BOILER DEFINITION

• Boiler, also called steam generator is the engineering device which

generates steam at constant pressure.
• It is a closed vessel, generally made of steel in which vaporization of
water takes place..
• Heat required for vaporization may be provided by the combustion
of fuel in furnace, electricity, nuclear reactor, hot exhaust gases, solar
radiations etc.
 TYPES OF BOILERS

(a) Based upon the b) Based upon utility of boiler: Boilers

orientation/axis of the shell: can be classified as
According to the axis of shell (i) Stationery boiler, such boilers are
boiler can be classified as vertical stationery and are extensively used in
boiler and horizontal boiler. power plants, industrial processes,
heating etc.(Babcock Wilcox, Benson)
(ii) Portable boiler, such boilers are
(i) Vertical boiler has its shell portable and are of small size. These can
vertical- Cochran be of the following types,
(ii) Horizontal boiler has its • Locomotive boiler, which are
shell horizontal-Lancashire exclusively used in locomotives.
(iii) Inclined boiler has its shell • Marine boiler, which are used for
inclined- Babcock Wilcox marine applications
 TYPES OF BOILERS

c.)Based on type of firing employed: d.) Based upon the tube content: Based on
According to the nature of heat addition the fluid inside the tubes, boilers can be,
process boilers can be classified as,
(i) Fire tube boilers, such boilers have the hot
(i) Externally fired boilers, in which heat gases inside the tube and water is outside
addition is done externally i.e. furnace is surrounding them. Examples for these boilers
outside the boiler unit. Such as are, Cornish boiler, Cochran boiler,
Lanchashire boiler, Locomotive boiler
etc. • Lancashire boiler, Locomotive boiler etc.

(ii) Internally fired boilers, in which heat (ii) Water tube boilers, such boilers have
addition is done internally i.e. furnace is water flowing inside the tubes and hot gases
within the boiler unit. Such as Cochran surround them. Examples for such boilers are
boiler, Babcock Wilcox boiler etc. Babcock-Wilcox boiler, Stirling boiler,
• La-Mont boiler, Benson boiler etc.
 TYPES OF BOILERS
• According to pressure inside Boiler-
• Based on circulation: According to the
flow of water and steam within the boiler • Low Pressure Boiler-
circuit the boilers may be of following Below 80bar –
types, Lancashire
(i) Natural circulation boilers, in • High Pressure Boiler-
which the circulation of water/steam Above 80 Bar
is caused by the density difference
which is due to the temperature Babcock- Wilcox
variation.(Babcock Wilcox boiler ) • Modern Boiler-
(ii) Forced circulation boilers, in Above 160 bar
which the circulation of water/steam Benson Boiler
is caused by a pump i.e. externally • Once Through /Super-critical Boiler
assisted circulation-La-Mont boiler, Above 221 Bar
Benson boiler etc.
Ramsin Bolier
 REQUIREMENTS OF A GOOD BOILER

• It should be capable of generating steam at desired rate at desired pressure and

temperature with minimum fuel consumption and cost.
• Boiler should have strength to withstand excessive thermal stresses.
• Boiler should occupy less floor area and space.
• It should be equipped with all necessary mountings.
• Boiler should have capability to get started quickly from cold.
• It should have sufficient steam and water storage capacity to meet fluctuation in
demand and to prevent fluctuation in steam pressure or water level.
• Boiler should have a constant and thorough circulation of water.
 . FOR DECIDING THE BOILER FOR ANY APPLIC ATION, GENERALLY
FOLLOWING CRITERION ARE MADE;

• (i) Steam pressure requirement

• (ii) Steam temperature requirement
• (iii) Steam generation rate
• (iv) Initial cost and constraints
• (v) Running and maintenance costs
• (vi) Availability of fuel and water
• (vii) Inspection and maintenance requirements.
 BOILER MOUNTINGS AND ACCESSORIES

