Download - Heat Exchanger

Appendix F -63

Production of 100,000 MTA Hydrogen

F.10 SIZING AND COSTING FOR HEAT EXCHANGER

Heat Exchanger, X-5Heat exchanger type 2 shell and 4 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side NgShell side SteamHeat duty (kW) 11666.670a) Equipment sizing

shell tubeStream Steam NG

617.60 330.86

579.55 607.25

344.10306.4057.71

334.10

R = ( eqn. 12.6 )= 0.138

S= ( eqn. 12.7 )= 0.964

Ft can be obtained from fig 12.19 ( vol. 6 ),

0.8900

Tin (K)

Tout (K)

T1(oC) = T2(oC) = t1(oC) = t2(oC) =

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =

T1 = inlet temperature to shellT2 = outlet temperature from shellt1 = inlet temperature to tubet2 = outlet temperature from tube

T2T1

t2

t1

Appendix F -64


( eqn. 12.4 )

74.9681

Therefore, the actual temperature difference is

66.7216

Assumption: (Table 12.1, 'Chem. Eng', Vol. 6)

U 454.264

Provisional area of heat exchanger, A can be obtained trough the formulae,

Provisional area, A 384.92164143.2620

b) Tube rating ( App.5.-2, Tranport Processes )Material Carbon steelBWG number 18

2.4419.0516.56

Material Thermal Conductivity ( W/m.K ) 16.3

0.1460

1.5718

Number of tube, Nt

2636

Tube pitch is the distance between tube centres and formulated as

DTlm can be calculated from the equation,

DTlm =

FtDTlm =

W/(C.m2)

m2

ft2

Length of tube Lt (m)Outer diameter, Dto (mm)Inner diameter, Dti (mm)

Heat transfer area of a tube, At

Area of one tube, At (m2)

(ft2)

Number of tube, Nt

ΔT lm=(T 1−t 2 )−(T2−t1 )

ln(T1−t 2 )(T2−t 1 )

Q=UA ΔTalignl ¿ lm ¿¿¿

A t=Lt πDalignl ¿ to ¿ ¿¿

A=Q

UΔT lm

N t=AA t

Appendix F -65


23.8125

From Table 12.4, Chemical Engineering , Vol. 6 ( 1st Edition )

0.249( 2 passes ) n 2.207

( eqn. 12.3b )

1269.1683

From Chemical Engineering , Vol. 6 (figure 12.10)Shell bundle clearance (mm) 72

For Split-ring floating head, Ds = Db + shell bundle clearance

1.3412

c) Tube side coefficient

Mean temperature (K)

Mean temperature (K) 469.0550

215.4105

659

0.1420

Tube pitch, Pt (mm)

Triangular pitch K1

The bundle diameter, Db

Bundle diameter, Db (mm)

Shell internal diameter, Ds (m)

Tmean =(Tc.in +Tc,out)/2

Tube cross-sectional area, At


Tube cross-sectional area, At mm2

Tube per pass = Nt

Total flow area (m2), AT


Pt=1 . 25×D to

Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -66


Mass flow rate (inside tube), m 10.1183 kg/s

71.2794

Physical properties of the tube side fluidPhysical properties of Water

1015.2654

7.94E-044.17172369041347 kJ/kg.K

0.09488828968 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr

linear velocity, u (m/s) 0.0702Reynold number, Re 1486.072Prandtl number, Pr 34.9211

147.3430

From figure 12.23, Chemical Engineering, Vol. 6

0.0035

( eqn. 12.15 )

96.26738( assuming viscosity of the fluid is identical at the wall and of the bulk fluid )

d) Tube side pressure drop

From figure 12.24 'Chemical Engineering'. Vol. 6

Fluid velocity, nf

mass velocity, nf kg/m2.s

water density, rt kg/m3

Viscosity of water, mtL Ns/m2

Heat capacity, Ctp

Thermal conductivity, ktf

L/Dti

Heat transfer factor, jh

Tube side heat transfer coefficient, hi

Tube side heat transfer coefficient, hi W/m2.C

v f=m / AT

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f

hi=k f jh RePr0 . 33

Dti ( μμw )

0 .14

Appendix F -67


0.0030

( eqn. 12.20 )where m = 0.25 for laminar flow, Re<2100 m = 0.14 for turbulent flow, Re>2100

0.0302 kPa (acceptable)

e) Shell side coefficient1.3412 m Baffle

diameter

1.2071 mBaffle Diameter 1.3396 m

23.8125 mm

( eqn. 12.21 )

0.3238

204583 kg/hr

175.5206

( eqn. 12.23 )

friction factor, jf

Tube side pressure drop, DPt

Np = number of tube side passes

Tube side pressure drop,

DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As

Cross flow area, As m2

Shell side mass velocity, Gs

Mass flow (inside shell), Ws

Shell side mass velocity, Gs kg/s.m2

Shell side equivalent diameter, De

ΔPs=N p [ 8 jf ( L/ Dti )(μ

μw)−m+2. 5 ]

ρus2

2

Baffle Diameter=D s−0 . 0016

Baffle Spacing , lB=0 .9∗Ds

A s=( p t−Dto )D s lB

pt

sss AwG /

De=1 .1Dto

( pz2−0.971 Dto

2 )

Appendix F -68


13.5265 mm

Mean temperature (C)

Mean temperature (C) 598.5750

Physical properties of shell fluid (light hydrocarbon)

Physical properties

3.9318

3.3589E-052.60682510137189 kJ/kg.K

0.1718 W/m.K

Reynold number, Re( eqn. 12.24 )

Reynold number, Re 2989.010Prandtl number, Pr 0.5096

Selecting 15% for baffle cutFrom figure 12.29, Chemical Engineering, Vol. 6

0.0100

( eqn. 12.25 )

303.966

f) Shell side pressure drop

44.6413 m/s


0.0800


Tmean = (Tshell.in +Tshell.out)/2

Fluid density, rs kg/m3

Viscosity, msL Ns/m2

Heat capacity, Csp

Thermal conductivity, ksf

Heat Transfer Factor, jh

Shell side heat transfer coefficient, hs

Shell side heat transfer coefficient, hs W/m2.C

Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -69


( eqn. 12.26 )

