Journal of applied science in the thermodynamics and fluid mechanics

Vol. 2, No. 2/2008, ISSN 1802-9388

ANALYSIS OF FIRE TUBE BOILER INFLUENCED BY DISSOLVED

SOLIDS IN FEED WATER
*Sandip SONAWANE, **Avinash PATIL

*SNJBs College of Engineering

Neminagar, Chandwad
ZIP- code-423 101, Nashik District, Maharashtra State, India
Phone: + (91) (2557) 235152 Fax: + (91) (2556) 256811
Email: sandipsonawane_2007@rediffmail.com
**PVP Institute of Technology
Budhgaon, Sangli
ZIP- code-416 304, Sangli District, Maharashtra State, India
Phone: + (91) (233) 2366398 Fax: + (91) (233) 2366185
Email: patilavi_karnal@yahoo.co.in

Fire tube boilers have been used throughout the world for over a century and have been one of the
mainstays behind process steam applications and industrial heating plants. The performance & life of boiler
depends on hardness of water, total dissolved solids (TDS), residual sulphite, residual Phosphate in water.
Dissolved solids deposited on the surface of boiler tube reduces rate of heat transfer from hot gases to
water/steam, as thermal conductivity of dissolved solids is very less. In this research paper, weight &
deflection due to dissolved solids are evaluated by using reverse osmosis (RO) water & soft water
alternatively as feed water for fire tube boiler. A result shows that weight & deflection are reduced by using
RO water for boiler.
During experimental investigation, 4 mm thick layer of dissolved solids is observed by using soft water for
boiler, whereas 0.5 mm of thin layer of dissolved solid is observed for RO water. As the thickness of
dissolved solid layer is less in case of reverse osmosis water, hence resistance to heat flow from hot gases
to water/steam is less. It resulted in increase of rate of heat transfer from hot gases to water. Also the
chances of crack formation is reduced. Analysis result shows that using RO water for boiler weight &
deflection are drastically reduced.

Keywords: TDS; RO; weight and deflection

1 INTRODUCTION
Fire tube boiler used for experimentation is located at M.B. Sugars & Pharmaceuticals Ltd., Malegaon, Dist.
Nashik (Maharashtra State), India. Schematic diagram of fire tube boiler is shown in figure. 1

Figure 1: Schematic diagram of two pass packaged fire tube boiler

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388
It is a horizontal, multitubular and two pass packaged type boiler that uses wood as fuel. There are 147 tubes
in first pass and 143 tubes in second pass. Combustion of fuel takesplace in furnace, hot gases flows
through boiler tube and water is contained in shell. Heat transfer takesplace from hot gases to water/steam.
Evaporative capacity of boiler is 4500 kg/hr.

2 EXPERIMENTAL INVESTIGATION

2.1 Experimental setup

Experimental setup consists of 'K' type thermocouples, pressure indicator, water flow meter & record of wood
(fuel) consumption. Thermocouples are inserted at first pass inlet, first pass exit, second pass exit to
measure temperature. Inlet temperature of water is measured by thermometer. Temperature of flue gases &
fuel consumption is measured to generate 4500 kg/hr steam at 10 bar pressure for using soft water & RO
water alternatively as feed water for boiler.

2.2 Experimental procedure

1. After blow down of water from boiler, fresh soft water is circulated through boiler with the help of
water pump. Combustion of fuel takes place in furnace. Hot gases start flowing through boiler tube.
Temperature of hot gases starts rising. Rate of heat transfer takes place from hot gases to water
containing in shell.
2. Once steam pressure reaches to 10 bar (functional requirement of industry), first pass inlet, first pass
exit and second pass exit temperatures of flue gases are recorded. Simultaneously the rate of fuel
consumption is measured.
3. Same experimental procedure is repeated for reverse osmosis water.

2.3 Observation table

Table 1:Observation Table
Reading using Reading using
Observed parameter
soft water RO water
Furnace Exit Temperature or First Pass Inlet
1050 0C 1007 0C
Temperature of flue gases
First Pass Exit Temperature of flue gases 775 0C 746 0C
Second Pass Exit Temperature of flue gases 260 0C 243 0C
Inlet Temperature of water 35 0C 35 0C
Exit temperature of steam 182 0C 182 0C
Fuel consumption for production of 4500 kg/hr steam 1164 Kg/hr 1074 Kg/hr
Thickness of total dissolved solids layer on the surface
4 mm 0.5 mm
of boiler tube
Blow down percentage 40 3

2.4 Analysis of soft & RO water

Feed water and boiler water parameters are tested in authorized laboratory (Konark Engineers, Nashik).
Feed water parameters and Boiler water parameters are given in table 2.

