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.
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.
Boiler Efficiency Improvement through Analysis of Lossesijsrd.com
Thermal is the main source for power generation in India. The percentage of thermal power generation as compare to other sources is 65 %. The main objective of thermal power plant is to fulfill the energy demands of the market and to achieve these demands; plant requires technical availability with the parts reliability and maintenance strategy. This paper deals with the determination of current operating efficiency of Boiler and calculates major losses for Vindhyachal Super thermal power plant (India) of 210 MW units. Then identify the causes of performance degradation. Also find the major causes of heat losses by Fault Tree Analysis (FTA) and recommends its appropriate strategy to reduce major losses. The aim of performance monitoring is continuous evaluation of degradation i.e. decrease in performance of the steam boiler. These data enable additional information which is helpful in problem identification, improvement of boiler performance and making economic decisions about maintenance schedule.
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.
Boiler Efficiency Improvement through Analysis of Lossesijsrd.com
Thermal is the main source for power generation in India. The percentage of thermal power generation as compare to other sources is 65 %. The main objective of thermal power plant is to fulfill the energy demands of the market and to achieve these demands; plant requires technical availability with the parts reliability and maintenance strategy. This paper deals with the determination of current operating efficiency of Boiler and calculates major losses for Vindhyachal Super thermal power plant (India) of 210 MW units. Then identify the causes of performance degradation. Also find the major causes of heat losses by Fault Tree Analysis (FTA) and recommends its appropriate strategy to reduce major losses. The aim of performance monitoring is continuous evaluation of degradation i.e. decrease in performance of the steam boiler. These data enable additional information which is helpful in problem identification, improvement of boiler performance and making economic decisions about maintenance schedule.
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
The Presentation discusses the Air-Heater Performance Indices and the Boiler Performance calculation. One can Calculate the air ingress in the air-heater and the boiler and losses incurred thereby. The presentation also describes in details about the boiler efficiency and its calculation.
Shall we see about the performance and analysis of the steam boiler
And how to working it
And the performance of steam boiler
And efficiency how to find
And application
Combustion sources such as furnaces and fired
heaters play a critical role in the process industry.
Unfortunately, combustion requires large amounts of
fuel (gas, fuel oil). As a result, combustion efficiency
directly influences the performance and operational
costs of production facilities. However, efficiency is not
the only concern. Compliance and safety are major
challenges as well.
Design With Solid works Software and Planning Calculation Analysis of Fire Tu...IJRES Journal
Steam boilers (boilers) is a closed vessel made of steel that is used to generate steam. In the modern era many industries such as household scale industries for the manufacture of oyster mushroom spawn to use aid as a supplier of steam boilers are used as a sterilization process baglog. Annually, the number of requests oyster mushroom spawn have been increases, so the boiler is very significant equipment to increase the number of baglog production as oyster mushroom growing media.To help to fulfill the small industryrequiremets for oyster mushroom nursery,plannedatype offire tubeboilerthatcanhelpthe availability ofsteam ina lowscalewithsteamoutputcapacity of70kg/ h, temperature120℃, pressure1.5barandusingmaterialsLPGfuelas a source ofheatenergy.From the results of this design, fire tube boiler have efficiency of 0.934 % . The kettle body is made from asphalt drums pertamina with the Cold Rolled Steel materials. Used asphalt drums because of its availability in the market more easier to obtained easily and the dimensions of asphalt drum capable of holding for temperature and pressure have been determined . As for the pipe material using Carbon Steel Tubing Boilers ASME SA - 178A GRADE A / SA - 214 (Plain Carbon).
The presentation discusses the various factors which affect the performance of Power Boilers including the quality of coal, airheater performance, air ingress etc.
The Presentation discusses the Air-Heater Performance Indices and the Boiler Performance calculation. One can Calculate the air ingress in the air-heater and the boiler and losses incurred thereby. The presentation also describes in details about the boiler efficiency and its calculation.
Shall we see about the performance and analysis of the steam boiler
And how to working it
And the performance of steam boiler
And efficiency how to find
And application
Combustion sources such as furnaces and fired
heaters play a critical role in the process industry.
Unfortunately, combustion requires large amounts of
fuel (gas, fuel oil). As a result, combustion efficiency
directly influences the performance and operational
costs of production facilities. However, efficiency is not
the only concern. Compliance and safety are major
challenges as well.
