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Investigation of Overall Efficiency Improvements and Saving Opportunities

for an Industrial Boiler

Conference Paper · April 2018

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 Investigation of Overall Efficiency
Improvements and Saving Opportunities
for an Industrial Boiler
Erhan Kayabasia*, Enes Kılınça, Rahman Çalhanb, Ahmet Cananc,
Abdulsamed Tabakc, Zafer Şahind, Kamil Arslana, Mehmet Özkaymakc,
Mehmet Özalpa

aDepartment of Mechanical Engineering, Faculty of Engineering, Karabuk University, Karabuk, Turkey.

*erhankayabasi@karabuk.edu.tr
bDepartment of Environment Engineering, Faculty of Engineering, Karabuk University, Karabuk, Turkey.
cDepartment of Energy Systems Engineering, Faculty of Technology, Karabuk University, Karabuk, Turkey.
dPower Plants Manager, Kardemir A.Ş., Karabuk, Turkey.

Abstract Fossil fuels commonly used in factories to provide heat

In this study, energy efficiency and saving opportunities
of an industrial boiler with a capacity of 100 t/h, were
investigated. Firstly, exhaust gas oxygen flowrate, flue
gas temperatures, fresh and preheated air speed,
temperature and pressure and fuel flowrates were
measured. In addition, all pipe network and surface of
the boiler were scanned by thermal camera to
determine total heat loss from the system. After the
measurements, energy and mass balance was
constituted by theoretical and real combustion
calculations in order to obtain the boiler energy
efficiency and energy saving potential. Consequently,
considerable energy and saving potential were
determined and some recommendations were noted
for the facility management in order to provide a
significant efficiency improvement, lower fuel
consumption, lower emissions and operating cost.
Keywords: Energy saving, combustion, steam boiler,
efficiency.
1. Introduction
Boilers are pressured steam tanks utilized for heating
water or producing steam to provide heating facility in
industries for electricity generation by driving steam
turbines for many of applications [1, 2]. Nearly 40% of
the world’s power is, obtained by boilers combusted
with pulverized coal and operated by steam turbines on
Rankine cycle [3–5]. A boiler design needs to be
validated in practice to be sustainable and reliable, and
the tenderer have to represent other installations
performed before already in operation. Boilers and
auxiliary equipment should be designed and erected in
accordance with the latest edition of section I of the
American Society of Mechanical Engineers (ASME)
boiler and pressure vessel code, including all published
[2].
and some electricity are varying in the amount of acid
gas they produce [2, 6]. Natural gas contains a very
limited quantity of Sulphur, while fuel oils can contain
up to 3% Sulphur. However, some fuels content such
as coal change from one region to other. In design and
arrangement of boilers some critical points must be
taken into account such as ease of operation, safety,
inspection, maintenance, repair, and cleaning [2].
Several fuel sources were used to heat boilers such as
wood, coal, oil, or natural gas. [2]. However, fossil fuels
such as coal, gas, oil etc., and nuclear energy, are
being used to generate most of world's electricity
demand and in general boilers are outstanding way to
convert these types of energy sources into electric
energy [7]. Therefore, efficiency improvement of a
steam boiler even though with a small potion, will
remove a large amount of energy consumption in
electricity [1, 5]. So, maximization of heat transfer to
the water and minimization of heat losses in the boiler
must be the main objectives. Heat can be lost from
boilers by a variety of methods, including hot flue gas
losses, radiation losses and, in the case of steam
boilers, blow-down losses [7].
That is because boilers are high cost energy
production units with the initial investment costs and
high operating expenses, a boiler must be selected
properly for its usage and periodical maintenances
must be performed to prevent unwanted and un
expected work breaks. In selection of a boiler, the main
principles such as determining of the operation
purpose, manufactured steam amount, pressure and
temperature, the inlet temperature of feed water,
hardness of water, type of fuel, lower heating value of
fuel and its analysis, and fuel cost must be taken into
consideration [8].
In this study a general energy efficiency inspection and
possible saving opportunities were investigated in
terms of the objectives mentioned above. According to
the measurements and calculations, present operating
conditions of the power plan was determined and
compared with the design parameters of boiler.
Regions causing efficiency loses were determined and
efficiency improvements options were recommended.
2. Experimental and Method
Gas analysis, velocity and temperature measurements
were performed to determine the energy saving
potential of OPG-3 steam boiler of Kardemir Power
