ENERGY RECOVERY FROM BOILER

BLOWDOWNWATER AT EDIBLE OIL REFINERY

A PROJECT REPORT

Submitted by

ARAVIND U (2127200301005)
JEYAPRAKASH C (2127200301018)

KRISHNA MOORTHY B (2127200301023)

In partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY

in

CHEMICAL ENGINEERING

SRI VENKATESWARA COLLEGE OF ENGINEERING

(An Autonomous Institution; Affiliated to Anna University, Chennai -600 025)
ANNA UNIVERSITY : CHENNAI 600 025

MAY 2024
 SRI VENKATESWARA COLLEGE OF ENGINEERING ANNA
UNIVERSITY, CHENNAI – 600 025
(An Autonomous Institution; Affiliated to Anna University, Chennai -600 025)

BONAFIDE CERTIFICATE
Certified that this project report “ENERGY RECOVERY FROM BOILER
BLOWDOWN WATER AT EDIBLE OIL REFINERY” is the bonafide work of
ARAVIND U (2127200301005), JEYAPRAKASH C (2127200301018) and
KRISHNA MOORTHY B (2127200301023) who carried out the project work
under my/our supervision.

SIGNATURE SIGNATURE
Dr. N. MEYYAPPAN Mr. M. RAMESH
INTERNAL SUPERVISOR EXTERNAL SUPERVISOR
Professor & Head Of The Department Production Manager
Department of Chemical Engineering Kaleesuwari Refinery Private Limited
Sri Venakateswara College of Engineering Medavakkam, Chennai-600100
Pennalur, Sriperumbudur-602117

SIGNATURE
Dr. N. MEYYAPPAN
PROFESSOR
HEAD OF THE DEAPRTMENT
Department of Chemical Engineering
Sri Venkateswara College of Engineering
Pennalur, Sriperumbudur – 602117.

Submitted for the project viva-voce examination held on______________________

INTERNAL EXAMINER EXTERNAL EXAMINER

 ABSTRACT

Blow down water is the part of water that is purposely drained during the boiler operation
to limit the level of impurities in boiler water to an acceptable level. So it is contains
large quantity of heat energy. The objective of the present work is to reduce the coal
consumption of steam boilers in the oil refinery company. This objective has been
achieved through designing and manufacturing of a heat exchanger consists of a shell
and tube heat exchanger to recover heat from surface blow down water. The experimental
results proved that the blow-down water can recover a energy of 1,304,784 KJ/day,
Which will save a mass of coal equals to 3,037.8 ton/ year. This heat recovering is done
by designing a shell and tube heat exchanger of 177 tubes and heat transfer area as 16.27
m2. By designing the shell and tube exchanger, the operating cost of economizer, boiler
will be reduced. Safety measures used for the handling of Dosing Agent in the boiler
house followed based on MATERIAL SAFETY DATA SHEET(MSDS). The cost
estimation has done for the boiler house, the pay back return will be estimated as 5 years
and the return of return as 7.78%.

Keywords: Boiler Blow down water, Economics, Material Safety Data Sheet, Heat
Exchanger

iv
 ACKNOWLEDGEMENT

We consider it as our great privilege to express gratitude and respect to all those who
helped and guided us throughout the completion of our B.Tech project, which inculcated
a strong sense of research in us.

We express our deepest gratitude to our, Dr. S. Ganesh Vaidyanathan, Principal, Sri
Venkateswara College of Engineering for being a source of inspiration to us and
constantly motivating us throughout the course of study in the college.

We express our sincere thanks to Dr. N. Meyyappan, Professor, Head of the Department
of Chemical Engineering for his permission and encouragement accorded to carry out
this project. He also acted as our project supervisor and we are grateful for his guidance,
advice and supervision. The valuable and useful ideas that he has shared with us was
very useful for the completion of this project.

We extend our sincere gratitude to our project coordinators, Mr. S. Jai Ganesh and
Dr. S. Rajasekar, both Assistant Professors, for their invaluable guidance and
unwavering support throughout this project.

We also express our appreciation to our external supervisor, Mr. M. Ramesh,

Production Manager at KALEESUWARI REFINERY PRIVATE LIMITED, for his
insightful input, encouragement, and direction.

We would also like to thank the following people at KALEESUWARI REFINERY

PRIVATE LIMITED, Mr. P. Ramachandran, General Manager-Product
Development, for his guidance, productive criticism and ideas for this project and also
Mr. M. Venkatesh, Engineer for his immense help in completing the project on time.

We are extremely grateful and to all our friends, faculty members and staff of the
Department of Chemical Engineering for their help and support.
v
 TABLE OF CONTENTS

CHAPTER NO TOPIC PAGE NO

ABSTRACT iv

ACKNOWLEDGEMENT v

LIST OF TABLES x

LIST OF FIGURES x

LIST OF SYMBOLS xi

1 INTRODUCTION 1

1.1 Company Profile 1

1.2 Process Description Of The Boiler
1
House
1
1.2.1 Fuel Handling
1.2.2 Fuel Preparation 1
1.2.3 Combustion
2
1.2.4 Heat Transfer
2
1.2.5 Steam Generation
1.2.6 Control System 2
1.2.7 Emission Control
2
1.2.8 Waste Management
2
1.2.9 Maintenance And Safety
1.2.10 Energy Efficiency 3
Optimization
3
1.3 General Introduction