Table 2: Analysis of soft and RO water

Feed Water Parameters

Actual using Actual using

Sr. No. Parameter Desirable RO water
soft water
1 PH 8.5 9.5 8.5 8.5
2 Hardness NIL 10 ppm NIL
3 Temperature 35 0C 35 0C 35 0C
4 Total Dissolved Solids (TDS) 0-100 802 ppm 40 ppm

Blow down water parameters

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388

1 PH 10.5 11.5 12 11
2 Total Dissolved Solids (TDS) Less than 3500 31600 ppm 1680 ppm
3 Residual Sulphite 30-40 NIL 40 ppm
4 Residual Phosphate 30-40 10 ppm 40 ppm
5 P-Alkalinity Less than 300 4600 ppm 40 ppm
6 Total Alkalinity Less than 700 5800 ppm 130 ppm
By using soft water as feed water for boiler, analysis report shows that, Total Dissolved Solids (TDS) and
alkalinity of blow down water are found very higher than desired range. To reduce corrosion and scaling
tendency, it is necessary to maintain the percentage of residual sulphite and phosphate within desired range.
Using soft water for boiler, residual sulphite and phosphate are found very low or nil. Scale formation on the
surface of boiler tube reduces the rate of heat transfer from flue gases to water. It causes overheating
of boiler tube and initiates crack formation. Figure 2 shows crack on surface of 1 st pass boiler tube. A failure
of boiler tube results in increase of blow down percentage. It resulted in production loss. Also for production
of 4500 kg/hr steam, fuel consumption is more by using soft water for boiler. Hence Reverse Osmosis (RO)
plant is installed at site for safe, efficient and prolongs working of fire tube boiler.

Figure 2: Crack on surface of boiler tube

3 ANALYSIS

3.1 Weight analysis (by using soft water for boiler)

By using soft water as feed water for boiler, 4 mm (average) thick dissolved solid layer is observed over
boiler tube during experimental investigation (see table 1).
Weight W acting on the surface of boiler tube due to dissolved solids:
W =V w ds , (1)
where V - means volume of water containing dissolved solids,
wds - means weight density of dissolved solids in water.
Calculated weight W is 10.98 N (See Weight analysis in appendix 1).

3.2 Weight Analysis (by using reverse osmosis water for boiler)
By using RO water as feed water for boiler, 0.5 mm (average) thin dissolved solid layer is observed over
boiler tube during experimental investigation. Calculated weight is 1.28 N (See Weight analysis in appendix 2).

3.3 Deflection Analysis (By using soft water for boiler)

Dissolved solids deposited on the surface of boiler tube acts uniformly distributed load (assumption) on the
boiler tube. Due to this boiler tube deflects.

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388

Figure 3: Deflection of boiler tube

Next equation shows Deflection magnitude at Center :

5ML3
= , (2)
384 EI
Deflection magnitude at Center is calculated to 1.45 mm. Calculation see in appendix 3.

3.4 Deflection Analysis (By using reverse osmosis water for boiler)
Deflection Analysis (By using reverse osmosis water for boiler) is calculated to 0.169 mm and it's calculation
is shown in appendix 4.

4 RESULTS
Table 3: Result Table
Using soft water for boiler Using RO water for boiler
Weight due to dissolved solids 10.98 N 1.28 N
acting on boiler tube
Deflection of boiler tube due to 1.45 mm 0.169 mm
deposition of dissolved solids
Blow down percentage 40 3
Total dissolved solids in boiler 31600 ppm 1680 ppm
water

REFERENCES
[1] FRIEDMAN, J., KOUNDAKJAN, P., NAYLOR, D., ROSERO, D.: Heat Transfer to Small Horizontal
Cylinders Immersed in a Fluidized Bed. Journal of heat transfer, 984 / vol. 128, October 2006.
[2] GHOSH, S., CHOI, J.: Modeling and Experimental Verification of Transient/Residual Stresses and
Microstructure Formation in Multi-Layer Laser Aided DMD Process. Journal of heat transfer, July 2006,
vol. 128 / 663.
[3] JASON, M., PORTER, M., LARSEN, M., E., WESLEY, J., B., HOWELL, J., R.: Metaheuristic
Optimization of a Discrete Array of Radiant Heaters. Journal of heat transfer, October 2006, vol. 128/
1031.
[4] JANI, S., SAIDI, M., H., MOZAFFARI, A., A.: Second Law Based Optimization of Falling Film Single
Tube Absorption Generator. Journal of heat transfer, 708 /Vol. 126, October 2004.
[5] KUMAR, P., K., VENKATARATHNAM, G.: Optimization of Matrix Heat Exchanger Geometry Journal of
heat transfer, August 2000, vol. 122/579.
[6] KUNDU, B., DAS, P., K..: Performance Analysis and Optimization of Annular Fin with a Step Change in
Thickness Journal of heat transfer, June 2001, Vol. 123 /601.
[7] Welding Technology Institute of Australia, Cracking in Fire Tube Boiler, TGN-PE-03, March 2006.
[8] MULL, T., V., HOPKINS, M., W., WHITE, D., G.: Numerical Simulation Models for a Modern Boiler
Design.
[9] Ken Ogiso, Assessment of Overall Cooling Performance in Thermal Design of Electronics Based on
Thermodynamics Journal of heat transfer, October 2001, Vol. 123 /999.
[10]ZHEN-HUA LIU, JIE YI: Augmentation of Laminar Forced Convective Heat Transfer of an Oil Flow in an
Enhanced Tube by EHD Effect Journal of heat transfer, February 2004, Vol. 126 /131.

