`

Ethiopian Institute of Technology - Mekelle

Department of Mechanical Engineering

Energy Management of a Boiler

By
Fissha Tsegay

Supervisor
Petros Gebray

Hosting Company:

Department of Mechanical Engineering

Mekelle
October 2011

Acknowledgement

1
It is difficult to acknowledge every individual who contributed valuable efforts when I did this
project, but it is worth mentioning some of them. First, I would like to thank my advisor Petros
Gebray for their invaluable advises and putting this project in to reality from scratch. I would
like also to thank Mr Dawit A. who is my supervisor, for his assistant in practical experience and
supplying necessary data to make the report complete.

Lastly, I would like to thank my friend Grimy Tsegazab for helping me by giving some sort of
information while doing my project.

Table of Contents
Acknowledgement 2

2
 CHAPTER ONE..............................................................................................................................4
1. Company profile..................................................................................................................4
1.1 Company Background............................................................................................................4
1.1 Company Production.......................................................................................................5
1.2 Main Products..................................................................................................................5
1.3 Main Customer................................................................................................................7
1.4 General Workflow of the Company.................................................................................7
1.6 Benefits of the internship 12
CHAPTER TWO 13
2. Project on Energy Management of boiler 13
2.1 Introduction...................................................................................................................13
2.2 Objective........................................................................................................................14
2.3 Motivations....................................................................................................................14
2.4 Problem of Statement...................................................................................................15
2.5 Significance of study......................................................................................................16
CHAPTER THREE 17
3.1 Methodology.................................................................................................................17
3.2 Literature review...........................................................................................................17
3.3 Heat loss and scaling in the boiler.................................................................................18
3.4 Methods of how to minimizing heat loss......................................................................28
3.5 De Scale..........................................................................................................................29
3.6 Cost analysis of fuel before de scale.............................................................................30
3.7 Chemical de scaling by hydrochloric acid......................................................................31
3.8 Cost analysis of fuel after de scale.................................................................................32
CHAPTER FOUR 34
4.1 Conclusions....................................................................................................................34
4.2 Recommendation..........................................................................................................34
Reference 35
Appendix 36

3
 CHAPTER ONE

1. Company profile

1.1 Company Background

Sheba Leather Industry plc is Feasibility study to establish the tannery completed in 1993.with
Initial capital was 94 million Birr under EFFORT with total production area of nearly 1720m2,
Sheba leather industry plc is furnished with new, state of-the-art production equipment and
machines acquired from the most respected companies/factories in the world wide leather
industry. The flexible and superior technological capacity we have, coupled with our highly
committed work force, gives us leverage to achieve our objectives and successfully compete in
the global market.
Our factory, on the outskirts of leather, is ideally situated for national and international
communication.
This web site allows us to deliver our goods on time to local and international customers.

Mission
To provide best leather products to the international market through maximum utilization of the
country’s hides & skins with continuous generation of wealth to the share holders thereby
contribute its share to the regional & national economy

Vision
Branded foot wear and glove to the international market by 2019.
Our vision is to become an exemplary organization in both the local and international leather
&leather production (shoe) market.
Exemplary in the sense that Sheba leather industry will be noted for;
 High quality products and services
 Value in return for money invested
 On time deliver
 Integrity
 Respect and dignity for employees
 Profitability
Strategy
 Develop one stop, shop marketing
 Continuously engage in employee and product development

4
  Invest continuously on advanced technology where practical and economical
 In calculate cost consciousness without compromising product excellence
 Give priority to understand customers needs and meet their specific
requirements
 Develop team spirit and sense of ownership
 Embrace open lines of company-wide communication
Core Values
• Customer first
• Loyalty
• Learning culture
• Commitment
1.1 Company Production

Sheba leather industry PLC produces both finished leather & shoe. It is designed to produce
women (with>10 modal) hose and gents shoe (with 10 modal), its designed different type of shoe
linae.
Sheba leather industry, Started production of pickle and Wet Blue Goat Skin on April 1, 2004
virtually for export. Undertaking an expansion project worth birr 300 million with the ultimate
objective of producing finished leather and leather articles
The project is divided into two phases i.e. project phase I, shoe production; project phase II is
tannery

1.2 Main Products

 Shoe: the following shoe linea type
 Carla
 Poul
 Carmen
 Rosy
 Venice
 John
 Janie
 Lucy
 Paric
 Lory
 Gilda
 Mart

 Tannery
 Lining
 Garment

5
  Upper(hayed)
 Glove
 Sade
And generally, the industry is under operation the 81 and finishing plant. It has
630.employees.those employers 152employees in tanner, 256employees and other
Employees work in different department like in HRD, marketing, engineering service, in
finance, and general marketing etc...

