This document summarizes improvements made to a paper machine's MG steam and condensate system. It was found that directing condensate directly from the MG to the boiler house via appropriately sized piping eliminated issues, improved efficiency, and reduced costs. Additional benefits were realized by installing a heat exchanger to further increase condensate return and recovery of flash steam. Overall, the changes reduced downtime, steam consumption, and improved condensate return and hot water availability for other processes.
Thermax Limited provides consulting services for efficient steam systems, including piping design, equipment selection, and design of condensate recovery and waste heat recovery systems. They offer utilities audits to analyze steam, compressed air, cooling, and power systems with the goal of optimizing costs. Their expertise includes selection and sizing of equipment such as pressure reducing stations, traps, and insulation. High-pressure condensate recovery systems can provide fuel savings of 15-20% by recovering heat from flash steam and condensate.
The document discusses efficient steam systems and generation. It provides information on fuel prices and calorific values, boiler efficiency and cost of steam for different fuels. It discusses optimal steam generation systems and factors to consider like steam demand, fuel selection, and cogeneration feasibility. Graphs show measured losses from boilers and comparisons of efficiency methods. The document emphasizes the importance of monitoring boiler parameters, automation, and intelligent control systems to improve efficiency. It also covers steam distribution, insulation, venting, metering and trapping to reduce losses across the steam system.
Improving Efficiency for Boiler and Steam SystemKamlesh Hariyani
In Steam Generation system, Cost of steam depends on Boiler efficiency. These slides are focusing on various aspects which plays important role in steam generation system.
This document presents a case study and methods to re-establish a condemned boiler. It includes an introduction, contents listing, acknowledgements, abstract on the Hindustan Storage & Distribution Company where the boiler is located, specifications and diagrams of the boiler, scope of dismantling and repair work, results of dismantling, scope of work after renovation including flue gas analysis and boiler tuning.
This document discusses performing a heat and mass balance (HMB) study on a cement plant. The objectives are to assess energy consumption, improve thermal efficiency, and identify areas of thermal losses. The study involves defining system boundaries, inputs, outputs, and performing mass balances. A case study on an ABC plant is presented where the overall mass balance was calculated based on measured input and output streams like kiln feed, fuel consumption, cooler vent air, and clinker production. The results can be used to optimize the pyroprocess and thermal energy usage.
This document provides 20 methods for improving boiler efficiency. Some key methods include reducing excess air, decreasing flue gas temperature, optimizing boiler operation, stopping steam leaks, reducing deposits in burners and on boiler surfaces, recovering heat from blowdown, and insulating boiler components to reduce heat loss. Implementing multiple efficiency improvements can potentially save up to 30% in fuel costs by lowering heat losses and improving combustion. Proper maintenance and optimization of boiler operations and components are important to maximize efficiency.
Thermax Limited provides consulting services for efficient steam systems, including piping design, equipment selection, and design of condensate recovery and waste heat recovery systems. They offer utilities audits to analyze steam, compressed air, cooling, and power systems with the goal of optimizing costs. Their expertise includes selection and sizing of equipment such as pressure reducing stations, traps, and insulation. High-pressure condensate recovery systems can provide fuel savings of 15-20% by recovering heat from flash steam and condensate.
The document discusses efficient steam systems and generation. It provides information on fuel prices and calorific values, boiler efficiency and cost of steam for different fuels. It discusses optimal steam generation systems and factors to consider like steam demand, fuel selection, and cogeneration feasibility. Graphs show measured losses from boilers and comparisons of efficiency methods. The document emphasizes the importance of monitoring boiler parameters, automation, and intelligent control systems to improve efficiency. It also covers steam distribution, insulation, venting, metering and trapping to reduce losses across the steam system.
Improving Efficiency for Boiler and Steam SystemKamlesh Hariyani
In Steam Generation system, Cost of steam depends on Boiler efficiency. These slides are focusing on various aspects which plays important role in steam generation system.
This document presents a case study and methods to re-establish a condemned boiler. It includes an introduction, contents listing, acknowledgements, abstract on the Hindustan Storage & Distribution Company where the boiler is located, specifications and diagrams of the boiler, scope of dismantling and repair work, results of dismantling, scope of work after renovation including flue gas analysis and boiler tuning.
This document discusses performing a heat and mass balance (HMB) study on a cement plant. The objectives are to assess energy consumption, improve thermal efficiency, and identify areas of thermal losses. The study involves defining system boundaries, inputs, outputs, and performing mass balances. A case study on an ABC plant is presented where the overall mass balance was calculated based on measured input and output streams like kiln feed, fuel consumption, cooler vent air, and clinker production. The results can be used to optimize the pyroprocess and thermal energy usage.
This document provides 20 methods for improving boiler efficiency. Some key methods include reducing excess air, decreasing flue gas temperature, optimizing boiler operation, stopping steam leaks, reducing deposits in burners and on boiler surfaces, recovering heat from blowdown, and insulating boiler components to reduce heat loss. Implementing multiple efficiency improvements can potentially save up to 30% in fuel costs by lowering heat losses and improving combustion. Proper maintenance and optimization of boiler operations and components are important to maximize efficiency.
Air compressors
Pump house
Steam header
Feed water System
Operating Parameters
Fuel Gas path
Ash content vs fuel efficiency
Operating alarms
operating instruments on panel
The document summarizes the differences between a typical coil type boiler system and a more efficient shell type boiler system. In a coil type boiler system, there are significant losses throughout the steam and condensate loop, with only 55% of the generated steam being used for process demand. A shell type boiler system recovers more condensate, reduces losses, and lowers the process steam demand, resulting in fuel savings of 25-30% compared to a coil type boiler. The shell type boiler provides dry saturated steam, steady loads, and increased productivity across several industries.
Boiler and steam system seminar short version 05 29-13Payden Sewell
This document provides information on boiler operations and efficiency. It discusses that a typical steam system loses 70% of its energy, with 28% lost in the boiler room and 42% lost in distribution. It also outlines various boiler types including watertube, firetube, and electric boilers. Key factors that impact boiler efficiency like combustion efficiency, radiation losses, and excess air are examined. The document emphasizes the importance of proper boiler maintenance, controls, and feedwater conditioning to maximize efficiency.
The document provides information on assessing the energy performance of boilers through testing. It discusses how boiler efficiency and evaporation ratio can decrease over time due to various factors like poor combustion, fouling, and deteriorating fuel/water quality. The purpose of performance testing is to determine the actual efficiency and compare it to design values in order to identify areas for improvement. Both direct and indirect testing methods are described as well as the necessary measurements, instruments, standards, and considerations involved in conducting the tests. Formulas are also provided for calculating efficiency using the indirect method by establishing heat losses from the boiler.
