Industrial Heat Balance, Waste Heat Recovery and Steam Networks
Thermal engineering calculators for rotary dryers, kiln thermal expansion, HRSG boilers, LMTD heat exchangers, steam traps, blowdown and thermal expansion.
Applies first law thermodynamics and mass conservation to size industrial direct-fired rotary dryers. Accurately determines hourly water evaporation, dried product yield, thermal heat duty, exhaust flue gas flow, drum dimensions, and acid dew point condensation margin.
Calculate rotary dryer heat and mass balance, flue gas volume and drum sizingCalculates rotary kiln and ball mill shell axial thermal expansion Delta-L, pier support reactions, roller-tyre Hertz contact stress, and axial downhill gravity thrust based on Hertzian contact theory and thermal beam mechanics.
Calculate rotary kiln axial thermal expansion and trunnion Hertz contact stressFollow ASME PTC 4.4 and EN 12952 standards to calculate flue gas waste heat recovery heat balance, saturated/superheated steam generation (t/h), evaporator pinch point, stack exhaust temperature, and standard coal savings.
Calculate waste heat boiler HRSG steam evaporation and pinch pointFollowing ASME PTC 4 and BS 845 boiler test standards, determine excess air ratio λ, stack thermal losses, net thermal efficiency, and annual fuel energy savings from flue gas O2% and stack temperature.
Calculate boiler combustion efficiency and excess air ratioCompliant with ASME PTC 4 Fired Steam Generators Performance Test Codes, BS 845 steam systems norms, and ISO 50001 Energy Management standard. Enter rated steam capacity (t/h), boiler operating pressure (bar), feedwater dissolved solids (TDS ppm), and maximum allowable boiler water TDS (ppm) to accurately calculate continuous blowdown rate B (%) and blowdown mass flow (kg/h) via dissolved solids mass balance. Configure flash vessel operating pressure to evaluate flash steam recovery fraction, flash steam flow rate (kg/h), plate heat exchanger residual heat recovery (kW), annual energy savings (GJ), natural gas fuel cost savings ($), and CO2 emission reduction, complete with recommended blowdown control valve size DN.
Calculate boiler blowdown rate and flash steam recoveryCalculates condenser baseline air in-leakage, Dalton vapor carryover, design suction volumetric airflow, startup hogging evacuation capacity, and liquid ring vacuum pump motor sizing per HEI Standards for Steam Surface Condensers.
Calculate steam surface condenser HEI air inleakage and vacuum pump capacitySize steam traps and calculate condensate load per Spirax Sarco and Armstrong engineering standards. Enter steam pressure, heat duty, backpressure, safety factor, and trap type to compute condensate generation, differential pressure, rated discharge capacity, flash steam ratio, and piping guidelines.
Calculate steam trap sizing and condensate loadCalculate steam distribution main and flash condensate recovery line nominal diameter DN, actual steam velocity, total friction pressure drop, and drip leg spacing based on ASME B31.1 and Spirax Sarco steam dynamics.
Size steam and condensate pipeline diameter and pressure lossCompliant with Tubular Exchanger Manufacturers Association TEMA R/C/B standards and ASME Section VIII pressure vessel codes, enter hot fluid type, cold fluid type, hot inlet/outlet temperatures (°C), cold inlet/outlet temperatures (°C), hot mass flow rate (t/h), exchanger configuration (1-2 single-shell two-tube pass / pure counterflow / 1-4 four-pass), tube outer diameter (19.05 mm or 25.4 mm), and tube length (m). Based on Fourier heat transfer and enthalpy balance equations, calculate thermal duty Q (kW), cold fluid flow demand (t/h), logarithmic mean temperature difference LMTD, baffle F-Factor correction, effective heat transfer area (m²), total tube count in 30° triangular pitch, and recommended cylindrical shell inside diameter (mm).
Calculate shell and tube heat exchanger area and tube countCompliant with TEMA and AHRI 450 water-cooled condenser standards, enter evaporator cooling duty (kW), compressor electrical input power (kW), refrigerant condensing temperature (°C), and cooling water inlet/outlet temperatures (°C). Select tube profile (low-fin copper, smooth copper, or 316L stainless steel) and refrigerant (R134a, R410A, R404A, or R717) to compute total heat rejection duty (kW), cooling water flow rate (m³/h & GPM), log mean temperature difference LMTD (°C), required surface area (m²), tube bundle count, and recommended nozzle DN size.
Size shell and tube condenser water flow and areaCalculate water chiller shell and tube evaporator chilled water flow, LMTD, overall heat transfer coefficient U, required surface area, and tube bundle count based on AHRI 550/590 and TEMA R standards.
Size shell and tube evaporator heat transfer area and water flowCalculate PHE surface area, LMTD, and plate counts per Alfa Laval and SWEP standards. Enter hot/cold fluid temperatures, duty Q, overall heat transfer coefficient k, and fouling resistance to compute temperature differentials, effective area, chevron plate counts, and mass flow rates.
Calculate plate heat exchanger LMTD and areaComplying with API 661 and ISO 13706 petrochemical air-cooled exchanger standards, calculate heat duty, LMTD, extruded aluminum finned tube area, air-side static pressure drop, and axial fan airflow power.
Size air-cooled heat exchanger tube bundle and axial fanCompliant with ASTM C680 Thermal Insulation Standards, ISO 12241 Thermal Insulation for Building Equipment and Industrial Installations, and GB/T 4272 technical general principles. Enter pipe nominal size DN, fluid operating temperature (°C), ambient air temperature (°C), ambient wind speed (m/s), insulation material (rockwool/glasswool/calcium silicate/aerogel/polyurethane), and designed insulation thickness (mm). Utilizes cylindrical logarithmic conduction coupled with exterior convection-radiation surface heat transfer to calculate outer cladding surface temperature (°C), heat loss per meter qL (W/m), total pipeline heat loss (kW), thermal efficiency (%), and personnel burn protection compliance, with comparison against bare pipes for annual fuel and dollar savings.
Calculate pipe insulation thickness and heat lossCalculate straight run pipe thermal expansion, EJMA recommended bellows stroke, cold pull pre-stretch, internal pressure thrust Fp, spring reaction, friction and anchor loads per EJMA and EN 14917. Inputs pipe length, material, operating/ambient temperatures, DN size, and design pressure.
Calculate pipe thermal expansion and bellows strokeEvaluate exhaust flue gas steam potential using the Waste Heat Boiler (HRSG) tool, size distribution piping with the Steam Condensate Pipe Calculator, and prevent water hammer using the Steam Trap Sizing tool.
Liquid-liquid duties favor Plate Heat Exchangers for high heat transfer coefficients and compact footprint; high-pressure and phase-change duties require Shell & Tube exchangers or Evaporators sized via corrected LMTD.
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Already have an account? Open your workspace →Under operating skin temperatures of 300-450 deg C, kiln shells expand tens of millimeters axially. Anchored at the thrust tire pier, expansion must slide freely over trunnion rollers verified against Hertz contact stress limits.
Insufficient air causes incomplete combustion losses and CO formation, while excess air introduces massive cold ballast volumes that spike dry flue gas stack heat loss. The tool maps oxygen assays to peak thermodynamic efficiency.
Pure counter-flow offers the maximum thermodynamic driving force. Multipass shell-and-tube units combine counter and parallel flow; if the geometry correction factor Ft drops below 0.8, severe thermal pinching and area explosion occur.
