NAVEED ANWAR
BSME01113020
NAVEED ZAFAR
BSME01113058
MUBASHIR AHSAN
BSME 01113088
What is a Boiler?
A water containing vessel in which
water is heated under pressure
Transfer heat from a fuel source (oil,
gas, coal) into steam
The steam or hot fluid circulates out
of the boiler for use in various
process or heating appliances.
HOW DOES A BOILER
WORK
Closed
system: when 100% of the
steam produced is returned to be
reused.
Examples of closed systems are
close steam heating, hot water
heating, and one-pipe systems.
Open system: a system that does not
return the condensate.
STEAM TO
PROCESS
EXHAUST GAS
STACK
VENT
DEAERATOR
PUMPS
ECONOMIZER
VENT
BOILER
BLOW DOWN
SEPARATOR
BURNER
WATER
SOURCE
FUEL
BRINE
SUPERHEATER COILS
Super heater coils are used in a boiler to generate
saturated steam. The super heater coils are specially used
inBoilersof Power plant.
We manufacture Super heater coils in various grades of
Alloy steel T1, T9, T11, T22, T9 & T91 and in stain less
steel tubes SS 304, SS310, SS316 and SS 347H with or
without support & Header as per customers drawing.
ECONOMISER COILS
Economizer coils are used in downstream of
Boiler bank to preheat the feed water
absorbing heat from hot exhaust gases.
Economizers are always water tube type
WATER WALL TUBES
These
are tubes in the Boiler where
water is evaporated to steam and
are also called Steam Generating
Tubes. These Tubes also form the
Walls of the Boiler and are hence
called Water Walls or Water Wall
Panels.
Check valve
Acheck valve,clack valve,non-return
valveorone-way valveis avalvethat normally
allows fluid(liquidorgas) to flow through it in
only one direction.
Check valves are two-port valves, meaning they
have two openings in the body, one for fluid to
enter and the other forfluidto leave.
HEAT EXCHANGERS
For pressure vessels and reaction vessels in M.S., Al,
Cupronickel, etc., Tube Weld employs the latest
techniques for expanding tube ends into tube
sheets. High pressure tests are always carried out on
these heat exchangers before they leave the factory.
Brass, copper, M.S. and S.S. tube sheets are used.
HEADERS
Headersform
an important part of
all types of boilers. Steam from the
generating tubes is collected in
headers which are therefore always
under pressure. This pressure may
vary from 300 psi to 2000 psi.
Types of boiler
1.
2.
3.
4.
5.
6.
Fire Tube Boiler
Water Tube Boiler
Packaged Boiler
Stoker Fired Boiler
Pulverized Fuel Boiler
Waste Heat Boiler
Fire Tube Boilers
The combustion gases pass
inside boiler tubes, and heat is
transferred to water on the shell
side.
Water Tube Boilers
Used for high steam demand and
pressure requirements
Capacity range of 4,500 120,000
kg/hour
Boiler water passes through the tubes
while the exhaust gases remain in the
shell side, passing over the tube
surfaces.
The features of water tube boilers are:
Forced, induced and balanced draft
provisions help to improve
combustion efficiency.
Less tolerance for water quality calls
for water treatment plant.
Higher thermal efficiency levels are
possible
. Packaged Boiler
To
Chimney
Oil
Burner
Comes in complete
package
Features
High heat transfer
Faster evaporation
Good convective heat
transfer
Good combustion
efficiency
High thermal
efficiency
Classified based on
Stoke Fired Boilers
a) Spreader stokers
Coal is first burnt in suspension
then in coal bed
Flexibility to meet load
fluctuations
Favored in many industrial
applications
5. Stoke Fired Boilers
b) Chain-grate or traveling-grate stoker
Coal is burnt on
moving steel grate
Coal gate controls
coal feeding rate
Uniform coal size
for complete
combustion
Pulverized Fuel Boiler
Pulverized coal powder
blown with combustion
air into boiler through
burner nozzles
Temperature at 1300
-1700C
Benefits: varying coal
quality coal, quick
response to load
changes and high preheat air temperatures
Waste Heat Boiler
Used when waste
heat available at
medium/high temp
Auxiliary fuel
burners used if
steam demand is
more than the
waste heat can
generate
Used in heat
recovery from
Assessment of a boiler
1.
