Steam generator part 1

BOILER
Prepared by:
Mohammad Shoeb Siddiqui
Sr. Shift Supervisor
Saba Power Plant

Steam Generator (Boiler)
Hello,
I am trying to explain about Steam Generator
(Boiler) in this session, due to length of said
presentation, I am deciding to divide it in three
parts.
Part 1 cover the “Introduction & Types of Steam
Generator”
Part 2 cover about the “Parts of Steam Generator
and Its Accessories & Auxiliaries” and
Part 3 cover the “Efficiency & Performance”
Prepared by:
Saba Power Plant

BOILER

Part 1
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Saba Power Plant

Steam Fundamentals
 Steam is uniquely adapted, by its availability and

advantageous properties, for use in industrial and
heating processes and in power cycles. The
fundamentals of the steam generating process and the
core technologies upon which performance and
equipment design are based are described in this
section

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What is Steam?
Steam is an invisible gas that's generated by
heating water to a temperature that brings it to
the boiling point. When this happens, water
changes its physical state and vaporizes, turning
from a liquid into a gas.

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How the Energy of Steam Is Used
The uses for steam are many and varied. Like :
1. Power Generation
2. Industrial Process
3. Heating
From the plastic and vinyl components of our
automobiles to the paints and stains we use on our
homes to the preparation and presentation of the food
we eat, steam is used in a variety of ways to make our
lives more comfortable and convenient.

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What is a Boiler?
 A boiler is an enclosed

vessel that provides a
means for combustion heat
to be transferred to water
until it becomes heated
water or steam.
OR
 Steam
generators,
or
boilers, use heat to convert
water into steam for a
variety of applications.
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What is a Boiler Capacity
 Boiler loads, or the capacity of steam

boilers, are often rated in boiler horse
powers (BHP), lbs of steam delivered
per hour, or BTU.
 Large boiler capacities are often given
in lbs of steam evaporated per hour
under specified steam conditions.
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Boiler Capacity
Boiler Horsepower - BHP
The Boiler Horsepower (BHP) is the amount of energy required to produce 34.5
pounds of steam per hour at a pressure and temperature of 0 Psig and 212 oF,
with feed water at 0 Psig and 212 oF.
A BHP is equivalent to 33,475 BTU/hr or 8430 Kcal/hr and it should be noted
that a boiler horsepower is 13.1547 times a normal horsepower.
1 horsepower (boiler) = 33445.6 Btu (mean)/hr
= 140671.6 calorie/min (thermo)
= 140469.4 calorie (mean)/min
= 140742.3 calorie (20oC)/min 9.8095x1010 erg/sec
= 434107 foot-pound-force/min
= 13.1548 horsepower (mech)
= 13.1495 horsepower (electric)
= 13.3372 horsepower (metric)
= 13.1487 horsepower (water)
= 9809.5 joule/sec
= 9.8095 kilowatt

Horsepower (hp) can be converted into lbs of steam by multiplying hp with 34.5.
or some time called 1 BHP = 33479 Btu/hr
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INTRODUCTION
STEAM TO POWER GENERATION,
INDUSTRIAL PROCESS & HEATING

EXHAUST GAS

STACK

VENT

DEAERATOR
BFW
PUMPS

ECONOMIZER

VENT

BOILER
BURNER

BLOW DOWN
SEPARATOR

WATER
SOURCE

FUEL
BRINE
CHEMICAL FEED
SOFTENERS

Figure: Schematic overview of a boiler room

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Classification

Steam
Generator
Boiler
Fuel
Fossil,
Waste,
Nuclear

Tube
Contain
Fire Tube,
Water Tube

Furnace
Natural,
Pressurized,
Induced,
Balance

Pressure
Method
Water
of Firing Circulation of Steam
Externally,
Internally,
HRSG

Natural,
Forced

Low,
Medium,
High

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Classification

Fossil Fuel

Fuel
Waste
Heat

Nuclear
Fuel

Waste
Fuel
Biomass

Oil
Natural Gas
Coal

Gas Turbine
Exhaust
Diesel or Gas
Engine Exhaust

Uranium

Bagasse

Fission

Rise Husk
Wood Pallets
Forestry Residues
Mill Residues
Agricultural Residues
Chemical Recovery Fuels
Animal Wastes
Dry Animal Manure
Wet Animal Manure
(Dairy Manure Slurry)

