Calculations of fuel on the basis of steam means it is one of the parts of inventory control. For proper inventory control, the organization is complete knowledge about how much amount of fuel required and based on that decide the margin money for working capital.
That is how much extra fuel keeping the side for better working so this article gives information about how to calculate the amount of fuel required, which factors are responsible for the steam generation and how to increase steam generation capacity with less time.
The vapor into which water is converted when heated, forming a white mist of minute water droplets in the air.
Material such as coal, gas, or oil that is burned to produce heat or power.
So following factors in which steam generation which is to be taken place
1- Fuel calorific value
the amount of energy produced by complete combustion of a material or fuel. Here the different fuel which has different calorific value.
|Fuel name||Fuel calorific value(Kcal/kg)|
During selection of fuel select most suitable for your process. Means during burning of coal you are burning pure carbon but in the case of wood burning wood is primarily cellulose which is complex sugar containing carbon hydrogen and oxygen so as compared to wood better steam generation takes place in coal So based on that your required fuel calorific value select fuel and based on your fuel selection steam generation taken place.
2- Output Pressure
The generally steam which is measured in the bar means pressure. So based on that your output pressure with the help of steam table calculate the specific enthalpy of steam in (Kcal/kg)
|Output pressure in bar||Specific enthalpy of steam(Kcal/kg)|
Means as your output pressure decreases then more amount of steam generated with per kg consumption of fuel.
3- Feed Water Temperature
The steam generation this is also mostly dependent on feed water temp. Suppose your feed water temp. is more, then more amount of steam generated within less time.
So that based on to that whatever steam condition as you want during process consider or if you want to make something arrangement then nowadays boiler is coming with modification in that preheating arrangement means water is hot before converted into steam so due to that more amount of steam generated within less time.
4- Boiler Efficiency
The boiler is that main part of the steam generation. But how much steam generated this is dependent upon efficiency. Generally boiler efficiency which is in between 75 to 80 %.
So following example how to calculate fuel consumption on the basis of steam.
Boiler Efficiency = [Steam (output pressure in bar- feed water temperature)]/(Fuel calorific value)
Boiler efficiency=75 % i.e. 0.75
Output pressure= 10 bar (664 from steam table value)
Feed water temperature =35 degree Celsius
Fuel is wood
Fuel calorific value=2500 Kcal/kg
Steam = [fuel calorific value * boiler efficiency] / (Output pressure in the bar- feed water temperature)
= (2500*0.75) / (664-35)
= 2.98 kg
It says that if you are burning 2500Kcal/kg wood with boiler efficiency is 0.75 and feed water temp. is 35 then you will get 2.98 kg of steam.
Generally in sizing department steam required is dependent on your production. Generally per kg of your yarn production 2.5kg steam required for sizing process.
Consider your per hour production is 194.5
= 486.25 kg of steam/hour
Fuel Consumption/Hour= (Steam Consumption/Hour)/(Steam produced/kg of wood)
= 486.25 / 2.98
Consider 14% losses taken place due to that starting of the boiler and less fuel calorific value.
Whatever fuel consumption is coming adding 14 % extra due to losses takes places.
Cost of wood/kg= 3 RS
Cost of fuel/hour = 222.45*3
The following table shows how much steam required/kg of different processing
|Pressure kier scouring||1.5|
|Open kier scouring &bleaching||0.7|
|Jigger scouring & washing||1.0|
|Jigger dyeing+ washing(reactive/vat/sulfur dyes)||2.0|
|Stenter (drying + finishing)||2.0|
|Felt calendar ( wet process)||1.0|
How To Increase Steam Generation With Less Time
1-Means during working the steam as we are calculated this will not get in actual because during working losses take places so that first analyze which losses take place. So following are the points to the reduction of losses.
Find out the leakage present on machine and pipelines if leakage is small make arrangement to loss of steam otherwise replace whole assembly or pipe. Due to leakage generated steam is going to waste because it cannot gives useful results and due to that leakage more amount of fuel consumption takes place and steam reduction takes place. To avoid these things correct the where leakages took place.
2-Proper Storage Of Fuel
The fuel should be stored in dry atmospheric condition. Why because to keep the value of fuel caloric value as it is. If it is stored in moist condition the amount of moisture present in wool increases and due to that increasing reduction in fuel calorific value and hence less amount of steam is generated and more amount of fuel consumption taken place hence to avoid this less steam and more fuel consumption it is better way to storage of it in dry atmospheric conditions.
3- Preheating Arrangement
Suppose your feed water is generally 27 to 30 degree Celsius but due to that less temperature less amount of steam generated within less time so that increasing feed water temperature before converted in to the steam making preheating arrangement like solar preheating due to use of this technology in boiler the feed water temperature is made 70 to 80 degree Celsius due to this more amount of steam generated within less time. And the reduction in the cost of fuel consumption.
So steam generation capacity mostly depends upon fuel calorific value, feed water temperature, output pressure, boiler efficiency. While changing the fuel calorific value, making preheating development and increasing boiler efficiency we can generate more amount of steam with less time.