Boilers & Thermic Fluid Heaters

Training Session on Energy Equipment
Boilers & Thermic Fluid Heaters

Boilers
www.energyefficiencyasia.org
Presentation from the mal Equipment/ Energy Efficiency Guide for Industry in Asia
UNEP 2006
Training Agenda: Boiler
Introduction Type of boilers Assessment of a boiler Energy efficiency opportunities mal Equipment/ Boilers
UNEP 2006
Introduction
What is a Boiler?
Vessel that heats water to become hot water or steam mal Equipment/ At atmospheric pressure water Boilers volume increases 1,600 times Hot water or steam used to transfer heat to a process
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Introduction
STEAM TO PROCESS
EXHAUST GAS VENT
STACK
DEAERATOR
PUMPS
ECONOMIZER
mal Equipment/ Boilers

VENT
BOILER
BURNER WATER SOURCE
BLOW DOWN SEPARATOR
FUEL
BRINE CHEMICAL FEED SOFTENERS
Figure: Schematic overview of a boiler room
UNEP 2006
UNEP 2006
Types of Boilers
What Type of Boilers Are There?
1. Fire Tube Boiler 2. Water Tube Boiler 3. Packaged Boiler mal Equipment/ 4. Fluidized Bed (FBC) Boiler Boilers 5. Stoker Fired Boiler 6. Pulverized Fuel Boiler 7. Waste Heat Boiler 8. Thermic Fluid Heater (not a boiler!)
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Type of Boilers
1. Fire Tube Boiler

Relatively small steam capacities (12,000 kg/hour) Low to medium steam pressures (18 kg/cm2) Operates with oil, gas or solid fuels
(Light Rail Transit Association)

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Type of Boilers
2. Water Tube Boiler

Used for high steam demand and pressure requirements Capacity range of 4,500 120,000 kg/hour Combustion efficiency enhanced by induced draft provisions Lower tolerance for water quality and needs water treatment plant
(Your Dictionary.com)
UNEP 2006
Type of Boilers
3. Packaged Boiler
To Chimney

Oil Burner
Comes in complete package Features o High heat transfer o Faster evaporation o Good convective heat transfer o Good combustion efficiency o High thermal efficiency Classified based on number of passes
(BIB Cochran, 2003)
UNEP 2006
Type of Boilers
4. Fluidized Bed Combustion (FBC) Boiler
Particles (e.g. sand) are suspended in high velocity air stream: bubbling fluidized bed mal Equipment/ Combustion at 840 950 C Capacity range 0,5 T/hr to 100 T/hr Boilers Fuels: coal, washery rejects, rice husk, bagasse and agricultural wastes Benefits: compactness, fuel flexibility, higher combustion efficiency, reduced SOx & NOx
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Type of Boilers
4a. Atmospheric Fluidized Bed Combustion (AFBC) Boiler
Most common FBC boiler that uses preheated atmospheric air as fluidization and combustion air
mal Equipment/ Boilers 4b. Pressurized Fluidized Bed Combustion (PFBC) Boiler
Compressor supplies the forced draft and combustor is a pressure vessel Used for cogeneration or combined cycle power generation
UNEP 2006
Type of Boilers
4c. Atmospheric Circulating Fluidized Bed Combustion (CFBC) Boiler
Solids lifted from bed, rise, return to bed Steam generation in convection section Benefits: more economical, better space utilization and efficient combustion
(Thermax Babcock & Wilcox Ltd, 2001)
UNEP 2006
Type of Boilers
5. Stoke Fired Boilers

a) Spreader stokers
Coal is first burnt in suspension then in coal bed Flexibility to meet load fluctuations mal Equipment/ Favored in many industrial applications Boilers
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Type of Boilers
5. Stoke Fired Boilers

b) Chain-grate or traveling-grate stoker
Coal is burnt on moving steel grate Coal gate controls coal feeding rate Uniform coal size for complete combustion
(University of Missouri, 2004)

UNEP 2006
Type of Boilers
6. Pulverized Fuel Boiler

Pulverized coal powder blown with combustion air into boiler through burner nozzles
mal Equipment/ Combustion temperature at 1300 Boilers
1700 C Benefits: varying coal quality coal, quick response to load changes and high preheat air temperatures
Tangential firing
UNEP 2006
Type of Boilers
7. Waste Heat Boiler

