SI No Calculation

1 Heating time using hot water (Non Isothermal Heating Medium)

2 Heating time using steam (Isothermal Heating Medium)
3 Cooling time using non isothermal cooling medium
4 Heating time using external Heat exchanger & Non Isothermal Heating Medium

5 Heating time using external Heat exchanger & Isothermal Heating Medium

6 Cooling time using external Heat exchanger & Non Isothermal Cooling Medium

7 Cooling time using external Heat exchanger & Isothermal Cooling Medium
Calculate the Heat Transfer coefficient for reactors based on different
8
agitator types & utility flow rate
Calculate the addition time required based on heat of the reaction,
9
Type of agitator, MOC & utility flow rate in a semi batch reactor
10 Scale up of reactor from lab to plant scale
11 Calculate the vacuum pump flow rate based on air leakage rate
12 Power required for pumping
13 Pump affinity law
14 Pipe flow distribution
15 Pressure drop across pipe lines
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Non Isothermal Heating
Reactor Contents
Mass M 72500 lb
Initial temp t1 120 °F
Final temp t2 200 °F
Sp.Heat Cm 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 180 BTU/hr ft2 °F

Heating Fluid
Inlet temp T1 230 °F
Sp.Heat Cw 1.2 Btu/ lb °F
Flow rate W 18000 lb/hr

Time required for heating

ln T1 - t1 = WCw x K-1 xt
T1 - t2 MCm K

K = e(UA/WC)

K 3.49034
Time reqd = 6.42 hrs
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Isothermal Heating
Reactor Contents
Mass M 50000 lb
Initial temp t1 68 °F
Final temp t2 257 °F
Sp.Heat Cm 0.5 Btu/ lb °F
Area A 100 ft2
HTC U 150 BTU/hr ft2 °F

Heating Fluid
Inlet temp T1 320 °F

Time required for heating

ln T1 - t1 = U A time
T1 - t2 MC

Time reqd = 2.31 hrs

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Non Isothermal cooling
Mass M 72500 lb
Initial temp T1 200 °F
Final temp T2 82 °F
Sp.Heat Cm 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 110 BTU/hr ft2 °F

Cooling Fluid
Inlet temp t1 72 °F
Sp.Heat Cw 1 Btu/ lb °F
Flow rate W 15500 lb/hr

Time required for cooling

ln T1 - t1 = WCw x K-1 xt
T2 - t2 MCm K

K = e(UA/WC)

K 2.89944
Time reqd = 19.11 hrs
= 1146.78 min
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Non Isothermal Heating
Reactor Contents
Mass M 72500 lb
Mass Flow rate w 20000 lb/hr
Initial temp t1 82 °F
Final temp t2 200 °F
Sp.Heat c 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 210 BTU/hr ft2 °F

Heating Fluid
Inlet temp T1 230 °F
Sp.Heat C 1.2 Btu/ lb °F
Flow rate W 15500 lb/hr

Time required for heating

ln T1 - t1 = wWC x K3-1 xt
T1 - t2 (K3wc-WC) M

K3 = eUA*(1/WC-1/wc)

K3 1.213548
Time reqd = 10.03 hrs
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Isothermal Heating
Reactor Contents
Mass M 72500 lb
Mass Flow rate w 20000 lb/hr
Initial temp t1 82 °F
Final temp t2 200 °F
Sp.Heat c 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 210 BTU/hr ft2 °F

Heating Fluid
Inlet temp T1 230 °F

Time required for heating

ln T1 - t1 = wc x K2-1 xt
T1 - t2 Mc K2

K2 = eUA/wc

K2 4.481689
Time reqd = 7.45 hrs
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Non Isothermal cooling
Mass M 72500 lb
Batch flow rate W 20000 lb/hr
Initial temp T1 200 °F
Final temp T2 82 °F
Sp.Heat C 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 180 BTU/hr ft2 °F

Cooling Fluid
Inlet temp t1 72 °F
Sp.Heat c 1 Btu/ lb °F
Flow rate w 15500 lb/hr

Time required for cooling

ln T1 - t1 = Wcw x K4-1 xt
T2 - t1 (K4wc-WC) M

K4 = eUA*(1/WC-1/wc)

