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ECONOMIZER3TRIAL
ECONOMIZER3TRIAL
ECONOMIZER3TRIAL
F9
Material Balance
F6 = F7
F8 = F9
Energy Balance
F6 F7
Water from Water to boiler
pump
Bagasse Full Load
Condition Sat. liquid
Temperature, T (0C) 124 160
Pressure, P (bar) 120 82
Enthalpy*, h (kJ/kg) 528.996 680.0395
Specific volume, v (m3/kg) 0.00106
Mass flow rate, m (kg/s) 39.283 39.283
Mass flow rate, m (ton/h) 141.4 141.4
Energy Consumption
Energy balance (kJ/s) 20780.55 26713.99
Change (kJ/s) 5933.44
Bagasse one third Load
Mass flow rate, m (kg/s) 15.43 15.43
Mass flow rate, m (ton/h) 55.539 55.539
Energy Consumption
Energy balance (kJ/s) 8162.41 10493.009
E (kJ/s) 2330.60
Coal Full Load
Mass flow rate, m (kg/s) 33.489 33.4889
Mass flow rate, m (ton/h) 120.56 120.56
Energy Consumption
Energy balance (kJ/s) 17715.47 22773.7748
E (kJ/s) 5058.31
Coal one third Load
Mass flow rate, m (kg/s) 11.16 11.16
Mass flow rate, m (ton/h) 40.187 40.187
Energy Consumption
Energy balance (kJ/s) 5903.60 7589.24
E (kJ/s) 1685.64
Where :
Th,i : Temperature of flue gas in
Th,o: Temperature of Flue gas out
m: Mass flow rate of Flue gas
Cp: Specific Heat Capacity of Bagasse or Coal
“Sankalp Shrivastav and Ibrahim Hussain indicate in their article "Design of Bagasse Dryer to
Recover Energy of Water Tube Boiler in a Sugar Factory" International Journal of Science and
Research 2:8 (2013) that bagasse Cp is 0.46 kJ/kg K, though that seems low by at least a factor
of 2 to me. Bagasse has a large cellulose component, and cellulose Cp is 1.3 to 1.5 kJ/kg K. The
other major components, water and lignin, are comparable (lignin) or much higher still (water).
Subbituminous coal heat capacity is about 1.6 kJ/kg K at room temperature according to L.L.
Isaacs and E. Tsafantakis, HEAT CAPACITIES OF ARGONNE.PREMIUM COAL SAMPLES
(no date given)…” (Prof. L. Baxter 2016, pers.comm. 4 February)
The enthalpy of coal was calculated using an electronic calculator as follows:
Bagasse:
Component % by g/mol g/kg fuel Mol/kg Mol/kg O2 Flue gases Flue gases Mol %
Mass fuel composition (mol/kg)
Carbon 49.2 12.01 492 x 40965861 40965861.78 CO2 40965861. 64.20
106 .78 78
Hydrogen 4.6 1.01 46 x 106 45544554 11386138.62 H2O 22772277. 35.69
.46 23
Oxygen 43 16.00 43 x 107 26875000 -13437500 O2 - -
Nitrogen 0.18 14.01 18 x 105 128479.6 128479.6574 N2 64239.828 0.1
574 7
Sulfur 0.02 32.06 2 x 105 6238.303 6238.303182 SO2 6238.3031 0.01
182 82
Total 63808617. 100
14
(Source: http://www.increase-performance.com/calc-flue-gas-prop.html)
Specific heat capacity of bagasse wet flue gas = 1.388 kJ/kg.K
Coal:
Componen % g/mo g/kg Mol/kg Mol/kg O2 Flue gases Flue gases Mol
t by l fuel fuel compositio (mol/kg) %
Mas n
s
Carbon 85 12.01 85000 70774.3 70774.3547 CO2 70774.3547 82.2
0 5
Hydrogen 3 1.01 30000 29702.9 7425.742574 H2O 14851.4851 17.2
7 5
Oxygen 2.5 16 25000 1562.5 -781.25 O2 - -
Nitrogen 1 14.01 10000 713.775 713.7758744 N2 356.887937 0.4
9 2
Sulfur 0.5 32.06 5000 155.957 155.9575795 SO2 155.957579 0.2
6 5
Total 86138.6853 100
7
The appropriate average temperature difference is a log mean temperature difference, ΔTlm.