Thermal Power plant familarisation & its AuxillariesVaibhav Paydelwar
PPT in Relation to Power Plant familarisation, Coal to Electricity Basics,Power Plant cycles, Concepts of Supercritical Technology Boiler, Concepts Of BTG Package as well as Balance of Plant
The document summarizes the failure history and root cause analysis of the superheater tubes in two high pressure boilers. The superheater tubes experienced premature failures due to overheating, with surface temperatures reaching 550-600°C. Analysis found the superheater design had too low pressure drop, inadequate steam velocities, and lack of screen tubes. Modifications reduced tube count, implemented a double stage design with attemperation, upgraded metallurgy, and increased pressure drop. The modifications eliminated overheating failures and improved performance.
1) Operating parameters like steam inlet pressure, temperature, and exhaust pressure/vacuum affect steam turbine efficiency and steam consumption significantly.
2) For a condensing turbine, increasing steam inlet pressure by 1 kg/cm2 reduces steam consumption by 0.3% and improves efficiency by 0.1%. Increasing steam temperature by 10°C reduces consumption 1.1% and improves efficiency 0.12%. Improving exhaust vacuum by 10mmHg reduces consumption 1.1% and improves efficiency 0.24-0.4%.
3) Similarly for a back pressure turbine, the document outlines the effects of changing operating parameters on steam consumption and efficiency.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
This document discusses boiler blowdown, which is the process of removing concentrated boiler water and replacing it with fresh feedwater. It provides information on:
- Common impurities in raw water that can cause scaling, sludge, corrosion, or foaming in boilers.
- Guidelines for maximum total dissolved solids levels in boiler water depending on boiler type to avoid issues.
- A formula for calculating the required blowdown rate to maintain a target boiler water total dissolved solids level based on feedwater quality and boiler steam rate.
- An example calculation of the blowdown rate required for a specific boiler operating at 10,000 kg/h steam with 250 ppm feedwater to maintain 2,500
The document discusses various components of a thermal power plant including a boiler, air preheater, and ash handling plant. It provides details on the types, operation, and technical specifications of these systems. The boiler section describes supercritical boilers and includes diagrams of boiler components. The air preheater section explains regenerative and recuperative types. The ash handling plant introduces the collection and disposal of ash from coal combustion.
Indian scenario of super critical power plants issues and challenges by ntpc...Ajay Singhal
This document discusses supercritical power plants in India, including:
1. NTPC operates several supercritical power plants in India with a total installed capacity of 3,300 MW. Their Sipat plant includes 3 x 660 MW supercritical units.
2. Supercritical technology provides benefits like reduced emissions, improved efficiency, and lower fuel costs compared to subcritical plants.
3. Operating supercritical plants presents issues and challenges related to boiler control, chemistry regimes, and performance optimization. NTPC's experience provides lessons for addressing these challenges.
Super Critical Technology-Fundamental Concepts about Super Critical Technolog...Raghab Gorain
Nicely describe everything about super critical technology in thermal power plant.This slide is very useful for the freshers.Anybody can get the basic fundamental idea about super critical technology from this slide. In India now we have to think some new technology for power sources as sub critical power plants are less efficient and emit more pollutant to the environment and the alternative is the 'Super Critical Power Plant'.
This document discusses boiler efficiency, including types of efficiency measurements like combustion efficiency, thermal efficiency, and seasonal efficiency. It explains what makes a boiler condensing and how condensing boilers can achieve higher efficiencies up to 98%. The document also covers relationships between flue temperature, condensing, and efficiency as well as considerations for applying condensing boilers.
This document provides information on Stork Thermeq B.V.'s spray-type deaerator system. It describes the deaerating process which involves heating, partial deaeration, and cooling of feedwater using a spray device, steam charging device, and vessel. It compares the layout and operation of spray-type deaerators to cascade or spray/tray-type systems, noting advantages of the Stork design including its more compact size, simpler operation, and flexibility. The document also outlines typical design parameters for pressure, capacity, materials used, and internal components.
Cheema Boilers Limited is hosting a national workshop on efficient operation and maintenance of boilers in Visakhapatnam on December 7-8, 2015. The document discusses various types of boilers such as water tube boilers, fire tube boilers, and biomass-fired boilers. It also covers topics like boiler efficiency calculation, flue gas emissions, dust collection systems, combustion air calculation and boiler water treatment.
This presentation summarizes retrofit options for aging methanol plants to improve efficiency and increase production. Some options discussed include adding a secondary reformer, pre-reformer, saturator, combustion air preheat, and replacing the existing converter. Modeling the entire plant is important for evaluating retrofit options. Partner selection, project management, and hazard reviews are also critical success factors. GBHE Catalysts offers detailed models, engineering expertise, and a one-stop shop for feasibility studies, front-end engineering, and retrofit design.
The document describes the auxiliary PRDS (pressure reducing and desuperheating) system used in thermal power plants. It has two identical systems - the turbine auxiliary steam system (TAS) and boiler auxiliary steam system (BAS). Low and high capacity auxiliary steam is derived from main steam and its pressure and temperature are reduced before supplying it to various locations in the plant for processes like deaeration, soot blowing, oil heating etc. The systems use control valves, isolating valves, desuperheaters and spray water to control pressure and temperature.
SEMINAR ON SUPER CRITICAL BOILER....SAMRIDDHA SHIL.....S@SSamriddha Shil
This document discusses supercritical pressure in water vapor cycles and supercritical boilers. It begins by explaining that the critical point in a water vapor cycle is where there is no clear distinction between the liquid and gas states of water, occurring at over 22.1 MPa and 374°C. It then shows a diagram of a supercritical boiler water cycle. The document goes on to compare supercritical boilers to subcritical boilers, noting advantages of supercritical boilers like higher efficiency, less infrastructure needs, better temperature control and load flexibility, and shorter startup times. It concludes that supercritical boilers result in less fuel consumption, emissions, costs and other economic and operational benefits compared to subcritical boilers.
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
boiler accessories, basics of economizer, types of economizer, air preheater, types of air preheater, reheater, basics of superheater, types of superheater.
This document discusses using cold boiler feed water from membrane deaerators for heat recovery in refineries. Specifically, it proposes supplying cold boiler feed water to waste heat streams to replace steam duty currently used in deaerators. As an example, it describes using cold feed water in the heat exchanger of a hydrocracker hydrogen production unit, which could recover more waste heat and reduce steam usage by 8.8 Gcal/h in the deaerator. Overall, maximizing heat recovery from waste streams with cold boiler feed water can significantly improve energy efficiency in refineries.
1. The document describes NTPC Sipat power plant which has a total installed capacity of 2980 MW from 3 units of 660 MW and 2 units of 500 MW.
2. The 500 MW units use supercritical boiler technology which allows higher efficiencies between 40-42% compared to subcritical plants.
