ME116P Weeks 1-4

Introduction to Industrial Plant
Engineering ME116P
INDUSTRIAL PLANT
ENGINEERING
WEEK 1
2020-2021/3T
Prepared by:
Engr. Manuel B. Rustria
March 18, 2021
3/18/2021 1
➢ Differentiate industrial plant from a central power plant station;
➢ Define industrial plant engineering and explain the basic design
concepts of industrial plant systems and equipment; and
➢ Enumerate the roles of mechanical engineers in an industrial
plant.
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INDUSTRIAL PLANT (MANUFACTURING PLANT OR
FACTORY)
➢ Industrial plants are
buildings on
industrial labor.
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FACTORY)
➢ A factory (previously manufactory) or manufacturing
plant is an industrial site, usually consisting of buildings
and machinery, or more commonly a complex having
several buildings, where workers manufacture goods or
operate machines processing one product into another.
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FACTORY)
➢ Factories arose with the introduction of machinery during
the Industrial Revolution when the capital and space
requirements became too great for cottage industry or
workshops.
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FACTORY)
➢ Early factories that contained small amounts of
machinery, such as one or two spinning mules, and fewer
than a dozen workers have been called “glorified
workshops.”
➢ Most modern factories have large warehouses or
warehouse-like facilities that contain heavy equipment
used for assembly line production.
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FACTORY)
➢ Large factories tend to be located with access to multiple
modes of transportation with some having rail highway
and water loading and unloading facilities.
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FACTORY)
➢ Factories may either make discrete products of some type
of material continuously produced such as chemicals,
pulp and paper or refined oil products.
➢ Factories manufacturing chemicals are often called plants
and may have most of their equipment – tanks, pressure
vessels, chemical reactors, pumps and piping – outdoors
and operated from control rooms.
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FACTORY)
➢ Oil refineries have most of their equipment outdoors.
➢ Discrete products may be final consumer goods, or parts
and sub-assemblies which are made into final products
elsewhere.
➢ Factories may be supplied parts from elsewhere or make
them from raw materials.
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FACTORY)
➢ Continuous production industries typically use heat or
electricity to transform streams of raw materials into
finished products.
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FACTORY)
➢ The term mill originally referred to the milling of grain,
which usually used natural resources such as water or
wind power until those were displaced by steam power in
the 19th century.
➢ Because many processes like spinning and weaving, iron
rolling, and paper manufacturing were originally powered
by water, the term survives as in steel mill, paper mill, etc.
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INDUSTRIAL PLANT (MANUFACTURING PLANT OR FACTORY)
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POWER STATION
➢ A power station, also referred to as a power
plant or powerhouse and sometimes generating
station or generating plant, is an industrial facility for
the generation of electric power.
➢ Most power stations contain one or more generators, a
rotating machine that converts mechanical
power into electrical power.
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POWER STATION
➢ The relative motion between a magnetic field and
a conductor creates an electrical current.
➢ The energy source harnessed to turn the generator varies
widely.
➢ Most power stations in the world burn fossil fuels such
as coal, oil, and natural gas to generate electricity.
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POWER STATION
➢ Others use nuclear power, but there is an increasing use
of cleaner renewable sources such as solar, wind, wave
and hydroelectric.
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POWER STATION
➢ Others use nuclear power, but there is an increasing use
of cleaner renewable sources such as solar, wind, wave
and hydroelectric.
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POWER STATION
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POWER STATION
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POWER STATION
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POWER STATION
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POWER STATION
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POWER STATION
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➢ Physical objects all came into being through the creative
application of technology.
➢ These everyday inventions did not miraculously appear
but originated in the minds of human beings and took
time to develop.
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➢ Engineering is the creative process of turning abstract
ideas into physical representations (products or systems).
➢ What distinguishes engineers from painters, poets, or
sculptors is that engineers apply their creative energies to
producing products or systems that meet human needs.
➢ This creative act is called design.
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➢ Engineering is the creative process of turning abstract
ideas into physical representations (products or systems).
➢ What distinguishes engineers from painters, poets, or
sculptors is that engineers apply their creative energies to
producing products or systems that meet human needs.
➢ This creative act is called design.
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➢ Most engineering designs can be classified as inventions-
devices or systems that are created by human effort and
did not exist before or are improvements over existing
devices or systems.
➢ Inventions, or designs, do not suddenly appear from
nowhere. They are the result of bringing together
technologies to meet human needs or to solve problems.
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➢ Sometimes a design is the result of someone trying to do
a task more quickly or efficiently.
➢ Design activity occurs over a period of time and requires a
step-by-step methodology.
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➢ Engineers primarily are problem solvers.
➢ What distinguishes design from other types of problem
solving is the nature of both the problem and the solution.
➢ Design problems are open ended in nature, which means
they have more than one correct solution.
➢ The result or solution to a design problem is a system that
possesses specified properties.
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➢ Design problems are usually more vaguely defined than
analysis problems.
• “Determine the maximum height of a snowball given
an initial velocity and release height.” This is an
analysis problem because it has only one answer.
• "Design a device to launch a 1-pound snowball to a
height of at least 160 feet," this analysis problem
becomes a design problem.
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• The solution to the design problem is a system having
specified properties (able to launch a snowball 160 feet),
whereas the solution to the analysis problem consisted of the
properties of a given system (the height of the snowball).
• The solution to a design problem is therefore open ended,
since there are many possible devices that can launch a
snowball to a given height.
• The original problem had a single solution: the maximum
height of the snowball, determined from the specified initial
conditions.
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➢ Solving design problems is often an iterative process: As
the solution to a design problem evolves, refining the
design continues.
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THE DESIGN PROCESS
➢ The five steps used for solving design problems are:
1. Define the problem
2. Gather pertinent information
3. Generate multiple solutions
4. Analyze and select a solution
5. Test and implement the solution
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➢ The first step in the design process is the problem
definition.
➢ This definition usually contains a listing of the product or
customer requirements and specially information about
product functions and features among other things.
➢ In the next step, relevant information for the design of
the product and its functional specifications is obtained
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➢ A survey regarding the availability of similar products in
the market should be performed at this stage.
➢ Once the details of the design are clearly identified, the
design team with inputs from test, manufacturing, and
marketing teams generates multiple alternatives to
achieve the goals and the requirements of the design.
➢ Considering cost, safety, and other criteria for selection,
