PRODUCTION OF HYDROCHLORIC ACID VIA SALT-SULFURIC ACID PROCESS

GROUP 1

ALDA, GLADYS
MALICDEM, ROXETTE
MAYO, CHARLES BONN KIRBY
OMELIS, ABBY GUIL
PALANOG, ANGELICA MARIE
TOMPONG, JOHNNICA MAY

1
Nomenclature

T ℃ Process Fluid Operating Temperature

m kg
day Mass Flowrate
MW kg
kmol Molecular Weight
Qr m3
s Volumetric Flowrate
𝜌 kg
m3 Density
µ kg
m−s Viscosity

D m Diameter
v m
s Velocity

NRe - Reynold’s Number

f - Fanning friction factor

FL J Friction Loss due to Pipeline

kg
FF J Friction Loss due to Valves and Fittings
kg
FM J Friction Loss due to Metering Device
kg
Fc J Friction Loss due to Sudden Contraction
kg
Fe J Friction Loss due to Sudden Enlargement
kg
ΣF J Total Friction Losses
kg
∆KE J Kinetic Energy
kg
∆PE J Potential Energy
kg
∆P J Pressure Head
ρ kg
W Watts Work

2
P kPa Pressure

G kg Mass Velocity
m2−s
z m Height

L m Length

Z - Gas-Compressibility Factor

R J Gas Constant
mol K
Cp J Specific Heat
kg − K
Cv J Specific Volume
kg − K
γ - Ratio of Specific Heat to Specific Volume

β - Ratio of Diameter

C - Drag Coefficient

α - Correction Factor for Reynold’s Number

ε ft Coefficient of Roughness

∆H J Enthalpy
kg
y - Correction Factor for Metering Device

g m Gravitational Acceleration
s2
gc kg − m Gravitational Constant
N − s2
A m2 Area

3
 LIST OF FIGURES
Figure 12.1 Pump Selection for Water Storage Tank to Spray Tower Absorber & Gas
Absorber Pipe Line
Figure 12.2 Pump Selection for Water Storage Tank to Rotary Cooler & Cooler Pipe Line
Figure 12.3 Pump Selection for Rotary Cooler to Cooling Tower Pipe Line

4
 LIST OF TABLES

Table 12.1 Storage Tank to Rotary Kiln Pipe Dimensions for 1 inch SCH40

Table 12.2 Valves and Fittings in Sulfuric Acid to Rotary Kiln Pipe Line

Table 12.3 Off-gases from Rotary Kiln Pipe Dimensions for 9 inch SCH40

Water Storage Tank to Spray Tower Absorber & Gas Absorber Pipe
Table 12.4 Dimensions for 1 inch SCH40

Table 12.5 Water Storage Tank to Split Point Pipe Dimensions for 1 inch SCH40

Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas
Table 12.6 Absorber Pipe Line

Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas
Table 12.7 Absorber Pipe Line to Pump Suction

Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas
Table 12.8 Absorber Pipe Line from Pump Discharge

Table 12.9 Recycled Sulfuric Acid from Quencher Pipe Dimensions for 1/2 inch SCH40

Table 12.10 Valves and Fittings in Recycled Sulfuric Acid from Quencher Pipe Line

Table 12.11 Off-gases from Quencher Pipe Dimensions for 8 inch SCH40

Water Storage Tank to Rotary Cooler & Cooler Pipe Dimensions for
Table 12.12 1 ¼ inch SCH40

Water Storage Tank to Split Point Pipe Dimensions for 1 ¼ inch SCH40
Table 12.13

Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler
Table 12.14 Pipe Line

Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler Pipe
Table 12.15 Line to Pump Suction

Table 12.16 Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler Pipe
Line from Pump Discharge

5
Table 12.17 Rotary Cooler to Cooling Tower Pipe Dimensions for 1 ¼ inch SCH40

Table 12.18 Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line

Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line to

Table 12.19 Pump Suction

Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line from
Table 12.20 Pump Discharge

Table 12.21 Cooler to Cooling Tower Pipe Dimensions for ¾ inch SCH40

Table 12.22 Valves and Fittings in Cooler to Cooling Tower Pipe Line

Table 12.23 Off-gases to Gas Absorber Pipe Dimensions for 7 inch SCH40

Table 12.24 HCl from Gas Absorber Pipe Dimensions for 1 inch SCH40

Table 12.25 Valves and Fittings in HCl from Gas Absorber Pipe Line

Table 12.26 Off-gases from Gas Absorber Pipe Dimensions for 3/8 inch SCH40

Table 12.27 Water to Scrubber Pipe Dimensions for ¼ inch SCH40

Table 12.28 Valves and Fittings in Water to Scrubber Pipe Line

Table 12.29 HCl from Scrubber Pipe Dimensions for 1 inch SCH40

Table 12.30 Off-gases from Scrubber Pipe Dimensions for 1/8 inch SCH40

6
 Sulfuric Acid Storage Tank to Rotary Kiln
Mass flow = 34,554.2800 kg/d
Density = 1,826.1 kg/m3
Viscosity = 0.0201 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 34,𝟓𝟓𝟒.𝟐𝟖 ⁄d 3
Qr = = kg = 2.19x10−4 m ⁄s
density (1,826.1 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 2.19E−04 m ⁄s
Area = = = 0.0002 m2
velocity 1 m⁄s

4xArea 4(1.46 E−03 m2 )

Diameter = √ =√ = 0.0167 m = 0.6574 in
π π

Nominal Pipe size is 1 inch SCH40

Table 12.1 Storage Tank to Rotary Kiln Pipe Dimensions for 1 inch SCH40
in m
ID 1.049 0.0266
OD 1.315 0.0334
Thickness 0.266 0.0068
**Perry’s Chemical Engineers’ Handbook 8th Edition

π
Actual Area = 4 x(0.0266 m)2 = 5.58x10−4 m2
3
2.19E−04 m ⁄s
Actual Velocity = = 0.3928 m⁄s
5.58𝐸−04 m2

Computing for Reynold’s Number:

m kg
Dvρ (0.0266 m)(0.3928 ⁄s) (1,826.1 m3 )
NRe = =
μ kg
0.0201 m − s

7
 NRe = 950.81 (LAMINAR)
16
𝑓=
NRe
16
𝑓=
950.81
𝑓 = 0.0168

Calculating frictional line loss per meter:

FL 2fv 2 2(0.0168)(0.3928 m⁄s)2

= = = 1.95x10−1 N⁄kg = 0.3559 kPa⁄m
L gcD 1(0.0266 m)

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 38.17 m
J
FL = (0.3559 N⁄kg) (38.17 m) = 7.44 ⁄kg

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.2 Valves and Fittings in Sulfuric Acid to Rotary Kiln Pipe Line
K Quantity kr
90 elbows 0.93 8 7.44
(short)
Globe valve 12 1 12
Check valve 4.5 1 4.5
Tee (used as ell) 1 2 2
TOTAL 25.94
**Perry’s Chemical Engineers’ Handbook 8th Edition

kf v2 (0.3928 m⁄s)2 J
FF = = 25.94 ( ) = 2.00
2gc kg − m kg
2 (1 2 )
N− s

8
FRICTION LOSS DUE TO METERING DEVICE
Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.67

Solving for throat velocity:

𝜋
Throat Area = 4 (0.2 x 0.0266 m)2 = 2.46x10−5 m2
3
2.19E−05 m ⁄s
Velocity, v2 = = 8.91 m⁄s
2.46E−05 m2

Then:

2x1x∆H
8.91 m⁄s = 0.67(0.1)√
1 − (0.2)4

J
∆H = 106.39 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (106.39 ⁄kg) = 101.70 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,520 m3
J
∆H 106.39 ⁄kg
Hm = ρ g = = 1.46 m = 57.67 inHg
( ρm )x g kg⁄ m
13,520 m3 ) x 9.81 ⁄s2
c
(
kg kg − m
1,826.1 ⁄m3 (1 )
N − s2

9
FRICTION LOSS DUE TO SUDDEN CONTRACTION
A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.3928 m⁄s)2 J
Fc = 0.5 ( ) = 3.86x10−2
kg − m kg
2 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT

α = 0.5 for laminar flow (Geankoplis, 1995)
v2
Fe =
2gcα

(0.3928 m⁄s)2 J
Fe = = 1.54x10−1
kg − m kg
2 (1 2 ) (0.5)
N− s

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 7.44 + 2.00 + 101.70 + 3.86E − 02 + 1.54E − 01 ) kg

J
ΣF = 111.33 kg

Kinetic Energy:
v2 = 0.3928 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc
(0.3928 m⁄s)2 − (0)2 J
∆KE = = 0.0771
kg − m kg
2 (1 2 )
N− s

10
Potential Energy:
∆z = −12m
∆zg
∆PE =
gc
−12m J
∆PE = = −117.72
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,826.1 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.0771 J kg day 1 hr
Ws = ( − 117.72 + 0 + 111.33) x (34,554.28 )( )( )
0.5 kg day 24 hrs 3600 s
𝐖𝐬 = −𝟐. 𝟒𝟗 𝐖

11
 Off-gases from Rotary Kiln

T=600 °C
Mass flow 28,691.69 kg/d
Density 0.6562 kg/m3
Viscosity 3.20 x10−5 kg/m-s
(Cp) 1063.32 J/kg-K
(Cv) 886.30 J/kg-K

To solve for the volumetric flow of the fluid:

mass flow rate

qf =
density
kg day 1h
28,691.69 ( )( )
d 24 hrs 3600 s
Qf =
kg
0.6562 3
m
m3
Qf = 0.5061
s
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005),
the velocity of the vapor inside the pipe should not exceed 15 to 30 m/s.

Setting the fluid velocity to 15 m/s to compute for the area of the pipe:

volumetric flow
Area =
fluid velocity
m3
0.5061
Area = s
m
15 s

Area = 0.0337 m2

12
Computing for the diameter of the pipe:
πD2
Area =
4

4(Area) 4(0.0337m2 )
Diameter = √ = √
π π
3.28 ft 12 in
Diameter = 0.2073 m ( )( )
1m 1 ft
Diameter = 8.1598 in

Nominal Pipe size is 9 inch SCH 40

Table 12.3 Off-gases from Rotary Kiln Pipe Dimensions for 9 inch SCH40
in m
ID 8.941 0.2271014
OD 9.625 0.244475
Thickness 0.684 0.0173736
**Perry’s Chemical Engineers’ Handbook 8th Edition

Computing the area of the standard pipe to be used:

πD2
Areastd =
4
π(0.2271 m)2
Areastd =
4
Areastd = 0.0405 m2

Thus, the fluid velocity inside the standard pipe:

m3
0.5061 s
Actual velocity =
0.0405 m2

m
Actual Velocity = 12.49
s
m kg
Dvρ (0.2271 m) (13.49 s ) (0.6562 m3 )
NRe = =
μ kg
3.23x10−5 m − s

NRe = 58,270.43 (TURBULENT)

13
Since Reynold’s number is >4000, the flow is TURBULENT:
1 ε 7 0.9
= −4 log [0.27 +( ) ]
√f D NRe

For a commercial steel pipe relative roughnessε = 0.00015 ft.

