THIRUMALAI CHEMICALS LTD

0 3/1/2017 CD VTS/NV TREEE-1 CLC-XXX 1 OF 4 P142

SALT TANK SIZING AND HEAT LOAD
CALCULATION SPEC SHEET
REV NO DATE PRPD CHKD PRJ. UNIT NO.
NO. NO.
Volume of Reactor
Shell side UNIT Volume
Shell I.D m 7
Shell Height m 3.9
Tube Sheet Height m 0.15
Effective Cylindrical height m 3.6
Extended Portion I.D m 8.21
Extended Portion Height m 1.18
Volume of cylindrical shell m3 138.54
Volume of extended portion (2 Nos) m3 17.06
Total Volume of reactor m3 155.60
Tube side
No. of Tubes 25000
Tube O.D m 0.03
Tube Height m 3.60
Occupied volume of tubes in shell side m3 63.62
Salt volume in the Reactor m3 91.98
Volume of Electric Heater
I.D of Electric Heater m 1.32
Length of electric heater m 5.62
Length of non heating Zone m 0.80
Volume of cylindrical shell m3 7.74
Volume of one Dish m3 0.30
Volume of non heating Zone m3 1.10
Salt volume in Electric Heater m3 6.94
Volume of Salt bath cooler and Super Heater
Shell Side Salt bath coole Super Heater
Shell I.D of Equipment m 1.70 0.95
Length Shell m 8.12 6.79
Volume of cylindrical shell m3 18.42 4.81
Volume of Dish m3 0.64 0.22
Total Volume of shell side m3 19.06 5.04
Tube side Salt bath coole Super Heater
No. of Tubes 1108 1053
Tube O.D m 0.03 0.016
Tube Height m 5.50 6.00
Occupied volume of tubes in shell side m3 4.31 1.27
Salt volume in the Salt Bath Cooler m3 14.75 3.77
Volume of Salt Pump
I.D of Pump m 1.50
Length Shell m 4.50
Volume of cylindrical shell m3 7.95
Required Salt Volume of two pumps m3 15.90
 THIRUMALAI CHEMICALS LTD
0 3/1/2017 CD VTS/NV TREEE-1 CLC-XXX 1 OF 4 P142
SALT TANK SIZING AND HEAT LOAD
CALCULATION SHEET
REV NO DATE PRPD CHKD PRJ. SPEC NO. UNIT NO.
NO.
Calculat
Calculated Calculated Volume As ed Mass
BASIS UNIT Volume by Mass at per data at
TCL 150oC, kg sheet, m3 150oC,
kg
Required volume of salt in Reactor@350 oC m3 91.98 181759.1 108.00 213408
Required volume of salt in Super Heater@300 C o
m3 3.77 7443.6933 2.78 5493.28
Required volume of salt in Salt bath cooler@300 oC m3 14.75 29155.777 13.40 26478.4
Required volume of salt in Electrical Heater@450oC m3 6.94 13714.365 6.94 13714.4
Required volume of salt in Salt pump@350 oC m4 15.90 31426.922
DN 600 Salt valve m3 2.1 4095.8 2.1 3847.1
DN 500 Balance valve m3 0.6 1122.1 0.6 1033.0
Required Qty of salt for reactor system @ 150 oC m3 135.99 268718 133.59 263974
Considered 10%excess qty of salt for reactor system@150 oC m3 149.59 295590 146.95 290372
PROPERTIES OF SALT 150oC 200oC 300oC 350oC 450oC
Salt Density (ρv) at 150oC kg/m3 1976 1943 1856 1819 1755
Salt Density (ρv) at 20oC (Powder) kg/m3 1185
Salt Density (ρv) at 20oC (Fused Solid) kg/m3 2018
Reference for Salt
Latent Heat of Fusion kCal/kg 20 properties and Heat
Specific heat Cpv for Solid kCal/kg.oC 0.32 transfer Coefficient
Specific heat Cpv for Molten at 150oC kCal/kg.oC 0.373 estimation
Viscosity, μv at 150oC kg/m.s 0.017770
DEGGENDORFER
Conductivity, Kv kcal/h.moC 0.521
Temp in (tv1) 0
C 20
Melting Point of Salt 0
C 143
Temp out (tv2) 0
C 180
Volumetric Expansion Co-efficient 1/0C 3.629
PROPERTIES OF STEAM
Steam Pressure bar(g) 15.0
Fluid Density (ρc) kg/m3 8.08
Cpc kCal/kg.oC 0.719
Viscosity, μc kg/m.s 1.57639E-05
Latent heat of vapourization kcal/kg 461.74
Conductivity, Kc kcal/h.moC 0.0344
Temp in (Tc1) 0
C 201.45
ASSUMPTION
L/D ratio 2.22
Thickness of tank sheet mm 16 Assumed as per MA Salt Tank
Time for melting of Salt hr 28
Time for heating of moltan Salt hr 20
ID of the Limpet Coil mm 77.9 3 inch as per MA SALT tank
Schedule of the Limpet Coil Sch 40
Pitch of the Coil mm 170
Level gauge elevation from the bottom of tank mm 50 As per MA Salt day tank 50mm
Excess salt quantity considered only for Heat load Calc % 20%
RESULT SUMMARY
Inner dia of tank mm 4500
Length of tank T/T mm 10000
Required Working Volume of Salt day tank m3 149.91
Estimated Working Volume of Salt day tank m3 150.09
Total Volume of Salt day tank m3 182.90
Heat required for melting of salt at 20hr duration kCal/hr 355883
Avg.Steam Required for melting of salt at 20hr duration kg/hr 771
Heat required for heating of moltensalt kCal 245577
Heat required for melting of salt at 28hr duration kCal/hr 12279
Avg.Steam Required for melting of salt at 28hr duration kg/hr 532
Total steam Required for Heating of Salt(melting+heating) kg/hr 1303
Total Heat required for melting of salt(melting+heating) MMkCal 12
Estimated melting time of Salt hr 20.00
Estimated heating time of Moltan Salt hr 20.00
Total time required for heating of salt (Calculated) hr 40
 THIRUMALAI CHEMICALS LTD

