Department of Textile Engineering

Project
of
“Study on Improving Dyeing Machine efficiency by
Recovering Energy from Boiler.”

Submitted by
Student Name ID No.
MD. DEDARUL ALAM EBTX140300431
MD. BALAYET HOSSEN EBTX140300435
JHUMANA SIDDIQA EBTX140300436

Supervisor:
Md. Tanjim Hossain

Senior lecturer and coordinator

Department of Textile Engineering

Northern University Bangladesh

December 2017 I
 Letter of Transmittal
December 2017

Md. Tanjim Hossain

Senior lecturer and coordinator

Department of Textile Engineering

Northern University Bangladesh (NUB)

Ashkuna, Dhaka-1212

Subject: Submission of project report.

Dear Sir,

With due respect, we the students of textile engineering, Northern University

Bangladesh (NUB) have successfully completed our project program. In this
stage we are submitting our project report on “fit assessment of bodice block
graded efficiency of boiler” as part of our B.Sc. in textile engineering
requirement that bears three (03) credit hours under your supervision. We are
submitting this report for our academic purpose only.

Would you please be kind enough to evaluate this dissertation with your valued
suggestions

Sincerely yours Sincerely yours Sincerely yours

………………………. ………………………….. …………………………..

Md. Dedarul Alam Md. Balayet Hossen Md. Jhumana Siddiqa
ID: EBTX140300431 ID: EBTX140300435 ID: EBTX140300436

II
 DEDICATED TO

My parents and the respected teachers who

always try to find ways and think to provide
which i do not know and don’t have

III
 NORTHERN UNIVERSITY BANGLADESH

Department of Textile Engineering

“Study on Improving Dyeing Machine efficiency by Recovering

Energy from Boiler”

A dissertation submitted to the Department of Textile Engineering in partial

fulfillment of the credit requirement for awarding the Bachelor Degree Textile
Engineering by the Northern University Bangladesh.
By

Submitted by
Student Name ID No.
MD.DEDARUL ALAM EBTX140300431
MD. BALAYET HOSSEN EBTX140300435
JHUMANA SIDDIQA EBTX140300436

Supervisor:
Md. Tanjim Hossain
Senior lecturer and coordinator
Department of Textile Engineering
Northern University Bangladesh

IV
 Approval

The project report on “Study on Improving Dyeing Machine efficiency by

Recovering Energy from Boiler.” submitted by Md. Dedarul Alam
(EBTX140300431), Md. Balayet Hossen (EBTX140300435) and Jhumana Siddiqa
(EBTX140300436) of the department of textile engineering, Northern
University Bangladesh, has been accepted as satisfactory for the partial
fulfillment of the requirements for the degree of Bachelor of Science (B.Sc.) in
Textile Engineering of the year of 2017 and approved to its style and contents.

Board of Examination

1)……………………………………..
Md. Tanjim Hossain
Senior lecturer and coordinator
Department of Textile Engineering
Northern University Bangladesh

V
 Declaration

This is to certify that this thesis is the result of the work of the undersigned. No
part of this work has been submitted elsewhere partially or fully for the award
of any other degree or diploma. Any material reproduced in this thesis has been
properly acknowledged.

Name: Md. Dedarul Alam……………………………...

ID: EBTX140300431

Name: Md. Balayet Hossen.…………………………….

ID: EBTX140300435

Name: Jhumana Siddiqa .…………………………........

ID: EBTX140300436

VI
 Acknowledgement

At first our gratefulness goes to Almighty Allah to give me strength and ability to
complete the project and this report. You have made my life more beautiful.
May you name be exalted, honored and glorified.

Md. Tanjim Hossain, Senior lecturer and coordinator, Department of Textile

Engineering. My supervisor, to whom we extremely indebted for this
tremendous support and guidance throughout my training period. Being
working with him I have not only earned valuable knowledge but was also
inspired by his innovativeness which helped enrich my experience to a greater
extent. His ideas and way of working was truly remarkable.

We are thankful to Md. Sofiqul Islam - Managing Director, Hams Garment’s Ltd
& Mr. Shamzzuman - Managing Director, Micro Fiber Ltd for helping us to
complete project work.

VII
 ABSTRACT
RMG sector is the backbone of today’s Bangladesh economy. If we can
Save Energy & improve improving productivity this will help us to improve
economic development for the country.

As today all European Buyer Focus on Green Projects / Leed Certified

Projects, This is a part of that work to save Energy from all area in the industry.

Because higher level of adoption of quality management systems and

business excellence models can help the organizations to improve their
competitiveness and performance.

Also productivity increases with improvement of quality as low quality

means high cost and loss of competitive position. Crosby states, “ If you
concentrate on making quality certain, you can probably increase your profit
by an amount equal to 5% to 10% of your sales”.

