Final Project Corrected

OPTIMIZATION OF FUEL EFFICIENCY IN SATURATED STEAM
BOILER IN SHEMU PLC|| 2012E.C
DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL

CHEMICAL AND BIOENGINEERING DEPARTMENT OF
CHEMICAL ENGINEERING
HOSTING COMPANY: SHEMU SOAP AND DETERGENT

(PLC)
PROJECT TITLE: OPTIMIZATION OF FUEL EFFICIENCY IN

SATURATED STEAM BOILER
DONE BY: ID NO
1. DEREJE SHIFERA………… R/0785/09

2. GETU MENGISTU………….. R/0796/09
3. IJARO KUFA ……………… R/0727/09
SUBMITTED TO…
SUBMISSION DATE…
DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

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ACKNOWLEDGEMENT
This project could not have been completed without the help of many individuals throughout the
course of the semester. We would like to thanks Mr. MESELE GIDEY plant supervisor for
their guidance throughout the design project. Additionally, we would like to thanks Dr. SELVA
KUMAR Who is our advisors Target for proposing this project, his willingness to provide
resources and his professional knowledge in aiding our process design. We would also like to
thank DIRE DAWA INSTITUTE OF TECHNOLOGY for initially working with us in
attempting to get internship experience. Lastly, we greatly appreciate the guidance and helpful
input during the design meeting from the following people: many workers of the company,
school of chemical and bioengineering and also we would like to thanks all friends that help
our project procedure.

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ABSTRACT
Energy saving is an important concern in every industrial process that could be achieved by
optimizing the fuel consumption. Significant part of operating cost of any industrial process is
associated with the fuel consumption. Therefore, optimization in fuel consumption can lead to a
significant energy saving and lower operational costs along with reduce green house gas
emissions. In this study the goal of fuel consumption optimization has been achieved by
optimizing the air fuel ratio of the steam boiler. The air to fuel ratio has been optimized by pre-
mixing of air and fuel before it is introduced to the furnace. This project is concerned with
calculating boiler efficiency as one of the most important types of performance measurement in
any steam power plant and the idea of the project is to monitor the boiler performance by the
way to control the heat rate of the boiler and operating the boiler more economical.
.

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TABLE OF CONTENTS
ACKNOWLEDGEMENT……………………………………………………………………………………………………………i
ABSTRACT………………………………………………………………………………………………………………………………ii
CHAPTER ONE………………………………………………………………………………………………………………………..1
INTRODUCTION………………………………………………………………………………………………………………………1
1.2 PROBLEM OF STATEMENT AND JUSTIFICATION……………………………………………………………….6
1.3.1 OBJECTIVE OF THE PROJECT…………………………………………………………………………………………6
1.3. 2 Main Objective……………………………………………………………………………………………………………...6
1.3 .2 Specific Objectives………………………………………………………………………………………………………..6
1.3.3 Significance of the project………………………………………………………………………………………………6
1.3.4 Scope of the project……………………………………………………………………………………………………….6
CHAPTER TWO……………………………………………………………………………………………………………..6
2. LITERATURE REVIEW……………………………………………………………………………………………………..7
2. 2.1.Selectio steam boiler…………………………………………………………………………………………….8
2.2.2. Maintenance Costs…………………………………………………………………………………………………………8
2.2.3. Boiler performance……………………………………………………………………………………………………..8
2 ,2. 4. Fuel Usage………………………………………………………………………………………………………………….9
2.2.5.Efficiency……………………………………………………………………………………………………………………9
2.2.6.Steam boiler Efficiency Feature Comparisons ……………………………………………………………….9
2.2.7 Number of boiler passes……………………………………………………………………………………………

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2.2.8. Burner / boiler compatibility……………………………………………………………………………………..10
2.2.9. maintenance required ……………………………………………………………………………………………..10

2.3.1. Repeatable air/ fuel control…………………………………………………………………………………….10
2.3.2. Heating Surface………………………………………………………………………………………………………11
2.3.3. Vessel design………………………………………………………………………………………………………….. 11
CHAPTER THREE …………………………………………………………………………………………………..12

METHOD AND METHODOLOGY …………………………………………………………………………12
3.2 Method………………………………………………………………………………………………………………………..12
3.1.1 Combustion Gas Cleaning and Heat Recovery From Combustion of Liquid Fuels……………13
3.2.2 Innovative System For heat Recover and Combustion Gas Cleaning………………………………….13
3.2.3 Combustion air preheater………………………………………………………………………………………………13
CHAPTER FOUR……………………………………………………………………………………………………………………14
4. RESULT AND DISCUSSION……………………………………………………………………………………..14
4.1 Stack loss method………………………………………………………………………………………………………15
4 .1.1. Impact and sensitivity of steam boiler …….....................................................................16
4.2.1. Flue Gas Temperature……………………………………………………………………………………………….16
4.2.2. Fuel specification……………………………………………………………………………………………………..16
4.2.3. Excess Air…………………………………………………………………………………………………………………17
4.2.4. Ambient…………………………………………………………………………………………………………………..17
4.2.5. Radiation and Convection losses………………………………………………………………………………17

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MAXIMIZATION OF FUEL EFFICIENCY IN SATURATED STEAM BOILER BY USING PREHEATING

CONTROL AIR –
MIXTURE…………………………………………………………………………………………………………………………18
CHAPTER FIVE………………………………………………………………………………………………………………….19
5 CONCLUSION AND RECOMMENDATION……………………………………………………………...19
5.1 Conclusion………………………………………………………………………………………………………19
5.2.Recommendation………………………………………………………………………………………………..19
REFERANCE …………………………………………………………………………………………………………………20
APPENDIX………………………………………………………………………………………………………………………….20

