STEAM BOILER IN SUGAR INDUSTRY

The function of boiler is to generate steam at desired

pressure and temp. by transferring heat producing by burning
of fuel( Bagasse) from water to change into steam.

Steam boiler is heart of sugar factory. If any

breakdown is occurred at steam boiler, whole sugar factory is
stopped indefinitely till the boiler is repaired and
commissioned.
The steam produced is used for :

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(i) Producing mechanical work by expanding it in steam
engine or steam turbine.

3
(ii) Heating the residential and industrial buildings
(iii) Performing certain processes in the sugar mills, chemical
and textile industries.
 Fuel
What is a Boiler ?
Air Electricity Water

Boiler
Converter

Residue / Ash

Steam to Process Emission

 HOW IS A BOILER SPECIFIED?
 Capacity - Steam generation in Tons / hr.
 Pressure - Steam Pressure in Bar or kg/cm2.
 Fuel – Solid, Liquid, Gas or Waste heat
 Type of firing - Manual, Automatic
 Efficiency - % .
 Design & Operations Code - IBR.
 Imp. Note - Indian Boilers Regulation is a
mandatory code for boiler design, manufacturing
and operation in India.
BOILER CODES :

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Design, Fabrication, Testing, Construction & Operation.
The following codes have been used widely :

6
[Link] 1950
[Link] Section-I
[Link] 1113
[Link] TRD 300
Classification of Boiler :
According to the direction of the axis of the shell
• Vertical
• Horizontal

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• Inclined (sometimes)

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According to the service to which the boiler is placed
• Stationary (Power plant, Industrial, Central heating)
• Portable
• Locomotive
• Marine
According to the Heat transfer Mode
Fire Tube Boiler (water is outside the tube while the hot
gas are inside the tube)
Ex. Cohran, Lancashire, Cornish, Locomotive etc…
Water Tube Boiler ( Contain large number of small tube through
which water circulates the fire and hot gas being outside the
tubes.)
Ex. Babcock & Wilcox, Striling and high pressure Boilers)
According to the type of fuel used
1) Solid (Coal, Bio mass)

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2) Liquid (Diesel, Bio fuel)
3) Gas fired (LPG, Bio gas)
4) Electric boilers 5) Nuclear fission
According to the method of circulation of water
1) Natural Circulation 2) Forced Circulation
According to steam pressure.
(i) Low pressure (ii) Medium pressure (iii) Higher pressure
According to position of furnace.
(i) Internally fired (ii) Externally fired

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How To Select a Boiler System ?
•Process demand of capacity
•Process demand of pressure
•Demand on steam quality
•Process Criticality of response to demand
•Fuel Used
•Water Quality
•Environmental Norms
 SELECTION BY FUELS
FUEL SELECTION

Availability Ease of Combustion Environmental Norms

CONSISTENCY FUEL RESIDUAL

OF SUPPLY CHARECTERISTICS DISPOSAL

FUEL EMISSION
HANDLING REGULATIONS

FUEL
STORAGE
 SELECTION BY WATER QUALITY

WATER QUALITY

SMOKE TUBE DESIGN WATER TUBE DESIGN

Normal water Quality Stringent Water Quality

Soft Water De Mineralised water

 TYPICAL INDUSTRIAL FUELS

Gas Liquid Solid

Natural Gas HSD / LDO Coal

Mineral
LPG FO / LSHS Lignite
Naptha RFO Petcoke
LNG (Liquid
natural gas)
Bio Gas Husk

Agro Based
Bagasse
Wood
Other agro wastes
 Steam Boilers
Definition of a Boiler

Boiler is defined as a closed metallic vessel in which the

water is converted into steam above the atmospheric
pressure by the application of heat generated by the
combustion of fuels.

Function of a Boiler

The function of a boiler is to generate & supply

the steam at the required constant pressure
with its qualityeither dry, wet or superheated.
 AS PER BOILER REGULATIONS ACT –
Definition of Boiler
According to Boiler Act, boiler means any closed vessel having
holding capacity 22.75 liters and pressure 3.5 Kg/cm2 & above be
used for steam generation under pressure, having installed
mountings.

