BOILER

INTRODUCTION

Ir. Sadani
WHAT IS A BOILE ?
R
A portable boiler(preserved, Poland)

A stationary boiler(United States)

 INTRODUCTIO
N
STEAM GENERATOR OR BOILER
A steam generator or boiler is usually a closed vessel made of
steel. Its function is to transfer the heat produced by the
combustion of fuel to water and ultimately to generate steam.
Fire Tube Boiler

Fire Tube Boiler

Water Tube Boiler

 BOILER
PROPERTIES
 (i) Safety. The boiler should be safe under operating conditions.
 (ii) Accessibility. The various parts of the boiler should
be accessible for repair and maintenance.
 (iii) Capacity. Should be capable of supplying steam according
to the requirements.
 BOILER
PROPERTIES
(iv)Efficiency. Should be able to absorb a maximum amount of heat
produced due to burning of fuel in the furnace.

(v) It should be simple in construction .

(vi) Its initial cost and maintenance cost should be low.

(vii) The boiler should have no joints exposed to flames.

(viii) Should be capable of quick starting and loading.

REQUIREMENT OF
BOILER
Generate maximum steam.

Light in weight and not occupy large

space. Proper safety regulations.

Cheaper in cost.

Easy cope up with fluctuating demands of

requirements.

Easily accessible for inspection and

repair.
 MATERIAL
S vessel in a boiler is usually made of
The pressure steel
(or alloy steel), or historically of wrought iron.
Stainless steel is virtually prohibited (by the ASME
Boiler Code) for use in wetted parts of modern
boilers, but is used often in super heater sections
that will not be exposed to liquid boiler water.
 MATERIAL
S steam models, copper or brass is
In live often
used because it is more easily fabricated in
smaller size boilers.
Cast iron may be used for the heating vessel of
domestic water heaters.
 FUE
The sourceLof heat for a boiler is combustion of any of
several fuels, such as wood, coal, oil, or natural gas.
Electric steam boilers use resistance- or immersion- type
heating elements.
Nuclear fission is also used as a heat source for
generating steam.
Heat recovery steam generators (HRSGs) use the heat
rejected from other processes such as gas turbines.

There is a new technology for energy at this time is geothermal

"Pot boiler" or "Haycock
boiler": a primitive "kettle"
Boilers can be classified into the following
configurations:
where a fire heats a partially-filled water container from
below. 18th century Haycock boilers generally produced and
stored large volumes of very low-pressure steam, often hardly
above that of the atmosphere. These could burn wood or most
often, coal. Efficiency was very low.
 CLASIFICATION OF STEAM
BOILER

 Though there are many classifications of steam boilers, yet

the following are important.
 ACCORDING TO THE CONTENTS IN THE TUBE:
a) fire tube or smoke tube boiler
b) water tube boiler.
 ACCORGING TO POSITION OF FURNACE:
a) Internally fired boilers
b) Externally fired boilers

 ACCORDING TO TYPE OF FURNACE:

c) Vertical boilers
d) Horizontal boilers

 ACCORDING TO NUMBER OF TUBES:

e) Single tube boilers
f) Multi tube boilers
 ACCORDING TO METHOD OF
CIRCULATION OF WATER:
a) Natural circulation boilers
b) Forced circulation boilers

 ACCORDING TO THE USE

c) Stationary boilers
d) Mobile boilers
 FACTOR SELECTING
BOILER
 Following factors should be considered
 Quality of steam required
 Steam Generation rate
 Accessibility of repair and inspection
 Area
 Cost
 Erection facility
 Fuel and Water available
 FIRE TUBE
A
BOILER
fire-tube boiler is a typeof boiler in which hot
gases from a fire pass through one or more tubes
running through a sealed container of water. The heat
energy from the gases passes through the sides of the
tubes by thermal conduction, heating the water and
ultimately creating steam.
Diagram of a fire-tube
boiler

