31/1

31

Economizers
Colin French CEng, FInstE, FBIMgt
Consultant

Contents
31.1 31.2 31.3 31.4 31.5 31.6 Introduction Oil and coal applications Gas-fired economizers Design Installation Condensing economizers 31/3 31/3 31/3 31/4 31/4 31/4

This page has been reformatted by Knovel to provide easier navigation.

31.1 Introduction
Economizers for boilers have been available for nearly 150 years, almost as long as boilers themselves. For modern shell boilers, high efficiencies have made it increasingly difficult to justify the use of an economizer, the final decision being based in terms of payback period, which is also heavily dependent on fuel prices. Watertube boilers, on the other hand, need an economizer section in the gas passes in order to obtain satisfactory efficiency. For this reason, the economizer is integrated into the overall design, normally between the convective super-heater and the air heater if fitted. In shell boilers with a working pressure of between 7 and 17 bar the temperature of the mass of water in the boiler is typically in the range of 170-21O0C. Allowing for, say a temperature difference of 30-5O0C between the exhaust gases and the water temperature, the boiler exit gas temperature cannot be economically reduced beneath about 200-26O0C, dependent on the operating pressure. It becomes necessary, therefore, to modify the process principles to achieve further heat utilization and recovery. By using an economizer this is done by conducting the feedwater supply to the economizer wherein the exhaust gas passes over tubes carrying the feedwater. The feedwater, normally at temperatures between 30 and 10O0C, represents a further cooling medium for the exhaust gases and provides the potential for the extra heat utilization. This is shown in Figure 31.1.

31.2 Oil and coal applications

Although it would be possible to design for an economizer gas exit temperature of 30-5O0C above the feedwater temperature, this would result in a temperature too close to the acid dewpoint of the gases. The acid dewpoint is the temperature at which acidic gases begin to condense out of the exhaust gas mixture. This is principally sulphuric acid due to the sulphur contained in the oil or coal. Although

the bulk gas temperature may be satisfactory, in practice, the surfaces close to the tube wall will be nearly at water temperature due to the high conductivity of the metal tube. This limits the minimum practical gas exit temperature from the economizer to, say, 170-18O0C, remembering, of course, that at low fire this will have fallen closer still to the acid dewpoint (which is typically in the range of 125-14O0C, dependent on the excess air and fuel sulphur content). The cold temperature of the heat transfer surface gives rise to heavy corrosion which would reach a peak at about 950C. The potential to recover heat from the gases of an oil or coal-fired boiler is therefore limited to a temperature drop from 24O0C to 17O0C. This results in a 3% saving. The average saving would be somewhat lower than this since fouling of the economizer surface is inevitable from the carbonaceous emissions of the firing of coal or oil. The design of the economizer must be robust enough to survive occasional excursions beneath the acid dewpoint and the effects of the methods used to clean the economizer periodically. This may take the form of rapping equipment to shake off deposits, sootblowing by steam or air and water washing with lances. Average savings of 2-3% combined with the cost necessary for a robust design have therefore limited the use to times when fuel prices are high or special applications where the boiler exit temperature is higher than usual. Developments using an additive to suppress the dewpoint are worth consideration, since this extends the heat-saving potential but, of course, there is an additional burden with the cost of the additive. Magnesium oxide is the most commonly used suppressant and this is injected into the gas stream to combine with the sulphuric acid to form magnesium sulphate (which also has to be removed regularly in addition to the soot).

