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BOILER

DEFINITION

A boiler or Steam generator is, usually, a closed vessel made of steel. Its

function is to transfer to heat produce by the combustion of fuel (solid, liquid

gaseous) to water, and ultimately to generate steam.

USAGES OF BOILER IN INDUSTRIES

The steam generated is employed for the following purposes:

i) For generating power in steam engines or steam turbines.

ii) In the textile industries for sizing and bleaching etc. and many

other industries like; Sugar mils, Chemical industries.

iii) For heating the buildings in cold whether and for producing hot

water for hot water supply.

FUNCTION / WORKING

The primary function/Working of a boiler is to produce steam at a given pressure and

temperature. To accomplish this, the boiler serves as a furnace where air is mixed with

fuel in a controlled combustion process to release large quantities of heat. The pressure-

tight construction of a boiler provides a means to absorb the heat from the combustion

and transfer this heat to raise water to a temperature such that the steam produced is of

sufficient temperature and quality (moisture content) for steam loads.

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OPERATION

The boiler has an enclosed space where the fuel combustion takes place, usually referred

to as the furnace or combustion chamber. Air is supplied to combine with the fuel,

resulting in combustion. The water in the risers or circulating tubes absorbs the heat of

combustion. The density difference between hot and cold water is the driving force to

circulate the water back to the steam drum. Eventually the water will absorb sufficient

heat to produce steam.

Steam leaves the steam drum via a baffle, which causes any water droplets being carried

by the steam to drop out and drain back to the steam drum. If superheated steam is

required, the steam may then travel through a super heater. The hot combustion gasses

from the furnace will heat the steam through the super heater’s thin tube walls. The steam

then goes to the steam supplies System and the various steam loads.

Some boilers have economizers to improve cycle efficiency by preheating inlet feed water

to the boiler. The economizer uses heat from the boiler exhaust gasses to raise the

temperature of the inlet feed water.

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TYPICAL FUEL BOILER

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FUEL BOILER COMPONENTS

STEAM DRUM

The steam drum separates the steam from the heated water. The water droplets fall to the

bottom of the tank to be cycled again, and the steam leaves the drum and enters the steam

system. Feed water enters at the bottom of the drum to start the heating cycle.

DOWNCOMERS

Down comers are the pipes in which the water from the steam drum travels in order to

reach the bottom of the boiler where the water can enter the distribution headers.

DISTRIBUTION HEADERS

The distribution headers are large pipe headers that carry the water from the down comers

to the risers.

RISERS

The piping or tubes that form the combustion chamber enclosure are called risers. Water

and steam run through these to be heated. The term risers refer to the fact that the water

flow direction is from the bottom to the top of the boiler. From the risers, the water and

steam enter the steam drum and the cycle starts again.
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COMBUSTION CHAMBER

Located at the bottom of a boiler, the combustion chamber is where the air and fuel mix

and burn. It is lined with the risers.

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CLASSIFICATION OF BOILERS

There are many classifications of steam boiler

01) ACCORDING TO THE CONTENTS IN THE TUBE

The steam boilers according to the contents in the tube may be classified as

a) Fire Tube or Smoke Tube Boiler

b) Water Tube Boiler

a) Fire Tube or Smoke Tube Boiler

In Fire tube and smoke tube boiler the flames and hot gases (exhaust gases),

produce by the combustion of fuel, pass through the tubes (called multi tubes),

which are surrounded, by water. The heat is conducted through the walls of

the tubes from the hot gasses to surrounding water.

b) Water Tube Boiler

In Water Tube steam Boiler the water is contain inside the tube which are

surrounded by flame and hot gasses from outside

02) ACCORDING TO THE POSITION OF FURNACE (HEATING

SURFACE)

The steam boiler according to the furnaces are classified as

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a) Internally fired Boilers

b) Externally Boilers

a) Internally fired Boiler

In internally fired steam Boilers the furnace is located inside the Boiler shell. Most of

the fired tube steam boilers are internally fired Boiler.

b) Externally Boiler

In Externally fired steam boiler, the furnace is arranged underneath in a brick–work

setting. Water tube steam boilers are always externally fired.

03) ACCORDING TO THE AXIS OF THE SHELL

The steam boilers, according to the axis boiler shell, may be classified as

a) Vertical Boilers

b) Horizontal Boilers

a) Vertical Boiler

In vertical steam boiler, the axis of the shell is vertical. Simple vertical boiler and

Cochran boiler are vertical boilers.

b) Horizontal Boiler

In Horizontal steams boiler, the axis of the shell is vertical. Lancashire boiler,

Locomotive boiler, and Babcock and Wilcox boiler are horizontal boilers.
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04) ACCORDING TO THE NUMBER OF TUBE

The steam boilers, according to the Number of Tubes, may be classified as

a) Single Tube Boilers

b) Multi tubular Boilers

a) Single Tube Boiler

In Single tube steam Boilers, there is an only one-fire tube or water tubes. Simple vertical

boiler and Cornish boiler is Single Tube Boiler.

b) Multi Tubular Boiler

In Multitubular steam boilers, there are two or more fire tubes or water tubes. Lancashire

boiler, Locomotive boiler, Cochran boiler, Babcock and Wilcox boiler are Multitubular

boilers.

In forced circulation steam boilers, there is forced circulation of water by a centrifugal

pump driven by some external power. Use of forced circulation is made in high-pressure

boilers such as La-Mont boiler, Benson boiler, Loeffler boiler and velcon boiler.
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06) ACCORDING TO THE USES

The steam boilers, according to their use, may be classified as:

a) Stationary Boilers

b) Mobile Boilers

a) Stationary Boilers

The stationary steam boilers are used in power plants, and in industrial process work.

These are called stationary because they do not move from one place to another.

b) Mobile Boilers

The Mobile steam boiler is those, which move from one place to another. These boilers

are locomotive and marine boiler.

07) ACCORDING TO THE SOURCE OF HEAT

The steam boilers may also be classified according to the source of heat supplied for

producing steam. These sources may be the combustion of solid, Liquid or gaseous fuel,

hot waste gases as by-products of other chemical processes, electrical energy or nuclear

energy, etc.