TYPES OF BOILERS

1.INDUSTRIAL BOILERS:
USED MAINLY IN PROCESS INDUSTRIES
-FBC, CFBC, STOCKER FIRED, WHRB

2.UTILITY BOILERS:
ELECTRICAL POWER GENERATION
- PF

HEAT TRANSFER SECTION

INDUSTRIAL

FURNACE
ECONOMISER
SUPER HEATER
BOILER BANK
AIR HEATER

UTILITY
FURNACE
ECONOMISER
SUPER HEATER
RE HEATER
AIR HEATER

Heat Transfer modes in Boilers:

Conduction
Convection
Radiation

Factors in deciding the Heat Transfer Surface:

Type of fuel & fuel firing rate

Allowable Metal temperatures for selected tubes
Available space for other equipments
Standards set by Government
Economical reasons like Initial cost , O&M cost,
manufacturing limitations

COMPARISION OF FURNACE FOR DIFFERENT FUEL

COAL

OIL

GAS

CIRCULATION SYSTEM
Types of Boiler Circulation
Natural Circulation:
Density difference is the driving force
Limited to drum pressure of 175 kg/cm2

Controlled Circulation
Mechanical pumps are used to over come the frictional
losses
Pressure beyond 175 kg/cm2

Combined Circulation
Phase transformation is absent
Operating pressure is 260 kg/cm2

SH

Eco.

Drum

SH

SH
Eco.

Eco.

Furnace wall

Circu. pump
Distribution Header

Natural

Furnace wall

Furnace wall

Distribution Header

Controlled

Circu. pump
Distribution Header

Combined

CIRCULATION RATIO
RATIO BY WEIGHT OF THE WATER FED TO THE STEAM
GENERATING CIRCUITS, TO THE STEAM ACTUALLY
GENERATED

UTILITY BOILERS 6 9
INDUSTRIAL BOILERS -- 8-- 30

0.7
DENSITY OF WATER
0.6
D 0.5
E
N

0.4
CRITICAL
POINT

S
I
T

0.3

Y 0.2
0.1
00

100

120

140

DENSITY OF STEAM
160
180
200
PRESSURE

220

240

WATER AND STEAM CYCLE

Eco
Super heaters

Final SH

Spray
Main
Steam O/L

BFP

Drum & Drum Internal

It houses the equipment needed for purification of steam.

The main components of Boiler Drum:

Turbo separator
Screen Dryer
Baffle Plate
STAGES OF STEAM & WATER SEPARATION :
Separation takes place in the concentric cylinder of
Turbo separator.
The second stage of separation takes place in the
corrugated sheets connected to the top of the Turbo
separator.
The third and final stage of separation takes place in
SCREEN DRYERS.

Sectional view of Drum

Factors for Efficient Combustion:

Time of Fuel residence in the furnace
Temperature inside the Furnace
Turbulence which cause rapid mixing of fuel and air

Water cooled furnace :

In the furnace combustion and heat transfer both are taking place
simultaneously
Due to heat transfer in the furnace , temperature of the flue gas
leaving the furnace is reduce to acceptable level.
Higher heat loading in the furnace is possible as the heat is
simultaneously removed by heat transfer

TYPES OF PF FIRING:

VERTICAL FIRING

HORIZONTAL
FIRING

CORNER FIRING (SIDE)

Air- Flue Gas Cycle

SUPER
HEATERS

ECONOMIZER

ID FAN

FURNACE
FD FAN

HOT SA
Coal
Oil

AIR HEATER

BOTTOM ASH
HOT PA TO MILLS

PA FAN

ESP

ADVANTAGES OF PULVERISED FUEL FIRING SYSTEM

Combustion is complete with low percentage of excess air
High combustion efficiency
Ability to burn wide variety of coals
Lower fan power
Fast response to load changes
Ease of burning alternately with, or in combination with gas and oil
Ability to release large amounts of heat

DIS ADVANTAGES OF PULVERISED FUEL FIRING SYSTEM

Added investment in coal preparation equipment
Added power needed for pulverizing coal
Large volume furnace needed to withstand high gas temperature
Investment in stack fly-ash removal equipment

UTILISATION OF AIR

COMBUSTION SECONDARY AIR

CONVEYING AND DRYING OF COAL - PRIMARY AIR
FEEDER AND COAL PIPES - SEAL AIR
SCANNER COOLING COOLING FAN

SADC
AIR

UOFA

AIR

LOFA

AIR

EE

COAL
OIL

COAL
OIL

COAL
AIR
COAL
OIL

COAL
EA

E
DE
D
CD
C
BC
B
AB
A
AA

VARIOUS LOSSES IN BOILER:

INFLUENCED BY EXCESS AIR
LOSS DUE TO DRY FLUE GAS
LOSS DUE UNBURNT GAS
LOSS DUE TO COMBUSTIBLE IN ASH
UNINFLUENCED BY EXCESS AIR
LOSS DUE TO MOISTURE IN FUEL
LOSS DUE TO DUE TO COMBUSTION OF
HYDROGEN
RADIATION LOSS
UNACCOUNTED LOSSES
LOSS DUE TO SENSIBLE HEAT IN BOILER REJECTS

AIR PRE HEATERS

RECUPERATIVE
a. TUBULAR AIR HEATER
b. PLATE TYPE AIR HEATER
c. STEAM AIR HEATER

REGENERATIVE
A. LJUNGSTORM TYPE
B. ROTHEMUHLE TYPE

SOME ADVANTAGES OF APH:

IMPROVED COMBUSTION
BURNING POOR QUALITY FUEL EFFICIENTLY
IN CASE OF PF BOILERS HOT AIR IS USED IN DRYING OF COAL AS
WELL AS IN TRANSPORTING THE PULVERIZED COAL TO THE
BURNERS
LESS UNBURNT IN THE FLUE GAS ,THUS COMPLETE COMBUSTION
IS ACHIEVED
INCREASES THE BOILER EFFICIENCY

ADVANTAGES OF REGENERATIVE
Compact and hence save space and structure
cost
Can be cleaned effectively during service
Can be used economically used in high capacity
boiler where heat transfer is high
Replacement cost and down is low
Holes in the element due corrosion does not
affect performance of APH
Deposits on the heat transfer surface does not
reduce the heat transfer
Arrangement is simple ,neat ,streamlined and
less costly.

SOOT BLOWERS:
All fuels when burnt will leave behind residue of combustion
,known as ash.
Removal of ash is essential for all methods of firing
With fuel bed firing ash is removed intermittently by shaking or
dumping.
In suspension firing ash particles gets carried through the gas
stream and retained in the boiler surfaces, which is periodically
cleaned.
Ash causes fouling of the furnace walls and gas passes, and
under some conditions may cause corrosion of these surfaces.
Ash in various form is removed with the help of Soot blowers,
which otherwise will affect the normal operation
Fuels Causing Deposits:

All Coals
Fuel Oils
Refinery Coke
Blast Furnace Gas etc

LONGER LIFE OF PRESSURE PARTS

a. Metal temperature at all the location should be kept
within the permissible limit

Tilting the burners

Operating lower tier burners
Soot blowing water walls
Reducing excess air
Raising the feed water temperature will help reduce the heat
pick up in SH
Irregular Ignition & Delayed combustion

b. Raising and lowering of the steam parameters beyond

the given value will reduce the life of the pressure parts.

c. In case of tube failure the boiler should be shutdown by normal

procedure at the earliest, otherwise it may damage the other
tubes by impingement and erosion.

d.
e.

f.

hearing the noise

difference between steam and water flow
Gas and steam temperature

Drum level should be maintained at the recommended value at all

operating conditions.
Re heater starvation should be avoided at all operating
conditions. During starting flue gas temperature should be
maintained below 540 deg.
Flue gas and steam temperature difference can be maintained by
adjusting the burners loading, location.

FLOW
Description

Unit

Boiler # 1

Boiler# 234

tph

285

390

tph

285

401

APH O/L Primary

tph

64.29

135

APH O/L Secondary

tph

188

299

Total Combustion Air

tph

303

491

tph

329

541

Steam
SH Outlet
Water
Feed water
Air

Flue Gas
FG leaving APH

PRESSURE STEAM & WATER

Description

Unit

Boiler # 1

Boiler# 234

SH Outlet

Kg/cm2

92

131

SH Outlet

Kg/cm2

96.78

Drum

Kg/cm2

99.35

143.3

Economiser Inlet

Kg/cm2

102.47

146.1

Economiser

Kg/cm2

1.96

2.84

Super Heater

Kg/cm3

7.35

12.24

Re heater

Kg/cm4

Steam

Pressure Drop

1.5

TEMPERATURE
Description

Unit

Boiler # 1

Boiler# 234

SH Inlet

DegC

369

522

SH Outlet

DegC

515

540

Economiser Inlet

DegC

235

235

Economiser Outlet

DegC

287

287

Ambient

DegC

33

33

AH Outlet Primary

DegC

287

277

AH Outlet Secondary

DegC

289

274

Furnace Outlet

DegC

1040

981

FG APH Inlet

DegC

320

305

FG APH Outlet

DegC

140

140

Steam

Feed Water

Air

Flue Gas

HEAT BALANCE
Description

Unit

Boiler # 1

Boiler# 234

Dry Gas

4.11

4.23

H2O & H2 in Fuel

4.93

6.15

H2O in Air

0.13

0.13

Unburnt Carbon

1.5

1.1

Radiation

0.25

Unaccounted

0.5

1.18

Manufacturer Margin

0.75

0.2

Total losses

12.17

12.99

Efficiency

87.83

87.01

Losses