HYBRID BOILER THERMODYNAMIC

CALCULATION
Instructions
INTRODUCTION

The procedure shown below is next to all needed to successfully use the software to
calculate heat transfer in HYBRID boiler. The data input process leads the user
step-by-step in an easy-to-follow self-explaining way. During geometry data input process a
corresponding general image of particular boiler design feature is displayed
illustrating the current to-be-entered value. Safety mechanism is incorporated preventing
geometrically incorrect data such as tube wall thickness that is greater than tube
inner diameter, exit water temperature that is lower than return one etc.
Hybrid coal fired boiler

10 t/h, 25 bar / 362.5 psi HYBRID COAL FIRED STEAM

BOILER

Step 1: Units choice (metric in this case). Use Arrow key to move up and down and Enter to
select. Mouse point + double click also works. Esc quits the program. Bottom line explains the
navigation. In general UP arrow brings you back to beginning of current section.
Step 2: Case description data entry. In last field Enter brings up next window. Use arrow keys,
Home and End to move up and down. Esc gets you back to Main menu.
Step 3: Fuel type choice (coal in this case).
Step 4: Boiler type choice (steam in this case).
Step 5: Steam pressure choice (if gage pressure is 9 bar the absolute pressure is 10 bar).

Step 6: Boiler design choice. In this case it is water tube furnace with double pass tubular
boiler in convective section.
Step 12: Enter coal composition.

Step 9: Combustion air is not preheated in this case (if it is the software asks for additional
data).
Step 10: Rest oxygen in flue gas entry. It's the value displayed by flue gas analyzer and is used
to calculate excess air (lambda value).
Step 13: Enter net coal rate (unburned coal deducted).

Step 14: Flue gas recirculation is not applied in this case (if it was software would ask for
additional data).
Step 15: Feed water temperature. Software displays saturated steam temperature calculated
from given steam pressure.
Step 7: In this step general image of chosen boiler design is shown. Pressing Enter advances
to next step.
Step 8: Outdoor air temperature (temperature of air coming in boiler room).

Step 17: Enter furnace length in flue gas flow direction.

Step 18: Enter thickness of furnace walls.

Step 20: Enter number of tubes in first tube set.

Step 21: Enter first tube set cooled tube length.

Step 22: Enter first tube set tube inner diameter.

Step 23: Enter first tube set tube wall thickness.

Step 24: Tubes in first tube set are empty in this case.

Step 27: Enter number of tubes in second tube set.

Step 38: Choose superheater tube rows arrangement (plain in this case).

Step 39: Enter number of superheater tubes in single row (software determines needed
number of tube rows to reach superheated steam design temperature.
Step 40: Enter distance between tubes center lines in single row. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.
Step 42: There is economizer in this case.

Step 54: Previous step was the last one in data entry process. Pressing Enter commences
calculation process, which takes few seconds or less.
Results display folows (provided geometry and operation data entered were correct and
around. Pressing Esc brings up Final menu. Move up and down with PgUp/PhDown, arrow
up/down keys, End key to jump to the end of results pages and Home to return to first results
page. Actual complete printout of results is shown at the bottom below.
Final menu displays various options. Input data can be changed till results meet user desire.
Results can be saved to file in folder where main program was installed to
(c:\BoilerDesignSoftware). Choose file name with txt extension (test.txt). If Graphs option is
selected the submenu shown in next image follows.
Flue gas enthalpy diagram shows flue gases energy flow starting with enthalpy at adiabatic
combustion temperature (point where flue gases contain heat released from combustion).
Pressing Enter brings back Graphs menu.
Flue gas temperature decrease in boiler diagram shows how flue gas temperature decreases
as gases pass over cooled area in boiler sections starting with adiabatic combustion
temperature. First break represents furnace exit, second break represents exit from first tube
set, and third break represents exit from second tube set. In reality line is smooth (logarithmic).
HEAT TRANSFER IN HYBRID BOILER (METRIC UNITS)
=============================================
DATE :AUGUST 19,2016
SUBJECT:HYBRID COAL BOILER
MAKE :-
REMARK :DEMO CALCULATION

