Boiler

Prepared By Dr. Bilal Shaukat (M.PHIL, DVM)

What is boiler:
Boiler is an apparatus to produce steam. Thermal energy
released by combustion of fuel is used to make steam at
the desired temperature and pressure.

The steam produced is used for following purposes.

 Heating the residential and industrial buildings
 Performing certain processes in the sugar mills,
chemical, solvent plant, feed mill and textile industries.
 Producing mechanical work by expanding it in steam
engine or steam turbine.
 Basics Of Boiler:

 Safety: The boiler should be safe under the

operating conditions.
 Accessibility: the various part of boiler should be
accessible for repair & maintenance.
 Capacity: Should be capable of supplying Steam
according to the requirements.
 Efficiency: Should be able to absorb a maximum
amount of heat produced due to burning of fuel in the
furnace.
 It should be simple in construction.
 Its initial cost and maintenance cost is low.
 It should be capable of quick starting and loading.
 Fire tube have
hot gases inside
the tube and
water
surrounding them.
 Fire Tube Boiler:
The combustion gases pass inside boiler tubes, and heat is
transferred to water present on the shell side.
• Relatively small steam capacities (12,000 kg/hour)
• Low to medium steam pressures
• Operates with oil, gas or solid fuels

 N ote:
 In Jadeed feed Mill they have 3 fire tube boiler.

 2 of them have capacity 6 tons per hour.

 While one have 18 ton per hour capacity.

1. Cornish boiler
2. Lancashire boiler
3. Scotch marine boiler
4. Locomotive boiler
5. Vertical fire-tube boiler
6. Packaged boiler
 Packaged boiler:
It comes in complete
package
Features:
 High heat transfer
 Faster evaporation
 Good convection
 Good combustion efficiency
 High thermal efficiency
 Classification based on
number of passes
 PARTS OF BOILER :
 Wood Furnace  Economizer
 Flow  Blow down valve
 Shell  Pressure Gauge
 Smoke Tubes(about 300)  Steam Header
 Water Column  Steam trap
 Main Stop Valve  Induced Fan (I.D)
 Safety Valve  Cyclone(dust collector)
 Main Hole or Inspection Hole  Feed Water Pump
 Forced Fan (F.D)
• PARTS • FUNCTIONS
• Wood furnace • Used to produce fire
which is used by boiler to
produce steam
• Water column • Shows level of water in
boiler
• Feed check valve • Keep water inside and
not let it to escape
• Blow down valve • To remove water before
maintenance
• Main stop valve • Control the steam
• Inspection hole • Used for inspection
• Safety valve • Remove extra pressure
when it is above the level
• Echonomiser • Waste gases used to
heat water entering the boiler
• Feed water pump • To supply water to
boiler
• Steam header • Divide the steam
• Steam trap • Divide the steam and
moisture
Parts
Induced draft fan
Forced draft fan
Function
It draws flue gases from the
system into the atmosphere
Forces outside air into heating
system.

Tem perature of steam :

At 150 psi (10 bar) working pressure, the temperature of steam
comes out of boiler is 170-180oC.
Fire tube boiler 1 Fire tube boiler 2

Furnace
Control valve
Safety valve Pressure Gauge

Gauge glass
Chemical tank
Water tank Cyclone, ID fan, and chimney

Cyclone, ID fan, and chimney

Processing of Fire tube boiler:

 Water from new tower(R.O) enters in feed water tank

 Water from feed water enters in economizer
 After being heated the water enter the shell of boiler and
submerged the Hot tubes of gases.
 Here water converts into steam and it came out of boiler
and being supplied to steam head
 From steam head it may goes towards feed
tower/Solvent plant
Processing of fire tube:
Gases flow:
 Pass1
 Ignite the wood, coal, oil and bagasse in furnace(1700 F)
 After that hot air may pass flue and take the first pass and
collide with baffle plate .
 Pass 2:
 After collision the hot air change their path and enter in
second pass and again collide (1500 F)
 Pass 3:
 After collision the gases enters in 3rd pass and went to the
economizer and escape from chimney.(350 F)
 Here the ash is collected by cyclone and gases are
exhaust through chimney with the aid of Induced draft fan
 Processing in 18 tons Fire tube boiler

