Working:
Feed water flowing into the boiler is first preheated in the
economizer, which recover the part or heat from the flue gases
flowing to the chimney and then going to the atmosphere. This
increases the efficiency as less heat must be supplied to the boiler.
The steam generated in the boiler may be wet or dry. It is
superheated in the superheater which again takes the heat from the
flue gases moving towards the chimney.
1.Coal and ash circuit: Coal arrives at storage yard and after
necessary handling it passes on to the furnace through fuel feeding
system. In case of palavering system, coal is pulverized and then
goes to the fuel burners. Ash resulting from combustion of coal gets
collected at the ash pit and is removed to ash storage yard by ash
handling equipment.
Coal Preparation
i) Fuel preparation system: In coal-fired power stations, the raw feed coal
from the coal storage area is first crushed into small pieces and then conveyed
to the coal feed hoppers at the boilers. The coal is next pulverized into a very
fine powder, so that coal will undergo complete combustion during combustion
process
Pulverizer is a mechanical device for the grinding of many different types of
materials. For example, the are used to pulverize coal for combustion in the
steam-generating furnaces of fossil fuel power plants. Types of
Pulverisers: Ball and Tube mills; Ring and Ball mills; MPS; Ball mill; Demolition
ii) Dryers: they are used in order to remove the excess moisture from coal
mainly wetted during transport. As the presence of moisture will result in fall in
efficiency due to incomplete combustion and also result in CO emission.
iii) Magnetic separators: coal which is brought may contain iron particles.
These iron particles may result in wear and tear. The iron particles may include
bolts, nuts wire fish plates etc. so these are unwanted and so are removed with
the help of magnetic separators.
Pulverizer : The coal is put in the boiler after pulverization. For this
pulverizer is used. A pulverizer is a device for grinding coal for
combustion in a furnace in a power plant.
Pulverising plant
In modern thermal power plant , coal is
pulverised i.e. ground to dust like size
and carried to the furnace in a stream of
hot air. Pulverising is a means of
exposing a large surface area to the
action of oxygen and consequently
helping combustion.
Pulverising mills are further classified
as:
1. Contact Mill
2. Ball Mill
3. Impact Mill
Draft system
The circulation of air is
caused by a difference in
pressure, known as Draft.
Draft
is a differential
pressure between atmosphere
and inside the boiler.
It is necessary to cause the
flow of gases through boiler
setting
It may be
1. Natural draft
2. Mechanical draft
Boiler
A boiler or steam generator is a closed vessel in which water under
pressure, is converted into steam.
It is one of the major components of a thermal power plant
Always designed to absorb maximum amount of heat released in the
process of combustion
Boilers
Tube contain
Water tube
Method of firing
Fire tube
Internally
Circulation of
water
Natural
Externally
Pressure of
steam
Forced
Low
High
Classification of boilers
Horizontal, vertical or inclined
Stationary and portable
Single tube and multi tube
Packaged Boiler
Stoker Fired Boiler
Pulverized Fuel Boiler
Waste Heat Boiler
Fluidized Bed (FBC) Boiler
Boiler
Relatively small
steam capacities
(12,000 kg/hour)
Low to medium
steam pressures
(18 kg/cm2)
Combustion efficiency
enhanced by induced
draft provisions
Packaged Boiler
To Chimney
Comes in complete
package
Features
High heat transfer
Faster evaporation
Good convective
heat transfer
Good combustion
efficiency
High thermal
efficiency
Oil
Burner
Classified based on
number of passes
Spreader stokers
burning
Coal fed continuously over
load requirements
Preferred over other type of
grate burning
Coal fed continuously over
stokers in industrial
application
(University of Missouri, 2004)
Advantages
Its ability to burn all ranks of coal from anthracitic to
lignitic, and it permits combination firing (i.e., can use coal,
oil and gas in same burner). Because of these advantages,
there is widespread use of pulverized coal furnaces.
Disadvantages
High power demand for pulverizing
Requires more maintenance, fly ash erosion and pollution
complicate unit operation
1-Water
tube
boiler
Fire tube
boiler
Simple vertical boiler
Cochran boiler
Locomotive boiler
Lancashire boiler
Benson boiler
BENSON BOILER
A high pressure, drum less, water tube steam boiler works
forced circulation.
