GIVEN DATA:

Fluid Handled:

Total flow rate (m3/hr): 19.5

Oil Flow rate (m3/hr):7.0
Water flow rate (m3/hr):12.5
Temperature: 60 C
S No.

Properties
3

Oil

Water

1.
2

Density (kg/m )
Viscosity (cP) at 60 C

897.6
65.3

980.6
0.5

3
4

Viscosity (cP) at 70 C
Specific Heat (kcal/kg C)

43
0.479

0.4
1.035

5
6

Thermal conductivity (kcal/m hr C)

Surface Tension (dynes/cm)

0.136
28.6

0.562
66

Over capacity factor on flow 110% of normal

Operating conditions:

Outlet temperature=70 C
Allowable pressure drop=0.5 kg/cm2
Water Content in oil at outlet(% v/v)= 1 (max)
Oil Content in water at outlet(ppm)= 125 (max)
Allowable liquid carry over in gas (L/mm/m3)=13.4 (max)

Fuel Data:
COMPOUND

MOLE%

MASS%

CH4
C2H6
C3H8
C4H10 (iso)
C4H10 (n)
C5H12 (iso)
C5H12 (n)
C6H14 (n)
C7H16
CO2
N2

97.15
0.6
0.205
0.081
0.002
0.009
0.006
0.002
0.005
1.34
0.6

93.45
1.05
0.53
0.3
0.01
0.04
0.03
0.01
0.03
3.55
1.0

PROBLEM STATEMENT:

Calculate:

Process fluid duty.

Assume flux=10000 BTU/hr /ft2
Heat Transfer Area, Diameter and length of fire tube.
Fired duty
Fuel LHV
Adiabatic fuel Temperature

PROCESS FLUIID DUTY:

Fluid temperature:

60 C

Outlet temperature:

70 C

T:

10 C

Density of oil (Ww):

897.6 kg/m3

Density of water (Wo):

Qo:

7 m3/h

Qw:

12.5 m3/h

980.6 kg/m3

Specific heat of oil (Co):

0.479 kcal/kg C

Specific heat of water (Cw):

1.035 kcal/kg C

Qo=WoCoT
= [Density of oil*Qo]*(Co)*(T)
=897.6*7*0.479*10
=30096 kcal/h

Qw=Ww*Cw*T
= (980.6*12.5)*1.035*10
=126865.125 kcal/h

Qlost= (0.1) q

q=Qo+Qw+Qlost
0.9(q) =30096+126865.125
q=174401 kcal/h

Total heat required=174401 kcal/h = Fluid duty

=692079.1 Btu/hr

Over capacity factor=110%

Therefore:
Fluid duty:
=761287 BTU/h
=0.76 MMBTU/hr

FIRED DUTY
Efficiency=70%
Therefore:
Fired duty=Process fluid duty/Efficiency
Fired duty=761287/0.7=1087552.85 Btu/h

SURFACE AREA REQUIRED:

Assume heat flux=10000 Btu/ (hr.ft2)
Area=Q/flux
=761287/10000
=76.13 ft2

DIAMETER AND LENGTH

The maximum allowable Heat Density should be 15000 BTU/hr. /sq. in

Therefore, the required fire tube should have:

NPS=14

O.D=350 mm

Length=64.3 m

CALCULATION OF L.H.V:

We list down the reactions:

1.
2.
3.
4.
5.
6.
7.

CH4+(1.2)(2)(O2+3.76N2)CO2+2H2O+0.4O2
C2H6+(3.5)(1.2)(O2+3.76N2)2CO2+3H2O+0.7O2
C3H8+(5)(1.2)(O2+3.76N2)3CO2+4H2O+O2
C4H10+(6.5)(1.2)(O2+3.76N2)4CO2+5H2O+1.3O2
C5H12+(1.2)(10)(O2+3.76N2)5CO2+10H2O+2O2
C6H14+(1.2)(9.5)(O2+3.76N2)6CO2+7H2O+1.9O2
C7H16+(1.2)(11)(O2+3.76N2)7CO2+8H2O+2.2O2

Heat of formation data:

Compound
CO2
H2O
CH4
C2H6
C3H8
C4H10 (iso)
C4H10 (n)
C5H12 (iso)
C5H12 (n)
C6H14
C7H16
NO2

Heat or formation (kJ/mol)

393.5
241.82
74.87
84.68
103.85
134.3
125.5
154.4
146.9
167.4
187.9
33.2

Heat of combustion for individual reactions:

r1= ((393.5+2*(241.82))-(74.87))

=802.27 kJ/mol

r2= (2*(393.5) +3*(241.82))-(84.68)

=1427.78 kJ/mol

r3= (3*(393.5) +4*(241.82))-(103.85)

=2043.93 kJ/mol

r4i= (4*(393.5) +5*(241.82))-(134.3)

=2648.8 kJ/mol

r4n= (4*(393.5) +5*(241.82))-(125.5)

=2657.6 kJ/mol

r5i= (5*(393.5) +10*(241.82))-(154.4)

