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Juan Harold Sosa-Arnao1; Marcelo Modesto1, Silvia A. Nebra2 1 State University of Campinas, Mechanical Engineering Faculty, Energy Department, P. O. Box 6122, CEP 13083-970, Campinas, SP, Brazil jhsosa@fem.unicamp.br 2 State University of Campinas, Interdisciplinary Center of Energy Planning, R. Shigeo Mori, 2013; 13083-770, Campinas, S.P., Brazil, silvia.nebra@pesquisador.cnpq.br
ABSTRACT This work analyzes and compares two proposals for determination of the bagasse boiler efficiency, one of it based on bagasse higher heating value (HHV), the other one based on bagasse lower heating value (LHV). The methodology of calculation, for both proposals, uses the heat loss method. The results, obtained through the two proposals, presented important differences; the boiler efficiency determined through the proposal of code ASME PTC 4.1, based on HHV, highlights the effect of bagasse moisture content upon boiler efficiency. This effect, in the Beatn and Lora proposal, is hidden, because the energy required to evaporate the bagasse moisture content and the water vapour from hydrogen contained in the fuel are discounted in the LHV calculation. Three types of boilers, with different capacity and leaving steam properties were analysed. Considering the boiler constituted by a sequential arrangement of a steam generator, an air heater and an economizer, a simulation was made determining the influence of the variation of the air heater exit gases temperature upon theirs performances. The performance analysis was based on the second law of thermodynamics. Keywords: bagasse, efficiency, exergy.
Nomenclature a= theoretical air flow, kmol/s; b, c, d= theoretical combustion products flow, kmol/s. e = air flow (kmol/s) f, g h, i = combustion products flow (kmol/s) exe= specific exergy [kJ/kg]; h= specific enthalpy [kJ/kg]; nf= fuel flow (kmol/s) HHV= Higher heating vale [kJ/kg]; LHV= Lower heating value [kJ/kg]; BMC = bagasse moisture content
m = mass flow rate [kg/s];
.
Greek symbols = enthalpy of water vaporization (kJ/kg); = Exergetic efficiency (%) Subscripts a, b, g, dg, w = air, sugar cane bagasse, gas, dried gas, water. H, C, O, N, H2O, S = hydrogen, carbon, oxygen, nitrogen, water and sulphur (%) l, sg, eco, ah, gr, wh= lost, steam generator, economizer and air heater, grate, washing. H2O,1 = Water vapour from fuel hydrogen H2O,2 = Water vapour formed from BMC. p = bleeding of boiler. chem., phy = chemical, physical. 1 = bagasse inlet to steam generator; 2 = steam outlet from steam generator 3 = gas outlet from steam generator; 4 = gas outlet from air heater; 5 = gas outlet from economizer; 6 = air inlet to air heater 7 = air outlet from air heater 8 = water inlet to economizer. 9 = water outlet from economizer 10 = bleeding outlet from steam generator.
Po= reference pressure [bar]; s= specific entropy [kJ/kg K]; To= reference temperature [K] w= bagasse water content [w.b.,%] z= mass fraction of the components of fuel [%] af= fuel ash fraction [%] cf= fixed carbon content [%] * = Referred to proposal II. qa= available heat of bagasse (kJ/kg) cp= specific heat of bagasse (kJ/kgK) Tsat = Temperature of saturation at boiler pressure (C)
I. Introduction
Brazil leads sugar cane producing countries. It is answerable for 25% of the world-wide production. The industry of sugar and alcohol is privileged, because it generates its own fuel, the sugar cane bagasse. This industry produces, by cogeneration, electrical energy for itself and for the market. Industrialization and population growth have led to a sharp increase in power demand. Thus, the economic and social growth of many countries is jeopardizing. In fact, in sugar cane producing countries, the cogeneration of energy in sugar cane mills is becoming an excellent alternative solution to this problem [1], [2] and [3]. Therefore, the study of the parameters that affects the bagasse boiler efficiency is becoming very important in the analysis of the sugar cane mills cogeneration system aiming to optimize its performance.
