Thermal Power plant Boiler Basics

What is Boilers:
“ Boiler is a steam generator, which converts saturated
water into steam by absorbing latent heat”, a boiler is
considered a steam generator that converts saturated
water into steam by absorbing latent heat. This process
involves the transfer of energy from the water, causing it
to undergo a phase change and transform into steam. The
steam generated can then be utilized for various
applications such as power generation, heating,
or industrial processes that require high-temperature
steam

Type of boilers for solid fuels:

1.Grate Boilers

2.Fluidized Bed Boiler- AFBC & CFBC

3.Pulverized fuel Fired Boiler(PF Fired Boiler)

4. WHRB(west heat Recovery Boiler)

 Boiler Accessories:
Boiler accessories are auxiliary devices that enhance
the efficiency and functionality of boilers. Here are
some common boiler accessories.

1.FD Fan 13- Shoot Blow System

2.SA Fan 14.DM water
3.PA Fan 15.Fuel Feeding
4.Furnace System
5.Feed Pump 16. Turbine
6. Economizer 17.Condencer
7.Evaporator 18.De-aerator
8. Boiler Drum 19.Coal mill
9. Air pre Heater 20. Cooling System
10. Electro Static precipitator 21. Transformer
11.ID Fan 22.Super heater
12.Stack 23.Reheater
FD Fan:
A Forced Draft (FD) Fan is an essential component in
a boiler system. Its primary function is to supply the
necessary air for combustion by pushing air into the
boiler’s combustion chamber. Here are some key
points about FD fans:
Location: FD fans are typically located at the inlet of
the boiler.
Function: They create a positive pressure in the
combustion chamber, ensuring efficient burning
Efficiency: By providing a controlled air supply, FD
fans help to improve combustion efficiency, reduce
emissions and enhance over all boiler performance.
A Forced Draft Fan designed for a
particular boiler must be able to
provide a sufficient quantity of air
which is the sum of both Primary and
Secondary air.
SA Fan: PA Fan:
A Secondary Air (SA) Fan in a boiler PA fans supply the necessary primary air to the
system plays a crucial role in ensuring boiler’s combustion chamber. This air mixes
efficient combustion. Here are some key with the fuel to ensure proper combustion.
points about SA fans: Primary air is generally the basic amount of air
Function: SA fans provide additional air required for complete combustion of fuel and it
required for the complete combustion of depends upon the composition and quantity of
fuel. This helps ensure that all the fuel is fuel required by the boiler. Different fuels will
burned efficiently, minimize un-burnt require a different amount of primary air.
particles and reducing emissions Primary air is generally provided from the
Location: These fans are typically bottom through the Air box and the fuel is
installed to supply air through nozzle fed either manually or through the screw
on the walls of the furnace. feeder into the furnace.
Efficiency: By Supplying necessary Primary air fans also help in segregating the
secondary air, SA fans help control the fuel particles so that each fuel particle could
combustion temperature and improve come in direct contact with the air resulting in
over all efficiency. the efficient combustion of fuel particles.
Boiler Feed Pump:
A boiler feed pump is a high-pressure centrifugal
pump that delivers feed water to the boiler drum
or steam generator. Its primary function is to
maintain the necessary water level within the
boiler and replenish the water consumed during
the steam generation process.
Types: Most boiler feed pumps are centrifugal
pumps, designed to handle high pressures and
temperatures.
Materials: They are often made from materials
like stainless steel or chrome steel to withstand
the harsh conditions inside a boiler.
Operation: These pumps operate at the high
speeds, typically between 5000 to 6000RPM, and
handle flow rates that match the steam
generation rate of the boiler.
Boiler Economizer:
•Boiler economizer is a heat exchanger installed on the
flue gas stack of a boiler. Its primary function is to
capture and utilize heat from the flue gases that would
otherwise be wasted. This process enhances the overall
energy efficiency of the boiler system.
•The economizer operates by transferring heat from the
