ANNALS of Faculty Engineering Hunedoara – International Journal

 ANNALS of Faculty Engineering Hunedoara – International Journal of Engineering Tome XII [2014] – Fascicule 3 [August] ISSN: 1584‐2673 [CD‐Rom, online] a free‐access multidisciplinary publication of the Faculty of Engineering Hunedoara Damjan STANOJEVIC, 2. Gradimir DANON, 3. Slobodan STEFANOVIC, 4. Nenad JANJIC 1. OBTAIN THE NECESSARY AMOUNT OF HEAT FROM BIOMASS IN BOILER FACTORY PLANT ʺSIMPOʺ IN VRANJE Higher School of Applied Professional Studies, Vranje, SERBIA Faculty of Forestry, Belgrade, SERBIA 1,3,4. 2
Abstract: This paper presents a method of obtaining heat in a boiler for producing saturated steam from biomass. The fuel used to generate heat is a sawdust. Sawdust is in certain quantities from the silo fed into the firebox, where its combustion. Sawdust comes from four plants, namely: the sawmill, the crusher, the final processing of massive and machining particle board. The maximum pressure that the boiler can produce is 8 bar, however, the pressure of saturated steam produced never exceeds 5 bar, depending on your needs and can move about 2‐3 bars. Steam temperature range from 120 to 150ΕC. Saturated steam system piping comes to production facilities and certain technological operations. Complete process for automatic operation of the boiler is controlled by PLC system. Keywords: biomass, sawdustand, heating energy 1. INTRODUCTION – OBJECT OF THE RESEARCH The study was carried out in the boiler plant (Figure 1) in company „Simpo“ a.d. Vranje. The company was unique in the European furniture industry for its unifying strategic concept phase of the manufacturing process ‐ from raw materials to final product within a business group. Figure 1: Schematic of the boiler plant sawdust in company Simpo a.d. Vranje 1. The flow of sawdust, 2. Cyclone, 3. Dispenser, 4. Worm conveyor, 5. Grating, 6. The primary air fan, 7. The flow of primary air to the bottom of the firebox, 8. The flow of primary air in the upper part of the combustion chamber, 9. Fan of secondary air, 10. The flow of secondary air, 11. Drain valve, 12. Ventilator for recycled air, 13. Recycled air inlet, 14. Flue piping, 15. A fan for the smoke, 16. A cyclone for separating the ash from the air, 17. Ashtray, 18. Chimney © copyright Faculty of Engineering ‐ Hunedoara, University POLITEHNICA Timisoara
195 | Fascicule 3 ISSN: 1584-2673 [CD-Rom, online] The approach based on various related entities that complement each other does business nezavisinim, safe, efficient and economical. The fact that SIMPO produces largest part of the material included in the single sets or any other product, it allows full control over the pace of the production process and the quality of each finished product. Thanks to this business concept, SIMPO provides quality controlled to the highest international standards, competitive prices, flexible delivery times and flexibility in relation to the specific requirements. In the factory is located the building boiler room in which are placed boiler fuel oil and sawdust. Manufacturer of the boiler is a German company Weiss. Sawdust is obtained as a by‐product of the processing of logs to the mill (Figure 2), with the final touches and massive plates, and crushing foreskins and other bulky waste produced by processing wood (Figure 3). Figure 2. Sawmill Simpo a.d. Vranje Figure 3. Crusher by which is obtained from the foreskins sawdust 1.1. Boiler plant In the building is situated the boiler brand ʺOmical‐Weissʺ (Figure 4), which is used to generate heat. Saturated water vapor in the gaseous state has a pressure for a maximum of 5 bar and a temperature of about 150 ˚C and it is used to heat the entire complex, the factory of decorative fabric (Dekor), for the operation of ʺfurnitureʺ, for the artificial drying of lumberThe boiler is equipped with all the necessary equipment for the safe and efficient operation of the plant. Monitoring of boiler plants perform two professional perpetrators per shift. From the silo (Figure 5) sawdust using gear delivered automatically. Dosage boiler is done automatically by a dispenser which sawdust dosed in sufficient quantities. Dispenser with the help of a screw conveyor transport the sawdust into the firebox. Measuring devices boiler directly served in the process of monitoring combustion efficiency. Combustion