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Table of contents
Table of contents..................................................................................................................................ii
General design issues ...........................................................................................................................1
Heat transfer modes .........................................................................................................................1
Conduction ...................................................................................................................................1
Convection ...................................................................................................................................1
Radiation ......................................................................................................................................2
Pressure losses..................................................................................................................................2
Definition .....................................................................................................................................2
Gas side pressure drop for inline tube arrangement.....................................................................3
Gas side pressure drop for staggered tube arrangement ..............................................................3
Choice of tube surface......................................................................................................................4
Sizing of heat transfer surfaces ........................................................................................................4
Furnace design .....................................................................................................................................6
General design..................................................................................................................................6
Furnace strain level ..........................................................................................................................7
Tube wall design ..............................................................................................................................8
Load characteristics..........................................................................................................................8
Fuel type effect on furnace size .......................................................................................................8
Typical furnace outlet temperatures.................................................................................................9
Furnace air levels ...........................................................................................................................10
CFB furnace design........................................................................................................................10
BFB furnace design........................................................................................................................12
Heat recovery steam generator (HRSG) design.............................................................................12
Furnace dimensioning, stirred reactor............................................................................................14
Superheater design .............................................................................................................................15
General ...........................................................................................................................................15
Design velocity ..............................................................................................................................15
Design spacing ...............................................................................................................................16
Tube arrangement ..........................................................................................................................17
Economizer design.............................................................................................................................18
General ...........................................................................................................................................18
Design method ...............................................................................................................................18
Air preheater design ...........................................................................................................................21
References ..........................................................................................................................................22
ii
t1 t 2
s
(1)
Heat power depends on the heat transfer area (A), temperature difference (t1-t2), thermal
conductivity of material () and the thickness of separating wall (s). The thermal conductivity is a
property of the material; metals conduct well heat whereas gases not. An example of thermal
conductivities in various materials is shown in table 1.
Table 1: Thermal conductivities for various materials.
Material
Copper
370
Aluminium
210
Steel
45
Stainless steel
20
Insulations
0,03-0,1
Convection
Convection is heat transfer between a moving fluid or gas and a fixed solid. Convection can be
natural or forced: if a pump, a blower, a fan, or some similar device induces the fluid motion, the
process is called forced convection. If the fluid motion occurs as a result of the density difference
produced by the temperature difference, the process is called free or natural convection.
Heat power by convection can be calculated as:
= c A(t1 t 2 )
(2)
The heat transfer coefficient c varies much depending on e.g. flow velocity, type of fluid motion
and pressure. Heat transfer coefficients of liquids are much higher than those of gases, as can be
seen in the comparison presented in table 2.
Fluid
Steady water
100-500
Water flow
500-10000
Water boiling
1000-60000
Steady air
3-15
Air flow
10-100
Radiation
Radiation, or more correctly thermal radiation, is electromagnetic radiation emitted by a body by
virtue of its temperature and at the expense of its internal energy. All heated solids and liquids, as
well as some gases, emit thermal radiation.
The importance of radiation heat transfer will increase, when the temperature becomes higher.
Radiation heat transfer is the main heat transfer mode for the furnace and radiation superheaters.
Emitted heat by radiation can be calculated as:
r = fwA(T f4 Tw4 )
(3)
where fw is the view factor between the flame and the water walls:
fw =
1
1
1
+
1
f w
(4)
where f is the emissivity of the flame (typically 0,35-0,85), w the emissivity of the water walls
(typically 0,6), the Stefan-Boltzmann constant (5,6787*10-8 W/m2K4), A the effective water wall
surface (m2), Tf the average gas temperature in the furnace and Tw the average water wall surface
temperature surrounding the flame.
Radiation heat can also be expressed as
= rad A(t1 t 2 )
(5)
Pressure losses
Definition
The difference between pressure gage readings in parts of a system operating with a positive
pressure relative to that of the atmosphere is generally called pressure drop. The pressure drop on
the gas side is equal to the friction losses, according to VDI Wrmeatlas [1]:
p gs = p f
(6)
2
(7)
where nr is the number of tube rows in the heat transfer unit, pd dynamic pressure calculated at
the gas side using the mean temperature and the smallest area. The single row pressure drop r for
inline tube arrangement is calculated as
r = l + t (1 e
Re1000
2000
(8)
where
0.5
l =
(4s t s l ) s t Re
0.94 0.6
(1 )
sl
0.47(s t /s l -1.5)
(0.22 + 1.2
+ 0.03( s t 1)( s l 1)
t = 10
(s t - 0.85)1.3
(9)
(10)
where l is the laminar part of the pressure drop coefficient, t is the turbulent part of the pressure
drop coefficient, s t is the dimensionless transverse pitch (s t = S t / d o ), s l is the dimensionless
longitudinal pitch (s l = S l / d o ) and Re is the Reynolds number, calculated at the gas side mean
temperature and smallest area.
