REGULAR Paper 2 – Set A

Section - II: SHORT DESCRIPTIVE QUESTIONS Marks: 8 x 5 = 40

(i) Answer all eight questions

(ii) Each question carries five marks
Determine the Energy Utilization Factor (EUF) from the following back pressure cogeneration
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plant diagram and data given.

Back Pr.Steam
P =4 kg/cm2
T
Q =165 °C
=12MT/hr Process
Plant Condensate
H =650kcal/kg
P= 4 kg/cm2
T= 165 C
o

Inlet Steam
P = 42 kg/cm2
T = 410 °C
Q = 12 MT/hr
BPT  Power
H = 760kcal/kg Alternator 0.7 MW

Back Pr Turbine
Cogeneration Plant

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Solution:
Input heat to turbine = 12,000 x 760 = 91,20,000 Kcal/hr ….(1 mark)
Useful heat to process Plant = 12,000 x 650-165 = 5820,000 Kcal/hr ….(1 mark)
Useful Electrical output in alternator = 700x860= 602000 Kcal/hr ….(1 mark)

Energy Utilization Factor (EUF) = [(602000+5820,000) /91,20,000] x 100

= 70.42%
….(2 marks)
For combustion of 500 kg/hr of natural gas containing 100% methane, calculate the
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percentage of CO2 in the flue gas while 15% excess air is supplied.

Ans:
CH4 + 2 O2  CO2 + 2H2O

1 mole of Methane requires 2 moles of Oxygen.

16 Kg of Methane requires 64 Kg of Oxygen.

16 Kg of Methane produces 44 Kg of CO2.

500 Kg/hr of Methane requires 2000 Kg/hr of Oxygen.

500 Kg/hr of Methane produce 1375 Kg/hr of CO2.

…. (1 mark)
Theoretical air required for combustion = 2000 / 0.23 = 8696 Kg/hr
…. (1 mark)
Considering 15% excess air,

Actual air supplied for combustion is = 8696 * 1.15

= 10,000.4 Kg/hr of air

…. (1 mark)

Flue gas generation with 15% excess air = 500 + 10,000.4

= 10,500.4 Kg/hr
…. (1 mark)
% CO2 in the flue gas = (1375 / 10,500.4)x 100

= 13.1 %
.… (1 mark)

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

In a sugar mill, a process requires 5000 kg/hr of dry saturated steam at 7 kg/cm 2 (g). For the
S-3
flow velocity not to exceed 28 m/s, determine the pipe diameter size for distribution of steam.
Specific volume at 7 kg/cm2 = 0.24 m3/kg.
Ans:

The velocity of steam maximum = 28 m/s

Specific volume at 7 kg/cm2 = 0.24 m3/kg

Mass flow rate = 5000 kg/hr

= 5000/3600 = 1.389 kg/sec

Volumetric flow = 1.389 x 0.24 = 0.333 m3/sec

…. (1 mark)
Therefore, using:

Volumetric flow rate(m3/s) = Velocity (m/s) x Cross sectional area (m2)

…. (1 mark)

4Volumetric flowrate
D   Flow velocity

40.333
D   28

D  0.123 m or123 mm
…. (3 marks)

Since the steam velocity must not exceed 28 m/s, the pipe size must be at least 123 mm; the
nearest commercially available size, 150 mm, would be selected.

Paddy husk is being used as a combustion fuel in a water tube boiler. The ultimate analysis
S-4
of fuel is given below. Calculate theoretical amount of air required per 100 kg of husk for the
combustion from the following data.

Ultimate Analysis of Typical Agro Residues %

Moisture 10.8
Mineral Matter 16.7
Carbon 34.0
Hydrogen 5.0
Nitrogen 0.9
Sulphur 0.1
Oxygen 32.5

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Ans:

Considering a sample of 100 kg of paddy husk.

Component in % (wt) in Equation Specific Actual

fuel fuel stoichiometric stoichiometric
oxygen required oxygen required

Carbon 34 C + O2 = CO2 2.67 90.78

12 + 32 = 44 (32/12) (34 x 2.67)

Hydrogen 5 H2 + 0.5 O2 = H2O 8.0 40.0

2 + 16 = 18 (16/2) (5 x 8)

Sulphur 0.1 S + O2 = SO2 1.0 0.1

32 + 32 = 64 (32/32) (0.1 x 1)

Oxygen 32.5 (-)32.5

Nitrogen 0.9 -

Moisture 10.8 -

Mineral matter 16.7 -

Total 100 98.38

….. (4 marks)

Total Oxygen required = 98.38 kg oxygen / 100 kg fuel

Therefore theoretical quantity of dry air reqd. = 98.38 / 0.23 =427.7 kg air / 100 kg fuel

(air contains 23% oxygen by wt.)

