ANALYSIS OF WASTE HEAT RECOVERY BOILER

Efficiency Evaluation of Boiler

Indirect Method

Direct Method

= 85.96%
8
1
.
0
2
%

T(
C)

Entropy kJ/kg.K

Properties of air

Viscosity is Calculated through Suther land

Thi
C

kg/m3
0.82747
150
2
0.81780
155
8
0.80836
160
8
0.79914
165
3
0.79012
170
7
0.78131
175
1
180 0.77269
0.76425
185
8

viscosity
Pa.s
2.37861E-05
2.39842E-05
2.41811E-05
2.43767E-05

conductivity
W/m.K

Cp
kJ/kg.K

Pr

0.69254
0.035155 1.023557386
7
0.69213
0.035498773 1.024417872
2
0.69173
0.035841094 1.025282289
2
0.69134
0.036181974 1.026150586
4

2.45712E-05 0.036521425 1.027022713 0.69097

0.69060
2.47646E-05 0.036859458 1.027898617
8
2.49568E-05 0.037196084 1.02877825 0.69026
0.68992
2.51478E-05 0.037531316 1.029661558
4

Density is Calculated through equation of state

Thermal Conductivity is calculated through polynomial curve fitting

Specific Heat is again calculated through polynomial curve fitting and

avialable in Cengel

Prandtl Number is calculated through the defination

ANALYSIS OF WASTE HEAT RECOVERY BOILER

HEAT TRANSFER ANALYSIS

overall heat transfer coefficient

Air Side Convective Heat Transfer:

Incorpera

1. Methods for Heat Transfer Analysis:

Log Mean Temperature Difference Method/ LMTD Method

Effectiveness NTU / NTU Method:

effectiveness for cross flow and source fluid unmixed

Schmidt

Water Side Convective Heat Transfer:

Economizer & Superheater

Evaporator

Tube conductivity

1. Total Heat Transfer:

Total Heat transfer By LMTD

13282.28621kW

Total Heat transfer By NTU

12928.03165kW

1.

OPTIMIZATION OF BOILER GAS SIDE PARAMETERS

Inlet gas temperature

Economizer

Evaporator

320

253
252

315

251

310

250

UoAo(W/K)
249

UoAo (W/K)
305

248
300
295
165

247
185

205

225

245

265

Inlet gas temperature (oC)

285

246
340

360

380

400

420

440

460

118.4
118.2
118
117.8
117.6
UoAo(W/K)
117.4
117.2
117
116.8
116.6
400

Superheater

420

440

460

480

500

520

Inlet temperature(oC)

Inlet gas temperature (oC)

Inlet gas flow rate

Economizer

Superheater

12

126

10

Evaporator

2.85E+02

8
6
UoAo (W/K)
4

124

2.80E+02

122
UoAo(W/K)

2.75E+02
UoAo
(W/K)
2.70E+02

120

2
0
40

2.90E+02

45

50

55

60

Mass flow rate of gas (kg/s)

65

2.65E+02

118
40 42 44 46 48 50 52 54 56 58 60

Mass flow rate (kg/s)

2.60E+02
40 42 44 46 48 50 52 54 56 58 60

Mass flow rate (kg/s)

Constant Inlet energy

Evaporator

Economizer

Superheater

0.9

0.67
0.66

0.9

0.65

0.89

Effectiveness 0.64
0.63

0.89
Effectiveness
0.88

0.62
0.61
45 47 49 51 53 55 57 59 61 63

Mass flow of gas (kg/s)

0.88
0.87
46

48

50

52

54

Mass flow (kg/s)

56

58

Evaporator

Economizer
0.67

0.9

0.66

0.9

0.65

0.89

Effectiveness 0.64
0.63

0.89
Effectiveness
0.88

0.62
0.61
150

0.88
200

250

Temperatre (oC)

300

0.87
300 320 340 360 380 400 420 440 460

Temperature (oC)

0.91
0.91
0.9
0.9
0.9
Effectiveness
0.9
0.9
0.89
0.89
46

48

50

52

54

56

Mass flow (kg/s)

Superheater
0.91
0.91
0.9
0.9
0.9
Effectiveness
0.9
0.9
0.89
0.89
390 410

430

450

470

Temperature (oC)

490

510

58

BOILER CUSTOMIZATION
Fin Spacing of the tubes

Economizer

Evaporator

3800

8700
8600
8500
8400
Heat
transfer (kW)
8300
8200
8100
8000
0
0.01 0.01 0.01 0.01 0.01 0.02

3600
3400

UoAo3200
(W/K)
3000
2800
2600

0.01 0.01 0.01 0.01 0.01 0.02

Fin Spacing

Fin Spacing (m)

Tubes Material

2040
2020
2000
1980
Heat1960
transfer (kW)
1940
1920
1900
1880
0
0.01 0.01 0.01 0.01 0.01 0.02

Finspacing (m)

Calculation of Changing Effect of Insulation Thickness on Heat Flux

Evaporator
Steel
U

Efficiency

grade
A36

0.857816

8548.5

2.41E+02

Superheater

1020

2.41E+02

0.857816

8
8548.5

1040

2.41E+02

0.857816

8
8548.5

304

2.40E+02

0.857412

8
8544.5

316

2.40E+02

0.857384

48
8544.2

405

2.41E+02

0.858001

7
8550.4

440A

2.41E+02

0.857899

28
8549.4

250
240
230
220
210
200
190
180
170
160
150

Heat flux loss (W/m2)

thickness of insulation

Diameter of the tubes

Superheater

Evaporator

110
100
90

UoAo (W/K)
80
70
60
0.01

0.02

0.02

0.03

Tube radius (m)

0.03

2.10E+02
2.00E+02
1.90E+02
1.80E+02
1.70E+02
UoAo
(W/K)
1.60E+02
1.50E+02
1.40E+02
1.30E+02
1.20E+02
0.01

Economizer
250
240
230
220(W/K)
UoAo
210
200

0.02

0.02

Tube radius (m)

0.03

0.03

190
0.01 0.01 0.01 0.02 0.02 0.02 0.02 0.02 0.03

Tube radius (m)