100T TANK INTERNAL HEATING COIL CALCULATION

CLIENT - PUMA ENERGY (AUSTRALIA)

HOLDINGS

VENDOR - NWEC

PROJECT NAME - BULWER ISLAND BITUMEN PLANT

LOCATION - 398, TINGIRA STREET, PINKENBA, QUEENSLAND

DOCUMENT TITLE - 100T TANK INTERNAL HEATING COIL CALCULATION

DOCUMENT NUMBER - TBA

1 11/13/2018 INCORPORATED CLIENT COMMENTS / ISSUED FOR RSK AK/ML

APPROVAL

0 11/3/2018 ISSUED FOR APPROVAL RSK AK/ML

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

PAGE 1 OF 7
 TABLE OF CONTENTS

1. Inputs - 3

2. Heat Transfer Rate Calculation - 4

3. Preliminary Sizing Calculation - 4

4. Overall Heat transfer co-efficient - 5

5. Sizing Calculation - 5

6. Pressure Drop Calculation - 6

7. Coil Pipe Thickness Calculation - 6

8. Design Summary - 7

9. References - 7

PAGE 2 OF 7
 INPUTS
Tank Title / Tag = T411/T412 100TON-CRUMBED RUBBER STORAGE TANK/TK-120/TK-130
Tank Design Code = API 650 Latest Edition
Tank Shell/Head Material = SA 36 M
Allowable stress @ 185 °C St = 114.500 Mpa = 16606.8510 psi
Tank Diameter Dt = 3200.00 mm = 10.4987 ft
Tank Height Ht = 15000.00 mm = 49.2126 ft
Tank shell/Head thickness tts = 8.00 mm = 0.0262 ft
Tank side fluid HLL HLL = 13320.00 mm = 43.7008 ft
Tank side fluid Freeboard = 1680.00 mm = 5.5118 ft
Tank Volume Vtt = 120.65 m3 = 4260.8536 ft3
Tank Operating Volume Vto = 107.14 m3 = 3783.6380 ft3
Tank Design Pressure Pt = 0.018 Mpa = 2.6107 psi
DESIGN BASIS

Tank Design Temperature Ttd = 265.00 °C = 509.0000 °F

Tank side fluid initial temperature Tti = 170.00 °C = 338.0000 °F
Tank side fluid final temperature Tto = 185.00 °C = 365.0000 °F
Coil Type = Internal Spiral type coil
Operation type = Batch Heating
Heat transfer type = Non Isothermal Heating Medium
Batch Cycle = 10 hours of batch, 2 batches per day
Agitation = Considered
Coil Material = SA 106 Gr. B
Allowable stress @ 265 °C Sc = 117.900 Mpa = 17099.9802 psi
Coil Design Pressure Pc = 5.00 Mpa = 725.1900 psi
Coil Design Temperature Tcd = 265.00 °C = 509.0000 °F
Coil side Inlet Temperature Tci = 240.00 °C = 464.0000 °F
Coil side Outlet Temperature Tco = 200.00 °C = 392.0000 °F
Heating Rate Requirement = 5.00 °C/hr. = 41.0000 °F/hr.
Tank side fluid = S45R(Bitumen&Crumb)
Density_Tank side 185 °C ρT = 1040.00 Kg/m3 = 64.8960 lb/ft3
Specific gravity_Tank side = 1.0400
Thermal conductivity_Tank side kT = 0.18 W/m °C = 0.1040 BTU/hr ft °F
Viscosity_Tank side @ 185 °C μT = 2.63 Pa-s = 6358.4025 lb/ft h
Specific heat capacity_Tank side CpT = 2.18 KJ/Kg °C = 0.5207 Btu/lb°F
FLUID PROPERTIES

Fouling factor_Tank side fT 0.00088 m2k/W = 0.0050 h ft2 oF/ Btu

Flow rate_Tank side (If Available)
Coil side fluid
Density_Coil side
Specific gravity_Coil side
Thermal conductivity_Coil side
Viscosity_Coil side @
mT = 9.26 Kg/s = 73455.2831 lb/hr
= Hot oil (TRANSCAL N)
240 °C ρC = 731.43 Kg/m3 = 45.6411 lb/ft3
= 0.7314
kC = 0.09 W/m °C = 0.0543 BTU/hr ft °F
240 °C μC = 0.0007 Pa-s = 1.6933 lb/ft h

PAGE 3 OF 7
 F

Specific heat capacity_Coil side CpC = 2.74 KJ/Kg °C = 0.6535 Btu/lb°F

Fouling factor_Coil side fC 0.00020 m2k/W = 0.0011 h ft2 oF/ Btu
Flow rate_Coil side (If Available) mC = - Kg/s = - lb/hr
Agitator diameter (Impeller) Da = 1475.00 mm = 4.8392 ft
AGITATOR

