Ultimate analysis: Carbon = 39.9%, Hydrogen = 2.48% , Sulpur = !.

38 %,
"itrogen = !.#$%, %&ygen = #.$# %, 'oisture =8% and (s = 42%. )e
analysis is based on *eigt basis. Consider 4% +arbon loss in +ombustion o,
(-.C system.
AIR REQUIREMENT CALCULATION
(mount o, o&ygen re/uired ,or burning +oal
C 0 %
2
C%
2
0 eat
12 2g o, +arbon rea+t *it 32 2g o, o&ygen to produ+e 44 2g o, +arbon di
o&ide. 3.e., one 2g o, +arbon re/uired 32412 = 2.### 2g o, o&ygen and produ+e
44412 = 3.###2g o, +arbon dio&ide.
!.3992g o, +arbon in +oal re/uire = !.39 & 2.### = 1.!#4 2g o, o&ygen
H
2
0 142%
2
H
2
% 0 eat
2 2g o, ydrogen rea+t *it 1# 2g o, o&ygen to produ+e 18 2g o, moisture. 3.e.,
one 2g o, ydrogen re/uires 1#42 = 8 2g o, o&ygen and produ+e 1842 = 9 2g
o, moisture.
!.!248 2g o, ydrogen in +oal re/uires = !.!248&8 = !.1984 2g o, o&ygen

S 0 %
2
S%
2
0 eat
32 2g o, sulpur re/uire 32 2g o, o&ygen to produ+e #4 2g o, sulpur di o&ide.
3.e., one 2g o, sulpur re/uire one 2g o, o&ygen and produ+e #4432 = 2 2g o,
sulpur di o&ide.
!.!!38 2g o, sulpur in +oal re/uire =!.!!38 & 1 = !.!!38 2g
te oter +omposition li2e nitrogen, argon5i, present6 is inert gas and it *ill not
rea+t *it o&ygen. 'oisture is in saturated ,orm and it does not re/uire
o&ygen.
)e total o&ygen re/uired = 1.!#4 0 !.1984 0!.!!38 = 1.2##2 2g
)e o&ygen present in ,uel = !.!#$# 2g
"et o&ygen re/uired = 1.2##2 7 !.!#$# = 1.198# 2g
(ir +ontains 23.18 % o&ygen by *eigt and en+e te air re/uired ,or 1.198#
2g o, o&ygen is = 1.198#4!.2318 = 8.1$# 2g o, dry air.
(mount o, *et air re/uired +onsidering #!% 9elati:e umidity = 8.1$# & 1.!13
= 8.244 2g.
Coal re/uires 2!% e&+ess air ,or +ombustion in (-.C system en+e *et air
re/uired ,or burning per 2g o, ,uel = 5.244 x 1.2 = 6.292 kg.
FLUE GAS GENERATION ESTIMATION
Carbon di o&ide produ+ed = 5!.399 7 !.!1886 & 3.### = 1.3918 2g
'oisture produ+ed = 5!.!248 & 9 6 = !.2232 2g.
'oisture in ,uel = !.!8 2g.
'oisture in air = !.!13 & #.212 = !.!8!$ 2g.
)otal moisture in ,lue gas = !.3839 2g
Sulpur di o&ide produ+ed = !.!!38 & 2 = !.!!$# 2g.
"itrogen in air = #.212 & !.$#88 = 4.$$39 2g.
"itrogen in ,uel = !.!!#$ 2g.
)otal nitrogen in te ,uel = 4.$$39 0 !.!!#$ = 4.$8!# 2g.
;&+ess o&ygen in gas = 5#.212 7 8.1$#6&!.2318 = !.2398 2g.
)otal -lue gas produ+ed
<er 2g o, ,uel = 1.391 0 !.3839 0 !.!!$# 0 4.$8!# 0 !.2398 = #.8!3 2g.

Ex.02 -ind te *eigt o, *ater present in atmosperi+ air at #!% relati:e
umidity and temperature 4!=C.
-or 4!=C, te saturation pressure o, *ater is = !.!$822# atm 5,rom steam
tables6
(t #!% 9H te partial pressure o, *ater :apour is !.# & !.!$822#
=!.!48138 atm
>eigt o, moisture present in air = !.#22 & <*451.!38 7<*6
= !.#22 & !.!48138
51.!38 7 !.!481386

= !.!283# 2g42g.
te e,,i+ien+y o, a boiler ,iring *it +oal as a ,uel a:ing ?C@ o, 32!! 2+al42g.
-urna+e is -luidiAed bed boiler. (pply (S'; <)C 4.1 indire+t metod to
+al+ulate te e,,i+ien+y. -lue gas temperature lea:ing te boiler is14!=C and
ambient air temperature is 4!=C. (s +ontent o, te ,uel is 42.3% and 2!% o,
total as is +olle+ted in bed and 8!% as is +arried in ,ly as. (s per lab
report te loss on ignition o, as samples +olle+ted in bed Aone and ,ly as
Aone is !.1% by *eigt and 4.4%by *eigt. )e boiler is operating at 2!%
;&+ess air and te dry 2g42g o, gas produ+ed =8.91 and dry 2g42g o, air
re/uired = 8.#9#. )e moisture and ydrogen present in te ,uel is #% and
2.$% respe+ti:ely.
.asi+ally ,ollo*ing are te losses present in boiler,
1.! Unburnt +arbon loss
2.! Sensible eat loss troug as
3.! 'oisture loss due to air
4.! 'oisture and +ombustion o, ydrogen in ,uel
8.! Bry ,lue gas loss
#.! 9adiation loss.
Unbun! C"b#n $#%% =4&
S'n%(b$' )'"! $#%% (n "%)*
-lyas = %-lyas &% o, as /ty & sp.eat 5)go 7 )amb6 &1!!4?C@
= !.8 & !.423 &!.22514!C4!6 1!!432!!
=!.233%
.ed as
= !.2&!.423&!.2259!!C4!61!!432!!
=!.8%
Sensible eat loss due to as = !.2330 !.8 =!.$33%
+'"! $#%% ,u' !# -#(%!u' (n "(
= 2g42g o, moist in air & 2g42g o, dry air5 ;ntalpy o, steam at )go in !.!13ata
7
;ntalpy o, steam at )amb in !.!13
ata6
= !.!13 & 8.#9# &5 ##!.337#18.2861!!432!!
=!.1!43%
"ote: )e abo:e implies tat te *ater :apour at ambient temperature at
partial pressure e&ists in steam ,orm and gets supereated at 14!=C
+'"! $#%% ,u' !# -#(%!u' (n .u'$ "n, /#-bu%!(#n #. )0,#g'n,
=5%o, moisture in ,uel 0 % o, ydrogen &8.9465;ntalpy o, steam 7
)amb61!!432!!
= 5!.!# 0 !.!2$&8.9465#88.3$ 74!61!!432!!
= 8.824%
"ote: )e abo:e implies tat te *ater moisture present in ,uel is in li/uid
,orm, during +ombustion it *ill absorb latent eat and supereat ,rom
+ombustion. )e ydrogen present in te ,uel rea+t *it o&ygen to ,orm *ater.
-rom +ombustion e/uation o, ydrogen it is ,ound tat 1 2g o, ydrogen ,orm
8.94 2g o, *ater.
10 .$u' g"% $#%%,
= 2g42g o, dry ,lue gas & 5;ntalpy o, gas at )go 7(ir entalpy at
)amb6&1!!432!!
=Dg42g o, dry ,lue gas & Speat 5)go 7)amb61!!432!!
=8.91 & !.24 &514! 74!61!!432!! = 4.433%
R",("!(#n $#%%,
-rom (.'( Cart te loss is estimated as =!.8%
"ote: 3n te indire+t metod .lo* do*n losses *ill not be +onsidered into
a++ount. 3t is assumed te boiler is operated under Aero present blo* do*n.
Ex02 ;stimate te -B and 3B ,an ,lo* and po*er re/uired ,or a bagasse ,ired
dumping grate boiler, *ose bagasse +onsumption at 1!!% 'C9 +apa+ity is
31!!! 2g4r and te boiler is operating at 38% e&+ess air. )e ,uel air
re/uirement is 3.9!9 2g42g o, ,uel and gas generation is 4.8$3 2g42g.
-B ,an
)otal air re/uirement = 31!!! & 3.9!9 = 1211$9 2g4r.
-an design ,lo* *it 18% margin = 1211$9 & 1.18453#!! &1.1286

= 34.31 m
3
4se+
-B ,an ead
<ressure ead re/uired ,or air ,lo* se+tions li2e aireater, air du+ts and grate
are to be +al+ulated. "o* in most o, te pra+ti+al appli+ations te pressure
drop *or2s out to be 1#8 mm >C and te same +an be assumed ,or tis
+al+ulation.
-B ,an ead *it margin = 1#8 & 1.2 = 2!!mm>+
-B ,an po*er re/uired.
= ,lo* & ead41!2 & e,,i+ien+y
= 34. 31 & 2!! 4 51!2 & !.86
= 84.!9 D>
'otor sele+ted = 84.!9 & 1.1 = 92.8 D> 5ne&t nearest motor standard is 11!
D>6
3B ,an
)otal gas produ+ed = 31!!! & 4.8$3 = 181!#3 2g4r.
-an design ,lo* *it 28% margin = 181!#3 & 1.28 & 52$3 014!6453#!!
&1.298&2$36

