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SWITCH GARMENT- WEBINARClean Combustion & Efficient boiler operation

8th June 2021 - Cambodia

Mr. Shailesh Shinde-Technical Advisor, Thermax Ltd, ThailandMr. Dushyant Tiwari, Country Head, Thermax Ltd, Vietnam

Energy | Environment | Chemical www.thermaxglobal.com

TYPICAL LOSSES IN BOILERS SYSTEM

STEPS TO IMPROVE BOILER EFFICIENCY

IIOT

AIR POLLUTION CONTROL EQUIPMENT

Content

THERMAX AT A GLANCE

STAGES OF BIOMASS COMBUSTION

TYPE OF COMBUSTOR

COMBUSTOR TECHNOLOGY


HEADQUARTERED IN

PUNE, INDIA

822MILLION USD COMPANY

14MANUFACTURINGFACILITIES

10 IN INDIA, 4 GLOBALINSTALLATIONS IN

C O U N T88 R I E S

R A N G E OFENGINEERING SOLUTIONS

C O U N T R I E S27GLOBAL NETWORK IN

SUBSIDIARIES30

Thermax at a Glance


Thermax Portfolio

Power Heating Cooling Water Chemical

Air Pollution Control

Wastewater Treatment

Hazardous WasteTreatment

Waste to EnergyGeneration

Waste

Utilities

Desired ProductsRaw Material


Type of Biomass combustors


Technology mapping: Combustor

Time

Fuel

Fle

xibi

lity

1980 1990 2000 2010

Stationary grate

Moving grate

Inclined Reciprocating

Grate

Horizontal Reciprocating

Grate

Combined Reciprocating

Grate

Underfeed Stoker

Combined UFS + Reciprocating

Grate

2018


Types of grate combustors

8RECIPROCATINGGRATE

STATIONARYGRATE BUBBLING BED

FLUDIZED BEDCOMBUSTOR


Typical losses in boiler


Key steps to improve boiler efficiency

Boiler Combustion Management i.e., Incomplete combustion minimization; Stack temperature control;

Implementation of draft control system & Variable Speed Drive - Excess air control

Investigate Opportunities for feed water quality improvements - Reduction of scaling

Combustion air pre-heating (A.P.H. ), Economizer & Condensate return

Improve Periodic Maintenance schedule – Weekly, Monthly & Quarterly.

Controlling boiler loading & fuel storage (avoid addition of surface moisture)


Good Practice & Recommendations - Fuel• Minimise incomplete combustion.• Symptoms :- Black smoke, high c.o. levels in flue

gas.

Why• Reduce fuel consumption by 3-5%.• Improve cost of steam.

How

• Improve fuel distribution, avoid excess fuel dumping.

• Air mixing with fuel & air distribution.


Good Practice & recommendation – I.D & F.D. Settings

• Avoid higher negative draft furnace pressure

Why

• It reduce unburnt fuel carry over & decrease emissions.

• 1% excess air reduction = 0.6% efficiency rise

How• Negative draft b/w -2 mm to -5 mm.w.c. via

manometer or water level gauge.


Good Practice & recommendation – Exhaust gas temperature

• Monitoring Flue gas temperature at chimney.• Temperature gauges at flue gas path.

Why

• Higher temperature Indicates poor heat transfer• Leads to excess fuel consumption.• Every 22oC increase in stack temperature = 1%

efficiency loss

How

• By cleaning smoke tube of boiler & economiser.• Proper blowdown & pre treatment of feed water


Good Practice & recommendation – Inlet air temperature

• Increase inlet combustion air temperature.

Why

• It improves boiler efficiency.• If combustion air temperature raised by 20°C• = 1% improve thermal efficiency.

How• By installation Air pre heater.


Good Practice & recommendation – Low water level

• Low water level condition – Major reason for boiler failure.

Why• Avoid fatal accident• 3 mm of soot = 2.5% increase fuel consumption.

How• Minimum water level of approximately 50% of the

gauge glass.


Tube bank failureOverheating & oxidized surface

Boiler water related issuesTypes of failure

Thermal cycling - Cracking

Dye penetration testVisual corrosion


Industrial Internet of ThingsBenefits to customers

In-context insights to help operators fix any operating parameters / issues

• Improving equipment efficiency

Challenge:

Lack of comprehensive view (observation-based monitoring & paper-based work instruction)

Data analytics to monitor real-time asset performance

• Improving equipment uptimesData analytics to monitor real-time asset performance

In-context suggestions to improve preventive maintenance practices ensuring effective sweating of assets & improved life.

Workforce performance / needs for improving productivity

• Reducing costs

Optimize energy costs Monitor asset health

LEVERAGING IIoT through-

Challenge:

Teams faced with limited resources & standardized preventive maintenance practices

Challenge:

Dealing with limited visibility into KPIs, asset health & workforce performance.


Parameters Required Electrostatic precipitator (ESP)

Bag Filter Scrubber Cyclone

Emission Desired (20 to 150 mg/Nm3)

Desired(20 to 150 mg/Nm3 About 150 mg/Nm3 Above 300 mg/Nm3

Pressure drop Across Equipment

Water Treatment Not Applicable Not Applicable High Not Applicable

Maintenance Nominal/Routine High due to frequent replacement of bags

High damage to ID fan, Slurry pumps, ETP/clarifier,

Scrubber throat erosion etc.

Erosion of internal parts due to dust abrasion

Capital Investment High High Less Less

Running Cost Lowest High Highest High

ID Fan Power Consumption

Operating Cost Very Low Low Highest In betweenFuture Retrofitting

costOnly Space need to be

provided in ducting, Field can be added

Space need to be provided in ducting, Field can be

added

Need to replace complete Equipment

Need to replace complete Equipment

Down time Very Rare High HIgh Very High

AIR POLLUTION CONTROL EQUIPMENTS


Thank You

Dushyant Tiwari Shailesh shinde

Energy | Environment | Chemical

For more information about Thermax:

Contact UsThermax Limited Thermax House 14, Mumbai – Pune Road Wakdewadi, Pune 411003, India

visit: www.thermaxglobal.com

Contact details:[email protected], Mobile:+84 [email protected]

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