Organic solvent properties density 1000 kg/m^3 Hvap 125 kCal/kg Cp 0.

55 kCal/kg*K water properties density 995 Cp 0.9

Reactor properties Cp_steel Density

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

7291.66667 kCal/hr Inlet 2 1 2" 3 Outlet 2 1 2" 3

Pipe length Valves Pipe Diameter Bends water flow velocity

Pipe length Valves Pipe Diameter Bends

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

7291.66667 kCal/hr Inlet 3 1 2" 2 Outlet 3 1 2" 3

Pipe length Valves Pipe Diameter Bends Height

Pipe length Valves Pipe Diameter Bends Height

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

15625 kCal/hr Inlet 6 1 2" 2 Outlet 6 1 2" 2

Pipe length Valves Pipe Diameter Bends Height

Pipe length Valves Pipe Diameter Bends Height

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

Pipe length Valves Pipe Diameter Bends Height

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

Pipe length Valves Pipe Diameter Bends Height

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

Total cooling flow rate required 10% extra

52355.566 Kg/hr 57.591122 m^3/hr 14.543213 Kg/s

Total heat load Actural TR TR with 15% extra

471166.7 Kcal/hr 124.5814 143.2686

or properties 0.47 7.9 kCal/kg*K g/cm^3

Reactor body 11.1419704 kCal/hr

11.1419704 kCal/hr

Reactor body 11.1419704 kCal/hr

11.1419704 kCal/hr

Reactor body 11.1419704 kCal/hr

Receiver

Temperature_Initial Temperature_Final Cooling Time Batch Mass Cp 11.1419704 kCal/hr

80 50 40 4800 0.55 1980 Inlet 10 1 1" 7

C C hr kg kCal/kg*K kCal/hr Outlet 10 1 1" 7

Pipe length Valves Pipe Diameter Bends Height

471200.0926 kCal/hr

DARCY FRICTION LOSS CALCULATOR FOR PIPES, FITTINGS & V

0.10 1462 0.044 0.00

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)

PIPES, FITTINGS & VALVES

TOTAL HEAD LOSS, hf (m) 0.01

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

Outlet 24 1 4" 5 m^3/hr mm m/s m

0.012849154 m^3/s

Outlet 6 1 2" 6 m^3/hr mm m/s m

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

Outlet 5 1 2" 7 m^3/hr mm m/s m

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)

50.8 mm 2.2 m/s 3.35 m 94052.12899

Total head loss

7.25

Inlet 8 1 2" 3 1.736111111 50.8 0.24 0.04 289901.2

Outlet 8 1 2" 3 m^3/hr mm m/s m

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

Outlet 10 1 1" 7 0.22 m^3/hr 25.4 mm 0.12 m/s 0.04 m 946999.3398

Inlet 10 1 1" 7

6.11111E-05 m^3/s

Inlet 20 1 1" 7 0.8 25.4 0.44 0.59 1458726.628

Outlet 20 1 1" 7 m^3/hr mm m/s m

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)

13 6.098611111 50.8 0.83 1.62 114522.3483 (assumed) Inlet

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

Cv = (Efficiency)^0.5 Hl = 0.424125042 m Static head loss 3m

assume 10 nozzles.

0.005168866 m^3/s

(Assumed)

0.000225051 m^3/s

R1+R2 R3 R4 R5 R6+R7 R8 R9 R10+R11

114522.3 2808067 3623218 1140457 5873.028 96043.98 2442464 59629.75

0.003618207 m^3/s

R12 R13 R14 R15 R16+R17 R18 R19

94052.13 946999.3 289901.2 1458727 842.8413 179286.9 2442464

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

Enthalpy (J/kg dry air)

220 200 180 160 140 120 100 80 31 33 35 37 39 41 43

Temperature (C)

Minimum gas flow rate =

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

For liquid rate

Tower cross section area = For gas flow rate = Tower cross section area = TL H* (eq.)

10^5/(H*-H) area*10^5

32 33 34 35 36 37 38 39 40 41 42 Area under the curve Ky*a*Z/G = Ky*a Z = = =

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

6 5 10^5/(H*-H) 4 3 2 1 0 80000 90000 100000 110000

2.786041 1.5 (value assumed) (Packed height)

2.93463 m

NtOG = 2.786041 HtOG = 1.053333

mperature

43

45

47

49

51

110000 120000 130000 140000 150000 160000 H (op.)

Cooling Tower 150 TR

Make up water TDS Blowdown water TDS 93.6 1112

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

2 Blow Down Loss Eavporation loss COC Blow Down Loss

Evap Loss / [ COC - 1] 0.88 m^3/hr 11.88034188 0.1 m^3/hr

3 Drift Loss Q Drift Loss

0.2% of Circulation rate 57.59112243 m^3/hr 0.115182245 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

Actual evaporation loss Optimum blow

= =

0.4 m^3/hr 0.08 m^3/hr

COC 11.88034 561.6

Pump calculation: Flow rate density g head efficiency Hydrulic power Shaft power

57.59112 1000 9.81 52.01597 0.75 8.163168 10.88422

m^3/hr Kg/m^3 m/s^2 m kW kW

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

Only one pump is operating at a time.

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

500ml 300ml 300ml 300ml

Daily Alternate Weeks Alternate Weeks Weekly

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

Cooling water flow rate = Cost of water per m^3 = Rs

57.59112243 m^3/hr 2.503305634

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

271411253 kcal/month 376960.07 kcal/hr 41884.453 kg/hr 48.167121 m^3/hr

m^3/hr Kg/m^3 m/s^2 m kW kW hr 1536.16 722.3458 263656.2

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 power op. cost = Rs

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

(keep L/G = constant)

(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