LMF MANUFACTURING - Bio Mass Wood Pellet Furnace & Corn Boiler
Furnace and boiler
-
Upload
mujeebmehar -
Category
Documents
-
view
225 -
download
0
Transcript of Furnace and boiler
-
7/29/2019 Furnace and boiler
1/91
1
Welcome to Training Programon
OPERATION OF FURNACES &BOILERS
-
7/29/2019 Furnace and boiler
2/91
2
MIND
SPIRIT
? YOUR EXPECTATIONS
-
7/29/2019 Furnace and boiler
3/91
3
Type of furnaces / boilers in refinery
Heater nomenclature
Associated equipments(Burners, APH, Soot blowers etc.)
Fuel System
Combustion
Q & A
Presentation Session 1
-
7/29/2019 Furnace and boiler
4/91
4
Types of furnaces
1. Natural draft furnaces (FCC, DHDS, Small furnacesin AU-I/II of JR, NSU, GR)
2. Balanced draft furnaces (All furnaces and boilers of
PDRP, AU-I/II/III/IV/V, new DCU and Russian Boilers
of BR, )3. Forced draft furnaces (New DHDT JR and Boiler-IV
BR)
4. Induced draft (VBU, JR)
-
7/29/2019 Furnace and boiler
5/91
5
Furnace
Convection
Natural Draft Furnace System
Oil
Radiation
Vertical firing
Old system
Hut type furnace
Horizontal firing
History Hut, Verticalcylindrical/ box type,balanced draft
Atomizing steam
-
7/29/2019 Furnace and boiler
6/91
6
Furnace
APH
Induced Draft
Fan
Damper
Balanced draft Furnace System
Oil FD fan
-
7/29/2019 Furnace and boiler
7/917
Boiler Economiser
APH
Induced Draft
Fan
Damper
Boiler System (balanced draft)
Oil FD fan
-
7/29/2019 Furnace and boiler
8/918
Boiler Economiser
APH
Boiler System (forced draft)
Oil FD fan
-
7/29/2019 Furnace and boiler
9/919
Furnace
APH in top of
convection bank
Forced draft Furnace System
Oil FD fan
-
7/29/2019 Furnace and boiler
10/9110
Furnace
Induced Draft
Fan
Damper
Induced draft Furnace System
Oil
Atomizing steam
-
7/29/2019 Furnace and boiler
11/9111
Heater Nomenclature
http://localhost/var/www/apps/conversion/tmp/scratch_6/2.%20heater%20nomenclature1.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/2.%20heater%20nomenclature1.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/2.%20heater%20nomenclature1.pdf -
7/29/2019 Furnace and boiler
12/9112
BURNERS
-
7/29/2019 Furnace and boiler
13/9113
Types of burners
1. Pressure atomized oil burners in Russian boilers2. Steam atomized oil burners in Boiler-IV and process
heaters
3. Mixed burners (Oil & Gas)
-
7/29/2019 Furnace and boiler
14/9114
Burners
Burners convert fuel oil into millions of small
dropletsprocess called atomization
High surface to volume ratio in oil to facilitate
evaporation and combustion
3 basic types of burners are pressure jet, air orsteam blast burners and Rotary Cup
TURNDOWN ratio is the relationship between the maximum
and minimum fuel input without affecting the excess air level
is called Turn-Down Ratio.
For example, a burner whose maximum input is 250,000
Kcals and minimum rate is 50,000 Kcals, has a Turn-Down
Ratio of 5 to 1.
-
7/29/2019 Furnace and boiler
15/9115
Energy Efficiency Measures
Replace old, oversized burnerandinefficient burners with modern, efficientand properly sized burner.
Consider variable firing rates and/or dual
fuel capabilities allowing you to choose low
cost fuel at any time.