the more promising alternatives are selected for further
analysis.
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➢ Detail design and analysis step enables a complete study
of the solutions and result in identification of the final
design that best fits the product requirements.
➢ Following this step, a prototype of the design is
constructed and functional tests are performed to verify
and possibly modify the design.
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➢ When solving a design problem, others may find at any
point in the process that they need to go back to a
previous step.
➢ The solution chosen may prove unworkable for any
number of reasons and may require redefining the
problem, collecting more information, or generating
different solutions.
➢ This continuous iterative process is represented in the
following Figure.
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THE DESIGN PROCESS
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➢ Oil and Gas
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➢ Oil and Gas
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➢Automotive Industry
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➢Automotive Industry
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➢Pharmaceutical Industry
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➢Pharmaceutical Industry
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➢Main Sectors Industry in Europe
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➢Main Sectors Industry in Europe
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https://en.wikipedia.org/wiki/Factory
https://en.wikipedia.org/wiki/Engineering_desi
gn_process
END.
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Methods of Handling Air Supply
ME116P
INDUSTRIAL PLANT
ENGINEERING
WEEK 2
2020-2021/3T
Prepared by:
March 27, 2021
3/23/2021 62
➢ Explain the methods of handling air supply into the room space;
and
➢ Solve problems on the methods of handling air supply into the
room space.
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The methods of handling air supply into the room
space include:
1. 100% Outdoor Supply Air, No recirculation
- uses 100% outdoor fresh air without recirculation.
2. Mixture of Outdoor Air and Re-circulated Air
- uses re-circulated air and mixes with outdoor air.
3. Outdoor Air and Re-circulated Air with External By-pass System
- replaces re-heater by an external by-pass system to modulate
supply air.
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Problems
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s
1. A space to be air-conditioned has a sensible heat load of 36 kW and a
latent heat load of 10.2 kW. The space is to maintained at 26°C DB and
50% RH. Outside air is at 32°C DB and 24°C WB temperatures. With a re-
heater to satisfy the space conditions, the conditioned air will enter the
space at 19°C. If 45% of the supply air is fresh air, and the rest is re-
circulated, find:
a. The volume flow rate of fresh air at supply conditions;
b. The apparatus dew-point temperature;
c. The refrigeration load in TR; and
d. The re-heater capacity.
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s
1. Solution:
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s
2. An assembly hall had to have an air-conditioning unit (ACU) installed that
would be maintained at 26 °C DB and 50% RH. The ACU delivers air at 15
°C DB and the calculated sensible heat load, QS, is 150 kW and latent heat
load, QL, is 51.3 kW. Twenty percent by weight of extracted air is made up
of outside air at 34 °C DB and 60% RH, while the remaining air is extracted
by the air conditioner from the assembly hall. Determine the refrigeration
load in TR and the ventilation load in kW.
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J.R. Francisco. (2006), Guidebook in AIR CONDITIONING – Analysis and Design, C& E Publishing
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BASIC COMPONENTS OF AHU AND FCU,
FAN AND DUCT SYSTEMS
ME116P
INDUSTRIAL PLANT
ENGINEERING
WEEK 3
2020-2021/3T
Prepared by:
March 30, 2021
4/8/2021 72
➢ Differentiate AHU from FCU, direct expansion refrigeration
system from chilled water system;
➢ Enumerate the components of AHU and FCU;
➢ Draw the schematic diagrams of AHU and FCU showing the
different components;
➢ Explain filter MERV rating and the different applications of the
MERV ranges;
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➢ Define clean room, enumerate its application in the industry,
and draw a schematic diagram of a clean room air conditioning
system;
➢ Identify the classifications of ducts system; and
➢ Solve problems on duct system.
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➢ In simple terms, an air handling unit (AHU) is a component of an
HVAC system that cools and distributes air into the space through a
duct.
➢ A fan coil unit (FCU) is a standalone system that circulates the
existing air in a small space, but it can also be a part of an HVAC
system.
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➢ AHU (air handling unit) and FCU (fan coil unit) are both included
in the HVAC systems. However, AHU differs in many ways from
FCU.
➢ AHUs are usually connected to a central HVAC system; whereas,
FCU can function or be installed independently. Thus, the AHUs
are used to ventilate an entire building whereas FCUs are used in
smaller and often local spaces only.
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➢ AHU is the bigger HVAC system, while the FCU is regarded as the
smaller version of the AHU.
➢ Hence, the smaller FCUs can be called as terminal units.
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➢ Because of the magnitude of the AHU system, it usually makes
use of the air from the outside environment.
➢ Thus, it treats outside air and brings it inside the vicinity with the
use of special ducts while an FCU system on the contrary just
circulates the inside air.
➢ The latter usually does not have any duct system that’s why it is
obviously smaller in size as previously mentioned. It is only
composed of a simple coil and fan.
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➢ Ordinarily, AHUs have certain features that are not present in
the FCU type.
➢ AHUs have several sections for reheating and even humidifying.
FCUs don’t have sections such as these.
➢ Perhaps the only advantage that the FCU has over the AHU is
that generally, FCUs can also handle water while the AHUs
basically handle air.
➢ AHUs can have several fans or blowers installed in its system.
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➢ The AHU’s blowers are placed at the point where the ducts
originate or at the terminal end of the air handler unit. FCUs
have a different approach to blowers.
➢ Because of their small size, fans are usually placed within the
same space as the units themselves.
➢ The result is a minor uncomfortable noise that can be heard
within the vicinity. This could be regarded as the single most
advantageous flaw of the FCU system.
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➢ In summary,
1. AHU is generally a bigger system than FCU.
2. AHU is more complex than the FCU; consequently, AHU is
often used in bigger establishments or spaces.
3. The AHU system usually channels air through ducts, whereas
the FCU doesn’t have any ductworks.
4. AHU system treats outside air while FCU system basically
recycles or re-circulates the air.
5. AHU has sections for reheating and humidifying, whereas the
FCU does not have such system.
6. FCU is often observed to be noisier than the AHU.
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DX CENTRAL AIR-CONDITIONING SYSTEM VS. CHILLED WATER
SYSTEM
➢ In the DX type of central air conditioning plants, the air used for
cooling the room is directly chilled by the refrigerant in the
cooling coil of the air handling unit.
➢ In case of the chilled water system, the cooling effect from the
refrigerant is first transferred to the chilled water, which is then
used to chill the air used for cooling the room.
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SYSTEM
➢ There is some loss of the cooling effect when it is being
transferred from the refrigerant to the chilled water and from
there to the air. Thus, the chilled water systems have lesser
cooling efficiency.
➢ The chilled water acts as the secondary medium for cooling the
room air in air handling unit.
➢ Further, the chilled water has to flow long distance along the
whole building.
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SYSTEM
➢ Thus, the chilled water flowing along the line gets heated due to
flow friction and also due to surrounding heat absorption.
➢ The chilled water also has to be pumped by the pump, which
adds more heat to it.
➢ Thus, as the chilled water flows from the chiller to the air
handling unit and again back to the chiller, apart from the heat
from air, it also absorbs lots of additional heat, which leads to
high increase in its temperature.
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SYSTEM
