Shell Balances….

Falling film over a plate / plane

 Falling film over
• Consider that a liquid is flowing over a
a plate / plane
vertical flat plate of length L & width W
• Such cases are seen across many chemical
processes such as:
• wetted wall columns
• evaporation of liquids
• gas absorption in liquids
• surface coatings

• Consider that a liquid is forming a film over the flat plate.

• Let the density  and the viscosity of the fluid  be constant.
• Liquid film thickness is  and is very small compared to the length
and width of the plate.
• Consider that the fluid is flowing in the z-direction. Only the
velocity vz is considered. Consider a shell at a distance x and
thickness Δx…………….& GRAVITY FLOW.......!!!!!
• Step 1,2,3 & 4 : Conservation of momentum balance equation, vz, Δy shell &
momentum balance for steady state conditions……
• Law of conservation of Momentum
Rate of momentum I/P – Rate of momentum O/P + {Sum of forces acting on the
system(gravity, pressure)} = 0………. (1)
Keep it in mind…..Rate = (Flux) x (Area)
Rate of momentum @ distance “x”,….. IP =
Rate of momentum @ distance “x+Δx”,….. OP =
Open atmosphere….
Gravity forces acting on the shell is = m g =
Substitute all the expressions in (1)…..

−
• Step 5: Formulate the Rearranging Eqn……. (2)
differential equation for the
momentum flux by Dividing both sides by ……
considering the shell
thickness approaching zero.
Thus, we will get the first
differential equation By applying the limit Δx  0……
………. (3)
• Step 6: Integrate the differential
equation formed to get the Integrating (3)…..
momentum flux distribution.

• Step 7: Apply B.C 1: @ x = 0….τxz = 0…sub in Eqn (4)..

the boundary  C1 = 0
condition and
find the ……(5) Momentum Flux Profile
constant value. Y= mX……form…..τxz linearly
changes with “x”
• Step 8: Apply the Newton’s law
of viscosity and obtain a
(5)===τxz = − μ
differential equation for the
velocity distribution. =−
• Step 9: Integrate the differential
equation to get the velocity
distribution. It will appear with a
=−
constant of integration.
• Step 10: Apply the boundary (6)== =
B.C 2: @ x = ….vz = 0 …
conditions to evaluate the constant
values. Get the velocity distribution
equation.
= = −

= =

Velocity profile
v parabolic profile with “x”
Summary……
Falling film over a flat plate…….
• Velocity profile is parabola

• Momentum flux is linear

……. (5)
• Step 11: From the velocity distribution, the other parameters such
as maximum velocity, average velocity, flowrate etc. can be
evaluated.

Maximum velocity……

• The maximum velocity of the fluid will be exhibited at the

surface…..
• ….i.e…..@ x = 0………vz  vz,max….

(6)==
= =
Volumetric Flowrate: Average velocity…… vz,av
The total volumetric flowrate of the
system, Q = =
• dQ is the volumetric flow rate from From Eqn ….( 99)
small strip of thickness dx
By using……Volumetric flowrate = velocity x area
=
Q= =

Q=
=
Q =
From Eqn ….( 7)
Q = =
• Falling film over a flat plate…. =
the Reynolds number is defined
as
For laminar flow, NRe < 20

For turbulent flow, NRe > 1500

Prob 1
• A solution which has the same property of water flows down through
a vertical wetted column at a rate of 0.124 kg/s per unit width of wall.
Calculate the film thickness and average velocity.
• Ans:

• Mass flowrate = vol flow rate x density

• Thickness = 0.339 mm
• Ave. velocity = 0.375 m/s
Prob 2
• An oil is flowing down a vertical wall as a film 1.7 mm thick. The oil density
is 820 kg/m3 and the viscosity is 0.2 Pa . S. Calculate the average velocity,
Reynolds number and the mass flow rate per unit width of wall:

Ans:
• Ave velocity = 0.042 m/s
• Re = 1.17
• Mass flowrate per width of wall = 0.0585 kg/s . m
Prob 1
• Thickness of a falling film. Water at 20°C is flowing down a vertical
wall with Re = 10. Calculate (a) the flow rate, in m3 per sec per m of
wall width, and (b) the film thickness mm
= =

= ⇒𝛿 =
3 𝑄
3
𝑔 𝑊( )
=  = 0.0923 mm

Q = 2.5 x 10 – 6 m3/s
 Special cases…..Inclined plates!!!!!
Forces acting
on inclined
plane

Net force = mg Sin

• Case 1: if the plate is inclined with an angle

“” with horizontal axis
• The gravity force expression will change!!!!

