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systems
Som Derashri
CEO
Academy for conservation of energy
Steam system components
Mainly consists of
• Steam Generation
• Distribution
• Utilization
Steam generation side aspects
• Selection of the • Fuel handling
boilers & capacity • Fuel substitution &
utilization flexibility
• Burner (or) firing • Blow down
system & controls • Flash steam recovery
• Combustion aspects • Water treatment
• Waste heat recovery • Scales & deposits
• Steam pressure
generation
• Insulation
Steam distribution & utilization -
aspects
• Steam distribution • Steam utilization
- Piping - Elimination
- Pressure drop possibilities
- Steam traps - Optimization
- Insulation - Low temperature
- Leakage processing
- Condensate recovery - Application of
alternatives
- Flash steam recovery
- Control systems
What to do in a steam audit
• It starts with preliminary visit & initial data collection (specification,
energy consumption, operating data, etc)
• Review of present energy consumption and operating parameters
• Measurements and conducting tests, trials & surveys
- Boiler efficiency and heat losses evaluation
- Surveys for steam pressure drop, insulation aspects, trapping,
leakage, etc.
- Steam and condensate balance
- Trials & demonstration
• Detailed analysis of observations and various parameters
• Identification of energy saving measures
• Evaluation of techno economic viability of the measures
Instruments required
- Flue gas analyzers
- Temperature probe and indicators
- Infrared pyrometer
- Draft gauges
- Pressure gauges
- Flow meters
- Electrical power analyzer
- TDS meters
Typical boiler efficiency of coal fired FBC
Based on heat loss method: figures are
Kcal/kg and in bracket (%)
Unburnt
Surface
Moisture in flue losses
Losss 42(1%)
gas 86 (2%) 255(6%)
Energy in fuel
4283(100%) Efficiency
3315 (77%)
Boiler 18TPH
(per kg of fuel)
Energy in Fuel
99.58%
Efficiency
Boiler 18TPH
83.69%
(per kg of fuel)
Sensible heat
H2 : (6.93%) Dry Flue gas (8.65%)
in fuel
(0.42%)
Factors affecting the boiler
efficiency
• Loading on the boiler
• Inefficient combustion – excess air or incomplete combustion
• Heat loss in dry flue gas losses vary from 8 to 35% depending upon
- The fuel
- Type of furnace
- Flue gas (temperature. Quantity
- Loading
- Burner, etc.
• Heat loss due to combustible in ash could be 2%–5%. Possible
causes for high losses are
- Poor air distribution
- To thick fire bed
- Uneven bed thickness
- Less residence time given to coal particle over the combustor, etc.
• Blow down heat losses
Blow down
- Blow down is given either of
- Instantaneous
- Instantaneous & continuous
- This loss varies between 1% to 10% and
depends on number of factors. Such as
- TDS allowable in the boiler water (100-
3000TDS)
- The quality of makeup water
- The amount of contaminate condensate
- Boiler load variation
% Blow down requirement = (S1 X 100)/(S2-S1)
Where S1: TDS in the feed water in ppm
S2 : Desired TDS in the boiler in ppm
Energy conservation measures in the blow down
- Automatic blow down control
- either by timed blow down control
- or by TDS monitoring (Most effective)
- Heat recovery by pre heating the feed water, etc
- Flash steam recovery from blow down
Waste Heat Recovery
• Most commonly used and very economical
• The sensible heat in flue gases can be recovered by
- Preheating the feed water or generating hot water
- Preheating the combustion air
• Factors to be considered are
- Flue gas quantity & temperature
- Sulfur content in the fuel and sulfur dew point
- Application potential
• For every 1 0C raise in the feed water temperature there is an
approximately 4 0C drop in the flue gas temperature.
• In other way every 60C raise in feed water temperature there is
reduction in fuel consumption by 1%.
• Every 200C raise in combustion air temperature the fuel
consumption will reduce by 1%
When to replace the boiler
FACILITY DESCRIPTION
1. Steam generation capacity : 200 tph 68 ATA & 485oC
4. Forced draft Fan supplies air for combustion and to primary air fans.
Boiler No. 1
The following are observed and measured parameters of boiler-1
Description Boiler – 1
Observed parameter Measured parameter
Steam flow 150 t/h -
Steam pressure 71 kg/cm2 -
Steam 490 oC -
Air temperature after air
Heater 310 oC -
Feed water temperature at
Economiser inlet 140 oC -
Flue gas temperature at
Economiser outlet 368 oC 344 oC
Description Boiler – 1
Observed parameter Measured parameter
Flue gas temperature at
air heater outlet 180oC 129oC
O2 in flue gas at air heater 3.8% 5.2%
O2 in flue gas at air heater
Outlet - 10.6%
CI in flue gas - Nil
Oxygen percentage indicated at 3.8% in the control room is far less than
measured value of 5.2% - calibration of oxygen analyser.
Measured flue gas temperature at air heater outlet at 129oC is much lower
the indicated temperature of 180 oC. Supported by higher oxygen of 10.6%
after air heater.
Low value of loss of ignition in bottom ash (1.235%) and fly ash (3.12%)
indicate good combustion ( 97% fineness) low electrical loading of
electrostatic precipitator indicate poor performance.
5.2% O2 load corresponds to 33% excess
By reducing to 4%, excess air reducing to 25%
Efficiency evaluation of boiler – 1
All the relevant parameters were used to determine efficiency by loss
method (indirect method) as per IS 8753, which is estimated to be 84.99%.
The various heat losses are :
Particulars Boiler – 1
Before After
Flue gas loss 11.03 10.103
Residue loss 2.79 2.79
Loss due to moisture 0.19 0.16
Radiation loss 1.00 1.0
Total loss 15.01 14.055
Boiler efficiency 84.99 85.94
Boiler No.3
Flue gas temperature at air heater inlet is 340oC as against the measured
value of 201oC.
Flue gas temperature at air heater outlet of 114oC is far less than the
requirement at around 160oC (observed oxygen is also higher at 9%)
The boiler-3 efficiency was evaluated by loss method as per IS 8753. The
various heat losses and efficiency of boiler No. 3 is as given below :
Sr.No Particulars Boiler-III
Before After
1 Flue gas loss 10.29 9.38
2 Residue loss 2.73 2.73
3 Loss due to moisture in air 0.13 0.14
4 Radiation loss 0.99 0.99
5 Total loss 14.14 13.24
6 Thermal Efficiency 85.86 86.76
BASIC DATA
BASIC DATA