The ALTERNATIVE

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Arkhangelsk TEC

Calculations of fuel economy for TM-84B boiler at Arkhangelsk heat-and-power station

        Calculation is made after the introduction of the improved regenerative air heater profiles installed by Northern Interindustry Company The Alternative for the boiler with the output of 420 tons of steam per hour.

        Approximate data for calculations:

  • = 28,000 kg/hour fuel (mazut) consumption at rated load;
  • V0 = 10.5 normal m3/kg - theoretically necessary air consumption for burning 1 kg of mazut;
  • am = 1.15 coefficient of surplus air before burners;
  • a = 0.31 kcal/normal m3 - heat capacity of air;
  • Q = 10,000 kcal/kg - heat content in 1 kg of mazut;
  • At = 50° additional air heating after regenerative air heater with the new profile;
  • T = 3,500 hours duration of boiler functioning per year at rated output of 420 tons of steam per hour (min).

        Fuel economy per year when using a regenerative air heater with additional air heating after installation of the improved profiles is (assuming that Ef = fuel economy):

formula01





        Assumed as:

  • At of gases = 28° lowering temperature of released gases;
  • = 0.38 kcal/normal m3 - gases heat capacity;
  • a of a regenerative air heater (a of RAH) = 1.35 coefficient of surplus air in gases per regenerative air heater;

        Fuel economy per year when the temperature of released gases is lowered after installation of the improved profiles into a regenerative air heater (assuming that Ef1 = fuel economy):

formula2

 

 

        Total fuel economy per year is:

E = Ef + Ef1 = 1,834.19 + 1,478.056 = 3,312.246 tons

        If the price of 1 ton of mazut is 140 EUR/ton (medium index according to the mazut prices inside Russia, year 2005), then the fuel economy per year will be:

140 3,312.246 = nearly 460 thousand EUR

        CONCLUSIONS:

  • Stable fuel economy in between repairs is expected.
  • The economy of peoples needs in electric power is expected when there is less stable resistance of regenerative air heaters (RAH) as well as less suction in regenerative air heaters (RAH).
  • There's no necessity to order expensive enamelled profiles for the cold layer.
  • Effectiveness of calorifiers work is growing.
  • Economy of financial means due to less cleaning or no need in cleaning profiles in the boilers.

  • strstrstr ECONOMICAL RESULTS OF PROFILES OPERATION AT ARKHANGELSK HEAT-AND-POWER STATION

            The analysis of boiler TM-84B, identification number 5, technical condition at Arkhangelsk heat-and-power station after routine repairs in 2005.

            In 2005 the improved profile by Vladimir D. Komiagin (produced by Northern Interindustry Company The Alternative, Severodvinsk town) was installed in regenerative air heater-54 of boiler TM-84B with the output of 420 tons of steam per hour, identification number 5, at Arkhangelsk heat-and-power station. After starting the boiler the following results have been received:

    • Boilers gross efficiency has increased to 0.93% and got 0.52% greater than the standard
    • The electric power usage on traction and blowing (0.79kWatt-hour/Gcal) has reduced and got 0.49kWatt-hour/Gcal less than the standard.
    • Air suction into the gas duct has got 3.2% less.
    • Profile resistance of boilers regenerative air heater has got 10% less.
    • Temperature head of regenerative air heater has got 1.5 times (17) less. This shows high thermal effectiveness of the installed profile.
    • The temperature of released gases has lowered for 19 and got 23 less than the norm.

            The opinion of specialists working at Arkhangelsk heat-and-power station (Maintenance Dpt.): Weve never had a better profile than this!

    strstrstrCALCULATION OF REDUCING EMISSION OF HARMFUL SUBSTANCES INTO THE ATMOSPHERE

            Due to the fuel economy after the introduction of the improved regenerative air heater-54 profiles for TM-84B boiler (with the output of 420 tons of steam per hour) installed by Northern Interindustry Company The Alternative at Arkhangelsk heat-and-power station:

    • Total fuel economy per year: 3,312.246 tons;
    • Norm of SO2 emission into the atmosphere: 44 kg/1 ton of average fuel;
    • Norm of NOx emission into the atmosphere: 2.52 kg/1 ton of average fuel;
    • Reduction of SO2 emission into the atmosphere: 44 / 1,000 3,312.246 = 145.74 tons per year;
    • Reduction of NOx emission into the atmosphere: 2.52 / 1,000 3,312.246 = 8.35 tons per year;
            <Upward>
    Severodvinsk TEC

