Power Stations Report 3

Boiler

Name: Ahmed Magdy Ibrahem Desouky

‫أحمد مجدي ابراهيم دسوقي‬

Section: 1

ID Number: 24

Code: 20190076

Supervised by : Professor Dr. Mohammed Nawar

Table of Contents
Introduction .................................................................................................................................................. 3
Boiler ............................................................................................................................................................. 3
Function of the boiler in power plants ......................................................................................................... 3
Components of the boiler ............................................................................................................................. 4
Burner ....................................................................................................................................................... 4
Combustion Chamber ............................................................................................................................... 4
Heat Exchanger ......................................................................................................................................... 4
Other Components ................................................................................................................................... 4
Classifications and Types of Boilers .............................................................................................................. 6
Classification based on Design: ................................................................................................................. 6
Fire-tube Boilers:................................................................................................................................... 6
Water-tube Boilers:............................................................................................................................... 6
Flash boiler: ........................................................................................................................................... 6
Electric Boilers:...................................................................................................................................... 6
Coil Boilers: ........................................................................................................................................... 6
Combi boilers: ....................................................................................................................................... 7
Condensing boilers:............................................................................................................................... 7
Based on Fuel Type: .................................................................................................................................. 7
Natural Gas Boilers: .............................................................................................................................. 7
Oil Boilers: ............................................................................................................................................. 7
Coal Boilers: .......................................................................................................................................... 7
Biomass Boilers: .................................................................................................................................... 7
Propane: ................................................................................................................................................ 7
Based on Application: ............................................................................................................................... 8
Residential Boilers:................................................................................................................................ 8
Commercial Boilers: .............................................................................................................................. 8
Industrial Boilers: .................................................................................................................................. 8
Based on Operating pressure.................................................................................................................... 8
Low-pressure boilers:............................................................................................................................ 8
High-pressure boilers: ........................................................................................................................... 8
Specifications of Boilers ................................................................................................................................ 9
Applications of Boilers ................................................................................................................................ 10

1
 Residential Applications: ......................................................................................................................... 10
Commercial Applications: ....................................................................................................................... 11
Industrial Applications: ........................................................................................................................... 11
Other Applications: ................................................................................................................................. 11
Boilers In Egypt ........................................................................................................................................... 12
Conclusion ................................................................................................................................................... 12
References .................................................................................................................................................. 13

2
• Introduction
Power station boilers are essential for electricity generation, converting fuel into
high-pressure steam that powers turbines.
Various fuels, including coal, natural gas, or biomass, are burned to produce heat,
turbines connected to generators.
Boilers are different in designs like fire-tube and water-tube, they play a vital role
in ensuring the efficiency and reliability of power generation.
technological advancements aim to enhance efficiency, reduce environmental
impacts, and improve the overall sustainability of power generation systems.

• Boiler

Boiler is an enclosed pressure vessel in which water is converted into steam by

gaining heat from burning fuel (coal , oil , gas …etc)
Boilers are used in power plants in order to produce high pressured steam, so that
the plant can generate electricity. Which has a great role in the Rankine cycle.
The boiler takes in energy from some form of fuel such as coal, natural gas,
or nuclear fuel to heat water into steam
The design of a boiler is an important factor in the power station’s efficiency , a
good design of a boiler can produce thousand tons of steam per hour and can have
an efficiency of 90%
Better design means a lower fuel requirement, lower costs and
lower emissions of pollutants.

• Function of the boiler in power plants

Boilers in power stations accumulates the steam and builds up pressure to expand it
in turbine and convert thermal energy into mechanical energy. The generator
which is connected to the turbine converts the mechanical energy into electrical
energy.

3
• Components of the boiler

Boilers consist of three main components which are :

- Burner
This is where mixing the air with the fuel happens , resulting in the combustion
which produces heat to produce steam.
The burner provides heat input by combustion of a heat source. In other words, it
initiates the combustion reaction within the boiler.
- Combustion Chamber
Combustion chamber is the part of a boiler in which the fuel/air mix burns. For this
reason, the combustion chamber is usually cast iron, and the temperatures inside
will rise to several hundred degrees. This process usually occurs in a very short
amount of time.
- Heat Exchanger
heat exchanger is a component of a boiler that allows heat to be exchanged
between two fluids or substances, usually water and gas, without letting the
substances mix together.
The heat exchanger of boiler allows the heat from the burner to heat the water in
system.
The job of the heat exchanger is to carry the heat from the burner to the water
without having direct contact with the water.
- Other Components
Responsible to send the right signal to the burner about when to
Aquastats stop or when to start the process.

