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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

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 Chapter 14
Print ISBN: 978-93-91595-34-0, eBook ISBN: 978-93-91595-42-5

Heat Transfer Analysis in 4-Pass 500HP Fire-Tube

Boiler
Ahmed Rahmani1* and Messaoud Djeddou2
DOI: 10.9734/bpi/naer/v10/3174F

ABSTRACT
This paper deals with a steady-state heat transfer analysis in a 4-pass fire-tube boiler. A
computational program has been developed to study the heat transfer between the combustion gases
and the boiler tube walls. On these surfaces, the energy balance was established, taking into account
the heat transfer by convection and thermal radiation. The heat transfer characteristics, namely, the
heat flux densities and the corresponding wall temperatures, are evaluated for different operating
conditions. The modeling approach was validated by comparing the calculated outlet gas temperature
against the experimental data, of the PFTA 500HP fire-tube boiler, for three types of fuels and various
operating pressures. The comparison shows that the calculation results are in good agreement with
the boiler's experimental data. A parametric analysis has also been conducted to investigate the
working pressure effect on the boiler thermal behavior.
Keywords: Fire-tube boiler; combustion; heat transfer; nucleate boiling; radiation; convection.

1. INTRODUCTION
Due to their operational flexibility, high long-term efficiency, and reliability, fire-tube boilers are used
broadly in combined heat and power [1]. Fire-tube boilers are chosen due to their capacity in providing
hot water and steam at reduced and medium pressures [2,3]. Recent progress in boiler design and
more efficient fire-tube layout has resulted in more compact, less costly packages, more accessible
for cleaning and inspection [4,5]. Accurate prediction of heat transfer characteristics is of significant
importance for boiler safety [6]. Several numerical and experimental studies have been conducted to
understand the thermal-hydraulic behavior of conventional boilers [7-10]. In the past, traditional
methods relied heavily on expensive experimentation and the building of scaled models, but now
more flexible and cost-effective approaches are available through the use of CFD techniques and
other advanced thermal-hydraulic system codes [11,12].
This work aims to elaborate a calculation program for estimating the heat transfer characteristics
between the combustion gases and the internal walls of a 4-pass 500HP fire-tube boiler. An energy
balance is established at these surfaces, considering both radiation and convection heat transfer. A
set of simplifying assumptions has been adopted to reduce the complexity of the boiler [13]. The plug-
flow furnace model was used to predict the variation of the thermal parameters throughout the gas
flow path. The boiling heat transfer at the boiler water-side was estimated using a set of empirical
correlations. The modeling validation was carried by comparing the calculated gas temperatures
exiting the boiler with the measured one for the steady-state regime under different operating
conditions. Furthermore, the pressure effect on the boiler's heat transfer characteristics has been
analyzed in this study.

2. BOILER MODELING AND SIMULATION

The plug-flow furnace model is used to simulate the heat transfer characteristics in the boiler [14].
This model is more appropriate to predict the peak heat flux density in the furnace. The four passes of
_____________________________________________________________________________________________________
1
Department of Mechanical Engineering, University of Oum El Bouaghi, 04000, Algeria.
2
Research Laboratory in Subterranean and Surface Hydraulics (LARHYSS), Faculty of Sciences and Technology, Mohamed
Khider University, Biskra, Algeria.
*Corresponding author: E-mail: mag_phy@yahoo.fr;
 New Approaches in Engineering Research Vol. 10
Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

the boiler were sliced into several elementary sections of length Δx in the gas flow path (Fig. 1). Each
element represents an isothermal gas volume enclosed by isothermal surfaces. An energy balance is
established for each control volume, taking into account the generated and the transferred power.

Fig. 1. Nodalization scheme for the boiler tubes

The internal energy for each volume is estimated by the gas enthalpy difference between the inlet and
the outlet of the element (Eq. 1). On the other hand, the gas energy variation represents the
difference between the heat released rate and the heat transferred to the surrounding water (Eq. 2).

