ACKNOWLEDGEMENT

I would like to thank Indian Oil Corporation Limited, Paradip Refinery for giving me the opportunity to carry out
my vocational training during the period of 15th May - 15th July 2018.
I would like to thank Mr. S.S Patra and Mr. G.K Prusty for providing the opportunity to do the training course
on refining process of crude oil and industrial work.
I would like to express my deepest appreciation to all those who helped me throughout my training period. A
special gratitude to Mr. Sunil Yadav for his contribution in stimulating suggestions and encouragement to
complete my project titled “To determine efficiency of Packinox used in Naphtha Hydrotreating Unit”. I
would also like to thank Mr. Debasish Bhutia and Mr. G.V Sathish for their constant inspiration and guidance
to impart knowledge on the subject for the training report within a short time period.
I would also like to extend my sincere gratitude to all the Shift-in-charges and operators of the various units and
other departmental in-charges under whose guidance I have learned in-depth about the refinery operations.
 INTRODUCTION

Paradip Refinery which is envisioned to be the Energy Gateway to Eastern India is Indian Oil’s 11th Refinery
with a capacity of 15 MMTPA. It was dedicated to the service of the nation by PM Shri Narendra Modi on
February 7, 2016. The most-modern refinery of the country, with a complexity factor of 12.2 based on Nelson
Index has been set up at an estimated cost of Rs. 34,555 crore which is Indian Oil’s largest investment on a single
project and it spreads over a total area of 3,345 acres, including about 300 acres for Refinery Township and about
100 acres of land for building two approach roads to connect the refinery site with the existing road network. It
is the first zero-residue refinery of the country capable of processing all types of heavy and sour crudes (low
sulphur crude from Nigeria, Angola & Malaysia, high sulphur crude from Iraq, Iran, Saudi Arabia & UAE and
heavy crude from Mexico, Egypt, Syria, Venezuela & Brazil).
The refinery is equipped with 11 crude oil tanks to store high-sulphur heavy crude, with 58 petroleum product &
intermediate tanks (including for liquid sulphur storage tanks). Apart from these liquid storage facilities, there are
LPG storage mounded bullets, propylene storage mounded bullets, Hydrogen and alkylation feed mounded
bullets. The crude is imported through Very Large Crude Carriers (VLCC) , unloaded through Single Point
Moorings (SPMs) and transferred through to the crude oil storage tanks through dedicated crude. The products
are dispatched through pipelines (20-25%), rail (20-25%), road (15-20%) & coastal (40-50%) movements.
The refinery is configured to process high-sulphur heavy crude oils with major secondary processing units like
Fluidised Catalytic Cracker, Delayed Coking Unit (DCU) for coke production, besides Diesel Hydro-treatment
and Catalytic Reformer, Alkylation unit, etc., for quality up gradation of products. It produces various petroleum
products like Petrol and diesel BS-IV quality, kerosene, Aviation Turbine fuel, Propylene, Sulphur and Petroleum
Coke. The refinery is also designed to produce Euro-V premium quality Motor Spirit and other green auto fuel
variants for export to advanced countries.
Paradip Refinery’s unique INDMAX (FCC) Unit technology, which has been indigenously developed by Indian
Oil's R&D Centre, is designed to produce 44% LPG, the highest yield from such plants. The commissioning of
INDMAX Unit at Paradip (capacity 4.17 Million Metric Tonnes Per Annum), marks a major milestone in the
history of Indian refining. With this, Indian Oil is now recognized globally as a technology licensor. The other
first-time technological features of the Refinery include Flue Gas Desulphurization facilities, Vapor Recovery
system from jetty loading and an alkylation process to get octane-rich low-benzene MS blend component, etc.
With an aim to add more value, a 700 KTA capacity Polypropylene (PP) Plant, based on Propylene recovery from
Cracked LPG generated from INDMAX Plant, is under implementation and is scheduled for completion by 2017-
18. The refinery also has plans to set-up an Ethylene Recovery Unit /Mono-Ethylene Glycol (MEG) are expected
to be completed by 2020-21.
The products from the Refinery meets the energy demands of the domestic market and partly the South-East Asia
export market. The finished petroleum products from Paradip Refinery is shipped to as far as Asia Pacific, Europe,
USA, and to the demand centres in the east of India, north east and to some southern states like Andhra Pradesh
and Telangana.
 Naphtha Hydrotreating Unit Overview
Process Licensor – UOP
Design feed capacity (NHT/NFU)-3.939/3.913MMTPA
MS mode feed capacity (NHT/NFU)-3.107/3.068 MMTPA
Turndown-50%
Capacity basis-8320 hrs/yr
OBJECTIVE:
NHT: - To remove S and N and other impurities and to saturate the olefins so as to prepare feed for HGU and
CCRU.
NFU:-To fractionate the hydrotreated naphtha for HGU (60oC-80oC) and CCR feed (102oC-199OC)
FEED SOURCE:
NHT:-
FEED SOURCE P/O/N/A
SRN AVU(Naphtha Splitter) 72/0/18/10
FCCMCN FCCU(Naphtha Splitter) 35/24/12/30
Coker Heavy Naphtha DCU 33/19/9/40
Stabilized Naphtha DHDT 58/7/15/20

