Separation Process lab report 2017-ch-

414

Separation Process Lab

LAB REPORT

Submitted To: Engr. Umair Furqan

Submitted By: Abdul-Rehman Shah
Registration No: 2017-CH-414
Separation Process lab report

LIST OF EXPERIMENTS
1. To calculate the number of transfer units for a tray dryer.
2. To calculate the critical moisture content of solid drying.
3. To measure the specific gravity, boiling point, pH, TDS of different samples of water in
RO plant.
4. Calculate the range, approach and effectiveness of the cooling tower.
5. Calculate the mass transfer coefficient of the cooling tower.
6. Distillation Column;
a) The specific gravity of the ethanol sample recovered from the
distillation column is 1.1. Compare the value of specific gravity of
pure ethanol and calculate the percentage composition of ethanol
recovered. Perform the mass balance on the column and calculate
the mass fraction on top and bottom of the column when the feed is
50% water and 50% ethanol.
b) Calculate the number of stages and composition on each plate by
using MaCabe Thiele method and Lewis Sorel method.
c) Calculate the plate efficiency of the column.

TRAY DRYER EQUIPMENT

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Separation Process lab report

Experiment No.1
Abstract:
Tray dryers are the simplest and least-expensive dryer type which operates by passing hot air
over the surface of a wet solid that is spread over trays arranged in racks. Drying is a mass
transfer process that involves removal of relatively small amounts of water or moisture contents
from a material or a process stream. The purpose of the experiment is to conduct a drying
process on banana fruits in order to determine its drying rate, moisture content, and the effect of
velocity of air on the drying rate of the banana. The banana is sliced thinly and arranged in the
tray. The mass of banana is weighted before and after the experiment. During the experiment, the
mass of banana is recorded every 10 minutes. The moisture content and the drying rate decreases
over time. The drying curve of the banana follows the theoretical drying curve. Drying time
comparison with other types of batch dryers show the trays dryer as the least effective. The
objectives are successfully obtained therefore the experiment is successfully done.
Objective:
To calculate the number of transfer units for a tray dryer.

Apparatus:
 Tray dryer as equipment

Working Principle:
The main industries for tray dryer exporters are pharmaceuticals. But it is also widely used
wherever we need drying of wet material during processing or at raw material stage, such as the
chemicals, F&B, dyes, and paint industry. The material to be dried is placed on the trays. The
heat in the dryer is produced by the heater at the base. Other than the hot air generated by the
oven, the other method is to have radiator coils that use steam for heat circulation. One can
choose the heating method as per preferences and material to be dried.
During the heating process the material to be dried is spread out on the trays. The heated air is
directed to flow in a circulation form. It flows over the material in the trays in a controlled flow.
Trays can have a solid, perforated or wire mesh base. A paper lining could be used to reduce
chances of contamination through contact with the tray.
The efficiency of the dryer depends on circulation and recirculation of the hot air. Apart from a
regular supply and presence of heated air, it also depends on supply of fresh air. The fresh is
combined with the heated air in fixed proportion for an efficient system. Such regulated drying is
also important to ensure to ensure uniform drying in the dryer where the bottommost tray drys at
the same pace as the trays placed on top. Apart from the double-walled construction, insulation is
also achieved by heating coils and fans.

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Separation Process lab report

Introduction:
Drying is a mass transfer process that involves removal of relatively small amounts of water or
moisture contents from a material or a process stream. In industries, drying process is often used
as the final step operation before packaging and selling products. The final product from drying
process must be in solid form, because all the moisture contents is being dried up. There are
many methods of drying such as application of hot air, contact drying, dielectric drying, freezing
drying and supercritical drying. This method of drying involves with different type of drying
equipment such as Tray dryers, Vacuum-shelf indirect dryers, Continuous tunnel dryers, Rotary
dryers, Drum dryers and Spray dryers.
The common type of dryer uses in many industrial applications involves tray dryers as their
drying operation. The dryers are made of tray held in a cabinet, which is connected to a source of
heated air. The operation mechanism of tray drying is the heat is channelled by an air current
sweeping across the trays, by conduction from heated trays or heated shelves on which the trays
lie, or by radiation from heated surfaces. The tray must be tight-fitting in the cabinet to air form
bypassing the material that needed to be dried. The drying time by using tray dryers usually need
a longer time. In industries, tray dryer operates about 12 to 48 hours for solids to be dried. This is
because tray dryers required low capital and maintenance cost but it have poor control and
chances to produces more variable product quality.

