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ISSN:2348-2079 Volume-6 Issue-1

International Journal of Intellectual Advancements

and Research in Engineering Computations

Performance Analysis of Economizer by Adding

Extra Coils
1 2 2 2 2
T.Venkateshan , T.Shathriyan , P.Mahaduraisamy , J.Chiffathulla , T.Vishnuprabhu
1 2
Assistant Professor, UG Students
Department of Mechanical Engineering,
Nanda Engineering College, Erode-52, Tamil Nadu, India.
1
venkateshaneil@gmail.com,2mahasmart812@gmail.com,2saranshathriayn896@gmail.com
Abstract -India’s energy market is one of the country a one from of energy to another”.Power generation is
fastest developing sectors. The electricity generated from a thermal power plant involves the following basic
thermal power plants contributes 68.14% of the total conversions of energy. Boiler is a combination of
generation. The availability of coal in the country such
heating surfaces in which superheated steam is
that the high grade of coal, which have higher calorific
generated from continuously fed water by utilizing
value, have been exhausted and progressively over
grades of coal are being made available for generation of
the heat energy of coal, which is fed into boiler
electricity in power plants.This has resulted in poor furnace together with the air, required for the
thermal efficiencies of power plants.The major loss of a combustion.Circulation through various heating
boiler is caused by the hot stack gases discharging to the surfaces, does the processes of conversion from
atmosphere in order to increase the efficiency of boiler. water to steam by addition of sensible heat, latent
But we have to extract maximum amount of heat from heat and superheat. Steam boiler consists only of the
the flue gases and increase the heat pick up the rate of containing vessel and conductive heating surface.
the rate of the feed water outlet in boiler.
Economizer is used to pre heat the boiler feed water
(adding sensible heat) before it enters the drum by
Index words - boiler, economizer, air pre-heater, thermal
absorbing heat from the flue gas.The most common
efficiency, heat exchanger. economizer design is the bare tube, in-line and cross
flow type to the hot flue gases and also the gas
1. INTRODUCTION velocity is another important for economizer
design.Bowl mill consist of stationary roller
mounted on an electrically driven rotating bowl.
Power generation in any country depends upon the
Coal fed through the hopper gets pulverized by
available resources in the country.The major sources
friction as it passes between the slides of the rollers
of power are thermal (coal), hydro (water) and nuclear
and bowl.
power plants. The hydro power generation is
dependent on periodic rainfall which is highly
uncertain and sites for hydro power plant cannot be
humanly created.Nuclear power generation is highly
capital based and requires advanced technological
developments and fuel resources .To overcome these
limitations, thermal power plants become necessity of
economic and abundant generation of power.thus
thermal power plants are major contributors of
country’s power generation. “Energy can neither be
created nor be destroyed; it can be transformed from

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Venkateshan T et al., Inter. J. Int. Adv. & Res. In Engg. Comp., Vol.–06(01) 2018 [716-720]

fan are reduced thus power consumption is reduced

and cost is reduced. Fuel consumption is also
reduced, thus fuel is saved and cost is reduced. By
comparing Rothemuhle with ljunstrom air leakage
are more, gas side efficiency and air side efficiencies
are less in Rothemuhle air preheater. The thermal
performance of the ljunstrom air preheater is better
than Rothemuhle

P.N.Sapkal et al [2]
Performed an analysis for the optimization of air
preheater design with inline & staggered tube
arrangement. The poor performance of an air
preheater in the modern power plants is one of the
Fig. 1 Thermal plant layout main reason for higher unit heat rate & is
The fuel and combustion air streams from these responsible for deterioration in boiler efficiency.. In
burners or compartments are directed tangentially to case of tubular air heaters a variety of single and
an imaginary circle and this creates a turbulent vortex multiple gas and air path arrangements can be used
motion of the fuel,air and hot gases ,which promotes to optimum performance. Modern tubular air heaters
mixing ,ignition energy availability and thus can be shop assembled into large, transportable
combustion efficiency.The proportioning of airflow is modules. Erosion of air preheater parts can be
done based on boiler load,individual burner load,by a controlled by reducing velocities, removing erosive
series of air dampers. elements from the gas stream, or using sacrificial
material. The performance of tubular air preheater
Each of the auxiliary and end air nozzles are provided can be evaluated with the help of CFD analysis for
with lower type regulating dampers, at the air entry to Inline & staggered tube arrangement with the latter
individual air compartment.The damper regulates on being more thermally efficient. The model can be
elevation basis,in unison, at all comers. Since used while selecting a new type of surface geometry
combustion is the surface reaction, greater the extent in order to have uniformly distributed flow pattern
of coal surface available, higher will be the rate of for optimizing the design of air preheater.
combustion. Hence, coal is pulverized to increase the
surface area per unit mass of fuel. The development of Sangeeth G.S et al [3]
growth of coal pulverize closely parallels the Performed an analysis for energy efficiency of the
development of pulverized coal firing technology. process or equipment should prove itself to be
Early systems used ball and tube mills to grind coal economically feasible for gaining acceptance for
and holding pins to temporarily store the coal before implementation. The focus of the present work is to
firing. Evolution of the technology to eliminate the study the effect of system modification for
bins and direct fire the coal pneumatically transported improving energy efficiency. The objective of the
from pulverizes required more responsive and reliable study was to analyze the overall efficiency and the
grinding equip men thermodynamic analysis of boiler. There are many
II. LITERATURE SURVEY factors, which are influencing the efficiency of the
V.Malikarjuna et al [1] boiler. The fuel used for combustion, type of boiler,
Preparing mathematical analysis an attempt has been varying load, power plant age, heat exchanger
made to study about the boiler and economizer. Hot air fouling they lose efficiency. Much of this loss in
is necessary for rapid combustion in the furnace and efficiency is due to mechanical wear on variety of
also for drying coal in milling plants .so an essential components resulting heat losses. Therefore, it is
boiler accessory which serves this purpose is air necessary to check all the equipments periodically.
preheater. The air preheater are not essential for Moreover, it is noticed that the overall efficiency of
operation of steam generator, but they are used where any boiler depends upon the technical difficulties
a study of cost indicates that money can be saved or under unpredictable conditions. Hence, a viable
efficient combustion can be obtained by their use. The study is carried out to assess the performance of
performance of the air preheater is improved. Load on boiler plant in this context. The paper set to show the