Steam Gas 2 3
AIR HEATER
Air 6
Bagasse 1
STEAM GENERATOR
4 9
ECONOMIZER
Water 8
10 Bleeding
5 Gas
Figure 1: Sequence arrangement is made up steam generator, air heater and economizer This paper was carried out with some data collected on Cruz Alta Plant, which belongs to Acar Guarani Company, Olmpia, So Paulo State. These data, collected from other members of the staff, were reported in [4].
equation. Ideal gas conditions were considered. Air composition was 21 % of oxygen and 79 % of nitrogen (the air humidity was not considered). One kilogram of dry mass of fuel was taken as a base. The balance equation for a stoichiometric combustion is presented in Eq.(1) for stoichiometric conditions and Eq.(2) for air in excess conditions.
(n C C + n H H + n O O ) + a (O 2 + 3.76 N 2 ) = b CO 2 + c H 2 O + d N 2
(1) (2)
The air excess is calculated by Eq. (3), which relates this parameter with the BMC, according [6]. (3)
The theoretical and excess air-fuel ratio, AFmolar,theo and AFmolar,exc, are presented in Eq. (4) and (5), respectively:
(4)
(5)
nf = nc + nH + nO
Therefore, the air excess is related to the BMC:
1+
(6)
(7)
q ph ,b = c p (T T0 ) , kJ/kg
Therefore, the available heat from fuel (qa) is:
(8)
qa = LHV + qb , kJ/kg
These authors considered the following heat loss:
(9)
(i)
Exhaust gases heat losses (q2). Among all heat loss fractions, this is the most significant and it is function of exhaust gas temperature [6]. In the enthalpy calculation of exhaust gas is considered the sensible heat from T T0. The next equation (10) allows to calculate it:
q2 =
(ii)
m g ( hg , 2 hg ,0 ) mb qa
(100 q4 ) , %
(10)
These losses are related to CO, H2 and CH4 formation, as well as other products resulting of an incomplete combustion. Those elements were previously neglected, thus this loss was done equal to zero. iii) Heat loss by incomplete combustion due to mechanical causes (q4): is a fraction referred to unburned fuel particles, that go out mixed with the ashes, or are carried by the exit gases. It is calculated by the following equation:
327.9 m ashes ,% q a
(11)
The correct way to calculate these losses would be equating all the heat exchanged by convection and radiation from boiler walls to the environment, but, in practice terms, this work is almost impossible, thus a solution for the q5 calculation is to use the ABMA standard radiation loss chart [7], which is based on an average boiler wall temperature, measured by the staff. To use this abacus, its calculation basis (HHV) needed to be taken into account and converted to that used by Beatn and Silva. These authors also presented a chart to determine the radiation and convection boiler heat loss, but it is only function of steam mass flow and does not offered difference when different pressure and temperature of boiler are used. So, it was not utilized. (v) Heat losses by slag and ashes (q6) The last lost fraction refers to sensible heat lost by slag and ashes. According [6], this fraction is responsible for less than 0.1 % of the available heat, therefore can be neglected. The boiler efficiency, obtained through this proposal, is determined from the sum of all heat loss fractions, Eq. (12).
(12)
This proposal requires the determination of losses, heat credits and the heat credits and ultimate analysis and higher heating value (HHV) of the fuel [7]. It considers the heat losses same than Beatn and Lora proposal (q3, q4, q5, and q6) but the base calculation is the HHV. There are differences in the analysis of boiler exhaust gas heat loss (q2). According ASME PTC 4.1, this heat loss is separated in dried gas heat loss (q2*), heat loss due water vapour from burning hydrogen (q8) and heat loss due BMC (q9).
qa = HHV + qb
(vi) Heat loss due sensible heat of dry gas (q2*),
(13)*
q2 =
*
mg hg ,5 (100 q4 ) mb qa
Heat loss due evaporation of water formed from hydrogen in the fuel (q8)
(14)*
vii)
q8 =
vii)
mH 2O , 2 hH 2O ,5 hH 2O ,0 mb qa
)100
(15)*
q9 =
mH 2O ,1 hH 2O ,5 hH 2O , 0 mb qa
)100 %
(16)*
The boiler efficiency, obtained through this proposal, is determined from the sum of all heat loss fractions, Eq. (17).
