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DESIGN AND ANALYSIS OF COMPACT BOILER

Technical Report · July 2018

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 9, Issue 7, July 2018, pp. 1525–1534, Article ID: IJMET_09_07_162
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=7
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

DESIGN AND ANALYSIS OF COMPACT

BOILER
Dr. Rajendra Prasad A, Dr. Vaidyanathan S and M. C. Anand Chakaravarthi
Professor, Sri Sairam Engineering College, Chennai, India

S.M. Suresh
Professor, B.M.S. College of Engineering, Bangalore, Karnataka, India

ABSTRACT
Package boilers occupy a larger share of market in numbers compared to
industrial and utility boilers. Almost all process industries such as the textile industry,
paper industry, plastic industry, food and pharmaceutical industry etc. employ
package boilers for heating. As such they consume large fraction of input energy not
only due to numbers but also due to less design freedom. Eventually, there is a quest
for ideas which can contribute considerably to the design and cost reduction of
package boiler.
This project discusses innovative idea of increasing convective heat transfer by
introducing turbulators. Initial experiment on improvement of heat transfer with
turbulator was encouraging. Turbulator increases convective heat transfer more than
50% to 100% and dispenses away large number of tubes. A one dimensional
mathematical model has been developed for the design and performance evaluation of
package boiler with trubulators and result has been compared with conventional
boiler. Analysis indicates that compact boiler with turbulators can be a good
alternative to multi-tubular boiler. A two pass boiler with turbultors give identical
performance to three pass multi-tubular boiler. Introduction of tabulators gives many
mores advantages apart from increasing the heat transfer and making boiler compact.
Compactness is achieved at the cost of increased pressure drop. These aspects have
been high-lighted in this study. Paper also discusses future scope of work before such
a boiler is introduced in market as a regular product. Paper is first part of an
integrated approach in design, modelling, and manufacturing of compact boiler.
Keywords: Turbulator, Compact boiler, multi-pass boiler.
Cite this Article: Dr. Rajendra Prasad A, Dr.Vaidyanathan S, M. C. Anand
Chakaravarthi and S.M. Suresh, Design and Analysis of Compact Boiler, International
Journal of Mechanical Engineering and Technology, 9(7), 2018, pp. 1525–1534.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=7

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 Design and Analysis of Compact Boiler

1. INTRODUCTION
First known use of steam boiler was made with Newcomen‟s engine in 1711 for draining
water from colliery for its safe operation [1]. Very little information is available on the design
and engineering of this boiler. Technological history of boiler can be traced back to the
development of Cornish boiler, which can be called as first successful commercial boiler [2].
Cornish boiler had single flue and resulted in engineering problems. This was improved upon
by incorporating additional flue in the boiler which was called Lancashire boiler. However,
Lancashire boiler is not just an addition of flue over Cornish boiler but resulted in more
uniform stress distribution, making it one of the most successful boilers of that era. This was
the time when the heat transfer technology was in its infancy and little knowledge was
available on heat transfer. Both Lancashire and Cornish boiler absorbed heat predominantly
by radiation and resulted in poor thermal efficiency.
These boilers were not only low efficient but were also dangerous and resulted in
explosion. Explosion of Sultana ship killing nearly 1200 persons being the most ferocious
accident [3]. At this time „Polytechnic Club‟ prevailed upon and codes were implemented for
the safe design and operation of boilers [4].
Better understanding of heat transfer resulted in development of multi-tubular boiler.
Multi-tubular boilers absorbs almost equal amount of heat by convection and radiation. Better
understanding of heat transfer resulted in higher thermal efficiency of boiler, which peaked to
88%. Subsequent to multi-tubular boiler no new innovation has been done on the
development of package boiler [5,6]. With better understanding of technology there appears
to be scope for further improvement, which can reduce manufacturing cost and make boiler
more compact [7]. Heat transfer enhancement, design, engineering and development of such a
compact boiler are the objective of this exercise.

