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Boiler Basics
Boiler Basics
BOILER BASICS
What is Steam Boiler.?
Boiler is an closed vessel in which water is heated to produce steam.
This steam shall be used for process / Power Generation.
Steam boilers under IBR means any closed vessel which is used for
generating steam
Water gets heated outside the tubes while the hot gases flows inside the
tubes.
Water Tube Boiler:
Water flows inside the tubes and the hot flue gases flow outside the
tubes.
Basics of Steam
Steam - Basics
At atmospheric condition
The volume of water expands 1650 times when it is converted into steam at
atmospheric condition.
Importance of Fuel
Reporting Fuel Analysis
Air Dried Basis (ADB):
Samples sent to lab are kept open to lab ambient condition for equilibrium
moisture. Datas reported on this basis is ADB basis.
As Received Basis (ARB):
In GCV all the vapor produced in combustion process is fully condensed. The
latent heat is added to GCV and thus GCV is higher to NCV.
Net calorific value informs that the water is removed as vapor with the
combustion products.
Moisture
Surface Moisture:
- The moisture which is held inside the molecular structure of the fuel.
- Difficult to remove.
Total Moisture = 30 %.
Inherent Moisture = 10 %.
Total Moisture = 30 %.
It chokes the APH tubes and starts corroding from inside the tubes.
Corrodes the back hand equipments like Dust collecting system, ID fan
flue gas ducting & steel chimney when it condenses.
Other Parameters
Ash
- Higher the ash content lower the GCV & high ash handling cost.
Sulphur Content
Fuel Size
- Lower the fuel size, higher the surface exposed to flame and better the
combustion.
- Higher the fines, more will be the carryover of fuel with ash.
What is the fuel used in 16 TPH
boiler.?
ESP
ID Fan
SA Fan
FD Fan
Moving Grate Boiler – Water & Steam Circuit
TO PROCESS MU WATER CONDENSATE
ECONOMISER
CHEMICAL
DOSING
STEAM
DEAERATOR STORAGE
TANK
F.P:01
F.P:02
Deaerator
Deaerator is used
for the removal of
oxygen (O2) and non
condensable gases.
Oxygen promotes
pitting corossion. It
affects the heat
transfer in
equipment
Deaerator (Contd)
The concentration of dissolved oxygen in water is very less at 100 Deg C. Hence the
temperature is maintained more than 100 Deg C in Deaerator.
Economiser
It enhances the efficiency of the boiler by abstracting the heat from flue gases.
Boiler Bank
Water is transferred to
waterwall panels
through Downcomer.
Membrane/Waterwall Panel
Air In
Air Out
The Air Preheater is the last heat recovery equipment which is situated last in the flue
gas path.
It is a cross flow heat exchanger which provides hot air for combustion.
Boiler Mountings & Accessories
Fittings or Devices which are necessary for safety and controls are known as
Mountings.
Fittings or Devices which are provided to increase the efficiency of boiler and
help in smooth running of boiler is known as Accessories.
Boiler Mountings
Safety Valve.
Pressure Gauge.
Fusible Plug.
Blowdown Valve.
Economiser.
Air Preheater.
Superheater.
Moisture Separator.
Steam Traps.
Boiler Basic Calculation
Feed water consumption:
Make Up Water
Steam to Deaerator
Feed Water
Condensate
Example : 01
Blowdown % : …….%
Example : 02
Blowdown % : …….%
Evaporation Ratio:
Example:
Heat Losses:
The purpose of dust collector is to trap the dust particles and to allow
only pure gases into the atmosphere.
Cyclone Separator
Wet Scrubber
Bag Filter
Gas
• In cyclone separator, the dust particles are
I/L removed by means of gravity and rotation.
Ash
Bottom
Fly Ash
Ash
Bottom Ash
Hot Ash collected from traveling grate of Boiler furnace is collected directly in to water filled
trough, where in a moving belt is installed to take out Wet Ash from the trough.
Fly Ash
Low pH
Pitting Corrosion due to
CORROSION Dissolved Gases,
Under Deposit corrosion,
Caustic Corrosion etc.
Chemical Dosing:
NaOH, Sodium hydroxide is used to elevate the pH in feed water.
Chemical Dosing.
Chemical Dosing:
Hydrazine (Should be handled with care)
Sodium Sulphite.
Total Hardness
Hardness is composed primarily of calcium and Magnesium minerals.