analysis and redesign of w- type radiant tube using finite element method

7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method

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ANALYSIS AND REDESIGN OF W- TYPE RADIANT

TUBE USING FINITE ELEMENT METHOD

INTERNAL GUIDE:

Mr.M.Varatharajulu,B.E., M.B.A

(Asst. Professor),

Dept. Of Mechanical Engg.

PRESENT BY

M.Akbar Ali

A.HajaSheikAlavuden

V .Saravanan

M .Venkateshwaran

EXTERNAL GUIDE:

Mr. A. Karuppiah. M.EManagerCold Mill (SSTP)BHEL. (Trichy)


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To analyze and to find out the failurecauses of the radiant tube.

Provide solution for the failure of radiantTube.

Comparing the solution with the existingdesign.


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INTRODUTION ABOUT RADIANT TUBE

Radiant tubes are heat transfer mountings.

Gases by convection and radiation transfers heat to the

radiant tube.

The heated tube transfers energy to the furnace, by means

of convection and radiative heat transfer.

There are three types of radiant tube P-type ,W-type& U-

type.

Our project is concerned with w-type radiant tube.

Material of the radiant tubes are nickel chrome steel.


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PROBLEM DESCRIPTON

Radiant tubes are designed to operate at 960C; the furnace

temperature is maintained between 700C and 1100C by a

design requirement based on the tube thickness.

Due to the uneven heating, the radiant tubes werefrequently damaged after their rated service.

In general, the damage style of a number of the tubes is

almost the same. The failure mode of the tubes appeared tobe in the surface of the tube, about 6590 cm from the

burner-mounting flange.


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METHODOLOGY

The analysis can be carried out using ANSYS software

In general, there are three steps in the development of

a finite element model.

Developing a geometrical model, selecting an

element, determining material properties and finally

converting the geometrical model to a finite element

model by griding.

Applying boundary and initial conditions, loading

and performing calculations based on the model.

Extracting results.


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Contd.

Modeling of the radiant tube was done by using Pro-e software.

The model is imported to the ANSYS and imported model is

meshed.

And finally using ANSYS software, the analysis of the radianttube was done.

The results were obtained for various parameters liketemperature distribution, equivalent stress and total

deformation. The results obtained for suggested model were compared

with the existing model.


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Contd.


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RESULTS & DISCUSSION

S.NoApproximate Distance from

burner-mounting flange (mm)

1 0 - 300

2 300 - 600

3 600 - 1000

4 1000 - 1500

5 1500 - 2500

6 2500 - 4500

7 4500 - 5000

8 5000 - 5500

9 5500 - 6000

10 6000 - 6600


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Suggestion IIt is suggested to increase the thickness of the wall in the Radiant tube.

Suggestion II

It is suggested to change the material properties, which will withstand the load

against the exiting failure.


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Observation From the above charts it is observed that the

temperature distribution, equivalent stress and thetotal deformation are high at the critical region in allthe cases.

The suggestion II model exhibits very low stress anddeformation compared to other two models.


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Material ComparisonExisting material properties Innovated material properties Reason and cause

Elements / Name of

the materialDIN17456 (STD) SA 106 Grade A.

C 0.35 to 0.55% 0.35To reduce the

hardenability

Si 1.0 to 2.0% 1.2

To increase the toughness

and strength at high

temperature

Mn 1.5% 1.5

To increase the resistance

to cracking at high

temperature

P 0.040 % 0.040To keep the same

weldability

S 0.030 % 0.030To keep the impact

toughness

Cr 27.0 to 30.0 % 30.00

To increase the corrosion

resistance at high

temperature

Ni 47.0 to 50.0 % 50.00 To increase the strength

Mo 0.05% 0.05

To increase the high

temperature tensile

strength

W 4.0 to 6.0 % 6To withstand the high

temperature


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Conclusion. Radiant tubes are designed to operate at 960C; but

the furnace temperature is required maintained

between 700C and 1100C, so it is required to

change the material of the radiant tube.

Analysis of the radiant tube carried out using ANSYSWORKBENCH Software

Results had been obtained for Temperature

distribution, Equivalent Stress and for Totaldeformation for different models.

Graphs have been plotted between Temperaturedistribution and distance, Equivalent stress and

distance and between total deformation and distance


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Contd.

Compared to the existing model, the suggested model I isfound to have 21.05% lesser stress and 21.05% lesser total

deformation.

Compared to existing model suggested model II have

34.21% lesser stress and 31.24% lesser deformation. By this analysis it is found that the suggested models have

higher strength and higher temperature withstanding

capability than the existing model.

It is suggested that to use model II for the effective usewithout fail for the longer period than the other two

models.


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THANK YOU

analysis and redesign of w- type radiant tube using finite element method

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