCH VAPOR LV'G (BOILER,EC ON,AIR HTR) 380 OF 193 °c TEMPERATURE OF QUENCH VAPOR ENTERING FURNACE 212 OF 100 0c

TEMPERATURE OF WATER ENTERING QUENCH VESSEL

TEMPERATURE RISE IN QUENCH WATeR

80 OF

132 OF ENTHALPY OF VAPOR LEAVING (BOILER, ECON., AIR HEATER) 1230.5QBtu/lb

ENTHALPY OF VAPOR ENTERING FURNACE 970.4 Btu/lb

ENTHALPY DIFFERENCE =( M - 970.4) + L

IN S. 1. UNITS = 2.326 x M

HEAT L OSS IN QUENCH VAPOR = K X N

307

392.10Btu/lb

10.94 Iltu/lb

27 °c

73 °c 2866.14 kJ / kg

2257.15 kJ/kg

910. 02 kl/kg

25. 45 k J/kg

I T E M �

30

31 A B

32

33

34

35

36

37

38

39

40


T EST FO R M FO R ABBREVIATE D E FFI C I E N CY TES T

1.0 BTU/LB = 2,3 2 6 KJ/KG HHV = 4,500 BTUILB

HEAT LOSS EFFI CI ENCY AS FI R E D FUEL

HEAT LOSS DUE TO DRY GAS Btu/lb kJ/ltg TO DRY GAS=ITEM 20 X Cp X (ITEM 21-ITEM 2]) = 5.9'1'19 X 0.24 X � 380 - 80 ) 430.41 1001.13

HEAT LOSS DUE MOISTURE IN FUEL ' , = ENTHALPY OF VAPOR AT 1.0 PSIA & t GAS LVG. - ENTHALPY OF LIQUID AT t AIR (ITEM #27) - ITEM 2 (ITEM 31A - ITEM 31B) -

X - 48.1 ) 265.31 61'1.10 - 0.224 ( 1232.5 - X

HEAT LOSS DUE TO H20 FROM COMB. OF H2 - 9 X ITEM 6. X (ITEM 31A - ITEM 31B) -

- 9 X 0.0364 X ( 1232.5 - 48.1 ) 388.01 902.51 -

HEAT LOSS DUE TO COMBUSTIBLES IN RESIDUE - ITEM 1 2 X 14,500 -

= Q.QllQ X 14,500 159.50 3'10.99

HEAT LOSS DUE TO RADIATlCI'<

(SEE ABMtI CHART FIG. #2 & ITEM 157) 19.35 45.01

UNACCOUNTED FOR LOSSES(PER MUTUAL AGREEMENT) 6.Z.IiQ 15'1.01

HEAT LOSS IN RESIDUE = 360 + 36G 32.14 '14.'16

HEAT LOSS DUE TO MOISTURE IN AIR

=ITEM 23 X ITEM 26x 0.489 (380 - 80) 5. 63 13.09

HEAT LOSS DUE TO QUENCH VAPOR = ITEM 36P 10.94 25. 45

TOTAL GUARANTEED 13'18.79 32Q7.0§ CALCULATED Hll,2� 3050,04

EFFICIENCY GUARANTEED :'1127.27 7259.95 •

CALCULATED 3188. '11 '1416.96

3SEE ASME STEAM TABLES

308

..l..\ 1_

0_

,_4_67 __ kJ /kg

LOSS X 100

II�O X 100 n

#31 X 100 n

#32 X 100 n

#33 X 100 #1

l!34 X 100 l!1

l!3�X 100 1I1

l!36X 100 n

1137 X 100 n

1138 X 100 l!1

LOSS %

9.56

5.90

8.62

3.54

0.43

1.50

O. '11

0.13

0.24

30.63

29.14

69.3'1

'10.86


TEST F OR M F O R ABBR E V I A T E D E F F ICIE N C Y TEST

ITEM * 41

42

43

44

45

46

47

48

49

50

51

52

53

54

55A

S T E A M PRESS URES & T E M P E R A T U R ES

SATURATED STEAM PRESSURES IN BOILER DRUM

SATURAIED STEAM TEMPERAT�E IN BOILER DRUM

STEAM PRESSURE AT SUPERHEATER OUTLET

STEAM TEMPERAT�E AT SUPERHEATER OUTLET

FEEDWA TER TEMPERATURE ENT'G (BOILER) (ECON.)

STEAM QUAL I TV UNIT QU A N TITIES

ENTHALPY SATURATED LIQUID

ENTHALPY (SAT.) (S.H.) STEAM

ENTHALPY OF FEEDWATER ENT'G (BOILER) ( ECON.)

