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1 SUPPORTING MATERIAL
2 A: Derived equations using published curves
3 Figure A-1: Relative Effectiveness Factor, α:

1
f(x) = − 0.00057932263814615 x⁴ + 0.0121342383107086 x³ − 0.0866281022898647 x² + 0.164758501302611 x
0.9 + 0.917482517482529
Relative effectiveness factor

0.8 f(x) = − 0.00110722610722612 x³ + 0.0293356643356645 x² − 0.289768148518149 x + 1.35161463536464

0.7
0.6 f(x) = − 0.00237762237762239 x³ + 0.0504595404595407 x² − 0.380479520479522 x + 1.2244055944056
0.5
0.4
0.3
0.2 f(x) = 0.000897435897435887 x³ − 0.0149999999999998 x² + 0.0593910256410248 x + 0.158557692307694
0.1
0
1.5 2.5 3.5 4.5 5.5 6.5 7.5
Ratio: Spacing C.C/Outside diameter
direct to 2nd row Polynomial (direct to 2nd row) direct to first row Polynomial (direct to first row)
total to one row Polynomial (total to one row) total to two row Polynomial (total to two row)
4
5 Figure A-2Overall exchange factor

0.9
f(x) = − 1.0955710955711 x² + 1.68055944055944 x + 0.220717948717948
0.8 f(x) = − 1.03263403263403 x² + 1.70118881118881 x + 0.137571095571095
0.7 f(x) = − 0.848484848484851 x² + 1.61090909090909 x + 0.0381212121212113
overall exchange factor F

0.6 f(x) = − 0.307692307692308 x² + 1.18783216783217 x − 0.0363426573426577

0.5

0.4

0.3

0.2

0.1
0.2 0.3 0.4 0.5 0.6 0.7
flue gas emissivity
Aw/xAcp=0 Polynomial (Aw/xAcp=0)
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1 Estimation of equations of overall exchange factor in term of flue gas emissivity

1.5 f(x) = 0.0369833333333334 x³ − 0.277350000000001 x² + 0.663466666666667 x + 1.1878

R² = 1
1

0.5

0 f(x) = − 0.00646666666666664 x³ + 0.0314999999999999 x² + 0.0493666666666668 x − 0.0363000000000001

0 R² = 1 0.5 1 1.5 2 2.5 3 3.5
-0.5 f(x) = − 0.0361166666666668 x³ + 0.282200000000001 x² − 0.784183333333334 x − 0.3077
R² = 1
-1

-1.5
Aw/αAcp
B Polynomial (B) C Polynomial (C)
2 A Logarithmic (A) Polynomial (A)

3 Estimation of equation of Constants in term of ratio A w/αAcp

4 Figure A-3Flue gas emissivity

0.8

0.7

f(x)
f(x) == −− 0.0092067932067932
0.00935464535464536 x² + 0.118133866133866
x² + 0.119802197802198 x + 0.285909090909091
x + 0.250818181818182
0.6
f(x) = − 0.00873926073926073 x² + 0.117742257742258 x + 0.213181818181818
f(x) = − 0.00798001998001998 x² + 0.112541458541459 x + 0.196636363636364
flue gas emissivity

0.5 f(x) = − 0.00748851148851147 x² + 0.108829170829171 x + 0.163545454545455

f(x) = − 0.00647652347652348 x² + 0.0995169830169831 x + 0.138022727272727
0.4

0.3

0.2

0.1

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5
Partial Pressure CO2&H2O * Mean beam length

TG=1000 Polynomial (TG=1000) TG=1400 Polynomial (TG=1400)

TG=1800 Polynomial (TG=1800) TG=2000 Polynomial (TG=2000)
TG=2400 Polynomial (TG=2400) TG=2800 Polynomial (TG=2800)

5
6 Estimation of equation of flue gas emissivity in term of product of P CO2&H2O*M.B.L
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0.4

0.3
f(x) = − 8.33738317757009E-05 x + 0.366410280373832
R² = 0.995853326555351
0.2

0.1 f(x) = − 1.0446261682243E-05 x + 0.132656230529595

R² = 0.82719158581254
0
500 1000f(x) = 1.64953271028037E-06
1500 x2000 2500
− 0.0113507788161994 3000 3500
R² = 0.953263378001046
-0.1

