Data Available for Calculations

Heater name
Location
Flue gas exit temperature, Te
Ambient air temperature
Combustion air temperature, Tt
Fuel gas temperature, Tf
Oxygen in the flue gas
Assumed radiation losses
Data of Fuel Composition, mol./vol.%
Methane
Hydrogen
Ethane
Ethylene
Propane
Propylene
Butane
Butylene
Pentane
Nitrogen
Carbon monoxide
Carbon dioxide
Hydrogen sulfide
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.
Additional Data
Cp of Air
Cp of Fuel

Calculations
% Excess Air
Actual Oxigen Required
Actual Air Required
Actual Air/lb of Fuel
Flue Gas/lb of Fuel

Results
Lower Heating Value, LHV

Calc. Stack Heat Losses, Qs

Assd. Radiation Heat Losses, Qr
Sensible Heat of Air, Ha
Sensible Heat of Fuel, Hf
Efficiency,

Data Available for Calculations

Plant 15-1F-1 (hydrogen heater)
Syncrude Canada Ltd., Fort McMurray,
Canada
348
50
68
77
3.2
2.5

F
F
F
vol.% (dry basis)
%

uel Composition, mol./vol.%

36.51
22.8
13.49
6.28
8.2
5.95
1.92
2.06
0.44
1.43
0.74
0.17
0.0048

s fired in the furnace.

ure to determine the thermal efficiency and

Additional Data
0.24
0.53

Btu/Lb.F
Btu/Lb.F

Calculations
16.35 %
287.37 moles/hr
39684.33 lb/hr
18.48 lb/lb of fuel
19.48 lb/lb of fuel

Results
20483.74 Btu/lb of Fuel

1522.46 Btu/lb
512.09 Btu/lb
35.48 Btu/lb
9.01 Btu/lb
90.09 %

of
of
of
of

Fuel
Fuel
Fuel
Fuel

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

No.
1
2
3
4
5
6
7
8
9
10
11
12
13

Fuel Component
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

Combustion Reactions
Moles of O2
Required
0.5
0.5
2
3.5
3
5
4.5
6.5
6
8
9.5
1
1.5

Vol. Fraction
(moles/hr)
36.51
22.80
13.49
6.28
8.20
5.95
1.92
2.06
0.44
1.43
0.74
0.17
0.0048
100.0

No.

Flue Gas
Component

1
2

CO2
H 2O

3
4
5

SO2
O2
N2
Total

mbustion Reactions
Moles of CO2
formed
0
1
1
2
2
3
3
4
4
5
6
0
0

Moles of H2O
formed

Moles of SO2
formed
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
Combustion Work Sheet

Mol. Wt.

Total Weight
16
2
30
28
44
42
58
56
72
28
28
44
34

(lb/hr)
584.16
45.6
404.7
175.84
360.8
249.9
111.36
115.36
31.68
40.04
20.72
7.48
0.1632
2147.8

Net Heating
Value

Heating value

Btu/lb
21500
51600
20420
20290
19930
19690
19670
19420
19500
0
4345
0
6550

Btu/hr
12559440
2352960
8263974
3567794
7190744
4920531
2190451
2240291
617760
0
90028
0
1069
43995042.36
20483.74

Flue Gas Heat Loss Work Sheet

Formed during
Comb.
Moles/hr
137.36
219.98

Mol. Wt.

Weight
44
18

lb/hr
6043.84
3959.73

Total Weight/lb of
fuel
2.81
1.84

0.0048
40.38
1081.06
1478.79

64
32
28

0.31
1292.23
30269.56

0.0001
0.60
14.09

rk Sheet
Theoretical or Stoichiometric
oxygen required
moles/hr
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

CO2 formed during

combustion

HO2 formed during

combustion

moles/hr

moles/hr

Enthalpy at Flue gas exit

Temp.

