DOEs BestPractices Steam End-User Training

SteamEndUserTraining SteamGenerationEfficiencyModule StackLossesSection

Slide1 StackLossesModule Whileblowdownandshelllossesarerelativelysmall,stacklossisalmostalwaysthelargestboilerloss. [SlideVisualStackLossTitlePage] EfficiencyDefinition RadiationandConvectionLossesShellLosses BlowdownLosses StackLosses Slide2 StackLosses Stacklossisgenerallycharacterizedintotwointerrelatedcategoriestemperature,andcombustion(orexcessair).Managingthestacklossisacritical factorinmanagingboilerperformance.Wewilldiscussbothoftheseaspectsofstacklosswewillstartourdiscussionsbyfocusingonfluegas temperature. Slide3 StackLossesTemp.Component [SlideVisualStackLossTemperatureComponentTitlePage] EfficiencyDefinition RadiationandConvectionLossesShellLosses BlowdownLosses StackLossesTemperatureComponent SteamEndUserTraining SteamGenerationModule StackLosses1

SteamGenerationEfficiency

SteamGenerationEfficiency

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DOEs BestPractices Steam End-User Training Slide4 FlueGasLoss Asignificantamountoffuelenergyresidesintheboilerexhaustgas.Thetemperatureoftheexhaustgasisanindicatoroftheamountofenergylost fromtheboiler.Fluegastemperatureisameasurementthatisrequiredtoreflectboilerperformance.Boilerfluegastemperatureshouldbemonitored withrespecttoambienttemperature Higherfluegastemperaturesindicategreaterloss.Itisgoodtoknowwhatcantypicallycausefluegastemperaturetoincrease. Slide5 BoilerDesign Boilerdesignisaprimaryfactorinestablishingthefluegastemperature.Aboilerwithmoreheattransferareawillbeabletoextractmoreenergyfrom thefluegas.Forexample,theonepassfiretubeboilerhasmuchlessheattransferareathanthethreepassfiretubeboiler.Iftheboilerswere operatingundersimilarcircumstancestheonepassboilerwilloperatewithahigherfluegastemperaturethanthethreepassboiler.Ofcourse,higher temperatureindicateslowerefficiency. [SlideVisualBoilerSchematic] Boilerschematicsareshownforaonepassandathreepassboilerconfigurations. Thesinglepass,oronepassboilerisshownontheleft.Fuelentersthecombustionzone,representedbyarectangle,whichissurroundedby boilerwater.Steamisreleasedthroughthetopoftheboiler.Exhaustgasesarereleasedfromtheboilerviathecombustionchamber.Afront viewoftheonepassboilerisindicatedbyasmallcircle(representingthefiretubeorcombustionzone)insidealargercirclerepresentingthe boiler. Thethreepassboilerormultiplepassboilerisshownontheright.Fuelentersthecombustionzone,representedbyarectangle,whichis surroundedbyboilerwater,howeverthereareseveralsmallrectangleofcombustionzonesinthelargeboilingwaterchamber,which representsthemultipletubesinsidetheboilerforheatexchange.Steamisreleasedthroughthetopoftheboiler.Exhaustgasesarereleased fromtheboilerviathemultiplefluegaspasses.Afrontviewofthethreepassboilerisindicatedbyasmallcircle(representingthefiretubeor combustionzone),manysmallercirclesrepresentingthemultiplefiretubepassesinsidethecombustionchamber,allinsidealargercircle representingthesteamliquidchamber. Slide6 EnergyRecoveryComponents Afeedwatereconomizerisaheatexchangerinstalledtotransferthermalenergyfromthefluegasintotheboilerfeedwater.Thisisacommonenergy recoverycomponentinstalledonboilers.Asimilardeviceisacombustionairheatertheseheatexchangersrecoverthermalenergyfromthefluegas bypreheatingcombustionairpriortoenteringthecombustionzone.Aboilerequippedwithoneoftheseenergyrecoverydeviceswilloperatewith lowerfluegastemperaturethanasimilarboilernotequippedwithone. SteamEndUserTraining SteamGenerationModule StackLosses2

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DOEs BestPractices Steam End-User Training [SlideVisualBoilerConfigurations] Boilerschematicsareshownforwatertubeboilerconfigurations,onewithafeedwatereconomizerheatrecoverydeviceontheexhaustgases, andthesecond,mostrightconfiguration,without. Bothschematicsdepictwatertubeboilers.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultipletubesforwatertomovethroughtheheatexchangearea.Thesteamoutletis shownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler. Themostleftschematicincorporatesaheatexchangerontheexhaustgasoutlet,whichappearsasaredserpentinelinethroughoutthe exhaustgasexitfromtheboilerthisisafeedwatereconomizer. Themostrightschematicdoesnothaveafeedwatereconomizershown. Slide7 FlueGasTemp.Limitations Caremustbetakentoavoidreachingtoolowofanexhaustgastemperature,asthiscouldcausecorrosivecondensatetoformintheexhaustgases.If thereissulfurinthefuel,sulfuricacidcouldform.Evenifthefueldoesnotcontainsulfur(liketypicalnaturalgas),wecontinuetobeconcernedabout corrosivecondensatebecausetheproductsofcombustionarecarbondioxideandwater,whichtendtocombinetoformcarbonicacid. [SlideVisualFlueGasTemperatureLimitationsGraph] Agraphicdepictsfuelsulfurcontentalongthexaxisasapercentofmass,beginningwith0%andincreasingto5%inincrementsof1.The verticaloryaxisdepictstheFlueGasExitTemperatureindegreesFahrenheit,beginningat100andincreasingto450degreesFahrenheitin incrementsof50degrees. Theaciddewpointlinebeginsat0%fuelsulfurcontentand250degreesFahrenheitandincreaseslinearlyuntil5%content,inwhichthetrend Lineincreasesabitsteeperwiththeresultof5%boilerloadand300degreesFahrenheit. Theminimumrecommendedfeedwatertemperaturelinebeginsat0%fuelsulfurcontentand225degreesFahrenheitandincreaseslinearly until5%content,inwhichthetrendLineincreasesabitsteeperwiththeresultof5%boilerloadand250degreesFahrenheit. Slide8 CondensingEconomizers Itisinterestingtopointoutherethatthewatervapor(steam)formedinthecombustionprocesscontainsasignificantamountofenergy.Ifthiswater vaporisallowedtocondensethencorrosionissuesresult.However,heatrecoveryheatexchangeequipmenthasbeendevelopedthatcanhandlethe corrosiveissuesandallowthewatervaportocondenseandreleaseitsenergy.Thesecomponentsareidentifiedascondensingeconomizers. SteamEndUserTraining SteamGenerationModule StackLosses3

