Boiler Steam and Hot Air Generation

What is Thermal System
Energy Conservation in Steam Generation and Distribution

D D Ananda Namal
Fuel System Generation System Distribution System Utilization System
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA
Fuel Sub System

Correctly Designed & Maintained Can be solved many problems Can be burnt efficiently
Fuel
What is fuel ? Fuel Classification Solid, Liquid, Gas Calorific Value (Heat Value, Heat of combustion) MJ/kg, MJ/m3,MJ/Lit
Main Components
Storage tanks Storage yards Pipes Pre Heaters Pumps Strainers Gauges
Calorific Value Firewood 18.5 MJ/kg of dry wood Saw dust 17.5 MJ/kg (Dry) Diesel 43.7 MJ/kg Furnace Oil (Medium) 43.4 MJ/kg Furnace Oil (Heavy) 42.5 MJ/kg Density Diesel 0.86 kg/lit Furnace Oil (Medium) 0.94 kg/lit Furnace Oil (Heavy) 0.95 kg/lit
Combustion
What is Combustion ? Reaction with Oxygen to Produce Heat
Fuel + Air Combustion Product + Heat
Mixing of fuel and air is very important
Fuel Combustion
C + O2 H2 + O2 C + O2 CO2 + 32,800 kJ/kg
H2O + 142,000 kJ/kg CO + 9300 kJ.kg
Theoretical Air Supply Reduced air & Excess Air Correct amount of Air
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA
Fuel Combustion Excess Air

Fuel Loss Less retention time Reduced Temperature
Recommended Excess Air Level
Fuel Combustion Reduced Air

Partial Combustion Emit CO Un Burnt C particles
C + O2 Gas Burners 10 15% Oil Burners 15 20 % Fire Wood - 40 50% C + O2
CO2
+ 32,800 kJ/kg
CO + 9300 kJ.kg
Efficient Combustion Fuel Combustion Factors Affecting Liquid Fuel Combustion Air-Fuel Ratio Viscosity Fuel Pressure Atomization Particle Size 20 - 40 m Small Escape without burning Large Incomplete combustion
There should not be any combustibles in Combustion Product
Combustion Efficiency (CE)

CE = CO2 CO2 +CO
Where CO2 = Concentration of CO2 CO = Concentration of CO

Fuel Handling
Fuel Storage Fuel Preparation
Fuel Storage
Why Do We Store fuel ?
Minimize Supply Risk Minimize production Damage Facilitate to prepare fuel
Main Tank Day Tank

Bulk Storage Daily Consumption
Water Mixed With oil

Main Tank
Oil Outlet Drain Valve
Trace of water can mix with oil Oil oxidized when water present Problems Flame off Unstable Flame Oil wastage due to slow burning Difficult to Ignite Heat loss due to Latent heat Corrosion and Nozzle blockage
Can Store Two Week Consumption Slope in direction of Drain Valve - to Foot Minimum installation height of outlet = 3
Use Wet Firewood

Day Tank Daily requirement Should have level indicator Insulate if heated Installed at a High level if heated
Installation of Strainers
Bowser
10 Mesh
Oil Preheating
20 Mesh
Main Tank
Day Tank
Prevent Dirt entering Clean Regularly

60-100 Mesh
Based on Viscosity Oil to be heated When Storage Pumping Before entering to the Burner Use Steam for oil pre heating Heated oil Line Should be insulated
Burner
40 Mesh Pre Heater
Oil Preheating (Contd)
Generation System
Oil Type Light Oil Medium Oil Heavy Oil
Class E F G
Storage Pumping Atomizing Temp (oC) Temp (oC) Temp (oC) 10 25 40 10-12 30-35 35-60 60-70 82-104 116-127
Steam Hot Water Thermic Oil Hot Air Direct Heat
E n e r g y i n t o
W A I R
Sensible Energy In Water Sensible & Latent Energy in Air (S&LE Air) Sensible Energy in Fuel (SE Fuel)
Boiler Energy Flow

mwCp,w(Tw-Ta)
E n e r g y i n t o
W SE Water A I S&LE Air R SE Fuel
SE Water S&LE Air
SE Water Radiation Loss (openings) Radiation E Absorbed By body Sensible Energy In Combustion Gases
Boiler Energy Flow

