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Sr.no. Observations and recommendations

1 Thermal Efficiency of the thermic fluid heater observed is 78.27 %.This is
comparatively towards lower side. Definitely its possible to enhance thermal efficiency
practically upto 86 % From the Flue gas analysis, observed CO2 % is upto 11.84 %.To
run thermic fluid heaters on higher combustion efficiencies i.e upto 88 to 90 % ,kindly
maintain CO2% inbetween 12 to 14 %. Lower percentage of Carbon dioxide in flue
gases indicates incomplete combustion of the fuel burned or inadequate supply of
stoichiometric oxygen (air) demand for complete combustion of unit volume of fuel.

2 From the running parameters of the Thermic Fluid heater it clears that Delta T
observed is 18 Deg.cen.For to get maximum output through heaters, Delta T should
achieve inbetween 18 to 24 Deg.cen.

3 Monitoring of Thermic fluid heater combustion efficiency on daily basis like checking of
Oxygen, Carbon dioxide and excess air percentage in the THF exit flue duct with the
help of portable fyrite instrument. Basically through Fyrite instrument we can measure
CO2% in the flue gas. From this measured CO2%,we can calculate the oxygen
percentage and excess air percentage in flue gas.

4 For better combustion in Thermic fluid heater, following parameters to be maintained,

a) Oxygen percentage in flue gas is in range of 2 to 5 %.

b) Carbon dioxide percentage in flue gas is in range of 10 to 14 %.

c) Excess air percentage is in between 10 to 20 % for liquid fuel fired Thermic fluid
heaters

5 Actual heat given by combustion of diesel in thermic fluid heater is 1596989 kcals/hr.

6 Heat taken by the thermic fluid supply to plant is 1250122 kcals/hr.

7 There are two possible reasons for not giving rated output of thermic fluid heater,
1) Demand load is more. and 2) Due to oil carbonization takes place inside the
thermic fluid transfer pipelines and hence no rise in Delta T across the Coil. Detailed
study is required for complete demand side analysis.

8 By Enhancement in EFFECTIVENESS of Thermic fluid Heater i.e increase in thermal
efficiency upto 86 %, we can definitely save diesel a lot.
Savings in rs.19.63 kg/hr x 24 hr x 350 days x rs.47.52 per lit x 0.40 = Rs.31,
34,267.13 /- (AED 1,64,961.42 /-) per annum.