STEAM BOILERS

Definition

A closed vessel in which steam is produced from

water by combustion of fuel
 Purpose of boilers
For generating power in steam engines or
steam turbines

In textile industries for sizing and bleaching

For heating the buildings in cold weather and

for producing hot water for hot water supply
 Primary requirements of a boiler

The water must be contained safely

The steam must be safely delivered in desired

condition (as regard its pressure, temperature,
quality and required rate)
 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
 Grate: it is a platform in the furnace upon
which fuel is burnt

Furnace: it is the chamber formed by the

space above the grate and below the boiler
shell, in which combustion takes place.

Water space and steam space : the volume of

the shell that is occupied by the water is
termed as water space while the entire shell
volume less the water and tubes is called steam
space
 Mountings: The items which are used for
safety of boiler are called mountings

Accessories: The items which are used for

increasing the boiler efficiency are called
accessories

Water level: The level at which water stands

in the boiler is called water level
 Refractory: insulation material used for lining
combustion chamber

Foaming: Formation of steam bubbles on the

surface of boiler water due to high surface
tension of water
 Scale: A deposit of medium due to extreme
hardness occurring on the water heating
surfaces of boiler because of an undesirable
condition in the boiler water

Blowing off: The removal of mud and other

impurities of water from the lowest part of the
boiler. Accomplished with the help of blow off
cock or valve

Lagging: Insulation wrapped on the outside of

the boiler shell or steam piping
 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

It is commonly employed for vertical and

locomotive boilers and does not find its
application in large capacity high pressure boilers

Also used where the space is not available for the

installation of feed pump
 Economizer
Is a device in which the waste heat of the flue
gases is utilized for heating the feed water

Economizers are of two types

Independent type
Integral type
 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
 Types of air preheaters
I. Tubular type

II. Plate type

III. Storage 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.
 Advantages of super heated steam

Steam consumption of the engine or turbine is reduced

Erosion of turbine blade is eliminated

Efficiency of the steam plant is increased

Losses due to condensation in the cylinders and the

steam pipes are reduced.
 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
 According to principle of operation the steam
separators are classified as follows

Impact or baffle type

Reverse current type

Centrifugal type
 Boiler mountings
Pressure gauge
Fusible plug
Steam stop valve
Feed check valve
Blow off cock
Mud and man holes
 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
 Working of Fusible plug
When the water level in the shell falls below the top
of the plug the steam cannot keep it cool and the
fusible metal melts due to over heating.
thus the copper plug drops down and is held with in
the gun metal body by the ribs.
Thus the steam space gets communicated to fire box
and extinguishes the fire.
 Thus damage to the fire box which could burn up is
avoided

By removing the gun metal plug and copper plug the

Fusible plug can be put in position again by inserting
the fusible metal usually lead or metal alloy
 Steam stop valve
A valve is a device that regulates the flow of a fluid
(gases , fluidized solids slurries or liquids) by
opening or closing or partially obstructing various
passageways
Function : to shut off or regulate the flow of steam
from the boiler to the steam pipe or steam from the
steam pipe to the engine
Steam stop valve
 Feed check valve
To allow the feed water
to pass in to the boiler

To prevent the back

flow of water from the
boiler in the event of the
failure of the feed pump
 Blow off cock
To drain out water from
the boiler for internal
cleaning inspection or
other purposes
 Mud and man holes
To allow men to enter in to the boiler for
inspection and repair
 Classification of boilers
Horizontal, vertical or inclined
Fire tube and water tube
Externally fired and internally fired
Forced circulation and natural circulation
High pressure and low pressure
Stationary and portable
Single tube and multi tube
 Horizontal, vertical or inclined

If the axis of the boiler is horizontal, vertical

or inclined then it is called horizontal, vertical
or inclined boiler respectively
 Fire tube and water tube
If hot gases are inside the tube and water is
outside the tube, it is called fire-tube boiler.
Examples: Cochran, Lancashire and
locomotive boilers
If water is inside the tube and hot gases are
outside the tube, it is called fire-tube boiler.

Examples: Babcock and Wilcox, Stirling,

Yarrow boiler etc
Externally fired and internally fired
The boiler is known as externally fired if the
fire is outside the shell.
Examples: Babcock and Wilcox, Stirling

The boiler is known as internally fired if the

furnace is located inside the boiler shell.