∆𝑄 = 𝑀𝑔 𝐶𝑝𝑔 ∆𝑇𝑔 (1)

∆𝑄 = (𝑞𝑟𝑒𝑙𝑒. − 𝑄𝑒𝑥𝑐ℎ. )∆𝑥 (2)

Then, the gas temperature difference between two adjacent volumes, ΔTg, may be expressed by Eq.
(3). Where Mg is the total mass flow rate of combustion gases and Cpg is the gas-specific heat
capacity. The recurrence formula, given by Eq. (4), enables the gas temperature Tg(j) calculation
along the gas flow path. Where, j = 1, 2…, N, denotes the element axial location.

𝑞𝑟𝑒𝑙𝑒. (𝑗) − 𝑄𝑒𝑥𝑐ℎ. (𝑗)

∆𝑇𝑔 (𝑗) = ( ) ∆𝑥 (3)
𝑀𝑔 𝐶𝑝𝑔 (𝑗)

𝑇𝑔 (𝑗) = 𝑇𝑔 (𝑗 − 1) + ∆𝑇𝑔 (𝑗 − 1) (4)

The heat release pattern along the flame is generally described by exponential [15], parabolic [16], or
simple form. In the present work, the parabolic shape proposed by Roesler is applied [17]. The heat
released rate, qrele, is calculated by multiplying the total generated power, Qf, by the fraction of heat
released along the furnace:

6 𝑥 𝑥²
𝑞𝑟𝑒𝑙𝑒. = 𝑄𝑓 [ ( − )] , 𝑓𝑜𝑟 𝑥 ≤ 𝐿𝑓 (5)
{ 𝐿𝑓 𝐿𝑓 𝐿²𝑓
𝑞𝑟𝑒𝑙𝑒. = 0 , 𝑓𝑜𝑟 𝑥 > 𝐿𝑓 (6)

Where, Lf, is the flame length and L, is the furnace’s total length.

2.1 Gas-side Heat Transfer

The heat transfer is estimated using the plug-flow furnace model [13,18]. This model is more
appropriate in predicting the axial distribution of the thermal parameters such as heat flux densities,
wall and gas temperatures, and heat transfer coefficients. The gas within the furnace is assumed to
be gray, the gas temperature is uniform in each volume cross-section, and the axial radiation heat
transfer is negligible. The heat exchange from the hot gases to the furnace's tube walls is carried out
by both radiation and convection [16,19]:

4
𝑄 = 𝑔𝑟𝑎𝑦 𝜎(𝑇𝑔4 − 𝑇𝑤𝑖 ) + ℎ𝑔 𝐴𝑖 (𝑇𝑔 − 𝑇𝑤𝑖 ) (7)

Where σ is the Stefan-Boltzmann constant, hg is the convective heat transfer coefficient from the gas
to the wall, Ai is the internal tube area, εg is the gas emissivity, and εw is the internal wall emissivity.
The total radiation transfer factor (gray) from the gas to the sink is expressed by:

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

−1
𝑔𝑟𝑎𝑦 = [1⁄𝜖𝑤 + 1⁄𝜖𝑔 − 1] (8)

The overall heat transfer coefficient (hi) is defined as the sum of convective and radiative heat transfer
coefficients from the gas to the sink (Eq. 9). The heat transfer coefficient, hg, is obtained from
McAdam's correlation (Eq.10), where di is the internal tube diameter.

4
𝜎𝑔𝑟𝑎𝑦 (𝑇𝑔4 − 𝑇𝑤𝑖 )
ℎ𝑖 = ℎ𝑔 + (9)
(𝑇𝑔 − 𝑇𝑤𝑖 )

𝑘𝑔 0.8 0.4
ℎ𝑔 = 0.023 𝑅𝑒 𝑃𝑟 (10)
𝑑𝑖

Thermo-physical properties of the combustion products, namely: Density (ρ g), specific heat capacity
(CPg), thermal conductivity (kg), dynamic viscosity (μg) and emissivity (εg), are given as a function of
temperature [20].

