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A-Z of Boiler Efficiency Boiler House Division

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Page 1: Boiler Eff

A-Z of Boiler Efficiency

Boiler House Division

Page 2: Boiler Eff

What’s Boiler Efficiency

Page 3: Boiler Eff

Boiler Efficiency is the percentage of heat input to the boiler which which

is utilized in generating steam.is utilized in generating steam.

Boiler Efficiency = Heat in the Steam generated

Heat supplied through Fuel combustion

Page 4: Boiler Eff

Measuring Boiler Efficiency

1. Direct Efficiency : % ηηηη = S (hs - FWT)

F X GCV

Where S = Steam generation in Kg/hr

hs = enthalpy of steam at op. Pr. In Kcal/kg

FWT = Feed water Temp

GCV = Gross calorific value of fuel in Kcal/kg

F = actual fuel flow in Kg/hr

Advantage:

It’s the true delivered boiler efficiency & covers all kind of losses

Disadvantage:

It doesn’t give break-up of losses

Page 5: Boiler Eff

2. Indirect Efficiency :

% η = 100 - All Boiler Losses

= 100 - stack loss L1

- loss due to water and hydrogen in fuel L2- radiation loss L3-Un burnt losses(L4)

So, % ηηηη = 100 - (L1+ L2 + L3+L4)

This is far more useful, as this gives break up of allboiler losses , emphasizing which area needs more attention.

Measuring Boiler Efficiency

Page 6: Boiler Eff

Measuring Boiler Efficiency

Radiation

Loss

(1-2%)

Blow-DownLoss

(2-5%)

Enthalpy Loss

(7-9%)

On-Off Losses

(0-2%)

Un burnt Losses

(0-6 %)

Stack Loss

(4-12 %)

Page 7: Boiler Eff

Boiler Operating Efficiency Facts

Boiler Efficiency Data Collected from over a 100

boilers for CII

Page 8: Boiler Eff

Gas Fired Boilers

50

55

60

65

70

75

80

85

90

1 2 3 4 5 6 7 8 9 10 11 12

8172.869.8IdealIn DirectDirect

Max Gap: 11%Max Gap: 11%

Page 9: Boiler Eff

Oil Fired Boilers

40

45

50

55

60

65

70

75

80

85

90

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49

8477.372.2IdealIn DirectDirect

Max Gap: 12%Max Gap: 12%

Page 10: Boiler Eff

Solid Fuel fired Boilers

40

45

50

55

60

65

70

75

80

85

90

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47

7864.860.9IdealIn DirectDirect

Max Gap: 18%Max Gap: 18%

Page 11: Boiler Eff

Cost of Boiler operation–Oil\Gas fuels

Capital Cost

15%

Electricity

cost

10%Maint Cost

5%

Water Cost

5%

Fuel Cost

65%

Capital Cost

Fuel Cost

Water Cost

Maint Cost

Electricity cost

Page 12: Boiler Eff

Cost of operation-Solid fuel

Fuel Cost

50%

Capital Cost

25%

Water Cost

5%

Maint Cost

10%

Electricity Cost

10%

Capital Cost

Fuel Cost

Water Cost

Maint Cost

Electricity Cost

Page 13: Boiler Eff

What affects Fuel Bill?

• Excess Air in flue gas%

• Feed Water Temperature

• Stack temperature

• Un burnts

• Number of Boiler On-Offs

• Scaling on tubes

• Soot Deposition

• Blow down TDS

• Moisture in Fuel

Page 14: Boiler Eff

What to Monitor inside Boiler House

1. Steam Flow

2. Steam Pressure

3. Fuel Flow

4. S: F ratio

5. Stack Temp

6. % O2 in Flue gas

7. Feed Water Temp

8. Blow down TDS

9. Furnace Pressure

Parameters to monitor

Variation in S:F

is ‘the’ culprit!

Page 15: Boiler Eff

Losses: Cause, Effect & ControlStack Loss causesStack Loss causes

1. Excess Air

2. High Stack Temp (due to Scale/soot

Deposition)