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DOEs BestPractices Steam End-User Training Condensingeconomizerscanimproveboilerefficiencymorethan10percentagepointswhichisexceptional.Condensingeconomizersareappliedin cleanfuelapplications(naturalgasandpossiblynumber2fueloil).Itisveryimportanttonotethatthefluegasmustbecooledtolessthan120Fto condensethemajorityofthewatervaporandrecovertheenergy.Asaresult,thestreamthatisheatedbythefluegasmustberelativelycoldlessthan 100Fandtheremustbealargeamountofmaterialtobeheated.Applicationslikefoodprocessingplantsareoftenthetargetlocationsforthis technology.Foodprocessingplantscommonlyhavelargeamountsofprocesswaterthatrequiresheating. Slide9 BoilerLoad Anotherfactorthatimpactsfluegasexhausttemperatureisboilerload.Typically,fluegastemperatureincreasesasboilerloadincreases.Thisissimply aresultofpassingmorematerialthroughaheatexchanger(theboiler).Thegraphoffluegastemperatureversusboilerloadisforaspecificboilerand isintendedtoindicateatypicaltrendthevaluesonthisgrapharereflectiveofaspecificboiler;thevalueswillbedifferentforyourboiler;but,the trendwillbesimilar. [SlideVisualBoilerLoadGraph] Agraphicdepictsboilerloadalongthexaxisasapercentofboilerfullload,beginningwith50%andincreasingto110%inincrementsof10. TheverticaloryaxisdepictstheFlueGasExitTemperatureindegreesFahrenheit,beginningat400andincreasingto600degreesFahrenheit inincrementsof50degrees. Thetrendlinebeginsat50%boilerloadand425degreesFahrenheitandincreaseslinearlyuntil100%load,inwhichthetrendLineincreasesa bitstepperwiththeresultof110%boilerloadand560degreesFahrenheit. Slide10 FailedFlueGasComponent Inalmostallboilers,thecombustiongasesareforcedtotakeaspecificpaththroughtheheatexchangesections.Bafflesorspecialductingisinplaceto ensurethegasestravelthroughtheboilerproperly.Ifabafflefails,thenthegascanbypassheattransfersectionsoftheboiler.Thefluegas temperaturewillincreaseasaresult.Thiscanberemediedbyrepairingthebaffle. [SlideVisualBoilerBaffleOperationandFailure] Boilerschematicsareshownfortwoboilerconfigurations,onewithbafflesoperatingproperlyandthesecondwithafailedbaffle. Thefirstconfiguration(ontheleft)depictsbafflesoperatingproperly.Theschematicdepictsawatertubeboiler,inwhichtwobafflesare shownasredverticallinesinsidetheboilerscombustionzone.Thecombustiongaspathisdepictedbygreenarrows,beginningwherethefuel andairentersatthelowerleftofthecombustionzone,throughthebaffleswhichinazigzagpaththroughthecombustionzone,thenoutthe combustionzonetoptotheboilerexhaust.Feedwaterentersatthetopofthesteamgenerationsectionatthesteamdrum.Thesteamoutletis shownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler. SteamEndUserTraining SteamGenerationModule StackLosses4

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DOEs BestPractices Steam End-User Training Thesecondconfiguration(ontheright)depictsaboilerwithafailedbaffle.Theschematicdepictsthesamewatertubeboiler,inwhichtwo bafflesareshownasredverticallinesinsidetheboilerscombustionzone.However,thesecondbafflehasasectionmissingatthetop,thus allowingthehotgas(depictedbyredarrows)topassstraighttotheboilerexhauststack,bypassingmostofthecombustionzone.Feedwater entersatthetopofthesteamgenerationsectionatthesteamdrum.Thesteamoutletisshownatthetopoftheboiler,aswellastheexhaust gasesleavingtheboiler. Slide11 Fouling Ifwehavewatersidescalingorfiresidefoulingoftheheattransfersurfaces,thesurfacesbecomeinsulated,andmoreenergyremainsintheexhaust gas.So,wewanttomakesurewemaintainwaterqualitytomakesuresolidsdonotprecipitateontheheattransfersurfaces.Also,wewanttokeepthe firesideofthetubesascleanaspossible.Firesidefoulingisusuallyaproblemwithsolidfuelsandheavyfueloils.Onlinesootblowingisthemethod usedforchronicfoulingconditions.Sootblowingistheactofinsertingalanceintothecombustionsideoftheboilertoallowahighvelocityjetofsteam orcompressedairtopassacrossthefouledsurfacestodislodgethefoulingmaterial. Watersidefoulingispreventedthroughboilerwaterchemistrycontrol.However,whenfoulingissignificant,treatmentmeasuresmayinclude chemicalstodescaletheboilerheatexchangesurfaces,orhydroblasting,bothofwhichrequireaboileroutage.Often,watersidefoulingresultsintube failures. [SlideVisualBoilerFouling] Theboilerconfigurationindicatesfuelandairenterontheleftsideoftheboilerscombustionzone.Internalbafflesaredepictedinwhite.The steamflowisdepictedasaredloopinsidethecombustionzone,betweenthebaffles.Feedwaterentersatthetopofthesteamgeneration sectionatthesteamdrum.Thesteamoutletisshownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler.

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SteamEndUserTraining SteamGenerationModule StackLosses5

DOEs BestPractices Steam End-User Training [SlideVisualInsertofPotentialEnergyLossResultingfromScaleDeposits] PotentialEnergyLossResultingfromScaleDeposits ScaleThickness[Inches] 1/64 1/32 3/64 1/16 Normal 1.0 2.0 3.0 3.9 FractionofTotalFuelInputEnergyLoss[%] ScaleType HighIron 1.6 3.1 4.7 6.2 Iron+Silica 3.5 7.0

NationalInstituteofStandardsandTechnology,Handbook115,Supplement1 Slide12 FlueGasTemp.Loss Thesearethecommonfactorsthatimpactfluegasexittemperaturetherearemanymore. Onefinalnote,excessair(extraairpassingthroughthecombustionzone)hasthepotentialofimpactingfluegasexhausttemperature.Typically, increasingtheamountofexcessairinthecombustionzonewillincreasethefinalfluegasexhausttemperature.Wewilldiscusstheprimaryissues associatedwithexcessairinthefollowingsection. Slide13 TemperatureLossManagementSummary Thefirststepinmanagingfluegasenergyistomeasureandmonitorfluegasexittemperature.Alongwiththiscriticalmeasurementambient temperatureshouldbenoted,because,ambienttemperaturewillhaveanimpactonthefinalfluegastemperatureoftheboiler.Additionally,because fluegastemperatureisafunctionofboilerloadthesteamproductionorfiringrateshouldbenotedalongwiththeseothermeasurements.These measurementswillallowperformancetrendsofyouboilertobenoted. SteamEndUserTraining SteamGenerationModule StackLosses6

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DOEs BestPractices Steam End-User Training Slide14 CombustionComponent

Now,wewillturnoutattentiontothecombustionsideofthestackloss.Thecombustionlosscentersonunburnedfuel,excessair,andotheritemsof thisnature. [SlideVisualStackLossCombustionComponentTitlePage] EfficiencyDefinition RadiationandConvectionlosses Shelllosses Blowdownlosses StacklossesCombustionComponent Slide15 PerfectCombustion Asanexample,wewillexaminethecombustionofasimplefuel,methane.Inaperfectworld,methanewillreactwithoxygentoreleaseenergyandform carbondioxideandwater.Inthisperfectarrangement,eachmoleculeoffuelwouldfindtwomoleculesofoxygeninordertocausecomplete combustion. [SlideVisualBasicCombustionEquation] Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsCarbonDioxide(CO 2 )and2moleculesofWater(H 2 O)+EnergyRelease Inthisinitialcombustiondiscussionmethaneandoxygenareusedastheonlycomponentsforsimplicity.Additionally,inertchemicals (nitrogen)arenotconsideredatthistime. Slide16 ActualCombustion Intherealworld,thecombustionprocessdoesnotproceedinaperfectmanner.Infact,thecombustionreactionmayyieldmorechemicalsthancarbon dioxideandwaterthecommonadditionalchemicalsformedarecarbonmonoxideandhydrogen.Additionally,oxygencanpassthroughthe combustionzoneandnotreactwithanyfuelexitingasoxygenmolecules.Similarly,methanecanpassthroughthecombustionzoneandnotreact withanyoxygenexitingasfuel. SteamEndUserTraining SteamGenerationModule StackLosses7 June28,2010

SteamGenerationEfficiency

DOEs BestPractices Steam End-User Training Aswelookatthesepossiblechemicalsthatcanformandbereleasedfromthecombustionzonesomegetourattentionmorethanothers.Forexample, carbonmonoxideisatoxicgasthatcancausedefinitehealthconcerns.Carbonmonoxideformswhenfuelfindsaninsufficientamountofoxygento completelyreact.Thefuelwillpartiallyreactandreleaseonlyaportionofthefuelenergyavailable.Thecarbonmonoxidecontainstheremainderofthe originallyresidentfuelenergy.Asaresult,carbonmonoxiderepresentsmorethansafetyandhealthissues,italsorepresentsaneconomicissue becausefuelenergywasexhaustedfromtheboiler.Infact,hydrogenandmethanepresentexactlythesameissuesnoneofthemaregoodtobreath,all arecombustibleandexplosive,andallrepresenteconomicexpenditureintheformofpurchasedfuel.Therefore,fromacombustionmanagement standpointitisessentialforallthefueltoreact. Conversely,ifoxygenpassesthroughthecombustionzoneitisnothazardous,itdoesnotpresentasafetyissue,anditrequiresverylittleeconomic investmenttoacquire. [SlideVisualActualCombustionEquation] Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsandenergyreleaseofalphamoleculesCarbonDioxide(CO 2 )andbeta moleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+deltamoleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane (CH 4 )+zetamoleculesofOxygen(O 2 ) RedcirclesencapsulatethegammamoleculesofCarbonMonoxide(CO),thedeltamoleculesofHydrogen(H 2 ),andtheepsilonmoleculesof Methane(CH 4 ) AgreencircleencapsulatesthezetamoleculesofOxygen(O 2 ) UnreactedCH4,CO,andH2arefuelsresultingfromincompletecombustion Wastingfuel Safetyhazard Healthandenvironmentalhazards