    Fuel economy for boiler 4 running on mazut with the output of 500 tons of steam\hour at Severodvinsk heat-and-power station 2. The result of regenerative air heater-88 operation after planned repair

            In table 1 you can see the results of air & gas temperature measurements before & after regenerative air heater-88 with the designed profile before planned repair:

  • In the hot layer of shaped plates with 30° of waves angle;
  • In the cold layer of enamelled corrugated aerodynamically smooth plates with variable pitch between longitudinal waves (typical cold profile).
  •         TABLE 1

    Boiler`s load
    tons of steam per hour
    Gas t
    at regenerative air heater`s inlet Ѱ

    Air t° at
    regenerative air heater`s outlet Ѱ

    t° of
    released gas Ѱ

    Air t°
    at regenerative
    air heater`s inlet Ѱ

    Gas t difference
    before RAH & air t difference
    after RAH C°

    500
    380
    304
    185
    70
    76

            In table 2 you can see the results of the same type of measurements when testing with the installed profiles offered by Northern Interindustry Company The Alternative made of shaped plates with the width of 0.7 mm in the hot layer & 1.2 mm in the cold layer.

            TABLE 2

    Boiler`s load
    tons of steam per hour
    Gas t
    at regenerative air heater`s inlet Ѱ
    Air t° at
    regenerative air heater`s outlet Ѱ
    t° of
    released gas Ѱ
    Air t°
    at regenerative
    air heater`s inlet Ѱ
    Gas t difference
    before RAH & air t difference
    after RAH C°
    250-365
    322-349
    295-316
    150-157
    95-96
    27-33

            Input data for calculations, close to the real ones:

  • = 33,500 kg/hour - fuel (mazut) consumption at rated load;
  • V0 = 10.5 normal m3/kg - theoretically necessary air consumption for burning 1 kg of mazut;
  • am = 1.05 coefficient of surplus air before burners;
  • a = 0.31 kcal/normal m3 - heat capacity of air;
  • Q = 10,000 kcal/kg heat content in 1 kg of mazut;
  • At = 40° additional air heating after regenerative air heater with the new profiles;
  • T = 4,000 hours duration of boiler functioning per year;

  •         Fuel economy per year when using a regenerative air heater with additional air heating after installation of the improved profiles is (assuming that Ef = fuel economy):

    formula03




            Assumed as:

  • At of gases=20° - lowering temperature of released gases;
  • = 0.38 kcal/normal m3 - gases heat capacity;
  • a of a regenerative air heater (a of RAH) = 1.14 - coefficient of surplus air in gases per regenerative air heater;
  •         Fuel economy per year when the temperature of released gases is lowered after installation of the improved profile into a regenerative air heater (assuming that Ef1 = fuel economy):

    formula4



            Assumed as:

  • Aa = 0.05 air suction reduction;
  • At = 100° temperature difference of taken up air that goes to the calorifiers
  •         Fuel economy caused by reduction of air suction due to the strengthening of shunts of the calorifiers:

    formula5



            Total fuel economy per year is:

    Et = Ef + Ef1 + Ef2 = 1,831.914 + 1,219.025 + 218.085 = 3,269.024 tons

            If the price of 1 ton of mazut is 140 EUR/ton (medium index according to the mazut prices inside Russia, year 2005), then the fuel economy per year will be:

    140 3,269.024 = nearly 455 thousand EUR

            If you use designed (usual, traditional) profiles, then there`s no additional fuel economy.
    The cost of these profiles isn`t higher than the cost of the designed profiles & even lower than the cost of the enamelled ones.

            Conclusions:

  • When using Vladimir D. Komiagins improved profiles, stable fuel economy in between repairs is guaranteed. And, considering less stable resistance of regenerative air heaters (RAH), there is the economy of peoples needs in electric power, taking into consideration less suction in regenerative air heaters (RAH), too.
  • Effectiveness of calorifiers work is growing.
  • There is the economy of financial means due to less cleaning or no need in cleaning profiles in the boilers. Spending on profile renewal, strengthening shunts on calorifiers, turning the sector plate and any other recommended actions are within the estimate of the planned boiler`s repair.
  • Complete recoupment of capital investment for the profile purchase isn't higher than 7.5% from the cold layer profile's planned operation life & isn't higher than 5% from the hot layer profile's operation life.
  • strstrstrECOLOGY

    Calculation of reducing emission of harmful substances into the atmosphere.