SUMMARY
_______

ADIABATIC COMBUSTION TEMPERATURE = 1372 °C

TRANSFERRED HEAT IN BOILER = 6365.3 kW
STEAM RATE = 9740.3 kg/h
BOILER I/O EFFICIENCY (FUEL LHV) = 91.2 %
BOILER I/O EFFICIENCY (FUEL HHV) = 83 %
UNACCOUNTED LOSS = 11.3 kW
UNACCOUNTED LOSS = .16 %
WATER EXIT TEMP. FROM ECONOMIZER = 143.4 °C
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 147.5 °C
COMBUSTION AIR MASS RATE = 13821.41 kg/h
RELEASED FLUE GAS MASS RATE = 15168.8 kg/h
CO2 MASS RATE IN FLUE GAS = 2.34 t/h
SUPERHEATED STEAM TEMPERATURE = 300 °C

INPUT DATA
__________

BOILER TYPE: STEAM

ABSOLUTE WORKING PRESSURE: 25 bar
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: FIRE TUBE
BOILER DESIGN: TUBULAR DOUBLE PASS
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: COAL

FUEL DATA
_________

CARBON-CONTENT = 42.47 %
WATER-CONTENT = 28.4 %
SULFUR-CONTENT = 1.44 %
HYDROGEN-CONTENT= 3.56 %
OXYGEN-CONTENT = 9.32 %
NITROGEN-CONTENT= .65 %
ASH-CONTENT = 14.16 %

FUEL LOWER HEATING VALUE= 16752.9 kJ/kg

FUEL LOWER HEATING VALUE= 4.7 kWh/kg
FUEL HIGHER HEATING VALUE= 18395.3 kJ/kg
FUEL HIGHER HEATING VALUE= 5.1 kWh/kg

FUEL RATE= 1500 kg/h

OUTDOOR AIR TEMPERATURE = 20 °C

FEED WATER TEMPERATURE = 105 °C
REST O2 IN FLUE GAS = 8 %
EXCESS AIR/LAMBDA VALUE = 1.6 -
TOTAL COOLED AREA IN BOILER= 135.639 m2

FURNACE GEOMETRY DATA

_____________________

FURNACE IS RECTANGULAR

FURNACE COOLED AREA = 14 m2

LENGTH IN FLUE GAS FLOW DIRECTION = 2.3 m
WALL THICKNESS = .006 m
CROSS SECTION IN GAS FLOW DIRECTION= 3 m2

GEOMETRY DATA OF FIRST TUBE ASSEMBLY

____________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 90
COOLED TUBE LENGTH = 5.25 m
TUBE INNER DIAMETER = .0625 m
TUBE WALL THICKNESS = .0036 m
CROSS SECTION BEFORE TUBES = 1 m2
CROSS SECTION AREA AFTER TUBES= 2 m2
COOLED AREA = 92.775 m2

GEOMETRY DATA OF SECOND TUBE ASSEMBLY

_____________________________________

NUMBER OF TUBES = 118

COOLED TUBE LENGTH = 5.25 m
TUBE INNER DIAMETER = .0625 m
TUBE WALL THICKNESS = .0036 m
CROSS SECTION AREA AFTER TUBES= 1 m2
COOLED AREA = 121.639 m2

THERE IS SUPERHEATER BETWEEN TUBE SETS

TUBE ROWS HAVE PLAIN ARRANGEMENT
SUPERHEATED STEAM DESIGN TEMPERATURE = 300 °C
TUBE SECTION LENGTH = 2 m
NEEDED TOTAL TUBE LENGTH = 900 m
NEEDED TOTAL TUBE AREA = 107.442 m2
TUBE OUTER DIAMETER = .038 m
TUBE WALL THICKNESS = .0036 m
NUMBER OF TUBES IN ROW = 25
NEEDED NUMBER OF TUBE ROWS = 19
DISTANCE BETWEEN TUBES IN ROW = .075 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS HAVE PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 105 °C