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CHAPTER ONE
INTRODUCTION
High efficiencies and low greenhouse gas emission along with energy saving are the main goals
of boiler optimization .Steam boilers are used in most of the industrial processes including power
plants, food industry, pharmaceuticals, fertilizer and refineries etc. Moreover, the flue gases
produced.as a result of fuel burning are the prominent source of greenhouse gases. Therefore,
optimization of fuel in boiler important for protecting the environment and reducing the energy
consumption. Fire tube boilers are extensively used in industry for steam generation and heating
purposes, making it one of the most energy consuming equipment. Most of the fire tube boilers
utilizes 75-80% of fuel supplied to furnace while rest is lost unburnt fuel in flue gases, making
the process highly energy intensive. This also results in the production of the flue gases with
high carbon an N Ox content. Since both the fuel and flue gases are in same phases, it is not
possible to completely recover the fuel from the stack flue gases. Therefore, optimization of
excess air in air-fuel mixture is very important. Different methods are used to optimize the airto
fuel ratio, thus improving the thermal efficiency and environmental performance of steam
boilers. In addition to amount, the temperature of air-fuel mixture (or excess air)effects the
efficiency of boiler. Excess cold air entering the combustion chamber results in an increase of
carbon monoxide(CO) emission due to quenching of combustion and combustion products,
serving as an indication of poor combustion efficiency.
The efficiency of the boiler depends on the ability of the burner system to provide the
proper air to fuel mixture throughout the firing rate, day in and day out, without the need
for complex set-up and adjustments. With advances in control technology, consistent,
repeatable burner control can now be accomplished in two different ways. The
conventional approach to burner control is commonly referred as single point positioning,
where a single control actuator will drive both the fuel valve and combustion air damper in
tandem. Most all boilers on the market are offered with this type of burner control system,
however not all designs are equal. Many designs utilize complex linkage assemblies with
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multiple pivots, pins, and other points that are subject to wear and “slop”. These complex
designs don’t hold precise air to fuel settings over time, resulting in the need to adjust the
burner to high excess air levels to compensate for the inconstency in the burner
performance. The fuel the boiler uses, and the monthly bill you pay, are based on the real
day to day efficiency of the unit, not the performance on day one. When evaluating
burners, insist on a simple, robust linkage assembly and an easily accessible burner design
for true efficiency and real day to day savings.
1.2 PROBLEM OF STATEMENT AND JUSTIFICATION
The present of energy demand overtaking energy supply top priority is given for energy
conservation programs and policies. The energy destruction fuel consumption of boiler that the
SHEMU PLC Company used and the cost required.for fuel are frequently rises from time to time.
This occurred due to the loss of boiler efficiency. The losses of boiler efficiency causes reduction of
stability of boiler operation, decrease steam production rate and giving rise of flue gas temperature.
In order to compensate the losses of steam production rate it needs high amount of fuel. This
increment of fuel consumption causes cost losses and carbon emission for environmental
pollution.There is theoretical or stoichiometric amount of air required for complete combustion of
fuel. In practice, combustion conditions are never ideal, and additional or “excess” air must be
supplied to completely burn the fuel. When the air falls below the stoichiometric value, there is
some fuel that is not burned completely. This partially burned fuel creates smoke, leaves deposits
on firesides, and creates environmental problems. Unburned fuel may also represent a significant
waste of energy. The amount of waste depends on the energy content of the unburned fuel.
1.3. Objective of Project
1 .3 .1 Main Objective
The main objective of the project was to optimization of fuel efficiency in saturated steam boiler.

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1.3 .2 Specific Objective
 Increasing the performance boiler efficiency

 Reducing environmental pollution
 Minimizing the cost
1.3.3 Significance of the project
The main benefits of this project are mitigate fuel consumption (cost loss) and carbon emission to
the environment.
1.3.4 Scope of the Project
The scope of this project is using preheating air mixture on the reduction of heat losses and
increasing the efficiency of fire tube steam boiler in SHEMU PLC.

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CHAPTER TWO
2. LITERATURE REVIEW
In the U.S. Energy Information Administration's (EIA) ANNUAL ENERGY OUTLOOK 2020
(AEO2020), projected volumes of U.S. net imports of crude oil are primarily driven by domestic
crude oil production and vary widely by case. The larger volumes of domestic production in the
High Oil and Gas Supply case relative to the Reference case result in the United States exporting
more crude oil than it imports (a net exporter) after 2024. In the High Oil Price case, the United
States is a net exporter of crude oil from 2023 through 2027 as a result of a decline in U.S.
petroleum consumption and higher domestic production, which also contribute to net exports. On
a combined crude oil and petroleum product basis, the United States became a net exporter in
September 2019.
AEO2020 presents a Reference case that represents EIA's best assessment of how U.S. and
world energy markets will operate through 2050, based on key assumptions intended to provide a
base for exploring long term trends. In addition to the Reference case, various side cases show
the effect of changing model assumptions on the projections. The High Oil Price and Low Oil
Price cases simulate international conditions outside the United States that could collectively
drive prices to their respective extremes, and the High Oil and Gas Supply and Low Oil and Gas
Supply cases vary production costs and resource availability within the United States only.
In the Reference case, U.S. crude oil production plateaus at approximately 14 million barrels per
day (b/d) in the mid-2020s and begins to decline in the mid-2040s (Figure1). Domestic production
in the High Oil Price case and the High Oil and Gas Supply case exceeds 19 million b/d in 2024 and
2050, respectively. Although production in the High Oil and Gas Supply case reaches its AEO2020
peak at the end of the projection period, crude oil production in the High Oil Price case quickly
declines in the mid-2020s from its peak of 19.3 million b/d as the resource is developed more
quickly, limiting the production from technological improvements that occur over time. Production
in the Low Oil Price case and the Low Oil and Gas Supply case declines throughout most of the
projection period to 8.6 million b/d and 7.9 million b/d, respectively, in 2050.

