CALCULATION
Instructions
INTRODUCTION
The procedure shown below is next to all needed to successfully use the software to
calculate heat transfer in HYBRID boiler. The data input process leads the user
step-by-step in an easy-to-follow self-explaining way. During geometry data input process a
corresponding general image of particular boiler design feature is displayed
illustrating the current to-be-entered value. Safety mechanism is incorporated preventing
geometrically incorrect data such as tube wall thickness that is greater than tube
inner diameter, exit water temperature that is lower than return one etc.
Hybrid coal fired boiler
Step 1: Units choice (metric in this case). Use Arrow key to move up and down and Enter to
select. Mouse point + double click also works. Esc quits the program. Bottom line explains the
navigation. In general UP arrow brings you back to beginning of current section.
Step 2: Case description data entry. In last field Enter brings up next window. Use arrow keys,
Home and End to move up and down. Esc gets you back to Main menu.
Step 3: Fuel type choice (coal in this case).
Step 4: Boiler type choice (steam in this case).
Step 5: Steam pressure choice (if gage pressure is 9 bar the absolute pressure is 10 bar).
Step 6: Boiler design choice. In this case it is water tube furnace with double pass tubular
boiler in convective section.
Step 12: Enter coal composition.
Step 9: Combustion air is not preheated in this case (if it is the software asks for additional
data).
Step 10: Rest oxygen in flue gas entry. It's the value displayed by flue gas analyzer and is used
to calculate excess air (lambda value).
Step 13: Enter net coal rate (unburned coal deducted).
Step 14: Flue gas recirculation is not applied in this case (if it was software would ask for
additional data).
Step 15: Feed water temperature. Software displays saturated steam temperature calculated
from given steam pressure.
Step 7: In this step general image of chosen boiler design is shown. Pressing Enter advances
to next step.
Step 8: Outdoor air temperature (temperature of air coming in boiler room).
Step 24: Tubes in first tube set are empty in this case.
Step 38: Choose superheater tube rows arrangement (plain in this case).
Step 39: Enter number of superheater tubes in single row (software determines needed
number of tube rows to reach superheated steam design temperature.
Step 40: Enter distance between tubes center lines in single row. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 42: There is economizer in this case.
Step 54: Previous step was the last one in data entry process. Pressing Enter commences
calculation process, which takes few seconds or less.
Results display folows (provided geometry and operation data entered were correct and
around. Pressing Esc brings up Final menu. Move up and down with PgUp/PhDown, arrow
up/down keys, End key to jump to the end of results pages and Home to return to first results
page. Actual complete printout of results is shown at the bottom below.
Final menu displays various options. Input data can be changed till results meet user desire.
Results can be saved to file in folder where main program was installed to
(c:\BoilerDesignSoftware). Choose file name with txt extension (test.txt). If Graphs option is
selected the submenu shown in next image follows.
Flue gas enthalpy diagram shows flue gases energy flow starting with enthalpy at adiabatic
combustion temperature (point where flue gases contain heat released from combustion).
Pressing Enter brings back Graphs menu.
Flue gas temperature decrease in boiler diagram shows how flue gas temperature decreases
as gases pass over cooled area in boiler sections starting with adiabatic combustion
temperature. First break represents furnace exit, second break represents exit from first tube
set, and third break represents exit from second tube set. In reality line is smooth (logarithmic).
HEAT TRANSFER IN HYBRID BOILER (METRIC UNITS)
=============================================
DATE :AUGUST 19,2016
SUBJECT:HYBRID COAL BOILER
MAKE :-
REMARK :DEMO CALCULATION
SUMMARY
_______
INPUT DATA
__________
FUEL DATA
_________
CARBON-CONTENT = 42.47 %
WATER-CONTENT = 28.4 %
SULFUR-CONTENT = 1.44 %
HYDROGEN-CONTENT= 3.56 %
OXYGEN-CONTENT = 9.32 %
NITROGEN-CONTENT= .65 %
ASH-CONTENT = 14.16 %
FURNACE IS RECTANGULAR
NUMBER OF TUBES = 90
COOLED TUBE LENGTH = 5.25 m
TUBE INNER DIAMETER = .0625 m
TUBE WALL THICKNESS = .0036 m
CROSS SECTION BEFORE TUBES = 1 m2
CROSS SECTION AREA AFTER TUBES= 2 m2
COOLED AREA = 92.775 m2
HEAT BALANCE
____________
Step 41: Enter number of superheater tubes connected to manifold (needed to calculate
superheated steam velocity in tubes).
Step 11: There is just one fuel type fired. Another one can be premixed.
Step 12: Fuel heating value is not measured in this case and software calculates it.
Step 25: Enter cross section area before first set of tubes (needed to calculate pressure drop).
Step 26: Enter cross section area after first tube set tubes (needed to calculate pressure drop).
Step 28: Enter second tube set length.
Step 31: Enter cross section area after tubes in second tube set (needed to calculate pressure
drop).
Step 32: Tubes in second tube set are empty in this case.
Step 33: There is tube array superheater in turnaround channel between tube sets.
Step 49: Enter number of tubes in individual row. Software will determine needed number of
tube rows.
Step 50: Enter distance between tubes in individual row. Note that smaller distance between
tubes results in higher the flue gas velocity between tubes, which leads to more intense heat
transfer and smaller size.
Step 52: Enter number of economizer tubes connected to manifold (needed to calculate water
velocity in tubes).
HEAT TRANSFER IN HYBRID BOILER (ENGLISH UNITS)
==============================================
SUMMARY
_______
INPUT DATA
__________
FUEL DATA
_________
CARBON-CONTENT = 42.47 %
WATER-CONTENT = 28.4 %
SULFUR-CONTENT = 1.44 %
HYDROGEN-CONTENT= 3.56 %
OXYGEN-CONTENT = 9.32 %
NITROGEN-CONTENT= .65 %
ASH-CONTENT = 14.16 %
FURNACE IS RECTANGULAR
NUMBER OF TUBES = 90
COOLED TUBE LENGTH = 17.224 ft.
TUBE INNER DIAMETER = 2.461 in
TUBE WALL THICKNESS = .142 in
CROSS SECTION BEFORE TUBES = 10.764 sq.ft.
CROSS SECTION AREA AFTER TUBES= 21.528 sq.ft.
COOLED AREA = 998.623 sq.ft.
HEAT BALANCE
____________