vi
2 LITERATURE SURVEY 6

2.1 Introduction 6

2.2 Literature Survey 6

2.3 Conclusion 8

3 FLOW SHEET 9

4 MATERIAL AND ENERGY 10

BALANCE

4.2 Mass Balance For Heat Exchanger 10

4.3 Energy Balance For Heat 10

Exchanger

4.5 Energy Balance For Economizer 11

4.6 Energy Balance For Boiler 11

5 HEAT EXCHANGER DESIGN 12

5.3 Heat Duty 14

5.4 Compute Lmtd 14

5.5 Area 14

5.6 No Of Tubes 14

5.7 Shell Diameter 14

5.8 Tube Side Heat Transfer 15

Coefficient

5.9 Shell Side Heat Transfer 15

Coefficient

vii
 5.10 Overall Heat Transfer Coefficient 16

5.11 Tube Side Pressure Drop 16

5.12 Shell Side Pressure Drop 16

6 ECONOMIZER DESIGN 18

6.2 Heat Duty 19

6.3 Lmtd 19

6.4 Tube Area 19

6.5 No Of Tubes 19

6.6 Pitch Of Tubes 19

6.7 Width Of The Tubes 19

6.8 Heat Transfer Coefficient For Tube 20

Side

6.9 Heat Transfer Coefficient For Gas 20

Side

6.10 Overall Heat Transfer Coefficient 20

6.11 Area Required 21

7 FIRE TUBE BOILER DESIGN 22

8 PROCESS SAFETY 26

8.1 Causes Of Accidents 26

8.2 Personal Protective Equipment 26

8.3 Material Safety Data Sheet 27

8.3.1 Chemical Products 27

8.3.2 Hazards Identification 28

viii
 8.3.3 First Aid Measures 28

8.3.4 Fire Fighting Measures 29

8.3.5 Accidental Measures 29

8.3.6 Handling And Storage 29

8.3.7 Exposure Controls 30

8.3.8 Physical And Chemical 30

Properties

8.3.9 Toxicological Information 31

8.3.10 Disposal Consideration 31

9 PROCESS ECONOMICS 32

9.1 Direct Cost 32

9.2 Working Capital Cost 33

9.2.1 Raw Material Cost 33

9.3 Payback Time 34

9.4 Rate Of Return 34

10 CONCLUSION 35

11 REFERENCE 36

ix
 LIST OF TABLES
CHAPTER NO. TITLE PAGE NO.

4.1 Mass Balance of Boiler 10

4.2 Mass Balance of Heat Exchanger 6

4.4 Mass Balance of Economizer 7

5.1 Data for Heat Exchanger 8

5.13 Summary of Heat Exchanger 12

6.1 Data for Economizer 13

6.12 Summary of Economizer Design 16

7.1 Data for Fire Tube Boiler 17

7.17 Summary of Fire Tube Boiler Design 20

9.1.1 Estimation of Equipment Cost 28

9.1.2 Estimation of Direct cost 28

9.2.2 Utilities Cost 29

9.2.3 Operating Labour Cost 29

9.2.4 Miscellaneous Cost 30

LIST OF FIGURES

CHAPTER NO. TITLE PAGE NO.

3.1 Process Flow Sheet of Boiler 9

Heat Recovery System in Edible Oil Refinery

x
 LIST OF SYMBOLS

SYMBOLS ABBREVIATION UNITS

mRO Mass flow rate of RO Water kg s-1

mBD Mass flow rate of blow down water kg s-1

mgas Mass flow rate of Flue Gas kg s-1

o
Thi Inlet Temp of Hot fluid C
o
Tho Outlet Temp of Hot fluid C

kBD Thermal Conductivity of Blow down W/m.k

CpBD Specific heat temperature kj kg-1 OC-1

µBD Viscosity of Blow down water Cp

O
Tci Inlet Temp of Cold Fluid C
O
Tco Outlet Temp of Cold Fluid C

KRO Thermal conductivity of Ro water W m-1.k-1

CpRO Specific heat of RO water kj kg-1 OC-1

µRO Viscosity of RO Water Cp

Di Inner diameter of the tube mm

Do Outer diameter of the tube mm

L Length of the Tube m

DS Shell Diameter m
O
ΔTLMTD LMTD C

Db Tube Bundle m

NRe Reynolds Number NA

xi
1
 CHAPTER 1
INTRODUCTION
1.1 Company Profile
Kaleesuwari started their illustrious journey back in 1973 to deliver "Health and
Happiness" to all households. The array of products are all specifically manufactured
with one sole objective, helming their narrative, to elevate one's holistic health.Since its
inception in 1973, Kaleesuwari has been synonmymous with great products. The launch
of Gold Winner was a watershed moment in the edible oil industry. Consistency &
Quality became cornerstones on which Kaleesuwari built a diverse portfolio comprising
food, personal care & home care products that bring heath & happiness to consumers.
Kaleesuwari has set its sights on international markets like USA, Canada, UK, France,
Australia, UAE, Kuwait, Qatar, Singapore, Malaysia, Hongkong, Myanmar & Sri lanka.
Kaleesuwari, headquartered in Chennai also has an office in Singapore. Kaleesuwari has
factories in 4 South Indian locations-Vengai Vasal near Chennai, Palani near Coimbatore
and Kakinada in Andhra Pradesh.

1.2 Process Description of the boiler house

A boiler house is a facility where boilers are housed and operated to generate steam or
hot water for various industrial, commercial, or residential purposes.

1.2.1 Fuel Handling: The process begins with the delivery of fuel to the boiler house.
Common fuels include natural gas, oil, coal, biomass, or electricity. The fuel is stored in
designated areas, often in large storage tanks or bunkers, depending on the type of fuel
used.

1.2.2 Fuel Preparation: If the fuel requires processing before combustion, such
as crushing and pulverizing for coal or biomass, this step occurs in the boiler
house. The fuel is prepared to optimize combustion efficiency and reduce
emissions.

1
1.2.3 Combustion: In the combustion chamber of the boiler, the prepared fuel
is burned to produce heat. Combustion can occur through various methods, such
as fluidized bed combustion, pulverized coal combustion, or gasification,
depending on the type of boiler and fuel used.

1.2.4 Heat Transfer: The heat generated from combustion is transferred to

water or steam circulating within the boiler's tubes or heat exchangers. This heat
transfer process raises the temperature of the water or generates steam, which is
then used for heating, power generation, or other industrial processes.

1.2.5 Steam Generation: If the boiler is producing steam, the generated steam
is collected and directed to a steam drum, where any moisture or impurities are
separated from the steam. The steam is then sent through piping systems to
various points of use within the facility.

1.2.6 Control Systems: Boiler houses are equipped with sophisticated control
systems to monitor and regulate various parameters such as fuel flow, air supply,
combustion temperature, steam pressure, and water level. These control systems
ensure optimal boiler performance, efficiency, and safety.

1.2.7 Emissions Control: To comply with environmental regulations, boiler

houses often incorporate emissions control equipment such as electrostatic
precipitators, scrubbers, or selective catalytic reduction systems to reduce the
release of pollutants such as particulate matter, sulfur dioxide, nitrogen oxides,
and carbon monoxide.

