TI 405 - Eng - ERK Vs Schnelldampferzeuger

No.
: TI-405_eng
Page
: 1 of 1
TECHNICAL INFORMATION
Rev.
: 1
Date
: 14.10.09
SCHNEIDER-Eckrohrboiler (natural circulation) vs.

One Through Steam Boiler (forced circulation)
Performance during sudden peak loads
pressure drop - recovery time - steam quality
To evaluate the performance of a steam boiler during sudden peak loads two situations during operation with two different boiler systems shall be analyzed. These two boiler systems
are the natural circulation type with the SCHNEIDER-Eckrohrboiler as a sample and the
forced circulation type or similar systems with the One Through Boiler as a sample.
Situation 1
The burner is operating within its turn down ratio.
Situation 2
The burner is switched off since the steam load is below minimum capacity of the burner.
Each steam boiler reacts with a pressure drop on each peak load hence the questions raised on this are
listed below
how big is the pressure drop
how long does it takes until the boiler is back on its regular operation pressure
what happens with the steam quality
any other impact on the boiler performance
Provided the function of the two boiler systems are known in general the impact of sudden peak loads shall
be analyzed with the SCHNEIDER-Eckrohrboiler as a natural circulation type and the One Through Boiler
as a forced circulation type.
For both boiler systems the same criteria are relevant
Note
the bigger the water content of the boiler
the clearer the separation of the internal water circulation and the external steam / condensate circulation
the bigger the boiler turn down ration is which means the lower the lowest steam load on which steam
can be extracted from the boiler
the bigger the burner turn down ratio
the shorter the running time for the boiler compound control is until ignition
the lower is the negative impact on the boiler performance, such as pressure drop and other performance data, during sudden peak load.
Under above criteria the performance of the two boiler systems during sudden peak loads shall be
evaluated.
Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc
SCHNEIDER International GmbH
Email / Internet
Hildburghauser Strasse 79
12249 Berlin, Germany
Tel.: +49-30-75 44 93 99-0
Fax: +49-30-75 44 93 99-21
info@schneider-kessel.com
www.schneider-kessel.com
No.
: TI-405_eng
Page
: 2 of 2
Rev.
: 1
Date
: 14.10.09

The SCHNEIDER-SCHNEIDER-Eckrohrboiler
Dampfentnahmeventil / main steam valve
13
Druckbegrenzer / pressure limiter
Niveauelektrode, max.. / level probe, high
14
Druckwchter / pressure monitor
Niveauelektrode, min. / level probe, low
15
Probenahmekhler / sample cooler
Sicherheitsventil / safety valve
15a
Absalzeinrichtung / continous blow down (TDS)
Entlftungsventil / venting valve
16
Abschlammventil / intermittend blow down
Speiseabsperrventil / feed stop valve
16a
Absperr-, Entleerungsventil / stop valve
6a
Speiserckschlagventil / feed check valve
17
Schauloch / view hole
Wasserstandanzeiger, dir. / water level gauge, direct
18
Brenner / burner
Wasserstandanzeiger, elektr. / water level gauge, electr.
19
Mannloch / man hole
Wasserstandregelung / water level control
20
Besichtigungsffnung / inspection opening
10
Manostatenbalken / pressure control manifold
21
Ablassstutzen / condensate drain
11
Manometer / pressure gauge
22
Abgaskammer / flue gas chamber
12
Druckregler / pressure control
optional

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Fax: +49-30-75 44 93 99-21
No.
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Rev.
: 1
Date
: 14.10.09

water content
There is no doubt about that the most important condition of being not sensitive against sudden peak loads is a large water content since the water content of a boiler is a thermal energy reservoir. Peak loads
result in pressure drop which means the enthalpy of the water drops accordingly and this enthalpy difference means additional steam generation.
Example:
water content up to low water level
: 2.0m
operation pressure at begin of pressure drop
: 65.0barg (~281C)
operation pressure at end of pressure drop
: 60.0barg (~276C)
enthalpy difference
: 26.82kJ/kg
steam generation out of enthalpy difference
: 34kg
On first sight it seems not to be that much but on second sight it looks different. Assuming an extreme
peak load occurred over 1 minute has resulted in this pressure drop of 5.0bar these 34.0kg of steam
would be equal to an hourly steam generation of 2040kg/h and that is actually impressive. Does this
peak load and pressure drop occurs during regular boiler operation of 100% load this would mean that a
boiler of a regular capacity of 7.5 t/h has a short time capacity increase of almost 30% up to 9.74t/h
This large energy reservoir is the guarantee for a short reaction time when peak loads occur even during
switch-off times of the burner.
Bottom Line :
The large water content of the SCHNEIDER-Eckrohrboiler secures low pressure drops and
short recovery time when peak loads occur.
Since any pressure drop goes along with an increase of water and steam volume the following issues are
of high importance.
clear separation of internal water circuit and external steam / condensate circuit
Because the SCHNEIDER-Eckrohrboiler has a defined and controlled water level due to the clear separation of the internal water circuit and external steam / condensate circuit the sudden increase of volume
during a sudden peak load results in a slightly and temporary lifted water level. Due to the large designed
steam drum there is never the risk of any carry over hence even during extreme peak loads absolute dry
saturated will be delivered to the consumer.

