BASICS OF RENEWABLE

ENERGY SOURCES
• RENEWABLE ENERGY : Renewable energy is energy produced from natural
sources that do not deplete or can be replenished within a human’s life
time.

• NON RENEWABLE OR CONVENTIONAL ENERGY:Those energies which

have been used for many decades. Eg : fossil fuels,nuclear resources.These
are limited and cannot be replenished.

• Renewable energy accounts for 13.5% of the world’s total energy supply,
and 22% of the world's electricity

• Renewable energy systems are a major topic when discussing the globe's
energy future for two main reasons:
1. Renewable energy systems provide energy from sources that will never
deplete.
2. Renewable energy systems produce less greenhouse gas emissions
than fossil fuel energy systems.
 Positives Vs negatives
• Just because an energy source is renewable doesn’t mean it’s 100 percent
environmentally safe.

• For instance, dams which harness the power of moving water can also harm
fish and wildlife.

• Wind turbines use the sun’s energy to generate clean electricity, but there
are environmental impacts from the manufacturing process.  

• Renewable energy resources cause much lighter environmental footprint than

fossil fuels.

• This is why renewable energy sources are so important – they are our ticket
to a less polluted world.
 Major Renewable energies
 The main 5 types of renewable energy are
• Solar energy
• Wind energy
• Hydroelectric energy
• Biomass energy
• Geothermal enegy
 Other forms of energy : Energy
from the tides, oceans and hot
hydrogen.
Sources of different renewable energies
• Most renewable energy is derived directly or indirectly from the
sun.
• Sunlight can be captured directly using Solar technologies.
• The sun's heat drives winds, whose energy is captured
with turbines.
• Plants also rely on the sun to grow and their stored energy can be
utilized for bioenergy

• Not all renewable energy sources rely on the sun. For

example,geothermal energy utilizes the Earth’s internal heat, tidal
energy relies on the gravitational pull of the moon,
and hydropower relies on the flow of water.
• Solar energy: This form of energy relies on the nuclear fusion power from
the core of the Sun. This energy can be collected and converted in a few
different ways.(Solar panels and photovoltaic cells)

• Wind energy:Wind can be considered a form of solar energy because the

uneven heating and cooling of the atmosphere cause winds (as well as the
rotation of the earth and other topographical factors). Wind flow can be
captured by wind turbines and converted into electricity.( Wind mills)

• Hydroelectric energy : This form uses the gravitational potential of

elevated water that was lifted from the oceans by sunlight. Most dams
that are being built have infrastructure that allows them to capture the
energy from the water.
•  Biomass energy: It is the term for energy from plants
• Geothermal energy : Within the Earth, there is a great deal of energy
trapped inside molten magma. All of this heat transfers itself to the deep
stores of water and air that flow through the Earth.
 Advantages

• They’ll never run out.

• They don’t damage our planet
• They’re low-maintenance energy sources.
• They’re good news for regional areas

Disadvantages

• Higher upfront cost. While you can save money by using renewable

energy, the technologies are typically more expensive
upfronttraditional energy generators.
• Intermittency.
• Storage capabilities.
• Geographic limitations.
Importance of renewable energy resources
• Non renewable energy resources are limitted and cause
atmospheric pollution when it burns.
• Renewable sources are infinite and ecofriendly.
• Renewable energies are  clean and inexhaustible
• Their costs are also falling and at a sustainable rate 
• Clean energy development is vital for combating climate change
and limiting its most devastating effects. 
 Renewable sources of energy
HYDR
O SOLAR

HYDR BIOF BIOMAS

OGEN UEL WIND
S

OCEAN
BIOG GEOTHE
THERM TIDAL
AL AS RMAL
 Solar energy
 Solar energy in one form or another is the source of nearly all energy
on the earth. Humans, like all other animals and plants, rely on the
sun for warmth and food. However, people also harness the sun's
energy in many other different ways.

 For example, fossil fuels, plant matter from a past geological age, is
used for transportation and electricity generation and is essentially
just stored solar energy from millions of years ago.

 Similarly, biomass converts the sun's energy into a fuel, which can
then be used for heat, transport or electricity.

 Wind energy, used for hundred of years to provide mechanical

energy or for transportation, uses air currents that are created by
solar heated air and the rotation of the earth. Today wind turbines
convert wind power into electricity as well as its traditional uses.
 Even hydroelectricity is derived from the sun. Hydropower
depends on the evaporation of water by the sun, and its
subsequent return to the Earth as rain to provide water in dams.

 Photovoltaics (often abbreviated as PV) is a simple and elegant

method of harnessing the sun's energy. PV devices (solar cells) are
unique in that they directly convert the incident solar radiation into
electricity, with no noise, pollution or moving parts, making them
robust, reliable and long lasting.

 Solar power is the conversion of energy from sunlight into

electricity, either directly using photovoltaics (PV), indirectly using
concentrated solar power, or a combination.

 Concentrated solar power systems use lenses or mirrors and

tracking systems to focus a large area of sunlight into a small beam.
Photovoltaic cells convert light into an electric current using the
photovoltaic effect
 Wind energy
Wind energy is a form of solar energy. Wind energy (or wind power)
describes the process by which wind is used to generate electricity.
Wind turbines convert the kinetic energy in the wind into mechanical
power. A generator can convert mechanical power into electricity.
Mechanical power can also be utilized directly for specific tasks such as
pumping water.
Wind is caused by the uneven heating of the atmosphere by the sun,
variations in the earth's surface, and rotation of the earth. Mountains,
bodies of water, and vegetation all influence wind flow patterns,
Wind turbines convert the energy in wind to electricity by rotating
propeller-like blades around a rotor. The rotor turns the drive shaft,
which turns an electric generator.
Three key factors affect the amount of energy a turbine can harness
from the wind: wind speed, air density, and swept area.
A wind turbine works on a simple principle: energy in the wind
turns two or three propeller-like blades around a rotor. The rotor is
connected to the main shaft, which spins a generator to create
electricity. Wind turbines are mounted on a tower to capture the
most energy. At 100 feet (30 meters) or more above ground, they
can take advantage of faster and less turbulent wind. Wind turbines
can be used to produce electricity for a single home or building, or
they can be connected to an electricity grid (shown here) for more
widespread electricity distribution.
 Geothermal energy
• Geothermal energy is the heat from the Earth. It's clean and
sustainable.
• Resources of geothermal energy range from the shallow
ground to hot water and hot rock found a few miles beneath
the Earth's surface, and down even deeper to the extremely
high temperatures of molten rock called magma.
• Almost everywhere, the shallow ground or upper 10 feet of
the Earth's surface maintains a nearly constant temperature
between 50° and 60°F (10° and 16°C).
• Geothermal heat pumps can tap into this resource to heat
and cool buildings.
• A geothermal heat pump system consists of a heat pump,
an air delivery system (ductwork), and a heat exchanger-a
system of pipes buried in the shallow ground near the
building.
• In the winter, the heat pump removes heat from the heat
exchanger and pumps it into the indoor air delivery system.
• In the summer, the process is reversed, and the heat pump
• Wells can be drilled into underground
reservoirs for the generation of electricity.
Some geothermal power plants use the steam
from a reservoir to power a turbine/generator,
while others use the hot water to boil a
working fluid that vaporizes and then turns a
turbine.

• Hot water near the surface of Earth can be

used directly for heat. Direct-use applications
include heating buildings, growing plants in
greenhouses, drying crops, heating water at
fish farms, and several industrial processes
such as pasteurizing milk.

• Hot dry rock resources occur at depths of 3 to

5 miles everywhere beneath the Earth's
surface and at lesser depths in certain areas.
Access to these resources involves injecting
cold water down one well, circulating it
through hot fractured rock, and drawing off
the heated water from another well.
• Tidal power is taken from the Earth's
oceanic tides. Tidal forces are
periodic variations in gravitational
attraction exerted by celestial
bodies.
• Tides are the rise or fall in the water
level due to the gravitational force of
the moon.
• These forces create corresponding
motions or currents in the world's
oceans. Due to the strong attraction
to the oceans, a bulge in the water
 biomass
Biomass is organic material that comes from plants and animals, and it is a
renewable source of energy.
Biomass contains stored energy from the sun. Plants absorb the sun's energy
in a process called photosynthesis. When biomass is burned, the chemical
energy in biomass is released as heat. Biomass can be burned directly or
converted to liquid biofuels or biogas that can be burned as fuels.
Examples of biomass and their uses for energy:
1. Wood and wood processing wastes—burned to heat buildings, to
produce process heat in industry, and to generate electricity
2. Agricultural crops and waste materials—burned as a fuel or converted to
liquid biofuels such as ethanol and biodiesel. These fuels can then be burned
for energy.
3. Food, yard, and wood waste in garbage—burned to generate electricity
in power plants or converted to biogas in landfills.
4. Animal manure and human sewage—converted to biogas, which can be
burned as a fuel. Biogas is prepared in special vessels called digesters.
5. Ethanol is made from crops such as corn and sugar cane that are
fermented to produce fuel ethanol for use in vehicles. Biodiesel is produced
from vegetable oils and animal fats and can be used in vehicles and as
heating oil.
 BIOFUEL
• It is a mixture of volatile , flammable hydrocarbons derived
from plant material or animal waste and used as a fuel.
• Some like wood can be used directly to produce heat. The
heat produced can in turn can be used to run generators in a
power plant to produce electricity.

• BIOETHANOL-Sugars and starches from sugarcane ,corn and

high cellulosic plants can be converted into ethanol, which is
used directly in internal combustion engines or is mixed with
gasoline.
• BIODIESEL-Oils from plants such as soya bean or oil palm can
be chemically processed or blended with petroleum diesel
fuel to make biodiesel.
 OCEAN ENERGY
• Ocean covers about 70% of the earth’s surface .
Ocean can produce two types of energy :
thermal energy from sun’s heat and mechanical
energy from the tides and waves.
• Ocean thermal energy is mainly used for
electricity production. There are three types of
electricity conversion systems :closed cycle ,
open cycle and hybrid.
• Ocean mechanical energy : tidal
energy(gravitational pull of moon) , wave
energy(wind).It is not constant.
 Hydroelectric power
• It is available in many forms , potential energy from high
heads of water retained in dams , kinetic energy from
current flow in rivers , kinetic energy from movement of
waves etc. By directing the water flow through a turbine
electricity is produced.
• The conversion efficiency of a hydroelectric power plant
depends mainly on the type of water turbine used and
can be as high as 95%for large installations.
• Main types of turbines used are:
a) Pelton turbine
b) Francies turbine
c) Propeller and Kaplan turbines
 BIOGAS
• Biogas is the mixture of gases produced by the
breakdown of organic matter in the absence of oxygen.
• It is produced by anaerobic digestion with methanogens
or anaerobic organisms in closed systems or by
fermentation of biodegradable materials. The closed
system is called a bioreactor or anaerobic digester.
• It may be composed of CH₄ ,CO₂, H₂S, moisture etc.

