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STEAM BOILER
High potential of the Group of Companies JSC Machine-Building Plant ZiO-Podolsk and JSC Engineering Company ZIOMAR enables them today to carry out a wide range of activities in the field of power machine-building.
The leader of Russian industry – Machine-Building Plant ZiO-Podolsk (ZiO) – traces its history back to the year 1919.
ZiO-PODOLSK is an industrial-engineering base for manufacturing of high-technology, competitive heat exchange equipment. Modern methods of production management and organization, as well as well-qualified personnel provide high quality and reliability of the manufactured equipment.
EC ZIOMAR employees perform complex research and development activities, equipment adjusting and examination of installations in operation for the purpose of their reconstruction and modernization.
Our customers are the largest generating and heat-and-power companies.
We will be glad if our acquaintance grows into a constructive and fruitful cooperation!
SPECIALIZATION
Main products for thermal power plants are boilers for power units with the capacity of 50-800 MW firing diverse fuels, designed on the basis of advanced engineering solutions. More than 700 boiler units with various capacity and parameters have been produced for 152 domestic and foreign power plants with the total capacity of more than 66 GW, including over 16 GW for export. The Enterprise has more than 70 years of experience in design and fabrication of boilers and other thermotechnical equipment for thermal power industry. Boilers produced under ZiO trademark are operated at power plants in 20 countries such as Russia, Poland, Romania, Kazakhstan, Ukraine, Bulgaria, Vietnam, Yugoslavia, Croatia, Macedonia, Greece, China and others. By agreement with the General Supplier or directly with the Customer the complete delivery of the boiler island, additionally to the boiler proper, can include the following:
• sootblowing equipment; • fuel supplying, coal grinding and
coal-pulverizing equipment; • draft equipment and turbo air
blowers; • air preheaters with piping and valves; • ash-cleaning equipment including
electrostatic precipitators; • steel structures of boiler island and
stack; • pulverized coal, gas and air lines
complete with valves and expansion joints;
• power plant pipelines; • single-turn actuators and their
connections; • other power equipment.
Boilers are supplied in modular units to facilitate and speed up their erection. Export boilers are fabricated in compliance with individual Customers’ technical assignments. The production is based on the high level of process procedure automation and mechanization.
At the present time a considerable part of power generating systems do not comply with up-to-date environmental, safety, efficiency and cyclic load capability requirements. The most practical way out is to modernize main power plant equipment. In such a case the required effect can be achieved with reduced material expenses, which is very important under modern economic conditions.
“ZiO-Podolsk” and EC “ZIOMAR” group of companies is paying greater attention to these issues, and it can propose a complex of original engineering solutions aimed at the modernization of the boiler equipment that was supplied earlier to power engineers of Russia and CIS countries.
The enterprise has developed and implemented engineering solutions aimed the extension of service life, producing of extra power with minimum expenses, improving of environmental performances and energy saving.
We propose a complex of original engineering solutions aimed at solving of the below mentioned problems and required for the modernization of the boiler equipment that was supplied earlier:
• extension of the unit load control range (extension of the stable operation threshold);
• boiler switchover to non-standard types of fuel;
• organization of nonslagging operation due to low temperature and stage-by-stage fuel combustion;
• improvement of fuel ignition stability and extension of the operating range without lighting;
• improvement of technical and economic indexes due to implementing of up-to-date engineering and design solutions;
• improvement of environmental performances and their brining to standard values.
The armory of the Special Design Bureau of Boiler Manufacture of EC “ZIOMAR” includes a range of engineering and process design solutions aimed at the burning process optimization and NOx level reduction to standard values without using special catalytic reactors:
• burning process organization with the supply of high-concentration pulverized coal;
4
SPECIALIZATION
• new designs of low emission burner units;
• stage-by-stage fuel combustion from the furance top to bottom and in a horizontal plane of each burner row;
• 3-stage fuel combustion with the use of reburning system;
• use of downdraft nozzles; • use of telescopic pulverized coal
dividers and special pulverized coal concentrators;
• high air heating • application of low temperature
tornado technology;• NOx selective noncatalytic reduction. Boiler thermal and hydraulic circuits
that allow sliding pressure operation are improved in order to ensure maximum boiler efficiency. The introduction of units with increased efficiency in compliance with the original engineering solutions of the plant is also a promising direction.
The company prepared technical proposals for ultra supercritical steam parameter coal-fired boilers for 660 MW units as well as proposals for the modernization of coal-fired boilers of operating power units with the capacity of 300 MW.
In order to satisfy the needs of industrial power production and public utilities the company constructed advanced tower type gas-and-oil-fired hot water boilers with the
thermal output of 70 and 120 Gcal/h that provide an opportunity for their installation in the compartments of ПТВМ hot water boilers that are out of date from moral and physical standpoint.
ZiO fabricates a wide range of equipment
for thermal power units: • low pressure and high pressure
heaters; • tight valves of pulverized coal, gas
and air lines (round, rectangular); • articulated and flexible non-metallic
expansion joints; • centrifugal and telescopic pulverized
coal dividers and concentrators; • steam and water heaters made of
spiral-finned tubes; • heating surfaces (plain-tube,
membrane, finned); • unified modules of tubular air
heaters; • other boiler equipment.
Great attention is paid to the upgrading of produced boilers by means of introducing new engineering solutions based on trade secrets of various areas of new equipment development, including the following:
• improvement of thermal and hydraulic circuits;
• optimized organization of burning and combustion process and control
of this process with due regard to the reduction of NOx emissions;
• prevention of abrasion and corrosion of heating surfaces;
• wider application of designs made of unified assemblies and components;
• introduction of heating surfaces made of longitudinal-finned and spiral-finned tubes;
• application of methods of exhaust gas deep cooling;
• use of tubular air heaters with the original staged air heating scheme.
Using the boiler equipment engineering experience the specialists of EC “ZIOMAR” developed and implemented the projects of coal-fired boiler modernization with the improvement of their technical and economic indexes and environmental performances at the below listed thermal power plants:
• Tom-Usinskiy GRES, 210 MW power unit;
• Lugansk TPP, 200 MW power unit; • Belovo GRES, 210 MW power unit; • Nazarovo GRES, 500 MW power
unit.
The main goal of ZiO-Podolsk and EC “ZIOMAR” boiler manufacturers is the creation of the advanced and competitive heat power equipment.
5
STEAM BOILER Пп-1050-255-545КГЖ
П-50Р
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 1050Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,9 (39,6)
Steam temperature, °C:primaryreheated
545545
Design fuel: Kuznetsky lean coal, natural gasHeat value:coal, Kcal/kggas, Kcal/nm³
58208623
Fuel flow rate, total:coal, t/h and gas, nm´³/hgas, nm³/h
123,781
Efficiency, %:when firing 85% of coal (as to heat) and 15% of gas (as to heat)when firing gas
89,393,5
Weight of metal, t:pressure partstotal of the boiler
21674211
Specific metal content, t/t/h:pressure partstotal of the boiler
2,064,01
6
This boiler is designed to run with turbine K-330-240, the design fuel is Kuznetsky lean coal and natural gas.