➢ The chiller has to remove this additional heat from the water due
to which its efficiency decreases or rather additional power is
required to remove this additional heat.
➢ In the DX type of central air conditioning plants, the refrigerant
travels only through the small distances and there is no pump
involved so the additional heat absorption is less, which makes
the DX plants even more efficient.
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SYSTEM
➢ In the direct expansion types of the central air conditioning
plant, the refrigerant like R22 flows through the whole air
conditioning system including the air handling unit.
➢ When the refrigerant flows in the refrigeration piping there is
lots of drop in its pressure.
➢ Thus, the length of the refrigeration tubing and the distance
between the condenser and the air handling unit should be kept
as minimum as possible.
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SYSTEM
➢ If the air handling unit is kept at the height more than the
condenser, the loss in pressure is pronounced since refrigerant
travelling from the condenser to the air handling unit is in liquid
state.
➢ As the distance between the air handling unit and the condenser,
the loss in pressure also increases.
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SYSTEM
➢ At certain point the losses may be so high that the refrigerant
may not be able to reach the air handling unit, leading to
complete failure of the system.
➢ At the larger height difference there is also oil return problem
from the refrigerant to the compressor.
➢ The height difference between the condenser and the air
handling units has to be quite reasonable so that they can
function well.
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SYSTEM
➢ Due to these reasons, in direct expansion type of the central air
conditioning, there is limitation on the distance between the
condenser and the air handling unit.
➢ The distance between the two cannot be too high. This limits the
application of the direct expansion type of central air
conditioning systems to the small buildings or a number of
rooms on the single floor. In such cases, the plant room and air
handling room and the rooms to be cooled are located on the
4/8/2021 91
same floor.
SYSTEM
➢ One of the solutions to increase the capacity of the DX systems
could be to increase the number of air handling units on upper
floors.
➢ But with this arrangement, there will be additional number of
joints in the refrigerant tubing from which there will be higher
chances of leakage of highly expensive refrigerant.
➢ This leads to too many operational and maintenance problems.
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SYSTEM
➢ It is suggested to employ compressor of very high capacity to
increase the refrigerant pressure, but this will lead to highly
excessive capital and running costs of the plant.
➢ This arrangement requires installation of compressor whose
capacity is much higher than needed.
➢ Thus, the direct expansion air conditioning systems are used only
for smaller buildings or various rooms on the same floor.
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SYSTEM
➢ There are no pressure loss problems in the chilled water system.
➢ In this system, chilled water is pumped by the pump at very high
pressure, which is good enough to carry it to various floors of the
multi-storey building.
➢ The losses in the pressure of water are accommodated by the
sufficient capacity of the pump, which has low capital and
running cost.
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SYSTEM
➢ Further, the water doesn’t carry any oil so there are no oil return
problems.
➢ In case of the chilled water system, compressor, condenser,
expansion valve and chiller are all kept at the same level in the
single plant room.
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SYSTEM
➢ Further, there is no problem concerning the height difference
between the condenser and the air handling unit since the
refrigerant does not flow to the air handling unit.
➢ The flow of the refrigerant is limited to the chiller plant.
➢ The water chilled in the chiller flows to the various air handling
units kept on different floors of the building.
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SYSTEM
➢ The whole arrangement and the structure of the chilled water
type of central air conditioning plant makes it more suitable for
cooling the large multi-storey buildings and even for very long
distances along the same floor level.
➢ This makes the chilled water central air conditioners more
popular than the direct expansion type ones.
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AIR HANDLING UNIT
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AIR HANDLING UNIT
➢ The definition of air handling unit from ANSI/AHRI Standard 430-
2009 states that it is "A factory-made encased assembly
consisting of a fan or fans and other necessary equipment to
perform one or more of the functions of circulating, cleaning,
heating, cooling, humidifying, dehumidifying and mixing of
air....“
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AIR HANDLING UNIT
➢ The AHU is used to control the following parameters of the
space.
▪ Temperature
▪ Humidity
▪ Air Movement
▪ Air Cleanliness
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AIR HANDLING UNIT
➢ Draw-Through or Blow-Through
There are basically two types of air handling unit that are in used
and they are the "Draw-Through" or "Blow-Through".
▪ In the Draw-Through type, the fan pulls the air through the
mixing box, filters and cooling coil before discharging it from
the fan outlet to the space to be conditioned or to the ducting
network. The design can be vertical or horizontal. In this case,
the section before the fan has negative pressure.
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AIR HANDLING UNIT
➢ Draw-Through or Blow-Through
▪ In the Blow-Through type, the fan blows the air through the
mixing box, filters and cooling coil before discharging them to
the space being conditioned or the ducting system. In this
case, the section after the fan has positive pressure.
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AIR HANDLING UNIT
➢ Components of Air Handling Unit
Here are some of the air handling unit components that may be
contained in the equipment.
▪ Housing
• The housing that contains all the other components of an
AHU is usually make of metal, some are painted to prevent
corrosion.
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AIR HANDLING UNIT
Here are some of the air handling unit components that may be
contained in the equipment.
▪ Housing
• The housing that contains all the other components of an
AHU is usually make of metal, some are painted to prevent
corrosion.
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AIR HANDLING UNIT
▪ Housing
• In sections where the fans and the coil are located, 1-2
inches of polyurethane foam or PU is used to insulate them
to prevent the condensation on the panel. Drain pan is also
used as a precaution in the event of condensation of water.
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AIR HANDLING UNIT
▪ Fan
• Centrifugal fan is used to circulate the air to the various
parts of the sections in the building.
• The typical types of fan available are
a) Backward Inclined,
b) Backward Curved,
c) Forward Curved and
d) Airfoil.
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AIR HANDLING UNIT
▪ Fan
• The selection of the fan will depend on the air volume and
the static pressure required of the system.
• Usually, the designer of the system will use a specialized
software to do this selection.
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AIR HANDLING UNIT
▪ Fan
• In order to reduce the effect of vibration on the panel, the
motor and the fan are usually installed on the vibration
isolator except when the drive assembly is external to the
fan casing.
• In recent years, the use of variable air volume (VAV) system
is becoming more popular as the volume of the air being
discharged can be varied depending on the load condition.
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AIR HANDLING UNIT
▪ Fan
• If the load is high, the fan speed will be higher and if the
load is lower, the speed of the fan will be lower.
• The speed of the fan is varied by using frequency inverter
instead of conventional motor such as PSC motor.
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AIR HANDLING UNIT
▪ Fan
• Frequency inverter provides better control of the fan speed
as a whole range of fan speed from super low to super high
can now be utilized based on the load conditions required.
• This technology has enabled better use of energy and is in
tandem with the move to go for greener energy.
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AIR HANDLING UNIT
▪ Cooling Coil
• Cooling Coil is used to cool and dehumidify the air.
• Both DX (direct expansion) cooling and CW (chilled water)
cooling coils are available for use depending on the system
design.
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AIR HANDLING UNIT