USES
• Electricity production , cooking, water heating .If
compressed it can replace CNG in vehicles etc.
 HYDROGEN FUEL

H₂+O₂ 2H₂O +energy

• It is a zero emission fuel when burnt with

oxygen.
• It can be used in electrochemical cells or internal
combustion engines to power vehicles(cars and
fuel cell buses), in spacecraft .
RENEWABLE ENERGY
RESOURCES
SOLAR ENERGY & WIND
ENERGY

BY
ALMA P
JOBY
18 – BDM -
 1

SOLAR ENERGY
 Solar power derives its energy
from sun , this energy is then
converted into thermal or
electrical energy

 Solar energy is known to be the

cleanest , along with the most
plentiful renewable resources
 2

SOLAR ENERGY
Apart from everyday applications of solar
energy , it is harnessed by two methods :

1) Photovoltaics (PV)
2) Solar thermal energy (STE)
 3

SOLAR ENERGY
PHOTOVOLTAIC SYSTEM SOLAR THERMAL ENERGY
 The application of solar cells  A technology which uses
to convert sunlight directly to solar energy to produce
electricity thermal energy, that is , heat
 Sunlight hit the solar panel  There are low , medium and
and absorbed by high temperature solar
semiconductor material such thermal collectors
as silicon  The first two types are flat
 Electrons are knocked loosely plates generally used to heat
from there atoms , which water
allow them to flow and thus  High temperature collectors
produce electricity concentrate sunlight with
 An array of solar panels mirrors or lenses and are
convert solar energy into DC used to produce electricity
 DC enters an inverter and it  This technique is known as
turns DC electricity into AC concentrated solar power
 The AC power enters the
utility panel in the house
 4

SOLAR ENERGY
Advantages Disadvantages
1. Renewable energy resource 1. Cost of purchase

2. Low cost of maintenance 2. Weather dependent

3. Solar energy storage is

3. Diverse application expensive

4.Reduces electricity bills 4. Uses a lot of spaces

5. Technology development 5. Associated with pollution

 5

WIND ENERGY
 Air in motion is called wind .

 Wind power is a renewable energy source

used to generate electricity by converting
wind energy into mechanical energy . This
mechanical energy is then converted into
electricity by the use of an electrical
generator located within each individual
wind machine.

 The energy of wind is harnessed with wind

turbines

 There are onshore farms and offshore

farms
 6
WIND MILL
• A wind mill is a device which works with energy of blowing
wind .
• It can be used to run water pumps , for grinding grains and to
produce
WIND electricity .
MILL FOR WIND MILL FOR GRINDING
PUMPING WATER GRAIN
 7
HOW IS WIND ENERGY
CONVERTED TO ELECTRICITY ?
 Wind turbine convert kinetic energy in the
wind into mechanical power

 This mechanical power can be used for specific

task ( grinding grain or pumping water ) or a
generator can convert this mechanical power
into electricity

 A wind turbine is opposite to that of a fan .

Instead of using electricity to make wind (fan) ,
wind turbines use wind to make electricity .
The wind turns the blades which spin the shaft
, which is in turn connected to a generator
and create electricity

 The energy in the wind turns two or three

 Wind turbines are mounted on tower to 8
capture the most energy . At 30 meters or
more above ground , they take advantage
of faster and less turbulent wind

 Wind turbines can be used to produce

electricity for a single home or building or
they can be connected to an electricity grid
for more wide spread electricity
distribution
ONSHORE WINDFARMS
OFFSHORE WINDFARM
 9

ONSHORE OR OFFSHORE
ONSHORE ? ONSHORE
ADVANTAGES

DISADVANTAGES
A regular onshore turbine  Wind turbines are noisy
lasts for about 20 years
 Each one can generate the
 Normally it takes about 2-3
same level of noise
months before the wind
turbine has paid itself back ,  Some people think that the
this also includes the energy
large towers of wind turbines
which is used to produce ,
destroys the view of the
install, maintain and remove
landscape
the wind turbine

 Cheaper foundation
• Worlds largest onshore wind farm is London Array
 1

ONSHORE OR OFFSHORE ? 0

OFFSHORE ADVANTAGES OFFSHORE

 An offshore wind turbine DISADVANTAGES
is stronger than onshore  More expensive to built
turbines
 More difficult maintain
 Lasts for about 25-30 and access
years and produce about
50% more energy than an
onshore turbine

 When a strong wind blows

it produces around 3-5
MW per hour
 Higher and more constant
wind speed
• Wanley Extension in United Kingdom is the largest offshore wind farm in the
world
37
 HYDROPOWER
• Hydro power also known as
hydraulic or water power is
derived from the force of
moving water.
• Electricity generated with
hydropower is called
hydroelectricity.
• It is considered a renewable
energy source because the
water cycle is constantly
renewed by the sun.
38
• Hydropower supplies over 19% of all
electricity in the world.
• It is generally far cheaper than fossil fuels
or nuclear fuel.
• Hydroelectricity is mostly generated in
dams.
• Water is first collected in dams and let
flow through turbines.
.
• The great advantage of this technology is
that the amount of energy produced can
be easily adjusted to the level of demand
by controlling the outflow of water.

39
• Another technology that utilizes a dam but no
reservoir is the run-of-the-river hydroelectric
generation.
• Tidal power technologies convert the energy
of tides into electricity .Tidal energy is
captured with tidal stream systems which use
the kinetic energy of moving water to drive
turbines.
• World leaders in hydropower use is China,
Brazil, Canada, USA and India

40
41
 BIOMASS
• Biomass is fuel that is developed from organic materials, a
renewable and sustainable source of energy used to create
electricity or other forms of power.
• Biomass consists of living or recently dead organisms or other
biological material ie. Carbon.
• Some examples of materials that make up biomass fuels are:
1. scrap lumber
2.forest debris
3.certain crops
4.manure
5.some types of waste residues.

42
• A plant especially grown to be used
for biofuel manufacturing is known
as an energy crop
• Biomass is a renewable source of
fuel to produce energy because:
 waste residues will always exist –
in terms of scrap wood, mill
residuals and forest resources; and
 properly managed forests will
always have more trees, and we
will always have crops and the
residual biological matter from
those crops.

43
Types of biomass
Biomass is available in all three basic forms of matter: Solid, Liquid, and
Gas, which themselves can be sub-divided into;
primary (produced by direct use of solar energy through
photosynthesis)
secondary (generated by the decomposition or conversion of organic
substances).
1. Solid Biomass – also known as “feedstock”, which are solid or
compressed pieces of organic matter in the form of pellets that release
their stored energy through combustion and burning. Eg. Wood, crop,
manure

2. Liquid Biomass – also known as “bio fuel”, is any kind of fluid or liquid

produced from solid matter that is still growing or has been alive at
some point which can be processed to produce a type of fuel. Eg.
Vegetable oils and ethanol
44
• Gas Biomass – also known as “biogas”, is any kind of natural
forming gas given off by decaying plants, rotting rubbish,
decomposing animals, slurry and manure that can be used as
a type of fuel.

45
Properties of wet steam

46
definition

 Wet steam is defined as steam which is partly vapor and

partly
Liquid suspended in it.
 The steam is wet that is, the water molecules are not
evaporated
Completely and all the latent heat has been absorbed .

47
Temperature-enthalpy graph for steam
formation

48
 Dryness fraction
 The steam dryness fraction is used to quantify the
amount of water within steam.
 If mg         mass of dry steam per kg of mixture
       mf         mass of suspended liquid water per kg of
mixture
                And dryness fraction,x=mg/(mg+mf)

For dry saturated steam,x=1

49
 Wetness fraction

• It is the ratio of the weight of water or moisture in

suspension in a wet steam sample to the total
weight of  wet steam.it is calculated by
substracting x from 1.
• Wetness fraction, (1-x)=mf/(mf+mg)
• Wetness fraction for saturated water =1,wetness
fraction for dry saturated Steam=0.

5
0
 enthalpy

 It may be defined as the quantity of heat required to

convert one kg of water at 0ᵒc,at constant
pressure ,into wet steam.
           h=hf+xhfg ,  WHERE h  IS  ENTHALPY OF 1 Kg OF WET

STEAM .                                                                  hf    IS    ENTHALPY OF 1Kg OF

WATER.

     hfg      IS   LATENT HEAT OF VAPORIZATION PER Kg .

5
1
 Specific volume of steam
IT IS THE VOLUME OF ONE Kg OF WET STEAM AND IS
DENOTED AS Vws
       Vws =X.Vg + (1-X)Vf
                             WHERE ,Vg IS THE VOLUME OF 1 KG OF DRY
STEAM
                                           Vf IS THE VOLUME OF 1 KG  OF WATER
 AT LOW PRESSURE ,THE VALUE OF Vf IS VERY SMALL AS
COMPARED TO Vg ;SO THE TERM (1-X)Vf MAY BE
NEGLECTED .THEN VOLUME OF 1KG OF WET STEAM=XVg.
        
52
 Work done during vapourization

• FOR ONE KG OF DRY STEAM ,EXTERNAL WORK DONE=P(Vg-Vf)

BUT THE PRODUCT PVf IS NEGLIGIBLE QUANTITY AND IS OFTEN
NEGLECTED .
  THEREFORE ,EXTERNAL WORK =PVg KJ/KG
AND FOR WET STEAM WITH DRYNESS FRACTION X,THE EXTERNAL
WORK DONE  =PXVg.
ACTUALLY THE LATENT HEAT OF VAPOURIZATION IS MORE THAN
THE WORK DONE.THUS HEAT IS REQUIRED TO OVERCOME THE
INTRA-MOLECULAR RESISTANCE TO CHANGE THE PHASE OF THE
     SUBSTANCE AND THE DIFFERENCE BETWEEN Hfg AND PVg IS
CALLED INTERNAL LATENT HEAT .
            THUS,Hfg= INTERNAL LATENT HEAT +PVg KJ/KG.
53
 Internal energy
• INTERNAL ENERGY IS THE TOTAL ENERGY STORED
IN THE STEAM .
• IT CAN BE CALCULATED FROM THE
FORMULA ,h=u+pvg.