Slide17 CombustionManagement1 Thefirstprincipleofcombustionmanagementisbasedonthefactthataddingextraoxygentothecombustionzoneessentiallyensuresthatallthefuel iscombusted.Inotherwords,inaperfectcombustionsituationonemoleculeoffuelmustencountertwomoleculesofoxygentoreactcompletely.Inthe realworldifmorethanenoughoxygenisaddedtothecombustionzone,theneachmoleculeoffuelwillfindenoughoxygentoreact.Theextraoxygen thatpassesthroughthecombustionzonewasacquiredwithminimalcost.Inotherwords,ifmorethanenoughoxygenispassedthroughthe combustionzoneitalmostensuresthatallthefuelburnsup.Thisisthefirstruleofcombustioncontroladdmoreoxygentothecombustionzonethan isnecessarytoensureallthefuelreactscompletely.

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DOEs BestPractices Steam End-User Training [SlideVisualActualCombustionEquation] Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsandenergyreleaseofalphamoleculesCarbonDioxide(CO 2 )andbeta moleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+deltamoleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane (CH 4 )+zetamoleculesofOxygen(O 2 ) RedcirclesencapsulatethegammamoleculesofCarbonMonoxide(CO),thedeltamoleculesofHydrogen(H 2 ),andtheepsilonmoleculesof Methane(CH 4 ) AgreencircleencapsulatesthezetamoleculesofOxygen(O 2 ) Slide18 CombustionManagement2 However,theextraoxygenaddedtothecombustionzoneenterstheboileratambienttemperatureandexitstheboileratfluegastemperature(450 degreesFahrenheitforexample).Theextraoxygengainedthistemperaturebyreceivingfuelenergyfuelwaspurchasedtoheattheextraoxygen.The energylossisactuallymuchmorethanjustheatingtheextraoxygen;because,ambientaircontainsalmost4moleculesofnitrogenforevery1molecule ofoxygen(3.76fortypicalair).Asaresult,alargeamountofnitrogenentersthecombustionzonewithanyexcessoxygen.Thisnitrogenentersat ambienttemperatureandreceivesfuelenergytoexittheboileratfluegastemperature.Themajorityofthecombustiongasisnitrogenahugeamount ofnitrogenisheatedbyfuelenergy.ThisbringsustoCombustionManagementPrincipleNumber2donotputtoomuchairintothecombustionzone. Stateddifferently,thetwoprinciplesofcombustionmanagementaretofirstprovideextraoxygentothecombustionzonetoensureallthefuelis consumed;andsecond,reducetheamountofextraairtolimittheenergyloss. [SlideVisualActualCombustionEquation] Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsandenergyreleaseofalphamoleculesCarbonDioxide(CO 2 )andbeta moleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+deltamoleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane (CH 4 )+zetamoleculesofOxygen(O 2 ) RedcirclesencapsulatethemoleculesofCarbonMonoxide(CO),themoleculesofHydrogen(H 2 ),andthemoleculesofMethane(CH 4 ) AgreencircleencapsulatesthemoleculesofOxygen(O 2 ) Combustionmanagementstrivestoeliminateunreactedfuelbyaddingextraoxygentothecombustionzone SteamEndUserTraining SteamGenerationModule StackLosses9 ExcessO 2 providedtothecombustionzoneessentiallyeliminatesunreactedfuel Oxygenentersboilerasambientairatsay,70oF(ambient) O 2 Enterswith4timestheamountofnitrogentoo! OxygenandNitrogenexitwithfluegasat500oFbygainingheatfromthefuel

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DOEs BestPractices Steam End-User Training [SlideVisualActualCombustionEquation] Methane(CH 4 )+2moleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)combustsandyieldsandenergy releaseofalphamoleculesCarbonDioxide(CO 2 )andbetamoleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+delta moleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane(CH 4 )+zetamoleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76 moleculeseach) Redcirclesencapsulatethe2moleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)ontheinputsideofthe equationandthezetamoleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)ontheresultssideoftheequation. Slide19 MinimumOxygenEvaluation1 Theprimarymeasurementrequiredforcombustionmanagementisfluegasoxygencontent.Inordertodetermineiftheamountofextraoxygenis appropriatelylowasecondmeasurementisrequiredthesecondmeasurementiscombustiblesconcentrationinthefluegas.Remember,combustion managementdesirestoaddenoughoxygentoburnupallthefuelbutnottoomuchsuchthatweexperienceasignificantenergyloss. Thisisagraphofatypicalburneroperatingwithnaturalgas.Mostburnerswilloperatewithminimalcombustiblesconcentrationforawiderangeof oxygencontent.Foragivenfuelloadasfluegasoxygencontentisreducedapointisreachedwherecombustiblesconcentrationincreasesdramatically. Thismarkstheminimumfluegasoxygencontentfortheburnerfuelload.Thisindicatestheconditionwheretheburnerperformanceisnotsufficientto mixairwithfuel.Combustioncontrolthenstrivestooperatethecombustionprocessasnearaspracticaltothisloweroxygenlimit.Itisimportantto establishbaselinecombustiblesconcentrationforeachboileroverawiderangeoffuelloading. [SlideVisualMinimumOxygenGraph] AgraphicdepictsFlueGasOxygencontentalongthexaxisasapercentoffluegasoxygencontent,beginningat0%andincreasingto9%in incrementsof1%.TheverticaloryaxisdepictstheCombustiblesinpartspermillion(ppm),beginningat0andincreasingtoover160ppmin incrementsof20ppm. Thegeneraltrendindicatescombustiblesconcentrationtoberelativelylowandconstantoverabroadrangeoffluegasoxygencontent.The concentrationincreasesdramaticallyasthefluegasoxygencontentdecreasesbelow2%.Combustiblesconcentrationalsoincreasesastheflue gasoxygencontentincreasesabove8%. Slide20 MinimumOxygenEvaluation2 Itmustbementionedthatseveralfactorsimpactthecombustiblesconcentrationinadditiontotheamountofexcessoxygeninthecombustionzone.In additiontoextraoxygeninthecombustionzone,theburnermustalsobeingoodcondition.Thepurposeoftheburneristothoroughlymixand SteamEndUserTraining SteamGenerationModule StackLosses10