Figure 1: shoes of the company

Figure 2: over head drear

6
 1.3 Main Customer

They have local and global customers of shoe and tannery

 Local customer of shoe:
 Tigray sales shop (out let)
 Addis Ababa agent -Addis Ababa
-Debrebirhan
-Hawasa
 Global customer of shoe:
 Franc (salamander)
 Sweden (tiger of Sweden)
 Italy (dyag)
 Local customer of tannery;
 Tigray -Adama garment in Adwa
- Gelila
 Addis Ababa -Mercato
-Tikur Abay
-Anbesa shoe industry

1.4 General Workflow of the Company

In Sheba leather industry all the required type and amount of production is controlled (planed) by
the planning department (planers).the planners are ordered to each area of production how
amount and what type are they to produce according their capacity and plane.
The production process is starting from selection department in which the input or the raw
material like sheep, goat and hide skins are changing from arrival of sheep, goat and hide skins
to finishing leather. From this product some of the product is marketing directly and the other
product is goes to the next processes. The next process is shoe making process. In this area the
finishing leather is changed to different type of shoo in production department. In shoo
production department the following General sequence of shoe making process is takes place:
1. Raw material Store
2. Cutting section-cut component
3. Upper preparation, where cut components ,are treated ,conditioned and
marking
4. Bottom preparation
5. Lasting/Assembling Section
6. Finishing and Packing Section
The Finished shoes store The next process is in finishing department is making shoo in different
line type like Carla,Poul,Carmen,Rosy,Venice,John,Janie,Lucy,Paric,Lory,Gilda,Marta

 Quality of the production is checked at every process or at each area of

production.
 ``?”Marketing also takes place at any time and area of production
according the customers demand.
Generally the overall work flow of the company is summarized as follow:

7
 Marketing

Tannery

Input(Raw material) Finishing leather Shoe production Assembling section Shoe

Quality
Planning (planer)

Figure 3: genera work flow of the company

8
 Hide Process Flow
Arrival of Hide
Trimming
Soaking - (22hrs)
Liming - (20hrs)
Fleshing
De-liming
Pickling & Tanning - (18hrs)
Pilling
Splitting
Sizing & Grading
Packing
Storage

Sorting Atonado Products

White Back Embossing
Shaving
Shaving
Crust Upper Re-tanning & Dying - (18hrs)
Re-tanning - (19hrs)
Pilling Shaving Pilling
Setting out Re-tanning & Dying - (20.5hrs) Setting Out
Vacuum drying Pilling Vacuum
Over Head drying Setting Out Over head drying
Vacuum Drying Vibratory Staking
Vibratory Stacking
Over Head Drying
Trimming Trimming
Vibratory Staking
Grading (Only Reject) Grading
Trimming
Thickness Checking Thickness
Grading
Rotter coater Spraying
Thickness
Spraying Hair Cell Print
Area Measuring
Embossing Grading
Packing
Spraying Thickness
Selection Area Measuring
Thickness
Packing
Area Measuring
Packing

Table 1 hide skin process

9
 Goat Process Flow
Arrival of Goat Skin
Trimming
Soaking - (18hrs)
Liming - (20hrs)
Fleshing
De-liming 18h
Pickling &tanning rs
Pilling
Sizing
Grading
Packing
Storage

G.C.S Upper & Lining Sorting Dyed Goat Lining

Finished Goat Suede Upper Samming

Re-tanning - (21hrs)
Shaving
Pilling Re-tanning - (21hrs)
Re-tanning & Dyeing - (9hrs)
Sam -Setting Pilling
Pilling
Over head drying Sam -Setting
Vibratory Saking Over head drying
Sam-Setting
Rotary Staking Vibratory Saking Vacuum drier
Trimming Rotary Staking Over head drier
Buffing Trimming Vibratory Staking
Dedusting Buffing Rotary Staking
Thickness Dedusting Trimming
Sizing Dyeing - (20hrs) Thickness
Selection Pilling Sizing
Area Measuring Sam-Setting Selection
Packing Over Head Drier
Area Measuring
Condition
Table 2: goat skin process flow Dry Milling (6hrs) Packing
Toggling
Trimming
Thickness
Sizing 10
Selection
Area Measuring
 Sheep Process Flow
Arrival of Sheep Skins
Trimming
Soaking
De-wooling & Liming
Fleshing
De-liming
Pickling
Pilling
Sizing
Grading
Packing
Storage

Napa soft Tanning Sorting Sheep Upper

Pilling Military
Sheep Upper Praga Pilling
Samming
Pilling Samming
Shaving
Samming Shaving
Re-tanning Re-tanning & Dying - (24hrs)

Pilling Shaving Re-tanning&dying

Re-tanning & Dying - (24hrs)
Sam-Setting Sam-Setting
Re-tanning - Pilling
(19hrs) Sam-Setting Pilling
Pilling
Sam-Setting Over head drier Vibratory Staking
Vacuume
Over head drier Vibratory Staking
Over head drier
Vibratory Staking Rotary Stacking
Rotary Stacking Rotary Stacking
Trimming
Trimming Trimming
Toggling
Buffing
Buffing
Dedusting Buffing
Dedusting
Thickness
Thickness Dedusting
Sizing
Selection Sizing Thickness
Selection
Out put Napa Sizing
soft Natural Area Measuring
Crust
Vibratory Staking Packing Selection
Dyeing (18.5hrs) 11
Area Measuring
Pilling
Packing
Sam-setting
Rotary Staking Toggling Sizing Thicknes Selection Area Measuring Packing
 Table 3: sheep skin process flow

1.6 Benefits of the internship

I have gained theoretical knowledge and practical skill:

