Beruflich Dokumente
Kultur Dokumente
• Combustion efficiency
• Thermal efficiency
• Distribution efficiency
• Utilization efficiency
• Overall efficiency
Boiler Capacity and Boiler Efficiency
Equivalent evaporation - kg/hr. steam at 100°C (540
kCal/kg)
– Used for expressing the steam generation capacity
Actual evaporation( H − h )
Equivalent evaporation =
540
– H is heat content of actual steam produced (kCal/kg)
– h is the heat content of the boiler feed water (kCal/kg)
– Pressure, temperature and dryness factor of the steam
and temperature of the feed water are needed
Boiler evaporation ratio – kg of steam generated from a kg
of fuel consumed
– 6 for coal and 13 for oil
Boiler efficiency
Boiler efficiency depends on
• Efficient combustion (combustion efficiency) of fuel
– Bottom ash and flyash should not have unbrunts
– Stack gases should not have CO and organic vapours
– Atomizing fuel, proper mixing and intimate fuel-air contact,
and availability of sufficient oxygen are important
– Heat generated depends on NCV of the fuel ( GCV!)
• Efficient use of the heat generated (thermal efficiency!)
– Should be used up in steam generation
– Heat losses should be minimum (or eliminated!)
– Stack losses, radiation losses and losses in bottom ash and
fly ash should be minimized
Boiler Efficiency
Parameters needed monitoring for boiler efficiency
calculations
• Steam parameters: generation rate, pressure,
temperature, and dryness factor
• Fuel parameters: consumption rate, ultimate analysis
(Carbon, Hydrogen, Sulfur, Oxygen, Moisture, and ash)
and GCV (NCV!)
• Feed water temperature (blow down not considered!)
• Flue gas parameters: temperature and oxygen (or CO2
and CO)
• Bottom ash and fly ash: GCV or unburnts
Boiler Heat Balance 1
Heat Loss in Dry Flue
Heat Loss in Flue Gas Gas
Water Heat Loss in Air
2
Unburnts
• Heat loss from bottom ash and fly ash
– Generation rate and GCV of bottom ash and flyash
– Or % combustibles can also be useful
• CO and organic vapours in stack gases (due to
incomplete combustion)
Boiler blow down losses are usually not considered
Factors Affecting Boiler Efficiency
• Equipment design (burner, boiler, etc.)
• Insulation conditions
• Heat recovery (economizer, air pre-heater, blow heat
recovery, etc.)
• Fuel quality (including moisture content)
• Operating parameters (excess air, loading factor, blow
down regulation)
• Condensate and heat contribution by return condensate
• Quality of feed water (TDS!)
• Maintenance (gas side and water side deposits and their
control)
Efficient Boiler Operation
Efficient combustion requires air in excess of stoichiometric
requirement
– Less air can result in incomplete combustion (inefficient
burning) and black smoke
– Excess air ensures efficient combustion and results in
white or clear smoke and excess heat loss in stack gases
– Efficient combustion is indicated by hazy brown smoke
from stack and minimal heat loss in stack gases
• Controlling excess air is most important
• Oxy-fuel technology and oxygen-enriched combustion
enhances boiler efficiency - minimizes stack loss (N2!)
Relation between Air Ratio and Heat Efficiency
Optimum
Heat Combustion
Region Combustion
Loss
Combustion Efficiency
Efficiency
Vent
Feed
Boiler
Heat Recovery from Blowdown Water Condensate
Return
(“ Flash” Steam) Deaerator
blow down
Mud-drum
blow down
Mid-drum
Heat
Flash Flash
exchanger Feed Steam
team
Feed ‘B’ tank
water Stea Condens
Flash
Separator
to m ate
Boil boiler trap Preheated
Down
Blow
er feed water
Feed Heat
Flash purrp Exchanger
vessel ‘ C Condens
‘
Blowdow To waste
Make up
ate
Water
n Steam Heat Cold
trap exchange feed
Auxiliary equipment consuming power
W = 0.00237
( D V) 2 W is steam flow rate (kg/hr.)
