Session III

Draft, Performance indicators, efficiency evaluation of furnaces and boilers

Draft
Draft at any point inside furnace is the difference in energy between column of hot gas and the atmosphere outside furnace Volume of gases increases with temperature and the weight per unit volume becomes less If the hot gas is confined in a column of suitable height, the buoyancy of the gas as contained in column is capable of creating draft or less than atmospheric pressure required to cause atmospheric air to be drawn into furnace.

Minimum Draft
Draft to overcome the pressure drop of combustion gases in their flow from furnace proper to the point of entry to stack (plus minus 0.03 inch WC) Increase in temperature increase draft Draft varies (-) 0.1 inch per 10 feet height in furnace at about 650 C. If the draft at arc is -0.01 inch WC at arc the draft at below 10 feet would be -0.13 inch WC

Natural draft furnace

Draft at convectional outlet -0.53 inch WC Convection bank Pr drop -0.5 inch WC Convection tube Shock tubes Arc draft -0.03 inch WC

Radiant tubes

Prime rule of furnace operation is such that there should never be positive pressure at any point within furnace structure
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Draft
Where to control? How to assess the profile of draft in case of pressurization of boiler / furnaces? Case on draft survey in Russian Boilers Case on VBU furnace

Performance indicators
The performance indicators of furnaces and boilers are: Excess Air Temperature of flue gas to stack

Optimising Excess Air

In practice Excess Air over Stoichiometric air is needed for complete combustion Less Air Incomplete combustion & Smoke More Air Heat loss through stack
CO2 or O2 values will indicate excess air level

Typical Excess Air Level for Oil Fuel is 15 25 %

Oxygen content in flue gas vs Excess air

% O2 2 3 4 5 6 7 8 9 10 Excess Air % 10 16 22 29 37 46 57 69 83

10 % reduction in excess air can increase efficiency by 1 %

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Relation Between Residual O2 and Excess air

250

200

Excess air (%)

150

100

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0 1 7 8 9 10 11 12 13 14 15 Oxygen (%) Relation between residual oxygen and excess air 2 3 4 5 6

How to find Excess Air?

O2 in flue gas from analyzer or portable instrument Excess air = (O2 %)* 100 / (21- O2 %) Excess air in flue gas having 3 % O2 in flue gas = (3*100)/(21-3)=16.6 say 17%

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How to find Excess Air?

ORSAT analysis of flue gas and read excess air from BETZ chart using data on O2 and CO2

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Where to measure Excess Air?

For combustion control measure O2 at ARCH for furnaces and at the inlet of super heater for boilers i.e. at end of fire box.

For effectiveness on air tightness track O2 content in flue gas at convection outlet and at APH outlet It is true that none of the furnaces nor boilers are air tight !
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How to control Excess Air?

Combustion Control Minimize Air ingress Operate and maintain APH to avoid air leak

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How to control Excess Air?

Combustion Control Better atomization of oil (right temp of oil, dry superheated atomizing steam) Delta P (Steam Oil) Supply of quality fuel oil as per design condition of burners Preparation of fuel oil tank (BS&W and foreign materials in oil)

Right quantity of combustion air

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How to control Excess Air?

Air ingress Ensure tight closing of peep holes / igniter points Seal all openings in convection banks i.e. return bend covers Ensure no leak in APH Apply castables at joints of return bend covers

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Flue Gas Sampling points

At ARCH for combustion control (continuous) At APH inlet for detecting air ingress in convection bank At APH out let for assessing leaks if any Ensure proper sample points (like that in DHDT)

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 Draft

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Efficiency evaluation of FURNACE & BOILER

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Boiler System

Boiler

Economiser

APH

Damper

Oil

FD fan

Induced Draft Fan

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Boiler and Furnace efficiency - Direct Method

EFFICIENCY = USEFUL ENERGY OUTPUT --------------------------------------ENERGY INPUT

DISADVANTAGES: ACCURACY DEPENDS UPON MEASUREMENT OF ENERGY UTILIZED & FUEL CONSUMPTION FOR 90 % OPERATING EFFICIENCY FURNACE 1% ERROR IN ESTIMATION RESULTS IN SIGNIFICANT VARIATION 90 +/- 0.9 = 89.1 TO 90.9 %
IT DOES NOT INDICATES CLUES TO OPERATING PERSONNEL
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Boiler & Furnace efficiency - Indirect Method