• Boiler Mountings- for Safe

Boiler accessories- they are to
operation of Boiler increase efficiency of Boiler.
(i) Water level indicator
(ii) Safety valves Boiler accessories are:
(iii) Fusible plug • (i) Superheater
(v) Pressure gauge • (ii) Economiser
(vi) Stop valve • (iii) Air preheater
(vii) Feed check valve
(viii) Blow off cock
(ix) Manhole and mud box
 WATER LEVEL INDICATOR:

• It is used for knowing the level of water in boiler as water level inside
boiler should not go below a certain limit.
• It has two tubes one is front glass tube while other is metal tube. Water
level is seen through glass tube which is made strong enough to
withstand high steam pressure and temperature.
• In case of breakage of glass tube the possibility of accident is
prevented by providing two balls
WATER LEVEL
INDICATOR-
 PRESSURE GAUGE:

• It is mounted at front top. Generally Bourdon type pressure gauge are

being used for pressure measurement.
• Pressure is continuously monitored so as to avoid occurrence of over
shooting of boiler pressure.
• Although safety devices to protect boiler against pressure rising beyond
a limit are provided but pressure gauges are also used for monitoring
pressure.
 FUSIBLE PLUG:

• It is a safety device used for preventing the level of water from going down
below a critical point and thus avoiding overheating. Fusible plug is mounted at
crown plate of combustion chamber.
• Fusible plug has gun metal body and a copper plug put with fusible metal at
interface of copper plug and gun metal body.
• As water level goes down the heat available from furnace could not be
completely utilized for steam formation and so the overheating may cause melting
of fusible metal. Fusible metal is a low melting point metal.
• Thus upon melting fusible plug falls down onto furnace and thus quenches
fire.
 SAFETY VALVE:

• Its function is to prevent the steam pressure from exceeding a limiting

maximum pressure value.
• Safety valve should operate automatically by releasing excess steam
and bring pressure down within safe limits.
• These are of different types such as -
dead weight safety valve
lever safety valve
spring loaded safety valve
SAFETY VALVES
 STOP VALVE:

• It regulates the flow of steam from the boiler .

• This is generally mounted on highest part of boiler shell and performs
function of regulating the flow of steam from boiler.
• Stop valve generally has main body of cast steel, valve, valve seat and
nut etc. are of brass.
• Stop valve can be easily operated by rotating the hand wheel which
causes lifting or lowering of spindle, thus causing opening or closing of
valve.
STEAM STOP VALVE
 FEED CHECK VALVE:

• It is a non return valve at the end of delivery pipe from feed water
pump and is placed on boiler shell slightly below normal water level.
• Feed check valve permits unidirec-tional flow of water from feed
pump to be boiler shell.
• Under normal running the pressure of feed water coming from pump is
more than pressure inside the boiler and so the feed water continues to
enter the shell.
• While during the non working of feed pump the pressure in boiler shell
is more and so the check valve gets closed.
BLOW OFF COCK
BOILER ACCESSORIES
 SUPERHEATER:

• Its purpose is to superheat steam and is a type of heat

exchanger in which steam flows inside tubes and hot gases
surround it.
• Heat is transferred mainly by convection and radiation.
 ECONOMIZER:

• It is also a heat recovery device in which feed water is heated from

heat available with exhaust gases. Thus hot feed water available from
economizer lowers the fuel requirement in combustion.
• It is also a type of heat exchanger having exhaust gas and feed water as
two fluids.
 AIR PREHEATER

• It is used for recovering the heat going along with exhaust gases by the
air before being sent to furnace. Heat is recovered by passing exhaust
gases through an air to air heat exchanger.
• It is heat exchanger which increases the temperature of Air going to
furnace by usibg the heat of combustion gases going to chimney
from economizer.
• Air preheaters are generally placed after economizer and before
chimney.
• Air when preheated before supply to furnace/combustion chamber
helps in achieving ‘faster rate of combustion’, ‘possibility of burning
FEED PUMP
BABCOCK AND WILCOX BOILER
• It is
Water Tube,
inclined tubes,
stationary,
internally fired
Natural Circulation
boiler.
 • Boiler Mountings- for Safe operation of
BABCOCK AND WILCOX BOILER Boiler