Theoretical knowledge on
 General knowledge of laws, codes, regulations, and procedures governing the boiler
industry.
 General knowledge of boiler combustion, i.e., fuel/air mixtures, etc.
 General knowledge of non-destructive testing procedures.
 General knowledge of welding procedures.
 General knowledge of personal safety in workplace procedures.
 Basic knowledge of boiler water chemistry, blow down procedures, etc.
Practical skill on
 Skill in recognizing non compliance and procedural irregularities.
 Skill in reading boiler plans, shop drawings, and diagrams.
 Steam Insulation
 Steam Trap Maintenance Program
 Steam System Critical Parameter Measurements
 Steam System Operating Practices
 Boiler Plant Operating Practices
 General Boiler Operation

Team work
Engineering is not a one man task it needs a cooperative mind which colleagues working around.
Here the other knowledge, I get from this program is team work place to work to gather in team
work by binge hand and glove exams one archives more.

Leadership
The other knowledge gained from this internship program is leader ship knowledge. During my
stay in Sheba leather industry I observe how a boss can work a conduct which its seniors
employer under his area in way of commanding in work task solving employment problem
selected which the work.

12
 CHAPTER TWO

2. Project on Energy Management of boiler

2.1 Introduction

Boiler is a closed vessel in which water is heated, steam is generated, superheated or any
combinations thereof under pressure or vacuum by the direct application of heat. in another
words boiler is heat from composition to be transferred in to the working media ( exchanger b/n
water and fire)
Steam generating unit defined as “a combination of apparatus for producing furnishing or re
covering heat together with the apparatus for transferring the heat made available to the fluid
being heat vaporized’’
There are two main types of boiler when considering the heat transfer means from gas to feed
water:
1. Fire tube boiler: - A type of boiler design in which combustion gases flow inside the tubes
and water flows outside the tubes.

Figure 4 Fire tube boiler

2. Water tube boiler:

A tube in a boiler having the water and steam on the inside and heat applied to the outside.
From the two type of boiler Sheba leather industry uses widely fire tube boiler. Energy crisis
as well as high cost of fuel energy in boiler results un proper uses of boiler tubes. Because,
specially, the Sheba leather industry retains a record of a lowest efficiency in energy
utilization it causes in sufficient energy managements on the boiler.
Energy management by definition total cost of energy consumption compared to total
export of the company. It’s depending on performance of the boiler. Most of the time %of
energy management of profitable company is<3% but in Sheba leather industry %of energy
management is almost 7%.

13
 Less % of energy management is our purpose since it leads to substantial saving of time and
fuel for the company.

Good energy management is an essential step we can all take towards overcoming the
mounting problems of the worldwide energy crisis and environmental degradation. In
particular, developing countries are interested to increase their awareness on the inefficient
power generation and energy usage in their countries. However, usually only limited
information sources on the rational use of energy are available. The know-how on modern
energy saves and conservation technologies should, therefore, be disseminated to
governments and industrial managers, as well as to engineers and operators at the plant level
in developing countries. It is particularly important that they acquire practical knowledge of
the currently available energy management’s technologies and techniques.
Less %tag of energy management boiler have the following advantages over high %tag of
energy management boiler
Cost effective
Minimize excess fuel consumption of the boiler,
Minimize excess consumption of the time,
Have comparatively long life,
Operate at comparatively high efficiency,

2.2 Objective

Main Objectives and goals

 To modify energy management of boiler and to save higher fuel consumption in Sheba
Leather Industry
Specific Objectives and goals
I have 3 major goals in this boiler project, these are
Goal1: Reduce the heat loss in the boiler
Goal2: reduce scaling in the boiler (descale)
Objective2.1chemicl cleaning of an industrial boiler
Goal 3: reduce smoking dust present in the internal body of the fire tub

Generally Objectives of boiler are

To release the energy in the fuel as efficient as possible.
To transfer the released energy to the water, and to generate steam as efficient as possible.
To separate the steam from the water ready for export to the plant, where the energy can be
transfer to the process as efficient as possible.

2.3 Motivations
 To save higher fuel consumption by using a energy management boiler.
 I have a higher interest doing on energy management boiler.
 I have an interest on thermodynamic of boiler.

14
 2.4 Problem of Statement

Energy is one of the most important ingredients in any industrial activities. However, its
availability is not infinite. Global energy crisis, as well as high cost of fuel resulted in more
activities to conserve energy to maximum extent. The Sheba leather industry retains a record of
the lowest efficiency in energy utilization and is one of the major energy consuming industrial.
Power dominates consumption pattern in boiler steam power plant, while thermal energy is
major for tannery process.