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Venkateshan T et al., Inter. J. Int. Adv. & Res. In Engg. Comp., Vol.–06(01) 2018 [716-720]

weakness of depending on energy analysis only boilers and then the efficiency calculation. The efficiency
as a performance measure that will help improve calculation by indirect method is the best way to
efficiency. account all the boiler losses. The flue gas loss is
always higher than any other losses. The flue gas
Gaurav T. Dhanre et al [4] loss can be minimized by heat extraction and proper
Performed an analysis for This reduction can be utilization. Moreover when the primary fuel is coal,
achieved by improving the efficiency of industrial it should be accounted that it is of higher calorific
operations and equipments. Energy audit plays an value, low moisture and low ash content.
important role in identifying energy conservation
opportunities in the industrial sector, while they do not
provide the final answer to the problem; they do help K.Sampath Kumar reddy et al [7]
to identify potential for energy conservation and
Performed an analysis for the Computational Fluid
induces the companies to concentrate their efforts in
Dynamics (CFD) approach is utilized for the
this area in a focused manner. which we are getting
creation of a two-dimensional model of the
from energy auditing . Hence there is a need to prefer
economizer coil. Using mild steel material in the
energy auditing of every plant once in an year. For the
economizer part it gives better performance
research, it is found that it is also possible to do
compared with the carbon steel material. The fluid
auditing at different load conditions and by
flow temperature, pressure is increase and velocity is
comparison we get the actual consumption as well as
decrease field of fluid flow within an economizer
wastage.
tube using the actual boundary conditions have been
analyzed using CFD tool. The CFD model may be
M. J. Poddar et al [5]
used to optimize its thermal performance by varying
As per the study carried out by, the share of energy
the location in the economizer and in turn improve
costs in total production costs can get improves profit
the performance of boiler. And
levels in all the industries.

It can be achieved by improving the efficiency of

industrial operations and equipments. Energy audit due to changing the material of economizer such as
plays an important role in identifying energy mild steel. Out let pressure of the economizer is
conservation opportunities in the industrial sector, increased and temperature is not varied but velocity
while they do not provide the final answer to the is decreased due to using the mild steel. Finally the
problem, they do help to identify potential for energy boiler efficiency is increased
conservation and induces the companies to concentrate
their efforts in this area in a focused manner. The III. CONSTRUCTION FEATURES
comparative study has been done. From the audit it is
concluded that the major reasons for having lower CLASSIFICATION OF BOILERS:
efficiency are poor quality of coal and air leakages.
Efficiency of the boiler is increased by 0.27% by
reducing air leakage about 6% in air heater. 1. Based on the working pressure
 Sub critical boiler (<222
Venkata Seshendra et al [6] bar)
Performed an analysis for the environmental issues  Super critical boiler (>222
and economy are the secondary factors to be bar)
considered after finding the losses. Due to increase in
fuel price and demand in more energy requirement in 2. Based on boiler layout
everyday life, proper utilization of materials and The mutual arrangement of the gas ducts of a
resources are necessary. This present deals with the boiler and the direction of combustion products in
aim of estimating the heat losses occurring in thermal them determine the layout.
power plant boilers and hence finding suitable ways  Single pass
for reducing it, hence allowing plants to achieve more  Two pass
performance, sustainability and cost-effective  Three pass
maintenance operation of a steam system. Thermal  Four pass
power plant is the detailed study of boiler in the plant  T type

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Venkateshan T et al., Inter. J. Int. Adv. & Res. In Engg. Comp., Vol.–06(01) 2018 [716-720]

3. Based on circulation of working fluid forced draft fans to supply air for combustion,
 Natural circulation or Drum type induced draft fans to eject combustion products, ash
 Forced circulation or Controlled removable systems, spray systems are connected
circulation with boiler.

