1. B OILER Presented by: Muhammad Azffar 55201112096 Mohamad Hanif bin Yusof 55201112125 Nor Aminah bt. Mohd Khalil 55201112073

2. W HAT IS A BOILER ?  Vessel that heats water to become hot water or steam  At atmospheric pressure water volume increases 1,600 times  Hot water or steam used to transfer heat to a process

3. 3 Thermal Equipment/ Boilers Introduction BURNER WATER SOURCE BRINE SOFTENERS CHEMICAL FEED FUEL BLOW DOWN SEPARATOR VENT VENT EXHAUST GAS STEAM TO PROCESS STACK DEAERATOR PUMPS Figure: Schematic overview of a boiler room BOILER ECO- NOMI-ZER

4. Type of boiler:  Fire tube boiler  Water Tube Boiler  Packaged Boiler  Fluidized Bed (FBC) Boiler  Stoker Fired Boiler  Pulverized Fuel Boiler

5. Fire Tube Boiler Hot gases from a fire pass through one or more tubes running through a sealed container of water Relatively small steam capacities (12,000 kg/hour) Operates with oil, gas or solid fuels

6. Used for high steam demand and pressure requirements. Forced, induced and balanced draft provisions help to improve combustion efficiency Less tolerance for water quality calls for water treatment plant. Water Tube Boiler

7. Packaged Boiler require less fuel and electric power to operate High thermal efficiency High heat transfer Faster evaporation Reduces operating cost

8. Fluidized Bed Combustion Boiler (FBC) Particles (e.g. sand) are suspended in high velocity air stream: bubbling fluidized bed Bed is where the coal or fuel spreads Fuels: coal, washery rejects, rice husk, bagasse and agricultural wastes Benefits: compactness, fuel flexibility, higher combustion efficiency

9. Stoker Fired Boiler the smallest units among hard coal fired boilers Coal is fed onto one end of a moving steel grate A coal gate is used to control the rate at which coal is fed into the furnace by controlling the thickness of the fuel bed Uniform coal size for complete combustion

10. P ULVERIZED FUEL BOILER  is an utility boiler that generates thermal energy by burning pulverized coal  Pulverized coal powder blown with combustion air into boiler through burner nozzles  Benefits: varying coal quality coal, quick response to load changes and high pre-heat air temperatures

11. M AINTENANCE OF BOILER OPERATION

12. A NNUAL MAINTENANCE & SHUTDOWN  Maintenance & shutdown usually done once in a year  Depends on when company want to do the shut down  Maintenance needed to ensure the boiler works efficiently  During shutdown or maintenance steam is not available for heating/ domestic hot water

13. B OILER WATER TREATMENT  Primary goal is to control solid cause deposit in boiler & control gas that cause corrosion  3 phases of water treatment in boiler system :  Blowdown Blowdown  External treatment External treatment  Internal treatment Internal treatment

14. B LOWDOWN  Classified into surface and bottom blowdown  Surface blowdown is removed from the steam drum at the top of the boiler  Bottom blowdown is removed from the mud drum at the bottom of the boiler  Maintains the total dissolved solid in the system

15. E XTERNAL TREATMENT  Major techniques employed for external treatment:  Clarification process  Filtration process  Softening action  De-alkalization action  De-mineralization technique  Removes hard salts, minerals and oxygen before the water enters the boiler  In some cases the treatment done outside the boiler system

17. I NTERNAL TREATMENT  Continue from external treatment to avoid catastrophic failure or any other unfavourable effect  Maintains proper water chemistry by adding chemical additives to the boiler water  Usage of natural & synthetic dispersant (lignosulphonates/maleic acrylate copolymer)  Softening chemicals (soda ash & sodium phosphate)  Eliminate oxides and dissolved oxygen present (ascorbic acid & hydrazine)

19. T YPE O F M AINTENANCE O PERATION E QUIPMENTS Normal Operating Water Level  Maintaining normal operating water level  Low water level is most common cause boiler failure How to Prevent  Automatic boiler feed water regulator is designed to maintain the proper water level in the boiler  The gage glass (sight glass) is a tube that indicates the water level in the boiler.

20. The Fuel System  Failure to maintain the equipment in good working order could result in higher fuel costs, the loss of heat transfer or even a furnace explosion.