Calcs Efficiency Gain From Decreasing Excess Air in Boilers (PF)

Input Data
Tca = temperature combustion air before burner (F) 70
Tex = temperature exhaust gasses (F) 367
EA = excess air (0=stoch, 0.1 = optimum) 1.02
Qng (mmBtu/h) = heat input to burner 7.300
Tw1 (F) 200
Tw2 (F) (for either "Steam" or "HotWater") 233
EAn = excess air (0=stoch, 0.1 = optimum) 0.10
"Steam" or "HotWater" Steam
If "Steam" then enter enthalpy of sat steam leaving boiler, hw2 (Btu/lb) 1158

Constants (for Natural Gas)

LHV = lower heating value (Btu/lb) 21,500
HHV = higher heating value (Btu/lb) 23,900
cpp = specific heat of products of exhaust (Btu/lb-F) 0.260
Tdpp = dew point temp of H20 in exhaust (F) 140
Afs = air/fuel mass ratio at stochiometric conditions 17.20

Calculated Values
hr (Btu/lb) = heat of reaction = LHV if Tex > 140 else HHV 21,500
Tc (F) = temp combustion = Tca+hr/[(1+(1+EA)(Afs))cpp] 2,383
Effc = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex)/HHV 78.4%
Qu (Btu/h) = Useful heat transferred to water = Qng x 10^6 x Effc 5,723,887
dt1 (F) = Tc - Tw1 2,183
dt2 (F) = Tex - Tw2 134
dtlm (F) = (dt2-dt1) / ln(dt2/dt1) 734
UA (Btu/h-F) = Qu / (dtlm) 7,794
Tcn (F) = new temp combustion = Tca+hr/[(1+(1+EAn)(Afs))cpp] 4,221
Effcn (with EAn but Tex const) = [1 + (1+EAn)(AFs)]*cpp*(Tc-Tex)/HHV 83.5%
dt1n (F) = Tcn - Tw1 4,021
Guess current dt2n (F) (lower than dt2….) 17
This should equal zero if dt2 is correct 0
Texn (F) = dt2n + Tw2 250
Effcn = [1 + (1+EAn)(AFs)]*cpp*(Tcn-Texn)/HHV 86.1%
Qngn (mmBtu/h) = Qu / (Effcn x 10^6) 6.652

Other Interesting Information (ALL THIS NEEDS REVISION FOR PF HX)

hw1 (Btu/lb) = 1 * (Tw1 - 32) 168
hw2 (Btu/lb) = if steam then hw2 = hw2 (in B17) else hw2 = 1 * (Tw2 - 32) 1158
mw (lb/h) = Qu / (hw2 - hw1) 5,782
mng (lb/h) = Qng x 10^6 / HHVng 305
mca (lb/h) = (1+ EA) x Afs x mng 10,612
mc (lb/h) = mng + mca 10,918
Qu (Btu/h) = mc x ccp x (Tc - Tex) (to check energy balances…) 5,723,887
mngn (lb/h) = Qngn x 10^6 / HHVng 278
mcan (lb/h) = (1+ EAn) x Afs x mngn 5,266
mcn (lb/h) = mngn + mcan 5,544
Tc* (F) = temp comb (with EAn but Tex const) = Tca+hr/[(1+(1+EAn)(Afs))cpp 4,221
E #VALUE!
NTU #VALUE!
UA (Btu/hF) = NTU x Cmin #VALUE!
CombEff.XLS

Input Data
EA = excess air (0=stoch, 0.1 = optimum) 0.10
Tca = temperature combustion air before burner (F) 70
Tex = temperature exhaust gasses (F) 350

Constants (for Natural Gas)

LHV = lower heating value (Btu/lb) 21,500
HHV = higher heating value (Btu/lb) 23,900
cpp = specific heat of products of exhaust (Btu/lb-F) 0.260
Tdpp = dew point temp of H20 in exhaust (F) 140
Afs = air/fuel mass ratio at stochiometric conditions 17.20

Calculated Values
hr = heat of reaction = (if Tex<140 then hr=HHV else hr = LHV) 21,500
Tc = temp combustion (F) = Tca+hr/[(1+(1+EA)(Afs))cpp] 4,221
Efficiency = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex)/HHV 83.9%
Graphs
Tc = 72+21500/(.26(1+17.5EA))
Eff = (1 + 17.5EA)*.26*(Tc-Ts)/23900

EA (%) Ts=300F Ts=400F Ts=500F Tc

0 85.4% 83.4% 81.3% 4,542
20 84.5% 82.1% 79.7% 3,831
40 83.6% 80.9% 78.1% 3,315
60 82.8% 79.6% 76.5% 2,923
80 81.9% 78.4% 74.8% 2,616
100 81.0% 77.1% 73.2% 2,369