Examples: Cochran, Lancashire

 Forced circulation and natural
circulation
In forced circulation type of boilers, the
circulation of water is done by a forced pump
Examples: Velox, Lamont, Benson boiler
In natural circulation type of boilers, circulation
of water in the boiler takes place due to natural
convection currents produced by the application
of heat
Examples: Lancashire, Babcock and Wilcox
 High pressure and low pressure
The boilers which produce steam at pressures
of 80 bar and above are called high pressure
boilers
Examples: Babcock and Wilcox, Velox,
Lamont, Benson boilers
The boilers which produce steam at pressure
below 80 bar are called low pressure boilers
Examples: Cochran, Cornish, Lancashire
and locomotive boilers
 Stationary and portable

Stationary boilers are used for power plant-

steam, for central station utility power plants,
for plant process steam etc

Mobile or portable boilers include locomotive

type, and other small unit for temporary use at
sites
 Single tube and multi tube
The fire tube boilers are classified as single
tube or multi-tube boilers, depending upon
whether the fire tube is one or more than one

Examples of single tube boilers are Cornish

and simple vertical boiler
 Comparison of fire tube and water
tube boilers
Particulars Fire-tube boilers Water-tube boilers
Position of water and hot Hot gases inside the tubes Water inside the tubes
gases and water outside the and hot gases outside the
tubes tubes
Mode of firing Generally internally fired Externally fired
Operation pressure Limited to 16 bar Can go up to 100 bar
Rate of steam production Lower Higher
Suitability Not suitable for large Suitable for large power
power plants plants
Risk on bursting Involves lesser risk of More risk on bursting due
explosion due to lower to high pressure
pressure
Floor area For a given power it For a given power it
occupies more floor area occupies less floor area
Construction Difficult Simple
Cont
Particulars Fire-tube boilers Water-tube boilers
Transportation Difficult Simple
Shell diameter Large for same power Small for same power
Chances of explosion Less More
Treatment of water Not so necessary More necessary
Accessibility of various Various parts not so easily More accessible
parts accessible for cleaning,
repair and inspection
Requirement of skill Require less skill for Require more skill and
efficient and economic careful attention
working
 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
 Consists of cylindrical barrel with rectangular
fire box at one end and smoke box at another
end

Hot gases generated due to burning of coal are

deflected by an arch of fire bricks, so that
walls of the fire box may be heated properly

The heat of the hot gases is transmitted into

water through the heating surfaces of fire tubes
Babcock and Wilcox 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
 At the rare end smoke box chimney is
provided for the rejection of exhaust gases
Hot gases passes through the furnace tube and
enter into the rear end smoke box and pass
through fire tubes to the front end smoke box
for final discharge through chimney
Water surrounding tubes get transformed into
steam and gets collected in steam space.
Oil is first heated up to 80oc by electric heater
before being supplied to burner for injection
into furnace tube.
 Blower is employed for atomization of furnace
oil into furnace

Such a boilers are capable of generating steam

up to 10-11 bar.
 Bent tube boilers
Straight tube boilers has many disadvantages like
1. They had less accessibility and poorer inspection
capability, considerable time, labour and expense were
required to open up or close the bolts in the headers,
and to remove and replace the gaskets
2. Inadequate design and imperfect fabrication of hand
hole caps (cleaning purpose) resulted in much leakage
3. Circulation was sluggish sluggish due to low head, and
limited steam disengaging surface made inadequate
separation of steam and water reducing steam rate
 Bent tube boilers offers many advantages over
straight-tube boilers

The notable among them being greater accessibility

for inspection, cleaning, and maintenance, and ability
to operate at higher steaming rates and to deliver drier
steam
Four drum stirling boiler
Five-drum form
 Water flows downwards from the mud drum to
headers feeding the tubes lining the walls of
the radiant surface
The low density steam-water mixture rises up
to the steam drum at the upper side
The steam is separated and flows to the central
drum, where it is removed
Feed water enters the drum at the left and
mixes with the saturated liquid in the drum
The cooled liquid flows down to mud drum
 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
 They strike against fire brick lining which directs
them to pass through number of horizontal tubes,
being surrounded by water

After which the gases escape to the atmosphere

through the smoke box and chimney

A number of hand holes are provided around the

outer shell for cleaning purposes
 Itis a component of steam generator
Basic requirements :
Through mixing of fuel and air
Optimum fuel-air ratios leading to most
complete combustion possible maintained over
full load range
Ready and accurate response of rate of fuel
feed to load demand
 Contd..