0 3/1/2017 CD VTS/NV SALT TANK SIZING AND HEAT LOAD TREEE-1 CLC-XXX 2 OF 4 P142
CALCULATION SPEC SHEET UNIT
REV NO DATE PRPD CHKD PRJ.
NO. NO. NO.
SIZING OF SALT DAY TANK As per TCL AS per Data sheet

Required Volume of salt for reactor system m3 149.59 146.95

Calculated Tank ID mm 4409.02 4382.92
Assumed Tank ID mm 4500 4500
Calculated Tank Length mm 10000 10000
Volume of cylinder portion in day tank m3 159.04 159.04
2:1 Elliptical dish volume(2 Nos) m3 23.86 23.86
Total Volume of Tank m3 182.90 182.90
MINIMUM HOLDUP VOLUME
Level gauge height from the bottom of tank mm 50 50
R-h 2.200 2.200
arc Cos (R-h)/R radiant 0.211 0.211
Wet Area of cylinder during min.hold up m2 0.03 0.03
Wet volume of cylinder during min.hold up m3 0.32 0.32
2:1 Elliptical dish volume(2 Nos) m3 0.0088 0.0088

m3 0.32 0.32
Minimum holdup volume of salt up to Level gauge Nozzle

Consideration of 100% salt

Consideration of 110% salt qty.
WORKING VOLUME AS PER TCL ESTIMATION qty.
UNIT @150oC @350oC @150oC @350oC
Volume of Salt with minimum holdup in salt tank m3 149.91 163.04 136.31 148.32
Maximum Salt level in the tank % 76.0% 83.0% 70% 75.2%
Maximum Salt level (Working) of Salt in tank mm 3420 3735 3127.50 3384
R-h 1170 1485 877.5 1134
arc Cos (R-h)/R radiant 1.02 0.85 1.17 1.04
Wetted Area of cylinder m2 12.97 14.11 11.80 12.83
Liquid Volume in the Cylinder m3 129.69 141.11 117.98 128.30
2:1 Elliptical dish volume(2 Nos) m3 20.39 22.02 18.55 20.18
Total Working volume m3 150.09 163.14 136.54 148.48
Total mass of Salt kg 296569 269796

