FINAL YEAR PROJECT REPORT
FINAL YEAR PROJECT REPORT
UNIVERSITY OF NAIROBI
DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING
Project title:
DESIGNING A BOILER CHIMNEY HEAT RECOVERY SYSTEM AGAINST
FOULING
POJECT CODE: FML 01/2014
Submitted by:
WANGILA ANTONY BARASA
F18/2448/2009
KARANJA SAMSON NGUGI
F18/2434/2009
Supervisor:
PROF. F. M. LUTI
APRIL 2014.
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DECLARATION STATEMENT
We declare that any information in this report, except where indicated and
acknowledged, is our original work and has not been presented before to the best
of our knowledge.
WANGILA ANTONY BARASA
F18/2448/2009
Signature¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
Date ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
KARANJA SAMSON NGUGI
F18/2434/2009
Signature¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
Date ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
APROVED BY:
Prof. F. M. Luti
(supervisor)
Signature¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
Date of approval¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..
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ACKNOWLEDGEMENT
We would like to acknowledge with appreciation the valuable guidance from our supervisor,
Prof. F. M. Luti. His monitoring and constant encouragement saw us through this project.
Our deep gratitude also goes to the following members of staff of the University¡¯s mechanical
workshop:
1. Mr. J Oduol (principal technologist)
2. Ms. Fey Airo
3. Mr. Stanley Njue.
4. Mr. James KimaniMwangi.
5. Mr. Simon Maina.
6. Mr. Peter Kogi.
7. Mr.JohnKahiro.
8. Mr. JacktonAnyona.
9. Mr. KenrthKaranja.
They were informative and cooperative whenever we required their technical assistance in their
respective fields.
Finally we would like to appreciate our parents, siblings , and friends for their support
throughout this project.
Karanja Samson Ngugi.
Wangila Antony Barasa.
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ABSTRACT
An initial design of chimney heat recovery heat exchanger was provided. The design had a
completely fabricated exchange core but an incomplete ducting system .
This report is based on the work undertaken to complete and test the gas to gas heat recovery
system. This system was specifically designed for boiler chimney and therefore the systems
ducting was designed to conform to the general boiler stack.
In the completion of the design, the major factor to consider was to design against fouling. The
system was therefore designed with means of reducing fouling such as provision for easily
replaceable particulate filter and quick washing system.
The project was hence done in the following manner.
1. Completing of the fabrication.
2. Research on ways of minimizing fouling .
3. Incorporating the ways arrived at in 1 above into the system design.
4. Testing of the model under forced convection condition.
The gases from a furnace were used to simulate industrial flue gases. The performance of the
model was used to project the optimum of prototype.
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LIST OF TABLES
Table 4: Design parameters¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..12
Table 5a: Flow rate against temperatures¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..¡¡¡¡...17
Table 5b:Air flow rate ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡.¡...17
Table 5c: Transient test¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡.¡...18
Table 5d:Determining cross-flow correction factors¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..22
Table 5e:Determined values of Q and U¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..22
Table 5f: Determination of effectiveness¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..¡...23
Table 5g: Determination o dwell time and normalized time¡¡¡¡¡¡¡¡¡¡¡¡....23
Table 5h:Determination of percentage heat recovered¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡24
Table 5i:Transient test analysis¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡.¡..24
LIST OF GRAPHS
Graph 5.1: U VS Q¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡.....25
Graph 5.2: Q VS ?¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡......26
Graph 5.3: ¦Å VS ?¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡.....27
Graph 5.4: Ta out VS ¦È¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..........28
Graph 5.5: Ta out vs ¦È*¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡..29
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