of 23
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Energy Conservation in Steam
Generation and Distribution
D D Ananda Namal
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
What is Thermal System
Fuel System
Generation System
Distribution System
Utilization System
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Sub System
Correctly Designed & Maintained
Can be solved many problems
Can be burnt efficiently
MainComponentsStorage tanks Pumps
Storage yards
Pipes Strainers
Pre Heaters GaugesN A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Fuel
What is fuel ?
Fuel Classification
Solid, Liquid, Gas
Calorific Value (Heat Value, Heat of combustion)
MJ/kg, MJ/m3,MJ/Lit
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Calorific Value
Firewood 18.5 MJ/kg of dry wood
Saw dust 17.5 MJ/kg (Dry)Diesel 43.7 MJ/kg
Furnace Oil (Medium) 43.4 MJ/kg
Furnace Oil (Heavy) 42.5 MJ/kg
Density
Diesel 0.86 kg/lit Furnace Oil (Medium) 0.94 kg/lit
Furnace Oil (Heavy) 0.95 kg/lit
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Combustion
What is Combustion ?Reaction with Oxygen
to Produce Heat
Fuel + Air Combustion Product + Heat
Mixing of fuel andair is very important
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Combustion
C + O2 CO2 + 32,800 kJ/kg
H2 + O2 H2O + 142,000 kJ/kg
C + O2 CO + 9300 kJ.kg
Theoretical Air Supply
Reduced air & Excess Air
Correct amount of Air
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Combustion
Excess Air Fuel Loss Less retention time
Reduced Temperature
Recommended Excess Air Level
Gas Burners 10 15%Oil Burners 15 20 %
Fire Wood - 40 50%
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Combustion
Reduced AirPartial Combustion
Emit CO
Un Burnt C particles
C + O2 CO2 + 32,800 kJ/kg
C + O2 CO + 9300 kJ.kg
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Combustion
Factors Affecting Liquid Fuel Combustion
Air-Fuel Ratio
ViscosityFuel Pressure
Atomization
Particle Size 20 - 40 m Small Escape without burning
Large Incomplete combustion
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Efficient Combustion
CE = CO2CO2 +CO
Combustion Efficiency (CE)
Where
CO2 = Concentration of CO2CO = Concentration of CO
There should not be any combustibles in
Combustion Product
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Fuel Handling
Fuel Storage
Fuel Preparation
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Minimize Supply Risk
Minimize production Damage
Facilitate to prepare fuel
Fuel Storage
Why Do We Store fuel ?
Main Tank
Day Tank
Bulk
Storage
Daily
Consumption
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Main Tank
Can Store Two Week Consumption
Slope in direction of Drain Valve - to Foot
Minimum installation height of outlet = 3
Drain Valve
Oil Outlet
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Water Mixed With oil
Trace of water can mix with oil
Oil oxidized when water present
ProblemsFlame off
Unstable Flame
Oil wastage due to slow burning
Difficult to Ignite
Heat loss due to Latent heat
Corrosion and Nozzle blockage
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Use Wet Firewood
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Day Tank
Daily requirement
Should have level indicator
Insulate if heated
Installed at a High level if heated
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Strainers
10
Mesh
40
Mesh
60-100 Mesh
20
Mesh
Bowser Main Tank
DayTank
BurnerPre
Heater
Prevent Dirt entering
Clean Regularly
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Oil Preheating
Based on Viscosity Oil to be heated When
StoragePumping
Before entering to the Burner
Use Steam for oil pre heating
Heated oil Line Should be insulated
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Oil Preheating (Contd)
Oil Type
Light Oil
Medium Oil
Heavy Oil
Class
E
F
G
Storage
Temp (oC)
10
25
40
Pumping
Temp (oC)
10-12
30-35
35-60
Atomizing
Temp (oC)
60-70
82-104
116-127
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Generation System
Steam
Hot Water
Thermic Oil
Hot Air
Direct Heat
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Boiler Energy FlowEn
e
r
g
y
i
n
to
t
h
e
S
y
s
t
e
m
A
I
R
F
U
E
L
Sensible & Latent
Energy in Air
(S&LE Air)
Sensible Energy in
Fuel
(SE Fuel)
Chemical Energy
in Fuel
(CE Fuel)
SE = maCp,a(Ta-Ta)
LE = mw(ha-ha)
mfCp,f(Tf-Ta)
WSensible Energy
In Water
mwCp,w(Tw-Ta)
mfCvf
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Boiler Energy FlowEn
e
r
g
y
i
n
to
t
h
e
S
y
s
t
e
m
A
I
R
F
U
E
L
S&LE Air
SE Fuel
CE Fuel
S&LE Air
SE Fuel
Energy
Release
At
Combustion
Partial
Combustion
Un burnt
Fuel
Radiation
Loss
(openings)
Radiation E
Absorbed
By body
Sensible
EnergyIn
Combustion
Gases
Latent Ene.
