FORM No.
009/0
TECHNICAL DATA SHEET Chap-I Sheet 2 of 7
1.0 GENERAL DATA
Owner M/s. EMPEE SUGARS & CHEMICALS LTD.
Project Co-Generation Project
(100% Bagasse , 80 % Imported coal based
Traveling Grate Cogeneration Boiler)
Ambasamudram
Tamil Nadu
Consultant M/s. Aqua therm Engineering Consultant (I) Pvt. Ltd .
Job No. JB0732
IWT No. 6219
Boiler Type Single Drum, Water tube, Membrane wall,
Natural circulation, Balanced draught, Top
supported, Outdoor, Traveling Grate boiler
Suitable for firing 100% Bagasse , 80% Imported
coal .
Installation Outdoor
Design Code IBR 1950 and its latest amendments upto Jan 2008
No. of boilers Two
2.0 DESIGN BASIS
Net Steaming capacity at MCR(Kg/hr) for Bagasse firing 135,000
Steam Pressure at main steam stop valve (Kg/cm2)(g) 109
Peak capacity of Boiler (Kg/hr.) 148,500
Minimum possible duration for peak capacity /Shift (8 hrs) 30 minutes
Minimum stable operating load 40500
Steam temperature at super heater outlet (Deg.C) 540 +/-5
Steam temperature control range 60-100%
Boiler design pressure 128.5 Kg/cm2(g)
Feed water temperature at De-aerator outlet and 130 °C / 210 °C
economizer inlet (operating)
De-aerator operating pressure 2.75 Kg/cm2(a)
De-aerator design temperature 150 °C
Dissolved oxygen in feed water (max.) 0.007 ppm
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
FORM No.009/0
TECHNICAL DATA SHEET Chap-I Sheet 3 of 7
Ultimate Fuel Analysis % by mass provided by the Purchaser
Elements Bagasse Imported Coal
Ultimate Analysis % weight % weight
Carbon 23.5 55.45
Hydrogen 3.25 5.49
Oxygen 21.75 10.76
Nitrogen 0 1
Sulphur 0 0.3
Ash 1.5 7.0
Moisture 50 20
GCV Kcal/ Kg 2272 5200
Gas temperature leaving air heater 150°C
Dust content in flue gases leaving the dust collection
100 mg/[Link].m.
system
The above guarantee is based on 35°C ambient temperatures, 60 % relative humidity and feed water inlet to
economizer temperature of 210°C.
[Link] DATA
3.1 Electrical system
LT distribution system
Voltage 415V ± 10%
Type 3 Phase , AC supply
Frequency 50 HZ± 5%
Control & Instrumentation
Voltage 220
Type 1 Phase
Frequency 50HZ
3.2 Compressed Air (Instrument air)
Pressure 7 Kg/cm2
Temperature Ambient
Dew Point -40°C
3.4 Cooling Water
Temperature 34 °C
Pressure 3.0 Kg/cm2
3.5 Auxiliary Steam
Deaerator auxiliary Steam Pressure (Kg/cm²g) 2.0
Temperature (0C) 138
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
FORM No.009/0
TECHNICAL DATA SHEET Chap-I Sheet 4 of 7
4. SITE DATA
Design Ambient Temperature 50°C(Electrical Design),
35°C(Performance Design)
Relative humidity (Design) 60 %
Basic Wind Velocity 136.8 km/h (As per IS: 875 standards).
Elevation from mean sea level 40 m above M.S.L
Wind Direction SW – NE
5. GEOGRAPHICAL DATA
Plant Location Ambasamudram,Tamil Nadu
Nearest Railway Station Thirunelveli
Nearest Airport Madurai
6.0 PERFRMANCE DATA
100 % MCR Bagasse 80% MCR Imported
6.1 Heat losses & Thermal Efficiency (%) Unit
coal.
Unburnt Carbon loss % 1.1 4.0
Dry gas loss % 4.63 5.07
Fuel moisture loss % 13.85 2.4
Hydrogen moisture loss % 8.06 5.91
Air moisture loss % 0.18 0.21
Radiation loss % 0.37 0.39
Unaccounted loss % 0.2 0.2
Manufacturer’s Margin % 0.61 0.53
Total % 29 18.71
Boiler Thermal Efficiency % 71 81.3
Unit 100 % MCR Bagasse. 80% MCR Imported
6.2 Temperature Profile
coal.
Data Data
6.2.1 Air Temperature Profile
Air heater inlet °C 38 38
Air heater outlet °C 206 181
6.2.2 Gas Temperature Profile Unit 100 % MCR Bagasse. 80% MCR Imported
coal.
Entering Superheater. °C 834 816
Leaving Superheater. °C 508 471
Entering Evaporator °C 501 464
Leaving Evaporator °C 420 392
Entering Economiser. °C 420 392
Leaving Economiser °C 263 244
Entering Air pre heater. °C 263 244
Leaving Air pre heater. °C 150 140
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
FORM No.009/0
TECHNICAL DATA SHEET Chap-I Sheet 5 of 7
6.2.3 Water Temperature Profile Unit 100 % MCR Bagasse. 80% MCR Imported
coal.
Economiser Inlet °C 210 210
Economiser Outlet °C 294 275
6.2.4 Steam Temperature Profile Unit 100 % MCR Bagasse. 80% MCR Imported
coal.