1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.2271 m) 58270.43

f = 0.0052
The mass, velocity is given as:
kg day 1h
𝑚̇ 28,691.69 ( )( ) 𝑘𝑔
d 24 hrs 3600 s
𝐺= = 2
= 8.20 2
𝐴 0.0405𝑚 𝑚 𝑠

Since the temperature is very high (873.15K), it can be assumed that the compressibility factor
approaches 1.0.
Z= 1.0
L = 16 m
𝑔
𝑀𝑊𝑎𝑣𝑒 = ((0.0221/18) + (0.5847/36.45) + (0.3932/98))−1 = 46.99 ⁄𝑚𝑜𝑙

4ZRTfLG 2
P2 = √P1 2 −
gcDMW

J kg 2
4(1) (8.314 ) (873.15 K)(0.0052)(28.5 m) (8.20 2 )
mol − K m s
P2 = √P1 2 −
kg − m g kg
(1 ) (0.2271 m) (46.99 )( )
N − s2 mol 1000 g

P2 = 101,190.26 Pa
Calculating the pressure drop for the purpose of checking the validity of the assumption, such
that, the pressure per 100m of pipe should not exceed 11 kPa

14
 4fLG2 G2 P2
∆𝑃 = + + ln ( )
2Dρ ρ P1
kg 2 kg 2
4(0.0052)(100m) (8.20 ) (8.20 ) 101,190.26
m2 s m2 s
∆𝑃 = + + ln ( )
kg kg 101,325
2(0.2271 m) (0.6562 3 ) 0.6562 3
m m

∆P = 0.5746 kPa

Since 0.5746 kPa is less than 11kPa, the assumption is VALID

POWER REQUIREMENT FOR COMPRESSOR

The power requirement of a compressor can be computed using the formula below:
𝛾−1
𝛾𝑅𝑇 𝑃2 𝛾
𝑊= [( ) − 1]
𝛾 − 1 𝑃1

𝐶𝑝
γ=
𝐶𝑣
Computing for the work of the compressor:
1063.32
γ= = 1.20
886.295

J 1.2−1
(1.2) (8.314 ) 873.15K 101,190.26 1.2
W= mol K [( ) − 1]
1.2 − 1 101,325

J
W = −9.66
mol

J mol 1000 kg day 1h

W = −4.23 ( )( ) (28691.69 ) ( )( )
mol 46.99 g kg d 24 hrs 3600 s

𝐖 = −𝟔𝟖. 𝟐𝟔 𝐖

15
 Branching 1
Water Storage Tank to Spray Tower Absorber (1) & Gas Absorber (2)
Water to Spray Tower 6066.1 kg/d
Absorber
Water to Gas Ab 22107.6 kg/d
Density 999.079 kg/m3
Viscosity 0.00115 kg/m-s

Combined Mass flowrate:

𝑘𝑔⁄
𝑚 𝑇 = 6,066.1 + 22,107.6 = 27173.7 𝑑
Solving for volumetric flowrate:
kg
mass flow rate 27173.7 ⁄d 3
Qr = = kg = 3.15x10−4 m ⁄s
density (999.079 ⁄ 3 )(86,400 s⁄d)
m

Calculating for the relationship between v1 and v2 using 1-inch schedule 40 as diameter

Table 12.4 Water Storage Tank to Spray Tower Absorber & Gas Absorber Pipe Dimensions for
1 inch SCH40
in m
ID 1.049 0.0266446
OD 1.315 0.033401
Thickness 0.266 0.0067564
**Perry’s Chemical Engineers’ Handbook 8th Edition

L1 = 3.65 m
L2 = 18.10 m

𝐿2 18.10
𝑣1 = 𝑣2 𝑥√ = 𝑣2 𝑥 √ = 2.23𝑣2
𝐿1 3.65

Solving for Individual velocities:

𝜋𝐷 2 𝜋(0.026646)2
Area, A = = = 5.58𝐸 − 4 𝑚2
4 4
3
Qr = 𝐴(𝑣1 + 𝑣2 ) = (5.58x10−4 )(2.12𝑣2 + 𝑣2 ) = 3.15x10−4 m ⁄s
v2 = 0.1750 𝑚⁄𝑠

16
v1 = 2.12(0.1750) = 0.3896 𝑚⁄𝑠
Computing for Reynold’s Number:

m kg
Dv1 ρ (0.02664 m)(0.3896 ⁄s) (999.079 m3 )
NRe1 = =
μ kg
0.00115 m − s

NRe = 9,018.84 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 +( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.02664 m) 9,018.84

𝑓1 = 0.0087

m kg
Dv2 ρ (0.02664 m)(0.1750 ⁄s) (999.079 m3 )
NRe2 = =
μ kg
0.00115 m − s

NRe = 4,050.03 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.02664 m) 4,050.03

𝑓2 = 0.0106

Calculating frictional line loss per meter:

FL 2f1 v1 2 2(0.0087)(0.3896 m⁄s)2
= = = 0.0986 N⁄kg = 0.0985 kPa⁄m
L1 gcD 1(0.02664 m)
FL 2f2 v2 2 2(0.0105)(0.1750 m⁄s)2
= = = 0.0244 N⁄kg = 0.00243 kPa⁄m
L2 gcD 1(0.02664 m)
Before split point
Setting v =1.5 𝑚⁄𝑠
3.15E − 04
𝐴= = 2.10x10−4 𝑚2
1.5

17
Nominal pipe size should be 1-inch SCH 40
Table 12.5 Water Storage Tank to Split Point Pipe Dimensions for 1 inch SCH40
in m
ID 1.049 0.0266446
OD 1.315 0.033401
Thickness 0.266 0.0067564
**Perry’s Chemical Engineers’ Handbook 8th Edition

L = 40.15 m

𝜋𝐷 2 𝜋(0.026646)2
Actual Area = = = 5.58x10−4 𝑚2
4 4
3.15𝐸−04
Actual velocity = 5.58𝐸−04 = 0.5646 𝑚⁄𝑠

m kg
Dvρ (0.02664 m)(0.5646 ⁄s) (999.079 m3 )
NRe = =
μ kg
0.00115 m − s

NRe = 13,068.87 (TURBULENT)

1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.02664 m) 13,068.87

𝑓 = 0.0080
𝐹𝐿 2f𝑣 2 2(0.0080)(0.5646 m⁄s)2
= = = 0.1913 N⁄kg = 0.1911 kPa⁄m
𝐿 gcD 1(0.02664 m)
Getting the pressure drop per meter of pipe:
∆𝑃 𝐹𝐿 𝐹𝐿 𝐹𝐿
= + + = 0.0985 + 0.0243 + 0.1911
𝑚 𝐿1 𝐿2 𝐿
∆𝑃
= 0.3140 kPa⁄m
𝑚
Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe pipe sized are VALID

FRICTION LOSS DUE TO PIPE LINE

FL = (0.0985 N⁄kg) (3.65 m) + (0.0243 N⁄kg) (18.10 m) + (0.1913 N⁄kg) (40.15 m) = 8.48 J⁄kg

18
 FL = 8.47 𝑘𝑃𝑎

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.6 Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas Absorber
Pipe Line
BEFORE SPLIT TO SPRAY TOWER TO GAS ABSORBER
POINT ABSORBER
K Quantity kr K Quantity kr K Quantity kr
90 0.45 7 3.15 0.45 3 1.35 0.45 4 1.8
elbows
Globe 6 1 6 6 0 0 6 0 0
valve
Tee 1 3 3 1 0 0 1 0 0
(ell)
check 2 1 2 2 0 0 2 0 0
valve
TOTAL 14.15 TOTAL 1.35 TOTAL 1.8
**Perry’s Chemical Engineers’ Handbook 8th Edition

kf v2
FF = ∑
2gc

(0.5646 m⁄s)2 (0.3896 m⁄s)2 (0.1750 m⁄s)2

= 14.15 ( ) + 1.35 ( ) + 1.8 ( )
kg − m kg − m kg − m
2 (1 ) 2 (1 ) 2 (1 )
N − s2 N − s2 N − s2
𝐽
FF = 2.3852 ⁄𝑘𝑔 = 2.3830 𝑘𝑃𝑎

FRICTION LOSS DUE TO CONTRACTION

0.5(0.5644 m⁄s)2 𝐽
𝐹𝐶 = = 0.0797 ⁄𝑘𝑔 = 0.0796 𝑘𝑃𝑎
2

FRICTION LOSS DUE TO EXPANSION

w / α = 1 (TURBULENT FOR BOTH FLOW 1 AND 2)

(0.3896 m⁄s)2 +(0.1750 m⁄s)2 𝐽

𝐹𝐸 = = 0.0912 ⁄𝑘𝑔
2𝑥1

FRICTION LOSS DUE TO METERING DEVICE

Orifice meter

19
 For flow 1

2g c ∆H
v1 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.02664 m = 0.0053 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.0053 m)2 = 2.23x10−5 m2
kg⁄
6,066.1
Velocity, v2 = d
= 3.15 m⁄s
kg
(2.23x10−5 m2 )(999.079 ⁄ 3 )(86400 𝑠⁄𝑑)
𝑚

Then:

2x1x∆H
3.15 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 13.32 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) ( 13.32 ⁄kg) = 12.79 J/kg

For flow 2

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2

20
 ∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.02664 m = 0.0053 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.0053 m)2 = 2.23x10−5 m2
kg⁄
22,107.6
Velocity, v2 = d
= 10.96 m⁄s
kg
(2.23x10−5 m2 )(999.079 ⁄ 3 )(86400 𝑠⁄𝑑)
𝑚

Then:

2x1x∆H
10.96 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 161.26 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (161.26 ⁄kg) = 154.81 J/kg

𝐹𝑀𝑇 = 12.79 + 154.81 = 167.60 J/kg

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 8.48 + 2.36 + 167.60 + 0.0797 + 0.0912 ) kg

J
ΣF = 178.63 kg

21
Kinetic Energy:
v2 2 − v1 2
∆KE = ∑
2gc
(0.5646 m⁄s)2 − (0)2 (0.3896 m⁄s)2 − (0.5646)2 (0.1750 m⁄s)2 − (0.5646)2 J
+ + = −0.0682
kg − m kg − m kg − m kg
2 (1 ) 2 (1 ) 2 (1 )
N − s2 N − s2 N − s2