(H2O) vapor
CE in
Combustion
Products
Radiation
Loss
Surface
Energy
absorbed
By
Water
LE Flue gas
SE Flue gas
CE Flue gas
EnergyIn Steam
Blowdown
Flue gas
Losses
W SE Water SE Water SE Water
SE Water
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Boiler
Energy BalanceStack Loss - 12 15 %
Surface Loss 0.5 2 %
Blowdown loss 1-2 %
Stack Loss
Blow down lossFuelAirWater
Surface Loss
SteamBoiler
Efficiency () = 1 Losses= heat gain by steam
Heat release by fuel
Indirect method
Direct MethodN A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Furnace/Kiln
Energy Balance
Stack Loss - 40 60 %Surface Loss 0.5 2 %
Product Sensible Losses 2-10 %
Fuel
Air
Stocks
Supports
Exhaust
Products
Supports
Surface
Structure
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Flue Gas Loss (Stack Loss)
Excess Air 15 20 %
Flue gas temperature.
- Recommended Steam Temp + 25oC
- increase due to Scale and Shoot
- Minimum 160 oC (Sulfur in fuel)
CO Incomplete Combustion
Unburnt C -
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Flue Gas Analysis
O2, CO2, CO, Temperature,Recommended O2.
- Liquid fuel 3-4 %
- Gases 2 - 3
Stack loss can be read from charts
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Heavy Oil
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Firewood
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Reduce Flue Gas Loss
Reduce Excess Air
Properly tune burners
Control Air dampers
Reduce leaks
Control Exhaust Temperature
Clean tubes
Remove scales
Mix Fuel and Air Properly
Correct amount of fuel
Use small Size
Create turbulence
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Clean Tubes
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Clean Combustion Chamber
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Keep Space for Combustion
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Create Turbulence
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Reduction of Surface Losses
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Radiation Losses through Furnace Surface
Acceptable temperature of outside surface
120
110
95
80
140
125
110
90
1300
1100
900
700
Side WallCeiling
Outside Surface
Temperature oC
Temperature
inside oC
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Radiation Losses through Openings
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Blow down Losses
To control the TDS and remove sludge
High BD rate Energy loss due to loss of steam
Low BD rate Energy loss due to scaling
Rate depend on the boiler Pressure
Type
Fire Tube package
Water Tube
TDS ppm
3500
4000
3500
2000-1400
1400 -1000
Pressure Psi
Up to 300
Up to 200
201-600
601 900
901 -1100N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Blow down Losses
% BD = TDS of Feedwater
TDS of Boiler water TDS of Feedwater
0
0.5
1
1.5
2
2.5
3
3.5
%FuelWastwd
0 1 2 3 4 5 6 7 8 9 10% Blowdown
3.6 barg 7 barg 10 barg 14 barg
Effect of Boiler Blowdown Rate
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Blow down Quantity
% BD (Required)= TDS of Feedwater X % makeup waterMaximum recommended TDS
BDF methods (Automatic)(Manual)
(Automatic)(Manual)
(Continuous)
(Intermittent)
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Waste heat Recovery
From
Flue Gas
Hot ProductCondensate
Blowdown
Flash Steam
For
Water pre heating
Combustion air preheatingIn put material pre heating
Fuel pre heating
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Combustion Air Preheat
0
1
2
3
4
5
6
7
EfficencyImprovement%
0 20 40 60 80 100 120 140 160 180Pre heat temperature C
Effect of Combustion Air Preheat
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Feed Water Preheat
0
2
4
6
8
10
12
Efficien
cyImprovement%
0 10 20 30 40 50 60Preheat Temperature C