=4231.3 kJ/mol

r5n= (5*(393.5) +10*(241.82))-(146.9)

=4238.8 kJ/mol

r6= (6*(393.5) +7*(241.82))-(167.4)

=3886.34 kJ/mol

r7= (7*(393.5) +7*(241.82))-(187.9)

=4259.34 kJ/mol

Mass fractions of fuel gas:

COMPOUND

MOLE%

MASS%

CH4
C2H6
C3H8
C4H10 (iso)
C4H10 (n)
C5H12 (iso)
C5H12 (n)
C6H14 (n)
C7H16
CO2
N2

97.15
0.6
0.205
0.081
0.002
0.009
0.006
0.002
0.005
1.34
0.6

93.45
1.05
0.53
0.3
0.01
0.04
0.03
0.01
0.03
3.55
1.0

Total heat of combustion:

(mass frac)*(heat of comb)/ (Mol wt.) *(1000*0.948/2.2) BTU/Lb
=20549.4 BTU/lb

FUEL QUANTITY REQUIRED:

Fire duty=1087552.85 BTU/h

LHV=20549.4 BTU/lb
Therefore:
Fuel required=53 lb/h

Product flue gases component:

S No.

Product component

Mole %

Mass %

CO2

8.1

12.8

H2O

16.1

10.4

O2

3.2

3.7

N2

72.6

73.1

Flue gas Molecular weight = (

Therefore, molecular wt. of Flue gas: (0.081*44) + (0.161*18) + (0.032*32) + (0.726*28)

Molecular weight=27.8

Amount of Flue gas per lb of fuel:

Basis: 453.6 g=1 lb
Fuel data:
Component
CH4
C2H6
C3H8
C4H10 (i)
C4H10 (n)
C5H12 (i)
C5H12 (n)
C6H14
C7H16
N2

Mass(g)
423.8
4.75
2.4
1.27
0.028
0.17
0.11
0.04
1.36
4.51

No. of moles
26.5
0.158
0.05
0.02
0.0004
0.0023
0.0015
0.0005
0.013
0.16

No. of moles of O 2 :26.5(0.4)+(0.7)(0.158)+0.054+(0.02)(1.3)+(0.0004)(1.3)+(2)(0.0023)+(2)(0.0015)

+ (1.9) (0.0005) + (2.1) (0.013)
=10.8 moles

Moles of N2:26.5*9.02+15.79*0.158+0.05*22.8+0.02*29.33+ (0.0004)*29.33+45.12*0.0023

+0.0015*45.12+42.86*(0.0005) +49.632*0.013+4.53
=248.6 moles

Moles of CO2:26.5+2*0.158+0.05*3+0.02*4+ (0.0004)*4+5*0.0023+0.0015*5+6*(0.0005) +7*0.013

=27.1 moles

Moles of H2O:26.5*2+3*0.158+4*0.05+0.02*5+ (0.0004)*5+10*0.0023+0.0016*10

+7*(0.0005) +7*0.013
=52.9 moles

Product Flue gas:

S No.

Product component

1
CO2
2
H2O
3
O2
4
N2
TOTAL:

No. of moles

Mass(g)

27.1
52.9
10.8
248.6

1192.4
952.2
345.6
6960.8
9451 g=20.8 lb

Therefore, Amount of flue gas per pound of fuel=20.8 lb

In this case, Amount of fuel=53 lbs
Therefore Amount of flue gas produced=53*20.8 lbs
=1102.4 lbs

Amount of Air per lb of fuel:

From Stoichiometry and No. of moles of fuel component,
No.of moles of air:=(26.5)(2)(1.2)+(3.5)(1.2)(0.158)+(5)(1.2)(0.05)+(6.5)(1.2)(0.02)+
(6.5)(1.2)(0.0004)+(1.2)(10)(0.002+(1.2)(10)(0.0016)+(1.2)(9.5)(0.0005)+(1.2)(11)(0.013)
=65.1 moles of air
Now,
Mass (g) =Molecular wt.*No. of moles
= (2(16) +3.76(28))*66.8
=8937 g
=19.78 lb

Therefore, Air per pound of fuel is 20.78 lb

Air required in this case= Amount of fuel (lb)*Air per pound of fuel
=53*20.78
=1101.3 lbs

ADIABATIC FLAME TEMPERATURE:

ni=No.of moles of component i

Cpi=Specific heat capacity of component i
Cp=n*(a+b*T)

(Cp)O2=n*(7.16+10-3T)

(Cp) CO2=n*(10.55+2.16*10-3T)

(Cp)H2O=n*(7.17+2.56*10-3T)

(Cp) N2=n*(6.83+9*10-4T)

Heat of combustion=795 kJ/mol

Therefore,
795= [0.396(7.16*T+10-3*T2/2) +1.974(7.17T+2.56*10-3*T2/2)
+0.9938(10.55+2.16*10-3T2/2) +8.946(6.83T+9*10-4T2/2)]
On solving, we get:

T=2028.7C