AIR COOLER PROCESS DATA SHEET

Job number Unit Type Item Page

10 Process licensing 07-3116 333 2AC EC-33301 1/5
Client : MANGALORE REFINERY AND PETROCHEMICALS LIMITED Date By Check By Rev
MANGALORE - INDIA Apr. 08 SMA PLE 0
Unit : MRPL PHASE III REFINERY PROJECT - DIESEL HYDROTREATING UNIT
Service : REACTOR EFFLUENT AIR COOLER

CHARACTERISTICS (1)
Tube surface m² (5) Total developed surface m² (5)

Tube Side Inlet Outlet

Fluid name Reactor Effluent (HC+H2+H2S+NH3+H2O) (4)
Fluid quantity, total kg/h 514 604 (6)
Vapor kg/h 61 543 29 959
(2) Liquid kg/h 453 061 484 645
Steam kg/h
Water kg/h 8784 23 219
Non condensable 0.71 (7)
(mole fraction on total inlet fluid)
(3) Temperature °C 150 50

Density (PT) kg/m3

Viscosity cP
Vapor Molecular weight kg/kmol
Specific heat kcal/kg.°C See Enthalpy tables:
Thermal cond. kcal/h.m.°C ET EC-33301 Design Case 1 - SOR
Density (PT) kg/m3
Liquid Viscosity cP
Specific heat kcal/kg.°C
Thermal cond. kcal/h.m.°C
Latent heat kcal/kg
(3) Inlet pressure kg/cm² g 65.6
Pressure drop (allowable) kg/cm² 0.5 (14)
Fouling resistance m².°C.h/kcal 0.0004

Air Side
Temperature (in) °C 38 (10)
Altitude m (5)

Heat exchanged MMkcal/h 41.69 (8)

Transfer rate kcal/h.m².°C (5)
Mean temperature difference °C (5)

GENERAL DESIGN INFORMATION (9)

Note Design conditions
Design pressure kg/cm² g 74.3
Temperature °C 175
Ext. Pressure FV @ Ambient
MDMT °C 16
Note Other operating conditions
(11) Pressure kg/cm² g 65.6
Temperature °C 250
Pressure kg/cm² g
Temperature °C
Pressure kg/cm² g
Temperature °C

MATERIAL AND CORROSION ALLOWANCE

REF: MACHADO 4 17:14:23 AIO_1.4c 419688979.rtf 
 AIR COOLER PROCESS DATA SHEET
Job number Unit Type Item Page
10 Process licensing 07-3116 333 2AC EC-33301 2/5
Client : MANGALORE REFINERY AND PETROCHEMICALS LIMITED Date By Check By Rev
MANGALORE - INDIA Apr. 08 SMA PLE 0
Unit : MRPL PHASE III REFINERY PROJECT - DIESEL HYDROTREATING UNIT
Service : REACTOR EFFLUENT AIR COOLER

Note Materials Corr. Allow. mm

(12) Material induced by fluid KCS HIC Resistant 6
characteristics

CONNECTIONS NOMENCLATURE
Note
(13) (15) Line size (in/out) in 26”/24”
Connections rating (in/out) 600 RF/600 RF

NOTES
General note Design conditions result from normal operation conditions. DETAIL ENGINEERING
CONTRACTOR must check that results obtained with these conditions are adequate
for all operating conditions.

(1) Based on Design Case 1- SOR.

(2) Including free water
(3) Normal operating conditions
(4) Presence of ammonium salts (NH4HS). Maximum concentration in aqueous phase: 3.5%wt.
(5) Refer to associated API data sheet.
(6) Design flowrate = 566 064 kg/h corresponding to 110% overdesign of normal operating flowrate. Turndown is 34% of
operating flowrate.
(7) Non condensables: H2, H2S, NH3, C1and C2.
(8) Duty design = 45.86 MMkcal/h corresponding to 110% overdesign of max. operating duty.
(9) The capacity of the selected recycle gas compressor (GB-33301) shall be taken into consideration by the engineering to
determine the maximum hydraulic case.
(10) Air design temperature
(11) Depressurization temperature associated to the normal operating pressure. Engineering to check the mechanical design of
this exchanger to endure such conditions.
(12) Wet H2S service. Refer to Axens recommendations of IN-43.
(13) Diameter of the process lines connected to the air cooler.
(14) Maximum allowable pressure drop at design flowrate.
(15) Variable speed driver on 50% of the fans to be implemented.
(16) Maximum velocity in nozzles: 7 m/s (at design capacity).
(17) Motors to be connected to emergency power.