….. (1 mark)

(a) Why should LPG cylinders not be stored in basements or cellars?

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(b) Why should the stack temperature of furnace oil fired boilers not be maintained below
160-170°C?

Ans:

(a) LPG is a predominant mixture of propane and butane. Both propane and butane are
denser than air. Consequently, the vapour flows along the ground into drains and sinks to
the lowest level of the surroundings and gets ignited at a considerable distance from the
source of leakage. Escape of even small quantities of LPG can give rise to large volume
of vapour mixture and can cause considerable hazard. Hence there should be adequate

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

ground level ventilation where LPG cylinders are stored. For this reason LPG cylinders
should not be stored in cellars or basements, which have no ventilation at ground levels.

….(2.5 marks)

(b) For fuels containing sulphur, low temperatures (below 160-170°C) of stack can lead to
sulphur dew point corrosion. The main disadvantage of sulphur is the risk of corrosion by
sulphuric acid formed during and after combustion, and condensing on cool parts of the
chimney or stack, air preheater and economiser.

….(2.5 marks)

Calculate the electricity consumption in an induction melting furnace from the following melt
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cycle data

Mild steel (MS) scrap charged : 1250 kg

Specific heat of MS : 0.68 kJ/kg 0C
Latent heat of MS : 270 kJ/kg
MS melting temperature : 1450 0C
Inlet MS charge temperature : 35 0C
Efficiency of furnace : 70%

Ans:

Theoretical energy required for melting = 1250 (0.68 x (1450 – 35) + 270)/3600

= 427.8 kWh

…. (3 marks)

Actual energy input to the furnace = 427.8 / 0.7

Electricity consumption = 611.2 kWh

…. (2 marks)

Feed water is provided to a boiler from the feed water tank at 60oC, temperature of
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condensate water returning to the tank is 80 oC, and temperature of makeup water is 27 oC.
What is the amount of condensate recovered?

Solution:

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

27x + (1 – x) 80 =60

Therefore x = 0.37
(37 percent makeup water or only 63 per cent of condensate is recovered).
….(5 marks)
Milk is flowing in a pipe cooler at a rate of 0.95 kg/sec. Initial temperature of the milk is 55 °C
S-8
and it is cooled to 18 °C using a stirred water bath with the constant temperature of 10°C
around the pipe. Specific heat of milk is 3.86 KJ/kg°C. Calculate the heat transfer rate
(kcal/hr) and also LMTD of the exchanger.

Ans:

Heat transfer in cooling milk = 0.95 * 3.86 * (55 – 18)

= 135.7 KJ/sec

=135.7 /4.18

= 32.46 kcal/sec

=(32.46*3600)= 116856 kCal/hr

…. (2.5 marks)

LMTD: DT1 = 55 – 10 = 45 °C

DT2 = 18 – 10 = 8 °C

LMTD of the heat exchanger = (45 – 8) / ln (45 / 8)

LMTD of the heat exchanger = 21.4 °C

…. (2.5 marks)

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

In a plant, a boiler is generating saturated steam of 10 TPH at a pressure of 7 kg/cm2(g)

S-1
with furnace oil as a fuel.
Feed water temperature = 60°C
Evaporation ratio = 14.
Calorific value of FO = 10000 kcal/kg
Specific gravity of FO = 0.95.
Enthalpy of steam at 7 kg/cm2(g) = 660 kcal/kg
Find out the efficiency of the boiler by direct method and volume of furnace oil tank (in m3)
required for 120 hrs of operation

Ans
E. R x (hg – hf) 14 x (660-60)
Effy = = = 84%
GCV 10000

(Note: Deduct 1 mark if 60 is not subtracted from 660)

Furnace oil requirement = 10 / 14 = 0.714 TPH = 714 kg/hr

For 120 hrs of operation, Furnace Oil requirement = 714 x 120 = 85680 kg
Oil tank volume = 85680 / (0.950/(1/1000)) = 90.189 m3

OR

E. R x (hg – hf) 14 x (660-60)

Effy = = = 84%
GCV 10000

Furnace oil requirement = 10 / 14 = 0.714 TPH = 714 kg/hr = 714 / 0.95 = 751.57 ltr/hr

For 120 hrs of operation, oil requirement = 751.57 x 120 = 90189 ltr
Oil tank volume = 90189 / 1000 = 90.189 m3

In a process plant, 30 TPH of steam after pressure reduction with pressure reducing valve
S-2
to 20 kg/cm2 gets superheated. The temperature of steam is 280oC. The management
wants to install a de-superheater to convert superheated steam into saturated steam at 20
kg/cm2 for process use, and its saturation temperature is 210oC.

