Maritime University of Szczecin
Akademia Morska w Szczecinie
2010, 24(96) pp. 33–40 2010, 24(96) s. 33–40
The analysis of thermal-oil heating systems with exhaust gas
heaters on motor ships
Analiza olejowych systemów grzewczych z nagrzewnicami
utylizacyjnymi na statkach motorowych
Ryszard Michalski, Wojciech Zeńczak
West Pomeranian University of Technology, Faculty of Maritime Technology Department of Heat Engines and Marine Power Plants
Zachodniopomorski Uniwersytet Technologiczny, Wydział Techniki Morskiej Katedra Maszyn Cieplnych i Siłowni Okrętowych
71-065 Szczecin, al. Piastów 41, e-mail: ryszard.michalski@zut.edu.pl, wojciech.zenczak@zut.edu.pl
Key words: ship’s heating system, thermal oil heater, exergetic analysis Abstract
The article characterises the properties of steam and special thermal oils as the basic heating media on motor ships. The features of the heating installations have been presented with the particular attention drawn to thermal oil installations in which exhaust gas heaters have been employed. Also an example of the comparative exergetic analysis has been included demonstrating the comparison between steam generation in exhaust gas boiler and oil heating system in the heater, assuming the identical heat flux transferred in the boiler and the heater from the exhaust gas to the heating medium (steam and thermal oil) and assuming identical increase of exhaust gas entropy in the heat exchangers under examination.
Słowa kluczowe: okrętowy system grzewczy, nagrzewnice olejowe, analiza egzergetyczna Abstrakt
W referacie scharakteryzowane zostały własności pary wodnej i specjalnych olejów grzewczych jako pod-stawowych czynników grzewczych na statkach motorowych. Przedstawiono cechy instalacji grzewczych ze szczególnym uwzględnieniem instalacji olejowych, w których występują nagrzewnice utylizacyjne. Zamiesz-czono także przykład porównawczej analizy egzergetycznej systemu wytwarzania pary w kotle utylizacyjnym oraz systemu podgrzewania oleju w nagrzewnicy przy założeniu jednakowego strumienia ciepła przekazywa-nego w kotle i nagrzewnicy od spalin do czynnika grzewczego (pary wodnej i oleju) oraz przy założeniu jed-nakowego przyrostu entropii spalin w rozpatrywanych wymiennikach ciepła.
Introduction
Mostly steam and special thermal oils have been applied as heating media on ships. Water or hot air have been used in a lesser degree and electric energy is used just occasionally. To obtain the high temperature of the heated media by using such media as water or steam it is necessary to apply sufficiently high pressure. The high pressure of steam is also necessary to make up for the pressure losses in the long cargo heating pipelines on some tankers. This fact increases the risk of the loss of
tightness and steam leakages and its condensate to the heated working media as well as to the cargo. This is absolutely not allowed, in particular while heating the concentrated acids and bases or liquid sulphur. In such cases, as well as on many other ship types, the special thermal-oils have been used as heat carriers which are characterised by the relatively stable physical and chemical properties within the broad range of the changes of their working temperatures. Additionally the oil heating systems are significant for their higher efficiency values as compared to the steam systems, do not
post the corrosion danger, are suitable for the full automation which allows their unmanned operation. The heat source in the ship’s heating systems is the energy coming from the combustion of fuels in the steam boilers or oil heaters. On the motor ships in high degree the waste heat energy is used in the form of the heat contained in the main engines exhaust gases.
Steam heating system
In the heating technology the saturated steam (dry or humid) is generally used, less frequently the slightly superheated steam. The advantage of the steam in relation to the other heating media is its constant temperature within the condensation process. The significant parameters of steam, as the heating medium, are the temperature and saturation pressure. As generally known, these values are closely interrelated. Thus the application of high pressure steam requires adequately high pressure values throughout the entire installation. The steam working temperature determines indirectly the required strength of the equipment used in the steam installation.