Naked eye view of lab equipment:

Theory:
Tray dryer operates by passing hot air over the surface of a wet solid that is spread over trays
arranged in racks. Tray dryers are the simplest and least-expensive dryer type. This type is most
widely used in the food and pharmaceutical industries. The advantage of tray dryers, apart from

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Separation Process lab report

their low initial cost, is their versatility. With the exception of dusty solids, materials of almost
any other physical form may be dried.
Drying process can be defined as the vaporization and removal of water or other liquids from a
solution, suspension, or other solid-liquid mixture to form a dry solid. It is a process that
involves heat and mass transfer. Drying occurs as a result of the vaporization of liquid by
supplying heat to wet feedstock, granules, and so on. Based on the mechanism of heat transfer,
drying is categorized into direct (convection), indirect or contact (conduction), radiant (radiation)
and dielectric or microwave (radio frequency) drying.
Heat transfer and mass transfer are crucial in drying processes. Heat is supplied to the product to
evaporate the liquid contained, and mass is transferred as a vapor into the surrounding gas. The
drying rate is determined by the set of factors that affect heat and mass transfer. Solids drying is
generally understood to follow two distinct drying zones, known as the constant-rate period and
the falling-rate period. The two zones are demarcated by a break point called the critical moisture
content.

Equipment Setup and apparatus to work with:

Utilities required:
 Electric supply
 Wet solid

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Separation Process lab report

 Stop watch
Procedure:
1. Take dry sand to fill the trays to a depth of about 10 mm each should be accurately
weighed before being saturated with water in a container.
2. The sand should be removed from the container and drained of excess 'free' water before
being loaded evenly and smoothly into the drying trays, taking care to avoid any
spillage.
3. The total weight of the wet sand should be noted before drying commences.
4. At some arbitrary time (t=0), switch on and set the fan speed control to produce an air
velocity of about 0.5 m/s, Measure the velocity of the air flow through the drier using
the digital anemometer.
5. Set the heater power control to a nominal setting and measure the dry and wet bulb air
temperatures upstream of the sand trays using the aspirating psychrometer.
6. Record the total weight of sand in the trays at regular time intervals until drying is
complete.
7. The experiment should be repeated for other air temperatures by increasing the power
supplied to the heater up to the maximum setting.
8. It is important to keep the air velocity constant and to use the same weight and
distribution of sand in each of the tests.
9. Stop the experiment when weight of dried solid become constant.
Observation and calculation:
Tray diameter =150 mm
Surface area of solid = A = 0.0706 m2
Diameter of orifice = 0.026 m
Diameter of the pipe = 0.052 m
Area of orifice = a0 = 0.0005311 m2
Area of pipe = ap = 0.0021237 m2
Weight of empty tray = 148 g
Weight of dry sand = S = 282 g
Weight of tray with wet sand = W = 323 g
Change in interval = ∆θ = 2
Moisture Content = X = (W – S) / S
Number of transfer coefficients = N = (S ∆X) / (A ∆θ)

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Separation Process lab report

Sr.# Time dt Weight of Weight of wet Mass of ΔX Sdx

N=
(t) wet solid solid(W) drying Adt
with solid(X)
(min) (grams)
(sec) tray(W’)
W −S
W= W’-148 X=
S
1 0 180 321 173 0.291 0
0
2 3 180 317 169 0.2611 0.0149 0.157381
3 6 180 315 167 0.2462 0.00746 0.078691
4 9 180 314 166 0.2388 0.0223 0.236072
5 12 180 311 163 0.2164 0.0149 0.157381
6 15 180 309 161 0.2014 0.0223 0.236072
7 18 180 306 158 0.1791 0.0149 0.157381
8 21 180 304 156 0.1641 0.0149 0.157381
9 24 180 302 154 0.1492 0.0223 0.236072
10 27 180 299 151 0.1268 0.022 0.236072
11 30 180 296 148 0.1044 0.0223 0.236072
12 33 180 293 145 0.0820 0.0447 0.472144
13 36 180 287 139 0.0371 0.00746 0.078691
14 39 180 286 138 0.0298 0.0447 0.472144
15 42 180 280 132 -0.0149 0.0298 0.314762
16 45 180 276 128 -0.044 0.0149 0.157381
17 48 180 274 126 -0.05970 0.0298 0.314762
18 51 180 270 122 -0.08955 0.022 0.236072
19 54 180 267 119 -0.1119 0.00746 0.078691
20 57 180 266 118 -0.1194 0.0149 0.157381
21 60 180 264 116 -0.1343 0.0149 0.157381
22 63 180 262 114 -0.1492 0.0223 0.236072
23 66 180 259 111 -0.1716 0.00746 0.078691
24 69 180 258 110 -0.1791 0.00746 0.078691
25 72 180 257 109 -0.1865 0.0074 0.078691

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Separation Process lab report

26 75 180 256 108 -0.19403 0 0

27 78 180 256 108 -0.19403 0 0
28 81 180 256 108 -0.19403 0 0

Method 2
Observations and Calculations:
Tray diameter =150 mm
Surface area of solid = A = 0.0706 m2

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Separation Process lab report

Diameter of orifice = 0.026 m

Diameter of the pipe = 0.052 m
Area of orifice = a0 = 0.0005311 m2
Area of pipe = ap = 0.0021237 m2
Weight of empty tray = 148 g
Weight of dry sand = S = 282 g
Weight of tray with wet sand = W = 323 g
Change in interval = ∆θ = 2
Moisture Content = X = (W – S) / S
Number of transfer coefficients = N = (S ∆X) / (A ∆θ)