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2.1 Selection of Steam Boiler
Selection of a boiler with “designed-in” low maintenance costs and high efficiency can really pay off
by providing ongoing savings and maximizing your boiler investment. The decision to purchase a
new boiler is typically driven by the needed replacement of an old boiler, an expansion of an
existing boiler room, or construction of a new boiler room facility.When considering the
replacement of an old boiler, review the following points to make sure you are performing a
comprehensive evaluation of your situation
2.2.1 Maintenance Costs
The old unit is costing you money in various ways, including emergency maintenance, downtime,
major maintenance requirements (past and pending), difficult–to–find and expensive parts
requirements, operator time in keeping the unit on-line, and overall vessel, burner, and refractory
problems. Many of these costs can be hidden within your overall maintenance budget. You are
paying the price for having outdated boiler room equipment. But the costs need to be investigated
and totaled
2.2.2. Boiler performance
New packaged firetube boilers have much higher performance standards than older design units.
Guaranteed high efficiency, high turndown, accurate and repeatable air to fuel ratio burner control,
programmable boiler controls, automatic fuel changeover, automatic excess air trim, ultra- low
emissions technology, and connectivity to building automation systems are available on premium
packaged firetube boilers. The result is automatic boiler control with lower operating costs for
your facility. All cost saving reason to consider a new packaged firetube boiler.
2.2 3. Fuel Usage
If your old unit is designed to fire low grade fuel oil, or if you need to evaluate propane or any other
different fuel capability, review the conversion costs along with existing maintenance, performance,
and efficiency issues to see if the time is right to consider a new boiler purchase. Many times an
investment is made in an old unit when the costs associated with the next major maintenance
requirement will justify a new unit. The result is wasted money on the old unit upgrade

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2.2.4. Efficiency
The data will give you a general idea of the differenceand similar add on devices may help pass an
initial efficiency test, but will cost you in increased maintenance and diminishing performance
down the road. In fact, you do not need high maintenance, boiler tube, add-on devices if the boiler
is designed for optimum flue gas velocities in the first place. Each boiler pass should be designed
with a cross sectional area to achieve optimal flue gas velocity, which in turn maximizes heat
transfer while also minimizing performance robbing soot buildup within the tubes. When it comes
to efficiency, the proof is indeed in the number of passes and optimized boiler pass design.
2.2.5 .Steam Boiler Efficiency Feature Comparisons
All firetube boilers are the same? Not true! The fact is there are key feature differences between
firetube boilers. The efficiency of a firetube boiler is not a mysterious calculation. High efficiency is
the result of tangible design considerations incorporated into the boiler. Reviewing some basic
design differences from one boiler to another can provide you with valuable insight on expected
efficiency performance. The following design issues should be considered during your boiler
evaluation.
2.2.6. Number of Boiler passes.
The number of boiler passes represents the number of times the hot combustion gasses travel
across the boiler (heat exchanger). A boiler with two passes provides two opportunities for the hot
gasses to transfer heat to the water in the boiler. A 4-pass design provides four opportunities for
heat transfer. The stack temperature of a 4-pass boiler will be lower than the stack temperature of
a 2 or 3-pass boiler, of the same basic design, operating under similar conditions. Because of this
fact, the 4-pass will have higher efficiency and lower fuel cost. This is not an opinion; it is basic heat
exchanger physics. The 4-pass design will yield a higher overall heat-transfer coefficient.
In an attempt to improve heat transfer, many boilers with fewer passes will employ after-the-fact
add-on devices within the tubes, or will be tested at less than full firing rate to prove lower stack
temperatures. Don’t be fooled. Turbulators

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and similar add on devices may help pass an initial efficiency test, but will cost you in increased
maintenance and diminishing performance down the road. In fact, you do not need high
maintenance, boiler tube, add-on devices if the boiler is designed for optimum flue gas velocities in
the first place. Each boiler pass should be designed with a cross sectional area to achieve optimal
flue gas velocity, which in turn maximizes heat transfer while also minimizing performance robbing
soot buildup within the tubes. When it comes to efficiency, the proof is indeed in the number of
passes and optimized boiler pass design.
2.2.7 Burner / boiler compatibility

The term packaged boiler is sometimes used even if a burner manufactured by one vendor is
bolted on to a boiler manufactured by a different vendor. Is bolting a “Buy-out” burner on a vessel
really a packaged boiler? And more importantly, why does it matter? A true packaged boiler/burner
design includes a burner and boiler developed as a single unit, accounting for furnace geometry,
radiant and convection heat transfer characteristics, and verified burner performance in the
specific boiler package. Development as a truly packaged unit assures the performance of the unit is
proven and verified during development.
You can install an engine designed for one make of car into an entirely different make of car. The
car will probably run and drive reasonable well. But what about performance? Will the car have
the same fuel efficiency and reliability as if it had left the factory that way? Is the engine really a
good fit for the car, or will there be problems and headaches down the road? If you need service,
who do you turn to? The engine manufacturer? The maker of the car?
A boiler provides the same scenario. The buy-out burner will fire the unit, however compromises
are made in the mating of the burner to the boiler, affecting performance, efficiency, or both. Can
the burner/boiler package achieve high turndown, fuel efficiency, and low emissions? Who will
guarantee the performance and who is accountable if it fails to perform? The burner manufacturer?
The maker of the boiler? Buy-out burner packaging can result in compromised performance, higher
start-up costs, and increased

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2.2.8. maintenance requirements
It also can cost you money every time you have a problem and the local service people cannot get
factory support. You may think you saved money with a buy-out burner package.
2.2.9. Repeatable air/ fuel control
The efficiency of the boiler depends on the ability of the burner system to provide the proper air
to fuel mixture throughout the firing rate, day in and day out, without the need for complex set-
up and adjustments. With advances in control technology, consistent, repeatable burner control
can now be accomplished in two different ways. The conventional approach to burner control is
commonly referred as single point positioning, where a single control actuator will drive both the
fuel valve and combustion air damper in tandem. Most all boilers on the market are offered with
this type of burner control system, however not all designs are equal. Many designs utilize
complex linkage assemblies with multiple pivots, pins, and other points that are subject to wear
and “slop”. These complex designs don’t hold precise air to fuel settings over time, resulting in
the need to adjust the burner to high excess air levels to compensate for the inconstency in the
burner performance. The fuel the boiler uses, and the monthly bill you pay, are based on the real
day to day efficiency of the unit, not the performance on day one. When evaluating burners,
insist on a simple, robust linkage assembly and an easily accessible burner design for true
efficiency and real day to day savings. With the recent advances in digital control technology,
many boilers can now be equipped with two point positioning (parallel positioning) systems,
where separate actuators are used to control the fuel and combustion air independently. These
systems, when paired with the latest in advanced programmable control technology, allow for
very precise air to fuel ratio control with excellent repeatability. These systems also allow
advanced options such as automatic fuel changeover and true combustion monitoring and
optimization (flue gas O2 adjustment) similar to a modern automobile, without the need for
complex linkages or additional add on devices. When
evaluating a parallel position system, insist on robust, high torque actuators that are field
replaceable without the need to recommission the boiler to return to operation. Insist on easy

