Novel Tube Design for Superheater Heat Exchanger Enabled via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal Additive Manufacturing, for instance, Laser-Powder Bed Fusion, has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements and the particle and flue gas flow characteristics around the differently shaped tubes. A thermo-mechanical Finite Element Analysis (FEA) was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed 2D thermal simulation has been performed to report the circumferential thermal variation on the tube. A Computational Fluid Dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren Optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.