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An Introduction to Boiler
Design Basics
Budi L Hakim
Boiler design basics
Summary
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, Examples, and Troubles
2
Boiler design basics
Summary
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, Examples, and Troubles
- GENERATE HEAT
- TRANSFER THE HEAT to WATER
- PRODUCE STEAM and
- CONVERT TO ENERGY
• Power Generation
• Industrial Processes
• Sea and land transportation
• District Heating
• Other special uses
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, Examples, and
Troubles
• From F to A to B
– liquid water warm-up
Temp. K
• B : evaporation begins
B C • B to C :
– mixture of water
(decreasing) and
steam (increasing)
A (increasing) called
called saturated
saturated
steam steam
F
Entropy
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124
D • C : evaporation
completed, steam
Temp. K still saturated
C • C to D
B
– steam is
superheated
• D
A – superheated
steam sent to
F turbine
Entropy
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124
D • D to E
– expansion in the
Temp. K steam turbine
C • E to F
B
– steam is
condensed and
cooled in the
condenser
A
E • F
F – water available for
Entropy a new cycle
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124
D
Temp. K
B C
A
E
F
Entropy
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, Examples, and
Troubles
• Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation
• Based on :
industrial, power generation,
• Intended use
shop or field assembled
• construction
grate, suspension, fluidized bed
• firing system hanged or bottom supported
• fuel
• Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation
• Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Coke
– fused solid residue from chemical processes involving
coal or oil
• Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
• Wood (20 MJ/Kg)
• Bark (mainly from paper mills)
• Food processing wastes
• Municipal and industrial refuses (7 to 15 MJ/Kg)
• Crude petroleum
– high amount of volatile compounds
• Fuel oil
Fuel
Fuel Oil FO
FO n°1
Oil Grade
Grade n°1 FO
FO n°2
n°2 FO
FO n°4
n°4 FO
FO n°5
n°5 FO
FO n°6
n°6
Distillate
Distillate Distillate Very
Type Very Light
Light Light
Light Residual
Type
Kérosene
Kérosene
Distillate Residual
Residual Residual
Residual
Residual
Color Light
Color Light Amber
Amber Black
Black Black
Black Black
Black
MJ/Kg
MJ/Kg 46,4
46,4 45,5
45,5 43,4
43,4 43,4
43,4 42,5
42,5
Sulfur
ulfur content,%
content,% 0,1
0,1 0,4
0,4 -- 0,7
0,7 0,4
0,4 -- 1,5
1,5 2.0
2.0 2.8
2.8
Atomizing temp Ambient
Atomizing temp Ambient Ambient
Ambient -4°C
-4°C min
min 50°C
50°C 93°C
93°C
• Natural gas
• Liquefied Petroleum gas (LPG)
• Refinery and oil gas,
• Gas from steel processing : coke oven and blast
furnace gas
Gas Propane
Gas Propane Butane
Butane Natural
Natural Gas
Gas LPG
LPG
C
C33H
H88 C4H10 mix
mix mix
mix
C4H10
MJ/Kg
MJ/Kg 50
50 46
46 47
47 45
45
• Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation
Air Ash
Drive shaft
Air Ash
Air
Fuel & Fuel &
sorbent sorbent
• Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation
• No circulation pump
• circulation driven by
density differences
between water and
steam/water mixture
• mixture
pressure increase
• pressure increase
detrimental to
detrimental
circulation : to
low
circulation : low
pressure boilers
pressure
only boilers
only
Date of last change Reference/Name of Presentation/SN 45
Controlled Circulation boiler
• circulation pump
• allow higher pressure
levels and hence,
capacities
• better load follow
capability
• more complex
• auxiliary consumption
• drum thickness
increase
• No drum
• once-through circulation
• fast start-up/shutdown
• invented by Sulzer of
Switzerland, now within
ALSTOM
• the « tower » type boiler
Secondary Feedwater
separator inlet
Water/steam
mixture from Primary
evaporator separator
Water level
Pure Water
Downcomers
Source : Combustion, Fossil Power J.G. Singer 1991, ch 7 p 16 fig 7
Date of last change Reference/Name of Presentation/SN 49
Boiler design basics
Summary
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, , Examples,
and Troubles
1 - Except HRSGs
Date of last change Reference/Name of Presentation/SN 51
Utility vs Industrial boilers (+)
1 - Except HRSGs
Date of last change Reference/Name of Presentation/SN 52
Shop vs site boiler construction
• Shop construction