HEAT ABSORBED IN STEAM (= ITEM 48-49)

BLo.o/-DOWN RATE

HEAT CONSUMED BY BLOW-DOWN = (ITEM 47-49) X ITEM 51 100

HEAT CONSLMED BY STEAM INCL. BLOW-DOWN = (ITEM 50 + 52)

H O U R L Y QUANTITIES

RATE OF SOLID WASTE FIRING

FUEL HEAT I/If'UT = ITEM 54 X ITEM 1 1000

55B� DRY AIR HEAT INPUT =

ITEM 54 X ITEM 23 (MAX%) X 0.24 (ITEM 28 - 27) 1000

55C� HEAT INPUT BY KlISTURE IN AIR =

55

56

57

58

59

ITEM 54 X ITEM 26 X 0.489:: (ITEM 28-27) 1000

TOTAL HEAT INPUT = 55A + 55B + 55C

TOTAL HEAT OUTPUT = ITEM 55 X ITEM 40 100

TOTAL EVAPORATION = ITEM 56 X 1000 ITEM 53

HEAT LOSS IN BLOW-DOWN = ITEM 57 X ITEM 52

RATIO STEAM GENERATED = ITEM 57 SOLID WASTE FIRED ITEM 54

x SPECIFIC HEAT OF WATER VAPOR

GUARANTEED CALCULATED

GUARANTEED CALCULATED

680 psia 4,688 KPa

500 OF 240 °c

615 psia 4,246 KPa

750 OF 399 °c 300 OF 149 °c 1. 0 1. 0

ppm ppm

487. 70 Btu/lb 1134. 4k.J

1378. 60 Btu/lb 3206. 6 kJ

269. 70 Btu/lb 627. 3 k1

1108. 90 Btu/lb 2579. 3 kJ

5.0 % 5.0 %

ZO. 9 Btu/lb 22,686 kJ

1119.80 Btu/lb 25.35 kJ

50,000 lb/Hr 22,686 kg/h

225,000 KB/Hr 65,941 k W

8,976 KB/Hr 2,631 k W

41 KB/Hr 12

234,017KB/Hr68,584 kW 162, 337KB/Hr47, 576 k W 165,824KB/Hr48,599 kW 144,970lb/Hr65,776 kg/h 148, 0841b/Hr67, 189 kg/h

1. 58 x10h/Hr 463. 1 kW 2. 90 Ib/lb 2. 90 kg/kg

� AIR PREHEAT CREDIT: USE ONLY WHERE STEAM AIR PREHEATER IS APPLIED

309

ITEM II

60

61

62

63

64

65

66


TEST FORM FOR ABBREVIATED EFFICIENCY TEST . .

DETERMINATION OF THE LOW HEATING VALUE (LHV)

BASED ON "AS FIRED" FUEL

A. CALCULATION BASED ON TOTAL MOISTURE IN FLUE GAS

MOISTURE IN REFUSE (ITEM #2)

MOISTURE FROM BURNING H2 ( 9 X ITEM #6)

MOISTURE FROM QUENCH(ITEM #3 6K)

MOISTURE IN AIR (ITEM #23 X 26)

TOTAL MOISTURE IN FLUE GASES

LATENT HEAT OF VAPOR AT ATMOSPHERIC PRESSURE*

HIGH HEATING VALUE (ITEM #1)

LESS LATENT HEAT OF MOISTURE (1040 X ITEM #(0)

LOW HEATING VALUE - (ITEM #1 - ITEM #(1)

LHVa 5.1. UNITS = ITEM #62 X 2.326

0.2240 1b/lb

0.3276 lb/lb 0.0279 lb/lb 0.0748 lb/lb 0.6543 lb/lb

1040 Btu/lb --

4,500 Btu/1b 680 Btu/lb

3,820 Btu/lb 8,885 kJ/kg

B. CALCULATION FOR MOISTURE IN SOLID WASTE & H2 BURNING ONLY

MOISTURE IN REFUSE (ITEM #2)

MOISTURE FROM BURNING H2 ( 9 X

TOTAL MOISTURE

HHV (ITEM U)

LESS LATENT HEAT OF MOISTURE

LHV (I TEM # 1 - ITEM #64)

LHVb - iTEM #65 X 2.326 -

ITEM #6)

(1040 X ITEM (3)

0.2240 lb/1b 0.3276 lb/lb 0.6616 lb/lb 4,500 Btu/lb

574 Btu/lb 3,926 Btu/l 9,132 kJ /kg

:CFACTOR TO REDUCE HIGH HEAT OF COMBUSTION AT CONSTANT VOLUME TO LOW HEAT OF COMBUSTION AT CONSTANT PRESSURE.

310

... " .. z :; w x '" '" o '" "

No. 01 Cooled furnoce Wall •

• 2 0 'O'OOO·IH 10.0 I 1 -!

a.

'.0 JI

••

.

�

A FURNACE WALL MUST H AVE AT LEAST ONE THIRD ITS

PROJECTED SURFACE COVERED BY WATER COOLED SURFACE

BEFORE REDUCTION IN RoADIATION LOSS IS PERMITTED

A IR THRU COOLED WALLS MUST BE USED FOR COMBUSTION

IF REDUCTION IN RADIATION LOSS IS TO BE MADE

EXAMPLE: UNIT GUAR. FOR MAX. CONT. OUTPUT OF 400 MILLION BTU/HR WITH THREE WATER COOLED

WALLS • LOSS AT 400' 0.33". LOSS AT 200· 0.68".

