Indirect heating

27-Oct-17 1
 Steam required for heating

(kcal)

(kcal/kg.°C)

27-Oct-17 2
Steam table

3
 Steam required for heating

27-Oct-17 4
Calculating steam required jacketed kettle
Inside the kettle there are 4,500 lt of
water (4.500 kg of water)
5 barg steam is used to raise the
water temperature from 40º C water
into 70º C hot water

The quantity steam required per-hour:

4500 x 1 x (70 – 40)
----------------------------= 270.98 Kg/hr
498.2

NOTE:
Cp of water = 1 Kcal/kg.ºC
Latent heat of steam of 5 barg
pressure = 498.2 kcal/kg
Specific heat of water = 1

27-Oct-17 5
 Steam calorifier (hot water heater)

27-Oct-17 6
Heating coil
 Calculating steam required calorifier
Inside the calorifier there are 4,500 lt
of water (4,500 kg of water)
5 barg steam is used to raise the
water temperature from 40º C water
into 70º C hot water in 2 hrs time

The quantity steam required:

4500 x 1 x (70 – 40)
----------------------------= 235.49 Kg/hr
498.2 x 2

NOTE:
Cp of water = 1 Kcal/kg.ºC
Latent heat of steam of 5 barg
pressure = 498.2 kcal/kg
Specific heat of water = 1

27-Oct-17 7
Calculating steam required heat exchanger
Water with flow rate of 2 m3/hr (2,000
kg/hr) is supplied to the plate & frame
heat exchanger
The water is heated by 5 barg
pressure steam from 40º C to 70º C

The quantity steam required per-hour:

2,000 x 1 x (70 – 40)
---------------------------- = 120.43 kg/hr
498.2

NOTE:
Cp of water = 1 Kcal/kg.ºC
Latent heat of steam of 5 barg
pressure = 498.2 kcal/kg
Specific heat of water = 1

27-Oct-17 8
Calculating steam required heat exchanger
Water with flow rate of 2 m3/hr (2,000
kg/hr) is supplied to the shell & tube
heat exchanger
The water is heated by 5 barg
pressure steam from 40º C to 70º C

The quantity steam required per-hour:

2,000 x 1 x (70 – 40)
---------------------------- = 120.43 kg/hr
498.2

NOTE:
Cp of water = 1 Kcal/kg.ºC
Latent heat of steam of 5 barg
pressure = 498.2 kcal/kg
Specific heat of water = 1

27-Oct-17 9
Calculating steam required heat exchanger
Oil with flow rate of 2 m3/hr is
supplied to the shell & tube heat
exchanger
The oil is heated by 5 barg pressure
steam from 40º C to 70º C

The quantity steam required per-hour:

2,000 x 0.90 x 0.42 x (70 – 40)
---------------------------- ------------
498.2

= 45.52 kg/hr

NOTE:
Oil specific gravity = 0.90
Oil specific heat = 0.42 Kcal/kg.°C
Latent heat of steam of 5 barg
pressure = 498.2 kcal/kg
27-Oct-17 10
27-Oct-17 11
Calculating steam required steam main distribution
Steam main distribution pipeline could be:
• A long steam piping from boiler to site (steam main  every 30 to 50
meter pipe distance needs a steam trap to drain the condensate)
• To have a good condensate draining through a steam trap  please
choose the correct size of the drip leg.

27-Oct-17 12
Calculating steam required steam main distribution

27-Oct-17 13
Calculating steam required steam main distribution
For example:
• 6” pipe insulated with 1” thick of calcium
silicate  we assume 75 % efficient
insulation
• Distance between steam trap = 30 m = 98.5
foot
• 1sq.ft of 6” pipe external surface is equivalent
with 0.576 foot of pipe
• Steam pressure = 60 psi
• A = 1.735 sq.ft (external area of 6” pipe)
• U = 2.7 btu/sq.ft/degree temperature/hr
• T1 = 307°F (steam temperature)
• T2 = 70°F (air temperature)
• E = (1 – insulation efficiency) = 0.25
• H = 904 btu/lb (latent heat of 60 psi steam)

• C = condensate in lbs/hr-foot = (1.735 x 2.7 x

(307-70) X 0.25/904 = 0.307 lbs/hr.ft  total
condensate in 98.5 foot of 6” pipe = 98.5 x
0.307 = 30.24 lbs/hr
27-Oct-17 14
Calculating steam required steam header

27-Oct-17 15
Calculating steam required steam branch

27-Oct-17 16
Calculating steam required steam separator

27-Oct-17 17
 Calculating steam required steam tracer
Steam tracing is a process that is designed to prevent heat loss through a steam heating system.
A common application for this process is in the oil industry, where the main pipe line at refineries or
petrochemical complex are commonly fitted with steam tracing equipment. Using this technique allows
manufacturers to control temperatures in their pipes, keeping their processes safe as well as efficient.
The general practice of heating piping as materials flow through it to keep the materials at a constant
temperature and compensate for heat loss is known as heat tracing. In the case of steam tracing, the heat is
accomplished with steam..
For steam tracing, a small diameter pipe is run alongside the large pipe used for the moving steam. A
conductive compound is smeared between the two pipes so heat will transfer easily from the steam pipe to the
main pipe. Both pipes are wrapped in insulation and jacketing to minimize heat loss as much as possible and
provide protection from the elements.
Steam tracing can be used to maintain a desired viscosity, prevent freezing of transported materials, or control
temperatures to keep pressure within safe ranges. These systems can be found in a variety of industrial
environments, along with the boilers and support equipment needed to keep the heat tracing system running.