The major problems of boiler and energy managements are heat loss, smoking dust present in the
internal body of the fire tub and scaling in the boiler. It is a series problem which exists in the
steam power plant of boiler and affects the energy management by excess fuel and time
consumption. Good steam boiler should possess high seam production rate, capable of quick
starting, absolutely reliable cost effective and no excess fuel and time consumption. Solving
those major problems make the company profitable.
Energy management in leather industry can be affected, in leather production, through processes
& machine modification, proper chemical cleaning & other energy management technologies
such as;
 Improvement of scaling on the fire tube
 Improvement in efficient fuel use
 Improvement in efficient use of steam
 Chemical cleaning
 Using of measuring instrument & automatic control

But in Sheba leather industry the above energy management technologies are not properly in
use. And it is steal a problem in the industry due to the absence of these energy management
technologies in the camp any there is;
o High energy consumption
o Un scheduled working of the machine
o Loss of energy due to different type of heat loss

Energy saving is an operation to grasp the actual situation of energy use in a factory precisely
and quantitatively and to carry out improvement measures in order to rationalize and economize
on it. But this is also a problem in this factory.

15
2.5 Significance of study
 To use less %of energy management boiler in sated of high %of energy management
boiler.
 To save leather Factory’s higher fuel consumption of boiler.
 To develop my knowledge in areas relating to the theory of operation, safe practices,
controls, repairs, maintenance, water chemistry and local jurisdictional requirements.
 To change my knowledge to practical skill.
 To study energy management of the company.
 To save Sheba leather industry higher fuel &time consumption of boiler.
 To develop my knowledge in designing of heat loss in the boiler.
 To change my theoretical knowledge to practical skill.
 To know the solution of heat loss in the boiler.

16
 CHAPTER THREE

3.1 Methodology

In my project I ‘am going to use both primary and secondary data sources.
Among the primary sources:

 Interview
 Visual Observation
 Observation the manual computer of marshal boiler

A. Data Collection
Data’s were collected from
 Documentation
 Questionnaires
 Tables
 Books
 Computers

B. Sampling

Sampling was used to take small data from the collected data’s. This sampling must be based on
the theoretical knowledge and interpretations of the data according to the study.
By gathering the input data from the Sheba leather, calculating the analysis of a boiler power
plant.
By considering the heat losses mechanisms.
By considering the effective energy management on the boiler.

C. Data Analysis

In this project simple analysis were used to calculate all the unknown data’s using different
formulas based on the definitions and specifications of energy analysis.

3.2 Literature review

To assist with the completion of this project, a comprehensive literature review of the
Mechanical Engineering topics which were essential to the development of this study was
conducted. Focused areas of research review included: energy managements of boiler, fuel
consumption, and Controls, and Engineering Economics. Further, appropriate topics of Energy
Efficiency and Energy managements were needed for this project, and in turn were introduced
and studied within this literature review.

17
 3.3 Heat loss and scaling in the boiler

Heat loss; Performance of the boiler, like efficiency and evaporation ratio reduces with time, due
to poor combustion, heat transfer fouling and poor operation and maintenance. Deterioration of
fuel quality and water quality also leads to poor performance of boiler. Efficiency testing helps
us to find out how far the boiler efficiency drifts away from the best efficiency. Any observed
abnormal deviations could therefore be investigated to pinpoint the problem area for necessary
corrective action. Hence it is necessary to find out the current level of efficiency for performance
evaluation, which is a pre requisite for energy conservation action in industry.

In Sheba leather industry the following type of heat loss are takes place
A. Loss due to dry flue gas (sensible heat)
 Heat loss due to dry flue gas
This is the greatest boiler loss and can be calculated with the following formula:

L1 = m*Cp*(Tf-Ta)

Where,
L1 = % Heat loss due to dry flue gas
m = Mass of dry flue gas in kg/kg of fuel
= Combustion products from fuel: CO2 + SO2 + Nitrogen in fuel +
Nitrogen in the actual mass of air supplied + O2 in flue gas.
(H2O/Water vapour in the flue gas should not be considered)
Cp = Specific heat of flue gas in kCal/kg
Tf = Flue gas temperature in oC
Ta = Ambient temperature in oC

Note-1: Simple method can be used for determining the dry flue gas loss as given below.
a) Percentage heat loss due to dry flue gas = m*Cp*(Tf-Ta)
Total mass of flue gas (m)/kg of fuel = mass of actual air supplied/kg of fuel + 1 kg of
Note-2: Water vapour is produced from Hydrogen in fuel, moisture present in fuel and air during
the combustion. The losses due to these components have not been included in the dry flue gas
loss since they are separately calculated as a wet flue gas loss.

B. Loss due to hydrogen in fuel (H2)

 Heat loss due to evaporation of water formed due to H2 in fuel
The combustion of hydrogen causes a heat loss because the product of combustion is water.
This water is converted to steam and this carries away heat in the form of its latent heat.

18
 L2 = 9*H2*{584+CP(Tf-Ta)}
Where
H2 = kg of hydrogen present in fuel on 1 kg basis
Cp = Specific heat of superheated steam in kCal/kgoC
Tf = Flue gas temperature in oC
Ta = Ambient temperature in oC
584 = Latent heat corresponding to partial pressure of water
vapor

C. Loss due to moisture in fuel (H2O)

 Heat loss due to moisture present in fuel

Moisture entering the boiler with the fuel leaves as a superheated vapor. This moisture loss is
made up of the sensible heat to bring the moisture to boiling point, the latent heat of evaporation
of the moisture, and the superheat required burin this steam to the temperature of the exhaust gas.
This loss can be calculated with the following formula:

L3 = M*{584+CP(Tf-Ta)}
Where
M = kg of moisture in fuel in 1 kg basis
Cp = Specific heat of superheated steam in
kCal/kgoC
Tf = Flue gas temperature in oC
Ta = Ambient temperature in oC
584 = Latent heat corresponding to partial pressure
of water vapor

D. Loss due to moisture in air (H2O)

 Heat loss due to moisture present in air
Vapour in the form of humidity in the incoming air, is superheated as it passes through the
boiler. Since this heat passes up the stack, it must be included as a boiler loss.

