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Other Ixtoksin tM
Series cia flulk M:ltcri:ds tJandfing'
Vol. , (I975 J77)
..
.
Uc-nd,ilc Coli; u:
Weichinc and rropoctiohintt of Bulk Solids
1975
ludwiJ:; RoUpe,:
tot &:A.RC'im~":
SILOS -Theory "nd Practice
1976
/
Dinribulcd by
TRANS TECII S. II.
eU....711 Acdcrmannsdn,f. Swiu:C'lland
Copyri,hl 0 '''71 by
Tran~ Tech Puhfic;a.ions
Claus. hal. Ccrnun~ ..
Printed in CC'nnany
This book. or pari' thelenf. m.IY 110' be ,crrt'fluccd in ..n)' (om' "'idKlutll,,:
w,iucnpcrriliuion of the publidlf'. AU"i~fS lC'krved.
,.
PREFACE
It was not the authors'purpose in writing this book to create a novel
or origins I contribution to the literature. As practicing engineers, our prime
concern is with the design of reliable slurry transportation systems, and
our intention was to communicate to people seriously interested-in this
field how the design of such systems might be intelligently approached.
In a sense, this book had its beginnings in the early 1950's, when the
senior author commenced a development program which culminated in
the successful operation of the Ohio coal pipeline. A basic conviction
arose as a result of the enormous development effort that went into the
design of that system. That conviction was that the key to the design of
slurry systems which would operate reliably lay, not in the selection of
exotic materials or the design of special equipment, but in the understanding and control of the slurry environment. More specifically, it was
felt that if thellow was homogeneous, the pipeline would be stable, that is,
the pressure drop would be constant with time, and also two other results
would naturally follow. One result was that if the corrosive environment
were controlled and made benign, the wear on the pipe would he ul)iform
and of such magnitude that a pipe life of over half a century could be
expected. The second result was that in a homogeneous regime the coal
itself wculd-notundergoany attrition during its travel, even over very
long distances.
These results were proven to be true in the actual operation of that line,
as well as in subsequent mineral and coal pipelines designed by the
techniques outlined in this book.
From this and subsequent experiences, it appeared that a book which
had in mind the practicing engineer was desirable. In order to test this idea,
the contents of ihe book were presented as an extension course at the
University of California. This permitted the authors to gain experience in
dealing with a group of practicing engineers and in determining their
interests and. reactions to the various topics. These classes definitely aided
in structuring the material.
,.
The book is therefore intensely practical and for that reason the
problems in each chapter were designed to facilitate the understanding
ofthe' material and alsoro permit the readeran opportunitytoacquire
confidence in his mastery of the material.
:'
i'
Lastly, I wish to acknowledge the very fine draftsmanship of Sam Lee
who is responsible for the illustrations and to Helena Troy for her
professional skill in organizing the physical aspects of the book.
E.],WAsr
San Francisco, California
September [976
CONTENTS
..
I.
4.
1/1
211
211
5.
Preface .............
Contents .... , .......
5
6
I}
Introduction
.
1,2,.
Hydraulic Characteristics of Slurries
1.2.1. Types of Slurry Behavior ......
1.2.2. Critical Velocity ...............
1.3.
General Design Considerations ...
1.4.
Concluding Remarks ..........
1.5.
References ...............
1.6.
Nomenclature ..........
I}
1.
1.1.
2.
2.1.
Introduction ... ! ,
2.2. . Energy Loss in Pipe Flow .......
2.3.
Reynolds Number and Flow Regimes
2.4.
Friction Factors .. '. .....
2.4.1. Laminar Friction Factors ....
2.4.2. . Turbulent Friction Factors
.
2.5.Boundary Layers and Turbulence .
2.5.1. The BoundaryLayer ..........
2.5.2. Development. of Boundary Layer ..
2.5.3. Friction Velocity ............
2.5.4. The Reynolds Stresses
.
.
2.5.5. .Concept of Mixing Length
2.5.6. Velocity Defect Law............
2.5.7. Viscous Sub-Layer ..... ,
.
2.6.
References ..................
2.7.
Nomenclature ...............
2.8.
Problems
,
.
3.
3.1.
Introduction
.
3.2.
The Nature of Fluid Drag ......
3.3.
Drag Force on a Sphere
.
3.3.1. Stokes Law
'"
.
3.~.2. General Theory
.
3.4.
Generalized Drag C~efficient Curves
3.4.1. Shape Factor ...............
3.4.2. Generalized Curves ,
.
3.4.3. Fall Diameter
.
3.5.
The Effect of Turbulence on Fluid
Drag ........................
3.6.
Effect of Concentration on Drag ...
3.7.
Effect of Cylindrical Wall of Con-
3.8.
3.9.
3.10.
3.11.
tenner
II
II
12
15
16
It;
It;
17
17
17
21
23
23
THE SUSPENSION OF
PARTICLES IN TURBULIiNT
FLOW
411
50
51
51
5(,
511
59
51}
6lf
61
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
G.
(,9
33
33
33
34
6.1.
6.2,
6.3.
{,I}
3-1
-II
6.3.1.
6.3.2.
6.4.
6.4.1.
6.4.2.
6:4.3.
6.5.
6.5.1.
6.5.2.
6.6.
Introduction ..................
Criteria for Homogeneity' .......
Determination ofTransition Velocities '"
,....;
.
.
Bingham Plastic. Fluids
Power Law Fluids
.
Laminar Flow ..............
Bingham Plastic Fluids ..........
Power Law Fluids ............
Generalized Correlation
.
Turbulent Flow ..............
Bingham Plastic Fluids .........
Power Law Fluids ............
Choice of Design Procedure .....
42
42
42
6.6.2.
6.7.
6.8.
43
6.9.
24
25
2(,
2/1
21}
31
J2
J2
32
35
3(,
37
3/1
411
40
41
Ileconlme'ltded Procedure
.
References
,
.
Nomenclature
.
P':oblems ....................
PHYSiCAL PROPERTIES OF
SUSPENSIONS . ".~'.: .. , ....
61
61
62
6.1
65
66
67
67
7ll
71
71
7-1
75
75
76
77
77
77
71}
IIll
III
III
/12
112
112
,,
7.
7.1.
7.2.
7.3.
7.3.1.
7.3.2.
7.4.
7.4.1.
7.4.2.
7.4.3.
7.5.
7.6.
7.7.
7.8.
FLOW OF HETEROGENEOUS
SUSPENSIONS
. 115
Introduction
. 85
Criteria for Heterogeneity ....... 86
Determination of Deposition Velo. 118
cities ....... .'
, 89
Uniformly Sized Particles
Mixed Size Particles ............ 93
Prediction of Friction Losses
. 93
Heterogeneous Systems ofUniformly- 93
Sized Particles' ................
Heterogeneous Systems ofMulti-Sized
94
Particles "':~"""""""""
The Compound System
. 95
Concluding Remarks
. 98
. 99
References ..,
Nomenclature
. 99
Problems .................... 1110
10.
10.1.
10.2
10.3.
10.4.
10.5.
10.6.
10.6.1.
10.6.2.
10.6.3.
10.7.
10.7.1.
10.7.2.
10.7.3.
10.8.
10.9.
10.10.
CORROSION-EROSION IN
SLURRY PIPEI.INES
.
Introduction ...........
Mechanism of Corrosion
.
.
Mechanism of Abrasion
Control of Abrasion
.
Control of Corrosion
;
.
Measurement of Corrosion-Erosion
Rate
.
Laboratory Test
.
Loop Tests
.
Measurement in the Pipeline
.
Economic Considerations
.
.
Use of Corrosion Inhibitors
Use of Protective Linings
.
Mechanical Deaeration .... '"
.
References
.
Nomenclature
.
Problems
.
141
141
141
143
144
145
146
146
147
1017
1411
1411
149
149
15f)
15f)
151
8.
i
I
9.
-=;i
9.1'
9.2.
9.3.
9.3.1.
9.3.2.
9.3.3.
9.3.4.
,9.3.5.
9.4.
9.5.
9.5.1.
9.5.2.
9.6.
9.7.
9.8.
9.9.
MECHANICAL AND
OPERATIONAL ASPECTS
Introduction
.
Choice of ['umps
.
Types of Slurry Pump
.
Positive Displacement Pumps
.
Centrifugall'umps
.
.
Mars Pump
Moyno Pump .................
SpecialPumps .........
Piping and Valves
.
Slurry Processing
.
Slurry Preparation .............
Slurry Utilization
.
Instrumentation and Control
.
.
References .' ~-,
, ,
Nomenclature "
.
Problems ....................
1/3
113
113
118
118
122
123
123
123
124
1211
1211
133
138
139
140
140
11.
ILL
11.2.
J 1.2.1.
11.2.2.
11.3.
11.4.
11.5.
11.5.1.
11.5.2.
11.6.
11.7.
11.8.
11.9.
I I.l O.
153
153
15-1
155
156
1%
15};
159
159.
162
16.1
163
16.4
1601
164
.
.
172
175
165
. 223
\
(
(
(
(
1.1 INTRODUCTION
i
The cost of the transportation of fawlllaterialsdred. years .and even lhoul\h; ii is lo~at~~i;;IJIYSO ...
from the sources to th~k 1Iitirnate m~rketshas~l'. mHesfromthecoast, itwas consideredh.laq:~s~ible.......
ways been a significant clement in m~rket prices:, '., Indeed, the interveningterra(ri i~exirell1~lrrllgged~ .
Not unnaturally, those rawmat~riald~P9~it~whiclJ:
. as shown in FigureH.The lise ofaslurf)'pip~li~e;
weremost accessible \~er~ dlefirst(ob~~xploit~d'Yhile.... which srarredoperaticn .in 1970, enabled this pre
other, less amenable clep<>sitswer~'eitIJc:rreglected' " . " body to be developed.'
i: ,
"'.'
or, in certain cases, consideredt~tallyuru..orkabli', '
i;
I on economic grounds. During the past two decades,
I
we have seen the growth of a transportation mode
The Black Mesa pipeline i':1 Arizona (Figure 1-2)
which has extended the economic reach of the minis another example of the impact of pipeline transerals industry in a most spectacular manner, \VIe
I are, of course, referring to the development of the
port on the economics of a project. This 273-mile,
18-inch diameter line transports coal to a 1.5 million
slurry pipeline.
k\VI power station on the Colorado River. It has an
annual design throughput of almost six million
In a relatively shcrt period of time, 'the largetons of coal.
,) scale transportation of solids by pipeline has moved
from ih" st"ilis of being ali iiltrigliilig, blit rather
risky possibility to its present status of a viable alterBlack Mesa is one of the latest developmentsin a
native to the conventional transportation modes.
field which had its modern beginnings in the 1950 s
'Table I-I tabulates the more important slurry pipewith the 108'mile, Ill-inch diameter Consolidation
lines in operation throughout the world. The numCoal pipeline in Ohio, and the American Gilsonite
ber of large pipelines built in the past five years is,
line i,nlJtah which was 72111iles long aJl(Ijnche.sin
in,itself, tcstimonyto the "coming of age" ofslurry
diameter. Before this, while therewere a.greatmany
pipeline technology. Undoubtedly, the driving
operational slurry pipelines, the concept had never
force behind the surge ofinterest in solids pipelines
been used for solids transportationover long distan, has primarily been one of economics, which will be
ces.
Since that time, a great deal of technical and
discussed in detail in Chapter II. Economic aspects
operating knowledge has been gained which, when
form a useful background to the' slurry pipeline field
coupled with the broad experience existing for short
as a whole. A good-example of the low transport
costs attainable using ilurry pipelines is the Savage
lines and for slurry handling systems in general, has
River iron ore pipeline in Tasmania. The existence
advanced the design and construction of long disof this ore deposit has been known for over a huntance systems from an art to a maturing technology.
10
SOLID -
uojno FLOW
,'- V
!.
..
,
Aerial Crossing
Savage R'IY.er Iron. Ore P'
,~:.Ipelono,
!;
length
(mile.)
COA[ "
C()N~OUDATlDN
BLACK MESA
T~/.
.108
213
,.
1.03&
180
ALTON
IRON'CONCENTRATE
SAVAGE RIVER
WAlplPI lIRO N SANDS)
53
&
PEIlACOLORA~A
. 28
'LAS TRUCHAS
SIERRA GRANDE
11
20
SAMAII~lJ
'.
253
COPPER'cONCENTRATE
BOlJllAINVlllE
WESTIR/AN
PINTO VAllEY
11
&9
II
LIMESTONE"
RUGBY
CALAVEIIAS
. ' Commttc
.
II I Slurry
Tabl, 11 Stleettd
;"
. "'plnn",
51
11
II
1.2 HYDRAULIC
CHARACTERISTICS OF
SLURRIES
1.2.1 Types of 51 urry Bella" lor
The now of mixtures-ofsolids ar.d liquids in pipes
differs from, he now of homogeneous liquids in a
number of ways. With liquids the complete range of
velocities is possible, alld the nature of the now (i.e.,
laminar, transition, or turbulent) c~n becharacrerized from aknowledge of'lhe physical properties of
the fluid and the pipe isy~tem. Characterization of
slurry now is not as-simple as for liquid Row for two
reasons. Firstly, there are, Juperimposed or! the properties of the liquid, the properti~s of the solid partides to be accounted foriand also the effect of the
particles on the mixture properties, Secondly,a
range of slurry behavior ,is possible dependingon
the particular, conditions; this latter point being best
illustrated by consideration of the two extremes, of
slurry now which can be.identified.
.. ;OJ!
',,"
:"j
Plpell~e
i_._._._.~AI!_._
Davis Dam
Kingman
Seligman
Williams
Flags1e"
ARIZONA
Prescoll
12
,
1.2.2 Crl tical Velocity:;'
Figure 1-3 shows typical friction loss-velocity
responses for both homogeneous and heterogeneous systems. Curve A is typical of a hererogeneous slurry. At pipeline velocities where full move'
ment of the solids occurs, the pressure drop (Ap) Velocity( V)response tends towards a position parallel to the response of the carrier fluid, andthe solids
distribution would be as shown for full suspension
in the sketch in Figure, 1-3. As the mean pipeline
velocity is decreased, the maldistribution or solids
becomes more andmore pronounced until atsome
point a stationary or sliding bed appears on the bottom of the pipe, as shown for subcritical velocity in
that figure. The Ap- V respcnse reflects this as the
hook in the curve, which is characteristic of heterogeneous slurries. (It should be noted t hat we are
dealing here with horizontal flow. In vertical pipes
these solids are easily transported since the particle
fall velocities are usuallymuch lower than normal
flow velocities).
.'
"
J
,I
13
en
en
-'
2:
l:;
IX:
, ,II
u.
""o-'
:' I
I.; !
,. I
~I
",;.
--
i; 'j
,~ ..'1
VT
VD - Typical deposition critical velo~ity.
VT - Typical viscous transition critical velocity
LOG VelOCITY
: ..
j,; .
DEPOSITION CONTROLLED
SLURRY
,'.
t' ,
FULL SUSPENSION
.,
i
FULL MOVEMENT
FULL TURBULENCE'
:: it
"I'
r ! 1:
"
SUBCRITICAL VElOCITY
1:........:....... .....::,.:.
...... ,...... .,'.."/:
.... . .1 L
.. ~
0"
: :
o : "
:..
1: ..;.. :.:
.. . ,.J1
:.:.;.. :
14
I.
Process Considerations
A. Hydraulics
o~
4. Determination
friction losses as a
function of diameter and velocity
E. Automation Control
I. Degree of automation,
P.O. pumps)
A. Investment
B. Operating Costs
Stability
E. Particle Degradation
A.
B.
C.
D.
!
Table 1-2: Outline of slurry 'pipeline design requirements
IS
~~~.
..r1~-{~"f.~it(
PREPARATION PLANT
1111
WATER. SUPPLY
,",
111111111
.;~t~~'.i'l,~~~
STOCK PILE
MINE
.'.
COAL CLEANING .
TANKAGE
~@----
,~.
"'~la.lll}i----\1JI~~-----S+-"""
;,
I PIPELINE SYSTEM>\<
. . -. .
"
~_
~
.
DEWATERING
I
I
,
<,
COAL
~t
r
I
I
. '~~
, . U
~:l~r.
....:n~*.
~~ I 'ri~~~l~
!
,- ...-......
.. '
PLANT
COAL BUYER
I'
!'
i.
r
, POWER PLANT
i;
!'
, BARGES
"
'I' ( ' ;
I: ,, ~:
I ,-,
II I
I . ,
II:
I. : ol..
~
II
'I
"I
II'
"
-'
;
FLOW IN PIPES
i
I
2.1 INTRODUCTION
,'..
-e-
,
.: . !
..
.; \......" I
/.....
,.~ ~~.
....
0",. Ii
'--::".,
I!
.>.
2.2
! .
'0
"-"
',
"
.; !
0"
Where:
"
D is the inside diameter ~f pipe
P. and 1', are pressures at sections I' and
respectively, as shown in r.igure 2-1
L is the distancebetweenyeclions I and 2.
, :1
19
where:
p is the density of fluid
u is the average velocity of flow
v is the dynamic viscosity
Jl is the absolute viscosity
D is the pipe diameter.
For pipes:
D - D (the diameter)
hup
-p-
_ 700
',-)
There have been a number of attempts to establish a stability parameter which is more general than
the Reynolds Number, i.e., one which would be independent of such things as change in flow configuration. LOHRENZ and KURATAm, attempted
to define an equivalent diameter which, when used
in conventional definitions of Reand of friction
factor, would permit laminar flow data for pipes,
parallel plates, and concentric annuli to be represented by a unique relationship. This method, which
treats pipes and parallel plates as two limiting cases
of annular flow, results in the use of the following
length scales (D in Eq, 2.2):
D- h
(f.ij
112
J ': .'
(;1
For annuli:
Ii:, ;1
~'"
('
;
D - 2 rO
+:ir,''
r,'"
Other formulations of a ,g~neral!zed stability parameter, such as thatdue to H,AN~S,u)concern themselves with a more fundamental approach..From an
engineering standpoint, it:'is more important to
recognize that a transitionexists than to logically.
quantify it; as long as consistency is maintained,
Reynolds Number
can be. defined
in a number of
. .. '.
I '
ways.
;""
~'
1:':1
'!
Turbulent
Slope 1.75 "
log
Tw
log u
Figur.23 Friction Loss "','lnus Velocity for Pipe Flow
r :
i'
. ,i;
i
'I l
I
t :
I,
I,:
2.4 FIUCTION FACTORS
.
'
/laminar
Lag'
I
I
Turbulenl
I ----/
I
I
I
~~I
(Eq. 2.3)
23001
--..J.
r
..
TranSItion
I
I
12800
LagRo
Figur. 24 V~rl.tJon In Friction Factor with
Rn-oolds NUmb'" for Smooth Pipe.
.i
.( _ .6.pD!l~~
(Eq.24)
.
pU
2
The numerator is representative offriction loss: the
denominator can be seen to be representative of'the
inertial forces, so th~tjis the ratio offrictioual forces
i'.:;
to inertial forces;
ii
!::
2.4.1
(E'I' 2.5)
. (Eq.2.6)
l
\
111us. we see that Equation 2.5 is simply the definition of viscosity, i.e.,
21
v.
Shear Stress
Rate of Shearing Strain
(Eq.2.8)
While the form of Equation 25 is specific for ITow
between parallel plates, Equation 2.8 is general and
applies irrespective of the ITow geometry. For laminar flow in pipes, it is possible to derive the following relationship between friction loss and mean
velocity of ITow:
Ap
32pU
L--
(Eq.2.9)
D1
Equation 2.9 which is, ofcourse, the familiar HagenPoiseuille formula,can be re~rranged in the form
~D
4L
f"
p- -8U
- - -8U
-
[) 0
(Eq.2.10)
"iI
II
,
I
fw
(Eq.2.3)
pU I
2
.1
r-~-Ji.
DUp
Re'
(Eq.2.11)
Thirdly, the friction loss in turbulent flow is sensitive to the roughness of the pipe, whereas this is not'
the case in laminar flow, The effect ofroughness has
been found to be of'the same type in a homogeneous
slurry ITow as in the carrier fluid.
,: .,!
..
In turbulent pipe 1T0wihe friction (actor isdefined on exactly the same basis as for laminarflow,
i.e., according to EquatiOl)'2.3. This form; which is
derived from din,ensioriahonsiderations; was first
employed by DARCY (or ITow in pipes. More
recently, STANTON and PANNELL (1914) and
BLASIUS (1913) endeavored to examinethe variation in "DMCY'S coefficient" with change in Reynolds Number. III both of these cases the experiments were conducted in smooth pipes. Blasius
found that for values ofReynolds Numbers 'up to
80,000, the friction (actor was represented by the
following equation:
.
f-
0.079
(Re)O.IS
(Eq. 2.12)
22
These experiments in which roughnesses were produced by glueing sand (0.1 to 1.6 mm in diameter)
to the pipe walls established that the friction factor
was also a function ofthe "relative roughness" of the
pipe, r.e.
u Mean
I-~=--
I
I'
u-Max.
(E'I. 2.14)
f - function(Re, c/D)
,:i TURBULENT
.. LAMINAR
COLEBROOK (1939) has proposed the following empirical equation for the commercially available pipelines:
:U.
1,
1
I
;<;j
I
D
_I _ 4 log 2 + 3.48 - 4 log
Vf
0.0553
R
(Eq.2.13)
eo.2Jl
The fact that the roughness of the pipe wall affected
the value of the ftiction factor waslirst established
by DARCY. Following thi,s~ the investigation of
rough pipe flow proceeded with considerable difficulty until the work of NIKURADSE in 1933.
Th~ (oUowjng'iott~ri;llInic form of N:IKURADSE's cqu~fion is more
f-0.0008 +
D
)
2e Re Vf
(Eq.2.15)
Equation 2.15 has been widely used, and it is the
basis of modern friction factor charts.
It has been found that at high Reynolds Numbers
the value of friction-factor becomes independent of
the Reynolds Number. For this region the last term
Vi
0.025
0.0225
"
'\;-LIMIT OF TRANSITION
0.020
I 0.05
"~'':"...-,----------------11
4.-:-
0.0175
0.015
0.014
0.013
0.012
0.011
0.010
II:
0 .. 0 1009
t;
-e 0.008'
u.
0.007
z 0;0065
0
;:: 0.008
0
0.0055
u. 0.005
0.0045
...,
0 04
~\,
,0.03
--...:,.,.------------,-----II.Q2
",
~---.::..,....-----------------'-___!.
0.015
:~~::=~=============~!
i
"
'"
a:
1 + 9.35
"
0.008
0.006
0.01
"
~----.::...:__.:-..--------------1,
O.lX",
"
\.
"
...
,;:,
l!
'.
~---::,.,----'--'----.:...--.---J 0.007
~~@~~~=!
-,
I
.0.004
c.
. 0.0035
TRANSITION REGION
0.003
0.0025
0.00225
0.002
234568
10'
3 .. 56
10'
REYNOLDS NUMBER.(
10 6
56 I
107
0O:b'~ 6
OUP)
At!.---;;-
Flgur.27 PIJM Friction F.etan 'or Turbulent Flow (Modified .ftft' Moody, t..F . runs. ASME. Vol. 66. P 611. 19441
'00,
6
II:
0.0008
0.001
0,0006
.J
w
,0.0004
II:
~.j:::
3 456
0.0000'
10"
on right hand side of Equation 2.15 becomes insignificant and the value of friction factor is obtained'
by dropping this term from EqJation 2.15.The
value of the Reynolds Number beyond which the
friction factor is independent of Reynolds Numbcr
is given by:
Re (critical) - 70
r~
(Eq. 2.16)
2J
"
., i
0.1
0.2
0.4 O.S'
..
IS
10
2025
0.05
0.04
O.OJ
0.02
0.01
0.008
0.006
0....
0.003
"'1
l:l 0002
.
w
;:,
!:
. ~
O.OC)1
0.0008
0.0006
,0.00040.0003
0.0002
o.ooot
0.000.08
0.000.08
0.000,04
0.000,03
0.000.02
o.ooo.Ot
..
0.000.008
0.000.001
\ -,
3 "
10
- ~:
:.;:
20 30 40 10
.,
....
~
'
'
100-200 300
: '.
24
. i
,
I
i
i
gradient
i
I
u .u
LAMINAR
BOUNOARY LAYER
: ;.
t,
i,
u U
I
I
,I
/liL
;
;
I
I
1....-;..
.>:
.-------.,
"7
u(x.v)
I
I_x
., .
TURBULENT
/TRANS'1
BOUNDARY LAYER
nON J
t-:P
:' I 1-;-
t-
FREE
STREAM flOI'!
,
'. ,
~i tends to
I
I
(1
I liT
II
I
u' U
..... ....
'(.
---Boundary laver
Thickness
'/
"7
/
./
.,
....
2.5.2 DeveIopmencofBoundary Layer
Consider the example ofa plate located in an IInbounded fluid and oriented parallel to the direction
of mean flow (Figure 2-9); t .
Since the fluid is unbounded, as it approaches the
plate it is completely free ofvelocity gradients. Over
the forward part of the plate, the flow in the boundary
layer is laminar; that is, it is: smooth and it proceeds
iustrealt\(inesapproximately parallel to the plate.
At a certain point, a rapid transition to turbulent
flow takes place. We have discussed in Section 2.2
the differences between laminar and turbulent flow
as they affect such things as friction loss. However,
the primarydifference between the two flows is that
whereas laminar flow is streamline, in turbulent
flo\v.thereis ageneral mean motion parallel to the
surface, butsuperimposed on this are rapid fluctuaticnswhich are random in magnitude and direction.
This wiH be discussed in more detail later in the
chapter." . . . . .
.
".,
. '
T - "
r: dy
at y - 0
(E".2.17)
T" return to pipe flow, we can see that the boundaryhyer will grow in all directions with distance
fro:: the entrance of the pipe. Figure 2-10 shows
rO\li,hly how a boundary layer (in this case a laminar
boundary layer) grows or "develops" in a pipe of
constant cross-section. The flow entering the pipe
exhibits no velocity arndient since it is unbounded.
In the initial part of the pipe the boundary layer
develops. This entry flow region is characterized by
r
r,
1
,
--- --- --
--+---'1--- --,
.---
.......
--
--~-f---f
--- ---
----
,
c]
!
I'
I
...
;:1'1
iI
,I'
!
Le - 0.028 0 Re
(Eq.2.18)
Forturbulent flow the entrance length is independent of the Reynolds Number and is approximately
equal to SO pipe diameters, The area of most
interest to pipeline designers is the behavior offullydeveloped turbulent pipe now; consequently, the
remainder of this chapter will be devoted to a brief
review of certain aspects of turbulent flow.
\rr.::p
(Eq.2.20)
.........
was the startlng.point. In analyzing Equation 2.20,
I'RANDTL found it particularly difficult to see any
connection between shear stress at the pipe wa II and
the pipe: radius R. Simply stated, his problem was
how to eliminate R from the equation.
i
By introducing the cl>ncept of friction velocity
and employing a velocity' ratio
U* and a relative
U. -
10
obtain
(Eq. HI)
(Eq.2.19)
,
The concept of a friction velocity emerged from
early work 01\ turbulent flow conducted by
PRANDTL PRANDTL, and others, were convin-
From the definition of friction factor and the definition of friction velocity (Equation 2.19), one can
obtain the following relationship between the friction velocity, friction factor, and the mean velocity
of flow:
.
26
(E'I. 222)
I
I
I
Y
I/
-- -.u 0+ u'
.--"-.-
J I--~x--;:/
/
'
.v._x 't'/
//
t.('.\.(
u-
~t'.t
U + u'
"._
(Eq. 223)
J.
t'" ..
Instantaneous Velocity
>....
'U
..J
>
,,
1 \....:.:...::.
rII. ', I':(:\~.".:.
TIME hI
Flgu,. 211 Contlnuou. Record of tM INt,ntanlOu, V'loclty ,t a Point In a Steady Turbul...t Flow
V + v' -v'
(Eq. 2.24)
\V -
(Eq.2.25)
stresses.
:i ;.
;: (0.10 U)
(~}O U) -
0.01
pD' ,
(pv'oxoz) v',
(pv'(Jxoz) (U+ u')
'.~.
""
and
The mean stresses on the face are found by dividing the forces by the area and takin the average.
This results in a normal stress of pv' ,a tangential
stress in the X-direction of PII'f,', and a stress in the
Z-direction of pv'iiT.
:J
'. r. .
...
(pv'oxoz) w'
and
..
\ :i
..
...
DU
28
,.
,
I:
it is certain that as measurement techniques continue to improve. the structure of turbulent suspension '/Iow will become known. not only through
velocity covariances, but also' through velocityconcentration covariances, A great deal of fundamental work is required in this area.
du
u(y-I) - u-I .-
dy
(Eq.2.26)
and
du
u(y+l) - u+1 ..-
dy
(Eq. 2.27)
II
--:-;-;
du du
r - -pu
v - constant X I' I'. (_._)
-dy
dy
If we include the constant and I' in the same constant /" we can write
-pll du dul
dy.dy
(Eq. 2.28)
where /. is proportional to the mixing length. COlliparing Equation 2.28 with Newton's Law, Equation
2.8, we can see that the termpll/ji!is equivnleut to
Tt--'------I
_/ du
i1Y
I
". v
(Eq. 2.29)
1t...=::::::::::-----..,.-~_
(E +1') du
dy
I, -xy
(Eq.2.30)
\I
I.)
( )
, . du
r - p(Kj'J -t1y
r
II
29
0.16
"
'~
>,/
1, 0 08
-Af/
'
I;;
u'
du
dy - xy
...
~-
/"
II
- 126
0"'-60 f t. _ 30.6
:1 "
I
smfJOlh
- 501
---- f.
.. . - 252
._.
i
o
-~-
0.2
0.8
0.6
\.0
u
I
Y
---10"
'
u"
K
Yo
Figur. 2 15
(Eq. 2.31)
C'C
0.16
I
Y
0.08
lL
r
0.02
-1-
0.\4
TlIUS,
.,....-- ...--c
0.12
':-II
0.10 - 1 -
0.06
--
0.04
~I:
o
--. ,,~
'/
X, ~
~h V
-".--
0.\
0.2
0.3
? :::::: ::.---
,/:'
0.5
"
oR -4.10)
o R-23.3.10' f----
,- -
0.4,
If _.
