HEATEX INDUSTRIES LTD

THERMAL ANALYSIS

for
3 TPH BOILER @ 12 kg/cm2

Fuel : FURNACE COIL

24-07-2017
HEATEX INDUSTRIES LTD
ANALYSIS: Thermal Analysis with Furnace Oil
MODEL HIL/300/12 Kg 24-7 2017

Boiler Details 3000 Kg/h FO Fired Boiler

Boiler Rating (From & at 30 oC) Q 3000 Kg/hr
Pressure P 12 Kg/cm2
Temperature T 191.6 Deg.C
Enthalpy of Steam at Boiler Outlet 665.3 Kcal/kg
Enthalpy of Water at Inlet 30 Kcal/kg
Enthalpy of Vaporisation 635.3 Kcal/kg
Fuel Used FURNACE OIL
Thermal efficiency targeted h 90 %
Theoritical Heat Required Qt 1867782 Kcal/hr
Heat Input to the Boiler Qi 2075313 Kcal/hr

Combustion

Calorific Value 9650 Kcal/Kg

Net Heat Input required Qn 2075313 Kcal/hr
Burner Rating 2413 kW
Fuel consumption 215 Kg/hr
Flame diameter 750 mm
Flame Length 2750 mm
Theoritical air required for combustion 14.00Kg/Kg of fuel
Excess air percentage 10.0 %
Actual A/F for combustion 15.40 Kg/Kg of fuel
Actual air used for combustion 3312 Kg/hr
Flue Gas 3527 Kg/hr
HEATEX INDUSTRIES LTD
CLIENT: Thermal Analysis with Furnace Oil
MODEL HIL/300/12 Kg
Furnace Details
Material of construction of Inner shell A 516 Gr. 70
Total Furnace Length More than 2500 (Total) 2568 mm
Thickness of shell 12 mm
ID of Inner Shell FURNACE 850 mm
OD of Inner Shell FURNACE 874 mm
CC Tube Plate diameter 1450 mm
Reversal Chamber thickness 16 mm
OD of the Reversal Chamber 1482 mm
Reversal Chamber Length 700 mm
ID of Accesss shell 550 mm
Accesss shell thickness 12 mm
OD of the Access shell 574 mm
Access shell Length 150 mm
Flow area in Furnace Af 0.57 m2
Flue Gas Velocity 1.73 m/s
Furnace bounding area of Furnace A 7.05 m2
Furnace bounding area of Furnace 3.26 m2
Heat Transfer area of Tube Plates 5.11 m2
Heat Transfer area of CC Tube Plates 2.59 m2
Heat Transfer area of Access Chamber 0.27 m2
Furnace Volume V 2.649 m3
Beam Length L 1.31 m
Furnace heat release rate 12000 Btu/hr/ft2
Skin Temperature of Tubes Ts 232 oC
879 oR
Furnace Temperature Tg 1076 oC
2429 oR
Flue Gas Outlet Temperature Te 1076 oC
Average Flue Gas Temperature Tavg 1076 oC
Density of Flue Gas r 0.27 Kg/m3
Specific heat of Flue gas Cp 0.335 Kcal/kg/oC
Viscosity of Flue gas m 0.047 cP
Thermal conductivity of Flue gas K 0.076 Kcal/kg/m/oC
Flue Gas Volume 13139.5 m3/hr
Heat Out in Flue gas at oC 1076 1235881 Kcal/hr
Heat transfer by radiation 839432 Kcal/hr
HEATEX INDUSTRIES LTD
CLIENT: Thermal Analysis with Furnace Oil
MODEL HIL/300/12 Kg
Beam Length - Combustion Chamber
Flow area in Furnace near flame Af 0.57 m2
Flue Gas Velocity 1.73 m/s
Furnace bounding area A 12.71 m2
Furnace Volume V 2.65 m3
Beam Length L 1.31 m
Partial Pressure of CO2 Pc 0.130 atm
Partial Pressure of H2O Pw 0.120 atm
Pc x L 0.561 ft.atm
Pw x L 0.518 ft.atm
Gas Emmisivity & Absorptivity - Combustion Chamber
Emmisivity of CO2 at Tg 2428.80 ec 0.140
Emmisivity of H2O at Tg ew 0.135
PcL (Ts/Tg) 0.20
PwL (Ts/Tg) 0.187
Emmisivity of CO2 at Ts 878.88 ec 0.082
Emmisivity of H2O at Ts ew 0.140
Absorptivity of CO2 at Ts ac 0.159
Absorptivity of H2O at Ts aw 0.239
Correction factor Cw 1.080
Ratio [CO2/(CO2 + H2O)] 0.520
PcL + PwL 1.08
Special Overlap correction Cso 3.00 %
Emmisivity of Flue Gas eg 0.29
Absorptivity of Flue Gas ag 0.39
Radiative Heat Transfer in Furnace - Combustion Chamber
