CFD Analysis of Revomax Reverse Flue Boiler

In this project, CFD analysis is being performed on Gresham?s Reverse flue boiler to estimate its steam production as well as use the results to improve the output of the boiler.Gresham?s reverse flue boiler is a variation of conventional boiler .These 4-ton boilers are currently installed onsite an

Project Title

CFD Analysis of Revomax Reverse Flue Boiler

Project Area of Specialization

Mechanical Engineering

Project Summary

In this project, CFD analysis is being performed on Gresham’s Reverse flue boiler to estimate its steam production as well as use the results to improve the output of the boiler.Gresham’s reverse flue boiler is a variation of conventional boiler .These 4-ton boilers are currently installed onsite and Gresham’s wants to use CFD modelling to determine the accuracy of readings obtained from these boilers onsite. These boilers have multiple air inlets and tubes with spring inserts which add to the complexity to the design of this boiler. To obtain accurate results, more refined grid sizes are used ranging in 0.5-3 million nodes. ANSYS is a software that has high hardware specifications requirements, but the specifications required to run the simulation on this boiler is greater than what is present on the computers used for daily tasks as their computational power aren’t able to cater to the required computational power for simulations .Therefore, a higher specification desktop machine is the only possible solution for successful completion of these simulations so that the industry’s requirement of accurate results is fulfilled.

Project Objectives

The main objective of this project is to predict an estimate steam production of Gresham’s reverse flue boiler compare the results with the boiler operating on-site. An extensive research is to be performed on the boiler with the sole purpose of improving the output of the boiler.  The research will allow industry to match the simulation results with the data recorded from boilers on site then take certain measures to make the boiler more efficient as well as reduce wastage of resources.These simulations may be used to devise methods which increase the productivity of boiler and it may be used to its fullest extent.The simulation software used for this project is ANSYS 19.2.

Project Implementation Method

CFD simulations are quite effective in simulating action of thermofluids in a system.Combustion is a complex phenomena and CFD is used widely to investigate turbulent flow and other complex phenomena throughout the volume of boiler and tubes.Th CFD simulations will be implemented on both the boiler furnace as well as the tubes.CFD softwares for e.g ANSYS  have unlimited functions and options for example different turbulence models,grid sizes which allow users to simulate the problem with higher accuracy.

Different turbulence models being used are namely k-epsilon, k-omega SST, transition k-kl-omega, Transition SST. Each successive turbulence models the case in a way that is more closely linked to the real problem. Different grid sizes being used are in the range of 0.5-3 million nodes. These variations help in providing validation of results and increases the accuracy of results obtained.

The boiler and tubes will first be desgined on SOLIDWORKS and the imported to ANSYS Workbench where mesh will be generated and simulations will be run with different variations.CFD Post will be used to produce all required contours,graphs and compile all data which are to be presented to the industry.

Benefits of the Project

The are quite a few benefits of this project.These simulation will provide industry the data to decide whether it is feasible to operatethe boiler with on current conditions or some changes are required.Improvements could reduce wastage of fuel and improve boiler's efficiency.CFD also is a safer method to implement new changes in the boiler before its tested in the real case scenario.Industry can benefit from this as the boiler's output improvement would benefit their productivity as boiler is fulfilling its purpose.The simulations also enhance our understanding regarding CFD softwares as well as about boiler working which is a main component in several industries The results will help in writing a research paper which improves several skills like research,writing,critical thinking etc that benefit in practical lives.

Technical Details of Final Deliverable

Turbulence model 
Fluid Species Transport model details :
Plots to be plotted portray trend of iterations and convergence
? Mesh details
? Fuel Flow and air velocity and pressure (prim and sec) Plot Convergence 
? Flue gas Composition Plot Convergence N2 O2 Ch4 CO and CO2
? Flue gas properties outlet CP , outlet Density , Volume mass-average CP and temperature
Convergence Plot 
? Outlet mass averaged temperature Convergence Graph
? Total Furnace heat transfer from surface Convergence Graph
Post processing required
? Furness Fluid domain Ch4 fraction Contour (Side view cross section)
? Furness Fluid domain Oxygen fraction Contour (Side view cross section)
? Furness Fluid domain Density contour (Side view cross section)
? Furness Fluid domain Velocity contour (Side view cross section)
? Furness Fluid domain Outlet CO fraction (Outlet surface)
Surface averaged and summed values required:
? Outlet Flue gas mass averaged temperature
? Outlet Flue gas mass averaged CO
? Outlet Flue gas mass averaged Co2
? Outlet Flue gas mass averaged O2
? Outlet Flue gas mass Flow rate
? Inlet prim and secondary area averaged pressure drop
? Total Heat transferred Radiation + Convection Outer surface.

Plots for Tube with spring inserts
Turbulence model 
Fluid Species Transport model details :
Plots required during convergence
? Mesh details
? Fuel Flow and air velocity and pressure (prim and sec) Plot Convergence 
? Flue gas properties outlet CP , outlet Density , Volume mass-average CP and temperature
Convergence Plot
? Outlet mass averaged temperature Convergence Graph
? Total Tube heat transfer from surface Convergence Graph
Post processing required
? Tube fluid domain pressure contour (Side view cross section)
? Tube fluid domain temperature contour(Side view cross section)
? Tube fluid domain Cp Contour (Side view cross section)
? Tube fluid domain Velocity contour (Side view cross section)
Surface averaged and summed values required:
? Outlet Flue gas mass averaged temperature
? Outlet Flue gas mass averaged velocity
? Inlet Flue gas area averaged pressure
? Total Heat transferred Convection Outer surface.

Final Deliverable of the Project

Software System

Core Industry

Energy

Other Industries

Core Technology

Others

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

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