hot flue gases to the incoming feed water. This preheats
the feed water, reducing the energy required to bring
the water to the desired temperature within the boiler.
Benefits of installing a boiler economizer
•Reduced fuel consumption: Economizers can reduce
fuel consumption by up to 20%, which can lead to
significant savings on energy costs.
•Reduced emissions: Economizers help to reduce
emissions by reducing the amount of fuel that needs to
be burned.
•Improved boiler efficiency: Economizers can
improve boiler efficiency by up to 10 to 12%.
Evaporators in Boiler:
An evaporator in a boiler is a component that
collects heat from combustion gases and
transmits it to the boiler’s water or steam.
This process converts water into steam, which
is then used in various industrial applications
such as power generating, heating.
Phase Change: One of the most critical
operations in an evaporator coil is the
conversion of liquid water into steam.
This phase transition necessitates a large
amount of energy, known as the latent
heat of vaporization. The evaporator coil
ensures that this energy is transported
efficiently, which improves the boiler’s
overall performance.
Air pre Heater:
An air pre heater is a device designed to heat air
before it enters another process, such as
combustion in a boiler. The primary goal is to
increase the thermal efficiency of the process by
recovering heat from the flue gases, which would
otherwise be lost.
•Air pre heater increase efficiency in industrial
processes by worming air before it enters a
combustion system
•Their effectiveness is measured by how much
they improve energy efficiency and reduce fuel
consumption
•Air pre heaters enhance the efficiency of heating
systems by worming up the air before it inters
the furnace.
Boiler ESP:
An electrostatic
precipitator is a type of filter
(dry scrubber) that uses static
electricity to
remove soot and ash from
exhaust fumes before they
exit the smoke stacks. This
one common air pollution
control device. Most power
stations burn fossil fuels such
as coal or oil to generate
electricity for use. when
these fuels undergo combusti
on, smoke is produced.
Induced Draught Fan:
An ID fan, or induced draft fan,
is a type of fan that is used to
remove flue gases from the
combustion chamber of a boiler.
It is typically located at the
outlet of the boiler and creates
a negative pressure in the
combustion chamber, which
helps to draw the flue gases out
of the boiler and into the flue
gas stack.
Boiler Stack:
A boiler stack, also known as a chimney , is
a critical component of a boiler system. It is
responsible for safely emitting the hot
gaseous byproducts of combustion out of
the system and into the atmosphere. Here
are some key points about the boiler stack:
Function: The primary function of the stack
is to discharge combustion gases, such as
carbon dioxide, water vapor, SOx ,NOx and
other byproducts, from the boiler. This
helps in maintaining a safe and efficient
operation of the boiler.
Stack Height: H=14(Q)^0.3 when the
power plant is less then 200MW.
Where Q= SO2 quantity in kg/hr
Above 200 MW to 500MW stack height
220 meter and above 500 MW stack height
275 meter.
AFBC Boiler:
AFBC means Atmospheric – Fluidized – Bed –
Combustion. The specialty in this boiler is to keep
furnace pressure at atmospheric conditions. The
burnt gases developed in the combustion chamber
are passes through the cyclone and are discharged
into the atmosphere.
Important parameters in AFBC Boiler:
1.Bed Height
2.Wind box pressure
3.Bed temperature/Furnace Temperature
4.Fuel Size
5.Bed Material Size
Fluidized Bed Compartment:
An Atmospheric Fluidized Bed Combustion
(AFBC) boiler typically has multiple
compartments in its air box to ensure even
distribution of air across the bed. The exact
number of compartments can vary depending
on the design and size of the boiler. Generally,
there are around 3 to 5 compartments.
CFBC Boiler: CFBC means circulating – fluidized – bed – combustion. In
this kind of boiler, the furnace gas is pressurized to
recirculate in the chamber. This recirculation of gases
captures the un-burnt carbon. Thus, the thermal efficiency of
a boiler is increasing because of gas recirculation.

