Professional Documents
Culture Documents
Project on
Submitted By:
Rakesh Kumar Singh 0210PGD042
Submitted To:
Mr. C. Sidda Raju
April 2010
1
DEPARTMENT OF POWER PLANT ENGINEERING
M.S.R.I.T.
Bangalore
CERTIFICATE
1
ABSTRACT
Metallurgy: In its general, modern sense, metallurgy is the science that studies
the chemical and physical properties of metals, including how they perform
when used for culturally useful industrial purposes. The term often refers to the
procedures used in extracting metals from ore, as well as to the processes
related to metals purification and alloy production.
Boiler Material: The material used for plates, rivets, braces, and all other parts
on which the structural strength of a high-grade boiler depends are made of a
low-carbon open-hearth steel in which is allowable only very small quantities
of phosphorus and sulphur. Nickel is often alloyed with this steel to improve its
tensile and elastic strength.
Heat treatment: Heat treatment is a method used to alter the physical, and
sometimes chemical properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many other
materials, such as glass. Heat treatment involves the use of heating or chilling,
normally to extreme temperatures, to achieve a desired result such as hardening
or softening of a material. Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering and quenching.
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OBJECTIVE
The principal aim of this project was to develop and demonstrate the suitability
of advanced materials and components for the power industry. Such materials
and components were aimed at steam temperatures of 620 - 650ºC. Specific
areas covered were:
• Development and assessment of improved alloys for boiler superheaters,
headers, pipework and furnace walls.
• Development of improved alloys for steam turbine high temperature rotor
forgings, castings, and bolting. Prototype component manufacture and
characterisation.
• Development and modelling of welding procedures and consumables for the
above groups.
• Accelerated alloy development and application through improved
understanding and modeling of microstructural evolution and its relationship to
mechanical properties.
• Characterisation of steam oxidation behaviour of new alloys, and modelling
of spallation.
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CONTENTS
Chapter
Page
TITLE.......................................................................................................... I
CERTIFICATE ...................................................................................................II
ABSTRACT.......................................................................................................
III
OBJECTIVE............ ..................................................................................IV
TABLE OF CONTENTS ...................................................................................V
WHAT IS A BOILER........................................................................................1
MATERIALS…....................................................................................................
2
FUEL…………....................................................................................................3
CONFIGURATIONS…………….......................................................................4
SUPERHEATED STEAM
BOILERS..................................................................5
SUPERCRITICAL STEAM
GENERATORS......................................................7
HYDRONIC
BOILERS........................................................................................8
BOILER FEED
WATER....................................................................................10
METALLURGY...............................................................................................11
1
HISTORY...........................................................................................................1
3
EXTRACTION...................................................................................................1
4
ALLOYS.............................................................................................................1
5
PRODUCTION...................................................................................................1
6
MICROSTRUCTURE…………………………………………………………
17
BOILER MATERIAL
……………………………………………………….18
HEAT TREATMENT……………………………………………….……….20
BOILER WATER
TREATMENT……………………………………………..21
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1
WHAT IS A BOILER?
A boiler is defined as "a closed vessel in which water or other liquid is heated,
steam or vapor is generated, steam is superheated, or any combination thereof,
under pressure or vacuum, for use external to itself, by the direct application of
energy from the combustion of fuels, from electricity or nuclear energy."
Also included are fired units for heating or vaporizing liquids other than water
where these units are separate from processing systems and are complete within
themselves. This definition includes water heaters that exceed 200,000 Btu/hr
heat input, 200 degrees Fahrenheit at the outlet, or 120 gallons nominal water
containing capacity.
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MATERIALS:
The pressure vessel in a boiler is usually made of steel (or alloy steel), or
historically of wrought iron. Stainless steel is virtually prohibited (by the
ASME Boiler Code) for use in wetted parts of modern boilers, but is used often
in super heater sections that will not be exposed to liquid boiler water. In live
steam models, copper or brass is often used because it is more easily fabricated
in smaller size boilers. Historically, copper was often used for fireboxes
(particularly for steam locomotives), because of its better formability and
higher thermal conductivity; however, in more recent times, the high price of
copper often makes this an uneconomic choice and cheaper substitutes (such as
steel) are used instead.
For much of the Victorian "age of steam", the only material used for boiler
making was the highest grade of wrought iron, with assembly by riveting. This
iron was often obtained from specialist ironworks, such as at Cleator Moor
(UK), noted for the high quality of their rolled plate and its suitability for high-
reliability use in critical applications, such as high-pressure boilers. In the 20th
century, design practice instead moved towards the use of steel, which is
stronger and cheaper, with welded construction, which is quicker and requires
less labor.
Cast iron may be used for the heating vessel of domestic water heaters.
Although such heaters are usually termed "boilers", their purpose is usually to
produce hot water, not steam, and so they run at low pressure and try to avoid
actual boiling. The brittleness of cast iron makes it impractical for high pressure
steam boilers.