2
1.2.8 Waste Management: Boiler houses may produce various waste streams,
including ash from solid fuel combustion or wastewater from boiler blowdown.
Proper waste management practices are implemented to handle and dispose of
these waste streams in an environmentally responsible manner.

1.2.9 Maintenance and Safety: Regular maintenance of boilers and associated

equipment is essential to ensure reliable and safe operation. Boiler house
personnel conduct routine inspections, cleaning, and repairs as necessary to
prevent breakdowns and ensure compliance with safety standards.

1.2.10 Energy Efficiency Optimization: Boiler houses often implement

energy efficiency measures such as heat recovery systems, cogeneration, or
combined heat and power (CHP) systems to maximize the utilization of heat
and minimize energy waste.

Overall, the operation of a boiler house involves a combination of fuel handling,

combustion, heat transfer, steam generation, control systems, emissions control,
waste management, maintenance, and energy efficiency measures to provide
reliable and efficient heat or steam production for various applications.

1.3 General Introduction:

Heat recovery from boiler blowdown water is a process aimed at capturing and
utilizing the thermal energy present in the hot blowdown water discharged from
boilers during routine blowdown operations. Boiler blowdown is necessary to
maintain water quality by removing impurities and dissolved solids, but it
results in the loss of valuable thermal energy contained in the hot water. Heat
recovery from boiler blowdown water offers a sustainable solution to harness
this wasted heat and repurpose it for various heating applications, thereby
improving energy efficiency and reducing operational costs.

3
1. Energy Conservation: Boiler blowdown water is typically discharged at high
temperatures, often exceeding 100°C (212°F), which represents a significant
amount of wasted thermal energy. Heat recovery systems are designed to
capture this heat energy and transfer it to a secondary fluid or process, such
as preheating boiler feedwater, domestic hot water, or space heating systems.
2. Operating Principle: Heat recovery from boiler blowdown water involves
the use of heat exchangers or heat recovery units to transfer heat from the
hot blowdown water to a cooler fluid, such as makeup water or return
condensate. The heat exchanger facilitates the transfer of thermal energy
while maintaining the separation of the blowdown water and the secondary
fluid to prevent contamination.
3. Benefits: Boiler blowdown water offers several benefits, including:
• Improved Energy Efficiency: By recovering and reusing the thermal
energy from blowdown water, facilities can reduce their energy
consumption and improve overall energy efficiency.
• Cost Savings: Heat recovery systems help reduce fuel consumption and
operating costs associated with heating water, resulting in potential cost
savings for facilities.
• Environmental Impact: Utilizing heat recovery from boiler blowdown
water helps reduce greenhouse gas emissions and environmental impact
by lowering energy consumption and dependence on fossil fuels.
4. Implementation Considerations: Factors such as boiler system design,
blowdown frequency, blowdown water temperature, flow rates, and the
availability of suitable heat recovery equipment need to be considered during
the implementation of heat recovery systems. Proper system sizing, design,
and integration are essential to maximize energy savings and ensure reliable
operation.

4
5. Regulatory Compliance: Heat recovery from boiler blowdown water may
also contribute to regulatory compliance with energy efficiency standards,
environmental regulations, and sustainability initiatives by demonstrating
efforts to reduce energy consumption and greenhouse gas emissions.

In summary, heat recovery from boiler blowdown water offers a sustainable

solution to capture and utilize wasted thermal energy, improve energy
efficiency, and reduce operational costs for facilities that rely on boiler
systems for heating and hot water generation.

5
 CHAPTER 2
LITERATURE SURVEY
2.1 INTRODUCTION:
During the span of this project work, we began by conducting a comprehensive literature
survey. This involved a review of many scholarly sources directly connected to our
project topic related to Heat Recovery System. By delving into academic journals, books,
and other credible online resources, we gained valuable insights into the current state of
progress within this field. The literature survey also proved useful in identifying any gaps
in research where our own work could contribute meaningfully. In brief, this exploration
of the relevant field strengthened the understanding in the Waste heat recovery system,
which made a big contribution to complete our Project work.
Boiler Blowdown: Boiler blowdown is the process of removing a portion of water from
a boiler to control the concentration of impurities. This water, being at high temperature
and pressure, contains significant thermal energy.
Heat Recovery Techniques: Common methods for heat recovery from boiler blowdown
include flash steam recovery, heat exchangers, and blowdown tanks.
Flash Steam Recovery: This method involves converting the high-pressure blowdown
water to lower pressure steam, which can be used for preheating boiler feedwater or other
processes. Studies have shown that flash steam recovery can significantly improve
overall boiler efficiency.

2.2 Literature survey:

Kulkarni et al. (2013) discuss about using a flash tank for steam recovery in a textile
mill resulted in energy savings of up to 12%.
Heat Exchangers: Plate heat exchangers or shell-and-tube heat exchangers are
commonly used to transfer heat from blowdown water to the incoming boiler feedwater.
This reduces the energy required to heat the feedwater, thereby improving boiler
efficiency.

6
A study by Smith et al. (2015) reported that using a plate heat exchanger for blowdown
heat recovery in a chemical plant resulted in a 5-7% improvement in boiler efficiency.

Thermodynamic and Economic Analyses:

Studies often include thermodynamic analyses to determine the potential energy savings
and efficiency improvements. Economic analyses are also conducted to assess the
payback period and return on investment for installing heat recovery systems.
An economic analysis by Jones and Robinson (2017) found that the payback period for
a blowdown heat recovery system in a medium-sized industrial boiler was less than two
years, with significant long-term cost savings.

Case Studies and Industrial Applications:

Case studies provide practical insights into the implementation and benefits of blowdown
heat recovery systems in various industries such as textiles, chemicals, and food
processing. A case study by Ahmed and Patel (2018) on a food processing plant
highlighted the installation of a heat recovery system that saved approximately 10% on
annual fuel costs and reduced CO2 emissions by 8%.

Technological Developments:
Advances in materials and heat exchanger design have improved the efficiency and
reliability of blowdown heat recovery systems. Innovations such as compact heat
exchangers and corrosion-resistant materials are particularly notable. A review by Zhang
et al. (2020) discussed recent advancements in compact heat exchanger technology and
their application in boiler blowdown heat recovery, highlighting improvements in heat
transfer efficiency and system durability.

