D-type water tube boiler with superheater and economizer

INTRODUCTION

The procedure shown below is next to all needed to successfully use the software to
calculate heat transfer in WATER TUBE boiler. The data input process leads the user
step-by-step in an easy-to-follow self-explaining way. During geometry data input process a
corresponding general image of particular boiler design feature is displayed
illustrating the current to-be-entered value. Safety mechanism is incorporated preventing
geometrically incorrect data such as tube wall thickness that is greater than tube
inner diameter, exit water temperature that is lower than return one etc.

WATER TUBE BOILER THERMODYNAMIC

CALCULATION
Instructions

18 MW, 25 t/h, 25 bar/362 psi D-TYPE GAS FIRED

STEAM BOILER WITH SUPERHEATER & ECONOMIZER
Step 2: Units choice (metric in this case). Use Arrow key to move up and down and Enter to
select. Mouse point + double click also works. Esc quits the program. Bottom line explains the
navigation. In general UP arrow brings you back to beginning of current section.
Step 3: Case description data entry. In last field Enter brings up next window. Use arrow keys,
Home and End to move up and down. Esc gets you back to Main menu.
Step 4: Fuel type choice (gaseous in this case).

Step 5: Boiler type choice (steam in this case).

Step 6: Enter steam pressure (if gauge pressure is 24 bar the absolute pressure is 25 bar).

Step 8: Combustion air is not preheated in this case (if it is the software asks for additional
data).
Step 10: Natural gas composition. Entering CH4 100% works satisfactory if exact analysis is not
available.
Step 9: Rest oxygen in flue gas entry. It's the value displayed by flue gas analyzer and is used
to calculate excess air (lambda value).
Step 11: Gas data entry as displayed on gas gage (or using gas standard conditions - 0°C gas
temperarure, 0 mbar overpressure and 1.013 mbar atmospheric pressure).
Step 12: Enter gas rate as displayed by gas gauge. Value corresponding to actual gas
conditions on gas gauge shall be entered not recalculated to standard conditions (modern gas
gauges display both values).
Step 13: Flue gas recirculation is not applied in this case (if it was software would ask for
additional data).
SteP 14: Feed water temperature. Software displays saturated steam temperature calculated
from given steam pressure.
 Step 7: Outdoor air temperature (temperature of air coming in boiler room).

Step 15: Enter cooled area in furnace. Make sure membrane width is deducted.

Step 17: Enter wall thickness of furnace walls. Since walls are made of tubes this is actually
tubes wall thickness.
Step 16: Enter furnace length.

Step 18: Enter furnace cross section in flue gas flow direction (needed to calculate flue gas
velocity).
Step 19: There is superheater in furnace.

Step 21: Enter superheated steam design temperature.

Step 23: Enter angle of attack under which flue gas enters superheater (90° in this case). It
can not be less than 10°.
Step 24: Enter superheater tube section length as shown in image.
Step 26: Enter superheater tube wall thickness.

Step 25: Enter superheater tube outer diameter.

Step 27: Enter superheater tubes arrangement (plain in this case-tubes in subsequent row are
in same line as those in preceding row).
Step 28: Enter number of superheater tubes in individual row. Software will determine needed
number of tube rows and by that size of superheater to meet set superheated steam design
temperature (if it can not be reached software will inform about that in results).
Step 29: Enter distance between superheater tubes center lines. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 30: Enter number of superheater tubes connected to manifolD (in this case it is same as
number of tubes in row). This is needed to calculate steam velocity in tubes.
Step 31: Enter stack connector cross section area (needed to calculate static pressure drop
and flue gas velocity in it).
Step 32: In this case there is economizer attached.

Step 33: Economizer is tube array shaped.

Step 34: Enter economizer tube section length (image illustrates it).

Step 35: Enter economizer tube outer diameter.

Step 36: Enter economizer tube wall thickness.

Step 38: Enter economizer tubes arrangement (plain in this case-tubes in subsequent row are
in same line as those in preceding row).
Step 39: Enter number economizer tubes in individual row. Software will determine needed
number of tube rows and by that the size of economizer for given conditions.
Step 41: Enter distance between economizer tubes center lines. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 42: Enter number of economizer tubes connected to manifold (in this case it is same as
number of tubes in row). This is needed to calculate water velocity in tubes.
Previous step was the last one in data entry process. Pressing Enter commences calculation
process, which takes few seconds or less.
Results display folows (provided geometry and operation data entered were correct and
around. Pressing Esc brings up Final menu. Move up and down with PgUp/PhDown, arrow
up/down keys, End key to jump to the end of results pages and Home to return to first results
page. Actual complete printout of results is shown at the bottom below.
Final menu displays various options. Input data can be changed till results meet user desire.
Results can be saved to file in folder where main program was installed to
(c\BoilerDesignSoftware). Choose file name with txt extension (test.txt).
If Graphs option in previous menu is selected two graphs can be displayed. Pressing Enter
brings back Graphs menu.
Flue gas temperature decrease in boiler diagram shows how flue gas temperature decreases
as gases pass over cooled area in boiler sections starting with adiabatic combustion
temperature. In reality line is smooth (logarithmic). Graphs displays flue gas temperature drop
in furnace as consequence of heat taken up by furnace walls.