K4 0.63367
Time reqd = 18.19 hrs
= 1091.62 min
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Isothermal cooling
Mass M 72500 lb
Batch flow rate W 20000 lb/hr
Initial temp T1 200 °F
Final temp T2 82 °F
Sp.Heat C 1.05 Btu/ lb °F
Area A 150 ft2
HTC U 180 BTU/hr ft2 °F

Cooling Fluid
Inlet temp t1 72 °F
Sp.Heat c 1 Btu/ lb °F
Flow rate w 15500 lb/hr

Time required for cooling

ln T1 - t1 = WC K1-1 xt
T2 - t1 MC K1

K1 = eUA/WC

K1 3.61725
Time reqd = 12.77 hrs
= 766.37 min
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Calculation of Heat transfer coefficient in reactor

Reactor data
Diameter of the tank T 108 in 9 ft
Impeller speed N 45 rpm 2700 rph
Impeller Dia Da 42 in 3.5 ft
Impeller power Hp 2 Hp
Agitator Type Anchor-1
Vessel jacket flow depth L 1 in 0.08 ft
Height of liquid in cylindrical section Z 96 in 8 ft

Properties of batch side fluid

Heat capacity Cp 0.997 Btu/lb °F
Sp gravity ℓb 1.0028 1002.8 62.60 lb/ft3
Bulk Viscosity µ 0.536 cp 1.29712 lb/hr ft
Viscosity at wall µw 1.45 cp
Thermal conductivity k 0.368 Btu/hr ft °F
Properties of jacket side fluid
Heat capacity Cp 1.01 Btu/lb °F
Sp gravity ℓb 65.2 lb/ft3
Bulk Viscosity µ 1.45 cp 3.509 lb/hr ft
Viscosity at wall µw 1.45 cp 3.509 lb/hr ft
Thermal conductivity k 0.335 Btu/hr ft °F
Liquid flow rate Q 0.22 cu ft / sec
Calculation
Batch Side calculation
Agitated batch liquid reynolds number
NRe = Da2 x N x ℓb / µ
= 1596296
Agitated batch liquid Prandlt number
NPr = Cp x µ / k
= 3.51
µ/µw = 0.370
Z/T = 0.889
Da/T = 0.389
a 1
b 0.67
M 0.18
hb T / k = a x Nre x NPr
b 1/3
x (µ/µw)
M

Agitated liquid Heat Transfer coefficient,hb = 709.84 Btu/hr ft2 °F

 Jacket Side calculation

Nu = A1 x NRe0.667 x NPr b x (u/uw)0.14 0.0243 0.4

A1 b
0.0265 0.3
Nu = hj Dj / Kj

Dj = Equivalent cross flow diameter of the

jacket
Nre = Dj V ℓj / µj
Dj - Jacket cross flow diamater = 4 x Acs /
Wetted
Acs = L x W = 0.667 ft2
Wetted = L x 2 + W x 2 = 16.167 ft
Dj = 0.165 ft
Aequivalent = 0.021 ft2
Velocity (V = Q/A) = 10.300 ft/sec 37082 ft/hr

NRe = 113650.5

NPr = 10.58

For cooling
A1 = 0.0243
b = 0.3

Jacket side Heat transfer coefficient, hj = 235.89 Btu / hr ft2 °F

Overall heat transfer coefficient

1/U overall = 1/hJ + 1/hB + 1/hDM

RDM = 1/hDM = 0.001

1/U overall = 0.0066

Uoverall = 150.42 Btu / hr ft2 °F

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A reactor 2.0 KL capacity is used to carryout an exothermic reaction at 80°C
The reaction calorimetry shows heat of the reaction of 15000 BTU/mole of reagent 'Z'.
If 5 mole of reagent Z is used calculate the addition rate
Cooling water is available at 0°C

U 55 BTU / hr sq F °F 264 kcal/hr m2 °C

A 7 m2
T 80 °C

Q 147840 kcal / hr

Heat of rxn 1000 kcal/mole

Addn Rate 29.568 lit/hr

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Two assumptions
- Power per unit volume is constant
- Tip speed is constant

Scale up (Lab scale data)

