Dr.

Albrecht Kaupp

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Parameters influencing boiler efficiency

Issue
Energy savings does not always imply efficiency improvement in boilers

Learning Objectives

Identifying parameters that efficiency.

influence

Knowing how to calculate the energy savings from parameters that do not influence thermal efficiency. Discussing the relative impact condensate return and blow down of

Assessing the effect of steam pressure changes. Recognizing the difference between an increase in steam generation and improvement in efficiency

Parameters influencing boiler efficiency

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NOTES

1. Introduction
Recall the general efficiency equation of a boiler
Adsorbed Heat Energy Input

!"

#he equation says nothing about the fact that not all adsorbed heat is useful heat. $or instance the blow down is certainly %adsorbed& heat but rarely %useful&. In other words the energy in the blow down will be lost to ambient but any change in the blow down rate will not affect the system efficiency. Equation !" was converted into another equation

=!

Losses
Energy Input

'"

It was shown that equation !" and equation '" are equal and should give the same result. #he energy input to the system is in the most simple case the energy of the fuel and the enthalpy of the combustion air. (owever one may as well add to the energy input the steam necessary to atomize the fuel) or the electricity needed to power all electric motors of the boiler. In large power plant boilers it is especially important to draw a system boundary and prepare a list of all energy flows that enter and leave the system boundary. *imilarly the sum of losses depends on what we call a loss. *ome obvious losses are the energy in the stac+ gas) the radiation and convection loss) and the refuse loss. (owever blow down is not considered a loss and therefore e,cluded from the sum. In fact the norms state no blow down is allowed during efficiency testing.

Parameters influencing boiler efficiency

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NOTES

2. Parameters that do not influence efficiency

-sing the efficiency simulator one will notice that system efficiency does not change at all if the following parameters are changed #he steam pressure #he steam temperature #he blow down fraction #he percentage of condensate return #he condensate return temperature

#he above parameters do not enter equation '" and consequently the system efficiency will not change. .evertheless lowering the steam pressure or temperature or increasing the condensate return and temperature will certainly save fuel. #here is absolutely nothing wrong with the definition of efficiency e,cept the fact that we may save fuel by not changing the system efficiency at all. /henever 0s ) #s) ,1D) ,con)#con) change the steam output changes as well) but the efficiency stays the same. 2onsequently we cannot calculate the fuel savings by the equation
3 Fuel Savings =

new old new

4"

Another peculiarity are the savings one may achieve by preheating the air or the feedwater. #he efficiency definition does not provide for entering the temperature of preheated air or feedwater) because preheating devices such as an economizer and air preheater are inside the system boundary. In other words preheating of the combustion air and the feedwater is ta+en into account through lowering the stac+ gas temperature.

Parameters influencing boiler efficiency

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3.

Requirements for Field Testin

1ecause is not affected by a change of the above mentioned parameters) but the steam flow is) we have a basic problem when conducting an efficiency test by the direct method. It will be necessary to +eep the steam pressure) steam temperature and feedwater temperature as stable as possible. In addition no blowdown should occur. *oot blowing must be also +ept to a minimum. #he boiler should be +ept in equilibrium) which is close to impossible with smaller boilers.

!. Fuel Sa"in Potential

*ince does not change for the above parameter we calculate the energy saving potential via the change in steam generation. !.1 Fuel sa"in #otential of chan e in condensate return

Any change in the condensate return fraction and temperature will change the steam output from *! to *' in tons of steam per ton of fuel fired". 2onsequently the change in steam output equals *5 *! 6 *' 7"

A negative * means more steam is generated. #he simulator besides calculating the efficiency also calculates the steam output for any given efficiency. 2onsequently we have a change in fuel consumption of
F = !88S S!

9"

where $ is the change in fuel consumption in 3. A negative $ means we save fuel while a positive $ implies an increase in fuel consumption.

Parameters influencing boiler efficiency

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NOTES

#here is another way to evaluate the savings. Increasing the condensate return and temperature will lower the adsorbed heat requirement to reach a given steam condition. /e define

H cond ! = x cond ! x H cond ' = x cond ' x

mF" hcond T! ) P " mF" hcond T' ) P "

:" ;"

#he enthalpy of the condensate return for the % as is % and the improved scenario. /here ,cond)i 5 the condensate return fraction) base msteam ,1D 5 the blow down fraction) base m$/ m$/ 5 the feedwater flow) t<ton of fuel #i 5 the temperature of the condensate return) =2 0 5 the condensate pressure) bar hcond 5 the enthalpy of the condensate as a function of #i and 0. $urthermore
H cond = x
!

mF" ( x cond !hcond ! x cond ' hcond ' )

>"

is the change in condensate enthalpy and therefore

F = !88H cond HH# $

?"

where $ is the change in fuel consumption in 3 and (($ f the (igher (eating @alue of the fuel. A negative number means savings. !.2 Fuel sa"in #otential of chan e in $lo% do%n

#he amount of feedwater released as blowdown is given as mF" = mF" x

!

!8"

where) m$/) is the feedwater flow in ton<ton of fuel and) ,1D )the blow down fraction. #he blow down is therefore e,pressed as a fraction of the feedwater and not as a fraction of the steam. 1oth definitions would wor+. #he adsorbed heat stored in the blowdown equals

Parameters influencing boiler efficiency

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NOTES

= mF" x

(h

hF" )

!!"

where) h1D) is the enthalpy of liquid water at the boiler drum pressure and h$/ is the enthalpy of the pressurized liquid feedwater. #he amount of fuel energy necessary to compensate for a change in blow down loss from ,1D! to ,1D' is
F = !88 mF" x
!'

!!

HH# $

" (h

hF" )

!'"

#he result is given in 3 . A negative number means fuel savings.

