:-

G
t10T
EXTRACTED SATURATED
GAS STEAM

0
APPROX.
900'F.
.....
z
0
a::
u..
2 3 --+ ETC. ZONES
SECTION "A- A"
PROCESS GAS OUT
OF Tt11RD PASS
(APPROX. 70% OF TOTAL)

a::
<
w
a::
SECOND PAss/
BOILER TUBES
r
I'
Fig. !-Manufacturers have offered boilers with heat transfer areas differiug by almost 100 perceut.
New Way-to Design Firetube Reactors
A satisfactory design method for
firetube reactors and boilers must show
the effect of furnace diameter, tube
diameter and the length of each. Such
a relationship is devised for a boiler
burning acid gases in a sulfur plant.
Method will apply to other processes
Antonio R. Valdes
Brown & Root, Inc., Houston
A RIGOROUS COMPUTATIONAL METHOD is proposed for
designing firetube reactors and boilers. Boiler manufac-
turers apparently use different "rules of thumb" when
quoting on a boiler burning ac.id gas in a sulfur plant.
On the basis of identical sulfur plant process require-
ments, boiler manufacturers have offered boilers with heat
transfer areas differing by almost 100 percent in some
cases, and about the same difference in cost. For this
reason, a generalized solution is developed.
The computational method described is specific to
sulfur plant boilers. However, it is not difficult to see how
the same procedure could apply to any process where
both radiant and convection heat transfer are removed
by the generation of steam. The method investigates the
effect of furnace diameters, tube diameters, and the
length of each in arriving at a satisfactory design.
FIRETUBE BOILER FOR SULFUR PLANT
It is proposed to derive the r ~ q u i r e d heat transfer area
of a firetube boiler for a sulfur plant. Since most sulfur
plants are designed on the basis of the Claus process or
its modification, this process will be considered to set
process conditions.
Briefly, the Claus process is based on producing ele-
mental sulfur by burning hydrogen sulfide under precisely
controlled conditions to achieve an H2S/S02 ratio of
2 to 1 in the products of combustion, and subsequently
reacting these gases in the presence of a suitable catalyst
to remove an additional amount of sulfur. Cooling after
each reaction condenses out the bulk of the sulfur formed.
Part of the cooling of the combustion flue gases is effected
by the generation of steam in a multi-pass firetube reactor
boiler. This paper deals with the design of this firetube
boiler.
The design is limited to a three-pass firctube boiler.
The first pass will consist of a tunnel furnace with an
acid gas burner at one end and a reversing chamber at
the other end. The second pass will consist of straight
lEW WAY TO DESIGN KtA\..IUK.;)
ubes rolled into both the front and rear tubesheets. The
mtlet of the second pass is located at the firing end of
the boiler. At this point approximately 30 percent of
gas passing through the first and second pass the botler
is removed and is used as a source of heat m another
section of the plant. The remaining 70 percent of the flue
gases is cooled further in the third pass tubes as shown
in Figure 1.
From a process standpoint, it is the
process gas be cooled from the theoreucal tem-
perature (the flame temperature) to the extractwn tem-
perature at the outlet of the second This
temperature is arbitrarily fixed and 1s approximately
900 F.
From a mechanical standpoint in the construction of
the boiler it is required that the length of the first pass
tunnel fu:Oace equal the length of the tubes employed in
the second and third passes.
These two restrictions, plus a further requirement that
the total pressure drop through the three passes not ex-
ceed a predetermined set value, will be the basis in ar-
riving at a satisfactory design.
It will be shown that there may be a great many pos-
sible tunnel diameters and tunnel lengths that, together
with various tube diameters, satisfy the restrictions im-
posed upon the solution. Each case will yield a different
intermediate temperature out of the tunnel and
each should result in a different unit cost.
GENERAL MOHOD OF DESIGN
Both the tunnel and tube passes will be divided into
known temperature zones. Expressions for radiant and
convection heat transfer in each zone will be established
in terms of the unknown area. It will be shown that the
area is the only unknO'I.vn and can be readily calculated.
Summation of the areas in each zone can then be made.
In the tunnel, zones will be taken from the burner end
to the outlet of the tunnel furnace. In the second pass,
zones will be taken from the inlet to the second pass (i.e.
outlet of tunnel) to the outlet of the second pass.
A satisfactory, or-more precisely-a possible, solution
to the problem is one resulting in equal tube and tunnel
lengths and also identical temperatures at the outlet of
the tunnel. The differential temperature across each zone
can be made as small as is desired. The smaller the zone,
the more accurate the results because of linear interpola-
tion of physical properties of the gaseous constituents.
The following assumptions will be made in the solution
of this problem:
The gas composition is known and . .from
the burner end of the tunnel to the outlet of the third
pass. (This is not strictly true as gas composition is a
function of temperature.)
The sulfur dew point temperature is known.
Heat transfer to the ambient surroundings is negligi-
ble.
224
..:Jt:l..Uuuu. ... ! - - -
terialS around the burner throat is negugwu:; .
The pressure level of the steam to be generated is
known.
Percentage of hydrocarbons and mercaptans in
acid gas is small-less than 2 percent by volume; the1r
presence, however, will be taken into account.
Temperature desired at the outlet of the second
pass is also known.
The general equation describing the steady state
ing transfer in Zone No. 1 of the tunnel furnace 1s
given by:
Q gl = (Qcsl)Ciame + (Qcallcaa + (Qcollconvecllon =
M (Cp)F(TF- 525)- M(Cp)
1
(T
1
- 525) + W.(hF- hl)
( 1)
where Qg
1
= Total heat given up by (i.e., removed from) gases
passing through the furnace in Zone I .
( Qcu) = Heat received by the tunnel furnace surface (cold
surface) from the source designated.
M = Total flow of process gas, but excluding sulfur
vapor (mols/hr).
( C ) F = Mean molal heat capacity for the gas at flame tern.
P perature, Tr, based on a reference temp. of 525R
(Btu/lb mol R)
( Cp)
1
= Mean molal heat capacity for the gas at the tem-
perature out of Zone I, T
11
based on a reference
temp. of 525 R (Btu/lb mol
0
R)
W
8
=Weight of sulfur vapor present in Zone 1 (lbs/hr)
hF = Heat capacity of sulfur vapor at the flame temper
ature (Btu/lb)
h
1
=Heat capacity of sufur vapor at the temperature
out of Zone No. 1 (Btu/lb)
Heat Transfer from a Luminous Flame: (Qm) cJame
Since, in sulfur plant reactor furnaces, the amount of
hydrocarbons is small and there is very little formation
of free carbon in the flame occasioned bv molecular break-
. down of high molecular weight it will be
assumed that radiation from flame luminosity is negligible,
i.e., (QCBl) 0.
Heat Transfer from Hot Gases: (Qr.s t) sna This is the
radiant heat transfer to the tunnel surface by the gas. It
has been shown that radiation from ,non-luminous gases
is due primarily to gases containing an asymetrical molec-
ular configuration.
1
In this particular case, the gases in-
volved are H20, C02, S02 and H2S.
Information in the literature on the radiation of gases
is available in two forms. In one form the rate of gaseous
radiation to absolute zero (Btujsq ft-hr ) is plotted as a
function of temperature and a parameter equal to the
product of the partial pressure of the gaseous constituent
and the average length of radiating beam.
In the other form, the emissivity of the gas is plotted
as a function of the same independent variables, tempera-
ture, partial pressure, and average length of radiating
beam. These emissivities are then applied as factors in the
Stefan-Boltzman equation.
HYDROCARBON PROCESSING
'
ln thts solutton, data plotted in the form of the first
method will be employed. Plots are available for H20,
C0
2
and S0
2