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Types of Boilers
1. Fire Tube Boiler

2. Water Tube Boiler
3. Packaged Boiler
4. Fluidized Bed (FBC) Boiler

5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler (HRSG)
8. Nuclear Steam Generating Systems
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CLASSIFICATION BASED ON PRESSURE
 Low pressure boiler under 20
kg/cm2.
 Medium pressure boiler 20 – 75
kg/cm2.
 High pressure boiler over 75
kg/cm2.
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Fire Tubes Vs Water Tubes Boilers
 Fire tubes boilers has a large volume of water, therefore










more flexible and can meet the sudden demand of steam
without much drop of pressure.
Fire tubes boiler is rigid and of simple mechanical
construction, so greater reliability and low in first cost.
Fire tube boilers can be made in smallest sizes therefore
simple to fabricate and transport, occupies less floor
space but more height.
Due to mostly externally fired water tubes boiler so
furnace can be altered considerably to meet the fuel
requirements.
Water tubes boilers are more readily accessible for
cleaning, inspection and repairs, compared to the fire
tube boilers.
Modern trend is in the favors of water tube boiler due to
continuous increase in capacities and steam pressures.
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FIRE TUBE BOILER

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FIRE TUBE BOILER
 Relatively small steam capacities (12,000 kg/hour),

3,500 to 35,000 lbs/hr (120 Bhp – 1,200 Bhp)
 Low to medium steam pressures (18 kg/cm2), 350

psig
 Operates with oil, gas or solid fuels
 Scotch Marine – most popular
 Two, three, and four pass designs
 Constant pressure with wide load fluctuations
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FIRE TUBE BOILER
 Simple Vertical Boiler
 Cochran Boiler
 Locomotive Boiler
 Lancashire Boiler
 Cornish Boiler
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FIRE TUBE BOILER

Simple Vertical Boiler:
The image shows the simplest form of an
internally fired vertical fire-tube boiler. It does
not require heavy foundation and requires
very small floor area.

Parts
• Cylinder Shell
• Cross Tubes
• Furnace or Fire Box
• Grate
• Fire Door
• Chimney or Stack
• Manhole
• Hand Hole
• Ash Pit

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FIRE TUBE BOILER

Cochran Boiler
It is a multi-tubular vertical fire
tube boiler having a number of
horizontal fire tubes. T is the
modification of a simple vertical
boiler where the heating surface has
been increased by means of a
number of fire tubes.
Parts
• Shell
• Crate
• Fire box
• Flue pipe
• Fire tubes
• Combustion chamber
• Chimney
• Man-hole

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FIRE TUBE BOILER

Locomotive Boiler

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FIRE TUBE BOILER

Lancashire Boiler
It is a stationary, fire tube, internally fired boiler. The size is approximately from
7-9 meters in length and 2-3 meters in diameter.

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FIRE TUBE BOILER

Cornish Boiler
 It is a similar type of Lancashire boiler in all respects, except

there is only one flue tube in Cornish boiler instead of two in
Lancashire boiler.
 The diameter of Cornish boiler is generally 1m to 2m and its
length various from 5m to 7.5m.
 The diameter of flue tube may be 0.6 times that of shell. as

compared to Lancashire boiler.

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WATER TUBE BOILER
• La-Mont boiler
• Loeffler boiler
• Benson boiler

• Babcock and Wilcox boiler

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WATER TUBE BOILER
 Fuel burned within combustion










chamber
Combustion gas surrounds water
tubes within vessel
Low water content allows rapid steam
production
Capable of high pressure and
superheated steam
Preferred ranges are below 3,500
lbs/hr (120 Bhp) and above 35,000
lbs/hr (1,200 Bhp)
Capacity range of 4,500 – 120,000
kg/hour
Used for high steam demand and
pressure requirements
Combustion efficiency enhanced by
induced draft provisions
Lower tolerance for water quality and
needs water treatment plant
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WATER TUBE BOILER
Water
tube
boilers
are
designed to circulate hot
combustion gases around the
outside of a large number of
water filled tubes. The tubes
extend between an upper
header, called a steam drum,
and one or more lower headers
or drums.
Almost any solid, liquid or
gaseous fuel can be burnt in a
water tube boiler.
Coal-fired water tube boilers
are classified into three major
categories: stoker fired units,
PC fired units and FBC boilers.