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DOEs BestPractices Steam End-User Training distributethefuelandtheair.Inorderforgoodcombustiontotakeplace,theairandfuelmustremaininthecombustionzoneasufficientamountof timetoallowcombustiontotakeplace,thecombustionzonemustbeatthepropertemperature,andthefuelandairmustmixthoroughly.The conditionoftheburnerimpactsallofthesefactors.BabcockandWilcoxidentifiytheseprimaryfactorsastheThreeTsofCombustion.TheReaction TIMEallowsthecombustiontobecomplete.TheReactionTEMPERATUREdrivesthechemicalreactiontocompletion.TheTURBULENCE(mixing)of thefuelandoxygenisneededtoreactcompletely.AdeficiencyinanyoneoftheseTswillresultinunreactedfuel. Slide21 OxygenLimits Manyfactorsimpactcombustionzoneoxygenlimits.Thetypeoffuelsignificantlyinfluencestheallowablecombustionzoneoxygenlimits.Allfuelsburn inthegasstate;therefore,naturalgasismorereadilycombustiblethanoilorcoal.Oilmustevaporateintothevaporstatethenburn.Coalmustdiffuse fromthesolidphasetothevaporstagebeforecombustioncantakeplace. Combustioncontrolmethodologyalsoinfluencesthecombustionlosses.Astheoxygencontentismaintainedtothepracticalminimumandcontrolled morepreciselythecombustionlossdecreases. Thetypeofburnerandtheconditionoftheburneralsoinfluenceoxygencontrolparameters. Thelocationoftheoxygenmeasurementcanbeasignificantfactorwhenoperatingboilerswithfluegaspressureslessthanatmosphericpressure.In thesesituationsanyopeningintheboilerwillleakairintothefluegasresultinginelevatedfluegasoxygencontentmeasurements. Generally,combustionparameterswillbesetsuchthatexcessoxygenincreasesasboilerloaddecreases.Theprimaryreasonforthisisthediminished turbulence(mixing)astheflowsthroughtheburnerdecrease.Elevatedburnerloadingresultsinexcellentmixing,whichallowsreducedoxygen operation. Slide22 TrimControl Typicallyinboilers,fuelflowiscontrolledbymeasuringsteampressureandadjustingfuelflowtomeetthepressuresetpoint.Ifsteampressure decreasesthefuelflowcontrollerwillincreasefuelflowfortheboilertogeneratemoresteamrestoringthesteampressuretothesetpoint. Converselyassteampressureincreases,fuelflowwillbedecreasedtoreducesteamproduction. Asthefuelflowintotheboilerchangescombustion,airflowmustalsochangetomaintainpropercombustionparameters.Combustioncontroltakes twoprimaryforms.Thefirsttypewewilldiscussisidentifiedascontinuousautomaticcontrol(alsoknownastrimcontrol).Inthiscontrolmethod combustionairflowiscontrolledbycontinuallymonitoringfluegasoxygencontentandadjustingtheairflowtomatchasetpoint.Thiscontrolcanbe veryeffectiveandefficient.

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DOEs BestPractices Steam End-User Training [SlideVisualAutomatic(Trim)Control] Theboilerconfigurationshowsafeedwatersupplyfromadeaeratordepictedbyabluerectanglewithadomeontopwhichutilizesapumpto sendfeedwatertothesteamdrumoftheboiler.Feedwaterentersthetopoftheboileratthesteamdrum,passesthroughtheboilertubes,then exitsassteamatthetopoftheboiler.Asteampressureindicatororgageisdepictedasasmallredcircleinthesteamoutlet. Justbelowtheboilerfeedwatersupply,acombustionairfanprovidesairtotheboilerscombustionzone.Theairflowiscontrolledbya damper,depictedasaslashintherectangularductworkleadingtotheboilerinlet.Thedamperiscontrolledbyacombustioncontroller device,asmallbluerectangle,whichcommunicateswithafluegasoxygensensor,asmallbluerectanglelocatedintheboilerexhaust.The signalsfromthefluegasoxygensensorandthesteampressureindicatorarerepresentedbyabluedottedline. Thecombustioncontrolisaccomplishedbyadjustingairflowintothecombustionzonetomakethefluegasoxygencontentmatchthesetpoint. Slide23 PositioningControl Theothercommontypeofcombustioncontrolinboilersissimpleandverycommon.Thissecondtypeofcontrolmanagesfuelflowthesamewayitis managedwithcontinuousautomaticcombustioncontrol.Ifsteampressuredecreases,fuelflowincreases,andviceversa.Combustionairflowcontrol isaccomplishedbymechanicallylinkingtheairflowcontroldevicetothefuelflowcontroldevice.Thisiscommonlycalledpositioningcontrolbecause theairflowcontroldevicewillhaveapositionthatisbasedsolelyonthepositionofthefuelflowcontroldevice.Itshouldbenotedthatthiscontrol doesnotincorporateanyactiveoxygenorcombustiblesmeasurements.Oxygenandcombustiblesmeasurementsareonlytakentoestablishthe positionrelationshipbetweenthefuelcontrollerandtheaircontroller.Afterthepositionrelationshipisestablishedoxygenandcombustibles measurementscease. Itshouldbenotedthatwhenpositioningcontrolisusedtheoxygencontentcannotbeminimizedbecauseofmanyfactors.Onefactorinfluencingthe airflowcontrollerpositionisambienttemperature.Ambienttemperatureisaconcernbecausethecombustionairfanisbasicallyaconstantvolume flowdevice(foragivencontrollersetpoint).Ifthepositionrelationshipisestablishedforarelativelycoolinletairtemperature,themassflowofair intothecombustionzonecouldbecomedangerouslylowastheinletairtemperatureincreases.Asaresult,positioningcontrolcanonlyattainmoderate efficiency. Tuningtheboileristheactofreestablishingthepositionrelationshipbetweentheairandfuel.Thistuningactivityiscompletedinthesamemannerthe originalairfuelcontrolpointpositionswereestablished.Theboilerisoperatedsteadilyatdiscretefuelinputpositionsandtheairflowcontroldevice positionisredefined.Theboilerwillbeoperatedatdiscreteloadsthroughouttheoperatingrangeoftheunit.Whilethefuelflowcontrolleris100 percentopen,forexample,thepositionoftheairflowcontrollerisadjusteduntilanappropriatefluegasoxygencontentisattained.Combustibles concentrationsshouldalsobemeasuredtoensureproperburneroperation.Thepositionrelationshipexerciseisrepeatedovertheoperatingrangeof theboiler(95percentload,90percentload,downtominimumload).Thisretuningactivityshouldbecompletedfrequentlytoensuresafeandefficient boileroperation. Pleasenotetherearemanyformsofcombustioncontrolbuttheconceptspresentedinthesetwocontroltechniquesarethefoundationsofall combustioncontrolmethods. SteamEndUserTraining SteamGenerationModule StackLosses12

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DOEs BestPractices Steam End-User Training Positioningcontrolisalsoknownasjackshaftcontrol. [SlideVisualAutomatic(Trim)Control] Theboilerconfigurationshowsafeedwatersupplyfromadeaeratordepictedbyabluerectanglewithadomeontopwhichutilizesapumpto sendfeedwatertothesteamdrumoftheboiler.Feedwaterentersthetopoftheboileratthesteamdrum,passesthroughtheboilertubes,then exitsassteamatthetopoftheboiler.Asteampressureindicatororgageisdepictedasasmallredcircleinthesteamoutlet. Justbelowtheboilerfeedwatersupply,acombustionairfanprovidesairtotheboilerscombustionzone.Theairflowiscontrolledbya damper,depictedasaslashintherectangularductworkleadingtotheboilerinlet.Thedamperiscontrolledbyacombustioncontroller device,asmallbluerectangle,whichcommunicateswithafluegasoxygensensor,asmallbluerectanglelocatedintheboilerexhaust.The signalsfromthefluegasoxygensensorandthesteampressureindicatorarerepresentedbyabluedottedline. Thecombustioncontrolisaccomplishedbyadjustingairflowintothecombustionzonetomakethefluegasoxygencontentmatchthesetpoint. Slide24 OxygenContentControlParameters Thistableisagoodindicatorofwhatyoushouldexpectfrommostboilersintermsofoxygenconcentrations.Itmustbenotedthatmanyfactorscan influencetheactualfluegasoxygencontentthesearesimplycommonlyobservedoperatingconditions.Thetwotypesofcontrolmethodology discussedareidentifiedinthetable,automaticcontrolandpositioningcontrol.Generally,thehigherfluegasoxygencontentvaluescorrespondwith lowburnerloadandthelowfluegasoxygencontentscorrespondwithhighburnerload.Lessexcessairisrequiredathigherburnerloadsbecausehigh velocitiesintheburnerenhancesmixingandthecombustionreactions. Excessairisnotedinthetableforreferencepurposes.Fluegasoxygencontentisthemeasuredvalue.Excessairiscalculatedfromthefuelcomposition andthemeasuredoxygenvalue.

