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The printable version of this page has now been replaced by The Steam and Condensate Loop Book View the complete collection of Steam Engineering Tutorials
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Steam generators
In many applications: The amount of steam required is too small to warrant a shell boiler, i.e. Less than 1 000 kg / h. The small process requiring steam operates on a day shift only, meaning that the plant would be started every morning and shut down every night. The capital cost of a conventional shell boiler would adversely affect the economic viability of the process. The level of expertise on site, as far as boilers are concerned, is not as high as would be required on a larger steam system. To meet these specific demands two types of boiler have been developed.
Coil boiler
These are a 'once through' type of water tube boiler, and referred to in some regulations as, 'boilers with no discernible water level'.
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Steam Tables
A comprehensive set of steam tables is available here.
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Water supply to the boiler will usually be at 10 to 15% above the steaming rate to: Ensure that all the water is not evaporated, thus ensuring that superheated steam is not produced. Provide a vehicle for the feedwater TDS to be carried through. If this vehicle was not available, the salts in the feedwater would be deposited on the insides of the tubes
Miscellaneous Boiler Types, Economisers and Superheaters : International site for Spirax Sarco and impair heat transfer, leading to over heating and eventually to tube failure. Clearly, a separator is an essential component of this type of boiler to remove this contaminated water. Being of the water tube type, they can produce steam at very high pressures. Typical applications for steam generators and coil boilers include laundries and garment manufacture, where the demand is small and the rate of change in load is slow.
comprehensive best practice guide to saving energy and optimising plant performance, this book covers all aspects of steam and condensate systems.
Miscellaneous Boiler Types, Economisers and Superheaters : International site for Spirax Sarco Top
Economisers
The flue gases, having passed through the main boiler and the superheater, will still be hot. The energy in these flue gases can be used to improve the thermal efficiency of the boiler. To achieve this the flue gases are passed through an economiser.
Fig. 3.4.3 A shell boiler with an economiser The economiser is a heat exchanger through which the feedwater is pumped. The feedwater thus arrives in the boiler at a higher temperature than would be the case if no economiser was fitted. Less energy is then required to raise the steam. Alternatively, if the same quantity of energy is supplied, then more steam is raised. This results in a higher efficiency. In broad terms a 10C increase in feedwater temperature will give an efficiency improvement of 2%. Note: Because the economiser is on the high-pressure side of the feedpump, feedwater temperatures in excess of 100C are possible. The boiler water level controls should be of the 'modulating' type, (i.e. not 'on-off') to ensure a continuous flow of feedwater through the heat exchanger. The heat exchanger should not be so large that: The flue gases are cooled below their dew point, as the resulting liquor may be acidic and corrosive. The feedwater boils in the heat exchanger.
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Superheaters
Whatever type of boiler is used, steam will leave the water at its surface and pass into the steam space. Steam formed above the water surface in a shell boiler is always saturated and cannot become superheated in the boiler shell, as it is constantly in contact with the water surface. If superheated steam is required, the saturated steam must pass through a superheater. This is simply a heat exchanger where additional heat is added to the saturated steam. In water-tube boilers, the superheater may be an additional pendant suspended in the furnace area where the hot gases will provide the degree of superheat required (see Figure 3.4.4). In other cases, for example in CHP schemes where the gas turbine exhaust gases are relatively cool, a separately fired superheater may be needed to provide the additional heat.
Miscellaneous Boiler Types, Economisers and Superheaters : International site for Spirax Sarco
Fig. 3.4.4 A water tube boiler with a superheater If accurate control of the degree of superheat is required, as would be the case if the steam is to be used to drive turbines, then an attemperator (desuperheater) is fitted. This is a device installed after the superheater, which injects water into the superheated steam to reduce its temperature. Top
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