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Energy Efficient Steam Systems
Energy Efficient Steam Systems
Introduction
Air, water and steam are three media commonly used to distribute
heat to process loads. However, steam has several advantages
compared to hot air and hot water. These advantages include.
The higher flow rates required by water and air require pipes and ducts
with larger diameters than steam pipes, which increases first cost and
heat loss. In addition, air and water do not propel themselves. Thus,
hot air and water distribution systems require fans or pumps, whereas
a steam distribution system does not require any additional propulsion
for outgoing steam and a very small pumping system for returning the
condensate to the boiler. Finally, because steam condenses at a
constant temperature, 100-psig steam could heat a process stream to
a maximum temperature of 338 F which is the temperature of the
steam. On the other hand, the temperature of water and air decrease
as heat is transferred; thus, if the heat in these examples was
delivered by a cross-flow heat exchanger, the maximum temperature
of the process stream would be 100 F less than the incoming
temperature of the air or water. Because of these advantages, steam
is the most widely used heat-carrying medium in the world.
Steam generators are like water-tube boilers, except that they are
made from light- weight materials. In many jurisdictions, the lack of a
dedicated pressure vessel enables steam generators to be used
without a boiler operator. The light weight materials and absence of a
large holding tank allow steam generators to come up to pressure
quickly in a manner of minutes. This enables steam-generators to be
turned on and off as needed, reducing standby losses. Installing the
water-tubes in a counter-flow configuration to the path of the
combustion gasses increases thermal efficiency.
Source: http://www.claytonindustries.com
Deaerator Tanks
Makeup water and condensate contain dissolved oxygen, carbon
dioxide and ammonia. These dissolved gasses reduce the conductivity
of the steam and hence its ability to transfer heat. More importantly,
oxygen is highly corrosive and leads to pitting and possible system
failure. Economizers are particularly susceptible to oxygen pitting. For
these reasons, oxygen is typically removed from steam systems by a
deaerator.
A deaerator works by spraying makeup water into a steam
environment and heating the makeup water to within about 5 F of
saturation temperature. At this temperature, the solubility of oxygen is
low and the makeup water contains very little oxygen. Oxygen and
flash vapor are vented to atmosphere. To function effectively, the
pressure of the dearator can only be a few psi above ambient pressure,
or else the oxygen will be forced back into the water.
Thottling Valves
Boilers are generally designed to operate at a specific pressure. For
safety reasons, boilers should never be operated above the rated
pressure. If the pressure of steam needed at the application is less
than the rated pressure of the boiler, the boiler can be operated at less
than the design pressure or the boiler can be operated at the design
pressure and the pressure of steam reduced through a valve located
between the boiler and the application. Operating at a lower pressure
will slightly increase the efficiency of the boiler because of the
decreased steam temperature and subsequent boiler skin losses.
However, it may also cause problems such as raising the level of water
in the boiler and reduced boiler heating capacity. A primary advantage
for operating the boiler at the design pressure and then reducing the
pressure through a valve is that the steam exiting the valve will be
slightly super heated, resulting in less water in the steam lines and
heat exchangers. Because of this, some consultants recommend that
steam boilers be operated at their design pressure, even if the steam is
to be used at lower pressures in the plant.
Steam Piping Systems
Steam is generally distributed to the plant through one or more large
steam mains which connect to smaller branch pipes. Condensate is
produced and carried along with the steam as steam condenses on the
inside surface of the pipes. Excess condensate can block steam flow
and cause serious pipe erosion. Thus, drip stations need to be
installed at all low points and ends of all mains at intervals of about
100 feet along the main. A drip station consists of a vertical section of
pipe at least 18 inches long installed on the underside of the main and
connected to a steam trap. Strainers should also be installed along the
piping system to filter out scale and solid contaminants.
The velocity of steam out of the boiler is determined by the outlet
nozzle. It is common practice to design piping systems for spaceheating applications for a velocity of about 6,000 ft/min and piping
systems for process-heating applications for a velocity of about 10,000
ft/min. Lower velocities reduce pressure loss, pipe erosion, water
hammer and noise as well as providing more efficient condensate
drainage.