Sr.# Time dt Weight of Weight of Mass of drying ΔX y 2− y 1

(t) wet solid wet solid(X) slope=
x 2−x 1
with solid(W)
(min)
tray(W’) W −S
(sec) X=
S
(grams)
W= W’-
148
1 0 180 321 173 0.291 0 0
2 3 180 317 169 0.2611 0.0149 8.27778E-05
3 6 180 315 167 0.2462 0.00746 4.14444E-05
4 9 180 314 166 0.2388 0.0223 0.000123889
5 12 180 311 163 0.2164 0.0149 8.27778E-05
6 15 180 309 161 0.2014 0.0223 0.000123889
7 18 180 306 158 0.1791 0.0149 8.27778E-05
8 21 180 304 156 0.1641 0.0149 8.27778E-05
9 24 180 302 154 0.1492 0.0223 0.000123889
10 27 180 299 151 0.1268 0.022 0.000122222
11 30 180 296 148 0.1044 0.0223 0.000123889
12 33 180 293 145 0.0820 0.0447 0.000248333
13 36 180 287 139 0.0371 0.00746 4.14444E-05

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Separation Process lab report

14 39 180 286 138 0.0298 0.0447 0.000248333

15 42 180 280 132 -0.0149 0.0298 0.000165556
16 45 180 276 128 -0.044 0.0149 8.27778E-05
17 48 180 274 126 -0.05970 0.0298 0.000165556
18 51 180 270 122 -0.08955 0.022 0.000122222
19 54 180 267 119 -0.1119 0.00746 4.14444E-05
20 57 180 266 118 -0.1194 0.0149 8.27778E-05
21 60 180 264 116 -0.1343 0.0149 8.27778E-05
22 63 180 262 114 -0.1492 0.0223 0.000123889
23 66 180 259 111 -0.1716 0.00746 4.14444E-05
24 69 180 258 110 -0.1791 0.00746 4.14444E-05
25 72 180 257 109 -0.1865 0.0074 4.11111E-05
26 75 180 256 108 -0.19403 0 0
27 78 180 256 108 -0.19403 0 0
28 81 180 256 108 -0.19403 0 0

In this method a graph is drawn between time (t) and mass of drying solid (X).
Graph;

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Separation Process lab report

Mass of drying solid vs Time

0.4
0.3
mass of drying sand(X)
0.2
0.1
0
0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 63 66 69 72 75 78 81
-0.1
-0.2
-0.3
time (min)

Experiment No. 2

i. Objective;

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Separation Process lab report

To calculate the critical moisture content of solid drying.

ii. Apparatus:
 Tray dryer as equipment

iii. Working Principle:

The main industries for tray dryer exporters are pharmaceuticals. But it is also widely used
wherever we need drying of wet material during processing or at raw material stage, such as the
chemicals, F&B, dyes, and paint industry. The material to be dried is placed on the trays. The
heat in the dryer is produced by the heater at the base. Other than the hot air generated by the
oven, the other method is to have radiator coils that use steam for heat circulation. One can
choose the heating method as per preferences and material to be dried.
During the heating process the material to be dried is spread out on the trays. The heated air is
directed to flow in a circulation form. It flows over the material in the trays in a controlled flow.
Trays can have a solid, perforated or wire mesh base. A paper lining could be used to reduce
chances of contamination through contact with the tray.
The efficiency of the dryer depends on circulation and recirculation of the hot air. Apart from a
regular supply and presence of heated air, it also depends on supply of fresh air. The fresh is
combined with the heated air in fixed proportion for an efficient system. Such regulated drying is
also important to ensure to ensure uniform drying in the dryer where the bottommost tray drys at
the same pace as the trays placed on top. Apart from the double-walled construction, insulation is
also achieved by heating coils and fans.
iv. Theory:
Tray dryer operates by passing hot air over the surface of a wet solid that is spread over trays
arranged in racks. Tray dryers are the simplest and least-expensive dryer type. This type is most
widely used in the food and pharmaceutical industries. The advantage of tray dryers, apart from
their low initial cost, is their versatility. With the exception of dusty solids, materials of almost
any other physical form may be dried.
Drying process can be defined as the vaporization and removal of water or other liquids from a
solution, suspension, or other solid-liquid mixture to form a dry solid. It is a process that
involves heat and mass transfer. Drying occurs as a result of the vaporization of liquid by
supplying heat to wet feedstock, granules, and so on. Based on the mechanism of heat transfer,
drying is categorized into direct (convection), indirect or contact (conduction), radiant (radiation)
and dielectric or microwave (radio frequency) drying.
Heat transfer and mass transfer are crucial in drying processes. Heat is supplied to the product to
evaporate the liquid contained, and mass is transferred as a vapor into the surrounding gas. The

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Separation Process lab report

drying rate is determined by the set of factors that affect heat and mass transfer. Solids drying is
generally understood to follow two distinct drying zones, known as the constant-rate period and
the falling-rate period. The two zones are demarcated by a break point called the critical moisture
content.
v. Experimental Apparatus;
Tray Drier Apparatus, Digital Weight Balance, Wet and Dry Bulb Thermometer, and
Stopwatch.

