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.

Lancashire boiler

The Lancashire boiler is similar to the Cornish, but has two large flues containing the fires instead of one. It is generally considered to be the invention of William Fairbairn in 1844, although his patent was for the method of firing the furnaces alternately, so as to reduce smoke, rather than the boiler itself. Stephenson's early 0-4-0 locomotive "Lancashire Witch" had already demonstrated the use of twin furnace tubes within a boiler 15 years earlier.

Fairbairn had made a theoretical study of the thermodynamics of more efficient boilers, and it was this that had led him to increase the furnace grate area relative to the volume of water. A particular reason for this was the so-far poor adoption of the Cornish boiler in the cotton mills of Lancashire, where the harder local coal couldn't be burned satisfactorily in the smaller furnace, in favour of the older low-pressure wagon boiler and its large grate.[8]

The difficulties of the Cornish boiler were that a boiler of any particular power would require a known area of furnace tube as the heating area. Longer tubes required a longer and more expensive boiler shell. They also reduced the ratio of grate area relative to the heating area, making it difficult to maintain an adequate fire. Increasing the tube diameter reduced the depth of water covering the furnace tube and so increased the need for accurate control of water level by the fireman, or else the risk of boiler explosion. Fairbairn's studies of hoop stress in cylinders also showed that smaller tubes were stronger than larger tubes. His solution was simple: to replace one large furnace tube with two smaller ones.

The patent showed another advantage of twin furnaces. By firing them alternately and closing the firebox door between firings, it was also possible to arrange a supply of air past the furnace (in the case of a Lancashire boiler, through the ashpan beneath the grate) which would encourage the flue gases produced by the fire to burn more completely and cleanly, thus reducing smoke and pollution. A key factor in this was the distinctive shuttered rotating air damper in the door, which became a feature from the 1840s.

Steam turbine generator

The turbine generator consists of a series steam turbines interconnected to each other and a generator on a common shaft. There is a high pressure turbine at one end, followed by an intermediate pressure turbine, two low pressure turbines, and the generator. As steam moves through the system and loses pressure and thermal energy it expands in volume, requiring increasing diameter and longer blades at each succeeding stage to extract the remaining energy. The entire rotating mass may be over 200 metric tons and 100 feet (30 m) long. It is so heavy that it must be kept turning slowly even when shut down (at 3 rpm) so that the shaft will not bow even slightly and become unbalanced. This is so important that it is one of only five functions of blackout emergency power batteries on site. Other functions are emergency lighting, communication, station alarms and turbogenerator lube oil.

Superheated steam from the boiler is delivered through 14–16-inch (360–410 mm) diameter piping to the high pressure turbine where it falls in pressure to 600 psi (4.1 MPa) and to 600 °F (320 °C) in temperature through the stage. It exits via 24–26-inch (610–660 mm) diameter cold reheat lines and passes back into the boiler where the steam is reheated in special reheat pendant tubes back to 1,000 °F (500 °C). The hot reheat steam is conducted to the intermediate pressure turbine where it falls in both temperature and pressure and exits directly to the long-bladed low pressure turbines and finally exits to the condenser.

The generator, 30 feet (9 m) long and 12 feet (3.7 m) in diameter, contains a stationary stator and a spinning rotor, each containing miles of heavy copper conductor—no permanent magnets here. In operation it generates up to 21,000 amperes at 24,000 volts AC (504 MWe) as it spins at either 3,000 or 3,600 rpm, synchronized to the power grid. The rotor spins in a sealed chamber cooled with hydrogen gas, selected because it has the highest known heat transfer coefficient of any gas and for its low viscosity which reduces windage losses. This system requires special handling during startup, with air in the chamber first displaced by carbon dioxide before filling with hydrogen. This ensures that the highly explosive hydrogen–oxygen environment is not created.

The power grid frequency is 60 Hz across North America and 50 Hz in Europe, Oceania, Asia and parts of Africa.

