FLUE GAS STACK TEMPERATURE AND STACK VELOCITY ESTIMATION

BY
ADEDIRAN BABALOLA, P. Eng, P.E
 BASIS

1. COMPLETE COMBUSTION

2. SUPPLY GAS TO LINE HEATER BURNER /PILOT IS FUEL GAS: 100 % METHANE

3. AIR SUPPLY IS PREDOMINATLY O2 AND N2;

4. WITH 40% EXCESS O2

5. ASSUME LINE HEATER CAPACITY: 500,000 Btu/hr (527,527.93 KJ/HR ≡ 146.54 KW)

 WRITE AND BALANCE STOICHIOMERY EQUATION

6. 2𝐶𝐻 + 2 𝑂 + 3.76𝑁 → 2𝐶𝑂 + 4𝐻 𝑂 + 7.52𝑁 + 9𝑂

 CHECK THE MOLE BALANCE TO ENSURE EQUAL MOLES OF REACTANT AND PRODUCT:
REACTANT:

MOLE VERIFICATION:
COMPONENT NO OF MOLES
CH4 2
O2 13
N2 7.52
TOTAL 22.52

PRODUCT:

MOLE VERIFICATION:
COMPONENT NO OF MOLES
CO2 2
H 2O 4
N2 7.52
O2 9
TOTAL 22.52
 COMPUTE MOLE AND MASS FRACTION OF REACTANT AND PRODUCT

7. MOLECULAR WEIGHT OF COMPONENT:

MW
CH4 48 KG/KGMOL
O2 32 KG/KGMOL
N2 28 KG/KGMOL
CO2 44 KG/KGMOL

H2O 32 KG/KGMOL

8. MOLE AND MASS FRACTION:

MOLE MASS MASS MOLE MOLE MASS MASS

FRACTION EQUV. FRACTION FRACTION FRACTION EQUV. FRACTION
REACTANT PRODUCT

CH4 0.09 96.00 0.13 CO2 0.09 88.00 0.12

O2 0.58 416.00 H2 O 0.18 128.00 0.18

0.58
N2 0.33 210.56 0.29 N2 0.33 210.56 0.29
O2 0.40 288.00 0.40
TOTAL: 1.00 722.56 1.00 1.00 714.56 1.00

9. FUEL GAS SUPPLY TEMPERATURE TO BURNER/PILOT:

ASSUME Tf: 50 oC ≡ 323.15 K ---------------------------(A) 40 % 40 %

EXCESS
EXCESS
O2
O2

 CALCULATE STACK TEMPERATURE:

I. USE CONVECTIVE HEAT TRANSFER:

𝑸 = 𝒉 ∗ 𝑨 ∗ (𝑻𝒔 − 𝑻𝒇 ) ------------------------(1.1)

where:
Q= Heat Transfer per unit time (W)
A= Area of object (m2)
H= Heat Transfer Coefficient (W/m2-k)
 Ts = Stack Temperature (K)
Tf = Fluid Temperature (K)

II. FLUE GAS HEAT TRANSFER COEFFICIENT (H):

H for flue gas

CO2 45 W/m2-K
H2O 500 - 10,000 W/m2-K Average 5250 W/m2-K
O2 10 W/m2-K
N2 61610 W/m2-K

III. CALCULATED HEAT TRANSFER COEFFICIENT OF FLUE GAS BASED ON MOLE OF

COMPONENT:

Calculated H:
CO2 4.00 W/m2-K
H2O 932.50 W/m2-K
N2 20573.14 W/m2-K
O2 4.00 W/m2-K
--------------------------------(B)

IV. STACK PIPE DIAMETER:

INSIDE DIAMETER
8 INCHES 206.4 mm 0.2064 m
OF PIPE (SCH 20): -------(C)

V. CALCULATE STACK PIPE AREA:

𝐴= − − − − − − − − − − − − − − − − − − − − − − − − − − − (1.2)

Calculated A (Area) 2.20

2
0.033 m ---------------------(D)

VI. HEAT TRANSFER Q IN WATTS:

Q 146535.52 W
--------------------------(E)

VII. RE-ARANGE EQUATION 1.1 WITH STACK TEMPERATURE (T S) THE SUBJECT OF THE
FORMULA:
𝑄
𝑇 = + 𝑇 − − − − − − − − − − − − − − − − − − − − − (1.3)
𝐴 ∗ (∑ 𝐻 )

Where:
 i = flue gas individual component

n = Total component

∑ = Summation of all components

INPUT ALL VALUES (EQUATIONS A, B, C, D, E AND F) IN EQUATION 1.3, WE HAVE:

TS 526.72 K
o
253.6 C

VIII. COMBUSTION EFFICIENCY FROM API SPECIFICATION 12 K (PAGE 24):

  CALCULATE STACK VELOCITY

10. COMPUTE MASS (M) AND VOLUMETRIC FLOW RATE (V) USING HEAT TRANSFER (Q) AND
LOWER HEATING VALUE (LHV):

Q 500000 BTU/HR 527527.93 KJ/HR

MOLE MASS MASS MOLE MOLE MASS MASS ` FLOW RATE

FRACTION EQUV. FRACTION FRACTION FRACTION EQUV. FRACTION (M3/HR)
REACTANT PRODUCT

CH4 0.09 96.00 0.13 CO2 0.09 88.00 0.12 0.67 KG/M
3 1.40
O2 0.58 416.00 H2O 0.18 128.00 0.18 0.7618 3 2.46
0.58 KG/M
0.33 210.56 0.29 0.33 210.56 0.29 1.25 3 2.82
N2 N2 KG/M
0.40 288.00 0.40 1.429 3 5.93
O2 KG/M
TOTAL: 1.00 722.56 1.00 1.00 714.56 1.00

3
` TOTAL: 12.60 M /HR
CH4 48 KG/KGMOL LHV CH4 50,000 KJ/KG
O2 32 KG/KGMOL
N2 28 KG/KGMOL OVERALL MASS RATE - ASSUME TOTAL FUEL GAS 10.55 KG/HR
CO2 44 KG/KGMOL
40% EXCESS OXYGEN 4.25 KG/HR
H2O 32 KG/KGMOL
TOTAL: 14.80 KG/HR

IX. CALCULATE VELOCITY USING THE FOLLOWING EQUATIONS:

𝑉= ----------------------------------------------------------------------------------(1.4)

STACK AVERAGE VELOCITY = FLOW RATE / AREA OF PIPE

376.68 m/h 6.278049979
1.0E-01 m/s
0.34 ft/s

Alternative equation for Velocity calculation (From CRANE Chapter 3, Page 3-17)

21220 ∗ 𝑊
𝑉 = −−−−−−−−−−−−−−−−−−−−−−−−−−− −(1.5)
𝑑 ∗ 𝜌

Where;
W = Mass flow rate (KG/HR)
d = Diameter of Pipe (MM OR M)
3
р = Density of Fluid (KG/M )

W= 14.80 KG/HR
d= 206.40 MM
р= 1.16 KG/M
3

V= 6.3 M/MIN
0.11 m/s
CONFIRM THE VELOCITY USING API SPECIFICATION 12 K; WE HAVE:

API SPECIFICATION 12 K (Page 22)

∗ ∗ ∗
𝑉 = ∗ −−−−−−−−−−−−−−−−−−−− −(1.6)

T o
R 581.67
Qg MMSCFD 0.011
Z 0.998
d in 8.13
P Psia 26.7

Vg 0.21 ft/s
0.1 m/s