REF: MACHADO 4 17:14:23 AIO_1.4c 419688979.rtf 
 AIR COOLER PROCESS DATA SHEET
Job number Unit Type Item Page
10 Process licensing 07-3116 333 2AC EC-33301 3/5
Client : MANGALORE REFINERY AND PETROCHEMICALS LIMITED Date By Check By Rev
MANGALORE - INDIA Apr. 08 SMA PLE 0
Unit : MRPL PHASE III REFINERY PROJECT - DIESEL HYDROTREATING UNIT
Service : REACTOR EFFLUENT AIR COOLER

Technology:

 See attached piping manifold drawing

 Maximum allowable velocity in tubes: 6m/s (at design capacity).
Minimum allowable velocity in tubes: 3m/s to avoid salt deposit (at turndown capacity).
 No U tubes but return boxes recommended. Inlet distribution and outlet collection piping to symmetrically
installed. The number of bundles shall be equal to 2,4, 8, …2N.
 Dead ends not allowed in header box to avoid stagnant liquid and minimize corrosion.
 Design of headers boxes to allow access for tube cleaning.
 Split header boxes required (to allow for thermal expansion).
 Fans to be shut down in an even manner
 See inlet and outlet piping manifold drawing herebelow.
 No drain points in header boxes (to avoid corrosion with stagnant liquid).
 Reducers in horizontal plane to have flat bottom.
 Piping arrangement from water injection point up to the Separator inlet :
- dead legs to be avoided,
- long radius elbows to be used.

REF: MACHADO 4 17:14:23 AIO_1.4c 419688979.rtf 
 AIR COOLER PROCESS DATA SHEET
Job number Unit Type Item Page
10 Process licensing 07-3116 333 2AC EC-33301 4/5
Client : MANGALORE REFINERY AND PETROCHEMICALS LIMITED Date By Check By Rev
MANGALORE - INDIA Apr. 08 SMA PLE 0
Unit : MRPL PHASE III REFINERY PROJECT - DIESEL HYDROTREATING UNIT
Service : REACTOR EFFLUENT AIR COOLER