TUBE SECTION LENGTH = 2 m
TOTAL TUBE LENGTH = 1250 m
TOTAL TUBE AREA = 151.2 m2
TUBE OUTER DIAMETER = .0385 m
TUBE WALL THICKNESS = .0036 m
NUMBER OF TUBES IN ROW = 25
NUMBER OF TUBE ROWS = 25
DISTANCE BETWEEN TUBES IN ROW = .075 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

STACK CONNECTOR CROSS SECTION AREA= .5 m2

CALCULATION RESULTS (CLEAN SURFACES ASSUMED)

____________________________________________

ADIABATIC COMBUSTION TEMPERATURE = 1372 °C

COMBUSTION AIR RATE = 10689.41 mn3/h

COMBUSTION AIR MASS RATE = 13821.41 kg/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 10689.41 m3/h
RELEASED FLUE GAS RATE = 11774.85 mn3/h
RELEASED FLUE MASS GAS RATE = 15168.8 kg/h
FLUE GAS NORM DENSITY = 1.29 kg/m3
RELEASED FLUE GAS MASS RATE = 15168.8 kg/h
FLUE GAS RATE AT BOILER EXIT TEMP. = 18137.63 m3/h
DEW POINT OF WATER VAPOR IN FLUE GAS= 47.5 °C
CONDENSATE (LATENT) HEAT = 684.3 kW
CONDENSATE MASS RATE IN FLUE GAS = 1027.96 kg/h
CO2 RATE IN FLUE GAS = 1189.88 mn3/h
CO2 MASS RATE IN FLUE GAS = 2336.37 kg/h
SPECIFIC CO2 EMISSION = 1.56 kg/kg
CO2 CONCENTRATION IN FLUE GAS = 10.11 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 18.34 vol%
H2O RATE IN FLUE GAS = 1278.94 mn3/h
WATER MASS RATE DELIVERED WITH AIR = 5.38 kg/h
H2O CONCENTRATION IN FLUE GAS = 10.86 vol%
SO2 RATE IN FLUE GAS = 15.1292 m3/h
SO2 MASS RATE IN FLUE GAS = 43.2398 kg/h
SO2 CONCENTRATION IN FLUE GAS = .1285 vol%
H2SO4 DEW POINT IN FLUE GAS < 166 °C
MAX. H2SO4 CONCENTRATION IN FLUE GAS= .00771 vol%
MAX. H2SO4 MASS RATE IN FLUE GAS = 1.6648 kg/h
N2 RATE IN FLUE GAS = 8452.44 mn3/h
N2 CONCENTRATION IN FLUE GAS = 71.78 vol%
O2 RATE IN FLUE GAS = 838.46 mn3/h
O2 CONCENTRATION IN FLUE GAS (WET) = 7.12 vol%

STEAM TEMPERATURE IN BOILER = 224 °C

VELOCITY IN BOILER FLUE APERTURE = 10.1 m/s
STATIC PRESSURE DROP IN BOILER = 15.19 mbar
STATIC PRESSURE DROP WITH ECONOMIZER = 15.51 mbar
TRANSFERRED HEAT = 6365.3 kW
STEAM RATE = 9740.3 kg/h
FEED WATER RATE = 10202.4 l/h
FLUE GAS TEMPERATURE FROM BOILER = 244 °C

TRANSFERRED HEAT IN ECONOMIZER = 444.2 kW

FLUE GAS EXIT TEMP. FROM ECONOMIZER = 147.5 °C
WATER EXIT TEMP. FROM ECONOMIZER = 143.4 °C
STATIC PRESSURE DROP IN ECONOMIZER = .32 mbar

