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A boiler is a device for heating water and generating steam above atmospheric
pressure. The boiler consists of a compartment where the fuel is burned and a
compartment where water can be evaporated into steam. The hot water or steam is
used to transfer heat to a process
STEAM TO PROCESS
STACK DEAERATOR
Economizer
PUMPS
VENT
BOILER BURNE
R WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
BRINE
CHEMICAL FEED
SOFTENERS
Fitting and devices which are necessary for the safety and control are knows as
boiler mountings
Fitting or devices which are provided to increase the efficiency of the boiler and
help in the smooth working of the plant are knows as boiler accessories
• Safety valve: It is used to relieve pressure and prevent possible explosion of a
boiler.
• Water level indicators: They show the operator the level of fluid in the boiler,
also known as a sight glass, water gauge or water column is provided.
• Bottom blow down valves: They provide a means for removing solid particulates
that condense and lay on the bottom of a boiler. As the name implies, this valve is
usually located directly on the bottom of the boiler, and is occasionally opened to
use the pressure in the boiler to push these particulates out.
• Continuous lowdown valve: This allows a small quantity of water to escape
continuously. Its purpose is to prevent the water in the boiler becoming saturated
with dissolved salts. Saturation would lead to foaming and cause water droplets to
be carried over with the steam - a condition known as priming.
• Hand holes: They are steel plates installed in openings in "header" to allow for
inspections & installation of tubes and inspection of internal surfaces.
• Steam drum internals, A series of screen, scrubber & cans (cyclone separators).
• Low- water cutoff: It is a mechanical means (usually a float switch) that is used
to turn off the burner or shut off fuel to the boiler to prevent it from running once
the water goes below a certain point. If a boiler is "dry-fired" (burned without
water in it) it can cause rupture or catastrophic failure.
• Surface blowdown line: It provides a means for removing foam or other
lightweight non-condensable substances that tend to float on top of the water
inside the boiler.
• Circulating pump: It is designed to circulate water back to the boiler after it has
expelled some of its heat.
• Feedwater check valve or clack valve: A no return stop valve in the feed water
line. This may be fitted to the side of the boiler, just below the water level, or to
the top of the boiler. A top-mounted check valve is called a top feed and is
intended to reduce the nuisance of lime scale. It does not prevent lime scale
formation but causes the limescale to be precipitated in a powdery form which is
easily washed out of the boiler.
• Desuperheater tubes or bundles: A series of tubes or bundle of tubes, in the
water drum but sometime in the steam drum that De-superheated steam. This is
for equipment that doesn't need dry steam.
• Chemical injection line: A connection to add chemicals for controlling feedwater
pH.
Steam accessories
Combustion accessories
• Pressure gauges:
• Feed pumps:
• Fusible plug:
• Inspectors test pressure gauge attachment:
• Name plate:
• Registration plate
WORKING
Many water-tube boilers operate on the principle of natural water circulation (also known
as 'thermo-siphoning'). This is a subject that is worth covering before looking at the
different types of water-tube boilers that are available. Figure A helps to explain this
principle:
Fig. A Natural water circulation in a water-tube boiler
• Cooler feed water is introduced into the team drum behind a baffle where,
because the density of the cold water is greater, it descends in the 'downcomer'
towards the lower or 'mud' drum, displacing the warmer water up into the front
tubes.
• Continued heating creates steam bubbles in the front tubes, which are naturally
separated from the hot water in the steam drum, and are taken off.
However, when the pressure in the water-tube boiler is increased, the difference between
the densities of the water and saturated steam falls, consequently less circulation occurs.
To keep the same level of steam output at higher design pressures, the distance between
the lower drum and the steam drum must be increased, or some means of forced
circulation must be introduced.
The energy from the heat source may be extracted as either radiant or convection and
conduction.
Convection section
This part is designed to absorb the heat from the hot gases by conduction and convection.
Large boilers may have several tube banks (also called pendants) in series, in order to
gain maximum energy from the hot gases.
Cooler feed water is fed into a drum, which is placed longitudinally above the
heat source. The cooler water falls down a rear circulation header into several
inclined heated tubes. As the water temperature increases as it passes up through
the inclined tubes, it boils and its density decreases, therefore circulating hot
water and steam up the inclined tubes into the front circulation header which
feeds back to the drum. In the drum, the steam bubbles separate from the water
and the steam can be taken off.
Typical capacities for longitudinal drum boilers range from 2 250 kg/h to 36 000
kg/h.
The cross drum boiler also has the added advantage of being able to serve a larger
number of inclined tubes due to its cross ways position.
Typical capacities for a cross drum boiler range from 700 kg / h to 240 000 kg/h.
Fig.2 Cross drum boiler
D-type boiler
This is the most common type of small-medium sized boilers, similar to the one
shown in the schematic diagram. It is used in both stationary and marine
applications. It consists of a large steam drum vertically connected to a smaller
water drum (a.k.a. mud drum) via multiple steam-generating tubes. These are
surrounded by walls made up of larger water filled tubes, which make up the
furnace.
