WELCOME TO SESSION

ON
BOILERS
FUNDAMENTALS/COMBUSTION

AJAY SHUKLA
„ In early 19th Century boiler were low pressure
„ Invention of water tube removed the pr barrier and
boiler pr rise to super critical
„ Between 70- 90 utility operated conservatively and
used low steam pr in
„ boiler . Now renewed interest in high efficiency
supercritical boiler .The interest arose from the
environmental need to attain higher efficiency and
dividend of higher eff is reduce CO2
EFFECT OF VARIOUS PARAMETERS IN
RANKINE CYCLE
„ SUPERHEATING – improves efficiency
„ INCREASING PRESSURE – marginal improvement in efficiency
„ LOWERING EXHAUST PRESSURE- improves efficiency
„ REHEATING – improves efficiency
„ REGENERATIVE FEEDWATER HEATING – improves efficiency
Boiler/ steam generator
ƒ Steam generating device for a specific purpose.

ƒ Capable to meet variation in load demand

ƒ Capable of generating steam in a range of

operating pressure and temperature

ƒ For utility purpose, it should generate steam

uninterruptedly at operating pressure and
temperature for running steam turbines.
Basic Knowledge of Boiler
„ Purpose
„ To produce steam (Main Steam and Reheat Steam) at rated
pressure and temperature
„ To Convert the heat of combustion of coal/oil/gas to
thermal energy of steam

„ Steam Parameters are decided by Turbine Cycle

Requirements

„ Steam Parameters adopted by NTPC

0 0
„ 200 MW: 157 bar MS Pressure, 540 C/540 C
0 0
„ 500 MW: 179 bar MS Pressure, 540 C/540 C
0 0
„ 660 MW: 246 bar MS Pressure, 545 C/563 C

„ Advanced Supercritical Parameter

0 0
„ 310 bar MS Pressure, 610 C/610 C
 Engineering Function
„ Selection of Unit Size
„ Based on load demand, coal and water availability.

„ Input from Feasibility Report

„ Selection of Steam Parameters

„ Choice of steam parameters is governed by overall cost of the
plant.
„ Sub-critical boilers are more suited in places where fuel cost is
low.
„ Both drum type and once through boilers are acceptable based

on manufacturer’s experience.
„ Super-critical boilers are costly because of greater use of high
temperature material in boiler pressure parts.

„ Selection of Firing System

„ Firing systems are generally left to manufacturer’s discretion as
each manufacturer prefers his standard design.
 CLASSIFICATION OF BOILER

Based on Steam Parameters

Sub Critical Super Critical

Operates below the critical pressure of Operates above the critical pressure of
water (221.2 bar) water (221.2 bar).

Once Through
No Thermodynamic fixed point i.e. Universal Pressure
evaporation point keeps shifting in the Operate at constant pressure
water tubes depending on firing rate.

Drum type Sliding Pressure

Provides a thermodynamic fixed point at Operate at sub-critical pressure at reduced
drum, which remains at constant temp. loads.

Natural Circulation
Boilers use the difference in water and
steam density to drive the water/steam
mixture through the water tubes.

Assisted Circulation
Boilers have Circulating Water Pump
which assists the natural convective flow
through the water tubes.
 CLASSIFICATION OF BOILER

Based on Flue Gas Arrangement

Two Pass Tower Type

Most of the SH, RH and Eco heat transfer
All heat exchangers are arranged
surfaces are placed in the horizontal and second
horizontally above the furnace. Provides
passes. Some pendant SH and RH surfaces placed
easy draining of the SH and RH tubes and
above the furnace. Pendant section tubes cannot
headers.
be drained.
 CLASSIFICATION OF BOILER

Based on Firing Arrangement

Wall Fired
Tangential Fired Downshot Fired
Burners are arranged in rows
Burners are arranged over Burners are arranged to fire
over many elevation on front
many elevation to fire around downwards in rows over many
and rear walls. Mill to burner
an imaginary circle. One mill elevation on front and rear
distribution optimized for
normally feeds one coal walls. Better suited to low
stable combustion at low loads.
elevation. individual Sec. Air volatile coals as it gives a high
Each burner flame independent
control is not provided. furnace residence time.
with individual Sec. Air control.
 CLASSIFICATION OF BOILER