54
 Specific entropy

Specific entropy of wet steam is equal to sum of

specific entropy of saturated water and change in
specific entropy during evaporation of dry fraction
of steam .it is denoted by sws 
              Sws =sfs + xsfg.

55
 DRY SATURATED STEAM

Steam which is not superheated and

though no moisture
is present in it is called “dry saturated
steam”.

2
 TEMPARATURE ENTHALPY GRAPH FOR
STEAM FORMATION

The line with red colour shows the dry saturated steam

3
PROPERTIES OF DRY SATURATED
STEAM
 SPECIFIC ENTHALPY OF DRY SATURATED
STEAM(hg)
The quantity of heat required to convert 1kg of
water at 00c in to dry saturated steam at given
constant pressure.It may denoted by hg.
It is equal to sum of specific heat of saturated
water & latent heat corresponding to given
saturation pressure & temperature.

4
SPECIFIC ENTROPY OF DRY SATURATED STEAM(sg)

It is the entropy of 1kg of dry saturated steam and

is given as the sum of entropy of1kg saturated water
and entropy change during evapouration.It is
denoted by sg.

5
SPECIFIC VOLUME OF DRY SATURATED STEAM(vg )

It is defined as the volume of 1kg of dry saturated steam

corresponding to given pressure.it is denoted by vg and
can be calculated experimentally .As dry saturated steam
is a gas ,its specific volume decreases with increase in
pressure or saturated temperature.

6
DRYNESS FRACTION

The dryness fraction of dry saturated steam is 1.

WETNESS FRACTION
The wetness fraction dry saturated steam is 0.

7
ADVANTAGES OF DRY SATURATED STEAM

 Improved product quality and productivity

 Temperature can be quickly & precisely established
 Smaller required heat transfer area,enabiling reduced
initial equipment outlay
 Safe,clean,low cost
 PROPERTIES OF SUPERHEATED STEAM

When the dry steam or saturated steam is

further heated at constant pressure ,thus
raising its temperature ,it is said to be
superheated steam. Since the pressure is
constant, the volume of superheated steam
increases.

(1)
SPECIFIC VOLUME OF SUPERHEATED STEAM

It is the volume of 1kg of superheated steam

and can be determined by assuming that the
steam behaves as a perfect gas. i.e, obeys the
gas law.It is denoted by Vsup .
Vg = Vsup
ts tsup
Vsup = Vg . tsup
ts
(2)
 ENTHALPY OF SUPERHEATED STEAM
• It is defined as the quantity of heat required to
convert 1kg of water at 0 C into the superheated
steam at given temperature and pressure .
It may be denoted as hsup
and is equal to the sum of specific enthalpy of dry
saturated steam and product of specific heat of
superheated steam (Cs) to degree of superheat.

(4)
Enthalpy of superheated steam,
hsup = hg + Cs(tsup -ts )
hg =specific
enthalpy of dry steam
ts =saturation
temperature

Cs = specific heat
tsup=temperature of superheated steam

(5)
INTERNAL ENERGY OF SUPERHEATED STEAM

Internal energy of superheated steam ,

usup = hsup - pvsup kJ/kg

usup=Internal energy of superheated steam

hsup=Enthalpy of superheated steam
Vsup=specific volume of superheated steam
(6)
ENTROPY OF SUPERHEATED STEAM
It is the sum of specific entropy of dry
saturated steam and entropy change
during superheating from saturation
temperature Ts to superheated
temperature Tsup.

(7)
ADVANTAGES OF SUPERHEATED STEAM
 The superheating is done in a superheater, which
obtains heat from waste furnace gases. These gases
would have otherwise passed uselessly .
 The temperature of superheated steam being higher,
it gives a high thermal efficiency in heat engine.
 It has high heat content and so high capacity of doing
work .Thus it results in an economy in steam
consumption.
(8)
 STEAM GENERATOR
It is a large apparatus used for converting water to steam.

USES
 For power generation in case of steam engine.
 For processing in case of industrial process like sizing,
bleaching, etc.
 For heating as in case of heating installation
for building.

1
 CLASSIFICATION OF BOILERS

Tube Furnace
Use content position Heat source Circulation

2
 STATIONARY AND MOBILE BOILERS

STATIONARY
• These are boilers which are stationary and cannot be moved
from one place to another.
• Boilers used in power plants.
MOBILE BOILERS
• Portable boilers means a boiler
permanently affixed to a trailer
with wheels, that is totally self
contained while operating.
• Boilers used in small coal field pits
3
 BASED ON TUBE CONTENT
WATER TUBE BOILER FIRE TUBE BOILER
• A  water tube boiler  is such kind of • A  fire-tube boiler  is a type of
 boiler  where the  water  is heated  boiler  in which hot gases pass
inside  tubes  and the hot gasses from a  fire  through one or more 
surround them. tubes  running through a sealed
• Babcock and Wilcox, Stirling container of water.
• Cornish, Lancashire

4
 BASED ON CIRCULATION
1. NATURAL CIRCULATION
• Circulation is achieved by the difference in density when
the water in the boiler is heated
• Circulation of water is by convection currents
• LANCASHIRE BOILER, BABCOCK AND WILCOX BOILER
2. FORCED CIRCULATION
•  An external pump is used to circulate water inside the boiler.
• The fluid is forced “once through” or controlled with partial
recirculation
• LAMONT BOILER, VELOX BOILER, BENSON BOILER

5
 BASED ON FURNANCE POSITION
1. EXTERNALLY FIRED
• The boiler is said to be external combustion boiler when
combustion take place outside the region of boiling water
•  BABCOCK AND WILCOX BOILER, STIRLING BOILER etc.

• INTERNALLY FIRED
• If the furnace region is completely surrounded by water-
cooled it is said to be internally fired boiler
• LANCASHIRE

6
 BASED ON HEAT SOURCE
1. Combustion of fuels
• Solid :- Coal, Wood
• Liquid :- Oils
• Gas :- Natural gas
2. Hot waste gases as by product of other chemical
process :- Propane
3. Electrical energy
4. Nuclear energy

7
 FIRE TUBE BOILERS
• The flames and hot gases produced by the
combustion of fuel pass through the tubes
which are surrounded by water .The heat is
conducted through the walls of the tubes from
the hot gases to the surrounding water.

78
 EXAMPLES:
• Simple vertical boiler
• Cochran boiler (Many small tubes)
• Lancashire boiler (Two large tubes)
• Cornish boiler (One large tube)
• Scotch boiler
• Locomotive boiler (Many small tubes)
• Velcon boiler

79
 IMPORTANT TERMS:
• Boiler shell-It is made up of steel plates bent into cylindrical
form and welded together . The ends of shells are closed
by means of end plates
• Combustion chamber-It is the space generally below the
boiler shell , meant for burning fuel in order to produce
steam from the water contained in the shell
• Grate-it is a platform in the combustion chamber , upon
which fuel is burnt . The grate generally consists of cast iron
bars which are spaced apart so that the air can pass
through them . The surface area of grate ,over which the
fire takes place is grate furnace

80
• Furnace-It is the space above the grate and below the boiler
shell , in which the fuel is actually burnt . The furnace is also
called fire box
• Heating surface-it is the part of boiler surface , which is
exposed to the fire
• Mountings-These are the fittings which are mounted on the
boiler for its proper functioning . They include water level
indicator , pressure gauge , safety valve etc. It may be noted
that a boiler cannot function safely without the mountings.
• Accessories-It helps in controlling and running the boiler
efficiently.

81
 FEATURES:
• The hot gases from the furnace pass through the
tubes which are surrounded by water
• It can generate steam only up to 24.5 bar
• The rate of generation of steam is low that is up to 9
tonnes per hour
• The floor area requirement is more that is about 8
meter square per tonne per hour of steam generation
• Its overall efficiency is only 75%
• the water does not circulate in a definite direction

82
ADVANTAGES DISADVANTAGES
• It can cope with sudden • The transportation and
increase in load but for a erection is difficult
shorter period • The bursting produces
• The operating cost is less greater risk to the damage
• The bursting chances are of property
less • It is not suitable for larger
• It is so easy to use , plants
operate , clean and • It does not use thermal
maintain radiation

83
 APPLICATIONS:
• Railways
• Marines
• Industrial sector

84
 1

BOILER
MOUNTINGS
THEY ARE SAFETY DEVICES FITTED ON BOILER
FOR SAFE AND EFFICIENT OPERATION

85
 BOILER MOUNTINGS
• Water gauge
• Pressure gauge
• Steam stop valve
• Feed check valve
• Blow down cock
• Fusible plug
• safety valve

2
86
 BLOW OFF COCK
• The principle functions are:-
1) To empty the boiler whenever
required
2) To discharge the mud scale
or sediments which are
accumulated at bottom of
boiler
• Fitted to bottom of the boiler

3 87
 MAINPARTS
• Conical plug is fitted to
casing
• Casing is packed with
asbestos packing
• Cocks helps to keep a
grip better under high
pressure
• Plugs held by a yoke
with 2 studs at both
sides

4
88
 FUSIBLE PLUG
 Fitted to the crown plate of the
furnace r fire box
 Function is t put off the fire in
furnace of boiler when the level
of water in boiler falles to
unsafe limit and thus avoids
explotion which may take place
due to overheating of furnace
plate

89
 WORKING
 During normal operation device
remains submerged in water, in
water space of boiler thus
temperature on no account can
exceed much more than
saturation temperature.
 Fusible plug is protected from
direct contact with water o
furnace gases by 2 plugs
1. Conical copper plug
2. Gun metal plug