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In closed consumer circuits (heat transfer in heat exchangers) this means ideal condition for the heat
transfer even during peak loads
Surface heat transfer coefficient for dry saturated steam
~ 70 kW/mK
In open consumer circuits (steam gets in direct contact with the product, i.e. splitter) absolute dry saturated steam is the main and essential condition for high production ratio and short production time. The
risk of contamination of the product due to carry over does not exist with the SCHNEIDER-Eckrohrboiler
since there simply is no carry over.
Another unique advantage of the SCHNEIDER-Eckrohrboiler and the clear separation between the internal water circuit and the external consumer circuit is the possibility of steam extraction at full operation
pressure even when the burner has stopped
Bottom Line
The clear separation between the internal water circuit and the external consumer circuit in
connection with the large water content as energy reservoir are further reasons for the trouble free operation even during sudden and extreme peak loads.
boiler turn down ratio

Because of the clear separation between the internal water circuit and the external consumer circuit the
SCHNEIDER-Eckrohrboiler has a boiler turn down ratio of 1:100 since steam extraction is possible even
when the burner has been switched off by the automatic pressure control system.
In One Through Boiler or similar boiler systems the feed water pump starts synchronously with the burner
and initiates an additional pressure drop due to the fact that cold water is fed into the boiler. In the
SCHNEIDER-Eckrohrboiler this is totally different. The water level in the boiler is kept constant and the
entire water content of the boiler is on evaporation enthalpy which means as soon as the burner ignition
occurs steam is generated at full operation pressure.
Bottom Line
The unbeatable advantage high turn down ratio of the SCHNEIDER-Eckrohrboiler secures the
lowest possible regeneration time after sudden peak loads
burner turn down ratio

A high burner turn down ratio is of high importance for the boiler performance during peak loads. However the burner turn down ratio shall not exceed the boiler turn down ratio in order to avoid possible boiler
damages due to no sufficiently cooled heating surfaces. For the SCHNEIDER-Eckrohrboiler this risk
does not exist as a result of the clear separation between the internal water circuit and the external consumer circuit. Hence there is no limitation set for the burner turn down ratio for the SCHNEIDEREckrohrboiler and the higher the better applies.
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Bottom Line
The higher the burner turn ratio is the faster is the boiler back on full load and full operation
pressure after a sudden peak load.
sequence control running time

The time it takes for the burner to be back on full capacity after the pressure control has switched it off
depends on the running time of burner sequence control. This running time compiles of
a. purging time to clean all boiler passes of gaseous remains of the fuel from burner inlet to stack.
b. checking time of tightness control of solenoid valves.
c.
running time of compound control on-off before ignition.
d. ignition
e. running time of compound control from ignition load to full load after ignition
The purging time can be adjusted in accordance with local situation since it depends on the boiler design
and the distance between boiler and stack. The running time of the compound control depends on the
burner brand. The remaining sequences of the running time however are fixed and cannot be changed or
adjusted.
Bottom Line
The shorter the running time of the sequence control the faster is the boiler back on full load
and full operation pressure after a sudden peak load.

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Rev.
: 1
Date
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The One Through Boiler

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Date
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water content
One Through Boiler have an extreme small water content which normally is less than 25% oft the water
content of the SCHNEIDER-Eckrohrboiler which means the energy quantum which can be accumulated
is small as well.
Bottom Line
The small water content of the One Through Boiler constitutes no energy reservoir as a buffer
during peak loads independent if the burner is in operation or not.
clear separation of internal water circuit and external steam / condensate circuit
This is the biggest difference between the two boiler systems under evaluation and it has the biggest impact on the boiler performance during peak loads. The One Through Boiler has no separation between
the internal water circuit and the external consumer circuit at all since there is only one circuit from the
boiler to the consumer from where it ends up in the condensate system. The feed water is forced by special circulation pumps into the boiler coil where is evaporated to almost 100%. An evaporation ratio of
100% is not possible due to the boiler system which means a steam / water mixture is leaving the boiler
with the ratio of the mixture depending on the boiler load. During a constant medium boiler load the evaporation ratio is rather high at full load or during peak load this ratio is rather low in other words the carry
over is varying with the boiler load. Main separation of water and steam occurs in a small separation vessel outside the boiler. Part of the separated water is extracted via a continuous blow down device and
hence lost. The other part of the carry over reaches as steam moisture the consumer. This moisture is
approx. 5% during medium constant load but increases during peak loads to 25% and more.
But there another significant disadvantage of this design. Due to this design of a coil as heating surface it
is not possible to install a blown system at the One Through Boiler in order to flush and remove chemical or other remains from the boiler. Hence these impurities remain in the carry over or in the boiler itself
meaning these impurities either reach the consumer or cover the water side heating surfaces where they
interrupt the heat transfer resulting boiler damage.
The impact of the steam moisture on the consumer might be described as follows
In closed consumer circuits (heat transfer in heat exchangers) this high content of carry over or high
steam moisture will extend the production time since the surface heat transfer coefficient is much lower
than for dry saturated steam.
Surface heat transfer coefficient for water is only
~ 4 kW/mK
Which means the higher the steam moisture the worse is the heat transfer
In open consumer circuits (steam gets in direct contact with the product, i.e. splitter) high steam moisture results in product contamination since the impurities in the carry over will come in direct contact with
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the product. Furthermore high steam moisture results in decreased production efficiency due to temperature fluctuation in the splitter.
For both circuits apply the high water and hence energy loss due to the blow down ratio of the
steam/water separator and the steam moisture.
Bottom Line
Due to the common steam/water/condensate of the One Through Boiler system the negative
impact on the boiler performance and hence on the production efficiency and product quality
during peak loads is significant
boiler turn down ratio