Shell side presure drop, 26979084.0816 Pa (acceptable)

26979.0841 kPa

g) Overall Coefficient

303.966

96.26738

5000

5500

16.30.01656

0.01905

Overall heat transfer coefficient can be calculated by using the formula

( eqn. 12.1 )Therefore,

0.0157305122079733

63.5707208245343

1

Shell side presure drop, DPs

DPs

Outside fluid film coefficient, hs, W/m2.oC

Inside fluid film coefficient, hi, W/m2.oC

Outside dirt coefficient (fouling factor), hod, W/m2.oC

Inside dirt coefficient, hid, W/m2.oC (from Table 12.2, vol. Six )

Thermal conductivity of the tube wall material, kw, W/m.oCTube inside diameter, Dti, m

Tube outside diameter, Dto, m

1/Uo =

Uo = W/m2.C

h) Number of baffle, Nb

Number of baffle, Nb

Nbaffle

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod

+d to ln (d to /d ti)

2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -70


Costing

Type Shell and tube

384.9216Material Carbon SteelFeed Pressure 5.07bar

With reference to costing method proposed by L.T. Biegler,Base Cost, C

Bare Module Cost, BMC For 100<S<10000 ft2,Co 5000So 400

Materials and Pressure Correction Factor, MPF a 0.65UF 3.219048

Total area (ft2) 4143.26Base cost, C ($) 22850.9134Modular factor, MF 3.29Design factor, Fd 1.0 (Floating head)Pressure factor, Fp 0Material factor, Fm 1 (CS/CS)MPF 1Bare module cost ($) 242,006.407Bare module cost (RM) 919,624.348

Area (m2)

C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd)

Appendix F -71


Heat Exchanger, X-11

Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side organic solventsShell side methanolHeat duty (kW) 3321.390

a) Equipment sizingshell tube

Stream methanol organic solvent300.15 284.15

294.15 289.79

R = ( eqn. 12.6 )R= 1.064

S= ( eqn. 12.7 )S= 0.353


0.9800

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =


ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t 2 )(T2−t 1 )


T2

T1

t2

t1

Appendix F -72


( eqn. 12.4 )

10.1789Therefore, the actual temperature difference is

9.9754


U 900




2.4419.0516.56


0.1460

1.5718Number of tube, Nt

2533


23.8125

DTlm =

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t 2 )(T2−t 1 )

Q=UA ΔTalignl¿ lm ¿¿¿


A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -73



0.249( 2 passes ) n 2.207

( eqn. 12.3b )

1246.5656



1.3246




215.4105

633

0.1364

Mass flow rate (inside tube), m 166.1064 kg/hr

Triangular pitch K1








Tube per pass = Nt



Fluid velocity, nf

Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -74


1217.4888

Physical properties of the tube side fluidPhysical properties

838.4112

5.15E-043.5453121354088 kJ/kg.K

0.57972579598 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


147.3430


0.0037

( eqn. 12.15 )




0.0034


density, rt kg/m3

Viscosity, mtL Ns/m2

Heat capacity, Ctp


L/Dti




friction factor, jf


v f=m / AT

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μk f


Dti ( μμw )

0 .14

Appendix F -75





diameter


23.8125 mm

( eqn. 12.21 )

0.3158

720925.4752 kg/hr

634.1155

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As







ΔPs=N p [ 8 jf ( L/ Dti )(μμw

)−m+2. 5 ]ρus

2

2


Baffle Spacing , lB=0 . 9∗Ds


pt

sss AwG /

De=1 . 1Dto

( pz2−0. 971 Dto

2 )

Appendix F -76



Physical properties of shell fluid

Physical properties

799.8603

5.1581E-043.69813443294356 kJ/kg.K

0.6155 W/m.K




0.0055

( eqn. 12.25 )

6057.223


0.7928 m/s


0.0630




Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf


Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

hs=k f jh RePr1/3

De ( μμw )

0 .14

Appendix F -77


( eqn. 12.26 )


1495.2290 kPa


6057.223

7406.777

5000

5500

16.30.01656

0.01905



0.00081141584494073

1232.41369543757

1

DPs







1/Uo =

Uo = W/m2.C



Nbaffle

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

C=C 0(S/S0)α

BMC= BC(C)×MF

MPF= Fm(Fp+Fd)

Appendix F -78


Costing

Type Shell and tube

369.9549Material Carbon SteelFeed Pressure 24 bar


For 100<S<10000 ft2,Co 5000

Bare Module Cost, BMC So 400a 0.65UF 3.219048

Materials and Pressure Correction Factor, MPF

Total area (ft2) 3972.98Base cost, C ($) 22236.0146Modular factor, MF 3.29Design factor, Fd 1.0 (Floating head)Pressure factor, Fp 0Material factor, Fm 1 (CS/CS)MPF 1Bare module cost ($) $235,494Bare module cost (RM) 894,878

Area (m2)

C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd)

Appendix F -79



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floaring headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Methanol recoveredShell side Light HydrocarbonHeat duty (kW) 3057.170


Stream Light Hydrocarbon Methanol573.15 290.15

548.97 295.97

R = ( eqn. 12.6 )R= 4.155

S= ( eqn. 12.7 )S= 0.021


1.0000

( eqn. 12.4 )

267.8952


Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =DTlm can be calculated from the equation,

DTlm =

ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -80


267.8952


U 400




2.4419.0514.83


0.1460

Number of tube, Nt

195


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -81


( eqn. 12.3b )

390.3703



0.4474




172.7542

49

0.0084


16873.2532








Tube per pass = Nt



Fluid velocity, nf

Methanol mass velocity, nf kg/m2.s

Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -82



803.3824

5.11E-043.68951132359407 kJ/kg.K

0.60890216686 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr

E.G. linear velocity, u (m/s) 21.0028Reynold number, Re 489687.564Prandtl number, Pr 3.0963

164.5314


0.0030

( eqn. 12.15 )

87584( assuming viscosity of the fluid is identical at the wall and of the bulk fluid )



0.0021

( eqn. 12.20 )