The boiler is double-furnace, supercritical, balanced-draft one with reheat and slag-tap removal. The both bodies are symmetric and have the same design.
The boiler is arch-type and arranged indoors. The heating surfaces are suspended to the boiler structures or supported by them.
The furnace chamber of each body has rectangular cross-section and is enclosed by vertical panels of intermediate and bottom radiation sections. The furnace chamber bottom is made tilted and equipped with two taps for liquid slag removal. The furnace chamber top is equipped with partition walls and the tubes of rear furnace water-wall of the middle radiation section form an aerodynamic nose. The surface of lower radiation section water-walls up to elevation of +15 725 is studded and covered with refractory.
Pulverized coal-storage system with installation of three ball-tube mills. The pulverized coal is fed to the furnace by means of concentrated coal flow pneumatic conveying system.
The furnace of each body is equipped with 6 main burners, 6 discharge nozzles, 12 gas injectors and 12 tertiary air nozzles.
To achieve the required minimum NOX emission when using coal, 85 % of pulverized coal (as to heat) with excess-air coefficient not less than 1 is burned in active combustion zone at the level of main burners. 15 % (as to heat) of natural gas is burned in reburning zone of gas injectors. The natural gas is combusted in recirculation gas medium. The tertiary air is supplied to
the furnace through tertiary air nozzles (in pulverized coal its part is 22 % from air supplied to the furnace).
Horizontal gas duct walls are made of upper radiation section panels that pass (without intermediate chambers) into ceiling wall surface over the furnace chamber and horizontal gas duct. The horizontal gas duct encloses two stages of a platen superheater I and II, installed subsequently in the direction of gas flow. Each stage is divided into outer and central platens.
In the body downtaking ducts the flue gas passes through the convection superheater, convection reheater II, convection reheater I and water economizer, which are made as horizontal packages.
The air supplied to the boiler unit is heated in the remote regenerative air heaters with diameter of 7m (two per body). The air heaters are located outside the boiler house.
The boiler water-steam circuit is equipped with shut-off, control and safety valves as well as steam and water samplers.
Water washing devices are applied for furnace cleaning. Should the platens require cleaning, long-retractable steam sootblowers could be installed. For this purpose special openings are provided in the side walls of upper radiation section.
The design provides for automation of supply, combustion and steam temperature control processes. When firing pulverized coal the range of boiler automatic control is 70-100 % keeping rated parameters. When firing natural gas the range of boiler automatic control is 60-100 % keeping rated parameters.
STEAM BOILER Пп-1050-255-545КГЖ
7
STEAM BOILER Пп-660-13,7 - 540ГМ
П-56
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 660Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
13,7 (140)2,5 (25,8)
Steam temperature, °C:primaryreheated
545545
Design fuel: natural gas, fuel oilHeat value:natural gas, kcal/Nm³fuel oil, kcal/kg
86809790
Flow rate:gas, nm³/hfuel oil, t/h
52,548,5
Efficiency, %:when firing natural gaswhen firing fuel oil
93,392,0
Weight of metal, t:pressure partstotal of the boiler
11652975
Specific metal content, t/t/h:pressure partstotal of the boiler
1,774,5
8
This boiler is designed to run with turbine K-200-130,
the design fuel is natural gas and fuel oil. The boiler is
double-furnace, once-through, balanced-draft, arch-
type one with reheat and is supported by his own steel
structure. It shall be installed in areas with arch-type up
to 8 points.
The furnace chamber of each body is open-type,
prismatic, with 4 opposite burners arranged on side
walls in one level (two burners on each wall).
To reduce NOx emissions at Keratzini TPP (Greece)
the furnace chamber was modernized: eight burners
were installed in two levels on side walls of each body,
tertiary air nozzles were installed over the second level
burners, recirculation of cold flue gases into the furnace
was organized via the burners and nozzles. After
modernization NOx emissions do not exceed 95 mg/
Nma at a=1,4.
The furnace chamber is completely water-walled.
The water-walls are made as horizontal-lifting panels
and form height along lower radiation section, middle
radiation sections (I and II), and upper radiation sections
(I and II).
The boiler has two similar convection passes.
Each convection pass, subsequently in the direction
of gas flow, houses the following heating surfaces: HP
convection superheater of I and II stage, LP convection
superheater, transition zone and economizer.
HP fluid flows from the boiler inlet to its outlet in two
parallel independently controlled streams (one for each
body), and LP fluid flows in four parallel streams.
HP superheat temperature is controlled with feed
water injection and LP superheat temperature is
controlled with bypass of steam-steam heat exchanger
and supply of recirculation gases into furnace bottom.
Air is preheated using regenerative air heaters with rotor
diameter 7200 mm; one of them is installed at each
boiler body outside the boiler house.
Casing is brickwork, lightweight, with liner.
Two circuits of shot-blasting are provided to clean the
heating surfaces from ash deposits. The regenerative
air heater is equipped with devices for soot-blowing and
washing.
The boiler is equipped with all necessary valves,
steam and water sampling devices, as well as
instrumentation. Boiler supply, superheat temperature
and combustion processes are controlled automatically.
Thermal protection facilities are provided for the boiler.
STEAM BOILER Пп-660-13,7 - 540ГМ
9
STEAM BOILER Пп-1650-25-545/545 КТ
П-57Р
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 1650Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,9 (39,7)
Steam temperature, °C:primaryreheated
545545
Design fuel:heat value, kcal/kgflow rate, t/h
3450327
Efficiency (guaranteed), % 91,8Weight of metal, t:pressure partstotal of the boiler
28709380
Specific metal content, t/t/h:pressure partsboiler total
1,745,68
10
This boiler is designed to run with 500MW turbine,
the design fuel is Ekibastuz high-ash black coal.
The boiler is single-furnace, once-through,
supercritical, balanced-draft, T-shaped one with reheat
and bottom-ash removal, it installed in boiler house.
The furnace chamber is open-type, prismatic, of
rectangular cross-section and is water-walled with
vertical membrane-finned tube panels and equipped
with 24 opposite pulverized-coal swirl burners arranged
on the furnace side walls in two levels.
The L-shaped divided water-walls are installed in the
furnace top to reduce gas mean and local temperature
at furnace outlet.
The water-walled horizontal gas ducts house platen
superheaters. Further in the direction of gas flow the
downtake convection passes house outlet convection
superheaters of the primary and secondary steam, the
cold stage of the superheater of the secondary steam
and water economizer.
Air is preheated by means of a large-block tubular air
heater mounted in a separate building with air flow as a
unique Z two-way crossing circuit.
The coal pulverizing system is of the direct fuel
injection type and equipped with six ball-race mills.
