Design of Transport Equipment:

First law flow system

𝑷 𝑔 𝑽𝟐 −𝒅𝑾𝒔 𝒅𝑸
∆( + 𝒁+ ) = − (∆𝒖 − )
𝝆 𝑔𝑐 𝟐 𝒅𝒎 𝒅𝒎

Injection work + potential energy+kinetic energy = - Shaft work - internal energy + heat.
Where:
P= pressure
𝜌 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
𝑍 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑎𝑏𝑜𝑣𝑒 𝑎 𝑑𝑎𝑡𝑢𝑚 𝑝𝑙𝑎𝑛𝑒
𝑉 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑜𝑤
𝑊𝑠 = 𝑠ℎ𝑎𝑓𝑡 𝑤𝑜𝑟𝑘 or pump work
* 𝑢 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐ℎ𝑎𝑟𝑔𝑒
∗ 𝑄 = ℎ𝑒𝑎𝑡
𝑚 = 𝑚𝑎𝑠𝑠
Δ𝑃
= 𝑖𝑛𝑗𝑒𝑐𝑡𝑖𝑜𝑛 𝑤𝑜𝑟𝑘
𝜌
𝑔
Δ𝑍 = 𝑃𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 𝐸𝑛𝑒𝑟𝑔𝑦
𝑔𝑐
Δ𝑉 2
= 𝑘𝑖𝑛𝑒𝑡𝑖𝑐 𝑒𝑛𝑒𝑟𝑔𝑦
2
𝒅𝑸
*All of the quantities in equation (pressure, density, etc.) except internal energy (∆𝒖) and heat ( ) can be directly
𝒅𝒎
measured.

𝒅𝑸
Evaluation of (∆𝒖 − ):
𝒅𝒎

A. For incompressible fluid (good approximation for most liquids and also for gases under certain
conditions):

𝒅𝑸
(∆𝒖 − ) = 𝑭𝒉 ~ 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 ℎ𝑒𝑎𝑡𝑖𝑛𝑔 (𝒏𝒐𝒏 − 𝒖𝒔𝒆𝒇𝒖𝒍 𝒇𝒐𝒓𝒎)
𝒅𝒎

Therefore, the first law flow system will be:

𝑷 𝒈 𝑽𝟐 −𝒅𝑾𝒔
∆( + 𝒁+ ) = − 𝑭𝒉 (𝑩𝒆𝒓𝒏𝒐𝒖𝒍𝒍𝒊 𝑬𝒒𝒖𝒂𝒕𝒊𝒐𝒏 𝒘𝒊𝒕𝒉 𝒇𝒓𝒊𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒉𝒆𝒂𝒕𝒊𝒏𝒈)
𝝆 𝒈𝒄 𝟐 𝒅𝒎
Fluid Transport Principle
Bernoulli’s Theorem - one classic example of the quantitative
application of the “Principle of conservation of
energy”.

PUMP
ZB
A

ZA

 All terms are energy / unit mass and g/gc  1.0

 Except for Z which is in feet ; all are unit force/unit mass which is
numerically equal to feet or meter head
 All terms in the equation are called “FLUID HEAD” and are equivalent
to pressures:
Z terms - potential head
V / 2 gc - velocity head
2

PV or P /  - Pressure head or hydraulic head

F -friction head
W -head added by pump (pump head)

Measurement of pump performance:

1. Capacity - rate of fluid flow through the pump ( m3/hr for liquid and
gases )
2. Head - total pressure differential measured immediately before
and after pump
 The pressure at any point in a liquid can be thought of as being caused by a vertical
column of the liquid
 The height of the column is called the Static Head and is expressed in terms of
feet or meter of liquid.
 The Static Head corresponding to any specific pressure is dependent upon the
weight of the liquid according to the following formula:

𝟐. 𝟑𝟏 (𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞, 𝐢𝐧 𝐩𝐬𝐢)
𝐇𝐞𝐚𝐝, 𝐢𝐧 𝐟𝐭. =
𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲
Total Dynamic Head (TDH) of pump

TDH = Total discharge head minus Total suction head

* Total suction head :
Static suction head/lift less other frictional head losses due
to valve , fittings and bends before the inlet flange of a pump
* Total discharge head:
Static discharge head plus other frictional head losses due
to valve, fittings and bends at the discharge flange of a
pump
Work performed in pumping:
Power Output = TDH x Fluid Capacity in a given time

(𝐓𝐃𝐇)(𝐐)(𝛒)
 𝐈𝐧 𝐤𝐢𝐥𝐨𝐰𝐚𝐭𝐭, 𝐏= 𝟑.𝟔𝟕 𝐱𝟏𝟎𝟓
TDH - in meter , column of liquid
𝐦𝟑
Q - flow rate in 𝐡𝐫
𝐤𝐠
 - fluid density in 𝐦𝟑
 (𝐓𝐃𝐇)(𝐐)(𝐬)
𝐈𝐧 𝐇𝐨𝐫𝐬𝐞𝐩𝐨𝐰𝐞𝐫, 𝐏= 𝟑.𝟗𝟔 𝐱𝟏𝟎𝟑
TDH - in feet , column of liquid
𝐠𝐚𝐥𝐥𝐨𝐧
Q - flow rate in 𝐦𝐢𝐧
s - specific gravity

Power input to a pump is greater that the power output because of internal
losses resulting to friction leakages.

BHP = Brake horsepower (BHP) or Pump input is the actual horsepower

delivered/supplied to the pump shaft.

P = Pump output or hydraulic horsepower (WHP) is the liquid

horsepower delivered or done by the pump.

𝐏𝐨𝐰𝐞𝐫 𝐎𝐮𝐭𝐩𝐮𝐭
𝐏𝐮𝐦𝐩 𝐄𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 = 𝒙 𝟏𝟎𝟎
𝐏𝐨𝐰𝐞𝐫 𝐈𝐧𝐩𝐮𝐭

𝐏
𝐓𝐡𝐞𝐫𝐞𝐟𝐨𝐫𝐞, 𝐏𝐮𝐦𝐩 𝐄𝐟𝐟𝐢𝐜𝐢𝐞𝐧𝐜𝐲 = 𝒙 𝟏𝟎𝟎
𝐁𝐇𝐏

 In recommending the motor size of the pump, pump efficiency

should always be considered.
CHACTERISTIC CURVES/ PUMP PERFORMANCE CURVES:
 Standard Electric Motor Sizes:

PUMP SELECTION:
METHOD 1: (p. 10-34 Ch.E HB 8th Ed)
Specific Speed (𝐍𝐬 ):
One of the parameters that is extremely useful in selecting a pump for a particular application is
specific speed (Ns ).
Specific Speed is a parameter that defines the speed at which impellers of geometrically similar
design have to be run to discharge one (1) gpm against a one-foot head. In general, pumps with a
low specific speed have a low capacity and high specific speed, high capacity:

In fps:
1
𝑁𝑄 2
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑆𝑝𝑒𝑒𝑑, 𝑁𝑠 = 3
𝐻4
𝑓𝑡 − 𝑙𝑏𝑓
𝑤ℎ𝑒𝑟𝑒: 𝑁 𝑖𝑛 𝑟𝑝𝑚, 𝑄 𝑖𝑛 𝑔𝑝𝑚 𝐻 𝑖𝑛 𝑜𝑟 𝑓𝑡 𝑐𝑜𝑙𝑢𝑚𝑛 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
𝑙𝑏𝑚
In S.I.:
1
𝑁𝑄 2
𝑆𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑆𝑝𝑒𝑒𝑑, 𝑁𝑠 = 3
1.16 𝐻 4
𝑚3
𝑤ℎ𝑒𝑟𝑒: 𝑁 𝑖𝑛 𝑟𝑝𝑚, 𝑄 𝑖𝑛 𝐻 𝑖𝑛 𝑚𝑒𝑡𝑒𝑟 𝑐𝑜𝑙𝑢𝑚𝑛 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
ℎ𝑟
METHOD 2:
Pump Chart/Nomograph (p. 10-27 Fig. 10-24 - Ch.E HB 8th Ed)

Different types of pump:

Pump- a devise or equipment used to transfer fluids from one
location to another by increasing the pressure of the fluid and
thereby supplying the driving force necessary for flow.
- power must be delivered to the pump from some outside
source thus electrical or steam energy maybe transformed into
mechanical energy which is used to drive the pump.
- Part of the mechanical energy is added to the fluid as work and
the rest is lost as friction due to the inefficiency of the pump
and drive.
Classification of pump as to type of fluid to de delivered:
a. Gas pump b. liquid pump
Classification of pump as to its purpose and usage:
1. Reciprocating or (+) displacement pumps with valve action
a. Piston pump b. Diaphragm c. Plunger
2. Rotary (+)-displacement pump with no valve action
a. Gear pump b. Lobe c. Screw d. eccentric-cam e. metering
3. Rotary centrifugal pump with no valve action
a. Open / closed impeller b. volute c. turbine
d.Chemical / Process pump
4. air-displacement system
a. air lift b. Acid eggs c. Blow cases d. Jet pumps
e. Barometric legs
Factors to consider in choosing a pump:
1. Amount of fluid that must be pumped. This factor determines the size of
the pump.
2. Properties of fluid:
Density and viscosity influence the power requirement for a given set of
operating condition
Corrosiveness determines the acceptable material of construction
If solid particles are suspended in fluid, this factor dictates the amount of
clearances necessary and eliminates the possibility of using certain types
of pump
3. The increase in pressure of fluid due to work input of the pumps. The head
change across the
pump is influence by the inlet and downstream-reservoir pressure, the
change in vertical height of the delivery line and frictional effect.
4. Type of flow distribution i.e. if pulsating flow is required or if operation is
intermittent, self-priming may be desirable.
5. Type of power supply i.e. reciprocating , rotary (+) displacement or
centrifugal are adaptable for use with electric motor or internal combustion
engine.
6. Cost and mechanical efficiencies of pump.
Reciprocating Pumps (Piston Drive)
 Delivers energy to a flowing fluid by means of a piston acting through a
cylinder.
 Steam is often employed as the source of power for this type. Also this can
be activated by other means such as rotating crankshaft operated by
electric motor.
 Had an advantage of being able to deliver fluids against a high pressure
and operates with good efficiency over a wide range of operating condition
 They cannot be used with fluids which contains abrasive solids. (Piston and
Plunger pump)
 Satisfactory for handling fluids with large amount of suspended solids at
low head (Diaphragm Pump)

Rotary Positive- Displacement pumps

 Combine rotary motion with a positive displacement of fluid
 Two (2) intermeshing gear are fitted into a casing with a sufficiently close
spacing to seal off effectively each separate tooth space.
 Gear rotates in opposite direction, fluid is trapped in each tooth space and
is delivered to the exit side of the pump
 No priming is required and practically used for highly viscous fluid and fluid
may be delivered at high pressure
 Cannot be used with non-lubricating fluids or with fluids containing solid
particles due to very small clearance.
Rotary Centrifugal pumps:
 The fluid is fed into the pump at the center of a rotating impeller and is
thrown outward by centrifugal force
 The fluid at the outer periphery of the impeller attains high velocity and
consequently high K.E.. Conversion of K.E. into pressure energy supplies
the pressure differential between suction & discharge side of the pump
 Simple in construction and is less expensive
 Fluid is delivered at uniform pressure without shock and pulsation
 They can be coupled directly to motor drives.
 Can handle liquids with large amount of solids
 Maintenance cost is lower than any other type of pumps
 Cannot be operated at high heads
 Usually must be primed and subject to air binding
 Not suitable for highly viscous fluid.

Affinity Laws for Centrifugal Pumps: (T10-13 p. 10-36 -Ch.E HB 8th Ed.)

Constant Impeller Diameter Constant Impeller Speed

Capacity 𝑄1 𝑁1 𝑄1 𝐷1
= =
𝑄2 𝑁2 𝑄2 𝐷2
Head 𝑇𝐷𝐻1 (𝑁1 )2 𝑇𝐷𝐻1 (𝐷1 )2
= =
𝑇𝐷𝐻2 (𝑁2 )2 𝑇𝐷𝐻2 (𝐷2 )2
Brake Horsepower 𝐵𝐻𝑃1 (𝑁1 )3 𝐵𝐻𝑃1 (𝑃1 )3
= =
𝐵𝐻𝑃2 (𝑁2 )3 𝐵𝐻𝑃2 (𝑃2 )3

Where:
Q = Fluid discharge rate
P = Power output or work done by pump
N = Impeller speed in rpm
TDH = Total dynamic head
D = Impeller Outer Diameter
BHP = Power input or supplied to the pump
Air displacement System:
 Movement of fluid is accomplished by the use of air pressure and not
through mechanical action of pistons, impellers or other devices
 Compressed air is introduce into the submerged end of the discharge pipe
at a specified distance below the liquid surface.. Because the air and liquid
mixture is lighter than the liquid below, the mixture rises through the
discharge pipe and is expelled into the overhead receiver at a distance
above the liquid surface.(Air lift–type)
𝐇𝐭
𝐕𝐀𝐢𝐫 = 𝟎. 𝟖
𝐇 + 𝟑𝟒
𝐂 𝐋𝐨𝐠 [ 𝐒 𝟑𝟒 ]
Where:
VAir = ft 3 of free air required to lift 1 gallon of H2 O
Ht = total lift in feet, or total distance from working surface of liquid to point of discharge
Hs = running submergence, or distance from liquid level to point of air inlet
C = constant to be taken fro the following table:
𝐋𝐢𝐟𝐭 (𝐇𝐭 ), 𝐢𝐧 𝐟𝐭 (𝐢𝐧𝐜𝐥𝐮𝐬𝐢𝐯𝐞) C, constant
10 to 60 245
61 to 200 233
201 to 500 216
501 to 650 185
651 to 750 156