Stack loss ControlStack loss Control

1. Keeping Air to Fuel Ratio right

2. Keeping % O2 within limit

• Oil Fired : 3-4.0 %

• Gas Fired:2-3%

• Solid Fired: 6-7%

3. Continuous monitoring of Stack Temp. Periodic tube cleaning

Page 16: Boiler Eff

Losses: Cause, Effects & Control

Boiler OnBoiler On--Off Loss CausesOff Loss Causes

1. Fluctuating steam load

2. Narrow operating pressure band

Boiler OnBoiler On--Off Loss EffectOff Loss Effect

1. Combustion destabilization

2. Un burnts

3. Lower combustion efficiency

Boiler OnBoiler On--Off Loss ControlOff Loss Control

1. Changing boiler parameters according to

steam demand

2. Fuel feeding according to the load

3. Widening operating pressure band

Page 17: Boiler Eff

Losses: Cause, Effects & Control

Blow down Loss CausesBlow down Loss Causes

1. Manual Blow down

2. TDS level above specified limit

Blow down EffectsBlow down Effects

1. Excess blow down is a direct loss

2. Lesser blow down leads to scale

deposition & lowers boiler efficiency

Blow down ControlBlow down Control

1. Automatic Blow down control

Page 18: Boiler Eff

Losses: Cause, Effects & Control

Radiation Loss causesRadiation Loss causes

1. Fluctuating steam load

2. Radiation loss reduces with increase in

load

Enthalpy Loss causesEnthalpy Loss causes

1. Fuel Hydrogen & Moisture content

Draft Loss causes & ControlDraft Loss causes & Control

1. Air leakage through Damper due to

chimney draft

2. Reducing on-off losses

Page 19: Boiler Eff

Boiler Efficiency Thumb rules

1. 2% Decrease in % O2 -----� 4% Efficiency improvement

2. 6 Deg C Increase in Feed water Temp due to condensate

recovery-------� 1% lesser Fuel Consumption

3. 20 Deg C decrease in Stack temp-------� 1% lesser Fuel

Consumption

4. 1% un burnts -------� 2% Excess Fuel Consumption

5. 3 mm soot deposition on tubes increases fuel consumption by

2%

Page 20: Boiler Eff

Scope for Saving

Ideal S:F Ratio =Boiler Rated Efficiency* GCV

(Steam Enthalpy at Op. Press-FWT)

e.g. for a Furnace Oil fired Boiler

FO calorific value : 9600 Kcal/kg

FWT: 70 Deg C

Steam enthalpy : 663 Kcal/Kg @ 9 Kg (g)

Ideal S:F Ratio =0.89* 9600

(663-70)= 14.4

Boiler Rated efficiency: 89 %

Page 21: Boiler Eff

If actual S:F ratio is 13

Scope of fuel saving = (13/14.4)*4.5

= 10 %

The gap calculated is between Actual & Ideal S:F.

Page 22: Boiler Eff

Boiler Efficiency Steam To Fuel ratio Extra fuel consumption

89% 14.40 Not Applicable

85% 13.75 5%

80% 12.90 11%

78% 12.62 13%

Boiler Efficiency Vs Extra Fuel Consumption Boiler Efficiency Vs Extra Fuel Consumption

Page 23: Boiler Eff

Copyright Forbes Marshall,

2006-07

Effimax: National Accolade

Page 24: Boiler Eff

Copyright Forbes Marshall,

2006-07

What is Effimax??

SCADA based Online Boiler Efficiency Measurement System

Online Boiler Efficiency Measurement

Combustion quality monitoring

Boiler House Losses Break up

Logging & Trending of Boiler Parameters

Web Connectivity-Remote boiler

monitoring

Useful Diagnostics/Continuous

Performance Evaluation

Page 25: Boiler Eff

Copyright Forbes Marshall,

2006-07

What Effimax helps in achieve??

Enhancing Boiler Efficiency

Knowing where we are??

Detailing areas of improvement

Knowing gap between ideal & actual

Efficiency

Effimax boiler data analysis

Fine tuning boiler SOP to meet loading

pattern

Fuel Bill Reduction

Page 26: Boiler Eff

EFFIMAX Variants with Application

Page 27: Boiler Eff

Copyright Forbes Marshall,

2006-07

Effimax 1000

Online Boiler Steam to Fuel Analyzer

What It’s? What It does?

Calculates S:F ratio

Calculates Boiler’s Direct Efficiency

Plots variation in S:F with Load

Monitors Steam Flow, Fuel Flow,

Feed Water Temp & Steam Pressure

Application

All Oil/gas fired boilers up to 2 TPH

Touch Screen Based System with PC

Connectivity

Page 28: Boiler Eff

Copyright Forbes Marshall,

2006-07

Effimax 2000

Online Boiler Efficiency Analyzer

What It’s? What It does?

Calculates Boiler’s in- Direct Efficiency

Break up of all boiler losses

(Stack Loss , Blow down Loss, Enthalpy

Loss , Radiation Loss)

Monitors Steam Flow, % O2 ,

Feed Water Temp , Stack Temp, Steam

Pressure, Boiler TDS,

Application

All Solid fuel fired Boilers

Touch Screen Based System with

PC Connectivity

Automatic Blow Down control

Minute, Hourly & Daily Summary

Report

Trending of Key parameters w.r.t Load

Page 29: Boiler Eff

Copyright Forbes Marshall,

2006-07

Effimax 3000

Online Boiler Efficiency Analyzer

What It’s? What It does?

