Steam Power Plants-II

Steam Power Plants-II
By
D Nagaraju
Asst.Professor
Department of Mechanical Engineering
GITAM University
VISAKHAPATNAM
ANDHRA PRADESH - INDIA
Boiler
Introduction
Type of boilers
Assessment of a boiler
Energy efficiency opportunities
2
Introduction
What is a Boiler?
• Vessel that heats water to become hot
water or steam
• At atmospheric pressure water
volume increases 1,600 times
• Hot water or steam used to transfer
heat to a process
© UNEP32006
Introduction
STEAM TO
EXHAUST GAS VENT
PROCESS
STACK DEAERATOR
PUMPS
ECO-
NOMI-
ZER
VENT
BOILER
BURNER
WATER
SOURCE
BLOW DOWN
SEPARATOR FUEL
BRINE
CHEMICAL FEED
SOFTENERS
Figure: Schematic overview of a boiler room 4

Boiler
Introduction
Type of boilers
Assessment of a boiler
5
Types of Boilers
1. Fire Tube Boiler

2. Water Tube Boiler
3. Packaged Boiler
4. Fluidized Bed (FBC) Boiler
5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler
8. Thermic Fluid Heater (not a boiler!)
6
Type of Boilers
1. Fire Tube Boiler
• Relatively small steam

capacities (12,000
kg/hour)
• Low to medium steam
pressures (18 kg/cm2)
• Operates with oil, gas
or solid fuels
(Light Rail Transit Association)

© UNEP72006
Type of Boilers
2. Water Tube Boiler

• Used for high steam
demand and pressure
requirements
• Capacity range of 4,500 –
120,000 kg/hour
• Combustion efficiency
enhanced by induced
draft provisions
• Lower tolerance for
water quality and needs
(Your Dictionary.com) water treatment plant
8
Type of Boilers
3. Packaged Boiler • Comes in complete

package
To • Features
Chimney
• High heat transfer
• Faster evaporation
• Good convective
heat transfer
• Good combustion
Oil
efficiency
Burner • High thermal
efficiency
(BIB Cochran, 2003)
• Classified based on
number of passes
9
Type of Boilers
4. Fluidized Bed Combustion

(FBC) Boiler
• Particles (e.g. sand) are suspended in high velocity
air stream: bubbling fluidized bed
• Combustion at 840° – 950° C
• Capacity range 0,5 T/hr to 100 T/hr
• Fuels: coal, washery rejects, rice husk, bagasse and
agricultural wastes
• Benefits: compactness, fuel flexibility, higher
combustion efficiency, reduced SOx & NOx
10
11
Type of Boilers
4a. Atmospheric Fluidized Bed

Combustion (AFBC) Boiler
• Most common FBC boiler that uses preheated
atmospheric air as fluidization and combustion air
4b. Pressurized Fluidized Bed

Combustion (PFBC) Boiler
• Compressor supplies the forced draft and
combustor is a pressure vessel
• Used for cogeneration or combined cycle power
generation
12
Type of Boilers
4c. Atmospheric Circulating Fluidized Bed

Combustion (CFBC) Boiler
• Solids lifted from bed,
rise, return to bed
• Steam generation in
convection section
• Benefits: more
economical, better space
utilization and efficient
combustion
(Thermax Babcock & Wilcox Ltd, 2001) 13

Type of Boilers
5. 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
14
Type of Boilers
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
(University of Missouri, 2004)

15
Type of Boilers
6. Pulverized Fuel Boiler

• Pulverized coal powder blown with combustion air
into boiler through burner nozzles
• Combustion
temperature at 1300 -
1700 °C
• Benefits: varying coal
quality coal, quick
response to load
changes and high pre-
heat air temperatures Tangential firing
© UNEP162006
Type of Boilers
7. 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 exhaust gases from
gas turbines and diesel
Agriculture and Agri-Food
engines
Canada, 2001 © UNEP172006
Type of Boilers
8. Thermic Fluid Heater

• Wide application for indirect process heating
• Thermic fluid (petroleum-based) is heat transfer
medium
• Benefits:
• Closed cycle = minimal losses
• Non-pressurized system operation at 250 °C
• Automatic controls = operational flexibility
• Good thermal efficiencies
18
Type of Boilers 3. Heat transfer
through heat
8. Thermic Fluid Heater exchanged
User equipment
2. Circulated
to user 4. Fluid
equipment returned to
heater
Control
panel
Insulated
outer wall
1. Thermic
fluid heated Blower
motor
Exhaust
in the heater unit

(Energy
Fuel oil
filter Machine India)
19
Industrial Boilers
 Steam generators
 Closed vessels
 made of steel and
 used for generation of steam
 vaporizing water
 combustion of fuels
 eg. coal,coke,oil,wood,saw dust and begesse etc.