Potential efficiency improvement-up to 5%
-
7/29/2019 Furnace and boiler
16/9116
DCU
-
7/29/2019 Furnace and boiler
17/9117
-
7/29/2019 Furnace and boiler
18/9118
-
7/29/2019 Furnace and boiler
19/9119
-
7/29/2019 Furnace and boiler
20/9120
-
7/29/2019 Furnace and boiler
21/91
21
-
7/29/2019 Furnace and boiler
22/91
22
-
7/29/2019 Furnace and boiler
23/91
23
-
7/29/2019 Furnace and boiler
24/91
24
-
7/29/2019 Furnace and boiler
25/91
25
-
7/29/2019 Furnace and boiler
26/91
26
-
7/29/2019 Furnace and boiler
27/91
27
-
7/29/2019 Furnace and boiler
28/91
28
-
7/29/2019 Furnace and boiler
29/91
29
-
7/29/2019 Furnace and boiler
30/91
30
-
7/29/2019 Furnace and boiler
31/91
31
-
7/29/2019 Furnace and boiler
32/91
32
Vacuum Unit
-
7/29/2019 Furnace and boiler
33/91
33
-
7/29/2019 Furnace and boiler
34/91
34
-
7/29/2019 Furnace and boiler
35/91
35
-
7/29/2019 Furnace and boiler
36/91
36
-
7/29/2019 Furnace and boiler
37/91
37
-
7/29/2019 Furnace and boiler
38/91
38
-
7/29/2019 Furnace and boiler
39/91
39
-
7/29/2019 Furnace and boiler
40/91
40
FCC
-
7/29/2019 Furnace and boiler
41/91
41
-
7/29/2019 Furnace and boiler
42/91
42
-
7/29/2019 Furnace and boiler
43/91
43
-
7/29/2019 Furnace and boiler
44/91
44
-
7/29/2019 Furnace and boiler
45/91
45
-
7/29/2019 Furnace and boiler
46/91
46
-
7/29/2019 Furnace and boiler
47/91
47
-
7/29/2019 Furnace and boiler
48/91
48
-
7/29/2019 Furnace and boiler
49/91
49
-
7/29/2019 Furnace and boiler
50/91
50
-
7/29/2019 Furnace and boiler
51/91
51
-
7/29/2019 Furnace and boiler
52/91
52
-
7/29/2019 Furnace and boiler
53/91
53
-
7/29/2019 Furnace and boiler
54/91
54
-
7/29/2019 Furnace and boiler
55/91
55
-
7/29/2019 Furnace and boiler
56/91
56
-
7/29/2019 Furnace and boiler
57/91
57
-
7/29/2019 Furnace and boiler
58/91
58
-
7/29/2019 Furnace and boiler
59/91
59
APHs
Ai h t
-
7/29/2019 Furnace and boiler
60/91
60
Air pre-heaters
Type Recuperative and regenerative
Recuperative Shell and tube type (all balance draft
furnaces and boilers)
Regenerative rotating metal element (Boiler-IV &
CO-Boiler)
-
7/29/2019 Furnace and boiler
61/91
61
SOOT BLOWERS
S t Bl
-
7/29/2019 Furnace and boiler
62/91
62
Soot Blowers
Motor driven (retractable / fixed)
Pneumatic driven (retractable / fixed)
Shot cleaning (old system)
F el S stem
-
7/29/2019 Furnace and boiler
63/91
63
Fuel System
Fuel oil tank, pump, heater, back pressure control
Ensure water free oil
Minimum ash and metal content
Catalyst particles not desired
Heat up to desired temperature for attaining desired
viscosity
Fuel gas system
Ensure condensate free fuel gas
Steady fuel gas pressure
Oil
-
7/29/2019 Furnace and boiler
64/91
64
Oil
The oil used in refinery is a blended fuel
consisting of residue from FCC, DCU and
AGO.
The important properties of oil are viscosity atburner tip, water content, density, specific
gravity, Calorific value, Sulphur, metal and
ash content.
-
7/29/2019 Furnace and boiler
65/91
65
COMBUSTION
-
7/29/2019 Furnace and boiler
66/91
66
What is COMBUSTION ?
