STYRENE COOLING SYSTEM

Objective To cool 3350 KL styrene monomer contained in tank from 30 deg initial temperature to 20 deg c final
temperature by cooling recycled pumped liquid in max duration 5 days.2 such tanks are working parallel. Two
units of below sizing to be installed

Tank capcity 3500 KL

used liquid capcity 3000 KL yellow fields are data entries

Density 0.901 kg/lt 3024 Conversion kcal/h to TR

sp heat 0.41 kcal/kg.dec
heat duty of tank liquid
mass of styrene in tank 2703000 kg
Initial temperature of tank liquid 30 degc
final temperature of tank liquid 20 degc

total heat removed from tank 11082300.0 kcal 16888380

Insulation heat in leak Tank piping pump loads total total
kcal/h kcal/h TR kcal
5806080
15 kw 16.00 TR
duration of cooling 5 days 9.6 4.26 TR total cooling req cooling value used
120 hr
AVERAGE hourly rate of cooling 92352.5 kcal/h 140736.5 kcal/h 140286 kcal/h
30.54 TR 46.54 TR 46.39 TR

voumetric flow rate of recycle liquid 30 m3/h

line size suggested 4 inch
100 mm
velocity in the line 1.06 m/s ok
mass flow rate of recycle liquid 27030 kg/h
for the base case load cooling temperature drop in the liquid 12.66 degc

SM from heat Initial middle Final

exchanger scenerio scenerio scenerio

Initial middle final

temp in degc 30 25 20 tank liquid temperature
temp out degc 17.341436 12.341436 7.34143634 Initial proposition

Brine (35% MEG and 65% water) is used as cooling medium

specific heat of brine 0.92 kcal/kg.degc
density of brine 1 kg/lt
If we design the HE at middle scanerio it performs better at initial sceanerio and lesser at final sceanerio
Brine temperature from chiller min -5 degc

Heat exchnager design and simulation sceanarios

counter current flow Intermediate scenerio base case initial scenario final scenario
simulated case 1 delT simulated case 2
styrene brine delT styrene brine styrene brine delT

wam end temp 25 3.571 21.43 degc 30 5.04831 24.95 degc 21 2.469599 18.53 degc
cold end temp 12.07 -5 17.07 degc 14.92 -5 19.92 degc 9.79 -5 14.79 degc

LMTD 19.17 degc LMTD 22.34 degc LMTD 16.59 degc

Q/LMTD 7476 Kcal/h.degc Q/LMTD 7480 Kcal/h.degc Q/LMTD 7488 Kcal/h.degc
U 500 w/m2k checked with base case checked with base case
flow
rate kg/h 27030 18172.2668 430 kcal/h.m2.degc 27030 18078 27030 18078
heat
duty kcal/h 143294.14 143294.139 A 17.39 m2 167121.1 167121.1 124232.58 124232.6
TR 47.385628 55.26491 41.0822
U 500 w/m2k U 500 w/m2k
430 kcal/h.m2.degc 430 kcal/h.m2.degc
HEAT EXCHANGER (HE) Base case A 17.4 m2 A 17.41 m2
Hot fluid Cold fluid
Styrene Brine
Flow rate kg/h 27030 18172
Temperature - IN degc 30 -5
Temperature - IOUT degc 14.92 5.0483
Heat duty kcal/h 167121.084
Op Pressure bara 3.5 4
CHILLER

brine temperature into chiller 3.571 degc 5 degc 1.94 degc capacity of Chiller
brine temperature from chiller -5 degc -5 degc -5 degc
Cooling duty 143294.139 Kcal/h 167121.08 Kcal/h 5 degc
flow rate of brine through chiller 18172.2668 kg/hr 18165.335 kg/hr 19457.55 kg/hr -5 degc
volumetric flow of brine 18172.2668 lt/h 18165.335 lt/h 19457.55 lt/h 166320 Kcal/h
18.1722668 m3/h 18.165335 m3/h 19.45755 m3/h 18078.261 kg/hr
18078.261 lt/h
47.385628 TR 55.264909 TR 41.0822 TR 18.078261 m3/h
Op Pressure 4 bara 4 bara
MIXING IN HOT BRINE TANK 55 TR
from chiller flow of 18172.2668 kg/h 18165.335 kg/h 19457.55 kg/h 4 bara
flow to cold brine tank 18172.2668 kg/h 18078 kg/h 18078 kg/h
brine to recycle from chiller to hot brine tank 0 kg/h 87.335217 kg/h 1379.553 kg/h

