Boilers and Burners Design and Theory- PDF

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Mechanical Engineering Series Frederick F.Ling Series Editor Springer New York Berlin Heidelberg Barcelona Hung Kong London Milan Paris Singapore Tokyo Introductory Attitude Dynamics F.P. Rirnrott Balancing of High-Speed Machinery M.S. Darlow Theory of Wire Rope, 2nd ed. G.A. Costello Theory of Vib...

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Boilers and Burners Design and TheoryDiepreye Enimizufa

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Springer New York Berlin Heidelberg Barcelona Hung Kong London Milan

Paris Singapore Tokyo

Introductory Attitude Dynamics F.P. Rirnrott Balancing of High-Speed Machinery M.S. Darlow

Theory of Wire Rope, 2nd ed. G.A. Costello Theory of Vibration: An Introduction, 2nd ed. A.A. Shabana Theory of Vibration: Discrete and Continuous Systems, 2nd ed.

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Prabir Basu

Cen Kefa Louis Jestin

Boilers and Burners Design and Theory

With 250 Figures

Springer

Prabir Basu Departmenl of Mechanical Engineering Technical University of Nova Scotia P.O.Box 1000 Halifax, Nova Scotia B3J2X4,Canada

Cen Kefa institute of Thermal Engineering Zhejiang University Zheda Road Hangzhou, Zhejiang 310027,China

Louis Jestin Department Equipment Electricite de France 12-14 Avenue Dutrievoz F-69628Villeurbanne, France Series Editor Frederick F. Ling Ernest F. Gloyna Regents Chair in Engineering Department of Mechanical Engineering The University of Texas at Austin Austin, TX 78712- 1063, USA and William Howard Hart Professor Emeritus Department of Mechanical Engineering, Aeronautical Engineering and Mechanics Rensselaer Polytechnic Institute Troy, NY 12 180-3590,USA Library of Congress Cataloging-in-Publication Data Basu, Prabir, 1946Boilers and burners : design and theory / Pnbir Basu. Cen Kefa, Louis festin. p. cm. (Mechanical engineering series) Includes bibliographical references. ISBN 0-387-98703-7 (hardcover : alk. paper) I. Steam-boilers-Design and construction. 2. Oil burners-Design and construction. I. Cen Kefa 11. Jestin, Louis. Ill. Title. IV. Series : Mechanical engineering series (Berlin. Germany) TJ290.B37 1999 62 1.1 '8--dd l 99- 17360

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Series Preface

Mechanical engineering, an engineering discipline borne of the needs of the industrial revolution, is once again asked to do its substantial share in the call for industrial renewal. The general call is urgent as we face profound issues of productivity and competitiveness that require engineering solutions, among others. The Mechanical Engineering Series features graduate texts and research monographs intended to address the need for information in contemporary areas of mechanical engineering. The series is conceived as a comprehensiveone that covers a broad range of concentrations important to mechanical engineering graduate education and research. We are fortunate to have a distinguished roster of consulting editors on the advisory board, each an expert in one of the areas of concentration. The names of the consulting editors are listed on the facing page of this volume. The areas of concentration are: applied mechanics; biomechanics; computational mechanics; dynamic systems and control; energetics; mechanics of materials; processing; production systems; thermal science; and tribology. I am pleased to present this volume in the series: Boilers and Burners: Design and Theory, by Prabir Basu, Cen Kefa, and Louis Jestin. The selection of this volume underscores again the interest of the Mechanical Engineering Series to provide our readers with topical monographs as well as graduate texts in a wide variety of fields. Austin, Texas

