Boilers and Thermic Fluid Heaters
Boilers and Thermic Fluid Heaters
Boilers and Thermic Fluid Heaters
Thermal Equipment/
Boilers
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
Introduction
Thermal Equipment/
Boilers
What is a Boiler?
Vessel that heats water to become
hot water or steam
At atmospheric pressure water
volume increases 1,600 times
Hot water or steam used to transfer
heat to a process
3
Introduction
STEAM TO
PROCESS
EXHAUST GAS
DEAERATOR
PUMPS
ECONOMIZER
Thermal Equipment/
Boilers
STACK
VENT
VENT
BOILER
BLOW DOWN
SEPARATOR
BURNER
WATER
SOURCE
FUEL
BRINE
CHEMICAL FEED
SOFTENERS
Thermal Equipment/
Boilers
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
Types of Boilers
Thermal Equipment/
Boilers
Type of Boilers
Thermal Equipment/
Boilers
Type of Boilers
Thermal Equipment/
Boilers
(Your Dictionary.com)
Combustion efficiency
enhanced by induced
draft provisions
Type of Boilers
Thermal Equipment/
Boilers
3. Packaged Boiler
To
Chimney
Oil
Burner
Comes in complete
package
Features
High heat transfer
Faster evaporation
Good convective
heat transfer
Good combustion
efficiency
High thermal
efficiency
Classified based on
number of passes
Type of Boilers
Thermal Equipment/
Boilers
Type of Boilers
Thermal Equipment/
Boilers
Type of Boilers
Thermal Equipment/
Boilers
Steam generation in
convection section
Benefits: more
economical, better space
utilization and efficient
combustion
12
Type of Boilers
Thermal Equipment/
Boilers
13
Type of Boilers
Thermal Equipment/
Boilers
14
Type of Boilers
Thermal Equipment/
Boilers
Combustion
temperature at 1300
-1700 C
Tangential firing
15
Type of Boilers
Thermal Equipment/
Boilers
16
Type of Boilers
Thermal Equipment/
Boilers
Benefits:
Closed cycle = minimal losses
Non-pressurized system operation at 250 C
Automatic controls = operational flexibility
Good thermal efficiencies
17
Type of Boilers
8. Thermic Fluid Heater
Thermal Equipment/
Boilers
User equipment
2. Circulated
to user
equipment
1. Thermic
fluid heated
in the heater
3. Heat transfer
through heat
exchanged
4. Fluid
returned to
heater
Control
panel
Insulated
outer wall
Blower
motor
unit
Fuel oil
filter
Exhaust
(Energy
Machine India)
18
Thermal Equipment/
Boilers
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
19
Assessment of a boiler
Thermal Equipment/
Boilers
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment
20
Assessment of a Boiler
Thermal Equipment/
Boilers
1. Boiler performance
Causes of poor boiler performance
-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality
Assessment of a Boiler
Thermal Equipment/
Boilers
Heat Balance
An energy flow diagram describes geographically
how energy is transformed from fuel into useful
energy, heat and losses
Stochiometric
Excess Air
Un burnt
Stack Gas
FUEL INPUT
STEAM
OUTPUT
Convection &
Radiation
Blow
Down
22
Assessment of a Boiler
Thermal Equipment/
Boilers
Heat Balance
Balancing total energy entering a boiler against the
energy that leaves the boiler in different forms
12.7 %
8.1 %
100.0 %
Fuel
1.7 %
BOILER
0.3 %
2.4 %
1.0 %
73.8 %
Heat in Steam
23
Assessment of a Boiler
Thermal Equipment/
Boilers
Heat Balance
Goal: improve energy efficiency by reducing
avoidable losses
Avoidable losses include:
- Stack gas losses (excess air, stack gas
temperature)
- Losses by unburnt fuel
- Blow down losses
- Condensate losses
- Convection and radiation
24
Assessment of a Boiler
Thermal Equipment/
Boilers
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
1)
DIRECT METHOD:
2) INDIRECT METHOD:
25
Assessment of a Boiler
Thermal Equipment/
Boilers
Assessment of a Boiler
Thermal Equipment/
Boilers
Quick evaluation
Few parameters for computation
Few monitoring instruments
Easy to compare evaporation ratios with
benchmark figures
Disadvantages
Assessment of a Boiler
Thermal Equipment/
Boilers
Principle losses:
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
vii) Radiation and other unaccounted losses
28
Assessment of a Boiler
Thermal Equipment/
Boilers
29
Assessment of a Boiler
Thermal Equipment/
Boilers
Disadvantages
Time consuming
Requires lab facilities for analysis
30
Assessment of a Boiler
2. Boiler Blow Down
Thermal Equipment/
Boilers
Assessment of a Boiler
Thermal Equipment/
Boilers
Continuous
Ensures constant TDS and steam purity
Heat lost can be recovered
Common in high-pressure boilers
32
Assessment of a Boiler
Thermal Equipment/
Boilers
33
Assessment of a Boiler
Thermal Equipment/
Boilers
Assessment of a Boiler
Boiler Feed Water Treatment
Thermal Equipment/
Boilers
Deposit control
To avoid efficiency losses and
reduced heat transfer
Hardness salts of calcium and
magnesium
Alkaline hardness: removed by boiling
Non-alkaline: difficult to remove
Assessment of a Boiler
Boiler Feed Water Treatment
Thermal Equipment/
Boilers
Conditions:
Feed water is low in hardness salts
Low pressure, high TDS content is tolerated
Small water quantities treated
Assessment of a Boiler
Boiler Feed Water Treatment
Thermal Equipment/
Boilers
Processes
a) Ion exchange
b) Demineralization
c) De-aeration
d) Reverse osmoses
37
Assessment of a Boiler
External Water Treatment
Thermal Equipment/
Boilers
b) Demineralization
Complete removal of salts
Cations in raw water replaced with hydrogen ions
38
Assessment of a Boiler
Thermal Equipment/
Boilers
Assessment of a Boiler
External Water Treatment
Thermal Equipment/
Boilers
Mechanical
de-aeration
Vent
Spray
Nozzles
Boiler Feed
Water
Stea
m
Scrubber
Section
(Trays)
Storage
Section
De-aerated
Boiler Feed
Water
Assessment of a Boiler
External Water Treatment
Thermal Equipment/
Boilers
Chemical de-aeration
Removal of trace oxygen with scavenger
Sodium sulphite:
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
41
Assessment of a Boiler
Thermal Equipment/
Boilers
Reversed osmosis
Higher concentrated liquid pressurized
Water moves in reversed direction
42
Assessment of a Boiler
Thermal Equipment/
Boilers
Fresh Water
Feed
Water
More
Concentrated
Solution
Concentrate
Flow
Water Flow
Semi Permeable
Membrane
43
Thermal Equipment/
Boilers
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
44
Thermal Equipment/
Boilers
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
45
46
Symptoms:
Smoke, high CO levels in exit flue gas
Causes:
Air shortage, fuel surplus, poor fuel distribution
Poor mixing of fuel and air
Oil-fired boiler:
Improper viscosity, worn tops, cabonization on
dips, deterioration of diffusers or spinner plates
47
Solid Fuels
Bagasse
Coal (bituminous)
Lignite
Paddy Husk
Wood
3.3
10.7
8.5
4.5
5.7
10-12
10-13
9 -13
14-15
11.13
Liquid Fuels
Furnace Oil
LSHS
13.8
14.1
9-14
9-14
48
Thermal Equipment/
Boilers
50
Thermal Equipment/
Boilers
52
53