IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 11, Issue 6 Ver. IV (Nov- Dec. 2014), PP 31-39
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Cfd Analysis of Gas Flow Behaviour in Economizer

Rajesh Holkar1,Bochare Ramdas2, Ekatpure Kunal3Babar Haridas4
(Assistant Professors, Department of Mechanical Engineering,SMSMP Institute of Technology and Research,
AKLUJ,India)

Abstract: Energy saving and efficiency are the key issues in power generation system not only from the view
point of fuel consumption, but also for the protection of global environment. Flue gas ducts are the major parts
of oil-fired power plant, which are used to exhaust flue gases from boiler. This paper presents an approach for
the economiser duct design. CFD analysis is used to compare the new economiser duct design with traditional
strategies. The most economical solution of this problem seems to distribute gas flow uniformly at inlet of
economiser by using vanes. So that effective heat transfer can be obtained .In the present work commercial
software ANASYS is used for the 3D simulation using its inbuilt K- Reliable model.
Keywords: Economizer, Economizer duct, vanes, k- Reliable model

I.

Introduction

Economiser performs a key function in providing high CFD modelling is a good tool to improve the
efficiency of thermal efficiency by recovering the low level energy economizer by improving gas flow
behaviour. Duct from the flue gas before it is exhausted to the atmosphere having rectangular cross area is
normally used in economiser recovers the energy by heating the boiler power plant. Gas flow distribution over
the heating equipment
feed water. Economiser is basically tubular heat transfer surfaces used to preheat
boiler feed water before it enters into steam drum.The economiser enables the boiler to operate at a much higher
rate of efficiency with the result of lowering the fuel usage requirements. This is due to the capture and
recycling of waste heat. The recovered heat is used to increase the temperature of the boiler feed water, which in
turn reduces the amount of additional heat required for steam production. This has a direct impact by reducing
the fuel requirement, hence reducing the running cost. An added benefit is the lowered environmental impact
linked to reducing the amount of carbon and the volume of flue gases entering the atmosphere via the boiler
chimney. Hence there is need for analysis of economiser to increase the efficiency of boiler and also reduce
emissions.The ultimate goal of economiser design is to achieve necessary heat transfer at minimum cost. A key
design criterion for economiser is maximum allowable flue gas velocity. Higher velocity provides better heat
transfer and reduces capital cost. So detail analysis of flue gas flow is needed to improve the duct design and its
internals.CFD modelling is a good tool to improve the efficiency of economiser. Duct having rectangular cross
sectional area is normally used in power plant. Gas flow distribution over heating equipment is very critical
problem in power plant. By providing inlet guide vanes at economiser inlet duct, we get effective heat transfer
in economizer.

II.

Simulation Set Up And Data Input

In ANSYS, the governing equations are discretized by using the finite Volume method The pressure
velocity coupling is achieved through the SIMPLE -algorithm.The grid-independent study is done for all cases
.All simulations are run in ANSYS K- reliable model. Boundary conditions used are flue gas mass flow rate
and temperature. It is assumed that all particles have attended their terminal velocity and have entered
perpendicular to the tube. The geometry of actual flue gas duct, its internal, tubes created in ANSYS design
modeller. Drawings of duct are used for geometry creation. Meshing is done in ANSYS meshing .Inlet surface
meshed and volume meshing done with tetrahedral. Further refinement of mesh is done by adaption by using
velocity gradient. Numbers of cells are varying as per geometry dimensions and requirement for grid
independent solution. Simulation is done on existing geometry of duct first by straight vanes and then geometry
by adding curved vanes.
Design data used
Table 1: Flue gas parameter
Inlet temperature
Mass flow rate
Specific heat kJ/kg K
Density (kg/m3)
Viscosity kg/mh
Thermal Conductivity kW/mK

337C
15.62 kg/s
1.12
1.337
0.101
0.00046

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Cfd Analysis of Gas Flow Behaviour in Economizer

Table 2: Water parameter
Inlet temperature
Mass flow rate
Density (kg/m3)
Specific heat kJ/kg K
Thermal Conductivity

120C
6.31 kg/s
913
0.42
1 kcal/m-hr-c

Table 3: Geometry of economizer

Tube

38.1 mm

Tube thickness

3.66 mm

Longitudinal Pitch

100 mm

Number of tubes wide

26

Number of tubes deep

22

III.

Numerical Simulation

Fluid carrier is phenomenon of great interest since it is frequently found in many scientific fields and
industrial processes. The numerical simulation of fluid transport used in ANSYS by fluid carrier requires the
modelling of the continuous phase (fluid), the discrete phase and the interaction between them. The continuous
phase-whether Liquid or gas is modelled using an Eulerian formulation The discrete phase flue gas may be
approached as an Eulerian or form a Lagrangian point of view. This has given place to two distinctive strategies,
the so called Eulerian-Eulerian and the Eulerian-Lagrangian methods. In the Eulerian-Eulerian approach, fluid
velocity and concentration fields are calculated for each point of the numerical domain.The Eulerian-Eulerian
method can be employed both using a one fluid formulation and a two fluid formulation.
In the later, mass conservation and momentum conservation equations are used to calculate the velocity
fields, so the phases are treated as two interpenetrating fluids which interact through their interfacial properties.
In the one fluid formulation, on the other hand, no momentum conservation equation is used. Flue gas velocity
is usually determined by an algebraic equation for the fluid slip velocity. One way or two ways coupling is
decided on the basis of mass flow .The interaction between phases is modelled according to the strength of the
coupling between them.
A K- Turbulence model
It is the most general-purpose CFD code and is considered the industry standard model. It has proven
to be stable and numerically robust and has a well established regime of predictive capability. Within ANSYS
the k- turbulence model uses mesh is very fine.
A.