,--
R'= {OS.10 3.
0.6
0.1
0.8
0.9
1.0
1.
Ttt- MIII'I", brtQthCur". 'or If)w n.y""ldl .Numh....
This dimensionless equation states that fora 'conthe turbulent flow pattern' will be
stant value of
identica I for any pipe diameter, roughness,etc.
II"
,I
,; \
or
du
II
~~
- ( I-
~-
f( ~) (Eq. 2.32)
311
"
'j
16
;.
,
15
rn,
14
13
r--
12
--
r
Unl.:l X -u
- -- log" ('-)
I(
"y
:'u*
(Eq.2.33)
II
-u
"::
,
ff
-O.lmm
-0.2tn'"
e 0.4",m I-- ~. a.8mm
-' 1- - - - - - c--.
-
.ftl
7
I
"r
loge - )
,,.....
(Eq.2.34)
V
l-
/'
,........,
0.1
-u
,',
1.0
14t
,-
_...
:\
U max
-0
"mIll:'"
I
;
.'
5.7~
of
10
Thus, the defect from the maximum velocity is related logarithmically to the distance from the wall.
Thus we have arrived at.albeit.incorrectly, the velocity-defect or outer Iogurithmic law of velocity
profile.x is of course the' von Karman constant
(- 0.4), and by changing froriJ narural logarithmics
to base 10 gives
'l '
U m 3X
(Eq.2.35)
~
~
~
/
~
~
.:~
",'/'
:>;.
<~
;'.:;
Figur. 217
><
V~'ocitv Curves for Contt.nt Disch.r,e .nd
V.rying Roughness: IHlghly Rough;
fl Mildly Rough; 111Smooth.IAfter Fritsch.
In ,Abh.i1dlunven .us dem Aerodynemlschen .
layer the turbulent tluctuations ofvelocity in absolute-tenus become small (the IO(;;llturbttlcnce inten-
.11
(Eq.2.36)
sity
,
~ remains large h1->wever): Consequently, the
\1.
j!
<5 -
(Eci. 2.38)
U'
jO
I, .
A knowlegde of the yiscom sub-layer is'of importance for a number of reasons; As canbeseen from
Equation 2.38: flow ~e1ocitydecreases (i.e., as II'
decreases), the sub-layer thickness .i increases, In
fact, in laminar 110w <5 I~ so large as to completely submerge any roughness elements of the size normally
encountered in pipe 110w., This explains why roughness has no elfect 011 laminar friction r.,ctors; it also
suggests that the size of the sub-layer relative to the
roughness elements is ofma;of importance with
regard 10 turbulence generation.
u
u'y
- . - 5.75 log (_ .._)
u
\'
+ 5.5
(Eq, 2.37)
t.
.:_.".
50
40
30
20
"':
'0'
<t::
~.:
10
~:
....
'tI:-:--
-I-I-
~1~ ~O~~
_.'
.c
iIo
"~'~j.rIOlt1 "
1\l1\~::"", -
L- l-.,
.. .'
,
I--
'rrif!
Niku,adse ExpetimenlS
liTllIII
1.1 I
. I
10
100
1,000
10.000
100,000
,,
'.
3l
I,
I-I
I
r
u
u'
(1960~
Roy~1
.'
2-7
2-8
2~9
I
I
',.,
2.7 NOMENCLATURE
. ,
D
E
L
:t~'!
""'j'
,
Pipe diameter
Eddy viscosity
Length .
L. Entrance length
P Pressure
R Pipe radius
Re Reynolds Number
U Mean velocity of flow
U Mean velocity of flow in X direction
U Friction velocity
V Mean velocity of (lowin Y direction
W Mean velocity of flow iii Z direction
du
Velociiy gradient
dy
f Friction factor
,-,
v
v'
w
w'
c5
Pipe roughness
.Ill' Friction loss
p Absolute viscosity,
v Kinematic viscosity
p Density
.
r
Shear stress
Cw
Wan shear stress
t:
2.8 PROBLEMS
2.1 AI 7.5 ineh (445 nun) inside diameter steel pipe
carries 4200 gpm (954 m)/hr) water at 68 0 F
(20 0 C). Determine Reynolds Number, friction factor, and friction loss per unit length of
pipe. Determine power required to pump
water over a distance of 100 miles (160 km) if
the static lift is 305 ft (J00 m) and the pump
efficiency is 70 percent.
2.2 Assuming that laminar-flow conditions existed
for the flow situation in Problem 2.1, determine
the friction losses.
2.3 If in Problem 2.1 thi fluid is other than water,
with a viscosity of 0.0135 Ibllt s (0.02 kg/iu-s)
and density of 73.5 Ib/n-'( II 80 kg/nr'), determine the friction losses. friction velocity. and
thickness of laminar sublayer.
2.4 Based on von Karman's similarity hypothesis,
prove that the velocity distribution iu rurbulenr
I
flow of circular pipe is given by the following:
U~:u
__
[In ( 1 -
(f:yii'~) + Yl-y7r~ ]
I:'
'/""1\1
"::~'
I
I
!
;)
N1
, i
. ~ .i
3.1 INTRODUCTION
So Ii", we have considered flow situations which
are essentially unidirccrionnl, with the fluid flowing ~
along a pipe or channel, In the present chapter.we
shall concern ourselves with the forces .cdng upon
body submerged in a flowing flnid. This, of
course, introduces the more complex problem of
three-dimensional flow, since in general the fluid
will be directed .11 around the ,body.
The reader will, no doubt, realize that a knowledge of the behavior ofa particlein a fluid is crucial
to the design of hydraulic transport systems in
which particle inertial effects are significant, i.e., for
heterogeneous systems. As with most aspects of
fluid dynamics, this subject does not lend itself
readily to theoretical analysis, and the advances in
knowledge to date have been based almost entirely
on empirical evidence. This chapter. is intended to
summarize the methods ofestimating settling velocity of solid particles.
i
!
,I
.;(~
.:
I
I
FLUID DRAG
In any discussion of the nature of the resistive, or'
drag, force experienced by a body .moving relative
to a fluid, one must inevitably arrive at the consideration of the behavior of the boundary layer formed
ncar the surface of the body. It has already been
shown in Chapter 2 that when a viscous fluid flows
over a surface, the velocity ofa layer off1uid close to
the surface is retarded relative to the mean velocity
of flow. This boundary layer increases in thickness
;)
.:
,
.
the formation of a separation eddy. (f separation
does occur, it will take place further from the leading
edgev the resulting eddies will be smaller, and the
total drag will he reduced from the laminar value.
As we will see later in this chapter. the occurrence of
this transition is usually 'V~II outside the range of
conditions experienced ii(slurry
pipeline systems.
,,
j::.'
,.
I' -
F/4rrr'
3w/d'
(EII.l2)
. 1'
24
pw)
F - 6 rrprw - ""(d"",~"p":"I'-p"") A . (~-2-)
(Eq. 3.3)
where' A is the projected area of the sphere, i.e.
Trd)/4. In Equation 3.3,the fluid density,p, is-used as
a dummy variable, which is particularly convenient
since in the flow region concerned. Fis independent
ofp.lfwe now define drag coefficient in the normal
way, i.e.,
F/A
Co -
'(Eq. 3.1)
where:
F is the drag force
I' is the /luid viscosity
.
r is tlie radius of the sphere
w is the relative velocity between fluid and particle.
..
.!
I
i
F
pAWl
(Eq. 3.4)
F-6rrprw
pW'12
From Equation 3.3 we can see that the drag coefficient is given by
C _ 24
o
Re
(Eq, 3.5)
i,
I
I.
I
:
I
. i~
"I.
II
~1()nON
3\
(~q.
(Eq. 3.7)
For the case of spheres settling under gravity, we
have .-~
100,000
I..10,000
a
!:!
...
'"G
--- :-,- -- -
-I-
-- ---
-- - - _It
1,000
10-9.
100
I-
10
1.0
-.
ex:
a
-- -I- I-
Cl
.-
i-
u.
u.
w
~.
--
--
I-
1-
i-
_.
- -
~-
.. - I- A -
l-
--
I';'
Co versUs
I-
- -.
I-
0.001
0.01
0.1
1.0
10
100
1.000
I-
0.1
0.0001
3.6)
J1
_ 4g (P':f)U
"
(Eq.3.12)
3pw,-
t'
g (p,-p)
ili-
,. :
(Eq.3.8)
Psl,l
Ii
I::
d/ -
. '
Dividing by Re gives
Cn
-Re
4g (P,-P)fl
- 3p'w,'
"--.,--
(Eq.3.1J)
(Eq. 3.14)
becomes
.[ ,4g (pi'"P)d
w, - -'--'-3C nP
(Eq.3.9)
where Co - fIRe)
As we have seen 'in Equation 3.5. the drag coefficient in the Stokes Law regime bears a simple relationship 10 'the particle Reynolds Number, viz, CD 24/Re. Thus, by substitution into Equation 3.9, the
terminal fall velocity can be obtained as
,
,r:
g (P,_p)d 2
18 .
for Re
fl, '
In the Newtons Law regime, CD is a constant independentofRe and is equal to 0.4. Therefore, in this
region. the terminal fall velocity is given by
for 1000
-I
(Eq. 3.11)
Provided that
til,
fd..11
I 'atron
f C0 o
ve 1ocrty
-Rf irom I"-:'Q\l;I[IOn
l it OW$ caIcu
.
e
3.13, hence of Re from the graph, hence Cn. From a
knowledge of particle diameter, Cn Re 2 can be calculated from Equation 3.14, hence Re from the
graph, hence CD'
<I
(Eq. 3.10)
w,
3.4GEN.ERALlZED DRAG
COEFFICIENT CURVES
'fhe preceding section of this chapter has asceri tained that for spherical particles. the evaluation of
drag coefficients is relatively straight forward. requir.ingonly :I. knowledge. of the terminal filII velocity
of the sphere. However, the foregoing analysis is. ill
itself, of liule lise to the design engineer Si'KC uni-
3 10
10
..
COlA! =
4
3
10
1
10.
~~
"1-
~'
l - i-
--
..
1/
-- I-... ....
-1"<7-,
.1-
l-
......
..
- _.
e:
".
l7"
__
..
ro-
b"'"
.
1
,
<,
~:.9,
....:
-. - ..- -- -- -I',
'
'
1-
10
./
1--
r: .
'
<;;;
10
---
--
./
'V">
./
<
...
"',1
<,
I-~
4 9 11',-1') /.l
JI"W 3
r--.~, I,
4.
10"
.17
....
6 ,8
, 4
.....
' "1
..
~;'i..'
~:~
.i
n. for
or
Sphe,..
ingequarion:
.
".~
F - K (6 ll/lrw)
(Eq, 3.15)
S.P. -
.=
yau
(Eq. 3.16)
i':
r
'ii' :
pea red to provide a satisfactory representation of particle shape, at least for the degree of refinement that
currently exists on this subject as a whole. This form
of shape t~ctor had been employed previously by
numerous workers, including McNOWN eta!' The
shape factor defined inEquation 3.16 is roughly
equivalent to sphericity-and, as tirst used, the axis c
was always taken as thataxis parallel to the direction
of motion. In the Stokes' regimethis can be important since at low Reynolds Numbers any'orientation
,is stable and shape factors in excess of unity can be
obtained. However, outside the Stokes Law regime
particles will fall so as to present the maximum
projected area as norrnalto the llow. Consequently,
c will always be the shortest of the three axes and
values of S.F. will be less than unity.
;.:"
, 'I,.,
I
I
II, ',
II
i'
:
, ,
I
.1M
"
(Eq. 3.17)
where tin is the diameter of a sphere having the same
volume as that of the particle itself Albertson's
studies showed that the shape factor deli ned by
Equation 3.16 was able (0 adequately characterize
both naturally-worn gravel and also crushed gravel,
However, he did find that the lines or constant
shape factor for the naturally-worn particles and the
crushed particles did not coincide. which is a point
to which we will return in the following section.
...:;
.8
'
....
-""
1//
..: .5
It-/
.:
//
2
/ ' ':! .
IU
.,- ,
::I! 1.0
"
:3
C>
>
/( ..
~'
,':
Natural Pallic!es
,,)!, ~
,
I
6
~7'
~-
"
1/
./~ I , I-
---
'-
I,
~~ 1- -. --- -
9-
"~ "
-~~<t>
.
~'I;'
.//c,~~
0.1
N.tufal Panicles
6
I
.1
_iL
.!:!
/j-"r"
.2
.3 .4
'0,
:1
".
.5
.6
.,~
Ii
/ ./'
...
~ .2 .1
...
/,
...
1.../
e-:
~
'
'<;'/.
-'"/--c,'V'
~V
t; .3 .
~~;71
.!:!
30
,,-,'
, I /
~.6
<,4
10
.7
a:
b (eml
.1
.8
.9
,
I.OU
.1
6 61.0
6 6 10
b,e lem)3
A':tI~nci b
30
JQ
')
I
10.0
ji
:1
. ~
1.0
,"
s'
.,
'
.....'..... '!
.. - .-'
- ._--- _. +-~-
-~ 1-'-'-
1--
9. ~f'
::::.::l!.Jl"
'j
--
-_.. -
--
'
.- ---
-r-\lTI-
I:::-r-.
- -~ ~
'<; r--,r-.
.-
I!
I,
--11-'--
-I---j
1- -,
.-.-
O. I
8 10
10'
JR.
'\0' . ,te" .
to'
Figure 3-5 0"9 CoeWclent 'IS. Revnolds:Numbet' for DiU.rent Shape Factors
f.f.e, Albertson. R'f. 3)
40
10
Il
~"
""S !'
s;.
c::;
u:
C>
a::
l"il
I~
or
.:I
10
.J
~~
~~ r-,
S H RES
~.,
~ l::l
1\
-,
1.0
-<!'\)<:1
,,'
Y"" .
I'-<.....
'K
I .
'!?
......
~. , r-.
~'
'
i;
S,F.0.3
/
)\i
'\
,..
.
..
I.P/iERdo\
,
1\
1",-
r-kt
fi>G
.\
..10.0
1/
1.000 '
.
1/
--
I:
'.
1- h
''\ 17
I?\
-7 -Il"
1\
1\
40.0
I\.,v 1\
In'
1/
~0;7
1-"
1--,.'
1\,
'
1\
1\
...
Il
',- I.-
1\
I-
",.
10,000
'9
"\\)
'Il
-- 1'71/
1'\ / 1\
\
1/
!\
\)
I}\
~k
~r--......I
.
\,000
,;8 ;
-\ 1/
'''I ~
/
,t;f!
...
,...:.~
t--.
~
, " 'to'
, , ....-1 C
~~'
~O
1/
f-- t;,
I----
~~~
,.
;-
\Il
':rr-
1\
--;
~ (~S.F:0.7
~
11 CR'
.) v
.,
lr 0
1\
~ r-, f\
1-'
Z
w
Il
-\
'\
'"
....
lOa
\Il"
i\l' ~ k../
1/
''<;
'\
~ t\. S( 1/
o
~.".
1.0
-=
1\
-s
10.000 '
0.1
40
(Eq, J.18)
,, .
"
'.
"
and :-
(Eq.3.J9)
r-- -l-.....-j.....-jl-
,
"
<:1
""'(":.;'1
'1""
'---I---/--I-
-I-=t=t=ttl
0.05+J~1=::j::=f=j=t:1==!==f=jH::l,
6
0.05 0.1
G'
1.0
FALL DIAMETER [mml
10.0
. i!
','
,I
'~
11
t.
II
Ii
r.
[
3.6 EHECl' OF
CONCENTRATION ON DRAG
The discussion so far was .applicable to single
particles settling in 'infinite fiuids. '\Vhell there are
a number of particles dispersed in a fluid, the fall
velocity of the particles-will .differ from that of a
single, particle, due to mutual interference. When a
group of randomly oriented particles settle' in a
fluid, the velocity of the cluster is found to be larger
than that of individual, particles'". This phenomenon is different from agglomeration since in
cluster the particles arenotin con~act, as the groups
are stabilized only by the fluid dynamics of the
system. As,the suspension concentration' increases,
particle .acceleration due to cluster formation becomes less marked as the increased drag from the
return Ilowing fluid begins to slow them down. At
still hlgherconcennntion solids seule as amass \vith
an interface between solid phase and the fluid.This
type of settling behavior is defined as: hindered
~tli~
.
'
se'Ulingre~ime,
In the hindered
the settling veltcitydecreases with.an.iocrease in solidsconcentration. For particles settling in Stokes Law region,the
effect of concentration is given by' the following
equation: 'lI,
'
-"I
'0
w
, _'__
e4.5
W OI
41
where:
w, - hindered settling velocity
wo, - settling velocity of single particle in infinite"
fluid
e - the volume fraction of voids.
In a suspension made up of a mixture of different size particles, the coarse' particles sell Ie in a
matrix or smaller particles. For" binary mixture.
DAVIES and KAYE'" have shown that the mixture
settles: \vith;.llIt segreg.uion when the distance between larger particles issuch as to trap the smaller
size particles. Thus. particle segregation would occur
up to a critical concentration beyond which the
smaller particles will remain trapped between larger
particles.
When coarse particles are suspended in a suspension of very fine particles; the settling velocity of
the coarse solids isappreciably reduced; The suspension of fine particles may exhibit non-Newtonian
properties. DuPLESSIS and i}NSLEyf,", have investigated seuling of particles in a daysuspensionexhibiting Bingham plastic behavior. They haveshown
that the-settling velocity of the particle decreases
the yield stress of theiclay suspension increases.
"5
-,.~
":
-"
:"
diameter (DJ
,.,
tooc -
0; "
,
D-
~L.
th~ ratio of rail. velocity of a
WID
(Eq.3.21)
(Eq.3.20)
!'
IiI I
I
'I'
1, ' '
,
"
42
I;
Here
I,
,it
rl'
W,
Will
,
- settling velocity in intinite.tluid
- settling velocity in a container ofdiameter 0
- diameter of the particle.
3.9 REl'ERENCES
3-1
,'
.1-2
I'
J-J
",
3.8 RECOMMENDED
PROCEDURE
,
.:'1'
. ~ :
,,
.'
.
Establish. theter~~ilJar settling velocity for the
parti~l~s',pfinte~estbymeans ,of experiment.
Since mosts'lurries contain particles of a fairly
wide granulometry, this will involve the separation of the solids into their respective sieve sizes. '
and the evaluationof the settling velocity for
several different sizes at the coarse end of the
size distribution.
'
~l"tllill('
J-4
J-S
3-6
J-7'
II:
"
.;
A~c.ni..
It has been the intention of this chapter to present a method of calculation of drag coeflicients for
the type of particle generally encountered in slurry
pipeline work. The drag coefficient so obtained may
be modified when used in pipeline flow due to, for
example, hindered settlillg effects. but in itself it
remains the most useful parameter for particle
characterization.
J-9
En"n...
ru.
3.10 NOMENCLATURE
A
Co
c,
C,
f-
Re
i CoRe
Cylinder diameter
Drag force
dw
Reynolds Number - -_P,
Il
w
w,
W OI
w'"
J.l
p
P.
!
3.1 Determine the settling velocity of. spherical
part ide having a density of 165.4 Ib,,/Ii' (2,650
kg/m") in water at 68' F(20' C) if the particle
diameter is 0.0197" (0.5 nun),
3.2 A naturally 1V0rn sediment particle has a nominal diameter of 0.00082 ft (250 microns), a
density of 1871b mlft l (3000 kg/m-'J,.nd a shape
factor of 0.7. Wh.t is its f.lI velocity in water at
68' F (20' q?'
"
r
/,
!
I
! .
"
-,
3.11 PROBLEMS
:
4. PHYSICAL PROPERTIES OF
~
SUSPENSIONS
4.1 INTRODUCTION
The design of. slurry pipeline is ultimately dependent upon how well the physicai properties of
the slurry can be evaluated, In some cases of commercial interest, for example fine limestone slurries,
it is possible to consider the slurry as a continuous
medium and to base the pipeline design upon the
average properties of this "fluid".' However, as later
chapters will show, this is not always so and for
other types of slurries consideration must be given
also to the properties of the individual slurry components.
In this chapter we discuss the more important
properties of suspensions, how they are measured,
and their significance in pipeline design.
'
4.2 DENSITY
There are three density terms involved in the
specification of'any suspension; namely.the density
of the panicles, the density of the suspending medium, and thede'lsity of the' suspension itself.
;' ;
-;) I
i
c..
(Eq.4.1
where
is the concentration of solids in percent
by weight. It is often convenient to express solids
concentrations in terms. of weight percent, particularly where one is dealing with pipeline capacities in
tonnage throughput. However, the mechanics of
46
pipeline !low are more directly related to the \'01ume of solids present, and the reader will see reference made later in the text to volume percent,
and volume fraction. <P, where <P - C,1I00.
c.:,
. "",
100 Cw/p,
C;
100-Cw
P,
CwPm
P,
+--"-'---""'PI'
(Eq, 4.2)
i.Cw
,l',::
.Cp
v
!I!
c, + (100",<:..)
.c, P,
--Pm
(Eq. 4.1)
(Eq.4.3)
4.3 VISCOSITY
An important effect of theaddition of solid particles toa fluid is its influence on the system viscosity. The presence of the particles invariably increases the suspension' viscosity to a value greater than
that of the fluid itself, and in many cases results in a
suspension which is non-Newtonian in character.
:
..
~
fi~ld
,,,i~~osi'ty
The
of suspension
has been one
upon which a certain amountof.controversy has
centered. This is'i1a~dly~surprisingwhen one examines the rather complex nature of suspensions.
Indeed, the conceptof a suspension viscosity is in
itself quite difficult. Admittedly, this is perhaps not
the case when one visually compares avery concentrated slurrywith the pure carrlerIluid.ns one nlight
compare a heavy oil with water. However, the mat, ter does not appear so simple in the case of a very
dilute suspension of large particles.
From an engineering standpoint, it is perhaps
better to visualize a suspension viscosity, not as a
"thickening" of the mixture vis-a-vis the carrier
tluid, but as defined in Equation 2.8, as a laminar
flow parameter which directlyrelates velocity grddient to shear stress. So while it is difficultto imagine a small number of large particles making a fluid
"thicker", it is easy to accept that 'these particles may
have an effect on the velo1:itydistribution in a laminar flow, and therefore on the viscosity.
Equation 4.4 applies to laminar flow of suspensions of rigid spheres in which the particles are large
compared to molecular, dimensions, but small with
respect to the characteristic length scale of the
measuring insrrunrent.Jt is assumed that the suspensions are extremely dilute; that is, that there arc no
particle interactions:
As pointed out by THOMAS,"ln'lOst theoretical
studies agree with the form of Equation 4.4 and although values of the constant as large as 5.5 have
been reported, it is generally accepted as stated. The
limitation on Equation 4.4 is that it is not valid for
concentrations greatly in excess of 1.0 percent
solids byvolume'P,
I
Jlm _
Jl."
I + K,
<[>
+ K, <[>, + K)
<{J)
+...
'
(1'q. 4.5)
where
Jlm - viscosity .of suspension
P. - viscosity of suspending medium
<[> - volume, concentration of solids
K" K" K) - constants.
II
"
II
ij
il
il
I
i
-Ii
Another equation for the viscosity of concentrated suspensions is that proposed by GAY, NELSON,
and ARMSTRONG:'.11
.
fl..
~,
- exp 2.
where <1>m is the maximum volumetric concentration attainable, It is interesting to note that since the
c[>
m
<1>
Pn.
I
1
~ ), Equation 4.7 expresses so e y as a crune"'m
fl.
..1
I
<1>
.\
,I
(Eq. 4.7)
tion of <1>m
~'ni'
'.
fl
_.J!!. -
Jln
rp
l.
}/JOI
(Eq, ~1.8)
i
which is similar to E1NS11E1N's Equation 4,4 except
ci>. -
that
.; .
'
<1>.
,i
}
",1!:)
'II'
I'I
:!,
in
10
>
UJ
>
(Cp) m
UJ
/'
o
l/
0.1
0.2
v.
,J
; .
I .
100
,.
0.3' 0.4
0.5
0.6
0.7
n.f. 4 n
.:'
(Eq.4.9)
.'_
a:
"
..
4.5 THERMAL
CONDUCTIVITY
'.'
'f
.
Methods have been proposed for the measurement ofthermalconductivities in suspensions, but
as with measurements in pure fluids, care must be
taken to avoid convection. In addition, the tendency
of the particle to settle must be either reduced or
eliminated.
."::
T
'I,
'I
r.'
\".
.,
i
(Eq.4.10)
4.6.1 Time-Independent
non-Newtonian fluids
du _ f (r)
dy
4.6 NON-NEWrONIAN
RHEOLOGY
In Chapter 2 we discussed the definition of viscosity for Newtonian fluids and saw that it was
given by the following equation:
,
~ du
p-r/,(--)
-: dy
(E'I. 4.11)
~; is completely defined
(Eq.2.8)
-.
It is possible to further sub-divide the category of
time-independent non-Newtonians, depending on
the behavior exhibited in laminar flow. into those
which exhibit a yield stress and those which do not.
Figure 4-2 shows typical flow' curves for the more
important types of time-independent non-Newtonians.
I
However,' thereisanilTll'ortant group of Iluids
whose shear diagrams or flow curves, as the shear
stress-shear rate curves are called, do not conform to
,I( (dll
dy )
(Eq. 4.13)
l:l
w
a:
l-
V>
a:
:J:
',
V>
S,r." -
1
Curv.e number two, Figure 4-2, shows a typic~1
pseudoplastic I1l1id. This nuid does not exhibit'
yield stress and has a Ilow.curvewhoseslope decreases with increasing rate of shearingstrain, until at
high shear rates a limiting slope is reached. TIle
rheology of pseudoplastics can be described by a
number of modei~:-the most commonly used being
the Ostwald-deWaele. or Power Law model:
",~
Ji. "
r"
dU
(--)
dy
(Eq. 4.14)
50
'. I
L
r.
I,
I,
#..
or
where:
D is pipe diameter
. V is average velocity of flow.
In addition. one has the value of the limiting viscoslty at high rates of shear, p"", with which to
characterize a non-Newtonian fluid (which may
or may not be equal to 'lor /l. depending on the
range of the measuring instruments).The choice of
which of the above constitutes a suitable viscosity
for prediction of pipeline behavior is discussed in
the later chapter on pipeline design.
,
I
~
<n.
...~
Z
011.,,1,,1\1
.
NEWTONIAN
""~
~
0-
-c
SHEAR RATE
'.J
~L'l'j
With Bingham plastics. the fluid can be categorized by the coefficient ofrigidity which isdimensionally the same as viscosity. hi the case Qf pipe flow
ofnon-Newtonians, it is possible to define an "effective viscosity" /l defined as.the ratio of shear stress
~o average shear rate at the boundary. For pipes, this
IS:
!
/l.
Tw '
--y
(Eq.4.15)
8D
which, as will be shown later, results in values of p.
for Bingham plastics and pseudoplastics as follows:'
p. -II [1
and
;0:; )
(Eq.4.16)
.
" ( 8V\ .'-.
P. - K' oj
(Eq.4.16)
'.
I
'. :1'
",.
Rheope::y and dilatancy are analogous in behavior, the controlling mechanisms again differing in
time scale.In the case ofa rheopectic fluid. the structure has, by virtue of attractive forces brought to
bear when the particles are in close proximity, a
certain stability which decays over a period of time.
Dilatant behavior on the other hand has no such
stabilizing forces and the structure decays as soon
as the shear limes are released. A typical shear diagram for a rheopectic fluid subjected to a continuously increasing rate of shear followed immediately by a continuously decreasing rate of shear is
shown in Figure 4-4.
51
l:l
uJ
...ee
'"
ee
s:z:
'"
4.7 MEASUREMENT
OF RHEOLOGY
The' essential featureof these devices is the measurement of the fricti6n 'loss associated with the
laminar flow of a fluid' at a known rate through a
tube of known dimensions. From a series of such
measurements' corresponding to a range of flow
rates, il is possible to construct the shear diagram for
the fluid under study (which is of course the objective of any viscomerric.measurernents]. The actual
construction details ofcapillary,tube viscometers
vary from instrumentto instrument (THOMAS,'''
BOWEN,t111 and SEVERS and AUSTIN,m), but
the basic operation is more or less general. The tubes
themselves range in diameter from 1/32-inch to 112inch andthelengths atlel internal bore are accurately
establis';e<!.The lubes, Me' long with respect to the
diameterso'as to eliminate uncertainties due to endeffects; THOMAS') used an
I'
The primary output from a capillary-tube viscometer is the so-called pseudo-shear diagram, which
is a plot of the average shear rate versus the shear
stress al the tube wall. which is (from Equation 2.10)
a plot of
8~ versus rw This
~~ versus r
5l
10
~:
>'
I":
j.:
(B~,)
, du
BV [ 3
l' ' din
]
(-)w - - + - --:=--=I dr
D 4 4 dl .Y'D)
:'
' n
j"
41
(Eq.4.17)
"
t1p
I
'
v:i~ue of ~.
'
corresponding
"
:~
Figure 4-5 presents a typical pseudo-shear diagram obtained by THOMAS'~I using capillary tubes
of various sizes. In this diagram it can be seen that
the laminar flow data fall on' single curve, while
, the turbulent flow data' are different for different
pipe sizes.This servesto illustrate a ratherimportant
point which must be borne in mind when selecting
tube diameters for capillary-tube viscometers, In
, addition to the usual type ofcorrections which must
be made 10 the /low data, e.g., entrance effects,static
head effects;etc, it may also be necessary to correct
lor the effective slipat the tube wall. In certain nonNewtonian materials,due to the velocitygradient in
the vicinity of the wall, some of the suspended matter may tend to move away from the wall region,
leaving a layer of the suspending liquid adjacent to
the wall. This leads to a reduction inapparen t viscosityat the wall, the consequences 'of which are
similar 10 those which would be expected if there
were actual slipping between the fluid and the surface. Sinceslip does not actuallyoccur, this phenomI
! enon is referred to as effective slip. III Figure 4-5,
since all the lamina(data~oincide, the effective slip
is zero over the range ot. D. and no correction is
necessary. THOMAS'" also presents a curve show-
I
I
I'"
..