Design With Solid works Software and Planning Calculation Analysis of Fire Tu...IJRES Journal
Steam boilers (boilers) is a closed vessel made of steel that is used to generate steam. In the modern era many industries such as household scale industries for the manufacture of oyster mushroom spawn to use aid as a supplier of steam boilers are used as a sterilization process baglog. Annually, the number of requests oyster mushroom spawn have been increases, so the boiler is very significant equipment to increase the number of baglog production as oyster mushroom growing media.To help to fulfill the small industryrequiremets for oyster mushroom nursery,plannedatype offire tubeboilerthatcanhelpthe availability ofsteam ina lowscalewithsteamoutputcapacity of70kg/ h, temperature120℃, pressure1.5barandusingmaterialsLPGfuelas a source ofheatenergy.From the results of this design, fire tube boiler have efficiency of 0.934 % . The kettle body is made from asphalt drums pertamina with the Cold Rolled Steel materials. Used asphalt drums because of its availability in the market more easier to obtained easily and the dimensions of asphalt drum capable of holding for temperature and pressure have been determined . As for the pipe material using Carbon Steel Tubing Boilers ASME SA - 178A GRADE A / SA - 214 (Plain Carbon).
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
Hello,
I am trying to explain about Steam Generator (Boiler) in this session, due to length of said presentation, I am deciding to divide it in three parts.
Part 1 cover the “Introduction & Types of Steam Generator”
Part 2 cover about the “Parts of Steam Generator and Its Accessories & Auxiliaries” and
Part 3 cover the “Efficiency & Performance”
Process Heaters, Furnaces and Fired Heaters: Improving Efficiency and Reducin...Belilove Company-Engineers
A process heater is a direct-fired heat exchanger that uses the hot gases of combustion to raise the temperature of a feed owing through coils of tubes aligned throughout the heater. Depending on the use, these are also called furnaces or red heaters. Some heaters simply deliver the feed at a predetermined temperature to the next stage of the reaction process; others perform reactions on the feed while it travels through the tubes.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
7. Method 1
Reduce Excess Air
Potential savingPotential saving :5%-10%
ProblemProblem :unneeded excess air is used, probably to dilute the flue gas so that
smoke is not seen.
SolutionsSolutions: reduce excess air to the minimum 10%-15% requird.
10. Normal combustion efficiencies for natural gas at different amounts of
excess air and flue gas temperatures are indicated below
68.271.975.679.382.810.081.6
72.175.278.281.284.17.044.9
74.076.779.582.184.75.028.1
75.477.980.482.885.23.015
76.078.480.883.185.42.09.5
600500400300200OxygenAir
Net Stack Temperature1)
(o
F)Excess %
Combustion Efficiency (%)
11. Flue Gas Loss Combustion Oil
The relationship
between temperature
difference flue gas and
supply air,
CO2concentration in
the flue gas, and the
efficiency loss in the flue
gas combustion oil, is
expressed in the
diagram below.
12.
13. Method 2
Decrease Flue-Gas Temperature
Potential savingPotential saving :1% for every 40°F.the potential saving are 3%,since many
stacks run 120°F too high.
ProblemProblem :Either excess air or fouling water and /or fire side tubes.
Solutions:Solutions:
1- If there is excess fuel,the fuel rate can be decreased to decease the
temperature .
2- if the tube are fouling up, steam production will suffer ,and the only solution
is to shut down and clean them up or blow soot on fireside.
2- An economizer may be economical (see method 15)
14. The TDS inside a boiler should be maintained at recommended levels else it can
lead to scaling of the boiler tubes and eventually failure of the tubes which is a
safety hazard.
18. Method 3
Reduce Boiler Pressure
Potential savingPotential saving :1%for every 70psig reduction
Problem :the boiler is being operated at a pressure higher
than necessary.
Solution :slowly reduce boiler pressure to a point where
the amount of steam produced is sufficient to fulfill plant
requirements
19. Method 4
Increase Fuel Oil Temperature
Potential saving : 5%
Problem :Atomize the fuel at the right
viscosity .Too high or too low a viscosity
will yield poor atomization and poor
efficiency .