Air H t

H S

 Employ water, steam or gas as operating medium. The operating medium

flows rapidly through an expanding nozzle and discharges into the throat
of a venturi. Use to remove air, gases, or vapor from condensers and
vacuum equipment like ‘steam jet ejectors’ (jet pump).
DESIGN PROBLEMS
From the piping system given below, determine the static pressure at the
pump inlet and at the pump discharge or outlet.
100’

20’ 10’

15’

50’ 20’

CV
2’ 3” Suction piping
HCL GV
65oC
1.1 SG 10’ 5’ 2” Discharge piping

5’
P
7’ GV 5’

Static Pressure in the reservoir (Pump inlet) :

Static Head = 10 ft.
𝟐. 𝟑𝟏 (𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞, 𝐢𝐧 𝐩𝐬𝐢)
𝐇𝐞𝐚𝐝, 𝐢𝐧 𝐟𝐭. =
𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲

𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲 (𝐇𝐞𝐚𝐝, 𝐢𝐧 𝐟𝐭. ) (𝟏. 𝟏)(𝟏𝟎 𝒇𝒕)

𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 , 𝐢𝐧 𝐩𝐬𝐢. = = = 𝟒. 𝟕𝟔 𝒑𝒔𝒊
𝟐. 𝟑𝟏 𝟐. 𝟑𝟏

Static Pressure in the reservoir (Pump Outlet/Discharge) :

Static Head = 60 ft.

𝟐. 𝟑𝟏 (𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞, 𝐢𝐧 𝐩𝐬𝐢)
𝐇𝐞𝐚𝐝, 𝐢𝐧 𝐟𝐭. =
𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲

𝐒𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐠𝐫𝐚𝐯𝐢𝐭𝐲 (𝐇𝐞𝐚𝐝, 𝐢𝐧 𝐟𝐭. ) (𝟏. 𝟏)(𝟔𝟎 𝒇𝒕)

𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 , 𝐢𝐧 𝐩𝐬𝐢. = = = 𝟐𝟖. 𝟓𝟕 𝒑𝒔𝒊
𝟐. 𝟑𝟏 𝟐. 𝟑𝟏
 20 ft (6.0975 m)

20’

Total Pipe length at the suction= 5+7+5 = 17 feet (5.183 m)

Total Pipe length at the discharge = 5+2+20+15+20+100+10 = 172 feet (52.439 m)
 Sp. Grav. (Head, in ft) (1.1)(30 ft)
Pressure, in psi = = = 14.286 psi
2.31 2.31
 • Flow rate = 140 gpm (32.2 cu. meter/hr) TDH =124.179
(37.86m)
• Pump Efficiency = 58%
𝟑.𝟔𝟓𝟒 𝐤𝐖
• 𝐁𝐇𝐏 = 𝐏𝐚𝐜𝐭𝐮𝐚𝐥 = = 𝟔. 𝟑 𝐤𝐖 ≈ 𝟔. 𝟓 𝐤𝐖
𝟎.𝟓𝟖

Gas Transport Equipment:

Gas handling equipment is used to transfer materials through pipe lines, during which just enough pressure
or head is generated to overcome line friction, or to raise or lower the pressure to some required operating
level in connected process equipment.
Movement of gas is being accomplished by:
A. Fans
- Fans are classified according to the direction of air flow.
- Used for low pressure drop, generally less than 3.447 kPa ( 0.5 psi). They are usually of the centrifugal or
the axial flow type.
- Used for ventilating work, supplying draft to boilers and furnaces, moving large volumes of air or gas through
ducts, supplying air for drying, conveying material suspended in the gas stream and removing fumes.
- Operating efficiencies of fans range from 40 to 70 %
Different types of fans :
 Centrifugal
 Centrifugal fans are classified according to their blade geometry—radial, forward curved, backward
curved, and airfoil. The major characteristic of radial fan is its ability to compress air/gases to a
higher pressure but delivers lower flow rates than the other fan types.
 In a centrifugal fan, air/gas flows along the fan shaft, turns 90° by the impeller, which imparts
kinetic energy to the air/gas as it flows radially outward. The kinetic energy is converted to
pressure as it leaves the fan parallel to the shaft.
 Axial flow
 In an axial flow fan, air/gas enters and leaves the fan parallel to the shaft.
 Axial fans consist of the tube axial fan and the vane axial fan, which are designed for a wide range
of flow rates at low pressures. These fans consist of a propeller enclosed in a duct. They are
limited to applications where the gas/air does not contain entrained solids.
Characteristics and applications of fans:
 Fans are used for high flow and low-pressure applications to move large volumes of air or gas through ducts
at near atmospheric pressures, supplying air for drying, cooling towers, removing fumes, and so on.
 Because the clearances between the impeller and the casing are large, the pressure developed is low, between
1.01 and 1.15 bar.
 In large buildings, blowers are often used due to the high delivery pressures needed to overcome the pressure
drop in the ventilation system. Most of these blowers are of the centrifugal type. Blowers are also used to
supply draft air to boilers and furnaces.
 Turbo-blowers
o Use to handle large volumes of gas or high flow rates at moderate differential pressure from 3.447
kPa (0.5 psi) up to several hundred kPa (up to 50 psi)
o Widely used in chemical industry for supplying plant air, conveying solid materials in suspension,
as exhausters and for ventilation, aeration, etc.
Pressure increases involved in fans, blowers, and compressors:
Fans: Low delivery pressures: 3% (<40 kPa)
Blowers: Delivery pressures <300 kPa
Compressors: Higher pressures: >300 kPa

Power output of the fan (P):

Power in kilowatt = 2.72 x 10 –5 Q p
Where: Q= fan volume, m3 per hour
p= fan operating pressure, cm water column

Power in horsepower = 1.57 x 10 –4 Q p

Where: Q = fan volume, ft3 per min
p = operating pressure, inches H2O column

 Fans accept gases at near atmospheric pressure and raise the pressure by approximately 3% (12 in. of water),
usually on air for ventilating or circulating purposes. Fans are made either with axial propellers or with a
variety of radial vanes. Backward curved vanes are preferable in most respects.

B. Blowers
 Blowers is a term applied to machines that raise the pressure to an intermediate level, usually to less than
40 psig, but more than accomplished by fans.

C. Compressors
 Compressors are any machines that raise the pressure above the levels for which fans are used. Thus, in
modern terminology they include blowers. The several kinds of commercial compressors are identified in
this classification:
1. Dynamic
a. Centrifugal (radial flow)
Maximum compression ratios of 3–4.5 per stage with a maximum of 8–12 per machine are
commonly used. Discharge pressures as high as 3000–5000 psia can be developed by centrifugal
compressors.
b. Axial flow
The axial flow compressor to possess a large number of blades attached to a rotating drum with
stationary but adjustable blades mounted on the case. These equipment are suited particularly to
large gas flow rates at maximum discharge pressures of 80–130 psia. Compression ratios
commonly are 1.2–1.5 per stage and 5–6.5 per machine, specific speeds of axial compressors are
in the range of 1000–3000 or so. Efficiencies are 8–10% higher than those of comparable
centrifugal compressors.

