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    Furnace Heater Design

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    Mubashir fareed
    This document outlines the steps for designing a furnace or fired heater. It discusses key design considerations like the radiant, convective, and bridge wall sections as well as tubes, burners, and insulation. A heat transfer equation is provided and the steps include: 1) determining design parameters, 2) assuming heat flux and surface temperature, 3) calculating temperatures, fuel usage, and air requirements, 4) determining number of tubes needed, 5) calculating heat losses, and 6) iterating calculations until gas outlet temperatures converge. Dimension ratios for box and cylindrical heaters are also outlined.

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    © All Rights Reserved
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    Furnace Heater Design

    Uploaded by

    Mubashir fareed
    98 views7 pages
    This document outlines the steps for designing a furnace or fired heater. It discusses key design considerations like the radiant, convective, and bridge wall sections as well as tubes, burners, and insulation. A heat transfer equation is provided and the steps include: 1) determining design parameters, 2) assuming heat flux and surface temperature, 3) calculating temperatures, fuel usage, and air requirements, 4) determining number of tubes needed, 5) calculating heat losses, and 6) iterating calculations until gas outlet temperatures converge. Dimension ratios for box and cylindrical heaters are also outlined.

    Original Description:

    furnace complete design with explained equations.

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    This document outlines the steps for designing a furnace or fired heater. It discusses key design considerations like the radiant, convective, and bridge wall sections as well as tubes, burners, and insulation. A heat transfer equation is provided and the steps include: 1) determining design parameters, 2) assuming heat flux and surface temperature, 3) calculating temperatures, fuel usage, and air requirements, 4) determining number of tubes needed, 5) calculating heat losses, and 6) iterating calculations until gas outlet temperatures converge. Dimension ratios for box and cylindrical heaters are also outlined.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    98 views7 pages

    Furnace Heater Design

    Uploaded by

    Mubashir fareed
    This document outlines the steps for designing a furnace or fired heater. It discusses key design considerations like the radiant, convective, and bridge wall sections as well as tubes, burners, and insulation. A heat transfer equation is provided and the steps include: 1) determining design parameters, 2) assuming heat flux and surface temperature, 3) calculating temperatures, fuel usage, and air requirements, 4) determining number of tubes needed, 5) calculating heat losses, and 6) iterating calculations until gas outlet temperatures converge. Dimension ratios for box and cylindrical heaters are also outlined.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    See discussions, stats, and author profiles for this publication at: https://www.researchgate.

    net/publication/281460206

    Handout: Steps for design of Furnace & Fired Heater

    Research · September 2015


    DOI: 10.13140/RG.2.1.4304.3049

    CITATIONS READS
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    1 author:

    Reyad Awwad Shawabkeh


    University of Jordan
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    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 ⎟ ⎥α 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 α CP is a factor by
    which ACP must be reduced to obtain effective cold surface.

    For natural convection situation, h ≈ 2 , A ≈ 2α CP ACP and f ≈ 0.57

    Therefore, the above equation could be written in the form:


    ∑Q ⎡⎛ T ⎞ ⎛ T ⎞ ⎤
    4 4

    = 0.173⎢⎜ G ⎟ − ⎜ S ⎟ ⎥ + 7(TG − TS )
    α CP ACP f ⎢⎣⎝ 100 ⎠ ⎝ 100 ⎠ ⎦⎥

    1. To design the furnace, the following should be either known or initially assumed
    • Total required heater duty [Btu/hr].
    • Efficiency, η
    • 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
    ∑Q = 2 × (Average flux ) then obtain
    ∑Q
    α CP ACP α CP ACP f
    3. Assume a tube surface temperature, TS and use the chart bellow to obtain outlet
    gas temperature, TG .
    Total required heater duty
    4. Calculate the heat liberated by fuel, QF =
    η
    QF
    5. Calculate the amount of required fuel, m fuel = , then calculate the
    Fuel value
    air
    required amount of air, mair = 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.
    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
    2πrLq
    14. Calculate the cold plane area, ACP = ctc × L × N
    15. calculate total α 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
    2/3(Furnace Volume)1/3
    1-2-1 to 1-2-4
    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 − αACP


    18. Obtain the gas emissivity, ε 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.
    AR
    19. Based the value of gas emissivity and the product obtain the overall
    αACP
    exchange factor, f from the figure bellow:
    20. Obtain the new value of
    ∑Q , then go back to step (3) to obtain the new
    α CP ACP f
    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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