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RAVI KUMAR
IIT Roorkee
BOILERS
A BOILER is an enclosed pressure vessel where heat
generated through the combustion of fuel is used for
converting water into steam.
The volume of water increases 1600 times when
converted into steam.
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boilers
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boilers
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Boiler Systems
Water Treatment system
Feed Water system
Steam System
Blow down System
Fuel Supply system
Air Supply system
Flue Gas system
Type of Boilers
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Fire tube boilers, typically have a lower initial cost, are more fuel
efficient (82%) and easier to operate, but they are limited generally
to capacities of 25 tons/hr and pressures of 17.5 kg/cm2. The
steam variation is less.
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Demerits
It is less suitable for impure and sedimentary water, as a small
deposit of scale may cause the overheating and bursting of
tube. Therefore, use of pure feed water is essential.
They require careful attention. The maintenance costs are
higher.
Failure in feed water supply even for short period is liable to
make the boiler over-heated.
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Packaged Boiler
Generally shell type with fire
tube design
High heat release rate in small
combustion space
More number of passes
Large number of small diameter
tubes leading to good
convective heat transfer
Higher thermal efficiency
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packaged boiler
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Boilers
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Lancashire Boiler
Cochran Boiler
Locomotive boiler
Babcock Wilcox Boiler
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Lankashire Boiler
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Lankashire Boiler
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Lankashire Boiler
It is a stationary, fire tube, internally fired boiler. The size is
approximately from 7-9 meters in length and 2-3 meters in
diameter.
It is stationary fire tube, internally fired, horizontal, natural
circulation boiler.
This is a widely used boiler because of its good steaming quality
and its ability to burn coal of inferior quality.
It has two large internal flue tubes having diameter between 80
cm to 100 cm in which the grate is situated.
This boiler is set in brickwork forming external flue so that the
external part of the shell forms part of the heating surface.
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Cylindrical shell
Furnace tubes, bottom flue and side flues
Grate
Fire bridge
Dampers
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Mountings
Pressure gauge and water level indicator provided at the front.
Safety valve, steam stop valve, low water and high steam safety
valve and man-hole are provided on the top of the shell.
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mountings
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mountings
Blow-off clock
It is situated beneath the front portion of the shell for the
removal of mud and sediments. It is also used to empty the water
in the boiler during inspection.
Fusible plug
It is provided on the top of the main flues just above the grate. It
prevents the overheating of the boiler tubes by extinguishing the
fire when the water level falls below a particular level. A low
water level alarm is mounted in the boiler to give a warning when
the water level falls below the preset value.
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Cornish Boiler
One large flue tube.
Shell length 4- 7 m
Shell diameter 1.25-1.75 m
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Chochran Boiler
It is very compact and requires
minimum floor area.
Any type of fuel can be used with
this boiler
Well suited for small capacity
requirements.
It gives about 70% thermal
efficiency with coal firing and about
75% with oil firing
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Chochran Boiler
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Locomotive Boiler
Locomotive boiler is a horizontal fire tube type mobile boiler.
The main requirement of this boiler is that it should produce
steam at a very high rate.
Therefore, this boiler requires a large amount of heating
surface and large grate area to burn coal at a rapid rate.
In order to provide the large heating surface area, a large
number of fire tubes are setup and heat transfer rate is
increased by creating strong draught by means of steam jet.
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Advantages
Large rate of steam generation per square metre of heating
surface. To some extent this is due to the vibration caused by
the motion.
It is free from brickwork, special foundation and chimney. This
reduces the cost of installation.
It is very compact. The pressure of the steam is limited to about
20 bar.
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Boiler Mountings
Components which are mounted over the body of the boiler
itself for the safety of the boiler and for complete control of the
process of steam genertion. They are integral part of the boiler.
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Safety Valve
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Fusible Plug
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Man Hole
A opening in boiler through which a man can enter a boiler for
cleaning and inspection purposes.
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Boiler Accessories
Installed either inside or outside the boiler to increase
efficiency of the boiler and to assist in the proper working of
the boiler.
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Air Preheater
It is a waste heat recovery device which is placed in the path of
the waste flue gases going to the chimney thereby abstracting
heat from the flue gases and transferring it to air before it is
used for combustion.
