Design of Superheater

Assuming the size of tube

From Standard Pipe Table
𝐷0 Outside diameter, m 0.603
Di Inside diameter, m 0.0525
.t Thickness, m 0.0039

Logarithmic Mean Temperature Difference

𝑡𝑔 𝐴 = 1200 ˚𝐶 𝑡𝑠1 = 280.9 ˚𝐶
𝑡𝑔 𝐵 = 634.360 ˚𝐶 𝑡𝑠2 = 470 ˚𝐶

Note: Due to low temperature of superheated steam at 𝑃2 the flue gas is not fully utilized
therefore 𝑡2 must be increased.
𝜃𝑚𝑎𝑥 = 𝑡𝑔 𝐴 − 𝑡𝑠2 = 1200 − 470 = 630 ˚𝐶
𝜃𝑚𝑖𝑛 = 𝑡𝑔 𝐵 − 𝑡𝑠1 = 634.36 − 280.9 = 353.46 ˚𝐶

Solving for Logarithmic Temperature Difference

𝜃𝑚𝑎𝑥 − 𝜃𝑚𝑖𝑛 630 − 353.36
𝐿𝑀𝑇𝐷 = = = 472.4847 ˚𝐶
𝜃𝑚𝑎𝑥 630
𝐼𝑛 𝐼𝑛
𝜃𝑚𝑖𝑛 353.36

Over – all Coefficient

1 1 𝑥 1
= + + 𝑂𝑣𝑒𝑟 𝑎𝑙𝑙 𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑈 ℎ1 𝑘 ℎ2
1
𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑇𝑢𝑏𝑒
𝑡
 𝐺𝑠
ℎ1 = 3.7 𝑋 103 𝐷 𝑖 2 𝐾1 [ ( )0.8 ] Steam film Coefficient
𝜇2
𝐺𝑔 0.6
ℎ2 = 0.0841 𝑋 𝑘2 𝐷 0−0.4 { [ ] } (0.884) gas Film Coefficient
𝜇2

From PPE by Morse Page 270 Fig. 9.6 Steam Film Coefficient indicates the Over- all
coefficient.
𝑘𝑔
1.033 ⁄ 2 𝑘𝑔⁄
𝑐𝑚
𝑃1 = 6.50 𝑀𝑝𝑎 [ ] = 66.26696274
0.101325 𝑚𝑝𝑎 𝑐𝑚2

𝑡𝑠1 + 𝑡𝑠2 280.9 + 470

𝑡𝑠𝑚 = = = 375.45 ˚𝐶
2 2

By 𝜇 𝑋 10−7 𝑘 𝑋 10−2
Extrapolation 𝑘𝑔⁄ 25.4 4.5
28.1
𝑐𝑚2
𝑘𝑔 28 5.2
56.2 ⁄ 2
𝑐𝑚
6.50 MPa 𝑘𝑔 28.93 5.292
66.2816 ⁄ 2
𝑐𝑚

𝜇 = 28.93 𝑋 10−7
𝑘 = 5.292 𝑋 10−2
𝐺𝑠 = 𝐺𝑎𝑠 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤
𝑘𝑔⁄
= 𝑢𝑠𝑒 390.6 𝑚2 − 𝑠 From page 279
390.6
ℎ1 = 3.7 𝑋 103 ( 0.0525)2 (5.292 𝑋 10−2 ) [ ( −7
)0.8 ]
28.93𝑋 10
= 0.0037 ( 1.8029) (0.05292) (3193795.056)

= 1127.4577 𝑘𝑐𝑎𝑙⁄
ℎ𝑟 − 𝑚2 − ˚𝐶

Conductance of tube
𝑘 = 39.7 𝑘𝑐𝑎𝑙⁄ℎ𝑟 𝑚 ˚𝐶 from page 267 Table 9 – 1 for Steel

𝑘 39.7 𝑘𝑐𝑎𝑙⁄ℎ𝑟 𝑚 ˚𝐶
= = 10,179.487 𝐾𝑐𝑎𝑙⁄
𝑡 0.0039 𝑚 ℎ𝑟 𝑚2 ˚𝐶
For gas film coefficient Fig. 9 – 6
From PPE by Morse Page 270 Fig. 9.6 Steam film Coefficient indicates the Over – all
coefficient