7
Environmental Impact:
Heat recovery from boiler blowdown contributes to energy conservation and reduces
greenhouse gas emissions, supporting sustainability goals.
A study by Green and Brown (2021) assessed the environmental benefits of blowdown
heat recovery systems in reducing the carbon footprint of industrial operations.

2.3 CONCLUSION:
The literature provided us with some valuable insights about the Waste Heat Recovery
System and the factors which are involved in its Designing. Understanding this
information and gaining data from these literatures we have Completed our Project.

8
• CHAPTER 3

FLOW SHEET

Figure 3.1 Process Flow Sheet of the Boiler Blow down heat recovery
system in edibile oil refinery.

9
 CHAPTER 4
MATERIAL AND ENRGY BALANCE
4.1MASS BALANCE FOR BOILER:
Component Input Output SI Unit

Water 3.47 0 Kg s-1

Steam 0 3.47 Kg s-1

4.2 MASS BALANCE FOR HEAT EXCHANGER:

Component Input Output SI Unit

RO Water 3.47 3.47 Kg s-1

Blow Down Water 1.57 1.57 Kg s-1

4.3 ENERGY BALANCE FOR HEAT EXCHANGER:

Energy gained by RO Water = Energy lost by Blow down water

QRO = mRo x cpRo x (t2-t1) = 3.47x4178x(318-293) = 362441.5 J/s = 362.44 KW.

QBW = m x cp x (T1-T2 ) = mBW x 4187.5x(95-40) = 362.44 KW

mBW = 1.57 Kg s-1

10
4.4 MASS BALANCE FOR ECONOMIZER:

Component Input Output SI Unit

RO Water 3.47 3.47 Kg s-1

Flue Gas 2.336 2.336 Kg s-1

4.5 ENERGY BALANCE FOR ECONOMIZER:

Energy gain by RO Water = Energy lost by Flue gases

Energy gain by RO Water = m x cp x (t2-t1) = 546.941 KW

546.941= mgas x cp x (T1-T2) = mgas x 1.11168 x 210.55 mgas = 2.336 Kg s-1

4.6 ENERGY BALANCE FOR BOILER:

Energy in = 14,000 KJ KG-1

Enegy out = Energy utilized for steam + Energy carried by flue gas

Energy utilized for steam = mass flow rate of steam/mass of coal x (Enthalpy of steam
– Enthalpy of water) = 3.472/mass of coal x (2784-610.59)

Energy Carried by Flue Gas = mass flow rate of flue gas/mass of coal x specific heat
capacity of flue gases x (Flue gas in-room Temperature)

= 2.336/mass of coal x1.097x (364-40) =2.336/mass of coal x1.097 x324

14000 = 3.472/mass of coal x (2784-610.59) + 2.336/mass of coal x1.097 x324

Mass of coal required = 0.5983Kg s-1 = 51,700 Kg day-1.

11
 CHAPTER 5

HEAT EXCHANGER DESIGN

TABLE 5.1 DATA FOR THE HEAT EXCHANGER

Physical Properties for Blow Down Water

Physical Properties Values SI Unit

O
Inlet Temperature -Thi 95 C
O
Outlet Temperature -Tho 40 C
O
Average Temperature - 67.5 C
Tavg

Density -P 980.87 Kg m-3

Thermal Conductivity-k 0.657 W m-1.k-1

Specific heat-Cp 4187.5 J Kg-1.k-1

Viscosity -µh 0.00047 Kg m-1.s-1

Mass flow rate-mh 1.57 Kg s-1

Fouling Factor 0.00035 m2k J-1

Total Dissolved Solid- 3000 ppm

TDS

Ph-Blow Down Water 11.39 NA

Physical Properties for RO Water

Physical Properties Values SI Unit

O
Inlet Temperature-Tci 20 C
O
Outlet Temperature-Tco 45 C

12
 O
Average Temperature - 32.5 C
Tavg

Density-p 996.875 Kg m3

Thermal Conductivity-k 0.6166 W m-1.k-1

Specific heat-Cp 4178 J kg-1.k-1

Viscosity-µc 0.00065 Kg m-1.s-1

Mass flow rate-mc 3.47 Kg s-1

Fouling Factor 0.00018 m2kJ-1

Total Dissolved Solid- 35.6 ppm

TDS

Ph-RO Water 6.91 NA

ASSUMPTIONS SI UNIT

U – Overall Heat Transfer 800 W m-2 k-1

Coefficient

Material of Construction Carbon steel NA

Thermal conductivity 45 W m-1 k-1

5.2 DIMENSIONS OF SHELL AND TUBE HEAT EXCHANGER

Tube Values SI Unit Shell Values SI Unit

Di 12 mm Ds 365.59 mm

Do 16 mm De 11.36 mm

Length - L 1.83 m

Thickness 2 mm

13
5.3 Heat Duty:

Q=mRO ×cp×(t2-t1)

= 3.47×4178×(318-293) =362441.5W = 3,62.44 KW

5.4 Compute LMTD:

ΔTLMTD = (95-45)-(40-20)/(ln((95-45)/(40-20)))

= 30/0.9162 = 32.74 OC

One shell pass and 2 tube passes

P = 45-20/95-20 =0.33

R = 95-40/45-20 = 2.2

FT = 0.85

ΔTm = FT ×LMTD =27.82 OC

5.5 Area:

Heat Transfer Area = Q/(U×ΔTm) = 362.441×1000/ (800×27.829) = 16.2798 m2

Area of one tube = π×Do×L = 1.83×16×10-3 = 0.09193 m2

5.6 No.of.tubes:

No. of. Tubes = Heat Transfer area / area of one tube = 16.2798/0.09193 = 177 Tubes

5.7 Shell Diameter :

Bundle diameter, Db = Do (Nt/k) (1/n) = 16(177.0893/0.249) (1/2.207)

Db= 313.5947 mm

Split Ring floating head

Bundle Clearance, Dc = 52mm

Shell Diameter, Ds = Db+Dc = 313.5947+52 = 365.5947mm

14
5.8 Tube side Heat Transfer Coefficient:

Cross sectional area of Tubes = π/4×(12)2 = 113.09 mm2

Tubes Per Pass = 177/2 = 89

Water Mass Velocity = mBd /crossectional area = 1.571/0.010

Water Mass velocity =15.71 kg s-1m2

Water Linear Velocity = 157.1/980.875 = 0.160 m/s

Nre = D×V×P/µ = 980.875×0.160×12×10-3/0.00047 = 4011.0638

Npr = µ×cp/k = 0.00047×4187.5/0.657 = 2.99

Nnu = Jh×(Pr)0.33×Re×(µ/µw)0.14 ,jh= 8x10-3

hi = 0.657/(12x10-3) x 8x10-3x4011.0638 x (2.99)0.33 = 2,521.7 W m-2.k-1

5.9 Shell Side heat Transfer Coefficient:

Baffle spacing = Ds/5 = 365.59/5 = 73.118mm

Tube Pitch = 1.25×Do = 20mm

Cross sectional area, As = (Pt-Do)/ Pt × Ds×Bs = (20-16)/20×365.59×73.118×10-6

=0.0053m2

Mass Velocity, Gs = m/As = 3.47/ 0.0053 = 654.71kg/sm2

Linear mass velocity, v = Gs/P = 654.71/996.875 = 0.656m/s

De = 1.1/do (Pt2-0.917do2) = 1.1/16(202-0.917(16)2) = 11.36mm

Nre = De×V×p/µ = 11.36×10-3 ×0.656×996.875/0.000653 = 11,389.74

Npr = cp×µ/k = 4178×0.000653/0.6166 = 4.4246

hs = k/De × Jh× Nre×(Npr)1/3×(µ/µw)0.14 = 0.6166/11.36×10-3× 11,389×4.243(1/3)×4×10-3

hs = 4059.6662 W m-2 k-1

15
5.10 Overall Heat Transfer Coefficient:

1/Uo = 1/hs + 1/Rdo + Do ln(Do/Di)/2×km + Do/Di × 1/Rdi + (Do/Di) ×1/hi

1/Uo = 0.000246 + 0.00018 + 0.0000511+0.000470 + 0.000528

1/Uo = 0.0014706

Uo = 867.33W m-2.K-1

%ERROR= (Ucal – Uass/Uass)×100 = (867.33-800/800)×100 = 8.4%

5.11 Tube Side Pressure Drop :

ΔPt = 2(8×jh×(L/Di)+2.5)pu2 /2

=2×8×2×10-3×(1.83×10-3 /12) +2.5 ×980.875 × 0.16022/2

= 62,933pa(10psi)

5.12 Shell Side Pressure Drop:

ΔPs= 8×jh×(Ds/de)×(L/lB)Pu2/2

= 89,838 pa(13psi)

16
5.13 Design Summary:

DESIGN RESULTS VALUES SI UNIT

Heat Duty-Q 362.441 KW

Heat Transfer Area-A 16.27 m2

No.of.tubes 177 NA

Tube Side Heat Transfer 2521.7 W m-2.k-1

Coefficient

Shell Side Heat Transfer 4059.66 W m-2.k-1

Coefficient

Overall Heat Transfer 867.33 W m-2.k-1

Coefficient

Tube side Pressure Drop 10 Psi

Shell Side Pressure Drop 13 Psi

17
 CHAPTER 6
ECONOMIZER DESIGN:
TABLE 6.1 DATA FOR ECONOMIZER
Physical Properties For water
Properties Values SI Unit
o
water inlet temperature 108 C
o
Water outlet temperature 145 C
O
Average water Temperture 126.5 C
Density 939.475 Kg m-3
Thermal Conductivity 0.68461 Wm-1.k-1
Viscosity 2.2×10-4 Kg m-1.s-1
Specific heat 4.260 KJ kg-1
Mass flow rate 3.47 Kg s-1
Fouling Factor 0.002 m2.oC W-1
Physical Properties for Flue Gases
O
Gas inlet Temperature 364 C
O
Gas outlet Temperature 153.45 C
O
Average Gas Temperature 258.725 C
Density 671.070 Kg m3
Thermal Conductivity 0.04497 W m-1.k-1
Viscosity 26.672×10-6 Kg m-1.s-1
Specific heat 1.1116 KJ kg-1
Mass flow rate 2.336 Kg s-1
Fouling Factor 0.000179 m2.OC W-1
MATERIAL DATA FOR ECONOMIZER
Material of Construction Mild Steel NA
Thermal conductivity of 55 W m-1.k-1
Mild Steel
TUBE DIMENSIONS
Outer Diameter 0.038 m
18
Inner Diameter 0.030 m
Length of the tube 0.004 m

6.2 Heat Duty:

Q = m×cp×ΔT
= 3.47×4.260×(145-108)
= 546.941KJ s-1

6.3 ΔTLMTD :
ΔTLMTD = (153.45-108) -(364-145)/ln (153.45-108/364-145)
=173.55/ln (1.572) = 110.40 oC

6.4 Tube Area:

A=π/4 × Di2 = 3.14/4 × (0.03)2
= 7.0686×10-4 m2

6.5 No. of. Tubes:

Nw = m/p×A×V = 3.47/939.475×7.0686×10-4×0.5
Nw = 10 tubes

6.6 Pitch of Tubes:

ST = Aff/L×Nw + do = 6.232/ (4×17) + 0.038 = 0.13 m

6.7 Width of the Tubes:

Width =ST×Nw
= 0.13×10.45 = 1.3585m

19
6.8 Heat Transfer Coefficient for tube side :

Npr = µ×cp/k = 2.2×10-4×4.260×1000 / 0.68461

= 1.368
Nre = P×V×Di / µ = 939.475×0.5×0.03 / 2.2×10-4
= 64,055.113
Nnu = 0.023(Re)0.8×(pr)0.4
Nnu = 182.55
hi = 182.55×0.68461/0.03 = 4166.07W m-2.k-1

6.9 Heat Transfer Coefficient for gas side:

Npr = 0.6583
Nre = 4×2.336/3.14×0.038×26.672×10-6 =29,360
Nnu = 0.33(Re)0.6×(pr)0.33 =0.33×293600.6×0.6580.33 = 137.778
ho = 137.778×0.038/0.04497 = 118.99070 W m-2.k-1

6.10 Overall Heat Transfer Coefficient:

1/U = do/hidi + 1/ho + do/2π×k×L ×ln(do/di) +ffid +ffod

= 0.038/0.030×4166.07 + 1/118.990+
0.038/2π×55×4×ln(0.038/0.030)+0.002+0.000179
= 0.0021855017
U = 457.56 Wm-2.k-1.