3. The plant sources coal from Dipika mines and water from Hasdeo barrage to operate its steam cycle.
Air compressors
Pump house
Steam header
Feed water System
Operating Parameters
Fuel Gas path
Ash content vs fuel efficiency
Operating alarms
operating instruments on panel
The document summarizes the differences between a typical coil type boiler system and a more efficient shell type boiler system. In a coil type boiler system, there are significant losses throughout the steam and condensate loop, with only 55% of the generated steam being used for process demand. A shell type boiler system recovers more condensate, reduces losses, and lowers the process steam demand, resulting in fuel savings of 25-30% compared to a coil type boiler. The shell type boiler provides dry saturated steam, steady loads, and increased productivity across several industries.
Boiler and steam system seminar short version 05 29-13Payden Sewell
This document provides information on boiler operations and efficiency. It discusses that a typical steam system loses 70% of its energy, with 28% lost in the boiler room and 42% lost in distribution. It also outlines various boiler types including watertube, firetube, and electric boilers. Key factors that impact boiler efficiency like combustion efficiency, radiation losses, and excess air are examined. The document emphasizes the importance of proper boiler maintenance, controls, and feedwater conditioning to maximize efficiency.
The document provides information on assessing the energy performance of boilers through testing. It discusses how boiler efficiency and evaporation ratio can decrease over time due to various factors like poor combustion, fouling, and deteriorating fuel/water quality. The purpose of performance testing is to determine the actual efficiency and compare it to design values in order to identify areas for improvement. Both direct and indirect testing methods are described as well as the necessary measurements, instruments, standards, and considerations involved in conducting the tests. Formulas are also provided for calculating efficiency using the indirect method by establishing heat losses from the boiler.
Thermal Power plant familarisation & its AuxillariesVaibhav Paydelwar
PPT in Relation to Power Plant familarisation, Coal to Electricity Basics,Power Plant cycles, Concepts of Supercritical Technology Boiler, Concepts Of BTG Package as well as Balance of Plant
The document summarizes the failure history and root cause analysis of the superheater tubes in two high pressure boilers. The superheater tubes experienced premature failures due to overheating, with surface temperatures reaching 550-600°C. Analysis found the superheater design had too low pressure drop, inadequate steam velocities, and lack of screen tubes. Modifications reduced tube count, implemented a double stage design with attemperation, upgraded metallurgy, and increased pressure drop. The modifications eliminated overheating failures and improved performance.
1) Operating parameters like steam inlet pressure, temperature, and exhaust pressure/vacuum affect steam turbine efficiency and steam consumption significantly.
2) For a condensing turbine, increasing steam inlet pressure by 1 kg/cm2 reduces steam consumption by 0.3% and improves efficiency by 0.1%. Increasing steam temperature by 10°C reduces consumption 1.1% and improves efficiency 0.12%. Improving exhaust vacuum by 10mmHg reduces consumption 1.1% and improves efficiency 0.24-0.4%.
3) Similarly for a back pressure turbine, the document outlines the effects of changing operating parameters on steam consumption and efficiency.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
This document discusses boiler blowdown, which is the process of removing concentrated boiler water and replacing it with fresh feedwater. It provides information on:
- Common impurities in raw water that can cause scaling, sludge, corrosion, or foaming in boilers.
- Guidelines for maximum total dissolved solids levels in boiler water depending on boiler type to avoid issues.
- A formula for calculating the required blowdown rate to maintain a target boiler water total dissolved solids level based on feedwater quality and boiler steam rate.
- An example calculation of the blowdown rate required for a specific boiler operating at 10,000 kg/h steam with 250 ppm feedwater to maintain 2,500
The document discusses various components of a thermal power plant including a boiler, air preheater, and ash handling plant. It provides details on the types, operation, and technical specifications of these systems. The boiler section describes supercritical boilers and includes diagrams of boiler components. The air preheater section explains regenerative and recuperative types. The ash handling plant introduces the collection and disposal of ash from coal combustion.
Indian scenario of super critical power plants issues and challenges by ntpc...Ajay Singhal
This document discusses supercritical power plants in India, including:
1. NTPC operates several supercritical power plants in India with a total installed capacity of 3,300 MW. Their Sipat plant includes 3 x 660 MW supercritical units.
2. Supercritical technology provides benefits like reduced emissions, improved efficiency, and lower fuel costs compared to subcritical plants.
3. Operating supercritical plants presents issues and challenges related to boiler control, chemistry regimes, and performance optimization. NTPC's experience provides lessons for addressing these challenges.
Super Critical Technology-Fundamental Concepts about Super Critical Technolog...Raghab Gorain
Nicely describe everything about super critical technology in thermal power plant.This slide is very useful for the freshers.Anybody can get the basic fundamental idea about super critical technology from this slide. In India now we have to think some new technology for power sources as sub critical power plants are less efficient and emit more pollutant to the environment and the alternative is the 'Super Critical Power Plant'.
This document discusses boiler efficiency, including types of efficiency measurements like combustion efficiency, thermal efficiency, and seasonal efficiency. It explains what makes a boiler condensing and how condensing boilers can achieve higher efficiencies up to 98%. The document also covers relationships between flue temperature, condensing, and efficiency as well as considerations for applying condensing boilers.
This document provides information on Stork Thermeq B.V.'s spray-type deaerator system. It describes the deaerating process which involves heating, partial deaeration, and cooling of feedwater using a spray device, steam charging device, and vessel. It compares the layout and operation of spray-type deaerators to cascade or spray/tray-type systems, noting advantages of the Stork design including its more compact size, simpler operation, and flexibility. The document also outlines typical design parameters for pressure, capacity, materials used, and internal components.
Cheema Boilers Limited is hosting a national workshop on efficient operation and maintenance of boilers in Visakhapatnam on December 7-8, 2015. The document discusses various types of boilers such as water tube boilers, fire tube boilers, and biomass-fired boilers. It also covers topics like boiler efficiency calculation, flue gas emissions, dust collection systems, combustion air calculation and boiler water treatment.
This presentation summarizes retrofit options for aging methanol plants to improve efficiency and increase production. Some options discussed include adding a secondary reformer, pre-reformer, saturator, combustion air preheat, and replacing the existing converter. Modeling the entire plant is important for evaluating retrofit options. Partner selection, project management, and hazard reviews are also critical success factors. GBHE Catalysts offers detailed models, engineering expertise, and a one-stop shop for feasibility studies, front-end engineering, and retrofit design.
The document describes the auxiliary PRDS (pressure reducing and desuperheating) system used in thermal power plants. It has two identical systems - the turbine auxiliary steam system (TAS) and boiler auxiliary steam system (BAS). Low and high capacity auxiliary steam is derived from main steam and its pressure and temperature are reduced before supplying it to various locations in the plant for processes like deaeration, soot blowing, oil heating etc. The systems use control valves, isolating valves, desuperheaters and spray water to control pressure and temperature.