• It is suitable for meeting demand of increased pressure • (i) Water level indicator
and large evaporation capacity or large sized boiler units • (ii) Safety valves

• It has three main parts: (i) Steam and water drum (ii) • (iii) Fusible plug
Water tubes (iii) Furnace • (v) Pressure gauge

• The function of steam drum- • (vi) Stop valve

• (vii) Feed check valve
a.) To store water and steam to meet variable load
requirement. • (viii) Blow off cock
• (ix) Manhole and mud box
b) To separate steam from water.
Boiler accessories- they are to increase
c.) To maintain desired PPM by phosphate injection. efficiency of Boiler.
Risers- Installed all around furnace wall .Tubes which are Boiler accessories are:
heated more and placed inside furnace. • (i) Superheater
Downcomers- Tubes which are heated less and placed • (ii) Economiser
outside furnace or away from furnace wall. • (iii) Air preheater
 STIRLING
BOILER-

It is-
Water tube,
stationary, Bent
tube, natural
circulation
boiler.
 STIRLING BOILER
• This is a water tube boiler in which bent tubes are connected to three or four drums together.
• Bent tubes are advantageous in respect to flexibility in maximizing heating surface and no
requirement of headers. For deflecting the hot gases the baffles areprovided. Here three steam
drums and one mud drum are used.
• Feed water enters the first steam drum located near the exit passage and pass through tubes to
mud drum and subsequently gets raised through tubes into other steam drum. Thus the water is
circulated so as to pick maximum heat from hot gases.
• Steam generated is collected in upper portion of steam drums from where it can be extracted
out.
• Hot gases coming from furnace area travel across the boiler and go out of exit passage after
transferring heat contained by them.
• Such boilers are capable of generating steam upto maximum pressure of 60 bar and steam
generation rate up to 50,000 kg/hr
 LANC ASHIRE BOILER- Boiler Mountings- for Safe
• It is a horizontal , low pressure , stationary , internally operation of Boiler
(i) Water level indicator
fired , natural circulation fire tube boiler. (ii) Safety valves
• It has a circular shell connected to end plates supported by gusset (iii) Fusible plug
plates. Two fire tubes run throughout the length of the boiler.. (v) Pressure gauge
• . Hot gases start from grate area, enter into fire tubes and come out (vi) Stop valve
at back of boiler from where these gases flow towards the front of (vii) Feed check valve
boiler through bottom flue. (viii) Blow off cock
(ix) Manhole and mud box
• Upon reaching the front these hot gases flow through the side flues Boiler accessories- they
and enter the main outlet. Outlet passage may also be used are to increase efficiency
commonly by more than one boilers. of Boiler.
• Working pressure in these boilers are in the range of 0.7 MPa to 2 Boiler accessories are:
MPa and efficiency of the boiler is about 65%–70%. Size of these (i) Superheater
boiler depends upon size of shell which may be 2 m to 3 m in (ii) Economiser
diameter and 6m to 10m in length. (iii) Air preheater
 LOCOMOTIVE BOILER-
• These boilers were invented for getting steam to run a steam engine used in locomotives.
• These are fire tube type of boilers. It has basically three parts i.e. smoke box, shell and fire box.
Inside fire box the fuel (coal) is burnt over the grate. For feeding fuel the fire hole is used.
• Hot gases produced in fire box are diverted by fire brick arch and enter into the fire tubes
surrounded with water.
• Steam produced gets collected in a steam drum fitted on top of the shell. Arrangement for super
heating is there in these boilers. As shown the wet steam goes through inlet headers of
superheater and after passing throughtubes,it returns to the outlet header of superheater and is
taken out for steam engine.
• A very large door is provided at the end of smoke box so as to facilitate cleaning and
maintenance of complete boiler.
• As it is a moving boiler, therefore, its chimney is completely eliminated.
• For expelling the burnt gases (draught) the exhaust steam coming out from steam engine is
being used. Thus it is an artificial draught used in these boilers for expelling burnt gases
COCHRAN
BOILER

