+ All Categories
Home > Documents > Heat Loss Calculations and Heater Selection Air and Gas

Heat Loss Calculations and Heater Selection Air and Gas

Date post: 04-Jun-2018
Category:
Upload: tgimran
View: 220 times
Download: 0 times
Share this document with a friend

of 7

Transcript
  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    1/7

    Technical

    I-16

    Low Temperature Heater Selection A

    ypical heater selection for the previousexample might be a type CAB heater withfinstrip elements. Available 15 kW stockheaters include a CAB-1511 with chromesteel elements or a CAB-152 with iron sheathelements, both rated at 26 W/in2. From theproduct page, the face area of a 15 kW CABheater is 1.19 ft2:

    Velocity (fps) = 450 ACFM =6.3 fps 1.19 ft2x 60 sec.

    Estima ting Sheath Operating Tempe rature The maximum operating sheath tempera-tures for finstrips are 750F for iron and 950Ffor chrome steel. Using graph G-107S for iron

    sheath finstrips, a 150F outlet temperatureand a watt density of 26 W/in2requires avelocity in excess of 9 ft/sec to keep sheathtemperatures below maximum permissiblelevels. With only 6.3 fps in the application, aCAB-152 heater with iron sheath elements isnot suitable. Using graph G-108S for chromesheath finstrips, approximately 3 ft/sec. airvelocity results in a maximum of 900F sheathtemperature. Since this is lower than theactual velocity of 6.3 fps, a CAB-1511 withchrome steel finstrips is an acceptable heaterselection. (Use graphs G-100S, G-105S,G-106S and G-132S for air heating with regularstrip and finstrip heaters.)

    High Temperature Heater Selection TypeTDH and ADHT heaters with tubular elementsare recommended for high temperature ap-plications. Steel sheath tubulars may be usedwhere the sheath temperature will not exceed750F. Finned tubulars can be used in applica-tions up to a maximum sheath temperature of1050F. INCOLOYsheath tubulars may beused for applications with sheath temperaturesup to 1600F. Allowable watt densities for tu-bulars and finned tubulars can be determinedby reference to graphs G-136S and G-151-1through G-156-1.

    Estima ting Sheath Operating Tempe rature

    Select a heater for a high temperatureapplication with an inlet air temperature of975F and a velocity of 4 ft/sec. Since thetemperature is above 750F, an INCOLOYsheath must be used. Using graph G-152-1the allowable watt density is 11 W/in2forsheath temperatures of 1200F or 22 W/in2fortemperatures of 1400F. In this application,a stock ADHT heater2with a standard wattdensity of 20 W/in2can be used.

    Note 2 Special ADHT duct heaters, deratedto the required watt density, can be suppliedwhen element ratings less than the standard20 W/in2are needed.

    Technical InformationDetermining Energy Requirements - Air & Gas HeatingAir & Gas Heating

    Air and gas heating applications can be dividedinto two conditions, air or gas at normalatmospheric pressure and air or gas under lowto high pressure. Applications at atmosphericpressure include process air, re-circulation andoven heating using duct or high temperatureinsert air heaters. Pressurized applicationsinclude pressurized duct heating and otherprocesses using high pressures and circula-tion heaters. Procedures for determining heatenergy requirements for either condition aresimilar except the density of the compressedgas and the mass velocity of the flow must beconsidered in pressurized applications. Selec-tion of equipment in both conditions is critical

    due to potentially high sheath temperaturesthat may occur.

    Determi ni ng Heat Requi rements for

    Atmospheri c Pressure Gas Heating

    The following formulas can be used to deter-mine kW required to heat air or gas:

    Equation A

    kW =CFM x lbs/ft3x 60 min x CpxT x SF3412 Btu/kW

    Where:CFM =Volume in cubic feet per minute

    Lbs/ft3

    = Density of air or gas at initial temperatureCp=Specific heat of air or gas at initial

    temperatureT=Temperature rise in FSF =Suggested Safety Factor

    For quick estimates of air heating require-ments for inlet temperatures up to 120F, thefollowing formula can be used.

    kW =SCFM x Tx 1.2 SF 3,000

    Where:SCFM =Volume of air in cubic feet per minute

    at standard conditions1(70 F atstandard atmospheric pressure)

    3,000 =Conversion factor for units, time andBtu/lb/F

    1.2 SF =Suggested safety factor of 20%

    Graph G-176S When airflow (ft3/min) andtemperature rise are known, kW requirementscan be read directly from graph G-176S.Note Safety factors are not included.

