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Lab02 Group15

The document outlines the laboratory practices for analyzing and optimizing a Diesel-fired fire-tube boiler system at Maliban Biscuits Pvt Ltd. It includes sections on boiler specifications, property method selection, process flowsheet development, design specification analysis, and optimization techniques aimed at improving performance and sustainability. The study emphasizes the importance of accurate simulations and sensitivity analyses to enhance combustion efficiency and reduce emissions.

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Chamudi Minali
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0% found this document useful (0 votes)
27 views43 pages

Lab02 Group15

The document outlines the laboratory practices for analyzing and optimizing a Diesel-fired fire-tube boiler system at Maliban Biscuits Pvt Ltd. It includes sections on boiler specifications, property method selection, process flowsheet development, design specification analysis, and optimization techniques aimed at improving performance and sustainability. The study emphasizes the importance of accurate simulations and sensitivity analyses to enhance combustion efficiency and reduce emissions.

Uploaded by

Chamudi Minali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

In21-S6-CH3170 - Laboratory Practices III

Lab 02 - Analysis and Optimization of a Combustion System

Group 15
Index Number Name
210702R WICKRAMARATHNE B.D.R
210704B WICKRAMARATHNE V.I.R.
210715J WIJERATHNA H.A.W.M.K.
210717R WIJERATHNE R.A.C.M.

Date of Submission: 13/07/2025


Department of Chemical and Process Engineering
University of Moratuwa
Table of Contents
1. Introduction .............................................................................................................................5
Boiler and Fuel Specifications ...................................................................................................6
1.1 Selected Industry ................................................................................................................6
1.2 Justification for Diesel Boiler Selection ................................................................................7
1.3 Key Specifications...............................................................................................................7
1.4 Component Identification ...................................................................................................8
2. Property Method Selection .......................................................................................................9
2.1 Selected Method.................................................................................................................9
2.2 Rationale for Accuracy in Combustion Simulations ..............................................................9
2.3 Selection Process ............................................................................................................. 10
3. Process Flowsheet Development ............................................................................................ 12
3.1 Process Flowsheet ............................................................................................................ 12
3.2 Details of Flowsheet ......................................................................................................... 12
3.3 Results of the Simulation .................................................................................................. 16
4. Design Specification Analysis ................................................................................................. 18
4.1 Design Specification 01 – Adjusting Air Flow Rate ............................................................... 18
4.2 Design Specification 02 – Adjusting Fuel Flow Rate ............................................................ 21
5. Sensitivity analysis ................................................................................................................. 24
5.1 Effect of Air pre-heating ..................................................................................................... 24
5.1.1 Conclusion................................................................................................................. 26
5.1.2 Recommendation ....................................................................................................... 27
5.2 Effect of Excess Air Ratio ................................................................................................... 28
5.2.1 Conclusion................................................................................................................. 30
5.2.2 Recommendation, ...................................................................................................... 31
5.3 Effect of Oxygen Enrichment ............................................................................................. 31
5.3.1 Conclusion................................................................................................................. 34
5.3.2 Recommendation ....................................................................................................... 34
6. Optimization .......................................................................................................................... 35
6.1 Optimization – 01 Waste heat minimization ....................................................................... 35
6.2 Optimization – 02 Minimization of harmful emissions ......................................................... 38
7. Heat Recovery ........................................................................................................................ 41
8. References............................................................................................................................. 43
List of figures

Figure 1 Included Components ....................................................................................................... 9


