International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 12, December 2014)

Energy Performance Assessment of Boiler at P.S.S.K. Ltd,

Basmathnagar, Maharashtra State
Sachin M.Raut1, Sanjay B. Kumbhare2, Krishna C. Thakur3
1
M.Tech in Thermal Engineering 4th sem, Patel College of Science and Technology, Bhopal, M.P., India
2,3
Assistant Professor, Dept. of Mechanical Engineering, Patel College of Science and Technology, Bhopal, M.P., India
Abstract— Energy Performance Assessment of Boiler is a Boiler is a closed pressure vessel in to which water can
vital concept in any sugar mill. Because, the heart of sugar be fed and by applying heat continuously, evaporated in to
mill is Boiler and to maximize efficiency and profit of sugar steam. The function of the boiler is to generate steam at the
mill, there is need to increase efficiency of Boiler. The Boiler desired conditions efficiently and with low operating costs.
efficiency can be evaluated by direct and Indirect method. In
Low pressure steam is used in process an application
direct method the energy gain by working fluid is compared
with energy content of fuel, while in case Indirect method whereas high pressure superheated steam is used for
various losses compared to the energy input. Present Research generating power via steam turbines. Boilers consist of a
paper deals with Energy Performance Assessment of co- number of tubes for maximum heat transfer. These tubes
operative sugar mill’s Existing boiler, with maximum runs between steam distribution drum at the top of the
continuous rating (MCR)-100 TPH and outlet steam boiler and water collecting drums at the bottom of the
parameter -110kg/cm2 and540°c and Bagasse used as a fuel at boiler. Steam flows from the steam drum to the super
Purna Sahakari Sakhar Karkhana (P.S.S.K.) Ltd, Basmath heater before entering the steam distribution system.
Nagar, District- Hingoli ,Maharashtra -431512.This research
work was conducted as per yearly procedure followed by the
Supplier of Boiler, Walchandnagar Industries Ltd, Pune for
II. METHODS TO CALCULATE THE BOILER EFFICIENCY
Energy Performance Assessment of Boiler through the Sugar industry is known as one of the major non
Indirect Method i.e. Heat Loss Method ASME PTC 4.1.So, conventional energy source industry in india.Because it
Boiler Efficiency, Evaporation Ratio and different Heat uses renewable sugar cane crop as the raw material, which
Losses analyzed by data collected from Daily Boiler Log Book gives output as a bagasse with sufficient calorific value.
within the last previous three year season’s 2011-12, 2012-13
Sugar industry mills attached with co-generation plant,
and 2013-14. From considering overall analysis and Research
Methodology, Heat losses due to hydrogen in fuel and due to both are in co-operative and private sector having great
moisture in fuel were found to be the major problems to importance in Indian economy. It gives revenues to
decrease the Performance of Boiler. Finally to overcome these government, is in the form of generation of power around 9
problems following suggestions was recommended (1) major states with 3600 MW by using bagasse as the
Installation of Dryer (2) Use of Solid Combustion Catalyst (3) renewable energy source.
Exchange Air Cooled Condenser with Water Cooled In any Sugar industry mills, there are lot of components
Condenser. are included. But out of that, Boiler is important than any
other. Any sugar industry mill heart component is Boiler
Keywords—Sugar Mill, Bagasse, Boiler, Boiler Efficiency,
Evaporation Ratio, Comparison Of Different Losses.
and to maximize beneficiary output from sugar mill, there
is need to maintain efficiency of Boiler with the design
I. INTRODUCTION efficiency. So, boiler efficiency test is necessary for find
out variation of boiler efficiency related to its MCR values.
Energy is an indispensable instrument in the progress of Hence it is necessary to find out the current level of
human race. Today’s high standard living has been possible efficiency for performance evaluation, which is mandatory
only through the judicious use of various energy resources for energy conservation action in industry.
at command. Realizing the fact that energy is the sinew of
economic growth, energy management and energy A. Boiler Efficiency
conservation are of paramount importance. The above Boiler efficiency is a relationship between energy
along with energy efficiency improvement are the only supplied to the boiler and energy output received from the
cost-effective and viable means of ensuring the proper use boiler. It is expressed in percentage.
of finite natural resources, minimizing operating expenses,
and increasing the profitability of enterprises. Boiler is one
of the important component in energy generation process
i.e. steam generation plant.
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Boiler efficiency classified into three major types The minor heat losses occurring in the boiler are:
1. Combustion efficiency: It gives an idea about the fuel L6- Loss due to moisture in air (H2O)
burning capability of a burner. It is the relationship L7- Loss due to incomplete combustion
between Quantity of fuel unburnt in the boiler with surplus In the above, loss due to moisture in fuel and the loss
exhaust air due to combustion of hydrogen are dependent on the fuel,
2. Thermal efficiency: It is related with to assess the and cannot be controlled by design
performance of heat exchangers units used in boilers. Boiler Efficiency by Heat loss method or Indirect
Thermal efficiency is not considered valuable for method =100 – (L1+L2+L3+L4+L5+L6+L7)
economics analysis since it does not take into account the The data required for calculation of boiler efficiency
radiation and convection losses occurring in the boiler using indirect method are:
sections.  GCV of fuel in kcal/kg.
3. fuel-to-steam efficiency: is helpful to determine the  Percentage of Oxygen in the flue gas.
overall efficiency of a boiler. Since, it takes into  Flue gas temperature in 0C (Tf).
consideration the heat exchanger effectiveness, radiation  Ambient temperature in 0C (Ta) and humidity of
and convections losses. air in kg/kg of dry air.
Most standards for calculation of boiler efficiency,  Water temperature at different levels.
including IS 8753, ASME Standard: PTC-4.1 Power Test  Ultimate analysis of fuel.
Code and BS 845 are designed for measurement of boiler  GCV of ash in kcal/kg.
efficiency. Unfortunately, all these standards do not include
blow down as a loss in the efficiency calculation. III. FORMULAE FOR COMPUTING VARIOUS LOSSES
The two major Methods employed to find out the fuel-
In order to calculate the boiler efficiency by indirect
to-steam efficiency of a boiler are explained below
method, all the losses that occur in the boiler must be
a. Input –output method or direct method: this method of established. These losses are conveniently related to the
efficiency is also known as direct method. For calculation amount of fuel burnt. In this way it is easy to compare the
of efficiency, it needs only the useful output (steam) and performance of various boilers with different ratings.
the heat input (i.e. fuel).
A. Theoretical air required for combustion
Boiler Efficiency =
[From flue gas analysis]
Where C, H2, O2 and S are the percentage of carbon,
Boiler Efficiency = hydrogen, oxygen and sulphur present in the fuel.
B. % Excess air supplied (EA)
[From flue gas analysis]
b. heat loss method or indirect method:it is also known as Normally, O2 measurements is recommended
heat balance efficiency measurements method. This method
of efficiency determination takes into account all kinds of C. Actual mass of air supplied /kg of fuel (AAS)
heat losses occurred inside the boiler. In this method the
boiler efficiency is calculated by summation of percentage
of all losses and deducts this resultant sum of losses from D. Percentage of heat loss due to dry flue gas (L1)
100 percent.
The major heat losses occurring in the boiler are:
Where,
L1- Loss due to dry flue gas.
L2- Loss due to hydrogen in fuel (H2) m = Mass of dry flue gas in kg/kg of fuel
L3- Loss due to moisture in fuel (H2O) = Combustion products from fuel: CO2 +SO2 +
L4- Loss due to surface radiation and convection. Nitrogen in fuel + Nitrogen in the actual mass of
L5- Loss due to unburnt carbon is ash. air supplied + O2 in flue gas.

