ENERGY BALANCE-PROPOSED HINCOL PROJECT- Rev 3

(Vizag project)

1 Design basis

o
Min ambient temperature 20 C
o
Max ambient temperature 45 C
Bitumen properties
3
Density of Bitumen 1000 Kg/M
Specific heat of Bitumen 0.45 Kcal/KgoC
o
Thermic fluid supply temperature 260 C
o
Thermic fluid supply temperature 230 C
Specific heat of Thermic fluid 0.6 Kcal/KgoC

2 Energy balance across Bitumen storage tank MT-1/T2/T3

Tank capacity 497 M3

Working capacity 447.3 M3
Total mass in storage tank 447300 Kg
2.1 Initial heat up : may not be regular case
o
Bitumen is received Tanker at 90 C min
o
which is then heated to 110 deg C 110 C in 36 Hrs

Preheating Heat load (continuous) 111825.0 Kcal/Hr

2.2 Heat loss : continuous

Storage tank is insulated , however Heat losses (continuous) 22097.81 Kcal/Hr (Refer coil design )

2.3 Temperature drop during night when plant/TFH is not in operation

Consider time during plant is shut during night 8 Hrs
Heat loss 22097.81 Kcal/Hr
Total heat loss during night 176782.47 Kcal
 o
Temperature drop during night after 8 hrs 109.12 C
During day start up liquid is heated back to 110 deg C in about 100 min
So, Intial preheating load 106069.48 Kcal/Hr

Maximum heat load per tank 128167.3 Kcal/Hr

Thermic fluid circulation /tank 7120.40 Kg/Hr
Thermic fluid circulation /tank 8.90 M3/Hr
Hot oil supply line 45.811 mm
50 NB
Considering peak load only for 1 tank
Total heat load 128167.3 Kcal/Hr

3 Outflow /suction heater

o
Bitumen is received from Main tank at 110 C
o
which is then heated to 135 deg C during transfer from Mother tank 135 C
via suction/outflow heater
Preheating load across suction/outflow heater
Bitumen transfer rate 48 TPH
Preheating Heat load (continuous) 540000 Kcal/Hr
Thermic fluid circulation /tank ( S: 260 / R:230 oC) 30000.00 Kg/Hr
3
Thermic fluid circulation /tank 37.50 M /Hr
Hot oil supply line 81.43 mm
80 NB
4 Energy balance across Bitumen Day tank T-4

Tank capacity 150 M3

Working capacity 135 M3
Total mass in storage tank 135000 Kg

o
Temperature inside day tank is maintained at 135 C
by intrenal coil supplied with thermic fluid.
Storage tank is insultaed , however Heat losses (continuous) 12936.02 Kcal/Hr (Refer coil design )
 Total Peak heat load 12936.0 Kcal/Hr

5 Energy balance across Bitumen Day tank T-5

Tank capacity 150 M3

3
Working capacity 135 M
Total mass in storage tank 135000 Kg
o o
Bitumen is received from Main tank at min 110 C and normal at 135 C
Coil is designed to maintain temperature for any heat losses
Storage tank is insulated, however Heat losses (continuous) 14630.9 Kcal/Hr (Refer coil design )

Maximum heat load per tank 14630.9 Kcal/Hr

o
Thermic fluid circulation /tank ( S: 260 / R:250 C) 2438.49 Kg/Hr
Thermic fluid circulation /tank 3.05 M3/Hr
Hot oil supply line 26.81 mm
40 NB
Total Peak heat load 14630.9 Kcal/Hr

6 Energy balance across CRMB/PMB tank : T6/T7/T8/T9

3
Tank capacity 100 M
Working capacity 80 M3
Total mass in CRMB tank 80000 Kg
o o
Bitumen is received from Day tank at lowest 110 C 135 C Normal
o
which is then it is heated to 185 C in 6 Hrs
o
and maintained at 185 C under agitation