Our Main objects to recovery all wastage (Blow down Heat Recovery,
Condensate Recovery, Cooling Water Recovery, and Use of Garments Cutting
Waste like Jute) and re use in the industry to save Money.

VIII
 Table of Content
Topic Page no

Chapter -01

1.1 Introduction 1

1.2 Thermal Energy Usage in Textile Industry 2

1.3 Sources of Waste Heat Recovery in Textile Industry 3

1.4Area of Energy can Recovery in Textile Industry 3

Chapter -02

2.1 What is Condensate Recovery? 4

2.2 Condensate can be reused in many different ways, for example 4
2.3 Condensate Recovery System Drawing 5

2.4 The Benefits of Condensate Recovery 6

Chapter -03

3.1 Automatic Blow down System 6-7

3.2 Reduced Fuel Costs 8

3.3 Lower Water-related Expenses 8

3.4 Positive Impact on Safety and the Environment 8-9

3.5 Boiler Blow down Recovery Drawing 10

3.6 Pay Back 11-12

IX
 Chapter -04

4.1 Wet Steam vs. Dry Steam: The Importance of the Steam Dryness Fraction13

4.2 Steam Dryness Fraction 13

4.3 Calculating the Total Heat of Wet Steam 14-15

4.4 Steam Dryness Decreases during Transport 16

4.5 Steam Trap Selection: How Application Affects Selection 17

Chapter no-05

5.1 Steam Trap Applications 18

5.2 For Steam Distribution Piping 19

5.3 For Steam-heated Equipment 19-20

5.4 For Tracer Lines 21

5.4 For Power-drive Equipment 21-22

Chapter no-06

6.1 What is Water Hammer/ Steam Hammer? 23

6.2 The Dangers of Water Hammer 23-24

6.3 Waste Water Heat Recovery 24-25

6.4) Step-By-Step Installation 26

6.5) Before You Start 27

6.6) Waste Water Heat Recovery System Drawing 27

X
 Chapter no-07

7.1 What is a Steam Boiler? 28

7.2 How Steam Boilers Work 28

7.3 More Dangerous than Hot Water Boilers 28-29

7.4 Transfer More Heat 29

7.5 Changing from Steam to Hot Water 30

7.6 Noisy Lines Are Common but Not Necessary 30

7.7 Increased Maintenance Requirements 31

7.8 Jute Fired Steam Boiler Drawing 31-33

7.9 Understanding the Efficiency Rating of Furnaces and Boilers 33-34

7.9.1 Retrofitting Your Furnace or Boiler 35

7.9.2 Replacing Your Furnace or Boiler 35-37

7.9.3 Maintaining Furnaces and Boilers 37-39

7.9.4 Maintaining Proper Ventilation for Combustion Systems 39

7.9.5 Chimneys 40-41

7.9.6 Other Ventilation Concerns 41

Conclusion 42

XI
 Chapter no -01

1.1) INTRODUCTION:

Bangladesh ranks third in the textile industry sector in the world. The
Bangladesh textile industry contributes about 14% to the industrial production,
4% to the GDP, and 17% to the country‟s export earnings [1]. Steam is required
in textile industry for different processes like dyeing, hot rinsing, etc. Hence,
steam generation in boiler requires huge amount of fuel. Efficiency of boiler is
50 to88%. Hence it is possible to recover heat which otherwise get wasted in the
atmosphere. Very high waste heat recovery potential exist in the textile
industry. By optimizing the blow down rate of boiler it is possible to save huge
amount of fuel per year. This improves profitability of industry by saving in fuel
cost. By using condensate as feed water for boiler large saving in fuel can be
achieved, as condensate contains 25-39% of energy as that of steam. When
pressure reduces it is possible to recover heat from steam in the form of flash
steam. It is possible to use waste water for heating feed water to the boiler, it
also reduces fuel required for steam generation. This also meets the guidelines
given by atmospheric norms. Waste heat recovery is also possible from hot
exhaust air & cooling water.

Page | 1
 1.2) THERMAL ENERGY USAGE IN TEXTILE INDUSTRY:

Thermal energy in textile mills is mainly consumed in two operations. They are
heating of water and drying of water. The Table-1 indicates the department wise
per cent steam consumption in a composite textile mill .It can be observed
maximum steam is consumed in processing department. All other department
have comparable steam consumption. Power dominates consumption pattern in
spinning/weaving, while thermal energy is major for chemical processing. It is
known that thermal energy in textile mill is largely consumed in two operations,
in heating of water and drying of water. Fuel consumption in textile mills is
almost directly proportional to amount of water consumed. Hence, if
consumption of water can be reduced, it will also save energy.

