Chapter Four Equipment Design

4.1 Design of Heat Exchanger

Syngas hot in=304.6℃ Water in=25℃

Water in=98℃ Syngas out=200℃

Tube side (syngas) shell side (water)

T1=304.6℃ t1=25℃

T2=200℃ t2=98℃

From energy balance

Q water = Q syngas

Q water = 516614.0602kJ/hr

Q water = 143.5 kW

mwater = 1693.039 Kg\hr = 0.470 kg/s

msyngas = 1324.115 Kg\hr = 0.367 kg/s

(T1 − t 2 ) − (T2 − t1 )
ΔTLM =
T − t2
ln ( 1
T2 − t1 )
(304.6 − 98) − (200 − 25)
ΔTLM =
(304.6 − 98)
ln
(200 − 25)

56
Chapter Four Equipment Design

ΔTLM = 46.688℃

Use one shell pass and tow tube pass

T1 − T2
R=
t 2 − t1
304.6 − 200
R= = 1.43
98 − 25
t 2 − t1
S=
T1 − t1
98 − 25
S= = 0.26
304.6 − 25
By R and S, ft=0.95

from ]11[

ΔTM = ft ∗ ΔTLM

ΔTM = 0.95 ∗ 46.688 = 44.353℃

From table (6.1) Typical Coefficient U=20 – 300 W/m2. ℃

from ]11[

U=280 W/m2. ℃
Q
A=
ΔTM ∗ U

143.5 ∗ 103
A= = 11.55m2
44.35 ∗ 280
Choose

d0 = 0.02m di = 0.016m L = 1.83m

Surface area of one tube = π ∗ d0∗ L

= 3.14 ∗ 0.02 ∗ 1.83

= 0.115 m2

57
Chapter Four Equipment Design

total area
No. of tube =
Surface area of one tube
11.55
= = 100 tube
0.115
As shell side fluid is relatively

Nt 1\n
Bandle dimeter Db = d0 ∗ ( )
K

100 1\2.207
= 20 ∗ ( )
0.249
Bandle dimeter=302.56 mm

Since the coolent the syngas (use is a spilt ring) internal floating head
type from [11] bundle dimeter

Clearance = 53 mm

Shell dimeter = 302.56+53

=355.56 mm

Syngas linear velocity

304.6 + 200
Mean syngas Temp. = = 252.3℃
2
π
Tube cross section area = ∗ 162 =201 mm2
4

Tube per pass =100\2=50

Total flowrate = 50*201*10-6

=0.01005 m2

Syngas mass velocity

0.3678
= =36.597 kg/s
0.01005

Syngas linear velocity

36.597
= = 0.268 m/s
136.16

58
Chapter Four Equipment Design

h i ∗ di
= jh Repr 0.33
kf
ρudi 36.16 ∗ 0.268 ∗ 16 ∗ 10−3
Re = =
μ 0.02257 ∗ 10−3
Re=25868

Cp ∗ μ 3.73 ∗ 103 ∗ 0.2257 ∗ 10−3

pr = =
K 0.2501
pr = 0.3366
μ
( ) = neglect
μw

L 1.83 ∗ 103
= = 114.375
di 16
From figure (21) jh = 3.6 ∗ 10−3

hi ∗ 16 ∗ 10−3
= 3.6 ∗ 10−3 ∗ 25868 ∗ (0.3366)0.33 ∗ 1
0.2501
hi = 1016.2644 W/m2 ℃

shell side coefficient

choose baffle side =Ds/5

355.56
= = 71.112 mm
5

Tube pitch =1.25do

=1.25*20

=25 mm
(Dt − do)DSTB
As =
Dt
(25 − 20) ∗ 355.56 ∗ 71.112 ∗ 10−6
As =
25
As = 0.005m2

59
Chapter Four Equipment Design

Ws
Gs =
As
1 1693.03
Gs = ∗
0.005 3600
Gs = 94.057 Kg\s m2
1.10
de = (pt 2 − 0.917 ∗ do2
do
1.10
de = (252 − 0.917 ∗ 202
20
de = 14.4mm

mean shell side temp.

