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Designing of a Fire Tube Boiler

Article · July 2020

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 Page # 1

Designing of a Fire Tube

Boiler

Author Name/s
Hamza Abbas (2017133)
Mir Muhammad Uzair (2017204)
Harib Khan (2017140)
Saddam Hussain (2017400)
Department of Mechanical Engineering
GIK Institute of Engineering Sciences and Technology
Topi, Distt Swabi

Problem statement: Design a steam boiler for a process

heating application with a capacity of 2 ton per hour that can
generate steam at temperature 184℃ and pressure in the
range of 0.7-2.5 MPa. The fuel can be either natural gas or oil
also take feed water temperature of 35 ℃ and stack
temperature of 115℃.
Abstract— Boilers are very good devices used to produce steam
by providing energy in the form of heat to the water. The boiler
discussed in this report is a fire tube boiler which is among the
popular types of the steam boilers due to its many useful properties
over the other types of boilers. The system proposed in this report is
a 2 ton per hour fire tube boiler that satisfies the conditions given the
problem statement like the temperature and pressure values as well
as the dimensions of the tubes and the shell. So we obtain a boiler
that is not only good in terms of required performance but is also
economical and environment friendly. The project is considered
successful and ready to be launched in the real system
implementations.
INTRODUCTION:
This steam is then taken out from the steam outlet for
utilizing for required purpose. The water is fed into the boiler
through the feed water inlet. As the steam and water is stored
is the same vessel, it is quite difficult to produce very high
pressure steam from. General maximum capacity of this type
of boiler is 17.5 kg/cm2 and with a capacity of 9 Metric Ton
of steam per hour. In a fire tube boiler, the main boiler vessel
is under pressure, so if this vessel is burst there will be a
possibility of major accident due to this explosion [1].
Types of Boiler
There are two main types of boilers
• Water Tube Boilers: Water tube boilers are used in
large power plants. In such type of boilers the water
runs through tubes while there is fire surrounding
them. These types of boilers are also ideal for high
pressure applications.

The boilers are widely used for heating applications. Fire

tube boiler is as simple as its construction. In fire tube boiler,
the fuel is burnt inside a furnace. The hot gases produced in
the furnace then passes through the fire tubes. The fire tubes
are immersed in water inside the main vessel of the boiler. Figure 2a: water tube boiler
As the hot gases are passed through these tubes, the heat
energy of the gasses is transferred to the water surrounds • Fire Tube Boilers: Fire tube boilers are usually used
them. As a result steam is generated in the water and for the small scale applications. One advantage that
naturally comes up and is stored upon the water in the same these boilers have over other types is that they are
vessel of fire tube boiler. compact in size and do not occupy much space.
 pressure. In other words this is a self pressure controlled boiler [3]
[4].

Advantages of Fire Tube Boiler

Figure 2b: Fire Tube Boiler
Working Principle of Horizontal Return Fire Tube Boiler
Disadvantages of Fire Tube Boiler
Horizontal (three pass reversal chamber) fire tube boiler is most
suitable for low capacity thermal power plant. The main
constructional features of this boiler are one big size steam drum
which lies horizontally upon supporting structures. There are
numbers of fire tubes come from furnace and also aligned
horizontally inside the drum. When the drum is filled with water
these tubes are submerged in water.1
1. Compact in construction.
2. Fluctuation of steam demand can be met easily.
3. Cheaper than water tube boiler.2
1. Due to large water the required steam pressure rising
time quite high.
2. Output steam pressure cannot be very high since the
water and steam are kept in same vessel.
3. The steam received from fire tube boiler is not very
dry.
4. In a fire tube boiler, the steam drum is always under
pressure, so there may be a chance of huge explosion
which resulting to severe accident. 3

METHODOLOGY
In the design of fire tube boiler in this CEP report includes various
steps given below:
• Design requirement
• Design consideration
• Design specifications [5]
• Dimensioning of the boiler Preparation of drawing.
Mechanical calculations
• Heat balance calculations
Figure 3: Schematic diagram of fire tube boiler • Efficiency and evaporation ratio
calculation
• Fuel cost estimation during boiler’s operation.

The fuels (normally coal / Natural gases) burnt in the furnace and
combustible gasses move into the fire tubes, travel through these
tubes from one side to front of the boiler drum and finally the gases
come into the smoke box. The hot gasses in the tubes under water Basic Design Requirement
transfer heat to the water via the tube walls. Due to this heat energy
steam bubbles are created and come upon the water surface. As ➢ The ability to meet the required efficiency and other
the amount of steam is increased in that closed drum, steam performance standards.
pressure inside the drum increases which increase significantly the ➢ Ability to meet the required level of pollutants emissions.
boiling temperature of the water and hence rate of production of
steam is reduced. In this way a fire tube boiler controls its own
➢ Compliance with the requirements of the Central Boards
of boiler and Pressure Vessel Inspectors.