AS PER BOILER REGULATIONS ACT–

Steam Pipes
As per Boiler Regulation Act steam pipes means any pipe through
which steam passes from boiler to the prime movers or other use
or both, when steam pressure is in the range of 3.5 Kg/cm2 &
above and the ID of pipe exceeds 254 mm along with connected
fittings of steam pipes.
Introduction:
 After Combustion heat is transferred into water till it
heated and becomes hot water / steam.

 The hot water or steam under pressure is then usable for

transferring the heat to process.

 Water is a useful and cheap medium for transferring heat to a

process. When water is boiled into steam, its volume increases
around 1,600 times, producing a force that is almost as
explosive as gunpowder. This causes the boiler to be
extremely dangerous equipment and it must be taken care.
The process of heating a liquid until reaches its gaseous state is
called evaporation.
Heat is transferred from one body to another:

[Link] - Transfer of heat from a hot body to a cold body without

medium
[Link] - The transfer of heat by medium, such as air or water

[Link]- transfer of heat by actual physical contact and molecule to

molecule.
CLASSIFICATIONS AND TYPES OF BOILERS
There are many types of boilers but generally they falls under two
categories:

 Fire tube or “fire in tube” boilers:-

Long steel tubes through which the hot
gasses from a furnace pass and around
which the water to be converted into
[Link] tube boilers have a lower initial
cost, are more fuel efficient and easy to
operate, but they are limited due to lower
capacity of 25 tons/hr and
pressures @ 17.5 kg/cm2.

Fire Tube Boilers : 1) Locomotive Boiler

2) Cochran Boiler
3) Cornish Boiler
FIRE TUBE BOILER
WATER TUBE OR “WATER IN TUBE” BOILERS
 The water passing through the tubes
and the hot gasses passing outside the tubes.
These boilers can be of single- or
multiple-drum type and can be built
to any steam capacity and pressure,
have higher efficiency than fire tube boilers.

Water Tube Boiler

1) Babcock & Wilcox Boiler
2) Stirling Boiler
3) Lamount Boiler
4) Yarrow Boiler
Water Tube Boiler Classification:
 Low pressure boiler -Pressure up to 21 kg/ cm2.
 Medium pressure boiler -Pressure 21 to 45 kg/ cm2.
 High pressure boiler - Pressure above 45 kg/ cm2.
 Supercritical pressure boiler - Pressure 225 kg/ cm2.
WATER TUBE BOILER
Advantages of Water Tube Boilers over Fire Tube
Boilers
1. Steam can be raised more quickly

2. Steam at higher pressures can be produced

3. Higher rate of evaporation

4. Sediment deposition is less

5. Suitable for any type of fuel and method of firing

6. Failure of one of the water tube will not affect the working of boiler

7. Occupies less Space

8. Easy maintenance.
 Difference/Comparison for fire tube & water tube
boiler
SR. PARTICULAR FIRE TUBE WATER TUBE BOILER
NO BOILER
1 Flow of water & Hot gases inside the tubes Water inside the tubes and hot
hot gases and water is poured from gases surround the tubes
outside
2 Mode of firing Internally fired Externally fired
3 Operating Low (Max. up to High ( Max. up to
pressure (17.5 kg/cm2.) 225 kg/cm2)
4 Rate of steam Low High
production
4 Applications Suitable for Ideally suitable for power
Chemical industries & not generation Plants & sugar
for power generation industries
5 Safety Safe, due to low pressure Not safe, due to high pressure

6 Treatment of Not essential Essential

water
7 Shell diameter Large for given capacity Small for given capacity
BOILER MOUNTINGS
Boiler mountings are required
To have complete control over the steam generation

Measurement of some of the important steam parameters

To provide safety to the boiler.

According to boiler act, The Boiler mountings are:

1) Pressure Gauge
2) Safety Valves
3) Water level Indicators
4) Feed Check Valves
5) Steam Stop Valve
6) Fusible plug
7) Blow of Cock
8) Man Holes & mud Holes
FUNCTIONS OF BOILER MOUNTINGS

Pressure Gauge:
It is used to indicate the pressure of steam inside the boiler drum.