Solution:
Preheat the fuel at 212°F-230°F or more so
that the fuel viscosity will be 100-300 sus
22. Method 5
Optimize Fuel Atomization Pressure
Potential saving: 1%
Problem :The fuel atomization pressure is
lower or higher than that specified by the
nozzle or burner design
Solution: Adjust fuel pressure according to
nozzle operating instructions
23. Method 6
Reduce Boiler blowdown
Potential saving : 1%
Problem :excessive blowdown due to poor water
treatment and /or poor operating practices .the
hot blowdown stream has energy that is lost
unless it is recovered (see Method 16)
Solution: control feed water quality with the
appropriate water treatment; review operation
Procedures
25. Method 7
Optimize Single-boiler Firing
Potential saving :5%-10%
Problem: A boiler may come on for afew
minutes and then be off for several
minutes, resulting in large energy losses
due to the removal of useful heat when the
boiler is off; or a boiler may “hunt” i.e. the
firing rate is continually adjusting ,resulting
in much more excess air.
26. • Solution :for an on –off boiler ,fire the
boiler at an intermediate rate or buy a
smaller boiler ; for boiler that “hunt” adjust
the firing so that larger steam – pressure
fluctuation are allowed.
27. Method 8
Optimize multiple-boiler operation
Potential saving :2%-5%
problem: A plant have tow or more boilers
operates them without distributing the load
according to the efficiency each boiler .
Solution : Obtain the efficiency of each
boiler vs. load ; adjust each boiler to
operate at peak efficiency.
30. Method 9
Stop Steam Leaks
Potential :5%-10%
Problem: piping leak
Solution: plug leak as soon as they appear
31.
32. • The biggest steam losses are caused by failing steam
traps or leaks into the steam system net. These
uncontrolled leaks can lead to enormous losses and also
enormous costs. The leaking traps can cause problems
with tracing of your equipment, problems with back
pressure into the condensate lines (which causes failure
of groups of steam traps), and make your cost for the
production of steam much higher. Problems with tracing
in one unit can be caused by leaking traps in a other unit
on the other side of the plant which indicates that
monitoring steam traps important is for the proper
working of your steam system.
39. In addition to costing energy, steam leaks waste boiler
water and chemicals, and it can be dangerous to people
and equipment.
40. NOTE:
One pound of 100 psi steam contains about 1,200 BTUs. If
the steam is produced at 85% efficiency, the input
energy is 1,200 / 85% = 1,411 BTUs per pound.
Therefore, 1,000 pounds of steam requires at least 1.4
million BTUs to produce it. (1,411 BTUs per pound x
1,000)
1 MCF of Natural Gas contains 1 million BTUs
Cost to produce 1,000 lbs of steam from natural gas = 1.4 x
$ per MCF of Natural Gas
When natural gas costs $7.00 per MCF, 1,000 lbs of steam
costs (1.4 x $7) = $9.80
46. Method 11
Reduce Deposits in Burner
Potential saving : 1%-5%
Problem : organic and inorganic deposits
build in burner, reducing atomization
efficiency and therefore reducing
combustion efficiency .
Solution : use a fuel oil additive with
detergent dispersant to keep burners
clean
50. Method 12
Reduce Scale and Soot Deposits on Fireside
Potential saving : 2% - 9%
Problem : soot and /or vanadium-based deposit
decrease the heat transfer rate. If all condition
are constant ,this decrease is noticeable when
the flue gas temperature increase with time.
Solution : treat fuel with additives to minimize
either soot deposits or vanadium-based scale.
Use soot blowers if available
60. Method 13
Reduce Scale and Deposits on Waterside
Potential saving : 2% - 4%
Problem : inorganic scale and deposits
decrease heat transfer rate ; i.e. flue gas
temperature increase with time.
Solution : treat feed water properly using
guidelines of boiler manufacturer or water
boiler standardizing
62. Fuel energy loss due to scale
Effect of Scale on Fuel Energy Losses
0
2
4
6
8
10
12
0
0.25
0.5
0.75
1
1.25
1.5
1.75
2
Scale Thickness,mm
%FuelLoss
High density
Medium Density
Low Density
65. Method 14
Increase Combustion Air
Temperature
Potential saving : 1%
Problem : preheat combustion air .every 40 °F rise
yields a 1% gain in efficiency.
Solution : there are several possible solutions:
relocate air intake duct so that a maximum air
duct temperature is obtained ,or install an air
preheater if possible and economically feasible.
67. Air Heaters
Air heaters cool flue gases before they pass into
the atmosphere, increasing fuel-firing efficiency
and raising the temperature of the incoming air
of combustion. In low pressure gas or oil-fired
industrial
boilers, air heaters function as gas coolers
as there is no need to preheat the oil or gas
in order for it to burn.
