ME241 SEMESTER PROJECT

Author 1: Anas Asif

2014048

u2014048@giki.edu.pk

Author 2: Abdullah Ather

2014012

u2014012@giki.edu.pk

Author 3: Hassan Bin Sultan 2014118

u2014118@giki.edu.pk

Thesis Statement:
An updated approach to increase the efficiency of industrial boilers after researching on
Gadoon Power Plant.

Outline:
1. Introduction
2. Literature Review
Major Boilers used in Pakistan ( Studied through Industrial Visits )
State of the art boilers ( Company Sites )
Under Research ( Journals/Books )
3. Discussion

Assessment of boilers
Boiler blow down
Feed water treatment
Visit of Gadoon Power Plant details
Sensors used in Pakistani Industries (not very accurate)
Sensors used in modern Industries
Steps to increase efficiency (Through Gadoon and Saudi Electricity
Power Plant experience)

4. Results
5. Conclusions/ Future Steps
6. References

Introduction:
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

Types of Boilers:
There
boiler
in
that
the
are
1.

are many types of

but we will discuss
detail only 3
we have seen in
industrial visit that
1,2 and 7.
Fire Tube Boiler

2.

Water
Tube
Boiler

3.

Packaged
Boiler

4. Fluidized Bed (FBC) Boiler

5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler

1) Fire Tube Boiler:

Relatively small steam capacities

(12,000 kg/hour)

Low to medium steam pressures (18

kg/cm2)

Operates with oil, gas or solid fuels

2) Water Tube Boiler:

Used for high steam demand and

pressure requirements

Capacity range of 4,500 120,000 kg/hour

Combustion efficiency enhanced by induced draft provisions

Lower tolerance for water quality and needs water treatment plant

7. Waste Heat Boiler:

Used when waste heat available at medium/high temp

Auxiliary fuel burners used if steam demand is more than the waste heat can
generate

Used in heat recovery from exhaust gases from gas turbines and diesel engines

Literature Review:

Waste Heat recovery Systems

Features

Waste gas heat of a sintering plant is recovered as steam or electric energy.

The heat recovery efficiency is 60% for waste gas from cooler and 34% for waste gas
from sintering machine proper.
Waste gas heat recovery from sintering machine proper also leads to the reduction of
coke consumption.
Applicability: Where the cooler is of a circular type or linear type.
CO2 emissions can be reduced, leading to a possibility of employing this system in a
CDM project.

Where they are used:

Basic Concept or Summary

Using this system, high-temperature waste heat of waste gas from a cooler and a
sintering machine proper is recovered as steam, which can also be used for electric
power generation.
The system is composed of a waste heat recovery boiler, economizer, demineralized
water supply equipment, de-aerator, steam drum, etc.
For realizing high-efficiency recovery, a high-temperature exhaust section is separated
from a low-temperature exhaust section and heat is recovered only from hightemperature exhaust section.
In waste heat recovery from a cooler, the exhaust gas the temperature of which is
lowered by heat exchange is sent back to the cooler and used again for sintered ore
cooling.
There are two types in waste heat recovery from a sintering machine proper: one is a
type where exhaust gas is directly sent to a gas treatment system after heat exchange
(non-circulating type) and the other is a type where it is reintroduced into the sintering
machine proper (circulating type).

Fire tube boilers (EUROPEAN BOILERS)

Shell boilers may also be referred to as 'fire tube' or 'smoke tube' boilers because the products of
combustion pass through the boiler tubes, which in turn transfer heat to the surrounding boiler water.
Several different combinations of tube layout are used in shell boilers, involving the number of passes the

heat from the boiler furnace will usefully make before being discharged.
Figures 3.2.1a and 3.2.1b show a typical two-pass boiler configuration.
Figure 3.2.1a shows a dry back boiler where the hot gases are reversed by a refractory lined chamber on
the outer plating of the boiler.

Fig. 3.2.1
Shell boiler - Wet and dry back configurations
Figure 3.2.1b shows a more efficient method of reversing the hot gases through a wet back boiler
configuration. The reversal chamber is contained entirely within the boiler. This allows for a greater heat
transfer area, as well as allowing the boiler water to be heated at the point where the heat from the
furnace will be greatest - on the end of the chamber wall.
It is important to note that the combustion gases should be cooled to at least 420C for plain steel boilers
and 470C for alloy steel boilers before entering the reversal chamber. Temperatures in excess of this will
cause overheating and cracking of the tube end plates. The boiler designer will have taken this into
consideration, and it is an important point if different fuels are being considered.

Several different types of shell boilers have been developed, which will now be looked at in more detail.

Lancashire boiler
Sir William Fairbairn developed the Lancashire boiler in 1844 from Trevithick's single flue Cornish boiler.
Although only a few are still in operation, they were ubiquitous and were the predecessors of the
sophisticated and highly efficient boilers used today.
The Lancashire boiler comprised a large steel shell usually between 5 - 9 m long through which passed
two large-bore furnace tubes called flues. Part of each flue was corrugated to take up the expansion when
the boiler became hot, and to prevent collapse under pressure. A furnace was installed at the entrance to
each flue, at the front end of the boiler. Typically, the furnace would be arranged to burn coal, being either
manually or automatically stoked.
The hot gaseous products of combustion passed from the furnace through the large-bore corrugated
flues. Heat from the hot flue gases was transferred into the water surrounding these flues.
The boiler was in a brickwork setting which was arranged to duct the hot gases emerging from the flues
downwards and beneath the boiler, transferring heat through the bottom of the boiler shell, and secondly
back along the sides of the boiler before exiting through the stack.
These two side ducts met at the back of the boiler and fed into the chimney.
These passes were an attempt to extract the maximum amount of energy from the hot product gases
before they were released to atmosphere.
Later, the efficiency was improved by the addition of an economiser. The gas stream, after the third pass,
passed through the economiser into the chimney. The economiser heated the feedwater and resulted in
an improvement in thermal efficiency.