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WATER TUBE BOILER
 Modular Boilers
 Array of smaller boilers meet
load more effectively without
cycling
 Improved combustion
efficiency
 Reduced jacket losses
 Fin tube design less durable
 Piping and controls
important
 Mostly for commercial
markets
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WATER TUBE BOILER
La-Mont boiler
A La-Mont boiler is a type
of forced circulation watertube boiler in which the boiler
water is circulated through an
external pump through long
closely spaced tubes of small
diameter. The mechanical
pump is employed to in order
to have an adequate and
positive circulation in steam
and hot water boilers.
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WATER TUBE BOILER
Loeffler Boiler
This is also a modern high pressure
water tube boiler using the forced
circulation principle and named after
Prof. Loeffler.
Salient features of Loeffler Boiler
The novel feature of the Loeffler Boiler is
to evaporate water solely by means of
superheated steam. The furnace heat is
supplied only to economizer and super
heater. In other words, steam is used as a
heat absorbing medium.
Capacity of the Loeffler boiler is about
100 tones/hr of superheated steam
generated at a pressure of 140 kg/sq.cm
and at a temperature of 500’C.
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WATER TUBE BOILER
Benson boiler
A Benson boiler is a type of
Once-Through
Boiler patented by Marc
Benson in Germany in 1923.

 A high pressure, drum less,

water tube steam boiler
works on forced circulation.
 Feed water enters at one end
and discharge superheated
steam at the other end.
 Feed pump increase pressure
of water to supercritical
pressure.
 Water directly transforms
into steam without boiling.
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WATER TUBE BOILER
Babcock and Wilcox boiler.
It is a water tube boiler used in steam power
plants. In this, water is circulated inside the
tubes and hot gases flow over the tubes.
The Babcock & Wilcox boiler is built in two
general classes, the longitudinal drum type
and the cross drum type. Either of these
designs may be constructed with vertical or
inclined headers.
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WATER TUBE BOILER
Babcock and Wilcox boiler.

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Packaged Boiler
• Comes in complete
package

• Features
• High heat transfer
• Faster evaporation
• Good convective heat
transfer
• Good combustion
efficiency
• High thermal
efficiency

To
Chimney

Oil
Burner

• Classified based on
number of passes
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Packaged Boiler
All have steam drums for the separation of the steam from the water, and one
or more mud drums for the removal of sludge .
“A Type”. This design is more susceptible to tube starvation if bottom blows
are not performed properly because “A” type boilers have two mud drums
symmetrically below the steam drum. Drums are each smaller than the single
mud drums of the “D” or “O” type boilers.

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Packaged Boiler
“D” type boilers have the most flexible design. They have a single steam drum
and a single mud drum, vertically aligned. The boiler tubes extend to one side
of each drum. “D” type boilers generally have more tube surface exposed to
the radiant heat than do other designs.

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Packaged Boiler
“O” design boilers have a single steam drum and a single mud drum. The
drums are directly aligned vertically with each other, and have a roughly
symmetrical arrangement of riser tubes. Circulation is more easily controlled,
and the larger mud drum design renders the boilers less prone to starvation
due to flow blockage, although burner alignment and other factors can
impact circulation.

