Practical Boiler. Operation Engineering and Power Plant FOURTH EDITION. Amiya Ranjan Mallick

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2 Practical Boiler Operation Engineering and Power Plant FOURTH EDITION Amiya Ranjan Mallick General Manager (Power Plant) B.K. Birla Group of Industries Maharashtra Delhi

3 PRACTICAL BOILER OPERATION ENGINEERING AND POWER PLANT, Fourth Edition Amiya Ranjan Mallick 2015 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Third Printing (Fourth Edition) August, 2015 Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111, Patparganj Industrial Estate, Delhi and Printed by Mohan Makhijani at Rekha Printers Private Limited, New Delhi

4 I dedicate this book to my Godlike uncle Sri Raghunath Mallick who has brought me from darkness and illuminated my life.

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6 Contents Preface xix Preface to the Third Edition xxi 1. Fundamentals Introduction Law of Conservation of Energy Temperature Absolute Temperature Pressure Gauge Pressure and Absolute Pressure Heat Specific Heat Work Power Energy Enthalpy Laws of Thermodynamics Specific Heat of Gas Thermodynamic Process of Perfect Gas Constant Volume or Isochoric Process Constant Pressure or Isobaric Process Constant Temperature or Isothermal Process Adiabatic Process or Isentropic Process Free Expansion Process Throttling Process Thermodynamic Cycle Carnot Cycle with Steam as Working Fluid Rankine Cycle Brayton Cycle 18 Exercises Heat Transfer Methods Introduction Heat Transfer by Conduction Fourier s Law Thermal Conductivity 23 v

7 vi Contents 2.3 Heat Transfer by Convection Newton s Law of Cooling Heat Transfer by Radiation Absorption, Reflection and Transmission of Radiation Emissivity Stefan Boltzmann Law Geometrical Factor or Configuration Factor Heat Transfer Methods in a Boiler 27 Exercises Fuel and Combustion Introduction Solid Fuel Wood Coal Coke Biomass Fuel Liquid Fuel Gaseous Fuel Blast Furnace Gas Coke Oven Gas Proximate Analysis and Ultimate Analysis of Fuel Proximate Analysis Ultimate Analysis Calorific value of Fuel Gross Calorific Value (GCV) or Higher Calorific Value (HCV) Net Calorific Value or Lower Calorific Value (NCV or LCV) Empirical Relationship of GCV, UHV, and NCV Combustion Chemistry of Combustion Some Important Properties of Coal Gradation of Coal Combustion of Coal Combustion of Pulverised Coal Combustion of Liquid Fuel Excess Air 44 Exercises Properties of Steam Introduction Formation of Steam Terms Associated with Steam Steam Table Mollier Diagram 52 Exercises 52

8 Contents vii 5. Boiler Feedwater Chemistry Introduction Removal of Undissolved Suspended Solid Materials from Water Sedimentation Filtration Coagulation Dissolved Salts and Minerals Internal Boiler Water Treatment Soda Ash (Sodium Carbonate or Na 2 CO 3 ) Treatment Phosphate Treatment or High Pressure (HP) Dosing Colloidal Treatment External Treatment of Feedwater Softener Demineralising (DM) Water Plant Reverse Osmosis Plant Removal of Dissolved Gases from Water Low Pressure (LP) Dosing Some Parameters of Boiler Feedwater Water Treatment of Supercritical Boiler 73 Exercises Introduction to Boiler Introduction Steam Generation in a Boiler Different Types of Boiler Fire Tube and Water Tube Boiler Straight Tube, Bent Tube, Horizontal, Vertical and Inclined Boiler Waste Heat Recovery Boiler (WHRB) Package and Small Boilers Subcritical and Supercritical Boiler Fuel-fired Boiler Travelling Grate-fired Boiler Spreader Stoker-fired Boiler Pulverised Coal (PC) fired Boiler Air System Pressure Parts (Heat Transfer Surfaces) Coal Feeding System Ash Handling Fluidised Bed Combustion (FBC) Boiler Atmospheric Fluidised Bed Combustion (AFBC) Boiler Circulating Fluidised Bed (CFBC) Boiler Supercritical Boiler Furnace Design Water and Steam Circuit Heat Recovery Area (HRA) 122

9 viii Contents Start-up System Wet Mode and Dry Mode Operation of Supercritical Boiler Materials Used in Supercritical Boiler Biomass-fired Boiler 124 Exercises Fuel Handling System Introduction Handling of Liquid Fuels Handling of LDO and HSD Handling of HFO, FO and LSHS Handling of Gaseous Fuel Handling of Solid Fuel: Coal Handling Plant Coal Transportation and Storage Coal Preparation Coal Pulverisation Handling of Other Solid Fuels 142 Exercises Air Path Introduction Basics of Fan Affinity Laws Fan Curve System Resistance Curves FD Fan FD Fan Air Flow Control Air Heater (or Air Preheater) Steam Air Heater Primary Air and Secondary Air Excess Air 153 Exercises Feedwater Path Introduction Deaerator Tray Type, Direct Contact Deaerator Basics of Pump Centrifugal Pump Positive Displacement Pump Boiler Feed Pump Boiler Drum Level Control Drum Level Control in Larger Capacity Boiler Feed Control Station Economiser 171

10 Contents ix 9.8 Evaporator Water Wall Boiling Principle Blowdown Gauge Glass Hydrastep Waterside Scaling and Corrosion Scaling Corrosion Priming, Foaming and Carryover 185 Exercises Steam Path Introduction Steam Drum Drum Internals Superheater Outlet Temperature at Various Loads for Different Types of Superheaters Methods of Superheater Temperature Control Gas Bypass Method Excess Air Control Method Tilting/Adjustable Burner Control Method Separately-fired Superheater Method Flue Gas Recirculation Method Coil Immersion in Boiler Drum Desuperheating or Attemperation Method Start-up Vent Safety Valve Basic Operation of Safety Valve Electromatic Pressure Relief Value Steam Vent Silencer Pressure Reducing and Desuperheating (PRDS) Station 203 Exercises Flue Gas Path Introduction Furnace Furnace Dimension Different Zones of Flue Gas Path Refractory and Insulation Refractory Insulating Material ID Fan Draft Natural Draft Artificial Draft (Mechanical Draft) 218

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