HEAT RECOVERY FROM BOILER

STACK
Proposed project for recovering heat from boiler for water heating

Written BY

JEFFREY PABGAUNGANA

CHEMICAL ENGINEERING INTERN

MAY 15, 2023

Windmill.co.zw
Contents
INTRODUCTION ....................................................................................................................................... 3
INDUSTRIAL WASTE HEAT. ................................................................................................................... 3
Problem statement ......................................................................................................................... 3
Aim .................................................................................................................................................. 3
Objective ......................................................................................................................................... 3
DESIGN CONSIDERATIONS................................................................................................................... 3
LIMITATIONS/CHALLENGES TO RECOVERING LOW-TEMPERATURE WASTE HEAT .............................. 3
LITERATURE REVIEW ............................................................................................................................... 5
INTRODUCTION ................................................................................................................................... 5
TYPES OF HEAT EXCHANGERS ............................................................................................................. 5
Classification of Heat exchanger based on flow arrangement: ....................................................... 5
Classification according to construction: ........................................................................................ 6
Overall Heat Transfer Coefficient and Fouling Factor.............................................................................. 7
Heat Exchanger Analysis: .................................................................................................................... 7
Energy Analysis of Heat Exchangers: ................................................................................................... 8
LMTD (log mean temperature difference): ......................................................................................... 8
For Parallel Heat Exchangers: .......................................................................................................... 8
For Counter Flow Heat Exchangers: ................................................................................................ 8
LMTD Using Temperature Profile: ................................................................................................... 9
Other technologies applied to waste heat recovery ..................................................................... 10
OVERALL HEAT TRANSFER COEFFICIENT ....................................................................................... 10
FOULING FACTOR .............................................................................................................................. 11
CHAPTER THREE .................................................................................................................................... 12
FOULING ............................................................................................................................................ 12
INTRODUCTION ............................................................................................................................. 12
FORMS OF FOULING...................................................................................................................... 12
DESIGN AGAINST FOULING ............................................................................................................... 13
Introduction of turbulent flow upstream of the exchange core ................................................... 13
Using corrugated plates ................................................................................................................ 13
Moisture separator. ....................................................................................................................... 13
Material choices ............................................................................................................................ 14
Assumptions about the heat exchangers analyzed; are: ·............................................................. 14
CHAPTER FOUR ..................................................................................................................................... 15
THE HEAT EXCHANGER SYSTEM DESCRIPTION.................................................................................. 15
COMPONENTS AND PROPERTIES .................................................................................................. 15
 Heat exchanger core ..................................................................................................................... 15
Entry duct ...................................................................................................................................... 16
Exit stream .................................................................................................................................... 16
Draught system ............................................................................................................................. 18
MODEL TESTS ........................................................................................................................................ 18
INTRODUCTION
INDUSTRIAL WASTE HEAT.
This is heat lost in industries through ways such as the discharge of hot combustion gases to the
atmosphere through chimneys, the discharge of hot wastewater, and heat transfer from hot surfaces.
This energy loss can be recovered through heat exchangers and be put to other use such as
preheating other industrial fluids such as water or air. This project focuses on recovering heat that is
lost through boiler stack flue gas.

The advantages of heat recovery include:

1. Increasing the energy efficiency of the boiler.

2. Decreasing thermal and air pollution dramatically.

Problem statement
There have been losses of energy that is being lost by the flue gas over the past years which can be
recovered.

Aim
To recover heat from boiler stack flue gas to pre heat water for bathing or any relevant use.

Objective
To recover at least 50% of the heat lost to the environment

Justification
Clean air released to the environment

Increasing the lifespan of the boiler stack after the new design.

DESIGN CONSIDERATIONS
In the designing of the exchanger, the following factors were put into consideration.

1. The exchanger surface has to be the most efficient and suitable for gas-liquid heat exchange.
2. The design has to consider the fouling effect of the flue gases.
3. The design has to allow for quick maintenance without interfering with the boiler operations.
4. The ducting design has to conform to the boiler chimney design.

Based on the above factors, the exchanger was designed to be of compact plate type. Various
designs for the exchange core were considered including cylindrical type (ducts). The plate type was
found to be more efficient and simpler in design but was more suitable for gas - to gas heat exchange
as it offers a higher surface for heat transfer.

