Chapter 6

Equipment Design
 In this chapter, as a practice of engineering we aim to design the required equipment for the
hydrocracking unit hich can be summarized as following:

1. Heat Exchanger
2. Air cooler
3. Reciprocating Compressor (K-100)
4. Pump (P-101)
5. Fired Heater (ATM-FH)
6. Trayed Tower (Sieve Tray)
7. Trayed Tower (Bubble Cap Tray)

6.1. Heat Exchanger

HEX 1 transfers heat between the HCU feed and the reactor effluent. The hot effluent preheats
the feed, improving energy efficiency and reducing external heating requirements.

6.1.1. Hand calculations

Data Given
Stream Tin oC Tout oC Flow Rate lb./hr. API Pin (psia)
Reactor effluent (Hot) 423.8 391.7 9.709*105 56.17 1885
HCU Feed (Cold) 183.1 270.5 6.649*105 21.36 2669

Q = 64*105 btu/hr
Step 1: calculate streams properties at Tmean

Property HCU Feed (shell) Reactor Effluent (Tube)

Tmean (F) 441 766
K (btu/ft.hr.f) 0.0645 0.0725
Cp (btu/lb.f) 0.61 1.13
Sp.Gr 0.78 0.6
µ (cp) 1.423 0.042

Step 2: calculate ΔTlm

ΔTlm = (ΔT1 – ΔT2) / ln(ΔT1/ΔT2)
ΔTlm = 323 F HOT 795 f

R=0.37 S=0.36 737 f 519 f

f=0.99 362 f COLD

Use 4 shells
ΔT2= 375 f ΔT1= 276 f
(ΔTlm)corrected=ΔTlm * f = 320 F
Assume U = 30 btu/ft2.f.hr
Area assumed = Q / (U*(ΔTlm)corrected) = 6667 ft2
Step 3: calculate layout
Do= 1 inche , Δ , P= 1.25 inche , BWG = 14
Al =0.2618 ft2/ft , Ai =0.00379 ft2 , Din = 0.834 inche , De = 0.72 inche
Step 4: calculate Ntubes
Assume L=32 ft
N = (Area assumed)/(Leff ×Al ) = (6667/(31.5*0.2618)=809 tube
Use 2-tube passes , floating head
Ntubes = 872 tube , I.Ds = 42 inche , n = 436 tube/pass
V = (tube side flow rate)/(n×density ×Ai×3600)= 4.36 ft/sec (between 4 : 6 ) safe
Step 5: check on U
Gt =(flow rate in tube)/(Ai×n) = 587600 lb/hr.ft2
Re = (Gt×Di)/μ = 400000 , L/Di = 461
From figure : JH = 800
hi=J×K/Di×((Cp×μ)/K )^(1/3)= 974
hio = hi×Di/Do = 813 btu/ft.f.hr
Use c = 0.25 inche , B = 8 inche , 25% baffle cut
as = (Ds×C×B)/(144×P)= 0.46704 ft2
Gs/shell = (shell flow rate)/as= 356000 lb/hr.ft2
Re = (Gs×De)/μ = 6300
From figure get JH = 43
ho= J×K/De×((Cp×μ)/K )^(1/3)= 161 btu/ft.f.hr
use Ri = Ro = 0.002
U =1/(1/hio+1/ho+Ri+Ro)= 87.5 btu/ft2.f.hr> 30 btu/ft2.f.hr safe
Step 6: check on excess area
Area req = Q/(U×ΔTlm) = 2290 ft2
 Area available = N×Ai×Leff = 2690 ft2 ( reduce L to 12 ft and X=0.25 ft)
Excess %=(available-required)/(required )×100= 17.5 % ( between 10% : 25 % ) safe
Step 7: check on shell side pressure drop
F= 0.0025 , Nc+1 = (L×12)/B = 18
ΔPs =(f×Gs^2×Ds×(Nc+1))/(5.22×10^10×De×sp.gr)= 8.2 psi < 10 psi safe
Step 8: check on tube side pressure drop
Using sp.gr and V we get ΔP1 = 0.9 psi/pass
ΔPReturn = 0.935 x 2 = 1.87 psi
F=0.0001
ΔPt =(f×G^2×L×Npass)/(5.22×10^10×Di×sp.gr)= 0.4 psi
ΔPTube = ΔP1 + ΔPReturn = 1.87 + 0.4 = 2.27 psi < 10 psi safe
Final Design :
1. Heat Exchanger type : Floating head
2. Fluid in shell : HCU Feed
3. Fluid in tupe : Reactor Effluent
4. L = 12 ft , 1 inch O.D , 1.25 Pitch , Δ
5. Nshells = 4 shell
6. Ntubes = 872 tubes / shell
7. Npases = 2 passes
8. ΔPshell = 8.2 psi
9. ΔPtube = 2.27
10. B =8 inch , 25 % baffle cut
11. Velocity in tube = 4.36 ft/s
12. Excess Area = 17.5%

6.1.2. EDR Software

Overall Performance
Design (Sizing) Shell Side Tube Side
Total mass flow rate lb/h 664900 970899.7
Vapor mass flow rate (In/Out) lb/h 0 0 0 0
Liquid mass flow rate lb/h 664900 664900 970899.7 970899.7
Vapor mass fraction 0 0 0 0
Temperatures °F 362 518.89 795 737
Bubble / Dew Point °F / / / /
Operating Pressures psi 2669 2662.55 1885 1882.73
Film Coefficient BTU/(h-ft²-F) 215.3 2411.52
Fouling Resistance ft²-h-F/BTU 0.002 0.003
Velocity (highest) ft/s 3.63 6.66
Pressure drop (allow./calc.) psi 10 / 6.45 10 / 2.27
Total heat exchanged BTU/h 63632780 Unit BEM 2 Pass 1 ser 1 par
Overall clean coeff. (plain/fin) BTU/(h-ft²-F) 173.66 / Shell size 42 - 144 in Hor
Overall dirty coeff. (plain/fin) BTU/(h-ft²-F) 93.08 / Tubes Plain
Effective area (plain/fin) ft² 2519.6 / Insert None
Effective MTD °F 318.36 No. 897 OD 1 Tks 0.165 in
Actual/Required area ratio (dirty/clean) 1.17 / 2.19 Pattern 30 Pitch 1.25 in
Vibration problem (HTFS) No Baffles Single segmental Cut(%d) 14.41
TEMA RhoV2 limit exceeded Yes Total cost 606964 Dollar(US)

Resistance Distribution
Overall Coefficient / Resistance Summary Clean Dirty Max Dirty
Area required (tube OD base) ft² 1151 2147.4 2519.6
Area ratio: actual/required 2.19 1.17 1
Overall coefficient BTU/(h-ft²-F) 173.66 93.08 79.33
Overall resistance ft²-h-F/BTU 0.0058 0.0107 0.0126
Shell side fouling ft²-h-F/BTU 0 0.002 0.0027
Tube side fouling ft²-h-F/BTU 0 0.003 0.0041
Resistance Distribution BTU/(h-ft²-F) ft²-h-F/BTU % % %
Shell side film 215.3 0.0046 80.66 43.23 36.85
Shell side fouling 499.98 0.002 18.62 21.79
Tube wall 1430.73 0.0007 12.14 6.51 5.54
Tube wall fouling* 334.98 0.003 27.79 32.53
Tube side film* 2411.52 0.0004 7.2 3.86 3.29
*
Based on outside surface – Area ratio: Ao/Ai = 1.49

TEMA sheet
Heat Exchanger Specification Sheet
1 Company: 2025 graduation project
2 Location: suez
3 Service of Unit: Our Reference:
4 Item No.: HEX 1 Your Reference:
5 Date: 20 mar Rev No.: Job No.:
6 Size : 42 - 144 in Type: BEM Horizontal Connected in: 1 parallel 1 series
7 Surf/unit(eff.) 2519.6 ft² Shells/unit 1 Surf/shell (eff.) 2519.6 ft²
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name HCU Feed reactor
effluent
11 Fluid quantity, Total lb/h 664900 970899.7
12 Vapor (In/Out) lb/h 0 0 0 0
13 Liquid lb/h 664900 664900 970899.7 970899.7
14 Noncondensable lb/h 0 0 0 0
15
 16 Temperature (In/Out) °F 362 518.89 795 737
17 Bubble / Dew point / / / /
18 Density (Vap / Liq) lb/ft³ / 48.672 / 48.672 / 37.44 / 37.44