Figure 2 Property Method Selection Assistant ............................................................................. 10
Figure 4 Selected Property Method .............................................................................................. 11
Figure 3 Component Type Selection ............................................................................................ 11
Figure 5 Process Flowsheet .......................................................................................................... 12
Figure 6 Inserting Fuel stream data .............................................................................................. 13
Figure 7 Inserting Air stream data ................................................................................................ 14
Figure 8 Inserting feed-water stream data .................................................................................... 15
Figure 9 Inserting Heat exchanger 01 data ................................................................................... 15
Figure 10 Inserting Heat Exchange 02 Data ................................................................................. 16
Figure 11 Result Summary 01 ...................................................................................................... 16
Figure 12 Result Summary 02 ...................................................................................................... 17
Figure 13 Results Summary 03 ..................................................................................................... 17
Figure 14 Define DS 01 ................................................................................................................ 18
Figure 15 Specs DS 01 .................................................................................................................. 19
Figure 16 Variables DS 01 ............................................................................................................ 19
Figure 17 Fortran Statement DS 01 .............................................................................................. 20
Figure 18 Results DS 01 ............................................................................................................... 20
Figure 19 Define DS 02 ................................................................................................................ 21
Figure 20 Specs DS 02 .................................................................................................................. 21
Figure 21 Variables DS 02 ............................................................................................................ 22
Figure 22 Fortran Statement DS 02 .............................................................................................. 22
Figure 23 Results DS 02 ............................................................................................................... 23
Figure 24 -Sensitivity analysis 01-Air preheating (Vary)............................................................. 24
Figure 25 -Sensitivity analysis 01-Air preheating (Define) .......................................................... 25
Figure 26 -Sensitivity analysis 01-Air preheating (Tabulate)....................................................... 25
Figure 27 -Sensitivity analysis 01-Air preheating (Results) ......................................................... 26
Figure 28 -Sensitivity analysis 01-Air preheating (Result graph) ................................................ 26
Figure 29 -Sensitivity analysis 02-Excess air ratio (vary) ............................................................ 28
Figure 30 -Sensitivity analysis 02-Excess air ratio (Define) ........................................................ 28
Figure 31 -Sensitivity analysis 02-Excess air ratio (Tabulate) ..................................................... 29
Figure 32 -Sensitivity analysis 02-Excess air ratio (Results) ....................................................... 29
Figure 33 -Sensitivity analysis 02-Excess air ratio (Results graph) ............................................. 30
Figure 34 -Sensitivity analysis 03-Oxygen enrichment (vary) ..................................................... 31
Figure 35 -Sensitivity analysis 03-Oxygen enrichment (Define) ................................................. 32
Figure 36 -Sensitivity analysis 03-Oxygen enrichment (Tabulate) .............................................. 32
Figure 37 -Sensitivity analysis 03-Oxygen enrichment (Results) ................................................ 33
Figure 38 -Sensitivity analysis 03-Oxygen enrichment (Result graph) ........................................ 33
Figure 39 Defining variables for optimizing efficiency ............................................................... 35
Figure 40 Objectives & constraints in optimization ..................................................................... 36
Figure 41 Identifying the varying variable ................................................................................... 36
Figure 42 Results of the optimization ........................................................................................... 37
Figure 43 Defining variables for optimizing emissions ................................................................ 38
Figure 44 Objectives & constraints in optimization ..................................................................... 38
Figure 45 Identifying the varying variable ................................................................................... 39
Figure 46 Fortran for optimization ............................................................................................... 39
Figure 47 Results of the optimization ........................................................................................... 40
Figure 48 Heat Recovery Setup .................................................................................................... 41
Figure 49 Results from Heat Streams of Heat Recovery Setup .................................................... 41

List of tables
Table 1 Boiler Specifications .......................................................................................................... 7
Table 2 Component Identification .................................................................................................. 8
Table 3Block Identification .......................................................................................................... 12
Table 4 Stream Identification........................................................................................................ 13
1. Introduction
Effective and economical utilization of energy is vital to today's industrial process. Steam-
generating industrial boiler plants play an important role in the generation of steam utilized in
various processes, such as process needs, power, and heating. In this laboratory exercise, our goal
is to model and examine a Diesel-fired fire-tube boiler. High-level research will entail the creation
of a process flowsheet in detail, design specifications for buildings, sensitivity analysis, and system
optimization in Aspen to improve performance and sustainability.

Fire-tube boilers are predominantly used in industrial applications because they are resilient and
have sufficient space to hold large amounts of steam. They are based on the principle that hot
combustion gases travel inside water tubes, thereby efficiently transferring heat and producing
steam. The fire-tube boiler is chosen for use in this laboratory experiment because it has
widespread use in industries as well as being dependable when it comes to producing steam.

The choice of Diesel as a source of fuel has several benefits, including greater control and better
combustion. We employed Diesel with N-decane, N-nonane, and Naphthalene[1].

Laboratory experiment is directed towards the achievement of a range of various goals:

1.Model Development: Creating a representative model of the fire-tube boiler would include
acquiring appropriate fuel and boiler data from literature or industry. Physical and chemical
properties of Diesel and boiler operating behavior will be incorporated within this model.

2.Selection of the Appropriate Thermodynamic Property Approach: For the correct


representation of combustion and heat transfer within the boiler, select the appropriate
thermodynamic property approach.

3.Process Flowsheet and Heat Losses: To ensure a proper representation of performance and
efficiency, design a suitable process flowsheet as per the boiler system with acceptable heat losses.

