15 MW, 23 t/h, 10 bar / 145 psi STEAM BOILER WITH

SUPERHEATER AND ECONOMIZER

3-pass boiler with superheater and economizer
INTRODUCTION

The procedure shown below is next to all needed to successfully use the software to
calculate heat transfer in 3-PASS FIRE TUBE boiler. The data input process leads the user
step-by-step in an easy-to-follow self-explaining way. During geometry data input process a
corresponding general image of particular boiler design feature is displayed
illustrating the current to-be-entered value. Safety mechanism is incorporated preventing
geometrically incorrect data such as tube wall thickness that is greater than tube
inner diameter, exit water temperature that is lower than return one etc.

FIRE TUBE BOILER THERMODYNAMIC

CALCULATION
Instructions
Step 1: Units choice (metric in this case). Use Arrow key to move up and down and Enter to
select. Mouse point + double click also works. Esc quits the program. Bottom line explains the
navigation. In general UP arrow brings you back to beginning of current section.
Step 2: Case description data entry. In last field Enter brings up next window. Use arrow keys,
Home and End to move up and down. Esc gets you back to Main menu.
Step 3: Fuel type choice (gaseous in this case).
Step 4: Boiler type choice (steam in this case).
Step 5: Heat transfer medium choice (water in this case).
Step 6: Enter absolute steam working pressure (if gage pressure is 9 bar the absolute
pressure is 10 bar).
Step 7: Boiler design choice. In this case it is 3-pass consisting of following sections: furnace
(1st pass), tube set (2nd pass), front turnaround channel, 2nd tube set (3rd pass) and exit
channel with stack connector.
Step 8: In this step general image of chosen boiler design is shown. Pressing Enter advances
to next step.
Step 10: Combustion air is not preheated in this case (if it is the software asks for additional
data).
Step 9: Outdoor air temperature (temperature of air coming in boiler room).
Step 12: Natural gas composition. Entering CH4 100% works satisfactory if exact analysis is not
available.
Step 11: Rest oxygen in flue gas entry. It's the value displayed by flue gas analyzer and is used
to calculate excess air (lambda value).
Step 13: Enter gas data as displayed on gas gage (or using gas standard conditions - 0°C gas
temperarure, 0 mbar overpressure and 1.013 mbar atmospheric pressure).
Step 14: Enter gas rate as displayed by gas gauge. Value corresponding to actual gas
conditions on gas gauge shall be entered not recalculated to standard conditions (modern gas
gauges display both values).
Step 15: Flue gas recirculation is not applied in this case (if it was software would ask for
additional data).
Step 16: Feed water temperature. Software displays saturated steam temperature calculated
from given steam pressure.
Step 17: Boiler load choice. It is important for calculation accuracy as different coefficients in
equation for heat transfer are used for various boiler loads.
Step 18: Enter furnace bottom area. Here so called jet impingement takes place, which
intensifies heat transfer. In so called dry back boilers furnace bottom area is 0 and no heat
transfer takes place there for it is not cooled.
Step 19: Enter wall thickness of furnace walls.
Step 20: Enter furnace cylinder length as depicted in image.
Step 22: There is turnaround chamber at furnace rear. Image depicts this situation.
Step 23: Turnaround chamber is circular.

Step 24: Enter length of turnaround chamber at furnace rear. Image illustrates it.

Step 25: Enter diameter of turnaround chamber at furnace rear. Image illustrates it.
Step 26: Enter number of tubes in 1st tube set.
Step 27: Enter 1st tube set cooled length.
Step 28: Enter tube inner diameter.

Step 29: Enter tube wall thickness.

Step 30: There are no turbulence promoters in 1st tube set in this case.

Step 32: Enter front tubesheet cooled area.

Step 31: Enter length of front turnaround channel.

Step 33: Enter front tubesheet wall thickness.

Step 35: In this case there is superheater in front turnaround channel.

Step 36: Enter superheater design temperature. It is temperature to to which steam is to be
superheated.
Step 37: Enter superheater tube section length (image illustrates it).

Step 38: Enter superheater tube outer diameter.

Step 39: Enter superheater tube wall thickness.