2. Positive displacement
a. Reciprocating piston
Reciprocating compressors are relatively low flow rate, high pressure machines. Pressures as high
as 35,000–50,000 psi are developed with maximum compression ratios of 10/stage and any
desired number of stages provided with intercoolers. The limitation on compression ratio
sometimes is due to the limitations on discharge temperature which normally is kept below 3008F
to prevent ignition of machine lubrications when oxidizing gases are being compressed, and to the
fact that power requirements are proportional to the absolute temperature of the suction gas.
b. Rotary (screws, blades, lobes, sliding vane etc.).
All of these types also are commonly used as vacuum pumps when suction and discharge are
interchanged. Their capacity ranges up to 12,000 CFM or more. Normal pressure boost is 3–20 psi,
but special units can boost pressures by 60–100 psi. In vacuum service they can produce pressures
as low as 2 psia.
The sliding vane compressor can deliver pressures of 50 psig or pull a vacuum of 28 in. of mercury.
A two-stage unit can deliver 250 psig.
Operating Range of Compressors:

D. Jet compressors : Utilize a high pressure gas to raise other gases at low pressure to some intermediate value by
mixing with them.
E. Vacuum pumps: Produce sub-atmospheric pressures in process equipment. Often they are compressors operating
in reverse but other devices also are employed.
F. Steam jet ejectors : Used primarily to evacuate equipment but also as pumps or compressors.
Different types of compressors:

TYPES OF COMPRESSORS

Ranges of pressures obtainable for different types of compressors

o Centrifugal: Over 345 bar (>5000 psig).
o Rotary screw: 20 bar (250 psig).
o Sliding vane: 10 bar (150 psig).
o Reciprocating: 6900 bar (100,000 psig).

 Positive Displacement Compressors:

A. Reciprocating Compressors:
 Reciprocating compressors are used mainly when high-pressure head is required at a low flow.
 Reciprocating compressor ratings vary from fractional to more than 30,000 kW (40,000 hp) per unit.
Pressures range from low vacuum at suction to 200 mPa (30,000 psi) and higher at discharge for special
process compressors.
 Reciprocating compressors are furnished either single stage or multistage. The number of stages is
determined by the overall compression ratio. The compression ratio per stage (and valve life) is generally
limited by the discharge temperature and usually does not exceed 4 although small-sized units (intermittent
duty) are furnished with a compression ratio as high as 8.
 On multistage machines, intercoolers are normally provided between stages to remove heat of compression
and reduce the temperature to approximately the temperature existing at the compressor intake.
 Such cooling (1) reduces the actual volume of gas going to the high-pressure downstream equipment (2)
reduces the power required for compression, and (3) keeps the temperature within safe operating limits.

 Reciprocating compressors should be supplied with clean gas as they cannot satisfactorily handle liquids
and solid particles that may be entrained in the gas. Liquids and solid particles tend to destroy cylinder
 lubrication and cause excessive wear. Liquids are non-compressible and their presence could rupture the
compressor cylinder or cause other major damage.
 Reciprocating Compressors can be use over a wide range of pressures and capacities but normally preferred
where high pressures are required at relatively low flow rates. Are furnished in either single-stage or
multistage types. Available at 1 to 3000 HP (Delivery pressure up to 4000 atm)
B. Rotary Compressors:
 Rotary compressors are very close to centrifugal and axial flow compressors. Like reciprocating
compressors, they are positive displacement type; however, unlike the reciprocating compressors, they do
not have very high vibration problem. They have a casing with one or more rotating elements that either
mesh with each other such as lobes or crews or displace a fixed volume with each rotation.
 Screw type of rotary compressor is generally appropriate for a flow range of 85–170 m3 /h and capable of
handling capacities up to about 4 x104 m3/h at pressure range of 2070– 2760 kPa (300–400 psig) at pressure
ratios of 4:1 and higher. Relatively small diameter rotors allow rotary speeds of several thousand rpm.
 Screw compressors are of two types, namely, dry screw compressors and oil-flooded screw compressors.
Oil-flooded screw compressors use oil for bearing lubrication as well as to seal the compression chamber.
They also remove heat generated during compression.
C. Dynamic Compressors
 Dynamic Compressors: The dynamic types include radial flow centrifugal, axial flow, and mixed flow
machines.
 They are rotary continuous flow compressors in which the rotating element (impeller or bladed rotor)
accelerates the gas as it passes through the element, converting the velocity head into static pressure, partially
in the rotating element and partially in stationary diffusers or blades.
 Centrifugal compressors are generally used for higher pressure ratios and lower flow rates compared to lower
stage pressure ratios and higher flow rates in axial flow compressors.
 Axial flow compressors are used mainly as compressors for gas turbines.
 Centrifugal compressors are used for high flow rates and, by staging, high differential pressures.
 Most widely used for compressing process gas, supplying air or oxygen to blast furnaces and pipeline booster
for natural gas.

Theory of Compression:

Polytropic Process

 A polytropic process obeys the relation :

𝐩𝐕 𝐧 = 𝐂
Where:
p = pressure V= Specific Volume n = polytropic index, any real number C = constant

 The polytropic process equation is particularly usefull for characterizing expansion and compression
process which include heat transfer.

 The range of polytropic index (n) from n= 0 to n = ∞ characterizes a very wide range of thermodynamic
processes such as:
𝐧
Isobaric 0
Isothermal 1
Isentropic 𝜸
Isochoric ∞
For continuous compression process (polytropic process),
𝐩𝐕 𝐧 = 𝐂 = 𝐜𝐨𝐧𝐬𝐭𝐚𝐧𝐭
If n=k = 1.0, isothermal compression
= ratio of specific heat at constant pressure to that at constant volume
𝐂
= 𝐏
𝐂𝐕

Polytropic Compression Curve

p2
n = 1 (isothermal)
𝐂𝐩
𝐧 = 𝐤 = 𝐂 (𝐚𝐝𝐢𝐚𝐛𝐚𝐭𝐢𝐜)
𝐕
n>k

p1

𝟐
𝐖 = ∫𝟏 𝐩𝐝𝐕
 Compression in reciprocating and centrifugal compressors is essentially adiabatic but it is not frictionless. The
pressure–volume behavior in such equipment often conforms closely to the equation
𝐩𝐕 𝐧 = 𝐩𝟏 𝐕𝟏 𝐧 = 𝐂 = 𝐜𝐨𝐧𝐬𝐭𝐚𝐧𝐭
 The amount of work required is dependent upon the polytropic curve involved and increasing values of n. The
path requiring least amount of input work is n = 1.0 (isothermal)
 Most compressors operate along a polytropic path approaching the adiabatic, and compressor calculations are
generally based on adiabatic curve.

Pressure, volume and temperature relations of perfect gases:

𝐤
𝐩𝟐 𝐕𝟏 𝐤 𝐓𝟐 𝐕𝟏 𝐤−𝟏 𝐩𝟐 𝐓 (𝐤−𝟏)
(𝐩 ) = (𝐕 ) (𝐓 ) = (𝐕 ) (𝐩 ) = (𝐓𝟐)
𝟏 𝟐 𝟏 𝟐 𝟏 𝟏

Adiabatic Compression:
(𝐤−𝟏)
𝐤 𝐩𝟐 𝐤
𝐀𝐝𝐢𝐚𝐛𝐚𝐭𝐢𝐜 𝐇𝐞𝐚𝐝 𝐢𝐧 𝐔. 𝐒. 𝐮𝐧𝐢𝐭𝐬 = [ ] 𝐑𝐓𝟏 [( ) − 𝟏]
𝐤−𝟏 𝐩𝟏

𝐤 (𝐤−𝟏)
[
] 𝐑𝐓𝟏 𝐩𝟐 𝐤
𝐀𝐝𝐢𝐚𝐛𝐚𝐭𝐢𝐜 𝐇𝐞𝐚𝐝 𝐢𝐧 𝐒. 𝐈. 𝐮𝐧𝐢𝐭𝐬 = 𝐤 − 𝟏 [( ) − 𝟏]
𝟗. 𝟖𝟎𝟔 𝐩𝟏
Where:
U.S. units S.I. units
R 1545 ft ∙ lbf 8314 j
, ,
MW lb ∙ °R MW kg ∙ K
T Gas temp., °R K
P Abs. gas pressure, psia kPa
Adiabatic Head Feet Meter
𝐖𝐎𝐑𝐊 = 𝐀𝐝𝐢𝐚𝐛𝐚𝐭𝐢𝐜 𝐇𝐞𝐚𝐝 𝐱 𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐅𝐥𝐨𝐰 𝐑𝐚𝐭𝐞
(𝐤−𝟏)
𝐤 𝐩𝟐 𝐤
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐢𝐧 𝐇𝐏 = 𝟒. 𝟑𝟔 𝐱 𝟏𝟎−𝟑 [ ] 𝑸𝟏 𝐩𝟏 [( ) − 𝟏]
𝐤−𝟏 𝐩𝟏

(𝐤−𝟏)
𝐤 𝐩𝟐 𝐤
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐢𝐧 𝐤𝐖 = 𝟐. 𝟕𝟖 𝐱 𝟏𝟎−𝟒 [ ] 𝑸𝟏 𝐩𝟏 [( ) − 𝟏]
𝐤−𝟏 𝐩𝟏
Where :
HP kW
ft3 m3
Q1 volume rate of gas flow, hr
min
p1 Abs. inlet pressure, psia kPa
p2 Abs. discharge pressure, psia kPa
K 1.39 to 1.41 (air & various number of diatomic gases)
Adiabatic discharge temperature:
(𝐤−𝟏)
𝐩𝟐 𝐤
𝐓𝟐 = 𝐓𝟏 ( )
𝐩𝟏
 If compression cycle approaches the isothermal condition, i.e. the case when several stages with intercoolers are
used:
𝐩𝟐
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐤𝐖 = 𝟐. 𝟕𝟖 𝐱 𝟏𝟎−𝟒 𝐐𝟏 𝐩𝟏 [𝐥𝐧 ( )]
𝐩𝟏
−𝟑
𝐩𝟐
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐇𝐏 = 𝟒. 𝟒 𝐱 𝟏𝟎 𝐐𝟏 𝐩𝟏 [𝐥𝐧 ( )]
𝐩𝟏
Multistage Compression
 For multistage compressors of 𝐍𝐬 ,number of stages with adiabatic compression in each stage, equal division of
work between stages and intercooling to the intake temperature :

𝐍𝐬 𝐏𝐨𝐮𝐭
𝐂𝐨𝐦𝐩𝐫𝐞𝐬𝐢𝐨𝐧 𝐫𝐚𝐭𝐢𝐨 𝐩𝐞𝐫 𝐬𝐭𝐚𝐠𝐞 = √
𝐏𝐢𝐧
𝐏𝐨𝐮𝐭
𝐰𝐡𝐞𝐫𝐞 ∶ = 𝐎𝐯𝐞𝐫𝐚𝐥𝐥 𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 𝐫𝐚𝐭𝐢𝐨
𝐏𝐢𝐧
(𝐤−𝟏)
𝟐. 𝟕𝟖𝐱𝟏𝟎−𝟒 (𝐤)(𝐍𝐬 )𝐐𝟏 𝐏𝟏 𝐏𝐨𝐮𝐭 𝐤𝐍𝐬
𝐓𝐨𝐭𝐚𝐥 𝐖𝐨𝐫𝐤 𝐢𝐧 𝐊𝐰 = [( ) − 𝟏]
(𝐤 − 𝟏) 𝐏𝐢𝐧

(𝐤−𝟏)
𝟒. 𝟒𝐱𝟏𝟎−𝟑 (𝐤)(𝐍𝐬 )𝐐𝟏 𝐏𝟏 𝐏𝐨𝐮𝐭 𝐤𝐍𝐬
𝐓𝐨𝐭𝐚𝐥 𝐖𝐨𝐫𝐤 𝐢𝐧 𝐇𝐏 = [( ) − 𝟏]
(𝐤 − 𝟏) 𝐏𝐢𝐧
(𝐤−𝟏)
𝐏𝐨𝐮𝐭 𝐤𝐍𝐬
∗∗∗∗ 𝐓𝟐 = 𝐓𝟏 ( )
𝐏𝐢𝐧
𝒑
 For reciprocating compressors, the compression ratio ( 𝒐𝒖𝒕 ) per stage is generally limited to 4 .
𝒑𝒊𝒏
 Generally, the maximum compression ratio is determined by the maximum allowable discharge gas
temperature
Compressor Efficiency
- ratio of power required for ideal adiabatic reversible process to power actually consumed.
- Isentropic Efficiency > Isothermal Efficiency
(70 to 90 % ) (50 to 70 % )

Summary of Characteristics of Different Types of Compressors

DESIGN PROBLEMS/APPLICATIONS:
Find the power required to drive an air compressor which has to compress 34 𝑚3 of air per minute from 1.013 bar to
4.052 bar and deliver it at the higher pressure. Assume that the index n for the compression curve is 1.25 . Design
and recommend a compressor for this purpose
𝐖𝐎𝐑𝐊 = 𝐀𝐝𝐢𝐚𝐛𝐚𝐭𝐢𝐜 𝐇𝐞𝐚𝐝 𝐱 𝐕𝐨𝐥𝐮𝐦𝐞𝐭𝐫𝐢𝐜 𝐅𝐥𝐨𝐰 𝐑𝐚𝐭𝐞
(𝐤−𝟏)
𝐤 𝐩𝟐 𝐤
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐢𝐧 𝐇𝐏 = 𝟒. 𝟑𝟔 𝐱 𝟏𝟎−𝟑 [ ] 𝑸𝟏 𝐩𝟏 [( ) − 𝟏]
𝐤−𝟏 𝐩𝟏

(𝐤−𝟏)
−𝟒
𝐤 𝐩𝟐 𝐤
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐢𝐧 𝐤𝐖 = 𝟐. 𝟕𝟖 𝐱 𝟏𝟎 [ ] 𝑸𝟏 𝐩𝟏 [( ) − 𝟏]
𝐤−𝟏 𝐩𝟏
 (𝟏.𝟒−𝟏)
−𝟒
𝟏. 𝟒 m3 𝟔𝟎 𝐦𝐢𝐧 𝟒𝟎𝟒. 𝟗𝟖 𝟏.𝟒
𝐖𝐎𝐑𝐊 𝐢𝐧 𝐢𝐧 𝐤𝐖 = 𝟐. 𝟕𝟖 𝐱 𝟏𝟎 [ ] (34 )( ) (𝟏𝟎𝟏. 𝟑𝟐𝟓𝐤𝐏𝐚) [( ) − 𝟏] = 𝟗𝟕. 𝟔𝟖𝐤𝐖
𝟏. 𝟒 − 𝟏 min 𝐡𝐫 𝟏𝟎𝟏. 𝟑𝟐𝟓
𝑚3 𝑓𝑡 3
Vol. capacity = 34 (1,199.78 ) and Discharge pressure =404.98 kPa (58.75 psig)
𝑚𝑖𝑛 𝑚𝑖𝑛
Using the Chart below, Reciprocating compressor is recommended.