BOILER I/O EFFICIENCY (FUEL LHV)= 91.2 %

HEAT BALANCE
____________

DELIVERED HEAT WITH FUEL = 1561747 kW

TRANSFERRED HEAT IN BOILER = 1301008.7 kW
THEORETICAL ADIABATIC COMB.TEMP.= 1969.6 °C
ACTUAL ADIABATIC COMB. TEMP. = 1904 °C
DISSOCIATION LOSS = 65279 kW
DISSOCIATION LOSS = 4.18 %
SUPERHEATER INJECTED WATER LOSS = 29111.9 kW
SUPERHEATER INJECTED WATER LOSS = 1.86 %
COAL RATE TO COVER ABOVE LOSS = 6452.94 kg/h
REHEATER INJECTED WATER LOSS = 10846.1 kW
REHEATER INJECTED WATER LOSS = .69 %
COAL RATE TO COVER ABOVE LOSS = 2404.15 kg/h
LOSS BY NOT RETURNED STEAM = 21880.6 kW
LOSS BY NOT RETURNED STEAM = 1.4 %
COAL RATE TO COVER ABOVE LOSS = 4850.06 kg/h
JACKET RADIATION LOSS = 589 kW
JACKET CONVECTIVE LOSS = 2302 kW
BOILER JACKET LOSSES = 2891 kW
BOILER JACKET LOSSES = .19 %
COAL RATE TO COVER JACKET LOSSES= 640.92 kg/h
COAL RATE TO COVER ABOVE LOSSES = 14348.06 kg/h
COAL RATE TO COVER ABOVE LOSSES = 14348.06 kg/h
STACK HEAT LOSS = 119994 kW
STACK HEAT LOSS = 7.68 %
UNACCOUNTED LOSSES = 9772.8 kW
UNACCOUNTED LOSSES = .63 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 1195.2 °C

MEAN FLUE GAS TEMPERATURE = 1281.8 °C
THERMAL RADIATION = 737.7 kW
CONVECTION = 228.9 kW
HEAT TRANSFERRED TO WALLS = 966.6 kW
AREA THERMAL LOAD = 69.04 kW/m2
VOLUME THERMAL LOAD = 1022.85 kW/m3
FLUE GAS VELOCITY = 6.21 m/s
WALL TEMP. ON FLUE GAS SIDE = 237.7 °C

HEAT TRANSFER IN FIRST TUBE ASSEMBLY

____________________________________

FLUE GAS EXIT TEMPERATURE = 423.4 °C

MEAN FLUE GAS TEMPERATURE = 743.7 °C
AREA THERMAL LOAD = 44.08 kW/m2
FLUE GAS VELOCITY = 44.12 m/s
THERMAL RADIATION = 389.6 kW
CONVECTION = 3700.2 kW
HEAT TRANSFERRED = 4089.8 kW
WALL TEMP. ON FLUE GAS SIDE= 231 °C
STATIC PRESSURE DROP = 10.2 mbar

HEAT TRANSFER IN SECOND TUBE ASSEMBLY

_____________________________________

FLUE GAS EXIT TEMPERATURE = 244 °C

MEAN FLUE GAS TEMPERATURE = 274.9 °C
AREA THERMAL LOAD = 2.49 kW/m2
FLUE GAS VELOCITY = 18.13 m/s
THERMAL RADIATION = 11.9 kW
CONVECTION = 290.7 kW
HEAT TRANSFERRED = 302.5 kW
WALL TEMP. ON FLUE GAS SIDE= 226 °C
STATIC PRESSURE DROP = 2.95 mbar

HEAT TRANSFER ON SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 300 °C

FLUE GAS EXIT TEMPERATURE = 308.3 °C
THERMAL RADIATION = 28.5 kW
CONVECTION = 533.7 kW
HEAT TRANSFERRED = 562.2 kW
STEAM VELOCITY IN TUBES = 13 m/s
FLUE GAS VELOCITY AROUND TUBES= 4.03 m/s
WALL TEMP. ON FLUE GAS SIDE = 309.5 °C
STATIC PRESSURE DROP = .18 mbar

HEAT TRANSFER ON TUBE ARRAY ECONOMIZER

______________________________________

WATER EXIT TEMPERATURE = 143.4 °C

MEAN FLUE GAS TEMPERATURE = 191.7 °C
FLUE GAS EXIT TEMPERATURE = 147.5 °C
THERMAL RADIATION = 15.7 kW
CONVECTION = 428.4 kW
HEAT TRANSFERRED = 444.2 kW
WATER VELOCITY IN TUBES = .151 m/s
FLUE GAS VELOCITY AROUND TUBES= 2.99 m/s
WALL TEMP. ON FLUE GAS SIDE = 145.7 °C
STATIC PRESSURE DROP = .32 mbar
Step 19: Enter furnace cross section area in flue gas flow direction as depicted in image.