ET EC-33301 Design Case 1 - SOR Mass flowrate kg/h 514 604

Temperature °C 150 144 138 132 125 118 110 102

Pressure kg/cm² g 65.6 65.6 65.5 65.5 65.4 65.4 65.4 65.3

Enthalpy MMkcal/h 61.61 58.41 55.20 51.99 48.78 45.58 42.37 39.16

Spec. Enthalpy kcal/kg 119.7 113.5 107.3 101.0 94.8 88.6 82.3 76.1

Wt pc vapor % 11.96 11.21 10.51 9.86 9.26 8.71 8.21 7.75

Wt pc free water % 1.71 2.15 2.56 2.91 3.23 3.50 3.74 3.94

VAPOR
Density kg/m3 11.27 10.84 10.42 10.03 9.666 9.328 9.019 8.742

Viscosity cP 0.014 0.013 0.013 0.013 0.013 0.012 0.012 0.012

Thermal Cond. kcal/h.m.°C 0.152 0.153 0.154 0.155 0.155 0.155 0.155 0.155

Heat Capacity kcal/kg.°C 1.320 1.371 1.426 1.484 1.545 1.610 1.677 1.746

Spec. Enthalpy kcal/kg 418.2 410.4 402.1 393.4 384.3 374.7 364.7 354.3

Mol. Weight kg/kmol 6.20 5.89 5.59 5.30 5.03 4.78 4.54 4.31

LIQUID
Density kg/m3 730.4 735.1 740.0 745.0 750.1 755.4 760.9 766.4

Viscosity cP 0.29 0.30 0.31 0.32 0.33 0.35 0.37 0.39

Thermal Cond. kcal/h.m.°C 0.092 0.092 0.093 0.094 0.095 0.096 0.096 0.097

Heat Capacity kcal/kg.°C 0.588 0.585 0.582 0.578 0.574 0.570 0.564 0.559

Spec. Enthalpy kcal/kg 79.2 76.0 72.6 69.0 65.2 61.3 57.1 52.7

Surf. Tension dyn/cm 22.1 23.6 25.0 26.3 27.6 28.9 30.0 31.2

WATER
Density kg/m3 916.8 922.2 927.8 933.4 939.2 945.0 950.8 956.6

Viscosity cP 0.18 0.19 0.20 0.21 0.22 0.23 0.25 0.27

Thermal Cond. kcal/h.m.°C 0.592 0.592 0.592 0.592 0.591 0.590 0.588 0.585

Heat Capacity kcal/kg.°C 1.008 1.008 1.008 1.008 1.008 1.008 1.007 1.005

Spec. Enthalpy kcal/kg 151.8 145.8 139.6 133.1 126.2 119.0 111.5 103.7

Surf. Tension dyn/cm 48.9 50.2 51.5 52.9 54.3 55.8 57.3 58.8

Note : BUB=Bubble Point ; DEW=Dew Point ; WAT=Water Dew Point

REF: MACHADO 4 17:14:23 AIO_1.4c 419688979.rtf 
 AIR COOLER PROCESS DATA SHEET
Job number Unit Type Item Page
10 Process licensing 07-3116 333 2AC EC-33301 5/5
Client : MANGALORE REFINERY AND PETROCHEMICALS LIMITED Date By Check By Rev
MANGALORE - INDIA Apr. 08 SMA PLE 0
Unit : MRPL PHASE III REFINERY PROJECT - DIESEL HYDROTREATING UNIT
Service : REACTOR EFFLUENT AIR COOLER

ET EC-33301 Design Case 1 - SOR Mass flowrate kg/h 514 604

Temperature °C 94 86 77 69 59 50

Pressure kg/cm² g 65.3 65.3 65.2 65.2 65.1 65.1

Enthalpy MMkcal/h 35.96 32.75 29.54 26.33 23.13 19.92

Spec. Enthalpy kcal/kg 69.9 63.6 57.4 51.2 44.9 38.7

Wt pc vapor % 7.34 6.96 6.63 6.33 6.06 5.82

Wt pc free water % 4.10 4.23 4.33 4.41 4.47 4.51

VAPOR
Density kg/m3 8.497 8.286 8.109 7.965 7.854 7.774

Viscosity cP 0.011 0.011 0.011 0.011 0.010 0.010

Thermal Cond. kcal/h.m.°C 0.154 0.153 0.151 0.150 0.148 0.146

Heat Capacity kcal/kg.°C 1.816 1.886 1.957 2.027 2.095 2.162

Spec. Enthalpy kcal/kg 343.3 331.7 319.5 306.6 293.0 278.5

Mol. Weight kg/kmol 4.11 3.92 3.75 3.59 3.45 3.32

LIQUID
Density kg/m3 772.2 778.0 784.0 790.1 796.3 802.7

Viscosity cP 0.42 0.46 0.50 0.55 0.61 0.68

Thermal Cond. kcal/h.m.°C 0.098 0.099 0.100 0.101 0.102 0.103

Heat Capacity kcal/kg.°C 0.552 0.545 0.538 0.530 0.521 0.512

Spec. Enthalpy kcal/kg 48.2 43.6 38.8 33.9 28.9 23.9

Surf. Tension dyn/cm 32.3 33.4 34.5 35.6 36.6 37.7

WATER
Density kg/m3 962.3 967.9 973.4 978.6 983.5 988.0

Viscosity cP 0.30 0.33 0.36 0.41 0.47 0.54

Thermal Cond. kcal/h.m.°C 0.582 0.578 0.572 0.566 0.559 0.551

Heat Capacity kcal/kg.°C 1.002 1.000 0.998 0.996 0.995 0.994

Spec. Enthalpy kcal/kg 95.7 87.3 78.7 69.8 60.7 51.3

Surf. Tension dyn/cm 60.4 61.9 63.5 65.0 66.6 68.1

Note : BUB=Bubble Point ; DEW=Dew Point ; WAT=Water Dew Point

REF: MACHADO 4 17:14:23 AIO_1.4c 419688979.rtf