Natural Gas Burner Efficiency

100.0%

90.0%
Efficiency

80.0%

70.0%
0 10 20 30 40 50 60 70 80 90 100
Excess Air (%)

Ts=300F Ts=400F Ts=500F

Calcs Efficiency Gain From Decreasing Excess Air in Boilers

Input Data
Tca = temperature combustion air before burner (F) 69
Tex = temperature exhaust gasses (F) 433
EA = excess air (0=stoch, 0.1 = optimum) 0.29
Qng (mmBtu/h) = heat input to burner 6.300
Tw1 (F) 150
Tw2 (F) (for either "Steam" or "HotWater") 210
EAn = excess air (0=stoch, 0.1 = optimum) 0.10
"Steam" or "HotWater" HotWater
If "Steam" then enter enthalpy of sat steam leaving boiler, hw2 (Btu/lb) 1000

Constants (for Natural Gas)

LHV = lower heating value (Btu/lb) 21,500
HHV = higher heating value (Btu/lb) 23,900
cpp = specific heat of products of exhaust (Btu/lb-F) 0.260
Tdpp = dew point temp of H20 in exhaust (F) 140
Afs = air/fuel mass ratio at stochiometric conditions 17.20

Calculated Values
hr (Btu/lb) = heat of reaction = LHV if Tex > 140 else HHV 21,500
Tc (F) = temp combustion = Tca+hr/[(1+(1+EA)(Afs))cpp] 3,635
Effc = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex)/HHV 80.8%
Qu (Btu/h) = Useful heat transferred to water = Qng x 10^6 x Effc 5,088,894
dt1 (F) = Tc - Tw2 3,425
dt2 (F) = Tex - Tw1 283
dtlm (F) = (dt2-dt1) / ln(dt2/dt1) 1,260
R = (Tw1-Tw2)/(Tex-Tc) 0.018737
P = (Tex-Tc)/(Tw1-Tc) 0.918799
F (0 to 1) = F(R,P) correction factor for tube-in-shell hotwater boilers 1.00
UA (Btu/h-F) = Qu / (F x dtlm) 4,038
Tcn (F) = new temp combustion = Tca+hr/[(1+(1+EAn)(Afs))cpp] 4,220
dt1n (F) = Tcn - Tw2 4,010
Guess current dt2n (F) (lower than dt2….) 194
This should equal zero if dt2 is correct 0
Texn (F) = dt2n + Tw1 344
Effcn = [1 + (1+EAn)(AFs)]*cpp*(Tcn-Texn)/HHV 84.0%
Qngn (mmBtu/h) = Qu / (Effcn x 10^6) 6.058

Other Interesting Information

hw1 (Btu/lb) = 1 * (Tw1 - 32) 118
hw2 (Btu/lb) = if steam then hw2 = hw2 (in B17) else hw2 = 1 * (Tw2 - 32) 178
mw (lb/h) = Qu / (hw2 - hw1) 84,815
mng (lb/h) = Qng x 10^6 / HHVng 264
mca (lb/h) = (1+ EA) x Afs x mng 5,849
mc (lb/h) = mng + mca 6,112
Qu (Btu/h) = mc x ccp x (Tc - Tex) (to check energy balances…) 5,088,894
mngn (lb/h) = Qngn x 10^6 / HHVng 253
mcan (lb/h) = (1+ EAn) x Afs x mngn 4,796
mcn (lb/h) = mngn + mcan 5,050
Cc (Btu/hF) 84,815
Ch (Btu/hF) 1,589
Cmin (Btu/hF) 1,589
Cmax (Btu/hF) 84,815
Cr = Cmin/Cmax 0.019
hxeff 0.919
E 1.158
NTU 2.615
UA (Btu/hF) = NTU x Cmin 4,156
Boiler Efficiency At Part Loads
Calcs Eff Gain For On/Off to Modulate Control

Input Data
Rated Burner Input (MBtu/h) = Qb 5.00
Tsteam or Thotwater (F) = Ts 210
Excess Air = EA 0.3
Tca = temperature combustion air before burner (F) 69
Tex = temperature exhaust gasses (F) 433
Diameter Boiler (ft) = Db 10
Length Boiler (ft) = Lb 20
Temp Boiler Skin (F) = Tb 130
Conv Coeff (Btu/h-ft2-F) = h 7
Temp Indoor Air (F) = Tia 65
Temp Outdoor Air (F) = Toa 50
Stack Height (ft) = Hs 30
Stack Diameter (ft) = Ds 3
Frac Time at Full Fire = PLR 0.25
Num cycles per hour = N 6
Post-fire purge time (min) = PstP 1
Pre-fire purge time (min) = PreP 1
Annual Boiler Operating Hours (h/yr) = HPY 8,088
Cost of Natural Gas ($/MBtu) = CNG 5.50