Page | 2
1.3) SOURCES OF WASTE HEAT RECOVERY IN TEXTILE
INDUSTRY:

1.4) AREA OF ENERGY CAN RECOVERY IN TEXTILE

INDUSTRY:

 Steam Condensate Recovery System for Boiler

 Flash Steam Recovery System for Boiler
 Automatic Blow Down Heat Recovery System for Boiler
 Heat Recovery from Hot Cooling Water of Dyeing Machine
 Heat Recovery from Hot Effluent Treatment Plant

Page | 3
 Chapter no -02

2.1) What is Condensate Recovery?

If 1 t/h of steam is supplied to equipment for a heating process,

then the same amount of condensate (1 t/h) needs to be discharged
from the equipment. Condensate recovery is a process to reuse the
water and sensible heat contained in the discharged condensate.
Recovering condensate instead of throwing it away can lead to
significant savings of energy, chemical treatment and make-up water.

2.2) Condensate can be reused in many different ways, for

example:

 As heated feed water, by sending hot condensate back to the boiler’s

deaerator

 As pre-heat, for any applicable heating system

 As steam, by reusing flash steam

 As hot water, for cleaning equipment or other cleaning applications

Page | 4
2.3) Condensate Recovery System Drawing:

Page | 5
2.4) The Benefits of Condensate Recovery:

Reusing hot condensate can lead to considerable savings in terms of energy

and water resources, as well as improve working conditions and reduce your
plant's carbon footprint.

Chapter no -03

3.1) Automatic Blow down System:

As water evaporates in the boiler steam drum, solids present in the feed
water are left behind. The suspended solids form sludge or sediments in the
boiler, which degrades heat transfer. Dissolved solids promote foaming and
carryover of boiler water into the steam. To reduce the levels of suspended
and total dissolved solids (TDS) to acceptable limits, water is periodically
discharged or blown down from the boiler. Mud or bottom blow down is
usually a manual procedure done for a few seconds on intervals of several
hours. It is designed to remove suspended solids that settle out of the boiler
water and form a heavy sludge. Surface or skimming blow down is designed to
remove the dissolved solids that concentrate near the liquid surface. Surface
blow down is often a continuous process. Minimizing blow down rate can
substantially reduce energy losses, as the temperature of the blown-down
liquid is the same as that of the steam generated in the boiler. Minimizing blow

Page | 6
down will also reduce makeup water and chemical treatment costs. Insufficient
blow down may lead to

Carryover of boiler water into the steam, or the formation of deposits.

Excessive blow down will waste energy, water, and chemicals. Minimizing blow
down rate can substantially reduce energy losses, as the temperature of the
blown-down liquid is the same.as that of the steam generated in the oiler.
Minimizing blow down will also reduce makeup water and Chemical treatment
costs.

Boiler water is given a blow down in order to keep the accumulated Total
Dissolved Solids in boiler water in check as the steam is evaporated from the
boiler.

The quantity of blow down required is:

Page | 7
3.2) Reduced Fuel Costs:

 Condensate contains a significant amount of sensible heat that can

account for about 10% to 30% of the initial heat energy contained in the
steam.

 Feeding the boiler with high-temperature condensate can maximize

boiler output because less heat energy is required to turn water into
steam. When efficiently recovered and reused, it can even be possible to
reduce boiler fuel needs by up to 10 to 20%.

3.3) Lower Water-related Expenses:

As long as any impurities picked up during condensate transport are

removed, condensate can be reused as boiler feed water, reducing

water supply and treatment costs, as well as costs associated with cold
water used to lower condensate temperatures before swearing, where
applicable.

3.4) Positive Impact on Safety and the Environment:

 Reducing boiler fuel needs through condensate recovery leads to less air
pollution by lowering CO2, NOx and SOx emissions.

 Additionally, condensate recovery lines can also limit vapor clouds to

reduce noise generated from atmospheric condensate discharge and
help prevent build-up of water on the ground, considerably improving a
plant’s work environment.

Page | 8
 Depending on the amount of condensate being recovered and reused,
other benefits may include a reduced need for boiler blow down
through better feed water quality, and less corrosion in the system as
water quality becomes more consistent throughout the grid.

Page | 9
3.5) Boiler Blow down Recovery Drawing:

Page | 10
3.6) Pay Back:

The benefits for proper boiler blowdown control include the following:

 Reduced operating costs (less feedwater consumption; chemical treatment

and higher heating efficiency)

 Reduced maintenance and repair costs (minimized carryover and deposits)

 Cleaner and more efficient steam

 Minimized energy loss from boiler blowdown can save about 2% of a

facility’s total energy use with an average simple payback of less than one
year.

The most common methodologies used for boiler blowdown control include:
(1) continuous, (2) manual and (3) automatic.

Continuous blowdown utilizes a calibrated valve and a blowdown tap near the
boiler water surface. As the name implies, it continuously takes water from the
top of the boiler at a predetermined rate to reduce the level of dissolved
solids. The rate is usually set slightly greater than necessary to be on the safe
side.