6
90
 Continues…..
• When water level in the shell falls below the top of plug ,
steam cannot keep it cool and fusible metal melts due to over
heating
• Thus copper plug drops down and is held within the gun meta
body by ribs.
• Thus the steam space gets communicated to firebox and
extinguishes the fire
• Damage to fire box is avoided
• By removing gun metal plug gun and copper plug the fusible
plug can be put in position again by interposing the fusible
metal
7
91
 SAFETY VALVES
• Devices for preventing explotions due to excessive internal
pressure of steam
• These are directly placed on boiler
• The function of safety valve is to blow off the steam when
pressure of steam inside the boiler exceeds working pressure
• Four types are:-
1. Lever safety valve
2. Dead weight safety valve
3. High steam &low water safety valve
4. Spring loaded safety valve
8

92
 2.SPRING LOAD SAFETY VALVE
 Function is to prevent steam
pressure in the boiler exceeding
desired rated pressure
 Therefore discharge capacity
should be equal to the
evaporative capacity so that
frequent build up of pressure
does not occur
 Preferred for locomotive
&marine boilers because it is
unaffected by jerks & vibrations
that may occur such devices
9
93
 DEAD WEIGHT SAFETY VALVE
 Steam pressure in upward
direction is balanced by
downward force of dead
weights
 Used in stationary boilers
 Usually used in Lancashire &
Low capacity boiler

10
94
 BOILER ACCESORIES
• These are those devices which are
installed with a boiler and its neighboring
area to increase the efficiency of the
boiler .
• These are not essential part of the boiler
and thus without installing these device
the boiler can be accomplished though at
lower efficiency.
95
IMPORTANT ACCESSORIES OF THE BOILER

• FEED WATER PUMP

• INJECTOR
• PRESSURE REDUCING VALVE
• ECONOMIZER
• AIR PRE HEATER
• SUPER HEATER
• STEAM DRIER OR SEPERATOR
• STEAM TRAP
96
 FEED WATER PUMP

• A boiler feed water pump is a specific type

of pump used to pump feed water into
a steam boiler.

97
• It helps to maintain proper working of a boiler
providing continues feed water supply.
• A continues feed water supply is essential for steam
boiler ;as it not only avoid overheating but any
further damage to the boiler.
•  Boiler feed water pumps are commonly centrifugal
pumps and reciprocating pump.
• A feed water pump is most often driven by an
electric motor for energy efficiency.

98
 PARTS

• One water pump and one steam cylinder.

• Slide valve arrangement
• Piston rod
• Piston
• Suction valve
• Delivery valve
• Valve rod
FEED WATER PUMP ; CONSTRUCTION
(DUPLEX FEED PUMP)
 INJECTOR
• Function of the injector is the same as that
of feed pump
i.e.; to deliver feed water to boiler under
pressure.
• In an injector, the water is delivered to the
boiler by steam pressure, the kinetic energy of
the steam is used to increase the pressure and
velocity of the feed water.

101
INJECTOR

102
 working
• With the rotation of the handle ,steam cone moves up
and down , the valve controls the steam flow through
the steam pipe.
• Water entering through the water pipe .
• The water flow is controlled by flow of steam.
• The sliding motion steam cone due to the steam
pressure of water flow is controlled.
• The steam and water are combining cone.
• The mixture then passes through the delivery cone and
there its kinetic energy is converted into pressure energy.

103
 ECONOMISER
It is a energy improving device that helps to
reduce the cost of operation by saving the
fuel.
The economizer in boiler tends to make the
system more energy efficient.
Mechanical devices intended to reduce energy
consumption, or to perform useful function
such as preheating a fluid.

104
ECONOMISER

105
 ECONOMIZER;WORKING
• The exhaust gases which are leaving the boiler
at such high temp is made to pass through the
economiser in order to provide the required
sensible heat to the water by increasing its
temperature , it will reduce the heat load on
the boiler to the greater extend
ECONOMIZER ;CONSTRUCTION
 PRESSURE REDUCING VALVE
• The function of pressure reducing valve is to
maintain constant pressure on its delivery
side of the valve irrespective of fluctuating
demand of steam from the boiler.
• Water which is being forced through the pipes
at high pressure before the valve will be
slowed down after the valve

108
 CONSTRUCTION &PARTS
• Steam inlet
• Valve A
• Valve rode B
• Loose fitting piston C
• Rubber diaphragm
• Spring
EXPANSION JOINTS

110
 An expansion joint or movement joint is an
assembly designed to safely absorb the
temperature-induced expansion and
contraction of construction materials, to
absorb vibration, to hold parts together, or to
allow movement due to ground settlements or
earthquakes.

2
 Structure Of Expansion Joint
1. Flange: A piping joint used to fasten
pipes using bolts and nuts.
2. Pipe: A piping material used for
transferring fluids.
3. Bellows: An essential part related to
the performance of expansion joints
such as flexibility.
4. Reinforcement Ring: It is used for
preventing deformation of the
bellows.
5. Internal Cylinder: It prevents pressure
loss and turbulent flow of fluids.
6. Limitation Flange: It is used for
attaching a limitation bolt.
7. Limitation Bolt: It suppresses
excessive extension to protect the
bellows.

112
 The different types of Expansion Joints are

1. Free Type
• The basic type of
expansion joint. Thrust
generated by internal
pressure is applied to
the fixed points.
• If high internal pressure
is applied, a
reinforcement ring is
used to prevent
deformation of bellows.
113
2. Free duplex type
• A duplex type can
be used if
displacement in the
direction
perpendicular to the
axis is large.

114
3. Outer Pressure type
(single type)
• This type is
characterized by the
structure where
internal pressure of the
fluid is applied in the
area between the inner
surface of the external
cylinder and the outer
circumference of the
bellows
115
4. Outer Pressure Type
(duplex type)
• This type is characterized
by the structure where the
internal pressure of the
fluid is applied in the area
between the inner surface
of the external cylinder and
the outer circumference of
the bellows.
• There is no risk of buckling
of the bellows even at high
pressure.
116
5. Hinge Type
• This type can absorb angular
displacement on a plane.
• It is ingested to restrain the
thrust generated by internal
pressure by a hinge pin, thus
applying no thrust at fixed
points.
• This can absorb displacement in
the axial direction.
• If high internal pressure is
applied, a reinforcement ring
can be used to prevent
deformation of the bellows.

117
 Application Of Expansion Joints
1. When the space constraints do not permit
providing adequate flexibility by conventional
methods for maintaining the system stresses
within acceptable limits
2. When conventional solutions create
unacceptable process conditions.
3. When it is not practical to limit the piping
induced loads on the terminal nozzles of the
connected equipment within admissible limits
by conventional methods.
118
4. When the equipment such as compressors,
turbines, pumps, etc. necessitate isolating
the mechanical vibrations from being
transmitted to the connected piping.

119
COCHRAN
BOILER
 What is cochran boiler?
● Cochran Boiler is a vertical drum axis, natural
circulated, natural draft, low pressure, multi-tubular,
solid fuel fired, fire tube boiler with internally fired
furnace
● It is the modified form of simple vertical boiler. In this
boiler, the fire tubes are placed horizontally. The
efficiency of this boiler is much better than the simple
vertical boiler.
● The Cochran boiler was produced by Cochran & Co. of
Annan, Scotland

1
SPECIFICATIONS

2
3
 PARTS OF BOILER
⮚ Shell: the main body of the boiler as shell. It has a vertical shall which
has hemispherical top head .This hemispherical top gives higher volume
to area ratio which increases steam capacity.

⮚ Grate :The area where fuel is placed known as grate.

⮚ Combustion chamber :It is at the bottom side of boiler. The
combustion camber is connected to the furnace.

⮚ Fire tube: There are various fire tubes which one end is connected to
furnace and other by chimney.

⮚ Fire hole : The small hole is provided at the bottom of the combustion
chamber to place fuel is known as fire hole.

4
⮚ Furnace: It works as mediator of fire tube and combustion
chamber.It is has also dome shaped top.The main advantages
of this shape is that it reflects back the un –burned charges
and the flue gases to the combustion.

⮚ Chimney:The flue gases leave atmosphere through chimney.

⮚ Fire brick lining: The brick lining outside the combustion

chamber prevent the overheating of it.
⮚ Manhole: A manhole is provided for the cleaning and
inspecting of the boiler from inside.

⮚ Flue Pipe: It is a small passage connecting the fire box and

combustion chamber. The hot gases enters into combustion
chamber through the flue pipe. 5
 Boiler mountings and accessories

● 1. Pressure Gauge: It measures the pressure of steam

inside the boiler.
2. Safety Valve: It blows off the extra steam when the
steam pressure inside the boiler reaches above safety level.
3. Water level Indicator: The position of the water level in
the Cochran boiler is indicated by the water level indicator.
4. Stop Valve: Stop valve is used to transfer steam to the
desired location when it is required. Otherwise it stops the
steam in the boiler.
5. Blow off Cock: It is used to blow off the settle down
impurities, mud and sediments present in the boiler water.
6
 WORKING
● In Cochran boiler first the fuel is inserted into the fire box and
placed on the grate. The fuel is ignited through the fire hole
provided at the right bottom of the boiler.

● The fuel is burnt in the fire box and due to the burning of the
fuel, smoke and hot flue gases emerges out. The hot flue gases
enter into the combustion chamber through flue pipes.

● From the combustion chamber hot gases enters into the fire
tubes. The fire tubes are surrounded by water. The hot flue gases
inside the tubes exchange the heat from the hot gases to the
water. Due to the exchange of heat, the temperature of the
water start increasing and it gets converted into steam. The
steam produced rises upward and collected at top of the boiler in
the hemispherical dome. 7
An anti-priming pipe is installed at top of
the boiler which separates the water
from the steam and makes it dry
steam. This dry steam is then transfer
to the turbines through the steam stop
valve.
● The hot flue gases and smoke after
exchanging heat moves to the smoke
box. From the smoke box the burnt
gases and smoke is discharge to the
atmosphere through the chimney.
● Burnt fuel is transferred to the ash
pit. Blow off cock is preset at left
bottom of the boiler and is used to
blow of the impurities, mud and
sediment from the boiler water.
8
● A fusible plug is also provided at top of the
combustion chamber. When the temperature of the
combustion chamber crosses the permissible level,
the fusible plug melts and the water through the
combustion chamber enter into the furnace of the
boiler and stop the fire. In this way a big fire
accident can be prevented to take place and also
protects the boiler from damage.

