GUJARAT TECHNOLOGICAL UNIVERSITY

CHANDKHEDA, AHMEDABAD
AFFILIATED
L.J.INSTITUTE OF ENGINEERING AND TECHNOLOGY
A REPORT ON:
BOILER TREATMENT

UNDER SUBJECT OF:

DESIGN ENGINEERING–IB
B.E. SEMESTER 4
CHEMICAL ENGINEERING
SUBMITTED BY:
GROUP OF 4
NO. NAME ENROLLMENT NO.
1 BHATIA HITESH 170320105002
2 HALANI RENISH 170320105012
3 SINGH ANSHUMAN 170320105053
4 TIRTHANI ROHIT 170320105059

Ms. Khushbu Bhalodiya – Faculty Guide

Mr. Dinesh Mehbubani – Head Of Department

ACADEMIC YEAR
2018-2019
 Contents

1. Introduction………………………………………1
1.1 Team Members………….........................1
1.2 Design Thinking………………………...1
2. Empathy Mapping…………………………….....2
2.1 AEIOU canvas……………………..........2
2.1.1 Environment……………………....2
2.1.2 Interaction………………………...3-4
2.1.3 Objects…………………………....4-5
2.1.4 Activities……………………….....6
2.1.5 Users……………………………....7-8
2.2 Mind Mapping…………………………..9
3. Empathy Canvas……………………………….....10
3.1 User……………………………………...10
3.2 Stakeholders………………………..........11-12
3.3 Activities………………………………...12-14
3.4 Storyboarding……………………............14-16
4. Ideation Canvas……………………………….......17
4.1 People…………………………………....17
4.2 Activities………………………………...17-18
4.3 Situation/Context/location……………....18
4.4 Props/possible Solutions………………...19-21
5. Product Development Canvas………………….....22
5.1 Purpose…………………………………..22
5.2 People…………………………………....23
 5.3 Product experience & Function…………23-24
5.4 Product features…………………………24-25
5.5 Components……………………………..25-26
5.6 Customer revalidation…………..............27
5.7 Reject/Redesign/Retain……………........28-30
6. LNM Canvas……………………………………..31
7. References………………………………..............32
 1. Introduction
Boiler Treatment
1.1 Team members
176736
TEAM ID -21468

NO. NAME
1 BHATIA HITESH

2 HALANI RENISH
3 SINGH ANSHUMAN
4 TIRTHANI ROHIT

Faculty Guide – Ms. Khushbu Bhalodiya

1.2 Design Thinking

Designing thinking refers to activities that designers apply during the process of designing.
Design thinking is a methodology that helps people to understand and develop creative
ways to solve a specific issue. When design principles are applied to strategy and
innovation the success rate for innovation dramatically improves. Examples of design led
companies are ONGC, ESSAR, and RELIANCE etc. Great design has that “wow” factor
that makes products more desirable and services more appealing to users. Design is
backbone of product as people would first see the product and if they find it appealing they
would use it.

1
 2. Empathy Mapping

2.1 AEIOU Canvas

2.1.1 Environment
For the environment canvas, we noticed the surroundings of the industry,
including the nearby rivers, landfills in order to take into account the atmosphere,
aesthetics of the industrial area. The following things were observed during the
visit :
• Release of green house gases
• Ash disposal as landfill and in rivers.
• Wildlife disturbance or displacement on account of the incessant disposal
of untreated waste generated by the industries.
• Absence of proper incentives to curb the effects of the polluted air being
released as a by product of several processes.
• Emissions of toxic gases dissolved in the water used in boiler.