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 International Journal of Emerging Technology and Advanced Engineering
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Cp = Specific heat of flue gas (0.23 kCal/kg oC) 1. Heat loss due to unburnt in fly ash
Tf = Flue gas temperature in oC
Ta = Ambient temperature in oC
E. Percentage of heat loss due to evaporation of water 2. Heat loss due to unburnt in bottom ash
formed due to H2 in fuel (L2)
Oxygen in air combines with hydrogen present in fuel to
form water and gets evaporated. Thus heat loss due to
evaporation of water. I. Heat loss due to moisture present in air (L6)
Vapour in the form of humidity in the incoming air, is
superheated as it passes through the boiler. Since this heat
Where, passes up the stack, it must be included as a boiler loss.
Cp =Specific heat of superheated steam (0.47kCal/kg oC)
H2 = kg of hydrogen present in fuel on 1 kg basis
584 = Latent heat corresponding to partial pressure of
Where,
water vapour.
Cp = Specific heat of superheated steam (0.47kCal/kg oC)
F. Percentage of heat loss due to moisture present in fuel AAS = Actual mass of air supplied per kg of fuel
(L3)
Humidity factor = kg of water/kg of dry air
Due to Moisture entering the boiler with the fuel this
heat loss occur. H. Heat loss due to incomplete combustion (L7)
Products formed by incomplete combustion could be
mixed with oxygen and burned again with a further release
of energy.
Where,
Cp = Specific heat of superheated steam (0.47kCal/kg oC)
Where,
M = kg of moisture in fuel in 1 kg basis
L5 = % Heat loss due to partial conversion of C to CO
G. Percentage of heat loss due to radiation and convection CO = Volume of CO in flue gas leaving economizer (%)
(L4)
CO2 = Actual Volume of CO2 in flue gas (%)
Normally surface loss and other unaccounted losses is C = Carbon content kg / kg of fuel
assumed based on the type and size of the boiler as given
below Having established the magnitude of all the losses
For industrial fire tube / packaged boiler = 1.5 to 2.5% mentioned above, a simple heat balance would give the
For industrial water tube boiler = 2 to 3% efficiency of the boiler. The efficiency is the difference
For power station boiler = 0.4 to 1% between the energy input to the boiler and the heat losses
calculated.
H. Heat loss due to unburnt carbon in ash (L5)
The calculation of the heat loss due to unurned carbon is IV. METHODOLOGY OF THE STUDY
based on the carobn content in boiler ash.assuming that the
boiler ash consists of the ash in fuel plus the unburned A. Study Site
carbenGenerally in solid fuel heat loss due to unburnt fly This study was carried out in Purna Sahakari Sakhar
ash and heat loss due to unburnt in bottom ash are Karkhana Ltd, Basmath Nagar, District-Hingoli, Pin Code-
considered. 431512 (Maharashtra state) as in a part of research.
M/S, Purna S.S.Karkhana Ltd (PSSKL) is one of the
pioneering co-operative sugar factory At Basmath Nagar,
Dist- Hingoli in marathwada region, (Maharashtra state)
Note: Generally, there are two different Heat losses by ash registered in year 1970 under the Maharashtra co-operative
considered societies act,1960.