SEMINAR ON SUPER CRITICAL BOILER....SAMRIDDHA SHIL.....S@SSamriddha Shil
This document discusses supercritical pressure in water vapor cycles and supercritical boilers. It begins by explaining that the critical point in a water vapor cycle is where there is no clear distinction between the liquid and gas states of water, occurring at over 22.1 MPa and 374°C. It then shows a diagram of a supercritical boiler water cycle. The document goes on to compare supercritical boilers to subcritical boilers, noting advantages of supercritical boilers like higher efficiency, less infrastructure needs, better temperature control and load flexibility, and shorter startup times. It concludes that supercritical boilers result in less fuel consumption, emissions, costs and other economic and operational benefits compared to subcritical boilers.
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
boiler accessories, basics of economizer, types of economizer, air preheater, types of air preheater, reheater, basics of superheater, types of superheater.
This document discusses using cold boiler feed water from membrane deaerators for heat recovery in refineries. Specifically, it proposes supplying cold boiler feed water to waste heat streams to replace steam duty currently used in deaerators. As an example, it describes using cold feed water in the heat exchanger of a hydrocracker hydrogen production unit, which could recover more waste heat and reduce steam usage by 8.8 Gcal/h in the deaerator. Overall, maximizing heat recovery from waste streams with cold boiler feed water can significantly improve energy efficiency in refineries.
1. The document describes NTPC Sipat power plant which has a total installed capacity of 2980 MW from 3 units of 660 MW and 2 units of 500 MW.
2. The 500 MW units use supercritical boiler technology which allows higher efficiencies between 40-42% compared to subcritical plants.
3. The plant sources coal from Dipika mines and water from Hasdeo barrage to operate its steam cycle.
Experimental Study on Heat Recovery from Continuous Blow down Water And Reduc...IJERA Editor
Waste heat is heat which is generated in a different process i.e by combustion of fuel, by chemical rection. The
important of heat is its value not quality. The planning of how to recover this waste heat depends in part on the
temperature of waste heat gases. The energy lost in waste heat can not be fully recovered but maximum quantity
of heat can be recovered and loss is minimized. Generally higher the temperature, higher the quality and then
more cost effective is the heat recovery.
Lots of heat is lost by blow down so it is necessary to recover this heat by addition of heat exchanger in
between this process. So this waste heat could be utilized to heat boiler water before going to de-aerator. By
applying this process we can easily reduce loss of heat and heat required to heat boiler water is reduced. Also
this blow down water we can utilized as feed water so consumption of feed water is also reduced. But this blow
water we cant utilized as boiler water because we rejected due to high TDS. If we utilized then TDS level in
boiler is increased. So it is beneficiary to use this at the starting of demineralization.
William Grant started his Scottish whiskey distillery in 1887. Today, this well-known brand has an enviable reputation for the quality of spirits they produce and distribute internationally. Always looking to see how they can improve, they approached Grundfos Pumps to review their energy efficiency. Having undertaken an initial energy check, Grundfos identified several areas where significant savings were possible.
Taking the advice offered, two new boiler feed support pumps were purchased, and their performance was measured over a 6-month period. Results showed electrical savings of £56k pa; the removal of the modulation valve saved £18k per boiler on maintenance costs; a reduction in breakdown and/or steam issues on site; improved steam quality and well as gas savings of up to 9%.
Thermodyne boilers can help you by saving upto 30% of the fuel cost by providing high efficiency boilers, Energy consultancy and customized heating solutions. Fuel saving are not only important for margins, but also for environment. Industry can count on Thermodyne because we believe in Enhancing Energy Efficiency.
Performance optimization of thermal systems in textile industriesIOSR Journals
Energy consumption has been growing very rapidly due to population growth, rapid urbanization
and industrial development. For future planning, it is important to know the current specific energy
consumption and the energy intensity in order to estimate future energy consumption. In the industrial sector
especially in textile units’ large amount of energy wasted due to improper working and lack of energy saving
measures. In this study, the various measures that causes the main energy losses are investigated .In the textile
dyeing sector, the main processes are associated with steam in various proportions. For the steam production,
steam boilers of different types are used for different applications. The efficiency of the boiler varies from one
industry to other based on various parameters such as quality of the water, fuel used, blow down quantity, etc.
Steam traps are also having influence on the boiler efficiency. In the case of steam leakage the performance of
the system decreases as the consumption of fuel increases to produce more steam. Thus by adopting various
recovery methods we can reduce the energy losses and fuel consumption.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document discusses investigating improvements to boiler efficiency through adding an additional bank of tubes to the economizer for supercritical steam power cycles. It begins by introducing economizers and how they recover heat from flue gases to preheat feedwater, improving boiler efficiency by 2-4% typically. The study aims to add another bank of tubes to existing economizers in NTPC units to further control pollutants and increase feedwater temperature for both subcritical and supercritical conditions. Heat transfer calculations are performed assuming the additional bank and comparisons are made between existing and modified unit efficiencies. Overall pros and cons of adding the extra bank of tubes in the economizer are examined.
This report summarizes a study of the steam circuit across three departments - Soap Processing (SPD), Soap Finishing (SFD), and Personal Products (PP) - at Unilever Bangladesh Ltd. It analyzes the existing steam distribution system and future steam requirements given changes in operations. The report recommends redesigning parts of the steam distribution lines and insulation to improve efficiency and reduce thermal losses. It also proposes a condensate recovery system to reuse flash steam and reduce water and energy costs. Key aspects covered include analyzing pipe sizes, insulation thickness, steam flow rates, a bill of quantities, types of steam traps used, and calculations on flash steam generation.
Different Types of heat pump water heaters, technological advancements and efficiency changes in each type with their advantages / disadvantages and future prospects.
Low charge ammonia vapour compression refrigeration system for residential ai...RAJESHKUMAR4616
Ammonia is widely used as a refrigerant in industrial systems for food refrigeration, distribution warehousing and process cooling. It has more recently been proposed for use in applications such as water chilling for air-conditioning systems but has not yet received widespread acceptance for this application. This project was envisaged to develop an ammonia vapour compression refrigeration system of 3 TR capacity for residential air conditioning and to analyze the minimum possible charge in order to reduce leakage hazards associated with the system. This would increase the use of ammonia in a more efficient way. It has Zero ODP and GWP which makes it to be environment friendly. Even though Ammonia is a cost effective and energy efficient alternative to conventional refrigerants like HCFCs and HFCs, etc., it is toxic. So, toxicity of ammonia needs to be addressed. This calls for low inventory of refrigerant in individual system. The present work aims at reducing the specific charge of ammonia for residential air conditioning system with air cooled condenser.
