Chapter 2 Heating Surfaces of a Boiler

Prof&Dr Zhongzhu Qiu 1

 Waterwall

Functions Structure and layout

• Enhance heat exchange and • Specification: Φ45, Φ51, Φ57,

save metal cost Φ60, Φ63.5, Φ76 , thickness: δ
• Decrease detrimental effect of ＝3～5mm
high temperature on furnace • Material: seamless steel tube
wall 10g, 15g, 20g
• Avoid agglomeration • Layout: single furnace, double
• Suspend furnace wall furnace
• Absorb radiant heat • Parameters: influence of s/d on
thermal performance

Prof&Dr Zhongzhu Qiu 2

 Waterwall
Types:
• Tube water wall：easy manufacture and swell evenly s / d  1.1 1.2
• Membrane water wall：good sealing、large heating surface、
easy installation (figure 2－3) s / d  1.3 1.35
• Rifled pipe：strong turbulence, against film boiling

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Interior rifled tube

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 Throttle ring

Filter

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 Superheater and Re-heater

Functions

Saturated or low Rated superheat

temperature steam steam
heating

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 Superheater and Re-heater
Features High
temperature
resistance
material
Bypass is needed for
protection when the
boiler is initiated or Low drag force
turbine is in load
rejection

Features

The layout is High flow rate

defined by boiler in high
parameters thermal load

The outlet steam

temperature
varies with the
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loading Qiu
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 只设整体旁路的称为一级旁路系统﹐其优点是系统简单﹑操作方便﹐
适用于再热器不需保护的机组﹔ 设有高压和中﹑低压旁路的称为两级旁路
系统﹐其优点是调节灵活﹐能有效地保护再热器﹐但系统较复杂﹔ 同时设
有整体旁路﹑高压旁路和中﹑低压旁路的称为三级旁路系统。这种系统最为
复杂﹐但有利于机组适应负荷变化的要求。

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Layout of superheater

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 Layout of re-heater

A. Three-stage arrangement (high T)

Figure 2-14 system of re-heater SG-1025/18.3-M833
Figure 2-15 process of re-heater SG-1025/18.3-M833

B. Two-stage arrangement (low T)

Figure 2-16 re-heater arrangement of 1000t/h once-through
boiler
Figure 2-17 re-heater arrangement of 670t/h boiler

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Structure of superheater and reheater
Convection, radiation,
Heat transfer
semi-radiation
classification
Counter-, parallel-,
Flow direction
combined-
Arrangement of
Vertical, horizontal
heating surface

Layout of tubes In-line, staggered

Single-, double-,
Tube bundle multiple-
platen-, wall-, snaked
Structure tubes
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 Convection superheater
• Location: horizontal or vertical flue gas duct
• Structure: coil tube
• Example: final superheater (parallel flow)
final re-heater (parallel flow)
primary superheater（counter flow）
low temperature re-heater（counter flow）
vertical low temperature superheater (counter)

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 Radiation
• location : wall or roof of the furnace and the duct

• Example: ceiling superheater, enclosure

superheater

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 Semi-radiation
• Location:
It is usually set on the top or the outlet of the furnace,
which can both absorbing the radiant heat and convectional
heat from flue gas.

• Structure: platen
•
• Example: Rear platen superheater

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 Economizer and Air heater
Rear heating surface or low temperature heating surface
Functions
 Decrease the temperature of flue gas

 Decrease evaporation surface：

Using low price economizer instead of high price
cooing wall
High efficient heat exchange (low temperature,
forced flow and counter flow)

 Decrease the temperature difference between feeding

water and drum in order to alleviate thermal stresses
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 Economizer and Air heater
Functions of air heater

 Decrease flue gas temperature further

Large capacity boiler，T of feeding water: 250-
280℃ > 120 ℃
 Dry coal milling system

 Enhance initiation

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 Economizer and Air heater
Economizer: types and tubes arrangement

1. tubular, cast(pressure < 4 MPa)

2. non-boiling、boiling(medium pressure)
capacity, heat absorption by evaporation
Use non-boiling
3. Staggered low fouling, strong heat exchange,
high abrasion
in-line good ash flowing, weak heat exchange,
low abrasion
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 Economizer and Air heater
Economizer: types and arrangement
4. Structure: coil tube
Tube, fin-type, film-type

Heat transfer enhancement, volume saving,

Prof&Dr Zhongzhu Qiu abrasion suppression38
Economizer and its pendant
tubes
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 Economizer and Air heater
Economizer: types and arrangement
5. Horizontal coil tube, facilitate to water conveyance
6. Counter flow, increase temperature difference of heat transfer
Water: bottom-up, easy for gas discharge, avoid corrosion
Flue gas: top-down, for ash blowing
7. Vertical to the front wall, parallel to the rear wall
Rear flue gas duct: Wide but shadow
vertically arranged: easily hang but high abrasion in the end of
tube
horizontally arranged: hard for hang but low abrasion
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Economizer recirculation pipe

When starting up, the steam flow rate

is lowdangerous

Natural circulation Controlled circulation

between down drum
between drum and economizer and economizer
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strongly propel,41safer
 Air heater(AH)
Types：

Tubular AH: small boilers, or CFB

Rotary AH (Regenerative AH): Applied in the boiler whose

capacity is above 300MW

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Tri-sectional Regenerative Air Preheater
 Characteristics of the Regenerative AH

 compact: high heat exchange density, 1/10 volume

of tubes；
 lighter and cost saving: heat reserve plate, thin
 flexible
 alleviate low temperature corrosion: temperature
changes in heat exchangers
 corrosion of heat surface will not increase air
leakage and easy for replacement
 large amount of air leakage between rotary and
static parts
 complicated structure，complex maintenance

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Commercial Applications

Rotating-plate (more)
Stationary-plate

A. Rotating part
Double-sectional (flue gas section, air section and sealed
section)
Large flue gas flow: 50%；Air: 30-40%

Tri-sectional (flue gas section, primary air, secondary air

and sealed section)
can use cold primary
Prof&Dr air fan, widely used
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Stationary-plate:

Stator(heat surface) includes rotary upper and

under cover

Reduce the weight of stator

Similar to Tri-sectional Regenerative Air Preheater

Stationary-plate separate primary and secondary air

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Stationary-plate type regenerative air heater
Air leakage

Primary problem for rotary air heater

Features: air  flue gas

Reasons：
1)Low residue air or flue gas in heat exchanger
2)Leakage of seal：gap between rotators and
stator
positive pressure in air side
negative pressure in flue gas side
Influences:
Increase electricity consumption of ID Fan and FD Fan,
heat loses in flue gas and can not supply enough air for
boiler Prof&Dr Zhongzhu Qiu 49