A Seminar on

Energy Assessment of Boilers

Guided By :
Dr. S. K. Mohapatra Senior Professor and Dean of Academic Affairs, Thapar University, Patiala
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Submitted By:
Mitesh Kumar 801183013 M.E(Thermal Engg.)

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Contents:
Introduction Assessment of a boiler Literature review Conclusion

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Introduction What is a Boiler?

Vessel that heats water to become hot water or steam At atmospheric pressure water volume increases 1,600 times Hot water or steam used to transfer heat to a process

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Introduction
STEAM TO PROCESS
EXHAUST GAS VENT

STACK

DEAERATOR

PUMPS

ECONOMIZER

VENT BURNER

BOILER
BLOW DOWN SEPARATOR

WATER SOURCE

FUEL
BRINE CHEMICAL FEED

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SOFTENERS

Schematic overview of a boiler room

Types of Boilers What Type of Boilers Are There?

1. 2. 3. 4. 5. 6. 7.

Fire Tube Boiler Water Tube Boiler Packaged Boiler Fluidized Bed (FBC) Boiler Stoker Fired Boiler Pulverized Fuel Boiler Waste Heat Boiler

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Assessment of a boiler Boiler performance

Causes of poor boiler performance

Poor combustion Heat transfer surface fouling Poor operation and maintenance Deteriorating fuel and water quality

Heat balance: identify heat losses Boiler efficiency: determine deviation from best efficiency

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Assessment of a Boiler Heat Balance

An energy flow diagram describes graphically how energy is transformed from fuel into useful energy, heat and losses
Stochiometric Excess Air Un burnt

F U E L IN P U T

Stack Gas S T E A M O U T P U Ash and Un-burnt T parts of Fuel in Ash

Convection & Radiation

Blow Down

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Assessment of a Boiler Heat Balance

Balancing total energy entering a boiler against the energy that leaves the boiler in different forms

12.7 % 8.1 %

Heat loss due to dry flue gas Heat loss due to steam in fuel gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss

100.0 % Fuel BOILER

1.7 % 0.3 % 2.4 % 1.0 %

73.8 %

Heat in Steam

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Assessment of a Boiler Heat Balance

Goal: improve energy efficiency by reducing avoidable losses
Avoidable losses include:
-

Stack gas losses (excess air, stack gas temperature) Losses by unburnt fuel Blow down losses Condensate losses Convection and radiation

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Assessment of a Boiler Boiler Efficiency

Thermal efficiency: % of (heat) energy input that is effectively useful in the generated steam

The energy gain of the working fluid (water and steam) is compared with the energy content of the boiler fuel.

The efficiency is the different between losses and energy input

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Assessment of a Boiler Boiler Efficiency: Indirect Method

Efficiency of boiler ( ) = 100 (i+ii+iii+iv+v+vi+vii)

Principle losses:
i) Dry flue gas ii) Evaporation of water formed due to H2 in fuel iii) Evaporation of moisture in fuel iv) Moisture present in combustion air v) Unburnt fuel in fly ash vi) Unburnt fuel in bottom ash vii) Radiation and other unaccounted losses
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Assessment of a Boiler Boiler Efficiency: Indirect Method

Required calculation data

Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content) % oxygen or CO2 in the flue gas Fuel gas temperature in C(Tf) Ambient temperature in C(Ta) and humidity of air in kg/kg of dry air GCV of fuel in kcal/kg % combustible in ash (in case of solid fuels) GCV of ash in kcal/kg (in case of solid fuels)

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Assessment of a Boiler Boiler Efficiency: Indirect Method

Advantages

Complete mass and energy balance for each individual stream Makes it easier to identify options to improve boiler efficiency

Disadvantages

Time consuming Requires lab facilities for analysis

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Literature review

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Tanetsakunvatana, et al[2006]

q2 Heat loss with the waste gas (%) q3 Heat loss by incomplete combustion (%) q4 Heat loss owing to unburned carbon (%) q5 Heat loss owing to radiation and convection (%) 5/25/12

Table 2 : Load at 6: 287 Mw 7: 249 Mw 8: 200 Mw

Table 3: LHV of Fuel: 8.08-11.85

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Lu, et al[2008]

Results :

Boiler efficiency is close to the assurance efficiency by manufacturer Dissipated heat loss 0.63% instead of 0.25%

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Gupta, et al[2011]
Results of efficiency test -1

Observations and recommendations:

Coal preparation and handling Excess air Soot blower operation Blowdown Insulation

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Results of efficiency test -2 Results :

Improved boiler efficiency 1% gain from excess air control 444.6 ton per annum coal saving Total monetary gains of Rs 34,12,395 per annum

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Conclusion:
Energy Efficiency opportunities
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Stack temperature control Feed water preheating using economizers Combustion air pre-heating Incomplete combustion minimization Excess air control Avoid radiation and convection heat loss Automatic blow down control Reduction of scaling and soot losses Reduction of boiler steam pressure Variable speed control Controlling boiler loading Proper boiler scheduling Boiler replacement

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References:
V. Tanetsakunvatana , V.I. Kuprianov,2007: Experimental study on effects of operating conditions and fuel quality on thermal efficiency and emission performance of a 300MW boiler unit firing Thai lignite, Fuel Processing Technology 88 (2007) 199 206

J. Y. Lu, X. F. Lu, G. Yin, H. Z. Liu,2008: Heat balance Analysis of BAIMAs 300 MW CFB boiler in China

Rahul Dev Gupta, Sudhir Ghai, Ajai Jain,2011: Energy Efficiency Improvement Strategies for Industrial Boilers, Journal of Engineering and Technology ,Jan-Jun 2011,vol. 1, issue 1

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www.manufacturing.energy.gov U.S. Department of Energys Advanced Manufacturing Office (AMO) www.beeindia.in Bureau of energy efficiency, a statutory body under ministry of power, government of India 2008 ASHRAE Handbook of HVAC Systems and Energy Description: Complete guide to steam systems design and equipment. Energy Efficiency Manual, Author: Donald R. Wulfinghoff Steam Plant Calculations Manual, Author: V. Ganapathy
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ASME-EA-32009 Energy Assessment for Steam Systems

Description: A detailed technical protocol for consistently conducting steam system assessments of highest quality.

www.plantsupport.com

Steam System Specialist Level OneTraining Manual

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Thank you

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