All parts overall heat transfer coefficients in correlation with design and off-design load conditions in a utility bagasse boiler

Abstract

Overall heat transfer coefficients of the four major sections in the 73 MW bagasse-fired boiler used in sugar industry were analyzed in correlation with the operating conditions. Comprehensive measurements were provided at different operating conditions including at design and off-design in relation to load generation and combustion performance on the firing grate. At the design condition, the overall heat transfer coefficients across the different sections, namely, the furnace, superheater, back tube and bank tube zones, were found uniformly within the range of 60–80 W/m2-K. Maintaining the overall heat transfer coefficient within this narrow range ensures that each section of the boiler is contributing optimally to the overall thermal efficiency. The optimal range of heat transfer coefficient in the furnace zone is within the range of 66–72 W/m2-K with 90 % of heat transfer in this zone occurring through radiation. While the high convection resulting from a high flue gas flow rate during off-designed condition leads to insufficient heat transfer in the furnace zone. Approximately 60 % of the heat uptake is instead absorbed by the bank tube section, which is strategically designed to capture the bypassed heat from the preceding section. It was also found that the overall radiative factor providing efficient heat transfer ranged from 0.48 to 0.63.