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© UNEP 2006
Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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© UNEP 2006
Introduction
What is a Boiler?
• Vessel that heats water to become
hot water or steam
• At atmospheric pressure water
volume increases 1,600 times
• Hot water or steam used to transfer
heat to a process
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© UNEP 2006
Introduction
STEAM TO
EXHAUST GAS VENT
PROCESS
STACK DEAERATOR
PUMPS
ECO-
NOMI-
ZER
VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
BRINE
CHEMICAL FEED
SOFTENERS
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Figure: Schematic overview of a boiler room © UNEP 2006
Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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© UNEP 2006
Types of Boilers
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© UNEP 2006
Type of Boilers
User equipment
2. Circulated
to user 4. Fluid
equipment returned to
heater
Control
panel
Insulated
outer wall
1. Thermic
fluid heated Blower Exhaust
motor
in the heater unit
(Energy
Fuel oil
filter Machine India)
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© UNEP 2006
Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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© UNEP 2006
Assessment of a boiler
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment
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© UNEP 2006
Assessment of a Boiler
1. Boiler performance
• Causes of poor boiler performance
-Poor combustion
-Heat transfer surface fouling
-Poor operation and maintenance
-Deteriorating fuel and water quality
Heat Balance
An energy flow diagram describes geographically
how energy is transformed from fuel into useful
energy, heat and losses
Stochiometric
Excess Air
Un burnt
Stack Gas
Heat Balance
Balancing total energy entering a boiler against
the energy that leaves the boiler in different forms
12.7 %
Heat loss due to dry flue gas
1.0 %
Heat loss due to radiation & other
unaccounted loss
73.8 %
Heat in Steam
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© UNEP 2006
Assessment of a Boiler
Heat Balance
Goal: improve energy efficiency by reducing
avoidable losses
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
Parameters to be monitored:
- Quantity of steam generated per hour (Q) in kg/hr
- Quantity of fuel used per hour (q) in kg/hr
- The working pressure (in kg/cm2(g)) and superheat
temperature (oC), if any
- The temperature of feed water (oC)
- Type of fuel and gross calorific value of the fuel (GCV) in
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kcal/kg of fuel © UNEP 2006
Assessment of a Boiler
Disadvantages
• No explanation of low efficiency
• Various losses not calculated
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© UNEP 2006
Assessment of a Boiler
Principle losses:
i) Dry flue gas
ii) Evaporation of water formed due to H2 in fuel
iii) Evaporation of moisture in fuel
iv) Moisture present in combustion air
v) Unburnt fuel in fly ash
vi) Unburnt fuel in bottom ash
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vii) Radiation and other unaccounted losses © UNEP 2006
Assessment of a Boiler
Advantages
• Complete mass and energy balance for each
individual stream
• Makes it easier to identify options to improve
boiler efficiency
Disadvantages
• Time consuming
• Requires lab facilities for analysis
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© UNEP 2006
Assessment of a Boiler
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© UNEP 2006
Assessment of a Boiler
• Continuous
• Ensures constant TDS and steam purity
• Heat lost can be recovered
• Common in high-pressure boilers
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© UNEP 2006
Assessment of a Boiler
b) Demineralization
• Complete removal of salts
• Cations in raw water replaced with hydrogen ions
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© UNEP 2006
Assessment of a Boiler
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© UNEP 2006
Assessment of a Boiler
Storage
• Vacuum type can reduce
Section O2 to 0.02 mg/l
De-aerated • Pressure type can
Boiler Feed
Water
reduce O2 to 0.005 mg/l
( National Productivity Council) 40
© UNEP 2006
Assessment of a Boiler
• Reversed osmosis
• Higher concentrated liquid pressurized
• Water moves in reversed direction 42
© UNEP 2006
Assessment of a Boiler
Semi Permeable 43
Membrane © UNEP 2006
Training Agenda: Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
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© UNEP 2006
Energy Efficiency Opportunities
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© UNEP 2006
Energy Efficiency Opportunities
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© UNEP GERIAP
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