BoilBal Spreadsheet
BoilBal Spreadsheet
BoilBal Spreadsheet
Superheater
Extraction
Steam
Steam
Drum
Turbine
Return
to
Hotwell
Blowdown
Deaerator
Condenser
Deaerator
Storage
Tank
Mud
Drum
Cooling
Water
Makeup
Hotwell
Flash
Tank To
Feedwater
Heater
Boiler
Feed
Pump
Heat
Recovery
System
Condensate
Polisher
Condensate
Extraction
Pump
Boil-Bal
Boiler Balance Calculations
Version 2.0 for Excel
(c) 2006
M A R V I N S I L B E R T and A S S O C I A T E S
23 Glenelia Avenue, Toronto, Ontario, Canada, M2M 2K6
Telephone: 1-416-225-0226
FAX: 1-416-225-2227
Internet: [email protected]
C-tower
Cooling-WATER calculations
Boil-Bal calculates the use and balance of water and energy within a boiler system. This latest
version includes the ability to calculate the water and energy savings achievable by adding a flash
tank and heat-exchanger to recover the residual heat present in the boiler blowdown. Boil-Bal
works with US, metric or imperial units or any combination of them and any currency. Boil-Bal
uses several very common calculations from the open literature, many of which are used by the
various water-treatment suppliers and consultants. To fully interpret the results, it should be noted
that actual conditions within a boiler may differ from those on which the calculations are based.
The differences are most pronounced at start-up or when changing load. While the calculations
have been shown to give a reasonable approximation in many applications, MS&A can assume no
responsibility for any decision based upon the results of the calculations.
MAKE-UP PLANT
leakage through
through ion exchange
CHEMICAL
ADDITION
LOSSES
MAKEUP
CONDENSATE RETURN
May be full-flow or
on a by-pass loop
CONDENSATE
POLISHER
(Optional)
Removal of
suspended solids
TURBINE AND/OR
PROCESS HEATING
Corrosion of metal
surfaces throughout
the cycle
DEAERATOR
Removal of
dissolved oxygen
BOILERS
Deposition of solids
on boiler tubes
CHEMICAL
ADDITION
FEEDWATER
Break up and transport
of existing deposits
STEAM
BLOWDOWN
Removal of
suspended solids
Blowdown: A small flow of concentrated water is taken from the boiler to prevent over
concentration of solids. The makeup brings in fresh water. The balance between the two,
results in a steady-state concentration. A higher blowdown rate results in a lower
concentration of impurities, but also removes more energy. Lowering the blowdown rate
reduces the energy penalty, but can not achieve as low a concentration of solids. Blowdown
can be continuous or intermittent. Its control can be a simple manual valve, or highly
automated with control based upon the signal from an on-line conductivity meter. Typically,
blowdown rates are less than 1% in the electrical generation plants. They may go to 5% in
industrial utilities where condensate is returned and much higher if it isn't.
-1-
Condensate Recovery: When the steam has done its work, it condenses back into a liquid.
This condensate is pure water with essentially no solids. If it can be returned to the boiler, it
eliminates the demand for makeup bringing new solids with it. In electrical generating
stations more than 98% of the condensate is returned. In industrial plants, the percentage
varies. It is not unusual to find systems where no condensate is returned. When it is returned,
there is always a concern that returned condensate may include impurities from condenser
leakage or hydrocarbons leaking from process heat exchangers. On-line monitors are
available for detecting condenser leakage or hydrocarbons in water.
Blowdown losses and condensate recovery are the major effects that govern the overall behaviour
of the system. Blowdown that is lost is also energy that is lost. Well designed systems may also
contain a flash tank that recovers energy from the blowdown by routing the flashed steam back to
the deaerator. Further energy recovery can be achieved by passing the hot liquid through heat
exchangers to heat the incoming feedwater. Lost condensate must be replaced. The best way to do
so it is bring it back. Plants with high rates of condensate recovery, also have low blowdown
rates. This should be an incentive to designers as they can reduce the need for a blowdown energy
recovery system if they use good quality make-up and a high condensate recovery.
The weight added through the pumps is usually calculated from the concentration in the day
tank times the drawdown in the tank.
The weight lost through blowdown is usually calculated from the measured concentration in
the blowdown times the blowdown flowrate.
There is one problem. It's not common to include instrumentation to measure the blowdown flow
due to the difficulties inherent with the two-phase flow that may occur in the line. The alternative
is to calculate it from the routine analyses used to monitor the boiler's performance. Many plants
assume some arbitrary flowrate based upon the number of turns on the valve, but that may not
really mean anything. Calculations tend to be more reliable with boilers that operate with a
measurable level of dissolved solids rather than those using ultrapure water.
As an example, data will be used from a typical industrial boiler supplied with softened make-up.
60,000 lb/hr of steam is supplied to heat a process. 20% of the steam (i.e. 12,000 lb/hr) is lost and
the remaining 80% (i.e. 48,000 lb/hr) is returned as condensate. These flows are fixed by the
systems design. A number of simple relationships become apparent from the mass balance:
FW = MU + CR
FW = BD + S
MU = BD + L
= CR + L
-2-
From these relationships, the following information can be derived and will cover essentially all
the calculations necessary to cover a boiler mass balance calculation.
Cycles of concentration can be evaluated relative to either feedwater or makeup concentration.
A subscript indicates which. The most common species is chloride as it tends to be easily
measured and remains in solution in the boiler at operating temperatures. In order to make the
necessary calculations, it is necessary to measure chlorides in the makeup, feedwater, blowdown
(i.e. in the boiler) and returns (i.e. in the condensate).
COC MU =
Cl BD
Cl MU
and
COC FW =
Cl BD
Cl FW
COC MU
100 = %MU
COC FW
where:
%CR = 100
Cl MU - Cl FW
Cl MU - ClCR
BD
= FW - S
FW
= MU - BD
100 S
100 - %BD
The calculation1 is based upon measured levels of chloride in the boiler. Taking as an example a
boiler fed by softened water. The measured chloride values through the system are:
ClMU = 30, ClFW = 6.5, ClBD = 300, ClCR = 0.1
From this the cycles of concentration can be calculated:
COC FW =
300
= 46.2
6.5
and
COC MU =
300
= 10
30
100
30 6.5
30 0.1
= 78.6%
%MU =
= 21.4%
%BD
%MU
21.4
=
COCMU 10.0
= 2.14%
%L
= 19.3%
-3-
The individual flows for a 60,000 lb/hr steaming rate can be calculated from the percentages:
FW =
S 100
60,000 lb/hr 100
=
100 - %BD
100 - 2.14
= 61,300 lb/hr
MU =
%MU FW
= 21.4% 61,300
= 13,100
BD =
%BD FW
= 2.14% 61,300
= 1,310
CR =
%CR FW
= 78.6% 61,300
= 48,200
%L FW
= 19.3% 61,300
= 11,800
If more condensate could be recovered, it would result in less blowdown and need less make-up.
Blowdown
Deaerator
BOILER
Flashed
Steam
Mud
Drum
to
Feedtrain
Flash
Tank
Hot
Water
Cooled
Water
US/Imperial units
SI metric units
steam is produced at a pressure of
100 psig/114.7 psia
steam production is
60,000 lb/hr
1.44 106 lb/day
the blowdown rate is
2.17%
3.1 104 lb/day
the make-up water temperature is
60F
the fuel cost is
$7.40/106 BTU
the boiler efficiency is
70%
to
Water-Treatment
Plant
from
Make-up
791 kPa
7.56 kg/s
6.5106 kg/day
1.4 104 kg/day
15.6C
$7.00/GJ
The thermodynamic data has been taken from a standard set of steam tables. It should be noted
that the tables are based upon absolute pressure and that the 100 psig will be found by looking up
114.7 psia. The symbol conventions used in the following calculation are:
Hf-P/T
Hfg-T
Energy lost
US/Imp
SI units
-4-
Energy cost
US/Imp
SI units
= $93/day
= $93/day
A well designed recovery system would include two components to recover energy. While either
or both can be used, the best recovery will be achieved from applying both.
Flash Tank: The first stage to recover energy from the blowdown is to have the high-pressure
water flash to steam that can be fed back into the process, usually into the deaerator. Assume the
deaerator is operated at 239F. The first stage is to measure the percentage of the blowdown that
is flashed to steam and use this to calculate the energy that can be recovered.
% flashed steam = 100 Enthalpy of water in boiler - Enthalpy of water at deaerator outlet
Latent heat of evaporation at deaerator outlet
H
-H
US/Imp
= 100 f-114.7 psi f-239F = 100 (308-209) BTU/lb = 10.4% or 0.104
H fg-239F
953 BTU/lb
H
-H
(718-482) kJ/kg
SI metric = 100 f-791 kPa f-115C = 100
= 10.4% or 0.104
H fg-115C
2216 kJ/kg
Once the percentage that flashes to steam is known, it is possible to calculate the energy that can
be recovered by feeding that flashed steam back into the process.
Energy recovered
US/Imp
SI metric
Energy cost
US/Imp
SI metric
=
=
=
=
=
= $39/day
= $39/day
Heat Exchanger: This water is still hot and some additional savings can be achieved by passing
it through a heat exchanger to boost the temperature of the incoming makeup or feedwater. If the
temperature can be reduced to 90F the additional energy recovered will be:
Energy recovered
US/Imp
SI metric
Energy cost
US/Imp
SI metric
=
=
=
=
=
-5-
= $44/day
= $44/day
Notes
C-tower
Setup
This worksheet sets up the units to be used for all the calculations. The appropriate
values will display when the units are selected..
Input
Enter the plant and system identification and the water and product information.
This information will be used for identifying the system in the subsequent
worksheets. If you do not want a title or note to appear, enter a blank. When
multiple units are offered, enter only one steam flow and/or pressure. Boil-Bal will
convert as needed.
Water
This sheet calculates the water consumption and costs. Enter the raw-water cost and
treated-water costs in the appropriate units. Boil-Bal will convert as needed. If the
cost for treated water includes the raw water cost leave the raw water cost blank. If
the water is not treated, leave the treated-water cost blank. Most treatment
processes have a waste stream. Estimate the percentage that goes to waster. With
RO, it could be 30-50%. If treated water is purchased at a fixed cost, the percentage
that goes to waster will likely be 0%.
Water Balance
Flowsheet
This page gives a flowsheet with the water balance shown for the various streams.
Energy
This sheet calculates the energy consumption and costs. Enter either metric or nonmetric units in the appropriate units, but not both. Boil-Bal will convert as needed.
The various calculated values are shown in both units in the lower table. The steam
table values are approximated from a curve fit. The fits is within 1 C or 1% of
the enthalpy for most of the range.
Energy Balance
Flowsheet
This page gives a flowsheet with both the energy and the water balance shown for
the various streams.
Treatment
Worksheet
This is an Excel spreadsheet. Additional worksheets can be added and customized to the user's
application. It is recommended that the existing structure be left intact and that individual values
be accessed by the formula "=existing cell" rather than doing any cutting and pasting. It is also
recommended that such customizing be done with a copy of the original.
-6-
Technical Support
FAQs
This section is a summary of questions that have popped up over the years. Users are encouraged
to supply additional questions as the user is the one with the questions. The developer tends to see
things in their sleep and can miss some critical points.
1. My load cycles from low to high output over the day. How does Boil-Bal handle that?
The chloride measurements that form the basis of the calculation are usually taken at a fixed
time during the day. The calculations will be based upon the load at that time. To get the
bigger picture, a program should be undertaken to do the testing under various load
conditions and develop some form of average condition.
2. Is there a way to do an accurate measurement of the blowdown rate?
The best way to do this is to run the blowdown through a cooler of some type and measure
the liquid flowrate. Ideas to do this have utilized sending the blowdown through a copper
tube. Bend the tube into a tight coiled and put it into a pail through which cold water is run
continuously. Various jury-rigged systems can be established based upon the ideas and
materials at hand.
3. I found that more than 30% of my steam as lost. Is that real?
Very likely. Unless you can measure or calculate it, you don't know how much is lost.
4. I use softened water. What would I gain by switching to demineralized water? Would
adding a demineralizer be cost effective as opposed to adding a heat recovery system?
Try reducing the chloride values for the make-up and feedwater. This will allow you to
simulate the changes. The blowdown rate will go way down.
5. Would adding a demineralizer to replace the softener be cost effective as opposed to
adding a heat recovery system?
Try simulating the conditions for adding the heat recovery and also for adding the
demineralizer. It's now a decision with respect to the engineering costs associated with both.
6. Would it be a good idea to recover some of that last condensate?
Definitely. The make-up requirements would be lower. Try reducing the chloride number on
the feedwater. This will allow you to simulate the changes.
7. You may contact us at the following addresses:
Mail:
Marvin Silbert and Associates
23 Glenelia Avenue, Toronto, Ontario, Canada, M2M 2K6
Telephone: 1-416-225-0226
Fax:
1-416-225-2227
E-mail:
[email protected]
WWW:
http://www.silbert.org
-7-
MN
Boil-Bal
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Developed by:
Boil-Bal uses a number of standard calculations readily available from the literature. To fully interpret the results, it should be
recognized that actual conditions within a cooling tower may differ from those on which the calculations are based due to factors such
wind speed and humidity. Although the calculations do give a reasonable average over the year, the author can assume no
responsibility for any decision based upon the results of the calculations.
This copy licensed to:
Note: The license prohibits making copies other than for backup purposes or operating on more than one computer at any given time.
Instructions:
General
To ensure that data is entered into the correct locations, those cells into which data entries are made are identified by their yellow
colour. The entries into those cells are identified with blue text. Protection in enabled, but no password is needed to disable it. If it is
disabled, be careful not to make any entries into cells with formulae in them.
Setup
This tab sets up the units to be used for all the calculations. The appropriate values will display when the units are selected.
Input
Enter the plant and system identification and the water and product information. This information will be used for identifying the
system in the subsequent worksheets.
The titles go into the cells marked in yellow. Their length is limited by the length of the boxes where the information is used.
If you do not want a title or note to appear, enter a blank
Enter only one steam flow and/or pressure. Boil-Bal will convert as needed.
What if?
To get a limited idea of what might change if:
a. the make-up quality is improved
go the other way if it deteriorates
Water
WaterBal-FS This page gives a flowsheet with the water balance shown for the various streams.
Energy
EnergyBal-FS This page gives a flowsheet with both the energy and the water balance shown for the various streams.
Workspace
Due to the large variety of chemical-treatment programs that are available for different boilers designs and operating pressures, there
is no generalized calculation that fits all. The table is offered only as a means to help the users estimate costs for their system. There
is no implied intent that the end result is either complete or accurate.
Customized
Worksheets
This is an Excel spreadsheet. Additional worksheets can be added and set up in any manner the user desires. It is recommended
that the existing structure be left intact and that individual values be accessed by the formula "=existing cell" rather than doing any
cutting and pasting. It is also recommended that such customizing be done with a copy of the original.
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L M
1 - IG/day
1 - $/day
2 - USG/day 2 - $/yr
3 - m /day
4 - IG/year
5 - USG/year
6 - m /year
Select >>>
Make-up
Raw Water
Treated Make-up
Total Make-up Cost
Losses
Treatment Losses
Blowdown
- Flashed Steam
- Discharged to Sewer
Condensate Lost
2
IG/yr
$/yr
12914365
11229883
20663
11230
31893
1684482
3368965
312550
3056415
7860918
2695
9568
888
8680
22325
1
$/kg
kg/day
kg/yr
1 - lb/hr
2 - lb/day
3 - kg/hr
4 - kg/day
5 - kg/s
6 - lb/yr
7 - kg/yr
Select >>>
3
Water Balance
Flows
Steam
Feedwater
Cond Return
Make-up
Blowdown
Losses
kg/hr
27223
29091
21396
5827
1748
4079
Boiler Pressure
Steam Temperature
Dearator Temperature:
Heat-Exchanger Outlet:
Make-up temperature
Energy Losses
- With No Recovery
- With Flash Tank
- & Heat Exchanger
Energy Savings
- With Flash Tank
- & Heat Exchanger
100
327
239
90
60
Million BTU/yr
9143
5588
1007
3555
4581
8136
psia
F
F
F
F
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XYZ Manufacturing
#2 Utility boiler
Operating with softened water
Phosphate-based treatment
Standard operation
Operating 24/7
STEAM PRODUCTION:
Flow
Pressure
60000 lb/hr
lb/day
kg/day
kg/hr
kg/s
60000
1440000
653180
27223
7.56
kPa
psig
100 psia
689.0 kPa
85.3 psig
100.0 psia
Temperature
Operation
lb/hr
lb/day
kg/day
kg/hr
kg/s
164 C
327 F
365 days/yr
SOLUBLE TRACER
Make-up
Feedwater
Steam Flow
Boiler Blowdown
Cond. Return
Losses
ppm Cl
30
6.5
100
0.1
%
21.4
106.9
100.0
6.42
78.6
15.0
kg/hr
5827
29091
27223
1748
21396
4079
COC
3.3
15.6
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Plant:
XYZ Manufacturing
System:
#2 Utility boiler
Note 1:
Note 2:
Note 3:
Note 4:
Operating 24/7
Flows
percent
kg/s
lb/yr
kg/yr
Steam
Feedwater
Condensate Returns
Make-up
Blowdown
100.00
106.86
78.60
21.40
6.42
6.00E+04
6.41E+04
4.72E+04
1.28E+04
3.85E+03
1.44E+06
1.54E+06
1.13E+06
3.08E+05
9.25E+04
2.72E+04
2.91E+04
2.14E+04
5.83E+03
1.75E+03
6.53E+05
6.98E+05
5.14E+05
1.40E+05
4.20E+04
7.56
8.08
5.94
1.62
0.49
5.26E+08
5.62E+08
4.13E+08
1.13E+08
3.38E+07
2.38E+08
2.55E+08
1.87E+08
5.10E+07
1.53E+07
14.98
8.99E+03
2.16E+05
4.08E+03
9.79E+04
1.13
7.88E+07
3.57E+07
Losses
lb/hour
lb/day
kg/hr
kg/day
+ Treatment Cost
1.00
$/1000 IG
$/1000 usg
$/m
Water Lost by
Treatment Process
$/1000 usg
$/m
IG/day
USG/day
m/day
35382
30767
42458
36920
161
140
$/day
15
IG/yr
usg/yr
m/yr
1.29E+07
1.12E+07
1.55E+07
1.35E+07
58702
51045
$/yr
Make-up
Raw Water
Treated Make-up
- Total Make-up Cost
Losses
Treatment Losses
Blowdown
- Flashed Steam
= Blowdown to Sewer
Condensate Lost
57
31
87
20663
11230
31893
4615
5538
21
1.68E+06
2.02E+06
7657
2695
9230
856
8374
21537
11076
1028
10048
25844
42
4
38
98
26
2
24
61
3.37E+06
3.13E+05
3.06E+06
7.86E+06
4.04E+06
3.75E+05
3.67E+06
9.43E+06
15313
1421
13893
35731
9568
888
8680
22325
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Make-up
30 ppm Cl
21.4 %
5827 kg/hr
Condensate Return
0.1 ppm Cl
78.6 %
21396 kg/hr
Feedwater
6.5 ppm Cl
106.9 %
29091 kg/hr
Losses
15.0 %
4079 kg/hr
HEAT
LOAD
DEAERATOR
Steam
100.0 %
27223 kg/hr
BOILER
COC - MU =
- FW =
3.3
15.6
Blowdown
100 ppm Cl
6.42 %
1748 kg/hr
XYZ Manufacturing
#2 Utility boiler
Operating with softened water
Phosphate-based treatment
Standard operation
Operating 24/7
D:\NetFiles\!sprdsht\VBaler\BoilBal.XLS
07-06-19
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Plant:
XYZ Manufacturing
System:
#2 Utility boiler
Note 1:
Note 2:
Note 3:
Note 4:
Heat Value:
3555
4581
8136
$/GJ
239 F
90 F
60 F
GJ/day
26.4
16.2
2.9
GJ/yr
9646
5895
1063
$/day
295
180
32
$/yr
107,582
65,748
11,852
10.3
13.2
23.5
3751
4833
8583
115
148
262
41,834
53,897
95,730
100
296
239
208
953
60
28
9.3
1160
1132
psia
BTU/lb
F
BTU/lb
BTU/lb
F
BTU/lb
%
BTU/lb
BTU/lb
58 BTU/lb
90 F
150 BTU/lb
7.807 $/GJ
689
688
115
483
2216
16
65
9.3
2699
1195
kPa
kJ/kg
C
kJ/kg
kJ/kg
C
kJ/kg
%
kJ/kg
kJ/kg
135 kJ/kg
32 C
158 kJ/kg
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BLOWDOWN DISCHARGED
1007 Million BTU/yr
3.06E+06 IG/yr
11852 $/yr - Energy
8680 $/yr - Water
20532 $/yr - Energy + Water
RAW WATER IN
1.29E+07 IG/yr
20663 $/yr
90 F
TREATMENT
TREATED MAKE-UP
60
MAKE-UP
PLANT
1.12E+07 IG/yr
31893 $/yr
21.4
5827
4581
53897
239 F
%
kg/hr
Million BTU/yr
$/yr - Energy
FEEDWATER
106.9 %
29091 kg/hr
HOT WATER
5588 Million BTU/yr
3.06E+06 IG/yr
65748 $/yr - Energy
8680 $/yr - Water
74429 $/yr - Energy + Water
CONDENSATE RETURN
78.6 %
21396 kg/hr
LOSSES
15.0 %
4079 kg/hr
7.86E+06 IG/yr
22325 $/yr - Water
DEAERATOR
239 F
HEAT LOAD
STORAGE TANK
FLASHED STEAM
3751 Million BTU/yr
3.13E+05 IG/yr
41834 $/yr - Energy
888 $/yr - Water
42721 $/yr - Energy + Water
BOILER
27223 kg/hr
100 psia
327 F
COC
- MU =
- FW =
FLASH TANK
3.3
15.6
STEAM
100.0 %
27223 kg/hr
BLOWDOWN
6.42 %
1748 kg/hr
9143 Million BTU/yr
3.37E+06 IG/yr
107582 $/yr - Energy
9568 $/yr - Water
117150 $/yr - Energy + Water
D:\NetFiles\!sprdsht\VBaler\BoilBal.XLS
XYZ Manufacturing
#2 Utility boiler
Operating with softened water
Phosphate-based treatment
Standard operation
Operating 24/7
07-06-19
A
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19
20
Plant:
XYZ Manufacturing
System:
#2 Utility boiler
Note 1:
Note 2:
Note 3:
Note 4:
TREATMENT COSTS
TREATMENT PRODUCTS:
........
to steam
........
"
........
to feedwater
........
"
........
to make-up
........
"
mg/L
10
10
10
10
10
10
$/kg
5.00
5.00
5.00
5.00
5.00
5.00
kg/day
0.3
0.3
0.3
0.3
0.1
0.1
$/day
1.36
1.36
1.45
1.45
0.29
0.29
6.21
kg/yr
99
99
106
106
21
21
$/yr
497
497
531
531
106
106
2268