73

Prabir Basu Cen Kef a Louis Jestin

Boilers and Burners

Design and Theory

With 250 Figures

Springer
Contents

Series Preface v
Preface vii

1 Introduction 1
1-1 Principles of Boiler Operation 1
1-2 Classification of Boilers 6
1-3 Description of Boilers 6
References 14

,2 General Design Considerations 15

2-1 Boiler Specifications 15
2-2 Design Steps 17
References 20

3 Fuel and Combustion Calculations 21

3-1 Features of Fuel 21
3-2 Stoichiometric Calculations 28
3-3 Enthalpy Calculation of Air and Combustion Products 36
3-4 Heat Balance 37
3-5 Generation of SO2 and NC\ 46
Nomenclature 48
References 51

4 Coal Preparation Systems for Boilers 52

4-1 Coal Preparation Systems 52
4-2 Pulverizing Properties of Coal 56
4-3 Pulverizing Air System 59
4-4 Size-Reducing Machines 63
4-5 Other Components for Coal Preparation Systems 70
4-6 Design of Coal Preparation System
for Pulverized Coal Boilers 73
 Contents

4-7 Fuel Feeding in Fluidized Bed Boilers 76

Nomenclature 78
References 79

Design of Oil Burners 80

5-1 Design of Oil Supply System 80
5-2 Oil Atomizers 82
5-3 Air Registers 108
5-4 Design Principles of Oil Fired Boilers 118
Nomenclature 125
References 127

Boiler Furnace Design Methods 128

6-1 General Design Principles 128
6-2 Flame Emissivity 135
6-3 Heat Transfer Calculations for the PC Boiler Furnace 140
6-4 Water Wall Arrangement 146
6-5 Fouling and Thermal Efficiency Factors
for Water Wall Tubes 147
6-6 Temperature Field Coefficient, M 149
6-7 Furnace Emissivity 150
6-8 Distribution of Heat Load in Furnace 151
Nomenclature 157
References 159

Convective Heating Surfaces 161

7-1 Design of Superheater and Reheater 161
7-2 Temperature Control in Superheater and Reheater 167
7-3 Adjustment of Heat Absorption in Superheater and Reheater . . . 172
7-4 Economizer 178
7-5 Air Heater 180
7-6 Arrangement of Back-Pass Heating Surfaces 185
7-7 Heat Transfer Calculations for Convective Heating Surfaces . . . 187
7-8 Design Methods of Convection Heating Surfaces 206
Nomenclature 207
References 211

Swirl Burners 212

8-1 Design of a Swirl Burner 212
8-2 Flow Resistance in Swirl Burners 225
8-3 Examples of Swirl Burners 226
8-4 Arrangement of Multiple Swirl Burners 230
8-5 Design Procedure of Swirl Burners 233
Nomenclature 239
References 241
 Contents xi

9 Design of Novel Burners 242

9-1 Types of PC Burners 242
9-2 PC Burner With Blunt Body 243
9-3 Precombustion Chamber Burner 246
9-4 Boat Burner 248
9-5 Co-Flow Jet Burner With High Differential Velocity 249
9-6 Counter-Flow Jet Burner 250
9-7 Dense and Lean Phase PC Burner 253
9-8 Down-Shot Flame Combustion Technique 257
9-9 Low NOX Burner 259
Nomenclature 266
References 267
10 Tangentially Fired Burners 269
10-1 General Descriptions 269
10-2 Design of Burners With Peripheral Air 279
10-3 Design of Tilting Burners 281
10-4 Burners for Bituminous Coal 284
10-5 Anthracite and Lean Coal Fired PC Burner 286
10-6 Brown Coal Fired Direct Burner 291
10-7 Multifuel Burner 293
10-8 Design Methods for Tangentially Fired Boilers 294
10-9 Example of Burner Design 297
Nomenclature 300
References 301
11 Fluidized Bed Boilers 302
11-1 Fluidized Bed Boiler 302
11-2 Major Features of Fluidized Bed Boilers 304
11-3 Basics of Fluidized Beds 309
11-4 Bubbling Fluidized Bed Boilers 314
11-5 Circulating Fluidized Bed Boilers 319
11-6 Distributor Plates 327
11-7 Loop Seals 331
11-8 Gas-Solid Separators 334
Nomenclature 340
References 344
12 Steam-Water Circulation in Boiler 347
12-1 Natural Circulation System 346
12-2 Calculations for Simple and Complex Tube Circuits 359
12-3 Two-Phase Flow Resistance 360
12-4 Height of Economizer Section in the Riser 362
12-5 Worked-Out Example 364
Nomenclature 369
References 371
xii Contents

13 Forced Circulation for Supercritical or Subcritical Boilers 372

13-1 General Description 373
13-2 Design Principle of Forced Circulation Boiler 374
13-3 Features of Forced Circulation Boilers 375
13-4 Supercritical Boilers 381

14 Corrosion and Fouling of Heat Transfer Surfaces 385

14-1 High-Temperature Corrosion of External Surfaces 386
14-2 Prevention of High-Temperature Corrosion 392
14-3 Low-Temperature Corrosion on External Surfaces 397
14-4 Corrosion and Scaling of Internal Surfaces 402
14-5 Fouling and Slagging 406
14-6 Calculation of Soot and Ash Deposition 412
14-7 Prediction of Slagging Potential 416
14-8 Design Measure for Reduction of Fouling and Slagging . . . . 421
Nomenclature 423
References 424

15 Erosion Prevention in Boilers 426

15-1 Theory of Erosion of Heating Surfaces 426
15-2 Worked-Out Example 431
15-3 Factors Influencing Tube Erosion 433
15-4 Analyses of Erosion of Tube Banks in Cross-Flow 436
15-5 Permissible Gas Velocity for Safe Operation 439
15-6 Erosion Protection for the Economizer,
Reheater, and Superheater 444
15-7 Erosion in Tubular Air Heaters 448
15-8 Erosion in Fluidized Bed Boilers 450
Nomenclature '. 454
References 456

16 Pressure Drop in Gas and Air Ducts 457

16-1 Draft Systems 457
16-2 Pressure Drop in Air and Gas Duct Systems 459
16-3 Pressure Drop Across Heating Surfaces 466
16-4 Pressure Drop in Natural Draft Gas Path 471
16-5 Pressure Drop Through Air Ducts 475
16-6 Selection of Fans 479
16-7 Pressure Drop Through Water or Steam Tubes 480
Nomenclature 481
References 483

17 Mechanical Design of Pressure Parts 485

17-1 Selection of Materials 485
17-2 Important Mechanical Properties of Various Materials . . . . . 487
 Contents xiii

17-3 Fundamental Metallurgical Concepts

to Improve Steel Properties 490
17-4 Design Methods 495
17-5 Thickness (Scantling) Calculations 509
Nomenclature 523
References 523

18 Tables of Design Data 524

Table 18-1 Specific heat of air, flue gas and
ash at atmospheric pressure 525
Table 18-2 Some physical properties of iron,
metal, and selected steels 526
Table 18-3 Linear thermal expansion of steel 526
Table 18-4 Specific heat capacity of steel 527
Table 18-5 Electrical resistivity of steel 527
Table 18-6 Thermal conductivity of steel 527
Table 18-7 Density, heat capacity, and heat conductivity
for metals 528
Table 18-8 Thermal properties of the saturated water and steam
(arranged by temperature) 530
Table 18-9 Thermal properties of the saturated water and steam
(arranged by pressure) 532
Table 18-10 Thermal properties of unsaturated water and
superheated steam at different pressures 534
Table 18-11 Conversion factors 541

Index 553