It is placed in the chimney above the preheater.
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Economiser
It recovers a part of heat from the heat carried away in the flue
gases up the chimney or stack and to utilize it for heating the feed
water supplied to the boiler.
Function: It is a device in which the waste heat of the flue gases is
utilsed for heating the feed water.
Advantages :
The temperature range between various parts of the boiler is
reduced which results in reduction of stresses due to unequal
expansion.
If the boiler is fed with cold water it may result in chilling the boiler
metal.
Evaporative capacity of the boiler is increased.
Overall efficiency of the plant is increased.
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Superheater
To increase the temperature of the steam above its saturation
point.
Super heaters are heat exchangers in which heat is transferred
to the saturated steam to increase its temperature.
Superheated steam has the following advantages :
Steam consumption of the engine or turbine is reduced.
Losses due to condensation in the cylinders and the steam
pipes are reduced.
Erosion of turbine blade is eliminated.
Efficiency of steam plant is increased.
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Steam Trap
Steam traps are a type of automatic valve that filters out
condensate (i.e. condensed steam) and non-condensable gases
such as air without letting steam escape.
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Steam Separator
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Feed Pump
To pump feed water to the boiler.
The reciprocating pumps run by steam from the same boiler to
which water is to be fed.
Rotary feed pumps are run either by a small steam turbine or
by an electric motor.
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La-Mont Boiler
First introduced by La-Mont
in the year 1925.
The capacity of La-Mont
boiler is about 50 T/hr of
superheated steam at a
pressure of 170 bar and at a
temperature of 500 oC.
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La-Mont boiler
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Benson Boiler
Capacity 150 T/hr at a pressure of 200
bar and at a temperature of 650 oC.
This boiler has a unique characteristic
of absence of steam separating drum.
The entire process of heating, steam
generation and superheating is done in
a single continuous tube.
Economiser
The feed water by means of the feed
pump is circulated through the
economiser tubes.
Hot flue gases pass over the economiser
tubes and the feed water is preheated
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Benson boiler
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Benson boiler
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Benson boiler
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Loeffler Boiler
Capacity 100 T/hr Pressure 140
bar. T= 500 oC
Water is heated solely by the
superheated steam
Furnace heat is supplied to
economizer and super heater
only.
This boiler can carry higher salt
concentration.
More compact than any
indirectly heated boilers having
natural circulation.
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Loeffler boiler
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Velox Boiler
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Boiler Performance
Evaporative capacity can be expressed in terms of:
kg of steam/hr
kg of hour/hr/m of heating surfacecs
kg of steam/kg of fuel fired
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Boiler Efficiency
Combustion Efficiency
indicates a burners ability to burn fuel measured by unburned
fuel and excess air in the exhaust.
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boiler efficiency
Thermal Efficiency
indicates the heat exchangers effectiveness to transfer heat from
the combustion process to the water or steam in the boiler,
exclusive radiation and convection losses
Fuel to Fluid Efficiency
indicates the overall efficiency of the boiler inclusive thermal
efficiency of the heat exchanger, radiation and convection losses output divided by input.
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Bituminous coal
17- 23
Butane
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Carbon
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Charcoal
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Coal (Lignite - Anthrasite) 15- 27
Coke
28- 31
Diesel
42
Ethanol
30
Kerosone
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Lignite
16
Methane
55
Petrol
44
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Excess air
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Equivalent Evaporation
Equivalent of evaporation of one kg of water at 100 oC at
standard atmospheric pressure of 101.3 kPa. Hence, equivalent
evaporation of 1 kg of water needs 2257 kJ of energy.
=
2257
Ms = kg of steam/kg of fuel
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Factor of Evaporation
Ratio of heat absorbed by 1 kg of feed water under working
conditions to that absorbed by 1 kg of water from and at 100 oC
and 101.3 kPa pressure.
=
2257
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Boiler Efficiency
Ratio of heat energy utilized by feed water for steam formation to
the generation of heat energy supplied by fuel.
Ma mass of steam/h
Mf mass of fuel/h
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Boiler Power
ASME has recommended a unit called boiler power which may be
used to measure the capacity of boiler.