BOILER DESIGN SOFTWARE

HEAT TRANSFER IN WATER TUBE BOILER (METRIC UNITS)
=================================================

DATE :MAY 13,2016

SUBJECT:D-TYPE WATER TUBE BOILER
MAKE :-
REMARK :DEMO CASE

SUMMARY
_______

DELIVERED HEAT WITH FUEL & AIR = 22076.2 kW

TRANSFERRED HEAT IN BOILER & ECO
UNACCOUNTED
UNACCOUNTED
STEAM RATE
SUPERHEATED STEAM TEMPERATURE
WATER EXIT TEMP. FROM ECONOMIZER
FLUE GAS EXIT TEMP. FROM ECONOMIZER=
I/O EFFICIENCY (FUEL LHV)
COMBUSTION AIR RATE
RELEASED FLUE GAS RATE
= 18240.5 kW
= 167.4 kW
= .76 %
= 24.6 t/h
= 350.5 °C
= 150.9 °C
237.3 °C
= 83.3 %
= 24077.78 mn3/h
= 26618.4 mn3/h

INPUT DATA
__________
BOILER TYPE: STEAM
ABSOLUTE WORKING PRESSURE: 25 bar
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: WATER TUBE
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: GAS

GAS DATA
________

CH4-CONTENT = 100 vol%

CONVERSION FACTOR TO NORM CONDITIONS= .9988

LOWER NORM HEATING VALUE = 35883 kJ/m3

LOWER NORM HEATING VALUE = 10 kWh/m3

HIGHER NORM HEATING VALUE= 39819 kJ/m3

HIGHER NORM HEATING VALUE= 11.1 kWh/m3

LOWER WOBBE INDEX = 42413.3 kJ/m3

HIGHER WOBBE INDEX = 47065.6 kJ/m3

GAS NORM DENSITY = .716 kg/m3

GAS DENSITY ACTUAL = .716 kg/m3
GAS OVERPRESSURE = 0 bar
ATMOSPHERIC PRESSURE= 1.013 bar
GAS TEMPERATURE = 0 °C

GAS RATE= 2200 m3/h

OUTDOOR AIR TEMPERATURE = 20 °C

FEED WATER TEMPERATURE = 105 °C
REST O2 IN FLUE GAS = 3 %
EXCESS AIR/LAMBDA VALUE = 1.15 -
TOTAL COOLED AREA IN BOILER= 183.929 m2

FURNACE GEOMETRY DATA

_____________________

FURNACE IS HORIZONTAL

FURNACE COOLED AREA = 153 m2

LENGTH IN FLUE GAS FLOW DIRECTION = 6.5 m
WALL THICKNESS = .0052 m
CROSS SECTION IN GAS FLOW DIRECTION= 10.2 m2
THERE IS TUBE ARRAY STEAM SUPERHEATER IN FURNACE
TUBE ROWS HAVE PLAIN ARRANGEMENT

SUPERHEATED STEAM ABSOLUTE PRESSURE = 25 bar

SUPERHEATED STEAM DESIGN TEMPERATURE = 350 °C
TUBE SECTION LENGTH = 1.7 m
FLUE GAS INFLOW ANGLE ON TUBES = 90 °
NEEDED TOTAL TUBE LENGTH = 258.4 m
NEEDED TOTAL TUBE AREA = 30.9 m2
TUBE OUTER DIAMETER = .0381 m
TUBE WALL THICKNESS = .0032 m
NUMBER OF TUBES IN ROW = 19
NEEDED NUMBER OF TUBE ROWS = 8
DISTANCE BETWEEN TUBES IN ROW = .1 m
NUMBER OF TUBES CONNECTED TO MANIFOLD = 19

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS HAVE PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 105 °C

TUBE SECTION LENGTH = 2.1 m
TOTAL TUBE LENGTH = 1197 m
TOTAL TUBE AREA = 143.3 m2
TUBE OUTER DIAMETER = .0381 m
TUBE WALL THICKNESS = .0032 m
NUMBER OF TUBES IN ROW = 19
NUMBER OF TUBE ROWS = 30
DISTANCE BETWEEN TUBES IN ROW = .1 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 19