1 3
https://www.electrical4u.com/fire-tube-boiler-operation- https://www.electrical4u.com/fire-tube-boiler-operation-
and-types-of-fire-tube-boiler/ and-types-of-fire-tube-boiler/
2
https://www.slideshare.net/juliawu6/advantage-and-
disadvantage-of-fire-tube-boiler
 ➢ The ability to meet the perceived needs of the customers
in terms of operational performance, reliability and
maintenance costs.
Design consideration for material selection
For an good design to be done, the knowledge of the materials
available as well as the properties they posses are very important
For the selection of the proper material to be used for the design
of the fire-tube boiler, we shall consider the factors which affect
the choice of material selected and used for design and there
reasons.
Factor to be consider
Furnace Fire-tubes Return chamber Main
shell Steam tubes
All the above factors totally depend upon the material selection for
the Boiler parts.
So our main purpose is to select right material for the
right part . to increase durability , cost and efficiency of the
boiler .now on the next page we have given the detail about
the selection of the material for the above parts and we also
given the Reason for the selection by taking different
perceptions under consideration .

• Suitability of the material for the working conditions

in service, considering characteristics such as;
appearance, thermal conductivity, rate of emissivity,
strength, stiffness, creep, etc.

• Availability of the material: the ease at which the

materials are seen or purchased in the market.

• Workability of the material: considering possible

methods of processing material selected into desired
shape such as; weld ability, machinability, formability,
and workability.

• Expected load or force as well as adequate strength in

conformity so as to function satisfactorily without
failure.

• Cost of the material (economic Figure 4: Tubes and furnace of fire tub tube boiler
consideration).

All the above factor that we have to take in Design Dimension According to ASME Standard:
consideration will be for the following parts of the
boiler.4 ASME standard values for
Diameter of Tubes = 0.05 m
Furnace Plate Thickness = 0.016 m

4
https://books.google.com.pk/books?id=eMElCQAAQBAJ&pg=
PA264&lpg=PA264&dq=For+an+good+design+to+be+done,+t
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on+of+the+proper+material+to+be+used+for+the+design+of+
the+fire-
tube+boiler,+we+shall+consider+the+factors+which+affect+th
e+choice+of+material+selected+and+used+for+design+and+t
here+reasons.&source=bl&ots=QgM-
X2N5rC&sig=ACfU3U2TTNbo5uwDSt_hG27CnTJVXGW6Xg&hl
=en&sa=X&ved=2ahUKEwjKgKmYxKzqAhUOCRoKHandCX8Q6
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ant%20For%20the%20selection%20of%20the%20proper%20
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Thickness of Tubes Diameter of the furnace (O.D.) = 0.586 m provided

Length of the furnace provided = 1.500 m

t= minimum wall thickness (in) P= design pressure (psi) Fire tubes :

D= Tube diameter (in) e= thickness factor (0 for strength Diameter of the smoke tubes =0.05 m
welded) S= Maximum Allowable Pressure (psi)
Thickness of the smoke tubes = 0.012 m
Length of the smoke tubes =5m

Tube plate:
t = 0.441 in
t=0.0112m
Number of the tube plates =2
However, the ASME standard value for main shell thickness is
Thickness of the tube plate = 0.012 m
0.012 m.
Length of the tubes: Diameter of the tube plate = 0.980 m
Reversal chamber dimensions:
Length of the chamber = 0.280 m
Diameter of the chamber = 0.980 m
Front chamber dimensions:
Length of the chamber = 0.280 m
= Pressure Difference (bar) Diameter of the chamber = 0.980 m
L = Length of pipe (m)
= Specific volume of gases (kg/ )
Others details:
= mass flow rate of gases (kg/h)
Volume of the furnace = 0.4099 m3
D = pipe diameter (cm) Volume of main shell = 10 m3
Volume of smoke tubes (30 in no.) = 0.09188 m3
Feed water quantity = 7000 kg /
hr.
EFFICIENCY CALCULATION FOR FIRE TUBE BOILER
L= 4.92 m The stoichiometric equation for the combustion of natural gas is
However, the ASME standard value for Length of as follows:
tube is 5.00 m CH 4 + 2O 2 + 7.52N 2 → CO 2 + 2H 2O + 7.52N 2
Mass of CO2= 1.02x44=44.88 kg
Mass of H2O= 2x18= 36 kg
Dimensions Provided Mass of N2= 7.62x28= 213.3 kg
Boiler main shell: Total mass= 294.24 kg
% CO2= 15.25%
Thickness of the main shell provided = 0. 05 m % H2O= 12.23%
Diameter of the main shell (I.D.) = 0.89 m provided % N2= 75.52%
Diameter of the main shell (O.D.) =0.94 m provided Steam Flow rate= 2000kg/h = 0.556 kg/s
Length of the shell provided =2 m
Stack loss =
Furnace: Stack loss of CO2= (0.1525) (0.556) (0.846)(80)
Stack loss of CO2 = 5.7385 kW
Stack loss of H2O = (0.1232) (0.556)(1.8723)(80)
Thickness of the furnace provided = 0.016 m
Stack loss of H2O = 10.2600 kW
Diameter of the furnace (I.D.) = 0.570 m provided
Stack loss of N2 = (0.7552) (0.556) (1.039) (80)
Stack loss of N2 = 34.901 kW
Total Stack loss= 50.89 kW = 183239.48 kJ/h
Total Stack loss= 50.89 kW = 183239.48 kJ/h
Mass of Fuel = 0.95(16) + 0.02(30) + 0.01(44) =
16.24 kg Thermal Efficiency = 63.4%
Mass of Air= 294.24 kg
Boiler efficiency= x 100
Air-Fuel Ratio =
X 100
Mass flow rate of fuel= 200kg/h = 3.33 kg/s
Mass of fuel burned= 16.24 kg/h = 0.004511 kg/s
Boiler Efficiency = 62.07%
Heating Value = 523000 KJ/kg
Burning rate = Q = 16.24 x 523000 COST OF FUEL:
Q = 8493520 kJ/h Mass of fuel burned= 16.24 kg/h = 0.004511 kg/s
Q= 2359.3 kW The average cost of natural gas in the country is = 139 Rs/kg
𝑘𝑔 𝑠 ℎ𝑜𝑢𝑟
𝐶𝑜𝑠𝑡 = 0.004511 ( ) ∗ 3600 ( ) ∗ 24 ( )
𝑠 ℎ𝑜𝑢𝑟 𝑑𝑎𝑦
𝑑𝑎𝑦
∗ 30 ( ) ∗ 139 (𝑅𝑠/𝑘𝑔)
𝑀𝑜𝑛𝑡ℎ
Combustion Efficiency=
Cost = Rs 1,625,259.168 / month

X 100

Combustion Efficiency= 2359.5-50.89/2359.5 X 100

CONSIDERED ASPECTS
Combustion Efficiency = 97.84%
The aspects to be considered include economics, social,
environment, ethics, management, technology, analysis, and
evaluation.
Energy output of steam= (h2-h1)

ENVIROMENTAL IMPACT OF THE FUEL (NATURAL

GAS)
The environmental aspect that should be kept under
consideration before the installation of the Fire tube boiler
1. The emission of the harmful gases like (SOx and NOx )
At 35 C --------------h1= 146.64kJ/kg 2. Emission of the carbon containing compounds5
The above-mentioned gases produced the following
phenomena which are harmful for all human
At 184 C : beings
• Greenhouse Effect
= • Ozone layer Depletion
At 184 C -------- h2 =2780.56 kJ/kg • Acid Rain etc
We are using natural gas as fuel because it is less harmful
E= 0.556*(2780.6-146.64) than other fuels such as oil and coal because of the
following reasons:
E = 1464.5 kW
The extreme flexibility of natural gas makes it one of the fuels
easier to use, whereas the low content of pollutants makes it an
environmentally friendly fuel. During combustion natural gas
Thermal Efficiency= 100 X
produces carbon dioxide and nitrogen oxides (NOx), albeit to
a lesser degree than other fuels.
Thermal Efficiency= 1464.5kW/(2359.5-50.89) X 100