= #1.2$ m
3
4se+
3B ,an ead
<ressure ead re/uired ,or gas ,lo* se+tions li2e -urna+e, .an2, ;+onomiser,
air eater, gas du+ts and dust +olle+tors are to be +al+ulated. "o* in most o,
te pra+ti+al appli+ations te pressure drop *or2s out to be 23! mm >C and
te same +an be assumed ,or tis +al+ulation.
3B ,an ead *it margin = 23! & 1.3 = 3!!mm>+
3B ,an po*er re/uired.
= ,lo* & ead41!2 & e,,i+ien+y
= #1.2$ & 3!! 4 51!2 & !.86
= 228 D>
'otor sele+ted = 228 & 1.1 = 24$.$ D> 5ne&t nearest motor standard is 28!
D>6
)able so*ing per+entage margin on ,lo* and ead re/uired ,or di,,erent
boiler appli+ation.
S." Bes+ription ?rate type (-.C C-.C %3E
,ired
1 -B -an -lo*
Head
18%
2!%
28%
28%
28%
28%
18%
2!%
2 3B -an -lo*
Head
28%
3!%
28%
28%
28%
28%
2!%
2!%
3 S(4<(4%- ,an -lo*
Head
1!%
18%
28%
28%
28%
28%
"ot
appli+able
+EAT TRANSFER IN FURNACE
-urna+e eat trans,er is a +omple& penomenon, *i+ +an not be +al+ulated
by a single ,ormula. 3t is te +ombination o, abo:e said tree modes o, eat
trans,er. Ho*e:er in a boiler ,urna+e eat trans,er is predominantly due to
radiation, partly due to luminous part o, te ,lame and partly due to nonC
luminous gases. %:erall eat trans,er +oe,,i+ient in ,urna+e is go:erned by
tree )Fs temperature, turbulen+e and time and +al+ulated by t*o parts.
H+ C eat trans,er +oe,,i+ient by +on:e+tion
Hr C eat trans,er +oe,,i+ient by radiation.
+EAT TRANSFER COEFFICIENT 34 CON5ECTION 6+/7
Heat trans,er by +on:e+tion may +arry out in turbulent or laminar ,lo* o, te
,luid. 3n ,or+ed +on:e+tion turbulen+e or laminar ,lo* depends on mean
:elo+ity, +ara+teristi+ lengt E, density and :is+osity. )ese :ariables are
grouped togeter in a dimensionless parameter +alled 9eynolds number.
9eynolds number is te ratio bet*een inertia ,or+e to :is+ous ,or+e.
R'0n#$,% nu-b' = 6-"%% x "//'$'"!(#n786%)'" %!'%% x /#%%
%'/!(#n"$ "'"7
M"%% = 9#$u-' x ,'n%(!0
A//'$'"!(#n = 9'$#/(!0 8 !(-'
5#$u-' = /#%% %'/!(#n"$ "'" x 9'$#/(!0
S)'" %!'%% = ,0n"-(/ 9(%/#%(!0 x 9'$#/(!0 g",('n!69 8 $7
R' = ,'n%(!0 x 9'$#/(!0 x /)""/!'(%!(/ $'ng!)
10n"-(/ 9(%/#%(!0.
>en 9e G 21!! ten ,lo* is turbulen+e
H 21!! ten ,lo* is laminar. 3n pra+ti+al +ase te ,lo* is most o,ten
turbulent only.
3n ,ree +on:e+tion turbulen+e or laminar ,lo* depends on te buoyan+y ,or+e
and temperature di,,eren+e, +oe,,i+ient o, :olume o, e&pansion. )ese
:ariables are grouped to ,orm dimensionless numbers +alled ?raso,, number
and <randl number. Eaminar or turbulen+e is identi,ied *it produ+t o,
?raso,, number and prandl number
>en, ?r.<r H 1!
9
,lo* is laminar
?r.<r G 1!
9
,lo* is turbulent.
1IMENSIONAL ANAL4SIS FOR +EAT TRANSFER
COEFFICIENT
)e eat trans,er +oe,,i+ient may be e:aluated ,rom +orrelation de:eloped by
dimensional analysis. 3n tis metod all te :ariables related to te
penomenon is grouped by e&perien+e *it elp o, basi+ ,undamental units
lengt, mass, time and temperature.
)e ,inal e/uation arri:ed ,or
FORCE1 CON5ECTION
= ,5E,U, ,I,2,Cp6 ,
*ere,
E +ara+teristi+ lengt 5meters6
U :elo+ity 5meters4se+ond6
density ( 2ilogram4 +ub.meter6
I dynami+ :is+osity52ilogram4meter. Hour6
2 termal +ondu+ti:ity 5*atts4meter=2el:in6
Cp spe+i,i+ eat5*att42ilogram.=2el:in6
Eet = . E
a
U
b

+
I
d
2
e
Cp
,
, *ere .,a,b,+,d,e,, are +onstants
;&pressing te :ariables in terms o, teir dimensions
')
C3
J
C1
= . E
a
.5E)
C1
6
b
.5'E
C3
6
+
.5'E
C1
)
C1
6
d
.5'E)
C3
J
C1
6
e
.5EK )
C2
J
C1
6
,
= ..E
a0bC3+Cd0e02,
. )
7bCdC3eC2,
. '
+0d0e
. J
CeC,
! = a 0 b 73+ 7d 0e 02,
C3 = Cb 7d 73e 72,
1 = + 0 d 0 e
C1 = Ce C ,
)e solution o, te e/uation gi:es,
a = +C1, b =+, d = C+ 0,, e = 1C,
) = 3. L
/:1
.U
/
.
/
.;
:/<.
.k
:1:.
.C=
.
by grouping te :ariables,
4E
C1
2 = ..5UE 4 I6
+
. 5I. Cp 426
,
"ussultes number = ..59eynolds number6
+
.5<randl number6
,
)e +onstants .,+,, are e:aluated ,rom e&perimental data.
-or turbulent ,lo* inside tubes and ,ully de:eloped ,lo* te ,ollo*ing e/uation
attributed to 'r.Bittus and .oelter,

"u = !.!23 9e
!.8
<r
n
*ere, n = !.4 *en te ,luid is eated
n = !.3 *en te ,luid is +ooled.
-or turbulent ,lo* outside tubes
"u = !.!3$ 9e
!.8
<r
n
*ere, n = !.4 *en te ,luid is eated
n = !.3 *en te ,luid is +ooled
FREE CON5ECTION
-ree +on:e+tion depends on buoyan+y ,or+e -, *i+ is de,ined by,
Eet a ,luid at )o *it density o +ange to temperature ) *it density ten,
- = 5o 76g4< = 55o46 7 16g
"o*,
L +oe,,i+ient o, :olume e&pansion
ten, 14 = 514o6 0 L5)oC)6,
o = 51 0 L M )6
5o4 6 7 1 = L M )
- = Lg M )
-or an ideal gas L is in:ersely proportional to temperature,5i.e. dimensional
number ,or L is J
C1
and - is J
C1
N E)
C2
NJ ie E)
C2
6
.y dimensional analysis,
= ..5-
a
.Cp
b
.E
+
.
d
.I
e
.2
,
6
')
C3
J
C1
= .O 5E)
C2
6
a
.5E
2
)
C2
J
C1
6
b
. E
+
.5'E
C3
6
d
.5'E
C1
)
C1
6
e
.5'E)
C3
J
C1
6
,
P
1 = d 0 e0 ,
= a 0 2b 0 + 73d 7e 0 ,
C3 = C2a 72bCeC3,
C1 = CbC,
sol:ing tis e/uation.
+ = 3a 7 1,d = 2a , e = b 72a, , = 1C b
= .O 5gL M )6
a
. Cp
b
. E
3aC1
.
2a
. I
bC2a
. 2
1Cb
6P
= .O 5gL M )E
3

2
4 IK 6
a
. 5I.Cp426
b
P 524E6
E42 = .. ?r
a
. <r
b
.
"u = .. ?r
a
. <r
b
.y large number o, e&periments made on ,luids it as been ,ound tat
e&ponents a and b are o, te same :alue. So te e&pression redu+e to "u =
..5?r.<r6
a
+EAT TRANSFER 34 RA1IATION +
3n ,urna+e eat trans,er is predominant by luminous and nonCluminous
radiation. ( general appro&imate e&pression may be *ritten ,or ,urna+e
absorption using Ste,an boltAman la*.
Q = ( R
*
S OR
g
)
g
4
7 T
g
)
S
4
P
R
g
= U
+
R
+
0 U
*
R
*
C M R
emissi:ity pattern o, tri atomi+ gases su+ as +arbon di o&ide and *ater
:apour are studied by 'r. Hottel and +arts are a:ailable to predi+t gas
emissi:ity as a ,un+tion o, :arious gas temperature, partial pressure and
beam lengt. 3 a:e also ,urnised te e&pression ,orm to ,ind gas
emissi:ity. >en R
+
and R
*
are ,ound ,rom grap
U
+
and U
*
+an be determined ,rom te ,ollo*ing e&pression or ,rom grap.
%ter*ise emissi:ity o, gas +an be dire+tly ,ound by te e&pression gi:en in
e/uation1.
!.222 1 1
U
+
= ;V< WWWWWWWWWWWWWWW C
X <
+
NE 0!.!38 ln2.8 ln5p 0 1.86
143
!.23 1 2
U
*
= ;V< !.842 C
5!.23 0<
*
NE !.$8 !.80<
*
0p
*ere p is gas pressure in bar5a6
E is beam lengt meter
U
*
and U
+
are pressure +orre+tion ,a+tor ,or gas pressure
absorpti:e o, gasses +an be determined at *all temperature.
T
g
= U
+
T
+
0 U
*
T
*
C M T
(t *all temperature +orre+tion,
<
+*
= <
+
5)
*
4)
g
6 <
**
= <
*
5)
*
4)
g
6
T+ = R
+*
5)
g
4)
*
6
!.#8
T* = R
**
5)
g
4)
*
6
!.48
R
+*
is a ,un+tion o, <
+*
.E and *all temperature ,or tis *e a:e to see te
emissi:ity in grap
R
**
is a ,un+tion o, <
**
.E and *all temperature ,or tis *e a:e to see te
emissi:ity in grap
pressure +orre+tion is same as gas emissi:ity ,a+tor.
M T = M R
*
= ,un+tion o, <
*
45<
+
0 <
*
6 , <
+*
.E 0 <
**
.E, and temperature o, *all
)e e,,e+t o, absorpti:ty is negligible en+e te same +an be negle+ted and a
generaliAed ,orm o, Q = ( R
*
R
g
S O)
g
4
7)
S
4
P +an be used.
Heat absorption by energy balan+e metod,
Q = O >
,
. lo*er eat :alue 7 >
g
.gas e&it entalpyP
>ere,
( e,,e+ti:e proYe+ted area o, eat trans,er in+luding *all opening
R
*
*all emissi:ity
R
g
gas emissi:ity
S Ste,an boltAman +onstant
)
g
-lue gas temperature o, mean teoreti+al ,lame temperature5adiabati+
temperature6
)
S
-urna+e *all temperature 53, +al+ulated ,or outside eat trans,er +oe,,i+ient
or +onsider saturation temperature i, +al+ulated ,or o:er all eat trans,er
+oe,,i+ient, te di,,eren+e *ill be o, :ery minor6.
>
,
-uel burnt
>
g
-lue gas produ+ed
?as emissi:ity R
g
= !.95 1C e
72.E
6ZZZZZZZZZZZZZZZZZZ1
)e emissi:ity o, ,lame is e:aluated by