Effect of Preheat of Boiler Feed Water Advantage of high temp FW
Energy Savings
Reduced DO level and associatedcost savings Maintain DesignBoiler output
Reduced thermal shock
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Blow down Heat Recovery
Energy Recovery = 87% of BD heat
Water Recovery = 14 % by mass of BD water
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Efficient Steam Generation - Summary
Combustion Control
Correct Air/Fuel ratio
Insulation Boiler, FW tank, Lines
Preheat combustion air
Pre heat feedwater
Condensate recovery
Correct BD rate
Steam to oil preheat
BD heat recovery
Correct Boiler capacity
Waste heat recovery
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Blow down Heat Recovery
Energy Recovery = 87% of BD heat
Water Recovery = 14 % by mass of BD waterN A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Distribution System
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Good Steam Distribution System
Good quality - No Water, No Air, No Dirt,
Right pressure
Correct Quantity -
Minimum cost Maintenance, Energy loss, Leaks,
Capital
Easy Operation - Good isolation, Easy access,
Better working environment
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
No WaterPoor heat transfer
Less heat content
High Pressure Drops
Erosion and Corrosion
Water hammer
K 60 to70
times steel
More SensibleportionReduced
effective
diameter
Longer time for
heating
Required high
pressure
Increased Energy
Loss
Steam 20-35 m/s, Water < 2 m/s
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Causes of Wet Steam
Boiler carry over
Poor insulation
Inadequate drainage
Water Accumulation
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
No Air
Poor heat transfer
Reduced Temperature
Delay in start up
Cold spot
Uneven temperature
Corrosion
K 1500
times steel
Partial Pressure
Causes of Air
With feed water
Steam shut off vacuum
@Condensation
Chemical Treatment
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Pipe Sizing Avoid over sizing/under sizing.
Over sized piping is more expensive Cost of insulation, supports and fittings The 3" pipe has 50% more external surface than 2"
pipe. Heat loss will therefore be 50% greater andthere will be 50% more Condensate in the pipeneeding removal.
Under Sized piping Unable to supply required Quantity
Erosion Pressure drops
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Insulation of Bare SurfacesAll the bare surfaces such as steam lines, valves,
flanges etc. should be insulated properly.
1 m1 m length of bare 2" pipe carrying steam oflength of bare 2" pipe carrying steam ofpressure of 150pressure of 150 psipsi can wastecan waste 350 lit350 lit of fuelof fuel
oil per annum oroil per annum orRs 15,000Rs 15,000 per annum.per annum.
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Advantages of Insulation
Reduced Heat Loss
Personal Safety
Better working environmentImproved labor productivity
Minimizing Condensate forming in the pipe
works and hence reduce risk of water hammer
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Insulation Thickness
Insulation thicknessdepend on Cost of Insulation
Material
Cost of Heat Loss
Economic ThicknessHas to be find
Tables are available tofind insulationthickness with surfacetemperature
Economic Thickness - Insulation
Thickness
Total Cost
Heat Loss
Cost
Insulation Cost
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Insulate Valves and Fittings Valve = 1 m of Pipe
Flange = 0.5 m of Pipe
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Insulation
cover with AL foil or sheetTo reduce radiation
To prevent damage
To prevent Get wet
Ends should be Covered Properly
Seem should correctly done
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes.
