Ergun Software for Boilers

A Simple and Intelligent Tool for Design of Boilers and Steam Generators

The software offers the following features:

1. Calculation of combustion and heat transfer efficiencies in accordance with AFNOR and PTC4.1 reception protocols.
2. Tools for evaluation of LHV and HHV (lower and higher heating values), Combustion test (flue gas composition for a given air excess) and mean Cp calculator (see Tools for more information)
3. Optimization of heat transfer system by PINCH technology (minimizing heat exchangers surfaces).
4. Design configuration (choice and placement of Superheaters, Reheaters and/or Wing Walls and External Heat Exchangers).
5. Choice of number of cyclones
6. Minimization of stack loss
7. Calculation of bed dimensions

 Unlike other simulation programs Ergun software does not work as a "Black Box". The program is designed to offer an "open work space". This means that the user's considerations are interactively involved in the project. After each step of calculation the results are presented in simple but useful diagrams and the user is invited to check the results obtained and to revise data if desired.

This interactive "Dispatching" of the global design procedure includes three simple steps that let the user to dynamically participate to the design project and to bring (in many cases) his own touch of design.

The main challenge in a Boiler Design project is always to reduce the construction costs while respecting the process specifications and environmental considerations. “Ergun  for Boilers” software makes possible to study rapidly the effect of each of the system parameters on the design characteristics.

Here is a sample of lines from a typical "Result File" :

RESULTS SUMMARY
=====================================
Flue gas composition in vol.%
O2 = 3.277E+00
N2 = 7.342E+01
CO2 = 1.437E+01
H2O = 8.935E+00
SO2 = 2.396E-04
CO = 2.985E-02
NO = 0.000E+00
NO2 = 0.000E+00
Ar = 8.598E-03

Design configuration & Efficiencies
====================================
Optimized design configuration: SH1/SH2-RH
Limiting step: Pinch between T_Eco_in and T_EA
Combustion Efficiency = 97.78
Boiler Efficiency (LHV basis) = 76.42
Boiler Efficiency (HHV basis) = 69.88

Flow rates
====================================
(C): Fuel feed rate (kg/s) = 1.710E+01
(A): Air feed rate Dry (kg/s) = 1.297E+02
(A): Air feed rate Humid (kg/s) = 1.314E+02
(C): Fuel feed rate (kg/s) = 1.710E+01
(C): Lime feed rate (kg/s) = 4.853E-01
(D): Steam flow rate (kg/s) = 9.720E+01
(K): Fly ash flow rate (kg/s) = 3.013E+00
(N): Flue gas flow rate (kg/s) = 1.460E+02

Heat duties
====================================
(B): Bed Boiler total heat duty (MW) = 1.420E+02
(B): Water walls heat duty (MW) = 1.420E+02
(B): Wing walls heat duty (MW) = 0.000E+00
..................................... Etc.

Resulted s team production scheme:

Ergun Boilers / Features

Example of some cyclone placement as a function of gas flow rate and bed dimensions.

Results are always presented in simple and comprehensible graphics adapted to each configuration.

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