R
,
= [ 5 1C e
72.E
6
*ere [ is te +ara+teristi+ ,lame ,illing :olume.
[ = 1.! ,or non luminous ,lame5pra+ti+al !.96 o, solid ,uels.
!.9! ,or luminous and semi luminous ,lame o, +oal .lignite \ us25(-.C 6
!.88 ,or luminous and semi luminous ,lame o, bagasse 5+on:entional
,iring6
!.$2 ,or luminous and semi luminous sooty ,lame o, li/uid ,uels
!.#2 ,or luminous and semi luminous ,lames o, re,inery gas ,uel %9
gas4oil
mi&ture
!.8! ,or luminous and semi luminous ,lames o, natural gas
E beam lengt meters = 3.4N :olume4sur,a+e area.
-or +uboid ,urna+e +amber and bundle o, tubes.
D attenuation ,a+tor, *i+ depends on ,uel type and presen+e o, as and its
+on+entration. -or nonCluminous ,lame
D = 5!.8 01.# <
*
6.51C!.38 )
'
41!!!65<
+
0 <
*
6
WWWWWWW
X5<
+
0<
*
6E
-or semi luminous ,lame, te as parti+le siAe and +on+entration is ta2en in
+al+ulation
D = 5!.8 01.# <
*
6.51C!.38 )
'
41!!!65<
+
0 <
*
6
WWWWWWWW 0 $I514d
m
K)
'
K6
142
X5<
+
0<
*
6E
d
m
mean e,,e+ti:e diameter o, as parti+le in mi+ron
d
m
13 ,or +oal ground in ball mills
1# ,or +oal ground in medium or ig speed mill
2! ,or +oal milled in ammer mill.
I C as +on+entration in gm4"m]3
)
'
7 ,urna+e mean temperature =25Some autors *ill +onsider tis as outlet
temperature, but it is +on:in+ing assumption tat in ,urna+e Aone temperature
*ill be uni,ormly spread troug out te ,urna+e by radiation e,,e+t 5speri+al6.
Hen+e +onsidering mean temperature ,or +al+ulating radiation eat trans,er
+oe,,i+ient *ill be more appropriate. ^ou +an appre+iate a notable
penomenon o, ,urna+e temperature depends on ,lame lo+ation inside te
,urna+e, in +ase ,lame is lo+ated at te +enter o, ,urna+e5li2e oil ,ired burners
5re,er e&ample166 mean temperature and outlet temperature *ill be at te
most e/ual and i, ,lame is lo+ated at one end o, te ,urna+e and radiation
beam tra:els a larger distan+e o, ,urna+e5li2e (-.C boilers assuming no ,ree
board +ombustion6 te ,urna+e temperature near ,lame *ill be iger and it
gradually degrees at te ,urna+e e&it.
-or luminous oil or gas ,lame
D = 51.# )
'
41!!!6 7!.8
<
*
and <
+
are partial pressure o, *ater :apour and +arbon di o&ide
(bo:e e/uations gi:e only )eoreti+al :alues ,or ,lame emissi:ity. 3n pra+ti+al
+ases a *ide :ariation *ould be o++urred due to:
1.! Combustion penomenon itsel,
2.! )e ,lame does not ,ill te ,urna+e ,ully. Un,illed portion are subYe+t to
only gas radiation
3.! )e emissi:ity o, radiation is ,ar belo* te ,lame emissi:ity. ;missi:ity o,
gas radiation may be in te range !.18 to !.3. )ere,ore o:erall
emissi:ity o, ,lame redu+es. Hen+e emissi:ity +anges *it respe+t to
lo+ation.
Bue to te abo:e ,a+t 3 a:e tried to gi:e te pra+ti+al :alues and graps ,or
te emissi:ity at appropriate pla+es ,or (-.C, Bumping grate and ,ired boilers
*it *or2ing o, e&ample.
)e eat trans,er by radiation is gi:en as Q = ( R
*
R
g
S O )
'
4
7 )
S
4
P. .ut
mostly te eat trans,er *ill be o, bot +on:e+tion and radiation o++uring
simultaneously and so to put bot pro+ess on a +ommon basis, *e may
de,ine a radiation eat trans,er +oe,,i+ient by symbol Hr.
Q
r
= H
r
. (. 5)
'
7 )
S
6
H
r
= S R
*
R
g
O)
'
4
C)
S
4
P45)
'
C)
S
6
>ile +onsidering te total eat trans,er by +on:e+tion and radiation
Q = 5H
+
0 H
r
6 ( 5)
'
7)
S
6 ,or ,ired ,urna+e *ere gas trougout ,urna+e is
same.
Q = 5H
+
0 H
r
6 ( Emtd ,or (-.C and 9adiation +ambers.
.y tis e/uations *e +an get teoreti+al Hr :alue but in pra+ti+e tese :alues
are +orre+ted by e,,e+ti:eness ,a+tor. )is depends on :arious manu,a+turers
e&perien+e on teir steam generator.5"ormally ,or oil ,ired boilers te :alue
*ill be o, !.$9 and gas ,ired boiler !.#$6.
. ;stimate -%) ,or te ,urna+e operating at 2!.## bara, a:ing ;<9S area
112mK and siAe 8.$4 & 3 & # m. ,iring EB% as ,uel a:ing EC@ o, 418#$ 2Y42g
and ,uel +onsumption 1.1# 2g4se+ and ,lue gas generated 19.!3 2g4se+ at
1!% e&+ess air. (ir re/uired 1$.8$ 2g4se+ at 2$=C. Consider a radiation loss
!.33% and *all emissi:ity !.88, eat trans,er e,,e+ti:eness !.$9. adYa+ent
radiation +amber e&tends by 1.!1 m lengt *ise.
T#!"$ )'"! (n!# Fun"/' "! 22>C "-b('n!.
Heat input by ,uel = 1.1# & 418#$ = 48.8#8 '>
9adiation loss = 48.8#8 &!.3341!! = !.1# '>
"ett eat input = 48.4!8 '>
+'"! "b%#b', b0 Fun"/'
9adiation +oe,,i+ient H
r
= S R
*
R
,
O)
'
4
C)
S
4
P45)
'
C)
S
6
-or oil ,ired boiler )mean is e/ual to )gas outlet
>all emissi:ity = !.88
-lame emissi:ity = !.$2 51Ce
C2l
6
(ttenuation ,a+tor 2 = 51.#)m41!!6C!.8
.eam lengt, l = 3.4&8.$4&3&#4258.$4&308.$4&#03&#6 = 2.82'
(ssume gas outlet temperature,1288=+ =1888=D
D =51.#&188841!!6C!.8 = 1.9928
-lame emissi:ity = !.$2&51 7e
71.9928 &2.82
6 = !.$18
Hr = 8.#$ & 1!]C8 &!.88&!.$18&51888
4
748$
4
6451888 748$6
= 18$.$#8 >4mD
4
"u = !.!3$ & 9e
!.8
&<r
!.3
?as properties at ,ilm temperature 512880 214642 = $49.8=C
Bynami+ :is+osity 2g4m.s = 4.132$# & 1!
C8
2g4ms
)ermal +ondu+ti:ity = !.!$2918 >4mD
<randtl number = !.$11

@elo+ity = 19.!3 45!.348 & 3&#6 = 3.!#4 m4s *ere !.348 is density 2g4m]3
!.8
H+ = !.!3$ & 3.!#4 &8.$4 &!.348 & !.$11
!.3
& !.!$2918
4.132$#&1!]C8 8.$4
= 8.$#9 >4mD
+'"! "b%#b', b0 Fun"/'
Q = 5H+ 0Hr6& e,,e+ti:eness ( Emtd
=58.$#9 0 18$.$#86& !.$9 & 112 &51888 C 48$6
= 18.34'>
+'"! "b%#b', b0 ",?"/'n! R",("!(#n /)"-b'
Heat absorbed by adYa+ent *all

= 8.#$ & 1!]C8 & !.$18 &51C!.$186 & 18 & !.88 &51888
4
748$
4
6
= 1.!31#'>
T#!"$ )'"! $#%! b0 G"%
= 18.34 01.!31# = 19.3$1# '>
+'"! b"$"n/' 6)'"! $#%! = )'"! g"(n',7
19.3$1# = 548.4!8 7 19.!3 & ;ntalpy o, lea:ing gas6
;ntalpy o, lea:ing gas = 1.82# 'Y42g -or tis gas temperature is 1288=C.
HEATER
INTRO1UCTION:
)e steam temperature abo:e its saturation temperature +orresponding to te
pressure is a+ie:ed by introdu+ing super eater +oils. 3n te modern
industrial *orld, it is e&pe+ted to get te ma&imum attainable temperature ,or
a pressure, sin+e te +y+le e,,i+ien+y depends on pressure and temperature.
.ut nature restri+ts te ma&imum temperature *it material a:ailability and
metallurgi+al limitations.
Super eater is a +riti+al se+tion, *ere ig metal *or2ing temperature
in:ol:es, sin+e *or2ing ,luid in super eater is ot steam *en +ompared
saturated *ater in oter regions. )e super eater *ill *or2 out appro&imately
8% o, te +ost o, te boiler and te material must be sele+ted +are,ully. 3,
improper sele+tion o, material leads losses due to o&idation and improper
siAing or ti+2ness sele+tion leads larger reser:e in ti+2ness *i+ is
une+onomi+al and lesser ti+2ness +ause tube ,ailure.
EFFECT OF FUEL ON SU@ER +EATER 1ESIGNA
)e me+ani+al arrangement o, super eaters is go:erned by ,a+tors li2e
,urna+e design i.e. ,urna+e outlet temperature *i+ is e&plained in ,urna+e
+apter, ,uel +ara+teristi+s, degree o, super eat and manu,a+turer pra+ti+e.
)e ,uel +ara+teristi+s su+ as as +ontent, as parti+le siAe, salts o, al2ali
metals li2e sodium and potassium *i+ :olatiliAe in te pro+ess o,
+ombustion and +ondenses as a sti+2y substan+e at a temperature
+orresponding to super eater tubes. )ese de+ide trans:erse pit+ing o,
super eater. Some ligt density ,uels li2e us2 burns at te top resulting
ig eat ,lu& input to super eater redu+ing eat trans,er area re/uirement
itsel,.
@OINTS TO 3E NOTE1 B+ILE 1ESIGNING SU@ER +EATER
1.! )e super eater sur,a+e re/uired to gi:e te desired steam temperature.
2.! )e gas temperature Aone in *i+ te sur,a+e is to be lo+ated.
3.! )e steam temperature re/uired
4.! )e type o, steel and oter material best suited to ma2e te sur,a+e and
its supports.
8.! )e rate o, steam ,lo* troug te tubes 5mass :elo+ity6 *i+ is limited
by permissible pressure drop, *i+ *ill e&ert a dominant +ontrol o:er
te tube metal temperature.
#.! )e arrangement o, sur,a+e to meet te +ara+teristi+s o, te ,uels
anti+ipated *it parti+ular re,eren+e to te spa+ing o, te tubes to pre:ent
a6 ;rosion
b6 (++umulation o, as and slag or to pro:ide spa+e ,or te remo:al o,
su+ ,ormation in te early stage.
$.! )e me+ani+al design and type o, super eater.
( +ange in any o, te ,irst si& items *ill +all ,or +ounter balan+ing +ange in
all oter items.
CLASSIFICATION OF SU@ER +EATERS
Super eaters are normally +lassi,ied as 9adiant and Con:e+tion super
eaters. 9adiant super eaters are lo+ated in te radiant Aone re+ei:ing
energy dire+tly ,rom te ,lame in te ,urna+e. Con:e+ti:e super eaters do
not re+ei:e ,urna+e radiation. ( ,e* super eaters re+ei:e energy partly ,rom
te ,lame are +alled semi radiant.
)e oter +lassi,i+ation o, super eaters depends on lo+ation arrangement
and ,lo* pattern.
1 9adiant super eater lo+ated at radiant Aone o, boiler
2 Con:e+tion super eater lo+ated at te +on:e+tion Aone o, boiler
3 3n modern ,luidiAed bed boilers, to a+ie:e iger steam temperature a
portion o, super eater lo+ated in te ,luidiAed bed +alled bed super
eaters.
1'='n,% #n ""ng'-'n!
1 HoriAontal 2. @erti+al 3. 3nline 4. Staggered
1'='n,% #n !)' .$#C ="!!'n
1. Cross ,lo* super eater
2. <arallel ,lo* super eater
3. Counter ,lo* super eater
HoriAontal arrangement o, super eaters a:e a ad:antage o, easy drainage,
*i+ is /uite important in boilers *ere sut do*n *ill be ,or longer periods.
Brainability elps in nonCa++umulation o, salts in *ater or steam inside te
tubes.
3n :erti+al arrangement te problem o, e&pansion +an be ta+2led easily tan
oriAontal arrangement.
Staggered bundles are di,,i+ult to +lean but tey o,,er a marginal impro:ement
in eat trans,er +oe,,i+ient. 3nline arrangement pro:ides lo*er gas side
pressure drop.
Counter ,lo* arrangement o,,ers a sligt impro:ement in log mean
temperature di,,eren+e and tere by de+reasing sur,a+e area +ompared to
parallel ,lo*. )e parallel ,lo* arrangement leads to +ooler tubes. 'etal
temperature +an be iger *it +ounter ,lo* arrangement sin+e bot gas and
steam temperature are iger at steam e&it portion.
1ESIGNING A SU@ER +EATER
Besigning a super eater or any oter eat trans,er in:ol:es tree steps one
is te termal design, se+ond is te me+ani+al design and oter is te
per,orman+e +al+ulation.
3n a termal design *e a:e to per,orm te eat duty, eat trans,er and
sur,a+e area re/uired ,or te 2no*n termal input and output parameters
3n a me+ani+al design ti+2ness and material *it standing +apa+ity are to
be +e+2ed.
<er,orman+e +al+ulation in:ol:es +on,irmation o, te designed e/uipment ,or
:arious loads.
O5ERALL +EAT TRANSFER ACROSS 3AND OF TU3ES
(++ording to te gentleman 'r. Colburn te ,ollo*ing e/uation +an be applied
,or gas4air ,lo*ing normal to te ban2 o, tubes
Nu%%'$!% nu-b' = 0.EE F 6R'0n#$,% nu-b'7
0.6
F 6@"n,$ nu-b'7
0.3
>ile +al+ulating 9eynolds number e&ternal tube diameter as to be used.
)is e&pression +an also e&pressed a,ter introdu+ing geometry ,a+tor.
?eometry ,a+tor - as to be ta2en ,rom grap depends on trans:erse pit+ to
diameter ratio and longitudinal pit+ to diameter ratio
Nusselts number = 0.35* F * (Reynolds number)
0.6
* (Prandl number)
0.3
(++ording to anoter gentleman 'r. ?rimson te outside eat trans,er
+oe,,i+ient *as e&plained by te ,ollo*ing e/uation
(rrangement -a+tor -
-or 3nline arrangement -or staggered arrangement
S)4d SE4B 1.28 1.8! 2.!! 3.!! 1.28 1.8! 2.!! 3.!!
1.28 9e
2!!!