Gravity forces acting on the shell is = mg Sin 

= g Sin 

Follow the same procedure for derivation!!!!

By applying the limit Δx  0……
………. (3) Q =
Momentum Flux
……(5) Profile
=− =

= From Eqn ….( 7)

=
Velocity profile
(6)==
= =

Maximum velocity……
 Special cases…..Inclined plates!!!!!
Forces acting
on inclined
plane

Net force = mg Sin

• Case 2: if the plate is inclined with an angle

“” with vertical axis
• The gravity force expression will change!!!!
Gravity forces acting on the shell is = mg Sin (90)
= mg Cos 
= g Cos 
Follow the same procedure for derivation!!!!
By applying the limit Δx  0……
………. (3) Q =

……(5) Momentum Flux

Profile
=− =

= From Eqn ….( 7)

=
Velocity profile
(6)==
= =

Maximum velocity……
Special cases…..Inclined plates!!!!!
Forces acting on inclined plane
• Incline…….
Annulus…..
Falling film over a plate / plane
FLOW OF A LIQUID FALLING FILM
• Let us consider that a liquid is
flowing over a vertical flat plate of
length L and width W
• Such cases are seen across many
chemical processes such as:
(a) wetted wall columns
(b) evaporation of liquids
(c) gas absorption in liquids
(d) surface coatings
• A horixontal annulus is 27 ft long. Outer radius of inner cylinder is
0.495” inner radius and outer radius is 1.1”. An aqueous solution of
sucrose is to be pumped having viscosity of 136.8 lbm /ft h. What is
the volumetric flow rate if the pressure drop is 5.399 psi.
Annulus problem
• An horizontal annulus is 27 ft long. The outside radious of iiner
cylinder is 0.495 in. The inside radius of outside cylinder is 1.1 in. The
fluid density is 80.3 lb/ft3 and viscosity is 136.8 lg m /ft s. What is the
rate of flow, the impressed pressure drop is 5.39 psi?

• K = KR/R = 0.495
• A solution which has the same property of water flows down through
a vertical wetted column at a rate of 0.124 kg/s. Assume the width of
Comparison of different transport
operations
 Comparison of different transport
operations
Momentum Transfer Heat Transfer Mass Transfer
Flux (Rate/area) Momentum flux, Heat flux, Mass flux,
 = F/A q = Q/A JA = rate of matter / area
= rate of momentum / area = rate of energy / area = (Matter amount /time) / Area
=(Momentum/time) / Area = (Energy /time) / Area (mol /s m2)
(N/m2) (J/s m2)

Driving force Velocity gradient (dv/dy) Temperature gradient (dT/dx) Concentration gradient (dCA/dx)

Transport Law Newton’s law of viscosity Fourier’s law of conduction Fick’s law of diffusion
Transport Equation

Transport Property
Diffusivity …..m2/s ……. m2/s .. m2/s

Momentum diffusion Thermal diffusion Matter diffusion

Comparison of different transport
operations
Momentum Transfer Heat Transfer Mass Transfer
Flux Momentum flux, Heat flux, q = Q/A Mass flux, JA
 = F/A = rate of energy / area = rate of matter / area
= rate of momentum / area = (Energy /time) / Area = (Matter amount /time) / Area
=(Momentum/time) / Area (J/s m2) (mol /s m2)
(N/m2)
Driving force Velocity gradient (dv/dy) Temperature gradient (dT/dx) Concentration gradient
(dCA/dx)
Transport Law Newton’s law of viscosity Fourier’s law of conduction Fick’s law of diffusion
Transport Equation