19 Viscosity cp / 1.423 / 1.423 / 0.042 / 0.042

20 Molecular wt, Vap
21 Molecular wt, NC
22 Specific heat BTU/(lb-F) / 0.61 / 0.61 / 1.13 / 1.13
23 Thermal conductivity BTU/(ft-h-F) / 0.064 / 0.064 / 0.725 / 0.725
24 Latent heat BTU/lb
25 Pressure (abs) psi 2669 2662.55 1885 1882.73
26 Velocity (Mean/Max) ft/s 2.87 / 3.63 6.56 / 6.66
27 Pressure drop, allow./calc. psi 10 6.45 10 2.27
28 Fouling resistance (min) ft²-h-F/BTU 0.002 0.002 0.003 Ao based
29 Heat exchanged 63632780 BTU/h MTD corrected 318.36 °F
30 Transfer rate, Service 79.33 Dirty 93.08 Clean 173.66 BTU/(h-ft²-F)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/vac/test pressure:g psi 2940 / / 2080 / /
34 Design temperature / MDMT °F 860 / 860 /
35 Number passes per shell 1 2
36 Corrosion allowance in 0.125 0.125
37 Connections In in 1 14 / - 1 12 / -
38 Size/rating Out 1 12 / - 1 16 / -
39 Nominal Intermediate / - / -

40 Tube No. 897 OD 1 Tks-Avg 0.165 in Length 144 in Pitch 1.25 in Tube pattern 30
41 Tubetype: Plain Insert:None Fin# #/in Material: Carbon Steel
42 Shell Carbon Steel ID 42 OD 64 in Shell cover -
43 Channel or bonnet Carbon Steel Channel cover -
44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -
45 Floating head cover - Impingement protection None
46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 14.41 H Spacing: c/c 8 in
47 Baffle-long - Seal type Inlet 20.375 in
48 Supportstube UBend 0 Type
49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(UW-20 'i')

50 Expansion joint - Type None

51 RhoV2-Inlet nozzle 1504 Bundle entrance 1319 Bundle exit 1916 lb/(ft-s²)
52 Gaskets - Shell side - Tube Side Flat Metal Jacket Fibe
53 Floating head
54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service
55 Weight/Shell 198993 Filled with water 204395.4 Bundle 39937.9 lb
56 Remarks
Setting plan
Tube sheet layout
6.2 Air Cooler
6.2.1 Hand Calculations
Data Given:
Diesel; Flow rate = 88000 lb/h, Tin = 473 ℉, Tout =300 ℉, API = 25
Air; tin = 80 ℉

Solution
Step 1: Calculate Heat Duty
Tmean = (473+300)/2 = 386.5℉
Using Tmean and API, get the physical properties of diesel
-From page 803 at Kern, K = 0.067 BTU/ft.℉.h
-From page 806 at Kern, Cp = 0.608 BTU/lb.
-From page 809 at Kern, sp.gr = 0.781
-From page 823 at Kern, μ= 0.67 cp =1.6147 lb/ft.h
Q = G Cp ∆ T =88000∗0.608∗( 473−300 )=9256192 BTU /h

Step 2: Assume U
-From page 415, Table 1→ U=23 BTU/ft2.℉.h
Step 3: Calculate tout of Air

∆ t=0.005∗U + [ 2 ]
T ¿ +T out
[
−t ¿ =.005∗23∗
473+300
2 ]
−80 =35.2 ℉

-From figure 1, page 415, get ∆t correction factor using ∆T = 173 ℉

Fc = 1.114
∆tcorr. = ∆t*Fc = 35.2*1.114 = 39.2 ℉
tout = tin + ∆tcorr = 80+39.2 = 119.2 ℉

Step 4: Calculate LMTD

Tin = 473℉
∆ T max−∆ T min 353.8−220 Diesel
∆ T lm= = =281.6
a) ∆ T max 353.8 ℉
ln ln Tout =300℉
∆ T min 220
b) Determine ∆Tlm correction factor tout=119.2℉

t out −t ¿ 119.2−80 tin=80℉ Air

P= = =0.0997
T ¿−t ¿ 473−80
T ¿−T out 473−300 ∆Tmax =353.8℉
R= = =4.41 ∆Tmin =220℉
t out −t ¿ 119.2−80
-From figure 2, page 417 → Fc = 0.975
 ∆Tlm corr. = ∆Tlm*Fc =281.6*0.975 = 274.56 ℉

Step 5: Calculate Area and Make Layout

Q 9256192 2
a) Areqd = = =1466 ft
U∗∆ T lm. c 23∗274.56
b) Choose a standard area from Table 11, page 416 that achieves these conditions
Astd > Areqd
Excess Area = (Astd-Areqd)/Areqd in the rage of 10 to 20 %
L/W ≥ 1.8
Fans/Unit = 2
Select Astd = 1713 ft2
A std − A reqd 1713−1466
Excess Area= ∗100 %= ∗100 %=16.85 %
A reqd 1466
Air Cooler Layout:
3
1 in O.D, Di=0.834 in, P=2 , BWG=14, no. of tube rows=4, W=10 ft, L=24 ft, one Bay,
8
2
fans/Bay=2, Astd=1713 ft

Step 6: Calculate Fan Power

1st Method
Fan Power
-From figure 3, page 427 using U=59BTU/ft2.℉.h → 2 = 1.59 hp/100ft2
100 ft
Fan Power 1.5
HP= ∗A std = ∗1713=25.695 hp
100 100
HP = 26 hp std

2nd Method
W∗L∗t ¿ +460 12∗30∗80+ 460
HP= ∗ρair = ∗0.075=27.51 hp
530 530
HP = 28 hp std
Select the highest value of the two methods.

So, Total HP = 28 hp std

Use 2 fans*14 hp

Step 7: Check ∆t Correction

1st Method
∆t = B/S
And knowing that no. of tube rows = 4 → B = 7590
S = Astd/Q = 1713*106/9256192= 185.065 ft2.h/MMBTU
∆tcorr. = 7590/185.065 = 41 ℉
∆tcorr. (check) (41℉) > ∆tcorr. (design) (35.2℉) SAFE

2nd Method
∆tcorr. = Q/(Gair*Cpair)
Gair = Face velocity*W*L*𝜌air
Knowing that no. of tube rows = 4 → face velocity = 33000 ft/h
Gair = 33000*12*30*0.075 = 891000 lb/h
∆tcorr. = 9256192/ (891000*0.245) = 42.4 ℉
∆tcorr. (check) (42.4℉) < ∆tcorr. (design) (35.2℉) SAFE

Step 8: Calculate Pressure Drop

1. No. of tubes, N = Astd/0.2618L = 1713/ (0.2618*30) = 219 tubes

2. Re
Gt = G/(ai*N) = 88000/ (0.00379*219) = 106022.82 lb/h.ft2
Ret = Gt*Di/μ = 106022.82 *0.0695/1.62 = 4563
G 88000
3. Vt = = =0.594 ft /s
3600∗62.4∗sp . gr∗N∗ai 3600∗62.4∗0.795∗219∗0.00379
-From page 214 at Ludwig using Vt and sp.gr → ∆Pr = 0.013 psi
∆Preturn= no. of passes * ∆Pr = 1*0.014 = 0.013 psi (air cooler is one pass)
4. From page 214 at Ludwig using Ret & Tube line → f = 0.00032
2
f ∗G t ∗L∗no . of passes 0.00035∗106022.822∗30∗1
∆Pt = 10
= 10
=0.0381 psi
5.22∗10 ∗Di∗sp . gr 5.22∗10 ∗0.0695∗0.781
∆Ptube = ∆Pt + ∆Preturn = 0.013+0.0381 = 0.0484 psi < 10 psi Safe

Final Design

 no. of tube rows=4

 W=12 ft
 L=30 ft
 one Bay
 fans/Bay=2
 Astd =1713 ft2
 Excess Area = 16.85 %
 HP = 28 hp std (use 2 fans*14 hp)
 6.2.2. EDR Software
Input Data

Process Data
Tube Side
In Out
Fluid name Diesel
Mass flow rate (total) lb/h 880000
Temperature °F 473 300
Vapor mass fraction 0 0
Operating pressure kgf/ 1.033
(absolute) Heat exchanged cm²
BTU/
h
Allowable pressure drop ps 10
Fouling resistance i m²- 2E-05
K/W

Outside Tube
Fluid name Air
Air/Gas mass flow rate lb/
Face velocity h ft/s
Required bundle pressure drop inH2
O
In Out
Air/Gas dry bulb design °F 80
Minimum ambient temperature °F 32
Operating pressure specification Altitude and Gauge
pressure
Altitude above sea level ft 0
Inlet pressure (gauge) atm 1
Inlet pressure (absolute) psi
Allowable pressure drop psi 10