Fig. 3.2.2
Lancashire boiler

Table 3.2.1
Size range of Lancashire boilers
Economic boiler (two-pass, dry back)
The two-pass economic boiler was only about half the size of an equivalent Lancashire boiler and it had a
higher thermal efficiency. It had a cylindrical outer shell containing two large-bore corrugated furnace flues
acting as the main combustion chambers. The hot flue gases passed out of the two furnace flues at the
back of the boiler into a brickwork setting (dry back) and were deflected through a number of small-bore
tubes arranged above the large-bore furnace flues. These small bore tubes presented a large heating
surface to the water. The flue gases passed out of the boiler at the front and into an induced draught fan,
which passed them into the chimney.

Fig. 3.2.3
Economic boiler (two-pass, dry back)

T
able 3.2.2
Size range of two-pass, dry back economic boilers

Economic boiler (three-pass, wet back)

A further development of the economic boiler was the creation of a three-pass wet back boiler which is a
standard configuration in use today, (see Figure 3.2.4).

Fig. 3.2.4
Economic boiler (three-pass, wet back)
This design has evolved as materials and manufacturing technology has advanced: thinner metal tubes
were introduced allowing more tubes to be accommodated, the heat transfer rates to be improved, and
the boilers themselves to become more compact.
Typical heat transfer data for a three-pass, wet back, economic boiler is shown in Table 3.2.3.

Table 3.2.3
Heat transfer details of a modern three pass, wet back, economic boiler

Packaged boiler
In the early 1950s, the UK Ministry of Fuel and Power sponsored research into improving boiler plant. The
outcome of this research was the packaged boiler, resulting from further development on the three-pass
economic wet back boiler. Mostly, these boilers were designed to use oil rather than coal.
The packaged boiler is so called because it comes as a complete package with burner, level controls,
feedpump and all necessary boiler fittings and mountings. Once delivered to site it requires only the
steam, water, and blowdown pipework, fuel supply and electrical connections to be made for it to become
operational.

Fig. 3.2.5
Modern packaged boiler

Table 3.2.4 demonstrates this, and other factors.

Table 3.2.4
Comparison of 5 000 kg / h boilers

Four-pass boilers
Four-pass units are potentially the most thermally efficient, but fuel type and operating conditions may
prevent their use. When this type of unit is fired at low demand with heavy fuel oil or coal, the heat
transfer from the combustion gases can be very large. As a result, the exit flue gas temperature can fall
below the acid dew point, causing corrosion of the flues and chimney and possibly of the boiler itself. The
four-pass boiler unit is also subject to higher thermal stresses, especially if large load swings suddenly
occur; these can lead to stress cracks or failures within the boiler structure. For these reasons, four-pass
boilers are unusual.

Reverse flame / thimble boiler

This is a variation on conventional boiler design. The combustion chamber is in the form of a thimble, and
the burner fires down the centre. The flame doubles back on itself within the combustion chamber to
come to the front of the boiler. Smoke tubes surround the thimble and pass the flue gases to the rear of
the boiler and the chimney.

Fig. 3.2.6
Thimble or reverse flame boiler

Researches done:
Investigation of Turbulators for Fire Tube Boilers Using Exergy
Analysis By
Betul AYHAN

The experimental setup was constructed in the Department of Mechanical Engineering

Laboratory of Karadeniz Technical University. It was tested to evaluate the boiler
efficiency according to TS 4040 standard, and to evaluate the second law efficiency of
thermodynamics for the cases with and without inserts under the same operating
conditions. Four new types of turbulator consisted of truncated hollow cones. They were
placed in tandem parallel to the gas flow direction to allow no contact with the fire tube
wall. The half-apex angles of the conical turbulators used in the experiments were 14
and 20. The number of the turbulators inserted in the of the boiler was 200, their

installation arrangements in the fire tubes were periodic, and their enlarging positions
were in accordance with the gas flow direction. It was found that turbulators increased
the boiler efficiency from 8% to 12% and the second law efficiency of the boiler from
24% to 27%. It is also shown that the one with the half-apex angle of 20 gives better
results, about 4% enhancement compared with the other ones. A fifth new tabulator,
consisting of a truncated half-cylindrical surface and placed in tandem with flow
direction, also periodically interrupted and transposed in the fire tube boilers, provided a
4% increase in the boiler efficiency. The second law efficiency of the boiler was
improved from 24% to 25.2%. It was also shown that there was no need to use an
excess fan for the flue gas in the chimney because of the very low pressure drops in the
new types of tabulator.

Fabrication of Pilot Multi-Tube Fire-Tube Boiler Designed For

Teaching and Learning Purposes in Mechanical Laboratory by
Gbasouzor Austine Ikechukwu, Member IAENG

The aim of this research is to design and fabricate pilot multi-tube boiler using a diesel
fired burner (C13H25)9to generate 80kg of steam per hour. The boiler tank is made of
pure mild steel. Mild steel is used to fabricate the fire tubes and other parts such as the
furnace, smokestack and return chamber that make up the boiler. The heating surface
area was increased for sake of efficiency and fast steam generation by reversing the
direction of the gas through a second and third parallel tube (three pass). The boiler
(which is fired by a diesel burner) generates dry saturated steam at a pressure of 1.
Stars and temperature of 111.4 C. It can be used for domestic and industrial purposes.
The fabricated fire tube boiler was tested to evaluate its performances, efficiency and
determine its evaporation ratio. The purpose of the performance test is to determine the
actual performance and efficiency of the oiler and compare it with design values or
norms. It is an indicator for tracking day-to-day and season-to-season variations inboiler
efficiency and energy efficiency improvements.
When the burner is turned on and ignition occurs which produces the required fire in the
furnace inside the furnace, a hot flue gas is produced which is forced through the
firetubes (by the he p of blower in the burner) and heat is thus transferred into the water

which in turn results in production of the required steam that may be used for industrial
purposes.
Result
The result in this case is a torque produced at a steam pressure of 1.5bar and a steam
temperature of 111.4 C also raising the temperature of the water from 30 C to a
generated steam quantity of 61.34kg/hr, with a diesel quantity of 5.2Htres/hr. The
efficiency of the burner after getting an adequate combustion air/fuel ratio and heat
delivery from the burner resulted into 64.3%. The efficiency of the boiler was also
calculated to be 69%.

