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