Department of Mechanical Engineering

A project Report on
DESIGNING A BOILER CHIMNEY HEAT RECOVERY SYSTEM
AGAINST FOULING…...

Submitted by
Name: Roll No.

1. Rakesh Paul 20600721052

2. Milan Giri 20600721032
3. Pradip Sarder 20600721034
4. Subhasis Giri 20600721035
5. Sandip Koyal 20600721053
6. Sanjib Das 20600721016
7. Somnath Sanki 20600721027
8. Samrat Sadhukhan 20600721042
9. Tanmoy Paul 20600721026
10. Nabjyoti Das 20600721048

Under the guidance of

RAJASHRI SUR
2024-2025

1
 CERTIFICATE OF APPROVAL

The forgoing project work entitled "Surface Roughness of Brass Material" is hereby approved
creditable model of project topic and has been presented in satisfactory manner to warrant its
acceptance as prerequisite the degree for which it has been submitted.

It is understood that by this approval, the undersigned do not necessarily

endorse any conclusion drawn or opinion expressed there in, but approve the

project work for which it is submitted.

………………………………. ………………………………

(Project Guide) (Principal)

………………………………………………..

(Head Of the Department)

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 DEPARTMENT OF MECHANICAL ENGINEERING
SEACOM ENGINEERING COLLEGE
JL- JALADHULAGORI, VIA ANDUL MOURI RD, DISTRICT,
SANKRAIL, HOWRAH, WEST BENGAL-711302

DECLARATION

We hereby declare the final project entitled “Surface Roughness of Brass Material" Submitted by

guidance and supervision in partial fulfilment of the requirement for the degree of

"Bachelor of technology" in “Mechanical Engineering from Seacom Engineering College,

under Maulana Abul Kalam Azad University of Technology, West Bengal, India.

……………………………………………. ………………………….. ………………………………………

(Head of the Department) (Project Guide) (Project Coordinator)

Department of Mechanical Engineering

Seacom Engineering College

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 ACKNOWLEDGEMENT

It gives us great pleasure to find an opportunity to express our deep and sincere gratitude to
us
project guide Asst. Prof. Sk Hedai and Tech. Asst. Mohan Kumar Maity, as well as Asst. Prof.
Pradip Kumar Mondal our Head of the Department. We do very respectfully recollect his
constant encouragement, kind attention and keen throughout the course of our work.
We humbly extend our sense of gratitude to other faculty members, laboratory staff, library
staff and administration of the institute of providing us their valuable help and time with a
congenital working environment.
Last but not the least, we would like to convey our heartiest thanks to all our classmate who
time to

time have helps us with their valuable suggestion during our project work.

Date: - 20-01-2025

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 ABSTRACT

Surface roughness is a component of surface texture. It is quantified by the

deviations in the direction of the normal vector of a real surface from its ideal
form. If these deviations are great, the surface is rough; if they are small, the
surface is smooth. Roughness normally considered being the high-frequency, short-
wavelength component of a measured surface Many experiments have been
conducted to determine the surface roughness of a material Different materials
have different test methods on the surface roughness. In general, all wanted to
achieve the same goal, that is to control the desired surface roughness via several
control variables such as in these studies are the cutting parameters and
maintaining the cutting force constant. This paper outlines machining experiments
conducted using the proposed technique indicate that using a suitable cutting
force signal, the surface roughness can be expected within 3% of the actual surface
roughness for numerous end-milling conditions. Simulation results are presented
to confirm the efficiency of a control mode

