Boiler Optimization PDF
Boiler Optimization PDF
Boiler Optimization PDF
INTRODUCTION
Optimising the performance of a boiler and its
associated steam distribution system reduces running
costs and improves site operations. Steam is used
extensively in industry as a heat transfer fluid and as a
source of energy to power mechanical plant and
equipment. As a heat transfer fluid, steam has an
advantage over fluids such as hot water and oil. It is able
to store very large quantities of heat, which can be given
up at constant temperature as the steam condenses.
Unfortunately more energy is lost in industry through
steam wastage than through any other medium.
Research studies by industry experts in the early
1990s suggested that losses from steam systems
make up approximately 35% of all identified potential
energy savings.
BOILER APPLICATIONS
Steam is produced in two types of boilers.
agitation of solutions;
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EFFICIENT OPERATION
For boiler optimisation it is important to address both
the combustion system, and the steam and feedwater systems.
Combustion efficiency
Combustion efficiency indicates the flue gas loss.
Boiler efficiency also includes the blowdown and
stand-by losses. Whether comparing new or existing
boilers, their most efficient operating point is usually
somewhere between 60% and 90% load.
Stable combustion requires three inputsfuel, oxygen
and a source of ignition. If the combustibles can
provide this third element as they burn, the source of
ignition can be turned off. In complete combustion a
number of things happen:
n
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BES T P R AC TI C E DE SI GN , T EC H NOL O GY AN D M A NA GE M EN T
pollution;
Gas-side fouling
The easiest fouling condition to correct is normally
the gas-side deposits. Natural gas generally does not
produce significant gas-side deposits if the burner is
functioning properly. Fuel oil combustion deposits consist
predominately of soft, black soot and are easily removed
with brushing. Lower grade fuel oil may contain large
quantities of alkaline sulfates and vanadium pentoxide
that cause more serious gas-side deposits.
These compounds have low fusion temperatures causing
them to slag and become deposited on convection
surfaces. Solid fuels, including coal and wood, produce
deposits that contain ash-based slag and soot.
Boiler gas-side temperatures are so high that ash
deposits on convection surfaces (that could have been
easily removed as they formed using a soot blower)
can become sintered, or melted, into glass-like masses
known as enamel. Any type of tube fouling acts as an
insulator between the flue gas and convection surface,
reducing the efficiency of the boiler or heater.
The cost of poorly maintained boiler tubes can be
estimated from the increase in stack temperature
compared to clean conditions.
The loss of boiler efficiency is approximately 1% for
every 4.5C increase in stack temperature above
baseline conditions.
Cleaning required
Monthly brushing
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Heat recovery
Stand-by losses
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Pipe losses
Steam pipes can be a major source of concern due
to direct heat transfer losses. Adequate insulation is
essential. For example, a one metre length of uninsulated
steam pipe carrying steam at 700 kPa will loose heat at
an annual rate equivalent to 1000 litres of fuel oil or
650 m3 (25 GJ or around $150) of natural gas per year.
mechanical;
thermostatic;
thermodynamic; and
miscellaneous.
Condensate return
Condensate discharged from process plant may
contain up to 25% of the heat added in the boiler and
in addition will be chemically treated water. Any
sensible heat still left in the condensate should be
returned to the feed tank. This water is free of
impurities and every 5C increase in the feed-water
temperature will save approximately 1% of the fuel
used to raise steam. Again, to maximise the recovery
of sensible heat, condensate lines should be insulated.
Waterside fouling
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CHECKLIST
Use the checklist below to ensure that a boiler
and steam distribution system is optimised.
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Recover heat from condensatepreheat feedwater through heat exchanger fitted after feedwater pumps.
BE S T P RA CT IC E D E S IGN , T E CH N OL O G Y A N D M ANA G EM EN T
CONCLUSION
There are many ways to ensure that boiler and steam
distribution systems operate at optimum efficiency.
Checking each of the areas identified as potential
problems will help achieve a system that runs as
efficiently as possible. Addressing the issues can
produce substantial savings as well as reduce
greenhouse gas emissions.