D is dia. of pipe in mm
U U is specific vol. m3/kg
V is velocity (m/sec.)
Can be helpful in finding right size of steam line
Oversizing of steam piping results in
– Greater heat loss and increased condensate generation
– Greater initial cost
Under sizing of steam piping results in
– Higher pressure drop and lower pressure at the user end
– Water hammering and erosion problems
Insulation
• For well insulated surfaces temperature difference between
insulated surface and ambient air is <10 to <20°C for a pipe
line of <250°C
• Needed to save energy, to control temperature and to better
working conditions
• Insulators are poor conductors of heat (have low thermal
conductivity, kCal/m.°C.hr.)
• Surface coefficient: total heat transfer to surroundings from hot
surface
• Wind speed and emissivity of the surface affects the value
• Emissivity, f (kCal/m2.°C.hr.) is ratio of heat transfer from a
surface to that of a black body
Wind Bare 25 mm 50 mm 75 mm 100 mm
1 m/sec. 4197 537 319 238 198
Insulation: Energy losses
• Heat loss from bare surfaces: both convective and radiative
losses
[ ( )
Q = 0.8612( qconv. + qrad . ) = 0.8612 εA Ts4 − Ta4 + CA( Ts − Ta ) ]
ε is emissivity of surface
• Heat loss from insulated flat surfaces (0.6 for oxidized Al)
A is surface area
( θ1 − θ 2 ) KA Q Ts and Ta Temperature in k
Q= θ2 =
+ θ3
L Af C coefficient of convection (5)
• Heat loss from insulated cylindrical surfaces
(θ1 − θ 2 ) A Q r1 Q is heat loss in kCal/hr
Q= θ2 = . + θ3 θ 1 is hot face temp. in °C
r2 1 r1 Af r2
r1 ln + + f θ 2 is cold face temp in °C
r1 K r2 θ 3 is ambient temp in °C
K thermal conductivity of insulation (kCal/hr.m.°C)
L is thickness of insulation (m)
f is surface coefficient
r1 and r2 are inner and outer radius
Steam traps
• Steam traps play vital role in maintaining the quality of
steam & efficiency of heating by draining the condensate
formed in the steam lines and users.
• Most commonly used are
– TD traps- intermittent application
– Float traps-continuous/intermittent
– Inverted Bucket traps - intermittent
– Bimetallic traps- semi continuous
• This is one of the very highly neglected areas in many
plants
• Continuous steam trap management will result is
sustaining energy saving by avoiding the losses.
Steam Utilization
Some of the steam saving techniques are
– Exploit alternative modes (Rad-heat gas heating element)
– Use of appropriate controls
– Utilize steam at lowest practicable pressure - low pressure
steam has more latent heat
– Reduction in process time and optimal loading
– Mechanical water removal and processing at lower water
content(decanters performance)
– Pre-heating the products (in evaporator section)
– Isolating the redundant pipes
– Provide dry steam to process
– Recover both condensate and flash steam
– Reduce the work to be done by steam
– Minimize barriers to heat transfer
Condensate and flash steam recovery
Condensate
• Has both energy value make-up water value
– Every 6°C raise of feed water temperature saves 1% of fuel
– Saves both water and water treatment chemicals
• Condensate recovery system costs
• Condensate receivers and flash tanks of the system serve to
reduce the steam entering the condensate return piping
Flash steam
• Condensate generated has the same pressure as the steam
• When comes out of a trap, the pressure drops to atmospheric
pressure, temp. of the condensate drops, and difference in
sensible heat evaporates water to form flash steam
Q is condensate generation rate
Q( S1 − S 2 ) S1 is sensible heat of high pressure condensate
Flash steam = S2 is sensible heat of low pressure condensate
L2
L2 is latent heat of flash steam at low pressure