Steam Boilers

Presentation

By

Prof. Vinay V. Ankolekar vinay.ankolekar@gmail.com 9762310273

Department of Mechanical Engineering Sinhgad Academy of Engineering, Kondhwa, Pune, Maharastra
Steam Boilers - VVA

Steam Boilers - VVA

What is a boiler?
A steam generator or boiler is, usually, a closed

vessel made of steel. Its function is to transfer

the heat produced by the combustion of fuel

(solid, liquid or gaseous) to water, and ultimately

to generate steam. The steam produced may be supplied :

Steam Boilers - VVA

What is a boiler?
1. To an external combustion engine ,i.e. Steam

engines or Turbines.
2. At low pressures for industrial process work

in cotton mills, sugar factories, breweries,

etc., and 3. For producing hot water, which can used for heating installations at much lower pressures
Steam Boilers - VVA

REQUIREMENTS OF A PERFECT STEAM BOILERS Should be absolutely reliable & capable of producing required steam per hr.

Simple in construction, easy for maintenance,

should be cheap.

Quick starting from cold

Strong enough against temp. stress & strains

Well designed combustion chamber with

minimum fuel consumption.
Steam Boilers - VVA

 Less floor area, space & light in weight Best gauges, safety valves and other

mountings
Easily accessible for inspection, cleaning and

repairs
The joints should be leak proof

It should comply with safety regulations

according to IBR 1923
Steam Boilers - VVA

Boilers or steam generators

A)FIRE TUBE BOILER 1)Locomotive boiler

2)Lancashire boiler
3)Cornish boiler

4) Cochran boiler B)WATER TUBE BOILER 1)Babcock & Wilcox boiler

2)Stirling boiler
Steam Boilers - VVA

FIRE TUBE BOILERS

Relatively small steam capacities (12,000 kg/hour) Low to medium steam pressures (18 kg/cm2) or 18 bar Operates with oil, gas or solid fuels

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FIRE TUBE BOILER

Steam Boilers - VVA

FIRE TUBE BOILER

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Steam Boilers - VVA

COCHRON BOILER

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Steam Boilers - VVA

COCHRAN BOILER
This is a fire tube boiler of vertical type. Maximize heating surface, Total heating surface area is 1025 times the grate area. It has cylindrical shell with hemispherical crown.

Steam Boilers - VVA

 Hemispherical geometry offers: maximum volume space for given

mass of material (steam), very good for strength and maximization of radiant heat absorption.

Steam Boilers - VVA

COCHRON BOILER
Fire box is also of hemispherical form.

These boilers are capable of generating steam up to pressure of 20 bar and steam generating capacity up to 3 TPH.
Boilers have dimensions ranging from 1 - 3 m diameter and 2 6 m height. 160 tubes

Efficiency of such boilers ranges between 70 and 75%.

Steam Boilers - VVA

HORIZONTAL FIRE TUBE BOILER

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MULTI PASS FIRE TUBE BOILER

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MULTI PASS FIRE TUBE BOILER

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LANCASHIRE BOILER

Steam Boilers - VVA

LANCASHIRE BOILER

Steam Boilers - VVA

Steam Boilers - VVA

LANCASHIRE BOILER

Steam Boilers - VVA

LANCASHIRE BOILER
It is a horizontal fire tube boiler.

Boiler is mounted on a brickwork.

It has a circular shell connected to end plates supported by gusset plates. Two fire tubes. Each fire tube has grate. Brick Arch
To deflect the flue gases upwards

Steam Boilers - VVA

LANCASHIRE BOILER
Hot gases start from grate area => fire tubes => back of boiler => bottom flue => front of boiler => side flues =>

chimney

About 85% of actual heat transferred is transferred through surface of fire tubes while 15% is transferred through bottom and side flues. Dampers are provided at the end of the shell flues for regulating the flow of flue gases to control steam generation rate.
Steam Boilers - VVA

LANCASHIRE BOILER
Efficiency of the boiler is about 65% 70%. Size of these boiler depends upon size of shell which may be 2 m to 3 m in diameter and 6m to 10m in length.

Steam Boilers - VVA

CORNISH BOILER

Steam Boilers - VVA

CORNISH BOILER
This is a horizontal fire tube boiler having single flue gas tube. Less steam generation rate compared to Lancashire Hot flue gases fire tube => two portions at the end (side flue passages) up-to the front of boiler => bottom flue gas passage => chimney at back. Hot gases thus traverse complete length thrice i.e. through main flue gas tube, side flues and bottom flues. Heat transfer is more from side flues than Steam Boilers - VVA bottom flue due to sedimentation in bottom.