▪ Cooling Coil
• These coils are arranged in rows with different fin spacing.
Aluminium fins and copper tubes are used in the design of
the coils.
• The corrosion resistance hydrophilic fins are also used due
to its lower cost and lower resistance to the air velocity.
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AIR HANDLING UNIT
▪ Filters
• Filters are to remove particles and contaminants of various
sizes from the air. The type of air filter being used will very
much depend on the application of the system.
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AIR HANDLING UNIT
▪ Filters
1) Panel Filter is a flat and rectangular in shape and
provides a minimum low efficiency filtration which is
acceptable to the air conditioning industry. The high
velocity filter is arranged vertically whereas the low
velocity filter is arranged in V shape. Typical air velocity
that moves through the filters is in the range of 2-3 m/s.
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AIR HANDLING UNIT
▪ Filters
2) HEPA Filter is very efficient and is able to achieve
efficiencies up to 99.97%, removing minute particles
and airborne bacteria from the air. It is usually used in
clean room applications such as semiconductor
production floor, operating theaters and critical
processes.
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AIR HANDLING UNIT
▪ Filters
3) Electrostatic Filter is used to remove particles from the
air by using highly charged electrodes that ionized the
air. Bag Filter is able to remove dust particles and is
thrown away after use. Roll Filter is used for high
velocity filtration where the used part is rolled up
automatically/manually.
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AIR HANDLING UNIT
▪ Humidifiers
• During winter, the humidity level of the air can be low
hence causing discomfort to the occupants. The humidity
of the air is increased by using the humidifiers. Here are the
commonly used humidifiers:
1) Spray Type has a header and spray nozzles that spray
water with a pressure of 15 psi or more.
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AIR HANDLING UNIT
▪ Humidifiers
2) Steam Pan Type has a pan and a heating coil to heat up
the water of the pan. The evaporation of water caused
by the heating will increase the humidity level of the
surrounding air.
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AIR HANDLING UNIT
▪ Humidifiers
3) Steam Grid Type has tiny holes on the pipe to distribute
the steam that flows through it. In this case, the water
that is heated up to produce the steam to be supplied to
the grid is conditioned to prevent odor being discharged
to the room.
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AIR HANDLING UNIT
▪ Mixing Box
• This box has air inlets that is attached to the dampers.
• This is the place where the outside air and the return air
are mixed to provide the correct proportion of air to be
distributed to the space that is to be conditioned.
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FAN-COIL UNIT
➢ Components of
Fan Coil Unit
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FAN-COIL UNIT
➢ A fan-coil unit is a terminal unit installed inside the conditioned
space or in the ceiling plenum just above the conditioned space.
➢ A fan-coil unit includes a small motor driven centrifugal fan or
two small centrifugal fans connected in parallel a finned coil filter
and outer casing and controls sometimes a cooling coil or a
heating coil may be connected in series along the airflow.
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FAN-COIL UNIT
➢ A fan-coil unit can be horizontal unit installed inside the ceiling
plenum, a vertical unit mounted on the floor under windowsill or
a stack unit installed vertically along the two sides of the
window.
➢ Vertical and stack units are usually used to offset the cold draft
on the inner surface of window glass or on the external wall
during cold weather.
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FAN-COIL UNIT
➢ Cold draft often flows downward along the glass because it is
heavier than the surrounding air.
➢ Warm air discharged from a fan coil during winter heating rises
the inner surface temperature of window glass.
➢ Horizontal and vertical fan-coil unit are available in standard sizes
of 02, 03, 04, 06, 08, 10, 12, 16, and 20.
➢ The 02 means a nominal flow rate of 200 cfm, 04 means 400 cfm
and so on.
4/8/2021 125
FAN-COIL UNIT
➢ Components of Fan Coil Unit
▪ Fan
• Double-width, double-inlet, forward-curved centrifugal fans
are usually used because of their compact size and lover
level.
• The fan wheels are usually made of aluminum or galvanized
steel with a diameter less than 10 inches (250 mm) in most
cases fan housing are die-formed with integral scrolls and
inlets.
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FAN-COIL UNIT
▪ Fan Motor
• Permanent-slip capacitor (PSC) motor and shaded-pole (SP)
motors are used.
• PSC motors have an efficiency f 55 to 70 percent which is
considerably higher than that of SP motors, which have 30
to 40 percent efficiency.
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FAN-COIL UNIT
▪ Coil
• Coils are usually made from copper tubes and aluminum
fins.
• Cooling-heating coil usually have two, three, or four rows of
fins, depending on the coil on the coil’s cooling capacity
and the sensible heat ratio of the cooling and
dehumidifying process.
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FAN-COIL UNIT
▪ Coil
• SHR, two-row coil and widely used four-row coil have a
greater dehumidifying capacity.
• Usually, there is only one coil for both heating and cooling.
• A separate electric heating coil is sometimes used with
two-stage step control in location where the heating
season is short or energy rates are low in winter.
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FAN-COIL UNIT
▪ Coil
• Manual air vents are installed to prevent the formation of
air pockets inside the water circuit.
• A galvanized—steel pan with an insulating liner is often
used to drain the condensation on the fan-coil unit.
• To reduce the air side pressure loss, the face velocity of the
air flowing through the coil is usually from 200 fpm (1m/s)
to 300 fpm (1.3 m/s)
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FAN-COIL UNIT
▪ Filters
• Usually low-efficiency, low-pressure drop permanent filter
are used.
• They are easy to clean and replace periodically.
• Sometimes disposable low efficiency fiberglass are used.
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➢ MERV is the Minimum Efficiency Reporting Value, which is the
scale designed by the American Society of Heating,
Refrigerating, and Air Conditioning Engineers (ASHRAE) to rate
the effectiveness of air filters.
➢ Basically, the higher MERV rating indicates higher filtering
performance.
➢ The most recommended MERV ratings for residential filters are
between MERV 7 and MERV 13.
➢ In fact, filters with these MERV ratings perform as efficiently as
true HEPA filters.
4/8/2021 134
➢ They all basically trap the same range of particulates,
particulates such as dust particles, mold spores, dust mite debris,
tobacco smoke, pet dander, and pollen, but each filter has a
higher capturing capacity the higher the MERV.
➢ There are really two different components of a MERV rating.
▪ One is the ability to remove large airborne particles, or
particles that are between 1 and 10 microns. These “large”
particles include pet dander, pollen grains, dust mite debris,
etc. However, the bulk of indoor air pollutants are in a smaller
size range.
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▪ MERV also rates the filter’s ability to remove submicron
particles, those that are smaller than 1 micron; this rating is
called the Microparticle Performance Rating (MPR), and some
filters are given just this rating.
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➢ A cleanroom or clean room is
an environment, typically used
in manufacturing, including of
pharmaceutical products or
scientific research, as well as
aerospace semiconductor
engineering applications with a
low level of environmental
pollutants such as dust,
airborne microbes, aerosol Cleanroom used for the production of microsystems.
The yellow (red-green) lighting is necessary for
particles, and chemical vapors.
4/8/2021
photolithography, to prevent unwanted exposure
of photoresist to light of shorter wavelengths.
144
➢ More accurately, a cleanroom
has a controlled level of
contamination that is specified
by the number of particles per
cubic meter at a specified
particle size.
Cleanroom from outside
4/8/2021 145
➢ To give perspective, the ambient air
outside in a typical urban
environment contains 35,000,000
particles per cubic meter in the size
range 0.5 μm and larger in diameter,
corresponding to an ISO 9 cleanroom,
while an ISO 1 cleanroom allows no
particles in that size range and only 12
particles per cubic meter of 0.3 μm
and smaller.
4/8/2021
Entrance to a cleanroom with no air shower 146
AIR FLOW PRINCIPLES
Air flow pattern for Air flow pattern for