The technological measures are provided for to
reduce NOx emissions from the boiler.
The primary steam superheat temperature is
controlled by changing the fuel-water ratio and by
double water injection. The secondary steam superheat
temperature is controlled through bypassing of steam-
steam heat exchanger.
The primary steam circuit of the boiler consists of two
separately controlled flows; the secondary steam circuit
comprises four flows.
Taking into account high ash content of Ekibastuz
coal (45-55% on dry basis) and its abrasiveness,
the boiler design was performed using the advanced
technical solutions oriented to guarantee of steady
pulverized coal ignition and good burnout, prevention
of abrasive wear of pulverized-coal ducts, convection
heating surfaces and gas ducts.
These boilers have shown good service in long-time
operation at a number of power plants.
STEAM BOILER Пп-1650-25-545/545 КТ
11
STEAM BOILER Пп-990-25-545 ЛТ
П-64
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 990Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,9 (39,7)
Steam temperature, °C:primaryreheated
545545
Design fuel:heat value, kcal/kgflow rate, t/h
2940235
Efficiency (guaranteed), % 87 ± 0,5Weight of metal, t:pressure partstotal of the boiler
24509500
Specific metal content, t/t/h:pressure partsboiler total
2,459,5
12
This boiler is designed to run with turbine 300 MW,
the design fuel is Yugoslavian low-grade lignite with
a wide range of moisture content (W=33-44%), ash
content (Aw=8-32%) and sulphur content (Scorn) up to
5,6%.
After modernization the boilers of this type were
delivered to Novo-Angrenskaya TPP to fire Angren
lignite (caloric content QPH =2940 kcal/kg, moisture
content 39,0%, ash content Aw = 13,4%.
The boilers of the second stage of Novo-Angrenskaya
TPP were modernized to fire natural gas.
The boiler is a once-through, single-furnace, closed,
T-shaped, supercritical one with reheat.
The furnace chamber is open-type, of rectangular
cross-section and is equipped with 24 opposite slot
burners and is completely water-walled with tubes
forming gas-intake ports above burners on side walls.
The boiler has two similar convection passes. To
preheat air ZIO-Podolsk cascade tubular air heater
is installed in a separate pass outside the boiler. This
prevents corrosion and choking of the air heater tubes
when the boiler fires high-sulphur fuel.
The fluid in the primary superheat path flows from the
boiler inlet to its outlet in two separating independently
controlled streams, and in the reheater it flows in four
parallel streams.
The primary steam superheat temperature
is controlled by injection, while reheated steam
temperature is controlled through bypass of steam-
steam heat exchanger.
The coal pulverizing system is of the direct fuel
injection type and equipped with eight fan-mills, type
EVT-KSG with let-down beater section and inertial
separators.
The boiler is delivered in large size modules.
The reliable, stable and slag-free operation of the
boiler furnace is ensured by a rather large sectional area
and volume of the furnace, three level arrangement of
slot burners along the long sides of the furnace, and fuel
gas drying.
Horizontal-inclined arrangement of water-wall tubes
reduces temperature unbalance, greatly improves
temperature conditions and raises reliability of the
furnace tubes.
Properly selected gas velocities in the convective
passes ensure slag-free operation of the convection
heating surfaces without abrasive wear.
STEAM BOILER Пп-990-25-545 ЛТ
13
STEAM BOILER Пп-2650-25-545/545 БТ
П-67
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 2650Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,7 (37,8)
Steam temperature, °C:primaryreheated
545545
Design fuel:heat value, kcal/kgflow rate, t/h
3740480
Efficiency (guaranteed), % 91Weight of metal, t:pressure partstotal of the boiler
750019400
Specific metal content, t/t/h:pressure partsboiler total
2,837,32
14
This boiler is designed to run with turbine 800 MW, the design fuel is Beresovo lignites of the Kansk-Achinsk deposits.
The boiler is a single-furnace, once-through, gas tight, balanced-draft, T-shaped, supercritical one with reheat and bottom-ash removal.
The furnace chamber is open-type, prismatic, of square cross-section and is completely water-walled with vertical membrane-finned tube panels and equipped with 24 tangential slot burners arranged in four levels on four walls, thereby creating a single rotating flame.
All the walls of the furnace chamber and gas ducts are all-welded of finned tubes, convection pass walls are made with a greater tube pitch.
Platen-type heating surfaces are arranged above the furnace and in the horizontal gas duct; the platens arranged first in the direction of gas flow are all-welded of finned tubes. The convection heating surfaces are located in downtaking passes within the medium temperature zone. All the convection heating surfaces are suspended from support tubes. The economizer is membrane type.
The primary steam superheat temperature is controlled by injection, while the secondary steam superheat temperature is controlled through bypass of steam-steam heat exchanger.
A tubular air heater is provided for air preheating. An excess air generating system is provided to reduce the exit gas temperature and raise the electrostatic precipitator efficiency.
The boiler is suspended from a building structures. Heat insulation is placed on the gas-tight boiler walls.
The boiler is delivered in large-size modules.
The temperature of gases in the flame core and at the furnace outlet is reduced due to the sufficient height of the furnace and supply of recirculation gases through the burners and to its top. Unburned carbon loss is reduced by feeding of hot air to the bottom ash hopper through a number of nozzles. There is combined cleaning system of the boiler heating surfaces from external ash deposits.
The coal pulverizing system is of the direct fuel injection type and equipped with fan-mills and fuel gas drying. Gas for drying is extracted at the area of the boiler turning chamber.
The boiler design provides for conditions required for repair of some boiler assembly units.
The main advanced design features of the boiler: gas-tight suspension structure, arrangement and design of heating surfaces, steam conditions and high unit power, meet the current trends and standards in the field of boiler manufacture.
STEAM BOILER Пп-2650-25-545/545 БТ
15
STEAM BOILER Пп-1650-25-545/545 КТ
П-76
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 1650Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,9 (40)
Steam temperature, °C:primaryreheated
545545
Design fuel:heat value, kcal/kgflow rate, t/h
5360207
Efficiency (guaranteed), % 91,5 ± 0,5Weight of metal, t:pressure partstotal of the boiler
473112100
Specific metal content, t/t/h:pressure partsboiler total
2,867,33
16
This boiler is designed to run with 500 MW power unit
of «Tzisuan» TPP (China), the design fuel is Chinese
black coal. The boiler is installed in high-seismicity (up
to 7 points) region.
The boiler is single-furnace, once-through,
supercritical, balanced-draft, T-shaped one with reheat
and bottom-ash removal. The boiler is of gas-tight
design, the furnace and convection passes are water-
walled with membrane panels.
The coal pulverizing system is of the direct fuel
injection type and equipped with eight ball-race mills.
The furnace chamber is of rectangular cross-section
and is equipped with 32 opposite burners arranged in
four levels.
The platen superheater is arranged at the furnace
outlet, further the horizontal gas duct house the platen
superheaters: final stages of the primary and secondary
superheaters.
The boiler has two similar convection passes, that
house, in the direction of the gas flow, the following
heating surfaces: inlet stages of the secondary
superheater, economizer.
The HP primary steam circuit consists of two
separately controlled flows; the secondary steam circuit
comprises four controlled flows.
The primary steam superheat temperature is
controlled by feed water injection, while the secondary
steam temperature is controlled through bypass of
steam-steam heat exchanger.
Air is preheated by means of four rotating regenerative
air heaters with diameter of 10 m with vertical shaft.
Steam and water sootblowing devices are applied for
cleaning the boiler heating surfaces.
Boiler lining is made as overtube insulation, fastened
on membrane panels. It is covered with metal sheets. The
boiler has no own framework and is suspended from the
building frame using intermediate steel structures. Boiler
supply, stem temperature and combustion processes
are controlled automatically. The boiler is equipped
with all necessary valves, steam and water sampling
devices, as well as instrumentation. The boiler design
provides for conditions required for repair of some boiler
assembly units.
STEAM BOILER Пп-1650-25-545/545 КТ
17
STEAM BOILER Пп-1650-25-545/545 БТ
П-78
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 1650Steam pressure, MPa (kgf/cm²)at boiler outletat reheater outlet
25,0 (255)3,9 (40)
Steam temperature, °C:primaryreheated
545545
Design fuel:heat value, kcal/kgflow rate, t/h
2580445
Efficiency (guaranteed), % 89,5 ± 0,5Weight of metal, t:pressure partstotal of the boiler
591214000
Specific metal content, t/t/h:pressure partsboiler total
3,588,48
18
This boiler is designed to run with 500 MW turbine,
the design fuel is Chinese lignite.
The boiler is single-furnace, once-through,
supercritical, balanced-draft, closed T-shaped one with
reheat and bottom-ash removal. The boiler is of gas-
tight design, the furnace and downtaking gas duct are
water-walled with membrane panels.
The furnace chamber is open-type, prismatic, of
square cross-section and is equipped with 32 pulverized-
coal direct-fired burners arranged in four levels.
The coal pulverizing system is of the direct fuel
injection type and equipped with eight fan-mills. The
furnace chamber heating surfaces are divided into lower
and upper radiation sections.
The platen multistage superheater is arranged at the
furnace outlet, further the horizontal gas duct house the
final convection stages of the primary and secondary
superheaters.
The boiler has two similar convection passes, that
house the following heating surfaces: inlet stage of the
secondary superheater, convection primary superheater
and economizer.
HP fluid flows from the boiler inlet to its outlet
in two separatw streams, and LP fluid flows in four
independently controlled streams. Four streams go into
two streams at the boiler outlet.
The HP steam superheat temperature is controlled
by changing of fuel-water ratio and feed water injections,
while the LP steam superheat temperature is controlled
through bypass of steam-steam heat exchanger.
The boiler is equipped with water sootblowing
system for furnace water-walls and steam sootblowing
system for heating surfaces in horizontal gas duct and
convection passes.
Air is preheated by means of four rotating regenerative
air heaters with diameter of 9.8 m with vertical shaft.
Boiler lining is made as overtube insulation, fastened
on membrane panels. It is covered with metal sheets.
The boiler has no own framework and is suspended from
the building frame using intermediate steel structures.
The boiler is equipped with all necessary valves, steam
and water sampling devices, as well as instrumentation.
Boiler supply, stem superheat temperature and
combustion processes are controlled automatically.
Thermal protection facilities are provided as required.
STEAM BOILER Пп-1650-25-545/545 БТ
19
STEAM BOILER Е-160-3,9-440 ГМ
П-95
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 160Steam pressure, MPa (kgf/cm²) 3,9 (39,8)Steam temperature, °C 440Design fuel:heat value, kcal/kgflow rate, t/h
790514,7х10³
Efficiency (guaranteed), % 94,0
20
This boiler is designed both to run with turbine and at cross-connection plants, the design fuel is natural gas (main fuel) and fuel oil (emergency fuel).
The boiler is gas-tight, single-furnace, drum, balanced-draft, natural circulation, top-supported one. The heating surfaces are arranged as horizontal arch. The boiler is suspended from its own framework, which may be supported by foundation or by natural base through its own support platform.
The boiler is appropriate for installation in limited spaces of existing buildings.
The boiler furnace and gas duct are water-walled with membrane panels:
• furnace is made of tubes 60 x 5 with spacers;• gas ducts are made of tubes 32 x 4 with spacers.“Penthouses” containing chambers and crossover
pipes of heating surfaces are located above the boiler and under it. The boiler water-steam circuit consists of the following three systems with one common drum:
• economizer and air-to-water heat exchanger;• circulation evaporating system;• superheater zone.Boiler evaporator includes water-wall section
(furnace water-walls) and convection section (evaporator-l and evaporator-2).
Boiler superheater includes gas duct water-walls and two-stage convection superheater (convection superheater-l and convection superheater-2).
Spray attemperator is installed between the first and second stage of convection superheater to control the superheated steam temperature downstream the boiler.
Economizer and evaporator-2 are made of spiral-finned tubes 32x4.
Convection superheater-l, convection superheater-2 and evaporator-l are membrane-type, made of tubes 42 x 4 with spacers.
Membrane water-wall box has two levels of stiffening beams.
The drum with internals is installed on central beams of the boiler framework.
Combustion equipment is made as follows:• front wall of the horizontal furnace chamber is
equipped with two levels of four dual-channel for air and dual-channel for gas oil/gas burners;
• the furnace side walls are equipped with four nozzles for tertiary air supply at burner elevations.
The cold gas recirculation is provided to reduce NOx formation, is fed to windbox upstream the burners.
The boiler is equipped with shut-off, control and safety valves as well as steam and water sampling devices.
Boiler design provides for steam blowing, chemical and water washing.
The boiler is insulated by plates mounted over the tubes. The boiler front, rear and side walls are covered with decorative metal sheets.
The boiler can be delivered both separately and together with the following auxiliaries:
• main induced-draft fan;• forced-draft fan;• induced-draft fan for gas recirculation;• gas-air ducts and gas-tight valves.
STEAM BOILER Е-160-3,9-440 ГМ
21
STEAM BOILER Е-50-0,7-250Г
П-102
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 50team parameters downstream the boiler:Temperature, ºCPressure, MPa (kgf/cm²)
210-2600,7 (7,1)
Steam temperature, °C 104Design fuel: heat value, Kcal/Nm³ 8540Fuel flow rate under the independent mode, Nm³/h 3870Efficiency (gross) at rated load and under independent mode of op-eration with district water heater in service, %:DesignGuaranteed
95,194,0
22
Steam boiler П-102 fires natural gas. It is designed for independent and combined operation with GTPP Ural-6000.
Drum-type boiler is of single-furnace design, with natural circulation and balanced draft.
Arc-arranged boiler is top supported.
The furnace and convective pass are enclosed with gas tight screens which consist of tubes and bars and thus form the all-welded construction. Insulation is provided on tubes. Decorative casing is made of metal.
The area along the gas flow downstream of the furnace and downstream of the point of GTPP Ural-6000
exhaust gas mixture is the location of the convective superheater, and the convective pass comprises the convective evaporator, economizer and district water heater.
Superheated steam temperature is regulated by spraying the feed water downstream the superheater.
The boiler is equipped with required steam and water valves, gas&air circuit is provided with control and shutoff valves, water and steam sampling devices are installed.
Main characteristics of the boiler are listed in the table.
STEAM BOILER Е-50-0,7-250Г
23
STEAM BOILER Е-210-9,6-540 КТ
ОР-210М
PERFORMANCE CHARACTERISTICSSteam capacity, t/h 210Steam pressure, MPa (kgf/cm²) 9,6 (98)Primary steam temperature, ºC 540Design fuel:heat value, kcal/kgflow rate, t/h
498727,0
Efficiency (guaranteed), % 92,0
24
Steam Boiler is designed to produce high pressure superheated steam for common station manifold, firing black Silesian coal of three types and mixture of the coals.
The rehabilitated boiler is of one-drum type with natural circulation, indoors installation.
The boiler has arch-type configuration with suspension of the heating surfaces (excluding tubular air heater) to roof covering disc plate and consists of prismatic open-type furnace chamber (riser gas duct) with 7920x7360 dimensions and a convection pass (downtaking backpass) connected with each other by a rotating gas duct with a platen superheater and 3 stages of a convection superheater. The backpass comprises 3 bundles (2 stages) of a water economiser and 3 passes of a tubular air heater along the gas flow. The furnace chamber, roof radiant tubes, the rotating gas duct and major part of the convection pass up to the economizer lower bank inlet are made of membrane water walls with strip spacer plate tubes, and they form a gas tight chamber.
The pulverized-coal system provides for a pulverized-coal intermediate hopper and for the installation of two ball pulverizers per boiler. Pulverized coal is supplied to the boiler furnace by means of the concentrated coal flow pneumatic conveying system with the use of high pressure turbo blowers.
NOx emissions in the boiler are decreased by the 3-stage fuel combustion circuit that provides for NOx reduction pulverized-coal stage. For this purpose the combustion chamber is fitted with eight straight-flow slot burners and four tertiary air-type burners, installed tangentially. The main burners are installed in two levels and the tertiary air-type burners are installed in one level over the main burners. Also the installation of 8 secondary air nozzles as well as 6 blocks of tertiary air nozzles is provided for this purpose.
Ash extraction is of dry and mechanical type, and it provides for the use of a scraper slag removal device.
Flue gas cleaning from ash takes places in the electrostatic precipitators.
Furnace chamber water walls are cleaned from possible ash and slag deposits by means of long-throw water soot-blowers, and platens are cleaned with long-retracting steam devices.
The boiler has balanced draft and it is intended to be operated under base-load conditions. The boiler is fitted with the required scope of automatic regulation, protection and interlocks facilities, remote control of valves and dampers, and also safety devices, instrumentation.
The boiler design provides for water and chemical cleaning, steam purges and mechanical repair.
The setting of gas tight chamber walls is made of insulation plates with outer sheathing formed by galvanized steel sheets.
STEAM BOILER Е-210-9,6-540 КТ
25
STEAM BOILER Еп-690-15,4-540 ЛТ
NEYVELI
PERFORMANCE CHARACTERISTICSSteam capacity, max., t/h 690Steam capacity, rated, t/h(corresponds to 210 MW) 592Steam pressure, MPa (kgf/cm²):at boiler outletat reheater outlet
15,4 (157,1)3,5 (35,7)
Steam temperature, ºC:primarydownstream reheater
540540
Design fuel:calorific value, kcal/kgconsumption, t/h
2350215
Efficiency (guaranteed), % 89,9
26
The boiler is designed for operation within 210 MW
unit with firing low-calorie Indian lignite with calorific
value of Q,r=2190-2730 kcal/kg, moisture of Wr=51-
55%, ash content of Аг=2,1-6% and sulphur content of
Sr=0,54-1,46%.
The boiler is of drum, single-furnace, reheat
subcritical pressure type with natural circulation,
bottom-ash removal and tower-type arrangement. The
boiler has a gas tight design the furnace and convection
pass enclosure made of membrane panels. The boiler
provides for the installation of 2 regenerative air heaters.
Water and steam purging devices are installed for
heating surface cleaning.
The square open furnace chamber is provided with
12 double straight-flow multi-channel burners installed
tangentially on all the furnace walls in two levels.
The direct injection firing system has six fan-mills
of MV 3400/900/490 type and supports fuel drying by
gas. The design of the fan-mills provides for a range of
engineering solutions that make it possible to regulate
mill fanning. The mills are equipped with the devices of
electrody-namic deceleration.
The pulverised coal and the drying agent are
distributed throughout the burners through the centrifugal
pulverized coal distributor intended for the division of the
fuel-air mixture among four combustion stages.
The two-stage combustion circuit with horizontal and
vertical fuel combustion is arranged in order to reduce
NOx emissions. The lower part of the dry bottom hopper
provides for the installation of an after-burning grate.
The processes of boiler feeding, superheated steam
temperature control, combustion and level-wise fuel
distribution are automated.
The boiler is designed together with ANSALDO
company. EC “ZIOMAR” performed the works on basic
and detailed engineering of the fuel preparation and
combustion system and fuel cleaning system as well as
on the detailed design and supply of a part of the heating
surfaces and the sets of coal-pulverizing and furnace
and burner equipment.
STEAM BOILER Еп-690-15,4-540 ЛТ
27
HOT WATER BOILER КВ-Г-81,4-150Н
BOILER PERFORMANCE CHARACTERISTICS
DESCRIPTIONVALUE
Basic conditions Forced conditionsHeating efficiency, MW (Gcal/h); 81,4 (70) 87,23 (75)District water flow through the boiler, t/h; 867 929Absolute water pressure at the boiler outlet, MPa (kgf/cm2) 1,2 (12) 1,2 (12)Maximum water circuit flow resistance, MPa (kgf/cm2) 0,25 (2,5) 0,33 (3,3)Water temperature at the boiler inlet, ºС 70 70Water temperature at the boiler outlet, ºС 150 150Furnace overpressure, Pa (kgf/m²) 197 (19,7) 236 (23,6)Excess air coefficient at the furnace outlet 1,1 1,1Exhaust gas temperature, ºС 115 120Fuel flow, nm3/h (t/h) 8598,7 (6,31) 9221,5 (6,76)Design boiler efficiency (gross), % 95 94,8NOX emissions downstream of the boiler (at α =1,4), mg/nm3 125 at most 125 at most CO emissions, mg/nm3 50 at most 50 at most
Boiler overall dimensions, m:Width along the column axes – 6,24Depth along the column axes – 6,24Height by the structure top elevation – 17,500
П-130
28
HOT WATER BOILER КВ-Г-81,4-150Н
The boiler is designed to burn natural gas. Gas is considered to be main and standby fuel. The boiler is intended for generating hot water used for district heating (the heat supply system is of closed type). It is a vertical water tube, tower-type, once-through, gas-tight, pressurized boiler suspended from its own structure.
The furnace and the convection pass formed by their front, rear and common side waterwalls are located in the boiler along the combustion product flow. The furnace and the pass are basically an integrated all-welded gas-tight structure.
The top headers of the furnace waterwalls and the convection pass give support to the metal sheet pass downstream of the boiler. The pass is under vacuum conditions created by the stack. The stack is located above the pass, and it is resting on its own structure. The stack structure is resting on the boiler structure. The pass and the stack are interconnected through a non-metallic expansion joint. The pass downstream of the boiler is the place where the silencer and the valve aimed at vacuum control downstream of the last stage along the gas flow are located.
The boiler furnace chamber is equipped with four swirl gas low-emissivity burners located in the opposite way in one row on its side walls. The combustion fuel is supplied via natural gas pipelines.
The required NOX emission level is achieved by using the flue gas recirculation from the convection pass to the forced draft fan suction. The boiler has water-cooled thermal insulation made of thermal insulating power
boards. The sheathing made of galvanized or aluminum corrugated plates is installed above the insulation.
Platforms, ladders, inspection doors and manholes are used for boiler operation, as well as for the performance of maintenance and adjustment works. There is provision for the system of potential leakage sealing with the blower head air in order to eliminate the possibility of flue gas entering the boiler house from the boiler operating under pressurized conditions. There is also provision for the air supply required for the sealing of furnace inspection doors, ignition control system ignitors, flame monitoring sensors and gas burner inspection doors. Manholes are sealed with the use of elastic gaskets.
The boiler water circuit is equipped with necessary valves, drains, vents and a water sampling device. The boiler design makes it possible to carry out water and chemical washes.
The boiler is equipped with process protections, interlocks, automatic regulators, I&C, remote control means. The boiler is designed to operate under basic (nominal) conditions and under forced conditions (with the increased heating efficiency) for a short period.
The boiler stable operation under basic conditions using main and standby fuel is maintained within the load range of 30÷107%. The same load range is the automatic control range.
Main design parameters of the boiler at the load of 100% are specified in the table
29
HOT WATER BOILER КВ-ГМ-140-150Н
BOILER PERFORMANCE CHARACTERISTICS
DESCRIPTION VALUEBasic conditions Forced conditions
Heating efficiency, MW (Gcal/h); 140 (120) 110 (95)District water flow through the boiler, t/h; 1483 2056Consumer district water flow, t/h 1483 1483Absolute water pressure at the boiler inlet, MPa (kgf/cm²) 1,42 (14,5) 1,6 (16,3)Absolute water pressure at the boiler outlet, MPa (kgf/cm²) 1,18 (12,0) 1,18 (12,0)Water temperature at the boiler inlet, ºС 70 115*Water temperature at the boiler outlet, ºС 150 160Temperature of water supplied to the system, ºС 150 133**Furnace overpressure, Pa (kgf/m²) 197 (19,7) 236 (23,6)Furnace pressurization, Pa (kgf/m²) 500 (50) at most 400 (40) at mostExcess air coefficient at the furnace outlet 1,05 1,1Exhaust gas temperature, ºС 108 210Design boiler efficiency (gross), % 95,5 90,8NOX emissions downstream of the boiler (at α=1,4), mg/nm³ 230 at most 300 at mostCO emissions, mg/nm³ 300 at most 300 at most* To be ensured due to hot water recirculation from the boiler ** To be ensured due to cold district water bypassing
Boiler overall dimensions, m:width along the column axes – 6,9depth along the column axes – 6,9height by the structure top elevation – 15,65
П-112
30
HOT WATER BOILER КВ-ГМ-140-150НThe boiler is designed to burn natural gas and oil. Gas
is considered to be main fuel, and oil is considered to be emergency fuel. The boiler is intended for generating hot water used for district heating (the heat supply system is of open type).
It is a vertical water tube, tower-type, once-through, gas-tight, pressurized boiler suspended from its own structure. The pass downstream of the boiler is under vacuum conditions created by the stack.
The furnace and the convection pass formed by their front, rear and common side waterwalls are located in the boiler along the combustion product flow. The furnace and the pass are basically an integrated all-welded gas-tight structure.
There are two possible alternatives of the gas exhaust duct layout:
1. The top headers of the furnace waterwalls and the convection pass give support to the pass downstream of the boiler. The pass is under vacuum conditions created by the stack. The stack is located above the pass, and it is resting on its own structure. The stack structure is resting on the boiler structure. The pass and the stack are interconnected through a non-metallic expansion joint. The pass downstream of the boiler is the place where the silencer and the valve aimed at vacuum control downstream of the last stage along the gas flow are located.
2. Exhaust gases are led to the stack available at the enterprise by means of installing a confuser with a pass being adjacent to it that rest upon the top headers of the furnace waterwalls and the convection pass.
The top part of the furnace along the gas flow is the location of the membrane convection heating surface (MCHS1) after which the convection heating surfaces (central CS2 and top CS3 bundles) made of tubes with spiral fins are located.
The boiler has a two-pass circulation circuit with water up flow through all the furnace waterwalls and MCHS1 and water down flow in CS2 and CS3.
There is provision for the use of two shock-wave generators installed on the boiler side walls between CS2 and CS3 aimed at the convection surface cleaning from external scaling in case of oil operation.
The decrease in NOX emissions requires the specification of the two-stage fuel combustion diagram in compliance with which the furnace chamber is equipped with four swirl oil and gas low-emissivity burners and tertiary blast nozzles located
at two levels on the side walls (burners are located at the bottom level, nozzles are located at the top level, each wall has two burners and two nozzles). The burners are located in the opposite way, and the nozzles are located tangentially to the conceptual circuit.
Each oil and gas burner of the boiler consists of a gas burner with a steam-mechanical oil atomizer installed in it. Combustion fuel is supplied through natural gas and oil pipelines. The burner has a two-port design as far as natural gas and air are concerned. Its air ports (a central and a peripherical port) are equipped with axial blade swirlers and valves at the port inlet that make it possible to adjust and control air flow through the ports for all operation conditions.
Outer surfaces of the boiler, gas pipelines and pipelines are thermally insulated. The design temperature on the outside of the insulation does not exceed 45ºC at the ambient air temperature of 25ºC. The boiler has water-cooled thermal insulation made of boards or basalt extra fine fiber. The sheathing made of galvanized or aluminum corrugated plates is installed above the insulation.
There is provision for the system of potential leakage sealing with the forced draft fan head air in order to eliminate the possibility of flue gas entering the boiler house from the boiler operating under pressurized conditions. There is also provision for the air supply required for the sealing of boiler valves (except for manholes), oil atomizers, ignition control system ignitors, burner flame monitoring sensors, inspection doors of the impact and wave cleaning device. Manholes are sealed with the use of elastic gaskets.
The boiler water circuit is equipped with necessary valves, drains, vents and a water sampling device. The boiler design provides for carrying out water and chemical washes.
Platforms, ladders, inspection doors, access doors and manholes are used for boiler operation, as well as for the performance of maintenance and adjustment works.
The boiler is equipped with the process parameter automatic control system, burner firing automated control, process protections and interlocks, remote control, auxiliary mechanisms as well as with the system of process parameter thermotechnical control.
The range of the boiler load automatic control in case of natural gas operation is 100-30%, and the range of the boiler load automatic control in case of oil operation (with Sp content that does not exceed 1.1%) is 78-30%.
Main design parameters of the boiler at the load of 100% are specified in the table.
31
STEAM BOILER Е-90-3,9-440Д
ADVANCED DEVELOPMENTS
BOILER PERFORMANCE CHARACTERISTICS
Type of fuelgas oil
atmospheric residue hydrocracking
Boiler steam capacity, t/h 90Superheated steam pressure, MPa 3,9Superheated steam temperature, ˚С 440Feed water temperature, ˚С 130Boiler dimensions, m:
• width along the column axes • depth along the column axes• height (main beam elevation)
9,29,8521,7
Boiler efficiency, % 93,7Boiler weight removal value, t 475,5
Е-90
32
STEAM BOILER Е-90-3,9-440Д
ADVANCED DEVELOPMENTS
The boiler is designed to generate superheated steam when firing gas oil and atmospheric residue hydrocracking. This is a single-furnace, one-drum steam boiler with natural circulation and close-coupled arch arrangement of heating surfaces for balanced draft operation that is equipped with gas oil firing installations. The boiler consists of a furnace chamber and a downtaking duct, protected by gas tight membrane walls, a drum, burner devices, a condensing unit, water and steam circulating tubes with an attemperator, water supply and steam discharge pipes and a tubular air heater.
The open-type furnace chamber is rectangular in section, and its plan dimensions are 4480х6800 mm. The lower part of the side waterwalls form a double-pitch bottom sloping towards the furnace center at an angle of 30º. The furnace chamber walls are made of plain tubes, and a bar is welded between them. The waterwalls have corresponding interconnections for burners, access doors, inspection doors and manholes. The gas tight boiler enclosures are equipped with stiffening rings in order to resist the pressure inside the furnace in case of possible puffs and to ensure that external loads are carried.
This boiler provides for the installation of semi-bottom burners in the amount of four pieces (two and
two opposed burners on each side wall located in one
row in the area where the furnace side walls are merging
into the bottom waterwall).
Steam superheat temperature is regulated with the
injection of the “internal” condensate in the attemperator.
There is provision for feed water injection as a stand-by
injection and an injection for the start-up period.
The tubular air heater on its own structure consists of
six tubes installed horizontally in one row throughout the
height. The air heater is equipped with blowing and fire
extinguishing devices.
The specified lifetime between overhauls is at
least 4 years. The designed life of the boiler pressure
elements with the design temperature corresponding to
the creeping area is at least 100 thousand hours for the
tubes of the heating surfaces and superheater chambers
and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%.
The allowable rate of load changing within the control
range of 30% - 70% is at least 1.5% per minute, and
it is at least 4% per minute within the control range of
70% - 100%. The boiler is operating under base load
conditions.
33
STEAM BOILER Е-120-9,8-515 ГМ
ADVANCED DEVELOPMENTS
Е-120
BOILER PERFORMANCE CHARACTERISTICS
Type of fuel natural gas oil
Boiler steam capacity, t/h 120Superheated steam pressure, MPa 9,8Superheated steam temperature, ˚С 515Feed water temperature, ˚С 132Boiler dimensions, m:
• width along the column axes • depth along the column axes• height (main beam elevation)
9,317,320,9
Boiler efficiency, % 94,5Boiler weight removal value, t 515
34
STEAM BOILER Е-120-9,8-515 ГМ
Steam boiler Е-120-9,8-515 ГМ is designed to generate superheated steam when firing natural gas and oil.
This is a single-furnace, one-drum steam boiler with natural circulation and close-coupled arch arrangement of heating surfaces for balanced draft operation that is equipped with burner devices for natural gas and oil firing. The boiler consists of a furnace chamber and a downtaking duct the walls of which are designed as gas tight panels made of tubes with a bar welded between them. The first stage convection superheater is located at the furnace outlet. The downtaking duct is the place when the second and the third stage convection superheater and a water economizer are located.
The open-type furnace chamber is of the prismatic form, and its plan dimensions are 7000х6240 mm. The front and rear waterwall panels in the furnace chamber bottom part are bent towards the furnace interior at an angle of 15° towards the horizontal plane, and they form the furnace bottom. The gas tight boiler enclosures are equipped with stiffening rings in order to resist the pressure inside the furnace in case of possible puffs and to ensure that external
loads are carried. The furnace chamber is equipped with eight swirl burners located in two rows on the furnace side walls.
The superheated steam temperature is regulated with the injection of feed water in the attemperators located between the stages of convection superheater 1 and between convection superheater 2 and convection superheater 3.
The tubular air heater is located downstream of the convection pass, and it consists of six pots.
The specified lifetime between overhauls is at least 4 years. The designed life of the boiler pressure elements with the design temperature corresponding to the creeping area is at least 100 thousand hours for the tubes of the heating surfaces and superheater chambers and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%. The allowable rate of load changing within the control range of 30% - 70% is at least 1.5% per minute, and it is at least 4% per minute within the control range of 70% - 100%. The boiler is operating under intermediate load conditions.
ADVANCED DEVELOPMENTS35
STEAM BOILER Е-220-3,7-420Г
ADVANCED DEVELOPMENTS
Е-220
BOILER PERFORMANCE CHARACTERISTICS
Type of fuel natural gas diesel oil
Boiler steam capacity, t/h 220Superheated steam pressure, MPa 3,7Superheated steam temperature, ˚С 420Feed water temperature, ˚С 150Boiler dimensions, m:
• width along the column axes • depth along the column axes• height (main beam elevation)
11,616,029,95
Boiler efficiency, %:• in case of natural gas firing • in case of diesel oil firing
93,491,06
Boiler weight removal value, t 760,2
36
STEAM BOILER Е-220-3,7-420Г
Steam boiler Е-220-3,7-420Г is designed to generate
superheated steam when firing natural gas as main fuel
and diesel oil as emergency fuel.
This one-drum steam boiler with natural circulation is
designed with the use of the close-coupled arrangement
of the boiler heating surfaces (Figures 1, 2). The boiler
consists of a furnace chamber, and it is equipped with
burner devices for natural gas and diesel oil firing. The
uptaking duct is the location area of the second stage
convection superheater, and the downtaking duct is the
location area of the first stage convection superheater.
The economizer and the tubular air heater are located in
the free standing gas duct along the gas flow.
The furnace chamber is of the prismatic form, and
it is rectangular in section with the dimensions along
the tube axes of 7200х9600 mm. The top part of the
rear waterwall evaporating tubes form a curtain wall
between the uptaking duct (above the furnace) and
the downtaking duct. The uptaking and the downtaking
ducts are enclosed by the furnace side waterwalls. The
walls of the furnace chamber, the boiler uptaking and
downtaking ducts are designed as gas tight panels
made of tubes with a bar welded between them.
The boiler side walls is the place where eight low-
emissivity burners are located opposedly in two rows.
Steam superheat temperature is regulated with the
injection of the “internal” condensate. There is provision
for feed water injection as a stand-by injection.
The tubular air heater consists of two parts designed
to have four air flows.
The specified lifetime between overhauls is at
least 4 years. The designed life of the boiler pressure
elements with the design temperature corresponding to
the creeping area is at least 100 thousand hours for the
tubes of the heating surfaces and superheater chambers
and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%.
The allowable rate of load changing within the control
range of 30% - 70% is at least 1.5% per minute, and
it is at least 4% per minute within the control range of
70% - 100%. The boiler is operating under intermediate
load conditions.
ADVANCED DEVELOPMENTS37
STEAM BOILER Е-310-9,8-540Г
ADVANCED DEVELOPMENTS
Е-310
BOILER PERFORMANCE CHARACTERISTICS
Type of fuel natural gas diesel oil
Boiler steam capacity, t/h 310Superheated steam pressure, MPa 9,8Superheated steam temperature, ˚С 540Feed water temperature, ˚С 150Boiler dimensions, m:
• width along the column axes • depth along the column axes• height (main beam elevation)
11,617,2831,3
Boiler efficiency, %:• in case of natural gas firing • in case of diesel oil firing
93,7689,61
Boiler weight removal value, t 905,1
38
STEAM BOILER Е-310-9,8-540Г
Steam boiler Е-310-9,8-540Г is designed to generate superheated steam when firing natural gas as main fuel and diesel oil as emergency fuel.
This one-drum steam boiler with natural circulation is designed with the use of the close-coupled arrangement of the boiler heating surfaces (Figures 1, 2). The boiler consists of a furnace chamber, and it is equipped with burner devices for natural gas and diesel oil firing. The uptaking duct is the location area of the first and second stage convection superheaters, and the downtaking duct is the location area of the third and fourth stage convection superheaters. The economizer and the tubular air heater are located in the free standing gas duct along the gas flow.
The furnace chamber is of the prismatic form, and it is rectangular in section with the dimensions along the tube axes of 7200х9600 mm. The top part of the rear waterwall evaporating tubes form a curtain wall between the uptaking duct (above the furnace) and the downtaking duct. The uptaking and the downtaking ducts are enclosed by the furnace side waterwalls. The walls of the furnace chamber, the boiler uptaking and downtaking ducts are designed as gas tight panels made of tubes with a bar welded between them.
The boiler side walls is the place where eight low-emissivity burners are located opposedly in two rows.
Steam superheat temperature is regulated with the injection of the “internal” condensate. First injection spray attemperators are installed between the first and the second stage convection superheaters, and the second injection spray attemperators are installed between the second and the third stage convection superheaters. There is provision for feed water injection as a stand-by injection.
The economizer with spiral finning consists of two parts. The tubular air heater consists of two parts designed to have four air flows.
The specified lifetime between overhauls is at least 6 years. The designed life of the boiler pressure elements with the design temperature corresponding to the creeping area is at least 100 thousand hours for the tubes of the heating surfaces and superheater chambers and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%. The allowable rate of load changing within the control range of 30% - 70% is at least 1.5% per minute, and it is at least 4% per minute within the control range of 70% - 100%. The boiler is operating under intermediate load conditions.
ADVANCED DEVELOPMENTS39
STEAM BOILER Е-500-13,8-560Д
ADVANCED DEVELOPMENTS
Е-500
BOILER PERFORMANCE CHARACTERISTICS
Type of fuel natural gas diesel oil
Boiler steam capacity, t/h 500Superheated steam pressure, MPa 13,8Superheated steam temperature, ˚С 560Feed water temperature, ˚С 230Boiler dimensions, m:
• width along the column axes • depth along the column axes• height (main beam elevation)
14,520,235,3
Boiler efficiency, % 93,8Boiler weight removal value, t 2511,17
40
STEAM BOILER Е-500-13,8-560Д
Steam boiler Е-500-13,8-560Д is designed to generate superheated steam when firing gas oil. This is a single-furnace, one-drum steam boiler with natural circulation and close-coupled arch arrangement of heating surfaces for balanced draft operation that is equipped with gas oil firing installations. The boiler consists of a furnace chamber and a downtaking duct, protected by gas tight membrane walls, a drum, burner devices, a condensing unit, water and steam circulating tubes with an attemperator, water supply and steam discharge pipes, outside-mounted cyclones and regenerative air heaters. The furnace chamber top part is the location area of the three stages of the platen superheater, and the downtaking duct is the location area of the three stages of the convection superheater and the economizer. The regenerative air heaters in the amount of two pieces are located outside of the boiler house.
The open-type furnace chamber is rectangular in section, and its plan dimensions are 10560х11280 mm. The lower part of the side waterwalls form the bottom sloping towards the furnace center at an angle of 30º. The furnace chamber walls are made of tubes, and a bar is welded between them. The waterwalls have corresponding interconnections for burners, access doors, inspection doors and manholes. The gas tight boiler enclosures are equipped with stiffening rings in order to resist the pressure inside the furnace in case
of possible puffs and to ensure that external loads are carried.
This boiler provides for the installation of semi-bottom burners in the amount of six pieces (three and three opposed pieces on each side wall located in the area where the furnace side walls are merging into the bottom waterwall).
Steam superheat temperature is regulated with the injection of the “internal” condensate. There is provision for feed water injection as a stand-by injection.
The regenerative air heaters with the rotor diameter of 6800 mm are installed in the amount of two pieces per boiler. The pattern of flue gas and air interdependent flow is counter flow.
The specified lifetime between overhauls is at least 5 years. The designed life of the boiler pressure elements with the design temperature corresponding to the creeping area is at least 100 thousand hours for the tubes of the heating surfaces and superheater chambers and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%. The allowable rate of load changing within the control range of 30% - 70% is at least 1.5% per minute, and it is at least 4% per minute within the control range of 70% - 100%. The boiler is operating under base load conditions.
ADVANCED DEVELOPMENTS41
NOTES:
42
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