,II
l~
I."'"
In
I
y.r
It'
!!.JO'V
~:
>1
,the
-I
... .'11
10
'r,.
.'
r-e-
BV ,~:,
c...e .""
~ ...
..
where
du
'
'
, (dr)w -;rate of shear at the wall
"
.
.
.
..
.. ,.
~,..
....'
.
~
()
. i
~.
TUBE DIA
IIncM
0.174
U
0.3'B
n 1.030
f'/-5.70ep
0
2
I
0.1
.-.
2
--
(sm/ce)
1000
635
196
1.90
1.90
1.90
TV O.69Ib/sQ"
TURBULENT FLOW
.-
1.0
100
ing the effect of slip (Figure 4-6) on the pseudoshear diagram. Clearly,' one can only evaluate
whether or not effectiveslip is taking place by using
tubes of various diameters. Should it prove necessary, MOONEyllJI has indicated how to correct the
values of flow velocity by mean' of an "effective
slip coefficient."
So far lye have seen how it is possible to establish
the shear and pseudo-shear diagrams using a capillary tube viscometer.The next question confronting
us relates to how we interpret the diagrams so obtained, bearing in mind that shear diagram and the
pseudo-shear diagram represent the point and integrated functions respectively. Let us consider the
general rheological equation given previously:
-du
"
dy ,
--f(f)
(Eq. 4.1 [)
"
800
VISCOMETER rUOE
OIMENSIONS
0:.
SUSPENSION
PROPERTIES
wo",
:<-0
. II
:>1-_
~o :>0 " .... 0 -'u-'
u
::; ....
00
.... o:
a;U.
>D:U'i'
:su. "':>
u.
600 -
\';
-I'::
1.47 0.127
J:tll 0.104
.
m400
I
f )
.......,.
>I~
'"
~
-c.l
300 -
i
i
'100 -
I
i
't'J
". f
0.4
lJ
.t
. . ;.i
Q - n [,J u
.
L;
.->:
---
0.6
0.8
1.0
!: 1"'"
.
. --.J11 ": . ' i2 f T dr
-.....
nR- - r/.:
()
i ;.;,
I:.
': i ; ( E q : 4 2 1 ) .
:r
iI
-du
--fer)
dr
. du(r) ]R
,J-;r;- dr n
ro.
(?: .f.
A
WAll SHEAR STRESS. (Tw ' 4 : . :::.)
I,
(Eq. 4.19)
0.2
dr
'~if
,,4
,./
r u
(Eq.4.20)
.;
if
(Eq. 2.1a)
"
/
/'
J'
/'~ V:
200 -
Q.-:.. "2 n
7
v
',1,
,.
~
l-
500
::'~
"'\'-'-"'"
r;
B'!l
s::"1:t.
I-
,,
r-
z.
IZ
;:: 5;::
700
S3
,,
't .
(Eq. 4.18)
-dJ
dr--f(r),
"<:<1
\;;i'0
T-
A~
2L
I
and that the shear stress at the wall. T';. can be written
as
so that
IT.. -
and therefore
)
ApR
2L.
(Eq. 2.1)
'.,
_ TW
- TW
(Eq.2.1O)
,..
For B.ingham plastics. we saw that the system rheology could be described by Equation 4.10
, 'I
'"
C-
du
dr
'I -
ro
'
and
for
f(c)-
C-Co
'I
To
f 'i(r-r)
'.
dr
")
b[1.._
r' ro]"
'1rw
f (c) - 0
Co
'I
(Eq.4.22)
which is the familiar BUCKING/lAM equation'!"
Equation 4.22 reduces to the Poiseuille equation for
0, i.e., for Newtonian flow. It is apparent that
Equation
4.22 cannot be solved directly for pressure
,
_ ..:.: :,.:.::,
'0 -
__
..
"
" . , ........
RATE OF SHEAR
.,,~
-,
!2
- 0.5 and 1.8% when !l!
- 004. Thus, in manv
~
~
.
applications, neglecting the final term gives values
of sufficient accuracy and allows simplification of
Equation 4.22 to give
rw
-"
(D8V) + 4J
(Eq. 4.23)
rn
~(8;)
55
~Iu j!._)~
\i K
dy
,,(K),
or
fer) -,
6rJV
dr
1 ,[ r Ii..
,I""
- -=-r,o. I
rw ,( 31~+I)Kn
(Eq.4.24)
P.
roD ] (Eq.4.16a)
rJ [I +
'j
n'
or
-..!!:.....[ ~ 1*
2V _
l:l
w
...
SLOPE' "
0:
'"
0:
Kj
3n+1
"
'~r
'"
:::1 ,-0
:r
Lt--_--!-
etC!
"'j
,;;,1,-)
II
,
I
"
I
I,
I
rw
(Eq. 4.25)
.'
8V .
so that a logarithmic plot of r" versus D (i.e.,
SHEAR RATE I 8~ I
"to,'
'( 4n ~"
an intercept equal to K, 3n+ I
(dU) "
'r- K dy
P. -
8V - K
(0-). ( )"
BV
D
, (Eq, 4.11)
" _ K'
re
"_I
4n
3n+1
,
" _1
BV
,"
,!;D
r
(Eq.4.16)
56
. where, .
I,
';r l
I'"
.,
1r ' 1..., -~
,
K' - K ( ,4n
3n+1
)"
CEq. 4..26)
.1' .
As with the Buckingham equation, Equation 4.25
reduces to the equation for Newtonian flow when
n - 1.0.
,I
INlllCATINt;
SCALE
, r
.~
I
I
I
Fj~ur. 4.10 Concentric Cvlinder Viscometer
M -2 ne'hr
(Eq. 4.28)
The shear stress -r at any point. since the Ilow is laminar, is given by Equation 2.8. i.e,
du
r-p , dy
but for the geometric configuration here we have
du
- - r dw
....
dy ,dr
where w is the angular velocity of the bob and r is
the distance fromthe center of rotation. So we (';111
now express the shear stress as a function of the rate
of change of tangential velocity with respect 10
radial position, i.e.,
dw
r-p (-r --)
dr
'
- 2nR uh x r w
,.......
surface area
no TATlNIJ
c p.aOB
AT SPE ED w
J"' "
M-
;~
RII
-,
,J
CEq. 4.27)
M - 2nrhp ( -r
'do}
Jr )
so that
(Eq. 4.29)
j'"J
2nhp
... w -
I ?"
dll
, dr
.;.. _ ... -
rdM
--- -
dr
I
"
M
2ndl
. ---1--
. I ( M~
ry 471hJR'f -
R.dr
Q-
R.
ro
r
r.
(Eq.4.3 1)
a-
MIl
- [ -R.r - -xR;r4nhp
I
(Eq. 4.30)
RATE OF SHEAR
F;gure 411 Aale of She.t She., Stren Oiagt.mOhtai"ed
from. Concentric Cvlinder Visco meier
This integration of the point function for a Bingham plastic is performed in a similar manner as
.
follows:
1
du
dr"
- - - - (r-r)
As before
and
---
du,
dr
Equation 4.3 I which reduces to the Margulesequation for r. - 0 is known as the Reiner-Riwlinequation, and it represents the pseudo-shear diagram for
a rotationalcouetre now situation. Atypical response is as shown in Figure 4'-11. In applying Equation 4.31, it is 'assumed that shearing is taking place
over the whole of the annulus and that the shear
stress at the outer wall, i.e., at R" is greater than T
In Figure 4-/1 it can be seen that the response is
actually similar .to the response one would expect
withacapillarytu beshenrdiagram.The yield stress,
r., is given.by die intersection of the curved portion
with the r-axis.The reason for the curvature is that
the shear stress at Rc has fallen below r. and that
shearing is not taking place across the whole of the
annulus. Equation 4.26 can only be applied to the
linear portion of the curve, the slope ofwhich gives
the coefficient of rigidity.
3Z
The integration of the rotational form for pseudoplastic is accomplished in asimilar manner and
yields the following equation:
Q _ (n)
(2nR~hK
11,,[ I _( ~rn
(Eq. 4.32)
This equation reduces to the Margules equation for
n -I. From experimental data, we obtain Q and J1l.
M can be converted to the shear stress at the wall of
the bob by
::IN
8'
t;1
~3:3
t;B2
'j
1 zo
tilW"1
crcr
t;~
crx
"oo
W
X
oo
c:
1:u
I',,,
",.
t.5
2.0
2.'
;3.0
ReiRb
o 16
-'
w
>
.,
:5
"
,"
l(~p
:/[7
.. ~
1/:
"
,i
.'",.""".~ ~
121
'
IRc - Z.ZI
/1 vv
.tZ"V L9
I
~ '12
z
aIRc-\562.51ZOO
/1 VI
1.0
'".I
!(J
24 _
Z8 _~L
o;!!
~
~ 3.01
400,
1-
:,
:'625
!{Rc 5:0)
600
800
""
'
\,000
'I"
48 REFERENCES
4.10 NOMENCLATURE
~-I
nlo~I;'S.
r.tll
4"
\"111 ...\
t 'lIilllllU
lin
1111:
-1-1
(;tn". r..
1-.1
4--1
r.
IN. f1.,Jft)
wi'"
~-;
-I-h
TIIO~IAS. D. G."rfajtfcu in rnrcfn,uion,tlRen'afchan Thermo,hn.1mic .rnl' Transport ru..p enle.... Amcriun Socicr~' Mech.
r:n~incC'n. ChJruer e l, M'I-Mb. NC'w \'nrk Uqhlt
-1-7
Rhe(l'n~y
-I_It
....'1
r.
D
I
K
Constant
Constant
Specific It~at
Volume percent solids
Weight percent solids
Pipe diameter
Instrument constant
Consistency of Power Law fluid
K'
K(_~')n
Cp
Cv
Cw
3n+I .
K.. K 2, K) Constants .'
L
Length
M
Torque
R
Rb
R.
Re
V
du
d;-
du
dy
h
k
~-IO
-I-II no.\'t'EN. R."t., "Scale up (or NonNewlonian Fluid Flo\",Ch.']'. En~. V. M. PI'. 119-122 (I96n
II
.6.1'
c[Jm
(IOH~
v. 2. p. 210 (l9JI).
yo,.kHQ"JI .
w
p
T
To
1".
Susr~nsions:
Po
c[J
fl
Radius of pipe
Radius of bob
Radius of cup
VDp
Reynolds N.umber - .-fl. Mean velocity of flow .
Subscripts
I
Liquid
m
Mixture
s
Solids
t.
\.
.,
i.
I,
I
,.
60
4.11 PROBLEMS
Determine the specific gravity ofslurry, volume
fraction ofsolids, and volume ratio for a magnetite-water slurry having 60 percent solids by
weight, given that the specific gravity of solids
is 5.0.
.
4.2 A siurry of raw salt and saturated brine flowing
out ofa pipeline is collected in a weighing tank.
If the weight of I cu.ft, volume of slurry is 82
pounds, and. the.density of the raw sa,ltand saturated brine is respectively 131 Ib/ft' and 74.8
Iblft', determine the solids concentration expressed in weight percent, volume percent, and
volume ratio.
,
Determine the viscosities of the slurries given
in Problems.d.I and 4.2, assuming that the slur'
ries exhibit Newtonian rheology, and slurry
temperature is 68' F. The viscosity of saturated
brine at 68' F is .2. centipoise.
';'?1
4.8 A narrow gap coaxial cylinder viscometer having a gap of 1.3 mrn and ratio of the radius of
bob to cup of0.946 I was used to obtain the following data (Table 1'-1) orr 05 weight percent
CMC aqueous solution:
Table P-I:
Speed
Setting
1
2
3
4
5
6
7
8
9
10
11
12
Speed
rpm
5.50
7.51
9.89
13.19
17.40
25.08
33.67
44.31
59.11
. _17.98
-.":!-13.2
.. '- 152.0
Shear
Scale
Rate, sec" Reading, %
11.2
15.0
19.7
26.3
34.7
50.0
67.2
88.4
117.9
155.6
225.9
'303.3
11.0
13.4
16.1
19.7
23.7
29.8
35.8
42.3
5004
59.6
75.0
89.0
,
I
.' I
.. I
I
5. TI-IE SUSPENSION OF
PARTICLES IN TURBULENT
,
FLOW
5.1 INTRODUCTION
In this chapter we will discuss the various factors
affecting the capacity of a turbulent flow to maintain particles in suspension. While this capacity
.cannot of course be considered a physical property
in the same sense as 'density or viscosity; we have
chosen to discuss it at this stage because it represents
'to SOllie extent a drawing together of the previous
three chapters. and its proper evaluation is crucial to
.
slurry pipeline design.
-,-,-J
5.2 THEORETICAL
CONSIDER~\TIONS
Undoubtedly, the work of O'BRIENfIlill 1934
with
i.e,
-,
E dc +wC "';'0
... , ;dy.,; . ;\ :;'-YL -.~ ';;: l .~~,)~
SOI.lD - I.IQUID !'LOW
,
E -PE m '
" ."
(E'l. 5.2)
log.
where P is a constant of ~roportionality.
c-; -
a)
w
Ym- Y x-p"u' log. ( - Y
Ym- a
or
c-pE
du
(Eq, 5.h)
(Eq, 2.26)
,m -dy
where
z __w_
p"u'
v
c-cw(l--'-)
Ym
and
E
m
_.:..:...!.-;..
du,
p dy:
Cw
(I-Y/Ym)
du
p dy
,I
- -log. (..L)
, "
Ym
(Eq. 5.3)
h-b.._ 1
Y
. . 0 f 'E
' 5.3 we Ilave d
du -II'
BY dJ'ffierentianon
quanon
so that Em can be written
[)'
")I
5.3 APPLICATION TO
CLOSE}) CHANNELS
(Eq. 5.4)
TII\~ previous analysis refers to suspensions 110wing in open channels. During the 1930's when a
which from Equation 5.2 gives us an expression for
E.. as a function of)', as follows:
(Eq. 5.5)
II
"\
great deal of interest was shown in this phenomenon, the major application of concern was in the
I field of civil engineering, and consequently emphasis was placed on theopen channel CaSe.Wenlust
now return to the problem of slurry pipelines and
how we may adapt the foregoing analysis to suit
these needs.
The first attempt to examine the behavior of
suspensions in closed channels was performed by
lSMAIL,61 in an experimental study following
h.1
log
C
w
c"
.. .... (y-a)
(Eq. 5.7)
',';
.'.
",
,.
'
P,
i
~~j
=1
.G '
1.8w
log,o CA' -. - (
{1l<lI"-
>
(Eq. 5.8)
f:"
._<;:(,r,fJ) _. ex!' [
ceO,O) . ,:i"
..
.
u* ' ro
(Eq. 5.9)
where a is the angle to the horizontal, all other terms
being as used previously or as shown in Figure 5-2.
m is given by the f~lIowing equation:
E
~ rou*
s
m---
log,o
%: -( ~:
20
lIMi~
)"< constant
18
(Eq, 5.10)
The reader will notice the repeated occurrence of
the group ~. and may at this stage wish to reread the
u
"0
- 95%CONFIDENCE
fOR PROBE SIZE ANAlYSES
IS .. 14
'0
z:12
c
~. 10
<
....
B
....
;/
8
6
4-
-:
/.
~ , .! /
d /
~ .;.{:S /
CONFIDENCE
lA t5 L 95%
LIMIT FOR PROBE
/ r
:~ v:
~ /
SIZE ANALYSES
NOTE:
Includes Bottom-Middle
MiddleTop
BulkTop
Cf)l1\n;uio;nns 'or 14 Mp.o;h \("
/;/ / '
o
8
10 12 14
OBSERVED (Vol.%1
16
18
20
fl.'
PARAMETERS ON C/CA
At this point it might prove useful if we examine
how ,\ change in one of the properties of a suspension would affect the suspension mechanism, ;IS
stnted by the hasic sediment suspension equation,
Equation -l.It); The l"lIm,jng seclion was presented
by WASP et al"l1 and shows the effect of variation
,in particle size. pipe diameter, etc, onthe CIC" value
,for a coal slurry. The presentation is based on, and
'is consistent with, actual data for coal slurry; however. the parameter changes have been exaggerated
as compared with the variations which might occur
in areal pipeline situation. Theextrapolations have
been effected using Equation 5.10, with values of K
and p observed in the real system.
r
i
I
I
1.0
r---=::::.::::::---------,
0.8
ce O.&
"U 0.4
Pipe 1.0.
0.2
seues ceee.
Flow
veteeuv
12.0 inches
-SOo:.byweighr
.6 hfsec
04-----...----,---.;:::::,,-1
lOp
10.000p
, lOOp
1.000p
PARTICLE DIA. (microns)'
0.8
---- - -
,
20.28 MESH
0.7
1
0.6
0.4
- -- --
---0.2 --- _
0.3
0.1
Solid~ s.g;
Slurry
to
'135
s.g. ""I~t48
- --
8
: 12
16
PIPE 1.0. (inche.)
"
20
24
.J.
Flow velocity on the other hand may be significant depending on the particle size. Figure 5-5
shows the variation of CICA for three particle sizes
as the mean flow velocity is varied between 2 'and
10 ft/sec. For the finest particles (65 x 100 mesh)
there is lillie or no effect, while there is a steep linear
variation for the coarsest. fraction(S x 14 mesh).
The intermediate fraction exhibits aspects of the
behavior of both the coarse and finefractions. From
10 ft/sec down to 6 ft/sec there is lillie variation; as
the velocity is further decreased and. CIC" falls
below O.S,the drop-off becomes much steeper. This
again illustrates the different controllingmechanisms, as were discussed with reference to Figure
5-3..1'he.65 x 100 mesh particles arc homogeneous
over the whole range, while the heterogeneous
l11echanism dominates the behavior of the S)( 14
mesh partiCles. The 20 x 28 mesh particles fall between the two, being homogeneous at high velocities
and heterogeneous a, low velocities. The reader
should establish where each of these three size fractions fall on Figure 5-3.
65 xllOOMESH
,
:20;2$110 511
. ,;-
./
1.0
V
,
0.9 -
II
,
0.8
I
/
0.7
,
.,
./
V
2
,/
\~ II> ~
vr
,
...
0.6
0.3
,_
45618
flOW VElOCITYllt./sec.l
0.2
10
0.1
/'
I,D. -12"
S"lids S.(I .... 1.35
Velocity ir ~6 "/sftc
./
80
0." C/C A
COAL SLU~RY AT 60 OF
;
5.6 REFERENCES
V.
5-1
/:
~
o
Pip~
80
30
40
50
60
70
.: SOUDSCONCENTRATION {wi. %1
r;
100
20
~I
Co>
~/
0.4
I,
~ 40
...;::
'Z: .
Co>
Flgur. 5-5 C/CA ..... Flow Velocltv 'or V.rlou. p.nicl. SizeS
(from R". 512)
w
~ 60
o
.,
~O.5
10
20
30
40
50
60
SOllDS CONCENTRAnON Iwt, %)
70
KO'!11i~,ht'n
rh)',ik, v. 7.II3Rlhtl'~
5-3
S~,l
SIfF.R\'(OOI),"T. K., Jnd ,VOER rz. n. It.. "M.m t',.lIUlt, be1~'C'C'n rh,11C'1," Ind. En~. Chern .. / . .11.10.1-1 (19-'9).
5-5
(19H~
(m5).
~'altr,"Trans;ASCE.-V;JII; 67~1.1l (I
~~6
Q1b).
~dimC'nl
(1952).
$-7
$-8
J.
:,,1
5-10 Irrr.N. A.
,I
~m..tm,;-.~
Jr.
r.. ....\
67
E,/E",
p
r
Density
Shear stress
Wall shear stress
'
5.8 PROBLEMS
5.1 According to HUNT the distribution of solids
in a ,channel is given by
5.7 NOMENCLATURE
C
dc
Em
E,
V
Z-
h-
Ym _ 1
r.
u
Ym
Y
Eslrotl lIRadial distance
Radius of pipe
Local velocity
Maximum velocity
Friction velocity - V Vj/2
Fall velocity of solids
.
Distance from a boundary
Distance from a boundary to the point of
maximum velocity.
,',
+ (l-C). Cw-O
pxu*
b
f
m-
'i:."j~":l
E, d--y
log
VR
vR: -
-1.8Z
where
I-C
VR-
5.2 For a 12"(305 mm) inside diameter slurry pipeline carrying slurryat a velocity of 6 ft/s (1.83
m/s), the wall shear stress is assumed to be 0.2
Iblft' (9.57 N/m'). 'Determine the maximum
particle size for which C/CA - 0.7 based on the
following data (rable P2):
i
-"'I
Tahlc 1'2:
Matcrial
='
Coal
Magnetite concentrate
Copper concentrate
Limestone
Slurry
i
Viscosity:
Centipoise
SI urry
Specific
Concenrrarion;
\'{I't%
Gravity
of So/ids
25
50
60
1.4
5.0
60
60
2.7
10
10
30
4.0
I,g
hr - 4 x IO"V' +
VC",J:r
5.6 Determine the CICA values for 0.12 111111 diameter magnetite particles of specific gravity
5.0 and shape factor 1.0 at a friction velocity of
0.25 It/s (0.076 m/s) for the following conditions (Table P-3):
where
hr is head loss in feet ofwafer per foot ofpipe,
V is the velocity of now in ft/s
C" is the drag coefficient
Table
p'.~:
\Y/t!~
Slurry
Visrositv.
Ccntip"ise
Shtrrl'
Specific
(i rav it)
45
50
55
60
2.8
3.0
5.0
14.4
1.563
1.667
Slurry
Concentra tion,
1.786
I. Ql.l
I:
i
.'
,-,
iI
'/
rd'
~.
'SUSPENSIONS
, ,
"
"
vo'
,,'
~(
~6.1 INTRODUCTION
,~.~
i
i
. ,}:.:-:,
.oj
I
I
=!
,J
)
<,
e,
TURBULENT
<l
'"
ooJ
LIIMINAR"
'__ VISCOUS
TRANSITION
:
VELOCITY
.',o
,
LOG iVT
LOG
':. :
L
,,
!
"j'
I"J'
.".
\:",'
i'
V
[
I
I
I
--j
i
,,
I
.I
j,
'j
..,,..1,
k;
.:
Since we make the distinction between homogeneous and heterogeneous flow, it follows that we
must in some manner quantify this point of separation; in other words, we must define what a homo, geneous slurry really is. In the strict sense, the reply
must be that a homogeneous slurry is one which
does not.exhibit a measurable concentration gradient 'of solids along the vertical axis of the pipe.
However, in the practical sense a better definition
would be that it is a slurry in which the inertial effect
of the suspended particles is relatively minor. This is
perhaps well illustrated by reference to Figure 5-3
which shows a plot of CICA versus coal partide size
for a given set of pipeline operating conditions.
Clearly, for particle sizes less than 100 microns,
Mate,iel
Sands
Specific
Gravity
Penicle
Reynolds
' Numb',r
Pipe
Reynold.
Number
0.273
0.0923
0.141
4912
26,000
21.000
92.000
1,843,000
0,;
COAL
LIMESTONE
MAGNETITE
UREOGINGS
1.40
2.70
4.90
2.65
1.00
0.295
0.147
0.470
'
r.bl. 6-1 Suml'Nry of Commercl.1 Slurrl"
50
65
60
15
10.02
10.75
9.625
12.75
5.0
3.5
&.0
18.0
0.625
0.653
0.612
0.001
it
6.3 DETERMINATION OF
TRANSITION VELOCITIES
DVp
..
r.
du
-r/(-)
(Eq.4.12)
.dy
Toll]) (E
6 I)
q. .
(Eq. 6.1a)
The effective pipeline viscosity which is defined
as
11. - Tw/(BV10)
(Eq. 6.2)
N II.
a.
16,800 (1 _ a.)}
(Eq, 6.4)
: "
'. :
10':,.,...-..;,-----------.:-----------------------,
, "
.'
::
;:.
! -: '1';.;, .
',~I
,:'::.
, z
.,,~,
a:;,:-i
~".:;.i
,:) .
,,'
z' ,
~ 10"
-oJ
LEGEND
";r~mcnllflck
sturrv
AJver :mud slurries
O' Cluy sluflV '
Q S.'W.1!llJslu.Jg&
... Thd~ sti.rries
Lim~ ,lull V
A
...
>w
a:
...
<
'
i:','
':
'.'
a:
(.)
10'
10'
10'
The term a. is the ratio ofthe yield stress to the pipewall.shear.stress.at transition, the subscript c indio
catil)l;C;ritical conditions, and is of course the ratio
.Of.lh~,,!"3dil1s of the unsheared central core of the
'pip~;~d:'i!leactuaIpjpe radius (see Chapter 4). The
" ' ali?f~~qua tjons aJlow calculaiion of(N.,), and Nil,
:~;
1 ~~ra!;;t~;ie:fs~e%,t:;:e~~;~;~~ef~;~~~::~~~
"
(Eq.4.22)
".'
solid line in
Figure 6-2.
,;""i+"'-'" ,;' ::
.1
>~:I
""1
'
P. - r w I (BVlD)
Rearranging gives:
'I
Substituting for rw from Equation 4.22 and simplifying gives the effective viscosity as
P. - 'II 1 +
;;,~
(Eq. 6.6)
(Eq. 4.13)
_
P.
(Eq. 6.5)
[I_4ro )
3 rw
'I
[robi,) _r._~
6TJV l 6 V
r.
10"
a:
a:
w
"
"
.'
- -- -
>a:
10"
..:
u
;::
o
'"
..J
o
2:
..J
a:
:-I"
1--1-
I:.~~
.
....
"
'0
- - - , - -, --
.'
"
2:
10'
:::l
7J
:,....---
I;
,\\(,"7'
O'?-"Y
,\\\~
~
. ./
0.1
fi
81.0
" 8'0
" "10'
_ TO 0
PLASTICITY NUMBER NPl - flV
"10'
',
t~i>'i
'iW
/1. -
roD
6VT
(Eq.6.7)
I.-
)\
'f"
that in fact V, is dependent upon both these variables but in each case the functional d'~pendence is
,'."er}' weak. Provided that it is used properly (i.e., that
its limita~ions. are recognized), Eq!,ati<;ll) ,6.8 yair "
provide a valuable first estimate of transition.veloc-,:
, i','
ity.
or
v
T
_I
(NRc). ro
6p
VT
1000 [ I + I/ 1 + D-ropIJOOO
'
--op'7 ]
I!
constant,Forf(l'iR.).~2
KL-;2;.1
where K isa
!.Qg....
for (NR. ). - 3000,K.- 22. Thus, from Equation 6.7
it is possible to approximate the transition velocity
provided that the yield stress of the slurry is known.
The reader will note that Equation 6.8 contains
neither slurry v,iscosity(or coefficient of. rigidity)
nor pipe diamet~. Experimental work has shown
('
fiQ1".C:
Wt.%
Solids
Oensity
lfb/It 3)
41.0
47.0
51.5
55.0
84.2
88.6 '
92.4 I
95.5 '
~l"'~i-)""
(dynes/em')
(podol
24
100
200
320
0.0710.051"
0.08
0.1110.13)
0.20
4.2
7.0
8.2
11.5
2.6
5.2
7.3
9.0
3.5(3.4)"
7.0
9.518.0)
11.0
~. I}', '>~
. !.
(Ref. 6-81
I
i/
"
l.' .
z,; :
.'
,.
r - K' (du
,
dy
Pup'
l2r,/l8u/8y)}
,
' . 2\/l(n)
Z- ~
2r w
where
(Eq. 6.10)
[i
DVp
z,.. - V14
n' (-J1-)
'I..
'
f. _ ~"'(n)
Il08
R-
(Eq.6.13)
Thus, knowing the tlow index II, it is possible to calculate the value of;;. Sincef-
(Eq.6.11)
I'
VI:
,~6
R.
for laminar
..
(Eq. 6.12)
(Eq.4.14b)
...
>"
1.0
0.8
0.6
0.4
0.2
0.0076
0.0072
0,0068
0.0066
0.0075
.~~
I:
75
.'
2.900
".
I'
LEGEND
Malenal
2.800
Symbol
2.100 -
'.'
Cal hoxymp.ihytc~llulme
(r
Carboxvmerhvteettotcse
Carbopor
Anasot Clay
Latex Susnensione
Cement Honk Slurries
Wate,:;:
..
Air
ED
Air
2.600
.to
"'
~
2.500
M
2,400
a:
I,
lij.
.
; .
2.300
2.200
Fihel"~Cp, Suspension
2,100
.j
.{,~;
2.000
I
1.900
0.1
0.2
0.3
0.4.0.5
0.6
0.1
0.8
0.9
FLOW INDEX
1.0
1.1
!:: 1.2
1.3
1.4
1.5
,'.'.
(n)
FJaur.8-4 Comperlto" of Calculated CrltfClI Roynolds Numbtr with Experiment.' Data for Pip. now of Power Lew Fluids
I_~-.:
P.
-5!.- _ K 8V
(8 y)
",1 (
( ,,"-I
_ K O S; )
4n ) "
3n+l
(Eq. 4.14b)
.i
tr'
r. '
~4
i: :
7,;
li
1.00-.--------------,
..
I'
:.,;
8V_ c" [I
D
'7
_1 CO +!(~"\.J
3 cw ,
.1
.f
""
.,
NH. = 0
cc
ro;
,.
111"10.10 10 10 10
1<' :
s.
1'
J,
~ 0.100
u
(Eq.4.21)
;t
Z
"
Equation 4.21 cannot be solved directly for Cw ; however by' neglecting the Iourth-power terms, an
approximate solution given by
.
e
...
cc
Cl
~0.010
...
(Eq.4.22)
is obtained.
"
'
I
~.
j .
;; .j'.\"
.;
Exact solutions of Equation 4.2 I are also available such as that due to McM1LLEN'Illand in particular HEDSTROM!~I Assuming the following functional form
0'001+--,----,---,---,----j
10
..........
.',
,
I
I
,
~1
'
,( 1'- <P,
\
- <P2
(Eq.6.14)
!'
[DVP
:roD'p]
(-'7-), (--,,'- )
,
(Eq. 6.15)
I
.
c" - K
i
I,
(Eq. 6.16)
(D )n( )"
8V
4n
3n+1
NR
Equation 6.16 can be expressed more conveniently in graphical fdlm as shown in Figure 6-5,
which gives a plot at/versus N R with Nil. as a para~.