 Water from water tank enters into the feed tank

 From there water will enter into the shell of the boiler
then it will go to the pipes present on the both sides
of the boiler
 Then the water will enter into the tubes present in the
furnace area and the steam will enter the shell of
boiler again
 It works as a economizer and reduces the cost about
10-15%
 Further procedure is same as 6tons boiler
 Processing in 18 tons Boiler
 Pass 1
 First ignite the fire using wood, coal, oil.
 F.D fan used as it gives hot air.
 The gases will travel from the furnace to the flues
and then will hit to the baffle plate
 Pass 2
 After hitting to a baffle plate gases will enter into
second pass which is in opposite to First Pass
 Pass 3
 After 2nd pass the gases will enter the 3rd pass and
before entering into the chimney the Ash in gases
collected by Cyclone with the aid of I.D fan
Water tank Water enter in boiler

Shell Pipe
 Flue Gas tubes(passes)

Control valve Inspection valve

Induced fan Pressure gauge
 Fire tube boiler is so easy to use, operate, clean and
maintain.
 Fire tube boiler can be used in small scale industries.
 Fire tube boiler is relatively cheaper than water
tube boiler.
 From the furnace combustion side, required time
to fill water is longer than to increase
temperature and pressure.
 The efficiency of heat transfer is low.
 In case of bombers fire tube boiler would be very
dangerous.
 The fire tube boiler can not produce steam at a
pressure higher than 250 pounds per square
inch.(17.23 Bar)
 Capacity of generated steam is limited .
 Use in power plants
 Heating a buildings
 Use in industrial sectors
 Use to turns the turbine
W ater Tube boiler
 Water Tube Boilers
In this type of boiler water passes through the tubes while the
gases remain in the shell side, passing over the tube
surfaces
• Used for high steam demand and pressure requirements
• Capacity range of 4,000 – 120,000 kg/hour
• Combustion efficiency enhanced by induced draft fans.
• Lower tolerance for water quality and needs water
treatment plant
• Note: Jadeed feed mill have water boiler of capacity 20 ton
per hr.
Water
tube
boilers
Types of W ater tube boiler

 Simple vertical boiler

 Stirling boiler
 Babcock
 Wilcox boiler
 D type boiler
BOILER MAIN COMPONENTS

LER SHELL-The outer

BOI
cylindrical portion of a pressure
vessel.

Steam Drum – Drum in which

water and steam present
BOILER MAIN COMPONENTS

Mud Ring or Mud Drum-A

typically cylindrical shaped
space at the bottom of the
water space. Sediment,
mud, and other impurities
gather there.

FURNACE - An enclosed
space provided for the
combustion of fuel.
BOILER MAIN COMPONENTS

SAFETY VALVE - A spring loaded

valve that automatically opens
when pressure attains the valve
setting.
Used to prevent excessive
pressure from building up in a
boiler.

 Glass gauge- A glass tube

used on steam boilers to give a
visible indication of the boiler's
water level
BOILER MAIN COMPONENTS
-Blow down line: A line
connection at the lowest
point for the removal of all
water from the boiler.

FEED PUMP - A pump that

supplies water to a boiler.
BOILER MAIN

COMPONENTS
Ash Pit-The ash pit is the
space where ashes
accumulate under the fire.
The ashes fall through the
fire grate into a (often)
removable box.
Grate
The Grate is a series of
bars or narrow plates in the
bottom of the fire box. The
ashes fall through the
grate into the ash pit.
BOILER MAIN COMPONENTS

Pressure Gauge.This
indicates the pressure of
the steam in the boiler.