THE FEASIBILITY OF USING WASTE HEAT BOILERS TO RECOVER

ENERGY FROM THE EXHAUST GASES OF ELECTRIC ARC
FURNACES EEC
Agreement No. EE-B-2-160-UK (N) FINAL TECHNICAL REPORT

INTRODUCTION
The proportion of steel manufactured by the electric arc process has steadily increased over the
past 30 years. In 1982, it accounted for about 34% of UK liquid steel production, and there are
over 250 electric arc furnaces in operation within the ECSC. Electrical energy is a major
contributor to the overall manufacturing cost, and its conservation is of prime importance. The
largest single source of energy loss from an electric arc furnace is via the waste gas stream,
and urgent consideration is being given to methods of reducing the quantity of energy lost in this
way, and to recovering heat from the exhaust gases. Scrap preheating is potentially the most
attractive method of energy recovery, but its effectiveness is often restricted because of practical
considerations. In general, steelworks use considerable quantities of steam for various
purposes. The objective of this study was to investigate the feasibility of using a waste heat
boiler to generate steam using energy recovered from the exhaust gases of an electric arc
furnace. The steam produced in this manner would replace that generated in conventional boiler
plant, thereby reducing energy costs. Case studies, based on a furnace producing special steels
within the British Steel Corporation, have been used to demonstrate the advantages and
disadvantages of this method of energy recovery in practical and economic terms.
THE WASTE GASES OF THE ELECTRIC ARC FURNACE
The volume, temperature, composition, and hence the energy content, of the waste gases vary
throughout the furnace cycle, and depend on such variables as the charge material, melt down
rates, oxygen practice, supplementary firing practice and the type of steel being produced'. A
survey of the literature was carried out at the beginning of the project and revealed a diversity in
the reports of the quantity of energy contained in the waste gases. Of the total energy input to

the furnaces, fractions of between 5 and 29%, accounting for 30 to 130 kW h/t of liquid steel,
were estimated to be lost in the exhaust gases2-1*. In order to produce reliable information,
detailed measurements were made on a number of furnaces within BSC using techniques
developed specially for use in the aggressive conditions to be found in the waste gases of
electric arc furnaces5' 6. The data obtained from a typical cast on a 180 t UHP electric arc
furnace; an average waste heat cycle. When continuous charging techniques or supplementary
firing with oxyfuel burners are employed, the rate of energy rejection in the waste gases may be
increased. An average waste heat cycle for 180 t furnace with continuous feeding of granulated
iron. In this case, the average rate of energy rejection is 15.5 MW, which for a charge of 180 t is
equivalent to a loss of about 200 kW h/t of liquid steel.

WASTE HEAT UTILISATION

In considering the practical applications of recovered waste heat from the arc furnaces, the
following factors should be taken into account:1. Changes in heat flow within the furnace cycle.
2. Forms in which the waste heat is recovered (e.g. scrap preheating, steam, electricity
generation).
3. Destination and transportation of recovered energy.
4. Reliability of recovery equipment, maximisation of furnace availability and ease of
maintenance.
5. Effect of the presence of the waste heat recovery unit on the operation of other items of plant.
6. Capital and operating costs. The exhaust gas leaves the arc furnace at a high temperature
and in principle should have considerable potential for energy recovery. However, its dirty
condition and variable nature create significant difficulties in achieving this end. Much of the
effort devoted to energy recovery has justifiably been concentrated on scrap preheating
because the recovered heat is returned to the process. Some examples of the scrap heating
techniques are basket preheaters, the BBC/Brusa rotary kiln process and the twin-shell
method'-11*. The first of these has been the most widely applied because of its relative
simplicity and its ability to be retrofitted in an established melting shop. A number of installations
are now operating successfully, but experience has shown that the quantity of energy which can
be recovered is restricted by practical considerations such as the need to avoid overheating the
charging basket, and to prevent welding and bridging in the charge. The reported energy
savings are in the region of 20 to 50 kW h/t, representing 10 to 25% of the total energy in the
waste gas. The more elaborate techniques suffer from the disadvantage of high capital cost,
high maintenance costs and unsuitability for incorporation into existing melting shops.
Consideration could be given to other uses for the waste heat, such as the production of hot
water for boiler feeding, space heating, district heating and amenity use15. However, a more
attractive alternative would be to provide energy for steam raising. Most steelworks require

considerable quantities of steam for process and heating purposes, and its generation from
waste heat would reduce the consumption of fuels in steam raising plant. The use of a waste
heat boiler would be particularly advantageous either in a melting shop where practical
considerations render scrap preheating uneconomic or in tandem with a preheater which
removes only a small fraction of the energy in the waste gas stream. To realize its economic
potential, a waste heat boiler system must fulfill a number of requirements:1. It should be capable of incorporation into the extraction system of the furnace with minimum
reorganization of the melting shop facilities and the existing waste gas handling equipment.
2. The steam cycle must be capable of being matched to the works demand and complemented
by existing steam raising plant.
3. The boiler must be reliable and easily maintained so that production stoppages are avoided.
4. The waste gas extraction system must operate without the boiler in service, if necessary.

Conclusions
The energy rejected in the waste gases of a UHP electric arc furnace has been shown to be in
the region of 200 kW h/t of liquid steel. Economic case studies of using steam derived from a
waste heat boiler to supply part of the demand for a works producing special steels indicate that
a payback of capital may be obtained over periods of 1.7 to 2.9 years. Based on an economic
lifetime of ten years, the rate of return on investment would range from 33-58%. The installation
of a boiler would therefore be a suitable topic for a Demonstration Project.