CORNISH BOILER
These boilers are generally capable of producing steam up to the rate of 1 to 1.5 TPH and max steam pressure up to 12 bar. Shell is generally of length 4 to 7 m and diameter 1.2 to 1.8 m.

Steam Boilers - VVA

LOCOMOTIVE BOILERS

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Steam Boilers - VVA

LOCOMOTIVE BOILERS

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32

LOCOMOTIVE BOILERS
These boilers were invented for getting steam to run a steam engine used in locomotives. These are fire tube type of boilers. It has basically three parts i.e. smoke box, shell and fire box.

Steam Boilers - VVA

LOCOMOTIVE BOILERS
To deflect the flue gases upwards

Hot gases produced in fire box are diverted by fire brick arch and enter into the fire tubes surrounded with water. Steam produced gets collected in a steam drum fitted on top of the shell. Arrangement for super heating is there in these boilers.

Steam Boilers - VVA

LOCOMOTIVE BOILERS
The wet steam goes through inlet headers of super-heater and after passing through tubes, it returns to the outlet header of super-heater and is taken out for steam engine. Its chimney is completely eliminated. For expelling the burnt gases (draught) the exhaust steam coming out from steam engine is being used. Thus it is an artificial draught used in these boilers for expelling burnt gases.
Steam Boilers - VVA

Steam Boilers - VVA

WATER TUBE BOILER

Steam Boilers - VVA

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 water treatment plant
Steam Boilers - VVA

BABCOCK AND WILCOX WATER TUBE BOILER

Water tube boiler have larger pressure ranges and larger sizes. Three main parts, steam and water drum, water tubes (100mm dia. and furnace.

Steam Boilers - VVA

Steam Boilers - VVA

BABCOCK AND WILCOX

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BABCOCK AND WILCOX

Steam Boilers - VVA

STIRLING BOILER
Example of water tube boiler where bent tube are used instead of straight tube which are used in Babcock and Wilcox boiler

Steam Boilers - VVA

STIRLING BOILER
This is a water tube boiler in which bent tubes are connected to three or four drums together. These bent tubes are inclined. Bent tubes are advantageous in respect to flexibility in maximizing heating surface and no requirement of headers. For deflecting the hot gases the baffles are provided.
Steam Boilers - VVA

STIRLING BOILER
Feed water => first steam drum located near the exit passage => tubes => mud drum => tubes => next steam drum. Thus the water is circulated so as to pick maximum heat from hot gases.

Steam Boilers - VVA

STIRLING BOILER
Steam generated is collected in upper portion of steam drums from where it can be extracted out. Hot gases coming from furnace area travel across the boiler and go out of exit passage after transferring heat contained by them. Such boilers are capable of generating steam up-to maximum pressure of 60 bar and steam generation rate up to 50 TPH.
Steam Boilers - VVA

Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES

Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES Items which are mounted on boiler for its safe operation & maintenance as per IBR. Different mountings are: (i) Water level indicator (ii) Safety valves (iii) High steam and low water safety valves (iv) Fusible plug (v) Pressure gauge (vi) Stop valve (vii) Feed check valve (viii) Blow off cock (ix) Manhole and mud box
Steam Boilers - VVA

Bourdon Pressure Gauge

Steam Boilers - VVA

Bourdon Pressure Gauge

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Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES

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Steam Boilers - VVA

Steam Boilers - VVA

Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES

Dead Weight Safety Valve

Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES

High pressure & Low steam safety Vale:

Steam Boilers - VVA

Steam Boilers - VVA

BOILER MOUNTINGS AND ACCESSORIES

Fusible Plug

Steam Boilers - VVA

Seam Stop Valve

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Steam Boilers - VVA

Blow off Valve

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Feed check Valve

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Steam Boilers - VVA

Steam Boilers - VVA

Superheater

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HIGH PRESSURE BOILERS

Requirements of High pressure Boiler:
1. Method of Water Circulation: Natural or Forced Circulation 2. Arrangement of Tubing & Boiler Drum: 3. Improved Method of Heating: Saving in Latent Heat Increasing velocity of Water 4. Method of Super Heating : Radiant Superheating

Convective Superheating
5) Water Softening:
Steam Boilers - VVA

Property diagrams for phase-change processes

The T-v diagram

T
p>pcr pcr

Critical point

Tcr
Subcooledliquid region Two phases Saturated Saturated liquid vapor

p=const<pcr

Superheated-vapor region

vcr

Steam Boilers - VVA

V m3/kg

ADVANTAGES OF HIGH PRESSURE BOILERS

1) Scale formation 2) Time Lag for Steam Generation 3) Compact & less Space 4) Load Fluctuations 5) Efficiency 6) Cost of Foundation & Erection
Steam Boilers - VVA

