CH3010 POWER PLANTENGINEERING
FORCED OR POSITIVE CIRCULATION BOILER
Forced (i.e., positive) Circulation boiler: In this, the water is the circulated
by mechanical means (pumps). The forced circulation helps in to increase the
water circulation along with uniform heat distribution throughout the boiler water
thus results in rapid steam generation at high pressure. The boilers of high capacity
such as Lamont, Velox, power boilers, etc. fall under this group.
Velox boilers:
The Velox boiler, characterised by its high-pressure water tube design, can also
function as a fire tube boiler when heat is supplied through the tube with water
surrounding it.
Working Principle of Velox Boiler
o First, the economizer is fed using a feed pump, where the water is heated but
not to its boiling point.
o The heated water is then transferred from the economizer to the water
circulating pump.
o Next, the water enters the tube evaporation section located within the
combustion chamber.
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
o Simultaneously, gas turbines drive an axial air compressor, converting gas
into mechanical energy.
o The compressed air from the air compressor enters the combustion chamber,
where additional heat is released by the fuel, increasing the flue gas velocity
to the speed of sound.
o Flue gas is the gas released from the atmosphere through a flue by a steam
generator or furnace.
o The flue gases pass through the fire tubes near the bottom of the combustion
gases, which are surrounded by evaporated water tubes.
o As high-speed water enters the evaporation tube, heat is rapidly transferred
due to the swift movement of both water and gas.
o This results in the formation of a mixture of water and steam, which is
separated by water and steam separators.
o The steam from the separator is then directed to the superheater and
subsequently utilised in the industrial process.
o The remaining water re-enters the evaporator tube, continuing the cycle until
it transforms into steam.
o The flue gases released from the fire tubes are sent to the superheater to heat
the steam further.
o Subsequently, the flue gas is routed to the gas turbine, driving its rotation.
o Finally, the gas passes through the economizer, initially responsible for
heating the water supplied by the feed pump.
Advantages of Velox Boilers
The advantages of the Velox boiler are:
o High thermal efficiency.
o Compact design.
o Quick start-up.
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
o Efficient heat transfer.
o Reduced fuel consumption.
o Minimal maintenance.
o Suitable for variable loads.
o Environmental friendliness.
Disadvantages of Velox Boilers
The various limitations are:
o High construction and maintenance costs.
o Limited efficiency at partial loads.
o Dependence on airflow and weather conditions.
o Large physical footprint.
o Environmental concerns related to water consumption and plume formation.
THERMAL FLUID HEATERS AND VAPORISERS
Introduction:
Thermal fluid heaters, also known as thermal oil heaters or hot oil heaters, are
systems designed to indirectly heat a fluid (usually a heat transfer oil) to transfer
heat to a process or equipment. Unlike steam boilers, thermal fluid heaters use a
closed-loop system, where the heat transfer medium does not undergo phase
changes during the heating process. This makes them suitable for a wide range of
applications.
The basic working principle involves heating a thermal fluid (often a synthetic oil
or glycol-water mixture) in a closed-loop system. The fluid is heated in a dedicated
heater unit using a fuel source, such as natural gas, diesel, or electricity. The heated
fluid then circulates through a network of pipes to transfer heat to the target
process or equipment. The closed-loop system ensures efficient heat transfer
without the need for pressurized vessels.
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
Components
The components of a Thermic Fluid Heater includes,
Heater Coils
Furnace
Expansion cum Deaerator
Circulating Oil Pump for High Temperature
Heat Recovery Units
Primary and Secondary Fans
Chimney
Pollution Control Equipment
Control Panel for Monitoring
Working Principle of Thermic Fluid Heater:
Thermic Fluid Heaters function in either the liquid phase or vapor phase. In
the liquid phase, thermic fluid heaters use a flooded pressure vessel to heat the heat
transfer fluid without vaporization taking place in the vessel. It is similar to hot
water boilers with a closed-loop system that is, either open or closed to the
atmosphere. On the other hand, the vapor phase uses a heater for vaporizing the
fluid internally within the vessel. It also uses a flooded heater for vaporizing the
fluid externally through a flash drum. The vapor phase with condensing steam
provides heat uniformly compared to the liquid phase.
The combustion air enters the burner fan inlet and travels upside between the
inner and outer jacket, preheating the air before its ingress in the top-mounted
burner. Hot gases pass across the length of the vessel in the first radiant pass. The
gases then pass through the inner row of coils in the second convection pass. The
third convection takes place as the gases continue back between the inner coil and
outer coil. The final pass occurs upwards between the outer coil and inner jacket to
the outlet of flue that leads to the fourth convection pass.
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
Usually, the heater design is similar to the fire-tube boiler or water-tube boiler that
is direct-fired by the fuel combustion. Depending on the operation requirements
and fluid used, heaters may operate at up to 750 ⁰F temperature. Generally, large-
sized heaters are field erected.
Types of thermal oils:
Thermal oils, also known as heat transfer fluids or hot oils, are specifically
formulated fluids used in thermal fluid heaters to transfer heat from the heater to
the process equipment. The selection of thermal oil depends on factors such as the
operating temperature range, thermal stability, environmental considerations, and
the specific requirements of the industrial process. Here are some common types of
thermal oils:
Mineral Oils:
Mineral oils are derived from petroleum and are the most basic type of
thermal oil. They are cost-effective and suitable for moderate-temperature
applications. However, they have limitations in terms of high-temperature stability.
Synthetic Oils:
Synthetic thermal oils are engineered fluids with superior thermal stability
and a broader temperature range compared to mineral oils. They are often used in
applications where high temperatures and extended service life are critical.
Silicone Oils:
Silicone-based thermal oils, such as polydimethylsiloxane (PDMS), offer
excellent thermal stability over a wide temperature range. They are resistant to
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
oxidation and can withstand high temperatures, making them suitable for
demanding applications.
Aromatic Oils:
Aromatic thermal oils are derived from aromatic hydrocarbons. They have
good thermal stability and are often chosen for applications with high-temperature
requirements. However, they may have higher viscosity compared to other types.
Hydrogenated Terphenyls (Hydrogenated Oils):
Hydrogenated terphenyls are synthesized by hydrogenating terphenyls.
These thermal oils offer improved thermal stability and oxidation resistance,
making them suitable for high-temperature processes.
Advantages:
1. Precise Temperature Control: Thermal fluid heaters offer precise
temperature control, crucial for processes with specific temperature
requirements.
2. High Efficiency: They provide high thermal efficiency due to the absence of
energy losses associated with condensation and blowdown, as seen in steam
systems.
3. Flexibility: Thermal fluid systems can operate at high temperatures and low
pressures, accommodating a variety of industrial processes.
4. Closed-Loop System: The closed-loop design minimizes the risk of
corrosion and scaling, enhancing system longevity.
5. Ease of Maintenance: These systems generally have lower maintenance
requirements compared to steam boilers.
Disadvantages:
1. Initial Cost: Thermal fluid heaters may have higher initial costs compared to
traditional steam boilers.
2. Heat Transfer Medium Selection: The choice of the heat transfer medium is
critical, and compatibility with the process is crucial. Incompatibility can
lead to degradation and reduced efficiency.
SHANMUGA PRIYA/AP,CHEMICAL
CH3010 POWER PLANTENGINEERING
3. Limited Pressure: Thermal fluid systems operate at lower pressures than
steam systems, limiting their use in certain applications.
Applications:
1. Chemical Industry: Used for heating reactors, distillation columns, and other
chemical processes.
2. Food Processing: Employed in applications like cooking, frying, and drying
in food processing plants.
3. Textile Industry: Utilized for heating dyeing machines, drying ovens, and
other textile processes.
4. Oil and Gas Industry: Applied in various processes such as heating and
conditioning in the extraction and refining of oil and gas.
5. Plastics Industry: Used in processes like extrusion, molding, and curing.
Benefits of Thermic Fluid Heaters over Steam Boilers:
No Corrosion or Water Carryover Issues
Blowdown, Steam Traps, Condensate Return Systems, Feedwater Treatment
Not Required
Low Maintenance without Any Retrofitting Requirements
High Operating Temperature with Minimal System Pressure
Single Fluid Required for Heating and Cooling Purposes
SHANMUGA PRIYA/AP,CHEMICAL