LIMITATIONS/CHALLENGES TO RECOVERING LOW-TEMPERATURE WASTE HEAT

Compared with the low-temperature waste heat, high-temperature waste heat is more easily to be
recovered due to its high energy level which could meet the user demand with different temperature
requirements. The high-temperature waste heat could also be used for power generation with
relatively mature technologies such as steam turbines or organic Rankine cycle.

For the same reason, the application of low-temperature waste heat recovery is limited by its
temperature level: suitable user demand is not always available, and the heat-power conversion is
not efficient for low-temperature waste heat. Besides, as the temperature level of low-temperature
waste heat is close to the ambient, heat exchange optimization is crucial to minimize the irreversible
loss during the waste heat recovery. All these issues lead to difficulties and challenges in effectively
achieving low-temperature waste heat recovery.

To address these issues, the paper first briefly summarizes our options for low-temperature waste
heat recovery. Then, the barriers that prevent the wide application of low-temperature waste heat
recovery are analyzed.
LITERATURE REVIEW
INTRODUCTION
Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at
different temperatures while keeping them from mixing. Heat transfer in heat exchangers involves
convection in each fluid and conduction through the wall separating the two fluids. To account for
the contribution of all the effects of convection and conduction, an overall heat transfer coefficient,
U, is used in the analysis. Heat transfer rate depends on the temperature differences between the
two fluids at the location and the velocity of the fluids (time of interaction) between the fluids.

TYPES OF HEAT EXCHANGERS

• Direct Transfer Type Heat Exchangers: In this type of heat exchanger, cold and hot fluids flow
simultaneously through the device and heat is transferred through a wall separating the
fluids.

• Storage Type Heat Exchangers: In Storage type of heat transfer from hot fluid to cold fluid
occurs through a coupling medium in the form of a porous solid matrix. The hot and cold
fluids flow alternatively through the matrix, the hot fluid stores heat in it and the cold fluid
extracts heat from the matrix.

• Direct Contact Type Heat Exchangers: This is one in which the two fluids are not separated.
If heat is to be transferred between a gas and a liquid, the gas is either bubbled through the
liquid or the liquid is sprayed in the form of droplets into gas.

Classification of Heat exchanger based on flow arrangement:

• Parallel Flow Exchanger: In a parallel flow Heat Exchanger, Hot and cold fluid enters at the
same end, flows in the same direction and leaves at the same end.
 • Counterflow Exchanger: In counterflow, fluids enter at the opposite end, flow in the
opposite direction and leave in the opposite direction.

• Crossflow Exchanger: In cross flow, two fluids flow in directions normal to each other. Cross
flow is further classified into unmixed or mixed depending upon flow. In Figure 1, cross-flow
is mixed as now fluid is free from moving in the transverse direction(direction parallel to the
tubes) In Figure 2, cross-flow is unmixed as plate fins force the fluid to flow through a
particular interfin spacing and prevent it from moving it in direction to parallel to tubes.
Since tube flow is unmixed, Thus, both fluids are unmixed in the finned exchanger while one
fluid is mixed other is unmixed in the unfinned exchanger. The presence of mixing has a
significant impact on heat transfer.

Classification according to construction:

• Shell-and-Tube Heat Exchanger: It Contains a large number of tubes packed in a shell. Heat
transfer takes place as one fluid flows inside the tubes and another fluid flows outside the
tube and inside the shells. Baffles are usually installed to increase the convection coefficient
of shell side fluid by inducing turbulence and a cross-flow velocity component. They also
support the tubes and reduce flow-induced tube vibration.
 • Plate Type Heat Exchanger: It has a series of large rectangular thin metal plates which are
clamped together to form a narrow parallel plate channel. Hot and cold fluids flow in
alternate passages. These are very suitable for liquid-to-liquid heat exchange applications.

• Compact Heat Exchanger: These heat exchangers have a dense array of finned tubes or
plates and are typically used when one fluid is gas. Thus they have a small convection
coefficient. Tubes may be flat or circular and fins may be flat or circular.

Overall Heat Transfer Coefficient and Fouling Factor

The overall Heat Transfer Coefficient is defined in terms of total thermal resistance to heat transfer
between two fluids.

