1. Energy Efficiency in Boiler Prepared by: Nimesh Gajjar

2. Energy Efficiency in Boiler
A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated water or steam.
IBR Steam Boilers means any closed vessel exceeding liter in capacity and which is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel, which is wholly, or partly under pressure when the steam is shut off.
IBR Steam Pipe means any pipe through which steam passes from a boiler to a prime mover or other user or both, if pressure at which steam passes through such pipes exceeds 3.5 kg/cm2.

3. Boiler Room Schematic
The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returned from the processes and (2) Makeup water (treated raw water) which must come from outside the boiler room and plant processes. For higher boiler efficiencies, the feed water is preheated by economizer, using the waste heat in the flue gas.

4. SYSTEMS APPROACH Efficient steam utilization
Efficient steam distribution
Efficient steam generation

5. EFFICIENT STEAM UTILISATION
Reduce the amount of heat load by good insulation.
Better design of dryers, heat exchangers and other end use equipment to improve their efficiencies.
Multi-pass dryers to improve efficiency.
End use equipment efficiencies have been improved considerably.
Double effect absorption chillers consume about 5 kg/hr/TR steam. Single effect chiller consume 8 kg/hr/TR

6. EFFICIENT STEAM UTILISATION
A laundry for finishing sheets had a capacity of 10 kg./hr.
Mechanical equipment like hydro extractor, spin dryer, remove large amount of water.
Hydro extractor removes water and leaves 48 kg. of water from 100 kg. Dry wet of sheet. This requires 62 kg. of steam.
Due to inefficient hydro extractor 52 kgs. of moisture remains. This requires 67 kg. of steam leading to 5 kg./Steam/hr. extra consumption.
About 0.4 kg of oil/hr. extra.

7. EFFICIENT STEAM DISTRIBUTION
Prevent steam leaks
Provide dry steam for process
Utilize steam at lowest pressure
Proper insulation of pipe lines
Condensate recovery
Flash steam recovery
Proper selection and maintenance of steam traps
Proper sizing of pipe lines

8. CHOICE OF FUELS
COAL IMPORTED
6000 KCAL/KG
COAL INDIAN
KCAL/KG
LIGNITE
3000 KCAL/KG
FURNACE OIL/LSHS
10,500 KCAL/KG
NATURAL GAS
KCAL/M3
AGRICULTURE RESIDUES
KCAL/KG
In India coal is the only option for any large size plant. Gas and oil prices are rising sharply and their use will be restricted to small and medium size plants.

9. Combustion in Boiler
Heat
Fuel
Combustion
Exhaust
Air

10. Introduction Boilers are used to convey heat for different process
applications
Steam is commonly used as heating medium.
Generated from easily available water
Able to store a large quantity of heat
Fuels namely coal, oil, gas, biomass, etc are used in
boilers
Fuel selection – availability and economics
Paper industries use low cost fuel such as black liquor

11. Introduction (contd..) Boilers can be categorized on the basis of
Water/flue gas passage
Fuel usage
Pressure generation
Motive of industry is to generate required quantity and
quality of steam at minimum possible cost.
It could be achieved by reducing avoidable heat losses
Or by improving the efficiency
Different boilers have different efficiency depending up
on type of fuel used

12. Thermal Efficiency Levels
Boiler Type
Efficiency – Indian Industries
Manually Fired
40-60
Stoker Fired Coal
Bagasse
65-70
55-60
Oil and Gas up to 20 tones per h
above 20 tones per h
70-80
80-85
Fluidized bed combustion
75-80
Waste heat
55-75
Pulverized fuel fired

13. Efficiency Evaluation of Boilers
Two methods for evaluating the efficiency of boilers
Direct and Indirect
Direct method- known as input-output method
Excellent for plant people for quick evaluation
Few parameters are required
Needs only few instrumentation for monitoring

14. Efficiency Evaluation of Boilers
Indirect method
Disadvantages of direct method can be overcome
It calculates various heat losses associated.
Efficiency is calculated by subtracting all heat loss
percentage from 100
Also known as heat loss method
Different heat losses are calculated in subsequent
slides

15. Type of losses in Boiler
Dry Flue Gas Losses
Heat Loss Due to Moisture in Fuel
Heat Loss Due to Moisture From Burning Hydrogen
Heat Loss Due to Moisture in Air
Heat Loss Due to Combustion in Refuse
Heat Loss Due to Formation of Carbon Monoxide
Heat Loss Due to Sensible Heat in Bottom Ash
Blow Down Loss
Loss Due to Surface Radiation and Convection

16. Losses in boilers

17. Possible Boiler Losses
FLUE GAS LOSS eg,
- excess air / temperature
- soot / slag deposits
- scale
- incomplete combustion
RADIATION LOSS
eg.,
- inefficient insulation
LOADING LOSS
eg.,
- excess boiler capacity
- variable demand
BOILER
HEAT
LOSS
Now to the very big subject of boilers.
There are atleast 4 main areas of boiler loss see OHT of course there will always be boiler losses and we can estimate the minimum theoritical courses In an ideal boiler there would be
- no excess combustion air
- no incomplete combustion
- fluegas exit at boiler water temperature
But there will still be losses
BLOWDOWN LOSS eg.,
- Non-optimal
water treatment

18. Factors Affecting Heat Generation Efficiency
Equipment Design
Operating Parameters & Controls
Provision of Waste Heat Recovery
Fuel Quality
Load Management
Maintenance / Adjustments
Energy
Management
There may be capital and/or process constraints applicable to some extend but most are in the reach of energy management (left side line)
Right choice of fuel and equipment is crucial during commissioning of the plant. This will dictate energy efficiency later. Boiler efficiency, especially at part loads (turndown ratio), range of fuel that can be fired, incase of solid fuel fired boilers are some of the key issues to be addressed.
The boiler should be operated with optimum excess air to maximum efficiency and so forth.
Inconsistent quality of coal impacts on efficiency.
An oxygen controller to regulate excess air is vital to high energy efficiency. When you have a bank of boilers, you have to optimise on number of boilers and which boilers to operate.
Frequent cleaning of flue and water sides are imperative to increased efficiency.

19. The typical steam system overall efficiency is about 35% as follows:
Example of System Loss
The typical steam system overall efficiency is about 35% as follows:
Here is an example from a cannery.
The boiler efficiency is 80% i.e. 80% of the heat in oil is transferred to steam. Heat loss in flow pipes is 5%. The product through the process of (saying boiling) absorbs 35% of the heat in steam. 25% of the heat goes as evaporation loss. The return line of condensate to boiler improves the boiler efficiency by 10% nett due to heat recovery.
i.e. the overall efficiency to the product is only 35%
Generation
efficiency
80%
Distribution
efficiency= 93%
(including condensate return)
Utilisation
efficiency
47%

20. Cleanliness of Boilers
FUEL = OIL
Clean Boiler
After 6 months without cleaning
Flue gas temperature, deg C
CO2 ,%
Air temperature, deg C
Efficiency, %
Annual Consumption, Toe
Annual losses, Toe
220 12 30 88
1000 -
300 12 30 84
1048 48
Cleaning boilers is important, an example :
If the boiler is to be operated continuously, provision for root blowers should be made to facilitate on line cleaning.
If the boiler is not frequently cleaned, the efficiency may drop approx.5% within 6 month!
You can imagine the value of such loss on a yearly basis.
Solution: brushing gas tubes of the boiler each month

21. ENERGY CONSERVATION OPPORTUNITIES : In Boiler Operations

22. 1. Reduce Stack Temperature
Stack temperatures greater than 200°C indicates potential for recovery of waste heat.
It also indicate the scaling of heat transfer/recovery equipment and hence the urgency of taking an early shut down for water / flue side cleaning.
22o C reduction in flue gas temperature increases boiler efficiency by 1%

23. Feed Water Preheating using Economiser
For an older shell boiler, with a flue gas exit temperature of 260 o C, an economizer could be used to reduce it to 200o C, Increase in overall thermal efficiency would be in the order of 3%.
Condensing economiser (N.Gas) Flue gas reduction up to 65oC
6 o C raise in feed water temperature, by economiser /condensate recovery, corresponds to a 1% saving in fuel consumption

24. 3. Combustion Air Preheating
Combustion air preheating is an alternative to feed water heating.
In order to improve thermal efficiency by 1%, the combustion air temperature must be raised by 20 oC.

25. 4. Incomplete Combustion (c c c c c + co co co co)
Incomplete combustion can arise from a shortage of air or surplus of fuel or poor distribution of fuel.
In the case of oil and gas fired systems, CO or smoke with normal or high excess air indicates burner system problems.
Example: Poor mixing of fuel and air at the burner. Poor oil fires can result from improper viscosity, worn tips, carbonization on tips and deterioration of diffusers.

26. 4. Incomplete Combustion (c c c c c + co co co co)
With coal firing: Loss occurs as grit carry-over or carbon-in-ash (2% loss).
Example :In chain grate stokers, large lumps will not burn out completely, while small pieces and fines may block the air passage, thus causing poor air distribution.
Increase in the fines in pulverized coal also increases carbon loss.

27. 5. Control excess air (For every 1% reduction in excess air ,0
5. Control excess air (For every 1% reduction in excess air ,0.6% rise in efficiency.)
The optimum excess air level varies with furnace design, type of burner, fuel and process variables.. Install oxygen trim system.

