ENHANCEMENT METHOD’S ON BOILER EFFICIENCY

Dewa Gede Sidan Magna Dinata1i, Guna Tiasa Priyangga1, Muhammad Ekti Ainanhar
Priaadzani 1, Nanda Aulia Ramadhandi Yogaswara1, Fabian Ardiansyah Ramadhan1
1
Department of Marine Engineering, Sepuluh Nopember Institute of Technology, Sukolilo 60111, Indonesia

Abstract. Since being first discovered by Thomas Savery in 1698, the boiler has undergone significant
developments. Boilers are required to develop and must work as efficiently as possible to help human
work. Factors that affect the efficiency of a boiler include mass flow, temperature and pressure of
steam entering the boiler, and temperature and pressure of steam coming out of the boiler.The main
components of this boiler will affect the efficiency of the boiler. In general, the first main part is the
main equipment consisting of Furnace (combustion chamber), Main steam drum, Super heater,
Reheater, Risers (evaporator pipe), Economizer, Burner. While auxiliary equipment consists of Force
draft fan, Induced draft fan, valves, control, and instruments. The third part is the balance of the boiler
which consists of a Deaerator, Feed water heater and blowdown system. By using several methods and
modeling in boiler work, such as the solar thermal energy method, the WHUS method, the basic
operating circuit method, the gaussian method,Fuzzy Arithmetical Modeling Method,Variable-
Frequency Drive Method and the CFD modeling method, it is hoped that the boiler can work efficiently
and be able to increase thermal efficiency by adjusted to the needs of the desired analysis.
Keywords: Boiler; Energy efficiency; Modelling; Power plant

1. Introduction
The industry is currently making rapid progress, these developments will create intense
competition among companies, so it is necessary to review the performance of the machine in
order to avoid energy waste. One of the industrial machines whose role is very important is
the boiler. The factors that affect the boiler efficiency value include mass flow, pressure and
temperature of the steam entering the boiler, as well as the pressure and temperature of the
steam coming out of the boiler. A boiler is a closed vessel where the heat of combustion is
channeled into the water until hot water or steam is formed. The important components in a
boiler are the burner, combustion chamber, heat exchanger and control system. The boiler
functions to convert heat energy from fuel to heat energy in steam, consisting of three main
parts, namely an economizer to heat water to the phase transfer point, an evaporator to
change the phase of water to steam and a superheater to further heat the steam to a certain
temperature. The first heat transfer is sub-cold transfer where the received heat is used to
raise the temperature until it reaches the saturated liquid temperature. The second process is
boiling with forced convection, where the boiling process of the working fluid gradually
becomes steam and finally saturated steam. In the boiler the combustion process occurs, the
basic principle of combustion is the fire triangle, where the fire triangle occurs when there are
three components, namely fuel, combustion air and heat. To produce complete combustion, a
proportional amount of fuel and air is needed, if the amount of air supplied is insufficient,
perfect combustion will not be achieved. The function of the combustion air together with the
fuel carries out the combustion process in the boiler combustion chamber (furnace). The
combustion process takes place continuously as long as the boiler operates, the combustion
air supply must also be carried out continuously. In general, the first main part is the main
equipment consisting of Furnace (combustion chamber), Main steam drum, Super heater,
Reheater, Risers (evaporator pipe), Economizer, Burner. While auxiliary equipment consists
of Force draft fan, Induce draft fan, valves, control, and instruments. The third part is the
 balance of the boiler which consists of a Deaerator, Feed water heater and blowdown system.
The main components of this boiler will affect the efficiency of the boiler.

2. Methods
Provide sufficient detail methods to allow the work to be reproduced. Methods already
published should be indicated by a reference: only relevant modifications should be
described.
Methodology text -methodology text -methodology text -methodology text -methodology
text -methoology text -methodology text -methodology text -methodology text -Methodology
text -methodology text -methodology text - methodology text - methodology text (Aparna et
al., 2016).

2.1. Solar Thermal Energy Method

Coal is currently the main source of electrical energy but coal has side effects such as NOx
and CO2 pollutants which are bad for the environment. Instead, many industries have started
to look at the potential for solar energy, but the electricity generated is often unstable and has
low intensity and investment is high enough so that solar energy is rarely used in commercial
operations. so that its application is more to help coal power plants with the help of solar
energy or what can be called the solar-aided power generation system (SAPG).
In boiler equipment there is usually an SCR de-NOx device found on air preheater and the
economizer. It can be seen that the temperature on the SCR de-NOx always drops below the
optimal temperature when under low and moderate load conditions. Therefore, SAPG can be
used to heat the water temperature in SCR de-NOx to keep it stable, namely by combining the
SAPG system with the SCR-deNox system so that it can increase the de-NOx process
temperature and increase the de-NOx efficiency. It can be seen in the figure below the
relationship between efficiency and temperature of the SCR de-Nox (Yuhan,ChengXu, 2017).