2. BOILER CONFIGURATION

Figure 1 Multi-tubular boiler

Figure 1 shows configuration of multi-tubular boilers which are in vogue. Often these
boilers are called three pass, horizontal, multi-tubular boiler. As the name suggests it consists
of number of small diameter horizontal tubes incorporated between tube plates. Boiler
consists of a combustion chamber, which is extended to the rear side to get complete
combustion. Combustion chamber is followed by a set of tubes called second pass of the
boiler. Heat is absorbed by gas radiation and convection in this section. Temperature of flue
gas drops to around 600 degree C at the exit of this section. Second pass is optionally
followed by another set of tubes called third pass of boiler. Heat is further absorbed by
convection in these tubes. However, due to low log mean temperature (LMTD) effectiveness
of this section is quite low.

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 Dr. Rajendra Prasad A, Dr.Vaidyanathan S, M. C. Anand Chakaravarthi and S.M. Suresh

Figure 2 Configuration of compact boiler with augmented heat exchanger

Figure 2 shows the configuration of proposed compact boiler with an augmented heat
exchanger. Combustion chamber is similar to that of multi-tubular boiler. This is followed by
a set of turbulators incorporated between two parallel longitudinal shells. As flue gases flows
through these section, high turbulence improves the heat transfer coefficient. Heat transfer
coefficient can be improved from 3 to 5 times, thereby reducing the overall heat transfer area
needed. This high heat transfer is achieved at the cost of increased pressure drop.

Figure 3 Arrangement of turbulator

Such a design gives multiple advantages some of which can be stated as follows.
1. Elimination of large number of tubes which reduces overall inventory.
2. Drilling tube holes and welding these tubes increases fabrication time. Elimination
of tubes reduces overall manufacturing cycle time.
3. Tubes are the first part to fail in the boiler. Absence of tubes reduces downtime of
boiler.
4. Design permits large steam space. Large steam space results in better quality steam
and reduces pressure fluctuation in boiler.
5. Boiler is more compact needing less space for installation and maintenance.

3. THERMAL DESIGN OF BOILER

Thermal design of package boiler essentially consists of combustion calculation and radiation
heat transfer in the furnace and convection heat transfer in the subsequent section. These are
explained in detail in the following section.

3.1. Combustion calculation

Combustion calculation is performed assuming stoichiometry combustion. Since a well-
designed boiler should have complete combustion stoichiometry is the chosen model.
Equilibrium kinetics and rate kinetics are not used for design as complete combustion is
desired. For the design purpose 15% excess air has been assumed, which is the optimum with
a well-designed combustion system. Table 1 shows the fuel composition. Fuel used in power
industries in India has been chosen for design purpose and high ash has been assumed. Table
2 shows the results of Stoichiometric combustion calculation. Radiation heat transfer has been
analysed assuming a well stirred model. Gas radiation is the predominant mode of heat

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 Design and Analysis of Compact Boiler

transfer. Analysis shows a stoichiometric air fuel ratio of 3.90 whereas actual air fuel ratio and
gas fuel ratio is 4.49 and 4.98 respectively. Entire calculations were performed by developing
a Matlab program. Output of Matlab model is shown in the subsequent sections. Predicted
flue gas exit temperature for the assumed configuration is about 350 degree C. This is in good
agreement with the design practice in vogue in the industries. Temperature can be further
reduced by installing an economiser at the downstream end.

Table 1 Gravimetric Analysis of Fuel

S.No. Element % Mass
1 Carbon 29.00
2 Hydrogen 2.40
3 Water Vapour 10.00
4 Sulphur 0.25
5 Oxygen 7.70
6 Nitrogen 0.65
7 Ash 50.00
8 Sulphur as SO4 0.00
9 Chlorine 0.00

Table 2 Flue gas Composition based on Stoichiometry

Element Mass % Mol %
Carbon dioxide 21.34 14.14
Sulphur dioxide 0.10 0.04
Water Vapour 6.03 12.23
Oxygen 2.72 2.48
Nitrogen 68.29 71.10