    Note 1 Based on an average density of 0.08lbs/ft3and a specific heat of 0.24 Btu/lb/F. Forgreater accuracy, use Equation A and valuesfrom the Properties of Air Chart in this section.

    Process Air Hea ting Calculation Example A drying process requires heating 450ACFM of air1from 70F to 150F. The existingduct- work measures 2 ft wide by 1 ft high andis insulated (negligible losses). To find heatingcapacity required, use Equation A:

    kW =450 ACFM x 0.08 x 60 x 0.24 x 80 x 1.2 SF 3412 Btu/kW

    kW =14.58

    Heater Selection

    Finstrip(CAB heaters), Fintube(DH heaters)or tubular elements (TDH, ADH and ADHTheaters) will all work satisfactorily in lowtemperature applications. Finstrips or finnedtubular elements are usually the most cost

    effective. Tubular elements are recommendedfor high temperatures. Once the desired typeof heating element is selected, the next stepis to calculate the air velocity and estimatesheath temperatures to verify that maximumoperating temperatures are not exceeded.Calculate the air velocity over the elementsand refer to allowable watt density graphs forestimated operating temperature.

    Calculating Air Velocity Air velocity can becalculated from the following formula:

    Velocity (fps) = Flow (ACFM) Area of Heater (ft2) x 60 sec.

    Graph G-176SAir Heating

    600

    F

    Rise

    550

    F

    Rise

    500F

    Rise

    450

    FRise

    400F

    Ris

    e

    350F

    Ris

    e

    300

    FRise

    250F

    Rise

    200

    FRise

    150F

    Rise

    100FR

    ise

    75FRise

    50FRise

    Based on Air Density of0.08 Lbs/Ft3 and a SpecificHeat of 0. 237 Btu/Lb/F

    0

    100 300 500 700 900 1100

    Air Volume (Cubic Feet Per Mi nute)

    17 0

    15 0

    13 0

    11 0

    90

    70

    50

    30

    10

    10

    Kilowatts

    Chromalox Technical Documents

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    2/7

    Technical

    I-17

    Air & Gas Heating wi th Str ip and

    Finstrip

    HeatersCustom De signs Strip and finstrip heatersare frequently mounted in banks by the enduser. Graphs G-105S and G-106S on this pagecan be used in conjunction with other graphsto determine maximum watt density forvirtually any custom design low temperatureheating application.

    Graph G-105S Strip HeatersTo use this graph:

    1. Selectmaximum desired outlet airtemperature on line A.

    2. Chooseeither chrome steel sheath or rustresisting iron sheath (points B) on thebasis of operating conditions.

    3. Selectminimum anticipated air velocityon B. Note natural circulation is equalto approximately one foot per second.

    4. Draw a straight line through points A and

    B to a reading on C. Read maximumallowable watts per square inch from line C.

    5. Selectdesired length heater with anequivalent watt density or less from theproduct page in this catalog.

    Graph G-106S FinstripHeatersTo use this graph:

    1. Selectmaximum desired outlet airtemperature on line D.

    2. Chooseeither chrome steel sheath or rustresisting iron sheath (points E) on thebasis of operating conditions.

    3. Selectminimum anticipated air velocityon B. Note natural circulation is equalto approximately one foot per second.

    4. Drawa straight line through points D andE to a reading on F. Read maximum

    allowable watts per square inch fromline F.

    5. Select desired length heater with anequivalent watt density or less from theproduct page in this catalog.

    Recomm endations for Custom Installations Strip heaters should always be mountedsideways in the ductwork with the narrowedges facing the air stream. The total numberof elements installed should be divisible by 3so that the heater load will be balanced on athree phase circuit.

    Technical InformationAllo wab le Watt Den sity & Heater Selec tio n - Air He ating

    Graph G-105S Str i p Heater Ai r Heati ng-Selecti on of Watt D ensi ty

    Graph G-106S Finstr ipHeater Air Heati ng-Selecti on of Watt D ensi ty

    W/In2

    20

    15

    10

    5

    0A B C

    OutletAirTemperature(F)

    70 0

    60 0

    50 0

    40 0

    30 0

    20 0

    10 0

    0

    16

    9 41

    169

    4

    1

    AirVelocity(F.P.S

    .)