This has a single drum, with feed water drawn from the bottom of the drum into
a header that supplies inclined water-tubes. The water tubes supply steam back
into the top of the drum. Furnaces are located below the tubes and drum. This
type of boiler was used by the Royal Navy's Leander class frigates. The Y160
variant used on the Batch 3 Leanders (e.g. HMS Jupiter) also incorporated
steam atomisation equipment on the fuel supply so that the diesel fuel entering
the boilers via the three main burners was atomised into a fine spray for better
flame efficiency. The superheat temperature of the Y160 was controlled
manually by the Boiler Room Petty Officer of the Watch between 7500F and
8500F and the steam supplied to the main turbines was at a pressure of 550 psi.
Bent tube or Stirling boiler
This type has three upper drums connected to two lower drums by water tubes.
These are mainly used as stationary boilers. There are also Stirling's that are
two drum, a steam drum and a mud drum. These are used mostly in industrial
settings (Paper Mills, etc). These are also a type of boiler you will see that will
burn multiple fuels, such as bark, bagasse, etc.
Yarrow Boiler
This type has three drums in a delta formation connected by
water tubes as shown in fig 9. The drums are linked by straight water tubes,
allowing easy tube-cleaning. This does however mean that the tubes enter the
drums at varying angles, a more difficult joint to caulk. Outside the firebox, a pair
of cold-leg pipes between each drum act as down comers. Due to its three drums,
the Yarrow boiler has a greater water capacity. Hence, this type is usually used in
older marine boiler applications. Its compact size made it attractive for use in
transportable power generation units during World War II. In order to make it
transportable, the boiler and its auxiliary equipment (fuel oil heating, pumping
units, fans etc.), turbines, and condensers were mounted on wagons to be
transported by rail.
Thornycroft Boiler
A single steam drum has
two sets of water tubes
either side of the furnace.
These tubes, especially the
central set, have sharp
curves as shown in fig11.
Apart from obvious
difficulties in cleaning
them, this may also give
rise to bending forces as
the tubes warm up, tending
to pull them loose from the
tube plate and creating a
leak. There are two
furnaces, venting into a
common exhaust, giving
the boiler a wide base
tapering profile.
FIRE TUBE
A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or
more tubes running through a sealed container of water. The heat energy from
the gases passes through the sides of the tubes by thermal conduction, heating
the water and ultimately creating steam. A fire tube boiler can be either horizontal
or vertical. A fire-tube boiler is sometimes called a "smoke-tube boiler" or "shell
boiler" or sometimes just "fire pipe".
Lancashire boilers
The boiler on display in the Power Hall is a modified Lancashire boiler. It was
made by W. & J. Galloway & Sons of Knott Mill, Manchester. One side has been
cut away to reveal the internal furnace tubes.
The high efficiency of the modified Lancashire boiler was the result of more than
100years of continuous development The first Lancashire boiler was developed
in 1844 by William Fairbairn. His Lancashire boiler had twin furnace tubes side-
by-side, which gave it a much larger heating surface than that of the Cornish
boiler. The addition of 'Galloway tubes', patented in 1848, brought a further
improvement in heat transfer and fuel efficiency. These were metal tubes that
crossed the hottest part of the furnace. They improved water circulation and
increased the area of the heating surface. Galloway tubes also acted as
stiffeners and greatly strengthened the main flues against collapse.
To produce steam, coal was
shovelled through the fire doors
at the end to maintain a fire in
each of the furnace tubes. A
typical Lancashire boiler would
consume around six tons of coal
per day. The level of the water in
the cylinder which surrounded
the internal fire tubes could be
monitored by checking the glass
gauges on the front of the boiler.
The water level would be
maintained by opening the water
feed valve, as required, to
replace the water that had been
converted to steam. The steam
pressure in the boiler was
indicated by the steam pressure
gauge, which is positioned just
above the water level gauges.
Lancashire boilers were surrounded by brickwork flues. This meant that the hot
flue gases produced by burning coal could circulate under and along the sides of
the boiler before reaching the chimney. Thus, instead of escaping straight up the
chimney and being wasted, the flue gases helped to heat the water in the boiler
Vertical Fire tube boiler
Vertical Fire tube boiler (VFT) is internally fired fire-tube boiler, it consists of vertical
cylindrical shell, containing a cylinder firebox and a number of small fire tubes.
The
vertical boiler is a simple type which consists of a firebox at the bottom and a
copper barrel with a smoke tube. It typically is used to drive stationary engines
and boats. Firing is accomplished by alcohol or solid fuel pellets.
Before selecting a vertical fire-tube boiler, you must know how much overhead
space is in the building where it will be used. Since this boiler sits in an upright
position, a room with a high ceiling is necessary for its installation.
Locomotive boiler
A locomotive boiler has three main components: a double-walled firebox; a
horizontal, cylindrical "boiler barrel" containing a large number of small flue-
tubes; and a smoke box with chimney, for the exhaust gases. The boiler barrel
contains larger flue-tubes to carry the super heater elements, where present.