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388
APPENDIX 1

Weight analysis (by using soft water for boiler)

Weight acting on the surface of boiler tube due to dissolved solids:
W =V w ds , (A1-1)
where V - means volume of water containing dissolved solids,
wds - means weight density of dissolved solids in water.

Figure A1-1: Dissolved solids deposited on boiler tube using soft water

2 2
V = D2 D0 L , (A1-2)
4

w ds =w , (A1-3)

TDS = 1.1 10 6 ( 1) , (A1-4)

where D2 - means diameter by considering dissolved solid layer (figure A1-1)

D2 = 76.1+ 4+ 4 = 84.1 mm = 0.0841 m,
Do - means outer diameter of boiler tube
Do = 76.1 mm = 0.0761 m,
L - means length of boiler tube
L = 1.082 m,
w -means weight density of water
W = 9810 N/m3 ,
TDS -means Total Dissolved Solids in blow down water (see table 2)
TDS = 31600 ppm ,
- means relative density

by putting D2 , Do and L in equation 2, V = 0.001088899 m3

by putting TDS=31600 ppm in equation 4, = 1.02872

by putting w & in equation 3, wds =10091.74 N/m3

by putting V and wds in equation 1, W = 10.98 N

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388
APPENDIX 2

Weight Analysis (by using reverse osmosis water for boiler)

By using RO water as feed water for boiler, 0.5 mm (average) thick dissolved solid layer is observed during
experimental investigation.
Hence, D 2 Diameter by considering dissolved solid layer = 76.1+ 0.5+ 0.5 = 77.1 mm = 0.0771 m (see
figure 4).

Figure A2-1: Dissolved solids deposited on boiler tube using RO water

Do - means outer diameter of boiler tube D0 = 76.1 mm = 0.0761 m

L - means length of boiler tube L = 1.082 m

w - means Weight density of water W = 9810 N/m3
TDS - means Total Dissolved Solids in blow down water TDS = 1680 ppm (see table 2)

by putting D 2 , D o & L in equation 2, V = 0.00013016 m3

by putting TDS in equation 4, = 1.001527
by putting w and in equation 3, w ds =9824.98 N/m3
by putting V and w ds in equation 1, W = 1.28 N

APPENDIX 3
Deflection Analysis (By using soft water for boiler)
Dissolved solids deposited on the surface of boiler tube acts uniformly distributed load (assumption) on the
boiler tube. Due to this boiler tube deflects.

Figure A3-1: Deflection of boiler tube

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 Journal of applied science in the thermodynamics and fluid mechanics
Vol. 2, No. 2/2008, ISSN 1802-9388

5ML3
Deflection magnitude at Center = (A3-1)
384 EI

D 4o Di4
I= (A3-2)
64
where W - means weight acting on boiler tube due to dissolved solids W = 10.98 N,
L - means length of boiler tube L = 1.082 m,
M - means moment M = W L = 10. 981 . 028=11. 28 Nm,
E - means modulus of elasticity of tube material E = 200 109 N/m2 ,
I - means mass moment of inertia,
Do - means outer diameter of boiler tube D0 = 0.0761 m,

Di - means inner diameter of boiler tube Di = 0.06878 m.

by putting D o and D i in equation 5, I = 547.64 10-9 m4

by putting M, L, E & I in equation 4, = 0.00145 m = 1.45 mm

APPENDIX 4
Deflection Analysis (By using reverse osmosis water for boiler)
W - means Weight acting on boiler tube due to dissolved solids W = 10.28 N
L - means Length of boiler tube L = 1.082 m
M= 1 . 281 . 082=1 .38 Nm (A4-1)
by putting M, L, E and I in equation A3-1, = 0.000169, m = 0.169 mm