To relate this loss to the mass of coal burned, the moisture content of the combustion air and the
amount of air supplied per unit mass of coal burned must be known.

The mass of vapor that air contains can be obtained from psychometrics charts and typical values
are included below:

19
 Dry- Wet Relative Kilogram water per Kilogram dry air (Humidity
Bulb Bulb Humidity Factor)

Temp oC TempoC (%)

20 20 100 0.016
20 14 50 0.008
30 22 50 0.014
40 30 50 0.024

L4 =AAS*Humidity
factor*CP(Tf-Ta)}
where
AAS = Actual mass of air supplied per kg of fuel
Humidity = kg of water/kg of dry air
factor
Cp = Specific heat of superheated steam in
kCal/kgoC
Tf = Flue gas temperature in oC
Ta = Ambient temperature in oC (dry bulb)

E. Loss due to carbon monoxide (CO)

 Heat loss due to incomplete combustion:
Products formed by incomplete combustion could be mixed with oxygen and burned again with a
further release of energy. Such products include CO, H2, and various hydrocarbons and are
generally found in the flue gas of the boilers. Carbon monoxide is the only gas whose
concentration can be determined conveniently in a boiler plant test.

%CO*C/(%CO+%CO2)*5744Kcal/kg
L5 =
L5 = Heat loss due to partial conversion of C to CO
CO = Volume of CO in flue gas leaving economizer (%)

20
CO2 = Actual Volume of CO2 in flue gas (%)
C = Carbon content kg / kg of fuel
or
When CO is obtained in ppm during the flue gas analysis
CO formation = CO (in ppm) x 10-6 x Mf x 28
(Mco)
Mf = Fuel consumption in kg/hr
L5 = Mco x 5744*
* Heat loss due to partial combustion of carbon.

F. Loss due to surface radiation, convection and other unaccounted.

 Heat loss due to radiation and convection:
The other heat losses from a boiler consist of the loss of heat by radiation and convection from the boiler
casting into the surrounding boiler house. Normally surface loss and other unaccounted losses is
assumed based on the type and size of the boiler as given below:
For industrial fire tube / packaged boiler = 1.5 to 2.5%

For industrial water tube boiler = 2 to 3%

For power station boiler = 0.4 to 1%

However it can be calculated if the surface area of boiler and its surface temperature are known
as given below:

L6 = 0.548 x [ (Ts / 55.55)4 – (Ta / 55.55)4] + 1.957 x (Ts – Ta)1.25 x

sq.rt of [(196.85 Vm + 68.9) / 68.9]
where
L6 = Radiation loss in W/m2
Vm = Wind velocity in m/s

21
 Ts = Surface temperature (K)
Ta = Ambient temperature (K)

Heat loss due to unburned carbon in fly ash and bottom ash:

Small amounts of carbon will be left in the ash and this constitutes a loss of potential heat in the
fuel. To assess these heat losses, samples of ash must be analyzed for carbon content. The
quantity of ash produced per unit of fuel must also be known.

G. UN burnt losses in fly ash (Carbon)

 Heat loss due to un burnt in fly ash.
L7=Total ash collected/kg of fuel burnt x G.C.V of fly ash

I.Un burnt losses in bottom ash (Carbon)

 Heat loss due to un burnt in bottom ash
L8=Total ash collected/kg of fuel burnt x G.C.V of bottom ash

Total amount of heat loss in the boiler

The following parameters need to calculate the amount of heat loss in the boiler.

a) Flue gas analysis

1. Percentage of CO2 or O2 in flue gas

2. Percentage of CO in flue gas
3. Temperature of flue gas

b) Flow meter measurements for

1. Fuel
2. Steam
3. Feed water
4. Condensate water
5. Combustion air

c) Temperature measurements for

1. Flue gas
2. Steam
3. Makeup water
4. Condensate return
5. Combustion air
6. Fuel

22
7. Boiler feed water

d) Pressure measurements for

1. Steam
2. Fuel
3. Combustion air, both primary and secondary
4. Draft
e) Water condition

Conversion formula for proximate analysis to ultimate analysis

%C = 0.97C+ 0.7(VM+0.1A) - M(0.6-0.01M)

%H2 = 0.036C + 0.086 (VM -0.1xA) - 0.0035M2 (1-
0.02M)
%N2 = 2.10 -0.020 VM

where C = % of fixed carbon

A = % of ash
VM = % of volatile matter
M = % of moisture

data collected from a marshal boiler using furnace oil as the fuel in Sheba leather industry.
Find out the boiler total energy lost in kCal/kg.