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and straightforward set-up, with the flexibility to achieve the optimum air to fuel curve for your
boiler, at your location, serving your systems. A well designed parallel positioning burner
system, with the addition of real time combustion monitoring and trim, will achieve the highest
level of day to day fuel savings possible. The second feature to look for in burner design is the
combustion air control damper. Low quality register or blade type damper assemblies tend to
have limited control of air at low firing conditions and also tend to be much less repeatable than
radial damper designs. A low quality blade or register damper will affect the burner in the same
way as a complex, low quality linkage. The result is inconsistent burner control and the need for
higher excess air to compensate. Insist in a high quality, robust damper to ensure the best day to
day efficiency. Along with the damper design and the burner control system, the design of the
combustion air fan should also be considered. Inexpensive squirrel cage type fans do not provide
stable and reliable air control in the way that a backward inclined fan can. A cast aluminum fan
assembly is preferred, providing tight tolerances for maximum efficiency and longer fan life.
Without a fan capable of delivering a stable and predictable supply of air, the best burner control
and damper designs available are wasted. This is especially true if a variable speed drive will be
used, which is becoming a more popular option to reduce the electrical consumption of the fan
and also as an additional means to trim excess air. The stable nature of a backward inclined fan
along with the high efficiency of cast fan construction result in high day to day efficiency and
repeatability, resulting in real fuel savings that pay dividends over the life of the boiler.
2. 3.1. Heating Surface
The heating surface in square feet per boiler horsepower represents, in general terms, how hard
the vessel is working. For the most part, firetube boilers today are designed with five square feet of
heating.
With the rapid improvement in computer technology, advanced computational fluid dynamics
modeling is now being used to develop designs that deviate from the standard. Firetube boiler
designs are available using as little as four square feet of heating surface, while achieving equal or
better efficiency than designs with the standard five, without compromising vessel longevity.
Precise engineering is crucial to achieve these results. Designs using less than the five square feet

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standard can only achieve these results through full optimization of all aspects of the heat transfer
process, from matched boiler/ burner development, optimized furnace design to achieve high
radiant heat transfer, optimized tube design, critical placement of the boiler passes within the
vessel, and even proper feedwater or return water circulation to further enhance overall heat
transfer. Not all boilers are created equal. When considering a design that uses less than the
standard, request the facts to back up the performance and longevity claims.
2.3.2.Vessel design.
Proper water circulation, low internal stresses, and easy accessibility for inspection and
maintenance are key criteria when evaluating the design of a pressure vessel.

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CHAPTER THREE
3.1. METHOD AND METHODOLOGY
3.2 Method
3.1.1 Combustion Gas Cleaning and Heat Recovery From Combustion of Liquid
Fuels method
Light fuel oil is most frequently burned in oil boiler-room of small and medium power. In terms of
the volume of production of vegetable oils in the world, rapeseed oil comes second after soya oil.
The EU countries are its largest producers. In these countries, rapeseed oil is most frequently used
for heating purposes. Oils for heating are characterized by high viscosity, high surface tension and
difficult ignition (it is a mixture of fractions boiling in a wide range of temperatures) and therefore
it is burned blended with fuel oil. The greatest advancement in new constructions is observed in
industrial fuel oil burners, which, in comparison with burners of small and medium power, are
characterized by very high emission of pollutants. Systems of automatic control and adjustment of
air flow to the boiler, which are used in modern boilers, allow maintaining energy efficiency at a
relatively high level Oil condensing boiler.
3.2.2 Innovative System For heat Recover and Combustion Gas Cleaning method
The solution which was developed and is discussed herein comprises an installation for
fuel saving, combustion gas cleaning and recovery of heat and water from combustion
gases produced in combustion chambers of boilers, combustion engines, gas turbines,
reaction chambers, etc., which use liquid or gaseous fuel, mainly biofuels. It is particularly
dedicated to devices of small and medium power, in which technologically advanced
methods of combustion gas cleaning are not used. As a result of fuel combustion in
combustion chambers, combustion gases of high temperature are produced, which are

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used to obtain a useful effect. Before combustion gases are released to the atmosphere,
they may be of a relatively high temperature, which is a measure of the effect of sensible
heat. They also contain water vapor which is the source of latent heat. Such combustion
gases should be used for the generation of secondary useful effects ,e.g.,external `heatingof
energy carriers and/or heating of substrates of the combustion process, i.e., air and/or fuel.
3.2.3. air pre- heater and economizer or waste heat recover method
Air pre-heater and economizer are heat transfer surfaces in which air temperature and water
temperature are raised by transferring heat from other media such as flue gas. Hot air is necessary
for rapid combustion in the furnace and also for drying coal in milling plants. So an essential boiler
accessory which serves this purpose is air pre-heater. This paper deals with the different ways to
obtain the maximum heat from the flue gas travelling through the air pre-heater and the
economizer zone to improve the boiler efficiency. In this paper the performance of the air pre-
heater has been studied on the basis of the combustion air passing through it. The correct
optimization of the combustion air can increase the boiler efficiency by 2-3%. It also ensures less
fuel consumption. By reducing the air pre-heater leakage the auxiliary power consumption is also
reduced. Thus the fuel is saved which leads to a considerable amount of profit.
3.2.4. shell Loss Method
Shell loss is the amount of fuel energy that leaves the boiler from its outer surface. The
surface of the boiler is above ambient temperature and hence, there is always a certain
amount of heat lost to the surroundings. This heat loss occurs due to radiation and
convection from the boiler surfaces. It is difficult to accurately measure the shell loss from
a boiler. It is generally estimated from some limited field measurements. The American
Society of Mechanical Engineers Performance Test Code 4 (ASME-PTC-4) provides a
detailed methodology for calculating this loss from the boiler surfaces.