=
21.296
100
"
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Numerical #1
Calculate the equivalent evaporation and efficiency of the boiler for
the following data:
Pressure of steam
900 kPa
Quality
0.9
Quantity of steam
5000 kg/h
Feed water temperature
30 oC
Coal consumption
700 kg/h
C.V. of coal
31.4 MJ/kg
What will be the saving in coal consumption per hour if the by putting
an economizers the temperature of feed water is raised to 95 oC and
other data remains the same except the boiler efficiency by 5%.
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Numerical #2
A boiler generates steam at 1.6 MPa pressure and 320 oC
temperature. The feed water temperature is 60 oC. The
calorific value of fuel fired in the boiler is 46.8 MJ/kg. the
ultimate analysis of fuel gives C=85% and H2=15%. Calculate:
minimum quantity of air required for complete combustion
of the fuel
Gross Calorific value of fuel
overall efficiency of boiler if the steam produced is 13 kg/kg
of fuel fired.
Latent heat of water vaour in the flue gases may be assumed
as 2510 kJ/kg.
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Boiler Trial
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Numerical #3
During the boiler trial following data were obtained:
Coal analysis dry: C=85.2%, H=4.8%, ash = 10%, GCV of dry coal
35 MJ/kg; moisture content 1.8%; coal consumption 1450 kg/h;
Boiler room temperature 25 oC; feed water temperature 55 oC;
steam pressure 1.2 MPa, steam temperature 250 oC; steam
raised 12500 kg/h; Analysis of dry flue gases by volume of
gases: CO2 =9.4%, O2 =11.1%, N2= 79.5%. The temperature of
gases in the uptake was 300 oC. Mean specific of dry gases
1.005 kJ/kg.
Prepare a complete balance sheet per kg of dry coal.
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boiler trial
Steam generated per kg of coal
Heat supplied per kg of coal
=> ?
9:
;
<=
kg/kg of coal
@@ ?"> A?"
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boiler trial
Heat supplied by coal
Heat in steam
Heat in dry products
Heat in vapour and gas
Heat in excess air
Heat unaccounted
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DRAUGHT
Small pressure difference causing flow of air and gases
through the boiler.
It is essential to supply a sufficient quantity of air for
combustion and to remove the product of combustion.
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Type of Draught
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Natural
Artificial
Steam Jet
Induced
Forced
Mechanical Jet
Induced
Forced
Forced
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Natural Draught
Difference between the pressure of column of hot gases in
chimney or stack and equal column if cold outside air.
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draught
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+ CD = CD
2ED + CD =ED O
GH
=F
I
0.287 273
=F
= 0.7734 F@
101.3
0.287 HN
HN
=F
=F
101.3
353
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GH
= 0.7734 F@
HN
Volume per kg of air at HN = 0.7734
273
HN
Volume m kg of air at HN =0.7734
F
273
H
Volume 1+m kg of air at H =0.7734
F+1
273
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HN
Volume m kg of air at HN =0.7734
F
273
; < O
273 F
PN =
0.7734 F HN
273
PN = 1.293
HN
353
PN =
HN
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; < O : F
273 F + 1
<Q ; ;P =
0.7734 F H
F + 1 273
F + 1 353
P = 1.293
=
F
H
F
H
For the chimney height H pressure drop
= QE PN P
1 F+1 1
= 353QE
HN
F H
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E =
P Q
1 F+1 1
F H
HN
E = 353QE
F + 1 353
.
.Q
HN
F
F H
E =E
1
F + 1 HN
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2Q E E
E
1
E
= 4.43 E
S
=T E
K = 1.1 for steel chimney and 0.825 for brick chimney
E
1.1 = 4.3 1
E
S
E
18.4
=
E
19.6
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Artificial draught
Advantages
Capable of consuming low grade fuel
Increase in evaporative power of boiler
Easy control of combustion and evaporation
Reduction of chimney height
Prevention of smoke
Improved efficiency
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Draft
Induced Draft Fan type
Forced Draft Fan Type
Advantages of forced draft over induced draft
Small fan size
No water cooled bearing
Less leakage
No heat loss
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THE END
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Chimney Efficiency
Ratio of the energy equivalent of draught produced by the fan
and the additional heat carried away by the gases in natural
draught system.
UVWXYZ[\ =
E
:] H H ,
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