It is
vertical,
stationary,
Internally
fired,
fire tube
boiler.
 COCHRAN BOILER
• This is a fire tube boiler of vertical type and came up as a modification over the simple vertical
boiler in order to maximize heating surface.
• Total heating surface area is 10–25 times the grate area. It has cylindrical shell with
hemispherical crown.
• Hemispherical geometry offers maximum volume space for given mass of material and is also
very good for strength and maximization of radiant heat absorption.
• Fire box is also of hemispherical form. Flue gases flow from fire box to refractory material lined
combustion chamber through a flue pipe.
• After coming out of fire tubes hot gases enter into smoke box having chimney upon it.
• As the fire box is separately located so any type of fuel such as wood, paddy husk, oil fuel etc.
can be easily burnt.
• These boilers are capable of generating steam up to pressure of 20 bar and steam generating
capacity from 20 kg/hr to 3000 kg/hr.
• Boilers have dimensions ranging from 1 m diameter and 2 m height to 3 m diameter and 6 m
 BENSON BOILER
• It is a water tube boiler capable of generating steam at supercritical pressure.
• It generates steam at supercritical pressure hence water flashes into vapour
without any latent heat requirement. Above critical point the water transforms into
steam in the absence of boiling and without any change in volume
• The supercritical steam generation does not have bubble formation and pulsations
etc.
• Steam generation also occurs very quickly in these boilers. As the pressure and
temperatures have to be more than critical point, so material of construction
should be strong enough to withstand thermal stresses. Feed pump has to be of
large capacity as pressure inside is quite high, which also lowers the plant
efficiency due to large negative work requirement.
• Benson boilers generally have steam generation pressure more than critical
pressure and steaming rate of about 130–135 tons/hr.
HIGH PRESSURE
BOILERS
 BOILER DRAUGHT

• . Draught refers to the pressure difference created for the flow of gases
inside the boiler
• Boiler unit has a requirement of the expulsion of combustion products and
supply of fresh air inside furnace for continuous combustion.
• The function of draught system is –
1. To supply required quantity of air to furnace for complete combustion of
fuel.
2. To remove the gaseous products of combustion from furnace and throw
these through chimney to atmosphere.
• Draught may be created naturally( by using of chimney) or artificially
by using some external device.
 NATURAL DRAUGHT
• The natural draught is produced by a chimney.
• Hot gases inside the chimney are lighter than the
outside cold air i.e. density difference of hot gases
inside chimney and cold atmospheric ai.
• It means that amount of draught produced by a
chimney depends upon flue-gas temperature.
Intensity of draught produced by chimney also
depends upon height of chimney.
• Efficiency of chimney:
• Chimney efficiency = Energy with unit mass of
gas in natural draught /Extra heat carried away in
natural draught compared to artifical draught by
unit mass of gas.
NATURAL DRAUGHT • ∆𝑷 = 𝒈𝑯 𝝆𝒂 − 𝝆𝒈
• 𝜌𝑎 = Density of air, Kg/m3
• 𝜌𝑔 = Density of combustion gases in Kg/m3.
• The density of air at temperature ,Ta

𝜌𝑎 = 353/Ta = 1.293 x 273 /Ta

The density of flue gases is given by
353 𝑚+1
𝜌g =
𝑇𝑔 𝑚
Draught is given by-

1 𝑚+1 1
P = 353 gH −
𝑇𝑎 𝑚 𝑇𝑔

Draught is given by in (terms of water column in mm)

𝟏 𝒎+𝟏 𝟏
h= 353 H − .
𝑻𝒂 𝒎 𝑻𝒈
CONDITION FOR MAXIMUM DISCHARGE THROUGH CHIMNEY

Head created by hot combustion

gases is given by-
𝒎 𝑻𝒈
𝑯𝒈 = 𝑯( . − 𝟏)
𝒎+𝟏 𝑻𝒂
 CHIMNEY EFFICIENCY

Chimney efficiency = Energy with unit mass of gas in natural draught /

Extra heat carried away in natural draught compared
to artificial draught by unit mass of gas.