This document discusses various methods for reducing steam pressure, including self-acting direct operating valves, pilot operated valves, pneumatic controls, electropneumatic controls, and electric controls. It provides diagrams to illustrate common pressure reducing station configurations, such as direct acting, pilot operated, pneumatic, electropneumatic, electric, parallel, and series arrangements. The advantages and disadvantages as well as typical applications are outlined for each pressure control method.
The document summarizes the dehydration plant at the Kandhkot Gas Field in Pakistan. The plant removes water and condensate from natural gas produced at the field. It includes slug catchers, scrubbers, filters, absorber towers that use glycol to remove condensate, and a glycol regeneration process. The clean gas is then metered and delivered to customers like WAPDA and SNGPL. Safety processes are in place at the gas wells that feed the plant and a compression station increases pressure before the gas is sent to transmission lines.
This document discusses pressure reduction in steam systems. It describes several types of pressure reducing valves: direct-acting self-acting bellows and diaphragm valves that reduce pressure proportionally based on downstream pressure; pilot-operated self-acting valves that provide tighter pressure control; and pneumatic control systems that offer highly accurate pressure regulation even at variable flows and pressures. Each type has advantages for different applications based on factors like required pressure control accuracy, expected flows, installation space, and costs.
This memo summarizes the design of a steam condenser for a 10MW power plant. Key aspects of the design include:
1. The condenser is single pass and single tube to condense steam from a turbine using cooling water at 25C from a river.
2. Calculations to determine the required heat transfer, mass flow rates, pressure drops and overall design took around 10-12 hours based on assumptions to simplify the complex real-world system.
3. The final design features 1703 condensing tubes that are 18 feet long in a 42 inch diameter cylindrical shell with 10 baffles and a triangular tube layout.
TENUGHAT THERMAL POWER STATION, T.T.P.S. LALPANIAAvinash Kumar
The document provides details about the Tenughat Thermal Power Station located in Lalpania, Jharkhand. It has an installed capacity of 420 MW from two 210 MW units that use coal from nearby mines. The power station uses a Rankine cycle with a steam turbine connected to a generator. It has a coal handling plant, boiler, economizer, water treatment plant, and ash handling plant as its main components. The boiler uses tubes to transfer heat from hot gases to water to produce steam. The steam then powers the turbine which spins the generator to produce electricity.
This document provides an overview of Sabar Dairy plant in Himmatnagar, India. It summarizes the plant's vision, products, and key components. The refrigeration plant uses an evaporative condenser and expansion valves in its refrigeration cycle. It also has 6 fire tube boilers ranging from 4.5 to 10 tons capacity that produce steam using biomass fuel. The document describes the basic components and functions of the refrigeration system, boiler, and their associated equipment and safety devices.
This document provides an overview of a training seminar on a summer internship at the Dholpur Combined Cycle Power Plant. It discusses the organization and various components of the power plant, including the gas turbine, heat recovery steam generator, steam turbine, condenser, turbo generator, excitation system, and 220kV switchyard. Key details are provided on the selection of the plant site, plant specifications and costs, equipment ratings, theories of operation, components and functions of the various systems. The document aims to educate interns on the technical aspects and working of the combined cycle power plant.
Steam is a widely used and efficient energy carrier that can be generated and distributed economically via centralized boiler plants. It can transfer large amounts of energy over long distances through relatively small diameter piping without needing pumps. Steam systems are flexible and easy to control by adjusting pressure. Modern steam systems are automated and efficient, providing energy for many industries and applications.
Soot Blowing Optimization- Field ExperiencePooja Agarwal
The document discusses soot blower optimization strategies implemented at Jindal Power Limited coal-fired power plants. Previously, all 56 furnace wall soot blowers were operated once every 8 hours, consuming substantial steam. Through a study, JPL found that operating soot blowers in certain areas and sequences had little effect on boiler parameters. This allowed reducing operations to only blowing 14 blowers once daily and 28 blowers every other day, saving over 1,300 tons of steam annually. Financial savings from reduced steam and coal usage were estimated at over 4 lakh rupees annually. The optimized strategy improved boiler performance and heat rate while reducing emissions and maintenance costs.
The document summarizes some common design issues encountered with chilled water systems and provides solutions. It describes 4 cases of chilled water system design mistakes: 1) a new variable primary flow system that had inaccurate flow sensing, insufficient loop volume, and improperly sized bypass piping; 2) converting an existing primary-secondary system to variable primary flow without ensuring accurate flow sensing; 3) connecting a heat recovery chiller in parallel without sufficient flow control; and 4) not properly positioning pumps to allow for minimum bypass flow in a conversion. The document provides recommendations to address these issues, such as using a more accurate flow meter, increasing loop volume with a buffer tank, properly sizing bypass piping, and considering a variable primary/variable secondary system
Similar to Condensate Collection By D K Singhal (20)
This document proposes a low-cost system for measuring steam flow in industrial processes. The system works by measuring the pressure drop across a steam pipeline, which is proportional to the square of the steam flow rate. A tank with a partition is installed in the pipeline, and the pressure difference is indicated by the water level in a gauge glass. By taking initial measurements and developing a plant-specific correlation, the steam flow can be estimated based on the pressure drop and used to optimize steam consumption. The proposed system provides a low-cost alternative for steam flow monitoring where more expensive meters cannot be afforded.
The document discusses design considerations for mild steel MG cylinders used in papermaking. It covers topics like material selection, plate testing, fabrication process including welding and stress relieving, and mechanical design factors like shell thickness and tie rods. Stress relieving is important to reduce residual stresses from fabrication and welding. An energy audit of the stress relieving process can ensure it is done correctly.
The document discusses the benefits of using treated effluent from waste paper based paper mills for irrigation purposes. It notes that contrary to popular belief, the effluent from these mills contains non-hazardous chemicals and its use has been shown to increase crop yields by up to 20% in some cases. The effluent is rich in nutrients and its use can improve soil quality while reducing farmers' costs and electricity usage. Several published studies on the effects of treated paper mill effluent irrigation are summarized, with most finding benefits to crop growth and yield. Results from a specific mill also saw sugarcane heights and production increase by around 20% when using the treated effluent for irrigation.
Optimization Of Grade Change By D K Singhaldeveshksinghal
This document describes how the author optimized the grade change process on a paper machine to minimize downtime through implementation of the critical path method. By analyzing each step in the process and identifying dependencies between steps, the author was able to reduce the downtime from 1.5-2 hours to under 1 hour. Further improvements like adding additional drainage lines reduced time further. For critical quality changes, modifications like using separate decker and tanks helped reduce changeover time significantly. Automating some steps through PLC control could reduce time by another 5-9 minutes. Overall, implementing CPM and related improvements reduced downtime by over 50-60% for grade changes.