Safety Valves:
It suddenly blows off the excess steam from the boiler drum.

Water Level Indicator:

It is used to indicate the level of water inside the boiler drum.
Steam Drum
Steam cock

Glass Water
Level
Protector Shield

Drain cock
Water
cock
FUNCTIONS OF BOILER MOUNTINGS

Feed Check Valve:

It supplies the additional water, when the level of water inside
the boiler drum falls.

Steam Stop Valve:

It is used to regulate the flow of steam from the boiler drum.

Blow off Valve:

It is used to remove periodically the sediments & also used
to empty water in the boiler when required.

Fusible Plug:
It is used to extinguish the fire in the furnace of the boiler
when the water level falls below the normal level.

Manhole:
It is an opening in the boiler shell through which a man can
go in for periodic inspection and cleaning.
BOILER AUXILIARIES

Boiler Auxiliaries are required in the boiler circuit to increase the boiler
efficiency

Boiler Auxiliaries :

1) Air Pre heater

2) Economizer
3) Super Heater
4) Boiler Feed Pump
5) F.D. Fan , I.D. Fan
6) Steam Separators
7) Steam Trap
8) Feed tank , DM Tank
9) De-Super heater
10) Deareator tank etc.
11) Chemical dosing pump
12) Soot blower
13) PRDS
14) Ash Handling system
FUNCTIONS OF BOILER AUXILIARIES
Air preheater:
It is a device, in which the waste heat of the flue gases is
utilized for preheating the air supplied for the combustion
of the fuel in the furnace.
Economizer:
It is a device, in which the waste heat of the flue gases is
utilized for preheating the feed water.
Super heater:
It is used to increase the temperature of the steam above
the saturation temperature.
Feed Pump:
It is used to force the feed water at higher pressure into
the boilers.

Steam Separator:
It separates the water particles from the steam flowing in
the pipe lines.

Steam trap:
It is used to drain off the condensed water accumulating
in the steam pipe lines while at the same time the high
pressure steam does not escape out of it.
 HEATING VALUE OF FUELS
GROSS OR HIGHER CALORIFIC VALUE OF BAGASSE:

Heat liberated by combustion of 1 Kg of bagasse at 00C and 760 mm of Hg

or 1.033 bar abs pressure, and all the products of combustion are at same
condition at 00C and 760 mm of Hg or 1.033 bar abs. pressure, i.e. vapours
formed by combustion of water and moisture in bagasse are considers
condensed.

GCV=4600(1-w)-1200s Kcal / Kg of bagasse

w = moisture per unit bagasse

s = pol per unit bagasse

Example: GCV=4600(1-0.48)-1200x0.018=2370.4 Kcal/Kg for w = 48%

and s=1.8%
 NET / LOWER CALORIFIC VALUE (NCV/LCV)

The amount of heat liberated by 1 Kg of bagasse taken at 00C & 1.033 bar
ab or 760 mm Hg pressure, but water formed by H2 combustion and as a
moisture remains in the vapour form i.e. latent heat of evaporation is
absorbed from released heat.

NCV=4250-1200s-4850w Kcal/Kg of mill bagasse.

If GCV = 4600 Kcal/Kg, NCV=4250 Kcal/Kg for w=0, s=0

GCV-NCV=350 Kcal/Kg.

The heat difference is due to formation of water vapour due to combustion

of H2 in bagasse.

NCV=4250 -1200 x 0.02 – 4850 x 0.50 =1801 Kcal/Kg, w=50%, s=2%

 FUELS AVAILABLE FOR FIRING IN BOILER

 Solid – wood, coal , Agricultural residue

 Liquid- Kerosene, Diesel oil, LDO, Furnace oil, LHSH


 Gaseous – Ethane , Methane, LPG etc

The selection fuel

 Depends furnaces and combustion equipments of boiler.

 Availability, storage, handling, pollution and landed cost of

fuel.

