Condensation heat transfer on tubes in actual flue gas

In order to improve boiler efficiency, latent heat recovery from flue gas is a very important concept. Condensation heat transfer on horizontal stainless‐steel tubes was investigated experimentally by using an actual flue gas from a natural gas boiler. The experiment was conducted at different air ratios of the flue gas and a wide range of tube wall temperatures. The condensation pattern was similar to a dropwise condensation near the dew point. By decreasing the wall temperature, the wall region covered with a thin liquid film increased. The heat and mass transfer behavior was well predicted with the analogy correlation at the high‐wall‐temperature region. At the low‐wall‐temperature region, the total heat transfer was higher than that predicted by the analogy correlation. © 2001 Scripta Technica, Heat Trans Asian Res, 30(2): 139–151, 2001     

An experimental study on vapor condensation of wet flue gas in a plastic heat exchanger

An experimental system investigating condensation heat transfer of wet flue gas was set up, and the heat transfer performance of vapor‐gas mixture with vapor condensation was discussed. The experimental results of laminar flow in a plastic longitudinal spiral plate heat exchanger were obtained and are in good agreement with the modified classical film model. It is shown that the plastic air preheater can avoid acid corrosion in the low‐temperature field for the boiler using fuel containing sulfur and recover latent heat of the water vapor of the wet flue gas. Also some SO₂ was scrubbed during the vapor condensing process in the heat exchanger. © 2001 Scripta Technica, Heat Trans Asian Res, 30(7): 571–580, 2001     

Theoretical prediction of sulfuric acid condensation rates in boiler flue gas

Prediction of acid condensation has a critical role in designing heat exchangers to recover water vapor from power plant flue gas. Rates of mass transfer for condensation of sulfuric acid vapors onto heat exchanger tubes were theoretically investigated and a computer program for numerical simulations of sulfuric acid (H₂SO₄) condensation in a flue gas condensing heat exchanger was developed. Governing equations based on mass and energy balances for the system were derived to predict variables such as flue gas exit temperatures, cooling water outlet temperatures, and molar fractions and condensation rates of water and sulfuric acid vapors. The associated equations were solved using an iterative solution technique and a one dimensional finite difference method with forward differencing. The Controlled Condensation Method (EPA Method 8B) was applied to experimentally obtain concentration profiles of sulfuric acid vapor in flue gas along downstream in the system. Predicted results of sulfuric acid vapor condensation were compared with empirical data for model validation, and the discrepancy is analyzed in terms of measurement and computation uncertainties. It is found that from both modeling and test results sulfuric acids as well as water vapors are reduced and separated in condensing heat exchanger due to mass transfer with condensation in flue gas. The modeling methodology described here is applicable to theoretical prediction of sulfuric acid and water condensation in full scale flue gas condensing heat exchanger applications.     

Modelling and analyses of heat exchangers in a biomass boiler plant

A boiler plant is presented, in which the fuel is dried before combustion in a silo with air. The drying air is heated in a recuperative heat exchanger by the heat of flue gases. Hot air is then blown through the bed of fuel in the drying silo, while the fuel dries and the air cools down and becomes humidified. Heat of the moist exhaust air of the silo is recovered for the drying air and combustion air by a recuperative heat exchanger. Modelling of the thermal behaviour of the plant helps in understanding complex interdependencies of the two heat exchangers, the boiler and the dryer. The models of the heat exchangers and applications in analysing the boiler system are described in this paper. Calculating the combinations of extreme operational conditions gives the input data needed in comparing different types of heat exchangers, dimensioning the heat transfer area, choosing the control strategy and selecting the operating parameters and set‐values of the control system. Results of verification measurements and practical operation at a 40 kW_th pilot plant and a 500 kW_th demonstration plant are also discussed. Using engineering correlation formulas for heat and mass transfer, an adequate accuracy between the model and the measurements was achieved. Fouling was detected to be a major problem with the flue gas heat exchanger. However, in absence of condensation, the increase of a fouling layer with respect to time was observed to be low. Fouling was also a problem with the drying exhaust gas heat exchanger, but after the installation of a simple dust collector, a reasonable cleaning period was achieved. A mixed‐flow configuration was found to be the most appropriate for the flue gas heat exchanger. In order to avoid condensation of the flue gas the drying exhaust gas heat exchanger is indispensable in Finnish climate in the considered system. In addition to this, it decreases the need of fuel. A parallel‐flow type was found the most appropriate as the drying exhaust gas heat exchanger. Copyright © 2004 John Wiley & Sons, Ltd.     