Calculates Boiler’s in- Direct Efficiency

& Steam to Fuel ratio

Break up of all boiler losses

(Stack Loss , Blow down Loss, Enthalpy

Loss , Radiation Loss)

Monitors Steam Flow, Fuel Flow ,% O2

Feed Water Temp , Stack Temp, Steam

Pressure, Boiler TDS

Application

All Oil/Gas fired Boilers above 2

TPH

Touch Screen Based System with

PC connectivity

Automatic Blow Down control

Minute, Hourly & Daily Summary

Report

Trending of Key parameters w.r.t Load

Page 30: Boiler Eff

Effimax Schematic

Page 31: Boiler Eff

Copyright Forbes Marshall,

2006-07

Hourly Report

Page 32: Boiler Eff

Analyzing Effimax reports

Page 33: Boiler Eff

EffiMax User interface

Page 34: Boiler Eff

Copyright Forbes Marshall,

2006-07

Hourly Report

Page 35: Boiler Eff
Page 36: Boiler Eff

S: F Variation

captured

Page 37: Boiler Eff

Variation in % O2

captured

Page 38: Boiler Eff

Variation in % O2

captured

Page 39: Boiler Eff

TDS maintained in the

boiler

Page 40: Boiler Eff

Variation in steam

pressure captured

Page 41: Boiler Eff

Boiler SOP as per EFFIMAX Reports

O2 variation Correct blower fan settings

ImpactImpact

Un burnts & stack

loss reduction

ActionAction

Boiler pressure variation Correct Operating pressure band selection

ImpactImpact

On Off loss reduction,

Improved dryness

ActionAction

Steam Load variation Correct Fuel Feed Rate determination

ImpactImpact

Improved combustion

efficiency

ActionAction

Page 42: Boiler Eff

Partial Reference List

TEXTILES

Indocount Kolhapur

Bindal Silk Surat

Welspun Gandhidham

Janaki Bhilwara

Sulzer Processor Bhilwara

Ranjan Processor Bhilwara

Sangam Processors Bhilwara

Anant Syntex Bhilwara

RSR Mohota Nagpur

Gimatex Nagpur

Shriji Prints Surat

Niharika Surat

Aishwarya Prints Surat

Alok Industries Vapi

SEP

Habib Agro Mysore

Cargill Gandhidham

Cargill Paradeep

Kanpur Edibles Kanpur

Sheel Chand Agro Rudrapur

Shri Shri Niwasji Raebareli

Astha Industries Rae bareli

Hemraj Oils Kolkata

Vaighai OIls Madurai

Amrit Banaspati Rajpura

Sita Edibles Nagpur

Page 43: Boiler Eff

Partial Reference List

PHARMA

Zydus Sikkim

Zydus Baroda

Hetero Hyderabad

DRL Vizag

DRL Hyderabad

Ranbaxy Mohali

Torrent Ahmedabad

Novartis Goa

Lupin Goa,Tarapur

Cipla Kurkumbh,Baddi,Sikkim

Piramal Hyderabad

Teva UP,Canada

Biological E Hyderabad

Syngenta Goa

BREWERIES & BEVERAGES

Balaji Breweries Chennai

Millenium Breweries Aurangabad

Som Breweries Bhopal

Fosters Aurangabad

UB Mangalore

UB-KBDL Bangalore

Pepsico Fritolays Kolkata

Pepsi Malaysia

Pepsi Aurangabad

Pepsi Mumbai

Coca Cola Ahmedabad

Brindavan Bottlers Lucknow

UB Daruhera,Delhi

Tata Coffee Madurai

Page 44: Boiler Eff

Partial Reference List

PAPER

Jollyboard Aurangabad

Madhya Desh Nagpur

Nithya Packaging Chennai

Modinagar Paper UP

Prolific Paper UP

Kaygaon Paper Aurangabad

Ganga Paper Pune

Banwari Paper Kashipur

Venkraft Paper Chennai

Ballavpur Paper Kolkata

Chandariya Paper Mills Kenya

Supreme Duplex Madurai

FOOD,FMCG

Nestle Malaysia

Nestle Manesar (Haryana)

Maccain Foods Ahmedabad

HUL Nashik

Haldiram Delhi,Nagpur

Dabur Delhi,Kolkata,Srilanka

P&G Baddi

Amul Dairy Baroda

Doodhsagar Ahmedabad

Sabar Dairy Ahmedabad

Page 45: Boiler Eff

Boiler’s with EFFIMAX operate 5-10% more

efficiently than without it!

Page 46: Boiler Eff

Boiler House DivisionForbes Marshall (P) Ltd

PB:29, Old Mumbai Pune

Highway

Kasarwadi, Pune