Figure 2.1. SCR de-NOx efficiency variation with the temperature (Source : Yuhan, 2017).
To maintain the stability of the SCR de-NOx temperature at the highest efficiency, solar
energy (SAPG) is needed with different load variations such as low load, high load and medium
load so that a large coal saving effect can be obtained and can increase the output power of the
boiler. (Yuhan,ChengXu, 2017).
 Figure 2.2 SAPG low load (Source : Yuhan, 2017).

At low load SAP is used to heat the exhaust gas so that the temperature that enters the SCR
de-NOx can be optimized.

Figure 2.3 SAPG High Load (Source : Yuhan, 2017).

At high loads, SAPG is used to heat the feed water

Figure 2.4 SAPG medium Load (Source : Yuhan, 2017)

In medium load, SAPG is used to heat exhaust gas and feed water.
2.2. Waste Heat Utilization System Method
Most of the research is more inclined to the utilization of waste gas by changing the layout
of a boiler. even though you can use the air preheater which is divided into high and low
temperature preheaters. and an additional economizer at low temperatures so that it is
 planned to receive an additional 9 MW from the 1000 MW power plant (Shengwei
Huang,Chengzhou Li, 2017).

Figure 2.5 Schematic of the considered coal-fired power plant with a conventional heat recovery
system (source : Shengwei Huang, 2017).

Figure 2.6 Schematic of the thermal system of a power plant with the improved WHUS. (source :
Shengwei Huang, 2017).
2.3. Basic Operating Circuit Method
So that the optimization of thermal conditions is carried out by selecting the basic
operating circuit in the boiler system to obtain maximum efficiency. Applied to boilers with a
capacity of 3 MW in the first type circuit developed, namely the boiler circuit with the pump
close to the return pipe as shown in Figure 2.7.

Figure 2.7 Boiler Circuit type 1 (source : Pavel A. Artamonov,2017).

In the type 2 circuit the pump is installed behind the pipe as in Figure 2.8 to avoid circulating
coolant in the boiler.
 Figure 2.8 Boiler Circuit type 2 (source : Pavel A. Artamonov,2017).

And for type 3 it has different circuits from the two types because it is given a temperature
detector, frequency converter, and flow rate meter as shown in Figure 2.9. (Pavel A.
Artamonov,2017).

Figure 2.9 Boiler Circuit type 3 (source : Pavel A. Artamonov,2017).

2.4. Gaussian Method

The Application of coal terminated heater burning and uses GP to plan a procedure for
decreasing Unburned Carbon Content in Fly Ash (UCC-FA) which is the most significant pointer of
kettle ignition proficiency. With disposing of the confounded physical instruments, constructing
an information driven model as GP is a compelling route for the proposed issue. Right off the bat,
GP is utilized to show the connection between the UCC-FA and kettle ignition activity boundaries.
The hyperparameters of GP model are streamlined through Genetic Algorithm (GA). At that point,
filled in as the target of another GA structure, the anticipated UCC-FA from GP model is used in
looking through the ideal activity plan for the evaporator ignition. Not the same as many existing
investigates on the comparative objective, utilizes GP that can give out mistake bar for every
expectation on displaying the connection between UCC-FA and heater ignition activity boundaries.
GA is misused in both demonstrating step and UCC-FA decrease venture as the analyzer. The
outcomes show that the proposed approach is achievable.
Moreover, we don't upgrade the pounded coal feeder speed for the low UCC-FA on the
grounds that the supervisors of the kettle moderately like to enhance the most tuned boundaries.
In any case, surely, the dispersion of coal feeder speed has some impact on UCC-FA since it might
change the air/coal proportion and the equalization of the heaters. Instinctively, we may improve
result in the event that we likewise upgrade the pummeled coal feeder speed (Chunlin Wang,Yang
Liu,2017).
Figure 2.10 The System flow (Source : Chunlin Wang,2017).

2.5. CFD Modelling Method

CFD (Computational Fluid Dynamics) can be used to predict combustion in a boiler by
using the temperature and time of the particles being worked in the operating state. Basically,
there is Unburn Carbon (UC) which is grouped into 2, namely the characteristics of coal and
the design of the combustion system. It can be seen that the characteristic of coal is the effect
of particle size. So that research was carried out with CFD boilers with stoker fuel to see the
effect of particles on coal. So that you can get the optimization of the efficiency in this stoker
boiler technology. In this study, CFD modeling focuses on simulating the effect of coal
particles in combustion because coal molecule size has a more noteworthy impact on the
temperature conveyance and response heat attributes looked at to the HHV (high heating
value) (Moch Agus Choiron, 2018).