Preheating load 300000 Kcal/Hr

Storage tank is insultaed , however Heat losses (continuous) 16384.30 Kcal/Hr (Refer coil design )
Peak heat load 300000 Kcal/Hr
Hot oil circulation 16666.67 Kg/Hr
Hot oil circulation 20.83 M3/Hr
Hot oil supply line 70.09 mm
 80 NB
Total Peak heat load for 2 Nos tanks 627566.94 Kcal/Hr

7 Energy balance across CRMB/PMB tank : T10/T11

Tank capacity 50 M3
Working capacity 40 M3
Total mass in CRMB tank 40000 Kg
o o
Bitumen is received from Day tank at lowest 110 C 135 C Normal
o
which is then it is heated to 185 C in 6 Hrs
and maintained at 185oC under agitation
Preheating load 150000 Kcal/Hr

Storage tank is insultaed , however Heat losses (continuous) 10043 Kcal/Hr (Refer coil design )
Total heat load 150000 Kcal/Hr
Hot oil circulation 8333.33 Kg/Hr
Hot oil circulation 10.42 M3/Hr
Hot oil supply line 49.56 mm
50 NB
Total heat load -Not considered for peak load 150000 Kcal/Hr

8 Energy balance across Premix tank : (ASSUMED SAME AS GOWAHATI)

3
Premix working capacity 16 M
Bitumen at 135oC is fed to Premix tank where other RMs about 12%
o
are fed and whole mass is heated and maintained at 185 C in 2 Hrs
Preheating load 158400 Kcal/Hr
Total heat load 158400 Kcal/Hr
Hot oil circulation 8800.00 Kg/Hr
Hot oil circulation 11.00 M3/Hr
Hot oil supply line 44.10 mm
50 NB
Total heat load for 1 Nos tank 158400 Kcal/Hr
9 EMULSION PLANT

9.1 Drum Melting ( not a continuous load)

Consider 200 Kg x 4 Nos of Emulsifier drums are heated/melted at 50-60 oC

in about 2-3 Hrs.

Total emulsifier Quantity 800 Kg

o
Initial temperature 5 C
o
Final temperature 60 C
Heating time 2 Hrs
Specific heat of emulsifier 1 Kcal/KgoC

Heating load 22000.0 Kcal/Hr

Consider 10%heat losses 2200 Kcal/Hr
Total heat laod 24200 Kcal/Hr

Drums are heated by circulation hot air at 80-85oCin closed encloser

Hot air requirement 19360.00 Kg/Hr

15007.75 NM3/Hr
Hot oil circulation 1344.44 Kg/Hr
Hot oil S/R 25 NB

9.2 Starch Soln Swelling Tank T- (Not a continuous load)

Starch soln is heated from 30 oC to 75oC by Hot water

Starch solution 200 Kg

Hot water at 60oC 900 Kg
o
Swelling temperature 75 C
o
Resultant temperature after mixing 55 C
Further heating time 0.5 Hrs
 Then heat load 44000 Kcal/Hr
thermic fluid circulation through jkt 2444.44 Kg/Hr
3
thermic fluid circulation through jkt 3.056 M /Hr
25 NB

12 SUMMARY -Thermic fluid

EQUIPMENT Peak Kcal/Hr

T-1/2/3 - ONE TANK CONSIDERED for peak load 128167.3
Outflow heater 540000.0
T-4/5 27566.9
T-6/7/8/9 (2 tanks considered for peak load) 627566.9
T-10/11 not considered for peak load 150000
Premix tank - not considered for peak load 158400
DRUM MELTING- not considered for peak load 22000.0
Starch cooker - One considered for peak load 44000.0
Total heat load 1367301.2
Consider 10% pipe line heat losses 136730.1

Therorotical heat load 1504031.3

Recommended capacity WITH LOSSES/EFFICIENCY 16.0 Lakh Kcal/Hr

Proposed TFH capacity 10 + 6 Lakh Kcal/Hr confirmed

Note: Different heating time cycles to stagger to meet duties of other equipments