Based on Bottom Ash

Wet Bottom Dry Bottom

Bottom Ash collected in slag Bottom ash is cooled in water in
form. Mostly used for low ash the hopper before removal in the
coals with low fusion clinker form. Suited for Indian
temperatures. coals with high ash content.
Boiler Classification (contd…)
ƒ Once Through Boiler
„ Continuous Path of water

through economizer to water

walls and to superheaters.
„ These are necessarily forced

circulation boilers.
„ They are suited for fast start-

up and load cycling, as the

thick drum is eliminated.
Once Through Boiler
Boiler Classification (contd…)

Drum Type Boiler Drum Type Boiler

(Natural Circulation) (Assisted Circulation)
Boiler Classification (contd…)

Supercritical Boiler Supercritical Boiler

(Universal Pressure) (Sliding Pressure)
OUTLINE

• Boiler fundamentals

• Boiler components (water side)

• Boiler combustion (air side)

• Boiler classification
Basic Knowledge of Boiler
 Basic boiler :

Steam

Water Steam / water system

Blow down

Mixing of fuel Furnace Heat transfer

Surface
and air Flue gas

AIR

Ash
FUEL
 Phenomenological Model

Hot Flue Thermal Structure Steam

Gas SH

Convection & Convection HT

Radiation HT

Drop in Enthalpy Rise in Enthalpy of

of Flue Gas Steam
Mechanism of Heat Transfer

Source/Supply Thermal Structure Sink /Demand

STEAM GENERATOR COMPONENTS
„ FURNACE
„ DRUM
„ BOILER CIRCULATING PUMPS
„ CONVECTION PASS
¾ SUPERHEATER
¾ REHEATER
¾ ECONOMISER
• AIR HEATER
• STEAM COILED AIR PREHEATER
• SOOT BLOWERS
• COAL FEEDERS
• PULVERIZERS
• COAL PIPING
• BURNERS
• IGNITOR AND WARM UP BURNERS
• DUCTWORK AND
• INSULATION AND LAGGING
BOILER LAYOUT AND PA FAN
 Reheater
S

Platen SHTR
Drum C
R
DPNL E
E
SHTR n

Gooseneck LTSH
Chimney
Downcomer

waterwall
Fireball Economiser

ID fan

ESP
APH

Bottom Ash
Water and Steam Circulation
System
„ Economiser
„ Boiler drum
„ Down Comers
„ Water walls
„ Primary super heater
„ Platen super heater
„ Final super heater
„ Reheater
Drum
„ The boiler drum forms a part of the
circulation system of the boiler. The drum
serves two functions, the first and primary
one being that of separating steam from the
mixture of water and steam discharged into
it. Secondly, the drum houses all equipments
used for purification of steam after being
separated from water. This purification
equipment is commonly referred to as the
Drum Internals.
Type of Circulation
¾ Natural circulation ƒ Density difference &
(upto 165 ksc) height of water
column
ƒ Assisted by external
¾ Forced/ assisted
circulating pump (CC/
circulation (185-200
BCW pump)
ksc)
¾ Once thru boiler
ƒ Below 221.5 bar
1. Sub critical
ƒ 240-360 bar
2. Supercritical
 Circulation ratio
It may be defined as the ratio of feed
water flow thru down comers to the
steam generated in water wall.