Increasing Natural Gas Boiler Efficiency by Capturing Waste Energy

from Flue Gas
Mark Schiffhauer, ATSI Engineering Services Cameron Veitch, Combustion
and Energy Systems, Scott Larsen, New York State Energy and
Development Authority

Introduction
Industrial process and heating applications continue to be powered by steam and hot
water. The mainstay technology for generating this energy is the water tube boiler.
Water tube boilers have proven to be highly efficient and cost effective in generating
energy for process applications.
The Olin Niagara Plant utilizes two water tube Nebraska packaged boilers to produce
saturated steam at 150 psig. Each boiler is rated at 75,000 pounds per hoursteam
capacity to provide steam for the process areas of the plant, as well as building heat.
The boilers are fueled by surplus hydrogen and natural gas. Hydrogen isproduced on
site as a bi-product of the
chlor-alkali process. Surplus hydrogen which is either not sold tocustomers or used
within the process is used as fuel.
Boiler efficiency, or fuel-to-steam efficiency, represents the difference between the
energy input (fuel) and energy output (steam). The Olin boilers utilize best practice
systems to maximize overall boiler efficiency, which include; O2-trim for combustion air
control, traditional feed water economizers to achieve 290 degrees Fahrenheit stack
gas, boiler blow down heat recovery, and steam condensate return. A schematic of
these systems is shown in figure 1

Despite these efforts, a significant amount of heat input to the boilers is still lost as both
sensible and latent heat energy, contained in the 290 degrees Fahrenheit stack flue gas
exiting the economizers. The boiler flue gas exiting the economizer still contains
significant energy that can be recovered and used to heat other process requirements
currently heated using natural gas and steam. Approximately 20 percent of the energy
input to boilers is typically lost as water vapor and stack gas heat exiting the boiler
economizers at approximately 290 degrees Fahrenheit. When natural gas is burned, 14
percent of the energy is lost because the hydrogen in the fuel combines with the oxygen
in the combustion air and is instantly vaporized by the heat of combustion to form water
vapor. The vaporization of this water consumes energy from the fuel that cannot be
recovered and used effectively unless you condense the energy backout of the flue gas
using a condensing economizer or similar method. For every pound of natural gas
combusted, 2.25 pounds of water vapor is produced and for every pound of hydrogen
combusted, 9 pounds of water vapor is produced.
If this energy can be captured and reused in the boiler process, the boiler efficiency can
be increased. Given that 12 weight percent of the flue gas is water, at 15 percent
excess air, a significant energy savings can be achieved through the recovery and use
of this latent heat. When the water vapor is condensed, the latent heatis recovered at
980 Btu per pound and each pound will save one cubic foot of natural gas. Olin chose
an indirect contact condensing economizer to recover the heat from the flue gas. The
indirect contact condenser prevents boiler make-up water from contacting the
condensate from the flue gas and also allows the flue gas to be cooled below the dew
point thereby extracting more heat. A condensing economizer is environmentally
favorable because it reduces CO2emissions. The Heat Recovery System allows less
fossil fuel to be burned causing a Flue Gas Boiler Stack First Effect Condensate 30,000
to 35,000 lb/hr 210 F to 185 F 290 F Boiler Feed water 227 F 110 F to 85 F Heat

Treated Water Make-up Economizer De-aerator Exchanger 50,000 to 55,000 lb/hr 35 F

to 70 F Condensate 140 F Recovery Condensate Returns Continuous System 10,000 to
15,000 lb/hr Blow down De-aerator 10 to 20 PSIG Combustion Air Heat Recovery
Steam Consumption 240 F to 260 F (as required) 100 F Purge Fuels Boiler to Sewer
Export Steam to Users ~ 80% Efficiency MM90,000 to 100,000 lb/hr Meter Meter 140
PSIG at 360F Hyper mix Steam Boiler Steam Export Steam direct reduction in the CO2
combustion product, and the CO2in the flue gas is absorbed in the condensed water
vapor reducing gas emissions from the stack. For each million Btu of fuel saved, the
emission of CO2is reduced by 118 pounds. The absorbed CO2and water provides an
additional benefit in that it creates a mild acid (carbonic acid) that can be used
neutralizing the boiler blow down solutions.
The Stack Heat Recovery System began operation in March 2009. After startup the
boiler make-up water inlet temperature was 38 degrees Fahrenheit and the outlet
temperature hit its set point of 195 degrees Fahrenheit as the system reached steady
state. Make-up water flow was 78 gpm resulting in energy transfer of around 6,125,000
Btu per hour. The west glycol circulation loop added another 450,000 Btu per hour to
the air handler inlet air. Operating date form the ConDex is logged inthe plant data
collection system. Operating date will be compared to historical date to measure energy
savings. The make-up water entering the DA Tank from the Condex is 100 degrees
Fahrenheit more that the water entering the tank last year on the same dates. As the
Heat Recovery System gains operating history, fuel consumption and steam production
will be measured and compared to historical consumption to evaluate savings. The
results will demonstrate lower energy use, which in turn lowers cost of production. The
strategy for quantifying the actual project benefits is to track actual natural gas
consumption in the boiler house per unit of steam delivered to plant users.
Modifying the boiler system to provide boiler make-up water heating via the ConDex
condensing heat exchanger allows excess energy currently available from the
condensate collection system to be used to heat combustion air entering the building.

Discussion:
1)Assessment of a Boiler:
1. Boiler performance :
Causes of poor boiler performance:
a. Poor combustion
b. Heat transfer surface fouling
c. Poor operation and maintenance
d. Deteriorating fuel and water quality

Heat balance:

Identify heat losses

Boiler efficiency:
Determine deviation from best efficiency

Heat Balance: An energy flow diagram describes geographically how energy is

transformed from fuel into useful energy, heat and losses
Stochiomet
ric
Excess Air
Stack Gas
Un burnt

FUEL
INPUT
Conv
ectio
n&
Radia
tion

Blo
w
Do
wn

STE
AM
OUT
PUT

Ash and
Un-burnt
parts of
Fuel in Ash

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

Boiler Efficiency :

Thermal efficiency: % of (heat) energy input that is effectively useful in the generated

BOILER
EFFICENCY
CALCULATION
1)DIRECT METHOD:
The energy gain of the
working fluid (water and steam)
is compared with the energy
content of the boiler fuel.

