5 Steam Star Super Plus

Corporate Communication.
Copyright Transparent Energy Systems Pvt. Ltd. All rights reserved

1
Natural Gas fired Steam Boiler
94 % Thermal Efficiency on GCV of NG
104 % Thermal Efficiency on NCV of NG
What is GCV of fuel
Any fuel contains constituents like C, H, O, S, N, H
2
O ( Water /
moisture) etc. in different proportion.
Combustion of combustibles like C, H, S etc. releases energy due
to exothermic nature of process.
Ratio of total energy ( kcal ) release due to combustibles to unit
mass ( kg ) of fuel is called as Gross Calorific Value ( GCV ).
GCV is expressed in kcal / kg
2
What is NCV of fuel
Combustion of H present in fuel forms H
2
O, which remains in flue gas. --------------M1
Moisture/water present in fuel evaporates and remains in flue gas. ------------------M2
Combustion air carries moisture, which evaporates and remains in flue gas.--------M3
M1 +M2 +M3 =Total water vapour present in flue gas.-------------------------M Total
Evaporation of M Total & to go to flue gas temperature requires energy, which is
taken from gross energy release during combustion.
Generally, the gas is never cooled less than its due point. As a result, heat carried
away by water vapour in the flue gas dose not become available for useful purpose.
Hence, GCV heat carried by water vapour =NCV of fuel.
NCV is also expressed in kcal/kg.
3
What is NCV of fuel
(contd)
It is customary to calculate thermal efficiency of fuel fired heaters on NCV of
fuel basis, since heat carried by water vapour is any way not available for heat
transfer. It is only NCV, which is available for heat transfer in heaters.
Hence,
4
Steam Boiler
Energy Supplied
Fuel Quantity X NCV
A
Heat carried by steam B
Heat carried by flue gas
Losses
Thermal Efficiency on NCV =B / A
Thermal efficiency on GCV
(Condensing Boiler)
In a Steam Boiler (which constitutes Evaporator +Economiser +Water
Preheater +Air Preheater etc.), when the flue gas is cooled uptoless than its
due point (57
o
Capprox.), the water vapour present in flue gas condenses
while releasing its latent heat of condensation.
This latent heat gets transferred to cooling medium i.e. feed water or
combustion air (depending upon design).
As a result, this latent heat becomes available and comes back to Steam
Boiler system.
Hence,
Thermal Efficiency on GCV =B/A
Energycarried by Steam B
Energycarried by flue gas
Losses
Steam
Boiler
Energy input
Fuel Qty. X GCV
A
Properties of Natural Gas
Composition (approx.)
Methane - 90 %
Ethane - 5.8%
Propane - 2.5 %
Butane - 0.5%
Pentane & Hexane - 0.3 %
Carbon Di Oxide - 0.5 %
Nitrogen - 0.4 %
Density 0.74 kg/SM
3
GCV 9500 kcal/SM
3
NCV 8570 kcal/SM
3
Condensing Boiler on Natural Gas
Natural Gas offers following benefits
The lowest flue gas due point
Highest water content in flue gas
Highest pH value of flue gas condensate (2.8 to 4.9)
(Condensate of FO/LDO/HSD are much more acidic)
Flue gases are extremely clean (free from Soot & Sulphur)
Combustion
Air
Schematic : The Condensing Boiler
C
H
I
M
N
E
Y
89%
95%
With Air preheater 98 %
With Water preheater 104 %
8
Condensing
Section
89% heat
absorption
Thermal Efficiency improvement (on NCV of fuel)
Air pre heater
or Feed Water
pre heater
Economizer
Fuel
Boiler
Steam
out
Make up water
HMBD with Water preheater
9
Sr. No Parameters at location * Unit Steam Condensate of 80
0
C
%Condensate 0 25 50 75 100
%Make up water 100 75 50 25 0
1 Flue gas outlet temperature Deg. C 44 44 52 57 100
2 Thermal Efficiency on GCV of Natural Gas % 94 94 91 88 86
3 Thermal Efficiency on NCV of Natural Gas % 104 104 101 98 96
Economizer
Water preheater
*
DA Tank
Evaporator
Combustion
Air
Fuel in
Thermal
Efficiency
89 %
Thermal
Efficiency
95 %
Steam Condensate return
from process
HMBD with Water preheater
CondensingBoiler with Waterpreheater
Unit Steam Condensate of 80
0
C
Sr. No. Parameters
%Condensate Qty 0 25 50 75 100
%Make up Water
Qty
100 75 50 25 0
1
Boiler Capacity
(F&A 100 deg.C)
kg/hr 1000 1000 1000 1000 1000
2
Actual Steam Generation from Serial No. 5 deg.
C at 10.54 bar(g)
kg/hr 851 869 886 905 924
3 Condensate Qty at 80 deg. C kg/hr 0 217 443 679 924
4 Make up Water Quantity at 30 deg. C kg/hr 851 651 443 226 0
5
Feed water temp. after Mixing condensate and
Make up Water
deg. C 30
0