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2.1.2 Interactions
During the industrial visit we asked certain questions to the technicians,
engineers, plant operators and the laborers working there. The question which we
asked relate to specifications such as operating temperature, operating cost,
efficiency etc. The questions which we asked are:-

Q. What is the maximum steam generating capacity of the boiler used in

your company?
Ans. The steam generating capacity of the boiler used in our company is 40000 kg
per hour.
Q. What is the maximum pressure of boiler?
Ans. The maximum pressure of the boiler is 42 bar.
Q. What is the length or size of boiler?
Ans. The diameter of the boiler is 6000-9000 mm.
Q. What is the efficiency of the boiler?
Ans. The efficiency of the boiler is 60-80%.

Q. Is there any substitution plan for boiler replacement?

Ans. Yes there is a substitution of boiler for emergency.

Q. Is your plant is government approved plant?

Ans. Yes our plant is fully approved by the government and follows the norms
setup by GPCB and CPCB.

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2.1.3 Objects

Objects here refer to the things(equipments, mountings, accessories etc.) used in

the boiler operated industries.

Accessories

Boiler accessories are those components which are installed either inside or
outside the boiler to increase the efficiency of the plant and to help in the proper
working of the plant.

1) Air Pre heater - It is a waste heat recovery device in which the air on its way
to the furnace is heated utilizing the heat of exhaust gases/flue gases. The
function of air pre-heater is to increase the temperature of air before enters the
furnace. It is generally placed after the economizer; so the flue gases passes
through the economizer and then to the air preheater. An air-pre heater
consists of plates or tube with hot gases on one side and air on the other. It
preheats to be supplied to the furnace. Preheated air accelerates the
combustion and facilitates the burning of coal.
2) Economizer - It is a device in which the waste heat of the flue gases is
utilized for heating the feed water. To recover some of the heat being carried

4
 over by exhaust gases, this heat is used to raise the temperature of feed water
supplied to the boiler.
3) Super heater – It increases the temperature of steam, generated by boiler,
above its saturation point. It is done to reduce the losses due
to condensation and to reduce the steam consumption by the turbine.

Mountings

Boiler mountings are the component which are mounted on the surface of the
boiler to ensure safety during operation. These are essential part of the boiler,
without which the boiler function is not achieved.

Some of the examples of mountings are water level indicator, safety valve,
pressure gauge, steam stop valve, main hole, feed check valve.

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2.1.4 Activities

The activities take into account the various unit operations and processes involved
in any boiler operated industries.

Some of the activities include:

• Fuel Storing
• Condensation
• De aeration
• Valve Operations
• Economization
• Pollution Control
• Specs check
• Boiler Blowdown

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2.1.5 Users
As with every product out there in the market, our product, that aims at reducing
the corrosion rates inside boiler and eliminate scale and sludge formations during
processing of water in the boiler ,targets a certain category of
people/organizations. These people/organizations include :
• Boiler Designer
• Pollution Control Board
• Operator
• Engineer
• Technician
• QC and QA
• R&D
• Safety Manager
• Production Manager
• Boiler Manufacturers

Some other users :-

A boiler is used wherever steam generation is required. The form and size
depends upon the application: mobile steam engine such as steam
locomotive, portable engines and steam-powered road vehicle typically
used as a smaller boilers that forms an integral part of vehicle; stationary
steam engines, industrial installation and power station will usually have a
larger separate steam generating facility connected to the point of use by
piping. A notable exception is the steam powered fireless locomotive,
where separately generated steam is transferred to the receive on the
locomotive. Thus our product is useful in power generation or electricity
producing companies.

Some chemical companies, such as petrochemical and other organic

chemical companies, need the boiler to heat or pressurize the surroundings
Chemical manufacturers primarily rely on natural gas, it also makes use of
diverse chemicals by-product that can be used as fuel, such as hydrogen or
other process or vent gases.Thus our product is also helpful in chemical
industries.

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176736

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2.2 Mind Mapping
A mind mapping is a powerful graphic technique which provides a universal key to
unlock the potential of the brain. It harnesses the full range of cortical skills-word, image,
logic, rhythm, color and spatial awareness–in a single, uniquely, powerful manner. Mind
mapping can be applied to every aspect of life where improved learning and clearer
thinking has to enhance human performance.

