a0 A 08 a KAJAN & 1 1992 Waste Heat Boiler Deskbook by V. GanapathyLibrary of Congress Cataloging-in-Publication Data Ganapathy, V. aste heat boiler deskbook / by V. Ganapathy. . cm. Includes Index. ISBN 0-88173-122-6 1. Waste heat boilers--Handbooks, manuals, etc. I. Title. TJ319.G36 1991 621.1’83--dc20 90-85871. CIP Waste Heat Boiler Deskbook | By V. Ganapathy. ©1991 by The Fairmont Press, Inc. All rights reserved. No part of this publi- cation may be nae or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or ‘any informa ae ‘storage and retrieval system, ‘without pérmission in writing from the pul Published by The Fairmont Press, Inc, 700 Indian Trail Lilburn, GA. 30247 Printed in the United States of America 0987654321 ISBN 0-68173-122-b FP ISBN O-13-950890-2 PH While every effort is made to provide dependable information, the publisher, authors, and editors cannot be held responsible for any errors or omissions, Distributed by Prentice-Hall, Inc. A Simon & Schuster Company Englewood Cliffs, NJ. 07632 Prentice-Hall International (UK) Limited, London Prentice-Hall of Australia Pty. Limited, Sydney Prentice-Hall Canada Inc., Toronto Prentice-Hall Hispanoamericana, S.A., Mexico Prentice-Hall of India Private Limited, New Delhi Prentice-Hall of Japan, Inc., Tokyo Simon & Schuster Asia Pte. Ltd., Singapore Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro 4 | |Contents Preface. Acknowledgements. List of Frequently Used Abbreviations Introduction... CHAPTER 1: Heat Recovery System: HRSGs for gas turbines..... Natural versus forced circulation boilers Auxiliary firing... Computing fuel requirements. HRSG system efficiency .. Fresh air firing HRSG design features. Fined surfaces and design. Steaming economizer: Emissions of NOx and C Methods of reducing pollutants Bypass dampers. Recent trends. STIG and Cheng cycle systems. Enhanced oil recovery applications Reciprocating engine heat recovery. Hydrogen plant waste heat boilers. Boilers for sulfuric acid plant... Incineration and heat recovery Solid waste incineration... RDF firing... Fluid bed combustors for MSW . Hazardous waste incineration. High temperature corrosion... vCHAPTER 2: Fire Tube Boilers... CHAPTER 3: Water Tube Boilers..... 4% Heat transfer calculations...... Heat recovery boilers..... Incineration of wood wastes, tire: Incineration of liquids, fumes, VOCs .. Air heating applications. Reference: Guidelines for fire tube boilers Design procedure... Determination of tube side coefficient. Example of design... Effect of tube size on design. Simplified approach to design Predicting boiler performance. Simplified approach to predicting performance: Checks for fouling ... Effect of scale on boiler performance Hydrogen plant boilers. Gas bypass flow calculations Determining heat losses from boiler.. References. Nomenclature Guidelines for water tube boiler: Convective heat transfer coefficient... Determination of tube side coefficient....... Non-luminous heat transfer coefficient Gas pressure drop calculations ... In-line versus staggered arrangement Design of evaporators Performance calculations Selecting designs with low pinch and approach points... Comparison of bare versus finned evaporator Radiant heat transfer... HRSG configuration and circulation. viCHAPTER 5: Specifying Waste Heat Boilers Design of superheaters Design procedure... Performance calculations... NTU method of performance calculations. Metal temperature calculation: External radiation... Flow in parallel streams Minimizing tube wall temperatures Steam temperature control. Design of economizer: Performance of complete HRS References. Nomenclature CHAPTER 4: Simulation of HRSG Design and Performance .... Importance of HRSG simulation. Design and performance calculations Design temperature profile... Guidelines for selecting pinch and approach points. Example of design. Performance calculation procedure. Software for HRSG simulation - COGEN Supplementary firing and HRSG efficiency. Improving efficiency of HRSG..... Deaeration steam calculations. Steam turbine calculations. Optimizing temperature profiles using COGEN. Using field data to simulate HRSG performance Multi-pressure HRSG design and performance simulation References... Nomenclature .. Application or system design Space and layout guidelines .. viiGas data. Boiler duty. Auxiliary fuel data. Emission data Feed water analysis, blow down Surface area, fin configuration... Cost data for fuel, electricity and steam. Drum sizing. References. APPENDIX A: Finned Tubes .. Heat transfer calculations Fin efficiency and effectiveness . Gas