4/8/2021 "Turbulent Cleanroom" "Laminar Flow Cleanroom"
147
AIR FLOW PRINCIPLES
➢ Cleanrooms maintain particulate-free air through the use of
either HEPA or ULPA filters employing laminar or turbulent air
flow principles.
➢ Laminar, or unidirectional, air flow systems direct filtered air
downward or in horizontal direction in a constant stream
towards filters located on walls near the cleanroom floor or
through raised perforated floor panels to be recirculated.
➢ Laminar air flow systems are typically employed across 80% of a
cleanroom ceiling to maintain constant air processing.
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AIR FLOW PRINCIPLES
➢ Stainless steel or other non shedding materials are used to
construct laminar air flow filters and hoods to prevent excess
particles entering the air.
➢ Turbulent, or non unidirectional, air flow uses both laminar air
flow hoods and nonspecific velocity filters to keep air in a
cleanroom in constant motion, although not all in the same
direction.
➢ The rough air seeks to trap particles that may be in the air and
drive them towards the floor, where they enter filters and leave
the cleanroom environment.
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AIR FLOW PRINCIPLES
➢ US FDA and EU have laid down guidelines and limit for microbial
contamination which is very stringent to ensure freedom from
microbial contamination in pharmaceutical products.
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Personnel contamination of cleanrooms
➢ In the healthcare and pharmaceutical
sectors, control of microorganisms is
important, especially microorganisms
likely to be deposited into the air
stream from skin shedding.
➢ Studying cleanroom microflora is of
importance for microbiologists and
quality control personnel to assess
changes in trends.
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PERSONNEL CONTAMINATION OF CLEANROOMS
➢ Shifts in the types of microflora may indicate deviations from the
“norm” such as resistant strains or problems with cleaning
practices.
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PERSONNEL CONTAMINATION OF CLEANROOMS
➢ In assessing cleanroom microorganisms, the typical flora are
primarily those associated with human skin (Gram-positive
cocci), although microorganisms from other sources such as the
environment (Gram-positive rods) and water (Gram-negative
rods) are also detected, although in lower number. Common
bacterial genera include Micrococcus, Staphylococcus,
Corynebacterium, and Bacillus, and fungal genera include
Aspergillus and Pencillin.
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CLEANROOM CLASSIFICATION AND STANDARDIZATION
➢ Cleanrooms are classified according to the number and size of
particles permitted per volume of air.
➢ Large numbers like "class 100" or "class 1000" refer to FED-STD-
209E, and denote the number of particles of size 0.5 µm or larger
permitted per cubic foot of air. The standard also allows
interpolation; for example SNOLAB is maintained as a class 2000
cleanroom.
➢ A discrete, light-scattering airborne particle counter is used to
determine the concentration of airborne particles, equal to and
larger than the specified sizes, at designated sampling locations.
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➢ Small numbers refer to ISO 14644-1 standards, which specify the
decimal logarithm of the number of particles 0.1 µm or larger
permitted per m3 of air.
➢ So, for example, an ISO class 5 cleanroom has at most
105 particles/m3.
➢ Both FS 209E and ISO 14644-1 assume log-log relationships
between particle size and particle concentration.
➢ For that reason, zero particle concentration does not exist. 9.[10]
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➢ Some classes do not require testing some particle sizes, because
the concentration is too low or too high to be practical to test for,
but such blanks should not be read as zero.
➢ Because 1 m3 is about 35 ft3, the two standards are mostly
equivalent when measuring 0.5 µm particles, although the
testing standards differ.
➢ Ordinary room air is around class 1,000,000 or ISO 9.
4/8/2021 156
ISO 14644-1 and ISO 14698
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DESIGN OF DUCT SYSTEMS
➢ A duct system consists of necessary sections of straight duct,
elbows, branch outlets and inlets, dampers, and such terminal
units as registers and diffusers.
➢ In designing the duct system, the pressure drop contributed by
heat-transfer coils and filters must also be included.
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➢ The chief requirements of duct system are:
1) that it conveys specified rates of airflow to prescribed
locations,
2) that it be economical in combined first cost, fan-operating
cost, and cost of building space occupied , and
3) that it not transmits or generates objectionable noise.
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➢ Since there are so many decisions to make in selecting the size of
ducts and fittings, and since each decision affects the remainder
of the system, the design of duct system is (or at least could be) a
sophisticated operation.
➢ The design procedures outlined next are simply methodical
procedures for arriving at duct sizes that are reasonable with
respect to space requirements and velocities.
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➢ There are three major design techniques in use:
1) velocity method,
2) equal-friction method, and
3) static-regain method.
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VELOCITY METHOD
➢ In this method of duct design, the velocities in the mains and
branches are selected and the pressure drops in all runs
calculated.
➢ The fan is selected to provide a pressure sufficient to meet the
requirements of the run with the highest pressure drop.
➢ Standard practice calls for installation of a balancing damper in
each branch line, and the damper in the run calling for highest
pressure difference is left completely open while the other
dampers are throttled to reduce the flow rate to the design value.
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VELOCITY METHOD
➢ No fixed recommendations can be given for the velocity to be
selected because the choice is a function of the economics,
space limitations, and type of acoustic treatment.
➢ High velocities result in high pressure drops that are costly in fan
power if they occur in the critical run.
➢ High velocities also result in increased noise generation.
➢ On the other hand, high velocities permit small ducts, which are
lower in first cost and require less space in the building.
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VELOCITY METHOD
➢ For air-duct system in public buildings with no extensive acoustic
treatment, typical velocities in the main duct are of the order of
5 to 8 m/s and in the branch ducts 4 to 6 m/s.
➢ Typical velocities for residential systems are lower and velocities
for industrial buildings are higher than those quoted for public
buildings.
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VELOCITY METHOD
Figure 6-13 Multibranch duct system