6.11 Area Required:

A = Q/U×ΔTLMTD = 546041/(457.56×110.40) =10.808m2

20
6.12 Design Summary:
DESIGN RESULTS VALUES SI UNIT
Heat Duty 546.941 KW
O
LMTD 110.40 C
No. of. Tubes 10.45 NA
Pitch of the Tubes 0.13 m
Width of the Tube 1.3585 m
Tube side heat Transfer 4166.07 W m-2.k-1
Coefficient
Heat transfer coefficient 118.990 W m-2.k-1
for shell side
Overall Heat Transfer 457.56 W m-2.k-1
Coefficient
Area Required 10.808 m2

21
 CHAPTER 7
FIRE TUBE BOILER DESIGN
TABLE 7.1 DATA FOR FIRE TUBE BOILER
DATA VALUE SI UNIT
o
Feed water Temp 145 C
O
Operating Temp 180 C
O
Steam Exit Temp 190 C
o
Furnace Temp 540 C
O
Flue Gas inlet temp 364 C
Boiler length 5 m
Boiler capacity 25000 litres
Furnace diameter 0.8 m
Air thermal conductivity 75 Wm-1.k-1
Water thermal
700 W m-1.k-1
Conductivity
Material of Construction Carbon steel NA
Thermal Conductivity of
48 W m-1.k-1
Carbon steel
Outer Tube Diameter 0.0560 m
Inner Tube Diameter 0.0500 m
Tube Thickness 0.003048 m
Main shell Thickness 0.00012 m
Drum Length 0.870 m
Drum Diameter 0.250 m
Feed Water Flow rate 3.472 Kg s-1
Steam Flow rate 3.472 Kg s-1

22
7.2 Mass flow rate of steam, ms = 3.47kg s-1

7.3Third pass temp, T3=Operating Temp + 100 = 180+100 =280oC

7.4 Second Pass Temp, T2= furnace temp+third pass temp = 540+280/2 = 410 oC
7.5 Air temp at 2nd pass, Tair 2 = furnace temp + second pass temp/2 = 540+410/2
= 475oC

7.6 Air temp at 3rd pass, Tair 3 = third pass temp + second pass temp /2 = 280+410/2
= 345OC

7.7 Thermal Conduction Through pass 2,

Q2/A2 = Tair2 – T opt temp / (1/hair + t tube/k tube + 1/hwater)
= 475-180/ (1/75 + 0.003048/48 + 1/700)
= 295 / (0.013+ 6.35×10-5 + 1.423×10-3)
Q2/ A2 = 20,355.95 W m-2
7.8 Thermal Conduction Through Pass 3,
Q3/A3 = Tair3 – Topt temp / (1/hair + ttube / k Tube + 1/hwater)
= 345-180/0.013 +6.358×10-5+1.428×10-3)
= 11,385.98 W m-2
7.9 Heat Input Required by the Boiler
Qin = m (hsteam-hFeed Water) = 3.472(2784.3-610.59)
= 7547.12 kw m-2
hsteam at 190 oC =2784.3 KJ Kg-1
h water at 145 oC = 610.59 KJ Kg-1

7.10 Heat at Pass 2,

Q2 = m(h2-hs)
= 3.472(3436.625 – 2784.3) = 2264.8kW
23
7.11 Heat at Pass 3,
Q3 = m(h3-hs)
= 3.472(3167.85 – 2184.3)
= 1331.68 Kw

7.12Area at pass 2,
Q2/A2 = 20.355Kw m-2
A2 = 2,264.8/20.355
A2=111.26m2

7.13 Surface Area,

Surface Area = 2×3.14×r×h + 2×3.14×r2
= 2×3.14×0.025×5 + 2×3.14×0.0252
= 0.78932 m2

7.14 Total No. of. Tubes in pass2(fire tube boiler)

= A2 at pass2/surface area
=111.26/0.78932
= 141 tubes

7.15 Total no. of, tubes in pass 3(fire tube boiler)

= A3 at pass 3 / surface area
= 116.967/0.789
= 148 tubes

7.16 Total No. Of. Tubes = 141+148 = 289 tubes

24
7.17 Design Summary Of Fire Tube Boiler:
Design Results Values SI UNIT
2nd pass temp 475 O
C
3rd pass temp 345 O
C
Thermal Conduction, Pass
20.355 Kw m-2
2
Thermal Conduction,
11.385 Kw m-2
Pass3
Heat Required By The
7547.12 KW
Boiler, Qin
Surface Area 0.78932 m2
No. Of. Tubes In Pass 2 141.01 NA
No. Of. Tubes In Pass3 148.18 NA
Total No. Of .Tubes 289.19 NA

25
 CHAPTER 8
PROCESS SAFETY

Safety department is a very important and necessary department in every industry

especially in chemical process industries without safety the industry cannot function
properly. Safety means to give safety to men and machines by preventing accidents in an
industry. Accidents may be defining as unexpected harmful events which may causes
injury to persons of damages property. If the accidents are not prevented, it will result in
the following,

• Reduced Production

• Increased cost

• Wastage in Resource

• Human sufferings

Therefore, accidents must be prevented in every industry.

8.1 CAUSES OF ACCIDENTS:

Analysis of accidents in different industries shows 88% of accidents are caused by human
causes 10% of the accidents are caused by mechanical failures and 21% accidents are
caused by nature. The main causes of accidents are,

• Unsafe condition

• Unsafe activities

• Environments factors

• Human factor

8.2 PERSONAL PROTECTIVE EQUIPMENT (PPE) NEEDED ON THE SPOT:

The following are the some of the important personal safety devices which may be used
in the industry.

• Hard Hat: Protects the head from falling objects and bumps in confined spaces.

26
 • Safety Glasses/Goggles: Shields the eyes from steam, hot water, and debris.