Steam condensing

The condenser condenses the steam from the exhaust of the turbine into liquid to allow it to be pumped. If the condenser can be made cooler, the pressure of the exhaust steam is reduced and efficiency of the cycle increases. The condenser is usually a shell and tube heat exchanger commonly referred to as a surface condenser. Cooling water circulates through the tubes in the condenser's shell and the low pressure exhaust steam is condensed by flowing over the tubes as shown in the adjacent diagram. The tubing is designed to reduce the exhaust pressure, avoid subcooling the condensate and provide adequate air extraction. Typically the cooling water causes the steam to condense at a temperature of about 35 °C (95 °F) and that creates an absolute pressure in the condenser of about 2–7 kPa (0.59–2.1 inHg), i.e. a vacuum of about -95 kPa (-28.1 inHg) relative to atmospheric pressure. The large decrease in volume that occurs when water vapor condenses to liquid creates the low vacuum that helps pull steam through and increase the efficiency of the turbines. The limiting factor is the temperature of the cooling water and that, in turn, is limited by the prevailing average climatic conditions at the power plant's location (it may be possible to lower the temperature beyond the turbine limits during winter, causing excessive condensation in the turbine).

From the bottom of the condenser, powerful condensate pumps recycle the condensed steam (water) back to the water/steam cycle.
A Marley mechanical induced draft cooling tower

The heat absorbed by the circulating cooling water in the condenser tubes must also be removed to maintain the ability of the water to cool as it circulates. This is done by pumping the warm water from the condenser through either natural draft, forced draft or induced draft cooling towers (as seen in the image to the right) that reduce the temperature of the water by evaporation, by about 11 to 17 °C (20 to 30 °F)—expelling waste heat to the atmosphere. The circulation flow rate of the cooling water in a 500 MWe unit is about 14.2 m³/s (225,000 US gal/min) at full load.

The condenser tubes are made of brass or stainless steel to resist corrosion from either side. Nevertheless they may become internally fouled during operation by bacteria or algae in the cooling water or by mineral scaling, all of which inhibit heat transfer and reduce thermodynamic efficiency. Many plants include an automatic cleaning system that circulates sponge rubber balls through the tubes to scrub them clean without the need to take the system off-line.

The cooling water used to condense the steam in the condenser returns to its source without having been changed other than having been warmed. If the water returns to a local water body (rather than a circulating cooling tower), it is tempered with cool 'raw' water to prevent thermal shock when discharged into that body of water.

Fuel processing

Coal is prepared for use by crushing the rough coal to pieces less than 2 inches (5 cm) in size. The coal is then transported from the storage yard to in-plant storage silos by rubberized conveyor belts at rates up to 4,000 short tons per hour.

In plants that burn pulverized coal, silos feed coal pulverizers that take the larger 2-inch pieces, grind them to the consistency of face powder, sort them, and mix them with primary combustion air which transports the coal to the furnace and preheats the coal to drive off excess moisture content. A 500 MWe plant may have six such pulverizers, five of which can supply coal to the furnace at 250 tons per hour under full load.

In plants that do not burn pulverized coal, the larger 2-inch pieces may be directly fed into the silos which then feed the cyclone burners, a specific kind of combustor that can efficiently burn larger pieces of fuel.

Fossil fuel power station

A fossil-fuel power station is a power station that burns fossil fuels such as coal, natural gas or petroleum (oil) to produce electricity.

Fossil-fuel power station are designed on a large scale for continuous operation. In many countries, such plants provide most of the electrical energy used.

Fossil fuel power stations have some kind of rotating machinery to convert the heat energy of combustion into mechanical energy, which then operate an electrical generator. The prime mover may be a steam turbine, a gas turbine or, in small isolated plants, a reciprocating internal combustion engine. Some thermal plants have the intermediate step of using the heat from combustion to produce steam, reducing overall efficiency of electricity production. All plants use the drop between the high pressure and temperature of the steam or combusting fuel and the lower pressure of the atmosphere or condensing vapour in the steam turbine.

Byproducts of power thermal plant operation need to be considered in both the design and operation. Sometimes waste heat due to the finite efficiency of the power cycle, when not recovered and sold as steam or hot water, must be released to the atmosphere, often using a cooling tower, or river or lake water as a cooling medium, especially for condensing steam. The flue gas from combustion of the fossil fuels is discharged to the air; this contains carbon dioxide and water vapour, as well as other substances such as nitrogen, nitrogen oxides, sulfur oxides, and (in the case of coal-fired plants) fly ash and mercury. Solid waste ash from coal-fired boilers must also be removed, although some coal ash can be recycled for building materials.

Fossil fueled power stations are major emitters of greenhouse gases (GHG) which according to the consensus of scientific organisations are a major contributor to the global warming observed over the last 100 years. Brown coal emits 3 times as much GHG as natural gas, black coal emits twice as much. Efforts exist to use carbon capture and storage of emissions but these are not expected to be available on a commercial scale and economically viable basis by 2025.

Gas turbine combined-cycle plants

One type of fossil fuel power plant uses a gas turbine in conjunction with a heat recovery steam generator (HRSG). It is referred to as a combined cycle power plant because it combines the Brayton cycle of the gas turbine with the Rankine cycle of the HRSG. The thermal efficiency of these plants has reached a record heat rate of 5690 Btu/(kW·h), or just under 60%, at a facility in Baglan Bay, Wales.

The turbines are fueled either with natural gas, syngas or fuel oil. While more efficient and faster to construct (a 1,000 MW plant may be completed in as little as 18 months from start of construction), the economics of such plants is heavily influenced by the volatile cost of fuel, normally natural gas. The combined cycle plants are designed in a variety of configurations composed of the number of gas turbines followed by the steam turbine. For example, a 3-1 combined cycle facility has three gas turbines tied to one steam turbine. The configurations range from (1-1), (2-1), (3-1), (4-1), (5-1), to (6-1)

Simple-cycle or open cycle gas turbine plants, without a steam cycle, are sometimes installed as emergency or peaking capacity; their thermal efficiency is much lower. The high running cost per hour is offset by the low capital cost and the intention to run such units only a few hundred hours per year. Other gas turbine plants are installed in stages, with an open cycle gas turbine the first stage and additional turbines or conversion to a closed cycle part of future project plans.

Haycock and wagon top boilers

For the first Newcomen engine of 1712, the boiler was little more than large brewer’s kettle installed beneath the power cylinder. Because the engine’s power was derived from the vacuum produced by condensation of the steam, the requirement was for large volumes of steam at very low pressure hardly more than 1 psi (6.9 kPa) The whole boiler was set into brickwork which retained some heat. A voluminous coal fire was lit on a grate beneath the slightly dished pan which gave a very small heating surface; there was therefore a great deal of heat wasted up the chimney. In later models, notably by John Smeaton, heating surface was considerably increased by making the gases heat the boiler sides, passing through a flue. Smeaton further lengthened the path of the gases by means of a spiral labyrinth flue beneath the boiler. These under-fired boilers were used in various forms throughout the 18th Century. Some were of round section (haycock). A longer version on a rectangular plan was developed around 1775 by Boulton and Watt . This is what is today known as a three-pass boiler, the fire heating the underside, the gases then passing through a central square-section tubular flue and finally around the boiler sides.

Return-flue boilers

A simple flue must be long if it is to offer adequate heating area. In a short boiler shell, such as required for a steam locomotive, this may be done by using a U-shaped return flue that bends back on itself.

Richard Trevithick had already used a return flue with his first 1802 Pen-y-darren engine and 1803 Coalbrookdale locomotive design. These boilers were heavily built of cast iron, short and flat-ended. His 1805 "Newcastle" locomotive began to show one characteristic feature of the return-flued boiler, a prominent dome shape to resist steam pressure in the solid end opposite both furnace and chimney. In this case, the boilermaking, now of wrought iron plates, must have been complicated by Trevithick's single long-travel horizontal cylinder (9 inch diameter × 36 inch stroke) which emerged through this domed end. This did make work easier for the fireman though, as he was no longer trying to reach a firedoor beneath the long crosshead of the piston.

William Hedley used this pattern of boiler for his 1813 locomotives Puffing Billy and Wylam Dilly. Through the Wylam colliery and its owner Christopher Blackett, Hedley would have been familiar with Trevithick's engine.

Power station

A power station is an industrial facility for the generation of electric power.

Power plant is also used to refer to the engine in ships, aircraft and other large vehicles. Some prefer to use the term energy center because it more accurately describes what the plants do, which is the conversion of other forms of energy, like chemical energy, gravitational potential energy or heat energy into electrical energy. However, power plant is the most common term in the U.S, while elsewhere power station and power plant are both widely used, power station prevailing in many Commonwealth countries and especially in the United Kingdom.

At the center of nearly all power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field and a conductor. The energy source harnessed to turn the generator varies widely. It depends chiefly on which fuels are easily available and on the types of technology that the power company has access to.

