International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622

NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences

(NCDATES- 09th & 10th January 2015)

RESEARCH ARTICLE OPEN ACCESS

Improving the Overall heat transfer coefficient of an Air Preheater by

Design, Fabrication and CFD Analysis
M.Nageswara rao*
*Assistant professor, Department of Mechanical Engineering, TKR Engineering College, Hyderabad.

ABSTRACT
An air preheater is a heat exchanger device designed to heat air before another process (for example, combustion
in a boiler) with the primary objective of increasing the thermal efficiency of the process. The purpose of the air
preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by
reducing the useful heat lost in the flue gas. This project mainly deals with design, modeling and fabrication and
cfd analysis of a shell and tube air preheater. Over all heat transfer coefficient of the shell and tube heat
exchanger is based on the results of effectiveness-ntu approach and lmtd approach. Drawing of various
components will be presented with the help of various software’s like solid works, proe, etc., even different
experimental results and trails will be analyzed and tabulated. Conclusion of the project will be the complete
presentation of thermal and mechanical design, fabrication model, Overall heat transfer coefficient and cfd
(computational fluid dynamics) analysis for the air preheater.
Keywords: air preheater, cfd, fabrication .

I. INTRODUCTION modeling and fabrication of shell and tube air

An air pre-heater is a general term to describe preheater including thermal design.
any device designed to heat air before another
process (for example, combustion in a boiler) with III. THEORETICAL BACKGROUND &
the primary objective of increasing the thermal CONSTRUCTION FEATURES
efficiency of the process. They may be used alone or Let us see each one it their detail with their basic
to replace a recuperative heat system or to replace a construction, working and related problems A bundle
steam coil. In particular, this article describes the of vertical tubes through which the flue gas flows
combustion air pre-heaters used in large boilers found downward and exchanges heat with ambient air
in thermal power stations producing electric power flowing horizontally across the exterior of the tubes.
from e.g. fossil fuels, biomasses or waste. Ref Fig3
The purpose of the air pre-heater is to recover the
heat from the boiler flue gas which increases the
thermal efficiency of the boiler by reducing the
useful heat lost in the flue gas. As a consequence, the
flue gases are also sent to the flue gas stack (or
chimney) at a lower temperature, allowing simplified
design of the ducting and the flue gas stack. It also
allows control over the temperature of gases leaving
the stack.There are two types of air pre-heaters for
use in steam generators in thermal power stations.
One is a tubular type built into the boiler flue gas
ducting, and the other is a regenerative air preheater.
These may be arranged so the gas flows horizontally
or vertically across the axis of rotation. Another type
of air preheater is the Regenerator used in iron or
glass manufacture.

II. SCOPE OF WORK

After studying the journal papers mentioned
above, it is understood that there are some gaps in
development of shell and tube air preheater. The Figure : Tubular Type Air Preheater
project is planned with the following work scope,

CMR Engineering College 45|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

The air enters the lower tube bundle from the discretization handles discontinuous solutions
right-hand side, exits on the left-hand side and then gracefully. The Euler equations and Navier–Stokes
enters the middle tube bundle on the left-hand side equations both admit shocks, and contact surfaces.
and exits on the right-hand side. Finally, the air enters Some of the discretization methods being used are:
the upper tube bundle on the right-hand side and exits FINITE VOLUME METHOD.The finite volume
on the left-hand side. In essence, such a design is method (FVM) is a common approach used in CFD
similar to the 3-pass design of (1) above except that codes, as it has an advantage in memory usage and
the air is in the tubes rather than outside the tubes. solution speed, especially for large problems,
Tubular preheaters consist of straight tube bundles high Reynolds numberturbulent flows, and source
which pass through the outlet ducting of the boiler term dominated flows (like combustion). In the finite
and open at each end outside of the ducting. Inside volume method, the governing equations partial
the ducting, the hot furnace gases pass around the differential equations (typically the Navier-Stokes
preheater tubes, transferring heat from the exhaust equations, the mass and energy conservation
gas to the air inside the preheater. Ambient air is equations, and the turbulence equations) are recast in
forced by a fan through ducting at one end of the a conservative form, and then solved over
preheater tubes and at other end the heated air from discretecontrolvolumes.
inside of the tubes emerges into another set of This discretization guarantees the conservation
ducting, which carries it to the boiler furnace for of fluxes through a particular control volume. The
combustion. finite volume equation yields governing equations in
the form,
IV. PROBLEMS
The tubular preheater ducts for cold and hot air
require more space and structural supports than a
rotating preheater design. Further, due to dust-laden where is the vector of conserved variables, is
abrasive flue gases, the tubes outside the ducting the vector of fluxes (see Euler equations or Navier–
wear out faster on the side facing the gas current. Stokes equations), is the volume of the control
Many advances have been made to eliminate this
volume element, and is the surface area of the
problem such as the use of ceramic and hardened
control volume element.
steel.