Inlet humidity parameter Default (not set)

Humidity ratio
Relative humidity (%)
 Overall Result Summary
1 Unit Length/Width/Height 31.9685 / 12.0157 / 0.6819 ft
Tube inclination 0
2 Baysperunit 1 Bundles per bay 1 Tube Rows 4 Passes 1 X-side flow direction 0
Degrees
3 Staggered-even rows to right Tube flow orientation Counter-current
4 Total surface 41972.3 Ext surface/bundle 41972.3 Bare/Bundle 1786.7 ft²
Ratio (Total/Bare) 23.49
5 Design with varying outside flo Performance of the Unit
6 Tube Side X-Side Heat Transfer Parameters
7 Process Data In Out In Out Total head load BTU/h
9293656
8 Total Flow lb/h 88000 981461.8 Effective MTD °F 283.7
9 Gas 981461.8 Actual/Reqd area ratio(dirty/clean) 1.05 / 1.05
981461.8
1 Vapor 0 0
0
1 Liquid 88000 88000 0 0 Coef/Resist (Bare) BTU/(h-ft²-F) ft²-h-F/BTU %
1
1 Cond./Evap. 0 0 Tube side film 21.56 0.0464 89.13
2
1 Temperature °F 473 300.01 80 119.31 Tube side fouling 8699.59 0.0001 0.22
3
1 Quality 0 0 Tube wall 5735.42 0.0002 0.34
4
1 Humidity ratio Outside fouling 9999.53 0.0001 0.19
5
1 Pressure (abs) psi 14 13.44 Outside film 189.81 0.0053 10.12
6
1 inH2O 813.59 813.59 Overall fouled 19.22 0.052
7
1 DP 0.56 0.31 Overall clean 19.3 0.0518
8
1 Velocity ft/s 0.56 0.5 10.77 11.56
9
2 Liquid Properties Tube Side Pressure Drop psi %
0
2 Density lb/ft³ 45.348 50.691 Inlet nozzle 0.02 3.47
1
2 Viscosity cp 0.269 1.2999 Inlet header 0 0.12
2
2 Specific heat BTU/(lb-F) 0.66 0.561 Inside tubes 0.04 7.15
3
2 Th Cond BTU/(ft-h-F) 0.056 0.069 Across pass 0 0
4
2 Surface lbf/ft Other header 0 0.14
5
2 Vapor Properties Outlet nozzle 0.5 89.12
6
2 Density lb/ft³ 0.147 0.137 Outside Pressure Drop inH2O %
7
2 Viscosity cp 0.0185 0.0195 Ground clearance 0 0
8
2 Specific heat BTU/(lb-F) 0.2409 0.241 Fan inlet 0.03 8.09
9
3 Th Cond BTU/(ft-h-F) 0.015 0.016 Bundle 0.32 91.57
0
3 Two-Phase Properties Louvers 0 0
1
3 Latent BTU/lb Steam Coil 0 0
2
3 Molecular weight 28.96 Plenum 0 0
3
3 Heat Transfer Parameters Heat Load BTU/h
4
3 Reynolds No. vapor 10636.09 Vapor 0
5 10090.97
3 Reynolds No. liquid 10236.77 2118.44 Cond./Evap 0
6
3 Prandtl No. vapor 0.71 0.7 Liquid 9293656
7
3 Prandtl No. Liquid 7.71 25.57 Input/Actual duty ratio 1
8
3 Tubes / Fin Last row number 4
9
4 Tubes per bundle 232 Tube OD / ID in 1 / 0.87 / / /
0
4 Tube material Carbon Steel Fin type G-finned
1
4 Length effective ft 29.4167 Fin material Aluminum 1060
2
4 Length actual ft 30 Fin tip diameter in 2.25
3
4 Transverse pitch in 2.3622 Fin thickness in 0.011
4
4 Longitudinal pitch in 2.0457 Fin frequency #/in 11
5
4 Pitch angle 30 Root diameter in 1
6
4 Th Cond BTU/(ft-h-F) 33.227 Th cond BTU/(ft-h-F) 129.353
7
4 Surface effectiveness 0.82 Surface effectiveness 0.82
8
4 X-side and Fan Header and Nozzles Weights lb
9
5 Type draft Forced Inlet Other Inlet header 1855.6
0
5 Fans/bay 2 Header type Box Box Other header 1855.6
1
5 Vol./fan(Act/Std) ft³/min 55607.2 Header depth in 11.811 Inlet nozzle 19.6
2 109204.4 11.811
5 Face vel. (Act/Std) ft/s 5.47 10.75 In Out Outlet nozzle 19.6
3
5 Fan diam./% cov. ft 9 36.83 No. of nozzles 1 1 Tubes and fins 7685.7
4
5 Sum./Win. des. Temp °F 80 32 Nozzle ID in 3.364 3.364 Side frms/supports 2807.1
5
5 Abs pwr/fan-Winter hp 4.8 Hom. Velocity ft/s 8.73 7.81 Bundle - dry 14243.2
6
5 Abs pwr/fan-Summer hp 4.4 Rho*V2 lb/(ft-s²) 3459 3094 Bundle - wet 16993.6
7
5 Drive efficiency 95 Unit bundles - dry 14243.2
8
5 Fan efficiency 65 Unit bundles - wet 16993.6
9

API Sheet
1 Company:
2 Location:
3 Service of Unit: Our Reference:
4 Item No.: Your Reference:
5 Date: Rev No.: Job No.:
6 Size & Type 31.9685 / 12.0157 ft Type Forced Number of Bays 1
7 Surf/Unit-Finned Tube 41972.3 ft² Bare area/bundle 1786.7 ft² Ratio (Total/Bare) 23.49
8 Heat exchanged 9293656 BTU/h MTD, Eff 283.7 °F
9 Transfer rate 0.82 Bare, Service 18.34 Clean 19.3 BTU/(h-ft²-F)
 10 PERFORMANCE DATA - TUBE SIDE
11 Fluid Circulated Diesel In / Out
12 Total Fluid Entering lb/h 88000 Density, Liq lb/ft³ 45.348 / 50.691
13 In / Out Density, Vap lb/ft³ /
14 Temperature °F 473 / 300.01 Specific Heat, Liq BTU/(lb-F) 0.66 / 0.561
15 Liquid lb/h 88000 / 88000 Specific Heat, Vap BTU/(lb-F) /
16 Vapor lb/h 0 / 0 Therm. Cond, Liq BTU/(ft-h-F) 0.056 / 0.069
17 Noncondensable lb/h 0 / 0 Therm. Cond, Vap BTU/(ft-h-F) /
18 Steam / Freeze Point °F
Water / Bubble / Dew point °F /
19
20 Molecular wt, Vap / Latent heat BTU/lb
21 Molecular wt, NC Inlet pressure (abs) 14
22 Viscosity, Liq cp 0.269 / 1.2999 Pres Drop, Allow/Calc psi 10 / 0.56
23 Viscosity, Vap cp / Fouling resistance ft²-h-F/BTU 0.0001
24 PERFORMANCE DATA - AIR SIDE
25 Air Quantity, Total 981461.8 lb/h Altitude 0 ft
26 Air Quantity/Fan 55607.2 ft³/min Temperature In 80 °F
27 Static Pressure 0.31 inH2O Temperature Out 119.31 °F
28 Face Velocity 5.47 ft/s Mass velocity 2896.1 lb/h/ft² Design Ambient 32 °F
29 DESIGN-MATERIALS-CONSTRUCTION
30 Design/Vac./Test Pres 50 / / psi Design temperature 700 °F
31 TUBE BUNDLE Header Tube
32 Size ft 31.9685 Type Box Material Carbon Steel
33 Number/bay 1 Material Carbon Steel Specifications
34 Tube Rows 4 Passes 1 OD 1 MinTk 0.06 in
5

35 Arrangement Plug Mat. no 232 Lng 30 ft

36 Bundles 1 par Gasket Mat. Pitch 2.3622 / 2.0457 30 Degrees
37 Bays 1 par Corr. Allow. in FIN
38 Bundle frame Inlet Nozzle ( 1 ) 3.364 in Type G-finned
39 MISCELLANEOUS Outlet nozzle ( 1 ) 3.364 in Material Aluminum 1060
40 Struct. Mount. Special Nozzles OD 2.25 Tks 0.01 in
1
41 Surf.Prep Rating Program no. 11 #/in DesTemp °F
42 Louvers TI PI Code ASME Code Sec VIII Div 1
43 Vibration Switches Chem Cleaning Stamp Yes Specs
44 MECHANICAL EQUIPMENT
45 Fan,Mfr., Model Driver, Type Program Speed Reducer, Type
46 No./Bay 2 RPM Mfr. Mfr.&Model
47 Dia. 9 ft Blade(s) No./Bay No./Bay
48 Pitch Angle RPM Rating hp
49 Blade(s) Hub Enclosure Ratio
50 hp/Fan 4.8 hp MinAmb V/Phase/Hz / / Support
51 ControlActionon AirFailure Louvers
52 Degree Control of Outlet Process Temperature
53 Recirculation Steam Coil No
54 Plot Area ft² Drawing No. Wt.Bundle 14243.2 Wt. Unit 14243.2 lb
55 Notes:
56
57
58