EFFICIENCY = USEFUL ENERGY OUTPUT - LOSSES ----------------------------------------------------ENERGY INPUT

ADVANTAGES:
LOSSES ARE ESTIMATED AND DEDUCTED FROM 100 IMPACT OF 1 % VARIATION ON EFFICIENCY IS 100 (10 +/- 0.1) = 90 +/- 0.1 = 89.9 TO 90.1 % IT INDICATES CLUES TO OPERATING PERSONNEL

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Define : Losses during Furnace Operation

FURNACE EFFICIENCY IS ALWAYS LESS THAN ONE DUE TO FOLLOWING LOSSES: SENSIBLE HEAT LOSS ALONG WITH DRY FLUE GAS LATENT HEAT LOSS DUE TO PRESENCE OF H2 IN FUEL

LOSS DUE TO MOISTURE IN FUEL

LOSS DUE TO MOISTURE IN AIR LOSS DUE TO INCOMPLETE COMBUSTION RADIATION & CONVECTION HEAT LOSS

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Calculation of Furnace efficiency Indirect Method

Fuel fired : Only IFO Fuel Composition: C=87 %, H2= 12 %, S = 0.7 %, Water = 0.2 %, Ash = 0.1 % GCV = 10400 Kcal /kg CO2 content in flue gas: 10.8 % O2 content in flue gas: 5 % Stack Temp : 170 C Ambient Temp : 30 C
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Calculation of Furnace efficiency Indirect Method

Theoretical Air required per kg of fuel: {11.6 C + 34.8 (H2-O2/8)+ 4.35 S} 100 = (11*87)+(34.8 * 12) + (4.35*0.4) 100 = 14.30 kg of air per kg of fuel Excess Air = 5 * 100 = 31.25 % (21-5)

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Calculation of Furnace efficiency Indirect Method

Actual Air supplied = 1.3125 * 14.3 = 18.77 kg of air per kg of fuel Mass of flue gas : Mass of CO2 + Mass of N2+ Mass of SO2+Mass of oxygen in flue gas = 0.87 * (44/12) + 18.77 * 0.77 + 0.007 * 2 + (18.77 14.30) * 0.23 = 3.19 + 14.45 + 0.014 + 1.028 = 18.68 kg of flue gas per kg of fuel

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Calculation of Furnace efficiency Indirect Method

L1 : Heat loss to dry flue gas M * cp * (Tf - Ta ) * 100 GCV = 18.68 * 0.23 * (170 30) * 100 10400 L2 : Loss due to hydrogen in fuel 9H2 {584 + 0.45 (Tf Ta)} * 100 10400 = 6.72 %
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= 5.78 %

Calculation of Furnace efficiency Indirect Method

L3 : Loss due to moisture in fuel M { 584 + 0.45 (Tf Ta)} * 100 GCV = 0.002 { 584 + 0.45 (170 30)}* 100 10400

= 0.01 %

L4 : Loss due to moisture content in air AAS * (Kg moisture per kg air) * 0.45 * (Tf Ta)* 100 GCV = 18.77 * 0.025 * 0.45 * (170 30 ) * 100 10400 = 0.28 %

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Calculation of Furnace efficiency Indirect Method

L5 : Heat loss due to partial combustion (formation of CO) = 0.02% L6: Radiation and Convection Loss = 2.09% Total Loss = (L1+L2+L3+L4+L5+l6) = ( 5.78+6.72+0.01+0.28+0.02+2.09) = 14.91% Efficiency = 100 14.91 = 85.09%

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Calculation of Furnace efficiency Indirect Method

20 C drop in stack temperature increases efficiency from 85.09% to 86.05% Drop in excess air from 31% to 20% increases efficiency from 86.05% to 86.5% 10 degree C drop in surface temperature increases efficiency from 86.5 % to 86.59%

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Success Factors of Boilers Efficiency

Stack temperature and oxygen content in flue gas leaving the stack are the results of: Combustion Efficiency Design of system Operational Efficiency Maintenance Effectiveness Monitoring & Control

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Performance indicators of Boilers

Flue gas temperature to stack

Level of excess air in flue gas

Reality byte: The temperature of flu gas leaving stack remains higher than desired Excess air level remains more than requirement

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Estimation of Stack Losses

Stack losses can be estimated with the help of flue gas temperature to stack and flue gas analysis

Monographs like BETZ energy chart can be used for assessing stack losses and furnace efficiency

