Working Principle of a Horizontal Fire Tube Boiler
Abstract
A horizontal fire tube boiler is a thermodynamic device used in a building or complex. It is the common fire tube boiler used in several industries, such as petrochemical, pharmaceutical, textile, and food processing. These industries already generate high thermal efficiency through their compact mechanism and small footprint.
This guide will explain how they work, popular types, their advantages, disadvantages, and real-world applications. EPCB Boiler has specialized in industrial boiler design for more than 70 years and would share the following tips to help us understand which Boiler you can select:
What Is a Horizontal Fire-Tube Boiler?
In a horizontal fire tube boiler, the cylinder boiler is filled with water and has a combustion chamber at the lower end. The combustion chamber fills with burning fuel (gas, oil, coal, etc) and generates hot gases passing through the fire tubes, transferring heat. This design is well-suited for small applications such as heating homes or businesses, while larger applications such as power plants use water-tube boilers more often.
A Horizontal Fire Tube Boiler has a simple structure
The horizontal fire tube boiler is made up of the following parts
2.1 Furnace
Furnace: The lower part of the boiler is where fuel is burned in a combustion chamber to produce heat. It is made of refractory materials to endure high temperatures. By optimizing the air-to-fuel ratio and airflow, the furnace achieves the greatest heat generated with the least emissions. The boiler’s performance and reliability depend, to a large extent, on the efficiency and effectiveness of the furnace.
2.2 Fire Tube
Fire Tube—A primary part of the Boiler, it provides two straight or arched tubes from the furnace to the cylinder for energy transfer. Hot combustion gases flow through these tubes, which are surrounded by water. In smaller boilers, consecutive tubes are used,, whereas curved tubes are used in larger boilers to enhance the heating surface area. The dissipated heat pipe also reduces the flue gas film’s thickness, increasing the thermal efficiency.
2.3 Boiler Drum
Fire tube boiler drum A fire tube boiler drum holds water and steam. It is above the fire tube connecting the furnace to the flue. The drum holds water, which is heated and turned into steam. The drum’s large capacity guarantees an uninterrupted steam supply, even during peak load conditions.
2.4 Flue
Hot gases escape via the flue, which is located at the top of the cylinder, chimney, or venting system. It is designed to create a path for the exhaust gases and not allow them back inside the space being lived in. Combined with the chimney, the flue is responsible for setting up proper airflow for combustion by pulling air in and exhaust gases out.
Working of Horizontal Fire Tube Boiler
Fuel is burned inside the horizontal fire tube boiler furnace to generate high-temperature flue gas. The gas travels through the fire tubes and transmits heat to the surrounding water. This is the steam or boiled water created as the water temperature rises. Steam may be used to drive machinery or industrial processes, while water can be used for heating or other purposes. Finally, the flue releases exhaust gases into the atmosphere.
Various types of horizontal fire tube boilers exist, each with distinct characteristics and uses:
4.1 Cornish Boiler
They are typically used as models for their ubiquitous hordes of powerful stationary steam engines. The Cornish Boiler has a cylindrical shell and a single large flue that runs the length of the boiler between it. The one end houses the firebox, and the flue gases travel through the flue and a series of tubes before venting to the atmosphere via a chimney. The design of this corrupt system makes heat transfer and combustion very efficient.
4.2 Locomotive Boiler
It is used for Boilin locomotives and is a horizontally placed cylindrical boiler. The firebox is located at one end, where the flue gases flow through a series of fire tubes and exit through a smokebox. The design ensures effective, rapid heat transfer and steam production.
4.3 Scotch Marine Boiler
Commonly used in boiler ships and industrial applications, the Scotch marine Boiler. It consists of a cylindrical shell containing two or more large flue tubes surrounded by water. Combustion hot gases flow through these tubes, heating the water and producing steam. This Boiler has Boilerustconstruction, meaning it simply has high efficiency with high pressures.
4.4 Horizontal Return Tubular (HRT) Boiler
HRT boiler is the earliest and simplest type of horizontal fire tube boiler. Its basic structure is a horizontally mounted cylindrical shell with several fire tubes. Hot gases pass through these tubes, heating nearby water and producing steam. The HRT boiler is durable, simple, and facile to maintain.
Horizontal Fire-Tube Boilers — Advantages and Disadvantages
5.1 Advantages
- Space-Saving Design: The horizontal configuration means these boilers can be installed in compact locations.
- Facile to Maintain: Fire tube arrangement makes it facile to access and maintain.
- Rapid Steam Production: These boilers can produce steam rapidly, making them suitable for applications that need a steam supply on demand.
- Economic Sluggishness: They are cost-effective compared to other larger and heavy-duty boilers, and therefore largely used for small to medium manufacturing industries.
5.2 Disadvantages
Limited Steam Pressure: Such a boiler is not suitable for high-pressure applications.
Reduced Efficiency: They are less efficient at generating steam, using more fuel to produce the same amount.
Sensitive to Scaling: Water impurities can lead to scaling, necessitating periodic maintenance and water treatment.
Limited Capacity: These are not ideal for applications that require large amounts of steam.
Vertical And Horizontal Fire Tube Boiler Differences
6.1 Layout Structure
In the case of horizontal boilers, the furnace and combustion chamber of the boiler body are located at both ends, and the flue is at the top. They’re known to have independent combustion chambers and flues, which means they need to get heat off one pipe and into another.
6.2 Scope of Application
Horizontal boilers are well adapted to small enterprises and dwellings, as they have a quick heating period and small external dimensions. Preferred Options: Vertical Boiler for higher output and efficiency (larger industrial applications)
6.3 Thermal Efficiency
Compared with horizontal boilers, the thermal efficiency is high, the combustion is thorough, the heating is fast, and the fuel economy is strong. Vertical boiler efficiency is lower and requires adjustment during operation.
6.4 Space Occupancy
Horizontal boilers occupy less area, making them a perfect fit for confined environments. Vertical boilers occupy more area and should ideally be installed in places where space is not a constraint.
Specific Case: EPCB’s WNS Series Horizontal Boiler
7.1 General Introduction
WNS series is a wet-back-type horizontal fire tube boiler that can be used for different fuels, such as heavy, light, natural, and city gas. It has low power consumption, a wide load regulation range, and completely automatic control.
7.2 Design Concept
The WNS boiler produced by EPCB uses an innovative “excellent flame compensation” design, which matches the burner’s flame parameters with the combustion chamber. This increases steam and water space, allows for stable operation during instantaneous demand peaks, and enhances heat transfer efficiency.
7.3 Key Features
Three-Pass Design–For more efficient heat transfer.
- Periodic surface profile: Airflow is disturbed and refocused around the pipes, strengthening the heat exchange process.
- Endure Stainless Steel Casing: Provides durability and corrosion resistance.
- Safety guaranteed by double layer sealing: Prevent gas leakage.
Conclusion
Industries that need horizontal fire tube boilers require compact, effective, and inexpensive steam generation. Although these boilers are limited to high-pressure applications, their advantages still make them preferable for small—to medium-sized enterprises. These boilers will evolve with continuous technological advancements, catering to diverse industrial needs.
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