25 + 98
= 62℃
2
ρ water = 1000 kg/m3

μ = 0.9804 mNs/m3

cp = 4.18 kJ/Kg. s

k = 0.66 W/m. c

Gde 94.057 ∗ 14.4 ∗ 10−3

Re = =
μ 0.8904 ∗ 10−2

Re = 1521.137

Cpμ 4.18 ∗ 103 ∗ 0.8904 ∗ 10−3

Pr = =
k 0.66
Pr = 5.63

Choose 25% buffle ut [11]

Jh=3.9*10-2

Without viscosity correction term

hs ∗ de
= jhRePr 0.33
kf
60
Chapter Four Equipment Design

hs ∗ 14.4 ∗ 10−3
= 3.9 ∗ 10−2 ∗ 1521.137 ∗ 5.630.33
0.66
hs = 4809.303 W/m2 ℃

Overall heat transfer coefficient U°

d°
1 1 1 d° ln( ) d° 1 d° 1
= + + di + ∗ + ∗
u° h° h°d 2kw di hid di hi
0.02
1 1 1 0.02 ln( ) 20 1 20 1
= + + 0.016 + ∗ + ∗
u° 4809.303 3000 2 ∗ 45 16 1016.2644 16 10000
u° = 514.1388W/m2 ℃

Pressure drop

Tube side [11]

Re=25868 jf=0.0031

L ρut 2
∆Pt = Np [8Jf ( ) + 2.5]
di 2
1.83 ∗ 103 136.16 ∗ 0.2682
∆Pt = 2 [8 ∗ 0.0031 ( ) + 2.5]
16 2

∆Pt = 52.188599 kpa

Shell side

Re=1521.137
Gs 94.057
us = =
ρ 1000

us = 0.094 m\s

from [11] at Re=1521.137

jf = 6 ∗ 10−2

Ds L ρus 2 μ −0.14
∆Ps = 8jf [( ) ( )] ∗( )
de LB 2 μw

61
Chapter Four Equipment Design

∆Ps = 1.347 Kpa

4.2 Design Cyclone separator

Table (4.1) particle distributor[11]

Particle 60 50 40 30 20 10 2
size(μm)

Percentage 95 80 70 40 20 15 7
by weight
less than

Table (4.2) chemical composition of rice husk ash[15]

Content %composition Density

Fe2O3 24.63 5.24

Sio2 67.3 2.65

CaO 1.36 3.34

Al2o3 4.9 3.95

Mgo 1.81 3.58

ρcomp.of ash = ∑ xi ρcomp.

= xFe2O3 ρFe2O3 + xsio2 ρsio2 + xCao ρcao + xAl2O3 ρAl2o3 + xMgo ρMgo

ρcomp.of ash = 3.377 Kg\m3

ρsyngas = ∑ xi ρcomp.

= xCO ρCO + xCO2 ρCO2 + xN2 ρN2 + xH2 ρH2 + xH2S ρH2S

ρsyngas = 1.054 Kg\m3

62
Chapter Four Equipment Design

At 15 percent of the particles are below 10 μm the high gas rate cyclone
will be required.

Flow rate of gas =1324.115 Kg\hr

Density of flue gases = 0.2166 Kg\ m3

m m
ρ= =V=
V ρ

1324.115
V= = 6113 m3 \hr
1.054
6113
V= = 1.69 m3 \s
3600
The range of optimum velocity of separator let (10-20 m\s)

Volumetric m3\s = uA

A= 1.69\15

A=0.1126 m2

From [11] high gas rate cyclone

A = 0.75DC ∗ 0.375DC

0.1126= 0.75DC ∗ 0.375DC

0.1126=0.28125DC2

DC=0.63 m

This is Cleary too large compared with the stander design dimeter
(0.203m) many units must be used a rough estimation of the number of
units is done As
0.63
Number of units = = 3.1 ≅ 3 cyclone
0.203
Cross sectional area of new cyclone
π 2
d
= 4
3