NFU:-
Feed- Hydrotreated mixed naphtha
Source- NHT
Catalyst- Ni-Mo, Co-Mo
PROCESS CHEMISTRY:
Naphtha Hydrotreating Unit
. Conversion of Organic S compounds to H2S:-
For bimetallic Platforming catalyst, the feed naphtha must contain less than 0.5 ppmw sulphur to optimize the
selectivity and stability characteristics of the catalyst.
 Conversion of Organic N compounds to NH3:-
Nitrogen removal is considerably more difficult than sulphur removal in naphtha hydrotreating. The rate of
denitrification is only about one-fifth the rate of desulfurization. Most straight run naphtha contain much less
nitrogen than sulphur, but the feed naphtha to Platforming catalyst contains a maximum of 0.5 ppmw nitrogen
and normally much less.
Any organic nitrogen that does enter the Platforming Unit will react to ammonia and further with the chloride in
the recycle gas to form ammonium chloride. Ammonium chloride will deposit in the recycle gas circuit or
stabilizer overhead system. Ammonium chloride salts can be removed by water washing.
Denitrification is favoured more by pressure than temperature. The ammonia formed in the denitrification
reactions is removed in the Hydrotreater reactor effluent wash water.

. Conversion of organic O compounds to water

Organically combined oxygen, such as a phenol or alcohol, is removed in the Naphtha Hydrotreating Unit by
hydrogenation of the carbon-hydroxyl bond, forming water and the corresponding hydrocarbon. Oxygenates are
typically not present in naphtha, but when present they are in very low concentrations. Any oxygenates in the
product will quantatively convert to water in the Platforming Unit.

.
.
. Saturation of Olefins
Hydrogenation of olefins is necessary to prevent fouling or coke deposits in downstream units. Olefins can
polymerize at the Platforming combined feed exchanger and thus cause fouling.
Most straight run naphthas contain only trace amounts of olefins, but cracked naphthas usually have high olefin
concentrations. Processing high concentrations of olefins in a Naphtha Hydrotreating Unit must be approached
with care because of the high exothermic heat of reaction associated with the saturation reaction.

.
.
.

Conversion of organic halides to hydrogen halides

Organic halides can be decomposed in the Naphtha Hydrotreating Unit to the corresponding hydrogen halide,
which is either absorbed in the reactor effluent water wash or taken overhead in the stripper gas. Maximum organic
halide removal is about 90 %. Periodic analysis of the hydrotreated naphtha for chloride content should be made,
since this chloride level must be used to set the proper Platforming Unit chloride injection rate. High feed
concentrations of chloride can result in corrosion downstream of the reactor.
C-C-C-C-C-C-Cl + H2---------> HCl + C-C-C-C-C-C
. Removal of organo-metallic compounds
Normally the metallic impurities in the naphtha feeds are in the part per billion (ppb) range and these can be
completely removed. The UOP Hydrotreating catalysts are capable of removing these compounds at fairly high
concentrations, up to 5 ppmw or more, on an intermittent basis at normal operating conditions. Some commonly
detected components found on used Hydrotreating Hydrocarbon® catalyst are arsenic, iron,calcium, magnesium,
phosphorous, lead, silicon, copper, and sodium.

Naphtha Fractionation Unit

Naphtha Fractionation Unit is designed to meet the feed requirements for the CCR Platforming Process Unit.
Feed to this unit is the net bottoms from the Stripper in the Naphtha Hydrotreating Process Unit. The Stripper net
bottoms exchanges heat with Stripper feed before entering the Naphtha Fractionation Unit. The temperature of
this stream is increased in the Feed-Bottoms Exchanger before entering the De-Pentanizer.
De-Pentanizer Column:
The purpose of De-Pentanizer is to remove C5 light hydrocarbons from the hydrotreated naphtha from the top of
the column. The De-Pentanizer contains 36 trays. Heat for the De- Pentanizer reboiler is supplied by de-
superheated MP Steam. About 638.5 m3/hr in Aromatics mode (502.8 m3/hr in MS mode) of sweet full range
Naphtha from Unit-040 Stripper at 1190C, heated further with De-Pentanizer bottom in De-Pentanizer
Feed/Bottoms Exchanger to 1420C and enters to De- Pentanizer at 20th tray, which operates at 2.8Kg/cm2g.
The overhead vapours (mainly C5 ) leaves top of the column, at 1020C get condensed to 910C. A 40 mm N2 line
is provided to meet the start-up requirement to maintain the system pressure. Non Condensable vapours at outlet
routed to top, through a dedicated free draining line. Net Overhead liquid from the De-Pentanizer Receiver
pumped by De- Pentanizer Overhead Pumps through De-Pentanizer net overhead cooler where it get cooled to
640C, then further cooled in De-Pentanizer net overhead trim cooler and sent to Hydrogen Generation Unit (HGU)
at 7.5Kg/cm2 g and 400C, facility to route Hydrotreated Light Naphtha to Storage tank also available.
Rerun Column:
The purpose of Rerun Column is to lift C6-C9 aromatics to the top of the column to meet CCR Platforming
Process Unit feed requirements. The Rerun Column contains 40 trays. Heat for the Rerun Column re-boiler is
supplied by de-superheated HP steam. De-Pentanizer bottoms enters 12th tray of Rerun Column which in turn is
cascaded with De-Pentanizer bottom level controller.
The overhead vapours leaves top at 900oC, gets condensed to 790oC in Rerun column overhead Condenser & gets
routed to Rerun column overhead receiver.
Overhead liquid from the Rerun Receiver is pumped Rerun column Overhead Pumps. One part returns back as
reflux .Another part passes through Rerun column overhead cooler (this will be switched off during MS mode
operation) where it gets cooled to 720oC, then further cooled in Rerun overhead trim cooler and sent to Hydrogen
Generation Unit (HGU) at 7.5Kg/cm2 g and 400oC, along with De-Pentanizer overhead product.
 Continuous Catalytic Reforming (CCR)
Design Feed Capacity-2.995MMTPA
MS Mode Feed Capacity-2.382MMTPA
Objective- To prepare high octane reformate for gasoline blending.
Feed- Hydrotreated Full Range Naphtha
Feed Source- NFU Rerun Column Bottoms
Feed Rate- 382m3/hr.
Specific Gravity- 0.753
PONA,wt%- 52/0/27/22
Product Specifications:-