STACK CONNECTOR CROSS SECTION AREA= .385 m2

CALCULATION RESULTS
___________________

ADIABATIC COMBUSTION TEMPERATURE = 1732 °C

COMBUSTION AIR RATE = 24077.78 mn3/h

COMBUSTION AIR MASS RATE = 31132.57 kg/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 25841.72 m3/h
RELEASED FLUE GAS RATE = 26618.4 mn3/h
RELEASED FLUE GAS MASS RATE = 35044.68 kg/h
FLUE GAS NORM DENSITY = 1.32 kg/m3
FLUE GAS RATE AT BOILER EXIT TEMP. = 49754.4 m3/h
DEW POINT OF WATER VAPOR IN FLUE GAS= 57.59 °C
CONDENSATE (LATENT) HEAT = 2508.49 kW
CONDENSATE MASS RATE IN FLUE GAS = 3810.33 kg/h
CO2 RATE IN FLUE GAS = 2200 mn3/h
CO2 MASS RATE IN FLUE GAS = 4319.77 kg/h
SPECIFIC CO2 EMISSION = 1.96 kg/m3
CO2 CONCENTRATION IN FLUE GAS = 8.26 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol%
H2O RATE IN FLUE GAS = 4740.62 mn3/h
WATER MASS RATE DELIVERED WITH AIR = 24.82 kg/h
H2O CONCENTRATION IN FLUE GAS = 17.81 vol%
N2 RATE IN FLUE GAS = 19021.45 mn3/h
N2 CONCENTRATION IN FLUE GAS = 71.46 vol%
O2 RATE IN FLUE GAS = 656.33 mn3/h
O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol%

DELIVERED HEAT WITH FUEL = 21902.1 kW

STEAM TEMPERATURE IN BOILER = 224 °C
VELOCITY IN BOILER FLUE APERTURE = 35.9 m/s
STATIC PRESSURE DROP IN BOILER = 4.685 mbar
STATIC PRESSURE DROP WITH ECONOMIZER = 6.86 mbar
TRANSFERRED HEAT IN BOILER & ECO = 18240.5 kW
STEAM RATE = 24.6 t/h
PART OF HEAT TAKEN UP BY FURNACE WALLS= 67.4 %
FLUE GAS TEMP. BEFORE ECONOMIZER = 361.6 °C

FLUE GAS EXIT TEMP. FROM ECONOMIZER = 237.3 °C

WATER EXIT TEMP. FROM ECONOMIZER = 150.9 °C
STATIC PRESSURE DROP IN ECONOMIZER = 2.174 mbar

I/O EFFICIENCY (FUEL LHV)= 83.3 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 361.6 °C

MEAN FLUE GAS TEMPERATURE = 874.9 °C
THERMAL RADIATION = 13907.4 kW
CONVECTION = 854.1 kW
HEAT TRANSFERRED TO WALLS = 14761.5 kW
AREA THERMAL LOAD = 96.48 kW/m2
VOLUME THERMAL LOAD = 330.35 kW/m3
FLUE GAS VELOCITY = 3.05 m/s
WALL TEMP. ON FLUE GAS SIDE= 239.7 °C

HEAT TRANSFER ON TUBE ARRAY SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 350.5 °C
MEAN FLUE GAS TEMPERATURE = 826.6 °C
FLUE GAS EXIT TEMPERATURE = 361.9 °C
THERMAL RADIATION = 575.6 kW
CONVECTION = 1570.2 kW
HEAT TRANSFERRED = 2145.7 kW
STEAM VELOCITY IN TUBES = 43.67 m/s
FLUE GAS VELOCITY AROUND TUBES = 15.72 m/s
WALL TEMP. ON FLUE GAS SIDE = 406 °C

HEAT TRANSFER ON TUBE ARRAY ECONOMIZER

______________________________________

WATER EXIT TEMPERATURE = 150.9 °C

MEAN FLUE GAS TEMPERATURE = 264.2 °C
FLUE GAS EXIT TEMPERATURE = 237.3 °C
THERMAL RADIATION = 97.7 kW
CONVECTION = 1235.6 kW
HEAT TRANSFERRED = 1333.3 kW
WATER VELOCITY IN TUBES = .486 m/s
FLUE GAS VELOCITY AROUND TUBES= 6.22 m/s
WALL TEMP. ON FLUE GAS SIDE = 154.1 °C
STATIC PRESSURE DROP = 2.174 mbar
HEAT TRANSFER IN WATER TUBE BOILER (ENGLISH UNITS)
==================================================