    AirVelocity(F.P.S.)Iron Sheath

    Chrome Steel Sheath

    W/In2

    25

    20

    15

    10

    5D E F

    Outl

    etAirTemperature(F)

    70 0

    60 0

    50 0

    40 0

    30 0

    20 0

    10 0

    0

    169

    4

    1

    AirV

    elocity(F.P.S.)Iron Sheath

    Chrome Steel Sheath

    30

    16

    9

    4

    1

    AirV

    elocity(F.P.S.)

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    3/7

    Technical

    I-18

    1F.P.SorFreeAir

    4F.P.S.

    9F. P.S.

    16F.P.S. DistributedAirVelocity

    4F.P.S.

    9F.P.S.

    16F.P.S. DistributedAir

    Velocity

    1F. P.S. orFreeAir

    1F.P.S. orFreeAir

    4F.P.S.

    9F.P.S.

    16F. P.S. DistributedAirVelocity

    16

    F.P.

    S.

    9F.P.S.

    4F.P.S

    .

    1F.P.

    S.

    Still

    Air

    Graph G-100S Str ip Heater (Chrome) Ai r Heati ng

    Allowable Watt Densit ies for 1000F Sheath Temp.

    4F. P. S.

    9 F.P.S.

    1F.P.S. orFreeAir

    16F.P.S. DistributedAirVelocity

    26

    24

    22

    20

    18

    16

    14

    12

    10

    8

    6

    4

    2

    0

    WattsPerSquareInch(W/In2)

    0 100 200 300 400 500 600 700 800 900 1000Outlet Air Temperature (F)

    When Calculating Heater Capacity, Use theMaxim um Outlet Temperature and the LowestAir Velocity. For Close Grouping of Heaters,

    Use 80% of the Calculated Value.

    NotesStrip Heaters

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    4/7

    Technical

    I-19

    800F

    1000F

    600F

    640F

    400F

    200F

    1200F

    1000F

    800F

    640F

    600F400F

    200F

    200F

    400F

    600F

    700F

    800F

    1000F

    1200F

    1400F

    200F

    400F

    600F

    800F

    840F

    1200F1400F

    1000F

    200F

    400F

    800F

    840F

    1000F

    1200F

    1400F

    600F

    400F200

    F

    600F

    800F

    910F

    1000F

    1200F

    1400F

    Graph G-154-1 Fint ube& Tubular H eaters

    Sheath Temperatures wi th 16 FPS Distr ibuted

    Air Veloci ty

    80706050403020

    100

    W

    attDensityinW/In2o

    fEffectiveLength

    FinnedTubularUnits

    0 200 400 600 800 1000 1200 1400

    Outlet Air Temperature (F)

    TubularUnits

    Limit for FinnedTubular for Normal

    Life Expectancy

    40

    35

    30

    25

    20

    15

    10

    5

    Graph G-155-1 Fint ube& Tubular H eaters

    Sheath Temperatures wi th 25 FPS Distr ibuted

    Air Veloci ty

    8070605040302010

    0

    WattDensityinW

    /In2o

    fEffectiveLength

    FinnedT

    ubularUnits

    0 200 400 600 800 1000 1200 1400

    Outlet Air Temperature (F)

    T u b u

    l a r U n i t s

    Limit for FinnedTubular for Normal

    Life Expectancy

    40

    35

    30

    25

    20

    15

    10

    5

    Graph G-156-1 Fint ube& Tubular H eaters

    Sheath Temperatures wi th 36 FPS Distr ibuted

    Air Veloci ty

    8070605040302010

    0WattDensityinW/In2o

    fEffectiveL

    ength

    FinnedTubularUnits

    0 200 400 600 800 1000 1200 1400

    Outlet Air Temperature (F)

    TubularUnits

    40

    35

    30

    25

    20

    15

    10

    5

    Limit for FinnedTubular for Normal

    Life Expectancy

    0 200 400 600 800 1000 1200 1400

    Technical InformationAllo wab le Watt Den sity & Heater Selec tio n - Air He ating