pressure drop . Tube wall and fin tip temperature. Design example... Comparison of bare versus finned evaporator... Comparison of in-line versus staggered arrangement Fin configuration and performance Importance of tube side coefficient Effect of fouling factors. Surface area and duty. Nomenclature References.. APPENDIX B: Low Temperature Corrosion..... Causes and cures. Methods of avoiding cold end corrosion Condensation on surfaces.. Corrosion is stacks, ducts. Heat loss calculations through multi-layer insulation. Hot casing design . Nomenclature References. viiiAPPENDIX C: Heat Transfer Equipment Vibration... APPENDIX D: Gas Turbine Data.. APPENDIX E: Gas and Steam Properties... Specific heat, viscosity, thermal conductivity of gases Enthalpy of gases... Estimating flue gas properties .. Effect of pressure on heat transfer Converting % volume to % weight. Properties of steam and compressed water APPENDIX F: Tube Thickness Calculations. Tubes and pipes subject to internal pressure. Designing vessels and tubes subject to external pressure. APPENDIX G: Conversion Factors... INDEXPreface During the past 20 years I have had the opportunity of engineering a wide variety of industrial boilers and Heat Recovery Steam generators. During the past 7 years at ABCO Industries in particular I have had the pleasure of custom designing over two hundred fire tube and water tube waste heat boilers, each with different gas/steam parameters, which are in operation in the USA and abroad; these units were built for diverse heat recovery applications such as gaseous, liquid, solid waste and hazardous waste incineration systems, gas turbine exhaust, effluents from chemical plants such as sulfuric acid and hydrogen plants, petro- chemical plants, cat crackers in refineries and for effluents from clean as well as dirty processes; the gas flow ranged from 2000 to 1.5 million pounds per hour, which implies a wide variety of boiler configurations and design features as you will see in the text. Energy management programs are vital to the economic life of any industry and heat recovery boilers play a dominant role in those projects which otherwise waste energy from hot flue gases. I decided to write this book after reviewing hundreds of specifications for heat recovery boilers prepared by consultants and would be users of the equipment; unfortunately several of them are poorly written without emphasis on the process aspects and optimization of installed plus operating costs, with a result that the end user or the owner gets an equipment which perhaps meets the budget requirement but which could incur significant operating costs in the form of higher gas pressure drop or fuel consumption or lower steam production year after year. The book addresses various aspects of heat recovery boilers, such as engineering, specifying, system design, optimization and performance evaluation. Hence engineers and managers involved in several disciplines of energy management including plant operation will find the book useful and informative. xiThe book is dedicated to professionals involved in any way with energy conservation and heat recovery. As pointed out by one, the earth is not for man, but man is for earth. Hence let us use the limited natural energy resources wisely with the future of mankind and the next generation in mind. V. Ganapathy xiiAcknowledgements I would like to thank ABCO Industries for their encouragement and support in the preparation of this book and for the use of several ABCO illustrations and photographs. I would also like to thank the following publications for permitting me to use my articles, which originally appeared in them: Power Power Engineering Chemical Engineering Oil and Gas Journal Hydrocarbon Processing Heating, piping and Air-conditioning Sci-Tech Publications Pennwell Books Marcel Dekker Inc. I would also like to thank ESCOA Corp for permitting me to use their correlations for extended surface heat transfer calculations. Several readers from various continents have been writing to me regarding my publications during the past several years, which has been indeed been motivating and I would like to thank them for their interest. V. Ganapathy | { |List of Frequently Used Abbreviations ABMA - American Boiler Manufactures Association ASME - American Society of Mechanical Engineers CO- Carbon Monoxide EOR - Enhanced Oil recovery FTB - Fire tube boiler GTE - Gas turbine exhaust HRSG - Heat Recovery Steam Generator MSW - Municipal Solid Waste NIMBY - Not in my back yard NOx - Nitrogen oxides NWL - Normal water level PPB - Parts per