EFISIENSI ENERGI

BAB 2
BOILER DAN FURNACE

Conny K. Wachjoe

Jurusan Teknik Konversi Energi

POLITEKNIK NEGERI BANDUNG

11/27/2017
1. Use an economizer to preheat boiler feed water using exhaust heat.
2. Recycle steam condensate.
3. Assess part-load characteristics and cycling costs to determine the
most-efficient mode for operating multiple boilers.
4. Preheat combustion air with waste heat using air pre heaters.
- (22 C reduction in flue gas temperature increases boiler
efficiency by 1 percent)
5. Install variable speed drives on large boiler combustion air fans with
variable flows.
6. Burn wastes if permitted.
7. Enhance oxygen trim control (e.g. limit excess air to less than 10
percent on clean fuels).
- (5 percent reduction in excess air increases boiler efficiency by 1
percent or 1
percent reduction of residual oxygen in stack gas increases
boiler efficiency by 1
percent).
8. Automate/optimize boiler blow down. Recover boiler blow down
heat.
9. Use boiler blow down to help warm the back-up boiler.
10. Consider exhaust heat to waste heat recovery boiler.
11. Automate/optimize boiler blow down. Recover boiler blow down
heat.
12. Use boiler blow down to help warm the back-up boiler.
13. Consider exhaust heat to waste heat recovery boiler.
14. Optimize de-aerator venting. Check for scale and sediment on the
water side
o (A 1 mm thick scale (deposit) on the water side could increase
fuel
consumption by 5 to 8 percent).
15. Check for soot, fly-ash, and slag on the fire side
o (A 3 mm thick soot deposition on the heat transfer surface can
cause an increase in fuel consumption to the tune of 2.5
percent).
16. Optimize boiler water treatment.
17. Consider multiple or modular boiler units instead of one or two large
boilers.
18. Start a boiler efficiency-maintenance program which should become
part of your continuous energy management program.
19. Insulate exposed heated oil tanks.
20. Clean burners, nozzles, strainers, etc.
21. Check oil heaters for proper oil temperature
1. Check for holes and other leakages in the oven walls.
2. Check infiltration of air: Use doors or air curtains.
3. Inspect seals.
4. Check if there is low feeding.
5. Inspect if the surface temperature is too hot.
6. Check if the temperature of exhaust gas is higher than 200C
for potential heat recovery and cost-effective opportunity.
7. Check if it is possible and cost-effective to install a flue gas
damper.
8. Check the chimney to see if the oven/dryer is provided with a
flue gas damper.
9. Ensure that flame does not touch the stock.
10. Ensure that the furnace combustion chamber is under slight
positive pressure.
11. Improve burner design, combustion control and
instrumentation.
12. Investigate cycle times and their reduction.
13. Match the load to the furnace capacity.
14. Monitor O/CO/CO and control excess air to the optimum
level.
15. Provide temperature controllers.
16. Use ceramic fibers in the case of batch operations
So % Carbon in fuel x mass of fuel = % Carbon in flue gas x mass of flue gas

Kilograms Dry Flue Gas % by weight of carbon in the fuel

=
Kilograms Fuel % by weight of carbon in dry flue gas

Kilograms Dry Flue Gas % carbon consumed + sulphur x 12/32

= ,,,,,,,,, 3
Kilograms Fuel % by weight of carbon in dry flue gas
The percentage of carbon monoxide in 1 kg of fuel

Kilograms CO (% carbon consumed+ % sulphur x 12/32) x 28 CO

= 7
Kilograms Fuel 12CO2 + 12CO
Qfm = cp (Tg Ta) . 8

Where
Qfm = Air Vapour Loss ( k i lojoules/kg vapour)
 BOILER HEAT BALANCE

In a relatively small boiler,

with a capacity of 10 MW, the
radiation and unaccounted
losses could amount to
between 1% and 2% of the
gross calorific value of the
fuel, while in a 500 MW
boiler, values of between
0,2% and 1 % are typical.
Excess air to achieve highest
possible efficiency for some
common fuels:
5 - 10% for natural gas
5 - 20% for fuel oil
15 - 60% for coal
Normal combustion efficiency for natural gas at different combinations of excess air and
flue gas temperatures are indicated below:

1)"Net stack temperature" is temperature difference between flue gas temperature inside the
chimney and room temperature outside the burner.
TERIMAKASIH