Another important parameter is the water evapo-ration specific enthalpy whose value decreases together with the pressure rise and the increase of the saturation temperature. It reaches the value equivalent to zero in the critical conditions (pk =
22.1 MPa, Tk = 647.3 K). From this point of view in
the heating installations there should be used steam of low pressure corresponding to the large value of the evaporation enthalpy. Within the practically used pressure range the value of the saturated steam specific enthalpy increases together with the pres-sure rise. The heating steam higher prespres-sure values correspond to its higher density which allows the application of lower diameter pipelines. However, it should be reminded that together with the pres-sure increase the water evaporation specific en-thalpy decreases which affects the heat exchange surface of the heaters. The finally adopted working parameters of the heating system are usually based on compromise. However it should be emphasised that the choice of the heating steam pressure chiefly depends on the temperature values to which the working media are to be heated in engine room. In the engine rooms of the ships which do not carry the heating requiring cargo the saturated steam under 0.4–0.8 MPa is used which correspond to the saturation temperature 416.75–443.57 K accord-ingly. The steam pressure values on tankers reach as high as 1.2 MPa (saturation temperature of 461.1 K). The reason to choose the higher pressure
values in such cases are inter alia larger pressure drops of steam in the long pipelines, a possibility of the reduction of the steam supply piping diameters, the reduction of heat exchange surface resulting from the higher temperatures and the ensuring of the heating medium and condensate flow without any additional equipment [1].
The condensate leaving the heaters is cooled down to the temperature approximately 343 K in the condensate cooler or in case of not excessively high temperatures – in hotwell. This operation is necessary to provide the protection for the boiler feed pump against cavitation and water evaporation in the suction stub pipe. However it causes some significant heat losses in the steam-water installa-tion thus visibly reducing the efficiency of the steam heating system.
Oil heating systems
The heating oils can be divided on account of their origin into the mineral and synthetic ones. The mineral oils, of natural origin, consist the mixture of many hydrocarbons, amongst which the satu-rated paraffin hydrocarbons are of the biggest im-portance. The chemical structure of mineral oils is very much varied and depends to a large extent on the origin of the raw material and the methods of its processing in the refineries. In the effect the proper-ties of the mineral oils are hardly reproducible and keep on changing in various manners during the use. The mineral oils may be used in the heating systems where the temperature of the medium does not exceed 593.15 K. In case of the necessity to use higher working temperatures the synthetic oils are applied which are the products of closely monitored chemical synthesis. Their chemical composition is more stabilised therefore they are easier reprodu-cible in the production in various factories which means keeping their properties as the same. Since the majority of the motor ships has no need to heat the working media up to very high temperatures, and the heat supply to the thermal oil is effected mainly in the exhaust gas heaters, the preferable heat carriers are the mineral oils. At the same time these are cheaper than the synthetic oils, easier available and non-toxic.
The thermal oils of less density have better thermal properties and provide better heat condu-ctivity. In case of thermal oils an important parame-ter is their viscosity because it influences the flow rate and nature, thus the intensity of the heat ex-change and provides the possibility of oil pumping in low temperatures. The relatively low viscosity of thermal oils and the large value of viscosity index
ensures the high coefficients of heat exchange and the constant properties within the wide temperature range as well we facilitates oil circulation while starting the heating system in low temperatures. Another significant parameter is also the solidifica-tion temperature. This is used to evaluate the pos-sibility of oil storage and transfer and its flow capacity inside the gravity-supplied system in low temperatures.
The mineral oils as opposed to the popular synthetic oils are characterised by the vapour low pressure (the less as the higher oil viscosity is). At the maximum working temperature it is usually lower than the atmospheric pressure owing to which it is possible to use so called non-pressure heating systems. In case it is necessary to use the higher temperatures, the need arises to apply, eg inside expansion tank, a minor overpressure of the inert gas, usually nitrogen or the adoption of the hermetic installations to prevent the formation of the vapour-locks.
The minimum working temperature of the heating system is determined by the oil capacity to circulate through the heater prior to its starting. The minimum temperature determinant is the corres-ponding oil viscosity with which the pumps are still capable of oil pumping (ca 300 cSt) [2].
Theoretically, in the oil heating installation the oil may be heated below the temperature deter-mining the beginning of its boiling (the temperature where the oil vapour pressure is equal to the ambient pressure). In practice the upper working temperature is limited by the value where oil thermal decomposition rapidly increases).
