Calculation of Emissivity of Process Gas

Project No. 16279S

Project Name BAPCO - JVTST

Process Gas Temperature Tg 1561.3 K

Process Gas pressure Pg 1.72810264 atm
Tube OD D 0.17 ft
Radius(Beam length), Le = 0.65*D Le 0.1083 ft
Total Gas Mass flowrate Wg 41637.6 kg/hr
Molecular weight of Process Gas MWg 28.66 kg/kgmol
Total Moles of Process Gas Mg 1452.81 kgmol/hr
Emmisivity Calculation of H2O:
Total Moles of Water vapor in Process Gas kgmol/hr 421.31
Mole fraction of water xi 0.290
Partial pressure of water vapor, xi.Pg Pw 0.5011 atm
Pw.Le 0.05 ft.atm

Emissivity of water vapor εw 0.018 from chart

(Pw + P)/2 1.115
Correction factor Cw 1.6 from chart

Emissivity of water vapor with Correction factor εw 0.0288

Emmisivity Calculation of CO2:
Total Moles of CO2 in Process Gas Mg 19.67 kgmol/hr
Mole fraction of carbondioxide xi 0.0135
Partial pressure of carbondioxide Pc 0.0234 atm
Pc.Le 0.0025 ft.atm
Emissivity of carbon dioxide εc 0.006 from chart
Correction factor Cc 1.2 from chart

Emissivity of carbon dioxide with correction factor εc 0.0072

Total Emmisivity Calculation for Gas:
PW/(Pw + Pc) 0.955 (X axis)
Le*(Pw + Pc) 0.057 (Y axis)
Emissivity correction factor Δε 0 from chart

Total emissivity of gas εg 0.036

Total Absorptivity Calculation for Gas:
Tube wall temperature (from HTRI) Ts 555.93 K
Pw.Le. (Ts/Tg) 0.02 ft.atm
Pc.Le. (Ts/Tg) 0.001 ft.atm

Emissivity of water vapor εw 0.035 from chart

Emissivity of carbon dioxide εc 0.005 from chart

Absorptivity of water vapor αw 0.089
Absorptivity of Carbon dioxide αc 0.0117
Absorptivity correction factor Δα 0.0000
Total Absorptivity of Gas αg 0.10
 11.52 W/m2.K
Radiation HTC for Gas, hr hr
2.07 BTU/ft2.hr.F
Tube side heat transfer coefficient hi 16.01 BTU/ft2.hr.F
Factor of Radiation heat transfer coefficient 1.12957
Charts: Emissivity of Water Vapor
Charts: Emissivity of CO2
Charts: Correction factor considering both Water Vapor and CO 2
Riser
1) andgeneration
Steam Downcomer rateSpacing
varies across the length of heat exchanger.

2) Gas (Inside) film coefficient (hi) can vary significantly over the length of heat exchanger
because of large change in physical properties.
3)Necessary to evaluate the heat transfer in incremental length of tubes. (No.of Increments is equal to the number of nozzles
4) Assume temperature difference and gas film transfer coefficient in each increment of tube length
and the assumptions are checked by actual calculation. If the assumptions proved to be invalid, then process
,must be repeated with modified assumptions.
5) Gas heat transfer coefficient must be based on gas physical properties at the average gas temperature
calculated for specific increment for tube length.

Project No. 16279S

Project Description BAPCO
Overall Heat duty of Waste Heat Boiler, Q BTU/hr 62895000
No.of Nozzles 4
Heat duty required, Qrequired BTU/hr 15723750
Gas Mass flow rate, M lb/hr 91791
Inside Diameter of tube, di ft 0.1270
Outside Diameter of tube, do ft 0.1667
Tube thickness, Tt ft 0.0198333333
Tube thermal conductivity, KTT BTU/hr-ft-F 25.94322
Number of Tubes, NT 680
Length of Tube, L ft 24
Tubesheet thickness ft 0.104
Effective length of Tube, Leff ft 23.79
Water Operating pressure, P psia 609.7
Saturation Temperature of Water, Tsat F 488
Gas Viscosity at Wall Metal temperature lb/hr-ft 0.028
Fouling resistance - shell side, ro ft2-hr-F/Btu 0.0007
Fouling resistance - tube side, ri ft2-hr-F/Btu 0.0000
Overdesign % 0

