1. Capture and Utilization of Carbon Dioxide Ethanol Production Presented By: Dana Al-Maiyas. Supervised By: Prof.Mohamad A.Fahim. Eng.Yousif Ismael.

2. Table of Contents 1.Introduction of heat exchanger. 2.Introduction of Shell & Tube heat exchanger. 3.Introduction of Plate heat exchanger. 4. Heater E-100 (Ethanol Plant ). 5. Cooler E-101 (Ethanol Plant ). 6. Heater E-100 (Car ). 7.Heater E-101 (Car ). 8.Cooler E-102 (Car ). 9.Heater E-103 (Car ).

3. Introduction A heat exchanger is a device built for efficient heat transfer from one medium to another, whether the media are separated by a solid wall so that they never mix, or the media are in direct contact.

4. Types of Heat Exchanger.

5. * shell and tube heat exchanger This type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. *Plate heat exchanger -Plates are attractive when material costs are high. -Plate Heat Exchanger are easier to maintain. - Plate Heat Exchanger are more suitable for highly viscous materials. -The temperature correction factor,Ft, will normally be higher with plate heat exchangers. -Large heat transfer area afforded by the plates

6. Assumptions 1-Assume a counter current flow heat exchanger because it provides more effective heat transfer. 2-The value of the overall heat transfer coefficient was assumed in the shell and tube heat exchanger design. 3-Assume the outer, the inner diameter and the length of the tube on both the Shell and tube heat exchanger design.

7. Design Procedures (A) Shell & Tube heat exchanger 1)Calculate Heat Load Heat Load= m*cp*(T2-T1) Where: m= mass flow rate ( Kg/h) cp= Heat capacity ( KJ/kg°C) T2= inlet temperature of shell side°C T1= outlet temperature of shell side°C

8. 2) Calculate Log mean Temperature difference ∆Tlm= ((T1-t2) – (T2-t1))/ln((T1-t2)/ (T2-t1)) where: ∆Tlm: Log mean temperature difference°C. T1 : Inlet shell side fluid temperature°C T2 : Outlet shell side fluid temperature °C t1 : Inlet tube side temperature°C t2: Outlet tube side temperature°C

9. 3) Calculate the two dimensionless temperature ratios: R= (T1-T2)/(t2-t1) S = (t2-t1)/(T1-t1) Where: T1 : Inlet shell side fluid temperature T2 : Outlet shell side fluid temperature t1 : Inlet tube side temperature t2: Outlet tube side temperature

11. 4) From Figure determine Ft by using R and S ratios Where : Ft : temperature correction factor. 5) Calculate True temperature difference ∆Tm= Ft *∆Tlm 6) Choose U from table depending on the type of flows in shell and tube sides. Where: U: Over all heat transfer coefficient.

12. 7) Calculate provisional area A=(m/cp*(t2-t1)) Where: m: mass flow rate of the tube side flow (kg/s). cp: mass heat capacity ( KJ/kg°C). t1 : Inlet tube side temperature. t2: Outlet tube side temperature. 8) Assume inlet tube diameter, outlet tube diameter, and tube length.

13. 9) Calculate area of one tube A = 3.14*L*do*10-3 Where: L: Tube length ( m) do: outlet diameter (mm) 10) Define number of tubes Nt=( Provisional Area / Area of one tube ) 11) Calculate bundle diameter Db=Do(Nt/K1)(1/n1) Where: Db: bundle diameter (mm). Do: tube outer diameter (mm). Nt: number of tubes. K1 and n1 are constants using triangle pitch of 1.25.

14. 12) From Figure determine bundle diametrical clearance.

15. 13) Calculate shell diameter Ds = Db+Dc Where: Db : bundle diameter( mm). Dc : clearance diameter( mm). 14) For Tube side coefficient calculate: - Mean temperature =((t1+t2)/2) - Tube cross sectional area A= (3.14/4)*di^2

16. - Tubes per pass = (Nt/2) - Total Flow area = (Tubes per pass * A) Where: A : Tube cross sectional area, m2 - mass velocity = (m/ Total Flow area) Where: m : mass Flow rate Tube side, kg/s - Linear velocity = (mass velocity/ ρ) Where: ρ : Tube Flow density, kg/m3

17. hi = ((4200*(1.35+0.02*t)*ut^0.8)/di^0.2) Where: hi : Tube inside coefficient, W/m2°C. t : Mean temperature ( °C). ut : Linear velocity ( m/s). di : Tube inside diameter ( mm). Or; hi= ((kf/di)*jh*Re*(Pr)^0.33)

19. 15) For Shell side coefficient calculate: - baffle spacing = (Ds/5) - Tube pitch = 1.25 * do - As = ((pt – do)*DslB/pt) Where: As : Cross Flow area, m2 pt : tub pitch lB : baffle spacing, m

