Data Available for Calculations

Heater name Plant 15-1F-1 (Hydrogen Heater)

Syncrude Canada Ltd., Fort McMurray,
Location Canada
Flue gas exit temperature, Te 348
Ambient air temperature 50
Combustion air temperature, Tt 68
Fuel gas temperature, Tf 77
Oxygen in the flue gas 3.2
Assumed radiation losses 2.5

Data of Fuel Composition, mol./vol.%

Methane 36.51
Hydrogen 22.8
Ethane 13.49
Ethylene 6.28
Propane 8.2
Propylene 5.95
Butane 1.92
Butylene 2.06
Pentane 0.44
Nitrogen 1.43
Carbon monoxide 0.7430
Carbon dioxide 0.1702
Hydrogen sulfide 0.0048

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 0.24
Cp of Fuel 0.53

Calculations
% Excess Air 16.35
Actual Oxigen Required 287.37
Actual Air Required 39684.57
Actual Air/lb of Fuel 18.48
Flue Gas/lb of Fuel 19.48

Results
Lower Heating Value, LHV 20483.02
Calc. Stack Heat Losses, Qs 1522.41
Assd. Radiation Heat Losses, Qr 512.08
Sensible Heat of Air, Ha 35.47
Sensible Heat of Fuel, Hf 9.01
Efficiency, ε 90.09
 Combustion Reactions
Moles of O2
Reaction Required
°F H2 + 0.5 O2 → H2O 0.5
CO + 0.5 O2 → CO2 0.5
°F CH4 + 2O2 → CO2 + 2 H2O 2
°F C2H6 + 3.5 O2 → 2 CO2 + 3 H2O 3.5
vol.% (dry basis) C2H4 + 3 O2 → 2 CO2 + 2 H2O 3
% C3H8 + 5 O2 → 3 CO2 + 4 H2O 5
C3H6 + 4.5 O2 → 3 CO2 + 3 H2O 4.5
C4H10 + 6.5 O2 → 4 CO2 + 5 H2O 6.5
C4H8 + 6 O2 → 4 CO2 + 4 H2O 6
C5H12 + 8 O2 → 5 CO2 + 6 H2O 8
C6H14 + 9.5 O2 → 6 CO2 + 7 H2O 9.5
S + O2 → SO2 1
H2S + 1.5 O2 → SO2 + H2O 1.5

No. Fuel Component Vol. Fraction

(moles/hr)
1 Methane (CH4) 36.51
2 Hydrogen (H2) 22.80
3 Ethane (C2H6) 13.49
4 Ethylene (C2H4) 6.28
5 Propane (C3H8) 8.20
6 Propylene (C3H6) 5.95
7 Butane (C4H10) 1.92
8 Butylene (C4H8) 2.06
9 Pentane (C5H12) 0.44
Btu/Lb.°F 10 Nitrogen (N2) 1.43
Btu/Lb.°F 11 Carbon Monoxide (CO) 0.74
12 Carbon Dioxide (CO2) 0.17
13 Hydrogen Sulfide (H2S) 0.0048
Total 100.0
% Total/lb of fuel
moles/hr
lb/hr
lb/lb of fuel
lb/lb of fuel
Flue Gas
No. Component

1 CO2
Btu/lb of Fuel 2 H2O
Btu/lb of Fuel 3 SO2
Btu/lb of Fuel 4 O2
Btu/lb of Fuel 5 N2
Btu/lb of Fuel Total
%
ombustion Reactions
Moles of CO2 Moles of H2O Moles of SO2
formed formed formed
0 1 0
1 0 0
1 2 0
2 3 0
2 2 0
3 4 0
3 3 0
4 5 0
4 4 0
5 6 0
6 7 0
0 0 1
0 1 1

Combustion Work Sheet

Net Heating Theoretical or Stoichiometric
Mol. Wt. Total Weight Heating value
Value oxygen required
(lb/hr) Btu/lb Btu/hr moles/hr
16 584.16 21500 12559440 73.02
2 45.6 51600 2352960 11.40
30 404.7 20420 8263974 47.22
28 175.84 20290 3567794 18.84
44 360.8 19930 7190744 41.00
42 249.9 19690 4920531 26.78
58 111.36 19670 2190451 12.48
56 115.36 19420 2240291 12.36
72 31.68 19500 617760 3.52
28 40.04 0 0 0.00
28 20.80 4345 90393 0.37
44 7.49 0 0 0.00
34 0.1632 6550 1069 0.01
2147.9 43995407.34 246.99
20483.02

