Process carried out in factory need steam of should be dry enough to give amount of heat to threads for drying them. But the problem is that steam coming to the process application area, is not dry enough to give satisfactory results. Steam produced at boiler is of required quality but when it reaches to application area it is of low quality. This is major concern for the factory employees. It also affects operation of process equipment as the equipment has to work under this faulty condition and this will lead to premature failure of process equipment.
Even this wet steam cause many other problems like corrosion of gauges, less heat transfer due to layer of water, premature failure due to corrosion of gauges, improper working of equipment under this condition, poor quality of product, higher fuel consumption and higher expense on fuel. This all problem is due to wet steam so we find that this problem is important to consider and there is lot of scope of savings in terms of cost as well as energy.Another problem was occurring with chimney. Main function of chimney is disposal of waste hot flue gases, produced at the end of combustion process in the furnace, to atmosphere. Here factory is using wood fired water tube boiler, so the wood is fired in the combustion chamber to produce steam in water tubes for process.
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Then this hot gases coming out of furnace is used for preheat water in economizer. Hot flue gases passing through economizer, will then come to chimney from where it will dispose to atmosphere. Chimney of circular cross section is used. Here the main problem in industry is that chimney is blocked in 6 to 7 days because of disposal of carbon on surface of the chimney wall.
Because of this workers have to clean the chimney every week otherwise the combustion process cannot be proceeded due to choke up of chimney. Boiler operation is off during cleaning of chimney and this makes the boiler to cool down. When the cleaning is done, the boiler can be used. When boiler is started again, it will take some hours to heat it up then it can give actually heat to the water to produce steam. This will lead to time consuming process as well as productivity is also affected. Due to this problem factory has to face the problems like less productivity, required more time to clean chimney and fully utilization of equipment is not achieved.
3.2 Major IssuesDuring visit we had found that there is certain problem in plant regarding to chimney and Quality of steam. Factory workers and senior employees decided to support and help us in our project.
They were ready to give any kind of information related to plant based on our project. As in factory two problems are there, so we have decided to include both problems in our project.1) Inefficient steam system3.2.1 Inefficient steam system:Steam quality is an important factor that affects the quality of product and fuel consumption of process, process time and is directly related to cost of product and cost of fuel.
Process carried out in factory need steam of enough dryness fraction that is steam should be dry enough to give amount of heat to threads for drying them and wet enough so that it will not damage the threads. Here we found that steam coming to the process application area, is not dry enough to give satisfactory results. Steam reached at application area is of less dry. Steam produced at boiler is of required quality but when it reaches to application area it is of low quality.
This is major concern for the factory employees. It also affects operation of process equipment as the equipment has to work under this faulty condition and this will lead to premature failure of process equipment.Even this wet steam cause many other problems like Corrosion of gauges, less heat transfer due to layer of water, premature failure due to corrosion of gauges, improper working of equipment under this condition, poor quality of product, higher fuel consumption and higher expense on fuel. This all problem is due to wet steam so we find that this problem is important to consider and there is lot of scope of savings in terms of cost as well as energy.
