To achieve as complete fuel burnout with as little excess air as possible, small wood log boilers (< 50 kW) use stage combustion. The first stage is often a process similar to downdraft gasification that consequently produces a flue gas laden with particulates. To prevent the build-up of solids and promote heat transfer in pipes of the convective part of these boilers, wire coils are used. The paper presents their in-situ examination together with CFD analysis. The analysis is carried out in a 460 mm long pipe, with a diameter of 82.5 mm, equipped with different wire coils for flue gas temperatures in the range between 300?C and 150?C. The analyzed coils are with and without a conical spring at their free end. The addition of this conical top is economical and should influence the rotation of the core flow. Proper pipe surface cleaning limited the analyzed wire coil designs to the dimensionless pitch, p/d, in the range between 0.36-0.61, dimensionless wire diameter e/d = 0.04-0.1, and pitch to wire diameter ratios p/e = 3.75-14.3, and three different angles (60?, 90?, and 120?) of the conical top. The goals are to find the optimal flue gas velocity for the given operating conditions, pipe, and wire coil dimensions, and to investigate the addition of the conical top on heat transfer enhancement. Several evaluation criteria are used to achieve the goals.

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Depending on their applications, heat losses from the shells of rotary kilns account for 3 to 25% of the total heat input. Over the hottest zone of the kiln shell, an annular duct with a variable diameter is formed. Two air streams entering the annulus at both ends flow to a common extraction point to receive the thermal power equal to the ambient heat loss of the bare kiln. The design does not require airtightness, utilizes the entire heat loss, and by the variation of the airflow can be used over the kilns with variable operating parameters (?20% heat loss), which show similar surface temperature patterns. The main disadvantage of the design is the approaching of the surfaces of the kiln and the recuperator at the outlet of preheated air. This means that for a given heat loss and a surface temperature pattern, the rotational eccentricity of the kiln shell is the most influencing parameter that defines the air preheating temperature and the efficiency of the recuperator. To solve the problem, 4 redesigns with: (i) double annuluses, (ii) the usage of radiation fins, (iii) air addition, and (iv) a combination of two basic designs are analyzed by the use of analytical and CFD models. From the listed redesigns: (i) could be used only to prevent overheating, (ii) has a modest positive effect, (iii) should be applied in combination with (iv).

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