10/16/2011

Training Session on Energy

Equipment

Training Agenda: Boiler

Boilers & Thermic

Fluid Heaters

Introduction
Type of boilers
Assessment of a boiler

Presentation from the

Energy Efficiency Guide for Industry in Asia

Energy efficiency opportunities

www.energyefficiencyasia.org

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Assessment of a boiler

Assessment of a Boiler

1. Boiler

1. Boiler performance
Causes of poor boiler performance

2. Boiler blow down

-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality

3. Boiler feed water treatment

Heat balance: identify heat losses

Boiler efficiency: determine
deviation from best efficiency
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Assessment of a Boiler

Assessment of a Boiler

Heat Balance

Heat Balance

An energy flow diagram describes geographically

how energy is transformed from fuel into useful
energy, heat and losses

Balancing total energy entering a boiler against

the energy that leaves the boiler in different forms
12.7 %

Stochiometric
Excess Air
Un burnt

8.1 %
1.7 %

100.0 %
BOILER

Stack Gas

Fuel

FUEL INPUT

STEAM
OUTPUT

0.3 %
2.4 %
1.0 %

73.8 %

Convection &
Radiation

Blow
Down

Ash and Un-burnt parts

of Fuel in Ash

Heat loss due to dry flue gas

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

Heat in Steam

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Assessment of a Boiler

Assessment of a Boiler

Heat Balance

Boiler Efficiency

Goal: improve energy efficiency by reducing

avoidable losses

Thermal efficiency: % of (heat) energy input that is

effectively useful in the generated steam

Avoidable losses include:

BOILER EFFICENCY
CALCULATION

- Stack gas losses (excess air, stack gas

temperature)
- Losses by unburnt fuel
- Blow down losses

1)

- Condensate losses
- Convection and radiation

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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

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Assessment of a Boiler

Assessment of a Boiler

Boiler Efficiency: Direct Method

Boiler Efficiency: Direct Method

Heat Input x 100

Q x (hg hf) x 100
Boiler efficiency () =
=
Heat Output
Q x GCV

hg -the enthalpy of saturated steam in kcal/kg of steam

hf -the enthalpy of feed water in kcal/kg of water
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
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Advantages

Quick evaluation
Few parameters for computation
Few monitoring instruments
Easy to compare evaporation ratios with
benchmark figures

Disadvantages

No explanation of low efficiency

Various losses not calculated
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Assessment of a Boiler

Assessment of a Boiler

Boiler Efficiency: Indirect Method

Boiler Efficiency: Indirect Method

Efficiency of boiler () = 100 (i+ii+iii+iv+v+vi+vii)

Required calculation data

Ultimate analysis of fuel (H2, O2, S, C, moisture
content, ash content)

Principle losses:

% oxygen or CO2 in the flue gas

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
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Fuel gas temperature in C (Tf)

Ambient temperature in C (Ta) and humidity of air in
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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Assessment of a Boiler

Assessment of a Boiler

Boiler Efficiency: Indirect Method

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

levels

Calculation of quantity blow down required:

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

Blow down (%) =

Feed water TDS x % Make up water

Maximum Permissible TDS in Boiler water

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Assessment of a Boiler

Assessment of a Boiler

Boiler Blow Down

Boiler Blow Down

Two types of blow down

Benefits

Intermittent

Lower pretreatment costs

Manually operated valve reduces TDS

Large short-term increases in feed water
Substantial heat loss

Continuous
Ensures constant TDS and steam purity
Heat lost can be recovered
Common in high-pressure boilers
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Less make-up water consumption

Reduced maintenance downtime
Increased boiler life
Lower consumption of treatment
chemicals

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Assessment of a Boiler

Assessment of a Boiler

3. Boiler Feed Water Treatment

Boiler Feed Water Treatment

Deposit control

Quality of steam depend on water

treatment to control

To avoid efficiency losses and

reduced heat transfer

Steam purity
Deposits
Corrosion

Hardness salts of calcium and

magnesium

Efficient heat transfer only if boiler

water is free from deposit-forming
solids

Alkaline hardness: removed by boiling

Non-alkaline: difficult to remove

Silica forms hard silica scales

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Assessment of a Boiler

Assessment of a Boiler

Boiler Feed Water Treatment

Boiler Feed Water Treatment

External water treatment:

Internal water treatment

Chemicals added to boiler to prevent scale

Different chemicals for different water types

Conditions:
Feed water is low in hardness salts
Low pressure, high TDS content is tolerated
Small water quantities treated

Removal of suspended/dissolved solids and

dissolved gases

Pre-treatment: sedimentation and settling

First treatment stage: removal of salts

Processes
a) Ion exchange
b) Demineralization

Internal treatment alone not recommended

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c) De-aeration
d) Reverse osmoses

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Assessment of a Boiler

Assessment of a Boiler

External Water Treatment

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)
replaced with sodium (Na) ions
Does not reduce TDS, blow down quantity and
alkalinity

c) De-aeration
Dissolved corrosive gases (O2, CO2)
expelled by preheating the feed water
Two types:

b) Demineralization

Mechanical de-aeration: used prior to addition

of chemical oxygen scavangers

Complete removal of salts

Chemical de-aeration: removes trace oxygen

Cations in raw water replaced with hydrogen ions

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Assessment of a Boiler

Assessment of a Boiler

External Water Treatment

External Water Treatment

Vent
Spray
Nozzles

Boiler Feed
Water

Stea
m

Scrubber
Section
(Trays)

Mechanical
de-aeration

Chemical de-aeration

O2 and CO2 removed by

heating feed water

Sodium sulphite:

Removal of trace oxygen with scavenger

Economical treatment
process
Vacuum type can reduce
O2 to 0.02 mg/l

Storage
Section

De-aerated
Boiler Feed
Water

( National Productivity Council)

Pressure type can

reduce O2 to 0.005 mg/l
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Reacts with oxygen: sodium sulphate

Increases TDS: increased blow down
Hydrazine
Reacts with oxygen: nitrogen + water
Does not increase TDS: used in high pressure
boilers

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Assessment of a Boiler

Assessment of a Boiler

External Water Treatment

External water treatment

d) Reverse osmosis

d) Reverse osmosis
Pressure

Osmosis
Solutions of differing concentrations
Separated by a semi-permeable membrane
Water moves to the higher concentration

Fresh Water

Feed
Water
More
Concentrated
Solution

Reversed osmosis
Concentrate
Flow

Higher concentrated liquid pressurized

Water moves in reversed direction

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Training Session on Energy

Equipment

Water Flow

Semi Permeable
Membrane

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Disclaimer and References

Boilers & Thermic

Fluid Heaters
THANK YOU
FOR YOUR ATTENTION

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 not accept responsibility for
the accuracy or completeness of the contents, and shall not
be liable 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)

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Full references are included in the textbook chapter that is

available on www.energyefficiencyasia.org

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