Plant. Mass and energy balances were established
using measurement data (temperature, pressure,
velocity, gas analysis). Moving from the mass and
energy balances, the efficiency in the steam boiler, the
areas of potential savings and the size of savings are
calculated.
In this study velocity, pressure and temperature
measurements were made for the flow energy balance
between the inlet and outlet of the boiler and the "inlet
air heater" inlet and outlet, and the existing meter flow
rates on the system were read in steam boiler. Values
from current counters (after confirming correctness) are
used in calculations. Boiler system was schematically
shown in Figure 1. The coal used as fuel for the
campaign was taken from the control room for coke
gas, blast furnace gas information. In order to obtain
the elemental analysis values of the coal sample
required to establish the energy and mass balance, the
coal sample fed to the boiler during the measurement
was taken and the elemental analysis of this coal
sample was carried out in the Mine Investigation and
Research Center (MTA). Using the obtained analysis
results (coal, coke oven and blast furnace gas) and
flow rates, the components and the components of the
combustion products were calculated. The calculated
values were also checked by the gas analysis,
pressure, speed and temperature measurements at the
boiler outlet and chimney exit.
Figure 1. General arrangement of boiler system in
Power Plant.
The water used, and the steam generated are taken
from the existing meters in the system. For analysis of
flue gas and boiler outlet gas, "TESTO 350" brand gas
analyzer operated by electro chemical detector method
was used. The speed and pressure values of the flue
gas are measured by the speed probe of this device
and the flue gas flow rate is calculated. After the
measurement of the flue gas feeds, the boiler
combustion gas flow rate is calculated by making use
of the percentage of flue output O2 and the O2
percentages measured at the boiler output. The
amount of leaking air was found by removing the boiler
combustion gas from the flue gas. If there is too much
leaking air; The amount of leaking air was found by
subtracting 10% of the combustion air.
According to TS4041, two methods can be used
directly or indirectly in the boiler heat recovery
calculation. In the first method: feeding water and
steam flowrates, temperature and pressures of feed
water and intermediate steam, fuel feed rate or
quantity, lower heating value of the fuel should be
measured. With the help of these measured values, the
boiler yield is determined by this equation.
(1)
Where, mb is measured steam flow (kg/h), ms is
measured water flow (kg/h), hb is steam enthalpy
(kcal/kg), hs is feed water enthalpy (kcal/kg), my is
measured fuel flow (kg/h) Hu is lower heat value of fuel
(kcal/kg).
In the indirect method, the thermal efficiency is
determined by following equation.
:1-z (2)
Here z (in%) indicates various thermal losses. In this
method: Flue gas analysis (temperature, velocity,
pressure, gas analysis in flue gas), burning air
temperature and temperature are measured, boiler
outer wall temperatures are measured, the amount of
bluff is determined, the lower temperature value of the
fuel is determined by elemental analysis.
Specific amount of air and specific amount of flue gas
are determined according to these measurement
results. Later, theoretical specific air volume,
theoretical specific amount of flue gas, excess air
coefficient, actual specific air and flue gas amount, flue
gas heat loss rate, ratio of incomplete combustion loss
(loss of work is usually found by taking advantage of
dust emission), the amount of unburned fuel loss,
percentage of bluff loss and the thermal efficiency is
calculated depending on them. The main factors that
affect productivity in boilers are: incomplete
combustion, air-fuel ratio heat loss due to water vapor
in the flue gas, flue gas temperature, fuel type, burners,
boiler load, heat losses from the boiler surface, heater
surface contamination.
3. Results and Discussion
3.1. Measurements and Calculation
The measured values before and after the steam boiler
rotary air heaters (Luvo) and the fuel consumptions are
given in Table 1. The results of analysis of coal, blast
furnace gas and coke gas fed to the boiler are given in
Table 2, Table 3 and Table 4, respectively.
 Table 1. Measured values before and after rotary air heaters and fuel flowrates.

Number Three Steam Boiler

O2 (%) Temp. (oC)
Exhaust Gas Before Left Luvo 2.56 312
Exhaust Gas After Left Luvo 8.86 126.7
Exhaust Gas Before Right Luvo 2.37 318
Exhaust Gas After Right Luvo 8.27 144.2
Coal Quantity (kg/h) 4400
Coke Gas (Nm3/h) 2200
3
Blast Furnace Gas (Nm /h) 26000

Table 2. Elemental analysis values of coal sample (% wt).

LHV HHV
Fuel C. C H N S O Ash Moist.
(kcal/kg) (kcal/kg)
Dry
67.95 3.86 1.47 0.84 8.49 15.79 - 6.452 6.658
base
Org.
60.61 3.45 1.31 0.73 7.57 13.79 12.65 5.562 5.815
base

Table 3. Blast furnace gas analysis values (% wt).