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The karkhana has original licenses from Ministry Of 5 Bagasse For Steam 95.6 TPH
Industrial Development dated 22 nd Jan 1973. Generation
6 Post Generation Of 32.5 %
1. Specification of boiler: The design of boiler is single
Bagasse
drum, natural circulation, and radiant furnace with water 7 1 %
cooled membrane walls, three stage superheater with inter Handling Loss
stage de-superheater and balanced draft. Boilers have all 8 Bagasse Available 31.5 %
accessories with economiser and air preheater. For Boiler
9 Bagasse On Cane 28.63 %
 Multi fuel fired boiler with maximum continuous
rating (MCR) -100 TPH. 10 Moisture 50.00 %
 Outlet steam parameter (working pressure):- 11 Pol 2.00 %
110kg/cm2 and540°c.
12 1.30 %
 The tolerance on superheater of outlet temperature Ash Content
(+/-) 5 °c. 13 Computed GCV At 2276 %
 The combustion system of boiler with travelling grate 50% Moisture
with spreader stoker. 500 days Boiler’s different performance parameters
 The boiler efficiency for bagasse is 100 % and coal is readings are studied for various observation and different
70 % on the basis of GCV. heat losses for research about the boiler performance from
 The dust concentration in the flue gases leaving the last 3 years.
boiler-max.150 Mg/Nm3 Following areas were covered during the test for
 Travel grate with continuous ash discharge and an measurements for different parameters considered as
overfeed stoker, with hydraulic drive. follows
 Fuel is burnt suspended in air above the grate and on
the travelling grate ash generated in boiler is B. Study Data
continuously discharge. This study work was focused on the improvements in
 Air seal provided in order to control the excess air boiler efficiency resulting from reduction in various heat
entry into the furnace. losses. By considering data referred by “Walchandnagar
 Boiler shall be capable of peak generation of 110 % Industries Ltd” Pune was conducted for boiler efficiency
of the MCR generation for a period of one hour in a measurements on 14 th to 16 th March 2014.
shift “Walchandnagar Industries Ltd” Pune was used Indirect
TABLE I method ASME PTC 4.1(2005) for the calculation So by
STUDY SITE FEATURES taking a reference of this Indirect method ASME PTC
4.1(2005) method and analysis of various parameter of
Sr. Particulars Value Unit boiler, related to different heat losses this research has been
No. conducted.
A General Details 1. Water / Steam parameters:
1 Area 8000 Hectors  Temperature and Pressure measurements of water at
2 Installed Cane 2500 TCD Economizer inlet and that of steam at boiler outlet.
Crushing Capacity  Steam flow rates(steam pressure, steam generation
3 Installed Co-Gen. 18.9 MW per hour)
Capacity  DM water quality
B Fuel (Bagasse) Details  Feed water analysis
1 Fuel Used In Boiler Wet Mill Bagasse  Fuel consumption rate per hour, humidity factor etc.
2 Cane Availability 5.6 Lakh Tons 2. Fuel:
Kg/Kg Of  Collection of Fuel samples.
3 Bagasse To Steam 2.6
Ratio Bagasse  Ultimate analysis of the Fuel (H2, O2, S, C, moisture
content, ash content)
4 Bagasse Used By 36 TPH
Boiler