This document discusses manpower training in small paper mills. It notes that small mills often lack formal training systems compared to larger mills. Lower level workers in small mills tend to be less skilled than higher levels. The document proposes several actions for small mill training, including regular knowledge tests, weekly quizzes, and developing multimedia training tools. It provides examples of gains from training, such as reduced paper weight variations and increased condensate return. Overall the document advocates for customized training approaches for small mills to improve worker skills and productivity.
This document summarizes improvements made to a paper machine's MG steam and condensate system. It was found that directing condensate directly from the MG to the boiler house via appropriately sized piping eliminated issues, improved efficiency, and reduced costs. Additional benefits were realized by installing a heat exchanger to recover latent heat from the condensate before it reached the boiler. This increased condensate return rates and reduced blowdown requirements. The low-cost modifications provided significant operational and financial benefits with short payback periods.
Benchmarking In Papermaking Processes By D K Singhaldeveshksinghal
Benchmarking is a technique used to compare process performance metrics between organizations producing similar products. This document discusses using benchmarking to analyze key performance indicators like water, power, and material consumption. It provides examples of single parameter benchmarks comparing values like specific water usage between different paper mills. The document also discusses limitations of some common benchmarks and proposes new benchmarks like virgin fiber consumption that provide a more accurate picture of environmental performance between countries. Overall, the document advocates for benchmarking as a tool to identify improvement opportunities and better understand relative process efficiency.
Optimization Of Grade Change By D K Singhaldeveshksinghal
The document describes optimization of the grade change process on a paper machine to minimize downtime through implementation of critical path method (CPM). CPM was used to analyze the sequence of activities during grade changes and identify opportunities to reduce dependencies between activities. This allowed certain activities to be performed in parallel, reducing the total time of grade changes by 15-20 minutes. Further improvements like adding additional drain/fill lines and automating some valves are suggested to reduce time further. For critical quality changes, modifications to the approach flow system were made to eliminate the need to clean some parts of the system simultaneously.
Benchmarking In Papermaking Processes By D K Singhaldeveshksinghal
Benchmarking is a technique used to compare process performance metrics between organizations producing similar products. This document discusses using benchmarking to analyze key performance indicators like water, power, and material consumption. It provides examples of single parameter benchmarks comparing values like specific water consumption between different paper mills. The document also discusses limitations of some common benchmarks and proposes better benchmarks like virgin fiber consumption that provide a more accurate picture of environmental performance between countries. Overall, the document advocates for benchmarking as a tool to identify improvement opportunities and monitor process performance over time.
[To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
This PowerPoint compilation offers a comprehensive overview of 20 leading innovation management frameworks and methodologies, selected for their broad applicability across various industries and organizational contexts. These frameworks are valuable resources for a wide range of users, including business professionals, educators, and consultants.
Each framework is presented with visually engaging diagrams and templates, ensuring the content is both informative and appealing. While this compilation is thorough, please note that the slides are intended as supplementary resources and may not be sufficient for standalone instructional purposes.
This compilation is ideal for anyone looking to enhance their understanding of innovation management and drive meaningful change within their organization. Whether you aim to improve product development processes, enhance customer experiences, or drive digital transformation, these frameworks offer valuable insights and tools to help you achieve your goals.
INCLUDED FRAMEWORKS/MODELS:
1. Stanford’s Design Thinking
2. IDEO’s Human-Centered Design
3. Strategyzer’s Business Model Innovation
4. Lean Startup Methodology
5. Agile Innovation Framework
6. Doblin’s Ten Types of Innovation
7. McKinsey’s Three Horizons of Growth
8. Customer Journey Map
9. Christensen’s Disruptive Innovation Theory
10. Blue Ocean Strategy
11. Strategyn’s Jobs-To-Be-Done (JTBD) Framework with Job Map
12. Design Sprint Framework
13. The Double Diamond
14. Lean Six Sigma DMAIC
15. TRIZ Problem-Solving Framework
16. Edward de Bono’s Six Thinking Hats
17. Stage-Gate Model
18. Toyota’s Six Steps of Kaizen
19. Microsoft’s Digital Transformation Framework
20. Design for Six Sigma (DFSS)
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Best practices for project execution and deliveryCLIVE MINCHIN
A select set of project management best practices to keep your project on-track, on-cost and aligned to scope. Many firms have don't have the necessary skills, diligence, methods and oversight of their projects; this leads to slippage, higher costs and longer timeframes. Often firms have a history of projects that simply failed to move the needle. These best practices will help your firm avoid these pitfalls but they require fortitude to apply.
Top mailing list providers in the USA.pptxJeremyPeirce1
Discover the top mailing list providers in the USA, offering targeted lists, segmentation, and analytics to optimize your marketing campaigns and drive engagement.
3 Simple Steps To Buy Verified Payoneer Account In 2024SEOSMMEARTH
Buy Verified Payoneer Account: Quick and Secure Way to Receive Payments
Buy Verified Payoneer Account With 100% secure documents, [ USA, UK, CA ]. Are you looking for a reliable and safe way to receive payments online? Then you need buy verified Payoneer account ! Payoneer is a global payment platform that allows businesses and individuals to send and receive money in over 200 countries.
If You Want To More Information just Contact Now:
Skype: SEOSMMEARTH
Telegram: @seosmmearth
Gmail: seosmmearth@gmail.com
The APCO Geopolitical Radar - Q3 2024 The Global Operating Environment for Bu...APCO
The Radar reflects input from APCO’s teams located around the world. It distils a host of interconnected events and trends into insights to inform operational and strategic decisions. Issues covered in this edition include:
Brian Fitzsimmons on the Business Strategy and Content Flywheel of Barstool S...Neil Horowitz
On episode 272 of the Digital and Social Media Sports Podcast, Neil chatted with Brian Fitzsimmons, Director of Licensing and Business Development for Barstool Sports.
What follows is a collection of snippets from the podcast. To hear the full interview and more, check out the podcast on all podcast platforms and at www.dsmsports.net
Understanding User Needs and Satisfying ThemAggregage
https://www.productmanagementtoday.com/frs/26903918/understanding-user-needs-and-satisfying-them
We know we want to create products which our customers find to be valuable. Whether we label it as customer-centric or product-led depends on how long we've been doing product management. There are three challenges we face when doing this. The obvious challenge is figuring out what our users need; the non-obvious challenges are in creating a shared understanding of those needs and in sensing if what we're doing is meeting those needs.
In this webinar, we won't focus on the research methods for discovering user-needs. We will focus on synthesis of the needs we discover, communication and alignment tools, and how we operationalize addressing those needs.