For efficiency,
Summary of Characteristics of Different Types of Compressors

Efficiency = 80%
𝟗𝟕.𝟔𝟖 𝐤𝐖
• 𝐏𝐚𝐜𝐭𝐮𝐚𝐥 = = 𝟏𝟐𝟐. 𝟏 𝐤𝐖 ≈ 𝟏𝟐𝟑 𝐤𝐖
𝟎.𝟖𝟎
……then proceed with the design procedure by choosing the type of compressor, Compressor
efficiency and size of the motor……

SOLID TRANSPORT EQUIPMENT

Bulk Density of Solid Materials

Material Average bulk Material Average bulk
density, lb/ft3 density, lb/ft3
Alum, lumpy 50-60 Lime, ground, ≤ 1/ 8 in. 60
Alum, fine 45-50 Lime, hydrated, ≤ 1/ 8 in. 40
Alumina 60 Lime, hydrated, pulverized 32-40
Alumina gel 45 Lime, pebble 53-56
Aluminum hydrate 18 Limestone, agricultural, ≤ 1/ 8 in 68
Ammonium chloride, crystalline 52 Limestone, crushed 85-90
Ammonium sulfate 45-58 Limestone dust 75
Antimony powder 44 Magnesium chloride 33
Asbestos shred 20-25 Manganese sulfate 70
Ashes, coal, dry, ≤ 3 in 35-40 Marl 80
Asphalt, crushed, , ≤ ½ in 45 Mica, flakes 17-22
Bagasse 7-10 Mica, ground 13-15
Baking Powder 41 Mica, pulverized 13-15
Bark, wood, refuse 10-20 Muriate of potash 77
Bauxite, crushed, ≤ 3 in 75-85 Napthalene Flakes 45
Bentonite,100 mesh &under 50-60 Oxalic Acid crystals 60
Bicarbonate of soda 41 Oyster shells, ground, ≤ ½ in 53
Boneblack,100 mesh& under 20-25 Oyster shells, whole 80
Bonechar,≤1/8 in 27-40 Phenol-formaldehyde powder 30-40
Bonemeal 55-60 Phosphate rock 75-85
Borate of lime 60 Phosphate sand 90-100
Borax, fine 53 Pthalic anhydride flakes 30-35
Boric acid, fine 55 Polyethylene pellets, high density 35-45
Calcium Carbide 70-80 Polyethylene pellets, low density 28-40
Carbon black, pellets 20-25 Polypropylene pellets 35-50
Carbon black, powder 4-6 Polystyrene cubes 35-40
Casein 36 Polyvinyl chloride pellets, compound 35-55
Cast-iron chips 130-200 Polyvinyl chloride resin,dispersion-type 12-18
Cement, Portland 65-85 Polyvinyl chloride resin, solvent, non- 20-35
solvent, suspension types
Cement, clinker 75-80 Potassium nitrate 76
Chalk, lumpy 85-90 Pumice, ≤ 1/8 in. 42-45
Chalk,100 mesh and under 70-75 Salt, common dry, coarse 45-50
Charcoal 18-25 Salt, common dry, fine 70-80
Cinders, coal 40 Salt cake, dry, coarse 85
Clay (see bentonite, fuller’s earth, 80-106 Salt cake, dry, pulverized 65-85
kaolin, marl)

Coal, anthracite 60 Saltpeter 80

Sand, bank, dry 90-110
Coal, bituminous, mined, <50 mesh 50
Sand, silica, dry 90-100
Coal, bituminous, mined, slack ≤½” 50 Sawdust 10-13
Coke, loose 23-32 Shale, crushed 85-90
Coke, petroleum, calcined 35-45 Shellac, powdered or granulated 31
Coke breeze, ≤ ¼ in 25-35 Silica gel 45
Copper sulfate Slag, furnace, granulated 60-65
Cork, fine ground 12-15 Slate, crushed, ≤ ½ in 80-90
Cork granulated 12-15 Slate, ground, ≤ 1/ 8 in 82
Cryolite 110 Soap beads or granules 13-55
Cullet 80-120 Soap chips 15-25
Dicalcium phosphate 43 Soap flakes 5-15
Dolomite, lumpy 90-100 Soap powder 20-25
Ebonite, crushed, ≤ ½ in. 63-70 Soapstone talc, fine 40-50
Epsom salt 40-50 Soda ash, heavy 55-65
Feldspar, ground, ≤1/ 8 in. 65-70 Soda ash, light 20-35
Ferrous sulfate 50-75 Sodium nitrate 70-80
Flour, wheat 35-40 Sodium sulfate (see salt cake) 85
Fluorspar 82 Starch 25-50
Fly ash, dry 35-45 Steel chips, crushed 100-150
Fuller’s earth, oil filter, burned 40 Sugar, granulated 50-55

Fuller’s earth, oil filter, raw 35-40 Sugar, raw, cane, or beet 55-65
Fuller’s earth, oil filter, spent 60-65 Sugar-beet pulp, dry 12-15
Glass batch 90-100 Sugar-beet pulp, wet 25-45
Glue , ground, ≤ 1/8 in. 40 Sulfur, crushed, ≤ ½ in. 50-60
Graphite, flake 40 Sulfur, lumpy, ≤ 3 in. 80-85
Graphite, flour 28 Sulfur, powdered 50-60
Gypsum, calcined, ≤ ½ in. 55-60 Talcum powder 40-60
Gypsum, calcined, powdered 60-80 Trisodium phosphate 60
Gypsum, raw, ≤ 1 in. 90-100 Virmiculite, expanded 16
Ice, crushed 35-45 Virmiculite ore 80
Ilmenite 140 Wood chips 10-30
Kaolin clay, ≤3 in. 163 Wood flour 16-36
Lead Arsenate 72 Zinc oxide, heavy 30-35
Lignite, air dried 45-55 Zinc oxide, light 10-15
Plant Design and Unit Op, Economics for Ch.E (Peters and Timmerhaus)
 𝒌𝒈
*Note: 𝐦 = 𝐬𝐨𝐥𝐢𝐝 𝐟𝐥𝐨𝐰𝐫𝐚𝐭𝐞, 𝒔𝒆𝒄 ; 𝐋 = 𝐥𝐞𝐧𝐠𝐭𝐡 𝐨𝐟 𝐜𝐨𝐧𝐯𝐞𝐲𝐨𝐫, 𝐦 ; ∆𝐙 = 𝐯𝐞𝐫𝐭𝐢𝐜𝐚𝐥 𝐥𝐢𝐟𝐭, 𝐦