2) INDIRECT METHOD:
The efficiency is the difference
between losses and energy input

steam

Boiler Efficiency by Direct Method:

Boiler efficiency ( )=

Q (hf fg)
Heat output
100=
100
Heat input
Q GCV

Where
hg -the enthalpy of saturated steam in kcal/kg of steam
hf -the enthalpy of feed water in kcal/kg of water
Q - quantity of steam generated per hour in kg/hr
GCV - the gross calorific value of the fuel

Advantages:
1. Plant people can evaluate quickly the efficiency of boilers
2. Requires few parameters for computation
3. Needs few instruments for monitoring

Disadvantages:
1. Does not give clues to the operator as to why efficiency of system is lower
2. Does not calculate various losses accountable for various efficiency levels

Boiler Efficiency by Indirect Method:

Efficiency of boiler () = 100 (i+ii+iii+iv+v+vi+vii)
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

Advantages:
1)Complete mass and energy balance for each individual stream
2)Makes it easier to identify options to improve boiler efficiency

Disadvantages:
1) Time consuming
2)Requires lab facilities for analysis

2. Boiler Blow Down:

Controls total dissolved solids (TDS) in the water that is boiled

Blows off water and replaces it with feed water

Conductivity measured as indication of TDS levels

Calculation of quantity blow down required:

Blow down()=

Feed water TDS Make up water

Maximum Permissible TDS Boiler water

Benefits:

Lower pretreatment costs

Less make-up water consumption

Reduced maintenance downtime

Increased boiler life

Lower consumption of treatment chemicals

3. Boiler Feed Water Treatment:

Quality of steam depend on water treatment to control:

1. Steam purity
2. Deposits
3. Corrosion

Efficient heat transfer only if boiler water is free from deposit-forming solids

Industrial Visit: (Gadoon Power Plant)

Objective:
Our group visited the industry with the mission to study the boilers and to analyze the
possible steps that should be taken in order to make those boilers more efficient.

Types of boilers in Gadoon:

There were 2 types of boilers present there:
1) Water tube boiler
2) Fire tube boiler

Working detail:

1) Water tube:

The hot gases from the engine(combustion chamber) at 450C and 30 mili bar
heat the water and convert it into steam.
In steam drum it enters at 18 bar and 210C. Here the steam and liquid water is
separated.
Economizer initial temperature is 60C and final is 150C.
Combustion gas enters at 450C and leaves at 150C.

2) Fire tube boiler:

It was used to make furnace oil hot for maintaining fluidity.

Low pressure saturated steam is passed to the furnace oil.
Combustion takes place at 800C to 900C.
Exhaust gases temperature was about
200C
Oil initial temperature was 25C and final
temperature was 90C

Photocell was used to detect combustion

Efficiency:
The efficiency of water tube boiler was 37%
After installing a waste heat recovery boiler the efficiency was increased to 40%
The efficiency could be further increased using oil instead of natural gas but the GM told
us that the gas was costing 9 rs per unit of electricity while diesel oil was costing 18 rs
per unit.

Sensors Used in Gadoon Industry:

Level Sensor:

zaLevel sensors detect the level of liquids and other fluids and
fluidized solids, including slurries, granular materials,
and powders that exhibit an upper free surface. Substances that
flow become essentially horizontal in their containers (or other
physical boundaries) because of gravity whereas most bulk solids
pile at an angle of repose to a peak. The substance to be
measured can be inside a container or can be in its natural form
(e.g., a river or a lake). The level measurement can be either
continuous or point values. Continuous level sensors measure
level within a specified range and determine the exact amount of
substance in a certain place, while point-level sensors only
indicate whether the substance is above or below the sensing
point. Generally the latter detect levels that are excessively high
or low.

RTT15 Temperature Transmitter

The Foxboro RTT15 Temperature Transmitters provide highly reliable, stable, and
accurate temperature measurements, using either RTD or thermocouple sensors.
This microprocessor-based transmitter is fully user-configurable and is available with a
choice of 4-20 mA/HART, Foundation Fieldbus, or Profibus communications.

Pneumatic Valves
Control valves are a fundamental component of any pneumatic system. Selecting
the right air valves to control system pressure, direction of flow and rate of flow is
crucial when designing fluid power circuitry. If the pneumatic valve is too big for
your application, you will be wasting air and money. If its too small, the actuator
will not function properly.
The Pneumadyne Advantage

Variety of porting options for plumbing convenience

Numerous configurations for added versatility

Flow rates range from 2.90 to 57 scfm at 125 psi

Poppet or spool designs

Operating pressures from 26 Hg to 150 psi

Miniature size is ideal for limited space applications

Colored nylon actuators for easy identification

Long product life

Plated for corrosion resistance

Photocell:
Description: This is a very small light sensor. A
photocell changes (also called a photodetector, photo
resistor, CdS or photoconductive cell) resistance depending
on the amount of light it is exposed to. These little sensors
make great ambient light triggers (when light in the room turns
on, do something).

Latest Sensors:
Waterflow sensors - C7195A/B
Waterflow sensors are primarily designed to measure the Domestic Hot
Water (DHW) flow rate in domestic appliances. The C7195A/B is a
mechanical water flow sensor. A turbine rotates with water flow. The
turbine supports a magnet which rotates in front of a Hall effect sensor.
This Hall effect sensor picks up the field of the magnet giving a pulsed
output. The output is directly proportional to the water flow through the
sensor. This frequency output is easily processed by an electronic
controller which can then modulate the burner load (for feedforward
loop) or simply open heat demand when the flow reaches its defined
minimum rate (electronic flow switch). The sensor body is constructed
from pressure and temperature resistant plastic, with easy connections
to traditional pipes used in domestic appliances. All parts in contact with
the potable water are made out of materials approved by the Water
Research Council.
Read more about the features and technical specifications in theproduct
handbook, available in PDF, (602 kb)

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Temperature sensors - T7335

The Honeywell Temperature Sensors have been developed for many

applications. These probes are used to measure the temperatur of
fluids, air an inert gas, in flue gas pipe, tanks, boilers and in ambient
(indoor or outdoor) etc. The sensor elements are usually thermistors
(NTC) but other types can be made available on request. The T7335
series are available as direct immersion sensors, well immersion
sensors and surface mount sensors. The sensors are available with
various NTC and shape combinations.
Read more about the features and technical specifications in theproduct
handbook, available in PDF, (2.143 kb)

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Water Valves - VC series (for combi-boilers only)