Potential Energy:
∆z1 = 1.95 m
∆z2 = 1.5m
∆z3 = 9.85m

∆zg
∆PE = ∑
gc
(1.95 + 1.5 + 9.85) x 9.81 𝑚⁄ 2
∆PE = 𝑠 = 130.473 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
999.079 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
−0.0682 J
Ws = ( + 130.47 + 0 + 178.63)
1.0 kg
J
𝐖𝐬 = 𝟑𝟎𝟗. 𝟎𝟒
kg

22
 kg day 1 hr
W = 3𝟎𝟗. 𝟎𝟒 x (27,173.7 )( )( ) = 97.20 𝑊
day 24 hrs 3600 s

Since the value is positive, a pump is required (Sinnot, 2005)

Line to Pump Suction

Table 12.7 Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas Absorber
Pipe Line to Pump Suction
Quantity Equivalent Length Diameter (m) Length (m)
90 1 35 0.026645 0.932575
Elbow
Check 1 9 0.026645 0.239805
valve
Globe 1 300 0.026645 7.9935
Valve
Tee 1 57 0.026645 1.518765
TOTAL 10.6847
**Perry’s Chemical Engineers’ Handbook 8th Edition

h = 8.26 m
Line Length to Pump = 7.13 m
Equivalent Line Length to Suction Pump = 7.13 10.6847 = 17.81 m
𝐹𝐿
𝐿𝑖𝑛𝑒 𝐿𝑜𝑠𝑠 = = 0.3140 𝑥 17.81 = 5.5930 𝑘𝑃𝑎
𝐿
999.079𝑥9.81𝑥8.26
𝑆𝑡𝑎𝑡𝑖𝑐 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = = 80.96 𝑘𝑃𝑎
1000
𝑆𝑢𝑐𝑡𝑖𝑜𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 101.325 − 5.5930 + 80.96 = 176.6880 𝑘𝑃𝑎
Line from Pump discharge

23
Table 12.8 Valves and Fittings in Water Storage Tank to Spray Tower Absorber & Gas Absorber
Pipe Line from Pump Discharge
Quantity Equivalent Diameter (m) Length (m)
Length
90 Elbow 13 35 0.026645 12.123
Globe 0 300 0.026645 0
Valve
Tee 2 57 0.026645 3.0375
TOTAL 15.1610
**Perry’s Chemical Engineers’ Handbook 8th Edition

h = 29 m
Line Length to Pump = 54.77 m
Equivalent Line Length to Suction Pump = 54.77 + 15.16 = 69.93 m
𝐹𝐿
𝐿𝑖𝑛𝑒 𝐿𝑜𝑠𝑠 = = 0.3140 𝑥 69.93 = 13.37 𝑘𝑃𝑎
𝐿
999.079𝑥9.81𝑥29
𝑆𝑡𝑎𝑡𝑖𝑐 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = = 284.23 𝑘𝑃𝑎
1000
𝐷𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 101.32 + 13.37 + 284.23 = 398.92 𝑘𝑃𝑎

PUMP SELECTION

Vapor pressure = 1.7065 kPa

𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 398.92 − 176.69 = 222.23 𝑘𝑃𝑎
(176.69 − 1.7065)(1000)
𝑁𝑃𝑆𝐻 = = 17.85 𝑚
(999.079)(9.81)
𝑆ℎ𝑢𝑡 − 𝑜𝑓𝑓 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 1.25(𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒) = 1.25(222.23) = 277.79 𝑘𝑃𝑎
222.23𝑥1000
𝑃𝑢𝑚𝑝 𝐻𝑒𝑎𝑑 = = 22.67 𝑚
999.079𝑥9.81
27.20 3
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = = 1.1 𝑚 ⁄ℎ𝑟
24
Using the graph, the pump needed to be used is a single-stage centrifugal pump.
Efficiency = 75%

24
 100.68
Actual Work = = 134.24 𝑊 = 0.18 ℎ𝑝
0.75

**Coulson & Richardson’s – Chemical Engineering Volume 6

Figure 12.1 Pump Selection for Water Storage Tank to Spray Tower Absorber & Gas Absorber
Pipe Line

25
 Recycled Sulfuric Acid from Quencher

T = 200 °C

Mass flow = 11,282.65 kg/d

Density = 1,528.19 kg/m3
Viscosity = 2.26 x10−4 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 11,282.65 ⁄d 3
Qr = = kg = 8.55x10−5 m ⁄s
density (1,528.19 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−5 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 8.55E−05 m ⁄s
Area = = = 8.55x10−5 m2
velocity 1 m⁄s

4xArea 4(8.55x10−5 m2 )
Diameter = √ =√ = 0.0104 m = 0.4107 in
π π

Nominal Pipe size is 1/2 inch SCH40

in m
ID 0.622 0.01580
OD 0.84 0.02134
Thickness 0.218 0.00554
Table 12.9 Recycled Sulfuric Acid from Quencher Pipe Dimensions for 1/2 inch SCH40

π
Actual Area = 4 x(0.01580 m)2 = 1.96x10−4 m2
3
8.55x10−5 m ⁄s
Actual Velocity = = 0.4359 m⁄s
1.96x10−4 m2

26
Computing for Reynold’s Number:

m kg
Dvρ (0.01580 m)(0.4359 ⁄s) (1,528.19 m3 )
NRe = =
μ kg
2.26x10−4 m − s

NRe = 46,666.38 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 +( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.01580 m) 46,666.38

𝑓 = 0.00722
Calculating frictional line loss per meter:

FL 2fv 2 2(0.00722)(0.4359 m⁄s)2

= = = 0.1737 N⁄kg = 0.2654 kPa⁄m
L gcD 1(0.01580 m)

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 32.38 m
J
FL = (0.1737 N⁄kg) (32.38 m) = 5.6239 ⁄kg

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.10 Valves and Fittings in Recycled Sulfuric Acid from Quencher Pipe Line
K Quantity kr
90 elbows 0.45 9 4.05
(short)
Tee 1 2 2
TOTAL 6.05
**Perry’s Chemical Engineers’ Handbook 8th Edition

kf v2 (0.4359 m⁄s)2 J
FF = = 6.05 ( ) = 0.5748
2gc kg − m kg
2 (1 )
N − s2
27
FRICTION LOSS DUE TO METERING DEVICE
Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.01580 m = 0.0079 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.0079 m)2 = 4.90x10−5 m2
3
8.55Ex10−5 m ⁄s
Velocity, v2 = = 1.74 m⁄s
4.90 x5 m2

Then:

2x1x∆H
1.74 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 3.8297 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (3.8297 ⁄kg) = 2.8723 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 12,855.75 m3
J
∆H 3.8297 ⁄kg
Hm = ρ g = = 0.0464 m = 1.8270 inHg
( ρm )x g kg⁄ m
12,855.75 m3 ) x 9.81 ⁄s2
c
(
kg kg − m
1,528.19 ⁄m3 (1 )
N − s2

28
FRICTION LOSS DUE TO SUDDEN CONTRACTION

A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.4359 m⁄s)2 J
Fc = 0.5 ( ) = 0.0475
kg − m kg
2 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT

α = 1.0 for turbulent flow (Geankoplis, 1995)
v2
Fe =
2gcα
(0.4359 m⁄s)2 J
Fe = = 0.095
kg − m kg
2 (1 ) (1.0)
N − s2
MECHANICAL ENERGY BALANCE
Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 5.6239 + 0.5748 + 2.8723 + 0.0475 + 0.095 ) kg

J
ΣF = 9.2134 kg

Kinetic Energy:
v2 = 0.4359 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc
(0.4359 m⁄s)2 J
∆KE = = 0.095
kg − m kg
2 (1 )
N − s2

29
Potential Energy:
∆z = 3.5 m
∆zg
∆PE =
gc
3.5m x 9.81 𝑚⁄ 2
∆PE = 𝑠 = 34.335 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,528.19 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.095 J kg day 1 hr
Ws = ( 34.335 + 0 + 9.2134) x (11,282.65 )( )( )
1.0 kg day 24 hrs 3600 s
𝐖𝐬 = 𝟓. 𝟕 𝐖

Since pump requirement is very small, no need for a pump.

30
 Off-gases from Quencher

Feed at T=200°C
Mass flow 23,475.14 kg/d
Density 0.6082 kg/m3
Viscosity 0.000026 kg/m-s
(Cp) 1114.3 J/kg-K
(Cv) 824.893 J/kg-K

To solve for the volumetric flow of the fluid:

mass flow rate

qf =
density
kg day 1h
23,475.15 ( )( )
d 24 hrs 3600 s
Qf =
kg
0.6082 3
m
m3
Qf = 0.4467
s
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005),
the velocity of the vapor inside the pipe should not exceed 15 to 30 m/s.

Setting the fluid velocity to 15 m/s to compute for the area of the pipe:

volumetric flow
Area =
fluid velocity
m3
0.4467
Area = s
m
15 s

Area = 0.0298 m2

31
Computing for the diameter of the pipe:
πD2
Area =
4

4(Area) 4(0.02852m2 )
Diameter = √ = √
π π
3.28 ft 12 in
Diameter = 0.1947 m ( )( )
1m 1 ft
Diameter = 7.6667 in

Nominal Pipe size is 8 inch SCH 40

Table 12.11 Off-gases from Quencher Pipe Dimensions for 8 inch SCH40
in m
ID 7.981 0.2027
OD 8.625 0.2191
Thickness 0.644 0.0164
**Perry’s Handbook for Chemical Engineers’ 8th Edition

Computing the area of the standard pipe to be used:

πD2
Areastd =
4
π(0.2027 m)2
Areastd =
4
Areastd = 0.03228 m2

Thus, the fluid velocity inside the standard pipe:

m3
0.4467 s
Actual elocity =
0.03228 m2

m
Actual Velocity = 13.8413
s
m kg
Dvρ (0.2027 m) (13.8413 s ) (0.6082 m3 )
NRe = =
μ kg
0.000026 m − s

32
 NRe = 65635.71

1 ε 7 0.9
= −4 log [0.27 +( ) ]
√f D NRe

For a commercial steel pipe relative roughnessε = 0.00015 ft.