Stefen Boltzman constant s 0.173 Btu/hr/ft2/oR4
Heat Transfer rate (Radiation) 3333841 Btu/hr
Heat Transfer rate (Radiation) 840128 Kcal/hr
Convective Heat Transfer in Membrane wall
Reynolds number 31224.2
Convective heat transfer coefficient 3.7 Kcal/hr/m2/oC
Heat Transfer rate (Convection) 56376 Kcal/hr
Total Heat Transfer in Furnace 896504 Kcal/hr
Flue Gas Outlet temperature Te 1028.29 oC
Radiation + Convection heat absorbed % of Input 43.20 %
HEATEX INDUSTRIES LTD
CLIENT: Thermal Analysis with Furnace Oil
MODEL HIL/300/12 Kg
2nd Pass - Tube Side
Flue Gas Flow Rate 3527 Kg/hr
Outer Diameter of Tube 50.8 mm
Thickness of Tube 3.66 mm
Inner Diameter of Tube 43.5 mm
No. of Tubes 90
Tube Length Effective 2568 mm
Flow Area of Flue Gas 0.134 m2
Heat Transfer Area of 2nd Pass 36.9 m2
Flue Gas Inlet temperature 1028.3 oC
Flue Gas Outlet temperature 460 oC
LMTD 500 oC
Average Flue Gas Temperature 744 oC
Density of Flue Gas r 0.35 Kg/m3
Specific heat of Flue gas Cp 0.285 Kcal/kg/oC
Viscosity of Flue gas m 0.040 cP
Thermal conductivity of Flue gas K 0.060 Kcal/kg/m/oC
Mass Velocity G 26393 Kg/hr/m2
Velocity of Flue Gas V 21.0 m/s
Reynolds Number Re 7969
Prandtl Number Pr 0.69
Nusselt Number Nu 37.72
Heat Transfer coefficient Flue gas hf 51.70 Kcal/hr/m2/oC
H.T.C Flue gas side corrected for Dirt hf 44.25 Kcal/hr/m2/oC
2nd Pass - Shell Side
Assume shell side h.t. coefficient ho 1464 Kcal/hr/m2/oC
tw 199.5 oC
Dtw 7.9 oC
From Fig 15.11 ho 1464 Kcal/hr/m2/oC
Hence Actual ho 1464.0 Kcal/hr/m2/oC
Clean Overall h.t. Coefficient Uc 43.0 Kcal/hr/m2/oC
Design Overall h.t. Coefficient Ud 40.5 Kcal/hr/m2/oC
Heat Transfer Rate 746580.6 Kcal/hr
Maximum Flux 20240.7 Kcal/hr/m2
7430.2 Btul/hr/m2
<
12000.0 Btul/hr/m2
HEATEX INDUSTRIES LTD
CLIENT: Thermal Analysis with Furnace Oil
MODEL & Analysis HIL/300/12 Kg
Heat Transfer - 3rd Pass
Flue Gas Flow Rate 3527 Kg/hr
Outer Diameter of Tube 50.8 mm
Thickness of Tube 3.66 mm
Inner Diameter of Tube 43.5 mm
No. of Tubes 64
Tube Length Effective 3418 mm
Flow Area of Flue Gas 0.095 m2
Heat Transfer Area of 3rd Pass 34.9 m2
Flue Gas Inlet temperature 460 oC
Flue Gas Outlet temperature 260 oC
LMTD 146 oC
Average Flue Gas Temperature 360 oC
Density of Flue Gas r 0.56 Kg/m3
Specific heat of Flue gas Cp 0.253 Kcal/kg/oC
Viscosity of Flue gas m 0.028 cP
Thermal conductivity of Flue gas K 0.037 Kcal/kg/m/oC
Mass Velocity G 37115 Kg/hr/m2
Velocity of Flue Gas V 18.3 m/s
Reynolds Number Re 16010
Prandtl Number Pr 0.68
Nusselt Number Nu 66.70
Heat Transfer coefficient Flue gas hf 57.14 Kcal/hr/m2/oC
H.T.C Flue gas side corrected for Dirt hf 48.91 Kcal/hr/m2/oC
3rd Pass - Shell Side
Assume shell side h.t. coefficient ho 1464 Kcal/hr/m2/oC
tw 193.8 oC
Dtw 2.2 oC
From Fig 15.11 ho 1464.0 Kcal/hr/m2/oC
Hence Actual ho 1464.0 Kcal/hr/m2/oC
Clean Overall h.t. Coefficient Uc 47.3 Kcal/hr/m2/oC
Design Overall h.t. Coefficient Ud 44.4 Kcal/hr/m2/oC
Heat Transfer Rate 226995 Kcal/hr
Maximum Flux 6502.1 Kcal/hr/m2
2387 < 12000.0 Btu/hr/m2
Heat Transfer Summary
Total Heat Transfer Area 90.1 m2
Radiant Zone - Furnace 47.9% 896504 Kcal/hr
2nd Pass 39.9% 746581 Kcal/hr
3rd Pass 12.1% 226995 Kcal/hr
Total Heat Transfer 100.0% 1870080 Kcal/hr
>
Required Heat Transfer Rate 100.1% 1867782 Kcal/hr