11.484𝑛 + 0.2272𝑛𝐻
𝜌𝑔 = 1.293 (11)
11.484𝑛 + (0.2272𝑛 + 0.71865)𝐻

𝑡𝑔 𝑡𝑔 2
𝐶𝑝𝑔 = 971.7 + 10.49𝑚 + (325.35 − 4.97𝑚) − (76.59 − 6.07𝑚) ( ) (12)
1000 1000

𝑡𝑔 𝑡𝑔 2
𝐾𝑔 = (21.924 − 0.0337𝑚 + (86.467 + 0.0966𝑚) − (12.9910.6229𝑚) ( ) ) 10−3 (13)
1000 1000

𝑡𝑔 𝑡𝑔 2
𝜇𝑔 = (16.86 − 0.1106𝑚 + (43.449 − 0.111𝑚) − (11.19 + 0.0985𝑚) ( ) ) 10−6 (14)
1000 1000

𝜀𝑔 = 0.30541 − (1.5698. 10−4 ) ∙ 𝑇𝑔 + (6.5718. 10−8 ) ∙ 𝑇𝑔 2 − (3.9107. 10−11 ) ∙ 𝑇𝑔 3

+ (8.4226. 10−15 ) ∙ 𝑇𝑔 4 (15)

The mass moisture percentage of the flue gas (m) is given by the following formula:

𝑚 = 8.936𝐻 ⁄(11.484𝑛 + 1 + 0.2272𝑛𝐻) (16)

Where H is the mass percentage of the hydrogen, n is the air index for the fuel.

2.2 Water-side Heat Transfer

At the water-side, the heat is transferred by the nucleate pool boiling heat transfer regime. For the
furnace horizontal cylinder, the predicted boiling heat transfer coefficient is obtained according to
Gorenflo correlation:
0.15
ℎ𝑜 = 5580𝐹𝑃𝐹 (𝑞𝑜 ⁄20000)0.9−0.3𝑃𝑟 (17)

Where, qo is the heat flux density and FPF is expressed by: 𝐹𝑃𝐹 = 1.73𝑃𝑟0.27 + (6.1 + 0.68/(𝑃𝑟2 ))𝑃𝑟2 .

In the convection section, the boiling heat transfer coefficient of the tube bundle is higher than that for
an individual tube (h1) in Eq. (17) due to the vapor bubbles’ agitation that enhancing the heat
transfers. By taking into account this effect, the heat transfer coefficient in the convection section
tubes may be calculated by the following formula [21]:

1
ℎ𝑜 = ℎ1 (1 + ) (18)
2 + 𝑞𝑜 ⁄1000

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

3. WORK PROCEDURE

3.1 Boiler Description

The studied unit is a 4-pass PFTA 500HP water-backed fire-tube boiler designed to produce 7.6 ton/h
of saturated steam at 25 bars. This type of boilers is firstly introduced in 1978 by the Johnston Boiler
Company [22]. This type of boilers has the benefits of low maintenance costs, high reliability, and high
efficiency, reaching 90%. It can be powered by natural gas or fuel oil. The total water amount in the
boiler is about 12 m 3. The furnace length is 5 m, and its internal diameter is 1.067 m. The convection
section in the boiler contains 232 tubes, which represent a heating surface of about 237.5 m². Fig. 2
shows a typical design of the 4-pass fire-tube boiler.

Fig. 2. A cross-sectional view of the 4-pass fire-tube boiler

From a heat transfer point of view, the boiler can be divided into two parts, namely: the radiation
section and the convection section. The first (1st pass) is a horizontal cylindrical tube in which the fuel
is burned to generate heat. The heat transfer within this section is performed mainly by radiation,
where convection may contribute by less than 20% [16]. The convection section is a horizontal
smoke-tube bank located above the 1st pass, recovering additional heat from the furnace gases at a
lower temperature level than the radiant section [23]. Boiler tubes are immersed in saturated water,
which absorbs heat enough to change into a vapor state. The dominant heat transfer mechanism in
this section is convection. Fuel and air are forced into the furnace to produce heat. The number of
tubes in each pass is selected to give similar velocities in each pass. Due to the forced-draft fan, the
combustion chamber is slightly under pressure to facilitate the evacuation of the fumes [15]. The hot
gases move from the radiation section toward the convection section, crossing the boiler passes, and
finally escape by the chimney to the atmosphere.