Geometry modelling
Geometry of all model are created in ANSYS design modeller.Fig.1,2,3 shows geometry of duct
without vanes(Baseline duct), with straight vanes and with curved vanes. Fig. 4 shows assembly of inlet duct
with curved vanes and economizer.
C. Meshing
The most important part in CFD simulation is discretization of geometry. Generally hexahedral and
tetrahedral meshes are used for CFD codes. Hexahedral mesh gives better results, but meshing is very difficult.
Here tetrahedral mesh generated in ANASYS meshing software. Fig 5, 6, 7 shows meshing of inlet duct
baseline duct, with straight vanes and with curved vanes.
Fig .8 shows meshing of economizer with curved vanes at its inlet duct.
D. Models

Fig.1 Geometry of baseline duct

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig .2 Geometry of inlet duct with straight vanes

Fig .3 Geometry of inlet duct with curved vanes

Fig .4 Geometry of inlet duct and economizer

Fig .5 Meshing of baseline duct

Fig .6 Meshing of inlet duct with straight vanes

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig.7 Meshing of inlet duct with curved vanes

Fig .8 Meshing of inlet duct and economizer

IV.

Result And Discussion

Fig .9 Pressure counter of baseline duct

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig .10 Velocity counter of baseline duct

Fig .11 Turbulence counter of baseline duct

Fig .12 Pressure counter of duct with straight vanes

Fig .13 Velocity conter of duct with straight vanes

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig .14 Turbulence counter of duct with straight vanes

Fig .15 Pressure counter of duct with curved vanes

Fig.16 Velocity counter of duct with curved vanes

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig .17 Turbulence counter of duct with curved vanes

Fig.18 Pressure counter of economizer with curved vanes

Fig.19 Temperature counter of economizer with curved vanes

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Cfd Analysis of Gas Flow Behaviour in Economizer

Fig .20 Turbulence counter of economizer with curved vanes

Fig .21 Velocity counter of economizer with curved vanes

4.1 Inlet duct without vanes (baseline duct)
Simulation is done on existing economizer duct without vanes and results of pressure contour, velocity
contour and turbulence are shown in fig 9,10,11. It is clear that velocity profile at the economizer section is not
uniform, mass flow distribution of gas over tubes is also non-uniform. Due to this heat transfer across tubes is
also ineffective, result of this increases heat transfer area.
4.2 Modification of inlet duct with straight vanes
Simulation is done on existing economizer duct with straight vanes and results of pressure contour,
velocity contour and turbulence contour are shown in fig.12,13,14. It shown that pressure drop is reduced by
50% compare to baseline duct. It is clear that velocity profile at the economizer section is not uniform, mass
flow distribution of gas over tubes is also non-uniform. Due to this heat transfer across tubes is also ineffective,
result of this increases heat transfer area. Turbulence levels are reduced compared to baseline model the flow is
improved still the flow pattern has to be optimized to improve the performance of the economizer.
4.3 Modification of inlet duct with curved vanes
Simulation is done on existing economizer inlet duct with curved vanes and results of pressure contour,
velocity contour and turbulence contour are shown in fig.15, 16, 17.It is indicated that velocity profile at inlet of
economizer is uniform. Mass flow distribution of gas over tube is also uniform.
4.4 Economizer with curved vanes at inlet duct
Simulation is by assembling economizer with curved vanes at its inlet duct .pressure contour,
temperature contour, turbulence contour and velocity contour are shown in fig.18, 19 ,20,21. It is noticed that
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Cfd Analysis of Gas Flow Behaviour in Economizer

nearly 100C drop of temperature of flue gas is reduced from inlet to oulet. It is also noticed that more static
pressure drop takes place at the middle.

V.

Conclusion

Specific issues like the undesirable effects of mal -distribution of heating and heated medium have
been understood through applications of CFD codes. Gas flow distribution or heat transfer into the economiser
section is improved through use of guide vanes at inlet of economiser duct. Analysis of economiser module was
carried out using K- model. The model was validated. The results of simulation indicate the uniform flow of
gas over tubes after adding the curved vanes at inlet of economizer duct. The results were compared with site
data and showed good agreement. CFD has earned a reputation of troubleshooting technique par excellence and
extensively in testing out new design variant. The results of the CFD analysis can be used in enhancing the heat
transfer in design of different type of economiser. Future direction would include development of model to
predict soot formation over tubes. In days to come, CFD would become integral design tool to predict various
operating scenarios of the product and thus improving the effectiveness of design process.

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