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SteamEndUserTraining SteamGenerationModule StackLosses13

DOEs BestPractices Steam End-User Training [SlideVisualTypicalFlueGasContentControlParametersTable] Fuel Natural Gas Number2 FuelOil Number6 FuelOil Pulverized Coal Stoker Coal AutomaticControl FlueGasO 2 Content Min. Max. [%] [%] 1.5 3.0 2.0 2.5 2.5 3.5 3.0 3.5 4.0 5.0 PositioningControl FlueGasO 2 Content Min. Max. [%] [%] 3.0 7.0 3.0 3.5 4.0 5.0 7.0 8.0 7.0 8.0 Higheroxygenlimitsarepairedtolowburnerloads. Loweroxygenlimitsarepairedwithhigherburnerloads. Slide25 StackLossEvaluation Insummary,stacklossisthelargestlossassociatedwithmostboilers.Managingstacklossiscriticaltocontrollingsteamsystemoperatingcosts.The measurementsrequiredtomanagestacklossarefluegasexittemperature,fluegasoxygencontent,ambienttemperature,boilerload,andfluegas combustiblesconcentration.Inordertoquantifythestackloss,thecriticalmeasurementsmustbeusedinconjunctionwithcombustioncalculations. Combustioncalculationscanbearrangedinmanyforms.Onestraightforwardformisastacklosstable. Slide26 StackLossNaturalGas Thestacklosstablespresentedherearejustoneformofcombustiondatausedtoquantifystackloss.Otherformsofstacklossinformationinclude computermodels,calculations,graphs,andnomographs.Allstacklossanalysesusethesameinitialinformationfluegastemperature,fluegasoxygen content,combustiblesconcentration,andfuelcomposition.Stacklosstablesareastraightforwardcommunicationvehicle.Stacklosscalculationsare basedonthedifferenceinfluegastemperatureandambienttemperaturethisisknownasthenetstacktemperature.Ambienttemperaturedoeshave SteamEndUserTraining SteamGenerationModule StackLosses14 AutomaticControl ExcessAir Min. Max. [%] [%] 9 18 11 14 14 20 18 21 25 32 PositioningControl ExcessAir Min. Max. [%] [%] 18 55 18 21 25 32 55 65 50 65

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DOEs BestPractices Steam End-User Training animpactonfluegastemperaturebecausesuchalargeamountofairpassesthroughtheboiler.Whenambientairtemperaturedecreasesfluegas temperaturewilldecrease. Theotherprimaryinputinformationrequiredtousestacklosscalculatorsistheamountofoxygeninthefluegas.Athirdmeasurementisalsorequired tocompletethestacklossanalysiscombustiblesconcentrationinthefluegas.Combustiblesconcentrationisofcourseameasureoftheunburnedfuel exitinginthefluegas.Combustiblesconcentrationslessthan100ppmgenerallyyieldnegligibleimpactonstackloss.Thestacklosstablesthatfollow areforvariouscommonfuels,thefluegascontainsnegligiblecombustibles,andwaterexitsasavapor(nocondensate). [SlideVisualStackLossTableforNaturalGas] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70

180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70

205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

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DOEs BestPractices Steam End-User Training Slide27 Number2FuelOil Thisstacklosstableiscompiledfornumber2fueloil.Number2fueloiliscommonhouseholdheatingfuelandisessentiallydieselfuel. [SlideVisualStackLossTableforNumber2FuelOil] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

180 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F] 9.5 9.6 9.8 10.1 10.3 10.6 10.9 11.3 11.7 12.2 250 70

205 10.0 10.2 10.4 10.7 10.9 11.3 11.6 12.1 12.6 13.1 275 70

230 10.5 10.7 11.0 11.3 11.6 12.0 12.4 12.8 13.4 14.1 300 70

255 11.0 11.3 11.6 11.9 12.2 12.6 13.1 13.6 14.3 15.0 325 70

280 11.5 11.8 12.1 12.5 12.9 13.3 13.8 14.4 15.1 15.9 350 70

305 12.1 12.4 12.7 13.1 13.5 14.0 14.6 15.2 16.0 16.8 375 70

330 12.6 12.9 13.3 13.7 14.2 14.7 15.3 16.0 16.8 17.8 400 70

355 13.1 13.5 13.9 14.3 14.8 15.4 16.1 16.8 17.7 18.7 425 70

380 13.7 14.1 14.5 15.0 15.5 16.1 16.8 17.6 18.5 19.6 450 70

405 14.2 14.6 15.1 15.6 16.2 16.8 17.5 18.4 19.4 20.6 475 70

430 14.7 15.2 15.7 16.2 16.8 17.5 18.3 19.2 20.3 21.5 500 70

455 15.3 15.7 16.3 16.8 17.5 18.2 19.0 20.0 21.1 22.5 525 70

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DOEs BestPractices Steam End-User Training Slide28 Number6FuelOil(LowSulfur) Number6fueloilisheavyfueloilitiscommonlysolidatroomtemperature.Oftennumber6fueloilisclassifiedintohighsulfurcontentandlow sulfurcontent. [SlideVisualStackLossTableforNumber6FuelOil(LowSulfur)] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

205 9.5 9.7 9.9 10.1 10.4 10.8 11.1 11.6 12.1 12.7 275 70

230 10.0 10.2 10.5 10.8 11.1 11.4 11.9 12.3 12.9 13.6 300 70

255 10.5 10.8 11.1 11.4 11.7 12.1 12.6 13.1 13.8 14.5 325 70

280 11.0 11.3 11.6 12.0 12.4 12.8 13.3 13.9 14.6 15.4 350 70

305 11.6 11.9 12.2 12.6 13.0 13.5 14.1 14.7 15.5 16.4 375 70

330 12.1 12.4 12.8 13.2 13.7 14.2 14.8 15.5 16.3 17.3 400 70

355 12.6 13.0 13.4 13.9 14.4 14.9 15.6 16.3 17.2 18.2 425 70

380 13.2 13.6 14.0 14.5 15.0 15.6 16.3 17.1 18.1 19.2 450 70

405 13.7 14.1 14.6 15.1 15.7 16.3 17.1 17.9 18.9 20.1 475 70

430 14.3 14.7 15.2 15.7 16.3 17.0 17.8 18.8 19.8 21.1 500 70

455 14.8 15.3 15.8 16.4 17.0 17.7 18.6 19.6 20.7 22.0 525 70

480 15.3 15.8 16.4 17.0 17.7 18.5 19.4 20.4 21.6 23.0 550 70

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DOEs BestPractices Steam End-User Training Slide30 TypicalEasternCoal Allcommonfuelshavearangeincomposition.Therangeincompositionofcommerciallyavailablenaturalgasisverysmallwhencomparedtothe variabilityofheavyfueloil.However,whenconsideringcoalstherangeinvariabilityisevengreater.Thesecoalandwoodstacklosstablesshouldbe consideredestimatesonly. [SlideVisualStackLossTableforTypicalEasternCoal] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

230 8.5 8.7 9.0 9.3 9.6 10.0 10.4 10.9 11.4 12.1 300 70

255 9.0 9.3 9.6 9.9 10.3 10.7 11.1 11.7 12.3 13.0 325 70

280 9.6 9.9 10.2 10.5 10.9 11.4 11.9 12.5 13.2 14.0 350 70

305 10.1 10.4 10.8 11.2 11.6 12.1 12.6 13.3 14.0 14.9 375 70

330 10.7 11.0 11.4 11.8 12.3 12.8 13.4 14.1 14.9 15.9 400 70

355 11.2 11.6 12.0 12.4 12.9 13.5 14.2 14.9 15.8 16.8 425 70

380 11.8 12.1 12.6 13.1 13.6 14.2 14.9 15.7 16.7 17.8 450 70

405 12.3 12.7 13.2 13.7 14.3 14.9 15.7 16.5 17.6 18.7 475 70

430 12.8 13.3 13.8 14.3 14.9 15.6 16.4 17.4 18.4 19.7 500 70

455 13.4 13.9 14.4 15.0 15.6 16.4 17.2 18.2 19.3 20.7 525 70

480 14.0 14.4 15.0 15.6 16.3 17.1 18.0 19.0 20.2 21.6 550 70

505 14.5 15.0 15.6 16.3 17.0 17.8 18.7 19.8 21.1 22.6 575 70

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DOEs BestPractices Steam End-User Training Slide32 TypicalGreenWood Greenwoodisaverycommonfuelinmanyindustries.Greenwoodrefersprimarilytotheportionsoftreesthatarenotusedinthepapermakingand lumbermakingprocesses.Barkandotherwoodchipsthathavebeenremovedfromfreshlycuttreesaretheprimarysourcesofgreenwood.Itis interestingtonotethatgreenwoodisgenerally50%liquidwater.Asaresult,thestacklossassociatedwithgreenwoodisveryhigh. [SlideVisualStackLossTableforTypicalGreenWood] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