Industry expert Scott Sehlhorst will:
• Introduce a taxonomy for user goals with real world examples
• Present the Onion Diagram, a tool for contextualizing task-level goals
• Illustrate how customer journey maps capture activity-level and task-level goals
• Demonstrate the best approach to selection and prioritization of user-goals to address
• Highlight the crucial benchmarks, observable changes, in ensuring fulfillment of customer needs
Zodiac Signs and Food Preferences_ What Your Sign Says About Your Tastemy Pandit
Know what your zodiac sign says about your taste in food! Explore how the 12 zodiac signs influence your culinary preferences with insights from MyPandit. Dive into astrology and flavors!
At Techbox Square, in Singapore, we're not just creative web designers and developers, we're the driving force behind your brand identity. Contact us today.
B2B payments are rapidly changing. Find out the 5 key questions you need to be asking yourself to be sure you are mastering B2B payments today. Learn more at www.BlueSnap.com.
HOW TO START UP A COMPANY A STEP-BY-STEP GUIDE.pdf46adnanshahzad
How to Start Up a Company: A Step-by-Step Guide Starting a company is an exciting adventure that combines creativity, strategy, and hard work. It can seem overwhelming at first, but with the right guidance, anyone can transform a great idea into a successful business. Let's dive into how to start up a company, from the initial spark of an idea to securing funding and launching your startup.
Introduction
Have you ever dreamed of turning your innovative idea into a thriving business? Starting a company involves numerous steps and decisions, but don't worry—we're here to help. Whether you're exploring how to start a startup company or wondering how to start up a small business, this guide will walk you through the process, step by step.
Company Valuation webinar series - Tuesday, 4 June 2024FelixPerez547899
This session provided an update as to the latest valuation data in the UK and then delved into a discussion on the upcoming election and the impacts on valuation. We finished, as always with a Q&A
Digital Marketing with a Focus on Sustainabilitysssourabhsharma
Digital Marketing best practices including influencer marketing, content creators, and omnichannel marketing for Sustainable Brands at the Sustainable Cosmetics Summit 2024 in New York
Building Your Employer Brand with Social MediaLuanWise
Presented at The Global HR Summit, 6th June 2024
In this keynote, Luan Wise will provide invaluable insights to elevate your employer brand on social media platforms including LinkedIn, Facebook, Instagram, X (formerly Twitter) and TikTok. You'll learn how compelling content can authentically showcase your company culture, values, and employee experiences to support your talent acquisition and retention objectives. Additionally, you'll understand the power of employee advocacy to amplify reach and engagement – helping to position your organization as an employer of choice in today's competitive talent landscape.
Structural Design Process: Step-by-Step Guide for BuildingsChandresh Chudasama
The structural design process is explained: Follow our step-by-step guide to understand building design intricacies and ensure structural integrity. Learn how to build wonderful buildings with the help of our detailed information. Learn how to create structures with durability and reliability and also gain insights on ways of managing structures.
Anny Serafina Love - Letter of Recommendation by Kellen Harkins, MS.AnnySerafinaLove
This letter, written by Kellen Harkins, Course Director at Full Sail University, commends Anny Love's exemplary performance in the Video Sharing Platforms class. It highlights her dedication, willingness to challenge herself, and exceptional skills in production, editing, and marketing across various video platforms like YouTube, TikTok, and Instagram.
Anny Serafina Love - Letter of Recommendation by Kellen Harkins, MS.
Condensate Collection By D K Singhal
1. Closing MG Steam &
Condensate System on a Paper
Machine
Abstract:
This paper presents how the ineffective condensate removal problem can be
eliminated from the MG by closing MG steam & condensate system just by
changing condensate piping of suitable size. In addition to a trouble free
operation, boiler fuel saving, lower dependency of equipments, electricity saving
can be achieved by directing condensate from MG directly to boiler house. In
addition, a higher condensate return can be obtained by recovering flash steam
fully or partially.
By:
D K Singhal
deveshksinghal@rediffmail.com
Chandpur Enterprises Ltd.,
Noorpur Road, Chandpur –246725
Dist. BIJNOR (U.P.), INDIA
1
2. Introduction:
Energy conservation has been a topic of interest for almost all involved in any
type of operation due to ever increasing costs of energy and fuel. As a tool of
energy conservation, system closure plays a vital role. As the paper making
involves drying of paper by utilization of latent heat content available in steam,
the condensate is generated. The purpose to recover the condensate generally is
to reuse heat content available in it, but, as a solution to a different problem, it
has been found that the condensate can be transferred more efficiently to boiler
house without much effort.
Case History:
In a particular case, it was observed that in a waste paper based mill, steam
consumption in hydrapulping or pulp mill-stock preparation section was virtually
nil. All the steam was being used only for paper machine. Once again, in absence
of any flow meter, a time totalizer was connected with the only boiler feed pump
and a daily reading was taken used to get the total run hours of boiler feed pump,
which multiplied with the pump flow rate gives steam consumption. Analyzing
the pump running hours on a daily basis, it was found that the boiler feed pump
run hours could be considered to be good indicative of steam consumption.
Since the beginning, the mill faced a problem of frequent vibrations in MG and
MG framings due to improper water removal from MG. After frequent problems,
it was thought that only one steam trap of 2” size was inadequate and another trap
of same size was installed in parallel to the previous one. The problem reduced
significantly, but still appeared almost every fortnight. Then alongwith inverted
bucket type, thermodynamic traps were also installed thinking that the bucket
might be stuck to the body of trap. The problem remained the same. Finally, a
bypass line was provided without any steam trap to condensate tank (Open to
atmosphere), so that in case any problem appears, the machine personnel may
empty out MG with that line. But, by this time the machine personnel were so
frightened of the problem that they made it a habit to use the bypass line always
open to condensate tank. This resulted in heavy steam losses and the steam
consumption increased by around 15-25% in a month as significant quantity of
steam was now being released to atmosphere along with condensate.
2
3. Action Taken:
To analyze the problem, data was collected on MG pressure during different
conditions. It was observed that the pressure remained at around 2.8 Kg/cm2g
during normal operation. During short breaks at wire, or MG-pope reel, the
pressure remained nearly the same as the duration of the break was of the order
of 1-4 minutes. For relatively longer breaks or small shuts of 15-45 minutes, such
as quality change, system washing, wire & felt cleaning, the pressure was kept at
around 1-1.5 bar. For longer shuts such as clothing change, monthly maintenance
shut etc. the pressure was reduced down to zero, but such instances were only just
a couple or so per month.
On the basis of above data it was thought if we could supply condensate directly
to the boiler house by means of pressure inside MG, saving on following points
could be achieved-
1. No breakdown due to MG hammering due to improper removal of
condensate.
2. No need of Condensate pump (3 HP) – a saving of around RS. 180/- per
day.
3. No wastage of flash steam near machine house resulting in boiler feed
water temperature increase by around 20 C, approximating a saving of
around RS. 250/- per day.