Step 16: Enter furnace cooled area.

BOILER DESIGN SOFTWARE

Graphs submenu contains two graphs.

Step 41: Enter number of superheater tubes connected to manifold (needed to calculate
superheated steam velocity in tubes).
Step 11: There is just one fuel type fired. Another one can be premixed.
Step 12: Fuel heating value is not measured in this case and software calculates it.
 Step 25: Enter cross section area before first set of tubes (needed to calculate pressure drop).

Step 26: Enter cross section area after first tube set tubes (needed to calculate pressure drop).
Step 28: Enter second tube set length.

Step 29: Enter second tube set tube inner diameter

Step 30: Enter tube wall thickness in second tube set.

Step 31: Enter cross section area after tubes in second tube set (needed to calculate pressure
drop).
Step 32: Tubes in second tube set are empty in this case.

Step 33: There is tube array superheater in turnaround channel between tube sets.

Step 34: Enter superheated steam design temperature.

Step 35: Enter superheater tube section length as depicted in image.

Step 36: Enter superheater tube outer diameter.

Step 37: Enter superheater tube wall thickness.
 Step 43: Economizer is of tube array design.

Step 45: Enter economizer tube section length as depicted in image.

Step 46: Enter economizer tube outer diameter.

Step 47: Enter economizer tubeswall thickness.

Step 48: Economizer tubes are arranged in plain fashion.

Step 49: Enter number of tubes in individual row. Software will determine needed number of
tube rows.
Step 50: Enter distance between tubes in individual row. Note that smaller distance between
tubes results in higher the flue gas velocity between tubes, which leads to more intense heat
transfer and smaller size.
Step 52: Enter number of economizer tubes connected to manifold (needed to calculate water
velocity in tubes).
HEAT TRANSFER IN HYBRID BOILER (ENGLISH UNITS)
==============================================

DATE :AUGUST 19,2016

SUBJECT:HYBRID COAL BOILER
MAKE :-
REMARK :DEMO CALCULATION

SUMMARY
_______

ADIABATIC COMBUSTION TEMPERATURE = 2502.3 F

TRANSFERRED HEAT IN BOILER = 649.3 HP
TRANSFERRED HEAT IN BOILER = 21.74 MMBTU/h
STEAM RATE = 10.74 short tons/h
BOILER I/O EFFICIENCY (FUEL HHV) = 83 %
UNACCOUNTED LOSS = 1.15 HP
UNACCOUNTED LOSS = .04 MMBTU/h
UNACCOUNTED LOSS = .15 %
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 297.5 F
FEED WATER EXIT TEMP. FROM ECO. = 290.1 F
COMBUSTION AIR RATE = 377584.23 st.cu.ft./h
RELEASED FLUE GAS RATE = 415925.5 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 0 short tons/h
SUPERHEATED STEAM TEMPERATURE = 572 F

INPUT DATA
__________

BOILER TYPE: STEAM

ABSOLUTE WORKING PRESSURE: 362.5 psi
HEAT TRANSFER MEDIUM: WATER
BOILER FAMILY: FIRE TUBE
BOILER DESIGN: TUBULAR DOUBLE PASS
BOILER MATERIAL: CARBON STEEL

FUEL TYPE: COAL

FUEL DATA
_________

CARBON-CONTENT = 42.47 %
WATER-CONTENT = 28.4 %
SULFUR-CONTENT = 1.44 %
HYDROGEN-CONTENT= 3.56 %
OXYGEN-CONTENT = 9.32 %
NITROGEN-CONTENT= .65 %
ASH-CONTENT = 14.16 %

FUEL LOWER HEATING VALUE = 7201.4 BTU/lb

FUEL HIGHER HEATING VALUE= 7907.4 BTU/lb

FUEL RATE= 3307.61 lb/h

OUTDOOR AIR TEMPERATURE = 68 F

FEED WATER TEMPERATURE = 221 F
REST O2 IN FLUE GAS = 8 %
EXCESS AIR/LAMBDA VALUE = 1.6 -
TOTAL COOLED AREA IN BOILER= 1460.001 sq.ft.