𝑡𝑔𝐴 + 𝑡𝑔𝐵 1200 + 634.360

𝑡𝑔𝑚 = = = 867.18 ˚𝐶
2 2
By Extrapolation
𝜇 𝑋 10−7 𝑘 𝑋 10−2
400˚C 33.6 4
500˚C 36.25 4.5
867.18 ˚C 45.980 6.3358

𝜇 = 45.980 𝑋 10−7
𝑘 = 6.3358 𝑋 10−2
𝑘𝑔⁄
𝐺𝑠 = 𝐺𝑎𝑠 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 = 𝑢𝑠𝑒 390.6
𝑚2 − 𝑠
From page 279
𝑊𝑔′ = 2 𝑊𝑠′
𝜋𝐷12
𝑊𝑠′ = 𝐺𝑠 ( )
4
𝑘𝑔
= 390.6 ⁄𝑚2 − 𝑠 (𝜋) (0.0525 𝑚)2
4

𝑘𝑔⁄
= 0.846 𝑠
𝑘𝑔⁄
𝑊𝑔′ = 2(0.846) = 1.691 𝑠

Assume
C = 165 mm
S = C – 𝐷0
= 165 – 0.0603 0.1047 m
H = 2.4 m Base on Standard length
𝐴𝑠′ = 𝐻. 𝑆. = 2.4 (0.1047 ) = 0.25128 𝑚2
𝑊𝑔′ 1.6911 𝑘𝑔⁄
𝐺𝑔 = = = 6.7299 𝑚2 − 𝑠
𝐴𝑔′ 0.25128
6.7300
ℎ2 = 0.0841 (0.884) (0.0603)−0.4 (6.3358 𝑋 10−2 ) { [ −7
]0.6 }
45.980 𝑋 10
𝑘𝑐𝑎𝑙⁄
= 0.074244 (3.0752) (0.063358) (5003.428) = 72.47542 ℎ𝑟 − 𝑚2 −˚𝐶

Solving for Heat of Conductance, U

1 1 𝑥 1
= + + ;
𝑈 ℎ1 𝑘 ℎ2
1 1 𝑋 1
= + +
𝑈 1127.4577 10179.487 72.47542
𝑘𝑐𝑎𝑙⁄
𝑈 = 67.6454083 ℎ𝑟 − 𝑚2 −˚𝐶

Solving for Heat from Superheater

𝑄𝑠𝑢𝑝𝑒𝑟ℎ𝑒𝑎𝑡𝑒𝑟 = 𝑈 𝐴 𝐿𝑀𝑇𝐷
𝑘𝑗⁄
= 30795.02 𝑠

𝑘𝑐𝑎𝑙⁄
= 26496671.128 ℎ𝑟

26496671.128
Total Surface Area 𝐴= = 818.63 𝑚2
67.6454 (478.48)
 𝑊𝑠 54.49
Number of elements, 𝑁𝑒 𝑁𝑒 = =
𝑊′𝑠 0.8456

= 64.44 𝑒𝑙𝑒𝑚𝑒𝑛𝑡
𝐴 818.63
𝐴𝑒 = =
𝑁𝑒 64.44
𝑚2
= 12.7038
𝐸𝑙𝑒𝑚𝑒𝑛𝑡

Length of Elements 𝐴𝑒 = 𝜋 𝐷0 𝐿𝑒
12.7038
𝐿𝑒 = = 67.0604 𝑚⁄𝑒𝑙𝑒𝑚𝑒𝑛𝑡
𝜋 (0.0603)
𝐿𝑒 67.060
𝑁𝑡 = = = 27.9416 𝑡𝑢𝑏𝑒𝑠
𝐻 2.4
Number of tubes Say use 28 tubes
𝑊 = 𝑁𝑒 (𝐷0 ) + (𝑁𝑡 + 1)𝑆
= 64.44 (0.0603) + (28 + 1)(0.1047)
Width = 6.92 𝑚
𝑊 = 𝑁𝑡 (𝐷0 ) + (𝑁𝑡 + 1)𝑆
= 28(0.0603) + (28 + 1)(0.1047)
Length = 4.7247 𝑚