5 steam star super plus

Corporate Communication. Copyright ©Transparent Energy Systems Pvt. Ltd. All rights reserved 1

Natural Gas fired Steam Boiler

94 % Thermal Efficiency on GCV of NG104 % Thermal Efficiency on NCV of NG

Corporate Communication. Copyright ©Transparent Energy Systems Pvt. Ltd. All rights reserved

What is GCV of fuel

• Any fuel contains constituents like C, H, O, S, N, H2O ( Water / moisture) etc. in different proportion.

• Combustion of combustibles like C, H, S etc. releases energy due to exothermic nature of process.

• Ratio of total energy ( kcal ) release due to combustibles to unit mass ( kg ) of fuel is called as Gross Calorific Value ( GCV ).

• GCV is expressed in kcal / kg

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What is NCV of fuel

• Combustion of H present in fuel forms H2O, which remains in flue gas. --------------M1

• Moisture/water present in fuel evaporates and remains in flue gas. ------------------M2

• Combustion air carries moisture, which evaporates and remains in flue gas.--------M3

• M1 + M2 + M3 = Total water vapour present in flue gas.-------------------------”M Total”

• Evaporation of “ M Total ” & to go to flue gas temperature requires energy, which is taken from gross energy release during combustion.

• Generally, the gas is never cooled less than its due point. As a result, heat carried away by water vapour in the flue gas dose not become available for useful purpose.

• Hence, GCV – heat carried by water vapour = NCV of fuel.

• NCV is also expressed in kcal/kg.

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What is NCV of fuel (cont’d)

• It is customary to calculate thermal efficiency of fuel fired heaters on NCV of fuel basis, since heat carried by water vapour is any way not available for heat transfer. It is only NCV, which is available for heat transfer in heaters.

• Hence,

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Steam BoilerEnergy Supplied

Fuel Quantity X NCV“A”

Heat carried by steam “B”

Heat carried by flue gas

Losses

Thermal Efficiency on NCV = B / A


Thermal efficiency on GCV(Condensing Boiler)

• In a Steam Boiler (which constitutes Evaporator + Economiser + Water Preheater + Air Preheater etc.), when the flue gas is cooled upto less than its due point (57 oC approx.), the water vapour present in flue gas condenses while releasing its latent heat of condensation.

• This latent heat gets transferred to cooling medium i.e. feed water or combustion air (depending upon design).

• As a result, this latent heat becomes available and comes back to Steam Boiler system.

• Hence,

Thermal Efficiency on GCV = B/A

Energy carried by Steam “B”

Energy carried by flue gas

Losses

Steam Boiler

Energy input

Fuel Qty. X GCV “A”


Properties of Natural Gas

• Composition (approx.)

§ Methane - 90 %

§ Ethane - 5.8%

§ Propane - 2.5 %

§ Butane - 0.5%

§ Pentane & Hexane - 0.3 %

§ Carbon Di Oxide - 0.5 %

§ Nitrogen - 0.4 %

• Density – 0.74 kg/SM3

• GCV – 9500 kcal/SM3

• NCV – 8570 kcal/SM3


Condensing Boiler on Natural Gas

Natural Gas offers following benefits –

ü The lowest flue gas due point

ü Highest water content in flue gas

ü Highest pH value of flue gas condensate (2.8 to 4.9) (Condensate of FO/LDO/HSD are much more acidic)

ü Flue gases are extremely clean (free from Soot & Sulphur)


Combustion Air

Schematic : The Condensing Boiler

CHIMNEY

89%95% With Air preheater – 98 %

With Water preheater – 104 %

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Condensing Section89% heat

absorption

Thermal Efficiency improvement (on NCV of fuel)

Air pre heater or Feed Water

pre heaterEconomizer

Fuel

Boiler

Steam out


Make up water

HMBD with Water preheater

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Sr. No Parameters at location * Unit Steam Condensate of 80 0 C

% Condensate 0 25 50 75 100

% Make up water 100 75 50 25 0

1 Flue gas outlet temperature Deg. C 44 44 52 57 100

2 Thermal Efficiency on GCV of Natural Gas % 94 94 91 88 86

3 Thermal Efficiency on NCV of Natural Gas % 104 104 101 98 96

Economizer Water preheater *

DA Tank

Evaporator

Combustion Air

Fuel in

Thermal Efficiency –89 %


Steam Condensate return from process


HMBD with Water preheater

Condensing Boiler with Waterpreheater

Unit Steam Condensate of 80 0C

Sr. No. Parameters% Condensate Qty 0 25 50 75 100

% Make up Water Qty

100 75 50 25 0

1Boiler Capacity(F&A 100 deg.C)

kg/hr 1000 1000 1000 1000 1000

2Actual Steam Generation from Serial No. 5 deg. C at 10.54 bar(g)

