Development of a New Model “MAGIC BOILER” for Faster Steam Production

A boiler, whether it is used for heating water, generating steam, or superheating steam, plays a crucial role as a closed vessel in various applications. From industrial to household use, boilers find wide-ranging importance. Particularly for Indonesian home industries, which predominantly focus on food or fashion production, boilers play a viral in their manufacturing processes. However, the significant energy consumption of boilers, combined with rising gas and electricity prices due to inflation, has led to an increase in production costs, posing challenges to companies’ profitability and sustainability. To address this issue, this paper proposes the development of a safe and energy-efficient electric water boiler known as the “MAGIC BOILER.” The distinguishing feature of the “MAGIC BOILER” lies in its unique design, incorporating an enhanced heating surface. This innovative design maximizes the heat output generated by the heater, ensuring efficient utilization of the electrical input, thus yielding a higher rate of heat transfer and steam production rate at a relatively lower cost.


Introduction
A boiler is a closed vessel in which water is heated, steam is generated, steam is superheated, or any combination of them, under pressure or vacuum for use externally to itself by the direct application of heat [1].Despite their ancient origins dating back to the first century, early boilers were limited in use and considered as mere novelties.In modern times, boilers have evolved significantly in design and functionality.They not only heat water but also convert it into steam, catering to a broad spectrum of applications ranging from industrial processes to household conveniences, such as electric kettles.
Indonesia's creative economy relies heavily on around 63 million MSMEs, predominantly in fashion and food sectors, contributing significantly to the nation's GDP [2].In this context, boilers play a pivotal role, facilitating heating and power generation in manufacturing.For instance, boilers are integral to the batik industry, used to remove residual candle wax from fabrics during the traditional resist painting process known as tjanting.In the food sector, boilers are essential for boiling soybeans in tofu production.
However, despite their advantages, boilers are associated with high energy consumption.The energy-intensive process of converting water to steam demands substantial power, and high energy costs exacerbate operational expenses.To address these challenges, a strategy is needed to optimize boiler energy usage while sustaining production levels.This paper presents a solution to tackle high energy consumption in boilers by introducing the "MAGIC BOILER."This novel electric water boiler focuses on an innovative heating element design that maximizes heat transfer efficiency.By enhancing the heating surface area, the "MAGIC BOILER" optimizes heat output for quicker steam generation, ultimately improving overall boiler performance.Through this approach, the study aims to establish pathways for developing more efficient and effective steam-producing boiler models.The main objectives of this study are:  Designing a boiler model that can achieve heating (temperature increase) and steam production rates five times that of conventional boilers. Creating a prototype of a heating element model with an improved heating capability by incorporating fins to increase the heating surface area.This will result in a larger contact area between the heater and the water. Conducting a comparative analysis between the performance of the "MAGIC BOILER" and a conventional boiler of the same dimensions and input power.

Heat transfer and its mechanism
Heat transfer is defined as the transfer of energy from one body or system to another as a result of a difference in temperature [3].It can occur through three mechanisms: convection, conduction, and radiation.These mechanisms can occur separately or simultaneously within the same system.While all objects emit radiation energy, its impact becomes significant at extreme temperatures.Therefore, heat transfer/loss by radiation is ignored due to its negligible effect in the context of the study.
In conduction, heat is transferred within a solid or between solid objects by direct contact.The rate of conduction [4] is described as follows: Convection (or convective heat transfer) is the heat transfer due to the movement of a fluid such as air or water.The equation for convection heat transfer [5] is described as follows:

Boiler and heating element
A boiler is an essential component commonly found in various heat exchangers.It is a closed vessel in which water is heated, steam is generated, steam is superheated, or any combination of them, under pressure or vacuum for use externally to itself by the direct application of heat [1].In modern boilers, a heating element is employed as the primary heat source.This heating element operates based on the principle of Joule heating, where a potential difference or voltage applied across conductors creates an electric field.The electric field accelerates charge carriers, giving them kinetic energy, which in turn generates heat within the boiler.

DAQ (Data Acquisition)
Data acquisition, often abbreviated as DAQ or DAS, is a process in which signals representing realworld physical phenomena are sampled and converted into a digital format with the use of sensors, measurement devices, and a computer.Together, these components form a DAQ system.