Consideration of 100% salt

WORKING VOLUME AS PER VENDOR DATA SHEET Consideration of 110% salt qty.
qty.
OF REACTOR, SBC, SUPER HEATER AND SALTPUMP UNIT @150oC @350oC @150oC @350oC
Volume of Salt with minimum holdup in salt tank m3 147.27 159.98 133.91 145.48
Maximum Salt level in the tank % 74.6% 81.3% 68.3% 73.8%
Maximum Salt level (Working) of Salt in tank mm 3357 3658.5 3073.5 3321
R-h 1107 1408.5 823.5 1071
arc Cos (R-h)/R radiant 1.06 0.89 1.20 1.07
Wetted Area of cylinder m2 12.72 13.85 11.57 12.58
Liquid Volume in the Cylinder m3 127.25 138.48 115.73 125.83
2:1 Elliptical dish volume(2 Nos) m3 20.02 21.67 18.18 19.80
Total Working volume m3 147.27 160.14 133.92 145.63
kg 291001 264623
 SALT DAY TANK SIZING AND HEAT
DOC NAME
LOAD CALCULATION
THIRUMALAI CHEMICALS LTD., DOC No.

SHEET No. 2 OF 4 DATE 2/22/2017

REV No. PRPD BY CHCKD BY APRVD BY

TREE-1
0 DC VN TSV

PLANT PA 142

SIZING OF SALT DAY TANK

Actual volume of salt m3 190.81
Calculated Tank ID mm 4797.67
Assumed Tank ID mm 5000
Calculated Tank Length mm 11000
Volume of cylinder portion in day tank m3 215.98
2:1 Elliptical dish volume(2 Nos) m3 32.72
Total Volume of Tank m3 248.71
MINIMUM HOLDUP VOLUME
Level gauge height from the bottom of tank mm 200
R-h 2.300
arc Cos (R-h)/R radiant 0.403
Wet Area of cylinder during min.hold up m2 0.26
Wet volume of cylinder during min.hold up m3 2.90
2:1 Elliptical dish volume(2 Nos) m3 0.1529

m3 3.05
Minimum holdup volume of salt up to Level gauge Nozzle
WORKING VOLUME
Required Working Volume of Salt m3 193.86 Actual+Holdup
Salt level in the tank % 75%
Maximum Salt level (Working) of Salt in tank mm 3750
R-h 1250
arc Cos (R-h)/R radiant 1.05
Wetted Area of cylinder m2 15.80
Liquid Volume in the Cylinder m3 173.76
2:1 Elliptical dish volume(2 Nos) m3 27.61
Total Working volume m3 201.37 397909 kg
 THIRUMALAI CHEMICALS LTD

0 3/1/2017 CD VTS/NV SALT TANK SIZING AND HEAT LOAD TREEE-1 CLC-XXX 3 OF 4 P142
REV NO DATE PRPD CHKD CALCULATION PRJ. SPEC NO. SHEET NO. UNIT NO.