Manual blowdown is accomplished at most plants by taking boiler water

samples once a shift and adjusting the blowdown accordingly. This grab sample
approach means that operators cannot immediately respond to changes in

Page | 11
feedwater conditions or variations in steam demand and scaling conditions can
occur and go undetected until the next sample check.

Automatic blowdown control is achieved by constantly monitoring the

conductivity value of the boiler water and adjusting the blowdown rate and
duration based on a specific conductivity set point.

This provides control of the water chemistry regardless of the boiler load
conditions. Actual operation data verifies that automatic control can maintain
boiler water conductivity consistently within 5% of the set point.

Page | 12
 Chapter no-04

4.1) Wet Steam vs. Dry Steam: The Importance of the Steam
Dryness Fraction:

Did you know that boilers do not generate 100% saturated steam (dry steam)?
When a steam boiler heats up water, bubbles breaking through the water
surface will pull tiny water droplets in with the steam. Unless a super heater is
used, this will cause the steam supply to become partially wet (wet steam)
from the added liquid.

4.2) Steam Dryness Fraction:

The steam dryness fraction is used to quantify the amount of water within
steam. If steam contains 10% water by mass, it's said to be 90% dry, or have a
dryness fraction of 0.9.

Steam dryness is important because it has a direct effect on the total amount
of transferable energy contained within the steam (usually just latent heat),
which affects heating efficiency and quality.

For example, saturated steam (100% dry) contains 100% of the latent heat
available at that pressure. Saturated water, which has no latent heat and
therefore 0% dryness, will only contain sensible heat.

Steam Dryness = 100% - [% Entrained Water] (by mass)

Page | 13
4.3) Calculating the Total Heat of Wet Steam:
Steam tables contain values such as enthalpy (h), specific volume (ν), entropy
(s), etc. for saturated steam (100% dry) and for saturated water (0% dryness),
but typically not for wet steam.

These can be calculated by simply considering the ratio of steam to water, as

described in the equations below:

Page | 14
The wetter the steam, the lower the specific volume, enthalpy, and entropy
will be because the dryness percentage is a factor of the 100% condition. Since
steam dryness has a significant effect on all these values, to enable greater
heating efficiency it is crucial to supply steam that is as close to being 100% dry
as possible.

Page | 15
4.4) Steam Dryness Decreases During Transport:

During transport, radiant heat loss from piping causes part of the steam to lose
some of its latent heat and revert back to water, thereby decreasing steam
dryness.

Page | 16
4.5) Steam Trap Selection: How Application Affects Selection:

Given the large variety of steam traps and their operating characteristics, users
may encounter some difficulty when trying to select the correct trap to most
effectively drain condensate from their steam applications.

Key trap selection considerations should include pressure and temperature

ratings, discharge capacity, trap type, body material, and many other relevant
factors. While it may seem daunting at first, this process can generally be
separated into four easy-to-understand steps:
Step 1:
Determine discharge requirements of the steam trap application (e.g. hot or
sub cooled discharge), and select the matching trap type.
Step 2:
Select trap model according to operating pressure, temperature, orientation,
and any other relevant conditions.
Step 3:
Calculate application load requirements and apply the trap manufacturer’s
recommended safety factor.
Step 4:
Base the final trap selection on lowest Life Cycle Cost (LCC)

The first article of this three-part series will focus on how the steam trap
application affects the steam trap selection process.

Page | 17
 Chapter no-05

5.1) Steam Trap Applications:

Steam traps are usually required to drain condensate from steam piping,
steam-using process and comfort heating equipment, tracer lines, and drive-
power equipment such as turbines. Each of these applications may require the
steam trap to perform a slightly different role.

Page | 18
5.2) For Steam Distribution Piping:

The role of steam distribution piping is to reliably supply steam of the highest
reasonable quality to the steam-using equipment or tracing lines. One of the
most important roles of steam traps on steam piping is to help prevent the
occurrence of water hammer. This is done by selecting a trap that is designed to
prevent condensate from pooling, which means traps with little to no sub
cooling of condensate (i.e. rapid near-to-steam temperature discharge) should
be chosen.

5.3) For Steam-heated Equipment:

Because the performance of steam-using process equipment and comfort
heating equipment (e.g. air heaters) is directly tied to productivity and product
quality, it's important to select a trap that helps shorten start-up time and does
not allow condensate to pool into the equipment, causing uneven heating, low
heat transfer, and other similar problems. Traps that continuously discharge
condensate are typically recommended for these applications.

Such applications may also experience stagnant start-up air left over from
condensed steam. As a result, an air venting function is also typically required
in the trap to remove air and other non-condensable gases trapped in
equipment and adjacent piping.

