Fluid Heaters
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Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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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
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Introduction
STEAM TO
EXHAUST GAS VENT
PROCESS
STACK DEAERATOR
PUMPS
ECO-
NOMI-
ZER
VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
BRINE
CHEMICAL FEED
SOFTENERS
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Figure: Schematic overview of a boiler room
Training Agenda: Boiler
Introduction
Thermal Equipment/
Type of boilers
Boilers
Assessment of a boiler
Energy efficiency opportunities
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Types of Boilers
3. Packaged Boiler
4. Fluidized Bed (FBC) Boiler
5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler
8. Thermic Fluid Heater (not a boiler!)
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Type of Boilers
capacities (12,000
kg/hour)
Low to medium steam
pressures (18 kg/cm2)
Operates with oil, gas
or solid fuels
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Type of Boilers
User equipment
2. Circulated
to user 4. Fluid
equipment returned to
heater
Control
panel
Insulated
outer wall
1. Thermic
fluid heated Blower Exhaust
motor
in the heater unit
(Energy
Fuel oil
filter Machine India)
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Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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Assessment of a boiler
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment
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Assessment of a Boiler
1. Boiler performance
Causes of poor boiler performance
-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality
Heat Balance
An energy flow diagram describes geographically
how energy is transformed from fuel into useful
energy, heat and losses
Stochiometric
Excess Air
Un burnt
Stack Gas
Heat Balance
Balancing total energy entering a boiler against the
energy that leaves the boiler in different forms
12.7 %
Heat loss due to dry flue gas
1.0 %
Heat loss due to radiation & other
unaccounted loss
73.8 %
Heat in Steam
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Assessment of a Boiler
Heat Balance
Goal: improve energy efficiency by reducing
avoidable losses
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
Disadvantages
No explanation of low efficiency
Various losses not calculated
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Assessment of a Boiler
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
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vii) Radiation and other unaccounted losses
Assessment of a Boiler
Advantages
Complete mass and energy balance for each
individual stream
Makes it easier to identify options to improve
boiler efficiency
Disadvantages
Time consuming
Requires lab facilities for analysis
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Assessment of a Boiler
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Assessment of a Boiler
Continuous
Ensures constant TDS and steam purity
Heat lost can be recovered
Common in high-pressure boilers
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Assessment of a Boiler
b) Demineralization
Complete removal of salts
Cations in raw water replaced with hydrogen ions
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Assessment of a Boiler
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Assessment of a Boiler
Reversed osmosis
Higher concentrated liquid pressurized
Water moves in reversed direction 42
Assessment of a Boiler
Semi Permeable 43
Membrane
Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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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
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13. Boiler replacement
Energy Efficiency Opportunities
Liquid Fuels
Furnace Oil 13.8 9-14
LSHS 14.1 9-14 48
Energy Efficiency Opportunities
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Energy Efficiency Opportunities
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