(17)*
In this work was considered, for both proposals, besides the heat losses mentioned above, the heat loss by bleeding in boiler (q7). This heat loss was considered corresponding at 2% of boiler steam mass, according [8].
Tg ,3 = 42,493Tsat
0 , 3962
(18) (19)
m (h
T (s
))
(20)
m g hg ,3 hg ,4 AirHeater = ma ha ( Tg ,3 ) ha ,6
100
(21)
3.4 Economizer
The inlet water temperature (Tw,6) was adopted as 112C [12]. The economizer exhaust gas temperature (Tg,4) was considered as 155C, which is a very common value in cane bagasse boilers. It was considered that 1.00% of interchanged heat is lost (Ql,Eco). The boiler inlet water temperature (Tw,1) is the unknown variable in the economizer energy balance Eq. (22):
(22)
The economizer exergetic efficiency was defined through two types of equations, Eq. (23) and (26). The differences between these equations are the irreversibility due to the gas loss, which was considered outside and inside the economizer control volume, respectively.
Economizer =
(23)
exeg , phy ,3 = hg , 4 hg ,0 T0 (s g , 4 s g , 0 ) exeg,chem = yCO2 exe + yH2Oexe chem ,CO chem ,H2O + yN2 exe chem , N2 2
(24) (25)
Economizer =
(mw + mp )(hw,9 hw,8 T0 (sw,9 sw,8 )) 100 ( ) m exe exe + g g , phy,3 g ,chem m (h h
(26)
(27)
(28) (29)
q5 =
The steam generator heat losses are obtained through the Eq. (30)
(30) (31)
m (h
T (s
))
(32)
boiler =
(33)
(34)
(35)
As an example, parameters, such as, mass flow, pressure, temperature, enthalpy, entropy and exergy of system fluxes are presented in the Tables I and II for two different situations. These values are presented at temperature gas outlet air heater (Tg,4=200C) and steam (P=21 bar) in Table I and (Tg,3=300C and Psteam=62 bar) in Table II. The bagasse is considered humid base. Table I: Parameters of system fluxes (Tg,4=200C; Ps,2=21 bar). Description 1 2 3 4 5 6 7 8 9 10 Bagasse Steam Exhaust gas Exhaust gas Exhaust gas Air Air Water Water Bleeding Flow (kg/s) 2 4.974 9.67 9.67 9.67 7.695 7.695 5.588 5.588 0.614 Pressure (bar) 21 Temperature (C) 35 320 360.5 200 155 25 260.6 102 123.3 214.9 Enthalpy (kJ/kg) 3066 396.4 202.3 149.5 0 241.1 427.5 517.9 920 Entropy (kJ/kgK) 6.818 8.255 7.902 7.785 6.884 7.479 1.328 1.562 2.47 Exergy (kJ/kg) 9959 819.1 333.7 248.8 226.9 0 63.66 36.15 56.83 188.1
21 21 21
Table II: Parameters of system fluxes (Tg,4=300C; Ps,2=62 bar). Description 1 2 3 4 5 6 7 8 9 10 Bagasse Steam Exhaust gas Exhaust gas Exhaust gas Air Air Water Water Bleeding Flow (kg/h) 2 4.266 9.67 9.67 9.67 7.695 7.695 4.645 4.645 0.379 Pressure (bar) 62 Temperature (C) 35 480 399.1 300 155 25 174.4 102 181.3 277.8 Enthalpy (kJ/kg) 3372 444.5 322.1 149.5 0 152 427.5 769 1224 Entropy (kJ/kgK) 6.8 8.329 8.132 7.785 6.884 7.297 1.325 2.145 3.046 Exergy (kJ/kg) 9959 1130 359.8 296.1 226.9 0 28.83 37.11 134 320.7
62 62 62
The distribution of boiler heat losses, for proposal I and II are presented in the Fig. 2 and 3, respectively.
