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Introduction to Boilers:
A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and cheap medium for transferring heat to a process. When water is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous equipment that must be treated with utmost care. The process of heating a liquid until it reaches its gaseous state is called evaporation. Heat is transferred from one body to another by means of:
- Radiation, which is the transfer of heat from a hot body to a cold body without a conveying medium
- Convection, the transfer of heat by a conveying medium, such as air or water
III. Conduction, transfer of heat by actual physical contact, molecule to molecule
The heating surface is any part of the boiler metal that has hot gases of combustion on one side and water on the other. Any part of the boiler metal that actually contributes to making steam is heating surface. The amount of heating surface of a boiler is expressed in square meters. The larger the heating surface a boiler has, the more efficient it becomes. The quantity of the steam produced is indicated in tons of water evaporated to steam per hour. Maximum continuous rating is the hourly evaporation that can be maintained for 24 hours. F & A means the amount of steam generated from water at 100°C to saturated steam at 100°C.
The boiler system comprises of: feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system
The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are:
- Condensate or condensed steam returned from the processes and
- Makeup water (treated raw water) which must come from outside the boiler room and plant processes.
For higher boiler efficiencies, the feed water is preheated by economizer, using the waste heat in the flue gas.