V. METHODOLOGY VII. DESIGN CALCULATIONS

The optimum thermal design of a shell and tube
In all of these approaches the same basic
heat exchanger involves the consideration of many
procedure is followed.
interacting design. Parameters which can be
 During preprocessing
summarized as follows:
 The geometry (physical bounds) of the problem
Process:-
is defined. 1. Process fluid assignments to shell side or tube side.
 The volume occupied by the fluid is divided into 2. Selection of stream temperature specifications.
discrete cells (the mesh). The mesh may be 3. Setting shell side and tube side pressure drop
uniform or non uniform. design limits.
 The physical modeling is defined – for example, 4. Setting shell side and tube side velocity limits.
the equations of motions + enthalpy + radiation 5. Selection of heat transfer models and fouling
+ species conservation coefficients for shell side and tube side.
 Boundary conditions are defined. This involves Mechanical:-
specifying the fluid behaviour and properties at 1. Selection of heat exchanger TEMA layout and
the boundaries of the problem. For transient number of passes.
problems, the initial conditions are also defined. 2. Specification of tube parameters - size, layout,
 The simulation is started and the equations are pitch and material.
solved iteratively as a steady-state or transient. 3. Setting upper and lower design limits on tube
 Finally a postprocessor is used for the analysis length.
and visualization of the resulting solution. 4. Specification of shell side parameters – materials,
baffle cut, baffle spacing and clearances.
VI. DISCRETIZATION METHODS 5. Setting upper and lower design limits on shell
The stability of the chosen discretization is diameter, baffle cut and baffle spacing.
generally established numerically rather than that of
analytically as with simple linear problems. Special
care must also be taken to ensure that the

CMR Engineering College 46|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

VIII. THERMAL DESIGN OF AIR CALCULATION OF AIR MASS FLOW RATE (m’a)
PREHEATER AND AIR VELOCITY:
The aim of the following design is to calculate  Volumetric flow rate (Qa) = 2.3 m3 /min =
overall heat transfer coefficient through LMTD 0.0383 m3/s ( From Blowerspecification)
method. This is done by assuming the exit  Air flow cross sectional area (Aa) = shell c/s –
temperatures of hot side and cold side. Fluid Flow n* π/4*d2m2
through Shell is air and exhaust gas from the diesel  Air velocity (Va) = Volumetric flow rate (Qa)/
engine flows through pipes. Air flow cross sectional area(Aa) =
INPUT DATA:- 0.0383/0.0328 = 1.167 m/s
 Inlet temperature of air (t1)= 33 °C (ambient)  Mass flow rate of air ( m’a ) = Volumetric flow
 Outlet temperature of air (t2) = 52.51 °C rate * density
(calculated from heat balance)  Density of air (from heat transfer data book) at
 Inlet temperature of gas (T 1) = 85 °C (measured) 33°C = 1.11539 kg/m3.
 Outlet temperature of gas (T2)= 5°C(say)  Hence the Mass flow rate of air ( m’a)= .044
 Tube inner diameter (di)= 19.05mm =0. 01905m kg/s
 Tube Outer diameter (do) = 22mm = 0.022m  Air flow cross sectional area (Aa)= 0.0328
 Shell Inner diameter (Di)= 220mm = 0.22m
 No of tube (n) = 15

