RELIANCE JAMNAGAR

RPCTEFH - SHEET-1 of 5
PROCEDURE FOR CALCULATION OF THERMAL EFFICIENCY OF FIRED HEATERS
THERMAL EFFICIENCY OF FIRED HEATER ENUMERATED BELOW IS BASED ON API 560
Definitions:
Thermal efficiency is defined as total heat absorbed divided by the total heat input.
Total heat absorbed is equal to the total heat input minus the total heat losses.
Total heat input is equal to the sum of the net heat of combustion of the fuel ( LHV ) and the sum of sensible heat
of the air, fuel and atomising medium to the system. In case of steam Air Preaheating, it also includes heat
input in steam for such purpose.
Total heat losses are equal to the sum of radiation heat loss and stack heat loss.
Radiation heat loss is a defined percentage of the net heat of combustion of the fuel
Stack heat loss is the total sensible heat of the flue gas components at the temperature of flue gas when it leaves
the last heat exchange surface.
Sensible heat correction is the sensible heat differential at test temperature when compared with a datum
temperature of 60deg. F ( 16deg C ) for air, fuel, and the atomising medium. { for steam as an atomising medium,
the datum enthalpy is 1087.7 Btu / l
EFFICIENCY = (TOTAL HEAT INPUT - TOTAL HEAT LOSSES ) / ( TOTAL HEAT INPUT ) * 100
Further details on the same are given in the API, a copy of which is being sent along with this communication.
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The following steps to be followed while using the worksheet.
1. Go to Tools ---> Options ----> Calculation; Select iteration. Input Maximum iterations 100 and Maximum Change 0.001.
Select Manual calculation
2. Fuel Oil and Fule Gas composition to be entered in "FUEL_DETAILS" sheet. Also enter LHV of Fuel Oil in the same sheet.
3. If O2 composition of stack is available on wet basis pl. use "EFF_CALCULATION_WET_BASIS" sheet, if it is available on
dry basis then use "EFF_CALCULATION_DRY_BASIS" sheet.
4. Input data in column "C" only in sheets "EFF_CALCULATION_WET_BASIS" or "EFF_CALCULATION_WET_BASIS"
5. After entering all the input data, Press F9 OR SAVE the file to refresh calculations.
PROCEDURE TO USE THE WORKSHEET
RELIANCE : RPCTEFH - SHEET- 2 of 5
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Fuel Oil
Fuel Composition wt%
C = 87.00%
H = 13.00%
LHV (Kcal/kg) 10000
Fuel Gas
Component Composition MW O
2
req. (Kgmol/hr) CO
2
gen (Kgmol/hr) H
2
O gen (Kgmol/hr) LHV
(Kcal/kgmol)
Nitrogen 6.10% 28 0 0.0000 0.0000 0
H2O 0.00% 18 0 0.0000 0.0000 0
H2S 0.00% 34 0 0.0000 0.0000 123810
NH3 0.00% 17 0 0.0000 0.0000 67744
CO2 0.60% 44 0 0.0060 0.0000 0
Hydrogen 23.80% 2 0.119 0.0000 0.2380 57796
methane 36.60% 16 0.732 0.3660 0.7320 191760
ethylene 10.20% 28 0.306 0.2040 0.2040 316190
ethane 18.10% 30 0.6335 0.3620 0.5430 341260
propane 1.80% 44 0.09 0.0540 0.0720 488520
