1.

Objectives
1.1. General objectives
1.2. Specific objective
2. Theoretical foundation

BOILERS

A boiler is a machine or engineering device that is designed to

generate saturated steam. This steam is generated through a heat transfer to
constant pressure, in which the fluid, originally in a liquid state, is heated and
change of state.

According to ITC-MIE-AP01, a boiler is any pressure apparatus in which heat

from any energy source is transformed into usable energy, through
of a means of transportation in liquid or vapor phase.

Boilers are a particular case in which temperatures are raised to high levels.
heat exchangers, in which a phase change occurs. They are also
pressure vessels, which are partly constructed with rolled steel
similarity of many gas containers.

Due to the wide applications of steam, primarily water steam,

boilers are widely used in the industry to generate it for applications such as:

• Sterilization (tindalization) is common to find boilers in hospitals, the

which generate steam to sterilize medical instruments, also in the
Industrial capacity dining halls generate steam to sterilize the cutlery.
like for the preparation of food in kettles.

• Heating other fluids, for example, in the oil industry, oils are heated.
Heavy ones to improve their fluency and steam is widely used.

Generate electricity through a Rankine cycle. The boilers are part

fundamentals of thermal power plants.

It is common to confuse a boiler with a steam generator, but their difference is that
the second generates superheated steam

MAIN TYPES OF BOILERS

Although there are numerous designs and patents for boiler manufacturing, each one
which may have their own characteristics, boilers can be classified into
two major groups; fire-tube boilers and water-tube boilers, some of which
The characteristics are indicated below.

Fire-tube boilers

They are called fire tubes because the hot gases come from combustion.
of a fuel, those that circulate inside tubes whose exterior is coated
through the boiler water. The fuel burns in a furnace, where it takes place
the heat transfer by radiation, and the resulting gases, are made to circulate to
through the tubes that make up the tubular bundle of the boiler, where the
heat exchange by conduction and convection. Depending on whether it is one or several times
that the gases pass through the tubular beam, there are boilers of one or more
steps. In the case of multi-pass boilers, in each of them, the gases only
they pass through a certain number of tubes, which is achieved through the
called smoke chambers. Once the heat exchange is completed, the smoke
they are expelled to the outside through the chimney.

WATER-TUBE BOILERS.

In these boilers, contrary to what happens in the fire-tube ones, it is the water that
it circulates through the interior of tubes that make up a closed circuit through the boiler
the tubes that make up the heat exchange surface of the boiler.
Additionally, they may be equipped with other heat exchange elements,
such as the superheater, reheater, economizer, etc.

These boilers consist of a chamber configured by water tubes, pipes and

refractory, or simply refractory, in which the combustion of
combustible and constituting the radiation zone of the boiler. From that hearth, the
hot gases resulting from combustion are conducted through the circuit of the
boiler, configured with tube panels and constituting the convection zone
from the boiler. Finally, the gases are released into the atmosphere through the
chimney. In order to obtain a higher efficiency in the boiler, they are often
provide elements, such as those already mentioned, economizers and preheaters, that
they make the temperature of the gases at their exit from the boiler lower,
thus making better use of the sensible heat of said gases

INSTANTANEOUS STEAM BOILERS

There is a variety of the above boilers, called vaporization boilers.

snapshot, whose schematic representation could be that of a tube heated by
a llama, where water enters from one end and exits in the form of steam from the other.
Since the possible volume of water is relatively small in relation to the
amount of heat injected, in a short time the boiler is ready to
to generate steam under the required conditions, hence the designation of boilers of
instant vaporization.

It is noted that in these boilers the flow of injected water is practically

equal to the steam flow produced, so a mismatch between the heat supplied and the
water flow would result in obtaining hot water or superheated steam, depending on
there was a lack of heat or it was higher than required.

ELEMENTS, TERMS AND COMPONENTS OF A BOILER

• Make-up water: It is the incoming water that feeds the system, generally
well water or network water with some chemical treatment such as demineralization.
• Condensate water: It is the water that comes from the condenser tank and that
represents the quality of the steam.

• Wet steam or saturated: Steam in optimal conditions.

• Wet or saturated steam: Steam with foam carryover from water

of high alkalinity.

Condenser: System that allows the vapor to condense.

Accumulation tank: It is the tank for the accumulation and distribution of steam.

Desaireador: it is the system that expels gases into the atmosphere.

Bottom purge: Evacuation of sludge and concentrate from the bottom of the boiler.

Surface purging: Evacuation of dissolved solids from the water level of the
caldera.

Furnace or home: Combustion heart of the system.

Combustible: Material that produces thermal energy when burned.

Boiler water: Internal circuit water of the boiler whose characteristics

they depend on the cycles and the incoming water.

Concentration cycles: Number of times the boiler water is concentrated

regarding the feed water.

Alkalinity: Level of salinity expressed in ppm of CaCO3 that confers a

concentration of carbonate and hydroxide ions that determines the pH value of
operation of a boiler, generally between 10.5 and 11.5.

Deoxygenation: Chemical treatment that removes oxygen from boiler water.

Incrustation: Sedimentation of solids with the formation of crystalline cores or

amorphous sulfates, carbonates or silicates of magnesium that reduce efficiency of
operation of the boiler.

Dispersant: Chemical system that keeps solids uncohesioned before a

embedding event.

• Anti-fouling: Chemical system that prevents the adherence of fouling solids.

in solution.

• Anticorrosive: Chemical system that provides protection through the formation of films.
protective against corrosive ions present in water

Operation of Industrial Boilers

Boilers are containers that operate under pressure through the

Constant heat transfer, in which liquids heat up and
Change of state. There are two types of boilers, the fire-tube boilers are the
that the liquid is in a container and is passed through tubes
through which high-temperature gases circulate as a result of a
combustion process the other type of boiler is called water-tube
they are those in which the workflow flows through
tubes during their heating

Boilers have a wide application in the industry as many depend on them.

products like hospitals that use them to sterilize medical instruments, also
in the oil companies to heat heavy oils to improve their flowability.

The water used in hot water and steam boilers (to produce it) needs
usually from a prior decalcification treatment, etc. to preserve the life of the
caldera in which, in addition to, at times, continuous purges of sludge and foams that
the process generates, which results in energy losses. On the other hand, it tends to be at
availability of users with ease and in abundance.

Every boiler will be equipped with one or more drain pipes, connected to the lowest point.
below the boiler and intended for the purges and systematic extractions of sludge.

The discharge of the purge tubes will be arranged in such a way that it does not pose a danger of
accidents for the staff and it can only be discharged into the sewer through a pond
intermediate retention or purging.

This retention pond must meet the following conditions: a) It will be easily accessible
for inspection and the extraction of sludge. b) The inspection covers or doors will have a
adjustments to prevent steam leaks. c) The tank will be equipped with a ventilation tube
metallic, with an exit to the outside of the room. d) The diameter of the exhaust pipe to the atmosphere
It must be larger than the diameter of the purge tube. e) It will have a valve at the lowest point.
that allows to drain all the purged water from the boiler when necessary

Another issue regarding industrial boilers is that they need good fuel,
they are characterized by a high calorific power, a specific degree of humidity and a
percentage of volatile materials and ashes. It is necessary to analyze the fuels that we are going to
Using in each device, chemical analysis is what allows us to distinguish the elements.
that are part of the fuel; there must be a correct accuracy between the 'air-fuel' mixture.
"combustible" otherwise not only can the industrial boiler be damaged but also may
serious accidents may occur. It is necessary to take all the necessary precautions before
manipulate these artifacts as their sources of energy.

HEAT LOSSES
The boiler system can have losses due to radiation, convection, and purging.
Radiation losses consist of the heat that escapes through the surface of the
walls. When heat is dissipated through fluids at different temperatures, it is called
convection. The losses due to purging consist of the heat that escapes when eliminating
the solids or impurities dissolved in the water, which have accumulated inside the boiler.

BOILER VAPORIZATION FACTOR

This factor corresponds to the amount of heat that must be absorbed by a kilogram of
liquid water heated to 100°C to become one kilogram of water vapor at
100°C
Vaporization Factor = Vapor enthalpy at 100° C - Liquid water enthalpy at 100° C
 URL_13_QUI03.pdf July, 2009. Pages 22a
34
Faculty of Engineering - Rafael Landívar University Magazine
Electronics No. 13
COMBUSTION EFFICIENCY
It is a measure of the effectiveness of the heat obtained from the combustion of the
fuel is converted into usable heat for the boiler. This efficiency can be
determine from the temperature of the combustion gas chimney, as well as from
the concentration of oxygen or carbon dioxide in them,
relying on pre-calculated graphs of efficiency versus temperature and composition of
oxygen in the combustion gases. See Annex No. 1.
BOILER EFFICIENCY
It corresponds to the percentage or ratio of the amount of steam produced in a boiler from
of the amount of heat supplied by the burned fuel. The efficiency of a
Caldera, it is the relationship between the energy absorbed for evaporation or steam generation.
(Q output) and the sum of energy introduced to the process (Q input).
Q output / Q input = Efficiency
The difference between the two is the energy lost in the process (heat expelled to the
atmosphere)
Input - Output = Loss
A boiler, in generic terms, is a heat exchanger since on one side it
adds fire and combustion gases and on the other side water that heats up and evaporates. The
boiler efficiency is the efficiency of the heat exchange process.
JUSTIFICATION

Steam boilers provide great advantages for many applications in various sectors.

industrial.

Here are some examples of these applications:

Food industry: industrial bakeries

butcher shops, rendering processes, food manufacturing
processed and baby food, drinks and products
dairy
Textile industry: rotary dryers, dyeing, balancing and
tissue.
Chemical industry: reactors and storage.
Pharmaceuticals: manufacturing of medications and
components, vaccines, sterile steam.
Cosmetics: perfumes, creams.
Paper/printing industry: drying tunnels,
printing drying, corrugated cardboard.
Cement industry: manufacturing of cement pieces.
Oil industry: distribution and storage of oils
heavy.
Timber industry: melanin and wood processes
laminated
Hospitals / Hotels: laundry, kitchen.
Automotive industry and surface treatment:
metal finishing, electro deposits.
Calculations

1.1. Data Sheet

Initial Mass of the Bottle = 68.61 kg

Final weight of the bottle = 66.85 kg
Initial Height of the Tank = 84.5 cm
Final Height of the Tank = 82 cm
Tank Diameter = 87 cm
1 hour and 36 minutes
Initial Water Temperature of the Tank = 12.3 °C
Final average temperature = 85 °C

1.2. Non-stationary phase

We find the mass of combusted LPG:

− =

( , − , ) = ,

We find the Volume of Water inside the Tank:

=× ×

=∗ ( , − )∗ ( )

= ,

= ,

Transforming that Volume into Mass:

= ∗

= , ∗ . = ,

Obtaining the Total Heat Gained by Water during the Heating Process:

= ∗ ∗( − )

= , ∗ . ∗( ° − ,)° = ,
∗°

1.3. Stationary phase

We found the mass of burned LPG:

− =

= , − , = ,

We calculate the Heat Transfer Rate:

= ∗ ∗( − )+ ∗

=[ , ∗ . ∗( , − ) ° ] [+ , ∗ (− .] )
∗°

=− .

We calculate the Heat Gain Rate:

 = 1+ 2

= 44.31+ 40.28

84.5 L

= ∗

= 84.5 L * 0.97

= 81,965 Kg

= ∗ ∗( − )

= , ∗ . ∗( − ,) °
∗°

= ,

Time ΔH [L] M=ρ*V Table bottle Used mass

[min] water[cm] [cm] [Kg] GLP [Kg]
0 84.5 69.39
26.46 83.5 7.8 44.31 42.981 68.61 0.78
81.86 82 7.1 40.28 39.072 66.85 1.76

1.4. Efficiency of the exchanger

= × %

.
= × %
.

= . %

1.5. Boiler efficiency

Total Calorific Power of the LPG Cylinder

 =∑ ∗
=

= .

Efficiency of the Non-Stationary Process:

= × %
∗

,
= × %
, ∗ .

= . %

Efficiency of the Stationary Process:

= × %
∗

.
= × %
. ∗ .

= . %

Total Efficiency:

= × %
∗
 , + .
= × %
. ∗ .

= . %

RESEARCH
BOILERS