Professional Documents
Culture Documents
Zahid Mehmood Qureshi
Zahid Mehmood Qureshi
4
Introduction:
• Increasing cost of production
• Increase in price of bagasse
• Need to be efficient instead of new
investment
• Environmental threat
• Source of additional revenue
• Potential source of diversification
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INTRODUCTION:
• Most industries have considered doing something about
moderating their energy consumption.
• An industry with large high temperature waste heat outflows
also has a high energy saving potential, since very often the
waste heat can be utilized instead of primary energy.
• Any attempt at improving the energy efficiency of a plant
requires that,
Energy efficiency of the individual components of
equipment must be refined.
Manner in which the equipment is operated.
FLUE GAS TEMPERATURE.
84.00%
82.00%
Percent Efficiency
80.00%
78.00%
76.00%
74.00%
72.00%
70.00%
68.00%
300F 350F 400F 500F 550F 600F 650F 700F
• Economizer is the waste heat recovery equipment & increases the feed
water temperature prior its entry into boiler.
• Waste heat directly substitute the cost of fuel.
• A well designed economizer can reduce the fuel consumption by 5-10%.
• About 4-10% capacity of boiler is increased by installation of economizer.
•Reduction in thermal stresses on boiler .
Bagasse : high value nowadays
Co-generation plant can generate power with a value of 5000 till 6000 PKR per tonnage.
Boiler efficiencies in the sugar mills are mostly between 68 and 77% on LCV basis.
Steam / bagasse ratio versus efficiency based on 52% moisture content:
• 2.2 means 79.2 % eff
• 2.1 means 75.6 % eff
Mostly seen
• 2.0 means 71.8 % eff
• 1.9 means 67 % eff
• 1.8 means 63.2 % eff
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Seen high contents of CO in flue gas and Unburned in ash
Caused mainly by:
• Leakages in flue tubes air preheater
• Overloading grate
• Poor spreading of bagasse
CO contents
• mostly 1000 to 4000 ppmv.
• Means 0.64 till 2.5% efficiency loss
• Also seen far above 10000 ppmv. Means more then 6.4% losses
• Regulation accept 800 ppmv. Losses are 0.5%
• New boilers with latest technology we run at 200 to 300 ppmv. Losses are 0.2%.
The Higher CO content indicate mostly higher unburned content in fly ash
In existing boilers seen ash samples of fly ash with 22% carbon in ash with LHV value of
1861 KJ/kg. This is seen with CO contents of approx. 300 till 1000 ppmv.
However also seen 59% carbon and LHV value of 4800 kcal/kg. The CO contents are then
6000 to far above 10000 ppmv.
Losses in efficiency are
• 1.6% on basis of 22% carbon
• 6.9 % on basis of 59% carbon
Reasons low efficiency
• Bagasse Feeding not constant.
• Leakage in flue gas air preheater. Causing bypass of air. Too less air in furnace
• Poor insulation
• No measurement of oxygen and CO levels in flue gasses and flue gas temperatures at different locations in boiler
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Efficiency calculation in indirect way/ as per indirect method
Q fuel Q nett
Boiler
Q air
Q stack
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What are the losses and possible savings in 25 bar boilers
New boilers have eff of 87.4 % with membrane walls and efficient combustion system and eco
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Efficiency of new boilers is 87.4 %:
Due to new technology
• with membrane walls
• improved firing systems
• Large economizers at outlet
• With steam air preheaters
17
Technology provided for improving efficiency in existing LP boilers to 84%
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Biomass decomposition
There have been hardly any studies available on bagasse based biomass decomposition.
There is some know how available which makes it possible to make some assumption.
Anaerobic digestion is the bacterial fermentation of organic material like bagasse in oxygen free condition.
It produces a gas composed of methane (CH4) and carbon dioxide (CO2). Called biogas
Optimum temperature for this process is 38 C.
in existing LP boilers
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Modification to screw feeders
Avoid lumps
10 mm free space
Increase size picker roller
21
Modification drum type feeders:
22
New feeders of twin roller type with picker roller
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Installation cold air spreader fan
Remove insulation
PI
4 spreaders installed
trimdamper
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Pulsating air damper
Pulsating damper
25
Over firing system
Mixing of CO and
unburned bagasse
particles with fresh
air above fire
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Baffle in hopper to improve Air distribution Under grate
800
Approx 920
500 1000
Cut hole 30
Existing air distribution improved air distribution
mm in plate
and weld to
0
65
duct
ox
Take 8 mm
thick plate of Duct approx. 920 * 650 mm
800
CS
Air duct
At hopper inlet
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Ensure spreading and air
distribution is equalized and
continuous
Different speed
Equalized spreading in
depth
28
Install venture for air measurement
Automatic combustion control is
accurate and excess air can be
minimized
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Multi cyclone
30
Improve the insulation
Insulation
wool is in
poor
condition
Not
gas
tight
Hot air Ducting to grade
At boiler roof
Steam outlet
line poor
insulated. No
thickness
At steam
leakages drum
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leakage
Check regularly the wall temperatures of casing and insulation cladding with infra red temperature meter.
If more then 50 or 60 C then take action.
Make schedule for which parts needs to be improved after season.
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Select the proper thickness and material
220
300
200
350
180
400
160 450
140 500
120 550
100
80
60
40
20
0
0 50 10 0 15 0 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 0 0 00
1
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Insulation main steam line proper and install supports for cladding. Rain water tight.
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Thank You for Your Kind Attention