 Steam used for producing power,for industrial process
work or for heating proposes.
20
Requirements of a Perfect Steam
Boilers
 Should be absolutely reliable,capable of producing
maximum steam at required pressure for minimum of fuel
consumption,with minimum attention and minimum initial
cost and operating cost.
 Simple constructions
 Quick starting from cold
 Strong enough against temp. stress & strains
 Well design combustion chamber
 Less floor area, space & light weight
 Best gauges,safety valves and other mountings
 Easily accessible for inspection,cleaning and repairs
21
Classification of Steam Boilers
 Vertical or Horizontal
 Stationary(Power plant,industrial,central heating and combined
power and heating boilers.),Portable,Locomotive or Marine
 Internally Fired or Externally Fired (Lancashire and Locomotive
Boilers)
 Solid,Liquid or Gas Fired
 Fire(Smoke)Tube:Water is outside the tubes while the hot gases
are inside the tubes
eg.Vertical,Cochran,Lancashire,Cornish,Locomotives,etc) or Water
Tube: Contain a large number of small tubes through which water
circulates,the fire and hot gases being outside of the
tubes.eg.Babcock and Wilcox, Stirling and High pressure Boilers
etc.)
22
Vertical Boilers
Used in small factories,small water supply
plants,cranes,excavators,winch engines in mines
and on sites of temporary nature such as
construction work etc.
Required minimum floor space,not required
elaborate foundations,and is portable.
Cheap,easy to start but inefficient due to large
wastage of fuel and less heating surface.
Vertical Boilers are:Simple(having one to three
cross tubes), fire tubes and water tubes types.
23
Simple Cross tube vertical boiler
 consists of a cylindrical shell surrounding a cylindrical fire box.
 heating surface is about 8-10 times the grate area.
 50% efficiency
24
Cochran Boiler
 It is well design of a Vertical multitubular fire tube boiler
 Improvement over the simple vertical boiler as it provides
greater heating surface.
 Total heating surface area is about 10-25 times the grate
area
 Efficiency 70-75%
 Ranges from 1m dia.X2m high,evaporation 20kg/hr to 3m
dia X6m high,evaporation 3000kg/hr.
25
Cochran Boiler contd….
26
Lancashire Boiler
Is horizontal smoke tube boiler size range from a
shell 2m diaX6m long to 3m diaX10m long
Working pressure range are up to 20kgf/cm2
Ratio of heating surface to grate area is 24-30
Efficiency is about 56% without economizer and
75% with economizer.
Similar to Cornish boiler,in Lancashire Boiler two
flue tubes but in Cornish boiler only one flue tubes
are there.
27
Lancashire Boiler contd……
28
Lancashire Boiler contd……
29
Locomotive Boiler
 Is an internally fired multitubular fire tube boiler
30
Babcock and Wilcox water tube
Boiler
 Water tube boiler having lager pressure ranges and larger
sizes.
 Three main parts, steam and water drum,water tubes and
furnace.
31
Stirling Boiler
 Example of water tube boiler where bent tube are used instead of
straight tube which are used in Babcock and Wilcox boiler
32
High Pressure Boilers
 Two types- Natural circulation & Forced circulation Boilers
33
High Pressure Boilers contd………
 La-Mont Boiler( Forced circulation Boiler)
34
Once-Through Forced Circulation
Boiler
 Does not required a steam and water drum,saving in weight
 Supercritical Pressure Boiler
 Two types- Benson and Ramzin
35
Ramzin Boiler
36
Loeffler Boiler
 Indirect heating is combined with forced circulation
37
Velox boiler
 Fire tube forced circulation Boiler
38
Fire tubes Vs water tubes Boilers
 Fire tubes boilers has a large volume of water,therefore more
flexible and can meet the sudden demand of steam without
much drop of pressure.
 Fire tubes boiler is rigid and of simple mechanical
construction,so greater reliability and low in first cost.
 Fire tube boilers can be made in smallest sizes therefore
simple to fabricate and transport, occupies less floor space
but more height.
 Due to mostly externally fired water tubes boiler so furnace
can be altered considerably to meet the fuel requirements.
 Water tubes boilers are more readily accessible for
cleaning,inspection and repairs,compared to the fire tube
boilers.
 Modern trend is in the favors of water tube boiler due to
continuous increase in capacities and steam pressures.
39
Mountings and Accessories
Fitting and devices which are necessary
for the safety and control are knows as
boiler mountings
Fitting or devices which are provided to
increase the efficiency of the boiler and
help in the smooth working of the plant are
knows as boiler accessories
40
41
Fittings - Safety
 Water level indicators
 Safety valves
 Combined high steam and low water safety
valve
 Fusible plug
42
Fittings - Control
 Pressure gauge
 Junction or stop valve
 Feed check valve
 Blow-off cock
 Man hole and Mud Box
43
Boiler Mountings and Accessories
 Fitting and devices which are necessary for the safety and
control are knows as boiler mountings
 Fitting or devices which are provided to increase the
efficiency of the boiler and help in the smooth working of
the plant are knows as boiler accessories.
Fittings which are essential from the safety
point of view are as follows,
 Water level indicators
 Safety valves
 Combined high steam and low water safety valve
 Fusible plug
44
Boiler Mountings and Accessories
contd….
Fittings which are essential from the control
point of view are as follows,
 Pressure gauge
 Junction or stop valve
 Feed check valve
 Blow-off cock
 Man hole and Mud Box
The important accessories are
 Superheater
 Economiser
 Air-preheater
 Feed pump or injector
45
Performance of a boiler
1. Boiler
2. Boiler blow down
3. Boiler feed water treatment
46
Performance of a Boiler
1. Boiler performance
• 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
47
Heat Balance
An energy flow diagram describes geographically
how energy is transformed from fuel into useful
energy, heat and losses
Stochiometric
Excess Air
Un burnt
Stack Gas
FUEL INPUT STEAM