Ultimate analysis
(%)

Carbon = 84
Hydrogen = 11

23
Nitrogen = 0.0
Oxygen = 0.5
Sulphur = 3.5
Moisture = 0.5
GCV of fuel = 10000 kCal/kg
Fuel firing rate = 2648.125 kg/hr
Surface = 40 oC
Temperature of
boiler
Surface area of = 90 m2
boiler
Humidity = 0.025 kg/kg of dry air
Wind speed = 3.02 m/s

Flue gas analysis

(%)

Flue gas = 360oC

temperature
Ambient = 26o C
temperature
Co2% in flue gas by = 10.8
volume
O2% in flue gas by = 7.4
volume

a) Theoretical air =
kg/kg of fuel.
required
[from fuel analysis]

= [(11.6 x 84) + [{34.8 x (11– 0.5/8)} + (4.35 x 3.5)] / 100

= 13.198 kg/kg of oil

b) Excess Air =
supplied (EA)
[from flue gas analysis]

24
 =

= 54.4 %
c) Actual mass of = {1 + EA/100} x theoretical air
air supplied/ kg of
fuel (AAS)
= {1 + 54.4/100} x 13.1985
= 20.3784 kg / kg of fuel
Mass of dry flue = Mass of (CO2 + SO2 + N2 + O2) in flue gas + N2 in air we are
gas supplying.

Mass of dry flue = 0.84x44 +0.035x64 +0+7.4x23/100+21.49x77/100

gas 12 32

= 20.3784 kg / kg of oil

Heat loss in dry flue = m*cp*(Tf-Ta)

gas L1 Total mass of flue gas (m) = mass of actual air supplied
(ASS)+ mass of fuel supplied
= 21.49 + 1=22.49

= 22.49*0.23*(360-26)

25
 = 1727.818 kCal/kg

Heat loss due to =9*H2*{584+CP(Tf-Ta)}

evaporation of =9*0.11*{584+0.45(360-26)
water due to H2
in fuelL2
=926.957 kCal/kg

Heat loss due =M*{584+Cp(Tf-Ta)}

to moisture in
fuelL3

=0.005*{584+0.45(360-26)

=3.6715 kCal/kg

Heat loss due to moisture in airL4 =AAS*humidityfactor*{CP(Tf-Ta)}

=21.36*0.025*0.45*(360-26)

=178.356 kCal/kg

Radiation and = 0.548 x [ (Ts / 55.55)4 – (Ta / 55.55)4] + 1.957 x (Ts – Ta)1.25
convection loss (L6) x sq.rt of [(196.85 Vm + 68.9) / 68.9]
= 0.548 x [ (313 / 55.55)4 – (299 / 55.55)4] + 1.957 x (353 –
303)1.25 x sq.rt of [(196.85 x 3.02 + 68.9) / 68.9]

= 1303 W/m2
= 1303 x 0.86
= 1120.58 kCal / m2

26
Total radiation and = 1120 .58 x 90 m2
convection loss per hour
= 100852.2 kCal
=2648.125

= 100852.2kCal
2648.125kg

= 38.2345kCal/kg
Normally it is assumed as 0.5 to 1 % for simplicity

Summary of Heat Balance for the Boiler Using Furnace Oil

Input/output Parameter kCal / kg of furnace oil %Loss

Heat Input = 6390 kCal/kg 100

Losses in boiler :
1. Dry flue gas, L1 = 1727.818 kCal/kg
2. Loss due to hydrogen in fuel, L2 = 926.957 kCal/kg

27
 3. Loss due to Moisture in fuel, L3 = 3.6715 kCal/kg

4. Loss due to Moisture in air, L4 = 178.356 kCal/kg

5. Partial combustion of C to CO, L5 = 0 0
6. Surface heat losses, L6 = 38.2345 kCal/kg

Total heat loss=L1+L2+L3+L4+L5+L6 = 1727.818 kCal/kg + 926.957 kCal/kg +3.6715

kCal/kg + 178.356 kCal/kg +38.2345 kCal/kg=2875.0365 kCal/kg

From the above analysis 55% heat is lost. There for we can minimize those heat losses by
different mechanism .b/se good boiler management is the following advantages:

 ADVANTAG OF GOOD BOILER MANAGEMENT

The qualities of a steam champion may be best described by an overview of his or her
managerial functions and concerns. The steam champion’s major activity groups are discussed in
the sections that follow. These include:
1. Performance management: the strategic evaluation of plant functions relative to industry
peers or benchmarks.
2. Operations management: the identification and implementation of maintenance and operations
processes that ensure reliable steam output.
3. Personnel management: the employ and development of human resources as needed to
perform system operations.
4. Business management: the analysis and communication of steam system performance in
relation to business priorities and goals.
5. Planning: the anticipation of changes in the business environment, including new
technologies, regulations, market conditions, and human resource issues.