 The knowledge of the fuel properties helps in selecting the right

fuel for the right purpose and efficient use of the fuel.
 PROPERTIES OF BAGASSE
The chemical composition of bagasse has a strong influence on its
combustibility.
The properties of bagasse are classified as
1. Physical properties
2. Chemical properties
Physical Properties
Heating Value: The heating value of bagasse varies from wet bagasse
to dry bagasse and pol % bagasse
GCVs and NCVs of bagasse

GCV OF BAGASSE
Parameter Wet bagasse Dry bagasse
GCV (kCal/kg) 2276 4600
NCV (kCal/kg) 1801 4250
Moisture % bagasse(W) - Moisture % bagasse(W) -0%,
50%, Pol % Bagasse (S) -0%
Pol % Bagasse (S) -2%
 PROXIMATE ANALYSIS OF BAGASSE

 Physical Composition of Cane

Sugar - 10 to 16%
Fibre - 12 to 16%
Water - 65 to 80%

 Physical Composition of Bagasse

Fibre - 45 to 53%
Water as Moisture - 47 to 53%
Sugar & Impurities (Brix) - 1.5 to 3%
 CHEMICAL PROPERTIES
Ultimate Analysis:
The ultimate analysis indicates the various elemental chemical
constituents such as Carbon, Hydrogen, Oxygen, Sulphur, etc. It is
useful in determining the quantity of air required for combustion and
the volume and composition of the combustion gases. This
information is required for the calculation of combustion chamber
temperature and the flue duct design etc.
Typical ultimate analysis of bagasse:

Chemical Composition of Bagasse: (Dry bagasse)

Carbon (c) - 46 to 48% - 47%

Hydrogen (H2) - 6 to 7% - 6.5 %
Oxygen (O2) - 43 to 45% - 44%
Ash - 2 to 3% - 2.5%
 ULTIMATE ANALYSIS OF BAGASSE
CHEMICAL COMPOSITION OF BAGASSE:
Chemical Composition Dry bagasse 50% moist. bagasse

Carbon 47.0 23.5

Hydrogen 6.5 3.25

Oxygen 44.0 22.0

Ash. 2.50 1.25

GCV (Kcal/kg) 4600 2276

NCV(Kcal/kg) 4250 1801

DENSITY OF CANE AT DIFFERENT LOCATIONS IN PREPARATION OF CANE AND
CANE MILLING
CANE PREPARATION
Tangled cane -150 kg/m³
Parallel cane -175 kg/m³
After kicker -225-250kg/m³
After Leveller -270- 280 kg/m³
After Fibrizer -650 kg/m³
MILL BAGASSE DENSITY
Mill No Bagasse Density kg/m³
I 1210
II 1230
III 1250
IV 1270
V 1290
VI 1310
DENSITY OF BAGASSE
Loose bagasse 120 to 170 kg/m³
Bailed Bagasse 300 to 600 kg/m³
Briquette press bagasse 720 to 880 kg/ m³
 COMBUSTION OF BAGASSE

Inlet to the furnace:

i) Bagasse, which contains C, O2, H2 & H2O as moisture

ii) Air for combustion contains O2 and N2.

Outlet from furnace

i) C + O2 =CO2,
ii) 2H2 + O2 =2H2O (water vapour) also water vapour of
moisture of bag.
iii) O2as excess O2 from bagasse or air
iv) N2 from air
Bagasse weight + weight of air = weight of gas + ash weight, (ash weight
is negligible) Weight of gas is Wg = 5.76 (1-w) m + 1 Kg / Kg of
bagasse.
COMBUSTION PRODUCT
Weight of air for combustion of bagasse:
Wa = 5.758 (1-w) m Kg / Kg of mill bagasse

Volume of air for bagasse combustion (Va)

Va = 0.773 x5.758 (1-w) m M3 / Kg of bagasse
= 4.4509(1-w) m M3 / Kg of mill bagasse
= 4.45(1-w) m M3 / Kg of mill bagasse at 0C& 1.033
bar abs. Pressure.
(0.733 M3 / Kg is sp. Vol. of air at ºC)

Volume of flue gas (Vg) = [4.45(1-w)×m+0.572w + 0.672]

m³/kg of bagasse at 0C& 1.033 bar abs. Pressure.