1.!# 1.!# 1.!$ 1.!! 1.21 1.1# 1.!# !.9#
8!!! 1.!4 1.!8 1.!3 !.98 1.11 !.99 !.92 !.98
2!!!! 1.!! 1.!! 1.!! !.98 1.!# 1.!8 1.!2 !.93
1.8 2!!! !.98 !.98 1.!3 1.!3 1.1$ 1.18 1.!8 1.!2
8!!! !.9# !.9# 1.!1 1.!1 1.1! 1.!# 1.!! !.9#
2!!!! !.98 !.98 1.!! !.98 1.!4 1.!2 !.98 !.94
2.!! 2!!! !.$3 !.$3 !.98 1.!8 1.22 1.18 1.12 1.!8
8!!! !.83 !.83 1.!! 1.!2 1.12 1.1! 1.!4 1.!2
2!!!! !.9! 1.!! 1.!! 1.!! 1.!9 1.!$ 1.!1 !.9$
3.!! 2!!! !.## !.## !.98 1.!! 1.2# 1.2# 1.1# 1.13
8!!! !.81 !.81 1.!2 1.!2 1.1# 1.18 1.11 1.!#
2!!!! !.91 !.91 1.!1 1.!! 1.14 1.13 1.1! 1.!2
Nusselts number = * (Reynolds number)
N
. and " are ,a+tors go:erned by te geometry, te :alues o, . and " is gi:en
in te table.
'any su+ persons *or2ed on te eat trans,er and ga:e :arious +orrelation
,or +ertain pre de,ined +ondition and en+e ,or pra+ti+al purposes +ertain
,a+tors to be +onsidered ,or its a++ura+y. 3 a:e also tried to gi:e tose
,a+tors in *or2ed e&amples.
3n te Colburn or ?rimson e/uation +orre+tion ,a+tor ,or te eat trans,er
+oe,,i+ient ,or gas angle o, atta+2 on te tube as to be +al+ulated into
a++ount.
Begree = 9! 8! $! #! 8! 4! 3! 2! 1!
-a+tor 1.! 1.! !.98 !.94 !.88 !.$8 !.#$ !.82
!.42
S)4B 1.28 1.8 2.! 3.!
SE4B . " . " . " . "
S)(??;
1.28
1.8
2
3
!.818
!.481
!.4!4
!.31
!.88#
!.8#8
!.8$2
!.892
!.8!8
!.4#
!.41#
!.38#
!.844
!.8#2
!.8#8
!.88
!.819
!.482
!.482
!.44
!.88#
!.8#8
!.88#
!.8#2
!.822
!.488
!.449
!.421
!.8#2
!.8#8
!.8$
!.8$4
3"E3";
1.28
1.8
2
3
!.348
!.3#$
!.418
!.29
!.892
!.88#
!.8$
!.#!1
!.2$8
!.28
!.299
!.38$
!.#!8
!.#2
!.#!2
!.884
!.1!
!.1!1
!.229
!.3$4
!.$!4
!.$!2
!.#32
!.881
!.!#33
!.!#$8
!.198
!.28#
!.$82
!.$44
!.#48
!.#!8
Corre+tion ,a+tor ,or . +orresponding to number o, tubes deep
"umber deep 1 2 3 4 8 # $ 8 9
1!
Staggered !.#8 !.$8 !.83 !.89 !.92 !.98 !.9$ !.98
!.99 1.!
3nline !.#4 !.8 !.8$ !.9 !.92 !.94 !.9# !.98
!.99 1.!
Simillarly Bittus \ .oelter +orrelation gi:es eat trans,er +oe,,i+ient on inside
tube.
Nusselts number = 0.0!3 * (Reynolds number)
0."
* (Prandl number)
0.3
Consider te super eater tubes o, outer radius r1 \ r2 respe+ti:ely. )ermal
+ondu+ti:ity o, material 2. Cold ,luid 5steam6 is ,lo*ing steadily inside te tube
),1 and ot ,luid ),2 steadily outside te tube. 3nner and outer *all
temperature t*1 \ t*2. Heat trans,er +oe,,i+ient o, steam and gas sides be
1 and 2. 52 in+ludes +on:e+tion eat trans,er and non luminous eat
trans,er as e&plained in ,urna+e +apter6
S);(' o ),2
t*2 outside +on:e.eat
trans,er =3
t*1
Hot gas
Condu+tion =2
i inside +on:e. eat trans,er
=1

),1 )ube ti+2nessFtF
Con:e+tion eat trans,er penomenon in super eater tube
/
l
= Q4l = i N2 N _ Nr1 O t*1 7 t,1P
ZZZZZZZZZZZZZZZZ.1
= 2N _ N 2 5t*2 7 t*164ln5r24r16
ZZZZZZZZZZZZZZ..2
= o N 2 N _ N r2 O t,2 7 t*2P
ZZZZZZZZZZZZZZZZ3
1 = 2 = 3
te eat trans,erred at a gi:en se+tion at gi:en time is e/ual.
t*1 7 t,1 = /
l
4 5iN2N_Nr16
t*2 7 t*1= /
l
N ln5r14r26
2N_N2
t,2 7 t*2 = /
l
45o N2N_Nr26
(dding te abo:e e/uations *e get,
/
l
1 ln5r24r16 1
t,2 7 t,1 = 0 0
2N_ ir1 2 or2
/
l
= 2N _ N5t,2 7 t,16
1 0 ln5r24r16 0 1
ir1 2 or2


Q4l = U Ot,2 7 t,1P
Bi:ide by _do
Q45_d
o
l6 = UOt,2 7 t,1P4_d
o
U = 2N _
_d
o
1 0 ln5r24r16 0 1
ir1 2 or2

U = 1
_d
o
1 0 ln5r24r16 0 1
2_ir1 2_2 2_or2

1 d
o
0 d
!
ln5d
!
4d
i
6 0 1



=
U idi 22 o
3ntrodu+ing ,ouling ,a+tors in steam side and gas side *e +an get,
1

do 0 d
!
ln5d
!
4d
i
6 0 1



= 0,,o
0,,i
U idi 22 o
3n te abo:e e/uation ea+ unit re,ers to a resistan+e in eat trans,er
14o is gas side eat trans,er resistan+e.5tis gi:es temperature drop in te
,ilm6
doln5do4di6422 is metal resistan+e5tis gi:es temperature drop in metal side6
do4idi is steam side eat trans,er resistan+e.5tis gi:es temperature drop in
steam side ,ilm6
,,o is outside ,ouling resistan+e
,,i is inside ,ouling resistan+e
-or e&tended sur,a+e ,ollo*ing eat trans,er +oe,,i+ient e/uation +an be
applied.
1

(
t
0 (
t
d
!
ln5d
!
4d
i
6 0 1



= 0,,o 0,,i (
t
4(i
U i(i (
*
22 U o
>ere, (
t
is total sur,a+e area.
(i is inside sur,a+e area.
(
*
is a:erage sur,a+e area.
U is ,in e,,e+ti:eness
Q = U N ( N Ot,2 7t,1P ,or spe+i,i+ tube, *ile +onsidering bundle o, tubes log
mean temperature as to be used.
Q = U N ( N lmtd.
METAL TEM@ERATURE CALCULATION A
Q = U N do N5)g 7 )s6 = i N di N 5)* 7 )s6
>ere )* is metal temperature =C
'etal temperature o, bare tube +an be estimated easily by +al+ulating :arious
temperature drop a+ross te resistan+e gi:en abo:e. )is simple e/uation is
appli+able ,or only bare tube sur,a+e. -or e&tended sur,a+e ,in temperature
+al+ulation in:ol:es a detailed pro+edure *i+ is dis+ussed separately.
STEAM TEM@ERATURE CONTROL
;nergy balan+e,
'1N H1 0 ' N H
,*
= '2H2ZZZZZZZZZZZZZZZZZ1
'ass balan+e,
'1 0 ' = '2ZZZZZZZZZZZZZZZZZZ.2
-rom 1 \ 2,
'1NH1 0 'NH
,*
= 5' 0 '16 NH2
Quantity o, *ater re/uired spray,
M = M1 F G +1 H+2I8G+2 H +
.C
I
Ex.01. Betermine te spray /uantity re/uired ,or a #!)<H boiler a:ing a
primary super eater steam outlet temp o, 332=C and se+ondary super eater
inlet steam to be desupereated to 31#=+. )e spray *ater temperature is
1!8=C.
;ntalpy o, <SH = $21.$ 2+al42g
;ntalpy o, SSH = $11.88 2+al42g
;ntalpy o, spray *ater = 1!8.8 2+al42g.
Spray *ater re/uired = 5$21.$ C $11.886N#!!!! = 9$4.$ 2g4r.
5 $11.88 71!8.86
Ex02. ;stimate te eat trans,er area re/uired ,or sur,a+e type desuper
eater immersed in drum *ater operating at a pressure o, 48 2g4+mK5g6 and
te steam at te outlet o, primary super eater is 38!=C and te steam
temperature at te inlet o, super eater is 38!=C. te steam ,lo* is 28!!!
2g4r.
)e eat trans,er +oe,,i+ient outside te tube to *ater is natural +on:e+tion
eat trans,er +oe,,i+ient, go:erned by te e/uation
"u = !.84 5 ?r <r6
!.28
`d3 Kg ) Cp !.28
`odo42 = !.84 K 2
(ssume sur,a+e type desuper eater o, tube diameter 38.1 & 3.28 mm
<roperties o, li/uid at ,ilm temperature 5saturation temperature at 48
2g4+mK5g66
Bensity o, li/uid 2g4m
3
= $8$.8 2g4m
3
(++eleration due ,o gra:ity = 9.81 m4se+K
Bynami+ :is+osity = !.!!!1!3!#$ 2g4ms
@olumetri +oe,,i+ient o, e&pansion L = !.284 14=C
<randtl number = !.83299
)ermal +ondu+ti:ity = !.!!!#1184 D*4m=C
Spe+i,i+ eat Cp = 4.94812 2Y42g
)emperature di,,eren+e bet*een *all \ *ater = 8= 5assumed6
!.28
!.!3813 & $8$.8K & 9.81&!.281& 8 & !.83299 & !.#1184
o = !.84 !.!!!1!3!#$K !.!381