r = l + t 1 e 1000
2
0. 5
280 s l 0.6 + 0.75
l =
1.6
(4st sl )c Re
where
c = st
; s l 2s t - 1/2
2
s
c = ( t ) 2 + s l ; s l < 2 st 1 / 2
2
(11)
(12)
(13)
1.2
+ 0.4 l 1 0.01 t 1
t = 2.5 +
1.08
st
sl
(s t 0.85)
(14)
= kATlm
(15)
Tmax Tmin
T
ln max
Tmin
(16)
Tmax = th1-tc2
Tmin = th2-tc1
(17)
Furnace design
General design
The main parameters for the furnace sizing are furnace dimensions (height, depth, width and
configuration), furnace wall construction and desired furnace outlet temperature.
The heat transfer surface area of furnace consists of sides, base and beak, which is an "L"-formed
bending of the evaporator tubes that protect the superheaters from radiation. Most of utility and
industrial boiler furnaces have a rectangular shape. A large number of package boilers have a
cylindrical furnace. Furnace bottom for typical PCF boiler is double inclined or v-form, as shown in
figure 5. Flat bottom is more typical for grate or bubbling fluidized bed boilers.
The ratio of height and width varies 1-5 for
boilers with two-pass layout. The larger the
boiler is, the larger is also the ratio. The largest
boilers have a width of 20 m and a height of 100
m. The fuel and vaporization efficiency
determines the size of the furnace. To be able to
dimension furnaces the overall mass balance,
heat balance and heat transfer must be specified.
A
V
(18)
(19)
b1
dg
4
w
( dg Tg
+ w dg w
(20)
dg Tw ) + c Aeff (Tg Tw )
4
b2
m& air
m& fi
m& ash
loss
exit
pa
(21)
b1b2 h
fur
net
Strain
[kW/m3]
Coal
145-185
Peat
~175
290-690
level
pa
b1b2
(22)
If the electric power of power plant is known, strain levels for the volume and base area can be
chosen from the graphs in figure 8, and thereby the physical dimensions of the furnace can be
determined.
0,25
[MW/m3]
[MW/m2]
0,20
0,15
0,10
0,05
0
200
400
600 MWe
200
400
600
MWe
(23)
The first two terms forms the effective projected radiant surface (EPRS), which is a widely used
concept.
du p
+ C1 + C 2
l
p + 2 p
2
n
(24)
where du is the outside diameter of tube, p the design pressure, l the design strength, n a safety
factor (usually 1,5), the strength factor (usually 1,0), C1 an additional thickness, (normally 10 %
of the wall thickness) and C2 an additional thickness considering corrosion.
Load characteristics
When designing of a steam-generating unit it is necessary to determine the following load
characteristics:
1. Minimum, normal and maximum load
2. Time duration of each load rate
3. Load factor
4. Nature of the load (constant or fluctuating)
The load factor is the actual energy produced by a power plant during a given period, given as a
percentage (share) of the maximum energy that could have been produced at full capacity during
the same period.
The design will determine the boiler's ability to carry a normal load at a high efficiency as well as to
meet maximum demand and rapid load changes. It will also determine the standby losses and the
rapidity with which the unit can be brought up to full steaming capacity. In smaller boiler sizes it is
possible to select a standardized unit that will meet the requirements; larger units are almost always
custom designed.
Firing oil in the furnace produces relatively small amounts of ash. Natural gas produces no ash. For
the same power output, due to the high ash content of coal, coal-burning boilers must have larger
furnaces and velocities of the combustion gases in the convection-based heat exchangers must be
lower. Figure 9 presents an example of the relative sizes of furnaces using three different fuels:
natural gas, oil and coal. The power of the boiler is the same in all three cases.
Coal
Natural gas
Oil
1,5*h
1,2*h
b1
b2
1,05*b1
1,06*b2
1,1*b1
1,12*b2
Ash characteristics; the control of ash behaviour at superheaters is a key design parameter
Fuel (gas and oil have low ash content and can have higher outlet temperatures)
Choice of superheater material
Desired superheating temperature
900 - 1000
950 - 1000
950 - 1000
Recovery boiler
900- 1050
1050 - 1150
Natural gas
900- 1200
Oil
900- 1200
10
The combustion air from the fan discharges pneumatically transports the solids for creating the
circulating fluid.
