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    Cal For Mass Flow Rate

    Uploaded by

    Chibuikem Uwandi
    Calculation for mass flow rate in a heater treater

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    Cal For Mass Flow Rate

    Uploaded by

    Chibuikem Uwandi
    1 views3 pages
    Calculation for mass flow rate in a heater treater

    Original Title

    CAL FOR MASS FLOW RATE

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    © © All Rights Reserved

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    DOCX, PDF, TXT or read online from Scribd

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    Calculation for mass flow rate in a heater treater

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    1 views3 pages

    Cal For Mass Flow Rate

    Uploaded by

    Chibuikem Uwandi
    Calculation for mass flow rate in a heater treater

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 3

    HEATER-TREATER DESIGN

    Vessel Dimensions

    Capacity and Volume Calculations:

     Flow Rate: 5,000 BPD (Barrels Per Day) = 794,936.5 LPD (Litres Per Day)
     Flow Rate in Litres Per Minute (LPM):
    794,936.5 LPD = 552 LPM
     Retention Time: 25minutes (typical retention time to allow effective separation)
     Required Volume:
    Volume = Flow Rate X Retention Time
    552 LPM X 25 minutes = 13,800 litres = 13.8 m³
    Adding a safety margin, we will design the vessel for 16,000 litres (16 m³) of
    volume

    Vessel Geometry

     Length: 10 meters.
     Diameter: 2.5 meters.
     Vessel Volume:
    Volume of cylinder = Area X Length
    2
    A=πr
    Volume = π × (1.25 m) ² × 10 m ≈ 49 m³ ≈ 49,000 liters.
    The vessel provides a significant margin above the required volume, allowing for
    efficient separation.

    Material Selection

    Material: Carbon steel (e.g., ASTM A516 Grade 70) with an internal corrosion resistant lining
    (such as epoxy coating or cladding with stainless steel).
    Corrosion Allowance: 5 mm.

    Operating Conditions

    Operating Temperature: 82°C to 121°C.


    Operating Pressure: 3.4 to 5.2 bar.

    Mass flow rate

     Convert Barrels to Cubic Meters

    1 barrel (bbl) = 0.158987m³

    So, 5,000 BPD:


    5, 000 x 0.158987

    5, 000 BPD = 794.935 m³/day

     To Calculate Mass Flow Rate

    Using a density of 944kg/m for crude oil (https://www.hilarispublisher.com/)

    Mass flow rate per day = 794.935 m³/day × 944 kg/m

    Mass flow rate per day = 75048.64 kg/day

    Mass flow rate per hour = 750418.64 / 24

    = 31267.4433 kg/h

    Heat Requirement

    Heat Input Calculation:

    Heat Required (Q):


    Q = m × Cp × ΔT
    Where:
    m = mass flow rate.
    Cp = specific heat of crude oil ≈ 2.1 kJ/kg°C.
    ΔT = temperature increase (from 20°C to 100°C ≈ 80°C).
    Estimated heat input:

    Q = 31,267.4433 × 2.1 × 80

    Q = 5,252,930. 475 kJ/h.


    Heat Source: Burner with a capacity of at least 5,252,930. 475 kJ/h.

    Safety and Control Systems

     Pressure Relief Valves: Set to release at 10 bar.


     Temperature Sensors and Controllers: To monitor and adjust the heating process.
    Fire Extinguishers: Strategically placed near critical equipment in the production area.

    Corrosion Rate:

    For Nigerian crude oil, the corrosion rate can vary but is often estimated at 0.1 to 0.2 mm/year
    for carbon steel. Using corrosion rate of 0.2mm
    For 25 years:

    C= 0.2 × 25 = 5 mm

    Wall Thickness Calculation

    The wall thickness of the HeaterTreater is calculated based on the ASME Boiler and Pressure
    Vessel Code (Section VIII):

    Formula:

    t = (P × D) / (2 × S × E) + C
    Where:
    t = minimum required wall thickness (excluding corrosion allowance).
    P = internal pressure (assume 5.2 bar, i.e., 520 kPa).
    D = internal diameter of the vessel (2.5 m).
    S = maximum allowable stress of the material (138 MPa for carbon steel at
    operating temperatures).
    E = weld joint efficiency (1.0 for seamless or fully radiographed welds).
    C = corrosion allowance (5 mm).
    Calculation:

    t = (520 kPa × 2,500 mm) / (2 × 138,000 kPa × 1.0) + 5 mm

    t ≈ (1,300,000) / (276,000) + 5 mm ≈ 4.71 mm + 5 mm = 9.71 mm


    Final Thickness:
    Nominal Thickness: Rounding up to the nearest available standard thickness, the nominal
    thickness is selected as 10 mm.
    With Corrosion Allowance: The effective thickness would be 10 mm at the start of operations,
    with an expectation of losing up to 5 mm over 25 years due to corrosion.

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