50T TANK EXTERNAL HEATING COIL (LIMPET) CALCULATION

PUMA ENERGY (AUSTRALIA)

CLIENT -
HOLDINGS

VENDOR - NWEC

PROJECT NAME - BULWER ISLAND BITUMEN PLANT

LOCATION - 398, TINGIRA STREET, PINKENBA, QUEENSLAND

DOCUMENT TITLE - 50T TANK EXTERNAL HEATING COIL (LIMPET) CALCULATION

DOCUMENT NUMBER - 4008-ETvd-1000

0 31-10-18 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

6. Coil Pipe Thickness Calculation - 6

7. Design Summary - 7

8. References - 7

PAGE 2 OF 7

Tank Title / Tag
Tank Design Code
Tank Shell/Head Material
Allowable stress @
Tank Diameter
Tank Height
Tank shell/Head thickness
Tank side fluid HLL
Tank side fluid Freeboard
Tank Volume
Tank Operating Volume
Tank Design Pressure
DESIGN BASIS
Tank Design Temperature
Tank side fluid initial temperature
Tank side fluid final temperature
Coil Type
Operation type
Heat transfer type
Batch Cycle
Agitation
Coil Material
Allowable stress @
Coil Design Pressure
Coil Design Temperature
Coil side Inlet Temperature
Coil side Outlet Temperature
Heating Rate Requirement
Tank side fluid
Density_Tank side
Specific gravity_Tank side
Thermal conductivity_Tank side
Viscosity_Tank side @
Specific heat capacity_Tank side
FLUID PROPERTIES
Fouling factor_Tank side
Flow rate_Tank side (If Available)
Coil side fluid
Density_Coil side
Specific gravity_Coil side
Thermal conductivity_Coil side
Viscosity_Coil side @
Specific heat capacity_Coil side
Fouling factor_Coil side
Flow rate_Coil side (If Available)
AGITATOR
Agitator diameter (Impeller)
Agitator Speed
Agitator Type/Constant
INPUTS
= T410 50TON-CRUMBED RUBBER BLEND TANK/TK-110
= API 650 Latest Edition
= SA 36 M
195 °C St = 114.500 Mpa = 16606.8510 psi
Dt = 3200.00 mm = 10.4987 ft
Ht = 9000.00 mm = 29.5276 ft
tts = 8.00 mm = 0.0262 ft
HLL = 6900.00 mm = 22.6378 ft
= 2100.00 mm = 6.8898 ft
Vtt = 72.39 m3 = 2556.5122 ft3
Vto = 55.50 m3 = 1959.9927 ft3
Pt = 0.018 Mpa = 2.6107 psi
Ttd = 265.00 °C = 509.0000 °F
Tti = 170.00 °C = 338.0000 °F
Tto = 195.00 °C = 383.0000 °F
= Spiral Half Pipe Coil welded to the shell
= Batch Heating
= Non Isothermal Heating Medium
= 10 hours of batch, 2 batches per day
= Considered
= SA 106 Gr. B
265 °C Sc = 117.900 Mpa = 17099.9802 psi
Pc = 5.00 Mpa = 725.1900 psi
Tcd = 265.00 °C = 509.0000 °F
Tci = 240.00 °C = 464.0000 °F
Tco = 200.00 °C = 392.0000 °F
= 5.00 °C/hr. = 41.0000 °F/hr.
= S45R(Bitumen&Crumb)
195 °C ρT = 1040.00 Kg/m3 = 64.8960 lb/ft3
= 1.0400
kT = 0.18 W/m °C = 0.1040 BTU/hr ft °F
195 °C μT = 2.63 Pa-s = 6358.4025 lb/ft h
CpT = 2.18 KJ/Kg °C = 0.5207 Btu/lb°F
fT 0.00088 m2k/W = 0.0050 h ft2 oF/ Btu
mT = 2.78 Kg/s = 22040.0771 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
CpC = 2.74 KJ/Kg °C = 0.6535 Btu/lb°F
fC 0.00020 m2k/W = 0.0011 h ft2 oF/ Btu
mC = - Kg/s = - lb/hr
Da = 1370.00 mm = 4.4948 ft
N = 39.00 rpm = 2340.0000 rph
Turbine a = 0.62
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HEAT TRANSFER RATE

Heat trasfer Rate Q = mT CpT ΔTT = mC CpC ΔTC

Flow rate_Coil side mc = 1.3829 Kg/s = 10975.7328 lb/hr

Heat trasfer Rate Q = 151.3465 KJ/s = 516757.94 BTU/hr

LMTD (Logarithmic Mean Temperature Difference)

Greater Terminal Temperature Difference GTTD = max ((Tci-Tto),(Tco-Tti)) = max ((240-195),(200-170))

GTTD = 45.0000 °C = 113.0000 °F

Smaller Terminal Temperature Difference STTD = min ((Tci-Tto),(Tco-Tti)) = min ((240-195),(200-170))

STTD = 30.0000 °C = 86.0000 °F

Logarithmic Mean Temperature Difference LMTD = (GTTD-STTD)/ln(GTTD/STTD) = ( 45-30 )/ln( 45/30 )

LMTD = 36.9946 °C = 98.5902 °F

ASSUMPTIONS FOR PRELIMINARY SIZING

2 2
Overall heat transfer co-efficient U = 45.0000 Btu/hr ft °F = 255.5218 W/m °C

Assumed from"Ludwig's Applied process design for chemical and petrochemical plants",TABLE 10-18,for HeatTransfer oil-Organics(Agitation)(25-50)

Coil Pipe Diameter D = 50 NPS = 2 in

Coil Pipe Outside Diameter dco = 60.3000 mm 80 SCH

Coil Pipe Thickness tc = 5.5400 mm = 0.2181 in

Coil Pipe Inside Diameter dci = 49.2200 mm = 1.9378 in

PROVISIONAL HEAT TRANSFER AREA

Surface Area S = Q/(U X LMTD)

2 2
S = 116.4772 ft = 10.8211 m

Length of coil Passage L = S/dci

= 219.8513 m = 721.2970 ft

Length of coil Passage = 240.0000 m = 787.4016 ft

Considered overdesign in Coil passage Length. = 9.1647 %

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TANK SIDE HEAT TRANSFER COEFFICIENT

Tankside heat transfer coefficient ht = a (Kt/Dt) ((Da2 N ρt)/μt)2/3 ((Cpt μt)/kt)1/3 (μbt/μwt)0.14

2 2
ht = 11.9774 Btu/hr ft °F = 68.0108 W/m °C

COIL SIDE HEAT TRANSFER COEFFICIENT

Coil side Velocity Vc = 1.9874 m/s = 23472.9829 ft/hr

Equivalent diameter for heat transfer De = 0.3105 ft = 0.094647 m

Reynolds Number Coil side NRe = 196461.6192

Prandtl Number Coil side NPr = 20.36649332

Coil side heat transfer coefficient hc = 0.027 (kc/De) (NRe)0.8 (NPr)0.33 (μbt/μwt)0.14 [1+3.5(De/Dc)]

2 2
hc = 1545.4136 Btu/hr ft °F = 8775.2650 W/m °C

OVERALL HEAT TRANSFER COEFFICIENT

Thermal conductivity of tank 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.

Overall heat transfer coefficient Ucal = 1/((1/ht) + ft + (tts/kt) + fc +(1/hc)

2 2
= 45.775681 Btu/hr ft °F = 259.9264 W/m °C

HEAT TRANSFER SURFACE AREA

Surface Area Scal = Q/(Ucal X AMTD) = (516757.9436/(45.7757 X 98.5902)

2 2
= 114.50 ft = 10.6377 m

Correction factor ct = 1.10

Taken from "Heat transfer design methods" by John J McKetta, for 2" pipe.