An important parameter is the specific heat ca-pacity of the heating medium. It influences the in-tensity of its heat transfer in the heating systems. A strong relation of its value to the temperature should be noted. For example at the temperature of 273.15 K the mineral oil heat capacity ranges within 1.76–1.83 kJ/kgK), whereas at the tempera-ture of 573.15 K it ranges within 2.83–3.02 kJ/kgK. The heat capacity values of the synthetic oils are less than those of the mineral oils [2]. As can be seen these are values approximately twice less than for the water. This means that the oils require twice as big flow (larger energy consumption) or the increase of the heat flux in oil heater (large and expensive boilers).
The heat conductivity of the mineral oils which is of major significance in the heat exchange, at the temperature of 273.15 K ranges within 0.129–0.135 W/mK, whereas at the temperature of 573.15 K it is within 0.11–0.114 W/mK [2]. This is higher than the specific heat capacity of the synthetic oils.
Oil during the operation within the heating sys-tem changes its chemical properties which is collo-quially referred to as the oil deterioration. These changes are mainly caused by the oxidation and thermal cracking, particularly in higher tempera-tures. The visible results of oil deterioration are the collecting of harmful substances such as resins and coal sediments. The sediments are partly suspended in oil and partly precipitated and deposited on the parts of the installation, and the additionally gene-rated organic acids have a corroding effect on metals. Also oil viscosity changes in a high degree in the result of the generation of compounds of larger molecular weight [3, 4].
Exergetic analysis [5] may become helpful for the calculations of the thermal processes, particu-larly effected within the relatively low temperatures of the working media. For this purpose it is useful to find the specific exergy of the working media participating in the processes under investigation. Assuming that the oil pressure does not exceed 0.3 MPa or is equal to the ambient pressure (in the non-pressure systems) and that the specific heat capacity value is constant, its specific exergy can be calculated from the equation (1).
ot ot ot p fT T T T T T c b ln (1)
where: cp – oil specific heat capacity, T – oil
tem-perature, Tot – ambient temperature.
On the basis of this relation the calculations of the exergy of the synthetic and mineral oils have been conducted at the ambient temperature of 303.15 K within the oil temperature variations within 313–633 K. The course of the changes of the oil specific exergy in the unction of its temperature is shown in figure 1. On the other hand the figure 2 shows the density of exergy for the oils and steam.
In comparison with the water and steam the exergy of oils is less. However, the density of the oil exergy is significantly bigger than the density of steam exergy, particularly within the high tempera-ture range. It should additionally be noted that the obtainment of the same temperatures for water and steam as well as for oil is connected with the necessity to apply very high pressures.
In the heat exchange systems the oil oxidation possibilities are limited since this is only in the expansion tank that the oil gets in contact with the air. The air whose solubility in oil reaches as far as nearly 10% volume may also enter the system through minor leakages [2].
The oils used in the heating systems are charac-terised by the high thermal stability and good
resis-tance to oxidation within the temperature ranges occurring in service. Owing to that the rate of their decomposition and oxidation is small which en-sures long period of oil usability without formation of sludge and sediments which are likely to be the cause of the disturbances in the operation of the heating system. It should be noted that the synthetic thermal oils ensure better thermal stability and higher resistance to oxidation as compared to the mineral oils.
The most important feature thanks to which the thermal oils tend to substitute the steam as the heating medium is the possibility of their appli-cation at the low values of the working pressures whose value depends almost entirely on the flow resistance in the heating installations. Thermal oil installation is either the installation of the open type, “non-pressure” (the oil compensation tank is connected with the atmosphere), or the closed type,
low-pressure with pressure values not exceeding 0.1–0.3 MPa [6]. This enables to obtain the temperatures up to 593.15 K for mineral oils or up to 633.15 K for the synthetic oils remaining in the liquid stage. The achieving of such high tempe-ratures of the heating steam would require the application of significantly more expensive, high- -pressure steam installation. Therefore the first ships where the oil heating system has been applied have been the tankers designed to carry heavy petroleum products, eg bitumen, asphalt where the required heating up temperatures are in the order of 493.15 K (the application of the steam system would necessitate the used of steam under 4 MPa). In case of the application of the cargo thermal oil heating, the system generally is used also to cover the remaining heating needs of a ship.
In the open type installations oils of large viscosity are used which are characterised by the high flashpoint ensuring better work safety. The closed type installations with oil of low viscosity are, however, more efficient [2].