LHV HHV
Fuel C. CO2 CO H2 N2
(kcal/Nm3) (kcal/Nm3)
Orig.
14.98 23.08 1.39 60.55 733 739
base

Table 4. Coke gas analysis values (%wt).

LHV HHV
Fuel C. CO2 C2H4 O2 CO H2 CH4 C2H6 N2 H2S Inert
kcal/Nm3 kcal/Nm3
Org.
1.75 0.55 0.57 5.94 60.35 21.31 1.61 6.59 0.39 0.94 3.970 4.488
base

Combustion gas analyzes were carried out using fuel quantities, boiler combustion gas oxygen percentage and
elemental analysis of the fuel, and the results are given in Table 5, Table 6 and Table 7.

Table 5. Elemental analysis of coal combustion products and flow rates.

Coal Combustion Products (Nm3/h)
Fuel C. % (ob) Stoc. O2 CO2 SO2 N2 Ar H2O O2 Other
C (%) 60.61 4978.10 4985.23 0.00 18553.23 220.98 435.55 0.00 2.38
H (%) 3.45 850.08 1.22 0.00 3168.22 37.74 1774.54 0.00 0.41
N (%) 1.31 0.00 0.00 0.00 46.11 0.00 0.00 0.00 0.00
S (%) 0.62 19.10 0.03 19.10 71.17 0.85 1.67 0.00 0.01
O (%) 7.57 -233.1 0.00 0.00 -868.9 -10.3 -20.4 0.00 -0.11
Ash (%) 13.7 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Moist. (%) 12.6 0.00 0.00 0.00 0.00 0.00 692.66 0.00 0.00
Sum (%) 100 5614.12 4986.47 19.10 20969.77 249.22 2884.02 0.00 2.68
Excess Air 1.17 0.00 3041.31 36.22 71.40 816.03 0.39
Gas C. % (ob): 15.08% 0.06% 72.59% 0.86% 8.93% 2.47% 0.01%

Table 6. Blast furnace gas analysis, flowrates and analysis of combustion products.
Combustion Products (Nm3/h)
Fuel Analysis % (ob) Stoc. O2 CO2 SO2 N2 Ar H2O O2 Other
CO2 14.98 0.00 3894.8 0.00 0.00 0.00 0.00 0.00 0.00
CO 23.08 3000.4 6005.1 0.00 11182. 133.19 262.5 0.00 1.43
H2 1.39 180.70 0.26 0.00 673.46 8.02 377.2 0.00 0.09
N2 60.55 0.00 0.00 0.00 15743 0.00 0.00 0.00 0.00
Inert 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Sum 100.0 3181.1 9900.1 0.00 27598.8 141.2 639.7 0.00 1.52
Excess Air 1.54 0.00 3999.35 47.64 93.89 1073.08 0.51
Gas C. % (ob): 22.76 0.00 72.64 0.43 1.69 2.47 0.00
 Table 7. Analysis of coke gas, analysis of combustion products and flowrates.
Fuel Combustion Products (Nm3/h)
Fuel Analysis % (ob) Stoc. O2 CO2 SO2 N2 Ar H2O O2 Inert Other
CO2 (%) 1.75 0.00 38.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00
C2H4 (%) 0.55 36.30 24.25 0.00 135.29 1.61 27.38 0.00 0.00 0.02
O2 (%) 0.57 -12.54 0.00 0.00 -46.74 -0.56 -0.56 0.00 0.00 -0.01
CO (%) 5.94 65.34 130.7 0.00 243.52 2.90 5.72 0.00 0.00 0.03
H2 (%) 60.3 663.85 0.95 0.00 2474.1 29.47 1385.7 0.00 0.00 0.32
CH4 (%) 21.3 937.64 470.1 0.00 3494.5 41.62 1019.6 0.00 0.00 0.45
C2H6 (%) 1.61 123.97 71.02 0.00 462.03 5.50 117.11 0.00 0.00 0.06
C2H2 (%) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H2S (%) 0.39 12.87 0.02 8.58 47.97 0.57 9.71 0.00 0.00 0.01
N2 (%) 6.59 0.00 0.00 0.00 144.98 0.00 0.00 0.00 0.00 0.00
Inert (%) 0.94 0.00 0.00 0.00 0.00 0.00 0.00 0.00 20.68 0.00
Sum (%) 100 1827.43 735.6 8.58 6955.7 81.12 2564.8 0.00 20.68 0.87
Excess Air 0.42 0.00 1083.1 12.90 25.43 290.6 0.00 0.14
Gas C. % (ob): 6.25 0.07 68.24 0.80 21.9 2.47 0.18 0.01