In our mind mapping canvas we have depicted the conditions before and after treatment
of boiler. Before treatment there were chances of explosion which led to disruption of the
safety of workers plus the excess wastage of fuel contributed to increase in the operating
cost. After treatment the boiler is safer to use, more reliable, has enhanced efficiency and
consumes less fuel for production of given amount of steam.

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 3. Empathy Canvas
3.1 User
Boiler is used to generate steam which is used for different processes such as heating, power
generation,sterilizing instruments etc. Industries that make use of boiler in one or the
other way in their operations include :
• Fertilizer Industry
• Steel Industry
• Refinery
• Sugar Industry
• Cement Industry
• Textile Industry
• Plywood Industry
• Rubber Industry
• Pulp and Paper Industry
• Food Industry
• Distilleries
• Dyers Industry
• Paint Industry
• Pharmaceutical Industry

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3.2 Stakeholders

Everything around the people impacts their lives in either a small or a big way.
Stakeholders are people, indirectly involved users, related to other users or in some other
way. Stakeholders can affect or affected by the organization’s activity, objectives and
policies. Some examples of key stakeholders are creditors, directors, employees,
government and its agencies, owners, suppliers, unions, and the community from which
the business draw its resources.

A company’s customers are entitled to fair trading practices but they are entitled to the
same consideration as the company’s employees. The stakeholders in the corporation are
the individuals and constituencies that contribute either voluntarily or involuntarily, to its
wealth creating capacity and activities, and that are therefore its potential beneficiaries
and risk bearers. The stakeholders in this case include :
• Boiler Designers
• Energy Engineers
• Hospitals
• Boiler Manufacturers
• Boiler Operated Industries

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 Boilers represent one of the hospital’s largest facilities related capital expenditures. They
are costly to purchase and expensive to operate, particularly as the cost of energy
continues to rise. Yet boilers, when properly sized, operated, and maintained, offer major
opportunities for hospitals to save energy resulting in financial and environmental
benefits. Companies have been manufacturing and offering different types of steam
boilers for hospitals over the past decades of years. For a small hospital, fire tube boiler,
are enough for the steam and heating. If it is supposed to power electricity for hospital
equipment, large water tube power plant boiler are much better.

3.3 Activities
Here in this case activities refers to the various unit operations, checks, manual settings ,unit
processes that we see in industries operated by boilers. These include :
*Sampling Of Feed Water :
The water before being fed into the boiler is sent for sampling where the
contents of the water are analysed. This analysis involves estimation of
dissolved salts ,gases, hardness causing ions , corrosion causing ions ,pH
measurement etc.
*Pre Treatment Of Boiler Feed Water :
This involves external treatment feed water before feeding it into the
boiler. This may include any of the following processes :
-Ion Exchange Process
-Lime Soda Process
-Zeolite-Permutit Process
-Reverse Osmosis

*Fuel addition and Burning

*Temperature Control
*Pressure Control
*Safety Analysis
*Water Level Check
*Steam Flow Rate Analysis

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*Internal Treatment Of Feed Water-
This involves addition of chemicals into the feed water to convert scale
and sludge causing water insoluble salts into harmless water soluble salts
or cause their precipitation and hence their removal as blowdown.
*Quantitative and Qualitative Analysis Of Steam Produced.
*Batch Efficiency Analysis
*Fuel By Product Disposal

Brief Description Of Feed Water Treatment :

Boiler water treatment is a type of industrial water treatment focused on
removal or chemical modification of substances potentially damaging to
the boiler. Varying types of treatment are used at different locations to
avoid scale, corrosion, or foaming. External treatment of raw water
supplies intended for use within a boiler is focused on removal of
impurities before they reach the boiler. Internal treatment within the boiler
is focused on limiting the tendency of water to dissolve the boiler, and
maintaining impurities in forms least likely to cause trouble before they
can be removed from the boiler in boiler blow down.