Calculate quantity of water at 30oC to be injected in de-super-heater to get the desired

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

saturated steam using the following data.

Specific heat of superheated steam = 0.45 kcal/KgoC,

Latent heat of steam at 20kg/cm2 = 450 kcal/kg

Ans Quantity of heat available above saturation = 30,000 x 0.45 x (280-210)

= 9,45,000 kCal/hr

Quantity of water required in de-superheater = Q x{1x (210-30) + 450}= 945000

= 1500 Kg/hr

A steam pipe of 100mm diameter is insulated with mineral wool. As a part of energy saving
S-3
measure, the insulation is upgraded with efficient Calcium silicate insulation. Calculate the
percentage reduction in heat loss due to above measure with the following data,

Boiler efficiency : 80%

Surface temperature with mineral wool : 95°C

Surface temperature with calcium silicate : 55°C

Ambient temperature : 25°C

Ans
Heat loss thru non-insulated pipe = [10 + (95 – 25) / 20] * (95 – 25) ]

= 945 kcal/hr-m2

Heat loss thru insulated pipe = [10 + (55 – 25) / 20] * (55 – 25) ]

= 345 kcal/hr-m2

% Reduction in heat loss = (945 – 345)*100 / 945

= 63.5 %

a) List any six losses in a Boiler

S-4
b) Name two sources of wet flue gas loss in a coal fired boiler

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

a)
Ans

(b)

Moisture in air, Moisture in fuel and H2 in fuel.

(a) Calculate the blow down rate for a boiler with an evaporation rate of 5 tons/hr, if
S-5
the maximum permissible TDS in boiler water is 3000 ppm and with 18 % make
up water addition. The feed water TDS is around 400 ppm.
(b) Briefly explain temporary hardness and permanent hardness in boiler water

Ans Feed water TDS x % Makeup

a) Blow down (%) = Permissible TDS in Boiler  FeedwaterTDS

Percentage blow down = 400 x 18/(3000 – 400) = 2.77 %

If boiler evaporation rate is 5000 kg/hr then required blow down rate is:
= 5000 x 2.77/100 = 138.5 kg /hr
(b) Ref Book-2 :; Page Nos. 45 & 46
Temporary hardness ; It is the hardness that can be removed by boiling. Calcium and
magnesium bi carbonate dissolve in water to form an alkaline solution and these salts
are called alkaline hardness. They decompose upon heating releasing carbon dioxide
and forming a soft sludge which settles out.
Permanent hardness: calcium and magnesium sulphates and chlorides, nitrates etc
when dissolved in water are chemically neutral and are known as non alkaline
hardness. These are called permanent hardness and form hard scale on the boiler
surface which are difficult to remove.

List down any five good practices in Furnaces for energy efficiency
S-6

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Bureau of Energy Efficiency
 REGULAR Paper 2 – Set A

Ans a) Improve capacity Utilisation

b) Minimise Excess air
c) Minimise heat loss due to radiation, walls and openings
d) Adopt Waste heat recovery
e) Ensure Complete combustion
f) Maintain Furnace in slightly positive pressure
g) Adopt Variable frequency drives for fans
h) Optimise cycle time.
i) Emissivity Coatings
Any five of the above can be awarded marks, 1 mark each.
A cogeneration plant has an electrical output of 5 MW with a back pressure turbine which
S-7
has a input steam conditions to the turbine as 32 TPH with Enthalpy of 3418 KJ/kg @ 64
ata and 500oC and the exit conditions of steam at the end of the back pressure turbine is
186oC, with enthalpy of 2835.8 KJ/kg. After the process heating, all the condensate @
730C returns to the boiler. Calculate the Heat to power Ratio and Energy Utilization factor
of the process. Fuel consumption of the boiler is 8.2 TPH Coal at 4800 GCV.

Ans
Heat to power Ratio = 32*((2835.8/4.18)-73)/(5*860) = 4.5
Energy Utilization Factor = ( 32* ((2835.8/4.18)-73) + 5*860))/(8.2*4800)
=68.7%

Two identical oil fired boilers of capacity 100 TPH are operated in a refinery. They have a
S-8
full load efficiency of 90%. The part load efficiencies at 70% and 40% load are 75% and
65% respectively. For meeting 140 TPH requirement of steam, which one of the case
would you prefer to run and estimate the % savings in the preferred case. The enthalpy of
steam generated is 550 Kcal/kg and feed water enters the boiler at 50°C in all the cases.
Calorific value of the fuel oil is 10,000 Kcal/hr.