CALCULATION OF GAS MASS FLOW RATE AND GAS VELOCITY

Mass flow rate of gas side: It is calculated by experiment on diesel engine silencer the procedure is the exhaust
gases in the silencer are cooled by water and reading are tabular

Table : Exhaust gas mass flow rate

Volumetric flow
Mw Mg
S.No. rate Twi°C Two°C Tgi°C Tgo°C
Kg/s Kg/s
V cc/s

1. V1=80 28.7 30.7 116.7 42 80* 10-3 4.26* 10-3

2. V2=60 28.7 38 128 47 60* 10-3 13.7* 10-3

3. V3=40 28.7 41 135 54 40* 10-3 12.09* 10-3

FROM HEAT BALANCE: Mass flow rate of gas (mg) = 0.0137 kg/s (Higher
Heat lost by gas is equal to heat gained by water. value of above three is considered)
Hence, Density of flue gas from heat transfer data book at
 mg*Cp*ΔTg= mw*Cp*ΔTw 85°C = 1.008 kg/m3
 mw1= ρ*V1=80* 10-3 Kg/s Volumetric flow rate gas = mass flow rate /density
 mw2 = ρ*V2=60* 10-3Kg/s cpw =4.18 kJ/kgk =0.0137/1.008 = 0.01367 m3/s
(from HT data book) Gas flow through one tube = volumetric flow rate/no
 mw3= ρ*V3=40* 10-3Kg/s cpg =2.1 kJ/kgk of tube =9.116* 10-4 m3 /s
(from Diesel engine lab manual) Velocity of gas in one tube = (gas flow through one
 mg1= mw*Cpw*ΔTw/Cpg*ΔTg tube/area of tube)
 mg1 =0.0426Kg/s  Area of tube = π/4*d2
 mg2=0.0137Kg/s  d=19.05mm
 mg3=0.01209Kg/s  Velocity of gas in one tube = 3.198 m/s

CMR Engineering College 47|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

CALCULATION OF AIR OUT LET CALCULATION OF AREA:-

TEMPERATURE: From the fundamental equations for heat transfer we
Heat balance heat load on gas side and air side get, Q = U A ΔTlmtd
Qg = Qa  Heat transfer rate Q = 0.862kw
 mg*Cpg*(Tg1 -Tg2) = ma*Cpa*(Ta1- Ta2)  overall heat transfer coefficient U = 5.716
 Cpa = 1.005 KJ/kgk W/m2K
 Cpg = 2.1 KJ/kgk  Corrected LMTD = 22.86
 Hence, 0.862*1000 = 5.716*A*22.86
Outlet temperature of air (Ta2) =52.510C  A= 6.59 m2
CALCULATION OF LMTD (LOG MEAN From Area =n πdL  6.59 =15* π *
TEMPERATURE DIFFERENCE): 0.01905 * L  L = 110.13 m
For Counter Current flow type Shell and Tube heat Therefore, Length of each tube required is 7.342m
Exchanger, A. CONTRUCTION DETAILS OF AIR
LMTD = (ΔT1- ΔT2)/ln(ΔT1/ ΔT2) PREHEATER:
 ΔT1 =Tg1 –Ta2=32.50C B. The following are the constructional details of
 ΔT2 = Tg2 –Ta1=220C the Air-preheater model:
Hence,
LMTD = (32.9 - 22)/ln(32.9/22) Table constructional details of the Air-preheater
LMTD = 26.900C model:
CALCULATION OF GAS SIDE HEAT Figure : drawing of an air-preheater
TRANSFER COEFFICIENT
Using Dittus Boelter equation:
Flow in tube Generalized equation is Nu = 0.023Re.8
Pr0.3Properties of air at Tf = (Tg1+Tg2)/2 Ns/m2 =
(85+55) / 2 = 70°C
 Density ρ = 1.053 kg/m3
 Absolute viscosity μ = 19.002*10-6 Ns/m2
 Prandtl number P r= 0.6989
 Thermal conductivity k = 0.02872 W/mK
 Velocity of gas in tube v = 3.198m/s
 D = shell diameter = 0.220m
Re = ρvD/ μ= 3376.004
Nu = 0.023Re.8 Pr0.3
 Nu = 0.023(3376.004)0.8 (0.6989)0.3 Figure : dimensional view of the shell
 Nu =13.73
hg=Nu*k/d