3
Because of the similarity of H2S and
H
2
0, H
2
S values will be taken from correlation plots
based on water.
\. The equation of radiant heat transfer from each gaseous
I
T
I
constituent to the surface is then:
(2)
where: e
8
=emissivity of the wetted surface of the tunnel.
(Wetted because the metal wall temperature is
below the sulfur dew point.)
S
1
=gas radiation as read from the aforementioned
plots and taken at an arithmatic average tem-
perature in the zone.
s. = radiation read from the aforementioned plots, but
taken at the surface temperature of the tunnel
(in this case, the sulfur dew point), and repre-
sents the amount of radiation from the surface
that is reabsorbed by the gas.
Notice (Qcs t) gns as well as the right-hand side of Equa-
tion ( 1) cannot be evaluated until the temperatures de-
fining Zone No. 1 are fixed. To dci this, the flame tem-
perature must first be determined by a heat balance in
which the net heat of reaction of all combustibles or re-
actants is set equal to the sensiole heat gained by the
products of reaction. The equation is derived by starting
with the heat capacity for the gas mixture.
i-= m
(Cp)
1
= 1: (m.f.)
1
(Cp)t,l
i=l
(3)
Where: ( Cp)
1
= Mean Molal Heat capacity for the gas mixture
at temperature, Tv based on a reference tem-
perature of 525 R (Btu/lb mol -F).
(m. f.)
1
=Mol fraction of each gaseous component
Then the heat balance becomes:
l=r
r, R
1
(t. H)
1
= M (Cp)t (T
1
-TR) + W
8
(h
1
-hR)
l : !
(4)
Where: R
1
= Quantity of each component in the acid gas fe ed
that undergoes a chemical change (mols/hr)
Also