Constants (for Natural Gas)

LHV = lower heating value (Btu/lb) 21,500
HHV = higher heating value (Btu/lb) 23,900
cpp = specific heat of products of exhaust (Btu/lb-F) 0.260
Tdpp = dew point temp of H20 in exhaust (F) 140
Afs = air/fuel mass ratio at stochiometric conditions 17.20

Calculations
For On/Off Control
Area Boiler (ft2) = Ab = (3.14 x Db^2 / 4) + (3.14 x Db x Lb) 785
Area Stack (ft2) = As = 3.14 x Ds^2 / 4 7.07
mng (lb/hr) = Qb (MBtu/h) x 10^6 (Btu/MBtu) / 21500 (Btu/lbng) 233
ma (lb/hr) = mng (lb/hr) x 17.2 (lba/lbng) x (1+EA) 5,200
Off-Cycle Pres Diff = dP(lbm/s2-ft) = hs(ft) x 32.2 x 14.7 x (1/Toa-1/Ts) / 53.34 x 144 18
Off-Cycle Velocity (ft/min) = Vs = (2 x dP (lbm/s2-ft) / 0.07 lbm(ft3))^0.5 430
Off-Cycle Flow (ft3/min) = VFRs = Vs (ft/min) x 60 min/hr) x As (ft2) 3,036
Skin Heat Loss (Btu/h) = Qsk = Ab (ft2) x h (Btu/h-ft2-F) x (Tb - Tia) F 357,175
Purge Loss (Btu/h) = Qp = ma x (PstP+PreP)/60 x (1-PLR) x .26 x (Ts x .9 - Tia) 33,530
Off-Cycle Stack Loss (Btu/h) = Qstoff = VFRs x 60 x (1-PLR) x 0.018 x (Ts x .9 - Tia) 304,913
hr (Btu/lb) = heat of reaction = LHV if Tex > 140 else HHV 21,500
Tc (F) = temp combustion = Tca+hr/[(1+(1+EA)(Afs))cpp] 3,609
Effc = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex)/HHV 80.7%
On-Cycle Stack Loss (Btu/h) = Qston = Qb x 10^6 x PLR x (1-Effc) 241,150
Total Losses (Btu/h) = Ql = Qsk + Qp + Qstoff + Qston 936,767
Total Heat Input (Btu/h) = Qin = Qb x 10^6 x PLR 1,250,000
Total Heat to Steam/Water (Btu/h) = Qu = Qin - Ql 313,233
Total Efficiency (On/Off Control) = Qu / Qin 0.251
For ModulationControl
Qu (Btu/h) = Useful heat transferred to water at full fire = Qng x 10^6 x Effc 4,035,399
dt1 (F) = Tc - Tw2 3,399
dt2 (F) = Tex - Tw1 223
dtlm (F) = (dt2-dt1) / ln(dt2/dt1) 1,166
R = (Tw1-Tw2)/(Tex-Tc) 0
P = (Tex-Tc)/(Tw1-Tc) 0.9343907
F (0 to 1) = F(R,P) correction factor for tube-in-shell hotwater boilers 1.00
UA (Btu/h-F) = Qu / (F x dtlm) 3,461
mc (lb/h) = mng + mca 5,433
Guess PLR until Qu,n = Qu,target (fraction of Qng at which to calc new eff) 0.234
Tex,n (F) at PLR = Tw2-(Tw2-Tc)*exp(-UA/(mc*PLR*cpp)) (assumes const UA and Tw2) 210.10
Effc,n = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex,n)/HHV 86.4%
Qu,n (Btu/h) = Useful heat transferred to water = Qng x PRL x 10^6 x Effc,n 1,010,559
Qu,target 1,008,850
Skin Heat Loss (Btu/h) = Qsk 357,175
Total Heat Input (Btu/h) = Qinm = (Qu + Qsk) / Effc,n 776,181
On-Cycle Stack Loss (Btu/h) = Qstonm = Qinm x (1-Effc,n) 105,774
Total Losses (Btu/h) = Qlm = Qsk + Qstonm 462,949
Total Heat to Steam/Water (Btu/h) = Qum = Qinm - Qlm 313,233
Avg Efficiency (Modulation Control) = Qum / Qinm 0.404
Savings
Total Gas Savings (Btu/h) = Qsh = Qin - Qinm 473,819
Total Gas Savings (MBtu/yr) = Qsy = Qsh x HPY / 10^6 3,832
Total Gas Savings ($/yr) = Qsy x CNG 21,077
Directly calcs Effc,n
Boiler Efficiency At Part Loads

