Computer-Aided Analysis of Innovative Thermal Enhancement Elements for Industrial Boilers

Computer-Aided Analysis of Innovative Thermal Enhancement Elements for Industrial Boilers

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The Czech Republic is transitioning to low-emission energy sources, planning to decommission coal-fired power plants by 2033. Combined cycle power plants (CCGT) are key to this transition, achieving around 60% efficiency by utilizing natural gas combustion and waste heat recovery in heat recovery steam generator (HRSG) boilers. This paper focuses on enhancing heat transfer in HRSG boilers using finned tubes, which increase the heat exchange surface area on the flue gas side. Three types of finned tubes are analyzed: Spiral Solid Fin, Serrated Fin SF, and Serrated Fin HF. The study uses the BoilerDesigner calculation program to compare their performance. Results show that Serrated Fin HF provides the highest heat output, making it optimal for HRSG design. The paper details the technical properties and performance metrics of each tube type, including heat output, pressure drop, overall heat transfer coefficient, and heat exchange area. Design considerations are discussed, with a focus on optimizing geometric design for desired performance. The study identifies optimal fin density for different configurations and recommends specific designs for superheaters in HRSGs. The paper concludes that further modifications could enhance performance, with Serrated Fin SF as a promising alternative for future research. The findings support the sustainable development of CCGTs and the transition to low-emission energy sources.

The Czech Republic is transitioning to low-emission energy sources, planning to decommission coal-fired power plants by 2033. Combined cycle power plants (CCGT) are key to this transition, achieving around 60% efficiency by utilizing natural gas combustion and waste heat recovery in heat recovery steam generator (HRSG) boilers. This paper focuses on enhancing heat transfer in HRSG boilers using finned tubes, which increase the heat exchange surface area on the flue gas side. Three types of finned tubes are analyzed: Spiral Solid Fin, Serrated Fin SF, and Serrated Fin HF. The study uses the BoilerDesigner calculation program to compare their performance. Results show that Serrated Fin HF provides the highest heat output, making it optimal for HRSG design. The paper details the technical properties and performance metrics of each tube type, including heat output, pressure drop, overall heat transfer coefficient, and heat exchange area. Design considerations are discussed, with a focus on optimizing geometric design for desired performance. The study identifies optimal fin density for different configurations and recommends specific designs for superheaters in HRSGs. The paper concludes that further modifications could enhance performance, with Serrated Fin SF as a promising alternative for future research. The findings support the sustainable development of CCGTs and the transition to low-emission energy sources.

combined cycle power plant (CCGT), heat recovery steam generator (HRSG), heat exchangers, serrated finned tubes, BoilerDesigner

combined cycle power plant (CCGT), heat recovery steam generator (HRSG), heat exchangers, serrated finned tubes, BoilerDesigner

CHUDÝ, D.; JEGLA, Z.

12.05.2025

Institute of Theoretical and Applied Mechanics of the Czech Academy of Sciences

Prague, Czech Republic

1805-8256

Engineering Mechanics ....

31

Česká republika

53

56

4

https://www.engmech.cz/im/proceedings/show_p/2025/53

em2025-53