Corrected Surface Area Scorct. = Scal X Ct = (114.5035 X 1.1)

2 2
= 125.95 ft = 11.7015 m

CALCULATION OF COIL SIZE ( D & L )

Considered coil dia = 2 NPS

Calculated Length of coil Passage Lcal = S/dci = (11.7015/0.0492)

= 237.7385 m = 779.9818 ft

Length of coil Passage LTaken = 240.0000 m = 787.4016 ft

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Considerations:
1) Vessel outer surface is fully insulated. So heat loss from shell to environment is negligible.
2) In LMTD calculation, Type of flow has been considered as counter flow because tank medium is under turbulence due to agitation.

COIL SIDE PRESSURE DROP

Equivalent Hydraulic radius DH = 0.1208 ft = 0.036831 m

Mass velocity G1 = 297.7273 lb/s ft2 = 1453.5045 Kg/s m2

2 X (0.023 / (((0.1208 X 297.73) /

Friction factor f = 2 X (0.023/((DHG1/μc)0.2)) =
1.6933)^0.2)

= 0.0250

Number of coils N = 2.0000 Nos.

Maximum Length of coil Passage per coil L = 120.0000 m = 393.7008 ft

(4 X 0.025 X 1148794192612.55
Pressure drop across coil ∆P = ( 4 f G 2 L ) / ( 2 g ρ DH ) = X 393.7008) / ( 2 X 144 X 4.18 X
10^8 X 45.6411 X 0.1208)

= 68.021100 psi = 0.4690 Mpa

COIL THICKNESS

Corrosion Allowance c = 3.20 mm = 0.0105 ft

Tank shell/head Inside radius Rt = 1600.00 mm = 5.2493 ft

Longitudinal tensile stress in shell S' 0 Pc R / 2t = (0.018 X 1600) / 2 X 8

= 1.80 Mpa = 261.0684 psi

Stress F = 1.5S - S' = (1.5 X 114.5) - 1.8

= 169.95 Mpa = 24649.2081 psi

Factor K = 2.75

Permissible Jacket Pressure P' = 61.80 Mpa = 8963.3484 psi

Check: P < P' = 5 < 61.8 - Acceptable

(5X24.61/(0.85X117.9)-(0.6X5))
Minimum half pipe coil thickness tcr = (Pc rc / (0.85 Sc-0.6Pc))+c =
+3.2

tcr = 4.4658 mm = 0.0147 ft

tcr tc
THICKNESS CHECK Safe
5.0240 < 5.5400

PAGE 6 OF 7
 DESIGN SUMMARY
Description Remarks SI unit BRITISH unit
Coil Type - = Spiral Half Pipe Coil welded to the shell
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
- = 5 hrs
from 170 to 195 °C
Agitation - = Considered
Coil Material - = SA 106 Gr. B
Coil Pipe Diameter - = 50 NPS = 2 in
Coil Pipe Thickness - = 80.00 SCH = 5.5400 mm
Coil pipe total length - = 240.00 m = 787.4016 ft
Number of coils - = 2.00 Nos.
COIL LENGTH

Coil -1 - = 120.00 m = 393.7008 ft

Coil -2 - = 120.00 m = 393.7008 ft
Coil -3 - = - - = - -
Coil -4 - = - - = - -
Pipe OD - = 60.30 mm = 2.3740 in
Pipe spacing between coils - = 19.00 mm = 0.7480 in
Coil pitch - = 79.30 mm = 3.1220 in
= 1.38 Kg/s = 516757.9436 BTU/hr
Flow rate_Coil side -
= 113.44 LPM @ 240.00 °C
Coil side Velocity - = 1.99 m/s = 23472.98 ft/hr
Pressure drop across coil For one coil = 0.47 Mpa = 68.02 psi
Coil Design Pressure - = 5.00 Mpa = 725.19 psi
Surface Area - = 11.70 m2 = 125.95 ft2
Overall heat transfer coefficient - = 259.93 W/m2 °C = 45.78 Btu/hr ft2 °F
TEMPERATURE SUMMARY
Batch initial Batch Final Coil inlet Coil outlet
170 oC 195 oC 240 oC 200 oC
338 oF 383 oF 464 oF 392 oF
General Notes:
* Inputs and design basis To Be Confirmed by client.
* Coil side flow rate, Velocity and Pressure drop To Be Confirmed by client.
* 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.

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