Reprinted from:

July 2005 issue, pgs 6369

Used with permission. www.HydrocarbonProcessing.com

Article copyright 2005 by Gulf Publishing Company. All rights reserved.

HEAT TRANSFER

BONUSREPORT

Simplify your thermal efficiency calculation

Standard charts and a spreadsheet help
S. PATEL, Syncrude Canada Ltd, Alberta, Canada

ost process engineers recognize the value of furnace efficiency calculations, yet many are intimidated by the idea of performing them. The thermal efficiency calculation is important for evaluating its furnace performance. Engineers can no longer hope to be successful in evaluating furnace operation without a grasp of fundamentals and their applications to solving furnace problems. Focusing on the fundamentals of furnace calculations provides a framework for engineers to gain information and understand operations. For anyone who routinely wants to perform efficiency calculations, a spreadsheet program is necessary. This article can help develop it. A previous article shows how to calculate the thermal efficiency using flue gas analysis.1 The method described in this article considers fuel gas analysis and stack temperature to calculate the thermal efficiency. The procedure uses standard charts for excess air and enthalpy of flue gas components to simplify the calculations. The difference between the simplified calculation and the correct one is smaller, and its impact on the final calculation is negligible. The method described is intended for fired heaters burning only gaseous fuels only. By understanding the procedure described, engineers will be able to calculate the following:

Lower heating value (LHV) or fuel heat of combustion Combustion air and flue gas flowrates Flue gas composition (both wet and dry basis) Furnace thermal efficiency.
Efficiency. The net thermal efficiency is equal to the total heat

absorbed divided by the total heat input. The heat absorbed is equal to the total heat input minus the total heat losses from the system. The net thermal efficiency for the arrangements shown in Fig. 1 can be determined by the following equation: Total heat input Stack heat losses Radiation heat loss Efficiency = 100 Total heat input Therefore, e=

( LHV + Ha + Hf ) Qs Qr 100 ( LHV + Ha + Hf )

(1)

FIG. 1

Eq. 1 can be used to determine the net thermal efficiency for these arrangements.

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BONUSREPORT

HEAT TRANSFER
Ha = lb of air Cpair (Tt Td ) lb of fuel

Hf = Cp fuel (Tf Td ) where: Cpair = Specific heat of air Cpfuel = Specific heat of fuel Tt = Combustion air temperature Tf = Fuel temperature Td = datum temperature (60F). Heat losses. Total heat loses are the sum of stack and radiation heat losses. The stack heat losses, Qs/lb of fuel, are determined from a summation of the enthalpy of the flue gas components at the stack temperature, Te. Fig. 2 is used to estimate the enthalpy of flue gas components/lb of fuel. One of the key steps in estimating the heat losses is to calculate the flue gas components produced/lb of fuel: Flue gas = Fuel + Combustion air So, the first step in calculating the heat losses is to determine how much combustion air/lb of fuel is required. Estimating the theoretical or stoichiometric moles of oxygen required to complete the combustion will help to calculate the combustion air. The theoretical moles of oxygen required for combustion are calculated using the combustion reactions shown in Table 1. For example, one mole of H2 requires 0.5 moles of oxygen. So, if H2 is one of the fuel components, the volume fraction of H2 is multiplied by 0.5 to calculate the moles of oxygen required by H2. The moles of oxygen required by other fuel components are calculated similarly. Once the total theoretical moles of oxygen are calculated, its very easy to calculate the moles of combustion air. Air is 21% oxygen by volume. So, Theoretical moles of combustion air = Moles of oxygen 100/21 The total theoretical moles of air are then corrected for excess air to get the actual moles of combustion air required. Remember, air. Actual moles of air = Theoretical moles of air + Excess

FIG. 2

Enthalpies of O2, N2, CO2, H2O and SO2.

where: e = Net thermal efficiency, % LHV = Heat input or lower heating value of the fuel, Btu/lb of fuel Ha = Heat input in the form of sensible heat of air, Btu/lb of fuel Hf = Heat input in the form of sensible heat of fuel, Btu/lb of fuel Qs = Calculated stack heat losses, Btu/lb of fuel Qr = Assumed radiation heat loss, Btu/lb of fuel Heat input. Total heat input is the sum of the fuel LHV and sensible heat of air and fuel. LHV/lb of fuel is calculated using fuel gas analysis and the net heating value of fuel components. The heat of combustion is calculated by multiplying the weight fraction of fuel components by its net heating value. The total heat of combustion is then divided by the total fuel weight to obtain the LHV. Ha and Hf are estimated using the following equations:

TABLE 1. Combustion reactions

Reaction H2 + 0.5O2 H2O CO + 0.5O2 CO2 CH4 + 2O2 CO2 + 2H2O C2H6 + 3.5O2 2CO2 + 3H2O C2H4 + 3O2 2CO2 + 2H2O C3H8 + 5O2 3CO2 + 4H2O C3H6 + 4.5O2 3CO2 + 3H2O C4H10 + 6.5O2 4CO2 + 5H2O C4H8 + 6O2 4CO2 + 4H2O C5H12 + 8O2 5CO2 + 6H2O C6H14 + 9.5 O2 6CO2 + 7H2O S + O2 SO2 H2S + 1.5O2 SO2 + H2O Moles of Moles of Moles of Moles of O2 required CO2 formed SO2 formed H2O formed 0.5 0.5 2 3.5 3 5 4.5 6.5 6 8 9.5 1 1.5 0 1 1 2 2 3 3 4 4 5 6 0 0 1 0 2 3 2 4 3 5 4 6 7 0 1 0 0 0 0 0 0 0 0 0 0 0 1 1

Based on percent oxygen content in the flue gas (generally, an oxygen analyzer reading is used here), excess air can be estimated using Fig. 3. This chart can be used for natural and refinery fuel gases. After correcting the theoretical moles of combustion air with excess air, the combustion air/lb of fuel is calculated by multiplying the moles of combustion air by 29 (MW of air) and then dividing by the total fuel weight. Once the quantity of combustion air is determined, the next step is to calculate flue gas components produced/lb of fuel. The flue gas components are mainly CO2, H2O, SO2, O2 and N2. Hence, Moles of flue gas components = CO 2 (Moles of CO 2 formed during combustion + Moles of CO 2 available as a fuel ) + H 2O (Moles of H 2O formed during combus-

HYDROCARBON PROCESSING JULY 2005

BONUSREPORT

HEAT TRANSFER
Ambient air temperature Combustion air temperature, F Fuel gas temperature, F Oxygen in the flue gas, vol.% Assumed radiation losses, % Fuel composition, mol./vol.% 50 68 77 3.2 (dry basis) 2.5 Methane: 36.51, hydrogen: 22.80, ethane: 13.49, ethylene: 6.28, propane: 8.20, propylene: 5.95, butane: 1.92, butylene: 2.06, pentane: 0.44, nitrogen: 1.43, carbon monoxide: 0.74, carbon dioxide: 0.17, hydrogen sulfide: 0.0048 Solution: Basis: 100 moles/hr of fuel is fired in the furnace. Follow this step-by-step procedure to determine the thermal efficiency and other parameters. LHV of fuel/lb of fuel. The fuel LHV is calculated using a combustion work sheet (Table 2). Instructions for developing the combustion work sheet are: Insert fuel composition in column A and its quantity as a volume fraction in column B. If the composition is expressed as a weight percent, then insert in column D. Insert mol. wt. of fuel components in column C. Multiply column B by column C to get the total weight in column D. Total column D on the total line to obtain total fuel flow. Therefore, Total fuel flow = 2,147.89 lb/hr Now, insert net heating value (Btu/lb) of all the components in column E (from process handbook). Multiply column D by column E to get the heating value of all the components in column F. Total column F on the total line. Divide the column F total by the column D total to obtain the fuel LHV. Therefore, LHV = 20,483 Btu/lb of fuel Combustion air/lb of fuel. From the combustion reactions shown in Table 1, each mole of CH 4 requires 2 moles of O2, etc. In your combustion work sheet, multiply 36.51 (CH4 mol fraction in column B) by 2 (moles of oxygen) to calculate theoretical or stoichiometric oxygen required for CH4 in column G and so on. Then total column G on the total line to obtain the quantity of total oxygen required. Therefore, Total theoretical (stoichiometric) oxygen required = 246.99 moles/hr Oxygen in the flue gas is reported as 3.2% vol. (dry). An estimated excess air corresponding to the 3.2% oxygen in the flue gas is 16.4%. (See Fig. 3 for relationship between oxygen content in the flue gas and excess air.) Therefore, Actual oxygen required = 246.99 1.164 = 287.50 moles/hr

