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Energy Saving Opportunities in Industries PDF
Energy Saving Opportunities in Industries PDF
TO
ENERGY SAVING
OPPORTUNITIES IN
INDUSTRIES
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2/22/2014
TO
STEAM BASICS
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hg = hf + hfg
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• Wet Steam
• Superheated Steam
• Flash Steam
– Flash steam is generated when condensate pressure is reduced.
– The specific heat capacity of liquid is lower at reduced pressure and the
excess heat (hf at P1 – hf at P2) is converted to steam at low pressure.
Saturated Steam
• Running of steam engines to do mechanical work.
• As energy storage which is extracted by heat transfer.
• Process heat transfer
• Pipeline tracing for maintaining constant process temperatures.
• Motive fluid for pumping hot steam condensate for reuse to boiler feed
water tank.
• Domestic use for cooking, steam cleaning of fabrics, aircraft food
trolleys and heating of buildings.
Superheated Steam
• Generation of electricity in steam turbines.
• Co generation of electricity in cogeneration steam at high pressure is
first used to generate electricity and then the low pressure steam is
used for other applications
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SERVICES SBU
STEAM PROPERTIES – SATURATED STEAM
• Sp. Volume
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UNITS OF MEASUREMENT OF
PROPERTIES OF STEAM SERVICES SBU
SI Units MKS
Heat kJ kcal
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Other units of pressure are Pa, kPa, MPa, atm, kg / cm2, mm Hg, MWC, psi.
1 atm = 14.696 psi = 1.013 bar = 101.3 kPa = 0.1013 MPa = 760 mm Hg=1.033 Kg/cm2
1 bar = 14.504 psi = 0.1 MPa = 100 kPa = 105 Pa = 0.9869 atm = 1.02 kg/cm2
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• Steam tables for saturated steam and superheated steam are different
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5. Total heat of steam does not show much change but the distribution
of total heat changes
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250
200
Temperature, oC
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Pressure Kg/Cm 2 (a)
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2
1.8
Specific Volume M3/Kg
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2
Steam Pressure Kg/Cm (a)
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APPLICATION OF STEAM
TABLE TREND SERVICES SBU
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COMPARISON
BOILER OPERATING AT DIFFERENT
SERVICES SBU
PRESSURES
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• Dry saturated
• No solids
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• Air enters as dissolved gases in boiler feed water and at every shutdown and gets carried to
heat transfer equipment traveling ahead of steam
• CO2 gets generated if bi carbonates are present in feed water which decompose at high
temperature in the boiler
• CO2 gets absorbed in condensate water due to its lower temperature from atmosphere
• Non condensable in steam lowers its partial pressure resulting in lowering of effective
steam temperature
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DE-AERATION..
SERVICES SBU
Oxygen and many other non-condensable gases enter the steam system through flanged
joints, rusted & leaking fittings.
Oxygen promotes corrosion of pipes and fittings. It affects the heat transfer in equipment.
The
12
D issolved O xyg en in p pm
10
0
1 32 50 65 82 10 0
Temperature in Deg C
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• Solution - Strainers
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TO
STEAM GENERATION
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• Source of energy
– Combustion of fuel
• Fuel conditioning
– Mechanism of burning the fuel efficiently
• Efficient burner
– Efficient transfer of heat to water
• Geometry of heat transfer area
– Effective absorption of heat by water in the boiler
• Adequate turbulence / velocity
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• SOLID FUELS
– Coal, Wood, Husk, Bagasse
• LIQUID FUELS
– Furnace Oil (FO) Light Diesel Oil (LDO)
– High Speed Diesel(HSD) LSHS / HPS
• GASEOUS FUELS
– Liquefied Petroleum Gas (LPG) Natural Gas (NG)
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• LIQUID FUELS
– Furnace Oil (FO)
– Light Diesel Oil (LDO)
– High Speed Diesel(HSD)
– Low Sulphur Heavy Stock (LSHS)
– Heavy Petroleum Stock (HPS)
• GASEOUS FUELS
– Liquified Petroleum Gas (LPG)
– Natural Gas (NG)
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• Solid Fuels
–Composition C, H, N, S, O2, H2O, Ash
–Composition H2O, Ash, Volatile matter, Fixed Carbon, GCV, NCV
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• Liquid Fuels
– Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
– Density, Flash point, Pour point, Sediments
• Gaseous Fuels
– Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
(Normally N, S, O2, Ash is absent)
– Density
– Chemicals present like Methane, Ethane, Propane,
Butane, etc. in volume percent
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• Site Analysis
– For Moisture % as fired condition
• ULTIMATE ANALYSIS
– C, H, N, S, O2, Ash, GCV, NCV
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• N2 & Ash just increase the load on combustion equipment. Ash is also
responsible for clinker formation
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– Shell boiler
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Boiler is rated on the basis of From and At 100oC basis written as F & A
100oC
Actual output from a boiler is always less than the F & A 100oC rating
Actual output from a boiler depends upon the feed water temperature.