Entering 1st Stage Superheater. °C 319 319
Leaving 1st Stage Superheater . °C 453 434
Entering 2nd Stage Superheater. °C 432 433
Leaving 2nd Stage Superheater . °C 540 540
Entering 3rd Stage Superheater. °C NA NA
Leaving 3rd Stage Superheater . °C NA NA
6.3 PRESSURE PROFILE
Unit 100 % MCR Bagasse. 100% MCR Imported
6.3.1 Air Pressures at :
coal.
FD fan outlet. mmwc 160 120
SCAPH inlet mmwc NA NA
SCAPH Otlet mmwc NA NA
Air heater inlet. mmwc 128 96
Air heater outlet. mmwc 45 34
Grate air plenum. mmwc 35 25
SA fan inlet. mmwc 20 15
SA fan outlet. mmwc 603 564
6.3.2 Flue Gas Pressures at :
Furnace outlet. mmwc -5 -3
Superheater inlet. mmwc -5 -4
Superheater outlet. mmwc -15 -9
Evaporator inlet. mmwc -15 -9
Evaporator outlet. mmwc -30 -17
Economiser inlet. mmwc -30 -17
Economiser outlet. mmwc -72 -40
Air heater Inlet. mmwc -107 -59
Air heater outlet.. mmwc -147 -81
ESP inlet. mmwc -161 -89
ESP outlet. mmwc -200 -111
Chimney inlet mmwc +10 +6
6.3.3 Steam side Pressure drop Unit 100 % MCR Bagasse. 80% MCR Imported
coal.
1st stage superheater Kg/cm2 3.15 2.90
2nd stage superheater Kg/cm2 4.80 3.20
3rd stage superheater Kg/cm2 NA NA
Desuperheater Link Kg/cm2 0.5 0.33
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
FORM No.009/0
TECHNICAL DATA SHEET Chap-I Sheet 6 of 7
6.3.4 Drum Pressure
Pressure Unit
Drum operating pressure at MCR Kg/cm2g 118.8
Drum design pressure Kg/cm2g 128.5
6.3.5 Gas Velocity (Average)
100 % MCR Bagasse. 80% MCR Imported
Locations Unit
coal.
Combustion chamber. m/s. 5.6 4
Superheater zone. m/s. 5 3.40
Evaporator. m/s. 5.52 3.71
Economiser m/s. 8.42 5.7
Air pre heater. m/s. 11.46 7.65
6.3.6 FLOW DATA
Description Unit 100 % MCR Bagasse. 80% MCR Imported
coal.
Steam flow at MS line Kg/hr. 135000 108000
Total air flow Kg/hr. 195868 169532
FD air flow Kg/hr. 117521 101719
SA air flow Kg/hr. 78347 67813
Fuel flow Kg/hr. 51506 15720
Flue Gas flow Kg/hr. 246443 183747
6.4 HEAT TRANSFER AREAS
6.4.1 PROVIDED HEATING SURFACE AREAS (IBR ) .
Zone Units AREA
Furnace
Front wall. m² 673.0
Rear wall. m² 663.0
Sidewall. m² 623.0
Evaporator m² 1116
Economizer m² 2841.0
Total heating surface area excluding forced flow m² 3075.0
6.4. 2. EFFECTIVE HEATING SURFACE AREAS.
Zone Units AREA
Primary Super heater m² 1822
Secondary Super heater m² 587
Air heater-I m² 3110
Air heater-II m² 3110
Evaporator m² 1063
Economizer m² 2811
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
FORM No.009/0
TECHNICAL DATA SHEET Chap-I Sheet 7 of 7
6.5 ASH DATA
6.5.1. Bottom Ash:-
Description Units 100% MCR Bagasse 80% Imported Coal
At boiler MCR Ash handling design At boiler Ash handling design
MCR
Front Ash Kg/hr. 238 466 828 1054
Riddling Kg/hr. 39 84 135 225
6.5.2 Fly Ash:-
Description Units 100% MCR Bagasse 80% Imported Coal
At boiler MCR Ash handling design At boiler Ash handling design
MCR
Air heater Kg/hr. 47 94 75 150
ESP Kg/hr. 550 1304 377 1506
6.6 WATER QUALITY REQUIREMENT:
6.6.1 Boiler Water Quality : Unit Data
Silica ppm 2.5
PH @ 25°C 9.5-10.5
Total Hardness ppm Nil
Dissolved O2 ppm Not Traceable
Total Dissolved solids ppm 100
Free Residual Phosphate(Max) ppm 20
Copper, Iron, Co2 Oil and Free chlorine ppm Nil
Permanganate (max) ppm Nil
Total Suspended solids ppm 5
Specific electrical Conductivity at 25°C Microsiemens 200
after degassing (max) / cm
6.6.2 Boiler Feed Water Quality : Unit Data
PH at 25°C 8.5 - 9.2
Suspended solid ppm 0.1
Iron, Copper, Co2 & Free chlorine ppm Nil
Total Hardness ppm Nil
Total dissolved solids ppm Nil
Silica ppm 0.02
Oil, Organic Matter etc. ppm Nil
Oxygen ppm 0.007
Residual hydrazine.(max) ppm 0.02
Permanganate (max) ppm Nil
Specific Electrical Conductivity at 25°C Micro 0.2
after degassing in Siemens/cm
Project: M/s. EMPEE Sugars & Chemicals ltd.
Job No : JB0732 Rev. No.: 0
1 X 135 TPH Travelling Grate Boiler
