EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

Industry standard 3-pass fire tube boiler

Geometry data input explanation for 3-pass fire tube boiler

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

H E A T T R A N S F E R I N B O I L E R __________________________________________ DATE :MARCH 20, 2013 MARK :MAKE :REMARK:DEMO FUEL TYPE: GASEOUS BOILER LIQUID BOILER BOILER BOILER BOILER TYPE: HOT LIQUID : WATER FAMILY: FIRE TUBE DESIGN: 3-PASS LOAD: 100% MATERIAL: CARBON STEEL

GAS DATA ________ N2-CONTENT CH4-CONTENT C2H6-CONTENT C3H6-CONTENT C4H10-CONTENT C5H12-CONTENT C6H14-CONTENT C7H16-CONTENT C8H18-CONTENT LOWER HEATING VALUE HIGHER HEATING VALUE GAS DENSITY GAS OVERPRESSURE ATMOSPHERIC PRESSURE GAS TEMPERATURE GAS RATE BOILER GEOMETRY DATA ____________________ FURNACE GEOMETRY DATA _____________________ FURNACE IS HORIZONTAL FURNACE IS CIRCULAR IN GAS FLOW DIRECTION THERE IS CIRCULAR TURNAROUND CHAMBER AT FURNACE EXIT = = = = = = = = = = = = = = = = 2.29 vol% 91.6 vol% 3.15 vol% 1.65 vol% .89 vol% .24 vol% .07 vol% .07 vol% .04 vol% 38237.3 kJ/m3 42283.4 kJ/m3 .796 kg/m3 0 mbar 1013 mbar 0 dC 1500 m3/h

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

INNER DIAMETER WALL THICKNESS LENGHT IN GAS FLOW DIRECTION CROSS SECTION AREA AFTER FURNACE INNER DIAMETER OF TURNAR. CHAMBER TURNAROUND CHAMBER LENGHT TURNAROUND CHAMBER COOLED AREA INNER TUBESHEET COOLED AREA

= = = = = = = =

1.888 m .016 m 5.47 m .491 m2 2.25 m .7 m 7.198 m2 2.25 m2

FURNACE COOLED AREA = 44.542 m2 BOTTOM COOLED AREA PER.TO GAS FLOW= 4.9 m2 GEOMETRY DATA OF FIRST TUBE ASSEMBLY ____________________________________ TUBES ARE HORIZONTAL NUMBER OF TUBES TUBE INNER DIAMETER WALL THICKNESS COOLED TUBE LENGHT COOLED AREA CROSS SECTION AFTER TUBES = = = = = = 92 .0825 m .0032 m 5.47 m 130.43 m2 2.5 m2

GEOMETRY DATA OF TURNAROUND CHANNEL ___________________________________ CHANNEL IS HORIZONTAL IN GAS FLOW DIRECTION CHANNEL WIDTH PERP. TO GAS FLOW CHANNEL HEIGHT PERP. TO GAS FLOW WALL THICKNESS COOLED AREA LENGHT IN GAS FLOW DIRECTION CROSS SECTION AFTER CHANNEL GEOMETRY DATA OF SECOND TUBE ASSEMBLY _____________________________________ TUBES ARE HORIZONTAL NUMBER OF TUBES TUBE INNER DIAMETER WALL THICKNESS COOLED TUBE LENGHT COOLED AREA = = = = = 62 .0825 m .0032 m 6.29 m 101.076 m2 = = = = = = 3.2 m .8 m .018 m 2 m2 .4 m .331 m2

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

CROSS SECTION AFTER TUBES

= 2.5 m2

GEOMETRY DATA OF CHANNEL AT BOILER EXIT _______________________________________ CHANNEL IS HORIZONTAL IN GAS FLOW DIRECTION CHANNEL WIDTH PERP. TO GAS FLOW CHANNEL HEIGHT PERP. TO GAS FLOW WALL THICKNESS LENGHT IN GAS FLOW DIRECTION COOLED AREA OTHER DATA __________ COMBUSTION AIR TEMPERATURE TEMP. OF LIQUID ENTERING BOILER LIQUID EXIT TEMPERATURE FROM BOILER EXCESS AIR/LAMBDA VALUE STACK CONNECTOR CROSS SECTION AREA TOTAL COOLED AREA TUBES/FURNACE AREA RATIO CALCULATION RESULTS ___________________ ADIABATIC COMBUSTION TEMPERATURE RELEASED HEAT BY COMBUSTION CONDENSATE HEAT IN FLUE GAS LIQUID RATE THROUGH BOILER LIQUID RATE THROUGH BOILER GAS VELOCITY IN BOILER FLUE APERTURE GAS SIDE PRESSURE DROP IN BOILER FLUE GAS RATE THROUGH BOILER BOILER THERMAL OUTPUT AVERAGE AREA THERMAL LOAD PERCENTAGE OF HEAT TAKEN UP IN FURNACE GAS EXIT TEMPERATURE FROM BOILER = = = = = = = = = = = = 1845 dC 16057.7 kW 1756.4 kW 474837 kg/h 489854 l/h 18.9 m/s 12.689 mbar 19170.7 m3/h 14409.7 kW 51.5 kW/m2 52.73 % 212.5 dC = = = = = = = 20 dC 71 dC 97 dC 1.15.5 m2 280.048 m2 5.2 = = = = = 3.2 m .8 m .018 m .4 m 2 m2