– integrated package with preassembled auxiliaries
– shipping routes from shop to site must be carefully
investigated
– all construction by shop staff
– option limited to small boiler
• Site construction
– shop-assembled components easy to ship
– significant amount of work by local staff
– option required for large utility boilers
– strong site construction supervision
Date of last change Reference/Name of Presentation/SN 53
Typical boiler specification
• Boiler
– Information related to the water and steam generating
equipment and unit designation
• Furnace
– Dimensions / Total Volume
• Superheater and reheater design
– mono/multistage, layout, pendant/panel/platen
• Air Heater
– regenerative bi/tri sectors, cold end plate material
• Economizer
– tube type, finned or plain,
• Fuel specification
• Combustion system
– fuel preparation and handling, burners type
• Operating Conditions
– Controll point, lowest load ensuring normal steam temp
– Maximum Continuous Rating (MCR)
– Guaranteed load, base for overall unit efficiency
guarantee
• Boiler Capacity
– steam flow rate at MCR
– control load : steam temp achieved and controlled
• Boiler Efficiency
– Efficiency of xx% means that xx% of the heat supplied
by the fuel is transferred to the water / steam mixture,
and 100 - xx% is lost
– 100% efficiency is not achievable in a cost effective way
• History
• Thermodynamics for beginners
• Boiler design
• Utilily versus Industrial boilers
• Boiler Construction, Examples, and Troubles
• Bottom supported
• Can be shop
constructed (package
boilers)
• All heat furnace and
heat exchangers rest
on ground
• thermal expansion
lateral and upwards
restrained
• sensitive to earthquakes
Date of last change Reference/Name of Presentation/SN 50
Small / Medium size Boilers
The ALSTOM« D » Package Boiler
– compact
– small capacity
– 100% shop assembled
– shipped on train or barges
– fast erection
• Type VP package
boiler
– compact size
– small capacity
– 100%
shop
assembled
– shipped on train or
barges
– fast erection
« VU60 » D type
package boiler
• up to 270 t/hr
(approx 90 MWe
power)
• Germany
• Niederaussem K
• 1012 MWe (gross)
• lignite
• once-through forced
circulation supercritical
• operation: 2002
• Fuel: lignite
• S t e a m 274 bar, 580°C/600°C
• 94.4 % efficiency
• USA • lignite
• Red Hills 2 x 250 MWe • Circulating
Fluidized
Bed
• operation: 2002
• Steam 184 bar,
541°C
• Bechtel
• Shoaiba, 3 x 350
MWe in Saudi Arabia
• Oil-fired
• 2 pass - subcritical
Controlled Circulation
• Operation: 2002
• Fuel: Oil & gas
• Steam 182 bar,
540°C/540°C
Menu Sub
Date of last change Reference/Name of Presentation/SN 65
Large size Boilers
• Egypt
• Suez 3 & 4 (and Aboukir)
• 2 x 325 MWe
• Oil or gas-fired
• drum boiler, 2 coupled
pass Controlled
Circulation
• Operation: 1987
• Fuel: Oil & gas
• Steam 181 bar,
541°C/541°C
RH
RH
SH
RH
SH EC0
Vaporizer
Radiant wall
reheater Convection
Superheater
Reheater or reheater
inlet header
Furnace Economiser
side wall
Furnace Furnace rear
front wall wall
Economiser
Downcomers inlet
Windbox
Burners Economiser
ash hoppers
Boiler water
circulating Ljungstrom®
pump Regenerative
Air heater
Mineral Ribbed
liner fibre outer casing
double
layer Galvanized
lagging hex mesh
Insulation
pins Tube wall
Horizontal
Pourable Buckstay
Insulation
Corner closure plate
Date of last change Reference/Name of Presentation/SN 71
Boiler Construction
: Combustion Area
• Two firing types
– tangential firing
– Front/wall firing
Tangential firing
Front firing
Burners are located on
one furnace wall or two
facing walls.
• Tube cleanliness
• Tube corrosion by combustion
byproducts
• Tube overheating
• Tube pitting
• Hydrogen-induced tube
embrittlement
• Tube ductile gouging
Electromechanical corrosion
Hydrogen-induced
tube burst : occurs
beneath a relatively
dense deposit
Fix : appropriate water
chemistry
Ductile gouging :
irregular wastage of the tube
meteal beneath a porous deposit
Water/steam
mixture from
evaporator
Rotor Housing
Intermediate
Discharge
Inlet
vanes
Inlet (Suction)
Inlet (Suction)
Inlet (Suction)
Discharge Discharge
Pump-End
Impeller Bearing Housing
Pump-End Heat-Exchanger
Journal Bearing Inlet Connection
• Capacity Factor
– energy generated by the unit during the reference period
divided by the energy that could have been generated
had the unit run at its full rating over the entire period
Boiler Design
Basics
Introduced !