Boilers and burners : design and theory

A joint effort of three continents, this book is about rational utilization of the fossil fuels for generation of heat or power. It provides a synthesis of two scientific traditions: the high-performance, but often proprietary, Western designs, and the elaborate national standards based on less advanced Eastern designs; it presents both in the same Western format. It is intended for engineers and advanced undergraduate and graduate students with an interest in steam power plants, burners, or furnaces. The text uses a format of practice based on theory: each chapter begins with an explanation of a process, with basic theory developed from first principles; then empirical relationships are presented and, finally, design methods are explained by worked out examples. It will thus provide researchers with a resource for applications of theory to practice. Plant operators will find solutions to and explanations of many of their daily operational problems. Designers will find this book ready with required data, design methods and equations. Finally, consultants will find it very useful for design evaluation.

Series Preface	p. v
Preface	p. vii
1 Introduction	p. 1
1-1 Principles of Boiler Operation	p. 1
1-2 Classification of Boilers	p. 6
1-3 Description of Boilers	p. 6
References	p. 14
2 General Design Considerations	p. 15
2-1 Boiler Specifications	p. 15
2-2 Design Steps	p. 17
References	p. 20
3 Fuel and Combustion Calculations	p. 21
3-1 Features of Fuel	p. 21
3-2 Stoichiometric Calculations	p. 28
3-3 Enthalpy Calculation of Air and Combustion Products	p. 36
3-4 Heat Balance	p. 37
3-5 Generation of SO[subscript 2] and NO[subscript x]	p. 46
Nomenclature	p. 48
References	p. 51
4 Coal Preparation Systems for Boilers	p. 52
4-1 Coal Preparation Systems	p. 52
4-2 Pulverizing Properties of Coal	p. 56
4-3 Pulverizing Air System	p. 59
4-4 Size Reducing Machines	p. 63
4-5 Other Components for Coal Preparation Systems	p. 70
4-6 Design of Coal Preparation System for Pulverized Coal Boilers	p. 73
4-7 Fuel Feeding in Fluidized Bed Boilers	p. 76
Nomenclature	p. 78
References	p. 79
5 Design of Oil Burners	p. 80
5-1 Design of Oil Supply System	p. 80
5-2 Oil Atomizers	p. 82
5-3 Air Registers	p. 108
5-4 Design Principles of Oil Fired Boilers	p. 118
Nomenclature	p. 125
References	p. 127
6 Boiler Furance Design Methods	p. 128
6-1 General Design Principles	p. 128
6-2 Flame Emissivity	p. 135
6-3 Heat Transfer Calculations for the PC Boiler Furnace	p. 140
6-4 Water Wall Arrangement	p. 146
6-5 Fouling and Thermal Efficiency Factors for Water Wall Tubes	p. 147
6-6 Temperature Field Coefficient, M	p. 149
6-7 Furnace Emissivity	p. 150
6-8 Distribution of Heat Load in Furnace	p. 151
Nomenclature	p. 157
References	p. 159
7 Convective Heating Surfaces	p. 161
7-1 Design of Superheater and Reheater	p. 161
7-2 Temperature Control in Superheater and Reheater	p. 167
7-3 Adjustment of Heat Absorption in Superheater and Reheater	p. 172
7-4 Economizer	p. 178
7-5 Air Heater	p. 180
7-6 Arrangement of Back-Pass Heating Surfaces	p. 185
7-7 Heat Transfer Calculations for Convective Heating Surfaces	p. 187
7-8 Design Methods of Convection Heating Surfaces	p. 206
Nomenclature	p. 207
References	p. 211
8 Swirl Burners	p. 212
8-1 Design of a Swirl Burner	p. 212
8-2 Flow Resistance in Swirl Burners	p. 225
8-3 Examples of Swirl Burners	p. 226
8-4 Arrangement of Multiple Swirl Burners	p. 230
8-5 Design Procedure of Swirl Burners	p. 233
Nomenclature	p. 239
References	p. 241
9 Design of Novel Burners	p. 242
9-1 Types of PC Burners	p. 242
9-2 PC Burner With Blunt Body	p. 243
9-3 Precombustion Chamber Burner	p. 246
9-4 Boat Burner	p. 248
9-5 Co-Flow Jet Burner With High Differential Velocity	p. 249
9-6 Counter-Flow Jet Burner	p. 250
9-7 Dense and Lean Phase PC Burner	p. 253
9-8 Down-Shot Flame Combustion Technique	p. 257
9-9 Low NO[subscript x] Burner	p. 259
Nomenclature	p. 266
References	p. 267