As steam condenses on a cold surface a thin film of condensate is
produced and any air entrained with the steam is released. Air in a
steam system steam causes two major problems. First, even a thin
layer of air on a heat transfer surface, dramatically reduces the heat
transfer across the surface (See figure below). For example a layer of
air 0.04 inches thick adds the same thermal resistance as a layer of
water 1 inch thick or a layer of iron 4.3 feet thick. Second, when air is
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Inverted bucket.
Float + thermostatic
Thermostatic
Thermodynamic
Steam Metering
Steam metering is expensive, but gives valuable information for
managing a steam system. Most steam meters work by measuring the
pressure difference across a pressure reduction valve and comparing
the output to calibrated values. High-quality steam metering devices
for a 4-inch steam pipe cost about $4,000.
(1)
(2)
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Turbulent: L3 T > 63
(3)
0.25
0.33
(4)
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(5)
(6)
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savings from insulating the pipe (Btu/hr) if the efficiency of the steam
system is 70%.
Input data are:
Calculations of current heat loss and thermal resistance of the pipe, Rp,
are:
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Thus, the heat loss, Qsav, and fuel, Qf,sav, savings from adding
insulation would be:
The same method can be used to calculate heat loss, and the savings
from insulating, walls of steam-heated tanks. The only modifications
required are when calculating the convection coefficient. When
determining whether the flow of air is laminar of turbulent, the
effective length is the wall height instead of pipe diameter, and the
relation for convection coefficient is for vertical surfaces instead of
pipes.
Example
The surface temperature of a steam-heated, un-insulated rectangular
tank with four walls with height 4 ft and length 8 ft is 160 F. The
temperature of fluid in the tank is 180 F, and the temperature of the air
and surroundings is 70 F. The surface emissivity of the tank is 0.70.
Calculate convection, radiation and total heat loss from the tank walls
(Btu/hr). The tank walls are insulated with 1 inch on insulation with
thermal resistance R = 2 hr-ft2-F/Btu per inch. The surface emissivity
of the insulation is 0.70. Calculate convection, radiation and total heat
loss from the insulated tank walls (Btu/hr). Calculate the heat loss and
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fuel savings from insulating the tank walls (Btu/hr) if the efficiency of
the steam system is 75%.
Input data are:
Note that radiation loss is less than convection heat loss at these
relatively low temperature differences between the surface and air.
To calculate the heat loss with insulation, an iterative method is used in
which the surface temperature of the insulation, Ti, is guessed until the
energy balance Equation 7 is satisfied. Equation 7 is satisfied when:
EB(Ti) = A (Tf Ti) / (Rw +Ri) - h A (Ti Ta) - A (Ti4 Ta4) = 0
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Thus, the heat loss, Qsav, and fuel savings, Qf,sav, from adding
insulation would be:
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Ultrasonic sensor
Temperature sensor
Excess flash
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on both sides may have failed open. A trap which is cold on both sides
may have failed closed and be flooded with water.
Flash: The enthalpy of condensate at atmospheric pressure is
substantially less than the enthalpy of condensate at the operating
pressure of a steam system. Thus, the energy released as the pressure
of condensate falls to atmospheric pressure, vaporizes some of the
condensate into flash steam. The quantity of condensate flashed
to vapor dramatically increases when live steam enters the condensate
return system. Thus, increased flash from the condensate return or
deaerator tank is an indicator of failed-open steam traps.
Estimating Savings from Repairing Steam Traps
The rate of steam loss through a leaking trap depends on the size of
the condensate orifice in the trap. Orifice size is a function of the size
of the trap and the differential pressure between the steam and
condenstate lines that the trap was designed for. Orifice sizes for
Sprirax Sarco float+thermostatic and inverted-bucket traps are listed
below. Orifice sizes for thermostatic and thermodynamic traps are
generally not specified; however the effective orifice size is similar to
the orifice size for inverted bucket and float+thermostatic traps.
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Combustion Efficiency
Boilers typically employ combustion to covert fuel energy into high
temperature thermal energy.
This section describes natural gas
combustion and how to calculate combustion air flow, combustion
temperature and the efficiency of the process. These results are used
extensively throughout this chapter.