Also, some steam-heated equipment might experience problems from a

modulating steam supply valve (e.g. control valve) that adjusts for heat
Page | 19
demand and subsequently lowers the delivered steam pressure below that of
the backpressure. When this phenomenon occurs, the condensate flow
“stalls”, and a different type of drainage device is needed. Under stall
conditions, a combination pump and trap supplied with a higher secondary
pressure is needed to power the condensate discharge through the trap (e.g.
Power Trap®).

Page | 20
5.4) For Tracer Lines:

Steam traps for tracer lines have different requirements because they are
typically used with copper piping (because of its high thermal conductivity) to
heat and maintain the fluidity of viscous fluids at temperatures below 100 °C
(212 °F). A trap that has been designed to counter blockage from copper
precipitate and that can efficiently use the sensible heat of steam/condensate is
required.

5.5) For Power-drive Equipment:

Power-drive equipment includes all turbines used in compressor, pump, or

generator applications, but may also include steam hammers or wheels. In each
power-drive application, condensate should be removed as quickly as possible
for safe and effective operation, and should not pool inside the equipment to
prevent damage.

Page | 21
Page | 22
 Chapter no-06

6.1) What is Water Hammer/ Steam Hammer?

Have you ever heard a loud 'BANG' or hammer-like sound after quickly turning
on or off a water faucet? This is the sound of water hammer in the water
piping system. In a factory, a pump starting up operation or shutting down, or
an air vent suddenly closing are examples of when this might occur.

In addition to water transport piping systems, water hammer also occurs in

steam and condensate recovery (i.e. water circulation) systems. This series of
articles will focus on water hammer in these latter two systems. Note that as
steam is involved, this type of water hammer is also sometimes referred to as
'steam hammer'.

6.2) The Dangers of Water Hammer:

When steam is first supplied to steam distribution piping or steam-using
equipment, a metallic and repetitive 'bang, bang, bang', or even sometimes a
violent 'boom' accompanied by vibration may be heard. Most steam users will
probably have experienced one of these at some time.

When water hammer occurs, a momentary abrupt pressure change of over 10

MPa may occur inside the piping.

This impact can severely jar piping, equipment or machinery housing, possibly
resulting in damage not only to gaskets in junctions, but also to valve flanges or
the valves themselves.

Page | 23
As soon as something like this, such as a valve, becomes damaged, large
quantities of steam or hot condensate begin blowing out, which could lead to a
serious accident. There have even been reports of deaths occurring as the
result of water hammer. In spite of this, there is remarkably little research or
literature devoted to its causes and prevention, and many steam users find
themselves at a loss with how to cope with the issue.

6.3) Waste Water Heat Recovery:

Drain-water heat recovery technology works well with all types of water
heaters, especially with demand and solar water heaters. Drain-water heat
exchangers can recover heat from the hot water used in showers, bathtubs,
sinks, dishwashers, and clothes washers. They generally have the ability to
store recovered heat for later use. You'll need a unit with storage capacity for
use with a dishwasher or clothes washer. Without storage capacity, you'll only

Page | 24
have useful energy during the simultaneous flow of cold water and heated
drain water, like while showering.

Some storage-type systems have tanks containing a reservoir of clean water.

Drain water flows through a spiral tube at the bottom of the heat storage tank.
This warms the tank water, which rises to the top. Water heater intake water is
preheated by circulation through a coil at the top of the tank.

Non-storage systems usually have a copper heat exchanger that replaces a

vertical section of a main waste drain. As warm water flows down the waste
drain, incoming cold water flows through a spiral copper tube wrapped tightly
around the copper section of the waste drain. This preheats the incoming cold
water that goes to the water heater or a fixture, such as a shower.

By preheating cold water, drain-water heat recovery systems help increase

water heating capacity. This increased capacity really helps if you have an
undersized water heater. You can also lower your water heating
temperature without affecting the capacity.

Page | 25
 6.4) Step-By-Step Installation:
 1.) Find the current temperature. Measure the beginning temperature of your
hot water using a thermometer at the tap farthest from the water heater.
Thermostat dials are often inaccurate.
 2.) Mark the setting, then turn down the thermostat. Mark the beginning
temperature on your water heater thermostat with a marker, and then turn
the thermostat down.
 3.) Measure and adjust. Wait a couple of hours, and then measure the water
temperature again at the farthest tap from the water heater. Several
adjustments may be necessary before you get the temperature you desire.
 4.) Mark the new temperature. If you are satisfied with the temperature, mark
the new temperature on the water heater thermostat with a marker, so that
you can make adjustments in the future if necessary.
 5.) Turn down or off when away. If you plan to be away from home for at least
3 days, turn the thermostat down to the lowest setting or completely turn off
the water heater. To turn off an electric water heater, switch off the circuit
breaker to it. For a gas water heater, make sure you know how to safely relight
the pilot light before turning it off.