Sectioned fire-tube boiler from a DRB Class

50 locomotive.
 WATER TUBE
BOILER
A water tube boiler is a type of boiler in which water
circulates in tubes heated externally by the fire. Water
tube boilers are used for high-pressure boilers. Fuel is
burned inside the furnace, creating hot gas which heats
water in the steam- generating tubes.
Schematic diagram of a marine-type water tube
boiler.
Diagram of a water-tube boiler.
 FLASH
BOILER
A flash boiler is a type of water-tube boiler, whose tubes are
strong and close together with water pumped through the
tubes. The tubes are kept very hot so the water feed is
quickly flashed into steam and superheated. They have these
advantages:
Less weight and bulk.
Less time to raise steam from cold.
A flash boiler is much easier than an ordinary boiler to
overheat, as there is no large reservoir of water to keep the
tubes from high temperature if the water flow is interrupted
or inadequate.
FLASH
BOILER
 FIRE TUBE BOILER WITH
WATER TUBE FIRE-BOXE
Sometimes the two above types have been
combined in the following manner: the firebox contains
an assembly of water tubes, called thermic syphons. The
gases then pass through a conventional fire tube boiler.
Water-tube fireboxes were installed in many Hungarian
locomotives, but have met with little success in other
countries.
Boiler for steam
locomotive.
 SECTIONAL BOILER
In a cast iron sectional boiler, sometimes "pork
Called a chop boiler" the water is
contained inside cast iron sections. These sections are
assembled on site to create the finished boiler.
Fabrication Boiler
Fabrication Boiler
Steam Power Plant
STEAM

FIRETUBES

• Application: hotel, heater, small

BURNE industrial process
R
• Fuel: Oil, Gas
• Steam capacity up to 5 Ton/h
• Saturated temperature
• Design pressure up to 2.5 Bar
• Fully shop assembly
• Application:
Auxiliary boiler,
industrial process
• Fuel: Oil and Gas
only
• Steam Capacity up
to 220 Ton/hr
• Design Pressure up
to 110 Bar
• Design Temperature
up
to 500o C
• Mainly shop
assembly, very
minimum site works
 WATER TUBE BOILER
 Used for high steam
demand and pressure
requirements.
 Capacity range of
4,500
– 120,000 kg/hour.
 Combustion efficiency
enhanced by induced
draft provisions.
  The water/steam circulates naturally by the density
different between the higher temperature fluid and
STEAM
(Ms)
the lower temperature fluid

Characteristic of Natural Circulation

 Circulation Ratio = Mw/Ms is low
WATER
(Mw)  The water wall tubes normally have
DOWNTAKE or DOWNCOMER

Steam +
Water larger diameter to reduce the pressure
drop of steam/water inside the tubes
 Friction factors that oppose circulation:
– friction between water and metal
HOT SIDE
COLD SIDE

tube (+ any scale deposit inside the

tube)
– friction in tube bent
– friction in lower drum and header
– friction around upper drum internal
 The water/steam circulates forced by circulating pump
 The circulating pump provide addition head to the existing thermal
head
Ms
Characteristic of Forced
 Circulation Ratio = Mw/MsCirculation
is high
Mw  The steam produced is higher then
Natural Circulation Boiler for the
COLD SIDE

same running time

 Furnished with Orifice located at the
inlet of Furnace Wall tubes to assist in
HOT SIDE

obtaining an adequate water flow of

varying length and heat absorbtion.
The other functions:
– create pressure drop
– measure the water flow
CIRCULATING
PUMP ORIFICE – regulate the flow balance
  Furnace
– radiation mode
 Radiant (Platen) Super heater
– luminous radiation mode
– non-luminous radiation mode
Econ.
– convection mode
 Convective (Spaced)
Super heater
– non-luminous radiation
mode
– convection mode
 Evaporator (Boiler Bank)
– convection mode
 Economizer
– convection mode
• Pressure Components (Mainly Water Circuit)
– Economizer
– Furnace and convection pass
– Water Circuits, including drums and steam
separators and re-heater.
– Attemparators
– Connection Piping and Headers
 Non- pressure Boiler Components
(Mainly Air & Fuel Component)
 Fuel preparation Equipment
 Burners
 Air Heaters
 Duct works and supports.
• Balance of Plant Equipments
– Fans
– Feed Pumps
– Pollution Control Equipments
– Controls
 Economizer
• Used for Feed Water
Heating.
• For adding heat at
higher temperature
• Use waste Heat
• Increases
Efficiency.
Burner
• Fuel
• Natural
Gas
• Oil
• Coal
Dust
• Quantity
• Boiler
Size
Mechanism of combustion
Design of Combuster / Burner

Energy/Heat
FUEL + Air +
Flue Gas
Main Components:
C , H, S, O, N
(Asphaltenes) – Fuel Oil
Some Problems :
+ 1. High Emission
2. Low Availability
Impurities: 3. Low Reliability
Sulfur, Vanadium, H2O, 4. High Corrosion
Organic material, etc. 5. High Maintenance
Air Heaters
Fabrication Boiler

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