Overall Performance

Design with varying outside flow Outside Tube Side

Total mass flow rate lb/h 981461.8 88000
Vapor mass lb/h 981461.8 981461.8 0 0
Liquid mass lb/h 0 0 88000 88000
Vapor mass quality 1 1 0 0
Temperature °F 80 119.31 473 300.01
Dew / Bubble Point temp °F
Humidity ratio
Operating pressure inH2O / psi 813.59 813.59 14 13.44
Film Coefficients BTU/(h-ft²-F) 189.81 21.56
Fouling resistance ft²-h-F/BTU 0.0001 0.0001
Velocity (highest) ft/s 10.77 / 11.56 0.56 / 0.5
Pressure drop (allow/Calc) inH2O / psi 27.68 / 0.011 10 / 0.56
Total heat exchanged BTU/h 9293656 Bays per unit 1 Tube OD 1 in
Overall bare coeff. (dirty/clean) BTU/(h-ft²-F) 19.22 / 19.3 Bundles/bay 1 Tube tks 0.065 in
Effective MTD °F 283.7 Tubes/bundle 232 Tube length 30 ft
Effective surface (bare tube) ft² 1786.7 Rows deep 4 Fin OD 2.25 in
Effective surface (total) ft² 41972.3 Tube passes 1 Fin tks 0.011 in
Area ratio dirty (actual/required) 1.05 Fans/bay 2 Fin frequency 11 #/in
 Resistance Distribution

Overall Coefficient / Resistance Summary Clean Dirty Max Dirty

Area required (total) ft² 39881.5 40046.9 41972.3
Area required (bare tube) ft² 1697.7 1704.7 1786.7
Area ratio: actual/required 1.05 1.05 1
Overall coefficient BTU/(h-ft²-F) 19.3 19.22 18.34
Overall resistance ft²-h-F/BTU 0.0518 0.052 0.0545
Outside fouling ft²-h-F/BTU 0 0.0001 0.0001
Tube side fouling ft²-h-F/BTU 0 0.0001 0.0001
Resistance Distribution BTU/(h-ft²-F) ft²-h-F/BTU % % %
Outside film 189.81 0.0053 10.17 10.12 9.66
Outside fouling 9999.53 0.0001 0.19 2.32
Tube wall 5735.42 0.0002 0.34 0.34 0.32
Tube wall fouling 8699.59 0.0001 0.22 2.66
Tube side film (bare) 21.56 0.0464 89.5 89.13 85.04
Setting Plan
Tube Layout
6.3. Reciprocating Compressor (K-100)

Data Given:

- Gas type is Pure Hydrogen

- Gas flow rate ( Q g )=188.56 MMSCFD
- Suction pressure ( P1 ) =142.7 Psia
- Discharge pressure ( P2 ) =1885 Psia
∘
- Gas inlet temperature ( T 1 )=150 F
∘
- Cooling Water / Air temperature ( t 1 )=80 F
Solution

⸪ the Gas flow rate is very large approximately close to 200 MMSCFD

⸫We use Four Similar Compressors in parallel and each Compressor has a Gas flow rate = 200/4 = 50
MMCSFD
Now , we design one of these Compressors

Step 1: Calculate the Compression Ratio (R)

P2 1885
Rc = = =13.2095≫ 4
P1 142.7

∴ We use Multi-stage Compressor

Step 2: Assume Number of Stages (n)

For 3 stages (n=3)

Rstage =√ 13.2095=2.364< 4 ∴ ok
3

Step 3: Calculate actual (corrected) " R " for each stage

∵ Qg =50 MMSCFD ∴ ∆ P Inter cooler =3 psi

 a) For 1st Stage

P1 ¿142.7 psia

P11 ¿ P1∗Rstage + ( ΔP2 )

P11 338.8428
¿ ∴ R 1= = =2.375
P1 142.7

b) For 2nd Stage

P22 ¿ P11 −ΔP=338.8428−3=335.8428 psia

P33 ¿ P 22∗Rstage +( ΔP /2)
P33 795.432
¿ ∴ R 2= = =2.368
P22 335.8428

c) For 3rd Stage

P44 =P33−ΔP=795.432−3=792.432 psia

P2=1885 p sia
P2 1885
∴ R3= = =2.379
P44 792.432

Step 4: Check on temperature after compression

 For Pure component

 From Table (124 ) We get K For Pure H 2
∴ K=1.41
st
a) For 1 Stage

b) For 2nd Stage

∘ ∘
T 3=tw +15=80+15=95 F+ 460 ¿ 555 R
¿ ¿

c) For 3rd Stage

∘ ∘
¿ T 5=tw +15=80+ 15=95 F+ 460=555 R
¿

Step 5: Horse Power Per Stage

Q ∗BHP
(i) BHP/¿ stage ¿ MMCFD (14.4 psia ,t )
1

¿¿

st nd rd
1 Stage 2 Stage 3 Stage

Qgs∗14.7 Qgs∗14.7 Qgs∗14.7

∗t suc + 460 ∗t suc + 460 ∗t suc + 460
14.4 14.4 14.4
Qg Q g1 = Q g 2= Q g3 =
60+460 60+460 60+460
50∗14.7 50∗14.7 50∗14.7
∗150+ 460 ∗95+460 ∗95+460
14.4 14.4 14.4
¿ ¿ ¿
60+ 460 60+ 460 60+ 460
 Q g1 =59.88 MMCFD Q g 2=54.48 MMCFD Q g3 =54.48 MMCFD

From Fig Using R1=2.375 , K =1.4 Using R2=2.368 , K =1.4 Using R3=2.379 , K =1.4

(12_21A) BHP BHP BHP

¿¿ ¿¿ ¿¿

BHP/¿ stage = 59.88 *54.4 = 54.48 *54.2 = 54.48 *54.6

=3257.472 HP =2952.816 HP =2974.608 HP

(ii)

BH P total ¿ ∑ BHP/ stage

¿ ¿ 9184.896 HP

(iii)

( BHP total )standard =1.1∗9184.896 ¿ 10103.3856 HP

¿ ¿

(v) ¿
st nd rd
1 Stage 2 Stage 3 Stage

3257.472 2952.816 2974.608

¿ ¿ ∗10110 ¿ ∗10110 ¿ ∗10110
9184.896 9184.896 9184.896

¿ 3586 HP ¿ 3250 HP ¿ 3274 HP

 Step 6: PD E V for each Stage

PD E V =¿ ¿

S PDEV
t
a
g
e

Psuc =P1 =142.7 psia=142.7−14.7=128 psig>10 psig

∴ X=0

3586∗10 4
1 PD E V 1= =4619.42 CFM >2000 CFM
(54.4)∗( 142.7−0 )

∴Use 2 Cylinder in Parallel

( 2 Cylinder * 2310 CFM )

Psuc =P22 =335.8428 psia=335.8428−14.7=321.1428 psig>10 psig

∴ X=0

3250∗10 4
PD E V 2= =1785.45 CFM <2000 CFM
2 (54.2)∗( 335.8428−0 )

∴Use One Cylinder

Psuc =P44 =792.432 psia=792.432−14.7=777.732 psig>10 psig

∴ X=0

3274∗10 4
3 PD E V 3= =756.7 CFM < 2000 CFM
(54.6)∗( 792.432−0 )

∴Use One Cylinder

6.4. Pump (P-101)
Data Given

Q 475 GPM
H 330 ft.Liq

Step 1: Calculate Pump Speed (N)

Q(gpm), H(Ft.liq) Frequency / Speed 50 HZ 60 HZ
Q < 100, H < 100 Low Speed 1450 rpm 1750 rpm
Q > 100, H > 100 High Speed 2950 rpm 3550 rpm

Selecting 50 HZ as electrical supply frequency, and high speed.

Then, Pump Speed (N) = 2950 rpm
Comment: Pumps are often designed for either 50 Hz or 60 Hz operation, and using a pump at
the wrong frequency can affect its speed, flow rate, and efficiency. Some pumps have variable
frequency drives (VFDs) to adjust their speed as needed.
Step 2: Calculate Specific Pump Speed (Ns)
N √Q
Ns=
( )
H 34
n
N in rpm, Q in gpm, H in ft,liq, and n is number of pumps in series
Connect two pumps in series, each with H = 330/2 = 165 ft.liq
2950 √ 475 = 1397 within range (1000 - 3000)
∴ N s=
maximum efficiency
¿¿

Step 3: Calculate Overall Pump Efficiency(η)overall

Using Q, and Ns from figure: (η)overall = 78 %

Step 4: Calculate blade velocity (Vf)

v f =ψ ¿
Ψ is assumed to be between (0.15- 0.3), and n is number of pumps in series
Assume Ψ =0.2
And, g=32.2 ft/s2 , H=330/2 ft.liq
Then, v f = 0.2*(√ 2∗32.2∗¿ ¿) = 20.6 ft/s

Step 5: Calculate Impeller (inlet, outlet) diameter (D1, D2)

Calculate Impeller (inlet, outlet) width (B1, B2)
 Q=v f π D1 B1=v f π D 2 B2
∴ D1 B1 = D2 B2
∴ n = B1 / D 1 n is between (0.1 - 0.4), and 0.12 is common
Assume n = 0.12
Then, Q=v f π D1∗n D1
Q in gpm, Vf in ft/s

∴ D1 = 12
√ Q ∕ 448.8
πn v F
= 12
√
475 ∕ 448.8
π∗0.12∗20.6
= 5 in (Standard)

, D2 = 2D1 = 2*4 = 10 in (Standard)

, B1= n D1 = 0.12* 5 = 0.5 in (Standard)
, B2 = 0.5 B1 = 0.5* 0.5 = 0.25 in (Standard)

Step 6: Calculate Impeller tangential velocity (u1, u2)

N
∗π∗D1
60
u1 =
12
N in rpm, D1 in inches
2950
∗π∗5
60 = 64 ft/s
∴ u1=
12
, u2 =2u1 = 2*64 = 128 ft/s
Step 7: Calculate manometric efficiency (η)manometric
( η ) overall
(η)manometric =
(η) mechaical
(η)mechanical is assumed to be between (0.85 - 0.88)
Assume (η)mechanical = 0.85
0.78
Then, (η)manometric = = 0.918 = 91.8 %
0.85

Step 8: Calculate Whirl velocity at impeller outlet (Vw2)

Vw =
( Hn )∗g
2
u2 (η)manometric
H in ft.liq, u2 in ft/s
330
(
)∗32.2
2 = 45.2 ft/s
∴Vw =
128∗0.918
2

, u2 = Vw1 + Vw2
∴ Vw1 = 128 – 45.2 = 82.2 ft/s
Step 9: Check on angles
 Inlet blade angle

θ= tan
u1( )
−1 v F
= tan ( )
−1 20.6
64
= 18° not within range (20° - 45° )

 Outlet blade angle

α = tan ( )
−1 v F
vw 1
= tan ( )
−1 20.6
82.2
=14 ° ( < 90 ° )

 Absolute outlet angle

β = tan ( )
−1 v F
vw 2
= = tan ( )
−1 20.6
45.2
= 24° not in range (10° - 20° )

Step 10: Check on speed ratio (∅ )

u2
∅=

√ n )g
2( H

128
∴∅=

√(
2
330
2 )∗32.2
= 1.24 good (<1.25)

Comment: reducing the pump speed ratio is preferred because it improves efficiency, reliability,
and operating conditions.

6.5. Fired Heater ATM-FH

Fluid Type Hydrocracker Gas oil (37.5 API)

Service Atmospheric dist. Heater
 Qduty 1.206*108 BTU/hr.
Flow Rate 5.393*105 lb/hr
Tin 340 F
Tout 590 F
Excess Air 20 %
Fuel type Refinery Gas
NHV 19700 BTU/lb

Step 1: Determining Efficiency of Fired Heater (ηFH)

I. Flue Gas Temperature calculation ( FGT )

∴ FGT =T ∈+150=340+150=490 ° f > 400 ° f (OK , No vapors condense).

II. Heat Available at FGT ( Ha @ FGT)

By using FGT and 20% Excess air from (Fig. 3) of Refinery Gas then
∴ H a @ FGT =17500 BTU /lb fuel

III. Efficiency of Fired Heater (ηFH)

Assuming losses are 2%

H a@ FGT
η FH = ∗100−2 %
NHV
17500
η FH = ∗100−2%
19700

∴ η FH =86.83 %> 80 % (OK , Fired Heater Efficiency is Safe).

Step 2: Determining Flue Gases and Air Flow Rates

8
Q duty 1.206∗10 6
I. Qfiring = = =138.9∗10 BTU /lb
η FH 0.8683

6
Qfiring 138.9∗10
II. GFuel ¿ = =7050 lb /hr
NHV 19700

III. Determining Flue Gases Flow Rate

From (Fig. 2) We can get lbflue gas/lbfuel By using 20% Excess air then (lbflue gas/lbfuel =19.9)
lb flue gas
Flue Gas Flow Rate= ∗fuel consumption
lb fuel
Flue Gas Flow Rate=19.9∗7050
∴ Flue Gas Flow Rate=140295 lb/hr

IV. Determining Air Flow Rate

Air Flow Rate = ( lblbfluefuelgas −1)∗fuel consumption

Air Flow Rate =( 19.9−1 )∗7050

∴ Air Flow Rate=133245 lb /hr

Step 3: Convection / Radiation Spli

I. Critical Temperature Calculation (Tc)
ΔT Con. Tc−T 1 1 1
= ( )
= : Common is then
ΔT Rad . T 2−Tc 3 2
5
12

ΔT Con. Tc−T 1 5
= =
ΔT Rad . T 2−Tc 12

ΔT Con. Tc−340 5
= =
ΔT Rad . 590−Tc 12

∴ Tc=414 ° f

II. Skin Temperature Calculation (Tm)

Tc+T 2
Tm= + 75
2
 414+590
∴ Tm= +75=577 ° f
2

III. Bridge Wall Temperature Calculation (BWT)

 Select Radiant Heat Flux (qr) 12000 BTU/ft2.hr, From (Table II) By using qr and Tm
From (Fig. 6) then (∴ BWT =1580 ° f )

 Heat Available at BWT ( Ha @ BWT) From (Fig.4) then

∴ H a @ BWT =11200 BTU /lb fuel

IV. Radiation Zone Efficiency

H a @ BWT
η Rad .= ∗100−2 %
NHV
11200
∴ ηRad .= ∗100−2 %=55 % (OK , Radiation Efficiency is Safe)
19700

Step 4: Radiation Section Design

I. Radiation Heat Duty (QRad.)

H a @ BWT∗Qduty
QRad .=
H a @ FGT
8
11200∗1.206∗10 6
∴ QRad .= =77.184∗10 BTU /hr
17500

6
QRad . 77.184∗10
= ∗100
Qduty 1.206∗108

QRad .
∴ =64 %(OK , Radiation section duty is OK .)
Qduty
II. Radiation Section Lay Out

1. Fluid mass velocity (G´)

 Assume G´ From ( Table. III ) then G´= (175 : 250) lb/ft2.s

Select 6in Tube Coil Heating From (Sch. 40) then

(do= 6.625˝ , di= 6.065˝ , t= 0.28˝ , at= 0.2006 ft2 , n= 4 tube/pass)
G
G ´=
3600∗at∗n
5
5.393∗10
G ´=
3600∗0.2006∗4
∴ G´ =187 lb/ft ². s (G ´ is∈range , OK )

2. Outside Area Of Radiation Section (AR)

QRad .
AR¿
qr
6
77.184∗10
AR¿
12000
∴AR¿ 6432 ft ²

3. Assume Number of vertical tubes (N) = 64 tubes

4. Tube Circular Diameter (TCD)

N∗C
TCD= Where “C” is bitch (2*d)
12 π
2∗6∗64
∴ TCD= =20´
12 π

5. Effective Tube Length (ETL)

ETL=TCD−1
∴ ETL=19´

Select Number tubes per row 8 tube/row (Ntube/row)

N tube /row∗ETL∗π do 8∗π∗6.625∗19

6. Area of One Horizontal Row (Aone row) ¿ ¿ =264
12 12
ft2

7. Vertical Tubes Area (AV) = AR – Aone row = 6432−264=6168 ft ²

Av 6168
=56 ´
8. Vertical Tubes length = Nv∗π do = 64∗π∗6.625
12 12

L 56
9. ∴ Ratio ¿ =2.8(OK , Between ( 2 :4 ))
D 20

Step 5: Shield Bank Section Lay Out

I. Calculation of Shield Bank Duty

Flue gas
BWT (°F)
BWT (°F) -210
Gas oil
TC (°F)
Tc (°F) - 15
 Flue gas
1580 °F
1370 °F
Gas oil
414 °F
399 °F
Δ T =1166 ° F
Δ T =971° F

ΔT max− ΔTmin 1166−971

= =1066 ° F
i. ΔTLm = ΔTmax 1166
ln ln
ΔTmin 971

ii. Area of Shield Bank (A shield) = 3 A One row of Radiation Section

∴ A Shield = 3 * 264 = 792 ft2

iii. Calculation of Heat Transfer Coefficient in Shield Bank

1. Heat Transfer Coefficient outside tubes (ho)

Ntube /row∗ETL∗(C−do) 8∗19∗(2∗6−6.625)

a. Shield Cross Section Area (AC.S) = = =
12 12
68 ft2

Flue Gas Flow Rate 140295

b. Flue Gas Mass Velocity (g) = = =0.57 lb /ft ². s < 1 lb/ft2.s
3600∗A C . S 3600∗68

BWT +(BWT −210) 1580+(1580−210)

c. Flue Gas Average Temp. (Tav) = + 460 = + 460 =
2 2
1935 °R = 1475 °F

2. Convection Heat Transfer Coefficient (hc)

0.6 0.28 0.6 0.28

2.14 g ∗Tav 2.14∗0.57 ∗1935
hc= 0.4
= 0.4
do 6.625

∴ hconv=6 BTU /ft ². ° f . hr (OK < 10 BTU /ft ². ° f . hr)

3. Radiation Heat Transfer Coefficient (hrg)

 hrg=0.0025 Tav−0.5=0.0025=0.0025∗1475−0.5

∴ hrg=3.1 BTU /ft ².° f . hr (OK <10 BTU /ft ².° f . hr )

4. Total Heat Transfer Coefficient outside tube (ho)

∴ ho=1.1 ( hc+hrg )=1.1 (6 +3.1 )=10 BTU /ft ².° f . hr (OK )

5. Heat Transfer Coefficient inside tubes (hio)

Tc+(Tc−15) 414+(414−15)
 Tm = = =406.5 ° F
2 2
 Physical properties of gas oil

i. Cp= 0.66 BTU/lb.°f

ii. K= 0.072 BTU/ft2.°f.hr
iii. μ = 0.605 lb/ft.hr
k
6. hi =0.027 ¿
di
BTU
∴hi = 271 2
. ° f . hr
ft
di 271∗6.065 BTU
∴hio = hi * = =248 2 . ° f . hr
do 6.625 ft
Km 12∗24 BTU
7. hcond. = = =1028.5 2 .° f . hr
do 0.28 ft

1 1
Ush =
( ho1 )+( hio1 )+( hcond
1
) ( )+ (
= 1
10
1
248 ) +(
1
1028 . 5
)
= 9.5 BTU /ft ².° f . hr (<10

BTU /ft ².° f . hr )

∴Shield Duty (Qsh) = Ush∗Ash∗∆ Tlm=9.5∗792∗1066=8.02∗106 BTU /hr

 Check flue gas temperature out of shield bank

H a@ BWT QRad
=
H a @Tsh QRad +QSh
6 6
H a @ BWT (QRad +QSh) 11200( 8.02∗10 +77.184∗10 )
H a @Tsh= =
QRad 77.184∗10 6
H a @Tsh=12300 BTU /lb fuel ( ¿ fig .3 ) then
∴ Tsh=1370°F (OK, Tsh = (BWT - 210))

Step 6: Convection Section Lay Out

I. Convection Section duty (QConv) = Qduty - (QRad.+QSh)

∴ Qcon=1.206∗108−( 8.02∗106 +77.184∗10 6 )=35.4∗10 6 BTU /hr

Flue gas
BWT (°F) - 210
FGT (°F)
Gas oil
TC (°F) - 15
T1 (°F)

Flue gas
1370 °F
490°F
Gas oil
399 °F
340 °F
ΔT =971 ° F
ΔT =150 ° F

ΔT max− ΔTmin 971−150

= =440 ° F
i. ΔTLm = ΔTmax 971
ln ln
ΔTmin 150

ii. Dimensions of fins

I. Number of fins (NF) = 3 fins/in
II. Height of fins (HF) = 0.75 in
III. Thickness of fins (tF) = 0.05 in
Select area of tubes with fins = (Atf) = 10.01 ft2/ft

Nrow
∗ETL∗( C−do )−( 2 N F∗H F∗t F )
iii. Fins Bank Free Area (FBFA) = tube
12
8∗19∗( 12−6.625 )−( 2∗3∗0.75∗0.05 )
∴ FBFA= =68 ft ²
12
Flue Gas Flow Rate 140295
 Flue Gas Mass Velocity (g´) = = =2063 lb /ft ². hr
FBFA 68
FGT +(BWT −210) 490+1370
 Flue Gas Mean Temp. (Tmean) = = =930 ° F
2 2
 Physical properties of Flue Gases

i. Cp= 0.28 BTU/°f.hr

ii. K= 0.03 BTU/ft2.°f.hr
iii. μ = 0.084 lb/ft.hr

iv. Heat Transfer Coefficient outside tubes (ho)

do∗g´ 6.625∗2063
i. Re = = =13560
12∗μ 12∗0.084
ii. From (fig. 7) then ∴ J= 0.0075
0.0075∗0.28∗2063
J∗Cp∗g ´ =5.5 BTU /ft ². ° f . hr
iii. ho= = 0.084∗0.28 2/ 3 (<10 BTU /ft ².° f . hr )
¿¿ ( )
0.03
iv. Efficiency of Fins (Ef): From (fig. 7) by using Fins dimensions mentioned above
then ∴ Ef = 90% (> 80%, OK)
ho 5.5
v. ho effective = ( Ef ( Atf −Ao )+ Ao ) = ( 0.8 ( 10.01−1.178 ) +1.178 )
Atf 10.01

∴ho effective = 4.5 BTU /ft ².° f . hr hr (¿ 10 BTU /ft ².° f . hr )

 Heat Transfer Coefficient inside tubes (hio) is the same in Shield Bank
BTU
∴hi = 271 2
. ° f . hr
ft
BTU
 hcond. is the same of Shield = 1028.5 2 . ° f . hr
ft
1 1

( )( )
Uconv = 1
ho
+
Atf
hi Ai
+(
Atf
hcond∗Ai ( )(
)
= 1
10
+
1 0.01
271∗1.587 ) +(
1 0.01
1028 .5∗1.587
)
= 7.7

BTU /ft ².° f . hr (<10 BTU /ft ².° f . hr )

 vi. Area of Convection section (Acon)
6
Qconv 35.4∗10 2
Acon = = =10450 f t
Uconv∗Δ Tlm 7.7∗440
vii. Surface Area per Row (A*conc)
2
Ntube ft
A*con ¿ ∗Atf ∗ETL=8∗10.01∗19=1522
row row
Aconv 10450
viii. Nrow = ¿ = =7 rows
A conv 1522

Step 7: Fired Heater Pressure Drop (Δp)

i. Gas oil physical properties at T1 = 340°F, T2 = 590°F

T 1+T 2 340+590
Tm = = =465° F
2 2
I. Sp.gr= 0.68
II. μ = 0.605 lb/ft.hr
di∗G ´∗3600 6.065∗187∗3600
ii. Re = 12∗μ = 12∗0.605 =562390 From mody then (F = 0.0043)

iii. Gas Oil density ( ρ ) = Sp.gr * 62.4 = 0.68 * 62.4 = 42.4 lb/ft3

iv. Leq calculation:

i. Leq cross over (Radiation ››››› Convection)
3∗30
Leq =2 ETL + 3 elbow =2∗19+ ∗6.065=83.5 ft
12

ii. Leq (Radiation)

50 di
Leq =2(Lv+3)+(passes-2)( Lv-1) +(passes-1)*
12
Nv 56
passes= = =16 passes
ntube/ pass 4
50∗6.065
Leq =2(56+3)+(16-2)( 56-1) +(16-1)*
12
Leq = 1267 ft

iii. Leq (Convection + Shield)

50 di
Leq =2(ETL+3)+(passes-2)( ETL+1.5) +(passes-1)*
12
passes=2 ( Nrow . conv + N row . sh ) =2 (7 +3 )=20 passes
 50∗6.065
Leq =2(19+3)+(20-2)( 19+1.5) +(20-1)*
12
Leq = 893 ft

iv. Leq total = Leq cross over + Leq (Radiation) + Leq (Convection + Shield)
Leq total = 83.5+¿ 1267 + 893 = 2243.5 ft

2 2
0.0051∗f ∗G´ ∗Leq 0.0051∗0.0043∗187 ∗2243.5
v. ΔP=
ρ∗di
=
42.4∗6.065
=6.7 psi
ΔP with20 % as safety factor=8 psi

Step 8: Stack Design

1. Stack Diameter (Dst)

i. Assume Flue gas mass velocity = 0.8 lb/ft2.s
Flue gas flow rate 140295 2
ii. Area of Stack (Ast) = = =49 f t
Flue gas mass velocity 3600∗0.8

iii. Stack Diameter (Dst) =

√ 4 A st
π √
=
4∗49
π
=7.9 ft 8 ft Stand.