Page | 26
 6.5) Before You Start:

 Consult your water heater owner's manual for instructions on how to operate
the thermostat.
 You can find a thermostat dial for a gas storage water heater near the bottom
of the tank on the gas valve. Electric water heaters, on the other hand, may
have thermostats positioned behind screw-on plates or panels.
 As a safety precaution, shut off the electricity to the water heater before
removing/opening the panels.
 Keep in mind that an electric water heater may have two thermostats—one
each for the upper and lower heating elements.

6.6) Waste Water Heat Recovery System Drawing:

Page | 27
 Chapter no-07

7.1) What is a Steam Boiler?

A steam boiler is a cast iron or steel container that’s designed to convert water
into steam for various heating applications or to turn a steam engine.

7.2) How Steam Boilers Work:

Water is stored in the tank of a steam boiler and it’s heated by natural gas,
propane, coal or an electric element. Once the water is converted to steam, it is
collected in an empty tank called a dome. Steam continually collects in the
dome and pressure levels within climb higher and higher. When the pressure
reaches a desired level, the steam is released through a valve to travel up
through pipes and around the home. The steam travels through a series of
radiators until enough heat energy is finally lost and it turns back to water once
again and drains back down to the boiler to be heated once again.

Steam boilers don’t require an electric pump for operation and that means that
no electricity is necessary in order for a steam heating system to function. The
steam’s pressure is used to generate movement through the system.

7.3) More Dangerous than Hot Water Boilers:

Unlike the hot water boilers and heating systems most commonly used today,
steam systems are kept at much higher pressures and temperatures, making

Page | 28
them more dangerous to use. Not only are the systems more of a burn hazard
since temperatures are so high, but there is always the risk of an explosion from
all the pressure built up. A set of failsafe’s are included in each steam heating
system, but if problems arises with one or more of these systems serious
problems can occur.

7.4) Transfer More Heat:

There’s a limit to how high the temperature of hot water systems can go because
when you go too high you get steam. Steam systems on the other hand aren’t so
limited because steam remains steam no matter how hot you get it. Many steam
systems operate at much higher temperatures than hot water systems. The steam
can transport more heat from radiator to radiator and achieve a higher
temperature output with a smaller radiator overall. Hot water radiators have to
be larger in order to get enough heat out into the room effectively.

Page | 29
7.5) Changing from Steam to Hot Water:

Many people are deciding to move away from a steam heating system in favor
of a hot water system. This seems like a good move since there are many
benefits of hot water systems, but in most instances it is a waste of money. It’s
common to believe that steam systems are less efficient than hot water systems,
but that is only mildly true. Optimized steam systems that are carefully
maintained are only slightly less efficient than hot water heaters. The price to
convert from a steam system to a hot water one is rarely justified by the
efficiency improvements, and you would be better served by upgrading the
existing steam system with a more efficient boiler and by enhancing insulation.

7.6) Noisy Lines Are Common but Not Necessary:

Steam boilers are commonly accompanied by loud banging noises and an

unpleasant hammering. This is a real problem that makes many homeowners
with steam systems consider switching to a new type of heater in the first place.
A banging noises usually means that one of the steam lines isn’t angled
properly, that the steam pressure is set too high, the steam traps have failed or
there is simply a clog in one of the lines. Having the system checked and
serviced by a professional is likely all that’s needed to get rid of that noise and
improve the system’s efficiency at the same time.

Page | 30
7.7) Increased Maintenance Requirements:

Steam systems have a series of traps at each of the radiators to help relieve
excess pressure. These traps fail every six years or so and they have to be
maintained carefully to keep them functioning properly until then. Taking care
of steam traps helps keep steam systems clean and functioning, but it is a lot of
work. You’ll have to check and top-off water levels periodically and make sure
that the main pressure relief valve is in working order. If you aren’t sure how to
service a steam system, it’s important to find a qualified technician. Regular
maintenance and annual service will help ensure your steam system provides
reliable and efficient heat time and time again.

7.8) Jute Fired Steam Boiler Drawing:

Page | 31
 Oil & Gas Fired Steam Boiler Drawing:

 Coal/Oil Fired Steam Boiler Drawing:

Page | 32
7.9) Understanding the Efficiency Rating of Furnaces and Boilers:

A central furnace or boiler's efficiency is measured by annual fuel utilization

efficiency (AFUE). The Federal Trade Commission requires new furnaces or
boilers to display their AFUE so consumers can compare heating efficiencies of
various models. AFUE is a measure of how efficient the appliance is in
converting the energy in its fuel to heat over the course of a typical year.

Specifically, AFUE is the ratio of annual heat output of the furnace or boiler
compared to the total annual fossil fuel energy consumed by a furnace or boiler.
An AFUE of 90% means that 90% of the energy in the fuel becomes heat for
the home and the other 10% escapes up the chimney and elsewhere. AFUE
doesn't include the heat losses of the duct system or piping, which can be as
much as 35% of the energy for output of the furnace when ducts are located in
the attic, garage, or other partially conditioned or unconditioned space.