Catalyst Composition- Pt (0.25%), chloride (1.0-1.1%). Pt, Cl on activated alumina

PROCESS CHEMISTRY:-
The purpose of the Platforming process is to produce aromatics from the naphthenes and paraffins, either for use
as a motor fuel (because of their very high octane ratings) or as a source of specific aromatic compounds. The
following reactions take place in the Platforming Process –
REACTIONS
1. Dehydrogenation of Naphthenes
2. Isomerisation of Naphthenes and Paraffins
3. Dehydrocyclization of Paraffins
4. Hydrocracking
5. Demethylation
6. Dealkylation of Aromatics

1. Dehydrogenation of Naphthenes
The final step in the formation of an aromatic from a naphthene (either a Cyclohexane or a Cyclopentane) is the
dehydrogenation of a cyclohexane. The reaction of a cyclohexane to the corresponding aromatic is extremely
rapid and essentially quantitative. Naphthenes are obviously the most desirable feed components because the
dehydrogenation reaction is easy to promote and produces by-product hydrogen as well as the aromatic
hydrocarbons. This reaction is very endothermic. It is promoted by a metal catalyst function and is favoured by
high reaction temperature and low pressure.
2. Isomerisation of Naphthenes and Paraffins
The isomerisation of a cyclopentane to a cyclohexane, must occur as the first step in converting the cyclopentane
to an aromatic. This isomerisation involves ring rearrangement and the probability for ring opening to form a
paraffin is quite high. Therefore, the reaction of alkyl cyclopentane to cyclohexane is not 100% selective. The
reaction is strongly dependent on the processing conditions.

3. Paraffin isomerisation
Paraffin isomerisation occurs readily in commercial Platforming operations but at typical operating temperatures
the thermodynamic equilibrium is not strongly in favour of the more desirable (higher octane) branched isomers.
In motor fuel applications this reaction does make a contribution to octane improvement of the naphtha.
Isomerisation reactions result from carbonium ion intermediate reactions. These reactions are promoted by the
acid function and are only slightly dependent on operating pressure.

4. Dehydrocyclization of Paraffins
It consists of a very difficult molecular rearrangement from paraffin to a naphthene. In the case of light paraffins,
equilibrium considerations limit this reaction. The paraffin cyclization step becomes easier as the molecular
weight of the paraffin increases, because of increased statistical probability for the formation of the naphthene.
Dehydrocyclization is favoured by low pressure and high temperature.

5. Hydrocracking
Because of the strained ring isomerisation and ring formation reactions that the feed alkyl cyclopentane and
paraffins must undergo, and because the catalyst needs to have an acid function, the possibility for acid-promoted
Hydrocracking, is strong. Paraffin Hydrocracking is relatively rapid and is favoured by high pressure and high
temperature. The disappearance of paraffins from the gasoline boiling range via Hydrocracking does concentrate
aromatics in the product and hence contributes to octane improvement.
6. Demethylation
Demethylation reactions occur only in very severe Platforming operations (high temperature and high pressure).
The reaction is metal catalysed and is favoured by high temperature and pressure.

7. Dealkylation of Aromatics
The Dealkylation reaction is also favoured by high temperature and high pressure
 POLYBED Pressure Swing Adsorption
Purpose: To recover maximum H2 ex- CCRU Net gas rich in H2+ C1+C2
Purifier consists of: 12 Adsorbent Beds (Primary Mode)
10 Adsorbent Beds (Alternate Mode)
Scope of adding 2 more Beds.
Operating Principle: Repeated cycle having two basic steps- Adsorption and Regeneration
Design H2 recovery: 86% in case of Primary Mode.
(96% Recovery on Tail Gas Recycle to Net Gas Compressor suction)
(85% in case of Alternate Mode.)

