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Mechanical Engineering
Steam Generator
A boiler (or steam generator, as it is commonly called) is a closed
vessel in which water, under pressure, is transformed into steam by
the application of heat
In the furnace, the chemical energy in the fuel is converted into heat,
and it is the function of the boiler to transfer this heat to the water in
the most efficient manner
Open vessels, generating steam at atmospheric pressure are not
considered to be boiler
ME 267
Department of Mechanical Engineering, BUET
1. Simplicity in construction, materials conductive to low maintenance
cost, high efficiency, and high availability
2. Design and construction to accommodate expansion and contraction
properties of materials
3. Adequate steam and water space, delivery of clean steam, and good
water circulation
4. A furnace setting conducive to efficient combustion and maximum
rate of heat transfer
5. Responsiveness to sudden demands and upset conditions
6. Accessibility for cleaning and repair
7. A factor of safety that meets code requirement
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Department of Mechanical Engineering, BUET
1. Electric power generation
2. Heating
o Space heating
o Hot water supply
3. Industrial Processes
Sugar mills
Chemical industry
Paper Industry
4. Marine Application
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Department of Mechanical Engineering, BUET
The boiler must be conservatively designed to ensure reliable
performance over the life of the plant
The term boiler setting was applied originally to the brick walls
enclosing the furnace and heating surface of the boiler. As the
demand grew for larger-capacity steam generating units, the brick
walls gave way to air-cooled refractory walls and then to water-cooled
tube walls
A boiler should be designed to absorb the maximum amount of heat
released in the process of combustion. This heat is transmitted to the
boiler by radiation, conduction, and convection, the percentage of
each depending on the boiler design
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Department of Mechanical Engineering, BUET
More emphasis is being placed on flexibility, boiler availability, safety,
efficiency of the fuel-burning equipment, and efficiency of the heat
transferred
The newer boilers are designed to be fully automated; their design
also must take into account the environmental control equipment that
is mandatory under regulations
Many boilers are designed to burn multiple fuels in order to take
advantage of the fuel most economically available
ME 267
Department of Mechanical Engineering, BUET
Boiling: After the boiling temperature is reached (e.g., 212F at an
atmospheric pressure of 14.7 psia), instead of the water temperature
increasing, the heat energy from the fuel results in a change of phase
from a liquid to a gaseous state, i.e., from water to steam. A steam-
generating system, called a boiler, provides a continuous process for
this conversion
Circulation: For most boiler or steam generator designs, water and
steam flow through tubes(water tube boiler). In order for a boiler to
generate steam continuously, water must circulate through the tubes.
Two methods are commonly used: (1) natural or thermal circulation
and (2) forced or pumped circulation
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Department of Mechanical Engineering, BUET
For a natural circulation system The fluid flow is induced by the
difference in the specific weight of the water and the average specific
weight of the water steam mixture
The total circulation rate depends on four major factors:
1. Height of boiler
2. Operating pressure
3. Heat input
4. Free-flow area
For a forced circulation system a pump is added to the flow loop, and the
pressure difference created by the pump controls the water flow rate.
These circulation systems generally are used where the boilers are
designed to operate near or above the critical pressure of 3206 psia
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Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
Steam-water separation:
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Department of Mechanical Engineering, BUET
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Department of Mechanical Engineering, BUET
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Department of Mechanical Engineering, BUET
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Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
Products of combustion pass through
tubes that are surrounded by water
They may be either internally fired or
externally fired
Internally fired boilers are those in
which the grate and combustion
chamber are enclosed within the
boiler shell
Externally fired boilers are those in
which the setting, including furnace
and grates, is separate and distinct
from the boiler shell
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Department of Mechanical Engineering, BUET
Fire-tube boilers are further classified as vertical tubular or horizontal
tubular
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Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
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Department of Mechanical Engineering, BUET
The products of combustion (called
flue gas) pass around tubes containing
water.
The tubes are interconnected
to common water channels and to the
steam outlet.
For some boilers, baffles to direct
the flue gas flow are not required.
For others, baffles are installed in
the tube bank to direct the flue gas
across the heating surfaces and to
obtain maximum heat absorption.
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Department of Mechanical Engineering, BUET
Advantages: Disadvantages:
Compactness Use of high voltage
No emissions High power costs
No stack requirements Availability, if it must be used
Quiet operation during other than off-peak
Low maintenance periods
Safety of operation Initial Cost
Absence of fuel storage
tanks
Ability to use electric power
during off-peak periods
Responsiveness to demand.
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Department of Mechanical Engineering, BUET
Comparison is made based on the following points
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Department of Mechanical Engineering, BUET
These are the devices which are used as integral parts of a boiler and
help in running efficiently.
Feed Pump
Super-heater
Economizer
Air Pre-heater
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Department of Mechanical Engineering, BUET
A boiler feed pump that transfers feedwater from the feedwater
heaters to the economizer or the boiler steam drum.
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Department of Mechanical Engineering, BUET
The function of the superheater is to increase the temperature of
saturated steam without raising its pressure.
Placed in the path of hot flue gases from the furnace.
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Department of Mechanical Engineering, BUET
An economizer is a heat exchanger located in the gas passage
between the boiler and the stack, designed to recover some of the heat
from the products of combustion.
Located after the superheater and the reheater and it increases the
temperature of the water entering the steam drum.
Consists of a series of tubes through which water flows on its way to
the boiler.
It may be-
Parallel flow: The flue gas and water flow in the same direction.
Counter flow: The flue gas and water flow in the opposite
direction.
Combination of the two.
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Department of Mechanical Engineering, BUET
An air preheater is used to recover heat from the exhaust flue gases.
Installed between the economizer and chimney.
Air required for the purpose of combustion is drawn through the air
preheater where its temperature is raised.
Advantages-
Gives higher furnace temperature more heat transfer increase
steam raising capacity of boiler.
Uses the lost heat and thus increase the efficiency around 2-10%.
Better combustion with less soot, smoke and ash.
Gives opportunity to use a low grade fuel.
Disadvantages-
Air preheaters increase the efficiency, this increase must be
evaluated against the added cost of installation, operation, and
maintenance
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Department of Mechanical Engineering, BUET
Air preheater (or air heater) consists of plates or tubes
having hot gases on one side and air on the other.
Generally two types- 1. Tubular or recuperative and 2.
Regenerative.
The tubular type consists of a series of tubes through which
the flue gases pass, with air passing around the outside of the
tube.
The regenerative air preheater transfers heat in the flue gas
to the combustion air through heat-transfer surface in a rotor
that turns continuously through the flue gas and airstreams at
slow speeds (1 to 3 rpm).
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Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
Boiler Mountings
These are the fittings, which are mounted on the boiler for its proper
and safe functioning.
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Department of Mechanical Engineering, BUET
Boiler Mountings: Water Level Indicator
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Boiler Mountings: Pressure Gauge
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Boiler Mountings: Safety Valve
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Boiler Mountings: Steam Stop Valve
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Boiler Mountings: Feed Check Valve
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Boiler Mountings: Blow off Cock
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Schematic of A Boiler Plant
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Department of Mechanical Engineering, BUET
Boiler Ratings and Performance
sg =
total energy added to the working fluid
100
total fuel - input energy
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Department of Mechanical Engineering, BUET
Boiler Ratings and Performance
Indirect Method:
HHV of fuel - total losses
= 100
sg HHV of fuel
Six major boiler losses are: DGL, ML, MCAL, ICL, UCL, RL
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Department of Mechanical Engineering, BUET