In case the heating installation is put out of operation, the application of oil to heat up the petroleum product cargoes eliminates the possibi-lity of the petroleum products entering the heating medium which might take place in the steam heating systems. This phenomenon is prevented by placing the oil expansion tank at the highest point of the entire installation [7].
If on ship’s board there is a need of steam, eg to conduct the technological processes (on fish factory trawlers, for tank cleaning, ice removal etc), it can be additionally produced in the steam generators heated with thermal oil.
The overall thermal efficiency of the thermal oil installation, reaching the value within 0.75–0.85, is higher than the efficiency of the steam installation (0.55–0.65) owing to the elimination of the heat losses occurring in the steam installations at the condensate side. Also the working medium losses in the thermal oil installations are smaller than the medium losses in the steam heating installations [7].
Owing to the possibility to apply the higher temperatures of the working medium in the thermal oil installations, there is no need to increase the heat exchange surface, and the low pressure pre-vailing in these installations causes that the invest-ment costs of such installations do not increase in comparison to the conventional steam installations. An opportunity to reduce the heat exchange surface within the oil heating process is the application of the fluidised-bed heaters, both for exhaust gas as well as the independent, oil-fired ones.
Fig. 1. The physical specific exergy values for the synthetic and mineral oils and dry saturated steam in the function of the temperature Tot = 303.15 K
Rys. 1. Egzergie fizyczne właściwe olejów: syntetycznego i mineralnego oraz pary wodnej nasyconej suchej w temepera-turze Tot = 303,15 K
Fig. 2. The density of the physical exergy values of synthetic and mineral oils and dry saturated steam in the function of the temperature Tot = 303.15 K
Rys. 2. Gęstość egzergii fizycznych olejów: syntetycznego i mineralnego oraz pary wodnej nasyconej suchej w funkcji temperatury Tot = 303,15 K S pe cifi c ex erg y, k J/ kg E xe rg y de nsit y, k J/ m 3 Temperature, K Temperature, K Min. oil Synth. oil Steam Min. oil Synth. oil Steam
The basic arrangements of the thermal oil heating installations with the exhaust gas heaters
In order to increase the general efficiency of ship’s engine room / power plant there are used the combined systems of thermal oil heating of the heating medium in the independent heater and in the exhaust gas heater utilising the main engines’ and at times also auxiliary engines’ exhaust gases. Both heaters can operate separately and / or jointly, ie in the parallel or series set-up. In the series operation as first the low temperature exhaust gas heater is applied. The parallel connection is applied in case when the large heat amounts are necessary for the cargo heating in cargo tanks of the ship. The oil-fired heater is automatically started, if the heat needs exceeds the exhaust gas heater production capacity. The figure 3 shows for instance the instal-lation with the exhaust gas heater operating in the series set-up with the independent heater.
Thermal oil heating installations with the inde-pendent and exhaust gas heater can totally replace
the steam installations on the majority of ships. Most frequently they are employed on: tankers for the carriage of high viscosity petroleum products, container ships, fish factory trawlers operating in Arctic waters, chemical tankers, ice-breakers.
In case of ship’s indirect propulsion with two medium-speed Diesel engines it is possible to apply two exhaust gas oil heaters which may operate in the parallel system or the series system (Fig. 4). Operation in the series system with the independent heater is also possible. Such arrangement provides possibilities of the heating system operation with various connection versions. This enables rational generation and use of energy [8].
More complex thermal oil installations are ap-plied on tanker used for the carriage of molten sul-phur. The sulphur during the transport should be stored at the temperature within 408.15–423.15 K when it shows the smallest viscosity and does not change its properties. The temperature increase above this value causes that the sulphur viscosity increases and it densifies around heating coils stick-ing to the pipes, which in effect creates their
Fig. 3. Oil heating installations by means of the independent and exhaust gas heaters operating in the series set-up; 1 – independent heater; 2 – exhaust gas heater; 3 – expansion tank; 4, 5 – circulating pumps; 6 – drain tank; 7 – storage tank; 8 – topping-up pump / replenish pump; 9 – oil cooler; 10 – deaerating heater [2]
Rys. 3. Instalacja podgrzewania oleju nagrzewnicą niezależną i utylizacyjną w układzie szeregowym; 1 – nagrzewnica niezależna; 2 – nagrzewnica utylizacyjna; 3 – zbiornik wyrównawczy; 4, 5 – pompy cyrkulacyjne; 6 – zbiornik ściekowy; 7 – zbiornik zapaso-wy; 8 – pompa uzupełniająca; 9 – chłodnica oleju; 10 – podgrzewacz [2]
to the consumers
efficient thermal insulation. This necessitates the application of the system with the heating medium of two different temperatures, the lower, not ex-ceeding 433.15 K in the sulphur heating installation and the higher, in the engine room’s heating instal-lation and ship’s general instalinstal-lation. One of the solutions may be two-line circulation installation where the thermal oil of lower temperature is heated in the heater by the high temperature circu-lation line oil [6].
