Chapter 7: Calculations: A Design of A 2 Pass Dry Back Steam Boiler A-Data Given
Chapter 7: Calculations: A Design of A 2 Pass Dry Back Steam Boiler A-Data Given
Calculations
Chapter 7
: Calculations
Data Given:
1- Boiler Dimensions/Data
Furnace
Inside Dia.
Outside Dia.
Area Inside
Area Outside
Length
w
f
Scale Thickness
ksteel
kscales
Smoke Tubes
Quantity
Diameter
Length
:
:
:
:
:
:
:
:
:
:
470 mm.
480 mm.
4.06 m2.
3.77 m2.
2500 mm.
0.8
0.4
0.5 mm.
54 W/m.K.
0.7 W/m.K.
: 79.
: 50 mm.
: 2000 mm.
2- Fuel Data
Firing Rate
Type
Calorific Value
A/F Ratio
Air Inlet Temp.
Water Inlet Temp.
Boiler Output Pressure
Steam
:
:
:
:
:
:
:
:
46.8 kG/hr.
Natural Gas (83.4% CH4, 15.8% C2H6, 0.8% N2)
57000 kJ/kG.
18.
40 C.
25 C.
12 Bar.
Saturated Steam.
Boilers Basics
Calculations
B- Calculations:
1- Furnace:
I- Combustion Equations:
Burning 100 KMol of fuel at A/F = 18
(83.4/16 CH4 + 15.8/30 C2H6 + 0.8/28 N2) + 13.11 (O2 + 3.76 N2)
6.26 CO2 + 12 H2O + 0.85 O2 + 49.323 N2
Mass Fraction for product gases
MfCO2
MfH2O
MfO2
MfN2
:
:
:
:
0.145
0.114
0.0143
0.727
Qr
ma , ha
Furnace
mf, C.V
( ma ha ) + ( mf C.V ) = Qr + ( mg hg ) -------1
mg , hg
Boilers Basics
Calculations
Where:
Qr in (Watt).
Tf = Tg (Assumed).
= 5.6710-8 (Stefan Boltzman).
mf = 0.013 kG/sec.
ma = 18 mf = 0.234 kG/sec.
mg = ma + mf = 0.247 kG/sec.
ha = Cpa ( Ta 298 )------- (Cpa to be calculated at Ta).
hg = Cpg ( Tg 298) -------- (Cpg to be calculated at Tg).
Awi = 3.69 m2.
Af = 0.769 m2.
1/fw = 1/f + Af / Awi ( 1/w 1 ) = 2.551.
fw = 0.392.
We will assume Tg = 1836.549 K
Cpg
Cpa
Qr
Twi
:
:
:
:
1.42668 kJ/kG.K
1.012 kJ/kG.K
193120.55 Watt.
527.987 K
Where:
Tb = 187.99 C (Saturated temp. at 12 Bar)
Rt = {ln(Do/Di)}/{2Lkst} + {X/kscAo} + {1/Aohb}
hb 2000 W/m2.K.
Rt = 0.00034692 m2.K/W.
Qr = (548.94 460.99) / 0.000318449 = 193130.905 Watt
Error % = 0.005 %.
Boilers Basics
Calculations
2- Smoke Tubes:
Tgo
Tgi
Qc = A.U.Tm ------- 5
Where:
Tgi = 1836.549K.
Tgo = To be Assumed
di = 44 mm.
Ai = 21.84 m2
U = (hg hb)/(hg + hb) hg
hg = (Nu.kg)/di
Nu = 0.023.(Re)0.8.(Pr)0.3
Re = (v.di.)/
v = Velocity inside smoke tubes (m/sec)
Values of (, , kg & Pr) to taken at average temperature.
Tav = (Tgi + Tgo)/2
Tm = {(Tgi Tb) (Tgo Tb)}/ln{(Tgi Tb)/ (Tgo Tb)}
We will assume Tg = 880 K
Tav
v
Cpav
kg
Pr
Re
Nu
hg
Tm
:
:
:
:
:
:
:
:
:
:
:
13858.275 K.
0.2465 kG/m3.
8.3417 m/sec.
1.2277 kJ/kG.K.
478.3810-7 N.sec/m2.
84.0310-3 W/m.K.
0.6975.
1891.26.
8.6336.
16.488 W/m2.K
804.7 C.
Boilers Basics
Calculations
3- Results:
Tgi
Twi
Tgo
Qr
Qc
Boiler Output
Boiler Efficiency
mst
Rating
:
:
:
:
:
:
:
:
:
1836.549 K.
527.987 K.
880 K.
193.12 kW.
289.77 kW.
482.89 kW.
65.187 %.
0.1802 kG/sec. (648.72 kG/hr).
22.69 kG/m2.hr
Manual Calculations
1836.549 K.
527.987 K.
880 K.
193.12 kW.
289.77 kW.
482.89 kW.
65.187 %.
0.1802 kG/sec. (648.72 kG/hr).
22.69 kG/m2.hr
Computer Program
1903 K.
559 K.
278 kW.
300 kW
578 kW
77 %.
0.238 kG/sec. (856.8
kG/hr.)
Boilers Basics
Calculations