The boiler turn down ratio of the One Through Boiler is determined by the min. water flow necessary to
cool and to protect the heating surfaces in order to avoid boiler damages. This basic condition limits the
boiler turn down ratio of the One Through Boiler to approx. 30:100. With every boiler/burner start the
forced circulation pump will start simultaneously too and feeds cold feed water through the coil which
results in an additional pressure drop.
Bottom Line
The One Through Boiler does not allow any steam extraction when the burner system is switched off. Operating the burner with closed main steam valve in order to keep the boiler in
operation condition is not possible as well.
burner turn down ratio

The burner and the boiler turn ration are exactly the same. Synchronization of burner-boiler-circulation
pump is mandatory for the One Through Boiler
Bottom Line
Influencing the performance of a One Through Boiler during peak loads by increasing the
burner turn down ratio is not possible
sequence control running time

For the One Through Boiler the same statements apply than for the SCHNEIDER-Eckrohrboiler

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Rev.
: 1
Date
: 14.10.09

CONCLUSION
The SCHNEIDER-SCHNEIDER-Eckrohrboiler
The SCHNEIDER-Eckrohrboiler is proof against sudden peak loads. Only slight and momentary pressure
drops occur with the steam quality remaining unchanged. The reasons for this performance are
large thermal energy reservoir because of large water content
absolute dry saturated steam because of clear separation of internal water circuit and external steam /
condensate circuit
short recovery time after sudden peak loads with unchanged high steam quality.
no carry over even during extreme peak loads.
steam extraction at operation pressure level secured even when the burner is switched off which means
boiler turn down ratio 1:100.
Burner can be operated to keep the boiler on operation pressure level even with closed main steam valve.
no limitation for burner turn down ratio which is only depending on the burner brand. This assures high
influence on the boiler performance.
all boiler loads can be covered by 1 boiler due to the boiler turn down ratio of 1:100.
The One Through Boiler

The One Through Boiler is not proof against sudden peak loads which results in significant pressure drops
along with worsening steam quality. The reasons are as follows:
no thermal energy reservoir because of negligible water content.
high steam moisture due to carry over.
high energy loss due to carry over along with high blow down ration in the separation vessel.
lifetime limited because no blown down system for the coil can be installed.
no steam extraction possible when burner has switched off.
boiler turn down ratio limited to 30:100. In order to overcome this disadvantage more units with smaller
capacities must be installed.

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Tel.: +49-30-75 44 93 99-0
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TI 405 - Eng - ERK Vs Schnelldampferzeuger

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No.

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

Dampfentnahmeventil / main steam valve

Druckbegrenzer / pressure limiter

Niveauelektrode, max.. / level probe, high

Druckwchter / pressure monitor

Niveauelektrode, min. / level probe, low

Probenahmekhler / sample cooler

Sicherheitsventil / safety valve

Absalzeinrichtung / continous blow down (TDS)

Entlftungsventil / venting valve

Abschlammventil / intermittend blow down

Speiseabsperrventil / feed stop valve

Absperr-, Entleerungsventil / stop valve

Speiserckschlagventil / feed check valve

Schauloch / view hole

Wasserstandanzeiger, dir. / water level gauge, direct

Wasserstandanzeiger, elektr. / water level gauge, electr.

Mannloch / man hole

Wasserstandregelung / water level control

Besichtigungsffnung / inspection opening

Manostatenbalken / pressure control manifold

Ablassstutzen / condensate drain

Manometer / pressure gauge

Abgaskammer / flue gas chamber

Druckregler / pressure control

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

operation pressure at begin of pressure drop

operation pressure at end of pressure drop

steam generation out of enthalpy difference

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

boiler turn down ratio

burner turn down ratio

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

sequence control running time

running time of compound control on-off before ignition.

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

The One Through Boiler

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

boiler turn down ratio

burner turn down ratio

sequence control running time

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

SCHNEIDER-Eckrohrboiler (natural circulation) vs.

The One Through Boiler

Doc.: TI 405_eng - ERK vs Schnelldampferzeuger.doc

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