C 43 55 68 80
6
Feed water temp. after WPH Outlet ( i.e. from
30 deg. C)
deg. C 87 104 102 101 80
7
Feed water temp. at inlet of DA Tank after
mixing with Condensate and WPH Water
deg. C 87 98 91 85 80
8 Thermal Efficiency on GCV of Natural Gas % 94.1 94.1 91.3 88.6 86.8
10 Flue Gas Outlet Temp. at Outlet of WPH deg. C 44 44 52 57 100
11 Water Condensate Quantity from Flue Gas kg/hr 51.7 51.70 27.60 0.00 0.00
10
HMBD with Air preheater
11
Economizer
Air preheater
*
Evaporator
Combustion
Air
Fuel in
Thermal
Efficiency
89 %
Thermal
Efficiency
95 %
Steam Condensate return
from process
FD Fan
Make up water
Sr. No Parameters at location * Unit Steam Condensate of 80
0
C
%Condensate 0 25 50 75 100
%Make up water 100 75 50 25 0
1 Flue gas outlet temperature Deg. C 57 57 57 57 57
2 Thermal Efficiency on GCV of Natural Gas % 88 88 88 88 88
Steam out
HMBD with Air preheater
12
CondensingBoiler with Airpreheater
Steam Condensate
Sr. No. Parameters
%Condensate Qty 0 25 50 75 100
%Make up Water Qty 100 75 50 25 0
1
Boiler Capacity
(F&A 100 deg.C)
kg/hr 1000 1000 1000 1000 1000
2
Actual Steam Generation from Serial No. 5 deg. C at
10.54 bar(g)
kg/hr 851 869 886 905 924
3 Condensate Qty at 80 deg. C kg/hr 0 217 443 679 924
4 Make up Water Quantity at 30 deg. C kg/hr 851 651 443 226 0
5
Feed water temp. after Mixing condensate and Make up
Water
deg. C 30
0
C 43 55 68 80
6 Combustion Air Outlet temp. from Airpreheater deg. C 101 101 101 101 101
7 Thermal Efficiency on GCV of Natural Gas % 88.5 88.5 88.5 88.5 88.5
8 Thermal Efficiency on NCV of Natural Gas % 98 98.0 98.0 98.0 98.0
9 Flue Gas Outlet Temp. at Outlet of WPH deg. C 57 57 57 57 57
10 Water Condensate Quantity from Flue Gas kg/hr 0 0 0 0 0
1 TPH f&a100 Boiler with Air Preheater
13
SAVING POTENTIAL BY USING TRANSPARENT MAKE CONDENSING BOILER
S.N. Parameter TESPL Make TESPL make Other Make
Condensing Steam
Boiler
Condensing Steam
Boiler
Steam Boiler
1 Thermal Efficiency on NCV (%) 98 95 92
2 Boiler Capacity (kg/hr) (f&a100) 1000 1000 1000
3 Heat Output (kcal/hr) 5,40,000 5,40,000 5,40,000
4 Heat Input (kcal/hr) 5,51,020 5,68,421 5,86,956
5 Fuel Natural gas Natural Gas Natural gas
6 Net Calorific Value (kcal / SCM ) 8500 8500 8500
7 Fuel Consumption in SCM/hr 64.82 66.87 69.05
8 Fuel Savings SCM/hr for NG 4.22 2.17 0.00
9 Annual Working Hours 8000 8000 8000.00
10 Annual Fuel Savings SCM/year for NG 33,729 17,415 0.00
11 Present Cost of Fuel Rs/SCM for NG 20 20 20
12 Annual Savings (Rs/year) as per present fuel cost Rs.6.8Lac / Yr Rs.3.48Lac / Yr 0.00
13
Average fuel cost (Rs/lit or Rs./SCM) over 15 years of life
(considering 10% increase per year)
42 42 42
14 Working hours for 15 years 15 Yrs 15 Yrs 15 Yrs
15
Savings in fuel cost over 15years of life of equipments
(CroresRs.)
Rs.2.13Crore Rs. 1.1Crore 0
Condensing boilers offered by TESPL
Designed for options of 0 % to 100 % condensate return from process.
Complete condensing Section is made of Stainless Steel
o Casing - SS 304
o Tubes- SS 304
o Drain valve Internals - SS 304
Flue gas condensate can be collected in a small tank of SS or FRP construction
for neutralization & disposal.
Condensing section can be bypassed by divertor valve & feed water bypass
line, in case of fuel shift from NG to FO/LDO/HSD.
Heating Surfaces are easy for maintenance, cleaning & repairs
14
Option I With Water Preheater Option II With Air Preheater
Accessories
External Structure Supported, Carbon steel with internal FRP lining or Stainless
Steel chimney confirming to IS 6533
Flue gas condensate transfer pump with level control
Flue gas condensate neutralization tank (FRP lined or stainless steel.)
Neutralized condensate discharge pump ( optional)
Pressurized fully automatic DA tank to remove dissolved oxygen from feed water
by steam preheating & without dozing of chemicals
Automatic continuous chemical dozing system.
15
Need for Pressurized DeareatorTank
In the Boiler without Economizer, feed water directly enters into Boiler /
Evaporator. Oxygen present in feed water instantly separates at operating
temperature of boiler (184
0
C approx), comes into steam space and goes out
with steam. This causes minimal corrosion due to oxygen.
In the Boiler with Economizer, feed water enters the Economizer first and
gradually heats up to 100