billion PPM - Parts per million RDF - Refuse Derived Fuel SCR - Selective Catalyst Reduction System STIG - Steam Injected Gas Turbine TDS - Total dissolved solids WHB - Waste Heat Boiler WTB - Water tube boiler VOC - Volatile Organic Compounds xv |Introduction The book is aimed at engineers, consultants and managers involved in specifying, operating, engineering, marketing and procuring waste heat boilers (WHBs) or heat recovery steam generators (HRSGs). It offers valuable information on not only the heat recovery systems in chemical plants, gas turbine cogeneration and combined cycle plants, solid waste, liquid and gaseous incineration systems and flue gas heat recovery in general, but also provides the characteristics of each system such as gas analysis, fouling and slagging tendencies, high and low temperature corrosion potential and the impact of these on design and performance aspects of HRSGs. During the past 15 years and particularly during the last 7 years at ABCO Industries I have had the opportunity of engineering a wide variety of fire tube and water tube waste heat boilers for different types of applications as mentioned above. Having designed over two hundred boilers with gas flows varying from 2000 to 15 million pounds per hour and steam flows varying from 2000 to 250,000 pounds per hour, I feel that custom designing HRSGs is an art as well as a science, as there are numerous configurations possible depending on economics, cleanliness of gas, gas and steam parameters and layout considerations. I have had also the opportunity of authoring four books and over 175 articles on heat recovery boilers and steam plant systems in journals such as Power, Power Engineering, Chemical Engineering, Heating Piping Air-Conditioning, Oil and Gas Journal, Hydrocarbon Processing, Plant Engineering; the feed back from the readers has been very encouraging, which prompted me to bring out this work. Another reason was that in the course of reviewing specifications on HRSGs from various consultants and engineering organizations, I felt that less emphasis was being placed on process and optimization aspects, which is very important in the ong run to the owner of the plant. Due to lack of knowledge on HRSGs and their performance xviiaspects, several of the specifications are poorly written and do not furnish adequate information to engineer an economically and technically sound design. Many engineers also lack knowledge or do not know how to evaluate alternate design options. For example if you read Appendix A, several examples are given to show that with finned tubes one can have a lower surface area and still transfer more energy by proper choice of fin configuration. Several engineers and purchase managers still purchase HRSGs for critical applications based on surface area and are of the view that more the surface area the better and a design with a lower surface area would not perform. Also, I have come across several specifications which do not place emphasis on HRSG operating costs; during the life time of the HRSG, the cost of moving the gas through the system due to high gas pressure drop or the cost of fuel which is required to generate a desired quantity of steam may be very significant. While the consultant looks at the initial cost alone, to the owner of the plant who has to pay for the fuel and electricity for years to come, the life cycle cost of the HRSG is important. Hence addition of secondary heat recovery surfaces such as condensate h;eater or economizer may have to be looked into, though the initial cost may be slightly more. A few examples on the subject of evaluating operating and life cycle costs are discussed in the book. This book offers useful information on design and off-design performance aspects of Heat recovery systems and components such as superheaters, evaporators and economizers, which are elaborated by over 65 fully worked out examples. You will find quantitative answers to commonly asked questions on heat recovery boilers and systems; some of them are: * How can one improve the efficiency of a HRSG system? © What is the effect of auxiliary firing on system efficiency? * How to compute the fuel requirements and oxygen consumption for gas turbine exhaust boilers? * How to select pinch and approach points? How do they vary with gas inlet conditions? © What is the effect of scale on boiler performance and tube wall temperatures and heat flux? © How to compute the dew points of hydrochloric acid, sulfuric acid, hydrobromic acid, nitric acid? xviii* Which is better arrangement for bare and finned