-0.2
bridge wall temperature in Fahrenheit
A Linear (A) C Linear (C) B
Linear (B)
1
2 Estimation of equation of Constants in term of bridge wall temperature
3

4 Figure A-4 Combustion air heat capacity in term of its temperature

5

1.015

1.013 f(x) = 3.9732142857156E-07 x² + 1.7374999999979E-05 x + 1.00559

R² = 0.999938372664853
1.011
Specific heat KJ/Kg.C

1.009

1.007

1.005

1.003

1.001
0 20 40 60 80 100 120 140
Air inlet temperature in Celsius
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1 Figure A-5 Excess air in term of oxygen analyzer reading

2

35

30
f(x) = 0.0239452628660087 x³ + 0.203162609855411 x² + 5.47463258956102 x − 0.080999440410153
R² = 0.999999994663848
25
excess air %

20

15

10

0
1 1.5 2 2.5 3 3.5 4 4.5 5
excess oxygen analyser reading %
3
4 Figure A-6 Water vapor pressure in term of temperature
5

0.6
f(x) = 8.8624275621E-09 x⁴ − 0.0000002354846392 x³ + 0.00003178764785 x² + 0.000184160911 x
Water vapor pressure in atm

0.5 + 0.007079298643
R² = 0.99999932916002

0.4

0.3

0.2

0.1

0
0 10 20 30 40 50 60 70 80 90
Temperature in Celsius
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1 Figure A-7 Program flow chart

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1 B: Operating Parameters for Case Studies (3) & (4)

2 Case study (3) Naphtha Hydrotreater Heater
3 Table (B-1): Fuel gas composition during period from 10/5/2016 to 24/8/2016
4

Date CH4 C2H6 C2H4 C3H8 C3H6 N.C4H10 I.C4H10 N.C5H12 C6+ H2 N2 CO2
10/05/2016 0.452 0.095 0.005 0.031 0.003 0.035 0.014 0.003 0.003 0.339 0.005 0.015
19/05/2016 0.414 0.097 0.005 0.031 0.003 0.038 0.013 0.003 0.003 0.377 0.005 0.011
23/05/2016 0.39 0.08 0.004 0.027 0.003 0.025 0.012 0.004 0.006 0.429 0.008 0.012
30/05/2016 0.38 0.098 0.005 0.037 0.004 0.046 0.02 0.003 0.003 0.39 0.005 0.009
01/06/2016 0.382 0.093 0.005 0.033 0.006 0.054 0.014 0.004 0.006 0.387 0.005 0.011
13/06/2016 0.368 0.089 0.006 0.031 0.003 0.038 0.015 0.006 0.004 0.423 0.005 0.012
15/06/2016 0.356 0.085 0.006 0.032 0.003 0.03 0.013 0.011 0.003 0.445 0.005 0.011
13/07/2016 0.436 0.041 0 0.02 0 0.018 0.01 0.006 0.003 0.435 0.009 0.022
20/07/2016 0.42 0.074 0.005 0.021 0.003 0.018 0.009 0.007 0.002 0.419 0.008 0.014
08/08/2016 0.373 0.087 0.005 0.032 0.004 0.037 0.016 0.006 0.006 0.417 0.006 0.011
10/08/2016 0.372 0.092 0.005 0.033 0.005 0.036 0.014 0.006 0.005 0.415 0.006 0.011
15/08/2016 0.361 0.093 0.006 0.034 0.005 0.037 0.015 0.006 0.003 0.425 0.005 0.01
17/08/2016 0.388 0.089 0.006 0.034 0.004 0.037 0.016 0.006 0.003 0.399 0.006 0.012
22/08/2016 0.394 0.094 0.006 0.031 0.005 0.032 0.016 0.006 0.003 0.39 0.009 0.014
24/08/2016 0.391 0.098 0.005 0.03 0.004 0.033 0.015 0.006 0.003 0.396 0.006 0.013
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6 Table (B-2): Operating parameters during period from 10/5/2016 to 24/8/2016
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Combustion
Fuelgasflowrate(calculatedatn AverageBridgeW RelativeH
Excess O2 AirTemperatur
ormalconditions) allTemperature umidity
Date e