5
http://cleanboiler.org/learn-about/boiler-efficiency-
improvement/boiler-combustion/
Moreover, coal and oil by-products also produce Sulphur
oxides and Sulphur dioxide (SO2), two pollutants toxic for
mankind and the atmosphere. Sometimes the natural gas can
be burnt with coal or oil (co-firing): this process can
significantly reduce the emissions of SO2 e NOx.
Cogeneration allows to consume 25% less of energy as
compared to a traditional plant and to reduce by 1% the
emissions of SO2 and by 50% NOx emissions, as compared to
a coal or oil-based plant, even if it makes use of anti-pollution
equipment.
As regards carbon dioxide in particular, the International
Energy Agency (IEA) assessed that, if the same amount of
energy is produced, carbon dioxide emissions caused by the
combustion of natural gas are smaller by 25% and 40% as
compared to those produced by the combustion of oil and
coal by-products.6
Finally, methane presents the advantage of being virtually
“invisible” both during ground transport and when it is
distributed in cities (it travels through underground pipes
and only pumping stations are at ground level), a feature only
few other energy sources share.
Moreover, since it is gaseous at room temperature (20°C),
should any leak occur during transport, it disperses into the
air, does not dirty, or pollute waters or the soil.
Natural gas can damage the environment if it is dispersed in
its natural state because it is one of the greenhouse gases. In
other words, after reaching the top layers of the atmosphere,
it stops and stays there for many years, contributing to the
formation of a gas layer that prevents the solar heat reflected
by the earth’s surface from being dispersed and leads to
global warming (i.e. the greenhouse effect).
Therefore, leaks of natural gas during its transportation
should be reduced to a minimum or eliminated: not only is it
a waste of a precious resource, but there is also the risk of
contributing to a potentially dangerous phenomenon for
mankind.
Ethics
Companies are required by the governing law to guarantee
their workers a safe working environment, respect the labour
rights and not exploit workers under any conditions.
Company installing the boiler has a moral and ethical
responsibility to ensure that the said boiler installed imposes
a health or safety risk to workers. Proper security and
surveillance also need to be carried out for the boiler to avoid
any untoward incident. Lastly, the company should also
ensure a transparent commercial and technical bidding
process prior to procurement of both the boiler and services
for installation to avoid any corruption in the procurement
department.7

Management
Before establishment of the plant, workers should be prepared to operate machinery. Even though boilers do not require separate
workers full-time, the company does however, need to ensure that third-party expertise can be called for in case of any incident or
malfunction. The safety and environmental risks also need to be accounted for in the company’s existing HSE standards and
procedures. Workers should be encouraged to raise safety cards if they feel the need for any improvement to the existing SOPs
without any hesitation. The safety of workers should be the highest priority of the managers and thus safety measure should be
implemented and practiced in the plan

REFERENCES

[1] S. A. P. S. D. J. Mohammed Shahid Adoni, "Analysis and Adaptation of Cost Effective Boiler," International Research
Journal of Engineering and Technology (IRJET), vol. 5, no. 3-march-2018, p. 4, 2018.

[2] A. I. B. T. Afolabi Morakinyo, "The Optimization of Operational Parameters of a Biomass Fire-in-tube Boiler Using
Taguchi Design Method," American Journal of Food Science and Technology, vol. 5, no. june-2017, p. 6, 2017.

6 7
http://www.eniscuola.net/en/argomento/natural- https://www.ilo.org/global/standards/subjects-covered-by-
gas1/environment-and-territory1/impacts-on-air/ international-labour-standards/occupational-safety-and-
health/lang--en/index.htm
[3] P. A. T. Abhay Sharma, "DESIGN OF THE HORIZONTAL FIRE TUBE BOILER FOR THE COMMERCIAL
COOKING OF INDIAN FOOD," Journal of Mechanical Engineering and Technology (JMET), vol. 5, no. december-
2017, p. 4, 2017.
[4] D. M. R. a. A. N. V. I I Komarov, "Improvement of fire-tube boilers calculation methods by the numerical modeling of
combustion processes and heat transfer in the combustion chamber," IOP Publishing Ltd, 2017.

[5] YCT steel company, [Online]. Available: http://yctsteels.com/pro05/f5720795-fe3d-a516-4d989c9a781f0b4a.shtml.

[6] VIRTUAL CHEMBOOK 2003, Combustion of Fossil Fuels, viewed 28 November 2019,
<http://chemistry.elmhurst.edu/vchembook/511natgascombust.html >.

[7] Tekashi Madara, Lee Min Hyun, Park Seokjin, and Y. Matsuri, “Industrial Boilers an In Depth Analysis,” IET Toyama
Japan, vol. 7, pp. 305–321, August 1998 [Digest 10th Industrial exhibition Japan, p. 409, 1999].

[8] ODESIE n.d, BOILER TYPES AND CLASSIFICATIONS, viewed 5 December 2019, <
https://www.myodesie.com/wiki/index/returnEntry/id/3061>.
[9] GI- Chal Yang, Sio-long Ao “ Transaction on engineering technologies: world congress on engineering” pg. 264-266

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