HIGH PRESSURE BOILERS

1) LA-MONT BOILER 2) LOEFFLER BOILER 3) ONCE-THROUGH: BENSON BOILER 4) VELOX BOILER 5) SCHMIDTH-HARTMANN BOILER 6) RAMZIN BOILER: Sub Critical 7) SUPER CRITICAL BOILER
Steam Boilers - VVA

 LA-MONT BOILER( Forced circulation Boiler)

1925,150 bar,30,000 t0 45,000 Kg/hr
Components:

Boiler Drum: Upper side

Radiant Evaporator Convective Evaporator Economiser Super heater Disadvantages: Bubble formation in tubes

Steam Boilers - VVA

LOEFFLER BOILER
150 bar,1 lakh kg/hr
Components: Boiler Drum: At Bottom Radiant Evaporator Convective Evaporator Economiser

Super heater
30 TO 40 % Steam To S.T. remaining To evaporator Feed rate of water & steam adusted Advantages: Scale formation is less
Steam Boilers - VVA Suitable

for marine application

ONCE-THROUGH FORCED CIRCULATION BOILER: BENSON BOILER

1922,500 bar,650 C,1.5 lakh kg/hr

Does not required a steam and water drum,saving in weight Supercritical Pressure Boiler Two types- Benson and Ramzin

Bubble formation in tubes avoided Components: Feed Pump: Operate above225bar Radiant Evaporator Convective Evaporator Super Heater

Economiser
Boiler Drum: Absent Super heater
Steam Boilers - VVA

BENSON BOILER
Advantages:
No Drum Light in Weight with high steam generation rate Less Space Boiler started in short time 10 to 15 min.

Disadvantages:
Scale formation since evaporation in tubes, water softening Over heating if water flow is insufficient

Steam Boilers - VVA

VELOX BOILER
Principle: Higher velocity of hot gases higher heat transfer rate Components: Boiler Drum: Absent Pressurized Combustion: Sonic Velocity Gas Turbinr & Compressor Convective Evaporator

Super Heater
Economiser:Uses G. T. Exhaust Super heater

Steam Boilers - VVA

Advantages:
Compact boiler Started quickly High thermal efficiency 90 to 95 % Flexibility of operation according to load

Disadvantages:
Can operate only on liquid or gaseous fuels.

Steam Boilers - VVA

SCHMIDTH-HARTMANN BOILER
Components:
Distilled Water Boiler Drum Super Heater Economiser: Super heater

No leakages between primary & secondary

Steam Boilers - VVA

Advantages:
Use impure water for steam generation, reduces softening cost Deposit in drum can easily brushed off Easily meet fluctuation of load Flexibility of operation according to load

Steam Boilers - VVA

ONCE THROUGH BOILER

Steam Drum is absent In one pass steam is superheated though one single continuous tube Operating above critical conditions Designed for steam generation rate 1.3 to 6.7 lakhs kg/hr

Starting time is less

Steam Boilers - VVA

ONCE-THROUGH FORCED CIRCULATION BOILER: BENSON BOILER

1922,500 bar,650 C,1.5 lakh kg/hr

Does not required a steam and water drum,saving in weight Supercritical Pressure Boiler Two types- Benson and Ramzin

Bubble formation in tubes avoided Components: Feed Pump: Operate above225bar Radiant Evaporator Convective Evaporator Super Heater

Economiser
Boiler Drum: Absent Super heater
Steam Boilers - VVA

BENSON BOILER
Advantages:
No Drum Light in Weight with high steam generation rate Less Space Boiler started in short time 10 to 15 min.

Disadvantages:
Scale formation since evaporation in tubes, water softening Over heating if water flow is insufficient

Steam Boilers - VVA

RAMZIN BOILER: Once through Sub Critical

1930 Soviet Russia, Pressure below 221.2 bar,1.3 to 6.7 lakhs/hr Components:

Boiler Drum: Absent

Radiant Heater: 0.8 Dry Convective Heater: Superheated by 20to50C

Super Heater: at 510C

Economiser:

Steam Boilers - VVA

SUPERCRITICAL BOILERS
Designed to operate at pressure above 240 bar Feed Water quality: Impurity 0.04 ppm Silica 0.01 ppm Capital cost is higher but operating cost is less Used for power plant above 300 MW Starting time is less Meet load fluctuations 20 to30 % higher heat transfer rate

Steam Boilers - VVA

SUPERCRITICAL BOILERS

Components:

Boiler Drum: Absent

Two burners Gas turbine & Compressor Low pressure turbine reheater & high pressure turbine

Steam Boilers - VVA

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

Steam Boilers - VVA

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

Steam Boilers - VVA