During normal Heat exchanger operation, surfaces are often subject to fouling by fluid impurities,
rust formation or other reactions between the fluid and the wall material. The subsequent
deposition of film or scale on the surface can greatly increase the resistance to heat transfer between
the fluids. This effect can be treated by introducing a thermal resistance known as the fouling factor.
Its value depends upon the operating temperature, fluid velocity and length of service of the heat
exchanger.

Thus, for a new heat exchanger fouling factor is zero and its value increases with time as solid
deposits on the heat exchanger surface.

Heat Exchanger Analysis:

To predict the performance of the heat exchanger we relate the heat transfer to the inlet and outlet
temperature of fluids, the overall heat transfer coefficient (U) and the total surface area for Heat
Transfer (A).
Energy Analysis of Heat Exchangers:
Hot fluid having inlet temperature Th,i and outlet temperature Th,o having specific heat cp,h and
cold fluid having inlet temperature Tc,i and outlet temperature Tc,o having specific heat cp,c. Hot
fluid flows with m ̇h and cold fluid with m ċ .

If q is total heat transfer between hot and cold fluids and negligible heat loss between surrounding
and heat exchanger, also neglecting kinetic and potential losses:

This is the energy equation.

LMTD (log mean temperature difference):

We can write Heat Transfer q as:

Where ∆𝑇𝑚 is the appropriate mean temperature difference. To perform a Heat Exchanger Analysis
∆𝑇𝑚 should be known.

For Parallel Heat Exchangers:

Taking some assumptions as

• Heat Exchanger is insulated from surrounding so that heat is exchanged between cold and
hot fluid only.

• Neglecting axial conduction

• Neglecting kinetic and potential Energy

• Assuming specific Heat and U constant

We can write:

For Counter Flow Heat Exchangers:

For the Counterflow Heat Exchanger also previous equation can be used, only endpoint
temperatures are different.
We can note for the same inlet and outlet temperature LMTD for counter flow exceed that for
parallel flow and hence for the same q and U area for counter flow is smaller than parallel flow Heat
Exchangers.

Remark:

Use of the LMTD Method for Heat Exchanger analysis is simple when inlet and outlet temperatures
are known otherwise NTU method is preferred.

LMTD Using Temperature Profile:

We can easily get LMTD with a temperature profile using the formula given below:

For Parallel flow Heat Exchanger:

For Counter Flow Heat Exchanger:

Remarks:
For Counterflow Heat Exchanger with equivalent Heat capacity (Ch = Cc ):

≫ ∆T1 = ∆T2 = ∆Tm

Other technologies applied to waste heat recovery

• Regenerators

This is a type of heat exchanger where heat from the hot fluid is intermittently stored in a
thermal storage medium before it is transferred to the old fluid. This type of heat exchanger
can be the same fluid. The fluid may go through an external processing step and then it flows
back through the heat exchanger in the opposite direction for further processing

• Recuperators
It is a counter-flow energy recovery heat exchanger used in industrial processes to recover
waste heat.
• Thermal wheel.
A rotary heat exchanger consists of a circular honeycomb matrix of heat-absorbing material
which is slowly rotating within the supply and exhaust air streams of an air handling system
• Economizer
In the case of process boilers, waste heat in the exhaust gas passed along a recuperator that
carries the inlet fluid for the boiler and thus decreases the energy intake of the inlet fluid.
• Run around the coil.
Comprises 2 or more multi-raw finned tube coils connected by a pumped pipe work circuit.

OVERALL HEAT TRANSFER COEFFICIENT

In the analysis of heat transfer in heat exchangers, various thermal resistances in the path of heat
flow from the hot to cold fluid are combined. Heat is first transferred from the hot fluid to the wall by
convection, through the mass by conduction and from the wall to the cold fluid by convection. Any
radiation effects are usually included in the convection heat transfer coefficients. The total thermal
resistance, R, for the whole system, is given by:- R= thermal resistance of inside flow + thermal
resistance of the systems material + thermal resistance of outside flow.

Where

• hi, ho= heat transfer coefficients for inside and outside flow respectively
• k= Thermal conductivity of the exchanger material
• R= Total thermal resistance from inside to outside flow
• t= Thickness of the heat exchanger material

• Ai, Ao= Inside and outside surface areas of the heat exchanger surfaces respectively.