DATE :MAY 13,2016

SUBJECT:D-TYPE WATER TUBE BOILER
MAKE :-
REMARK :DEMO CASE

SUMMARY
_______

DELIVERED HEAT WITH FUEL & AIR = 2252 HP

TRANSFERRED HEAT IN BOILER & ECO = 1860.71 HP
STEAM RATE = 27.1 short tons/h
SUPERHEATED STEAM TEMPERATURE = 662.9 F
WATER EXIT TEMP. FROM ECONOMIZER = 303.6 F
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 459.1 F
I/O EFFICIENCY (FUEL HHV) = 74.7 %
COMBUSTION AIR RATE = 850504.34 st.cu.ft./h
RELEASED FLUE GAS RATE = 940247.2 st.cu.ft./h

INPUT DATA
__________
BOILER TYPE: STEAM
ABSOLUTE WORKING PRESSURE: 362.5 psi
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: WATER TUBE
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: GAS

GAS DATA
________

CH4-CONTENT = 100 vol%

CONVERSION FACTOR TO NORM CONDITIONS= .9468

LOWER NORM HEATING VALUE = 963.1 BTU/cu.ft.

HIGHER NORM HEATING VALUE= 1068.8 BTU/cu.ft.

LOWER WOBBE INDEX = 4555.8 BTU/cu.ft.

HIGHER WOBBE INDEX = 5055.5 BTU/cu.ft.

GAS NORM DENSITY = .045 lb/cu.ft.

GAS DENSITY ACTUAL = .045 lb/cu.ft.
GAS OVERPRESSURE = 0 psi
ATMOSPHERIC PRESSURE= 14.7 psi
GAS TEMPERATURE = 32 F

GAS RATE= 77692.3 cu.ft./h

OUTDOOR AIR TEMPERATURE = 68 F

FEED WATER TEMPERATURE = 221 F
REST O2 IN FLUE GAS = 3 %
EXCESS AIR/LAMBDA VALUE = 1.15 -
TOTAL COOLED AREA IN BOILER= 1979.796 sq.ft.

FURNACE GEOMETRY DATA

_____________________

FURNACE IS HORIZONTAL

FURNACE COOLED AREA = 1646.878 sq.ft.

LENGTH IN GAS FLOW DIRECTION = 21.325 ft.
WALL THICKNESS = .205 in
CROSS SECTION IN GAS FLOW DIRECTION= 109.792 sq.ft.

THERE IS TUBE ARRAY STEAM SUPERHEATER IN FURNACE

TUBE ROWS HAVE PLAIN ARRANGEMENT
SUPERHEATED STEAM ABSOLUTE PRESSURE = 362.5 psi
SUPERHEATED STEAM DESIGN TEMPERATURE = 662 F
FLUE GAS INFLOW ANGLE ON TUBES = 90 °
TUBE SECTION LENGTH = 5.577 ft.
NEEDED TOTAL TUBE LENGTH = 847.8 ft.
NEEDED TOTAL TUBE AREA = 332.918 sq.ft.
TUBE OUTER DIAMETER = 1.5 in
TUBE WALL THICKNESS = .126 in
NUMBER OF TUBES IN ROW = 19
NEEDED NUMBER OF TUBE ROWS = 8
DISTANCE BETWEEN TUBES IN ROW = 3.937 in
NUMBER OF TUBES CONNECTED TO MANIFOLD = 19

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS ARE IN PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 221 F

TUBE SECTION LENGTH = 6.89 ft.
TOTAL TUBE LENGTH = 3927.165 ft.
TOTAL TUBE AREA = 1556.817 sq.ft.
TUBE OUTER DIAMETER = 1.5 in
TUBE WALL THICKNESS = .126 in
NUMBER OF TUBES IN ROW = 19
NUMBER OF TUBE ROWS = 30
DISTANCE BETWEEN TUBES IN ROW = 3.937 in
NUMBER OF TUBES CONNECTED TO MANIFOLD= 19

STACK CONNECTOR CROSS SECTION AREA= 4.144 sq.ft.