2. Stack Height (Hst)

i. Assume Draft = 0.9 in.H2O

ii. Draft=0.52 Hst∗Pa∗ (

1
−
1
Ta FGT )
Where Tais ambient temp .

0.9 ¿ 0.52 Hst∗14.7∗(

540 490+ 460 )
1 1
iii. −

iv. Hst =¿147 ft 150 ft Stand . From (fig. 14-6) Nelson Hst =¿144 ft
150 ft Stand . (>80 ft, OK)
6.6. Trayed Tower (Sieve Tray)
Data Given

Property Liquid Vapor

Flow Rate 520 GPM 290 ft3/sec
Density 42.52 lb/ft3 0.2074 lb/ft3
Viscosity 0.3334 cp 9.984*10-3 cp
Surface Tension 13.3 dyn/cm

Step 1: Select Tray’s Spacing (H), and Liquid head over sieve (hls)
Select H = 18 in, hls = 2 in (Atmospheric service)
Step 2: Determine Tower’s Diameter (Dtower)
i. Determine effective tray spacing (S)

S = H - 2.5hls
∴ S = 18-2.5*2 = 13 in
ii. Use Hunt’s entrainment equation
 ( )( )
3 ⋅2
73 v
ⅇ =0.22 =0 ⋅05
σL s
σ L in (dyn/cm), S in (inches), and v in ft/s

Solving the equation,

( )( )
3⋅ 2
73 v
ⅇ =0.22 =0 ⋅05
13.3 13

∴ v = 4.8 ft/s

iii. Use Continuity equation

π 2
V= D v
4
V in (ft3/s), D in (ft), and v in ft/s

Solving the equation,

π 2
290= D ∗4.8
4

∴ D = 8.77 ft = 10 ft (Standard)

Step 3: Determine Type

of Flow
Using D, and Lgpm from the
following figure:
∴ Type of flow: Cross flow

Step 4: Determine Tray Layout

a) Size of holes (do)
3
do = in (Clean Service)
16
b) Hole’s spacing (C)
3
C=3.6 do = 3.6 * = 0.675 in = 0.75 in (Standard)
16
c) Tray thickness (t)
as D > 3 ft ∴ t = 0.25 in
d) Area hole % ( β )
do
Using = 0.25, from the following figure:
C
∴ β = 5.5 %

e) Orifice coefficient (Co)

do
Using = 0.75, from the following figure:
t

∴ Co = 0.84

Tray dimensions
Lw dw Ad . c
= 0.67 = 0.125 = 0.075
D D AT
 LW = 0.67 * 10 = 6.7 ft = 6.7 * 12 = 80.4 in
 dw = 0.125 * 10 = 1.25 ft = 1.25 * 12 = 15 in
π 2 π
 AT = D = * 102 = 78.54 ft2
4 4
Step 5: Check on residence time (tr)

2
0.075∗Π D ∗H
∗60∗7.48
4 12
t r=
Lgpm
Solving the equation,
 = 7.62 sec > 5 sec
2
0.075∗Π 10 ∗18
∗60∗7.48
4 12
∴ tr =

(Ok)
520

Tray dynamics

Step 6: Minimum hole velocity (Fs min)

a. Assume Fs < 14
b. Calculate dry tray pressure drop (hdt)

( )( )
2
2 ρw 1−B
h ⅆt =0.003 F s 2
ρL C0

3 3
ρw = 62.4 Ib/ft , ρ L= 42.52 Ib/ft , β = 5.5 %, Co =
0.84
c. Effective liquid head (he):
Using Fs < 14, hls = 2 in.liq, from the
following figure:

∴ he = 1.75 in.liq

d. Total head (ht)

Draw a line between Fs and ht intersecting line A, in the following figure:
 Fs hdt he ht
∴ Fs min = 13
13 1.05 1.75 2.8

12 0.89 1.75 2.64

11 0.75 1.75 2.5

Step 7: Maximum hole velocity (Fs max)

a. Assume Fs > 14
b. Calculate dry tray pressure drop (hdt)

( )( )
2
2 ρw 1−B
h ⅆt =0.003 F s 2
ρL C0

ρw = 62.4 Ib/ft3, ρ L= 42.52 Ib/ft3, β = 5.5 %, Co = 0.84

c. Effective liquid head (he):

Using Fs > 14, hls = 2 in.liq
∴ he = 1.57 in.liq
d. Hd foam = 2 (hls + he + hdt) = H

Fs hdt he Hd foam
∴ Fs max = 29
28 4.87 1.57 16.88

29 5.23 1.57 17.6

30 5.6 1.57 18.34 > H

Step 8: Design basis
Fs min+ Fs max 13+29
1. Fs design = = = 21
2 2

2. hdt design = 0.003 F

2
( )(
s design
ρL C0)
ρw 1−B2
2

∴hdt design = 2.74 in.liq

3. he design = 1.57 in.liq Fs design > 14
4. ht design = hdt design + he design = 1.57 + 2.74 = 4.31 in.liq
ht ρ L 4.31∗42.52
5. ∆ P = 3 = 3 = 0.1 psi < 0.2 psi (Ok)
12 12

Step 9: Height of liquid over weir (how)

( )
2
Lgρm
h ow=0.092 3
Lw

Lgpm = 520 gpm, Lw = 6.7 ft

Solving the equation,

( )
2
520 3
∴ how =0.092 = 1.67 in.liq > 0.25 in.liq (Ok)
6.7

Step 10: Number of required holes (Nreq)

a. Find (Nholes / in2 )
Using C (pitch), from the following figure:
 C= 0.75 in ∴ Nholes / in2 = 2.3

b. Area of single hole (ao)

4 ( )
π 2 π 3 2
a 0= d 0 =
4 16
= 0.02765 in2

c. Orifice velocity ( v 0)
F s design 21
v 0= = = 46.11 ft/sec
√ ρ v √ 0.2074
d. Calc. Nreq
144 V 144∗290
Nreq = = = 32800 holes
v 0 a0 46.11∗0.0276

Step 11: check on available number of holes (Navailable)

Assume β 1 = 5 in, β 2 = 3 in, α =1.75∈¿

a. Deff = 12D - 2α = 12 * 10 – 2 * 1.75 = 116.5 in

π 2 π
b. Adeff = D eff = = * (116.5)2 = 10660 in2
4 4
c. dw1 = β 1+ dw - α = 5+15-1.75 = 18.25 in
d. dw2 = β 2+ dw – α = 3+15-1.75 = 16.25 in
dw 1 18.25 dw 2 16.25
= ∗100 = 16 % = ∗100 = 14 %
Deff 116.5 Deff 116.5

dw 1 dw 2 A1 A2
Using values of and , we get ( , ) from the following figure:
Deff Deff Adeff Adeff
 A1 A2
∴ = 10.5 % , = 8.5 %
Adeff Adeff

A1 A2
e. Aeff = Adeff (1 - − ) = 10660 (1 – 0.105 – 0.085) = 8635 in2
A deff A deff
N holes
f. Navailable = * Aeff = 2.3 * 8635 = 19860 holes < Nreq
ⅈ n2
Comment: reduce α , β , and dw .
Safety area of operations
1. Minimum liquid load (Lgpm min) (at how = 0.25 in.liq)

( ) = 0.25
2
Lgρm min
h ow=0.092 3
Lw

∴ Lgpm min = 30 gpm

2. Maximum liquid load (Lgpm max) (at tr = 5 sec)

2
0.075∗Π D ∗H
∗60∗7.48
4 12 =5
t r=
Lgpm max

2
0.075∗Π ¿ 10 ∗18
∗60∗7.48
4 12 =5
Lgpm max
 ∴ Lgpm max = 793 gpm

3. Minimum Vapor load (Vmin)

F s min 13
 v 0 min = = = 28.5 ft/s
√ ρv √ 0.2074
N holes
 Navailable = * Aeff = 2.3 * 8635 = 19860 holes
ⅈ n2
a0 0.0276
 Vmin = v 0 min * Navailable * = 28.5 * 19860 * = 108.5 ft3/s
144 144