Case 1: both the boilers operated at 70 TPH capacity each.

Case 2: one at full load capacity and other at 40% capacity.

Case-1:
Ans
Amount of Fuel energy required when both the boilers are run at 70% load i.e, at 70
TPH load
Enthalpy change = (550 – 50) = 500 Kcal/kg

= (2 * 70 * 1000 * 500)/ (0.75 * 10000)

= 9333 Kg/hr (or) 9.33 Tons/hr
Case-2:
Amount of Fuel required when one boilers is running at full load at 100 TPH and
other at part load of 40 TPH

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Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

Enthalpy change = (550 – 50) = 500 Kcal/kg

= (100 * 1000 * 500) / (0.9*10000) + (40 * 1000 * 500) / (0.65*10000)

= 5555 + 3076.9
= 8.63 Tons/hr
Fuel required for Case 2 is less & hence Case 2 is preferred
% Fuel Savings = (9.33 – 8.63) / 9.33 x 100

= 7.5 %

S-1 Explain the working of Thermic fluid heating system and why it is preferred to
steam heating in some cases?

Ans
Thermic Fluid Heaters:

• At high temperatures, steam requires a corresponding high operating

pressure and establishing high temperatures with steam can be very
cumbersome and expensive in some cases.
• In thermic fluid heaters, a special type of oil-synthetic / mineral is used as
heat carrier. This fluid can be heated up to 300oC at atmospheric pressure.
In comparison steam would require a pressure of 85 bar to obtain this
temperature.
…………………….2.5 marks

Advantages:

– High temperature operation at atmospheric pressure

– Optional temperature level set points
– No supply or treatment of hot water and hence no heat loss due to
condensate flash steam
– No risk of corrosion
– Easy to operate

Functioning of Thermic Fluid Heaters

• Heat is transferred to the fluid through radiation. The hot thermic-fluid is

circulated to various process equipments such as dryers, heaters, de-
odouriser etc. where it gives up the heat. The return oil at a temperature 10
to 20 0C less, comes back to the thermic-fluid heater to get heated up again.
The circulation is carried out by a thermic fluid circulation pump.
• The thermic-fluid heater operates between two temperature ranges. Once
the upper limit is reached the burner is switched OFF or goes into the low
fire mode. In the case of solid fuel fired system the ID fan switches OFF on

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Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

reaching the upper limit. When the temperature reaches the lower limit due
to heat transfer in the process, the burners come ON again and in case of
solid fuels, the ID fan comes ON again.

• Since the thermic fluid heaters operate at a high temperature (250 – 300
0
C), the leaving exhaust gas temperatures are more than the fluid
temperature. Hence, the heat loss through the flue gas is a major
component of fuel losses. This offers potential for heat recovery if there is a
suitable application.
• The capacity is specified in terms of Lakh kilo calories per hour or Million kilo
calories per hour.

(Pg no 56 of Book 2 for explanation)

…………………….2.5 marks

In a car manufacture company, Propane is used as fuel in heaters for preheating paints.
S-2
Calculate the Air to Fuel ratio for complete combustion of C3H8 (Propane), if 15% excess
air is supplied to the heater.

C3H8 + 5 O2 --> 3 CO2 + 4 H2O

Ans
…………………….1 mark

1 mole of propane requires 5 moles of Oxygen.

Molecular weight of Propane is 44 Kg per mole.

…………………….1 mark

44 Kg of Propane requires 160 Kg of Oxygen.

Theoretical air required for combustion = 160 / 0.23 = 695.6 Kg/hr

…………………….1.5 marks

Excess air supplied is 15 %.

Actual air supplied for combustion is = 695.6 * 1.15

= 800 Kg/hr of air

Air to Fuel ratio = 800 / 44

= 18.18 or 18.2

…………………….1.5 marks

To meet a process plant’s heat and power requirements, high pressure steam at 70 MT/hr
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passes through a back pressure steam turbine, for power generation and the exhaust

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Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

steam is sent for thermal process requirements in the plant. With the following operating
data, calculate the heat to power ratio in kW/kW if the turbine and generator efficiencies
are 90% and 92% respectively.