The VC series 2-position hydronic valves are used in domestic and

small commercial applications to control the flow of hot and/or cold
water. They consist of an actuator, valve and a cartridge assembly. 2way valves are designed for ON-OFF "zone" control of domestic
systems. 3-way valves can be piped for either diverting or mixing valve
applications in domestic central heating and/or cooling systems. Both
versions can be used to control individual fan coil, baseboard radiator or
convector applications. Depending on the model selected they can be
controlled by a low or line voltage SPST or SPDT controller, such as a
room thermostat, aquastat or flow switch.

high resolution picture, (30 kb)

Read more about the features and technical specifications in theproduct

handbook, available in PDF, (492 kb)

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Water Valves - CWVA (for combi-boilers only)

The CWVA 2-position hydronic valves are used in domestic and small
commercial applications to control the flow of hot and/or cold water.
They consist of an actuator and a valve. 3-way valves can be piped for
either diverting or mixing valve applications in domestic central heating
and/or cooling systems. Depending on the model selected they can be
controlled by a low or line voltage SPST controller, such as a room
thermostat, aquastat or flow switch. The 2 wires Vdc version can be
controlled by a -10Vdc/20Vdc reverse-phase system. The actuator head
is removable without affecting the integrity of the water system. All
actuator versions are interchangeable with any valve body, offering the
highest flexibility for boiler production line assembly and maintenance.
3-way valves are suitable for both diverting water from AB to A or to B
and from A or B to AB.

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Pilot Burners

Pilot Burners are suitable for all gas fired domestic appliances. A pilot
burner is an integral part of a gas safety system, working in conjunction
with the combination gas valve control and with the safety ignition
electronic for intermittent pilot ignition systems. The primary function of
a pilot burner is to create and maintain a pilot flame which must be
proven within a certain period (thermocouple or ionization current) and
then to ignite the main burner from the established flame. The presence
of a flame prior to main burner ignition ensures a very reliable burner
start because the flame is communicated to the main burner by cross
lighting from the pilot flame.

high resolution picture, (138 kb)

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Thermocouples

Thermocouples Q309A, Q331A and Q335A,C are thermo-electric

devices designed for use with Honeywell pilot burners to prove the
presence of the pilot flame in gas heating control equipment. When
heated by the pilot flame a small DC voltage is generated across the
"HOT" and "COLD" junction of the thermocouple, this voltage is used to
hold in the power unit in the pilotstat controlling main gas flow to the
heating equipment. In the event of pilot flame failure the DC voltage is
no longer generated, the power unit drops out and gas flow to the
burner equipment shuts off.
high resolution picture, (19 kb)
Read more about the features and technical specifications in
theinstruction sheet of thermocouples, available in PDF, (85 kb)

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Aquastats - L41/L61

Honeywell manufactures a comprehensive range of water temperature

thermostats (trade name Aquastat) for controlling and limiting boiler
water temperature in hydronic heating systems. These sensitive, fast
response devices are available in either direct, panel or surface mount
versions.
Read more about the features and technical specifications in theproduct
handbook, available in PDF, (815 kb)

Pressure Sensing Devices - C4065/C6065

The C4065/C6065 differential air pressure switch for forced flue

combustion type burner system functions as a (combustion) airflow
supervision with a safe start interlock. The C4065/C6065 differential
pressure switch is designed to be used on air or combustion products.
The C6065AH and C6065FH with enhanced accuracy are according the
requirements of high efficiency appliances. The C6065 differential air
pressure switch series authorises the boiler to start only when the air
flow is sufficient and stops it before toxic gases are expelled.
Read more about the features and technical specifications in theproduct

high resolution picture, (36 kb)

handbook, available in PDF, (678 kb)

Pressure Sensing Device - IS Series

The IS Series of pressure sensing switches is designed to be used in gas combustion system appliances,
where the combustion air is fully dependant on the fan. Therefore, this air flow must be closely monitored. The
IS Series pressure sensing switches adress this need, with a highly reliable and well-proven design. The IS
Series offers a proven integrated compression spring and precision snap acting electrical switch. The
switches are specifically designed to yield narrow switch differentials, as well as to hold tight setpoint
tolerances throughout a wide temperature range.

Boiler Electronics
Automatic Ignition Control - S4560, S4561, S4563
The S4560 provides automatic ignition and control for use on gas fired
appliances. The system provides safe start check, automatic spark
ignition and flame supervision by ionisation.
The S4561C/D provides automatic ignition and control for fan assisted
burners. The S4561A/B/P/Q provides automatic ignition and control for
atmospheric burners. Some of the features are flame supervision,
external reset, alarm and high limit connection, full operating sequence
after flame loss and protective impedance on flame rod. Functional
options include extended spark ignition and stabilisation time.

high resolution picture, (69 kb)

The S4563 ignition control provides automatic ignition and flame

supervision either in direct gas burner or in intermittent pilot gas burner
applications with safety timer. Some of the features are flame
supervision, external reset and alarm, full operating sequence after
flame loss and protective impedance on flame rod. Opions include
extended spark ignition, Intermettent Pilot applications and combined
ignition rod/flame sensing.
S4560, S4561 and S4563 are EN 298 approved.
List of approvals
S4560
S4561
S4563
Read more about the features and technical specifications in
theinstruction sheet of S4560, available in PDF, (466 kb)

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CVI - S4565/S4575/S4585

The Combined Valve and Ignition (CVI) system has been developed for
application in gas fired domestic central heating boilers, combi boilers
and warm air furnaces or water heater appliances with an automatic
ignition system. The Combined Valve and Ignition (CVI) system controls
and performs all the functions required for safe ignition, flame
supervision and for safely regulating the gas flow to the pilot and/or
main burner. The CVI consists of a specially designed gas valve family
of the VK41.. series and a dedicated ignition controls family of the series
S4565, S4575 and S4585 which is connected directly on to it. The
S4565/S4575 ignition controls are not intended for direct exposure to
flame envelope. S4565, S4575 and S4585 ignition controls give
excellent performance and a high reliability standard. There are
versions available for different ignition systems like Direct Burner
Ignition (S4565), Hot Surface Ignition (S4575) and Intermittent Pilot
ignition (S4565/S4585).
CVI is ANSI Z21.20 and EN 298 approved.
List of approvals

high resolution picture, (118 kb)

Read more about the features and technical specifications in theproduct

handbook, available in PDF, (1.048 kb)

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CCI S4564 A-T, BF, DF, QF, TF, AT-TT

The Compact Combined Ignition (CCI) system has been developed for
application in appliances with an automatic ignition system and has
larger capacity that the CVI system. For these systems, the S4564 A..T,
BF, DF, QF, TF, AT..TT ignition controls are used in conjunction with the
Compact gas controls. The combined system of ignition control and gas
valve thus provides programmed safe light up, flame supervision and
control of gas flow to the main burner and/or pilot burner of the
appliance. The CCI consists of a gas valve of the Compact series
(V46../V86..) and a dedicated ignition control of the series S4564 which
is connected directly to it.

high resolution picture, (20 kb)

CCI is EN 298 approved.