• Face Shield: Provides additional protection for the face from splashes and burns.

• Heat-Resistant Gloves: Protects hands and forearms from burns when handling hot
equipment or materials.

• Safety Boots: Steel-toed boots provide protection against falling objects and
hazards on the ground.

• Heat-Resistant Clothing: Such as coveralls or aprons made from materials like

Nomex or Kevlar to protect against heat and flames.

• Respiratory Protection: Depending on the environment, respirators or masks may

be necessary to protect against airborne particles or gases.

• Ear Protection: If working in noisy environments, earplugs or earmuffs can prevent

hearing damage.

• Fall Protection Equipment: For workers accessing elevated areas, such as ladders
or platforms, harnesses and lanyards should be used.

• Safety Harness: Used in situations where there is a risk of falling, such as working
at heights or in confined spaces.

It's important for workers in boiler houses to be properly trained in the use of PPE and to
regularly inspect and maintain their equipment.

8.3MATERIAL SAFETY DATA SHEET(MSDS) FOR DOSING AGENT USED IN

BOILER:

8.3.1. .Chemical Product and Company Identification:

Product Name: Cyclohexylamine

Chemical Formula: C6H13N

COMPANY IDENTIFICATION

Supplier: Pure Chemicals Group. CHENNAI

27
8.3.2.Hazards Identification :

Potential Acute Health Effects: Very hazardous in case of skin contact (irritant), of eye
contact (irritant), of ingestion, of inhalation. Hazardous in case of skin contact
(permeator). Corrosive to skin and eyes on contact. Liquid or spray mist may produce
tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract.
Skin contact may produce burns. Inhalation of the spray mist may produce severe
irritation of respiratory tract, characterized by coughing, choking, or shortness of breath.
Severe over-exposure can result in death. Inflammation of the eye is characterized by
redness, watering, and itching. Skin inflammation is characterized by itching, scaling,
reddening, or, occasionally.

Potential Chronic Health Effects: The substance is toxic to the nervous system, upper
respiratory tract. Repeated or prolonged exposure to the substance can produce target
organs damage. Repeated or prolonged contact with spray mist may produce chronic eye
irritation and severe skin irritation. Repeated or prolonged exposure to spray mist may
produce respiratory tract irritation leading to frequent attacks of bronchialinfection.

8.3.3.First Aid Measures :

Eye Contact: Check for and remove any contact lenses. Immediately flush eyes with
running water for at least 15 minutes, keeping eyelids open. Cold water may be used. Do
not use an eye ointment. Seek medical attention.

Skin Contact: If the chemical got onto the clothed portion of the body, remove the
contaminated clothes as quickly as possible, protecting your own hands and body. Place
the victim under a deluge shower. If the chemical got on the victim's exposed skin, such
as the hands: Gently and thoroughly wash the contaminated skin with running water and
non-abrasive soap. Be particularly careful to clean folds, crevices, creases and groin.
Cold water may be used. If irritation persists, seek medical attention. Wash contaminated
clothing before reusing.

Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin
with an anti- bacterial cream. Seek immediate medical attention.

28
Inhalation: Allow the victim to rest in a well ventilated area. Seek immediate medical
attention.

Ingestion: Do not induce vomiting. Examine the lips and mouth to ascertain whether the
tissues are damaged, a possible indication that the toxic material was ingested; the
absence of such signs, however, is not conclusive. Loosen tight clothing such as a collar,
tie, belt or waistband. If the victim is not breathing, perform mouth-to-mouth
resuscitation. Seek immediate medical attention.

8.3.4.Fire Fighting Measures:

Flammability of the Product : Flammable.

Auto-Ignition Temperature : 293°C (559.4°F)

Fire Fighting Media and Instructions: Flammable liquid, soluble or dispersed in water.

SMALLFIRE: Use DRY chemical powder. LARGE FIRE: Use alcohol foam, water
spray or fog. Cool containing vessels with water jet in order to prevent pressure build-
up, autoignition or explosion.

8.3.5. Accidental Release Measures :

Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place
in an appropriate waste disposal container. If necessary: Neutralize the residue with a
dilute solution of acetic acid.

Large Spill: Flammable liquid. Corrosive liquid. Keep away from heat. Keep away from
sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-
combustible material. Do not get water inside container. Do not touch spilled material.
Use water spray curtain to divert vapor drift. Prevent entry into sewers, basements or
confined areas; dike if needed. Eliminate all ignition sources. Call for assistance on
disposal. Neutralize the residue with a dilute solution of acetic acid. Be careful that the
product is not present at a concentration level above TLV. Check TLV on the MSDS and
with local authorities.

29
8.3.6. Handling and Storage:

Precautions: Keep locked up Keep container dry. Keep away from heat. Keep away from
sources of ignition. Ground all equipment containing material. Do not ingest. Do not
breathe gas/fumes/ vapour/spray. Never add water to this product In case of insufficient
ventilation, wear suitable respiratory equipment If ingested, seek medical advice
immediately and show the container or the label. Avoid contact with skin and eyes.

Storage: Flammable materials should be stored in a separate safety storage cabinet or

room. Keep away from heat. Keep away from sources of ignition. Keep container tightly
closed. Keep in a cool, well-ventilated place. Ground all equipment containing material.
A refrigerated room would be preferable for materials with a flash point lower than
37.8°C (100°F).

8.3.7.Exposure Controls/Personal Protection:

Engineering Controls: Provide exhaust ventilation or other engineering controls to keep

the airborne concentrations of vapors below their respective threshold limit value. Ensure
that eyewash stations and safety showers are proximal to the work-station location.

Personal Protection: Face shield. Full suit. Vapor respirator. Be sure to use an
approved/certified respirator or equivalent. Gloves. Boots.

Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator.
Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation
of the product. Suggested protective clothing might not be sufficient; consult a specialist
BEFORE handling this product.

Exposure Limits: TWA: 10 (ppm) TWA: 40 (mg/m3)Consult local authorities for

acceptable exposure limits.

8.3.8. Physical and Chemical Properties:

Physical state and appearance : Liquid.

Odor : Fish. Amine like

30
 Molecular Weight : 99.17 g/mole

Color : Colorless to light yellow.

pH : 11

Boiling Point : 134.5°C (274.1°F)

Melting Point : -17.7°C (0.1°F)

Specific Gravity : 0.8647

Vapor Pressure : 10.7 mm of Hg.