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A first order of magnitude shell loss is provided in Table 3 below as a guide. The shell loss
estimation methodology utilizes the characteristic temperature of a boiler surface, surface
area and an estimated ambient surface airflow velocity. These estimates are used to
complete a heat transfer analysis for all of the surfaces of the boiler and yield an estimate
for the overall boiler shell loss. This technique is simple; however, the results must be
considered a general estimate.
table 3: First order shell Loss Guide
shell Loss Gross estimate Field evaluations
steam Production rating boiler Full-Load shell Loss estimate

Minimum Maximum Maximum Minimum
[Tph] [Thp] [Tph] (Thp)
Water T ube 5 50 2.0 0.3
Water tube 50 500 0.6 0.1
Water Tube 500 5000 0.2 0.1
Fire tube 0.5 20 1.0 0.1
It should be noted that the boiler shell loss magnitude is constant and is independent of the boiler
load. Shell loss is expressed as a percent of fuel input energy. Hence, shell loss (%) increases as the
boiler load reduces. For most well-maintained boilers, the full load shell loss is expected to be
~0.1% to 2% of total fuel input energy.
example An ASME type investigation of the shell loss for the 20 Tph natural gas boiler indicates that
the shell loss is ~0.5%. The measured natural gas flow rate is 1,693 m³/hr (28 m³/min) and the
cost of natural gas is ($1.0/m³). Estimate the fuel input energy cost associated with the shell loss.
From the information provided,
• mfuel = 1,693 m³/hr • kfuel = 1.0 $/m³ • λshell = 0.5%
kShell = mfuel × kfuel × shell KS hell = 1,693 × 1.0 × 0.005 = $8.47/hr

Kshell = 8.47 × 8,760 ≈ $74,200/yr

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3.2.5. blow down Loss
Boiler feedwater is treated make-up water and condensate. However, there are still dissolved
chemicals in boiler feedwater which do not exit the boiler with the steam because they are not
soluble in steam. As a result, the concentration of these chemicals increases in the boiler.
Elevated concentration of chemicals in boilers can result in serious operational problems and
boiler integrity can be damaged. These problems could include but are not limited to: foaming
resulting in liquid carryover, scaling on the water-side of the tubes resulting in tube leaks and
failures, loose sludge in the boiler water, etc.
Blowdow is the primary mechanism that controls the water chemistry of the boiler water.
Blowdown controls the concentration of dissolved and precipitated chemicals in the boiler and
ensures that the boiler functions reliably and is not subject to an unplanned shutdown or failure.
Generally, blowdown is controlled based on boiler water conductivity. Conductivity is a direct

measurement that can continuously provide an indication of boiler water quality. However,
conductivity must be correlated to individual chemical contaminants through periodic water
analysis. Conductivity and the results of specific boiler water testing aid in adjusting the
blowdown rate.
It should be noted that blowdown is saturated liquid at boiler pressure. Hence, there is a
significant amount of thermal energy associated with blowdown. As blowdown is discharged
from the boiler, this thermal energy (which was provided by the fuel) is lost. The ratio of this
energy lost to the total fuel input energy is the blowdown loss - λblowdown
Utilizing conventional flow meters for measuring blowdown flow is difficult because blowdown
is saturated water which will flash at the slightest pressure drop. Most flow meter devices will
impose a sufficient pressure drop that results in a two-phase flow that is impossible to measure.
Hence, in order to measure blowdown, a particular chemical composition in the feedwater and in
the boiler water is measured. The chemical component measured in the analysis must be of
sufficient concentration to allow an accurate measurement. The ratio of that chemical’s

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concentration in the feedwater to its concentration in the boiler water is used to establish the
blowdown rate. Blowdown flow (β) as a percent of feedwater flow is therefore as follows:
β=
Blowdown Flow
Feed water Conductivity Feed water Flow Blow down Conductivity
where hblowdown and hfeedwater are the enthalpies of the blowdown and feedwater streams,
respectively.
Calculate the amount of blowdown and blowdown loss for the 20 Tph natural gas fired boiler
operating at 25 bars. Boiler feedwater is supplied at 30 bars, 110°C. Additional information
about the fuel flow rate and water chemistry is provided below.
 HHV of natural gas = 54,220 kJ/kg (40,144 kJ/m³) •

 Fuel supply = 1,693 m³/hr (28 m³/min)
 Fuel cost = $1.0/m3 •
 Conductivity for blowdown = 2,000 mmhos/cm
 Conductivity for feedwater = 100 mmhos/cm
 Makeup water temperature: 20°C
Blowdown mass flow rate is calculated from the information provided as follows:
𝐹𝑙𝑜𝑤 𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦
β =𝐵𝑙𝑜𝑤𝑑𝑜𝑤𝑛 𝐹𝑙𝑜𝑤 ≈ 𝐹𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟 𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦
𝐹𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟 𝐵𝑙𝑜𝑤𝑑𝑜𝑤𝑛
𝛽
𝑚𝑏𝑙𝑜𝑤𝑑𝑜𝑤𝑛 = ( − 𝛽) 𝑚𝑠𝑡𝑒𝑎𝑚
1
𝛽 =Feedwater Conductivity/Blowdown Conductivity
100/2000=0.05
Kbd_system = mfuel × kfuel × λbd_system