Backflow valve acts as a safety unit, allowing the flow of the

Backflow Valve fluid only in a single direction

Pushes the hot water out through the supply lines to the
radiators or other distribution lines. The circulation pump plays
Circulator Pumps a crucial role in the functioning of your boiler and must be well
maintained to ensure the system is working as efficiently as
possible

4
 The system controls allow the user to set water temperature, air
and fuel supply mixtures, internal pressure and ignition.

The controls regulate how often the burner fires, the quality of
Controls the mixture of fuel and oxygen, the rate at which it uses the
fuel, and how hot the water will get.

The controls are also an important part of the safety system of

your boiler.
A deaerator is a device that removes oxygen and other
dissolved gases from liquids.

Deaerators/Condensers A condenser is a heat exchanger that removes the latent heat

from the exhaust so that it condenses and can be pumped back
into the boiler.

Economizer A heat exchanger that is in the exhaust from a boiler

Exhaust Stack Safely expels spent fuel away from the building’s exterior.
Responsible for protecting the boiler from excessive pressure
Expansion Tank and ensures its safety along the process.
the supply lines are the pipes that distribute the hot water or
steam to distributor.
Supply Lines These parts of boiler are pipes that are responsible for
delivering the heated stream of fluid to the distribution points in
the boiler.
Refractory materials that are used for filling any gaps and/or
Refractory openings that may be around the fire box. This helps ensure the
fire stays in the fire box.
Return lines are responsible for bringing the cooled fluid or the
Return Lines cooled steam back to the boiler to heat it up again.
A superheater is an integral part of a boiler.
Superheater is placed in the path of hot flue gases from the
Superheater furnace. The heat recovered from the flue gases is used in the
steam before entering into the turbine.

5
• Classifications and Types of Boilers
Boilers can be classified based on various factors,
including their design, fuel type, and application.
- Classification based on Design:
Fire-tube Boilers:
These boilers have tubes filled with water and the hot gases from combustion pass
through these tubes. They are typically used for low-pressure steam and hot water
applications.

Water-tube Boilers:
In water-tube boilers, water flows through the tubes, and the hot gases from
combustion surround the tubes. They are commonly used for high-pressure steam
and hot water applications.

Flash Boiler:
A particular kind of water-tube boiler called a flash boiler pumps water through
closely spaced tubes. A flash boiler is not the same as a mono-tube steam
generator, where the tube is not replaced with water over time. The tube of a flash
boiler is maintained at such a high temperature that the water supply is instantly
flashed into steam and superheated.

Electric Boilers:
Electric boilers use electricity as the source of heat and do not require combustion.
They are compact and often used in residential or small-scale applications.

Coil Boilers:
Also known as instantaneous or flash boilers, heat water on demand as it flows
through a heat exchanger. They are often used for domestic hot water supply.

6
Combi Boilers:
Combine space heating and domestic hot water production in a single unit.

Condensing Boilers:
Condensing boilers are designed to extract additional heat from the combustion
gases by condensing the water vapor present in the exhaust. This increases the
efficiency of the boiler and reduces energy waste.

- Based on Fuel Type:

Natural Gas Boilers:
These boilers use natural gas as the primary fuel source. They are popular due to
the availability and relatively low cost of natural gas.

Oil Boilers:
Oil-fired boilers use oil as the fuel source. They are commonly used in areas where
natural gas is not readily available.

Coal Boilers:
Coal-fired boilers burn coal to generate heat. However, their use has declined due
to environmental concerns and the availability of cleaner fuel alternatives.

Biomass Boilers:
Biomass boilers use organic materials, such as wood pellets, agricultural waste, or
dedicated energy crops, as fuel. They are considered a renewable energy option.

Propane:
Typically used in rural areas or for backup power.
7
 - Based on Application:
Residential Boilers:
These boilers are designed for heating homes and providing hot water for domestic
use.

Commercial Boilers:
Commercial boilers are larger and more powerful than residential boilers. They are
used in buildings such as offices, hotels, schools, and hospitals to provide heating
and hot water.

Industrial Boilers:
Industrial boilers are used in various industries, including manufacturing, chemical
processing, refineries, and power generation. They can produce high-pressure
steam or hot water for industrial processes.

- Based on Operating pressure

Low-pressure boilers:
Operate below 15 psi, commonly used in residential settings.

High-pressure boilers:
Operate above 15 psi, typically used in industrial applications.

8
• Specifications of Boilers

Specifications of boilers depend on their type, size, and intended application.

- Specifications of boilers :
Capacity: The capacity of a boiler refers to the amount of steam or hot water it can
produce per unit of time. It is usually measured in terms of pounds of steam per
hour (lb/hr) or gallons of hot water per hour (gal/hr).

Pressure: Boiler pressure is the measure of the force exerted by steam or water
within the boiler. It is typically expressed in pounds per square inch (psi) or bar.
The pressure rating of a boiler determines its suitability for different applications
and operating conditions.