Step 40: Enter superheater tubes arrangement (plain in this case-tubes in subsequent row are
in same line as those in preceding row).
Step 41: Enter number of superheater tubes in individual row. Software will determine needed
number of tube rows and by that size of superheater to meet set superheated steam design
temperature (if it can not be reached software will inform about that in results).
Step 42: Enter distance between superheater tubes center lines. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 43: Enter number of superheater tubes connected to manifold (in this case it is same as
number of tubes in row). This is needed to calculate steam velocity in tubes.
Step 44: Enter number of tubes in 2nd tube set.

Step 45: Enter 2nd tube set cooled length.

Step 46: Enter tube inner diameter.

Step 47: Enter tube wall thickness.
Step 48: There are no turbulence promoters in tubes in 2nd tube set in this case.
Step 49: Exit channel is rectangular in this case (image may differ from actual case).
Step 52: Enter length of exit channel.
Step 51: Enter wall thickness in exit channel.
Step 50: Enter cooled area in exit channel (actually net area of rear tubesheet).
Step 54: Enter stack connector cross section area (needed to calculate static pressure drop
and flue gas velocity in it).
Step 55: In this case boiler gas economizer attached.

Step 57: Enter economizer tube section length (image illustrates it).
Step 58: Enter economizer tube outer diameter.
Step 59: Enter economizer tube wall thickness.

Step 60: There are no fins on economizer tube (in case of solid fuel this question will not
appear).
Step 61: Enter economizer tubes arrangement (plain in this case-tubes in subsequent row are
in same line as those in preceding row).
Step 62: Enter number economizer tubes in individual row.

Step 63: Enter distance between economizer tubes center lines. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 65: Enter number of economizer tubes connected to manifold (in this case it is same as
number of tubes in row). This is needed to calculate water velocity in tubes.
Previous step was the last one in data entry process. Pressing Enter commences calculation
process.
Results display folows (provided geometry and operation data entered were correct and
around. Pressing Esc brings up Final menu. Move up and down with PgUp/PhDown, arrow
up/down keys, End key to jump to the end of results pages and Home to return to first results
page. Actual complete printout of results is shown at the bottom below.
Final menu displays various options. Input data can be changed till results meet user desire.
Results can be saved to file in folder where main program was installed to
(c:\BoilerDesignSoftware). Choose file name with txt extension (test.txt).
Flue gas enthalpy diagram shows flue gases energy flow starting with enthalpy at adiabatic
combustion temperature (temperature at which flue gases contain heat released from
combustion). Pressing Enter brings back Graphs menu.
Flue gas temperature decrease in boiler diagram shows how flue gas temperature decreases
as gases pass over cooled area in boiler sections starting with adiabatic combustion
temperature. First break represents furnace exit, second break represents exit from 1st tube
set (line drops there steeply because of superheater in turnaround channel). In reality line is
smooth (logarithmic).
Step 21: Enter furnace cylinder length as illustrated in image.

BOILER DESIGN SOFTWARE

Step 34: Enter channel cross section in flue gas flow direction as shown in image.
There are two graphs available.

Step 53: Enter exit channel cross section in flue gas direction.

HEAT TRANSFER IN FIRE TUBE BOILER (METRIC UNITS)

================================================

DATE :SEPTEMBER 12,2016

SUBJECT:3-PASS FIRE TUBE BOILER
MAKE :-
REMARK :DEMO CALCULATION

SUMMARY
_______

TRANSFERRED HEAT IN BOILER = 15009.6 kW

STEAM RATE = 22.4 t/h
BOILER I/O EFFICIENCY (FUEL LHV) = 88.6 %
BOILER I/O EFFICIENCY (FUEL HHV) = 79.6 %
WATER EXIT TEMP. FROM ECONOMIZER = 117.4 °C
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 153.4 °C
COMBUSTION AIR MASS RATE = 24056.98 kg/h
RELEASED FLUE GAS MASS RATE = 27024.14 kg/h
CO2 MASS RATE IN FLUE GAS = 3.34 t/h

INPUT DATA
__________

BOILER TYPE: STEAM

ABSOLUTE WORKING PRESSURE: 10 bar
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: FIRE TUBE
BOILER DESIGN: 3-PASS
BOILER LOAD: 100%
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: GAS

