Retrofitting of Existing Boilers to

Biomass Boilers

Yoshio HIRAYAMA
TechnoSoft Co.,Ltd.
Energy Efficiency of Boilers
 Energy Efficiency of Boiler
Net Heat Value required for Steam Generation
Boiler Energy Efficiency (η) =
Combustion Heat of Fuel
Boiler Efficiency
General Boiler 65-70%
Water Tube / Fire Tube > 80%
Electric Generation + Wood Drying (*) 90%

Water Content and Heating Value of Wood

Water Content (%) Heating Value (MJ/Dry-kg)
0 1
20 2/3
40 1/3
 Boiler Heat Balance 1
Heat Loss in Dry Flue Gas
Heat Loss in Flue Gas
Water Heat Loss in Air

Heat Transfer in Vaporizer

Heat Supply
to Boiler
Effectively
Exchanged
Heat Transfer in Super Heater
Heat
Heat Transfer in Economizer

6 Other Heat Loss

5
4 Unburned Carbon in Flue Gas
3 Unburned Material
Radiation Heat Loss
 Heat Loss from Boiler
Loss
1 Heat loss in dry flue gas
2 Water heat loss in air
3 Radiation heat loss
4 Unburned fuel
5 Unburned carbon in flue gas
6 Other heat loss
Contents
Sensible heat loss of flue gas
Largest heat loss
Latent heat loss to vaporize water in air
Heat loss from outer surface of furnace to
atmosphere
Flammable material unburned and remained in
residue
CO or carbon
Blowing or atomizing steam loss
 Location of Boiler Heat Loss
Other Heat Loss
6 Unburned Carbon in Flue Gas 1 Heat Loss in Flue Gas

2 Water Heat Loss in Air

Steam 5
Flue Gas

3
Radiation Heat Loss

Air

Biomass Fuel

Water

4 Unburned Material
 Measures of Improving Boiler Efficiency
Improving Concept Actual Measures Remarks
Reduction of flue gas a Installation of air pre-heater Excess temperature reduction causes
temperature low-temp corrosion
b Installation of economizer
Depending on sulfur contents
c Scale removal on heat-transfer Outer Soot blower
surface (Soot / Ash)
Inner Water quality management
Chemical cleaning
Reduction of water in fuel d Sun-drying / Steam drying

Reduction of radiating heat e Increase thickness of insulation Considering Economics

loss
Unburned Fuel f Control of air / fuel ratio Pulverization of solid fuel
Installation of O2 analyzer
Reduction of dry gas Adjustment of air feed
quantity
Leak prevention g Periodical clearance check Leakage of pre-heated air to flue gas
side
Leak increase with time
Drain recovery h Recovery as boiler feed Drain has high latent heat
Reuse as heating medium of de-
aeration
 Energy Conservation Measures of Boiler
Leak Prevention
g
Installation of Installation of
a Air Pre-Heater b Economizer
Steam

Flue Gas

Economizer
c Scale Removal on Heat Transfer Surface

Reduction of Optimum Air Ratio

Radiation Heat Loss e
Reduction of
d water in fuel Air Air Pre-Heater
Biomass Fuel

Water

Air/Fuel Ratio Control h Drain Recovery

f /O2 Analyzer
 Air Pre-Heater

Plate Type Radiation Type

Bare Tube Type

Leak Prevention
Dust Handling
High Temperature Resistance
Boiler Water Quality by Steam Pressure
Steam Pressure Maximum Maximum Maximum
Total Dissolved Alkalinity Hardness
Solids (TDS)
kg/cm2 PPM
0-21 3,500 700 <20
-31.5 3,000 600 0
-42 2,500 500 0
-52.5 2,000 400 0
-62 1,500 300 0
-105 1,250 250 0
-140 750 150 0
-210 150 100 0
 Effect of Impurity of Water
Qualities Components Effects by Degradation
Total Dirt, Silt, Biological Insoluble iron Clog Valves and Strainers
Dissolved Growth, Vegetation, Excessive Sludge Build-Up
Solids Insoluble organic
matter and Minerals

Alkalinity Calcium, Magnesium Primary Source of Scale

and Silica

Hardness Bicarbonates, Form Carbon Major Factor in the Corrosion

Carbonates, Dioxide in of Condensate Lines
Hydroxides, Silicates, Steam
Borates, Ammonia,
Phosphates, and
Organic Bases
Foaming and Carryover
 Relation between Air Ratio and Heat Efficiency
Optimum
Heat Combustion
Region Combustion
Loss
Combustion Efficiency
Efficiency

Energy Loss by Imperfect Heat Loss by Excess Air

Combustion
1.15 1.3 Air Ratio
2.74 4.85 O2 Content in Flue Gas (%)