  Drying chamber
 Air Blower
 Heater
 Orifice in air duct
 Tray
 Balance
 Flow meter
 Air valve to control air flow
 Temperature sensor

vi. Procedure:
1. Take dry sand to fill the trays to a depth of about 10 mm each should be accurately
weighed before being saturated with water in a container.
2. The sand should be removed from the container and drained of excess 'free' water before
being loaded evenly and smoothly into the drying trays, taking care to avoid any
spillage.
3. The total weight of the wet sand should be noted before drying commences.
4. At some arbitrary time (t=0), switch on and set the fan speed control to produce an air
velocity of about 0.5 m/s, Measure the velocity of the air flow through the drier using
the digital anemometer.
5. Set the heater power control to a nominal setting and measure the dry and wet bulb air
temperatures upstream of the sand trays using the aspirating Psychrometer.

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Separation Process lab report

6. Record the total weight of sand in the trays at regular time intervals until drying is
complete.
7. The experiment should be repeated for other air temperatures by increasing the power
supplied to the heater up to the maximum setting.
8. It is important to keep the air velocity constant and to use the same weight and
distribution of sand in each of the tests.
9. Stop the experiment when weight of dried solid become constant.

 Observations and calculations:

Tray diameter = 150mm
Surface area of solids = 0.0706m2
Diameter of orifice = 0.026m
Diameter of pipe =0.052m
Area of orifice = a0= 0.0005311m2
Area of pipe = ap=0.002123m2
Surface area of solid = A = 0.0706 m2
Weight of dry solid = S = 291-150=141g
Weight of tray = 150 g
t = Time = θ
G = Mass Velocity
W = Weight of wet Solid=330-150=220 g
X = Mass of drying solid
N = Number of transfer unit

Sr.# Time (t) Delta t Weight of wet Mass of drying Delta X Sdx
(min) (sec) solid(W) solid(X)
N=
Adt
(grams) W −S
X=
S
1 0 180 330-150=180 0.276596 0 0
2 3 180 326-150=176 0.248227 0.028369 0.314762
3 6 180 322-150=172 0.219858 0.028369 0.314762
4 9 180 320-150=170 0.205674 0.014184 0.157381
5 12 180 316-150=166 0.177305 0.028369 0.314762
6 15 180 313-150=163 0.156028 0.021277 0.236072
7 18 180 311-150=161 0.141844 0.014184 0.157381
8 21 180 308-150=158 0.120567 0.021277 0.236072
9 24 180 305-150=155 0.099291 0.021277 0.236072
10 27 180 302-150=152 0.078014 0.021277 0.236072
11 30 180 298-150=148 0.049645 0.028369 0.314762
12 33 180 295-150=145 0.028369 0.021277 0.236072
13 36 180 292-150=142 0.007092 0.021277 0.236072

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Separation Process lab report

14 39 180 289-150=139 -0.01418 0.021277 0.236072

15 42 180 286-150=136 -0.03546 0.021277 0.236072
16 45 180 282-150=132 -0.06383 0.028369 0.314762
17 48 180 280-150=130 -0.07801 0.014184 0.157381
18 51 180 277-150=127 -0.09929 0.021277 0.236072
19 54 180 274-150=124 -0.12057 0.021277 0.236072
20 57 180 270-150=120 -0.14894 0.028369 0.314762
21 60 180 268-150=118 -0.16312 0.014184 0.157381
22 63 180 267-150=117 -0.17021 0.007092 0.078691
23 66 180 265-150=115 -0.1844 0.014184 0.157381
24 69 180 262-150=112 -0.20567 0.021277 0.236072
25 72 180 262-150=112 -0.20567 0 0
26 75 180 262-150=112 -0.20567 0 0

For critical moisture content we need to draw graph between number of transfer units (N) and
mass or drying solid (X).
Graph:

RO PLANT

Experiment No.3

Abstract:

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 Separation Process lab report

Reverse Osmosis (RO) is a separation technique that is suitable for a wide range of applications,
especially when salt and/or dissolved solids need to be removed from a solution. Accordingly,
RO can be used for seawater and brackish water desalination, to produce both water for
industrial application, and drinking water. It can also be applied for the production of ultrapure
water (e.g. semiconductor, pharmaceutical industries) and boiler feed water. In addition, RO
membrane systems are used for wastewater and water reuse treatments.
RO is currently considered one of the most economic and effective process for water
desalination. Accordingly, it is often the appropriate technique to treat solutions having salt
concentrations from 100 to over 50,000 mg/ liter. Solutions with salinity from surface water to
sea water, and even brines, can be treated by RO membrane.
In operation, the RO membrane system is continuously supplied with feed water which produces
a constant water movement from feed to concentrate. When in cross-flow operation, there is little
accumulation of the rejected solutes and fouling or scaling can be minimized.
Objective:
To measure the;

 Specific gravity
 Boiling point
 pH
 total dissolved salts (TDS)
of different samples of water.