(Eq.4.24)
DVp
_
Re
P.
,I
,I
I
17
(0 )".,(. )"
r ' sv
1', - ,
~n
CEq.
.In+1
1>.20)
Figure 6-1i shows the application of this genetalized correlation to a great deal of published data as
performed by METZNER and REED. The agreement in the laminar flow, regime is excellent. The
'use of the procedure has advantages over Equation
4.24 since no assumption .has been made as to the
constancy of K' and ,1'. The use of this generalized
correlationin turbulent flmJ is not as satisfactory,
as will be seen in the next s~ction.
;;
II !
~' :
1.0
(Eq, 6.17)
"-
a:
o
....
e..>
-e
u.
t;
z
'"
z
z
f-
r.
(PV'/2) '
f-
K,~~r 16~
pV-/l - o"'yl-n'
o"'yl.n
N R. -
(Eq.6.19)
I-- f.
I--
~ ttr
GE
100
,0F
K,~140+a
1~1~1~ll
. ,
TA
'.1,000
REYNOLDS NUMBE R.
""
.........
10,000
On" V 2 np .
Figure 66 FrictionFaClor
(Eq.6.18)
20
1"I-
0.01
0.0002
,1'~
u.
...~ -
u.
, .....
0.10
a:
'
./
100.00
r.
78
. ~ .: ,
I:
"'f'..
,t.,'
..
'
:;:~
;';
"d;:
16
"
.:!.~:
.... 10.
,',0
t= "
.. ....
'~
.... :
...
.,
10
'tl
A
.~---
r-,
,.
.':
-n..!..
~..
r,..
4IogINA."fil- 0.4
"-,
10
;~
,
N.A~
~I\
u.
-,
i--.
'%:
--...- r--
~.p bn-,,.,
'
"'-
I
.3
10
z
".j
'.
103
...
..
'0.
.A~
.~ ~
,
635
196
Ty
'"
;;:
2
1000
0,,318
1.030
." -5.70cp
f'
0.124
P .1.909m /a:
;::
z
~ 10
0
A
f'.!! .- ~
z
.
....,.. L_
.........
..
. ...,. .......... ......
'" """" I;;;
~ ~.Qiib ..............
~ ..,;;0
10"
,,,ur.107 Friction Factor n,\ R'vnold. HumIN' Plot for. TVPlcat NonNewtonl.n SU1fMmion 1It,,",.tl". , TUM
DI'me1., Iff.et Whan tM l'fNt'''' Vb.Gllty II UNcI In tht c.t",laUon o' the " .,nold. Number.
fhern A~....11'
.......
"~.
LID
r-, ,
:a:
\.
Ii OIJ ''-0:
:IO~ "':'
he-
(bl
-'
1\
~,
p ...
10
:t
ill'
:~
-...
--,
'. '''10'3
t;
r-, ~ \
."
""
f\
'
,
i'v.
\.
:!
.:.: .
\.
-,
: ...
"'.--
'2
...
1'\
K.
,l~: &:
;cj
1\
p...,
~\
1\
16. _
1'NA.
. "1<
~!
(I
a 105
n.ow
Of HOMOGENEOUS SUSPENSIONS
differ mainly in their definitions of Reynolds Numbers. i.e., in the choice of viscosity. We saw in Section 6.3 that two viscosities could be used for establishill~ the viscous transition velocity for a Bingham
plastic fluid. the coefficient of rigidity '7. which is
the same as p,_ for a Bingham plastic, and the effective viscosity P.' We will now examine the use of
these viscosities for correlation of turbulent flow
data for Bingham plastics.
Many workersCIJIlHIlIS!in this field have coneluded that if Reynolds Number isdefined on the
basis of the coefficient of rigidity, then the friction
factors.in the turbulent flew regime will be correlated on the conventional Newtonian chart (Moody
diagram) fortheparticular pipe roughness. This of
course is a very attractive approach from an engineering standpoint since the value of'7 is relatively
simple to obtain and the designer is completely
familiar with the Moody chart.
..
(Eq.6.21)
19
and recommended a procedure by which the coefficients 8 and b could be calculated from the system
properties.
THOMAS"l also demonstrated the effect of
using an c1Tecti~e viscosity defined as,
p, - '7 [ I
+ ~~~ I
(Eq. 6.6)
..
(Eq. 6.19)
so
1"-
1\
,
'"
1\
,
0.01
'"'1-.
-?~
r .....
"-
'.
ii- .
a:
o "; ~,I
j ~'
.,
"
"'
""....
t""
~ ."~
;:: .... .
oz
,.;.',
~
::;. ;,).!,i
"If
.~ ."
i'
r-.... ~
" .....
--
'.
;11.'
"j
..
2:.
:t ,'11 ,
0.001
ro
1-.
L L
1"1:: /
t; .. '," .:
---- --... -.
, .... -
,.., t-
.... r--r-I--..
r--.
I'
I
I
r--. r-...
r--
r-,.:..;
......
REYNOLDS NUMBER.
'-
_
N ='OnV'l."p
Re
'-,~~
I,D _
1"- r_
sr
'
,!
1-- -N.
.
1.1
...
-,
1'-
r- "'l{
...
" "{Q
10,OOQ
-'...
1,000
.~
'I
...!L.
>-
r-r--;
Oll S
I- 1-1"-
'Expl.'rilmmtal Rl!gions
EXltUPOT"" R"9i
I.
1--
I'--~T
100,000
7
Figure G8 Flnnl Friction Fllclor Design Ch"rt for Nnwlon;an and NonNewtonian Fluids
.:.
'
If the pipeline designer is able to designate a particular system as either a Bingham plastic or a Power
Law"f1uid;theprevious sedioil~ willenable him to
predict thefriction losses to be expected in any pipeline flow. If, as is moreoften the case; a particular
system can be adequatelydescribed by either model.
the designer is presented with a dilemma which, in
/ spite of his good intentions. the generalized design
methods do not [l1l1yallsO"'er; A. great.deal.has.been
written as to which is the 'best" rheological model
or the 'correct" viscosity to use and rather than add
yet another inconclusive. chapter to this argument.
we would prefer that the' reader draw his own con-
elusions,
We would however offer some background i;lrormarion and some practical comments on thc use of
I)
'\
-,
82
6.7'R~FERENCES
.,
"I. ....
6.8 NOMENCLATURE
!'
n-J '. HANKS. R. W. MA Generali1.C'd Criterion for l.aminar-Turbu'i-. lent Transhlcn in the Flew of Fluids." Union CarbideCo. (No\'.
:;U?
62i.'
4n r
K'- K ( )n+1
A constant in
K.
"
...
"
~".'-
."
'
,'\
'
L
Nne
--
N,.
N Re
Nie
6-7,
N R"
'~"l
- ,,'
""
I
I
Yr
. .
du
dy
(I959~
!t.
"
-",'
"''-
",,'
6-14
p
r
Friction factor
. Power Law index
Radial distance from pipe axis
Ratio of yield stress to pipe wall shear at
transition critical velocity
P.
P,
PM
Shear rate
y-
Length
Hedstrom Number
Plasticity Number
Reynolds Number
Generalized Reynolds Number (see Eq. 6.19)
Reynolds Number at transition critical velocity
Pipe radius
Average velocity of flow
Transition critical velocity
St~p~it!y parameter Eq. 6.10
Index in Eq. 6.21
Eq. 6.8
n'-
s-rr'. WASP.E. J.
K'
8'-'
Apparent viscosity
Effective viscosity
. Viscosity at inllnile rate of shear
Density
Shear stress
Yield stress
Wall shear stress
Coefficient of rigidity
'C1V62j:' -_.
6.9 PROBLEMS
1959~
) :1
<,
6-18 HANKS. R. \Y!. and RICKS, 8. L. -T,;ans;eion.al and TurbuIe-.ic Pipellow orpseuc.t?pl.as~c Fluids," Jr. Jlydronaulics. V.9.
pp. 39-44 U.n. 1975).
I
I
..
6.2 Assuming that turbulent flow occurs in a pipeline ill an effective Reynolds Number of 3000
prove th;1l the critical velocity for a Bingham
plastic suspension having a yield stress r, and a
plastic viscosity '1l1owing through a pipe ofdiameter D can be approximated by the following
expression:
v _
1500,/
Dp
6.3 The following data were obtained for a limestone suspension having 60 percent solids by
weight. Determine the values of larninar-turbulent transition velocities. Compute the value of
the critical velocities using Bingham plastic
model for these data, (Data taken from Ref. 6-6.
Table II).
D - 0.812 inch
Velocity
Friction Loss
cmls
Dyneslcm'-cm
347
323
297
226
181
137
89.3
120
36
44.2
1106
1001
843
540
350
204
141
159
110
127
-;;-:-~__;--Friction Loss
D - 3.05.-'i"'n"c:..:.h
Velocity
cm/s
Dynes/cur'-cm
83.H
70.'1
50.0
34.3
29.9
34.3
34.3
31.4
20.9
25.3
265
14.3
7.7
9.8
8.7 centipoise
0.86 Ibrlft'
Friction Loss
Dynes/cm'e-cm
287
241
186
152
109
69.8
51.2
37.5
12.2
349
257
165
113
62.7
60
56.7
58.2
50
-,
83
em Is
"
;i
Plastic viscosity
Yield stress
Velocity of flow
Specific gravity of solids
- 22 centipoise
-53 Dynes/em/
-4 ftls (1,22 m/s)
- 2.7
H4
"
Plastic viscosity
Yield stress
Power Law coefficient
Power Law exponent .
63 centipoise
50 Dynes/em!
25 Dynes-sec?"/cm 1
0.3
'.
'
',r
... - ...
._"- .....
i
-': .
:<:J
:\/1
.,-':.-
J
; ,,-I
-'::'.:9
!
~:::
7.1 INTRODUCTION
'
0-
<I
o
'"
-'
,,
Vo:
, lOG V
fig ll, . 7.1 Friction Loss
VI.
86
"
i.
i ':
'
O...ription
and
Rtfar.nco
250
250
250
250
250
0.00
0.21
0.00
0.00
0.49
. 440
440
440
2040
2040
2040
2040
0.01
0.01
0.01
0.00
0.00
0,00
0.00
230
230
230 .
230
230
585
585
585
585
585
1150
1150
1150
0.02
0.03
0.04
0.05
0.06
0.00
0.00
0.00
0.00
0.01
0.00
0.00
0.00
1.0
l.0
l.0
1.0
1.0
1.50
1.84
2.00
2.60
3.00
T
T
Water
Water
Water
Water
Water
Water
Water
5.90
5.90
5.90
5.90
.: 5.90
' 5.90
5;90
5.0
10.0
15.0
2.5
7.9
7.5
10.0
8.1
8.7
8.9
7.2
7.9
8.3
8.6
T
T
T
T
T
: 4.25
4.25
, 4.25
. 4.25
4.25
' 4.25
' .: 4.25
4.25
. 'i *4.25
'''? 4.25
: :4.25
'4.25
4.25
5.0
10.0
15.0
20.0
25.0
5.0
10.0
15.0
20.0
25.0
5.0
10.0
15.0
6.01
6.35
6.81
7.72
8.00
6.54
6.95
7.28
9.72
9.85
8.27
7.60
8.77
!
:'/,'1
'~"
Particle
Oia. (d)
(microns!
1.05
1.05
l.05
5.50
5.50
;~.
Vo
(It/sec/
Flow Regim.
(L z laminar)
(T z Turbuland
t:'~:':1
". i
"
T
T
T
C
CA
-"'.,:I
'I
i
\
T
T
T
T
T
T
l
T
l
T
T
',
I
I
I
,,
Ii
I
i
I
~)
Oestrip'ion
.nd
Reference
Vehicle
Pipe 1.0.
linches)
Solids Cont..
tVol. %)
Vo
lIt/secl
W.ter
Wale,.
Waw
Water
Waler
Waler
Water
W.ter
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
1.60
1.80
2.00
2.10
2.20
2.26
2.33
2.40
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
0.50
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.0
2.0
3.0
4.0
5.0
6.0
1.0
8.0
10.0
12.0
14.0
16.0
. 18.0
1.0
2.0
3.0
4.0
5.0
6.0
1.0
8.0
10.0
12.0
14.0
16.0
18.0
R7
Flow Regime
= lamlUar)
Particle
Oia. III)
IT Turbulentl
----
(,"(crons}
T
T
T
T
T
T
T
T
!680
GilD
I.
2260
2260
2260
2260
2260'
2260
2260
2260
2260
2~60
2260
221;0
2260
2205
2205
2205
2205
2205
2205
2205
2205
2205
2205
2205
2205
2205
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
J38.
138
138
138
138
138
138
138
138
138
138
138
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
.0.10
0.10
(L
680
680
680
680
680
680
...L
CA
0.00
0.00'
0.00
0.00
0.00
0.00
0.00
0.00
:"1
I
I
,I
i
.I
~j
.j
I,
I
I
I
,,
i"f
I
I
i.
I
I
,i
I..
)
l~llIlTllef: 761
Iron (Ref. 161
Iron (Ref. 16)
Iron IRef. 76)
Iron (Ref. 16)
Iron (Ref. 16)
Iron (ReI.1-61
Iron (Ref.7-61
I,on (ReI. 7-61
I,on (ReI. 7-6)
lron (Ref. 7-61
lren (ReI. 7-6)
"Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Kerosene
Ke,osene
Kerosene
i.oo
1.00
1.00
1.00
0.75 .
0.15 .
0.15
0.15
0.15
0.15
0.15
0.75
0.15
0.15
0.15
0.15
1:0
2.0
4.0
5.0
.6.0
7.0
8.0!
10.0
12.0
14.0
16.0
18.0
0.40
0.60
0.75
0.80
0.90
1.00
1.02
1.05
1.02
1.00
0.80
0.75
0.60 ~ .. '.-
l
I.
0.95
1.00
1.05
1.10
1.15
1.20
1.24
1.28
1.36
1.47
1.55
1.63
1.70
T
T
T
T
T
T
T
T
T
T
T
T
T
4.00
4.55
4.90
5.05
5.05
5.05
5.05
5.00
4.90
4.82
4.10
4.60
T
T
T
T
T
l
l
l
l
l
l
l
l
L
L
T
T
T
T
T
T
T
!(i,!l;':ll; ;
.l;W;:t:~
,.
:f:i'H'
q:>;
C
w
log C" - -4.5 ( ;)* )
:t;
;}:,!':
!
(Eq.7.1)
the particles would be transported as a heterogeneous suspension. CHARLES C4 ' suggested that
Equation 7.1 should be modified to
;
-.
> 0.13
u
(Eq.7.la)
11ft ....nllllily
(Eq, 7.2)
II'
"'11
(Eq. 5.8)
In this context we will define the deposition veloc-
"LUW
or HeTEROGENEOUS SlJSI'\;NSIONS
89
:i
'-;i
Vo - Fl [2gD ( P~~I
WIl
(Eq.7.3)
"T'"'--------------.,
10.0
...
r-.
WI .
~l.O-Li.~...,,...~~~ti~::
DURAND
CORRELATION
m
rn
05?
-
lLa
(Eq. 7.4)
, (P,-PI )111
,
PI
>
oJ
U.
from which we see that the term FL is in fact a modified Froude Number at deposition. 11IUS, while
transition velocities are Reynolds Number depen-
~SinCiair
,LEGEND
IRet
'""Durand . '(Ref.
a,Durand
(ReI.
tr Yotsukura (ReI.
o Yotsukura (ReI.
Yotsukura IRef.
o Wicks
(Ref.
+ Wicks
{Ref.
20)
16)
16)
19)
19)
19)
18)
18)
0.1+------'-,.--------1
I
1.0
100
10
,Cv"S%
"
/3;
'Cv 2%
-e
U.
Cv' 51'
oJ
U.
"
,2
R.r. 721 -,
-0
I'
SS
8}
,i
t .. - 8
i
LEGbND
" Sinclair
f:Ref.
'" Yotsukur~ IRef.
o YOlSukur~ IRef.
,. YOlSukurl ('Ref.
o Wicks
/iRe',
,+ Wicks
' (:Ref.
',,1<-: 1
j"
20)
191
19)
19)
18)
18)
, 0,1 +--------r"--'--'-j--'---'-l
,
~
10.0
',
50.0
SOLIDS CONCENTRATION. Cy (Yelume %1
.F
. ...;,1,0
'~
,VO -
( '"l"'[
L87~J
2gD
(P~~'
(Eq.7.5)
If it is assumed that Equation 7.5 describes the behavior 'of dil ute suspensions and also the effect of
particle diameter and accepting that the form of the
DURAND correlation adequately represents the
effect'~f concentration, WASP et alII) reasoned that
an equation in the form
.'.'
(Eq.7.6)
tool.
. :
..
..."-'
Coal - Sinclair (Ref.
o Iron - Sindair (Ref.
20)
20)
0.1+-------r
I ------j
10.0
50.0,
1.0
SOLIDS CONCENTRATION. Cy (Volume %)
Figure 75 Deposition Velocity for Coal and Iron Suspensions
(from Ref. 71J
91
I
r
i
[
,.
, I '
.;..: :L~o
~d~O")~D~Ooro[P~;I fJ
Ii.
.
I,
.-4,90
I '
I
I,
o
!:!..s.
_ I + 2.8 (..z.
,i
I
. I )
)10<t>ln
u~o
u*o
,i
I.
(Eq. 7.7a)
. (Eq. 7.7b)
;vhere:
wi-settling velocity of particle in carrying fluid
: . under quiescent conditions
u o -friction velocity at deposition for limiting
: case of infinite dilution
u"~ ~friction velocity at deposition for the slurry
; . at .given concentration
<t> l -volume fraction solids in the slurry
d : -particle diameter
D -pipe diameter
Ps -solids density
-liquid density
v -kinematic viscosity of water
",. '1
"
I
!
);?Ij .
.(d
U ..
)2.71
(Eq. 7.7c)
PI
1.0
-f-
~~
e,
a.'
Q'l
'-
.'
0,,
a
\'1)
-e
...
,,0
"
I'.~
MOTION
,1.
Q,.
I 0.10
1\
Q,
SHIELDS CUR'I
E
I
3
,j.
;11, !
.... \! .'
.
~ II".
'!.;
0.01
0.1
:,
1.0
10
u.d
!.: .:
' .,j
'.'
II
Figure 76 Shields Diagram: Dimensionless Critical Shear Stress vs. Shear Reynolds Number.
,)
'
NO ~OT'~N
..
.....
100
1000
.,
~.
6,
...
'
:4
?":
. ';'.
sc
~~
"
" 6.
,'r:l,,!
,~"y
"
i)
:,1
; j
e,,"
1
"
,
~
~
~"
, ,.,',1.
..
'
~
I
~'" 0.05 ",
"" 0.02/
O,OI~
, j'4
. .',
, ;
.1
,:
10
..
."
'I
,yo.l/l'.
, 10'
0.2
'
~.
1'.
~I
;k
~,
'
/ I'.
~I ,
I,V'
,J
I,
!L
~i0
r-,
1'.
I .........
@
I
I
10
~.
_.-
ell
,..-
~"',
.'
I'\.
.
Minimum Transport
Homogeneous Flow
Transverse Waves
longiludinal Waves'
HelerogeneousFlow
,,- r;:,
....
,.'
I .
Ii
6.
.'
, ...
.'
"
s: "
"
-.."
r\j-:
.
"
\,,\,..
"
"...
,"
.'
,
/ /
i"
~~ ., r-,
:"
'*i '\
\'
1/
,'\"A
I"
Fl1
i--' Jo'.......
",:~.
,
..'
i~
.~
~'"j
.~
,.
"
~II /
<,
1YI
,, il/,'I rr-.,
, ,
'
",
~,
'
,tn,
v ~ !U" <"
y/
1'... UJ
Kr
'
200'
100
l'
....
Y...
~
r,@
~ 0.51
~
I "
fJ
. f!'.
r -..
~,
,,
,l,-'<J
',!- -~;~/
! .(
\t
,
>
V, ,.r, lY>-
" V
"
1,'"V
~~7
"',
I
!
20 '
~
~
!!-. 'j ;I
UO'
'I
'j
I'
. ji 1
",
~'?-
&< 1)
/r'-.1)
-/'
,,-"-"
d
1<-<&-
I'
Homogeneous 'Flow
,
I.2
10,
10
dUo'l"
Figur.77 Gene,.lIzed Phase Dlagram.for Suspension Transport.
IA.ng' p. 'Y nd E Ph.... App'Y te O.n.lIy A.Il.1p p
-pllPI.5S/
point of initial movement of particles. For openchannel flow this point is described by the familiar
,Shields Curve (Figure 7~6) which isessentially a plot
of ~r!t.ica! shear stress versus the particle Reynolds'
.",
dlt"
,Nurtber (
We saw in Chapter 2 that the
7)'
lhick~ess
-',
If U
(Eq. 2.32)
2.5
. Va
V9ii
2.0
-:
......
_.
.'.J
,.
1.5
t.o
o
0.05
0.10
0.15
0.20
INPUT VOLUME FRACTION SOI.lOS (CI
.,
effect using the same parameters to define minimum transport as are used to identify initial movement. Further work covering ripple and dune formation was conducted by THOMAS,c~1 and the culmination of this work was the forrnulation''" of a
generalized phase diagram for suspension transport
,~
. du"'o
'"
-y-.
The solid hne
IS
-7 versus
Ii 0
. ..
.< __
au
v
0_
I
For mixed sands of more than 0.44 mm diameter,
COr-JDOLI()S andCI-IAPUScl l , have developed
a correlation between the deposition veloCity and
slurry concentration as shown in Figure 7-8. The
correlation is independent of particle diameter.
SINCLAIR'61 and SPELLS(l21 ha~e used ass as the
particle size to be-used in their correlations. Here
7.4 PREDICTION OF
FRICTION LOSSES
It was noted earlier that in heterogeneous /low the
presence of the solids had only a minor effect on the
system rheology, namely, a slight increase in suspension viscosity as given by EINSTEIN's relationship
(or a form of it):
(Eq. 4.4)
II
!.
I;: .
I"
I:
I,
I'
94
'.- I===I"~'~
. -~i\-=-~
-- ._~ .. :.
--I-'\-' .
.
..::.-...:.., -;.::,
::';$'::lllL
,-,- : I-h-
of,.,
: ~ '.
-: .
(Eq.7.8)
.....
.:
where:
fm -.friction factor for mixture
r. - friction factor for liquid
C - volume fraction solids
K -constant -80 to 150
g ":" acceleration due to gravity'
D ~ pipe diameter
V - -,velocity of flow
P. . ~ density of solids
P, .- pellsi!y of liquid
Co ":-. drag coefficient "
,.
'~fl'.:, 1
Iii
'
5.0
10.0
.'
50.0 100.0
PI
-vgO -.rc=
P,.PI v-n
2
... - ..
Flgur.79
..
1\
'
~;f!
lows.: :r"
SLOPE' -
fiC
"'.;jo';
against
2'
V ( P, )''C
gD P,_PI Y VO
(Eq. 7.9)
and shows that the increase in friction loss of the
slurry over that ofthe carrier fluid flowing under the
same conditions, expressed 'as a fraction, of the
carrier fluid friction loss, is a function of the Froude
Number.theconcentraticn of solids, the relative
density and the particle drag coefficient. This "over
pressure'las giveri by Eqllation ].9 is forhorizontal
flowandnisults frornthe rna/distribution of solids
acrossthe pipe. In vertical pipe flows this.concentration gradient does not occur, as long as the flow
velocity is greater than the faU velocity ofthe partic-,
les, and the friction loss can be calculated asEqr ,a
homogeneous' suspension, :employing' of, course,
the correct specific gr~vity and viscosity terms.
7.4.2,Heterog~neous Systems
of Multi-Sized Particles
DURAND's work was carried out using closely
graded particle size fractions and, apart from some
disagree/l'lenton the numerical value ascribed 10
the constants in Equations 7.8 and 7.9, the work is
generally accepted;' We will now See how DURAND'scorreialion can be applied to the more realistic situation of a heterogeneous flow in which the
particle size varies over a wide range. Clearly, the
problem is one of how to ascribe the correct weighting to each particle size.
\1
I
I
I
I
I
i
,I
.-:,1
;i
'j
.,
log - - -1.8 ( - - )
fJxu*
CA
(Eq. 5.8)
Jllustrarive Example
Determine the friction loss for an iron concentrate slurry flowing in a 12 inch inside diameter
horizontal pipe. The following data are ,given:
Pipr
Roughness
Solids
Specific gravity
Shape factor
Size consist:
- 0.002 inch
-5.0
- 1.0
% Weight
- 0.0059
+0
5.0
10.0
85.0
- 23% volume
- 68 F
- 0.0059 ft slurrylft
- 0.01 13 ft water/It
2nd lura/ion
Now check the vehicle and bed part for each
size solids by using CICA criteria. For each size
fraction, the vehicle part is assumed as equal to
theproduct of CICA for the size fraction times
the volume concentration of that size fraction.
The remainder of the solids is assumed to be
heterogeneously distributed.. ';
Now,
Slurry.visccsity;
Vol.'% Solids
Viscosity, Centipoise
log ClCA
-1.8 wlpxu
Assume p - I
x -0.4
','
','1
Sobaion
Since the vehicle and heterogeneous (bed) part
of the solids is notknown, an assumption will
h~~~',!O he made. The simplest assumption is
either to assume all solids to form vehicle or
/lon~ ~fthe solids to form vehicle. In the present analysis, we will assume that all of the
solids become part of the vehicle. Thus. in the
first'iteration, there will be no bed pressure
drop. '
'
Is/Iteration
Concentration of solids
in vehicle
Viscosity of vehicle
'I
Slurry density
I
1.1
- 23% (VoL)
- 7.9 centipoise
- 0.23 X 5 + 0.77
Velocity of flow
Pipe diameter
... Reynolds Number
Relative pipe roughness', '
0.002
'
-'12
- 1.92 gm/cm'
- 4.5 ftls
- 12 inches
.... [02 X 105
- 0.00017
Referring to Figure 2-7 (Chapter 2). the friction Iactor isf> 0.0047
. . ',AfV?
;'; Friction loss - 2 D .,;,; 0.0059 ftlft.
- 4.5 0.0059/2
' - 0.244 ft/s
I
"I
Llphed -
82
LIp water
gD (s-l)
<Pb d [ V1 {Co
- 1.887
i
I
----"-~,;'::";/ '.,,"'~
.,.::/"
_
... ..
.'{
'.-'
'
'
wI
._. , Settling
Size "
Fraction
Tyler Mem
Mean
Dia-cm.
Itl
(21
FIRST ITERATION
100x 200
0.0111
0.0059
200 x 325
0.0021
-325
--.
Velocity, W
It/sic
VolumeI'
Solids
1004>
.-p" U.
C/C A
~,..
_..
-1.82
10
(3)
(4)
(5)
(6)
0.00858
0.00242
0.00031
1.15
2.30
19.55
TOTAL
SECOND ITERATION
100x 200
0.0111
0.0059
200 x 325
0.0021
- 325
0.00858
0.00242
0.00031
-23.00
1.15
2.30
19.55
.'].W
0.0877
0.02476
0.00317
0.6950
0.9025
0.9872
TOTAL
THIRD ITERATION
0.0111
0.00980
100x 200
0.00277
0.0059
200 x 325
0.00035
0,0021
- 325
TOTAL
1.15
2.30
19.55
0.09373
0.02649
0.00335
.. ~.':'" ... ,~
0.6781
0.8960
0.9862
.... _.. -'
1004> veh
(4)-(6)
(7)
1.15
2.30
19.55
Settling
Drag
Velocity in Coefficient
(4)-(7) Water, It/sec
CD
1004> bed
(8) .
0
0
0
-23.00 - 0
0.80
2.08
19.30
(91
0.08812
0.02490
0.00315
(10) .
8.9
53.6
1190.0
/l p bed
-3/4 6.31 bed /lp
CD
Vehicle
x 1111
(11)
(12)
0.194
0.050
0.005
0
0
0
0.00428
0.00069
0.00025
0.35
0.22
0.25
--0.82
22.18
0.78
2.06
19.28
0.37
0.24
0.27
0.88
---.22.12
-0
0.00522
-.
. . _.
(13)
/lp
Slurry
(12)+113)
-114)
0.0113
0.0113
0.0110
0.011 0
0.0169
0.01622
0.00452
0.00075
0.00027
.-.-.-. ..
0.00554
,-.
Table 7-2 Estimate of Slurry Friction Lo,. for an Iron Slurry
""
,<
':,'
- 0,0110 + 0.00554
- 0.01659 n water/It
This compares with 0,01622 Ii water/It computed during lhe 2nd Iteration, The difference
between the two results is less than 5 percent.
Therefore. use 0.01659 ft water/li as the final
value for friction loss.
JrJ Iteration
Friction loss
for slurry
- 0.01622 ft water/It
.', Friction factor
for slurry
- 0.00675
.', Friction velocity - 4.5 1/ 0.0067512
- 0,2614 ft/s
Next compute the CICAand Llp"d as given in
Table 7-2. The Llp bcd becomes 0.00554 ft water/ft
The vehicle
concentration
.. - 22.12%
.', Vehicle Sp. Gr.
i , - 1.885
and vehicle viscosity: - 7.0 centipoise
! - 1.125 x lOs
.', Reynolds Number
,', Friction factor
'. - 0,00466
,', Friction loss
- 0.00586 ft vehicle/ft
," - 0.01l0 ft water/It
\I
7.6 REFERENCES
i
\
!
.!
1-Z
1-J
7-4
7-S
i ' . '
7-18
.'
Th.
7-7
7-8
7-9
ntOMAS. O. G.,Periodic Phenomena ~ervcd withSpherieal Particles in Horizont.al Pipes,M Science, v_ 144.pp, SJ4-SJ6
(M.y 1964~
7.7 NOMENCLATURE
or
1-11
I~~).
u'
"
p
LIp
d
Pm
Po
K
V
rJj
.J
~ 7-1
1
I
I
I
99
P,
P,
Drag coefficient
Ratio of volumetric concentration o( solids
at 0.08 D (rom top to that at pipe axis
Pipe diameter
Coefficient in Equation 7.4
~Qe.fficient in Equation 7.6
..Constant
.. Mean velocity of flow
Deposition critical velocity
Particle diameter
Particle diameter such that 85%by weight o(
the particles are smaller than d 85
Acceleration due. to gravity
Friction (actor (or liquid
Friction (actor (or slurry
Frielion velocity.