Steam lines should be supported and
anchored at proper intervals and
locations in order to prevent
sagging.
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
Steam lines should be arranged with a fall in the
direction of flow
A fall of around 40 mm to 10m (1/2" to 10 ft) is
adequate
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
In steam lines condensate should bedrained at regular intervals
Drain points should be formed in
average of intervals of 100 - 150 ft.
Lines.
should also be drained at any low
point where condensate cancollect.
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Drain points should be constructed
Properly
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Drain points should be constructed
Properly
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
Branch Connection
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
No Water Collection pockets
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.Correctly install strainers
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Installation of Steam Pipes Contd.
At the point of
steam usage the use
of a strainer should
be considered
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Allowance for Expansion
Provision should be made for expansion
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Allowance for Expansion
Expansion Fittings Should installed Correctly
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Stop Steam Leak
Live steam leaks through holes, faulty
valves, joints etc. will loss steam
considerably in a steam system.Apart from loss of energy, the loss of
valuable treated water has to be
considered
As an example steam of pressure 150 psi
leaks through 3mm hole will loss about
30kg of steam per hourN A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11
SEA / JICA / SLEMA
Pressure Selection
Depending on the Temperature, Heat
Transfer rate
Low pressure steam content High Latent
heat
Use lowest possible pressure
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N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Pressure Reduction
Low pressure steam occupying a large
volume and therefore to distribute lowpressure steam required large pipes and
fittings.
Pipe lines should be designed to
distribute high pressure steam and the
pressure should be reduced at the point of
usage
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Pressure Reduction
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Pressure Reduction
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Contains about 25% of Energy
Good Quality Water
Savings in Water and Chemical
Condensate Recovery
7/28/2019 Boiler Steam and Hot Air Generation
20/23
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Utilization System
Dryers
Heaters
Heat Exchangers
Pans
Radiators
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Maintain Correct Process Parameters
TemperaturePressures
Flow rates
Calibrated Gauges
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
TEMPERATURETEMPERATURE
ENERGYENERGY
P4P4
P3P3
P2P2
P1P1
POINT OF DRY
SATURATED STEAM
P4P4
POINT OF
SATURATED WATER
P1P1
Process parameters
Use steam at lowest possible pressure
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Efficient Steam Distribution - Summary
Correct Pipe Sizing
Correct pipe aligning
Correct water removal
Correct supporting
Correct insulation
Air removal
Use of flash steam
Correct steam trapping
Prevent leaks
Correct isolation
7/28/2019 Boiler Steam and Hot Air Generation
21/23
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
What is Steam
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Properties of Steam
Heat Content of Steam
0
500
1000
1500
2000
2500
3000
0 1 2 3 4 5 6 7 8 9 10
Pressure -Barg
k
J
/k
g
Latent Heat
Sinsible Heat
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Properties of Steam
Temperature of Steam
0
50
100
150
200
0 1 2 3 4 5 6 7 8 9 10
Pressure Barg
Tem
peratur
eoC
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22/23
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Properties of Steam
Specific Volume of Steam
0.0
0.5
1.0
1.5
2.0
0 1 2 3 4 5 6 7 8 9 10
Pressure - Barg
m
3/k
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
STEAM UTILATION
Process Heating Power Generation
Shaft Power Application
Ejector Pumps and Vacuum
Creation
Cooling
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
STEAM UTILATION
What need in Process Heating ?
Heat - MJ
Temperature - 0 C
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
STEAM UTILATIONWhy Steam Used ?
Steam Vs Hot Water
High heat Content (Latent & Sensible)@ 10 barg ,188 o C
Hot Water 798.8 kJ/kg
Steam 2784.8 kJ/kg
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23/23
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
STEAM UTILATIONWhy Steam Used ?
Heat Release at ConstantTemperature
N A T I O N A L E N E R G Y M A N A G E R T R A I N I N G P R O G R A M M E JANUARY 2 0 11SEA / JICA / SLEMA
Steam Used for Process Heating
Direct Indirect
