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Kg/m^3 kCal/kg*K
SSR I3 reactor mass Product Reactor capacity Temperature_Initial Temperature_Final Cooling Time Batch Mass Cp Total heat
Condenser Rx OCN 6 86 55 0.8 5500 0.55 117218.8 Inlet 10 1 2" 6 kl C C hr kg kCal/kg*K kCal/hr Outlet 6 1 2" 6 Kg/hr Time of operation mass collected Heat of vap. 48 hr 2800 kg 125 kCal/kg
SSR I2 reactor mass Product Reactor capacity Temperature_Initial Temperature_Final Cooling Time Batch Mass Cp Total heat
Condenser Rx OCN 6 86 55 0.8 5500 0.55 117218.8 Inlet 8 1 2" 6 kl C C hr kg kCal/kg*K kCal/hr Outlet 5 1 2" 7 Time of operation mass collected Heat of vap. 48 hr 2800 kg 125 kCal/kg
SSR I0 reactor mass Product Reactor capacity Temperature_Initial Temperature_Final Cooling Time Batch Mass Cp Total heat
Condenser OCA 148 90 1.5 6800 0.55 144613.3 Inlet 11 1 2" 5 kl C C hr kg kCal/kg*K kCal/hr Outlet 7 1 2" 3 Time of operation mass collected Heat of vap. 48 hr 6000 kg 125 kCal/kg
WTFE and Condenser Product name Feed inlet temp. Feed outlet temp. Distillate flow rate Boiling point Cp Latent heat of vap. Total heat WTFE OCN (80% cond.) 213 C 205 C 50 Kg/hr 210 C 0.55 kCal/kg*K 125 kCal/kg 5000 kCal/hr Inlet 2 1 2" 2 Outlet 2 1 2" 3 Condenser OCN (20% cond.) 205 C 40 C 50 kg/hr 210 C 0.55 kCal/kg*K 125 kCal/kg 5787.5 kCal/hr Inlet 5 1 2" 2 Outlet 4 1 2" 3
Dry vac. Pump Material name Flow rate Inlet temp. Outlet temp. Total heat condenser 1 & 2 water 7000 kg/hr 32 C 39 C 44100 kCal/hr Inlet Outlet
4 2 2" 2
5 2 2" 3
Oil vacc. pump Cooling water flow rate Inlet temp. Outlet temp. Total heat 800 32 39 5040 kg/hr C C kCal/hr
11.1419704 kCal/hr
11.1419704 kCal/hr
Receiver
471200.0926 kCal/hr
Calculated Head Loss in Fittings, Valves, Entrances & Exits K 5 0.05 0.6 2.3 0.4 0.6 0.9 7 0.9 0.2 10 1 0.5 1 1.8 0.6 0.01 Qty 0 2 0 0 0 0 23 0 0 0 0 0 0 0 0 0 Sub Total K 0 0.1 0 0 0 0 20.7 0 0 0 0 0 0 0 0 0 20.8
Angle Valve Ball Valve, Full Port Butterfly Valve Check Valve, Swing Type Elbow 45 Degrees Elbow 90 Degrees, Long Radius Elbow 90 Degrees, Standard Flow Meter, Turbine Type Foot Valve Gate Valve Globe Valve Pipe Entrance, Inward Projected Pipe Pipe Entrance, Sharp Edge Pipe Exit Tee, Standard, Flow Through Branch Tee, Standard, Flow Through Run Head Loss - Valves & Fittings (m)
0.016597
Sub Total K
4" line from cooling tower to SSR 13: Inlet Pipe length 25 BF valves 4 Pipe dia. 4" Bends 8 Water flow rate 46.25695473 diameter 101.6 fluid velocity 1.58 Head loss 2.88 Resistance (R6+R7) 5873.027675 From 4" pipe line to SSR 13 reactor: Inlet Pipe length 10 Ball valves 1 Pipe dia. 2" Bends 6 Water flow rate 18.60791936 diameter 50.8 fluid velocity 2.04 Head loss 4.27 Resistance (R8) 96043.97749
0.012849154 m^3/s
Reactor coil head loss: Length 104 m Diameter 80 mm flow rate 18.60792 m^3/hr Velocity 2.06 m/s Head loss 5.3 m Total head loss = 9.57
From 4" pipe line to SSR 13 condenser: Inlet Outlet Pipe length 4 2 Ball valves 1 1 Pipe dia. 2" 2" Bends 3 3 Water flow rate 0.810185185 m^3/hr diameter 50.8 mm fluid velocity 0.11 m/s Head loss 0.01 m Resistance (R9) 2442464.327
Spiral condenser head loss: Length m Diameter mm Flow rate 0.810185 m^3/hr Velocity m/s Head loss 1m Total head loss = 1.01
4" line from SSR 13 connection to SSR 12 conncetion: Inlet Outlet Pipe length 10 10 Ball valves 1 1 Pipe dia. 4" 4" Bends 0 0 Water flow rate 13.83572874 m^3/hr 0.003843258 m^3/s diameter 101.6 mm fluid velocity 0.47 m/s Head loss 0.05 m
Resistance (R16+R17)
842.8413092
