Steam Generators and Waste Heat Boilers : For Process and Plant Engineers

The text shows how design and performance calculations of complete steam generators and waste heat boilers of fire tube and water tube type may be done using basic heat transfer principles. It discusses recent developments in boiler technology, explores novel design ideas for improving efficiency, and lowering operating costs. In addition, it presents examples of problems with steam generators and HRSGs that are faced by plant engineers, along with solutions. Appendices provide heat transfer correlations in all three systems of units.

Incorporates Worked-Out Real-World Problems

Steam Generators and Waste Heat Boilers: For Process and Plant Engineers focuses on the thermal design and performance aspects of steam generators, HRSGs and fire tube, water tube waste heat boilers including air heaters, and condensing economizers. Over 120 real-life problems are fully worked out which will help plant engineers in evaluating new boilers or making modifications to existing boiler components without assistance from boiler suppliers. The book examines recent trends and developments in boiler design and technology and presents novel ideas for improving boiler efficiency and lowering gas pressure drop. It helps plant engineers understand and evaluate the performance of steam generators and waste heat boilers at any load.

This book begins with basic combustion and boiler efficiency calculations. It then moves on to estimation of furnace exit gas temperature (FEGT), furnace duty, view factors, heat flux, and boiler circulation calculations. It also describes trends in large steam generator designs such as multiple-module; elevated drum design types of boilers such as D, O, and A; and forced circulation steam generators. It illustrates various options to improve boiler efficiency and lower operating costs. The author addresses the importance of flue gas analysis, fire tube versus water tube boilers used in chemical plants, and refineries. In addition, he describes cogeneration systems; heat recovery in sulfur plants, hydrogen plants, and cement plants; and the effect of fouling factor on performance. The book also explains HRSG simulation process and illustrates calculations for complete performance evaluation of boilers and their components.

• Helps plant engineers make independent evaluations of thermal performance of boilers before purchasing them
• Provides numerous examples on boiler thermal performance calculations that help plant engineers develop programming codes with ease
• Follows the metric and SI system, and British units are shown in parentheses wherever possible
• Includes calculation procedures for the basic sizing and performance evaluation of a complete steam generator or waste heat boiler system and their components with appendices outlining simplified procedures for estimation of heat transfer coefficients

Steam Generators and Waste Heat Boilers: For Process and Plant Engineers serves as a source book for plant engineers, consultants, and boiler designers.