4. Maximum Vapor load (Vmax)

F s max29
 v 0 max = = = 63.7 ft/s
√ ρ v √ 0.2074
a 0.0276
 Vmax = v 0 max * Navailable * 0 = 63.7 * 19860 * = 242 ft3/s <
144 144
Voperating

Comment: we must reduce the operating vapor load to be less than Vmax.
6.7. Trayed Tower (Bubble Cap)
Data Given
Property Liquid Vapor
Flow Rate 520 GPM 290 ft3/sec
Density 42.52 lb/ft3 0.2074 lb/ft3
Viscosity 0.3334 cp 9.984*10-3 cp
Surface Tension 13.3 dyn/cm

Step 1: Select Tray’s Spacing (H), and Liquid head over sieve (hls)
Select H = 24 in, hls = 2 in , C = 0.16 ft/s (Atmospheric service)
Step 2: Determine Tower’s Diameter (Dtower)

 Vmax =c ρl−ρv
ρv √ √
= 0.16 42.52−0.2074 =2.3 ft /¿ s
0.2074

V max 2.3
 Vc.s = = =2 ft / s (vc.s < 3
1.15 1.15
ft/s, OK, safe)

 Dtower =
√ 4V
π∗v c . s √
=
4∗290
π∗2
=13.9 ft 15 ft (standard )

(Dtower is > 10 ft we will choose 6 in cap)

Dimensions Parameter 6 in Cap
Outer cap diameter A 6 in
Inner cap diameter B (dc) 5.875 in
Cap Cap spacing K 8.125 in
Internal cap area ac 27.11 in2
Distance between rows M 7.03 in

Outer diameter of riser C (dro) 4.1875 in

Inner diameter of riser D(dr) 4.062 in
Internal riser area E(ar) 12.962 in
Riser Annular riser area J(aa) in2 13.338
Reversal riser area H(ar´) 13.55 in2

Slot width W 1.875 in

Slot area per cap as 22.2 in2
Slot
Skirt hieght SH (SR) 0.5 in
Step 3: Determine Type of Flow
Using D, and Lgpm from the following figure

∴ Type of flow: Cross flow

Step 4: Determine Number of required caps (Nreq.)

3.4 3.4
 Vpulsation = = =7.5 ft / s
√ ρv √ 0.2074
3.4 12.1
 Vconing = = =26.6 ft /s
√ ρv √ 0.2074
2 2 ft
 Vslots = Vconing= ∗26.6=17.7
3 3 s

V 290
=
 Nreq. = slots∗as 22.2∗17.7∗0.6 = 178 caps
v ∗0.6
144 144
Step 5: Tray Layout
Lw dw Ad . c
( = 0.67 , = 0.125 , = 0.075)
D D AT
1. Centric row’s caps (Nc)
Select α =1.5∈¿ then
2. 12 D=2 α + (Nc -1)*K+ dcap
12 *15 = 2*1.5 +(NC -1)*8.125 + 6
∴ Nc = 22 Caps
3. Number of rows (Nr)
Select β=3∈¿ then
12∗D−2 β−2 dw−dcap 12∗15−2∗3−2 ( 15∗0.125∗12 )−6
4. Nr = +1= +1=17 rows
M 7.03

Navai. =22 + 2 (21+20+19+18+17+16+15+14) = 302 caps >>>>> Nreq, OK safe.

¿ ¿ and β ) are larger than assumed, OK, safe.

Tray Dynamics
1. Good liquid distribution
2/ 3 2/ 3
l 520
how = 0.092( ) =0.092( ) =1.3∈.liq >>>>> 0.25¿ . liq (OK)
lw 0.67∗15
hw = SH + SR + W +hls – how = 0.5 + 0.5 +1.875 + 2 -1.3 = 3.6 ¿ >>>>> 1 ¿ (OK)

2. Good vapor distribution (Tray stability)

 First: Calculation of hcap
hcap ´
hcap =
Cw
 In riser:
69.1124
hr = ¿
ρl

 In reverse and annulus:

36.8284
hra = ¿
ρl
  In slots:
19.15
hs = ¿
ρl

 Parameter (For Cw calculation)

P=
8.36
Ncaps
∗V∗
√
ρv 8.36
=
ρl 302
∗290∗
0.2074
42.52 √
=0.56

hc´ = hr + hra + hs = 0.29 + 0.21 + 0.11 = 0.61 in. liq

Cw = 0.36 From fiq.(13-53)

hcap ´ 0.61
∴ hcap = = =1.7∈. liq
Cw 0.36
 Second: Calculation of Δh

 Amin = Lw (hw+how) – Ncaps. last row ((dro*SH) + dcap (hw+how-SH))

= 0.67*12*15(1.3+3.6)-14((4.1875*0.5)+6(1.3+3.6-0.5))
= 192 in2

0.32∗L 0.32∗520 ft
 Vl.max = = =0.86 ≪¿ 1 ft / sOK
Amin 192 s
 Δh = (0.55 + 0.044Nrows)*Vl.max = (0.55 + 0.044*17)*0.860.75 = 1.16 in.liq

Δ h 1.16
∴ = =0.68 Close ¿ 0.5 ,OK , Tray is stable .
h cap 1.7
3. Flooding test
 Hclear = hw + how + Δh + Δp
 Δp = hc + hls + Δh/2 = 1.7 + 2 + 1.16/2 = 4.28 in.liq = 0.1 psi <<<< 0.2 psi (OK)
 Hclear = 1.3 + 3.6 + 1.16 + 0.1 = 6.16 in.liq
 Hfoam = 2 Hclear = 12.32 in <<<< H + how (OK)

4. Residence time

52.87 D ² 52.873∗15²
 tr = = =23 sec ¿ ≫5 sec (OK )
l 520
5. Entrainment test
 

( )( ) ( )( )
3⋅ 2 3 ⋅2
73 v 73 2 lbm . liq
ⅇ =0.21 =0.21 =0.006
13.3 Heff 13.3 24−2.5(1.3 +3.6+1.16 /2) lbm . vap
lbm .liq
<<<< 0.1 (OK )
lbm. vap
6. Safety area of operation

 Minimum vapor load (Vpulsation)

3.4 3.4
vpulsation = = =7.5 ft / s
√ ρv √ 0.2074
0.6∗as∗Ncaps 7.5∗0.6∗22.2∗302 3
Vmin = vpuls * = =210 f t /s
144 144

 Maximum vapor load (Vconing)

3.4 12.1
Vconing = = =26.6 ft /s
√ ρv √ 0.2074
0.6∗as∗Ncaps 26.6∗0.6∗22.2∗302 3
Vmax = vconing * = =743 f t /s
144 144

 Minimum liquid load (how = 0.25 in.liq)

2/ 3 2/ 3
l l
how = 0.25=0.092( ) =0.092( ) ∴Lmin = 54 gpm
lw 0.67∗15

 Maximum liquid load (tr = 5 sec)

52.87 D ² 52.873∗15²
tr = 5 = = ∴Lmax = 2380 gpm
lmax lmax

Comparison between Bubble cap and Sieve tray

Bubble Cap Sieve

D
i
a
m
15ft 10 Ft
e
t
e
r
T 24 In 18 In
r
a
y

S
p
a
c
i
n
g
L
i
q
u
i
d

O
v
e
r
2 In 2 In
T
r
a
y

(
H
l
s
)
H 1.3 In.Liq 1.67 In.Liq
e
i
g
h
t

O
f

L
i
q
u
i
d

O
v
e
r

W
e
i
r

(
H
o
w
)
P
r
e
s
s
u
r 0.1 Psi/Tray 0.1 Psi/Tray
e

D
r
o
p
R
e
s
i
d
e
n
c
e
23 Sec 7.6 Sec
T
i
m
e

(
T
r
)
E lbm .liq lbm .liq
n 0.1 0.05
lbm. vap lbm. vap
t
r
a
i
n
m
e
n
t
M
i
n
i
m
u
m

V
7.5 ft /s 108.5 ft3/s
a
p
o
r

L
o
a
d
M
a
x
i
m
u
m

V 3
743 f t /s 242 ft3/s
a
p
o
r

L
o
a

54 gpm
d
M 30 gpm
i
n
i
m
u
m

L
i
q
u
i
d

L
o
a
d
M
a
x
i
m
u
m

2380 gpm
L
i 793 gpm
q
u
i
d

L
o
a
d