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Fluidized Bed Combustion
(FBC) Boiler
• Particles (e.g. sand) are suspended in high
velocity air stream: bubbling fluidized bed
• Combustion at 840 – 950 C
• Capacity range 0,5 T/hr to 100 T/hr
• Fuels: coal, washery rejects, rice husk,
bagasse and agricultural wastes

• Benefits: compactness, fuel flexibility, higher
combustion efficiency, reduced SOx & NOx
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Fluidized Bed Combustion (FBC) Boiler
Fluidized bed combustion (FBC) is a combustion technology
used in power plants. Fluidized beds suspend solid fuels in
upward-blowing jets of air during the combustion process. The
result is a turbulent mixing of gas and solids. The tumbling
action, much like a bubbling fluid, provides more effective
chemical reactions and heat transfer.
Since limestone is used as particle bed, control of sulfur dioxide
and nitrogen oxide emissions in the combustion chamber is
achieved without any additional control equipment. This is one
of the major advantages over conventional boilers.
Combustion process requires the three “T”s that is Time,
Temperature and Turbulence. In FBC, turbulence is promoted by
fluidisation. Improved mixing generates evenly distributed heat
at lower temperature. Residence time is many times greater than
conventional grate firing. Thus an FBC system releases heat more
efficiently at lower temperatures.

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principle of fluidisation

Fixing, bubbling
and fast fluidized
beds
As the velocity of a
gas flowing through
a bed of particles
increases, a value is
reaches when the
bed fluidises and
bubbles form as in a
boiling liquid. At
higher velocities the
bubbles disappear;
and the solids are
rapidly blown out of
the bed and must be
recycled to maintain
a stable system.
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Fluidized Bed Combustion
(FBC) Boiler
FBC systems fit into essentially
two major groups, atmospheric
systems (FBC) and pressurized
systems (PFBC), and two minor
subgroups, circulating fluidized
bed (CFB) & bubbling fluidized
bed (BFB).
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Advantages of Fluidised Bed Combustion Boilers
1. High Efficiency
FBC boilers can burn fuel with a combustion efficiency of over 95%
irrespective of ash content. FBC boilers can operate with overall efficiency of
84% (plus or minus 2%).
2. Reduction in Boiler Size
High heat transfer rate over a small heat transfer area immersed in the bed
result in overall size reduction of the boiler.
3. Fuel Flexibility
FBC boilers can be operated efficiently with a variety of fuels. Even fuels like
flotation slimes, washer rejects, agro waste can be burnt efficiently. These can
be fed either independently or in combination with coal into the same furnace.
4. Ability to Burn Low Grade Fuel
FBC boilers would give the rated output even with inferior quality fuel. The
boilers can fire coals with ash content as high as 62% and having calorific value
as low as 2,500 kcal/kg. Even carbon content of only 1% by weight can sustain
the fluidised bed combustion.
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5. Ability to Burn Fines
Coal containing fines below 6 mm can be burnt efficiently in FBC boiler,
which is very difficult to achieve in conventional firing system.
6. Pollution Control
SO2 formation can be greatly minimised by addition of limestone or dolomite
for high sulphur coals. 3% limestone is required for every 1% sulphur in the
coal feed. Low combustion temperature eliminates NOx formation.
7. Low Corrosion and Erosion
The corrosion and erosion effects are less due to lower combustion
temperature, softness of ash and low particle velocity (of the order of 1
m/sec).
8. Easier Ash Removal – No Clinker Formation
Since the temperature of the furnace is in the range of 750 – 900o C in FBC
boilers, even coal of low ash fusion temperature can be burnt without clinker
formation. Ash removal is easier as the ash flows like liquid from the
combustion chamber. Hence less manpower is required for ash handling.
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9. Less Excess Air –
Higher CO2 in Flue Gas The CO2 in the flue gases will be of the order of 14 – 15%
at full load. Hence, the FBC boiler can operate at low excess air - only 20 – 25%.
10. Simple Operation, Quick Start-Up
High turbulence of the bed facilitates quick start up and shut down. Full
automation of start up and operation using reliable equipment is possible.
11. Fast Response to Load Fluctuations
Inherent high thermal storage characteristics can easily absorb fluctuation in fuel
feed rates. Response to changing load is comparable to that of oil fired boilers.
12. No Slagging in the Furnace-No Soot Blowing
In FBC boilers, volatilisation of alkali components in ash does not take place and the
ash is non sticky. This means that there is no slagging or soot blowing.
13 Provisions of Automatic Coal and Ash Handling System
Automatic systems for coal and ash handling can be incorporated, making the plant
easy to operate comparable to oil or gas fired installation.
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14 Provision of Automatic Ignition System
Control systems using micro-processors and automatic ignition equipment
give excellent control with minimum manual supervision.
15 High Reliability
The absence of moving parts in the combustion zone results in a high
degree of reliability and low maintenance costs.
16 Reduced Maintenance
Routine overhauls are infrequent and high efficiency is maintained for long
periods.
17 Quick Responses to Changing Demand
A fluidized bed combustor can respond to changing heat demands more
easily than stoker fired systems. This makes it very suitable for applications
such as thermal fluid heaters, which require rapid responses.
18 High Efficiency of Power Generation
By operating the fluidized bed at elevated pressure, it can be used to
generate hot pressurized gases to power a gas turbine. This can be
combined with a conventional steam turbine to improve the
efficiency of electricity generation and give a potential fuel savings
of at least 4%.
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a. Atmospheric Fluidized Bed Combustion

