Sinai University

Faculty of Engineering

Thermal Power Station

ENM 4231
Credit Hours
Lecture Lab/Tutorial Total
2 2 3
Assoc. Prof- Ashraf Amin
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Ashraf.eltrahy@su.ed.eg
 Steam generators technology
Steam Boilers
What is a Boiler?
• Vessel that heats water to become hot water or steam
• Hot water or steam used to transfer heat to a process

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 A boiler should fulfill the following requirements :

(i) Safety. The boiler should be safe under operating conditions.

(ii) Accessibility. The various parts of the boiler should be accessible for repair and
maintenance.

(iii) Capacity. The boiler should be capable of supplying steam according to the requirements.

(iv) Efficiency. To permit efficient operation, the boiler should be able to absorb a maximum
amount of heat produced due to burning of fuel in the furnace.

(v) Its initial cost should be low.

(vi) The boiler should be capable of quick starting and loading.

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 Types of Boilers
The boilers can be classified according to the following criteria.
1-According to flow of water and hot gases.
- Water tube. - Fire tube.
2-According to position of furnace.
-Internally fired -Externally fired

3-According to the position of principle axis.

- Vertical -Horizontal -Inclined.
4-According to application.
- Stationary -Mobile, (Marine, Locomotive).
5-According to the circulating water.
-Natural circulation -Forced circulation.
6-According to steam pressure.
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- Low pressure -Medium pressure -Higher pressure.
 Type of Boilers
. Fire Tube Boiler . Water Tube Boiler

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 Comparison of fire tube and water tube boilers
Particulars Fire-tube boilers Water-tube boilers
Position of water and hot Hot gases inside the tubes and water Water inside the tubes and hot gases
gases outside the tubes outside the tubes

Mode of firing Generally internally fired Externally fired

Operation pressure Limited to 16 bar Can go up to 100 bar
Rate of steam production Lower Higher
Suitability Not suitable for large power plants Suitable for large power plants

Floor area For a given power it occupies more For a given power it occupies less floor
floor area area
Construction Difficult Simple
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 -Natural circulation -Forced circulation.

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 Components of Steam Boiler
-Furnace (burner- evaporator tube)

2- Superheater coils

3- Economizer coils

4- Air heater

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 Superheated steam to Turbine
ms = 150 ton/hrs, P

Dry Steam
s

Steam Sla
g scr
een Flue gases Flue gases

Superheater

ce

Economizer
R

Hot feed water

rna
ec

Water wall
ir
cu

Below down tubes

Fu
la

Feed water
tio

pump
n

Flame

Chimney
Flue gases

Fuel Hot air Cold air

Air heater
Burner

Waste gases

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Lay-out of boiler components
Horizontal fire tube boiler

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Vertical water tube boiler

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 Heat balance of boiler and boiler efficiency
Q i  Q fuel  Q air
Q fuel    H.V
m f

Q air  C
m air p  air ( t hot air  t sourr )

Direct boiler efficiency:

Q useful
b 
Qi
Q useful  m s (h s . s  h fw )  Q others
Q others  Q below down  Q reheat
Indirect boiler efficiency:
Q i  Q useful  Q Loss

Q Loss  Q fuel loss  Q radloss  Q wastegases

b  100  ( q loss ) indirect boiler efficiency

qi
q loss is the relative heat loss ( )
Qi
b  100  (q 2  q 3  q 4  q 5 )

q2 relative heat loss by waste gases

q3 relative heat loss by incomplete combustion
q4 relative heat loss with unburned carbon
q5 relative heat loss due to physical heat of slag
.
Q wastegases m g C pg ( Twg  Tca )
q2  
Qi Qi
 Example
A steam boiler generates 100 ton/hr of steam at 50 bar and 450 oC. The boiler operates
at the following conditions:
-Feed water temperature is 150 oC,
-Cold air temperature is 35 oC, and hot air temperature equals 120 oC,
--Fuel with 40000 kJ/kg heating value and air-fuel ratio is 21,
-The adiabatic flame temperature is 1800 oC,
-The value of heat added by radiation is 25% of the evaporator heat added,
If the boiler efficiency is 95% calculate the following:
i- The temperature gradient along the boiler sections,
ii- The radiant surface area of evaporator: if fuel emissivity is 0.95. Assume any
missing data.
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iii-
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Estimate the super heater and economizer area if U is 12 kW/m .k.
 ms =150 ton/hrs, Pss= 50 bar, tss =450 oC (hss)
H.V = 40000 kJ/kg

Q fuel    H.V
m f
TFe
A/F = 21 TSHe

 m
m  m

gas f air

mbw =0
TECe mfw =ms
Qevap (w.w.t)= Q conv + Q rad
Tha =150 oC Tca =35 oC
Qevap (w.w.t)= Q conv + Q rad
.
Q useful m s ( h ss  h fw )
b  
Q
17 i
Q fuel  Q air Twg =150 oC
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- Heat Transfer method

- Tube geometry

- Flow direction of steam

and gases
- Heat Transfer method

a- Radiant superheater
b- Convective superheater
c- Semi-Radiant superheater
Radiant and Convective Superheater and Reheater
- Tube geometry

a- from finned tubes b-from cross-finned (gilled

tubes)

From special materials (stainless-sameless) , with inner diameter between 30-50 mm of supreheaters and about 60
mm of reheaters…..why???????????
Generally, 50.8 and 63.5 mm tubes are extensively used for SH application in power boilers and 38.1, 44.5, and 50.8
mm tubes in industrial boilers.
- Flow direction of steam and gases

a- counter flow b-parallel flow c-d- mixed flow

a platen is a set of closely packed tubes appearing like a plate. Platen surfaces are placed in the upper part,
the open pass, of the furnace and are meant to pick up heat entirely by radiation. There is a strong slagging
tendency of the flue gases in the temperature range in which the platens are located— approximately 1000–
1200°C.
Photo of Platen Superheater
 - Economizers
- Coils from steel pipes with Usually smaller tubes with 38.1, 44.5 and 2.5-3 mm thickness are connected with header.
-it should reject gases or steam from inside economizer. why?????????????????
- It can be classified to non-boiling economizer and boiling economizer (x<=0.25)

(a) Single tube per loop. (b) Two tubes per loop.
 - Air Preheaters
The air heater is usually the last heat trap in the boiler. Air heater exit gas
qu = qf + qair Tfw
temperature should be higher than the corrosion limit of the AH internals Tg5
Tg5 = 350-450 oC Tha

and the downstream equipment. Air heaters generally operate in a Twg= 120-160 oC
Tca
temperature range of 450–120°C on the gas side and 150–450°C on air side.
Twg

1- Tubular air heater (Recuperative) 2- Rotary regenerative air heater