GAS DATA
________

CH4-CONTENT = 100 vol%

CONVERSION FACTOR TO NORM CONDITIONS= .9814

LOWER NORM HEATING VALUE = 35883 kJ/m3

LOWER NORM HEATING VALUE = 10 kWh/m3

HIGHER NORM HEATING VALUE= 39819 kJ/m3

HIGHER NORM HEATING VALUE= 11.1 kWh/m3

LOWER WOBBE INDEX = 42413.3 kJ/m3

HIGHER WOBBE INDEX = 47065.6 kJ/m3

GAS NORM DENSITY = .716 kg/m3

GAS DENSITY ACTUAL = .69 kg/m3
GAS OVERPRESSURE = .02 bar
ATMOSPHERIC PRESSURE= 1.013 bar
GAS TEMPERATURE = 10 °C
GAS RATE= 1700 m3/h

OUTDOOR AIR TEMPERATURE = 15 °C

FEED WATER TEMPERATURE = 105 °C
REST O2 IN FLUE GAS = 3 %
EXCESS AIR/LAMBDA VALUE = 1.15 -
TOTAL COOLED AREA IN BOILER= 404.369 m2
TUBES/FURNACE AREA RATIO = 8.27

FURNACE GEOMETRY DATA

_____________________

FURNACE IS HORIZONTAL
FURNACE IS CIRCULAR

FURNACE BOTTOM AREA = 3.8 m2

WALL THICKNESS = .025 m
LENGTH IN FLUE GAS FLOW DIRECTION = 6.5 m
FURNACE COOLED AREA = 43.376 m2
INNER DIAMETER = 1.5 m

THERE IS CIRCULAR TURNAROUND CHAMBER AT FURNACE EXIT

TURNAROUND CHAMBER LENGTH = 1 m

INNER DIAM. OF TURNAROUND CHAMBER= 2.2 m
FRONT TUBESHEET COOLED AREA = 12.746 m2

GEOMETRY DATA OF TUBE ASSEMBLY AFTER FURNACE

____________________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 143

COOLED TUBE LENGTH = 6.5 m
TUBE INNER DIAMETER= .0625 m
TUBE WALL THICKNESS= .0037 m
COOLED AREA = 182.507 m2

GEOMETRY DATA OF TURNAROUND CHANNEL

___________________________________

FRONT TUBESHEET COOLED AREA = 1.2 m2

WALL THICKNESS = .022 m
LENGTH IN GAS FLOW DIRECTION = .4 m
CROSS SECTION IN GAS FLOW DIRECTION= 2.7 m2

THERE IS SUPERHEATER IN TURNAROUND CHANNEL

TUBE ROWS HAVE PLAIN ARRANGEMENT

SUPERHEATED STEAM DESIGN TEMPERATURE = 210 °C

TUBE SECTION LENGTH = 1 m
NEEDED TOTAL TUBE LENGTH = 550 m
NEEDED TOTAL TUBE AREA = 65.7 m2
TUBE OUTER DIAMETER = .038 m
TUBE WALL THICKNESS = .003 m
NUMBER OF TUBES IN ROW = 25
NEEDED NUMBER OF TUBE ROWS = 23
DISTANCE BETWEEN TUBES IN ROW = .1 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

GEOMETRY DATA OF SECOND TUBE ASSEMBLY

_____________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 118

TUBE INNER DIAMETER= .0625 m
TUBE WALL THICKNESS= .0037 m
COOLED AREA = 176.086 m2

GEOMETRY DATA OF CHANNEL AT BOILER EXIT

_______________________________________

CHANNEL IS RECTANGULAR

COOLED AREA = 1.2 m2

WALL THICKNESS = .022 m
LENGTH IN GAS FLOW DIRECTION = .4 m
CROSS SECTION IN GAS FLOW DIRECTION= 2.7 m2

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS HAVE PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 105 °C

TUBE SECTION LENGTH = 2.4 m
TOTAL TUBE LENGTH = 1200 m
TOTAL TUBE AREA = 113.1 m2
TUBE OUTER DIAMETER = .03 m
TUBE WALL THICKNESS = .003 m
NUMBER OF TUBES IN ROW = 20
NUMBER OF TUBE ROWS = 25
DISTANCE BETWEEN TUBES IN ROW = .1 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

STACK CONNECTOR CROSS SECTION AREA= .5 m2

CALCULATION RESULTS (CLEAN SURFACES ASSUMED)

