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This paper is concerned with boilers and feed systems in power stations of relatively modern design—in general, those commissioned since 1945. The author considers a number of inter‐related factors, commonly accepted as being influential in corrosion, in relation to boiler‐water and feed‐water control. These factors are: boiler design, insoluble boiler deposits, chemical conditions of boiler water and feed water, low‐load and off‐load water conditions and hide‐out.

Corrosion problems in low‐pressure boiler plant systems arise chiefly in the following system components:— (i) Water Side of Boiler (Internal). (ii) Fire Side of Boiler (External). (iii) Boiler Chimney. This article discusses corrosion problems relating to low‐pressure steam boilers operating at a maximum pressure of 200 psi, space heating boilers operating on closed water circuit and domestic hot water boilers operating on a direct tap‐water circuit.

The inspection of steam plant by Engineer Surveyors, either in accordance with statutory regulations when out of service, under working conditions, or at times of trouble, often reveals instances of corrosion. In the past, pitting and corrosion was a regular feature in practically all shell boilers, and not uncommon in watertube boilers, but in recent times this has become comparatively rare. This in itself is a tribute to the realisation, with the advent of the package boiler, of the necessity for boiler feedwater treatment and the maintenance of satisfactory conditions in boiler water in the lower pressure range.

Introduction Of the aspects of corrosion observed during the nineteenth century, those associated with boiler corrosion received the most systematic and exhaustive investigations. The main reason for this was that corrosion was one of the causes of boiler explosions and these caused many deaths during this period.

The purpose of this paper is to study the effect of a computational grid in computational fluid dynamics‐based mathematical modeling, focusing on but not limiting the attention to industrial‐scale boilers.

A full boiler model is used to show the difficulties related to judging iteration and discretization errors in boiler modeling. Then, a single jet is studied in detail to determine the proper degree of local grid refinement required in the vicinity of jets in the full boiler model. Both a nonreactive axisymmetric jet exhausting into a quiescent atmosphere and a reactive jet exhausting into a crossfiow are studied.

Over two million computational cells are required for the grid‐independent solution for a single jet. Local grid refinement is shown to be a good option for improving the results consistently without an excessive increase in the number of computational cells. Using relatively coarse grids of tetrahedral cells with a finite‐volume‐based solver may cause serious errors in results, typically by overpredicting the jet spreading rate and underpredicting the mean axial centerline velocity. Relatively coarse grids of hexahedral cells are less prone to error in a case where a jet exhausts into a quiescent atmosphere. However, their performance deteriorates when a crossfiow is introduced. As assumed, the differences in the predicted reaction rate and species concentrations are significant in the reactive case. It is confirmed that the standard k‐ε model tends to overpredict the axisymmetric jet spreading rate. The estimated inlet turbulence intensity is not among the most critical factors in modeling. Estimations of the axisymmetric jet centerline velocity from the analytical correlation may not coincide with the modeling results.

The error caused by the computational grid may easily dominate the errors caused by simplifying models used in industrial‐scale boiler modeling (turbulence, combustion, radiative heat transfer, etc.).

The present study deals with grid independency issues in industrial‐scale boiler modeling in a systematic and profound manner.

The purpose of this paper is to show possible approaches which can be used for modeling complex flow phenomena caused by swirl burners combined with simulating coal combustion process using air- and oxy-combustion technologies. Additionally, the response of exist boiler working parameter on changing the oxidizer composition from air to a mixture of the oxygen and recirculated flue gases is investigated. Moreover, the heat transfer in the superheaters section of the boiler was taken into account by modeling of the heat exchange process between continuum phase and three stages of the steam superheaters.

An accurate solution of the flow field is required in order to predict combustion phenomena correctly for numerical simulations of the industrial pulverized coal (PC) boilers. Nevertheless, it is a very demanding task due to the complicated swirl burner construction and complex character of the flow. The presented simulations were performed using the discrete phase model for tracking particles and combustion phenomena in a dispersed phase, whereas the Eulerian approach was applied for the volatile combustion process modeling in a gaseous phase.

Applying the air- to oxy-combustion technology the temperature in the combustion chamber, decreased for investigated oxidizer compositions. This was caused by the higher heat capacity of flue gases which also influences on the level of the heat flux at the boiler walls. Simulations shows that increasing the O₂ concentration to 30 percent of volume base in the oxidizer mixture provided the similar combustion conditions as those for the conventional air firing. Moreover, the evaluated results give a good overview of differences between approaches used for complex swirl burners simulations.

Nowadays, the numerical techniques such as computational fluid dynamic (CFD) can be seen as an useful engineering tool for design and processes optimization purposes. The application of the CFD gives a possibility to predict the combustion phenomena in a large industrial PC boiler and investigate the impact of changing the combustion technology from a conventional air firing to oxy-fuel combustion.