Nozzle position 1 2
Gas Inlet temperature, TH F 2351 1913.450
Gas Outlet temperature, Tc F 1913.450 1475.900
(Assumed) Incremental length of tube, L ft 2.021 3.012
Length from Tube sheet, LT ft 2.021 5.033
Length from Tube sheet with Overdesign, L T ft 2.021 5.033
Fraction of Effective tube length 0.085 0.212
Gas viscosity at Inlet temperature,µi lb/hr-ft 0.1330 0.1168
Gas viscosity at Outlet temperature,µo lb/hr-ft 0.1168 0.1089
Gas specific heat at Inlet temperature, Cp i BTU/lb-F 0.34 0.325
Gas specific heat at Outlet temperature,Cp o BTU/lb-F 0.325 0.3100
Gas thermal conductivity at Inlet temperature, K i BTU/hr-ft-F 0.066 0.056
Gas thermal conductivity at Outlet temperature, K o BTU/hr-ft-F 0.056 0.046
Average Gas Viscosity,µ lb/hr-ft 0.1249 0.1128
Average Gas specific heat,Cp BTU/lb-F 0.3325 0.3175
Average Thermal conductivity, K BTU/hr-ft-F 0.0610 0.0510
LMTD F 1634.48 1193.34
Area of Tubes,A ft2 719.71 1072.40
Heat Flux, q BTU/hr.ft2 21847.48 14662.27
Correction factor, FP 1.91 1.91
shell side heat transfer coefficient, ho BTU/hr.ft2.F 3408.26 2605.97
Gas Mass Velocity per tube lb/hr.ft2 10655.99 10655.99
Reynold's Number per tube, Nre 10831.57 11992.51
Prandtl Number per tube, Pr 0.68 0.70
Tube side heat transfer coefficient, hi BTU/hr.ft2.F 16.01 14.70
Resistance of tube wall, rw hr.ft2.F/BTU 0.0009 0.0009
Factor for Radiation heat transfer 1.1240 1.1240
Actual tube side heat transfer coefficient, h i BTU/hr.ft2.F 17.9904 16.5216
Overall Heat transfer coefficient - fouled, U BTU/hr.ft2.F 13.37 12.29
Calculated Heat duty, QCAL BTU/hr 15723750.00 15723750.00
Result ok ok
rajagopalans:
First assume some incremental length of tube
and calculate Q and then use goal seek to match
with Q req by adjusting Incremental length
value.

Nozzle
Gas Temperature Tube length (Inches) heat duty Location from
(deg F) from Front Tubesheet (MMBtu/hr) Tubesheet
(Inches)

2351 0 0
1913.5 24.257 15.72375 12.128
1475.9 60.400 31.44750 42.328
1038.4 123.356 47.17125 91.878
600.8 311.169 62.89500 217.262
equal to the number of nozzles)

d, then process

temperature

Temp
26.998
2351
1913.450
600.8

2351
1475.900
3 4 600.8
1475.9 1038.4
1038.350 600.80
5.246 15.651 2351
10.280 25.931 1038.350
10.280 25.931 600.8
0.432 1.090
0.1089 0.0842
0.0842 0.0677
0.31 0.295
0.295 0.28
0.046 0.036
0.036 0.026
 0.0965 0.0760
0.3025 0.2875
0.0410 0.0310
747.91 276.07
1867.95 5572.51
8417.66 2821.66
1.91 1.91
1793.78 859.62
10655.99 10655.99
14021.32 17816.90
0.71 0.70
13.46 12.28
0.0009 0.0009
1.1240 1.1240
15.1330 13.7992
11.25 10.22
15723750.00 15723750.00 62895000.00
ok ok
Heat duty

0
15723750.000
62895000

0
31447500.000
62895000

0
47171250.000
62895000