Methanol density, rt kg/m3

Viscosity of Methanol, mtL Ns/m2

Heat capacity, Ctp


L/Dti



Tube side heat transfer coefficient, hi (W/m2.C)

friction factor, jf


u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14


μw)−m+2. 5 ]

ρus2

2

Appendix F -83


where m = 0.25 for laminar flow, Re<2100 m = 0.14 for turbulent flow, Re>2100


e) Shell side coefficient0.4474 m

Baffle diameter


23.8125 mm

( eqn. 12.21 )

0.0360

204584.6683 kg/hr

1577.4795

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As









μw)−m+2. 5 ]

ρus2

2



As=( p t−Dto )D s lB

pt

sss AwG /

De=1 .1Dto

( pz2−0. 971 Dto

2 )

Appendix F -84




Physical properties

8.3574

1.2178E-052.95453136063117 kJ/kg.K

0.1169 W/m.K




0.0040

( eqn. 12.25 )

978.2222


188.7524 m/sFrom figure 12.30 'Chemical Engineering'. Vol. 6

0.0590

( eqn. 12.26 )



Heat capacity, Csp




Shell side heat transfer coefficient, hs (W/m2.C)

Linear velocity, us

Linear velocity, us

friction factor, jf


Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

hs=k f jh RePr1/3

De ( μμw )

0 .14

Appendix F -85



1794482.9301 kPa


978.2222

87584

5000

5000

16.30.01483

0.01905



0.00164017232653821

609.692032855247

5

Costing

Type Shell and tube


DPs







1/Uo =

Uo = W/m2.C (acceptable)



Nbaffle

Area (m2)

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod

+d to ln(d to /d ti)

2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -86



For 100<S<10000 ft2,Co 5000




C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -87



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side WaterShell side light hydrocarbonHeat duty (kW) 12112.210


Stream Light HC Water548.97 364.25

453.15 373.15

R = ( eqn. 12.6 )R= 10.766

S= ( eqn. 12.7 )S= 0.048


1.0000

( eqn. 12.4 )

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =


ΔT lm=(T 1−t 2 )−(T2−t1 )

ln(T1−t 2 )(T2−t 1 )


T2

T1

t2

t1

Appendix F -88


127.4583Therefore, the actual temperature difference is

127.4583


U 500




2.4419.0516.56


0.1460

1.5718

Number of tube, Nt

1302


23.8125


DTlm =

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -89


0.249( 2 passes ) n 2.207

( eqn. 12.3b )

921.8256



0.9918




215.4105

325

0.0701


Triangular pitch K1








Tube per pass = Nt



Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -90


4654.5408


1015.2654

7.94E-044.1715617374329 kJ/kg.K

0.6155814452 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


147.3430


0.0032

( eqn. 12.15 )


Fluid velocity, nf


density, rt kg/m3


Heat capacity, Ctp


L/Dti




v f=m / AT

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f

hi=k f jh RePr0 .33

Dti ( μμw )

0 .14

Appendix F -91




0.0028




Baffle diameter


23.8125 mm

( eqn. 12.21 )

0.1771

206584.6683 kg/hr

324.0801

friction factor, jf




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As







)−m+2.5 ]ρus

2

2




pt

sss AwG /

Appendix F -92


( eqn. 12.23 )

13.5265 mm




Physical properties

8.2657

1.7348E-052.36028628549583 kJ/kg.K

0.0933 W/m.K




0.0090

( eqn. 12.25 )

260.998






Heat capacity, Csp





De=1 .1Dto

( pz2−0. 971 Dto

2 )

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

Appendix F -93


39.2078 m/s


0.0770

( eqn. 12.26 )

Shell side presure drop, 55360755.6653 Pa ((acceptable)

55360.7557 kPa


260.998

20116.7

5000

5000

16.30.01656

0.01905


( eqn. 12.1 )

Linear velocity, us

Linear velocity, us

friction factor, jf


DPs







us=Gs / ρ

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Appendix F -94


Therefore,

0.00440056025829428

227.243791995616

2

Costing

Type Shell and tube



For 100<S<10000 ft2,Co 5000




1/Uo =

Uo = W/m2.C



Nbaffle

Area (m2)

Nb=( L/ lB)−1

C=C 0(S/S0)α

BMC= BC(C)×MF

MPF= Fm(Fp+Fd)

C=C0( S/ S0 )α

BMC=BC(C )×MF

MPF=Fm( F p+Fd )

Appendix F -95



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Light HydrocarbonShell side Light HydrocarbonHeat duty (kW) 333.960

a) Equipment sizingShell tube

Stream Light HC Light HC358.15 330.62

353.15 331.19

R = ( eqn. 12.6 )R= 8.772

S= ( eqn. 12.7 )S= 0.021


0.9900

( eqn. 12.4 )

24.6788

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

ΔT lm=(T 1−t 2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -96



24.4320Assumption: (Table 12.1, 'Chem. Eng', Vol. 6)

U 300




2.4419.0513.51


0.1460

1.5718

Number of tube, Nt

312


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -97


( eqn. 12.3b )

482.6161



0.5406




143.3695

78

0.0112


14787.7565








Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -98



838.8251

5.16E-043.54274740819102 kJ/kg.K

0.58032666372 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


180.6070


0.0030

( eqn. 12.15 )




0.0020

( eqn. 12.20 )

density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf


u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f

hi=k f jh RePr0 .33

Dti ( μμw )

0 .14


μw)−m+2.5 ]

ρus2

2

Appendix F -99





diameter


23.8125 mm

( eqn. 12.21 )

0.0526

95470.78911 kg/hr

504.1011

( eqn. 12.23 )

13.5265 mm





DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As









μw)−m+2.5 ]

ρus2

2




pt

sss AwG /

De=1 .1Dto

( pz2−0. 971 Dto

2 )

Appendix F -100



Physical properties

8.3574

1.2178E-052.95453136063117 kJ/kg.K

0.1169 W/m.K




0.0057

( eqn. 12.25 )

440.9838


60.3179 m/s


0.0660



Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -101


( eqn. 12.26 )


172611.7908 kPa


440.9838

72842.92

5000

5000

16.30.01351

0.01905



0.00296983413601567

336.719141272179

4

Costing

Type Shell and tube



DPs







1/Uo =

Uo = W/m2.C



Nbaffle

Area (m2)