Heat content

64
131

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

Btu/lb of Fuel
179.41
242.27

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

46
63
75

0.0066
37.84
1062.94
1522.46

SO2 formed during

combustion
moles/hr
0
0.00
0.00
0
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.0048
0.0048

1. Efficiency

2. Heat Input

3. Heat Losses
Flue gas = Fuel + Combustion air

Theoretical moles of combustion air = Moles of oxygen x 100/21

Actual moles of air = Theoretical moles of air + Excess air.
Moles of flue gas components:

O2 (Moles
(Moles of
of N2
oxygen
supplied
Moles
of ox
N2
available
fromair
+ Moles
o
CO2 (Moles of CO2 formed during combust
SO2 (Moles of SO2 formed during combust
H2O (Moles of H2O formed during combust

xygen
supplied
Moles
of oxygen
used during
combustion)
2 available
fromair
+ Moles
of N2 available
as athe
fuel)
CO2 formed during combustion + Moles of CO2 available as a fuel )
SO2 formed during combustion + Moles of SO2 available as a fuel)
H2O formed during combustion + Moles of H2O available as a fuel)

% Oxigen in the flue Gas (dry basis)

0.9
1.3
1.7
2.1
3.3
4.1
4.9
5.7
6.3
7.7

% Excess air
4
6
8
10
17
22
28
34
39
53

Temperature, F
240
680
1080
1240
1600
1680
1760

Enthalpy of O2, Btu/lb

40
140
240
280
380
400
420

Temperature, F
200
600
760
1000
1360
1440
1720

Enthalpy of N2, Btu/lb

38
140
180
240
340
360
440

O2 in the flue gas - Excess Air Relationship

60
50

f(x) = 0.0271281529x^3 + 0.0838802637x^2 + 4.661078729x - 0.3000454637

R = 0.9999484855

40
30
20
10
0
0

Enthalpy of O2, Btu/lb

500
400
f(x) = - 9.78854434103918E-009x^3 + 4.94384604505521E-005x^2 + 0.1868710193x - 7.4057583487
R
= 0.9999291763
300
200
100
0
0

200

400

600

800

1000

1200

1400

1600

1800

2000

Enthalpy of N2, Btu/lb

500
400= 6.68569718964655E-009x^3 - 5.72544455931094E-006x^2 + 0.2531471654x - 12.2111443824
f(x)
R = 0.9999347057
300
200
100
0
0

200

400

600

800

1000

1200

1400

1600

1800

2000

Relationship

1078729x - 0.3000454637

8710193x - 7.4057583487

00

1800

Temperature, F
200
280
620
980
1040
1160
1240

2000

Temperature, F

1471654x - 12.2111443824

00

Temperature, F
240
660
740
1040
1240
1440
1640

1800

2000

300
440
640
840
1060
1280
1760

Enthalpy of CO2, Btu/lb

40
140
160
240
300
360
420

Enthalpy of CO2, Btu/lb

500

400
f(x) = - 9.36013202267857E-009x^3 + 6.0270695992598E-005x^2 + 0
R
= 0.9999553559
300
200
100
0
0

200

400

600

800

1000

1200

14

Enthalpy of H2O, Btu/lb

Enthalpy of H2O, Btu/lb
60
100
260
440
470
530
580

700

600
f(x)
500= 5.22198900680078E-008x^3 - 7.45719416969238E-005x^2 + 0.50
R = 0.9999161349
400
300
200
100
0
0

200

400

600

800

1000

Enthalpy of SO2, Btu/lb

350

Enthalpy of SO2, Btu/lb

40
60
100
140
180
220
320

300= 4.25696336097086E-009x^3 - 3.18206525134094E-006x^2 + 0.1

f(x)
R
= 0.9995278879
250
200
150
100
50
0
200

400

600

800

1000

1200

1400

f CO2, Btu/lb

0695992598E-005x^2 + 0.1877364303x - 8.2289204269

1000

1200

1400

1600

1800

f H2O, Btu/lb

6969238E-005x^2 + 0.5097961458x - 38.8957868533

800

1000

1200

1400

f SO2, Btu/lb

525134094E-006x^2 + 0.1837477099x - 17.0730092956

1200

1400

1600

1800

2000