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HEAT TRANSFER IN A
CATALYTIC REFORMER
REACTOR FEED EFFLUENT
EXCHANGER
Eric O. Okeke
Nigerian National Petroleum Corporation
APACT 06, Oxford, 3-5 May, 2006
Introduction,
Problem analysis,
Method of solution & evaluation Target,
Application of engineering software tools
HYSYS & STX,
Engineering solution
NNPC
INTRODUCTION
Refiner depends
gasoline,
NNPC
on
catalytic
reformer
for quality
Catalytic Reformer
Effluent
Charge Heater
Feed
Feed
Effluent
THE PROBLEM
NNPC
Stream
CRU Feed
Tube-side
RXT Efflt
Shell-side
Inlet
Outlet
Pressure
Flow, kg/hr
Temp, C
Temp, C
kg/cm2
Hvy Naphtha,
Rec gas
(96%H2)
142,454
93
484
18.2
Hydrocarbon
& H2 (Reactor
products)
142,454
545
135
14.4
Inlet
Outlet
Pressure
Flow, kg/hr
Temp, C
Temp, C
kg/cm2
Hvy Naphtha,
Rec gas
(95%H2)
54,500
87
368
18
Hydrocarbon
& H2 (Reactor
products)
54,500
467
149
13
Composition
Stream
CRU Feed
Tube-side
RXT Efflt
Shell-side
NNPC
Composition
Exchanger B
Hydrogen
NNPC
IMPACT ON OPERATIONS
Engineering solution,
Confirm solution by re-evaluation/re-design
NNPC
CES
Vertical
No of Trains - 1
Fluid Name
Total Flows,
Vapour
Liquid
Temperatures
Density
Viscosity
Specific heat
Thermal conductivity
Latent Heat
Inlet pressure
Viscosity
Pressure drop
Fouling resistance required
Heat exchanged
NNPC
Shells/train - 2
kg/hr
kg/hr
kg/hr
Liquid (Vapour)
Liquid (Vapour)
Liquid (Vapour)
Liquid (Vapour)
In parallel
Shell Side
Inlet
Outlet
Effluent
H2 + HC
142,454
142,454
138,396
4,058
Tube Side
Inlet
Outlet
Feed
H2 + HC
142,454
68,998
142,454
73,456
545
135
93
C
(3.93)
727(7.19)
671(6.73)
kg/m3
(0.02) 0.269(0.012) 0.28(0.011)
cp
(1.003)
0.52(0.93)
0.58(0.91)
kcal/kgC
(0.203) 0.101(0.102) 0.106(0.112)
kcal/mmC
kcal/kg
14.4
18.2
kg/cm2G
13.8
8
m/s
0.6
0.3
kg/cm2
0.00004
0.00004
mm2C/kcal
MTD (corrected) 67.3
50,810,000 kcal/hr
484
(6.12)
(0.019)
(0.96)
(0.177)
1.
2.
3.
4.
Shell - ID 1,300 mm
NNPC
Where
U =
1
1
ho
0.023di
hi =
km
ro
diGi
i
+ rw
0.8
do
km
ri
di
Cpii
1/3
hi
i
iw
0.14
NNPC
If heat transfer enhancement is only for inside of the tubes using inserts,
equation 3 applies, and U becomes Ue , and hi, hie.
Then solving equations 2 to 6, assuming the resistance to heat transfer
across the wall is negligible hw , and the difference
NNPC
So that
hie
hi
ho (A + A)
hoA hiA
1.
2.
3.