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FUEL:
The source of heat for a boiler is combustion of any of several fuels, such as
wood, coal, oil, or natural gas. Electric steam boilers use resistance- or
immersion-type heating elements. Nuclear fission is also used as a heat source
for generating steam. Heat recovery steam generators (HRSGs) use the heat
rejected from other processes such as gas turbines.
3
CONFIGURATIONS:
• Fire-tube boiler. Here, water partially fills a boiler barrel with a small
volume left above to accommodate the steam (steam space). This is the
type of boiler used in nearly all steam locomotives. The heat source is
inside a furnace or firebox that has to be kept permanently surrounded by
the water in order to maintain the temperature of the heating surface just
below boiling point.
• Water-tube boiler. In this type, the water tubes are arranged inside a
furnace in a number of possible configurations: often the water tubes
connect large drums, the lower ones containing water and the upper ones,
steam and water; in other cases, such as a mono tube boiler, water is
circulated by a pump through a succession of coils. This type generally
gives high steam production rates, but less storage capacity than the
above.
• Fire-tube boiler with Water-tube firebox. Sometimes the two above types
have been combined in the following manner: the firebox contains an
assembly of water tubes, called thermic syphons.
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• Sectional boiler. In a cast iron sectional boiler, sometimes called a "pork
chop boiler" the water is contained inside cast iron sections. These
sections are assembled on site to create the finished boiler.
Most boilers heat water until it boils, and then the steam is used at saturation
temperature (i.e., saturated steam). Superheated steam boilers boil the water and
then further heat the steam in a super heater. This provides steam at much
higher temperature, but can decrease the overall thermal efficiency of the steam
generating plant due to the fact that the higher steam temperature requires a
higher flue gas exhaust temperature. There are advantages to superheated steam
and this may (and usually will) increase overall efficiency of both steam
generation and its utilisation considered together: gains in input temperature to
a turbine should outweigh any cost in additional boiler complication and
expense.
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The super heater works like coils on an air conditioning unit, however to a
different end. The steam piping (with steam flowing through it) is directed
through the flue gas path in the boiler furnace. Some super heaters are radiant
type (absorb heat by radiation), others are convection type (absorb heat via a
fluid i.e. gas) and some are a combination of the two. So whether by convection
or radiation the extreme heat in the boiler furnace/flue gas path will also heat
the super heater steam piping and the steam within as well. It is important to
note that while the temperature of the steam in the super heater is raised, the
pressure of the steam is not: the turbine or moving pistons offer a "continuously
expanding space" and the pressure remains the same as that of the boiler.[6] The
process of superheating steam is most importantly designed to remove all
droplets entrained in the steam to prevent damage to the turbine blading and/or
associated piping.
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SUPERCRITICAL STEAM GENERATORS:
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HYDRONIC BOILERS:
Hydronic boilers are used in generating heat for residential and industrial
purposes. They are the typical power plant for central heating systems fitted to
houses in northern Europe (where they are commonly combined with domestic
water heating), as opposed to the forced-air furnaces or wood burning stoves
more common in North America. The hydronic boiler operates by way of
heating water/fluid to a preset temperature (or sometimes in the case of single
pipe systems, until it boils and turns to steam) and circulating that fluid
throughout the home typically by way of radiators, baseboard heaters or
through the floors. The fluid can be heated by any means...gas, wood, fuel oil,
etc, but in built-up areas where piped gas is available, natural gas is currently
the most economical and therefore the usual choice.
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Hydronic systems are being used more and more in new construction in North
America for several reasons. Among the reasons are:
• They are more efficient and more economical than forced-air systems
(although initial installation can be more expensive, because of the cost
of the copper and aluminum).
• The baseboard copper pipes and aluminum fins take up less room and
use less metal than the bulky steel ductwork required for forced-air
systems.
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period of time than air does, so the furnace does not have to switch off
and on as much.
• They do not introduce any dust, allergens, mold, or (in the case of a
faulty heat exchanger) combustion byproducts into the living space.
2
BOILER FEED WATER:
A boiler is a device for generating steam, which consists of two principal parts:
the furnace, which provides heat, usually by burning a fuel, and the boiler
proper, a device in which the heat changes water into steam. The steam or hot
fluid is then re-circulated out of the boiler for use in various processes in
heating applications.
2
returned to the boiler.
2
METALLURGY:
In its general, modern sense, metallurgy is the science that studies the chemical
and physical properties of metals, including how they perform when used for
culturally useful industrial purposes. The term often refers to the procedures
used in extracting metals from ore, as well as to the processes related to metals
purification and alloy production. It also refers to the craft of making culturally
useful objects out of metal, or metalworking. The practice of metalworking has
been carried out over thousands of centuries.
Evidence of this science and craft dates back roughly 6,500 years. Copper, tin,
silver, and meteoric iron, which was used by the Egyptians to make weapons,
all underwent some form of metalworking process in various ancient cultures.