propylene 0.00% 42 0 0.0000 0.0000 460430
iC4 0.00% 58 0 0.0000 0.0000 633040
iC4= 0.00% 56 0 0.0000 0.0000 603350
nC4= 0.00% 56 0 0.0000 0.0000 607370
nC4 0.90% 58 0.0585 0.0360 0.0450 635040
cis-2-C4= 0.00% 56 0 0.0000 0.0000 605730
trans-2-C4= 0.00% 56 0 0.0000 0.0000 604730
iC5 0.00% 72 0 0.0000 0.0000 780130
nC5 0.00% 72 0 0.0000 0.0000 782050
CP 0.00% 68 0 0.0000 0.0000 468290
C6+ 0.00% 78 0 0.0000 0.0000 928950
98.10% 17.90 1.94 1.03 1.83 10750 Kcal/kg
Note: Please input your data in "B" Column only
Rest all data is calculated by Excel.
RELIANCE : RPCTEFH - SHEET- 3 of 5
FUEL COMPOSITION INPUT SHEET
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AIR
INPUT OUTPUT
1 FO Firing rate (Kg/hr) 3496 Fired Duty (MMKcal/hr) 35.0
Sencible Heat Input ex FO (MMKcal/hr) 0.15
2 FG Firing rate (Kg/hr) 0 Heat Input ex Atomising Steam (MMKcal/hr) 0.11 Cp, av., (Air) (Kca/0K,Kgmole) 6.96 STACK Mol% Kgmol/hr
Heat Input ex Steam Air Preheating (MMKcal/hr) 0.01 Cp, av., (H2O) (Kca/0K,Kgmole) 7.94 CO2 = 11.02% 253.5
3 Mol. % O2 in Flue Gas (Wet Basis) 2.60 Heat Input ex Pilot Gas (MMKcal/hr) 0.00 RADIATION LOSS O2 = 2.60% 59.8
4 Stack Temp. (
o
C) 200.0 Total Heat Input (MMKcal/hr) 35.2 Qr (MMKcal/hr) = 0.52 M (Kgmol/hr) (Dry) 2032.7 N2 = 69.84% 1605.8
5 Ambient Temp. (
o
C) 30 H2O (V) (Kgmol/hr) 52.8 31.0 H2O 16.53% 380.1
6 Relative Humidity of Air 60.0% Total Loss Enthalpy of air (MMKcal/hr) 0.01 100.00% 2299.1
7 Moles Water Vap./ Moles Dry Air 0.026 1. Through Flue Gas (MMKcal/hr) 2.93 200.0 Stack
8 Radiation loss (percent of heat released) 1.50% 2. Through Radiation Loss (MMKcal/hr) 0.52
9 Air inlet temp. after steam heater 31.0 Total 3.5
PROCESS FLUID IN Heat Loss through Stack
10 Atomizing Steam flow (TPH) 1.8 1. Through Dry Flue Gas (kcal/hr) 2400145
11 Pilot Gas flow (kg/hr) 0.0 Total Heat Absorbed (MMKcal/hr) 31.79 2. Through Water Vap. (kca/hr) 527734
12 Fuel Oil Inlet Temp. (
o
C) 120 Total (MMKcal/hr) 2.93
13 Fuel Oil Sp. Heat. (Kcal/kg/0K) 0.48 Thermal Efficiency ( h ) = 90.20%
14 Enthalpy of Atomising Steam (Kcal/kg) 673 Excess Air Used = 16.3%
Cp, av., (CO2) (Kca/0K,Kgmole) 9.75
Flue Gas Composition Mole % Cp, av., (O2) (Kca/0K,Kgmole) 7.19
CO2 = 11.02% Cp, av., (N2) (Kca/0K,Kgmole) 6.99
O2 = 2.60% Cp, av., (H2O) (Kca/0K,Kgmole) 8.17
N2 = 69.84%
H2O = 16.53% PROCESS FLUID OUT
Fuel Gas
Heat Supplied ex Fuel Gas (MMKcal/hr) 0.00
FUEL OIL
wt% Kg/hr
C = 87.00% 3041.5
H = 13.00% 454.5 AIR
M (kg/hr) = 3496.00
Cal. Value (Kcal/kg) 10000
Heat Supplied ex Fuel Oil (MMKcal/hr) 34.96
Note: 1. Please input your data in "C" Column only
2. Ambient Temp. use as datumtemp. for simplification of calculation
RELIANCE : RPCTEFH - SHEET- 4 of 5
CALCULATED DATA WITH DIAGRAM
HEATER
FIRED
WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER
(BASIS: O2 ANALYSIS IN FLUE GAS ON WET BASIS)