List of approvals
Read more about the features and technical specifications in theproduct
handbook, available in PDF, (292 kb)

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Logic Control

Honeywell logic controls provide functionality to your boiler options: DHW temperature control, CH
temperature control, pump control, water valve control, fan speed control, outside temprature sensor control,
water temperature rise control.

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Digital Boiler Control

CVBC
The Combined Valve Boiler Control (CVBC) is the combination of a
VK41.. gas control and a S4965 Electronic Boiler Control. The electronic
control consists of safety and non-safety or logic control functions. The
standard control function of a gas fired heating appliance can be
performed within one single control box, which can easily be clicked on
the gas control. The system provides optimized and programmed safe
light up and flame supervision of the main burner as well as boiler
control for temperature, pump, fan, 3-way valve and other control

high resolution picture, (18 kb)

functions. Within the CVBC family several versions with specific control
functions or sets are available:

CVBC-m: Integrated Gas Control Safety System with Gas

Modulation

CVBC-sQuare: Integrated Electronic Gas/Air and Adaptive

Control System

CVBC-vf: Integrated 1:1 Gas/Air Control safety System with

venturi and fan

CVBC-LoCon: Integrated Boiler Load Control System

Within the CVBC-system, all boiler control functions are concentrated in

one reliable and optimized system. The system is specially designed to
provide the optimum solution in gas fired appliances with DSI or IP
ignition system. Functions are on/off, high low or full gas modulation of
the main burner.
CVBC is EN 298 approved.
List of approvals
Read more about the features and technical specifications in theproduct
handbook, available in PDF, (291 kb)

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MCBA

The GasModul MCBA uses analogue sensors (NTC) to measure

temperature. Protection of the gas boiler is achieved by use of two
independent NTC - Sensors. This protection incorporates amongst other
things the absolute value, the differential value and the temperature
increase per second of the NTC 1 and NTC 2 sensors.
List of approvals

high resolution picture, (15 kb)

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Valves:

Please select
Compact
Compact Automatic
CVI
CVI-m

Compact

Automatic Complete system with System

Ignition
Boilers Electronics
Valve

Compact gas controls are servo-operating combination

gas controls and comprise a pilotstat, an operator and a
straight line servo pressure regulator or throttle. The
Compact combination gas controls can provide fully
automatic control of a combi boiler when used in
conjunction with a Honeywell pilot burner, thermocouple
and room or boiler thermostat. Compact combination gas
controls comprise a standard body to which a range of
sub-assemblies are factory fitted to give various system
options. This makes boiler system design much easier as
technical specifications and most unit dimensions are the
same for all system options. Options include servo
pressure regulation, throttle valve, (switchable) softlite,
electrical or mechanical modulation and high-low control
for the complete range of control applications.
Compact is EN 126 approved.
List of approvals
Read more about the features and technical specifications
in theproduct handbook, available in PDF (1.016 kb).
top

Compact Automatic

The Compact Automatic is used in a system context in

conjunction with either a direct spark ignition (DSI),
intermettent pilot (IP) of Hot Surface Ignition control
module and associated devices to provide programmed
safe light-up and supervision of the main burner of an
appliance. Compact Automatic combination gas controls
comprise a standard body to which a range of subassemblies are factory fitted to give various system
options. This makes boiler system design much easier as
technical specifications and most unit dimensions are the
same for all system options. Options include servo
pressure regulation, throttle valve, (switchable) softlite,
electrical high-low control and electrical or mechanical

modulation for the complete range of control applications.

Compact Automatic combinations gas controls are
available in line of low voltage versions and in three
capacity ratings for total system versatility. Customer
specific voltage models are also offered.
Compact Automatic is EN 126 approved.
List of approvals
Read more about the features and technical specifications
in theproduct handbook, available in PDF (1.768).
top

CVI Gas Control

The Combined Valve and Ignition (CVI) system has been

developed for appliances with an automatic ignition system.
The gas controls have been designed to have the
S4565/S4575/S4585 series ignition control (see boiler
electronics) attached directly to the valve. The combined
system then provides programmed safe light up, flame
supervision and regulation of gas flow to the main burner
and/of pilot burner of the appliance. The automatic gas
control comprises a standard body to which a range of
features can be included to give various functional options.
These options include servo pressure regulation, throttle
valve regulation, fully adjustable softlite, gas/air control 1:1 or
amplified and electrical high-low or modulating control to fulfil
the complete range of control applications.
CVI Gas Controls is EN 126 approved.
List of approvals
Read more about the features and technical specifications in
the product handbook, available in PDF (364).
top

CVI-m

The Combined Valve and Ignition Modulating system (CVI-m) has

specially been developed for applications in gas fired appliances with
direct burner ignition that require electric modulating control of the gas
input. The system has been designed to have a S4565.M series ignition
control attached directly onto the valve. The combined system then
provides programmed safe light up, flame supervision, regulation and
modulation of Hi-Lo control of the gas flow to the main burner of the
appliance. The CVI-m system comprises a modulating gas control with
on/off regulating and modulating function and an ignition control with
integrated power supply for the electric modulating operator. The CVI-m
gas control comprises a standard body to which a range of features can
be factory included to give various functional options. These functional
options include: servo pressure regulation and modulating control to
fulfil a range of control applications.