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

C=C 0(S/S0)α

BMC= BC(C)×MF

MPF= Fm(Fp+Fd)

Appendix F -102



For 100<S<10000 ft2,Co 5000




C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -103



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Organic SolventsShell side Light HydrocarbonHeat duty (kW) 18412.370


Stream Light HC organic solvent623.15 299.36

483.15 330.62

R = ( eqn. 12.6 )R= 4.479

S= ( eqn. 12.7 )S= 0.097


0.9900

( eqn. 12.4 )

233.9635

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

ΔT lm=(T 1−t 2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -104



231.6238


U 350




2.4419.0514.83


0.1460

1.5718

Number of tube, Nt

1555


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -105


( eqn. 12.3b )

999.3252



1.0713




172.7542

389

0.0672


2473.2820




Tmean =(TK.in +TK,out)/2




Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -106


Physical properties of the tube side fluid Physical properties

838.4112

5.15E-043.5453121354088 kJ/kg.K

0.57972579598 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


164.5314


0.0033

( eqn. 12.15 )




0.0029

density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14

Appendix F -107





diameter


23.8125 mm

( eqn. 12.21 )

0.2066

204584.0255 kg/hr

275.0769

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As








μw)−m+2. 5 ]

ρus2

2




pt

sss AwG /

De=1 .1Dto

( pz2−0.971 Dto

2 )

Appendix F -108





Physical properties

6.0172

2.3856E-052.41040091250368 kJ/kg.K

0.1416 W/m.K




0.0070

( eqn. 12.25 )

393.3391


45.7151 m/s


0.0720




Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jhRePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -109


( eqn. 12.26 )


48784.3821 kPa


393.3391

13419.93

5000

5000

16.30.01483

0.01905



0.00324129909514685

308.518273274221

2


DPs







1/Uo =

Uo = W/m2.C



Nbaffle

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

C=C 0(S/S0)α

Appendix F -110


Costing

Type Shell and tube



For 100<S<10000 ft2,Co 5000




Area (m2)

BMC= BC(C)×MF

MPF= Fm(Fp+Fd)

C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -111



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side MethanolShell side Natural GasesHeat duty (kW) 1088.150


Stream Natural Gases Methanol429.30 295.97

387.57 298.04

R = ( eqn. 12.6 )R= 20.159

S= ( eqn. 12.7 )S= 0.016


1.0000

( eqn. 12.4 )

110.2436

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -112



110.2436


U 300




2.4419.0514.83


0.1460

1.5718

Number of tube, Nt

225


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -113


( eqn. 12.3b )

416.4211



0.4714




172.7542

56

0.0097


14746.8378








Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -114



814.0675

5.30E-043.66328876558271 kJ/kg.K

0.60959368776 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


164.5314


0.0028

( eqn. 12.15 )




0.0019

density, rt kg/m3

Viscosity of E.G, mtL Ns/m2

Heat capacity, Ctp


L/Dti




friction factor, jf

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14

Appendix F -115





diameter


23.8125 mm

( eqn. 12.21 )

0.0400

40225.6368 kg/hr

279.3250

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As








μw)−m+2.5 ]

ρus2

2




pt

sss AwG /

De=1 .1Dto

( pz2−0. 971 Dto

2 )

Appendix F -116





Physical properties

1.9887

1.8326E-052.99569121652991 kJ/kg.K

0.0745 W/m.K




0.0075

( eqn. 12.25 )

266.2769


140.4561 m/s


0.0730




Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -117


( eqn. 12.26 )


267886.2437 kPa


266.2769

69599.49

5000

5000

16.30.01483

0.01905



0.0043771889231655

228.457125692628

5


DPs







1/Uo =

Uo = W/m2.C



Nbaffle

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

C=C 0(S/S0)α

Appendix F -118


Costing

Type Shell and tube



For 100<S<10000 ft2,Co 5000




Area (m2)

BMC=BC (C)×MF

MPF= Fm(Fp+Fd)

C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -119



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side MethanolShell side WaterHeat duty (kW) 1107.710


Stream Water Methanol358.15 298.04

349.12 300.15

R = ( eqn. 12.6 )R= 4.280

S= ( eqn. 12.7 )S= 0.035


1.0000

( eqn. 12.4 )

54.4668

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -120



54.4668


U 500




2.4419.0514.83


0.1460

1.5718

Number of tube, Nt

279


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -121


( eqn. 12.3b )

458.4250



0.5304




172.7542

70

0.0120









Tube per pass = Nt



Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -122


11912.7959


814.0675

5.30E-043.66328876558271 kJ/kg.K

0.60959368776 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


164.5314


0.0029

( eqn. 12.15 )




0.0020

Fluid velocity, nf

E.G mass velocity, nf kg/m2.s

density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf

v f=m / AT

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14

Appendix F -123





diameter


23.8125 mm

( eqn. 12.21 )

0.0506

109113.8792 kg/hr

598.4902

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As








μw)−m+2.5 ]

ρus2

2




pt

sss AwG /

De=1 .1Dto

( pz2−0.971 Dto

2 )

Appendix F -124





Physical properties

965.3964

5.8331E-044.18173789157996 kJ/kg.K

1.1730 W/m.K




0.0055

( eqn. 12.25 )

9275


0.6199 m/s


0.0650




Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -125


( eqn. 12.26 )


2624.5425 kPa


9275

58231.88

5000

5000

16.30.01483

0.01905



0.000733119206563126

1364.03464954631

4

Costing

Type Shell and tube

40.6747Material Carbon SteelFeed Pressure 1.01325 bar


DPs







1/Uo =

Uo = W/m2.C



Nbaffle

Area (m2)

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -126



For 100<S<10000 ft2,Co 5000




C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -127



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Organic SolventsShell side WaterHeat duty (kW) 5635.519


Stream Water organic solvent349.12 289.79

303.15 299.36

R = ( eqn. 12.6 )R= 4.804

S= ( eqn. 12.7 )S= 0.161


0.9600

( eqn. 12.4 )

27.6817


26.5745

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

FtDTlm =

ΔT lm=(T 1−t 2 )−(T2−t 1 )

ln(T1−t2 )(T2−t1 )


