CHEMCAD and Solids

The process of crystallization, fusion, and melting are too complex to approach with general
rules. For most systems, only an empirical model is accurate. As such, process simulators do
not inherently address solids.

CHEMCAD provides two approaches to dealing with solids. A third approach is recommended
as an analog model that is often used as a workaround

Defined Solids

Select Thermophysical > Solids > Identify Solid Components to define a component as a
solid. The vapor pressure of solid components is ignored for flash calculations. In separation
units, the solid components will always leave with the heavy liquid stream. Heat capacity data
is taken for the solid, if present.

You can select Thermophysical > Solids > Particle Size Distribution to specify the particle
size distribution (PSD) of a solid.

The various solids handling unit operations can be used with defined solids. Several solid
separation UnitOps in CHEMCAD use the PSD for solid separation.

Electrolyte Salts

Using the true species electrolytes model, you can define an electrolyte as a possible
precipitate. The electrolyte model will determine whether the salt precipitates during the flash
calculation of a stream. A precipitated salt follows the same behavior as a defined solid. If you
have solubility data for a salt, it can be regressed into the electrolyte system. The heat of
solution for an electrolyte salt can be regressed into the electrolyte system.

Analog Model

If you have temperature-dependent solubility data for the system of your process, you can
regress temperature vs. solubility data into a kinetic expression. You can create a separate
component as a solid; use a kinetic reactor to change the component to a solid component.

Baghouse Filter (BAGH)

The BAGH module simulates or rates the operation of a standard fabric filter dust collector.
The module calculates the collection efficiency and pressure drop or flow through the dust bed
and fabric. Collection efficiency is defined by entering a particle size versus efficiency table.
By defining the flow resistances of the bed and fabric and the cleaning cycle, the user may
calculate either the flow or the pressure drop.

Specifications Tab

Select Calculation Mode

0  =        Specify number of cells and time of filtration. Calculate pressure drop.

1  =        Specify number of cells and allowable pressure drop. Calculate filtration time.

2  =        Specify filtration time and allowable pressure drop. Calculate number of cells.

Number of cells

The number of cells is required for rating calculations (mode 0 or 1).

Time of filtration

Filtration time is required for mode 0 or 2. Default is 30 minutes. Units are from engineering units
setting.

Pressure drop

Maximum allowable pressure drop is required for mode 1 or 2.

Cloth resist. factor

Default value is 0.84 (in. H2O) / (centipoise) / (ft./min.). Pressure drop through the cloth is
expressed as:

Dc   =   Kc  *  vis  *  Vf

where

Dc        =        cloth pressure drop, in. H2O.

vis        =        fluid viscosity, centipoise.

Vf        =        superficial velocity of gas through cloth, ft/min.

Dust resist. factor

Default value is 0.1 (in. H2O) / (centipoise) / (grains/ft2) / (ft/min).  Pressure drop through the
dust layer is expressed as:
Dd   =   Kd   *  vis  *  M s *  Vf

where

Dd        =        dust pressure drop, in. H2O.

vis        =        fluid viscosity, centipoise.

Ms        =        Mass of solids per unit of cloth area, grains/ft2.

Vf        =        Superficial velocity of gas through cloth, ft/min.

Cells cleaned

At any given time, a defined number of cells may be out of service for cleaning.  This number
is required for both design and rating calculations.  Default value = 1.

Bags per cell

Required input, default = 78.

Bag diameter

Required input, default = 0.5 ft.

Filter area per bag

Required input, default = 16 ft2.

Calculated Results

Pressure drop

Calculated pressure drop for mode 0.

Efficiency

Calculated overall efficiency, solids collected / solids in feed.

Floor space

Calculated floor space, all modes.

Gas velocity
Calculated gas velocity through active filters, all modes.

Performance table

The baghouse model uses an empirical efficiency model since there is no usable theoretical
model. You can enter a table of collection efficiencies versus particle size on Screen no. 2;
otherwise, the Sylvan chart with the following efficiency data will be used:

Efficiency
Particle Size (microns)
0.3 0.50
0.45 0.60
1.0 0.75
1.5 0.80
3.5 0.90
7.5 0.95
11.0 0.97
24.0 0.99
Topology

A BAGH unit has one inlet and two outlets. Cleaned gas exits in the first outlet. Collected dust
exits in the second outlet.

Methods

The method involves summing the pressure drops through the cloth (Dc) and the dust (Dd)
according to the following equation:

Dp  =  Dc  +  Dd

Given the required input flow and its calculated viscosity, you can specify two of the three
variables: pressure drop (Dp), number of cells, or filtration time. Cell and bag geometry will
convert flow rate into velocity for use in the pressure drop equations. Specific resistance
parameters (Kc and Kd) are usually part of the users' and vendors' art and experience, but
Perry's Handbook can provide some guidance.