Radiation Loss Surface SE Water Energy In Steam
SE Fuel
SE = maCp,a(Ta-Ta) LE = mw(ha-ha)
t F h U e
E S L
y s t e m
Chemical Energy in Fuel (CE Fuel)
mfCp,f(Tf-Ta)
t F h U e
mfCvf
S L y s t e m
CE Fuel
Energy Release At Combustion
Energy absorbed By Water
Latent Ene. (H2O) vapor LE Flue gas
Blowdown
Flue gas SE Flue gas CE in Losses Partial Combustion Combustion Products CE Flue gas Un burnt FuelN A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Boiler
Water Air Fuel Blow down loss
Stack Loss Steam Boiler Surface Loss Efficiency () = 1 Losses Indirect method = heat gain by steam Heat release by fuel Direct Method
Furnace/Kiln
Fuel Air Stocks Supports Exhaust Products Supports Surface Structure
Energy Balance
Stack Loss - 12 15 % Surface Loss 0.5 2 % Blowdown loss 1-2 %
Energy Balance
Stack Loss - 40 60 % Surface Loss 0.5 2 % Product Sensible Losses 2-10 %
Flue Gas Loss (Stack Loss)

Excess Air 15 20 % Flue gas temperature. - Recommended Steam Temp + 25oC - increase due to Scale and Shoot - Minimum 160 oC (Sulfur in fuel) CO Incomplete Combustion Unburnt C -
Flue Gas Analysis
O2, CO2, CO, Temperature, Recommended O2. - Liquid fuel 3-4 % - Gases 2 - 3 Stack loss can be read from charts
Heavy Oil
Firewood
Reduce Flue Gas Loss

Reduce Excess Air Properly tune burners Control Air dampers Reduce leaks Control Exhaust Temperature Clean tubes Remove scales Mix Fuel and Air Properly Correct amount of fuel Use small Size Create turbulence
Clean Tubes
Clean Combustion Chamber
Keep Space for Combustion
Create Turbulence
Reduction of Surface Losses
Radiation Losses through Furnace Surface
Radiation Losses through Openings
Acceptable temperature of outside surface Temperature inside oC 1300 1100 900 700 Outside Surface Temperature oC Ceiling 140 125 110 90 Side Wall 120 110 95 80
Blow down Losses

To control the TDS and remove sludge High BD rate Energy loss due to loss of steam Low BD rate Energy loss due to scaling Rate depend on the boiler Pressure
Type Pressure Psi TDS ppm 3500 4000 3500 2000-1400 1400 -1000
Blow down Losses

% BD = TDS of Feedwater TDS of Boiler water TDS of Feedwater
Effect of Boiler Blowdown Rate
3.5 3
% Fuel Wastwd
2.5 2 1.5 1 0.5 0 0 1 2

3.6 barg
Fire Tube package Up to 300 Water Tube Up to 200 201-600 601 900 901 -1100
4
7 barg
6
10 barg
8
14 barg
10
% Blowdown
Blow down Quantity

% BD (Required)= TDS of Feedwater X % makeup water Maximum recommended TDS
Waste heat Recovery

From Flue Gas Hot Product Condensate Blowdown Flash Steam For Water pre heating Combustion air preheating In put material pre heating Fuel pre heating
BDF methods (Intermittent)
(Automatic) (Manual)
(Automatic) (Continuous) (Manual)

Feed Water Preheat Combustion Air Preheat

Effect of Combustion Air Preheat
7 6
Efficency Improvement %
Effect of Preheat of Boiler Feed Water

12
Efficiency Improvement %
10 8 6 4 2 0 0 10 20 30 40 50 60
Advantage of high temp FW Energy Savings Reduced DO level and associated cost savings Maintain Design Boiler output Reduced thermal shock
5 4 3 2 1 0 0 20 40 60 80 100 120 140 160 180
Preheat Temperature C
Pre heat temperature C
Blow down Heat Recovery
Efficient Steam Generation - Summary