T2T1

t2

t1

Appendix F -128



U 600




2.4419.0515.75


0.1460

1.5718

Number of tube, Nt

2420


23.8125


0.249( 2 passes ) n 2.207

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 .25×D to

Appendix F -129


( eqn. 12.3b )

1221.0397



1.2990




194.8531

605

0.1179

Mass flow rate (inside tube), m 166.2194 kg/hr

1409.7780








Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -130



838.8215

5.16E-043.54274740819102 kJ/kg.K

0.58032666372 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


154.9206


0.0036

( eqn. 12.15 )




0.0033

( eqn. 12.20 )


density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf



u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14


μw)−m+2. 5 ]

ρus2

2

Appendix F -131




diameter


23.8125 mm

( eqn. 12.21 )

0.3038

109113.8792 kg/hr

99.7838

( eqn. 12.23 )

13.5265 mm





DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As











pt

sss AwG /

De=1 . 1Dto

( pz2−0.971 Dto

2 )

Appendix F -132


Physical properties

965.3964

5.8331E-044.18340762759332 kJ/kg.K

1.1730 W/m.K




0.0130

( eqn. 12.25 )

3753.935


0.1034 m/s


0.0850

( eqn. 12.26 )



Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf


Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

hs=k f jh RePr1/3

De ( μμw )

0 .14

Appendix F -133



42.2016 kPa


3753.935

8333.3

5000

5500

16.30.01575

0.01905



0.000942604074700494

1060.89080966231

1

Costing

Type Shell and tube

353.4419Material Carbon SteelFeed Pressure 25.7 bar


DPs







1/Uo =

Uo = W/m2.C



Nbaffle

Area (m2)

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

C=C0( S/ S0 )α

Appendix F -134


Bare Module Cost, BMC For 100<S<10000 ft2,Co 5000So 400

Materials and Pressure Correction Factor, MPF a 0.65UF 3.219048


BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -135



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side light hydrocarbonShell side natural gasesHeat duty (kW) 2437.400


Stream Natural Gases Light Hydrocarbon387.57 284.15

294.15 333.15

R = ( eqn. 12.6 )R= 1.907

S= ( eqn. 12.7 )S= 0.474


0.8000

( eqn. 12.4 )

26.2197

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =


DTlm =

ΔT lm=(T 1−t 2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -136



20.9758


U 300




2.4419.0515.75


0.1460

1.5587

Number of tube, Nt

2652


23.8125


0.249( 2 passes ) n 2.207

FtDTlm =

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1



A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -137


( eqn. 12.3b )

1272.7693



1.3498




194.8531

663

0.1292


35.5055








Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -138



2.6873

8.10E-0610.8426291635825 kJ/kg.K

0.14327499494 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


154.9206


0.0038

( eqn. 12.15 )




0.0035

density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf

u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14

Appendix F -139





diameter


23.8125 mm

( eqn. 12.21 )

0.3279

40225.6368 kg/hr

34.0729

( eqn. 12.23 )

13.5265 mm




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As








μw)−m+2.5 ]

ρus2

2

Baffle Diameter=D s−0 .0016



pt

sss AwG /

De=1 .1Dto

( pz2−0. 971 Dto

2 )

Appendix F -140




Physical properties of shell fluid (stream)

Physical properties

1.9887

1.8326E-052.99569121652991 kJ/kg.K

0.0745 W/m.K




0.0025

( eqn. 12.25 )

708.9748


17.1332 m/s


0.0500




Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=kf jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -141


( eqn. 12.26 )


1334.9745 kPa


708.9748

2031.431

5000

5000

16.30.01575

0.01905



0.00255895713832139

390.784192913826

1


DPs







1/Uo =

Uo = W/m2.C



Nbaffle

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -142


Costing

Type Shell and tube



For 100<S<10000 ft2,Co 5000




Area (m2)

C=C0( S/ S0 )α

BMC=BC (C )×MF

MPF=Fm( F p+Fd )

Appendix F -143



Heat exchanger type 1 shell and 2 tubesDesign type Split-ring floating headHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Organic SolventShell side MethanolHeat duty (kW) 1044.601


Stream Methanol Organic Solvent294.15 263.15

292.26 284.15

R = ( eqn. 12.6 )R= 0.090

S= ( eqn. 12.7 )S= 0.677


0.9800

( eqn. 12.4 )

17.8860


17.5283

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

FtDTlm =

ΔT lm=(T 1−t 2 )−(T2−t 1 )

ln(T1−t2 )(T2−t1 )


T2

T1

t2

t1

Appendix F -144



U 450




2.4419.0515.75


0.1460

1.5587Number of tube, Nt

907


23.8125


0.249( 2 passes ) n 2.207

W/(C.m2)

m2

ft2




(ft2)

Number of tube, Nt

Tube pitch, Pt (mm)

Triangular pitch K1




A=Q

UΔT lm

N t=AA t

Pt=1 . 25×D to

Appendix F -145


( eqn. 12.3b )

782.6410



0.8556




194.8531

227

0.0442


103.8450







Tube per pass = Nt



Fluid velocity, nf


Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

v f=m / AT

Appendix F -146



2.6873

8.10E-0610.8426291635825 kJ/kg.K

0.14327499494 W/m.K

Linear velocity, u

Reynold number, Re

Prandtl number, Pr


154.9206


0.0030

( eqn. 12.15 )




0.0023

( eqn. 12.20 )where m = 0.25 for laminar flow, Re<2100

density, rt kg/m3


Heat capacity, Ctp


L/Dti




friction factor, jf


u=v f / ρ

Re=ρuDti

μ

Pr=Cp μ

k f


Dti ( μμw )

0 .14


)−m+2. 5 ]ρus

2

2

Appendix F -147


m = 0.14 for turbulent flow, Re>2100



Baffle diameter


23.8125 mm

( eqn. 12.21 )

0.1318

720925.4752 kg/hr

1519.6103

( eqn. 12.23 )

13.5265 mm





DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As











pt

sss AwG /

De=1 . 1Dto

( pz2−0.971 Dto

2 )

Appendix F -148


Physical properties of shell fluid (stream)