4.Design Specifications: To calculate the volume of air and fuel needed for a specific boiler load,
consult design specifications. For proper combustion conditions, this would imply that the oxygen
percentage in flue gas must be constant.

5.Validation: To check whether the model is accurate and reliable, compare model output from
simulation with real operating data.
6.Sensitivity Analysis: In a bid to comprehend how different factors affect combustion products
as well as flame temperature, perform sensitivity analysis. Preheating of the air, excess air, and
enrichment in oxygen within the combustion air are all encompassed under this.

7.Optimization: Apply the optimization techniques in efforts to attain some objectives, such as
reducing the energy consumption and emissions harmful to the environment. Optimization of the
efficiency without going against the environmental standards, balance has to be attained.

8.Heat recovery potential: Assess the heat recovery potential of the flue gas to pre-heat the
combustion air or feed water and increase overall combustion efficiency.

The objective of this laboratory exercise is to apply an interdisciplinary methodology of


simulation, analysis, and optimization to understand and improve the performance of a Diesel-
firing fire-tube boiler.

Boiler and Fuel Specifications


Choice of an industrial boiler system depends on steam requirement, fuel supply, process
suitability, and operating efficiency. For Maliban Biscuits Pvt Ltd, a diesel-fired fire tube boiler
has been chosen as it is compatible for the use of medium-pressure steam that is commonly used
in food processing. Diesel-fired boilers can provide a consistent supply of steam for various
heating and drying processes involved in biscuit manufacturing, such as dough preparation, baking
operations, cleaning, and sanitizing.

1.1 Selected Industry


Maliban Biscuits Pvt Ltd is the industry for biscuit manufacturing under this case study. Steam
boilers are used in this industry for:

• Process Heating: Hot water heating, dough mixing, and jacket equipment.
• Oven Humidification: Regulating the humidity level during baking.
• Cleaning and Sanitation: Steam sterilization equipment.
• Utility Operations: Compressed air system support and overall plant heat needs.

The food processing industry requires a consistent and hygienic source of steam to maintain
product quality, food safety standards, and efficient operations.
1.2 Justification for Diesel Boiler Selection
For Maliban Biscuits Pvt Ltd, the choice of a diesel-fired boiler is justified by several operational
advantages:

• Reliability: Diesel-fired boilers are known for stable and continuous steam generation,
which is crucial in round-the-clock food production environments.
• Fuel Availability: Diesel fuel is readily available in Sri Lanka in all locations with no need
for pipeline reliance.
• Operational Versatility: For areas where natural gas supply does not exist; diesel boilers
can be installed and ready to operate instantly.
• Cost Savings: Diesel systems are less expensive than electric boilers for large-volume
steam generation.
• Quick Start-Up: Diesel boilers have faster start-up times, which is suitable for batch
operation and variable loads.

Even though diesel fuel contains a higher carbon content than natural gas, it is still a good
alternative for Maliban operations because of the high reliability of the plant, process flexibility
requirements, and present infrastructure constraints. Future dual fuel or biodiesel conversion
options are also possible to further promote sustainability.

1.3 Key Specifications


The modeled boiler has the following parameters:

Table 1 Boiler Specifications

Parameter Value

Type Fire tube boiler

Steam capacity 2500 kg/h

Operating pressure 6.9 barg

Designed Saturation Temperature 1720C

Fuel type Diesel


Fuel consumption 300 kg/h

Efficiency 85% without recovery

1.4 Component Identification

Table 2 Component Identification

Diesel Flue Gas

Component Formula Component Formula

N-Decane C10H22 N-Decane C10H22

N-Nonane C9H20 N-Nonane C9H20

Naphthalene C10H8 Carbon-monoxide CO

Sulphur S Carbon-dioxide CO2

Toluene C7H8 Naphthalene C10H8

Water H2O

Oxygen O2

Nitrogen N2
Figure 1 Included Components

2. Property Method Selection


2.1 Selected Method
We selected the Peng-Robinson equation of state as our main property method in Aspen Plus to
conduct this combustion simulation.

Peng-Robinson is suit for,

• High-pressure systems – Ideal for our 10-bar boiler.

• Hydrocarbons combustion – Satisfactory VLE of flue gases components and diesel fuel.

• Industry default – Typical for combustion and refinery processes.