This paper gives good overview on existing technique, approaches used for modeling PC boiler equipped with complex swirl burners. Additionally, the novelty of this work is application of the heat exchanger model for predicting heat loses in convective section of the boiler. This usually is not taken into account during simulations. The reader can also find basic concept of oxy-combustion technology, and their impact on boiler working conditions.

In a new build waste incinerator, the waste (refuse derived fuel) was burned on a discontinuous moving grate. Frequent furnace overpressure peaks occurred because of this firing method and as a result, flue gas and fly‐ash were pushed out of the boiler and into the building. During the plant start up period, a seal in a water‐feed pipeline broke, and a large amount of condensed steam was discharged into the boiler house. Shortly thereafter, very severe corrosion was noticed on the galvanised gangways, steel building components, the boiler aluminium sheeting and on processing lines. A theoretical study of the condensation of the flue gas indicated that sulphuric acid would condense before it reached the external aluminium sheeting and that under normal conditions, dry hydrochloric acid fumes would be removed by the boiler house ventilators. However, the steam leakage had caused the hydrochloric acid to be dissolved in the condensed water and that had resulted in the severe corrosion damage, which had become evident subsequently.

Hot corrosion is the major degradation mechanism of failure of boiler and gas turbine components. The present work aims to investigate the hot corrosion resistance of detonation gun sprayed (D-gun) Cr₂O₃-75 per cent Al₂O₃ ceramic coating on ASTM-SA210-A1 boiler steel.

The coating exhibits nearly uniform, adherent and dense microstructure with porosity less than 0.8 per cent. Thermogravimetry technique is used to study the high temperature hot corrosion behavior of bare and coated boiler steel in molten salt environment (Na₂SO₄-60 per cent V₂O₅) at high temperature 900°C for 50 cycles. The corrosion products are analyzed by using X-ray diffraction, scanning electron microscopy (SEM) and field emission scanning electron microscope/energy-dispersive analysis (EDAX) to reveal their microstructural and compositional features for elucidating the corrosion mechanisms.

During investigations, it was found that the Cr₂O₃-75 per cent Al₂O₃ coating on Grade A-1 boiler steel is found to be very effective in decreasing the corrosion rate in the molten salt environment at 900°C. The coating has shown lesser weight gains along with better adhesiveness of the oxide scales with the substrate till the end of the experiment. Thus, coatings serve as an effective diffusion barrier to preclude the diffusion of oxygen from the environment into the substrate boiler steel.

Therefore, it is concluded that the better hot corrosion resistance of the coating is due to the formation of desirable microstructural features such as very low porosity, uniform fine grains and the flat splat structures in the coating; as compared to the bare substrate under cyclic conditions.

This research is useful for coal-fired boilers and other power plant boilers.

This research is useful for power generation plants.

There is no reported literature on hot corrosion behavior of Cr₂O₃-75 per cent Al₂O₃ coating deposited on the selected substrates by D-gun spray technique. The present work has been focused to study the influence of the Cr₂O₃-75 per cent Al₂O₃ coating developed with D-gun spraying technique on high temperature corrosion behavior of ASTM-SA210-A-1 boiler steel in an aggressive environment of Na₂SO₄-60 per cent V₂O₅ molten salt at 900°C under cyclic conditions.

The purpose of this paper is to evaluate the energy, economic and environmental performance of commercial water heating systems in Hong Kong special administrative region (SAR), China.

The research team contacted 50 facilities managers in Hong Kong, and 16 of them agreed to participate in this territorial-wide survey. The overall efficiency of different water heating systems was determined through measurements of inlet water temperatures, outlet steam/water properties, the amount of steam/water produced and the amount of energy consumed. The cost effectiveness and the amount of greenhouse gases produced per megajoule (MJ) output were also determined.

Results show that electric water heating systems had the highest mean overall efficiency, followed by gas- and oil-fired systems. However, the difference between the mean overall efficiency of the three types of water heating systems was not statistically significant, as the systems had been inspected and maintained regularly. Oil-fired systems were found to be the most cost-effective when taking fuel prices into consideration. Environmental analysis showed that gas-fired systems produced the least amount of greenhouse gases per MJ output.

Water heating is one of the major uses of energy in buildings. Hence, the efficiency of a water heating system can have a significant effect on the overall performance of a building. This paper not only provides insight on the energy performance but it also evaluates the economic and environmental performance of water heating systems.

Combustion modifications to minimize NO_X emissions have magnified the importance of waterwall corrosion in coal‐fired boilers. The physics and chemistry controlling corrosion processes can be highly non‐linear and are challenging to describe in terms of their likely overall combustion behavior. This paper describes the application of a multi‐point, real time corrosion surveillance system to a large boiler firing high sulfur coal. This technology, incorporating electrochemical sensing and wireless signal transmission, enables combustion engineers and plant operating personnel to make informed decisions regarding the quantitative relationships between operating conditions, NO_X emissions, and any resultant extent/magnitude of waterwall corrosion.