Gas side heat transfer coefficient (hg) =

(13.73*0.02872/0.01905) = 20.69 W/m2K
CALCULATION OF OVERALL HEAT
TRANSFER COEFFICIENT:
We know that 1 / U = (1 / ha)+ (do / kmetal*ln(d0/di)
+ (1 / hg )
Where, U = The overall heat transfer coefficient
W/m2K
kmetal= Thermal conductivity of the material W/mK
h = Heat transfer coefficient W/m2K
The factor (do / kmetal*ln(d0/di ) is negligible, and
substituting all the other values, We get,
Overall heat transfer coefficient U = (1 / 8.22) + 0+
(1 / 20.69) = 5.716 W/m2K.
Calculation of Heat Load, Q: Figure :Shell with Tubes and baffle during
Heat Load, Q = ma*cpa*(Ta1- Ta2) = manufacturing Internal View:
0.044*1.005*(52.51-33) = 0 .862 KW

CMR Engineering College 48|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

Figure:Shell with Tubes during manufacturing

External View

Figure : Assembly to an Engine Exhaust:

IX. RESULTS IN CFD ANALYSIS

Fluid Temperature
Solid Temperature

CMR Engineering College 49|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

Animation Plot Thermal conductivity

0.6

Thermal conductivity[W/(m*K)]
0.5

0.4

0.3

0.2

0.1

0
-1000 0 1000 2000 3000

Temperature[°C]
Engineering Database

Gases EXPERIMENTAL READING AND

Air CALCULATIONS
Path: Gases Pre-Defined The following is the experimental procedure:
Specific heat ratio (Cp/Cv): 1.399  Connect the APH to the Diesel engine silencer
Molecular mass: 0.0290 kg/mol outlet with a hosepipe, union/coupling
 Fix the blower to air inlet pipe firmly. Use tape
Dynamic viscosity if necessary.
 Insert thermocouple in the port provided at gas
0.00012 inlet pipe
 Start the diesel engine
0.0001  Switch on blower and Thermocouple
Dynamic viscosity[Pa*s]

0.00008  Thermometer is also used to measure

temperature
0.00006  Wait for some time until the air outlet
0.00004 temperature becomes steady
Based on the experimental readings, thermal
0.00002 design of air preheater is verified by using NTU
0 method
-1000 0 1000 2000 3000
AIM: Cross verifying the experimental air outlet
temperature with that calculated by NTU method
Temperature[°C]
CALCULATION OF AIR OUTLET
TEMPERATURE USING NTU METHOD:
Specific heat (Cp) Heat transfer rate, Q = mg*Cpg*ΔTg kW
3500 Where,Mass flow rate gas = 0.0137 kg/s
Cpg = 2.1 kJ/kgk
3000 Temperature inlet of gas = 65 °C
Specific heat (Cp)[J/(kg*K)]

2500 Therefore, Q = 0.0137*2.1*(65-Tgo)

Heat capacity of gas (C) = mg.cpg = 0.0137*2.1=
2000
28.77 W/K ---------------(1)
1500 Heat capacity of air = ma.cpa = 0.044*1.005=
42.22 W/K ---------------(2)
1000
Comparing the two values in Equation (1) & ( 2)
500 Cmin = 28.77 w/k and Cmax = 42.22 W/K
0
Effectiveness, Є = actual heat transfer/ideal heat
transfer
-1000 0 1000 2000 3000
i.e.Є = Qactual/Cmin(Tg1- Ta1)
Temperature[°C]  Tg1=65, Ta1=33