27-Oct-17 18
 Calculating steam required steam tracer

27-Oct-17 19
 Calculating steam required steam tracer
For example:
• The main crude oil pipe size is 6” sch 40
• We use one tracer tube  the horizontal distance of the tracer tube = L = 5 meter = 16.5
foot
• Steam pressure = 3 barg = 43.5 psig
• Initial crude oil temperature = 70°F
• Final crude oil temperature = 140°F
• ∆T = (140 – 70) = 70°F
• The main pipe & tracer tube is insulated  the insulation efficiency = 75 %
• S = The lineal length of the 6” pipe based on the outer heating surface = 0.576
• U = 2.35 btu/sq.ft/degree temperature/hr

Q = (16.5 x 2.35 x 70 x 0.25)/(0.576 x 904)

= 1.30 lbs/hr

27-Oct-17 20
 Calculating steam required steam tracer

NOTE:
The lineal feet of 6” pipe is equal to 0.576 external surface of the pipe
The lineal feet of 20” pipe is equal to 0.191 external surface of the pipe

27-Oct-17 21
 Calculating steam required steam tracer

27-Oct-17 22
Calculating steam required superheat steam

27-Oct-17 23
Calculating steam required superheat steam

27-Oct-17 24
 Calculating steam required air heater

27-Oct-17 25
 Calculating steam required air heater
Manufacturers of unit heaters and air heater
batteries usually give the output of their heaters in
kW at a working pressure.
From this, the condensing rate can be calculated
by dividing the heat output by the enthalpy of
evaporation of steam at this pressure.
For example:
44 KW unit air heater
Steam pressure = 3.5 bar (latent heat = 2120
kj/kg)
The solution will be in kg/s  multiplying by 3 600
(seconds in an hour) will give the solution in kg/h.

Note:
The constant 3 600 is included in the formula to
27-Oct-17 give flowrate in kg/h rather than kg/s. 26
 Calculating steam required air heater
If the manufacturer air heater’s figures
are not available but the following are
known:
• The volumetric flowrate of air being
heated.
• The temperature rise of the air
being heated.
• The steam pressure in the heater.
We can use the equation below.

27-Oct-17 27
 Calculating steam required air heater

27-Oct-17 28
 Calculating steam required air heater

27-Oct-17 29
 Calculating steam required air heater

27-Oct-17 30
 Calculating steam required air heater

27-Oct-17 31
 Calculating steam required Evaporator

27-Oct-17 32
 Calculating steam required Evaporator

Horizontal tube evaporator Vertical tube evaporator Vertical short ube evaporator

27-Oct-17 33

Falling film evaporator

 Calculating steam required Evaporator

27-Oct-17 34
 Calculating steam required Evaporator

27-Oct-17 35
 Calculating steam required Evaporator

27-Oct-17 36
Calculating steam required stationary chamber

27-Oct-17 37
Calculating steam required stationary chamber

27-Oct-17 38
Calculating steam required rotating dryer

27-Oct-17 39
Calculating steam required rotating dryer

27-Oct-17 40
Calculating steam required rotating dryer

27-Oct-17 41
Calculating steam required rotating dryer

27-Oct-17 42
 Calculating steam required flash tank

27-Oct-17 43
 Calculating steam required flash tank

27-Oct-17 44
 Calculating steam required flash tank

27-Oct-17 45
 Calculating steam required flash tank

27-Oct-17 46
 Direct heating

27-Oct-17 47
Calculating steam required direct injection
NOTE:
CP of water = 1 Kcal/kg.°C
Enthalpy (latent heat + sensible heat) of
steam at 5 barg steam = 658.3 Kcal/kg
Water enthalphy @ 70° C = 70 Kcal/kg
27-Oct-17
Inside the tank there are 4,500 lt of
water (4,500 kg of water)
5 barg steam is directly injected into
the water to raise the water
temperature from 40º C water into 70º
C hot water in 2 hours time
The quantity steam required:
4500 x 1 x (70 – 40)
----------------------------= 114.7 Kg/hr
(658.3 – 70) x 2
Steam is directed into the water’
We have to use the enthalpy (latent
heat + sensible heat) of steam.
Enthalphy of 5 barg steam = 658.3
kcal/kg
Since the water to be heated at 70º c
 We have to include the enthalphy
48 of
this 70º C water too