IDEAS home Printed from https://ideas.repec.org/a/eee/energy/v307y2024ics0360544224024496.html
   My bibliography  Save this article

Numerical simulations and an experimental study for optimal design of a 1500 kW water-tube condensing boiler

Author

Listed:
  • Ahmadi Babadi, Keyvan
  • Khorasanizadeh, Hossein
  • Mirzazadeh, Ghorbanali
  • Mirzazadeh, Soheil

Abstract

The present study is focused on investigating the condensation process and numerical simulation for optimal design of a 1500 kW water-tube condensing boiler. The specific geometry of the heat exchanger of this boiler involves compact arrangement of spiral coils to enhance heat transfer efficiency and achieve high capacity. Experimental validation is conducted on a 580 kW condensing boiler. Numerical simulations of the flow for gas and water sides of the boiler are performed in parallel using the ANSYS-FLUENT software with the k-omega (SST) turbulence model. Twelve models with different combustion chamber dimensions, coil numbers and revolutions are considered. Important design criteria include flue gas temperature, combustion chamber pressure and water pressure drop in the coils. The results indicate that increasing effective heating surface area and reducing coils gap decrease flue gas temperature to the dew point. Increasing coil revolutions has a greater impact on flue gas temperature and boiler weight compared to increasing coil numbers. With the same number of coils, by adding an extra revolution the weight is increased approximately 17 % and the effective heating surface area about 21 %. On the other hand, for the same number of revolutions, each additional spiral coil increases both of the weight and the effective heating surface area approximately 4 %. Moreover, with an increase in the number of the coils and a decrease in the number of revolutions, the pressure within the combustion chamber is decreased. By reducing the gap size, the flue gas temperature is reduced approximately 2 °C and the combustion chamber pressure is increased about 18 %. Base on the design criteria, the model six with 27 spiral coils and 7–8 revolutions, is identified as the optimal design. This progress and capability allows the design and manufacture of high-capacity boilers for residential sector as well as for industrial applications.