3.2. Radiation heat transfer model

Combustion chamber, also called flue, is the zone of radiation heat transfer. Radiation heat
transfer has been modelled assuming flame radiation and gas radiation. Assuming complete
combustion adiabatic flame temperature has been calculated. For the stated fuel adiabatic
flame temperature is found to be approximately 1725º C.
Carbon dioxide, water vapour and sulphur dioxide are the diatomic gases emitting gas
radiation. Charts for the calculation of emissivity and absorptivity of Carbon dioxide and
Water vapour are given by Hottel and Saroffim [8]. In this chart properties are expressed as
function of partial pressure, mean beam length, and temperature. However, pressure
correction factor need to be applied to the radiation properties calculated by these curves for
the pressures other than zero and 1 atmosphere. An additional correction factor is needed for
the spectral overlap of carbon dioxide and water vapour band width. Thus a complete
modelling of gas radiation needs usage of number of curves as given by Siegel and Howell [9]
and Mikheev [10]. However, instead of adopting graphical approach a mathematical model
has been developed on Matlab to calculate contribution of gas radiation as a function of
geometric and thermal properties. Emissivity of carbon dioxide and water vapour were
expressed as a function of mean beam length and temperature. All the influencing factors
mentioned in the approach of Saroffim have been considered in the mathematical model. Due
to the proprietary nature of work complete model cannot be presented here and only steps are
mentioned below.
1. Calculate partial pressure of carbon dioxide and water vapour from combustion
analysis.
2. Calculate mean beam length of furnace from its geometry.

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 Dr. Rajendra Prasad A, Dr.Vaidyanathan S, M. C. Anand Chakaravarthi and S.M. Suresh

3. Calculate radiation properties of Carbon dioxide, water vapour and sulphur

dioxide.
4. Calculate all the correction factors.
5. Calculate effective emissivity of gas volume at the temperature.
6. Calculate radiation heat transfer by Stefan Boltzmann law.
It was found that results of mathematical model compares well with graphical approach.
Such a model exonerates one from limited size curves and improves the accuracy of
calculation encountered in graphical procedure.

3.3. Convection Heat Transfer

Improvement of convection heat transfer without incorporating tubes is the kernel of this
study, as avoidance of tubes gives innumerable advantages. Extended surface and installation
of inserts are the two common method adopted for enhancing heat transfer in convection
zone. These are alternatively known as passive and active techniques. First alternative called
passive technique is commonly used in economizers and waste heat boiler where average
temperature is low. This cannot be effectively applied at high temperature zone of steam
generators and boilers. Incorporation of inserts which is called active technique and thereby
designing a compact boiler is the objective here. Inserts do not call for permanent
modification and enhances heat transfer due to following reasons;
i. By agitation.
ii. By mixing.
iii. Cross stream secondary circulation.

Table 3 Boiler Design Parameters

Parameter Value / Description
A stationary two pass horizontal
Boiler description: shell type tubeless boiler in all
welded construction.
5000 kg/h, at outlet steam pressure,
Steam generation rate when feed water temperature is 80º
C.
Feed water temperature 80 deg C
Steam outlet pressure 10.5 kg/cm2 (150 psig)
Steam temperature 186.43deg C (Saturated steam)
Boiler design pressure 17.5 kg/cm2 (250 psig)
Design excess air 15%
Internal diameter of
650 mm.
furnace
Length of furnace 4000 mm.
Internal diameter of rear
975 mm
combustion chamber
Length of rear combustion
860 mm
chamber
Number of furnace tube 1
Thickness of furnace and
25 mm
rear combustion chamber
Flue gas outlet
250º C.
temperature from boiler
Draught Balanced draught.
Turbulator pitch for 180
150 mm.
degree helix
Thickness of turbulator 2.5 mm

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 Design and Analysis of Compact Boiler