____________________________________________

ADIABATIC COMBUSTION TEMPERATURE = 1761 °C

COMBUSTION AIR RATE = 18605.56 mn3/h

COMBUSTION AIR MASS RATE = 24056.98 kg/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 18605.56 m3/h
RELEASED FLUE GAS RATE = 20499.29 mn3/h
RELEASED FLUE MASS GAS RATE = 27024.14 kg/h
FLUE GAS NORM DENSITY = 1.32 kg/m3
FLUE GAS RATE AT BOILER EXIT TEMP. = 32017.62 m3/h
DEW POINT OF WATER VAPOR IN FLUE GAS= 57.26 °C
CONDENSATE (LATENT) HEAT = 1902.32 kW
CONDENSATE MASS RATE IN FLUE GAS = 2888.51 kg/h
CO2 RATE IN FLUE GAS = 1700 mn3/h
CO2 MASS RATE IN FLUE GAS = 3338 kg/h
SPECIFIC CO2 EMISSION = 1.96 kg/m3
CO2 CONCENTRATION IN FLUE GAS = 8.29 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol%
H2O RATE IN FLUE GAS = 3593.73 mn3/h
WATER MASS RATE DELIVERED WITH AIR = 13.93 kg/h
H2O CONCENTRATION IN FLUE GAS = 17.53 vol%
N2 RATE IN FLUE GAS = 14698.39 mn3/h
N2 CONCENTRATION IN FLUE GAS = 71.7 vol%
O2 RATE IN FLUE GAS = 507.17 mn3/h
O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol%

STEAM TEMPERATURE IN BOILER = 179.9 °C

VELOCITY IN BOILER FLUE APERTURE = 17.8 m/s
STATIC PRESSURE DROP IN BOILER = 22.55 mbar
STATIC PRESSURE DROP WITH ECONOMIZER = 23.1 mbar
TRANSFERRED HEAT = 15009.6 kW
STEAM RATE = 22424.4 kg/h
FEED WATER RATE = 23488.3 l/h
AREA THERMAL LOAD = 35.96 kW/m2
PART OF HEAT TAKEN UP BY FURNACE WALLS= 38.16 %
FLUE GAS TEMPERATURE FROM BOILER = 194.6 °C

TRANSFERRED HEAT IN ECONOMIZER = 327.6 kW

FLUE GAS EXIT TEMP. FROM ECONOMIZER = 153.4 °C
WATER EXIT TEMP. FROM ECONOMIZER = 117.4 °C
STATIC PRESSURE DROP IN ECONOMIZER = .55 mbar
BOILER I/O EFFICIENCY (FUEL LHV)= 88.6 %

HEAT BALANCE
____________

DELIVERED HEAT WITH FUEL = 16945 kW

TRANSFERRED HEAT IN BOILER= 15010 kW
DISSOCIATION LOSS = 754 kW
DISSOCIATION LOSS = 4.45 %
STACK LOSS = 1081 kW
STACK LOSS = 6.38 %
BOILER JACKET LOSSES (est)= 85 kW
BOILER JACKET LOSSES (est)= .5 %
UNACCOUNTED LOSS = 15.2 kW
UNACCOUNTED LOSS = .09 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 1110.7 °C

MEAN FLUE GAS TEMPERATURE = 1411.1 °C
THERMAL RADIATION = 4398.5 kW
CONVECTION = 2885.7 kW
HEAT TRANSFERRED TO WALLS = 7284.2 kW
AREA THERMAL LOAD = 167.93 kW/m2
VOLUME THERMAL LOAD = 1114.99 kW/m3
FLUE GAS VELOCITY = 19.88 m/s

HEAT TRANSFER ON FURNACE BOTTOM= 1906.1 kW

WALL TEMP. ON FLUE GAS SIDE = 478.3 °C

HEAT TRANSFER ON CIRCULAR PART = 4328.9 kW

WALL TEMP. ON FLUE GAS SIDE = 261.9 °C

HEAT TRANSFER IN FURNACE TURNAROUND CHAMBER

HEAT TRANSFER ON CIRCULAR PART = 817.4 kW

WALL TEMP. ON FLUE GAS SIDE = 249.7 °C
HEAT TRANSFER ON INNER TUBESHEET= 231.8 kW
WALL TEMP. ON FLUE GAS SIDE = 248 °C

HEAT TRANSFER IN TUBE ASSEMBLY AFTER FURNACE

____________________________________________

FLUE GAS EXIT TEMPERATURE = 323.5 °C

MEAN FLUE GAS TEMPERATURE = 638.2 °C
AREA THERMAL LOAD = 39.18 kW/m2
FLUE GAS VELOCITY = 43.32 m/s
THERMAL RADIATION = 640.1 kW
CONVECTION = 6510.8 kW
HEAT TRANSFERRED = 7150.9 kW
WALL TEMP. ON FLUE GAS SIDE= 187.4 °C
STATIC PRESSURE DROP = 11 mbar