PNEUMATIC CONVEYORS
One of the most important material-handling techniques in the chemical industry is the movement
of material suspended in a stream of air over horizontal and vertical distances ranging from a few
to several hundred feet. Materials ranging from fine powders through 6.35-mm (d-in) pellets and
kg kg
bulk densities of 16 m3 to more than 3,200 m3.
The capacity of a pneumatic-conveying system depends on:
a. Product bulk density (and particle size and shape to some extent)
b. Energy content of the conveying air over the entire system,
c. Diameter of conveying line
d. Equivalent length of conveying line.
Type of pneumatic conveying system:
a. Pressure b. Vacuum c. Combination pressure and vacuum,
d. Fluidizing e. Blow tank.

Design of Pneumatic Conveyor Procedure

METHOD A. Analytical Method
Total Power Requirement for Pneumatic Conveyor, 𝑷𝑻𝒐𝒕𝒂𝒍 :
𝐏𝐓𝐨𝐭𝐚𝐥 = 𝐏𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 + 𝐏𝐟𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐜𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 = 𝐏𝐂 + 𝐏𝐟
𝐏𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 , (𝐏𝐂 ):
(k−1)
−4
k p2 k
PC , in kW = 2.78 x 10 [ ] Q1 p1 [( ) − 1]
k−1 p1
𝐏𝐟𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐜𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 , (𝐏𝐟 ):
Pf = Pf air + Pfsolid
Where:
𝐏𝐟 𝐚𝐢𝐫 = [𝐅𝐜 + 𝐅𝐞 + ∑ 𝐅] (𝐦̇𝐚𝐢𝐫 )
K c 𝜐𝑎𝑖𝑟 2 A2
Fc = ; K c = 0.75 (1 − )
2α A1
A2
Usually ≈ 0.75
A1
∝= 0.5 (streamline flow)& 1.0 (turbulent)
𝜐𝑎𝑖𝑟 2
F𝑒 = Usually ∝= 0.5 (streamline flow)& 1.0 (turbulent)
2α
𝜐 2
f ( 𝑎𝑖𝑟 ∑
2 ) (L + Le )
∑F = or
D
Where:
L = Pipe length
f = 0.015 (constant for air at high 𝑅𝑒 )
L
Le = (tube diameter) ∑(No. of fittings) (D of the fitting type)

𝐏𝐟 𝐬𝐨𝐥𝐢𝐝 = [𝐖𝐊𝐄 + 𝐖𝐋 + 𝐖𝐬𝐟 + 𝐖𝐞 ](𝐦̇𝐬𝐨𝐥𝐢𝐝 )

2
υs
=[ + ΔZ g + fs L g + no. of elbows(1.155fs υs 2 )] (𝐦̇𝐬𝐨𝐥𝐢𝐝 )
2
Where: fs = sliding friction ≈ Tan (35°~45°) ≈ 1.0
Design Problem:
kg
A 0.154-m diameter tube is used by a pneumatic conveyor to transport a finely crushed material with a bulk density of 1000 at
m3
kg
a solid transport rate of 2.5 . The 100-m conveyor tube contains two 90 long sweep and provides a lift of 15 m. Air for the
o
sec
m
transport is available from another source at a velocity of 73.4 , at a temperature of 38℃, a pressure of 101.3 kPa. After
sec
compression and cooling of the gas, the inlet conditions to the pneumatic conveyor system are 38℃ and 186 kPa.
What is the theoretical power requirement for this solids transport system.
Given:
kg kg
Solid ∶ Bulk ρs = 1000 3 ; ṁs = 2.5
m sec
m
Air: υair = 73.4 T = 38℃ ; P = 101.3 kPa;
sec
PM 1 atm(29.1) kg
ρair = = = 1.14 3
RT 0.08205(38 + 273.15)K m
System: Length = 100 m ; 90° Elbows − 2 pcs. Vertical lift = 15 m (T = 38℃ P = 186 kPa)
Required: Theoretical power requirement for this solids transport system.
Solution:
𝐏𝐓𝐨𝐭𝐚𝐥 = 𝐏𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 + 𝐏𝐟𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐜𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 = 𝐏𝐂 + 𝐏𝐟
Assume pressure drop through the conveyor : (−∆P) = 40 kPa (i.e. P1 = 186 kPa P2 = 146 kPa)
m π(0.154m)2 kg kg
Mass Flow rate of air = ṁair = υair Aρair = (73.4 )[ ] (1.14 ) = 1.5586
sec 4 m3 sec

(186+146)𝑘𝑃𝑎
Average Density of air inside the pneumatic system: (T= 38℃ ; 𝑃𝑎𝑣𝑒 = = 166 𝑘𝑃𝑎
2
1 atm
166 kPa ( ) (29.1) kg
Average ρair = 101.325 = 1.867 3
0.08205(38 + 273.15)K m

Average Density of the solid and air mixture:

𝑚̇𝑠 + 𝑚̇𝑎𝑖𝑟 2.5 + 1.5586 𝑘𝑔
𝜌𝑚𝑖𝑥𝑡 = = = 4.847 3
𝑚̇𝑠 𝑚̇𝑎𝑖𝑟 2.5 1.5586 𝑚
+ +
𝜌𝑆 𝜌𝑎𝑖𝑟 1000 1.867
Average velocity of air inside the conveyor:
kg
ṁair 1.5586 m
Using ṁair = υair Aρair ; Average υair = = sec = 44.82
A ρair π(0.154m)2 kg sec
[ ] (1.867 3 )
4 m

A. Power to compress the Air:

𝐏𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 , (𝐏𝐂 )
(k−1)
k p2 k
Power in kW = 2.78 x 10−4 [ ] 𝑄1 p1 [( ) − 1]
k−1 p1
kg 3600sec (1.4−1)
1.4 1.5586 ( ) 186 1.4
Pc = 2.78 x 10 −4
[ ][ sec 1hr ] (101.3) [( ) − 1] = 91.98 kW
1.4 − 1 kg 101.3
1.14 3
m

Using centrifugal compressor with efficiency = 80%,

 𝟗𝟏. 𝟗𝟖 𝒌𝑾
𝐀𝐜𝐭𝐮𝐚𝐥 𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐨𝐫 𝐏𝐨𝐰𝐞𝐫, 𝐏𝐜 = = 𝟏𝟏𝟓 𝐤𝐖
𝟎. 𝟖𝟎
B. Power to convey pneumatically:

𝐏𝐟𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐜𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 , (𝐏𝐟 )

