Steam Efficiency Workshop I

Boiler & Steam System Efficiency

Mr. Dennis Acton

Mr. Harry Taplin

The Gas Company

Energy Resource Center
Wednesday, April 3, 2002
Improving Boiler and Steam System
Efficiency
● When conditions are not observable or
known, the assumption is often made
that they are negligible.

● In Steam Systems most of the losses are

not observable and are far from
negligible.
APR98.PPT - 2
1. Measure and Manage [2M] .
Change from an operational to a
management philosophy.

2. Operate with minimum excess air

3. Operate with minimum exhaust

gas temperatures

4. Capture latent heat energy from

boiler exhaust with new condensing
heat recovery technologies.
Rule of Thumb

Every 11 deg F that has to be

added to boiler feed water
costs 1% in system efficiency.

APR98.PPT - 3
Rule of Thumb
One Btu raises the temperature of one pound
of water one degree F

One Lb Steam = 1,100 Btu

One lb water 11F = 11 Btu

11 = 1%
1,100

APR98.PPT - 3
 [Return Hot Condensate]
Steam Distribution System
Steam Load
Condensate
Steam 190F
Output City Water
Vent 105C
Water
Feedwater Softener
Fuel In
Boiler Heater
50F
To Boiler 28C

Every pound of hot condensate lost in this system

costs 16% in boiler fuel to heat cold makeup to
the original condensate return temperature.
[190-50]/[1000 x .8] = 16%
RCVY1.PRS

APR98.PPT - 4
 Steam Leak

[Repair All System Steam Leaks]

Steam Leak
Steam Distribution System
Steam Load
Condensate
Steam 190F
Output City Water
Vent 105C
Water
Feedwater Softener
Fuel In
Boiler Heater
50F
Feedwater 28C
To Boiler

Every Pound of lost steam in this system costs

117% in boiler fuel to replace.
1+ [190-50]/[1000 x .8] = 117%

RCVY2.PRS

APR98.PPT - 5
 [Heat makeup with blowdown]
Steam Distribution System
Steam Load
Condensate
Steam
Output Feedwater City Water
To Boiler
Feedwater 130F 50F
Heater
Fuel In 72C 28C Water
Boiler Softener

Blowdown Heat Exchanger

Boiler Blowdown

Dump 90F/50C

Heating makeup with boiler blowdown achieves a

10% fuel savings for each pound of water heated.
[130-50]/[1000 x .8] = 10%

RCVY4.PRS

APR98.PPT - 6
 Steam Distribution System

Deareator
Steam
Steam Traps
Output
Flash Steam
Steam
Vent

Fuel In
Boiler
Pressurized Vented Tank
Tank 5% - 35% Losses

The pressure let-down through steam traps can

cause 10% to 35% flash steam in recovery system
piping. When vented to atmosphere this condition
could represent a 5% to 35% system energy loss,
depending on conditions.
RCVY5.PRS

APR98.PPT - 7
 [Heat makeup with blowdown]

Flash Steam

Makeup Water Out

Deareator
Fuel In
Boiler Makeup Water In

Boiler Blowdown

Flash Tank Blowdown Heat Exchanger

Dump 90F/50C

Use flash steam from blowdown in deareator

RCVY6.PRS

APR98.PPT - 8
Make-up Water Meter Tracks
System Problems
● When you lose water or steam from
the system through leaks, it will
register on the make-up water
meter.

APR98.PPT - 9
 Condensate Temperature
Indicates Problems
● Leaking
or blowing traps raise
condensate temperature.

● Insulation
problems or flooding
lower condensate temperature.

APR98.PPT - 10
Trap Problems

● Flash steam from normal [healthy]

traps can waste more energy than
the boiler.

● Steam Leaks from defective traps

can ruin your bank account.

APR98.PPT - 11
Rule of Thumb

A 2% change in Oxygen or
10% change in excess air
changes efficiency by 1%

APR98.PPT - 13
Improving Boiler Efficiency

● Stack Losses
– Excess Air
– Exhaust Temperature

APR98.PPT - 12
Rule of Thumb

A 40 0F Change in boiler
exhaust temperature
changes efficiency by 1%

APR98.PPT - 14
 Acid Dew Point
● In the past, boilers were designed to
maintain exhaust temperatures above
the Acid Dew Point for high sulfur fuels
in use at the time.

● Boilers have switched to natural gas or

other low sulfur fuels without
considering efficiency opportunities
from lower exhaust temperatures.

APR98.PPT - 15
 Passive Corrosion Control
● Thicker cold end materials designed to
last longer
● Special alloy steels with high corrosion
resistance
● Special coatings
» Teflon
» Epoxies
» Ceramics
» Glass

APR98.PPT - 16
Corrosion Control

Minimum Metal
Temperatures
Vs.
Minimum Exhaust Gas
Temperatures

APR98.PPT - 17
 Air Heater Comparisons
[Minimum Metal Temperatures]

Regenerative
Sulfur
– Natural Gas <0.1% 1500F

– Oil/Gas <1% 2100F

APR98.PPT - 18
 Air Heater Comparisons
[Minimum Metal Temperatures]
Recuperative
Sulfur
– Natural Gas <0.1% 2000F

– Distillate Oil <1% 2200F

APR98.PPT - 19
 Exhaust Gas Heat Recovery
Options
Exhaust Gasses Air Preheater
110 F

Economizer

Boiler

Fule Gas Condensing

Heat Recovery
APR98.PPT - 20
HEATER1.PRS
 The Economizer

1. Steam/Water temperature in a 150 psi boiler is 366 F

2. Exhaust gas temperature design is 150 F
above steam temperature.
3. 336 F + 150 F is 486 F [without economizer]

1. Water from the deareator enters the economizer.

2. Typical boiler feedwater to the economizer is
in the range of 227 F [5 psi] to 250 F [15 psig]
490 F – 290 F = 200 F 200F / 40 = 5%
Exhaust Gas
Condensing Heat Recovery

5% to 13%
Potential
Efficiency Gains

APR98.PPT - 21
 Exhaust Gas
Condensing Heat Recovery
• Natural Gas - 23% Hydrogen

• Each lb of natural gas burned

produces 2 lb water

•Each lb water [as vapor] in boiler

exhaust contains about 1,200 Btu
APR98.PPT - 23
 Exhaust Gas
Condensing Heat Recovery
• Each lb of natural gas burned
[22,000 Btu/lb] produces 2 lb water vapor
in the exhaust with 2,400 Btu

• Moisture loss from burning a pound

of natural gas is 11%

2,400 Btu = 11% Loss

22,000 Btu
APR98.PPT - 24
 110 F
Condensing Tower
Heat Exchanger

50F

Exhaust Gasses
System
Load

Boiler

125F 100F
Fule Gas Condensing
Heat Recovery

APR98.PPT - 22
 Benefits From Exhaust Gas
Condensing Heat Recovery
● Increased efficiency to over 95%

● Improved capacity over 11%

● Cost savings 12% - 16%

APR98.PPT - 25
Benefits From Exhaust Gas
Condensing Heat Recovery
● Reduced particulate emissions,
slight NOx reduction
● For each million Btus/hr capacity,
40,000 gallons of clean water is
created a year.
● Carbon dioxide equivalent green
house gas prevention is about 20
pounds per million Btus

APR98.PPT - 26
END OF PRESENTATION