-
7/29/2019 Furnace and boiler
67/91
67
-
7/29/2019 Furnace and boiler
68/91
68
Oil Combustion
Stoichiometric ortheoreticalair is idealamount of air required for burning 1 kg of
fuel
1 kg of fuel oil requires ~14.1 kg of air forcomplete combustion
C + O2 CO 2 + 8084 Kcals/kg of Carbon
2C + O2 2 CO + 2430 Kcals/kg of Carbon2H 2 + O2 2H2O + 28,922 Kcals/kg of Hydrogen
S + O2 SO2 + 2,224 Kcals/kg of Sulphur
Combustion products
-
7/29/2019 Furnace and boiler
69/91
69
Combustion products
CO2, H2O, SO2
CO is undesirable loss of fuel
Water vapour carries away heat as water is in
vapour form i.e. latent heat loss
Gas fuel more hydrogen more latent heat loss
Stoichiometric Air requirement
-
7/29/2019 Furnace and boiler
70/91
70
Stoichiometric Air requirement
The furnace oil quality is as under:
Constituents % weight
Carbon 85.9
Hydrogen 12
Oxygen 0.7
Nitrogen 0.5
Sulphur 0.5
H2O 0.35
Ash 0.05
Stoichiometric Air requirement
-
7/29/2019 Furnace and boiler
71/91
71
Stoichiometric Air requirement
Basis : 100 Kg of furnace oil
C + O2 = CO2
12 + 32 = 44
12 Kg of carbon requires 32 Kg of Oxygen to
form 44 Kg of CO2
1 Kg of Carbon requires 32/12 = 2.67 Kg of
Oxygen
85.9 Kg of C + (85.9 x 2.67) O2 = 315.25 Kgof CO2
Stoichiometric Air requirement
-
7/29/2019 Furnace and boiler
72/91
72
Stoichiometric Air requirement
2H2 + O2 = 2H2O
4 + 32 = 36
4 Kg of hydrogen requires 32 Kg of Oxygen to
form 36 Kg of H2O
1 Kg of hydrogen requires 32/4 = 8 Kg of
Oxygen
12 Kg of H2 + (12 x 8) O2 = 108 Kg of H2O
Stoichiometric Air requirement
-
7/29/2019 Furnace and boiler
73/91
73
Stoichiometric Air requirement
S + O2 = SO2
32 + 32 = 64
1 Kg of sulphur requires 32 Kg of Oxygen to
form 64 Kg of SO2
0.5 Kg S + (0.5 x 1) O2 = 1Kg of SO2
Stoichiometric Air requirement
-
7/29/2019 Furnace and boiler
74/91
74
Stoichiometric Air requirement
Total oxygen required = (229.35+96+.5)=325.85 Kg
Oxygen already present in fuel = 0.7 Kg
Additional oxygen required = 325.85 - .7 = 325.15 Kg
Theoretical quantity of dry air required = 325.15/0.23
= 1413.69 Kg
Theoretical air required per Kg of fuel = 1413/100
= 14.13 Kg of air
Theoretical CO2 content in fuel gas
-
7/29/2019 Furnace and boiler
75/91
75
Theoretical CO2 content in fuel gas
Nitrogen in flue gas (QTY air O2) = 1413.69 325.15
= 1088.54 Kg
Moles of CO2 = 315.25/44=7.16
Moles of Nitrogen = 1088.54/28=38.87
Moles of SO2 = 1/64 = 0.016
Total moles = 46.06
Theor % CO2 by volume = (7.16/40.06)*100=15.5%
Flue gas components with excess air
-
7/29/2019 Furnace and boiler
76/91
76
Flue gas components with excess air
% CO2 measured in flue gas = 10% by volume
Excess air = [(Theoretical CO2%/actual CO2%)-1]x100
= 55%
Theoretical air for 100 Kg of fuel burnt = 1413.69 Kg
Supply with 55% excess air = 1413.69 x 1.55
= 2191.22 Kg
Excess air quantity = 2191.22 1413.69 = 777.53 Kg
Oxygen = 777.53 x .23 = 178.83 Kg
Nitrogen = 777.53 178.83 = 598.7 Kg
Final components of flue gas with 55% excess air
-
7/29/2019 Furnace and boiler
77/91
77
CO2 = 315.25 Kg = (315.25/44) = 7.16 moles
SO2 = 1 Kg = 1/64 = 0.016 moles
Oxygen = 178.83 Kg = 178.83 /32 = 5.59 moles
Nitrogen = 1687.24 Kg = 1687.24 / 28 = 60.25 moles
Total moles = 73.016
Theor %CO2 by volume = (7.16/73.016)x100=9.8%
Theor % O2 by volume = (5.59/73.016)x100=7.6%
3 T f C b ti
-
7/29/2019 Furnace and boiler
78/91
78
3 Ts of Combustion
TIME
Sufficient time for complete combustion
TURBULENCE
Intimate mixing of fuel and air (primary air, secondary
air, tertiary air and angle of contract of air with fuel)
TEMPERATURE
Temperature high enough to ignite and maintain
ignition of fuel (viscosity of oil at burner tip 15-20 CST,
heating of oil)
What are the various types
-
7/29/2019 Furnace and boiler
79/91
79
What are the various typesof combustion?