10 Tangentially Fired Burners	p. 269
10-1 General Descriptions	p. 269
10-2 Design of Burners With Peripheral Air	p. 279
10-3 Design of Tilting Burners	p. 281
10-4 Burners for Bituminous Coal	p. 284
10-5 Anthracite and Lean Coal Fired PC Burner	p. 286
10-6 Brown Coal Fired Direct Burner	p. 291
10-7 Multifuel Burner	p. 293
10-8 Design Methods for Tangentially Fired Boilers	p. 294
10-9 Example of Burner Design	p. 297
Nomenclature	p. 300
References	p. 301
11 Fluidized Bed Boilers	p. 302
11-1 Fluidized Bed Boiler	p. 302
11-2 Major Features of Fluidized Bed Boilers	p. 304
11-3 Basics of Fluidized Beds	p. 309
11-4 Bubbling Fluidized Bed Boilers	p. 314
11-5 Circulating Fluidized Bed Boilers	p. 319
11-6 Distributor Plates	p. 327
11-7 Loop Seals	p. 331
11-8 Gas-Solid Separators	p. 334
Nomenclature	p. 340
References	p. 344
12 Steam-Water Circulation in Boiler	p. 347
12-1 Natural Circulation System	p. 346
12-2 Calculations for Simple and Complex Tube Circuits	p. 359
12-3 Two-Phase Flow Resistance	p. 360
12-4 Height of Economizer Section in the Riser	p. 362
12-5 Worked-Out Example	p. 364
Nomenclature	p. 369
References	p. 371
13 Forced Circulation for Supercritical or Subcritical Boilers	p. 372
13-1 General Description	p. 373
13-2 Design Principle of Forced Circulation Boiler	p. 374
13-3 Features of Forced Circulation Boilers	p. 375
13-4 Supercritical Boilers	p. 381
14 Corrosion and Fouling of Heat Transfer Surfaces	p. 385
14-1 High-Temperature Corrosion of External Surfaces	p. 386
14-2 Prevention of High-Temperature Corrosion	p. 392
14-3 Low-Temperature Corrosion on External Surfaces	p. 397
14-4 Corrosion and Scaling of Internal Surfaces	p. 402
14-5 Fouling and Slagging	p. 406
14-6 Calculation of Soot and Ash Deposition	p. 412
14-7 Prediction of Slagging Potential	p. 416
14-8 Design Measure for Reduction of Fouling and Slagging	p. 421
Nomcnclature	p. 423
References	p. 424
15 Erosion Prevention in Boilers	p. 426
15-1 Theory of Erosion of Heating Surfaces	p. 426
15-2 Worked-Out Example	p. 431
15-3 Factors Influencing Tube Erosion	p. 433
15-4 Analyses of Erosion of Tube Banks in Cross-Flow	p. 436
15-5 Permissible Gas Velocity for Safe Operation	p. 439
15-6 Erosion Protection for the Economizer, Reheater, and Superheater	p. 444
15-7 Erosion in Tubular Air Heaters	p. 448
15-8 Erosion in Fluidized Bed Boilers	p. 450
Nomenclature	p. 454
References	p. 456
16 Pressure Drop in Gas and Air Ducts	p. 457
16-1 Draft Systems	p. 457
16-2 Pressure Drop in Air and Gas Duct Systems	p. 459
16-3 Pressure Drop Across Heating Surfaces	p. 466
16-4 Pressure Drop in Natural Draft Gas Path	p. 471
16-5 Pressure Drop Through Air Ducts	p. 475
16-6 Selection of Fans	p. 479
16-7 Pressure Drop Through Water or Steam Tubes	p. 480
Nomenclature	p. 481
References	p. 483
17 Mechanical Design of Pressure Parts	p. 485
17-1 Selection of Materials	p. 485
17-2 Important Mechanical Properties of Various Materials	p. 487
17-3 Fundamental Metallurgical Concepts to Improve Steel Properties	p. 490
17-4 Design Methods	p. 495
17-5 Thickness (Scantling) Calculations	p. 509
Nomenclature	p. 523
References	p. 523
18 Tables of Design Data	p. 524
Table 18-1 Specific heat of air, flue gas and ash at atmospheric pressure	p. 525
Table 18-2 Some physical properties of iron, metal, and selected steels	p. 526
Table 18-3 Linear thermal expansion of steel	p. 526
Table 18-4 Specific heat capacity of steel	p. 527
Table 18-5 Electrical resistivity of steel	p. 527
Table 18-6 Thermal conductivity of steel	p. 527
Table 18-7 Density, heat capacity, and heat conductivity for metals	p. 528
Table 18-8 Thermal properties of the saturated water and steam (arranged by temperature)	p. 530
Table 18-9 Thermal properties of the saturated water and steam (arranged by pressure)	p. 532
Table 18-10 Thermal properties of unsaturated water and superheated steam at different pressures	p. 534
Table 18-11 Conversion factors	p. 541
Index	p. 553

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