EFFICIENCY (BASED ON LOWER FUEL HEATING VALUE - DIN METHOD) BOILER EFFICIENCY COMBUSTION (STACK) EFFICIENCY FLUE GAS LOSSES FLUE GAS LOSSES = = = = 89.7 % 91.1 % 8.9 % 1422.1 kW

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

EFFICIENCY (BASED ON HIGHER FUEL HEATING VALUE - ASME METHOD) BOILER EFFICIENCY 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 ________________________ GAS EXIT TEMP. MEAN GAS TEMP. AREA THERMAL LOAD VOLUME THERMAL LOAD GAS VELOCITY RADIATION CONVECTION HEAT TRANSFERRED GAS SIDE PRESSURE DROP = = = = = = = = = 1030.3 dC 1395.7 dC 170.6 kW/m2 887.3 kW/m3 10.4 m/s 4854.2 kW 2564.2 kW 7598.7 kW .03 mbar = 5158.6 kW = 206.8 dC = = = = = = 80.9 % 82.3 % 17.7 % 3178.5 kW .5 % 80.3 kW

HEAT TRANSFER ON CIRCULAR PART WALL TEMP. OF CIRCULAR PART

HEAT TRANSFER IN FURNACE TURNAROUND CHAMBER HEAT TRANSFER ON REAR WALL REAR WALL TEMPERATURE HEAT TRANSFER ON INNER TUBESHEET INNER TUBESHEET WALL TEMPERATURE HEAT TRANSFER ON CIRCULAR PART WALL TEMP. OF CIRCULAR PART = = = = = = 2206.6 kW 417.5 dC 233.5 kW 216.5 dC 539.4 kW 171 dC

HEAT TRANSFER IN FIRST TUBE ASSEMBLY ____________________________________ GAS EXIT TEMP. MEAN GAS TEMP. AREA THERMAL LOAD GAS VELOCITY RADIATION CONVECTION HEAT TRANSFERRED WALL TEMP. ON GAS SIDE WALL TEMP. ON LIQUID SIDE GAS SIDE PRESSURE DROP = = = = = = = = = = 409.5 dC 665.7 dC 40.5 kW/m2 37.2 m/s 518.7 kW 4769.5 kW 5288.2 kW 114.2 dC 111.7 dC 5.09 mbar

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

HEAT TRANSFER IN TURNAROUND CHANNEL ___________________________________ GAS EXIT TEMP. MEAN GAS TEMP. GAS VELOCITY AREA THERMAL LOAD RADIATION CONVECTION HEAT TRANSFERRED WALL TEMP. ON GAS SIDE WALL TEMP. ON LIQUID SIDE GAS SIDE PRESSURE DROP = = = = = = = = = = 406.9 dC 408.2 dC 5.2 m/s 10.5 kW/m2 4.99 kW 16.08 kW 21.1 kW 99.2 dC 95.5 dC .02 mbar

HEAT TRANSFER IN SECOND TUBE ASSEMBLY _____________________________________ GAS EXIT TEMP. MEAN GAS TEMP. AREA THERMAL LOAD GAS VELOCITY RADIATION CONVECTION HEAT TRANSFERRED WALL TEMP. ON GAS SIDE WALL TEMP. ON LIQUID SIDE GAS SIDE PRESSURE DROP = = = = = = = = = = 213.3 dC 295.6 dC 14.8 kW/m2 33.5 m/s 46.1 kW 1449.4 kW 1495.4 kW 98.2 dC 97.4 dC 7.21 mbar

HEAT TRANSFER IN CHANNEL AT BOILER EXIT _______________________________________ GAS EXIT TEMP. MEAN GAS TEMP. AREA THERMAL LOAD GAS VELOCITY RADIATION CONVECTION HEAT TRANSFERRED WALL TEMP. ON GAS SIDE WALL TEMP. ON LIQUID SIDE GAS SIDE PRESSURE DROP = = = = = = = = = = 212.5 dC 212.9 dC 3.1 kW/m2 3.7 m/s 1.03 kW 5.23 kW 6.3 kW 99 dC 94 dC .347 mbar

EXAMPLE OF HEAT TRANSFER CALCULATION OF 3-PASS FIRE TUBE BOILER WITH BOILER DESIGN SOFTWARE

Flue gas enthalpy diagram

Flue gas temperature course in boiler