The CFBC is also capable of using low-grade coal, biomass,

sludge, waste plastics, and waste tires as fuel.
CFBC Boiler is Single Compartment fluidized Boiler.

CFBC Boiler main components:

Combustion Chamber: This is where the fuel is burned. The
chamber contains a fluidized bed of solid particles (like sand
or limestone) that are kept in suspension by the upward
flow of air.
Cyclone Separator: This component separates the solid
particles from the flue gas. The heavier particles are
recirculated back into the combustion chamber to ensure
complete combustion.
Return Leg and Loop Seal: These components help in
recirculating the separated particles back into the
combustion chamber. The loop seal prevents the backflow
of gases.
 AFBC/CFBC Boiler Specification:
Bed Material Size of AFBC/CFBC Boiler: Bed Height/FD Air Pressure
0.85 mm to 2.36 mm( not bellow should be 0.85 mm) for AFBC/CFBC Boiler:
Less then 1mm not allowed more then 20% Static Bed height for
Distribution: 0.85 to 1 mm-10% AFBC/CFBC Boiler is to be
1 to 1.5 mm- 50% maintained 250 t0 300 mm
1.5 to 2.36 mm-40% during initial light up of the
When bed material size <1mm are increased more than boiler.
10 % then bed material will flow outside of the boiler and Expand bed height for
it will increase the bed material consumption and AFBC/CFBC boiler is to
increase the incomplete combustion of fuel. maintain 500 mmwc.
Size of Coal for AFBC/CFBC: 0 to 10mm FD Discharge pressure is to
Less then 1mm not allowed more then 20% be maintained 600 to 650
Distribution: 1 to 5 mm-70% mmwc.
5 to 8 mm- 20% High wind box pressure
0 to 1 mm-10% increase the erosion of bed
When fines are increased more than 20 % un-burnt coil and un-burnt carbon in
carbon increase in fly ash and higher size of the coal fly ash and reduce the
increase the erosion and block the Fuel nozzle. efficiency
Fuel: Indian /Imported Coal, Lignite, Rice Husk, Washery Low wind box pressure will
Rejects, Petcoke, Dolachar reduce the fluidization and
bed temperature
Pulverized Fuel(PF) fired Boiler:
A pulverized coal-fired boiler is an industrial
boiler that generate thermal energy by
burning pulverized coal.
In pulverized coal boiler, the coal is
pulverized to a fine powder, so that less than
2% is +300 micro meter and 70 to 75 % is
bellow 75 microns. The pulverized coal is
blown with part of the combustion air into
boiler plant through a series of burner
nozzles. Combustion take place at the
temperature from 1000-1300 degree C,
depending largely on coal grade.
Flue Gas form in the furnace passes over the
super heater, economizer, ESP and finally is
evacuated by the induced draught fan into
the chimney.
PF Fired boiler Component and specifications:
Pulverized fuel (PF) fired boilers have several key components and specifications that
ensure efficient and effective operation. Here are the main components and their typical
specifications.
• Coal mill- Ball tube mill/bowl mills/vertical spindle mill/high speed impact mills
• Coal mill Temp-60 to 65 degree C
• Pulverized fuel burner- 75 % used 200 mess size & 2% used 60 mesh
• Oil burner- oil support is required when boiler is lit up & when low VM coal are used.
• Fuel Firing range -24 meter to 35 meter
• Burner Tilt= -30 to +30 degree
• Firing Elevations: AB,BC,CD,DE
• Firing type- Front firing/corner firing
• Spiral water wall- In high pressure PF fired boiler used spiral water wall in place of
vertical evaporator wall tube.
• Bottom De-ashing System
• Flame Scanner- Measure flame intensity
• Clinkers Grinder-Before removing bottom Ash, fouling lumps required to grind .
PF Fired Boiler Diagram:
 Power Plant Boiler Basic Calculations:
Evaporation Ratio= Quantity of Steam Generation/ Quantity of Fuel Consumption

Excess Air % = [(Maximum O2/CO2)-1]x100

Boiler efficiency by Direct method:

Boiler efficiency = Heat output/ Heat Inputx100

η = Q𝑜/ Q𝑖 ∗ 100
= Q∗(Hg − Hf) /q∗ GCV of fuel∗ 100

Where 𝑄𝑜 is heat output and 𝑄𝑖 is heat input

Hg = Steam enthalpy , Hf = Feed water Enthalpy

Q= Fuel Consumption
B η Calculation by Indirect method:

• By this method, efficiency could be measured

easily by measuring all the losses occurring in the
boiler.
•The following losses were applicable to all the fuel
used, weather it is solid, liquid or gas fired boiler.
L1 – loss due to dry flue gas
L2 – loss due to hydrogen in fuel
L3 – loss due to moisture in fuel
L4 – loss due to moisture in air
L5 – loss due to CO formation
L6 – loss due to un-burnt fuel in fly ash
L7 – loss due to un-burnt fuel in bottom ash
L8 – loss due to radiation and convection
(surface loss)
Boiler efficiency = 100 − Total Losses
= 100 − (L1+ L2+L3 +L4 + L5 + L6 + L7 + L8 )
SFC(Specific Fuel Consumption)- fuel consumption per day(MT)/unit Gen
per day(MW)
Power Plant PLF Calculation:
Peak load Factor(PLF)=Average load(MW)/peak load(MW)X100

THR & GUHR Calculation:

Turbine Heat Rate= Main Steam Flow*(Main Steam Enthalpy- Feed water
Enthalpy)/Load(MW)*100

GUHR(Gross Unit Heat Rate)= THR/Boiler Efficiency*100

Sub critical Boiler-
THR = MS Flow *(MSE - FEW) + CRH Flow *(HRHE - CRHE ) + RH Spray Flow *( HRHE -
Spray Water E)+ SH Spray Flow * (FEW - spray Water E))/ Load

Gross Unit Heat Rate by direct method:

GUHR = (Coal Consumption x Coal GCV + Oil Consumption x Oil CV )/ Generation

Thanks for Your Attention