Energy Efficiency Opportunities

1. Stack temperature control
2. Feed water preheating using
economizers
3. Combustion air pre-heating
4. Incomplete combustion minimization
5. Excess air control
6. Avoid radiation and convection heat loss
7. Automatic blow down control
8. Reduction of scaling and soot losses
9. Reduction of boiler steam pressure
10. Variable speed control
11. Controlling boiler loading
12. Proper boiler scheduling

13. Boiler replacement

1. Stack

Temperature Control

Keep as low as possible

If >200C then recover waste heat

2. Feed

Water Preheating Economizers

Potential to recover heat from 200 300 oC flue gases

leaving a modern 3-pass shell boiler

3. Combustion

Air Preheating

If combustion air raised by 20C = 1% improve thermal

efficiency

4. Minimize

Symptoms:

Incomplete Combustion

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

Coal-fired boiler: non-uniform coal size

5)Excess Air Control

Excess air required for complete combustion

Optimum excess air levels varies

1% excess air reduction = 0.6% efficiency rise

Portable or continuous oxygen analyzers

6. Radiation and Convection Heat Loss

Minimization

Fixed heat loss from boiler shell, regardless of boiler

output

Repairing insulation can reduce loss

7. Automatic Blow Down Control

Sense and respond to boiler water conductivity and pH

Outcomes of the visit:

1) We came to know the types of boilers mainly used in the
industries.
2) We saw different sensors and their functionality in different
applications.
3) We were taught about the boiler components and their functions.
4) We studied the flow diagrams in the control room.
5) Learned how to read the flow diagrams.
6) Learned the importance of sensors.

Control room Images:

Flow Diagram:

Results including our own proposals: (By case studies)

1) Heat the air before entering the combustion chamber. Through case studies we have
learned that if we increase the temperature of the gas by 20C before entering the
chamber the efficiency would increase by 1%
2) We can raise the temperature of the entering air in the combustion chamber by 20C
if we install a heat exchanger in the path of the exhaust gases.
3) Refine the entered gas by eliminating all the impurities in the air like CO, CO 2, SO2,
NO, etc. If able to do so the efficiency would be raised by 0.7%
4) Reduce the area of the pipes and surfaces where there is a chance of heat loss with
the surroundings. This may increase efficiency up to 0.4%
5) Feed water tank should be as large as possible to maintain the temperature
difference between combustion chamber and the feed water.
6) Fuel to Air ratio should be optimized with the help of accurate sensors.
7) Old sensors should be replaced with the latest ones that are already mentioned
above.
8) Overhauling of the boiler timely. If it is really old and inefficient then replace the boiler
instead of wasting money on it.

Condensing Technology
ADVANCEMENT
you can run natural gas, propane gas and even bio gas (used in Germany) without any field adjustments.(less losses)

The Vitodens uses Lambda Pro burner to get close to near-perfect combustion(perfect combustion happens in
theory only)
It squeezes every BTU from the fuel as possible.
Lambda Technology produces extremely low emissions and an added bonus is it can automatically adjust to
different gas qualities. In fact, you can run natural gas, propane gas and even bio gas (used in Germany) without any
field adjustments.
Extremely low water temperatures using a smart weather-compensated control that adjusts the system water
temperatures according to outdoor conditions.
This money-saving concept also reduces jacket losses and makes your home more comfortable by
eliminating temperature swings that can make you feel too warm one minute and too cold the next minute.

The main and most expensive component of a hot water boiler is the heat exchanger. The Vitodens heat
exchanger is made out of high-grade 316 titanium stabilized stainless steel.
This is a must when using Condensing Technology. Stainless steel is the only type of material that can withstand
the corrosiveness of the flue gases.
How Much Can You Save?
If you live in a 2000 square foot home and plan on staying there for the next 20 years and have a boiler that is only
80% efficient you can expect to pay (based on todays fuel prices) a whopping $54,000.
Condensing technology can save you 30%, or over $16,000.

Boilers have moved from non-condensing to condensing. The European market led the
development of stainless-steel and cast-aluminum heat exchangers that could extract heat
from not only a flame, but the warm, moist flue products produced by combustion. This
technology was the push the industry needed to propel thermal efficiency from the high-80percent range to 98 to 99 percent, which is possible when boilers are fired in optimal
condensing conditions.

Conclusions / Future steps:

1) We will check our proposals from experts like 1 st class boiler engineer.
2) We will check the feasibility of our proposals.

3) We would try to make a boiler sample with maximum efficiency possible.

4) We would study more about the modern techniques like condensing technology.

References
http://www.iaeng.org/publication/WCE2014/WCE2014_pp1478-1486.pdf
http://journals.tubitak.gov.tr/engineering/issues/muh-01-25-4/muh-25-4-1-97077.pdf
http://www.alfalaval.com/globalassets/documents/industries/marine-andtransportation/marine/whr.pdf
http://www.jase-w.eccj.or.jp/technologies/index.html
http://www.garioninaval.com/wpress/wp-content/uploads/downloads/2011/11/FIRETUBE-STEAM-BOILERS1.pdf
https://www.google.com.pk/url?
sa=t&rct=j&q=&esrc=s&source=web&cd=16&cad=rja&uact=8&ved=0ahUKEwjE2r3igtXJ
AhUGyRQKHZaFDy44ChAWCEAwBQ&url=http%3A%2F%2Fbookshop.europa.eu
%2Fes%2Fdesign-of-waste-heat-boilers-for-the-recovery-of-energy-from-arc-furnacewaste-gases-pbCDNA09850%2Fdownloads%2FCD-NA-09-850-EN-C
%2FCDNA09850ENC_001.pdf%3Bpgid
%3DIq1Ekni0.1lSR0OOK4MycO9B0000wVMYJ0Hr%3Bsid%3DKLD7DC2CcML7CnkJXhlq0-nZdPlfipRLmM%3D%3FFileName%3DCDNA09850ENC_001.pdf%26SKU
%3DCDNA09850ENC_PDF%26CatalogueNumber%3DCD-NA-09-850-ENC&usg=AFQjCNGG6PZVH4UpcdI8qmJAWclTodoSpA
http://www.slideshare.net/mnceeInEx/condensing-boilers-34635669?qid=7a6972e94a80-48f3-946b-348504a6583b&v=qf1&b=&from_search=1
http://www.spiraxsarco.com/Resources/Pages/Steam-Engineering-Tutorials/the-boilerhouse/shell-boilers.aspx