BOILER MAIN COMPONENTS

Feed Check Valve. The

high pressure feed water is
supplied to the boiler
through this valve. This
valve opens towards the
boiler only and feeds the
water to the boiler.
Steam Stop
Valve/Control.
It regulates the flow of
steam supply outside.
 Processing of D-type water tube boiler

 Shower the coal with water, after that crush it in

coal crusher
 Then put it in bucket that is being lifted by the pulley
 And dumped into the furnace
 Here the coal is ignited by aid of FD fan and the
gases will boil the water present in tubes
 After that gases will pass through the economizer
and through the cyclone here the ash is collected
and the gases are being sucked by the ID fan
 Wet scrapper will shower the gases, so that the
sediments(harmful gases, ash) presents in the
gases will settle down in wet scrapper and the
smoke will be exhausted by the chimney
Bucket Coal crusher

FD Fan ID fan
 Processing of D-type water tube boiler:
 Water from feed water tank enters in economizer
 After passing through the economizer the water may
enters in the steam drum present in shell of boiler
 Water enters in mud drum(here the sledge settle down)
through the water tube.
 With the aid of down comer water enters in header, here
boiling start and steam produce.
 Steam enters in steam drum again with the help of tubes
attached directly to header.
 Steam now enters in steam head from steam drum.
 After that steam is being supplied to the solvent plant/feed
mill as per demand.
Stream head, Feed water tank water tube boiler

Economizer Condensation pipe

Inspection hole Glass gauge

Pressure Gauge Temperature sensor

Blow down line Air vents
Wet scrapper, Chimney Stop valve

Water inlet Safety valve

 1. Its evaporative capacity is larger and the steam
pressure range is also high.

 2. Heating surfaces are more effective as the hot

gases travel at right angles to the direction of water
flow.

 3. The combustion efficiency is higher because

complete combustion of fuel is possible as the
combustion space is much larger.
 4. The thermal stresses in the boiler parts are less
as different parts of the boiler remain at uniform
temperature due to quick circulation of water.

 5. The boiler can be easily transported and easily

its different parts can be separated.

 6. All parts of the water tube boilers are easily

accessible for cleaning, inspecting and repairing.
Demerits

a
: 1. It is less suitable for impure and sedimentary
water, as small deposit of scale may cause the
overheating and bursting of tube. Therefore, use of
pure feed water is essential.

2. They require careful attention. The maintenance

costs are higher.

3. Failure in feed water supply even for short period

is liable to make the boiler over-heated.
Pressure Units

1 bar = 14.5 psi

1 kg/cm2 = 14.2 psi
1MPa (Mega pascal)= 10 bar

6 ton boiler working pressure:

10 bar (145 psi)

18 ton boiler working pressure:

17 bar (250 psi)
 Chem icals U sed In Feed W ater Tank:
 Oxygen Scavenger
 Sludge Dispersant

 N ote: These chemicals are continuously pumped in the

Feed Water Tank at the dose rate of 1 kg per 24 hour for each
chemical in
 Function Of Chem icals

Oxygen Scavenger Sludge Dispersant

 Oxygen Scavenger are Sludge Dispersant is used in the
added to enclosed treatment to keep the sludge
packaging to help remove particles dispersed throughout
or decrease the level of the Boiler water.
oxygen in the package.
 They are used to help
maintain product safety &
extend shelf life of a Boiler
to prevent it from
corrosion.
 E.g Sodium Sulphite &
Hydrazine e.t.c
 TYPEAS OF STEAM:
There are three types of Steam.
 Wet Steam (50% moisture)
 Saturated Steam or dry steam (3-5% moisture and
mostly used)
 Superheated steam (full dry)
 W ET STEAM:
Wet Steam is that water vapour that includes water
droplets.

 SATU RATED STEAM (Dry Steam ):

Saturated steam result when water is heated to the boiling
point and then vaporized with additional heat

 SU PER-HEATED STEAM:
Super-heated Steam is a steam at temperature higher than its
boiling point for pressure, which only occurs when all liquid water
has evaporated or has been removed from the system.