5.1.

x Cooler-102

The heat duty of cooler-102 is obtained from the energy manual calculation shown in
Chapter 4 Section 4.1.3, which is 12530661 kJ/hr. The heat duty is then substituted into the
equation below to calculate the area, A of the cooler.

𝑄 = 𝑈𝑖 𝐴𝐹𝑇 ∆𝑇𝐿𝑀

where 𝑄 : Heat duty

𝑈𝑖 : Overall heat transfer coefficient

𝐴 : Total heat transfer area

𝐹𝑇 : Correction factor

∆𝑇𝐿𝑀 : Log mean temperature difference

Water is used as cooling medium as it is abundant, easily available and low cost. Besides, the
flow of chemical mixture stream is counter-current to the cooling water to ensure high heat
transfer.

Th,in
151.82°C

Th,out Tc,out
25.00°C 48.89°C
Tc,in
20.00°C

Figure X: Log mean temperature profile

First, ∆𝑇𝐿𝑀 is determined using the following equation:

(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 ) − (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )

∆𝑇𝐿𝑀 =
(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 )
ln
(𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )
(151.82 − 48.89)℃ − (25.00 − 20.00)℃
∆𝑇𝐿𝑀 =
(151.82 − 48.89)℃
ln
(25.00 − 20.00)℃
∆𝑇𝐿𝑀 = 32.38℃
∆𝑇𝐿𝑀 = 32.38 𝐾

After that, correction factor, 𝐹𝑇 is calculated by determining the following parameters:

𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛
𝑅= 𝑆=
𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛
(151.82 − 25.00)°C (48.89 − 20.00)°C
= =
(48.89 − 20.00)°C (151.82 − 20.00)°C
= 4.3898 = 0.21916

Figure X: Temperature-driving-force correction factor for 3-6 shell-and-tube exchanger

Based on Figure X, FT is 1 at R = 4.3898 and S = 0.21916 for 3-6 shell-and-tube exchanger.

From the Product and Process Design Principles (4th Edition) textbook, FT is always less than
1. Yet, it is desirable to have a value of FT of 0.85 or higher. Since the calculated R and S
values give a value of FT higher than 0.85 for 3-6 shell and tube head exchanger, it is chosen
as the desirable equipment for cooler-102.
Next, 𝑈𝑖 is calculated based on the below equation:
1
𝑈𝑖 =
𝐷 1 𝐷 𝑡 𝐷 1
𝑅𝑓,𝑜 𝐷𝑖 + (𝐷 𝑖 ) + 𝑤 (𝐷 𝑖 ) + + 𝑅𝑓,𝑖
𝑜 ℎ𝑜 𝑜 𝑘 𝑤 𝑚 ℎ𝑖

Yet, ℎ𝑖 and ℎ𝑜 are first determined in order to solve for 𝑈𝑖 . They are calculated based on
Dittus-Boelter equation and Kern’s correlation respectively.