Turn down ratio: 35% of design feed rate.

Time: 400 s for one Adsorber Bed

Adsorption Step
1. The Feed Gas (PSA inlet CCRU Off gas rich in H2 + C1+C2) enters the bottom through the Feed Valve.
2. Impurities (C1+C2) are selectively adsorbed & purified H2 product is delivered.
3. The concentration of impurities are greatest at the bottom of the Adsorber & sharply decreases towards
the top of the Bed.
4. Out of 12 Adsorbers, 3 are in adsorption stage at any one time. The timing of Adsorption steps for these
3 Adsorbers will be staggered such that at any one time one Adsorber will be switched to Adsorption step.
Regeneration Step
The Adsorber laden with Impurities is regenerated (Desorbed of Impurities) by
1. Co-current Depressurization (Equalization & Provide Purge Steps) with pure H2 remaining in the Bed.
2. Next by Blow Down to Tail Gas Surge Tank Pressure.
3. Then by Counter current Depressurization with pure H2 from another Adsorber Bed (Receive Purge Step).
4. The Desorbed Bed is repressurized to Adsorption Pressure for H2 recovery.

Tail Gas is generated during Blow down & in Receive Purge Steps.
 Aim of the Project:-
To find the efficiency of the plate type heat exchanger (PACKINOX)
 PLATE TYPE HEAT EXCHANGER (PACKINOX)

The Packinox Heat Exchanger is a very large welded plate Heat Exchanger composed of a welded plate heat
transfer bundle and of a pressure vessel. In operations the welded plate is always protected and kept under positive
external pressure by the highest pressure stream (the recycle gas, which is fed directly into the shell).
The secondary components are:
 Headers to allow fluid distribution inside the welded plate bundle.
 Expansion bellows to compensate different thermal expansion between the bundle and the vessel.
 Spray bars for liquid feed injection.
The Packinox heat exchanger is installed vertically and the hot effluent from the last reactor enters the heat
exchanger at the top and flows downwards as it is being cooled ( Flow Path=Effluent inlet, hot end bellows,
effluent header, plate bundle, cold end bellow, effluent outlet).
The cold combined feed enters the heat exchanger at the bottom and rises as it is being heated (Flow path=Recycle
gas inlet + venturi (vapour), liquid feed + spray bars (liquid), plate bundle, feed header, hot end bellows, feed
outlet).
True counter current heat transfer takes place inside the bundle, which is made of thin stainless steel corrugated
plates formed by explosion, stacked and edge welded together.
This heat exchanger bundle is designed to optimise the thermal and hydraulic performance of the exchanger. The
base components are long corrugated stainless steel thin plates which provide high thermal and hydraulic
efficiency, high heat transfer rate, high flow turbulence and low pressure drop.
 Large plates up to 2m width and 15m length.
 Smooth surfaces and constant thickness.
 No residual stresses.
Long corrugated plates are formed by explosion under water which provides a smooth surface and constant
thickness of the corrugated plates which significantly reduces fouling. Also the stresses are evenly distributed on
the plate and consequently the stress peaks are much low.
Each individual odd or even plate is equipped with longitudinal inlet and outlet spacers whose design depends on
plate width.
The assembly of odd and even plates gives alternate channels for combined feed and effluent. Fluids distribution
inside the channels is ensured by header boxes and inlet and outlet spacers.
Plates are stacked, then welded to each other along the edges (welded wall), providing for a tight, stiff and rugged
bundle assembly.
The chevron pattern of the plate corrugations provides tens of thousands of plate-to-plate contact points
eliminating plate vibration at all flow rates. Because the chevron pattern of each plate is the diametrical opposite
of the plates above and below it, flow turbulence and distribution are further enhanced. Homogeneous flow
distribution means even temperature distribution across the bundle eliminating the uneven thermal stresses
resulting from bad distribution. Plates are subjected to very low mechanical stresses. Because the bundle is
suspended vertically from a unique header box support system, each plate supports only its own weigh