3.2 Calculation Procedure

The overall calculation scheme for the complete model is presented in Fig. 3. Thermal properties of
the combustion products like emissivity, heat capacity, thermal conductivity are correlated versus gas
temperature. The material tube's conductivity was also correlated versus wall temperature and its
emissivity is εw=0.85.

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

Fig. 3. Adopted sequences for solution

4. RESULTS AND DISCUSSION

4.1 Modeling Validation

In order to validate the computer code, the calculated gas temperature is compared with the
experimental one for different operating pressures and three types of fuel. The boiler operating data
can be found in Ref. [22]. Table 1 summarizes the comparison between the predicted gas
temperatures exiting the boiler and the measured one. As could be seen, good agreement is obtained
against the boiler data for various operating conditions. The maximum error in predicting the boiler
outlet gas temperature is 9%. All the calculated temperatures exceed the measured values. This
deviation is probably due to neglecting heat transfer at the transition boxes between the boiler passes.
As reported by Beyne et al. [24], these transition boxes contribute by over 7% to the total heat
transfer.

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

Table 1. Comparison between calculated and experiment data of the boiler outlet gas
temperature

Working Natural Gas (0.11 kg/s) Fuel oil #2 (0.114 kg/s) Fuel oil #6 (0.134 kg/s)
pressure Experiment Calculatio Experimenta Calculatio Experimenta Calculatio
(bar) al data (°C) n (°C) l data (°C) n (°C) l data (°C) n (°C)
0.689 136.7 149.0 141.7 150.7 147.2 158.1
3.447 168.9 180.0 173.9 181.7 180.0 189.0
6.895 191.7 201.5 196.1 203.2 202.8 210.4
10.34 207.2 216.6 212.2 218.3 218.9 225.4
13.79 219.4 228.6 224.4 230.2 231.7 237.2
17.24 230.0 238.6 235.0 240.2 242.2 247.2
20.68 238.9 246.3 243.9 248.8 251.7 255.8

4.2 Boiler Performances

In this section, a qualitative analysis is carried out to study the operating pressure effect on heat
transfer performances. The axial profiles of gas temperature, heat flux density, heat transfer
coefficient, wall temperatures, and heat exchanged power along the boiler passes are analyzed. Fig.
4 shows that the operating pressure hasn't a notable influence on the gas temperature.

Fig. 4. Gas temperature profile along the boiler passes

Fig. 5. Heat flux density distribution along the gas flow path

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

The variation of the heat flux density along the boiler tubes is shown in Fig. 5. The peak heat flux is
situated in the radiation section (1st pass), which attains 105 kW/m². The pressure variation hasn't a
remarkable effect on the heat flux, especially in the convection section. The increase in the operating
pressure influences the water's physical properties and increases the boiling heat transfer (Fig. 6),
where the maximum value of the pool boiling heat transfer coefficient is 15.81 kW/m²K. The
calculation shows that a large proportion of the heat transfer rate takes place in the radiation section.
This increase in the heat exchange is due to the slight elevation in the wall temperature that increases
the bubble vapor generation (Fig. 7).

Fig. 6. Variation of the water-side heat transfer coefficient along the gas flow path

Fig. 7. Variation of the internal/external tube wall temperature along the gas flow path

Fig. 7 shows the variation of the internal and external wall temperature under the pressure effect. As
the pressure increases, the saturation temperature increases and consequently, the wall temperature
increase. The temperature difference between the inner and outer wall is widened due to the
decrease of the material thermal conductivity at this location.