.
on
of
the
2-
3-
4-
5-
Light in weight.
6-
may be employed.
rate.
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.
50
51
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.
52
53
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.
54
55
56
Locomotive Boiler
Is an internally fired multitubular fire tube boiler
57
58
Stirling Boiler
Example of water tube boiler where bent tube are used instead of
straight tube which are used in Babcock and Wilcox boiler
59
60
61
Once-Through Forced
Circulation Boiler
62
Ramzin Boiler
63
Loeffler Boiler
Indirect heating is combined with forced circulation
64
Velox boiler
Fire tube forced circulation Boiler
65
66
Fire-tube boilers
Water-tube boilers
Mode of firing
Externally fired
Operation pressure
Limited to 16 bar
Lower
Higher
Suitability
Risk on bursting
Floor area
Construction
Difficult
Simple
Cont
Particulars
Fire-tube boilers
Water-tube boilers
Transportation
Difficult
Simple
Shell diameter
Chances of explosion
Less
More
Treatment of water
Not so necessary
More necessary
Accessibility of various
parts
More accessible
Requirement of skill
Lancashire boiler
Reliable, has simplicity of design, ease of
operation and less operating and maintenance
costs
Commonly used in sugar-mills and textile
industries where along with the power steam
and steam for the process work is also needed
Cont
Consists of cylindrical shell inside which two large
tubes are spaced
Shell is constructed with several rings of
cylindrical from it is placed horizontally over a
brick work which forms several channels for the
flow of hot gases
The furnace is placed at the front end of each
tube
Locomotive boiler
Cont
It consists of a drum connected to a series of
front end and rear end header by short riser
tubes
To these headers are connected a series of
inclined (150 or more) water tubes
A hand hole is provided in the header in front of
each tube for cleaning and inspection of tubes
Cont
Feed valve is provided to fill the drum and
inclined tubes with water
Through the fire door fuel is supplied to grate
where it is burnt
The hot gases are forced to move upwards
between the tubes by baffle plates
The water from the drums flows through the
inclined tubes via down take header and goes
back into the shell in the form of water and
steam via uptake header
Nestler boiler
Nestler boiler
Fire tube type of fired horizontal axis boiler
The boiler shell consists of two mild steel thick
plates with large number of fire tubes fitted
between two plates
A bigger diameter furnace tube extending
from burner end to other end is used for
carrying hot flue gases from one smoke box to
other smoke box
Five-drum form
Cochran boiler
One of the best types of vertical multi-tube boiler
Consists of a cylindrical shell with a dome shaped top
where the space is provided for steam
The furnace is one piece construction and is
seamless
Cont..
Its crown has a hemispherical shape and thus
provides maximum volume of space
The fuel is burnt on the grate and ash is collected
and disposed from the ash pit
The gases of combustion produced by burning the
fuel enter the combustion chamber through the flue
tube
Boiler shell
Combustion chamber
Furnace
Grate
Heating surface
Mounting
Accessories
Pressure Gauge
Blow of cock
Steam stop valve
Pressure gauge
To record the steam pressure at which steam is
generated in the boiler
A bourdon pressure gauge in its simplest form consists
of a simple elastic tube
One end of the tube is fixed and connected to the
steam space in the boiler
Other end is connected to a sector through a link
Pressure gauge
Fusible plug
To extinguish fire in the event of water level in
the boiler shell falling below a certain
specified limit
It is installed below boilers water level
Boiler terms
Shell: Consists of one or more steel plates bent
into a cylindrical form and riveted or welded
together. The shell ends are closed with end
plates
Setting: The primary function of setting is to
confine heat to the boiler and form a passage for
gases. It is made of brick work and may form the
wall of the furnace and combustion chamber
Boiler accessories
Feed pumps: Used to deliver feed water to the
boiler. It is desirable that the quantity of water
supplied should be at least equal to that
evaporated and supplied to the engine
Two types of which are commonly used as
feed pumps are (1) reciprocating pump (2)
rotary pump
Injector
Function of injector is to feed water into the
boiler
Economizer
Is a device in which the waste heat of the flue
gases is utilized for heating the feed water
Air Pre-heater
The function of the air pre-heater is to increase the
temperature of air before it enters the furnace.