0
C approx. before entering Evaporator. This results
into gradual separation of oxygen from feed water. This oxygen sticks inside
Economizer tubes and corrodes tube internal surface.
In Atmospheric DeareationTank, feed water is heated up to 90
0
C approx.,
which results into 99% oxygen separation. This water is good enough for
Boiler without Economizer.
16
Need for Pressurized DeareatorTank
contd
Pressurized Deareator Tank heats up feed water at 105
0
C. This results into
oxygen separation upto99.9 %. This feed water becomes suitable for entering
into Economizer.
Balance oxygen in feed water is removed by chemical dosing. Pressurized
Deareator Tank drastically reduces dependency on the level of accuracy of
chemical dosing.
Hence, Pressurized deareator Tank is a must for Boiler with Economizer.
17
Chimney options
External Structure Supported Chimney is much more advantageous over Self
Supported Chimney.
Chimney is designed as per IS 6533
Supporting structure is designed as per IS 800
Design wind velocity as per IS 875 Part III
Chimney duct material options
o Carbon Steel duct with intenal FRP lining.
o Stainless Steel duct of 2 mm thickness
Supporting Structure material Carbon Steel
18
Advantages of Externally structure supported
Chimney over Self Supported one
The chimney is cylindrical with lower wall thickness. The chimney is supported
by an external carbon steel structure.
It is easily supported by external CS Structure uptothe top to take care of
wind loads and ease of maintenance.
The chimney is made from pieces 6m long for ease of transportation.
It is light in weight as compared to self supported chimney. Hence
transportation and erection is quite easy.
No need of heavy foundations. Cost of civil foundation work is lowest.
The ladder can be inside the structure giving better safety for personnel.
Chimney can be easily painted from outside due to supporting structure.
In case top piece falls down due to corrosion, it falls within external structure,
avoiding major accident.
19
Chimney-Comparison
Sr.
No.
Parameter Conventional,
Self
Supported
Carbon Steel duct
with internal FRP
Lining
Stainless Steel duct
1
Acidcorrosion
resistance
Low High High
2
Corrosion
allowance
Needed Not needed Not needed
3
Weight Heavy Light Light
4
Transportation/
erection
Difficult Easy Easy
5
Initial cost High Low Medium
6
Maintenance /
Painting
Difficult Easy Easy
7
Foundation VeryHeavy Light Light
20
External Structural Supported Chimney
21
Performance Tests
Thermal Efficiency measurement as per BS 845 Part I
BS 845 Part II
Third party verifications offered for efficiency & output
Petroleum Conservation & Research Association (PCRA)
Any other competent agency of repute
22
Performance measurement instrumentation
Continuous on line real time measurement and recording of
o Flow measurements with totalization - Steam, Feed Water, Fuel,
Fuel gas condensate ( optional)
o Temperatures Steam
Feed water inlet to economizer
Feed water inlet to boiler
Water inlet to deareator tank
Flue gas temperature at boiler outlet, economizer outlet &
water preheater outlet
Water inlet & outlet to water preheater
o Pressure Steam pressure on Evaporator
Economizer inlet feed water
Water preheater inlet & outlet
o Oxygen Oxygen content in flue gas
23
PCRA Test Certificates
24
Past achievements of Transparent in Oil &
Gas fired Boilers
Sr.
No
Description Fuel Model Year of
introduction
1 93% efficient instant Steaming
Boiler
Oil / Gas STEAMPACK 1985
2 93% efficient Thermal Oil Heater Oil / Gas FLUIDTHERM 1985
3 93% efficient Smoke Tube Boiler Oil / Gas STEAMSTAR 1989
4 95% efficient Smoke Tube Boiler Oil / Gas STEAMSTAR 1996
5 98% super efficient SteamBoiler Gas STEAMSTAR 2010
6 102%super efficient Steam Boiler Gas STEAMSTAR -
SUPERPLUS
2010
25
TESPL is first in India to introduce -
26
Thank You for your attention
TRANSPARENT ENERGY SYSTEMS PVT. LTD.
PushpaHeights, Bibwewadi Corner,
PUNE,
INDIA
Tel. No. : +91 20 24211347 / 24215665
Fax : +91 20 24212533
Email : trans@pn2.vsnl.net.in,
projectsales@tespl.com
Website: www.tespl.com

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Corporate Communication.

Copyright Transparent Energy Systems Pvt. Ltd. All rights reserved

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