Used when waste heat available at medium/high temp Auxiliary fuel burners used if steam demand is more than the waste heat can generate Used in heat recovery from exhaust gases from gas turbines and diesel engines
Agriculture and Agri-Food Canada, 2001
UNEP 2006
Type of Boilers
8. Thermic Fluid Heater
Wide application for indirect process heating Thermic fluid (petroleum-based) is heat transfer medium mal Equipment/ Benefits: o Closed cycle = minimal losses Boilers o Non-pressurized system operation at 250 C o Automatic controls = operational flexibility o Good thermal efficiencies
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Type of Boilers
8. Thermic Fluid Heater

2. Circulated to user equipment
3. Heat transfer through heat exchanged
User equipment

1. Thermic fluid heated in the heater
4. Fluid returned to heater
Control panel Insulated outer wall
Blower motor unit Fuel oil filter
Exhaust
(Energy Machine India)

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UNEP 2006
Assessment of a boiler
1.Boiler 2.Boiler blow down 3.Boiler feed water treatment
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Assessment of a Boiler
1. Boiler performance
Causes of poor boiler performance
o o o o
mal Equipment/ Boilers Heat balance: identify heat losses Boiler efficiency: determine deviation from best efficiency
Poor combustion Heat transfer surface fouling Poor operation and maintenance Deteriorating fuel and water quality
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Heat Balance
An energy flow diagram describes geographically how energy is transformed from fuel into useful energy, heat and losses
Stochiometric Excess Air Un burnt

FUEL INPUT
Stack Gas STEAM OUTPUT
Convection & Radiation
Blow Down
Ash and Un-burnt parts of Fuel in Ash
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Heat Balance
Balancing total energy entering a boiler against the energy that leaves the boiler in different forms
12.7 % 8.1 % 1.7 % Heat loss due to dry flue gas
mal Equipment/ Boilers 100.0 %

Fuel
Heat loss due to steam in fuel gas

Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss
BOILER
0.3 % 2.4 % 1.0 %
73.8 %
Heat in Steam
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Heat Balance
Goal: improve energy efficiency by reducing avoidable losses
mal Equipment/ Avoidable losses include: Boilers Stack gas losses (excess air, stack gas
temperature) Losses by unburnt fuel Blow down losses Condensate losses Convection and radiation
UNEP 2006
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is effectively useful in the generated steam
BOILER EFFICENCY CALCULATION
1. DIRECT METHOD:
The energy gain of the working fluid (water and steam) is compared with the energy content of the boiler fuel.
2) INDIRECT METHOD:
The efficiency is the different between losses and energy input
UNEP 2006
Boiler Efficiency: Direct Method

Boiler efficiency ( ) =
Heat Input x 100 Q x (hg hf) x 100 = Heat Output Q x GCV
hg -the enthalpy of saturated steam in kcal/kg of steam mal Equipment/ hf -the enthalpy of feed water in kcal/kg of water Boilers Parameters to be monitored: Quantity of steam generated per hour (Q) in kg/hr Quantity of fuel used per hour (q) in kg/hr The working pressure (in kg/cm2(g)) and superheat temperature (oC), if any The temperature of feed water (oC) Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of fuel
UNEP 2006
Boiler Efficiency: Direct Method

Advantages
Quick evaluation Few parameters for computation mal Equipment/ Few monitoring instruments Boilers Easy to compare evaporation ratios with benchmark figures
Disadvantages
No explanation of low efficiency Various losses not calculated
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Boiler Efficiency: Indirect Method