1
=Standard heat of reaction for each of the re-
actants, R" (Btu/lb mol)
T t = Trial temperature which must be varied until both
sides of equation are equal (
0
R)
T R = 525 R; reference temperature on which the Mean
molar heat capacity values are based; i.e., 65F.
h
1
= Heat capacity of superheated sulfur vapor at tem-
perature T
1
.
hn =Heat capacity of sulfur at 65F. (This value is so
small by comparison to other values that it can be
assumed to be zero for this calculation).
(Cp)t ,t =a+ (b/2)(T
1
+TR)-
(c/3)(T
1
2
+ T
1
Tn+Tn
2
) - d(l!1\TR) (5)
Where: ( Cp) u, = Mean molal heat capacity for each com-
ponent between reference temperature 525
0
R and the trial temp. T t (in degrees Ran-
kine)
May 1965, Vol. 44, No. 5
and values of a, b, c and d are:
4
a b c d
C0
2
10.34 0.00152
634,0(
H
2
S 7.15 0.00184
Nz
6.45 0.00080 0.025 X JQ-6
HP
6.95 0.00180 0.100 X lQ-6
S0
2
11.4 0.000786 640,0
Thus, the equation with which the flame temperatun is
determined is given by:
R1 (Cnlt,t] (T1 - - Tn ) + w . 1
; )
Where: r = the number of reactants
i = i-th. reactant or i-th product
m = the number of products excluding sulfur vapor
t = t-th. trial
.
Heat Transfer by Convection ( Q
081
) c-o nv.
(Qculcom. = UlAl (MTD)
Since the temperature limits of Zone No. 1 are arbitra ly
fixed, ( MTD) can be calculated. A
1
is the unknown to
be determined, and U
1
must be evaluated as follows:
l I
h + rg! + rm + r . + -h
g
where: hg = gas film coefficient
h
8
= steam film coefficient = 2,000
rgr =fouling resistance on the gas side= 0.0050
r
6
= fouling resistance on the steam side= 0.0005
rm = thermal resistance through metal wall = 0.0001
All values are assignable, with the exception of hg.
h. =l6.6(Go.) [ (Cnh+ (Cp)l]
g n o.z 2
G =Mass velocity inside of tube O!"tunnel (lb/ sec-sq ft )
D =Tunnel or tube diameter (i nches )
7)
l)
It be apparent at this point that the generali :d
equation for heat transfer in Zone No. 1 has the for 1:
M (Cp) F (TF-TR)-M (Cp)
1
(T
1
-Tnl +w. (hF-h
1
)=
I = rn
Al 1: es (St- Ss) + UlAt (MTD) 1
l =l
The only unknown in this equation is A
1
and it can >e
solved rigorously. For Zone No. 2, the' correspond tg
relation is:
l =m
1: t
8

( MTD)
2
( J)
l=l
Here again, the only unknown is A
2

The length of each zone can be determined soot iS
each zone area is known, i.e. ,
Thus, the iterative procedure can be continued until te
'-lEW WAY TO DESIGN FIRETUBE REACTORS . . .
length of the tunnel, as determined by the sum of the
zone lengths, equals or is plus or minus a few previously
assigned inches from the assumed tunnel length.
At this point, a tunnel diameter, length and the tem-
perature of the gas leaving the tunnel should be recorded
and serve as the basis for investigating the second pass
tubes. This is accomplished by picking a tube diameter
and arbitrarily setting a trial mass velocity. Setting the
allowable pressure drop to 1.00 psi. Applying the follow-
ing expression for pressure drops inside of tubes (TEMA,.'
Section 8, 3rd Edition ) will permit a check of the selected
mass velocity.
= 5 ( y [ + 0.0416 ( J (11)
where: t.P = Pressure drop (lb/sq in)
N
1
= Number of tube passes = one in this case
L =Tube length (feet)
GT =Mass velocity through tubes (lb/hr sq ft )
p =Density (lb/cu ft )
d
1
=Inside diameter of tube (inches)
f
1
=Friction factor inside tubes
rp = ( Z!Zw)
0

