BOILERS

A boiler is an enclosed vessel used for generating hot water or steam using fuels like furnace oil, HSD, LDO, LPG, CNG, Fire wood, Coal, Lignite, etc. CALORIFIC VALUE: COAL: 3585 6453 Kcal/kg FURNACE OIL: 10000 Kcal /kg TYPES OF BOILER USED IN APOLLO TYRES LTD (ATL): 1. Coal Fired AFBC Water Tube Balanced draught boiler 2. Furnace oil Fired 3 pass boiler. Deareator Chimney Steam to Process Steam to Deareator
Condensate return from Process

Schematic overview of a Furnace Oil boiler:

Air Pre Heater

Ambient Air

Dearea tor

Vent

Feed Water Pump

Boiler
Blow down Separator

Burner

Fuel LPG Pilot Gas

LP Dosing DM Plant / Make up Line

HP Dosing Steam Water Fuel Flue Gas Ambient Air Condensate

FURNACE OIL FIRED BOILER DETAILS / SPECIFICATION OF FURNACE OIL FIRED BOILERS: BOILER MAKE CAPACITY TYPE PRESSURE WORKING Furnace Oil Boiler Shellmax Oilon Burner 12 TPH from and at 100C. Heating Surface 240m2 FO Fired Fire tube, 22 Kg/cm2 Burner: 706 kg/hr with 1:4 turn down ratio. OPERATING 20 Kg IBR IBR/NON IBR

WORKING PROCEDURE OF FURNACE OIL FIRED BOILER: The feed water from DM plant with TDS and pH are 150 to 250 PPM and 7.5 to 8 is sent to the Deareator tank which is used for mechanical oxygen scavenging i.e. removal of dissolved oxygen and other non condensable gases. The water from Deareator tank and condensate is pumped to boiler through feed water pump for the conversion of steam. To start up the boiler, PLC is initially started by setting it to the firing mode. Furnace Oil is heated gradually up to 12Cin an oil pre heater through electrical heater. After pre-purging The ambient air is taken from the atmosphere and the flue gases emitting out from the boiler is used to pre heat this ambient air. The preheated ambient air is then sent to the boiler for fast ignition. The excess flue gas is sent to the atmosphere through chimney. The steam is then sent for process and part of the steam is sent to the Deareator for raising the temperature of the condensate water and removes the dissolved oxygen. Low Pressure (LP) dosing is done at Deareator by adding Sodium bi Sulphate (NaSo4) for removing of the remaining oxygen in the Deareator. High Pressure (HP) dosing is done at boiler by adding Antiscalant, Dispersant, etc. this done to avoid scale formation and corrosion. Why blow down is needed?

The feed water in the boiler contains some dissolved solids; these solids can remain and accumulate inside the boiler as the boiler operation continues which may lead to corrosion, Scale formation. In order to avoid this, the TDS should be maintained at 3500 PPM maximum
Why 100% condensate is needed to be collected? In order to operate steam boilers at higher efficiency level, we will have to get back the entire condensate of steam back to the feed water tank. We cannot afford to allow the steam to escape to atmosphere. To accomplish this condensate recovery, steam traps are essential components. The objective is to keep the temperature of the feed water as close to 100C as possible.

COAL FIRED BOILER LAYOUT: Steam to Process Ash Silo AHS

Wind Box

Water tube Boiler

Bank Tubes

MDC

Economizer

Air Pre heater

ID Fan Chimney ESP

PA Fan

FD Fan

FD Duct

Steam

Ambient Air Coal from Bunker

Packet Feeder

Deareator

Feed Water Pump

MDC Mechanical Dust Collector ESP Electro Static Preceptor ID Fan Induced Draught Fan CHS Coal Handling System AHS Ash Handling System Flue Gas Steam Water Ash

COAL FIRED BOILER DETAILS / SPECIFICATION OF COAL FIRED BOILERS: BOILER MAKE CAPACITY TYPE PRESSURE WORKING Coal Fired Boiler Veeson 24TPH Water Tube, Bi-Drum, 22Kg/cm2 Natural circulation, Balanced Draft, AFBC(Atmospheric Fluidized Bed Combustion) OPERATING 21 Kg/cm2 IBR IBR/NON IBR

FLUIDIZED BED: When an evenly distributed air or gas is passed upward through a fine bed of solid particles, such as sand at certain velocity of air or gas gradually increased, a stage is reached when the individual particles are suspended in the air stream the bed is called fluidized. With further increase in air velocity, there is bubble formation, vigorous turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid bubbling fluidized bed. PURGING SYSTEM: Before starting the combustion, the left over combustion products is to be purged out from the shell of the boiler. Economizer: To recover heat from flue gas and to preheat the feed water to bank tubes for process. Air pre heater: To recover heat from flue gas and to preheat the FD air for better combustion in the furnace. MDC Mechanical Dust Collector: It is used to collect the heavy dust from the flue gas through baffle plates. ESP Electro Static Precipitator: ESP is used for ionizing the flue gas and improves the SPM removal and conveyed to ash silo by using Rapping Mechanism. In ESP the SPM level should be maintained 50 mg/nm as per the norms. The SPM is Suspended particulate matter
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IMPORTANT PARAMETERS OF COAL FIRED BOILER Boiler Steam Pressure - 20 to 21 Kg/cm2 Bed height - 300 to 350 mm Bed Temperature - 750 to 900C Air Box pressure 300 mmwc PA pressure - 700 to 900 mmwc Economizer inlet water temperature - 105C Air Pre Heater flue gas outlet temperature - 140 to 150C Boiler feed water pH - 8 to 9 Feed water Hardness - < 5 PPM Feed water TDS - < 10 PPM Boiler water pH - 10 to 10.5 Boiler water TDS - < 1000 PPM

IMPORTANT PARAMETERS OF FURNACE OIL BOILER Boiler Steam pressure 20 to 21 Kg/cm2 Air pre heater flue gas outlet temperature - 160C FO Temp - 110C to 120C FO Inlet & Outlet Pressure Boiler feed water pH - 8.5 to 9.5 Feed water Pump - 18.5 m3/hr, 262 Meters of Liquid Column Feed water Hardness less than 5 PPM / Nil Feed water TDS- less than 10 PPM Boiler water PH 10.5 to 11.5 Boiler water TDS 3500 PPM