HEAT EXCHANGER DESIGN Process Design

Flow rate of Methanol, (Kg/h) Temperature of Methanol, T1 (0C) Temperature of Methanol, T2 (0C) Temperature of Water, t1 ( 0C ) Temperature of Water, t2 (0C )

150000.00 90.00 45.00 20.00 40.00

Heat Exchanger Type : Split ring floating head type Choose Baffle Cut, % 25.00 Shell Passes Tube Passes 1.00 2.00

Heat Exchanger Design: Actual Value ||||||||------DATA-------|||||||| Flow rate of Methanol, (Kg/h) Heat capacity of methanol, (KJ/Kg 0C) Heat capacity of Water(Coolant/Hot fluid), (KJ/Kg 0C) Temperature of Methanol, T1 (0C) Temperature of Methanol, T2 (0C) Temperature of Water, t1 ( 0C ) Temperature of Water, t2 (0C ) Heat Load (KW or KJ/s) Cooling Water Flow,m (Kg/s) Logarithmic mean temp. difference, Tlm, 0C R S Ft Corrected Mena Temperature Difference, T m ###################################### Assume Overall Heat Transfer Coefficient, U W/m2 0C Provisional Area of exchanger, A, m 2 Tube length,L (m) Outside Diameter, Do (mm) Inside Diameter, Di (mm) MOC of tube Area of One tube, A (m 2) No. of tubes, NT 150000 2.84 4.2 90 45 20 40 5325 63 36.1 2.25 0.29 0.87 31

25

700 244 4.83 20 16 Steel 0.303 806

TRUE

25

Triangular Pitch / Square Pitch, Pt (mm) 25 No. of tube Passes 2 K1 0.249 n1 2.207 Bundle Diameter, Db (mm) 779 Tubes in Centre row 31.15628523 Heat Exchanger Type : Split ring floating head type From Graph, bundle diameter clearance Vs Bundle diameter for differnet type of exchanger, take value of bundle diameter Clearance Bundle Diameter Clearance (mm) Shell Diameter, Ds (mm) =================================== Tube Side Coefficient, hi, (W/m2 0C) Mean Water/coolant temperature, (0C) Tube cross-sectional area, (mm 2)

65 844

30 201.06

Tubes per pass Viscosity of water, (mNs/m2) Thermal Conductivity,(W/m0C) Reynold No. Total flow area, At (m2) Water mass velocity, (Kg/m2 s) Density of water, (kg/m3) Water linear velocity, (m/s) Tube Side Coefficient, hi, (W/m2 0C)

403 0.8 0.38 15647 0.081 782 993 0.79 4007

Shell Side Coefficient, hs (W/m2 0C) Baffle Spacing, (mm) Cross flow area, As (m 2) Mass velocity, Gs (Kg/s m 2) Equivalent diameter, de (mm) Mean Shell side temperature, ( C) Methanol density, (kg/m3) Methanol viscosity, (mNs/m2) or cP Thermal Conductivity, (W/m 0C) Reynold No. Prandtl No. Choose Baffle Cut, % From Graph Jh Shell Side Coefficient, hs (W/m2 0C) Mean temp. diff. across all resistance, (0C) Temp. diff across methanol film, (0C) Mean wall temperature, (0C) Overall Coefficient Thermal Conductivity of steel (W/m 0C) Fouling Coefficinet(Dirt Factor), (W/m2 0C) Overall Coefficient, U0 (W/m2 0C) Area required, (m 2) A0, (m2) % Excess Area Tube side Pressure Drop Tube side Friction factor, jf Tube side Pressure Drop, (N/m 2) Shell side Pressure Drop Linear velocity, (m/s) Shell side Friction factor, jf Shell side pressure drop, (N/m2) Pressure drop reduction,shell side,(N/m 2) heat transfer coefficient,shell side, w/m 2 0C
0

