Training Manual on Energy Efficiency - APO Asian Productivity ...

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<strong>Training</strong> <strong>Manual</strong> on Energy Efficiency for Small and Medium Enterprises 2.8 TIPS FOR ENERGY EFFICIENCY IN BOILERS • Establish a boiler efficiency-maintenance program. Start with an energy audit and follow-up, then make a boiler efficiency-maintenance program a part of your continuous energy management program. • Preheat combustion air with waste heat. Add an economizer to preheat boiler feed water using exhaust heat. (Every 22 • Use variable speed drives on large boiler combustion air fans with variable flows instead of damper controls. • Insulate exposed hot oil tanks. • Clean burners, nozzles, and strainers regularly. • Inspect oil heaters to ensure proper oil temperature. • Close burner air and/or stack dampers when the burner is off, to minimize heat loss up the stack. • Introduce oxygen trim controls (limit excess air to less than 10% on clean fuels). ° C reduction in flue gas temperature increases boiler efficiency by 1%.) (Every 5% reduction in excess air increases boiler efficiency by 1%; every 1% reduction of residual oxygen in stack gas increases boiler efficiency by 1%.) • Automate/optimize boiler blowdown. Recover boiler blowdown heat. • Optimize de-aerator venting to minimize steam losses. • Inspect door gaskets for leakage avoidance. • Inspect for scale and sediment on the water side. (Every 1mm-thick scale (deposit) on the water side could increase fuel consumption by 5%–8 %.) • Inspect heating surfaces for soot, fly-ash, and slag deposits on the fire side. (A 3mm-thick soot deposition on the heat transfer surface can cause an increase in fuel consumption of 2.5%.) • Optimize boiler water treatment. • Recycle steam condensate to the maximum extent. • Study part–load characteristics and cycling costs to determine the most efficient combination for operating multiple boiler installations. • Consider using multiple units instead of one or two large boilers, to avoid partial load inefficiencies. - 20 -
3. ENERGY EFFICIENCY IN STEAM DISTRIBUTION AND UTILIZATION 3.1 INTRODUCTION Steam is used for generating power as well as for process heating applications in industries such as sugar, paper, fertilizer, refineries, petrochemicals, chemicals, food, synthetic fiber and textiles. The following characteristics of steam make it so popular and useful to the industry: • Highest specific heat and latent heat; • Highest heat transfer coefficient; • Easy to control and distribute; • Cheap and inert. 3.2 IMPORTANT PROPERTIES OF STEAM Liquid enthalpy (also known as “Sensible Heat”) When water is first heated to the boiling point, it is called sensible heat addition (with change in temperature); liquid enthalpy (hf) is the “enthalpy” (heat energy) available when it is in the water form, and is typically represented in kCal/kg. Enthalpy of evaporation (also known as “Latent Heat”) Once water reaches its boiling point, the enthalpy of evaporation (hfg) is the additional heat energy to be added to this hot water in order to change it into steam. There is no change in temperature during evaporation, hence the name latent heat. The temperature at which water boils is also called the boiling point or saturation temperature. This value depends on the steam pressure and increases as the steam pressure increases. As the steam pressure increases, the useful latent heat energy in the steam (enthalpy of evaporation) actually decreases. The total heat carried by dry saturated steam or enthalpy of saturated steam is given by the sum of these two enthalpies (hf +hfg). If the heat energy added is less than required latent heat, wet steam is produced, which contains partial water content, and the total heat carried by such wet steam will be lower than that of dry saturated steam. It is detrimental to use wet steam for process and steam distribution. Dryness fraction is the property which tells us how dry the steam is. If saturated steam is heated further to a still higher temperature, it starts behaving like a hot gas, and this steam is called superheated steam. Superheating is the addition of heat to dry saturated steam without an increase in pressure. The temperature of superheated steam, expressed as - 21 -
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Annex S. No. Enconomic Opportunity
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