Parameters influencing boiler efficiency

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%&%'(I)%)
E,ercises e,plore the impact of fuel savings with respect to reduction in blow down and increase of condensate return. In addition the impact of unstable pressure and temperature conditions during efficiency testing are discussed.

Tas& 1
2onsider a 2oal 1 fired boiler of !88 tons<hour steam output. *team pressure is :9 bar 798 =2" and feedwater temperature at !'9=2 and pressure of ;' bar. 2ondensate return before the dearator tan+ is 78 3 at :8 =2. Annual fuel consumption equals >8)888 tons of 2oal 1 for the %as is& condition. #he system efficiency is >83. #here is no blow down . 2alculate the annual fuel savings in tons) if condensate return is increased from 78 3 to >8 3 and temperature from :8 =2 to >8 =2. $ollow the steps and use equation > and ?. )teps
((@ of 2oal 1) AB<ton *pecific enthalpy of condensate at :8 =2) AB<ton *pecific enthalpy of condensate at >8 =2) AB<ton Enthalpy of condensate flow at :8 o2) AB Enthalpy of condensate flow at >8 o2) AB Annual fuel energy supply) AB<year Adsorbed heat %as is&) AB<ton of steam $eedwater tons<ton of fuel 2hange in feedwater enthalpy) AB<ton of fuel 0ercent reduction in fuel consumption) 3

'esults

Parameters influencing boiler efficiency

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Tas& 2
Assume the boiler in tas+ ! has !8 3 blowdown. (ow does this affect the fuel consumption reduction calculated in tas+ !. 0roceed by assuming the annual steam generation is !8 3 less. #he new annual fuel savings areCDDDDDDDD3

Tas& 3
2onsider a small boiler of ! t<h saturated steam at : bar. $eedwater temperature is >8 =2 at a pressure of > bar. #he %as is % blowdown equals !4 3 and is therefore high. Annual steam generation equals :)888 tons. A light fuel oil of ((@5 77 AB<+g is fired. $uels costs are : 1aht<+g. *ystem efficiency equals >' 3. 2alculate the annual cost savings if we reduce blow down from !43 to 9 3. -se equation !' and follow the steps. Do the savings Eustify this recommendation.F Are there any possible negative side effectsF )teps
Enthalpy of $/ at >8 =2 and > bar) AB<ton Enthalpy of $/ at saturation pressure of : bar Annual feedwater) tons<year Adsorbed heat of feedwater) AB<ton (igher (eating @alue) ((@f) AB<ton Reduction in fuel consumption) 3 Reduction in fuel consumption) tons<year Reduction in fuel costs) 1aht<year

'esults

#he recommendation is attractive% not attractive to the client because ofC DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD 0ossible negative side effects areC

Parameters influencing boiler efficiency

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DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD

Tas& !
In previous lectures and e,ercise we have for convenience made some simplifications that do not reflect reality. $or instance the various flows of the water6steam circuit such as saturated steam flow) superheated steam flow) condensate return and feedwater flow have different pressures. /hile we were always careful to state the temperature we sometimes ignored the pressure differences of the liquid phases. E,plore the small or large errors we may commit by ignoring pressure differentials. #he first e,ercise concerns a : bar boiler where the feedwater enters at > bar instead at : bar. )teps
Enthalpy of $/ at >8 =2 and : bar) AB<ton Enthalpy of $/ at saturation pressure of : bar Adsorbed heat of feedwater at : bar) AB<ton Enthalpy of $/ at >8 =2 and > bar) AB<ton Adsorbed heat of feedwater at > bar) AB<ton 0ercent difference in adsorbed heat

'esults

Did we overestimate or underestimate the steam output by assuming feedwater at : bar instead > barFDDDDDDDDDDDDD #he second e,ercise concerns a boiler of !:8 bar superheated steam 988 =2 steam temperature".2alculate the difference in adsorbed heat for feedwater pressures of !:8 bar and !;9 bar and #5 !78 =2.

Parameters influencing boiler efficiency

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)teps
Enthalpy of $/ at !78 =2 and !:8 bar) AB<ton Enthalpy of steam 988 =2 and !:8 bar") AB<ton Adsorbed heat of feedwater at !:8 bar) AB<ton Enthalpy of $/ at !78 =2 and !;9 bar) AB<ton Adsorbed heat of feedwater at !;9 bar) AB<ton 0ercent difference in adsorbed heat

'esults

Tas& '
Assume during an efficiency test it was not possible to +eep the steam pressure stable. @ariations from 4> bar to 7' bar were observed. *uperheated steam temperatures were relatively stable at 798 =2. #he average boiler efficiency was >;3 measured by the indirect method for 2oal A operation. $eedwater conditions were !'8 =2 and 79 bar. .o blow down and soot blowing was allowed during testing. Assume the two e,tremes of #he steam pressure was always at 4> bar #he steam pressure was always at 7' bar 2alculate the adsorbed heat and the tons of steam generated per ton of fuel for the given efficiency of >;3. Is the difference in steam generation largeF )teps
Enthalpy of $/ at !'8 =2 and 79 bar) AB<ton Enthalpy of steam 798 =2 and 4> bar") AB<ton Adsorbed heat of feedwater at 4> bar) AB<ton Enthalpy of steam 798 =2 and 7' bar") AB<ton Adsorbed heat of feedwater at 7' bar) AB<ton #ons of steam<ton of fuel at 4> bar steam #ons of steam<ton of fuel at 7' bar steam 0ercent difference in steam generation) 3 0ercent difference in fuel consumption) 3

'esults

Parameters influencing boiler efficiency

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NOTES

2ould the pressure fluctuation have any influence with respect to overshadowing some of your energy conservation recommendations. E,plainC DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD