KZ Energetik LLC has produced, installed and commissioned a combined transportable boiler plant TKU-3,5R (E) with a steam capacity of 8 tons of steam / hour for the Rozhysche Cheese factory. The boiler unit modules are made in the corporate colors of the customer.
Installation Summary:
The transportable boiler plant TKU-3,5R (E) with a steam capacity of 8 t / h is designed to generate dry superheated steam with a working pressure of up to 1.3 MPa.
The boiler room is a complete factory-assembled set of equipment installed in transportable block modules and designed for operation in open areas.
The boiler consists of separate blocks (modules) in which the equipment is located that ensures the operation of the boiler room.
Since in the future it is planned to increase the productivity of the boiler room to 10 t / h, the auxiliary equipment is selected taking into account the prospects.
After installation and connection of all pipelines, the boiler room represents itself as a single boiler unit, consisting of the following units:
- boiler room metalwork (4 modules (an operator’s cabin, workshop room / laboratory assistant’s office, bathroom is provided));
- steam boilers: E-2.5-1.4R (E) -250 with a pre-furnace SAS-2000, economizer EB-2.5R (E), ash collector SZCh and smoke exhaust DN-9 - 2 pcs .; E-4.0-1.4-250G (E) with a gas burner Unigas R93, economizer EB- 4.0 (E), smoke exhaust DN-9;
- boiler feed system, consisting of a sodium cation exchange water treatment plant BWT with a capacity of 10 m 3 / h, automated atmospheric deaerator DА-10 / 8А (the deaerator must be installed at a mark of at least 6 m from the boiler floor level to ensure selection of boiler feed pumps), feed pumps (2 pcs. per boiler (1 slave. + 1 rez.)), a tank of chemically treated water stock of 5 m 3 (the tank is installed under the roof of the module), a water pump, two pumps for supplying chemically purified water to the deaerator (1 slave. + 1 res.), plate steam-water heat exchanger with a capacity of 10 m 3 / h for heating chemically purified water, a tank for collecting condensate with a volume of 3 m 3 , two pumps for supplying condensate to the deaerator (1 work. +1 res.);
- DHW heating unit with a heating capacity of 1.2 MW (plate-type steam-water heat exchanger, circulation pump, shut-off and control valves, instrumentation);
- boiler room heating and ventilation systems (forced-air ventilation and heating installation with electric heater, forced-air axial fan, exhaust fan);
- electrical equipment;
- steam collector with metering unit SVP-2500;
- control systems (automation of boilers "Alpha-M-XXI" based on BAU-TP-1) and instrumentation.
To determine the oxygen content in the flue gases of the boilers, a portable gas analyzer-oxygen meter Dozor-S-M-D is provided.
The boiler room is equipped with a chimney Ø630 mm, 21 m high, connecting flues (flue gases are removed from solid fuel boilers to the customer's chimney).
The boiler room provides technological accounting of gas, electricity, steam, return condensate, heat, source water.
Description of the boiler room:
The boiler room operates according to the following scheme: the pellet is fed via a fuel conveyor to the loading devices, from where it is fed by a screw to the pre-furnaces where the fuel is burned. Hot flue gases from the pre-furnace are fed to steam boilers E-2.5-1.4P (E) -250. Natural gas is supplied to the burner of a gas boiler through a medium pressure gas pipeline. The gas pipeline has a gas meter, an electromagnetic shut-off valve.
Boilers are supplied with water from the DA-10 / 8A deaerator using boiler feed pumps. Water passes through economizers, after which it is supplied to the upper booms of boilers.
Saturated steam from the boilers is fed to superheaters, then to the steam collector, and then to the consumer.
Periodic purging of boilers is carried out through valves installed at the lower points of the collectors of the side screens.
The feed water for boiler feed is supplied by the HVO pump to the chemical water treatment plant, then to the chemically purified water reserve tank. Chemically purified water is pumped by a thermal unit through a heat exchanger (where it is heated to a temperature of 70 ° C) is supplied to a deaerator.
Condensate from consumers is returned to the condensate tank. By condensate pumps, condensate is pumped into the tank of chemically purified water.
The hot water supply unit consists of a heat exchanger, a circulation pump, shut-off and control valves, instrumentation.
Part of the saturated steam from the boilers is selected for supplying chemically purified water for heating, for heating water in the hot water supply unit, for the needs of the deaerator.
On the side wall of the furnace of solid fuel boilers, doors and ash-pans are organized to clean the boiler from ash. The frequency of cleaning is determined during the commissioning of the boiler and depends on the ash content of the fuel.
To extinguish and cool the ash before unloading, a pipeline with process water is supplied to the boilers.