• Tg,a is temperature of flue gases in artificial draught

• Tg temperature of flue gases in natural draught.
• C p, g, J/kg K is specific heat of hot flue gases .
MECHANICAL DRAUGHT-
 FORCED DRAUGHT:

• It is the arrangement in which high pressure air is delivered to the

furnace so as to force flue gases out through stack.
• It is positive pressure draught in which fan is placed at base of boiler
before grate.
• Air under pressure may be fed to stokers or grate for which a
fan/blower is put at the bottom of furnace.
• Due to pressurised air the pressure inside furnace becomes more than
atmospheric pressure so it should be properly sealed, otherwise gas may
leak.
 INDUCED DRAUGHT:

• Fan is located at base of chimney in induced draught so as to reduce

pressure at fuel bed below atmospheric pressure.
• Induced draught is the one in which the suction created on furnace
side draws flue gases and throws them out through small
chimney/stack.
• The fan in induced draught shall handle hot flue gases. Power
required to drive the fan/blower in case of induced draught is less
than that in case of forced draught fan.
 COMPARISON OF FORCED AND INDUCED DRAUGHT:

• Power requirement is more in case of induced draught fan blower as

compared to forced draught.
• Induced draught fan/blower withstands high temperature, so the fan cooling
requirements are very stringent as compared to forced draught.
• Combustion rate is better in case of forced draught system as compared to induced
draught system.
• Maintenance is easy in forced draught fan as compared to induced draught
due to their locations.
• Leakage of atmospheric air into furnace due to sub atmospheric pressure inside the
induced draught system causes dilution of flue gases. In case of forced draught,
the pressure inside is more than atmospheric pressure so chances of leakage of
furnace gases out to atmosphere are there.
 BALANCED DRAUGHT:
• Sometimes , forced draught or induced draught alone is not suitable for
boiler unit due to their own inherent limitations.
• It is combination of forced draught and induced draught.
• Both forced draught fan/blower and induced draught fan/blower
are employed.
• Forced draught fan ensures complete supply of air for proper
combustion after overcoming all resistances while induced draught fan
takes care of post combustion resistances, thus ensuring complete
removal of flue gases.
 BOILER EFFICIENCY
• It is Ratio of heat actually used for steam generation and total heat available due to
combustion of fuel in boiler.
• Boiler efficiency = Heat used in steam generation /Total heat available due to fuel
burning.
𝒎. 𝒉−𝒉𝒘
• Boiler efficiency =
𝒎𝒇 . 𝑪𝑽
❖mf is the mass of fuel burnt per hour,
❖C.V. is calorific value of fuel used (kcal/kg)
❖m is mass of steam generated per hour
❖Enthalpies h and hw are that of final steam and feed water, kcal/kg
 EQUIVALENT EAPORATION

