The illustration shows a horizontal fire-tube boiler, with hot gas passing through tubes surrounded by water. Explore tube surface area and a hypothetical heat-to-steam calculation. The scale-loss assumptions are illustrative and do not predict a real boiler.
Worthington Boiler Interactive Calculator
Enter tube count, diameter, length, assumed heat flux and scale thickness. The calculator reports tube surface area and a steam-rate scenario using fixed heat and scale assumptions.
Equation Used
- Inputs are user-supplied scenario values.
- The displayed equations are evaluated directly.
- Entered efficiencies, shares, limits and factors are not predicted.
- The visual is schematic and not dimensional.
- Strength, fatigue, wear, variation, controls and safety compliance are omitted unless explicitly calculated.
How the Worthington Boiler Works
The tube bundle provides surface through which heat can pass from the gas to the surrounding water. The animation illustrates this arrangement; it does not solve combustion, circulation or steam generation.
What This Calculator Represents
The scale penalty, temperature indicator and fixed latent heat are assumptions, not validated performance curves. Actual steam production depends on pressure, feedwater enthalpy, combustion and heat transfer. No pressure rating, structural capacity, water-level limit or safe operating condition is calculated.
Calculation Method
Tube area = tube count × π × tube diameter × tube length. Clean steam-rate scenario = entered heat flux × area × 3600 / 2047, using a fixed latent heat of 2047 kJ/kg. The illustrative scale penalty is min(40%, 17.5 × scale thickness in mm / 1.5). The steam-rate scenario is reduced by that percentage. The stack-temperature-rise indicator is 100 × scale thickness in mm / 1.5.
How to Read the Result
Change one input at a time to compare its effect. Apply the assumptions stated beside the equations when interpreting each result.
Assumptions and Limits
The scale penalty, temperature indicator and fixed latent heat are assumptions, not validated performance curves. Actual steam production depends on pressure, feedwater enthalpy, combustion and heat transfer. No pressure rating, structural capacity, water-level limit or safe operating condition is calculated.
Frequently Asked Questions
Does the scale result predict the effect of a real deposit?
No. Deposit composition and heat-transfer conditions are not modeled. The displayed scale penalty and stack-temperature indicator are hypothetical comparisons.
Does the latent-heat value follow boiler pressure?
No. The calculation uses a fixed 2047 kJ/kg value. It does not calculate steam properties at a selected pressure.
Is the drawing suitable for manufacturing?
No. It is a schematic explanation and does not specify manufacturing dimensions, tolerances or materials.
Do these results establish safe operating limits?
No. Assess the complete equipment, loads, materials, controls and applicable requirements separately.
References
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