M.S.

This research is concerned with the presentation of pressure drop experimental results across a restriction of trefoil geometry (tube support plate) used in steam generators. The pressure drops were obtained for single-phase and two-phase of air, water, and their mixtures. The tests were performed at atmospheric conditions (pressure and temperature). The loss coefficients associated with these pressure drops were experimentally determined, and empirical correlations for the results were developed. The results were compared with previous studies done on other geometries with air-water mixtures, and also to a similar geometry with steam-water mixture.

Master of Science

The importance of the feedwater problem and the meager knowledge of existing feedwater conditions make it desirable to conduct a study of boiler salines at the V.P.I. power plant. A determination of the critical concentrations of the boiler salines at various loads was to be made and an optimum operating concentration established. An investigation was to be made to determine the difference, if any, between the boiler salines taken from the steam drum and the boiler salines taken from the mud drum. A more efficient feedwater system was to be investigated. The ultimate purpose is, obviously, to improve the efficiency with which the water is used at the V.P.I. power plant. Besides the aid that such a study will be to the operators of the V.P.I. power plant, it is possible that men operating similar units elsewhere will also benefit by the information found. 1. The average concentration of total solids in the raw water was found to be 221 ppm. The average concentration of total solids in the feedwater was found to be 86 ppm. These values should be used in calculating boiler blow-down. 2. For a load of 25,000 lb./hr., carryover starts at a concentration of 4,500 ppm. Keeler Co. states that no trouble should be encountered under normal operation with a concentration of 3,500 ppm. The No. 5 Boiler can be safely operated at a concentration of 2,500 ppm. total solids. The boiler will operate at a concentration of 5,500 ppm. total solids if the load is constant. 3. A straight line relationship exists between methyl orange alkalinity and total solids. This is shown in Fig. 5. This graph should be used in the plant to convert “M. O.” to total solids. 4. Neither pH nor specific gravity should be used to control boiler saline concentration. 5. If foaming troubles are to be avoided, a method of rust removal from the feedwater must be found. 6. Boiler No. 5 should not be abused. Normal operation should involve no sudden increase in load in excess of 3,000 lb./hr. 7. Under present operating conditions, the blow-down should be reduced. 8. The proposed change should be adopted. / Master of Science

Master of Science

M.S.

M.S.

M.S.

In attempting to use the 4-1 mixture for Boiler No. 6 in the Virginia Polytechnic Institute Heating and Power Plant, the problem of maintaining proper depth of field bed had arisen. This problem seemed to warrant an investigation, which was subsequently made. The fuel bed depth that will give the best results for a boiler depends on many factors, and it is best determined by boiler tests. Therefore, the authors decided to investigate the effect of the field bed depth on the boiler performance and to determine the optimum field bed depth, when the 4-1 mixture was used and the load was 50,000 pounds of steam per hour. This investigation consisted of the collection and evaluation of data obtained from the boiler tests at various field bed depths. During the boiler tests, some of the variables were held as constant as possible in order to obtain comparative results. The fuel bed depths tested were 2-¾, 4, and 5-½ inches. The optimum depth of fuel bed is that fuel bed which would give the highest boiler efficiency and good boiler control. The results of the tests showed that the boiler efficiency remained approximately constant between 2-¾ and 4 inches of the fuel bed depths and decreased as the fuel bed depth was increased above 4 inches. But, at 2-¾ inches of the fuel bed, close attention was necessary to control the boiler, whenever the load swung, or there was a change of the quality of fuel fed into the furnace. The authors, therefore, conclude that Boiler No. 6 should have a fuel bed depth between 3 and 4 inches deep when the 4-1 mixture is used and the load is about 50,000 pounds of steam per hour. / Master of Science

The operating characteristics of a boiler prove that pressure can usually be maintained by the supply of fuel and air, regardless of the combustion efficiency; however, to achieve the desired efficiency the burning of the fuel must take place with a minimum amount of excess air. Thus the criterion for boiler operation becomes percent co. in the flue gas. With a CO₂ meter on the control board of the Number Six Boiler it became desirable to acquaint the boiler operators with the conditions in the boiler for a corresponding reading on the CO₂ meter. The percent CO₂ in the flue gas of Number Six Boiler has four effects on the operating characteristics of the boiler when operating under a steam demand of 50,000 pounds per hour. First, it effects the energy loss due to dry exit gases; second, it effects the energy loss due to unconsumed carbon in the refuse; third, it effects slagging and possible deterioration of the refractory walls in the combustion space, and last, it effects the temperature of the refuse as it is discharged from the grate. From a survey of the data obtained from the test runs a decrease in the energy loss due to dry flue gas is seen with an increase in the percentage of CO₂ in the exit gases. This indicates the desirability of operating the boiler at as high a CO₂ as possible in regard to losses occurring from dry flue gases. Similarly, the energy loss to unconsumed carbon in the refuse decreased with an increase in CO₂. Though this is contrary to results obtained in most boilers, the low CO₂, indicating a high excess air, resulted in the boiler being cooled below maximum combustion temperature; consequently, a high percentage of carbon in the refuse occurred with the low CO₂ This too indicates the desirability to operate the boiler at a high percent CO₂. The limiting factors on the maximum percent CO₂ at which the boiler can be operated, with a steam demand of 50,000 pounds per hour, occurred at 12.9 percent CO₂. At this condition the walls began to Slag. This can be harmful to the walls, eventually causing their replacement, an economical loss which would outweigh the slight advantage of increased efficiency when operating at this percent CO₂ over a long period of time. The test runs were not long enough to determine the maximum effect slag would have on the boiler walls; nevertheless, it was noted during the test that slag running off the walls caused the fuel bed to become distorted and that the slagging has necessitated replacing parts of the front wall. Another economical loss would result from the increase temperature of the refuse discharged from the grate when operating at a higher CO₂. Since the refuse is manually removed from the ash pit to the vacuum ash removal system, and since there is a limit to the temperature the operator can withstand and still remove the ashes efficiently, the hotter refuse requires a longer time to be pulled from the ash pit. An additional load of 4,000 pounds of steam per hour, therefore, must be carried over the prolonged period. The optimum percentage of CO₂ for a single boiler is that which will minimize the total losses due to dry flue gases and unconsumed carbon in the refuse and yet keep the refractory deterioration and temperature of the refuse as low as possible. The desirable percentage of CO₂ to be maintained in Number Six Boiler for operation at a load of 50,000 pounds of steam per hour is 12 percent. This allows a maximum feasible boiler efficiency of 73 percent and corresponds to an excess air of 39 percent. It is not feasible to operate the boiler above 12 percent CO₂ because of the increase cost of maintenance due to the formation of slag on the walls and the increased time required to remove the refuse. A CO₂ recorder is a desirable method of obtaining combustion efficiency when the same type of fuel is fired, but it requires periodical checks to maintain it in proper adjustment. / Master of Science