Geothermal heat pump

In the geothermal industry, low temperature means temperatures of 300 °F (149 °C) or less. Low-temperature geothermal resources are typically used in direct-use applications, such as district heating, greenhouses, fisheries, mineral recovery, and industrial process heating. However, some low-temperature resources can generate electricity using binary cycle electricity generating technology.

Approximately 70 countries made direct use of 270 petajoules (PJ) of geothermal heating in 2004. More than half went for space heating, and another third for heated pools. The remainder supported industrial and agricultural applications. Global installed capacity was 28 GW, but capacity factors tend to be low (30% on average) since heat is mostly needed in winter. The above figures are dominated by 88 PJ of space heating extracted by an estimated 1.3 million geothermal heat pumps with a total capacity of 15 GW.[1] Heat pumps for home heating are the fastest-growing means of exploiting geothermal energy, with a global annual growth rate of 30% in energy production.[9]

Direct heating is far more efficient than electricity generation and places less demanding temperature requirements on the heat resource. Heat may come from co-generation via a geothermal electrical plant or from smaller wells or heat exchangers buried in shallow ground. As a result, geothermal heating is economic at many more sites than geothermal electricity generation. Where natural hot springs are available, the heated water can be piped directly into radiators. If the ground is hot but dry, earth tubes or downhole heat exchangers can collect the heat. But even in areas where the ground is colder than room temperature, heat can still be extracted with a geothermal heat pump more cost-effectively and cleanly than by conventional furnaces. These devices draw on much shallower and colder resources than traditional geothermal techniques, and they frequently combine a variety of functions, including air conditioning, seasonal energy storage, solar energy collection, and electric heating. Geothermal heat pumps can be used for space heating essentially anywhere.

Geothermal heat supports many applications. District heating applications use networks of piped hot water to heat many buildings across entire communities. In Reykjavík, Iceland, spent water from the district heating system is piped below pavement and sidewalks to melt snow.Geothermal desalination has been demonstrated.

Coal

Coal is a readily combustible black or brownish-black sedimentary rock normally occurring in rock strata in layers or veins called coal beds. The harder forms, such as anthracite coal, can be regarded as metamorphic rock because of later exposure to elevated temperature and pressure. Coal is composed primarily of carbon along with variable quantities of other elements, chiefly sulfur, hydrogen, oxygen and nitrogen.

Coal begins as layers of plant matter accumulate at the bottom of a body of water. For the process to continue the plant matter must be protected from biodegradation and oxidization, usually by mud or acidic water. The wide shallow seas of the Carboniferous period provided such conditions. This trapped atmospheric carbon in the ground in immense peat bogs that eventually were covered over and deeply buried by sediments under which they metamorphosed into coal. Over time, the chemical and physical properties of the plant remains (believed to mainly have been fern-like species antedating more modern plant and tree species) were changed by geological action to create a solid material.

Coal, a fossil fuel, is the largest source of energy for the generation of electricity worldwide, as well as one of the largest worldwide anthropogenic sources of carbon dioxide emissions. Gross carbon dioxide emissions from coal usage are slightly more than those from petroleum and about double the amount from natural gas.Coal is extracted from the ground by mining, either underground or in open pits.

Solar power

A solar photovoltaic power plant uses photovoltaic cells to convert sunlight into direct current electricity using the photoelectric effect. This type of plant does not use rotating machines for energy conversion.

Solar thermal power plants are another type of solar power plant. They use either parabolic troughs or heliostats to direct sunlight onto a pipe containing a heat transfer fluid, such as oil. The heated oil is then used to boil water into steam, which turns a turbine that drives an electrical generator. The central tower type of solar thermal power plant uses hundreds or thousands of mirrors, depending on size, to direct sunlight onto a receiver on top of a tower. Again, the heat is used to produce steam to turn turbines that drive electrical generators.

There is yet another type of solar thermal electric plant. The sunlight strikes the bottom of a water pond, warming the lowest layer of water which is prevented from rising by a salt gradient. A Rankine cycle engine exploits the temperature difference in the water layers to produce electricity.

Not many solar thermal electric plants have been built. Most of them can be found in the Mojave Desert of the United States although Sandia National Laboratory (again in the United States), Israel and Spain have also built a few plants.