Frederick F. Ling

Mechanical Engineering Series Frederick F. Ling Series Editor

Advisory Board

Applied Mechanics

EA. Leckie University of California, Santa Barbara

Biomechanics

V.C. Mow Columbia University

Computational Mechanics

H.T.Yang University of California, Santa Barbara

Dynamical Systems and Control

K.M.Marshek University of Texas, Austin

Energetics

J.R.Welty University of Oregon, Eugene

Mechanics of Materials

I. Finnie University of California, Berkeley

Processing

K.K.Wang Cornell University

Production Systems

G.-A. Klutke Texas A&M University

Thermal Science

A.E. Bergles Rensselaer Polytechnic Institute

Tribology

W.O.Winer Georgia Institute of Technology

Preface

Modern society owes a great deal to fossil fuels, which have accelerated man's progress from the cave to the present age of jets and computers. Utilization of this precious gift of nature is central and critical to our lives. This book is about rational utilization of fossil fuels for generation of heat or power. The book is intended for undergraduate and graduate students with an interest in steam power plants, burners, or furnaces. For researchers, it is a resource for applications of theory to practice. Plant operators will find solutions to and explanationsof many of their daily operational problems. Designers will find this book fiiled with required data, design methods, and equations. Finally, consultants will find it useful for design evaluation. This book uses a format of theory-based practice. Each chapter begins with an explanation of a process. Then it develops equations from first principles and presents experiment-based empirical equations. This is followed by design methodology, which in many cases is explained by worked-out examples. Thus, the book retains the interest of the reader and help remove doubts if any on the theory. The present monograph is a joint effort of writers on three continents-Asia, Europe, and North America-and a marriage of two scientific traditions-Eastern and Western. In the West, boilers and burners are designed for high levels of performance, but their design methods and data are buried under commercial secrecy. Very few books or even research papers are available giving exact design standards. Thus, there is limited opportunity for information exchange on design data and methodologies. The energy industry in the Eastern European countries and China, on the other hand, did not have much commercial impetus for burying their design standards under secrecy. So their design methods and data were freely exchanged, and debated in the scientific community. Eventually, they formed into national standards. These elaborate thermal design standards were developed on the basis of experience in the design and operations of thousands of boilers and burners. However, the difference in language and scientific conventions prevented easy access of Western readers to this wealth of information available in China and Eastern European countries. The present book synthesizes design methods and data from both sides of the scientific world and presents the same in a simple Western format.

The book greally benefitted from diverse professional backgrounds of three authors. Professor Cen Kefa, Head of the Institute of Thermal Power Engineering of Zhejiang University, is holder of the coveted distinction of Academician for his lifelong contribution to the Chinese boiler industry. He received his early education in boilers and power plants in the former Soviet Union. Thereafter, he worked closely with Chinese boiler and burner industry manufacturers perfecting their design standards. The research and development work he and his colleagues have carried out in the past four decades on boilers and burners greatly contributed to this book. Dr. Louis Jestin, Head of the Heat Exchanger Section of the Fossil Fuel Division of the Electricite de France, is a specialist in heat transfer. He is involved in the design review of all new circulating fluidized bed boilers commissioned by this company. His team also carried out in-depth technical analyses of several supercritical boiler projects. His intimate contact with modern fossil fuel boilers and familiarity with European designs greatly enriched this book. Dr. Prabir Basu, Professor in Mechanical Engineering in Dalhousie University and President of Greenfield Research Inc., is a specialist in fluidized bed boilers. He carried out extensive design and development work in government research laboratory, boiler manufacturing company, and universities. He participated in the development of the Indian boiler standard. His research and design experience in fluidized bed boilers contributed much to this book. We thank Mr. S.S. Kelkar, Ex-Vice President, Deutsche Babcock Power System Ltd., India, who used his 30 years experience of boiler design and familiarity with German, British, Indian, and U.S.boiler codes to write Chapter 17 on pressure part design. Our special thanks go to Prof. Jianren Fan, Prof. Qiang Yao, and Dr. Zuohe Chi for their significantcontributions to a number of chapters in this book. Their tireless effort in data collection, draft preparation, and figure drafting provided critical support to this project. Dr. Jayson Greenblatt and Prof. David Mackay proofread many versions of the manuscript. Dr. Leming Cheng, Mrs. Sanja Boskovic, and Mr. Animesh Dutta greatly helped with preparation of the final manuscript. Finally the authors thank their waves for their support to this project. Prabir Basu Halifax, Nova Scotia, Canada Cen Kefa Hangzhou, Zhejiang, China Louis Jestin Lyon, France

Contents

Series Preface Pmface 1 Introduction 1.1 Principles of Boiler Operation . . . . . . . . . . . . . . . . . . . 1-2 Classification of Boilers . . . . . . . . . . . . . . . . . . . . . . . 1-3 Description of Boilers . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v vii

1 1 6 6 14

2 General Design Considerations

15 15 17 20

3 Fuel and Combustion Calculations 3- 1 Features of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Stoichiometric Calculations . . . . . . . . . . . . . . . . . . . . . 3-3 Enthalpy Calculation of Air and Combustion Products . . . . . . 3-4 Heat Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Generation of SO2 and NOx . . . . . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 21

2- 1 Boiler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Coal Preparation Systems for Boilers 4- 1 Coal Preparation Systems . . . . . . . . . . . . . . . . . . . . . . 4-2 Pulverizing Properties of Coal . . . . . . . . . . . . . . . . . . . 4-3 Pulverizing Air System . . . . . . . . . . . . . . . . . . . . . . . 4-4 Size-Reducing Machines . . . . . . . . . . . . . . . . . . . . . . 4-5 Other Components for Coal Reparation Systems . . . . . . . . . 4-6 Design of Coal Preparation System for Pulverized Coal Boilers . . . . . . . . . . . . . . . . . . . . .

