Superheated steam boilers

Most boilers produce steam to be used at saturation temperature; that is, saturated steam. Superheated steam boilers vaporize the water and then further heat the steam in a superheater. This provides steam at much higher temperature, but can decrease the overall thermal efficiency of the steam generating plant because the higher steam temperature requires a higher flue gas exhaust temperature. There are several ways to circumvent this problem, typically by providing an economizer that heats the feed water, a combustion air heater in the hot flue gas exhaust path, or both. There are advantages to superheated steam that may, and often will, increase overall efficiency of both steam generation and its utilisation: gains in input temperature to a turbine should outweigh any cost in additional boiler complication and expense. There may also be practical limitations in using wet steam, as entrained condensation droplets will damage turbine blades.

Superheated steam presents unique safety concerns because, if any system component fails and allows steam to escape, the high pressure and temperature can cause serious, instantaneous harm to anyone in its path. Since the escaping steam will initially be completely superheated vapor, detection can be difficult, although the intense heat and sound from such a leak clearly indicates its presence.

Superheater operation is similar to that of the coils on an air conditioning unit, although for a different purpose. The steam piping is directed through the flue gas path in the boiler furnace. The temperature in this area is typically between 1,300–1,600 degree Celsius (2,372–2,912 °F). Some superheaters are radiant type; that is, they absorb heat by radiation. Others are convection type, absorbing heat from a fluid such as a gas. Some are a combination of the two types. Through either method, the extreme heat in the flue gas path will also heat the superheater steam piping and the steam within. While the temperature of the steam in the superheater rises, the pressure of the steam does not: the turbine or moving pistons offer a continuously expanding space and the pressure remains the same as that of the boiler.[5] Almost all steam superheater system designs remove droplets entrained in the steam to prevent damage to the turbine blading and associated piping.

Industrial cooling towers

Industrial cooling towers can be used to remove heat from various sources such as machinery or heated process material. The primary use of large, industrial cooling towers is to remove the heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semi-conductor plants, and for other industrial facilities such as in condensers of distillation columns, for cooling liquid in crystallization, etc. The circulation rate of cooling water in a typical 700 MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic metres an hour (315,000 U.S. gallons per minute) and the circulating water requires a supply water make-up rate of perhaps 5 percent (i.e., 3,600 cubic metres an hour).

If that same plant had no cooling tower and used once-through cooling water, it would require about 100,000 cubic metres an hour and that amount of water would have to be continuously returned to the ocean, lake or river from which it was obtained and continuously re-supplied to the plant. Furthermore, discharging large amounts of hot water may raise the temperature of the receiving river or lake to an unacceptable level for the local ecosystem. Elevated water temperatures can kill fish and other aquatic organisms. (See thermal pollution.) A cooling tower serves to dissipate the heat into the atmosphere instead and wind and air diffusion spreads the heat over a much larger area than hot water can distribute heat in a body of water. Some coal-fired and nuclear power plants located in coastal areas do make use of once-through ocean water. But even there, the offshore discharge water outlet requires very careful design to avoid environmental problems.

Petroleum refineries also have very large cooling tower systems. A typical large refinery processing 40,000 metric tonnes of crude oil per day (300,000 barrels per day) circulates about 80,000 cubic metres of water per hour through its cooling tower system.

Cooling towers

All thermal power plants produce waste heat energy as a byproduct of the useful electrical energy produced. The amount of waste heat energy equals or exceeds the amount of electrical energy produced. Gas-fired power plants can achieve 50%* conversion efficiency while coal and oil plants achieve around 30-49%*. The waste heat produces a temperature rise in the atmosphere which is small compared to that of greenhouse-gas emissions from the same power plant. Natural draft wet cooling towers at nuclear power plants and at some large fossil fuel fired power plants use large hyperbolic chimney-like structures (as seen in the image at the left) that release the waste heat to the ambient atmosphere by the evaporation of water (lower left image). However, the mechanical induced-draft or forced-draft wet cooling towers (as seen in the image to the right) in many large thermal power plants, nuclear power plants, fossil fired power plants, petroleum refineries, petrochemical plants, geothermal, biomass and waste to energy plants use fans to provide air movement upward through downcoming water and are not hyperbolic chimney-like structures. The induced or forced-draft cooling towers are typically rectangular, box-like structures filled with a material that enhances the contacting of the upflowing air and the downflowing water.

In areas with restricted water use a dry cooling tower or radiator, directly air cooled, may be necessary, since the cost or environmental consequences of obtaining make-up water for evaporative cooling would be prohibitive. These have lower efficiency and higher energy consumption in fans than a wet, evaporative cooling tower.

Where economically and environmentally possible, electric companies prefer to use cooling water from the ocean, or a lake or river, or a cooling pond, instead of a cooling tower. This type of cooling can save the cost of a cooling tower and may have lower energy costs for pumping cooling water through the plant's heat exchangers. However, the waste heat can cause the temperature of the water to rise detectably. Power plants using natural bodies of water for cooling must be designed to prevent intake of organisms into the cooling cycle. A further environmental impact would be organisms that adapt to the warmer plant water and may be injured if the plant shuts down in cold weather.

In recent years, recycled wastewater, or grey water, has been used in cooling towers. The Calpine Riverside and the Calpine Fox power stations in Wisconsin as well as the Calpine Mankato power station in Minnesota are among these facilities.

Fairbairn's five-tube boiler

William Fairbairn's work on the Lancashire boiler had demonstrated the efficiency virtues of multiple furnaces relative to a reduced water volume. It was also widely understood that higher steam pressures improved the efficiency of engines. Fairbairn's research on the strength of cylinders led him to design another improved boiler, based around far-smaller tube diameters, which would thus be able to operate at higher pressures, typically 150 psi (10 atm). This was the "five tube" boiler, whose five tubes were arranged in two nested pairs as water drum and furnace, with the remaining tube mounted above them as a separate steam drum. The water volume was extremely low compared to previous boiler designs, as the furnace tubes almost filled each of the water drums.

The boiler was successful according to its goals and provided two large furnaces in a small water capacity. The separate steam drum also aided the production of "dry" steam, without the carryover of water and risk of priming. However it was also complex to manufacture, and did not offer a great deal of heating area for the work involved. It was soon superseded by multi-tube boilers such as the locomotive and the Scotch boilers.