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3. Flue gas/Ash analysis: 6. Format’s used for data collection:
 Collection of Ash samples for un burnt analysis.  Daily 3 shift wise “BOILER LOG SHEET” formats
 Online readings for Flue gas analysis. of previous three years i.e., from boiler have been
 Percentage of Oxygen or CO2 in the flue gas. installed.
 Flue gas temperature in 0C (Tf)  Daily “BOILER WATER ANALYSIS REPORT” of
previous three years i.e., from boiler has been
4. Surface Conditions: installed.
 Measurements of Surface Temperatures.  “ENERGY AUDIT REPORT” of co-gen plant
submitted by “Enrich Consultant’s”, Pune as per
5. Other data: directives of Maharashtra Electricity Regulations
 GCV of fuel in kcal/kg. Commission (MERC).
 Percentage combustible in ash (in case of solid  “EFFICIENCY CALCULATION REPORT” given
fuels). by supplier of Boiler “Walchandnagar Industries Ltd,
 GCV of ash in kcal/kg (in case of solid fuels). Pune. Where boiler efficiency was calculated by
 Ambient temperature in 0C (Ta) and humidity of air Indirect method ASME PTC 4.1(2005) was used for
in kg/kg of dry air. the calculation and losses were identified.
 Weather any heat recovery devices are attach or not,
if attach, than its data.

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TABLE II
DAILY THREE SHIFT WISE DISTRIBUTION CONTROL ROOM BOILER LOG SHEET

V. OBSERVATION AND SIMULATION A. Fuel Analysis Of Bagasse

 By considering data referred by “Walchandnagar In the following table, we present the details ultimate
Industries Ltd” Pune was conducted boiler efficiency analysis of bagasse shown, which were used as the fuel.
measurements on 14th to 16 th March
2014.Walchandnagar Industries Ltd was used Indirect
method ASME PTC 4.1(2005) for the calculation and
losses were identified.

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TABLE III b. Heat input data
FUEL ANALYSIS OF BAGASSE
Quantity of Bagasse consumed (Input): 38.5 TPH
GCV of Bagasse (GCV)
= 4600 x (1– w) – (1200 x s)
Where,
w = moisture in bagasse
s = bagasse pol in %
GCV = 4600 x (1– w) – (1200 x s)
= 2276 kcal/kg
Therefore, Boiler efficiency ( 

