Energy Management In Industry Assignment

Name : Dwi Anggraini

NIM : 03012681318008


WATER TUBE BOILER AND FIRE TUBE BOILER

A. Water Tube Boiler
A water tube boiler is a type of boiler in which water circulates in tubes
heated externally by the fire. Fuel is burned inside the furnace, creating hot gas
which heats water in the steam-generating tubes. In smaller boilers, additional
generating tubes are separate in the furnace, while larger utility boilers rely on the
water-filled tubes that make up the walls of the furnace to generate steam. The
heated water then rises into the steam drum. Saturated steam is drawn off the top
of the drum. In some services, the steam will reenter the furnace through a super
heater to become superheated. Superheated steam is defined as steam that is
heated above the boiling point at a given pressure. Superheated steam is a dry gas
and therefore used to drive turbines, since water droplets can severely damage
turbine blades.
Cool water at the bottom of the steam drum returns to the feed water drum via
large-bore down comer tubes', where it pre-heats the feed water supply. (In large
utility boilers, the feed water is supplied to the steam drum and the down comers
supply water to the bottom of the water walls). To increase economy of the boiler,
exhaust gases are also used to pre-heat the air blown into the furnace and warm
the feed water supply. Such water tube boilers in thermal power station are also
called steam generating units. The older fire-tube boiler design in which the
water surrounds the heat source and the gases from combustion pass through tubes
through the water space is a much weaker structure and is rarely used for
pressures above 350 psi (2.4 MPa). A significant advantage of the water tube
boiler is that there is less chance of a catastrophic failure, there is not a large
volume of water in the boiler nor are there large mechanical elements subject to
failure.

Fig 1, Schematic diagram of a marine-type water tube boiler

Design Variations
1. D-type boiler
The 'D-type' is the most common type of small- to medium-sized boilers,
similar to the one shown in the schematic diagram. It is used in both stationary
and marine applications. It consists of a large steam drum vertically connected
to a smaller water drum (a.k.a. "mud drum") via multiple steam-generating
tubes. These are surrounded by walls made up of larger water-filled tubes,
which make up the furnace.
2. M-Type Boilers
The M-Type boilers were used in many US WWII warships including
hundreds of FLETCHER class destroyers. Three sets of tubes form the shape
of an M, and create a separately fired superheater that allows better superheat
temperature control. In addition to the mud drum shown on a D-type boiler, an
M-Type has a water-screen header and a water wall header at the bottom of
the two additional rows of vertical tubes and down comers.

3. Low Water Content
The 'Low Water Content' boiler has a lower and upper header connected
by water tubes that are directly impinged upon from the burner. This is a
"furnace-less" boiler that can generate steam and react quickly to changes in
load.
4. Babcock & Wilcox boiler

Fig 2, Babcock & Wilcox boiler
Designed by the American firm of Babcock and Wilcox, this type has a single
drum, with feed water drawn from the bottom of the drum into a header that
supplies inclined water-tubes. The water tubes supply steam back into the top of
the drum. Furnaces are located below the tubes and drum.
5. Stirling boiler
The Stirling boiler has near-vertical, almost-straight water tubes that zig-
zag between a number of steam and water drums. Usually there are three
banks of tubes in a "four drum" layout, but certain applications use variations
designed with a different number of drums and banks.
They are mainly used as stationary boilers, owing to their large size, although
the large grate area does also encourage their ability to burn a wide range of fuels.
Originally coal-fired in power stations, they also became widespread in industries
that produced combustible waste and required process steam. Paper pulp mills
could burn waste bark, sugar refineries their bagasse waste. It is a horizontal type
of boiler.
1. Yarrow

Fig 3, End-view of a Yarrow boiler
Named after its designers, the then Poplar-based Yarrow Shipbuilders, this
type has three drums in a delta formation connected by water tubes. The drums
are linked by straight water tubes, allowing easy tube-cleaning. This does,
however, mean that the tubes enter the drums at varying angles, a more
difficult joint to caulk. Outside the firebox, a pair of 'cold-leg' pipes between
each drum act as 'down comers'.
Due to its three drums, the Yarrow boiler has a greater water capacity.
Hence, this type is usually used in older marine boiler applications. Its compact
size made it attractive for use in transportable power generation units
during World War II. In order to make it transportable, the boiler and its
auxiliary equipment (fuel oil heating, pumping units, fans etc.), turbines,
and condensers were mounted on wagons to be transported by rail.
2. White-Forster
The White-Forster type is similar to the Yarrow, but with tubes that are
gradually curved. This makes their entry into the drums perpendicular, thus
simpler to make a reliable seal.
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3. Thornycroft