Calculation of ℎ𝑖

ℎ𝑖 𝐷𝑖 𝐷𝑖 𝐺 0.8 𝐶𝑝 𝜇 0.3
= 0.023 ( ) ( )
𝑘 𝜇 𝑘

𝐷𝑖 = 0.62 x 0.0254 m = 0.015748 m

1
𝜌𝑚𝑖𝑥 = 𝑉
𝑚𝑖𝑥

1
= 𝑚̇
∑𝑖 𝑖 𝑉𝑖
𝑚𝑇̇

1
= 𝑚̇𝑏𝑒𝑛𝑧𝑒𝑛𝑒 𝑚̇ 𝑚̇
𝑉𝐵𝑒𝑛𝑧𝑒𝑛𝑒 + 𝑐𝑢𝑚𝑒𝑛𝑒 𝑉𝑐𝑢𝑚𝑒𝑛𝑒 + 𝐷𝐼𝑃𝐵 𝑉𝐷𝐼𝑃𝐵
𝑚̇𝑇 𝑚̇𝑇 𝑚̇𝑇

1
= 𝑘𝑔⁄ 𝑘𝑔 𝑘𝑔
19.80413 ℎ𝑟 𝑚3 51021.62 ⁄ℎ𝑟 𝑚3 41.14087 ⁄ℎ𝑟 𝑚3
𝑘𝑔⁄ (0.00122787 𝑘𝑔 ) + 𝑘𝑔⁄ (0.00125767 𝑘𝑔 )+ 𝑘𝑔⁄ (0.00125377 𝑘𝑔 )
51082.565 ℎ𝑟 51082.565 ℎ𝑟 51082.565 ℎ𝑟

= 795.1304 kg/m3

Assuming 𝑛𝑡 is 35 tubes per pass,

𝜋𝐷𝑖2
𝐴𝑐 = 𝑛𝑡
4

𝜋(0.015748 m)2
= 4
× 35

= 0.00681724 m2

𝑚̇⁄
𝜌𝑚𝑖𝑥
𝑣𝑖 = 𝐴𝑐

51082.565 𝑘𝑔/ℎ𝑟
⁄795.1304 kg/𝑚3
= 0.00681724 𝑚2
 = 9423.7897 m/hr
9423.7897
= 3600
m/s

= 2.6177 m/s

𝐺 = 𝜌𝑣𝑖

= 795.1304 kg/m3 x 2.6177 m/s

= 2081.4283 kg/(m2‧s)

𝑚̇
𝑘 = ∑𝑖 𝑚̇ 𝑖 𝑘𝑖
𝑇

𝑘𝑔⁄ 𝑘𝑔⁄
19.80413 ℎ𝑟 (0.1239 51021.62 ℎ𝑟 (0.1213
= 𝑘𝑔 𝑊/(𝑚 ∙ 𝐾)) + 𝑘𝑔 𝑊/(𝑚 ∙ 𝐾)) +
51082.565 ⁄ℎ𝑟 51082.565 ⁄ℎ𝑟
𝑘𝑔
41.14087 ⁄ℎ𝑟
𝑘𝑔 (0.1392 𝑊/(𝑚 ∙ 𝐾))
51082.565 ⁄ℎ𝑟

= 0.121315 W/m‧K

𝑚̇
𝜇 = ∑𝑖 𝑚̇ 𝑖 𝜇𝑖
𝑇

𝑘𝑔⁄ 𝑘𝑔
19.80413 ℎ𝑟 51021.62 ⁄ℎ𝑟
= 𝑘𝑔 (0.000305594 𝑃𝑎 ∙ 𝑠) + 𝑘𝑔 (0.000331893 𝑃𝑎 ∙ 𝑠) +
51082.565 ⁄ℎ𝑟 51082.565 ⁄ℎ𝑟
𝑘𝑔
41.14087 ⁄ℎ𝑟
𝑘𝑔 (0.000363159 𝑃𝑎 ∙ 𝑠))
51082.565 ⁄ℎ𝑟

= 0.000331908 Pa‧s

𝑚̇
𝐶𝑝 = ∑𝑖 𝑚̇ 𝑖 𝐶𝑝 𝑖
𝑇

𝑘𝑔⁄ 𝑘𝑔⁄
19.80413 ℎ𝑟 (1.9041 51021.62 ℎ𝑟 (1.9731
= 𝑘𝑔 𝑘𝐽/(𝑘𝑔 ∙ 𝐾)) + 𝑘𝑔 𝑘𝐽/(𝑘𝑔 ∙ 𝐾)) +
51082.565 ⁄ℎ𝑟 51082.565 ⁄ℎ𝑟
𝑘𝑔
41.14087 ⁄ℎ𝑟
𝑘𝑔 (1.9818 𝑘𝐽/(𝑘𝑔 ∙ 𝐾))
51082.565 ⁄ℎ𝑟