Temperature: The temperature specification of a boiler indicates the maximum

temperature that the boiler can reach. It is important to ensure that the boiler is
designed to handle the required temperature for the intended application.

Efficiency: Boiler efficiency refers to the ratio of heat output to the fuel input,
indicating how effectively the boiler converts fuel into usable heat. It is usually
expressed as a percentage. Higher efficiency boilers are more energy-efficient and
can help reduce fuel consumption and operating costs.

Fuel Type: The fuel type specification indicates the type of fuel that the boiler is
designed to use, such as natural gas, oil, coal, biomass, or electricity. The fuel type
determines the combustion process and the associated equipment required for fuel
delivery and combustion control.

Design Pressure: The design pressure is the maximum allowable pressure that a
boiler is designed to withstand. It ensures the safe and reliable operation of the
boiler under normal operating conditions.

9
Emissions: For boilers that combust fossil fuels, emissions specifications may be
provided to indicate the maximum allowable levels of pollutants, such as nitrogen
oxides (NOx), carbon monoxide (CO), and particulate matter. Compliance with
emissions regulations is important for environmental considerations.

Safety Features: Boilers often include various safety features, such as pressure
relief valves, temperature controls, flame safeguards, and low-water cutoffs. These
features help ensure safe operation and protect against potential hazards.

• Applications of Boilers
Boilers play a vital role in various aspects of our lives, providing heat and power
across different sectors.

- Residential Applications:
Space Heating: Boilers are commonly used to heat homes and buildings through
radiators, baseboards, or hydronic air handlers. They offer efficient and reliable
heating solutions.
Domestic Hot Water: Boilers can also provide hot water for showers, faucets,
washing machines, and dishwashers. This eliminates the need for separate water
heaters and offers a convenient all-in-one solution.
Combi Boilers: These compact units combine space heating and domestic hot
water production, ideal for smaller homes or apartments.

10
 - Commercial Applications:
Office Buildings and Hotels: Boilers provide efficient heating and hot water for
large buildings and complexes. They can be customized to meet specific needs and
ensure consistent comfort.
Restaurants and Food Processing: Boilers are used for cooking, cleaning, and
various processing tasks in the food industry. They offer reliable and controllable
heat sources for various operations.
Laundromats and Dry Cleaners: Boilers provide hot water for washing and
drying clothes in commercial laundry facilities. They ensure efficient and high-
volume water heating capabilities.

- Industrial Applications:
Power Generation: In thermal power plants, boilers generate steam to drive
turbines and produce electricity. They are crucial components in energy production
infrastructure.
Manufacturing Processes: Boilers are used for heating various materials and
processes in diverse industries like chemical manufacturing, textile production, and
food processing.
Sterilization and Disinfection: Boilers provide steam for sterilizing medical
equipment and disinfecting surfaces in healthcare facilities.

- Other Applications:
Steam Cleaning: Boilers generate high-pressure steam used for cleaning various
surfaces and equipment, offering a powerful and effective cleaning method.
Humidification: In controlled environments like greenhouses or museums, boilers
can be used to generate steam and maintain proper humidity levels.
Snow Melting: Boilers can be used to melt snow and ice on sidewalks, parking
lots, and other outdoor areas, ensuring safe and clear access.

11
• Boilers In Egypt
The most common boiler types in Egypt: Natural gas and electric boilers.
Availability: Natural gas availability can vary depending on the region.
Climate: Egypt's warm climate might require less heating than colder regions,
impacting boiler size.
Local regulations: Check local regulations regarding boiler installation and safety
standards.

• Conclusion

In summary, power station boilers are vital for electricity generation, converting
heat into steam to drive turbines.
Ongoing advancements aim to make boilers more efficient and eco-friendly. As the
world seeks cleaner energy solutions, integrating renewables like biomass and
solar becomes crucial.
Balancing energy demands, environmental concerns, and technological progress is
key for a reliable and sustainable energy future.

12
• References

1. Boiler Manufacturers Association - https://www.abma.com/

2. • U.S. Department of Energy - Boilers -

https://www.federalregister.gov/documents/2020/01/10/2019-
26356/energy-conservation-program-energy-conservation-standards-
forcommercial-packaged-boilers

3. • National Board of Boiler and Pressure Vessel Inspectors -

https://www.nationalboard.org/

4. • American Society of Mechanical Engineers (ASME) - https://www.asme.org/

5. • Types of Boilers and Their Applications - https://cleaverbrooks.com/trends-

inprocess-heating

6. • Choosing the Right Boiler for Your Needs -

https://www.consumerreports.org/appliances/boilers/buying-guide/

7. • How Boilers Work - https://ranshaw.com/help-guides/tips/how-does-a-

boiler-work

13