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Furnace efficiency AU-4

Basis Throughput : 7600 MT per day, % SRF 1.14% Stack temperature 265 C = 509 F Ambient temperature = 30 C = 86 F Flue gas analysis : CO2 9.5%, O2 6% Excess air = about 40% APH under maintenance

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Furnace efficiency AU-4

Connect 9.5 % on CO2 scale with 6 % on O2 scale Read gas loss = 2.51% per 100 F of difference between stack and ambient Sensible heat loss = 2.51 * (509 86) / 100 = 10.62% Read latent heat loss from scale 2 = 8% Stack loss = 10.62 + 8 = 18.62 % Setting loss say 2 % Efficiency = (100 18.62 2) x 100 / (100 8) = 86.29%

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Furnace efficiency AU-4

Current efficiency = 86.29% Achievable efficiency = 90% Deviation in efficiency = - 3.71% Additional Fuel consumption = 3.59 MT per day = 3.59 x 18,000 = Rs. 64,557/- per day

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Boiler efficiency B-4

Basis Stack temperature 180 C = 360 F Ambient temperature = 30 C = 86 F O2 analyzer : 4% CO2 about 12% Excess air = about 22%

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Boiler efficiency B-4

Connect 12 % on CO2 scale with 4 % on O2 scale Read gas loss = 2.3% per 100 F of difference between stack and ambient Sensible heat loss = 2.3 * (360 86) / 100 = 6.29% Read latent heat loss from scale 2 = 6.5% Stack loss = 6.29 + 6.5 = 12.79 % Setting loss say 2 % Efficiency = (100 12.79 2) x 100 / (100 6.5) = 91.1% (erroneous as temperature and O2 are not at same point)

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Boiler efficiency B-4

Connect 8 % on CO2 scale with 7 % on O2 scale Read gas loss = 2.61% per 100 F of difference between stack and ambient Sensible heat loss = 2.61 * (360 86) / 100 = 7.14% Read latent heat loss from scale 2 = 9% Stack loss = 7.14+9 = 16.14 % Setting loss say 2 % Efficiency = (100 16.14 2) x 100 / (100 9) = 89.9%

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Case study on Furnace

Type of furnace: Forced Draft, Vertical cylindrical Impact of variation in stack temperature at constant oxygen level of 6 % Impact of variation in O2 content in flue gas at constant stack temperature of 325 o C

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Case study - Impact of stack temperature at constant oxygen level of 6 %

STACK TEMP (o C ) vs EFFICIENCY
85
EFFICIENCY (%)

84.5 84 83.5 83 82.5 82 325 320 315 310 83.31 83.79 83.55 84.03

84.27

305

STACK TEMP (o C)

20 o C drop in stack temp reduces fuel consumption by 1 %

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Case study - Impact of variation in O2 content in flue gas at constant stack temp of 325 o C
OXYGEN (%) vs EFFICIENCY

88 87 86 85 84 83 82 6

EFFICIENCY (% )

86.29 84.88 83.31 5 83.84 4

OXYGEN (% )

85.73

1% drop in O2 content in flue gas reduces fuel consumption by 0.5 to 1 %

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Case study - Combined effect of variation in O2 content in flue gas & stack temp
Increase in stack temp with decrease in oxygen level With decrease in supply rate of air to furnace at high firing rate, the oxygen level in flue gas comes down but stack temperature increases marginally.

This effect is mainly due to un-cleaned surface in convection bank.

Observation based on furnace where fuel fired is 80 % oil and 20 % gas This also occurs where area in convection section is less

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Case study - Combined effect of variation in O2 content in flue gas & stack temp
Decrease in stack temp with decrease in oxygen level This phenomena observed in the furnace of Delayed Coking Unit Whenever air supply is controlled at high firing rate, stack temperature drops and skin temperature of coils in radiation section increases The fact More heat is available for absorption

90 % fuel fired in this furnace is refinery fuel gas

Cleaner heating surface due to type of fuel used
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Case study - Combined effect of variation in O2 content in flue gas & stack temp
Decrease in stack temp with increase in supply of air (increase of oxygen level in flue gas) Stack temperature drops due to heat absorbed by additional quantity of air. Less heat is available for process Skin temperature drops with high level of excess air

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Case studies on combined effect of variation in O2 content in flue gas & stack temp

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EFFICIENCY OF FURNACE IN DCU

Target 4.0% 23% 165 90% Actual 7.9% 55.3% 215 86.53% 1.69 23660

O2 Content in flue gas Excess Air Stack Temp o C Furnace Efficiency Fuel saving Potential (MT/Day) Saving potential , Rs per Day