OUTPUT
Convection & Blow Ash and Un-burnt parts

Radiation Down of Fuel in Ash
48
Heat Balance
Balancing total energy entering a boiler against the
energy that leaves the boiler in different forms
%
Heat loss due to dry flue gas
% Heat loss due to steam in fuel gas

%
100.0 % Heat loss due to moisture in fuel
BOILER %
Fuel Heat loss due to moisture in air
2% Heat loss due to unburnts in residue
%
Heat loss due to radiation & other
unaccounted loss
%
Heat in Steam
49
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
50
Boiler Efficiency
Thermal efficiency: % of (heat) energy input that is
effectively useful in the generated steam
BOILER EFFICENCY
CALCULATION
1) DIRECT METHOD: 2) INDIRECT METHOD:

The energy gain of the The efficiency is the
working fluid (water and steam) different between losses
is compared with the energy and energy input
content of the boiler fuel.
51
Boiler Efficiency: Direct Method

Heat Outputx 100 Q x (hg – hf) x 100
Boiler efficiency () = =
Heat Input qx GCV
hg -the enthalpy of saturated steam in kcal/kg of steam
hf -the enthalpy of feed water in kcal/kg of water

Parameters to be monitored:
- Quantity of steam generated per hour (Q) in kg/hr
- Quantity of fuel used per hour (q) in kg/hr
- The working pressure (in kg/cm2(g)) and superheat temperature
(oC), if any
- The temperature of feed water (oC)
- Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of
fuel
52
Boiler Efficiency: Direct Method

Advantages
• Quick evaluation
• Few parameters for computation
• Few monitoring instruments
• Easy to compare evaporation ratios with
benchmark figures
Disadvantages
• No explanation of low efficiency
• Various losses not calculated
53
Boiler Efficiency: Indirect Method

Efficiency of boiler () = 100 – (i+ii+iii+iv+v+vi+vii)
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 fly ash
vi) Unburnt fuel in bottom ash
vii) Radiation and other unaccounted losses
54

Required calculation data
• Ultimate analysis of fuel (H2, O2, S, C, moisture
content, ash content)
• % oxygen or CO2 in the flue gas
• Fuel gas temperature in ◦C (Tf)
• Ambient temperature in ◦C (Ta) and humidity of air in
kg/kg of dry air
• GCV of fuel in kcal/kg
• % combustible in ash (in case of solid fuels)
• GCV of ash in kcal/kg (in case of solid fuels)
55
Advantages
• Complete mass and energy balance for each
individual stream
• Makes it easier to identify options to improve
boiler efficiency
Disadvantages
• Time consuming
• Requires lab facilities for analysis
56
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 of quantity blow down required:
Feed water TDS x % Make up water

