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    Furnace Heater Design

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    INDRAJIT SAO
    1. The key steps for designing a furnace or fired heater include determining the total required heat duty, efficiency, fuel value, temperatures, tube specifications, heat absorbed and released. 2. An initial assumption is made for the total heat absorbed by the cold plane area and an average flux value. With the assumed tube surface temperature, the gas outlet temperature can be estimated. 3. Parameters like the required fuel amount, air ratio, heat contributions, and number of tubes are then calculated. The design is iterated, updating the gas temperature estimate until the value converges.

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    © All Rights Reserved
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    Furnace Heater Design

    Uploaded by

    INDRAJIT SAO
    156 views6 pages
    1. The key steps for designing a furnace or fired heater include determining the total required heat duty, efficiency, fuel value, temperatures, tube specifications, heat absorbed and released. 2. An initial assumption is made for the total heat absorbed by the cold plane area and an average flux value. With the assumed tube surface temperature, the gas outlet temperature can be estimated. 3. Parameters like the required fuel amount, air ratio, heat contributions, and number of tubes are then calculated. The design is iterated, updating the gas temperature estimate until the value converges.

    Original Description:

    FURNACE HEATER DESIGN

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    1. The key steps for designing a furnace or fired heater include determining the total required heat duty, efficiency, fuel value, temperatures, tube specifications, heat absorbed and released. 2. An initial assumption is made for the total heat absorbed by the cold plane area and an average flux value. With the assumed tube surface temperature, the gas outlet temperature can be estimated. 3. Parameters like the required fuel amount, air ratio, heat contributions, and number of tubes are then calculated. The design is iterated, updating the gas temperature estimate until the value converges.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    156 views6 pages

    Furnace Heater Design

    Uploaded by

    INDRAJIT SAO
    1. The key steps for designing a furnace or fired heater include determining the total required heat duty, efficiency, fuel value, temperatures, tube specifications, heat absorbed and released. 2. An initial assumption is made for the total heat absorbed by the cold plane area and an average flux value. With the assumed tube surface temperature, the gas outlet temperature can be estimated. 3. Parameters like the required fuel amount, air ratio, heat contributions, and number of tubes are then calculated. The design is iterated, updating the gas temperature estimate until the value converges.

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    © All Rights Reserved
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    of 6

    Steps for design of Furnace/Fired Heater

    By
    Dr. Reyad Shawabkeh
    Department of Chemical Engineering
    King Fahd University of Petroleum & Minerals
    e-mail: [email protected]
    Note: some of the information including figures and charts were obtained from Kern,
    Process Heat Transfer. Others were obtained from internet HeaterDesign site.

    In design of fired heater the flowing main


    features should be considered:

    Radiant section
    Convective section
    Bridge wall section
    Tubes, pipes and their
    specifications
    Burner
    Insulation and heat loss.

    The total hourly heat transfer to cold surface is estimated by the relation
    T 4 T 4
    qT = 0.173 f G S CP ACP + hA(TG TS )
    100 100
    Where f is the overall exchange factor. TG is the temperatures of the flue gases leaving
    the radiant section and TS is the surface temperature of the tubes. Both temperatures are
    in degree Rankin. ACP is the equivalent cold plane surface, ft2, and CP is a factor by
    which ACP must be reduced to obtain effective cold surface.
    For natural convection situation, h 2 , A 2 CP ACP and f 0.57
    Therefore,
    Q

    the

    above

    equation
    could
    4
    T T
    = 0.173 G S + 7(TG TS )
    CP ACP f
    100 100

    be

    written

    in

    the

    form:

    1. To design the furnace, the following should be either known or initially assumed
    Total required heater duty [Btu/hr].
    Efficiency,

    Fuel value [Btu/hr].


    Air to fuel ratio
    Temperature of inlet air [oF].
    Amount of atomizing steam and ratio [lb steam/lb fuel].
    Tubes diameters, d o , and tubes center-to-center distance, ctc, [in.]
    Exposed tube length, L [ft].
    Average flux for both radiant and convective sections, q [Btu/hr.ft2].

    2. Assume

    CP ACP

    = 2 (Average flux ) then obtain

    CP ACP f

    3. Assume a tube surface temperature, TS and use the chart bellow to obtain outlet
    gas temperature, TG .

    4. Calculate the heat liberated by fuel, QF =

    Total required heater duty

    5. Calculate the amount of required fuel, m fuel =

    QF
    , then calculate the
    Fuel value

    air
    m Fuel
    Fuel
    6. Assume 25% excess air, then the Total required amount of air = 1.25 m air
    7. Calculate the inlet heat by air, Qair = mair Cp air (Tair .in Tref . ) . Assume Tref = 60 oF.
    required amount of air, mair =

    8. Usually the amount of atomizing steam is 0.3 lb/lb Fuel. Therefore, Total
    atomizing steam required is equal to 0.3m fuel
    9. Amount of heat associated by steam is Qsteam = msteam Cp steam (Tsteam.in Tref )

    10. Calculate heat absorbed by the furnace wall. Usually Qwall = 2% QF


    11. Calculate the heat of exhaust gases, Qexhaust = m fuel (1 + G ' )Cp average (TG 520) ,
    where TG is in [oR] and G ' is the air to fuel ratio.

    The average specific heat, Cp average = xi Cp i , xi is the mass fraction of the exit
    gases such as excess air, CO2, H2O, steam, and others (if applicable).
    12. The

    net

    heat

    liberated,

    Q = Q fuel + Qair + Qateam + QR Qwall Qexhaust

    where QR for re-circulating gases and may be neglected in your calculations.


    13. Calculate the number of tubes required to exchange the desired heat,
    Q
    N tubes =
    where r = d o / 2
    2rLq
    14. Calculate the cold plane area, ACP = ctc L N
    15. calculate total for single raw, refractory backed surface from the Figure
    bellow:

    16. Assume furnace shape as shown in the Figure bellow

    Calculate the top and bottom surfaces, side


    surfaces, Bridge surface, and end wall surfaces.
    Then total exposed area, AT is the sum of all
    areas calculated above.
    The dimensions ratios of length, width and
    height should be 3:2:1. Based on this ratios, the
    mean length of radiant beams can be calculate
    using the table bellow:

    For Box Type Heaters

    Dimension Ratio

    Mean Beam Length

    1-1-1 to 1-1-3
    1-2-1 to 1-2-4

    2/3(Furnace Volume)1/3

    1-1-4 to 1-1-inf

    1 x Smallest Dimension

    1-2-5 to 1-2-inf

    1.3 x Smallest Dimension

    1-3-3 to 1-inf-inf

    1.8 x Smallest Dimension

    With the box dimensions, length, width, and


    height being in any order
    For Vertical Cylindrical Heaters

    Length/Diameter < 2 (((L/D)-1)*0.33 + 0.67)*D


    Length/Diameter >= 2 Diameter

    17. Calculate the effective refracting surface, AR = AT ACP


    18. Obtain the gas emissivity, gas based on the product pL from the figure bellow:
    Where pL is the product of the Partial Pressure of the carbon dioxide and water
    times the Beam Length, in atm-ft.

    19. Based the value of gas emissivity and the product


    exchange factor, f from the figure bellow:

    AR
    obtain the overall
    ACP

    20. Obtain the new value of

    CP ACP f

    , then go back to step (3) to obtain the new

    value of gas temperature, TG . Compare the obtained new value with old one. If it
    is closed then your assumption is valid; tabulate your results. Otherwise, used the
    new value of TG and continue until the difference between two values of this
    temperature is negligible.

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