Volume of gas or air at temp. at tºC = volume at 0ºC ×[ (273+t)/273 ]

m³/kg of bagasse at that temp.
 Calculation of excess air:

Excess is air estimated by measuring volume of CO2 or O2 in flue gas

volume of CO2 % in flue gas. The volume of CO2 is calculated on dry gas
basis.
The dry gas is the volume of gas after passing / bubbling the gas through
water, as vapours are present in the gas and condensed in water, gas is
assumed as dry gas

Excess air ratio m =19.8 / CO2 %

CO2 range from 12-16% & excess air from 25-65%
Example:
m =19.8 / 14.7=1.35 for CO2 = 14.7%
 Effect of CO2 is 19.87% at m=1,
 Optimum is 14 to 15%.
 For lower CO2, the excess air is more, flue gas sensible
heat loss and lower furnace temperature.
 If CO₂ is more than 15% then there is possibility of CO in
the flue gas indicates incomplete combustion i.e. poor
combustion

Similarly, excess air can be calculated by ratio of volume

of O2 in flue gas to volume of dry gas.

O2 = 0.933(1-w)(m-1) / 4.455(1-w) m-0.061 (1-w)-0.01

m= 1.35 for O2 = 5.5%
REDUCTION IN WEIGHT BY DRYING OF BAGASSE:

weight of dried bagasse x=(1-w)/(1-w1) Kg

Where, w- moisture of bagasse before drying, w1- moisture of bagasse

after drying

Example: x=(1-0.5)/(1-0.4)=0.833 Kg (w=50% w1=40%)

Example - To calculate the bagasse weight after drying ,intial bagasse

moisture is 52% and final bagasse moisture is 46%. Intial weight of
bagasse is 500 kg.
LOSSES IN BOILER

There are two types of losses in boiler

These losses are calculated on GCV

1) Calculated losses :
• Condensation loss =18-22 % on GCV
• Sensible Heat loss = 8-10 % on GCV

2) Estimated losses :
• Unburned Fuel Loss = 2-3 % on GCV
• Incomplete combustion loss = 0.5 –1 % on GCV
• Radiation Loss = 0.5 –1 % on GCV

* Total Losses in the Boiler = 29- 37 % on GCV

 LOSS OF HEAT DUE TO INCOMPLETE COMBUSTION:

 About 8000-8100 Kcals/Kg of heat is liberated by

complete combustion of C to CO2

 Only 2415 to 2430 Kcals/Kg heat is liberated by partial

combustion of C to CO.

 Each % of CO by volume in gas results loss of heat of

about 4.36 %.

 This in complete combustion heat loss due to insufficient

capacity of FD or ID or lower combustion temperature.
FEED TO BOILER AND OUT FROM BOILER
Steam to fuel ratio (Evaporation ratio) at various
pressure of boiler (B.P.1.5Kg/cm2)
Boiler working Steam to fuel
Pressure (Kg/Cm2 ) Ratio (Kg)
21 2.34
32 2.28
45 2.22
64 2.12
Steam to fuel ratio: G.C.V.x Boiler Efficiency
(H1-H2)
H1=Enthalpy of super heated steam
H2=Enthalpy of feed water
GCV = 2276 Kcal/kg
Efficiency = 67% on GCV
H1=Enthalpy of super heated steam @ 21 kg/cm2, 3400C = 745Kcal/kg
H2=Enthalpy of feed water @900C temperature = 90Kcal/kg
S/B ratio = (2276 x 0.67) /(745-92)
= 2.34 Kg of steam / kg of bagasse
STEAM PRESSURES AND TEMPERATURES FOR DESIGNING THE
SUPER HEATER COILS