Efficiency of boiler ( ) = 100 (i+ii+iii+iv+v+vi+vii)
mal Equipment/ Principle losses: Boilers i) Dry flue gas

ii) Evaporation of water formed due to H2 in fuel iii) Evaporation of moisture in fuel iv) Moisture present in combustion air v) Unburnt fuel in fly ash vi) Unburnt fuel in bottom ash vii) Radiation and other unaccounted losses
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Required calculation data
Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content) % oxygen or CO2 in the flue gas mal Equipment/ Fuel gas temperature in C (Tf) Ambient temperature in C (Ta) and humidity of air in Boilers kg/kg of dry air GCV of fuel in kcal/kg % combustible in ash (in case of solid fuels) GCV of ash in kcal/kg (in case of solid fuels)
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Advantages
Complete mass and energy balance for each mal Equipment/individual stream Makes it easier to identify options to improve Boilers boiler efficiency
Disadvantages
Time consuming Requires lab facilities for analysis
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Assessment of a Boiler 2. Boiler Blow Down
Controls total dissolved solids (TDS) in the water that is boiled Blows off water and replaces it with feed water Conductivity measured as indication of TDS mal Equipment/ levels Boilers Calculation of quantity blow down required:
Feed water TDS x % Make up water Blow down (%) = Maximum Permissible TDS in Boiler water
UNEP 2006
Boiler Blow Down

Two types of blow down Intermittent
o o o
o o o
mal Equipment/ Boilers Continuous
Manually operated valve reduces TDS Large short-term increases in feed water Substantial heat loss Ensures constant TDS and steam purity Heat lost can be recovered Common in high-pressure boilers
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Boiler Blow Down
Benefits Lower pretreatment costs Less make-up water consumption mal Equipment/ Reduced maintenance downtime Boilers Increased boiler life Lower consumption of treatment chemicals
UNEP 2006
3. Boiler Feed Water Treatment
Quality of steam depend on water treatment to control Steam purity mal Equipment/ o o Deposits Boilers o Corrosion Efficient heat transfer only if boiler water is free from deposit-forming solids
UNEP 2006
Assessment of a Boiler Boiler Feed Water Treatment
Deposit control To avoid efficiency losses and reduced heat transfer Hardness salts of calcium and mal Equipment/ magnesium Boilers
o o
Alkaline hardness: removed by boiling Non-alkaline: difficult to remove
Silica forms hard silica scales
UNEP 2006

Internal water treatment
Chemicals added to boiler to prevent scale Different chemicals for different water types Conditions: mal Equipment/ o Feed water is low in hardness salts Boilers o Low pressure, high TDS content is tolerated o Small water quantities treated Internal treatment alone not recommended
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External water treatment:
Removal of suspended/dissolved solids and dissolved gases Pre-treatment: sedimentation and settling mal Equipment/ First treatment stage: removal of salts Boilers Processes 1. Ion exchange 2. Demineralization 3. De-aeration 4. Reverse osmoses
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Assessment of a Boiler External Water Treatment

a) Ion-exchange process (softener plant)
Water passes through bed of natural zeolite of synthetic resin to remove hardness Base exchange: calcium (Ca) and magnesium (Mg) mal Equipment/ replaced with sodium (Na) ions Boilers Does not reduce TDS, blow down quantity and alkalinity
b) Demineralization
Complete removal of salts Cations in raw water replaced with hydrogen ions
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External Water Treatment
c) De-aeration Dissolved corrosive gases (O2, CO2) expelled by preheating the feed water mal Equipment/ Two types: Boilers o Mechanical de-aeration: used prior to addition
o
of chemical oxygen scavangers Chemical de-aeration: removes trace oxygen
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Vent Boiler Feed Water Spray Nozzles
Mechanical de-aeration
Steam
mal Equipment/ Boilers Scrubber Section (Trays)

Storage Section
O2 and CO2 removed by heating feed water Economical treatment process Vacuum type can reduce O2 to 0.02 mg/l Pressure type can reduce O2 to 0.005 mg/l
De-aerated Boiler Feed Water
( National Productivity Council)