3.4 Methods of how to minimizing heat loss

With the rising cost of fuel prices, industries that use steam boilers for heating or power generation are
hard pressed to operate at peak efficiencies.
While steam consumption, leakages, and other heat transmission losses can contribute to the overall
energy bill, this article focuses on the heart of the steam generator - the boiler. Controlling the boiler is
utmost importance in any steam generation energy saving program. Below are some ways to minimize th
above heat loss:

1. Reducing excess air

2. Installing economizer
3. Reducing scale and deposits
4. Reducing blow down
5. Recovering waste heat from blow down

28
 6. Stopping dynamic operation
7. Reducing boiler pressure
8. Operating at peak efficiency
9. Preheating combustion air
10.Switching from steam to air atomization
11.Switching to lower cost fuel

3.5 De Scale

Scale on boiler: the scale is main problem of heat loss in the boiler by increasing thickness of
fire tub. During scaling over the fire tub decrease heat transfer from the fire tub to water. The
scale is then analyzed using several different techniques in order to determine its composition.
The scale density is determined gravimetrically after dissolution of scale in inhibited HCl The
nee d to clean is based on the scale density. In Sheba leather industry the scale density is
85mg/cm2 .this is high density scale and it needs chemical clean within three months. But in
Sheba leather industry can’t use chemical clean uses wire brush for de scaling the internal part of
the fire tub, and remove the external part of the fire tub by hammer. For example in heat
exchanger mouth of the boiler. It is not good for the boiler life. It can’t work properly for long
period of time this type of mechanism causes.failerity in the fire tube, heat exchanger tubes and
other mechanical components. The best mechanisms for de scaling the boiler are using chemical
materials.

Figure 5: heat transfer with and without deposit

3.6 Cost analysis of fuel before de scale

When the boiler is not clean and scaling at the starting condition the water change to steam takes
120mints and works16hours per day to produce 1016tons of steam. 

29
The Boiler will need 650 liter of oil ferns per 16hr; here one liter will cost 14.50 Birr so the total
cost of ferns oil for one day will be 9,425 Birr.
For one hour the cost of fuel will be 9,425/16 =589.0625 Birr.
For one week the cost of fuel will be 9,425*7=65,975Birr
Total running cost of the company =almost 942,500Birr per week
Therefore

%tag of Energy management of the company will be calculated as follow

%of EM = (cost of fuel/total running cost of the company)*100
= (65,975Birr/942,500Birr)*100%
=7%

Chemical selection
Parameters:
-Scale density- 85mg/mc2
-The chemical selected for the de scaling is hydrochloric acid from table 4
-Descale time is chemical clean within three months
-Running cost for chemical de scaling=900.765birr per one descale
- Fuel consumption of the company=40.625liter per hour

Table4: shows the range of scale density encountered, along with the
appropriate action required,

Table 4: scale density and required action

3.7 Chemical de scaling by hydrochloric acid

Hydrochloric Acid - Inhibited hydrochloric acid is a most widely used solvent since it produces
good solubility with a wide variety of scales, is economical and is easy to handle. It shows good

30
corrosion characteristics when adequately inhibited and the process is controlled within the
accepted limits. It is not compatible with stainless steels. Table 4 indicates hydrochloric acid
cleaning stage control parameters.
The need to chemically clean an operating boiler is usually determined from an inspection of a
particular unit performed during planned inspections. An inspection should target specific areas
in the boiler known to be problematic areas of excessive corrosion or scaling.

The decision why I used hydrochloric acid as chemically clean:

1. After study overall efficiency
2. Hot spots - as evidenced by infrared inspection
3. Tube failure during normal operation
4. Checking the tube samples is the most reliable and effective mean

The Steps to Boiler Chemical Cleaning

Cleaning a boiler usually consists of a combination of the following stages:
 Mechanical cleaning
 Water flushing
 Alkaline treatment
 Solvent cleaning
 Neutralization and passivation
Mechanical cleaning and water flushing: can remove loose scale and other debris from the
boiler.
Alkaline treatment removes oils and hydrocarbons that might interfere with the dissolution of
the scale by acid solvents. 0
The solvent cleaning stage is the process in which inhibited acid is used to remove scale form the
boiler. Once the scale is removed in the solvent stage, fresh active metal is exposed.
The neutralization and passivation stages are designed to remove any last traces of iron oxides
and to replace the active metal with a well-passivity surface layer.
Fouling composition, quantity and distribution will vary considerably between one boiler to
another and even within the same boiler at various times during its life span. It is therefore
essential in each case to select a specific treatment or series of treatments that will be most
effective in achieving thorough and safe cleaning to the desired standards.
This segment provides a guide to the selection of treatments.
 The primary criteria that must be satisfied are:
 1st The treatment must be safe to use and compatible with the materials of
construction of the equipment to be cleaned.
 2nd The foul ant must show sufficient solubility in the treatment selected so when
it is considered together with any insoluble matter that may reasonably be
expected to detach fully during the process, it will achieve the desired degree of
cleaning.

Chemical Cleaning Evaluation

Inspection of the boiler after the chemical cleaning is crucial to determine if the procedure has
been successfully completed. Visual and video scope inspections determine the effectiveness of
31
the cleaning. There should be no visible traces of water and loose or adherent scale inside the
boiler drums and tubes. Remove the corrosion coupons and the polarization probes, visually
examine them, determine their weight loss and calculate the loss of metal thickness (usually < 25
microns) due to chemical cleaning.

Scale Density after cleaning - Cut a tube sample after chemical cleaning and determine the
density of any deposit. Use Table for evaluating the effectiveness of chemical cleaning.