HEAT TRANSFER IN TURNAROUND CHANNEL

___________________________________

FLUE GAS EXIT TEMPERATURE = 266.2 °C

MEAN FLUE GAS TEMPERATURE = 294 °C
FLUE GAS VELOCITY = 4.38 m/s
THERMAL RADIATION = 1.01 kW
CONVECTION = 1.93 kW
HEAT TRANSFERRED TO WALLS = 2.94 kW
WALL TEMP. ON FLUE GAS SIDE= 183.6 °C

HEAT TRANSFER ON SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 210 °C

FLUE GAS EXIT TEMPERATURE = 268.1 °C
THERMAL RADIATION = 26.4 kW
CONVECTION = 441.8 kW
HEAT TRANSFERRED = 468.2 kW
STEAM VELOCITY IN TUBES = 62.89 m/s
FLUE GAS VELOCITY AROUND TUBES= 7.46 m/s
WALL TEMP. ON FLUE GAS SIDE = 217.1 °C
STATIC PRESSURE DROP = .76 mbar

HEAT TRANSFER IN SECOND TUBE ASSEMBLY

_____________________________________

FLUE GAS EXIT TEMPERATURE = 194.5 °C

MEAN FLUE GAS TEMPERATURE = 228.5 °C
AREA THERMAL LOAD = 3.37 kW/m2
FLUE GAS VELOCITY = 28.9 m/s
THERMAL RADIATION = 14.5 kW
CONVECTION = 578.6 kW
HEAT TRANSFERRED = 593.1 kW
WALL TEMP. ON FLUE GAS SIDE= 182.6 °C
STATIC PRESSURE DROP = 9.71 mbar

HEAT TRANSFER IN CHANNEL AT BOILER EXIT

_______________________________________
FLUE GAS EXIT TEMPERATURE = 194.6 °C
MEAN FLUE GAS TEMPERATURE = 194.6 °C
AREA THERMAL LOAD = .004 kW/m2
FLUE GAS VELOCITY = 3.61 m/s
THERMAL RADIATION = 0 kW
CONVECTION = .005 kW
HEAT TRANSFERRED TO WALLS = .005 kW
WALL TEMP. ON FLUE GAS SIDE= 194.9 °C

HEAT TRANSFER ON TUBE ARRAY ECONOMIZER

______________________________________

WATER EXIT TEMPERATURE = 117.4 °C

MEAN FLUE GAS TEMPERATURE = 173.2 °C
FLUE GAS EXIT TEMPERATURE = 153.4 °C
THERMAL RADIATION = 19.2 kW
CONVECTION = 308.4 kW
HEAT TRANSFERRED = 327.6 kW
WATER VELOCITY IN TUBES = .581 m/s
FLUE GAS VELOCITY AROUND TUBES= 2.75 m/s
WALL TEMP. ON FLUE GAS SIDE = 118.3 °C
STATIC PRESSURE DROP = .55 mbar
HEAT TRANSFER IN FIRE TUBE BOILER (ENGLISH UNITS)
=================================================

DATE :SEPTEMBER 12,2016

SUBJECT:3-PASS FIRE TUBE BOILER
MAKE :-
REMARK :DEMO CALCULATION

SUMMARY
_______

TRANSFERRED HEAT IN BOILER = 1531.1 HP

TRANSFERRED HEAT IN BOILER = 51.25 MMBTU/h
STEAM RATE = 24.7 short tons/h
BOILER I/O EFFICIENCY (FUEL HHV) = 79.6 %
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 308.1 F
FEED WATER EXIT TEMP. FROM ECO. = 243.3 F
COMBUSTION AIR RATE = 657207.9 st.cu.ft./h
RELEASED FLUE GAS RATE = 724100.65 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 0 short tons/h
SUPERHEATED STEAM TEMPERATURE = 32 F

INPUT DATA
__________
BOILER TYPE: STEAM
ABSOLUTE WORKING PRESSURE: 145 psi
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: FIRE TUBE
BOILER DESIGN: 3-PASS
BOILER LOAD: 100%
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: GAS

GAS DATA
________

CH4-CONTENT = 100 vol%

CONVERSION FACTOR TO NORM CONDITIONS= .9643

LOWER NORM HEATING VALUE = 963.1 BTU/cu.ft.