Steam Inlet conditions Steam outlet conditions

Pressure = 50 bar Pressure = 10 bar
Temperature = 530°C Temperature = 280°C
Enthalpy of steam = 3515 kJ/kg Enthalpy = 3020 kJ/kg
Enthalpy of water = 782 kJ/kg

– Power generated = 70 * 1000 * (3515 - 3020) * 0.90 * 0.92 / 3600

Ans
= 7969.5 kW
…………………….2 marks
– Heat input to process = 70 * 1000 * (3020-782) / 3600 = 43517 kW
– …………………….2 marks
– Heat to power ratio = 43517 / 7969.5 = 5.46 kW/kW
…………………….1 mark

a) Explain why de-superheating is done after pressure reduction in PRVs?

S-4
b) Why is correction factor required for estimation of LMTD?

a) A reduction in steam pressure through a pressure reducing valve (PRV) is an

Ans
isenthalpic process. Saturated steam when reduced to a lower pressure results in
super heated steam. Since process requires only saturated steam, de-superheating
is often required, to compensate for superheat gained in PRV application due to
isenthalpic expansion.

…………………….2.5 marks

b) In multi pass shell and tube heat exchangers, the flow pattern is a mixture of co-
current and counter current flow, as the two streams flow through the exchanger in
the same direction on same passes and in the opposite on others. For these
reasons, the mean temperature differences is not equal to the logarithmic mean.
However it is convenient to retain the LMTD by introducing a correction factor, F
which is appropriately termed as the LMTD correction factor.

…………………….2.5 marks

S-5 What happens to steam properties such as saturation temperature, enthalpy of saturated
water, latent heat of steam, enthalpy of steam and specific volume of steam, if the steam
pressure is increased?
a) Saturation Temperature increases
Ans
b) Enthalpy of saturated water Increases.
c) Latent heat of steam decreases

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Bureau of Energy Efficiency
 Paper 2 – Set A with Solutions

d) Enthalpy of steam increases

e) Specific Volume decreases
…………………….5 marks
( each point carries one mark respectively)

S-6 Two identical biomass fired boilers of capacity 10 TPH are operated in a chemical industry.
They each have a full load efficiency of 80%. The part load efficiencies at 70% and 40%
load are 75% and 68% respectively. For meeting 14 TPH requirement of steam, would you
prefer to run both the boilers at 7 TPH capacity or one at full load capacity and other at 40%
capacity. Estimate the % savings in the preferred case.

Ans Fuel energy required when both the boilers are run at 7 TPH load

Governing equation to be used :

(Fuel reqd) = [(Qty stm) * (Enth steam – Enth feedwater)] / [( GCV Fuel) * (Effy boiler)]

(Fuel reqd) = [(Qty stm) * (∆h) / (Effy boiler)]

Where : ∆h = is same in both cases = [Enth steam – Enth feed-water) / ( GCV Fuel)]

Fuel required = (2*7*∆h) / (0.75) = 18.67 h

…………………….1 mark
Fuel energy required when one boiler is running at full load and the other at part load
of 40%
Fuel required = [(10*∆h) / (0.8)] + [(4*∆h) / (0.68)]= 18.38 h
…………………….2 marks
The case where one boiler is running at full load and the other at part load of 40% is
preferred
…………………….1 marks
• % savings = [(18.67 h) – (18.38 h)] * 100 / (18.67 h)
= 1.55%
…………………….1 mark

S-7 A reheating furnace is operating with deteriorated wall insulation. The existing
average outer surface temperature of the furnace (of area = 100 m2) with
surrounding ambient air temperature of 40ºC, is recorded to be 120ºC. After
revamping the refractory, the furnace outer surface temperature reduces to 50ºC.
If the fuel oil (GCV = 11,000 kcal/kg) cost is Rs. 25,000 per tonne, and efficiency of
the furnace is 35%, estimate annual savings for 300 working days per year.

Ans Rate of heat loss from furnace surface (existing)

S = [10+(Ts – Ta) / 20] x ( Ts- Ta)
kcals/hr/m2 Heat loss = S x A
120 40 
= 100m2 x [10+ ] (120-40) kcals/hr /m2
 
 20 
= 112.0 x 103 kcal/hr
…………………….1 mark

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Bureau of Energy Efficiency
 Rate of heat loss from furnace surface after revamping insulation refractory
50  40
= 100 [ 10 + ] (50-40)
20
= 10.5 x 103 kcal/hr
…………………….1 mark
Energy savings kcal/hr = (112-10.5)x 10 3

= 101.5x103 kcal/hr
Annual energy savings = (112-10.5) x 103 x 300 x 24
= 7.308 x 108 kcal/yr
…………………….1 mark
5
7.308x108
Annual fuel oil savings = = 1.9 x 10 kg of fuel
0.35x11000
……………………. 1 mark
1.9x105 x25000 6
Annual Cost savings = = Rs.4.75 x 10
1000
…………………….1 mark
The efficiency of a boiler on GCV basis is 85%. The fuel contains 1.0 % moisture and 12 %
S8
hydrogen. The GCV of fuel is 10,500 Kcal/kg. What is the boiler efficiency on the basis of
net calorific value?