● Various boiler mounting and accessories are

attached to the boiler for its efficient working .
9
 Advantages and Disadvantages

● Low rate of steam generation

❖ Low initial installation cost
● Inspection and maintenance is
❖ It requires less flora area
difficult

❖ Easy to operate and handle ● High room head is required

for its installation due to the
❖ transportation of cochran
vertical design.
boiler is easy
● It has limited pressure

❖ It can use all type of fuel range.

STIRLING BOILER

RESIKA K.R
18-BDM-25

131
 WHAT IS STIRLING BOILER?

o The stirling boiler is an early form of water-

tube boiler,used to generate steam in land
based stationary plants.
o This boiler was first designed in the year of
1888 by Alan Stirling so we refer the boiler as
Stirling Boiler. Because of the huge capacity
we can use this boiler in central power
stations.

132
 features
Externally fired
Natural circulation
Bent tube boiler
Water tube boiler
Working pressure:60 bar(max)
Steaming capacity:5000kg/hr

133
MAIN PARTS

134
 CONSTRUCTION
Steam drum is a collection vessel for steam & water. Here water &
steam is separated. It has steam separators. Steam goes from top
side to superheater & water goes from the bottom through down
comer Mud drum, then to furnace bottom ring headers (bottom
of furnace water wall).
• Mud drum: a cylindrical formed space at the base of the water
space .the impurites like mud , sediment, and other will be
gathered.
• Superheater: It increases the temperature of saturated steam to
the required temperature before discharging it from steam stop
valve.
•  

135
• Bent tube boiler:Since the tubes are bent, the
mechanical stresses due to expansion of
the pipes during heating can not effect the
system much.
• Safety Valve: It blows off the extra steam when
the steam pressure inside the boiler reaches
above safety level.
• chimney:the flue gases leave atmosphere
through chimney
136
• Grate :The area where flue is placed known as grate
• Furnace: It is the space above the gate and the boiler shell in
which the fuel is actually burnt the furnace is also called fire box.
• Baffle:Baffle plates are present in between water tubes and it
allows the zigzag motion of hot flue gases from the furnace.

• . Blow off Cock: It is used to blow off the settle down impurities,
mud and sediments present in the boiler water.
•  Stop valve: It is the largest valve on the steam boiler. It is used to
control the flow of steam from boiler to the main steam pipe.

137
 WORKING OF STIRLING BOILER
• It consist of three upper drums known as steam drums and a
lower drum known as mud or water drum.
• The steam drums are connected to mud drum by banks of bent
tubes .
• The steam and water space of the steam drums are
interconnected with each other to obtain water and steam
balance.
• Steam drum -1 are attached with saftey valves and drum -2 is
attached with pressure gauge and drum -3 is attached feed check
valve. Mud drum is attached with blow off valve
• Water is fed through the feed check valve to the steam drum -3
which then passes through the mud drum

138
In the mud drum foreign particles get settled down and are
removed through the blow off valve at regular intervals.pure
water goes to the steam -1 and steam drum -2
 steam drums are connecting with equalizing and circulating
tubes.the circulating tubes which equalizing the level of
water in steam drums and while the equalizing tubes
equalize the level of steam in the drums.The hot flue gases
are produced in fire
The hot flue gages are deflected by the brick arch to move
upward between the water tube and it have baffle which
ensure proper heating of the water tubes

139
Absorbing the heat the water flowing in the bends
water tubes converted into steam.this steam moves
upwards and collected steam drums
Saturated steam is extracted from drum and supplied
to the super heater and its converts saturated steam
into super heated steam which can be collected from
steam stop valve
Ash produce from the fuel is collected in the ash pit.
while smoke is allowed to escape into the
atmosphere through a chimney .
140
 Advantages
• Due to number of drum,it has high steam
production ie, 5000kg/hr
• It has high pressure operation with less
pressure drop
• Free expansion and contraction provided by
bent tubes thus prevents undue thermal stress
• Flexibility is design is also permitted.

141
 Disadvantages
• Stirling boiler is more difficult to clean and
inspect the bent tube.
• It is larger in size
• Temperature of super heater is limited

142
BABCOCK & WILCOX BOILER

Nilmiya Kurien
18-BDM-23

143
 What is Babcock & wilcox boiler
 Discovered by George herman babcock &
stephen wilcox.
  Babcock and Wilcox boiler is a natural
circulation, externally fired medium pressure,
stationary horizontal water tube boiler in
which water is flow in the inclined tubes. 

144
Main parts

145
 Construction
1. Drum : horizontal axis drum which contains water &
steam.
2. Down take header: receives water from the drum.
3. Up take header : it transports the steam from the
water tubes to the drum.
4. Water tubes: in which water flows and gets
converted to steam. It is inclined at an angle 10-15
degree with the horizontal. So water tubes do not
fully filled with water and the water & steam
separated out easily.
146
5. Super heater : it increases the temperature of
saturated steam to the required temperature
before discharging it from steam stop valve.
6. Grate : it is a base on which the burning of
the fuel takes place.
7. Baffle plates : allows the zigzag motion of hot
flue gases from the furnace.

147
 Working
 Water starts to come in the water tubes from
drum through down take header.
The water present in the inclined water tubes gets
heated up by the hot flue gases produced from
the burning o coal in the grate.And it is forced to
move in zigzag way with the help of baffle plates.
The hot flue gases come in contact with water
tubes , it exchanges the heat with water and
converts into steam.

148
The steam generated is moved upward and through
uptake header it gets collected at upper side in the
boiler drum.
An anti-priming pipe is provided in the drum. It filters
the water content from the steam and allows only
dry steam to enter into super heater .
The super heater receives the water free steam from
the anti-priming pipe. It increases the temperature
of steam to desired level and transfers it to steam
stop valve.
149
The superheated steam from the steam stop
valve is either collected in a steam drum or
made to strike on the steam turbine for
electricity generation.

150
 Application
The Babcock & wilcox boiler are generally used
to produce high pressure steam in power
generation industries. The high pressure
steam so generated is used to produce
electricity.

151
 Advantages
o Steam generation capacity is high. It is about
2000-4000 kg/hr.
o It occupies less space.
o Replacement of defective tubes is easy.
o It is the only boiler that is used to generate
large quantity of heat in power stations.
o Inspection of this type of boiler can be done in
anytime during its working.
152
 Disadvantages
 High maintanance cost.
 It is not much suitable for impure and sedimentary water .
In case of impure and sedimentary water , scale may be
deposited on the tubes and this leads to overheating and
bursting of tubes . That’s why water treatment is must
before feeding into the boiler.
 Continuous supply of feed water is required for the
working. In the case if feed water is not continuously
supplied even for a short period of time , the boiler get
overheated. Water must be carefully watched during the
operation of the babcock & wilcox boiler.
153
SIMPLE VERTICAL BOILER

154
 CONTENTS

 Introduction
 Construction
 Principle/working
 Application of simple vertical boiler
 ADVANTAGES
 DISADVANTAGES

155
 Introduction
 A vertical boiler is a type of fire-tube or water-tube boiler.

 The boiler barrel is oriented vertically.

 It is used for a variety of steam-powered vehicles and other mobile machines,

including early steam locomotives.
 It is used for low steam production.

 Usually simple vertical boiler produces an around 10 bar of pressure and have steam
generation capacity up to 1000 kg per hour.
 The steam produced in simple vertical boiler is used for low working conditions like
small power plants generating the current.
 Simple vertical boiler efficiency is nearly 50%.

 Boilers have steam generation capacity up to 1000 kg per hour and maximum steam
pressure up to 10 bar.
156
CONSTRUCTION

157
 CONSTRUCTION
 CYLINDRICAL SHELL

The shell is vertical and it attached to the bottom of the furnace. Greater portion of the shell is full of
water which surrounds the furnace also. The shell may be about 1.25m diameter and 2.0m height.
 CROSS-TUBE

One or more cross tubes are either riveted or flanged to the furnace to increase the heating surface
and to improve the water circulation.
 FURNANCE(OR FIRE BOX)

Combustion of coal takes place in the furnace(fire box)

 GRATE

It is the placed at the bottom of fire box and coal is fed on it for burning.
 FIRE DOOR

Coal is fed to the grate through the fire door.

158
o CHIMNEY ( OR STACK):
The chimney (stack ) passes from the top of the fire box through the top of the shell.
o MAN HOLE:
I. On the top of the shell to enable a man to enter into it
II. To inspect and repair the boiler from inside it.
III. Meant for cleaning the interior of the boiler shell and the exterior of the combustion
chamber and stack(chimney).
o HAND HOLES:
These are provided in the shell opposite to the end of each cross tube for cleaning.
o ASHPIT:
It is provided for collecting ash deposit, which can be removed away at the interval.
o FUSIBLE PLUG:
It is used to protect the boiler against damage when the water level is low during
over heating.

159
o PRESSURE GAUGE:
It indicates the pressure of the steam inside the boiler.
o WATER GAUGE:
This indicates the water level in the boiler.
o SAFETY VALVE:
It prevent an increase of steam pressure in the boiler above its design pressure.
o STEAM STOP VALVE:
It regulate the flow of steam supply to requirement
o FEED CHECK VALVE:
To supply high pressure water pass into the boiler.

160
 WORKING PRINCIPLES
 The fuel(coal) is fed into the grate through the fire hole and is burnt.

 The ash pit place below the grate collect the ashes of the burning fuel.
 Boiler drum is filled with water, the flue Gas from the furnace rise in the
tube .
 The exchange of heat takes place between water and flue gases.
 The combustion gas flows from the furnace, passes around the cross tube.

 The water temperature rises and it converts into steam and the flue gases
temperature drops
 Low temperature flue gases enters into the environment via chimney.

 The boiler is fitted with all the mounting as per IBR.

161
 APPLICATION OF SIMPLE VERTICAL BOILER
 Simple vertical boiler is used in railway locomotives i.e. Railway
steam engine.
 It is used in the road vehicles like steam wagon(steam lorry or steam
wagon).
 Simple vertical boiler have a very famous application in steam tractor.
 It is also used in boat especially smaller one to power the engine.
 In some parts of the world simple vertical boiler are used in steam
donkeys.
 Simple vertical boilers are also used in the steam cranes and steam
shovels.
 In dairy industry it is used in :
o heat treatment of dairy product
o Dairy processing
162
 ADVANTAGES OF SIMPLE VERTICAL BOILER

 Low initial cost because of lesser parts.