169 0.028 975 14.2 68 750 0.34 0.19 40728 5.082105263 25 0.0032 2998 38 9 59

0.917

50 5000 877 193.4887179 244.6031474 26.10554386 232.186461

0.004 7495.406533

1.30 0.04 344947.7501 86236.93752 1721.855673 86.2369375

Heat capacity of methanol, (KJ/Kg 0C) Methanol density, (kg/m3) Methanol viscosity, (mNs/m2) or cP Thermal Conductivity, (W/m 0C) Heat capacity of Water(Coolant/Hot fluid), (KJ/Kg 0C) Viscosity of water, (mNs/m 2) Thermal Conductivity,(W/m0C) Density of water, (kg/m3)

2.84 750 0.34 0.19 4.2 0.8 0.38 993

Assume Overall Heat Transfer Coefficient, U W/m 2 0C Tube length,L (m) Outside Diameter, Do (mm) Inside Diameter, Di (mm) MOC of tube K1 n1 Thermal Conductivity of steel (W/m 0C) Fouling Coefficinet(Dirt Factor), (W/m 2 0C)

700 4.83 20 16 Steel 0.249 2.207 50 5000

TRUE

25

0.917

Ft From Graph Jh Bundle Diameter Clearance (mm) Tube side Friction factor, jf Shell side Friction factor, jf Assume viscosity correction factor is equal to one.

0.87 0.0032 65 0.004 0.04

temp. F to C, K and R heat capacity cal/mol K to KJ/kg C pressure N/m2 to kpa and bar pressure mm Hg to psf, psi,N/m2 Density of liq, g/cc to kg/m3 liquid density, (kg/m3)

36.66666667 2.84 68.409 1428.752515 790 992.8961361

309.6666667 557.4 18 684.09 68409 9.921892466 68409.04 0.79 30 303

98

513.11 5.459 0.30542 647.13 0.081

Thermal Conductivity, (W/m C)

0.38213422

1.950133

Typical Overall Heat Transfer Coefficients- For Refining Operation Btu/h ft2 0F to W/m2 0C 199 256 35 45

Alkylation

Range, (Btu/h.ft.F)

Debutanizer Condenser Debutanizer Reboiler (STM)

75 85

90 100

Deisobutanizer Feed Preheater (STM) Deisobutanizer Condenser Deisobutanizer Reboiler (STM)

75 80 90

100 90 100

Depropanizer Feed Preheater (STM) Depropanizer Condenser Depropanizer Reboiler (STM) Depropanizer Feed/Btms Exchanger Olefin Feed Chiller Refrigeration Condenser Rerun Tower Preheater (STM) Rerun Tower Condenser

90 90 75 60 70 90 60 65

100 100 95 80 80 100 80 80

Rerun Tower Reboiler (STM) Rerun Tower Bottoms Cooler

80 50

100 70

Amine Treating

Range, (Btu/h.ft.F)

Rich/Lean Amine Exchanger Regenerator Condenser Regenerator Reboiler (STM) Lean Amine Cooler

75 70 100 80

90 90 120 90

Catalytic Cracking

Range, (Btu/h.ft.F) Naphtha Cooler Feed / DFO DFO Cooler DFO Cooler (300-400 F) Gas Oil / DFO Gas Oil / Quench Gas Oil / Tar Quench or STB / Feed Quench / BFW Quench or STB Cooler Quench and/or STB Cooler (300-400 F) Quench Steam Gen. Reduced Crude / Quench Reduced Crude / Tar Sep. Btms. SYN Tower Condenser 55 35 45 80 40 35 30 35 60 30 50 70 35 30 30 65 45 55 100 50 50 40 45 80 50 70 90 45 40 40

Crude Distillation

Range, (Btu/h.ft.F) Crude / Heavy Gas Oil Crude / Kerosene Crude / Light Gas Oil Crude / Naphtha 40 35 40 40 50 45 50 50

