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BOILER PLANT
5 Bar, Comp. air/steam for atomisation
Steam HP Dosing (Phosphate) 12 Bar/190o C
Bio Gas from ETP FD Fan Air 75 KW 35640m 3 540mm WC Condensate return LP dosing (Oxytreat)
Economiser
160o C 66m
Chimney 125o C
8.95 KW 36 m 3/hr 1.5m DM water tank 250 m 3 2.8 KW 48.1 m 3/hr 21.5m
Drain
Heat loss due to dry flue gas Dry Flue Gas Loss steam in flue gas Heat loss due to Heat loss due to moisture in fuel
8.1 % 1.7 %
100.0 % Fuel
BOILER
0.3 %
Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss
2.4 % 1.0 %
73.8 %
Heat in Steam
In order to improve thermal efficiency by 1%, the combustion air temperature must be raised by 20 oC.
Air preheater
Heat Pipe
Pulverised coal
Coal
Thermax Boiler
6 TPH 10.75 Kg/cm2 Coconut shell fired Primary Air Fan Secondary Air Fan
Economiser
Dust Collector
14 % 9%
By damper control O2 in flue gas brought down from 14 to 9 % Correspondingly excess air from 200 to 75 % Savings in coconut shell consumption 5 %
Automatic blowdown controls can be installed that sense and respond to boiler water conductivity and pH. A 10% blow down in a 15 kg/cm2 boiler results in 3% efficiency loss.
Boiler Blowdown
Blow down (%) = Feed water TDS x % Make up Permissible TDS in Boiler - Feed water TDS
If maximum permissible limit of TDS as in a package boiler is 3000 ppm, percentage make up water is 10% and TDS in feed water is 300 ppm, then the percentage blow down is given as : 300 x 10 = 3000 300 = 1.11 %
If boiler evaporation rate is 3000 kg/hr then required blow down rate is: 3000 x 1.11 = 100 = 33 kg/hr
Cleaning :
Incorrect water treatment, poor combustion and poor cleaning schedules can easily reduce overall thermal efficiency However, the additional cost of maintenance and cleaning must be taken into consideration when assessing savings.
Every millimeter thickness of soot coating increases the stack temperature by about 55oC. 3 mm of soot can cause an increase in fuel consumption by 2.5%. A 1mm thick scale (deposit) on the water side could increase fuel consumption by 5 to 8%
Energy saving in Boiler ID fan by speed reduction through pulley change or VSD
8
1470 RPM
10
26 kW 1181 RPM
Motor
Fan
Inverter
6
1470 RPM
10
14 kW 882RPM
Belt can be eliminated Fan can be Directly driven thus eliminating the belt losses
Change setting to 20 %
Nil overflow
Savings -
Rs. 75,000/year
100
= Mass flow rate of thermic fluid, KW / hr. = Specific heat of thermic fluid, KCal /Kg0C = Quantity of fuel consumed, Kg / hr. = Forward temperature of thermic fluid 0C. = Temperature of fluid at return condition 0C. = Gross calorific value of fuel, Kcal / Kg.
12.Boiler Replacement
If the existing boiler is :
Old and inefficient, not capable of firing cheaper substitution fuel, over or under-sized for present requirements, not designed for ideal loading conditions replacement option should be explored. The feasibility study should examine all implications of long-term fuel availability and company growth plans. All financial and engineering factors should be considered. Since boiler plants traditionally have a useful life of well over 25 years, replacement must be carefully studied.
Fuel Preparation:
Sieve the fines before feeding to crusher External drying of fuel moisture using waste heat, solar etc
Speed vs Power
% Speed 100 90 80 70 60 50 % Power 100 73 51 34 22 13
Fan Laws
Q H P
w w w
N
2 N 3 N
Speed