20. Gs = (Ws / As) Where: Ws : Fluid flow rate on the shell side, kg/s - Equivalent diameter = (1.1/do)*(pt2-0.917do2) - Mean Shell side temperature = (T1+T2/2) - Reynolds number ( Re) = Gs de / µ - Prandtl number (Pr) = Cp µ / κ - hs = (kf*jh*Re*Pr(1/3)/de) and from figure @ Re we find jh. 16) Calculate over all coefficient 1/Uo= (1/ho)+(1/hod)+(doln(do/di)/(2kw))+(do/di) (1/hid)+(do/di)(1/hi)

21. Where: Uo: the overall coefficient, W/m2°C ho: outside fluid film coefficient, W/m2 °C,from table hi: inside fluid film coefficient.,from table hod : outside dirt coefficient (fouling factor) hid: inside dirt coefficient, W/m2°C kw: thermal conductivity of the tube wall material di : tube inside diameter, m do : tube out side diameter, m

22. 17) Calculate pressure drop for: - Tube side: ∆Pt = Np(8*jf*(L/di)+2.5)*(ρut^2/2) Where: ∆Pt : tube side pressure drop, pa Np : number of tube side passes ut : tube side velocity (m/s) L : length of one tube ( m) Jf : tube side friction factor from figure @Re

24. -S-Shell side : ∆P = 8*jf*(Ds/de)*(L/lB)*(ρ*us^2/2) Where: ∆P : shell side pressure drop (pa) Ds : shell diameter (m) lB : baffling spacing ( m) Jf : tube side friction factor from figure @Re

26. 18) Thickness: (t) = ((Pri)/(SEj-0.6P)) + Cc Where : P: maximum internal pressure, kPa ri: inside radius of shell, m Ej: efficiency of joints as a fraction S: maximum allowable stress(for carbon steel), kPa Cc: allowance for corrosion, m

27. Results Heater E-100Equipment Shell and tube heat exchangerType Carbon SteelMaterial of construction 2224Qtotal (kW) 146.4613845U(W/m² °C) 500Inlet temperture, Shell side °C 100Oultlet, Shell side °C 24.12Inlet temperature, Tube side °C 305Outlet temperature, Tube side °C 562Number of tubes 0.725373277Shell diameter, m 126.2069742LMTD, °C 103.8333078Heat exchanger area, m² Glass woolInsulation $49,800 Cost, $

28. Heater E-101Equipment Shell and tube heat exchangerType Carbon SteelMaterial of construction 4909Qtotal (kW) 79.999986U(W/m² °C) 752.3Inlet temperture, Shell side °C 45Oultlet, Shell side °C 25 Inlet temperature, Tube side °C 300Outlet temperature, Tube side °C 163Number of tubes 16.999544Shell diameter, m 138.6193LMTD, °C 408.20342Heat exchanger area, m² Glass woolInsulation $92,400Cost, $

29. (B) Plate heat exchanger For the second plant (the car ),I used plate heat exchangr. The molar flow was too small.and I could not use shell & tube heat exchanger in the car. By assuming ; d= 0.001 ft =0.000304 m L=0.1 m (Number of transfer Unit ) NTU= (T1-T2)/∆Tlm Typically, the NTU will range from 0.5 to 4, and for most applications will lie between 2 to 3. 1:1 pass arrangement

30. Area required = ((Q*1000)/( U* Ft*∆Tlm)) Number of plates =(( Area required)/(3.14*L*d))

31. Results Heater E-100Equipment Plate heat exchangerType MetalMaterial of construction 9.37E-02Qtotal (kW) 2000U(W/m² °C) 25Inlet temperture, process °C 78.17Oultlet, °C 100Inlet temperature, steam °C 50Outlet temperature, steam °C 2.274244508Number of transfer Unit 23.37919244LMTD, °C 22 Number of plates 0.002104957Heat exchanger area, m² Glass woolInsulation

32. Heater E-101Equipment Plate heat exchangerType MetalMaterial of construction 2.88E-01Qtotal (kW) 2000U(W/m² °C) 25.01Inlet temperture, process °C 700Oultlet, °C 800Inlet temperature, steam °C 200Outlet temperature, steam °C 5.036624733Number of transfer Unit 134.0163375LMTD, °C 13Number of plates 0.002104957Heat exchanger area, m² Glass woolInsulation

33. Heater E-103Equipment Plate heat exchangerType MetalMaterial of construction 1.88E-02Qtotal (kW) 2000U(W/m² °C) 25Inlet temperture, process °C 96.8Oultlet, °C 150Inlet temperature, steam °C 70Outlet temperature, steam °C 1.465734889Number of transfer Unit 48.98566618LMTD, °C 2 Number of plates 0.000198958Heat exchanger area, m² Glass woolInsulation

34. Cooler E-102Equipment Plate heat exchangerType MetalMaterial of construction 3.20E-01Qtotal (kW) 2000U(W/m² °C) 917.39Inlet temperture, process °C 305Oultlet, °C 20Inlet temperature, water °C 70Outlet temperature, water °C 1.186550523Number of transfer Unit 516.1095025LMTD, °C 3.342291517Number of plates 0.000319042Heat exchanger area, m² Glass woolInsulation