Theory
i. Osmosis:
In order to understand the term "reverse osmosis", the term "osmosis" must first be understood.
To do this, the term "Chemical Potential" is defined first. It is the inequality of the chemical
potential between, say, fresh and brackish waters that is the driving force for osmosis. A
solution's chemical potential is determined by the following:
a) Concentration of salts in the water.
b) The temperature of the water (expressed in absolute terms).
c) The pressure of the solution.
The concentration of salts in the water supply has an inverse effect on the chemical potential
of the solution, whereas the temperature and pressure have a direct effect. Therefore, at
constant temperature and pressure of a solution, increased salt content results in decreased
chemical potential. This process is shown as;

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 Separation Process lab report

This figure shows a vessel filled with waters of two different salt concentrations. These are
separated by a semi-permeable membrane.
A semipermeable membrane has small pores that block contaminants but allow water
molecules to flow through. In osmosis, water becomes more concentrated as it passes
through the membrane to obtain equilibrium on both sides. Reverse osmosis,
however, blocks contaminants from entering the less concentrated side of the membrane.
For example, when pressure is applied to a volume of saltwater during reverse osmosis, the
salt is left behind and only clean water flows through.

ii. Reverse Osmosis:

Reverse osmosis is a process which occurs when pressure, greater than the osmotic pressure, is
applied to the concentrated solution. Water is forced to flow from the concentrated to the diluted
side, and solutes are retained by the membrane as shown below;

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 Separation Process lab report

iii. Working of Reverse Osmosis plant:

Diffusion is the movement of molecules from a region of higher concentration to a region of
lower concentration. Osmosis is a special case of diffusion in which the molecules are water and
the concentration gradient occurs across a semipermeable membrane. The semipermeable
membrane allows the passage of water, but not ions or larger molecules (eg; glucose, urea,
bacteria). Diffusion and osmosis are thermodynamically favorable and will continue until
equilibrium is reached. Osmosis can be slowed, stopped, or even reversed if sufficient pressure is
applied to the membrane from the 'concentrated' side of the membrane.
Reverse osmosis occurs when the water is moved across the membrane against the concentration
gradient, from lower concentration to higher concentration. To illustrate, imagine a
semipermeable membrane with fresh water on one side and a concentrated aqueous solution on
the other side. If normal osmosis takes place, the fresh water will cross the membrane to dilute
the concentrated solution. In reverse osmosis, pressure is exerted on the side with the
concentrated solution to force the water molecules across the membrane to the fresh water side.
The  ‘bad’  water  is  the  water  that  contains  all  of  the  contaminants  that  were  unable  to
pass  through  the  RO   membrane  and  is  known  as  the  concentrate,  reject,  or  brine.  All
three terms  (concentrate,  reject,  and  brine)  are   used  interchangeably  and  mean  the  same
thing. Below is  a  simple  schematic  that  shows  how  an  RO  system  works;

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 Separation Process lab report

iv. Capability of RO plant;

A reverse osmosis system is one of the most extensive methods of filtration. It removes 98% of
dissolved solids, which makes it healthier to drink. A water distiller is the only other drinking
water system that also reduces TDS, but it's less efficient than an RO system. 

 Harmful dissolved contaminants reduced

 Sodium reduced 
 Bad tastes and odors reduced
 Reverse Osmosis is very effective in treating brackish, for both large and small flows
applications. Some examples of industries that use RO water include pharmaceutical,
boiler feed water, food and beverage, metal finishing and semiconductor manufacturing
to name a few.

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Separation Process lab report

Lab Performance

i. Equipment:
 Reverse osmosis (RO) plant

ii. Utilities required:

 samples of water
 Thermometer
 Beakers
 Burner
 China dish
 Weighing balance
 pH indicator

iii. Naked eye view of lab equipment:

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Separation Process lab report

iv. Procedure:
 A sample of tap water is taken and it is poured to Reverse Osmosis (RO) plant.
 Water moves through the different sets of membranes and gets purified.
 Another water sample is taken at this point and this is demineralized water.
 Then different minerals are added to this water which are required for water to be
drinkable.
 Again, the sample of product water is taken and send to chemistry lab.
 In lab different tests are applied and characteristics of two samples are compared.

v. Total dissolved solid (TDS);

In this test we determined the amount of solids dissolved in the sample of water by heating it in
oven when water evaporates then after measuring the weight we determine it. According to
World Health Organization, (TDS) level less than 300 mg/liter is considered as excellent,
between 300 and 600 mg/liter is good, 600-900 is fair, 900 – 1200 is poor and TDS level more
than 1200 mg/liter is unacceptable. In India, if the TDS level is above 500mg/liter, the water is
considered as dis agreeable.

vi. Observations and Calculations:

 Room temperature = 25 ᵒC

 Table 1;

(Comparison of properties of water gained from different sources)