FIG. 3

Relationship between oxygen content in the flue gas and excess air.

tion + Moles of H2O available as a fuel) + SO2 (Moles of SO2 formed during combustion + Moles of SO 2 available as a fuel) +O 2 (Moles of oxygen supplied Moles of oxygen used during the combustion) + N2 (Moles of N2 available from air + Moles of N2 available as a fuel) The moles of CO2, H2O and SO2 formed during combustion are calculated using the reactions shown in Table 1. The method will be the same, which is used for calculating oxygen requirements. Once the total moles of flue gas components are determined, the flue gas components/lb of fuel is calculated by multiplying the moles of flue gas components by its molecular weight and then dividing by the total fuel weight. The flue components produced/lb of fuel calculation requires correction for the moisture coming with the air and fuel, but this step can be eliminated since its impact on the final calculation is negligible. The radiation heat loss, Qr / lb of fuel is determined by multiplying the LHV by radiation loss expressed as a percentage. Generally, this loss is between 2% and 4%.
Sample problem:

Heater name Location Flue gas exit temperature, F

Plant 15-1F-1 (hydrogen heater) Syncrude Canada Ltd., Fort McMurray, Canada 348

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HEAT TRANSFER

TABLE 2. Combustion work sheet

A Fuel Component B C Vol. fraction, Mol. wt. (moles/hr) D (B X C) Total weight (lb/hr) E Net heating value, Btu/lb 21,500 51,600 20,420 20,290 19,930 19,690 19,670 19,420 19,500 0 4,345 0 6,550 F (D X E) G H Heating Theoretical or CO2 formed value, Stoichiometric during Btu/hr oxygen combustion, required, moles/hr moles/hr 12559440 2352960 8263974 3567794 7190744 4920531 2190451 2240291 617760 0 90393 0 1069 43,995,407 20,483 73.02 11.40 47.22 18.84 41.00 26.78 12.48 12.36 3.52 0.00 0.37 0.00 0.01 246.99 36.51 0.00 26.98 12.56 24.60 17.85 7.68 8.24 2.20 0.00 0.74 0.00 0.00 137.36 I H2O formed during combustion, moles/hr 73.02 22.80 40.47 12.56 32.80 17.85 9.60 8.24 2.64 0.00 0.00 0.00 0.0048 219.98 J SO2 formed during combustion, moles/hr 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.0048 0.00480

Methane (CH4) Hydrogen (H2) Ethane (C2H6) Ethylene (C2H4) Propane (C3H8) Propylene (C3H6) Butane (C4H10) Butylene (C4H8) Pentane (C5H12) Nitrogen (N2) Carbon monoxide (CO) Carbon dioxide (CO2) Hydrogen sulfide (H2S) Total Total/lb of fuel

36.51 22.80 13.49 6.28 8.20 5.95 1.92 2.06 0.44 1.43 0.74 0.17 0.00480 100.00

16.00 2.00 30.00 28.00 44.00 42 58 56 72 28 28 44 34

584.16 45.60 404.70 175.84 360.80 249.90 111.36 115.36 31.68 40.04 20.80 7.48 0.16 2,147.89

Air is 21% oxygen by volume, Therefore, Actual air required = 287.50 (100/21) = 1,369.02 moles/hr = 1,369.02 29 (mol. wt. of air) = 39,702 lb/hr Actual air/lb of fuel = 39,702/2,147.89 = 18.48 lb/lb of fuel Flue gas/lb of fuel. Flue gas = Fuel + Combustion air = 2,147.89 lb/hr + 39,702 lb/hr = 41,850 lb/hr Flue gas/lb of fuel = 41,850/2,147.89 = 19.48 lb/lb of fuel

TABLE 3. Flue Gas Heat Loss Work Sheet

A B C D (B X C) E F G (E X F) Flue Gas Moles/hr Mol. wt. Weight, Total Enthalpy Heat content, component lb/hr weight/lb at 348F Btu/lb of fuel of fuel CO2 H2O SO2 O2 N2 Total 137.53 219.98 0.0048 40.51 1082.96 1480.98 44 18 64 32 28 6051.45 3959.73 1296.20 30322.83 2.82 1.84 0.60 14.12 62 128 44 65 73 174.68 235.97 0.0063 39.23 1030.58 1480.46

0.31 0.0001

Flue gas composition. From the combustion reactions shown in Table 1, each mole of CH4 produces 2 moles of CO2, 1 mole of H2O and, etc. In your combustion work sheet, multiply 36.51 (mole fraction of CH4) by 2 (moles of CO2) to calculate the moles of CO2 formed in column H, etc. Repeat this step for H2O and SO2 and calculate the moles of H2O and SO2 formed in columns I and J, respectively. Total columns H, J and I. Therefore, Total CO2 formed Total H2O formed Total SO2 formed = 137.36 moles/hr = 219.98 moles/hr = 0.0048 moles/hr

Flue Gas. CO2 in the flue gas = CO2 formed during combustion + CO2 reported as a fuel = 137.36 moles/hr + 0.17 moles/hr = 137.53 moles/hr H2O in the flue gas = H2O formed during combustion + H2O reported as a fuel = 219.98 moles/hr + 0 = 219.98 moles/hr SO2 in the flue gas = SO2 formed during combustion + SO2 reported as a fuel = 0.0048 moles/hr + 0 = 0.0048 moles/hr O2 in the flue gas = Actual O2 supplied Actual O2 used during combustion = 287.50 246.99

HYDROCARBON PROCESSING JULY 2005

= 40.51 moles/hr N2 in the flue gas = N2 from air (moles of air moles of oxygen) + N2 reported as a fuel = (1,369.02 287.50) + 1.43 = 1,082.95 Moles/hr
Wet basis vol%/mol% 9.29 14.85 0.00032 2.74 73.12 100 Dry basis vol%/mol% 10.91 0.00 0.00038 3.21 85.88 100.00

Therefore,
Components CO2 H2O SO2 O2 N2 Total moles/hr 137.53 219.98 0.0048 40.51 1,082.95 1,480.98

Stack Heat Losses Qs/lb of fuel. The stack heat losses are determined from a summation of the heat content of the flue gas components at the exit flue gas temperature. The stack or flue gas exit temperature is 348F. The heat content of flue gas is calculated using the stack heat loss work sheet (Table 3). Instructions for developing the stack heat loss work sheet are: Insert flue gas components in column A and its quantity in column B. Insert mol. wt. of flue gas components in column C. Multiply column B by column C to obtain the total weight in column D. Now, divide column D by total fuel weight (2,147.89 lb/hr) to obtain flue gas components/lb of fuel in column E. In column F, insert the enthalpy values for flue gas components. Refer to Fig. 2 to get the enthalpy of flue gas components at 348F. Now, multiply column E by column F to calculate the heat content of flue gas in column G. Total column G to obtain the Qs at 348F.

Therefore, Qs = 1,480.46 Btu/lb of fuel Radiation heat loss Qr/lb of fuel. The radiation heat loss is determined by multiplying heat input fuel LHV by the radiation loss expressed as a percentage. The radiation heat loss is 2.5%. Therefore, Qr = 20,483 0.025 = 512 Btu/lb of fuel Sensible heat correction for combustion air, Ha/lb of fuel. Ha = lb of air/lb of fuel Cpair (Tt Td ) = 18.48 0.24 (68-60) = 35.48 Btu/lb of fuel Sensible heat correction for fuel Hf /lb of fuel. Hf = Cpfuel (Tf Td ) = 0.53 (77 60) = 9.01 Btu/lb of fuel Net thermal efficiency. The net thermal efficiency can then be calculated as follows (Eq. 1):
Efficiency =

( 20, 483 + 35.48 + 9.01) (1, 480.46 512) 100 ( 20, 483 + 35.48 + 9.01)
(1)

= 90.29%

Sanjay Patel is associate process engineer, technical services, for

Syncrude Canada Ltd., Canada. He has 12 years experience in the areas of operation, technical services, process automation and controls, and projects. Mr. Patels previous experience includes operation, troubleshooting and debottlenecking of an oxo alcohol plant and synthesis gas reformer; and commissioning and startup of worlds largest grassroots refinery (Reliance Industries Ltd.) at Jamnagar, India. At Reliance worked as an assistant manager. He graduated from D.D.I.T, Gujarat University, India, and is a registered professional engineer in the province of Alberta, Canada. Mr. Patel can be contacted via e-mail at: s.patel@shaw.ca.

Article copyright 2005 by Gulf Publishing Company. All rights reserved.

Printed in U.S.A.