Luthfi Ma'arif - Steam Boiler and Combustion Process

STEAM BOILER AND
COMBUSTION PROCESS
By: Luthfi Ma’arif

04 March 2021
CLASSIFICATION OF BOILER
Fuel Combustion
• Coal fired boiler • Stoker firing
a. • Oil fired boiler b. • Fluidized bed firing
• Gas fired boiler • Tangential firing
• Muti fuel fired boiler • Wall firing, etc
Steam Pressure Circulation

• Sub-critical pressure boiler • Natural circulation boiler
c. • Super-critical pressure boiler
d. • Controlled circulation boiler
• Ultra super-critical pressure • Once-through boiler
boiler
COMBUSTION TYPE OF
BOILER
 Tangential firing
The rotating flame rotation ensures thorough
mixing in the furnace, resulting in perfect
combustion and uniform heat distribution.  Wall firing
A boiler that has pulverized coal burners
arranged on the walls of the furnace. The
flames extend perpendicularly into the furnace
area.
CIRCULATION TYPE OF
BOILER
 Natural circulation  Forced circulation
Achieved by the difference in density when the A pump is used to circulate water inside the
water in the boiler is heated boiler.
BOILER
 Subcritical
The phase formed in the boiler is not
homogeneous, so this type of boiler requires a
steam drum/boiler drum to separate the two
phases to be heated again into superheated
steam which is used to rotate the turbine blade.
BOILER
 Supercritical There is no difference between the liquid phase
and the vapor phase. this boiler does not
require a steam drum, so it is often called a one
through boiler.
BOILER COMPONENT
 Boier steam drum
Steam Drum is one of the components in a water pipe boiler that functions as a reservoir for a
mixture of water and water vapor, and also functions to separate water vapor from water in the
process of superheater steam formation.
 Spray attemperators
A spray of water to reduce the steam temperature that is limited as per the operational
requirements
 Safety valve
To protect boiler pressure part and boiler related pressure piping when overpressure condition
arise
FUEL AND FANS SYSTEM
 Coal feeders
Receive coal from coal silos and control the amount of coal delivered to pulvurizers
 Pulvurizer
Grinding : reduce coal size to allow coal to circulate within the pulvurizer
Drying : hot air primary air input + residence time in the mill
Classification : produce coal so that 70% will pass through 200 mesh screen
 Burners
An equipment used for the process of burning fuel in the combustion chamber continuously at a
certain pressure and temperature. There are 48 coal burners are arrange 6 level at 8 corner
 Ignitors
Provide a source of ignition and help stabilized burner flames at relatively low coal input
 Primary air
Provide the required air flow to the transport of pulvurized coal to the burners and provide air
flow
 Forced draf fans
Provide the necessary amount of combustion air for the burners

 Induced draft fans
Serve to remove flue gas from the boiler and fabric filter and also control furnace draft pressure
during unit
 Booster fan
Provide boost flow from ID fans through the FGD system and out the stack
 Gas air heater
To transfer heat from the flue gas leaving the boiler to the incoming cold primary and secondary
air
 Sootblowers
To remove slag and fouling from boiler tube surface

 Thermoprobes
To monitor the gas temperature within the convection pass during start-up to prevent
overheating the superheater and reheat tubes
COAL SPESIFICATION
 Classification of coal:
1. Antrachite, has the highest fixed carbon content 86-98% and heating value of 13,500-
15,600 btu/lb
2. Bituminous, has 46-86% fixed carbon content and a heating value of 11,000-15,000 btu/lb
3. Sub-Bituminous, has a 46-60% fixed carbon content and a heating value of 8,300-13,000
btu/lb
4. Lignite, has a 46-60% fixed carbon content but the lowest heating value 5,500-8,300 btu/lb
COAL SPESIFICATION
 Ignition temperature
The ignition temperature of a substance is the least temperature at which the substance

starts combustion. Substances which spontaneously ignite in a normal atmosphere at naturally
ambient temperatures are termed pyrophoric
Coal Ignition Temp (oC) Burnout Time (s)

Anthracite 600 1,9
Bituminous 500 1,6
Char bituminous 550 1,8
Lignite 400 1,1
PRE COMBUSTION
Pulvurized coal particle size
1. The particle size distribution of the Pulvurized Fuel (PF) will affect the combustion
2. The larger particle, the lower its surface area
3. Low NOx coal burners designed for 200 mesh (75 micron) particle size
4. Particle that too large have an insufficient surface area to combust fully and will drop into
ash at the bottom of the furnace
5. Particle are too small have an excessive surface area and will combust too rapidly, it will
increasing the flame temp and increase level NOx
COMBUSTION
 Combustion is chemical reaction between fuel and oxygen that producing heat
 Combustion process constrain:
High ash content
Large amount of water in the fuel
Small of volatile matter of hydrogen
Large particle of fuel
COMBUSTION
Time: adequate time must be provided in the
furnace to complete the combustion process
T T
Temperature: adequate heat must be avaliable and Turbulance: adequate mixing of the fuel and air is
maintained to ignite and sustain the combustion required for ignition, flame stability and complete
process combustion of the fuel
COMBUSTION
 Too much or too little fuel with the available combustion air may potentially result in
unburned fuel and carbon monoxide generation
 Excess air is required for ensuring the perfect combustion, but too much excess air will result
in heat and efficiency loss
COMBUSTION
Pre-requisites of optimum combustion
 Coal preparation
Coal feed quality and size shall be consistent
Coal fineness >70 passing a 200 mesh screen
 Distribution to burner:
Primary air flow shall be acurately and controlled
Fuel line minimum velocity shall be 3300 ft/min
Fuel line shall be balanced by “clean air” test to within 2% of average
Fuel line shall be balanced by “dirty air” test to within 5% of average
Fuel line shall be balanced in fuel flow to within 10% of average
POST COMBUSTION
Result from coal burning is exhaust gas that contain pollutant such as:
Fly ash
NOx
SOx
If the Nox and Sox not controlled it will causing acid rain. Another concern is heavy production
of greenhouse gases, namely carbon dioxie from coal combustion.
To fulfill the enviromental requirement it is necessary:
Capture equipment particle (ESP)
Flue gas desulphurization (FGD)
De-NOx equipment
SLAGGING AND FOULING
 Slagging is the phenomenon attachment of coal ash particles either solid or molten form, on
the surface wall of heat that is located in the zone of high temperature combustion gas, as a
result of coal combustion process
 Slagging reduce the heat absorption in the furnace, therefore leads to increase furnace exit
temperature
 Fouling is the phenomenon of sticking and piling ashes on the wall of heat (superheater and
reheater) installed in an environment where the temperature of the gas at the rear of the
furnace is lower than the softening temperature of the ash
THANK YOU

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STEAM BOILER AND

By: Luthfi Ma’arif

Steam Pressure Circulation

Provide the necessary amount of combustion air for the burners

To remove slag and fouling from boiler tube surface

The ignition temperature of a substance is the least temperature at which the substance

Coal Ignition Temp (oC) Burnout Time (s)

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