CMR Engineering College 50|P a g e

 International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622
NATIONAL CONFERENCE on Developments, Advances & Trends in Engineering Sciences
(NCDATES- 09th & 10th January 2015)

 Є = 0.0137*2.1*1000*(65-Tgo)/28.77*(65- XI. CONCLUSIONS

33) 1. Thermal design of Air preheater model is cross
verified by NTU method
Air Air Gas 2. Air and Gas outlet temperature from experiment
Gas
inlet out outlet are 47°C and 46°C which are close to that
S.no inlet
temp temp temp obtained by NTU method 43.66°c and 49.35°C
temp °c
°c °c °c 3. The difference in the temperature may be due to
fouling in gas and distribution of flow due to
vibration of the system
1. 33.4 47 65 46
REFERENCES
[1] A numerical model for the analyses of heat
transfer and leakages in a rotary air
preheater Bostjan Drobnic, Janez Oman ,
2. 33.4 44 60 37
Matija Tuma.
[2] To optimise air preheater design for better
performance P.N.SAPKAL,
P.R.BAVISKAR, M.J.SABLE,
NTU= [-1/(1+C2 )][ln{(2/Є)-1-C-(1+ C2)}/ {(2/Є)-1-
C+(1+ C2)}] (From HT data book ) S.B.BARVE.
C = Cmin/Cmax = 0.6817 [3] Opportunities for heat exchanger
Also NTU= UA/ Cmin = .716*0.5924/28.77 = 0.117 applications in environmental systems R.K.
Substituting all values in the above NTU equation: Shaha, B.Thononb, D.M. Benforadoc.
0.117= [-1/(1+0.68172 )][ln{(2/0.03125(65- Tgo))-1- [4] Performance Evaluation of air pre heater at
0.6817-(1+ 0.68172)}/ {(2/0.03125(65- Tgo))-1- off Design condition Rakesh kumar, sanjeev
C+(1+ C2)}] From the above equation gas outlet jain.
temperature is calculated as Tgo = 49.35°C [5] REGENERATIVE AIR PREHEATERS
From heat balance , Qg= Qa WITH FOUR CHANNELS IN A POWER
 mg*Cp*ΔTg = ma*Cpa*ΔTa PLANT SYSTEMChi-Liang Lee.
 0.0137*2.1*(65-49.35)= 0.044*1.005*(Tga- [6] Optimization of Air Preheater Design for
3) the Enhancement of Heat Transfer
 0.4502=0.044*1.005*(Tga-33) Coefficient P. N. Sapkal, P. R. Baviskar, M.
Therefore the calculated air outlet temperature of air J. Sable & P. A. Makasare.
out let Tga = 43.66°cHence the outlet temperatures [7] Mercury emission control from coal
are matching and design air preheater is verified. combustion systems. A modified air
preheater solutionK. Schofield.
[8] Efficient use of primary sources of energy
X. DISCUSSION OF RESULTS AND S. A. M. Said and M. A. Habib.
CONCLUSIONS RESULTS [9] Integrated assessment of boiler auxiliary
1. Thermal Design of Air pre heater is done by equipment performance deviations in coal
fixing air and gas out let temperature and a heat fired power plants. Inmaculada Arauzo and
transfer area of 6.59 m2 is obtained. cristobal cortes.
2. A pro type of air pre heater (Shell and tube type) [10] Tubular Exchanger Manufacturers
is fabricated for a heat transfer area of 0.5924 m2 Association, “Standards of the Tubular
as for higher air outlet temperature the air Exchanger Manufacturers Association,” 7th
preheater size increases which is not economic ed., TEMA, New York(1988).
for a lab model.
3. Exit temperatures of Air preheater model
 Air outlet temperature = 47°C
 Gas outlet temperature = 46°C
4. Exit Temperature of air preheater CFD model is
a) Solid temperature Result
Air outlet temp = 42.700C
Flue gas outlet Temp = 67.07oC
b) Fluid Temperature Result
Air outlet temp = 42.650C
Flue gas outlet Temp = 67.18oC

CMR Engineering College 51|P a g e