1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.2027 m) 65635.71

f = 0.0052
The mass, velocity is given as:
kg day 1h
𝑚̇ 23,475.14 ( )( ) 𝑘𝑔
d 24 hrs 3600 s
𝐺= = 2 = 8.4183 2
𝐴 𝜋(0.2027 m) 𝑚 𝑠
4
Solving for P2:
Z= 0.998 ≈ 1.0 (Using Van der Waals Equation )
L = 22.62 m

4ZRTfLG 2
P2 = √P1 2 −
gcDMW

J kg 2
4(1) (8.314 ) (473.15 K)(0.0052)(22.62 m) (8.4183 2 )
mol − K m s
P2 = √P1 2 −
kg − m g kg
(1 ) (0.2027 m) (20.65 )( )
N − s2 mol 1000 g

P2 = 101,172.23Pa
Calculating the pressure drop for the purpose of checking the validity of the assumption, such
that, the pressure per 100m of pipe should not exceed 11 kPa

4fLG2 G2 P2
∆𝑃 = + + ln ( )
2Dρ ρ P1

33
 kg 2 kg 2
4(0.0052)(100m) (8.4183 ) (8.4183 ) 101,172.23
m2 s m2 s
∆𝑃 = + + ln ( )
kg kg 101,325
2(0.2027 m) (0.6082 3 ) 0.6082 3
m m

∆P = 707.96 Pa

Since 0.708 kPa is less than 11kPa, the assumption is VALID

POWER REQUIREMENT FOR COMPRESSOR

The power requirement of a compressor can be computed using the formula below:
𝛾−1
𝛾𝑅𝑇 𝑃2 𝛾
𝑊= [( ) − 1]
𝛾 − 1 𝑃1

𝐶𝑝
γ=
𝐶𝑣
Computing for the work of the compressor:
1114.3
γ= = 1.351
824.893

J 1.351−1
(1.351) (8.314 ) (473.15 K) 101,172.23 1.351
W= mol K [( ) − 1]
1.351 − 1 101,325

J
W = −5.93
mol

J mol 1000 kg day 1h

W = −5.93 ( )( ) (23,475.14 ) ( )( )
mol 20.65 g kg d 24 hrs 3600 s

𝐖 = −𝟕𝟖. 𝟎𝟖𝐖

Branching 2
34
 Water Storage Tank to Rotary Cooler (1) & Cooler(2)
Water to Spray Tower Absorber 48,073.59 kg/d
Water to Gas Ab 14,393.98 kg/d
Density 999.079 kg/m3
Viscosity 0.00115 kg/m-s

Combined Mass flowrate:

𝑘𝑔⁄
𝑚 𝑇 = 48,073.59 + 14,393.98 = 62,467.57 𝑑
Solving for volumetric flowrate:
kg
mass flow rate 62,467.57 ⁄d 3
Qr = = kg = 7.24x10−4 m ⁄s
density (999.079 ⁄ 3 )(86,400 s⁄d)
m

Calculating for the relationship between v1 and v2 using 1 1/4-inch schedule 40 as diameter

Table 12.12 Water Storage Tank to Rotary Cooler & Cooler Pipe Dimensions for 1 ¼ inch
SCH40
in m
ID 1.38 0.035052
OD 1.66 0.042164
**Perry’s Chemical Engineers’ Handbook 8th Edition

L1 = 33.5 m
L2 = 34.66 m

𝐿2 33.5
𝑣1 = 𝑣2 𝑥√ = 𝑣2 𝑥 √ = 1.02𝑣2
𝐿1 34.66

Solving for Individual velocities:

𝜋𝐷 2 𝜋(0.03505)2
Area, A = = = 9.65x10−4 𝑚2
4 4
3
Qr = 𝐴(𝑣1 + 𝑣2 ) = (9.65x10−4 )(1.02𝑣2 + 𝑣2 ) = 7.24x10−4 m ⁄s
v2 = 0.3718 𝑚⁄𝑠
v1 =1.02(0.3718) = 0.3782 𝑚⁄𝑠
Computing for Reynold’s Number:

35
 m kg
Dv1 ρ (0.03505 m)(0.3782 ⁄s) (999.079 m3 )
NRe1 = =
μ kg
0.00115 m − s

NRe = 11,515.71 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.03505 m) 11,515.71

𝑓1 = 0.0080

m kg
Dv2 ρ (0.03505 m)(0.3718 ⁄s) (999.079 m3 )
NRe2 = =
μ kg
0.00115 m − s

NRe = 11,321.36 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.03505m) 11,321.36

𝑓2 = 0.0081

Calculating frictional line loss per meter:

FL 2f1 v1 2 2(0.0080)(0.3718 m⁄s)2
= = = 0.0656 N⁄kg = 0.0655 kPa⁄m
L1 gcD 1(0.03505 m)
FL 2f2 v2 2 2(0.0078)(0.3782 m⁄s)2
= = = 0.0636 N⁄kg = 0.0636 kPa⁄m
L2 gcD 1(0.03505 m)
Before split point
Setting v =1.5 𝑚⁄𝑠
7.24E − 04
𝐴= = 4.82x10−4 𝑚2
1.5

Nominal pipe size should be 1 1/4-inch sch. 40

36
 Table 12.13 Water Storage Tank to Split Point Pipe Dimensions for 1 ¼ inch SCH40
in m
ID 1.38 0.035052
OD 1.66 0.042164
**Perry’s Chemical Engineers’ Handbook 8th Edition

L = 40.32 m

𝜋𝐷 2 𝜋(0.03505)2
Actual Area = = = 9.65x10−4 𝑚2
4 4

7.24x10−4
Actual velocity = 9.65x10−4 = 0.7499 𝑚⁄𝑠

m kg
Dvρ (0.03505 m)(0.7499 ⁄s) (999.079 m3 )
NRe = =
μ kg
0.00115 m − s

NRe = 22,837.07 (𝐓𝐔𝐑𝐁𝐔𝐋𝐄𝐍𝐓)

1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.02664 m) 22,837.07

𝑓 = 0.0070
𝐹𝐿 2f𝑣 2 2(0.0070)(0.7499 m⁄s)2
= = = 0.2254 N⁄kg = 0.2252 kPa⁄m
𝐿 gcD 1(0.03505 m)

Getting the pressure drop per meter of pipe:

∆𝑃 𝐹𝐿 𝐹𝐿 𝐹𝐿
= + + = 0.0656 + 0.0636 + 0.2252
𝑚 𝐿1 𝐿2 𝐿
∆𝑃
= 0.3543 kPa⁄m
𝑚

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe pipe sized are VALID

FRICTION LOSS DUE TO PIPE LINE

FL = (0.0656 N⁄kg) (33.5 m) + (0.0636 N⁄kg) (34.66 m) + (0.2252 N⁄kg) (40.32m) = 13.49 J⁄kg

FL = 13.48 𝑘𝑃𝑎
37
FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.14 Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler Pipe Line
BEFORE SPLIT TO ROTCOOL TO COOLER
POINT
K Quantity kr K Quantity kr K Quantity kr
90 elbows 0.45 4 1.8 0.45 8 3.6 0.45 4 1.8
Globe 6 1 6 6 1 6 6 1 6
valve
Tee (ell) 1 1 1 1 2 2 1 0 0
Check 2 1 2
valve
TOTAL 10.8 TOTAL 11.6 TOTAL 7.8
**Perry’s Chemical Engineers’ Handbook 8th Edition

kf v2
FF = ∑
2gc

(0.7499 m⁄s)2 (0.3718 m⁄s)2 (0.3782)2

= 10.8 ( ) + 11.6 ( ) + 7.8 ( )
kg − m kg − m kg − m
2 (1 ) 2 (1 ) 2 (1 )
N − s2 N − s2 N − s2
𝐽
FF = 4.4055 ⁄𝑘𝑔 = 4.4014 𝑘𝑃𝑎

FRICTION LOSS DUE TO CONTRACTION

0.5(0.7499 m⁄s)2 𝐽
𝐹𝐶 = = 0.1406 ⁄𝑘𝑔 = 0.1405 𝑘𝑃𝑎
2

FRICTION LOSS DUE TO EXPANSION

w / α = 1 (TURBULENT FOR BOTH FLOW 1 AND 2)

(0.3718 m⁄s)2 +(0.3782 m⁄s)2 𝐽

𝐹𝐸 = = 0.1406 ⁄𝑘𝑔 = 0.1405 𝑘𝑃𝑎
2𝑥1

FRICTION LOSS DUE TO METERING DEVICE

Orifice meter
For flow 1

38
 2g c ∆H
v1 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0. 03505 m = 0.0070 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.0070 m)2 = 3.86E − 05 m2
kg⁄
48,073.59
Velocity, v1 = d
= 14.43 m⁄s
kg
−4 2
(3.86x10 m )(999.079 ⁄ 3 )(86400 𝑠⁄𝑑)
𝑚

Then:

2x1x∆H
14.43 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 279.29 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) ( 279.29 ⁄kg) = 268.12 J/kg

For flow 2

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2

39
 ∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0. 03505m = 0.0070 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.0070m)2 = 3.86x10−4 m2
kg⁄
14,393.98
Velocity, v2 = d
= 4.32 m⁄s
kg
−4 2
(3.86x10 m )(999.079 ⁄ )(86400 𝑠⁄𝑑)
𝑚3

Then:

2x1x∆H
4.32 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 25.04 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (25.04 ⁄kg) = 24.04 J/kg

𝐹𝑀𝑇 = 268.12 + 24.04 = 292.15 J/kg

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF =( 13.49 + 4.4055 + 292.15 + 0.1406 + 0.1406 ) kg

J
ΣF = 310.33 kg

Kinetic Energy:
v2 2 − v1 2
∆KE = ∑
2gc

40
 (0.7499 m⁄s)2 − (0)2 (0.3718)2 − (0.7499)2 (0.7499 m⁄s)2 − (0.3782)2 J
+ + = −0.1406
kg − m kg − m kg − m kg
2 (1 ) 2 (1 ) 2 (1 )
N − s2 N − s2 N − s2

Potential Energy:

∆zg
∆PE = ∑
gc
(0 − 11 m)x 9.81 𝑚⁄ 2 + (0 − 4.5)x 9.81 𝑚⁄ 2
∆PE = 𝑠 𝑠 = −152.055 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
999.079 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
−0.1406 J
Ws = ( − 152.055 + 0 + 310.33)
1.0 kg
J
𝐖𝐬 = 𝟏𝟓𝟖. 𝟏𝟑
kg
J kg day 1 hr
W = 158.13 x (62,467.57 )( )( ) = 𝟏𝟓𝟖. 𝟏𝟑 𝑾
kg day 24 hrs 3600 s

Since the value is positive, a pump is required (Sinnot, 2005)

Line to Pump Suction
h = 8.26 m

41
Table 12.15 Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler Pipe Line to
Pump Suction
Quantity Equivalent Length Diameter (m) Length (m)
90 1 35 0.035052 1.22682
Elbow
Globe 1 300 0.035052 10.5156
valve
Check 1 9 0.035052 0.315468
valve
TOTAL 12.05789
**Perry’s Chemical Engineer’s Handbook 8th Edition