63
Chapter Four Equipment Design

=0.1638 m2

New DC
π 2
A= dc
4
DC new=0.46 m

Try three cyclone is parrales , DC =0.46m

Flow rate per cyclone =6113\3=2037 m3\hr

From equation 4.1

1\2
DC2 3 Q1 ∆P1 μ2
d2 = d1 [( ) ∗ ∗ ∗ ]
DC1 Q2 ∆P2 μ1
1\2
DC2 3 Q1 ∆P1 μ2
Scaling factor =[( ) ∗ Q2 ∗ ∆P2 ∗ μ1]
DC1

DC1= dimeter of the standard cyclone = 8 inch (0.203m)

DC2= dimeter of the proposed cyclone =0.46 m

Q1= standard flow rate for high through put design = 669 m3\hr

Q2= proposed flow rate = 2037 m3\hr

∆P1= solid fluid density difference in standard conditions =

2000kg\m3

∆P2= density difference in proposed design = 2137 kg\m3

Viscosity syngas =∑ xi Vi

= xCO VCO + xCO2 VCO2 + xN2 VN2 + xH2 VH2 + xH2S VH2S

=0.36*1.74+0.22*1.47+0.163652*2.51+0.255*1.53+0.0289*1.8
0.01 CP
= 0.8109 pa. s ∗
1Pa. s
Vsyngas=0.081cp

μ1 = test fluid viscosity (air at 20℃) = 0.0180 Ns\m

64
 Chapter Four Equipment Design

μ2 = viscosity proposed fluid

1\2
DC2 3 Q1 ∆P1 μ2
d2 = d1 [( ) ∗ ∗ ∗ ]
DC1 Q2 ∆P2 μ1
1\2
d2 DC2 3 Q1 ∆P1 μ2
= [( ) ∗ ∗ ∗ ]
d1 DC1 Q2 ∆P2 μ1
1\2
d2 DC2 3 Q1 ∆P1 μ2
= [( ) ∗ ∗ ∗ ]
d1 DC1 Q2 ∆P2 μ1
1\2
d2 0.46 3 669 2000 0.081
= [( ) ∗ ∗ ∗ ]
d1 0.203 2037 3377 0.018

Scaling factor =3.19

1 2 3 4 5 6 7

Mean Efficiency
Particle Per cent in particle at scale size Collected Carding at Per cent all
(2)∗(4)
size (μm) range size/scalin % figure (2)(5) exit
100
g factor (10.46b)

>60 10 15 83 8.3 1.7 4.33

60-50 15 14 81 12.15 2.85 7.266

50-40 10 11 72 7.2 2.8 7.1392

40-30 30 9 65 19.5 10.5 26.77

30-20 20 6 52 10.4 9.6 24.47

20-10 5 4 43 2.15 2.85 7.266

10-2 8 2 11 0.88 7.12 18.154

2-0 2 1 10 0.2 1.8 4.59

Overall collection efficiency 60.78 39.22 100

65
Chapter Four Equipment Design

Pressure drop calculation

Area of intel duct

Dc=0.46

From figure (4.6)b

A1=0.75Dc*0.375Dc

A1=172.5*345

A1=59512 mm2

Cyclone surface area =π*460*(690+1150)

As=2.657*106 mm2

FC taken as 0.005
FC∗As
φ=
A1

0.005 ∗ 2.65 ∗ 106

=
59512
=0.22
rt 460 + (345\2)
= = 3.67
re 172.5
some from figure (4.7)

ϑ = 1.3

2037 106
u1 = × = 9.5m\s
3600 59512
π ∗ 172.52
Area of exit pipe =
4
Area of exit pipe=23358 mm2

2037 106
u2 = ∗ = 24m\s
3600 23358

66
Chapter Four Equipment Design

from equation 4.2

ρF 2rt
∆P = ∗ [u1 2 [1 + 2ϑ2 ( − 1)] + 2u2 2 ]
203 re
∆P = cyclone pressure drop (milibar)

1 m bar=10.47 mmH2O

ρF=gas density (Kg\m3)

u1 =intel duct velocity m\s

u2 =exit duct velocity m\s

rt=radius of circle to which the center line of inlet is tangential (m).

re=radius of exit pipe (m).

