Best Tips for Energy efficiency in thermal power plant
in this article we discussed about the Energy efficiency in thermal power plant , how to get energy efficiency from the steam system ?, and how to get energy efficiency through insulation , furnace & from waste heat recovery.
Energy efficiency through Furnaces
*Improve all the operation equipment like burner design, combustion control and instrumentation.
*During operation ensure that the furnace combustion chamber is under slight positive pressure
*Ceramic fibres must be used in the case of batch operations
*Use doors or air curtains against infiltration of air
*During the boiler operation Monitor O2 /CO2/CO and control excess air to the optimum level for better energy efficiency
*Retrofit with heat recovery device
*Investigate cycle times and reduce
*Provide temperature controllers like desuperheater
*Ensure that flame does not touch the stock during the operation
Energy efficiency through Steam System
-Preheat of boiler feed-water.
-Recover boiler blow down.
-Check operation of steam traps.
-Remove air from indirect steam using equipment
(0.25 mm thick air film offers the same resistance to heat transfer as a 330 mm thick copper wall)
-Inspect steam traps regularly and repair malfunctioning traps promptly.
-Consider recovery of vent steam (e.g. – on large flash tanks).
-Use waste steam for water heating.
-Use an absorption chiller to condense exhaust steam before returning the condensate to the boiler.
-Fix steam leaks and condensate leaks in pipelines from boiler and turbine side if any .
(it is considered that if a 3 mm diameter hole on a pipe line carrying 7 Kg/cm2 steam would waste 33 Kilo liters of fuel oil per year)
-if any work orders for repair of steam leaks that can’t be fixed during the heating season due to system shutdown requirements. Tag such type of leakage with a durable tag with a good description.
-Use back pressure steam turbines to produce lower steam pressures.
-Use more-efficient steam desuperheating methods during operation .
-Ensure process temperatures are correctly controlled by the operator .
-Maintain lowest acceptable process steam pressures.
-Reduce hot water wastage to drain.
-Remove or blank off all unused steam piping.
-Ensure condensate is returned or re-used in the process for better thermal efficiency .
(it is considered that if 6 degree Celsius raise in feed water temperature by economizer/condensate recovery corresponds to a 1% saving in fuel consumption, in boiler)
-Use electric pumps instead of steam ejectors when cost benefits permit
-Establish a steam efficiency-maintenance program.
-For getting the energy efficiency Start energy audit and follow-up, then make a steam efficiency-maintenance program a part of your continuous energy management program.
Energy efficiency through Insulation
*Repair damaged insulation.
(it is estimated that if a bare steam pipe of 150 mm diameter and 100 m length, carrying saturated steam at 8 kg/cm2 would waste 25’000 litres furnace oil in a year)
*any hot or cold metal or insulation.
*for getting the energy efficiency replace wet insulation if any found
*Use an infrared gun to check for cold wall areas temperature during cold weather or hot wall areas during hot weather.
*Ensure that all insulated surfaces are cladded with aluminum
*Insulate all flanges, valves and couplings
*Insulate open tanks like blow down trench, boiler steam drum , Deaerators tank etc.
(it is assumed that if 70% heat losses can be reduced by floating a layer of 45 mm diameter polypropylene (plastic) balls on the surface of 900C hot liquid/condensate)
Energy efficiency through Waste heat recovery
-Use chiller waste heat to preheat hot water.
-Use heat pumps for getting the better energy efficiency
-Use absorption refrigeration.
-Thermal wheels, run-around systems, heat pipe systems, and air-to-air exchangers is used in the waste heat recovery for getting the better energy efficiency
-for getting the energy efficiency recover heat from flue gas, engine cooling water, engine exhaust, low pressure waste steam, drying oven exhaust, boiler blow down, etc.
-Recover heat from incinerator off-gas.
-Use waste heat for fuel oil heating, boiler feedwater heating, outside air heating, etc.
Heii all power engineers myself joginder chauhan . i am the founder of my website www.askpowerplant.com. i am also a power engineer and having the more than 5 year experience in the field of power sectors during this time period i learn about different power technology like AFBC , CFBC , TRAVELLING GRATE , PULSATING GREAT , PF BOILER , WHRS and many more things . my motive from this site sharing my power sector knowledge each and everyone who belonging to this field , in this website i share information related to boiler operation , boiler maintenance , turbine operation & maintenance , boiler & turbine question answer , D.M plant , and all topic related to power plant sector please join this website for latest updation regarding power plant ………..thanks ( JOGINDER CHAUHAN )