230 35.7 36.0 36.3 36.7 37.1 37.5 38.0 38.6 39.3 40.2 300 70

255 36.7 37.1 37.5 37.9 38.4 39.0 39.6 40.4 41.3 42.4 325 70

280 37.1 37.4 37.8 38.2 38.7 39.3 39.9 40.7 41.5 42.5 350 70

305 38.1 38.6 39.0 39.6 40.2 40.9 41.7 42.6 43.7 45.0 375 70

330 38.4 38.9 39.3 39.8 40.4 41.1 41.8 42.7 43.7 44.9 400 70

355 39.6 40.1 40.6 41.3 42.0 42.8 43.7 44.8 46.1 47.6 425 70

380 39.8 40.3 40.8 41.4 42.1 42.9 43.7 44.7 45.9 47.3 450 70

405 41.0 41.6 42.2 42.9 43.8 44.7 45.8 47.0 48.5 50.2 475 70

430 41.2 41.8 42.4 43.0 43.8 44.7 45.6 46.8 48.1 49.7 500 70

455 42.5 43.1 43.9 44.7 45.6 46.6 47.8 49.2 50.9 52.9 525 70

480 42.6 43.2 43.9 44.7 45.5 46.5 47.6 48.9 50.3 52.1 550 70

505 44.0 44.7 45.5 46.4 47.4 48.6 49.9 51.5 53.3 55.5 575 70

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DOEs BestPractices Steam End-User Training Slide33 CombustionManagement Insummary,propercombustionmanagementrequiresaddingenoughoxygentothecombustionzonetoburnallofthefuelbutnotaddingtoomuchair tomakesurethethermallossisminimized.Combustionmanagementstrategyinitiateswithmeasuringtheconditionofthecombustionprocess, utilizestheexistingequipmenttomanagethecombustionprocesstothebestextentpractical,andtoexaminetheopportunitiestomodifyoperations andequipmenttofurtherimprovecombustionperformance. [SlideVisualCombustionManagementSummary] Combustionmanagementprinciples: Addenoughoxygentoreactallofthefuel. Minimizetheamountofextraairtolimittheenergyloss. Monitorcombustiblestoidentifyproblems. 1. Measuretheoxygencontentofboilerexhaustgas. Continuously. Periodically. 2. Controloxygencontentwithinaminimumandmaximumrange. Continuousautomaticcontrol. Positioningcontrol. 3. Challengethecontrolrange. Combustiblesmeasurement. Burnerrepair. Controlupgrade. Combustiontuning. Slide34 StackLossExample Letsreturntoourexampleboiler,takesomemeasurements,andestimatetheboilerefficiency.Forourexampleboilerwehavemeasuredthefluegas temperaturetobe450F,ambienttemperaturetobe70F,andthefluegasoxygencontenttobe7.0%.Combustiblesconcentrationwasmeasuredtobe lessthan10ppm,whichisnegligiblysmall.

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DOEs BestPractices Steam End-User Training [SlideVisualStackLossExample] DeterminetheStackLoss(NaturalGas) Combustionanalyzerdata: FluegasO2content7%byvolume FluegasCO2content6%byvolume FluegasCOcontent~0ppm Fluegasunburnedfuel~0% Fluegastemperature450F Intakeairtemperature70F Fueltemperature70F 380Fnetfluegastemperature

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DOEs BestPractices Steam End-User Training Slide35 StackLossNaturalGas1 Wetakethesemeasurementstothestacklosstablefornaturalgas. [SlideVisualStackLossTableforNaturalGas] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70

180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70

205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

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DOEs BestPractices Steam End-User Training Slide36 StackLossNaturalGas2 Thisdataidentifiesthestacklosstobe21.2%. [SlideVisualStackLossTableforNaturalGas] FlueGas Oxygen Content WetBasis[%] StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70

180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70

205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

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DOEs BestPractices Steam End-User Training Slide37 StackLossExample Thisinformationallowsagrossestimateofboilerefficiencytobeestablishedas78.8%,whichis100%minusthestacklossof21.2%. [SlideVisualStackLossExample] Thisinformationallowsagrossestimateofboilerefficiencytobeestablishedas78.8%(10021.2). DeterminetheStackLoss(NaturalGas) Combustionanalyzerdata: FluegasO2content7%byvolume FluegasCO2content6%byvolume FluegasCOcontent~0% Fluegasunburnedfuel~0% Fluegastemperature450F(380Fnet) Intakeairtemperature70F Fueltemperature70F StackLoss 21.2% Combustionefficiency78.8%

Slide38 StackLossCalculator TheSteamSystemAssessmentToolcontainsanotherformofstacklosscalculator.Thiscalculatorallowsfluegastemperature,ambienttemperature, andfluegasoxygencontenttobeinputwithstacklossforvariousfuelsastheoutput.

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DOEs BestPractices Steam End-User Training [SlideVisualStackLossCalculator] SteamSystemAssessmentTool StackLossCalculator BasedonuserinputsofStackTemperature,AmbientTemperatureandStackOxygenContent,anestimatewillbeprovided oftheheatlossfromtheboilerstack. Lossesareexpressedasapercentageoftheheatfired. StacklossesarerelatedtoSSATBoilerEfficiencyasfollows: SSATBoilerEfficiency=100%StackLoss(%)ShellLoss(%) ShellLossreferstotheradiantheatlossfromtheboiler.Typically<1%atfullload,12%atreducedload. InputData StackGasTemperature(F) AmbientTemperature(F) 450 70 F F StackGasOxygenContent(%) 7 % StackTemperatureAmbientTemperature=380F

Note:Stackgasoxygencontentisexpressedonamolarorvolumetricbasis

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DOEs BestPractices Steam End-User Training

Results EstimatedStackLossesforeachofthedefaultfuelsareasfollows: NaturalGas Number2FuelOil Number6FuelOil(LowSulfur) Number6FuelOil(HighSulfur) TypicalEasternCoal(Bituminous) TypicalWesternCoal(Subbituminous) TypicalGreenWood Slide39 IndirectEfficiencySummary Otherinvestigationshaveyieldedestimatesoftheshelllossandtheblowdownloss.Otherlossesareconsiderednegligibleforthisboiler.Asaresult, boilerefficiencycanbedeterminedinanindirectmannerbysubtractingtheselossesfromaperfectlyefficientboiler.Thismethodestimatestheboiler efficiencytobe77.4%. Onceagain,wegetindirectefficiencybysubtractingthepercentageofeachlossfrom100percent. Thisindirectefficiencyevaluationisinexcellentagreementwiththepreviouslydetermineddirectboilerefficiencyof77.1%. [SlideVisualBoilerLossIndirectEfficiencyEquations] n indirect =100percentE losses IndirectBoilerEfficiencyisequalto100%minusthesumofallboilerlosses. SteamEndUserTraining SteamGenerationModule StackLosses26 21.3 % 16.8 % 16.4 % 16.6 % 15.0 % 16.5 % 27.4 %

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DOEs BestPractices Steam End-User Training n indirect =100percentshellblowdownstackmisc IndirectBoilerEfficiencyisequalto100%minustheshelllosses,minustheblowdownlosses,minusthestacklosses,minusthemiscellaneous losses. n indirect =100%21.2%0.9%0.5%0% n indirect =77.4% n direct =77.1% Abbreviations n indirect =indirectefficiency n direct =directefficiency(classic) E losses =sumofalllosses Slide40 StackLossesExample [SlideVisualStackLossExampleTitlePage]

SteamGenerationEfficiency
EfficiencyDefinition RadiationandConvectionlosses Shelllosses Blowdownlosses StacklossesExample

Slide41 BoilerLossExample1

Ourexampleboilerisoperatingwithanefficiencyofabout77%.Typicalnaturalgasfiredboilerefficiencyis83%andhigherefficienciesareattainable. Asaresult,weareexpectingthisboilerwillhaveimprovementopportunities.

