Peralatan dan Mesin Industri (TIN326) -

Ono Suparno

Industrial Equipment and Mechinary (TIN326)

BOILER

Ono Suparno

Department of Agroindustrial Technology

IPB University
Bogor
TIN326-Ono Suparno 1

WATER PHASE CHANGE ENERGY

• Sensible heat = heat that causes an increase or decrease in

temperature, but the phase does not change
• Latent heat = heat required to change the phase of an object, but
the temperature remains constant
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STEAM
Ø A fluid which is the gas phase of water, when is heated
to a boiling temperature under a certain pressure.
Ø Colourless, not even visible when in a pure dry state.
Ø Water vapour was first used as a working fluid by
James Watt, who is the inventor of the piston steam
engine.
Ø Water vapour does not follow the gas laws perfectly,
until it is completely dry (100% vapour content).

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STEAM FORMATION PROCESS

a-b = heat applied to raise the water
temperature from 0 oC to 100 oC
under heating up to 100 oC (under
atmospheric pressure 1 atm = 1.003
kg/cm), sensible heat.
b-c = heat applied to change the
phase from 100 oC of water to 100
oC of saturated steam (at latent
heat).
Q1 Q2 Q3 c-d = heat applied to raise the
temperature of 100 oC of saturated
steam to dry steam (further steam
heating) in the sensible heat
process.

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ADVANTAGES OF USING WATER VAPOUR

AS A WORKING MEDIUM
Ø Has the ability to receive large amounts of heat
Ø Produced from materials that are cheap and
easy to obtain
Ø Can work at high pressure
Ø Non-flammable and non-toxic
Ø Quickly conducts heat

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TYPES OF STEAM

1. Wet steam, steam that still contains fine

droplets of water
2. Saturated steam, steam that is between wet
steam and dry steam (steam that does not
contain water droplets anymore)
3. Superheated steam (dry steam), steam
produced by the process of superheating of
saturated steam

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Ø The quality of hot water vapour is expressed in

%, for example 95%
Ø Saturated dry steam ≈ 95% dry steam
Ø Energy ≈ 95% x 970.4 Btu/lb ≈ 921.8 Btu/lb

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BOILER
v A closed steam boiler and the heat of
combustion is passed on to the water until it
becomes steam.
v The hot steam under pressure can be used for
an industrial process.

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BOILER SYSTEM PARTS

1. Fuel system, the whole system for heating a

steam boiler, fuel equipment depends on the
type of fuel.
2. Hot steam system, a system that
accommodates steam needs and controls it
according to production needs, and regulates
steam pressure according to production
needs.
3. Feed water system, a boiler system that
supplies all water exits into the boiler drum.
TIN326-ONO SUPARNO 9

BOILER MAIN COMPONENTS

1. Furnace (combustion chamber) as a tool to

convert chemical energy into heat energy
2. Steam drum that converts combustion energy
(heat energy) into steam potential energy
(heat energy)

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IDEAL BOILER REQUIREMENTS

1. Can produce maximum amount of steam with minimum amount
of fuel.
2. Steam capacity and working pressure must be constant.
3. The combustion device is able to burn the fuel elements
perfectly so that optimal results can be obtained.
4. Water circulation must be good in order to obtain an even
temperature throughout the boiler, so the absorption of heat by
water is more effective.
5. The boiler construction is simple, so that the manufacturing,
operation and maintenance costs are more economical and
space-saving.
6. The boiler equipment must function properly, so that the boiler
can operate properly and safely.

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Types of Boiler
1. Fire-tube boilers
Ø It is the development of the fire tunnel boiler by
adding fire pipes, where the hot gases from the
combustion chamber flow in it, so that it will heat
and evaporate the water around the fire pipes.
Ø Fire pipes are submerged in water to be evaporated.
Ø The volume of water is approximately 3⁄4 from the
boiler tank.
Ø Widely used for processing industries ranging from
small to medium scale.

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2. Water-tube boilers
Ø Boiler feed water flows through the pipes into the
drum.
Ø The circulating water is heated by the combustion
gases to form steam in the steam region of the
drum.
Ø This boiler is chosen if the steam demand and steam
pressure are very high such as a boiler for electric
power generation.

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Fire-tube boilers

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Fire-tube boilers
Advantages:
• Does not require high quality boiler filling water.
• Simple construction for easier maintenance.
• Sludge deposits are easier to clean.

Weakness :
• Preheating takes a long time.
• The resulting vapour pressure is low.
• The resulting steam capacity is small.