Friction velocity at deposition (or the slurry
at given concentration
Friction velocity at deposition (or limiting
case o( infinite dilution
Settling velocity of solids
Ratio o( the mass transfer coefficient to momen turn transfer coefficient
. Fricli~n Joss per unit length'
Thickness of the laminar sublayer
Viscosity of slurry
Viscosity of suspending fluid
vonKarman constant
Kinematic viscosity of water
Volume [raction solids in slurry
Liquid density
Solids density
1,:;.,
FLOW OF HETEROGENEOUS SUSPENSIONS
Fi.':,100
h: .',
[:i..(.8 P~6BLEMS
. ,
t: ~:r
f.r:7.!
':' (.'
':, ,' :. . .
:.
i /' ( - . "
Determine the value of CICA at critical deposition relocity for the top size fraction of an iron
conbce.nttate slurry from the following data
(Ta Ie, P4). The top size fraction is 210 micron
diameter. The specific gravity of the solids is
5.245".;"
"
,.
Slurry
Concentration
(Volume "1l
:1
4.235
40.4
35.2
30.1
25.5
20.4
!
.j:
Slurry
Viscosity
(Centipoise)
Critical
Deposition
Velocity (ft/s)
Friction Loss
(ft \Vater/100 ft).
22.0
12.0
7.0
5.0
3.0
4.7
4.1
3.5
3.5
. 4.0
6.72
4.06
2.58
2.32
2.58
<;I~f~ 6.240
28.7
24.5
20.1
15.1
6.5
4.5
3.0
2.5
3.4
3.6
5.1
6.2
1.28
1.48
2.49
2.92
8.240
29.7
26.6
24.7
20.2
15.2
7.0
5.5
4.5
3.0
2.5
3.8
3.6
3.7
5.3
6.8
1.40
1.10
1.15
1.89
2.61
30.2
24.8
20.6
7.0
4.5
3.0
15.1
2.5
3.4
3.9
5.1
7.0
0.69
0.79
1.24
1.90
20.3
13.2
3.0
2.0
5.4
7.7
1.00
1.71
7.3 Determine the wall shear stress at critical deposition velocity using THOMAS' correlation for
. a coal slurry carried ill a 17.25 inch diameter
pipeline. Assume coal particles uo belOO .
micron diameter with a shape factor 01'0.7.The
specific gravity of the coal is 1.4. The volume
concentration of solids in the slurry is 40 percent.
10.360
12.400
101
I',
Percent by Weight
+200
3.81
200-270
4.13
270-325
3.81
-325
88.25
Assume the solid particles to be spherical.
Wei/tht %
Viscosity (cp)
40
2.7
.1.0
50
60
14A
Pipe roughness - 0.0012 inch
Table P'5
Pipe
Diameter
(Inch)
2.056
4.235
Slurry
Concentration
(Volume %)
Critical
Deposirjon
Velocity.Ift/s)
36.7
23.7
12.2
4.8
4.5
3.9
6.4
37.9
23.9
5.6
5.6
11.6
6.240
8.210
31.0
7.5
22.8
17.0
7.3
11.4
7.2
28.2
22.8
17.7
7.7
7.8
7.3
7.9
8.1
11.1
I'
10.360
35.0
"29.0
23.2
17.6
I
I
8.7
I
8.3
8.8
8.8
Friction Loss
(ft waterIlOO.ft)
14.61
857
650
8:13 "
5.05
"3.96
5.21
4.27
3.82
3.38
3.47
3.17
2.89
2.73
3.83
3.05
2.99
2.47
12AOO
", -,
28.1
25.0
23.9
17.7
I3A
9.2
8.5
8.6
9.1
9.1
2.72
2.27
2.22
2.20
2.05
102
Table P6
Weight %
Solids
Viscosity
(Centipoise)
38
Velocity
(ft/s)
3.3
5.6
7.7
10.4
0.0106
0.0204
0.0358
,0.0680
2.7
4.9
8.0
8.7
0.0064
0.0190
0.0453
0.0524
6.5
2.8
5.0
6.1
7.6
8.8
0.0088
0.0238
0.0309
0.0450
0.0482
14.0
3.4
5.0
6.5
7.1
0.0101
0.0262
0.0408
0.0514
4.5
l'
,I'.'
49
5.0
:'l;
, !1
.
',.
,:
58.5
64.8
_._.
Rifermces
I) FADOICK.R. R... A Miner..l Slurry
I
i
I.
Friction Loss
(ftlft)
HANDLING
.,
8.1
INTRODUCfION
, .
Plastics
HEAT TRANSFER
IN SLURRIES
8.2
'I
.
,
~I
, .
: .~ .: ' t ,~"
" ':,
This section outlines briefly some of the experi! mental work which bears on the subject; theoretical
treatment oflaminar flow is neglected but is discussed in detailed reviews e1sewhere.II)(2'AIso excluded
. is.thetreatmentof Newtoniansuspensions; it is
assumed that the reader is familiar with the heat
transfer correlations for Newtonian fluids which are
directly applicable to those types of suspensions,
provided that the system properties are determined
as outlined in CHapter 4.
.
;11 -
1.615
(D:P}W .
(Eq.8.1)
where:
C. - specific heat
D - pipe diameter
(Eq.8.2)
I ." -,.
:
!
I. ~'
;."
"J~ ture" .s
P' . ",fluid density
I,,
rlHJ lo
..
"
i.".. ,: .;.,
Ii ;':
-,
',r,)' '.
OIA.
:wi . I;:
t;,;
.r~r:::.
","
r: ';'
!:
'if
.
1'
I.IH
'10 I
;":: ::i,~'t~I:;':
:~:.'~.j:F:,
.. ,
0.318
0.318
0 0.318
o 1.030
.to. 1.030
'0.318
1.030
378
252
126
175
87
378
175
104
104
104
104
104
134
134
0.075
0.075
0.075
0.075
0.075
0.46
0.46
0.0019
0.0019
0.0019
0.0019
0.0019
0,0055
0.0055
I.
- ..
... ,
, H
..
.......
..
.. '
2
<,
r-..
I;
' .".
.,
'.;
"
......
.'
<:.
r-
'.
"-
'
'.
"
.......Vl 'A.
...
"
;
, .
,'
3..
.t
'.""', c'
"'I"
..
-.
..
.....
....
.'
..
r-,
h
CpIJ 2/3 L 1/3 ll w 0.14
I ~ fvlfw
.10
DVp -2/'
'Hrr(cpG)(T) (0) (T)
'1-14fVl3fwl tf.fV/3fw\41
>1.615(""1/)
: .~: "j::':
I
I
Ibllhl Isecl
.'
.......
', ............
r--,
7
Ibl",. h.
---
11.
t.
SLURRY OeNSITY
Ib/cu. n,
,
2
L/o
"
,..
' . !;
-I I
finch)
! ~: ~: . ..
-r
.~
.:
<;
! ..
;
t
7f' ~
10
REYNO~OS
3..
OV
7 8
...
10
,11
Figul.8' Laminar Heat TnnsleN;har3cterinics of ThOZ Slurries Compared with Theoretical Equalion
(from Ref. 83'
':-
....
......
r-,
~6781~
10
.",.,
HANDLING
107
1.
(Eq.8.9)
and
PmP, (0D
1\
-1.0
(Eq. 8.10)
n; )
P "
0 ' l-c
_ _ 0.092 g u, _r ( - - )
VT
0,
1/1
e',l
'(.!.'!.)
,0,
Ap
.e
(Eq.8.11)
"
~T term.
108
. ,,
", ~',
. -.
'
(Eq.8.12)
N~ -.,p (N Nil.. N f , )
(Eq. 8.13)
'.
a:
~'I
"1
I
I
divided by the square of the Reynolds Number.
.
The methods available for use with fluids described by Power Law or generalized Power. Law forms
are a great deal more complex and their inclusion'
is not. justified by the scope of this text. The reader
il referred to the admirable treatments of WILKINSQN~'~~Il~SJ<ELLAND.12lpartkularlytlleJatter
4.10'
-a
I ,I
"I'
"
10
I11II1
10
c0
fr",1l'
.
vesser. Dj -. 13.00 lnf:hes.
Dj/DT: 0.67. Hj/Or .' 0,33
H/OT
' I.on
pOUlOS TESTEO
-a
"ue
~
.~
..
4'l.
z
z
;::
u
z 10
:>
"
u.
a:
w
~
0
~ ...
a.
.' 1"0
('_logNR~)
Np.(-P)/(N
F)
i
PN J O 5
to
10-'
I I I 11 II
,10
I.ul!.
r--
'" ... -
.,.
..
1:5
~)
..
IU
I I II
,10 I
10'
10
'f
p--f.
(Eq. 8;14)
. t IliS agarnst
.
V N R.',
015
and p Iotung
tIie group D
ASTARITA et al(') were able to eliminate this diameter effect, as shown in Figure 8-5.
.'\..
:' :
..
~'
.i
t--
ppm
125
y1.1S
,~
L.>
pO.1S,
I,
,:.
!;~~,:~lr:r-;.
;
'! ':
''',,,.;
r\..,
4
~.;
.-
-.
"
...
!.
AO2.05em
1.10,
0.69
'
2, 000
. 10 '
NRe :
t", ; ~',
'
I, 000
,
,10
,).t
./..:(': ~ ~j I ~,~
500'
Ii!
':'-.;,-
"
10'3
.;>
j,
irUmi
-.
'I'
250
--
, I
. ;., .. t
.,~
. '.
.~
8.5 REFERENCES
... , .
1.0
I,.,~,
., ,
ppm
125.
.1 I
,
:".-~
~ t ~. ',
I'
' ,
{j;r;',::';;'::'~:'
: , ~'. . t '.
-t-t-+t-tfHf--0.5
8-1
SKEllAND. A. H. r.. NonNn\'loni.llI Flowand Heat Transfer." John Wi'cY & Son. tee, New York (I~67).
8-J
I, \I
.,
0.5
, 250
tctistiCJofNon-Nc\\'lonian"Aqucous'ThoriumOxide'Su~ptri~
. 0,5
500
8-4
lami~arRc~ion
0.8
0.3
1,000
I ' ""1
8is
0.3
2,000
0,1
10'
0.15
V NRe
10
'e!!"i, ,in,~_u,1i,:ll~T~~~_f~rJJsC'udorJ~stic_food"Malcriahin
8-6
ME,ZNER. A, 8.nd FRIEND, P. S" ""... Transr.r.o TutbuInd. En,. Chern., V. 51, pp. 879-
I~nl Non.~ewlon;anFluids,"
hec .1)
889 (/uly
1,959~
"
~igu',
8-5 Plotl of
,
If,om
PYI.
R,'. 891
0.15
'.
81
IIELATELJ
~HC
~_q
8-10
f
fo
g
I\SfARII'A. G..(;nECO. (;..IIIU NICOOF.MO.l.. ..A l'ln-nntncl1oln~ic.lllnterpr('r.ltioll .lntl Correfneiou nfO'3f: R~du(lion'
AIChE.ltltIfI1JI. v, I~. p. 5(J~ IJuly (1Itlql.
KOl.AR. V.. "\hcoI~IJ'lic Fluid.$ulid Flow in I'ip<"." hI Infl.
Cent. on 11"U,3U\ic 'f,.lmport of Solid1: in Pipes, RIIRA Fluid
EII~I1~ .. CtJlllid,J.~U. K. Paper FIeSept. PliO).
,I
h
III
k
n
Us
II
Friction factor
Friction factor
Acceleration due to gravity
Film coe'Cficient of heat transfer.
Heat transfer coefficient
Thermal conductivity
Power Law index
. ve I"
Slip
ocrty - ('gdllp ) "'
,
8.6 NOMENCLATURE
B
C.
8.7 PROBLEM
8.1 Determine the agitator horsepower requirement for a 20 ft diameter tank containing an
iron concentrate slurry. The height of liquid
level in the tank is 20 ft. The agitator diameter
is 6 ft and isinstalled 3 ft above-the tank bottom. The slurry concentration is is% solids
volume. The specific gravity ofsolids is 5:0. the '
particle size is 30 microns. and the suspending
fluid is water.
'
, '
by
9. MECHANICAL AND
OPERATIONAL ASPECTS
,~
9.1 INTRODUCTION
:!
114
','
Maximum f J)
Pres'surls
, (p,;)
.. :;:\
" ."
J,
~I
M.ximum(2J
Muimum
Meehln;clr
Efficiency
Panicle Size
Commlnts
920
85-90
8 Mesh
2700
85 - 90
8 Mesh
50,000
40- 75
0'
flow
(U.S. gpm)
(J)
..
'.'
'.
350a,- 4000
.PLUNGER
PISTON
'; ,~
CENTRIFUG~L~GbO"
~. "~~"~
'I'
'Nci!t~s:
.' ,'.;~:{
700
Series Ins.allation
low capital cost
),
"
:Ii
For
..
~.
-,
'~.
-,:
, F6C,
. F::.,
, "
which is highly abrasive, normal practice is to employ plunger pumps. equipped with a flush-water
system to ensure that the plunger is kept free of
abrasive particles. Less abrasive slurries can be
handled using piston pumps. In general, piston
pumps have greater throughputs but lower discharge
pressure capability than plunger pumps. so that in
, J.
.,
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liii "
&If;'J''
...... "', .
,~ ,
.
",.
'~
"
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,
,,(
i.i '
'.,
'.",
V:.station spadng,spares,andntai~tenarce'costs
: ~l!Sho~1d be c13selyscrutinized..,..... .' . ,
'.
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116
SOLID - LIQUID
F~OW
"
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",.ECIfANICM. AND OI'ERA nONA!. ASI'I'CTS
117
"
Figur.9-4 Savage Rivet Slurrv Pipeline
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,
--,I
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...
''''
'fr
II
I'
;\
I, \
~.~1tf\...
.' ,r..... -',
}
"r,
1\',
,..
. ..,
' '10.
-. ':'~;';'''''''''''':'':,,;t.: - ...:
-..
:.... ';':~)<.\~{~~""'%'~!';""i;:i;._<"
__'
., - -
PUIllPS
.Pis!~~ahaplullirpumps;typicalofthose. used
Figure 9&
~ougainvill.
... =-. -
newer version of this piston pump. This "third generation" pump delivers 2100 U.S. gpm: at a pressure
of 1100 psi.
p,,,,,,,
"q.~ 'l'r"Y..
.. Padlinlf
Pllln,.r
CI.~sh..d
;COlllltl:lill"nl'
C~lnh""1 ,
,:'::.,"
Packing -
BlIs,hing
V.I.e,
.... 'h_l.
=
Gland
lantern Rings
Fi911'~
g.g
Pf~"'9~'
liquid
Pump -Fluid End
Flow
I.W
.....,-.,--:-,--'-------------'-,
....
r.
,
::I
::
~
:'
1110
....
. "-_ _ "
--1
0
.;:._
1'.0'
~ u..
_---'-
__ -J.-
i,
i
..
... --..-
----_.
~---
.,
.,: n-
:!
-_.. -.
~-_
.... _-,.
"-r-:, ..:
1
lott ._ . .
-t-_..
; 0'
...;.---'---,-""---'--------1
~
,1*
1~~14"
1m
1m
~'U\"C.,lCUY:
1m
~"
:.IIS G.....
Fluid End' ,
The fluid e~d ofa plunger pump may consist of
two or more single acting plungers, .individual or
monobloe fluid cylinders, and a suction and a
discharge valve f~r', each cylinder (see Figures 9-9
and 9-;10): h:phe:case'<ifa piston pump, single or
double acting pistons would, take the place of the
,
. ..
.'
plungers {Figure 9-8).'
.
. " ' ,
,-
t
I
Speed Control
Slurry pipelines utilizing positive displacement
pumps usually have at least two variable speed
I
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Low Ah,asivily
(Piston)
High, Abta3ivi.ty
1100
3000
500
VALVES
PISTON ROO
PLUNGER SLEEVE
PISTON LINE R
BRASS BUSHINGS
PACKING
,I
(Plunger)
120
425
425
I)
:;~i'
:r
Typical Ranges
Cenls/Ton/Pump S.al;on
",.I
.)
I
!,
I
!
0.3-0.8
, 0.6 - 1.2
. 2.5 - 5.0
3.0-6.0
COAL
LIMESTONE
COPPER CONCENTRATE
MAGNETITE CONCENTRATE
. FLUID DRIVE
,d I.
'it
::
EDDY CURRENT ; .
WOUND ROTOR MOTOR
WITH lIQUlollHEOSTAT
SYNCHROORIVE ..
POLE CHANGING' i .
SQUIRRel CAGE,.'
Where Used
.i CONSOLIDATION
COALkSAVAGE RIVER,
SLAC MESA
.
CALAVERAS, WAIPIPI
I
BOUGA,,.VILlE
WEST IRIAN
TRINIDAD
',I
.;
~i. l l .
:~
",
TvpeSpeedCont,ol
. 4000
6000
III
"""
.
"
",'
112
an emergency shutdown. The restart ofa slurry pipeline containing thousands of tons of solid material
requires time to accelerate the system to normal
velocity.During' this period the pumps are required
to operate at very low tlows and high discharge
pressures,. Most couplings are constant torque devices. and' the energy so dissipated would be totally
absorbed by the speed, control' device. thereby
requiring a fairly large cooling system. ,
r
dist~n~e,slu~rt.
On' long
pipeline systems, they
sen'e,as .charge pumps prbviding suction pressure
required for the mainline reciprocating pumps.
Centrifugal PUIllPS are also used to pump slurry
through a' "safety loop", thereby permitting, the
system operator to monitor the slurry for quality
control purposes before committing it to the pipe"
line, .
Design Considerations:
The casing pressureicapacity of a centrifugal
slurry pump is limited by. the vertical split-casing
design necessary foreasy replacement of the impeller and the wear-linings of the casings. For rubberlined pumps the impeller tip speed is generally
limited to 4400 feet per minute to minimize \Vear.
The resulting limitation on pump speed reduces the
maximum head that a rubber-lined centrifugal
slurry pump can develop. Rubber-lined pumps are
generally limited to fine slurries in which the 'naximurnpartide size'is less tl~aneight mesh. '
i
f,I
12J
It is significant that thi~ installation is unprecedented in hydraulic hoisting with regardto its 7.200
foot depth.
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.."'V, ". ,,,.,:,"'1 '00' U "......." '10' ....
olio""'..... 'U"" ,,,"':In<MIl ,,,t "'jf'_,. '''''''UGIO
'.'\11 0 .'oU 111'''' ,'tV" .'.h.......,,.U "'H
Iff '''' 11m.. ', 0.,,1,. II , .. " .. , .. , _.
, .. ,
.f,
'..".
Cut _U """"If
, C ..... 'W'''''I
~U
~IYI
\'r.~"L
It
U '"
lOCC"'_'''''fO
'tJIIW'''I''~t1OK,,,I'rof
.'
--
oo,"c.''<G """'fill
,"tOIlC'''' "'_IV'
,",....".,.,,,
,,,
'.'I'S"
"'''0'",
free-moving rubber spherical "piston" which alternately 'drives the slurry from the vessel and drives
the water back to the mixing tanks.
I
"j"-'1
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!
125
STEP 3#=~~~_~.===="",~,
Q.
STEP
)
2~~~====~
,
,.
Vibrations associated with positive displacement
pumps have been a problem for many years.and the
designer must pay particular attention to the questions of pulsation dampening and piping supports.
Inadequate dampening and poor station piping
design can result in excessive pump maintenance
costs. and increased fatigue failures in piping and
instrumentation,
sucticnpiping,
Vibrations in pump station piping are induced
by '''CSSII,e transients Ofl1l0derate freqllency, reslJlting from rapid opening and closing ofpumpsuction
and discharge valves, (They are not caused by unbalanced forces of the pump which are compensated
lor in the design and structural integrity or the
pump's foundation.)
I
=
:.Y'
presstir~t"alJS.ieii
A meiIiQdfor.ll,eaS1Jril'irapid
IS
at the slJ5tio,~and dischargeofa po,si~ivedisl'l~ce'
ment pump.utilizesa presstire transdu2e(and an
oscilloscope. A Polaroid' call1er~ isheIl'ftil, using a
time e~poslJ.reofthe s~m~durati(,n,as.the:pump.
stroke.:This.:.produces a.~ecor(r'pf.t(lei pr~~sur~'
transient foionerevoliJti()!lo,fth~;Ji~mp~;T(lis, .
metho~\Vasu~ed to investigate prdsureira~sients
on tlie~uction and dischargepipi~gQfduplex
piston pumps.
A typical pressure transient for the disch~rge of a .
duplex, double acting piston pump is 'shown in
Figure 9-' IS. The average wave, if plotted through
SOI.lD - I.IQUID
126
the mean of the higher frequency pressure Iluctuation, is asscocia(fd \vithdte;i1tmnaIHow variation
of the pump. Tf,eampli'ud,e of this average wave
can berequced:bY il,stilll;atil1jl ofadditional dampener capacity; Ifif)epres~lire r4rialioll ofone pulse is
withi~'a lewp~Weiitoflfie'(olaldisch'lrge pressure.
iris norl1)aIlY<:QJtsidef~~ Il.\aldampeningis adequate, The spik~~ indicated lh Fi!iure,9~(5 is typical
ofa shockwav~tesulting'frql1)the sudden opening
of the pumpdischarge,,,~lve,'
'." ,.. .0
-.... " ' ".' ;
~
'~
:.;;
l :; ,
',"C
now
The suction conditions ol'the first positive displacement pump station in a slurry system are particu" larly important since it is normally fed by centrifu- "
. gal pumps. Figure 9-16 shows a typical suction
pressure trace .of a suction directly from a slurry
, storage tank. Note the, typical "saw tooth" pattern
of the mean of the trace. When a piston starts on a
suction stroke. the suction valve opens and the
suction pressure drops. The suction pressure then
builds up before the next suction valve opens. In
this period the flow is accelerating in the suction
piping. The energy in the suction system is supplied
by a centrifugal slurry pump. so /low and head
continually vary.
""'
..
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out the means to.facilitate both regular and omslonal malntenance. Some of the operations which
i,
, I
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~mCIIANICI\l.
The above considerations apply much more strongly when heterogeneous slurries are being transported.
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tI'GNVUOCItY - -
..~ '-::.
..no
.'.
_ ..... _ .....
-=: '_
~
.:~~
A'!tAsrOIf, C101l'N"ltfAY
'0''''''0
.- -;
1,"'''''10 IY stlDlIiIIC
Olt 10UIIC'''G,A"flCIrs
Other thanmanufacturing~b;'siQe;~riQ?s,the
limiting factor fOf the minilllll ll1wall. thi~kne.sse~
for cross countryline.pipe is usuallyexternal.loading. A'convenrional rule-of-thumb.is thittthe ratio
of pipe outside diameter towall thicknessshould be
lessthall'128.
"
"
.. I
=
127
........'10' ,,,,..'U,,,,
Material
Gray.i-t-y
Maximum
Plr1icle
ma Mell.
GllSONITE
1.05 .
Yes
COAL
1.40
Yes
LIMESTONE
2.70
48
No
Impactors, bal(mills
COPPER
4.30.
65
No
MAGNETITE
4.9
t50
No
Specific
,I
Special
12"
Prep.ration
Required
Size Reduction
Equipment
Commonly U..d
I
pumping velocities (and costs) and higher wear
. rates. The ultimnte choice of particle size range
depends upon:
=[
_.
--
There are many types of mills available for crushillgalld grinding ores. The most common include
autogeneous.Impact cage, rod, and ball mills. Selection of the most suitable mill depends on the
characteristics of the ore, particularly. hardness, and
the required fineness of the final product.
(;rit:tgingl'ower;MetaILoss.
While many crushing and grinding mills are sized
based .on manufacturer's experience or tests, the
horsepower requirements fOf grinding with rod or
ball mills have been correlated to a theoretical Work
Index (\Vi) by F. C. BONO,'8) The Work Index in
BOND's Third Theory is a property of the material'
to. be, ground (determined bya laboratory 'test or,
preferably, from commercial or pilot-plant ex-
IJO
Fig.ur. 920. Preparing Coal for Slurry Transport Involves Screening. Crushing. Grinding. and Storave In Mi)dng Tanks.
r-"...
1-"
perience). BOND's app~oach gives excellent estimates of grinding-power. requirements, and many
millinginstallations have been sized on this basis;
ho,~ever. it.is .a. big step' from a fractional-horsepo)"er .Iaboratory-millInvolving a few pounds of
sample, tq a.multithousand-horsepower commercial
mill, processing millions oftons per year. Needless
to say, great care, and.judgmentmust be used in
,
making such: extrapolations;
v
MaterIal Size
99% Passing
1}sin.
lin.
!lIn.
:t.'
10 Wi
(pl ll
10 Wi
(p)1I2 .
Jx
318 'ia
3 mesh
4 mesh
6 mesh
1.34
"::,
Where,:<
'.'
WLWork Index
. ' ..
P the 'size in microns that 80% of the product
passes
F .the 80% passing feed size, microns
W .grinding-powerrequirement; hp-hr/short ton
This equationis also useful for estimating the effects
ofvariablechangeson a commercial milling operation.
..
..
.
Work hld~xe~"frOQ)ma~y t~ts are available'" 1'0'
and general values,for most materials can usually be
located fa! prelil~inary, horsepower calculations;
In.
mesh
10 mesh
14 mesh
20 mesh
28 mesh
35 mesh
. 48 mes~
6511lesh
, 1.00 mesh,
150 mesh
200 mesh
325 mesh.
For P .. Microns
(fJY, or (pry,
25,000
18,000
12,000
8,000
158.0
134,0
109.5
92,2
6,000
4.200
3,000
2,100
.1,500
1,000
800
500
77.4
64,8
54,8
45,8
400
270
150
105
n
55 '
.36
20
38,7
31.6
28.3
23.4
20.0
16.4
12.25
10.25
8.48
7.42
6.0
4.47
1.1,1
"-,.---,----,----,---,.---,
"'-1---
.20
!
e
%
::i
1.15 .
e
~
;!
...5- - :_ _
.-t-'---+--...,f----l---..:.ii'---l
.. .,.
,
D,'
ABAASION 'NDU. AI
..
t ..
tIf'Wtll'"
"M
u ....
L.
_1"_,,,_
.-..- -
W-Wp-Wf
- 9.0-2.2 - 6.8 hp-hr/ton
Therefore, ifit is necessary to grind'l,OOO tons/hrof
this coal to 80% passing 300 microns.the minimum
milling horsepower will be:
,I'
~I
."
BOND tabulates Abrasion Indexes from numerous tests. This tabulation was the source of, the
Abrasion Indexes used' in the metal-consumption
calculations shown on Table 9-7. For example.fhe
AbrasionIndex for limestone, ,taken as 0.0238,;
gives a metal usage (from Fig. 9-22) for wet ball milling of 0.052 Ib ofrneralpergrinding horsepowerhour. Using the' previously calculated grinding
power for this limestone and product size of 11.2
hp-hr/ton (fable 9-7),a metal consumption of
0.052 lb/hp x 11.2 hp-hr/ton - 0.58Ib/tqn of limestone ground results.
, .12
Horsepower
Work IUdel.Wi
Feed sin. 80"~ passmg
IF'
microns
5000
PloduCI sile'. 80') passinq
(PJ microns
300
WI IFig.9-211
2.2
Wp IFig. 9211 '
. ; 9.0:
5000
5000
5000
150
2.3
13.5
100
2.2
16.0
55
2.3
23.0
lime- Copper
~ ..!!!!!!.. 0 Ma,Retill
13.6
IV
11.7
11.4
:.6.8,
11.2
--13.8 20.7
. Metal consumption
8.n 8all
Rod
8all
Mill. wei
Abrasion Index. Ai
0.02 0.0238 0.1472 0.2217
0.053
0.52 0.143 0.164
A,lh/llph' mg. 9221
Melal consumption, A x W,
1.97
3.4
Ibllon
0.36
5.8
Rel.tive ,rlnding costs. eIIon
Power .1t1kwh> '
Mel,l &llOMh
TOlal
Relalive Clut
5.1
3.6
8.4
0.58
8.7
' '1.0
14.2
1.6
10.3
19.7
15.4
34.0
30.3
3.5
49.4
5.7
-- --
',.
-\--
-~
--------- ----
.. -.,.,',
.:..~
\
\
\
\
HopPfl Bollom
to Conu"tlll' Solids
\
\
Rotalin, Jr'
"It"Pr,$Wt':
...~
$'uIfY
..... :.uP~.t".'.
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Chemical Treatments
Corrosion in a pipeline transporting a water/
solids slurry is controlled by, adding,corrosion inhibitors alid will be discussed in detail in Chapter 10.
Shear-thinning materials. or dispersants. such as
lignin compounds and polyphosphates, are exampies of materials that are effective .in breaking-up
agglornerates. Such chemicals are used in the cement
industry. These materials reduce the electric charges
on the edge ofthe particles so that they are dispersed
in the fluid trapped in the agglomerates. This fluid is
now released and becomes part ofthe free fluid. The
effect is to increase the dilution of the slurry. A
su rprising reduction in pressure losses is possible
with low-dosage levels.
Drag reducers suppress turbulence in the pipe.
These materials are usually macromolecules of very
large molecular weight (large-chain polymers). The
exact mechanics ofhow they reduce turbulence is
not understood. They are quite effective in astonishingly smallquanritlesinnonslurry systems; but
they are less, effective in slurry systems because
considerable suppression of turbulent energy dissipation has already taken plaCl.(I<lln addition, most
slurry systems operate near the laminar-turbulent
transition point where turbulent dissipation is not
ftryh~.
-,
I.lJ
, ,-
SUlItllT
. ItDIIAn
"'lolltllltf'UW
, , -... 0...-...,11
-~ltI,I .., _
;."
... ;'
/.4.'
..~' ::::.\
134
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necessary for laboratory analyses such as slurry percent solids and size distribution; If the slurry is outside.the specification for pumping, then the retentiontime in storage can Ill: used to carry out corrective .rneasures without shutting 'down the system,
Air-1'7aur Connections> Suitable air-water connections at the top of the tank for lancing purposes
are desirable.' These connections can also beused
during a power failure or to get a stalled agitator restarted.
Agitatcd Storage
The calculation of mixing-power requirements
has been' amply covered in' Reference 15 and in
Chapter 8 so there is no reason to cover this subject
here.
The Mohave coal tanks, with 6 million gal in useful capacity per-tank, are the largest agitated slurry
tanks in existence, being 125 ft dia. by 85ft high.
The agitator-drive horsepower is 500, the upper
larger agitator blade is 34 ft dia., and the lower agitator blade is 29 ft dia. These blades rotate at a speed of
7,rpm.
material,
Viscosity -
(LlPDI4L)
(8VID)
Shear stress
Shear level
an
In
agitated slurry tank, we may write the expression:
8V _ ( Tank velocity parameter
--=-""i'--,i"-'=-o.<.J;';::';'::=:':':"-) - KNc
0 , ' Tank distance parameter
";f;'
::l.
"
where.:
V - linearvelochy
D - dia. of pipe
L -Jengthofpipe
P - pressure'
N ~ agltatcr.speed in revolutions per second.
I~
~IECIIANICAl
I )
IL
I
t
L
!
L
,
t,
'!
i
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I
.l'r
L
I
I
I
\
L
~I
ri
i,.
J,
f
I,
~
~
I)
Thickening of Slurry
The thickening ofa slurry priorto pipeline pumping is necessary with some slurry pipelines. This is
r,
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.I"j
;':;;'
(;~>,
t, ,
'... '
t' r,
i" ,
j
A critical factor in the design ofa decant thickening pond is the depth of settled solids. The greater
the bed depth. the higher the concentration of settled solids in the pond. An advantage of this method
in the dewatering of a coal slurry is illustrated in
Figure 9-26.
Dewatering a Slurry
The principal aim in dewatering a slurry is to
recover the solids with a minimum moisture conlent. Clarification of the liquid phase of the slurry is
usually ofsubsidiary importance. Table 9-8 shows a
selection of available dewatering equipment for
solids recovery. In most cases. a centrifuge or a filter
is necessary.
, c.
1oll.$OtlOS.V",'
1$ ,SOtlOS IV PI
Maior
Function
Operation
General
Equipment
Classification
Solidhowl
centri'fuge
Continuous
Centrifugal
IiIter
Equipment
Subclassification
Cylindercontrol bowl
(vertical. horizontal);
solid/scree'" howl
cornbinatiOl!.
. Conical screen (helix
conveyor. o~cillalor);
cylinder screen
(pusher, conveyor).
ROI-nry- belihl~tlll,.
horizonlill helt,
hOfizUlltalllim.
Olher
~Ilflr.ial
Cenuifugal
filler
Recover
lolidl
Balch
.utomltic
Balch
Verlical,lerfmilled besket.
C.OIISlil11 lSIUlP.tl;
horilontal'Iaskel.
variable. SlIced.
Vertical baskel. cunSlill11
t"n,d; hn,ilnnl,d
leal.
~1I~CIIANleAL
I'I, -,
rI
..........
_. -
> .... ~-
~,-
i ~ t/~'~;Tt,
f
--
<:.,
I,
I
=..r:
,-.. --,
i,
,J
I";.ttL'
:;. I
i'
I
~.
~,~,,:=-r::;':i:
f,r:,"
'
137
-. . _.~,
~_.-.-
i II
! II '
.\
-.'.
l'(
Dewatering-System Example
, '
A typical slurry-dewatering facility is the .system
now in operation at Mohave Generating Station,
Clark County, Nev. This system convertswater-coal
slurry into a coal cake containing 25% moisture.The
cake feeds directly to pulverizers and the pulverized
coal is direct-fired into the furnace.
Dewatering of the slurry requires two stages: centrifuges and then thermal dryilig.
The first-stage prccess'<schematic is shown in
Figure 9-28.Slurry feed, drawn directly fr()rrialiagi~
,Cffl,,",UGf
,
". . . . ."
....
e..,lfil lJt'l
4-_,~""""
_ _-s
ClAAAI((OCUlAJOA
tated:slurrY storage. tank, is pumped t6 the, cenrrifuges.In a centrifuge, the coal cake discharges directly to the pulverizer,
Centrifuge emuenlc~)I1tai~s a s~all percentage
of very finecoalparticles.Iminus.Sz.S. mesh). This
coal' is recovered in a thickening loop, where the
138
".'.!
........-.
.......... ................ _
_
~.
Figure
9~29 Con';.nt~~i111
Coal handling for conventional coal firing involves conveyors, crushers, storage bunkers and
feeders. The system for direct firing of coal slurry
requires only a storage tank and a recycle pipe loop.
Allthewater in the slurry vaporizes in the furnace.
The resultant heat loss due to the latent heat of
vaporization amounts to approximately 5% loss of
the coal's Btu value.
9.6 INSTRUMENTATION
AND CONTROL
The control of a slurry pipeline system is accomplished -with the same push-button ease as with a
conventional liquid or gas pipeline. Certain precautions must be taken with regard to selection and setup of primary measuring elements, but providing
that this is done, a slurry system, even a multi-.
station system; can be fully automated;
"
the initial station with personnel provided at intermediate stations for maintenance and remedial
purposes only.
I
I
I
!
1:-
'-'::,
I
!
I
I
d
'.'1
=1
I
I
IJ
IH
.- "-r
. ,
9.7 REFERENCES
9-1
9-2
9-3
9-4
O.n.
1972).
9-5
9-6
LINK.}. M. and TUASON,C. E.,-Pipe Weuio Ilydr.1ulicTr;lnsport o( Solids.~ presented ~t American Minint Congress. Las
VeJ!:n. Nc'v'd.1 (Ocr. 1971).
14lJ
9-7
9.8 NOMENCLATURE
11..8
9-9
D Pipe diameter
F Size in microns that 80% of the feed passes
L 'Length
N Agitator rpm
P Size in microns that 80%of the product passes
Y . Mean velocity of flow
W Grinding power requirements, hp-hr/shortton
WI .Work Index
Ap Friction loss
I
.
,!
I
I
!"
9-10 BOND.F.C.. "Mel,,1 We." in'Crushin. and Clindin,,- presented 2t.56thAnnu,1 McC'cingAIChE. Houston. Tu.n:(Dcc.196J).
end
Cap~city DClermina-
9-12
~Marconano
9-15
I
9-16.
~j
'I
I
CHAr~IAN,
HOLLAND, F. and
F.. Liquid Mixing and
- Processtni in Stirred .Tanks." Reinhold Publishing Co. New
Yolk (I966~
.. .
:.
9-21 RUSHTON,
J. nd
HILLESTAD.
J.
.i
!~64) .
9.9 PROBLEMS
9.1 A coal slurry pipeline is designed to transport
4000 gpm coal slurry. The pipe inside diameter
is 17.5 inch and the length of the pipe is 130
miles. If the friction loss is 25 psi/mile and the
pipe is on level ground, determine the pump
size assuming that minimum number of pump
stations. are to be. used. The abrasivity of the
slurry (Miller Number) is 20.
9.2 For the slurry- pipeline system considered in
Problem. ?.I. it is desired to provide agitated
slurry st~rage ianks having 6.hour storagecapacity. Determine the size of the lank. Also determine the agitator power required assumlug that
OJ horsepower per 1000gallons oftank volume
is needed.
9.3 For the coal slurry system considered in Problem9.1, determine the grinding horsepower per
ton of coal if the Work Index for coal is 11.4.
The feed size, F, is 5000 microns and the pro'
duct size, P, is 300 microns.
.,
':':.,
10.
.. :':'
CORROS~N-EROSION IN
SLURRy"'iRIPELINES
10.1 INTRODUCTION
The majority ofslurry pipelines are made of mild
steel. Loss of pipe metal' due 10 corrosion and abrasion plays an important role in their design. The
external corrosion of the slurry pipeline does not
differ from that ofIiquid pipelines. The internal corrosion in a slurry environment could be appreciably
different from that in thecarrier fluid, The presence
of solids could accelerate the corrosion rate. Solids
can also produce abrasion of the pipe. To prevent
premature failure of the pipeline, it is necessary to
provide additional steel to take care of internal cor. rosion and abrasion. Long-distance slurry pipelines
are generally designed to provide an effective life of
15 to 75 years. Unless the metal loss is adequately
controlled, the pipe will need costly replacement,
In this chapter we will examine the mechanism of
corrosion and abrasion in a slurry environment and
the methods of controlling them: The external pipe
corrosion will not be considered.
Corrosion and abrasion are expected to.be acting
simultaneously in a slurry pipeline. However, the
. mechanism as well as the methods of controlling
corrosion is different from that of abrasion. The
. mechanism of corrosion and abrasion is therefore
. considered separately.
I
10.2 MECHANISM
OF CORROSION
The intemal corrosion is caused. by the slurry
water. Corro'sion is an electro-chemical. phenomenon. It requires, the following elements:
.'
(Eq. 10.1)
(Eq. 10.3)
J4Z
.~(
AIIOol
Ih
'_lf~""'.h
I
..
il~
ITI,
".-.4o'lf~_I"IO"J,
'''10"1,.''0,.'',0-''.10''',
I.10M" . - !J~. "10
COIUIOSlO/lll
Moaller
OlYlIflllllOUClIOll
50
, 40
~
,g
----
I .I. ".
,"-'-
~ 30
c(
'"
o
C;; 20
o
tx:
'"
o
L:::!:L::;:~t:::::i::::-l-l-/
(.) 10
o:
o
'!'
.I .
\
DISTILLED WATER lwilh 0'Y900
., I "
'1>-..i..
'8
, ' 12
16
20
24
TIME (houn'
Flgur.,0-2 EIf.cl of Sand on
Cor~os~n
Fjllllrei6:':'isl,c.lwstll~ ~ifee:t9f adding sand particles on the corrosion rate ofliistill"d water. The
corrosion rate is substantially increased by sand
particles when oxygen 'is present. However, in the
absence of oxygen, .the corrosion rate does not
change by the addition of sand particles. This illustrate.sth~tthesolidserode the, protective film arid
, .increase the corrosion rate only when the environ.ment.is corrosive.
.
, Figure 10-3 shows the two corrosion probes used
in these tests. The surface of the probe exposed to
-, sand-water slurry looks bright while the one exposed
to distilled water looks dull. This confirms our ob"
II
10.3 MECHANISM
OF ABRASION
143
Characteristics of solids
- size and size distribution
- hardness
- density,
'-shape
- composition
Characteristics of the liquid phase
- corrosiveness
- density
- viscosity
Condition of flow'
- laminar or turbulent
- heterogeneous l'f homogeneous
- velocity of [low
9
8
CORUNDUM
TOPAZ
QUARTZ
FELDSPAR
APATITE
,4
FLUORITE
CALCln
W
...J
0(
~+~~
<.>
'"
:I:
"'-.1'& ~o
,,~+.,yof,o
en
::E
GYPSUM
...J
0(
z
!:!
-..
"
a:
~'Yo?
9", "'1
~+ '~?)-t~
<:!<)-
AUSTENETIC MARTENSITIC
MANGANEZE
WHITE
,STEEL
, I~ON
INew Condition
,NI HARD,
Wo' I( Hardens
15/3
Under ImpaclJ
ALLOY
''-,
GENERAL
PLASTICS
!
5
10
316SS
AND
ALUM.
BRONZE
GREY;'CAST,
IRON I
,-- ----j :
50
100
CA
'28%CR.
40,SS IRON
500
1,000
2,000
BRINEll SCALE
t,
\.
'..",
..
Figur. 10=4 Appro_linit. ComfMrfson of Hardness ~.Iues of V.rious Com~on Ofe Mi,,!erals ~nd Metals
. ' fho".-R.f."1012)
,~
144
, :~ ,
\ {I
.t
.s :
"
W
100
.... W.
~~:liE 80
",I-::>
-e i;i:! 60
w
ux
~"'< 40
zW:liE
0"'",
in <020
0'"
0:<
"
10 20 30 40 5060 70' 80 90
, I~PIN9EMENrANGlE (degree'
100
.... w
<",
ee <:liE
"' .... ::>
......,0.
'
oq;.
80
. ~";
~ ffi :!60
~ux
ffi;1
Z
0'"
"",~;.!...
f!}
40
. Q. C
Ui~
0",020
""/~
GI~
. 4~
"'<
W
,
10 20 30 40 50 60 70 80 90 ..
IMj>INGEME~T ANGLE (degree)
100
<'" . 30
"'<:;;
",I-::>
< ffi:;; 60
NATURAL RUBBER
wux
u.:;; 40
oa.~
.
~a:<
Z
a;
C;;
<020
o~'-r-t---,--,-:::;:::::::;::"",..""'l
o 10 2030 4.0 60 60 70 80 90,
IMPINGEMENT ANGLe' (degree'
."\
'\.
",,:
...
,..'
.... w
','
fIll (J mil).
"!lr
,i
I
i
10.5 CONTROL
OF CORROSION
TI
I
=
Various types of'inhibitors may be used to reduce
corrosion rate. The inhibitors may be anodic,
cathodic, or mixed. The anodic inhibitors stifle the
anodic reaction.' Usually these inhibitors are
oxidants which. produce 'insoluble substances
directly at thea~ode. The coat formed is usually
only a few molecules thick and the metal appearance
1)
. I
146
;'.
,j
. ,
~,,:
'~,":
F"=
.'
'
. "'r:=.
If
r--.E
r
I
.........
y H11
~
=
..
.r:
'
,'io.6 MEASURItMENTOI:
CORROSION-EROSION RATE
!';
Vlnl
..
.- '
. '
.,
bi
','
)t:
,
\'
'\
[J
220...,...--------------,
200
>. 180~ 160
r
IL
l-
il
I
I
0::.80'
\
a:
. .
Li
I ,
,I
L't
d
"1 I
"~ I
I i
L
i
,
;
:'~') I,
I '
r-
r
I
=l !
!
[,
120
in 100
i,
!....
,
, ;: 140-
"
60:
40 ~
.. <c
20'"
...' ...........
- ...
o0
2 .; 6
Figur. 10-7
18
8 10 12 14 16
20
HOURS AFTER MIXING
24 26
.
10.6.3 Measurenlent
in the Pipeline
.'
.
..
! '
TIle corrosion spool produces results after a relatively long time interval. The short term corrosion
rates can be 'determined by installing a corrosion
, probe ill the pipe. The probe will be similar to the
one used in the laboratory test. The corrosion probe
is exposed toahigher rate ofabrasion, and therefore
it might produce a hjgher corrosion rate compared
1~8
,~FLANGES
'
TIE ROOS
ALTERNATELY SPA.CED
--.
,,
TEST./
SECTION
,
MADE UP OF:
lOR MORE:
SPOOL
:
'/ ,.
,"
PIEces
IO"LONG:
PIPELINE
II'
f I
II
II
II
I.
:
COUPLING-~
r.
!'
i :
,.! '
<I,r
I,
I
I
~!! :
':,1 '
.,
~
I
I
I
:{jl
<'.~,
.,
!. -...... . .
10.7 ECONOMIC
CONSIDERATIONS
The control of corrosion-erosion in a slurry pipe, line can be achieved either by modifying the slurry
or by modifying the pipeline. For short lengths of
pipe, the use of protective linings could be advan.tageous.tFor long-distance pipelines, the use of
'protecriveIinings lhayfio( be feasible becauseof
higher cost.
, In determining the wall thickness of the pipeline.
certain, corrosion allowance is added to the wall .
thickness requirement based on allowable working
pressure. As noted before the abrasive metal loss is
prevented by the proper selection of the velocity,
solids size consist, and slurry concentration. The
corrosion metal loss is-determined using various
types of inhibitors. Based on these data, a corrosion
inhibitor is, selected" that is environmentally
acceptableand economically justifiable. The use of
inhibitors, linings, or extra metal allowance will
deperidupon economics.
'
S _ D x 7.83
5280 x 62.34
x
2000
,
144,
PYm
1000
- 0.0281 DPYm
Simile
' " .
(Eq. lOA)
.
Mechanical Deaeration
10.7.3
_ (1'+ prY
S/yr.-mi
IH
f.
100
W
- +100- W
Ps
x 62.34
W x 0.01
2000
X 3600 X 24 X 365 F
tons/year
.; .
10-:10,
(Eq. 10.5)
Money available for inhibitor, Mi, is therefore given
as follows:
Annuity
solids throughput,
5.24 PY (m-m') p IW + Ps (100 - Wl!
-4
DV FW Ps II - (I + prY' ' 'XIO
.,
cents/ton mile
11JI"
(
"'_1....."_
I ..
- 2
1O-1PYm .
cents/sq.ft
- .
cents/sq.ft
. (Eq. 10.6)
._
'
11/
, ......
I.
V-
!
,
.. "'T
;~
.,
l--
-~
..
..
u
IV
'~
141
I::
"
t ..
i ..
Tltc:costof intc:;n~llining;i~n~';'~lly~~pre~~ed
as cents per square feet ofpipe area. The area ofa one
mile length of pipe is given as 1382.3 Dsquare feet.
:2:
.. .
I,
..,
M _ 2.81 DPYm
L
1382.3 D
(Eq. 10.7)
";,
10.7.2
0.00536 D 1 VFW P,
W + P, (100 _ W) mH.lion tons per year
M1 -
,.,j
"-
'
"
""M' ." .. ,.
o ue to Corro.lon
!from Ref.
'!(). 11 I
. ISO
,-r---.,..----.,__
:,.-'r~'""'.._7_:.....,?:'_;..__:;,
N,
10-8
JACKSON~
J_,_,
,"
:,'
". '
;'
'l
10.9 NOMENCLATURE
10.8 REFERENCES
10-1 . CrOLAC. 5.. VASII.ESCU. E.. STRETCU, M..
and
JOACHIMESCU, 0., "Metal PiuinJ: Comuion," Imcrnational
Chern. Enp~.. V. 14. pp. 2~4-241 (April 1974).
16-2 BIITER... J. G. A.... A Study of Broden Phenomena, Put 1,W.... V. 6. pp. 5..21 U.nJF.b. I96J).
10-3 BITTER.
Phenomena, Put 2,
1.
't~)
.I
II
,.
I
10.10 PROBLEMS
,
I
Ii
151
Cost of steel. P
Life of project, Y
Rate of interest, 100 p
Corrosion rate of slurry
Corrosion rate of
inhibited slurry
Corrosion rate of
deaerated slurry
Annual operating cost
of deaeration plant
Capital cost of
deaeration plant
Cost of inhibitor
Velocity, V
Operating factor, F
Density of solids p,
Weight % W .
Length of pipe;L
Cost of linings
- 500 $/ton
- 25 years
- 10% per year
- 40 mpy
-4 mpy
-2 mpy
- 2 cents/ton
- $ 3.000,000
- 6 cents/ton
- 5.5 lils
-0.95
-5 .
-60
- Variable
- 5 $/ft 1
ASPECTS
11.1 INTRODUCTION
.'
')
I
This chapter will be limited to discussion. of the
economics of slurry pipelining, It will..be further
limited to materials which will have significant
immediate application for slurry pipelines. Those
materials are coal, iron concentrates.copperconcentrates, and limestone for Portland.cement manufacture. The list will beaugmented by phosphate
minerals when theValep phosphate line ilJ Brazil is
commissioned in 1978. Two factors are common for
a successful application of slurry pipelines to
compete with other transportation modes:
Coal'"
,
- 2,983
Iron Concentrate!"
104
Copper Concentrates"!
20
Limestone (for Porrland'"
Cement)
- 545
.j
'"
r ,
II.
!. . j ...J_
:.i
..'\\.~
_.
I. ... ...,<'
,';#..<f.
\.
."
i
. .. ,.
...
;
t1S
\(NO.,..!!.:!!,!1~~ __51
_.~
-_ -
;....:~.-..-.::
/ . , .
------:.
.J-=====----'-'-....:......:_'--.:--L.-/
ltrl 111) ""
ltl' I'" 1!1' 1'1' "'0 Jtll 'til,' "13 JU' .,IS
.,,~
The second factor limiting this list is the amenability of the material 10 transportation crosscountry in a liquid medium, generally water. For
a cross-country solids pipeline to be practical. the
slurry is designed to be stable hydraulically. This
means, basically, that the particle top size is limited so that the velocity in the system can be kept
to a modest level and so that there will not he
any abrasive wear of the mainline pipe and the
slurrycan-be shu! dO\VII ill the pipeline and
restarted without difficulty.
Previous chapters have reviewed the technical
requirements in transporting these materials and
the physical dimensions of the systems that transport them. The economics of pipeline transportation systems will now be discussed. One important
feature which will be discussed in depth is the'
impact of escalation on tlie transportation costs in
slurry pipelines as a function of power, labor, and
materials cost escalation: as contrasted with rail
transportation .
,
SOLID LIQUID I:LOW
154
.o'i.
';'1]
Slurry Malerl.,
System or location
lenglh
(miles)
Annu.1
Oiameter
Throughput
Inilial
{inched (million tons/yr.1 Operalion
IEXISTING I '
COAL
LIMESTONE
, COPPER CONCENTRATE L
'f
i
Black Mesa
Calaveras, ..
Bougalnville
West Irian
Pinto Valley
273
11
17
69
11
ia,
7
.'(
. 6,
4
4
53
4
1.8
30
9
8
12
'B
4.8.
1.5
1.0
0.3
0.4
1970
1971
1972
1912
1974
2.3
1967
1971
1971
t974
to
1.0
1.8
liN PROGRESSl
" COAL
.!
'It
24
10
38
25
2.1
12
20
10
10
,,-'
;"
'.
t5
2.2
"':
.L~L I
\L
IL
Ll
.............,
____
IN'AOORISS
,I,ANHIO
cppper producers, yet requires only a six-inch diameter pipeline to transport all the concentrate
produced.
I1
Cement, due to economics, is traditionally produced locally from local raw materials. This will
limit the length and diameter of pipelines designed
for limestone.
. Phos ph ,11 e will become a candidate for longdistance slurry pipelines as a result of the need to lise
The physical properties of these four commercialIy transported minerals are as follows:
Solids
Specific
(ira"ity
Coal
Limestone
Phosphate
Copper Concentrate
Iron Concentrate,
1-4
2.7
3.2
4.3
4.9
Maxi mum
Particle
Size; .
8 mesh
48 mesh
48 mesh
65 niesh
100 mesh
AverngeSlurry
Concentration
%SoJjds hy Weight
.50
70
65
55
60
1%
11.2.2 Equipment
As mentioned above, the homogeneous nature of
these slurries; by choice, is such that a buried carbon
steel line pipe, with welded joints, is used for their
commercial transportation. This allows the welldeveloped system of cross-country pipeline construction to be used with the inherent economies of
this production line technique of pipeline installation.
All the commercial slurry' pipelines shown in
Table 11-1 use positive displacement type pumps.
except one: The Pefia Colorada System in Mexico
is a gravity flow system. Positive displacement
pumps are selected because of their higher pressure
capabilities and higher operating efficiency as compared to centrifugal pumps. Commercially available
pumps for slurry pipeline service range up to about
1750 horsepower with annual capacities per pump
of three to five million tons.
EC:ONO~IIC
A~I'EC:TS
AND flNANCIA I.
100
.'
80
I,
,
"- _.
'
60
t40
- --
--
I-'-
'"
w
w
. _. ,
'O~I.;;.-
,V ~'\~;;'-;:;-
I-
:>!
./
10
0:
/.~1?
\)~I:.\)
\~G'
~111.COG
'
COG~\G'''''' .
I:.
~ --
v
./
~
, . .,~I."
Do
::
=v
.: 20
.'
,':,<.
~~~~
"". 4~S'\\),
:\~
,.
'~'\~
~I:.<r;~
\\I:.\) G\\G'
"
~<r;
.,<;/."
,\.
...:-
- - .- -
',,',
"
., ..
9S~
Operating Factor
Velntilv :05.5 fps
Solid, ConclIJnlrations - Weight %
0.2
0.4
0.6
0.8 1.0
2.,0
,4.0
"
"
2
6.0
8.0 10.0
,..
'
40.0
20.0
..
$fURy
"pelfn. - Wat".Requlrements
---
158
MINE
OEWATER
stURRY PRE'ARAHON
fNO USE
COAL
SURFACE
.,
MINING
STEAM
POwlR PLANT
00
TRANS
SlIIrMfNT
..
IRON
,
Q;
;;
;;
..'"
~
TRANSPORTArlOH
DEW",En A
PHlHIZE
.:;:
COPPER
illASl
FURNACE
'"!::
!::
..
:
Q;
;;
.'
rRA"$PORTAJlON
DEWAnR
M
M
.
'"
e
SMHTER
!::
.
..
LIME STONE
:1
..
,-,.'
'RANSPORTAJION
_.
-
.
BlEND Wit u AOOtlIONA.l
COMPONENtS - fEED TO KilN
since the coal must be ground to pass 4N.mcsh before entering pulverized coal fired boilers. The coal
application provides an opportunity fur the slurry
to be designed for the system, taking into consideration the coal cleaning. slurry prcpamtion.transporration. dewatering, and utilization process.
11,4 ENVIRONMENTAL
IMPACT
The photograph titled "Along the Route of the
Black Mesa Pipeline" (Figure 11-6) visually SUIIIjnarizes the environmental impact of slurry pipe'lines. The impression given is one of little or no
effect-of the pipeline system 011 the environment
and this is, generally speaking, a fair assessment of
'the situation.
. Cross-country pipelines. including sluuy pipelines, are buried 2112 to 3 feel underground. They
are out of sight and silent. rum p stations ale usually
"electric motor-driven, hence have no effluent gas.
ECON()~lIC
~
~
I
- ~_.,-,-.........':!.
'.,
:~f
....
.
'
'.~:
....
l'
:~~.
',
....
"
.-'
,j
'
-,
"
<iI
..
.....
,
... ,.
,..'.
........
-.
..
..
~"
'
'
, "
'". .'
'
.. '-
I
I
7-8
COAL CONVERSION
1-2
COAL SLURRY
=,I
I
1975
TOTAL "NEW"
CONTRACTS
ITEM
ASSUMPTION
I.
Revenue
9~'9Y2
9.0
90,000
Mills/Ton Mile;
TRANSPORTATION COSTS
Crew (train
and locomotive)
Fuel
'Termintll.Loadi.ng and Unloading
Indire'ct.:Labor :Co's U
Total Train Op~ratQrs .
MAINTENANCE
Locomot ives
Freight Cars
Total Maintenance
Depr,
. Interest
3,000
3,000
1,900
21.200
3.200
Track
Other-lilt!'. Shops and Suppliec;
EQUIPMENT
Freight Cars
6,300
7,000
320
23.000
2.000
28,000
i'
Ii
"
2,400
2,400
4,880
244
5,124
Locomotives
'i ..
Depr.
I
Interest
add5%'down .
Total-locomotive exp.
TotalEquipment
MISCELLANEOUS
Indirect Taxes and Exps.
Misc. Overhead
'Total Expenses
As a % of Revenues
MillslToiiMile
3,000
3.000
6.000
~
6,300
11.424
2.100
3.000
400
66.644
74.0
3% revenues
5% revenues
0.4% revenues
7.4
Table.113 Revenueand Co,t ProJec:llons for Burfing10n North,;" Railr~ad, U~S.'A. Per U'nit _Tral~ Round Trip Hltul
IOerlved from Ref. SI
H;ONO~IIC
..
..."
...
.
'O.
161
y----..,.---
-,
.,
j'
u
"
RAlL .TOOll'UlU!'
!,.
..
"
"
J '''AGE . Slllll.4llES
"
HOIf
.:: ,
A.Jt","I1t""8"""~,,,,"I~.~ ,~"..
r" ..
"
"" ...
".l----\------C.----------l
1:"';S
',"
tIll
AHIfUAI'HAOUCH'UJ - Moff,...
I
-.
'O
"
r....
"
. .,
..
'.'-
1-
<I
(.. . ,. . ;'C.:) I
. I
-:
! I
.' I ;
=1I
0.1
O.l
0.4
0.6
0..
1.0
'.0
zc
:,':
lIm;""~n.
6.0
a,0
10.0
lO.O
16l
.,
11.5.2.Escalation i .
The most important aspect.of a slurry pipeline
., from an economic standpoint is its low escalation
rate. The pipeline capital intensive and rail is labor
intensive. For example, in the United States a 1000
mile,25 million Tq'(coal slurry pipeline system will
require only 325 Ten for its operation and maintenance. while the ,ailroad willrequire 2575 people.
Man-power and otlie~ resource comparisons ofpipelines versus unit tfains for this case are shown in
Figure 11-9. The following is a summary of the
slurry pipelin.ecos~breakdown between fixed and
variable costsgiven by MONTFORT et al.(7)
i,
~AI~
\.."
'7.5 ..
nAIL
5.5
Oi~ll FU4'1
.;.;,j;$28elfl'.
RAIL
1.'
__ fl4/Icm
. Sf EEL
REOUIREMENTS
. 'RELATIVE
ENEROV
RA~Y
costs
6%
5%
5%
100%
Total
Ratio -
Western AAR
.'960
1961
1962
1963
1964
1965
1966
1967
1968
1969
1970
1971
1972
77.4
79.7
81.7
82.2
84.4
89.7
93.0
100.0
105.1
111.6
122.8
134.4
145.5
163.6
187.4
/1973
Co, Fud
MANPOWER.
REQUIREMENTS
Variable
Power
Labor
Supplies
84%
Fixed
1974
Average
%
Change
GNP Dellator
Index
%
Change
% Change
AJ\R Indexl
GNP
Deflator
103.29
10~.G2
2.97
2.50
0.61
2.68
6.28
3.G8
7.53
5.10
6.18
117.59
122.30
128.20
1O.0~
135.2~
9.45
8.26
12.44
14.55
141.60
146.10
154.31
170.18
105.78
107.17
108.85
110.86
113.9~
1.29
1.11
1.31
1.57
1.85
2.78
3.20
4.01
4.82
5.49
4.70
3.18
5.62
10.28
2.30
2.25
0.47
1.71
3.39
1.32
2.35
1.27
1.28
1.83
2.01
2.60
2.21
1.42
1.89
'on
30 YEAn OI)EnAJlON
Figure 11 9
1.1
.'
Power
Labor
Supplies
I
!
period of time could be expected to produce reactions negating the basic parameters.
1.0
1.3
0.7
:'
Pipelines are relatively insensitive. to escalation
due to their capital-intensive nature.
11.7 ADDENDUM
The following discussion only applies when' the
..
':.~.
~~
;1
I
..
--'
-"-'
--1-'
......
.
"
..............
'.1"\ue
'''(lIN(
"
II
"UR
"
Flgur", t, '0 'nfl,tlon Effect on Coat T,amport CostsBasis 3.6% GNP 'nflation R.t.
"
In any.year, the capi\al charge will be the summation'of Debt Interest. Cost + Gross Return on
Equity' + Annual' Amortization Charge + Ad
Valorem Tax Charge.
includes Income
In
'. I
I
I
F, ($/ton) - C [
(F~
will be:
I
I
For the last year, the capital charge (F,) will be:
.,:
(D) (1)
(I-D) (R)
F,. - C ( 100Y +100 (1- T)
Mich. (19;4).
V
+ Y+ '100 J
11.9 NOMENCLATURE
1 +-~
-C (D)(I)(Y+I).+ (I-D)(Rl+_
100
2Y
(I,
T)
IOU
Y
100
.
,
C
D
F
I
R
T
V
Y
U.lO PROBLEMS
11.1 Determine the levelized capital charges for a
slurry pipeline project based on the following
data:
Ii,
:!1 ~
I;,'
U.S REFERENCES.
11-1 1'J70Millt'I;JI, YC3rhuuk. V. W,
Olflce (972).
If,)n~r''Il.llinil
us,
(jo\'crnnu:nll',illiinte
lI-l MONAGIIAN. U. Moo "Iron Orcin Canad". 1970... 19110,CJIlJ,di.an Miiljl1~ sud M'f.11Iurt:i~al Rul!clin;-pp; -S9-100{Otl.
1971;.
CIIl:Rlie,t1
APPENDIX
Sr F~~lIrr A-/
.j
.~
t
l
L
,
l-
,L
-5.0
<P - volume fraction solids
-0.25
.. p-2.0
i
Next find the density difference,
Ap -P,-P
-3.0.
,~
,. '-:)
;:"';:.~
"'cr'
'~':I
ir-
.1
-.
!
,
'=="7 i
Sa Figttrc A-2
--
P flUID (gm/cm 3,
i
"
It
Iii
.:-"???? ?
b\r.:
ew "u.
"-d
tiP (gm/cm 3,
o
llJ
C'
!
"
!
"~
- -',"
V'~ ..,0>'.00
, ,,0
~(i i i i Ii
lao
(oJ
a PIVOT AXIS
"
W
,
....
.""
j
,fJ'I 0''''
I
.'
$'D~
0.0.
<1
. "
.:;::-=
W
,
ti~
"c -c
~~
"-d
,
,!"
0.'
<10.
>w
, '", , , , ,
,,"'w
,.:.
Il POISE
-I
O',""O"DO
, , ,
,'''''
I,
1
1
\
1
-,
'\ 1
Y
1
1
1=
ft,)
"u.
"''''''''0lJ''''''
O'
\
,!
,.,c ..,c
""
0
,0
"
. !
l i,
Il POISE
! ~;
i
I I I I
iii
w " "
iii iii
'"
',"
~"
~,
.~..
II
."
I (' i
VI
'"
I I
"'..
":V'Ch"'''~O
I"
.w
-.OIt""ChUo
"
i".'-Vow
I
...
Ul
) ) )-
\
\
\
a PIVOT AXIS
/
/
0 0 0 0 0 ....
u.
,
~ :"'o,~o
I
1 ,
V.I
Ntw
0/;'" (,
.f!
P FLUID Igm/cm 3)
d
,:,
o.!
<1"-
Q,d
"
::N
a c
(,";) en
>w
"
I
I
II
i
. ,I
I
i
I
I
F!(W;
I
JOHN 1'. KENNY, Project Manager in the pipeline design group of R. J. Brown and Associates.
During the last ten years he has participated in
various slurry pipeline projects, from feasibility
studies through pipeline start-up.
He is currently involved in the design and installation of off-shore pipeline systems.
He holds a B.Sc. (Eng.), Chemical Euginecring from
University College London, where he also undertook three years of postgraduate studies in the
turbulent flow of suspensions.
,-,
I
L'.
L
L
L
L
SOLUTIONS TO PROBLEMS
CHAPTER 2
z.:
F.I'.S. Systcm
Metric System
Q - 954 lll'/hr
1 felsec
- 4.200 gpm x 448.83 gpm
- 9.36
re Isec
v- ~ -
A - 0.156 Ill!
v-
5.6 ft/sec
1.7 m/sec
- Lcp, - 10-)
Reynolds No., Re -
- 1000 kg/nr'
L
L
- 0.265 nr'zsec
.: hr
3600 sec
,
.J
L
L'
Re -7.6
J.I
N. sec/lll!
x lOs
L.
j-0.00375
4JV!
IJr/L - 2gD
--
Friction loss
4 x 0.00375 X 5.6!
2 x 32.2 x 1.458
.-
4
2
- 0.005 ft/ft
- 0.005
x 0.00375 x If
x 9.8 T x 0.445
111/111
x 0.005
I
.
111
.,
583.5
Power -
.!!?.sec
x 294$
~
kW
. 265 -se-c x 900 m :{.O 0(j806 kg m/sec
Power - - - - - - - 7 . " : , . - - - - " ' - - 0.7
ft Ib
550 - - - '. 0.7
sec. hp
- 3.11 J kW
- 446.1 h~ :
.
'.
;
I .
I,
.
r~'l
;. .! ~ \
.
265 x 900
or Metric hp - 0.7 x 75 - 4540
J.:
16
16
. ."..
.s
_c
2.1 x 10 .
0.00375
<
- 2.8 x 10-'
lim
(m/m)
This shows that laminar friction 16ss for this case is only 0.56% of the total friction loss.
2.3 If in Example 2.1 the Iluidis other than water, with a viscosity of 0,0135 Ibm. sec (0.02 kg/m. sec) and
density of 73.5 Ib/Ii) (1180 kg/nr'), determine the friction losses, friction velocity and thickness of
laminar sub-layer. '
6.72 x 10-'
73.5
0.0135
x 62.34
- 4.46 x 10'
For e/D -0.0001 'and Re - 4.46 x 10', the value of
. friction factor'
friction loss'
- 0.0054
_If _ 4jl"
L
2gD'
!!l.
_ 0005
L
.
if
1...'
IJ
L
L
,,
I'
.i;
) i
SOLUTIONS
1',1'.5, SI'SICm
Merrie System,
Friction loss
"
L
L'
L
-<,I
L
L
I
,J
LlI
Ll
L!
n lluid
O,Oll72
0529 lb/Ir' fi
73.5 lb/Ir'
'<--Iluid
m lluid
1180 kg!rll'
N/m'
Ilr - 0,0072 ----"" / '" - .._- / ----..- III
m lluid
0, I02 kg/m
rt
0.529
Ib
it'
m-nl
I'
tricnon ve ocuy,
III
4
- 9.27 N/m'
- 0.1929 Iblft'
C'
'
1.458 ft
ir _ /
9.27
1180
- 0.087 in/sec
- 0.29 ftlsec
Thickness of laminar sublnyer
"
0.02
0.087 x 1180
5 X 0.0135
0,29 x 73.5
-0.0001 m
- 0.003 ft
2.4 Based on VON KARMAN's similarity hypothesis prove that the velocitvdistribution in turbul
now of circular pipe is given by the following:
where Von is the maximum velocity at pipe centerline, V is the velocity at a distance J' from the I
wall, k is von Karman constant, '. is the pipe radius and /I' is the friction velocity,
dl//dy
- constant
d '/1/dy'
IL
\I
,
'j
But r
-'w
,
!
2
,
( I - Jolr.)'I' an d,{II,
d/ IS negative
dlllidl
,', (dilld.J,)l
k
- - 11*
I
VI-Jolr.
, I
~ r----- - - - -2k -I I - y/r + const,
'dllidy
II'
Now, as y - 0, dllidy "" very large quantity
,I
"
,', dllidy - 0
,', const, - 2krulll'
,"
1-
Yl- Jolr.
II
aty -
TO J It -
11* [ VI - J'I", + In (I
-T
Um
,'.Um -0
,', II
or
VI - J'lr..) J+ const,
TII' [ VI - J'lr. + In (I
+ const,
I
- y'l - J'lr.)
1+
U"'
SOLUTIONS TO PROBLEMS
CHJ-\PTER 3
3.1 To determine the settling velocity aLI spheric. I particle having a density or I (,5A Ibn/Ii' (2.650 kg/rrr') in
water at 611 OF (20 e). The particle diameter is 0.0197 inch (0.5 mm),
..'
,.
For water at 68 OF, the density of water is 62.3 Ibm/ft J and its viscosity is 1.08 x lO,s fr2/sec.
As a first step apply Stokes Law:'
g(PI-P')d 1
18 pr\'
71' -
--
where:
32.2 ft/sec 1
165.4 Ibm/f!'
62.3 Ibm/fr!
LOll >( lO's ftl/sec
- 0.0197 inch - 0.0016~ ft
g
P.
P,
v
..1t1
32
(165.4 - 62.3)
j8x 62.3 x 1.08 x 10"
1.08
>(
10"
CiI>.R e -
'!&Jp. -
Pr) d'
i
.\p, v "
I
;/J
-,
- 26R7
,.
;:: ~ .
I:,
180
f
Now
1f'd
Re-'v
,'.1/1 -
- 0.263 It/sec,
,
;
For water at 20' C.the density of water is 1000 kg/m s and its viscosity is 10-6 mT/sec.(As illustrated in the
solution for fps system of units, Stokes Law is not applicable).
Determine the diameter term
I
Ci R 2
4 x 9.81 x (2,650-1,000) x (0.0005)' _ 2687
n e - :
3 x 1000 X 10-11
.' - ...
Referring to Figure 3-2. read the value of Re - 40
, ., ,
r,
3.2 Given d - 0,00082 ft (250 microns)
Dele~lI1jne
1t'.
",'Ii
SOLUTIONS
i)
1'.1'.5. System
L
i; L
i';
,11
dn
0.00082 ft
-0.00025 m
I'!
I~ L
s> 32.2
I:
L
L
L
I
.:;:'
.~~~
- I b
.'. C, -
1f X
(0.00082)3
6
(I.Oll
.'. 1" -
-.0328 m/sec
- 0.108 ft/sec
it,
3.3 Assume the same particle as in Example 3.2 except that the nominal diameter is to be derermi r
Cw'" 2 x
111
J2'~0~1~8~~ X
; 2 x 9;ill x 10'
(0.0328)'
IO-
-0.56
- 0.56
/
~.
From Figure 3-6, for C, - 159.0 and a shape factor of 0.7: Re - 8.2
1'.1'.5. System
=1
tt
I
L
10-')'
- '159
2 x 32.2
- 159
~"I
m'/sec
. f
, I'n
.;.
- 0.00082 ft
I~Z
3..l Assuming that rhc.parricle given in EX;IJ1Iple 3.Z settles in a fluid of density IZ4.1> Ib",/II \ (ZOOO kglIll')
and viscosity 3.2-1 :< 10' fl: Isec (3 ,.; 10-; m'/sec). determine its settling velocity.
The value of P< -.J!!... for this
PI
,'.
C< - 159
.>(
GISC
.'
0.5 I'
-Z-,;"
I)
9iiir
- ( .II'~-l
,,
'ii
First determine the fall velocity of spherical particle.
1'.1'.5. System
32.2
-18 x 3.24 x
10-' x (0.00082)"
9.81
- 18
x 3 x0.510" x (00025)'
. 0 .
- 0.00186 ft/scc
.', Re - 0.0048 .'. Stokes Law is applicable and therefore no correction for shape factor is needed.
(See Fig. 3-6).
.'. Settling velocitye- 0.00186 It/sec
- 0.00057 m/sec
3.5 Determine the value of drag coefficient for the particle given in Example 3.2.
,.j
F.P.S. System
j
4 x 32.2
[<~~- 3 x 0.108/ x; 2 x 0.00082
!!'~
;
....
-6
CD-~
310
4 x 9.81
- 3
(0.0328)'
0.00025
-6
3.6 Determine the value of drag coefficient for the particle given in Example 3.2 assuming that its shape
factor is 1.0.
In Example 3.2, the value of C. was obtained as 159. The corresponding Reynolds Number and drag
coefficients from Figure 3-6 are 9.5 'mel 4.3, respectively,
I~,
1
I
~.
,\,7 Determine the sell ling velocity illld drag coefficient Ior a !OO micron diameter spherical particle having
.1 specitic g"wily of 5.0 i~1 il slurry having an effective density of 2000 kg/ l1/ and an effective kinematic
!I-
I-
'
tI
1(1
-18 x
5-2
.J'
2 x 2.5 Yo 10-" x (10 ).
- 3.27
10'> m/sec
100 pm
I ()"J m
9.81
1(1d
Re -
v -
3.27
2.5
10'> X 10"
X 10.6
- O.1.l
I
I
qi0
I
I
I
I
-I
I
'I'
SOLUTIONS TO PROBLEMS
CHAPTER 4
.1.1 Giuor:
c. -
60. I
p, - 5 X
I gm/cm',
pw - I gnj/cm'
p .. -
!.
c. + 100-Cw
p,
(Ell. 4,1)
pw
100
---60 + 40
- 1.923
(Eq. 4.2)
0.6
I'
I
I
1.923
5
- 0.231
i"
,
.
Volume of solids
Volume
rauo
-V"I'
f ,.rqUl'd,
0 ume 0
- 0.3
.I
we get
c, -1001"(
!'n. -1")
Pm
- 100
P'-PI
IJI
82-74.8
--I
--_._)
. 82
IJ 1-74.8
- 20.5%
c.-Cw 1"Pm
- 20.5
(Eq.4.2)
82
131
.
- 12.8%
c.
<t> -100-0.128
<t>
....
j,
i.
h
~
4.3 To determine the viscosities of the slurries given in Examples 4.1 and 4.2, assuming that the slurries
exhibit Newtonian rheology, and slurry temperature is 68 0 F. The viscosity of saturated brine at 68" I: is
2 centipoises.
a. Example 4.1
The volume fraction of solids </> in this case is 0.231. Referring to Figure 4-1 or by using Equation 4.6. we
j
obtain
p ... - 2.24
po
po - I centipoise
:1
=[
i
I
b. Example 4.2
The volume fraction of solids </>in this case is 0.128
.'. /.1m _ 1.51
/.10
/.10 - 2 centipoise
4.4 To determine the amount olheat required to heat a coal-water slurry containing 50% coni by weight from
an initial temperature or7ll' I' to a linalteml'eraturc or 120' Fgiveu that the specilic heat or coa I is 0.3 Btll!
lb OF and the slurry flow rate is 4000 gpm. Specific gravity of coal is 1.4
Gi1'(1/: Q
- 4000 gpm
,,
Cps -IU
Crm -
+ c, C"I
C,_, C"
100
0.3 :< 50 + 1
100
- 0.65 Btll/ib
50 + 50 - 1.167
1.4 -1
'j.
50
100
:I
4000
1.167
1.167:< 8.34lb/min
8.34 (120-70)
0,65 Btu/min
- 1,264,900 Btu/min.
4.5 If the Btu content ofdelivered coal is 10,000 Btu/lb, what percent of this Btu is used in heating the slurry
from 70 0 P to 1200 J considered in Example 4.4.,
Mass flow rate of delivered coal:" 4000
.', Btu of coal delivered - 4000 x 1.167
X
X
1,264,900
100
6501
- 194,655,600 X
- 0,
,e.
4.6 Givm:
To Find:
...
SOl.UTIONS
Now
,[
\. II
,r :
I
I
I
\1
.
,,,.
,11
2nRh'!Jp
"'--h - ~ -
,[I
lR/D
.";;J
(R e - Rh ' )
., .".,'
'>1
. '.
( Rh )! _ ( ~96
n;
3.13
.
..)'hob-
f _ 0.894
15.92 x 2
.1
0.106 -300 sec
4.7 Suppose that f~~ particular co-axial cylinder viscometer the viscosity corresponding to 100% scale reading is 64.7 centipoise. Find the shear stress at the bob jn Dynes/em! for an 89% scale reading. for the
configuration given in Example 4.6.
",i
Now. r - py
At 100% scale. p - 64.7 centipoise; therefore. for 89%' scale, p - 64.7. x 0.89 - 57.58 centipoise.
y.". - 300 sec" from Example 4.6 ,
.'. r - 300 X
57.58
1
1iiO172.7 Dynes/em
:.;
4.8 First convert the scale .readings to shear stress in Dynes/em! by rnultiplyi;lg:the scale reading with 1.858
Shear Stress
Shear Rate
(sec
ol
=1
iI I
I'
I
i
,:1.[. 'J
;;'11
(I5}"lcs/crn
11.2
15.0
19.7
26.3
34.7
50.0
67.2
88,4
117.9
:155.6
225.9
30.1.3
21.6
26.3
31.6
38.7
46.5
58.5
70.3
83.0
98.9
117.0
147.2
171.7
!'I i
!I
,.
SOI.lIl-I.IQIIIJ) FI.OW
INS
Plot these data as shear stress versus shear rate as shown in Figure 4-13.
The shear stress of interest is 100 to 150 Dynes/em'. Fitting straight line through the points Iyin!: in this
shear stress region. we see that the line intersects the shear stress axis at 50 Dynes/cur', which is the value
of yield stress.
,
The coefficient of rigidity is given by the slope of this line which is 0.427 Dyne-sec/cur'
"
T. -
50 Dynes/cm l
As can be seen from Figure 4-13. Bingham plastic model does not fit the data outside the shear stress range
of 120 10 24G Dynes/emf,
N 200..----------'-----,
~
1l 150
e>~ 100
w
a:
In
a:
-0:
w
iJi
,/'..t
50
,/
'COEFFICIENT
OF RIGIDITY.
11- SLOPE OF THE LINE
0.427 Oyne - stc/CID~
"
...!
..
VIELD STRESS.
....
~:.;'::
TO- 50 Oyne/cm2.
...
0+-.1---'--...:..--'-------1
o 50100 150 200 250 300 350
SHEAR RATE bec- 1)
shear slress
,,- shear rate
-,
Shear Stress
(Dynes/em")
Viscosity
(centipoise)
21.6
26.3
31.6
38.7
46.5
58.5
70.3
83.0
98.9
117.0
147.2
174.7
193
175
160
147
134
117
105
94
84
75
65
58
IL
IRQ
SOI.lHIONS
Figure 1-1-1 shows rhcplor of viscosity as a function of shear rate, (Note that the material is shear thinning),
Ii 200.,,--\- - - - - - - - - - - ,
II
.~ 150
E
~
;;;
en
LI
I
,
50
0-1-------.,------1
o 50 100 ISO 200 250 300 350
SHEAR RATE ISec- 1)
,"II :)
- 100
4.10 T" lit the Power Law model. 1'101 shear stress versus shear rare on 101(101( paper and determine the value of
n as the slope of the straight line passing through the data points,
.
.,~<.-
~l
Figure 4-15 shows a log-log plot of shear stress versus shear rare.
!
Now (or Power Law fluid. log, = ,,'logy + log"
~.
')
;'''.':..:~
'L!
~!; .!
, i
At
'1=
.'. 1I~
0.63
,~
I'
I
It can be seen (rom Figure 4-15 that the rower Law fits the data quite well. The value of effective viscosity
versus shear rate is given below and plotted in Figure 4-16:
Shear Rate
(sec")
Effective Viscosiiy
(cenripoisc} . ,,:
,(b)""
r
=
, i
.~
T
I -
r.,
i
)
11.2
15.0
19.7
26.3
34.7
50.0
67.2
88,4
117.9
155.6
225.9
303.3
198
177
159
141
126
III
99
90
81
73.6
643
58.1
i'
Inti
,..
"
3x 1 0 "
0 '
-,-
-;-_..,......,..,
PROBLEM 48
: ;
-'-_...:....--:..-1
1 xl0CJ-1dO
x1 0 0
Sx100
11
,!
.. -
'00.-
150
.~
100
(;;
u
en
50
100
150
200
250
300
350
SOLUTIONS TO PROBLEMS
CHAPTER 5
5.1
Let
dC dC
dVR
1 dVR
------:<----(I-C) . I{)' dVR
I{)'
I{J'
Now
l d VR
.
,(I-q -.d-+(I-q CX
.I'
dVR
I{)'
C'
I-C
i.e,
,-+-lU-O
r.e.
dVR
E.--+
IIR
I{)'
1t'-()
.-.
-
X 7U-0
". ;1
.:,,1 r>:
'l",
VR
log 11& - -1.8 Z.
5.2 Giuen: D .. I Ii
V - 6 (tis
rw - 0.2 Iblft 1
!
.:;
Now,
log
s;..C:, -1.8
lit
I (jJ;m ')
(Eq.5.8)
where
fl
... J.()
-0.38
n"
-l~~&
ClC, -0.7
,.
.'. 7(1 -
(Eq.5.12)
0.083/ IfP
,!
where
;{' ~ settling velocity of solids in the slurry
p - density of slurry, Ibn/fe.
The maximum particle size is given by the diameter of the particle having settling velocity equal to 'i',
The values of 10 for the four different materials are given as follows:
Material
\Vt.%
P
( ib/ft')
Coal
Magnetite
Copper
Limestone
50
60
60
60
72.8
120.0
113.5
100.3
1tJ
( ft/scc)
0.0097
0.0076
0,0078
0.0083
,,"
, ,
~
j::
';"
Assuming Stokes Law. the particle size is given by the following equation:
.
",
"_/_18
g(p' .... p)
f.J7t1_
Materinl
Coal
Magnetite
Copper
Limestone
-,
( 1f:'~"tJ)
i f.J
( Ibm/fe-sec)
d
(Ct)
1"tlp
Rc - _.-
87.4
312.0
249.6
168.5
0.0168
0.0067
0.0067
0.0202
0.00250
0.00039
o.os
0.OOO~6
0.00117
/I
0.1
o.os
o.os
SOI.UTIONS
log
~-
fI ")
Now,
where,
f)-1ft
g
- 32.2 fl/sec l
(Eq. 5.1.1)
1f
--Xg
0.-1
67.8
542.0
0.6
1830.0
0.2
1{1
(p. - p) pi
fI
C;,
111
He
( fl/sec )
0.0738
0.164
' 0.246
4.5
20.0
45.0
Ci,
8.5
3.5
2.3
4
Now calculate the value ofbr fordifferelll values of Vusing Equation 5.13.The results are tabulated below:
;
!';,elide
br for Velocity -
Sill: (null)
12
0.2
0.0507
0.07,14
0.0925
0.0743
0.0902
0.1022
0.1
0.6
12
16
0.1150
0.639
0.775
0.864
0.774
0.963
1.0 II
1.047
0.1268
0.1359
0.853
0.908
Next e;tleul.teC-i'C"
Panicle
Size [mm)
12
16
0.2
0.4
0,6
0.281
0,099
0.045
0.353
0.123
0.052
0.434
0.170
0.077
5.4 CICA is given by Equation 5.8, The valuesof the sell ling velocity of solid 7f' and the friction velocity 11*
should be calculated to determine CIC".
Estimate 'if 1U
Particle diameter - 0.1 mm - 3.28 x
Hr' ft
- 62.4/(0.4515 + 0.55)
. fluid density
Ib..
- 97.5 Ii'
Fluid viscosity
.. :/
.' . -: Diameter term
(
,'\
t ;;:j
1.::1.;.
- CuRel
-70.2
.'. Re - 2.5
,'. 7U
Estimat
0.0525 It/sec
Ii;'
11.045 x 32.2
-I'
97.5'
- 0588 It/sec
.',
..
1'1,'
5.5 Tho inclusion ofclay iucreases the viscosity ofthe slurry which in turn reduces the settling velocity "hand
particles. Thus the value of CIC;, will increase due to the inclusion of clay, First estimate settling velocity
of sand in water.
'
"
J.I -
, Ibm
1.2 CI' - 8.06 x HI" ---ft/sec '
i
- 62.4
p,-
.)
I(r'
Lfb~
r
1654 Ibm
it'
'
I'
- 375
is 15
Diameter term
_ 375 x ( 1.2 )
2 ,
'
"
- 8.4
J:el,!
- 0.059 ft/se~
0.5 fr/sec
r
,I
"
i
i
III
sot.tn - I.IQ.UIO
"'6
FI.OW
5.6 The fi-iCdon\"c!odty 1f~"'(U5 It/sec. The setrling velocity is estimated using Stokes formula. (The particle
Reynolds Numberwas found to be less than 1 in all cases).The CICh values are estimated as shown in the
following table:
I'
Slurrv
Settling
Conccnrrariuu Vdocil~. 1('
(Wt ....)
(It/sec)
45
50.
55
3.16 x
2.86 X
1.66 x
5.50 x
60
10,2
10,2
10-2
10')
ClG.,
0252
0.287
0.486
0.187
?i
I,
If the CIC., at 45% concentration is to be made equal to that at 55% concentration slurry, the settling
velocity of solids should be made equal in both slurries,
For Stokes Law, 1U varies inversely with the slurry viscosity.
:1
:;
. ,,
3.16 X 10,2
,'. fI - 1.66 X 10-2 X 2.8
.- 1.904
x 2.8
-,
SOLUTIONS TO PROBLENIS
CHAPTER 6
6.1 Gitvn
fl----
60 +40
2.7
-,
- 1.607
<. '
I]
Diameter. D (em)
Nile
2
20
40
5.1
5.1
2,1
10'
10
10'
Next determinc the vahle of thecriticalReynolds Number by referring to Figure 6-2. The laminarturbulent transition velocity is obtained by using the following equation:
,
,
v, [em/sec]
Diameter,
D (em)
, 2
20
40
5.1
5.1
104
10"
2.1
10'
6.3
2.7
4.6
X
X
X
10'
10'
10'
135
58
49
The effective viscosity for a Bingham plastic fluid is given by Equation 6.6
ro D
p.-,/+-6 V
i.e,
(Eq, 6.6)
VDp
_
R
roD
'/+ 6
I
:\{
"'I
~,~
roD
.. V. D'P - 30lJO ,/ + 500 V.
i
\I~ 2 _ 3000 'II~ . _ 500 ro - 0
t.e.
Dp
.' .
V. _ 1500 '1 J
, Dp
.. ISOO 1/
Dp
i/ ()OO()
11)2 + 2000 r
Dp
p
2.
[1 + /1+ drol?]'
4500,l
SOI.UTlONS
(d for computing laminar-turbulent transiti~nvelocit). the coefficient of rigidity. '1. and the yield stress z..
need to be evaluated. Therefore, compilte the rate of shear, 8 V/I). and the wall shear mess rwI) - 0.812" - 2.06 em
8 II
IF
Velocitv, I'
(em/sec)
(sec")
rw
(Dynes/em")
"j'
i~
347
323
297
226
181
137
89.3
120
36
44.2.
;;1
\.
I'
.J
iI'
1
1,348
1.254
1.153
878
703
532
347
466
140
172
287
241
186
152
109
69.8
51.2
37.5
12.2
568
477
368
301
214
13.8
101
74
24
570
516
434
278
180
105
73
82
57
60
.' - ..
_.....
..
i
352
260
167
114
63
61 .
57
59
51
D - 3.05" - 7.75 em
83.3
70.4
50.0
26.5
'14.3
7.7
9.8
86.5
72.7
51.6
27.4
14.8
7.9
I
10.1
66.5
57:9
66.5
66.5
60.8
40.5
49.0
="i
Next plot the wall shear stress rw as. a function of rate of she or 8 V/D as shown in Figure 6-9.
lOU,
From l'igure fi-9 we get the critical rate of shear 8 I',I/) as.the value whenthe linear portion of CUI ve ends,
The values 01'8 I'~//) lor the 2.06 em and -1.04 em.tubes are 465 sec-land 2 15 scc'", respectively, There are
. no tutbulcnt.datafor the 7.75 em tube.Therefore, the critiCal velocity lor 7.75 CI1\ cannot be estimated.
The observed critical velocities are:
2.06 em tube,
4.0'1 cm tube.
I,~ I'~ -
120 ern/sec
109 em/sec
The laminar flow data for all the three tube; faU on a single line AB show,; in Figure 6-9. The intersection
of this line with the wall shear stress axis gives 4/3 times the yield stress.
Therefore. yield stress r. - 37.5 Dynes/em'.
The cqel1icien't
of" rigidity I/is given by the slope of the line AB.
I
,
','" ,i'
Therefore 1/ - 0.067 poise.
:W'
",~.
Now:;~bmpute lh~ilaminar'turbulent transition critical velocities for the three tubes by computing the
Heds(rolu Nuinb,:, and the corresponding critical Reynolds Number. : .
~::;
n:,'.; ',r
Llcdstrmu Number
Critical Reynolds
Nile
Number N'
(em/sec]
2.06
4.04
7.75
5.7
2.2
8.1
5.770
9,260
14,600
117
96
79
X
X
10'
10'
10'
5UO
PAO,WIUJ
'"i 400
E
IN'
--
>
iHiYiiiosulus ,...'J
.SfJJ'll~JtrSl .... I
(OI'U("", 01 IIfGIOf" or' StO" ortll'f
""'''''01$1
.."
o~, "'''',10''
,! 300
;
.:
100
~.,
.
:'"0
:~
";',
"
a'a
.
- - - --_.-
~fE~!'!!
O-If"...: h"
A_c ...... h ..
200
'"
,
.:
fZ'
200
300
.:.
a
~
l:1~
.i
.-
._--- .'--.- ..
.....
.--
->
-:
...,/
400
500
600
700
nATE OF SIlEAR(SV/D. S-I,
__._--
.
..
..
SOO
900
1.000
SOI.UTIONS
201
'.Pip!, diameter, D. -
ft.
I
I
I
i:
I:
ro plf
Hedstrom Number. Nile . -::1'1
- 7,3 X 107
0.422
II -
2400
1.61
.'.
V~
\Ie 1.S78
X
89.4
1.1323 x 0,3
X
- 5.5 ft/sec,
n -
x 10" lbr-scc/It 7
r. - O.W, Ib,lft 1
1.81
- 2.78shlglli .'
lU.!