ƒ CR = 30-35 Industrial boilers

ƒ CR = 6-8 Natrual cir. Boilers
ƒ CR = 2-3 Forced cir. Boilers
ƒ CR = 1 Once thru boilers (Sub critical)
ƒ CR = 1 Supercritical boilers
Waterwall construction
„ Made of carbon steel (Grade-C) hollow
circular tubes and DM water flows inside
„ Waterwalls are stiffened by the vertical stays
and buck stays to safeguard from furnace
pressure pulsation & explosion/ implosion
„ The boiler as a whole is hanging type,
supported at the top in large structural
columns.
„ Vertical expansion is allowed downwards and
provision is made at bottom trough seal near
ring header.
 Superheater & Reheater
ƒ Heat associated with the flue gas is used in
superheaters & Reheater, LTSH, economiser.
ƒ Maximum steam temperature is decided by the
operating drum pressure and metallurgical
constraints of the turbine blade material.
ƒ Reheating is recommened at pressure above
100 ksc operating pressure. Reheating is done
at 20-25% of the operating pressure.
ƒ Carbon steel, alloy steel & SS used for tubing of
SH & RH.
Superheaters
„ Convection Superheaters
„ Radiant Superheaters
„ Important Components of Boiler
• Economizer
• Boiler drum
• Water wall
• Superheater
• Reheater
„ Boiler Pressure Part Design
„ Code – IBR/ASME.
„ Selection of Material based on:
„ Creep and Fatigue strength at
design temperature.
„ Fire side oxidation resistance.
„ Design Temperature and thickness:
as per IBR.
„ Allowable stress for chosen material
– as per ASME.
TWO PASS BOILER ARRANGEMENT
More Details of Pulverized Fuel fired SG
Boiler Auxiliaries
 TO
Session on
Boiler

Combustion
-BOILER=CONTROLLED COMB.+HEAT TRANSFER

-CHEMICAL =THERMAL

-COMBUSTION-FUEL,TEMP,O2

-FUEL - BITUMINOUS COAL

 Boiler fundamentals

Combustion in furnace :-
• Pulverized fuel by coal burners
• Ignition temp. By oil firing
• O2 by means of fans.

Reactions:-
• C+O2 = CO2,
• 2H2+O2 = 2H2O
• S+O2 = SO2
• Theoretical air = O2/.233
Boiler fundamentals

FACTORS AFFECTING COMBUSTION-

TIME,TEMP., INTER MIXING OF AIR WITH
FUEL(TTT), COAL FINENESS,
I. Excess Air:-
- (20%)-bituminous coal
-(15%)-lignite
A. Lower excess air:-
-High unburnt loss
B. Higher excess air:-
-Higher heat loss (ma*cpa*dt)
 Combustion
•Burning of fuel (chemical reaction)
•Rapid combination of o2 with fuel, resulting in the release of
heat
•For fuel to burn ,the following conditions must be present
• The fuel must be gasified
•The oxygen and fuel mixture should be proper.
•Temp should be above ignition
 FUELS
Combustible
substances which,
when combined with
oxygen in air & ignited,
burn giving heat.
 CLASSIFICATION OF
FUELS

Solids Liquids Gaseous

Coal Kerosene Natural gas

Lignite Petrol Methane
Peat HSD LPG
Bagasse LDO Producer
Gas
Husk FO
LSHS
MAIN CONSTITUENTS OF
FUEL
Carbon
Hydrogen
Sulphur
Nitrogen
Oxygen
Water
Vapour
Ash
 PROXIMATE ANALYSIS OF TYPICAL INDIAN COAL

DESIGN W ORST BEST

TOTAL MOISTURE % 15 16.5 14

ASH % 42 44 38
VOLATILE MATTER % 21 19.5 23
FIXED CARBON % 22 20 25

TOTAL % 100 100 100

PROPERTIES OF FUEL
(Typical Analysis of F.O.)
Carbon 83.52%
Hydrogen 11.68%
Sulphur 3.27%
Calorific value 10,000 Kcal/kg
Sp. Gravity at 30oC 0.95
Flash point 65oC
Viscosity at 40oC 1500 RW Sec No 1
Water Percentage 0.15
Sediment Percentage 0.3 (Variable)
 COMBUSTION
• Combustion is rapid oxidation of fuel resulting in
constituents getting converted into respective
oxides, liberating heat.
Fuel +Air Oxides + Heat (Prs of
combustion)
C +O2 : CO2 + Heat 43,968 Kcal
2H2 +O2 : 2H2O + Heat 61,979 Kcal
S +O2 : SO2 + Heat 3175 Kcal
Incomplete Combustion
2C + O2 : 2CO + Heat 26,429 Kcal
1 Kg of liquid fuel + 15 Kg of Air Oxides +
 COMBUSTION PROCESS

