Boilers & Fired System

Adnan Rauf.
Assistant Professor,
Biomedical Engineering Center,
&
Electrical Engineering Department, UET,
KSK Campus.

1
 Introduction
Boilers and other fired systems are the most
important energy consumers.
Almost 2/3rd of the fossil-fuel energy
consumed in the US involves the use of a
boiler, furnace or other fired system.
Even most electric energy is produced using
fuel-fired boilers. Over 68% of the electricity
generated in the US is produced through the
combustion of coal, fuel oil and natural gas.
2
 Introduction
Unlike many electric systems, Boilers and
Fired Systems are not inherently energy
efficient.
This chapter and the following chapter on
Steam and Condensate Systems
examine how energy is consumed, how
energy is wasted, and opportunities for
reducing energy consumption and costs in
the operation of boiler and steam plants. 3
 Introduction
A list of energy and cost reduction measures
is presented, categorized as: load reduction,
waste heat recovery, efficiency
improvement, fuel cost reduction, and other
opportunities.
Several of the key opportunities for reducing
operating costs are presented ranging from
changes in operating procedures to capital
improvement opportunities. 4
 Introduction
In addition to energy saving opportunities,
this chapter also describes some issues
relevant to day-by-day operations,
maintenance and troubleshooting.

5
 Analysis of Boilers & Fired
Systems
Combustion of fuel with air takes place in
boilers and other fired systems, such as
furnaces and ovens for the purpose of
releasing chemical heat energy.
The purpose may be to raise the
temperature of an industrial product as part
of a manufacturing process
It may be to generate high temperature, high
pressure steam in order to power a turbine. 6
 Boiler Energy Consumption
Theenergy consumption of boilers, furnaces
and other fire systems can be determined
simply as a function of load and efficiency.

Energy Consumption = Load/ Efficiency

7
 Boiler Energy Consumption
Cost of operating a boiler or fired system can
be determined as :

Energy Cost = (Load/ Efficiency) X Fuel Cost

In order to reduce boiler energy

consumption, one can either reduce the load,
increase the operating efficiency, reduce the
unit fuel energy cost or combinations.
8
 Boiler Energy Consumption

This is not as simple as it sounds, Load

varies as a function of the process being
supported.
The Efficiency varies as a function of the
load and other functions, such as time or
weather.
Fuel cost may also vary as a function of time
(such as in seasonal time of use, or spot
market rates). 9
 Balance Equations
Balance equations are used in an analysis
of a process which determines inputs and
outputs to a system.

Severaltypes of balance equations can be

used, but most important of them are the
Heat Balance and Mass Balance
equations.
10
 Heat Balance Equation
A heat balance is used to determine
whether all heat energy entering and leaving
a system is equal or not.
Assuming that energy can neither be
created or destroyed, all energy can be
accounted for in a system analysis.
Energy in equals to energy out.

11
 Heat Balance Equation
In a simple furnace system, energy enters
through the combustion air, fuel, and mixed-
air duct. Energy leaves the furnace system
through the supply-air duct and the exhaust
gases.
In a boiler system, the analysis can become
more complex.

12
 Heat Balance Equation
Energy input comes from the following:
Condensate return, make-up water,
combustion air, fuel, and maybe a few
others depending on the complexity of the
system.
Energy output departs as the following:
steam, blowdown, exhaust gases,
shell/surface losses, possibly ash, and other
discharges depending on the complexity of
the system. 13
 Mass Balance
A mass balance is used to determine
whether all mass enters and leaves a
system equally or not.
In case of a steam boiler, a mass balance
can be used in the form of water balance
(steam, condensate return, make up water,
blowdown and feed water).

14
 Mass Balance
A mass balance can also be used for water
quality or chemical balance (total dissolved
solids or other impurity).
The mass balance can also be used in the
form of a combustion analysis (fire-side
mass balance consisting of air and fuel in
and combustion gases and excess air out.)
This type of analysis is the foundation for
determining combustion efficiency and
determining the optimum air to fuel ratio. 15
Efficiency of Boilers & Fired System
There are two primary methods of
determining efficiency:
The Input-Output method
Heat-Loss Method
The efficiencies determined by these
methods are Gross efficiencies as
apposed to Net efficiencies which would
include the additional energy input of
auxiliary equipment such as combustion air
fans, fuel pumps, etc. 16
 Net Combustion Efficiency Vs
Gross Combustion Efficiency
Net combustion efficiency calculations
assume that the energy contained in the
water vapour which is formed as a product
of combustion is recovered and is not
exhausted from the flue or stack.
Gross combustion efficiency calculations
assume that the energy contained in the
water vapour is not recovered.
17
 Net Combustion Efficiency Vs
Gross Combustion Efficiency
Typically the difference between the value of
net combustion efficiency and the value of
gross combustion efficiency for a natural
gas fuelled boiler is around 8% with the net
value being higher than the gross value.
Most boiler manufacturers now quote their
boiler efficiencies based on the net
combustion efficiency.
18
 Combustion Efficiency
Combustion Efficiency is similar to the
heat loss method, but only the heat losses
due to the exhaust gases are considered.
Combustion efficiency can be measured in
the field by analyzing the products of
combustion of exhaust gases.
Typically measuring either Carbon dioxide
(CO2) or Oxygen (O2) in the exhaust gas
can be used to determine the combustion
efficiency as long as there is excess air. 19
 What is Excess Air
Excess air, is the amount of air above that,
which is theoretically required for complete
combustion.
Perfect mixture of air and fuel to achieve
complete combustion is not possible without
excess air in real world.
If excess air is reduced, incomplete
combustion begins to occur resulting in the
formation of Carbon monoxide, Carbon,
smoke and in extreme cases, raw unburned
20
fuel.
 Combustion Efficiency

Incompletecombustion is inefficient,
expensive and frequently unsafe.

Therefore,some amount of excess air is

required to ensure complete and safe
combustion.

21
 Drawback of Excess Air
Excess air is also inefficient as it results in
the excess air being heated from ambient air
temperatures to exhaust gas temperatures
resulting in a form of heat loss.

Therefore while some excess air is required

it is also much desirable to minimize the
amount of excess air.
22
 Energy Conservation Measures
For Boilers & Fired Systems
Load Reduction
Insulation
steam lines and distribution system
condensate lines and return system
heat exchangers
boiler or furnace
Repair steam leaks
Repair failed steam straps 23
 Load Reduction
Return condensate to boiler
Reduce boiler blowdown
Improve feedwater treatment
Improve make-up water treatment
Repair condensate leaks
Shut off steam tracers during the summer

24
 Load Reduction
Shut off boilers during long periods of no
use
Eliminate hot standby
Reduce flash steam loss
Install stack dampers or heat traps in natural
draft boilers
Replace continuous pilots with electronic
ignition pilots
25
 Waste Heat Recovery (a form of
load reduction)
Utilizeflash steam
Preheat feed-water with an economizer
Preheat make-up water with an economizer
Preheat combustion air with a recuperator
Recover flue gas heat to supplement other
heating system, such as domestic or service
hot water, or unit space heater
26
 Waste Heat Recovery (a form of
load reduction)
Recover waste heat from some other
system to preheat boiler make-up or
feedwater
Install a heat recovery system on incinerator
or furnace
Install condensation heat recovery system
indirect contact heat exchanger
direct contact heat exchanger
27
 Efficiency Improvement
Reduce excess air
Provide sufficient air for complete
combustion
Install combustion efficiency control system
Constant excess air control
Minimum excess air control
Optimum excess air and CO control
Optimize loading of multiple boilers 28
 Efficiency Improvement
Shut off unnecessary boilers
Install smaller system for part-load operation
Install small boiler for summer loads
Install satellite boiler for remote loads
Install low excess air burners
Repair or replace faulty burners
Replace natural draft burners with forced
draft burners
Install turbulators in firetube boilers
29
 Efficiency Improvement
Installmore efficient boiler or furnace
system
high-efficiency, pulse combustion, or
condensing boiler or furnace system
Clean heat transfer surfaces to reduce
fouling and scale
Improve feed-water treatment to reduce
scaling
Improve make-up water treatment to reduce
scaling 30
 Fuel Cost Reduction
Switch to alternate utility rate schedule
interruptible rate schedule
Purchase natural gas from alternate source,
self procurement of natural gas
Fuel switching
switch between alternate fuel sources
install multiple fuel burning capability
replace electric boiler with a fuel-fired
boiler 31
 Other Opportunities
Install variable speed drives on feed-water
pumps
Install variable speed drives on combustion
air fan
Replace boiler with alternative heating
system
Replace furnace with alternative heating
system
Install more efficient combustion air fan
32
 Other Opportunities
Install more efficient combustion air fan
motor
Install more efficient feed-water pump
Install more efficient feed-water pump motor
Install more efficient condensate pump
Install more efficient condensate pump
motor
33
 Requirements to Get Maximum
Benefits of Excess Air
Toobtain the maximum benefits of an
excess-air-control program, the following
modifications, additions, checks or
procedures should be considered.