含湿混合气体水平管外对流冷凝换热实验研究

回收烟气中的潜热和显热在提高锅炉效率和环境保护方面都具有重要意义。主要针对含湿混合气体在水平单管管外的对流冷凝换热进行了实验研究。通过对实验数据的分析,得到了烟气进口温度、冷却水进口温度、水蒸气的质量分数以及Re的变化对含湿混合气体在水平单管管外冷凝换热的影响。     

Analysis of two‐stage waste heat recovery based on natural gas‐fired boiler

Waste heat recovery (WHR) is crucial to the efficiency improvement of natural gas‐fired boiler systems. Two‐stage WHR systems based on the natural gas‐fired boiler were analyzed from the viewpoints of thermal efficiency and heat transfer irreversibility. An overall entransy dissipation‐based thermal resistance was derived to evaluate the irreversibility of WHR, including the entransy dissipations during condensation and in absorption heat pump (AHP). Compared with the basic WHR system, the two‐stage WHR systems have higher boiler efficiency and less irreversibility. The air‐humidified system recycles both the heat and vapor in flue gas, while the unutilized latent heat in the recovered vapor causes the boiler to be less efficient than the AHP system. Investigation on heat exchanger effectiveness of two‐stage WHR systems illustrated: in the two‐stage WHR system with air humidification, the increasing effectiveness of both heat exchangers could effectively increase boiler efficiency and reduce heat transfer irreversibility. In the two‐stage WHR system with AHP, boiler efficiency has a local optimum when the dew point occurs near the outlet of the first heat exchanger; increasing the second heat exchanger effectiveness is more efficient in improving boiler efficiency. The present work may provide available references and guidance for the design and optimization of the two‐stage WHR systems.     

耒阳电厂670 t/h煤粉锅炉排烟温度偏高原因分析及改造设计

通过对耒阳电厂670 t/h锅炉排烟温度偏高问题的分析,指出了造成排烟温度升高的主要原因.并就光管、鳍片和螺旋肋片管式省煤器,从传热方面、制造方面及投资方面进行了比较,经过热力计算及经济技术分析,提出了采用部分螺旋肋片管对省煤器进行改造的方案,并给出了设计计算的结果,计算表明该方案能降低锅炉排烟温度,提高锅炉效率,具有显著的节能效果.     

径向错列翅片管内凝结对流换热数值模拟分析

采用数值模拟方法,对径向错列翅片管内含不凝结气体水蒸气的凝结对流换热及阻力特性进行了综合分析。将编写的自定义函数(UDF)导入ANSYS FLUENT软件,对新型强化管传热性能和阻力性能进行了数值模拟,并根据管长方向壁面上蒸汽质量分数的变化情况,讨论分析了凝结过程中翅片管传热性能的变化规律。分析结果表明:与光管相比,内翅片管的强化传热效果随翅数增多、翅片换热接触面积增大而更加显著;另一方面,翅片管的流动阻力相应增大,对管路换热产生不良影响。在所研究翅型范围内16翅y=2x~2型翅片管综合强化换热效果更优;此外随着换热过程的持续,蒸汽凝结逐渐放缓;入口速度增大导致水蒸气凝结不充分,对换热效果的提升有一定制约。     

燃气锅炉烟气在滴型管外传热特性的数值分析

在回收燃气锅炉烟气余热时,采用特殊管型强化传热以吸收烟气中大量的水蒸气所携带的显热和潜热,可以降低锅炉的排烟温度,提高锅炉的热效率。对滴型管和圆管烟气侧传热特性进行数值计算,通过对计算结果的分析比较,探讨了影响传热的因素,得出滴型管的传热特性优于圆管的结论,为特殊管型在冷凝换热器中的应用提供参考。     

Experimental Study on the Heat and Mass Transfer of Teflon-Coated Tubes for the Latent Heat Recovery

Abstract

The heat and mass transfer on stainless steel and Teflon-coated tube surfaces in a steam-air mixture flow were experimentally studied to obtain design data for a heat exchanger to be used in the latent heat recovery from flue gases. The test section consisted of three horizontal tubes with a pitch of 67 mm. The diameter of the tubes was 25.4 mm, and the tube wall thickness was 1.2 mm. The steam-air mixture flowed vertically from top to bottom. The Teflon coating degraded the overall heat transfer coefficient by 19%, as compared to the bare stainless steel tube. The degradation of the overall heat transfer coefficient of the Teflon-coated tube comes from the additional heat transfer resistance due to Teflon coating. Its magnitude on heat transfer resistance is comparable to the in-tube heat transfer resistance. Nusselt and Sherwood numbers of Teflon-coated surfaces have a different trend compared to bare stainless steel surface in the higher Reynolds number of our test. The higher contact angle of the condensate on the Teflon-coated surface, about 25°, is the reason for the kind of trend observed.     

