Boiler Circulation System

COAL TO ELECTRICITY
 Boiler Circulation

• Water must flow through the heat absorption surface of the boiler in order that it
be evaporated into steam.

• In drum type units (natural and controlled circulation) the water is circulated
from the drum through the generating circuits and back to the drum where
steam is separated and directed to the superheater.

• The water leaves the drum through the downcomers at a temperature slightly
below saturation temperature.

• The flow through the furnace wall is at saturation temperature. Heat absorbed in
water wall is latent heat of vaporization creating a mixture of steam and water.

• The ratio of the weight of water to the weight of steam in the mixture leaving the
heat absorption surfaces is called Circulation Ratio.

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Boiler Circulation

The purpose of the steam-water flow circuitry is to provide the desired steam
output at the specified temperature and pressure.

The flow also ensures effective cooling of the tube walls under expected
operating conditions, provided the unit is properly operated and maintained.

A number of methods have been developed. These systems are typically

classified as either re-circulating or once-through.

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Boiler Circulation

Recirculating: In recirculating systems, water is only partially evaporated

into steam in the boiler tubes. The residual water plus the makeup water
supply are then recirculated to the boiler tube inlet for further heating and
steam generation.

A steam drum provides the space required for effective steam-water

separation.

Once through systems provide for continuous evaporation of slightly

subcooled water to 100% steam without steam-water separation. Steam
drums are not required.

These designs use forced circulation for the necessary water and steam-
water flow.

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Boiler Circulation

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Types of circulations

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Types of Circulations Contd..

3/17/20 Fußzeilentext 7
Natural vs Forced Circulation

1. Natural circulation is most effective where there is a considerable

difference in density between steam and water phases

2. As the pressure increases, the difference in density between water and

steam reduces.

3. Thus the hydrostatic head available will not be able to overcome the
frictional resistance for a flow corresponding to the minimum requirement
of cooling of water wall tubes.

4. Therefore natural circulation is limited to boiler with drum operating

pressure around 175 Kg/cm2.

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Natural vs Forced Circulation

5. Beyond 180 Kg/cm2 of pressure, circulation is to be assisted

with mechanical pumps, to overcome frictional losses. To regulate
the flow through various tubes, orifice plates are used. This system
is applicable in the high sub-critical regions (say 200 Kg/cm2).

6. Forced circulation is, however, used where the boilers are

designed to operate near or above the critical pressure.

7. Beyond the critical pressure, phase transformation is absent,

and hence once through system is adopted.

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 Circulation in Boiler
The steam generator has to produce steam at highest purity, and
at high pressure and temperature required for the turbine. Water
must flow through the heat absorption surface of the boiler in
order that it be evaporated into steam Natural circulation is the
ability of water to circulate continuously, with gravity and
changes in temperature being the only driving force known as
"thermal head“.

The ratio of the weight of water to the weight of steam in the

mixture leaving the heat absorption surfaces is called
Circulation Ratio.

Cold feedwater is introduced into the steam drum where, because the density of the
cold water is greater, it descends in the 'downcomer' towards the lower bottom ring
header, displacing the warmer water up into the front tubes.
Continued heating creates steam bubbles in the front tubes, which are naturally
separated from the hot water in the steam drum, and are taken off.
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Circulation Ratio Value

CR = 6-8 Natural cir. Boilers

CR = 3-4 Forced cir. Boilers
CR = 1 Supercritical boilers

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Criticality of Drum Level control

Boiler drum level control is critical for both plant

protection and equipment safety and applies equally
to high and low levels of water within the boiler drum.

The purpose of the drum level controller is to bring

the drum up to level at boiler start-up and maintain
the level at constant steam load.

A dramatic decrease in this level may uncover boiler

tubes, allowing them to become overheated and
damaged. An increase in this level may interfere with
the process of separating moisture from steam within
the drum,
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Types of Drum level control

The Three main options available for drum level

control are Single element drum level control

Two element drum level control

Three-element drum level control

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 Natural Circulation & Forced Circulation

Natural Circulation
 The downcomer contain
relatively cold water, whereas the
riser tube contain steam water
mixture ,whose density is
comparitively less .this density
difference is the driving force ,for
the mixture. (thermo-siphon
principle)
 Circulation takes place at such a
high rate that the driving force
and frictional resisitance in water Natural Circulation Forced Circulation
wall are balanced. CR = 7-8

Assisted Circulation
 Beyond 180 Kg/cm2 of pressure, circulation is to be assisted with mechanical
pumps, to overcome frictional losses. To regulate the flow through various tubes,
orifice plates are used. This system is applicable in the high sub-critical regions
(say 200 Kg/cm2). CR = 4
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Why controlled circulation is required?