28. 6.Radiation and Convection Heat Loss
The surfaces lose heat to the surroundings depending on the surface area and the difference in temperature between the surface and the surroundings.
The heat loss from the boiler shell is normally a fixed energy loss, irrespective of the boiler output. With modern boiler designs, this may represent only 1.5% on the gross calorific value at full rating, but will increase to around 6%, if the boiler operates at only 25 percent output.
Repairing or augmenting insulation can reduce heat loss through boiler walls

29. 7.Automatic Blowdown Control
Uncontrolled continuous blowdown is very wasteful.
Automatic blowdown controls can be installed that sense and respond to boiler water conductivity and pH.
A 10% blow down in a 15 kg/cm2 boiler results in 3% efficiency loss.

30. BLOWDOWN HEAT LOSS
This loss varies between 1% and 6% and depends on a number of factors:
Total dissolved solids (TDS) allowable in boiler water
Quality of the make-up water, which depends mainly on the type of water treatment installed
(e.g. base exchange softener or demineralisation):
Amount of uncontaminated condensate returned to the boiler house
Boiler load variations.
Correct checking and maintenance of feedwater and boiler water quality, maximising condensate return and smoothing load swings will minimise the loss.
Add a waste heat recovery system to blowdowns
Flash steam generation

31. Blowdown Heat Recovery
Efficiency Improvement - Up to 2 percentage points.
Blowdown of boilers to reduce the sludge and solid content allows heat to go down the drain.
The amount of blowdown should be minimized by following a good water treatment program, but installing a heat exchanger in the blowdown line allows this waste heat to be used in preheating makeup and feed water.

32. Blowdown Heat Recovery
Heat recovery is most suitable for continuous blowdown operations which in turn provides the best water treatment program.

33. 8.Reduction of Scaling and Soot Losses
In oil and coal-fired boilers, soot buildup on tubes acts as an insulator against heat transfer. Any such deposits should be removed on a regular basis. Elevated stack temperatures may indicate excessive soot buildup. Also same result will occur due to scaling on the water side.
High exit gas temperatures at normal excess air indicate poor heat transfer performance. This condition can result from a gradual build-up of gas-side or waterside deposits. Waterside deposits require a review of water treatment procedures and tube cleaning to remove deposits.
Stack temperature should be checked and recorded regularly as an indicator of soot deposits. When the flue gas temperature rises about 20oC above the temperature for a newly cleaned boiler, it is time to remove the soot deposits

34. Cleaning :
Incorrect water treatment, poor combustion and poor cleaning schedules can easily reduce overall thermal efficiency
However, the additional cost of maintenance and cleaning must be taken into consideration when assessing savings.
Every millimeter thickness of soot coating increases the stack temperature by about 55oC. 3 mm of soot can cause an increase in fuel consumption by 2.5%.
A 1mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%

35. 9. Reduction of Boiler Steam Pressure
 Lower steam pressure gives a lower saturated steam temperature and without stack heat recovery, a similar reduction in the temperature of the flue gas temperature results. Potential 1 to 2% improvement.
Steam is generated at pressures normally dictated by the highest pressure / temperature requirements for a particular process. In some cases, the process does not operate all the time, and there are periods when the boiler pressure could be reduced.
Adverse effects, such as an increase in water carryover from the boiler owing to pressure reduction, may negate any potential saving.
Pressure should be reduced in stages, and no more than a 20 percent reduction should be considered.

36. 10.Variable Speed Control for Fans, Blowers and Pumps
Generally, combustion air control is effected by throttling dampers fitted at forced and induced draft fans. Though dampers are simple means of control, they lack accuracy, giving poor control characteristics at the top and bottom of the operating range.
If the load characteristic of the boiler is variable, the possibility of replacing the dampers by a VSD should be evaluated.

37. 11. Effect of Boiler Loading on Efficiency
As the load falls, so does the value of the mass flow rate of the flue gases through the tubes. This reduction in flow rate for the same heat transfer area, reduced the exit flue gas temperatures by a small extent, reducing the sensible heat loss.
Below half load, most combustion appliances need more excess air to burn the fuel completely and increases the sensible heat loss.
Operation of boiler below 25% should be avoided
Optimum efficiency occurs at 65-85% of full loads

38. 12.Boiler Replacement If the 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 replacement option should be explored.
The feasibility study should examine all implications of long-term fuel availability and company growth plans. All financial and engineering factors should be considered. Since boiler plants traditionally have a useful life of well over 25 years, replacement must be carefully studied.

39. Case Study: Existing: High radiation loss from Moulds

40. Reduced heat loss through insulation
Insulated Mould