CALCULATION RESULTS
___________________

ADIABATIC COMBUSTION TEMPERATURE = 3150 F

COMBUSTION AIR RATE = 850504.34 st.cu.ft./h

COMBUSTION AIR MASS RATE = 68649.54 lb/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 912812.35 cu.ft./h
RELEASED FLUE GAS RATE = 940247.2 st.cu.ft./h
RELEASED FLUE GAS MASS RATE = 77276.04 lb/h
FLUE GAS NORM DENSITY = .082 lb/cu.ft.
FLUE GAS RATE AT STACK TEMPERATURE = 1757484.76 cu.ft./h
DEW POINT OF WATER VAPOR IN FLUE GAS= 135.67 F
CONDENSATE (LATENT) HEAT = 255.89 HP
CONDENSATE (LATENT) HEAT = 8.57 MMBTU/h
CONDENSATE MASS RATE IN FLUE GAS = 8402.05 lb/h
CO2 RATE IN FLUE GAS = 77711.05 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 9525.4 lb/h
SPECIFIC CO2 EMISSION = 1.96 lb/st.cu.ft.
CO2 CONCENTRATION IN FLUE GAS = 8.26 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol%
H2O RATE IN FLUE GAS = 167453.91 st.cu.ft./h
WATER MASS RATE DELIVERED WITH AIR = 54.73 lb/h
H2O CONCENTRATION IN FLUE GAS = 17.81 vol%
N2 RATE IN FLUE GAS = 671898.45 st.cu.ft./h
N2 CONCENTRATION IN FLUE GAS = 71.46 vol%
O2 RATE IN FLUE GAS = 23183.8 st.cu.ft./h
O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol%

DELIVERED HEAT WITH FUEL = 2234.2 HP

DELIVERED HEAT WITH FUEL = 74.79 MMBTU/h
STEAM TEMPERATURE IN BOILER = 435.1 F
VELOCITY IN BOILER FLUE APERTURE = 117.78 ft/s
STATIC PRESSURE DROP IN BOILER = 1.881 inWC
STATIC PRESSURE DROP WITH ECONOMIZER = 2.754 inWC
TRANSFERRED HEAT IN BOILER & ECO = 1860.71 HP
TRANSFERRED HEAT IN BOILER & ECO = 62.29 MMBTU/h
STEAM RATE = 27.1 short tons/h
PART OF HEAT TAKEN UP BY FURNACE WALLS= 67.4 %
FLUE GAS TEMP. BEFORE ECONOMIZER = 682.9 F

FLUE GAS EXIT TEMP. FROM ECONOMIZER = 459.1 F

WATER EXIT TEMPERATURE FROM ECONOMIZER= 303.6 F
STATIC PRESSURE DROP IN ECONOMIZER = .873 inWC

I/O EFFICIENCY (FUEL HHV)= 74.7 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 682.9 F

MEAN FLUE GAS TEMPERATURE = 1606.8 F
VOLUME THERMAL LOAD = .95 HP/cu.ft.
HEAT TRANSFER INTENSITY = 1.094 sq.ft./HP
THERMAL RADIATION = 1418.7 HP
CONVECTION = 87.1 HP
HEAT TRANSFERRED TO WALLS = 1505.8 HP
GAS VELOCITY = 10 ft/s
WALL TEMP. ON FLUE GAS SIDE= 463.5 F

HEAT TRANSFER ON TUBE ARRAY SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 662.9 F
MEAN FLUE GAS TEMPERATURE = 1519.9 F
FLUE GAS EXIT TEMPERATURE = 683.5 F
THERMAL RADIATION = 58.71 HP
CONVECTION = 160.17 HP
HEAT TRANSFERRED = 218.89 HP
STEAM VELOCITY IN TUBES = 143.29 ft/s
FLUE GAS VELOCITY AROUND TUBES = 51.585 ft/s
WALL TEMP. ON FLUE GAS SIDE = 762.8 F

HEAT TRANSFER ON TUBE ARRAY ECONOMIZER

______________________________________

WATER EXIT TEMPERATURE = 303.6 F

MEAN FLUE GAS TEMPERATURE = 507.5 F
FLUE GAS EXIT TEMPERATURE = 459.1 F
THERMAL RADIATION = 10 HP
CONVECTION = 126 HP
HEAT TRANSFERRED = 136 HP
WATER VELOCITY IN TUBES = 1.593 ft/s
FLUE GAS VELOCITY AROUND TUBES= 20.4 ft/s
WALL TEMP. ON FLUE GAS SIDE = 309.3 F
STATIC PRESSURE DROP = .873 inWC
Step 1: Upon launching the software the opening screen appears. Press Enter to commence
with data input process.
Step 20: Enter superheated steam absolute pressure (it can not be higher than steam presure
in boiler).
Step 22: Enter water injection rate for superheater steam temperature attemperation if any
(none in this case). This is measured value.
Step 37: There are no fins on economizer tube.
Step 40: Enter number of economizer tube rows. If too many software will issue and alert.
Flue gas enthalpy diagram shows flue gases energy flow starting with enthalpy at adiabatic
combustion temperature (temperature at which flue gases contain heat released from
combustion).