14
=Viscosity correction factor inside tubes
based on turbulent flow
Z =Viscosity at the mean fluid (centipoise)
Z.,. = Viscosity at mean tube wall temperature ( centi-
poise)
The factor f
1
must be read from the standard correlation
of f
1
vs. the Reynolds Number:
0.0344d
1
GT
Re =
(12)
If the selected mass velocity, in conjunction with the
previously chosen tube diameter and length results in a
pressure drop in excess of 1.00 psi, a lower mass velocity
must be tried and both Re and AP recalculated, until a
satisfactory value of G is found. When a satisfactory mass
velocity has been obtained, the number of tubes is im-
mediately known by:
K
2
= (M) (M.W.)
GT (al)
(13)
where: N
2
=Number of tubes
a
1
= Inside area of one tube (sq ft)
M = Mols/ hr of gas flowing, as defined earlier
M.W. = Mol ecular weight of the gas.
About the author
ANTONIO R. VALDES is a process engi-
nee?' with Brown & Root, Inc. He re-
ceived a B.S. degree in chemistry from
the University of California and a B.S.
degree in chemical engineering from
The University of Texas. His industrial
experience includes three years as as-
sistant plant superintendent with Jabo-
nera del Pacifico and project engineer-
ing responsibility with Texas Gulf
Sulphur Co. and Filtrol Corp. He has
been with Brown & Root for the past eleven years as a
process design engineer [o1 various HPJ plants.
226
At thlS pmnt, lilt: :.t:\..vuu t'"- -- _ _
perature zones as was done with the tunnel furnace.
Equations similar to Equation (9) and (10) can be set
up and the required areas of each zone determined. The
length of each zone in the second pass cal} be calculated
from the relation:
AA
LzA = -d N for the first zone,
j 2 '1i
( 14)
AB
Lz
8
= d, N '1T' for the second zone, etc.
I
The lengths LZA, Lz
8
, Lzc . . . are progressively added
until their sum is equal to, or plus or minus a few pre-
viously assigned inches from, the assumed tube length.
The first tube diameter and number selected will un-
doubtedly be unsatisfactory, i.e. when the heat transfer in
the last temperature zone down to 900 F is calculated,
the sum of the zone lengths may be a great deal shorter
than the required tube length, or conversely, before the
last zone is reached, the sum of the zone lengths may
exceeded the required tube len..,.th.
Consequently, care must be exercised to employ the
highest mass velocity within pressure drop limitations. If
no satisfactory solution is then possible, the tube diameter
must be changed until all possible tube diameters have
been tried. After all tube diameters for the second pass
have been exhausted, tube diameter selections for the
third pass should be made.
For the third pass tubes, previous experience has shown
that belO\.v 900 F heat transfer by radiation is negligible.
This probably accounts for less than one-half of one per-
cent. For this reason, it can be omitted in this case.
As before, .U T across the third pass is broken up into
convenient zones and equations set up similar to Equa-
tion ( 9) and ( 10). Zone lengths as before are added to-
gether until the outlet temperature from the third pass
occurs at approximately tho required tube length, and
within a prescribed pressure drop of not more than 0.5
psi . When all possible tube diameters have been tried, a
complete cycle of computational steps will have been com-
pleted. The entire set of calculations must now be per-
formed starting with a new tunnel furnace length and the
same previously selected tunnel furnace diameter. After a
satisfactory design, or designs, have been obtained with
the second length, a third length may be chosen, and a
third set of complete calculations run off. Three judici-
ously selected tube and tunnel lengths should be sufficient.
The full panorama of satisfactory possibilities has not
yet been exhausted. Tunnel diameters must now be va ried.
For each tunnel diameter a complete set, or series, of heat
transfer and pressure drop calculations must be made.
The results of these calculations will yield a good many
"possible" designs that satisfy the many restrictions im-
posed. From a practical, economic standpoint, however,
some of the "possible" solutions may not be satisfactory.
For example, a design to meet the required performance
may be composed of 8-foot tube and tunnel lengths, but
require an entirely uneconomical boiler diameter of, say,
12 feet.
HYDROCARBON PROCESSING
G
STEPWISE COMPUTER PROCEDURE
(See Guide Chart, Figure 2)
1. DETERMINATION OF THE THEORETICAL FLAME
TEMPERATURE
[Using Equation ( 6))
1. Look up a trial flame temperature : T t
2. Look up reacting components: R
1
3. Look up standard heat of reactions:

4. Multiply dte mob o each component in the acid gas feed
undergoing chemical change by the standard heat of re-
action: R
1

5. Add these products to get left side of Equation (6) and
store the sum.
6. Look up the reference temperature: ( 525 R = T &)
7. Calculate the Mean Molal Heat Capacity (Cp)
1
of each
component by performing the following steps:
a) Look up a gas component in the flue gas.
b) Look up corresponding values of constants a, b, c and d.
c) Calculate value of (Cp )
1
for the component selected
from Equation ( 5) and store the result.
d) Repeat steps 7a) , b), and c) for each and every one of
the components, excluding sulfur vapor.
8. Calculate the Mean Molal Heat Capacity, (Cp) v for the
gas mixture at T t by performing the following steps:
a) Look up a gas component in the flue gas
b) Look up its corresponding value of ( CP} t, l
c) Look up its corresponding mol fraction, (m.f. )
1
d) Calculate (m..)
1
(Cp)t.l and store result.
e) Repeat steps Sa), b), c), and d) for each and every
one of the component.s, excluding sulfur vapor.
f) Calculate (Cp)t from Equation (3) and store result.
9. Look up value of M and store.
10. 'Calculate: M(Cp) t (T
1
-TR) and store result.
11. Look up value of W
1
12. Look up corresponding value of ht
13. Look up corresponding value of hR, (included for the sake
of generality.)
14. Calculate: W
8
(ht - hr)
15. Add results of steps 14 and 10 and store result.
16. Find the absolute value of (Step 15 -Step 5) and store
results.
17. Look up value of ll (arbitrarily assigned) .
18. If the result of Step 16 < ll, T
1
shall be considered the
correct flame temperature, and its value stored and print1d,
and designated as T r
19. If the results of Step 16 > ll, calculate (Step 15-Step 5).
20. If (Step 15- Step 5) > 0, select a second value of Tt
that is lower than the first value of T t chosen by a pre-
selected valut:.
21. If (Step 15 -Step 5) < 0, select a second value of T t
that is higher than the first value of T t chosen by the same
pre-selected value as used in Step 20.
22. Continuing from either Step 20 or Step 21, repeat Steps 1
thru 20 or 21 until a correct flame temperature has been
reached, by satisfying the conditional Step 18.
II. DmRMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE 1 OF THE TUNNEL FURNACE
[Using Equation (9)]
23. Look up T
1
, which determines the lower temperature limit
of Zone 1.
24. From Storage, take the last value calculated for (Cp)t, This
value now represent. the mean molal heat capacity for
the gas mixture at flame temperature: (Cp)F
25. Calculate: M (Cp)l' (Tr- TR) and .store.
26. Determine (Cp )
1
by carrying out Steps 7 and 8 based on
temperature T
1

May 1965, Vol. 44, No. 5
r>
I
I
I
I
I
I
I
L-
..---
>
1
I
I
I
I
I
I
I"'
I
>
(START)
+
SELECT
TRIAL FLAME
TEMPERATURE
+
HEAT BALANCE
BETWEEN REACTANTS
AND PRODUCTS
-------
ARRIVE AT
CORRECT FLAME
TEMPERATURE