Higher the feed water temperature higher is the output
If a boiler is rated as 1,000 kg/h F & A 100oC it means the boiler is rated
to give output of 539.4 kcal/kg of steam
But the process conditions determine the heat load or steam requirement
in a plant
This means higher the feed water temperature lower will be the fuel
consumption
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• TWO METHODS
– Direct Efficiency
– Indirect Efficiency
• As per some standard like BS 845 Part 1 Or ASME PTC 4.1
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• INDIRECT METHOD
• Efficiency = 100 – all losses
– Losses are
• Dry flue gas loss
• Moisture loss
• Hydrogen loss
• Un burnt loss
• Refuse loss, Un burnt in fly ash and bed ash
• Radiation loss
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Losses are:
L1 Loss due to sensible heat of flue gases
L2 Loss due to Hydrogen and moisture in fuel and moisture in
combustion air
L3 Loss due to un-burnt gases in flue has (CO loss)
(required if CO>1000 ppm as per BS 845)
L4 Un-burnt loss – bed ash
L5 Un-burnt fly ash loss
L6 Radiation loss
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Total loss, Lt
Lt gr = (L1 + L2 + L3 + L4 + L5 + L6) gr
Thermal Efficiency, E
E gr = 100 – Lt gr
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• Fuel consumption
• Water consumption
• Steam output
• Stack temperature
• O2 / CO2 in flue gas from chimney
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SERVICES SBU
*
FLOW METERS –
WATER
TM
A ZFLO-W
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SERVICES SBU
5 5
6 6
10 2
11
15 9 12
13
7
8 14
8
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16
45°
SERVICES SBU
D
17
5xD
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2. Steam is formed and taken out of the boiler continuously and does not carry and dissolved solids.
3. If operated like this quantity of solids will go on increasing and will exceed the maximum solubility
at operating temperature. Solids will start separating out and will start depositing on the heat transfer
surfaces in the form of scale.
4. This scale is hard and can cause mechanical damage to the boiler as well as hinder heat transfer as it
is bad conductor of heat
5. Such scale forming is to be prevented and is dine by ensuring that the quantity of dissolved solids
never exceed the maximum solubility level with adequate safety margin
6. This limit is 3500 ppm and is achieved by draining calculated amount of boiler water continuously in
a controlled way (SABCO) or periodically manually.
7. The quantity of water to be drained is calculated by mass balance as per the following formula;
Blow down percentage = { Feed water TDS / ( Boiler water TDS – Feed water TDS) } x 100
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BLOWDOWN LOCATIONS IN
STEAM BOILER SERVICES SBU
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ENERGY SAVING
OPPORTUNITIES - BOILER SERVICES SBU
• Install SOTC on boiler feed water tank for efficient thermal de-
aeration
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STEAM DISTRIBUTION
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• Install header in boiler house near ground level with valves and an air
vent
• Use zero leakage valves like bellow seal valves
• Use NRV in steam line if more than one boilers are connected to the
header
• Ensure correct size of Piping
• Provide header drain arrangement every 30 m of horizontal steam pipe
run
• Provide air vent, vacuum breaker and drain steam trap at the end of
steam header
• Provide moisture separators at entry to each steam using plant or
critical equipment
• Insulate even valves and flanges in steam lines
• Use pressure reducing stations
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• Process Design
– Superheated steam
• Lines sized at velocity of upto 45 m/s
– Saturated steam
• Lines sized at velocity of 30 m/s for long lines
• Lines sized for 35 m/s for short lines
– Wet Steam
• Lines sized at velocity of 10 to 15m/s
– Steam Header
• 10 to 15 m/s
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m = 3600 . u . a . ρ
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100 426 0.85 509 1.01 761 1.51 1016 2.02 1207 2.40 1525 3.03
150 915 1.82 1094 2.17 1638 3.25 2185 4.34 2596 5.15 3279 6.51
200 1578 3.13 1882 3.74 2825 6.61 3765 7.47 4473 8.88 5650 11.21
250 2444 4.85 2943 5.84 4379 8.69 5839 11.59 6933 13.76 8757 17.38
300 3566 7.08 4259 8.45 6386 12.76 8515 16.90 10113 20.07 12774 25.35
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1. Body
2. Cover
3. Cover Gasket
4. Bi-metallic Plate
5. Strainer
6. Seat
7. Valve
8. Adjustment Screw
9. Cover Bolts
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SS STRAINER
SERVICES SBU
BODY
DISCHARGE
BOLT
SS COVER SS DISC
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SS COVER
SS BODY
SERVICES SBU
THERMOSTATIC CAPSULE
SS STRAINER
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SS COVER
SS BALL
SS GASKET
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TO
LEARNING THE BASICS OF
STEAM UTILISATION
&
CONDENSATE RECOVERY
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• Direct Heating
– Total enthalpy of steam available for heating which is higher that
latent heat
– Product gets contaminated
– Product gets diluted
– No steam traps are required
– Condensate can not be recovered for re use
• Indirect heating
– Only latent heat available for heating which is lesser than total
enthalpy of steam
– Most of the industries use indirect method of heating
– Condensate can be recovered for re use provided same heat
transfer area is not used for heating and cooling like coil in a
reactor
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• Steam traps are automatic valves which work on the principle of difference in
property of steam
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SERVICES SBU
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EXPECTATIONS FORM A
STEAM TRAP SERVICES SBU
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STEAM TRAPS
SERVICES SBU
1 Boiler Header 2
4 Steam Separators 3
5 Tracing Lines 2
7 Submerged Coils 2
9 Jacketed Kettles 3
10 Evaporators 2
11 Flash tanks 3
12 Platen Presses 2
17 VAM 2
Note:
If the operating pressure differential varies to a very low value increase the safety factor
RECOMMENDED STEAM
TRAPS FOR EQUIPMENT SERVICES SBU
• Float tarps
– With thermostatic vent
• These are the normal traps
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SERVICES SBU
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SERVICES SBU
BODY
SS DISC
SS SEGMENT
SERVICES SBU
CENTERING
HOOP SS
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• A steam trap blowing live steam will make a low pitch whistle
• When a test valve is provided you can open it and observe the operation
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• Water hammer
water hammer can destroy thermostatic element or crush ball float
• Dirt
Dirt can plug strainer or lodge on the pin or seat. Dirt can plug the vent
hole in bucket traps causing them to fail shut
• Pressure rating
the trap seat pressure rating must be higher than the maximum steam
pressure or the trap will fail closed
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SERVICES SBU
ADVANTAGES OF CONDENSATE RECOVERY
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Flash Vessel De-aerator head & Immersion tube Condensate transfer pump
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ECONOMICS OF CONDENSATE
SERVICES SBU
RECOVERY
• Good payback period for low cost fuels like agro waste,
wood brickets, etc.
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• Boiler
1. Efficient burner operating at low excess air so that we
get low excess air and high CO2 in flue gas
2. Instruments for O2, and stack temperatures
3. Fuel flow meters for liquid / gaseous fuel, steam flow
meter and water flow meter
4. Boiler performance monitoring system
5. Boiler surface blow down control and heat recovery
system
6. Heat recovery units for extracting heat from flue gas
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TO
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SERVICES SBU
PROBLEMS WITH LEAKING VALVES
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A process requires 25,000 kg/h of water to be heated from 30oC to 75oC. Steam
is available at 10 kg/cm2 as well as 3.5 kg/cm2. Select the steam pressure
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USE OF TEMPERATURE
CONTROLLERS SERVICES SBU
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ΔT (Normal) 80 – 30 50oC
ΔT (Overheating) 85 – 30 55oC
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CASE STUDY 4
USE OF BIMETALLIC STEAM TRAP IN PLACE OF THERMODYNAMIC TYPE
For Thermax Chemical @ 6 bar
For TD trap For BM trap
Legend Description Unit Readings Readings SERVICES SBU
to Time at start up HH: mm 11:00 11:30
M1 Mass of water initially kg 15.55 15.8
T1 Temperature of water initially Deg C 32 31
t1 Time at end HH: mm 11:15 11:45
M2 Mass of water at end kg 17.65 16.85
T2 Temperature of water at end Deg C 54 40
Tc Tempearature of condensate before trap Deg C 158.826 158.826
Em Live steam Heat content at available pressure Kcal / kg 659.3636364 659.3636364
Lm Mass of Live steam Kg 0.24 0.03482795
T Duration of trial min 15 15
Lm Mass of Live steam Kg / Hr 0.97 0.14
Live steam saving with BM kg/hr 0.84
SERVICES SBU
CASE STUDY 5 CONDENSATE RECOVERY SYSTEM
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SERVICES SBU
CASE STUDY 6 BLOW DOWN HEAT RECOVERY
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• V K TRAMA
MOBILE 09890040272
E MAIL vktrama@yahoo.co.in
• Sushama Garud
Mobile 02066155577
E mail info.c&hservices@thermaxindia.com
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SERVICES SBU
THANK YOU
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