Input Data
Tca = temperature combustion air before burner (F) 69
Tex = temperature exhaust gasses (F) 433
EA = excess air (0=stoch, 0.1 = optimum) 0.30
Qng (mmBtu/h) = heat input to burner at full load 5.000
Tw2 (F) (for either "Steam" or "HotWater") 210
PLR = fraction of Qng at which to calc new eff 0.5

Constants (for Natural Gas)

LHV = lower heating value (Btu/lb) 21,500
HHV = higher heating value (Btu/lb) 23,900
cpp = specific heat of products of exhaust (Btu/lb-F) 0.260
Tdpp = dew point temp of H20 in exhaust (F) 140
Afs = air/fuel mass ratio at stochiometric conditions 17.20

Calculated Values
Tw1 (F) = Tw2 for this calc since this calc assumes constant Tw 210
hr (Btu/lb) = heat of reaction = LHV if Tex > 140 else HHV 21,500
Tc (F) = temp combustion = Tca+hr/[(1+(1+EA)(Afs))cpp] 3,609
Effc = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex)/HHV 80.7%
Qu (Btu/h) = Useful heat transferred to water = Qng x 10^6 x Effc 4,035,399
dt1 (F) = Tc - Tw2 3,399
dt2 (F) = Tex - Tw1 223
dtlm (F) = (dt2-dt1) / ln(dt2/dt1) 1,166
R = (Tw1-Tw2)/(Tex-Tc) 0
P = (Tex-Tc)/(Tw1-Tc) 0.934391
F (0 to 1) = F(R,P) correction factor for tube-in-shell hotwater boilers 1.00
UA (Btu/h-F) = Qu / (F x dtlm) 3,461
mng (lb/h) = Qng x 10^6 / LHVng 233
mca (lb/h) = (1+ EA) x Afs x mng 5,200
mc (lb/h) = mng + mca 5,433
Tex,n (F) at PLR = Tw2-(Tw2-Tc)*exp(-UA/(mc*PLR*cpp)) (assumes const UA and Tw2) 235.29
Effc,n = [1 + (1+EA)(AFs)]*cpp*(Tc-Tex,n)/HHV 85.7%
Qu,n (Btu/h) = Useful heat transferred to water = Qng x PRL x 10^6 x Effc,n 2,143,311
Calculating Stack and Shell Losses For Idle Boiler

Input Data
Tsteam or Thotwater (F) = Ts 150
Diameter Boiler (ft) = Db 10
Length Boiler (ft) = Lb 20
Temp Boiler Skin (F) = Tb 80
Conv Coeff (Btu/h-ft2-F) = h 7
Temp Indoor Air (F) = Tia 65
Temp Outdoor Air (F) = Toa 50
Stack Height (ft) = Hs 30
Stack Diameter (ft) = Ds 3
Frac Time at Full Fire = PLR 0

Calculations
Area Boiler (ft2) = Ab = (3.14 x Db^2 / 4) + (3.14 x Db x Lb) 785
Skin Heat Loss (Btu/h) = Qsk = Ab (ft2) x h (Btu/h-ft2-F) x (Tb - Tia) F 82,425

Area Stack (ft2) = As = 3.14 x Ds^2 / 4 7.07

Off-Cycle Pres Diff = dP(lbm/s2-ft) = hs(ft) x 32.2 x 14.7 x (1/Toa-1/Ts) / 53.34 x 144 12
Off-Cycle Velocity (ft/min) = Vs = (2 x dP (lbm/s2-ft) / 0.07 lbm(ft3))^0.5 356
Off-Cycle Flow (ft3/min) = VFRs = Vs (ft/min) x 60 min/hr) x As (ft2) 2,515
Off-Cycle Stack Loss (Btu/h) = Qstoff = VFRs x 60 x (1-PLR) x 0.018 x (Ts x .9 - Tia) 190,153

Total Losses (Btu/h) = Ql = Qsk + Qstoff 272,578

PRL Eff Eff Norm exp(Y) ln(Y)
1 0.808 1 2.718282 0
0.9 0.822 1.017327 2.765791 0.017178
0.8 0.836 1.034653 2.814131 0.034067
0.7 0.847 1.048267 2.852704 0.047139
0.6 0.855 1.058168 2.881089 0.056539
0.5 0.86 1.064356 2.898973 0.06237 3.5
0.4 0.863 1.068069 2.909756 0.065853
0.3 0.864 1.069307 2.91336 0.067011 3
0.2 0.864 1.069307 2.91336 0.067011
0.1 0.864 1.069307 2.91336 0.067011 2.5