At elevated temperatures and pressures within a boiler, water exhibits

different physical and chemical properties than those observed at room
temperature and atmospheric pressure. Chemicals may be added to
maintain pH levels minimizing water solubility of boiler materials while
allowing efficient action of other chemicals added to prevent foaming, to
consume oxygen before it corrodes the boiler, to precipitate dissolved
solids before they form scale on steam-generating surfaces, and to remove
those precipitates from the vicinity of the steam-generating surfaces.

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3.4 Story Boarding
SAD
On visiting one of the boiler operated industries we were informed that the operations had
become inconsistent on account of scale and sludge deposition in the inner walls, tubings
and floors of the boiler. Scale and sludge deposition had led to the following problem:
1. Wastage of fuel- Scales have poor thermal conductivity, therefore the rate of heat
transfer from the boiler to water inside is greatly reduced. Hence extra heat is to
be supplied to the boiler thus increasing fuel consumption. Wastage of fuel
depends upon the thickness of scale.
2. Decrease in efficiency- Deposition of scale in the valve and condensers of the
boiler choke them partially. This result in the decrease in efficiency.
3. Lowering boiler safety- Due to scale formation which is poor conductor of heat,
the boiler is to be overheated in order to continue the supply of heat. Overheating
makes the boiler material softer and weaker. Therefore distortion of boiler tubes
take place and the boiler become unsafe to bear the pressure of steam.
4. Danger of explosion- Due to uneven expansion the thin layer cracks, as a result
the water comes in the contact with the overheated part of the boiler resulting in
excess steam formation which leads to boiler explosion.

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HAPPY
On providing various possible solutions and treatments we were glad to hear from them
that the amount of excess fuel consumed for a given amount of steam produced decreased
abruptly. Further methods incorporated for scale and sludge removal and disposal
ensured and guaranteed safety and prevention of disaster like explosion and distortion of
boilers gave the workers, laborers and operators a sigh of relief. All in all the
incorporations and up gradation led to increase in the operating efficiency.

15
16
 4. Ideation Canvas.

4.1 People
These include people who are direct users of our product or are affected by the product or
whose work involves effects of our product indirectly.
• QC & QA Manager
• Technician
• Boiler Designer
• R&D
• Production Manager
• Labourers

4.2 Activities
Doer Activity

QC & QA Manager Feed water sample analysis & qualitative

and quantitative analysis of steam
produced
Operator Setting boiler conditions

Laborers Sludge collection, boiler floor cleaning

Engineer Plant management & Water conditioning

Technician Repairing machinery

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4.3 Situation/Context/Location
We also observed particular or as in general activities occurring at place that might
affect our project in some or the other way. These include :
• Noisy environment.
• Steam leakage
• Distortion of boiler
• Suffocation
• Industrial Estate
• Easy waste disposal
• Scale and sludge formation
• Burning of fuel in large quantities
• Attainment of high temperature & pressure zones
• Handling of high energy content steam in bulk
• Transmission through pipelines and final use of steam for various utility

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4.4 Possible Solutions

• Changing material of construction : The pressure vessel of a boiler is usually made

of steel (or alloy steel), or historically of wrought iron. Stainless steel especially is not
used in wetted parts of boilers due to corrosion and stress corrosion
cracking.[3] However, ferritic stainless steel is often used in superheated sections that
will not be exposed to boiling water. Further material that doesn’t corrode under such
high temperature conditions can be developed.

• External Treatment Of Boiler Feed Water : This involves external treatment feed
water before feeding it into the boiler. This may include any of the following
processes :
-Ion Exchange Process
-Lime Soda Process
-Zeolite-Permutit Process
-Reverse Osmosis
• Internal Treatment Of Water : This basically involves addition of chemicals into
the feed water to convert scale and sludge causing water insoluble salts into harmless
water soluble salts or cause their precipitation and hence their removal as blowdown.
This may also include physical methods of treatment.