Transport Property
Diffusivity
Momentum diffusion Thermal diffusion Matter diffusion
 Chemical Engineering

Transport Phenomena

Reaction Kinetics Momentum Mass

Heat
Transport Phenomena…….
• “Transport Phenomena” is a subject of interest to many scientists and engineers in their respective fields of study. This subject, apart from
being of prime interest to chemical engineers, is also increasingly gaining popularity and application in the fields of agriculture, biology,
biotechnology and nanotechnology
• The subject of transport phenomena covers mainly three aspects: momentum transfer, heat transfer and mass transfer.
• In the field of chemical engineering,
• the momentum transfer occurs in industrial operations such as mixing, sedimentation, fluid flow and filtration.
• Heat transfer occurs in conduction and in convection transfer of heat during evaporation and drying,
• mass transfer takes place in operations such as distillation,
absorption, chemical reactions, liquid–liquid extraction, crystallization and adsorption

• Generally a question is asked, why do we need to study these three phenomena together? There are
reasons for it.

• Let us take a simple process where the raw materials are transported from the storage vessel to the reactor.
• So, the fluid flow phenomenon comes into the picture.
• Then, if the reaction in the reactor takes place at high temperatures, then the raw materials have to be
heated.
• After the reaction, the separation processes take place with a view to isolating the product in pure form. The mass transfer
operations such as distillation, absorption or crystallization may also take place.
• The mechanisms of these three transport phenomena are closely related. Also, the governing
mathematical equations are similar in nature.
Transport laws
• Transport Phenomena relate to the tendency of temperature,
concentration, and velocity to attempt towards uniform values.
• They are a generic group of processes, by which a quantity (matter,
heat or momentum) is transferred from regions of high concentration,
temperature or fluid velocity, to those regions where this quantity is
lower.
• Transport in a chemical or mechanical process can be classified into three types:

• [1] Momentum transport deals with the transport of momentum in fluids and that is fluid
dynamics.
• [2] Energy transport deals with the transport of different forms of energy in a system and is
also known as heat transfer.
• [3] Mass transport deals with the transport of various chemical species themselves.