8.3.9.Toxicological Information:

Routes of Entry: Dermal contact. Eye contact. Inhalation. Ingestion.

Toxicity to Animals: Acute oral toxicity (LD50): 156 mg/kg [Rat].

Acute dermal toxicity: (LD50): 276 mg/kg [Rabbit].

Chronic Effects on Humans: CARCINOGENIC EFFECTS: A4 (Not classifiable for

human or animal.) by ACGIH. The substance is toxic to the nervous system, upper
respiratory tract.

Other Toxic Effects on Humans: Very hazardous in case of skin contact (irritant), of
ingestion, of inhalation. Hazardous in case of skin contact.

8.3.10. Disposal Considerations: Waste Disposal: Waste must be disposed of in

accordance with federal, state and local environmental control regulations.

31
 CHAPTER 9
PROCESS ECONOMICS
The following calculations are performed to determine the payback period and rate of
return for the Boiler plant.
9.1 Estimation of the direct cost
• Equipment cost
• Land cost
• Installation Cost
• Piping and Instrumentation cost.
9.1.1 Estimation of Equipment cost
S.no Unit No. of units Rate/unit Cost in Rs:
Shell and Tube
1. 1 15,000,00 15,000,00
Heat Exchanger

Total EquipmentCost:15,00,000

9.1.2 Estimation of Direct Cost:

S.no Direct Cost Total cost in Rs.
1 Process Equipment Cost 15,00,000
2 Installation Cost (20% EC) 3,00,000
3 Instrumentation Cost(15%EC) 2,25,000
Piping and pumping
4 2,25,000
Cost(15%EC)
5 Electrical Cost (10%EC) 1,50,000
6 Building Cost(50%EC) 7,50,000
7 Land Cost(50%EC) 7,50,000
8 Service facilities(10%EC) 1,50,000
Total :40,50,000
Working capital = 25% Direct cost = Rs.10,12,500

32
Start Up capital = 10% Direct cost = Rs.4,05,000
Total Expenditure = Direct cost + Working Cost + Start up capital = Rs.69,67,500

9.2. Working Capital cost

• Raw material cost
• Utilities cost
• Salaries for employers
• Miscellaneous Cost
9.2.1 Raw material cost
Cost of coal after project 18,922,200 kg/year = 60,55,10,400
Cost of coal before project 21,960,000 kg/year = 70,27,20,000
9.2.2 Utilities cost:
S.no Utilities cost Cost/year in Rs.
1. Electricity 50,00,000
TOTAL 50,00,000

9.2.3 Operating Labour Cost:

Annual salary Total Salary
S.NO Post No. of. Post
in Rs in RS
1. Head of Department 1 12,00,000 12,00,000
2. Manager 1 7,00,000 7,00,000
3. Junior Engineer 5 4,80,000 24,00,000
4. Skilled labour 15 2,50,000 37,50,000
Helper/Unskilled
5. 10 1,10,000 11,00,000
Labour

TOTAL: 91,50,000

33
9.2.4 Miscellaneous cost:
S.no Miscellaneous cost Cost/year in Rs:
1. Maintenance, Repair Cost (6% DC) 2,43,000
2. Equipment Depreciation (10%DC) 4,05,000
3. Insurance(1%DC) 40500
TOTAL 6,88,500

Working Capital = Raw Material Cost + Utility Cost + Labour Cost+ Miscellaneous Cost
= 60,55,10,400 + 50,00,000 + 91,50,000 + 6,88,500 = Rs.61,58,48,900

9.3 Payback Time:

Cost of coal before project = Rs.70,27,20,000
Cost of coal after project = Rs.60,55,10,400
Gross Profit = 70,27,20,000 – 60,55,10,400 = Rs.9,72,09,600
Tax = 40% of GrossProfit = Rs.3,88,83,840
Net income = 9,72,09,600 - 3,88,83,840 = 5,83,25,760
Pay back time = Fixed capital investment / (Total income – working capital – Tax)
= 69,67,500/ (9,72,09,600-61,58,48,900-3,88,83,840)
= 4.985 = 5 years

9.4 Rate of Return :

Rate of Return = (Net Profitx100)/Total Capital Investment
= 5,83,25,760x100/69,67,500 = 7.78%

34
 CHAPTER 10
CONCLUSION

The Energy was recovered from the boiler blow down water by designing shell
and tube heat exchanger containing 177 tubes, heat transfer area 16.27. By
recovering energy from the boiler blow down water, the coal consumption was
reduced to 51,700 kg/day. Around 8,300 coal was saved, the cost estimation has
done for the boiler house and the payback period for the boiler house was
estimated.

35
 CHAPTER 11
REFERENCE

1. Bengtson H. (2010). “ Heat Exchanger Design”.

2. Green, D. W & Robert H. P. (1997). Chemical Engineers’ Handbook,
(Seventh Edition).
3. Zhang H, Wang H, Zhu X, Qiu YJ, Li K, Chen R, Liao Q. “A review of
waste heat recovery technologies towards molten slag in steel industry.
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4. Williams, J. B., Thomas W & Dong-Hoon H. (2002). “ Heat Exchanger”,
1st edition.
5. Coulson & Richardson’s “CHEMICAL ENGINEERING VOLUME 6
FOURTH EDITION” Chemical Engineering Design R.K.SINNOTT,
Year 2005.
6. Kulkarni, V., et al. (2013). "Energy Savings Through Steam Recovery in
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7. Smith, A., et al. (2015). "Efficiency Improvement in Chemical Plant
Boilers Using Heat Exchangers." Energy and Fuels.
8. Jones, R., & Robinson, P. (2017). "Economic Analysis of Blowdown Heat
Recovery Systems." Industrial Energy Review.
9. Ahmed, M., & Patel, N. (2018). "Case Study: Blowdown Heat Recovery
in Food Processing." Journal of Energy Management.
10.Zhang, H., et al. (2020). "Advancements in Compact Heat Exchanger
Technology for Industrial Applications." Applied Thermal Engineering.
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Systems in Industrial Boilers." Journal of Sustainable Engineering.

36