Mechanical performances key indicators

Two types of indicators may be used to detect any mechanical troubleshooting:
A. Thermal & hydraulic performances
The parameters to monitor being:
- HAT (Hot Approach Temperature) = T3 - T2 = Effluent (Hot Stream) Inlet Temperature -
Combined Feed (Cold Stream) Outlet Temperature.
- ΔP1 = DPR1 = ΔP Combined Feed (Cold Stream) Pressure Drop.
- ΔP2 = DPR2 = ΔP Effluent (Hot Stream) Pressure Drop.
- ΔP Spray Bars = DPR4 = P2 – P1 = Liquid Feed inlet Pressure – Recycle gas inlet Pressure.
Note: For P2 = Liquid Feed inlet Pressure: if not taken at spray bars inlet, pressure shall be corrected of any liquid
column height.
- T Shell = T5 = Pressure Vessel Skin Temperature.
B. Unit performances. The unit parameters to follow are depending of the process units and are mainly product
quality:
Catalytic Reforming Units: Octane number, Naphthene content into the product.
Paraxylene production Units: Product quality & purity.
LAB production Units: Product quality & purity.
The 4 methods that can be used in-service for determining the exchanger inter-circuit leakage in Packinox are:
1. Quantitative chemical analysis of 2 samples: naphtha-feed & stabilised reformate product,
2. Quantitative chemical analysis of 3 samples: naphtha-feed & 2 de-pentanized products at exchanger
effluent inlet & product separator,
3. Chemical tracer (Phenol or Cresol) – Continuous tracer injection,
4. Radioactive Tracer injection – Slug injection.
Methods 1 and 2 are used for Catalytic Reforming units.

Mechanical Troubleshooting
Potential mechanical troubleshooting are:
- EXPANSION BELLOWS & WELDED WALL FAILURE: “One shot” phenomenon.
- CROSS CHANNELS CONTAMINATION.
The immediate impact of cross channel contamination troubleshooting will be a decrease in product quality &
purity.
Expansion Bellows and/or Welded Wall failure - Low Mechanical
Severity:
ΔP1 or ΔP2 : Stable or small increase
HAT : Rapid increase (such as + 10°C in one day)
TShell: Rapid decrease (such as 100°C in one day)
Chemical cleaning with ammonia water solution and then replacement of expansion bellows, or welded wall crack
repair is the solution for the above problem.

Cross channel contamination:

Based on PACKINOX’s experience, cross channel contamination has always been the consequence of specific
conditions such as but not limited to:
- plugging of effluent, which creates an uneven flow & temperature distribution in the plate bundle which results
in thermal & mechanical stresses.
-unit restart with high temperature difference between reaction zone and PACKINOX Heat Exchanger
Solution for above problem:
a) Repair of the PACKINOX Heat Exchanger.
b) Avoid the cause (cause being identified after performances analysis + observed defects).

Thermal & Hydraulic performances troubleshooting

a) Increase of fuel consumption in the Heater
b) Increase of power consumption at Recycle Gas Compressor.
Plugging and/or fouling have an impact on Heat Exchanger mechanical behaviour by creating channelling with
associated thermal & mechanical stresses.
In each troubleshooting the associated potential impact on Heat Exchanger mechanical behaviour is described in
term of mechanical severity (Low, medium and high).
Potential thermal & hydraulic performances troubleshooting are:
1. Fouling - regular deposit into the heat exchanger.
2. Plugging - localised at the inlet section of the heat exchanger. “one shot” phenomenon.
3. Expansion bellows & welded wall failure -“one shot” phenomenon.
4. Spray bars plugging (spray bars = liquid feed distributors) - most often “one shot” phenomenon and at
start-up.
Fouling - Low to Medium Mechanical Severity:
ΔP1 or ΔP2: Regular increase (such as + 0.2 to 0.5 kg/cm² in one year)
HAT: Regular increase (such as + 10 to 20°C or more in one year)
T Shell: Normal
The heat exchanger has FOULING.
This can occur on effluent stream (ΔP2 increase) and/or combined feed stream (ΔP1 increase).
Plate Heat Exchanger Advantages
1. Easy to Remove and Clean
You simply remove the tie bolts and slide back the movable frame. The plate pack can then be inspected,
pressure cleaned, or removed for refurbishment if necessary.

2. Expandable
A significant benefit of the plate heat exchanger is that it is expandable, allowing an increase in heat
transfer capability. As your heat transfer requirements change, you can simply add plates instead of
buying an entire new frame unit, saving time and money.

3. High Efficiency
The pressed plate patterns and narrow gaps allow for very high turbulence at relatively low fluid velocity.
Combined with counter directional flow results in very high heat transfer coefficients.
Compact Size The high efficiency requires less heat transfer area resulting in a much smaller heat
exchanger than would be necessary for the identical effectiveness of other heat exchanger
 types. Typically a plate heat exchanger requires 20-40% less space than required by a shell & tube heat
exchanger.

4. Close Approach Temperature

The same features that give the plate heat exchanger its high efficiency also makes it possible to reach
close approach temperatures which is particularly important in heat recovery and regeneration
applications. Approach temperatures of 1ºF are possible.

5. Multiple Duties in a Single Unit

The plate heat exchanger can be built in sections, separated with simple divider plates or more complicated
divider frames with additional connections. This makes it possible to heat, regenerate, and cool a fluid in
one heat exchanger or heat or cool multiple fluids with the same cooling or heating source.

6. Avoid cross contamination

Each medium is individually gasketed and as the space between the gaskets is vented to the atmosphere,
cross contamination of fluids is eliminated.

7. Less Fouling
Very high turbulence is achieved as a result of the pattern of the plates, the many contact points, and the
narrow gap between the plates. This combined with the smooth plate surface reduces fouling considerably
compared to other types of heat exchangers.