    Graph G-151-1 Fint ube& Tubular Heaters

    Sheath Temperatures wi th 1 FPS Distr ibuted

    Air Veloci ty

    80706050403020

    100

    W

    attDensityinW/In2o

    fEffectiveLength

    FinnedTubularUnits

    0 200 400 600 800 1000 1200 1400

    Outlet Air Temperature (F)

    TubularUnits

    40

    35

    30

    25

    20

    15

    10

    5

    Limit for FinnedTubular for Normal

    Life Expectancy

    Graph G-152-1 Fint ube& Tubular Heaters Sheath

    Temperatures wi th 4 FPS D istr ibuted Air Veloci ty

    8070

    605040302010

    0

    WattDensityinW/In2o

    fEffectiveLength

    FinnedTubularUnits

    Outlet Air Temperature (F)

    TubularUnits

    40

    35

    30

    25

    20

    15

    10

    5

    Limit for FinnedTubular for Normal

    Life Expectancy

    Graph G-153-1 Fint ube& Tubular H eaters

    Sheath Temperatures wi th 9 FPS Distr ibuted

    Air Veloci ty

    8070605040302010

    0

    WattDensityinW/In2o

    fEffec

    tiveLength

    FinnedTubularUnits

    0 200 400 600 800 1000 1200 1400

    Outlet Air Temperature (F)

    TubularUnits

    40

    35

    30

    25

    20

    15

    10

    5

    Limit for FinnedTubular for Normal

    Life Expectancy

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    5/7

    Technical

    I-20

    Air & Gas Heati ng Cryogeni cs

    Industrial gases are usually stored in a liquidstate with heat being added to vaporize andboil off the gas as usage requires. Generalheat equations apply except that pipes, tubesand vessels containing the cryogenic fluid orgas frequently represent a heat source ratherthan a heat loss. If the size and materials ofthe tanks or vessels are known, then heatcalculations for the temperature rise can beperformed as in standard vessel heating orboiler problems. The following example istypical of a cryogenic heating application.

    Problem Vaporize and preheat 30,000SCFH of liquid Nitrogen (N

    2) from -345F to

    70F at atmospheric conditions. The proper-ties of N2from Cryogenic Gas Tables are:

    Boiling point, -320F Specific heat Btu/lb/F =0.474 (liq.), 0.248 (gas) Latent heat of vapor-ization =85.7 Btu/lb Atm. density of N

    2at 32F

    =0.0784 lb/ft3.

    Solution Amount of liquid N2to be vaporized

    30,000 SCFH x 0.0784 lb/ft3=2,352 lbs/hr

    1. Raiseliquid from -345F to -320F (boilingpoint) T=25F.

    kW =Wt xCpxTx SF 3412 Btu/kW

    Where:Wt =Weight of material in lbsCp=Specific heat of the liquid N

    2T=Temperature rise in FSF =Suggested safety factor of 20%

    kW =2,352 lbs x 0.474 x 25 x 1.2 =9.8 kW 3412 Btu/kW

    2. Vaporizethe liquid N2

    kW =2,352 lbs x 85.7 x 1.2 =70.9 kW 3412 Btu/kW

    3. Raisethe temperature of the N2from

    boiling point -320F to 70F T=390F.

    kW =2,352 lbs x 0.248 x 390 x 1.2 =80 kW 3412 Btu/kW

    Total kW/hr required =9.8 +70.9 +80 =169.7

    Equipment Recommendations Generally,cryogenic applications utilize both a vaporizerunit and a gas preheater. High watt densityheaters immersed in the cryogenic fluid canbe used for the vaporizer. Standard circulationheaters and watt densities are recommendedfor gas preheating. Protect the heater termi-nals from frost and moisture with elementseals and liquid tight terminal covers.

    45Max.

    30Max.

    30Max.

    45Max.

    Air Flow

    4. TotalkW =2.86 +0.47 +0.70 =4.03 kW

    5. For Oven Applications, add 30% to coverdoor losses and other contingencies. kWhrequired (including safety factor) is

    kWh =kW =4.03 kW =5.37 kW x 1.3 =6.98 kW t 0.75 hrs

    Equipment Recommendations Severalprocess air heaters, including strip heaters, fin-strips, bare tubulars or type OV oven heaters,are suitable for oven heating applications.

