A Brief Discussion on Boilers

Abdul Hannan
Waheed Ahmad
Taha Khan
Hassan Mahmood
Fakhar Anwaar
Nafees Ahmad


Introduction
Types of Boilers
Assessments of Boilers
Energy efficiency opportunities

What is a Boiler?

It is a closed vessel in which the heat produced by the
combustion of fuel is transferred to water for its
conversion into steam at the desired temperature &
pressure.
At atmospheric pressure the water volume increases to
1,600 times.

Boilers, were a major part of the Industrial Revolution
beginning about 1700 A.D. They are major consumers
of industry & building energy consumption today
Industry boilers are used for power generation process
heat(e.g., refineries, petrochemical, paper mills, tire
manufacturing etc) & heating
In buildings, boilers are used for steam primary heat,
terminal reheat systems. Water heating & absorption
chillers

Horizontal and Vertical boiler
Fire tube and water tube Boiler
Externally and Internally fired boiler
Forced and Natural Circulation boiler
High, Medium and Low pressure boiler
Stationary and Portable boiler
Single and Multi tube boiler
If the axis of the boiler is vertical then its called
vertical boiler. E.g. Cochran boiler

If the axis of the boiler is horizontal then its called the
horizontal boiler. E.g. Locomotive boiler, Lancashire
boiler.
The fire tube boiler, the oldest design, is made so the
products of combustion pass through tubes
surrounded by water in a shell
The furnace/flame volume can either be inside or
external to the shell that contains the water.
The upper steam capacity of fire tube boiler is about
20,000 lbm/hr, & the peak pressure obtainable is
limited by their large shells to about 300 psi.
Fire-tube boilers are used for heating systems









Horizontal, four pass, forced draft fire tube boiler
It can be seen here that the hot gases are in the tube &
water is surrounding them
A water-tube boiler is one in which the products of
combustion pass around the outside & heat tubes
containing the water
The water tube diameter is much smaller than the
shell diameter of a fire-tube boiler, so much higher
pressures can be obtained, well over 2000 psi
The furnace & boiler tube area must be surrounded by
a heavily insulated refractory wall to prevent heat
transfer through the boiler walls
The boiler in which the
water is inside the tube &
hot gases surround them is
called water-tube boiler

E.g., Babcock & Wilcox
Boiler


All the largest boilers used for heating & industrial
purpose are packaged boilers
They are factory built & shipped whole or in modular
components to the customer.
Many are constructed in an elongated shape that will
fit through large building doors with minimal fitting
adjustment required
In the boiler if the fire is outside the shell, that boiler
is known as externally fired boiler. E.G., Babcock &
Wilcox boiler
The boiler in which the furnace is located inside the
boiler shell it is known as internally fired boiler E.g. ,
Cochran Boiler, Lancashire Boiler


In the boiler if the circulation of water is done by a
pump ten they are known as forced circulation boiler.

E.g. , Benison Boiler, Lamont Boiler


In the boiler if the circulation of water takes place due
to difference in density resulting from different in
temperature, it is known as natural circulation boiler

E.g. , Lancashire Boiler


It is one in which the working pressure of the boiler is
more than 25 bar.

E.g. , Babcock & Wilcox boiler


It is that boiler whose working pressure is between 10-
25 bars

E.g. , Lancashire Boiler & Locomotive Boiler


It is that boiler whose working pressure is between 3.5-
10 bar.

E.g. , Cochran boiler

The boilers having only one fired tube or water tube
are called single tube boilers.
E.g. , Cornish Boiler

The boilers having two or more fire or water tube for
the circulation of hot gases or water are called multi
tube boiler
E.g. , Lancashire boiler, Babcock boiler & Wilcox boiler

Thermal efficiency of boiler is defined as the
percentage heat input that is effectively utilized to
generate steam. There are two methods to calculate
the boiler efficiency
1. The Direct Method
2. The Indirect Method

Boiler Efficiency = Q * (H-h)/(q * GCV) * 100
Where
Q = quantity of steam generated per hour (kg/hr)
H = Enthalpy of saturated steam (kcal/kg)
h = Enthalpy of feed water (kcal/kg)
q = Quantity of fuel used per hour (kg/hr)
GCV = Gross Calorific Value of the fuel (kcal/kg)
.

Air preheater.
Economizer.
Super heater.
De-super heater.
Boiler feed pump.
Forced draft and induced draft fans.
Mechanical separator.
Equipment tanks
Feed water tanks
De-aerator
Continuous blow down expander
Drainage expander
Chemical dosing system.
Soot blowers and wall blowers.
Pressure reduction valve.
Pulverizers and fuel firing system.
Ash handling systems.


Thanks for your
Attention