MWt T° P
density of gas = ∗ ∗
V° T P°

MWt syngas = ∑ xi MWt

mCO mCO2 mN2 mH2

= ∗ MWt CO + ∗ MWt CO2 + ∗ MWt N2 + ∗ MWt H2
mT mT mT mT
mH2S
+ ∗ MWt H2S
mT

MWt syngas = 22.62

22.62 273 1
density of gas = ∗ ∗
22.4 373 1
density of gas = 0.739 Kg\m2
0.739
∆P = ∗ [9.52 [1 + 2 ∗ 1.32 (2 ∗ 3.67 − 1)] + 2 ∗ 242 ]
203
∆P = 1.56 bar=121.0332 mmH2O

This pressure drop looks reasonable

67
Chapter Four Equipment Design

345 mm
172.5 mm

460mm 690 mm
1150 mm

172.5mm

Figure (4.6) proposed cyclone design, all dimension (mm)

68
Chapter Four Equipment Design

4.3 Reactor Design

reaction time = 1 hr [14]

C + H2 O ⟶ CO + H2

wt C = 364.035 kg

wt H2O = 272.97 kg

ρC = 0.288 kg/m3

ρC = 1000 kg/m3
w 364.035
Vcarbon = = = 1264
ρ 0.288
30.336
CC° = = 0.024
1264
xA = 0.75

CC = CC°(1 − XA)

= 0.024(1 − 0.75)

CC = 6 ∗ 10−3

−rA = KCAn
(1 − XA)
CC = CC°
1+∈ XC
CC = 6 ∗ 10−3

−rA = K[CC][CH2O]

−rA = 1 ∗ [6 ∗ 10−3 ][CH2O]

P
[CH2O] =
RT
9.114 psia ∗ 1 kg/ms 2 1J ∗ 1kJ
∗
kJ 2
8.314 ∗ 323K 14.7 ∗ 1 kg/ms ∗ 1000J
kgmol

69
Chapter Four Equipment Design

[CH2O] = 0.2308 kmol/m3

−rA = 1 ∗ [6 ∗ 10−3 ][0.2308]

−rA = 1.3848 ∗ 10−3

XC
dAC
τ = CC° ∫
0 −rA
0.75
dAC
τ = 0.024 ∫
0 1.3848 ∗ 10−3

τ = 12.998 sec
CC° × V
τ=
FC°
1 kgmol 1 hr
FC° = 933.424 Kg\hr ∗ ∗
27.35 3600s
FC° = 9.5 ∗ 10−3 kgmol/s
τ ∗ FC°
V=
CC°
12.998 ∗ 9.5 ∗ 10−3
V= = 5.14
0.024
PV1 PV2
=
T1 T2
V2=?
Kg 1 kgmol 1hr
F2 = 1324.115 ∗ ∗
hr 26.7 kg 3600s

F2=0.014 kgmol\s
(PV)1 (nRT)2
=
(PV)2 (nRT)1
0.014 Kgmol 22.4 911.4 273
V2 = ∗ ∗ ∗
s 1 kgmol 14.7 psi 773

V2 = 6.407 m3 /s

70
Chapter Four Equipment Design

V2 = 1.49 m3 /s ∗ 4.3 s

V2 = 6.407 m3

V of gasifier=V solid+ Vgas

V of gasifier=5.14+6.404

V of gasifier=12 m3

dimeter of gasifier

V of gasifier=A*L
π 2
V= d L
4
L
=3−6
D
L
= 4.5
D
L = 4.5D
π 2
12 = d ∗ 4.5D
4
D=1.5 m

L=4.5*1.5

L=6.76≈7

71