Where,
Q = Quantity of steam generated per hour (kg/hr)
B. Boiler data Analysis
q = Quantity of fuel used per hour (kg/hr)
In the following table, we present the Boiler data
GCV = Gross calorific value of the fuel (kCal/kg)
Analysis of boiler where bagasse, is used as the fuel.
hg = Enthalpy of steam (kCal/kg)
TABLE IV
BOILER DATA ANALYSIS
hf = Enthalpy of feed water (kCal/kg)
Boiler efficiency
= 104.5 TPH x (829.88 kCal/kg – 178.62 kCal/kg) x 100
38.5 TPH x 2276 kCal/kg
= 77.66 %
Evaporation Ratio
= 104.5 Tonne of steam / 38.5 Tonne of bagasse.
= 2.71
2. Indirect Method:
Step -1. Find Theoretical Air Requirement
a. Theoretical air required for combustion
= [(11.6 x C) + {34.8 x (H2 – O2 / 8)} + (4.35 x S)]
C. Boiler Efficiency /100 kg/kg of fuel.
= [(11.6 x 23.17) + {34.8 x (4.10 – 21.33 /8)} + (4.35 x
1. Direct Method:
0)] /100
a. Heat output data = 3.185 kg/kg of bagasse.
Quantity of steam generated (output): 104.5 TPH
Step -2. To Find Excess Air Supplied On The Basis Of %
Steam Pressure: 110 kg/cm2(g)
O2
Steam Temperature: 540 0C
Enthalpy of steam at 110 kg/cm2 (g) pressure: b. % Excess air supplied (EA)
829.88 kCal/kg (Calculated by Molier Chart) = O2% x 100 / (21- O2%). [From flue gas analysis]
Feed water Temperature: 1750 C
= 4.90 x 100 / (21- 4.90)
Enthalpy of Feed Water: 178.62 kCal/kg (calculated by
Molier chart) = 30.43 %
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Step – 3. To Find Actual air Supplied (AAS) NOTE: Here L6 and L7 Heat losses are neglected. So,
values of that were not considered in boiler efficiency.
c. Actual mass of air supplied /kg of fuel (AAS)
Boiler efficiency by indirect method
= {1+ EA / 100} x theoretical air
= 100 – (L1+ L2+ L3+ L4+ L5)
= {1+ 30.43 / 100} x 3.23
= 100 – (4.42 + 10.198+ 13.818+ 1.00+ 0.46)
= 4.213 kg/kg of bagasse = 100 – 29.896
Step – 4. To find out the actual mass of dry flue gas (m) = 70.104 %
d. To find out the actual mass of dry flue gas (m) Computation of steam to fuel ratio (evaporation ratio)
= Mass of CO2 + Mass of N2 content in the fuel + Mass = [(GCV of bagasse x Boiler efficiency) / (H steam – Hfeed
of N2 in the combustion air supplied + Mass of oxygen water)]
in flue gas = [(2276 x 0.701) / (829.88 – 178.62)]
= (C x 44/12) + [(N2 / 100) + (Actual mass of air x 77 / = 2.45 kg of steam / kg of bagasse.
100)] + [(Actual mass of air – Theoretical air) x 23 /
From above simulation, heat balance sheet formed.
100] Data analysis can be done as per given below:
= (0.2317 x 44/12) + [(0.1 / 100) + (4.213 x 77 / 100)] +
 Analysis of three season’s (2011-12, 2012-13, 2013-
[(4.213 – 3.187) x 23 / 100]
14) considered.
= 4.285 kg/kg of bagasse.  Analyse 500 days different parameters readings are
Step – 5. To Find All Losses studied for the research about the boiler performance,
from last 3 years performance of boiler
1. Percentage Heat loss due to dry flue gas (L1)  Analyse season wise (three years season’s) weekly
= [m x C p x (T f – Ta) / GCV of fuel] x 100 parameter readings, on the basis of random sampling.
Here research instrument used-Microsoft excel sheet.
= [4.285 x 0 .24 x (140 – 40)] / 2276] x 100
= 4.42 % TABLE V
BOILER HEAT BALANCE SHEET
2. Percentage Heat loss due to evaporation of water formed
due to H2 in fuel (L2)
= {9 x H2 x [584+ Cp (Tf –Ta)] / GCV of fuel} x 100
= {9 x 0.041 x [584+0.45 (140 – 40)] / 2276} x 100
= 10.198 %
3. Heat loss due to moisture present in fuel (L3)
= {M x [584 + CP (Tf –Ta)] / GCV of fuel} x 100
= {0.50 x [584 + 0.45(140 – 40)] / 2276} x 100
= 13.818 %
4. Heat loss due to radiation (L4)
= 1.00 % (Here Radiation loss is always taken as a
constant value)
5. Heat loss due to unburned carbon in ash (L5)
= {[Quantity of ash in fuel x GCV of ash] / GCV of
fuel} x 100
= {[0.013 x 800] / 2276} x 100
= 0.46 %

