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Packaged

Boiler
Kawasaki Boiler History

In 1899, Kawasaki developed


Cornish Boiler (smoke (fire) tube boiler)
In 1917, Kawasaki developed
Takuma Boiler (water tube boiler)
In 1951, Kawasaki developed SG steam generator (HRSG)

In 1966, Kawasaki released “KS Series” (smoke (fire) tube boiler)

In 1977, Kawasaki released “KD Series” (water tube boiler)

In 2000, Kawasaki released “IF Series” (Large capacity (more than 2


ton) multi tube once-through boiler)
In 2009, Kawasaki started sales of “IF Series” to overseas countries

Kawasaki has over-100-year history


in Boiler Industry.
© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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Supply Record <Boiler>
CUSTOMERS WORLDWIDE − Packaged boiler

VIETNAM

JAPAN
UAE TAIWAN
PHILIPINES
THAILAND
MALAYSIA
SINGAPORE
INDONESIA

# In the orange countries, KTE has an after sales service agent.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Clients Record

Our Clients

Tire / Rubber Paper / Cardboard

Foods / Beverages Vehicles

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Boiler Market in Japan

Water Tube Boiler Fire Tube Boiler


1.9% 1.6%

HRSG
3.9%

10,481ton
(2016) Once Through
Boiler (below 2
ton)
Once Through 35.0%
Boiler (over 2 ton)
57.6%

#Japan Boiler Association Market database

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Structure of Smoke (Fire) Tube Boiler

Exhaust
Gas Steam
Exhaust Steam
Gas

Combustion
Feed Gas
Water

Combustion
Gas

Burner
Combustion
Gas

Combustion
Gas
Feed
Fuel Fuel
Water

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Structure of Water Tube Boiler

Heated Feed
Water
Feed
Steam
Water
Steam

Combustion
Combustion
Gas
Burner Gas
Exhaust
Feed Gas
Water
Economizer
Combustion Evaporation
Gas
Fuel Combustion Recover waste
Gas heat
Fuel
Exhaust Feed water coming into the ※Economizer::
Gas boiler evaporates by Heat recovery device utilizing
combustion energy remaining
and generated steam goes
up

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Structure of Once Through Boiler (IF, KF)

Fuel Feed
Steam Fuel
Water
Exhaust Steam
Gas

Burner

Combustion
Gas Combustion Exhaust
Gas Gas

Economizer
Heated
Feed Feed Water
Water Recover
waste heat
Combustion
Feed water coming into Gas
the boiler evaporates by
combustion energy and ※Economizer : Heat recovery
generated steam goes up. device utilizing exhaust gas

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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What is Steam Boilers

Used for
“Manufacturing Process”
Boilers are able to provide
high pressure and high
temperature inexpensively.

Ex.) Steam Press. 0.78MPa [Temp. 174℃]


Demand of “Pressure” and “Heat” from
steam exists in industrial plants!

Once-through
Boiler
Fuel : Natural Gas, LPG, Diesel Oil and others

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Summaries (1)

Why is Once-through Boiler popular in Japan?

High Quick
Efficiency Start-up

High Quality
Compact
Steam

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Summaries (2)

A Comparison of KTE’s Line-up Boiler


Once-through Once-through
Water Tube Smoke Tube (KF) (IF)
Actual
Evaporation
t/h 5 5 1.68×3 5
Weight ton 12 11.5 2.4×3=7.2 7.8
Retained 275×3
Water Volume
L/t 3,000 6,000 =825 990
Cold start
benefit
Min 40 40~60 10 15
Intermittent
Combustion Continuous Continuous
(3 positions)
Control
Intermittent
Water Feeding Continuous Continuous
(2 positions)

1st Grade driver &


License (in Malaysia) 2nd Grade driver×2 2nd Grade driver
1st or 2nd Boiler Engineer

Heating Surface Area 1,174 693 106×3=318 317

Max. Boiler Efficiency (%) 94 92 98 98


Dimension (m2) 25 12.6 2.5×3=7.5 7.3
Note) The boiler efficiency is indicated on the steam pressure of 0.49Mpa, the feed water temperature
of 15 deg C and the room temperature of 35 deg C. The boiler efficiency shall have +/-3%
allowance in concideration of the mesurement tolerance.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features [ IF series ]

1.Capacity 2.5 ∼ 5 t/h Big Once-through Boiler

2.Maximum
Working Pressure 0.98 / 1.56 / 1.96/ (3.2) MPa

3.License Not required in Japan 2nd grade driver can use in Malaysia

4.Efficiency 98% for Gas Fired,95% for Oil Fired (with Economizer)

PI Control Pressure Fluctuation: ±0.01 MPa


5.Control (with de-aeration device) Range of combustion:30∼100%(Oil)
17∼100%(Gas)

6.Life Cycle More than 15 years De-aeration device, PI combustion

Equivalent Performance
7.Steam Dryness More than 99.5%
& High dryness
☆Harmonized Multi-Control for more than 2 Boilers
8.Option
☆100% Drain Recovery at high pressure

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features 1 [ PI Control ]

Combustion - PI Control

Feed Water Supply - PI Control


100
PI Control
Boiler Efficiency[%]

98
17%
96

94

92 Three position
Control Boiler
90

80
0 20 40 60 80 100 120
Boiler Load[%] (Gas Fired)
No Boiler Efficiency drop at low load Partial Load Efficiency is High

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features 1 [ PI Control ]

Stable Steam Pressure


kPa
0.85
PI Control
0.80 (IF)

0.75

0.70
Three
Position
Control
0.65

Steam Load 42%⇒75%


0.60
-40 -20 0 20 40 60 80 100 120 140 160
Sec.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features 2 [ Water Supply Control ]