There are three types of combustion: -- Perfect -- Complete -- Incomplete
Perfect Combustionis achieved when all the fuel is burned using only the
theoretical amount of air, but perfect combustion cannot be achieved in aboiler.
Complete Combustion is achieved when all the fuel is burned using theminimal amount of air above the theoretical amount of air needed to burnthe fuel. Complete combustion is always our goal. With completecombustion, the fuel is burned at the highest combustion efficiency with
low pollution.
Incomplete Combustion occurs when all the fuel is not burned, whichresults in the formation of soot and smoke.
Critical success factor of combustion
-
7/29/2019 Furnace and boiler
80/91
80
Critical success factor of combustion
Atomization
Mixing of oil and air (oil pressure drop and air
pressure drop)
A i i
-
7/29/2019 Furnace and boiler
81/91
81
AtomizationOil as a liquidmust be converted to oil as gas
(vapour) before it can mix with air and begin to burn
Oil is passed to burner through atomizer which
converts liquid oil into millions of tiny droplets 10-50
micron size
Tremendous increase in the ratio of surface to mass
permitting substantially instantaneous heat absorption
by droplets to change physical state from oil to gas in
micro second
A i i
-
7/29/2019 Furnace and boiler
82/91
82
AtomizationAtomization with the help ofsteam, air or high
pressure gas
Pressure atomization TPS old Russian boilers
Mechanical atomization Swirl chamber and rotary
cup
F f i i
-
7/29/2019 Furnace and boiler
83/91
83
Factors of atomizationOil temperature at burner tip for attaining 15-20 CST
Dry atomizing steam
Delta P between steam and fuel about 2 Kg/Cm2
Cleanliness of burner
Impurities in oil like water, catalyst particles and metal
contents etc.
What the Nozzle Does
-
7/29/2019 Furnace and boiler
84/91
84
What the Nozzle Does
Atomizing speeds up the vaporization process
One litre of oil becomes 15 billion droplets at 7kg/cm2
with size 0.0002 inch 0.010 inch
Metering deliver a fixed amount of atomized fuel to the
combustion chamber
Patterning
uniform spray
pattern and spray angle
What Affects Droplet Size?
-
7/29/2019 Furnace and boiler
85/91
85
What Affects Droplet Size?
Higher Flow Rate Nozzles usually producelarger droplets
Wider Spray Angles produce smaller droplets
High Viscosity fuel produces larger droplets inthe spray
Heating Fuel reduces its viscosity and produces
smaller droplets.
Increasing Fuel Pressure reduces droplet size.
-
7/29/2019 Furnace and boiler
86/91
86
Spray at 10 psi pressure Spray at 100-psi pressure
Spray at 300-psi pressure
Effects of Viscosity
-
7/29/2019 Furnace and boiler
87/91
87
On Nozzle Performance
The nozzle orifice is polished to
a glasslike finish Dont ruin it with
-
7/29/2019 Furnace and boiler
88/91
88
a glasslike finish. Don t ruin it witha wire or pin, or by bumping it with a
wrench. This can cause streaks in thespray.
Dont blow into the nozzle. While
-
7/29/2019 Furnace and boiler
89/91
89
this may seem to be the handiest and
quickest way to clean a nozzle, yourun the risk of contaminating it instead.
Make sure the fuel tank is clean.W t d l d i th t k
-
7/29/2019 Furnace and boiler
90/91
90
Water and sludge in the tank can
clog lines, filter or nozzles.
-
7/29/2019 Furnace and boiler
91/91
Thank YouThank You