LIQUID FUEL
PRESSURISED + PREHEATED

ATOMISED

HEATED BY FURNACE HEAT

VAPORISED

IGNITED BY FLAME

COMBUSTION
 COMBUSTION
REACTIONS

C O C O
C

O O 2C + O2 2CO + LESS HEAT

C

COMBUSTION INCOMPLETE
 COMBUSTION
REACTIONS
O
C
C O
O
O C+O CO2 + HEAT
2

H O H O
H H H H

O O 2H2 + O2 2H20 + HEAT

H H
COMBUSTION COMPLETE
COMBUSTION
FLAME & FLAME FRONT
* FLAME :
„ IT IS AN ENVELOPE OR ZONE WITHIN WHICH
COMBUSTION REACTION IS OCCURRING AT SUCH A RATE
AS TO PRODUCE VISIBLE RADIATION.

* FLAME FRONT :
„ IT IS THE 3 D CONTOUR ALONG WHICH COMBUSTION
STARTS
„ IT IS THE DIVIDING LINE BETWEEN FUEL-AIR MIXTURE
AND COMBUSTION PRODUCTS.

REF. : NORTH AMERICAN COMBUSTION HANDBOOK

 EXCESS AIR
Fuel + Theoretical air required + 15% to 40% T.A. Combustion

FOR COMPLETE COMBUSTION...

: Fuel has to be atomised.
: Raise the temperature to ignition temperature.
: Electrical spark of ignition.
: Proper mixing of fuel and air.
: Distribution of Primary and Secondary air.
GOOD COMBUSTION
REQUIRES .......

Ñ 3 T’s - TIME, TEMPERATURE & TURBULENCE

Ñ PROPER PROPORTIONING OF FUEL & AIR

Ñ CORRECT CONTROL OF FUEL & AIR

Ñ THOROUGH MIXING OF FUEL & AIR

Ñ INITIAL & SUSTAINED IGNITION
MEASUREMENT OF COMBUSTION

CO2 : 12 - 13%

SMOKE INDEX : 2-3

STACK TEMPERATURE : As per design.

O2 : 3%
Arrangement of fuel input in
furnace
ƒ Coal is pulverized in mills at a fineness of 70% thru
200 mesh. Dried powdered coal is conveyed to
furnace (at a temperature < 95-100oC)

ƒ Total coal flow is distributed among running mills

and fed thru coal burners at 20-25 m/sec.

ƒ Coal flow is arranged in tiers. Maximum heat release

rate must not exceed plain area heat loading. It
generates excessive NOx and making ash fused.
Combustion air arrangement in
furnace
ƒ Fuel air is supplied around coal nozzles (at velocity
of 30-35 m/sec).

ƒ Secondary air is supplied in adjacent tiers of sec. air

dampers from wind box (Hot air from Secondary
APH)

ƒ Overfire/ Tempering air is supplied at the top of the

burnaer zone for NOx control.

ƒ Gas recirculation is adopted for steam temperature

control in oil/ gas fired units.
ƒ Furnace draft is maintained at -5 mmwcl with Forced
and Induced draft fans (balanced draft)
 Pulverized Fuel Boiler (Contd..)
Advantages
„ Its ability to burn all ranks of coal from
anthracitic to lignitic, and it permits
combination firing (i.e., can use coal, oil and
gas in same burner). Because of these
advantages, there is widespread use of
pulverized coal furnaces.
Disadvantages
„ High power demand for pulverizing
„ Requires more maintenance, flyash erosion
and pollution complicate unit operation
SAFETIES
ý Unauthorised flame presence during pre-purge
and after controlled shut down.
ý Pilot flame safety
ý Main flame safety
ý High gas pressure safety
ý Low gas pressure safety (optional)
ý Double Block & Bleed valves in main gas line
ý Combustion air failure safety
ý Interlock with boiler safeties
THANK YOU