• There exists a large variety of the boilers in terms of their arrangement, efficiency, steam
generation rate, steam condition, type of fuel used, firing method and draught etc.
• For comparing one boiler with other any of the above parameters can not be considered as
they are interdependent.
• For comparing the capacity of boilers working at different pressures, temperatures,
different final steam conditions etc. “equivalent evaporation is used.
• . Equivalent evaporation refers to the quantity of dry saturated steam generated per unit time
from feed water at 100C to steam at 100C at the saturation pressure corresponding to 100C.
• Equivalent evaporation=
Mass of steam generated per hour 𝒙 Heat supplied to generate steam in boil𝒆𝒓
Heat supplied for steam generation at 100 C from water at 100 C i.e. (Latent heat)
• Heat supplied for generating steam at 100C from water at 100C at respective saturation
pressure is 538.9 or 539 kcal/kg = 2257 KJ/Kg
𝒎. 𝒉−𝒉𝒘 𝒎. 𝒉−𝒉𝒘
• Equivalent evaporation in(Kg/Kg of fuel) = =
𝟓𝟑𝟗 𝟐𝟐𝟓𝟕
EQUIVALENT EVAPORATION
 BOILER TRIAL
• Boiler trial refers to running the boiler under test conditions for its
performance estimation.
• It gives the steam generation capacity of boiler, thermal efficiency of plant
and heat balance sheet of the boiler.
• Under trial the boiler is run for quite long durations so as to attain steady state.
Generally the boilers are run for 4 to 6 hours duration for the boilers of oil fired
type and coal fired types. Duration of boiler run for attaining steady state changes
from boiler to boiler.
• Observations are taken after the boiler attains steady state for a duration ranging
from 10–15 minutes.
• Measurements are made for fuel supply, combustion analysis, steam
generation rate and its quality/state, flue gas and their analysis, temperature
and pressure at salient locations and all other measurements as required for
 HEAT BALANCE SHEET

• Total Heat -
• Q = mf .CV
• mf is the mass of fuel burnt per hour, C.V. is calorific value of fuel used
(kcal/kg).
• Heat used for generation-
• Qsteam = msteam (h – hw)
• msteam is mass of steam generated per kg of fuel burnt,
• h is enthalpy of final steam produced
• hw is enthalpy of feed water.
• :
 HEAT LOSS TO DRY FLUE GASE

• Qdry flue = mdfg Cpg (T g – Ta)

• where mdfg is mass of dry flue gas per kg of fuel,

• Cpg is specific heat of dry flue gas and
• Tg and Ta are temperature of flue gas and air entering combustion
chamber.
 HEAT LOST DUE TO INCOMPLETE COMBUSTION

• Heat loss due to incomplete combustion = Heat released when carbon burns into
CO2 – Heat released when carbon burns into CO.
• During complete combustion of carbon into CO2, 3.38 104 KJ of heat is
released.
• with incomplete combustion of carbon into CO, 1.012 104 KJ of heat is
released by burning one kg, of carbon.
• Hence heat loss due to incomplete combustion of one kg of carbon shall be =
2.368 104 KJ per kg of carbon.
• where fCO and fCO2 are percentage by volume of CO and CO2 present in flue
gases, fC is fraction of carbon present in per kg of fuel.
𝒇𝒄𝒐
• Heat loss due to incomplete combustion = x fc x 2.368 104 ,
𝒇𝒄𝒐 + 𝒇𝑪𝑶𝟐
kJ/kg of fuel
 HEAT LOSS TO STEAM IN FLUE GASES

• Qsteam in flue = ms (hs1 – hf1)

• where ms is mass of steam produced per kg of fuel,

• hs1 is enthalpy values of steam at gas temperature Tg and partial
pressure of vapour in flue gas.
• hf1 is enthalpy of water at mean boiler temperature.
 HEAT LOST IN UNBURNT FUEL :

• Qunburnt = mubf . CV

• where mubf is mass of unburnt fuel per kg of fuel

• CV is calorific value of fuel
 HEAT LOSS DUE TO MOISTURE IN FUEL:

• Qmoisture = mmoist (hs2 – hf2)

• where mmoist is mass of moisture per kg of fuel burnt, hs2 is

enthalpy of final steam produced.
• and hf2 is enthalpy of water at boiler furnace temperature.
 HEAT LOSS DUE TO CONVECTION, RADIATION AND OTHER
UNACCOUNTABLE LOSSES