Agitator Speed N = 29.00 rpm = 1740.0000 rph

Agitator Type/Constant Turbine a = 1.50

HEAT TRANSFER RATE

Flow rate_Coil side mc = 2.7654 Kg/s = 21947.9875 lb/hr

Required Heat Transfer Rate QR = 302.6450 KJ/s = 1033352.13 BTU/hr

Heat Maintenance Load QM = 45.0000 KJ/s = 153648.14 BTU/hr

Heat trasfer Rate Q = QR + QM Q = 347.6450 KJ/s = 1187000.27 BTU/hr

LMTD (Logarithmic Mean Temperature Difference)

Greater Terminal Temperature Difference GTTD = max ((Tci-Tto),(Tco-Tti)) = max ((240-185),(200-170))

GTTD = 55.0000 °C = 131.0000 °F

Smaller Terminal Temperature Difference STTD = min ((Tci-Tto),(Tco-Tti)) = min ((240-185),(200-170))

STTD = 30.0000 °C = 86.0000 °F

Logarithmic Mean Temperature Difference LMTD = (GTTD-STTD)/ln(GTTD/STTD) = ( 55-30 )/ln( 55/30 )

LMTD = 41.2449 °C = 106.2408 °F

ASSUMPTIONS FOR PRELIMINARY SIZING

Overall heat transfer co-efficient U = 15.0000 Btu/hr ft2 °F = 85.1739 W/m2 °C

Assumed from"Ludwig's Applied process design for chemical and petrochemical plants",TABLE 10-18,for HeatTransfer oil-Organics(Agitation)

Coil Pipe Diameter D = 80 NPS = 3 in

Coil Pipe Outside Diameter dco = 88.9000 mm 80 SCH

Coil Pipe Thickness tc = 7.6200 mm = 0.3000 in

Coil Pipe Inside Diameter dci = 73.6600 mm = 2.9000 in

PROVISIONAL HEAT TRANSFER AREA

Surface Area S = Q/(U X LMTD)

S = 744.8491 ft2 = 69.1987 m2

Coil pipe Surface area Sc = 0.9160 ft2/ft

PAGE 4 OF 7
Taken from Pressure Vessel Design Manual, Dennis R. Moss, Michael M., Table 5-3, for 3" pipe.

Length of coil Passage L = S/ (Sco)

= (744.8491) / (0.916) m

= 813.1540 ft = 247.8493 m

Length of coil Passage = 250.0000 m = 820.2100 ft

OUTSIDE COIL HEAT TRANSFER COEFFICIENT

Outside coil heat transfer coefficient hi = 0.17 (Kt/dco) ((Da2 N ρt)/μt)2/3 ((Cpt μt)/kt)1/3 (Da/Dt)0.1 (dco/Dt)1/2 (μbt/μwt)ɳ

hi = 16.5155 Btu/hr ft2 °F = 93.7794 W/m2 °C

INSIDE COIL HEAT TRANSFER COEFFICIENT

Coil side Velocity Vc = 0.8872 m/s = 10478.9859 ft/hr

Mean diameter of coil Dc = 2.1500 m = 7.053785 ft

Reynolds Number Coil side NRe = 68258.0855955659

Prandtl Number Coil side NPr = 20.3664933197248

Inside coil heat transfer coefficient hci = 0.027 (kc/dci) (NRe)0.8 (NPr)0.33 (μbt/μwt)0.14 [1+3.5(dci/Dc)]

hci = 135.4105 Btu/hr ft2 °F = 768.8963 W/m2 °C

OVERALL HEAT TRANSFER COEFFICIENT

Thermal conductivity of coil material @ 265 °C kt = 50.74 W/m °C = 29.3277 BTU/hr ft °F
Taken from ASME Sec II part D, Table TCD, for material group A.

Log mean diameter dcm = 81.041314 mm = 0.2659 ft

Overall heat transfer coefficient Ucal = 1/( (1/hi) + ft + ( (tc/kt) X (dco/dcm) ) + fc + ( (1/hci) X (dco/dci) )

= 13.066717 Btu/hr ft2 °F = 74.1963 W/m2 °C

HEAT TRANSFER SURFACE AREA

Surface Area S = Q/(Ucal X AMTD) = (1187000.27/(13.07 X 106.24)

= 855.05 ft2 = 79.4370 m2

COIL SIZE ( D & L )

PAGE 5 OF 7
Considered coil dia = 3 NPS

Calculated Length of coil Lcal = S/Sc = (79.437/0.916)

= 933.4640 ft = 284.5198 m

Length of coil LTaken = 288.0000 m = 944.8819 ft

Considerations:
1) Deleted.
2) In LMTD calculation, Type of flow has been considered as counter flow because tank medium is under turbulence due to agitation.