Heat transfer research on vapor‐gas mixture with condensation in a vertical tube

The convection‐condensation heat transfer of vapor‐gas mixtures in a vertical tube was studied theoretically and experimentally. The effects of the condensation of a small amount of water vapor (8 to 20%) on heat transfer in a vertical tube were discussed. Comparisons show that theoretical solutions obtained through modified film model and experimental results are in good agreement. The results show that the condensation heat transfer of a small amount of water vapor and single‐phase convection heat transfer in the vapor‐gas mixtures are of the same order of magnitude, and these two modes of heat transfer could not be neglected. © 2002 Wiley Periodicals, Inc. Heat Trans Asian Res, 31(7): 531–539, 2002; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10055     

300MW循环流化床锅炉屏式受热面传热系数计算及其变化规律

根据300MW循环流化床（CFB）锅炉现场测试数据并结合以往CFB锅炉传热系数的研究成果,建立了屏式受热面烟气侧的传热模型,包括辐射传热模型和对流传热半经验公式．利用该模型对某300MWCFB锅炉在94％锅炉最大连续蒸发量（BMCR）工况下炉膛内屏式受热面的传热系数进行了计算,分析了屏式受热面管间节距、炉膛温度、工质温度、壁面黑度及烟气速度等因素对传热系数的影响．结果表明：烟气速度、炉膛温度和壁面黑度对传热系数的影响较大,所建立的传热模型能够合理地反映主要因素对CFB锅炉屏式受热面传热的影响．     

低温烟气凝结换热及对天然气热效率的影响实验研究

为研究烟气露点附近及以下的低温烟气对流凝结换热规律与烟气换热对天然气利用热效率的影响,建立了烟气在翅片管换热器内对流凝结换热实验系统,研究了不同烟气温度、水蒸气含量对烟气凝结换热的影响,得出了烟气凝结换热实验准则关联式,分析对比了天然气利用热效率实验值与理论值.实验结果表明:当被加热水温度为23℃,烟气出口温度为73℃...     

The latent heat recovery from boiler exhaust flue gas using shell and corrugated tube heat exchanger: A numerical study

The excessively increasing environmental concerns along with reducing fossil fuel resources introduce the trend of increasing the efficiency of boiler via implementing waste heat recovery. In the present study, the potential of latent heat recovery is investigated in the middle‐size boiler exhaust flue gas using the shell and corrugated tube heat exchanger. The main purpose of the present study is efficiency growth in flue gases using latent heat recovery of the steam energy. The heat recovery analysis is evaluated by a validated computational fluid dynamics model by a commercial software. For this study, the effect of different tube arrangements, number of tubes, and flow direction in the shell on heat transfer and pressure drop were investigated. The results showed that in‐line arrangement of the tubes in the shell presents better thermal performance and also high pressure drop among the other arrangements. As a result, by considering the thermal performance and pressure drop, radial arrangement shows higher performance. According to the obtained results from Section 2 of the present study, by considering the radial arrangement of tubes in the shell, as the number of tube rises, the thermal performance declines.     

An Experimental Study on Latent Heat Recovery of Exhaust Wet Flue Gas

The experiment was conducted to investigate the heat transfer performance of wet flue gas in a vertical tube. The factors influencing the convective condensation of wet flue gas were experimentally investigated. The measured results indicate that the convective heat transfer of bulk flow and condensation heat transfer of vapor have significant contribution to the total heat transfer and the dominant transport mechanism is dependent upon the vapor fraction in mixture.     

Bubble behavior in vertical tube banks installed in a fluidized bed

Fluidized bed combustion is one of the advantageous technologies for coal and/or incineration firing especially with respect to the environmental protection of emissions, such as NO_x/SO_x. Bed material movement in such a fluidized bed has a prime importance in the heat transfer process. Thus, quantitative measurement of the bed material movement and the void fraction are indispensable for better understanding of the fluidized bed. In this investigation, neutron radiography is applied to visualize the bed material movement in a simulated fluidized bed heat exchanger installed with vertical tubes. Bubble behavior and void fraction profile are obtained by the image processing technique. Bubble movement is highly restrained by these vertical tubes, so that the bubbles rise up along the tube. The bubble diameter is well correlated by the modified Mori and Wen's correlation taking into account the pitch of the tube arrangement. The bubble rise velocity and void fraction are well correlated by applying the drift‐flux model. © 2003 Wiley Periodicals, Inc. Heat Trans Asian Res, 32(8): 727–739, 2003; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10127     