Figure 2.11 Stoker Boiler (Source : Moch Agus Choiron, 2018)

2.6. Fuzzy Arithmetical Modeling Method

The method was used at the three stages of the steam turbine . Graph was used in to
model the boiler system . The boiler system consists of subsystems such as furnace ,
superheater , drum , riser and reheater . Give adequate detail strategies to permit the work to
be duplicated. Techniques previously distributed ought to be demonstrated by a reference:
just important adjustments ought to be portrayed.. Using certain parameters on FAMOUS
applicaton ar software (Wan Munirah Wan Mohamada, Tahir Ahmada, Niki Anis Ab Karima,
Azmirul Ashaaria, 2018).
Figure 2.12 Structure of the software FAMOUS (Source : Wan Munirah Wan Mohamada, Tahir
Ahmada, Niki Anis Ab Karima, Azmirul Ashaaria, 2018).

2.7. Variable-Frequency Drive Method

The investigation of the working methods of the warming heater plant was completed
based on two administrative conditions. The principal condition gives the temperature 𝜏ℎ1𝑠
of the coolant released from the source at a given relative stream rate 𝐺̅ℎ1𝑠. This temperature
gives the planned inside temperature 𝑡𝑖𝑑 for the current outside temperature 𝑡𝑒 (Andrey
Pyati, Aleksander Shempelev, and Ekaterina Popova,2018).

Figure 2.13 The design scheme of the boiler plant and pressure plots for the basic mode ( Source :
Andrey Pyati, Aleksander Shempelev, and Ekaterina Popova,2018)
3. Results and Discussion
3.1. Results of Solar Thermal Energy Method in Boiler
The heat transfer area of all heat exchangers isn't huge, which is reasonable an feasible in
engineering.

Figure 3.1 The design Thermal parameters of the primary heat exchangers in the proposed
SAPG. (Source : Yuhan, 2017).

The following conclusions can be drawn: (1) The solar input of all loads is the same (24.5
MWth); (2) For high loads, solar energy enters the regeneration cycle by heating the
feedwater, Steam turbine deflation can save 24.5 MWh of heat; (3) For low load, solar energy
Increase the combustion air temperature, resulting in an immediate energy input of 24.5
MWth Adding boilers may produce more live steam; (4) For medium load, solar energy is 17.0
MWh Energy enters the boiler by increasing the temperature of the combustion air, and 7.5
MWh of it enters Regeneration cycle by heating feed water.

3.2 Results of Waste Heat Utilization System Method in Boiler

In this research, by using WHUS's thermodynamics and technical and economic concepts,
it was found that the utilization of low-temperature exhaust gas was based on the utilization
of energy cascades, and found that:

1. In the conventional WHUS, the heat of the generator is only reduced by 42.56 kj/kwh.
2. In terms of improving WHUS, low-temperature heat from the kettle island and turbine
island is used to preheat the air. In this way, the bay air temperature of the air
preheater will expand. In addition, the tour return exhaust pipe can be combined with
the spare high-temperature pipe gas (cooling from 372 to 131°C) to heat the feed water
and the combined water. Obtained 19.51 MW increase and 143.35 kj/kwh decreased
thermal efficiency.

3.3 Results of Basic Operating Circuit Method in Boiler

 Algorithms that allow the development of boiler loop control in power plants Scaling the
coolant flow rate and user thermal load to the specified value 25℃ temperature difference С
on the delivery and return pipeline. energy Calorie expenditure is calculated based on the
average monthly calorie expenditure value . The annual energy consumption of the third
category is 21264 kWh.

Figure 3.2 Annual consumed heat and electric energy (Source : Shengwei Huang, 2017).
To calculate the investment cost Only consider the component and material costs of the
boiler loop manifold. other The capital cost items (wiring costs, transportation costs,
purchasing and storage costs, etc.) are It is equal for all types and can be ignored. The
operating cost of the third type will exceed The combined profit obtained within three years
using the second type becomes The most profitable of all the boiler circuit operation types
studied.

3.4 Results of Gaussian Method in Boiler

Figure 3.3 Energy consumption (Source : Chunlin Wang,2017).

