Heater Calculation and Design Data

Make up
water tank

Accumulator

Water booster
pumps (2 Nos)
Exhaust
Capacity:68 m 3/hr
Pressure: 22 m

50oC
53.2oC

Digester

Flame Arrestor

Gas Blower
From DAF Float
70oC

Boiler
Saacke (Existing)
Capacity: 455 m 3/hr
Pressure: 4 kPa

General
Heat capacity water
Calorific Value of methane
Methane content of digester gas
Air temperature
HTC (convective) to air
HTC (convective) to air with wind
Insulation Conductivity
Steel Conductivity

kJ/kg.C
MJ/Nm
% (v/v)
C
W/m.C
W/m.C
W/m.K
W/m.K

Plate Heat
Exchanger

Capacity:1,000 kW
Pressure: 750 kPa

24oC

Alfa Laval
Model: M6-MFM
Capacity:320 kW
Pressure: 750 kPa

1020
27
22
34

21,451 MJ/h
5,959 kW
850 kW

0.05
45

Common
mm
mm
mm
m2
mm
W/m.C
W/m.C
C
W/m
W/m

Length

Flow
Flow
Velocity
Temperature - outlet

m/h
l/s
m/s
C

HEX Washwater
Temperature - primary inlet
Temperature - primary outlet
Temperature - secondary inlet
Temperature - secondary outlet
Secondary flow in
Capacity
LMTD
HTC
Heat transfer area

C
C
C
C
l/s
kW TH
K
W/m.K
m

HEX DAF Float

Temperature - primary inlet
Temperature - primary outlet
Temperature - secondary inlet
Temperature - secondary outlet
DAF Float flow (max)
Heat capacity DAF Float
Capacity
LMTD
HTC
Heat transfer area
HEX Phase 1 & 2 Dig Feed
Temperature - primary inlet
Temperature - primary outlet
Temperature - secondary inlet
Temperature - secondary outlet
Dig Feed flow (max)
Heat capacity Dig Feed
Capacity
LMTD
HTC
Heat transfer area

125
3
50
0.027
85
0.51
0.52
70.01
21.99
22.33
3
67.32
18.7
0.68
70.01

To WW
HEX
100
3
50
0.024
72
0.43
0.44
70.01
18.64
18.93
5
16.92
4.7
0.20
70.00

70.00
53.20
24.10
50.00
3.0
320
24.3
6,704
2

To DAF
HEX
80
3
50
0.020
62
0.37
0.38
70.01
15.94
16.18

To Phase
1 & 2 Dig
100
3
75
0.041
82
0.33
0.34
70.00
14.31
14.46

100

550

21.6
6.0
0.29
69.94

28.8
8
0.19
69.76

As per Alfa Laval data sheet

C
C
C
C
l/s
kg/h
kJ/kg.C
kW TH
K
W/m.K
m

69.94
64.56
30.00
40.00
6 <= based on 105 m3/hr max. hourly flow, 20% is CGW after DAF.
21,600
2.25
135
32.19
29
149,870

C
C
C
C
l/s
kg/h
kJ/kg.C
kW TH
K
W/m.K
m

69.76
60.19
30.00
40.00
8 <= based on 583 m3/hr max. hourly flow digester feed.
28,800
4.00
320
29.98
29
330,788

Primary Side Return Pipelines

Common
Diameter

mm

Wall thickness
Insulation thickeness
LMR
Heat transfer
Heat transfer (with wind)
Temperature - inlet
Heat loss
Heat loss (with wind)

mm
mm
mm
W/m.C
W/m.C
C
W/m
W/m

125
3
50
85
0.51
0.52
59.72
16.72
16.99

Length

Temperature - outlet

59.71

Temperature - Heater Return

59.71

Water Heater
Energy
Boiler Comb eff
Say
Digester gas flow

kW
%
kW
kW
m/h

To DAF Float

Heat Exchanger
DAF

DAF

Phase 1 & 2 Dig

Heat Exchanger

4.18
35.05
60%

Primary Side Feed Pipelines

Diameter
Wall thickness
Insulation thickeness
Area
LMR
Heat transfer
Heat transfer (with wind)
Temperature - inlet
Heat loss
Heat loss (with wind)

Capacity:17 m 3/hr
Pressure: XX m

Washwater

804
85%
946
1,000
162.01

From WW From DAF To Phase

HEX
HEX
1 & 2 Dig
100
80
100
0.008
3
3
3
50
50
75
72
62
82
0.43
0.37
0.33
0.44
0.38
0.34
53.20
64.56
60.19
11.36
13.92
14.31
11.53
14.13
14.46
5
53.20

100
64.50

550
59.96

Phase 1 & 2 Dig Feed

Phase 1 & 2 Dig Feed