Dt1 0.108 m
H1 0.108 m
Vol 0.001 m3 1.00 Lit
Da1 0.043 m
N1 400 rpm 6.67 rps
Density 1300 kg/m3
Viscosity 1000 CP 1.0000 kg / m s

Scale up times 1000 times

Assumption, Power per unit volume is constant

N2 = N1 x (1/R) power 2/3
Ratio 10 = V2 1/3

V1
N2 1.44 rps 86.2 rpm
Np 5 (Assume)

Da2 0.433614 m
Dt2 1.084035 m
V2 1000.00 L
Nre 351.0687

P 295.2272 J/sec 0.30 KW 0.40 hp

0.515162 hp (30 % Loss)

Assuming Tip speed is constant

N2 = N1 / R
N2 0.666667 rps 40 rpm

Nre 162.9517 J/sec

P 29.52272 J/sec 0.03 KW 0.04 hp

0.051516 hp (30 % Loss)

- The assumption is also based on power per unit volume as constant

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Designing Based on pressure drop test

Example
Total System Volume V = 350 ft3
System Evacuation to Pi = 2 in Hg Abs
Final Pressure Pf = 3 in Hg Abs
Drop test period t = 10 min
Desired operating pressure Po = 1 in Hg Abs

Pump capacity required Q = (Rise in pressure) x System volume (V)

time (t) x Desired operating pressure (Po)

Q = 35 CFM

Designing Based on pump evacuation time

Total system volume V = 100 ft3

Initial pressure Pi = 760 mm Hg abs
Final pressure Pf = 50 mm Hg abs
Evacuation time t = 2.25 min

Pump capacity required Q = V x ln(Pi/Pf)

t

Q = 120.9 ACFM

Once the pump size is selected, we must recalculate the evacuation time by using that pump's average
capacity.

Designing Based on Air Leakage Rate

Assuming the inlet gas composition is only air at 75°F

Fall in vacuum 300 mm Hg/hr

Total System volume V = 5000 lit
Temperature T = 75 °F
Initial Pressure Pi = 760 mm Hg Abs
Operating Pressure Po = 100 mm Hg Abs
Air Leakage rate 2.348 kg/hr

The capacity in ACFM can be calculated using

ACFM = ( m / Mwt ) x (379/60) x (Initial pressure / Operating Pressure) x (460+T/520)

ACFM S = 8.82 ACFM

Correction factor Fc = 0.85

Corrected capacity Sc = 10.37 ACFM

Based on this, from the pump manufacturer curve required CFM, hp & gpm of water for service can be obtained

Designing for air & solvent vapour

Composition of vapours are Air + Methanol Vapour + water vapour

Fall in vacuum 300 mm Hg/hr

Total System volume V = 5000 lit
Temperature T = 104 °F
Initial Pressure Pi = 760 mm Hg Abs
Operating Pressure Po = 50 mm Hg Abs
Methanol vapour = 15 kg/hr
Water vapour = 5 kg/hr
Air Leakage rate = 2.23 kg/hr
Total = 22.23 kg/hr

Compound Qty % weight Mwt

Methanol 15.0 67.48 32.0
Water 5.0 22.49 18.0
Air 2.2 10.02 29.0

Calculating average molecular weight = 27.00

ACFM S = 85.74 ACFM

Correction factor Fc = 0.85

Corrected capacity Sc = 100.87 ACFM

ystem volume (V)
erating pressure (Po)

at pump's average

0.4 atm
5 m3
296.9 K

5.18 lb/hr
or service can be obtained

0.394737 atm
5 m3
313.0 K

4.91 lb/hr
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Power Required for pumping

Flow rate Q 300 m3/hr 0.0833 m3/sec 83.33 kg/sec

Density ℓ 1000 kg/m3
Pump head required H 25 m
Pump efficiency η 0.75

Power Required P 2777.8 kg m / sec 37.04 hp

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Affinity Laws
Q, Flow Proportional N
H, Head Proportional N2
P , Power Proportional N3

Example

Data
Initial RPM N1 1500 rpm
Initial flow Q1 400 m3/hr
Initial Head H1 25 m
Power P1 49.4 hp