The above facts show that the energy production process is accompanied by high
specifications Low energy consumption and low energy efficiency. Not only need to start again
In some cases, it has production capacity and can rebuild factories and facilities. in order to To
improve energy efficiency, it is necessary to invest to generate income and In the long run,
energy can be saved. After restoration of production capacity and necessary reconstruction
Plants and facilities, investment in improving energy efficiency is critical.
The estimated total installed heat capacity is approximately 5,730 MW. The analysis
determined that the total heat capacity installed in permanent and seasonal operation was
3,140 MW. It can be considered that the ability to participate is very low, but it may be the
reality is that the trend of professional dynamics is increasing, and the number of
implementations is increasing recent energy saving projects.

3.5 CFD Modelling Method in Boiler

 In this study, CFD analysis for stoker terminated heater on the impact of molecule size
and properties of coal is researched. Investigation of fine coal aggregation in a CBFB by
exploratory methodology signifies that an appropriate expansion of fine coal particles (in size
of 0.45–0.9 mm) in the medium can diminish the bed thickness adequately. Impact of two
kinds of coal with various attributes was looked at on the level of fouling in a high temp water
stoker-terminated kettle after it has been terminated for an all-encompassing timeframe.
In the past investigation of CFD examination for stoker terminated kettle more reasonable
benchmark coal ignition was created with the warmth exchanger models . In the investigation
of mathematical demonstrating methods, it gives more figuring time and computationally
costly. Thus, CFD demonstrating with representations and speedy expectations become a
significant work to assess distinctive fuel choices and its trademark.

Figure 3.4 Maximum temperature graphic (Source : Moch Agus Choiron, 2018)

The maximum temperature of the first to fourth models is 1440.95, 1473.85, 1347.72 and
1617.17 [K]. The heat of reaction distribution is given by Complete combustion with a
stoichiometric mixture. of Model No. 4 shows the heating zone in the upper left of the interior
Allow heat load in The location of the boiler.

3.6. Fuzzy Arihmetical Method’s

Using the FAMOUS, the input parameters of the steam turbine system (HP, IP and LP) are
expressed by the parameters of the fuzzy model p1 (inlet pair that from the overheating
section of the boiler), p2 (steam inlet pressure), p3 (steam inlet that temperature), p4 (steam
inlet ow enthalpy) and p5 (steam inlet flow density). Membership functions are derived from
quasi-Gaussian distributions as illustrated in figures 2 {4.
Figure 3.5 Fuzzy input parameters of high-pressure section of a steam turbine system (a) p1 (Inlet
steam ow from boiler superheat section), (b) p2 (Inlet steam pressure), (c) p3 (Inlet steam ow
temperature), (d) p4(Inlet steam ow enthalpy) and (e) p5(Inlet steam ow density). (Source : Wan
Munirah Wan Mohamada, Tahir Ahmada, Niki Anis Ab Karima, Azmirul Ashaaria, 2018 )
Figure 3.6 Relative in uence measure i for output Pou in (a) high pressure, (b)intermediate pressure
and (c) low pressure section of a steam turbine system.

3.7. Variable-Frequency Drive with Different Methods of Heat Supply Regulation

The calculation data table presents the annual performance characteristics of the boiler
and district heating network in all considered modes of regulation of heat supply and the use
of VFD. From the correlation with the fundamental mode (STC) we can make the
accompanying determinations: The use of a VFD on the standard temperature control graph
(STC + VFD) eliminates the pressure and energy losses on the flow controller in the network
RN, on the recirculation controller RTr, on the pressure controller RP and reduces the energy
losses on the temperature controller RT by almost 3 times, which is explained by a reduction
pressure in the supply pipe of the boiler room [22,23]. The thermal power of the boiler room
does not change and the electricity consumption is halved.

Figure 3.7 Duration of the 1 °С intervals of the outdoor air. (Source : Andrey Pyati, Aleksander
Shempelev, and Ekaterina Popova,2018)
4. Conclusions
The modeling of the boiler is important in increasing the efficiency of the boiler
itself. At this time, the methods carried out, namely the solar thermal energy method, the
WHUS method, the basic operating circuit method, the anti-fouling ceramic coating
method, the gaussian method, and the CFD modeling method can reduce energy savings,
especially fuel consumption and can increase the efficiency of thermal performance from
the boiler. The method or model studied provides a new concept of the importance of the
efficiency of the boiler, but it must also be based on a detailed analysis so that accurate and
significant method data can be obtained as a basis for decision making.

Acknowledgements
In preparation of our paper, we had to take the help and guidance of some respected
persons, who deserve my deepest gratitude. As the completion of this paper gave me much
pleasure, I would like to show my gratitude Prof. Semin, S.T., M.T., Ph.D., Course Instructor, on
Department of Marine Engineering,FTK,ITS for giving me a good guidelines for paper
throughout the paper guideline. We would also like to expand our gratitude to all those who
have directly and indirectly guided me in writing this assignment.

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