HIGHER NORM HEATING VALUE= 1068.8 BTU/cu.ft.

LOWER WOBBE INDEX = 4555.8 BTU/cu.ft.

HIGHER WOBBE INDEX = 5055.5 BTU/cu.ft.

GAS NORM DENSITY = .045 lb/cu.ft.

GAS DENSITY ACTUAL = .043 lb/cu.ft.
GAS OVERPRESSURE = .29 psi
ATMOSPHERIC PRESSURE= 14.7 psi
GAS TEMPERATURE = 50 F

GAS RATE= 60034.9 cu.ft./h

OUTDOOR AIR TEMPERATURE = 59 F

FEED WATER TEMPERATURE = 221 F
REST O2 IN FLUE GAS = 3 %
EXCESS AIR/LAMBDA VALUE = 1.15 -
TOTAL COOLED AREA IN BOILER= 4352.595 sq.ft.
TUBES/FURNACE AREA RATIO = 8.27

FURNACE GEOMETRY DATA

_____________________

FURNACE IS HORIZONTAL
FURNACE IS CIRCULAR

FURNACE BOTTOM AREA = 40.903 sq.ft.

WALL THICKNESS = .984 in
LENGTH IN FLUE GAS FLOW DIRECTION = 21.325 ft.
FURNACE COOLED AREA = 466.898 sq.ft.
INNER DIAMETER = 59.055 in

THERE IS CIRCULAR TURNAROUND CHAMBER AT FURNACE EXIT

TURNAROUND CHAMBER LENGTH = 3.281 ft.

INNER DIAM. OF TURNAROUND CHAMBER= 86.614 in
TURNAROUND CHAMBER COOLED AREA = 137.193 sq.ft.

GEOMETRY DATA OF TUBE ASSEMBLY AFTER FURNACE

____________________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 143

COOLED TUBE LENGTH = 21.325 ft.
TUBE INNER DIAMETER= 2.461 in
TUBE WALL THICKNESS= .146 in
COOLED AREA = 1964.487 sq.ft.

GEOMETRY DATA OF TURNAROUND CHANNEL

___________________________________

FRONT TUBESHEET COOLED AREA = 47.244 in

WALL THICKNESS = .866 in
LENGTH IN GAS FLOW DIRECTION = 1.312 ft.
CROSS SECTION IN GAS FLOW DIRECTION= 29.063 sq.ft.

THERE IS SUPERHEATER IN TURNAROUND CHANNEL

TUBE ROWS HAVE PLAIN ARRANGEMENT

SUPERHEATED STEAM DESIGN TEMPERATURE = 410 F

TUBE SECTION LENGTH = 3.281 ft.
NEEDED TOTAL TUBE LENGTH = 1804.5 ft.
NEEDED TOTAL TUBE AREA = 706.751 sq.ft.
TUBE OUTER DIAMETER = 1.496 in
TUBE WALL THICKNESS = .118 in
NUMBER OF TUBES IN ROW = 25
NEEDED NUMBER OF TUBE ROWS = 23
DISTANCE BETWEEN TUBES IN ROW = 3.937 in
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

GEOMETRY DATA OF SECOND TUBE ASSEMBLY

_____________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 118
COOLED TUBE LENGTH = 24.934 ft.
TUBE INNER DIAMETER= 2.461 in
TUBE WALL THICKNESS= .146 in
COOLED AREA = 1895.376 sq.ft.

GEOMETRY DATA OF CHANNEL AT BOILER EXIT

_______________________________________

CHANNEL IS RECTANGULAR

COOLED AREA = 12.917 sq.ft.

WALL THICKNESS = .866 in
LENGTH IN GAS FLOW DIRECTION = 1.312 ft.
CROSS SECTION IN GAS FLOW DIRECTION= 29.063 sq.ft.

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS ARE IN PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 221 F

TUBE SECTION LENGTH = 7.874 ft.
TOTAL TUBE LENGTH = 3937.008 ft.
TOTAL TUBE AREA = 1228.913 sq.ft.
TUBE OUTER DIAMETER = 1.181 in
TUBE WALL THICKNESS = .118 in
NUMBER OF TUBES IN ROW = 20
NUMBER OF TUBE ROWS = 25
DISTANCE BETWEEN TUBES IN ROW = 3.937 in
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

STACK CONNECTOR CROSS SECTION AREA= 5.382 sq.ft.