Blow down (%) =
Maximum Permissible TDS in Boiler water
57
Boiler Blow Down

Two types of blow down
• Intermittent
• Manually operated valve reduces TDS
• Large short-term increases in feed water
• Substantial heat loss
• Continuous
• Ensures constant TDS and steam purity
• Heat lost can be recovered
• Common in high-pressure boilers
58
Boiler Blow Down

Benefits
• Lower pretreatment costs
• Less make-up water consumption
• Reduced maintenance downtime
• Increased boiler life
• Lower consumption of treatment
chemicals
59
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 deposit-forming
solids
60
Boiler Feed Water Treatment

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
• Silica forms hard silica scales

61
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
62

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
63
External Water Treatment

a) Ion-exchange process (softener plant)
• Water passes through bed of natural zeolite of
synthetic resin to remove hardness
• Base exchange: calcium (Ca) and magnesium (Mg)
replaced with sodium (Na) ions
• Does not reduce TDS, blow down quantity and
alkalinity
b) Demineralization
• Complete removal of salts
• Cations in raw water replaced with hydrogen ions
64

c) De-aeration
• Dissolved corrosive gases (O2, CO2)
expelled by preheating the feed water
• Two types:
• Mechanical de-aeration: used prior to addition
of chemical oxygen scavangers
• Chemical de-aeration: removes trace oxygen
65

Mechanical
Vent
de-aeration
Spray
Boiler Feed Nozzles • O2 and CO2 removed by
Water
heating feed water
Stea
Scrubber m
• Economical treatment
Section
(Trays) process
• Vacuum type can reduce
Storage
Section O2 to 0.02 mg/l
• Pressure type can
De-aerated
Boiler Feed reduce O2 to 0.005 mg/l
Water
( National Productivity Council)
66

Chemical de-aeration
• Removal of trace oxygen with scavenger
• Sodium sulphite:
• Reacts with oxygen: sodium sulphate
• Increases TDS: increased blow down
• Hydrazine
• Reacts with oxygen: nitrogen + water
• Does not increase TDS: used in high pressure
boilers
67

d) Reverse osmosis
• Osmosis
• Solutions of differing concentrations
• Separated by a semi-permeable membrane
• Water moves to the higher concentration
• Reversed osmosis
• Higher concentrated liquid pressurized
• Water moves in reversed direction
68
External water treatment
d) Reverse osmosis
Pressure
Feed Water Fresh Water
More
Concentrated
Solution
Concentrate Water Flow
Flow
Semi Permeable Membrane
69
Introduction
Type of boilers
Performance of a boiler
70
Energy Efficiency Opportunities
1. Stack temperature control

2. Feed water preheating using economizers
3. Combustion air pre-heating
4. Incomplete combustion minimization
5. Excess air control
6. Avoid radiation and convection heat loss
7. Automatic blow down control
8. Reduction of scaling and soot losses
9. Reduction of boiler steam pressure
10. Variable speed control
11. Controlling boiler loading
12. Proper boiler scheduling
13. Boiler replacement
71
1. Stack Temperature Control

• Keep as low as possible
• If >200°C then recover waste heat
2. Feed Water Preheating

Economizers
• Potential to recover heat from 200 – 300 oC flue
gases leaving a modern 3-pass shell boiler
3. Combustion Air Preheating

• If combustion air raised by 20°C = 1% improve
thermal efficiency 72
4. Minimize Incomplete Combustion

• Symptoms:
• Smoke, high CO levels in exit flue gas
• Causes:
• Air shortage, fuel surplus, poor fuel distribution
• Poor mixing of fuel and air
• Oil-fired boiler:
• Improper viscosity, worn tops, cabonization on
dips, deterioration of diffusers or spinner plates
• Coal-fired boiler: non-uniform coal size
73
5. Excess Air Control

• Excess air required for complete combustion
• Optimum excess air levels varies
• 1% excess air reduction = 0.6% efficiency rise
• Portable or continuous oxygen analyzers
Fuel Kg air req./kg fuel %CO2 in flue gas in practice
Solid Fuels
Bagasse 3.3 10-12
Coal (bituminous) 10.7 10-13
Lignite 8.5 9 -13
Paddy Husk 4.5 14-15
Wood 5.7 11.13
Liquid Fuels
Furnace Oil 13.8 9-14
LSHS 14.1 9-14
74
6. Radiation and Convection Heat