The minimum amount of air required for complete combustion is called
the stoichiometric air. Air consists of about 1 mole of oxygen to 3.76
moles of nitrogen. Assuming that natural gas is made up of 100%
methane, the equation for the stoichiometric combustion of natural gas
with air is:
CH4 + 2 (O2 + 3.76 N2) CO2 + 2 H2O +7.52 N2
(17)
The ratio of the mass of air required to completely combust a given
mass of fuel is called the stoichiometric air to fuel ratio, AFs. AFs can
be calculated using the molecular masses of the air and fuel at
stoichiometric conditions. For combustion of natural gas in air, AFs is
about:
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energy fuel energy supplied is the higher heating value of the fuel.
Using this approach, the combustion efficiency, is:
= [{1 + (1 + ECA) AFs} Cpg (Tc Tex)] / HHV
(22)
The dew-point temperature of products of combustion is about 140 F.
If the products of combustion leave the process at temperature of less
than the dew-point temperature the water vapor will condense to a
liquid and release energy. To include this effect, the efficiency equation
can be written:
If Tex > 140 F then hfg = 0 Else hfg = HHV LHV
= [{1 + (1 + ECA) AFs} Cpg (Tc Tex) + hfg] / HHV
(22b)
The three required input values for computing combustion efficiency,
entering combustion air temperature, T ca, exhaust gas temperature,
Tex, and excess combustion air, ECA, can be measured using a
combustion analyzer. The quantity of excess air in the combustion
gasses is sometimes expressed as fraction oxygen. For methane
(natural gas) the conversion between fraction oxygen, FO 2, and excess
combustion air, ECA, are:
FO2 = 2 ECA / (10.52 + 9.52 ECA)
(23)
Example
A boiler consumes 100,000 Btu/hr of natural gas. An analysis of the
exhaust gasses finds that the fraction of excess air is 30% and the
temperature of the exhaust gasses is 500 F. Calculate combustion air
flow (lb/hr), exhaust gas flow (lb/hr), combustion temperature (F) and
the combustion efficiency.
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Thus, mass flow rate of combustion air is 94 lb/hr and the mass flow
rate of the combustion gasses is 98 lb/hr.
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Most boilers use linkages that connect natural gas supply valves with
combustion air inlet dampers. As the natural gas valve closes, the
mechanical linkages close dampers on the combustion air supply to
attempt to maintain a constant air/fuel ratio. If the exhaust gasses
contain too much excess air, the linkages can be adjusted to tune the
air/fuel ratio so that the exhaust gasses contain about 10% excess air.
Mechanical linkages vary the position of the inlet air damper with
natural gas supply.
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Example
A boiler burns 2,000 mmBtu of natural gas per year at a cost of $10
/mmBtu. The average temperature of the incoming combustion air is
70 F and the average temperature of the exhaust is 450 F. The fraction
excess air in the exhaust is measured to be 50%, but is reduced to
10% by adjusting the inlet combustion air dampers. Calculate a) the
projected annual cost savings ($/yr) and b) the projected savings as a
percent of current annual natural gas use.
The initial efficiency is:
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The heating energy delivered to the process, Qp, is the product of the
initial fuel use, Qf1, and the initial efficiency, Eff1.
Qp = Qf,1 x Eff1
The heating energy delivered to the process remains constant. The
new fuel use, Qf2, with the higher efficiency, Eff2, is:
Qf,2 = Qp / Eff2
The fuel use savings, Qf,sav, would be:
Qf,sav = Qf,1 - Qf,2
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Unfortunately, the linkages between the fuel valve and combustion air
dampers seldom function perfectly. Thus, the air/fuel ratio is seldom
held constant over the firing range. For example, the figure below
shows that excess air varies from 120% at low fire to 38% at mid file to
42% at high fire. This indicates that the linkages were incapable of
sufficiently reducing combustion air to match fuel supply at low fire.
The high level of excess air at low fire causes the efficiency of the
boiler to drop, even though the lower exhaust temperature should
drive the efficiency higher. In cases like this, it is often very difficult to
adjust the linkages so that excess air is constant at 10% at all firing
levels. However, it is usually possible to adjust the linkages so that the
minimum level of excess air is about 10%, and the excess air at other
firing rates drops by about the same percentage.
