Heat Transfer Water Tube Boiler

EXAMPLE OF THERMODYNAMIC CALCULATION OF D-TYPE WATER TUBE BOILER WITH SUPERHEATER AND ECONOMIZER USING BOILER DESIGN SOFTWARE

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HEAT TRANSFER IN BOILER *********************** DATE :MARK :D-TYPE WATER TUBE MAKE :REMARK:DEMO FUEL TYPE: GASEOUS LIQUID : WATER BOILER TYPE: STEAM MAX. ABSOLUTE WORKING PRESSURE: 25 bar BOILER FAMILY: WATER TUBE GAS DATA -------CH4-CONTENT

= 100 vol%

LOWER HEATING VALUE = 35883 kJ/m3 HIGHER HEATING VALUE = 39819 kJ/m3 GAS DENSITY = .716 kg/m3 GAS OVERPRESSURE = 0 mbar ATMOSPHERIC PRESSURE = 1013 mbar GAS TEMPERATURE = 0 dC GAS RATE = 1150 m3/h COMBUSTION AIR TEMP. = 20 dC

BOILER GEOMETRY DATA -------------------FURNACE DATA ............ FURNACE IS HORIZONTAL THERE IS TUBE ARRAY SUPERHEATER IN FURNACE TUBE ROWS HAVE PLAIN ARRANGEMENT TUBE SECTION LENGTH TOTAL TUBE LENGTH NUMBER OF TUBE ROWS DISTANCE BETWEEN TUBE ROWS

= = = =

1.7 m 129.2 m 4 .1 m

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NUMBER OF TUBES IN ROW = DISTANCE BETWEEN TUBES IN ROW= NUMBER OF TUBES LIQUID ENTERS= TUBE OUTER DIAMETER = TUBE WALL THICKNESS =

19 .1 m 19 .0381 m .0032 m

FURNACE WIDTH PERP. TO GAS FLOW FURNACE HEIGHT PERP. TO GAS FLOW WALL THICKNESS LENGTH IN GAS FLOW DIRECTION CROSS SECTION AREA AFTER FURNACE FURNACE COOLED AREA

= = = = = =

2 m 5.1 m .0032 m 6.5 m .385 m2 92.3 m2

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER ...................................... MATERIAL: CARBON STEEL TUBE ROWS HAVE INDENTED ARRANGEMENT LIQUID TEMPERATURE ENTERING ECO = CROSS SECTION IN GAS FLOW DIRECTION= ECO STACK CONNECTOR CROSS SECTION = TUBE SECTION LENGTH = NUMBER OF TUBE ROWS = DISTANCE BETWEEN TUBE ROWS = NUMBER OF TUBES IN ROW = DISTANCE BETWEEN TUBES IN ROW = NUMBER OF TUBES LIQUID ENTERS = TUBE OUTER DIAMETER = TUBE WALL THICKNESS =

102 dC 2.3 m2 .4 m2 2.1 m 19 .1 m 19 .1 m 19 .0381 m .0032 m

OTHER DATA ---------FEED LIQUID TEMPERATURE EXCESS AIR/LAMBDA VALUE

= 102 dC = 1.1 -

STACK CONNECTOR CROSS SECTION AREA TOTAL COOLED AREA

= .385 m2 = 92.3 m2

CALCULATION RESULTS ------------------ADIABATIC COMBUSTION TEMPERATURE RELEASED HEAT BY COMBUSTION CONDENSATE HEAT IN FLUE GAS TEMPERATURE OF LIQUID/STEAM IN BOILER GAS VELOCITY IN BOILER FLUE APERTURE

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= = = = =

1895.5 dC 11549.7 kW 1290.6 kW 224 dC 18.8 m/s


GAS SIDE PRESSURE DROP IN BOILER GAS SIDE PRESSURE DROP WITH ECONOMIZER FLUE GAS RATE THROUGH BOILER BOILER THERMAL OUTPUT STEAM RATE FEED LIQUID RATE AVERAGE AREA THERMAL LOAD PERCENTAGE OF HEAT TAKEN UP IN FURNACE GAS EXIT TEMPERATURE FROM BOILER

