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STACK DEAERATOR
PUMPS
ECO-
NOMI-
ZER
VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
CHEMICAL FEED
SOFTENERS
By- Mukesh Jha
Sr.Engineer -Projects,
a2z Powercom Pvt.Ltd.
SOFTENERS
Boiler-
A ‘Boiler’ means a pressure vessel in which steam is generated
for use external to itself by application of heat which is wholly
or partly under pressure when steam is shut off but does not
include a pressure vessel
(1) With Capacity less than 25 ltrs (such capacity being
measured from the feed check valve to the main steam stop
valve);
(2) With less than 1 kilogram per centimeter square design
gauge pressure & working gauge pressure; or
(3) In which water is heated below one hundred degree
centigrade .
‘Boiler component’ means Steam piping , Feed water piping,
Economizer ,Super heater, any mounting or other fitting and
any other external or internal part of a Boiler which is
subjected to pressure exceeding one kilogram per centimeter
square gauge.
“Steam Pipe "means any pipe through which steam passes if-
(1)The pressure at which the steam passes through such pipe
exceeds 3.5kg/cm^2 above atmospheric pressure, or
(2)Such pipe exceeds 254 mm in internal diameter and pressure
of steam exceeds 1kg/cm^2.above the atmospheric pressure.
and includes in either case any connected fitting of a
steam pipe.
At atmospheric pressure water volume increases
1,600 times
STEAM TO
EXHAUST GAS VENT
PROCESS
STACK DEAERATOR
PUMPS
ECO-
NOMI-
ZER
VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
CHEMICAL FEED
SOFTENERS
Figure: Schematic overview of a boiler room
Boiler Systems
Water treatment system
Steam System
Advantages
Its ability to burn all ranks of coal from anthracitic to
lignitic, and it permits combination firing (i.e., can
use coal, oil and gas in same burner). Because of
these advantages, there is widespread use of
pulverized coal furnaces.
Disadvantages
High power demand for pulverizing
Requires more maintenance, flyash erosion and
pollution complicate unit operation
Type of Boilers
6. Waste Heat Boiler
An Overview-
Combustion process requires the three “T”s that is Time, Temperature and
Turbulence. In FBC, turbulence is promoted by fluidisation. Improved
mixing generates evenly distributed heat at lower temperature. Residence
time is many times greater than conventional grate
firing. Thus an FBC system releases heat more efficiently at lower
temperatures.
Fixing, bubbling
and fast fluidized
beds
As the velocity of a
gas flowing through
a bed of particles
increases, a value is
reaches when the
bed fluidises and
bubbles form as in a
boiling liquid. At
higher velocities the
bubbles disappear;
and the solids are
rapidly blown out of
the bed and must be
recycled to maintain
principle of fluidisation
a stable system.
Since limestone is used as particle bed, control of sulfur dioxide and nitrogen
oxide emissions in the combustion chamber is achieved without any additional
control equipment. This is one of the major advantages over conventional
boilers.
Almost all AFBC/ bubbling bed boilers use in-bed evaporator tubes
in the bed of limestone, sand and fuel for extracting the heat from
the bed to maintain the bed temperature. The bed depth is usually 0.9
m to 1.5 m deep and the pressure drop averages about 1 inch of water per
inch of bed depth. Very little material leaves the bubbling bed – only about
2 to 4 kg of solids are recycled per ton of fuel burned.
Bubbling Bed Boilers
In the bubbling bed type boiler, a layer of solid particles
(mostly limestone, sand, ash and calcium sulfate) is
contained on a grid near the bottom of the boiler. This layer
is maintained in a turbulent state as low velocity air is forced
into the bed from a plenum chamber beneath the grid. Fuel
is added to this bed and combustion takes place. Normally,
raw fuel in the bed does not exceed 2% of the total bed
inventory. Velocity of the combustion air is kept at a
minimum, yet high enough to maintain turbulence in the
bed. Velocity is not high enough to carry significant
quantities of solid particles out of the furnace.
This turbulent mixing of air and fuel results in a residence time of up to five
seconds. The combination of turbulent mixing and residence time permits
bubbling bed boilers to operate at a furnace temperature below 1650°F. At
this temperature, the presence of limestone mixed with fuel in the furnace
achieves greater than 90% sulfur removal. Boiler efficiency is the percentage
of total energy in the fuel that is used to produce steam. Combustion
efficiency is the percentage of complete combustion of carbon in the fuel.
Incomplete combustion results in the formation of carbon monoxide (CO)
plus unburned carbon in the solid particles leaving the furnace. In a typical
bubbling bed fluidized boiler, combustion efficiency can be as high as
92%. This is a good figure, but is lower than that achieved by
pulverized coal or cyclone-fired boilers. In addition, some fuels that are
very low in volatile matter cannot be completely burned within the
available residence time in bubbling bed-type boilers.
Features of bubbling bed boiler
Fluidised bed boiler can operate at near atmospheric or elevated
pressure and have these essential features:
• Tubes above the bed which extract heat from hot combustion gas
before it enters the flue duct.
Bubbling Bed Boiler-1
Bubbling Bed Boiler-2
2. Pressurised Fluidised Bed Combustion
System (PFBC).
6. Pollution Control
SO2 formation can be greatly minimised by addition of limestone or dolomite
for high sulphur coals. 3% limestone is required for every 1% sulphur in the
coal feed. Low combustion temperature eliminates NOx formation.
i) Refractory Lining
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment
Performance of a Boiler
1. Boiler performance
• Causes of poor boiler performance
-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality
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
Stack Gas
Heat Balance
Balancing total energy entering a boiler against
the energy that leaves the boiler in different forms
%
Heat loss due to dry flue gas
%
Heat loss due to radiation & other
unaccounted loss
%
Heat in Steam
Performance of a Boiler
Heat Balance
Goal: improve energy efficiency by reducing avoidable losses
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
Disadvantages
• No explanation of low efficiency
• Various losses not calculated
Performance of a Boiler
Principle losses:
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
Performance of a Boiler
Advantages
• Complete mass and energy balance for each
individual stream
• Makes it easier to identify options to improve
boiler efficiency
Disadvantages
• Time consuming
• Requires lab facilities for analysis
Performance of a Boiler
• Continuous
• Ensures constant TDS and steam purity
• Heat lost can be recovered
• Common in high-pressure boilers
Performance of a Boiler
b) Demineralization
• Complete removal of salts
• Cations in raw water replaced with hydrogen ions
Performance of a Boiler
Storage
• Vacuum type can reduce
Section O2 to 0.02 mg/l
De-aerated • Pressure type can
Boiler Feed
Water
reduce O2 to 0.005 mg/l
( National Productivity Council)
Performance of a Boiler
• Reversed osmosis
• Higher concentrated liquid pressurized
• Water moves in reversed direction
Performance of a Boiler
External water treatment
d) Reverse osmosis
Pressure
More
Concentrated
Solution
Concentrate Water Flow
Flow
Solid Fuels
Bagasse 3.3 10-12
Coal (bituminous) 10.7 10-13
Lignite 8.5 9 -13
Paddy Husk 4.5 14-15
Wood 5.7 11.13
Liquid Fuels
Furnace Oil 13.8 9-14
LSHS 14.1 9-14
84
Energy Efficiency Opportunities