(AFBC) Boiler
Atmospheric fluidized beds use limestone or
dolomite to capture sulfur released by the
combustion of coal. Jets of air suspend the
mixture of sorbent and burning coal during
combustion, converting the mixture into a
suspension of red-hot particles that flow like
a fluid. These boilers operate at atmospheric
pressure.
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b. Pressurized Fluidized Bed Combustion (PFBC) Boiler
• Compressor supplies the forced draft and combustor is a
pressure vessel
• Used for cogeneration or combined cycle power generation.
• The first-generation PFBC system also uses a sorbent and
jets of air to suspend the mixture of sorbent and burning
coal during combustion. However, these systems operate at
elevated pressures and produce a high-pressure gas stream
at temperatures that can drive a Gas Turbine. Steam
generated from the heat in the fluidized bed is sent to
a Steam Turbine, creating a highly efficient Combined
Cycle system.
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PFBC Boiler for Cogeneration

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Atmospheric Circulating Fluidized Bed
Combustion (CFBC) Boiler
•

Solids lifted from bed,
rise, return to bed

•

Steam generation in
convection section

•

Benefits: more
economical, better space
utilization and efficient
combustion

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This CFBC technology utilizes the fluidized bed
principle in which crushed (6 –12 mm size) fuel and
limestone are injected into the furnace or
combustor. The particles are suspended in a stream
of upwardly flowing air (60-70% of the total air),
which enters the bottom of the furnace through air
distribution nozzles. The fluidising velocity in
circulating beds ranges from 3.7 to 9 m/sec. The
balance of combustion air is admitted above the
bottom of the furnace as secondary air.
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Bubbling Bed Boilers
In the bubbling bed type boiler, a layer of solid particles
(mostly limestone, sand, ash and calcium sulfate) is
contained on a grid near the bottom of the boiler. This
layer is maintained in a turbulent state as low velocity
air is forced into the bed from a plenum chamber
beneath the grid. Fuel is added to this bed and
combustion takes place. Normally, raw fuel in the bed
does not exceed 2% of the total bed inventory. Velocity
of the combustion air is kept at a minimum, yet high
enough to maintain turbulence in the bed. Velocity is
not high enough to carry significant quantities of solid
particles out of the furnace.
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Bubbling Bed Boilers
Features of bubbling bed
boiler
Fluidised bed boiler can operate at near
atmospheric or elevated pressure and
have these essential features:
• Distribution plate through which air is
blown for fluidizing.
• Immersed steam-raising or water
heating tubes which extract heat directly
from the bed.
• Tubes above the bed which extract heat
from hot combustion gas before it enters
the flue duct.

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Stoke Fired Boilers
Stokers are classified according to the method
of feeding fuel to the furnace and by the type
of grate. The main classifications are spreader
stoker and chain-gate or traveling-gate stoker.
a) Spreader stokers
•

Coal is first burnt in
suspension then in coal bed

•

Flexibility to meet load
fluctuations

•

Favored in many industrial
applications
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Stoke Fired Boilers
b) Chain-grate or traveling-grate stoker
• Coal is burnt on moving
steel grate
• Coal gate controls coal
feeding rate
• Uniform coal size for
complete combustion

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Pulverized Fuel Boiler
•

Coal is pulverized to a fine
powder, so that less than 2%
is +300 microns, and 70-75%
is below 75 microns.

