Standard Design Steps For Radiant Section:

Calculation of Q/Acp.f

Calculation of Gas Temperature at bridge Wall

No. of Tubes in Radiant Section

Calculation of Beam Length

Dimensions of Radiant Section

Verification of Overall Exchange Factor

Verification of Gas Temperature

Verification of Radiant Heat Duty

Volume of Radiant Section

Mass Flow Rate of Feed

539.766Kg/ min

Inlet Temperature of feed

T1

616.33 K

Outlet Temperature of Feed

T2

671.89 K

Required Heat Duty

6.07 106 KJ/hr

I have assumed that 70 % of the required heat duty is obtained in the

radiant section.
So,
Assumed Radiant heat Duty

0.70 4.55 106

3.185 106 KJ/hr

Assume that Flux

30000 KJ / hr.m2

Assume that Overall Exchange factor

0.57

Step 1:
Calculation of Q/Acp.f:

(Note: The assumption of overall exchange factor is based on the Example

19.1 page#702 Process Heat Transfer by KERN )
Q/Acp

Q/Acp.f

2 Average Flux

2 30000

60000 KJ/ hr

60000 / 0.57

105263.158 KJ /hr

Step 2:
Calculation of Gas Temperature at bridge Wall:
Cross Over Temperature

= Tc

T2 0.7 (T2 T1)

=671.89 0.7 (671.89- 616.33)

Tube Skin Temperature

=Ts

633 K

(Tc + T2) / 2 + 100

752.44 K

From Process Heat Transfer By D.Q.Kern graph# 19.14 Pages # 699

Gas Temperature over Bridge wall

=Tg

1150 K

Step 3:
No. of Tubes in Radiant Section:
From Petroleum Refinery Engineering By W.L.Nelson graph # 23.9
Page # 887
Length of Tube
Diameter of tube
Center to Center Distance
Surface Area / tube

No. of Tubes

=
=

L
D

20 ft

6.096 m

5 in

0.127 m

10 in =0.833 ft

0.254 m

DL

3.1415 0.127 m 6.096 m

2.5 m2

Q / (Flux Area)

4.185 106 / (30000 2.5)

50

=0.417 ft

Step 4:
Calculation of Beam Length:
Length

Center to Center Distance

Width

L =

6.096 m

0.254 m

= W =

Height of Bridge Wall

Furnace Volume

(6.096+1)(0.254)

1.802 m

=H

(6.096+1)(0.254)

1.802 m

V =
=

L:W:H

(L+1) (C-C distance)

(L+1) (C-C distance)

6.096 1.802 1.802

19.795 m3

6.096 : 1.802 : 1.802

3 :1 :1

FromProcess Heat Transfer By D.Q.Kern page #691

As our length, width and height ratio is 3 :1 :1, so formula to calculate the
beam length of tube is:
Mean Beam Length

2/3 (Furnace Volume in m3)1/3

1.802 m

C-C distance tube length

0.254 6.096

1.548 m2

0.254 / 0.127 m

Step 5:
Dimensions of Radiant Section:
Acp/tube

C-C distance / Outer Dia of Tube

FromProcess Heat Transfer By D.Q.Kern page #688

from graph 19.11

0.60

=1.78

 Acp/tube

1.548 0.60

Total Acp

0.929 50

=46.44m2

End Walls

WH2

=6.494 m2

Side Walls

LH2

= 21.97m2

Floor and Arch

WL2

=21.97 m2

=0.929m2

Total Area of radiant Section

=

= At =

6.494 + 21.97 + 21.97

50.434 m2

Effective refractory Area

= Ar =

Ar/ Acp

At - Acp

50.434 46.44

4 m2

4/46.44

0.086

Step 6:
Verification of Overall Exchange Factor:
At Tg = 1144 K and Ts = 752.44 K FromPetroleum refinery Engineering By
W.L.Nelson page #605 graph # 18.10
The value of (PCO2 + PH20)

(PCO2 + PH20)L

0.236 atm

= 0.23 7.293 m
=1.721 atm.m =

5.467 atm.ft

Emissivity of flue gases from the graph # 18.9 Page #604 Petroleum Refinery
Engineering by W.L.Nelson
Eg