Steam Outlet
Steam
Water
Steam Drum
Downcomer
Water
Wall
Fuel
Limestone
Compact
Separator
Economizer
Air
heater
Combustion
Chamber
Fly Ash
compact.eng/comflow.ds4/0801/tap
Bottom
Ash
To Ash Silos
Induced Draft
Fan
The amount of cyclones also has an influence on the shape of furnace. Flue gas must flow to the
cyclone fast enough (20 m/s), and the diameter of the cyclone must be below 8 m in order to get an
efficient removal of solids.
Circulating fluidized bed boilers have a number of unique features that make them more attractive
than other solid fuel fired boilers. Fuel flexibility is one of the major attractive features of CFB
boilers. A wide range of fuels can be burned in one specific boiler without any major change in the
hardware. The combustion efficiency of a CFB boiler is high. It is generally in the range of 99,5 to
97,5 %. Sulphur capture in a CFB is very efficient, due to the possibility to inject sulphur absorbing
limestone directly into the bed. A typical CFB boiler can capture 90 % of the sulphur dioxide. The
low emission of nitrogen oxides is also a major attractive feature of CFB boilers.
11
The temperature of a BFB furnace outlet is 700-1000 C, and the air factor is usually 1,1-1,4. Air is
fed in several phases. The temperature of air varies from 20 to 400 C. The overall thermal
efficiency of a BFB boiler is around 30%.
BFB furnaces with an atmospheric operational pressure are mainly used for boilers up to about 25
MWe, although there are a few larger plants where a BFB boiler has been used to retrofit an
existing unit. There are hundreds of small BFBC units in China.
the pinch-point of the evaporator and the approach temperature of the economizer
the pressure drop of the flue gas side of the boiler
optimization of the heating surfaces
12
Flue Gas
OUT
Feedwater
IN
Economizer
Evaporator
Superheater
HP Steam
OUT
Fuel
IN
Supplementary burner
Flue Gas
IN
Heating surfaces of a heat recovery steam generator are usually heat transfer packages, which
consist of spiral-finned tubes. The thickness of the fin is 1-2 mm, the height 8-16 mm and the fin
distance 3,2-8 mm. Tube sizes vary a lot.
700
F lu e g a s s t r e a m
Water/steamstream
600
Temperature [C]
500
400
300
200
100
Superheater
Evaporator
Economizer
0
0%
10 %
20 %
30 %
40 %
50 %
60 %
70 %
80 %
90 %
100 %
T [C]
200 (100-300)
180 (100-250)
130 (100-180)
PCF, lignite
120 (100-150)
150 (100-200)
BFB
130 (100-150)
CFB
14
Superheater design
General
The production of steam at higher temperature than the saturation temperature is called
superheating. The temperature added to the saturation temperature is called the degree of superheat.
Superheated steam has no moisture; hence it is less erosive and corrosive than wet saturated steam
carrying droplets. In order to have a sustainable turbine operation, the steam cannot contain any
moist at all.
The design procedure for a superheater can be divided into the following steps:
Design velocity
Superheaters transfer heat from flue gas to steam. Heat transfer between two gases is not very
effective compared to heat transfer from gas to fluid. For that reason, steam must flow fast enough
(10-20 m/s) in order to give the superheater tubes enough cooling. Lower steam pressure weakens
the heat transfer rate, so with lower pressures, steam must have a greater velocity (15-40 m/s).
When flue gas is cooled, its volume decreases. In order to keep a constant flow rate of the flue gas,
the cross-sectional flow area decreases as well. In the radiant superheater, the velocity of gas is very
small (< 5 m/s). In the convection superheater, the velocity can be quite large (15-30 m/s). The
maximum velocity depends on the fuel used. To limit pressure-part erosion from fly ash, the flue
gas velocity must not exceed certain limits. Depending upon the ash quantity and abrasiveness, the
design velocity is generally 16-18 m/s. A furnace that burns coals yielding a heavy loading of
erosive ash (usually indicated by a high silica/aluminium content) may have a design velocity of
approximately 15 m/s. Such velocities are based on the predicted average gas temperature entering
the tube section, at the maximum continuous rating of the steam generator fired at normal excess-air
percentage.
15
Design spacing
Superheater of boiler consists of banks of tubes. A system of tubes is located in the path of the
furnace gases in the top of furnace. Heat transfer in superheaters is based mainly on radiation, but in
the primary superheaters convection often plays a major role.
