Radiant Section Calculation:-

Assumption:-
Radiant flux = 68100kJ/hr.m2
Duty:-
Enthalpy = 746.67 kJ/kg at 280 C, 998.71 kJ/kg at 350 C
Duty=7793.10822(998.71-746.67)
= 1964174.996 kJ/ hr
Net Heat Release:-
qn=1964174.996/0.75 =2.62 106 kJ/ hr
Flue Gas with 25% excess air:-
= (3.02 106 kJ/ hr) (1010 lb/MM Btu)
=0.38kg/s
Approximate Radiant Duty:-
q
r =1964174.9960.7=1374922.497 kJ/ hr

Tube Wall Temperature:-

Inlet temperature of the fluid = T1 = 280 C

Outlet temperature of the fluid = T2 = 350 C

Cross over temperature = Tc = T2 0.75(T2 T1) = 297.5oC

Average fluid= Tf=(Tc+T2)/2 = 338.75C=641.75F

Tube skin temperature = Ts = Tf +100 =741.75F=394.3 oC

Radiant Surface:-

Art = qr /assumed flux = 1374922.497/ 68100

=20.19 m2
 Now, we select Tube Dimensions which are
O.D = 0.0381m
Length= 6.1 m
For a Standard Tube Spacing (C) of two nominal diameters
C = 8" = 0.203 m
Exposed surface per linear m
a= O.D
= 0.0381
=0.1197m

Total exposed radiant length= Art /a

=20.19/0.1197
=168.67 m
Surface area/ tube= DL
= 0.7301 m2
Number of Tubes=NRT= Art / (aL)
=27.65
=28 tubes
Corrected Radiant Surface area= NRT DL

=23.37m2

Dimensions of the radiant section:

Now, we move towards the Dimensions of Furnace for which the configuration of tubes
is

o No. of tubes for rectangular section = 20

o No. of tubes for arc section = 4

o No. of tubes for shield section = 4 (for two rows)

Length=L = 6.1 m

Tube in one row =10

 Width=W= [( shield tubes+1)+ (arc tubes+1)]* (c-c distance) = 2.03m

Height of bridge wall=H= (10+1) (c-c distance) = 2.233 m

23
3
L H W
Beam length = = 2.02m

Spacing Ratio=C-C/O.D
=5.33
From Fig 19.11 Kern
= 0.47
Cold Plate Area
Shield tubes, Acp=46.10.203=4.9532m2

Wall tubes, Acp=206.1.203=24.766m2

Acp=4.9532+0.47(24.766)
=16.59m2
Envelope Area
=2(2.032.233)+2(6.1(2.03+2.233))
=61.07m2
Radiant section Area
AR=61.07-16.59
=44.48m2
AR/ Acp =2.68
Furnace Volume

=6.12.032.233=27.65m3
Mean Beam Length,L
2 3
L H W
= 3

=2.02 m
The value of (Pco2 + PH2O) = 0.23 atm
(Pco2 + PH2O)L = 0.232.02 =0.4637 atm.m
 Since there is no Preheated air or fuel, the heat rate of
combustion air, qn,
equals the heat rate of fuel equals the zero. Assume the heat
loss from tubes,

qL,divided by the rate of heat combustion, q n,or, qL/qn=0.02.

Estimate that the average fire box temp. is 565.6C

Emissivity=0.39
Exchange Factor, F=0.69
AcpF=11.45 m2

qn/AcpF= 228820.96kJ/m2.hr

For this type of furnace assume that exit gas temperature is the
same as average fire box temperature 565.6C

tg2=tg= 565.6C

qg2/qn=0.29 (from fig 1.10)

qR/AcpF =(1-0.02-0.25) 228820.96

= 167039.3kJ/m2.hr

Figure shows a small portion of Figure 1.11 with a absorption

curve for

394.3 oC tube wall. Plot the calculated qR/AcpF of

195029.35kJ/m2.hr

At the assumed fire box temperature of 565.6C.This lies to the

left of
Absorption curve, so try another calculation of 787.8C.
Emissivity=0.38
Exchange Factor, F=0.68
AcpF=11.28 m2

qn/AcpF=232269.5 kJ/m2.hr
 For this type of furnace assume that exit gas temperature is the
same as average fir box temperature 787.8C

tg2=tg= 787.7C

qg2/qn=0.37from fig 1.10)

qR/AcpF =(1-0.02-0.37) 300497.512

= 141684.4kJ/m2.hr
Plot this on the figure and join two calculated points by a straight
line. It crosses the absorption curve at 672 C. this is the fire box
temperature

qg2/qn=0.36 from fig 1.10)

qR=1612000kJ/hr
qR/ART= 68977.32kJ/m2.hr

Convection Section Calculation:-

Standard design steps for convective section.

HEAT DUTY
NUMBER OF TUBE REQUIRED
CONVECTION SECTION AREA
In convective section rest of the heat duty will be obtained.

Qc = Q required Qr = 352174.996 kJ /hr

Cross over temperature: Tc = 80.4 C

Inlet temperature of the Natural Gas: T1 = 280 C

Stack Heat Content/Release

 QS Qw QR QC
1 ( )
Qn Qn Qn Qn

QS

Qn
1-0.02-0.75

=0.23

Stack gas temperature: Ts = 482 C

Temperature differences

Hot=672 C -80 C =592C

Cold=482 C -280 C=202C

LMTD=362.71 C

Mean gas film temperature: Tf = 0.5 (T1 + Tc +LMTD)

= 361.375C

Gross width (G.W) = (No. of shield tubes+0.5) (C C distance)

=0.9135m

Free width (F.W) = (G.W)-(No. of shield tubes) (tube OD)

=0.7615m

Free area (F.A) = (F.W) (tube length)

=4.65m2

Mass velocity at minimum cross section

 G=0.35/4.65

=0.08 kg/m2.s

Overall heat transfer coefficient UC in convection section is

UC= (a+bG+cG2) (4.5/d)0.25

Where

d is the tube outside diameter (in)

G is the flue gas mass velocity

a=2.461-0.759Z+1.625Z2

b=0.7675+21.3732-9.6625Z2

c=9.7938-30.809Z+14.333Z2

Z=TF/1000 average out side film temperature

Uc = 16.49 KJ/hr m2 C

QC
AC
U C LMTD
Surface required for the convective heat transfer =

=352174.996/1
6.49362.71=58.88 m 2

No. of tubes for the convective section = 58.88 m2 / 3.146.10.0381

=80.68 tubes

=82 tubes