This document provides information on different types of boilers used in industrial and utility applications. It discusses the key components and heat transfer processes in industrial and utility boilers. The document also covers topics like circulation systems, combustion principles for different fuels, and boiler efficiency parameters like circulation ratio and heat balance.
This document provides information on different types of boilers used in industrial and utility applications. It discusses the key components and heat transfer processes in industrial and utility boilers. The document also covers topics like circulation systems, combustion principles for different fuels, and boiler efficiency parameters like circulation ratio and heat balance.
This document provides information on different types of boilers used in industrial and utility applications. It discusses the key components and heat transfer processes in industrial and utility boilers. The document also covers topics like circulation systems, combustion principles for different fuels, and boiler efficiency parameters like circulation ratio and heat balance.
This document provides information on different types of boilers used in industrial and utility applications. It discusses the key components and heat transfer processes in industrial and utility boilers. The document also covers topics like circulation systems, combustion principles for different fuels, and boiler efficiency parameters like circulation ratio and heat balance.
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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.