FURNACE GEOMETRY DATA

_____________________

FURNACE IS RECTANGULAR

FURNACE COOLED AREA = 150.695 sq.ft.

LENGTH IN FLUE GAS FLOW DIRECTION = 7.546 ft.
WALL THICKNESS = .236 in
CROSS SECTION IN GAS FLOW DIRECTION= 32.292 sq.ft.

GEOMETRY DATA OF FIRST TUBE ASSEMBLY

____________________________________

TUBES ARE HORIZONTAL

NUMBER OF TUBES = 90
COOLED TUBE LENGTH = 17.224 ft.
TUBE INNER DIAMETER = 2.461 in
TUBE WALL THICKNESS = .142 in
CROSS SECTION BEFORE TUBES = 10.764 sq.ft.
CROSS SECTION AREA AFTER TUBES= 21.528 sq.ft.
COOLED AREA = 998.623 sq.ft.

GEOMETRY DATA OF SECOND TUBE ASSEMBLY

_____________________________________

NUMBER OF TUBES = 118

COOLED TUBE LENGTH = 17.224 ft.
TUBE INNER DIAMETER = 2.461 in
TUBE WALL THICKNESS = .142 in
CROSS SECTION AREA AFTER TUBES= 10.764 sq.ft.
COOLED AREA = 1309.306 sq.ft.

THERE IS SUPERHEATER BETWEEN TUBE SETS

TUBE ROWS HAVE PLAIN ARRANGEMENT

SUPERHEATED STEAM DESIGN TEMPERATURE = 572 F

TUBE SECTION LENGTH = 6.562 ft.
NEEDED TOTAL TUBE LENGTH = 2952.8 ft.
NEEDED TOTAL TUBE AREA = 1156.501 sq.ft.
TUBE OUTER DIAMETER = 1.496 in
TUBE WALL THICKNESS = .142 in
NUMBER OF TUBES IN ROW = 25
NEEDED NUMBER OF TUBE ROWS = 19
DISTANCE BETWEEN TUBES IN ROW = 2.953 in
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

GEOMETRY DATA OF TUBE ARRAY ECONOMIZER

______________________________________

TUBE ROWS ARE IN PLAIN ARRANGEMENT

WATER TEMPERATURE ENTERING ECONOMIZER= 221 F

TUBE SECTION LENGTH = 6.562 ft.
TOTAL TUBE LENGTH = 4101.05 ft.
TOTAL TUBE AREA = 1642.817 sq.ft.
TUBE OUTER DIAMETER = 1.516 in
TUBE WALL THICKNESS = .142 in
NUMBER OF TUBES IN ROW = 25
NUMBER OF TUBE ROWS = 25
DISTANCE BETWEEN TUBES IN ROW = 2.953 in
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25

STACK CONNECTOR CROSS SECTION AREA= 5.382 sq.ft.

CALCULATION RESULTS (CLEAN SURFACES ASSUMED)