To extinguish fuel in a box with a screw between the loading device and the pre-furnace, a pipeline with technical water is brought to the tank with a supply of water on the loading device, and further, directly to the box.
Installation Specifications:
The values indicated in the table are provided when burning wood chips or pellets with a granule size of not more than 30 mm from hardwood, humidity up to 10%, natural gas (when using another type of fuel, the values may differ from those indicated).
|
№ |
Parameter Name |
Dimension |
Magnitude |
|
1 |
Nominal steam capacity: - general - two boilers Е-2,5-1,4-250Р(Э) - boiler Е-4,0-1,4-250Г(Э) |
t/h |
8 4 4 |
|
2 |
Thermal power |
MW |
5,6 |
|
3 |
The range of changes in boiler performance: - Е-2,5-1,4-250Р(Э) - Е-4,0-1,4-250Г(Э) |
% |
40-100 30-100 |
|
4 |
The parameters of the coolant. Dry superheated steam: - pressure (excessive) - temperature Water for domestic hot water: - pressure (no more) - temperature (feed / ref.) |
MPa °С
MPa °С |
0,9 250
0,6 55/5 |
|
5 |
The efficiency of the boiler, not less than: - Е-2,5-1,4-250Р(Э) - Е-4,0-1,4-250Г(Э) |
% |
78 94 |
|
6 |
Overall dimensions of a boiler room, no more: - length - width - height (without deflector) |
mm |
12300 14280 3580 |
|
7 |
Mass of the boiler room (only modules with boilers and equipment, without taking into account the mass of ash collectors, smoke exhausters, fuel hoppers) |
t |
85 |
|
8 |
Estimated fuel |
|
Wood chips, pellets / Natural gas |
|
9 |
Fuel consumption (depends on the calorific value of the fuel, given tentatively): - wood chips, pellets - natural gas |
Kg/h нм3/h |
792 326 |
|
10 |
Necessary pressure of natural gas at the inlet to the boiler room |
kPa |
6 |
|
11 |
Explosive, explosion and fire hazard category |
|
Г |
|
12 |
Fire resistance of building structure |
|
IIIa |
|
13 |
Class of constructive fire hazard |
|
С0 |
|
14 |
Functional Fire Hazard Class |
|
Ф5.1 |
|
15 |
Boiler category for reliability of heat supply to the consumer |
|
2 |
|
16 |
Average service life, not less |
h |
60000 |
Architectural and construction solutions:
The boiler room metalwork is a room consisting of separate modules (blocks) fastened together by pins.
The module is a heat-insulated base with a height of 140 mm, on which heat-insulated walls are placed with a thickness of 100 mm, as well as a heat-insulated roof with a thickness of 60 mm. Rockwool mineral wool mats with a thickness of 100 mm are used as insulation. The module is made of channel 14P, pipes of rectangular section 100 × 100 mm, pipes of rectangular section 60 × 40 mm, angle 50 × 50.
The gable roof is removable. The roof is fixed to the module using bolt connections. In the upper part there are two deflectors (on each module) for removing hot air from the area above the boiler. At the ends of the roofs are ventilation openings covered with louvres. The openings are used to supply air to the ventilation and heating installations, to remove air from the boiler room with an exhaust fan.
Outside, the module is sheathed with a metal profile sheet with a polymer coating. The sheet is fastened with self-tapping screws. The roof is sheathed outside with a 2 mm thick steel sheet, followed by painting. The connection of the casing with the roof frame is made by welding. Inside, the module and the roof are sheathed with steel sheet with a thickness of 0.8-1.0 mm, followed by painting. Fastening sheets - self-tapping screws. The boiler room floor is made of 4 mm thick corrugated steel sheet.
The openings between the blocks from the side of their connection for the duration of transportation are closed with temporary removable sheets. During installation at the "Customer" the modules are placed on a flat platform and pulled together with pins through openings in the protruding parts of the base.
The joint between the roofs in order to prevent water from entering the boiler room is closed by a special drain.
On the end walls of the boiler room there are two doors that open outwards. Also, on the longitudinal and end walls of the modules there are windows. Glazing of window and door openings provides natural lighting for the boiler room and the required area of easily erasable structures.
Fuel is supplied to the pre-furnace by a loading device. Fuel is supplied to the loading device from the fuel hopper by a conveyor. The fuel supply system to the loading device is provided separately in the boiler room binding project.
Ash removal from the pre-furnace is done manually through the technological door on the left side of the pre-furnace and is removed from the boiler through one of the doors.
Chimney is metal, in the frame, without insulation. The foundation for the pipe, ash collectors, smoke exhausters - reinforced concrete (provided for in a separate project).
Layout of equipment in TKU-3,5R (E)
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