Design of Steam Boiler

Developed Boiler Horsepower

(𝑚𝑠 + 𝑚𝑚 (3600)[(ℎ1 − ℎ12 )]
𝐷𝐵𝐻 =
35322
1.02(54.49)(3600)[(2778.45 − 828.46)]
=
35322
=11025.77 𝐵𝑜. 𝐻𝑝.
Rated Boiler horsepower
𝐷𝐵𝐻 11025.77
𝐵𝑅 = 𝑋100% 𝑅𝐵𝐻 =
𝑅𝐵𝐻 120

= 116.3102396 𝐵𝑜. 𝐻𝑝.

Where BR= Boiler rating (100% to 150% say use 150%)

Heating Surface of Boiler Tubes

𝐻. 𝑆.
𝑅𝐵𝐻 =
𝐾
Where:
H.S.= Boiler Heating Surface
K = 0.91 for water Tube
= 1.0 for fire tube
From PPE by Morse page 295
H.S. = 116.3102 (0.91)
= 105.8423 𝑚2

Total number of tubes

From page 8-187 Table 8.t.23 of Mark’s Mechanical Engineering
Handbook
𝐷0 Schedule # Thickness (mm)
2” = 0.060325m 40 3.91
𝑈𝑠𝑒 𝐿 = 20 𝑓𝑡 = 6.098 𝑚
𝐻. 𝑆. = 𝜋𝑑0 𝐿𝑡 𝑛𝑡

105.842318
𝑛𝑡 =
𝜋(0.060325)(6.098)
= 91.5915 𝑡𝑢𝑏𝑒𝑠 𝑆𝑎𝑦 92 𝑇𝑢𝑏𝑒𝑒𝑠
Note: Lay-out the tube and choose best design fitted for the plant see page.

Design of Furnace
Computed heat of fuel Energy – in Make- up Water
𝑄𝑎 = 2958.64kJ/S = 2,545,674.95 Kcal/hr
Computed heat of fuel Energy – in Heat from Air.
𝑄𝑓 = 135,489.21KJ/S = 116,577,714.15Kcal/hr
Solving for Total Heat, 𝑄𝑡
𝑄𝑡 = 𝑄𝑓 + 𝑄𝑎 = 116,577,714.15 + 2,545,674.95
= 119,123,389.1 Kcal/hr

Area of Furnace
From page 314, PPE by Morse
𝑄𝑡
𝐴=
𝐻𝑅𝑅
HRR ranges from 675,000 to 1,350,000 Kcal/𝑚2 − ℎ𝑟
Use 1,350,000 Kcal/𝑚2 − ℎ𝑟

Substitute Value
 119,123,389.1
𝐴= = 108.2940𝑚2
1,100,000
But A = L X W ; L = 1.25W then A = 1.25𝑊 2
Solving for W,

𝐴 108.29
𝑊 = √1.50 = √ 1.50
= 8.497 𝑚 ; 𝐿 = 12.7455 𝑚

Volume of Furnace
From page 314, PPE by Morse
𝑄𝐹𝑢𝑒𝑙 & 𝐴𝑖𝑟
𝐴= HRR ranges from 133,500 to 445,000 𝐾𝑐𝑎𝑙⁄𝑚2 − ℎ𝑟
𝐻𝑅𝑅𝑉𝑜𝑙𝑢𝑚𝑒

Use 300,000 𝐾𝑐𝑎𝑙⁄𝑚2 − ℎ𝑟

Substitute Value
𝑄𝑓𝑢𝑒𝑙 + 𝑄𝑎𝑖𝑟 116,577,714.15 + 2,454,674.95
𝑉= = = 440,781 𝑚3
𝐻𝑅𝑅𝑣𝑜𝑙𝑢𝑚𝑒 270,255 𝐾𝑐𝑎𝑙⁄𝑚2 − ℎ𝑟

Height of Furnace
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐹𝑢𝑟𝑛𝑎𝑐𝑒 440.781 𝑚3
𝐻= = = 4.0701 𝑚
𝐴𝑟𝑒𝑎 𝑜𝑓 𝐹𝑢𝑟𝑛𝑎𝑐𝑒 108.29 𝑚2

Design of Stack

Solving for 𝑃𝐴𝐼𝑅 , 𝑃𝑎 and 𝑃𝐹𝑙𝑢𝑒𝑔𝑎𝑠 , 𝑃𝑔

𝑡𝐷𝐵 = 32˚𝐶 ; 𝑇𝐷𝐵 = 305 𝐾
𝑡𝑔𝐷 = 616.74˚𝐶 ; 𝑇𝑔𝐷 = 889.89 𝐾
 𝑃 101.325 𝑘𝑔
𝑃𝑎 = = = 1.158 ⁄ 3
𝑅𝑇 0.287(305) 𝑚

𝑃𝑔=0.536 𝑘𝑔⁄ 𝑓𝑟𝑜𝑚 𝑐𝑜𝑚𝑏𝑢𝑠𝑡𝑖𝑜𝑛 𝑜𝑓 𝐹𝑢𝑒𝑙

𝑚3 ,

Solving for Discharge of gas, 𝑉𝑔

𝐾𝑔𝐹𝑙𝑢𝑒 𝑔𝑎𝑠⁄
𝑊𝑔 = 51.85 𝑠𝑒𝑐 ,
From 3nd Checking, Superheater
𝑊𝑔 51.85 3
𝑉𝑔 = = = 96.735 𝑚 ⁄𝑠𝑒𝑐
𝑃𝑔 0.536

Tabulation for Economical Size of Stack

x V H, m D, m HxD x V H, m D, m HxD
1 1 33.29 10.25 341.20 9 9.15 41.90 4.47 187.18
2 2 33.46 7.59 254.13 10 10.16 44.95 4.42 198.69
3 3 33.80 6.43 217.24 11 11.18 48.96 4.43 216.74
4 4 34.34 5.74 197.18 12 12.19 54.22 4.50 243.78
 5 5 35.10 5.29 185.66 13 13.21 61.47 4.65 285.64
6 6.1 36.26 4.95 179.29 14 14.21 71.67 4.91 352.05
7 7.12 37.68 4.72 177.92 15 15.21 87.23 5.37 468.7
8 8.13 39.52 4.57 180.47
Choose the Minimum H x D use 7.12 m/s se graph
From the graph of Economical size of stack, page the actual velocity of gas at
lowest point in the curve yield to
𝐷𝑚 = 0.004 𝑉 𝑣 2 𝑃𝑔 , page 495 for Mechanical Draft
Substitute value
𝐷𝑚 = 0.004(7.12)2 (0.536) = 0.109𝑐𝑚
𝐷𝑠 = 𝑆𝑡𝑎𝑡𝑖𝑐 𝐷𝑟𝑎𝑓𝑡 𝐿𝑒𝑡 𝑢𝑠𝑒 2 𝑐𝑚
Solving for Total Draft, 𝐷𝑇
𝐷𝑇 = 𝐷𝑆 + 𝐷𝑀 = 2 + 0.109 = 2.109 𝑐𝑚
Solving for Draft for stack, 𝐷30

𝑉𝑔2
𝐷30 = 𝑘(𝑃𝑎 − 𝑃𝑔 ) – 0.007578 𝑃𝑎 √
𝑉𝑔

k for Steal Stack = 2.4

Substitute Value

(7.12)2
𝐷30 = 2.4(1.158 − 0.536) − 0.007578(1.158)√
96.735

𝐷30 = 1.4928 − 0.008771535(13.7533) = 1.3721 𝑚

Height of Stack
The height should be higher than the tallest structure in the vicinity say use factor of 10
𝐷𝑇 2.496
𝐻= (20) = (20) = 30.74 𝑚
𝐷30 1.3721
Diameter of Stack
𝛿𝑔 = 𝐴 𝑉𝑔 = 0.7854𝐷2 𝑉 𝑔
 96.735
𝐷=√ = 4.16 𝑚
7.12

Assume 1˚ angle
X = H tan 1˚ = 30.74 tan 1˚ = 0.54 m
Solving for diameter of Base
𝐷𝐵𝑎𝑠𝑒 = 𝐷 + 2𝑋
= 4.16 + 2 (0.54)
= 5.24 m