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 For three years season’s 72 weeks parameters  From that 9 average values, data interpretation graphs
readings are considered. has been drawn.
 For every season 24 weeks parameters readings are
And, from that graphs –
considered.
 On each micro soft excel sheet simultaneously season  Reasons for decreasing the efficiency of boiler
wise 8 weeks data calculated and average values calculated.
calculated for 8 weeks.  Values of different heat losses (L1,L2,L3,L4,L5) and its
 In this way, for 72 weeks, averages of 9 values are effect on efficiency of boiler
calculated.  Remedies have been calculated.
TABLE VI
THREE YEAR’S AVERAGE PARAMETERS PERFORMANCE SHEET

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VI. DATA INTERPETATION AND RESULTS  Heat loss due to moisture in fuel (%) having highest
values.
A. Figure 1 Shows
 Heat loss due to hydrogen in fuel (%) having average
 When evaporation ratio value having range between value in between 10-11 %.
2.6-2.10, efficiency is above 69.50 %.
 But when evaporation ratio value increases above
given range, efficiency (%) decreases.
 So for increase in efficiency evaporation ratio should
be maintained i.e. factors –quantity of mass consumed
quantity of steam generated.

Fig. 3 Comparisons Of Different Heat Losses In Boiler

D. Figure 4 Shows
 It is seen that, quantity of steam generated (TPH) and
mass of fuel consumed (TPH) are both directly
proportional to each other.
Fig. 1 Evaporation Ratio With Efficiency In %

B. Figure 2 Shows
 It is seen that, efficiency (%) varies according to
values of O2 % in dry flue gas.
 Efficiency is directly proportional to O2 % in dry
flue gas.

Fig. 4 Quantity Of Steam Generated And Quantity Of Mass

Consumed

E. Figure 5 Shows
 It is seen that, Excess Air Supplied (%) and Actual
Air Supplied (Kg/kg) are both directly proportional to
each other.
Fig. 2 O2 In Flue Gas With Efficiency %
.
C. Figure 3 Shows
 It is seen that, heat loss due to moisture in fuel and
heat loss due to hydrogen in fuel having large values
as compare with other losses.

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Fig. 5 Actual Air Supplied And Excess Air Supplied Fig. 7 Heat Loss In Hydrogen In Fuel% (L2) And Efficiency %

F. Figure 6 Shows H. Figure 8 Shows

 It is seen that, within a specific range of values,  It is seen that, Efficiency (%) and Heat loss due to
Efficiency % and Heat loss in dry flue gas (%) are moisture in fuel (%) (L3) and are both directly
both inversely proportional to each other. proportional to each other.
 Efficiency is tends to decreases when values of Heat  But after a specific range Efficiency (%) is decreases
loss in dry flue gas (%) increases. when values of Heat loss due to moisture in fuel (%)
(L3) suddenly increases.

Fig. 6 Heat Loss In Dry Flue Gas % (L1) And Efficiency %

Fig. 8 Heat Loss Due To Moisture In Fuel% (L3) And Efficiency %
G. Figure 7 Shows
 It is seen that, Efficiency % and Heat loss due to VII. CONCLUSIONS
hydrogen in fuel (%) (L2) are both directly
proportional to each other. Conclusion derived from the data related to the boiler,
heat loss due to hydrogen in fuel and heat loss due to
 But after a specific range Efficiency (%) is decreases
Moisture content in the fuel will affect the efficiency.
when values of Heat loss due to hydrogen in fuel (%)
Here by using bagasse as a fuel average boiler efficiency
(L2) suddenly increases.
for last three years is 69.61%.

