ECONOMIZER DESIGN

Inlet gas temperature 255C

Outlet gas temperature ?
Gas mass flow rate 49.86 kg/sec
Specific heat 1.020505 kJ/Kg C
Inlet water temperature 40C
Outlet water temperature 196.284 -26.284 = 170C
Enthalpy inlet hf40C 167.53 kJ/Kg
Enthalpy outlet hf170C 719.08 kJ/Kg
Mass flow of water 5.75 kg/sec

The outlet temperature of water is taken short of the saturation temperature at operating
pressure of 13 bars, in order to prevent steaming.

Now applying energy balance;

Energy gain by water = Energy lost by the gases

Energy gain by feed water =m (h out h in)

E gain = 5.75(719.08 167.53)

E gain = 3171.41 kW

Therefore energy gain by water is equal energy loss by the gases

q Gain, HO =q lost, gas

3171.41 KW=m C p T

3171.41 =49.86 1.020505 (Tin Tout)

(Tin Tout) gas =62.32C

Tout =255 -62.32

T out , gas =192.67C

TEMPERATURE FOR TRANSPORT PROPERTY
Average temperature of gas

255+192.67
T g, a v g= =223.83C
2

Average temperature of water

170+40
T w, a v g= =105C
2

Average film temperature of gas

Properties of fluid such as density viscosity prandtl number etc are calculated at the film
temperature (temperature of the fluid at solid fluid interface). Since temperature is
changing continuously along the flow direction, therefore finding the mean of mean
temperature of water and flue gases.

( , + , )
Tf = =164.42C
2

Log-mean temperature-difference (LMTD)

Since the purpose of economizer is to preheat the fluid, therefore counter flow
configuration is used. Otherwise disturbance would be created through steaming,
especially when the flow is downward.

Log mean temperature difference of parallel flow is less than that of counter flow. We select
parallel flow configuration.

( )
T LMTD = Ta
In
Tb

Ta = Tg, out Tw, in

T b = Tg , in T w , out

T gas, in 255C
T gas, out 192.67C
T water, in 40C
T water, out 170C
 [(192.6740) (255170)]
T LMTD =[ 192.6740 ]
ln( )
255170

T LMTD =115.55C

ASSUMING A SUTAIBLE TUBE SIZE

Assuming the diameter of tubes and thickness in accordance with mass flow rate.

Outer diameter

OD =38 mm=0.038m

And thickness

t=4mm=0.004m

Now internal diameter would be;

OD -2(t) = ID

Di =ID = 38-(4x2)

Di =ID =30mm=0.03m
Area for one tube

A = (Di) 2=/4(0.03)2
4

A = 7.068610-4m2

Number of tubes

Nw=
AV

For density taking average temperature of water in economizer

170+40
T avg, w = = 105C
2
1 1
f 105C = = = 957 kg/m3
0.001045

m = 5.76kg/sec

A = 7.068610-4m3

V=1.5m/sec (Assumed)

5.75
N w=
(9577.0686104 1.5)

N w=5.66 6

6 tubes are quite low; it will increase the length of tubes so;

V=0.5m/sec (Assumed)
 5.75
N w=
(9577.06861040.5)

=17.000117 tubes

Thus 17 tubes are quite reasonable for lesser frontal area. This would curtail the length of
the tubes.

TUBES SPECS FOR ECONOMIZER

Outer diameter 38mm

Inner diameter 30mm
Thickness 4mm
Number of tubes 17
Area 7.068610-4m2

FIXING THE GAS MASS VELOCITY

Gas mass velocity is basically the mass flux (amount of exhaust gas passing through per
unit area). The range for the gas flux typically ranges from 6 to 16 kg/m2sec depending
upon the type of gas which ascends from dirtiest to clean.

m=AV

=V=G

Setting up =G=8kg/m2sec for cement industry exhaust gas;

[Reason: acoustic cleaning system]

m
G= A ff

49.86
Aff = 8

Aff=6.232m2
Now length of economizer tubes can be calculated.

PITCH OF TUBES

Length of the tube can be evaluated by the formula

A ff= L x (ST-do) N w

Setting up length up to 4 meters

Since length of the tubes is fixed therefore only variable is the transverse pich in the
equation.
A ff
ST= LN w + do

Then;
6.232
S T= +0.038
(417)

ST=0.13m

WIDTH OF TUBES
Since number of tubes are known and we have find the pitch. Now setting the width for
bank of tubes.
 Width=S TN w

=0.1317

=2.204m

ESTIMATING THE OVERALL HEAT TRANSFER CO EFFICIENT

Overall heat transfer coefficient is useful for finding the surface area for heat transfer. Since
convective heat transfer coefficient of gas side has much lower value than water side,
therefore gas side coefficient is the governing parameter. Even though they dont have
much impact, but for higher accuracy we have considered it.

Also we have to consider the fouling factor on gas side and corrosion factor on water side.
Therefore the equation for overall coefficient becomes

1 do 1 do do
= + + ln( )+ffid+ffod
hidi ho 2KL di

For water side

Inner diameter=30mm=1.181 inch

(Average temperature)HO=105C=221F

Mass flow rate=5.75kg/sec =20.7tonns/hr

=45635.68 lb/hr.

At average temperature of water 105C properties are

f=957kg/m3

f=26010-6 Ns/m2
 Prf =1.61

Kf=68310-3 W/m.k

Using correlation for inside heat transfer coefficient

NU=0.023(Re)0.8(Pr)0.4

NU =0.023(VD/)0.8 (Pr)0.4

9570.50.03 0.8
NU=0.023 ( ) (1.61)0.4
260106

NU= 173 = = 173

1730.683
hi= h=3.94 KW/m2K
0.03

For water side NU=173

hi=(3.94)KW/m2K

For gas side

Properties of gases evaluated at the film temperature

255+192.67
Tg , avg = 255
2

C p=0.2219495 Kcal/kg

C p=0.932188 KJ/kg

=0.653566 kg/m.hr

=1.8143210-4 KJ/m sec

K=0.285340 kcal/m.hr

K=3.3289610-4 KJ/m sec

PRANDTL NO.

Pr= = 0.5081

 =0.5 KG/m3

= =3.628610-4 m2/sec

REYNOLD NO.

Gd o
Re= =80.038/1.8143210-4

Re=1676

NUSSELT NO.

For outside heat transfer co efficient using correlation

Nu = 0.33FH FN Re0.6 Pr0.33

Nu =0.3311(1676)0.6(0.5081)0.33

Nu =22.701

hodo
= 22.701

(22.7013.3289104 )
ho =
0.038

ho = 198.865 W/m2
 (h water side 20h gas side)

Using tube material to be mild steel thermal conductivity=55W/m.k

Now;

1 do 1 do do
= + + ln( )+ffid+ffod
hidi ho 2KL di

1 0.038 1 0.038 0.038

=( ) +( )+( )In( )+0.002+0.000179
U 0.033940 198.865 2554 0.03
1
= 3.21510-4 + 5.0310-3 + 0.001 + 0.000179 + 6.4984
U

U= 152.97W/m2K

FLOW AREA REQUIRED

3171.41103
A= =
UTLMTD (152.97115.55)
 A = 179.42m2

NUMBER OF TUBES HIGH REQUIRED

1
NH=

179.42 1
NH=
17 0.0384

NH=24.3 25