Physical properties

799.8603

5.1581E-043.69813443294356 kJ/kg.K

0.6155 W/m.K




0.0008

( eqn. 12.25 )

134265.25076058


1.8998 m/s


0.0320



Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf

Re=Gs De /μ

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -149


( eqn. 12.26 )


6319.0964 kPa


134265.25076058

4690.617776129

5000

5000

16.30.01575

0.01905



0.000818373044027

1221.93663060944

2

Costing

Type Shell and tube



DPs







1/Uo =

Uo = W/m2.C



Nbaffle

Area (m2)

hs=k f jh RePr1/3

De ( μμw )

0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -150



For 100<S<10000 ft2,Bare Module Cost, BMC Co 5000

So 400a 0.65

Materials and Pressure Correction Factor, MPF UF 3.21904761904762


C=C0( S/ S0)α

BMC=BC(C )×MF

MPF=Fm( F p+Fd )

Appendix F -151


Heater X-34

Heat exchanger type Split flow shell and 2 tubesDesign type Fixed and U-TubeHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side Organic solventShell side SteamHeat duty (kW) (Q) 12935.46000

a) Equipment sizingshell (t) tube (T)

Stream Steam523.15 331.19

423.15 353.15

R = ( eqn. 12.6 )R= 4.55373406193079

S= ( eqn. 12.7 )S= 0.1144

Ft can be obtained from eqn 12.8 ( vol. 6 ),

0.976

Organic solvent

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)

Ft =

T1 = inlet temperature to tubeT2 = outlet temperature from tubet1 = inlet temperature to shellt2 = outlet temperature from shell

T2

T1

t2

t1

Appendix F -152


( eqn. 12.4 )

127.0090


124.0151


U 800

Provisional area of heat exchanger, A can be obtained trough the formula,

Provisional area, A = 130.3819

= 1403.4194

Material Stainless SteelBWG number 16

4.8819.0515.7544.0

0.2921

3.1437


DTlm =

ΔTm = FtΔTlm =

W/(ºC.m2)

m2

ft2

b) Tube rating ( From App.5.-2, Tranport Processes by, Christie J. Geankoplis )

Length of tube Lt (m)Outer diameter, Dto (mm)Inner diameter, Dti (mm)Material Thermal Conductivity ( W/m.K )


Area of one tube, At (m2) =

(ft2) =

ΔT lm=(T 1−t 2 )−(T2−t 1 )

ln(T1−t2 )(T2−t1 )

Q=UA ΔTalignl¿ lm ¿¿¿A=

QUΔT lm


Appendix F -153


Number of tube, Nt

446


23.8125

From Table 12.4, Chemical Engineering , Vol. 6 ( 1st Edition ), page 523Triangular pitch K1 0.249( 2 passes ) n 2.207

( eqn. 12.3b )

567.6654



0.62767




Number of tube, Nt

Tube pitch, Pt (mm)




Tmean =(TH.in +TH,out)/2

N t=AA t

Pt=1 . 25×D to

Pt

Db=D to( N t / K1 )1 /n

Appendix F -154


194.8531

223

0.0434941


4980.0634

Physical properties of the tube side fluid (simulation result)Physical properties of organic solvent

838.4112

5.15E-043.5453121354088 kJ/kg.K

0.57972579598 W/m.K1 cp (Ns/m2) = 1.00E-03

Linear velocity, u

Reynold number, Re Prandtl number, Pr



Tube per pass = Nt



Fluid velocity, nf

Fluid mass velocity, nf kg/m2.s

organic solvent density, rt kg/m3

Viscosity of , mtL Ns/m2

Heat capacity, Ctp


A t=πDti2

¿4 ¿¿

¿

AT =N t A t

v f=m / AT

u=v f / ρ

Re=ρuDti

μPr=

Cp μk f

Appendix F -155


steam linear velocity, u (m/s) 5.9399Reynold number, Re 1.5237E+05Prandtl number, Pr 3.1481

309.8413


0.00320

( eqn. 12.15 )




0.00250


257.2607 kPa

2.5389655289586

L/Dti




friction factor, jf




DPt (atm)

hi=k f jh RePr0 .33

Dti ( μμw )

0 .14


)−m+2. 5 ]ρus

2

2

B159

cclw:

Appendix F -156



Baffle diameter


23.8125 mm

( eqn. 12.21 )

0.070913

65.102979 kg/s

918.0619

( eqn. 12.23 )13.5265 mm


Mean temperature (ºC) 473.1500

Physical properties of shell fluid (steam)

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As









pt

sss AwG /

De=1 .1Dto

( pz2−0. 971 Dto

2 )



Appendix F -157


Physical properties

0.4211

1.82E-051.98692E+00 kJ/kg.K

0.0381499 W/m.K


Reynold number, Re 6.8153E+05Prandtl number, Pr 0.9490


0.0009

( eqn. 12.25 )

1700.322135865


2179.9965 m/s


0.0340

( eqn. 12.26 )

Shell side presure drop, 109108878.2618 Pa

109108.8783 kPa 1076.820905618



Heat capacity, Csp





Linear velocity, us

Linear velocity, us

friction factor, jf


DPs (atm)

m/Re es DG

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

ΔPs=8 jf ( Ds /D e)( L/ lB )ρus

2

2( μ

μw)−0 . 14

Appendix F -158



1700.322135865

26202.7833

5000

5000

44.00.01575

0.01905



0.001117368503781

894.959896055954

8

i) Costing (Guthrie's Modular Method)

Total area of the Heat Exchanger = 130.3819 = 1403.4180838

Operating Pressure = 4.75 bar405.6

126.00Update factor = 405.6

126.00

= 3.21904761904762

With reference to costing method proposed in Systematic Method of Chemical ProcessDesign by L.T. Biegler.