31.3 Gas-fired economizers

Far greater potential exists for gas-fired economizers, since the gas is virtually free of sulphur. The limitation in gas temperature is the ability of the water to extract the heat, although the water vapour in the gas caused by the combustion of hydrogen does give rise to a water dewpoint at 550C. This should be avoided, since general corrosion can take place in the latter rows of the economizer and in the exhaust gas ducts and chimney. Normally, this only occurs for short periods during starting from cold, but it should be minimized. Since no serious problems exist with corrosion, the materials of construction can be cheaper and the thicknesses reduced. Fouling coefficients do not need to be incorporated into the design calculations as the surfaces remain clean indefinitely. This in itself provides a secondary benefit in that the pitching of fins may be reduced without the risk of reducing flow. A saving of (typically) 5% can be made with gas-fired economizers, and as this is related to the boiler output it represents a saving of 6.25% in fuel consumed. Gross heat-saving potential may be determined in relation to feedwater temperature and excess air level are shown in Figure 31.2.

Temperature 0C

Combustion 1st convective 2nd convective pass chamber pass Economizer Boiler Figure 31.1 Temperatures in three-pass boilers and economizers

n=1.5
% Flue gas loss (gross basis)

n=1.4 n=1.3 n=1.2 n=1.15 n=1.1 n=1.0

fluid velocities, careful design to promote turbulence by staggered pitching enhances the heat transfer coefficient. The heat transfer area, A, can be greatly increased by using finned tubes, but care must be taken to ensure good conduction of heat away from the fin into the tube and subsequently into the water. Some common fin types are shown in Figure 31.3 while Figure 31.4 shows some of the attachment methods employed to ensure satisfactory fin to tube heat transfer. Design and manufacture is normally to BS 1113:1998 but with the advent of the Pressure Equipment Directive 97/23/EC(PED) will be implemented under the Pressure Equipment Regulations 81200011:10999 (PER) throughout Europe and will revert to EN 12952 Watertube Boilers, for most industrial applications there being no lesser Standard which is relevant to economizers. Designs are therefore to very stringent requirements so problems are rarely found. Typical constructional arrangements (including tube layout) are shown in Figure 31.5.

31.5 Installation
Flue gas temp. 0C (based on 2O0C ambient temp.) Figure 31.2 Total heat in gas-fired boiler exhaust

31.4 Design
The driving force for heat transfer is temperature difference, and this is maximized through the economizer by arranging for concurrent flow through the passages. In other words, the colder feed water is made available to the coolest gases. This gives the highest overall average temperature difference throughout the length of the economizer, and is characterized by the logarithmic temperature difference AT/ m :
AT
- (Tgi ~ TW2) - (Tgi - Tw\) lm ~\ogn[(Tgl-Tw2)/(Tg2-Twl)]

Due to interruptible gas tariffs, it is often necessary to adopt gas as the primary fuel and burn oil in periods of interruption when gas is unavailable. This means that the economizer has to be arranged so that when oil firing, the flue gases are bypassed around the economizer. The bypass duct must also contain a damper to simulate the economizer gas resistance so that the burner back pressure remains the same for both fuels. Installation may be simplified by using an economizer where the manufacturer has integrated the dampers for isolating and trimming, together with the bypass ducting into the basic design. Figure 31.6 shows a typical installation layout without this feature.

31.6 Condensing economizers

The restrictions on feedwater temperature dictated by condensate rates and the need to minimize oxygen corrosion limit further development of the performance of conventional economizers. As mentioned earlier, it becomes necessary to revise the whole philosophy if enhanced heat recovery is desired. If the gas can be reduced in temperature to beneath the water dewpoint of approximately 550C there exists a potential heat saving due to the latent heat of condensation of the water vapour as well as the sensible heat also contained in the exhaust gases. This quantity of water vapour is considerable (in the case of natural gas firing of the order of 1 ton per hour for a lOton/h steam boiler). Once again, the potential can only be realized provided a requirement exists for such heat. This heat is of relatively low grade and therefore requires a large mass flow rate of water to absorb it. A typical figure might be of the order of twice the boiler feedwater flow rate and at a temperature of mains water. This precludes the use of the boiler feedwater, and therefore special low-temperature processes must be integrated into condensing economizer scheme. The temperature rise of this water would probably be about 450C. Assuming the exhaust gases are cooled

The amount of heat (Q\) that may be transferred is controlled by:

Q1 = ATlm -U-A

where U = overall heat transfer coefficient and A = heat transfer area. To achieve a cost-effective design of economizer it is necessary to maximize the overall heat transfer coefficient and the surface area within the economizer. The heat transfer coefficient, [/, can be maximized by the highest practical velocities that can be achieved for both the water and the gas. Water-side pressure loss is limited by the available spare pressure rise from the feed pump. This is often limited to 0.2-1.0 bar, as it is not generally economic to replace the feed pump. Gas-side velocities are generally limited by the available spare fan head from the burner. Once again, it is not normally economic to replace this in the case of retrofitted economizers or, for that matter, to install an induced-draught fan downstream of the economizer. In addition to maximizing

(a) Wound on - plain fin

(b) Wound on - with turbulence inducing segments

(c) Lamel fin - square or rectangular continuous

Figure 31.3 Common fin types

(d) Lamel fin - non continuous

(a) Cast iron finned

(b) L type resistance welded

(c) I type resistance welded

(d) Ploughed and grooved Figure 31.4 Fin attachment methods

(e) Crimped on fin

(f) Integrally finned

Economizer frame

Tube stack Ductwork Water out

Water in

Exhaust gases

Economizer frame

Water in Water out

Ductwork

Heat exchanger (tube nest) Exhaust gases

Figure 31.5 Economizer-typical designs

By-pass/trim damper Modulating feed control valve

Isolating damper

Chimney

Relief valve Economizer

Isolating damper

Hot well

Feed pump

Boiler

TC
By-pass

Heat exchanger Orifice

Automatic temp Control valve

By-pass duct Figure 31.6 Typical installation layout

Notes: 1. Fuel-Natural gas 2. Combustion @ n=1.15

25O0C Damper isolating/ oil firing Existing exhaust gas duct Main chimney

Dew point 54.970C

H2O wet

Rear smokebox

Draught controller 4O0C Induced draught fan

Boiler % Flue gas loss (gross basis) Gas analysis % by volume

CO2 dry CO2 wet

Damper' isolating/ draught control

Water out

Water in

Auxiliary chimney

O2 dry O2 wet-

Condensate to drain Figure 31.8 Condensing economiser layout

Flue gas temp. 0C (Based on 2O0C Ambient temp.) Figure 31.7 Sensible and latent heat savings potential and gas analysis with condensing economizers

from, say, 23O0C to 4O0C, the gross heat saving would be approximately 13%, yielding a fuel saving of over 15%. The term 'fuel saving' needs to be qualified, since the use of the heat in the water will be given to a process which may be unrelated to boiler demand. Examples of suitable applications occur in industrial size laundries, horticultural soil heating, food industries, abattoirs and swimming pool heating. The success of such schemes is highly dependent on matching supply and demand together with a basic lowgrade heat requirement. The total heat remaining in the exhaust gases of the boiler are shown in Figure 31.7 illustrating the potential savings. Condensing economizers are constructed from corrosion-resistant materials (notably aluminium or stainless steel), since the condensed water vapour in the gas is slightly acidic (typically, with a pH of 3-5). This is

because some carbonic and nitric acid is formed in the condensing of the products of combustion and also as a result of other acidic gases in the atmosphere. Provided the correct choice of materials is made, corrosion life should not become problematic. A typical arrangement of a condensing economizer is shown in Figure 31.8. Note that an induced-draught fan is almost mandatory, since a high pressure loss is inevitable with such low-grade heat recovery. The design of such economizers often takes the form of a large shell and tube heat exchanger, but the conventional economizer construction of watertubes is quite feasible. Condensate from the exhaust gases are normally discharged to the drainage system. More recently condensing economizer technology has found favour in the domestic and commercial heating sectors where the cost has been minimized by integrating the principle into the boiler. Condensing boilers of this type take advantage of relatively low hot water return temperatures especially during warming up of the system and during very cold weather.