CALCULATION RESULTS (CLEAN SURFACES ASSUMED)

____________________________________________

ADIABATIC COMBUSTION TEMPERATURE = 3202.4 F

COMBUSTION AIR RATE = 657207.9 st.cu.ft./h

COMBUSTION AIR MASS RATE = 53047.37 lb/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 657207.9 cu.ft./h
RELEASED FLUE GAS RATE = 724100.65 st.cu.ft./h
RELEASED FLUE GAS MASS RATE = 59590.17 lb/h
FLUE GAS NORM DENSITY = .082 lb/cu.ft.
FLUE GAS RATE AT STACK TEMPERATURE = 1130965.17 cu.ft./h
DEW POINT OF WATER VAPOR IN FLUE GAS= 135.06 F
CONDENSATE (LATENT) HEAT = 194.06 HP
CONDENSATE (LATENT) HEAT = 6.5 MMBTU/h
CONDENSATE MASS RATE IN FLUE GAS = 6369.36 lb/h
CO2 RATE IN FLUE GAS = 60049.45 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 7360.54 lb/h
SPECIFIC CO2 EMISSION = 1.96 lb/st.cu.ft.
CO2 CONCENTRATION IN FLUE GAS = 8.29 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol%
H2O RATE IN FLUE GAS = 126942.19 st.cu.ft./h
WATER MASS RATE DELIVERED WITH AIR = 30.72 lb/h
H2O CONCENTRATION IN FLUE GAS = 17.53 vol%
N2 RATE IN FLUE GAS = 519194.25 st.cu.ft./h
N2 CONCENTRATION IN FLUE GAS = 71.7 vol%
O2 RATE IN FLUE GAS = 17914.75 st.cu.ft./h
O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol%

STEAM TEMPERATURE IN BOILER = 355.8 F

VELOCITY IN BOILER FLUE APERTURE = 58.36 ft/s
STATIC PRESSURE DROP IN BOILER = 9.05 inWC
STATIC PRESSURE DROP WITH ECONOMIZER = 9.27 inWC
TRANSFERRED HEAT = 1531.1 HP
STEAM RATE = 49447.4 lb/h
STEAM RATE = 24.7 short tons/h
FEED WATER RATE = 6204.96 gal/h
HEAT TRANSFER INTENSITY = 2.934 sq.ft./HP
PART OF HEAT TAKEN UP BY FURNACE WALLS= 38.16 %
FLUE GAS TEMPERATURE FROM BOILER = 382.3 F

TRANSFERRED HEAT IN ECONOMIZER = 33.4 HP

TRANSFERRED HEAT IN ECONOMIZER = 1.12 MMBTU/h
FLUE GAS EXIT TEMP. FROM ECONOMIZER = 308.1 F
WATER EXIT TEMPERATURE FROM ECONOMIZER= 243.3 F
STATIC PRESSURE DROP IN ECONOMIZER = .22 inWC

BOILER I/O EFFICIENCY (FUEL HHV)= 79.6 %

HEAT BALANCE
____________

DELIVERED HEAT WITH FUEL = 1922.6 HP

DELIVERED HEAT WITH FUEL = 64.36 MMBTU/h
TRANSFERRED HEAT IN BOILER= 1531.1 HP
TRANSFERRED HEAT IN BOILER= 51.25 MMBTU/h
DISSOCIATION LOSS = 76.9 HP
DISSOCIATION LOSS = 2.57 MMBTU/h
DISSOCIATION LOSS = 4 %
STACK LOSS = 304.4 HP
STACK LOSS = 10.19 MMBTU/h
STACK LOSS = 15.83 %
BOILER JACKET LOSSES (est)= 9.6 HP
BOILER JACKET LOSSES (est)= .32 MMBTU/h
BOILER JACKET LOSSES (est)= .5 %
UNACCOUNTED LOSS = 1.6 HP
UNACCOUNTED LOSS = .05 MMBTU/h
UNACCOUNTED LOSS = .08 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 2031.3 F

MEAN FLUE GAS TEMPERATURE = 2572 F
VOLUME THERMAL LOAD = 3.22 HP/cu.ft.
HEAT TRANSFER INTENSITY = .628 sq.ft./HP
THERMAL RADIATION = 448.7 HP
CONVECTION = 294.4 HP
HEAT TRANSFERRED TO WALLS = 743.1 HP
GAS VELOCITY = 65.217 ft/s