(rtfscd
j'
r""""
12.5
S.U
1.25
Rcvnolds
No.
N.,.
Friction
Factor
Pricrion
toss
(rt/rt)
ZOOO
80U
200
U.O u
O.05U
OA8U
12.1 U
7..16
4A~
L"UI Modd
J>
16/N < e-
' ,.
N R.
- 23.8 vt,SlI
Velocity
(fr/sec)
N.<
Friction
Loss
(psi/mile)
12.5
5.0
1.25
0.0125
0.053
0.473
1280
302
34
1\.63
7.91
4.41
c!
I
I"'-"
.~
h.6
/l
~.
/1
I'
15.1
111111 ...
15..1 em
I
.'
L
NR.
FDp
/1
L
Yield stress
II
= - -..-
14,270
53 Dynes/em!
<:
14,270
. .
'!f V
.'. Friction loss -2--[')
g
n
6.7
-0.165
- 34.3 Dynes-sec"
- 15.2 cm
D
V
. -.
,.s /cm
l "
122 COl/sec
tr Vl.np
N Rc -
K' 8""
- 2580
e-
0.0064
- 49 psi/mile
6.8
- 15.2 COl
0.63 poise
- 50 Dynes/em!
n rn
p
V
NRc
.'.
,'.
,'.
.',
,
"
-,
1:693 gm/cm!
- 122 em/sec.
- 4983 .
-
ZO'
0.3
f(
25 Dynes-sec"JIcm!
NRc~-
2015
6.9 Giuen
Find
a)
- 8" - 0.67 fl
p,
- 2.7
- 1/(0.7/2.7
'1
- 0.40/1.788 c/ll11sec
- 0.224 c/ll11sec
- 2.41 x 10,4 ft11sec
+ 0.3) -
1', fora)
To -
100 Dynes/em!
h)
To -
25 Dynes/cm1
To -
N
.'.
II, -
DIp To
0.67 1 X 111.6 x 0.21
'1 - 32.2 x (8.36 x 10"r
-46750
:
h) T.
.'. N R"
- 12000
.". V,
- 4.3 ft/sec .
l
.'. v.: -
11690
1.2 It/sec,
SOLUTIONS TO PROBLEMS
CHAPTER 7
'1
where
-1.0
- 0.38
11*
in the slurry
I'''''.~--;D",,,-cf/;-;4L7'
.~
o -
The friction loss for slurry is given in terms offt water/IOO ft. Divide this value by the specific gravity of
the slurry to obtain friction loss in feet of slurry per 100 feet.
The sell ling velocity of the 210 micron diameter panicle is estintatcd using the slurry viscosity and the
slurry density.
.
.
-.
The computed values of the settling velocity, 1l1, and the fri~ii;'n velocity /I. are given' in the '(ollowing
table. The values of CICA are also given in the same table. Notice that the. value of CICA at critical
deposition velocity is Jess than 0.1 for most of the runs.
",
[
:
Fall
Velocity
Pipe
Slurry
Diameter
Concentration
(Vol%)
Slurry
1/*
1"
SI" Gr.
(ft/see)
(ft/see)
CICA
4.235
40.4
35.2
30.1
25.5
20.4
2.715
2.494
2.278
2.082
1.866
0.265
0.215
0.179
0.178
0.198
0.00907
0.0181
0,0334
0.0499
0.0761
0.688
0.399
0.131
0.047
0.015
6.24
28.7
24.5
20.1
2.218
2.040 '
1.853
1.641
0.155
0.174
0.237
0.273
i>~0367
0.0562
00758
0.08.n
0.076
0.030
0.031
0.036
29.7
26.6
24.7
20.2
15.2
2.261
2.129
2.049
1.857
1.645
0.185
0.169
0.176
0.237
0.296
0.0336
0.0447
0.0560
0.0764
0.0833
0.138
0.056
0.031
O.oJO
0.046
(inch)
Friction
Velocity
8.24
,
"
10,36
12.-1
30.2
24.8
20.6
15. t
2.282
2.053
1.874
1.641
0.145
0.164
0.214
0.284
0.0334
0.0559
0.0759
O.OS34
O.OSI
0.024
O.O2!
20.3
1.1.2
1.862
1.560
0.2II
0.302
O.U7/)
0.100
0.020
0.027
I).(J-I t
In the given example the values of the variables are 'as follows:
- 322 ft/sect
;., 2.658
The values of h for the different runs arc summarized in the following table. Notice that the average value
of FL is 0.95. There is very little effect of the slurry concentration on the value of h
i
Pipe
Diameter
(inch)
(1)
2.056
4.235
. 624
Slurrj-
Concentration ."
l'L ..-
(\' () I';')
.U .
(2) r
VI,
1f2,~f) (s-I)
Slurry
51" Gr.
Predicted
Observed
(3)
(4)
(5)
(6)
36.7
23.7
12.2
1.12
1.05
0.91
1.608
1.393
1.202
0.366
(lOO326
0.279
0.35-1
0.291
0.27.1
37.9
23.9
11.6
1.04
0.91
0.91
1.628
1.396
1.192
0.476
0.423
0.361
0,377
0,32 t
0.307
31.0
22.8
17.0
11.4
1.01
0.98
0.98
0.97
'1.514
1.378
1.282
1.189
0.518
0.481
0.450
0.415
O.JSO
O.J60
0..'53
0..145
"
.:!l)7
SOI.UTlONS
~.21
18.2
22.8
17.7
11.1
0.90
0.91
O.Ql
n.95
1.468
1..\78
I.l<l.!
1.1 8'
Ill..!6
35.1)
0.91
2ll.!)
Il.R(,
0.91
URO
1.'181
1..18:;
1.l91
1.192
0.88
0.81
0.82
0.87
0.87
1.466
1.415
1.396
1.293
1.111
t
I
28.1
15.0
23.9
17.7
13.4
11.'1
,
I
~
uvz
1.1.2
17.6
11.6
o.sz
II: is given
Now
si:
4.9 ( dll. ~) ( .z.,
D . )0"
1.1
Ito
Ilere,
(to .~
i,
!
..::
(5_1)".n . (Eq,
E 7.7..a) "
0.07 ftlsec
0.Q1 stoke ... 1.076 x lO's (i1/sec.
d -O.Q1S em - 5.906 x 10" ft
5 - 2.658
10 -
1/ -
..
0.640
0.410
().(,I I
11..178
0.580
0547
0.504
0..187
O..!87
O.M7
0.6.10
0.614
0.585
O.5S4
0.393
0.365
(UM
(1.376
0.\74
O.J79
To calculate II:, the value of II.' is first calculated hy using Equation 7.7 (a). The value of the settling
velocity of solids in the suspending fluid must be determined first.
. .
The particle size is 60 x 100 mesh which is 180 microns....
The specific gravity of solids - 2.658
The viscosity of water - I centipoise
Therefore the settling velocity, 1/1, of solids - 0.07 fr/sec,
I,
(UM
OJ56
(U51
0..15"
IL
O.55R
o.s .\1
0.501
0.458
II.' -
0.11755 D"AIH.
where D is in inch.
i.
lOR
The values of 1/.' for different pipe diameters are given as follows:
1/.," (ft/sec)
2.lJ56
4.235
6.240
8.210
10.360
12.400
0.1600
lJ.2182
0.2577
0.2898
0.3202
0.3458
'.
(Eq. 7.7b)
..
'j
"
-. ""
The values of
of results.
II. were calculated using this equation and are summarized in column (5) of the summary
It should" be noted that the THOMAS method consistently overestimates the critical friction velocity,
7.3 Giucn:
'
d - 0.02 em - 6.56
..
-'
1[1, -
1O-~ ft
10. 5 ft'/sec
0.0286 It/sec
{t"I
1'~
Ito
t.e,
I
0.02.86 _ 0.01 ( 6.56 x 10. ~(:'~
1.076 x 10 .
4
II.
.'. II" -
0.066 fl/sec.
i.1I
SOI.UTlONS
I
' I k,till,"1
N
I OW ( ll'r' If - " - I.~ e t 1.111 5.
I'
.'.11* -
110 "
(l.U66 tr/sec
[t
The settling velocity, 1,*, in water is given by the Stokes LIIV, i.e.,
s s-1 tl 2
18 v
1{1- ,~ -
L
where .~ - 32.2 ft/sec 2
v-
6.84
x I0-,' it7...~c'
110
110
* - 0.233 fUsec
'tI/v - 2.13<5
.'. Equation 7.7 a does not apply since the particle is smaller than the thickness
s. _ 0.01 ( till *
1/:10
.'. fl*'"
)271
(Eq. 7.7 c )
0.179 ft/sec
7.5 Gitvn:
d' - 0.007
Clll -
2.3 )( 10-' rt
s - 3.0
D - 1.4375 ft
0.35
v - 1.076 x 10'; ft 2lsec.
!
1
'
111)
.-, -
..
7.6 Let us assume that all of the solids become part of the vehicle. Thus, in the first iteration, there will be no
bed pressure drop .
.'.
{j
'1
lst It..ration
Concentration of solids in vehicle - 56'%. wt
?~""j'
-21.l% (Vol)
- 6.4 cpo
- 1.791
Velocity of 110w, \I
... 5 It/sec
Pipe diameter. D
... 0.0002
Reynolds Number'
... 66,400
-'1
'!IV!
... 2gD
... 0.0155 Ii vehicle/ft
... 0.0278 Ii water/ft.
Znd Iteration
Now calculate the vehicle and bed part for each size solids by using C/G/o. criteria.
Now,
'.
log CIG"
Assume
- -1.8 ,,,Ip/(J/"
P -I
x -0.4
S( lI.VTI( lNS
!II
The seuling velocity lit is estimated using vehicle properties. Table 7-3 summarizes the calculated value,
of ;," and Cic;,. The vehicle and bed part forearh size fraction is next calculated. The pressure drop due to
bed part is estimated using DURAND's equation. In DURAND's equation the value of the drag
coefficient is computed using the properties of water, Therefore, the settling velocity and the corresponding drag coefficient are also given in Table 7-3. For estimating the bed pressure drop, the value offriction
loss lor water flowing at the same velocity as the Slurry is needed. The Reynolds Number for water flowing
at S li/sec in 0.131 inch pipe is 2.4 x 10'. The relative pipe roughness is 0.0002, .'. the friction factor is
0.0043 ..'. friction loss for water - 0.013 Ii water/ft.
From DURAND's equation. the bed pressure drop is given by
- 4.1
Y.
liD (5-1) .,
I"
V fen
<Ph'" [ 1
<P""" (Cnr m
ft water/ft.
The L1f't"" values for each size fraction were calculated using this equation. The calculated values are given
in Table 7-3. The total bed pressure drop for 2nd Iteration equals 0,00242 Ii water/It.
=0
54.5%
- 5 cp.
of the vehicle
- 1.754
Reynolds Number
- 83.250
- 0.00488
- 0.0148 ft vehicle/It
- 0.0260 ft water/It
- L1{'h,"
+ L1P"'hk"
- 0,00242 + 0.0260
- 0.02842 ft water/It
The value of friction loss estimated in lst Iteration was 0.0278 ft waterlft which is lower than the new
as ,the slurry friction loss.
value, Therefore adapt 0.02842 ft waterlft
.
.J
)~",l:;:;~:'_"_': __"
..
:~,~_. .~
_._-----
...
t
Settling
Volume %
Tvler Mesh
Mean
Dia.
Velocity, W
ltlsee
Solids
100 rP'
w
.-13K U.
C/CA
-1.82
10
tu
(2)
(31
(4)
(51
(6)
0.01010
0.00485
0.00282
0.00054
0.81
0.88
0.81
18.70
Size
Fraction
--
- 325
0.0111
0.0063
0.0048
0.0021
TOTAL
(4) (6)
17I
Set-tli~g"
Drag
Velocity in Coefficient
FIRST ITERATION
>200
200x 210
210x 325
100rPveh 100Q;bed
(9)
0.0122
0.0243
0.0141
0.0027
21.20
CD
110l
11.2
56.0
126..8
1386.0
D.P
t. P bed
Slurrv
-3/4
-3/4 !J.P
CD
Vehicle (12)+(lJ)
'4.1 rPCobed
1111
(12)
0.1600
0.0488
0.0265
0.0044
0
0
0
0
0
--
1131
(14)
g'"
e
0.0218
-0.0218
e-
e
."
r0
SECollo ITERATION
+ 20r.
200x 270
210x 315
- 325
0.0111
0.0063
0.0048
0.0021
0.01010
0.00485
0.81
0.88
0.00282
0.00054
0.81
18.70
TOTAL
T.able 7-3 Estimate of Slurry Friction Loss
0.1053
0.0505
0.0294
0.0056
0.6464
D.8110
0.8853
0.9169
0.52
0.11
0.72
18.21
20.22
0.29
0.11
0.09
0.43
-0.98-
0.00190
0.00034
0.00010
0.00008
0.00242
--0.0260
0.02842
- -------
SOI.U'IIONS
7.7
(;ii.'fll:
Pipe diameter
- 6,13I inch
Pipe roughness
- n.5ll rt
- n,nn 12 inch
Relative roughness
n,nnn2
VDp
v
_
Re
where
v-
D - pipe diameter, ft
p - slurry density
,
- slurry specific gravity x 62.4 Ib/ft J
v - slurry viscosity
- slurry viscosity in centipoise x 6.72 x
Ilr' lb/It-scc.
-.
The calculated values of the slurryspeeific gravity and the Reynolds Number are summarized in Table 7-4.
Friction f~ctor,
~gD
- 2slt'
!Jp - friction loss in ft water/It
where
- 32.2 ft/sec 1
.
I"
0.010
:;
t
et 0
u,
>4
....
2_1 ....
t;
2
0-"
ii:
u,
.,.---r-,-,..,.....".......,...-...,..........,.---,
I Ii.,
Ii. I
I
II.
-- I : NEIVT
.
~._, ' . . (flO. ONIIIN,
I I
,-
.l
,--..".'
.
, .... 1-l ..
"1__! r! i.iI it" DATA CU~VE'
0.0002
~"r-~ __ ....
..
PROBLEM 7-7
I"
lurhulencesupression
2
. --!.
..:.
3 .5.7.'105
1- -
I
2
.1.: . -
VDP
~14
,)
~i.,l
Figure 7-10 shows friction factor as a function of Reynolds Number. The Newtonian relationship for"
relative roughness of 0.0002 is also shown in this figure. This figure shows that the majority ordata points
lie below the Newtonian line indicating turbulence suppression.
,
,
1
I
SOLUTIONS TO PROBLEM
CHAPTERS
X.I Gium.
0, - 20 ft .
H - 20 ft
0;-6ft
/{;-3ft
</J .. 25%
s - 5.0
1-
p, - 62.4
Now the power, 1', required per uuit tank volume VT , is given
by
P
O
I
(.!.':.)
--0092
Vr
gil, _r
D; (2)112
e
rU IJ, Jp
(Eq. 8.11)
where
VT - : x 202 x 20
= 6280 nJ
e
- [ - 0.25 - 0.75
l1p
0.0689 Ii/sec
VT - 5.06 n Ibr."./sec
- 9.2 X IO-l HP
..P- 58 I-1P
i.e. use a 60 HP agitator.
5.8 slug/.ftJ
GxP
1716 :< r
where
G - !low rate in gpm
P - pressure difference in psi
( - pump efficiency
Assuming a pump efficiency of 85%, the required horsepower of the pump drive is 1485. Therefore, usc
0;
(I'
..
where
III is grinding power requirement in hp-hr/short ton
Wi is the work index
Substituting the values of Wi, I' and F; we get
\l7 - 6,7 hp-hr/tou
kWh
- 6.7 hp-hr :~ 0.746 I---I--Iton
11'- If
- 5 kWh/ton
- 4000 x 6 x 60
- 1,440,000 gallons
- 193,000 cu. ft
SOl t ., 10""
21i
f)
-~f)",
Using I hree storage tanks, diameter ofeach tallk - 43.4 feel. i.e.usc 3-1 a IIk~ 44 ndiameter and having 44 Ii
liquid depth. Allowa free hoard of2 ft to get a toral depth of each tnnk'equal ro 46ft.
.
Agrtator
.I
lp -' OJ
:~
14'W =
3-
I 44
.J
;",.,
":~
SOLUTIONS TO PROBLEMS
CHAI)TER 10
10-1 The corrosion allowance - 4 mp)' (mils per year)
-
Life of project
- 25 years
Therefore,
For an 18 inch pi!>e the maximum allowable pressure is given by the following formula:
where
.' ..
Using this formula, the allowable stresses for various wall thicknesses are calculated as follow"
:-- -I
'~-:-"~'
~:2~.'
'
Wall Thickness
:tflCr n.tinch
Corrosion
Maximum
\~eigh[
Wall Thickness
(inch)
Allowable
Pressure (psi)
l'1(le
( tons/mile)
0.250
0.281
0.312
0.344
0.150
0.181
0.212
0.299
620
750
880
1010
124-1
129.4
155.8
171.6
of
-~i
I
i
Tho prG5~urQ in tho pipe \'arioAlinmly between 1000 psi at the inlet end and 50 p5i allha Ol1llet end, The
pipe Ivnllllll.kneu "In be "leettll 'ueh Ihnt the pressure in the pipe is leu than the maximum allowable
pressure. The required wall thickness and the lengths of pipe of each wall thickness are 'given as follows:
~
I
SOI.l'TIONS
\\':tll
Thickness
IUSO
O.2H I
0..112
IU-l-l
From
~Iile
PoSt*
20
13
Ii
219
To
Mile P051
Lcngt l)
(miles)
SO
20
13
6
.10
7
7
1\
Sled
(tons)
372.1
906
1091
1030
TOI'II 67S0 10m
., This is the distance in miles from the inlet where the pressure in the pipe is equal to the maximum
allowable pressure,
10,2 If the corrosion allowance is not used, then the maximum allowable pressure for various wall thicknesses
will be as follows. The necessary lengths and weight are estimated in Problem 10.1.
.'.
Wall
Thickness
(inch)
Maximum
Allowable
Pressure
(psi)
From
Mile Post
To
Mile Post
'1
0.250
1038
50
,.:
i::~
..
Length
(miles)
Weight
(tons)
50
6205
When the corrosion allowance of 0.1 inch is used, the total steel requirement becomes 6750 tons as
shown in Problem 10.1. Therefore the additional steel required for corrosion allowance is 545 tons.
The cost of steel is. $ 300/ton; therefore the cost of extra steel used for corrosion allowance equals
$ 163,500,
10.3 To select the most economical method of corrosion control for a 12 inch diameter magnetite slurry
pipeline based on the following assumptions:
1.W
25
u::
w
In
u. _
20 .- ..
~~
en
1A7~~
'"<l-~
'<';
7 v
15
.2
;;; '=
"':!!
z
..
./
5-
v'.
.7,
10-
en
.,'
~'
00
~~---
....
u.,
,,~
.'
,."" :
"
~f
/..'
o- .c..;..::
o
50
100
150
LENGTH OF PIPE IMiles'
200
~21
Velocity
v- 5.5 fi/sec
IF-60
;1.
b. COJ/I!!" Lil/il/,gs
Capital cost of installing linings
12
- 11 X
.... -
T2x 5280 X L X .H
=82,938 L $
.'. Saving in capital cost -85,662 L $
c. Cost of inhibitor
X
X
d. Cost of Dcacration
The operating cost of deaeration plant - 2 cents/ton
.', Present value of this cost ..... 0.843 X 10' $
The capit;11 cost of deaeration plant - 3 x 10' $
,'. Total cost of deaeration - 3.843 x 106 S
Figure 10-1 I shows-the savings in cost of steel for the three alternate methods of corrosion control. It can
be seen that the relative advantages of the three methods depend upon the length of the pipe.
:)
.'
SOLUTIONS TO PROBLEMS
CHAPTER 11
11.1 The levclizcd ~apital charge FI. is given by
.
1'1. - C
[ (0)(1) (Y+l)
100 2'[
(I-O)(R)
(T=n 100 +
I
V j
Y + 100
Where
C - capital cost of project/toll
- S 750 lIIillioll/20 million
. - S .17.5/toll
1 - % annual interest - 10
Y - period of amortization of capital - 20 years
I
"F, ~
[0.75 X 10
.21_+0.25X20XO.l8+_1j+OOI5X375
, .. ,I. 37.5
100
X 2(20),
0.5
20'
.
, - 1.48 + 3.38 + 1.88 + 0.56 '
7.30/ton.
,
;-s
'
i" '
. R. - 0.10
I. Return 011 equity,
.'.FI. - $ 5.80/ton
I. 1- 5%
123
Subject Index
l\hr:t"icllI
OCC:lndn~ US
n. 11 Mill.. 129
n\';lril1~
Lift: Ilq
1Iin~11JI11 "I:l\Ii( ;5. 76
- LJlllin.tr How
76
- Turbulent rIIIW n.1 C1
n.
- O<linicinn 85 .
- Mixed Silc P.lnicle, 93
- Unilormly Sized r.U1icles R9 - 9.l
l>ew;ucrinE: 136
- Ccntrifu~s 136. 137
- Cyclones IJ6
- V.ItlUlm Fillers 136
Uilal:lnl 49
Or2~ Cf~(fieicnc .l4
- elml J:i
- GenerJliled Curves J6
Dug Fnrcc: JJ
- Form j)
2 Sphere J.I
- Vi~cous JJ
On,:: Reduccrs IlJ
Dr2R Rwuctinn 109
I>ur;utds Cundalin" R9,94'
- On
(~II:ln:r;1S f.iml~tfllu:
Sr,u:m 115
Cm:nie:icnc uf IliJ.:itfhr 54
<:ufchrnuk I:clu:uinn 22
CUlnlllllmd S},..rem 115
<:nm:c:ncr:nilln Gr:ulh:nt 62. 86
- C/C" 62. 86. Kg. 1-19
- Criteti.. for I ''''Itrott-cncity 1'6.87,88
- Ctiteti.. 10' IlnnlOltCncilY 70
- Effed nf Conccll1rJ1i"n 65
- EI(c(1 of Particle Size 65
- Effect of fire Oi.tn1C:ler 65
- r:llcc! of Vdodty 65
Clln";"lent:~ 49
Cnn\nlid.tliun ell.I' l'iIH.-line 9, 118
Cum;eniun T"hlc:\ 170. 171
C:unlin1-:S~st(,'m 121
Curru"inn
- I\lIow.lnce Ihl
- Control of 145
- Inhibitor 14~
- I.uur T~S1S 141
- M~.nurCl1iC"1 1-16. 141
- M~dl.lIli~m of 1-11
- Probe 1-16
- R.lle J.f6
- SJ'O'~ 147
C:urrtl\illll-I:rminn It;1Il"; 1-1, 1-16
- M.limen.mce '4. 120,121
- Or~rJtinF: 1-1
- TrJlnrorufiun
C~'dunc~ I lb
Q.
16
86.8R
frit:liun 1.11\\ 11
- njn~h.lI11 PI.uric 76_ 77. 19
- Compound S)'ncm qs - Q8
- Heterogeneous Slt~re"liion 94
- I J(llllllg,CIICOUli Su~rcmion 79
- Ncwloni;1Il 20
- l'cwer I.JW 77. 79. 80
Fromlc Nmnber 89
GriO(lin~
Cml 1.11
Metnl l.oss HI
Mill. 129
Power 129, 130, 131
\'(.'ork Index 12q
Grm~ N:1tful1:t1 !'rmlnce (GNP) 162,I6J
IlaJtcnr'l)i:-;ctlillc fnrmul:r 51
Hardne..s 14.1
l leat Tran..fct
- Biueham 1'j;nlit:s-lamin:1r Flow 10.1
- 8in~h'lI11 rl:tlilks-Turbulent FI"w 105
- Power Lew fluid..lJminar JOS
- Power Law Pluids-Turbulenr 105
Jfcd~t'rmn Number 71
Jfclcru~ellcuu~ f;Jnw 70
lI,.dr:llllic Mil1illJ: 124
Impact C1gC 129
Inhc:r'cl1l Moiseure 58
tnhihiwfS 148
Innrumcnt:uinn
- Den.~iIY Me:1,suremcnt tJ9
- OifferC'nti2f l'rC'!'..ure 139
- Flow McasuremcnI 1J9
Linin~li
Fall f)i:llnclcr 40
- Protective 1,16
l.uddUlI'I,cr 12.l
flu\\'
- IlcternJeneous 12. 70, 8S
- f Iomogeneous 12. 70
- Inlcrmedi.tle 10,11
- Llminar 18
- Turbulcnl 18
Hnw Mc:ecr 1)9
Fluid
I
- Oil.lt.tnt 49
l\br~t1lc~
F.<'U:lli()O 51
- Non-Newtonian 48
- rseudopbstic 49
- Tirne-lndependeut Ut
f1uiJ-(nurlinft..UI
Flui.1 End 119. 120
fUrln Drag JJ
Frieciun Faclf)' 20
- ChJfI 12
- lJmin.tr 20
- Turhulent 21
- Slurries lOS
Mix;nR,tcn~lh28
.1
Ncwwns Law 71
Numin:ll Di,uncler 38
(}:trckle: Si1.c
- Sieve Siles 168
,~;
;'"'1.''j
I'iu;nn loll
1'''',Slidt)" (".I,uuber 71. 72
I'uiscuillc: Equation S4
I'ule Amplitude Mudu':uiun 121
Power
I~"d
119
rs
Prc:sliurc: I)nlp
'I
- B,d 95
- Vchidc9S
Pressure Transient t2S
PuJ'i:ttion Dampening 125
Pumps
- Centrifugal Ill. 122
- Eflicicncy 122
- lockhoppcr 123
-
Mars 123
M.yn. 123
".. '
Piston J 13. 114
]
Plunger 114
l
Positive Displacement 113. 118 122
Selection' 113
Slug 124
Itdm:r'R:iwlin f:'lu:uilln 57
!lest:trt i21. 122
Rl'llInltl~ NUIIII,,:r 18
- Critical 19.71,71, 7J
- Generalized 77. 19
Rt.'~;ni)lc.kStrl,.'Ss26
Rhcnll'~."
- 8inghanl l'I.U1ic 48
- Oil.uant -19
- fluid .48
- MC';uurC'I1Il:!llt 51
- Non-Newtonian 48
- Pseudoplastic 49
- Rheopectic 50
- Thi:H"roriC 50
- Tlme-lndepeudem Ncn-Newtouian 48
Il!~i~\~~~trr:
RiJII",hnc:" uf 11ipc 21
- I\b'olul: 23
-I.
J".
- J\~il.ll(d I J.l
- J\nrilinn in 1\~il.Urd T.lOks I J.J
- C:11'.lcitr I.U
~ ..Elltl:r~('tlC)' ...1J4
~ N(JI1-I\~i1.1tcd 1J.S
Stlllblycr 9Z
Sus\'cn"illn
- Newrcnian 58 '
- Non-Newtonian 58
- Rhcolofl:Y 58
. ....
....
;HI~ll\lIIi 1~I\\III1IIIt.III~1
"c1ndn'
- Cfitic,,1 12
- - Drfrtt
I.JW
29. >2
-lhicklt~u
.I"
Vi5cu1.if\" 4b
- APr.trC'lit 71
- of Concentrated Su~rC'mion~ 46
- Definition of 20
- Edd) 28
- Eflc-cth,c 71.73.76.81
- UmitillJC 71
- of NonNrwlnni,lU Su~pensions Sit
- SutrC'mion 4b. 93
- Waler 169
Vi5CClllltfl,.r
- C.'I,ilbr~' Tube 51
- Co"xi~1 C~'lifldrr S6
Vuhum:tric Efficient}' 120
von Karman ClIl1stant 10.62
W:ti,'il,j Irnn';:IfH''l S~"UtUl 11f'~"121
":tear
Sp1chrudrh(, 121
T"!ILI6~
Tr;rm,jcnt
-AhrJsh'(' 14.1
- Cuni,ng Hi
Hffifft~I\'''I\'ln
W"t~llri:an Sr~u.. m ,J 16
Advertising Section
A 13
A3
All
A 10.
A8
Holthuis B.V.
P.O.Box 249, NL-Vcnlo, Holland.
A 10
Imodco, Inc.
. -10960 Wilshire Blvd., Los Angeles, California 90024, USi\:. -' ....
A9
Imodco Ltd.
87 Jermyn Street, London SWI Y 6JO, England
A9
A 15
','
,.,.
A}
A5
A4
A6
A7
Wa rlllanlllternaiional,lnc.
P.O.Box 7610, Madison; Wisconsin 53707, USA
A7
A7
Al
Wood pipe:.
The economical answer
to sUurry iIransporta~6on.
""
.,-
,-'
,,'
'.
......
,-,
t,
Sleel
BTUI
lhlcltnf'S.
Sq. FI.I
(ineht'sl Hr Ide;, F.
Malerlal
420.0
5.3
Concrete
0.25., I.6BO.0
5,0
1.1
Type of s,lurry
. pH
Temperature
,'-
J
~I
f
r
Ii
,1.,
Ii"
i
,I
,I
'I
,'I
Ii
-,
,I
XPAN-CRT-5750-FS-10l
Dado que las curvas de funcionamiento de las bomb as entregadas
po r los fabricantes e s t an hechas para agua pur a , se debe
corregir la altura de impulsion mediante la siguiente
expresion:
Hw
= ....!:!L
[m . c al
HR . Cs
III..
en que:
:',
Hw
Hs
HR
=
=
=
d"o =
=
S
Cs =
r~!
dicrtfsl
250692
,,'"
igual a 60
24
I
I
XPAN-CRT-5750-FS-101
9.2.3 Bombas de desplazamiento positivo
Los criterios para 1a seleccion de bomb as de desplazamiento
positivo son los siguientes:
I)
r
,
[HP]
Nt
En que:
Ps
PT
= potencia
bombeo
= potencia
teorica
I
i
=~
N..
Qp
Hs\
= p.~-x~~~.
..
75
N..
= eficiencia
-~
= Ne ER Cs
3 ]
Hw)
Mcrtfsl
250692
J
-, .'
J
,\
Nt
= eficiencia
Cs
= coeficiente
de motor y transmision
de seguridad
0,95 pulpa no espumosa
0,75.pulpa.espumosa
25