8. Lower Costs
High heat transfer coefficients mean less heat transfer area and smaller heat exchangers, and sometimes
even less heat exchangers. This and less space requirements, reduced flow rates, and smaller pumps
means.
 Heat Transfer Coefficient (NTU method)

If more than one of the inlet and outlet temperature of the heat exchanger is unknown, LMTD may be obtained
by trial and errors solution. Another approach introduce the definition of heat exchanger effectiveness (Є), which
is a dimensionless with ranging between 0 to1.

Є = Qact / Qmax

Where, Qmax is the maximum possible heat transfer for the exchanger. The maximum value could be attained if
one of the fluids were to undergo a temperature change equal to the maximum temperature difference present in
the exchanger, which is the difference in the entering temperatures for the hot and cold fluids.

Let C = mCp

Qact = Ch(Thi - Tho) = Cc(Tco – Tci)

The maximum possible heat transfer when the fluid of small C undergoes the maximum temperature difference
available
Qmax = Cmin (Thi - Tci)
Qact = Є Cmin (Thi - Tci)
Combining all three equations
Є = Ch(Thi - Tho) / Cmin (Thi - Tci) = Cc(Tco – Tci) / Cmin (Thi - Tci)
For Ch < Cc : Єh = (Thi - Tho) / (Thi - Tci)
For Ch > Cc : Єc = (Tco – Tci) / (Thi - Tci)

Using following equation

ln(Tho - Tco) / (Thi - Tci) = -UA(1/Ch + 1/Cc )
(Tho - Tco) / (Thi - Tci) = exp[-UA(1/Ch + 1/Cc )]
From energy balance,
Tco = Tci + Ch / Cc(Thi - Tho)
From above all equations

Єh = 1- exp[(-UA / Ch)(1+(Ch / Cc))] / (1+(Ch / Cc))

Єc = 1- exp[(-UA / Cc)(1+(Cc / Ch))] / (1+(Cc / Ch))
So effectiveness can be written as:
Є = 1- exp[(-UA / Cmin)(1+(Cmin / Cmax))] / (1+(Cmin / Cmax))
The terms UA/Cmin is called the Number of transfer units (NTU) since it is indicative of the size of the heat
exchanger, i.e
NTU = UA/Cmin

As Cmin / Cmax  0
Є = 1 – exp(-NTU)

Theoretical Calculation

Specific heat of cold fluid (Cpc) = 0.626 Kcal / kgoC

Specific heat of hot fluid (Cph) = 0.922 Kcal / KgoC
Mass flow rate of cold (feed) fluid (ṁh) = 2533.54 Kgmol / hr
Mass flow rate of hot (Effluent) fluid (ṁc) = 19794.93 Kgmol / hr

Tcin = 144oC
Tcout = 467oC Total Area of plate=12*(length*width)
Thin = 499oC = 12*(15 m*2 m) = 360m2
Thout = 117oC

Ch = ṁhCph = 19794.93*0.922
= 18250.92 Kcalmol / g.hroC
Cc = ṁcCpc = 2533.54*0.626
= 1585.99 Kcalmol / g.hroC
As Ch > Cc, then
Єc = (Tco – Tci) / (Thi - Tci)
= (467-144) / (499-144)
= 0.909
From effectiveness formula

Є = 0.909 = 1- exp[(U*360 / 1585.99) / (1+(1585.99 /18250.92) )] / (1+(1585.99 /18250.92) )

U = 4.233 KW / m2oC
As this U value is theoretical so it is Uclean means it doesn’t contains any fouling factor (Rf)

Practical Calculation
Specific heat of cold fluid (Cpc) = 0.626 Kcal / kgoC
Specific heat of hot fluid (Cph) = 0.922 Kcal / KgoC
Mass flow rate of cold (feed) fluid (ṁh) = 2533.54 Kgmol / hr
Mass flow rate of hot (Effluent) fluid (ṁc) = 19794.93 Kgmol / hr

Tcin = 145.2oC
Tcout = 455.7oC Total Area of plate=12*(length*width)
Thin = 496.53oC = 12*(15 m*2 m) = 360m2
Thout = 111oC

Ch = mhCph = 19794.93*0.922
= 18250.92 Kcalmol / g.hroC
 Cc = mcCpc = 2533.54*0.626
= 1585.99 Kcalmol / g.hroC

As Ch > Cc, then

Єc = (Tco – Tci) / (Thi - Tci)
= (455.7-145.2) / (496.53-145.2)
= 0.884
From effectiveness formula

Є = 0.884 = 1- exp[(U*360 / 1585.99) / (1+(1585.99 /18250.92) )] / (1+(1585.99 /18250.92) )

U = 3.472 KW / m2oC
As this U value is theoretical so it is Udirty means it contains fouling factor (Rf)
Efficiency of plate type heat exchanger = (Udirty / Uclean)*100
=82.02 %

Heat Transfer Coefficient (LMTD Method)

Disregarding heat losses to the atmosphere, which are negligible, the heat lost (heat load) by one side of a plate
heat exchanger is equal to the heat gained by the other. The heat load (Q) is expressed in kW or kcal/h.
Logarithmic mean temperature difference (LMTD) is the effective driving force in the heat exchanger.
T1 = Inlet temperature of hot side
T2 = Outlet temperature of hot side
T3 = Inlet temperature of cold side
T4 = Outlet temperature of cold side
Overall heat transfer coefficient (U) is a measure of the resistance to heat flow, made up of the resistances
caused by the plate material, amount of fouling, nature of the fluids and type of exchanger used. Overall heat
transfer coefficient is expressed as W/m2 °C or kcal/h.m2 °C.