q2
q3
q4
q5
q6
q7
q2
q3
q4
q5
q6
q7
q8
q9
In case of proposal I, the biggest heat loss is represented by the exhaust gas heat loss (q2=9.4%), which corresponds the 68.5% of total heat loss. The other heat losses, such as, that due chemical
unburned (q3=0%), mechanical unburned (q4=1.9%), radiation and convection (q5=0.46%), slag (q6=0%) and bleeding (q7=2%) are lower. In case of proposal II, the biggest heat losses is represented by the evaporation of BMC (q9=14%), the second biggest is due to the evaporation of water vapour formed from hydrogen in the bagasse (q8=8.2%), then comes the heat loss due dry exhaust gas (q2 =5.5 %). The other heat losses, such as, q3= 0%; q4= 0.73%; q5= 0.37% and q6= 0% are lower. The boiler efficiency, for both proposals, is presented in the Fig. 4. The efficiency of proposal I was higher than that obtained through proposal II, about 25%. In both cases, the boiler efficiency does not vary with the outlet gas temperature of air heater, but varies slowly when exit steam temperature and pressure increase. This happens because that when the boiler output energy increases the proportional radiation and convection heat loss (q5) decreases whilst the others proportional heat loss does not vary. The boiler exergetic efficiency does not vary with the outlet gas temperature of air heater but increases when the steam exit temperature and pressure increase (Fig. 5). The maximum value (31.70%) is observed in the maximum value of steam temperature and pressure whilst the first law boiler efficiency, by both proposals, was 69.2 % and 86.3 %.
Proposal I
Proposal II
200 220 240 260 280 300 Outlet Gas Temperature of Air Heater (C)
Figure 4: Boiler Efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature.
200 220 240 260 280 300 Outlet Gas Temperature of Air Heater (C)
Figure 5: Boiler Efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature.
In Fig 6, the steam generator exergetic efficiency decreases slowly with the air heater outlet gas temperature increase. The increase of steam temperature and pressure produces the increase of steam generator exergetic efficiency. The Fig. 7 shows the air heater exergetic efficiency with the outlet gas temperature of air heater. The air heater exergetic efficiency increase when the outlet gas temperature of air heater decrease. The same behaviour is presented by the air heater effectiveness showed in Figure 10.
36
60 40 20 0
24
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
Figure 6: Steam generator exergetic efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature - (Proposal I and II)
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
Figure 7: Air heater exergetic efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature Proposal I and II
The economizer exergetic efficiency was analyzed through two view points. The first considered that the gas irreversibility, in the economizer outlet, is not carried by economizer (Fig. 8), and the second considered that the gas irreversibility is carried by economizer (Fig. 9).
Economizer Exergetic Efficiency (%)
Economizer Exergetic Efficiency (%)*
70
15
60
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
Figure 8: Economizer exergetic efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature - The economizer does not carried the gas irreversibility Proposal I and II
Figure 9: Economizer exergetic efficiency with Outlet gas temperature of air heater for different levels of boiler pressure and temperature - The economizer carried the irreversibility of gas. Proposal I and II.
40
20
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
200 220 240 260 280 300 Outlet gas Temperature of Air Heater (C)
Figure 10: Air heater effectiveness with Outlet gas temperature of air heater for different levels of boiler pressure and temperature.