Total stoichiometric combustion gas, theoretical Air and Flue Gas Flowrates
combustion air, excess air, theoretical total combustion Theoretical Exhaust Gas (Nm3/h) (ob) 77.760
air and boiler exhaust gas emissions and excess air Theoretical Combustion Air (ob) 51.634
ratio are calculated using the components of Table 5, Excess Air 10.595
Excess Air Boiler Outlet Exhaust Gas Flowrate 88.355
Table 6 and Table 7 and are given in Table 8. The
Air entering to Boiler (Nm3/h) 62.229
calculated values are also measured at the exit of the Excess Air Coefficient 20.52%
chimney, to ensure accuracy.
Using the measurement results and the calculated
Table 8. Boiler burning gas, theoretical combustion air, values, the energy balance for the boiler is established
excess air flow and ratio. and given in Table 9.

Table 9. Boiler energy balance.

Flowrate
O2 Temp. Cp (kcal/kg.
Inputs (kg/h Q (kcal/h) %
(%) (°C) kcal/Nm3 K)
Nm3/h)
Coal
4400 6452 28388800 37.11
(combustion heat)
Coal
4400 100 0.900 396000 0.52
(sensible heat)
Blast Furnace Gas
26000 733 19058000 24.91
(combustion heat)
Blast Furnace Gas
26000 50 0.326 423540 0.55
(sensible heat)
Coke Gas
2200 3970 834000 11.42
(combustion heat)
Coke Gas
2200 25 0.328 18024 0.02
(sensible heat)
Burning air
62229 21 262.3 0.323 5271622 6.89
(sensible heat)
Water 83600 170 1 14212000 18.58
Total 76.501985 100
Flowrate Cp
Temp.
Outputs (kg/h. O2 (kcal/kg. Q (kcal/h) %
(C)
Nm3/h) kcal/Nm3 K)
Steam 80000 65.336.000 85.40%
Boiler Exhaust Gas 88355 2.47 315.00 0.359 9.983.316 13.05%
Losses
(surface heat. 1.182.669 1.55%
air humidity. bluff. etc.)
Total 76.501.985 100
Steam boiler efficiency was calculated by using steam For calculation of leakage air loss of rotary air heaters,
flowrate, enthalpy values of steam and water, and total the values of coal, blast furnace gas and coke gas
fuel heat, and the results were given in Table 10. analysis values and flue gas composition before and
after rotary air heaters were used and the results are
Table 10. Boiler energy efficiency. given in Table 11.
Boiler Efficiency
Table 11. Rotary air heater leaking air quantities.
Steam flowrate (mb) 80 000 kg/h
Steam input enthalpy (ib) kcal/k Luvo Outlet Oxygen Ratio 8.86%
816.7
g Total Boiler Outlet Exhaust Gas Flow (Nm 3/h) 44.406
Water inlet enthalpy (is) kcal/k Left
170 Total Rotary Heater Outlet Gas Dispenser
g Luvo 68.290
(Nm3/h)
Enthalpy difference (ib-is) kcal/k Leakage Air Amount (Nm3/h) 23.884
646.7
g
Luvo Outlet Oxygen Ratio 8.27%
The heat supplied to the water (Qs = mb(ib- 51 124
kcal/h Total Boiler Outlet Exhaust Gas Flow (Nm3/h) 43.952
is)) 000 Right
Total Rotary Heater Outlet Gas Dispenser
Total fuel heat (Qy) 57 018 Luvo 65.015
kcal/h (Nm3/h)
364
Overall efficiency (Qs/Qy) 89.66% Leakage Air Amount (Nm3/h) 21.063

3.2. Potential saving opportunities
One of the most significant savings potential seen in
boilers with a rotary air heater is leakage air losses in
the rotary air heater. In rotary type air heaters, it is
practically impossible to completely prevent the amount
of leakage air. However, a leak in the boiler
combustion air up to a maximum of 10% of the air flow
is acceptable. The amount of leakage air loss can
easily be determined by O2 measurements made at
the boiler outlet and the flue gas outlet. Leakage airflow
over specific heat of the gas, the flue gas and ambient
temperature was calculated using the energy loss and
saving potential and the results are presented in Table
12.