Pressure [ kg /cm2] Super heater Temperature [0C

10 230
14 250
21 340
32 380
45 440 /490
67 500
87 515
110 540
BOILER HEAT BALANCE

Boiler efficiency

 Condensation heat loss

 Sensible heat loss, heat loss due to un-burnt bagasse loss

 Radiation heat loss, heat loss due to incomplete combustion

 Steam to bagasse weight ratio

Direct and indirect method of boiler efficiency detection measures for boiler

efficiency improvement

 Heat balance.
Methods of determining boiler efficiency:
 Direct method of determining boiler efficiency
 Indirect method of determining boiler efficiency
Direct method of determining boiler efficiency:
• It is the ratio of heat out put to heat input
• Heat output is the heat gained by feed water to form steam
• The heat out put is then estimated as, Ws x (H-h) Kcal/ hr
• where, Ws - weight of steam is in Kg/hr is calculated from boiler
steam flow meter and feed water flow meter
• The enthalpy of boiler outlet super heated steam is estimated
with the help of average boiler super heater steam pressure
temperature chart
• The sensible heat in feed water is estimated with the help of feed
water temperature recorder chart.
• The heat input is calculated only by knowing the weight of
bagasse burnt in Kg per hour and by knowing average bagasse
Gross Calorific Value in Kcal/Kg. Then the input heat is Wb x
GCV Kcal/hr.
Boiler efficiency (nb GCV)
= Ws x (H-h) x 100
Wb x GCV
% Boiler efficiency on GCV.

Boiler efficiency (nb NCV) = Ws (H-h) x 100

Wb x NCV
% Boiler efficiency on NCV.

ADVANTAGES OF DIRECT METHOD :

 Plant people can evaluate quickly the efficiency of boilers.
 Requires few parameters for combustion.
 Needs few instruments for monitoring.

DISADVANTAGES OF DIRECT METHOD:

 Does not gives clues to the operator as to why efficiency of
system is lower.
 Does not calculate various losses accountable for various
efficiency levels.
INDIRECT METHOD:
 There are reference standards for Boiler Testing at site using
indirect method namely British Standard, BS 845 : 1987, and
USA Standard is ASME PTC-4-1 power test code steam generating
units.
 Indirect method also called as heat loss method.
 The efficiency can be arrival at, by subtracting the heat loss
fractions from 100.
 The standards don’t include blow-down loss in the efficiency
determination process. A detailed procedure for calculating
boiler efficiency by indirect method is given below. However, if
may be noted that the practicing energy mangers in industries prefer
simple.

CALCULATION PROCEDURES:
The principle losses occurs in boilers:
 Loss of heat due to dry flue gas
 Loss of heat due to moisture in fuel and combustion air.
 Loss of heat due to combustion of hydrogen.
 Loss of heat due to radiation.
 Loss of heat due to un-burnt.
BOILER EFFICIENCY (nb) :
Boiler efficiency is the ratio of useful heat out put to heat input as gross calorific
value. Heat out put is the heat, gained by feed water to form steam.

Boiler efficiency = Heat Output / Heat Input

= (Heat Input – Heat losses) / Heat Input
= (GCV – Heat losses) / GCV

Heat losses = Lc + Ls + Lu + Lr + Li Kcal/Kg of bagasse.

Heat output= Heat Input – Heat losses
= GCV- (Lc + Ls + Lu + Lr + Li)

= NCV - (Ls + Lu + Lr + Li)

= (NCV – Ls) α ×β× γ Kcal/Kg of bagasse.

α=(1-Lu/GCV), β=(1-Lr/GCV), γ=(1-Li/GCV)

are coefficient of heat loss for un-burnt bagasse, radiation and incomplete
combustion loss respectively.
BOILER EFFICIENCY: nb
= (NCV – Ls)α.β.γ.100 / GCV %

Calculate boiler efficiency for- w=48%,s=1.5%,CO2=15%,Tg=150 0C, Ta=30 0C,

Lu=2.5%, Lr=0.5%,Li=0.5%.
Heat Output = (NCV–Ls)α.β.γ Kcal/Kg of Bagasse.
Boiler efficiency: Heat O/P/Heat I/P: ήb = (NCV–Ls)α.β.γ.100/GCV %
NCV=(4250 - 1200 x 0.015–4850x0.48)=1904 Kcal/Kg bagasse.
Sensible heat (Ls)={[(1–w)(1.4m–0.13)]+0.5)}×(Tg–Ta)
m=19.8/CO2% m=19.8/15=1.32
={[(1–0.48)(1.4 x 1.32–0.13)]+0.5)}(150–30)=167.20 Kcal/Kg bagasse
α=(1–Lu)=(1–0.025)=0.975
β=(1–Lr)=(1–0.005)=0.995
γ=(1–Li)=(1–0.005)=0.995
=(1904-167.20)×0.975x0.995x0.995x100/2374=1676.48x100/2374 = 70.61%
The indirect method may be more accurate as only losses are

estimated ,as the loss is only one third of the total heat input ,hence

any error in estimation will be on the lower side as against

estimation of two thirds output heat quantity in the direct method .