Chemical Methods Physical Methods

Phosphate Conditioning Radioactive cond.
Sodium meta-aluminate conditioning Electrical cond

Other corrosion prevention methods :

Corrosive compounds, especially O2 and CO2 must be removed,

usually by use of a de aerator. Residual amounts can be removed
chemically, by use of oxygen scavengers. Additionally, feed water
is typically alkalized to a pH of 9.0 or higher, to reduce oxidation
and to support the formation of a stable layer of magnetite on the
water-side surface of the boiler, protecting the material underneath
from further corrosion. This is usually done by dosing alkaline
agents into the feed water, such as sodium hydroxide (caustic soda)
or ammonia. Corrosion in boilers is due to the presence of dissolved
oxygen, dissolved carbon dioxide, or dissolved salts.

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Sludge and Scale disposal:

Deposits reduce the heat transfer in the boiler, reduce the flow rate
and water is evaporated must be removed, because they will
become concentrated in the liquid phase and require
excessive "blow-down" (draining) to prevent the formation of solid
precipitates. Even worse are minerals that form scale. Therefore,
the make-up water added to replace any losses of feed water must
be de mineralized/de ionized water unless a purge valve is used to
remove dissolved minerals.

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21
 5 Product Development Canvas

5.1 Purpose

Following are the main purposes of boiler treatment:

1. To systemize the process.
2. To remove dissolved gases such as oxygen from the water.
3. To control sludge formation, thus preventing carry over into system.
4. To determine the amount of impurities thus determining the amount of treatment
required.
5. To maintain and provide residual residual reserve of chemicals.
6. To improve efficiency thus increasing boiler life.
7. For economical operation of boiler.
8. To exercise careful control over boiler treatment chemicals.
9. Prevent scale formation in the boiler.
10. To prevent corrosion in the boiler feed system by maintaining the boilers water
alkalinity.

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5.2 People

These include people who are direct users of our product or are affected by the product or
whose work involves effects of our product indirectly.

1. QC & QA Manager
2. Technician
3. Boiler Designer
4. R&D
5. Production Manager
6. Laborers

5.3 Product Experience And Functions

After using our product the customer are feeling convenient. They are satisfied by our
easy handling. Moreover the relaxation on customer’s face is defining their experience.
On providing various possible solutions and treatments we were glad to hear from them
that the amount of excess fuel consumed for a given amount of steam produced decreased
abruptly. Further methods incorporated for scale and sludge removal and disposal
ensured and guaranteed safety and prevention of disasters like explosion and distortion
of boilers gave the workers, labourers and operators a sigh of relief. All in all the
incorporations and up gradations led to increase in the operating efficiency.

23
5.4 Product Features

The following are the features of the boiler that follows our methods and specs :

1. The boiler is having maximum steam generation rate with minimum

fuel consumption.
2. It can be started or stopped quickly.
3. Its initial cost, running and maintenance cost is not high.
4. Its erection time is less, and its parts are easily dismountable.
5. The boiler is having positive controls and safety apparatus.
6. It is having a high rate of heat transfer and better combustion efficiency.
7. It is able to accommodate the load variation.
8. It occupies less floor space.
9. It is trouble free and require less attention and less maintenance.
10. It is free from manufacturing defects.
11. Mud does not get deposited on the heating surface. Soot or scale is not be
deposited on the tubes.
12. All parts of the boiler is accessible for cleaning and inspection.
13. It is conform to Indian Boilers Regulations Acts.
14. Able to deliver steam with high dryness fraction.
15. Correctly sized.
16. It is equipped with safety interlocks.
17. It is energy efficient.
18. It is easy for maintenances and inspections.
19. It is truly packed and easy to install.
20. It is equipped with a good burner.
21. It is having high quality accessories installed properly.

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 22. It is equipped with online monitoring and blowdown control system.
23. It is having correct engineering design.