1.5

0.5

0
0 0.2 0.
3.5

2.5

2 Eff
Eff Norm
1.5 exp(Y)
ln(Y)
1

0.5

0
0 0.2 0.4 0.6 0.8 1 1.2
Calcs Eff Gain For On/Off to Modulate Control

Input Data
Rated Burner Input (MBtu/h) = Qb 21.00
Tsteam or Thotwater (F) = Ts 170
Excess Air = EA 0.3
Combustion Efficiency at Full Fire = Effc 0.850
Diameter Boiler (ft) = Db 10
Length Boiler (ft) = Lb 20
Temp Boiler Skin (F) = Tb 130
Conv Coeff (Btu/h-ft2-F) = h 7
Temp Indoor Air (F) = Tia 65
Temp Outdoor Air (F) = Toa 50
Stack Height (ft) = Hs 30
Stack Diameter (ft) = Ds 3
Frac Time at Full Fire = PLR 0.25
Num cycles per hour = N 6
Post-fire purge time (min) = PstP 1
Pre-fire purge time (min) = PreP 1
Annual Boiler Operating Hours (h/yr) = HPY 8,088
Cost of Natural Gas ($/MBtu) = CNG 5.50

Calculations
For On/Off Control
Area Boiler (ft2) = Ab = (3.14 x Db^2 / 4) + (3.14 x Db x Lb) 785
Area Stack (ft2) = As = 3.14 x Ds^2 / 4 7.07
mng (lb/hr) = Qb (MBtu/h) x 10^6 (Btu/MBtu) / 21500 (Btu/lbng) 977
ma (lb/hr) = mng (lb/hr) x 17.2 (lba/lbng) x (1+EA) 21,840
Off-Cycle Pres Diff = dP(lbm/s2-ft) = hs(ft) x 32.2 x 14.7 x (1/Toa-1/Ts) / 53.34 x 144 14
Off-Cycle Velocity (ft/min) = Vs = (2 x dP (lbm/s2-ft) / 0.07 lbm(ft3))^0.5 384
Off-Cycle Flow (ft3/min) = VFRs = Vs (ft/min) x 60 min/hr) x As (ft2) 2,711
Skin Heat Loss (Btu/h) = Qsk = Ab (ft2) x h (Btu/h-ft2-F) x (Tb - Tia) F 357,175
Purge Loss (Btu/h) = Qp = ma x (PstP+PreP)/60 x (1-PLR) x .26 x (Ts x .9 - Tia) 99,940
Off-Cycle Stack Loss (Btu/h) = Qstoff = VFRs x 60 x (1-PLR) x 0.018 x (Ts x .9 - Tia) 193,257
On-Cycle Stack Loss (Btu/h) = Qston = Qb x 10^6 x PLR x (1-Effc) 787,500
Total Losses (Btu/h) = Ql = Qsk + Qp + Qstoff + Qston 1,437,871
Total Heat Input (Btu/h) = Qin = Qb x 10^6 x PLR 5,250,000
Total Heat to Steam/Water (Btu/h) = Qu = Qin - Ql 3,812,129
Avg Efficiency (On/Off Control) = Qu / Qin 0.726
For ModulationControl
Skin Heat Loss (Btu/h) = Qsk 357,175
Combustion Efficiency at PLR = Effcpl = Effc + .055/.75 x (1-PLR) 0.905
Total Heat Input (Btu/h) = Qinm = (Qu + Qsk) / Effcpl 4,606,965
On-Cycle Stack Loss (Btu/h) = Qstonm = Qinm x (1-Effcpl) 437,662
Total Losses (Btu/h) = Qlm = Qsk + Qstonm 794,837
Total Heat to Steam/Water (Btu/h) = Qum = Qinm - Qlm 3,812,129
Avg Efficiency (Modulation Control) = Qum / Qinm 0.827
Savings
Total Gas Savings (Btu/h) = Qsh = Qin - Qinm 643,035
Total Gas Savings (MBtu/yr) = Qsy = Qsh x HPY / 10^6 5,201
Total Gas Savings ($/yr) = Qsy x CNG 28,605
Off-Cycle Pres Diff = dP(lbm/s2-ft) = hs(ft) x 32.2(ft/s2) x 14.7psi x (1/Toa-1/Ts)(1/R) / 53.34(lbf-ft/lbm-R) x 144(in2/ft2)

Based on published curves

-R) x 144(in2/ft2)