• Qunaccounted = (mf .CV) – (Qsteam + Qincomplete +

Qdry flue + Qsteam in flue + Qunburnt + Qmoisture)
 NUMERICAL-1

• A boiler uses 200 Kg/h of coal. The 𝟏 𝒎+𝟏 𝟏

temperature of air supplied is 300K and h= 353 H − .
𝑻𝒂 𝒎 𝑻𝒈
average temperature of flue gases leaving
the chimney is 650K. The 33 m high steel
353 𝑚+1
chimney produces a draught of 20mm of 𝜌g =
𝑇𝑔 𝑚
water column. Determine the following-
a)quantity of air supplied per Kg of coal
b) The draught in terms of column of hot Head created by hot combustion
gases is given by-
gases. 𝒎 𝑻𝒈
c) Base diameter of chimney assuming that 𝑯𝒈 = 𝑯( . − 𝟏)
𝒎+𝟏 𝑻𝒂
10% of theoretical draught is used for
creating velocity of gases through chimney.
NUMERICAL-2
• Given: T g = 300 + 273 = 573 K, SOLUTION
• Ta = 17 + 273 = 290 K,
• T g, a = 150 + 273, H = 60 m,
• m = 19 kg air per kg of fuel,
𝟏 𝒎+𝟏 𝟏
• T g, a = 423 K Draught in mm of water column h= 353 H − .
𝑻𝒂 𝒎 𝑻𝒈
• Draught = 34.13 mm of water column
• Chimney efficiency = 0.3431%
• Extra heat carried by flue gases per kg of
fuel
• = (19 + 1) (T g – T g, a)
• = 20 1.0032 (C p, g 573 – 423)
• = 3009.6 kJ per kg of fuel
 NUMERICAL-3-
• From steam table at 10 bar,
• Determine the actual evaporation per kg hf = 762.81 kJ/kg, h g = 2778.1 kJ/kg hfg =
of coal and the equivalent evaporation if 2015.29 kJ/kg
during boiler trial of one hour duration
following observations are made: • Enthalpy of steam steam generated, h = hf + x
hfg = 762.81 + 0.95 2015.29
• Feed water supply temperature: 27C
• h = 2677.34 kJ/kg
• Mean steam generation pressure: 10 bar.
• Mass of water evaporator per hour = 2500 + 300
• Dryness fraction of steam generated: = 2800 kg/hr
0.95
• Water evaporated per kg of coal = 2800 /275 =
• Feed water supplied: 2500 kg/hr 10.18 kg per kg of coal.
• Coal burnt: 275 kg/hr • Actual evaporation = 10.18 kg per kg of coal
• Mass of water in boiler after trial = 300 • Equivalent evaporation = 12.08 kg per kg of
kg less than that at commencenent of coal
trial.
𝒎. 𝒉−𝒉𝒘 𝒎. 𝒉−𝒉𝒘
Equivalent evaporation in(Kg/Kg of fuel) = =
𝟓𝟑𝟗 𝟐𝟐𝟓𝟕
 NUMERICAL-4

• A boiler is being tested for 24 hours and during this trial steam
at average pressure of 10 bar, dry saturated is produced from
15 ton of water consuming 1.5 ton of coal. Composition of coal
has 3% moisture and 4% ash. Feed water is added at 35°C.
Calorific value of coal: 30100 kJ/kg Determine, (i) the boiler
efficiency, (ii) the equivalent evaporation per kg of dry coal.
iii) the equivalent evaporation per kg of combustible present in
coal.
 SOLUTION 𝒎. 𝒉−𝒉𝒘
Boiler efficiency =
𝒎𝒇 . 𝑪𝑽
• Enthalpy of steam generated = h g at 10 bar = 2778.1 kJ/kg =h
• Heat supplied per kg of water for steam generation = 𝒉 − 𝒉𝒘
= 2778.1 – 4.18 x 35 = 2631.8 kJ/kg
• Steam generated per kg of coal = m= 15 x 103 / 1.5 x 103 = 10 kg
• Boiler efficiency = 0.8744 or 87.44%