4. No moving parts in the system, (pumps, steam traps etc.) hence no
maintenance.
Now, the steam flow rate was computed by multiplying boiler feed pump running
hours with pump flow capacity. With this value, the condensate flow velocity
was calculated. It was observed that the nominal speed was of the order of 0.2
m/s only in a 2” pipeline. In order to increase the flow velocity so that the
pressure drop in the line increases, and hence steam flashing is reduced, the
pipeline diameter was reduced to 20 mm ID only for a length of around 2 Mts.
The purpose of smaller pipe section was to ensure that pressure drop across
complete pipeline is lower, while, only a narrow path is available for the
condensate and steam thus ensuring lower steam losses. This line was then
directed to boiler feed water tank. The steam losses were found to be reduced
drastically after this scheme was implemented. At first time, when the machine
was started after a long shut of a few days due to some other reason, improper
condensate removal was observed initially due to low MG pressure. Hence a
3
4. bypass line was fitted in order to drain the condensate during startups. This line
was used for nearly one hour during startup, and as soon as the MG pressure
reached to normal value, condensate was directed to boiler directly. The total
investment incurred for the modification of pipelines, giving extra valves, labour
for fitting work etc. was calculated to be of the order of RS. 4000/- only.
Furthermore, as fitted earlier, three steam traps were freed from the system,
which could be used elsewhere, if required.
Steam Wastage from Proposed System:
One may question the utility of proposed system that in absence of any steam
trap, a lot of steam will be wasted. It was tried to evaluate the quantity of
maximum possible steam wastage by the proposed method. The following
assumptions are being taken:
Diameter of pipeline: 20 mm
Steam pressure inside MG 2.8 Kg/cm2
Steam velocity in the pipeline 20 m/s
Volumetric flow rate of steam 3.14 * 0.02 * 0.02 * 20 / 4 m3/sec.
= 0.00628 m3/sec
= 22 m3/hr
At 2.8 Kg/cm2g, specific volume 0.49 m3/Kg
Steam Flow Possible in the line 22/0.49 Kg/Hr.
= 44 Kg/Hr.
If the normal steam consumption is of the order of 2200 Kg/hr, the maximum
possible steam loss accounts for a maximum of 2%. Furthermore, as proposed
hereunder, instrumentation can be used to reduce these losses to zero.
Instrumentation:
Many mills may like to add instrumentation to such systems. A logic has been
developed for incorporation of the instrumentation for automatic control of
condensate flow to the boiler house.
1. A pressurized condensate tank is used to receive all condensate from MG.
This tank is connected without any inlet valve.
4
5. 2. At the bottom of tank a pipeline is connected which transfers the
condensate to boiler house. The pipeline is so designed that the condensate
flow rate in the line is of the order of 2-3 m/s. This is done to ensure that
only condensate with no or very less steam is sent to boiler house.
3. The above pipeline has a control valve which controls the level in the tank
using lever transmitter and a controller. If the level is high, the control
valve is opened, and if the level is low, the control valve opening reduces.
4. Another ON/OFF type drain valve (solenoid valve) is fitted in the bottom
of tank that opens up if either the level is higher than alarm value or the
pressure is below a critical value at which condensate ceases to flow to
boiler house.
5. A manual drain valve is provided in the tank for draining this tank during
emergency. Safety valve of course is not very much needed, as in this tank;
pressure cannot be more than MG pressure. Still, if desired so, a safety
valve may be given.
Earlier, it was decided to observe the performance of above system for a few
months, before investing for the instrumentation as discussed above. Later on
when it was found that no MG hammering was observed after modification in
condensate piping, even in two years. Again steam consumption did not increase
using above system, the installation of instrumentation was ruled out and decided
to let system work as it is. It was also noted that using the above system, the
boiler feed water temperature that remained to the tune of 60 deg. Centigrade,
could be increased to 95 deg. Centigrade. In this way, no steam was required to
further heat up the condensate.
Installation of Heat Exchanger:
To further increase the condensate return, it was planned to install a heat
exchanger in the condensate line. This heat exchanger acts as heat exchanger as
well as a condenser. The fresh water is passed through the heat exchanger and hot
water coming out of heat exchanger is used for different purposes, within the
plant. The amount of flash vapors can be calculated as under-
Steam Pressure in MG: 2.8 Kg/cm2
Condensate Pressure: 2.8 Kg/cm2
Condensate Enthalpy: 141.8 Kcal/Kg
After flashing, condensate enthalpy 99.2 Kcal/Kg
Flash Vapor enthalpy: 638.8 Kcal/Kg
Flash Vapors generated (141.8-99.2)/(638.8-99.2)
5
6. = 0.0789 Kg/Kg steam
= 8%
By installing the heat exchanger, condensate return was increased by 8%,
obviously, as more condensate was being available, the blow down could be
reduced significantly without any problem. Even if the gains due to application of
hot water in different applications are ignored, the reduced blow downs make the
investment very much viable with a payback period of a few months. The above
systems have been discussed in figures 1,2, and 3 given at the end of this paper.
Overall Benefits:
By the proposed work, the following benefits were observed-
1. The MG hammering problems were completely eliminated. Hence down
time due to above problem was reduced by 100%.
2. Steam consumption was reduced by nearly 5%.
3. Condensate return was increased to 92-95%.
4. Blow downs were drastically reduced.
5. Hot water became available for pulp mill and paper machine showering
purpose, using the waste heat with flash steam.
6. Application of boiler descaling chemicals was completely eliminated.
7. If there is some air present inside MG, heat transfer is reduced drastically.
This air also restricts to flow of condensate through steam trap. With the
system discussed above, such possibilities are completely eliminated, and
even the production can be increased to certain extent.
Conclusion:
After modification in condensate piping, and installation of heat exchanger,
condensate return about 95% could be achieved. After successful operation for a
long time, it is now clear that the best way for condensate removal to let it flow
without any restriction.
6
7. Hot Water To
Process
Vapours
Cooling Water Condenser
Hot
Condensate
Evaporator Heat Exchanger
Boiler Feed Tank
Fig. 1: System for Improving Condensate Return
7
8. Pressure
Gauge
LIC
Feed Pressurised Condensate To Boiler House
Low
Pressure
Switch
Manual Drain Valve
Automatic Drain Valve
(to open if pressure is low, or level is high)
Fig. 2: Instrumentation Schematic for Direct Condensate Transfer
8
9. Hot Cooling Water
Pressurised Condensate
From Dryer 1
Dryer 2
Dryer 3
Dryer 4
Dryer 5
Cooling Water To Boiler House
Intermediate
Condensate
Collecting
Tank
Fig. 3: Heat Exchanger for Condensate Heat Recovery for
Multiple Dryers
9