5.5 Components

Objects or components here refer to the things(equipments,mountings,accessories etc.)

used in the boiler operated industries.

Accessories

Boiler accessories are those components which are installed either inside or
outside the boiler to increase the efficiency of the plant and to help in the proper
working of the plant.

1. Air Pre heater - It is a waste heat recovery device in which the air to on
its way to the furnace is heated utilizing the heat of exhaust gases/flue
gases. The function of air pre-heater is to increase the temperature of air
before enters the furnace. It is generally placed after the economizer so the
flue gases passes through the economizer and then to the air preheater. An
air-pre heater consists of plates or tube with hot gases on one side and air
on the other. It preheats to be supplied to the furnace. Preheated air
accelerates the combustion and facilitates the burning of coal.
2. Economizer - It is a device in which the waste heat of the flue gases is
utilized for heating the feed water. To recover some of the heat being

25
 carried over by exhaust gases, this heat is used to raise the temperature of
feed water supplied to the boiler.
3. Super heater – It increases the temperature of steam, generated by boiler,
above its saturation point. It is done to reduce the losses due
to condensation and to reduce the steam consumption by the turbine.

Mountings

Boiler mounting are the component which are mounted on the surface of the
boiler to have safety during operation. These are the essential part of the
boiler, without which the boiler function is not done.

Some of them are water level indicator, safety valve, pressure gauge, steam
stop valve, main hole, feed check valve.

26
5.6 Customer Revalidation

After using our product the customers have had many revalidations .Some of the
customers have a problem with the design of the boiler. They are facing a problem in
installing the boiler in their company. The large space that it occupies is one of the major
problems. It is very difficult to install the mountings and accessories over boiler surface
on account of its material is the complaint of certain types of industries. Some of them
feel that it is very economic and that its material suits their purpose while some feel the
opposite. The main problem which arises while using our product is that is gives lesser
efficiency than required though being economic in some cases. This is one of the main
issues that we have identified with and we are ready to redesign the boiler with enhanced
specs so that the above mentioned issues are solved.

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5.7 Reject, Redesign And Retain

REJECT : The boiler is giving lesser efficiency in some cases where foaming,
priming and caustic embrittlement on account of contaminants in the feed water are
frequent therefore we should work on the specs that solve this discrepancy .

REDESIGN:-Some customers have issue with the boiler design therefore we should
be ready with a redesign of the boiler with specs that make it easy to install. Also we
need to provide certain spaces over the boiler surface to allow easy installation of
mountings and accessories. Also we need to decrease the boiler floor space for some
customers. Most of our customers use Lime Soda for external treatment of feed
water. The excess sodium carbonate in case of Lime Soda process undergoes
decomposition in high pressure boilers leading to formation of NaOH.

Na2CO3 + H2O 2NaOH + CO2

Further ,the most common measure to prevent foaming and priming is to maintain
the concentration of solids in the boiler water at reasonably low levels. Avoiding
high water levels, excessive boiler loads, and sudden load changes also helps. Very
often contaminated condensate returned to the boiler system causes carry-over
problems. In these cases the condensate should be temporarily wasted until the
source of contamination is found and eliminated. The use of chemical anti foaming
and anti priming , mixtures of surface-active agents that modify the surface tension
of a liquid, remove foam and prevent the carry-over of fine water particles in the
stream, can be very effective in preventing carry-over due to high concentrations of i

RETAIN :- We should definitely retain some of the short run economic aspects of
the boiler. For some customers the boiler material has fit their purpose economically
and keeping in mind these short term economic aspects we should bring about some
more modifications for their sustenance in the long run.

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6 Learning Needs Matrix Canvas

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 7 References
1. Engineering Chemistry : Fundamentals And Applications By Shikha Agarwal
(Cambridge University Press)
2. Elements Of Mechanical Engineering By H.G. Katariya , J.P Hadiya , S.M. Bhatt

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