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 CONTENTS

CHAPTER ONE……………………………………………………………..8
1.0 NTRODUCTION ………………………………………………....8
1.1. Industrial waste heat…………………………………………………………......8
1.2 Design considerations…………………………………………………………….8
1.3 Challenges to to recovering low temperature waste heat………………………...8
CHAPTER TWO
2.0 LITERATURE REVIEW………………………………………….9-14
2.1 INTRODUCTION……………………………………………………………....9
2.2 TYPES OF HEAT EXCHANGERS……………………………………………9
2.2.1 Double pipe heat exchanger (simplest heat exchanger)………………...9
2.2.2 The compact heat exchanger……………………………………………10
2.2.3 Shell and tube heat exchanger………………………………………….11
2.2.4 Plate heat exchangers……………………………………………….......12
2.2.5 Other technologies applied to waste heat recovery……………………..12
1.2.5.1Regenerators…………………………………………………...13
1.2.5.2 Recuperators…………………………………………………..13
2.2.5.3 Thermal wheel………………………………………………...13
2.2.5.4 Economizer…………………………………………………....13
2.2.5.5 Run around coil……………………………………………….13
2.3OVERALL HEAT TRANSFER COEFFICIENT……………………………....13
2.4 FOULING FACTOR………………………………………………………….....14
CHAPTER THREE
3.0FOULING…………………………………………………………15-17
3.1 INTRODUCTION……………………………………………………………....15
2.4.1 Scaling/precipitation…………………………………………………..15
2.4.2 Particulate fouling……………………………………………………15
2.4.3 Chemical /corrosion fouling………………………………………….16
2.4.4 Solidificationfouling…………………………………………………16
3.2 DESIGNS AGAINST FOULING……………………………………………...16
3.2.1 Provision of particulate filters…………………………………........16
3.2.2 Introduction of turbulent flow upstream of the exchange core…….17

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CHAPTER FOUR
4.0 THE HEAT EXCHANGER SYSTEM DESCRIPTION………………18-21
4.1 COMPONENTS AND PROPERTIES…………….………………………………..18
4.1.1 Funnel shaped duct………………………………………………….....18
4.1.2 Ducts………………………………….………………………………..19
4.1.3 Heat exchanger core…………………………………………………....20
4.1.4 Draught system…………………………………………………………21
4.1.5 CONCLUSION…..……………………………………………………………..22
4.1.6 RECOMMENDATION…………………………………………………………23
4.1.7 REFERENCES………………………………………………………………….24

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CHAPTER ONE
1.0 INTRODUCTION
1.1. INDUSTRIAL WASTE HEAT.
This is heat lost in industries through ways such as discharge of hot combustion gases to the
atmosphere through chimneys, discharge of hot waste water, heat transfer from hot surfaces.
This energy loss can be recovered through heat exchangers and be put to other use such as
preheating other industrial fluids such as water or air.
This project focuses on recovering heat that is lost through boiler chimney flue gas. The
advantages of heat recovery include:
i). Increasing the energy efficiency of the boiler.
ii). Decreasing thermal and air pollution dramatically.
1.2 DESIGN CONSIDERATIONS
In the designing of the exchanger following factors were put to consideration.
1. The exchanger surface has to be the most efficient and suitable for gas-gas heat
exchange.
2. The design has to consider the fouling effect of the flue gases.
3. The design has to allow for quick maintenance without interfering with the boiler
operations.
4. The ducting design has to conform to the boiler chimney design.
Based on the above factors, the exchanger was designed to be of compact plate type. Various
designs for the exchange core were considered including cylindrical type (ducts).
The plate type was found to be more efficient and simpler in design. It was also more suitable
for
gas - to gas heat exchange as it offers higher surface for heat transfer.
1.3 CHALLENGES TO RECOVERING LOW TEMPERATURE WASTEHEAT
(HODGE B.K, 1990)
Corrosion of heat exchanger surface: as the water vapor contained in the exhaust gas cools some
of it will condense and deposit corrosive solids and liquids on the heat exchanger surface. The
heat exchanger must be designed to withstand exposure to these corrosive deposits. This
generally, requires using advanced materials, or frequently replacing components of the heat
exchanger, which is often uneconomical.
Large heat exchanger surface required for heat transfer; since low temperature waste heat will
involve a smaller temperature gradient between two fluid streams, larger surface areas are
required for heat transfer. This limits the economy of heat exchangers.
Finding use for low grade heat: recovering heat in low temperatures range will only make sense
if the plant has use for low temperature heat.