SELECT TUNNEL
FURNACE
DIAMETER

SELECT TUNNEL
FURNACE
LENGTH
+
HEAT BALANCE
AT ZONE I
OF TUNNEL
+
ARRIVE AT
TEMPERATURE AT
TUNNEL OUTLET

SECOND
ASS TUBE
DIAMETER

SELECT
TRIAL MASS
VELOCITY

CALCULATE
ll Pz THRU
SECOND PASS
I I
I 1..
I
-------+
I
I
I
I
I
I '
' I
I
I
I
I
I
I
I
I
I
I
I
L--
ARRIVE AT
A SATISFACTORY
MASS VELOCITY
+
HEAT BALANCE
AROUND ZONE A
OF SECOND PASS
+
DETERMINE
LENGTH OF
SECOND PASS
- -----
ARRIVE AT
TEMPERATURE OUT OF
SECOND PASS TUBES
ct
I+-
1+-
I
cp
SELECT TUBE
r--> DIAMETER FOR
I THIRD PASS
I
J.
..->
SELECT
I
TRIAL
I MASS VELOCITY
I
J. I
I
CALCULATE liP3
I
I THRU
I
THIRD PASS
I
L------- -
ARRIVE AT
I
A SATISFACTORY
I
I MASS VELOCITY
I
+
I
I
HEAT BALANCE I
I
AROUND ZONE I
I
I OF THIRD PASS
I
+
I
I
DETERMINE
I
I
LENGTH OF
I
THIRD PASS TUBES
I
L----------
ONE COMPLETE CYCL
OF CALCS. COMPLETEr
AT THIS POINT
4
r.
D
\(
FINAL PRINT OUT
OF POSSIBLE
REACTOR DESIGNS
I
+
SELECTION OF
DESIGN SPECS.
FOR FABRICATION
J.
c
END
'
I
l
Fig. 2-This guide will help you set up a computer progr; 1.
27. Calculate: M (Cp)
1
(T
1
-TR)
28. Look up h
1
29. Calculate: W, (hp-h
1
)
30. Look up the emissivity of the wetted surface of the tum I,
ea.
31. Calculate the ari'thmetic average temperature in Zone
TF,t = (Tp+ Tl)/2.
32. Look up sl at temperature T F,l for each of the gase IS
components.
33. Look up the sulfur dew point temperature, T Dp
34. Look up s. at temperature T Dp for each of the gaseous c1 1-
ponents.'
7
lEW WAY TO DESIGN FIRETUBE REACTORS
l=m
5. Calculate 2: e, (S
1
- S
8
) (For sulfur plants, m will al-
1=1
ways be assumed to be 5, corresponding to C0
2
, H
2
S, N
2
,
HzO and S0
2
)
36. Look up the temperature corresponding to the saturated
steam temperature at the design pressure, T sT
37. Calculate (MTD).
38. Look up: h
8
39. Look up: r
1
g
40. Look up: r
8
41. Look up: rm
42. Calculate: l/h
1
43. Look up first choice of tunnel diameter: D
44. Calculate: '1702/4
45. Look up molecular weight of the gas mixture, M.W.
46. Calculate the mass velocity, G:
M(M.W.)
G = 90077'02
47. Calculate: [(Cp)p +Cp)
1
]/2
48. Calculate : = 8.3 [ [ + (Cp)
1
J
49. Calculate: 1/hg
50. Add the following steps: 39, 40, 41, 42, and 49, and store
the sum.
51. Calculate

U
1
= 1/( Step 50)
52. Calculate: U
1
(MTD)
1
Step 25- Step 27 + Step 29
53. Calculate A
1
: A
1
=

54. Calculate the length of Zone 1, Lz
1
:
12A
1
Lzt = 7r D
Ill. DETERMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE 2 OF THE TUNNEL FURNACE
(Using Equation (10))
55. Look up T
2
, which determines the lower temperature limit
of Zone 2.
56. Repeat Steps 24 through 54 inclusive, noting the following
requirements:
1 ) T
1
replaces T t'
2) T
2
replaces T
1
3) (Cp)
1
replaces (Cp)F
4) Physical properties of the gas components based on T F
must be replaced by the corresponding ones at T
1

5) Physical properties of the gas components based on T
1
must be replaced by the corresponding ones at T
2

