economics of furnace

7/30/2019 Economics of Furnace

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Session IV

TROUBLE SHOOTING & ECONOMICS

OF

FURNACES & BOILERS OPERATION


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HIGHLY COMPETITIVE

DEPENDENCY OF SUSTAINING PROFITABILITY IS

SHIFTING

FROM : TRADITIONAL ECONOMIC POWER

TO ==> KNOWLEDGE BASE TECHNIQUES

INTEGRATION OF ORGANIZATION, TECHNOLOGY ANDPEOPLE ARE THE ENERGY MANAGEMENT ASPECTS

BUSINESS ENVIRONMENT


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ENERGY LOSS OTHER COST

INPUT OUTPUT

FOR IMPROVING PROFIT ===> MINIMISE COST

ENCON for Profitability


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PROFITABILITY EQUATION

PROFIT = SP COST (INPUT COST AND OP. COST)

SP & OPERATING COST ARE MARKET DRIVEN ONLY OPTION LEFT IS COST REDUCTION.

(90% of input cost is crude cost. Out of balance 10%,5 % is establishment cost. So option left is to make

profit from balance 5% of cost)

ENCON for Business Success


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Governments Commitment for reducing emission of

green house gases by 20 % (min) 25 % (max) over

the level of 2005 by 2020.

Emission of CO2 from stack of furnaces, boilers GTs

exhaust and flare etc. in Refineries

Our contribution to protect the mother EARTH

through ENCON!

ENCON for minimizing Global Warming


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COST OF FUEL IS ABOUT 50 % OF TOTAL OPERATING COST

0.1 % REDUCTION IN FUEL CONSUMPTION @ 13.5 MMTPA CRUDETPUT = REDUCTION OF FUEL CONSUMPTION BY 13500 MT / YR.

FINANCIAL BENEFIT = RS 2340 LAKHS / YR.

FUEL CONSUMING CENTERS ARE BOILERS AND FURNACES

NEED OF THE HOUR IS EFFICIENT USE OF ENERGY

FuelCost


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Contribution to reduction of green house

gas emission

Impact of reducing fuel consumption by 0.1% on crude

Tput :

Reduction in Fuel consumption 135000 MT

CO2 emission per MT of LSHS is about 2.8 MT

Reduction in CO2 emission = 13500 * 2.8 = 37800

MT per Year


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Fuel losses during operation of furnaces & boilers

1. Air ingress through pee holes, return bend header

covers, openings at convection bank, opening of

burner inspection holes etc. in case of balanced draft

furnaces and boilers

2. In addition to above, opening of air registers in idle

burners in natural draft furnaces

3. Leak in air pre-heaters

4. Operation of boilers & furnaces with very high draft


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Fuel loss due to opening of Peep hole

Peep hole of size 10 x 6

Velocity of air ingress 5 Mtr per second

Quantity of air = (0.25 x 0.15 x 5 x 0.29 x 3600) =

195.75 Kg per hour = 1550340 Kg per year

Heat loss considering 150C delta T= (1550340 x

0.23 x 150) / 1000000 = 53.48 Mkcal per year

= 5.35 SRFT per year= 96300 Rs per year


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AU-4 APH failure

Operation of APH with damper full open Damper control on off

Non-functional of Temp indication

Culture of operation is to monitor stack temp and

not at ID suction

Cost of APH Rs 15 lacs + installation Rs 15 lacs


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Furnace efficiency AU-4

Current efficiency = 86.29%

Achievable efficiency = 90%

Deviation in efficiency = - 3.71%

Additional Fuel consumption = 3.59 MT per day

= 3.59 x 18,000= Rs. 64,557/- per day


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Heat loss through stack B-4

Air leak in APH

Such regenerative APHs are leak prone

Heat loss = Qty of excess air x 0.23 x (stack tempamb

temp) Kcal/hr

Power loss for pumping excess air

= (Flow in M3/sec) X head MMWC / (120xStatic eff. Of fan)


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Power loss due to leak at ID suction

Pumping of air

Increase in power consumption of about 15 KWH

Fuel loss per year = (Power in MWH * power en. Factor*

330) SRFT per year

Provide metallic bellow instead of cloth.


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Case studies

Burner replacement ( scopeVBU)

Fuel oil line tracing

Water content in fuel oil

Air distribution survey at burner tip

Clinker formation at burner tip NRV in atomising steam line

Sulphur dew point corrosion


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Heat Recovery

Operation of APH

Why APH leaks?

Who is responsible?

What can we do to avoid failure of APHs?

What is the loss by not operating APHs?


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Hazards & Safety precautions

Puffing in furnaces Explosions

Pressurization of furnaces

Formation of clinker / choking of oil burners/oil

leak below burner leading to explosion


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Hazards & Safety precautions

Puffing in furnaces Explosions

Pressurization of furnaces

Formation of clinker / choking of oil burners/oil

leak below burner leading to explosion


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Precaution during Decoking

Oil vapor cloud was observed during strating ofdecocking operation in one of the refinery

Precaution

Ensure opening of water to decocking pot before

starting of decocking operation / steaming.


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Precaution in fuel oil system

Oil Vapor cloud was observed from vent of fixedroof fuel oil tank

Cause

High water content in Fuel Oil

Double steam tracing with MP Steam

Effect

Vaporization of water in tank

Precaution

Make Fuel Oil water-free

Heat only upto desired temperature


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Clinker formation at Burner Tip

Subsequent to preceding event lot of Clinkerformation was observed at burner tip followed by

burner cleaning

Cause

Steam to F.O. tank was closed & Fuel Oil

temperature at burner tip was not sufficient for

atomization.


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Fire in Air Duct

Clinker formation at burner tip led to improperatomization , drip of oil into air duct followed by

back fire and fire in air duct.

Precaution

Regular visual inspection of burner tip

Maintain desired temperature of Fuel Oil to

achieve desired viscosity


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Precaution in fuel oil system

At PDRP Fuel Oil tanks are floating roofEnsure water draining before pumping


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Troubleshooting
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THE I DO FACTOR

YES

I TOLD YOU SHALL FIND OUT

IT WILL NOT WORK THE WAY

EFFORT

LEAVE ME ALONE INTERNALISATION

YES NO

COMMITMENT ========= >


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Thank YouThank You

economics of furnace

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