� 2. � o ... z w u '" w .. '" '" o -' z o ... c o c '"

.a

••

1-

Tn_ Rodiation Loss Volu .. Obtained From Tl'lis Cury. o r .

for a Differential of 50 F Between Surface and Ambient

Temperatures and for on Air Velocity of 100 Feel per Minut.

Over th, Surface. Any Correction for Other Conditi ons snould

be mode in Accort.lance with FiO_ 3 PaOli 170 In the 1957 Manual of A STM Standards on Refroctory Mol,rials

H"

�� Em � mt�

'$!IS tr -ffi �-=-L''tri --j-I ',',,' OUTPUT

�'+HJ�lli...L.LllJ-LJ�,-,:I I�II I� 1111 ! 111111111 I 11 11111111111 I 1 1 11111I1 I 3 <4 , 6 7 8 9 10 20 30 40 50 60 80 100 ZOO 300 400

ITEM *

5

6

6

6

7

8

9

C

H" ••

H

H

0

N

S

Wal.r Woll Faclor

Air Cooled Wall Faclor ACTUAL OUTPUT MILLION BTU PER HOUR

FIG. 1 ABMA STD RADIATION LOSS CHART


TEST FORM FOR ABBREVIATED EFFICIENCY TEST

DETERMINATION OF THE HIGH HEATING VALUE OF SOLID WASTE BY THE BOJE FORMULA

FOR A GIVEN SOLID WASTE COMPOSITION THE HHV CAN BE RECHECKED BY THE FOLLOWING METHOD

AMBIENT REF. TEMP.

O F °c

32 o

68 20

80 26.7

WEIGHT FRACTION Ib/lb = kg/kg

0.2574

0.0364 0.2643

0.0058

0.0021

COMBUST! BLE Btu/lb kJ/kg

14, 9 7 6

4 9,37 4

4 9,406. 4 114,919

4 9,527 115,200

- 4,644 - 10,802

2,700 6,280

4,500 10,467

HHV = A X B Btu/lb kJ/kg

3,855 8,967

1,803 4,194 - 1,227 - 2,854

16 37

9 21

3 COMBUSTIBLE 0.5660

2 MOISTURE

4 ASH

TOTAL

0.2240

0.2100

1.0000 4,456 10.365 �FOR H2 VALUES AT OTHER AMBIENT AIR TEMPERATURES

311

, ,

-Ln_R_: -', , " , .

, 'r : .

•

Incinerator Zurich I HEAT INPUT - 148,811,250 Btu/h - 43,612 kW

REFUSE THROUGHPUT - 20.66/12. 51 sh.t/h - 18.75/11. 35 t/h

REFUSE NET HHV - 3,300/6500 Btu/1b - 7.675 MJ/kg/15.12 MJ/kg

STEAMING RATE - 98.519 Lb/h - 44.7 t/h

DESIGN PRESSURE - 650 psig - 4.4& kPa

OPERATING PRESSURE - 525 psig - 3.63 kPa

SUPERHEATER STEAM - 788 of - 420 °c

FEEDWATER TEMP. - 302 of - 150 °c

FIG. 2 TYPICAL INCINERATOR-BOILER UNIT

established by mutual consent as 1.5 percent. The heat loss due to radiation is based on values deter

mined by the ABMA Standard Radiation Loss Chart

(See Fig. 1) which is also used by the ASME Power Test Code PTC 4.1, for steam generating units.

HIGH AND LOW HEATING VALUES

While it is customary to use the high heating values of a fuel in ASME practice to determine boiler efficiency, the low heating value is generally

applied to boiler calculations throughout Europe.

Chart 8, shows how to determine the low heating value where the high heating value has already been established.

Chart 9 permits a recheck of the higher heating value by the BOJE method which can be used with , fair accuracy to determine the HHV of other solid waste compositions than those indicated in Chart 1.

SUMMARY

The procedure for performance test calculation can be a guide for engineers until a new ASME Abbreviated Efficiency Test Form is developed by PTC-33. Special consideration has been given for ease of convertibility to S. I. Units. Weight fractions have been applied wherever possible, so that Standard American Units are equivalent to S. I. Units. It

may seem cumbersome to enter various figures on

different pages but a certain amount of backtrack

ing cannot be avoided. Wherever this becomes necessary the item numbers serve to simplify this procedure.

CONCLUSION

Figure 2 illustrates a typical Incinerator-Boiler

312

REFERENCES Unit of the type and size outlined in this example.

Actual performance tests along these lines have been conducted in this country and abroad and it

is hoped that the procedure outlined will help to establish a new standard for realistic efficiency

testing oflarge incinerators with energy recovery.

"Steam Generating Units," ANSI/ASME Power Test Code

PTC4.1,1964.

"Large Incinerators," ANSI/ASME Performance Test Code

PTC 33, 1978.

ASME Steam Tables, 1967.

Key Words Analysis

Boiler Burning

Combustion Heat

Refuse

Thermal

313

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