= 1949$ >4mK=D
3nside eat trans,er +oe,,i+ient is go:erned by ,or+ed +on:e+tion,
"u = !.!23 9e
!.8
<r
!.4
<roperties o, steam at a:erage temperature 538! 038!642 = 3#8=C
Bensity o, steam 2g4m
3
= 1#.1#9 2g4m
3
Bynami+ :is+osity 2g4ms = 2.281$8 & 1!
C8
<randtl number = !.98$#
)ermal +ondu+ti:ity >4m=C = 8.948 & 1!
C2
@elo+ity inside te sur,a+e assume 28 m4se+
9eynolds number = 1#.1#9 & 28 & !.!31#42 .281$8 & 1!
C8
= 889812
`i = !.!23 & 889812
!.8
& !.98$#
!.4
& !.!31#48.948 & 1!
C2
= 4$#.# *4mKD
'etal resistan+e = d
!
ln5d
!
4d
i
6 42 Dm
'etal +ondu+ti:ity = 49.8 *4mD
'etal resistan+e = !.!381 & ln5!.!3814!.!31#6
2 & 49.8
= $.1988 & 1!
C8
%:erall eat trans,er +oe,,i+ient
14U = 14o 0 14i 0 9m 0 ,,i 0 ,,o
inside and outside ,ouling ,a+tor due to s+ale assume = !.!!!2 mK4*=D
14U = 141949$ 0 14$4# 0 $.1988 & 1!
C8
0 !.!!!2
%:erall eat trans,er +oe,,i+ient = #!1.!4 >4mKD
Heat trans,er area re/uired = Q4Ulmtd
= 28!!!5 3188.49 7 3!83.!86 &1!!!
3#!!& #!1.!4 & 55 38!C38!64ln512349366
= 8.12 mK
Ex.0E. Cal+ulate gas outlet temperature ,or a super eater intended to raise
steam ,rom 214=C to 288=C. steam ,lo* 18.28 2g4se+, pressure 2! bar5a6,
tube siAe 38.1 & 3.28 mm t2 and termal +ondu+ti:ity 49.844 >4mD. )e
gas ,lo* 19.!3 2g4se+, inlet temperature is #89=C and te pattern o, ,lo* is
+ounter, ,urna+e *idt is 3.!# meter and lengt 2.$meters, tube pit+ing *idt
side 8!mm and dept side $8mm, inline arrangement, number o, tubes in
steam side pat is $4. Heat trans,er area o, super eater 88 s/.m. te super
eater *as en+losed in a *ater *all a:ing ;<9S area o, 21 s/.m and gas is
,lo*ing 9!= to super ater tubes. Consider eat trans,er e,,e+ti:eness o, 82%
and $1% ,or en+losure. <artial pressure o, *ater =!.1188 bar and +arbon di
o&ide = !.1249bar.
Steam inlet temperature = 214=C
Steam outlet temperature = 288=C
(:erage steam temperature = 23#=C
@#='!('% #. %!'"-
Bensity 2g4+u.m = 9.328189
Bynami+ :is+osity 2g4ms = 1.$2232 & 1!
C8
<randtl number = 1.!83
)ermal +ondu+ti:ity >4mD = 4.34#819 & 1!
C2
Steam :elo+ity = 18.28 & 4 459.3281 &$4&_ & !.!31#K6
= 28.228m4s
-or+ed +on:e+tion inside eat trans,er +oe,,i+ient is

Hi = !.!23 & 9e
!.8
& <r
!.4
& 24di
!.8
9.328&!.!31#& 28.288 !.4
= !.!23& & 1.!83 & 4.34#819 &1!
C2


1.$223 & 1!
C8
!.!31#
= 1182 >4s/.mD
-or+ed +on:e+tion outside eat trans,er +oe,,i+ient is
(ssume gas outlet temperature as 8#!=C
-ilm temperature = 5a:erage o, gas temperature 0 a:erage o, steam
temperature42
=5#89 08#! 0214 0 288644
=422.$8=C
G"% =#='!('% "! .($- !'-='"!u'
Bensity 2g4+u.m = !.8!3
Bynami+ :is+osity 2g4ms = 3.1$98 & 1!
C8
<randtl number = !.$12#
)ermal +ondu+ti:ity >4mD = !.!8198
-or inline arrangement
S)4d = 8!438.1 = 2.!99a SE4d = $8438.1 = 2.!4$

(rrangement ,a+tor ,e = 1.18
?as ,lo* area = 53.!# & 2.$ 7 3$ &!.!381&2.$6 = 4.4888s/.m
?as :elo+ity = 19.!345!.8!3 & 4.48886 = 8.49 m4s
9eynolds number = 8.49 &!.8!3 & !.!38143.1$98&1!
C8
= 811#.8
+ = !.28$ & ,e& 9e
!.#
&<r
!.3#4
& 24d
= !.28$ &1.18& 811#.8
!.#
& !.$12#
!.3#4
&!.!81984!.!381
= #8.88 >4s/.mD
9adiation eat trans,er +oe,,i+ient
.eam lengt = 3.4 &5!.!8 &!.!$8&1C!.!!114645_&!.!381&16 = !.1448$#m
(ttenuation ,a+tor = 5!.8 01.#&!.1188651C!.38&588341!!!665!.1188 0 !.12496
X55!.11880!.12496&!.1448#6
= !.8439
emissi:ity o, gas = !.9 &51Ce
C!.8439&!.1448#
6
= !.1!388
r = 8.#$ & 1!
C8
& !.88 & !.1!388&5883
4
78!9
4
6
5883 78!96
= $.218 >4s/mD
total gas side eat trans,er +oe,,i+ient = + 0 r = #8.88 0 $.218 = $8.$98
>4s/mD
1 d
o
0 d
!
ln5d
!
4d
i
6 0 1



=
U idi 22 o
= !.!381451182&!.!31$6 0 !.!381 ln5!.!3814!.!31$6 0
14$8.$98
2 & 49.844
U = #9.898 >4s/.mD
Heat trans,erred to super eater tubes,

Q = U & e,,e+ti:eness & (& lmtd
= #9.898 & !.82 & 88 & 3$2 = 1.8$# '>.
+'"! !"n%.'', !# C"!' C"$$ 'n/$#%'*
"egle+ting metal resistan+e and internal +ondu+tan+e te +on:e+tion eat
trans,er +oe,,i+ient be #8.88 *4s/.mD and nonCluminous radiation eat
trans,er be
r = 8.#$ & 1!
C8
& !.88 & !.1!388&5883
4
748$
4
6
5883 748$6
= #.9838 *4s/mD
o = #8.88 0 #.9838 = $8.83 >4S/mD
Q = $8.83 & !.$1 & 21 & 393 = !.442# '>.
)otal eat gained by super eater and en+loser is = 1.8$#3 0 !.442# = 2.319
'>.
)otal eat lost by gas = ?as ,lo* & 5entalpy di,,eren+e6
= 19.!3 & 5$82.#3 7 #29.4#6 41!!! = 2.34 '>.
Ex 05 -ind te steam side pressure drop ,or a supereater, te steam ,lo*ing
troug te super eater is 88!!! 2g4r and te %utlet pressure o, steam is
19 2g4+mK5a6 and te number o, parallel pat is $4 nos. and +oil de:eloped
lengt is estimated as 11.#4m, it as 3 nos. 18!= bends and 2 nos. 48= bends.
)e steam inlet +ondition is dry saturated and outlet +ondition is 288=C. te
super eater tube siAe is 38.1mm & 3.#4mm in+luding te positi:e toleran+e o,
te tube.
Super eater steam ,lo* 2g4r :88!!!
Steam ,lo*4+oil 2g4se+:!.2!#
Steam parameter at inlet
)emperature =C : 2!9.84
<ressure 2g4+mK5a6: 19.345assumed by trial
and error6
Steam parameter at outlet
)emperature =C : 288
<ressure 2g4+mK5a6: 19
(:erage steam <arameter
)emperature =C : 232.42
<ressure Dg4+mK5a6:19.1$
Bensity 2g4+u.m: 9.2!$39
Bynami+ :is+osity Dg4s.m : 1.$1 & 1!
C8
@elo+ity troug tubes = !.2!# & 4
9.2!$39& _&5!.!3!82K6
=29.99 m4s
9eynolds number = b:d4 = 9.2!$39 & 29.99& !.!3!8241.$1& 1!
C8
= 49$#$9
-ri+tion ,a+tor = , = 5!.39#449e
!.3
6 0 !.!!84
= 5!.39#4449$#$9
!.3
6 0!.!!84 =!.!131484
<ressure loss in straigt lengt = ,l:K42g d
=!.!131484 & 11.#4 & 29.99K452&9.81& !.!3!826 = 22$.88 'g+
= 22$.88 & 9.2!$39 = 2!9! 2g 4 mK or mm>+
= !.2!9 2g4+mK.
<ressure loss in .ends,
-or 18!= bend = !.4$:K42g
-or 48= bend = !.12:K42g
)otal bend loss = 5 3&!.4$ 0 2& !.126 29.99K&9.2!$39 452 & 9.816
= #9#.4 mm>+ = !.!#9# 2g4+mK
<ressure loss in entry and e&it
;ntry and ;&it loss = 1.8 & 29.99K & 9.2!$39452 & 9.816
= #33 mm>C = !.!#33 2g4+mK
)otal pressure drop = !.2!90!.!#9#0!.!#33 =!.3419 2g4+mK
SIJE OF T+E 1RUM
)e steam drum must be large enoug to a++ommodate drum internals, te
ne+essary steam sur,a+e ,or steam separation and *ater olding +apa+ity.
)e drum also pro:ide su,,i+ient spa+e ,or +ange in *ater le:el tat o++ur
*it +ange in load. ( sudden in+rease in steam demand +ause a temporary
pressure surge, until ,iring rate is in+reased su,,i+iently ,or more steam
generation. Buring tis inter:al due to lo*er pressure, steam :olume
trougout te boiler is in+reased 5pressure T 14:olume6. )is results in
S>;EE raise in *ater le:el in te drum. )e raise in *ater le:el depends on
te rate at *i+ eat and ,eed inputs +an be +anged to meet te load
demand. )e iger te drum diameter better te +ontrol o, raise in *ater
le:el
3n ?) H9S? during starting te steam generation +ause sudden in+rease in
drum le:el and it is estimated tat $!% o, te e:aporator *ater gets raised
into te drum. Hen+e te during start up te H9S?s are started *it lo*
*ater le:el and at on+e te in+reased *ater le:el goes to igCig le:el blo*
do*n :al:e *ill be opened to +ontrol te in+rease in *ater le:el. "ormally
blo* do*n :al:e ,or H9S?s are siAed based on te same, by ,inding te $!%
e:aporator :olume less te drum :olume bet*een lo* to igCig. )is
di,,eren+e in *ater as to be dis+arged *it in 2 to 3 minutes.
STEAM S@ACE
3n te steam drum *ater and steam regions are +learly separated, te spa+e
abo:e te normal *ater le:el is +alled steam spa+e. Steam spa+e go:erns
te steam loading o, te drum. Steam loading is te ratio bet*een steam
spa+e and te spe+i,i+ :olume o, te steam ,or pressure it is
operating5']34m]3r6. Steam loading ,or di,,erent pressures is ,i&ed by te
manu,a+tures a++ording to teir pra+ti+e or e&perien+e. Steam loading is one
o, te important de+ision ,a+tor in de+iding te siAe o, te drum. Steam
loading ensures te :elo+ity o, separation in te inter pase and steam +arry
o:er.
Eet E be te lengt o, steam drum and B be te internal diameter, r be te
radius and & be te distan+e ,rom +enter line to normal *ater le:el.