Arduino UNO Arduino
UNO is an open-source microcontroller board based on the ATmega328P microcontroller [6].
A microcontroller refers to a compact computer system integrated onto a single VLSI (Very Large Scale Integration) circuit chip.It typically includes one or more CPUs, memory, and programmable input/output peripherals, enabling it to perform specific tasks and execute operations within an embedded system.In the context of this study, the Arduino is employed to measure both the temperature on the surface of copper plates and the temperature of the water.

Temperature sensors MAX6675 and DS18B20
The MAX6675 is a wire-programmable temperature sensor designed to perform cold-junction compensation and digitize signals from type-K thermocouples.Its data output is presented in a 12-bit resolution, SPI-compatible, read-only format.
In this research, the DS18B20 temperature sensor is utilized.The DS18B20 is a digital thermometer that communicates through a 1-Wire bus, requiring only a single data line (along with ground) for both communication and power supply ("parasite power").These sensors exhibit high accuracy and can operate within a wide temperature range.They can be easily integrated with various microcontrollers, including Arduino, utilizing a single digital pin [7].

Methodology
The research methodology used in this research is shown in the figure below: This research aimed to find a way to optimize boiler energy usage while maintaining output rates using the available resources.To that end, efforts were made to develop a new boiler model known as the "MAGIC BOILER": a safe and energy-efficient electric water boiler with a larger heating surface area that maximized potential heat output from the given electrical input, resulting in faster heat transfer and higher steam production rates.
The research started by identifying the issue, which was the boiler's high energy consumption affecting the cost of operating domestic boilers in Indonesian home industries, and proposed a solution: the "MAGIC BOILER."After conducting a literature review and drawing relevant information from the available sources, the design process for the "MAGIC BOILER" began.This process comprised a few stages: (1) creating the boiler's 3D model on CAD software; (2) determining the heat transfer coefficient between the copper surface and water for further calculations; and (3) designing the size and shape of the heating fins based on the experiment results mentioned earlier.
The subsequent manufacturing process also comprised several stages: (1) installing the fins on the heater; (2) applying modifications to the boiler; (3) placing temperature and pressure sensors as safety measures; and (4) adding insulation to the outer layer of the boiler.The "MAGIC BOILER" was then tested and compared to a conventional boiler of similar design.The test results were evaluated to determine whether the "MAGIC BOILER" met its design goals.Finally, data analysis was conducted to summarize the research findings, identify sources of error, and provide suggestions and recommendations for future research.

Boiler Design
The "MAGIC BOILER" was designed to facilitate an efficient steam production process.For the material, aluminum with a thickness of 1.2 mm was used.Its dimensions measured 650 mm in diameter and 600 mm in height.It had a water-holding capacity of 200 liters.Built-in sensors allowed for the assessment of temperature and pressure inside the boiler during its operation.Additionally, a water level indicator was provided, enabling the user to monitor the real-time water level within the boiler.Figure 2 depicts the isometric, front, and side views of the "MAGIC BOILER."AutoDesk Inventor had been utilized in the design process of the 3D model.The CAD software had been selected over manual drawing due to its enhanced accuracy in rendering precise dimensions.Drawings could also be generated in both 2D and 3D formats and rotated for comprehensive visualization.

Determining the Heat Transfer Coefficient Between Copper Surface and Cooling Water
The heat transfer coefficient is a quantitative characteristic of convective heat transfer between a fluid medium (a fluid) and the surface (wall) flowed over by the fluid [8].It is important to note that fluid properties, including density, can vary with temperature, impacting the heat transfer coefficient.To accurately simulate boiler conditions, an experiment was conducted to determine the heat transfer coefficient between copper surfaces and water, as copper was chosen for its favorable thermal conductivity.This experiment aimed to observe temperature changes, heat flux, and the heat transfer coefficient, providing valuable data for further analysis.

Experimental Setup
The experimental setup consisted of a cylindrical container (202 mm height, 122 mm diameter) with 1.4 liters of water, containing a steel-based strip heater covered in 0.5 mm thick copper plates.Sensors, including MAX6675 and DS18B20, connected to an Arduino UNO, were used to measure the surface temperature of the copper plates, ambient temperature, and water temperature.Calibration using Kalman Filtering was performed on the sensors, and an Arduino Sketch code captured temperature readings at 10-second interval [9][10][11].A voltage regulator and wattmeter were included to regulate the electrical input, measure voltage, current, and power supplied to the heater, and to maintain a constant input voltage for steady-state conditions.submerged in the water and placed near the heater with the aid of a clamp.Lastly, the DS18B20 sensor (DS1) was utilized to measure the ambient (room) temperature outside the container.