•

Pulverized coal powder blown
with combustion air into boiler
through burner nozzles

•

Combustion temperature
1300 -1700 °C

•

Benefits: varying coal quality
coal, quick response to load
changes and high pre-heat air
temperatures

at

Tangential firing

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Pulverized Fuel Boiler

Advantages
 Its ability to burn all ranks of coal from anthracitic to

lignitic, and it permits combination firing (i.e., can
use coal, oil and gas in same burner). Because of
these advantages, there is widespread use of
pulverized coal furnaces.

Disadvantages
 High power demand for pulverizing
 Requires more maintenance, fly ash erosion and

pollution complicate unit operation
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Waste Heat Boiler
• Used when waste heat
available at medium/high
temp
• Auxiliary fuel burners
used if steam demand is
more than the waste heat
can generate
• Used in heat recovery
from exhaust gases from
gas turbines and diesel
engines
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Waste Heat Boiler (HRSG)
• A waste heat boiler can be
economically installed wherever
waste heat can be available at
medium or high temperatures.
• Wherever the steam demand is
more than the steam generated
during waste heat, auxiliary fuel
burners are also used. If there is no
direct use of steam, the steam may be
let down in a steam turbine-generator
set and power produced from it. It is
widely used in the heat recovery from
exhaust gases from gas turbines and
diesel engines.
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Heat recovery steam generator (HRSG), located at
the exhaust end of gas turbine or Engine. During plant
operation, the gas turbine engine discharges a high volume of
exhaust flue gas containing a considerable amount of thermal
energy. The HRSG reclaims the exhausted thermal energy for
the purpose of generating superheated steam for use in the
steam turbine generator. Efficient reclamation of the gas
turbine exhaust prevents wasted energy, resulting in a
significant increase of overall plant efficiency. The installation
of the HRSG gives the plant its ’combined cycle’ status, in that
it represents a major component of the Rankine cycle portion
of the power plant.
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Nuclear Steam Generating Systems

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Steam generators
are heat exchangers used
to convert water
into steam from heat
produced in a
nuclear reactor core.
They are used in
pressurized water reactors
(PWR) between the
primary and
secondary coolant loops.
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Nuclear steam generating systems include a series of
highly specialized heat exchangers, pressure vessels,
pumps and components which use the heat generated by
nuclear fission reactions to efficiently and safely generate
steam. The system is based upon the energy released when
atoms within certain materials, such as uranium, break
apart or fission. Fission occurs when a fissionable atom
nucleus captures a free subatomic particle – a neutron.
This upsets the internal forces which hold the atom
nucleus together. The nucleus splits apart producing new
atoms as well as an average of two to three neutrons,
gamma radiation and energy.
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In commercial power plants steam generators can
measure up to 70 feet (~21m) in height and weigh as
much as 800 tons. Each steam generator can contain
anywhere from 3,000 to 16,000 tubes, each about
three-quarters of an inch (~19mm) in diameter. The
coolant (treated water), which is maintained at high
pressure to prevent boiling, is pumped through
the nuclear reactor core. Heat transfer takes place
between the reactor core and the circulating water
and the coolant is then pumped through the
primary tube side of the steam generator by coolant
pumps before returning to the reactor core. This is
referred to as the primary loop.

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Types
Westinghouse and Combustion Engineering designs have
vertical U-tubes with inverted tubes for the primary water.
Canadian, Japanese, French, and German PWR suppliers use
the vertical configuration as well. Russian VVER reactor
designs use horizontal steam generators, which have the
tubes mounted horizontally. Babcock and Wilcox plants
have smaller steam generators that force water through the
top of the OTSGs (once-through steam generators; counterflow to the feedwater) and out the bottom to be recirculated
by the reactor coolant pumps. The horizontal design has
proven to be less susceptible to degradation than the vertical
U-tube design.

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Saba Power Plant
shoeb.siddiqui@sabapower.com
shoeb_siddiqui@hotmail.com
www.youtube.com/shoebsiddiqui

Steam generator part 1

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