Proposed Modifications in Boiler Feed Tank for Improved Efficiency

 
Proposed Modifications
in
Boiler Feed Tank
 
By:
D K Singhal
deveshksinghal@gmail.com
 
Conventional Boiler Feed Tank
 
The fundamental object of having a boiler
feed tank is to ensure uninterrupted
supply of boiler feed water to the boiler.
 
2
 
deveshksinghal@gmail.com
 
Problems with Existing Tank
 
A boiler feed water tank is generally a
huge tank suitable of storing sufficient
feed water for 3-4 hours of operation.
That is why, it cannot be kept pressurized
(or fully closed) easily and economically.
With open tank, flash vapors coming out
result in significant energy losses.
 
3
 
deveshksinghal@gmail.com
 
Problems with Existing Tank
 
Big size results in increased insulation
costs.
Furthermore, as the surface area is high,
heat losses are significant even after good
insulation.
 
4
 
deveshksinghal@gmail.com
 
Proposed Approach
 
Proposed approach uses two separate
tanks connected to each other.
One tank contains cold makeup water,
and needs no insulation.
The second tank is relatively small, which
can be insulated easily and efficiently.
 
5
 
deveshksinghal@gmail.com
 
Cold Make Up Water Tank
 
This tank can be made suitable sized to
hold adequate make up water in case
there is inadequate condensate supply.
The elevation of this tank is as per the
boiler designer recommendations, as its
head will give sufficient NPSH to feed
pump.
 
6
 
deveshksinghal@gmail.com
 
New Small Hot Condensate Tank
 
The proposed small hot condensate tank
is a small tank strategically placed in the
circuit.
Its capacity should be adequate for
typically 15-20 minutes of operation.
As the size is substantially small, it can be
properly insulated.
 
7
 
deveshksinghal@gmail.com
 
New Small Hot Condensate Tank
 
This tank has an outlet to boiler feed
pump near the top.
The make up water enters the tank at the
bottom.
At extreme top, there is a small venting
line that vents flash vapors generated by
condensate to the top of cold make up
water tank.
 
8
 
deveshksinghal@gmail.com
 
The Scheme
 
9
 
deveshksinghal@gmail.com
 
Small Tank
 
The small tank is a closed vessel in which
hot condensate enters from the top.
The condensate is removed from top,
thus, hotter condensate goes to boiler
feed pump.
In case condensate supply is lesser than
that required by boiler feed pump, cold
makeup water enters from the bottom.
 
10
 
deveshksinghal@gmail.com
 
Small Tank
 
Thus, the cold water enters the boiler if
and only if all hot condensate has been
consumed.
As the make up supply is without a valve,
there is no risk of tank becoming empty
and dry run of boiler feed pump.
 
11
 
deveshksinghal@gmail.com
 
Small Tank
 
In case the boiler feed pump is off, and
condensate is coming from process, the
same pushes the colder water at the
bottom of small tank back to the main
feed water tank through make up line.
Even if some hot condensate is pushed
back through this line, this returns back
when the pump is restarted.
 
12
 
deveshksinghal@gmail.com
 
Insulation
 
The small tank and the make up water
line (as it may get flooded with hot
condensate occasionally) needs insulation.
Being this tank much smaller, you can
insulate it well.
Typically, the insulation costs are reduced
to just 15-20% only.
 
13
 
deveshksinghal@gmail.com
 
Main Feed Water Tank
 
This way, the main feed water tank
remains at lower temperature, and hence
no insulation is required.
 
14
 
deveshksinghal@gmail.com
 
Thank You.
 
D K Singhal
+91-9412713426
deveshksinghal@gmail.com
 
15
 
deveshksinghal@gmail.com
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The proposed modifications in the boiler feed tank aim to enhance efficiency by utilizing two separate tanks for cold makeup water and hot condensate. This innovative approach addresses the limitations of existing large tanks, reducing energy losses and insulation costs. By incorporating a small hot condensate tank and a cold makeup water tank, the system can provide uninterrupted feed water supply to the boiler with optimized insulation and energy usage.


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  1. Proposed Modifications in Boiler Feed Tank By: D K Singhal deveshksinghal@gmail.com

  2. Conventional Boiler Feed Tank The fundamental object of having a boiler feed tank is to ensure uninterrupted supply of boiler feed water to the boiler. deveshksinghal@gmail.com 2

  3. Problems with Existing Tank A boiler feed water tank is generally a huge tank suitable of storing sufficient feed water for 3-4 hours of operation. That is why, it cannot be kept pressurized (or fully closed) easily and economically. With open tank, flash vapors coming out result in significant energy losses. deveshksinghal@gmail.com 3

  4. Problems with Existing Tank Big size results in increased insulation costs. Furthermore, as the surface area is high, heat losses are significant even after good insulation. deveshksinghal@gmail.com 4

  5. Proposed Approach Proposed approach uses two separate tanks connected to each other. One tank contains cold makeup water, and needs no insulation. The second tank is relatively small, which can be insulated easily and efficiently. deveshksinghal@gmail.com 5

  6. Cold Make Up Water Tank This tank can be made suitable sized to hold adequate make up water in case there is inadequate condensate supply. The elevation of this tank is as per the boiler designer recommendations, as its head will give sufficient NPSH to feed pump. deveshksinghal@gmail.com 6

  7. New Small Hot Condensate Tank The proposed small hot condensate tank is a small tank strategically placed in the circuit. Its capacity should be adequate for typically 15-20 minutes of operation. As the size is substantially small, it can be properly insulated. deveshksinghal@gmail.com 7

  8. New Small Hot Condensate Tank This tank has an outlet to boiler feed pump near the top. The make up water enters the tank at the bottom. At extreme top, there is a small venting line that vents flash vapors generated by condensate to the top of cold make up water tank. deveshksinghal@gmail.com 8

  9. The Scheme deveshksinghal@gmail.com 9

  10. Small Tank The small tank is a closed vessel in which hot condensate enters from the top. The condensate is removed from top, thus, hotter condensate goes to boiler feed pump. In case condensate supply is lesser than that required by boiler feed pump, cold makeup water enters from the bottom. deveshksinghal@gmail.com 10

  11. Small Tank Thus, the cold water enters the boiler if and only if all hot condensate has been consumed. As the make up supply is without a valve, there is no risk of tank becoming empty and dry run of boiler feed pump. deveshksinghal@gmail.com 11

  12. Small Tank In case the boiler feed pump is off, and condensate is coming from process, the same pushes the colder water at the bottom of small tank back to the main feed water tank through make up line. Even if some hot condensate is pushed back through this line, this returns back when the pump is restarted. deveshksinghal@gmail.com 12

  13. Insulation The small tank and the make up water line (as it may get flooded with hot condensate occasionally) needs insulation. Being this tank much smaller, you can insulate it well. Typically, the insulation costs are reduced to just 15-20% only. deveshksinghal@gmail.com 13

  14. Main Feed Water Tank This way, the main feed water tank remains at lower temperature, and hence no insulation is required. deveshksinghal@gmail.com 14

  15. Thank You. D K Singhal +91-9412713426 deveshksinghal@gmail.com deveshksinghal@gmail.com 15

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