The first evidence of a standard metallurgy technology appeared during the
Bronze Age, which started around 3,500 BC, when it was discovered that by
heating and combining copper and tin, a bronze alloy could be created. The
Iron Age began around 1,200 BC when the Hittites discovered how to extract
iron from ore and work it to advance their cultural aims. Georg Agricola,
considered to be the father of metallurgy, detailed ore mining and metal
extraction procedures, as well as other aspects of the science, in his 16th
century book, De re metallica.
In general, elemental metals, in their pure native form, are too soft for industrial
uses. That is why the science of metallurgy tends to focus on the manufacture
of alloys, in which metals are combined together or with non-metals. Steel and
cast irons are examples of iron-carbon alloys. Aluminum, copper, iron,
magnesium, and zinc are the metals that are used most, usually in their alloy
forms.
2
HISTORY:
The first evidence of human metallurgy dates from the 5th and 6th millennium
BC, and was found in the archaeological sites of Majdanpek, Yarmovac and
Plocnik, Serbia. These examples include a copper axe from 5,500BC belonging
to the Vincha culture.[1] Other signs of human metallurgy are found from the
third millennium BC in places like Palmela (Portugal), Cortes de Navarra
(Spain), and Stonehenge (United Kingdom). However, as often happens with
the study of prehistoric times, the ultimate beginnings cannot be clearly defined
and new discoveries are continuous and ongoing.
Mining areas of the ancient Middle East. Boxes colors: arsenic is in brown,
copper in red, tin in grey, iron in reddish brown, gold in yellow, silver in white
and lead in black. Yellow area stands for arsenic bronze, while grey area stands
for tin bronze.
Silver, copper, tin and meteoric iron can also be found native, allowing a
limited amount of metalworking in early cultures. Egyptian weapons made
from meteoric iron in about 3000 B.C. were highly prized as "Daggers from
Heaven".[2]. However, by learning to get copper and tin by heating rocks and
combining those two metals to make an alloy called bronze, the technology of
metallurgy began about 3500 B.C. with the Bronze Age.
The extraction of iron from its ore into a workable metal is much more difficult.
It appears to have been invented by the Hittites in about 1200 B.C., beginning
the Iron Age. The secret of extracting and working iron was a key factor in the
2
EXTRACTION:
3
ALLOYS:
3
PRODUCTION:
1
MICROSTRUCTURE:
3
BOILER MATERIAL:
The material used for plates, rivets, braces, and all other parts on which the
structural strength of a high-grade boiler depends are made of a low-carbon
open-hearth steel in which is allowable only very small quantities of
phosphorus and sulphur. Nickel is often alloyed with this steel to improve its
tensile and elastic strength.
The elastic strength, rather than the tensile strength of the material, is of first
importance, as the permanent safety of the boiler depends upon all stresses
remaining within the elastic limit. A good margin between the elastic and the
final strength of the material provides a ductility or elongation which will many
times save actual and disastrous disruption under pressure by allowing the
material to bulge out or otherwise stretch greatly before it breaks.
1
bolts, and material for boiler braces are required to exceed slightly the
requirements specified for plates.
HEAT TREATMENT:
2
Metals can be heat treated to alter the properties of strength, ductility,
toughness, hardness or resistance to corrosion. Common heat treatment
processes include annealing, precipitation strengthening, quenching, and
tempering. The annealing process softens the metal by allowing recovery of
cold work and grain growth. Quenching can be used to harden alloy steels, or
in precipitation hardenable alloys, to trap dissolved solute atoms in solution.
Tempering will cause the dissolved alloying elements to precipitate, or in the
case of quenched steels, improve impact strength and ductile properties.
1
1
BOILER WATER TREATMENT:
The treatment and conditioning of boiler feed water must satisfy three main
objectives:
• Corrosion protection
1
External treatment
1
when the dissolved solids in the raw water are very
high.
Certain natural and synthetic materials have the ability to remove mineral ions
from water in exchange for others. For example, in passing water through a
simple cation exchange softener all of calcium and magnesium ions are
removed and replaced with sodium ions. Since simple cation exchange does not
reduce the total solids of the water supply, it is sometimes used in conjunction
with precipitation type softening. One of the most common and efficient
combination treatments is the hot lime-zeolite process. This system of
treatment accomplishes several functions: softening, alkalinity and silica
reduction, some oxygen reduction, and removal of suspended matter and
turbidity.
Internal treatment
Internal treatment can constitute the unique treatment when boilers operate at
low or moderate pressure, when large amounts of condensed steam are used for
feed water, or when good quality raw water is available. The purpose of an
internal treatment is to
1) react with any feed-water hardness and prevent it from precipitating on the
boiler metal as scale;
2) condition any suspended matter such as hardness sludge or iron oxide in the
boiler and make it non-adherent to the boiler metal;
4) eliminate oxygen from the water and provide enough alkalinity to prevent
boiler corrosion.
2
In addition, as supplementary measures an internal treatment should prevent
corrosion and scaling of the feed-water system and protect against corrosion in
the steam condensate systems.