A steam generator, commonly referred to as a boiler, is a mechanical device that uses heat from fuel or other energy sources to convert water into hot water or steam. The term "boiler" originally described a container used for heating water over fire, while the "furnace" refers to the area where fuel is burned. Together, they form the two main components of a boiler system.
According to the "Special Equipment Safety Supervision Regulations," any device with a volume of 30 liters or more is classified as a boiler. Most steam generators available on the market have a capacity below this threshold, meaning they are not subject to strict regulatory oversight, which reduces installation and operational costs.
Steam generators are essential in various applications, including power generation, industrial processes, marine operations, and locomotion. Power station boilers, along with steam turbines and generators, form the core of thermal power plants. Industrial boilers provide steam for production and heating, while waste heat boilers recover energy from exhaust gases, contributing to energy efficiency. Marine and locomotive boilers serve specialized purposes, driving machinery on ships and trains respectively.
Boilers can be categorized based on their use, pressure levels, and design. Common classifications include industrial boilers, power station boilers, marine boilers, and locomotive boilers. Pressure levels range from low to ultra-high, with specific values such as 3.9 MPa for medium-pressure power station boilers and 0.5 MPa to 2.5 MPa for industrial boilers.
The working principle of a boiler involves the combustion of fuel, typically coal, to produce high-temperature flue gases. These gases transfer heat to water in the boiler's tubes, converting it into steam. This steam is then used to drive turbines or for industrial applications. Key components include the economizer, superheater, and air preheater, each playing a vital role in improving efficiency and reducing emissions.
In terms of circulation modes, boilers can operate through natural circulation, forced circulation, direct current, or combined cycles. Each mode affects how water and steam move within the system, influencing performance and safety.
Flue gas purification systems are crucial for reducing pollutants like particulate matter, sulfur oxides, and nitrogen oxides. Techniques such as electrostatic precipitation, bag filtration, and wet scrubbing help meet environmental standards. Additionally, desulfurization and denitrification methods are employed to minimize harmful emissions.
Ash and slag generated during combustion are collected and disposed of using water or mechanical means. Efforts to recycle these byproducts into construction materials or insulation have gained traction, promoting sustainable practices.
Thermal efficiency is a key metric for evaluating boiler performance. Modern power station boilers can achieve efficiencies over 90%, while industrial boilers often reach 75% or higher. Heat loss occurs through various channels, including unburned fuel, incomplete combustion, and exhaust gases.
Pure steam generators, used in specialized applications like pharmaceuticals and laboratories, ensure high-purity steam. These systems separate impurities through multiple stages of evaporation and condensation, ensuring clean, dry steam for critical processes.
Overall, steam generators play a vital role in energy production and industrial operations, requiring careful design, operation, and maintenance to ensure safety, efficiency, and environmental compliance.
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