Heat transfer characteristics in a small-scale fluidized bed boiler

Heat transfer characteristics in a small-scale fluidized bed boiler (2MW_th) were studied using lignite and corn cob as fuels. Depending on air velocity, the heat transfer rates from bed to water membrane wall and from hot flue gas to convective tube bank were in the ranges 75–55% and 25–45% of the total heat absorbed by the boiler, respectively. At designed capacity, the heat transfer flux based on bed cross sectional area and on water membrane wall area were about 0·45 and 0·15 MWm⁻², respectively. Under the conditions studied, it was found that the overall heat transfer coefficient between bed and water membrane wall was 100–300 W m⁻² K⁻¹, whereas that between flue gas and convective tube bank was 10–30 Wm⁻² K⁻¹. The study of heat transfer to a horizontal tube immersed in the bed as well as placed in the freeboard region were also studied. The effective heat transfer coefficients were found to be 300–800 W m⁻² K⁻¹ for in-bed tube and 30–150 W m⁻² K⁻¹ for the freeboard region, depending on air velocity. Comparison of these data with those predicted by both modelling and correlation reported in the literature was also made. For the immersed tube, good agreement was observed for low air velocity, while at high air velocity the experiment produced results twice those estimated from modelling and correlation. For the freeboard region, the model gave a fair prediction.     

Experimental study on titanium heat exchanger used in a gas fired water heater for latent heat recovery

In general, latent heat recovery is usually accompanied by the corrosion of the heat exchanger, which is caused by the strongly acidic condensate when the temperature of the flue gas is lowered below the acid dew point. The present study has been conducted to investigate the heat and mass transfer characteristics in a titanium heat exchanger with excellent corrosion resistance used for waste heat recovery with the condensation arranged in a gas fired water heater. In addition, the thermal efficiency of the gas fired water heater was evaluated based on the net calorific value at the maximum rated output during latent heat recovery from the exhaust flue gas. Parametric studies were conducted for the flue gas flow rate, inlet temperature and mass flow rate of the supplied water, respectively. Different arrangements of the tubes of the heat exchanger including in-line and staggered configurations were investigated. The experimental results indicate that the thermal efficiency of the gas fired water heater with a latent heat recovery (LHR) heat exchanger was enhanced by about 10% compared with conventional instantaneous water heaters, i.e., water heaters without heat recovery. In addition, in terms of the Nusselt number and the Sherwood number, the heat and mass transfer performance of the staggered tube bank type were approximately 50% and 10% higher than that on the in-line tube bank type when the Reynolds number of the flue gas was 10³.     

Theoretical research of convective condensation heat transfer for mixture gas on a horizontal tube

The mechanism of convective condensation heat transfer of moist mixed gas across a horizontal tube was studied in this paper. The models referring to how the liquid film flows and the heat transfers on the tube are set up by combining modified film model and Nusselt condensation theory. The effects of Re number, wall temperature, and water vapor concentration on condensation heat transfer are discussed. Results predict that the film thickness profile on the tube is influenced greatly by vapor shear force on liquid film. Local Nusselt number depends remarkably on gas phase heat resistance, which is different from pure vapor and very similar to single‐phase gas. © 2007 Wiley Periodicals, Inc. Heat Trans Asian Res, 36(6): 324–333, 2007; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20169     

Heat and mass transfer in a reforming catalyst bed: Analytical prediction of distributions in the catalyst bed

Heat and mass transfer characteristics within a reforming catalyst bed have been analytically investigated. A numerical analysis was carried out in a two‐dimensional steady‐state model of a reforming catalyst bed. The reforming tube was filled with catalyst and the tube wall was uniformly heated; a mixture of steam and methane was reformed through the catalyst bed. The predicted distributions of temperature, formed gas composition, methane conversion rate, and heat transfer coefficient in the catalyst bed are in good agreement with the experimental data. The effects of space velocity, steam carbon molar ratio, and wall temperature on the heat transfer coefficient were analytically presented. From temperature and composition distributions simulated by the two‐dimensional analysis, the effects of the above‐mentioned factors and diffusion on both heat and mass transport phenomena were qualitatively predicted. © 2003 Wiley Periodicals, Inc. Heat Trans Asian Res, 32(4): 367–380, 2003; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10101