Two types of construction are ECONOMIZER:

predominant for the design of steam generators. They
are single pass and two pass boilers. The single pass
Economizer is arranged the 2nd pass of the boiler in
boiler has found no wide use in India. At thermal
which feed water is heated from 247-272* and sent
power station for sub critical boilers, two pass systems
to the boiler drum.
is employed. The two pass boilers consist of two
vertical shafts connected at the top by a horizontal gas
duct. The first pass serves as the boiler furnace. The
water wall tubes are arranged around the side and
align the whole height of the furnace champer.They
are heated directly by the radiant heat of the flame.
The second vertical shaft and the horizontal duct that
connects it with first pass serve for accommodating
super heating heater surfaces, which receive heat by
convection. The heating surfaces like platen SH, re
heater, pendent SH are placed in the horizontal duct
&low temperature SH and economizer are in second
pass of boiler.
Fig: 3 Economizer

The convective super heaters are the system of a large Economizer is used to pre heat the boiler feed water
number of tubes connected by headers at the inlet and (adding sensible heat) before it enters the drum by
outlet end. The water wall outlet headers, super header absorbing heat from the flue gas. The most common
and boiler drum are placed at the penthouse. economizer design is the bare tube, in-line and cross
flow type to the hot flue gases and also the gas
velocity is another important for economizer design.

IV. EXTRA ADDING COILS IN EXISTING

ECONOMIZER:
In economizer extra tubes should be added
to utilize the waste. In economizer extra coils or
tubes are added on the basis of area available in
economizer. In economizer if number of tubes is
increased heat transfer rate of flue gas to feed water
increases which in turn reduces the consumption of
coal consequently increases efficiency of the system.

CALCULATION:
Length of each coil = 9m=9000mm
Diameter of coil=0.120m
Fig: 2 Boiler Area of a coil= (2*3.14*r*r) + h (2*3.14*r)
= (2*3.14*0.6*0.6) + 9(2*3.014*0.6)
The important components of the steam generator such =3.482m2
as boiler drum with internals, the furnace water wall Total area of 78 coils=3.482*78
panels, super heaters, pre heater, de super heater, and =271.44 m2
economizer are mostly suspended from the structural Total area of 243 coils=243*3.482
steel work. Various sub systems like coal /oil burners, =846.126 m2

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Venkateshan T et al., Inter. J. Int. Adv. & Res. In Engg. Comp., Vol.–06(01) 2018 [716-720]

Total surface area of economizer=1230.52 m2

Total surface area of (243+78) coils= 1117.56 m2 5. K. Sampath Kumar Reddy, and Dr B.
Total available area in economizer is 1230.5 m2 and Veerabhadra Reddy “Performance of the
the area required for addition of 78 coils is 271.4 m2. Boiler and To Improving the Boiler
Efficiency Using Cfd Modeling”,[IOSR-
V.CONCLUSION JMCE],Vol.08,Issue.06, 2013.

6. M. J. Poddar, and Mrs. A.C.Birajdar,

Thus by adopting the proposed optimization, the ”Energy Audit a Boiler- A Case
efficiency of the boiler can be increased and Study”,[IJERT],Vol.02,Issue.06,pp.1660-
consumption of coal is reduced. In air pre heating 1666,2013.
system, the outlet temperature of air heater can be
reduced from 163°c to 147°c. For every 22°c of 7. Venkata Seshendra Kumar Karri, “A
temperature reduction the boiler efficiency is gained theoretical investigation of efficiency
by 1%. As per the suggested optimization savings per enhancement in thermal power plants”
annum is around 1.130 crores per annum. By ,modern mechanical
implementing heat exchanger after pre heater, a engineering,Vol.02,pp.106-113. 2012.
portion of feed water can be preheated without use of
economizer. This can save consumption of coal up to
1000 tons of coal. This methodology proposed in the
project can be used as guidance. By changing up
parameters and testing the boiler regularly these logics
can be further improved and the work can be extended.
Based on the addition and alteration the efficiency can
be increased.

VI. REFERENCES

1. V.Malikarjuna, N. Joshua, And B. Rama

Bhopal Reddy, 2014 “Improving boiler
efficiency by using air preheated
“,international journal of advanced research
in engineering and applied
sciences,Vol.03,Issue.02,PP.11-24,2014.

2. P.N.Sapkal, P.R. Navistar, M.J. Sable, And

S.B.Barve,. “To optimize air preheater design
for better performance”, new aspects of fluid
mechanics, heat transfer and environment,
2015.

3. Sangeeth G.S, And Praveen Marathon,.

“Efficiency improvement of
boilers”,[IRJET],Vol.02,Issue.05, 2015.

4. Gaurav T. Dhanre, Urvashi T. Dandre, and

Kraal Mudale, 2014. “Review paper on
energy audit of a boiler in thermal power
plant”, international journal of engineering
research and general science, Vol.02,
Issue.06, 2014.

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