Papers by Keyword: Boiler

Abstract: The present research targeted the measurement of flue gas flow rates in industrial boiler applications, to improve boiler efficiency in Sri Lanka. This study discussed three methodologies for flow measurement and placed significant emphasis on the benefits of thermal mass flow meters, given their accuracy and reliability, especially within low flow rates. A thorough literature review was conducted to pinpoint critical parameters involved in the generation of boiler performance: flue gas composition and draft regulation. This research spotlights the deficiency in the current measurement practices, hence, a systematic approach to develop, a cost-effective and regionally adaptable solution is presented for the flue gas flow measurement. The investigation validates the proposed measurement techniques by using a combination of theoretical analysis and CFD simulations and demonstrates that the simulated flow rates are close to calculated values, with minimum differences of 0.000461 kg/s. results imply that the optimization of flue gas flow measurement can result in significant enhancements in combustion efficiency. The research ultimately contributes to the betterment of boiler operation practices in Sri Lanka by providing recommendations for future studies and practical implementations to enhance resource management and environmental sustainability within the industrial sector.

Abstract: The study assesses the efficiency of the heat-insulating coating on the surface of the PSV-250 steam-water heater, valves, and pipelines. The efficiency was evaluated using a non-contact method as part of a comprehensive study of heat losses through thermal imaging. During the inspection of the heater’s thermal condition, elements with surface temperatures ranging from +60 °C to +224.5 °C were identified, which poses a hazard from an occupational safety perspective. To prevent burns to maintenance personnel and reduce heat losses that lower the efficiency of thermal equipment, these surfaces must be insulated. To address the identified issues, it is recommended to install special removable insulation or apply a thermal insulation coating based on a liquid ceramic composite material.

Abstract: Superheater pipes in boilers generally experience failure due to extreme operating conditions, such as high temperatures and pressures, often leading to ruptures on the pipe surface. These failures reduce the boiler system’s efficiency and increase the risk of further, costly damage. Therefore, it is important to conduct a failure analysis on the ruptured pipe area to enhance the reliability and operational lifespan of the boiler superheater pipes. This study uses several methods to analyze superheater pipe failure, including visual observation and chemical composition testing, which showed a carbon content of 0.228%, classifying the material as low carbon steel. This was also confirmed by microstructure analysis. Hardness testing revealed an average hardness value of 140.9 HV, whereas the expected hardness should be around 180 HV. In the hardness test, there is a difference of 40 HV from the hardness value that meets the standard, which is an indication of material failure. Additionally, in the SEM test, fine defects were found along the grain, and the tested pipe that experienced rupture was already very thin, with many deposits found on the pipe walls.

Abstract: Boilers in the manufacturing industry have an important role in the production process. Boilers can produce steam, which is used in the production process. Steam produced by boilers can also be used as a power plant where the steam flow is used to drive a turbine. Several manufacturing industries that utilize boilers include the food, beverage, petrochemical, and fertilizer industries. Boiler B 03, which operates in one of the subsidiaries of PT Pupuk Indonesia Group, is the focus of this research because of an issue in which this boiler cannot produce steam according to its design capacity. Based on the problem, through this research an investigation will be carried out to improve the reliability of the B 03 boiler system and what components cause the boiler cannot operate according to design capacity. A boiler that cannot produce steam according to its design capacity can be ascertained to have low efficiency in manufacturing. Boiler B 03 is included in the category of water tube boilers. In this type of boiler, the water or steam pipe is in the pipe with the combustion flame being outside. The method used to find the root of the problem to improve the performance of the boiler system is by using the failure mode effect & criticality analysis (FMECA). By using the FMECA method, it is hoped that all problems in the B 03 boiler can be identified and, as a result, the company can determine the priority of repairs to the boiler components and the company can obtain recommendations regarding steps in improving the boiler production system.

Abstract: Boiler is one of the critical parts and plays an important role in Steam Generation Power Plant. It transforms the chemical energy of fuel into heat or thermal energy. During plant operations, some problems occurred in the boiler and Superheater leakage is the heaviest problem that interfered the whole operations, and the units needed to stopped for maintenaces outages. Failure analysis is necessary to determine the cause of failure. Root Caused Failure Analysis methods was through mechanical tests in the laboratory, which is Visual Observation included Macrofractography Structure examination, Metallographic or Microstructure Examination, Hardness Test. The metallographic examination result shows that the microstructure of the base metal is ferrite pearlite, and there is no indication of microstructure changes in tube as effect from high operation temperature. Likewise, microstructure in the weld region is in normal conditions, no weld failure phenomenon. Hardness value for base metal, weld and HAZ area are still in a good condition. Macrofractrography structure examination shows that the fracture is in mechanical fatigue condition. Based on those results the source of the tube leak is not caused by operating errors, inside or outside deposit nor weld failure. Superheater tube failures caused by mechanical factors, namely due to cyclic tensile stress as result in vibration by gas flow coupled with an increase in the local area due to the welding heat, therefore, increases the rate of crack propagation. To verified the data from mechanical test, CFD simulation will be used. CFD can detect the direction of the gas flow around the Superheater tube. The simulation result shows the possibility of turbulence flow around the tube, which creates the vibrations on the tube due to gas flow velocity. Thus, the superheater tube leakage mostly because vibration that create cyclic tensile stress.

Abstract: It was found that slagging in high temperature zone is one of the major problems in the refinery, petrochemical, pulp and paper, and steel industries; especially in biomass and coal pulverized power plant. Slagging conditions are critical factors influencing reliability and availability on a biomass utility boiler. In this study, several types of slagging were collected for chemical analysis. It was revealed that the chemical composition and other properties of received slagging showed unique results based on the type of feedstock fuel materials.

Abstract: Biomass fly ash is an ash combustion product. It is composed of the particulates (fine particles of fuel) driven out of biomass-fired boilers together with the flue gases. The understanding of the behaviour and property of fly ash is very important in order to predict the consumable part lifetime inside industrial boiler system. In this research study, the several characterization processes were carried out. It was revealed that biomass fly ash obtained from different sources presented unique property and more results were displayed in experimental result section.

Abstract: This article focuses on the estimation of a proper logarithmic damping decrement in industrial boilers when flue gases travel in the vertical direction. The structure for this type of facility is quite unified worldwide. The structural conception is rather simple, and the response to any static loading is predictable. Nevertheless, with regard to dynamics and damping, some specifics in the detailed solution make this system unique. For the purpose of this analysis, a Plexiglas scale model was prepared at a geometric scale of 1:20. A set of experimental modal analyses was performed on the model. Each test focused on the damping effect of specific details and compared it with the common structure without a damping effect. Finally, a site modal analysis was conducted on an actual boiler located in the CHP Torun Plant in Poland. The upper part of the structure was reinforced to have a horizontal deflection of 8 mm and was suddenly released. The resulting movement was recorded with an HD camera linked to a theodolite. Experimental results on the scale model of the actual structure confirmed that damping of this type of structure is significantly higher than that considered for common steel structures.

Abstract: The paper summarizes the results of an extensive metallographic and microfractographic analysis of the relevant parts of a boiler, the aim of which was to establish the causes of the explosion of the boiler (or to contribute to the explanation of the causes).

Abstract: The remarkable growth of palm oil industry in Malaysia is undeniable. Approximately, one million ton of crude palm oil is produced by the industry in a month, thus put Malaysia as one of the largest producer in the world. Most of the mills are operated on cogeneration system, where the biomass residue of palm fibre and shell are used as fuel in the mill boilers mostly to generate steam and also electricity. This practise however produced considerable amount of particulates in terms of fly ash emitting to the environment. Thus, this study is to evaluate the particulate emission from five palm oil mill boilers with steam capacity ranging from 17-35 tonne/h. The results showed that the average particulate emission concentration exiting the stack was 2.21±1.20 g/Nm³ (corrected to 7% oxygen concentration), ranging from 0.42 to 3.77 g/Nm³. The study suggests that the fuel feed rates of fiber and shell was one of the parameters affecting the emission concentration in the boiler. Particulate morphology were also being presented in this study.