Prepare : CPK PWOG-HZL-6033-PR-RE-001

Review : CPK Rev B

Thermal Design of Water Cooled
Duct Approve : NVR Sheet 1 of 6

Date :09.05.2021

Thermal Design of Water Cooled Duct

OWNER
HINDUSTHAN ZINC LIMITED

PREPARED BY
M/S PWOG PLANT ENGINEERING PVT LTD

B 09.05.2021 ISSUED FOR DESIGN CPK CPK NVR

A 23.04.2021 ISSUED FOR APPROVAL CPK CPK NVR
REV REV DATE PURPOSE PREPD REVWD APPD
 Prepared by Pavan Date Checked VRN Date 9-May-21 Plant HZL, Rajpura
Project Duct Modification Works File
Thermal Design of Water Cooled Duct Sheet 2 of 6

BASIS / SUMMARY

1 Heat transfer calculations were performed to check the length of water cooled duct required to
cool down exhaust gas from 800 ͦC to 300 ͦC.

2 Heat flow profile (heat transfer from high to low temperature):

- Convective heat transfer from exhaust gas to duct wall
- Conduction through duct wall
- Convective heat transfer from duct wall to cooling water

3 Properties and conversions used in calculations are extracted from HYSYS

4 Counter flow configuration of Exhaust gas and cooling water (typical sketches):

Flue Gas In
1780 mm

1600 mm
Cooling Water Out

Cooling Water In

Flue Gas Out

5 Water cooled duct length required to cool exhaust gas from 800 ͦC to 300 ͦC is 26 m

6 Existing water cooled duct length approx. 14 m

7 New water cooled duct required for extension is 12 m.

8 Exhaust Gas Heat loss profile:

Exhaust Gas
Exhaust Gas Exhaust Gas Inlet
Outet Duct Length (m) Remarks
Flow (Nm3/hr) Temperature ͦC
Temperature ͦC

Existing 14m duct

45000 800 500 14 (Refer Attachment 1)
New duct
45000 500 442 3 (Refer Attachment 2)
New duct
45000 442 391 3 (Refer Attachment 3)
New duct
45000 391 340 3 (Refer Attachment 4)
New duct
45000 340 300 3 (Refer Attachment 5)
 Prepared by Pavan Date Checked NVR Date 9-May-21 Plant HZL, Rajpura
Project Duct Modification Works File
Thermal Design of Water Cooled Duct Sheet 3 of 6
1
2 INPUT
3 Duct Jacket
4 Mass flow m kg/hr 52500
5 Inlet temperature T1 °C 800 30.0
6 Outlet temperature T2 °C 300 40.0
7 Heat capacity cp kcal/kg-°C 0.1 1.0
8 Density r kg/m3 0.30 1000
9 Viscosity m cP 0.01 1.00
10 Thermal conductivity k kcal/hr-m-°C 0.19 0.67
11
12 Duct metal thermal condutivity k 34.5
13 Duct OD in 63.4
14 Thk in 0.4
15 Duct ID in 62.6
16 Jacket ID in 70.1 OK
17
18 Rd Duct hr-m-°C/kcal 0.0000
19 RD Jacket hr-m-°C/kcal 0.0000
20
21
22 OUTPUT
23 HEAT BALANCE
24 Duct Jacket
25 Flow rate kg/hr 52500 236250
26 T1 °C 800.0 30.0
27 T2 °C 300.0 40.0
28 Q kcal/hr 2362500
29
30 THERMAL SIZING
31 Area of jacket m2 132.1
32 Length of jacket m 26
33 Duct OD in 62.6
34 Jacket ID in 31.5
35 Ud 38
36 Resistance Jakcet Jacket Rd Wall Duct Rd Duct side
37 10% 0% 1% 0% 89%
38
39 HYDRAULICS Duct Jacket
40 Velocity m/s 24.5 0.1
41 Pressure drop Bar 0.00017 0.00005
42
43
44
45
46
47