Hot air temp to furnace is 279 o C against normal of 305 o C

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ACTION FOR IMPROVING EFFICIENCY OF FURNACE IN DCU

Closing of stack damper Control of excess air

Sealing of openings in return bend covers of convection bank

Provision of sample points at convection outlet, APH inlet and APH outlet for monitoring of O2 profile in flue gas along the path of flue gas The sample point as above shall be used for leak test of APH Provision of draft gauge at APH inlet / outlet for assessing pressure drop
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EFFICIENCY OF FURNACE IN CDU

O2 Content in flue gas Excess Air Flue gas Temp at ID suction o C Target 4.0% 23% 150 Actual 7.6% 53.3% 193

Stack Temp o C Furnace Efficiency

Fuel saving Potential (MT/Day) Saving potential , Rs per Day

150 92%

172 88.38%
1.17 16405

Hot air temp to furnace is 140 o C against normal of 175 o C

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ACTION FOR IMPROVING EFFICIENCY OF FURNACE IN CDU

Hot water washing of APH / Revamp of APH Control of excess air

Stack temperature is indicating lower due to air ingress from flange just below the thermocouple point in stack
Sealing of openings in return bend covers of convection bank

Provision of sample points at convection outlet, APH inlet for monitoring of O2 profile in flue gas along the path of flue gas
The sample point as above shall be used for leak test of APH

Provision of draft gauge at APH inlet / outlet for assessing pressure drop
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Factors of stack losses

1. Incomplete combustion Incomplete combustion leads to formation of CO & soot. Insufficient Turbulence : Non-uniformity in distribution of air for furnace with forced draft fan. Insufficient air supply may be due to malfunctioning of air dampers

Lower Temperature of fuel oil and lower viscosity at burner tip leads to incomplete combustion
Presence of water in fuel / atomizing steam results in poor atomization of fuel, formation of small fire balls which leads to formation of soot and increased stack temperature Formation of coke / clinker at burner tip affects combustion
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Factors of stack losses

2. Soot blowing system Improper soot blowing system results in increased stack temperature and loss of fuel

Positioning of soot blowers and supply of steam quality affects soot blowing
3. Firing rate

Increase in firing rate increase stack temperature

4. Position of main stack damper Design of main stack damper affects stack loss Position of main stack damper also has direct impact on stack loss
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Factors of stack losses

5. Excess Air
Supply of excess air leads to increased stack loss and additional fuel consumption.

6. Mechanical effectiveness / Air Ingress

Fire box and flue gas side remains under negative pressure Any loose fittings results in air ingress and loss of heat through stack 7. Peep holes Improper closing of peep holes leads to air ingress and stack loss. 8. Malfunctioning of monitoring instruments Oxygen analyzers are installed with good intention. But these instruments fail very often which affects control of excess air.
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Opportunities for minimizing stack losses

Uniform air distribution to burners
The oil must be heated to desired temperature at burner tip Water free oil to burner

Regular cleaning of burners to minimize clinker formation

Use of dry superheated steam for atomization Use of castables for sealing openings in convection bank of furnaces Installation of glass window peep holes in place of door type peep holes Survey of APH for leak Use of portable oxygen analyzers for monitoring of oxygen profile in flue gas.
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REVAMP OF FURNACE IN CRUDE DISTILLATION UNIT

convection

APH

Furnace
ID

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Issue of Monitoring and control of stack gas temperature and oxygen in flue gas
Questions are: a. Where should you measure the stack gas temperature and why do you recommend this location? b. Which is the best solution to measure either O2 or CO2 in stack gas and why is it the best solution? c. Where should you place the oxygen sensor and why do you select this location?

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Issue of Monitoring and control of stack gas temperature and oxygen in flue gas
Question: a. Where should you measure the stack gas temperature and why do you recommend this location? Answer: Measure stack temperature at final exit point of boiler i.e. at APH outlet of ID suction. For balanced draft furnace measure flue gas temperature at final stack

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Issue of Monitoring and control of stack gas temperature and oxygen in flue gas

Question: a. Which is the best solution to measure either O2 or CO2 in stack gas and why is it the best solution? Answer: Best solution is to measure oxygen in flue gas.

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Issue of Monitoring and control of stack gas temperature and oxygen in flue gas
Question: a.Where should you place the oxygen sensor and why do you select this location?

Answer: The oxygen sensor should be placed at the end of fire box / radiation section.

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Thank You

Barauni Refinery In harmony with nature

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