Page 21
Kblowdown=1693× 0.0137 =$23.2/hr.
Kbd_ system = 23.2 × 8,760 ≈ $203,180/y
table 3.1 stack Loss table for natural
(Reference: Combustion model developed by Greg Harrell, Ph.D., P.E.) stack Loss table for typical
natural Gas
Flu Flue Com

e Gas O2 b Net Stack Temperature
Gas Conten Conc 100 128 156 183 211 239 267 294 322 350 378 40
O2 t Dry [ppm 6
Con Basis ]
tent [%]
We
t
Bas
is
[%]
1 1.2 0 13. 14. 15. 16. 18. 19. 20. 21. 22. 23. 24. 25
6 7 8 9 0 1 2 3 4 6 7 .9
2 2.4 0 13. 14. 16. 17. 18. 19. 20. 21. 23. 24. 25. 26
8 9 1 2 4 5 7 9 1 2 4 .6
3 3.6 0 14. 15. 16. 17. 18. 20. 21. 22. 23. 25. 26. 27
0 2 4 6 8 0 3 5 7 0 3 .5
4 4.7 0 14. 15. 16. 18. 19. 20. 21. 23. 24. 25. 27. 28
2 5 7 0 3 6 9 2 5 8 2 .5
5 5.8 0 14. 15. 17. 18. 19. 21. 22. 24. 25. 26. 28. 29
5 8 2 5 9 2 6 0 4 8 2 .6
6 6.9 0 14. 16. 17. 19. 20. 22. 23. 24. 26. 27. 29. 30
8 2 6 1 5 0 4 9 4 8 3 .8
7 8.0 0 15. 16. 18. 19. 21. 22. 24. 25. 27. 29. 30. 32
1 6 1 7 2 8 3 9 5 1 7 .3
8 9.1 0 15. 17. 18. 20. 22. 23. 25. 27. 28. 30. 33. 34
5 1 8 4 1 7 4 1 8 5 9 .0
9 10.1 0 16. 17. 19. 21. 23. 24. 26. 28. 30. 32. 34. 35
o 7 5 2 0 8 6 5 3 1 0 .8
10 11.1 0 16. 18. 20. 22. 24. 26. 28. 30. 32. 34. 36. 38
5 4 3 2 2 1 1 1 1 1 1 .1
Actual Exhaust Tem 121 149 177 204 232 260 288 316 343 371 399 42
Ambient Temp 7
21 21 21 21 21 21 21 21 21 21 21 21

Page 22
Estimate the stack loss on a 20 Tph operating boiler that has the following conditions:
 HHV of natural gas = 54,220 kJ/kg (40,144 kJ/m³)
 Fuel supply = 1,693 m³/hr (28 m³/min)
 Fuel cost = $1.0/m3 • Stack temperature: 200°C
 Flue gas oxygen: 5%
 Negligible combustibles were found in stack gas analysis
 Ambient air temperature: 20°C
Table 3.1: Examble Boiler – Stack Loss
Natural Gas 18.3%
Number 2 Fuel Oil 14.0%
Number 6 Fuel (Lower Sulfur) 13.5%
Number 6 Fuel (Higher sulfur) 13.7%
Typical Eastern Coal ( Bituminuos) 12.0%
Typical Western Coal (Subbituminuos) 13.6%
Typical Green Wood 24.7%
Estimate the boiler efficiency (Indirect Efficiency Calculation) based on the different losses
calculated in the previous sections on the 20 Tph natural gas operating boiler.
ηboiler = 100 - λshell – λ blowdown – λ stack – λ miscellaneous
η boiler = 100 - 0.50 - 0.79 - 18.3 - 0.0
η boiler = 80.4%
Note that the results from the in this method of calculating boiler efficiency (80.4%) compare well
with the direct method of calculating efficiency (80%). These values are within the uncertainty
limits given the accuracy levels of the measurements.

Page 23
CHAPTER FOUR
4. RESULT AND DISCUSSION
4.1Stack Losses Method
This method is to satisfy or success to find the boiler efficiency rather above method
.Because the people can evaluate the efficiency of the plant boiler quickly, requires few
parameters and needs few instruments for monitoring. In this study the stack loss method
or flue gas recirculation was used to analyze the steam boiler.
Stack temperature is a measure of the heat carried away by dry flue gases and the moisture
loss. It is a good indicator of boiler efficiency. The stack temperature is the temperature of
the combustion gases (dry and water vapor) leaving the boiler and reflects the energy that
did not transfer from the fuel to the steam or hot water. The lower the stack temperature,
the more effective the heat exchanger design, and the higher the fuel-to-steam efficiency.
This temperature represents the major portion of the energy not converted to usable output. The
higher the temperature, the less energy transferred to output and the lower the boiler efficiency.
When stack temperature is evaluated, it is important to determine if the value is proven and Add
flue gas heat recovery equipment where justified. It is important that the combustion air be
delivered in just the amount needed for complete combustion.
From the above calculation are the way to design boiler efficiency, the actual boiler
efficiency and cost lost are improving by using stack loss method. It is fuel consumption
increases from day to day. Any efficiency verification testing will be based on the stack los

Page 24
table 5: Flue Gas control Parameters (Courtesy: US DOE ITP Steam
( Best Practices End User Training Program)
Fuel Automatic control Positioning control Automatic control Positioning

Flue Gas o2 content Flue Gas o2 content excess Air control excess
Air
Min. [%] Max. Min. [%] Max. Min. [%] Max. Min. [%] Ma
[%] [%] [%] x.
[%]
Natural 1.5 3.0 3.0 7.0 9.0 18 18 55
Gas
Numb. 2.0 3.0 3.0 7.0 11 18 18 55
2 Fuel
Oil
Numb. 2.5 3.5 3.5 8.0 14 21 21 65
6 Fuel
Oil
Pulveri 2.5 4.0 4.0 7.0 14 25 25 50
zed
Coal
Stoker 3.5 5.0 5.0 8.0 2o 32 32 65
Coal
In order to estimate the potential benefit of minimizing excess air it will be necessary to evaluate
the total boiler operating costs and the current and new operating boiler efficiencies. The equation
below calculates the cost savings for the energy savings opportunity.
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
σ = (𝐾𝑏𝑜𝑖𝑙𝑒𝑟 (1 ÷ 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑁𝑒𝑤
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦)
where σ is the fuel cost savings, Kboiler is the current operating cost of the boiler, ηcurrent and
ηnew are the current and new boiler operating efficiencies, respectively.
The 20 Tph natural gas-fired operating boiler has a positional controller that is periodically re-
tuned. Estimate the annual energy cost savings opportunity for implementing an automatic oxygen
trim controller for managing the excess air on the boiler. Neglect the shell and blowdown losses for
the boiler efficiency calculations.
 HHV of natural gas = 54,220 kJ/kg (40,144 kJ/m³)