Sr. Properties Tap Water Product Water
#
1 PH 6.3 4.54
2 Boiling point 3.63 0.13
3 TDS (g/l) 0.675 0.54
4 Specific gravity 1.024 0.9987

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 Table 2;

(Calculation for specific Gravity)

Weight of the bottler=19.10g
Tap water Product water
Weight with water=45.47g Weight with water=44.4g

Water weight= 45.47-19.10=26.37g Weight of water=44.5-19.10=25.4g

Volume of the bottle=25ml
Density=mass/volume= Density=mass/volume =25.4/25=1.016g/ml
26.37/25=1.0548g/ml
Density of water=1g/cm3=1g/ml
S.G=1.0548/1=1.0548 S.G=1.016/1=1.0548

vii. Results
Tap water fed to the RO apparatus resulted in decreasing the values of its prescribed parameters
as expected, also RO system suggested that the conductivity of the water decreases along with
the TDS removal through RO membrane since it is a function of TDS. Moreover, the pH value
of the RO water has been lowered from the feed PH. The reason is the increase acidic nature of
the permeate water due to the presence of CO2.
viii. Warning:
Do not run water with temp over 50℃ through the unit under any conditions. First thing that has
to be done each morning is to run water through "Pure water" for 10 seconds before using or
drinking. If unused for 2 days or more "Pure water" for 60 seconds before drinking or using.

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COOLING TOWER

Introduction:
Cooling tower is a specialized heat rejection device. It is a heat exchanger that involved
the direct contact of hot water and cool dry air to extracts waste heat and release it to the
atmosphere. During this heat transfer process, a small amount of water is evaporated causing the
air temperature and the air humidity to increase to a certain degree. A cooling tower is applied in
different fields and industries including oil refineries, petrochemical industries, nuclear power
plant food processing plant and electric power generation plant.
Water which has been heated by industries processes is pumped to the top of the cooling
tower. Nozzle is used to spray the hot water evenly around the cooling tower. In an open circuit
cooling tower, hot water flows down the cooling tower through gravitational forces to pass
through a series of labyrinth-like packing structure. This is because the packed column increases
the contact area of hot water and dry air to maximize the air-water interface. As the water flows
through the cooling tower, electric air blower is used to supply the flow of air so that heat
exchange is able to occur between the hot water and cool dry air. After the water is cooled down,
it is sent back to the industries processing unit to absorb heat.
Theory:
When a component is transferred from a gas phase to solution in a liquid phase, the latent heat
associated with the condensation is evolved. In the operations where mass transfer proceeds by
equimolar counter diffusion, as in distillation or in operations where latent heat effect are small,
as in liquid –liquid extraction, gas absorption in dilute solutions, and leaching, heat transfer is of
minor importance as a rate controlling mechanism. In others, particularly where there is a net
transfer of mass from gas phase to condensed phase or vice versa, the heat transfer rate is
important. In these cases, heat transfer significantly limits the rate at which mass can be
transferred. Of those operations where both heat transfer and mass transfer affect the rate,
humidification and dehumidification involve two components and two phases. The liquid phase,
most often water, is single component, and the gas phase consists of a non-condensable gas,
usually air, in which some vapor from the liquid phase is present.

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Air Cooled V.S Water Cooled:

Whenever we talk about cooling towers, the comparison of two systems comes up. Each has its
pros and cons, but in dry areas often, air cooled chillers are more preferable. Also when the
reliability of the plant is very important and the dependency on water supply must be avoided.
This is usually the case for mission critical facilities such as data centers.
One of the main differences between the two systems is the absence of a cooling tower in an air-
cooled chiller system bringing benefits such as less maintenance and service requirement.

Efficient Working:

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Separation Process lab report

Cooling towers may be generally cost-effective for industrial cooling compared to other options,
but efficiency challenge can be a letdown. Monitoring the efficiency factor is crucial as it ensures
the following:

 Reduced water consumption

 Energy savings
 Extended equipment service life
 Reduced operating costs
To keep the cooling tower running efficiently, three things are important: understand the type of
cooling tower you are using, use chemicals efficiently and track down system water loss.

Industrial Applications:

 Water cooled air compressors

 Plastic Injection & Blow Moulding Machine
 Die casting machine
 Refrigeration and chilling plant
 Cold storage
 Anodizing processes plant
 Electrical power generation plant
 Water cooled air conditioning systems and VAM machines

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Separation Process lab report

Experiment No.4

i. Objective:
Calculate the range, approach and effectiveness of the cooling tower.
ii. Lab Equipment and Apparatus:
 Cooling Tower
 Stop Watch
 IL measuring cylinders
iii. Naked eye view of lab equipment:

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Separation Process lab report

iv. Procedure:
 Make-up tank of cooling tower is filled with water using 1L measuring cylinder.
 Water flow rate and blower speed are adjusted to 7.0 liters per minute and scale of 3/13
respectively.
 After 5 minutes, T1 ,T2 ,T3 ,T4 ,T5 ,T6 ,T7, T8 and T9 are recorded in a table.
 At the same condition, another 2 sets of result are recorded at an interval of 3 minutes which
is at the 8th and 11th minutes.
 The speed of blower is then adjusted to the scale of 6/13 and 9/13 at the same water flow
rate.
 Steps 1 to 5 are repeated at the water flow rate of 7.5 and 8.0 liters per minute.
 Results are recorded and tabulated in tables.