Vessel Side Limpet Coil Side

Description Unit Qty Description Unit Qty
Volume m3 182.90 Diameter m 0.0779
Operating Volume m3 150.09 Pitch m 0.17
Mass of Salt in tank kg 296569 Fluid Density (ρc) kg/m3 8.08
Excess amount of salt considered kg 59314 Cpc kCal/kg.oC 0.67
Mass of Salt in tank with Excess of kg 355883 Viscosity, μc kg/m.s 1.576E-05
L/D ratio 2.2222222 Conductivity, Kc kcal/h.moC 0.03440
Diameter m 4.5 Temp in (Tc1) 0
C 201.45
Height m 10.0 Latent heat of Vaporization kCal/kg 461.74
Operating Height m 10.0 Mass Flow rate, Wc kg/hr 771
Shell Thickness
Fluid Density (ρv)Fusion Solid m 0.016 Volumetric Flow rate m3/hr 95.39
@20 Co
kg/m3 2018 No. of rotations 10
Cpv(Solid) kCal/kg.oC 0.32 Length of limpet m 314
Viscosity, μv kg/m.s 0.017770 Hydraulic mean dia m 0.048
Conductivity, Kv kcal/h.moC 0.521 Flow area m2 0.002
Temp in (tv1) C 0
28 Flow velocity m/s 14.897
Salt Melting temperature C 0
143 Reynolds No. 363370
Latent Heat Of Fusion kCal/kg 20 Friction factor 0.003
Heating time (θ) for melting of salt Hr 20 Prandtl No. 1.105
Energy Required for melting of salt Kcal 7117653.58 Nusselt no. 812.413
Rate of Energy kCal/hr 355883 Nusselt no. 0.002
Grashof number 4.8E+15 Heat Transfer coefficient, hc kcal/m2.h.C 587.261
Prandtl No. 39.2918 Fouling Resistance 0.0006
Nusselt No. 67857.66 Overall heat transfer coefficient kcal/m2.h.C 286.253
Heat Transfer Coefficient, hv kcal/m2.h.C 7856.41 Pressure Drop kg/cm2 0.777
Vessel Surface Area m2 141.37 Total Pressure Drop kg/cm2 0.805
Vessel MOC thermal conductivity kcal/h.moC 15.05 Heat Output kcal/hr 355883
Mv.Cpv(Liquid side) 113882.5 Heat Transfer area of limpet m2 46.968
Wc.Cpc (Coil side) 10328.0
ln(Tc1-tv1)/(Tc1-tv2) 1.133
k 3.675848
k/k-1 1.37
Calculated Heating time hr 17.2
 THIRUMALAI CHEMICALS LTD
0 3/1/2017 CD VTS/NV SALT TANK SIZING AND HEAT TREEE-1 CLC-XXX 4 OF 4 P142
REV NO DATE PRPD CHKD LOAD CALCULATION PRJ. SPEC NO. SHEET NO. UNIT NO.

Vessel Side Limpet Coil Side

Description Unit Qty Description Unit Qty
Volume m3 182.90 Diameter m 0.0779
Operating Volume m3 150.09 Pitch m 0.17
Mass of Salt in tank kg 296569 Fluid Density (ρc) kg/m3 8.08
Excess amount of salt considered kg 59314 Cpc kCal/kg.oC 0.67
Mass of Salt in tank with Excess of Viscosity, μc kg/m.s 1.576E-05
20% (Mv) kg 355883
L/D ratio 2.22222222 Conductivity, Kc kcal/h.moC 0.03440
Diameter m 4.5 Temp in (Tc1) 0
C 201.45
Height m 10.0 Latent heat of Vaporization kCal/kg 461.74
Operating Height m 10.0 Mass Flow rate, Wc kg/hr 532
Shell Thickness m 0.016 Volumetric Flow rate m3/hr 65.82
Fluid Density (ρv) Fusion Solid at
kg/m3 1976 No. of rotations 10
150oC
Cpv(molten salt) kCal/kg.oC 0.373 Length of limpet m 314
Viscosity, μv kg/m.s 0.017770 Hydraulic mean dia m 0.048
Conductivity, Kv kcal/h.moC 0.521 Flow area m2 0.002
Temp in (tv1) C
0
143 Flow velocity m/s 10.280
Temp out (tv2) C
0
180 Reynolds No. 250744
Assumed Heating time (θ) for salt Hr 20 Friction factor 0.004
Energy Required for melting of salt Kcal 4911536.851 Prandtl No. 1.105
Rate of Energy kCal/hr 245577 Nusselt no. 603.784
Grashof number 1.5E+15 Nusselt no. 0.002
Prandtl No. 45.7995 Heat Transfer coefficient, hc kcal/m2.h.C 436.452
Nusselt No. 48418.47 Fouling Resistance 0.0006
Heat Transfer Coefficient, hv kcal/m2.h.C 5605.78 Overall heat transfer coefficient kcal/m2.h.C 241.961
Vessel Surface Area m2 141.37 Pressure Drop kg/cm2 0.406
Vessel MOC thermal conductivity kcal/h.moC 15.05 Total Pressure Drop kg/cm2 0.421
Mv.Cpv(Liquid side) 132744.2 Heat Output kcal/hr 245577
Wc.Cpc (Coil side) 10637.0 Heat Transfer area of limpet m2 46.968
ln(Tc1-tv1)/(Tc1-tv2) 1.002
k 2.910680
k/k-1 1.52
Calculated Heating time hr 19.1
Total Amount of Salt 296569 kg/hr
Mass fraction of KmNO3 45%
Mass of KmNO3 133456 kg/hr
Mass fraction of NaNO3 55%
Mass fraction of NaNO3 163112.9 kg/hr