From 4" pipe line to SSR 12 reactor: Inlet Pipe length 8 Ball valves 1 Pipe dia. 2" Bends 6 Water flow rate 13.02554355 diameter 50.8 fluid velocity 2.04 Head loss 4.27 Resistance (R18) 179286.9038
Reactor coil head loss: Length 104 m Diameter 8 mm flow rate 13.02554 m^3/hr Velocity 2.06 m/s Head loss 5.3 m Total head loss = 9.57
From 4" pipe line to SSR 12 condenser: Inlet Outlet Pipe length 4 2 Ball valves 1 1 Pipe dia. 2" 2" Bends 3 3 Water flow rate 0.810185185 m^3/hr diameter 50.8 mm fluid velocity 0.11 m/s Head loss 0.01 m Resistance (R19) 2442464.327
Spiral condenser head loss: Length m Diameter mm Flow rate 0.810185 m^3/hr Velocity m/s Head loss 1m Total head loss = 1.01
From 4" pipe line to SSR 10 reactor, its condenser and receiver and to oil vaccume pump: Connecting pipe head loss: Inlet Outlet Pipe length 16 16 Ball valves 0 0 Pipe dia. 2" 2" Bends 4 4 Water flow rate 18.02549726 m^3/hr 0.005007083 m^3/s diameter 50.8 mm fluid velocity 2.47 m/s Head loss 5.62 m Resistance (R10+R11) 59629.75119 To SSR 10 reactor: Pipe length Ball valves Pipe dia. Bends Water flow rate Inlet Outlet 11 7 1 1 2" 2" 5 3 16.06938614 m^3/hr Reactor coil head loss: Length 100 m Diameter 80 mm flow rate 16.06939 m^3/hr Velocity 1.78 m/s Head loss 3.9 m
diameter fluid velocity Head loss Resistance (R12) To SSR 10 Condenser: Pipe length Ball valves Pipe dia. Bends Water flow rate diameter fluid velocity Head loss Resistance (R14) To SSR 10 Receiver: Pipe length Ball valves Pipe dia. Bends Water flow rate diameter fluid velocity Head loss Resistance (R13) To oil vaccume pump: Pipe length Ball valves Pipe dia. Bends Water flow rate diameter fluid velocity Head loss Resistance (R15)
7.25
Shell & Tube condenser head loss: Length 56 m Diameter 15 mm Flow rate 0.062004 m^3/hr Velocity 0.1 m/s Head loss 0.4 m Total head loss = 0.44
Inlet 10 1 1" 7
6.11111E-05 m^3/s
0.000222222 m^3/s
From cooling tower to WTFE and dry vaccume pump: Connection line head loss: Inlet Outlet Pipe length 29 29 Ball valves 1 1 Pipe dia. 2" 2"
Bends Water flow rate diameter fluid velocity Head loss Resistance (R1+R2) To WTFE: Pipe length Ball valves Pipe dia. Bends Water flow rate diameter fluid velocity Head loss Resistance (R3) To condenser: Length Diameter Flow rate Velocity Head loss Resistance (R4)
10 m^3/hr mm m/s m
0.001694059 m^3/s
Outlet
0.555555556 m^3/hr mm m/s 0.6 m 2808067.29 (assumed) m mm 0.643055556 m^3/hr m/s 1m 3623218.38
0.000154321 m^3/s
0.000178627 m^3/s
To dry vaccume pump: Pressure drop 1.1 Kg/cm^2 head loss 11 m Flow rate 4.9 m^3/hr Resistance (R5) 1140457.016 head loss in spray nozzle:
0.001361111 m^3/s
assume 10 nozzles.
0.005168866 m^3/s
(Assumed)
0.000225051 m^3/s
0.003618207 m^3/s
R1-R5 m R10-R15 R8&R9 (assumed) R16-R19 0.000225051 m^3/s Total Overall resistance Head loss with 15% extra, hL
Upper half 1.50896E-06 662709.8 777232.2 Lower half 1.58233E-05 63197.75 122827.5 1.89628E-05 52734.78 5.98707E-06 167026.5 167869.3 2.49198E-05 40128.68 46001.71 2.30249E-05 43431.16 34.6773113 m 52.01596695 m
0.004463718 m^3/s
er head loss:
0.000482253 m^3/s
Design flow rate Hot water temp.(T1) Cold water temp.(T2) Wet bulb temp.(Twb) Dry bulb temp.(Tdb) Range Approach Effectiveness Equillibrium line T 32 33 34 35 36 37 38 39 40 42.5 43.5 45 46.5 50
52355 42 32 29 35
Kg/hr C C C C
10 C 3 C 0.769231
H 110 115 121 128 135 141 150 156 163 185 200 216 230 258
Enthalpy vs Temperature
260 240
Temperature (C)
6.84184626
Actual gas flow rate = 1.5*Minimum gas flow rate = 10.26277 Kg dry air/s H2 = = 154333.3 J/Kg dry air 2.7 Kg/m^2*s 5.386375 m^2 1.58 Kg/m^2*s 6.495424 m^2 H (op.) (This one is to be used.)