Figure 11: Economizer effectiveness with Outlet gas temperature of air heater for different levels of boiler pressure and temperature.
The economizer exergetic efficiency increases when the outlet gas temperature of air heater increases, the same tendency observed for the effectiveness, (Fig.10 and 11). Exit steam temperature and pressure increasing produce also an increase of the exergetic efficiency. When the economizer carried the gas loss irreversibility, its exergetic efficiency strongly drops (Fig.9).
Conclusions
The increase of steam temperature and pressure permits to improve the boiler and its peaces of equipment performance and efficiency. The behaviour of the exergetic efficiency of both heat exchangers, air heater and economizer follows the same tendency as the effectiveness. The distribution of heat losses according the proposals I and II are different because the base calculation is different. The proposal I discounted in LHV calculation the heat absorbed to evaporate the water formed in the combustion reaction from bagasse hydrogen and also BMC, therefore it is not observed the heat losses by bagasse hydrogen and BMC (q8 and q9) in this proposal. The proposal II highlights these heat losses, which are the bigger in the proportional distribution. The authors recommend the use of the proposal II on the analysis of bagasse boilers
since that through this it is easier to decide the improvements aiming the bagasse boilers optimization.
Acknowledges
The authors wish to thank CNPq (Proc. 142135-2003-8; and Proc. 305720/2003-1) and Fapesp (Proc. 2001/14302-1) for their financial support.
VI. REFERENCES
Ibarra, L.R.F., Medelln, A.M.A. Energy saving and cogeneration potential in Mexican sugar mills, Int. Sugar J. 2004 ;Vol. 106, no 1264, pp. 210-221. [2] Sharma M.P., Sharma, J.D., 1999, Bagasse based Co-generation system for Indian Sugar Mills, Renewable Energy, Vol. 16, pp. 1011 1014. [3] Therdyothin A., Bhattacharya C., Tabucanon M. Evaluation of alternatives to increase the electrical generation capacity of Thai sugar mills, Energy Vol. 17 (1992) No. 3, pp. 247-254. [4] Snchez Prieto, M.G., Carril, T.P., Nebra, S.A. Analysis of the Exergetic Cost of the Steam Generation System of the Cruz Alta Mill, In Proceedings of the 16 th Brazilian Congress of Mechanical Engineering 2001, Uberlndia, Brazil, pp. 206 215 (in Portuguese). [5] Baloh T., Wittwer E., Energy Manual for Sugar Factories (1995) 200. [6] Beatn, S.P., Lora E.S. Test of Thermal Balance in Bagasse Steam Boilers, Departamento de Termoenergtica, Facultad de Ingenieria Mecnica. I.S.P.J.A.M., Cuba, 1991, (in Spanish). [7] ASME PCT 4.1. Steam Generating Units. Power test codes, The American Society of Mechanical Engineers, United Engineering Center, New York N.Y. 10017, 1975. [8] Acosta J. The boiler efficiency fueled bagasse. Int. Sugar J. 1995; Vol. 97, 1158: 248- 255. [9] Sosa-Arnao J.H., Llagostera, J., Nebra, S.A. Study of operation parameters of power generation systems on sugar cane mills, In Proceedings of the 18 th Brazilian Congress of Mechanical Engineering 2005, Ouro Preto, in CD-ROM. [10] E. Hugot. Manual for sugar engineers, (1964) 803. [11] Dalmazo , C.A., 2005, Private Communication, Equipalcool industry. [12] Snchez Prieto, M.G., Cogeneration Alternatives in Sugar and Alcohol Factories, Case of Study, Ph.D. Thesis, State University of Campinas (in Portuguese), 2003. [13] Sosa-Arnao, J. H.; Nebra, S. A. ; The Exergy of Sugar Cane Bagasse; 14th European Biomass Conference & Exhibition: Biomass for Energy, Industry and Climate Protection, 17-21 October, 2005, Palais des Congrs, Paris, France [1]