Steam Boiler Design

Developed Boiler Horsepower

(m𝑠+𝑚𝑚)(ℎ1−ℎ12)
DBH = 35322
1.02 ( 51.89302
49.685 ) ( 3600 ) ( 2747.05
2754.9 − 838.95
852.45 )
DBH =
35322
DBH =10220.77588
9849.677 boiler hp
Rated Boiler Horse Power
DBH
BR =
RBH
x100% BR = Boiler Rating (100% to 150%)

115%
Use 120%

9849.677
10220.77588
RBH =
1.15
1.2
RBH =8887.6312
8208.064 boiler hp
Heating Surface of Boiler Tube

RBH = 𝐻.𝑆. H.S = Boiler Heating Surface

𝑘 k = 0.91 for water tube boiler
H.S. = 8887.6312
8208.064 ( 0.91 )
7469.338 m2
=8087.74439
Total Number of Tubes
From page 8-187 Table 8.7.23 of Mark’s Mechanical Engineering Handbook

Do Schedule # thickness
2“ 0.060325 m 40 3.91 Use L = 20 ft = 6.098 m
H.S. = π do Lt nt
8087.74439
nt 7469.338
=
( 3.1416 ) ( 0.060325 ) ( 6.098 )
6999
nt = 6463.20
6998.28747 tubes = 6464 tubes

Choose the appropriate types and design of boiler

John Mark P. Asuncion ME-4A

 Furnace Design
Qf = 109110.44
117979.7863 kj/s = 93880875.717
101468591.6 kcal/hr Computed heat of fuel

Qa = 2593.83014
3465.32 kj/s = 2981632.887
2230825.291 kcal/hr Computed heat of
fuel
QT = Qf + Qa = 96862508.6
103699416.9 kcal/hr

Area of Furnace
Q t
A =
HRR
1300000 675,000 to 1,350,000 kcal
page 314
m2hr

Use 1,200,000
1,250,000 kcal

96862508.6
103699416.9 m2hr
A= = 94.27220
77.49 m2
1250000
1,100,000

A = l x w But L = 1.25 w

A = 1.25 w (w)

A
W=√
94.27220
77.49
1.25 = W = √ 1.25

W= 7.87
8.68434 m L =10.85618
9.84 m
Volume of Furnace
𝑄𝐹uel and air 𝑄
V = HRR 𝐹uel and air
volume = HRR volume

HRR for small plant

133,500 to 445,000 kcal

kcal
m2hr page 314 Use 400,000
450,00 m2hr

( 101468591.6
93880875.717 + 2230825.291
2981632.887 )
V=
450000
400,000 = 215.2500
259.24854 m3

Height of Furnace

V 215.2500 m3
H= = 259.24854 2.75000
A 94.27220 = 2.7778 m
77.49 m2
 Design of Stack

To get ⍴air and ⍴flue gas

⍴a and ⍴g
P
⍴a =
RT
tdb = 32
Tdb = 305
324.66834
tgD = 397.49
TgD = 597.66834
670.49 K

⍴a = 101.325
= 1.158
1.15754 kg/m3
0.287 ( 305 )

⍴g = 0.5733
0.64437 kg/m3 from Fuel and Combustion

wg
Vg = 42.02
45.43407 𝐦𝟑
⍴g = 73.295
70.50929
0.5733
0.64437 𝐬
For Economical Size of Stack

Choose the minimum velocity

Vg = 15.21 m/s See economical stack for actual velocity of gas The
lowest point in the curve
Dm = 0.004 Vg2 ⍴g page 495 mechanical draft
Dm = 0.004 ( 15.21 ) 2 (0.64437
0.5733 ) = 0.530
0.59628 cm
Ds = 2 cm static draft
DT = 2 + 0.59628
0.530
DT = 2.530
2.59628 cm Total draft
g5
D30 = k ( ⍴a - ⍴g ) - 0.007578 ⍴a √ V Diameter of Stack
Vg

K = 2.4 for steel stacks

15.212
D30 = 2.4 ( 1.15754
1.158 -
0.64437
0.5733 ) - 0.007578 ( 1.15754
1.158 ) √
108.616
70.50929

D30 = 1.23161
1.4028 - 0.0087718
0.008715 (1.81137
1.78 ) = 1.21572
1.3865 m
Height of Stack
Dt
( )
2.59628
H =
D30 ( 10 = 1.21572
1.3865
2.530 10

H = 18.2474
21.35590
m The height should be higher than the tallest
structure in the vicinity use 10
Diameter of Stack
𝜋
Vg = A Vg = D 2 Vg
4
4Vg 4 (70.50929
73.295 )
D = √πV = √
𝜋 ( 0.7854 ) ( 15.21 )
g
D = 2.48
2.42948 m

Assume 1⁰ angle
x = H tan 1⁰
x = 21.35590
18.25 tan 1⁰
x = 0.32
0.37277 m

Dbase = D + 2 x = 2.48
2.42948 + 2 (0.37277
0.32 )
Dbase = 3.12
3.17502 m