Boiler & Steam

Boiler Type
• Cylindrical boilers: • Water tube boilers:
- Vertical boiler; - Natural circulation boilers;
- Less area & easy installation
- Small capacity - Circulation due to density difference
- Moisture contain in steam
- Difficult to clean & inspect - Small to large capacity
- Boiler efficiency is about 50 – 85 % - About 80 % are of this type
- Flue tube boiler - Force Circulation boilers
- Long time to generate steam
- Less pressure fluctuation - Possible to decrease diameter & thickness
- Easy to clean & inspect - Water tube piping can be freely constructed
- Boiler efficiency is about 50 %
- Less scale formation
- Smoke tube boiler - Once through boilers.
- Short time to generate steam
- Difficult to clean inside - Less expensive
- Boiler efficiency is about 70 %
- Easy to operate (minor industry, hospital,
- Flue & smoke tube boiler; etc.)
- Combination of flue tubes & smoke tubes - Higher boiler efficiency of 80 – 90 %
- Improve heat transfer
- Easy installation & less expensive (water tube)
- Boiler efficiency is about 80 – 90 %
Heating Surface VS Evaporation Rate
 Boiler Problems
(caused by water)
• Scale Problem;
- Low Pressure Boiler;
- Poor water quality
- Poor condition (incomplete control of softener)
- Incomplete control of boiler water (blow down etc.)
- Insufficient of chemical injection amount
- High Pressure Boiler;
- Poor water quality
- Contamination by metal hydrates (poor pretreatment)
- Impurity leakage from production process
- Unsuitable chemical injection point
• Corrosion Problem;
- Low Pressure Boiler;
- Insufficient pH control and oxygen scavenging
- Recovery of condensate containing corrosion product
- During shutdown or idling period
- High Pressure Boiler;
- Corrosion product in feed/condensate lines
- Insufficient pH control and oxygen scavenging
- Insufficient boiler water control on pH and P-alkalinity
- Increase of boiler pH caused by Na+ leakage from
deminwater
- During shutdown or idling period
 Boiler Problems
(caused by water)

• Carryover problem;
- Low Pressure Boiler;
- Sudden change load
- Insufficient boiler operation control
- Malfunction of steam separator and feed water control
- Impurity leakage from production process
- High Pressure Boiler;
- Abnormal boiler water quality (silica)
- Suspended solids and metal hydrates
- Sudden change of load
- Unsuitable chemical injection point
- Impurity contamination from process
 Internal Boiler Water Treatment
• Boiler Treatment Chemicals;
- Scaling convert to suspended fine sludge
- Kept adequate alkalinity (pH) to reduce silica scale
- Remove dissolved oxygen
- Prevent corrosion by CO2 and O2 in steam and condensate line
- Prevent transfer solid from boiler water to steam.
• Boiler Compounds;
- Phosphate base
- Non-phosphate base
• Sludge Dispersant;
- Natural polymer
- Synthetic polymer
• Oxygen Scavenger;
- Sodium Sulfite (Na2SO3)
- Hydrazine (N2H4)
• Corrosion Inhibitors;
- Volatile amines (R – NH2)
• Antifoaming Agent;
- Amide/alcohol/fatty acid ester based
• Multipurpose Boiler Chemicals;
- Phosphate based multipurpose chemicals
- Non-phosphate based multipurpose chemicals
 Energy-saving for Boiler
• Reduction of Blow-down;
- Function of enthalpy of boiler water – feed water
• Recovery Condensate;
- Function of enthalpy of condensate water – feed water
• Prevention of decrease in Thermal Efficiency
- Function of reducing overall heat transfer
• Heat Recovery
- Function of increasing enthalpy of feed water
• Prevention of Steam Leakage;
- Function of enthalpy of steam – feed water.
 Steam
• Saturated Steam :
- Steam with condition of temperature and pressure at boiling point
- If some energy transferred from saturated steam than some steam
will condense with out change in temperature if pressure not
changes.
- Has latent heat
• Superheated Steam:
- Steam with condition that temperature higher than boiling point at
that pressure.
- If some energy transferred from superheated steam than
temperature will reduce at the same pressure until steam become
saturated steam.
- Has latent heat and sensible heat
 Steam Trap
(condensate forms in the distribution system due to unavoidable radiation)

• Inverted bucket;
- mechanical trap that operate on the difference in density between
steam and condensate.
• Float & Thermostatic;
- mechanical trap that operates on both density and temperature
principles.
• Control Disc;
- time delayed device that operates on the velocity principles
• Bimetallic Steam Trap;
- bimetallic element nickel – chrome will expand than tight shutoff in
increasing temperature.
• Thermostatic;
- steam increasing pressure inside the thermostatic element, causing
the trap to close.
Heat Radiation Schema
Inverted Bucket Steam Trap
Float & Thermostatic Steam Trap
Controlled Disc Steam Trap
Bimetallic Steam Trap
Thermostatic Steam Trap