Experiment Procedure
The experiment began by introducing electricity to the system, converting it into heat energy through Joule heating in the heater.As the heater's temperature increased, heat was exchanged between the heater and its surroundings, leading to the warming of the water.The input voltage was regulated at 50 V using a voltage regulator to maintain a consistent electrical current and allow the system to reach a steady state.Real-time temperature observations of the heater and water were made using Arduino IDE, along with measurements of electrical power, time to reach steady state, peak temperatures, and average temperatures during steady state.These variables were crucial for calculating the heat transfer coefficient.Experimental testing involved varying voltage values (50 V, 60 V, and 70 V) while keeping the working surface area constant.Calculations were performed using equations and data from Table 1 to obtain the desired values.

Mathematical Modelling
After obtaining experimental data, calculations were done using the below-mentioned equations and data as listed in Table 1 to achieve the heat transfer coefficient to temperature difference equation.Temperature difference between the surface of the copper-plated heater and the water: Heat flux = Heat transfer coefficient

Results and Discussion
The purpose of this experiment was to calculate the heat transfer coefficient and heat flux between the copper surface and cooling water.A steel heater plate was immersed in water, serving as the working fluid.By applying electricity to the heater, Joule heating converted electrical energy into heat, raising the temperature of the heater and its surroundings.The resulting temperature variations were recorded and analyzed using the previously mentioned equations.Average values were calculated to facilitate data presentation and analysis.The results indicate that increasing the electrical input to the heater leads to a higher heat transfer coefficient and heat flux, resulting in a larger temperature difference between the copper surface and water.The lowest average temperature difference of 3.83 K is observed with an electrical input of 17.5 W, corresponding to a heat transfer coefficient of 614.32 W/m 2 K and a heat flux of 2353.48W/m 2 .Conversely, the highest heat transfer coefficient of 1017.15W/m 2 K is observed at a temperature difference of 4.21 K and an electrical input of 31.85W, indicating a heat flux of 4283.33 W/m 2 .These findings suggest that a greater temperature difference facilitates a higher rate of heat transfer between the copper surface and water.

Heating Element and Fins Design
The design of the fins drew inspiration from the working principle of heat sinks, which leverage the re-circulation and aerodynamic features of the fan blades to enhance convection.Following this principle, copper fins were incorporated onto the heating element to expand the working surface area and facilitate the movement of lower-temperature fluid across the enlarged surface area, effectively dissipating heat.Copper was specifically chosen for the fins due to its high thermal conductivity, which allows for faster heat transfer and enhances the heating ability of the heater.In order to achieve the desired shape, copper plates underwent a heat treatment process to increase their malleability.Subsequently, they were bent and wrapped around the shaft of the heater before being allowed to cool down.The cooling procedure served to both strengthen the metal and ensure its secure attachment to the heater.However, it should be noted that this design was not yet finalized, as the precise dimensions would be determined based on the actual sizing of the heater.

Conclusion
Based on the research that has been conducted so far, several conclusions can be made:  The experiment revealed a directly proportional relationship between the temperature difference of two objects and the rate of heat transfer between them.Larger temperature differences corresponded to increased heat flux and higher heat transfer coefficients during the heat transfer process. For a temperature difference range of 3.83-4.21K,the average heat flux and heat transfer coefficient between the copper surface and water were calculated to be 3368.84W/m 2 and 875.65 W/m 2 K, respectively. Subsequent stages of our research will involve simulating the operational conditions of the boiler.Utilizing our latest findings, we will estimate the time required for a conventional boiler to initiate steam production.Subsequently, we will design copper fins that enable the "MAGIC BOILER" to significantly increase heating and steam production time by 500%.

Figure 1 .
Figure 1."MAGIC BOILER" research and development methodology

Figure 2 .
Figure 2. The isometric (with the heating element and pressure sensor), front, and side (without the heating element and the pressure sensor) views of "MAGIC BOILER" 3D model.

Figure 4 .
Figure 4. Four measuring points: one on top of each copper plate, one in the water, and one outside the container.

Figure 5 .
Figure 5. Schematic diagram of the experimental setup.

Figure 6 .
Figure 6.The isometric, front, and side views of the fins

Table 1 .
Experimental results from a heated copper-plated heater submerged in water in a steadystate condition for various electrical inputs.

Table 2 .
Heat flux and heat transfer coefficient values generated by the experimental results.