Heat Balance for

Steam Generator
(Boiler)
Alarca, Braza, Gabriel, Sebastian
Introduction
• A boiler is a device used to
create steam by applying heat
energy to water.

• The two main boiler types are

fire-tube boilers and water-
tube boilers.
 • flue gases are directed
through vertical or
horizontal steel tubes that
are surrounded by the water
for heating, and typically go
through two, three, or four
passes, or changes in
direction.

Firetube Steam
Generator
 • the arrangement is reversed.
Instead of the water being
outside the tubes, it
circulates inside the tubes
and is heated externally by
the combustion gases. Fuel is
burned inside the furnace,
which heats the water in the
steam-generating tubes. The
water then rises to the
steam drum where saturated
steam is drawn from the top
of the drum.
Watertube Steam
Generator
HISTORY/INNOVA
TION

• The steam-generating
boiler’s roots go back to
the late 1700s and early
1800s with the
development of the
kettle-type boiler, which
simply boiled water into
steam. The water was
placed above a fire box
and then boiled into
steam
HISTORY/INNOVA
TION

• 1795 With the coming of

Watt’s engine, steam was
required in greater volume.
As a result, ‘haystack’ boiler
became elongated and
finally developed in to the
‘Wagon Boiler’.
 HISTORY/INNOVA
TION

• 1804 Trevithick’s Cornish boiler was

the fore-runner of modern boiler
practice; being of cylindrical form
with a large fire tube running
through the center, it had the best
shape to resist the internal forces.

• Unfortunately, the necessarily large

fire tube limited the steam space in
the top of the boiler and left a
shallow depth of water above the
hottest part of the fire so that even
this design was likely to explode if
the water level was allowed to fall
below normal working level.
 HISTORY/INNOVA
TION

• 1844 The Lancashire boiler was

patented by Fairbairn. This
design had two smaller fire tubes
instead of the one large tube of
the Cornish boiler.
• These smaller tubes were subject
to less strain, while allowing an
increased fire grate and heating
surface, it also meant a much
greater depth of water could be
maintained over the fire tube.
 HISTORY/INNOVA
TION

• the Babcock & Wilcox boiler was

developed by a firm with the
same name as the boiler. This
boiler design was developed and
patented in 1867
• This boiler has only one tank, the
steam drum positioned at the
top of the boiler. The steam
drum is partly filled with water
and the other part contains wet
water vapor. The typical design of
this boiler is water pipes that are
designed to be tilted to form a
15 ° angle. This slope serves to
ensure the occurrence of natural
circulation of water-water vapor
in the boiler.
 Major
Components of a
Boiler

Economizer
Boiler Tubes
Steam Drums
Super Heaters
Re-heaters
Air Pre-heaters
Burners
 • Economizers are heat
exchangers that transfer
heat to boiler feed water
while cooling gases entering
intermediate and final
absorption towers.
• First part of the boiler
through which feedwater
flows and is heated by the
flue gases.

Economizers
 • Metal tubes located
inside of boilers that
heat water in order to
produce steam.
• It is that part of the
steam generator where
steam is generated from
saturated water

Boiler Tubes
Steam Drums

• It is the unit in which steam is separated

from the steam-water mixture
•  It is a reservoir of water/steam at the top
end of the water tubes. The drum stores
the steam generated in the water tubes
and acts as a phase-separator for
the steam/water mixture.
 • Bundles of boiler tubes located in
the path of the hot flue gases in
which the saturated steam is
superheated
• A superheater is a vital part of the
a boiler system that is used to
increase the overall efficiency of a
thermal power plant. More
specifically, it is a device which
converts wet steam (saturated
steam) into dry steam as dry
steam contains more thermal
energy. Dry steam is also less
likely to condense within the
engine cylinders or the casing of a
steam turbine

Superheaters
 • Bundles of boiler tubes
through which steam
expanded in the high stage
turbine is reheated by
extracting heat from the hot
combustion gases
• Reheater is a part of boiler
which to reheat steam
output from the first level of
steam turbine. Reheated
steam will again absorb the
heat energy from boiler to
be used in the next level
steam turbine. 
Reheaters
Air pre-heaters

• Units in which the incoming air is heated

by using the energy of the outgoing flue
gases. Atmospheric air is pre-heated to a
temperature of about 350C.
 • Boiler burners are the
functional component of
boilers that provide the heat
input by combustion of a
fossil fuel, including natural
gas, with air or oxygen. They
are available either as part of
the boiler package from the
manufacturer, as stand-
alone products for custom
installations, or as
replacement products.

