Miscellaneous Boiler Types, Economisers and Superheaters Module 3.

Block 3 The Boiler House

Module 3.4
Miscellaneous Boiler Types,
Economisers and Superheaters

The Steam and Condensate Loop

3.4.1

Block 3 The Boiler House

Miscellaneous Boiler Types, Economisers and Superheaters Module 3.4

Miscellaneous Boiler Types,

Economisers and Superheaters
Steam generators
In many applications:
o
o

The amount of steam required is too small to warrant a shell boiler, i.e. Less than 1 000 kg / h.
The small process requiring steam operates on a day shift only, meaning that the plant would
be started every morning and shut down every night.
The capital cost of a conventional shell boiler would adversely affect the economic viability of
the process.
The level of expertise on site, as far as boilers are concerned, is not as high as would be
required on a larger steam system.

To meet these specific demands two types of boiler have been developed.

Coil boiler

These are a once through type of water tube boiler, and referred to in some regulations as,
boilers with no discernible water level.
Flames

m kg /h dry saturated steam to plant

Boiler coil

10% water with impurities

to waste / recycle

m kg /h + 10%
Feedwater

Fig. 3.4.1 Coil boiler

Water supply to the boiler will usually be at 10 to 15% above the steaming rate to:
o

Ensure that all the water is not evaporated, thus ensuring that superheated steam is not
produced.
Provide a vehicle for the feedwater TDS to be carried through. If this vehicle was not available,
the salts in the feedwater would be deposited on the insides of the tubes and impair heat
transfer, leading to over heating and eventually to tube failure. Clearly, a separator is an essential
component of this type of boiler to remove this contaminated water.

Being of the water tube type, they can produce steam at very high pressures.
Typical applications for steam generators and coil boilers include laundries and garment
manufacture, where the demand is small and the rate of change in load is slow.

3.4.2

The Steam and Condensate Loop

Miscellaneous Boiler Types, Economisers and Superheaters Module 3.4

Block 3 The Boiler House

Vertical tubeless packaged steam boiler

Various models are available with outputs in the range 50 to 1 000 kg /h, and pressures up
to 10 bar g. Boiler heights vary typically from 1.7 m to 2.4 m for outputs of about 100 kg /h to
1 000 kg /h respectively.

A cross section of the design is shown in Figure 3.4.2. Note the downward path of the flame, and
the swirling action. The heat path is reversed at the bottom of the boiler and the hot gases rise,
releasing heat to the fins.
Also note the small quantity of water in the boiler. This allows the boiler to be brought up to
operating temperature very quickly, typically 15 minutes. However, this small quantity of water
means that only a small amount of energy is stored in the boiler, consequently it is not easily able
to cope with sudden and maintained changes in load. If the load change occurs faster than the
boiler can respond, then the pressure inside the boiler will drop and ultimately the boiler will
prime with feedwater. This is aggravated by the small water surface area, which gives high steam
release velocities. However, the path of the steam is vertically up and away from the water
surface as opposed to horizontally over the water surface (as in a shell boiler), and this minimises
the effect
Burner supply
Feedwater supply

Steam outlet

Air fan unit

Combustion chamber
1st pass, downward

Finned convection
2nd pass, upward
Water

Fig. 3.4.2 Vertical tubeless packaged steam boiler

The Steam and Condensate Loop

3.4.3

Block 3 The Boiler House

Miscellaneous Boiler Types, Economisers and Superheaters Module 3.4

Economisers

The flue gases, having passed through the main boiler and the superheater, will still be hot. The
energy in these flue gases can be used to improve the thermal efficiency of the boiler. To achieve
this the flue gases are passed through an economiser.
Feedwater
tank

Chimney
Economiser

Feedwater line

Feedwater line

Feedwater line

Boiler

Fig. 3.4.3 A shell boiler with an economiser

The economiser is a heat exchanger through which the feedwater is pumped. The feedwater
thus arrives in the boiler at a higher temperature than would be the case if no economiser was
fitted. Less energy is then required to raise the steam. Alternatively, if the same quantity of
energy is supplied, then more steam is raised. This results in a higher efficiency. In broad terms a
10C increase in feedwater temperature will give an efficiency improvement of 2%.
Note:
o Because the economiser is on the high-pressure side of the feedpump, feedwater temperatures
in excess of 100C are possible. The boiler water level controls should be of the modulating
type, (i.e. not on-off) to ensure a continuous flow of feedwater through the heat exchanger.
o

The heat exchanger should not be so large that:

- The flue gases are cooled below their dew point, as the resulting liquor may be acidic
and corrosive.

- The feedwater boils in the heat exchanger.

3.4.4

The Steam and Condensate Loop

Miscellaneous Boiler Types, Economisers and Superheaters Module 3.4

Block 3 The Boiler House

Superheaters

Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam
space. Steam formed above the water surface in a shell boiler is always saturated and cannot
become superheated in the boiler shell, as it is constantly in contact with the water surface.
If superheated steam is required, the saturated steam must pass through a superheater. This is
simply a heat exchanger where additional heat is added to the saturated steam.
In water-tube boilers, the superheater may be an additional pendant suspended in the furnace
area where the hot gases will provide the degree of superheat required (see Figure 3.4.4). In
other cases, for example in CHP schemes where the gas turbine exhaust gases are relatively cool,
a separately fired superheater may be needed to provide the additional heat.
Saturated steam
Stack

Superheated steam

Superheater pendant

Heat

Water tube boiler

Fig. 3.4.4 A water tube boiler with a superheater

If accurate control of the degree of superheat is required, as would be the case if the steam is to
be used to drive turbines, then an attemperator (desuperheater) is fitted. This is a device installed
after the superheater, which injects water into the superheated steam to reduce its temperature.

The Steam and Condensate Loop

3.4.5

Block 3 The Boiler House

Miscellaneous Boiler Types, Economisers and Superheaters Module 3.4

Questions
1. What is the main advantage of a vertical tubeless packaged steam boiler when compared
with a shell boiler ?
a| There is little water stored in the boiler

b| Water level controls are not required

c| Steam can be raised in 15 minutes

d| It is quick to respond to steam load changes

2. From the following identify a reason why the water supply rate to a coil boiler is 10%
greater than the steam requirement ?
a| The excess water is a vehicle for the feedwater TDS to be carried through

b| To even out stresses within the boiler

c| It is easier to control the degree of superheat in the steam produced

d| It is easier to control the water flowrate

3. How is a dry steam supply assured from a coil boiler package ?

a| Through an intermittent water supply

b| It isnt, the steam will be wet

c| By using a superheater

d| By using a separator

4. What effect can a rapid load change have on a vertical tubeless packaged steam boiler ?
a| No effect

b| The water level will drop

c| The boiler will react quickly

d| The boiler will prime with feedwater

5. What is the purpose of an economiser ?

a| To cool boiler exhaust gases to below dew point

b| To reduce the amount of energy required in the production of steam

c| To enable more steam to be produced from a boiler

d| To utilise heat from boiler exhaust gases

6. Why are superheaters normally associated with water tube boilers rather than with
shell boilers ?
a| Control of the degree of superheat is easier with a water tube boiler than a shell boiler
b| Water tube boilers always incorporate superheaters

c| Turbines need high pressure superheated steam and this is more readily available from
water tube boilers

d| Because water tube boilers produce wet steam and superheating is therefore usual

Answers

1: c, 2: a, 3: d, 4: d, 5: d, 6: c

3.4.6

The Steam and Condensate Loop