AS THE PRESSURE
INCREASES,THE DIFFERENCE
IN DENSITY BETWEEN WATER
AND STEAM REDUCES .
THUS THE HYDROSTATIC
HEAD AVAILABLE WILL NOT
BE ABLE TO OVERCOME THE
FRICTIONAL RESISITANCE
FOR A FLOW
CORRESPONDING TO THE
MINIMUM REQUIREMENT OF
COOLING OF WATER WALL
TUBES.
NATURAL CIRCULATION IS
LIMITED TO 175KSC
Diff in Density

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2. Controlled Circulation System

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3.Combined circulation system:

 Circulation ratio=2
 No use of drum
 Use of controlled circulation pump
 Use for pressure above 200kg/cm2.

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Nucleate boiling, DNB and Film Boiling

Boiling is the formation of vapor

bubbles at the heating surface.
These bubbles form at
nucleation sites whose number
and location depend upon the
surface roughness or cavities,
fluid properties, and operating
conditions. The boiling heat
transfer coefficient is very
sensitive to the temperature
difference.

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Economiser

Boiler Economizer are feed-water heaters in which the heat

from waste gases is recovered to raise the temperature of
feed-water supplied to the boiler.

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 Economiser
The economizer preheats the feed water by utilizing the residual heat of the
flue gas.
It reduces the exhaust gas temperature and saves the fuel.
Modern power plants use steel-tube-type economizers.
Design Configuration: divided into several sections : 0.6 – 0.8 m gap

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Tube Bank Arrangement

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Finned Economizers

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Thermal Parameters of Economizer

 Out side diameter : 25 – 38 mm.

 Tube thinckness: 3 – 5 mm
 Transverse spacing : 2.5 – 3.0
 Longitudinal spacing : 1.5 – 2.0
 The water flow velocity : 600 – 800 kg/m2 s
 The waterside resistance should not exceed 5 – 8
%. Of drum pressure.
 Flue gas velocity : 7 – 13 m/s.

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Advantages of Economiser

6oC raise in feed water temperature, by economizers

corresponds to a

1% saving in fuel consumption

220 C reduction in flue gas temperature increases boiler

efficiency by 1%

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Location and Arrangement

 Ahead of air-heaters
 Following the primary super-heater or re-
heater
 Counter-flow arrangement
 Horizontal placement (facilitate draining)
 Supported to prevent sagging, undue
deflection and expansion .
 Stop valve and non-return valve
incorporated to ensure recirculation in
case of no feed-flow
 Ash hopper below as flue gas takes a
turn

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Type of Construction

Plain Tube : Several banks of tubes with either-in-line

or staggered type formation. Staggered arrangement
induces more turbulence than the in-line
arrangement. This gives a higher rate of heat transfer
and requires less surface but at the expense of higher
draught loss.

Welded Fin-tube : Fin welded design is used for

improving the heat transfer.

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Downcomers

There are six down comers in (500 MW) which carry

water from boiler drum to the ring header.
They are installed from outside the furnace to keep
density difference for natural circulation of water &
steam.

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 WATER WALLS

HEATING AND EVAPORATING THE FEED WATER

SUPPLIED TO THE BOILER FROM THE
ECONOMISERS.

THESE ARE VERTICAL TUBES CONNECTED AT THE

TOP AND BOTTOM TO THE HEADERS.

THESE TUBES RECEIVE WATER FROM THE BOILER

DRUM BY MEANS OF DOWNCOMERS CONNECTED
BETWEEN DRUM AND WATER WALLS LOWER
HEADER.

APPROXIMATELY 50% OF THE HEAT RELEASED BY

THE COMBUSTION OF THE FUEL IN THE FURNACE
IS ABSORBED BY THE WATER WALLS.
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Construction of Water Walls

Tangent tube The

construction consists of
water wall placed side by
side nearly touching each
other. An envelope of thin
sheet of steel called "SKIN
CASING" is placed in
contact with the tubes,
which provides a seal
against furnace leakage.

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Construction of Water Walls

A number of tubes are joined by a

process of fusion welding or by means
of steel strips called 'fins’

• Increase in efficiency
• Better load response. simpler
combustion control.
• Quicker starting and stopping
• Increased availability of boiler.
• Heat transfer is better
• Weight is saved in refractory and
structure
• Erection is made easy and quick

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 Water wall specification

NO OD(MM)

FRONTWALL 283 51

SIDEWALLS 444 51

REAR WALLS 283 51

ROOF 142 57

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