Loss Minimization
• Fixed heat loss from boiler shell, regardless of
boiler output
• Repairing insulation can reduce loss
7. Automatic Blow Down Control

• Sense and respond to boiler water conductivity
and pH
75
8. Scaling and Soot Loss Reduction

• Every 22oC increase in stack temperature = 1%
efficiency loss
• 3 mm of soot = 2.5% fuel increase
9. Reduced Boiler Steam Pressure

• Lower steam pressure
= lower saturated steam temperature
= lower flue gas temperature
• Steam generation pressure dictated by process
76
10. Variable Speed Control for Fans,

Blowers and Pumps
• Suited for fans, blowers, pumps
• Should be considered if boiler loads are
variable
11. Control Boiler Loading

• Maximum boiler efficiency: 65-85% of rated load
• Significant efficiency loss: < 25% of rated load
77
12. Proper Boiler Scheduling

• Optimum efficiency: 65-85% of full load
• Few boilers at high loads is more efficient than
large number at low loads
13. Boiler Replacement

Financially attractive if existing boiler is
• Old and inefficient
• Not capable of firing cheaper substitution fuel
• Over or under-sized for present requirements
• Not designed for ideal loading conditions
78
79
The two main functions of any draught system
are:
1. To supply sufficient quantity of air to the
furnace for the complete combustion of fuel.
2. To remove the flue gases (products of com-
bustion) from the furnace for their exit to the
atmosphere through chimney (stack).
80
• Draught at any point in the air / gas passage is
the difference between absolute air / gas
pressure at that point and the ambient
atmospheric pressure.
• It is +ve, if Pgas > Patm and -ve, if P gas < Patm
81
NATURAL DRAUGHT
82
• The natural draught is produced by the action of
chimney or stack.
• Its amount is dependent upon the average
temperature difference between the flue gases
within the chimney and the outside air and also
on the height of the chimney above the level of the
furnace grate.
• Weather conditions, boiler operating conditions
and the height of the chimney have a considerable
effect on the amount of natural draught.
83
MECHANICAL DRAUGHT
84
• This type of draught is needed when the natu-
ral draught produced by a chimney is not suf-
ficient or where a certain draught must be
maintained irrespective of weather conditions.
• Boilers with mechanical draught do not need so
high a chimney as is necessary with natural
draught.
• Mechanical draught is of two types: forced
draught and induced draught.
85
Position of I.D. Fan
86
Position of F.D. and I.D fans
87
The F.D. fans are placed at the air entrance to
the air preheater. The total system up to the
stack entrance is under positive gauge pressure.
They handle cold air. So, they have many
advantages as compared to I.D. fans:
1. Lower maintenance costs.
2. Consume less power
3. Their load is reduced by the absence of
additional gas equivalent of the fuel used.
4. So, capital and operating costs are lower.
88
• The total system is put under pressure (pressure
furnace). So, the drawbacks are:
1. Gas tight furnace construction to avoid leakage
of various gases from the furnace walls.
2. Special attention must be given to the design of
inspection doors, soot, blower boxes and fuel
igniter openings
89
• I.D. fans are located in the gas stream between
the air-preheater and the stack, either before or
after the dust collector.
• They discharge essentially at atmospheric
pressure and place the entire system under
negative pressure.
• Their power consumption is greater as compared
to F.D. fans and they must also handle corrosive
combustion gases and ash
90
• I.D. fans are seldom used alone. When both F.D.
and I.D. fans are used, the F.D. fans push
atmospheric air through the air-preheater,
dampers; various airducts and burners into the
furnace.
• The I.D. fans suck the combustion gases from the
furnace through the heat transfer surface
(Superheaters, reheaters, economisers and gas
side air preheater) and into the stack.
91
• The chimney, because of its height, adds a
natural draught of its own. Such a system is
called "Balanced Draught". It means that the
pressure in the furnace is approximately
atmospheric. Actually, it is kept at a slightly
negative pressure to ensure that any leakage
would be inward.
92
PERFORMANCE OF BOILERS
• The quantity of steam generated per hour is
known as evaporating capacity of a boiler. The
evaporating capacity and amount of heat
supplied are considered in dealing with the
performance of a steam boiler.
• The heat liberated may also be utilized in
economizer, air preheater and super heater and
some of the energy tends to leave with the flue
gases through the chimney.
• It is necessary to draw up heat balance sheet for
a boiler to know the heat distribution in boiler.
93
EQUIVALENT EVAPORATION
Equivalent evaporation may be defined as the mass of water that would
be evaporated from and at 1000 c and atmospheric pressure to form dry
saturated steam by the same amount of heat which produces the steam
under actual conditions.
1) Feed water supplied at 1000 c and atmospheric pressure (1.01325
bar)
2) Steam is evaporated from and at 1000 c and just dry and saturated.
Equivalent evaporation , me = ms (H2-hw1)/L100 kg/hr