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1. Heater must be provided:- 3. Use of water cooled condenser instead of air cooled
From the overall analysis and results it is found that, condenser:-
Heat loss due to moisture due to hydrogen in the fuel (L 2) In sugar factory air cooled condenser for a cooling range
and Heat loss due to moisture in the fuel (L3). These both of 10 °C and an approach of 5 °C, while operating under
losses are more responsible for decreasing the boiler the atmospheric wet bulb temperature of about 27 °C is
performance. used. Instead of air cooled condenser use of water cooled
Part or all of a primary stream of bagasse from the sugar condenser for effectiveness increase in above properties of
mill is dried from its initial moisture content, e.g. in the condensate, so boiler efficiency is increased.
order of 50%, to a lower moisture content, e.g. in the order
of 35%, using a portion of the hot flue gases from the REFERENCES
boilers which are used to supply power for the sugar mill [1] “Energy Performance Assessment Of boiler “, Bureau Of Energy
Efficiency.PP.1-22.
operation.
[2] Boiler Efficiency calculation report by supplier of boiler Walchand
The resulting drier material is separated to (i) an Nagar industries Ltd, Pune for PSSK Ltd, Basmath Nagar as per
oversize particle stream (ii) a secondary stream of fine ASME PTC 4 (2005) method, March 2014.
particle size. An oversize particle stream which may be [3] Energy Audit Report of PSSK Ltd, Basmath Nagar for Boiler
sent directly to the boiler for burning or to storage in the Efficiency, Enrich consultants, Pune as per directives of Maharashtra
bagasse house. Due to this, boiler loss must be increased electricity regulation commission (MERC).
(presence of moisture as well as hydrogen in fuel). So, [4] Trushar Patel and Divyesh Patel "Energy Analysis and Efficiency
Assessment of Water Tube Boiler" IOSR Journal of Mechanical and
instead of this secondary stream, with optional addition of Civil Engineering IOSR-JMCE, (Volume 11, Issue 3 Ver. VI May-
oversize particles from the primary drying operation, is Jun. 2014).
then dried in contact with another portion of hot flue gases [5] Rajendra N. Todkar1,P.E.Chaudhari,U.M.Shirsat" Waste Heat
in the separate Heater to reduce moisture content. Recovery To Increase Boiler Efficiency Using Bagasse As Fuel"
So Heater must be provided before bagasse is feed to the international journal of mechanical engineering and technology
(IJMET),(Volume 5, Issue 2, Feb-2014).
boiler. By use of heater, the above losses must be
[6] Chetan T. Patel "Efficiency With Different Gcv Of Coal And
minimized by 70 %.
Efficiency Improvement Opportunity In Boiler" International
2. Use Of Solid combustion catalyst: Journal of Innovative Research in Science, Engineering and
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By use of solid combustion catalyst for example [7] S. Krishnanunni1, Josephkunju Paul C "Evaluation of Heat Losses in
THERMACT B increasing boiler efficiency, one can save Fire Tube Boiler", International Journal of Emerging Technology
fuel input to power plant and also earn carbon point and and Advanced Engineering, (Volume 2, Issue 12, December 2012).
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Engineering Research (Volume 3, Issue 7, July-2012)
primarily carbon the helps breaking the bond between the
[9] Amit Kumar Jain "An Approach towards Efficient Operation of
two hydrogen and oxygen molecule. The THERMACT-B Boilers", International Journal of Scientific and Engineering
then increases the reactivity between the carbon and the Research,(Volume 3, Issue 6, June-2012).
moisture in bagasse. THERMACT-B was added directly [10] Rahul Dev Gupta, Sudhir Ghai, Ajai Jain. “Energy Efficiency
into bagasse feeders with the help of Vibro-feeder Improvement Strategies for Industrial Boilers: A Case Study”.
assembly. The feed rate of THERMACT-B was controlled Journal of Engineering and Technology. Vol 1. Issue 1.Jan-June
2011
by the Vibro-feeder and regulator as per the bagasse
[11] V. K. Gaudani, Energy Efficiency in Thermal System. Vol. III.
consumption. 1kg of THERMACT-B is dosed for 20 tons IECC Press. Delhi 2009.
of bagasse.

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