0.7

Now Overall Exchange Factor is calculated from the graph 19.15 page # 700
Process Heat Transfer By D.Q.Kern.
f
Q/Acp.f

0.82

4.185 106 / 46.45 0.82

108026.89

KJ/ hr. m2

(That is nearly equal to its supposed value verifying its correctness)

Step 7:
Verification of Gas Temperature:
From Process Heat Transfer by D.Q.Kern graph #19.14
Against Q/Acp.f
Tg

1144 K

Heat Contained by Flue gases:

From Fig#14.3 page 423 on Petroleum Refinery Engineering by W.L.Nelson at
1144K ;
Heat Contained by Flue gases =

Qg

1.82 106

Step 8:
Verification of Radiant Heat Duty:
Actual Heat Removed in Radiant Section=
=

Qf + Qa Qg Qw
4.185 106

KJ /hr

Step 9:
Volume of Radiant Section:
Volume of Radiant Section:

= Vr =

LWH

6.096 1.802 1.802

19.79 m3

Standard Design Steps for Convective Section:

Heat Duty

LMTD

Mean gas Film Temperature

Overall Convective Heat Transfer Co-efficient

Calculation of Mass Velocity of Flue Gases

Convective Section Area

No. of Tubes Required

Step 1:
Heat Duty:
In convective section rest of the heat duty will be obtained.
Heat absorbed in convective section

= Qc =

Qreqd -

6.07106 -

7.0 104 KJ/ hr

Qr

4.185 106

Stack temperature of the flue gases:

Net Heat Contained by Flue gases after=

Qs + Qb

Convective Section

1.274 106 +

1.814 106 KJ/hr

5.4 105

From Petroleum Refinery Engineering By W.L.Nelson page #423

Graph # 14.3
Stack gas Temperature

= Ts =

700 K

Cross Over Temperature

= Tc =

633 K

Inlet Temperature of Oil

= T1 =

616.33 K

Temperature of flue gases

= Tg =

1144 K

after Radiant Section

Temperature of flue gases at the exit

221 K

Step 2:
LMTD:
For Counter Flow:
LMTD

T1- T2 / ln (T1/ T2)

T1

1144 633

511 K

T2

700 616.33

83.67K

LMTD

236.16 K

0.5 (T1 + Tc + LMTD)

742 K

Step 3:
Mean gas Film Temperature:
Tf
Step 4:

Calculation of overall heat transfer coefficient:

From page#613 of Petroleum Refinery Engineering by W.L.Nelson :
Uc

5.2 BTU/hr.ft2 F

Step 5:
Surface Area Required:
Surface required for the Convective

1.89 106 /106236.16

75.50 m2

heat transfer

Step 6:
No. of Tubes:
Selecting four tubes per pass with 0.11 m OD and 0.20 m Centre to centre
distance.
No.of Tubes for Convective Section

Surface Area / D L

75.50 / 3.14 0.127 6.096

31

SPECIFICATION SHEET OF
FURNACE:
ITEM
TYPE
Mass Flow rate of Feed
Inlet Temperature = T1
Outlet Temperature =T2
Total heat duty required, QF
heat of combustion value of natural gas
Fuel required for liberation of Heat
Total air supplied
Total moles of combustion products
Heat contained by flue gases (Qg)
Heat absorbed in radiant section, Qr
Heat absorbed in convective section
Heat absorbed in breeching section
Heat contained by the stack gas
Gas Temperature over Bridge wall
No. of Tubes in radiant section
Total Area of radiant Section
Height of the chimney
No.of Tubes for Convective Section
Temperature of the flue gases emitting
from the stack

FURNACE
Vertical natural draft furnace
539.766 kg/min
616.33 K
671.89 K
6.07 106 KJ/ hr
54400.43 KJ / Kg
111.576 Kg / hr
77114.05 gm-mol / hr
84308.931 gm-mol / hr
1.82 106 KJ/hr
4.185 106 KJ/ hr
70000 KJ/hr
1.274 106 KJ/ hr
5.46 105
1150 K
50
50.434 m2
70 ft
31
221 C