EVALUATION REQUIREMENTS
NNPC
HYSYS CAPABILITIES
HYSYS SOLUTION
Stage-wise approach:
Involved iteration:
Evaluate results
NNPC
Involved iteration:
Evaluate results
NNPC
HYSYS ENVIRONMENT
NNPC
20.0000
600
300
15.0000
360
400
10.0000
450
5.0000
484
500
400
LMTD
300
TubeAtotl
200
100
27,
2
35, 50
0
37, 00
5
40, 00
0
42, 00
5
45, 00
0
47, 00
5
50, 00
0
52, 00
5
55, 00
0
71, 00
225
0.0000
NNPC
L T M D & T u b e c o m b in e d
o u t le t T e m p
U A ( a t I n d ic a t e d T e m p s )
0
300.00 360.00 400.00 450.00 484.00
Targeted ExchangerB Tube Outlet Temp. C
120.00
T em p era tu res C
T em p era tu res C
115.00
110.00
105.00
100.00
95.00
27
,2 5
35 0
,0 0
37 0
,5 0
40 0
,0 0
42 0
,5 0
45 0
,0 0
47 0
,5 0
50 0
,0 0
52 0
,5 0
55 0
,0 0
71 0
,2 2
5
27,
25
35, 0
00
37, 0
50
40, 0
00
42, 0
50
45, 0
000
47,
500
50,
000
52,
500
55,
000
71,
225
90.00
NNPC
440.0
T u b e s sid e T e m p s, C
540.0
490.0
440.0
390.0
340.0
290.0
240.0
TubeA
TubeB
TubeAB
340.0
ShellA
290.0
ShellB
240.0
ShellAB
190.0
140.0
2 7 ,2 5 0
3 5 ,0 0 0
3 7 ,5 0 0
4 0 ,0 0 0
4 2 ,5 0 0
4 5 ,0 0 0
4 7 ,5 0 0
5 0 ,0 0 0
5 2 ,5 0 0
5 5 ,0 0 0
7 1 ,2 2 5
2 7,
3 5 ,2 5 0
3 7 ,0 0 0
5
4 0, 00
4 2 ,0 0 0
4 5 ,5 0 0
4 7 ,0 0 0
5 0 ,5 0 0
0
5 2, 00
5 5 ,5 0 0
7 1 ,0 0 0
2 25
90.0
NNPC
S h e ll- sid e T e m p s, C
390.0
STX CAPABILITIES
SENSITIVITY ANALYSIS
NNPC
Result showed:
0
00
0,
12
0,
11
-20.00
-25.00
-30.00
-35.00
-40.00
1.00
0.80
0.60
0.40
0.20
142,454
120,000
115,000
110,000
105,000
100,000
95,000
90,000
85,000
80,000
75,000
70,000
65,000
60,000
0.00
Flowrate kg/hr
NNPC
00
0
00
0,
10
90
,0
0
0
,0
0
80
70
,0
00
60
,0
00
54
,5
00
-15.00
Flowrate (kg/hr)
-10.00
55,000
0.00
-5.00
54,500
Vibration Index
5.00
Heat duty
10
0,
00
0
11
0,
00
0
12
0,
00
0
90
,0
00
80
,0
00
70
,0
00
Mean Temperature
60
,0
00
90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
54
,5
00
Heat Duty
consistently
increase with flow
rate,
Flowrate, kg/hr
Difference (MTD)
increase with duty
MTD
80.00
result
70.00
MTD
Similar to HYSYS
75.00
65.00
60.00
55.00
50.00
He at Duty
NNPC
65
,7
12
60
,2
36
54
,7
60
49
,2
84
43
,8
08
38
,3
32
32
,8
56
29
,8
44
45.00
100,000
80,000
60,000
SPDc
40,000
TPDc
20,000
12
0,
00
0
11
0,
00
0
10
0,
00
0
90
,0
00
80
,0
00
70
,0
00
60
,0
00
0
54
,5
00
PressureDrops- Shell/Tube
Flowrates, kg/hr
1,700.00
1,500.00
1,300.00
1,100.00
900.00
700.00
500.00
300.00
SFCoef
Flowrate , kg/hr
NNPC
12
0,
00
0
11
0,
00
0
10
0,
00
0
90
,0
00
80
,0
00
70
,0
00
T FCoef
60
,0
00
54
,5
00
F
ilm
C
oefficients
1,000.00
900.00
800.00
700.00
600.00
500.00
400.00
300.00
200.00
100.00
0.00
SrateC
90
,0
00
10
0,
00
0
11
0,
00
0
12
0,
00
0
80
,0
00
70
,0
00
Srate
60
,0
00
54
,5
00
Transfer Rates
Flowrate kg/hour
NNPC
Bundle
Entrance
at Nozzle
First
Baffle
Chord
Central
Baffle
Spacing
Last
Baffle
Chord
Bundle
Exit at
Nozzle
Vibration
Index
54,500
142,450
0.8
Flowrate
NNPC
ENGINEERING SOLUTION
Tube vibration
Retrofit design
NNPC
TUBE VIBRATION
NNPC
145.00
135.00
125.00
ShellABC
115.00
ShellAB
71,225
55,000
52,500
50,000
47,500
45,000
42,500
40,000
37,500
95.00
35,000
105.00
27,250
A
B
C
/A
B
Shell sideT
em
psFor
510.00
500.00
490.00
T ubeABC
480.00
T ubeAB
470.00
71
,2
25
52
,5
00
47
,5
00
42
,5
00
37
,5
00
460.00
27
,2
50
T
ubesideT
em
psForA
B
C
/A
B
NNPC
NNPC
CONCLUSION
1.
2.
3.
4.
NNPC
RECOMMENDATION
1.
2.
3.
4.
5.
6.
NNPC
NNPC