LITERATURE REVIEW

Insulation
Some of the important aspects of the insulating materials in boilers are as follows:
Unlike the refractory materials, which are substantially mineral-based and
therefore capable of withstanding the highest temperatures and erosion, the
insulation materials are no mineral (except for ceramic fibers), can stand up
to temperature no higher than 1650oC, and do not have any abrasion
resistance.
The insulating materials possess much lower heat conductivity, several times
lower than those of the refractory materials.
The insulating materials are fluffy and hold lot of air, which contributes to
the reduced heat flow.
Thermal conductivity for insulating materials rises steeply with temperature.
Insulation materials in boiler practice are available in mainly four forms:
1. Reformed shapes and slabs
2. Mattresses
3. Plastic cement
4. Loose fill
The insulating materials used in boilers are as follows:
1. Calcium silicate in block forms
2. Mineral/slag wool
3. Ceramic fiber
4. High-temperature plastic
a. Calcium silicate (CaSiO3) is a popular block insulation up to 650C, available in
preformed shapes or blocks. It is particularly suitable for piping and valves.
The blocks are ideal for insulating the hoppers and ducts from inside for metal
protection where there is no abrasive ash.
b. Mineral or slag or rock wool is made from blowing the slag produced in steel
mills into fi ne fiber by steam or air jets. Mineral wool has practically displaced the
glass wool, which contains glass fibers because of human health considerations. It
is also slightly cheaper.
c. In blanket form, the wool is held in place by wire mesh on one or both sides,
depending on the application, and is used up to 650C. For vertical walls of a

furnace, resin bonding of the mattress is usually preferred, as the wool is held in
place without settling at the bottom due to the slight vibrations in the walls.
Typically, densities of 100140 kg/m3 are employed for normal applications.
d. When clay is used as a binder and the wool is molded at high temperature and
pressure, mineral wool blocks are formed and can be used up to 1050C. These
blocks are used for insulating the boiler and membrane walls.
e. Ceramic fiber linings are produced by melting the aluminasilica china clay and
blowing air to form fibers of 50100 mm long and 3 m in diameter. They are
offered in block or mattress form capable of withstanding very high temperatures.
The blocks substitute for insulating bricks, and the mattresses can be used for high
temperatures. They have good acid resistance but lower alkali resistance. Ceramic
fiber is useful when temperatures as high as 1650Care encountered. This material
is reserved only for special applications due to its high cost. Lining of the inlet duct
downstream of burners in HRSG is a typical application.
f. High-temperature plastic is insulating plastic cement made from mineral wool
and clay, and is suitable up to 1050C for use on irregular shapes and for filling
gaps in block insulation.

INSULATION CALCULATION
FINDING THE CASING TEMPERATURE OF AQC BOILER
AT CURRENT OPERATING CONDITION:
FIELD DATA:
1. Boiler whole casing is rectangular
Dimensions:
Height = 25m
Width = 3.6m
Length = 12m

2.

Insulation type
Rockwool
Thickness = 50mm
Thermal conductivity = 0.035 W/m k

3. Inner wall temperature of boiler ( Steady state)

T i = 400

4. Ambient Temperature
T a = 30

5. Emissivity
e= 0.9 ( galvanized iron casing)

6. Average wind velocity

5 m/s

To find the casing the iteration has to be done because the heat loss is not known
HEAT FLOW DIAGRAM:

Ti
400

RESISTANCE DIAGRAM:

RADIATIV
E
RESISTAN

Ti
400

Ta
30

INSULATI
ON
RESISTAN

CONVECTIVE
RESISTANCE

ASSUMPTIONS:
Steady State
One dimensional heat flow
The resistance between inner surface and outer surface of boiler walls is
negligible
Since the steady state condition considered
Heat flow inner wall casing
Heat flow casing environment

K = thermal conductivity of Rockwool = 0.0035 W/m k

L = thickness = 50mm
Q '' = heat flux (W/m^2)
V = Velocity of wind = 5m/s

FORMULA USED:
1. FOURIER LAW

Q=

KAdT
L

Q' ' =

KdT
L

2. V.GANAPATHY CORRELATION:
The heat flux is given by:

2
2
1.25
Q = 5.67e-11e( ( 273+Tc ) (273+ Ta ) ) +0.00195 ( TcTa )
''

V +21
21

0.5

])

1000

K (T iT c )
V +21
2
2
1.25
= 5.67e-11e( ( 273+Tc ) ( 273+ Ta ) ) +0.00195 ( TcTa )
L
21

0.5

])

1000

ITERIATION FOR CASING TEMERATURE:

Tc( K)

Ti ( K)

Ta( K)

303

673

303

0.035

0.05

0.9

304

673

303

0.035

0.05

0.9

305

673

303

0.035

0.05

0.9

306

673

303

0.035

0.05

0.9

307

673

303

0.035

0.05

0.9

308

673

303

0.035

0.05

0.9

309

673

303

0.035

0.05

0.9

310

673

303

0.035

0.05

0.9

311

673

303

0.035

0.05

0.9

312

673

303

0.035

0.05

0.9

313

673

303

0.035

0.05

0.9

314

673

303

0.035

0.05

0.9

315

673

303

0.035

0.05

0.9

316

673

303

0.035

0.05

0.9

317

673

303

0.035

0.05

0.9

318

673

303

0.035

0.05

0.9

319
320

673
673

303
303

0.035
0.035

0.05
0.05

0.9
0.9

5
5

Rw( Total
Resistan Q(Fouri Q(Ganapat
ce)
er)
hy)
1.42857
1
259
0
1.42857
1
258.3
7.876168
1.42857
1
257.6
16.63
1.42857
1
256.9
25.85607
1.42857
1
256.2
35.44069
1.42857
1
255.5
45.32443
1.42857
1
254.8
55.46995
1.42857
1
254.1
65.85134
1.42857
1
253.4
76.4495
1.42857
1
252.7
87.24967
1.42857
1
252
98.24012
1.42857
1
251.3
109.4113
1.42857
1
250.6
120.7552
1.42857
1
249.9
132.265
1.42857
1
249.2
143.9352
1.42857
1
248.5
155.7606
1.42857
1
247.8
167.7369
1.42857
247.1
179.8604

321

673

303

0.035

0.05

0.9

322

673

303

0.035

0.05

0.9

323

673

303

0.035

0.05

0.9

324

673

303

0.035

0.05

0.9

325

673

303

0.035

0.05

0.9

326

673

303

0.035

0.05

0.9

327

673

303

0.035

0.05

0.9

1
1.42857
1
1.42857
1
1.42857
1
1.42857
1
1.42857
1
1.42857
1
1.42857
1

246.4

192.1276

245.7

204.5355

245

217.0814

244.3

229.7629

243.6

242.5778

242.9

255.5242

242.2

268.6002

Casing temperature:
Tc
Tc

= 325 K
= 52

CALCULATION OF CHANGING EFFECT OF INSULATION

THICKNESS ON HEAT FLUX
By changing the thickness of the Rockwool the variation of heat flux can be
obtained.
The method used in finding the heat flux is again by iteration. After the thickness is
selected one can find the casing temperature consequently the heat flux by iteration
using above mentioned scheme.
The result of the effect is given as:

250
240
230
220
210
200
190
180

Heat flux loss (W/m2)

170
160
150

thickness of insulation
Range of thickness selected = 50-75 mm (as provided by the manufacturer of
Rockwool insulation standard)
RESULT:
The heat flux is decreased by increasing the thickness of the insulation
Potential outcome will be decrease in heat loss from the AQC boiler and
increase in the efficiency