 Fuel supply = 1,693 m³/hr (28 m³/min)
 Fuel cost = $1.0/m3
 Stack temperature: 200°C
 Flue gas oxygen: 5%

Page 25
 Negligible combustibles were found in stack gas analysis

 Ambient air temperature: 20°C
The boiler operating cost was calculated in the earlier section as follows:
Kboiler = 1,693 × 1.0 = $1,693/hr Kboiler = 1,693 × 1.0 × 8,760 = $14,830,680/yr
Current stack loss was calculated from the US DOE SSAT Stack Loss calculator and is 18.3% for 5%
flue gas oxygen, 200°C stack temperature and 20°C ambient temperature. Hence, the current boiler
efficiency is ηcurrent is 81.7%.
From Table 5, it can be observed that commercially available automatic oxygen trim controllers can
control the flue gas oxygen within 3%. Assuming that the stack temperature does not change, the
new stack loss is calculated to be 17.4%. Hence, the new boiler efficiency is ηnew is 82.6%.
The energy cost savings for minimizing the excess air by implementing an automatic oxygen trim
controller are calculated as follows:
σExcessAir = Kbd

Page 26
4 .1.1 .Impact and Sensitivity Steam Boiler
4.2.1. Flue Gas Temperature
Flue gas temperature or “stack temperature” is the temperature of the combustion gases as they
exit the boiler. The flue gas temperature must be a proven value for the efficiency calculation to be
reflective of the true fuel usage of the boiler. A potential way to manipulate an efficiency value is to
utilize a lower-than-actual flue gas temperature in the calculation.
4.2.2. Fuel specification
The fuel specification can also have a dramatic effect on efficiency. In the case of gaseous fuels, the
higher the hydrogen content, the more water vapor is formed during combustion. This water vapor
uses energy as it changes phase in the combustion process. Higher water vapor losses when firing
the fuel result in lower efficiency. This is one reason why fuel oil fires at higher efficiency levels
than natural gas. To get an accurate efficiency calculation, A fuel specification that represents the
jobsite fuel to be fired must be used.
4.2.3. Excess Air
Excess air is the extra air supplied to the burner beyond the required air for complete combustion
of the fuel. Excess air is supplied to the burner because a boiler firing without sufficient air, or “fuel
rich”, is operating in a potentially dangerous condition. Therefore, excess air is used to provide a
safety factor above the theoretical air required for combustion.
In ultra-low emission burners, excess air is also used to eliminate CO production and particulate,
and reduce the formation of oxides of nitrogen (NOx) to very low levels by controlling the
temperature of the flame. Because excess air is heated by the flame, it takes energy away from
combustion, thus taking away potential energy for transfer to the water in the boiler. In this way,
Page 27
excess air reduces boiler efficiency. Seasonal changes in temperature and barometric pressure can
cause the excess air in a boiler to fluctuate 5% - 10%. Furthermore, firing at low excess air levels
can result in high CO and boiler sooting, specifically if the burner has complex linkage and lacks
proper fan design. The fact is even burners theoretically capable of running at less than 15% excess
air levels rarely are left at these settings in actual practice. A realistic excess air level for a boiler in
operation is 15% if an appropriate safety factor is to be maintained.
4.2.4. Ambient Temperature
Ambient temperature can have a dramatic effect on boiler efficiency. A 40 deg. F variation in
ambient temperature can affect efficiency by 1% or more. Most boiler rooms are relatively warm.
Therefore, most efficiency calculations are based on 80 deg. F ambient temperatures.
4.2.5. Radiation and Convection losses
Radiation and convection losses represent the heat losses radiating from the boiler vessel. Boilers
are insulated to minimize these losses. However, every boiler has radiation and convection losses.
Efficiency is sometimes represented without any radiation or convection losses. This is not a true
reflection of the efficiency of the boiler. Cool surface temperatures on the boiler are an indication of
low radiation and convection losses. In this way, the boiler construction and design can have an
impact on these losses.
Maximization of Fuel efficiency in saturated Steam Boiler by using Preheating of

Controlled Air-Fuel Mixture
The methods highlighted above will help to minimize the energy and heat loss as a result of
inherent restrictions in boiler design. To further increase efficiency of steam, hot water or
process heating systems, it depends, ultimately, on the system design. Facilities owners will have
to ensure boilers are sized according to process requirements, and keep in mind that using a
number of integrated smaller boilers to handle peak demand and possible expansion, rather than
one over-sized boiler. By adopting these methods and strategies, industrial facilities owners will

Page 28
be able to gain from the improved energy efficiency of boilers and lower operating costs. Rather
than and more to improve the steam boiler are ,selection of a boiler with “designed-in” low
maintenance cost and high efficiency can provide outstanding savings every year and
maximization your boiler investment for today and the future. Boiler can waste a lot of heat
during the combustion process, especially if that heat isn't being transferred into steam or hot
water. Recovering this wasted energy with economizers helps to improve combustion heat
transfer and increase boiler efficiency. So the improvement and increases of boiler efficiency are
important to following data collected.
 Check and verify the boiler efficiency regularly. Monitor and compare the boiler
performance related data to standard targets regularly.
 Monitor the flue gas combustibles and the combustion excess air regularly. Adjust as
conditions change. Operating your boiler with an optimum amount of excess air will
minimize heat loss up the stack and improve combustion efficiency.
 The optimum amount of excess air required for the combustion reaction depends on fuel
composition and the type of boiler used. Heavier fuels require higher excess air and the
stoker fired boilers need more air than oil fired boilers.
 Check for and eliminate the entrance of unwanted air into the boiler and flue gas exhaust
system.
 Keep burners adjusted to optimum efficiency. Establish a burner maintenance schedule.
Inspect and replace fault burn.