%age of Hydrogen in fuel %age of moisture in fuel

NCV = GCV – [9 x +----------------------------------] x584
100 100

12 1.0
NCV = 10500 – [ 9 x ----- + -------- ] x 584
100 100

= 10500 – [ 9 x 0.12 + 0.01] x 584

= 10500 - 636.56
= 9863.44 = 9863 kcal / kg
…………………….3 marks
85
Boiler efficiency on NCV =-----------------10500
9863

= 90.5%
…………………….2 marks

(i) Answer all Eight questionss

(ii) Each question carries Five marks

S1 Write short notes on wet and dry methods of preservation of boiler.

Ans Refer BEE Guide Book 2- Chapter 2, Page No: 54 - 55

S2 Explain the phenomenon of water hammer in steam system and how it can be eliminated ?

Refer BEE Guide Book 2- Chapter 3, Page No: 91

Ans
S3 A counter flow double pipe heat exchanger using hot process liquid is used to heat water which
flows at 20 m3/hr. The process liquid enters the heat exchanger at 180 0C and leaves at 130
0C. The inlet and exit temperatures of water are 30 0C and 90 0C. Specific heat of water is
4.187 kJ/kg K. Calculate the heat transfer area if overall heat transfer coefficient is
820 W/m2 K. What would be the percentage increase in the area if fluid flow were parallel
assuming same overall heat transfer coefficient?
 Counter Flow
Ans  Water inlet temperature 30 0C
 Water outlet temperature 90 0C
 Flow rate of water 20 m3/hr
 Heat content in water = 20000*(60)* 4.187=5024400 kJ/hr=1395.6 kW
 Process fluid inlet temperature = 180 0C
 Process fluid outlet temperature = 130 0C
 ΔT1=90, ΔT2 =100
 TLMTD = (ΔT1- ΔT2)/(ln(ΔT1/ ΔT2)) = 10/ln(100/90) = 94.91 0C
 U = 820 W/m20C
 H= UATLMTD = 1395.6*1000/(95*820) = 17.9 m2

Parallel flow:

ΔT1=150, ΔT2 =40

 TLMTD = (ΔT1- ΔT2)/(ln(ΔT1/ ΔT2)) = 110/ln(150/40) = 83.2 0C
 U = 820 W/m20C
 H= UATLMTD = 1395.6*1000/(83.2*820) = 20.45 m2

% Increase in area = ((20.45-17.9)/17.9) x 100 = 14.24 % increase

A continuous process industry is operating with a 2 MW DG Set with 80 % load to meet the
S4 power requirements of the plant. The specific fuel consumption of the DG set is 4 kWh/liter. On
energy auditor’s suggestion, a waste heat recovery boiler was installed to recover heat from
exhaust gas and generating 800 kg/hr of saturated steam at 10 kg/cm2.

The waste heat recovery boiler operating data are given below.
• Feed water temperature = 60 oC

• Enthalpy of steam at 10 kg/cm2 = 660 kCal/kg

• Specific gravity of diesel = 0.85
• GCV of diesel = 10500 kCal/kg
Calculate the following. (each carries 2.5 Marks)
a) Efficiency of DG set before waste heat recovery boiler installation
b) Cogeneration system efficiency after waste heat recovery boiler installation
Diesel consumption Litre / hour
Ans
= ((2 x 1000) x 0.8 )) / 4 = 400 litre / hour
a) DG set efficiency
= 2000 kWh/hr x 0.8 loading x 860 kcal/kWh x100 = 38.54 %
400 lit x 0.85 kg/lit x10500 kcal/kg
b) Co-gen System Efficiency after WHR boiler installation
[ 2000 kW x 0.8 loading x 860 kcal/hr/kW + (800 kg steam /hr x (660-60) kcal/kg ]x100 = 52%
[ 400 lit x 0.85 kg/lit x10500 kcal/kg]
S5 A coal fired thermic fluid heater is used to supply heat to a dryer. The hot oil circulation is
supplied at 270 oC, with a flow of 100 m3/hr and operating with temperature difference of 20
oC. Estimate the coal requirement if the thermal efficiency of the heater is 65 % and GCV of the
coal is 4200 kCal/hr.