    Pressure Drop for Process Air Heaters

    The pressure drop through TDH and ADHprocess air heaters with bare tubular or finned

    tubular elements, CAB heaters with finstripelements, and ADH and DH air heaters withfinned tubular elements will vary considerablydepending on product design and construc-tion. Chromalox sales engineering can providepressure drop calculations for virtually anyduct heater (or circulation heater) application.Graphs G-112S3, G-189S1, G-227-2, andG-227ADH on the following page provideguidance for estimating the pressure dropfor many Chromalox process air heaters1.Graph G-189S1 can be used for most finnedtubular applications providing the elements aremounted in a three or six row configuration.

    Transitions in Ducts In some air distributionsystems, the duct heater may be considerablylarger or smaller than the associated ductwork.The duct heater can be adapted to different sizeductwork by installing a sheet metal transition.The transition must be designed so that theslope on the upstream side of the equipment islimited to 30 (see below). On the leaving side,the slope should not be more than 45.

    Note 1 Contact the factory for pressuredrop calculations for duct heaters mountedlengthwise or in series and for GCH gas circula-tion heaters. These applications require specialcalculations for proper application and air

    handler sizing.

    Technical InformationDetermining Energy Requirements - Air & Gas Heating

    Ma terial Recommendations Ordinarycarbon steel is subject to brittle fractureat temperatures below -20F and is gener-ally not recommended. Stainless steel, highnickel bearing alloys or aluminum alloys maybe used. Use Teflonfor gaskets asTeflonremains pliable at low temperatures.

    Air & Gas Heati ng Batch Ovens

    Most oven applications consist of heating workproduct inside an insulated enclosure. Heatloss calculations involve the determination ofthe heat requirements to heat the enclosureand work product using heated air circulatedby natural or forced convection. Any make upor ventilation air must also be considered. Thefollowing example outlines the calculation of

    the heat required for a typical oven heatingapplication.

    Problem An oven with inside dimensions of2 ft H x 3 ft W x 4 ft D is maintained at 350F.

    The oven has sheet steel walls with 2 inches ofinsulation and is ventilated with 400 cfh (ft3/hr)of 70F air which exhausts to the outside toremove fumes. The oven is charged with 250lbs of coated steel parts on a steel tray weigh-ing 40 lbs. The process requires the parts to beheated from 70F to 350F in 3/4 hour.

    Weight of steel =290 lbsSpecific heat of steel 0.12 Btu/lb/FWeight of air =0.080 lbs/ft3at 70FSpecific heat of air =0.24 Btu/lb/FTemperature rise =280FSurface losses with 2 inch insulation =18 W/ft2/hr at 280F temperature difference (GraphG-126S)Surface area of oven =52 ft2Time =3/4 hr (0.75)Airflow rate =400 ft3/hr

    Solution

    1. CalculatekWh required to heat metal.

    kW =290 lbs x 0.12 Btu/lb/F x 280F =2.86 kW 3412 Btu/kW

    2. CalculatekWh required to heat ventilated air

    kW=400 cfh x 0.080 Lbs x 0.24 Cpx 280 T x 0.75 t=0.47kW3412 Btu/kW

    Where:cfh =Air flow rate (400)Lbs/ft3=Density of air (0.080)Cp=Specific heat of air (0.24)T=Temperature rise (280)=Time in hours (0.75)

    3. Calculatesurface losses. Since the oven isalready at temperature, losses are at fullvalue.

    kW =18 W/ft2/hr x 52 ft2area x 0.75 hr=0.70 kW 1,000 W/kW

    Recommended D imensions

    for D uct Transi ti ons

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    6/7

    Technical

    I-21

    ADHT

    M=9.5

    "ADHM

    =18.375

    "

    ADHM=9

    .5"

    ADHTAir

    Heaters

    ADH

    AirH

    eater

    s

    Pr

    essureDropI

    nchesofWater

    (Psi=

    InchesofWaterx0.0

    361)

    2. 0

    1. 0

    0. 7

    0. 5

    0. 3

    0. 1

    0.07

    0.05

    0.03

    0.01

    Thre

    eRow

    sC

    rosswis

    e

    AnyR

    ati

    ng

    Lengthwis

    eT

    DH

    -24

    Length

    wis

    eT

    DH

    -18

    Leng

    thwis

    eTDH

    -12

    Lengthw

    iseTDH-6

    TDH Mounted Lengthwisein Duct

    AirFlow

    TDH-6TDH-12TDH-18TDH-24TDH Mounted Crosswisein DuctAirFlow

    0.20

    0.18

    0.16

    0.14

    0.12

    0.10

    0.08

    0.06

    0.04

    0.02

    0

    Thre

    eRows

    M=9.5"Six

    Rows

    M=18.