Crude / Reduced Crude Crude / Vac. Tar Heavy Gas Oil Cooler Heavy Gas Oil Steam Gen. Kerosene Cooler Light Gas Oil Cooler Lube Dist. / Crude Naphtha Cooler Reduced Crude / Gas Oil Reduced Crude / Naphtha Reduced Crude Cooler Tower Overhead / Crude Tower Condenser Vac. Tar / Steam Gen. Vac. Tar Cooler (box)

25 25 50 100 55 45 40 60 35 40 20 30 45 45 10

35 30 50 120 65 55 50 70 45 50 30 40 55 55 20

Hydrodesulfurization

Range, (Btu/h.ft.F) Charge / Reactor Effluent Charge / Gas Oil Product Charge / HTS Off Gas HTS Off Gas / Water Condenser Stripper Feed / Gas Oil Product Stripper Bottoms Cooler Stripper Condenser Total Gas / Gas Oil Product 60 55 50 75 55 65 55 55 70 65 60 85 65 75 65 65

Light Ends Processing

Range, (Btu/h.ft.F) Absorber Intercooler Compressor Contactor Cooler Deethanizer Condenser Deethanizer Reboiler Debutanizer Feed / Btms 60 75 80 80 60 70 90 100 100 70

Debutanizer Feed Preheater (STM) Debutanizer Condenser Debutanizer Condenser Aftercooler Debutanizer Reboiler (STM) Depropanizer Feed / Btms Depropanizer Condenser Depropanizer Reboiler (Hot Oil) Depropanizer Reboiler (STM) Fractionating Abs. Reboiler Gasoline Cooler Lean Oil / Rich Oil Exchanger Lean Oil Cooler Propane and/or Butane Cooler Stabilizer Btms. / Feed Stabilizer Condenser Stabilizer Reboiler

80 75 40 80 70 90 55 80 75 70 45 60 75 65 70 75

100 90 50 100 90 100 65 100 90 80 55 70 85 75 90 100

Lube & Wax Processing

Extraction Solvent Vapor / Extract Mix (75% Solvent) Treating Tower Intercooler Solvent / Charge Oil Solvent Water Cooler Raffinate Oil / Raffinate Oil Mix Raffinate Oil / Water Cooler Solvent / Raffinate Oil Mix Raffinate Oil Mix / Steam Raffinate Oil Mix / Steam Evaporator (80% Solvent) Raffinate Oil Mix / Steam Evaporator (45% Solvent) Raffinate Oil Mix / Steam Evaporator (13% Solvent) Atmospheric Solvent Vapors / Extract Mix Extract / Water Cooler (Submerged Coil) Dry Solvent Vapor (Vacuum) / Water Condenser (+Subcooling) CBM / Water Condenser (Subcooling to 150F) Vacuum Pump Aftercooler Steam / Steam Superheater 20 25 60 20 Range, (Btu/h.ft.F)

225 100 40 90 60 60 30 35 90 70 40 60 10 15 60 120 10 15

Extract Mix / Steam Evaporator (80% Solvent) Extract Mix / Steam Evaporator (45% Solvent) Extract Mix / Steam Evaporator (13% Solv ent) Extract Mix / Solvent Vapor (80% Solvent) Extract Mix / Solvent Vapor (45% Solvent) Extract Mix / Solvent Vapor (13% Solvent) Wet Solvent Vapor (Vacuum) / Water Condenser (+Subcooling) Extract Mix (10% Solvent) / Extract Mix (80% Solvent) Dewaxing Cold Pressed Oil Mix / Solvent Cold Slack Wax Mix / Steam Flue Gas / Ammonia Chiller Flue Gas / Water Cooler Hot Solvent / Wax Oil Pressed Oil / Pressed Oil Mix Pressed Oil / Water Cooler (to 150F) Slack Wax / Slack Wax Mix Solvent / Ammonia Chiller Solvent / Cold Slack Wax Mix Solvent / Water Cooler (5# delta P) Solvent / Water Cooler (1# delta P) Solvent Vapor / Pressed Oil Mix Solvent Vapor / Slack Wax Mix Solvent Vapor / Pressed Oil Solvent Vapor / Solvent Vapor / Solvent Ratio) Solvent Vapor / Solvent Ratio) Solvent Vapor / Subcooling) Steam Steam Ratio) Steam Ratio) Steam Ratio) Steam Ratio) Steam Ratio) Steam Ratio) Pressed Oil Slack Wax Mix (3:1 Slack Wax Mix (4:1

