Welcome to our Website! Here the interested expert and other public have an access to
what was thus far an exclusive domain of a few dedicated specialists. The specialized
software tool for a thermodynamic calculations of fossil fuel fired boilers has been
developed. It is based on the
new theoretical findings on heat transfer in boilers with
proven +/-2% uncertainty (see Underlying theory tag for more explanation). It can be
applied to carry out tasks like these:
  • HEAT TRANSFER ANALYSIS IN BOILER OF GIVEN DESIGN FIRED WITH ANY
    FOSSIL FUEL OR EXHAUST GAS (WASTE HEAT RECOVERY BOILER) FOR ANY
    OPERATING CONDITIONS (PRESSURE / WATER TEMP., COMBUSTION AIR
    TEMP., EXCESS AIR / REST OXYGEN, FLUE GAS RECIRCULATION ETC.).
  • BOILER DESIGN OPTIMIZATION.
  • SOFTWARE ALSO ACCEPTS MIXTURE OF TWO SOLID FUELS. THIS WAY A
    BOILER FIRED WITH TWO FUELS AS FOUND IN COAL POWER PLANTS WHERE
    BIOMASS OR WASTE DERIVED FUEL (RDF) IS COFIRED WITH COAL CAN BE
    HANDLED.

There is
no limitation in boiler size, which means also power plant boilers can also be
handled irrespective from their size.

The software is
simple to use and a person skilled in the art gets along with it in a single
go. A great care has been taken to make its use
simple and straightforward and the
examples are given (see side menu), which are actually complete
instructions for the
user.

The software calculates a heat transfer in
fossil fuel (oil, gas, biomass, waste derived
fuel) fired
fire-tube and water-tube steam, hot water and waste heat boilers of
arbitrary geometry operated at arbitrary operating conditions with pressure up to
180 bar
/ 2610 psi and combustion air temperature of up to 400°C/750 F and higher. Version for
pressure up to
400 bar / 5800 psi is in final stage of development (supercritical boilers)

The software calculates steam
superheater, reheater and economizer and
determines the optimum
size of these for the given conditions (see sample calculations).

Every boiler consists of one or more
segments. Software can accept up to 6 sections
such as furnace (with or without rear turnaround chamber); one or two channels; one two
or three sets of tubes (as found in 2-pass, 3-pass and 4-pass boilers) and calculates
conditions in each segment. The segments can be combined and by that next to
every
known boiler design can be handled (with
exception of a few special cases for which the
dedicated proprietary procedures were developed). A list of boiler
designs the software
can handle is shown
here.

Heat transfer medium, a  
liquid can be following (more can be added as needed):
  • water
  • Rankine cycle liquid.

Input and output
values can be either in Metric or English units.

During data entry process
screenshots are saved to the disk giving the user a footage
of the calculation process (files are deleted when software starts or re-starts; hence if
user intents to keep these files he or she shall relocate them prior restarting the software
or returning to start screen by pressing Esc twice when in Final menu).

Boiler design is trial & error process, which this software helps to accomplish faster, with
less effort and higher accuracy
.

Discrepancy sources between measured and calculated values

There are always differences between calculated and actual values. The discrepancies
are of an operational (fouling, scaling on gas and water side) and of mathematical nature
(heat transfer equations are always derived from experiments). In general, for new and
well maintained boilers the discrepancy to actual values is between 1-2% (boiler output,
steam capacity)
.

Impact of fouling

The software assumes clean surfaces in the boiler as appearing during commissioning
process. Over time boiler performance becomes affected by fouling, soot and scale
deposits. Its magnitude depends on fuel, operating conditions etc..

Condensing boilers

Boilers which cool down the flue gases below the water dew point are so called
condensing boilers. In best case the condensation rate will not exceed 40%. In case of
gaseous fuel this would correspond to a maximum 4-5 percentage points efficiency
increase (half of that in case of solid and liquid fuels). Since the condensation rate can
not be accurately predicted, maximum efficiency increase is known and condensing
boilers are of the proprietary designs, those boilers are not covered with this software.
When the water vapor dew point in flue gases is reached an alert about the impending
condensation is issued, though.
INTRODUCTION
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FOR FIRE-TUBE & WATER-TUBE BOILERS