HigH efficiency Condensing Economizers
Transcript of HigH efficiency Condensing Economizers
HigH HigH efficiency efficiency CondensingCondensingCondensingCondensingEconomizersEconomizers
COGENERATION RENEWABLE
HVAC
efficiency efficiency CondensingCondensingCondensingCondensingEconomizersEconomizers
COGENERATION ELECTRICAL RENEWABLE TECHNOLOGY
HVAC PLUMBING
CONDENSING ECONOMIZERS – KEY TO A SUCCESSFUL
Energy costs are the highest in recent history. Implementation of efficiencies in thermal processes is a vital element in streamlining rising energy costs.
Installation of condensing economizers could help companies improve overall heat recovery and steam system efficiency by even up to 15% (in standard applications).
SUCCESSFUL HEAT RECOVERY PROJECT
In the boiler room CESeconomizers transfer their waste heat to either the feed water or combustion air pre-heaters, essentially converting standard boilers into condensingboilers.
Covering a wide range of boiler sizes (from 250 kW to up to 6 000 kW), the CESdelivers real energy and cost savings for commercial and industrial installations.
CES economizers are an integral part of any efficiency improvement program. The total range includes 6 economizer models.
CES features and benefits:• increased systemefficiency• real energy and costsavings• converts standard boilers into condensing boilers• increases existing boiler efficiency by up to20%• feasible for boiler systems ranging from 250 kW to 6 000 kW• unique tube design for optimal thermal performance• easy installation, lowm
Typical economizer applicationsinclude:• Dying process• Absorption Chiller• food processingplants
FLUE GAS TEMPERATURE
BOILER INPUT
BOILER OPERATING TIME
ENERGYSAVING
PAYBACK SUMMARY
ANNUAL NATURAL GAS SAVINGS
ANNUALCO2REDUCTION
ANNUAL COST SAVINGS
*(natural gas avg price = 106 Rs/m3)
• food processingplants• pulp and paper mills• textile plants• Power plants• dairy processing facilities• hospitals• hotels
MONEY SAVINGS WITH CES ECONOMIZERS!!!Approximate energy savings achieved with CES4.5
economizer model:
INPUT DATAHOT WATER INLET TEMPERATURE 30°C
220°C
1 450kW
(145 m3/h – natural gas flow)
8 400 h/yr (full load operation)
15.7%
191 226 m3
382 452 kg
2,0270,000 Rs*
Latent11%
LatentHeatloss<
UP CHIMNE
Fluegasloss=3to5%UP CHIMNEY
Conventional boiler heat flow
35.0
34.0
33.0
32.0
31.0
30.0
29.0
28.0
27.0
26.0
25.0
24.0
23.0
22.0
21.0
20.0
19.0
18.0
17.0
16.0
15.0
14.0
13.0
12.0
11.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0 10 15 20 25
Ene
rgy
savi
ng
s(%
)
30 35 40
Temperature of hot water entering
ENERGY RECOVERY FROM COOLING FLUE GAS
Fuel input =111%
Flue gas loss < 1 % UPCHIMNEY
Latentheat11%
Latentheat < 2%
CHIMNEY
Boilerstand-byandjacketloss< 1%
INTOMECHANICAL ROOM+6%9%
Condensing boiler heat flow
60 65 70
Flue gas
inlet
temperature
450°C
400°C
350°C
300°C
280°C
260°C
240°C
220°C
200°C
180°C
160°C
500°C
45 50 55
entering the economizer(0C)
ECON
Economizer’s simple technology and lack of moving parts gives it a very long and relative maintenance-free life cycle. Simple paybacks for condensing economizers are often less than 2 years.
The unique design of the heat exchanger tubes, the so-called “tear-drop” shape, guarantees maximum heat transfer sur- face contact with the flue gas, while decreasing the creation of flow wakes. The tubes are strategically positioned in a matrix to optimize the thermodynamic process, by inducing gas turbulence and increasing the heat transfer rate, and minimizing overall gas pressure drops through the system.
heat exchanger with unique
design
exhaustoutlet
stainlesssteelcondensate bottomdish
exhaust inlet
stainless steel inlet
The stainless steel durable construction is designed to with-stand the corrosive effects of condensing flue gases, and is insulated to minimize heat losses.
ECONOMIZER CONSTRUCTION MATERIAL:• stainless steel 316L or 304L
-for economizers working with gas-fired boilers• stainless steel 904L
-for economizers working with heavy-oil fired boilers (optional)
WORKING PRESSURE 11 BAR
flue gas inlet
ECONOMIZER ONSTRUCTION
nozzleforoutlet waterconnection
heat exchanger – tubetype unique “tear-drop shape”
design constructed from a highgrade stainlesssteel
flue gas outlet
durable solid standconstruction
made ofcarbonsteel
waterconnection
CES casing– easily removable metalpanelsinsulated with mineral wool allow for inside surface inspection andcleaning
eLINEmodel E35.1
in its casing
wool
E
GH
BJ
A
F
D
Exhaust Outlet
Exhaust Inlet
Technical Product Specifications
ModelNominal Boiler Input Exhaust Inlet E
kW MBTUH ømm øin
CES 3.2 1
A
mm in
B
mm in
Larger sizes (multiple-units) or custom-designed
CES 3.2 1
CES 3.3 3
CES 3.4 5
CES 3.6 6
CES 3.8 7
CES 3.9 8
CES 4.2 11
CES 4.4 13
CES 4.5 15
C
Water Inlet
Water Outlet
Exhaust Outlet Water Inlet Water Outlet Drain Nozzle
ømm øin mm in mm in mm in
J
mmin
designed economizers available upon individual request.
Condensing Economizer Increases Condensing Economizer Increases Efficiency OverEfficiency Over
CH4 + 2O2 + 7.52N2
16 lb1 lb
One lb of CH4 produces 2.25 lb
One lb of Natural Gas (1005 Btu/ft3) produces
• Water in products of combustion is vaporized due to heat of
• Water vapors absorb about 10% of fuel input
• Energy lost to atmosphere with exhaust gases through
• Heat of vaporization can be recovered if flue gases are cooled below water dew
• When water vapour condenses, it releases heat of vaporization
• Condensing economizer recovers both heat of condensation (latent heat) and sensible
Basic Concepts Basic Concepts of of Condensing Heat RecoveryCondensing Heat Recovery
Condensing Economizer Increases Condensing Economizer Increases Boiler Boiler Efficiency OverEfficiency Over 90%90%
CO2 + + 7.52 N22H2O
36 lb2.25 lb
produces 2.25 lb of H2O(1005 Btu/ft3) produces 2.14 lb of water
Water in products of combustion is vaporized due to heat of combustion
through stack
Heat of vaporization can be recovered if flue gases are cooled below water dew point
When water vapour condenses, it releases heat of vaporization
Condensing economizer recovers both heat of condensation (latent heat) and sensible heat
Condensing Heat RecoveryCondensing Heat Recovery
Condensation Starts Below Water Dew Point
Dew point varies with O2, CO2 and H2Oin products of combustion
Example: For 4% O2, CO2 is 9.5%
Dew Point = 57 C
93C/200F
• X-axis: Exit Flue Gas Temp
• Y-axis: Efficiency – percent of high
heating value
• Latent heat transfer starts at 59 C
• Excess air 15%
• Entering flue gas temp 232 C
• Exit Flue gas temp 42 C
• Efficiency w/o economizer 80%
• Efficiency with condensing
economizer 95%
Email: [email protected]
Website: www.coenergiesystem.com , Mobile
Address 1: A 421, Block-1, Gulshan-e-Iqbal
Site: Industrial Plot No. 3/10, 3/11 SurbeyNo. 3, Karachi, Pakistan.
Condensation Starts Below Water Dew Point
Mobile No: 03208304070
Iqbal, Karachi-75300, Pakistan.
Surbey Street No. 1, Shah Faisal Colony
ConEconomizer
Boiler4%
Boiler FW 127 C
Flue Gas 149 C
Natural Gas
3275 m3/hr
Feedwater Economizer
BoilerExcess O2: 4%Efficiency: 83% With Econo
Steam
149 C
Energy SavingCondensing Economizer
42 C
Condensate ReturnDeaerator/
Condensate Tank
Steam
Steam production
Make-up water flow rate
Make-up water temperature entering condensing economizer
Make-up water temperature leaving condensing economizer
Flue gas temperature leaving condensing economizerEnergy recovered
Boiler operating hoursGas costEnergy cost savings
Gas Saving Potential
ondensing Economizer
Steam Production 45 Ton/hr @ 100 psig
Boiler Blowdown
Boiler Make-up Water 50%, (23 ton/hr)
Flue Gas
30 C
93 C
149 C
Potential with Condensing Economizer
42 C
Return
45 Ton/hn
50%
entering condensing economizer30 C
up water temperature leaving 93 C
42 C
7.55 MMBtu/hr
8000 hrsRs1283/MMBtu77,493,200 Rs