Continuous and reliable ignition of fuel

Practicaldistillation of volatile components of

coal followed by adequate action

Adequatecontrol over point of formation and

accumulation of ash, when coal is the fuel
 Solid fuels fired

Hand fired Stoker fired Pulverized fuel fired

Underfeed stockers Overfeed stockers

Unit system Central system Both

 Liquid fuel fired

Injection system

Evaporator system

Combination of both
 Gaseous fuel fired

Atmospheric pressure system

High pressure system

 Initialcost of equipment
Sufficient combustion space and its liability to
withstand high flame temp
Area of grate
Operating cost
Minimum smoke nuisance
Flexibility of operation
Arrangements for through mixing of air with fuel for
efficient combustion
 A stoker is a power operated fuel feeding
mechanism and grate
A cheaper grade of fuel can be used
A higher efficiency can be attained
A greater flexibility of operations assured
Less smoke produced
Generally less building space is necessary
Can be used for small or large boiler units
Very reliable , maintenance charges are reasonably
low
 Practically immune for explosion

Reduction in auxiliary plant

Capital
investment as compared to pulverized fuel
system is less

Some reserve is gained by the large amount of coal

stored on the grate in the event of coal handling plant
failure
 Construction is complicated

Incase of very large units the initial cost may be rather

higher than with pulverized fuel

Thereis always a certain amount of loss of coal in the

form of riddling through the gates

Sudden vibrations in the steam demand cannot be met

to the same degree
 Troubles
due to slagging and clinkering of
combustion chamber walls are experienced

Banking and stand by losses are always present

Structural
arrangements are not so simple and
surrounding floors have to be designed for
heavy loadings

Thereis excessive wear of moving parts due to

abrasive action of coal
 In overfeed stokers the coal is fed into the grate
above the point of air admission
The fuel bed section receives fresh coal from top
surfaces
The ignition plane lies between green coal and
incandescent coke
The air enters the bottom of the grate under
pressure
In flowing through the grate opening the air is
heated while it cools the grate
 Thewarm air then passes through a layer of hot
ashes and picks up the heat energy

Theregion immediately above the ashes contains

a mixture of incandescent coke and ash, coke
content increasing upward direction

Asthe air comes in contact with incandescent

coke, the O2 reacts with carbon to form CO 2

Water vapor entering with the air reacts with coke

to form CO2, CO and free H2
 Upon further travel through the incandescent
region some of the CO2 reacts with coke to
form CO

Hence no free O2 will be present in the gases

leaving the incandescent region

Freshfuel undergoing distillation of its volatile

matter forms the top-most layer of the fuel bed
 Heat
for distillation and eventually ignition
comes from

1. By conduction from the incandescent coke

below
2. From high temperature gases diffusing through
the surface of the bed
3. By radiation from flames and hot gases in the
furnace
4. From the hot furnace walls
 The ignition zone lies directly below the raw
fuel undergoing distillation
To burn gases additional secondary air must be
fed into the furnace to supply the needed
oxygen
The secondary air must be injected at
considerable speed to create turbulence and to
penetrate to all parts of the area above the fuel
bed
The combustible gases then completely burn in
the furnace
 Fuel,coke and ash in the fuel bed move in the
direction opposite to that of air and gases