Estimation of boiler efficiency by indirect method is more easy as

comparatively instruments are sufficient for collecting the data.

 MEASURES TO IMPROVE BOILER EFFICIENCY

The boiler efficiency improves with higher NCV which depends on lower
bagasse moisture. About 65-75% of heat loss in condensation is due to
bagasse moisture. Lower bagasse moisture by slow speed milling with
higher quantity and temperature of imbibition water helps to increase
bagasse temperature or bagasse sensible heat or drying of bagasse while
traveling from last mill to boiler.

 The sensible heat loss in flue gases is monitored by maintaining internal

and external heating surface of super heater coils ,boiler bank tubes
,economizer and air pre heater as0C clean as possible ,the higher heating
surface of economizer and air pre heater reduces the flue gas temperature
,however this needs the techno- economic evaluation .
 Monitoring the balance draught helps to monitor. Automation of
monitoring CO2 and balance draught gives better results ,this also
reduces the heat loss due to un burnt bagasse flying with the flue
gas due unwanted higher draught .
 Boiler tubes as front and side water wall reduces the radiation heat
loss as the temperature of the tubes are near to steam saturation as
against combustion temperature .
 Insufficient draught ,excess bagasse feeding, low combustion
temperature due to higher bagasse moisture to furnace, ….etc
leads to incomplete combustion of bagasse resulting in formation
and presence of carbon monoxide in the flue gases
Temp. of Combustion Chamber Depends upon-

* Moisture % Bagasse
* Excess air
* Combustion Air Temp. from Air heater
* Draft of Furnace ( I.D.& F.D.)
* If Color of Flame in the Furnace is golden, indicates the is
combustion is complete
* Combustion chamber Temp. should be in the range
between 900 to 1100 0C
* When Temp. of combustion is continuously 11000C(+) , then silica
melts & forms clinkers. It is bad conductor of heat.
DIFFERENT TYPES OF FURNACES FOR BURNING BAGASSE

 Step grate

 Horse shoe

 Ward furnace,

 spreader stoker

 Inclined water cooled

 Travelling grate
Steam Distribution at various station in Factory

Station % [Link] required on Cane

Juice Heater 15-18
Evaporator 2-10
Pan Boiling 20-25
Sulphur Burner Etc. 3-5

Total Steam consumption on cane = 40-58%

As per Central Govt. Norms i.e. 50 % on cane

Boiler Cap. required =TCH x % Steam Consum. x Safety factor

For 100 TCH Cap. of Boiler =100 x 0.5 x 1.15

=57.5 T/Hrs.
Steam and power balance of Factory
Plant capacity – 2500TCD, Boiler pressure- 21 kg/ cm2,
[Link] turbine- 1200 BHP,
[Link] turbine- 500 BHP
[Link] Turbine- 2500KW
Capacity of plant/Hr- 2500/22=115TCH
Semi Electric driven plant
Electric power required: 17 KW/TCH
Electric power required; 115×17=1955 KW
Exhaust production by steam turbine
[Link] Turbine= BHP of mill ×specific steam consumption(kg/BHPhr)
=1200 × 17 = 20400 Kg/hr
[Link] Turbine =500 × 17 =8500 Kg/hr
3. Power Turbine = 1955 × 13=24415 Kg/hr
Total exhaust produced= 20.4+8.5+24.4=53.3T/hr
Exhaust production % cane= 53.3/115 ×100= 46.34% on cane
 How to Improve the boiler Efficiency

