A Cause Effect Analysis of Furnace Heat Transfer

BY
P M V Subbarao
Associate Professor
Mechanical Engineering Department
I I T Delhi
Closed form solutions for performance analysis of complex heat
transfer devices..
Cause Effect Analysis
Combustion is a primary cause
Steam Generation is an ultimate effect.
Heat transfer is a mediation.
Combustion causes the generation of heat in side furnace volume.
Heat generation causes the production of high temperature gases.
These high temperature gases cause the Radiation and convection heat
transfer processes.
Heat Transfer processes carry the thermal energy to furnace wall &
steam tubes.
Conduction through the tubes and walls causes the convection inside
the tubes.
Convection Causes the generation of steam.
A cause effect analysis can simplify the design analysis of a furnace.
Analysis of the Primary Cause
Reactants Products

i j
j j i i
P Y R X
At a given temperature the Gibbs free energy of products is less
than Reactants.
Depending on the effectiveness of heat release rate, the sensible
energy of products will be higher than sensible energy of reactants.
Hence, the temperature of products of combustion is very high.
Chemical Energy Thermal (Sensible) Energy
exchange
i j
j j i i
Q h Y h X

+

The temperature of the gases in an adiabatic furnace attain a
maximum temperature called adiabatic flame temperature.
General Design Principles
The effective heat release rate is depends on the size of furnace.
The furnace should provide the required physical environment and the
time to complete the combustion of fuel.
The furnace should have adequate radiative heating surfaces to cool
the flue gas sufficiently to ensure safe operation of the downstream
convective heating surface.
Aerodynamics in the furnace should prevent impingement of flames on
the water wall and ensure uniform distribution of heat flux on the
water wall.
The furnace should provide conditions favoring reliable natural
circulation of water through water wall tubes.
The configuration of the furnace should be compact enough to
minimize the amount of steel and other construction material.
Determination of Furnace Size
What is the boundary of a furnace?
The boundary of a furnace is defined
by
Central horizontal plane of water wall
and roof tubes
Central horizontal lines of the first set
of super heater panels.
o = 30 to 50
O

| > 30
O
= 50 to 55
O

E = 0.8 to 1.6 m
d = 0.25 b to 0.33 b

Design Constrains:Heat Release Rate
Heat Release Rate per Unit Volume, q
v
, kW/m
3
Heat Release Rate per Unit Cross Sectional Area,q
a
,
kW/m
2

Heat Release Rate per Unit Wall Area of the Burner
Region, q
b
, kW/m
2

The maximum allowable heat flux of the water wall is
restricted by its water-side burnout (dryout) heat flux.



Heat Release Rate per Unit Volume, q
v

The amount of heat generated by combustion of fuel in a unit effective
volume of the furnace.
3
/ m kW
V
LHV m
q
c
v
-
=
-
s
r
c
v
Vt
LHV m
q
Where, m
c
= Design fuel(coal) consumption rate, kg/s.
V = Furnace volume, Cu. m.
LHV= Lower heating value of fuel kJ/kg.
A proper choice of volumetric heat release rate ensures the critical fuel
residence time.

Fuel particles are burnt substantially
The flue gas is cooled to the required safe temperature.

Heat Release Rate per Unit Cross Sectional Area,q
a

The amount of heat released per unit cross section of the furnace.
Also called as Grate heat release rate.
2
/ m kW
A
LHV m
q
grate
c
A
-
=
A
grate
is the cross sectional area or grate area of the furnace, Sq. m.
This indicates the temperature levels in the furnace.
An increase in q
a
, leads to a rise in temperature in burner region.
This helps in the stability of flame
Increases the possibility of slagging.

A
Heat Release Rate per Unit Wall Area of the Burner Region

The burner region of the furnace is the most intense heat zone.
The amount of heat released per unit water wall area in the burner
region.
( )
2
/
2
m kW
H b a
LHV m
q
b
b
+
=
-
a and b are width and depth of furnace, and H
b
is the height of burner
region.
This represents the temperature level and heat flux in the burner
region.
Used to judge the general condition of the burner region.
Its value depends on Fuel ignition characteristics, ash characteristics,
firing method and arrangement of the burners.
Furnace Depth & Height
Depth to breadth ratio is an important parameter from both combustion
and heat absorption standpoint.
Following factors influence the minimum value of breadth.
Capacity of the boiler
Type of fuel
Arrangement of burners
Heat release rate per unit furnace area
Capacity of each burner
The furnace should be sufficiently high so that the flame does not hit
the super heater tubes.
The minimum height depends on type of coal and capacity of burner.
Lower the value of height the worse the natural circulation.

Furnace Depth & Height
Basic Geometry of A Furnace
safe v
c
q
LHV m
V
,
-
=
safe A
c
grate
q
LHV m
b a A
,
-
= =
( )
safe b
b
q
LHV m
H b a
,
2
-
= +
safe f f
h h
,
>
safe
b b >
Dimensions of A 500 MW(e) Plant Furnace
HT Areas of A 500 MW(e) Plant Furnace
Analysis of the Secondary Cause
Emissive power of flame:


| | kW T A Q
fl flame emi

4
oc =
-
How to find the area of a Flame ?
Where c
flame
is the emissivity of flame.

How to Find the Emissivity of A Flame
Flame Length, m
Analysis of the Tertiary Cause
Radiation heat transfer

Where c
eff
is the emissivity of flame and water wall system.


| | kW T T AF Q
wa fl eff rad

4 4
=
-
oc
( )( )
wa fl
wa fl
eff
c c
c c
c

=
1 1 1
Heat flux is non uniform.
Wall temperature is non uniform.
This effect is another cause for further analysis.
Distribution of Heat Flux on Furnace Walls
| | kW T T F t z y x q
wa fl eff
) : , , ( ' '
4 4
= c o
Analysis of the Last but One Effect
Final effect : T
fl
gets changed to Furnace Exit
GasTemperature.
Due to energy lost by hot gases.
Loss due to Environment
Energy absorbed by water walls
Energy lost by hot gasses from flame to exit.
{ } kW T T C m Q
FEGT ad p
g
loss g

,
=
- -
{ } kW T T C
F
A
m Q
FEGT ad p
act
fuel
loss g
1
,

|
.
|

\
|
+ =
- -
T
flame

T
fe

(

=
- - -
fe ad loss g
Q Q Q
,

i j
Pj Pj Ri Ri
h Y h X
Mixed Adiabatic Temperature of the Gases

i j
Pj Pj Ri Ri
h Y h X

} }

i j
T
T
P Pi p Pj
T
T
R Ri p Ri
ad
ref
R
ref
dT c Y dT c X
, ,
kgK kJ
T
C
T
C
T
C C c
p
/
1000 1000 1000
3
3
2
2 1 0
|
.
|

\
|
+
|
.
|

\
|
+ + =