Formation of Black Smoke Optimum Increase of NOx

(Insufficient Air) Air Ratio (Excess Air)
 Effect of Air Ratio Reduction (Heavy Oil A)
Flue Gas Temperature :2000C, 3000C, 4000C

2000C
3000C
4000C
O2 in Flue Gas
O2 in Flue
Fuel Gas
Reduction
Ratio (%)

Previous Air Ratio

=
Air Ratio after Reduction
 Oxygen Analyzer

Portable Type Small Size

Measurement: O2, CO, NO, Pressure, Temperature

Calculation: CO2, NOx, Fuel/Air Ratio, Waste Gas Loss

and Combustion Efficiency
 Energy Management Procedure in Factory
Management Leader: President or Factory Manager
Organization Establishment of Energy Conservation Department
Employee’s Education
Full Participation
Advices from Outer Expert

Energy Conservation Clarifying Target by Managements (Objectives, Period and Fund)

Target Realistic Target, Planning and Implementation
Energy Consumption Installation of Measuring Instruments
Situation Quantitative Analysis of Energy Flow
Analysis of Correlation between Operating Condition and Energy Consumption
Record of Measured Value, Arrangement and Graphic Display
Management of Unit Energy Consumption
Energy Unit Energy Ratio like Energy Cost
Consumption
Proposal of Improving Extraction of Problems and Provision of Improving Plan
Plan Realistic Implementing Plan (Removal of Un-Proper Plan)
Implementation Management Cycle of PDCA (Plan, Do, Check and Action)
Publicizing to All Related Personnel
Management of Promoting Procedure
Standardization of Energy Conservation Activity
 Procedure of Energy Audit in Factories
Basic Data Investigation

Status of Energy Management Current Energy Consumption

Electric Facilities Heat Facilities Common Facilities

Lightening Thermal Insulation Heat Pump System

Water Supply / Discharge Preventing Radiation Cogeneration System

Power Steam System Air Conditioner

EL Receiving / Distribution Furnace Combustion Revamping

Air Compressor Waste Heat Recovery Process Improvement

 Energy Auditing Check List (Attached)
• Commercial Sector
– Building Structure
– Renovation and Expansion
– Operation / Maintenance / Management
• Industrial Sector
– Improvement of Fuel Combustion
– Heating, Cooling and Heat Transfer
– Prevention of Heat Loss
– Recovery and Utilization of Waste Heat
– Improvement of Conversion between Heat and Power
– Prevention of Electricity Loss
Boiler Retrofitting
 Waste
Waste gas
Fly ash Waste gas
treatment

>850℃
2nd combustion air

Fly ash

Feeder

Stoker

Main ash

Separator
Fusion Fused ash
Stoker-fired Furnace Furnace
and Ash Fusion Iron Ineligibles

Metal /
Slag
1st combustion air
 Fluid Bed Furnace and Ash Fusion
Waste Waste gas
Fly ash Waste gas
>850℃ treatment
Breaker / Feeder

Sand circulation Conveyer

Fly ash

Air for fluidity and

combustion

Vibrating sieve

Fusion
Incombustibles, Ash Fused ash
Furnace

Iron Ineligibles
Metal /
Slag
 Rotary Kiln type Thermal Decomposition
Gasification Fusion Furnace
Hot air
Waste Return Waste gas
Decomposed treatment
Gas
Breaker

Kiln
Fusion
Feeder Furnace

Residue
Cooling
conveyer

Secondary
air
Air heater
Separator

Fused ash
Valuable Slag
Metal Crusher
Retrofitting to Biomass Boiler and Key Issues

Oil
Coal Gas

Biomass

• Operation Stoppage during Retrofitting Work

– At least, One Month
– Loss to be Taken into Account of Economics
– Pre-Fabrication and Good Scheduling
• Avoidance of Capacity Reduction
– Biomass Energy: Low Heating Value
– 50% of Existing Capacity
Retrofitting Concept by Thai K. Boiler Co., Ltd.

Retrofitted Boiler

New Hybrid Boiler

 Main Parts of Retrofitting to Biomass Fuel
(Same Capacity Base)
Fuel of Target Boiler Gas Oil Coal
Boiler Type Fire Box Fire Box Fixed Bed Moving Fluid Bed Rotary
Gas Burner Oil Burner Bed Kiln

Utilization of Existing Boiler

Facilities Economizer / Super-heater
Flue Gas Exhausting
Fuel Feeding
Ash Treating
Retrofitting of Existing Fire Box
Facilities
IDF Burner
FDF
Installation of New Burner
Facilities Fuel Feeding
Ash Treating
 Thank
Thank you
you
for
for your
your attention
attention