• Equivalent evaporation per kg of dry coal =(10 x 2631.8) / 2257 x 0.97

• Equivalent evaporation per kg of dry coal = 12.02 kg
• Equivalent evaporation per kg of combustible = 12.53 kg
 NUMERICAL-5

• A boiler generates 5000 kg/hr steam at 20 bar, 0.98 dry from feed
water supplied to it at 60°C. Boiler sums on coal supplied at the rate
of 600 kg/hr and air supplied at the rate of 16 kg per kg coal. The
calorific value of coal is 30000 kJ/kg and boiler room temperature is
20°C. Considering 86% of heat being lost with flue gases. Determine
temperature of flue gases leaving boiler. Take specific heat of flue
gases as 1.005 kJ/kg·K
 SOLUTION
• Mass of steam generated per kg of coal = 5000 /600 = 8.33 kg steam per kg coal
• Enthalpy of final steam produced at 20 bar, 0.98 dry
• hfinal = hf at 20 bar + 0.98 × hfg at 20 bar
hfinal = 908.79 + (0.98 × 1890.7) = 2761.67 kJ/kg
• Enthalpy of feed water, hwater = hf at 60° C = 251.13 kJ/kg
• Heat utilized for steam generation = 8.33(2761.67 – 251.13) = 20912.8 kJ per kg of coal
• For the given coal, the heat lost per kg of coal = 30,000 – 20912.8 = 9087.2 kJ per kg coal.
• Heat lost with flue gases = 0.86 × 9087.2 = 7814.9 KJ per kg coal
• Let the temperature of flue gases leaving boiler be Tgas.
• Heat lost with flue gases = 7814.9 = (mflue + mair) × c p gas (Tgas – 293)
• = (16 + 1) × 1.005 × (T gas – 293)
• Tgas = 750.37 K = 477.37°C
N UM ERICA L -6- D RAW UP A H EAT BA LA NCE SH EET F O R THE BOI LER I N K J PER K G
O F D RY COA L A ND A LSO D E T E RMI N E THE BOIL E R EF FI CIEN CY AN D
E FF E CTIVE N ES S OF AI R H EATE R FO R TH E F OL L OW ING DATA O BTAI NE D D U RING
BOI L E R TRIA L . TH E BOI LE R H AS E CO NO MIS E R AN D AI R PRE H EAT E R AS TW O
A CCE S S O RI E S I N I T

• Atmospheric air temperature: 15C • Temperature of air entering boiler furnace

= 120C
• Steam generation: 40 bar, 400C
• Dry coal composition by mass = 84% C,
• Steam generated per kg of coal = 8 kg 4% H2, 7% O2 and remainder ash
• Feed water temperature at inlet to economiser = • Dry flue gas composition by volume =
27C 12.5% CO2, 7.5% O2, 80% N2
• Feed water temperature at exit of economiser • Datum temperature = 15°C
= 137C
• Calorific value of coal = 32600 kJ/kg
• Moisture in coal burnt = 1.5%
• For air and dry flue gas, cp =1.0032 kJ/kg
• Flue gas temperature entering air heater =300C K Partial pressure of vapour in flue gas =
• Flue gas temperature leaving air heater and 0.075 bar Specific pressure of vapour =
entering chimney = 150C 2.0064 kJ/kg K
NUMERICAL-7
 NUMERICAL-8

• A boiler generates 7.5 kg of steam per kg of coal burnt at a

pressure of 11 bar, from feed water having a temperature of 70
oC. The efficiency of boiler is 75% and factor of evaporation
1.15. Specific heat of steam at constant pressure is 2.3.
Calculate: (i) Degree of superheat and temperature of steam
generated; (ii) Calorific value of coal in kJ/kg; (iii) Equivalent
evaporation in kg of steam per kg of coal.