Q = m · Cp · δt
Q = U · A . ΔTLMTD
Where
Q = heat load (kW) m = mass flow rate (kg/s)
Cp = specific heat (kJ/kg °C) A = heat transfer area (m2)
δt = temperature difference between inlet and outlet on one side (°C)
U = heat transfer coefficient (W/m2 °C)
ΔTLMTD = log mean temperature difference
The overall heat transfer coefficient can be calculated by equating both equations.
Theoretical Calculation:
ΔT1 = T1–T4 =499-467=32°C
ΔT2 = T2–T3=144-117=27°C
ΔTLMTD = (32-27)/ ln (32/27) = 29.42°C
Now,
m1· Cp1· δt = Qc = 48536.3027 KW
m2 · Cp2 · δt = Qh = 82569.9853 KW
(Qh +Qc ) / 2 = U · A . ΔTLMTD

65553.144 = U * 360 * 29.42

U=6.1859 KW/m2.°C
Practical Calculation:
ΔT1 = T1–T4 =496.53-455.7=40.83°C
ΔT2 = T2–T3=145.2-111=34.2°C
ΔTLMTD = (40.83-34.2)/ ln (40.83/34.2) = 37.42°C
Now,
m1· Cp1· δt = Qc = 46657.9628 KW
m2 · Cp2 · δt = Qh = 83333.0011 KW
(Qh +Qc ) / 2 = U. A. ΔTLMTD
64995.482 = U * 360 * 37.42
U = 4.821 KW/m2.°C
Efficiency:
Utheoritical = 6.1859 KW/m2.°C
Upractical = 4.821 KW/m2.°C
Efficiency= Upractical/ Utheoritical
= 4.821/6.1859 = 77.89%

Heat Transfer Coefficient (Nusselt number)

In heat transfer at a boundary (surface) within a fluid, the Nusselt number (Nu) is the ratio
of convective to conductive heat transfer across (normal to) the boundary. In this context, convection includes
both advection and diffusion. Named after Wilhelm Nusselt, it is a dimensionless number. The conductive
component is measured under the same conditions as the heat convection but with a (hypothetically) stagnant (or
motionless) fluid. A similar non-dimensional parameter is Biot number, with the difference that the thermal
conductivity is of the solid body and not the fluid. This number gives an idea that how heat transfer rate in
convection is related to the resulting of heat transfer rates in conduction. EXAMPLE: A system consisting of a
hot fluid getting heated which is in contact with a metal wall.
A Nusselt number close to one, namely convection and conduction of similar magnitude, is characteristic of "slug
flow" or laminar flow. A larger Nusselt number corresponds to more active convection, with turbulent
flow typically in the 100–1000 range.
The convection and conduction heat flows are parallel to each other and to the surface normal of the boundary
surface, and are all perpendicular to the mean fluid flow in the simple case.

where h is the convective heat transfer coefficient of the flow, L is the characteristic length, k is the thermal
conductivity of the fluid.

There are a total of six parameters involved in this problem: h, V, D, v, kf , cp . The temperature dependence of
properties is implicit and is only through the variation of thermal properties. Density ρ is included in the kinematic
viscosity, v=µ / ρ. According to the Buckingham theorem, it is possible for us to reduce the number of parameters
by three. Therefore, the convection coefficient relationship can be reduced to a function of only three variables:
Nu=hD/kf , Nusselt number, Re=VD/v, Reynolds number, and Pr=v / α, Prandtl number.

This conclusion is consistent with empirical observation, that is Nu=f(Re, Pr). If we can determine the Reynolds
and the Prandtl numbers, we can find the Nusselt number and hence, the heat transfer coefficient, h.
Dittus-Boelter equation:
Nu = 0.023Re0.8Prn
where n=0.4 for heating, n=0.3 for cooling. The range of validity: 0.7<Pr<160, Re>10,000, L/D>=10

