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 efficiency is defined as total heat absorbed divided by the total heat input.
absorbed is equal to the total heat input minus the total heat losses. Total heat absorbed is
Total heat input is
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
losses are equal to the sum of radiation heat loss and stack heat loss. RELIANCE : RPCTEFH - SHEET- 2 of 5
PROCEDURE TO USE THE WORKSHEET
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. RELIANCE : RPCTEFH - SHEET- 3 of 5 FUEL COMPOSITION INPUT SHEET Fuel Oil Fuel Composition wt% C= 87.00% H= 13.00%
LHV (Kcal/kg) 10000
Fuel Gas Component Composition MW O2 re q. (K gm ol/ hr ) CO2 g en (Kg mo l/h r) H2O 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 RELIANCE : RPCTEFH - SHEET- 4 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON WET BASIS) CALCULATED DATA WITH DIAGRAM 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 Steam APH Heat Input ex Steam Air Preheating (MMKcal/hr) 0.01 Cp, av., (H 2O) (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. ( C) o 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 o 5 Ambient Tem . 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 Combustion APH 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 P il ot Gas flow (k g/ hr) 0.0 Total Heat Absorbed (M MKcal/hr) 31.79 2. Through Water Vap. (kca/hr) 527734 o 12 Fuel Oil Inlet Temp. ( C) 120 Total (MMKcal/hr) 2.93 13 Fuel Oil Sp. Heat. (Kcal/kg/0K) 0.48 Thermal Efficiency 90.20% 14 Enthalpy of Atomising Steam (Kcal/kg) 673 Excess Air Used = 16.3% Cp, av., (CO 2) (Kca/0K,Kgmole) 9.75 Flue Gas Composition Mole % Cp, av., (O 2) (Kca/0K,Kgmole) 7.19 CO2 = 11.02% FIRED Cp, av., (N 2) (Kca/0K,Kgmole) 6.99 O2 = 2.60% HEATER Cp, av., (H 2O) (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 d ata in "C" Column only
2. Am bient Temp. use as datum temp. for simplific ation of calculation
Confidential - Property of Reliance
RELIANCE : RPCTEFH - SHEET- 5 of 5 WORKSHEET FOR EFFICIENCY CALCULATION OF FIRED HEATER (BASIS: O2 ANALYSIS IN FLUE GAS ON DRY BASIS) CALCULATED DATA WITH DIAGRAM 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 Steam APH Heat Input ex Steam Air Preheating (MMKcal/hr) 3.47 Cp, av., (H 2O) (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. ( C) o 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 o 5 Ambient Temp. ( C) 30 H2O (V) (Kgmol/hr) 158.2 109.0 100.00% 5648.9 6 Relat ive 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 Combustion APH 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 P ilot Gas fl ow (kg /h r) 21.1 Total Heat Absorbed (M MKcal/hr) 98.0 2. Through Water Vap. (kca/hr) 1448942 o 12 Fuel Oil Inlet Tem . C 70 Total (MMKcal/hr) 7.79 13 Fuel Oil Sp. Heat. (Kcal/kg/0K) 0.48 Thermal Efficiency 90.4% 14 Enthalpy of Atomising Steam (Kcal/kg) 683 Excess Air Used = 19.4% Cp, av., (CO 2) (Kca/0K,Kgmole) 9.69 Flue Gas Composition Mole % Cp, av., (O 2) (Kca/0K,Kgmole) 7.17 CO2 = 11.23% FIRED Cp, av., (N 2) (Kca/0K,Kgmole) 6.97 O2 = 3.68% HEATER Cp, av., (H 2O) (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" Colum n only
2. Ambient Temp. use as datum temp. for simplific ation of calculation