Boiler
2.
Boiler blow down
3.
Boiler feed water treatment
Assessment of a Boiler
Causes of poor boiler
performance
-
Poor combustion
Heat transfer surface fouling
Poor operation and maintenance
Deteriorating fuel and water quality
Heat balance: identify heat losses
Boiler efficiency: determine deviation
from best efficiency
Heat Balance
Balancing
total energy
entering a boiler against the
energy that leaves the boiler
in different forms
12.7 %
8.1 %
100.0 %
Fuel
1.7 %
BOILER
0.3 %
2.4 %
1.0 %
73.8 %
Heat loss due to dry flue gas
Heat loss due to steam in fuel gas
Heat loss due to moisture in fuel
Heat loss due to moisture in air
Heat loss due to unburnts in residue
Heat loss due to radiation & other
unaccounted loss
Heat in Steam
Heat Balance
Goal: improve energy efficiency by reducing avoidable losses
Avoidable
losses include:
Stack gas losses (excess air, stack gas
temperature)
Losses by unburnt fuel
Blow down losses
Condensate losses
Convection and radiation
Boiler Efficiency
Thermal
efficiency: % of (heat)
energy input that is effectively
useful in the generated steam
BOILER EFFICENCY
CALCULATION
1)
DIRECT METHOD:
The energy gain of the
working fluid (water and steam)
is compared with the energy
content of the boiler fuel.
2) INDIRECT METHOD:
The efficiency is the
different between losses
and energy input
26
UNEP 2006
Boiler Efficiency: Direct Method
Boiler efficiency () =
Heat Input x 100
Q x (hg hf) x 100
=
Heat Output
Q x GCV
hg -the enthalpy of saturated
steam in kcal/kg of steam
hf -the enthalpy of feed
water in kcal/kg of water
gross calorific value of the
fuel (GCV) in kcal/kg of fuel
Boiler Efficiency: Indirect Method
Efficiency
of boiler () = 100
(i+ii+iii+iv+v+vi)
Principle losses:
i. Dry flue gas
ii. Evaporation of water formed
due to H2 in fuel
iii. Evaporation of moisture in fuel
iv. Moisture present in combustion
air
v. Unburnt fuel in ash
vi. Radiation and other
unaccounted losses
2. Boiler Blow Down
Controls total dissolved solids (TDS)
in the water that is boiled
Blows off water and replaces it with
feed water
Conductivity measured as indication
of TDS levels
Calculation ofFeed
quantity
down
water TDS x blow
% Make up
water
Blow down (%) =
required: Maximum Permissible TDS in Boiler water
Boiler Blow Down
Benefits
Lower pretreatment costs
Less make-up water consumption
Reduced maintenance downtime
Increased boiler life
Lower consumption of treatment
chemicals
3. Boiler Feed Water Treatment
Quality of steam depend on
water treatment to control
Steam purity
Deposits
Corrosion
Efficient heat transfer only if
boiler water is free from depositforming solids
Deposit control
To avoid efficiency losses and
reduced heat transfer
Hardness salts of calcium and
magnesium
Alkaline hardness: removed by
boiling
Non-alkaline: difficult to
remove
Boiler Feed Water Treatment
Internal water treatment
Chemicals added to boiler to prevent scale
Different chemicals for different water
types
Conditions:
Feed water is low in hardness salts
Low pressure, high TDS content is
tolerated
Small water quantities treated
Internal treatment alone not recommended
External water treatment:
Removal of suspended/dissolved solids and
dissolved gases
Pre-treatment: sedimentation and settling
First treatment stage: removal of salts
Processes
a) Ion exchange
b) Demineralization
c) De-aeration
d) Reverse osmoses