6) The following units are not temperature dependent and
will remain constant in all calculations required for
Zone 2 and additional zones of the tunnel furnace:
(a) Constants a, b, c, & d (d) Ta = 525 R (g) TDp
(b) (m.f. )
1
(e) W
8
(h) S,
(c) M (f) e, (i) m
(j) TsT (n) rm
(k) h
8
(o) G
(I) ( p) D
(m) r
8
(q) M.W.
[Note: At this point, repetition of Steps 24 to 54
inclusive will add 31 steps to the numbering
system, so the next step will be Step 88)
88. Add the areas of Zone 1 and Zone 2 and store the sum
(Step 53+ Step 86) .
8!1. Aelel tne v. - - -.
(Step 54 + Step 87)
90. Look up the value of L
91. Find the absolute value of ((Step 89) -L)
92. Look up the value of fJ (also arbitrarily pre-assigned)
93. If the result of Step 91 < 11, it shall be assumed that a pos-
sible tunnel design has been achieved, and the following
values shall be printed out:
a) The total length of the tunnel (Step 89)
b) The tunnel diameter, D, (Step 43)
c) Total heat transfer area in the tunnel (Step 88)
d) The gas temperature out of the tunnel (Step 55)
94. If the results of Step 91 > {3, calculate (Step 89) -L
95. If (Step 89) - L > 0, a possible tunnel design has also been
achieved, but some final interpolation will be required. Print
out the following values:
a) The total length of the tunnel (Step 90)
b) The tunnel diameter (Step 43)
c) Total heat transfer area in the tunnel:
AT= A
1
+ A
2
[ (L- L
1
)/L
2
]
d) The gas temperature out of the tunnel :
Tx=T
1
-(T
1
-T
2
) [(L-L
1
)/ L
2
]
IV. DETERMINATION OF THE REQUIRED AREA AND
LENGTH OF ADDITIONAL ZONES OF THE TUNNEL
FURNACE
96. If (Step 89) - L < 0, additional zones must be determined.
Look up T
8
, which determines the lower temperature limit
of Zone 3.
97. Carry out Step 56, making all the necessary and correspond-
ing replacement of values between Zone 3 and Zone 2 that
were required previously between Zone 2 and Zone 1.
98. Repeat steps corresponding to Step 88 through Step 95 in
elusive.
99. If a final tunnel furnace length is not obtained by executing
the steps outlined by Step 98, Step 96 will have to be carried
out as will a whole sequence of steps corresponding to Step
56 thru Step 95 inclusive until either conditional Step 93 or
Step 95 has been satisfied.
V. SELECTING A MASS VELOCITY AND DETERMINING
THE NUMBER OF TUBES IN THE SECOND PASS OF
THE W. H. BOILER
[Using Equation ( 11 ) ]
1. Look up a tube diameter, d
1
2. Look up a mass velocity, GT
3. Look up N
1
4. Look up p
5. Look up z ... (based on a mean tube wall temperature corre-
sponding to saturated steam temperature plus 20 F)
6. Look up the final temperature out of the tunnel furnace, T.
7. Calculate the mean gas temperature in the second pass of
the boiler, tm
2
: tm
2
= (1/2) (Tx+900) = (1/2)Tx+450
8. Look up Z at a temperature corresponding to tm
2
9. Calculate= (Z/Z.,)O.H
10. Calculate the Reynolds No. from Equation (12) .
11. Look up the friction factor f
1
corresponding to Re value cal-
culated in Step 10.
12. Calculate AP from Equation ( 11).
'13. Look up the value of;., (also arbitrarily assigned)
14. If the absolute value of (.iP-1.00) < ;., the value of G.r
selected is satisfactory.
15. If (AP -1.00) > ;., calculate (AP- 1.00)
16. If the result of Step 15 > 0, select a lower mass velocity and
repeat Step 2 thru Step 14 inclusive.
17. If the result of Step 15 < 0, select a higher mass velocity and
repeat Step 2 thru Step 14 inclusive.
18. Look up a
1
HYDROCARBON PROCESSING
:;
19. Determine the required number of tubes, N
2
, by Equation
( 13 ) .
VI. DETERMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE A OF THE SECOND PASS OF
THE W. H. BOILER
20. Look up T A which determines the lower temperature limit
of Zone A.
21. From storage, take the last value calculated for M(Cp)x
(T.-Tal. i.e., the heat content of the gases entering the
se ond pass above the reference temperature T a
22. Determine (Cp)A by carrying out Steps !.7. and 1.8. but
based on TA.
23. Calculate; M(Cp)A (TA-TR)
24. Look up: hA
25. Calculate W
8
(hx - hA)
26. Look up the emissivity of the wetted surface of the tubes, e
8
.
27. Calculate the arithmetic average temperature in Zone A:
Tx,A = (Tx+TA)/2
28. Look up SA at temperature T x. A for each and every one of
the gaseous components.
l = m
29. Calculate: 1:, e. (SA- S
8
)
I = 1
30. Calculate; ( 11TD) A
Tx-TA
( MTD) A = ( )
Tx-TsT
In T r
A - ST
31. Look up first choice of tube diameter: d
1
32. Calculate; 7Td
1
2/4
(GT)O.a
33. Calculate;

