Tutorial Steam Generation

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Tutorial – Steam Generation

Q1
An essential oil manufacturing plant has a 2.5 TPH (F & A 100 C) packaged firetube boiler and operates at 10 bar
g. The feedwater temperature is 68 °C. The boiler is operated at 80% of the maximum rated capacity. A newly
recruited process engineer was asked to find the effectiveness in current blow down method. She found the
following information after a detailed study on the current practice.

Boiler capacity = 2.5 TPH


Steam Pressure = 11 bar
Blowdown valve diameter = 2 inch
Holdup volume = 5 m3
Boiler feed water TDS (Total Dissolved Solids) = 300 ppm (average from the lab tests)
TDS in the blow down water = 2700 ppm (average from the lab tests)
Recommended TDS for packaged firetube boilers = 3500 ppm
Condensate return = 25% of the Boiler Feed Water
Pressure in Flash Tank = 1 bar
Ambient temperature = 30 C
Flash Tank diameter = 0.6 m
(1 TPH = 1000 kg/h, 1 kg/cm2 = 0.98 bar)

a) What is the steam output of the boiler?


b) What is the current Blow Down percentage (BD%) and the blow down rate based on steam output?
c) Calculate the TDS of the Make Up water in ppm?
d) After presenting the finding of the process engineer, senior maintenance engineer asked her to reschedule the blow
down operation and maintain the blow down at recommended rate. Calculate the energy saving from the suggested
change.
e) Briefly explain why blowdown is required.
f) Calculate the total blowdown time required per day using Table Q2.
g) Determine the energy savings by using the flash tank.

Table Q1: volume of boiler Water Blow Liter/minute at various pressure and valve size

P T Flow rate (liters/min)


kg/cm2 °C 1" pipe 1.5" pipe 2" pipe 2.5" pipe 3" pipe
7.04 167.22 435.84 1089.6 1852.32 2655.9 4767
8.8 178.33 463.08 1198.56 2015.76 2941.92 5039.4
10.56 185.56 503.94 1307.52 2233.68 3214.32 5448
12.32 191.67 544.8 1416.48 2451.6 3541.2 5856.6
14.08 197.78 599.28 1525.44 2669.52 3813.6 6265.2
15.85 202.78 653.76 1634.4 2860.2 4086 6673.8
17.61 207.78 708.24 1743.36 3105.36 4358.4 7082.4
21.13 216.11 789.96 1906.8 3386.84 4712.52 7845.12
24.65 223.89 817.2 2070.24 3650.16 5066.64 8607.84
28.17 231.11 926.16 2233.68 3940.72 5420.76 9397.8
31.69 237.22 1007.88 2397.12 4194.96 5774.88 10187.76

Q2

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