Page 29
CHAPTER FIVE
5.1. CONCLUSION AND RECOMMENDATION
5.1 .1 Conclusion
In this study, the objective of fuel optimization is achieved by increasing the efficiency of fire
tube boiler and extracting the maximum energy from stack flue gases. The air-fuel mixture is
introduced to furnace instead of separate air and fuel streams. Moreover, the air to fuel ratio is
also optimized by reducing the excess air from 15% to 10%, thus improving the quality of flue
gases. Taking care of the steam distribution system provides one of the best opportunities for
savings. The cost of maintaining steam traps and checking piping flanges and valves for leaks
requires little or no capital investment
In general installing air preheated coupled with modified air to fuel ratio has increased the
boilers efficiency by reducing the fuel consumption and extracting the maximum energy from
stack flue gas.

Page 30
5.2.2 Recommendation
When we enter to in the factory we have seen all the production process of soap and detergent.
During our four months of internship experience period we have seen some positive and negative
sides about the internship hosting company. In this part of our project it have been try to suggest
some ideas for our internship hosting company.
 For new purchases, it is prudent to invest on a product that meets the best efficiency
standards and do not require any waste heat recovery add-ons.Soa high efficiency boiler
must be built with an optimum condition.
 Condensate recirculation is unsuitable only where there is possibility of condensate being

contaminated because of process leaks and direct process contact. So the contaminated
condensate must be segregated from the pure stream; otherwise it may lead to bigger
failures, safety and efficiency issues. As such, it should be avoided.
 The steam piping should be sized, based on both ‘permissible velocity’ and the available
‘pressure drop’ considerations in the line. SoSelecting a higher pipe size will reduce the
pressure drop and thus the energy cost. However, higher pipe size will increase the initial
installation cost. Hence, care should be taken in selecting the optimum pipe size.

Page 31
REFERANCE
( 1) Brooks C (2010) Boiler Efficiency Guide. Cleaver Brooks.
(2) Energy Efficiency Best Practice Guide
(3). Power plant engineering by P K Nag, Third Edition.
(4).Virendra Nagar, Dr. V. K. Soni, Dr. V. K. Khare, Boiler Efficiency Improvement through Analysis
of Losses IJSRD
( 5).www.google.com
APPENDAX
1. PLC……………………………………………………. private limit company

2. CB………………………………………………………. Commercial boiler

Page 32

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OPTIMIZATION OF FUEL EFFICIENCY IN SATURATED STEAM

BOILER IN SHEMU PLC|| 2012E.C

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL

HOSTING COMPANY: SHEMU SOAP AND DETERGENT

PROJECT TITLE: OPTIMIZATION OF FUEL EFFICIENCY IN

1. DEREJE SHIFERA………… R/0785/09

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

1.2 PROBLEM OF STATEMENT AND JUSTIFICATION……………………………………………………………….6

1.3.1 OBJECTIVE OF THE PROJECT…………………………………………………………………………………………6

1.3. 2 Main Objective……………………………………………………………………………………………………………...6

1.3 .2 Specific Objectives………………………………………………………………………………………………………..6

1.3.3 Significance of the project………………………………………………………………………………………………6

1.3.4 Scope of the project……………………………………………………………………………………………………….6

2. 2.1.Selectio steam boiler…………………………………………………………………………………………….8

2.2.2. Maintenance Costs…………………………………………………………………………………………………………8

2.2.3. Boiler performance……………………………………………………………………………………………………..8

2 ,2. 4. Fuel Usage………………………………………………………………………………………………………………….9

2.2.6.Steam boiler Efficiency Feature Comparisons ……………………………………………………………….9

2.2.7 Number of boiler passes……………………………………………………………………………………………

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

2.2.8. Burner / boiler compatibility……………………………………………………………………………………..10

2.2.9. maintenance required ……………………………………………………………………………………………..10

2.3.3. Vessel design………………………………………………………………………………………………………….. 11

CHAPTER THREE …………………………………………………………………………………………………..12

3.2.3 Combustion air preheater………………………………………………………………………………………………13

4. RESULT AND DISCUSSION……………………………………………………………………………………..14

4.1 Stack loss method………………………………………………………………………………………………………15

4 .1.1. Impact and sensitivity of steam boiler …….....................................................................16

4.2.1. Flue Gas Temperature……………………………………………………………………………………………….16

4.2.2. Fuel specification……………………………………………………………………………………………………..16

4.2.3. Excess Air…………………………………………………………………………………………………………………17

4.2.5. Radiation and Convection losses………………………………………………………………………………17

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

MAXIMIZATION OF FUEL EFFICIENCY IN SATURATED STEAM BOILER BY USING PREHEATING

5 CONCLUSION AND RECOMMENDATION……………………………………………………………...19

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

1.2 PROBLEM OF STATEMENT AND JUSTIFICATION

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

1.3 .2 Specific Objective

 Increasing the performance boiler efficiency

1.3.3 Significance of the project

1.3.4 Scope of the Project

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

2.1 Selection of Steam Boiler

2.2.1 Maintenance Costs

2.2.2. Boiler performance

2.2 3. Fuel Usage

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

2.2.5 .Steam Boiler Efficiency Feature Comparisons

2.2.6. Number of Boiler passes.

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

2.2.7 Burner / boiler compatibility

DIRE DAWA INSTITUTE OF TECHNOLOGY SCHOOL OF CHEMICAL AND BIOENGINEERING

2.2.8. maintenance requirements

2.2.9. Repeatable air/ fuel control