v. Observations and Calculations:

 Air Calculations:

Inlet Outlet:
T=22 ºC T=43 ºC

 Water Calculations:

Inlet Outlet:
T=45 ºC T=41 ºC

 Temperature Range:

T1-T2= 45-41 = 4 ºC
Dry Bulb Temperature = 16 ºC
Temperature Approach = 41-16 = 25 ºC

 Effectiveness:

Range
Effectiveness=
( Range+ Approach )
4
= x 100
4+ 25

= 13.7%

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Separation Process lab report

Experiment No.5
i. Objective:
Calculate the mass transfer coefficient of the cooling tower.
ii. Observations and Calculations:

 Water Calculations:

Inlet Outlet:
T=45 ºC T=41 ºC
Hot water flow rate = 7.6 LPM = 0.09 kg/s

 Air Calculations:

Inlet Outlet:
T=22 ºC T=43 ºC
Manometer Reading = ∆H = 0.073 m
Humidity= 56% Humidity= 77%
Hsat=0.0165 kg H2O/ kg dry air Hsat=0.0557 kg H2O/ kg dry air
H=0.095 kg H2O/kg dry air H=0.044 kg H2O/kg dry air

 Enthalpy of air at inlet

Hy1 = (1.005 + 1.88 H1) T1 + 2501 H1

Hy1= 24.26 kJ/ kg dry air

 Enthalpy of air at outlet

Hy2 = (1.005 + 1.88 H2) T2 + 2501 H2

Hy2= 156 kJ/ kg dry air

 Flow Rate Calculation

Vair = ((2.8 x 10-3 + 4.56 x 10-3) (H)) Ti

Vair = 0.847 m3/kg of dry air
G = 0.0137 √ (∆x/∆H)

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Separation Process lab report

G = 0.127 kg of dry air/sec

 Heat Calculation

Q = G (Hy2 - Hy1)
Q = 0.127 (156-42.26)
Q = 0.0139 kJ/s

 Enthalpy of air at saturation

Inlet:
Hy1’ = (1.005 + 1.88 H1’) T1 + 2501 H1’
Hy1’= 62.81 kJ/ kg dry air
Outlet:
Hy2’ = (1.005 + 1.88 H2’) T2 + 2501 H2’
Hy2’= 187 kJ/ kg dry air

iii. Cooling Tower Enthapy Calculations:

Sr. # Temperature Enthalpy at

Saturation
1 20 57.5
2 22 62.81
3 25 76
4 30 100
5 35 129
6 40 167
7 43 187
8 45 214
9 47 259

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Separation Process lab report

Enthalpy Calculations
300

250

200
Enthalpy

150

100

50

0
20 22 25 30 35 40 43 45 47
Temperature

Cooling Tower Enthalpy Calculations

 From Graph:
∆H1 = 130 ∆H2 = 56 ∆Hm = 95
f=∆Hm/∆H2-∆Hm/∆H1
f= 0.95
NOG= (H2-H1)/(f∆Hm)
NOG = 1.23
HOG=z/NOG=0.772/1.23
HOG =0.624 m
G
K GA=
M B P H OG
0.127
K GA=
28.84 ×101.325 ×0.624
K GA = 6.9 × 10 -8 kg-mol/ m 2 sec-Pa.

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Separation Process lab report

DISTILLATION COLOUMN
Introduction:
Separation process consist of distillation that can purified the organic liquid. This process
separating mixture into two or more products that consist of different boiling points through the
vaporization of a liquid mixture components and the recycling of counter-current gas liquid flow
in the column. Therefore, the liquid phase richer is less volatile which has higher boiling point
and the vapor phase is more volatile with the lower boiling point component. Distillation process
is the most of common separation used in industry because its known as 90% efficiency in
separation process and significantly user of energy in the heating process that necessarily
involved. The apparatus used in the distillation process is Distillation Column. The column of the
distillation column has many types of tray such as bubble cap trays, sieve tray and packed bed
column. The principal of bubble cap tray is not a counter current flow but cross flow on every
stage while sieve tray flow with counter current flow. Furthermore, packing column can have a
lower pressure drop and good for thermally sensitive liquid. To determine the appropriate tray, it
will consider the fouling tendency, allowable of pressure drop and turndown requirement in the
column.