Table 12. The amount of savings to be achieved by avoiding leakage air loss.
Saving Amount to be Obtained by Avoiding Leakage Air Loss
Leakage air gas flowrate(Nm3/h) 44.948
Combustion air flowrate (Nm3/h) 62.229
Acceptable leakage rate (Nm3/h) 6.223
Excess leaking air flow (Nm3/h) 38.725
Burner air temperature after oven (oC) 262.35
Ambient temperature (oC) 42.00
cp (after rotary air heater) (kcal/Nm3 K) 0.323
cp (at ambient temperature) (kcal/Nm3 K) 0.311
Energy saving (kcal/h) 2.774.183
Annual boiler operating time (h) 6.823
Annual energy saving (kcal) 18.928.249.030

In order to determine the surface losses in the boilers,
the entire boiler surface was scanned with the thermal
camera and weakly insulated areas were
photographed and photographed. In addition to the
problematic areas, thermal photographs taken for
information are also given in this section. If the weakly
insulated areas specified in the thermal photos are
strengthened, it will be possible to save energy in a
certain way. Since the total profit share is not
considered to be very important for the project, no
calculation has been done to eliminate the surface heat
losses.
Energy savings, savings on coal equivalent and annual
financial value in case of elimination of leaking air
losses in rotary air heaters are given in Table 13
.

Table 13. Total savings.

Energy Annual
Saving Type Coal Equivalent (kg/h)
(kcal/h) Financial Value (USD)
Preventing excessive
2.774.183 430 238.341
leakage air loss
1 ton of coal = 81.24 USD
1 USD = 2.97 TL

Rotary air heaters require replacement of the rotary air prevention of excess leaking air, and energy savings
heaters to prevent excessive leakage air loss. When will be achieved due to the airbag being reduced by the
the rotary air heaters are replaced, there will be a throttle. The savings to be made by the throttle in the
reduction in the FD and ID fan loads with the FD and ID fans. The total amount of savings to be
made by clogs in the FD and ID fans with the
prevention of excess leaking air, the investment
Table 14. The investment amount for the rotary air heaters and the payback period.
Investment
Saving Type
Type
Prevention of leakage air loss Replacement of rotary air heaters
1 Euro = 1.13 USD
* Investment costs for rotating air heaters have been received from price proposal (€ 372 880) previously given in Euros by
Siterm company.
** The total saving amount includes the amount of savings that will be caused by reducing the leaking air with the throttle in the
FD and ID fans.
4. Conclusion
Energy efficiency studies were carried out in the steam
boiler of the power plant. The necessary calculations
were made by using the measurement and existing
meter values, the mass and energy balance were
established, and the savings potentials were revealed.
As a result of calculations, it has been found that the
boiler is operated close to the design conditions. The
main saving options identified were leakage air loss
and insulation losses in rotating air heaters. According
to this, the findings of the steam boiler are presented
as follows: It is determined that the boiler is working
close to the boiler design conditions, and that there is a
saving potential in the rotary air heaters. Saving
options identified were leakage air loss and insulation
losses in rotating air heaters. Carbon monoxide value
was read at 25 ppm in boiler burning gas
measurements. However, it was found that the boiler
was operated with an air excess coefficient of 20.52%
on average. This value is an appropriate value for the
boiler. However, if the right luvo air excess coefficient
is less than that of the left luvo, and if the combustion
gas measurements are less than the reading of the
carbon monoxide value, the combustion air for the right
luvo can be increased a little more. The investment in
reducing the loss of air leaks in boilers will be possible.
The boiler yield for normal operating conditions was
89.66%, the total saving potential was 2 774 183 kcal/h
5. References
1. Barma, M. C., Saidur, R., Rahman, S. M. A.,
Allouhi, A., Akash, B. A., and Sait, S. M., "A
review on boilers energy use, energy savings,
and emissions reductions", Renewable And
Sustainable Energy Reviews, 79 (March
2016): 970–983 (2017).
2. Bahadori, A., "Steam boilers 4", Essentials of
amount of the rotary air heaters and the payback
period are given in Table 14.
Cost of Total Savings Repayment Period
Investment (USD) * Amount (USD) ** (Year)
416 321 238.341 1.75
and the coal equivalent of this energy was found to be
238 341 USD.
The entire boiler surface was scanned with a thermal
camera to identify the site losses and the poorly
insulated areas were photographed. If the weakly
insulated areas specified in the thermal photos are
strengthened, it will be possible to save energy in a
certain way. As the project shows that the total profit
share is not very important, no calculation has been
done to eliminate the surface heat losses.
Some of the measuring equipment’s in the boilers were
found to be receiving healthy measurements, while
others were found to read values outside the
acceptable limits. Nevertheless, no comparison was
made since coal, blast furnace gas and coke gas
quantities used as fuel for rescue cannot be measured.
The amount of cargo used in the field is not
measurable in the present case and is determined by
calculation.
Periodic control and calibration of the measuring
system is required for the measurement equipment to
make accurate measurements. Operating the boiler
under optimum conditions and calibrating the
measuring systems together with revising the boiler
control system and switching to the automation system
will save energy.
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