It is placed after the economizer.
Flue gases pass through the economizer and then to
the air preheater
Degree of preheating depends on
Type of fuel
Type of fuel burning equipment, and
Rating at which the boiler and furnace are
operated
Tubular type
II.
Plate type
Super heater
The function of a super heater is to increase
the temperature of the steam above its
saturation point
The super heater is very important accessory
of a boiler and can be used both on fire tube
and water tube boilers.
Steam separator
The function of a steam separator is to
remove the entrained water particles from the
steam conveyed to the steam engine or
turbine.
It is installed as close to the steam engine as
possible on the main steam pipe from the
boiler
Superheater :
Superheater is a component of a steam-generating unit in which steam, after it
has left the boiler drum, is heated above its saturation temperature. The amount
of superheat added to the steam is influenced by the location, arrangement, and
amount of super heater surface installed, as well as the rating of the boiler. The
super heater may consist of one or more stages of tube banks arranged to
effectively transfer heat from the products of combustion. Super heaters are
classified as convection , radiant or combination of these.
Reheater : Some of the heat of superheated steam is used to rotate the turbine where it
loses some of its energy. Reheater is also steam boiler component in which heat is added to
this intermediate-pressure steam, which has given up some of its energy in expansion
through the high-pressure turbine. The steam after reheating is used to rotate the second
steam turbine where the heat is converted to mechanical energy. This mechanical energy is
used to run the alternator, which is coupled to turbine , there by generating electrical energy.
Economiser
Flue Gases coming out of the boiler carry lot of heat. An economiser
extracts a part of this heat from flue gases and uses it for heating feed
water. This use of economiser results in saving coal consumption and
higher boiler efficiency
Economizer
Air preheater
After
flue
gases
leave
economiser, some further heat
can be extracted from them and
used to heat incoming air.
Cooling of flue gases by 20
degree centigrade increases the
plant efficiency by 1%.
Air preheaters may be of three
types
Plate type
Tubular type
Regenerative type
Contd..
Continuous and reliable ignition of fuel
Practical distillation of volatile components of
coal followed by adequate action
Adequate control over point of formation and
accumulation of ash, when coal is the fuel
Turbine
Steam turbine
A steam turbine converts heat energy of steam into mechanical energy
and drives the generator. It uses the principle that steam when issuing
from a small opening attains a high velocity. This velocity attained
during expansion depends on the initial and final heat content of the
steam. This difference b/w initial and final heat content repesents the
heat energy converted into kinetic energy.
These are of two types :Impulse turbine
Reaction turbine
Turbine
Impulse -H.P Turbine
Reaction - L.P & I.P turbine
TYPES OF TURBINE
PRECIPTATOR AND STACK : ELECTRO-STATIC PRECIPTATOR For general mankind, today an Eco
friendly industry is must. As far as air pollution is concerned now a
day various flue gases filter are there in service. The choice depends
on the size of suspended particle matter. These filters are E.S.P.
Fabric filter high efficiency cyclone separations and stalling room.
Fop fly ash, where the particle size vary from 0.75 microns to 100
micron use gradually use E.S.P. to purify the flue gases due to its
higher efficiency & low running cost etc.
In an ESP the dust lidder gas is passed through an intense electric
field, which causes ionization of the gases& they changed into ion
while travelling towards opposite charged electrode get deposited
as particles and thus dust is electric deposited an electrode creating
the field. It is continuous process.
The gas exiting the boiler is laden with fly ash.The fly ash is removed
by electrostatic precipitators and passes through stack in
environment.
Precipitators
The waste gases from the
boiler are first passed through
precipitators to separate the
solid dust particles. The fly ash
is collected at these
precipitators.
The condenser condenses the steam from the exhaust of the turbine into liquid
to allow it to be pumped. If the condenser can be made cooler, the pressure of
the exhaust steam is reduced and efficiency of the cycle increases. The functions
of a condenser are:1) To provide lowest economic heat rejection temperature for steam.
