Documente Academic
Documente Profesional
Documente Cultură
Technology Concept
$$$
Extremely Uniform Heating Absolute Temperature Limit on Heated Surfaces High Heat Delivery Fast Recovery from Cold Spots Heats Unusually Shaped Heat Exchangers Uniformly
Classes of Steam
Used in Hospitals, District Steam Systems, Some Industrial Strictly Industrial and Power Generating Applications Increase in Expense with Each Higher Class
Generation
Boilers
Fire-tube or water-tube
Heat recovery
generators
Typical Boiler
Generation
Water tube
fuel burned within combustion chamber combustion gas surrounds water tubes within vessel
Fire tube
fuel burned in combustion chamber combustion gases flow through tubes water surrounds tubes
Generation
Fire tube
Generation
Water tube
Generation
Modular Boilers
load more effectively without cycling Improved combustion efficiency Reduced jacket losses Fin tube design less durable Piping and controls important Mostly for commercial markets
Generation
Distribution Systems
Steam traps Collection tanks Flash steam recovery Pumps Deaerator Economizer
Typical Applications
Exceptions
Hospitals need steam for sterilizers Older district heating systems Industrial plants which require process steam
Low operating costs Minimal downtime Reduced emissions Effective process control
$$$
Reduce downtime Eliminate maintenance crises Improve process control Minimize safety hazards
Benchmarking
Profile your existing system Calculating the cost of steam ($/ thousand lbs)
Separating process boiler load from seasonal heating Steam System Assessment Tool (US DOE) Fuel Water Chemicals
Rough estimate: Total Steam Cost ($/MMBtu) = Fuel Cost ($/MMBtu) x 130%
Incorrect air/fuel ratio combustion inefficiency Lack of insulation Insufficient trap maintenance Steam leaks No heat recovery Insufficient water treatment/blowdown issues Frequent boiler cycling Water hammer Poor record keeping
In theory . . .
PERFECT COMBUSTION
FUEL (C2H)
EXCESS O2
Too much air = excess heat loss in stack Too little air = wasted fuel
Insulation
*Based on 8,000 hours of operation, 85% efficient boiler, mineral fiber insulation with
all purpose jacket
US DOE Industries of the Future Workshop Series
Insulation
Steam traps
Expect 15% to 30% failure every 3 to 5 years Easily tested using ultrasonic equipment Steam trap example problem
Steam Leaks
The table can also be used to determine steam losses through steam traps that have failed open.
US DOE Industries of the Future Workshop Series
Vent Condensers
Economizer/ Recuperator
Recuperators
Recover heat to
combustion air Require steady boiler loading
Economizers
Recover heat to
boiler feed water Require continuous feed water flow
Boiler Recuperator
Boiler Recuperator
Boiler efficiency indirectly proportional to stack temp Causes of excess stack temps:
Excess air Fouled waterside surfaces Fouled fireside surfaces Overfiring Insufficient heat transfer surface High steam pressure
Excess air - adjust air/fuel ratio Fouled surfaces - can be detected by visual inspection Overfiring Flue temp must be at least 50F over the minimum allowable
Boiler Recuperator
Boiler conditions:
450F stack temperature 80 inlet air 4% O2 in stack Current natural gas consumption: 67,286 MMBtu/year Current natural gas cost: $5.90/MMBtu Net stack temp: 450 - 80 = 370 Net stack temp w/recuperator: 280F New efficiency current efficiency = efficiency gain 83.0% - 80.7% = 2.3%
continued
US DOE Industries of the Future Workshop Series
Energy Savings:
= current use x (1- (old efficiency/new efficiency)) = 67,286 MMBtu x (1 (0.807 / 0.830)) = 1,865 MMBtu/yr = energy savings x energy cost = 1,865 MMBtu/yr x $5.90/MMBtu = $11,000/yr
Cost savings:
Vent Condensers
Vent
Boiler
Mid-drum blow down Mud-drum blow down
Fee d Water
Deaerator
Flash Steam
Approximate Savings:
Flash Separator
Blow Down
Prehe ate d fe ed wate r Heat Exchange r
Make up Water
Boiler cycle:
Pre-purge fan removes combustible gases from boiler Firing interval Post-purge gases removed again Idle period
Short cycling
Causes:
Boiler oversized for expansions that never happened Energy conservation measures have reduced heat
demand Space heating based on design-basis temperature conditions Space heating sized for quick recovery from night setbacks
Green areas represent energy that will be wasted while the boiler is not firing but the fan is in pre-purge or post-purge phase.
US DOE Industries of the Future Workshop Series
Backpressure Turbines
pressure Require
Combustion analysis testing equipment Removable valve insulation Trap analysis with ultrasonic equipment Steam flow metering Gas sub-metering Continuous blow down and conductivity metering Exhaust stack economizers Modular boiler systems Direct contact water heaters
How to start
Utility bill analysis Steam trap inventory Combustion testing Ensure all insulation is in good shape Optimize boiler blowdown Monitor boiler cycling during periods of low demand Check for applications for new technologies
Heating Load
25,000
20,000
15,000
Process Load
10,000
5,000
Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May
Best Practices
Steam leak reporting mechanism for all staff Insulation standards formalized
Benchmarking
Monitoring needs
Daily Natural Gas Usage (meter on each boiler) Daily Steam Production (meter on boiler water feed) Daily Water Usage (meter on make-up water feed) Chemical Costs (compare to water usage)
Implementation of Improvements
Assessing the entire system (supply and demand) Identifying opportunities Quantifying benefits and costs Implementing most feasible projects
ISO 14000
In house assessment
GO TO Assessment Resources Listing
Tools Tools available available from from US US DOE DOE Steam Steam Challenge Challenge Program Program
Assessment Resources
BACK
expertise in industrial steam systems, also will perform energy assessments for industrial clients. Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provide energy assessments (including steam systems) free of charge to qualified industrial clients. US DOE Steam Challenge Program http://www.oit.doe.gov/bestpractices/steam/ - provides a wide range of technical assistance materials, tools, and services to the industrial market. National Association of Energy Service Companies http://www.naesco.org/ - trade organization of companies that will perform energy audits and finance improvements. Steam System Survey Guide http://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.p df - guide to assessing industrial steam systems. Rutgers IAC Self Assessment Guide http://iac.rutgers.edu/manuals/selfassessment.pdf - guide to assessing industrial plants for energy efficiency.