Calculation
Diameter of heat exchanger=d=5.39m
Cross sectional Area= π*d2/4=22.81 m2
Thickness of heat transfer surface=δ=9mm
Thermal conductivity of material separating the media=λ=18.9 W/m°C
FEED:
Density=ρ=740kg/m3 Total area of heat transfer = (4.456*1.944) m2
Specific Heat=Cp=0.893 kcal/kg.°C = 8.662 m2
Thermal Conductivity=0.126 kcal/hr.m.°C
Viscosity= µ=0.018cp
Molar flow rate=m=14208.19 kmol/hr
Molar mass=M=102g/mol
Mass flow rate=ṁ=m*M=1449235.38=4020.565 kg/s
Velocity=v=ṁ/(A* ρ)=4020.565/(8.662*200)=2.3m/s
Reynolds Number=Re= ρ*v*d/µ =200*2.3*5.39/0.018*10-3 = 137744444
Prandtl Number=Pr=µ*Cp/k =0.018*10-3*0.893/(0.126/3600)= 0.459
Nusselt Number=Nu=0.023*Re0.8*Pr0.4=54665.35
Now , Nu=h1L/k
h1=Nu.k/L=54665*0.126/15
h1=459.188 kcal/hr.m2.°C = 0.533 KW / m2.oC

EFFLUENT:
Density=ρ=836kg/m3
Specific Heat=Cp=0.682 kcal/kg.°C
Thermal Conductivity=0.0876 kcal/hr.m.°C
Viscosity= µ=0.012cp
Molar flow rate=m=19794.93 kmol/hr
Molar mass=M=102.48g/mol
Mass flow rate=ṁ=m*M=2028584.43=5630.49 kg/s
Velocity=v=ṁ/(A* ρ)=5630.49/(8.662*232)=2.81 m/s
Reynolds Number=Re= ρ*v*d/µ =232*2.81*5.39/(0.012*10-3) = 292820733
Prandtl Number=Pr=µ*Cp/k =0.012*10-3*0.682/(0.0876/3600)= 0.3363
Nusselt Number=Nu=0.023*Re0.8*Pr0.4=88247.018
Now, Nu=h2L/k
h2=Nu.k/L=88247.018*0.0876/15
h2= 515.3 kcal/hr.m2.°C = 0.598 KW/m2.oC
Fouling factor, Rf this is for naphtha media in plate type heat exchanger= 0.00018
(This is taken from http://www.engineeringpage.com/technology/thermal/fouling_factors.html)
1 1 1 9
= + +
𝑈𝑐𝑙𝑒𝑎𝑛 .533 .598 18.9
1
Uclean= 4.02 KW/m2.°C

= 0.248756 KW/m2.°C

1 1 1 9
= + + +0.18
𝑈𝑑𝑖𝑟𝑡𝑦 .533 .598 18.9
1
Udirty = 4.2 KW/ m2.°C

= 0.23809 KW/ m2.°C

Efficiency = Udirty / Uclean
= 0.23809/0.248756
= 95.71%

Results & Discussion

Design Data of Plate type heat exchanger:-
Overall heat transfer Coefficient (U) range = 1000-4000 W/m2oC
Fouling factor, Rf = 0.00018 for Naphtha medium in exchanger
Sl. Process U (Theoretical) U (Practical) Efficiency Rf
No (W/m2oC) (W/m2oC) (%) (m2oC/ W)
1 NTU method 4233 3472 82.02 0.0000517
2 LMTD Method 6189 4821 77.89 0.00458
3 Nusselt number method 248.75 238.09 95.71 0.00018
Three different approaches are used to calculate the heat transfer coefficient of the Packinox heat exchanger in
order to find out its efficiency.
The overall heat transfer coefficient obtained using NTU method lies within the design range.
The results obtained using LMTD method are quite larger than the design values since LMTD approach cannot
be used in this case since phase change occurs in the heat exchange. Moreover the specific heats of the fluids
don’t remain constant in the process.
The values of overall heat transfer heat transfer coefficient obtained using Nusselt number method are quite
smaller than the design values since in this method due to the high temperature difference between the inlet and
the outlet of the heat exchanger viscosity changes by 10 folds. This also changes Prandtl number and Reynolds
number which ultimately affects Nusselt number
To improve the efficiency of Plate type heat exchanger by reducing the fouling factor the following methods can
be used they are:
Off line methods consist on stopping the heat exchanger service and dismount and clean the surfaces
directly. There are many methods used: manual cleaning, jet cleaning, blasting. These methods are simple but
require stopping the plant. They suppose a cost during the operation of the plant.
On the other hand, in line methods don’t require the stop of the plant. These methods are applied during
operation and we can find upstream filtration, back flushing, flow excursion… These methods increase the initial
cost of the plant but avoid plant shutdowns and reduce the maintenance costs of the plant.

Conclusion
The efficiency of the Packinox heat exchanger is found to be 82.02% by NTU method which is in the design
range. The decrease in the efficiency is detected at the control panel if there is a fall in the temperature of the feed
outlet of the heat exchanger by 5 to 10oC (normal feed outlet temperature = 467oC). While shell and tube heat
exchangers have been the mainstay of industry for many decades, plate heat exchangers are overtaking them in
many sectors due to compactness, efficiency and ease of maintenance. The efficiency can be improved by
reducing the fouling factor which is done by injecting a mixture of sodium carbonate and hot water. However,
naphtha feed does not create much fouling. As a result, fouling is rare in case of Packinox and doesn’t require
much maintenance.

References
1. https://www.alfalaval.in
2. www.csidesigns.com
3. https://ceng.tu.edu.iq