Academic Year 2013-14 School of Industrial Engineering

Lecture Notes for

Energy Systems and Low Carbon Technologies

Boilers
prof. Stefano Consonni Department of Energy

Physical process
fuel oxidizing agent combustion

The physical process includes two steps: 1) combustion 2) heat transfer Physically simultaneous.

flue gases

heat transfer heat carrier heat carrier

(cold)

(hot)

AY 2013-14 Steam Generators prof. S. Consonni

example: fireplace and stove

a simple fireplace

and a more evolved stove.

AY 2013-14 Steam Generators prof. S. Consonni

example: heat recovery fireplace

AY 2013-14 Steam Generators prof. S. Consonni

Steam Generators
Steam generators and heat recovery system include many subsystems: 1. furnace and combustion system, 2. boiler or steam generating bank, 3. steam superheaters/reheater,

4. 5. 6. 7. 8. 9. 10. 11. 12.

economizer, steam drum, attemperator and steam temperature control system, air heater, fuel handling system, flue gas treatment systems ash handling system gas-side cleaning equipment ducts, fans, etc.

AY 2013-14 Steam Generators prof. S. Consonni

Steam Generators
Steam generators can be classified by various criteria: 1.Fuel (gaseous, liquid, solid) 2.Circulation method (natural, forced, once through)

3.Main heat transfer process (radiation, convection, indirect heating) 4.End use (heating, industrial process, electric utility) 5.Capacity

AY 2013-14 Steam Generators prof. S. Consonni

Small capacity boilers

smoke tube boiler - single pass -

AY 2013-14 Steam Generators prof. S. Consonni

Small capacity boilers

Smoke tube boilers P evap. < 15 bar

AY 2013-14 Steam Generators prof. S. Consonni

Smoke tube boiler

why the number of tubes of 2nd pass > 3rd pass ?

http://www.boiler.de/eng/steamboiler/system.html

AY 2013-14 Steam Generators prof. S. Consonni

Smoke tube boiler

10

to the stack

Smoke-tube boiler with wet end plate

AY 2013-14 Steam Generators prof. S. Consonni

Smoke tube boiler

different views of a smoke tube boiler: internal and external

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AY 2013-14 Steam Generators prof. S. Consonni

Water tube boiler

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AY 2013-14 Steam Generators prof. S. Consonni

Water tube boiler

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flue gases

air

AY 2013-14 Steam Generators prof. S. Consonni

Membrane walls of combustion chamber

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Most of the heat transfer takes place by RADIATION

AY 2013-14 Steam Generators prof. S. Consonni

Boiler casing

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AY 2013-14 Steam Generators prof. S. Consonni

Convective section

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Convection heat transfer becomes the dominant heat transfer mode for gas temperatures below 9001000C Given the small gas-side heat transfer coefficient and the relatively small T between the gas and steam/water, it requires large heat transfer areas

AY 2013-14 Steam Generators prof. S. Consonni

Diathermic oil boilers ORC

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- In case of small size applications, water does not work very well since small scale steam turbines are characterized by low efficiency (size of the blades) and excessive complexity (multi-stage expansion).
- A solution use of Organic Rankine Cycle where high-molecularmass organic fluids are utilized. Their thermodynamic properties guarantee the absence of moisture during and at the end of the expansion. - But these organic fluids have a low decomposition temperature they can not exchange heat directly with the flue gases need to exchange with an intermediate heat transfer fluid. Diathermic oils suit this necessity properly, as: they are thermally stable they are not chemically aggressive

they do not change phase in the range of working temperatures ( safety) they can bare high temperatures being at low levels of pressure
AY 2013-14 Steam Generators prof. S. Consonni

Diathermic oil boilers

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Elementary setup for diathermic oil boiler

AY 2013-14 Steam Generators prof. S. Consonni

Organic Rankine Cycle

Diathermic oil boilers

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Organic Rankine Cycle

AY 2013-14 Steam Generators prof. S. Consonni

Spiral tubes

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AY 2013-14 Steam Generators prof. S. Consonni

Small capacity boilers - pellet

water tube

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smoke tube

AY 2013-14 Steam Generators prof. S. Consonni

Large boilers for power production

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AY 2013-14 Steam Generators prof. S. Consonni

Large water tube boiler with membrane23walls

550 MW Radiant boiler for pulverized coal.

AY 2013-14 Steam Generators prof. S. Consonni

Large water tube boiler with membrane24walls

Economizer with steel finned tubes

AY 2013-14 Steam Generators prof. S. Consonni

Heating surface configuration

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AY 2013-14 Steam Generators prof. S. Consonni

Natural Circulation

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R = Circulation factor Ratio between Water mass flow rate in the downcomer and Steam mass flow rate at risers outlet

AY 2013-14 Steam Generators prof. S. Consonni

Boiling conditions

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R = Circulation factor Ratio between Water mass flow rate in the downcomer and Steam mass flow rate at risers outlet

AY 2013-14 Steam Generators prof. S. Consonni

Boiling conditions

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AY 2013-14 Steam Generators prof. S. Consonni