Expressing the thermal resistance R as an overall heat transfer coefficient based on either the fluid
inside or outside surface of the heat exchanger surface areas:

If the wall thickness is small and its thermal conductivity is high the material resistance may be
neglected and hence the overall heat transfer coefficient becomes:

In applications of heat exchangers, accumulation of deposits mostly from combustion, on the heat
exchanger surface causes additional thermal resistance, a condition known as fouling. Effects of
fouling are introduced in the heat transfer coefficient in the form of a fouling factor. The total
thermal resistance then became:

Where Fi and Fo are the fouling factors on the inside and outside surfaces respectively.

FOULING FACTOR
The performance of heat exchangers usually deteriorates with time due to the accumulation of
deposits on the heat transfer surface. The accumulation of deposits leads to increased resistance to
heat transfer and causes the rate of heat transfer in a heat exchanger to decrease. This accumulation
of deposits on the heat transfer surface is known as fouling and the net effect of fouling is
represented by a fouling factor, Rf, which is a measure of the thermal resistance introduced by
fouling.
CHAPTER THREE
FOULING
INTRODUCTION
Fouling is a general term that includes any kind of deposits of extraneous material that appear on the
heat transfer surface during the lifetime of the heat exchanger.

Fouling reduces heat transfer across the exchanger surface hence reducing the efficiency of the heat
exchanger. The fouling deposits also reduce the flow cross-section area causing a pressure
differential across the heat exchanger which in turn increasing on the fan power required. It might
also eventually block the heat exchanger.

Different kinds of fuel produce different degrees of fouling, most fuel produces just soft black soot
that gets deposited on the exchanger surface.

This can easily be removed by brushing and sand washing. However, lower-grade fuel oil(principally
no.6.oil or resid) contains large quantities of alkaline sulfates and vanadium pentoxide that cause
scaling due to their lower fusion temperatures.

The forms of fouling may therefore include

• Particulate fouling.
• Scaling/precipitation.
• Chemical/corrosion fouling.
• Solidification.

FORMS OF FOULING
Scaling/precipitation: - scaling/precipitation occurs as a result crystallization of dissolved substance
onto the heat transfer surface. These deposits can be removed by scratching or by cleaning via
chemical treatment. This is the most common type of fouling.

Scaling/precipitation can be reduced by treating the fluid flowing past the heat exchanger before it
reaches the heat exchanger surface.

Particulate fouling
This results from the accumulation of solid particles suspended in the process fluid onto the heat
transfer surface. Such solid particles can be removed by use of filters to treat the process fluid before
it reaches the heat exchanger surface.

Chemical /corrosion fouling

In this case, the surfaces are fouled by an accumulation of the products of chemical reactions on the
surfaces. This form of fouling can be avoided by coating the heat exchanger surfaces with glass. Heat
exchanger surfaces can also be fouled by the growth of algae in warm fluids (chemical fouling) which
can be prevented by chemical treatment.

Solidification fouling

The crystallization of a pure liquid or one component of the liquid phase on a sub-cooled heat
transfer surface. The mechanism of fouling is complicated and no reliable techniques are available
but there are means of reducing fouling. The methods mostly used to reduce fouling include the use
of filters and increasing the fluid flow to ensure turbulent flow.
 As a general rule, fouling rates tend to be higher on the liquid than on the gas side, and higher on
the hot than on the cold fluid side.

DESIGN AGAINST FOULING

It was our duty to consider the effect of fouling upon the heat exchanger's performance during the
desired operation lifetime and make provisions in our design for sufficient extra capacity to ensure
that the exchange will meet process specifications up to shut down for cleaning.

The mechanical arrangements that are necessary to permit easy cleaning were considered. In the
design, the following measures have been taken to reduce the rate of fouling.

i. moisture separator.
ii. Introduction of turbulent flow upstream of the exchanger core.
iii. Using corrugated plates
iv. Maximizing flow velocity

Introduction of turbulent flow upstream of the exchange core

The cone shape element at the gas-duct entry causes turbulence as it suddenly opens into the larger
gas duct .this causes turbulence. This turbulent flow of air picks with it some of the particles that
stick on the exchanger surface due to its drag effect. This helps to reduce fouling.

Turbulence only minimizes the rate of fouling. But the fouling still takes place. This, therefore,
implies that the exchanger will require maintenance (cleaning). Various ways could be used in
cleaning the exchanger. In the design, I consider using the following methods.