Annulus between two shells is the zone where inserts are employed and heat is absorbed by
convection. These annuli carry inserts which are also called turbulators. A large number of
designs are possible with inserts and each need separate study. Bergels [11] have documented
these studies. Twisted tape has been chosen as the inserts due to its ease of manufacturing and
self-cleaning possibility. Thin metallic strip with width slightly less than internal diameter of
tube is twisted to a constant pitch helix. Three possible designs of twisted tapes are,
a. Full length twisted tape.
b. Modified twisted tape.
c. Compound enhancement twisted tape.
First occupies the full length of heat transfer channel. Modified twisted tapes are of short
length placed at the inlet of tube. Compound enhancement tapes are used with one or more
enhancement techniques. This investigation is done with full length twisted tape. Apart from
improvement in heat transfer such a design offers other mechanical advantages.
Heat transfer with inserts depends on number of parameters viz. thickness of tape, helical
flow path, pitch to diameter ratio, and fin effects. Mathematically it can be expressed as
Nu = Nu (Gz, Re, Ra, y, Pr , ) 1
Among the large numbers of available models, three models viz;,Drizius, Ibragimov, and
Manglic et.al. Were attempted [12]. Literature review indicates that most analysis with inserts
have been carried out for heat transfer inside pipe. Gupte and Date [13] have numerically
analysed heat transfer in an annulus. No experimental information is available on flow
through annulus with turbulator in turbulent flow. In this design analysis model of Manglik &
Bergles for turbulent has been adopted for the turbulators design and analysis.
Model developed in this investigation combines all the steps mentioned above. It includes
combustion, radiation and convection heat transfer. Thus complete boiler can be designed and
analysed as one run through program. This is the aim of boiler industry. Model can be further
linked to the mechanical design of boiler, which has been kept separate from this paper. Table
3 below show boiler design parameters as well process design parameter.

3.4. Experimental Work

Prior to taking up modelling work, a simple experiment was performed to check the veracity
of concept. This was the mini-project of under graduate study [14]. Due to lack of resources
and time constrain complete study could not be performed and it is suggested this work may
be further undertaken. Results were conducted by heating water by means of flue gas
generated by electrical heating. Success of this unpublished work and concept is the impetus
for current endeavour. Turbulator parameters are shown in Figure 3.

3.5. Results and Discussion

Eleven iterations were needed for the convergence of model when maximum error in exit
temperature is 0.1%. Convergence has been attempted in the flue gas exit temperature. Since
the model is highly non-linear initial guess value is needed for one parameter. Guess value
was provided for flue gas exit temperature from the boiler. Model was not found to be
sensitive to initial guess value of exit temperature. Number of convergence was found to be
same for initial guess value of temperature between 200 to 5000C.
Model analysis indicates that it is possible to develop a tubeless boiler with turbulators
giving identical performance to a multi-tubular boiler. Output from the Matlab program model
is shown in the following sections. For the performance evaluation purpose parameters to be
compared are total heat transfer, flue gas temperature and boiler efficiency, while achieving

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 Dr. Rajendra Prasad A, Dr.Vaidyanathan S, M. C. Anand Chakaravarthi and S.M. Suresh

convergence in flue gas exit temperature from the boiler. These parameters match well with
conventional multi-tubular boiler confirming the efficacy of tubeless boiler.
Model run shows that the Total heat transferred in the boiler with installation of turbulator
is 3238.6 kW. This is about 108% of expected output from the boiler. Calculated flue gas
outlet temperature is 343 degree C, which is in conformity with the observation with most fire
tube boilers. Almost all fire tube boilers in multi-tubular construction give flue gas outlet
temperature around 350 deg C. Further reduction is flue gas outlet temperature can be
achieved by putting an external economiser. For the above flue gas temperature thermal
efficiency works out to be 77.38%. Installation of economizer will bring this flue gas
temperature further down and make a tubeless boiler thermally as lucrative as a multi-tubular
boiler. Calculated value of heat transfer coefficient with inserts of chosen design works out to
be 165.56 W/m2 K. Average heat transfer coefficient in second pass of multi-tubular boiler
normally ranges between 30 to 35 W/m2 K. This shows the importance of turbulator. Heat
transfer area needed with this high heat transfer coefficient is approximately 25 m 2.
Convection heat transfer in the boiler is around 68%.Complete result of model run is shown
below.