Finally the choice of a given heating system are chiefly determined by the cargo heating conditions, costs of construction and operation of the instal-lation.
The manufacturers of the thermal oil heating systems assure that the heater heat exchange surfaces should not be bigger than in the steam installation, if oil temperature not less than 533 K is assumed. However, choosing such temperature put out of the question the application of exhaust gas boiler operating independently. It is only possible for the boiler to operate in the series set-up with the
oil-fired heater which would heat up the oil. Such system, however, does not offer such energy savings as the parallel system with the exhaust gas heater operating independently while at sea. This will be connected with the increase of the heat exchange surface of the heaters. The preliminarily conducted calculations have proven that in case of eg engine room’s tank heating coils the total length of the pipes has increased by approximately 30% in relation to the length of the heating coils in the steam system [2].
Exergetic analysis of the heat exchange process in the steam-water boiler and oil heater
The calculations have been carried out under assumption of the identical heat flux transferred in the boiler from the exhaust gas to the heating medium (steam or oil) and under assumption of the identical increase of the exhaust gas entropy in both kinds of heaters. Do odbiorników Z odbiorników 3 6 8 9 11 4 5 7 10 to the consumers
from the consumers
Fig. 4: Thermal oil heating system with two exhaust gas heaters; 1 – storage tank; 2 – drain tank; 3 – independent heater; 4, 5 – ex-haust gas heaters; 6 – oil surplus cooler; 7 – transfer pump; 8, 9 – circulating pumps; 10 – expansion tank; 11 – deaerating heater [8] Rys. 4. Olejowy system grzewczy z dwiema utylizacyjnymi nagrzewnicami; 1 – zbiornik zapasowy; 2 – zbiornik ściekowy; 3 – nagrzewnica niezależna; 4, 5 – nagrzewnice utylizacyjne; 6 – chłodnica nadmiarowa oleju; 7 – pompa transportowa; 8, 9 – pom-py obiegowe; 10 – zbiornik ekspansyjny; 11 – odgazowywacz [8]
The ratio of the increase of the entropy of the heating media (steam and oil) has been determined as:
p wz
p ol ol pol ol p ol s s m T T c m S S ln (2)
ol ol
pol wz p p ol T T c i i m m (3) thus:
p wz
ol ol
ol ol wz p p ol T T s s T T i i S S ln (4) where: mol,mp – stream of oil or generated steam;p p i
s , – entropy and specific enthalpy of the steam at the saturation line; s ,w iwz – entropy and specific enthalpy of the boiler feed pump; Tol,Tol – thermal oil temperature at the heater outlet and inlet; cpol – thermal oil specific heat capacity (constant value assumed).
For the purposes of comparison of the steam and oil systems the constant value of the oil temperature has been assumed at the return to the heater (Tol1 =
303.15 K). On the other hand, the temperatures of boiler feed water (Tw1) have been changed within
323.15–343.15 K. As displayed by the calculations performed, the increase of the temperature of both media at the outlet from the heat exchangers, with the assumed identical exhaust gas entropy incre-ases, bigger increases of the entropy of the thermal oil do occur than the increases in water and steam entropy. This leads to the bigger increase of entropy within the process of oil heating as compared to the water and steam heating. This is the result of the faster drop in entropy increase in the steam generation process in relation to the thermal oil heating system. However, it should be noted that the higher temperatures of steam correspond to higher saturation pressures and lower evaporation enthalpy. The courses of the changes in the entropy increases are illustrated by the curves in figure 5.
