Design of a boiler waste heat

and water recovery system

Bvuchete Munyaradzi N0107413Z

Background

Aim

To design a boiler waste heat and water

recovery system in order to optimize boiler
efficiency

Objectives

To conduct an energy and water audit

To design a boiler blow down system
To design a closed loop condensate reticulation system
To design an economizer
To develop a PLC program for the monitoring and control of the boiler waste
heat and water recovery system

NEED JUSTIFICATION
Reduce energy losses :blowdown ,condensate, flue gases
Eco-efficiency: max output from the non renewable fuel
Cleaner production & resource efficiency: waste
minimization, environmental protection from pollution
Reduction in costs: coal cost, chemical cost, water cost, fuel cost

METHODOLOGY

1. Literature review
2. Data collection
3. Concept generation and Concept Selection

4. Modeling and Simulation

LITERATURE REVIEW
Heat exchangers
Pumps
Liquid level sensors
Valves
Programmable Logic Controllers
Vessels and tanks

Concept 1

advantages

disadvantages

Occupies less space

No blowdown water recovery

High thermal recovery efficiency

Chemicals in water flushed to drain

Easy of maintenance

No pollution control from flue gases

Concept 2

advantages

disadvantages

Potential increase of boiler efficiency and a reduction of coal

Potential of corrosion of economizer due to condensation of

usage by the boiler system

flue gases (sulphur and nitrogen oxides which cause acidic

conditions)

Blowdown water recovered and reused

Maintenance challenge of economizer due to clogging with

particles carried by the flue gases.

Significant heat energy recovered

Chemicals saved

Flash steam and its energy wasted to to the atmosphere

Concept 3

advantages

disadvantages

Potential increase in boiler efficiency and a reduction in coal

Maintenance challenges because of many moving elements

consumption

in the system

Condensate recovery result in reduction of boiler water usage

Water wastage

and reduction of chemicals used

Most significant amount of heat energy recovered

Flash steam and its energy wasted

The induced fan consumes electricity

High temperature instability of the boiler feed water tank due

to the cold water being added in the tank

Concept 4

Cleaner production
Maximum heat and water recovered
Improved boiler efficiency
Reliable and non labour intensive
Expensive to implement

CONCEPT 4 CHOOSEN

QUESTIONS ??? AND COMMENTS

$$$? RECOVER waste
heat ENERGY AND
Recycle WATER???

Thank you!!!