Flue Gas Heat Loss Work Sheet

Formed during Total Weight/lb of
Mol. Wt. Weight
Comb. fuel Enthalpy at Flue gas exit Temp.
Moles/hr lb/hr
137.36 44 6043.97 2.81 64
219.98 18 3959.73 1.84 131
0.0048 64 0.31 0.0001 46
 40.38 32 1292.23 0.60 63
1081.06 28 30269.74 14.09 75
1478.80
CO2 formed during HO2 formed during SO2 formed during
combustion combustion combustion
moles/hr moles/hr moles/hr
36.51 73.02 0
0.00 22.80 0.00
26.98 40.47 0.00
12.56 12.56 0
24.60 32.80 0.00
17.85 17.85 0.00
7.68 9.60 0.00
8.24 8.24 0.00
2.20 2.64 0.00
0.00 0.00 0.00
0.74 0.00 0.00
0.00 0.00 0.00
0.00 0.0048 0.0048
137.36 219.98 0.0048

Heat content

Btu/lb of Fuel
179.40
242.25
0.0066
 37.84
1062.90
1522.41
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 of

N2 (Moles of N2
oxygen supplied
available from–air
Moles of oxygen
+ Moles used d
of N2 availabl
CO2 (Moles of CO2 formed during combustion + Moles o
SO2 (Moles of SO2 formed during combustion + Moles o
H2O (Moles of H2O formed during combustion + Moles o
 d –air
om Moles of oxygen
+ Moles used during
of N2 available as athe combustion)
fuel)
during combustion + Moles of CO2 available as a fuel )
uring combustion + Moles of SO2 available as a fuel)
during combustion + Moles of H2O available as a fuel)
 O2 in the flue gas
% Oxigen in the flue Gas (dry basis) % Excess air
60
0.9 4
1.3 6 50 f(x) = 0.0271281529x^3 +
1.7 8 R² = 0.9999484855
2.1 10 40
3.3 17
30
4.1 22
4.9 28 20
5.7 34
10
6.3 39
7.7 53 0
0 1 2 3

Enthalpy
Temperature, F Enthalpy of O2, Btu/lb
450
240 40
400= - 9.78854434103918E-09x^3 + 4.94
f(x)
680 140
350= 0.9999291763
R²
1080 240 300
1240 280 250
1600 380 200
1680 400 150
1760 420 100
50
0
0 200 400 600 800

Enthalpy
Temperature, F Enthalpy of N2, Btu/lb 500
200 38 450
600 140 f(x)
400= 6.68569718964655E-09x^3 - 5.725
R²
350= 0.9999347057
760 180
300
1000 240 250
1360 340 200
1440 360 150
1720 440 100
50
0
0 200 400 600 800
2 in the flue gas - Excess Air Relationship

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

R² = 0.9999484855

1 2 3 4 5 6 7 8 9

Enthalpy of O2, Btu/lb

854434103918E-09x^3 + 4.94384604505521E-05x^2 + 0.1868710193x - 7.4057583487

91763

200 400 600 800 1000 1200 1400 1600 1800 2000

Enthalpy of N2, Btu/lb

69718964655E-09x^3 - 5.72544455931094E-06x^2 + 0.2531471654x - 12.2111443824

347057

200 400 600 800 1000 1200 1400 1600 1800 2000
 Enthalpy of CO2, Btu/l
Temperature, F Enthalpy of CO2, Btu/lb 450
240 40 400= - 9.36013202267857E-09x^3 + 6.0270695992598E-05x^2
f(x)
660 140 350= 0.9999553559
R²
740 160 300
1040 240 250
1240 300 200
1440 360 150
100
1640 420
50
0
0 200 400 600 800 1000 1200

Enthalpy of H2O, Btu/lb

700
Temperature, F Enthalpy of H2O, Btu/lb
600
200 60 f(x) = 5.22198900680078E-08x^3 - 7.45719416969238E-05x^2 +
280 100 500
R² = 0.9999161349
620 260 400
980 440 300
1040 470 200
1160 530
100
1240 580
0
0 200 400 600 800 100

Enthalpy of SO2, Btu/l

350
Temperature, F Enthalpy of SO2, Btu/lb
300= 4.25696336097086E-09x^3 - 3.18206525134094E-06x^2
f(x)
300 40
R² = 0.9995278879
440 60 250
640 100 200
840 140
150
1060 180
1280 220 100

1760 320 50
0
200 400 600 800 1000 1200 1400
 nthalpy of CO2, Btu/lb

57E-09x^3 + 6.0270695992598E-05x^2 + 0.1877364303x - 8.2289204269

0 600 800 1000 1200 1400 1600 1800

nthalpy of H2O, Btu/lb

E-08x^3 - 7.45719416969238E-05x^2 + 0.5097961458x - 38.8957868533

400 600 800 1000 1200 1400

Enthalpy of SO2, Btu/lb

6E-09x^3 - 3.18206525134094E-06x^2 + 0.1837477099x - 17.0730092956

0 800 1000 1200 1400 1600 1800 2000