    375"

    0. 7

    0. 5

    0. 3

    0. 1

    0.07

    0.05

    0.03

    0.01

    PressureDropI

    nchesofWater

    (Psi=

    InchesofWaterx0.0

    361)

    Graph G-189S1 Pressure Drop Vs. Veloci ty

    FintubeElements and Ai r Heaters

    0 5 fps 10 fps 15 fps 20 fps 25 fps 30 fps 35 fps 0 300 fpm 600 fpm 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

    Air Velocity (Std. Air)

    Note Contact factory for pressure drop calculations for finned tubular element airheaters mounted lengthwise in duct.

    PressureDropI

    nchesofWater

    (Psi=

    InchesofWaterx0.0

    361)

    Graph G-227ADH Pressure Drop Vs. Veloci ty ADH

    and ADHT Tubular Element Ai r Heaters

    0 5 fps 10 fps 15 fps 20 fps 25 fps 30 fps 35 fps 0 300 fpm 600 fpm 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

    Air Velocity (Std. Air)

    ADH or ADHT MountedCrosswise i n Duct

    AirFlow

    Note Contact factory for pressure drop calculations for ADH/ADHT air heatersmounted lengthwise in duct and ADHT heaters where M is greater than 9.5"

    Technical InformationDeter m ining Pressur e Dr op - Air and Gas Heat ing

    600

    500

    400

    300

    200

    100

    0

    Approximate

    TerminalBoxTemperature(F)

    Graph ADHTB ADH/ADHT Terminal Box Tempera-

    tures Field Wi r ing Selecti on Guide

    0 200 400 600 800 1000 1200

    Outlet Air Temperature (F)

    Data only valid for ADH or ADHT air heatersinstalled in bottom or sides of duct

    Graph G-112S3 Pressure Drop Vs. Veloci ty Finstr ip

    and CAB Ai r Heaters

    1. 0

    0. 5

    0. 3

    0. 1

    0.07

    0.05

    0.03

    0.01

    0.007

    0.005

    0.003

    0.001

    0 5 fps 10 fps 15 fps 20 fps 25 fps 30 fps 35 fps 0 300 fpm 600 fpm 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

    Air Velocity (Std. Air)

    Based on 1-5/8" spacingand 4.7 fins per linear i nch

    Triple RowDouble RowSingle Row

    PressureDropI

    nchesofWater

    (Psi=

    InchesofWaterx0.0

    361)

    0 5 fps 10 fps 15 fps 20 fps 25 fps 30 fps 35 fps

    0 300 fpm 600 fpm 900 fpm 1200 fpm 1500 fpm 1800 fpm 2100 fpm

    Air Velocity (Std. Air)

    Finned Tubulars MountedCrosswise in Duct

    AirFlow

    Graph G-227-2 Pressure Drop Vs. Veloci ty

    TDH Tubular Element Air Heaters

  • 8/13/2019 Heat Loss Calculations and Heater Selection Air and Gas

    7/7

    Technical

    I-22

    Technical InformationDetermining Energy Requirements - Air & Gas Heating

    Air & Gas Heating wi th

    Cir culat ion Heaters

    To calculate the heat energy requirements forheating compressed air or gases, the first stepis to determine the flow rate in pounds perhour. If the density of the air or gas under theactual pressure is known, the kW require-ments can be calculated directly. The followingexample illustrates this procedure.

    Example Heat 20 ACFM of air at 30 psig from60F to 210F. From the Properties of Air Chart,the density of air at 60F and 30 psig is 0.232lb/ft3with a specific heat of 0.24 Btu/lb/F. ThekW required can be calculated from the formula:

    kW =ACFM x lbs/ft3x 60 min x CpxT x SF3412 Btu/kW

    Where:ACFM =Actual flow in ft3/min at inlet

    temperature and gauge pressure (psig)Lbs/ft3= Actual density at inlet temperature

    and gauge pressure (psig)Cp=Specific heat of air or gas at inlet

    temperature and gauge pressure (psig)T=Temperature rise in FSF =Suggested Safety Factor

    kW =20 x 0.232 x 60 x 0.24 x (210 - 60F) x 1.2

    3412kW =278.4 lbs/hr x 24 x 150 x 1.2 =3.52 kW 3412

    When the density and specific heat of a gas ata specific temperature and pressure are un-known, the actual flow rate can be con-verted to a known pressure and temperatureusing the physical laws of gases.