Thermal power station

In thermal power stations, mechanical power is produced by a heat engine that transforms thermal energy, often from combustion of a fuel, into rotational energy. Most thermal power stations produce steam, and these are sometimes called steam power stations. Not all thermal energy can be transformed into mechanical power, according to the second law of thermodynamics. Therefore, there is always heat lost to the environment. If this loss is employed as useful heat, for industrial processes or district heating, the power plant is referred to as a cogeneration power plant or CHP (combined heat-and-power) plant. In countries where district heating is common, there are dedicated heat plants called heat-only boiler stations. An important class of power stations in the Middle East uses by-product heat for the desalination of water.

The efficiency of a steam turbine is limited by the maximum temperature of the steam produced and is not directly a function of the fuel used. For the same steam conditions, coal, nuclear and gas power plants all have the same theoretical efficiency. Overall, if a system is on constantly (base load) it will be more efficient than one that is used intermittently(peak load).

Besides use of reject heat for process or district heating, one way to improve overall efficiency of a power plant is to combine two different thermodynamic cycles. Most commonly, exhaust gases from a gas turbine are used to generate steam for a boiler and steam turbine. The combination of a "top" cycle and a "bottom" cycle produces higher overall efficiency than either cycle can attain alone.

Flued boiler

A shell or flued boiler is an early, and relatively simple, form of boiler used to make steam, usually for the purpose of driving a steam engine. The design marked a transitional stage in boiler development, between the early haystack boilers and the later multi-tube fire-tube boilers. A flued boiler is characterized by a large cylindrical boiler shell forming a tank of water, traversed by one or more large flues containing the furnace. These boilers appeared in the early part of the 19th century and some forms remain in service today. Although mostly used for static steam plants, some were used in early steam vehicles, railway locomotives and ships.

Flued boilers were developed in an attempt to raise steam pressures and improve engine efficiency. Early haystack designs of Watt's day were mechanically weak and often presented an unsupported flat surface to the fire. Boiler explosions, usually beginning with failure of this firebox plate, were common. It was known that an arched structure was stronger than a flat plate and so a large circular flue tube was placed inside the boiler shell. The fire itself was on an iron grating placed across this flue, with a shallow ashpan beneath to collect the non-combustible residue. This had the additional advantage of wrapping the heating surface closely around the furnace, but that was a secondary benefit.

Although considered as low-pressure today, this was regarded as high pressure compared to its predecessors. This increase in pressure was a major factor in making locomotives such as Trevithick's into a practical proposition.

Cornish boiler

The simplest form of flued boiler was Richard Trevithick's "high-pressure" Cornish boiler, first installed at Dolcoath mine in 1812. This is a long horizontal cylinder with a single large flue containing the fire. As the furnace relied on natural draught, a tall chimney was required at the far end of the flue to encourage a good supply of air (oxygen) to the fire.

For efficiency, Trevithick's innovation was to encase beneath the boiler with a brick-built chamber. Exhaust gases passed through the central flue and then routed outside and around the iron boiler shell. To keep the chimney clear of the firing space, the brick flue passed first underneath the centre of the boiler to the front face, then back again along the sides and to the chimney.

Cornish boilers had several advantages over the preceding wagon boilers: they were composed of mostly curved surfaces, better to resist the pressure. Their flat ends were smaller than the flat sides of the wagon boiler and were stayed by the central furnace flue, and sometimes by additional long rod stays. A less obvious advantage was that of boiler scale. Wagon or haystack boilers were heated from beneath and any scale or impurities that formed a sediment settled upon this plate, insulating it from the water. This reduced heating efficiency and could in extremis lead to local overheating and failure of the boiler plates. In the flued boiler, any sediment fell past the furnace flue and settled out at the bottom of the boiler shell, where it had less effect.

In model engineering, the Cornish boiler, particularly when fitted with Galloway tube is an excellent choice for gas-fired boilers and model steam boats. It is simple to build and as efficient as any small-scale boiler.

Butterley Boiler

The Butterley or "whistle mouth" boiler is a little-known design derived from the Cornish pattern, produced by the noted Butterley boilerworks of Derbyshire. It is basically a Cornish boiler with the lower half of the shell around the furnace removed, so as to permit a large fire to be lit. This made it popular in the textile mills of the Pennines, where the hard Northern coal was of less calorific value than the Welsh coal used in the South West and required a larger fire. Alternatively it may be considered as a shortened Cornish boiler with a waggon boiler placed in front of it with a larger fire beneath that. It suffers the same drawback as the wagon boiler: the concave firebox plate is mechanically weak and this either limits the working pressure or requires extra mechanical staying.