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DOEs BestPractices Steam End-User Training [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide42 BoilerLossExample2 Arethereareasofinterest?Aretheremeasurementsthatindicateimprovementsmaybepossible? [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide43 BoilerLossExample3 Thefluegasexhausttemperatureisnotextremelyhigh;however,450Fiswellabovethepracticallimitoffluegastemperatureforanaturalgasfired boiler.Itiscommontodesignnaturalgasfiredboilerstooperatewithfluegastemperatureslessthan300F. Additionally,thefluegasoxygencontentappearstobeelevated7%fluegasoxygencontentistheupperendoftypicalfornaturalgasboilers. Atthispointwedonotknowifthereareproblemswiththeboiler,iftheboilerhasalwaysoperatedwiththeseconditions,orifrecentchangeshave resultedintheseconditionsbutwedoknowthattheprimaryboilermeasurementsindicateinvestigationshouldbegin. [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. SteamEndUserTraining SteamGenerationModule StackLosses28

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DOEs BestPractices Steam End-User Training Aquestionatthetopoftheslideasks: Arethereanyinterestingareasofinvestigation?

Slide44 BoilerLossExample4 Letsstartourinvestigationbytargetingthefluegasoxygencontenttheremaybeadjustmentswecanmaketotheboileroperationsimmediatelyand beginsavingfuelnow. [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide45 BoilerLossExample5 Ourinvestigationoftheboileridentifiesthatpositioningcontrolisusedtomanagethecombustionoperations. [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide46 FlueGasContentControlParameters1 Recall,mostnaturalgasfiredboilersoperatingwithpositioningcontrolwilloperatewithfluegasoxygencontentrangingfrom3%to7%.Ourexample boilerisoperatingattheupperendofthisrange;however,wealsorememberthatthehigheroxygencontentisrequiredforlowerboilerloads.This boilerisoperatingatafairlyheavyloadgreaterthan80%.

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DOEs BestPractices Steam End-User Training [SlideVisualTypicalFlueGasContentControlParametersTable] Fuel NaturalGas Number2 FuelOil Number6 FuelOil Pulverized Coal StokerCoal Slide47 FlueGasContentControlParameters2 Asaresult,wewouldexpectthisboilertooperatewithfluegasoxygencontentcloserto3%. Now,beforewespendalotoftimeandenergyattemptingtoreducethecombustionzoneoxygencontentletsgetanunderstandingofthesavings potential.Rememberthefluegasanalysisdataindicatedtherewerenegligiblecombustiblesintheexhaustgas.Thisleadsustoexpectthattheburner canoperatewithlessexcessair.Atthispointwearenotsurewhattheminimumfluegasoxygencontentisforthisburnertooperatewithgood performance.However,wefullyexpectthisburnertobeabletooperatewithlessthan5%oxygen.Letsestimatethesavingsopportunityassociated withreducingthefluegasoxygencontentto5%.Thiswillhelpusunderstandhowinterestedweshouldbeintuningtheboiler. AutomaticControl FlueGasO 2 Content Min. Max. [%] [%] 1.5 3.0 2.0 3.0 2.5 2.5 3.5 3.5 4.0 5.0 PositioningControl FlueGasO 2 Content Min. [%] 3.0 3.0 3.5 4.0 5.0 Max. [%] 7.0 7.0 8.0 7.0 8.0 AutomaticControl ExcessAir Min. [%] 9 11 14 14 20 Max. [%] 18 18 21 25 32 PositioningControl ExcessAir Min. [%] 18 18 21 25 32 Max. [%] 55 55 65 50 65

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DOEs BestPractices Steam End-User Training [SlideVisualTypicalFlueGasContentControlParametersTable] Fuel NaturalGas Number2 FuelOil Number6 FuelOil Pulverized Coal StokerCoal Slide48 StackLossNaturalGas Thestacklosstableisanexcellentvehicletohelpidentifythetuningopportunity.Wewilltakeaconservativeapproachandassumewecantunethe boilerto5%oxygenwearefairlyconfidentwecanusetheexistingcombustioncontrolsandachieveevenloweroxygencontent;but,rightnowwe areinterestedtocharacterizetheopportunity. Ifthecombustionzoneoxygencontentisreducedfrom7%to5%andthefluegastemperatureremainsconstant,thestacklosswillreducefrom21.2% to19.9%.Thesevaluescanbeusedtoestimateoverallboilerefficiencybysubtractingthemfrom100%. AutomaticControl FlueGasO 2 Content Min. Max. [%] [%] 1.5 3.0 2.0 3.0 2.5 2.5 3.5 3.5 4.0 5.0 PositioningControl FlueGasO 2 Content Min. [%] 3.0 3.0 3.5 4.0 5.0 Max. [%] 7.0 7.0 8.0 7.0 8.0 AutomaticControl ExcessAir Min. [%] 9 11 14 14 20 Max. [%] 18 18 21 25 32 PositioningControl ExcessAir Min. [%] 18 18 21 25 32 Max. [%] 55 55 65 50 65

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DOEs BestPractices Steam End-User Training [SlideVisualStackLossTableforNaturalGas]

StackLossTablefor NaturalGas

FlueGas Oxygen Content WetBasis[%] 155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70 180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70 205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

Slide49 BoilerTuningPotentialAnalysis Theseefficiencyestimatescanbeusedtoestimatethefuelcostimpactassociatedwithtuningtheboiler.Theequationpresentedhereisverysimple; however,itisarigorousrepresentationoftheeconomicimpactofboilerefficiencychanges.

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DOEs BestPractices Steam End-User Training Thiscalculationindicatestuningtheboilerhasapotentialofreducingfuelconsumptionmorethan200,000dollarsayear.Tuningthepositioning controlsofanaturalgasfiredboilerwilltypicallyrequireatechnicianlessthanadaytocomplete.Thetuningactivityisrelativelylowcost.Inother words,weareveryinterestedintuningthisboiler. Infact,wedidtunethisboilerandweachievednominally5%oxygeninthecombustionzone.Thecombustiblesconcentrationremainednegligible throughoutthetuningactivity.Actuallyduringthetuningactivitythecombustionzoneoxygencontentwasreducedtolessthan2%withminimal increaseincombustiblesconcentration.Anoxygencontentlessthan3%isconsideredoutsidethetypicalrangeforpositioningcontrol.Operatorsatthe sitewerereluctanttotunetheboilertolessthan5%oxygenbecauseofhistoricallyoperatingathighervalues. Therefore,wewanttoexaminetheimpactoftransitioningfrompositioningcontroltocontinuousautomaticcontrol. [SlideVisualImprovedEfficiencySavingsfor5%O 2 inExample] O savings ={1(n existing /n adjusted )}(K boiler ) Thesavingsisequalto1minustheexistingboilerefficiencydividedbytheadjustedboilerefficiencyadjusted;multipliedbycostsoftheboiler. O savings ={1(78.8%/80.1%)}13,000,000dollars/year=220,000dollars/year Thesavings(Sigmasubscriptsavings)isequalto1minusthe78.8%dividedby80.1%;multipliedby13,000,000dollarsperyearequals 220,000dollarsperyear.

