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INTERNATIONALJournal of Mechanical
JOURNALEngineering
OFandMECHANICAL
Technology (IJMET), ISSN 0976 – 6340(Print),
ENGINEERING
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
AND TECHNOLOGY (IJMET)
ABSTRACT
Economizer is the best mechanical component which is used for trapping the heat of flue
gasses. Economizers can be best applied in electricity generating power plants. Best way of
utilisation of flue gas heat is by transferring it to the boiler feed water. Hence economizers are
designed in such a way that feed water is allowed to pass the economizer through pipes. Economizer
shell is completely filled with the flue gasses. There is a cross flow heat exchange process takes
place between boiler feed water and flue gas. Boiler feed water is heated up to its boiling temperature
by consuming the heat from flue gas. Hence as the boiler feed water is already preheated the amount
of fuel burnt to generate steam is reduced in this way in boilers. This paper explains about one of the
ways to increase the heat transfer rate of economiser. Heat transfer is always enhanced by increasing
the surface area of heat transfer between heat exchanging bodies. Hence by providing addition area
between the flue gas and boiler feed water we can increase the heat transfer. Additional area is
provided with the help of fins which are considered as extended surfaces. A CFD (Computational
Fluid Dynamics) analysis is carried with two cases with and without fins. Analysis of two cases is
carried out to determine, how much value of heat transfer has enhanced with fins.
NOMENCLATURE
ρ = density of fluid
u = initial velocity
p = pressure
f = body force
Q = vector variable
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
F = vector fluxes
V = volume of control volume
A = area of control volume
Ri = equation residual
Wi = weight vector
Ve = volume of element.
k = turbulence kinetic energy
Ԑ = dissipation rate
ω = specific dissipation rate
Gk = generation of turbulence kinetic energy due to mean velocity gradients
uj = jth Cartesian component of the instantaneous velocity
τij = viscous stress tensor
fi = the body force
h = static enthalpy
Gb = generation of turbulent kinetic energy that arises due to buoyancy
YM = represents the fluctuating dilation
Sε, Sk = source terms defined by the user.
C1ε, C2ε, Cµ = constants that have been determined experimentally
σk, σε = turbulent Prandtl numbers for the turbulent kinetic energy, its dissipation rate.
S = mean rate-of-strain tensor.
1. INTRODUCTION
Economizer is a mechanical component which helps in pre heating of water which is feed
into boiler. It is a part of steam generating unit which intended to reduce energy consumption of
boilers in particular. Generally in power plants water which is introduced into boilers is called as
boiler feed water. This water is converted into steam after absorbing the heat which is produced from
combustion of fossil fuel. Combustion of fossil fuels gives flue gases as by products. These gases
have lower level of thermal energy within them which is trapped. Economizer carries a vital role in
trapping this heat and transferring it to the boiler feed water. Hence economizer acts as an external
heat transfer device where heat transfer takes place from flue gases to the boiler feed water. This
action preheats the boiler feed water; thereby reducing the amount of fuel required to convert the
boiler feed water into steam. Economizer is a tubular structure with main objective of obtaining
lower cost efficient and maximum heat transfer rate with the boiler feed water. This action of
economizer helps in economic production of power in power plants. It reduces the operating costs of
power plant also.
Heat is considered to be a form of energy. So as the saying goes energy is neither created nor
destroyed, we should not allow the heat to go out as waste in the flue gases. One of the ways to
conserve the heat energy which is going out as waste in the exhaust gasses is to extract the heat and
transfer it to a boiler feed water. One of the important components of heat transfer system in power
plants is the economizer. Economizer is widely used equipment in various industries such as power
generation, petroleum refining, chemicals paper, refrigeration and also in HVAC (Heating
Ventilation and Air Conditioning). According to a market survey conducted in Europe, economizers
are used in about 42% of the power plants. It also used for the heat exchange process in Nuclear
industry as well. Hence there arises a need for analysis of Economizer.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
heat exchanging bodies. Hence this paper explains about the analysis which is carried out on an
economizer which has fins attached to its tubes. As these fins are considered as extended surface
areas, hence there is increase in heat transfer between the boiler feed water and flue gas. Orientation
of the fins surface with respect to the direction of flue gas, type of fins shapes, dimensions of the fins
and the material used as fin all play a significant role in the heat transfer between two bodies.
2. LITERATURE SURVEY
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
3D CFD tool is used for analysis and flow of the flue gases over the coils has been observed. The
effect of provision of arresters on the surface temperature, the flue gas temperature, pressure and
velocity field of fluid flow within an economizer tube using the actual boundary conditions have
been analyzed using CFD tool. The optimum dimensions of arrester and feasible inclination is
recommended as a result of the study. The authors have analyzed the performance and tried to
comment on this issue too.