Fig 4, End-view of a Thornycroft boiler
Designed by the shipbuilder John I. Thorny croft & Company, the Thorny
croft type features a single steam drum with two sets of water tubes either side
of the furnace. These tubes, especially the central set, have sharp curves. Apart
from obvious difficulties in cleaning them, this may also give rise to bending
forces as the tubes warm up, tending to pull them loose from the tube plate and
creating a leak. There are two furnaces, venting into a common exhaust, giving
the boiler a wide base tapering profile.
4. Forced-circulation boiler
In a forced-circulation boiler, a pump is added to speed up the flow of
water through the tubes.

B. FIRE TUBE BOILER
A fire-tube boiler is a type of boiler in which hot gases from a fire pass
through one or more tubes running through a sealed container of water.
The heat of the gases is transferred through the walls of the tubes by thermal
conduction, heating the water and ultimately creating steam.
The fire-tube boiler developed as the third of the four major historical types of
boilers: low-pressure tank or "haystack" boilers, flued boilers with one or two
large flues, fire-tube boilers with many small tubes, and high-pressure water-tube
boilers. Their advantage over flued boilers with a single large flue is that the many
small tubes offer far greater heating surface area for the same overall boiler
volume. The general construction is as a tank of water penetrated by tubes that
carry the hot flue gases from the fire. The tank is usually cylindrical for the most
partbeing the strongest practical shape for a pressurized containerand this
cylindrical tank may be either horizontal or vertical.
This type of boiler was used on virtually all steam locomotives in the
horizontal "locomotive" form. This has a cylindrical barrel containing the fire
tubes, but also has an extension at one end to house the "firebox". This firebox has
an open base to provide a large grate area and often extends beyond the
cylindrical barrel to form a rectangular or tapered enclosure. The horizontal fire-
tube boiler is also typical of marine applications, using the Scotch boiler. Vertical
boilers have also been built of the multiple fire-tube type, although these are
comparatively rare: most vertical boilers were either fluid, or with cross water-
tubes.

Operation

Fig 5, Schematic diagram of a "locomotive" type fire-tube boiler
In the locomotive-type boiler, fuel is burnt in a firebox to produce hot
combustion gases. The firebox is surrounded by a cooling jacket of water
connected to the long, cylindrical boiler shell. The hot gases are directed along a
series of fire tubes, orflues, that penetrate the boiler and heat the water thereby
generating saturated ("wet") steam. The steam rises to the highest point of the
boiler, the steam dome, where it is collected. The dome is the site of
the regulator that controls the exit of steam from the boiler.
In the locomotive boiler, the saturated steam is very often passed into
asuperheater, back through the larger flues at the top of the boiler, to dry the
steam and heat it to superheated steam. The superheated steam is directed to the
steam engine's cylinders or very rarely to a turbine to produce mechanical work.
Exhaust gases are fed out through a chimney, and may be used to pre-heat the
feed water to increase the efficiency of the boiler. Draught for fire tube boilers,
particularly in marine applications, is usually provided by a tall smoke stack. In all
steam locomotives since Stephenson's Rocket, additional draught is supplied by
directing exhaust steam from the cylinders into the smokestack through a blast
pipe, to provide a partial vacuum.
Modern industrial boilers use fans to provide forced or induced draughting
of the boiler. Another major advance in the Rocket was large numbers of small-
diameter fire tubes (a multi-tubular boiler) instead of a single large flue. This
greatly increased the surface area for heat transfer, allowing steam to be produced
at a much higher rate. Without this, steam locomotives could never have
developed effectively as powerful prime movers.

Types Of Fire Tube Boiler
1. Cornish boiler
The earliest form of fire-tube boiler was Richard Trevithick's "high-
pressure" Cornish boiler. This is a long horizontal cylinder with a single large
flue containing the fire. The fire itself was on an iron grating placed across this
flue, with a shallow ash pan beneath to collect the non-combustible residue.
Although considered as low-pressure (perhaps 25 psi) today, the use of a
cylindrical boiler shell permitted a higher pressure than the earlier "haystack"
boilers of New comen's day. As the furnace relied on natural draught (air
flow), a tall chimney was required at the far end of the flue to encourage a
good supply of air (oxygen) to the fire. For efficiency, the boiler was
commonly encased beneath by a brick-built chamber. Flue gases were routed
through this, outside the iron boiler shell, after passing through the fire-tube
and so to a chimney that was now placed at the front face of the boiler.

