(Air quenched cooler) AQC boiler

Superheater
length of the tube
Diameter of tube
No. of tube
No. of passes
fina diameter
fin spacing

10.2 m
38 mm
136
2
80 mm
10 mm/fin
Evaporator

tube length
Diameter of the tube
No. of tube
No of passes
Fins diameter
Fin spacing

10.2 m
38 mm
308
100 mm
10 mm/fin
Economizer

Tube length
Diameter of the tube
No. of tube
No. of passes
Fins diameter
Fin spacing

10.2 m
38 mm
102
80 mm
10 mm/fin
Wall

Insulation material
Insulation thermal conductivity
Insulation thickness
Inside material
Thermal conductivity of the material
Outside material
thermal conductivity of the material

rockwool
0.033
50 mm
Mild steel
26-37.5
Galvanized iron
30

Boiler Geometry
Shape
Height
Length
Width
Tubes placing
tube spacing
Tube material
themal conductivity

rectangular
25 m
12 m
3.6 m
staggered
50 mm
Mild steel

for flue gases convective ht coeff (economizer)

SL
ST
SL SQUARE
ST SQUARE
SL^2+ST^2
SD
ST+D
(ST+D)/2
AS 70.7>44 SO
Vmax= (ST/(ST-D))V
ST-D
ST/(ST-D
V=MASS FLOW RATE/DENSITY*AREA
DENSITY* AREA
MASS FLOW RATE
V
Vmax= (ST/(ST-D))V
RE
Vmax*D
RE=Vmax*D/VISCOSITY
C1
m
C2
NUSSELT NO
Nu=C1*C2*RE^m*Pr^0.36*(Pr/Prs)^0.25
RE^m
Pr^0.36
Pr/Prs
(Pr/Prs)^0.25
Nusselt no
Nu=hD/k
Nu*k
h=Nu*k/D
tube wall resistance for finned tubes
r=t/2k((d+2Nw(d+w))/(d-t))
d-outer dia of tube
w-fin hi8
t-tube wall thickness
N-no. of fins per m
k-thermal condutivity
D-inner dia of tube
2k

t/2k
2Nw
d+w
d-t
2Nw(d+w)
d+2Nw(d+w)
d+2Nw(d+w))/(d-t)
r=t/2k((d+2Nw(d+w))/(d-t))
Overall ht coeff (U)
U=1/((1/h+ro)(1/Ef)+r+(1/hi)(Ao/Ai))
h-ht coeff of shell side fluid
ro-fouling resistance on outside of tube
Ef--fin efficiency
r-wall resistance
hi- ht coeff of tube side fluid
Ao-outside surface area
Ai-inside surface area
tube side convection coeff (eco)
RE
RE=4*mass flowrate/3.14*D*VISCOSITY
mass flow rate
viscosity
D
4*mass flow rate
3.14*D*viscosity
Re
flow is turbulent
Pr
NUSSELT NUMBER
NU=0.023*Re^0.8*Pr^0.4
Re^0.8
Pr^0.4
Nu
h=k*Nu/D
k
k*Nu
h=k*Nu/D
Overall ht coeff
UoAo
hi
Ai

ho
Aunfinned
Afin
k
L
ro
ri
Ef-fin eff
Rfo-fouling factor
hiAi
2*3.14*k*L
ho*Aunfinned
ho*Ef*Afin
ro/ri
ln(ro/ri)
ln(ro/ri)/2*3.14*k*L
1/hiAi
ho*Aunfinned+ho*Ef*Afin
1/(ho*Aunfinned+ho*Ef*Afin)
1/hiAi + ln(ro/ri)/2*3.14*k*L + Rco + 1/(ho*Aunfinned+ho*Ef*Afin)
1/[1/hiAi + ln(ro/ri)/2*3.14*k*L + Rco + 1/(ho*Aunfinned+ho*Ef*Afin)]
EFF OF FIN
t
r2c=r2+t/2
r1
r2c/r1
Lc=L+t/2
Ap=Lc*t
k*Ap
ho/kAp
(ho/kAp)^0.5
Lc^1.5
Lc^1.5*(ho/kAp)^0.5
From Figure Ef
LMTD
Thi
Tho
Tci
Tco
T1
T2
T1-T2
T1/T2

ln(T1/T2)
LMTD
HEAT TRANSFER
Q=Uo*Ao*LMTD
Q

Nominal T
500
gas
composition

50
mm
50
mm
2500
2500
5000
70.710678119
88
44

O2
N2
Ar
CO2
other

20.95
78.09
0.933
0.03
-0.003

Prs

0.7069

12
4
Err:508
49.5
1.62
6.48
0.24624
Err:508
0.35
0.6
0.97

FROM TABLE
FROM TABLE
ASSUMING NO. OF ROWS =10

185.48978387
Err:508
0.99449
0.9986
55.393253759
Err:508
56

0.04
0.021
0.001
98
0.038564275
0.038
Err:508

m
m
m

assume

0.03889
4.116
0.061
0.039
0.251076
0.291076
7
0.27223

56
0.001
0.27223

1.217064

5.75
6.35E-04
0.038
23
7.57682E-005
303557
4.16

24310.405428
1.7686314045
988.91136942
6.33E-01
625.98089685
16473

16473
1.217

m sq.

56
1.646
27.8
26
10.2
0.02
0.019
0.56
0.000176
20047.641
1665.456
92.176
871.808
1.0526
0.0512632939
3.08E-05
0.00004988
965.0366
1.03E-03
1.12E-03
892

0.001
4.05E-02
2.00E-02
2.025
2.05E-02
0.0000205
5.33E-04
105065
324.13731658
0.0029351533
0.9513927202
0.56

230
165
40
195
35
125
-90
0.28

Rco=Rfo/Ao
Ao

1.02E-05
17.214

-1.273
70.7

63064.4

Nominal P(ba
1.01
Column1
density
viscosity
0.768
0.6739
0.973
1.0594

3.94E-05
3.82E-05
2.88E-04
2.18E-05

conductivityColumn2

Pr

0.0412
0.038
0.0265
0.0381

0.716
0.7
0.66
0.725

1.205 1.82E-05
0.024
0.707117 4.08E-005 0.0385643

Err:509
0.703007

average of outlet and inlet