A B C D E G H I J K L
 Prepared by Pavan Date Checked NVR Date 9-May-21 Plant HZL, Rajpura
Project Duct Modification Works File
Thermal Design of Water Cooled Duct Sheet 4 of 6
1
2 HEAT BALANCE
3 Duct Jacket
4 Mass flow m kg/hr 52500 236250
5 Inlet temperature T1 °C 800 30
6 Outlet temperature T2 °C 300 40
7 Temperature difference DT °C 500 10
8 Heat capacity cp kcal/kg-°C 0.1 1.0
9 Q Heat flow Q kcal/hr 2362500
10 Density r kg/m3 0.3 1000
11 Viscosity m cP 0.01 1.00
12 Thermal conductivity k kcal/hr-m-°C 0.19 0.67
13
14 LMTD Counter flow
15 Hot end approach DTh °C 760
16 Cold end approach DTc °C 270
17 LMTD °C 473
18
19 Hydraulics
20 Duct OD in 63.4
21 Thk 0.4
22 Duct ID 62.6
23 Jacket ID in 70 OK
24
25 Cross Section Area in m
26 Duct m2 1.9856 Eq dia 62.6 1.590
27 Jacket m2 0.5028 Eq dia 31.5 0.800
28
29 Velocity
30 Duct m/s 24.48
31 Jacket m/s 0.13
32
33 DIMENSIONLESS NUMBERS NRE Pr Pr^1/3
34 dvr/m cpm/k
35 Duct 1297560 0.0 0.25
36 Jacket 104426 5.4 1.75
37
38 jH factor (Kern) jH = (hD/k) * (cpm/k)^(-1/3) * (m/mw)^(-0.14) Nu * (Pr)^(-1/3) * (m/mw)^-0.14
39 Duct From curve 1448 Curve interpolated 1448
40 Jacket From curve 258 Curve interpolated 258
41
42 HT Coeff Ignore m/mw
43 Duct hi = jH * (Pr^1/3)*k/D kcal/hr-m-°C 43
44 Jacket ho = jH/(Pr^-1/3)*k/D kcal/hr-m-°C 378
45
46
47

A B C D E G H I J K L
 Prepared by Pavan Date Checked NVR Date 9-May-21 Plant HZL, Rajpura
Project Duct Modification Works File
Thermal Design of Water Cooled Duct Sheet 5 of 6
1
2 AREA CALULATION
3
4 Ud
5 1/Ud = 1/ho + 1/hi * do/di + Rdi *do/di + Rdo + x/k
6
7 Duct OD do m 1.610
8 Duct ID di m 1.590
9 Duct thickness x m 0.010 RESISTANCE
10 Duct metal thremal conductivity k 35 0.0003 1%
11 Duct side HT coeff hi 43 0.0235 89%
12 Dirt factor in Duct Rdi 0.0000 0.0000 0%
13
14 Jacket side HT coeff ho 378 0.0026 10%
15 Rdo Rdo 0.0000 0.0000 0%
16 0.0265
17 1/Ud = 1/ho + Rdo + x/k + Rdi*do/di + 1/Hi * do/di 0.0265
18 Ud kcal/hr-m-C 38
19
20 Q Heat duty Q kcal/hr 2362500
21
22 LMTD Being true counter current no FT applicable °C 473.5
23
24 Area Reqd m2 132.1
25
26 LENGTH CALCULATION
27 Area m2 132.1
28 Length = A / (p * D) m 26
29
30
31 PRESSURE DROP CALCULATION - Method-1
32 Duct Jacket
33 Dia m 1.590 0.800
34 Cross section area m2 1.9856 0.5028
35 Velocity 24.48 0.1
36 NRE 1297560 104426
37 Friction factor 0.003 0.005
38 Friction loss bar 0.00 0.00
39 Press drop bar 0.000174 0.000054
40
41
42
43
44
45
46
47

A B C D E G H I J K L
 Kern Kern Cal
NRE jH jH
2500 10 24
3000 13 25
4500 20 29
9500 40 41
30000 100 89
45000 150 124
70000 200 181
100000 260 248
130000 300 313
170000 400 397
200000 450 458
400000 800 818
550000 1000 1035

1200

1000
f(x) = − 1.21620638493552E-09 x² + 0.00244947910823692 x + 17.8496805040253
800

600
Column D
Polynomial (Column D)
400

200

0
0
0 00 0 00 0 00 0 00 0 00 0 00
1 00 2 00 3 00 4 00 5 00 6 00