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CHAPTER TWO
2.0LITERATURE REVIEW
2.1 INTRODUCTION
Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at
different temperatures while keeping them from mixing with each other. Heat transfer in heat
exchangers involves convection in each fluid and conduction through the wall separating the two
fluids. In order to account for the contribution of all the effects of convection and conduction, an
overall heat transfer coefficient, U, is used in the analysis. Heat transfer rate depends on the
temperature differences between the two fluids at the location and the velocity of the fluids (time
of interaction) between the fluids.
2.2TYPES OF HEAT EXCHANGERS
Due to the different types of applications for heat exchanges, different types of hardware and
different configurations of heat exchanges are required. This has resulted to different designs of
heart exchangers which includes and not limited to.
2.2.1Double pipe heat exchanger (simplest heat exchanger)
Consists of two concentric pipes of different diameter. In application, one fluid passes through
the pipe of smaller diameter while the other flows through the annular space between the two
pipes. The flow of fluids can be arranged into:-
i). Parallel flow.(Cengel, 2002)
Both fluids (hot fluid and cold fluid) enter the heat exchanger at the same end and move in the
same direction to leave at the other end as shown in the figure below.

Fig a (i) Fig a (ii)

Fig a. (i) shows the flow regimes while fig a (ii) shows the associated temperature profiles.

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 (ii). Counter flow(Cengel, 2002)
In these types of arrangement, the cold and hot fluids enter the exchanger at opposite ends and
flow in opposite directions as shown in the figure below:

Fig b(i) Fig b(ii)

Figure b (i) shows the flow regimes and figure b (ii) shows the associated temperature profiles.

2.0.1 The compact heat exchanger

This type of heat exchanger is designed to allow a large heat transfer surface area per unit
volume. The ratio of the heat transfer surface area of a heat exchanger to its volume is called
the area density β. Heat exchangers with β >700 are classified as compact heat exchanger e.g.
car radiator, human lung am0ongest others. They allow high heat transfer rates between fluids
in a small volume. They are therefore best suited for applications with strict limitations on the
weight and volume of heat exchanger. They are mostly used in gas-to-gas and gas-to-liquid
heat exchanger to counteract the low heat transfer coefficient associated with fluid flow with
increased surface area. The two fluids in this type of heat exchangers move in directions
perpendicular to each other, a flow configuration referred to as cross-flow. This type of flow
may be classified as unmixed or mixed.
i). Unmixed flow
Plate fins force the fluid to flow through a particular inter-fin spacing and prevent it
from moving in the transverse direction.

ii). Mixed flow

The fluid is free to move in the transverse direction. The presence of mixing can have
adverse and significant effects on the heat transfer characteristics of a heat exchanger.

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(Cengel, 2002)

Ross-flow Cross-flow
(unmixed) (mixed)

Tube flow Tube flow u6

(unmixed) (unmixed)

(Ozisk, 1985)

Plate fin Circular tubes

Flat tubes
Fig c. compact heat exchangers
2.0.2 Shell and tube heat exchanger
Contains a large number of tubes packed in a shell with their axes parallels to that of the shell. One
fluid flows through the tubes while the other flows through the shell but outside the tubes. Baffles’
placed in the shell increases the flow time of the shell-side fluid by forcing it to flow across the
shell thereby enhancing heat transfer in addition to maintaining uniform spacing between the
tubes.These baffles are also used to increase the turbulence of the shell fluid. The tubes open to
some large flow areas called header at both ends of the shell. These types of heat exchanger can
accommodate a wide range of operating pressures and temperatures. They are easier to
manufacture and are available at low costs. Both the tube and shell fluids are pumped into the heat
exchanger and therefore heat transfer is by forced convection. Since the heat transfer coefficient
is high with the liquid flow, there is no need to use fins. They can also be classified into parallel
and counter flow types.

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(Ozisk, 1985)

Tube Tube
outlet inlet
baffles

Tube inlet
Shell
outlet
Fig d. shell and tube heat exchan one shell pass and one tube pass ( cross-counter
flow configuration ) ger with

2.0.3 Plate heat exchangers(Ozisk, 1985)

They are usually constructed of thin plates which may be smooth or corrugated. Since the plates cannot
sustain as high pressure and or temperatures as circular tubs, they are generally used for small and low to
moderate pressure/temperatures. Their compactness factor is also low compared to other types of heat
exchangers. The plates can be arranged in such a way that there is cross- flow i.e. the hot and cold fluids
flowing in directions perpendicular to each other to enhance the heat transfer characteristic.

