Chapter 2 Boiler System

HEAT and ELECTRCITY GENERATION
BOILER SYSTEMS
What is a boiler?
 Vessel that heats water to become hot water or steam

 At above atmospheric pressure water volume may increases 1,600 times
 Hot water or steam can be used to transfer heat to a process
 2 Types of Boiler:
 WATER TUBE
 FIRE TUBE
 FACTORIES AND MACHINERY (STEAM BOILER AND UNFIRED PRESSURE
VESSEL) REGULATIONS, 1970
 Factories and Machinery (Certificates Of Competency Examinations) Regulations,
1970 and Factories and Machinery (Person In Charge) Regulations, 1970
Introduction
STEAM TO
EXHAUST GAS VENT
PROCESS
STACK DEAERATOR
PUMPS
ECO-
NOMI-ZER
VENT
BOILER
BURNER
WATER SOURCE
BLOW DOWN
SEPARATOR FUEL
BRINE
CHEMICAL FEED
SOFTENERS
3
Figure: Schematic overview of a boiler room
Main Feature Of Boiler:
TWO important streams which are:
a.) Water/Steam Stream ( normally in tubes ).
b.) Fuel Stream

(Coal/Biomass or Fuel Gas such as
Methane/Propane ).
Boiler Components
1. Drum – Main steam drum/ - Lower drum
2. Header
3. Boiler tube – Riser / generating tube
- Downcomer tube
- SH tube
4. Tube plates
5 Furnace / chamber
6. Baffle plate
7. Door – Explosion door - Expansion door - Inspection door
BBB / SHMS
Boiler Components
8. Fan – FD fan/ - ID fan - Secondary air fan

9. Shoot blower
10. Economizer
11. Heaters
12. Dust cyclone
13. Burner
14 Fire grate – moving - sliding
- damping
BBB / SHMS
Induced Draft (ID) Fan:- A fan is used
to extract the air from boiler post
combustion via (Electrostatic
Precipitator if present) to exhaust
through the chimney.
Forced draft (FD) Fan:- A fan is used

to force air into the boiler to provide
air for combustion.
An electrostatic precipitator (ESP) is

a device to separate fine particles
from a flue gas by charging the
particles and driving them toward the
collecting plate using electrostatic
forces.
Palm Oil Mill Boiler
BBB / SHMS
Steam Turbine
Boiler Make-up Water (BFW) specifications
Boiler Make-up Water (BFW)
Boiler corrosion leads to localized pitting and/or thinning of pipe and tube
surfaces, resulting in leaks and tube failures.
Corrosion also leads to fouling when precipitated metals settle onto

heat exchange surfaces. These problems can lead to costly downtime
and repairs.
Boiler Make-up Water (BFW)
In the presence of oxygen and water, boiler system

corrosion occurs as metals attempt to revert to their
natural state (such as iron oxide Fe2O3 or Fe3O4).
Other problems include corrosion beneath deposits

and in mechanically-stressed areas, and corrosion
due to the presence of carbon dioxide dissolved in
water (condensate).
Boiler corrosion is accelerated by high

temperatures and low pH. Boiler operations should
also be continually monitored for hardness, iron,
copper, oxygen, and pH.
PALM OIL MILL BOILER SYSTEM
To process
Boiler
Deaerator Chemical dosing
1600kW B.P.V
Boiler feed Turbine
pump
Deaerator
pump
Feed water tank

PALM OIL MILL BOILER
 Fuels (fibre & shell) are

used to boil water for
steam generation at
pressure of 22 barg.
 To generate steam for
turbine operation to
produce electricity.
 To generate steam for
other processes.
STEAM TURBINE
 Converts part of the thermal energy of the steam
into mechanical energy.
 The driven equipment is a generator, then convert
this mechanical power into electrical power.
THERMAL DEAERATOR
 A device for air removal and is used to remove

dissolved gases (an alternate would be the use
of water treatment chemicals) from boiler
feedwater to make it non-corrosive.
 The feedwater is sprayed in thin films into a

steam atmosphere allowing it to become
quickly heated to saturation.
The purposes of Thermal Deaeration(Deaerator):
1. To remove oxygen, carbon dioxide and other non-condensable gases

from feed water.
2. To heat the incoming makeup water and return condensate to an
optimum temperature.
3. Minimizing solubility of the undesirable gases.
4. Providing the highest temperature water for injection to the boiler.
HEAT & POWER GENERATION
Superheater
header
1. BOILER: FUEL (PALM SHELL & FIBRE) Steam Water level

Drum gauge
2. STEAM TURBINE
Mud /water
drum
Steam drum after cleaning
Front
Header
Back Header
Header Blowdown valve
Header
Side
Header
PUMP
VIEW INSIDE THE BOILER
Boiler’s side brick wall was demolished to View inside the boiler
install new tube
New generating tube

The Simple Ideal Rankine Cycle
Power Plant Boiler
TO HP TURBINE
TO IP TURBINE
SECONDARY FINAL
SUPERHEATER SUPERHEATER
PRIMARY
SUPERHEATER
DOWNCOMER
RISER RISER
REHEATER
FROM HP TURBINE EXHAUST
ECONOMIZER
SECONDARY TO STACK
RAPH AIR
ESP
FGD
HOT SECONDARY
AIR ESP
ID FAN
FD FAN BFP
BOILER FEEDWATER
Power Plant Boiler Arrangement
Types Of Boiler:
 Fire Tube Boiler
 Water Tube Boiler
 Packaged Boiler
 Fluidized Bed (FBC) Boiler
 Stoker Fired Boiler
 Pulverized Fuel Boiler
Fire Tube Boiler
Fire Tube Boiler
•Hot gases from a fire pass

through one or more tubes
running through a sealed
container of water
•Relatively small steam
capacities (12,000 kg/hour)
•Operates with oil, gas or
solid fuels
Water Tube Boiler
Water Tube Boiler
• Used for high steam demand

and pressure requirements.
• Forced, induced and
balanced draft provisions help
to improve combustion
efficiency
• Less tolerance for water
quality calls for water
treatment plant.
Packaged Boiler
Packaged Boiler
•require less fuel and

electric power to operate
•High thermal efficiency
•High heat transfer
•Faster evaporation
•Reduces operating cost
Fluidized Bed Combustion Boiler (FBC)
Fluidized Bed Combustion Boiler (FBC)
• Particles (e.g. sand) are

suspended in high velocity air
stream: bubbling fluidized bed
• Bed is where the coal or fuel
spreads
• Fuels: coal, washery rejects,
rice husk, bagasse and
agricultural wastes
• Benefits: compactness, fuel
flexibility, higher combustion
efficiency
Stoker Fired Boiler
Stoker Fired Boiler
•the smallest units among hard coal

fired boilers
•Coal is fed onto one end of a
moving steel grate
•A coal gate is used to control the
rate at which coal is fed into the
furnace by controlling the thickness
of the fuel bed
•Uniform coal size for complete
combustion
Pulverized fuel boiler
 An utility boiler that generates thermal energy by
burning pulverized coal
 Pulverized coal powder blown with combustion air into
boiler through burner nozzles
 Benefits: varying coal quality coal, quick response to
load changes and high pre-heat air temperatures
BOILER BLOWDOWN
 Boiler blowdown is the removal of water from a boiler.
 Purpose of blowdown: Remove suspended solid and total dissolved solids TDS)
present in the boiler.
 The impurities can remain and accumulate inside

the boiler as the boiler operation continues.
 The increasing concentration of dissolved solids
may lead to carryover of boiler water into the
steam, causing damage to piping, steam traps
and even process equipment.
 The increasing concentration of suspended solids
can form sludge, which impairs boiler efficiency
and heat transfer capability,
There are two types of boiler blowdowns: Manual and Automatic
MANUAL BLOWDOWN:
 Plants using manual blowdown must check samples many times a day or according to a set
schedule, and adjust blowdown accordingly.
 With manual boiler blowdown control, operators are delayed in knowing when to conduct
blowdown or for how long. They cannot immediately respond to the changes in feedwater
conditions or variations in steam demand.
AUTOMATIC BLOWDOWN:
 An automatic blowdown control constantly monitors boiler water conductivity and adjusts the
blowdown rate accordingly to maintain the desired water chemistry.
 A probe measures the conductivity and provides feedback to the controller driving a
modulating blowdown valve.
 An automatic blowdown control can keep the blowdown rate uniformly close to the maximum
allowable dissolved solids level, while minimizing blowdown and reducing energy losses.
The blowdown amount required can be significantly affected by the feedwater quality. Therefore,
improving feedwater quality through makeup water treatment and chemical treatment in the boiler
system can reduce blowdown rate.
In addition to proper blowdown practices, including the use
of automatic blowdown control, reducing cost and heat loss
associated with boiler blowdown can also be achieved
through recovering the heat/energy in the blowdown.
Schematics of a Flash Tank System

The blowdown water has
the same temperature and
pressure as the boiler water.
Before this high-energy
waste is discharged, the
resident heat in blowdown
can be recovered with a
flash tank, a heat
exchanger, or the
combination of the two.
Schematics of a Flash Tank – Heat Exchanger System

Chapter 2 Boiler System

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HEAT and ELECTRCITY GENERATION

 Vessel that heats water to become hot water or steam

TWO important streams which are:

a.) Water/Steam Stream ( normally in tubes ).

b.) Fuel Stream

8. Fan – FD fan/ - ID fan - Secondary air fan

Forced draft (FD) Fan:- A fan is used

An electrostatic precipitator (ESP) is

Corrosion also leads to fouling when precipitated metals settle onto

In the presence of oxygen and water, boiler system

Other problems include corrosion beneath deposits

Boiler corrosion is accelerated by high

Feed water tank

 Fuels (fibre & shell) are

 A device for air removal and is used to remove

 The feedwater is sprayed in thin films into a

1. To remove oxygen, carbon dioxide and other non-condensable gases

1. BOILER: FUEL (PALM SHELL & FIBRE) Steam Water level

Steam drum after cleaning

Header Blowdown valve

New generating tube

FROM HP TURBINE EXHAUST

•Hot gases from a fire pass

• Used for high steam demand

•require less fuel and

• Particles (e.g. sand) are

•the smallest units among hard coal

 Boiler blowdown is the removal of water from a boiler.

 The impurities can remain and accumulate inside

Schematics of a Flash Tank System

Schematics of a Flash Tank – Heat Exchanger System

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