is used chips from sawmill, the crusher, the final processing and the processing of massive particle board. Figure 4. Boiler biomass Omical‐Weiss in Figure 5. Silos from which automatically doses company Simpo a.d. Vranje the sawdust in the furnace boiler Technical data of the boiler plant The maximum permitted production of saturated steam is 6000 kg/h and the maximum overpressure is 8.3 bar. The maximum permitted capacity is 4,750 kW furnace with the degree of utilization of 82‐84%. As regards the combustion of chopped wood, the heating value of which is 196 | Fascicule 3 ANNALS of Faculty Engineering Hunedoara – International Journal of Engineering dimensioned 4,76 Kw.h/Kg at a water content of 10%. Bulk density of sawdust is 250‐350 kg/m3, the maximum fuel flow of 998 kg/h, a minimum 400 kg/h. According to the documentation for the boiler, fuel type sawdust and wood waste from the dust of uniform amount ie. natural wood with no binders, no layers of plastic, that is not treated with wood preservatives. However, in practice it is different that is used and the waste of machining particle board containing a binder. The nitrogen content is max. 3%, with no harmful ingredients, foreign bodies and dirt. Ash content is up to 1%, ash melting point is higher than 1.100 ˚C, grain size 0.5 ‐ 30mm. Firebox Firebox allows complete combustion of biomass with minimal emission levels of pollutants in flue gases. The firebox has a movable grid, with automatic regulation of the thickness of the fuel. Fence is inside the chamotte big enough and very well insulated so that heat exchange with the environment is minimal. This allows burning and raw (wet) fuels. Temperature of the outer surface lining of the boiler are measured. External paneling furnaces of metal panels that provide round‐the use of preheated air. In this way, almost completely reduce heat loss by radiation and provides additional preheating combustion air. The design is compact combustion chamber comes over and fitted so that the installation simple and short. Fireplaces doors are easy to open, big and well insulated, so it lets you manually fire up the torch of sawdust. Softening and warming water To a flask 2 m3 capacity is fed into by 100 kg of the salt granules. Then examine the hardness of the water, and if it turns out that the water is hard, access to the process of softening water. The procedure takes about 1 hour and receives about 280 ‐ 300 m3 of water. From there, the water flows in a degasser where preheating is carried out at a temperature water of 80 ‐ 100 ˚C. Heating is done by means of steam coming from the network. In addition, the elimination of the degasser, and dissolved gases, primarily oxygen as natural water generally contain a certain amount of dissolved gases. For example, the oxygen, nitrogen or carbon dioxide. In a few cases, the water contains hydrogen ‐ sulphide or methane. Carbon dioxide and hydrogen ‐ sulphide, dissolved in water increases the corrosive effect of water, which adversely affects the boiler. Mechanized equipment for the collection and removal of ashes Below the boiler, set the container capacity of 200 liters, and is set below the opening through which the ashes from the grate and the space under the grate falls down. The vessel was placed on a trolley which is moved axially by side carriers. Multi cyclone filter of flue gases It consists of a number of small cyclone separators which operate on the principle of centrifugal separation of particles that still have sufficient gravity Figure 6. Multi cyclone filter of flue gases for centrifugal separation. Cyclonic separators are installed in a well‐insulated compact unit. Featured ash is collected at the bottom of the multi‐