Corrugations

(or fins)

Hot
air
Parallel plates
inlet
Cold air inlet
Fig e. plate type compact heat exchanger (cross flow)
2.0.4 Other technologies applied to waste heat recovery
1.2.51Regenerators
This is a type of heat exchanger where heat from the hot fluid is intermittently stored in a thermo storage
medium before it is transferred to the old fluid. In this type of heat exchanger can be the same fluid. The
fluid may go through an external processing step and then it is flowed back through the heat exchanger
in the opposite direction for further processing 1.2.5.2 Recuperators

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It is a counter-flow energy recovery heat exchanger used in industrial processes to recover waste heat.
2.2.5.3 Thermal wheel.
A rotary heat exchanger consists of a circular honeycomb matrix of heat absorbing material which is slowly
rotating within the supply and exhaust air streams of an air handling system.
2.2.5.4 Economizer.
In case of process boilers, waste heat in the exhaust gas passed along a recuperator that carries the inlet fluid for
boiler and thus decrease energy intake of the inlet fluid.
2.2.5.5 Run around coil.
Comprises 2 or more multi-raw finned tube coils connected to each other by pumped pipe work circuit.

2.1 OVERALL HEAT TRANSFER COEFFICIENT

In analysis of heat transfer in heat exchangers, various thermal resistances in the path of heat flow from the hot to cold
fluid are combined.
Heat is first transferred from the hot fluid to the wall by convection, through the mass by conduction and from the
wall to the cold fluid by convection. Any radiation effects are usually included in the convection heat transfer
coefficients.
The total thermal resistance, R, for the whole system is given by:-
R= thermal resistance of inside flow + thermal resistance of the systems material + thermal resistance of outside flow
1 1 𝑡
R=
+ +
𝐴𝑖ℎ𝑖
𝐴𝑜ℎ𝑜 𝑘𝐴𝑚

Where hi, ho= heat transfer coefficients for inside and outside flow respectively k= Thermal
conductivity of the exchanger material
R= Total thermal resistance from inside to outside flow t=
Thickness of the heat exchanger material

𝐴𝑜−𝐴𝑖
A = = logarithmic mean area, m2
m A𝑜
𝑙𝑛( )
A𝑖

Ai,Ao= Inside and outside surface areas of the heat exchanger surfaces respectively.
Expressing the thermal resistance R as an overall heat transfer coefficient based on either the fluid inside or
outside surface of the heat exchanger surface areas:-
1 1
U=
andU =
o
𝐴𝑜𝑅
i

𝐴𝑖𝑅

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If the wall thickness is small and its thermal conductivity is high the material resistance may be
neglected and hence the overall heat transfer coefficient becomes:-

1
=
Ut 1
+
1

ℎ𝑖 ℎ𝑜

In applications of heat exchangers, accumulation of deposits mostly from combustion, on the heat
exchanger surface causes additional thermal resistance, a condition known as fouling. Effects of
fouling are introduced in the heat transfer coefficient in the form of a fouling factor. The total
thermal resistance then became:-
1 𝐹𝑖 t 𝐹𝑜 1
R= + + + +
𝐴𝑖ℎ𝑖 𝐴𝑖 𝑘𝐴𝑚 𝐴𝑜 𝐴𝑜ℎ𝑜

Where Fi and Fo are the fouling factors on the inside and outside surfaces respectively.

2.2 FOULING FACTOR

The performance of heat exchangers usually deteriorates with time due to accumulation of deposits
on the heat transfer surface. The accumulation of deposits leads to increased resistance to heat
transfer and causes the rate of heat transfer in a heat exchanger to decrease. This accumulation of
deposits on the heat transfer surface is known as fouling and the net effect of fouling is represented
by a fouling factor, Rf, which is a measure of the thermal resistance introduced by fouling.

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CHAPTER THREE
3.0 FOULING

3.1 INTRODUCTION

Fouling is a general term that includes any kind of deposits of extraneous material that appears on
the heat transfer surface during the lifetime of the heat exchanger.