69. Method 15
Increase Feedwater Temperature
Potential saving :3%
Problem : raise water temperature
Solution : the equipment needed is an
economizer that uses the heat from flue gases, if
economically feasible. Also , the water can be
preheated using the waste heat from blowdown
(method 16).
10°F rise in feedwater temperature raisea
efficiency 1%
70. Economizers
Economizers help to improve boiler efficiency by
extracting heat from the flue gases discharged
from the final superheater section of a
radiant/reheat unit or the evaporative bank of a
non-reheat boiler. Heat is transferred to the
feedwater, which enters at a much lower
temperature
than saturated steam.
74. Method 16
Recover Heat Energy From Blowdown
Potential saving : 1%
Problem : preheat water by recovering energy from
blowdown.
Solution : add flash tank to system .the blowdown is
flashed by lowering the pressure in the flash tank;
the steam produced is then vented into the feed
water to boiler .some 50% of the heat in the
blowdown is recovered. Send blowdown at 220°F
to wast.
75. • Also aflash tank may be added ,followed
by aheat exchanger to extract one-third
more energy from the blowdown before
going to wast.
83. Method 17
Energy Recovery From Excessive Steam
Pressure
Potential saving :variable
Problem : use throttling or back pressure
turbine .
Solution : the idea is to utilize the energy
from steam rather than to decrease its
pressure though a throttling valve
87. Replace Pressure-Reducing Valves
with Backpressure Turbogenerators
Many industrial facilities produce steam at a higher pressure than is demanded
by process requirements. Steam passes through pressure-reducing valves
(PRVs,
also known as letdown valves) at various locations in the steam distribution
system to let down or reduce its pressure. A non-condensing or backpressure
steam turbine can perform the same pressure-reducing function as a PRV,
while
converting steam energy into electrical energy.
In a backpressure steam turbogenerator, shaft power is produced when a
nozzle
directs jets of high-pressure steam against the blades of the turbine’s rotor. The
rotor is attached to a shaft that is coupled to an electrical generator. The steam
turbine does not consume steam. It simply reduces the pressure of the steam
that is subsequently exhausted into the process header.
88. Consider Installing High-Pressure Boilers
with Backpressure Turbine-Generators
When specifying a new boiler, consider a high-pressure boiler with a backpressure
steam turbine-generator placed between the boiler and the steam distribution
network. A turbine-generator can often produce enough electricity to justify the
capital cost of purchasing the higher-pressure boiler and the turbine-generator.
Since boiler fuel usage per unit of steam production increases with boiler pressure,
facilities often install boilers that produce steam at the lowest pressure consistent
with end use and distribution requirements.
In the backpressure turbine configuration, the turbine does not consume steam.
Instead, it simply reduces the pressure and energy content of steam that is subsequently
exhausted into the process header. In essence, the turbo-generator
serves the same steam function as a pressure-reducing valve (PRV)—it reduces
steam pressure—but uses the pressure drop to produce highly valued electricity
in addition to the low-pressure steam. Shaft power is produced when a nozzle
directs jets of high-pressure steam against the blades of the turbine’s rotor. The
rotor is attached to a shaft that is coupled to an electrical generator.
89. Method 18
Reduce Heat Losses in Boiler, Steam and
Valves
Potential saving :5% - 8%
Problem : heat is lost by radiation and convection
through the walls of uninsulated or poorly
insulated boiler surfaces and piping.
Solution : use a surface thermometer and
determine where heat losses are present ; then
insulate.
98. Method 19
Use Fuel Oil Rather Than Natural Gas
Potential saving : 2%
Problem : If the price of natural gas is the
same or higher than that of fuel oil,which is
more economical?
Solution: use fuel oil.even if both cost the
sam per MMBtu,fuel oil gives about a 2%
higher efficiency than natural gas ,the
99. • The reason for this is that natural gas has
more hydrogen atoms per unit weight than
fuel oil. therefore, more water is formed
from the gas, the the latent heat of
vaporization of water is lost when the
water vapor leaves the stack.
• MMBtu=Million Metric British Thermal
Units
100.
101.
102.
103. Method 20
Change From Steam to Air Atomization
Potential saving : 1%
Solution : use are atomization for fuel oils.
The energy required to produce the are of
atomization is a small fraction of the
energy required to produce the steam of
atomization.