Combustion Control Correct Air/Fuel ratio Insulation Boiler, FW tank, Lines Preheat combustion air Pre heat feedwater Condensate recovery Correct BD rate Steam to oil preheat BD heat recovery Correct Boiler capacity Waste heat recovery
Energy Recovery = 87% of BD heat Water Recovery = 14 % by mass of BD water

Blow down Heat Recovery
Distribution System
Energy Recovery = 87% of BD heat Water Recovery = 14 % by mass of BD water

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA
Good Steam Distribution System

Good quality - No Water, No Air, No Dirt, Right pressure Correct Quantity Minimum cost Maintenance, Energy loss, Leaks, Capital Easy Operation - Good isolation, Easy access, Better working environment
Reduced effective diameter
No Water
K 60 to70 times steel
Poor heat transfer More Sensible Less heat content portion High Pressure Drops Erosion and Corrosion Water hammer
Longer time for heating Required high pressure
Steam 20-35 m/s, Water < 2 m/s
Increased Energy Loss
Causes of Wet Steam

Boiler carry over Poor insulation Inadequate drainage Water Accumulation
K 1500 times steel
No Air
Causes of Air
Poor heat transfer With feed water Reduced Temperature Steam shut off vacuum Delay in start up @Condensation Cold spot Chemical Treatment Uneven temperature Corrosion Partial Pressure
Pipe Sizing
Avoid over sizing/under sizing. Over sized piping is more expensive
Cost of insulation, supports and fittings The 3" pipe has 50% more external surface than 2" pipe. Heat loss will therefore be 50% greater and there will be 50% more Condensate in the pipe needing removal.
Insulation of Bare Surfaces

All the bare surfaces such as steam lines, valves, flanges etc. should be insulated properly.
Under Sized piping

Unable to supply required Quantity Erosion Pressure drops
1 m length of bare 2" pipe carrying steam of pressure of 150 psi can waste 350 lit of fuel oil per annum or Rs 15,000 per annum.
Advantages of Insulation
Reduced Heat Loss Personal Safety Better working environment Improved labor productivity Minimizing Condensate forming in the pipe works and hence reduce risk of water hammer
Insulation Thickness
Insulation thickness depend on
Cost of Insulation Material Cost of Heat Loss Economic Thickness Has to be find
Economic Thickness - Insulation

Total Cost Cost Heat Loss Cost Insulation Cost Thickness
Tables are available to find insulation thickness with surface temperature
Insulate Valves and Fittings

Valve = 1 m of Pipe Flange = 0.5 m of Pipe
Installation of Insulation
cover with AL foil or sheet
To reduce radiation To prevent damage To prevent Get wet
Ends should be Covered Properly Seem should correctly done
Installation of Steam Pipes.

Steam lines should be supported and anchored at proper intervals and locations in order to prevent sagging.
Installation of Steam Pipes Contd.

Steam lines should be arranged with a fall in the direction of flow A fall of around 40 mm to 10m (1/2" to 10 ft) is adequate

In steam lines condensate should be drained at regular intervals Drain points should be formed in average of intervals of 100 - 150 ft. Lines. should also be drained at any low point where condensate can collect.
Drain points should be constructed Properly
Drain points should be constructed Properly
Installation of Steam Pipes Contd. Branch Connection

No Water Collection pockets

Correctly install strainers

At the point of steam usage the use of a strainer should be considered
Allowance for Expansion