𝐏𝐟 = 𝐏𝐟 𝐚𝐢𝐫 + 𝐏𝐟𝐬𝐨𝐥𝐢𝐝
Where:
𝐏𝐟 𝐚𝐢𝐫 = [𝐅𝐜 + 𝐅𝐞 + ∑ 𝐅] (𝐦̇𝐚𝐢𝐫 )
K c υair 2 A2 A2
Fc = ; K c = 0.75 (1 − ) Usually ≈ 0.75
2α A1 A1
Therefore K c = 0.1875
∝= 0.5 (streamline flow) & 1.0 (turbulent)
𝑈𝑠𝑒 ∝= 0.5
m
υair = 44.82
sec
m 2
K c υair 2 (0.1875)(44.82 ) m2
Fc = = sec = 188.33
2α 2(0.5) sec 2
υair 2
Fe = Usually ∝= 0.5 (streamline flow)& 1.0 (turbulent)
2α
m 2
(44.82 ) m2
Fe = sec = 2008.83
2(0.5) sec 2
𝜐𝑎𝑖𝑟 2
f( ) (L + ∑ Le )
2
∑F =
D
Where:
L = Pipe length = 100 m
f = 0.015 (constant for air at high 𝑅𝑒 )
L
Le = (tube diameter) ∑(No. of fittings) ( of the fitting type)
D

m 2
(44.82 )
0.015 [ sec ] [100 + (0.154m)(2)(23)]
2 m2
∑F = = 10,476.32
0.154m sec 2
𝐓𝐡𝐞𝐫𝐞𝐟𝐨𝐫𝐞, 𝐏𝐟 𝐚𝐢𝐫 = [𝐅𝐜 + 𝐅𝐞 + ∑ 𝐅] (𝐦̇𝐚𝐢𝐫 )
𝐦𝟐 𝐤𝐠 𝐉
𝐏𝐟 𝐚𝐢𝐫 =[𝟏𝟖𝟖. 𝟑𝟑 + 𝟐𝟎𝟎𝟖. 𝟖𝟑 + 𝟏𝟎, 𝟒𝟕𝟔. 𝟑𝟐 ] 𝟐 (𝟏. 𝟓𝟓𝟖𝟔 ) = 𝟏𝟗, 𝟕𝟓𝟐. 𝟖𝟗 ≈ 𝟏𝟗. 𝟕𝟓𝐤𝐖
𝐬𝐞𝐜 𝐬𝐞𝐜 𝐬𝐞𝐜
𝐏𝐟 𝐬𝐨𝐥𝐢𝐝 = [𝐖𝐊𝐄 + 𝐖𝐋 + 𝐖𝐬𝐟 + 𝐖𝐞 ](𝐦̇𝐬𝐨𝐥𝐢𝐝 )
 υs 2
=[ + ΔZg + fs Lg + no. of elbows(1.155fs υs 2 )] (𝐦̇𝐬𝐨𝐥𝐢𝐝 )
2

m 2
(44.82 ) m m m 2 𝐤𝐠
sec
𝐏𝐟 𝐬𝐨𝐥𝐢𝐝 = [ + (15m) (9.81 2
) + (1.0)(100m) (9.81 2
) + 2 (1.155(1.0) (44.82 ) )] (𝟐. 𝟓 )
2 sec sec sec 𝐬𝐞𝐜
𝐦𝟐 𝐤𝐠 𝐉
𝐓𝐡𝐞𝐫𝐞𝐟𝐨𝐫𝐞, 𝐏𝐟 𝐬𝐨𝐥𝐢𝐝 = [𝟏𝟎𝟎𝟒. 𝟒𝟐 + 𝟏𝟒𝟕. 𝟏𝟓 + 𝟗𝟖𝟏 + 𝟒𝟔𝟒𝟎] (𝟐. 𝟓 ) = 𝟏𝟔, 𝟗𝟑𝟏 ≈ 𝟏𝟔. 𝟗𝟑 𝐤𝐖
𝐬𝐞𝐜 𝟐 𝐬𝐞𝐜 𝐬𝐞𝐜

𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐂𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 (𝐏𝐟 ) = 𝐏𝐟𝐚𝐢𝐫 + 𝐏𝐟𝐬𝐨𝐥𝐢𝐝 = 𝟏𝟗. 𝟕𝟓𝐤𝐖 + 𝟏𝟔. 𝟗𝟑 𝐤𝐖 = 𝟑𝟔. 𝟔𝟖 𝐤𝐖

Using Efficiency of conveying = 70% ,

𝟑𝟔. 𝟔𝟖 𝐤𝐖
𝐀𝐜𝐭𝐮𝐚𝐥 𝐏𝐨𝐰𝐞𝐫 𝐨𝐟 𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐏𝐧𝐞𝐮𝐦𝐚𝐭𝐢𝐜 𝐂𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 (𝐏𝐟𝐜𝐚𝐜𝐭𝐮𝐚𝐥 ) = = 𝟓𝟑 𝐤𝐖
𝟎. 𝟕𝟎

Total Power of Pneumatic Conveying System

𝐓𝐨𝐭𝐚𝐥 𝐏𝐨𝐰𝐞𝐫 (𝐏𝐓𝐨𝐭𝐚𝐥 ) = 𝐏𝐂𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐨𝐧 + 𝐏𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐜𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠
= 𝐏𝐂 + 𝐏𝐟 = 𝟏𝟏𝟓 𝐤𝐖 + 𝟓𝟑 𝐤𝐖 = 𝟏𝟔𝟖 𝐤𝐖
Checking for the assumed (−∆𝐏) = 𝟒𝟎 𝐤𝐏𝐚,
𝐦𝟐 ∙ 𝐤𝐠
𝐏𝐟 𝟑𝟔. 𝟔𝟖
∆𝐏 = ( ) (𝛒𝐦𝐢𝐱𝐭 ) = ( 𝐬𝐞𝐜 𝟐 ∙ 𝐬𝐞𝐜 ) (𝟒. 𝟖𝟒𝟕 𝐤𝐠 ) = 𝟒𝟑. 𝟗 𝐤𝐏𝐚
𝐦̇𝐚 + 𝐦̇𝐬 𝐤𝐠 𝐤𝐠 𝐦𝟑
𝟏. 𝟓𝟓 + 𝟐. 𝟓
𝐬𝐞𝐜 𝐬𝐞𝐜
METHOD B. Nomograph from ChE Handbook by Perry -7th Edition)
𝐒𝐲𝐬𝐭𝐞𝐦 𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 𝐋𝐨𝐬𝐬 = ∆𝐏 = 𝟑𝟑 𝐤𝐏𝐚

𝐀𝐜𝐭𝐮𝐚𝐥 𝐏𝐨𝐰𝐞𝐫 𝐨𝐟 𝐅𝐫𝐢𝐜𝐭𝐢𝐨𝐧𝐚𝐥 𝐏𝐧𝐞𝐮𝐦𝐚𝐭𝐢𝐜 𝐂𝐨𝐧𝐯𝐞𝐲𝐢𝐧𝐠 (𝐏𝐟𝐜𝐚𝐜𝐭𝐮𝐚𝐥 ) = 𝟓𝟐 𝐤𝐖