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VELOCITY METHOD
➢ In the duct system shown schematically in Fig. 6-13, the airflow-
rate requirements at outlets 1 to 5 will all be known from the
cooling and heating-load calculation, so the flow rate in each of
the sections A to I can be computed.
➢ In applying velocity method of duct design, velocities will be
selected for all the sections and the pressure drop in each run
calculated using applicable relations for straight ducts, elbows,
and branch takeoffs and manufacturer’s date for other
components, e.g., coils and filters.
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VELOCITY METHOD
➢ Suppose that the calculation results in the pressure drops shown
in Table 6-5.
➢ A fan could be selected to develop 92 Pa at the total flow rate,
the balancing damper left open in run A-C-G-H and the dampers
in the other runs partially closed to provide 92 Pa pressure drop
in all these runs at the desired flow rates.
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VELOCITY METHOD
➢ An improved design results if one or more sections of run A-C-G-H
are enlarged to reduce the critical pressure drop.
➢ It is also possible to reduce the size of sections in the other runs
while staying within velocity constraints, since excess pressure
drop available.
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EQUAL-FRICTION METHOD
➢ There are several versions of the equal-friction method but one
that often results in a superior design is to select the pressure
drop to be available in the duct system and size the ducts to
dissipate this pressure.
➢ The steps in this design method are as follows:
1. Decide what pressure drop will be available.
2. Compute the equivalent length of all runs (the sum of the
length of straight duct plus the equivalent length of fittings).
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3. Divide the available pressure drop by the equivalent length of
the run having the longest equivalent length.
4. With the pressure gradient from step 3 and the flow rate in
each section of the longest run, select the duct size of all
those sections, using Fig. 6-2.
5. For the remaining sections, select the size to use in available
pressure drop but stay within velocities appropriate for noise
restrictions.
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➢ In step 2 the equivalent length can be computed by dividing the
coefficient of the V2𝜌/2 term in the equation for the pressure loss
of the fitting by f/D for duct of the same size.
➢ Elbows might be equivalent to 3 to 12 m and branch takeoffs 20 m
of straight duct.
➢ In step 5 some sections of the main duct might have been
selected in sizing sections in the critical run.
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➢ If the critical run in the system shown in Fig. 6-13 is A-C-G-H, for
example, the size of A will be specified in step 4, so the pressure
available to section B should be computed and the size of B
chosen to dissipate the available pressure.
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PROBLEMS
6-1 Compute the pressure drop of 30°C air flowing with a mean
velocity of 8 m/s in a circular sheet-metal duct 300 mm in
diameter and 15 m long, using (a) Eqs. (6-1) and (6-2) and (b) Fig.
6-2. Ans. (a) 36 Pa
6-2 A pressure difference of 350 Pa is available to force 20°C air

