LPPTA Technical Training Package

BOILER

LIST OF CONTENTS

Types of Boilers
Introduction to T11 Boilers
Process Description
Component Details

TYPES OF BOILERS
Steel Boilers

Firetube Type
Watertube Type
8
8
8
8

Horizontal Straight Tube

Bent Tube
(Natural Circulation)
(Positive Circulation)

Shell Type

Cast Iron Boilers

Special Design Boilers

Nuclear Reactors

TYPES OF BOILERS (contd.)

Fire Tube vs. Water Tube

Fire Tube
8 Straight tube boilers
8 Product of combustion contained in tubes
8 Water surrounds the tubes
8 Large water storage capacity Installed cost is less than that of a
corresponding watertube boiler
8 Suitable for low pressure application (15 20 bar)
8 Suitable for small steam demand (<10 Ton/hr)
8 Limited in physical size and design adaptability

TYPES OF BOILERS (contd.)

Fire tube vs. Water Tube

Water Tube
8 Horizontal straight tube or bent tube
8 Tubes contain steam and water
8 Heat is applied to outside surface
8 Initial cost is higher than that of a corresponding firetube boiler
8 Used exclusively for high pressure applications (>20 bar) and high
steam demand
8 Inherently safe

TYPES OF BOILERS (contd.)

Boiler Circulation

Flow of water or steam within the boiler is called

circulation.

Steam is much higher than water rises rapidly.

Movement of steam through the water creates

turbulence and hence circulation.

Function of water flow is fed to each tube receiving

heat to keep its surface thoroughly wetted.

TYPES OF BOILERS (contd.)

Natural Circulation
Natural circulation is the movement of circulating
fluid because of difference in density between steam
and water.
When Natural circulation is the sole motive force, the
designer does not have full control.
Performance tests are required to judge
performance.
Positive Circulation
At very high pressures, the ratio of density of water
to saturated steam drops down significantly.
Thus the circulation head is reduced as the density
differential decreases.
A sufficient head is provided by pumping in order to
have forced circulation.

INTRODUCTION TO T11 BOILERS

Manufacturer: AALBORG

Type: AX-4. Single drum, watertube boiler with

natural
Circulation

Finned tube economisers to increase BFW

temperature thereby increasing efficiency and reducing
fuel consumption

Two HP Steam Boilers are employed to produce 11 to

60 Ton/hr (MCR) each at 101 bara and 312 C

PROCESS DESCRIPTION

Steam Generation

MCR (per boiler): 60 Ton/hr

Normal Operation: 34 Ton/hr (56% MCR)

Peak rate: 66 Ton/hr (110% MCR)

Minimum rate: 11 Ton/hr (18% MCR)

Minimum steam dryness: 99.95%
Under normal conditions boilers will operate together
to supply steam for process use.
BFW is provided to the boiler from a common header.
BFW is pre-heated from 155 C to 226 C through
economiser.
Maximum permitted noise level without acoustic
protection is 85 dBA.

PROCESS DESCRIPTION (contd.)

Continuous blowdown will pass to a low pressure

flash drum from which LP steam is recovered.

Soot blowing and atomising steam is taken off the

steam system. Superheated steam is used for soot
blowing and atomising.

On initial start-up, steam will not be available and

compressed air will be used for atomisation.

Boiler flue gases discharge into a multi flue stack.

Combustion air is supplied by FD fans, one for each

boiler.

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COMPONENT DETAILS

Steam Drum

Steam drum has a diameter of 1400 mm and length

of 8800 mm.

Wall thickness is 55 mm.

Tubes

Outside diameter: 57 mm, 5 mm.

Forced Draft Fan

Fan is driven by electric motor: 132 kW.

Combustion air is provided at the rate of 53,028

kg/hr.

At MCR, FD fan consumes 90 kW.

Economiser: Aalborg
BFW is pre-heated from 155 C to 226 C.
Flue gas temperature is reduced from 559 C to 266
C.

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