Line Length to Pump = 7.26 m

Equivalent Line Length to Suction Pump = 7.26 + 12.05789 = 19.32 m
𝐹𝐿
𝐿𝑖𝑛𝑒 𝐿𝑜𝑠𝑠 = = 0.2254𝑥 19.32 = 6.8442 𝑘𝑃𝑎
𝐿
999.079𝑥9.81𝑥8.26
𝑆𝑡𝑎𝑡𝑖𝑐 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = = 80.96 𝑘𝑃𝑎
1000
𝑆𝑢𝑐𝑡𝑖𝑜𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 101.325 − 6.8442 + 80.96 = 175.44 𝑘𝑃𝑎
Length from Pump discharge
h = 29 m

Quantity Equivalent Length Diameter (m) Length (m)

90 15 35 0.026645 13.98863
Elbow
Globe 0 300 0.026645 0
Valve
Tee 3 57 0.026645 4.556295
TOTAL 18.54492
Table 12.16 Valves and Fittings in Water Storage Tank to Rotary Cooler & Cooler Pipe Line
from Pump Discharge

Line from Pump = 101.22 m

Equivalent Line Length to Suction Pump = 18.54492 + 101.22 = 119.765 m
𝐹𝐿
𝐿𝑖𝑛𝑒 𝐿𝑜𝑠𝑠 = = 0.2254 𝑥 119.765 = 26.97 𝑘𝑃𝑎
𝐿

42
 999.079𝑥9.81𝑥29
𝑆𝑡𝑎𝑡𝑖𝑐 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = = 284.23 𝑘𝑃𝑎
1000
𝐷𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 101.32 + 26.97 + 284.23 = 412.53 𝑘𝑃𝑎

Pump Selection
Vapor pressure = 1.7065 kPa

𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 412.53 − 175.44 = 237.09 𝑘𝑃𝑎

(175.4368 − 1.7065)(1000)
𝑁𝑃𝑆𝐻 = = 17.7258 𝑚
(999.079)(9.81)

𝑆ℎ𝑢𝑡 − 𝑜𝑓𝑓 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 1.25(𝐷𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒) = 1.25(237.09 ) = 296.36 𝑘𝑃𝑎

237.09𝑥1000
𝑃𝑢𝑚𝑝 𝐻𝑒𝑎𝑑 = = 24.19 𝑚
999.079𝑥9.81

62.53 3
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = = 2.6 𝑚 ⁄ℎ𝑟
24

Using the graph, the pump needed to be used is a single-stage centrifugal pump.
Efficiency = 75%

158.13 𝑊
Actual Work = = 𝟏𝟓𝟐. 𝟒𝟒 𝑾 = 𝟎. 𝟐𝟎𝟒𝟒 𝒉𝒑
0.75

43
 **Coulson & Richardson’s – Chemical Engineering Volume 6

Figure 12.2 Pump Selection for Water Storage Tank to Rotary Cooler & Cooler Pipe Line

44
 Rotary Cooler to Cooling Tower

T = 90 °C
Mass flow = 48,073.59 kg/d
Density = 988.04 kg/m3
Viscosity = 5.47 x10−4 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 𝟒𝟖,𝟎𝟕𝟑.𝟓𝟗 ⁄d 3
Qr = = kg = 5.63x10−4 m ⁄s
density ( 988.04 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 5.63x10−4 m ⁄s
Area = = = 5.63x10−4 m2
velocity 1 m⁄s

4xArea 4(5.63x10−4 m2 )
Diameter = √ =√ = 0.0268 m = 1.1054 in
π π

Nominal Pipe size is 1 ¼ inch sch40

Table 12.17 Rotary Cooler to Cooling Tower Pipe Dimensions for 1 ¼ inch SCH40
in m
ID 1.38 0.03505
OD 1.66 0.04216
Thickness 0.280 0.00711
**Perry’s Chemical Engineer’s Handbook 8 Edition
th

45
 π
Actual Area = 4 x(0.03505 m)2 = 0.000965 m2
3
5.56x10−4 m ⁄s
Actual Velocity = = 0.5836 m⁄s
0.000965 m2

Computing for Reynold’s Number:

m kg
Dvρ (0.03505 m)(0.5836 ⁄s) (988.04 m3 )
NRe = =
μ kg
5.47 E − 04 m − s

NRe = 36,982.81 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.03505 m) 36982.81

𝑓 = 0.0065
Calculating frictional line loss per meter:

FL 2fv 2 2(0.0065)(0.5836 m⁄s)2

= = = 0.1265 N⁄kg = 0.1250 kPa⁄m
L gcD 1(0.03505 m)

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 78.71 m
J
FL = (0.1265 N⁄kg) (78.71 m) = 9.9605 ⁄kg

46
FRICTION LOSS DUE TO VALVES AND FITTINGS:
Table 12.18 Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line
K Quantity kr
90 elbows 0.45 10 4.5
Globe valve 6 0 0
Check valve 2 0 0
Tee 1 2 2
TOTAL 6.5
**Perry’s Chemical Engineer’s Handbook 8th Edition

kf v2 (0.5836 m⁄s)2 J
FF = = 6.5 ( ) = 1.1069
2gc kg − m kg
2 (1 )
N − s2
FRICTION LOSS DUE TO METERING DEVICE
Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.03505 m = 0.00701 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.00701 m)2 = 3.86x10−4 m2
3
5.63x10−4 m ⁄s
Velocity, v2 = = 14.59 m⁄s
3.86x10−4 m2

Then:

2x1x∆H
14.59 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 285.56 ⁄kg

47
 FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (285.56 ⁄kg) = 274.14 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,472 m3
J
∆H 285.56 ⁄kg
Hm = ρ g = = 2.1349 m = 84.05 inHg
( ρm )x g kg
13,472 ⁄m3 9.81 m⁄s 2
c
( )x
kg kg − m
988.04 ⁄m3 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN CONTRACTION

A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.5836 m⁄s)2 J
Fc = 0.5 ( ) = 0.085
kg − m kg
2 (1 2 )
N− s

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT

α = 1.0 for turbulent flow (Geankoplis, 1995)
v2
Fe =
2gcα

(0.5836 m⁄s)2 J
Fe = = 0.1703
kg − m kg
2 (1 ) (1.0)
N − s2

48
MECHANICAL ENERGY BALANCE
Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 9.9605 + 1.1069 + 274.14 + 0.0851 + 0.1703 ) kg

J
ΣF = 285.46 kg

Kinetic Energy:
v2 = 0.5836 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc
(0.5836 m⁄s)2 J
∆KE = = 0.1703
kg − m kg
2 (1 2 )
N− s
Potential Energy:
∆z = 8 m
∆zg
∆PE =
gc
8 m x 9.81 𝑚⁄
∆PE = 𝑠 2 = 78.48 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,528.19 3
m

49
OVERALL MECHANICAL ENERGY BALANCES
∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.1703 J kg day 1 hr
Ws = ( + 78.48 + 0 + 285.46 ) x (𝟒𝟖, 𝟎𝟕𝟑. 𝟓𝟗 )( )( )
1.0 kg day 24 hrs 3600 s
𝐖𝐬 = 𝟐𝟎𝟐. 𝟔𝟎 𝐖

Since the value is positive, pump is required (Sinnot, 2005)

LINE TO PUMP SUCTION
Line length = 2.61 m
kPa
Line Loss = 2.61 m(0.1503 ) = 0.3922 kPa
m

Table 12.19 Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line to Pump Suction
K Quantity kr
90 elbows 0.9 1 0.9
Tee 1.4 1 1
TOTAL 1.45
**Perry’s Chemical Engineer’s Handbook 8th Edition

kg
k f v2 ρ 1.45 x(0.5836m⁄s)2 988.04
m3
Fittings Loss = = N = 0.2440 kPa
2gc 2
(1
kg−m
)(1000 m2 )
N− s2 kPa
( )
J kg
Fc ρ 0.0851 (988.04 3 )
kg m
Contraction Loss = 2g = N = 0.0841 kPa
c kg−m 2
(1 2 )(1000 m )
N− s kPa

Pressure Losses = Line Loss + Fittings Loss + Contraction Loss

Pressure Losses = (0.3922 + 0.2440 + 0.0841) = 0.6544 kPa
Static Pressure:
height : 1.05 m
kg m
ρgh 988.04 (9.81 2 )(1.05 m)
m3 s
= = N = 10.1773 kPa
gc 2
kg−m m
(1 )(1000 )
N− s2 kPa

50
Upstream pressure: 101.325 kPa
Suction Pressure = upstream pressure – pressure losses + static pressure
Suction Pressure = (101.325 – 0.6544 + 10.1773) kPa = 110.85 kPa

LINE FROM PUMP DISCHARGE

Line length = 76.10 m
kPa
Line Loss = 76.10 m(0.1265 ) = 9.5151 kPa
m

Table 12.20 Valves and Fittings in Rotary Cooler to Cooling Tower Pipe Line from Pump
Discharge
K Quantity kr
90 elbows 0.45 9 4.05
Gate valve 0.17 0 0
Tee (ell) 1 1 1
TOTAL 5.05
**Perry’s Chemical Engineer’s Handbook 8th Edition

kg
k f v2 ρ 5.05 x(0.5836m⁄s )2 988.04
m3
Fittings Loss = = N
= 0.8497 kPa
2gc 2
(1
kg−m
)(1000 m2 )
N− s2 kPa
( )
ρ(Fe + Fm )
Dynamics Loss = Fittings Loss + Line Loss + gc

kg J
988.04 (0.1703+274.14)
m3 kg
Dynamics Loss = 0.8499 kPa +9.5151 kPa + N
= 281.39 kPa
(1
kg−m
)(1000 m2 )
N− s2 kPa

Static Pressure:
height : 6.95 m
kg m
ρgh 988.04 (9.81 2 )(6.95 m)
m3 s
= = N = 67.3641 kPa
gc 2
kg−m m
(1 )(1000 )
N− s2 kPa

Discharge Pressure:
operating pressure: 101.325 kPa

51
Discharge Pressure = Dynamic Loss + Equipment Operating Pressure + Static Pressure

Discharge Pressure = (281.39 + 101.325 + 67.3641) kPa = 450.08 kPa

PUMP SELECTION
Differential Pressure = Discharge Pressure – Suction Pressure
Differential Pressure = (450.08 – 110.85) kPa
Differential Pressure = 339.24 kPa

Suction pressure−Vapor pressure

NPSH available =
ρg

H2O has a vapor pressure of 1.705 kPa (Table 2-8 from Perry’s Handbook 8th edition)
N
110.8479 −1.705 kPa kg−m m2
NPSH available = kg m 𝑥 (1 ) (1000 )
988.04 (9.81 2 ) N− s2 kPa
m3 s

NPSH available = 11.26 m

Differential Pressure
Pump Head =
ρg
N
339.24 kPa kg−m m2
Pump Head = kg m 𝑥 (1 ) (1000 )
988.04 (9.81 2 ) N− s2 kPa
m3 s

Pump Head =35 m

Shut - off Pressure = 1.25 x Differential Pressure

Shut - off Pressure = 1.25 (339.24 kPa)
Shut - off Pressure = 424.04 kPa

kg⁄ 1 day
mass flowrate 48,073.59 d(24 hrs) m3
Capacity = = kg⁄ = 2.0273
density (988.04 ) hr
m3

From the figure, the pump to be used is multi-stage stage pump.