Inside dirt coefficient, hid, W/m2.oC (Table 12.2, vol. Six )



1/Uo =

Uo = W/m2.C



Nbaffle

m2

ft2

CE Plant Cost Index for 2003, CEI 03 =CE Plant Cost Index for 1968 1/2, CEI 68 =

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -159


Base Cost,

C0= 5000S0= 400

0.65Updated Bare Module Cost : BMC= (UF)(MPF+MF-1) (BC)


Total area (ft2) 1,403.41808Base cost, C ($) 11,305.834Modular factor, MF 3.2900Design factor, Fd 0.8500Pressure factor, Fp 0.0000Material factor, Fm 2.5000MPF 2.1250

160,679.59Bare module cost (RM) 610,582.44

Utility cost:H (250C, 475 kPa,super) = 2961.85 kJ/kgH (150C, saturated) = 632.1 kJ/kgΔ H = 2329.75 kJ/kg

== 5.5523 kg/s= 5552.3 g/s= 308 gmol/s

The amout of water need to be heated to obtain the amount of steam;= 5.5523 kg/s= 19988 kg/hr= 19.9883= 172,698.5933

Assume the water will be flowed to the incinerator to generate steam before flowing to the heater, therefore, no extra heating cost is needed.

Assume water cost = RM 1.15Total cost of water RM/yr = 198,603.38

α=

Updated bare module cost ($)

Steam flow, mc Qmax/ΔH

m3/hrm3/yr

/m3

Appendix F -160


Cooler X-35

Heat exchanger type Split flow shell and 2 tubesDesign type Fixed and U-TubeHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side R-12Shell side waterHeat duty (kW) (Q) 68805.55600


Stream Methanol R-12299.82 479.75

324.82 368.15

R = ( eqn. 12.6 )R= 0.224014336917563

S= ( eqn. 12.7 )S= 0.6202


0.950

( eqn. 12.4 )

105.7872

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =


T2

T1

t2

t1

ΔT lm=(T 1−t2 )−(T2−t 1)

ln(T1−t 2 )(T2−t 1 )

Appendix F -161



100.4978


U 454.264



= 1622.2900

b) Tube rating


4.8819.0515.7544.0

0.2921

3.1437

Number of tube, Nt

516


ΔTm = FtΔTlm =

W/(ºC.m2)

m2

ft2




(ft2) =

Number of tube, Nt

Q=UA ΔTalignl¿ lm ¿¿¿A=

QUΔT lm


N t=AA t

Pt=1 . 25×D to

Appendix F -162


23.8125


( eqn. 12.3b )

606.1934



0.66919




194.8531

258

0.0502772

Tube pitch, Pt (mm)







Tube per pass = Nt



Pt

Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -163


Mass flow rate (inside tube), m -12.7199

-252.9944


5.9838

1.06E-050.567650181120466 kJ/kg.K

0.00834125294 W/m.K1 cp =

Linear velocity, u


steam linear velocity, u (m/s) -42.2799Reynold number, Re -3.7741E+05Prandtl number, Pr 0.7185

309.8413


0.00270

( eqn. 12.15 )

( assuming viscosity of the fluid is identical at the wall and of the bulk fluid )


Fluid velocity, nf

Fluid mass velocity, nf



Heat capacity, Ctp


L/Dti




v f=m / AT

u=v f / ρ

Re=ρuDti

μPr=

Cp μk f


Dti ( μμw )

0 .14

Appendix F -164



0.00170


71.8151 kPa

e) Shell side coefficient0.6692

0.6023Baffle Diameter 0.6676

23.8125

( eqn. 12.21 )

0.080608

200.257076

2484.3456

( eqn. 12.23 )

friction factor, jf




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As

Cross flow area, As






)−m+2. 5 ]ρus

2

2


pt

sss AwG /

De=1 .1Dto

( pz2−0.971 Dto

2 )



B153

cclw:

Appendix F -165


13.5265




Physical properties

799.8603

5.16E-043.69813E+00 kJ/kg.K

0.6155396 W/m.K




0.0028

( eqn. 12.25 )


3.1060






Heat capacity, Csp





Linear velocity, us

Linear velocity, us

De=1 .1Dto

( pz2−0.971 Dto

2 )

m/Re es DG

hs=k f jh RePr1/3

De ( μμw )

0 .14

us=Gs / ρ

Appendix F -166


0.0500


618.6333 kPa



Therefore,

-0.0019335603433026

-517.180652501363

7

friction factor, jf


DPs







1/Uo =

Uo = W/m2.C



Nbaffle


2

2( μ

μw)−0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -167




Operating Pressure = 4.75

405.6126.00

Update factor = 405.6126.00

= 3.21904761904762

With reference costing method proposed in Systematic Method of Chemical ProcessDesign by L.T. Biegler.

Base Cost,

C0= 5000S0= 400



Total area (ft2) 1,622.28846Base cost, C ($) 12,422.650Modular factor, MF 3.2900Design factor, Fd 0.8500Pressure factor, Fp 0.0000Material factor, Fm 2.5000MPF 2.1250



α=


Appendix F -168


Cost of Coolant:Mass flowrate of R-12 needed = -12.7199Assume that the coolant R-12 will be recycled in a cycle in 10 minutes, which equal to 600s.Total of coolant needed = -7631.9152From the website, we obtained 50 pound of R-12a is sold at US 160;Price for coolant = US 3.2 /pound = RM 27.02 /kgThe cost for coolant = RM -206231.309417173

Cost of Mechanical Refrigeration Unit:For the coolant/refrigerate to cold down to its initial temperature for recycling to the cooler X-35,an air cooled mechanical refrigeration unit is installed. From Ulrich (1984);The rate of heat absorbtion, Q = 68805.55600The temperature of coolant = 479.75000

= 206.60000From Figure 5-11, Ulrich (1984);Bare module cost for the air-cooled refrigeration unit = US $Updated factor = 1.29Updated module cost, BMC = US $ 1,935,000.00

= RM 7,353,000.00

Appendix F -169


Split flow shell and 2 tubesFixed and U-Tube

HorizontalHorizontal

11

R-12water

68805.55600


Appendix F -170


(standard length of tubes are 8, 12, or 16 ft, pg 520, Vol6 )

(A.3-16)

Appendix F -171


mm2

Appendix F -172


kg/s

1.00E-03

Prandtl number, Pr

-483.8899

kg/m2.s

Ns/m2

W/m2.C

Pr=Cp μ

k f

Appendix F -173


( eqn. 12.20 )