Suggested Citation

  • Ahmadi Babadi, Keyvan & Khorasanizadeh, Hossein & Mirzazadeh, Ghorbanali & Mirzazadeh, Soheil, 2024. "Numerical simulations and an experimental study for optimal design of a 1500 kW water-tube condensing boiler," Energy, Elsevier, vol. 307(C).
    • Handle: RePEc:eee:energy:v:307:y:2024:i:c:s0360544224024496
    DOI: 10.1016/j.energy.2024.132675
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0360544224024496
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.energy.2024.132675?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Lee, Seungro & Kum, Sung-Min & Lee, Chang-Eon, 2011. "Performances of a heat exchanger and pilot boiler for the development of a condensing gas boiler," Energy, Elsevier, vol. 36(7), pages 3945-3951.
    2. Liu, Fengguo & Zheng, Longfeng & Zhang, Rui, 2020. "Emissions and thermal efficiency for premixed burners in a condensing gas boiler," Energy, Elsevier, vol. 202(C).
    3. Mohr, Manuel & Klančišar, Marko & Schloen, Tim & Samec, Niko & Kokalj, Filip, 2018. "Numerical analysis of a non-steady state phenomenon during the ignition process in a condensing boiler," Energy, Elsevier, vol. 158(C), pages 623-631.
    4. Echi, Souhir & Bouabidi, Abdallah & Driss, Zied & Abid, Mohamed Salah, 2019. "CFD simulation and optimization of industrial boiler," Energy, Elsevier, vol. 169(C), pages 105-114.
    5. Men, Yiyu & Liu, Xiaohua & Zhang, Tao, 2021. "A review of boiler waste heat recovery technologies in the medium-low temperature range," Energy, Elsevier, vol. 237(C).
    6. Badr, O. & Probert, S. D., 1993. "Oxides of nitrogen in the Earth's atmosphere: Trends, sources, sinks and environmental impacts," Applied Energy, Elsevier, vol. 46(1), pages 1-67.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Bartosz Ciupek & Andrzej Frąckowiak, 2024. "Review of Thermal Calculation Methods for Boilers—Perspectives on Thermal Optimization for Improving Ecological Parameters," Energies, MDPI, vol. 17(24), pages 1-15, December.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Yılmaz, Semih & Kumlutaş, Dilek & Yücekaya, Utku Alp & Cumbul, Ahmet Yakup, 2021. "Prediction of the equilibrium compositions in the combustion products of a domestic boiler," Energy, Elsevier, vol. 233(C).
    2. Yılmaz, Semih & Kumlutaş, Dilek & Özer, Özgün & Yücekaya, Utku Alp & Avcı, Hasan & Cumbul, Ahmet Yakup, 2024. "Parametric investigation of premixed gas inlet conditions effects on flow and combustion characteristics," Applied Energy, Elsevier, vol. 353(PA).
    3. Ahmadi, Ziaulhaq & Zabetian Targhi, Mohammad, 2021. "Thermal performance investigation of a premixed surface flame burner used in the domestic heating boilers," Energy, Elsevier, vol. 236(C).
    4. Jun Liu & Yuyan Zhou & Lihua Chen & Lichuan Wang, 2023. "Assessing the Impact of Climate Change on Water Usage in Typical Industrial Enterprises," Sustainability, MDPI, vol. 15(13), pages 1-18, June.
    5. Li, Xinli & Wang, Yingnan & Zhu, Yun & Yang, Guotian & Liu, He, 2021. "Temperature prediction of combustion level of ultra-supercritical unit through data mining and modelling," Energy, Elsevier, vol. 231(C).
    6. Xue, Wenyuan & Lu, Yichen & Wang, Zhi & Cao, Shengxian & Sui, Mengxuan & Yang, Yuan & Li, Jiyuan & Xie, Yubin, 2024. "Reconstructing near-water-wall temperature in coal-fired boilers using improved transfer learning and hidden layer configuration optimization," Energy, Elsevier, vol. 294(C).
    7. Ma, Yuxin & Gao, Enyuan & Zhang, Xiaosong & Huang, Shifang, 2024. "Parametric analysis and design optimization of a fully open absorption heat pump for heat and water recovery of flue gas," Applied Energy, Elsevier, vol. 375(C).
    8. Piotr Jóźwiak & Jarosław Hercog & Aleksandra Kiedrzyńska & Krzysztof Badyda & Daniela Olevano, 2020. "Thermal Effects of Natural Gas and Syngas Co-Firing System on Heat Treatment Process in the Preheating Furnace," Energies, MDPI, vol. 13(7), pages 1-15, April.
    9. Darbandi, Masoud & Fatin, Ali & Bordbar, Hadi, 2020. "Numerical study on NOx reduction in a large-scale heavy fuel oil-fired boiler using suitable burner adjustments," Energy, Elsevier, vol. 199(C).
    10. Zhang, Hongsheng & Liu, Xingang & Hao, Ruijun & Liu, Chengjun & Liu, Yifeng & Duan, Chenghong & Qin, Jiyun, 2022. "Thermodynamic performance study on gas-steam cogeneration systems with different configurations based on condensed waste heat utilization," Energy, Elsevier, vol. 250(C).
    11. Xiao, Guolin & Gao, Xiaori & Lu, Wei & Liu, Xiaodong & Asghar, Aamer Bilal & Jiang, Liu & Jing, Wenlin, 2023. "A physically based air proportioning methodology for optimized combustion in gas-fired boilers considering both heat release and NOx emissions," Applied Energy, Elsevier, vol. 350(C).
    12. Aminmahalati, Alireza & Fazlali, Alireza & Safikhani, Hamed, 2021. "Multi-objective optimization of CO boiler combustion chamber in the RFCC unit using NSGA II algorithm," Energy, Elsevier, vol. 221(C).
    13. Yee Van Fan & Zorka Novak Pintarič & Jiří Jaromír Klemeš, 2020. "Emerging Tools for Energy System Design Increasing Economic and Environmental Sustainability," Energies, MDPI, vol. 13(16), pages 1-25, August.
    14. Badr, O. & Probert, S. D., 1995. "Sinks and environmental impacts for atmospheric carbon monoxide," Applied Energy, Elsevier, vol. 50(4), pages 339-372.
    15. Srivastava, Mayank & Sarkar, Jahar & Sarkar, Arnab & Maheshwari, N.K. & Antony, A., 2024. "Thermo-economic feasibility study to utilize ORC technology for waste heat recovery from Indian nuclear power plants," Energy, Elsevier, vol. 298(C).
    16. Robert Ștefan Vizitiu & Ștefănica Eliza Vizitiu & Andrei Burlacu & Chérifa Abid & Marius Costel Balan & Nicoleta Elena Kaba, 2024. "Experimental Investigation of a Water–Air Heat Recovery System," Sustainability, MDPI, vol. 16(17), pages 1-11, September.
    17. Horvat, Ivan & Dović, Damir & Filipović, Petar, 2021. "Numerical and experimental methods in development of the novel biomass combustion system concept for wood and agro pellets," Energy, Elsevier, vol. 231(C).
    18. Saberi Moghaddam, Mohammad Hossein & Saei Moghaddam, Mojtaba & Khorramdel, Mohammad, 2017. "Numerical study of geometric parameters effecting temperature and thermal efficiency in a premix multi-hole flat flame burner," Energy, Elsevier, vol. 125(C), pages 654-662.
    19. Liu, Fengguo & Zheng, Longfeng & Zhang, Rui, 2020. "Emissions and thermal efficiency for premixed burners in a condensing gas boiler," Energy, Elsevier, vol. 202(C).
    20. Soltanian, Hossein & Targhi, Mohammad Zabetian & Pasdarshahri, Hadi, 2019. "Chemiluminescence usage in finding optimum operating range of multi-hole burners," Energy, Elsevier, vol. 180(C), pages 398-404.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:energy:v:307:y:2024:i:c:s0360544224024496. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.journals.elsevier.com/energy .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.