90 70 40 90 115 55 35 105 15

30 45 6 10 30 10 20 65 40 25 30 60 10 90 70 45 100 65 80 90 80 90

Water Condenser (No 100 15 15 70 100 125

/ Steam Superheater / Pressed Oil (2:1 Solvent / Pressed Oil (3:1 Solvent 35 / Pressed Oil (4:1 Solvent / Slack Wax Mix (1:2 Solvent 15 / Slack Wax Mix (2:1 Solvent

70 60

/ Slack Wax Mix (3:1 Solvent 70

Steam / Slack Wax Mix (4:1 Solvent Ratio) Warm Wash Heater Wax Oil Mix / Ammonia DP Chiller (with Scrapers) Wax Oil Mix / Ammonia DP Chiller (without Scrapers) Wax Oil Mix / Pressed Oil Mix DP Exchanger Wax Oil Mix / Water Cooler Wet Solvent Vapor Condenser (with Subcooling)

125 100 30 20 15 20 30 75

Naphtha Hydrotreating & Reforming

Range, (Btu/h.ft.F) Pretreater Reactor Effluent / Charge (Cold End) Pretreater Reactor Effluent / Charge (Hot End) Pretreater Reactor Effluent Condenser Naphtha Splitter Feed / Botomms Naphtha Splitter Condenser Reactor Effluent Condenser Reactor Effluent / Feed (Cold End) Reactor Effluent / Feed (Hot End) Splitter or Stripper Feed / Pretreater Effluent Stabilizer Reboiler (Hot Oil)

65 70 80 65 65 80 70 80 75 75

75 80 90 80 75 100 85 90 85 95

Thermal Cracking

Range, (Btu/h.ft.F)

Coker Combination TWR Condenser Gas Oil / Gas Oil

40 30

50 40

G.O. Cracker O'hd Condenser Gas Oil Reflux Steam Gen. Gasoline / Naphtha Charge Thermal Tar Cooler (box) Thermal Tar Steam Gen. Top Reflux / BFW Top Reflux / Naphtha Top Reflux / Naphtha Charge Top Reflux Cooler

45 80 60 10 40 60 60 50 55

65 90 80 20 50 80 80 60 65

Typical Overall Heat Transfer Coefficients SHELL AND TUBE EXCHANGERS U(W/m2 0C)

Hot fluid

Cold fluid

HEAT EXCHANGEERS Water Organic solvent Light oil Heavy oil Water Organic solvent Light oil Heavy oil 850-1500 100-300 100-400 50-300

Gases COOLERS Organic solvent Organic solvent Light oil Heavy oil Water

Gases

Water Brine Water Water Brine

250-750 150-500 350-900 60-300 600-1200

Gases HEATERS Steam Steam Steam Steam Steam Dowtherm Dowtherm Flue gases

Brine

15-250

Water Organic Solvent Light oil Heavy oil Gases Heavy oil Gases Steam

1500-4000 500-1500 300-900 60-450 30-300 50-300 20-200 30-100

Flue

Hydrocarbon vapours

30-100

CONDENSERS Aqueous vapours Organic vapours Organic(non-condensable) vacuum condensers VAPORISERS Steam Steam Steam

water water water water

1000-1500 700-1000 500-700 200-500

Aqueous solution Light organics Heavy organics

1000-1500 900-1200 600-900

Tube side heat transfer factor

Bundle diameter clearance

For shell side HTC

For shell side Pressure drop