m3/hr kg/hr Celsius % % Celsius

10/05/2016 515.6 381.70 691.575 4.95 60 25
19/05/2016 442.6 317.03 675.165 1.568 56 24
23/05/2016 542.8 355.86 689.625 4.215 60 26
30/05/2016 540.6 401.88 714.24 2.987 61 35
01/06/2016 567.8 430.22 718.34 4.901 51 37
13/06/2016 482 336.677 685.52 4.263 61 31
15/06/2016 590.9 397.498 707.985 3.576 63 28
13/07/2016 544 328.800 671.065 3.331 69 31
20/07/2016 570.7 359.350 638.24 3.528 58 31
08/08/2016 404.3 286.463 638.24 4.263 67 31
10/08/2016 403.5 285.099 658.75 3.625 57 31.7
15/08/2016 448.5 313.223 660.9 3.283 58 30.5
17/08/2016 471.2 337.390 617.925 4.312 61 31.2
22/08/2016 376.2 269.695 624.48 4.606 62 31
24/08/2016 393.1 279.024 691.575 4.263 63 31.4

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1 Table (B-3) T.M.T thermocouples reading during period from 10/5/2016till 24/8/2016
2
3

Date Measured Average T.M.T for 4 passes Calculated T.M.T at average B.W.T Deviation,

10/05/2016 419.09 436.22 4.087

19/05/2016 419.96 438.59 4.437
23/05/2016 431.03 442.66 2.699
30/05/2016 433.71 443.32 2.215
01/06/2016 437.42 442.89 1.251
13/06/2016 442.20 452.19 2.259
15/06/2016 431.43 434.94 0.814
13/07/2016 433.52 432.42 -0.254
08/08/2016 398.50 404.57 1.525
10/08/2016 398.34 401.96 0.908
15/08/2016 420.42 410.52 -2.355
17/08/2016 424.04 398.92 -5.926
22/08/2016 400.78 387.87 -3.221
24/08/2016 405.14 385.80 -4.774
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5 Case study (4) Recycle Gas Heater
6 Table (B-4) fuel gas composition during period from 30/7/2016 till 18/8/2016
7
8
Date 30-7-2016 1-8-2016 2-8-2016 14-8-2016 15-8-2016 17-8-2016 18-8-2016

Component/time 18:00 00:00 6:00 00:00 6:00 12:00 18:00 12:00 18:00 00:00 6:00 00:00 6:00

Methane 39.4 40.1 38.6 39.5 39.6 37.5 36.6 38 38 38 38.8 37.3 37.5

Ethane 8.3 8.7 8.9 8.2 8.2 9.6 9.4 9.2 9.2 8.7 8.9 8.7 8.7

Ethylene 0.6 0.6 0.6 0.5 0.5 0.6 0.6 0.6 0.6 0.5 0.6 0.5 0.5

propane 2.8 2.8 2.8 2.8 2.8 4.2 4 3.6 3.6 3.3 3.4 3.3 3.3

propylene 0.4 0.4 0.4 0.4 0.4 0.8 0.7 0.5 0.5 0.4 0.4 0.4 0.4

N-Butane 1.3 1.2 1.2 1.2 1.3 1.5 1.5 1.5 1.5 1.5 1.6 1.4 1.4

Iso-butane 3.3 3.1 2.8 3.2 3.2 3.9 3.8 3.7 3.7 3.6 3.7 3.4 3.4

N-Pentane 0.8 0.7 0.7 0.8 0.8 0.7 0.7 0.6 0.6 0.6 0.6 0.6 0.6

Iso-Pentane 0.5 0.5 0.6 0.3 0.4 0.4 0.5 0.4 0.4 0.3 0.3 0.3 0.3

Hexane 40.9 39.8 41.7 41.4 40.8 39.1 40.7 40.1 40.1 41.3 39.9 42.3 42.1

Hydrogen 0.6 1 0.8 0.6 0.9 0.7 0.5 0.6 0.6 0.6 0.6 0.6 0.6

CO2 1.1 1.1 0.9 1.1 1.1 1 1 1.2 1.2 1.2 1.2 1.2 1.2
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1 Table (B-5) Operating parameters during period 30/7/2016 till 18/8/2016

2
3

Measuring Fuel gas flow Relative Air inlet Excess O2 ,% Bridge Wall
time rate,Kg/hr humidity,% temperature,0C Temperature,0C