tubes, in-line or staggered? ¢ How do boilers with finned tubes compare with bare tube design for the same duty? * How to compute the gas temperature at the SCR at off-design conditions. ¢ How to avoid high and low temperature corrosion problems? * How to use field data to predict off-design performance or fouling of HRSGs? * With finned tubes can you transfer more duty with less surface area? What is the effect of fin configuration? * How to size and predict off-design performance of fire tube and bare/finned water tube boilers, superheaters, economizers? * How to compute tube wall and fin tip temperatures? * How to compute thickness of tubes subject to internal or external pressure? «How much gas should be bypassed for gas temperature control? * What is the effect of gas pressure on heat transfer? ¢ How to evaluate HRSGs for possible noise and vibration problems? The first chapter deals with heat recovery systems. HRSGs are used in various applications such as gas turbine exhaust, incineration systems, chemical plants and refineries to mention a few. In order to design a HRSG for any application, the characteristics of the gas stream are important. For example, auxiliary firing in gas turbine HRSGs is discussed in depth with examples on computing fuel requirements, oxygen consumption, impact on system efficiency and emissions. Features of boilers such as natural or forced circulation, single or multiple gas pass design, insulated casing or fully water cooled membrane wall construction are discussed, along with methods of minimizing steaming concerns in economizers. Various aspects of WHBs in Municipal Solid Waste (MSW) applications, Refuse Derived Fuel (RDF) fired units and other incineration systems are discussed with emphasis on type of boilers, whether fire tube or water tube, fouling and slagging concerns and high and low temperature corrosion potential. Methods of minimizing these concerns through boiler design and selection of steam parameters are addressed. The second and third chapters deal with Design and off-design performance calculation procedures for fire tube and water tube xixboilers with bare and extended surfaces. Plant engineers can use the simplified procedures described in the text for instance to check for fouling, estimate bypass flow for gas temperature control or estimate the gas temperature at the Selective Catalytic Reduction system SCR) at different load conditions. Effect of tube size and arrangement whether in-line or staggered on design and performance is elaborated quantitatively. Examples are also given on how to compute the tube wall temperatures, including the effect of scale. Arrangement of headers on flow mal-distribution in superheaters and the effect of tube configuration on direct radiation to tubes are also discussed. Circulation aspects are also discussed along with various configur- ations available for superheaters, evaporators and economizers. Simulation of single or multi-pressure unfired or fired HRSGs can be performed using the methodology described in chapter 4. Guidelines on selecting pinch and approach points are discussed. One can predict the performance of complex unfired and fired multi- pressure HRSGs under different load conditions without actually designing the unit. Such studies would be helpful to consultants in simulating the entire combined cycle or cogeneration plant behavior and economics. Methods of improving the efficiency of HRSG systems through addition of condensate heater, deaerator coil or heat exchanger are addressed. Examples illustrate how one can also optimize the temperature profiles b;y rearranging the heating surfaces. Methods of computing deaeration steam requirements and power output from steam turbines are discussed with examples. The software COGEN which is used in HRSG evaluations is recom- mended to those involved in engineering combined cycle and cogeneration projects, as on can simulate complex HRSG systems without actually designing the plant,saving a lot of engineering time Chapter 5 shows how one should specify waste heat boilers from the process view point. Adhering to the guidelines will save a lot of time for both the boiler designer and the purchasing manager responsible for evaluating alternate bids. Advantages of extended surface over bare tube is discussed in detail with examples in Appendix A. Effect of arrangement of tubes ie, in-line versus staggered and the selection of fin configuration are elaborated. Examples also show how one can transfer more energy with less surface area with finned tubes. The effect of tube side XX