52
 **Coulson & Richardson’s – Chemical Engineering Volume 6

Figure 12.3 Pump Selection for Rotary Cooler to Cooling Tower Pipe Line

The efficiency of MULTI-STAGE centrifugal pumps is 75% (Sinnot, 2005)

W 202.5 W
Pump Actual Work=0.75s = 0.75
= 𝟐𝟕𝟎. 𝟏𝟑 𝐖

53
 Cooler to Cooling Tower

Feed at T = 90°C
Mass flow = 14,393.98 kg/d
Density = 988.04 kg/m3
Viscosity = 5.47 x10−4 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 14,393.98 ⁄d 3
Qr = = kg = 1.69x10−4 m ⁄s
density ( 988.04 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 1.69x10−4 m ⁄s
Area = = = 1.69x10−4 m2
velocity 1 m⁄s

4xArea 4(1.69x10−4 m2 )
Diameter = √ =√ = 0.0147 m = 0.5769 in
π π

Nominal Pipe size is 3/4 inch sch40

Table 12.21 Cooler to Cooling Tower Pipe Dimensions for ¾ inch SCH40
in m
ID 0.824 0.02093
OD 1.05 0.02667
Thickness 0.226 0.00574
**Perry’s Chemical Engineer’s Handbook 8th Edition

π
Actual Area = 4 x(0.02093m)2 = 0.000344m2
3
1.69 E−04 m ⁄s
Actual Velocity = = 0.4901 m⁄s
0.000344 m2

Computing for Reynold’s Number:

54
 m kg
Dvρ (0.02093 m)(0.4901 ⁄s) (988.04 m3 )
NRe = =
μ kg
5.47 E − 04 m − s

NRe = 18,544.97 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.02093 m) 18,544.97

𝑓 = 0.0077
Calculating frictional line loss per meter:

FL 2fv 2 2(0.0077)(0.4901 m⁄s)2 J

= = = 0.1769 ⁄kg = 0.1748 kPa⁄m
L gcD 1(0.02093 m)

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 38.75 m
J J
FL = (0.1769 ⁄kg) (38.75 m) = 6.85 ⁄kg

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.22 Valves and Fittings in Cooler to Cooling Tower Pipe Line
K Quantity kr
90 elbows 0.45 10 4.5
(short)
TOTAL 4.5
**Perry’s Chemical Engineer’s Handbook 8th Edition

kf v2 (0.4901 m⁄s)2 J
FF = = 4.5 ( ) = 0.5404
2gc kg − m kg
2 (1 )
N − s2

55
FRICTION LOSS DUE TO METERING DEVICE
Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.02093 m = 0.008372 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.008372 m)2 = 5.505x10−4 m2
3
1.69x10−4 m ⁄s
Velocity, v2 = = 3.0631 m⁄s
5.505x10−4 m2

Then:

2x1x∆H
3.0631 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 12.28 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (12.28 ⁄kg) = 10.32 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,472 m3
J
∆H 12.28 ⁄kg
Hm = ρ g = = 0.0918m = 3.62 inHg
( ρm )x g kg⁄ m
13,472 m3 ) x 9.81 ⁄s 2
c
(
kg kg − m
977.88 ⁄m3 (1 )
N − s2

56
FRICTION LOSS DUE TO SUDDEN CONTRACTION

A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.4901 m⁄s)2 J
Fc = 0.5 ( ) = 0.06
kg − m kg
2 (1 2 )
N− s

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT

α = 1.0 for turbulent flow (Geankoplis, 1995)
v2
Fe =
2gcα
(0.4901 m⁄s)2 J
Fe = = 0.1201
kg − m kg
2 (1 2 ) (1.0)
N− s

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 3.8544 + 0.5404 + 10.32 + 0.06 + 0.1201 ) kg

J
ΣF = 17.89 kg

Kinetic Energy:
v2 = 0.4901 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc

57
 (0.4901 m⁄s)2 J
∆KE = = 0.1201
kg − m kg
2 (1 )
N − s2
Potential Energy:
∆z = −4.45 m
∆zg
∆PE =
gc
−4.45 m x 9.81 𝑚⁄
∆PE = 𝑠 2 = −43.6545 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,528.19 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.1201 J kg day 1 hr
Ws = ( − 43.6545 + 0 + 317.89) x (14393.98 )( )( )
1.0 kg day 24 hrs 3600 s
𝐖𝐬 = −𝟒. 𝟐𝟕 𝐖

58
 Off-Gases to Gas Absorber

T=65.16 °C
Mass flow 23,475.14 kg/d
Density kg/m3
0.8867
Viscosity 1.79 x10−4 kg/m-s

(Cp) 1.0933 J/kg-K

(Cv) 0.806 J/kg-K

To solve for the volumetric flow of the fluid:

mass flow rate

qf =
density
kg day 1h
23,475.15 ( )( )
d 24 hrs 3600 s
Qf =
kg
0.8867 3
m
m3
Qf = 0.3064
s
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005),
the velocity of the vapor inside the pipe should not exceed 15 to 30 m/s.

Setting the fluid velocity to 15 m/s to compute for the area of the pipe:

volumetric flow
Area =
fluid velocity
m3
0.3064 s
Area = m
15 s

Area = 0.0204 m2

59
Computing for the diameter of the pipe:
πD2
Area =
4

4(Area) 4(0.0204 )
Diameter = √ =√
π π
3.28 ft 12 in
Diameter = 0.1613 m ( )( )
1m 1 ft
Diameter = 6.3494 in

Nominal Pipe size is 7 inch SCH 40

Table 12.23 Off-gases to Gas Absorber Pipe Dimensions for 7 inch SCH40
in m
ID 7.023 0.17838
OD 7.625 0.19368
Thickness 0.602 0.01529
**Perry’s Chemical Engineer’s Handbook 8th Edition

Computing the area of the standard pipe to be used:

πD2
Areastd =
4
π(0.17838 m)2
Areastd =
4
Areastd = 0.02499 m2

Thus, the fluid velocity inside the standard pipe:

m3
0.3064 s
Actual velocity =
0.02499 m2

m
Actual Velocity = 12.2607
s

60
 m kg
Dvρ (0.17838 m) (12.2607 s ) (0.8867 m3 )
NRe = =
μ kg
1.79 E − 05 m − s

NRe = 108,100.01 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.17838 m) 108,100.1

𝑓 = 0.0048
The mass, velocity is given as:
kg day 1h
𝑚̇ 23,475.14 ( )( ) 𝑘𝑔
d 24 hrs 3600 s
𝐺= = 2 = 10.8716 2
𝐴 𝜋( 0.17838 m) 𝑚 𝑠
4

Solving for P2:

Z= 0.59 (Using Van der Waals Equation )
L = 20.67 m
𝑔
𝑀𝑊𝑎𝑣𝑒 = ((0.2537/18) + (0.7463/36.45))−1 = 28.93 ⁄𝑚𝑜𝑙

P1 = 101,325 Pa

4ZRTfLG 2
P2 = √P1 2 −
gcDMW

J kg 2
4(0.59 ) (8.314 ) (338.31 K)(0.0048)(20.67 m) (10.8716 2 )
mol − K m s
= √(101,325 Pa)2 −
kg − m g kg
(1 ) (0.17838 m) (28.93 )( )
N − s2 mol 1000 g

P2 = 101,250.94 Pa

61
Calculating the pressure drop for the purpose of checking the validity of the assumption, such
that, the pressure per 100m of pipe should not exceed 11 kPa

4fLG2 G2 P2
∆𝑃 = + + ln ( )
2Dρ ρ P1
kg 2 kg 2
4(0.0048)(100m) (10.8716 2 ) (10.8716 2 ) 101,250.94
m s m s
∆𝑃 = + + ln ( )
kg kg 101,325
2(0.17838 m) (0.8867 3 ) 0.8867 3
m m

∆P = 845.46 Pa
∆P = 0.8455 kPa

Since 0.8455 kPa is less than 11kPa, the assumption is VALID

POWER REQUIREMENT FOR COMPRESSOR

The power requirement of a compressor can be computed using the formula below:
𝛾−1
𝛾𝑅𝑇 𝑃2 𝛾
𝑊= [( ) − 1]
𝛾 − 1 𝑃1

𝐶𝑝
γ=
𝐶𝑣
Computing for the work of the compressor:
1.0933
γ= = 1.3565
0.806
J 1.3565−1
(1.3565) (8.314 ) (338.31 K) 101,250.94 Pa 1.3565
W= mol K [( ) − 1]
1.3565 − 1 101,325 Pa

J
W = −2.0565
mol
J mol 1000 kg day 1h
W = −2.0565 ( )( ) (23,475.14 ) ( )( )
mol 28.93 g kg d 24 hrs 3600 s

𝐖 = −𝟏𝟗. 𝟑𝟐

62
 HCl from Gas Absorber

Feed at T = 38.5 °C
Mass flow 44,409 kg/d
Density 1,173.59 kg/m3
Viscosity 5.27 x10−4 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 𝟒𝟒,𝟒𝟎𝟗 ⁄d 3
Qr = = kg = 0.000438 m ⁄s
density (1,173.59 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 0.000438 m ⁄s
Area = = = 0.000438 m2
velocity 1 m⁄s

4xArea 4(0.000438 m2 )
Diameter = √ =√ = 0.02361 m = 0.9297 in
π π

Nominal Pipe size is 1 inch sch40

Table 12.24 HCl from Gas Absorber Pipe Dimensions for 1 inch SCH40
in m
ID 1.049 0.0266
OD 1.315 0.0334
Thickness 0.266 0.0068
**Perry’s Chemical Engineer’s Handbook 8th Edition

π
Actual Area = 4 x(0.0266 m)2 = 5.58x10−4 m2
3
0.000438 m ⁄s
Actual Velocity = = 0.7855 m⁄s
5.58x10−4 m2

Computing for Reynold’s Number and Fanning Friction:

63
 m kg
Dvρ (0.0266 m)(0.7855 ⁄s) (1,173.59 m3 )
NRe = =
μ kg
5.27x10−4 m − s

NRe = 46,597.77 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.0266 m) 46,597.77

𝑓 = 0.00657
Calculating frictional line loss per meter:

