CFD Based Design and Thermal Analysis of Combustion Chamber in Industrial Boilers

Abstract

Combustion chambers in industrial boilers operate under extremely high temperatures and complex flow conditions, where efficient fuel combustion and heat transfer are critical for performance and emission control. Improper combustion leads to energy loss, incomplete fuel utilization, high emissions, and thermal damage to chamber walls. In addition to fluid flow characteristics, thermal effects play a crucial role in combustion efficiency, flame stability, and heat transfer within the chamber. The present study focuses on the Computational Fluid Dynamics (CFD) analysis of combustion processes in industrial boiler combustion chambers using ANSYS Fluent, incorporating both fluid dynamic and thermal aspects. The work aims to analyze temperature distribution, flame characteristics, species concentration, and heat transfer behavior under varying operating conditions such as air–fuel ratio, inlet velocity, and fuel type. A combustion model combined with turbulence and radiation models is employed to simulate the combustion process, enabling accurate prediction of flame structure, temperature fields, and pollutant formation such as NOx and CO. Furthermore, the study extends to thermal protection and material enhancement techniques, including the use of refractory materials and thermal coatings to withstand high temperatures and reduce heat losses. Design optimization of combustion chamber geometry is carried out to improve mixing, enhance combustion efficiency, reduce emissions, and achieve uniform temperature distribution. Additional objectives include evaluating different fuels, analyzing thermal stresses, and studying coupled thermo-fluid effects for improved durability. The outcomes of this study will contribute to enhanced boiler efficiency, reduced emissions, improved thermal performance, and extended service life of combustion chambers.