Consider specific heat & density of the thermic fluid to be 0.55 kcal/kg oC& 820 kg/m3
respectively.
Ans Absorbed heat in thermic fluid = m * Cp * ∆ T
= (100 * 820) * 0.55 * 20
= 902000 kcal/hr
Thermal efficiency of the heater = absorbed duty / input heat duty
Mass of coal required = absorbed duty / (efficiency * calorific value of coal)
= 902000 / (0.65 * 4200)
= 330.4 kg/hr
In a heat exchanger, steam is used to heat 3000 litres/hr of furnace oil from 30 oC to 100 oC.
S6 The specific heat of furnace oil is 0.22 kCal/ kg/ oC and the density of furnace oil is 0.95. How
much steam per hour is needed if steam at 4 kg/cm2 with latent heat of 510 kCal/kg is used ?

If steam cost is Rs.4/kg and electrical energy cost is Rs.8/kWh, which type of heating would be
more economical in this particular case? (assume no losses in electrical and steam heating
process)
Total heat required = m Cp ∆T
Ans
= (3000 x 0.95) x 0.22 x (100-30)

= 43890 kcal/hr

a) Amount of steam required = 43890/510

= 86 kg/hr

Steam cost = 86 x Rs.4

= Rs. 344/hr

b) Amount of electricity required = 43890/860

= 51 kWh

= 51 x Rs. 8

= Rs.408/ hr

Answer : Steam heating will be more economical

Calculate the reduction in pressure drop in meters when pipe diameter is increased from 250
S7 mm to 350 mm for a length of 500 meters. The water velocity is 2 m/s in the 250 mm diameter
pipe, and friction factor is 0.005.

Ans Pressure drop = 4fLV2/ 2gD

Pressure drop with250 mm = (4 x 0.005 x 500 x 22 )/ (2 x 9.81 x 0.250)

= 8.155 m

Velocity of water in pipe of 350 mm diameter

= (0.25 x 0.25 x 2) /(0.35 x 0.35) = 1.02 m/s

Pressure drop with350 mm = (4 x 0.005 x 500 x1.022 )/ (2x9.81 x0.350)

= 1.515 m

Pressure drop reduction = 8.155 – 1.515 = 6.64 m

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S8 In a process plant 200 kg/hr of hot condensate at 6 bar(g) having a sensible heat of
166 kCal/kg is discharged. The plant also requires low pressure steam at a pressure of 1 bar(g)
for heating application. Find out the quantity of flash steam generated in the flash vessel in
kg/hr. The condensate at a pressure of 1 bar(g) has a sensible heat of
120 kCal/ kg and a latent heat of 526 kCal/kg.
S1 – S2
Ans Flash steam available % =----------------× 100
L2
Where,

S1 = is the sensible heat of higher pressure steam

S2 = is the sensible heat of steam at lower pressure

L2 = is the latent heat of flash steam at lower pressure

166 - 120
Flash steam generated = (--------------------) × 200 Kg/hr = 17.49 kg/hr
526

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S1 In an industry, an electrical oven consuming 1100 kWh/batch, is proposed for replacement, by a FO fuel fired oven.
Calculate the simple payback period, given the following data:

Number of batches / years = 4000

Efficiency of electric oven = 82%
Efficiency of FO fired oven = 55%
Cost of FO = Rs.35,000/Tonne
GCV of FO = 10,200 kcal/kg
Electricity cost = Rs.6.0/kWh
Investment for FO fired oven = Rs. 125 Lakhs

Ans :

Useful heat, required per batch = (1100 x 860 x 0.82)

= 7,75,720 kcal/batch
FO input per batch = (7,75,720 /(0.55 x 10,200))
= 138.27 kg FO/batch
FO cost per batch = (138.27 kg FO/batch x Rs.35/kg FO)
= Rs.4,839.45
Electricity cost per batch = (1,100 kWh/batch x Rs.6.0/kWh)
= Rs.6,600
Cost savings per batch on account of replacement = (Rs.6,600 – Rs.4,839.45)
= Rs.1,760.55
Annual cost savings at 4000 batches per year = (1,760.55 x 4000)
= Rs.70,42,200
(Or) = Rs.70.422 lakhs
Investment = Rs.125 lakhs
Simple payback period = (125/70.422)
= 1.78 years
S2 In a process plant, 30 TPH of steam, after pressure reduction to 20 kg/cm 2(g), through a pressure reducing valve, gets
superheated. The temperature of superheated steam is 350 oC. The management desires to install a de-super heater to
convert the superheated steam into useful saturated steam at 20 kg/cm 2(g) for process use. The saturated steam
temperature is 210oC.