o B
2 T
a b & n*l

`
+
E
Sin T = a24oa
`T = Sin
C
5&4r6
J = 518! 7 2T6
`ab = 2 a+
= 2.r. Sin5J426
)e area o, te ar+ oa+b = _ & BK &J
4& 3#!
)e area o, triangle oab =142 . ab . V
)e area a+ba = area ar+ oa+b 7 triangle oab
)e steam spa+e area in +ylinder = _BK C area a+ba
4
Steam spa+e :olume = 5 _BK 44 C area a+ba6 5E 02l6 0 2 :olume o, dised
ead
`abo:e normal *ater
le:el
@olume o, dised ead ,or di,,erent sapes.
)^<; -UEE @%EU';
']3
@%EU'; U<)% "%9'(E
>();9 E;@;E
']3
S;'3 ;EE3<S%3B(E
_. B
3
424 _.K.51.8B 76412
H;'3 S<H;93C(E
_.B
3
412 _.K.51.8B 764#
)%93S S<H;93C(E
Ex 01 ;stimate te sell ti+2ness re/uired ,or a single drum boiler, *ose
design pressure is $3 2g4+mK and te internal diameter is 13!!mm. )e drum
is lo+ated outside te gas pat.
Single drum te ligament e,,i+ien+y is 1. Ho*e:er ,or pra+ti+al estimation !.98
is +onsidered.
(s per 3.9 2$! regulation
'inimum ti+2ness re/uired ) = <BiWWW 0 C
2,; 7<
= $3 & 13!!WWWWWWWWWW 0 !.$#2
52& 123!.4 & !.98 7$36
= 42.## mm5o:er tis tinning allo*an+e ,or rolling as to be +onsidered6
"ote. Stress :alue 123!.4 2g4+mK is +al+ulated ,or te saturated temperature
o, boiler design pressure. 3, te drum is e&posed in gas pat additional
temperature allo*an+e o, 28=C as to be added to saturated temperature and
,or tis stress :alue as to be +onsidered.
Ex.02 ;stimate te ti+2ness re/uired ,or te 2:1 semi ellipsoidal ead as per
3.9, *ose design pressure is $3 2g4+mK and te inside diameter is 13!!mm.
( opening in te dised end o, siAe 848 & 8!! mm is made ,or man ole
opening. )e material o, +onstru+tion is S( 81# ?r.$!.

3 18!

#!

33 18!
3nside 848&8!! opening
'inimum re/uired ti+2ness ,or dised end +al+ulated as per 3.9 2$$ \ 2$8
amendment 1998.
>.< = 2,5)CC645BD6
>ere,
) = 'inimum ti+2ness
>.< = 'a&imum *or2ing pressure
B= %utside diameter = 5 13!!0 2&)6
`, = (llo*able Stress = 123!.4 2g4+mK 5(s per (S'; se+tion 33 part B 19986
D= Sape ,a+tor
C= (n additi:e ti+2ness = !.$8mm
9ein,or+ement o, large openings
`d = Biameter o, opening = 848 mm
(= ;,,e+ti:e +ross se+tion o, rein,or+ement in mmK5saded portion6
) = 'inimum ti+2ness o, dised ead = 49 mm5assume6

Eimit o, 9ein,or+ement
)t = (+tual ti+2ness o, te noAAle
E2 =Xd.)t
WWWWWWW
=X5844 &#!6 = 18!.83 mm
Sin+e te lent o, te noAAle proYe+tion inside te dised end is 18!H 18!.83,
te *ole lengt is +onsidered ,or +ompensation.
(rea o, rein,or+ement
3 = #! &18! & 2 =18!!! mmK
33= 44.3 & 21! &2 = 18#!# mmK
3 0 33 = 18!!!0 18#!# =3##!# mmK
3maginary diameter = d 75(4)6 = 848 C 3##!#449
= C:e
(ssuming di =1 Sin+e te :alue is negati:e
Conditions
)4B H !.1 di4B H !.8
)4B = 4941398
=!.!38H!.1
di4B =141398 =!.!!!$H!.8 .ot +onditions are ,ull,illed.
`di4XB) = 14X5 1398&496 = !.!!38
9e,. -ig 23CB )e least :al:e o, di4XB) =1
)e same is +onsidered ,or +al+ulation
-or Semi elliposidal ead
H4B = 3$441398 = !.2#$ 5H is eigt o, dised ead ,or semi ellipsoidal
5 53B4460 )6
D = 1.1 ,rom ,ig 23CB
Hen+e 'inimum ti+2ness = >.< & B& D 0 C
2,
= $3 & 1398 & 1.1 0 !.$8 = 4$.!8
2 & 123!.4
= 49 mm sele+ted is su,,i+ient. 5%:er te sele+ted ti+2ness dising tinning
allo*an+e as to be +onsidered6
Ex 0E ;stimate 'anole noAAle ti+2ness ,or te abo:e problem.
(s <er 3.9 3385a6
)i+2ness = <.BWWWW 0C
2, 0 <
= $3 & 848WWWWW 0 ! = 18.$!2
5 2& 123!.4 0$36
)e noAAle ti+2ness pro:ided #!mm5>i+ is used in rein,or+ement
+al+ulation o, te abo:e problem6
)e pro:ided ti+2ness as to be +ross +e+2ed, by +ompensation
+al+ulation.
(s per 3.9 2$9,
3nside diameter o, noAAle dn = 848 72&#! = 428
(+tual noAAle ti+2ness tn =#!mm
(+tual dised end ti+2ness ts = 49 mm
Stress :alue ,or noAAle ,n =123!.4 2g4+mK
Stress :alue ,or sell ,s = 123!.4 2g4+mK
;/ui:alent ti+2ness o, noAAle5en6
= <dn452,C<6 0 C
= $3 & 428WWWWWW 0 !.$8 =13.$8
52& 123!.4 7$36
;/ui:alent ti+2ness o, dised end 5es6
= 4$.!8 mm
(s per 3.9 tree +onditions,
`b1 = minimum o, 2.8ts or 2.8tn
`b2= minimum o, 2.8ts or 2.8tn o, proYe+tion ti+2ness
Ci = ma&imum o, 5ts0$#6 or dn42
`b1 = 2.8 &49 = 122.5 or 2.8 &#! =18!
b2 = 2.8&49 = 122.5 or 2.8&#! = 18! or proYe+tion 18!mm
Ci = 42842 = 212.5 or 549 0$# =1286
)e bolded :alues to be ta2en into a++ount ,or +al+ulation
Se+tional area at V = dn &es
= 428& 4$.!8 = 2!!!9 mmK
Se+tional area at ^ = 25tnCen6b15,n4,s6 0 2tnb25,n4,s6 0 25tsCes6Ci
=25#!C13.$86122.85123!.44123!.46 0 2&#!&122.8&5123!.44123!.46 02549 7

4$.!86212.8
= 2#8$4.28mmK
(rea V H (rea ^
Compensation sall be +onsidered ade/uate *en te se+tional area V to be
+ompensated measured troug te a&is o, te sell is less tan te
+ompensating are ^. 3n oter *ords area V sould be less tan (rea ^ ,or
te design to be satis,ied, i, V area is greater tan area ^ additional
+ompensation pad to be pro:ided or ti+2ness o, noAAle to be in+reased.
3n our +ase +ondition is satis,ied and en+e tere is no need ,oe e&ternal
+ompensation pad.

Ex 04 ;stimate te ti+2ness re/uired ,or end plate o, ti+2ness or +losing te
man ole noAAle.
'an ole opening 5ma&6 = 848 7 2&#! = 428mm
'an ole opening 5min6 = 8!! 7 2&#! =38!mm
(s per 3.9 3425b6 ,
WWWW
'inimum end plate ti+2ness = c%pening dia & X5<D4,6P 0 C
C= 1mm
-or +ylindri+al ends
D= !.19 ,or ends integral *it or ,langed and butt *elded to te eader.
= !.28 ,or ends dire+tly strengt *elded to te eader
-or re+tangular ends,
%pening dia = 'inimum *idt bet*een te *alls o, re+tangular eader
D= !.32 ,or ends integral *it or ,langed and butt *elded to te eader.
= !.4! ,or ends dire+tly strengt *elded to te eader
3n our +ase ;llipsoidal eader is assumed as i, +ir+ular eader4noAAle and
+e+2ed ,or bot maYor and minor a&is.
WWWWWWWWWWWWW
= 428 &X5$3&!.1964123!.4 01 = 4#.123 mm
<ro:ided ti+2ness = #8mm
Ex 05 -ind ma&imum allo*able un+ompensated opening +an be made in te
abo:e drum.
(s per 3.9 18$,
WWWWWWWWW
Un+ompensated %pening d = !.8X5Bi0)6)0"
Bi = 3nternal diameter o, te Sell
) = )i+2ness o, sell
" = 3 *ere ; does not e&+eed !.8
= 3&X51C;6 in oter +ases
!.8
; = )e re/uired ti+2ness o, a seamless unpier+ed Sell di:ide by
Cal+ulated ti+2ness
Bi =13!!mm
) = 42.##ZZZZ,rom problem 8.1
)s = $3 & 13!!WWWW 0 !.$#2 = 4!.8!8
52& 123!.4 7$36
;= 4!.8!8442.## =!.949
WWWWWWW
" = #&5X51C!.9496 = 1.38
WWWWWWWWWWWWWWWWWWWWW
'a&. Un+ompensated %pening siAe = !.8X513!!042.##642.## 0 1.38
=119.##mm
E9"=#"!# "n, '/#n#-(K'
Besign a ,eed *ater eater ,or a 1! tp boiler *ose e&aust gas ,lo* is
21388 2g4r at an outlet temperature is 188=C and te desirable outlet
temperature is 14!=C. )e ,eed *ater is a:ailable at #!=C.
3. Heat duty 5gas side6
= 21388 5 48.2# 7 3#.!96
=28989! 2+al4r
>ere 48.2# 2+al42g entalpy o, gas at 188=C and 3#.!9 2+al42g entalpy o,
gas at 14!=C.
33. >ater outlet temperature to = 28989!41!!!! 0 #!
=88.98=C.
333. -or te eat e&+anger, gas is ,lo*ing inside te tube internal eat trans,er
+oe,,i+ient go:erns te o:erall eat trans,er +oe,,i+ient. )e o:erall eat
trans,er +oe,,i+ient is around 88% o, inside eat trans,er +oe,,i+ient.
(ssume gas :elo+ity inside te ,lue tubes 18 m4se+.
-lo* area re/uired to maintain te :elo+ity in tubes
= 21388 51#2.8 02$36453#!!&2$3&1.298&186 =!.48$1#mK
)ube sele+ted 8!.8 & 3.28
3@. "umber o, tubes = !.48$1# 45_5!.!8!8 7 2&!.!!3286K = 31# tubes.
@. Heat trans,er +oe,,i+ient
G"% =#='!('% "! "9'"g' !'-='"!u' 162.5>C.
)ermal +ondu+ti:ity = 31.228 & 1!
C3
2+al4mr=C
Dinemati+ :is+osity = 28.8$$ & 1!
C#
mK4se+
<randtl number = !.#$$8
9eynolds number = :d4

