Draft Required to Establish Air Flow

Air in

Flue as out
Draught
Draught

Natural draught
Artificial draught
Mechanical or fan draught Steam jet draught
Induced Balanced
Forced
Induced
Forced


Natural draught
Caused due to;

-Difference in temperature (and so density) between a column
of hot gases inside the chimney and a similar column of
normal atmospheric air outside the chimney.
-measured by water column of water in manometer.
- In ordinary chimney,draught is less than 12mm of H2O
column or 177.72 N/M2

Natural Draft
H
chimney
T
atm
T
gas
A
B
p
A =
p
ref +
Ap

) (z T
dz
R
pg
dp

=
Z
ref

}

+ =
A
ref
Z
Z
air air
ref A
z T
dz
R
pg
p p
) (
}

+ =
B
ref
Z
Z
gas gas
ref B
z T
dz
R
pg
p p
) (
Natural Draft
Natural Draft across the furnace,
Ap
nat
= p
A
p
B






The difference in pressure will drive the exhaust.
Natural draft establishes the furnace breathing by
Continuous exhalation of flue gas
Continuous inhalation of fresh air.
The amount of flow is limited by the strength of the draft.


Mechanical (Artificial)Draft : Induced Draft
H
chimney
T
atm
T
gas
A
B
p
B =
p
fan,s
p
A =
p
atm +

atm *
g
*
H
chimney
B
Essential when Natural Draft cannot generate required amount of breathing
Mechanical (Artificial)Draft : Forced Draft
H
chimney
T
atm
T
gas
A
B
p
B =
p
atm +

gas *
g
*
H
chimney
p
A =
p
fan
Mechanical (Artifical)Draft : Balanced Draft
H
chimney
T
atm
T
gas
A B
p
B =
p
fan,s
p
A =
p
fan.b
B
Pressure drop in Air and Gas Duct Systems
Bernoulli equation pressure drop across a flow passage



2
2
2
2
2
2
1
2
1
1
1
2 2
P
gZ
u P
m
W
gZ
u P A
+ + + =
A
A
+ + +
Pa
u
d
L
f p
dl
2
2

= A
Frictional resistance along flow path:
where f = coefficient of friction
L = length of the duct, m
d
dl
= equivalent diameter of the duct, m
= density of air or gas calculated at the mean gas temperature, kg/m
3

u = cross section average velocity of air or gas in the duct, m/sec

Equivalent diameter for rectangular duct is given as
( )
( )
25 . 0
625 . 0
3 . 1
b a
ab
d
dl
+
=
2
9 . 0
Re
74 . 5
7 . 3
log
0625 . 0
(
(

)
`

|
.
|

\
|
+
|
|
.
|

\
|
=
dl
d
k
f
where a and b are sides of the duct, mm.

The coefficient of friction for flow through tubes can be approximated as
shown below,
for 5000 < Re<10
8
,

10
-6
< (k/d
dl
)<0.01

Minor Losses

Calculation of Local pressure drops:





where p = local pressure drop
K = local resistance factor,
= density of air or gas at the position of the pressure drop
calculated, kg/m
3

u = velocity of air through the fittings m/s.

Pa
u
K p
l
2
2

= A
Pressure drop across a burner



pa



K = 1.5 for tangential burner
3.0 for swirl burner


2
2
u
K P

= A
Pressure drop across heating surfaces
Pressure drop across tube bundles:


Inline arrangement: K = n K
0
Where n = number of tube rows along the flow direction
K
0
= loss coefficient for one row of tubes

K
0
depends on
1
= s
1
/d
,

2
= s2/d
,
= (s
1
- d )

Where s
1
is lateral pitch & s
2
is longitudinal pitch

If
1
<=
2
:


K
0 =
1.52 (
1
1)
0.5

0.2

Re
0.2


If
1
> 2

:
K
0
= 0.32 (
1
1)
0.5

( 0.9)
0.2

Re
0.2/




Pa
u
K p
b t
2
2

= A
S
1
S
2
Staggered Arrangement
The loss coefficient is obtained as
K = K
0
(n+1)
Where K
0
is the coefficient of frictional resistance of one row of tubes

