E-3: Product gas cooler Values as applicable

Syngas Stream  
Q,kJ/h -72007.911
Ms, kg/h 1158.620
T1, C 60.000
T2, C 40.000
Cph, kJ/kg C 2.500
Cooling Water Stream  
Mw = Q / Cpc * (T3 - T4)  
T3, C 30.000
T4, C 35.000
Cpw, kJ/kg C 4.180

At steady state conditions:

Q −72007.911 kg
M w= = =3445.355
Cpw∗( T 3−T 4 ) 4.18∗(30−35) h

LMTD:

θ1=T 1−T 4 =60−35=25 C

θ2=T 2−T 3=40−30=10 C

θ1−θ2 25−10
LMTD= = =16.370 C
θ1 25
ln
( ) ( )
θ2
ln
10

For Ft correction factor:

T 1−T 2 60−40
R= = =4
T 4 −T 3 35−30

T 4−T 3 35−30
S= = =0.167
T 1−T 3 60−30
For a 1 Shell, 2 Tube pass, and from the chart given in the reference

F t=0.8

MTD=F t∗LMTD=0.8∗16.370=13.096 C

For Area:

From the table given in the reference

 kJ
U =576
hr m 2 C

¿ U∗A∗MTD
Q 72007.911
A= = =9.546 m 2
U∗MTD 576∗13.096

For Tube Specifications:

From table 12.3 from the reference:

Tube outer diameter , d o=16 mm

Tube inner diameter , d i=10 mm
Tube thickness t t =3 mm
From the reference, the optimum tube length to shell diameter ratio is about 5 to 10.
Assume L=5 m

Areaof one tube , A tube

¿ 3.142∗do∗L=3.142∗16∗10−3∗5=0.251m 2
A 9.546
No .of tubes , N t = = =38.03
Atube 0.251
Bundle diameter
1
N
D b =do∗ t
K1( ) n1

Nt: No. of tubes

Db: Bundle diameter, mm
do: Tube diameter, mm
From Table 12.4 from the reference

For triangular pitich

pt =1.25 d o=1.25∗16=20 mm
K 1=0.249
n1 =2.207

1 1
Nt 38.03
Db=do∗ ( )
K1
n1
=16∗ ( 0.2 49 ) 2.207
=156.194 mm

For shell specifications:

typical shell clearance , SC=20 mm
shell diameter , D s=Db + Sc =156.194 +20=176.194 mm

For shell side heat transfer coefficient, hi

pt: tube pitch, mm 20.00

do: outside tube dia., mm 16.00
Ds: Shell inside dia., mm 176.194
 Lb: Baffle spacing, mm 35.4

( pt −d o )∗Ds∗Lb
Area for cross flow , A s=
pt ( 35.4
= (2 0−16 )∗176.194∗
20 )
=0. 0 01m
2

For an equilateral triangular pitch arrangement

de= ( 1.10
do )
2 2
∗( p t −0.917∗d o ) =
1.10
16
2 2
∗( 20 −0.917∗16 )=0.01 1 m

Ws
Shell side mass velocity ,Gs=
As
Gs
Shell side fluid velocity , us=
ρ
kg
fluid flow rate on the shell side ,Ws=0.957
s
kg
fluid density , ρ=1000
m3

Ws 0.957 kg
Gs= = =763.704
As 0.0 01 s m2

Gs 763.704 m
us= = =0 764
ρ 1000 s

m Ns
Viscosity of shell side fluid , μ=0.89
m2

de∗us∗ρ
Reynold s ' number , ℜ= =9744.255
μ

T 3 +T 4 30+35
Mean Shell Temperature , T sm= = =32.5 C
2 2

W
the Thermal Conductivity of Shell Fluid , kw=0.66
mC

C P∗μ
Pr= =5. 639
kw
L
=500
di
From the reference, we can get jh=0.004

0.14
hi∗di μ
[ kf ]
= jh∗ℜ∗P r 0.33∗
μw ( )
We neglect (μ/μw), and solve for hi
 W
hi=4438.733
m2 C

For Tube side Heat Transfer Coefficient, hoi

T 1 +T 2 60+ 4 0
Mean Wall Temperature T tm= = =50 C
2 2

Tube Cross Sectional Area , A t= ( 3.142

4 )∗d i =(
2 3.142
4 )
2
∗10 =78.55 m m2

Tubes per pass=18.988

Total Flow Area , Atot=( Tubes per pass )∗A t=18.988∗78.55=0.0 01m 2

kg
Density of gas fluid is givenby ρgas =20
m3

Gas mass velocity, Gs 763.704 

Ws, kg/m2 s 65.92
Gas linear velocity, ug  
ug, m/s 19.98
Thermal conductivity of gas is given by k_g  
Viscosity of gas is given by μ  
k_g, W / m C 0.13
μ, Ns / m2 0.00

di∗ug∗ρgas 16∗19.98∗3.30
Reynolds Number , ℜ= = =26769.95
μ 0.0000394

Cp∗μ 0.0000394
Prandtl Number , Pr=
kg
=4.18∗ (
0.13
=1.31 )
L
=312.5
di
From figure given in the reference
jH, 0.00
ho, W / m2 C 921.17

Overall Heat Transfer Coefficient, Uo

The expression to estimate Uo is:

(1/Uo)=(1/ho)+do∗ln (do /di)/2∗kw+(1/hi)∗(do /di)

1 m2 C
( )
Uo
=0.01
W
 W
Uo=134.98
m2 C