Design of Main Header System to operate multi-

ion exchange column with a single pump for leach

processing.

Tanvir Ahmad Hashmi

February 26, 2021

Report 3rd Week

Department of Chemical Engineering

Pakistan Institute of Engineering and Applied Sciences
P. O. Nilore, Islamabad, Pakistan
Steps to be followed in header design:
In most piping designs, the primary requirement is to find an inside diameter that will permit a
certain required throughput at a given pressure drop. This usually involves a trial-and-error
procedure. A diameter is chosen and the pressure drop is calculated for the required throughput.
If the calculated pressure drop is too great and by-passing the design criteria like erosional
velocity, noise etc., a larger diameter is taken for the next trial. If the pressure drop is smaller than
necessary, a smaller diameter is chosen.
Energy losses due to pipe friction:
Pressure drop due to friction losses in pipe can be calculated using Darcy-Weisbach, Hazen-
Williams or Manning equation. Hazen-Williams equation is an empirical relation and used only
for water. Main disadvantage of this equation is that it does not account for temperature and
viscosity variations. Manning equation is also an empirical based relation which can only be used
for water at normal temperatures. Darcy-Weisbach equation is widely used now-a-days for pipe
friction losses. [1]
In Darcy-Weisbach equation, pressure drops in pipe due to friction losses is a function of flow
rate, density, viscosity, pipe diameter, pipe surface roughness & length of pipe which is given by:
[2]

𝐿𝑒
∆𝑃𝑓 = 2𝑓𝑓 ( )𝜌𝑢2
𝑑𝑖 (1)

𝑤ℎ𝑒𝑟𝑒; ∆𝑃𝑓 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 (𝑃𝑎)

𝑓𝑓 = 𝑓𝑎𝑛𝑛𝑖𝑛𝑔 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝑁𝑜𝑛 − 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛𝑎𝑙 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦)
𝐿𝑒 = 𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝐿𝑒𝑛𝑔𝑡ℎ (𝑚)
𝑑𝑖 = 𝑝𝑖𝑝𝑒 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 (𝑚)
𝑘𝑔
𝜌 = 𝑓𝑙𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 ( ⁄ 3 )
𝑚
𝑚
𝑢 = 𝑓𝑙𝑢𝑖𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 ( ⁄𝑠)

Two variants of friction factors have been used in Darcy-Weisbach equation i.e., fanning friction
factor and Darcy friction factor. Moody used Darcy friction factor in his renowned chart i.e.,
Moody Chart 1944, though now both version of diagrams has been prepared. Darcy friction factor
is four times greater than fanning friction factor. [3]

𝑓𝑑 = 4𝑓𝑓
(2)
𝑓𝑑 = 𝐷𝑎𝑟𝑐𝑦 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 (𝑁𝑜𝑛 − 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛𝑎𝑙 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦)
Thus, (1) becomes,
𝐿𝑒 𝜌𝑢2
∆𝑃𝑓 = 𝑓𝑑 ( )
𝑑𝑖 2 (3)

Darcy frictional factor is a non-dimensional quantity which is function of Reynolds’s number and
pipe roughness. [4] [5]
Eq. (3) incorporates losses due to fittings, elbows etc. as here equivalent length is considered
instead of simple piping length. Method to calculate equivalent length will be discussed later.
In laminar flow regime, Darcy friction factor is given as: [4]
64
𝑓𝑑 = (4)
𝑅𝑒
It is shown in Moody chart at extreme left for laminar flow.
It should be noted that in laminar flow fd is independent of roughness of pipe but varies only with
Re number.
In turbulent flow region, three categories exist: flow in smooth pipes, flow in rough pipe with high
velocities, and flow in transition zone. For flow in smooth pipes, fd vary with Re as shown by lower
curve labelled as smooth pipes in Moody chart. This clearly implies that fluid properties influence
flow through entire range of Re number. Glass pipes, smooth tubing and smooth pipes with large
diameters fall into this category. [1]
Equation (5) described that region in Moody chart.
For entire turbulent regime in smooth pipes, Darcy friction factor is: [4]
1
= 2.0 log(𝑅𝑒√𝑓𝑑 ) − 0.08 (5)
√𝑓𝑑

Flow in rough pipe with high velocities is depicted as horizontal lines in Moody chart showing that
flow in entirely independent on fluid properties and only depends on pipe roughness as given by
equation (6). [1]
For turbulent flow regime in rough pipes, is given by equation: [4]
1
= 1.14 − 2.0log (∈⁄𝑑 ) (6)
√𝑓𝑑 𝑖

∈= absolute roughness given in Perry’s Chemical Engineering Handbook. [2]

Third category of turbulent flow lies between curve for smooth pipes and broken line in Moody
chart termed as transition region. This type of flow usually occurs in commercial pipes. Colebrook
developed a relation between friction factor, relative roughness and Re number best describing
the transition curves. [1]
1 9.35
= 2.0log (∈⁄3.75𝑑 + ) (5)
√𝑓𝑑 𝑖 𝑅𝑒√𝑓𝑑

Relative roughness to be used in Moody chart is as follows:

∈
𝑒= (6)
𝑑𝑖

Note that these are mathematical equation from which friction factor can be calculated.
Whereas, same can also be calculated using Moody chart.

Equivalent Length:
Any obstruction to flow will cause decrease in pressure (loss of energy). Obstruction could be in
the form of fittings, elbows, tees or valves used to isolate or control fluid flow. One method to

Figure 1 Moody chart [7]

incorporate the effect of pressure drop caused by such piping items is to used the length of pipe
that will cause same pressure drop as of fittings, tees etc. do. This length will be calculated as
equivalent length which is mainly sum of actual piping length and length of pipe causing pressure
drop equivalent to piping items.
References

[1] E. F. Brater, H. W. King, J. E. Lindel and C. Y. Wei, "Pipes," in Handbook of Hydraulics, 7th ed.,
McGraw Hill, 1996.

[2] J. N. Tilton, "Fluid and Particle Dynamics," in Perry's Chemical Engineers' Handbook, 7th ed.,
McGraw Hill, 1997.

[3] J. McGovern, "Technical Note: Friction Factor Diagrams for Pipe," School of Mechanical and
Transport Engineering, pp. 1-16, 10 03 2011.

[4] G. O. Brown, "The History of Darcy_Weisbach Equation for Pipe Flow Resistance," pp. 1-11,
October 2002.

[5] R. K. Sinnott, "Piping and Instrumentation," in Chemical Engineering Design, 4th ed., vol. 6,
Coulson & Richardson's Chemical Engineering Series, 2005, pp. 194-240.

[6] C. F. Colebrook, "Turbulent Flow in Pipes, with Particular Reference to the Transition Regino
between Smooth and Rough Pipe Laws," J. of Inst. Civil Engg., vol. 11, p. 133, 1939.

[7] L. F. Moody, "Friction Factor for Pipe Flow," Transactions of the A.S.M.E, 1944.