kg/hr 851 869 886 905 924

3 Condensate Qty at 80 deg. C kg/hr 0 217 443 679 924

4 Make up Water Quantity at 30 deg. C kg/hr 851 651 443 226 0

5Feed water temp. after Mixing condensate and Make up Water

deg. C 30 0C 43 55 68 80

6Feed water temp. after WPH Outlet ( i.e. from 30 deg. C)

deg. C 87 104 102 101 80

7Feed water temp. at inlet of DA Tank after mixing with Condensate and WPH Water

deg. C 87 98 91 85 80

8 Thermal Efficiency on GCV of Natural Gas % 94.1 94.1 91.3 88.6 86.8


10 Flue Gas Outlet Temp. at Outlet of WPH deg. C 44 44 52 57 100

11 Water Condensate Quantity from Flue Gas kg/hr 51.7 51.70 27.60 0.00 0.00

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HMBD with Air preheater

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Economizer Air preheater *Evaporator

Combustion Air

Fuel in



Steam Condensate return from process

FD Fan

Make up water

Sr. No Parameters at location * Unit Steam Condensate of 80 0 C

% Condensate 0 25 50 75 100

% Make up water 100 75 50 25 0

1 Flue gas outlet temperature Deg. C 57 57 57 57 57

2 Thermal Efficiency on GCV of Natural Gas % 88 88 88 88 88


Steam out


HMBD with Air preheater

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Condensing Boiler with Airpreheater

Steam Condensate

Sr. No. Parameters% Condensate Qty 0 25 50 75 100

% Make up Water Qty 100 75 50 25 0

1Boiler Capacity(F&A 100 deg.C)

kg/hr 1000 1000 1000 1000 1000

2Actual Steam Generation from Serial No. 5 deg. C at 10.54 bar(g)

kg/hr 851 869 886 905 924

3 Condensate Qty at 80 deg. C kg/hr 0 217 443 679 924

4 Make up Water Quantity at 30 deg. C kg/hr 851 651 443 226 0

5Feed water temp. after Mixing condensate and Make up Water

deg. C 30 0C 43 55 68 80

6 Combustion Air Outlet temp. from Airpreheater deg. C 101 101 101 101 101

7 Thermal Efficiency on GCV of Natural Gas % 88.5 88.5 88.5 88.5 88.5

8 Thermal Efficiency on NCV of Natural Gas % 98 98.0 98.0 98.0 98.0

9 Flue Gas Outlet Temp. at Outlet of WPH deg. C 57 57 57 57 57

10 Water Condensate Quantity from Flue Gas kg/hr 0 0 0 0 0


1 TPH f&a 100 Boiler with Air Preheater

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SAVING POTENTIAL BY USING TRANSPARENT MAKE CONDENSING BOILER

S.N. Parameter TESPL Make TESPL make Other Make Condensing Steam

BoilerCondensing Steam

Boiler Steam Boiler

1 Thermal Efficiency on NCV (%) 98 95 922 Boiler Capacity (kg/hr) (f&a 100) 1000 1000 10003 Heat Output (kcal/hr) 5,40,000 5,40,000 5,40,0004 Heat Input (kcal/hr) 5,51,020 5,68,421 5,86,9565 Fuel Natural gas Natural Gas Natural gas6 Net Calorific Value (kcal / SCM ) 8500 8500 85007 Fuel Consumption in SCM/hr 64.82 66.87 69.058 Fuel Savings SCM/hr for NG 4.22 2.17 0.009 Annual Working Hours 8000 8000 8000.00

10 Annual Fuel Savings SCM/year for NG 33,729 17,415 0.00

11 Present Cost of Fuel Rs/SCM for NG 20 20 20

12 Annual Savings (Rs/year) as per present fuel cost Rs. 6.8 Lac / Yr Rs. 3.48 Lac / Yr 0.00

13 Average fuel cost (Rs/lit or Rs./SCM) over 15 years of life (considering 10% increase per year) 42 42 42

14 Working hours for 15 years 15 Yrs 15 Yrs 15 Yrs

15 Savings in fuel cost over 15 years of life of equipments (Crores Rs.) Rs. 2.13 Crore Rs. 1.1 Crore 0


Condensing boilers offered by TESPL

§ Designed for options of 0 % to 100 % condensate return from process.

§ Complete condensing Section is made of Stainless Steel

o Casing - SS 304

o Tubes- SS 304

o Drain valve Internals - SS 304

§ Flue gas condensate can be collected in a small tank of SS or FRP construction for neutralization & disposal.

§ Condensing section can be bypassed by divertor valve & feed water bypass line, in case of fuel shift from NG to FO/LDO/HSD.

§ Heating Surfaces are easy for maintenance, cleaning & repairs

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Option – I – With Water Preheater Option –II – With Air Preheater


Accessories

• External Structure Supported, Carbon steel with internal FRP lining or Stainless Steel chimney confirming to IS 6533

• Flue gas condensate transfer pump with level control

• Flue gas condensate neutralization tank (FRP lined or stainless steel.)