2. Lancashire boiler

Fig 6, Lancashire boiler
The Lancashire boiler is similar to the Cornish, but has two large flues containing
the fires. It was the invention of William Fairbairn in 1844, from a theoretical
consideration of the thermodynamics of more efficient boilers that led him to
increase the furnace grate area relative to the volume of water. Later
developments added Galloway tubes (after their inventor, patented in 1848),
crosswise water tubes across the flue, thus increasing the heated surface area. As
these are short tubes of large diameter and the boiler continues to use a relatively
low pressure, this is still not considered to be a water-tube boiler. The tubes are
tapered, simply to make their installation through the flue easier.

3. Scotch marine boiler
The Scotch marine boiler differs dramatically from its predecessors in
using a large number of small-diameter tubes. This gives a far greater heating
surface area for the volume and weight. The furnace remains a single large-
diameter tube with the many small tubes arranged above it. They are connected
together through a combustion chamber an enclosed volume contained
entirely within the boiler shell so that the flow of flue gas through the fire
tubes is from back to front. An enclosed smoke box covering the front of these
tubes leads upwards to the chimney or funnel. Typical Scotch boilers had a pair
of furnaces, larger ones had three. Above this size, such as for large steam
ships, it was more usual to install multiple boilers.

4. Locomotive boiler
A locomotive boiler has three main components: a double-walled firebox;
a horizontal, cylindrical "boiler barrel" containing a large number of small
flue-tubes; and a smoke box with chimney, for the exhaust gases. The boiler
barrel contains larger flue-tubes to carry the super heater elements, where
present. Forced draught is provided in the locomotive boiler by injecting
exhausted steam back into the exhaust via a blast pipe in the smoke box.
Locomotive-type boilers are also used in traction engines, steam
rollers, portable engines and some other steam road vehicles. The inherent
strength of the boiler means it is used as the basis for the vehicle: all the other
components, including the wheels, are mounted on brackets attached to the
boiler. It is rare to find super heaters designed into this type of boiler, and they
are generally much smaller (and simpler) than railway locomotive types.
The locomotive-type boiler is also a characteristic of the overtype steam
wagon, the steam-powered fore-runner of the truck. In this case, however,
heavy girder frames make up the load-bearing chassis of the vehicle, and the
boiler is attached to this.

5. Taper boiler
Certain railway locomotive boilers are tapered from a larger diameter at
the firebox end to a smaller diameter at the smoke box end. This reduces
weight and improves water circulation. Many later Great Western
Railway and London, Midland and Scottish Railway locomotives were
designed or modified to take taper boilers.
6. Vertical Fire-Tube boiler
A vertical fire-tube boiler (VFT), colloquially known as the "vertical
boiler", has a vertical cylindrical shell, containing several vertical flue tubes.

7. Horizontal Return Tubular boiler

Fig 7, Horizontal Return Tubular boilers from the Staatsbad Bad Steben GmbH
Horizontal Return Tubular boiler (HRT) has a horizontal cylindrical shell,
containing several horizontal flue tubes, with the fire located directly below the
boiler's shell, usually within a brickwork setting

8. Admiralty-type direct tube boiler
Extensively used by Britain, before and in the early days of ironclads, the
only protected place was below the waterline, sometimes under an armoured
deck, so to fit below short decks, the tubes were not led back above the
furnace but continued straight from it with keeping the combustion chamber in
between the two. Hence the name, and considerably reduced diameter,
compared to the ubiquituous Scotch or return tube boiler. It was not a great
success and its use was being abandoned after the introduction of stronger side
armouring the furnace crowns, being very near the water-level, are much
more liable to over-heating. Further, on account of the length of the boiler, for
an equal angle of inclination, the effect on the water-level is much greater.
Finally, the unequal expansion of the various parts of the boiler is more
pronounced, especially at the top and bottom, due to the increased ratio
between the length and the diameter of the boiler; the local strains are also
more severe on account of the comparatively feeble circulation in long and
low boilers. All these also resulted in a shorter life. Also, the same length of a
combustion chamber was much less effective on a direct tube than on a return
tube boiler, at least without baffling.

9. Immersion Fired Boiler
The Immersion Fired boiler is a single pass fire-tube boiler that was
developed by Sellers Engineering in the 1940s. It has only fire tubes,
functioning as a furnace and combustion chamber also, with multiple burner
nozzles injecting premixed air and natural gas under pressure. It claims
reduced thermal stresses, and lacks refractory brickwork completely due to its
construction.