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BOILER BASICS
STEAM
BOILER
WATER
AIR + FUEL
Boiler Classification
Boilers are classified into different types based on Type of combustor,
Steam pressure, Fuel fired etc., Main two classifications are
Basics of Steam
Steam - Basics
958.38 Kg/m3.
0.58 Kg/m3.
The volume of water expands 1650 times when it is converted into steam at
atmospheric condition.
Importance of Fuel
Calorific Value
Calorific value is the heat produced by the combustion of a unit quantity of
fuel in a bomb calorimeter with oxygen under a specified set of conditions.
Moisture
Surface Moisture:
- The moisture which is present on the surface of the fuel particle.
- Can be removed easily when it is exposed to atmosphere.
= 5300 Kcal/Kg.
Total Moisture
= 30 %.
Inherent Moisture
GCVAFB
= 10 %.
= .. Kcal/Kg.?
= 5888.89 Kcal/Kg.
Total Moisture
= 30 %.
GCVAFB
= .. Kcal/Kg.?
Other Parameters
Ash
- Higher the ash content lower the GCV & high ash handling cost.
Sulphur Content
- Corrodes the back hand equipments due to Sulphur condensation.
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.
Imported Coal:
Coffee Spent:
GCV (AFB)
: <5000 Kcal/Kg.
GCV (AFB)
: <3000 Kcal/Kg.
Total Moisture
: <30 %.
Total Moisture
: >50 %.
Boiler - Working
ESP
ID Fan
SA Fan
FD Fan
MU WATER
CONDENSATE
DEAERATOR STORAGE
TANK
F.P:01
F.P:02
DOSING
STEAM
CHEMICAL
ECONOMISER
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)
Economiser
Boiler Bank
It is the tube nest
connecting
Steam
drum and Mud drum.
In this zone some
quantity of water is
converted into steam.
Water is transferred to
waterwall
panels
through Downcomer.
Membrane/Waterwall Panel
It is the zone where water
partially converted into steam.
The arrangement is of tube and
fin construction so that it forms a
gas tight chamber.
It ensures the flue gas gets
cooled down before entering
boiler bank zone.
Air Preheater
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.
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.
Water Level Gauge.
Pressure Gauge.
Fusible Plug.
Blowdown Valve.
Feed Check valve.
Air Vent Valve.
Boiler Accessories
Economiser.
Air Preheater.
Superheater.
Boiler Feed Water Pumps.
Pressure Reducing Valve.
Moisture Separator.
Steam Traps.
Steam to Deaerator
Feed Water
Condensate
Percentage of Blowdown:
Example : 01
Feed water TDS
: 250 PPM.
: 2500 PPM.
Blowdown %
: .%
Example : 02
Feed water TDS
: 100 PPM.
: 2500 PPM.
Blowdown %
: .%
Evaporation Ratio:
Example:
Steam Generated
: 200 Tons/Day.
Fuel Consumed
: 38500 Kg/Day.
Evaporation Ratio
: ..
HL 2
HL 3
HL 4
HL 5
HL 6
HL 7
HL 8
Dust Collector
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
Cyclone Separator
Gas
O/L
Gas
I/L
Wet Scrubber
Bag Filter
Ash
Bottom
Ash
Fly 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
Parameters
Feed Water
Boiler Water
Condensate
pH at 25 Deg C
8.5 9.5
10.5 - 11
6.5 7.5
Hardness
Nil
Nil
Nil
TDS
<50 PPM
<2000 PPM
Nil
SCALING
CORROSION
Low pH
Pitting Corrosion due to
Dissolved Gases,
Under Deposit corrosion,
Caustic Corrosion etc.
CARRYOVER
High TDS
pH
Acid
pH = 7 -
Neutral
pH > 7 -
Base
Chemical Dosing:
NaOH, Sodium hydroxide is used to elevate the pH in feed water.
Morpholine/Ammonia are volatile chemicals used for pH improvement in feedwater.
Dissolved Oxygen
Dissolved gases depend on source of water.
Dissolved gases such as oxygen and CO2 are naturally occurring.
It leads to pitting corrosion.
At high temperature, even a small O2 leads to high rate of corrosion.
Chemical Dosing:
Hydrazine (Should be handled with care)
Sodium Sulphite.
Total Hardness
Hardness is composed primarily of calcium and Magnesium minerals.
These are primarily responsible for scale formation.
Corrosion Dissolved O2
Carryover TDS
Thank You