____________________________________________

ADIABATIC COMBUSTION TEMPERATURE = 2502.3 F

COMBUSTION AIR RATE = 377584.23 st.cu.ft./h

COMBUSTION AIR MASS RATE = 30477.19 lb/h
COMBUSTION AIR RATE AT GIVEN TEMP. = 377584.23 cu.ft./h
RELEASED FLUE GAS RATE = 415925.5 st.cu.ft./h
RELEASED FLUE GAS MASS RATE = 33448.28 lb/h
FLUE GAS NORM DENSITY = .08 lb/cu.ft.
FLUE GAS RATE AT STACK TEMPERATURE = 640679.16 cu.ft./h
DEW POINT OF WATER VAPOR IN FLUE GAS= 117.4 F
CONDENSATE (LATENT) HEAT = 69.8 HP
CONDENSATE (LATENT) HEAT = 2.34 MMBTU/h
CONDENSATE MASS RATE IN FLUE GAS = 2266.73 lb/h
CO2 RATE IN FLUE GAS = 42030.45 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 5151.86 lb/h
SPECIFIC CO2 EMISSION = 1.56 lb/lb.
CO2 CONCENTRATION IN FLUE GAS = 10.11 vol%
MAX. CO2-CONCENTRATION IN FLUE GAS = 18.34 vol%
H2O RATE IN FLUE GAS = 45176.21 st.cu.ft./h
WATER MASS RATE DELIVERED WITH AIR = 11.86 lb/h
H2O CONCENTRATION IN FLUE GAS = 10.86 vol%
SO2 RATE IN FLUE GAS = 534.4112 st.cu.ft./h
SO2 MASS RATE IN FLUE GAS = 95.3469 lb/h
SO2 CONCENTRATION IN FLUE GAS = .1285 vol%
H2SO4 DEW POINT IN FLUE GAS < 331 F
MAX. H2SO4 CONCENTRATION IN FLUE GAS= .00771 vol%
MAX. H2SO4 MASS RATE IN FLUE GAS = 3.671 lb/h
N2 RATE IN FLUE GAS = 298567.24 st.cu.ft./h
N2 CONCENTRATION IN FLUE GAS = 71.78 vol%
O2 RATE IN FLUE GAS = 29617.19 st.cu.ft./h
O2 CONCENTRATION IN FLUE GAS (WET) = 7.12 vol%

STEAM TEMPERATURE IN BOILER = 435.1 F

VELOCITY IN BOILER FLUE APERTURE = 33.06 ft/s
STATIC PRESSURE DROP IN BOILER = 6.1 inWC
STATIC PRESSURE DROP WITH ECONOMIZER = 6.23 inWC
TRANSFERRED HEAT = 649.3 HP
STEAM RATE = 10.74 short tons/h
FEED WATER RATE = 2695.2 gal/h
FLUE GAS TEMPERATURE FROM BOILER = 471.1 F

TRANSFERRED HEAT IN ECONOMIZER = 45.3 HP

TRANSFERRED HEAT IN ECONOMIZER = 1.52 MMBTU/h
FLUE GAS EXIT TEMP. FROM ECONOMIZER = 297.5 F
WATER EXIT TEMPERATURE FROM ECONOMIZER= 290.1 F
STATIC PRESSURE DROP IN ECONOMIZER = .13 inWC

BOILER /O EFFICIENCY (FUEL HHV)= 83 %

HEAT BALANCE
____________

DELIVERED HEAT WITH FUEL = 172085.5 HP

DELIVERED HEAT WITH FUEL = 5760.62 MMBTU/h
TRANSFERRED HEAT IN BOILER = 132715.4 HP
TRANSFERRED HEAT IN BOILER = 4442.69 MMBTU/h
THEORETICAL ADIABATIC COMB.TEMP.= 3577.3 F
ACTUAL ADIABATIC COMB. TEMP. = 3459.2 F
DISSOCIATION LOSS = 6659.1 HP
DISSOCIATION LOSS = 222.92 MMBTU/h
DISSOCIATION LOSS = 3.87 %
SUPERHEATER INJECTED WATER LOSS = 2969.7 HP
SUPERHEATER INJECTED WATER LOSS = 99.41 MMBTU/h
SUPERHEATER INJECTED WATER LOSS = 1.73 %
COAL RATE TO COVER ABOVE LOSS = 191714.91 lb/h
REHEATER INJECTED WATER LOSS = 1106.4 HP
REHEATER INJECTED WATER LOSS = 363.08 MMBTU/h
REHEATER INJECTED WATER LOSS = .64 %
COAL RATE TO COVER ABOVE LOSS = 71426.53 lb/h
LOSS BY NOT RETURNED STEAM = 2232 HP
LOSS BY NOT RETURNED STEAM = 74.72 MMBTU/h
LOSS BY NOT RETURNED STEAM = 1.3 %
COAL RATE TO COVER ABOVE LOSS = 144093.68 lb/h
BOILER JACKET HEAT LOSS = 295 HP
BOILER JACKET HEAT LOSS = 9.87 MMBTU/h
BOILER JACKET HEAT LOSS = .17 %
COAL RATE TO COVER JACKET LOSSES= 19041.54 lb/h
STACK HEAT LOSS = 25012.9 HP
STACK HEAT LOSS = 837.31 MMBTU/h
STACK HEAT LOSS = 14.54 %
UNACCOUNTED LOSSES = 996.9 HP
UNACCOUNTED LOSSES = 33.37 MMBTU/h
UNACCOUNTED LOSSES = .58 %