Provision should be made for expansion
Allowance for Expansion

Expansion Fittings Should installed Correctly
Stop Steam Leak

Live steam leaks through holes, faulty valves, joints etc. will loss steam considerably in a steam system. Apart from loss of energy, the loss of valuable treated water has to be considered As an example steam of pressure 150 psi leaks through 3mm hole will loss about 30kg of steam per hour
Pressure Selection
Depending on the Temperature, Heat Transfer rate Low pressure steam content High Latent heat Use lowest possible pressure
Pressure Reduction
Low pressure steam occupying a large volume and therefore to distribute low pressure steam required large pipes and fittings. Pipe lines should be designed to distribute high pressure steam and the pressure should be reduced at the point of usage
Pressure Reduction
Pressure Reduction
Condensate Recovery Contains about 25% of Energy Good Quality Water Savings in Water and Chemical
Utilization System
Maintain Correct Process Parameters Temperature Pressures Flow rates
Dryers Heaters Heat Exchangers Pans Radiators
Calibrated Gauges
Process parameters Use steam at lowest possible pressure

TEMPERATURE P4 P3 P2 P1 P4 P1
Efficient Steam Distribution - Summary

Correct Pipe Sizing Correct pipe aligning Correct water removal Correct supporting Correct insulation Air removal Use of flash steam Correct steam trapping Prevent leaks Correct isolation
POINT OF SATURATED WATER
POINT OF DRY SATURATED STEAM

ENERGY
What is Steam
Properties of Steam
Properties of Steam
Temperature of Steam 200 Tem perature o C
7 8 9 10
Heat Content of Steam

3000 2500 2000 1500 1000 500 0
0 1 2 3 4
150 100 50 0 0 1 2 3 4 5 6 7 8 9 10 Pressure Barg

k J /k g
Latent Heat
Sinsible Heat
Pressure -Barg
Properties of Steam
Specific Volume of Steam
STEAM UTILATION
Process Heating Power Generation Shaft Power Application Ejector Pumps and Vacuum Creation Cooling
2.0 1.5 m 3/k g 1.0 0.5 0.0 0 1 2 3 4 5 6 7 8 9 10 Pressure - Barg

STEAM UTILATION
What need in Process Heating ?
STEAM UTILATION
Why Steam Used ?
Heat - MJ Temperature - 0 C
Steam Vs Hot Water High heat Content (Latent & Sensible)

@ 10 barg ,188 o C Hot Water 798.8 kJ/kg Steam 2784.8 kJ/kg
STEAM UTILATION
Why Steam Used ?
Steam Used for Process Heating

Direct Indirect
Heat Release at Constant Temperature

Boiler Steam and Hot Air Generation

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Boiler Steam and Hot Air Generation

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What is Thermal System

Energy Conservation in Steam Generation and Distribution

Fuel System Generation System Distribution System Utilization System

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Fuel Sub System

Mixing of fuel and air is very important

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

H2O + 142,000 kJ/kg CO + 9300 kJ.kg

Fuel Combustion Excess Air

Fuel Combustion Reduced Air

C + O2 Gas Burners 10 15% Oil Burners 15 20 % Fire Wood - 40 50% C + O2

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

There should not be any combustibles in Combustion Product

Combustion Efficiency (CE)

Where CO2 = Concentration of CO2 CO = Concentration of CO

Main Tank Day Tank

Bulk Storage Daily Consumption

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Water Mixed With oil

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Use Wet Firewood

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Prevent Dirt entering Clean Regularly

Oil Preheating (Contd)

Oil Type Light Oil Medium Oil Heavy Oil

Steam Hot Water Thermic Oil Hot Air Direct Heat

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Boiler Energy Flow

W SE Water A I S&LE Air R SE Fuel

SE Water S&LE Air

Boiler Energy Flow

Chemical Energy in Fuel (CE Fuel)

Energy Release At Combustion

Energy absorbed By Water

Latent Ene. (H2O) vapor LE Flue gas

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Flue Gas Loss (Stack Loss)

Flue Gas Analysis

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Reduce Flue Gas Loss

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Clean Combustion Chamber

Keep Space for Combustion

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Reduction of Surface Losses

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Radiation Losses through Furnace Surface

Radiation Losses through Openings

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA

Blow down Losses

Blow down Losses

2.5 2 1.5 1 0.5 0 0 1 2

N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11 SEA / JICA / SLEMA