Design of waste heat recovery system for a Hieza boiler in a Soap Industry

Department of Mechanical Engineering ,SIT,Mangalore

6.1 Calculations for the Corresponding Mass flow rate of Fuel
Mass of one Mole (k mole) is the number of grams (kg) equal to thr
relative atomic mass
The general formula for Furnace oil is C
20
H
42
. This is because furnace oil is
complex mixture of hydrocarbons and is higher fraction obtained while refining.
Since the C
20
H
42
is largest member in the composition of Furnace oil the
chemical formula is taken in order to ensure complete combustion of the
furnace oil. Also furnace contains 3% by weight of sulphur which results in the
formation of sulphur di oxide. This sulphur di oxide reacts with water and
readily forms Sulphuric acid. This sulphur di oxide eats away the metal parts
while condensing in the economizer .Thus it limits the maximum amount of
heat recoverable from the exhaust gases.
S + O2 SO2 (Sulphur Dioxide) (g)

2S + 3O2 2SO3 ( Sulphur Trioxide) (g)


SO2 + H2O (l) H2SO3 (suplhurous acid)


SO2 + H2O (l) H2SO4 (sulphuric acid) (l)


It is important for one mole of fuel C
m
H
n
there is exactly [m= (n/4)] moles of
oxygen for complete combustion.
Therefore one mole of C20 H42 combines with 61/2 moles of oxygen.

C
20
H
42
+ (61/2) O
2
20 CO
2
+ 21H
2
O

Simlarly sulphur undergoes oxidation to form sulphur di oxide.
S+O
2
SO
2
(g).

From the above it is clear that if the temperature of the flue gas is 100
o
C, the
water vapour in the flue gas starts to condense
[6]
. Meanwhile sulphur di oxide
reacts with aqueous water to form sulphur di oxide. So in order to avoid thr
formation of sulphur di oxide the temperature of the flue gases must not be
cooled below or equal to 100
o
C.In this case the otlet of chimney is 140
o
C in
order to be in safer side. Also the condensation of water on the tube surface
increases the convection resistance and reduses the heat transfer rate
[6].


Design of waste heat recovery system for a Hieza boiler in a Soap Industry

Department of Mechanical Engineering ,SIT,Mangalore


So the maximum heat that can be removed from the flue gas is restricted by the
minimum temperature allowed.

The maximum heat recovered is equal to M
e
*C
pe
* (T- T
out
) kJ/s

6.2 Calculation of Specific Heat of exhaust gases.
We know that
C
Pm
= (m
CO2
*C
pCO2
)+(m
H2O
*C
pH2O
)+(m
SO2
*C
pSO2
)+(m
N2
* C
pN2
)
m
e
Where C
Pm
is the Specific heat of exhaust gas in kJ/kg K
m
CO2
= 0.0281286*10
3
*0.97*880/282.336=0.08497kg
m
H20
= 0.0281286*10
3
*0.97*378/282.336=0.03656kg
m
H20
= 0.0281286*10
3
*0.03*62.065/32.065=0.001633kg
m
N2
= 0.41084*0.768=0.3155kg
The specific heat of all the constituent gases are taken at 616K
C
pCO2
=1.0836kJ/kgK.
C
pH2O
=2.02524kJ/kgK.
C
pSO2
=0.64kJ/kgK.
C
pN2
=1.07852kJ/kgK.
Therefore,
C
Pm
= (0.08497*1.0836)+(0.03656*2.02524)+(0.001633*0.64)+(0.3155*1.0785)
(0.08497+0.03656+0.001633+0.3155)
=1.156=1.16kJ/kgK



Design of waste heat recovery system for a Hieza boiler in a Soap Industry

Department of Mechanical Engineering ,SIT,Mangalore