4. MODEL RESULTS
4.1. Result
Thermal model of Compact Boiler Design
Title : 5.00 TPH COMPACT BOILER DESIGN
Objective: Final Year 2016 Project. Development of 5 TPH Boiler
Guide : Dr. S. Vaidyanathan.
Professor- Department of Mechanical Engineering.
-----------------------------------------------
Date of execution: 08-Jul-2016
Two Pass Boiler (Single convection pass)
------------------------------------------

Table 4 Boiler Design Parameters

Boiler pressure 11.50 [bar]
Steam generation rate 5000 [kg/h]
Steam Temperature 186.043 [deg C]
Enthalpy of steam at exit 2782.250 [kJ/kg]
Feed water inlet temperature 80.000, [deg C]
Enthalpy of water at inlet 335.012 [kJ/kg]

Table 5 Assumed fuel composition

Carbon 29.00 %
Hydrogen 2.40 %
Water vapour 10.00 %
Sulphur 0.65 %
Oxygen 7.70 %
Ash 50.00 %
Sulphur as SO4 0.000 %
Calorific value 11723.04 [kJ/kg]
Assumed excess air 15.00 %

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 Design and Analysis of Compact Boiler

Table 6 Furnace flue dimension

Diameter of flue 650.00 [m]
Length of flue 4000.00 [m]
Length of flue 1.00 [m]

4.2. Output
Table 7 Combustion analysis
Thermal efficiency
Fuel consumption
Stoichiometric air fuel ratio
Air fuel ratio
Gas fuel ratio
Molecular weight of flue
gas
Mass flow rate of flue gas
77.38 %
0.301 [kg/s] 1084.689 [kg/h]
3.90176 [SAir]
4.48702 [kgA/kgF]
4.97989 [kgA/kgF]
29.17 [kg/mol]
5401.634 [kg/h] 1.500 [kg/s]

Table 8 Flue Gas composition

% By mass % By mol
Carbon dioxide 21.33755 14.14148
Water vapour 6.03021 12.23406
Sulphur dioxide 0.10030 0.04567
Oxygen 2.71954 2.47892
Nitrogen 68.28627 71.09987

Table 9 Furnace Radiation

Total radiation heat transfer 779.13227 [kW/m2]
Volume of combustion chamber 1.33 [m3]
Adiabatic flame temperature 2199.84 [deg C]
Overall gas radiation 72.12607 [kW/m2]
Total gas radiation 589.13593 [kW/m2]

Table 10 Flame Radiation

Calculated flame temperature 1726.763 [deg C]
Overall radiation 0.0000 [kW/m2]
Total flame radiation 0.0000 [kW/m2]
Total radiation heat transfer 779.13227 [kW/m2]
Percentage radiation 26.07186 [%]
Furnace exit temperature 1344.18432 [deg C]
Mass rate of flue gas 5401.63356 [kg/h]
Heat liberation rate in the
1.794 [MW]
furnace

Table 11 First Pass detail

No of iterations needed 11
Error in first pass calculation 0.096 %
Gas inlet temperature to the pass 1344.184 [deg C]
Gas outlet temp from the pass 343.792 [deg C]
Average temperature in first pass 843.82 [deg C]
Density of gas in first pass 0.32006 [kg/m3]
Viscosity of gas
5.68597E-005 [Ns/m2]
in first pass
Thermal conductivity in first
0.07012 [W/mK]
pass
Specific heat in first pass 1.37605 [kJ/kg K]
Heat transfer area in first pass 24.68 [m2]

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 Dr. Rajendra Prasad A, Dr.Vaidyanathan S, M. C. Anand Chakaravarthi and S.M. Suresh

Flow area in first pass 1.005 [m2]

Gas velocity in first pass 27.63 [m/s]
Overall heat transfer coefficient 24.91 [W/m2 K]
U0 with inserts 165.56 [W/m2 K]
Log mean temperature difference 501.45 [deg C]

Table 12 Heat Transferred in the boiler

Total radiation heat transfer 779.13227 [kW]
Percentage Xtr in furnace 26.07186 {%]
Convection heat transfer in 1st
2048.92192 [kW]
Pass
Percentage Xtr in 1st Convection
68.56244 {%]
Pass
Heat transfer in the economiser 410.53889 [kW]
Percentage Xtr in Economiser 13.73774 {%]
Total heat transfer in the boiler 3238.59308 [kW]
% Total heat trasnfer in the
108.37204 [%]
boiler
Exit temperature from the boiler 343.79 [deg C]
Thermal efficiency on GCV 77.38 %
Mass flow rate of flue gas 5401.634 [kg/h]
Pressure drop in the system 1.316 [mm of Hg]
Actual boiler output f and at 100
5.92 [tph]
C
Total Heat Transfer Area (ID
36.23 [m2]
based)
Enthalpy at the outlet of
630.60000 [kJ/kg]
economiser
Enthalpy of feed water at Eco
335.01200 [kJ/kg]
inlet
Temperature of feed water at
80.00000 [deg C]
Eco inlet
Error in exit temperature 223.724 %

4.3. Part Load Operation

All boilers are expected to perform diligently at part load operation. Model was executed for
50% and 25% load. At 50% load convergence was achieved in 6 iterations. At part load heat
transfer coefficient in convection section drops to around 90 W/m2 K. This is expected due to
lower turbulence and lower overall flue gas velocity. Similarly at quarter load overall heat
transfer coefficient drop to about 50 W/m2 K, which is also as per norms. Convergence of
model could again be achieved at 6 iterations.

5. CONCLUSION
Following conclusions are drawn from this study.
1. A two pass boiler with turbulator can be the alternative for a three pass multi-tube
boiler.
2. A simple one dimensional model with two zones can predict the performance of
compact boiler with turbulators.
3. There is a scope of further analytical study on this subject which can be topic of
good research.

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 Design and Analysis of Compact Boiler

SCOPE OF FURTHER WORK

There is large scope to continue this work. Scope is in theoretical modelling as well as actual
development. Some of them are enumerated below.
1. Very little work has been done in heat effect of turbulators in annulus. Analysis by
Saha et. al. [15] is the only known work. No information is available in open
literature on the validation of this simulation.
2. All work pertains to investigation with single turbulator as reported by Kim [16].
In boiler application number of turbulators will be placed along the periphery of
combustion. Effect of one turbulator on the other needs to be investigated.
3. Calculation of number of turbulators for the generation of intended heat transfer
needs to be confirmed. In the present analysis this aspect has been extended from
one turbulator. It needs further investigation.
4. Optimum shape and design of turbulator is critical area of research. Analysis
should be done with different shape and design of turbulators.
5. Performance data over a long period can be obtained only by constructing a boiler
and gathering data over a period of time.

REFERENCES
[1] Babcock and Wilcox;“Steam its generation and Use” , 1978, page 3 ;
[2] Carl D. Shields; “Boilers: Types, characteristics, and Functions”, F.W. Dodge
Corporation, 1961; Chapter 1 and 2.
[3] Accident of Sultana ship.
[4] Polytechnic club,
[5] Personal communication with Dr. Bimal Acherjee; Former Director, Calorex India Private
Limited.
[6] Personal Communication; Anna Chattrey U.N. Late; Former Technical Director; 3M
Boilers Private Limited.
[7] Heat transfer enhancement.
[8] Hottel H.C. and Saroffim A.F; “Radiative Transfer”; McGraw Hill Book Co. (1978).
[9] Siegel R. and Howell J.R; “Thermal Radiation Heat Transfer”, McGraw-Hill Kogaksha
Ltd. 1972; chapter 17.
[10] Mikheyev M. “Fundamentals of Heat Transfer”; Peace Publishers, Moscow.
[11] Bergels: “Techniques for increasing heat transfer” ; Handbook of heat transfer, Rohsenow
J.P., Hartnett , Cho Y.I. , Chapter 11, MacGraw Hill, New York.
[12] Advances in Heat Transfer, v 36, Thomas F. Irvine, Jr (1922-2001) Memorial Volume;
Academic Press-2001, pp 184-257.
[13] Gupte N and Date A. W. “Friction and heat transfer characteristics of helical turbulence
air flow in annuli”, Journal of Heat Transfer, vol 111, pp 337-341.
[14] Aasha R, Shanmugapriya M. Guide – Dr. S. Vaidyanathan; 3rd Engineering Project;
Sairam Engineering College; 2015
[15] Saha S.K., Gaitonde U.N., Date A.W. “Heat transfer and Pressure Drop characteristics of
laminar flow in a circular tube fitted with regularly spaced twisted tape element”,
ExpTherm Fluid Sci., vol 2, pp 310-322
[16] Nae – Hyun Kim, “Principles of Enhanced Heat Transfer‟ Taylor and Francis, 2005, Ch 7

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