Combustion APH

SteamAPH
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AIR
INPUT OUTPUT
1 FO Firing rate (Kg/hr) 4000 Fired Duty (MMKcal/hr) 104.5
Sencible Heat Input ex FO (MMKcal/hr) 0.08
2 FG Firing rate (Kg/hr) 6000 Heat Input ex Atomising Steam (MMKcal/hr) 0.16 Cp, av., (Air) (Kca/0K,Kgmole) 7.01 STACK Mol% Kgmol/hr
Heat Input ex Steam Air Preheating (MMKcal/hr) 3.47 Cp, av., (H2O) (Kca/0K,Kgmole) 8.05 CO2 = 11.23% 634.5
3 Mol. % O2 in Flue Gas (Wet Basis) 3.68 Heat Input ex Pilot Gas (MMKcal/hr) 0.23 RADIATION LOSS O2 = 3.68% 207.9
4 Stack Temp. (
o
C) 184.0 Total Heat Input (MMKcal/hr) 108.4 Qr (MMKcal/hr) = 2.61 M (Kgmol/hr) (Dry) 6084.2 N2 = 85.09% 4806.5
5 Ambient Temp. (
o
C) 30 H2O (V) (Kgmol/hr) 158.2 109.0 100.00% 5648.9
6 Relative Humidity of Air 60.0% Total Loss Enthalpy of air (MMKcal/hr) 3.47 H2O 1155.0
7 Moles Water Vap./ Moles Dry Air 0.026 1. Through Flue Gas (MMKcal/hr) 7.79 184.0 Stack
8 Radiation loss (percent of heat released) 2.50% 2. Through Radiation Loss (MMKcal/hr) 2.61
9 Air inlet temp. after steam heater 109.0 Total 10.4
PROCESS FLUID IN Heat Loss through Stack
10 Atomizing Steam flow (TPH) 2.2 1. Through Dry Flue Gas (kcal/hr) 6339413
11 Pilot Gas flow (kg/hr) 21.1 Total Heat Absorbed (MMKcal/hr) 98.0 2. Through Water Vap. (kca/hr) 1448942
12 Fuel Oil Inlet Temp. (
o
C) 70 Total (MMKcal/hr) 7.79
13 Fuel Oil Sp. Heat. (Kcal/kg/0K) 0.48 Thermal Efficiency ( h ) = 90.4%
14 Enthalpy of Atomising Steam (Kcal/kg) 683 Excess Air Used = 19.4%
Cp, av., (CO2) (Kca/0K,Kgmole) 9.69
Flue Gas Composition Mole % Cp, av., (O2) (Kca/0K,Kgmole) 7.17
CO2 = 11.23% Cp, av., (N2) (Kca/0K,Kgmole) 6.97
O2 = 3.68% Cp, av., (H2O) (Kca/0K,Kgmole) 8.15
N2 = 85.09%
H2O = 0.00% PROCESS FLUID OUT
Fuel Gas
Heat Supplied ex Fuel Gas (MMKcal/hr) 64.50
FUEL OIL
wt% Kg/hr
C = 87.00% 3480.0
H = 13.00% 520.0 AIR
M (kg/hr) = 4000.00
Cal. Value (Kcal/kg) 10000
Heat Supplied ex Fuel Oil (MMKcal/hr) 40.00
Note: 1. Please input your data in "C" Column only
2. Ambient Temp. use as datumtemp. for simplification of calculation
RELIANCE : RPCTEFH - SHEET- 5 of 5
CALCULATED DATA WITH DIAGRAM
HEATER
FIRED
WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER
(BASIS: O2 ANALYSIS IN FLUE GAS ON DRY BASIS)

Combustion APH

SteamAPH
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