= 13.3 ((Cp)x + (Cr)A]
I 1 I
34. Calculate: U = h +

+ rm
2
+ .r
82
+ h
A g2 s2
(Note: Here, the subscript "2" is used to indicate "2nd pass"
so as not to confuse these values with the previous
ones employed in the tunnel furnace. However, since
values do not change for h
6
, rgr r
8
, rm; the following
relation below can be used to simplify the nomen-
clature.)
1 1 1
U = h+rgr+rm+r.+h
A g2 s
35. Calculate: U A
36. Cal culate: U A (MTD) A
37. Calculate AA:
(Step VI.21.)- (Step VI.23.) +(Step VI.25.)
A" = (Step Vl.29.) + (Step VI.35.)
38. Cal ulate the length of Zone A, LzA from Equation ( 14).
VII. DETERMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE B OF THE SECOND PASS OF
THE W. H. BOILER
It should be clear without going into a stepwise outline how
Zone B and additional zones of the second pass can be dealt
with. The procedure here is similar to that outlined in Section
III and Section IV.
VIII. SELECTING A MASS VELOCITY AND DlTERMIN-
ING THE NUMBER OF TUBES IN THE THIRD PASS
OF THE W. H. BOILER
The sequence of steps involved here is similar to those outlined
in Section V. The only difference arises in the selection of num-
May 1965, Vol. 44, No. .s
her of tubes, (Step V. 19), where M must now be reduced by
the amount of hot gases extracted out of the second pass. This
amount depends on the process design and is known at the time
of designing the W. H. Boiler.
IX. DmRMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE I OF THE THIRD PASS OF THE
W. H. BOILER
The sequence of steps involved in this section is similar to
those outlined in Section VI. The outlet temperature of the third
pass is arbitrarily fixed, and in general is not critical for the
W. H. Boiler is usually followed by a sulfur cendenser in which
the process gas is cooled further. The selection of the outlet tem-
perature should be made, however, judiciously. The question of
whether a square foot of heat transfer surface in theW. H. Boiler
vs. that in the Sulfur Condenser is more or less expensive is not
the sole consideration. Different levels of steam pressure in these
two units will also influence the selection.
Since radiant heat transfer is not significant below 900 F, the
following corresponding steps can be omitted: VI. 26, 27, 28,
and 29. The calculation of the heat transfer area in Zone I of
the third pass corresponds to a step similar to Step VI. 36, but
modified as follows:
(Step Vl:21 ) -(Step VI.23) +(Step VI.25)
Ar = (Step VI.35)
X. QETERMINATION OF THE REQUIRED AREA AND
LENGTH OF ZONE II OF THE THIRD PASS OF THE
W. H. BOILER
The sequence of steps required for these determinations hav1
been previously outlined in Sections II, III, and IV. Here again
those steps pertaining to radiant heat transfer may be omitted
The method of determining the total area of the third pass a
well as the number of tubes should be apparent.
At this point, one complete cycle of all necessary calcul atior
has been performed. As shown on the preliminary flow char
Figure 2, it is now necessary to repeat the entire cycle by makin
a second selection for a tunnel furnace length. Specifically, th
means going back to Step III.90. After a second complete eye
of calculations from Step III.90 to the last step in Section )
the entire sequence is repeated for all tunnel furnace lengt
included in the data. From experience we can limit the numb
of different tunnel lengths to approximately 10 to 12 differc
values.
To complete the design, different furnace tunnel diamct(
must now be investigated. A second tunnel diameter must
selected and the entire cycle of calculations must be repeated
each tunnel length selected. Specifically, this means repeati 5
Steps 11.43 through the last step in Section X. Here again, fr n
experience, a list of approximately 6 to 8 possible diameters r
a specific design is all that is required in the data.
This completes the entire program for the generalized des n
of firetube boilers. It should be self-evident that the use o a
computer will permit one to design the unit rigorously, and aff d
the designer the opportunity of specifying two or three poss le
mechanical and structural designs and arrive at the most econo .l-
eal arrangement.
LITERATURE CITED
'McAdams, William H., Heat Transmission, Third Edition, McGraw- ill,
pp. 99-10!>, New York (1954).
Trinks, Willibald, Indunrial Furnaces, Vol. 1, Filth Edition, Wiley,
pendix II, New York (1961).
I McAdaw, William H., Heat Transmission, Second Edition, McGraw :ill,
p. 71, New York (1942).
Clarke, Loyal, Manual For Process Engineering Calculation.s, First Ed on,
McGraw-Hill, p. 103, New York (1947) .
29