K
0
depends on
1
= s
1
/d
,
= (s
1
- d ) / (s
2
l

- d )


Where s
2
l

is the diagonal tube pitch given by

s
2
l

= ( 0.25 s
1
2
+ s
2
2
)

and K
0
can be written as,
K
0
= C
s
Re
-0.27

C
s
is design parameter of the staggered banks

S
1
S
2

For 0.17 <= <= 1.7 and
1
>= 2.0
,
C
s
= 3.2

If
1
< 2.0,then C
s
given as

C
s
= 3.2 + (4.6 2.7 )(2 -
1
)

For = 1.7 5.2, C
s
= 0.44(+1)
2


Total gas side pressure drop


Pa


where EAp
1
= total pressure drop from the furnace outlet to the
dust collector, Pa

EAp
2
= pressure drop after the dust collector, Pa

= ash content in the glue gas, kg/kg

p
a v
= average pressure of the gas, Pa

p
g o
= flue gas density at standard conditions, kg/Nm
3

| |
(

EA + + EA = A
av
o g
sy
P
p p p
101325
293 . 1
) 1 (
2 1

The ash fraction of the flue gas calculated as,

where o
f h
= ratio of fly ash in flue gas to total ash in the fuel
A = ash content of working mass, %
V
g
= average volume of gas from furnace to dust collector
calculated from the average excess air ratio, Nm
3
/kg of fuel

g o g
h f
V
A

100
=
The pressure drop from the balance point of the furnace to the chimney
base is

Ap
rest
= Ap
exit
+ Ap
gas
Ap
nd

where Ap
exit
= pressure drop up to the boiler outlet

Total losses
Ap
Percent Boiler Rating
Burner Losses
APH Losses
Ducts & dampers losses
Air Pressure Losses
Total losses
Ap
Percent Boiler Rating
Furnace, SH & RH Losses
Economizer Losses
Ducts & dampers losses
Draught Losses
FD
Fan
Duct APH Duct Furnace Duct APH
Back
pass
ESP
ID
Fan
Chimney
D
u
c
t

D
u
c
t

Modeling of 210 MW Draught System
Pressure drop calculation in air & gas path and its
comparison with design value.
Assessment of ID and FD fan power as a function of
furnace pressure.
Assessment of effective kinetic rate coefficient as a
function of furnace pressure.

Pressure Variation
Pressure Variation in Air & Gas Path at Full Load
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
3000
1 2 3 4 5 6 7 8 9 10 11 12
Path Element
P
r
e
s
s
u
r
e

(
P
a
)
Calculated (215 MW) Design (210 MW)
Duct FD Fan Duct SCAPH APH Duct
Wind
Box
Boiler APH ESP ID Fan
Off Design Pressure Variation
Pressure Variation in Air & Gas Path at Part Load
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
1 2 3 4 5 6 7 8 9 10 11 12
Path Element
P
r
e
s
s
u
r
e

(
P
a
)

Calculated (168 MW) Design (168 MW)
ID Fan ESP Boiler APH
Wind
Box
Duct APH Duct SCAPH Duct FD Fan
Draught Control
Windbox Pressure Control
Combustion and Draught Control
The control of combustion in a steam generator is extremely critical.
Maximization of operational efficiency requires accurate combustion.
Fuel consumption rate should exactly match the demand for steam.
The variation of fuel flow rate should be executed safely.
The rate of energy release should occur without any risk to the plant,
personal or environment.

The Model for Combustion Control
Parallel Control of Fuel & Air Flow Rate
Flow Ratio Control : Fuel Lead
Flow Ratio Control : Fuel Lead
X
E
Cross-limited Control System
Oxygen Trimming of Fuel/air ratio Control
Combined CO & O
2
Trimming of Fuel/Air Ratio Control