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Industrial Boiler Project Final Report
Industrial Boiler Project Final Report
BY
Batch 2020-2024
BACHELORS OF TECHNOLOGY
IN
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Industrial Steam Boiler
CERTIFICATE
Submitted by
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Industrial Steam Boiler
ACKNOWLEDGEMENT
Vanshita Totalu
Department of Mechanical
SGGGSIE&T | NANDED
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Industrial Steam Boiler
ABSTRACT
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Industrial Steam Boiler
INDEX
• Introduction……………………………………………………………………06
• Use of Steam Boilers in the Ice Cream Industry…………………07
• Factors to Consider while selecting Boiler for Milk Industry
and Milk Processing Operation………………………………………..09
• Boiler Efficiency……………………………………………………….…11
1. Water Treatment………………………………………………………….11
2. Fuel in Boiler………………………………………………………………..12
3. Energy Management……………………………………………………..14
4. Heat Recover……………………………………………………….………..17
5. Efficiency Improvement………………………………………….……..20
• Conclusion…………………………………………………………………..23
• Future Direction………………………………………………………….24
4. Challenges ………………………………………….…………………………28
• Case Study…………………………………………………………………..32
• References………………………………………………………………….33
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Industrial Steam Boiler
INTRODUCTION
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Industrial Steam Boiler
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Industrial Steam Boiler
Apart from these, the boiler for generating steam sterilizes the boiler
and equipment involved during the processing operation and heats the
dairy plants themselves to ensure that there are not any bacteria present
in the processing operation.
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Dairy industries use boilers on long cycles which means that they
function for a longer duration. It leads to a high level of pollution that
causes harm to the climate. It is, therefore, important that the boilers
are environmentally friendly and contribute toward sustainable
development.
Highly Efficient:
Needless to say, a boiler for milk dairy should be highly efficient and
durable to ensure the smooth functioning and maintenance of the dairy
industry.
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• BOILER EFFICIENCY
The boiler efficiency can be increased by different practices
such as water treatment, alternative fuel, energy management,
and heat recovery.
2. FUEL IN BOILER -
A boiler needs a fuel system to convert feed water into steam or hot
water. The fuel system is an important part and plays a vital role in
every boiler. Most commonly, fossil fuels such as coal, petroleum-
based oils, natural gases, and biomass are used as the fuel for the boilers
which are high in cost. Refuse Derived Fuel (RDF) is a kind of
alternative solid fuel that is derived from domestic or
industrial municipal solid wastes such as non-recyclable plastics,
paper cardboard, labels, and generally corrugated materials. RDF
poses huge environmental benefits and reduces fuel costs as less and
less fossil fuel is required. The calorific value of the RDF is around
16.72 MJ/kg.
The calorific value of palm fibers is 9.2 MJ/kg and the calorific
value of palm shells is 16.9 MJ/kg. In sugar industries, the by-product
of sugar production is the fibrous waste of sugar cane called bagasse,
and this is used as an alternative fuel for the boilers to generate
electricity. The calorific value is 9.6MJ/kg
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3. ENERGY MANAGEMENT
A process of analyzing how efficiently energy is being used in a
system is called energy management. A mostly higher amount of
energy usage is occurred due to the operation of the boiler. Under
the energy management concept, we can take several efficiency-
maximizing steps to improve boiler performance. An idea about
boiler performance can be obtained through boiler efficiency and
evaporation ratio calculations
A. Makeup water management
− Keep records on makeup water to detect any leak or loss.
− Maximize the efficiency and the capacity of the existing feed
water preheating system.
− Improve feed water treatments to minimize blowdown losses. −
Use economizers to preheat makeup water.
− Use a heat exchanger to preheat makeup water by using the heat
of blowdown water.
B. Condensate and blowdown system management
− Utilizing condensate return in greater percentage will reduce the
energy required to produce steam.
− Monitor the quality of condensate return.
− Properly control the blowdown. improper control may lead to
scale formation inside the boiler resulting in overheating and
ultimately causing boiler tube failure.
− Take blowdown flash steam into a flash steam tank and use it for
other heating applications such as for de-aerators
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4. HEAT RECOVERY
the boiler room, this may be due to the boiler and stack losses. We can
either extend the air intake upward or force the hot air to the inlet
location. If the heat loss is mainly due to the boiler wall insulation, the
boiler should be considered. Also, we can recover heat from the
exhaust gas to heat feed-water supply and inlet air to save energy and
fuel.
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The blowdown process is used to control the TDS inside the boiler by
releasing boiler water and sediments through the blowdown valve.
Through the blowdown, a considerable amount of heat is also released
into the surrounding.
D. Waste-Heat Boilers
This kind of boiler is used for heat recovery in big industries which
having many boilers, gas turbines, incinerators, etc. Flue gas of those
boilers and turbines flows through a series of water tubes. Thus, the
water vaporized in the tubes and collected in a steam drum. The
pressure and rate of steam generation mainly depend on the
temperature of waste heat. If this is not enough, we can use a separate
burner to acquire the required state.
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Most commonly water is used as a heat transfer medium for all the
boilers as it is readily available everywhere. Instead of using water,
Thermic fluids can be used as a heat transfer medium. The main
advantage of Thermic fluid over water is, that there is mostly no heat
lost by the media, only heat transfer happens. So, this will eliminate
the need for blowdown as there will be no settling particles in it.
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5 EFFICIENCY IMPROVEMENTS
B. Air Preheater -
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E. Economizer
The purpose of the economizer is to recover heat from the flue gas
by preheating feed-water or combustion air. But there's a problem
that affects the efficiency of the economizer because of corrosion
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Fouling, scaling, and soot builds a layer in the inner surface of boilers
and acts as insulators and it causes the reduction of heat transfer. The
scale is forming due to calcium, magnesium, and silica in most water
suppliers. The combustion system must be repaired or returned and
relevant actions should be performed to boost water softening and
maintain a lower level of total dissolved solids.
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• CONCLUSION
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• FUTURE DIRECTION
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Technical features
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Improved design
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Benefits
loads. Capital costs are about half that of coal boilers where 90%
Efficiency
Responsiveness
Durability
Safety
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Network Integration
Reduced downtime
Fewer parts and quicker annual surveys (less than a week) mean
lower O&M costs.
Dry steam
The vertical structure produces dryer steam – typically about 99.8
% dryness fraction.
Challenges
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Regulatory requirements
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Fuel and steam costs for Electrode, Diesel and Gas Steam Boiler
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• CASE STUDIES
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• REFERENCES
• https://rakhoh.com/en/steam-boilers-in-dairy-industry-its-use-and-
important-
factors/#:~:text=Use%20of%20Steam%20Boiler%20in%20Dairy%20Ind
ustries%3A&text=Steam%20boilers%20are%20used%20for,and%20othe
r%20milk%20processing%20operations?utm_source=canva&utm_mediu
m=iframely
• https://www.electrosteam.com/?utm_source=canva&utm_medium=iframe
ly
• https://en.m.wikipedia.org/wiki/Electric_steam_boiler?utm_source=canva
&utm_medium=iframely
• https://en.wikipedia.org/wiki/Refuse-
derived_fuel#:~:text=RDF%20can%20be%20used%20in,the%20Waste%
20Incineration%20Directive%20apply.?utm_source=canva&utm_medium
=iframely
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Link:
www.walkofood.com
www.nicicecreams.com
Google Location:
https://goo.gl/maps/47rMKA68biKPM2wx7
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