* To increase the Calorific Value of Bagasse

* To reduce the Losses of Boiler
* To clean the [Link] Boiler
* To keep Excess Air % proper
* To use the quality water in the boiler
* To keep the CO2 percentage at 14.5 %
* Percentage of CO Should not be increased above 0.5
* Steam traps, valves , pipes should be made leak proof
* soot blower and blow down should be regular
* The boiler furnace should be cleaned in the running season shift wise
 Energy Conservation in Boiler

• Feed water preheating by using Economizer

• Combustion Air Preheating by using air heater
• Avoid incomplete combustion
• Excess Air Control
• Reduce the radiation & convection Heat losses
• Automatic Blow down control
• Reduction of Scaling and soot losses
• Reduction of boiler steam pressure
• Variable speed control for fans, blowers & pumps
• Effect of boiler loading on efficiency
• Proper boiler scheduling
• Boiler replacement
 STEAM CHARACTERISTICS
Absolute pressure – is a total pressure.
Absolute pressure = Gauge pressure + Atmospheric pressure

Gauge pressure - is pressure indicated by gauge. All gauges are calibrated to read
zero at atmospheric pressure.

Atmospheric pressure – is the pressure in the surrounding air at the surface of

the earth.

Specific heat- If the same amount of heat energy is supplied to equal quantities of
water and juice, their temperature goes up by different amounts. This property is
called the specific heat of a substance.
It is defined as the quantity of heat required to raise the temperature of 1kg of a
substance through 1oC.
 Sensible heat– It is that heat which when added or subtracted results in a change
of temperature.

Q = mass x specific heat x increase in temperature

Q = m x Cp x Δt

Phase Change-
1. The change of state from the solid state to a liquid state is called fusion.
2. The fixed temperature at which a solid changes into a liquid is called its melting
point.
3. The change of a state from a liquid state to a gas is called vaporization.

Latent heat
It is the change in heat content of a substance, when its physical state is
changed without a change in temperature.
Why steam is use for power generation and process

Steam

Steam has been a popular mode of conveying energy, since the industrial
revolution. The following characteristics of steam make it so popular and
useful to the industry:

• High specific heat and latent heat

• High heat transfer coefficient

• Easy to control and distribute

• Cheap and inert

 Steam Turbines:
Types of turbines:

1)Impulse&reaction turbines: single stage ,Back pressure &condensing .

*Impulse turbine: When total pressure drop in nozzle only then it is called impulse
turbine.

*Reaction turbines: When pressure drop in fixed nozzle & Blades is called as reaction
turbine.

*Condensing turbine: condensing turbine is turbine whose exhaust connection is

connected to a condenser.

*Back Pressure turbine: Where the steam leaves the turbine with certain pressure to
the process.
Condensing turbine
Specific steam consumption:(Kg/Kwh)

• Power house turbine:860/(H1- H2) na ×nm ×ng

H1=Enthalpy of super heated steam

H2=Enthalpy of exhaust steam
na=efficiency of alternator
nm=efficiency of turbine (Mech.)
ng=efficiency of gearing

• Mechanical driven turbine:632/(H1-H2)x nm × ng

(Kg/Hphr)
1KWH=860Kcal
1HPH=632Kcal
Parameters on which [Link] consumption Depends :

1) Pressure and Temp. By increasing the inlet steam Pressure & [Link]
consumption Decreases

1) Load: Load on the turbine is higher side [Link] Decreases.

3) Ex. pressure & Temp.: Ex. pressure & [Link] [Link] consumption
decreases

4) No. of stages : no. of stages in the turbine increases [Link] consumption

decreases
 Station wise Power required Fully Elect. Driven
Plant
STATION RANGE AVERAGE POWER %
KW/TCH KW/TCH
Cane 3.5 to 9.5 6.5 23.21
Preparation
Cane Milling 5 to 7 6.0 21.43
Steam 3 to 5 4.0 14.29
Generation
Cond.& Cooling 2 to 5 2.5 8.92
C/F Machine 2.5 to 3.5 3.0 10.72

Other Power for 5 to 7 6.0 21.43

Pumps & etc.
Total 24 to 32 28 100%