Burners
PROBLEM: Data from a test on the stoker-fired
steam generator of the Federal power plant are as
follows:
Ultimate Analysis of coal as follows: Refuse Analysis:
C=12.2 A=87.8
C=76.4 Coal Rate: 8985 Kg/hr
H=4.5 Dry flue gas analysis:
CO2=15.73 O2=3.13 N=81.11 CO=0.03
O=2.6 Flue Gas temperature: 317.22°C
N=1.3 Steam Data:
Pressure:1.88Mpaa
S=1.4
Quality:99.5%
A=10.1 Steam Rate: 88236 Kg/m
Feedwater Data:
W=3.7
Temperature:50°C
HHV of coal as fired: 134110 Air Data:
btu/lb(31195KJ/kg) Temperature: 15.6°C (60°F)
Relative Humidity: 40%

Calculate a complete Energy balance

PRELIMINARY SOLUTION
MAJOR SOLUTION
•Q1 =WsΔhs+WAΔhR+WBΔhB  Q=9HΔh
3
Q1=9.82Kg/kg(2780-209.3)KJ/Kg
Q1=25245.2KJ/Kgf Q3=9(0.045)(3041.6)KJ/Kg
Q2=WΔh Q3=1231.85 KJ/Kgf
Δh=1066+0.5tg-ta
Since tg=317.22°C=60.3°F>557.5°F Q4=WAVX0.47(tg-ta)BTU/lb
Δh=1066+0.5(603)-60
0.47BTU/lb°RX
Δh=1307.5Btu/lb X 1.055
  𝐾𝐽
X
Δh=3041.6 KJ/Kg
𝐵𝑇𝑈 Q4=1.97KJ/Kg°K
Q2=0.037(3041.6)KJ/Kg
Q2=112.54KJ/Kg
•Q4  =WAV=1.97(tg-ta)°C
WAV=WA X W
WA=WDG+8(H-)-CF-S-N
WDG=(CF+0.4255)
CF=C- X CR
CF=0.764-X 0.122
CF=0.75
WDG=(0.75+0.4255(0.014))
WDG=12.25 Kg/Kgf
WA=12.25+8(0.045-)-0.75-0.014-0.013
WA=11.805Kg/Kg
Q4=((11.805Kg/Kg)(0.004381Kg/Kg))(1.97)(317.22-15.6)(KJ/Kg)
Q4=30.72KJ/Kg
•Q 5=WDGX CpDG(tg-ta)
Q5=(12.25Kg/Kgf)(1.0062)(317.22-15.6)KJ/Kg
Q5=3717.75 KJ/Kgf

Q6=WDG( X 4380BTU/lb
Q6=WDG() X 10221.43KJ/Kg
Q6=12.25() X 10221.43 KJ/Kg
Q6=34.29KJ/Kg
•Q 7=WRCR X 14544
()===0.115
CR=0.122 lbC/lbR
Q7=()(0.122lbC/lbR)(14544 BTU/LbC)
Q7=204.05 BTU/lb
Q7=474.68 KJ/Kg

Q8=HHV-ΣQ1-Q7
ΣQ1-Q7=30847.03 KJ/Kg
Q8=31195KJ/Kg-30847.03 KJ/Kg
Q8=347.97 KJ/Kg
FOR PERCENTAGE
Q/HHV X 100
Q1=80.93
Q2=0.36
Q3=3.95
Q4=0.10
Q5=11.92
Q6=0.11
Q7=1.52
Q8=1.12
_________
100%
PROBLEM-The following are Data collected for a boiler
using coal as the fuel. Find out the boiler efficiency by
indirect method
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