1. Blowing
2. Washing

The system was designed with a slit on the wall of the flue gas duct downstream of the exchanger.
This allows overhead water washing. Pressurized water mixed with abrasives e.g. fine sand is used to
remove soot that cannot be removed by blowing air past the exchanger. The abrasives help in
scrubbing the surface.

Before washing a lid is installed at the inlet flue gas duct to prevent water from entering the boiler.
During washing the waste water drains out of the system through the outlet ducts at the base of the
flue gas inlet duct.

Using corrugated plates

The heat exchanger plates are pressed in a so-called herringbone corrugation pattern. When two
plates are superimposed with opposing herringbone patterns, this type of corrugation generates a
helix-like flow with very high turbulence, thus producing the essential condition for achieving high
transfer coefficients and effective heat exchanger self-cleaning. By changing the plate corrugation
pattern, the heat exchanger can be used in different processes, even those with very dirty media.

Moisture separator.
A moisture separator is used to remove suspended water particles from the flue gas line and supply
dry flue gas to the outlet duct, increasing operational efficiency.

Maximizing flow velocity

Increasing the flow velocity will increase the shear stress on the heat transfer surface; if the foulant
layer is susceptible to removal, this will increase the removal rate and reduce the rate of fouling
resistance growth, and the asymptotic value of the foulant layer. Maximizing flow velocity within
allowable pressure drop limits will frequently minimize the fouling resistance if the foulant layer is
easily removable. This is typically the case for particulate fouling.

Material choices
The material chosen for the heat exchanger must be suitable for the type of physical construction,
be compatible with the fluid temperature ranges expected, and not be corroded by the fluids. Cost is
a significant concern as well, while thermal conductivity is rarely a significant issue.

Assumptions about the heat exchangers analyzed; are: ·

1. There is no heat transfer between the fluid streams and the outside environment ·
2. There are no leakages from the fluid streams to each other or the environment ·
3. No heat is generated or lost via chemical or nuclear reactions, mechanical work, or other
means ·
4. There is no heat conduction along the length of the heat transfer surface, only in the
direction of the normal of the surface ·
5. No flow maldistribution: fluid flow rates are equally distributed throughout the whole cross-
sectional areas of flow ·
6. Where temperature distribution transverse to the flow direction is relevant, any fluid flow
can be considered either completely mixed or completely unmixed ·
7. Properties of fluids are constant inside the heat exchanger ·
8. The overall heat transfer coefficient is constant at all locations of the heat exchanger.
CHAPTER FOUR

THE HEAT EXCHANGER SYSTEM DESCRIPTION

COMPONENTS AND PROPERTIES

Every part of the system is described and explained in this section, the system was designed to have
the following characteristics

DESIGN PARAMETERS OF THE HEAT EXCHANGER

Table 1

Plate depth 6mm

Inlet water temperature 20-26℃

Outlet water temperature ℃

Inlet flue gas temperature 140-160℃

Outlet flue gas temperature To be calculated

Volume of core 20l

Plate thickness 0.1mm

Effectiveness 0.75

𝑈𝐴 To be measured

Number of passages for flue gas 30

water 30
R To be calculated

Heat exchanger core

It consists of aluminium plates 0.1mm thick with a depth of 6mm and width of 0.5mm gasketed
together. The sealant has good heat resistance properties. The sealant also has good elastic
properties that ensure sealing even during plate expansion. Galvanized binding wires were used to
hold the exchange core fit in the frame and at the centre by aluminium spacers that ensured even
spacing between plates to reduce pressure drop.

core dimensions core structure design

Entry duct

It provides an end that can be covered by a lid during cleaning to prevent water from entering the
boiler. Small holes are left at its joint to the gas duct to allow water out. It has a base diameter of
48cm (same as a boiler chimney), a neck which is 30cm long and a 68cm square joint.

Exit stream

Base diameter of 48cm

Ducts

Cold water in Hot water out

Flue gas
outlet duct

Moisture
separator

Heat
exchanger core

Entry duct
 heat to
boiler id fan precipitator boiler stack
exchanger atmosphere

Draught system
It consists of an electric motor with 40hp(same as boiler stack motor).

MODEL TESTS
RESULTS AND ANALYSIS