= 18 & !.!443 428.8$$ & 1!C#
= 23282.889
H)C = !.!23 9e
!.8
<r
!.3
D4d
= !.!23 & 523282.8896
!.8
& 5!.#$$86
!.3
& 531.228 &1!
C3
4!.!4436
= 39.2 2+al4mKr=C
)e o:erall eat trans,er +oe,,i+ient = !.88 &39.2 =33.32 2+al4rmK=C.
@ Heat trans,er area re/uired = Q45U& Emtd6
= 28989!4533.32 &89.186
= 8$.49mK
@3 Heat trans,er lengt
= 8$.4945_& !.!4436 = #28 m
"umber o, tube re/uired = 31#
)ube lengt = #28431# = 1.98 m
Considering tube lengt ,or *elding to te tube seet +learan+e 1! mm on
bot sides
)ube siAe +osen 2.! m.
Ex.01. Cal+ulate gas outlet temperature ,or a e:aporator intended to
generate steam ,lo* 18.28 2g4se+, pressure 2! bar5a6, tube siAe 38.1 & 3.28
mm t2 and termal +ondu+ti:ity 49.844 >4mD. )e gas ,lo* 19.!3 2g4se+,
inlet temperature is 118!=C and te pattern o, tube arrangement ,urna+e
*idt is 3.!# meter and lengt 2.$meters, tube pit+ing *idt side 8!mm and
dept side $8mm, inline arrangement, number o, tubes in *idt side 3# and
dept side 2!. Heat trans,er area o, e:aporator 24# s/.m. te e:aportor *as
en+losed in a *ater *all a:ing ;<9S area o, 2# s/.m and gas is ,lo*ing 9!=
to e:aporator tubes. Consider eat trans,er e,,e+ti:eness o, 82% and $1% ,or
en+losure. <artial pressure o, *ater =!.1188 bar and +arbon di o&ide =
!.1249bar.
(ssume gas outlet temperature as #88=C
Heat loss by te gas = 19.!3 N5 1418.1 7 $48.946 = 12$91.2 D>
3nside eat trans,er +oe,,i+ient = 14!!! >4mK=C 5assume6
G"% =#='!('% "! "9'"g' !'-='"!u' = 919>C
Bensity 2g4+u.m = !.299
Bynami+ :is+osity 2g4ms = 4.8$3 & 1!
C8
<randtl number = !.$1
)ermal +ondu+ti:ity >4mD = !.!83
-or inline arrangement
S)4d = 8!438.1 = 2.!99a SE4d = $8438.1 = 2.!4$

(rrangement ,a+tor ,e = !.98 5,rom tables6
?as ,lo* area = 53.!# & 2.$ 7 3# &!.!381&2.$6 = 4.888s/.m
?as :elo+ity = 19.!345!.299 & 4.8886 = 13.9# m4s
9eynolds number = 13.9# &!.299 & !.!38144.8$3&1!
C8
= 34$8.8
+ = !.28$ & ,e& 9e
!.#
&<r
!.3#4
& 24d
= !.28$ &!.98& 34$8.8
!.#
& !.$1
!.3#4
&!.!834!.!381
= $2.1 >4s/.mD
9adiation eat trans,er +oe,,i+ient
.eam lengt = 3.4 &5!.!8 &!.!$8&1C!.!!114645_&!.!381&16 = !.1448$#m
(ttenuation ,a+tor = 5!.8 01.#&!.1188651C!.38&5119241!!!665!.1188 0 !.12496
X55!.11880!.12496&!.1448#6
= !.#94$
emissi:ity o, gas = !.9 &51Ce
C!.#94$!.1448#
6
= !.!8#1$
r = 8.#$ & 1!
C8
& !.88 & !.!8#1$&51192
4
7488
4
6
51192 74886
= 11.83 >4s/mD
total gas side eat trans,er +oe,,i+ient = + 0 r =$2.1011.83 = 83.#3 >4s/mD
1 d
o
0 d
!
ln5d
!
4d
i
6 0 1



=
U idi 22 o
= !.!3814514!!!&!.!31$6 0 !.!381 ln5!.!3814!.!31$6 0
1483.#3
2 & 49.844
U = 82.88 >4s/.mD
Heat trans,erred to e:aporator tubes,
Q = U & e,,e+ti:eness & (& lmtd
= 82.88 & !.82 & 24# & #$3 = 112!# D>.
+'"! !"n%.'', !# C"!' C"$$ 'n/$#%'*
"egle+ting metal resistan+e and internal +ondu+tan+e te +on:e+tion eat
trans,er
+oe,,i+ient be 82.88 *4s/.mD
Q = 82.88 & !.$1 & 2# & #$3 = 1!28 D>.
)otal eat gained by e:aporator and en+loser is = 112!# 0 1!28 = 12231 D>.
+EAT TRANSFER IN AIR +EATER
)e operation region in:ol:es lo* temperatures, *ere eat trans,er ta2es
pla+e predominantly troug +on:e+tion and little +ondu+tion. Sin+e te
ti+2ness o, tube is :ery less +ondu+tion eat trans,er +an be negle+ted.
Con:e+tion eat trans,er ta2es pla+e in t*o modes
16 ?as to metal eat trans,er
26 metal to air eat trans,er.
(s te air eater is lo+ated in +old end o, eat trans,er side, nonCluminous
radiation *ill be :ery negligible and en+e te same +an be eliminated.
5(bo:e 4!!=C non luminous radiation eat trans,er *ill be negligible6.
)e o:er all eat trans,er +oe,,i+ient +an be estimated as per te deri:ation
gi:en in te super eater +apter. 3n tat e/uation negle+ting ,ouling
resistan+e and metal resistan+e *e *ill get
U = o & idi4do
5o 0 idi4do 6
@RACTICAL GUI1E LINES FOR 1ESIGNING AIR +EATER.
1.! ?as or air :elo+ity inside tube as to be limited to ma&imum o, 18 to 18
meters4se+ and out side tube as to be limited to # to $ meters4se+
beyond
*i+ ysterisis *ill o++ur.
2.! )e air or gas passes o:er te tubes, *ere te lesser number o, tubes
deep
arranged tis is to a:oid iger pressure drop.
3.! )e unit eigt o, tube sould not e&+eed 3.8 meters to a:oid :ibration
problem
and pre,erable eigt be 2 to 3m bet*een tube seets.
4.! 3n -.C and +on:entional boilers it is desirable to eat te air not more
tan
18!=+, in order to a:e a better +ooling ,or grate or Bistributed plate.
8.! "ormally a tube diameter 8!.8 mm or #3.8 mm *ill be used.
Ex 01 Besign tubular air eater ,or 2!! )<H steam generator a:ing
,ollo*ing parameter,
?as ,lo* 2g4r = 2$21#!
(ir ,lo* 2g4r =21318#
(ir inlet temperature = 2#.#$=+
?as 3nlet temperature =2$1.3=+
?as %utlet temperature =1#!=+
Eet te air eater be +ross type and staggered arrangement and te boundary
+ondition o, air eater be
-lue gas inlet temperature =+ )
gi
-lue gas outlet temperature =+ )
go
(ir inlet temperature =+)
ai
(ir outlet temperature =+)
ao
'ass o, gas ,lo* 2g4r m
g
'ass o, air ,lo* 2g4r m
a
Heat duty Ql = mg 5Hgi7 Hgo6 2+al4r
= 2$21#! 5 $8.93C44.12446 = 8.#8# &1!
#
2+al4r
(ir outlet temperature = cQl45+po Nma6d 0 )ai
=8.#8# &1!
#
0 2#.#$ = 194.4$
!.242&21318#
(ssuming optimal :elo+ity o, 18m4se+
?as ,lo* area = ,lue gas ,lo* N 5)ga:02$36
3#!!N 2$3 N 1.218N18
= 2$21#! & 5 218.#8 02$36453#!!&2$3&1.218&186 = $.4!#8 mK
(ssume #3.8 & 2.!# mm tube siAe
"umber o, tubes = ?-( N 445_ N dK6
= $.4!#8 &4 4_& !.!8938K = 2#$8
(rrangement 88 & 3! =2#4! tubes 5:elo+ity *or2s out to be 18.198m4s6
Heigt o, air eater tube may be +onsidered as
` = 8.8 m 5 3ntermediate support to be +onsidered6
(ir ,lo* area = 5num. o, tubes in air pat N pit+ 7 num. o, tubes in air pat N
od6
= 8.8 588& !.!8! 7 88 &!.!#386 = $.98# mK
(ir :elo+ity = ma N 5)aa: 02$36
3#!! N2$3 N (-(N density o, air
= 21318# &5 11!.338 02$364 53#!! & 2$3& $.98# & 1.2936
= 8.!81 m4s
<roperties o, gas at mean gas temperature,
Spe+i,i+ eat = !.288# 2+al42g=C
).+ondu+ti:ity = !.!383 >4m=D =!.!329 2+al4mr=C
@is+osity = 2.39 & 1!
C8
2g4 mse+
Bensity o, gas = !.#8!4 2g4m
3
<roperties o, air at mean air temperature,
Spe+i,i+ eat = !.241 2+al42g=C
).+ondu+ti:ity = !.!3248 >4m=D = !.!2$9 2+al4mr=C
@is+osity = 2.221# & 1!
C8
2g4 mse+
Bensity = !.92!8 2g4m
3
G"% %(,' )'"! !"n%.' /#'..(/('n!*
"u = !.!23 9e
!.8
<r
!.3
9eynolds number = 18.198 & !.!8942 & !.#8!442.39 & 1!
C8

=28$11
<randtl number =!.288# & 2.39 & 1!
C8
&3#!!4!.!329 =!.$4#9
`g = !.!23 & 28$11!.8 & !.$4#9!.3 & !.!3294!.!8942
= 39.3# 2+al4rmK=C
(ir side eat trans,er +oe,,i+ient,
"u = !.3 9e
!.#
9eynolds number = 8.!1# & !.!#38 & !.92!8 42.221# & 1!
C8
= 21!9$
`a = !.3 & 21!9$
!.#
& !.!2$94!.!#38 = 81.81 2+al4rmK=C
14U = do4dig 0 14a 0 do ln5do4di6
2Dm
14U = !.!#38 0 1481.81 0 !.!#38 & En5!.!#384!.!89426
!.!8942 & 39.3# 2 & 49.14
U = 21.4# 2+al4rmK=C
Considering an e,,e+ti:eness ,a+tor !.8
)e %:erall eat trans,er +oe,,i+ient is 21.4#&!.8 = 1$.1#8 2+al4mKr=C
(ssuming Counter ,lo*
Emtd = 51#!C2#.#$6C 52$1.3 7 194.4$6
EnO51#!.C2#.#$6452$1.3 7194.4$6P
= 1!2.49=
(s te ,lo* is not per,e+tly +ounter ,lo*, +orre+tion ,a+tor in lmtd o, !.98 as to
be made.
Corre+ted Emtd = !.98& 1!2.49 = 9$.3# =
Heat trans,erred = U ( Emtd
Heat trans,er area arranged in t*o blo+2s
( = 8.#8# & 1!
#
41$.1#8 & 9$.3#
9e/uired eat trans,er area = 81$8.#8 mK.
<ro:ided eat trans,er area in t*o blo+2s = 2&_&!.!#38&8.8&88&3! = 8$93 mK
G"% %(,' @'%%u' ,#=,
`, = !.18449e
!.2

, = !.1844 28$11
!.2
= !.!2414
<ressure drop = !.!2414&8.84!.!8942 & 18.198K & !.#8452&9.816
=1$.89 mm>+
-or t*o <asses = 1$.89 &2 = 38.$8 mm>+
;ntry and e&it loss = 1.8 & 2 & 18.198K & !.#8452&9.816 = 24.!1# mm>+
-or t*o passes gas side
)otal pressure drop = 38.$8 0 24.!1# = 89.$9# mm>C
A( %(,' @'%%u' ,#=,
`, = 1.#3249e
!.18