2) To convert exhaust steam to water for reserve thus saving on feed water
requirement.
3) To introduce make up water.
Condenser
These condensers are heat exchangers which convert steam from its
gaseous to its liquid state, also known as phase transition.
In so doing, the latent heat of steam is given out inside the
condenser. Where water is in short supply an air cooled condenser is
often used.
An air cooled condenser is however significantly more expensive and
cannot achieve as low a steam turbine backpressure (and therefore
less efficient) as a surface condenser.
The purpose is to condense the outlet (or exhaust) steam from steam
turbine to obtain maximum efficiency and also to get the condensed
steam in the form of pure water, otherwise known as condensate, back
to steam generator or (boiler) as boiler feed water.
Condensers are classified as (i) Jet condensers or contact condensers (ii) Surface
condensers.
In jet condensers the steam to be condensed mixes with the cooling water and
the temperature of the condensate and the cooling water is same when leaving
the condenser; and the condensate can't be recovered for use as feed water to
the boiler; heat transfer is by direct conduction.
In surface condensers there is no direct contact between the steam to be
condensed and the circulating cooling water. There is a wall interposed between
them through heat must be convectively transferred.The temperature of the
condensate may be higher than the temperature of the cooling water at outlet
and the condnsate is recovered as feed water to the boiler.Both the cooling
water and the condensate are separetely with drawn.Because of this advantage
surface condensers are used in thermal power plants.Final output of condenser
is water at low temperature is passed to high pressure feed water heater,it is
heated and again passed as feed water to the boiler.Since we are passing water
at high temperature as feed water the temperature inside the boiler does not
dcrease and boiler efficincy also maintained.
Cooling tower
The cooling tower is a semi-enclosed device for evaporative cooling of water by
contact with air. The hot water coming out from the condenser is fed to the tower on
the top and allowed to tickle in form of thin sheets or drops. The air flows from
bottom of the tower or perpendicular to the direction of water flow and then exhausts
to the atmosphere after effective cooling.
The cooling towers are of four types:
1. Natural Draft cooling tower
2. Forced Draft cooling tower
3. Induced Draft cooling tower
4. Balanced Draft cooling tower
Cooling Towers :The condensate (water) formed in the condeser after condensation is
initially at high temperature.This hot water is passed to cooling towers.It is a tower- or
building-like device in which atmospheric air (the heat receiver) circulates in direct or
indirect contact with warmer water (the heat source) and the water is thereby cooled
(see illustration). A cooling tower may serve as the heat sink in a conventional
thermodynamic process, such as refrigeration or steam power generation, and when it is
convenient or desirable to make final heat rejection to atmospheric air. Water, acting as
the heat-transfer fluid, gives up heat to atmospheric air, and thus cooled, is recirculated
through the system, affording economical operation of the process.
Two basic types of cooling towers are commonly used. One transfers the heat from
warmer water to cooler air mainly by an evaporation heat-transfer process and is known
as theevaporative or wet cooling tower.
Evaporative cooling towers are classified according to the means employed for producing
air circulation through them:atmospheric, natural draft, and mechanical draft. The other
transfers the heat from warmer water to cooler air by a sensible heat-transfer process and
is known as the nonevaporative or dry cooling tower.
Nonevaporative cooling towers are classified as air-cooled condensers and as air-cooled
heat exchangers, and are further classified by the means used for producing air circulation
through them. These two basic types are sometimes combined, with the two cooling
processes generally used in parallel or separately, and are then known as wet-dry cooling
towers.
Evaluation of cooling tower performance is based on cooling of a specified quantity of
water through a given range and to a specified temperature approach to the wet-bulb or
dry-bulb temperature for which the tower is designed. Because exact design conditions are
rarely experienced in operation, estimated performance curves are frequently prepared for
a specific installation, and provide a means for comparing the measured performance with
design conditions.
Hand fired
Underfeed stockers
Unit system
Stoker fired
Overfeed stockers
Central system
Both
Injection system
Evaporator system
Combination of both
Contd..
Boiler Controls