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Water-tube boilers

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Water-tube boilers
Advantages :
• Able to work with high pressure.
• The weight of the boiler is relatively light.
• Large capacity.
• Can be operated quickly, so in a short time has been able to
produce steam.

Weakness:
• Boiler construction is no longer simple, so maintenance is more
difficult.
• The filling water must always be clean, so that the formation of
boiler stones does not occur.
• Planning is more difficult so it is expensive.

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Equipment
Pressure gauge (manometer)
Water level measuring cup
Safety valve
Water pump
Safety plug

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1. boiler drum with insulation

2. reversing chamber
3. pressure regulators
4. over pressure cut-off
5. manometer with control valve
6. water level regulator and 1st low
water cut-off
7. 2nd low water cut-off
8. control panel
9. main steam valve
10. safety valve
11. Two water gauges
12. flue-gas connection
13. safety flap
14. feed pump(s) complete with fittings
15. base frame
16. oil-, gas-or dual fuel burner

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FACTORS AFFECTING BOILER PERFORMANCE

1. Pressure
2. Temperature
3. Capacity
4. Efficiency

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PRESSURE

Ø Pressure generated from the steam boiler.

Ø The pressure on the boiler shows how far the
workload from the boiler and can be seen from
a pressure gauge.
Ø The lower the pressure generated in the boiler,
the better the boiler will work.

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TEMPERATURE

Ø The heat generated by a steam boiler, usually

measured in Celsius or Kelvin.
Ø High temperatures are greatly influenced by the length
of time the machine works.
Ø Steam boiler temperatures:
1. Super heater steam, the resulting temperature is
according to the desired design on the boiler.
2. Saturated steam, the resulting temperature is in
line with the pressure.

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CAPACITY

Ø The maximum capacity of the boiler to produce steam

in ton/hour.
Ø A measure that states the boiler's ability to generate
hot steam.
Ø Expressed in boiler horse power (BHP) ≈ 33,472
Btu/hour ≈ heat to evaporate 34.5 lb of water (100 oC)
Ø In practice à kg of hot steam/hour

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EXAMPLE
A total of 2,000 lb of water with a specific heat capacity of 1.0 is
heated from 60 oF to 160 oF for 1 hour. Calculate the boiler capacity!
Answer:
Boiler capacity
weight of water per hour x specific heat x change in temperature
= -------------------------------------------------------------------------------------
33,472 Btu/hour

= (2,000 x 1.0 x 100) / 33,472 = 5.96 BHP

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EFFICIENCY

Ø Efficiency is a barometer of the performance of an

engine.
Ø Steam boiler engine efficiency: the value of the boiler
performance capability level obtained from the
comparison between the energy output and the
energy input.
Ø The direct method or input-output; output (steam),
input (fuel).

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BOILER EFFICIENCY
!"!#$% &'()'(
𝐵𝑜𝑖𝑙𝑒𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = x 100%
!"!#$% *")'(
+ (-$ .-/)
𝜂 𝐵𝑜𝑖𝑙𝑒𝑟 = x 100%
1 x 234

Q = Total steam yield (kg/hour)

q = Total fuel consumption (kg/hour)
hg = Enthalpy of saturated steam (kcal/kg)
hf = Enthalpy of feed water (kcal/kg)
GCV = Gross heat value of fuel (kcal/kg)

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EXAMPLE
Boiler with total steam yield of 1,416.667 kcal/hour, total fuel consumption of 235
kcal/hour, steam pressure of 8.9260 bar, and gross heat value of fuel 4,150
kcal/kg. Temperature of steam 75 oC and temperature of feed water 50 oC. What
is the % efficiency of the boiler?
Answer:
Q = 1,416.667 (kcal/hour), q = 235 (kcal/hour), P steam = 8.9260 bar, t steam =
175 oC, t fw = 50 oC, GCV = 4,150 (kcal/kg)
To find enthalpy steam, and enthalpy feed using chemicallogic steamtab
companion software, we get: hg = 2,772.71 kJ/kg and hf = 209.342 kJ/kg
Then convert from kJ/kg to kcal/kg
hg = 2,772.71 (kJ/kg) = 662.4 (kkal/kg)
hf = 209.342 (kJ/kg) = 50.012 (kkal/kg)

1,416.667 × (662.4 − 50.012)

ƞ Boiler = -------------------------------------- × 100%
235 × 4,150
= 88.91%
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ono.suparno@apps.ipb.ac.id
http://ono.suparno.staff.ipb.ac.id

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