HAD-WHRB_WT ] Waste heat recovery boiler of water-tube type for sulfuric acid plant
This program is designed to design the Waste Heat Boiler (WHB) under flue gas conditions. It is a water tube type boiler which recovers this heat by flowing waste gas of high temperature. Steam condition can be double pressure condition, duct burner can be calculated. The components of the waste gas can be calculated in the following common clean gas and other waste gas conditions such as CO, SO2, SO3, and H2S.
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* Thermal Design Calculation of Heat Recovery Steam Boiler for a Sulfur Plant *
* Programmed & Verified by Constant Date : May 15 2010 *
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Customer : PLANT
Service : Design_100%_load
Flue gas composition
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Molecule Vol Fr. Wt Fr.
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H2 0.000000 0.000000
CH4 0.000000 0.000000
C2H6 0.000000 0.000000
C3H8 0.000000 0.000000
iC4 0.000000 0.000000
nC4 0.000000 0.000000
C5+ 0.000000 0.000000
H2S 0.000000 0.000000
HCL 0.000000 0.000000
H2O 0.000000 0.000000
O2 11.440000 10.400019
N2 73.069992 58.157188
CO2 1.650000 2.063020
CO 0.000000 0.000000
SO2 4.670000 8.499416
SO3 9.180000 20.880369
GAS FLOW 146569. kg/hr 93339. Nm3/hr 1.5703 kg/Nm3 40.71 kg/sec
MODULE NUMBER 1
GAS SIDE HP_SH
GAS FLOW kg/hr 146569.
INLET PRESSURE mmAq 6210.0
PRESSURE DROP mmAq 58.9
INLET TEMPERATURE deg C 633.0
OUTLET TEMPERATURE deg C 472.8
TEMPERATURE DIFF. deg C 160.2
SPECIFIC HEAT kcal/kg-C 0.2387
HEAT REJECTED Gcal/hr 5.605
SETTING LOSS % 0.2000
FOULING FACTOR m2-hr-c/kcal 0.00020
MODULE NUMBER 1
TUBE SIDE HP_SH2
FLUID FLOW kg/hr 47122.
INLET PRESSURE(abs) bar 48.57
OUTLET PRESSURE(abs) bar 48.31
TUBE PRESSURE DROP bar 0.26
ADDITIONAL PRESSURE DROP bar 0.00
INLET TEMPERATURE deg C 263.0
OUTLET TEMPERATURE deg C 437.8
TEMPERATURE DIFF. deg C 174.8
HEAT ABSORBED Gcal/hr 5.594
FOULING FACTOR m2-hr-c/kcal 0.00020
ATEMP FLOW kg/hr 0.
BLOWDOWN % 0.00
Extraction Flow (Water) kg/hr 0.
Extraction Flow (Steam) kg/hr 0.
Pinch Point deg C 35.02
Aproach Point deg C 174.76
Gas Side
Inlet Velocity m/sec 10.1
Outlet Velocity m/sec 8.4
Max Fin Temp deg C 0.0
Max Tube Temp deg C 464.4
Min tube Temp deg C 290.2
Water Side
Inlet Velocity m/sec 6.9
Outlet Velocity m/sec 10.8
Steam/Water Density kg/m3 18.5663
Velocity Requirements : Superheaters
MODULE NUMBER 1
TUBE SIDE HP_SH2
Max Velcity (Sup.) kg/hr-m2 2929.4
Mass Velcity kg/hr-m2 605.3
Min Velcity (Sup.) kg/hr-m2 1464.7
Tube & Pipe Pressure drop(kg/cm2-a)
MODULE NUMBER 1
TUBE SIDE HP_SH2
INLET PRESSURE(abs) kg/cm2 49.53
OUTLET PRESSURE(abs) kg/cm2 49.26
TUBE PRESSURE DROP kg/cm2 0.27
ADDITIONAL PRESSURE DROP kg/cm2 0.00
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* Thermal Design Calculation of Heat Recovery Steam Generators. Ver. 2.0 *
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GAS SIDE HP_SH Total
Heating Surface m2 425.6 425.6
Finned Outside Surface Area m2/m 0.0999
Tube Diameter mm 31.80
Tube Min Thickness mm 4.0000
Tube Length mm 3000.0
Tube Material A213 TP304
Tube Design Temp (Standard) C 464.