Calculate the quantity of water required to be injected at 30 oC, in the de-super heater, in order to obtain the desired
saturated steam, using the following data:

 Specific heat of superheated steam = 0.45 kcal/kgoC

 Latent heat of steam at 20 kg/cm2(g) = 450 kcal/kg

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Ans :

 Quantity of heat available above saturation = (30,000 x 0.45 x (350-210))

= 18,90,000 kcal/hr
By Heat & Mass balance: Q x{1 x (210-30) + 450} = 18,90,000
 Quantity of water (Q) required
to be added in de-super heater = 18,90,000/{1 x (210-30) + 450}
= 18,90,000/630
= 3000 kg/hr
S3 In an industry the process equipment needs 5000 kg/hr of saturated steam at 10 kg/ cm2(g). For a steam velocity of
25 m/sec, what will be the diameter of the steam pipe in ‘mm’, given that the specific volume of steam at 10 kg/ cm 2(g)
is 0.1802 m3/kg.
Ans :
Specific volume of steam at 10 kg/cm2(g) = 0.1802 m3/kg
Flow rate = 25m/sec
Mass flow rate = 5000 kg/hr
= 1.389 kg/sec
Volume flow rate = 1.389 x 0.1802
= 0.25 m3/sec
Volume flow rate is also = (π/4 x D2) x25
2
Therefore, (π/4 x D ) x 25 = 0.25
Hence, diameter of steam pipe line ‘D’ = [(0.25/((π/4) x 25)]0.5
= 0.1128m
or 112.8 mm
S4 An economizer was installed in an oil fired boiler. The following data was obtained after commissioning the economizer.
 Air to fuel ratio = 18
 Evaporation ratio of the boiler = 12.5
 Specific heat of flue gas = 0.25 kcal/kg°C.
 Condensate recovery in the plant = Nil.
Calculate the rise in temperature of feed water across the economizer, corresponding to a drop in flue gas temperature
from 280 °C to 190 °C.
Ans :
Steam generated per kg of fuel, (from evaporation ratio) = 12.5 kg
Required combustion air per kg of fuel, (from air to fuel ratio) = 18 kg combustion air/kg fuel oil
Flue gas generated per kg of fuel = (18 +1)
= 19 kg flue gas/kg fuel oil
Heat balance across the Economizer : Heat given by flue gas = Heat received by water
((19 x 0.25 x (280-190)) = (12.5 kg x 1kcal/kgoC x ∆T)
Rise in temperature of water ∆T = 34.2 °C
S5 Compute the heat loss in percentage, due to unburnt in fly ash and bottom ash, for an AFBC Boiler, using Indian coal,
with:

 GCV = 4200 kcal/kg.

 % Ash in coal = 38.8
 Ratio of bottom ash to fly ash = 15: 85
 GCV of fly ash = 452.5 kcal/kg
 GCV of bottom ash = 800 kcal/kg
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Ans:
Unburnt in fly ash
Amount of fly ash in 1 kg of coal = (0.85 x0.388)
= 0.3298 kg fly ash/kg coal
GCV of fly ash = 452.5 kcal/kg fly ash
Heat loss in fly ash = (0.3298 x 452.5 kcal per kg fly ash)
= 149.23 kcal/kg coal
% Heat loss in fly ash = (149.23 x 100 /4200)
= 3.55 %

Unburnt in bottom ash

Amount of bottom ash in 1 kg of coal = 0.15 x 0.388
= 0.0582 kg bottom ash/kg coal
GCV of bottom ash = 800 Kcal/kg bottom ash
Heat loss in bottom ash = (0.0582 x 800 kcal per kg bottom ash)
= 46.56 kcal/kg coal
% Heat loss in bottom ash = (46.56 x 100 /4200)
= 1.11 %

S6 List five main parameters considered for the selection of refractories? (Each 1 Mark)
Ans : (Page No:166, Sec 5.11)
S7 What is the significance of volatile matter, in case of solid fuels?

Ans : (Page No: 9)

S8 (i) List three functions of a steam trap. (3 Marks)

(ii) Explain the working principle of thermodynamic trap. (2 Marks)
Ans :
(i) List three functions of a steam trap. (Page 82)
(ii) Explain the working principle of thermodynamic trap. (Page 86-87)

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