 Low maintenance cost.
 Simple working.
 Easy to install and replace .
 Occupy small space on ground.
 Simple vertical boiler have water level tolerance.

163
 DISADVANTAGES OF SIMPLE VERTICAL
BOILER

 Vertical design limits its working in many

places.
 Because of the limited grate area steam
production is limited.
 Impurities settle down at the bottom thus
prevent water from heating.
 Boiler tubes must be kept short to minimize
height.As a result, much of the available heat is
lost through the chimney, as it has too little
time to heat the tubes.
164
BOILER DRAUGHT

165
BOILER DRAUGHT is the pressure difference between the
atmosphere and the pressure inside the boiler

Main objects of producing draught in a boiler

are:
 To provide an adequate supply of air for the
fuel combustion.
 To exhaust the gases of combustion from the
combustion chamber.
 To discharge these gases to the atmosphere
through the chimney.
166
CLASSIFICATION

167
 CLASSIFICATION
• NATURAL DRAUGHT: It is the draught produced by
a chimney due to the difference of densities
between the hot gases inside the chimney and cold
atmospheric air outside it.
• ARTIFICIAL DRAUGHT: It may be a mechanical
draught or a steam jet draught .The draught
produced by a fan or blower is known as
mechanical or fan draught where as the draught
produced by a steam jet is called steam jet draught.

168
 TYPES
1. CHIMNEY DRAUGHT
• The draught produced by means of a chimney
alone
• It is a natural draught and has induced effect
inside the chimney
• Atmospheric air is heavier than the hot gases
• It varies with climatic conditions, temperature
of furnace gases and height of chimney.

169
170
2.STEAM JET DRAUGHT
• Simple and cheap method
• Exhaust steam, from a non condensing steam
engine is used for producing draught
• Mostly used in locomotive boilers
• INDUCED STEAM JET: steam nozzle placed in
the chimney
• FORCED STEAM JET: steam nozzle placed in
the furnace

171
172
 ADVANTAGES
• Simple and easy to maintain
• Low maintenance cost
• Occupies very little space or no space
• It does not require external power
DISADVANTAGES
• Draught is only possible after steam gets
produced

173
 2

ARTIFICIAL DRAUGHT
• If the draught is produced by steam jet or fan , it
is known as Artificial draught.
• Artificial draught is classified into two: Steam jet
draught and Mechanical draught.
• The draught produced by a fan or blower is
known as Mechanical or fan draught whereas
the draught produced by a steam jet is called
Steam jet draught.
• The artificial draught is provided when natural
draught is not sufficient. It may be induced or
forced.
 3

INDUCED FAN DRAUGHT

• Induced draught fan is located near or
at the base of the chimney.
• In an induced fan draught, a centrifugal
fan is placed in the path of the flue
gases before they enter the chimney.
• It draws the flue gases from surface
and forces them up through the
chimney.
 4
Induced fan draught Forced fan draught
 5

FORCED FAN DRAUGHT

• In the forced draught, a fan or blower is

installed near or at the base of the boiler.

• In the case of forced fan draught, the fan

is placed before the grate, and air is
forced into the grate through the closed
ash pit.
 6
BALANCED DRAUGHT
• It is a combination of the induced and
forced draught system.
• It is an improved type of draught produced
by running both induced and forced draught
fans simultaneously.
 7
Comparison between Forced & Induced
draught
Forced Draught Induced Draught
1. The fan is placed before the grate. 1. The fan is placed after the fire
2. The pressure inside the furnace is grate.
above the atmospheric pressure. 2. The pressure inside the furnace is
3. It forces fresh air into the below the atmospheric pressure.
combustion chamber. 3. It sucks hot gases from the
combustion chamber, and forces
4. It requires less power as the fan them into the chimney.
has to handle cold air only. 4. It requires more power as the fan
5. The flow air through grate and has to handle hot air and flue
furnace is more uniform. gases.
6. As the leakages are outward, 5. The flow of air through grate and
therefore there is a serious danger furnace is less uniform.
of blow out when the fire doors are 6. As the leakages are inward,
opened and the fan is working. therefore there is no danger of
blow out. But if the fire doors are
 8
Advantages of mechanical draught
• It is more economical
• It is better in control
• The flow of air through the grate and furnace
is uniform
• It’s rate of combustion is very high
• Low grade fuel can be used
• The air flow can be regulated according to the
changing requirements
• It is not affected by atmospheric temperature
• It reduces the amount of smoke
• It reduces the fuel consumption
 9
Disadvantages of mechanical draught

• It’s initial cost is high

• It’s running cost is also high
• It has increased maintenance cost
CALCULATION OF
HEIGHT OF THE
CHIMNEY
Shobitha Anna Jose
18-BDM-28
182
 PRINCIPLE
• Outside air is cooler than the air inside the
furnace. So the cooler air will move through
the furnace into the chimney. It will push hot
gases to pass through the chimney.
• Chimney draught varies with height of
chimney , temperature etc.

183
184
 TERMS USED
H = height of chimney above the fire gate(mm)
h = draught required in terms of mm of water
T1 = absolute temperature of air outside chimney in K
T2= absolute temperature of flue gas inside the chimney in
K
V1 = volume of outside air at T1 in m 3/kg of fuel
V2 = Volume of flue gases inside the chimney at T2in m3/kg
of fuel
m = mass of air used /kg of fuel
m+1 = mass of flue gases /kg of fuel
185
 CALCULATION
• Volume of air per kg of fuel at NTP,
P0V0=mRT0
Vo=mRT0 =0.773m m3/kg of fuel
Po
Volume of outside air at T1 K = V1 = V0T1
T0
= mT 1/353

186
• Density of outside air, ρ1 = m
mT1
353
Pressure due to similar column of outside air=
P1=Hρ1g
=3463H N/m2
T1

187
According to Avogadro’s law,flue gas at NTP
occupies same volume as that of air at NTP
so, volume of flue gas at 0 ˚C
=0.773 m m3/kg of fuel
Volume of flue gas at T2 K, V2= mT2
353
Density of flue gas at T2 K, ρ2 =353(m+1)kg/m3
mT2
Pressure due to column of hot gases at the base of
chimney ,P2=ρ2Hg =3463(m+1)H/mT2

188
P =P1-P2
= 3463H - 3463 (m+1)H N/m2
T1 mT2

h= 353H[ 1/T1 – m +1/mT2 ] mm of

water

189
LANCASHIRE BOILER

190
 INTRODUCTION
● Invented by Sir William Fairbairn(1844)
● Horizontal stationary fire tube boiler (flue gases flows through the
fire tube, situated inside the boiler shell)
● Internally fired boiler (furnace placed inside the boiler)
● Diameter of shell:2-3m
● Length of shell:7-9m
● Max.working pressure-16bar
● Steam capacity-9000kg/hr

191
 PARTS
● Grate-contain fuel for combustion
● Feed valve-used to enter fuel material inside the grate
● Fire hole-used to introduce the fire spark
● Safety valve-to release the pressure
● Bottom flue-flue present at the bottom of the shell and take hot
gases from the front to back of the boiler
● Side flue-flue present at both sides of the shell, take hot gases from
back to the main outlet

192
● Blow off clock-for removal of mud and sediments,placed at front
section
● Fusible plug-to prevent the coil tubes over heating, extinguishing the
fire when water level is low
● Manhole-used for cleaning inside the boiler
● Low water alarm-gives alarm when water level is below safety line

1
1
19
 PRINCIPLE
● Works on basic principle of heat exchanger
● Shell and tube type heat exchanger in which the gases flow through
the tubes and the water flows through the shell
● Heat is transfer from flue gases to the water through convection.

196
 WORKING
• Hard fuel is burned at the grate , water is pumped into the shell through the economizer. It increases the temperature of
the water. The fire tube of this boiler is fully immersed into the water. Hard fuel is fired at the grate. This is the first
heating process and it produces flue gases.
•Then generated flue gases pass through the fire tube. This flue gas can pass from one side to another side, inside the
boiler fire tube. Boiler fire tubes can transfer 80 to 90 percent of total heat to the water.
•After this process remaining flue gases pass from the side passage of the boiler. It can transfer another 6 to 8 percent of
heat to water.
• Brick wall creates heat transfer channel. Brick wall also works as a heat insulator.
• When water absorbs heat then it becomes steam. Steam stored at the top section of the shell.  Then an anti priming
pipe separates the generated steam from the water. Then a steam stop valve received generated steam.
•There is a blow-off valve is present at the bottom section of this boiler. By this valve, we can clean mud and also drain the
water.

197
 ADVANTAGES
● Easy to clean and inspect
● More reliable and can generate large amount of steam
● Less maintanance
● It is a natural circulation boiler, so low electricity consumption
● It can easily meet with load requirement
● High thermal efficiency-80-90%

198
 DISADVANTAGES

● Require more floor space

● It has leakage problems
● Requires more time to generate steam
● Cannot generate high pressure steam if required
● Grates are situated at the inlet of fire tube, which has small
diameter.so the grate area is limited in this boiler

199
BABCOCK & WILCOX BOILER

200
 What is Babcock & wilcox boiler
 Discovered by George herman babcock &
stephen wilcox.
  Babcock and Wilcox boiler is a natural
circulation, externally fired medium pressure,
stationary horizontal water tube boiler in
which water is flow in the inclined tubes. 

201
Main parts

202
 Construction
1. Drum : horizontal axis drum which contains water &
steam.
2. Down take header: receives water from the drum.
3. Up take header : it transports the steam from the
water tubes to the drum.
4. Water tubes: in which water flows and gets
converted to steam. It is inclined at an angle 10-15
degree with the horizontal. So water tubes do not
fully filled with water and the water & steam
separated out easily.
203
5. Super heater : it increases the temperature of
saturated steam to the required temperature
before discharging it from steam stop valve.
6. Grate : it is a base on which the burning of
the fuel takes place.
7. Baffle plates : allows the zigzag motion of hot
flue gases from the furnace.