An all-electric furnace or boiler has no flue loss through a chimney. The AFUE
rating for an all-electric furnace or boiler is between 95% and 100%. The lower
values are for units installed outdoors because they have greater jacket heat loss.

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 However, despite their high efficiency, the higher cost of electricity in most
parts of the country makes all-electric furnaces or boilers an uneconomic
choice. If you are interested in electric heating, consider installing a heat pump
system.

Read about the standards for residential furnaces.

You can identify and compare a system's efficiency by not only its AFUE but
also by its equipment features.

Old, low-efficiency heating systems:

 Natural draft that creates a flow of combustion gases

 Continuous pilot light
 Heavy heat exchanger
 56% to 70% AFUE.

Mid-efficiency heating systems:

 Exhaust fan controls the flow of combustion air and combustion gases
more precisely
 Electronic ignition (no pilot light)
 Compact size and lighter weight to reduce cycling losses
 Small-diameter flue pipe
 80% to 83% AFUE.

High-efficiency heating systems:

 Condensing flue gases in a second heat exchanger for extra efficiency

 Sealed combustion
 90% to 98.5% AFUE.
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 7.9.1) Retrofitting Your Furnace or Boiler:

Furnaces and boilers can be retrofitted to increase their efficiency. These

upgrades improve the safety and efficiency of otherwise sound, older systems.
The costs of retrofits should be carefully weighed against the cost of a new
boiler or furnace, especially if replacement is likely within a few years or if you
wish to switch to a different system for other reasons, such as adding air
conditioning. If you choose to replace your heating system, you'll have the
opportunity to install equipment that incorporates the most energy-efficient
heating technologies available.Retrofits are fuel-specific, so see the following
sections for retrofit information:

 Gas-Fired Furnaces and Boilers (includes units fired with natural gas and
propane)
 Oil-Fired Furnaces and Boilers.

Other retrofitting options that can improve a system's energy efficiency include
installing programmable thermostats, upgrading ductwork in forced-air systems,
and adding zone control for hot-water systems, an option discussed in Heat
Distribution Systems.

7.9.2) Replacing Your Furnace or Boiler:

Although older furnace and boiler systems had efficiencies in the range of 56%
to 70%, modern conventional heating systems can achieve efficiencies as high
as 98.5%, converting nearly all the fuel to useful heat for your home. Energy
efficiency upgrades and a new high-efficiency heating system can often cut your
fuel bills and your furnace's pollution output in half. Upgrading your furnace or
boiler from 56% to 90% efficiency in an average cold-climate house will save
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1.5 tons of carbon dioxide emissions each year if you heat with gas, or 2.5 tons
if you heat with oil.

If your furnace or boiler is old, worn out, inefficient, or significantly oversized,

the simplest solution is to replace it with a modern high-efficiency model. Old
coal burners that were switched over to oil or gas are prime candidates for
replacement, as well as gas furnaces with pilot lights rather than electronic
ignitions. Newer systems may be more efficient but are still likely to be
oversized, and can often be modified to lower their operating capacity.

Before buying a new furnace or boiler or modifying your existing unit, first
make every effort to improve the energy efficiency of your home, then have a
heating contractor size your furnace. Energy-efficiency improvements will save
money on a new furnace or boiler, because you can purchase a smaller unit. A
properly sized furnace or boiler will operate most efficiently, and you'll want to
choose a dependable unit and compare the warranties of each furnace or boiler
you’re considering.

When shopping for high-efficiency furnaces and boilers, look for the ENERGY
STAR® label. If you live in a cold climate, it usually makes sense to invest in
the highest-efficiency system. In milder climates with lower annual heating
costs, the extra investment required to go from 80% to 90% to 95% efficiency
may be hard to justify.

Specify a sealed combustion furnace or boiler, which will bring outside air
directly into the burner and exhaust flue gases (combustion products) directly to
the outside, without the need for a draft hood or damper. Furnaces and boilers
that are not sealed-combustion units draw heated air into the unit for
combustion and then send that air up the chimney, wasting the energy that was
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 used to heat the air. Sealed-combustion units avoid that problem and also pose
no risk of introducing dangerous combustion gases into your house. In furnaces
that are not sealed-combustion units, back drafting of combustion gases can be a
big problem.

High-efficiency sealed-combustion units generally produce an acidic exhaust

gas that is not suitable for old, unlined chimneys, so the exhaust gas should
either be vented through a new duct or the chimney should be lined to
accommodate the acidic gas (see the section on maintaining proper ventilation
below).

7.9.3) Maintaining Furnaces and Boilers:

The following maintenance should be provided by a heating system

professional.