7
Tower cross section area = For gas flow rate = Tower cross section area = TL H* (eq.)
10^5/(H*-H) area*10^5
111000 118000 125000 130000 138000 145000 156000 159000 168000 178000 188000
95000 101000 107000 113000 117000 123000 130000 137000 140000 148000 156000 2.786041
6.25 5.88235294 5.55555556 5.88235294 4.76190476 4.54545455 3.84615385 4.54545455 3.57142857 3.33333333 3.125
36397.06 34313.73 34313.73 21288.52 27922.08 29370.63 29370.63 12175.32 27619.05 25833.33 278604.1
2.93463 m
mperature
43
45
47
49
51
COOLING TOWER & ITS SYSTEM By process requirement By process requirement By process requirement As per prevailing atm condition Circulation Flow Suply Temperature Return Temperature Wet Bulb Temperature Approach Range COC 57.59112243 m^3/hr 42 32 29 3 10 11.88034188 C C C C C
As per CW treatment
CT Makeup Reuirement 1 Evaporation Loss Q Range Evaporation loss 0.00153 * Range * Circulation 57.59112243 m^3/hr 10 C 0.88 m^3/hr
CW MAKE UP FLOW = Evap loss + B.D. loss + Drift Loss CW Make up 1.08 m^3/hr
This Cooling Tower is operating at very high COC i.e. 11.88 that can cause scalling in fills and pipes.
Optimum COC
= =
Pump calculation: Flow rate density g head efficiency Hydrulic power Shaft power
Pump and Fan Operating cost: Pump 1 Pump 2 Fan Actual amp. 17.6 8.4 9.3 Amp. Power 12547.2532 5988.461744 6630.083 W Operation time 24 (optional) 14 hr Cost per day 2258.50557 696.1587 2954.66425 Total electricity cost/day=Rs Make up water cost: MW per day 25.8554733 m^3 Cost of MW 15 /m^3 Total water cost per day = Rs 387.8321001 Chemical cost: Chemical
Amount
Frequency
Cost per Cost per kg (Rs) month 151 214 214 337 2265 128.4 128.4 404.4
MAX Treat 2521 MAX Treat 606 MAX Treat 608 MAX Treat 2001
Total chemical cost per month = Rs Total Chemical cost per day = Rs
Maintanence and labor cost per day = Rs Total cost per day Total cost per hr = = Rs Rs 3460.03635 144.1681812
2926.2 97.54 20
ating at a time.
Pump power saving by using VSD: Assume that CT 6 works on peak load for 15 days and at 60% of peak load for the rest of the month. Q1 Q2 169632033.3 kcal/15days 101779220 kcal/15days (at peak load) (at 50% of peak load)
Total heat load for a month Total heat load per hr Pump flow rate required with 15% extra Pump power calculation: Flow rate 48.16712057 density 1000 g 9.81 head 52.01596695 efficiency 0.8 Hydrulic power 6.827376733 Shaft power 8.534220917 operation time 24 Operating cost per day Cost saving per day Pump saving per year = Rs = Rs = Rs
Fan power saving by using variable drive motor: L G 41884.45267 36945.96981 32253.1382 18997.0984 6.630082645 1193.414876 kg/hr kg/hr m^3/hr acfm KW /day
Fan BHP = Air Volume @Fan in ACFM x Total Pressure in inch Aq. / (Fan Total Efficiency x 6356) Total Pressure in inch Aq. 2.379515 L/G Lnew Gnew 1.417084627 41884.45267 kg/hr 29556.77584 kg/hr 15197.67872 acfm 7.112 HP
(Fan BHP)new
5.30341749 KW Op. time 24 hr Fan new operating cost = Rs 954.6151 /day Cost saving = Rs Cost saving = Rs 238.799728 /day 87161.90072 /year
Cost savings by installing side stream filters: Assume reduction of 50% in Blow down and 25% in chemical cost. water saving = 0.108 m^3/day cost of makeup water = Rs water cost saving per day = Rs Chemical cost saving per day = Rs Cost saving per day Cost saving per year = = Rs Rs 15 per m^3 1.62 24.385 26.005 /day 9491.825 /year