FL 2fv 2 2(0.00657)(0.7855 m⁄s)2

= = = 0.3045 N⁄kg = 0.3573 kPa⁄m
L gcD 1(0.0266 m)

Since friction loss per meter is LESS THAN 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 10.14 m
J
FL = (0.3045 N⁄kg) (10.14 m) = 3.0872 ⁄kg

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.25 Valves and Fittings in HCl from Gas Absorber Pipe Line
K Quantity kr
90 elbows 0.45 3 1.35
Gate valve 6 0 0
Check Valve 2 0 0

TOTAL 1.35
**Perry’s Chemical Engineer’s Handbook 8th Edition

64
 kf v2 (0.7855 m⁄s)2 J
FF = = 1.35 ( ) = 0.4165
2gc kg − m kg
2 (1 )
N − s2

FRICTION LOSS DUE TO METERING DEVICE

Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.0266 m)2 = 1.39x10−4 m2
3
0.000438 m ⁄s
Velocity, v2 = = 3.1419 m⁄s
1.39x10−4 m2

Then:

2x1x∆H
3.1419 m⁄s = 0.61(0.1)√
1 − (0.2)4

J
∆H = 12.4356 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) (12.4356 ⁄kg) = 9.3267 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,472 m3

65
 J
∆H 12.4356 ⁄kg
Hm = ρ g = = 0.1104 m = 4.3476 inHg
( ρm )x g kg
13,472 ⁄m3 9.81 m⁄s2
c
( )x
kg kg − m
1,173.59 ⁄m3 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN CONTRACTION

A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.7855 m⁄s)2 J
Fc = 0.5 ( ) = 0.1542
kg − m kg
2 (1 )
N − s2
FRICTION LOSS DUE TO SUDDEN ENLARGEMENT
α = 1.0 for turbulent flow (Geankoplis, 1995)
v2
Fe =
2gcα

(0.7855 m⁄s)2 J
Fe = = 0.3085
kg − m kg
2 (1 ) (1)
N − s2
MECHANICAL ENERGY BALANCE
Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 3.0872 + 0.4165 + 9.3267 + 0.1542 + 0.3085 ) kg

J
ΣF = 13.2931 kg

Kinetic Energy:
v2 = 0.7855 m⁄s
v1 = 0

66
 v2 2 − v1 2
∆KE =
2gc
(0.7855 m⁄s)2 − (0)2 J
∆KE = = 0.3085
kg − m kg
2 (1 )
N − s2
Potential Energy:
∆z = −2.26 m
∆zg
∆PE =
gc
−2.26 m J
∆PE = = −22.1706
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,826.1 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.3085 J kg day 1 hr
Ws = ( − 22.1706 + 0 + 13.2931 ) x (44,409 )( )( )
1.0 kg day 24 hrs 3600 s
𝐖𝐬 = −𝟒. 𝟒𝟎𝟒𝟒 𝐖

67
 Off-Gases from Gas Absorber

Feed at T=38.5 °C
Mass flow 173.74 kg/d
Density kg/m3
1.3777
Viscosity 1.52 x10−4 kg/m-s

(Cp) 0.6351 J/kg-K

(Cv) 0.8783 J/kg-K

To solve for the volumetric flow of the fluid:

mass flow rate

qf =
density
kg day 1h
173.74 ( )( )
d 24 hrs 3600 s
Qf =
kg
1.3777 3
m
m3
Qf = 0.00146
s
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005),
the velocity of the vapor inside the pipe should not exceed 15 to 30 m/s.

Setting the fluid velocity to 15 m/s to compute for the area of the pipe:

volumetric flow
Area =
fluid velocity
m3
0.00146 s
Area = m
15 s

Area = 9.7306 E − 05 m2

68
Computing for the diameter of the pipe:
πD2
Area =
4

4(Area) 4(9.7306x10-4 )
Diameter = √ = √
π π
3.28 ft 12 in
Diameter = 0.01113 m ( )( )
1m 1 ft
Diameter = 0.4382 in

Nominal Pipe size is 3/8 inch SCH 40

Table 12.26 Off-gases from Gas Absorber Pipe Dimensions for 3/8 inch SCH40
in m
ID 0.622 0.01580
OD 0.84 0.02134
Thickness 0.218 0.00554
**Perry’s Chemical Engineer’s Handbook 8th Edition

Computing the area of the standard pipe to be used:

πD2
Areastd =
4
π(0.01580 m)2
Areastd =
4
Areastd = 0.000196 m2

Thus, the fluid velocity inside the standard pipe:

m3
0.00146 s
Actual velocity =
0.000196 m2

m
Actual Velocity = 7.4455
s

69
 m kg
Dvρ (0.01580 m) (7.4455 s ) (1.3777 m3 )
NRe = =
μ kg
1.52x10−4 m − s

NRe = 10,682.83 (TURBULENT)

1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.01580 m) 10,682.83

𝑓 = 0.008776

The mass, velocity is given as:

kg day 1h
𝑚̇ 173.74 ( )( ) 𝑘𝑔
d 24 hrs 3600 s
𝐺= = 2 = 10.2576 2
𝐴 𝜋( 0.01580 m) 𝑚 𝑠
4

Solving for P2:

Z= 0.93 (Using Van der Waals Equation)
L = 13.21 m
𝑔
𝑀𝑊𝑎𝑣𝑒 = ((0.0344/18) + (0.9656/36.45))−1 = 35.21 ⁄𝑚𝑜𝑙

P1 = 101,325 Pa

4ZRTfLG 2
P2 = √P1 2 −
gcDMW

J kg 2
4(0.93 ) (8.314 ) (311.65 K)(0.008776)(13.21 m) (10.2576 2 )
mol − K m s
= √(101325)2 −
kg − m g kg
(1 ) (0.01580 m) (35.21 )( )
N − s2 mol 1000 g

70
 P2 = 100,277.41 Pa
Calculating the pressure drop for the purpose of checking the validity of the assumption, such
that, the pressure per 100m of pipe should not exceed 11 kPa

4fLG2 G2 P2
∆𝑃 = + + ln ( )
2Dρ ρ P1
kg 2 kg 2
4(0.008776)(100m) (10.2576 ) (10.2576 ) 100,277.41
m2 s m2 s
∆𝑃 = + + ln ( )
kg kg 101,325
2(0.01580 m) (1.3777 3 ) 1.3777 3
m m

∆P = 8,561.53 Pa
∆P = 8.561 kPa

Since 8.561 kPa is less than 11kPa, the assumption is VALID

POWER REQUIREMENT FOR COMPRESSOR

The power requirement of a compressor can be computed using the formula below:
𝛾−1
𝛾𝑅𝑇 𝑃2 𝛾
𝑊= [( ) − 1]
𝛾 − 1 𝑃1

𝐶𝑝
γ=
𝐶𝑣
Computing for the work of the compressor:
0.6351
γ= = 1.3829
0.8783

J 1.3829−1
(1.3829) (8.314 ) (311.65K) 100,277.41 Pa 1.3829
W= mol K [( ) − 1]
1.3829 − 1 101,325 Pa

J
W = −26.8893
mol

71
 J mol 1000 kg day 1h
W = −26.8893 ( )( ) (173.74 ) ( )( )
mol 35.21 g kg d 24 hrs 3600 s

𝐖 = −𝟏. 𝟓𝟑𝟓𝟕 𝐖

72
 Water to Scrubber
Mass flow = 272.14 kg/d
Density = 988.04 kg/m3
Viscosity = 0.0005465 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 272.14 ⁄d 3
Qr = = kg = 3.19x10−4 m ⁄s
density (988.04 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4 power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 3.19x10−4 m ⁄s
Area = = = 3.19x10−4 m2
velocity 1 m⁄s

4xArea 4(3.19x10−4 m2 )
Diameter = √ =√ = 0.002015 m = 0.07932 in
π π

Nominal Pipe size is 1/4 inch sch40

Table 12.27 Water to Scrubber Pipe Dimensions for ¼ inch SCH40

in m
ID 0.269 0.0068326
OD 0.405 0.010287
Thickness 0.136 0.0034544
**Perry’s Chemical Engineer’s Handbook 8th Edition

π
Actual Area = 4 x(0.0068326m)2 = 3.67x10−4 m2
3
3.19x10−4 m ⁄s
Actual Velocity = = 0.0869 m⁄s
3.67x10−4 5

Computing for Reynold’s Number:

73
 m kg
Dvρ (0.0068326 m)(0.0869 ⁄s) (988.04 m3 )
NRe = =
μ kg
5.47x10−4 m − s

NRe = 1,074.02 (LAMINAR)

16 16
f=N = 1,074.02 = 0.0149
Re

Calculating frictional line loss per meter:

FL 2fv 2 2(0.0149)(0.0869 m⁄s)2

= = = 0.033 N⁄kg = 0.0326 kPa⁄m
L gcD 1(0.0068326 m)

Since friction loss per meter is EQUAL TO 0. 5 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 22.11 m
J
FL = (0.0326 N⁄kg) (8 m) = 0.7288 ⁄kg

FRICTION LOSS DUE TO VALVES AND FITTINGS:

Table 12.28 Valves and Fittings in Water to Scrubber Pipe Line
K Quantity kr
90 elbows 0.45 11 4.95
Globe valve 6 1 6
Gate valve 6 1 6
Tee 1 4 4
TOTAL 20.95
**Perry’s Chemical Engineer’s Handbook 8th Edition

kf v2 (0.0869 m⁄s)2 J
FF = = 20.95 ( ) = 0.07918 ⁄kg
2gc kg − m
2 (1 )
N − s2
FRICTION LOSS DUE TO METERING DEVICE
Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

74
Setting the throat diameter to 20% of the pipe diameter:
γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.0068326 m = 0.001367 m
Solving for throat velocity:
𝜋
Throat Area = 4 (0.2 x 0.001367 m)2 = 1.47x10−6 m2
3
3.19x10−6 m ⁄s
Velocity, v2 = = 2.17 m⁄s
1.47x6 m2

Then:

2x1x∆H
2.17 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 6.34 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) ( 6.34 ⁄kg) = 6.08 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,472 m3
J
∆H 6.08 ⁄kg
Hm = ρ g = = 0.0474 m = 1.8656 inHg
( ρm )x g kg
13,472 ⁄m3 9.81 m⁄s2
c
( )x
kg kg − m
1,166.69 ⁄m3 (1 )
N − s2

75
FRICTION LOSS DUE TO SUDDEN CONTRACTION
A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.0869 m⁄s)2 J
Fc = 0.5 ( ) = 0.0019
kg − m kg
2 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT

α = 0.5 for laminar flow (Geankoplis, 1995)
v2
Fe =
2gcα

(0.0869 m⁄s)2 J
Fe = = 0.0076
kg − m kg
2 (1 2 ) (0.5)
N− s

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF = 0.7288 + 0.07918 + 6.0849 + 0.0019 + 0.0076) kg

J
ΣF = 6.9023 kg

Kinetic Energy:
v2 = 0.0869 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc
(0.0869 m⁄s)2 J
∆KE = = 0.0076
kg − m kg
2 (1 2 )
N− s

76
Potential Energy:
∆z = 7 m
∆zg
∆PE =
gc
7 m x 9.81 𝑚⁄ 2
∆PE = 𝑠 = 68.67 J
kg − m kg
(1 )
N − s2
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,166.69 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.0072 J kg day 1 hr
Ws = ( + 68.67 + 0 + 6.9023) x ( 272.14 )( )( )
0.5 kg day 24 hrs 3600 s
𝐖𝐬 = 𝟎. 𝟐𝟒 𝐖

Since pump requirement is very small, no need for a pump.