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Chemical de-aeration
Removal of trace oxygen with scavenger Sodium sulphite: o Reacts with oxygen: sodium sulphate mal Equipment/o Increases TDS: increased blow down Boilers Hydrazine o Reacts with oxygen: nitrogen + water o Does not increase TDS: used in high pressure boilers
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External Water Treatment

d) Reverse osmosis Osmosis
o o o o o
mal Equipment/ Boilers Reversed osmosis
Solutions of differing concentrations Separated by a semi-permeable membrane Water moves to the higher concentration Higher concentrated liquid pressurized Water moves in reversed direction
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External water treatment

d) Reverse osmosis
Pressure

Feed Water More Concentrated Solution
Concentrate Flow
Fresh Water
Water Flow
Semi Permeable Membrane
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Energy Efficiency Opportunities
1. Stack temperature control 2. Feed water preheating using economizers 3. Combustion air pre-heating 4. Incomplete combustion minimization 5. Excess air control 6. Avoid radiation and convection heat loss mal Equipment/ 7. Automatic blow down control Boilers 8. Reduction of scaling and soot losses 9. Reduction of boiler steam pressure 10.Variable speed control 11.Controlling boiler loading 12.Proper boiler scheduling 13.Boiler replacement
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Energy Efficiency Opportunities 1. Stack Temperature Control

Keep as low as possible If >200C then recover waste heat
mal Equipment/ 2. Feed Water Preheating Boilers Economizers

Potential to recover heat from 200 300 oC flue gases leaving a modern 3-pass shell boiler
3. Combustion Air Preheating

If combustion air raised by 20C = 1% improve thermal efficiency
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4. Minimize Incomplete Combustion

Symptoms:
o
Smoke, high CO levels in exit flue gas
Causes:
o o
o
mal Equipment/ Boilers Oil-fired boiler:
Air shortage, fuel surplus, poor fuel distribution Poor mixing of fuel and air
Improper viscosity, worn tops, cabonization on dips, deterioration of diffusers or spinner plates Coal-fired boiler: non-uniform coal size
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5. Excess Air Control

Excess air required for complete combustion Optimum excess air levels varies 1% excess air reduction = 0.6% efficiency rise Portable or continuous oxygen analyzers

Fuel
Solid Fuels Bagasse Coal (bituminous) Lignite Paddy Husk Wood Liquid Fuels Furnace Oil LSHS
Kg air req./kg fuel

3.3 10.7 8.5 4.5 5.7
%CO2 in flue gas in practice

10-12 10-13 9 -13 14-15 11.13
13.8 14.1
9-14 9-14
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Energy Efficiency Opportunities 6. Radiation and Convection Heat Loss Minimization

Fixed heat loss from boiler shell, regardless of boiler output Equipment/ Repairing insulation can reduce loss
mal Boilers
7. Automatic Blow Down Control

Sense and respond to boiler water conductivity and pH
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Energy Efficiency Opportunities 8. Scaling and Soot Loss Reduction

Every 22oC increase in stack temperature = 1% efficiency loss 3 mm of soot = 2.5% fuel increase
mal Equipment/ Boilers 9. Reduced Boiler Steam Pressure

Lower steam pressure = lower saturated steam temperature = lower flue gas temperature Steam generation pressure dictated by process
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Energy Efficiency Opportunities 10. Variable Speed Control for Fans, Blowers and Pumps
Suited for fans, blowers, pumps Should be considered if boiler loads are variable
11. Control Boiler Loading

Maximum boiler efficiency: 65-85% of rated load Significant efficiency loss: < 25% of rated load
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12. Proper Boiler Scheduling

Optimum efficiency: 65-85% of full load Few boilers at high loads is more efficient than large number at low loads
mal Equipment/ Boilers 13. Boiler Replacement

Financially attractive if existing boiler is Old and inefficient Not capable of firing cheaper substitution fuel Over or under-sized for present requirements Not designed for ideal loading conditions
UNEP 2006
Training Session on Energy Equipment
Boilers & Thermic Fluid Heaters mal Equipment/

Boilers
THANK YOU FOR YOUR ATTENTION
UNEP GERIAP
Disclaimer and References
This PowerPoint training session was prepared as part of the project Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific (GERIAP). While reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced, UNEP does mal Equipment/ not accept responsibility for the accuracy or completeness of the contents, and shall not be liable Boilers for any loss or damage that may be occasioned directly or indirectly through the use of, or reliance on, the contents of this publication. UNEP, 2006. The GERIAP project was funded by the Swedish International Development Cooperation Agency (Sida) Full references are included in the textbook chapter that is available on www.energyefficiencyasia.org
UNEP 2006

Boilers &amp; Thermic Fluid Heaters

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Training Session on Energy Equipment