204
Construction_&_Working_of_Babcock_&_Wilcox_Boiler_-_Magic_Marks.mp4

205
 Working
 Water starts to come in the water tubes from
drum through down take header.
The water present in the inclined water tubes gets
heated up by the hot flue gases produced from
the burning o coal in the grate.And it is forced to
move in zigzag way with the help of baffle plates.
The hot flue gases come in contact with water
tubes , it exchanges the heat with water and
converts into steam.

206
The steam generated is moved upward and through
uptake header it gets collected at upper side in the
boiler drum.
An anti-priming pipe is provided in the drum. It filters
the water content from the steam and allows only
dry steam to enter into super heater .
The super heater receives the water free steam from
the anti-priming pipe. It increases the temperature
of steam to desired level and transfers it to steam
stop valve.
207
The superheated steam from the steam stop
valve is either collected in a steam drum or
made to strike on the steam turbine for
electricity generation.

208
 Application
The Babcock & wilcox boiler are generally used
to produce high pressure steam in power
generation industries. The high pressure
steam so generated is used to produce
electricity.

209
 Advantages
o Steam generation capacity is high. It is about
2000-4000 kg/hr.
o It occupies less space.
o Replacement of defective tubes is easy.
o It is the only boiler that is used to generate
large quantity of heat in power stations.
o Inspection of this type of boiler can be done in
anytime during its working.
210
 Disadvantages
 High maintanance cost.
 It is not much suitable for impure and sedimentary water .
In case of impure and sedimentary water , scale may be
deposited on the tubes and this leads to overheating and
bursting of tubes . That’s why water treatment is must
before feeding into the boiler.
 Continuous supply of feed water is required for the
working. In the case if feed water is not continuously
supplied even for a short period of time , the boiler get
overheated. Water must be carefully watched during the
operation of the babcock & wilcox boiler.
211
STIRLING BOILER

212
 WHAT IS STIRLING BOILER?

o The stirling boiler is an early form of water-

tube boiler,used to generate steam in land
based stationary plants.
o This boiler was first designed in the year of
1888 by Alan Stirling so we refer the boiler as
Stirling Boiler. Because of the huge capacity
we can use this boiler in central power
stations.

213
 features
Externally fired
Natural circulation
Bent tube boiler
Water tube boiler
Working pressure:60 bar(max)
Steaming capacity:5000kg/hr

214
MAIN PARTS

215
 CONSTRUCTION
Steam drum is a collection vessel for steam & water. Here water &
steam is separated. It has steam separators. Steam goes from top
side to superheater & water goes from the bottom through down
comer Mud drum, then to furnace bottom ring headers (bottom
of furnace water wall).
• Mud drum: a cylindrical formed space at the base of the water
space .the impurites like mud , sediment, and other will be
gathered.
• Superheater: It increases the temperature of saturated steam to
the required temperature before discharging it from steam stop
valve.
•  

216
• Bent tube boiler:Since the tubes are bent, the
mechanical stresses due to expansion of
the pipes during heating can not effect the
system much.
• Safety Valve: It blows off the extra steam when
the steam pressure inside the boiler reaches
above safety level.
• chimney:the flue gases leave atmosphere
through chimney
217
• Grate :The area where flue is placed known as grate
• Furnace: It is the space above the gate and the boiler shell in
which the fuel is actually burnt the furnace is also called fire box.
• Baffle:Baffle plates are present in between water tubes and it
allows the zigzag motion of hot flue gases from the furnace.

• . Blow off Cock: It is used to blow off the settle down impurities,
mud and sediments present in the boiler water.
•  Stop valve: It is the largest valve on the steam boiler. It is used to
control the flow of steam from boiler to the main steam pipe.

218
 WORKING OF STIRLING BOILER
• It consist of three upper drums known as steam drums and a
lower drum known as mud or water drum.
• The steam drums are connected to mud drum by banks of bent
tubes .
• The steam and water space of the steam drums are
interconnected with each other to obtain water and steam
balance.
• Steam drum -1 are attached with saftey valves and drum -2 is
attached with pressure gauge and drum -3 is attached feed check
valve. Mud drum is attached with blow off valve
• Water is fed through the feed check valve to the steam drum -3
which then passes through the mud drum

219
In the mud drum foreign particles get settled down and are
removed through the blow off valve at regular intervals.pure
water goes to the steam -1 and steam drum -2
 steam drums are connecting with equalizing and circulating
tubes.the circulating tubes which equalizing the level of
water in steam drums and while the equalizing tubes
equalize the level of steam in the drums.The hot flue gases
are produced in fire
The hot flue gages are deflected by the brick arch to move
upward between the water tube and it have baffle which
ensure proper heating of the water tubes

220
Absorbing the heat the water flowing in the bends
water tubes converted into steam.this steam moves
upwards and collected steam drums
Saturated steam is extracted from drum and supplied
to the super heater and its converts saturated steam
into super heated steam which can be collected from
steam stop valve
Ash produce from the fuel is collected in the ash pit.
while smoke is allowed to escape into the
atmosphere through a chimney .
221
 Advantages
• Due to number of drum,it has high steam
production ie, 5000kg/hr
• It has high pressure operation with less
pressure drop
• Free expansion and contraction provided by
bent tubes thus prevents undue thermal stress
• Flexibility is design is also permitted.

222
 Disadvantages
• Stirling boiler is more difficult to clean and
inspect the bent tube.
• It is larger in size
• Temperature of super heater is limited

223
 1

BOILER DRAUGHT
 2

ARTIFICIAL DRAUGHT
• If the draught is produced by steam jet or fan , it
is known as Artificial draught.
• Artificial draught is classified into two: Steam jet
draught and Mechanical draught.
• The draught produced by a fan or blower is
known as Mechanical or fan draught whereas
the draught produced by a steam jet is called
Steam jet draught.
• The artificial draught is provided when natural
draught is not sufficient. It may be induced or
forced.
 3

INDUCED FAN DRAUGHT

• Induced draught fan is located near or
at the base of the chimney.
• In an induced fan draught, a centrifugal
fan is placed in the path of the flue
gases before they enter the chimney.
• It draws the flue gases from surface
and forces them up through the
chimney.
 4
Induced fan draught Forced fan draught
 5

FORCED FAN DRAUGHT

• In the forced draught, a fan or blower is

installed near or at the base of the boiler.

• In the case of forced fan draught, the fan

is placed before the grate, and air is
forced into the grate through the closed
ash pit.
 6
BALANCED DRAUGHT
• It is a combination of the induced and
forced draught system.
• It is an improved type of draught produced
by running both induced and forced draught
fans simultaneously.
 7
Comparison between Forced & Induced
draught
Forced Draught Induced Draught
1. The fan is placed before the grate. 1. The fan is placed after the fire
2. The pressure inside the furnace is grate.
above the atmospheric pressure. 2. The pressure inside the furnace is
3. It forces fresh air into the below the atmospheric pressure.
combustion chamber. 3. It sucks hot gases from the
combustion chamber, and forces
4. It requires less power as the fan them into the chimney.
has to handle cold air only. 4. It requires more power as the fan
5. The flow air through grate and has to handle hot air and flue
furnace is more uniform. gases.
6. As the leakages are outward, 5. The flow of air through grate and
therefore there is a serious danger furnace is less uniform.
of blow out when the fire doors are 6. As the leakages are inward,
opened and the fan is working. therefore there is no danger of
blow out. But if the fire doors are
 8
Advantages of mechanical draught
• It is more economical
• It is better in control
• The flow of air through the grate and furnace
is uniform
• It’s rate of combustion is very high
• Low grade fuel can be used
• The air flow can be regulated according to the
changing requirements
• It is not affected by atmospheric temperature
• It reduces the amount of smoke
• It reduces the fuel consumption
 9
Disadvantages of mechanical draught

• It’s initial cost is high

• It’s running cost is also high
• It has increased maintenance cost
BOILER DRAUGHT

233
BOILER DRAUGHT is the pressure difference between the
atmosphere and the pressure inside the boiler

Main objects of producing draught in a boiler

are:
 To provide an adequate supply of air for the
fuel combustion.
 To exhaust the gases of combustion from the
combustion chamber.
 To discharge these gases to the atmosphere
through the chimney.
234
CLASSIFICATION

235
 CLASSIFICATION
• NATURAL DRAUGHT: It is the draught produced by
a chimney due to the difference of densities
between the hot gases inside the chimney and cold
atmospheric air outside it.
• ARTIFICIAL DRAUGHT: It may be a mechanical
draught or a steam jet draught .The draught
produced by a fan or blower is known as
mechanical or fan draught where as the draught
produced by a steam jet is called steam jet draught.

236
 TYPES
1. CHIMNEY DRAUGHT
• The draught produced by means of a chimney
alone
• It is a natural draught and has induced effect
inside the chimney
• Atmospheric air is heavier than the hot gases
• It varies with climatic conditions, temperature
of furnace gases and height of chimney.

237
238
2.STEAM JET DRAUGHT
• Simple and cheap method
• Exhaust steam, from a non condensing steam
engine is used for producing draught
• Mostly used in locomotive boilers
• INDUCED STEAM JET: steam nozzle placed in
the chimney
• FORCED STEAM JET: steam nozzle placed in
the furnace

239
240
 ADVANTAGES
• Simple and easy to maintain
• Low maintenance cost
• Occupies very little space or no space
• It does not require external power
DISADVANTAGES
• Draught is only possible after steam gets
produced

241
CALCULATION OF
HEIGHT OF THE
CHIMNEY

242
 PRINCIPLE
• Outside air is cooler than the air inside the
furnace. So the cooler air will move through
the furnace into the chimney. It will push hot
gases to pass through the chimney.
• Chimney draught varies with height of
chimney , temperature etc.

243
244
 TERMS USED
H = height of chimney above the fire gate(mm)
h = draught required in terms of mm of water
T1 = absolute temperature of air outside chimney in K
T2= absolute temperature of flue gas inside the chimney in
K
V1 = volume of outside air at T1 in m 3/kg of fuel
V2 = Volume of flue gases inside the chimney at T2in m3/kg
of fuel
m = mass of air used /kg of fuel
m+1 = mass of flue gases /kg of fuel
245
 CALCULATION
• Volume of air per kg of fuel at NTP,
P0V0=mRT0
Vo=mRT0 =0.773m m3/kg of fuel
Po
Volume of outside air at T1 K = V1 = V0T1
T0
= mT 1/353

246
• Density of outside air, ρ1 = m
mT1
353
Pressure due to similar column of outside air=
P1=Hρ1g
=3463H N/m2
T1

247
According to Avogadro’s law,flue gas at NTP
occupies same volume as that of air at NTP
so, volume of flue gas at 0 ˚C
=0.773 m m3/kg of fuel
Volume of flue gas at T2 K, V2= mT2
353
Density of flue gas at T2 K, ρ2 =353(m+1)kg/m3
mT2
Pressure due to column of hot gases at the base of
chimney ,P2=ρ2Hg =3463(m+1)H/mT2

248
P =P1-P2
= 3463H - 3463 (m+1)H N/m2
T1 mT2

h= 353H[ 1/T1 – m +1/mT2 ] mm of

water

249
SIMPLE VERTICAL BOILER

250
 CONTENTS

 Introduction
 Construction
 Principle/working
 Application of simple vertical boiler
 ADVANTAGES
 DISADVANTAGES

251
 Introduction
 A vertical boiler is a type of fire-tube or water-tube boiler.

 The boiler barrel is oriented vertically.

 It is used for a variety of steam-powered vehicles and other mobile machines,

including early steam locomotives.
 It is used for low steam production.

 Usually simple vertical boiler produces an around 10 bar of pressure and have steam
generation capacity up to 1000 kg per hour.
 The steam produced in simple vertical boiler is used for low working conditions like
small power plants generating the current.
 Simple vertical boiler efficiency is nearly 50%.

 Boilers have steam generation capacity up to 1000 kg per hour and maximum steam
pressure up to 10 bar.
252
CONSTRUCTION

253
 CONSTRUCTION
 CYLINDRICAL SHELL

The shell is vertical and it attached to the bottom of the furnace. Greater portion of the shell is full of
water which surrounds the furnace also. The shell may be about 1.25m diameter and 2.0m height.
 CROSS-TUBE

One or more cross tubes are either riveted or flanged to the furnace to increase the heating surface
and to improve the water circulation.
 FURNANCE(OR FIRE BOX)

Combustion of coal takes place in the furnace(fire box)

 GRATE

It is the placed at the bottom of fire box and coal is fed on it for burning.
 FIRE DOOR

Coal is fed to the grate through the fire door.

254
o CHIMNEY ( OR STACK):
The chimney (stack ) passes from the top of the fire box through the top of the shell.
o MAN HOLE:
I. On the top of the shell to enable a man to enter into it
II. To inspect and repair the boiler from inside it.
III. Meant for cleaning the interior of the boiler shell and the exterior of the combustion
chamber and stack(chimney).
o HAND HOLES:
These are provided in the shell opposite to the end of each cross tube for cleaning.
o ASHPIT:
It is provided for collecting ash deposit, which can be removed away at the interval.
o FUSIBLE PLUG:
It is used to protect the boiler against damage when the water level is low during
over heating.

255
o PRESSURE GAUGE:
It indicates the pressure of the steam inside the boiler.
o WATER GAUGE:
This indicates the water level in the boiler.
o SAFETY VALVE:
It prevent an increase of steam pressure in the boiler above its design pressure.
o STEAM STOP VALVE:
It regulate the flow of steam supply to requirement
o FEED CHECK VALVE:
To supply high pressure water pass into the boiler.

256
 WORKING PRINCIPLES
 The fuel(coal) is fed into the grate through the fire hole and is burnt.

 The ash pit place below the grate collect the ashes of the burning fuel.
 Boiler drum is filled with water, the flue Gas from the furnace rise in the
tube .
 The exchange of heat takes place between water and flue gases.
 The combustion gas flows from the furnace, passes around the cross tube.

 The water temperature rises and it converts into steam and the flue gases
temperature drops
 Low temperature flue gases enters into the environment via chimney.

 The boiler is fitted with all the mounting as per IBR.

257
 APPLICATION OF SIMPLE VERTICAL BOILER
 Simple vertical boiler is used in railway locomotives i.e. Railway
steam engine.
 It is used in the road vehicles like steam wagon(steam lorry or steam
wagon).
 Simple vertical boiler have a very famous application in steam tractor.
 It is also used in boat especially smaller one to power the engine.
 In some parts of the world simple vertical boiler are used in steam
donkeys.
 Simple vertical boilers are also used in the steam cranes and steam
shovels.
 In dairy industry it is used in :
o heat treatment of dairy product
o Dairy processing
258
 ADVANTAGES OF SIMPLE VERTICAL BOILER

 Low initial cost because of lesser parts.

 Low maintenance cost.
 Simple working.
 Easy to install and replace .
 Occupy small space on ground.
 Simple vertical boiler have water level tolerance.

259
 DISADVANTAGES OF SIMPLE VERTICAL
BOILER

 Vertical design limits its working in many

places.
 Because of the limited grate area steam
production is limited.
 Impurities settle down at the bottom thus
prevent water from heating.
 Boiler tubes must be kept short to minimize
height.As a result, much of the available heat is
lost through the chimney, as it has too little
time to heat the tubes.
260
AIR COMPRESSORS AND
IT’S CLASSIFICATION

1
 AIR COMPRESSORS
 An air compressor is a mechanical device which
produces the compressed air i.e. which
increases the pressure of air above the
atmospheric pressure as per the requirement
and stores it in a high pressure vessel. 
 In air compressor, normal atmospheric air is
sucked in and is compressed continuously.
 It can be run or derived by an electric motor, IC
engine or steam engine etc.
2
TYPES OF AIR COMPRESSORS

Based on working
a) Reciprocating air compressor
b) Rotary air compressor
According to action
a) Single acting air compressors
b) Double acting air compressors
According to number of stages
a) Single stage air compressors
b) Multi stage air compressors
3
 RECIPROCATING AIR
COMPRESSORS ROTARY AIR COMPRESSORS

•Pressure of air is increased •Pressure of air is increased by

with the help of a moving piston squeezing action of air

• Maximum delivery pressure= • Maximum delivery pressure is

1000 bar 10 bar
•Maximum free air discharge is •Maximum free air discharge
300 m3 /min 3000 m3 /min
•Low discharge at high pressure •High discharge at low pressure
•Low speed •High speed
•Intermittent air flow •Continuous air flow

•Air is less clean since it comes •Air is more clean since it does
in contact with lubricating oil not comes in contact with
lubricating oil

4
TYPES OF ROTARY COMPRESSORS
1. Roots blower compressor: Consists of two
rotors with lobes rotating in an air tight casing
which has an inlet and outlet ports.
2. Vane blower compressors: Consists of a disc
rotating eccentrically in an air tight casing
with inlet and outlet ports.
3. Centrifugal blower compressors: Consists of
a rotor or impeller to which a number of
curved vanes are fitted symmetrically.
4. Axial flow compressors: It consists of a
number of rotating blade rows fixed to a
rotating drum.
5
 VANE BLOWER AIR COMPRESSOR

ROOT BLOWER AIR COMPRESSOR

266
 AXIAL AIR COMPRESSOR

CENTRIFUGAL AIR COMPRESSOR

267
 SINGLE STAGE AIR MULTI STAGE AIR
COMPRESSOR COMPRESSORS
•It is a type of reciprocating •It is a type of reciprocating
air compressor. air compressor.
•It contains a cylinder, •Two or more cylinders are
pistons, inlet valve and provided in series with an
outlet valve. inter cooling system.

8
 DOUBLE STAGE AIR COMPRESSOR

SINGLE STAGE AIR COMPRESSOR

269
SINGLE ACTING AIR DOUBLE ACTING AIR
COMPRESSOR COMPRESSOR
•It consists of a single cylinder •It also contains only a single
which only takes in and cylinder which takes in and
discharge air at one end. discharge air at both ends

10
 APPLICATIONS
 It is used in operating pneumatic drills,
riveters, paint spraying.
 Also used in starting and super charging of
Internal Combustion engines.
 Used in operation of lifts, air motors, jet
engines and so on.
 In industries it is used for producing blast of
air in blast furnace and bessemer converters.

11
MULTI-STAGE AIR COMPRESSION

272
DEFINITION..

Two or more cylinders are provided in series

with intercooling arrangement between them.
• INTERCOOLING.
It is used to reduce the temperature of
compressed air during the compression
stages.

273
 ADVANTAGES OF MULTISTAGE
COMPRESSION.
• The work done per kg of air is reduced in multistage
compression with intercooler as compared to single
stage compression for the same delivery pressure.

• It improves the volumetric efficiency for the given

pressure ratio.

• The sizes of two cylinders may be adjusted to suit the

volume & pressure of the air.

274
• It reduces the leakage loss considerably.

• It provides effective lubrication because of

lower temperature range .

• It reduces the cost of compressor.

275
 A schematic arrangement for a two stage
reciprocating air compressor with water cooled
intercooler;

276
277
 WORKING....
• The fresh air is sucked from the atmosphere in
the low pressure cylinder during its suction
stroke at intake pressure P1 & temperature T1.
• The air after compression in the L.P cylinder is
delivered to the intercooler at pressure P2 &
temperature T2 .
• Now the air is cooled in the intercooler at
constant pressure P2 and from temperature T2
to T3.
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• After that air is sucked in the high pressure
cylinder during its suction stroke.

• Finally , the air , after further compression in

the H.P cylinder is delivered by the
compressor at pressure P3 and temperature T4.

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Assumptions in Two-stage compression with
intercooler
• The effect of clearance is neglected.
• There is no pressure drop in the intercooler.
• The compression in both the cylinders is
Polytropic.
• The suction and delivery of air takes place at
constant pressure.

280
 TYPES OF INTERCOOLING.
1. Complete or Perfect intercooling
When the temperature of the air leaving the
intercooler(T3) is equal to the original
atmospheric air temperature (T1),then the
intercooling is known as complete or perfect
intercooling.

281
2.Incomplete or imperfect intercooling

When the temperature of the air leaving the

intercooler (T3) is more than the original
atmospheric air temperature(T1),then the
intercooling is known as incomplete or
imperfect intercooling.

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WORK DONE BY A TWO STAGE RECIPROCATING
AIR COMPRESSOR WITH INTERCOOLER

• When the intercooling is incomplete..

283
284
• When the intercooling is complete..

285
 POWER

• P = W*NW
60
NW=number of working Strokes per minute.
Unit is in watts.

286