, = 1.#324 21!9$
!.18
= !.3##8
"umber deep = 3! nos4pass
<ressure drop = !.3##8 & 3! & 2 & 8.!81K & !.92!8452&9.816 =##.89 mm>C
3LOB1OBN
3n spite o, all treatment, boiler *ater *ill +ontain dissol:ed solids. 3n order to
2eep te le:el o, total dissol:ed solids in boiler *itin te limits and to remo:e
any sludge, loose s+ales and +orrosion produ+ts, a +ertain /uantity o, boiler
*ater sould be regularly drained. )is pro+ess is 2no*n as blo* do*n. )e
blo* do*n +an be intermittent say on+e a si,t or +ontinuous. )e /uantity o,
te *ater to be blo* do*n *ill depend on te dissol:ed solids entering te
boiler troug te ,eed *ater and te ma&imum tolerable le:els o, tese salts
in te boiler *ater. >ile determining te dissol:ed solids +ontent in te ,eed
*ater it is ne+essary to ta2es into a++ount not only te original dissol:ed
solids but also te dissol:ed solids added in te ,orm o, dosing.
C#n!(nu#u% b$#C ,#Cn
Continuous blo* do*n is a +ontinuous remo:al o, boiler *ater +ontrolled by a
spe+ially designed adYustable :al:e or by an ori,i+e plate. )e installation o,
eat re+o:ery e/uipment in +ontinuous system may be e+onomi+ally Yusti,ied.
Suspended solids may blo+2 or erode te adYustable :al:e or ori,i+e plate and
+ontinuous blo* do*n is tere ,ore limited to te +ontrol o, dissol:ed solids.
(dditional manual blo* do*n is ne+essary to +ontrol suspended solids and
pre:ent te build up o, sludge.
>en boiler *ater ,rom ig pressure is suddenly redu+ed to lo* pressure
blo* do*n *ater, *ater entalpy *ill drop and steaming *ill o++ur. 3n utility
boilers re+o:ering tis blo* do*n ,las steam pro:es e+onomi+al. )e
/uantity o, ,las steam generated is te produ+t o, ratio bet*een di,,eren+e in
boiler *ater entalpy and blo* do*n *ater entalpy to latent eat o, blo*
do*n *ater and blo* do*n /uantity.

In!'-(!!'n! b$#C ,#Cn
3ntermittent blo* do*n may be e,,e+ted by spe+ially designed :alues eiter
operated manually or automati+ally +ontrolled by timers, ,eed *ater ,lo* and
+ondu+ti:ity. 3t sould be noted tat te most e,,e+ti:e intermittent blo* do*n
is a+ie:ed by ,re/uent ,ull open operation ,or sort inter:als rater tan small
e&tended in,re/uent operation. 3t is not pra+ti+able to re+o:er *aste eat ,rom
in,re/uent intermittent blo* do*n.
Ex.04 -ind te blo* do*n /uantity and ,las steam produ+ed ,or a 1#!tp
boiler operating at a pressure o, 12! bar5a6 and te permissible sili+a +ontent
in ,eed *ater and boiler *ater be !.!1ppm and !.8ppm respe+ti:ely. )e
,las steam blo* do*n :essel is maintained at 4.8 bar5a6.
3$#C ,#Cn Lu"n!(!0
Continuous blo* do*n = S & 1!!
5 C 7S6

= !.!1 & 1!!45!.8 7!.!16 = 1.2# %
.lo* do*n /uantity = !.!12# & 1#! = 2.!28 tp
F$"%) %!'"- /"$/u$"!(#n
;ntalpy o, boiler *ater lea:ing te drum = 1491.2 2Y42g
(t 12! bar5a6
;ntalpy o, *ater in blo* do*n tan2 at = #23.14 2Y42g
4.8 bar5a6
;ntalpy o, ,lased steam in blo* do*n = 2$43.88 2Y42g
)an2 at 4.8 bar5a6
Eatent eat o, ,lased steam at 4.8 bar5a6 = 212!.41 2Y42g
-las steam per+entage = entalpy o, boiler *ater 7 entalpy o, blo* do*n
*ater
Eatent eat o, blo* do*n *ater
= 51491.2 7 #23.146& 1!!4212!.41 = 4!.94%
-las steam /uantity = 2.!28 & !.4!94 =!.829 tp.
BOILER THERMAL EFFICIENCY CALCULATIONS
The thermal efficiency calculations boiler is as follows.
I. THERMAL EFFICIENCY CALCULATION FOR BOILER
Boiler Details:
Boiler Make : Thermax
Fuel : coal
Capacity : 8.00 TP
! !team Pressure : "#.$8 %& ' cm
(
!team Temperature : (00)C
Ambient Conitions:
Temperature : *")C
umi+ity : ,$-
Obser!ations:
!team Pressure . "#.$8 %& ' cm
(
!team Temperature . (00)C
Fee+ water temperature at the inlet of the /conomiser 0 #1)C
Fee+ water Temperature at the outlet of the /conomiser 0 ""*)C
Flue &as Temperature at the !tack . "#$)C.
Fuel firin& rate . 8$0 %&'hr
!team &eneration rate . 8000 %&'hr
23era&e !urface Temp . $$)C
23era&e !urface 2rea . ,,.,0 m
(
Percent C4
(
in flue &as . "5.$
Percent 4
(
in flue &as . $
Percent C4 in flue &as . 0.$$
Cal"#lations:
Ultimate Anal$sis O% T&e F#el
Carbon 67t8 : ,0.,0-
y+ro&en 67t8 : *.10 -
4xy&en 67t8 : "1.0" -
2sh 67t8 : (.50 -
Moisture 67t8 : "".(0-
9ross Calorific 3alue : ,5$# %cal ' %&
Basis : "00 %& of fuel
I. FUEL ANALYSIS as %ire Basis:
Constit#ents Mass '()* (mole T&eo. O
+
re,#ire
C ,0.,0 $.0$ $.0$

(
*.10 ".1$ 0.1#$
4
(
"1.0" 0.$1 .0.$1
2sh (.50 . .
Moisture "".(0 .,(( .
$.5#"
Theoretical 2ir Fuel ratio is
$.5#" x 5.#, x (1
62F8 Theo : ;;;;;;;;;; : #.$$( %& of air'%& of fuel
"00
4
( $
- /xcess air : ;;;;; : ;;;;; : *".($-
(" 0 4
(
(" 0 $
2ctual 2ir fuel ratio is
%& of air
62F8 actual : #.$$( x ".*"($ : 1.10 ;;;;;
%& of fuel
/xcess 4
(
: $.5#" x 0.*"($ : ".#01 %mol
/xcess <
(
: $.5#" x *.#, x ".*" : (,.11 %mol
II. Dr$ Fl#e )as Anal$sis
Constit#ents (mole Mole - Mass. ()
C4
(
$.0$0 "5.150 (((.(0
!4
(
0.0*, 0."0,0 (.*050
4
(
".#01 $.0$#0 $5.,88
<
(
(,.111 #1.810 #$$.1#(
**.#15 "0#,.*8
III. As& Anal$sis
=t has been obser3e+ that the mass of un burnt carbon in the fly ash &enerate+
is 0.0"(1 %&.

Losses Cal"#lation:
/. Dr$ %l#e )as loss:
>uantity of flue &as &enerate+ 6m
+&
8:
"0#,.*8
m
+&
: ;;;;;; : "0.#, %&'%& of fuel
"00
?ry flue &as loss
m
+&
C
p&
6T
&
0 T
a
8
6@
"
8 : ;;;;;;;;;;; x "00
9CA of fuel
"0.#, x ".005 x 6"#$ 0 *"8
: ;;;;;;;;;;;; x "00
(#0*$
L
/
0 1.23-
+. H$ro)en Moist#re Loss: 'L
+
*
1 M 6
3
0
f
8
6@
(
8 : ;;;;;;;;; x "00
9c3 of fuel

A
at "#$)C : (8*".*$ %B' %&

f
at *")C : "(1.8 %B' %&
1 x 0.0*1 x 6(8*".*$ 0 "(1.88
@
(
: ;;;;;;;;;;;;; x "00
(#0*$
L
+
0 4.13-
4. F#el Moist#re Loss: 'L
4
*
m
w
6h
3
0 h
f
8
@
*
: ;;;;;;;; x "00
9c3 of fuel

3
at "#$)C : (8*".*$ %B'%&

f
at *")C : "(1.8 %cal ' %&
0.""( x 6(8*".*$ 0 "(1.88
@
*
: ;;;;;;;;;; x "00
(#0*$
L
4
0 /./3-
5. Air Moist#re loss 'L
5
*

ma w Cp3 6T& 0 Ta8
@
5
: ;;;;;;;;;; x "00
9c3 of fuel
%& of water
w : 0.0(5 ;;;;;; 6at ,$- C D *")C8
%& of +ry air

1.10 x 0.0(5* x ".88 x 6"#$.*"8
@
5
: ;;;;;;;;;;;;;;; x "00
(#0*$
L
5
0 3 .+46-
1. Heat loss #e to in "om7lete "omb#stion 'L
1
* :
-C4 $#55
@$ : ;;;;;; x m
cb
x ;;;;;; x "00
-C4
(
E -C4 ((#(
-C4
(
0 "5.$0 -

-C4 0 0.$$-



0.$$ ,0.,0 (*$,#
@
$
: ;;;; x ;;;; x ;;; x "00
"5.$0 E 0.$$ "00 (#0*$
L
1
0 /.24-
8. Heat loss #e to #nb#rnt in %l$ as& '-* 'L
8
*: 9
Mass of unburnt carbon in fly ash F *(#$0
@
,
: ;;;;;;;;;;;;;;;;; x "00
9CA of fuel
@
,
: 0.0"(1 F *(#$0
;;;;;;; x "00
(#0*$
L
8
0 /.18-
:. Raiation an Con!e"tion Loss 'L
:
* :
Ca+iation @oss 6@
#
8
( )
1
1
]
1

+
+
,
_

+
,
_

1 . ,8
1 . ,8 "1,
1$# . "
$$ . $$ $$ . $$
$58 . 0 @
($ . "
5 5
$
Vm
Ta Tg
Ta Ts
( )
1
1
]
1

+
+
,
_

+
,
_

1 . ,8
1 . ,8 $ . * "1,
*0* *"* 1$# . "
$$ . $$
*0*
$$ . $$
*"*
$58 . 0
($ . "
5 5
: $"1.*, 7'm
(
: $"1.*, x ,,.,

: *5.$81 k7
*,00 *5 "8 . 5 1$00
("( . (
-

Heatloss
L
:
0 - "on!e"tion an raiation loss 0 3.15+-
Gseful heat @s : ms x 6hs.h
fw8
m
f
: 8000 x 6(#10.**08
.....................
8$0
: (*"$( kBl'k&
Gnaccounte+ losses : "00 . H6@s'9CA I"008 E J
$
"
lossesK
: "00 . H8$.,5 E$.1E*.$E"."E0.(*8E".1*E".$,K
:"00. 11.8,8
:0."*(-
@
8
: $"1.*, 7'm
(
$"1.*,
: ;;;; x ,,., : *5.$81 %7
"000
*5.$81 x *,00
- @oss 6@#8 : ;;;;;;;;;;; : .$5(-
8$0 x ,5$# x 5."8#
L
6
0 .15+-
Boiler : "00 0 6@
"
E @
(
E @
*
E @
5
E @
$
E @
,
E @
#
E @
8
8
Boiler : "00 0 6$.10 E *.$0 E "."0 E 0.(*8 E ".1* E ".$, E 0.$5(8
Boiler 0 61.+4-
/3aporation ratio :
%& of steam &enerate+
%& of fuel consumption
:
(0L000 6%& ' hr8
"0L000 6%& ' hr8
: (