Calculation of a kerosene-Crude Oil Exchanger: 19867.

346kg/hr (43,800 lb/hr) of a 42

API kerosene leaves the bottom of a distilling column at 198.889C (390F) and will be
cooled to 93.3333C (200F) by 67585.2631 kg/hr (149,000 lb/hr) of 34 API mid-continent
crude coming from storage at 37.7778C (100F) and heated to76.6667C(170F). A 68.9476
kPa (10 psi) pressure drop is permissible on both streams and in accordance, a combined dirt
factor of 0.003 should be provided. Available for this service is a 21 ¼ in. ID exchanger
having 158, 1 in. O.D, 13 BWG tubes 16” long and laid out on 1 ¼ in. square pitch. The
bundle is arranged for four passes and baffles are spaced 5 in. apart.
Will the exchanger be suitable; i.e. what is the dirt factor?
Solution:
Exchanger:
Shell side
ID = 21 ¼ in = 539.75 mm
Baffle Space = 5 in. = 127 mm
Passes = 1
Tube Side
Number of tubes = 158
Length = 16’ = 406.4 mm
OD = 1 in. = 25.4 mm
13 BWG, 1 ¼ inch square pitch.
Passes = 4
(1) Heat Balance:
Kerosene, Q = 19867.346×2.533×(198.889-93.3333) = 5312013.078kJ/hr
Mid-continent crude, Q = 67585.2631×2.051532(76.6667-37.7778) =5392075.48kJ/hr
(2) t:
Hot Fluid Cold Fluid Difference
471.889 High Temp 349.6667 122.2223
366.3333 Lower Temp 310.7778 55.5555
105.5557 Differences 38.8889 66.6668

66 .6668
LMTD =  84 .5532 K
 122 .2223 
ln  
 55 .5555 
R = 105.5557/38.8889 = 2.714
38.8889
S= = 0.241
198.889−37.7778
FT = 0.905
t = 0.905 × 84.5532 = 76.52 K
(3) Tc and tc:
tc
 0.455
th
Kc = 0.2 (crude oil controlling)
Fc = 0.42
Tc= 200 + 0.42×190=280F = 137.778C = 410.778K
tc= 100 +0.42×70 = 129.4F = 129.4F = 402.4 K
Since the flow area of both the shell and tube sides will be nearly equal, assume the
larger stream to flow in the tubes and start calculation on the tube side.
Hot fluid: shell side, Kerosene
(4’) Flow area, as= ID×C’B/PT =539.75×6.35×127/31.75 = 13709.65mm2
=0.01370965 m2
(5’) Mass vel, Gs= W/as = 19867.346/(0.01370965) = 1449150.489 kg/hr m2
(6’) Re = DeGe/µ at 410.778 K
µ=0.4×2.42= 0.97 lb/ft hr = 1.4438 kg/m hr
De = 0.0825 ft = 0.0251625 m
Re= 0.0251625×1449150.489/1.4438 = 25255.748
(7’) jH = 93
(8’) At 410.778 K
c= 0.59 Btu/(lb)( F) = 2.470212 kJ/Kg K
k = 0.0765 Btu ft/ h ft2 F = 0.4766 kJ m/h m2 K
1 1
 c  3  2.470212  1.4438  3
     1.95591
 k   0.47664 
1

(9’) ho = jH k  c  3 s = 93 ×
0.4766
 1.95  3445 .35
De  k  0.0251625
(10’) Tube- wall temperature:
ho / s 169
tw = tc+ (Tc  tc )  129  (280  129 )  221 F  378 K
hio / t  ho / s 109  169
(11’) At tw = 378 K, µw =0.56×2.42 = 1.3552 lb/ft hr = 2.0172 kg/m hr
0.14 0.14
    1.4438 
x   
    0.9542
 w   2.0172 
ℎ𝑜
(12’) Corrected coefficient, ho= 𝜙 𝜙 = 169×0.96 = 162 Btu/hr ft2 F = 0.91982 kW/m3K
(4) Flow area, a’t = 0.515 in2 = 0.00033225 m2
at =Ntat/144n = 158×0.00033225/4 = 0.0131238 m2
(5) Mass vel, Gt = w/at = 67585.2631/0.0131238 = 5149824.22 kg/ hr m2
(6) Re = DGt/µ; At 129F,
µ= 3.6×2.42 = 8.7 lb/ ft hr = 12.947 kg/m hr
D = 0.81/12 = 0.0675 ft = 0.020574 m
Re = 0.020574×5149824.22/12.947 = 8170.030
(7) L/D = 16/0.0675 = 237
jH = 31
(8) At tc=129F
c= 0.49 Btu/lbF = 2.0515 kJ/kg K
 k = 0.077 Btu/(hr)(ft2)(F/ft) = 0.47975 kJ m/h m2 K
1 1
 c  3  2.0515  12 .947  3
     3.81
 k   0.47975 
1

(9) hi = jH k  c  3 t = 31×
0.077
 3.81  135
De  k  0.0675

hio hi ID 0.81
(10)    135   109
t t OD 1

(11) At tw = 221F, µw = 1.5×2.42 = 3.63lb/ ft hr = 5.40 kg/m hr

ℎ𝑖𝑜
(12) Corrected coefficient, hio= 𝜙 𝜙 = 109×1.11 = 121 Btu/hr ft2 F = 0.68703 kW/m3K

(13) Clean overall coefficient Uc

hio ho 0.68703  0.91982
Uc =   0.393281 kW / m2 K
hio  ho 0.91982  0.68703

(14) Design overall coefficient UD:

a”= 0.2618 ft2/lin ft
Total surface, A = 158×16’0”×0.2618 = 662ft2= 61.5018m2

𝑄 5312013.078
UD= = = 1021.54 kJ/hr m2 K = 0.2837 kW/ m2 K
𝐴∆𝑡 61.5018×84.55
(15) Dirt Factor Rd:
U C  U D 0.3932  0.2837
Rd =   0.9816 m2K/KW  0.0009816m2K/W
U CU D 0.3932  0.2837