3.8 Cost analysis of fuel after de scale

After descale when the boiler is clean and no scale, at the starting condition the water change to
steam takes 45mints.
Saving time per day =120min-45min=75min
Saving fuel per day= (75/60*)40.625=50.7812liter
Saving money per day=50.7812*14.50=736.3281birr
The Boiler will need 543.22 liter of oil ferns per 14hr, 15min; here one liter will cost 14.50
Birr so the total cost of ferns oil for one day will be 7876.69Birr.
For one week the cost of fuel will be 7876.69*7=55136.83Birr
Total running cost of the company =almost 941,118Birr per week
Cost of the chemical =472.543Birr at one month
Chemical cleaning cost in a week=472.54/4=118.135and
Chemical cleaning cost =118.135/7=16.879123Birr per day
Therefore
%tag of Energy management of the company will be calculated as follow
%of EM= [{cost of fuel per week+ cost chemical clean per week} *100]/ (Total running
cost of the company)

= [{55136.83+118.135}*100]/941,118
=5%
Company profit by this project=[ cost of ferns oil for one day before chemical cleaning-{
cost of chemical cleaning per day +cost of ferns oil for one day after chemical cleaning}]
Company profit= [9,425-(7876.69+16.78)]
= 719.45 Birr per day
Here, the company has 719.4581Birr neat profit per day

Also yearly profit of the company from the project:

Yearly profit=719.4581Birr*365
=262602.2065Birr

32
 CHAPTER FOUR

4.1 Conclusions

The chemical clean selected is good enough to saves the company money due to increase
heat transfer but, the problem is the scaling of boiler. if the company wants to save this
amount of money the boiler scale boiler is de scale by chemical cleaning Here, working
in the group of Sheba leather industry P.L.C as an intern student gave me a clue about
how my future looks like besides these, knowing and experiencing all work ethics and
procedures was a chance the internship period gave me.

Now a days the productivity and the profit of a company depends on balancing it
expenses with its income, different companies will expense more money for Energy
matter but it’s not more common to manage their energy after the installation of their
boiler in working. on this project I tried to put how much money does the company cost
due to scale in the fire tube the cost of chemical cleaning and how to select the good
chemical cleaning by the mentioning different type of acids with different chemical
property and about how much money does the company cost due to the scaling of boiler.

In the recommendation part I had put some points and method on how to save the
company money which is wasted improperly.

33
 4.2 Recommendation

Here, the company cost a total of 840,823.651Birr per week which is unnecessary waste the heat
loss cost too much money the cause for the scale of boiler is the company used untreated water,
therefore before scaling water treat meant basic alternative for saving money of the company
The chemical clean selected is good enough to saves the company money due to increase heat
transfer but, the problem is the scaling of boiler. if the company wants to save this amount of
money the boiler scale then boiler is de scale by chemical cleaning.

Reference

1. Sheba Leather Industry, Marshal Boiler manual, Wukro 2008

2 R. K. Rajput, A text book of power plant engineering, 3rdedition, New Delhi 2005
3. E. Rathakrishnan, Fundamentals of EngineeringThermodynamics, 2nd, New Delhi 2006
4. Frank P.Iincropera and David P. Dwwitt. Introduction to heat transfer. Third Edition

34
Appendix

Table A: Mechanical specification

Modal Size 178B(MARSHALL B)

Operation High/medium/low
Fuel oil Light oil –(70second red woodNo1@400c)
Heavy oil –(220 to 4300 seconds red wood No@400c)
Oil pump capacity 600Lit/hour
Atomizer Size-9.5 on low fire
Size-9.5 on medium fire
Size-9.5 on high fire
Type 3 phase smoke tub ,package
Boiler capacity 2800kg/hr
Design pressure 10.54kg/cm2
Fuel used FO
Steam out let size 80NB
Auxiliary valve size 25NB
Safety valve size 40x65NB
Feed water isolation 40NB
valve size
Level gauge 20NB
Level controller 25NB
Insulation Rock wool matters 75mm thick Density 100kg/m3
cladding Steel sheet, duly painted

35
Table B: Electrical specification

Fan + fuel pump motor rating 7.5kw(10HP)

Heater rating 12kw
Electricity supply Power supply voltage-440v 3phase
Frequency-50HZ
Control supply(volt) 230v single phase

Table C: Fuel oil details

Furnace oil
Composition(%v/v)
C-84.00
H2-11.00
S-3.5
N-Nil
O2-Nil
H2O-1
ASH-0.5
Ash%Wt-0.1
Flash point-66min
Kinematic viscosity-125-180cst at 500c
Pour point 0c-27 max
Sediment%wt-0.25 max
NCV of fuel-9650kcal/kg

Moisture = 0.5
GCV of fuel = 10000 kCal/kg
Fuel firing rate = 2648.125 kg/hr
Surface Temperature of boiler = 40 oC
Surface area of boiler = 90 m2

36
Humidity = 0.025 kg/kg of dry air
Wind speed = 3.02 m/s

Table D:Steam management curve

37
Table E:steam tables

38
Table F:Pipeline capacity and pressure factor table
39
Table G: Guidelines for Water Quality

40
41