Designing of Air Cooler

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 Anas Javaid

Mohammed Saqib
Malik Qadeer Ali Raza

Mohammad Iqbal

(06-CHEM 51) (06-CHEM-57) (06-CHEM-91) (06-CHEM-93) (06-CHEM-97)

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Assume that a typical hydrocarbon naphtha liquid from a fractionation tower-side cut stream is to be cooled to 150 F the naphtha stream enters the air cooler at 250 F at a flow rate of 273,000 lb/hr. the physical tube side properties at the average temperature of 200 F are
K = 0.0766 btu ft/hr ft2 F Cp = 0.55 btu/lb F Uvis = 0.51 cp Inlet temperature of air = t1 = 100 F

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Heat duty Q = m Cp dT = 15,015,000 BTU/hr Assuming Ux to be 4.5 according to the table 5.4 Temperature difference for air dT = ((Ux + 1)/10) x ((T1 + T2)/2 t1) = 54 F dT = t2 t1 t2 = 154 F
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LMTD

= =

(dt1 dt2)/ log(dt1/dt2) 70.5 F

Assuming number of passes is three, therefore Ft is 1 Corrected LMTD = 70.5 F Tube outside extended area Ax = Q/(Ux x LMTD) = 48356 ft2
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Face Area Calculation FA = Ax/ APSF APSF value is obtained from the table 5.3 FA = 407 ft2/ft2 Width W = FA/L Suppose length is equal to 30 ft then W = 13.6 ft Fans required = 2
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Number of tubes NT = Ax / (APF x L) APF value is noted from the values mentioned in table 5.3 = 300 tubes Modified Reynold Number Calculation Ai = 3.1416 (Di/2)2 = 0.5945 in2 GT = (144 x Wt x Np)/ (3600 x NT x Ai) = 184 lb/sec ft2 NRe = (Di x GT)/ Uvis = 314
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J = exp[-3.913+3.968 x (log NR)-0.5444 x (log NR)2+0.04323 x (logNR)3 0.001379 x (log NR)4] = 2027 Tube Inside Film Coefficient HT= J * K * (Cp * Uvis/K)1.3/Di = 275 BTU/hr ft2 F AIR FLOW WA = Q/(Cp x dt) Cp= 0.24 WA = 1157400 lb/hr
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Mass Flow Rate GA = WA/FA = 2844 lb/hr ft2 Extended Tube Film Coefficient HA = exp[ -7.1519+1.7837 x (log GA) 0.076407 x (log GA)2] = 9 BTU/ hr ft2 F Overall Heat Transfer Coefficient Ux = 1/[(1/HT)*(AR*Do/Di)+ RDt * (AR*Do/Di) + (1/HA)] AR = 21.4 From table 5.3 RDt = Fouling Factor = 0.001 Ux = 4.44 btu/ h ft2 F
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Fan Area per Fan FAPF = 0.4 x FA/ number of fans = 84 ft2 Fan diameter Dfan = (4 FAPF/3.1417)0.5 = 11 ft Air side static pressure loss( DPAT) Calculation Tav = dt/2 + t1 = 127 F
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Static pressure loss of air flow across each single tube row DPA

DPA = exp[1.82 * log GA - 16.58] = 0.122 inch of water per tube row DPAT = 4 x DPA/DR Where DR = 0.9 at 127 F from table 5.5 DPAT = 0.54 inch of water
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Fan inlet actual volumetric flow ACFM = WA/[ DR * 60 * 0.075] Where DR = 0.95 at 100 F from table 5.5 ACFM = 271000
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Pforce = DPAT + [(4* ACFM)/(4009 * 3.1417 * Dfan 2)]2 = 0.67 inch of water Fan horse power Bhp = [ACFM per fan * Pforce]/ (6387*Efficeincy) Assume Eff= 70% Bhp = 20.3 Hp
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Investor Chemical Process Design by Dougles & Ervin

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