Considering a counter flow heat exchanger,
and
Q: energy absorbed
A: surface area
Assumptions:
1. Negligible heat loss to the surroundings.
2. Negligible kinetic and potential energy changes.
3. Constant properties.
4. Negligible tube wall thermal resistance and fouling factors.
5. Fully developed conditions for the water and flue gas (incropera et al. 2011).
Bagasse Coal
Full load One third Full load One third
load load
Th,i(oC) 384.2 384.2 384.2 384.2
Th,o (0C) 293.3238801 293.299901 290.136375 290.0904135
Tci (oC) 124 124 124 124
Tco(oC) 160 160 160 160
T1(oC) 224.2 224.2 224.2 224.2
T2 169.3238801 169.299901 166.136375 166.0904135
ΔTlm (oC) 54.8761199 54.90009897 58.06362499 58.10958649
(Coulson)
The following assumptions are made in the derivation of the temperature correction factor Ft, in
addition to those made for the calculation of the log mean temperature difference:
1. Equal heat transfer areas in each pass.
2. A constant overall heat-transfer coefficient in each pass.
3. The temperature of the shell-side fluid in any pass is constant across any crosssection.
4. There is no leakage of fluid between shell passes.
Bagasse Coal
Full Load One third Load Full Load One third Load
R 2.524336664 2.525002749 2.612878472 2.61415518
S 0.138355111 0.138355111 0.138355111 0.138355111
Ft (0C) 0.985506 0.98550009 0.98470536 0.984693589
Tm (0C) 54.08074542 54.1040525 57.17556274 57.22013726
Area
Bagasse Coal
Full Load One third Load Full Load One third Load
q 5933.44 2330.6 5058.31 1685.64
Tm 54.08074542 54.1040525 57.17556274 57.22013726
u 0.065 0.065 0.065 0.065
A(m2) 1687.914832 662.7116262 1361.073685 453.2132273
Tube Length
Shell-diameter-to-tube-length ratio should be within limits of 1/5 to 1/15 (Subbarao n.d; Kakaç
1991). In his article Design and Rating of Shell and Tube Heat Exchangers John E. Edwards
(2008) mentions that the preferred tube length to shell diameter ratio is in the range 5 to 10.
Normally the shell diameter is taken to be within the range 150mm to 1067mm (Coulson). For
this design of the heat exchanger the initial shell diameter is taken to be 1067 mm and the ratio
of L: Ds are taken to be 10.
Tube length = (10 x diameter of shell) = 10 x 1.067 = 10.67 m
Number of tube
n = A/(pie x Do x L)
= 1687.914832/ (pie x 0.02 x 10.67)
= 2517.7
= 2518
Bundle diameter
= 2518/2 = 1259
Total flow area
Where,
hi: The tube side coefficient
di: The inside diameter
Re: Reynold’s number
Pr: Prandlt Number
μ: Viscosity of water
Reynold’s Number
Prandlt number
Where;
Cp: The specific heat of water (4.2 KJ/ kg oC)
Kf: Thermal conductivity of water
Pr = (4.2 x 103 x 0.8 x 10-3)/ 0.59
=5.7
Shell diameter
Given that the economizer is a u-tube with a shell bundle diameter of 1.37 m, the bundle
diametrical clearance is read on the Figure 12.10 of Richardson and Coulson and is found to be
18 mm.
Ds = 1.37 + 0.018
= 1.388 m
The shell diameter was also calculated using the excel flowsheet designed by Mr Prem Baboo
and was found to be 1.445 m.
HEAT EXCHANGER SHELL ID CALCULATIONS
Table1
By Simple geometry
Triangular Pitch 0.031 Meter
Area of the Pitch 0.001 Meter2
Total Area 2.129 Meter2
Bundle ID 1.647 Meter
Shell Id 1.697 Meter
Prem Baboo
Baffle spacing
= Ds/5 =1.4/5 = 0.28 m
Cross-flow area
Where
Gs: the Mass velocity of the flue gas
De: Equivalent Diameter
Mu: Viscosity of Flue gas
0.0248 centipoise = 0.0000248 Ns/m2
Re= (600 x 0.01097)/ 0.0000248 = 265,403.2258
Prandlt number
A baffle cut of 25% is chosen; the value of jh is calculated by extrapolation from the following
graph and is found to be 0.13.
Neglecting the viscosity correction, the shell side coefficient, hs is calculated to be 88,910.54778
W/m2 oC using the Eq. below: