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Tube side
Fluid
Mixed gases
Mineral oil
Flow rate(Kg/s)
23.8125
414.7357
Temperature C(in/out)
643/180
25/200
Operating pressure
(kPa)
Material
15200
7000
Incoloy 800
Incoloy 800
Tlm =
443 C155 C
443
ln
155
= 274.25 C
Correction factor, F
P=
t 2t 1
T 1t 1
180 C643 C
25 C643 C
R=
= 0.749
T 1T 2
t 2t 1
25 C200 C
180 C643 C
= 0.378
F= 0.955
Number of tubes,
A= n(DL)
1542.60m = n( x 0.05m x 12m)
n = 819 tubes
Tube side
fluid
Mixed gases
Water
Flow rate(Kg/s)
23.8125
294.9621
Temperature C(in/out)
183/43
25/48
Operating pressure
(kPa)
material
15200
5500
Incoloy 800
Incoloy 800
= 58.06 C
Correction factor F,
P=
t 2t 1
T 1t 1
48 C183 C
25 C183 C
R=
= 0.854
T 1T 2
t 2t 1
25 C48 C
43 C183 C
= 0.164
F= 0.96
Number of tubes,
A= n (DL)
2312.59 m = n ( x 0.05m x12m)
n =1227 tubes
A heat exchange system was designed for the ammonia synthesis section to cool the input and
output stream of the ammonia synthesis reactor. Stream from the mixer is cooled from 643 C to
180 C and it is exchanged with a cool stream of mineral which is heated from 25 C to 200 C.
Mineral oil is used as the cool stream because of its high boiling point (358 C). The stream enters
the reactor at 180 C. This stream consists mainly of hydrogen and ammonia and small fraction
of carbon dioxide, carbon monoxide, nitrogen, methane, oxygen and argon. The stream must be
cooled before entering the reactor because the input temperature will affect the output
composition of the reactor.
The stream that exits the reactor is cooled from 183 C to 43 C by exchanging heat with water
from 25C to 48C. The stream is cooled before entering the throttling valve that condenses the
ammonia into liquid. Water is chosen as the cool stream due to its high heat capacity, low
viscosity and low cost. The stream contains higher fraction of ammonia and lower fraction of
hydrogen and nitrogen as compared to the stream entering the reactor.
Shell and tube design was selected for both heat exchangers because of its high heat transfer
efficiency and easy maintenance. A counter current flow heat exchanger is preferred as the
cooling stream can exceed the temperature of the hot stream outlet temperature and making it
possible to extract more heat from the hot stream. Double pass heat exchanger is chosen because
it provides a greater amount of heat transfer as compared to single pass heat exchanger.
Hot fluid (mixed gases) is allocated to the shell side and water to the tube side. This is because
the hot fluid enters as a vapor. Vapor have lower heat transfer coefficient compared to liquid. By
setting the vapor into the shell side, pressure drop across the shell side is thus reduced and also
provide a higher heat transfer coefficient.
The material selected for both of the heat exchanger is Incoloy 800 which is a nickel-iron and
chromium alloy because it can tolerate high temperature and can resist hydrogen embrittlement.
The heat transfer surface area calculated from energy balance was found to be 1454.05 m with
772 tubes for heat exchanger 1 and 2188.05m with 1161 tubes for heat exchanger 2. Both heat
exchangers have tubes of have 50mm diameter and 12m U-tube length arranged in triangular
(30) layout.