            Due to the fuel economy when introducing the improved profile of Vladimir D. Komiagin (on RAH-88) for the boiler with the output of 500 tons of steam per hour that works on mazut (Severodvinsk heat-and-power station 2):
  • RAH-88 boiler with the output of 500 tons per hour;
  • Total fuel economy per year: 3,269.024 tons;
  • Norm of SO2 emission into the atmosphere: 44 kg/1 ton of average fuel;
  • Norm of NOx emission into the atmosphere: 2.52 kg/1 ton of average fuel;
  • Reduction of SO2 emission into the atmosphere: 44 / 1,000 3,269.024 = 143.84 tons per year;
  • Reduction of NOx emission into the atmosphere: 2.52 / 1,000 3,269.024 = 8.24 tons per year;

  •         <Upward>
    Iriklinskaya GRES

    Fuel economy for the boiler with the output of 1,000 tons of steam\hour running on natural gas with installed RAH-88 profiles.

            Calculations are made on the basis of the regenerative air heater (RAH) tests results with the profiles manufactured by «The Alternative» company in year 2005, taking into account the boiler performance at Severodvinsk heat-and-power station 2 before & after changing RAH-88 profiles to the analogical ones. Also the boilers performance is counted. The boilers run on natural gas & their output is 1,000 tons of steam\hour. The calculations are made for the boiler with 100% rated load.

            In table 3 you can see the results of air & gas temperature measurements before & after regenerative air heater-88 with the designed profiles before planned repair:

            TABLE 3

    Boiler`s load
    tons of steam/hour
    Gas t
    at regenerative air heater`s inlet Ѱ
    Air t° at
    regenerative air heater`s outlet Ѱ
    t° of
    released gas Ѱ
    Air t°
    at regenerative
    air heater`s inlet Ѱ
    Gas t difference
    before RAH & air t difference
    after RAH C°
    1,000
    375
    312
    133
    9
    58

            Input data for calculations, close to the real ones:

  • B = 68,000 normal m3/hour - fuel (gas) consumption at rated load;
  • V = 10.5 normal m3/normal m - theoretically necessary air consumption for burning 1kg of gas;
  • Am = 1.05 - coefficient of air surplus before burners;
  • = 0.31 - kcal/normal m3 - heat capacity of air;
  • Q = 10,000 kcal/kg - heat content in 1 normal m3;
  • Ate = 30C - additional air heating after regenerative air heater with the new profile;
  • T = 4,000 hours - duration of boiler functioning per year (with load close to normal).
  • Minimal expected increase of boilers efficiency will be 1.5-2% (practically, it can be up to 5-6%).
  •         Fuel economy per year with additional air heating after a regenerative air heater when the improved profiles manufactured by «The Alternative» company are installed (assuming that Ef1 = fuel economy):

    formula09




            Assumed as:

  • AtT = 25C - lowering temperature of released gases;
  • = 0.38 kcal/normal m3 - gas heat capacity;
  • a of RAH = 1.14 coefficient of surplus air in gas per regenerative air heater;
  •         Fuel economy per year when the temperature of released gases is lowered after a regenerative air heater when the improved profiles are installed (assuming that Ef2 = fuel economy):

    form 08




    Total fuel economy per year is:

    Ef = Ef1 + Ef2 = 2,788.88 + 3,093.04 = 5,881.92 thousand normal m3 for normal boilers load.

            If the price of 1 thousand m3 of natural gas is 29.90 Euro (medium index inside Russia, year 2005), then the fuel economy per year will be:

    29.905,881.92 = 175,869.41 EUR

            If you use designed (usual, traditional) profiles, then theres no additional fuel economy.

            Conclusions:

  • The effectiveness of the profiles manufactured by The Alternative company is two times higher than the effectiveness of the typical (designed, usual) ones.
  • Self-repayment of the profiles manufactured by The Alternative company is high, both in the boilers running on mazut & natural gas.
  • When using Vladimir D. Komiagins improved profiles, stable fuel economy in between repairs is guaranteed. And, considering less stable resistance of regenerative air heaters (RAH), there is the economy of peoples needs in electric power as well as stable functioning of regenerative air heaters (RAH) during all service life of profiles.
            <Upward>
  • EnSERTIKO


    The production is certified
    in EnSERTIKO system

    Figures showing your boilers functioning
    after installation of the profiles made by us
    will tell you more than you can hear now.
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