cyclones and fall into the ashtray. Furthermore, from ashtrays to help pužastog ash conveyor is moved to the container (Figure 6). Set pipeline to connect the boiler, filters and fan flue with chimney Pipelines for the transport of smoke made of steel sheet thickness of 3 mm with all necessary flanges, doubles and cleaning openings. Thermal insulation of the pipeline has not yet been set up so that the touch can feel a great warmth to the walls of the pipeline. Microprocessor device It is used to regulate the automatic operation of the boiler, taking from the silo and the dosage of fuel into the combustion chamber, combustion, treatment and discharge of of flue gases up the 197 | Fascicule 3 ISSN: 1584-2673 [CD-Rom, online] chimney. Programming is called. free programming, so it is possible to adjust the program to the specific needs of each user, as well as changes in the work. Software monitoring of boiler includes automatic control system (SAU) and a system of automatic regulation (SAR), with the help of SCAD applications to conduct automated process (called PLC). The automatic boiler operation, starting from the mixing of fuel and exclusions in the warehouse and its transport to the boiler bunkers through the fuel trim, its combustion grate and maintain constant pressure in the combustion chamber through the fan flue gas, ash handling management and maintenance of constant steam pressure with continuous measurement flow of steam and feed water, controlled by PLC system. Related equipment with the boiler: 9 Programming and control box with all accessories, 9 Hardware and Software 9 Communication with the facility through display with keyboard, 9 Communication with the desktop computer, 9 Signalling and reports of malfunctions (Figure 9) 9 Electrical (cabling from the command of the closet to the ports on the plant) Electrical connections (motor power) 9 Primary Air Fan 5.5kW 9 Ventilator secondary air 5,5 kW 9 Fan recycled air 7,5 kW 9 Fan flue gas 30 kW 2. RESEARCH MATERIAL AND WORK METHOD In order to calculate the consumption of sawdust to produce saturated steam in a steam boiler WEISS biomass was measured moisture samples. Sawdust that comes to boiler installation is obtained from four plants and: 1. Sawmill, 2. From the crusher, 3. Final mass of the processing, and 4. With the processing of particle board. The samples needed for research are taken from four plants, wrapped in foil so as not to lose moisture (Figure 7). Figure 7. Samples were collected from all four plants from which it gets dust Figure 8. The tubes in which the sample is measured by the humidity in the laboratory 198 | Fascicule 3 ANNALS of Faculty Engineering Hunedoara – International Journal of Engineering Samples were then shipped to the laboratory of the Faculty of Forestry in Belgrade where each cut into eight tubes (Figure 8). In each test tube was measured by the humidity, and then calculated by the arithmetic mean of all moisture specially parts for each of the samples, in order to obtain more accurate results, the sample moisture. The boiler plant is done and testing of fuel Figure 9. The control panel of the boiler plant properties of sawdust where the duration of the Weiss
measurement of four hours in the span of ten minutes measured temperature furnaces, water temperature and the temperature of the flue gases. Sensing a temperature of values is done from the control panel (see Figure 9). 3. THE MEASUREMENT RESULTS Results of measuring moisture samples The results which were obtained by measuring the moisture content of samples are shown in Table 1. Samples whose humidity measured from beech (sawmill, crushers and final processing) and raw chipboard (particle board machining). Table 1: Results of measuring moisture samples Mass A R T v A1 23,34 34,08 19,25 34,37 A2 21,91 33,89 18,94 34,37 A3 25,08 34,2 20,51 34,55 A4 26,22 33,78 20,75 34,47 A5 24,23 33,96 20,05 34,25 A6 23,17 33,75 19,27 34,32 A7 22,85 33,65 19,66 33,82 A8 21,97 34,21 19,4 33,78 By the crusher Mass A R T Б1 24,18 34,3 26,12 35 Б2 23,63 33,94 26,6 35,07 Б3 23,22 34,41 26,3 33,8 Б4 23,46 34,52 25,94 34,45 Б5 24,31 34,73 26,03 34,24 Б6 23,28 33,97 25,91 34,16 Б7 23,16 34,59 26,87 34,37 Б8 23,22 34,35 25,73 34,39 Finala Mass A R T В1 15,98 33,76 20,57 34,42 В2 16,03 34,13 20,92 33,85 В3 16,83 35,36 20,75 34,03 В4 16,45 35,14 21,05 33,71 В5 16,43 34,47 20,79 34,14 В6 16,67 34,59 21,27 34,12 В7 15,94 34,22 21,13 34,1 В8 16,01 34,21 20,92 33,92 Plywood Mass A R T Г1 11,61 34,05 15,93 33,96 Г2 11,63 34,12 15,94 33,78 Г3 11,25 33,75 15,92 33,48 Г4 11,68 33,81 15,91 33,77 Г5 11,75 34,09 15,97 33,85 Г6 11,07 33,74 15,95 33,74 Г7 11,58 33,92 15,95 33,88 Г8 11,5 33,78 16,1 33,87 Sawmill Mass
as 12,61
11,89
13,21
13,62
13,19
12,61
12,43
11,86
Mass
22,06
21,67
20,82
20,89
21,78
20,78
20,93
20,78
Mass
14,96
15,22
16,03
15,69
15,57
15,8 15,09
15,29
Mass
10,96
10,98
10,62
11,02
11,08
10,36
10,84
10,79
A R T 34,04
33,94
34,07
33,91
33,96
33,75
33,6 34,17
A 34,3 33,84
34,29
34,41
34,64
33,88
34,58