HEAT TRANSFER ON FURNACE BOTTOM= 194.4 HP

WALL TEMP. ON FLUE GAS SIDE = 892.9 F

HEAT TRANSFER ON CIRCULAR PART = 441.6 HP

WALL TEMP. ON FLUE GAS SIDE = 295.7 F

HEAT TRANSFER IN FURNACE TURNAROUND CHAMBER

HEAT TRANSFER ON CIRCULAR PART = 83.4 HP

WALL TEMP. ON FLUE GAS SIDE = 481.5 F
HEAT TRANSFER ON INNER TUBESHEET= 23.6 HP
WALL TEMP. ON FLUE GAS SIDE = 478.5 F

HEAT TRANSFER IN TUBE ASSEMBLY AFTER FURNACE

____________________________________________

FLUE GAS EXIT TEMPERATURE = 614.3 F

MEAN FLUE GAS TEMPERATURE = 1180.7 F
HEAT TRANSFER INTENSITY = 2.693 sq.ft./HP
FLUE GAS VELOCITY = 142.128 ft/s
THERMAL RADIATION = 65.3 HP
CONVECTION = 664.2 HP
HEAT TRANSFERRED = 729.5 HP
WALL TEMP. ON FLUE GAS SIDE= 369.3 F
STATIC PRESSURE DROP = 4.41 inWC
HEAT TRANSFER IN TURNAROUND CHANNEL
___________________________________

FLUE GAS EXIT TEMPERATURE = 511.2 F

MEAN FLUE GAS TEMPERATURE = 561.1 F
FLUE GAS VELOCITY = 14.369 ft/s
THERMAL RADIATION = .1 HP
CONVECTION = .2 HP
HEAT TRANSFERRED TO WALLS = .3 HP
WALL TEMP. ON FLUE GAS SIDE= 362.48 F

HEAT TRANSFER ON SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 410 F

FLUE GAS EXIT TEMPERATURE = 32 F
THERMAL RADIATION = 2.69 HP
CONVECTION = 45.07 HP
HEAT TRANSFERRED = 47.76 HP
STEAM VELOCITY IN TUBES = 206.317 ft/s
FLUE GAS VELOCITY AROUND TUBES= 24.474 ft/s
WALL TEMP. ON FLUE GAS SIDE = 422.8 F
STATIC PRESSURE DROP = .31 inWC

HEAT TRANSFER IN SECOND TUBE ASSEMBLY

_____________________________________

FLUE GAS EXIT TEMPERATURE = 382.2 F

MEAN FLUE GAS TEMPERATURE = 443.3 F
HEAT TRANSFER INTENSITY = 31.327 sq.ft./HP
FLUE GAS VELOCITY = 94.802 ft/s
THERMAL RADIATION = 1.5 HP
CONVECTION = 59 HP
HEAT TRANSFERRED = 60.5 HP
WALL TEMP. ON FLUE GAS SIDE= 360.7 F
STATIC PRESSURE DROP = 3.9 inWC

HEAT TRANSFER IN CHANNEL AT BOILER EXIT

_______________________________________

FLUE GAS EXIT TEMPERATURE = 382.3 F

MEAN FLUE GAS TEMPERATURE = 382.2 F
FLUE GAS VELOCITY = 11.851 ft/s
THERMAL RADIATION = 0 HP
CONVECTION = .001 HP
HEAT TRANSFERRED TO WALLS = .001 HP
WALL TEMP. ON FLUE GAS SIDE= 382.8 F
HEAT TRANSFER ON TUBE ARRAY ECONOMIZER
______________________________________

WATER EXIT TEMPERATURE = 243.3 F

MEAN FLUE GAS TEMPERATURE = 343.7 F
FLUE GAS EXIT TEMPERATURE = 308.1 F
THERMAL RADIATION = 2 HP
CONVECTION = 31.5 HP
HEAT TRANSFERRED = 33.4 HP
WATER VELOCITY IN TUBES = 1.907 ft/s
FLUE GAS VELOCITY AROUND TUBES= 9.007 ft/s
WALL TEMP. ON FLUE GAS SIDE = 245 F
STATIC PRESSURE DROP = .22 inWC
Step 56: Economizer tube section length.