Water Level Control


Ideal Water Level Control system is adopted!
Purpose Prevention of Water Tubes Overheat
& Maintain Steam Dryness
Water Level
Controller
Steam-Water
Separator
Water Level
Controller

△L
△L

(Controlled ②
Level)
① ①
(Controlled
Feed Water
Level)

Feed Water

Fig. A:Steam-Water Separator Control Method Fig. B:Body Control Method

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features 3 [ Boiler Life ]

Long Life
Less
Long Life of Product corrosion
1) Built-in Deaerator
& Unique water feeding
・Lower dissolved oxygen level
2) Water Level Control:
Steam-Water Separator Method
・Prevention of Water Tubes
Overheat

3) PI Control for Combustion


Proportional Combustion Control Feed
Water

Relief of Heat Stress to Body

Prevention of
Thermal Fatigue Breakdown

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Features 4 [ Condensate Return]

1) 100% drain recovery is possible.


(Realized due to PI control in combustion and feed water control)
(Traditional once-through boiler condensate recovery rate is only 70%)

2) Drain recovery is possible together with economizer.


(In addition to high pressure condensate recovery, exhaust gas recollection is possible)

Machine
Load
Burner
PI Control

Pressure
Condensate
Control valve
water Pot
Overflow Stable
Make up condensate
water water flow

Feed Condensate
Water Return pump
tank
Feed water
Economizer
(PI Control)

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Introduction of KTE Boilers Lineup

10,000
20,000
30,000
40,000
7,000
Steam Output Kg/h 500 1,000 1,500 2,000 3,000 4,000 5,000 6,000

KD Series
Water Tube
Boiler 4,000 30,000

KS Series
Smoke(Fire)
Tube Boiler 1,000 10,000

IF Series

2,516 5,031
Multi Tube
Once-Trough KF Series

606 1,677

HRSG KS-HR Series


Smoke Tube
Type 400 10,000

HRSG RGA Series (KDF Series)


Water Tube
Type 5,000 35,000

HRSG Multi Tube RF Series


Once-Through
Type 2,500 5,000

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

1. Food industry
Sterilization of Heating Steam
Steam Boiler Heating / Cooking
beverages / Foods Cooker

Steam Steam Steam


[Heat] [Heat] [Heat]

Steam Piping

Steam is used for sterilization of foods, heating


cooking device and steam cookers.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

1-1. Sterilization of beverages & foods

Raw materials are Trim poor ones off Rinse the material out Crush the materials
brought

Press out juice from Sterilize the juice Store the juice in the Pack the juice in
the raw material tank cartons

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Usage of Steam Boilers

1-2. Heating Cooking Device

Bring ingredients Cook rice Cook fried (Heat the fryer and
(by specialized rice cooker) control its temperature)

Deliver dishes Wash dishes Disinfect and store dishes

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Usage of Steam Boilers

1-3. Heating Steam Cooker

Process ingredients in the Put it into steamer and steam Cut and form it
blender

Mix sweet bean and Put it into the mold Put them into steamer Complete
sugar and steam

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Usage of Steam Boilers

2. Paper and Chemical industry


Corrugated Paper
Steam Boiler Heating chemicals Tire Manufacturing
(Carton Box)

Steam Steam
Steam
[Press.] [Press.]
[Temp.]
[Temp.] [Temp.]

Steam Piping

Steam is used for pasting corrugated paper,


heating chemicals and vulcanization of tires.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

2-1. Corrugated Paper Manufacturing

Material paper is delivered Put material paper into Paste paper


corrugating machine

Printing
Corrugated paper is made Cut corrugated paper

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Usage of Steam Boilers

2-2. Heating Solvent & Chemical Products

Heat source for Heat chemical for An appropriate Control temperature to


distillation chemical reaction temperature keep its quality

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Usage of Steam Boilers

2-3. Tire Manufacturing Process

Prepare a secondhand tire Grind tread rubber with a buffing Apply rubber cement uniformly
machine and adjust shape and and put a tread rubber sheet
size

Place it in a mold and bring heat Remove the tire after Finished tires are precisely
and pressure to it in a certain vulcanization inspected and delivered
time for vulcanization

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

3. Concrete and Metal


Coating for metal
Steam Boiler Making concrete Cleaning metals
cable

Steam Steam Steam


[Press.] [Press.] [Press.]
[Temp.] [Temp.] [Temp.]

Steam Piping

Steam is used for curing concrete, cleaning


metals before painting and vulcanization
of vinyl chloride coating for metal cable.
© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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Usage of Steam Boilers

3-1. Curing Concrete

1. Silica stone, cement and calcined lime are mixed with water to make mother water.
2. Reinforcing steel mat with anti-corrosion treatment is set in a mold.
3. Mother water is cast in a mold and then lead it to form by chemical reaction.
4. The material is hardened in a high pressure and high temperature curing kiln named
“autoclave”.
5. Treat surfaces carefully.
6. After severe quality check, complete concrete panels are delivered.

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

3-2. Material & Automobile Manufacturing

Control temperature in the Clean the surface of the products Dry the products after painting
production line with high pressure steam before
painting

© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved


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Usage of Steam Boilers

3-3. Electric Cable Manufacturing

Make PCV (coating material) Wire drawing process Coat PE or PVC as insurant
(Kneading process) Conductor is drawn and around wire conductor
extended (Insulation process)

Make them twisted pair or quad Interweave copper wire or tinned Coat PE or PVC sheath around
wire (Thread process) wire with insulation core or twisted the twisted core
core (Interweave process) (Sheath process)

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© 2015 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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