COIL PHYSICAL DIMENSIONS

Baffle width B = 247.00 mm = 0.8104 ft

Baffle wall offset Bc = 47.00 mm = 0.1542 ft

Maximum Mean diameter of coil Dcmax = 2212.0000 mm = 7.2572 ft

Minimum space between blade to coil = 282.35 mm = 0.9263 ft

Minimum Mean diameter of coil Dcmin = 2128.6000 mm = 6983.5960 ft

Mean diameter of coil Check Dcmin < Dc < Dcmax = (2128.6 < 2150 < 2212) = SAFE

pcmax pcmin
Coil Pitch pc = 200.00 mm = 0.6562 ft
381.0000 152.4000

No of coils = 4

Length per coil = 72.00 m = 236.2205 ft

Number of turns of spiral N = L / √((πDc2)+pc2) = 236.22048/sqrt(156.333 + 0.4306)

Number of turns of spiral N = 18.8667

Taken Number of turns of spiral N = 19.00

Actual length of coil La = N √((πDc2)+pc2) = 19 X sqrt(156.333 + 0.4306)

Actual length of coil La = 237.89 ft. = 72.5089 m

COIL SIDE PRESSURE DROP

Friction factor f = 0.0219

Taken from "Moody Diagram", for the respective Reynolds number and roughness factor.

PAGE 6 OF 7
Straight line Pressure drop ∆PL = 0.8940 psi = 0.0062 Mpa

Pressure drop ∆P = 8.0023 psi = 0.0552 Mpa

DESIGN SUMMARY
Description Remarks SI unit BRITISH unit
Coil Type - = Internal Spiral type coil
Operation type - = Batch Heating
Heat transfer type - = Non Isothermal Heating Medium
Batch Cycle - = 10 hours of batch, 2 batches per day
Heating rate - = 5 °C/hr. = 41.0000 °F/hr.
Time required to heat vessel contents
- = 3 hrs
from 170 to 185 °C
Agitation - = Considered
Coil Material - = SA 106 Gr. B
Coil Pipe Diameter - = 80 NPS = 3 in
Coil Pipe Thickness - = 80.00 SCH = 7.6200 mm
Coil pipe total length - = 72.51 m = 237.8900 ft
Number of coils - = 4.00
Coil -1 - = 72.00 m = 236.2205 ft
COIL LENGTH

Coil -2 - = 72.00 m = 236.2205 ft

Coil -3 - = 72.00 m = 236.2205 ft
Coil -4 - = 72.00 m = 236.2205 ft
Pipe OD - = 88.90 mm = 3.5000 in
Coil pitch - = 200.00 mm = 0.6562 ft
= 2.77 Kg/s = 1187000.27 BTU/hr
Flow rate_Coil side -
= 226.85 LPM @ 240.00 °C
Coil side Velocity - = 0.89 m/s = 10478.99 ft/hr
Pressure drop - = 0.06 Mpa = 8.00 psi
Coil Design Pressure - = 5.00 Mpa = 725.19 psi
Surface Area - = 79.44 m2 = 855.05 ft2
Overall heat transfer coefficient - = 74.20 W/m2 °C = 13.07 Btu/hr ft2 °F
TEMPERATURE SUMMARY
Batch initial Batch Final Coil inlet Coil outlet
170 oC 185 oC 240 oC 200 oC
338 oF 365 oF 464 oF 392 oF

PAGE 7 OF 7
General Notes:
* Deleted.
* Deleted.

* Inputs, which are not provided from client side had been assumed to proceed calculation. FYI, If there is any change in Inputs/
Design Basis, Coil size may change.

References:
Heat Transfer Design Methods by 'John J. McKetta'.
Hand Book of chemical Engineering Calculation 3rd Edition by 'Micclas P. Chopey'.
Applied Process Design for Chemical and Petrochemical Plants by 'Ludwig' Volume 3.
Heat Transfer in Agitated Jacketed Vessels, 'Robert Dream', Chemical Engineering, January 1999.
Pressure Vessel Design Manual, Dennis R. Moss, Michael M.

PAGE 8 OF 7
Internal Spiral type coil 180
Internal Hairpin type coil 120

Batch Heating
Batch Cooling Internal Spiral type coil
Continous Heating Internal Hairpin type coil
Continous Cooling

Considered
Not Considered

Acceptable
Not Acceptable

1
0

Safe
Not Safe

Isothermal Heating Medium

Isothermal Cooling Medium
Non Isothermal Heating Medium
Non Isothermal Cooling Medium

Turbine
Paddle
Anchor
Propellor
Password 4008

Input status
Confirmed
Not provided
Assumed

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PAGE 16 OF 7
Inputs
Vessel Diameter D = 10.5 ft
Vessel Height H = 49.2125 ft
Liquid Height HL = 43.7007 ft
Fluid Weight W = 100 ton = 220462 lb
Density ρT = 64.9251 lb/ft3
Specific gravity Sg = 1.04
Volume of vessel contents Vto = 3395.63589 ft3 = W / ρT
Calculated liquid height HLC = 39.2099536 ft
Required Rate of heating = 5 oC/hr
Initial temperature Ti = 170 oC
Final temperature To = 185 oC
Time required to heat total vessel contents Tr = 3 hrs = (185-170)/5
Quantity of liquid to be heated G = 1131.87863 ft3/hr = Vto / Tr
Mass flow rate mT = 73454.3957 lb/hr = 62.4 G Sg
= 9.25510695 Kg/s
 X Y
1 250 51.4
2 275 50.3

X 265 50.74
 UNIT CONVERSION KG/S → LPM
INPUTS
Specific gravity of medium = 0.7314
Mass flow rate = 1.2293 Kg/s
= 100.845