Raw fuel continually drops on the surface of

the bed

The rising air feed cools the ash until it finally

rests in a plane immediately adjacent to the
grate
 Types of overfeed stokers

1 Travelling grate stoker

Chain grate type

Bar grate type

2 Spreader stoker
 A chain grate stoker consists of flexible endless
chain which forms a support for the fuel bed
The chain travels over sprocket wheels one at
the front and one at the rear of furnace
The front sprocket is connected to a variable
speed drive mechanism
The grate should be saved from being
overheated, for this, coal should have sufficient
ash content which will form a layer on grate
 Simple in construction
Initial cost low
Maintenance charges low
Self-cleaning stoker
Giving high release rates per unit volume of
the furnace
Heat release rates can be controlled just by
controlling the speed of the chain
 Preheated air temperatures are limited to 180 0C
maximum
The clinker troubles are very common
There is always some loss of coal in the form
of fine particles through riddlings
Ignition arches are required
This cannot be used for high capacity boilers
 In this type of stoker the coal is not fed into
furnace by means of grate
The function of the grate is only to support a
bed of ash and move it out of the furnace
From the coal hopper, coal is fed into the path
of a rotor by means of a conveyor
And it is thrown into the furnace by the rotor
and burnt in suspension
The air for combustion is supplied through the
holes in the grate
 The secondary air to create turbulence and
supply oxygen for thorough combustion of
coal is supplied through nozzles located
directly above the ignition arch
Unburnt coal and ash are deposited on the
grate which can be moved periodically to
remove ash out of the furnace
Spreader stokers can burn any type of coal
 A wide variety of coal can be burnt
This stoker is simple to operate, easy to light
up and bring into commission
The use of high temperature preheated air is
possible
Operation cost is considerably low
The clinking difficulties are reduced even with
coals which have high clinkering tendencies
 Volatile matter is easily burnt
Fire arches etc. Are generally not required
with this type of stokers
 Itis difficult to operate spreader with varying
sizes of coal with varying moisture content
Fly-ash is much more
No remedy for clinker troubles
There is a possibility of some fuel loss in the
cinders up the stack because of the thin fuel
bed and suspension burning
 Hand fired system

Manual feeding system

Very old system

Used in small scale applications.

Hand fired system
 Air entering through the holes in the grate
comes in contact with the raw coal
Then it passes through the incandescent coke
where reactions similar to overfeed system
takes place
The gases produced then pass through a layer
of ash
The secondary air is supplied to burn
combustible gases
The underfeed principle is suitable for burning
the semi-bituminous and bituminous coal
 High thermal efficiency as compared to chain
grate stokers
Combustion rate is considerably higher
The grate is self cleaning
Part load efficiency is high particularly with
multi retort type
Different variety of coal can be used
Much higher steaming rates are possible with
this type of stoker
 Grate bars, tuyeres and retorts are not
subjected to high temp as they remain contact
with fresh coal
Overload capacity of the boiler is high as large
amount of coal is carried on the grate
Smokeless operation is possible even at very
light load
With use of clinker grinder, more heat can be
liberated out of the fuel
 Substantial amount of coal always remains on
the grate so that boiler may remain in service
in the event of temporary breakdown of the
coal supply system
It can be used with all refractory furnaces
because of non-exposure of stoker mechanism
to the furnace
 High initial cost
Require large building space
The clinker troubles are usually present
Low grade fuels with high ash content cannot
be burnt economically
Contd..
 Coal is reduced to a fine powder with the help
of grinding mill and then projected into the
combustion chamber with the help of hot air
current
The amount of air (secondary air) required to
complete the combustion is supplied separately
to the combustion chamber
The resulting turbulence in the combustion
chamber helps for uniform mixing of fuel and
air
 The amount of air which is used to carry the
coal and dry it before entering into the
combustion chamber is known as primary air
The efficiency of the pulverized fuel firing
system mostly depends upon the size of the
powder
 Any grade of coal can be used since coal is
powdered before use
The rate of feed of the fuel can be regulated
properly resulting in the economy
Since there is almost complete combustion of
the fuel there is increased rate of evaporation
and higher boiler efficiency
 Greater capacity to meet peak loads
The system is practically free from sagging and
clinkering troubles
No stand by losses due to banked fires
Practically no ash handling problems
No moving parts in the furnace is subjected to
high temperatures
This system works successfully with or in
combination with gas or oil
Much smaller quantity of air is required as
compared to that of stoker firing
 Practically free from clinker troubles
The external heating surfaces are free from
corrosion
It is possible to use highly preheated secondary
air which helps for rapid flame propagation
The furnace volume required is considerably
less
 High capital cost
Lot of flyash in the exhaust, which makes the
removing of fine dust uneconomical
The possibility of explosion is more as coal
burns like a gas
The maintenance of furnace brick work is
costly
Special equipment is needed to start this system
 Skilled operators are required
A separate coal preparation plant is necessary
High furnace temps cause rapid deterioration
of the refractory surfaces of the furnace
Nuisance is created by the emission of very
fine particles of grit and dust
Fine regular grinding of fuel and proper
distribution of burners is usually difficult to
achieve
 Self study topics

1. Schematic diagrams of modern steam

generators

2. Cyclone furnace

3. Fluidized bed combustion

THANK YOU