34
 Key Elements for Maximum
Efficiency
Ensure that the furnace boundary walls and
flue work are airtight and not a source of air
infiltration or exfiltration.

Thereare different tests to locate leakage

problems. Such as

35
 Leakage Tests
A light test whereby a strong spotlight is
placed in the furnace and the unit is
inspected externally.

The use of Pyrometer to obtain a

temperature profile on the outer casing. This
test generally indicates points where
insulation has deteriorated.
36
 Leakage Tests
A soap-bubble test on suspected
penetration points or seal welds.

A smoke bomb test an external

examinations for traces of smoke
Use of a thermographic device to locate
Hot Spots which may indicate faulty
insulation or flue-gas leakage.
37
 Heat Recovery Program
Steam Boilers, process fired heaters and
other combustion or heat transfer furnaces
can get benefit from a heat recovery
program.
Specifically economizers and air preheaters
come under this category. Economizers
are used to extract heat energy from the flue
gas to heat the incoming liquid process feed
stream to the furnace. 38
 Heat Recovery Program
Air
Preheaters lower the flue gas
temperature by exchanging heat to the
incoming combustion air stream.

Coststo implement this energy conservation

opportunity can then be compared against
the potential benefits.

39
 Requirements for Maximum
Economy
Anoptimized loading schedule will allow any
plants steam demand to be met with the
minimum energy input.

Some general points to be considered when

establishing such a schedule are as follows.

40
 Requirements for Maximum
Economy (Boilers)
Boilersgenerally operate most efficiently at
65 to 85% full load rating.

Centrifugalfans at 80 to 90% design rating.

Equipment efficiencies fall off at higher or
lower load points, with the decrease most
pronounced at low-load conditions.

41
 Requirements for Maximum
Economy (Boilers)
Itis usually more efficient to operate a
lesser number of boilers at higher loads than
a larger number at low loads.

Boilers should be put into service in order of

decreasing efficiency starting with the most
efficient unit.

42
 Requirements for Maximum
Economy (Boilers)
Newer units and units with higher capacity
are generally more efficient than are older,
smaller units.

Generally,steam plant load swings should

be taken in the smallest unit.

43
 Use of High Pressure Boilers
The boilers in a plant that operate at the
highest pressure are usually the most
efficient.
It is therefore, desirable to supply as much
of the plant demand as possible with these
units provided that the high-grade energy in
the steam can be effectively used.

44
 Boiler Blowdown
In the generation of steam, most water
impurities are not evaporated and thus
concentrate in the boiler water.
The concentration of the impurities is usually
regulated by the adjustment of the
continuous blowdown valve, which controls
the amount of water ( and concentrated
impurities) purged from the steam drum.
45
 Boiler Blowdown
When the amount of blowdown is not
properly established and / or maintained,
either of the following may happen.
If too little blowdown, sludge deposits and
carry over will result.
If too much blowdown, excessive hot water
is removed, resulting in increased boiler fuel
requirements and boiler feed water
requirements. 46
Thank You

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