A.N. Aziz, P. Siregar, Y.Y. Nazaruddin, and Y. Bindar [6] work on “Improving the
Performance of Temperature Model of Economizer Using Bond Graph and Genetic Algorithm”. The
mathematical model of economizer, based on physical laws is derived using bond graph
methodology. Pseudo multi-energy bond graph, which employs mass flow-rate and enthalpy flow-
rate as flow variables, as well as pressure and temperature as effort variables, is used in achieving
that. Overall heat transfer coefficient of economizer is obtained by using logarithmic temperature
mean difference between flue gas and boiler feed water. A modification of overall heat transfer
coefficient in the form of parameterized polynomial is also done by using the help of genetic
algorithm technique. A step simulation of the model at maximum, continuous, and minimum boiler
operating condition demonstrates, that model’s performance has been improved.
Computational Fluid Dynamics CFD is one of the best suited software for the analysis of
flow patterns which involve the dynamic parameters in the flow. It is very stable robust and accurate
in providing the required outputs. Generally experiments on moving fluid particles are not feasible.
Dynamics study on moving particles involves many complex calculations and large variables. But
their analysis can be easily carried with the help of CFD.
Continuity equation:
+ ( ) = 0 (1)
Momentum equation
+ . v) = - p T f (2)
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
Energy equation:
ρ
(ρh) + (ρujh) = - + + uj + τij (3)
Above equations along with many other equations depending on the type and problem of
flow are considered as PDE’s Partial Differential Equations. These equations when subjected to
discretization give out a set of algebraic equations. These algebraic equations contain terms that have
been used for specifications of that particular flow and also these equations contain our required
output parameters. After solving these equations, the solution of these algebraic equations is found
with the CFD program called as FLUENT. This process of solving the flow problem involves
generation of output at each element nodes for accurate and precise results.
Analysis in CFD involves repeated and sequential solving of algebraic equations. The main
purpose for this repeated iterations is to improve the quality of solution constantly after each and
every iterations. The process of iterations is continued until convincing values of the global residuals
are obtained. Global residuals are difference between the values of output parameters obtained in the
current and previous solution which are averaged over the entire computational domain. After
continuous iterations a state of “convergence” is obtained where the residuals have decrease by 4-5
orders of magnitude. One of the most important points to be considered when working with CFD
software is that the quality of its output is completely dependent on the quality of its input. Hence
when best quality inputs are given to the solver best quality outputs are obtained for the analysis.
µ
(ρk) + (ρkui) =
{[µ+ ] } + Gk + Gb – ρε - Ym + Sk (4)
µ ε ε Є
(ρε) + (ρεui) = {[µ+] } + C1ε (Gk+C3εGb) – C2ερ + St (5)
ε
µ t = ρCµ (6)
ε
Gk = -ρui’uj’ (7)
S = √2SijSij (8)
µ! $
Gb = βgi (9)
"#
Ym = 2 ρЄMt2 (10)
All the above terms have been defined in the nomenclature which is specified before the
starting of paper.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
4. ANALYSIS OF ECONOMIZER
Analysis of heat exchanger to optimize the heat transfer takes place in two cases. First case is
plain tube economizer and second case is finned tube economizer. In order to provide accurate
results, the input boundary condition parameters are obtained from a real time coal fired power plant.
The table below represents the values which are given to fluent solver
The geometric specifications of the computational domain are not in accordance with the real
time economizer design because of lack of proper computer capacity, but the domain is scaled as per
the power plant dimensions. And the table represents them
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
In the modeling of case 2, only one finned tube economizer pipe is considered. From the
analysis of case 1 it is seen that temperature profile of all the water tubes are same and uniform.
Hence analysis of one finned tube gives information about all the remaining tubes in the economizer
shell.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
In the case 2 conduction, there is increase in the thickness of tube because of fins. When we
are considering the conduction formula the thickness of tube material is inversely proportional to the
thermal conductivity. So as the thickness increases when the fins are considered conduction in case 2
decreases.
5. RESULTS
These results are obtained after detailed analysis of economizer with two cases.
Case 1
Figure 4: Heat transfer along the economizer water tube (Static Temperature)
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
Figure 5: Heat transfer along the economizer water tube (Velocity Vector)
Figure 6: Heat transfer along the economizer shell tube (Velocity Vector)
Figure 7: three dimensional graph showing temperature profile of shell and water tube
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
Case 2
6. CONCLUSION
Hence from the analysis it is found that heat transfer rate has been enhanced by providing the
fins in case 2. As they are considered as extended heat transfer surface areas there is significant
increase in heat transfer rate. Other technical explanation for the increase in heat transfer is, by
creating fins in the case 2, uniform flow of flue gas in the economizer is disturbed. Where as in case 1
there is no obstruction in the motion of flue gas. Because of fins there is disturbance in its flow, which
creates turbulence into the motion of flue gas. This turbulence energy is transferred to the fins in the
water tube. Due to this more amount of heat is transferred to the fins. Hence more amount of heat is
transferred in the second case than the first case. And this heat energy is transferred to water flowing in
the tube. So in this way we experience increased heat transfer because of the external fins which act as
increased heat transfer area and also due to generation of turbulence.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 5, Issue 3, March (2014), pp. 66-76, © IAEME
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