All systems:

 Check the condition of your vent connection pipe and chimney. Parts of the
venting system may have deteriorated over time. Chimney problems can be
expensive to repair, and may help justify installing new heating equipment that
won't use the existing chimney.
 Check the physical integrity of the heat exchanger. Leaky boiler heat
exchangers leak water and are easy to spot. Furnace heat exchangers mix
combustion gases with house air when they leak—an important safety reason to
have them inspected.
 Adjust the controls on the boiler or furnace to provide optimum water and air
temperature settings for both efficiency and comfort.

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 If you're considering replacing or retrofitting your existing heating system, have
the technician perform a combustion-efficiency test.

Forced Air Systems:

 Check the combustion chamber for cracks

 Test for carbon monoxide (CO) and remedy if found
 Adjust blower control and supply-air temperature
 Clean and oil the blower
 Remove dirt, soot, or corrosion from the furnace or boiler
 Check fuel input and flame characteristics, and adjust if necessary
 Seal connections between the furnace and main ducts.

Hot Water Systems:

 Test pressure-relief valve

 Test high-limit control
 Inspect pressure tank, which should be filled with air, to verify that it's not filled
with water
 Clean the heat exchanger.

Steam Systems:

 Drain some water from the boiler to remove sediments and improve the heat
exchange efficiency
 Test low-water cutoff safety control and high-limit safety control

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 Drain the float chamber to remove sediments, which will prevent the low-water
cutoff control from sediment clogs
 Analyze boiler water and add chemicals as needed to control deposits and
corrosion
 Clean the heat exchanger
 See also steam radiators.

7.9.4) Maintaining Proper Ventilation for Combustion Systems:

Anytime you maintain, retrofit, or replace a gas or oil heating system you need
to be concerned with air quality. Combustion air is needed by all oil and gas
heating systems to support the combustion process. This air is provided in some
homes by unintentional air leaks, or by air ducts that connect to the outdoors.
The combustion process creates several byproducts that are potentially
hazardous to human health and can cause deterioration in your home. You can
protect yourself from these hazards, as well as maintain energy efficiency, by
ensuring that your chimney system functions properly and that your heating
system is properly ventilated. In some cases, installing a sealed-combustion
furnace or boiler can also help.

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 7.9.5) Chimneys:

Properly functioning chimney systems will carry combustion byproducts out of

the home. Therefore, chimney problems put you at risk of having these
byproducts, such as carbon monoxide, spill into your home.

Most older furnaces and boilers have naturally drafting chimneys. The
combustion gases exit the home through the chimney using only their buoyancy
combined with the chimney's height. Naturally drafting chimneys often have
problems exhausting the combustion gases because of chimney blockage, wind
or pressures inside the home that overcome the buoyancy of the gases.

Atmospheric, open-combustion furnaces and boilers, as well as fan-assisted

furnaces and boilers, should be vented into masonry chimneys, metal double-
wall chimneys, or another type of manufactured chimney. Masonry chimneys
should have a fireclay, masonry liner or a retrofitted metal flue liner.

Many older chimneys have deteriorated liners or no liners at all and must be
relined during furnace or boiler replacement. A chimney should be relined when
any of the following changes are made to the combustion heating system:

 When you replace an older furnace or boiler with a newer one that has an AFUE
of 80% or more. These mid-efficiency appliances have a greater risk of
depositing acidic condensation droplets in chimneys, and the chimneys must be
prepared to handle this corrosive threat. The new chimney liner should be sized
to accommodate both the new heating appliance and the combustion water
heater (if present) by the installer.
 When you replace an older furnace or boiler with a new 90+ AFUE appliance or
a heat pump. In this case, the heating appliance will no longer vent into the old

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chimney, and if the combustion water heater is present it will now vent through
an oversized chimney. This oversized chimney can lead to condensation and
inadequate draft. The new chimney liner should be sized for the water heater
alone, or the water heater in some cases can be vented directly through the wall.

7.9.6) Other Ventilation Concerns:

Some fan-assisted, non-condensing furnaces and boilers, installed between 1987

and 1993, may be vented horizontally through high-temperature plastic vent
pipe (not PVC pipe, which is safely used in condensing furnaces). This type of
venting has been recalled and should be replaced by stainless steel vent pipe. If
horizontal venting was used, an additional draft-inducing fan may be needed
near the vent outlet to create adequate draft. Floor furnaces may have special
venting problems because their vent connector exits the furnace close to the
floor and may travel 10 to 30 feet before reaching a chimney. Check to see if
this type of venting or the floor furnace itself needs replacement. If you smell
gases, you have a venting problem that could affect your health. Contact your
local utility or heating contractor to have this venting problem repaired
immediately.

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Conclusion:

Apart from saving energy, we can achieve sustainable development with waste
heat recovery as dependence on fossil fuels is reduced . Performance of thermal
systems is enhanced in addition with reduction in pollution . From the case
studies it has been estimated that payback period of investment for the waste
heat recovery system is in between one to two years for most of the systems.
Hence waste heat recovery is highly economical.

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