Schematic of Large Boiler

Drum
Slag
Screen
RR
RS

CR

CS

E
APH

Water-wall

ESP
Ring
Header

Water Wall
Water Wall

Superheater

Drum
Internal

Types of Firing
Stoker/Grate Firing: Suitable for relatively small
boilers (Steam Generation <65 tons/hr).
Burner Firing: Can be oil, gas or coal (in pulverized
form) firing.
Cyclone Furnace Firing:
Fluidized Bed Firing: Suitable for low grade solid
fuels.

Stoker Fired Boiler

Combustion
Efficiency Low
Coal lumps are fired.
Problem associated
with oxygen diffusion.
Chance of incomplete
combustion and
unburnt fuel loss is
high.

Pulverized Coal Fired Boiler

PA carries the
coal to the
furnace
through burner

Drum

CR

RR
RS

CS

PA is 30% 50% of total

air

E
APH

Amount of PA
depends on
moisture
content of coal

Coal Dust + PA
from APH

SA from APH

ESP

Pulverization Systems
Central type and Individual type
Unit-1

Unit-2

Mill-1

Mill-2

Unit-3

Unit-1

Unit-2

Mill-3

Individual Type

In central type:
cost is low
Reliability Low
Logistics is complicated

Central PF
Mill/Bunker
Central Type

Unit-3

Closed Type Pulverization System

Raw Coal
Bunker
Coal
Feeder
Dust
Separator
Secondary
Mill air (SA)

Boiler

Coal
Burner

Air
Pre-heater

Cold air for mill

ventilation

Primary air (PA)

(250oC 400oC)

Closed Type Individual System

FD Fan

Open type Pulverization System

Dust
Collector

Separated gas

Cyclone
Raw Coal
Bunker

SA

Boiler

Coal
Feeder

Grinding
Mill

Air
Pre-heater
PA
FD Fan
Dust Bunker PF Feeder
Hot gas

Open Type Individual System

Turbulent Burners and Arrangements

Fuel-oil
burner

Secon
dary
air

Fuelair
mixture

Two Scroll Burner

Vorticity Parameter, n = 4Vt / Va
Vt : maximum tangential component of
the flow velocity at the burner exit
Va : axial velocity component.
n ranges from 1.5 to 5
Primary flow velocity: 16 25 m/s
Secondary flow velocity: 1.3 to 1.4 times
primary velocity

Two Scroll Burners in which

two scrolls are provided for
whirling the dust-air mixture and
secondary air
Single Scroll Burners in
which the dust-air mixture is
supplied in a straight flow and
spread by a dissector and the
secondary air is whirled in a
scroll.
1 kg to 3.8 kg of fuel per
second
25 MW to 100MW of power

Turbulent Burners and Arrangements

Front Firing

Opposed Firing

Opposed Firing on
Sidewalls

Straight Flow Burners and

Arrangements
Primary flow velocity: 20-28
m/sec
Secondary flow velocity: 1.5 to
1.7 times primary flow velocity

Fuel-air
mixture
Secondary
air

Straight Flow Burner

Opposed
Displaced
Firing

Corner Firing with

Encountering Jets

Corner Firing with

Tangential Jets

Vertical
Firing

Dry and Wet Bottom Furnaces

Molten slag

Furnace
Burner

Furnace
Burner

Ash
hopper
Water tank

Dry Bottom Furnace

Slag tank/Water tank

Wet Bottom Furnace

Cyclone Furnace
Secondary air
Cooling water

Molten slag

Air + Fuel

Schematic Diagram of a Cyclone

Furnace

High heat release rate

Water cooled surfaces are studded
and covered with refractory chrome
ore.
Crushed coal used (95% will pass
through a 4-mesh screen)
Primary air is about 20% of the
combustion air
Secondary air velocity around 300
ft/s.
The incoming coal particles are
thrown to the walls by centrifugal
force, held in the slag and
scrubbed by the high velocity
tangential secondary air.
Very high heat loss through molten
slag

Fluidized Bed Combustion

CD Ac f (vf2/2) = Vs s g
CD is the drag coefficient
Ac is the cross sectional area of the particle
f is the fluid density, vf is the fluid velocity
Vs is the volume of the particle
s is the density of the particle
W

For spherical particles

vf = [(8/3CD)(s/f)(rg)]
r is the radius of the particle

Fluidized Bed Boiler

Flue gas
Drum
Cyclone

Convective
Tube-bank
Coal &
Limestone
Hopper

Submerged
Tube-bank
PA + Fuel

FD Fan

SA
Bed Drain Tube

Fluidized Bed Boiler

Desulphurization is accomplished by the addition of limestone
directly to the bed together with the crushed coal. Limestone
absorbs sulphur dioxide with the help of oxygen from the excess air.

CaCO3 + SO2 + (1/2)O2 CaSO4 + CO2

The calcium sulphate produced in this process is a dry waste product
that is either regenerated or disposed off. Reductions in sulphur
dioxide up to 90% have been achieved in fluidized bed pilot plants.

Fluidized Bed Boiler: Advantages

Low combustion temperatures
Allows inferior grades of coal to be used without slagging problems.
The carbon and ash carryover in the flue gas does not reach
temperatures at which they become soft and foul heat transfer surfaces.
The low temperature combustion results in substantial reduction in the
emission of oxides of nitrogen.
Cheaper alloy materials may be used resulting in economy of
construction.
Absence of pulverization equipment, resulting in further economy through
power savings.
A fluidized bed combustor can be designed to incorporate the boiler within
the bed, resulting in surface heat transfer rates that are 2 to 3 times
higher than a conventional boiler. A fluidized bed steam generator is
therefore much more compact than a conventional one of same capacity.
Reduction in sulphur dioxide: lower stack temperature can be achieved
because less acid is formed as a result of the condensation of water
vapour.