34,34
A 33,76
34,1 35,25
35,03
34,46
34,59
34,12
34,13
A 33,92
34,09
33,65
33,72
34,02
34,1 33,79
33,85
18,06
17,65
18,22
19,36
18,26
17,66
18,95
17,9
R 25,77
25,95
25,53
25,03
24,98
24,71
24,97
24,96
R 20,44
20,8
20,51
20,88
20,63
21,1
20,8
20,77
R 15,66
15,65
15,64
15,67
15,68
15,66
15,65
15,73
30,96
31,14
31,96
31,89
31,65
31,49
31,1 30,5 T 34,44
34,43
32,99
33,47
33,42
33,37
33,45
33,37
T 33,78
33,67
33,84
33,39
33,74
33,48
33,33
33,57
T 33,76
33,7 33,4 33,64
33,82
33,61
33,85
33,68
Moisture Density of The density of the wet wood absolutely dry wood
85,09 1,04 0,66 84,27 0,99 0,64 89,86 1,03 0,67 92,51 1,09 0,65 83,70 1,04 0,67 83,74 1,04 0,67 83,83 1,02 0,63 85,24 0,98 0,64 86,03 1,03 0,65 9,61 0,77 0,72 9,04 0,75 0,72 11,53 0,76 0,72 12,30 0,76 0,72 11,62 0,79 0,75 12,03 0,77 0,74 10,65 0,73 0,72 11,74 0,76 0,73 11,07 0,76 0,73 6,82 0,67 0,64 5,32 0,66 0,64 4,99 0,67 0,66 4,84 0,66 0,64 5,52 0,67 0,65 5,51 0,66 0,65 5,63 0,65 0,64 4,71 0,66 0,64 5,42 0,66 0,64 5,93 0,63 0,61 5,92 0,63 0,61 5,93 0,63 0,60 5,99 0,64 0,62 6,05 0,64 0,61 6,85 0,61 0,58 6,83 0,63 0,61 6,58 0,62 0,60 6,26 0,63 0,61 199 | Fascicule 3 ISSN: 1584-2673 [CD-Rom, online] Results of measuring the temperature of the boiler Temperature of the outer lining of the boiler were measured by laser thermometer on all four sides of the boiler at different heights. The arithmetic mean of all the measured temperature of the outer lining of the boiler was 420C. In the course of 4 hours that is from 10.00h to 14.00h the 25 times temperature readings are taken repeatedly from the display window of the dashboard. Read the temperature of the boiler combustion chamber, inlet water temperature in the boiler and flue gas temperature. The results obtained by measuring the temperature in the boiler plant are shown in Table 2. Table 2: Results of measuring the temperature in the boiler plant type Weiss Order number of measurements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Measurement time 10.00 10.10 10.20 10.30 10.40 10.50 11.00 11.10 11.20 11.30 11.40 11.50 12.00 12.10 12.20 12.30 12.40 12.50 13.00 13.10 13.20 13.30 13.40 13.50 14.00 Temperature furnace (0C) 896 896 889 890 890 895 896 890 892 890 888 885 885 891 894 891 888 888 890 893 893 892 885 890 893 The boiler water temperature (0C) 98 98 95 96 95 96 97 96 95 95 94 93 93 95 96 96 94 93 95 96 97 97 98 98 96 t of flue gas (0C) 152 153 159 164 163 160 165 168 168 152 150 153 158 162 160 156 158 162 164 163 159 150 149 154 160 Navigating temperature furnaces, water and flue gases is shown in diagrams 1,2 and 3. Diagram 1. Trends t firebox expressed in 0C Diagram 2. Trend t input water expressed in 0C Diagram 3. Trends t flue gases expressed in 0C 200 | Fascicule 3 ANNALS of Faculty Engineering Hunedoara – International Journal of Engineering 4. CALCULATION OF FUEL CONSUMPTION The calculation of sawdust to produce saturated steam in a steam boiler biomass WEISS 1. Technical characteristics of the boiler WEISS: − Production of steam 6000 kg/h − Maximum operating pressure of 8 bar. − Thermal power sawdust and wood waste (0.5 to 30mm) Hd = 10‐12MJ/kg moisture content in fuel from 10 to 12%, the density of sawdust 250‐350kg/m3 − Efficiency Boiler 82%. − For p=8 bar follows from the i‐s diagram enthalpy i1 = 2768KJ/kgK, enthalpy of condensate t= 90C i2 = 417KJ/kgK. 2. The necessary amount of of fuel for 6000kg/h steam: − B = 6000 x (2768‐417) / (11000 x 0,82) = 1564kg/h respectively − B1 = 1564 kg/h : 6t/h = 261 kg/t steam Means for a ton of steam that they receive in a steam boiler biomass should be used 260 kg of sawdust. Empirically, the price of steam produced in the steam boiler fuel oil is 32‐36 Euro/t, while the price of steam from wood sawdust and woodchips from 20‐22 Euro/t. Calculation of the required amount of fuel for the production of amounts of steam to be transferred plant decorative fabrics During the studies the amount of steam that is dispatched decorativeness was 5.2 t/h. Steam pressure was 5 bar. Thermal power of sawdust is Hd = 10‐12 MJ/kg. Efficiencies boiler 82%. For the saturated vapor pressure p=5 bar from the tables for saturated steam specific enthalpy of steam is i1=2749 KJ/kg. Condensate temperature 90˚C enthalpy is i2=417 KJ/kg The required amount of fuel of 5.2 t/h of steam: − B= 5200 x (2749‐417) / (11000 x 0,82) = 1345kg/h respectively − B1= 1345 kg/h : 5,2t/h = 259 kg/t steam This means that for the production of quantities of steam required decorativeness required 1345 kg per hour of sawdust, or 259 kg of saturated steam per ton. 5. CONCLUSION Company engaged in the processing of wood can produce a large amount of energy from nothing else than the rest that occurs during processing. The rest of the processing that occurs in the company Simpo Vranje is large (Odrubci – when shortening of logs, stubs – with a side timber sawing, cut‐outs – the processing of lumber to length, the processing boards in width), small (dust, dust, wood flour) and crust. Wood processing and wood waste from wood processing used for heating production halls for various technological operations where heat is required for the technological process, then drying and steaming of timber in ethics and so on. It is very important that waste used in the right way from an economic as well as from the standpoint of environmental protection. Specifically, if a certain amount of thermal energy produced from biomass that we get in our factory as a by‐
product, less steam will set aside to pay for electricity. On the other hand, if the wood waste burned in the boiler, thereʹs nothing that goes to landfill and thus, recall, does not create methane which is 21 times more harmful than carbon dioxide. Company ʺSimpoʺ a.d. Vranje, the resulting saturated steam in the boiler use for heating buildings (administrative buildings, production facilities, etc.), the lumberyard in artificial dryers, individual heating machine where the high temperature required for the execution of technical operations (eg. storey fusing presses), for the operation of upholstery factory, etc. From the boiler room to the factory of decorative fabric that various amounts of saturated vapor, depending on the demand for heat. During the research, the amount of steam that was delivered to decorativeness was 5.2 t/h. The required amount of fuel heating value of from 10 to 12 MJ/kg, for the production of 5,2 t/h of 201 | Fascicule 3 ISSN: 1584-2673 [CD-Rom, online] saturated steam which goes to decorativeness is 1345 kg/h. This means that we need for a ton of steam 259 kg of sawdust. Since the goal of this paper is to show how the budget and getting cheaper, and the required amount of heat from of sawdust, certain measurements were performed. In the boiler plant on the dashboard, at intervals of 10 minutes for a period of 4 hours, read in the combustion chamber temperature, feed water into the boiler and flue gas temperature. Temperature of furnaces are ranging from 885 ΕC to 896 ΕC, the water temperature of 93 ΕC and 98 ΕC, a temperature of flue gases from 149 ΕC to 168 ΕC. The results are presented in tabular and graphical (diagrams). Temperature of the outer lining of the boiler are measured by a laser thermometer, and on all four sides of the boiler at different heights. The arithmetic mean of all the measured temperature of the outer lining of the boiler is 42 ΕC. In addition to temperature, humidity and the measured sample to determine the humidity of the fuel. Otherwise, fuel moisture has a very large impact on the amount of heat. Samples were collected at four plants where it comes from dust (saw mills, crushers, final processing and processing of massive particle board). Samples were cut into eight tubes and measured the humidity of each specimen in a laboratory in the Faculty of Forestry in Belgrade. Mean humidity of the sample from the sawmill is 86.03%, with 11.07% crusher, the final processing massive 5.42% and the operation of machining particle board is 6.26%. Results moisture content and density of the samples are given in tables. At the end it was calculated the required amount of sawdust to obtain a certain amount of heat in the boiler plant Weiss. Has come to the conclusion that for a ton of steam that they receive in a steam boiler biomass should be used 260 kg of sawdust, and from interviews with employees led to the information that the price of the steam produced in the steam boiler fuel oil is 32‐36 euro/t, while the price of steam produced by burning wood chips and sawdust in a steam boiler Weiss is 20‐22 Euro/t, which is about 40% cheaper. For the quantity of heat which is consumed by the company, the savings are very large. REFERENCES [1.]
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