By adjusting
Final RPM N2 1400 rpm

Result
Final flow Q2 373 m3/hr
Final Head H2 21.8 m
Final Power P2 40.1 hp

By reducing rpm by 6.67 %

Head reduced by 12.89 %
Power reduced by 18.70 %
 Pipe flow distribution

Data
Density ℓ 1000 kg/m3
Viscosity µ 0.8275 cp 0.00083 kg/m sec
Flow rate Q 500 m3/hr 0.13889 m3/sec
Pipe Dia D 10 in 0.254
Acceleration, g 9.8 m/s2

Calculation
Area A 0.05 m2
Velocity V 2.74 m/s
Reynolds Number NRe 841775.2

Friction Factor f 0.002988

Dia (m) Length (m)
0.14 30

0.09 60

0.20 40

Flow rate A (m3/sec)

0.1389 These values are ar
solving the constra
by Solver Add-In
Calculation
0
Pipe Dia (m) Length(m) f V,m/s hf Q (m3/sec) Q (m3/hr)
AaB 0.14 30 0.00299 2.69726 0.9506 0.0415 149.40
AbB 0.09 60 0.00299 1.5292 0.9506 0.0097 35.00
AcB 0.20 40 0.00299 2.79193 0.9507 0.0877 315.60
Target Cell
500.00 This cell is to have th
Solver such a way that the
and 3 are zero.
Cons-1 0.00000
Cons-2 0.00000
Cons-3 0.00000

* Head loss across the pipe line is equal

Equations Used

Equation of Continuity:
Q_A = Q_a + Q_b + Q_c

Equality of Pressure drops:

DelP due to friction in Pipe AaB = DelP due to friction in Pipe AbB
This program will run with Macros.
Set your macros setting to low and then proceed
the calculation.

These values are arrived from

solving the constraints 1, 2 and 3
by Solver Add-In

Target Cell
This cell is to have the value of Q, in
such a way that the constraints 1,2,
and 3 are zero.
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A 35o API distillate is being transferred from a storage tank at 1 atm absolute pressure to
a pressure vessel at 50 psig by means of the piping arrangements shown in figure.
The liquid flows at the rate of 23100 lb/hr through 3 inch Schedule 40 steel pipe; the
length of the straight pipe is 450 feet. Calculate the minimum horsepower input to the
pump having an efficiency of 60 percent.

The properties of the distillate are: viscosity = 3.4 cP, density = 52 lb/ft3.

The following are the data for the pipe and fittings:
For 3 inch Schedule 40 Nominal pipe, OD = 3.5 inch; Thickness = 0.216 inch
Flow coefficients for the fittings (K) are:
Gate valve = 0.25; 90o elbow = 0.9; Check valve = 10

Friction factor can be calculated from Blasius equation. Account for entry and exit losses
also.

Conversion Factors
1 feet 0.3048 m
1 lb 0.454 kg
1 inch 0.0254 m
1 centipoise 0.001 kg/m.sec
1 atm 14.7 psi
1 atm 1.01E+05 N/m2
g 9.812 m/sec2

Data given: Converted data:

Mass flow rate 23100 lb/hr = 2.913167 kg/sec
Density r 52 lb/ft3 = 833.7087 kg/m3
Viscosity m 3.4 cP = 0.0034 kg/m.sec
 Pipe OD 3.5 inch
Pipe thickness 0.216 inch
Pipe length L 450 feet = 137.16 m
Vertical height z1-z2 70 feet = 21.336 m
Pump efficiency (in fraction) 0.6

Loss coefficient of Gate Valve 0.25

Loss coefficient of elbow 0.9
coefficient of check valve Valve 10

Pipe ID D 3.068 inch = 0.077927 m

Pressure at 2 P2 50 psig = 3.45E+05 N/m2
3.401361 34013.61
Calculations:
Volumetric flow rate Q 0.00349 m3/sec
Velocity v 0.7326 m/sec
Reynolds Number NRe 13999
Friction factor f 0.00726

hf of pipe 1.3985 m

v2/2g 0.02735 m
hf of Gate valve 0.00684 m
hf of 2 number of elbows 0.04923 m
hf of Check valve 0.27351 m

hf of sudden contraction at inlet 0.01094 m

hf of sudden expansion at outlet 0.02735 m

Total frictional head 1.76642 m

Pump head 22.561 m

Minimum power for the pump 1074.81 Watt