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DOEs BestPractices Steam End-User Training Slide50 FlueGasContentControlParameters Continuousautomaticcontrolisexpectedtobeabletooperatewithcombustionzoneoxygencontentrangingfrom1.5%to3.0%.Fieldtrialsindicate theburnerperformswellwithreducedcombustionzoneoxygencontent.Wecancompleteanotheranalysistodeterminetheimpactoftransitioningto continuousautomaticcontrol. [SlideVisualTypicalFlueGasContentControlParametersTable] Fuel NaturalGas Number2 FuelOil Number6 FuelOil Pulverized Coal StokerCoal AutomaticControl FlueGasO 2 Content Min. Max. [%] [%] 1.5 3.0 2.0 3.0 2.5 2.5 3.5 3.5 4.0 5.0 PositioningControl FlueGasO 2 Content Min. [%] 3.0 3.0 3.5 4.0 5.0 Max. [%] 7.0 7.0 8.0 7.0 8.0 AutomaticControl ExcessAir Min. [%] 9 11 14 14 20 Max. [%] 18 18 21 25 32 PositioningControl ExcessAir Min. [%] 18 18 21 25 32 Max. [%] 55 55 65 50 65

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DOEs BestPractices Steam End-User Training Slide51 StackLossNaturalGas Theanalysisproceedsexactlylikethetuningcalculations.Thecurrentstacklossis19.9%andtheconservativeestimateoffutureoperationsis18.8%. [SlideVisualStackLossTableforNaturalGas] StackLossTablefor NaturalGas

FlueGas Oxygen Content WetBasis[%] 155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70 180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70 205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

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DOEs BestPractices Steam End-User Training Slide52 AutomaticCombustionControl Basedontheoperatingcostofthetunedboilerthesavingsestimateexceeds150,000dollarsayear. Thissimplifiedanalysisindicatesattractivesavingsopportunitiesassociatedwithtuningtheboilerandwithinstallingacontinuousautomatic combustioncontroller.Atthistimethecostofinstallingacombustioncontrollerisnotknownbutitisexpectedtorequirelessthan$150,000 warrantingfurtherinvestigation. 450oF70oF=380oFNetStackTemperature CurrentEfficiency At7%O 2 ,n=100%21.2%=78.8% ImprovedEfficiency At5%O 2 ,n=100%19.9%=80.1% At3%O 2 ,n=100%18.8%=81.2% [SlideVisualAdditionalEfficiencySavingsfor3%O 2 inExample] O savings ={1(n existing /n adjusted )}(K boiler ) Thesavingsisequalto1minustheexistingboilerefficiencydividedbytheadjustedboilerefficiencyadjusted;multipliedbycostsoftheboiler. O savings ={1(80.1%/81.2%)}12,780,000dollars/year=166,000dollars/year Thesavings(Sigmasubscriptsavings)isequalto1minusthe80.1%dividedby81.2%;multipliedby12,780,000dollarsperyearequals 166,000dollarsperyear. Slide53 BoilerLossExample Wehavesetthestrategyforcombustionmanagementforthisboilertunetheexistingboilercombustioncontrols,exploreinstallingcontinuous automaticcombustioncontrol,andcontinuallychallengethecontrolparameters. Nowwearereadytoexaminethefluegastemperatureimpacts.Thefluegastemperatureisnominally450F,whichisnotexcessivelyhighbutitis muchgreaterthantheminimumallowable. SteamEndUserTraining SteamGenerationModule StackLosses36

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DOEs BestPractices Steam End-User Training [SlideVisualBoilerLossExample] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide54 ElevatedFlueGas1 Asweexaminethepossiblereasonsforthecurrentfluegastemperaturewefindthattheboilerwaterqualityismaintainedwellwithinacceptable ranges,thefuelusedhasminimalpotentialforfouling,andtheboilerisoperatingwithindesignsteamproductionlimits.Theseissuesdonotidentify anyopportunitiestoallowthefluegastemperaturetobecorrected. [SlideVisualWatertubeBoiler] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load. Slide55 ElevatedFlueGas2 Anexaminationoftheoriginaldesigninformationoftheboilerrevealstheboilerwasoriginallydesignedwithafeedwatereconomizer.Inthepastthe feedwatereconomizerexperiencedsometubefailuresandwasdecommissioned. [SlideVisualWatertubeBoiler] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load.

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DOEs BestPractices Steam End-User Training Slide56 FeedwaterEconomizerEvaluation Installinganewfeedwatereconomizerwillallowustorecoverfluegasthermalenergybypreheatingboilerfeedwater.Anewfeedwatereconomizer couldbedesignedtoreducethefluegastemperatureto300Forevenless.Thestacklosstablecanbeusedtoestablishanestimateofthefuelsavings potential. [GraphicalDescriptionWatertubeBoiler] Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit. Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear. Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load.

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DOEs BestPractices Steam End-User Training Slide57 StackLossNaturalGas Thecurrentstacklossis19.9%(wehaveonlytunedtheboiler.Wehavenotinstalledcontinuousautomaticcombustioncontrol).Theeconomizerwill reducethestacklossto15.8%. [SlideVisualStackLossTableforNaturalGas] StackLossTablefor NaturalGas

FlueGas Oxygen Content WetBasis[%] 155 13.1 13.2 13.4 13.6 13.8 14.1 14.4 14.7 15.1 15.5 225 70 180 13.6 13.8 14.0 14.2 14.5 14.8 15.1 15.5 16.0 16.5 250 70 205 14.1 14.3 14.6 14.8 15.1 15.5 15.9 16.3 16.8 17.4 275 70

StackLoss[%offuelhigherheatingvalueinput] NetStackTemperature[F] {Differencebetweenfluegasexhausttemperatureandambienttemperature}

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 ActualExhaustT [F] AmbientT[F]

230 14.7 14.9 15.2 15.5 15.8 16.2 16.6 17.1 17.7 18.4 300 70

255 15.2 15.5 15.8 16.1 16.5 16.9 17.4 17.9 18.6 19.4 325 70

280 15.8 16.1 16.4 16.7 17.2 17.6 18.1 18.8 19.5 20.3 350 70

305 16.3 16.6 17.0 17.4 17.8 18.3 18.9 19.6 20.4 21.3 375 70

330 16.9 17.2 17.6 18.0 18.5 19.1 19.7 20.4 21.2 22.2 400 70

355 17.4 17.8 18.2 18.7 19.2 19.8 20.5 21.2 22.1 23.2 425 70

380 18.0 18.4 18.8 19.3 19.9 20.5 21.2 22.1 23.0 24.2 450 70

405 18.5 18.9 19.4 20.0 20.5 21.2 22.0 22.9 23.9 25.2 475 70

430 19.1 19.5 20.0 20.6 21.2 22.0 22.8 23.7 24.8 26.1 500 70

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DOEs BestPractices Steam End-User Training ImprovedEfficiencywith5%BoilerTuning At5%O 2 and380oF,n=100%19.9%=80.1% FurtherImprovedEfficiencybyAddingFeedwaterEconomizer 300oF70oF=230oFNetStackTemperature At5%O 2 and230oF,n=100%15.8%=84.2% Slide58 EconomizerPotentialAnalysis Theefficiencyimprovementcalculationindicatesthefuelsavingsismorethan600,000dollarsayear.Afeedwatereconomizerisexpectedtorequire lessthan500,000dollarstopurchaseandinstall.Asaresult,thisprojectisrecommendedtoexplorefurther. [SlideVisualSavingsCalculation] O savings ={1(n existing /n adjusted )}(K boiler ) Thesavingsisequalto1minustheexistingboilerefficiencydividedbytheadjustedboilerefficiencyadjusted;multipliedbycostsoftheboiler. O savings ={1(80.1%/81.2%)}12,780,000dollars/year=166,000dollars/year Thesavings(Sigmasubscriptsavings)isequalto1minusthe80.1%dividedby84.2%;multipliedby12,780,000dollarsperyearequals 615,000dollarsperyear. Slide59 StackLossReductionSummary Managingstacklossisacriticalfactorinimprovingboilerefficiency.Significantemphasisshouldbeplacedonmeasuringthecriticalparametersthat identifyboileroperatingcharacteristics.Challengingfluegastemperature,oxygenvalues,andcombustiblesconcentrationsareallaspectsofboiler management.

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DOEs BestPractices Steam End-User Training [SlideVisualStackLossReduction] Measure,record,andcompare o Fluegasexittemperature Andintermediatetemperatures o Fluegasoxygencontent o Boilerload o Ambienttemperature o Fluegascombustibles Reducefluegasexittemperature o Repairfailedcomponents o Cleanfireside o Maintainwaterside o Installheatrecoverycomponents Feedwatereconomizer Combustionairpreheater Reduceexcessair o Tuneboilercombustionprocess o Installautomaticcombustioncontrol o Challengecontrolparameters

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