• Three key processes are

• [1] Matter diffusion (Fick’s Law),
• [2] Conduction, or thermal diffusion (Fourier’s Law),
• [3] Viscosity, or momentum diffusion (Newton’s Law),
• Diffusion – Fick’s law
• Variations of concentration in a medium, for example, lead to the
relative motion of the various chemical species present, and this mass
transport is generally referred to as diffusion. The spreading of mass
from highly concentrated areas to less concentrated areas. is one
form of mass transfer. It can also be described using Fick's first law:
• J = - E dc/dx Here, c is the mass concentration of the species being
dispersed, E is the dispersion coefficient, and x is the position in the
direction of the concentration gradient.
• Conduction – Fourier’s law
• Fourier's law, states that the rate of heat transfer through a material is
proportional to the negative gradient in the temperature and to the
area, at right angles to that gradient, through which the heat flows.
• q = - k dT, q is local flux density, - k is material’s thermal conductivity
and dT is a temperature gradient
• Viscosity, or momentum diffusion- Newton’s Law
• Newton's law of viscosity and states that the shear stress between adjacent fluid layers is
proportional to the
• a negative value of the velocity gradient between the two layers.
• F /A = "eta" ∆Vx/∆z, eta is viscosity, ∆Vx/∆z is the velocity gradient
• There are notable similarities in the commonly used approximate differential equations for
momentum, heat, and mass transfer. The molecular transfer equations of Newton's law for fluid
momentum at low Reynolds number (Stokes flow), Fourier's law for heat, and Fick's law for mass
are very similar, since they are all linear approximations to transport of conserved quantities in a
flow field. At higher Reynolds number, the analogy between mass and heat transfer and momentum
transfer becomes less useful due to the nonlinearity of the Navier-Stokes equation (or more
fundamentally, the general momentum conservation equation), but the analogy between heat and
mass transfer remains good. A great deal of effort has been devoted to developing analogies among
these three transport processes so as to allow the prediction of one from any of the others.
• The driving force for mass transfer is usually a difference in chemical
potential when it can be defined, though other thermodynamic
gradients may couple to the flow of mass and drive it as well. A chemical
species moves from areas of high chemical potential to areas of low
chemical potential. Thus, the maximum theoretical extent of a given
mass transfer is typically determined by the point at which the chemical
potential is uniform. For single-phase systems, this usually translates to
uniform concentration throughout the phase, while for multiphase
systems chemical species will often prefer one phase over the others and
reach a uniform chemical potential only when most of the chemical
species has been absorbed into the preferred phase, as in liquid-liquid
extraction.
• Rate of transport = Driving force / Resistance
• Flux = Rate of transport / area
• While thermodynamic equilibrium determines the theoretical extent of a given mass transfer operation, the actual rate
of mass transfer will depend on additional factors including the flow patterns within the system and the diffusivities of
the species in each phase. This rate can be quantified through the calculation and application of mass transfer
coefficients for an overall process. These mass transfer coefficients are typically published in terms of dimensionless
numbers, often including Péclet numbers, Reynolds numbers, Sherwood numbers, and Schmidt numbers, among others.
• These mass transfer coefficients are typically published in terms of dimensionless numbers, often including Péclet
numbers, Reynolds numbers, Sherwood numbers, and Schmidt numbers, among others.
• Mass transfer is the net movement of mass from one location, usually meaning stream, phase, fraction, or component,
to another. Mass transfer occurs in many processes, such as absorption, evaporation, drying, precipitation, membrane
filtration, and distillation. Mass transfer is used by different scientific disciplines for different processes and mechanisms.
The phrase is commonly used in engineering for physical processes that involve diffusive and convective transport of
chemical species within physical systems.
• Some common examples of mass transfer processes are the evaporation of water from a pond to the atmosphere, the
purification of blood in the kidneys and liver, and the distillation of alcohol. In industrial processes, mass transfer
operations include the separation of chemical components in distillation columns, absorbers such as scrubbers or
stripping, adsorbers such as activated carbon beds, and liquid-liquid extraction. Mass transfer is often coupled to
additional transport processes, for instance in industrial cooling towers. These towers couple heat transfer to mass
transfer by allowing hot water to flow in contact with air. The water is cooled by expelling some of its content in the form
of water vapor.
• Mass (or heat) transfer between flowing fluid and reactor internals is usually described in terms of dimensionless numbers:
• For mass transfer: Sherwood number Sh, is a function of Reynolds number Re, and Schmidt number Sc = μρ−1·D−1 that characterizes
diffusional properties of flowing media. D is the mass diffusivity (m2/s), μ is the dynamic viscosity of the fluid, ρ is the density of the
fluid.
• For heat transfer: Nusselt number Nu, is a function of Reynolds number Re, and Prandtl number Pr = Cp μ/k that characterizes
thermal properties of the fluid. μ dynamic viscosity, k : thermal conductivity, Cp: specific heat,
• Sometimes, only one of the transport characteristics—either heat or mass transfer—is known. Then, the Chilton-Colburn analogy may
be used to derive the missing equation. The analogy is strictly valid for the turbulent flow, however, it is commonly applied to the
flow-through packed columns, monoliths, or solid foams. The analogy assumes identical mechanisms of heat and mass transfer, thus
the dependence of Sherwood and Nusselt numbers on the Reynolds number has to be identical. The usual form of the Chilton-
Colburn analogy is:
• j=Nu/Re x Pr^1/3 = Sh/ ReSc^1/3.
• The so-called Colburn factor j is assumed to be a function of Reynolds number and is identical for heat and mass transfer.
• Briefly,
• Sherwood number Sh: The Sherwood number (Sh) also called the mass transfer Nusselt number. It is a dimensionless number used in
the mass-transfer operation. It represents the ratio of the convective mass transfer to the rate of diffusive mass transport
• Schmidt number Sc: Schmidt number (Sc) is a dimensionless number defined as the ratio of momentum diffusivity (kinematic
viscosity) and mass diffusivity, and is used to characterize fluid flows in which there are simultaneous momentum and mass diffusion
convection processes.