Theory:
From the distillation column system, there are two principle method that need to be followed in
order to carry out the experiment which is batch distillation method and continuous steady state
distillation process. Batch distillation process is the process when there is no reflux and the vapor
that boiling the liquid mixture to be separated and condensing vapor not allowing any liquid to
return into the top column. Therefore, the continuous distillation process is vice versa. Some
example of continuous distillation is flash distillation (single stage partial vaporization) and
rectification distillation.
The separation of distillation process that use heating power can separate the vapor and liquid
phase. Heating element installed at the bottom of to ensure the liquid mixture evaporates in the
whole column. The vapor phase will rise up into the condenser and the product will be entering
into the distillate tank, meanwhile the liquid will go downward as a waste or bottom products.
There are two heat exchangers above the distillation column. The function of the second
exchanger acts as condenser which allow the vapor leaving the first exchanger using cooling

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Separation Process lab report

water. Then the reflux tank will be filled with the condensate that flow from condenser. The
electromagnetic controlled in the column by switching of on and off controlled the reflux ratio.
The remaining from the reflux tank then turned back to the top of the column. The separation
behaviour of the column can be analysed by the sample’s analysed for each stage. Therefore, the
refractive index of every sample analysed by refractor meter. The rectification is the mass
transfer between the two phases in equilibrium.
 Flow diagram for common distillation process is given as;

Performance comparison is given as follows;

 Batch Distillation:
a) Determine the composition of the liquid that is in the holding reservoir containing the
mixture by using the boiling point test and an x, y, T plot for methanol-water.
b) Use the Lab View program to initiate startup of the heating process to the reboiler.
c) Allow distillation column to reach steady-state.
d) Do composition analysis on the distillate (boiling point test).
e) Record time and volume readings in the re-boiler from the time the reboiler begins to

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Separation Process lab report

boil.

 Continuous Distillation:
a) Repeat steps 1-3 from above procedure.
b) Record the temperatures of each tray while at steady-state.
c) Perform calculations with the data obtained to determine tray efficiency.

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Separation Process lab report

Experiment # 6

i. Objective:
a) The specific gravity of the ethanol sample recovered from the distillation column is 1.1.
Compare the value of specific gravity of pure ethanol and calculate the percentage
composition of ethanol recovered. Perform the mass balance on the column and calculate
the mass fraction on top and bottom of the column when the feed is 50% water and 50%
ethanol.
b) Calculate the number of stages and composition on each plate by using MaCabe Thiele
method and Lewis Sorel method.
c) Calculate the plate efficiency of the column.

ii. Observations and Calculations:

 Specific Gravity Calculations

Specific Gravity = 1.1
Literature Value of 98%Ethanol at 25ᵒC = 0.79117
1.1−0.79117
Relative Error = ∗100
1.1
= 28.07%
Xf = 0.5
1.1−0.79
Now composition of water in top product = × 100=39.24 %
0.79
So ethanol in top product = 100-39.24 = 60.75%
 This gives;
Xd = 0.61
Xw = 0.39
 Mass Balance on Column
For 100 kmol of feed, an overall mass balance gives
100 = D + W
 Balance on Ethanol gives;
100 x 0.5 = 0.61 D +0.39 W
50 = 0.61 (100 – W) + 0.39 W

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Separation Process lab report

50 = 61 – 0.61 W + 0.39 W
11 = 0.22 W
W = 50
100 = D + 50
D = 50
As by reference to example 11.7
Ln = 3D = 3 x 50 = 150
Vn = Ln + D = 150 + 50 = 200
Thus the top operating line from the equation 11.35

yn = 0.75 xn+1 + 0.1525

Since the feed is all liquid at boiling point, this will run down as increased flux to the plate
below.
Lm = Ln + F =150 +100 = 250
Vm = Lm – W =250 – 50 = 200
Using 11.37 equation for bottom plate

ym = 1.25 xm+1 – 0.0975

 Equilibrium Data:

Mole fraction of alcohol in liquid Mole fraction of alcohol in vapor

0.1 0.43
0.2 0.526
0.3 0.577
0.4 0.615
0.5 0.655
0.6 0.70
0.7 0.754
0.8 0.82
0.89 0.89

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Separation Process lab report

Equlibrium Curve
1
Mole Fraction of Alcohol in Vapor 0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.89
Mole Fraction of Alcohol in liquid

 From graph;
Yn = 0.61 so xn = 0.39
ym = 1.25 xm+1 – 0.0975
yn- 1= 1.25 x 0.386 – 0.0975 = 0.385
xn-1 = 0.085
This shows that there is a single theoretical plate by Lewis Sorel Method.
The number of plate by McCabe Thiele Method is also one as shown below:

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Separation Process lab report

McCabe Thiele Method

 Plate Efficiency of the Column

The efficiency is given by
N OG
ϵ=
N OL
 Where NOG and NOL are given by;
y e- y n
N OG = ln ( )
y e- y n-1
x n+1- x e
N OL = ln ( )
x n- x e
Where ye and xe are calculated by
ye = mxn and xe = myn
ye = 0.2067 and xe = 0.3233
So putting values in their respective formulas,
0.2067 −0.89
N OG = ln ( )=0.10
0.2067 − 0.82

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Separation Process lab report

0.89−0.3233
N OL = ln ( )=0.17
0.8− 0.3233
0.10
ϵ= =0.5882× 100=58.82 %
0.17

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