77
 HCl from Scrubber
Mass flow = 444.09 kg/d
Density = 1,166.69 kg/m3
Viscosity = 2.26 x10−4 kg/m-s

Solving for volumetric flowrate:

kg
mass flow rate 444.09 ⁄d 3
Qr = = kg = 4.41x10−6 m ⁄s
density (1,166.69 ⁄ 3 )(86,400 s⁄d)
m

Maximum velocity for volumetric flowrates with x10−4power should not exceed 1 to 3 m/s
(Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005).
Setting velocity to 1 m/s:

3
volumetric flowrate 4.41x10−6 m ⁄s
Area = = = 4.41x10−6 m2
velocity 1 m⁄s

4xArea 4(4.41x10−6 m2 )
Diameter = √ =√ = 0.0024 m = 0.0932 in
π π

Nominal Pipe size is 1 inch SCH40

Table 12.29 HCl from Scrubber Pipe Dimensions for 1 inch SCH40
in m
ID 0.269 0.0068326
OD 0.405 0.010287
Thickness 0.136 0.0034544
**Perry’s Chemical Engineer’s Handbook 8th Edition

π
Actual Area = 4 x(0.0068326m)2 = 3.67x10−5 m2
3
4.41x10−6 m ⁄s
Actual Velocity = = 0.1202 m⁄s
3.67x10−5 m2

Computing for Reynold’s Number:

m kg
Dvρ (0.0068326 m)(0.1202 ⁄s) (1,166.69 m3 )
NRe = =
μ kg
2.26x10−4 m − s

78
 NRe = 4,247.19 (TURBULENT)
1 ε 7 0.9
= −4 log [0.27 + ( ) ]
√f D NRe
1m
1 0.00015 ft ( ) 7 0.9
= −4 log [0.27 3.28 ft + ( ) ]
√f (0.0068326 m) 4,247.19

𝑓 = 0.01175
Calculating frictional line loss per meter:

FL 2fv 2 2(0.01175)(0.1202 m⁄s)2

= = = 0.0496 N⁄kg = 0.05 kPa⁄m
L gcD 1(0.0068326 m)

Since friction loss per meter is EQUAL TO 0. 05 kPa⁄mthe velocity is VALID

FRICTION LOSS DUE TO PIPE LINE

Length of pipe = 4.66 m
J
FL = (0.0496 N⁄kg) (4.66 m) = 0.2313 ⁄kg

FRICTION LOSS DUE TO METERING DEVICE

Orifice meter

2g c ∆H
v2 = Cγ√
1 − β4

Setting the throat diameter to 20% of the pipe diameter:

γ = 1.0 (liquid)
β = 0.2
∴ C = 0.61
Device Diameter:
Device Diameter = 0.2*0.0068326 m = 0.001367 m
Solving for throat velocity:

79
 𝜋
Throat Area = 4 (0.2 x 0.001367 m)2 = 1.47x10−6 m2
3
4.41x10−6 m ⁄s
Velocity, v2 = = 3.00 m⁄s
1.47x10−6 m2

Then:

2x1x∆H
3.00 m⁄s = 0.61(1.0)√
1 − (0.2)4

J
∆H = 12.11 ⁄kg

FM = y ∆H
y = 1 − β2 (for orifice)
J
FM = (1 − 0.22 ) ( 12.11 ⁄kg) = 11.62 J/kg

Using mercury as metering fluid:

kg⁄
ρm = 13,472 m3
J
∆H 12.11 ⁄kg
Hm = ρ g = = 0.1067 m = 4.2072inHg
( ρm )x g kg⁄ m
13,472 m3 ) x 9.81 ⁄s2
c
(
kg kg − m
1,166.69 ⁄m3 (1 )
N − s2

FRICTION LOSS DUE TO SUDDEN CONTRACTION

A2 v 2
Fc = 0.5 (1 − )
A1 2gc
A2
≈ 0 (negligible)
A1

(0.1202 m⁄s)2 J
Fc = 0.5 ( ) = 0.0036
kg − m kg
2 (1 )
N − s2

80
FRICTION LOSS DUE TO SUDDEN ENLARGEMENT
α = 1.0 for turbulent flow (Geankoplis, 1995)
v2
Fe =
2gcα

(0.1202 m⁄s)2 J
Fe = = 0.0072
kg − m kg
2 (1 ) (1.0)
N − s2

MECHANICAL ENERGY BALANCE

Total Friction Losses:

ΣF = FL + FF + FM + Fc + Fe
J
ΣF =0.2313 + 11.62 + 0.0036 + 0.0072 ) kg

J
ΣF = 11.8632 kg

Kinetic Energy:
v2 = 0.1202 m⁄s
v1 = 0
v2 2 − v1 2
∆KE =
2gc
(0.1202 m⁄s)2 J
∆KE = = 0.0072
kg − m kg
2 (1 )
N − s2
Potential Energy:
∆z = −4.66m
∆zg
∆PE =
gc
−4.66 m x 9.81 𝑚⁄ 2
∆PE = 𝑠 = −45.7146 J
kg − m kg
(1 )
N − s2

81
Pressure Head:

∆P 101.325 kPa − 101.325 kPa

= =0
ρ kg
1,166.69 3
m

OVERALL MECHANICAL ENERGY BALANCES

∆KE ∆P
Ws = + ∆PE + + ΣF
α ρ
0.0072 J kg day 1 hr
Ws = ( − 45.7146 + 0 + 11.8632) x (444.09 )( )( )
1.0 kg day 24 hrs 3600 s
𝐖𝐬 = −𝟎. 𝟏𝟕𝟒𝟎 𝐖

82
 Off-Gases from Scrubber

Feed at T=51 °C
Mass flow 1.79 kg/d
Density kg/m3
1.287
Viscosity 1.36 x10−5 kg/m-s

(Cp) 0.8783 J/kg-K

(Cv) 0.6351 J/kg-K

To solve for the volumetric flow of the fluid:

mass flow rate

qf =
density
kg day 1h
1.79 ( ) (3600 s)
d 24 hrs
Qf =
kg
1.287 3
m
−5
m3
Qf = 1.6098 x10
s
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005),
the velocity of the vapor inside the pipe should not exceed 15 to 30 m/s.

Setting the fluid velocity to 15 m/s to compute for the area of the pipe:

volumetric flow
Area =
fluid velocity
m3
1.6098x10-5
Area = s
m
15 s

Area = 1.0732x10-6 m2

83
Computing for the diameter of the pipe:
πD2
Area =
4

4(Area) 4(1.0732x10-6 )
Diameter = √ = √
π π
3.28 ft 12 in
Diameter = 1.1689x10-3 m ( )( )
1m 1 ft
Diameter = 0.04602 in

Nominal Pipe size is 1/8 inch SCH 40

Table 12.30 Off-gases from Scrubber Pipe Dimensions for 1/8 inch SCH40
in m
ID 0.269 0.006833
OD 0.405 0.010287
Thickness 0.136 0.0034544
**Perry’s Chemical Engineer’s Handbook 8th Edition

Computing the area of the standard pipe to be used:

πD2
Areastd =
4
π(0.006833m)2
Areastd =
4
Areastd = 3.67x10−5 m2

Thus, the fluid velocity inside the standard pipe:

m3
1.6098x10-5
Actual velocity = s
3.67x10-5 m2

m
Actual Velocity = 0.4394
s

84
 m kg
Dvρ (0.006833 m) (0.4394 s ) (1.287 m3 )
NRe = =
μ kg
1.36x10-5
m−s
NRe = 283.04 (LAMINAR)

16
𝑓=
NRe
16
𝑓=
283.04
𝑓 = 0.0565
The mass, velocity is given as:
kg day 1h
𝑚̇ 1.79 ( )( ) 𝑘𝑔
d 24 hrs 3600 s
𝐺= = 2 = 0.5650 2
𝐴 𝜋( 0.006833m) 𝑚 𝑠
4

Solving for P2:

Z= 0.87 (Using Van der Waals Equation)
L = 0.7 m

4ZRTfLG 2
P1 = √P2 2 +
gcDMW

P2 = 1atm

J kg 2
4(0.87) (8.314 ) (324.15 K)(0.0565)(0.7 m) (0.5650 2 )
mol − K m s
P1 = √P2 2 +
kg − m g kg
(1 ) (0.006833 m) (34.20 )( )
N − s2 mol 1000 g

P1 = 101327.52 Pa
Calculating the pressure drop for the purpose of checking the validity of the assumption, such
that, the pressure per 100m of pipe should not exceed 11 kPa

85
 4fLG2 G2 P2
∆𝑃 = + + ln ( )
2Dρ ρ P1
kg 2 kg 2
4(0.0565)(100m) (0.565 ) (0.565 ) 101,325
m2 s m2 s
∆𝑃 = + + ln ( )
kg kg 101,327.52
2(0.006833) (1.287 3 ) 1.287 3
m m

∆P = 0.411 kPa

Since 0.411 kPa is less than 11kPa, the assumption is VALID

POWER REQUIREMENT FOR COMPRESSOR

The power requirement of a compressor can be computed using the formula below:
𝛾−1
𝛾𝑅𝑇 𝑃2 𝛾
𝑊= [( ) − 1]
𝛾 − 1 𝑃1

𝐶𝑝
γ=
𝐶𝑣
Computing for the work of the compressor:
0.8783
γ= = 1.3829
0.6351

J 1.3829−1
(1.3829) (8.314 ) (324.15 K) 101,325 1.3829
W= mol K [( ) − 1]
1.3829 − 1 101,327.52

J
W = 0.0669
mol

J mol 1000 kg day 1h

W = 0.0669 ( )( ) (1.79 ) ( )( )
mol 35.2674 g kg d 24 hrs 3600 s

𝐖 = 𝟒. 𝟎𝟓x10−5 𝐖

Since pump requirement is very small, no need for a pump.

86