= = = = = = = = =

.01 mbar 2.89 mbar 13338.2 m3/h 9746.2 kW 14173.3 kg/h 14816.3 l/h 105.6 kW/m2 100 % 260.2 dC

ECONOMIZER THERMAL OUTPUT GAS EXIT TEMPERATURE FROM ECONOMIZER LIQUID TEMPERATURE FROM ECONOMIZER GAS SIDE PRESSURE DROP IN ECONOMIZER

= = = =

360.4 kW 191.5 dC 123.7 dC 2.89 mbar

EFFICIENCY (BASED ON LOWER FUEL HEATING VALUE - DIN METHOD) BOILER EFFICIENCY BOILER EFFICIENCY WITH ECONOMIZER EFFICIENCY INCREASE BY ECONOMIZER COMBUSTION (STACK) EFFICIENCY FLUE GAS LOSSES FLUE GAS LOSSES

= = = = = =

84.4 % 87.5 % 3.1 % 92.4 % 7.6 % 882.9 kW

EFFICIENCY (BASED ON HIGHER FUEL HEATING VALUE - ASME METHOD) BOILER EFFICIENCY BOILER EFFICIENCY WITH ECONOMIZER EFFICIENCY INCREASE BY ECONOMIZER COMBUSTION (STACK) EFFICIENCY FLUE GAS LOSSES (LATENT HEAT INCLUDED) FLUE GAS LOSSES (LATENT HEAT INCLUDED) BOILER JACKET LOSSES (AS SET BY DIN 4702 T3) BOILER JACKET LOSSES (AS SET BY DIN 4702 T3) HEAT TRANSFER IN FURNACE ........................ STEAM GENERATED GAS EXIT TEMP. MEAN GAS TEMP. AREA THERMAL LOAD VOLUME THERMAL LOAD GAS VELOCITY RADIATION CONVECTION HEAT TRANSFERRED GAS SIDE PRESSURE DROP

= = = = = = = = = =

14782.4 kg/h 260.2 dC 650.8 dC 105.6 kW/m2 174.2 kW/m3 1 m/s 9624 kW 122.1 kW 9746.2 kW .005 mbar

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= = = = = = = =

75.9 % 78.7 2.8 % 83.9 % 16.1 % 2173.5 kW .4 % 57.7 kW


HEAT TRANSFER ON SUPERHEATER (ENERGY CONSUMING PART) SUPERHEATED STEAM TEMPERATURE CONVECTION RADIATION HEAT TRANSFERRED GAS VELOCITY AROUND TUBES STEAM VELOCITY IN TUBES WALL TEMPERATURE ON GAS SIDE WALL TEMPERATURE ON STEAM SIDE GAS SIDE PRESSURE DROP

= = = = = = = = =

262 dC 60.8 kW 340.8 kW 401.6 kW 1.4 m/s 1.258 m/s 534 dC 531.7 dC .003 mbar

HEAT TRANSFER IN TUBE ARRAY ECONOMIZER ...................................... HEAT CONTENT OF ENTERING GASES = HEAT TRANSFERRED = MEAN TEMP. IN ECONOMIZER = LIQUID EXIT TEMP. FROM ECONOMIZER= GAS EXIT TEMPERATURE = GAS VELOCITY AROUND TUBES = LIQUID VELOCITY IN TUBES = WALL TEMPERATURE ON GAS SIDE = WALL TEMPERATURE ON LIQUID SIDE = GAS SIDE PRESSURE DROP =

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1344.3 kW 360.4 kW 219.5 dC 123.7 dC 191.5 dC 8.6 m/s .015 m/s 149.4 dC 149.1 dC 2.89 mbar

Heat Transfer Water Tube Boiler

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