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Types, Combustion, Performance Evaluation, Feed Water Treatment, Blow Down, Improving Availability (Reducing Tube Failure, Soot

Blowing and Reducing Soot Deposition, Preservation, Start-up and Shutdown procedure), Thermic Fluid Heaters, Energy Conservation Opportunities.

Figure 2.1 Boiler System Schematic

Packaged Boiler: The packaged boiler is so called because it comes as a complete package. Once delivered to site, it requires only the steam, water pipe work, fuel supply and electrical connections to be made for it to become operational. Package boilers are generally of shell type with fire tube design so as to achieve high heat transfer rates by both radiation and convection (Refer Figure 2.4).

The pulverized coal is blown with part of the combustion air into the boiler plant through a series of burner nozzles. Secondary and tertiary air may also be added. Combustion takes place at temperatures from 1300-1700C, depending largely on coal grade. Particle residence time in the boiler is typically 2 to 5 seconds, and the particles must be small enough for complete combustion to have taken place during this time. This system has many advantages such as ability to fire varying quality of coal, quick responses to changes in load, use of high pre-heat air temperatures etc.

Water/steam is used as heat carrier in many heating applications. However, at high temperatures, steam requires a corresponding high operating pressure. Industrial heating systems, a high temperature level is often a great advantage, and establishing this with steam can be very cumbersome and expensive in some cases. In thermic fluid heaters, a special type of oil-synthetic / mineral -is used as heat carrier. This fluid can be heated up to 300oC at atmospheric pressure. In comparison steam would require a pressure of 85 bars to obtain this temperature. There are several advantages in using thermic fluids compared to steam systems. The most obvious advantages are as follows.

The Table 2.5 gives the theoretical amount of air required for combustion of various types of fuel. Excess air is required in all practical cases to ensure complete combustion, to allow for the normal variations in combustion and to ensure satisfactory stack conditions for some fuels. The optimum excess air level for maximum boiler efficiency occurs when the sum of the losses due to incomplete combustion and loss due to heat in flue gases is minimum. This level varies with furnace design, type of burner, fuel and process variables. It can be determined by conducting tests with different air fuel ratios.

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