30/7/2016
06:00 PM 1827.3 61 282 4.164 726.35
01/08/2016
12:00 AM 1784.8 54 285.81 4.38 722
06:00 AM 1762.3 54 285.81 4.34 722
02/08/2016
12:00 AM 1784.3 56 285.81 4.4 726.35
06:00 AM 1779.1 56 284.44 4.37 726.35
14/08/2016
12:00 PM 1743.2 58 287.17 4.359 726.35
06:00 PM 1731.3 58 287.17 4.416 722.05
15/08/2016
12:00 PM 1716.3 55 283.03 4.149 730.65
06:00 PM 1726.3 55 285.51 4.169 722.05
17/08/2016
12:00 AM 1720.3 68 284.44 4.405 722.05
06:00 AM 1730.6 68 281.77 4.09 730.65
18/08/2016
12:00 AM 1711 61 287.17 4.454 722.05
06:00 AM 1698.6 61 284.44 4.284 722.05
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1 TABLE (B-6) T.M.T thermocouples reading at period from 30/7/2016 till 18/8/2016
2
3

Maximum tube metal temperature,0C

Calculated T.M.T
Average T.M.T
DATE

Deviation
PASS 10#
PASS 3#

PASS 7#
PASS 2#

PASS 4#

PASS 5#

PASS 6#

PASS 8#

PASS 9#
PASS1#

%
30/7/2016 534.5 543.8 556.3 553.2 559.5 547.01 537.6 534.5 543.88 N.A 545.6 514.2 -5.749
6:00PM
01/8/2016 528.2 540.6 547.1 547.1 553.2 540.76 531.3 531.3 540.76 N.A 540.1 515.9 -4.456
12:00 AM
01/8/2016 528.2 537.6 547.1 547.1 553.2 540.76 531.3 531.3 540.76 N.A 539.7 515.4 -4.505
06:00AM

02/8/2016 531.3 540.7 550.1 550.1 556.4 543.8 534.5 531.3 540.76 N.A 542.1 521.8 -3.740
12:00 AM
02/8/2016 528.2 537.6 547.1 547.1 553.2 540.7 531.3 531.3 540.76 N.A 539.7 524.4 -2.833
06:00AM
14/8/2016 525.1 537.6 543.8 543.8 553.2 540.7 531.3 528.2 534.51 N.A 537.6 530.3 -1.351
12:00 PM
14/8/2016 528.2 537.6 543.8 543.8 553.2 537.6 531.3 528.2 534.51 N.A 537.6 522.5 -2.808
06:00PM
15/8/2016 525.1 534.5 540.7 540.7 550.1 537.6 528.1 528.2 534.51 N.A 535.5 540.7 0.974
12:00 PM
15/8/2016 525.1 534.5 543.8 540.7 550.1 534.5 528.1 528.2 534.5 N.A 535.2 524.8 -1.938
06:00 PM
17/8/2016 525.1 537.6 543.8 543.8 550.1 534.5 528.2 525.1 534.5 N.A 536.6 525.3 -2.087
12:00 AM
17/8/2016 528.2 537.6 543.8 543.8 553.3 540.76 531.3 528.2 537.6 N.A 538.3 538.8 0.088
06:00 AM
18/8/2016 525.1 534.5 543.8 543.8 550.1 537.6 528.2 528.2 534.5 N.A 536.2 526.1 -1.904
12:00 AM
18/8/2016 525.1 534.5 543.8 540.7 550.1 537.6 528.2 528.2 537.6 N.A 536.2 526.8 -1.761
06:00 AM
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13 C: Hot oil heater data sheet & tube layouts

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2

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4

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7 Figure C-1: hot oil heater process fluid, Tube metal temperature design conditions
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3 Figure C-2: Elevation and Plane view of radiation section

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5 Figure C-3: coil configuration inside radiation section
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1 D:Pacol Unit process heater data sheet & tube layout

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4 Figure D-1:Pacol unit heater process fluid, Tube metal temperature design conditions

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3 Figure D-2: Elevation and Plane view of radiation section

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5 Figure D-3: coil configuration inside radiation section

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1 E: HCU Reactor feed heater data sheet

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4 Figure E-1: Process fluid and combustion design conditions
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2 Figure E-2: coil layout design inside radiation section

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4 Figure E-3: fuel gas composition at normal conditions

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1 F: Naphtha Hydrotreater charge heater Drawings

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7 Figure F-1: Side and Plane view of radiation section

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10

11

12

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14 G: Recycle Gas Heater Drawings

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4 Figure G-1: Side and Plane view of radiation section

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