Forced draught is provided in the locomotive boiler by injecting exhausted
steam back into the exhaust via a blast pipe in the smoke box
If the gas stream is dirty(as in MSW When a large duty has to be transferred at a
applications)provision can be made for cleaning low log-mean-temperature-difference as in gas
using soot blowers or rapping mechanisms. turbine exhaust HRSG applications, surface
Wide spaced tubes can be used at the gas inlet area required gets enormous and very long
to minimize bridging of slag deposits and tube tubes are required, adding to the gas pressure
spacing can be decreased as the gas is cooled. drop. The shell diameter becomes huge; hence
This flexibility does not exist in fire tube unsuitable except in very small gas turbine
designs. Horses generating low pressure saturated
steam.
Super heaters if used can be located at the
optimum gas temperature region shielded by Economizer and superheated can be added but
any number of screen tubes. In fire tube boiler the location for superheated is either at the gas
the choice is at the gas inlet or exit. inlet or exit, making it difficult to come up with a
good design if corrosive conditions are present.
Due to low water volume, the startup time is
lesser and response to load changes is faster If slagging is a concern, then fire tube designs
compared to fire tube boilers. are generally not suitable as the tube inlet can
be plastered with slag. The gas inlet
If the gas pressure is high, say above 5 psig temperature has to be reduced through flue gas
,the shell/casing design gets complicated and recirculation or the gas can be cooled in an
expensive though it can be done. external water cooled furnace, making it a
difficult design.
For multiple pressure designs as in gas A separate steam drum with internals is
turbine exhaust applications, water tube is the required if good steam purity(0.05 to 1 ppm)
only choice. has to be achieved.
FUELS
Many different solid, liquid, and gaseous fuels are fired in boilers. Sometimes,
combinations of fuels are used to reduce emissions or improve boiler performance. Fuels
commonly fired in boilers include fossil, biomass, and RDFs as well as other types of
fuels and fuel combinations.
Coal, petroleum-based oils, and natural gas are fossil fuels commonly fired in ICI boilers.
However, other forms of solid, liquid, or gaseous fuel derived from these fossil fuels are
sometimes included in this category. One of these fuels, which is referred to as tire-
derived fuel (TDF), consists of shredded vehicle tires.
Another boiler fuel is referred to as biomass. Biomass is renewable organic matter.
Examples of biomass include fast-growing trees and plants, wood and wood waste,
agricultural crops and residue, aquatic plants and algae, animal wastes, and organic
municipal and industrial wastes.
RDF is a potentially valuable energy source. It consists of MSW that has been processed
using size reduction and material recovery techniques to eliminate materials such as
aluminum, steel, glass, plastic, and rock.
Common types of fuels fired in boilers are listed in Table A*.
Fuel Description
Any liquid or gaseous substance produced at chemical manufacturing plants or
By-product/waste petroleum refineries (except natural gas, distillate oil, or residual oil) and combusted in
a steam generating unit for heat recovery or for disposal.
Organic matter that is used as fuel is called biomass; biomass is a nonfossil fuel that
Biomass includes materials such as wood, biogases, nut hulls, rice hulls, corncobs, coffee
grounds, and tobacco stems
Coal is a brown-to-black combustible sedimentary rocklike material composed
Coal principally of consolidated and chemically altered plant material that grew in
prehistoric forests; it includes all solid fuel classified as anthracite, bituminous,
subbituminous, or lignite coal, coal refuse, or petroleum coke.
Waste products of coal mining, physical coal cleaning, and coal preparation operations
Coal refuse containing coal, matrix material, clay, and other organic and inorganic materials
Distillate oil Fuel oils that contain 0.05 wt % nitrogen or less and comply with the specifications for
fuel oil
Refuse, more than 50% of which is waste containing a mixture of paper, wood, yard
Municipal-type waste, food wastes, plastics, leather, rubber, and other noncombustible materials such
solid as metal, glass, and rock, which are usually removed prior to combustion
waste and RDF
A naturally occurring mixture of hydrocarbon gases found in geologic formations,
Natural gas beneath the earth’s surface, of which the principal constituent is methane, or LP gas
Oil Crude oil or petroleum or a liquid fuel derived from crude oil or petroleum, including
distillate and residual oil.
Propane Propane is a heavy gaseous fossil fuel processed from crude petroleum and natural gas.
Residual oil Crude oil and fuel oil Nos. 1 and 2 that have nitrogen content greater than 0.05 wt %,
and all fuel oil
Any solid, liquid, or gaseous fuel derived from solid fuel for the purpose of creating
Solvent-derived useful heat and includes, but is not limited to, solvent-refined coal, liquefied coal, and
fuel gasified coal.
Oil that contains no more than 0.5 wt % sulfur and that, when combusted without SO2
Very low sulfur emission control, has a SO2 emissions rate equal to or less than 215 ng/J (0.5 lb/MBtu)
oil heat output.
Wood, wood residue, bark, or any derivative fuel or residue thereof, in any form,
Wood including, but not limited to, sawdust, sander dust, wood chips, scraps, slabs, millings,
shavings, and processed pellets made from wood or other forest products.
Wood residue Bark, sawdust, slabs, chips, shavings, mill trim, and other wood products derived from
wood processing and forest management operations.
Nuclear energy Nuclear fission is also used as a heat source for generating steam.