ms = mass of stem produced at given condition,Kg/h
H2 = enthalpy of stem produced at the given condition [at super heater
out let],KJ/Kg
hw1 =enthalpy of feed water at pump out let (i.e., at the inlet of
economiser)KJ/Kg
Heat utilised in boiler to produce steam =ms (H2-hw1) 94
L100 =latent heat at 1000 c
=2256.9KJ/Kg
[H2-hw1/L100] is called as factor of evaporation
Therefore
Equivalent evaporation =ms X factor of evaporation
Boiler thermal efficiency: Heat utilised to form steam

Heat released by the fuel
ms(H2-hw1 )
=
mf x C V
m =ms/mf ,mass of steam generated per kg of fuel
95
Heat balance:
Heat supplied in fuel =mf x C V
Heat distribution:
1.)Heat utilised by feed water to form steam = m(H2-hw1)
m = mass of steam generated /Kg of fuel
2.) heat lost through exhaust gases = mg . Cp .(tg –tr)
mg =mass of exhaust gases per Kg of coal
3.) heat lost due to unburnt fuel = muf x CV
muf = mass of unburnt fuel per kg of fuel
4.) heat lost to moisture = m1(H12-hw1)

m1 = mass of moisture per kg of coal
hw1 =enthalpy of water
H12 = enthalpy of steam formed .KJ/Kg 96

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Steam Power Plants-II

Figure: Schematic overview of a boiler room 4

1. Fire Tube Boiler

1. Fire Tube Boiler

• Relatively small steam

(Light Rail Transit Association)

2. Water Tube Boiler

3. Packaged Boiler • Comes in complete

4. Fluidized Bed Combustion

4a. Atmospheric Fluidized Bed

4b. Pressurized Fluidized Bed

4c. Atmospheric Circulating Fluidized Bed

(Thermax Babcock & Wilcox Ltd, 2001) 13

5. Stoke Fired Boilers

5. Stoke Fired Boilers

(University of Missouri, 2004)

6. Pulverized Fuel Boiler

7. Waste Heat Boiler

8. Thermic Fluid Heater

in the heater unit

 eg. coal,coke,oil,wood,saw dust and begesse etc.

• Heat balance: identify heat losses

FUEL INPUT STEAM

Convection & Blow Ash and Un-burnt parts

% Heat loss due to steam in fuel gas

2% Heat loss due to unburnts in residue

Avoidable losses include:

1) DIRECT METHOD: 2) INDIRECT METHOD:

Boiler Efficiency: Direct Method

hg -the enthalpy of saturated steam in kcal/kg of steam

hf -the enthalpy of feed water in kcal/kg of water

Boiler Efficiency: Direct Method

Boiler Efficiency: Indirect Method

Boiler Efficiency: Indirect Method

Boiler Efficiency: Indirect Method

2. Boiler Blow Down

Feed water TDS x % Make up water

Boiler Blow Down

Boiler Blow Down

3. Boiler Feed Water Treatment

• Efficient heat transfer only if boiler

Boiler Feed Water Treatment

• Silica forms hard silica scales

Boiler Feed Water Treatment

Internal water treatment

Boiler Feed Water Treatment

External Water Treatment

External Water Treatment

External Water Treatment

External Water Treatment

External Water Treatment

Feed Water Fresh Water

Semi Permeable Membrane

1. Stack temperature control

1. Stack Temperature Control

2. Feed Water Preheating

3. Combustion Air Preheating

4. Minimize Incomplete Combustion

5. Excess Air Control

Fuel Kg air req./kg fuel %CO2 in flue gas in practice

6. Radiation and Convection Heat

7. Automatic Blow Down Control

8. Scaling and Soot Loss Reduction

9. Reduced Boiler Steam Pressure