1st Edition
Steam Generators and Waste Heat Boilers For Process and Plant Engineers
Combustion Calculations
Introduction
Moisture in Air
Combustion Calculations
Estimation of Heating Values
Burner Selection
Combustion Temperatures
Simplified Procedure for Estimating Combustion Temperatures
Gas Turbine Exhaust Combustion Calculations
Boiler Efficiency
Firing Fuels with Low Heating Values
Firing of Multiple Fuels
Emission Conversion Calculations: Steam Generators
Converting ppmvd of NOx to mg/Nm3
Converting Turbine Exhaust Emissions
Low-Temperature Corrosion in Boilers
Condensation of Acid Vapors in Low-Temperature Heat Sinks
References
Steam Generator Furnace Design
Advantages of Water-Cooled Furnaces
Heat Release Rates
Furnace Exit Gas Temperature Evaluation
Empirical Formula for Furnace Duty Estimation
Furnace Duty with Combination Firing
Distribution of Heat Flux around Tubes and Fins
Distribution of Radiation to Tube Banks
Relating Heat Flux from Furnace to inside Tubes
External Radiation to Heat Transfer Surfaces at Furnace Exit
Terms Frequently Used in Furnace Performance
Estimating Boiling Heat Transfer Coefficient
Estimating Fin Tip Temperature
Boiling Process
Boiler Circulation
Thom’s Method for Estimating Losses
Circulation Calculations
Flow Stratification in Horizontal Tubes
Correlations for CHF (Critical Heat Flux) and Allowable Steam Quality
Circulation Problems
Guidelines for Good Circulation System Design
References
Steam Generators
Introduction
Large Package Boilers
Water-Cooled Furnaces
Major Changes in Boiler Design
Absence of Air Heater
Emissions Affect Steam Generator Designs
Custom-Designed Boilers
Novel Ideas
Boiler Classification
Improving Boiler Efficiency
Steam Generators for Oil Sands Application
Superheaters
Steam Generators with Import and Export Steam
Flow in Parallel Paths
Steam Inlet and Exit Nozzle Location
Off-Design Performance of Superheater
Case Study of a Superheater with Tube Failure Problems
Steam Generator Design and Performance
Performance without Economizer
Tube Wall Temperature Estimation at Economizer Inlet
Methods to Minimize Low-Temperature Corrosion Problems
Precautions to Minimize Corrosion in Operation
Water Chemistry, Carryover, Steam Purity
Fire Tube Boilers
References
Waste Heat Boilers
Introduction
Water Tube Waste Heat Boilers: Sizing and Performance
Kalina Cycle
Fluid Heaters and Film Temperature
Design of Fire Tube Boilers
Air Heaters
Heat Pipes
Design of Tubular Air Heaters
Waste Heat Boiler Data (Thermal Design)
References
HRSG Simulation
Introduction
What Is HRSG Simulation?
Applications of HRSG Simulation
Understanding Pinch and Approach Points
Estimating Steam Generation and Gas–Steam Temperature Profiles
Why Cannot We Arbitrarily Select the Pinch and Approach Points?
Why Should Pinch and Approach Points Be Selected in Unfired Mode?
Simulation of HRSG Evaporator
Supplementary Firing
Off-Design Performance Evaluation
How Accurate Is Simulation?
Steaming in Economizer
Field Data Evaluation
Single- or Multiple-Pressure HRSG
Split Superheater Design
Fresh Air Firing
Efficiency of HRSG
Cogeneration Plant Application
Optimizing HRSG Arrangement
Application of Simulation to Understand the Effect of Ambient Conditions
Applying Margins on Exhaust Gas Flow and Temperature
Conclusion
References
Miscellaneous Boiler Calculations
Condensing Economizers
Wall Temperature of Uninsulated Duct, Stack
Insulation Calculations
Drum Coil Heater: Bath Heater Sizing
Checking Heat Transfer Equipment for Noise and Vibration Problems
Steam Drum Calculations
Estimating Flow in Blowdown Lines
Theory
Flow Instability in Two-Phase Circuits
Transient Calculations
Fan Calculations
References
Appendices
Conversion Factors
Glossary
Nomenclature
Index
Biography
V. Ganapathy is a consultant on steam generators and waste heat boilers based in Chennai, India. He has over 42 years of experience in the engineering of steam generators and waste heat boilers with emphasis on thermal design, performance, and heat transfer aspects. He also develops custom software on boiler design and performance. He holds a bachelor’s degree in mechanical engineering from IIT Madras and an MSc (Engg.) from Madras University. Ganapathy has published over 250 articles on steam generators and thermal design and has authored five books on boilers, the latest being Industrial Boilers and HRSGs (Taylor & Francis Group, Boca Raton, Florida).
"This book will surely help consultants and manufacturers in closing the "gaps" that they may have in thermal performance of oil / gas fired boilers and heat recovery steam generators. …This is a "down to earth" book on the subject."
—S.Damodaran, Director, Thermodyne Technologies Private Limited, Chennai, India"This book is an ideal reference for anyone involved in the heat transfer field. It is practical for use as a reference by plant personnel who need an answer "right now" but it is detailed enough to allow consulting engineers, process engineers, manufacturing engineers, designers and even students to get a comprehensive understanding of how the equipment works and how to make sure what they have designed is really in the best interest of the plant."
—Bob Stemen, Applied Heat Recovery, USA
