Steam generators

lecture No.-2
Dr. Rajeev Trehan
Head, Department of Industrial and Production Engineering
Advisor, Centre of Training and Placement
Dr.B R Ambedkar National Institute of Technology Jalandhar
Contents

Firetube boilers
Type of firetube boilers
Watertube boilers
Type of watertube boilers
Difference between firetube boiler and water tube boiler
Firetube boilers

the flames and hot gases, produced by the combustion of fuel, pass through the tube (called
multi-tubes) which are surrounded by water. The heat is conducted through the walls of the
tubes from the hot gases to the surrounding water. Examples of the fire tube boilers are:
Simple vertical boiler, Cochran boiler, lanchashire boiler, Cornish boiler, scotch marine
boiler, locomotive boiler, and Velcon boilers
Types of firetube boiler

Simple vertical boiler

Cochran boiler
lanchashire boiler
Cornish boiler
Scotch marine boiler
Locomotive boiler
Velcon boilers
Simple Vertical boiler
A simple vertical boiler produces steam at a low
pressure and in small quantities. It is, therefore, used
for low power generation or at places where the space
is limited. The construction of this type of boiler is
shown in figure.
It is consist of a cylindrical shell surroundings a nearly
cylindrical firebox. The firebox is slightly tapered
towards the top to allow the ready passage of the
steam to the surface. At the bottom of the fire box, is a
grate. The fire box is fitted with two or more inclined
cross tubes. The inclination is provided to increase the
heating surface as well as to improve the circulation of
water. An uptake tube passes from the top of the fire
box to the chimney. The handholes are provided
opposite to the end of each water tube for cleaning
deposites. A manhole is provided at the top for a man
to enter and clean the boiler. A mudhole is provided at
the bottom of the shell to remove the mud, that settles
down. The space between the boiler shell and fire box
is filled with water to be heated.
Cochran boiler or vertical
multitubular boiler
A Cochran boiler is considered to be one of the most
efficient type of such boilers. It is an improved type of
simple vertical boiler.
The boiler consist of an external cylindrical shell and a fire
box. The shell and fire box are both hemispherical. The
hemispherical crown of the boiler shell gives maximum
space and strength to withstand the pressure of steam inside
the boiler. The hemispherical crown of the crown of the fire
box is also advantageous for resisting intense heat. The fire
box and the combustion chamber is connected through a
short pipie. The flue gases from the combustion chamber
flow to the smoke box through a number of smoke tube.
These tubes generally have 62.5mm external diameter and
are 165 in number. The gases from the smoke box pass to
the atmosphere through a chimney. The combustion
chamber is lined with fire bricks on the shell side. A
manhole near top of the crown on the shell is provided for
cleaning.
At the bottom of the fire box, there is a grate(in case of coal
firing) and the coal is fed through the fire hole. If the boiler
is used is used for oil firing, no grate is provided, but the
bottom of the fire fox is lined with firebricks. The oil burner
is fitted at the fire hole.
 Scotch marine boiler
A "Scotch" marine boiler (or simply Scotch boiler) is a
design of steam boiler best known for its use on ships.
The general layout is that of a squat horizontal cylinder.
One or more large cylindrical furnaces are in the lower
part of the boiler shell. Above this are many
small-diameter fire-tubes. Gases and smoke from the
furnace pass to the back of the boiler, then return through
the small tubes and up and out of the chimney. The ends
of these multiple tubes are capped by a smokebox,
outside the boiler shell. The Scotch boiler is a fire-tube
boiler, in that hot flue gases pass through tubes set within
a tank of water. As such, it is a descendant of the earlier
Lancashire boiler, and like the Lancashire it uses
multiple separate furnaces to give greater heating area for
a given furnace capacity. It differs from the Lancashire in
two aspects: many small-diameter tubes (typically 3 or 4
inches [76.2 or 101.6 mm] diameter each) are used to
increase the ratio of heating area to cross-section.
Secondly, the overall length of the boiler is halved by
folding the gas path back on itself.
Lanchashire boiler
The Lancashire boiler is similar to the
Cornish, but has two large flues containing the
fires instead of one. This boiler consists of a
horizontal cylindrical shell filled with water. It
uses to surround by two large fire tubes. Heat
exchanging is the basic working principle of
this boiler. It is has a shell and tube type heat
exchanging system. Generally, the flue gases
pass through the fire tubes and water flows
through the shell. In this way, the heat is
transfer from flue gases to the water. It is a
low pressure, internally fired, natural water
circulation boiler. That’s means this boiler
uses the natural current to flow the water
inside the boiler during its operation.
Cornish boiler
Cornish Boiler is a fire tube boiler. It was first
adapted by Richard Trevithick’s and, first
installed at Dolcoath mine in the year of 1812.
This boiler has a long horizontal cylinder with
a single large flue containing the fire. Cornish
boiler design has similarity with the
Lancashire Boiler. Cornish Boiler cylindrical
shell is about 1.25 m to 1.75 m in diameter.
The length of the shell can be varied from 4 to
7 meter. It has only one internal flue tube
inside the boiler and diameter of the flue tube
is 0.6 times the diameter of the cylindrical
shell.
Locomotive Boiler
A locomotive boiler is a Fire Tube Boiler. It is
a horizontal drum axis, multi-tubular boiler.
Because this boiler has 116 general fire tubes
and 38 super-heated fire tubes. Locomotive
Boiler is an internally fired boiler. That’s
means boiler furnace located inside the main
boiler shell or barrel. This boiler uses solid
fuel like coal. It is also a forced circulation,
mobile or portable type, and medium pressure
fire tube boiler. The most common use of this
boiler is in railway locomotive engines and in
the marine sector because of its mobility. This
boiler has a high steam generation rate
Water tube boilers

in water tube steam boilers, the water is contained inside the tubes (called water tubes)
which are surrounded by flames and hot gases from outside. Examples of water tubes are :
babcock and wilcox boiler, stirling boiler, la mont boiler, benson boiler, yarrow boiler and
Loeffler boiler.
Babcock and wilcox
boilers
This is a water tube boiler, used in steam
power plants. In this type of boiler, water is
circulated inside the tubes and hot gases flow
over the tubes. It is a straight tube, stationary
type water tube boiler. It consists of a steam
and water drum. It is connected by a short
tube with uptake header or riser at the back
end. Furnaces are located below the tubes and
drum.
 La-Mont boiler
A LaMont boiler is a type of forced circulation water-tube boiler[1] in
which the boiler water is circulated through an external pump through long
closely spaced tubes of small diameter. The mechanical pump is employed
in order to have an adequate and positive circulation in steam and hot water
boilers. A centrifugal pump which forms the heart of this boiler is
responsible to circulate water within the boiler system. It receives water
from the drum and delivers this water to a distribution header as shown in
the diagram here. The number of headers may differ in numbers and
depends on the size and boiler design of each boiler.The boiler heating
surfaces includes a number of tubes arranged in a parallel form and the inlet
ends are welded to the distributors or the headers. A circulation pressure is
to be provided during the installation of the pump as per the boiler design
and it should be sufficient to over come the resistance offered by the tubes.
An even circulation takes place with the helps of the inlet nozzles provided
at the inlet of tubes which creates the differential pressure adequate to cover
the variations occurring at fluctuating loads or uneven firing conditions. The
riser tubes outlet is welded to the collector headers and also directly to the
drum containing steam and water
Loeffler boiler
Loeffler boiler is a water tube boiler used for
generating steam by the burning of fuel which
is coal and further that is used for generation
of power. It is another extension of the
Lamont Boiler.
But the difference between Lamont and
Loeffler boiler is the Loeffler boiler can
generate steam with the use of saltwater and
there is no problem of Salt and sediment under
the boiler but in case of LaMont boiler it can
generate steam from the saltwater there is a
problem of salt and sedimenLoeffler boiler
generates steam 100 tones per hour.t under the
boiler surfaces.
Benson Boiler
Also known as supercritical steam generator is
a type of boiler that operates at supercritical
pressure, frequently used in the production of
electric power. n contrast to a subcritical
boiler in which bubbles can form, a
supercritical steam generator operates at
pressures above the critical pressure – 22
megapascals (3,200 psi). Therefore, liquid
water immediately becomes steam. Water
passes below the critical point as it does work
in a high pressure turbine and enters the
generator's condenser, resulting in slightly less
fuel use. The efficiency of power plants with
supercritical steam generators are higher than
with subcritcal steam
Difference between firetube boiler and water
tube boiler
Water tube boiler Fire tube boiler
The water circulates inside the tubes which The hot gases from the furnace pass through
are surrounded by hot gases from the the tubes which are surrounded by water.
furnace.
It can generate steam upto 24.5 bar.
It generates steam at a pressure upto 165 bar.
The rate of generation of steam is low, i.e,
The rate of generation of steam is high, i.e, upto 9 tonnes per hour.
upto 450 tonnes per hour.
The floor area required is more, i.e, about 8
For a given power, the floor area required sq-m per tonne per hour of steam generation.
for the generation of steam is less, i.e, about
5 sq-m per tonne per hour of steam Its overall effieciency is only 75%.
generation.
Over-all effieciency with economiser is upto
90%.
Difference between firetube boiler and water
tube boiler
Water tube boiler
It can be transported and erected easily as
its various parts can be separated.
It is preferred for widely fluctuating
loads.
The direction of water is well defined.
The operating cost is high
The bursting chances are more.
It is used for large power plants.
Fire tube boiler
The transportation and erection is
difficult.
It can also cope reasonably with sudden
increase in load but for a shorter period.
The water does not circulate in a definite
direction.
The operating cost is less.
The bursting chances are less.
It is not suitable for large plants.
Queries
Thank you