through a circular sheet-metal duct 450 mm in diameter and 25
m long. Using Eq. (6-1) and Fig. 6-1, determine the velocity.
Ans. 25.6 m/s
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PROBLEMS
6-3 A rectangular duct has dimensions of 0.25 by 1 m. Using Fig.
6-2, determine the pressure drop per meter length when 1.2
m3/s of air flows through the duct. Ans. 0.65 Pa/m
6-4 A sudden enlargement in a circular duct measures 0.2 m

diameter upstream and 0.4 m diameter downstream. The
upstream pressure is 150 Pa and downstream is 200 Pa. What is
the flow rate of 20°C air through the fitting? Ans. 0.467 m3/s
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PROBLEMS
6-5 A duct 0.4 m high and 0.8 m wide, suspended from a ceiling
in a corridor, makes a right-angle turn in the horizontal plane. The
inner radius is 0.2 m, and the outer radius is 1.0 m, measured
from the same center. The velocity of air in the duct is 10 m/s.
To how many meters of straight duct is the pressure loss in this
elbow equivalent? Ans. 15 m.
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PROBLEMS
6-6 A 0.3- by 0.4-m branch duct leaves a 0.3- by 0.6-m main duct
at an angle of 60°. The air temperature is 20°C. The dimensions
of the main duct remain constant following the branch. The flow
rate upstream is 2.7 m3/s. What is the pressure (a) downstream
in the main duct and (b) in the branch duct? Ans. (a) 346 Pa, (b)
209 Pa
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PROBLEMS
6-7 in a branch entry, an airflow rate of 0.8 m3/s joins the main
stream to give a combined flow rate of 2.4 m3/s. The air
temperature is 25°C. The branch enters with an angle 𝛽 = 30°
(see Fig. 6-12). The area of the branch duct is 0.1 m2,and the
area of the main duct is 0.2 m2 both upstream and downstream.
What is the reduction in pressure between points u and d in the
main duct?Ans. 95 Pa
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PROBLEMS
Figure 6-20 Duct system in Prob. 6-8

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PROBLEMS
6-8 A two-branch duct system of circular duct is shown in Fig. 6-
20. The fittings have the following equivalent length of straight
duct: upstream to branch, 4 m; elbow, 2 m. There is a negligible
pressure loss in the straight-through section of the branch. The
designer selects 4 Pa/m as the pressure gradient in the 12- and
15-m straight sections. What diameter should be selected in the
branch section to use the available pressure without dampering?
Ans. 0.35 m
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BOOK
▪ Stoecker, W.F. and Jones, J.W. (2nd Ed.). Refrigeration and Air
Conditioning.
WEBSITES
▪ http://www.differencebetween.net/object/difference-
between-ahu-and-fcu/
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▪ http://www.brighthubengineering.com/hvac/50414-comparison-of-dx-and-
chilled-water-central-air-conditioning-plants/
▪ https://en.wikipedia.org/wiki/Cleanroom
▪ https://www.airconditioning-systems.com/air-handling-unit.html
▪ https://www.slideserve.com/edana/duct-design
▪ http://technicaltheory.blogspot.com/2015/07/components-of-fan-coil-
unit.html
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Water Supply, Quality and
Distribution System
ME116P
INDUSTRIAL PLANT
ENGINEERING
WEEK 4
2020-2021/3T
Prepared by:
April 6, 2021
4/5/2021 185
➢ Explain factors in selecting water sources;
➢ Draw schematic diagram for each water source;
➢ Identify water quality requirements for each industrial
/manufacturing set-up;
➢ Draw and explain water softening using sodium zeolite water
softener; and
➢ Draw and explain water de-ionization/ demineralization.
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Introduction
➢ Water is essential for life, but for many people, the quantity of
water available may be minimal, and the water may be of poor
quality.
➢ This presentation outlines some of the issues which need to be
considered when planning improvements to supplies, to ensure
that the most appropriate sources of water are selected.
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1. Rainwater
➢ Collecting rainwater from either an existing roof structure or a
ground catchment area can provide a useful supplementary
source of water even if it is not used as the main supply.
➢ Storage tanks are usually required to make the best use of
rainwater.
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2. Surface water
➢ When rain falls to the ground it becomes surface water, where it
may move across the ground in the form of streams or rivers, or
remain in one place in the form of ponds or lakes.
➢ Surface water is easily polluted and can be affected by wide
seasonal variations in turbidity ('muddiness') and flow.
➢ Variations in turbidity present a challenge for the effective
operation of treatment processes, while variations in flow affect
the location and design of abstraction structures.
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Surface water
➢ Surface water, however, is often the easiest to access (see
illustration)
4/5/2021 191
3. Groundwater
➢ Some surface water sinks into the
ground and becomes groundwater.
➢ Here it can remain for a long time in an
aquifer — spaces underground which
can hold water because the
surrounding earth and rock is
impervious (does not let water
through).
4/5/2021 192
Groundwater
➢ Groundwater may be obtained in several ways:
▪ Water from mountain springs can often be transmitted to
areas of demand by gravity, limiting the operation and
maintenance requirements of a supply system.
4/5/2021 193
Groundwater
▪ Shallow wells can also provide a supply system with minimal
operation and maintenance requirements — particularly if
they are well-constructed, protected, and fitted with a hand
pump. For larger supplies, diesel or petrol pumps may be used
in place of hand pumps. Shallow wells can often be
constructed using local techniques and labour.
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Groundwater
▪ Shallow or deep boreholes usually require drilling equipment
and an experienced drilling team, but they can provide high-
yield supplies of good-quality water. Groundwater, however,
may be affected by high levels of chemicals, such as fluoride
or chloride.
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Groundwater
➢ Locating groundwater can be difficult. The presence of existing
wells with good, stable yields, other positive hydrological
features, or information from satellite images can highlight
groundwater potential but, following this, extensive field trials
are usually required to determine acceptable borehole locations.
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➢ Three primary factors in selecting a water source for
development involve
• water quantity - amount of water that is available at the
source and the amount of water that will be required or
demanded for use.
• water reliability – ability to supply the required amount of
water for as long as needed.
• water quality - potable and palatable, it must be tested to
determine the existence of any impurities that could cause
4/5/2021 disease, odor, foul taste, or bad color. 198
➢ Once the water source has been selected, development
of the source can begin.
➢ Developing a water source includes all work that
increases the quantity and improves the quality of the
water or makes it more readily available for treatment
and distribution.
➢ In developing a source, the engineer may use the
construction of dams, digging or drilling of wells, and
other improvements to increase the quantity and quality
of the water.
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1. DISTRIBUTION MAINS. Distribution mains are the
pipelines that make up the distribution system. Their
function is to carry water from the water source or
treatment works to users.
2. ARTERIAL MAINS. Arterial mains are distribution mains
of large size. They are interconnected with smaller
distribution mains to form a complete gridiron system.
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3. STORAGE RESERVOIRS. Storage reservoirs are structures
used to store water. They also equalize the supply or
pressure in the distribution system. A common example
of a storage reservoir is an aboveground water storage
tank.
4. SYSTEM ACCESSORIES. System accessories include the
following:
a. BOOSTER STATIONS. Booster stations are used to
increase water pressure from storage tanks for low-
4/5/2021pressure mains. 203
b. VALVES. Valves control the flow of water in the
distribution system by isolating areas for repair
or by regulating system flow or pressure.
c. HYDRANTS. Hydrants are designed to allow water
from the distribution system to be used for fire-
fighting purposes.
d. METERS. Meters record the flow of water in a part
of the distribution system.
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e. SERVICE CONNECTIONS. Service connections are
used to connect individual buildings or other
plumbing systems to the distribution system mains.
f. BACKFLOW PREVENTERS. A cross-connection is any
connection between a potable and nonpotable
water system through which a contaminating flow
can occur. Backflow preventers, such as air gaps and
vacuum breakers, are used to prevent flow through
potential cross-connections.
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https://www.youtube.com/watch?v=NQFrSnm2V6U 205
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Heavy water using industries can include food, paper, chemicals, refined
petroleum, or primary metals.
1. Ultrapure water use in semiconductor manufacturing
➢ Water is an essential component for the manufacturing of
semiconductors and chips which are used everyday in computers, cell
phones and automobiles. Ultrapure water is used throughout the process,
including to remove impurities from silicon wafers. For example, a single
8” wafer, which is the foundation for approximately 100 chips, may require
up to 2,000 gallons of UPW. As a result, semiconductor producers are
focusing on ways to recycle, reuse and reduce the amount of water
needed for operations. One notable case study is US firm Intel, which
is creating its biggest water-reuse development as part of its new D1X
factory in Hillsboro.
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2. Cooling water
➢ Cooling systems are used to remove heat from processes or
equipment. Heat removed from one medium is transferred to
another medium, or process fluid, which most often is water.
According to the SUEZ Water Technologies Handbook, the driving
force for the transfer of heat is the difference in temperature
between the two media, which in most cooling systems, is in the
range of 10-200 degrees F. Many of the properties of water,
including the behaviour of the contaminants it contains, are
affected by temperature. As a result, the tendency of a system to
corrode, scale, or support microbiological growth is also affected
4/5/2021 212
by water temperature.
3. Water use in the oil & gas markets
➢ Globally the oil and gas industry represents less than 5% of

total withdrawal but the sectors have an important role to play in
protecting the quality of water in the areas they operate. Water
is a raw material used and produced in high quantities in the oil
industry, from extraction activities through to refineries and
petrochemicals. Uses include: injection water, production water,
process water, wastewater, rainwater, cooling water, tank
cleaning water, and others.
4/5/2021 213
4. Water use in pulp & paper mills
➢ Despite digitalisation prompting a move away from printed
products, the pulp and paper sector remains one of the largest
users of industrial process water in the US and the second largest in
Europe. Water is intricately associated with 85% of all the three
stages of paper production namely, pulp making, pulp processing,
and paper/paper board manufacturing, and their associated
activities of cooking, bleaching, and washing. A high quantity of
water consumed in the pulp and paper industry is used only for
processing, thus, leading to the generation of large volumes of
contaminated wastewater.
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Industrial water quality requirements will vary considerably
depending on the application, region and local governance.
➢ For example, ultrapure water for food & beverage
manufacturing will differ to water needed for oil & gas extraction
and treatment. Even within these segments, water quality will vary
between foods – for example dairy to confectionary, and drinks,
from soft beverages to alcoholic beverages. Coupled with local
regulations and globally it is a complicated mixture of quality
requirements. However, water in the food industry should meet
the requirements of local standards for safe drinking water or
meet the requirements of the World Health Organisation (WHO)
Guidelines for Drinking-water Quality.
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Even under ultrapure water classification, there can be five grades of pure
water available, each defined by various standards and conventions. Even the
definition of ‘high purity’ water is used to describe a range of pure water
specifications.
➢ Each grade of pure water is used in a number of applications, that include
• Deionised Water – medium pressure boiler feed, renal dialysis make-up,
battery top-up;
• Purified Water – pharmaceuticals, cosmetics, chemical manufacturing;
• Apyrogenic Water – vial washing, tissue culture, water for injections;
• High Purity Water – high pressure boilers, combined heat and power
systems, laboratories;
• Ultrapure water – micro electronics, supercritical boilers. Ultrapure water
typically
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has a TOC limit of 0.05 mg/l as C and a resistivity of 18 Megohm.cm.
217
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➢ Hard Water means mainly when the ions of chloride, sulfate and
bicarbonate of calcium and magnesium are dissolved in water.
➢ Ferrous iron can also be present; in presence of oxygen it turns
into ferric iron.
➢ These minerals dissolve in water depends on pressure,
temperature, turbulence and pH levels.
➢ The main source of hard water is ground water.
➢ Rain water is purely soft water.
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➢ But as the water travels through soil and rock, it dissolves a little
amount of minerals like salt of calcium and magnesium and
holds in solution. Therefore water becomes hard.
➢ Water is universal solvent and easily contaminant.
➢ Rain water absorbs carbon di-oxide from the air and that is
making the water acidic (very weak carbonic acid). This rain
water reacts with the limestone, dolomite and chalk rocks on
earth and form water soluble bicarbonate ions.
4/5/2021 220
➢ The equation for the reaction is:
Water + carbon di-oxide + calcium carbonate = calcium bicarbonate
H2O (l) + CO2 (g) + CaCO3 (s) → Ca(HCO3)2 (aq)
➢ The degree of hardness increases if the calcium and magnesium
content is large.
➢ Basically hardness is two types;
▪ permanent hardness, and
▪ temporary hardness.
4/5/2021 221
▪ Permanent hardness cannot be removed by boiling the water.
▪ It is generally caused by the ions of chloride and sulfate of
calcium and magnesium.
▪ To removed permanent hardness needs chemical processing
(using a water softener or ion exchange column).
Total Permanent Hardness = Calcium Hardness + Magnesium Hardness
▪ Total permanent water hardness calculated as equivalent of
calcium carbonate.
4/5/2021 222
▪ Temporary hardness occurs when the bicarbonate of calcium
and magnesium is present in water.
▪ This temporary hardness can be easily removed by boiling the
water.
▪ When water is boiled the bicarbonate convert in to carbonate;
this is insoluble in water.
▪ As a result it is easily removed and water becomes soften.
4/5/2021 223
4/5/2021 224
➢ There are different water softener are used depends on the
application and condition of water hardness.
➢ Following water softeners are used for water softening.
• Ion exchange water softener
• Cold and hot lime-soda process
• Zeolite or permutit water softener
• Reverse osmosis water softener
• Electric or Magnetic water softener (electrodialysis process)
4/5/2021 225
➢ This type of water softener works on the ion exchange principle.
➢ In ion exchange process, water passes through a bed, generally
made by sulfonated polystyrene divynalbenzene spherical resin.
➢ This resin beads is supersaturated with sodium.
➢ During the water softening this sodium ions are exchange by the
hardness ions.
➢ Again these sodium ions are regenerated by passing a brine
solution through the ion exchange column.
4/5/2021 226
➢ In the lime-soda water softener process, soluble magnesium and
calcium salts are made insoluble salts like calcium carbonate and
magnesium hydroxide by the treatment with calcium hydroxide
and soda ash.
➢ After removal of this precipitate, soft water is obtained. Before
water treatment, first calculate the amount of temporary and
permanent hardness, and then estimate the amount of lime and
soda ash.
➢ In this lime-soda water softener process, both temporary and
permanent hardness are removed. There are two type lime-soda
process; cold lime-soda process and hot lime-soda process.
4/5/2021 227
➢ Zeolite is a porous natural mineral and its general chemical
formulae AlxSiyO2(x+y) (without water molecules).
➢ The natural zeolite that is used as water softener is gluconites or
greensand.
➢ But permutit is the artificial zeolite that is most used in water
softening.
➢ The general chemical formula of permutit is Na2O, Al2O3, nSiO2,
xH2O.
➢ They can exchange cation, hence can remove calcium and
magnesium ions from water.
➢ As a result water becomes soften.
4/5/2021 228
➢ In the Reverse Osmosis (RO) water softener system, a semi-
permeable membrane is used as a filter.
➢ In this process, water is allowed to pass through the membrane
with the help of osmotic pressure.
➢ As a result, pure water is passing the other side leaving the
contaminant behind.
➢ When the concentrations of a particular species exceed the
solubility product, then it is precipitate.
4/5/2021 229
➢ In this water softener, process creates a magnetic field and hard
water is passing through the magnetic field.
➢ Hard water contains cations and anions which are positively and
negatively charged respectively.
➢ Hence they can be influence by the magnetic field and separate
from the water.
➢ Therefore water becomes soften.
4/5/2021 230
4/5/2021 231
➢ Demineralization of water is a process that removes minerals
from water and produced demineralized water.
➢ Shortly, it is called dm water or demi water. It is water softening
process.
➢ The most common dm water processes are distillation,
deionization, membrane filtration (reverse osmosis or
nanofiltration), and electrodialysis.
➢ This water is not free from some uncharged molecules like
viruses or bacteria and organic contaminants.
4/5/2021 232
➢ The transportation of demi water is very significant as it is highly
aggressive for metals and other plumbing materials.
➢ Comparably plastic materials are safe for transportation and
storage.
4/5/2021 233
pH Value of dm Water
➢ The pH value of demineralized water should be 7.0 but it is
slightly acidic.
➢ Reason, the carbon dioxide dissolves in it from the air; until
reaches dynamic equilibrium with the atmosphere.
➢ The dissolved carbon dioxide reacts with the water and creates
carbonic acid.
4/5/2021 234
pH value of dm water
➢ H2O + CO2 → H2CO3 (carbonic acid)
➢ Only fresh dm water has neutral pH value 7.0, but after a few
hours; it will capture carbon dioxide from the atmosphere and
become slightly acidic.
➢ In this way the pH value can be 5.5.
4/5/2021 235
DM water conductivity
➢ As the demineralization of water is minerals removing process
and the electric current is related to minerals, therefore the
demineralized water has a very low electric conductivity.
➢ It has no fixed value. It has a higher conductivity value than
deionized water.
➢ The dm water conductivity unit is expressed as
millisiemens/meter (mS/m) or microsiemens/centimeter
(µS/cm).
➢ Generally it is less than 2 mS/m, even lower than 0.1 mS/m.
4/5/2021 236
DM Water TDS Value
➢ The TDS value of water depends on the amount of minerals that
are dissolved in water.
➢ When the minerals like calcium bicarbonate, magnesium sulfate,
and sodium chloride increases then the TDS value increases.
➢ Consequently, the process of demineralization of water
decreases the TDS. It should be always less than 10 mg/l, even as
low as 1 mg/l.
4/5/2021 237
Demineralized Water Uses
➢ The water that contains the minerals like calcium bicarbonate,
magnesium sulfate, and sodium chloride can hamper different
stages on chemical or physical process of chemical industries.
➢ They require low salt or low conductivity water.
➢ DM water is free of minerals salt, so this water is suitable for
those industries.
➢ For example demi water is used in boiler feed water, textiles,
pharmaceuticals, breweries, swimming pools, potable water,
hospitals, automobile, lead-acid batteries, fertilizers, cooling
systems.
4/5/2021 238
Drinking Demineralized Water
➢ A certain amount of minerals are important parts of drinking
water.
➢ Internationally maximum acceptable levels of inorganic and
organic substances have been established to assure the safety of
drinking water.
➢ Different minerals increase the taste of water.
➢ As the dm water almost completely free from minerals; it has
poor taste and thirst-quenching characteristics.
4/5/2021 239
Drinking Demineralized Water
➢ Moreover, trace amount of certain minerals provide the health
benefits, so the consumption of this water is not good for health.
➢ In addition, the demi water tends to take out minerals from food
and electrolytes from the body, so it is also not suitable for
cooking purposes.
4/5/2021 240
Difference between Demineralized and Distilled Water
➢ Both the demineralized and distilled water are purified water.
➢ Although distillation process is one kind of demineralization of
water system but they have a clear difference.
➢ The major difference is that the distilled water is free of both the
organic and inorganic contaminants; even it is also free of
uncharged molecules such as viruses or bacteria whereas
demineralized water is only free of mineral ions, but not free of
uncharged molecules like viruses or bacteria and organic
substances.
➢ Distilled water is much purer than dm water but it is more costly.
4/5/2021 241
References
• https://www.coursera.org/lecture/engineering-humanitarian/water-source-
selection-AcdDr
• https://pas.org.in/Portal/document/ResourcesFiles/pdfs/Module_1%20Basics%2
0of%20water%20supply%20system.pdf
• http://www.navybmr.com/study%20material/14265a/14265A_ch3.pdf
• http://mwss.gov.ph/learn/metro-manila-water-supply-system/
• http://www.tpub.com/inteng/2k.htm
• https://www.aquatechtrade.com/news/industrial-water/industrial-water-
essential-guide/
4/5/2021 242
THANK YOU.
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Introduction to Industrial Plant

Cleanroom from outside

Air flow pattern for Air flow pattern for

Figure 6-13 Multibranch duct system

6-2 A pressure difference of 350 Pa is available to force 20°C air

6-4 A sudden enlargement in a circular duct measures 0.2 m

Figure 6-20 Duct system in Prob. 6-8

➢ Globally the oil and gas industry represents less than 5% of

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