HEAT TRANSFER IN FURNACE

________________________

FLUE GAS EXIT TEMPERATURE = 2183.4 F

MEAN FLUE GAS TEMPERATURE = 2339.2 F
VOLUME THERMAL LOAD = 2.95 HP/cu.ft.
HEAT TRANSFER INTENSITY = 1.528 sq.ft./HP
THERMAL RADIATION = 75.3 HP
CONVECTION = 23.4 HP
HEAT TRANSFERRED TO WALLS = 98.6 HP
GAS VELOCITY = 20.371 ft/s
WALL TEMP. ON FLUE GAS SIDE = 459.8 F

HEAT TRANSFER IN FIRST TUBE ASSEMBLY

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FLUE GAS EXIT TEMPERATURE = 794 F

MEAN FLUE GAS TEMPERATURE = 1370.7 F
HEAT TRANSFER INTENSITY = 2.394 sq.ft./HP
FLUE GAS VELOCITY = 144.735 ft/s
THERMAL RADIATION = 39.7 HP
CONVECTION = 377.5 HP
HEAT TRANSFERRED = .4 HP
WALL TEMP. ON FLUE GAS SIDE= 447.8 F
STATIC PRESSURE DROP = 4.1 inWC

HEAT TRANSFER IN SECOND TUBE ASSEMBLY

_____________________________________

FLUE GAS EXIT TEMPERATURE = 471.1 F

MEAN FLUE GAS TEMPERATURE = 526.8 F
HEAT TRANSFER INTENSITY = 42.425 sq.ft./HP
FLUE GAS VELOCITY = 59.487 ft/s
THERMAL RADIATION = 1.2 HP
CONVECTION = 29.7 HP
HEAT TRANSFERRED = 0 HP
WALL TEMP. ON FLUE GAS SIDE= 438.8 F
STATIC PRESSURE DROP = 1.19 inWC

HEAT TRANSFER ON SUPERHEATER

SUPERHEATED STEAM TEMPERATURE = 572 F

FLUE GAS EXIT TEMPERATURE = 32 F
THERMAL RADIATION = 2.91 HP
CONVECTION = 54.44 HP
HEAT TRANSFERRED = 57.35 HP
STEAM VELOCITY IN TUBES = 42.657 ft/s

HEAT TRANSFER ON TUBE ARRAY ECONOMIZER

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WATER EXIT TEMPERATURE = 290.1 F

MEAN FLUE GAS TEMPERATURE = 377.1 F
FLUE GAS EXIT TEMPERATURE = 297.5 F
THERMAL RADIATION = 1.6 HP
CONVECTION = 43.7 HP
HEAT TRANSFERRED = 45.3 HP
WATER VELOCITY IN TUBES = .496 ft/s
FLUE GAS VELOCITY AROUND TUBES= 9.802 ft/s
WALL TEMP. ON FLUE GAS SIDE = 294.3 F
STATIC PRESSURE DROP = .13 inWC

FLUE GAS VELOCITY AROUND TUBES= 13.237 ft/s

WALL TEMP. ON FLUE GAS SIDE = 589.1 F
STATIC PRESSURE DROP = .07 inWC
Step 51: Enter number of economizer tube rows.
Step 53: Enter stack inner cross section (needed to calculate flue gas velocity in it and
pressure drop).