HOT BRINE PUMP

To take hot brine from hot brine tank and pump to Chiller.
From chiller the cold brine devides into two parts , one goes to hot brine tank (recycle mixing)
and other part goes to cold brine tank
Volumetric flow capacity of hot brine pump 18.1722668 m3/h 18.16534 m3/h 19.45755 m3/h
Head developed
(to flow thorugh chiller and piping upto cold brine tank)

COLD BRINE TANK

chilled brine is collected in cold brine tank
COLD BRINE PUMP
To take cold brine from cold brine tank and pump through HE
flow capacity max of three cases 18172.2668 kg/hr 18078 kg/hr 18078 kg/hr
Volumetric flow capacity 18172.2668 lt/h 18078 lt/h 18078 lt/h
18.1722668 m3/h 18.078 m3/h 18.078 m3/h
head developed
to overcome frictional drop in piping between chiiled brine pump,
HE, He exchanger brine path, from He as hot brine to hot brine tank

Total cooling produced

middle zone hot zone cold zone
duration hr 26.295437 22.546419 71.15814
cooling generated
kcal 3767982 3767982 8840160

total cooling kcal 16376124

required kcal 16888380
excess kcal -512256
% -3.033186

Rate of cooling and temp drop/h

mass of liquid in tankkg 2703000 2703000 2703000

cooling rate kcal/h 143294.139 167121.08 124232.6
sp heat kcal/kg/degc 0.41 0.41 0.41
temp drop /h deg/h 0.1293 0.1508 0.1121
degc drop 3.4 3.4 3.4
26.295437 22.546419 30.33006

Total time to cool the tank content

hr 79.1719185 40.828
available time hr 120
 Density Density-
Flow -SM SM cP SM Water cp watr U
50 KL/h 0.8966 0.41 1 0.92 3024 528.9 kcal/h.m2.degc
44830 kg/h

Case-1
time to
mass cold cool to
T1 T2 t1 t2 Delta1 Delta2 Q DelLN UA m (CHB) M(SM) TR- CHB area tank generation losses kcal/h degc/hr hr/degc next step
C C C C C C kJ C kg/h kg/h Tonns m2 kg kcal/h TR hr
30 20.951 -5 5 25.951 25 166317.6 25.47 6529.3 18078 44830 55.00 12.34 2689800 166317.6 13.86 41913 0.11281 8.86 8.86
29 20.21 -5 4.71423 25.21 24.28577 161564.77 24.74 6529.2 18078 44830 53.43 12.34 2689800 161564.766 13.86 41913 0.1085 9.22 18.43
27 18.727 -5 4.14281 23.727 22.85719 152060.96 23.29 6529.2 18078 44830 50.28 12.34 2689800 152060.956 13.86 41913 0.09988 10.01 20.02
25 17.244 -5 3.57138 22.244 21.42862 142557.15 21.83 6529.2 18078 44830 47.14 12.34 2689800 142557.146 13.86 41913 0.09126 10.96 21.92
23 15.761 -5 2.99996 20.761 20.00004 133053.34 20.38 6529.2 18078 44830 44.00 12.34 2689800 133053.336 13.86 41913 0.08264 12.10 24.20
21 14.522 -5 2.1587 19.522 18.8413 119061.71 19.18 6207.7 18078 44830 39.37 11.74 2689800 119061.711 13.86 41913 0.06996 14.29 14.29
20 13.771 -5 1.88336 18.771 18.11664 114482.41 18.44 6207.7 18078 44830 37.86 11.74 2689800 114482.414 13.86 41913 0.0658 15.20
107.73 hr 4.49 days
Case-2
30 21.774 -5 5 26.774 25 151192.8 25.88 5842.8 16434 44830 50.00 11.05 2689800 151192.8 13.86 41913 0.09909 10.09 10.09
29 21.009 -5 4.71422 26.009 24.28578 146871.94 25.14 5842.7 16434 44830 48.57 11.05 2689800 146871.941 13.86 41913 0.09517 10.51 21.01
27 19.479 -5 4.14279 24.479 22.85721 138232.41 23.66 5842.7 16434 44830 45.71 11.05 2689800 138232.415 13.86 41913 0.08734 11.45 22.90
25 17.949 -5 3.57137 22.949 21.42863 129592.89 22.18 5842.7 16434 44830 42.85 11.05 2689800 129592.889 13.86 41913 0.07951 12.58 25.16
23 16.419 -5 2.99994 21.419 20.00006 120953.36 20.70 5842.7 16434 44830 40.00 11.05 2689800 120953.363 13.86 41913 0.07167 13.95 27.91
21 14.889 -5 2.42852 19.889 18.57148 112313.84 19.22 5842.7 16434 44830 37.14 11.05 2689800 112313.837 13.86 41913 0.06384 15.66 15.66
20 14.124 -5 2.14281 19.124 17.85719 107994.07 18.48 5842.7 16434 44830 35.71 11.05 2689800 107994.074 13.86 41913 0.05992 16.69
122.73 hr 5.11 days
 Density
Flow SM Density SM cP styrene water cP watr U
30 KL/h 0.901 g/cc 0.41 kcal/kg.dec 1 0.92 3024 528.9 kcal/h.m2.degc
27030 kg/h