Number of Transverse Tubes 35.5 1420.0
Transverse Spacing mm 74.000
Number of tubes on w/steam side 5.
Number of tube passes 8.
Number of Longitudinal Rows 40.
Longitudinal Spacing mm 60.000
Tube Arrang.(1=Stagg,2=lnline) 1.
Finned Type.(0=No,1=Solid,2=Serr) 0.
Flow Type.(C=1,P=2) 1.
Fin Height mm
Fin Thickness mm
Fin pitch mm
Fin per Meter ea/m
Fin per Inch ea/in
Fin Material
Fin Segment mm
Fin Base Height mm
Width of HRSG m 2.6640
Baffle of Inner Casing mm 7.95000
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* Heat Transfer *
MODULE NUMBER 1
TUBE SIDE HP_SH
HEAT ABSORBED(LMTD) Gcal/hr 5.806846
HEAT ABSORBED(Correc.) Gcal/hr 5.806846 5.806846
U Correction factor 1.0000
LMTD Correction factor 0.9922
UO kcal/m2-hr-c 67.405571
UO X U Corr f kcal/m2-hr-c 67.405571
RTO m2-hr-C/kcal 0.0148356
RO m2-hr-C/kcal 0.0129150
RWO m2-hr-C/kcal 0.0002649
RIO m2-hr-C/kcal 0.0016557
HC kcal/m2-hr-c 77.502998
HR kcal/m2-hr-c 1.144395
HO kcal/m2-hr-c 77.429466
HI kcal/m2-hr-c 962.326
KW kcal/m-hr-c 17.271378
KF kcal/m-hr-c 0.000000
Fin Efficiency 0.000000
F_T(Sub Cooled. Factor) 0.000000
R_T(Saturated Nucleate Boiling) 0.000000
K_T(Superheater Factor) 0.354689
Enthapy of Inlet Flue Gas kcal/kg 153.63
Enth. of Outlet Flue Gas kcal/kg 110.80
Enth. of Inlet Water/Steam kcal/kg 667.63
Enth. of Outlet W/S kcal/kg 786.34
INLET PRESSURE(abs) kg/cm2 49.53
OUTLET PRESSURE(abs) kg/cm2 49.26
HEAT REJECTED Gcal/hr 5.605 5.605
HEAT ABSORBED Gcal/hr 5.594 5.594
Cp of flue gas(in) kJ/kg-degC 1.016111
Cp of flue gas(out) kJ/kg-degC 0.981183
Vis of flue gas(in) kg/m-sec 0.00003897
Vis of flue gas(out) kg/m-sec 0.00003424
K of flue gas(in) W/m-degC 0.055675
K of flue gas(out) W/m-degC 0.047935
rho of flue gas(in) kg/m3 0.757843
rho of flue gas(out) kg/m3 0.920624
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* ASME Tube Wall Thickness Calcuation (ASME Section 1 ) *
MODULE NUMBER 1
TUBE SIDE HP_SH
Tube Material A213 TP304
Tube Diameter mm 31.80
Tube Thickness(initial) mm 4.0000
Min. Wall Thickness(PG27.2.1) mm 2.7886
Corrosion allowance mm 1.0000
Min. Wall Thickness(Ca=0.0) mm 1.7886
Design Pressure (Pin x1.1) bar 53.43
Max. Allowed Working Press bar 97.05
Max. Allowed Stress (Mater.) bar 494.60
Tube Material A213 TP304
Tube Design Temp (Standard) C 478.
Max. Allowed Tube Temp.(Only) C 816.
Max. Oxidizer Tube Temp.(Only) C 816.
Fin Material SUS304
Fin Design Temp (Standard) C 14.
Max. Allowed Fin Temp.(Only) C 871.
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* Weight of Tube & Fin *
MODULE NUMBER 1
TUBE SIDE HP_SH2
Tube Weight of unit meter kg/m 2.81
Tube Weight of 1 tube kg 8.42
Tube Weight of total kg 11794.34 11794.34
Fin Weight of unit meter kg/m 0.00
Fin Weight of 1 tube kg 0.00
Fin Weight of total kg 0.00 0.00
Tube & Fin Weight of 1m kg/m 2.81
Tube & Fin Weight of 1 tube kg 8.42
Tube & Fin Weight of total kg 11794.34 11794.34