IMPROVING THE BOILER EFFICIENCY BY LOSS

MINIMIZATION AT NFL BATHINDA

MIDWAY REPORT

Submitted by:
Gaurav Kumar (101301025)
(Student of B.E. Chemical engineering at
Thapar University)
In the fulfilment of 10 weeks training of the Project
Semester
Under the guidance of
Mr Prempal Singh Chauhan

TABLE 0F CONTENTS

1. INTRODUCTION --------------------------------------------- 3

2. BRIEF ON PROJECT------------------------------------------4

3. WORK DONE----------------------------------------------------5

4. MAJOR CHALLENGE-----------------------------------------6

4. REMAINING TASKS-------------------------------------------6
5. RESULTS----------------------------------------------------------7

INTRODUCTION

National Fertilizer Limited, a Mini Ratna Company, is the second largest

producer of nitrogeneous fertilizers in the country with 17% share in domestic
production of urea achieved in the country
It was incorporated on August 23, 1974 with two manufacturing units at
Bathinda and Panipat.NFL, a profitable public sector undertaking operates
under the administrative control of Department of Fertilizers in the Ministry
of Chemicals & Fertilizers. The company is making constantly profits of 156
crores from year 2013-14. The companys strength lies in the sizeable
presence , skilled manpower, marketing and distribution network nationwide.
NFLs mission is to be a market leader in fertilizers and a significant player in
all its other business, reputed for customer satisfaction, reasonable reward to
shareholders, ethics, professionalism and concern for ecology & the community.
Aiming towards further growth, company has already initiated action for
various clean development mechanism projects to reduce green house effect so
as to earn credits in terms of carbon.

2. BRIEF ON PROJECT
Efficiency
of a boiler reduces with time, due to poor
combustion, heat transfer fouling and poor operation and
maintenance. Deterioration of fuel quality and water quality
also leads to poor performance of boiler. Efficiency testing helps
us to find out how far the boiler efficiency drifts away from the
best efficiency. Any observed abnormal deviations could
therefore be investigated to pinpoint the problem area for
necessary corrective action. Hence it is necessary to find out
the current level of efficiency for performance evaluation at
regular intervals, which is a pre requisite for energy
conservation action in industry.
The objective of the project is to estimate the current boiler
efficiency and compute the results to find out how much its

deviates from the designed efficiency and find the reasons

behind the deviations and suggest the changes to be done in
order to achieve the best efficiency.

3.WORK DONE

1. Analyzed the requirements of

Plant.

2. Understood the basic working

Generation Plant.

the

Steam Generation

principle of the Steam

3. Calculated the Evaporation ratio of

generation plant

boiler-3 of steam

4. Calculated the current efficiency of the boiler by Indirect

method

5. Analyzed
follows:-

the various losses in the boiler which are as

a) Heat loss due to dry flue gas

b) Heating value loss due to hydrogen in fuel
c) Heat loss due to moisture in fuel
d) Heat loss due to moisture in air
e) Heat loss due to partial combustion
f) Heat loss due to surface radiation

g) Heat loss due to fly ash and bottom ash

6. Learnt the various Safety Precautions during performing

any task

7. Learnt how to work in the group and complete tasks with

co-ordination with various departments

8.

Learnt how to consult and work with the experts in

various fields

4. MAJOR CHALLENGE
The major challenge faced during the project was that the
boiler was not steady , many a times during operation and I had
to wait a long for boiler to achieve the steady state. Due to
unsteady or changed steady state I had to start my sampling
process again to take the readings at new steady state.

5. REMAINING TASKS
1October-15November
Identify the various loss sources and investigate them
Suggest new methods to reduce loss
Find the errors or effects of new methods and rectify them

16 November-30 November

Estimate the efficiency of the boiler by indirect method

Suggest the changes to be done in the concerned
department for increasing the efficiency.

1December-31December
Submit the project report in the department highlighting
the work done
Understand the basic principles of how water is cleaned
for making the steam in offsites and utility plant

RESULTS
The results mentioned below are dated as of 30 September 2016
1. Efficency by direct Method

= 75.37 %

2. Evaporation ratio

= 4.73

3.Various heat losses

calculated are mentioned below as
percentage of total heat given by the fuel

Various heat losses in boiler

1. Dry flue gas loss

6.92

2.Loss due to hydrogen in fuel

6.071

3. Loss due to moisture in fuel

0.231

4. loss due to moisture in air

0.321

5. Surface heat losses

1.1

6. Loss due to Unburnt in Fly ash

8.66

7. Loss due to Unburnt In bottom ash

3.09