Design Basis
Case-1
mass cold time to cool
T1 T2 t1 t2 Delta1 Delta2 Q DelLN UA m (CHB) M(SM) TR- CHB area tank generation losses kcal/h degc/hr hr/degc to next step
C C C C C C kJ C kg/h kg/h Tonns m2 kg kcal/h TR hr
30 14.92 -5 5.0491 19.92 24.95 167133.8 22.34 7481 18078 27030 55.27 14.14 2689800 167133.79 16 48384 0.11 9.29 9.29
29 14.35 -5 4.7619 19.35 24.24 162357.5 21.7 7481 18078 27030 53.69 14.14 2689800 162357.47 16 48384 0.10 9.68 19.35
27 13.21 -5 4.1877 18.21 22.81 152807 20.43 7481 18078 27030 50.53 14.14 2689800 152807.03 16 48384 0.09 10.56 21.12
25 12.07 -5 3.6134 17.07 21.39 143256.6 19.15 7481 18078 27030 47.37 14.14 2689800 143256.59 16 48384 0.09 11.62 23.25
23 10.94 -5 3.0392 15.94 19.96 133706.2 17.87 7481 18078 27030 44.21 14.14 2689800 133706.15 16 48384 0.08 12.93 25.85
21 9.797 -5 2.465 14.8 18.54 124155.7 16.6 7481 18078 27030 41.06 14.14 2689800 124155.71 16 48384 0.07 14.55 14.55
113.41 4.726 days
Case-2
30 16.29 -5 5.0491 21.29 24.95 151934.8 23.07 6585 16434 27030 50.24 12.45 mass tankkcal/h TR kcal/h degc/hr 11.04 11.04
29 15.68 -5 4.7619 20.68 24.24 147593.6 22.41 6585 16434 27030 48.81 12.45 2689800 151934.77 17.2 52013 0.09 11.54 23.08
27 14.47 -5 4.1877 19.47 22.81 138911.6 21.09 6585 16434 27030 45.94 12.45 2689800 147593.62 17.2 52013 0.09 12.69 25.38
25 13.25 -5 3.6135 18.25 21.39 130229.7 19.78 6585 16434 27030 43.07 12.45 2689800 138911.65 17.2 52013 0.08 14.10 28.20
23 12.03 -5 3.0393 17.03 19.96 121547.7 18.46 6585 16434 27030 40.19 12.45 2689800 130229.67 17.2 52013 0.07 15.86 31.72
21 10.82 -5 2.465 15.82 18.53 112865.7 17.14 6585 16434 27030 37.32 12.45 2689800 121547.69 17.2 52013 0.06 18.12 18.12
20 10.21 -5 2.1779 15.21 17.82 108524.7 16.48 6585 16434 27030 35.89 12.45 2689800 112865.71 17.2 52013 0.06 19.51
2689800 108524.72 17.2 52013 0.05 days
137.54 5.731
SUMMARY
NEW EXCHANGER
Velocity ( 4") TR Styrene Brine Area Time
m/s M3/h kg/h T1 T2 kg/h t1 t2 m2 hr Days
1.7 53 50 44830 30 21.28 18078 -5 5 11.8 112.7 4.70
1.1 53 30 27030 30 15.47 18078 -5 5 13.37 112.7 4.70 Basis
1.7 50 50 44830 30 21.77 16434 -5 5 11.04 122.7 5.11
1.1 50 30 27030 30 16.29 16434 -5 5 12.3 122.7 5.11

Note
Pump Minimum Flow 30 m3/h
U (Considered)=615 w/m2.degc