28 36 37 46 48 51

52 52 56 59 63 70

73

4-7

Fuel Feeding in Fluidized Bed Boilers . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 78 79

5 Design of Oil Burners 5- 1 Design of Oil Supply System

80 80 82 108 118 125 127

6 Boiler Furnace Design Methods 6-1 General Design Principles . . . . . . . . . . . . . . . . . . . . . . 6-2 Flame Emissivity . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Heat Transfer Calculations for the PC Boiler Furnace . . . . . . . 6-4 Water Wall Arrangement . . . . . . . . . . . . . . . . . . . . . . 6-5 Fouling and Thermal Efficiency Factors for Water Wall Tubes . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Temperature Field Coefficient. M . . . . . . . . . . . . . . . . . 6-7 Furnace Ernissivity . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Distribution of Heat Load in Furnace . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128 128 135 140 146

.................... 5-2 Oil Atomizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Air Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Design Principles of Oil Fired Boilers . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 149 150 151 157 159

7 Convective Heating Surfaces 161 7- 1 Design of Superheater and Reheater . . . . . . . . . . . . . . . . 161 7-2 Temperature Control in Superheater and Reheater . . . . . . . . . 167 7-3 7-4 7-5 7-6 7-7 7-8

Adjustment of Heat Absorption in Superheater and Reheater . . . Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of Back-Pass Heating Surfaces . . . . . . . . . . . Heat Transfer Calculations for Convective Heating Surfaces . . . Design Methods of Convection Heating Surfaces . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Swirl Burners

8- 1 8-2 8-3 8-4 8-5

Design of a Swirl Burner . . . . . . . . . . . . . . . . . . . . . . Flow Resistance in Swirl Burners . . . . . . . . . . . . . . . . . . Examples of Swirl Burners . . . . . . . . . . . . . . . . . . . . . Arrangement of Multiple Swirl Burners . . . . . . . . . . . . . . Design Procedure of Swirl Burners . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172 178 180 185 187 206 207 211

212 212 225 226 230 233 239 24 1

9

Design of Novel Burners 9- 1 Types of PC Burners . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 PC Burner With Blunt Body . . . . . . . . . . . . . . . . . . . . 9-3 Precombustion Chamber Burner . . . . . . . . . . . . . . . . . . 9-4 BoatBurner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Co-Flow Jet Burner With High Differential Velocity . . . . . . . 9-6 Counter-Flow Jet Burner . . . . . . . . . . . . . . . . . . . . . . 9-7 Dense and Lean Phase PC Burner . . . . . . . . . . . . . . . . . 9-8 Down-Shot Flame Combustion Technique . . . . . . . . . . . . . 9-9 Low NO. Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 Tangentially Fired Burners 10-1 General Descriptions . . . . . . . . . . . . . . . . . . . . . . . 10-2 Design of Burners With Peripheral Air . . . . . . . . . . . . . 10-3 Design of Tilting Burners . . . . . . . . . . . . . . . . . . . . . 10-4 Burners for Bituminous Coal . . . . . . . . . . . . . . . . . . . 10-5 Anthracite and Lean Coal Fired PC Burner . . . . . . . . . . . 10-6 Brown Coal Fired Direct Burner . . . . . . . . . . . . . . . . . 10-7 Multifuel Burner . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Design Methods for Tangentially Fired Boilers . . . . . . . . . 10-9 Example of Burner Design . . . . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

242

242 243 246 248 249 250 253 257 259 266 267

269 269 279 281 284 286 291 293 294 297 300 301

Fluidized Bed Boilers 1 1.1 Fluidized Bed Boiler . . . . . . . . . . . . . . . . . . . . . . . 1 1-2 Major Features of Fluidized Bed Boilers . . . . . . . . . . . . I 1-3 Basics of Fluidized Beds . . . . . . . . . . . . . . . . . . . . . 11-4 Bubbling Fluidized Bed Boilers . . . . . . . . . . . . . . . . . 11-5 Circulating Fluidized Bed Boilers . . . . . . . . . . . . . . . . 11-6 Distributor Plates . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-7 Loop Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-8 Gas-Solid Separators . . . . . . . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

302 302 304 309 314 319 327 331 334 340 344

12 Steam-Water Circulation in Boiler 2 - 1 Natural Circulation System . . . . . . . . . . . . . . . . . . . . 12-2 Calculations for Simple and Complex Tube Circuits . . . . . . 12-3 Two-Phase Flow Resistance . . . . . . . . . . . . . . . . . . . 12-4 Height of Economizer Section in the Riser . . . . . . . . . . . 12-5 Worked-Out Example . . . . . . . . . . . . . . . . . . . . . . . Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

347 346 359 360 362 364 369 371

372 13 Forced Circulation for Supercritical or Subcritical Boilers 13- 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . 373 13-2 Design Principle of Forced Circulation Boiler . . . . . . . . . 374

13-3 Features of Forced Circulation Boilers . . . . . . 13-4 Supercritical Boilers . . . . . . . . . . . . . . .

. . . . . . . . 375 . . . . . . . . 381

14 Corrosion and Fouling of Heat Transfer Surfaces 14-1 High-Temperature Corrosion of External Surfaces . . . . . . . 14-2 Prevention of High-Temperature Corrosion . . . . . . . . . . . 14-3 Low-Temperature Corrosion on External Surfaces . . . . . . . 14-4 Corrosion and Scaling of Internal Surfaces . . . . . . . . . . . 14-5 Fouling and Slagging . . . . ...