0.708759851386908 atm

Baffle

m diameter

mm

mm

kg/s

m2

kg/s.m2

Appendix F -174


mm

12056.9102221634

m/s

W/m2.C

Appendix F -175


( eqn. 12.26 )

6.10543585855115 atm

12056.9102221634

-483.8899

5000

5000

44.00.01575

0.01905

( eqn. 12.2 )

Appendix F -176


bar

With reference costing method proposed in Systematic Method of Chemical Process

m2

ft2

Appendix F -177


kg/sAssume that the coolant R-12 will be recycled in a cycle in 10 minutes, which equal to 600s.

kg

For the coolant/refrigerate to cold down to its initial temperature for recycling to the cooler X-35,

KWKoC

1,500,000

Appendix F -169


Cooler X-35

Heat exchanger type Split flow shell and 2 tubesDesign type Fixed and U-TubeHeat exchanger orientation HorizontalTube inlet direction HorizontalNumber of parallel plate 1Tube side stream feed 1Tube side R-12Shell side methanolHeat duty (kW) (Q) 26.08619


Stream Methanol R-12294.15 263.15

293.15 278.15

R = ( eqn. 12.6 )R= 0.0666666666666667

S= ( eqn. 12.7 )S= 0.4839


0.980

( eqn. 12.4 )

22.2714


21.8260

Tin (K)

Tout (K)

(T1-T2)/(t2-t1)

(t2-t1)/(T1-t1)


DTlm =

ΔTm = FtΔTlm =


T2

T1

t2

t1

ΔT lm=(T 1−t2 )−(T2−t1 )

ln(T1−t2 )(T2−t1 )

Appendix F -170



U 800



= 16.0811


4.8819.0515.7544.0

0.2921

3.1437

Number of tube, Nt

5


23.8125

W/(ºC.m2)

m2

ft2

b) Tube rating ( From App.5.-2, Tranport Processes by, Christie J. Geankoplis )




(ft2) =

Number of tube, Nt

Tube pitch, Pt (mm)

Q=UA ΔTalignl ¿ lm ¿¿¿A=

QUΔT lm


N t=AA t

Pt=1 . 25×D to

Appendix F -171



( eqn. 12.3b )

74.9336



0.12493

c) Tube side coefficientMean temperature (C)


194.8531

3

0.0004984








Tube per pass = Nt



Pt

Db=D to( N t / K1 )1 /n

A t=πDti2

¿4 ¿¿

¿

AT=N t A t

Appendix F -172


5762.4214


5.9838

1.26E-050.605556213507121 kJ/kg.K

0.0106691796 W/m.K1 cp = 1.00E-03

Linear velocity, u


steam linear velocity, u (m/s) 963.0037Reynold number, Re 7.2007E+06Prandtl number, Pr 0.7154

309.8413


0.00270

( eqn. 12.15 )


Fluid velocity, nf

Fluid mass velocity, nf kg/m2.s



Heat capacity, Ctp


Ns/m2

L/Dti




v f=m / AT

u=v f / ρ

Re=ρuDti

μPr=

Cp μk f

hi=kf jh RePr0 . 33

Dti ( μμw )

0 .14

Appendix F -173




0.00170


37256.6692 kPa

367.6947371 atm

e) Shell side coefficient Baffle

0.1249 m diameter


23.8125 mm

( eqn. 12.21 )

0.002810

11.173788 kg/s

3977.1254

friction factor, jf




DPt

Shell diameter, Ds

Baffle spacing, lB

Tube pitch, Pt

Cross flow area, As






μw)−m+2. 5 ]

ρus2

2


pt

sss AwG /



B152

cclw:

Appendix F -174


( eqn. 12.23 )13.5265 mm




Physical properties

1.9887

1.83E-052.99569E+00 kJ/kg.K

0.0745250 W/m.K




0.0008

( eqn. 12.25 )

11697.42886






Heat capacity, Csp





De=1 .1Dto

( pz2−0. 971 Dto

2 )

m/Re es DG

hs=k f jh RePr1/3

De ( μμw )

0 .14

Appendix F -175



1999.8619 m/s


0.0320

( eqn. 12.26 )


408105.7128 kPa 4027.690232 atm


11697.42886

11791.9849

5000

5000

44.00.01575

0.01905


( eqn. 12.2 )

Therefore,

0.000671145088401414

1489.99078929696

Linear velocity, us

Linear velocity, us

friction factor, jf


DPs







1/Uo =

Uo = W/m2.C



us=Gs / ρ


2

2( μ

μw)−0 .14

1Uo

= 1hs

+ 1hod


2k w+

d to

d ti× 1

hid+

d to

dti× 1

hi

Nb=( L/ lB)−1

Appendix F -176


42



Operating Pressure = 4.75 bar405.6

126.00Update factor = 405.6

126.00

= 3.21904761904762

With reference to costing method proposed in Systematic Method of Chemical ProcessDesign by L.T. Biegler.

Base Cost,

C0= 5000S0= 400



Total area (ft2) 16.08113Base cost, C ($) 619.066Modular factor, MF 3.2900Design factor, Fd 0.8500Pressure factor, Fp 0.0000Material factor, Fm 2.5000MPF 2.1250


Nbaffle

m2

ft2


α=


Appendix F -177


Utility cost:

Cost of Coolant R-12:Mass flowrate of R-12 needed = 2.8719 kg/sAssume that the coolant R-12 will be recycled in a cycle in 10 minutes, which equal to 600s.Total of coolant needed = 1723.1226 kgFrom the website, we obtained 50 pound of R-12a is sold at US 160;Price for coolant = US 3.2 /pound = RM 27.02 /kgThe cost for coolant = RM 46562.6019443245

Cost of Mechanical Refrigeration Unit:For the coolant/refrigerate to cold down to its initial temperature for recycling to the cooler X-36, an air cooled mechanical refrigeration unit is installed. From Ulrich (1984);The rate of heat absorbtion, Q = 26.08619 KWThe temperature of coolant = 263.15000 K

= -10.00000 oCFrom Figure 5-11, Ulrich (1984);Bare module cost for the air-cooled refrigeration unit = US $ 15,000Updated factor = 1.29

19,350.00 = RM 73,530.00

Updated module cost, BMC = US $

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