A superheater must be built so that it superheats approximately the same amount of steam from low
to high loads. This can be achieved by a proper choice of radiative and convective superheating
surfaces. Changing tube lengths between passes can control temperature differences. The outermost
tube that receives the most radiative flux should be shorter than the rest of the tubes. Proper
superheater arrangement also eliminates much of the problems with uneven or biased flue gas flow.
Figure 14 and 15 shows examples of the arrangement of superheater and reheater surfaces in the
form of a process scheme.
Superheated
Steam OUT
Feedwater
IN
Saturated
Steam IN
Superheater III
Superheater II
Superheater I
Superheated
Steam OUT
Reheated
Steam OUT
Feedwater
IN
Reheater
IN
Saturated
Steam IN
Reheater II
Superheater III
Superheater II
Reheater I
Superheater I
16
Tube arrangement
Clear lane
Tubes in superheaters can be arranged according to inline or staggered arrangement (figure 16).
Inline tube arrangement is preferred for fouling boilers, PCF, bark and recovery. Staggered
arrangement is preferred for oil, gas and heat recovery steam generator. As free space with
staggered arrangement is much smaller than with inline arrangement the reason for decreased
fouling with inline is evident.
Inline
Staggered
17
Economizer design
General
An economizer consists of an arrangement of tubes through which the feed water is passed
immediately before entering the boiler. The combustion gases leaving the boiler convection
surfaces pass over these tubes. As the entering feed water has a lower temperature than that of the
boiler steam, the heat transfer is more effective at this point than in the convection surfaces of the
boiler. This fact has prompted the present trend in boiler design to increase the economizer surface
and proportionally decrease the generator-heating surface. Economizers can be made of cast iron or
steel tube. Finned tubes are used, unless the flue gases origins from fuels with high ash content.
Design method
The following variables will be chosen
Inside and outside tube diameters di and do, from which we can calculate the wall thickness:
d di
= o
(25)
2
Distance of tubes in direction of flow and in side direction: s1 and s2 (named a and b in
figure 19)
The size of flue gas channel: b1 and b2
The number of tubes in one row (counter-flow) can then be calculated as:
M =
b2
s2
(26)
The cross-sectional area of the flue gas channel can then be calculated from equation 27.
Afg = b1b2 Mdob1
(28)
(29)
4 A fg
(30)
T fg sup + T fgeco
2
(31)
18
The outside convection heat transfer coefficient is calculated from the following equation (turbulent
gas flow):
Nu =
oc d h
= C Re m Pr 0,31
fg
-> oc =
fg
dh
C Re m Pr 0,31
(32)
where fg is the thermal conductivity of the flue gas, Pr is Prandtl number, of flue gas, o the
outside convectional heat transfer coefficient and Re Reynolds number, which can be calculated as:
Re =
d h w fg
(33)
where wfg is the flue gas velocity in the flue gas channel, dh the hydraulic diameter of the channel
and the kinematic viscosity of flue gas.
The needed tube surface area in the economizer can then be calculated as:
A=
G
k
(34)
where G is the conductance (kW/K) and k the heat transfer coefficient, which can be calculated
according to equation 35:
d
1
1
= o +
+
+ mdirt
k d i i o
1
do
(35)
where di and do are the inside and the outside tube diameter [m] respectively, i and o the inside
and outside heat transfer coefficient respectively, the tube wall thickness, the thermal
conductivity and mdirt the heat transfer resistance of a tube with a dirt layer on its surface. The
outside heat transfer coefficient is the sum of the outside radiative and convective heat transfer
coefficients:
o = oc + rad
(36)
(37)
A
At M
(38)
19
(39)
20
21
References
1. VDI Wrmeatlas
2. (Alvarez: Energiteknik, p. 368)
3. M. Huhtinen, A. Kettunen, P. Nurminen, H. Pakkanen, Hyrykattilatekniikka, Oy Edita Ab,
Helsinki 1994, ISBN 951-37-1327-X
4. Opetusmoniste kevt 2000: Ene-47.110 Yleinen energiatekniikka, er 1, HUT
5. Opetusmoniste kevt 2000: Ene-47.124 Hyrykattilatekniikka, er 1, HUT
6. Opetusmoniste kevt 2000: Ene-47.124 Hyrykattilatekniikka, er 2, HUT
7. V. Meuronen, 4115 Hyrykattiloiden suunnittelu, Opetusmoniste 1999, LTKK, ISBN 951764-382-9
8. Combustion Fossil Power Systems
9. E.Vakkilainen, Steam boilers Thermal design of boiler parts, lecture notes
22