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

Fig. 8 shows the profile of the heat transferred power along the furnace tube (1st pass). The
numerical calculation results showed that the amount of heat transferred to the water is 1.06 MW. In
the combustion chamber (1st pass), the radiation heat transfer rate is evaluated to 877 kW, which
represents 82.65% of the total exchanged power. The convection part in this section is estimated to
184 kW, which denotes that the convection process contributes by about 17.34% to the total heat
transfer. The heat transfer within the boiler furnace is performed mainly by radiation.

Fig. 8. Exchanged power along the combustion chamber

Fig. 9 depicts the heat transferred power along the 4-pass of the boiler. The total exchanged power
from the combustion gases to the boiler water is 4.63 MW. In the convection section (1st, 2nd and 3rd
pass), 3.57 MW was transferred to the water within the tube bundles, which represents about 77% of
the total exchanged power in the whole boiler. In the furnace (1st pass), the rate of heat transferred is
about 23%. This is mainly due to the high heat transfer area of the convection section compared to
the radiation section.

Fig. 9. Power distribution along the gas flow path

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Heat Transfer Analysis in 4-Pass 500HP Fire-Tube Boiler

5. CONCLUSION

In this work, a numerical simulation is carried out to analyze the thermal behavior of a 4-pass fire-tube
boiler. A calculation program has been developed to study the heat transfer characteristics of the
PFTA 500HP boiler operation for several steady-state operating conditions. The calculation program
is based on heat transfer laws between hot gases and the boiler's internal walls, using the plug-flow
furnace model. The obtained results are compared to the boiler operating data for several operating
conditions. The comparisons show a good agreement between the calculations and the boiler data.
The calculation results show that the convection mode is the dominant heat transfer mode, which
participates by about 80% in the heat exchange in the considered fire-tube boiler. A parametric
analysis has been performed to evaluate the operating pressure effect on the boiler heat transfer
characteristics. The analysis results show that increasing the working pressure increases the heat
transfer, especially at the boiler water-side.

ACKNOWLEDGEMENTS

The authors gratefully acknowledge Dr. Zakaria Haddad and Dr. Omar Meglali from the University of
M’sila for their kind cooperation.

COMPETING INTERESTS

Authors have declared that no competing interests exist.

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Biography of author(s)

Prof. Ahmed Rahmani

Department of Mechanical Engineering, University of Oum El Bouaghi, 04000, Algeria.

He is a full professor in the Mechanical Engineering Department, Larbi Ben M'hidi University, Oum El Bouaghi-Algeria. His
research interests lie in the area of safety analysis of thermal installations, renewable energies and solar desalination. He is the
author of more than 20 research papers in international peer reviewed journals that have significant impact on
Scientific and academic community. He currently serves on the editorial boards of the Journal of New Technology and Materials
(2170-161X) and the Journal of Renewable Energies (1112-2242). He has served as a reviewer for more than 20 journals in
different ISI journals.

Dr. Messaoud Djeddou

Research Laboratory in Subterranean and Surface Hydraulics (LARHYSS), Faculty of Sciences and Technology, Mohamed
Khider University, Biskra, Algeria.

He was born in Biskra, Algeria, in 1971. He received the Engineer diploma from the Hydraulic Department, Biskra University,
Algeria, in 1996 and the M.S. from National High School of Water Engineering and Environment, Strasbourg, France and Ph.D.
degrees from Biskra University, Algeria, in 2005 and 2014, respectively. Currently, he is an Assistant Professor at the Hydraulic
Department, Oum El-Bouaghi University, Algeria. His research interests include application of Machine Learning, ANN's, Hybrid
modelling, and Data mining in Thermo-Hydraulics, Water engineering and Air quality.
_________________________________________________________________________________
© Copyright (2021): Author(s). The licensee is the publisher (B P International).

DISCLAIMER
This chapter is an extended version of the article published by the same author(s) in the following journal.
American Journal of Chemical Engineering, 2(5): 65-70, 2014.

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