E-1: Syngas product cooler Values as applicable

Syngas Stream  
Q,kJ/h -3279043.44
Ms, kg/h 4991.65
T1, C 800.00
T2, C 500.00
Cph, kJ/kg C 2.36
Cooling Water Stream  
Mw = Q / Cpc * (T3 - T4)  
T3, C 30.00
T4, C 100.00
Cpw, kJ/kg C 4.18

At steady state conditions:

Q −3279043.44 kg
M w= = =11206.57
C pw ( T 3 −T 4 ) 4.18∗( 30−100 ) h

LMTD:

θ1=T 1−T 4 =800−100=700 C

θ2=T 2−T 3=500−30=470 C

θ1−θ2 700−470
LMTD= = =577.39 C
θ1 700
ln
( ) ( )
θ2
ln
470

Correction factor:

T 1−T 2 800−500
R= = =4.29
T 4 −T 3 100−30
T 4−T 3 100−30
S= = =0.09
T 1−T 3 800−30
For a 1 shell, 2 tube pass and from the chart given in the reference:

F t=0.8

MTD=F t∗LMTD=0.8∗577.39=461.91 C

For area:

From the table given in the reference:

KJ
U =108
hr m2 C
Q=U∗A∗MTD
Q 3279043.44
A= = =65.73 m2
U∗MTD 108∗461.91
For tube specifications:

From table 12.3 from the reference:

Tube outer diameter , d o=20 mm

Tube inner diameter , d i=16 mm
Tube thickness t t =2 mm
From the reference, the optimum tube length to shell diameter ratio is about 5 to 10.
Assume L=5 m

Areaof one tube , A tube

¿ 3.142∗do∗L=3.142∗20∗10−3∗5=0.31 m2
A
No .of tubes , N t = =212.03
Atube
Bundle diameter
1
N
Db =do∗ t
K1 ( ) n1

Nt: No. of tubes

Db: Bundle diameter, mm
do: Tube diameter, mm
From Table 12.4 from the reference

For triangular pitich

pt =1.25 d o=1.25∗20∗10−3=25 mm
K 1=0.25
n1 =2.21

1 1
N 212.03
Db=do∗ t
K1 ( ) n1
=20∗ (
0.25 ) 2.21
=423.69mm

For shell specifications:

typical shell clearance , SC=56 mm
shell diameter , D s=Db + Sc =423.69+56=479.69 mm

For shell side heat transfer coefficient, hi

pt: tube pitch, mm 25.00

do: outside tube dia., mm 20.00
Ds: Shell inside dia., mm 479.00
Lb: Baffle spacing, mm 95.80

( pt −d o )∗Ds∗Lb
Area for cross flow , A s=
pt ( 95.8
= (25−20 )∗479.69∗
25 )
=0.01 m
2

For an equilateral triangular pitch arrangement

de= ( 1.10
do )
2
∗( p t −0.917∗d o ) =
1.10
2
20
2
∗( 25 −0.917∗20 ) =0.01 m 2

Ws
Shell side mass velocity ,Gs=
As
Gs
Shell side fluid velocity , us=
ρ
kg
fluid flow rate on the shell side ,Ws=3.11
s
kg
fluid density , ρ=1000
m3

Ws 3.11 kg
Gs= = =311 2
As 0.01 sm

Gs 311 m
us= = =0.311
ρ 1000 s
 m Ns
Viscosity of shell side fluid , μ=0.89
m2

de∗us∗ρ
Reynold s ' number , ℜ= =5409.70
μ

T 3 +T 4 30+100
Mean Shell Temperature , T sm= = =65 C
2 2

W
the Thermal Conductivity of Shell Fluid , kw=0.66
mC

C P∗μ
Pr= =5.64
kw
L
=312.50
di
From the reference, we can get jh=0

0.14
hi∗di μ
[ kf ]
= jh∗ℜ∗P r 0.33∗
μw ( )
We neglect (μ/μw), and solve for hi

W
hi=1540.15
m2 C

For Tube side Heat Transfer Coefficient, hoi

T 1 +T 2 800+500
Mean Wall TemperatureT tm= = =650 C
2 2

Tube Cross Sectional Area , A t= ( 3.142

4 )
∗d i =(
3.142
2
4 )
2
∗16 =201.09 m m 2

Tubes per pass=104.60

Total Flow Area, Atot=( Tubes per pass )∗A t=104.6∗201.09=0.02 m2

kg
Density of gas fluid is givenby ρgas =3.30
m3

Gas mass velocity, Gs  

Ws, kg/m2 s 65.92
Gas linear velocity, ug  
ug, m/s 19.98
 Thermal conductivity of gas is given by k_g  
Viscosity of gas is given by μ  
k_g, W / m C 0.13
μ, Ns / m2 0.00

di∗ug∗ρgas 16∗19.98∗3.30
Reynolds Number , ℜ= = =26769.95
μ 0.0000394

Cp∗μ 0.0000394
Prandtl Number , Pr=
kg
=4.18∗ (
0.13 )
=1.31

L
=312.5
di
From figure given in the reference
jH, 0.00
ho, W / m2 C 921.17

Overall Heat Transfer Coefficient, Uo

The expression to estimate Uo is:

(1/Uo)=(1/ho)+do∗ln (do /di)/2∗kw+(1/hi)∗(do /di)

1 m2 C
( )
Uo
=0.01
W

W
Uo=134.98
m2 C

Pressure Drop Calculations

For Tube Side Pressure Drop

ℜ=26769.95

L rho∗u g2
ΔP=Np∗[8∗jf ∗
di ( )
+ 2.5]∗
2 ( )
From the reference

jf =0.04
ΔP=134.98 kPa

For Shell Side Pressure Drop

ℜ=5409.70

Ds L rho∗u s 2
ΔP=8∗ jf ∗
de( )( )(
∗
Lb
∗
2 )
From reference

jf =0.06

ΔP=0.05 kPa