Forced/Assisted Circulation

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Once through

Assisted/Forced circulation Natural circulation Assisted/Forced circulation

AY 2013-14 Steam Generators prof. S. Consonni

Steam Drum

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Vertical cyclone separator

AY 2013-14 Steam Generators prof. S. Consonni

Water drum with riser tubes

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AY 2013-14 Steam Generators prof. S. Consonni

Supercritical boilers
Increasing efficiency

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requires to produce steam at supercritical pressure (>220 bar) in a once through boiler instead of natural circulation boilers used for subcritical power plants. A critical aspect of this class of boilers is that in case of unbalanced flow rates among different pipes thermal stress may arise in pipes with the lower heat transfer coefficient (the ones with the lower flow rates)
AY 2013-14 Steam Generators prof. S. Consonni

Circulation systems

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AY 2013-14 Steam Generators prof. S. Consonni

Closed domes for coal storage

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AY 2013-14 Steam Generators prof. S. Consonni

Coal-fired boiler
traveling grate

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vibrating grate

AY 2013-14 Steam Generators prof. S. Consonni

Coal-fired boiler

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AY 2013-14 Steam Generators prof. S. Consonni

Pulverizer
the oldest pulverizer design: balland-tube

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horizontal high speed pulverizer

AY 2013-14 Steam Generators prof. S. Consonni

Pulverizer
vertical air swept wheel pulverizer

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grinding mechanism

pulverized coal recirculation

AY 2013-14 Steam Generators prof. S. Consonni

Ljungstrom air pre-heater

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AY 2013-14 Steam Generators prof. S. Consonni

Membrane walls with burner housings

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AY 2013-14 Steam Generators prof. S. Consonni

Conventional Burners

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Circular Burners
AY 2013-14 Steam Generators prof. S. Consonni

Cell Burners

Conventional Burners

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S type burner: larger swirl components and better secondary air control
AY 2013-14 Steam Generators prof. S. Consonni

Low NOx burners (3rd generation)

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AY 2013-14 Steam Generators prof. S. Consonni

Staged combustion Reburning Low NOX burner

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Low NOX burner

AY 2013-14 Steam Generators prof. S. Consonni

Combustion chamber

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AY 2013-14 Steam Generators prof. S. Consonni

Plant configuration
CROSSOVER, 3 bar Turbina T/pompa 580 C, 26 bar 580 C, 90 bar 580 C, 300 bar
iniezione di ammoniaca

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SH

~
Trafil.

LP

LP

IP

HP

VHP RH1 RH2

ARIA

SCR high dust

polverino di carbone

preriscaldatore aria

CAMINO

0.05 bar CONDENSATORE

ESP
Trafilamenti 315 C
calce / calcare scamb.coda

DEGASATORE RIGENERATORI LP POMPA ESTRAZ.CONDENSATO TURBOPOMPA DI ALIMENTO RIGENERATORI HP

FGD
gesso

AY 2013-14 Steam Generators prof. S. Consonni

Waste-to-Energy plant
Membrane walls covered with refractories

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Convective section

Open passes

AY 2013-14 Steam Generators prof. S. Consonni

Waste Combustion grate furnace

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1 FEED HOPPER

5 9

2 FEEDER 3 GRATE 4 ASH DISCHARGER SCORIE

2 8 3

5 FURNACE 6 STEAM HETAED AIR PREHEATER 7 UNDERFIRE AIR 8 FLUE GASES RECIRCULATION 9 OVERFIRE AIR

6
Fonte: Martin Gmbh

AY 2013-14 Steam Generators prof. S. Consonni

Waste handling system

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Fonte: Martin Gmbh

AY 2013-14 Steam Generators prof. S. Consonni

Sistema di combustione Combustion Grate

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The grate is designed to support and to transport the refuse while simultaneously stoking or mixing the refuse during the combustion process

Different types of grate depending on fuel LHV and manufacturer: horizontal/inclined stationary or moving Water or air cooled reciprocating, roller, travelling, vibrating, etc.

AY 2013-14 Steam Generators prof. S. Consonni

SistemaGrate di combustione Vibrating

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Sistema di combustione Travelling Grate

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AY 2013-14 Steam Generators prof. S. Consonni

Sistema di combustione Reciprocating Grate

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Reverse Acting Grate

Gravity

Thrust of moving bars

Mixing of waste bed

Fonte: Martin Gmbh

AY 2013-14 Steam Generators prof. S. Consonni

Sistema di combustione Grate furnace

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Fonte: Martin Gmbh AY 2013-14 Steam Generators prof. S. Consonni

Combustion air distribution

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SA: secondary air PA: primary air

Fonte: Chungen Yin,, Lasse A. Rosendahl, Sren K. Kr 2008 AY 2013-14 Steam Generators prof. S. Consonni

Underfire air distribution

Primary air

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Fonte: Martin Gmbh

AY 2013-14 Steam Generators prof. S. Consonni

Overfire air distribution

Secondary air 2 nozzles rows

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4 nozzles rows

Fonte: Martin Gmbh

AY 2013-14 Steam Generators prof. S. Consonni

Sistema di combustione Bottom ashes discharger

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From grate end T = 300C

Water level= air seal for combustion chamber

T= 90C

To vibrating conveyor

Fonte: Martin Gmbh AY 2013-14 Steam Generators prof. S. Consonni