2.

11 Steam Generator Materials

2.11.1 Pressure Parts Materials Selection

The chosen material was Nickel-Based Alloys (Inconel, 825). These materials offer exceptional

resistance to high-temperature oxidation and corrosion. They are suitable for severe

environments, such as those encountered in high-pressure boilers. Inconel 825 has a tensile

strength of approximately 760 MPa (110,000 psi). It has a yield strength of approximately 345

MPa (50,000 psi)

2.11.2 Structural parts materials selection

For the structural parts section of the steam generator, the chosen material was Austenitic

stainless steels which offer good corrosion resistance and high-temperature strength, making

them suitable for steam generator tubes and pressure vessels.

2.11.3 Bricks, refractory, insulation, and lagging materials selection

All the nonferrous parts of a boiler are known as bricks, refractory, insulation, and lagging

(BRIL). The boiler setting or enclosure, which is the assembly surrounding all the hot parts, is

substantially made of BRIL so that;

1. The heat is contained within the boiler.

2. Heat loss is restricted to a minimum.

3. Personnel safety is ensured.

As the boiler sizes have increased along with greater water wall cooling and more sophisticated

steels, the significance of BRIL has considerably altered. With the improved awareness for

esthetics, environment, and human comfort, there is more insulation and lagging in boilers and

the increased use of membrane panels and the progressive discontinuance of many mass burning

practices have made the refractory bricks practically obsolete and increased the use of castable

refractories (GazoGenerator, 2013)

Refractories

Pure silica or silica combined with other materials is used to create silica refractories. They have

strong strength at high temperatures, excellent thermal resistance, and little thermal expansion.

Coke ovens, glass industry furnaces, and other high-temperature applications frequently use

silica refractories.

Insulation

Insulating materials

A common insulating material noted for its superior thermal performance, fire resistance, and

soundproofing properties is mineral wool, which includes rock wool and glass wool. It is used in

a variety of places, including HVAC ducts, walls, and roofs.

Lagging

Lagging is a material providing heat insulation for a boiler, pipes, etc. It is a kind of galvanized

sheet that is typically 1 mm thick and used as protective gear to act as an insulator between tiny

gaps of machinery to regulate the amount of heat transmission and heat flux.
 2.12 Pipe/tube wall thickness calculation

For thickness of tube,

PD
t= +0.005 D+e
2 Sw+ P

14.898675 MPa( 885 mm)

t= + 0.005(885 mm)+0.15
2(275 MPa)(0.77)+14.898675 MPa

t=34.65111137 mm

For Piping, Drums, Shells, and Headers based on strength of weakest course,

PD
t= +C
2 SE+2 yP

14.898675 MPa(885 mm)

t= +1.74 mm
2(275 MPa)(1)+2(0.7)(14.898675 MPa)

t=24.83737978 mm

2.8 Motor Drives Sizing

Fan Drive Motor Sizing

Compressibility 1.0 1.05 1.1 1.15

Factor

Pressure Ratio 1.0 0.98 0.97 0.95

 Table xx. Compressibility Factor

Forced Draft Fan

1
3 1417.52 Pa
after altitude correction m 1000
P=design duty x ( )=31.72780611
fan efficiency s 0.7

= 64.24971388 x 1.15 = 73.88717096 kW

Induced Draft Fan

1
3 1447.68 Pa
after altitude correction m 1000
P=design duty x ( )=53.8886012
fan efficiency s 0.75

= 104.0179336 x 1.15 = 119.6206236 kW

For Pump Power

P pump =(9.837 x 0.954 x volume flow x static head )/fan efficiency

3
m
P pump =(9.837 x 0.954 x 0.1051425394751 x 933.0764376 m) /0.75
s

P pump =1227.567741 kW