• Neutralized condensate discharge pump ( optional)

• Pressurized fully automatic DA tank to remove dissolved oxygen from feed water by steam preheating & without dozing of chemicals

• Automatic continuous chemical dozing system.

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Need for Pressurized Deareator Tank

• In the Boiler without Economizer, feed water directly enters into Boiler / Evaporator. Oxygen present in feed water instantly separates at operating temperature of boiler (184 0C approx), comes into steam space and goes out with steam. This causes minimal corrosion due to oxygen.

• In the Boiler with Economizer, feed water enters the Economizer first and gradually heats up to 100 0C approx. before entering Evaporator. This results into gradual separation of oxygen from feed water. This oxygen sticks inside Economizer tubes and corrodes tube internal surface.

• In Atmospheric Deareation Tank, feed water is heated up to 90 0C approx., which results into 99% oxygen separation. This water is good enough for Boiler without Economizer.

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Need for Pressurized Deareator Tank cont’d

• Pressurized Deareator Tank heats up feed water at 105 0C. This results into oxygen separation upto 99.9 %. This feed water becomes suitable for entering into Economizer.

• Balance oxygen in feed water is removed by chemical dosing. Pressurized Deareator Tank drastically reduces dependency on the level of accuracy of chemical dosing.

Hence, Pressurized deareator Tank is a must for Boiler with Economizer.

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Chimney options

• External Structure Supported Chimney is much more advantageous over Self Supported Chimney.

• Chimney is designed as per IS – 6533

• Supporting structure is designed as per IS – 800

• Design wind velocity as per IS 875 Part – III

• Chimney duct material options –o Carbon Steel duct with intenal FRP lining.

o Stainless Steel duct of 2 mm thickness

• Supporting Structure material – Carbon Steel

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Advantages of Externally structure supported Chimney over Self Supported one

• The chimney is cylindrical with lower wall thickness. The chimney is supported by an external carbon steel structure.

• It is easily supported by external CS Structure upto the top to take care of wind loads and ease of maintenance.

• The chimney is made from pieces 6m long for ease of transportation.

• It is light in weight as compared to self supported chimney. Hence transportation and erection is quite easy.

• No need of heavy foundations. Cost of civil foundation work is lowest.

• The ladder can be inside the structure giving better safety for personnel.

• Chimney can be easily painted from outside due to supporting structure.

• In case top piece falls down due to corrosion, it falls within external structure, avoiding major accident.

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Chimney-Comparison

Sr. No.

Parameter Conventional, Self

Supported

Carbon Steel duct with internal FRP

Lining

Stainless Steel duct

1 Acid corrosion resistance

Low High High

2 Corrosion allowance

Needed Not needed Not needed

3 Weight Heavy Light Light

4 Transportation/erection

Difficult Easy Easy

5 Initial cost High Low Medium

6 Maintenance / Painting

Difficult Easy Easy

7 Foundation Very Heavy Light Light

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External Structural Supported Chimney

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Performance Tests

• Thermal Efficiency measurement as per BS 845 – Part I

BS 845 – Part II

Third party verifications offered for efficiency & output

• Petroleum Conservation & Research Association (PCRA)

• Any other competent agency of repute

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Performance measurement instrumentation

• Continuous on line real time measurement and recording of

o Flow measurements with totalization - Steam, Feed Water, Fuel,

Fuel gas condensate ( optional)

o Temperatures – Steam

– Feed water inlet to economizer

– Feed water inlet to boiler

– Water inlet to deareator tank

– Flue gas temperature at boiler outlet, economizer outlet &

water preheater outlet

– Water inlet & outlet to water preheater

o Pressure – Steam pressure on Evaporator

– Economizer inlet feed water

– Water preheater inlet & outlet

o Oxygen – Oxygen content in flue gas

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PCRA –Test Certificates

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Past achievements of Transparent in Oil & Gas fired Boilers

Sr. No

Description Fuel Model Year of introduction

1 93% efficient instant Steaming Boiler

Oil / Gas STEAMPACK 1985

2 93% efficient Thermal Oil Heater Oil / Gas FLUIDTHERM 1985

3 93% efficient Smoke Tube Boiler Oil / Gas STEAMSTAR 1989

4 95% efficient Smoke Tube Boiler Oil / Gas STEAMSTAR 1996

5 98% super efficient Steam Boiler Gas STEAMSTAR 2010

6 102% super efficient Steam Boiler Gas STEAMSTAR -SUPERPLUS

2010

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TESPL is first in India to introduce -

Corporate Communication. Copyright ©Transparent Energy Systems Pvt. Ltd. All rights reserved 26

Thank You for your attention

TRANSPARENT ENERGY SYSTEMS PVT. LTD.Pushpa Heights, Bibwewadi Corner, PUNE, INDIA

Tel. No. : +91 20 24211347 / 24215665Fax : +91 20 24212533Email : [email protected],

[email protected] : www.tespl.com

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5 steam star super plus

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