Fouling reduce heat transfer across the exchanger surface hence reduces efficiency of the heat
exchanger. The foulingdeposits also reduce flow cross-section area causing a pressure deferential
across the heat exchanger which in turn increasing on the fan power required. It might also
eventually block the heat exchanger.

Different kinds of fuel produce different degrees of fouling .most fuel produce just soft black soot
that get deposited on the exchanger surface.

This can easily be removed by brushing and sand washing. However lower grade fuel
oil(principally no.6.oil or resid)contain large quantities of alkaline sulfates and vanadium
pentoxide that causes scaling due to their lower fusion temperatures.

The forms of fouling may therefore include

• Particulate fouling.
• Scaling/precipitation.
• Chemical/corrosion fouling.
• Solidification.

2.3 FORMS OF FOULING

2.3.1 Scaling/precipitation: - scaling/precipitation occur as a result crystallization of
dissolved substance on to the heat transfer surface. These deposits can be removed by
scratching or by cleaning via chemical treatment. This is the most common type of fouling.
Scaling/precipitation can be reduced by treating the fluid flowing past the heat exchanger
before it reaches the heat exchanger surface.

2.3.2 Particulate fouling

This result from the accumulation of solid particles suspended in the process fluid onto the
heat transfer surface. Such solid particles can be removed by use of filters to treat the
process fluid before it reaches the heat exchanger surface.
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 2.3.3 Chemical /corrosion fouling
In this case, the surfaces are fouled by accumulation of the products of chemical reactions
on the surfaces. This form of fouling can be avoided by coating the heat exchanger surfaces
by glass. Heat exchanger surfaces can also be fouled by growth of algae in warm fluids
(chemical fouling) which can be prevented by chemical treatment.

2.3.4 Solidification fouling

The crystallization of a pure liquid or one component of the liquid phase on a sub cooled
heat transfer surface.
The mechanism of fouling is complicated and no reliable techniques are available but there are
means of reducing fouling. The methods mostly used to reduce fouling include use of filters and
increasing the fluid flow to ensure turbulent flow.

3.2 DESIGN AGAINST FOULING

It was our duty to consider the effect of fouling upon the heat exchanger performance during the
desired operation lifetime and make provisions in our design for sufficient extra capacity to ensure
that the exchange will meet process specifications upto shut down for cleaning.

We were also to consider the mechanical arrangements that are necessary to permit easy cleaning.

In our design, the following measures have been taken to reduce the rate of fouling.

I. Provision for particulate filters.

II. Introduction of turbulent flow upstream of the exchanger core.

3.2.1 Provision of particulate filters

At the entry of the flue gas duct is attached, a cone shaped duct to whose narrower end can
be attached diesel particulate filter. The particulate filter is designed to remove fuel
particulate matter (soot) from the fuel gases. The efficiency of the filter is inversely
proportional to the pressure that is build up due to resistance to gas flow. It is therefore
difficult to achieve 100 percent efficiency through filtration, as there must be a
compromise between efficiency and pressure buildup .the best filters are therefore broad
band filters that can filter particles of diameters between 0.2-150µm.
The filters can easily be removed through a door on the side of the side duct for cleaning.

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 3.2.2 Introduction of turbulent flow upstream of the exchange core

The cone shape element at the gas-duct entry causes turbulence as it suddenly opens into
the larger gas duct .this causes turbulence. This turbulent flow of air picks with it some of
the particles that stick on the exchanger surface due to its drag effect. This helps to reduce
on fouling.

The above filtration and turbulence only minimizes rate of fouling. But the fouling still
takes place. This therefore implies that the exchanger will require maintenance (cleaning).
There are various ways that could be used in cleaning the exchanger. In the design we
consider using the following methods.
1. Blowing
2. Washing

The system was designed with a slit on the wall of the flue gases duct downstream of the
exchanger .This allows the overhead water washing.

Pressurized water mixed with abrasives e.g. fine sand is used to remove soot that cannot
be removed by blowing air past the exchanger. The abrasives help in scrubbing the surface.

Before washing, the particulate filter is removed and replace with alid to prevent water
from entering the broiler.

During washing the waste water drains out of the system through the outlet ducts at the base of
the flue gas inlet duct.

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CHAPTER FOUR

4.0 THE HEAT EXCHANGER SYSTEM DESCRIPTION

4.1 COMPONENTS AND PROPERTIES
Every part of the system is described and explained in this section. From the previous report, the system
was designed to have the following characteristics

TABLE 4
DESIGN PARAMETERS OF THE HEAT EXCHANGER.
Core dimensions L1 0.3m
L2 0.2m
L3 0.3m
Plate spacing mm 3
Air temperature at inlet °C 26
Air temperature at °C 200
outlet
Gas temperature at inlet °C 450
Gas temperature at °c 200
outlet
Aft. m2 0.06
2
Afr m 0.09
Core volume m3 0.018
Plate thickness b mm 1.83
αa m-1 615.555
αg m-1 613.888
Aa m2 11.08
Ag m5 11.05
Effectiveness 0.75
Ua W/m2K 3.683
R 0.96
Number of passages Air side 23
Gas side 23

4.1.1 Funnel shaped duct

This is a short cone shaped duct that is welded of the entry to the flue gas duck upstream of the
exchanger core.

It provides an end that can be covered by alid during cleaning to prevent water from
entering the boiler. Small holes are left at its joint to the gas duct to allow water out.

18
 During normal boiler operation gas filler can be put at this narrow end to trap carbon
particles from reaching the exchanger core. It was constructed from mild steel sheet (16
gauge)

Fig f. Funnel shaped duct

4.1.2 Ducts
The system has four ducts which are
a) Air inlet duct made from galvanized iron sheet (32 gauge)
b) Air outlet duct also made from galvanized iron sheet (32gauge) and is connected to the
air fan.
c) Gas inlet duct constructed from mild steel sheet (16gauge) to be able to support the
whole system and the rest of the chimney above.
d) Gas outlet duct: also constructed from mild steel sheet (16gauge) so as to hold the rest
of the chimney above the exchange.

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Air duct Flue gas duct

Figs.j: showing air duct and flue gas duct.

4.1.3 Heat exchanger core:

It consists of 134 parallel aluminum plates (32gauge) of dimensions 0.3m by 0.2m enclosed in
a mild steel flanged rectangular frame.
The plates were sealed alternately using silicon sealant. The sealant has good heat resistance
properties. The sealant also has good elastic properties that ensure sealing even during plate
expansion. Galvanized binding wires were used to hold the exchange core fit in the frame and
at the centre by aluminum spacers that ensured even spacing between plates.

20
 Flue gas side

L2

L1

L3
Air side

Fig 4.2 Heat exchanger core.

4.1.4 Draught system

If consists of a electric motor driven (centrifugal) fan which operate at constant speed of 1389
rpm. This fan was driven by a single-phase synchronous motor.

21
 5. CONCLUSION
The objective of this project was completion and testing of boiler chimney heat recovery heat
exchanger system that could be used to recover heat lost through flue gases. A plate type heat
exchanger was used in the design. The systems model was completed and tested under forced
convection conditions. From the performance of the model the optimum operating conditions
were obtained as:
Overall heat transfer coefficient U= 0.778kW/m2K
Amount of heat recovered Q =3.4 kW
Effectiveness ε = 40%
T air in = 22.70C, T air out = 1940C, T g in = 4820C, T g out 2530C

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 6. RECOMMENDATIONS
After completion, testing and analysis of the performance of the exchanger the following
recommendations were made:
4.1.5 The exchanger core plate spacing should be increased to improve on air flow. This will also
increase time required before maintenance as it will slow the rate of blockage due to fouling on the
gas side. The negative effect of this is that it will redue the number of plates and hence the
amount of heat recovered but it is still a worth change for the lifetime of the plates.
4.1.6 An allowance for expansion of the plates should be provided at the ends of the plates. This is to
eliminate the slaking that was observed during testing of the exchanger. Slaking of the plates
increases resistance to flow.
4.1.7 The height, L2, of the heat exchanger should be increased to increase the time for the flue gases to
exchange heat with air.
4.1.8 The filters can be fabricated and installed and the model tested for fouling.

23
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