It should be noted that the increase in the boiler feed water temperature is accompanied by the growth of the ratio of the increase of the oil entropy to the increase of water and steam entropy. Similar as in figure 5 is the nature of the course of the curves in figure 6, illustrating the ratio of the in-crease of the entropy of oil to the inin-crease of the entropy of water and steam in the function of the
heating media temperature for the various tempera-tures of oil at the heater inlets with the boiler feed water constant temperature (Tw1 = 303.15 K).
1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 425 435 445 455 465 475 485 495 505 515 525 535 545 555 565 575 R at io o ft he e nt ro py in cr ea se s o f t he rm . oi l a nd w at er a nd s te am Temperature, K Tw1 = 323.15 K Tw1 = 333.15 K Tw1 = 343.15 K
Fig. 5. The ratio of the increase of the oil entropy to the increase of the water and steam entropy in the function of the temperature of the heating media for various temperatures of boiler feed water Tw1. Oil temperature at the heater inlet Tol1 =
343.15 K
Rys. 5. Stosunek przyrostu entropii oleju do przyrostu entropii wody i pary w funkcji temperatury czynników grzewczych dla różnych temperatur wody zasilającej kocioł Tw1. Temperatura
oleju na wejściu do nagrzewnicy Tol1 = 343,15 K
0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04 1.05 1.06 1.07 445 455 465 475 485 495 505 515 525 535 545 555 565 575 R at io o ft he e nt ro py in cr ea se s o f t he rm . oi l a nd w at er a nd s te am Temperature, K Tol1 = 400.15 K Tol1 = 423.15 K Tol1 = 443.15 K
Fig. 6. The ratio of the increase of oil entropy to the increase of water and steam entropy in the function of the heating media temperature for the various temperatures of thermal oil Tol1.
The temperature of boiler feed water Tw1 = 303.15 K.
Rys. 6. Stosunek przyrostu entropii oleju i pary w funkcji temperatury czynników grzewczych dla różnych temperatur oleju grzewczego Tol1.Temperatura wody zasilającej kocioł
Tw1 = 303,15 K
The increase in the working media temperature causes that the ratio of the entropy increase of the oil in oil exhaust gas heater in relation to the entro-py increase of the water and steam in exhaust gas boiler grows. With the lower temperature range the increases of entropy in the oil boiler may be lower than in the steam boiler. The increase of the oil
Tw1 Tw1 Tw1 Tol1 Tol1 Tol1 R at io o f th e en tr op y in cr ea se s of th em . oi l a nd w at er a nd s te am R at io o f th e en tr op y in cr ea se s of th em . oi l a nd w at er a nd s te am
temperature on the return line to the heaters causes that entropy increases get less, thus the ratio of the increase of entropy of the oil system in relation to the steam system gets smaller for the same values of oil and water temperatures at the outlets of the boilers. This is the case in the actual systems where the thermal oil temperature at the return to the hea-ter is significantly higher than the boiler feed wahea-ter temperature.
The analysis conducted covered only one link in the entire chain of transformations related with the heating process on a ship. Similarly conducted analysis for the remaining elements of the whole heating system will allow to fully evaluate their efficiency. The outline of such analysis has been presented in [8].
Conclusions
The analysis of the thermal oil systems pre-sented in the article shows that they might form a good alternative for the steam system which is nowadays commonly used on the majority of ships. The advantages of the thermal oil system have been observed and appreciated already long ago, inter alia in the German shipyards where ships are very often equipped with the installations of such type. The shipowners reluctance to the application of such solutions may result from the limited know-ledge of the thermal oil systems. The smaller heat exchange surfaces in the steam-water installations in comparison to the oil systems are accompanied by the high costs of the high pressure installation and the steam boiler itself as well as the additional equipment such as boiler water treatment plant, inspection tanks, condensate cooler, dehydrators etc. as well as their lower efficiency. The economic advantages to be achieved through the application
of the thermal oil systems include amongst others fuel savings and the savings of the ship’s mainte-nance costs owing to their longer life and unat-tended / unmanned operation.
References
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The study financed from the means for the education within 2009–2012 as own research
project No. N N509 404536.
Recenzent: dr hab. inż. Andrzej Adamkiewicz, prof. AM Akademia Morska w Szczecinie