Example
A boiler operates 4,000 hours per year at low fire, 2,000 hours per year
at mid fire, and 2,000 hours per year at high fire with excess air and
exhaust temperatures shown in the figure above. Boiler fuel
consumption is 4 mmBtu/hr at low fire, 12 mmBtu/hr at mid fire, and
20 mmBtu/hr at high fire. Ambient temperature is 70 F. Calculate
annual fuel energy savings (mmBtu/year) from adjusting the linkages
so the minimum excess air is 10%, and the excess air at other firing
rates is decreased by the same percentage.
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The heating energy delivered to the process, Qp, is the product of the
initial fuel use, Qf1, and the initial efficiency, Eff1.
Qp = Qf,1 x Eff1
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The heating energy delivered to the process remains constant after the
efficiency is improved. The new fuel use, Qf2, with the higher
efficiency, Eff2, is:
Qf,2 = Qp / Eff2
The fuel use savings, Qf,sav, would be:
Qf,sav = Qf,1 - Qf,2
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Example
A boiler operates 4,000 hours per year at low fire, 2,000 hours per year
at mid fire, and 2,000 hours per year at high fire with excess air and
exhaust temperatures shown in the figure below. Boiler fuel
consumption is 4 mmBtu/hr at low fire, 12 mmBtu/hr at mid fire, and
20 mmBtu/hr at high fire. Ambient temperature is 70 F. Calculate
annual fuel energy savings (mmBtu/year) from installing an O2 trim
system so the minimum excess air is 10% across the firing range.
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The new combustion efficiencies, Eff2, if the excess air was held to
10% across the firing range would be:
The heating energy delivered to the process, Qp, is the product of the
initial fuel use, Qf1, and the initial efficiency, Eff1.
Qp = Qf,1 x Eff1
The heating energy delivered to the process remains constant after the
efficiency is improved. The new fuel use, Qf2, with the higher
efficiency, Eff2, is:
Qf,2 = Qp / Eff2
The fuel use savings, Qf,sav, would be:
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The heating energy delivered to the process, Qp, is the product of the
initial fuel use, Qf1, and the initial efficiency, Eff1.
Qp = Qf,1 x Eff1
The heating energy delivered to the process remains constant. The
new fuel use, Qf2, with the higher efficiency, Eff2, is:
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Qf,2 = Qp / Eff2
The fuel use savings, Qf,sav, would be:
Qf,sav = Qf,1 - Qf,2
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Tc2
Qact
Th2
Tc1
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Next, calculate the heat transfer from the hot exhaust gasses, h, to the
cold feedwater, c, using the heat exchanger effectiveness method.
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time to transfer heat to the steam as they pass through the boiler.
Thus, it is advantageous to control the boiler with modulation control
and avoid cycling.
In most boilers with on/off control, it is possible to upgrade to
modulation control. In addition, modulating burners typically have a
minimum firing rate of 25% to 33% of maximum output. If steam
demand is less than the minimum firing rate, the boiler cycles on and
off. Installing a burner with a smaller minimum firing rate can
eliminate the on/off cycling and reduce fuel use.
Example
A boiler operating with on/off control consumes 6,300,000 Btu/hr at full
fire. At full fire, the temperature of the exhaust gasses are 450 F and
the excess air in the exhaust gasses is 20%. The temperature of
combustion air entering the boiler is 70 F. The boiler operates 8,400
hours per year and fires at full fire 70% of the time. The boiler cycles
off two times per hour, and purges natural gas from inside the boiler
for 1 minute after cycling off and for 1 minute before reigniting. The
saturation temperature of steam in the boiler is 335 F. The cost of
natural gas is $10 /mmBtu. If the boiler were operated in modulation
mode, calculate the fuel savings from eliminating purge losses
(mmBtu/yr), the fuel savings from improving combustion efficiency
(mmBtu/yr), and the overall cost savings ($/yr)
The mass flow rate of exhaust gasses at full fire is:
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Source: http://www.spiraxsarco.com/
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The heating energy delivered to the process, Qp, is the product of the
initial fuel use, Qf1, and the initial efficiency, Eff1.
Qp = Qf,1 x Eff1
The heating energy delivered to the process remains constant. The
new fuel use, Qf2, with the higher efficiency, Eff2, is:
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Qf,2 = Qp / Eff2
The fuel use savings, Qf,sav, would be:
Qf,sav = Qf,1 - Qf,2
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