= 1.97308 kJ/kg‧K

= 1973.08 J/ kg‧K

ℎ𝑖 𝐷𝑖 𝐷𝑖 𝐺 0.8 𝐶𝑝 𝜇 0.3
= 0.023 ( ) ( )
𝑘 𝜇 𝑘
 ℎ𝑖 (0.015748) (0.015748)(2081.4283) 0.8 (1973.08)(0.000331908) 0.3
= 0.023 ( ) ( )
0.121315 0.000331908 0.121315
ℎ𝑖 = 2909.0267 W/𝑚2 ∙ 𝐾

Calculation of ℎ𝑜

ℎ𝑜 𝐷 𝐷𝐺 0.55 𝐶𝑝 𝜇 1/3
= 0.36 ( ) ( )
𝑘 𝜇 𝑘

𝐷𝑜 = 0.75 x 0.0254 m = 0.01905 m

𝑄 = 𝑚̇𝑤𝑎𝑡𝑒𝑟 𝐶𝑝,𝑤𝑎𝑡𝑒𝑟 ∆𝑇
𝑄
𝑚̇𝑤𝑎𝑡𝑒𝑟 = 𝐶
𝑝,𝑤𝑎𝑡𝑒𝑟 ∆𝑇

12530661.3 𝑘𝐽/ℎ𝑟
= 𝑘𝐽
(4.1793 )(48.89−20.00)𝐾
𝑘𝑔∙𝐾

= 103782.207 kg/hr

= 103782.207 kg/3600 s

= 28.8284 kg/s

𝜋𝐷2
4(𝑃𝑡2 − 𝑜)
4
𝐷=
𝜋𝐷𝑜

𝜋(0.01905)2
4((0.0254 𝑚)2 − )
4
= 𝜋(0.01905)

= 0.0240704 m

𝑚̇𝑠
𝐺= 𝐷
𝐵𝐷𝑠 (1− 𝑜)
𝑃𝑡

28.8284 kg/s
= 0.01905 m (⸪ 𝐵 = 0.5𝐷𝑠 and 𝐷𝑠 is first assumed to be 25
(0.5×0.635 𝑚)(0.635 𝑚)(1− )
0.0254 𝑚
in. = 0.635 m)
= 571.9564 kg/(m2‧s)
 ℎ𝑜 𝐷 𝐷𝐺 0.55 𝐶𝑝 𝜇 1/3
= 0.36 ( ) ( )
𝑘 𝜇 𝑘

ℎ𝑜 (0.0240704 ) (0.0240704 )(571.9564) 0.55 (4179.3)(0.000727096) 1/3

= 0.36 ( ) ( )
0.6209 0.000727096 0.6209
ℎ𝑜 = 3549.9497 W/𝑚2 ∙ 𝐾

Hence, 𝑈𝑖 is determined using the values of ℎ𝑖 and ℎ𝑜 calculated above and assuming 𝑅𝑓,𝑜 ,
𝑡 𝑤 𝐷𝑖
𝑅𝑓,𝑖 and ( ) are negligible
𝑘𝑤 𝐷𝑚

1
𝑈𝑖 =
𝐷 1 𝐷 𝑡 𝐷 1
𝑅𝑓,𝑜 𝐷𝑖 + (𝐷 𝑖 ) + 𝑤 (𝐷 𝑖 ) + + 𝑅𝑓,𝑖
𝑜 ℎ𝑜 𝑜 𝑘𝑤 𝑚 ℎ𝑖
1
𝑈𝑖 =
1 0.015748 1
0+ ( ) + 0 + 2909.0267 + 0
3549.9497 0.01905
𝑈𝑖 = 1743.2301 W/𝑚2 ∙ 𝐾

Then, the total heat transfer area, 𝐴 is determined by the following equation:

𝑄 = 𝑈𝑖 𝐴𝐹𝑇 ∆𝑇𝐿𝑀
𝑄 = 𝑈𝑖 (𝜋𝐷𝑖 𝐿𝑁𝑡 )𝐹𝑇 ∆𝑇𝐿𝑀
𝑄 = 𝑈𝑖 (𝜋𝐷𝑖 𝐿 ∙ 6𝑛𝑡 )𝐹𝑇 ∆𝑇𝐿𝑀
12530661.3 × 1000
= 1743.2301[𝜋(0.015748 )(20 × 12 × 0.0254)6𝑛𝑡 )(1)( 32.38 )
3600
𝑛𝑡 = 34.2568 ≈ 35 𝑡𝑢𝑏𝑒𝑠 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠

Next, the total number of tubes is calculated as followed:

𝑁𝑇 = 𝑛𝑡 × 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠

𝑁𝑇 = 35 × 6
𝑁𝑇 = 210 𝑡𝑢𝑏𝑒𝑠
Costing of Cooler-102

The formula to calculate the f.o.b purchase cost of cooler is shown below:

𝐶𝑃 = 𝐹𝑃 × 𝐹𝑀 × 𝐹𝐿 × 𝐶𝐵

where 𝐹𝑃 : Pressure factor

𝐹𝑀 : Material factor for various combinations of tube and shell material

𝐹𝐿 : Tube-length correction

𝐶𝐵 : Base cost

𝐹𝑃 is calculated based on the following equation:

𝑃 𝑃 2
𝐹𝑃 = 0.9803 + 0.018 ( ) + 0.0017 ( )
100 100
At pressure of 1 bar (14.5038 pisg),

14.5038 14.5038 2
𝐹𝑃 = 0.9803 + 0.018 ( ) + 0.0017 ( )
100 100
𝐹𝑃 = 0.9829

𝐹𝑀 is determined with the following equation:

𝐴 𝑏
𝐹𝑀 = 𝑎 + ( )
100

Since carbon steel is used as materials of construction for shell and tube, values of a and b
are 0.00. Hence, 𝐹𝑀 = 1

Since tube length of cooler is 20 ft, 𝐹𝐿 is 1.00 based on Product and Process Design Principles
(4th Edition), Page 462.
By assuming the cooler is a fixed head heat exchanger, 𝐶𝐵 is calculated from the equation
below:

𝐶𝐵 = exp {11.4185 − 0.9228[ln(A)] + 0.09861[ln (A)]2}

A = 𝜋𝐷𝑜 𝐿𝑁𝑡
0.75
= 𝜋( 12 ft)(20 𝑓𝑡)(210)

= 824.6681 ft2

𝐶𝐵 = exp {11.4185 − 0.9228[ln(824.6681)] + 0.09861[ln (824.6681)]2 }

= $15809.02

Inserting the values of 𝐹𝑃 , 𝐹𝑀 , 𝐹𝐿 𝑎𝑛𝑑 𝐶𝐵 into the 𝐶𝑃 equation.

𝐶𝑃 = 𝐹𝑃 × 𝐹𝑀 × 𝐹𝐿 × 𝐶𝐵

𝐶𝑃 = 0.9829 × 1 × 1.00 × $ 15809.02

𝐶𝑃 = $15539.42

Lastly, the bare-module cost, 𝐶𝐵𝑀 is generated with the equation below:

𝐶𝐸 𝑖𝑛𝑑𝑒𝑥 𝑜𝑓 2018
𝐶𝐵𝑀 = 𝐶𝑃 × × 𝐹𝐵𝑀
𝐶𝐸 𝑖𝑛𝑑𝑒𝑥 𝑜𝑓 2013

The 𝐹𝐵𝑀 value of cooler-102 is 3.16 as it utilises shell-and-tube heat exchanger. The value is
obtained from Product and Process Design Principles (4th Edition), Page 441, Table 16.11.

603
𝐶𝐵𝑀 = $15539.42 × × 3.16
567
𝐶𝐵𝑀 = $52222.32