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Chapter 7: Calculations: A Design of A 2 Pass Dry Back Steam Boiler A-Data Given

This document provides calculations for designing a 2-pass dry back steam boiler. It includes data for the boiler dimensions, fuel properties, and operating conditions. The calculations determine: 1) Combustion equations and heat release in the furnace using the 1st law of thermodynamics. This gives the flue gas temperature as 1836.5K. 2) Heat transfer and flue gas temperature drop in the smoke tubes using heat transfer equations. This gives an outlet flue gas temperature of 880K. 3) The boiler output of 482.89kW, efficiency of 65.2%, and steam generation rate of 0.18kg/s by combining the furnace and smoke

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Wael Abdel-Mageed
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348 views6 pages

Chapter 7: Calculations: A Design of A 2 Pass Dry Back Steam Boiler A-Data Given

This document provides calculations for designing a 2-pass dry back steam boiler. It includes data for the boiler dimensions, fuel properties, and operating conditions. The calculations determine: 1) Combustion equations and heat release in the furnace using the 1st law of thermodynamics. This gives the flue gas temperature as 1836.5K. 2) Heat transfer and flue gas temperature drop in the smoke tubes using heat transfer equations. This gives an outlet flue gas temperature of 880K. 3) The boiler output of 482.89kW, efficiency of 65.2%, and steam generation rate of 0.18kg/s by combining the furnace and smoke

Uploaded by

Wael Abdel-Mageed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Boilers Basics

Calculations

Chapter 7

: Calculations

A Design of a 2 Pass Dry Back Steam Boiler


A-

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

II- Applying 1st Law of Thermodynamics on Furnace

Qr
ma , ha
Furnace
mf, C.V

( ma ha ) + ( mf C.V ) = Qr + ( mg hg ) -------1

Qr = Af..fw ( T4f T4w )------ 2

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

We will check results as follows:

Qr = (Twi - Tb)/Rt ------- 3

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 = mg Cpg ( Tgi Tgo ) --- 4

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

Qc = 0.2471.2277(1836.549 880) = 290.0657 kW.


Qc = 21.8416.488804.7 = 289.770796 kW.
Error % = 0.1 %

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

4- Comparison between Computer Program & Manual Results


Tgi
Twi
Tgo
Qr
Qc
Boiler Output
Boiler Efficiency
mst
Rating

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

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