2.2 Rationale for Accuracy in Combustion Simulations


For combustion systems an accurate description is worthwhile for the following reasons:

1. Averages Correct Phase Behavior


• Gas (CO₂, N₂) and liquid (H₂O) are the combustion products in diesel-engine
exhaust gas.
• Not ideal gas, Peng-Robinson satisfactorily models this mix model.
2. Calculates Realistic Heat Effects
• Non-ideal reaction enthalpy changes are considered.
• Energy balance for our boiler (e.g., calculations for heat loss) is essential to
employ.
3. Compared to Industrial Data
• Peng-Robinson binary interaction parameters match real diesel combustion.

4. Limitations & Assumptions

• Ignores soot formation (small impact on energy balance).


• Additive-free diesel fuel assumed (ignores additives; acceptable for this lab
scale).

2.3 Selection Process

Figure 2 Property Method Selection Assistant


Figure 4 Component Type Selection

Figure 3 Selected Property Method

:
3. Process Flowsheet Development
The process flowsheet using the Aspen Plus software was developed. This part of the
assessment explains the blocks used in the simulation, their purposes, and the results
obtained from the simulation.

3.1 Process Flowsheet

Figure 5 Process Flowsheet

3.2 Details of Flowsheet


Used blocks, streams and their purpose of adding them are below.

Table 3Block Identification

Model Standard model Purpose

COMBUST RGibbs Combustion inside the boiler

HE1 Heater Extract heat from combustion gas

HE2 Heater Extract heat from effective heat


Table 4 Stream Identification

Stream name Stream type Purpose

AIR Material Air flow

FUEL Material Fuel flow

COMGAS Material Combustion gas flow

FLUEGAS Material Flue gas after extracting effective heat

THEAT Energy Effective transferred heat

FWATER Material Feed water flow

WHEAT Energy Wasted heat

STEAM Material Steam flow

Figure 6 Inserting Fuel stream data


Figure 7 Inserting Air stream data

Figure 8: Inserting Feed waterstream data


Figure 8 Inserting feed-water stream data

Figure 9 Inserting Heat exchanger 01 data


Figure 10 Inserting Heat Exchange 02 Data

3.3 Results of the Simulation


The following results were obtained from the above developed process flowsheet.

Figure 11 Result Summary 01


Figure 12 Result Summary 02

Figure 13 Results Summary 03


Since the expected results are achieved, this process model is used here onwards for the
other simulation objectives of the assessment.

4. Design Specification Analysis


The Aspen Plus design specification feature was employed in order to achieve the optimal air and
fuel flow rates of this diesel-fired boiler with a requirement of 3% O₂ concentration in flue gas,
which is a crucial parameter for proper combustion. The O₂ concentration was taken as the
measured variable and the air flow rate was varied in the simulation, and the optimal working
conditions were found out automatically. Such technique allows full combustion of the fuel with
minimal excess air, balancing efficiency and emissions in sugar plant applications

4.1 Design Specification 01 – Adjusting Air Flow Rate


A new Design Spec was defined in Aspen Plus to manage combustion variables. In this example,
the chosen controlled variable is O2 content in flue gas and the manipulative variable is air flow
rate.

Figure 14 Define DS 01

The O₂ concentration in flue gas (OFRAC) was set as the measured variable. A target of
3% (0.03) with a tight tolerance of 0.01 ensured precise control.
Figure 15 Specs DS 01

With diesel fuel flow fixed at 300 kg/h, the air flow rate was chosen as the manipulated
variable.

Figure 16 Variables DS 01
The following equation was given for the Fortran statement of the Aspen Plus software
for the calculation of O2 fraction in the flue gas.

Figure 17 Fortran Statement DS 01

The simulation converged, calculating an optimal air flow of 176.742 kmol/h.


This achieved 5.59982 kmol/h O₂ in the flue gas.

Figure 18 Results DS 01
4.2 Design Specification 02 – Adjusting Fuel Flow Rate
Same as the above simulation a new Design Spec was defined in Aspen Plus to manage
combustion variables. In this example, the chosen controlled variable is O2 content in flue
gas and the manipulative variable is fuel flow rate.

Figure 19 Define DS 02

The O₂ concentration in flue gas (OFRAC) was set as the measured variable. A target of
3% (0.03) with a tight tolerance of 0.0001 ensured precise control.

Figure 20 Specs DS 02
The fuel flow rate was chosen as the manipulated variable of the simulation.

Figure 21 Variables DS 02

The following equation was given for the Fortran statement of the Aspen Plus software
for the calculation of the O2 fraction in the flue gas.

Figure 22 Fortran Statement DS 02


The simulation converged, calculating an optimal fuel flow of 2.44092 kmol/h. This
achieved 5.59982 kmol/h O₂ in the flue gas

Figure 23 Results DS 02
5. Sensitivity analysis
In order to optimize the combustion efficiency of an industrial boiler, sensitivity analysis using
Aspen Plus simulation was performed. The analysis examined the effect of changes in
three important parameters; air preheating temperature, excess air ratio, and oxygen enrichment
on boiler performance indicators such as fuel consumption, flue gas temperature, and CO₂
concentration. Understanding the impact of these variables is important to optimize energy
utilization, minimize fuel consumption, and enhance overall process efficiency.
The findings of this study form the basis of informed decision-making in boiler operation and
design.

5.1 Effect of Air pre-heating

Figure 24 -Sensitivity analysis 01-Air preheating (Vary)


Figure 25 -Sensitivity analysis 01-Air preheating (Define)

Figure 26 -Sensitivity analysis 01-Air preheating (Tabulate)


Figure 27 -Sensitivity analysis 01-Air preheating (Results)

Figure 28 -Sensitivity analysis 01-Air preheating (Result graph)

5.1.1 Conclusion
The simulation analyzed the impact of varying the air preheating temperature between 300
K and 750 K on the performance of the industrial boiler. The results show a clear
trend: fuel consumption is decreased with a rise in the air preheating temperature. Specifically,
fuel flowrate decreases from around 1800 kg/h at 300 K to around 1500 kg/h at 750
K, equivalent to a 17% fuel saving. This is because of the higher thermal input from the preheated
air, which reduces the energy required from the fuel to produce ignition and sustain combustion.

The airflowrate also decreases slightly with increasing preheat temperature, reflecting better
combustion efficiency and perhaps reduced excess air requirements. More importantly, the flue
gas temperature rises steadily with air preheating, from around 750 K to 900 K, demonstrating that
more heat is conveyed in the flue gas, a desirable situation for heat recovery equipment like
economizers.

From the result graph, the negative trend of fuel consumption and positive trend of flue gas
temperature with increasing air temperature are clear indications of higher efficiency. The
slope, nevertheless, flattens out after ~600 K, indicating diminishing returns at high preheat
temperatures. So, while air preheating boosts efficiency and reduces fuel cost,
practical factors such as equipment material and heat exchanger cost should be considered.

5.1.2 Recommendation
• Install or upgrade air preheaters to raise the combustion air temperature, ideally between
600–750 K.
• Implement waste heat recovery systems (i.e., economizers) to preheat inlet air efficiently.
• Select materials and insulation that can resist high air temperature.
• Avoid over-preheating beyond ~750 K due to diminishing efficiency gains as well
as potential material limitations.
• Regularly monitor preheater performance to maintain constant air inlet temperature.
5.2 Effect of Excess Air Ratio

Figure 29 -Sensitivity analysis 02-Excess air ratio (vary)

Figure 30 -Sensitivity analysis 02-Excess air ratio (Define)


Figure 31 -Sensitivity analysis 02-Excess air ratio (Tabulate)

Figure 32 -Sensitivity analysis 02-Excess air ratio (Results)


Figure 33 -Sensitivity analysis 02-Excess air ratio (Results graph)

5.2.1 Conclusion
The air excess ratio was varied from 1.0 (stoichiometric combustion) to 2.0 (100% excess air).
The simulation result shows that higher excess air improves combustion completeness up to
initial increases, but higher increases lead to inefficiency. For instance, at an excess air ratio of
1.0, the fuel flowrate is around 1500 kg/h, whereas it linearly increases to 1800 kg/h at a ratio of
2.0, indicating 20% higher fuel consumption due to increased heat loss in the flue gas.

The mole fraction of CO₂ in the flue gas drops from 0.13 at stoichiometric combustion to 0.065
at 2.0 excess air ratio, indicating clearly the effect of dilution by excess nitrogen and oxygen.
The flue gas temperature also drops from about 930 K at 1.0 to 780 K at 2.0, which means that
an increased quantity of heat is carried away with the flue gases instead of being utilized in the
boiler.

The result plot graphically confirms these trends. The fuel consumption curve increases with
increasing air ratio, and the CO₂ mole fraction decreases. These are good indicators of energy
loss and reduced combustion efficiency at high excess air levels. There is an optimum point
between 1.1 and 1.3 where combustion is complete without excess air adding to thermal losses.
5.2.2 Recommendation,
• Maintain the excess air ratio in the optimal range of 1.1–1.3
to achieve maximum combustion with minimum heat loss.
• Avoid high excess air ratios (>1.4), which cause noticeable efficiency loss and higher fuel
consumption.
• Constantly monitor the combustion conditions using oxygen sensors or flue gas analyzers.
• Employ an automatic control system to control air flow based on real-time oxygen or
CO₂ concentrations in the flue gas.
• Regular burner tuning and maintenance should be done to prevent air imbalance.

5.3 Effect of Oxygen Enrichment

Figure 34 -Sensitivity analysis 03-Oxygen enrichment (vary)


Figure 35 -Sensitivity analysis 03-Oxygen enrichment (Define)

Figure 36 -Sensitivity analysis 03-Oxygen enrichment (Tabulate)


Figure 37 -Sensitivity analysis 03-Oxygen enrichment (Results)

Figure 38 -Sensitivity analysis 03-Oxygen enrichment (Result graph)


5.3.1 Conclusion
Oxygen enrichment was studied by increasing the O₂ concentration in combustion air from 21%
(normal air) to 35%. Simulation showed significant improvement in combustion efficiency and
heat transfer. Fuel consumption decreased from ~1800 kg/h at 21% O₂ to 1500 kg/h at 35%
O₂, an ~17% fuel consumption saving. This is due to the higher oxygen partial pressure,
which boosts the combustion rate and reduces unburned hydrocarbons.

The CO₂ mole fraction in the flue gas increased from 0.09 to 0.15,
indicating greater conversion of fuel and lower dilution with nitrogen. The flue gas temperature
also rose from 750 K to 860 K, indicating a higher flame temperature and more efficient use
of heat. Both these trends can be seen in the result graph, where fuel consumption is plotted as a
downward-sloping curve and CO₂ concentration as an upward-sloping curve with increasing
oxygen.

However, it must be noted that increased flame temperatures can lead to both increased NOx
emissions and possible thermal stress on furnace hardware. Thus, though oxygen enrichment is
highly effective, it must be used with careful control.

5.3.2 Recommendation
• Add oxygen to combustion air to 30–35% O₂ for high-capacity or high-efficiency boiler
applications.
• Ensure judicious control of oxygen flow to avoid too high flame temperatures and material
stress.
• Compare cost-benefit of oxygen generation or buying versus fuel saved.
• Implement NOx emission controls (e.g., flue gas recirculation or staged combustion)
if oxygen enrichment is used.
• Routine inspection of boiler components for thermal degradation caused by high flame
temperatures.
6. Optimization
Utilizing Aspen Plus optimization tools, boiler performance was enhanced by reducing harmful
emissions and energy consumption while maintaining system efficiency and safety. To determine
the optimal configuration, the process involves defining objectives, constraints, and key operating
conditions. This demonstrates how boiler operation can become more economical and
environmentally friendly through optimization.

6.1 Optimization – 01 Waste heat minimization

Figure 39 Defining variables for optimizing efficiency


Figure 40 Objectives & constraints in optimization

Figure 41 Identifying the varying variable


Figure 42 Results of the optimization

By fine-tuning air and fuel flow rates, the optimization process decreased waste heat and raised the boiler's
overall efficiency. The findings show a noticeable reduction in energy loss, showing that process
optimization can improve thermal performance while maintaining operational safety by reducing excess
heat.
6.2 Optimization – 02 Minimization of harmful emissions

Figure 43 Defining variables for optimizing emissions

Figure 44 Objectives & constraints in optimization


Figure 45 Identifying the varying variable

Figure 46 Fortran for optimization


Figure 47 Results of the optimization

By selecting ideal oxygen levels and operating conditions, the optimization resulted in a decrease
in carbon monoxide (CO) emissions. However, as the fuel's fixed sulfur content stayed constant
throughout the process, sulfur emissions could not be reduced. This demonstrates that fuel
composition is a major factor in sulfur-related emissions, even though operating conditions can
lower some pollutants.
7. Heat Recovery
To recover the heat of the flue gas, an air preheater was added to the base boiler system. The effect
on the system's overall thermal efficiency was examined through simulation.

Figure 48 Heat Recovery Setup

Figure 49 Results from Heat Streams of Heat Recovery Setup


To recover waste heat from flue gas and transfer it to the incoming combustion air, the simulation
included an air preheater. As a result, the air stream's temperature increased (Tbegin < Tend),
indicating that heat was absorbed. showing effective heat transfer. This procedure decreased
energy losses, increased thermal efficiency, and decreased the amount of fuel needed for
combustion. The result indicates that the heat recovery system successfully enhances the energy
utilization within the boiler.
8. References
[1] “Boiler Operation - MLBN.pdf.”

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