    Example Heat 45 ACFM of Nitrogen (N2) at

    35 psig from 50F to 300F. From the Physicaland Thermodynamic Properties of CommonGases Chart, the density of Nitrogen at 70F is

    0.073 lb/ft3

    with a specific heat of 0.2438Btu/lb/F. Convert 45 ACFM at 35 psig and50F to SCFM of Nitrogen at 70F using thefollowing formula:

    SCFM =ACFM x Actual psia x Standard T 14.7 psia Actual T

    SCFM =Std. ft3/min at 14.7 psia and 70FACFM =Actual flow in ft3/min at inlet

    temperature and gauge pressure (psig)Actual psia =gauge pressure in lb/in2+14.7 psia14.7 psia =absolute pressure in lb/in2

    T =Rankine (F +460)

    SCFM =45 x (35 +14.7) x (70 +460) 14.7 psia (50 +460)

    SFCM =158.1 ft3/min

    Using the calculated SCFM in place of ACFM inequation A, the kW required is:

    kW =158.1 x 0.073 x 60 x 0.2438 x (300 - 50) x 1.2 3412kW =14.8 kW

    Determining Maximum Sheath

    & Chamber Temperatures

    When heating air or gases in insulated pipechambers or circulation heaters, the pipe wall

    temperature will normally exceed the outletgas temperature. Excessively high wall and/orsheath temperatures can create an unsafe ordangerous condition. Maximum sheath andchamber temperatures can be estimated usingthe mass velocity of the gas and Graph G-237.In the above air heating example, assume a4.5 kW Series 3 heater rated 23 W/in2hasbeen selected. From Chart 236, the free crosssectional area of a Series 3 (3 inch) heater is0.044 ft2. Calculate mass velocity from thefollowing equation:

    Mass Velocity =Flow lbs/hr 3,600 sec

    (lbs/ft

    2

    /sec) Free area ft

    2

    hrMass Velocity =(278 lbs/hr)3,600 sec 0.044 ft2 hr

    Mass Velocity =1.75 lbs/ft2/sec

    On Graph G-237, locate the mass veloc-ity (1.75) on the horizontal axis. From thatpoint, locate a 23 W/in2curve. Read acrossto the vertical axis (sheath temperature riseabove outlet temperature) to 880F. Adding880F +210F (outlet temp.) =1090F sheathtemperature. Averaging the sheath and outlettemperatures (1090F +210F 2), yields amaximum chamber temperature of 650F.

    Since the maximum chamber wall temperatureis less than 750F, a stock GCH heater with acarbon steel vessel and INCOLOYelementsrated 23 W/in2can be used.

    3W/In2

    6W/In2

    9W/In2

    12W/In2

    15W/In2

    18W/In2

    23W

    /In2

    28W/In2

    30W/In2

    20W/In2

    25W/In2

    Graph G-237 Sheath Temperature Vs. Mass Veloci ty

    Maximum

    SheathTem

    peratureRise

    AboveOutletGasTemp.

    (F)

    0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

    1400

    1200

    1000

    800

    600

    400

    0

    200

    Mass Vel ocity (Lbs/Ft2/Sec)

    NotRecommended

    Chart 236 Circulati on Heaters

    Free Internal Cross Sectional AreaPipe BodyNom. IPS

    (Std.)

    TotalArea(Ft 2)

    FreeArea(Ft2)

    No.0.475"

    Elements

    2

    3

    0.023

    0.051

    0.018

    0.044

    2

    3

    5

    8

    0.139

    0.355

    0.124

    0.303

    6

    18

    10

    12

    0.566

    0.785

    0.481

    0.696

    27

    36

    14

    16

    18

    0.957

    1.268

    1.622

    0.847

    1.091

    1.357

    45

    72

    108


Recommended