forbes marshall boilers

www.forbesmarshall.com


Energy Balance in a typical steam and condensate loop

Generation 100%

80%Distribution losses

3-5%

Boiler House Losses 15-18%

Trap & Condensate 20%

Process demand 55%


Condensate Drained and Flash steam

vented @3bar

Losses from traps – 75 Kgs/hr

Moisture drained.. 350 Kgs/hr

Feed Water Tank@ 30 Deg C

Process demand 500Kgs/hr dry steam

Boiler required capacity = 1010Kgs/hr

Typical Steam & Condensate Loop Coil Type


High Fuel Bill !!!Poor Product

Quality !!!

High Water

consumption !!!

Corr

osio

n of

Equi

pmen

t !!!

Wet Steam !!!

Poor Life of the Coil

boilers !!!

High Cycle Times !!!

High Steam Loads !!!

The Issues


FWT@ 90 Deg C

Moisture Drained 2%

Condensate Recovery 20%

Process Steam Demand Reduced to 450 Kg/hr

The Solution : Shell Type Boiler


Coil Type Boiler Shell Type Boiler

The Difference


Advantages


SOUNDS EXCITING !!!

A few more reasons to Change


Parameters Fuel Savings Criteria Consumption

Coil Type Boiler 48.75 lt/hr 28% Eff = 75% dryness fraction = 80%

Coil Type Boiler 49.85 lt/hr 30% Eff = 75% dryness fraction = 65%

Shell Type Boiler 35.49 lt/hr Eff = 89% dryness fraction = 98%

Savings due to

Flash Steam recovery Right Trapping

Dry Steam generation

Temperature & Pressure Control

Low Cost of Ownership


Actual Savings ofActual Savings of

25 - 30%25 - 30%


Industry Coil Boiler Shell Boiler

Pharma Industry in Pune

Heating period for 100 ml (Autoclave) 55 mins 35 mins

Heating period for 500 ml (Autoclave) 66 mins 50 mins

Distilled water o/p from Multicolumn 200 lit 275 lit

Bottling Company

Bottles produced per Minute (BPM) 340 500

Rubber Company

Batch Time 8 Hrs 6 Hrs

Pieces per month 109,000 167,000

Increased Productivity


Coil Boiler Shell Boiler

Steam Quality Wet Dry Saturated

Constant Load Poor Steady

Fluctuating Load Water carry over as Steady due to sufficient

no steam space steam space

Instantaneous Loads Pressure Drop Steady Output

The 2 Q’s ….


Savings in Water


Partial List of industries using Shell Type boilers –

1. Food 13. Personal Products2. Garments 14. Beverages3. Chemicals 15. Packaging Industries4. Cattle feed 16. Plastics5. Dairy6. Educational Institutes7. Rubber8. Hotels9. Hospitals10. Formulations11. Pharmaceuticals12. Glass

More than 200 boilers in operation in the industries which traditionally used coil type boilers

Reference List


The Old System

Feed Water Tank@ 30 Deg C

35% Moisture at 180 Deg C drained

Condensate Drained and

Flash steam vented @3bar

TD traps..!

850kg/hr600 kg/hr

Pressure Drop..


Problems


FWT@ 90 Deg C

Condensate at 95 Deg C

Condensate at 95 Deg Crecovered

Recoverable Flash Steam @ 3 bar

1TPH boiler, dry steam load – 550Kgs/hr

Changed to FT

traps..!

No Pressure Drop..

The Solution !


o Fuel consumption reduced from 5 Tankers per 2 months to 4 tankers per 2 month.

(Saving of 6 tanker of 10000 Kg/Year)

o Reduced load on ETP… Practically the ETP remains idle now.

o For a Drum Heating process – The heating time has reduced from 10 hrs to 4 hours.

o Reactor heating process – 14 hrs to 8 hrs. (Endothermic Reaction)

Results Speak for themselves


More improvements and Benefits

forbes marshall boilers

Business

wet steam

dry steam load

typical steam

comconsumptioncoil type

shell type boilers

high steam loads

coil type boilerswww

bar1tph boiler