ChE 61 : PROCESS EQUIPMENT DESIGN

STUDENT NAME: Michael Alex S. Mabao

EMAIL: mmichaelalexx@gmail.com
DEPARTMENT: Department of Chemical Engineering
SIGNATURE: ______________________________
PROBLEM 5.3

A liquid is contained in a reactor vessel at 115 bar absolute pressure. It is transferred to a storage
vessel through a 50 mm internal diameter commercial steel pipe. The storage vessel is nitrogen
blanketed and pressure above the liquid surface is kept constant at 1500 N/m2 gauge. The total
run of pipe between the two vessels is 200 m. The miscellaneous losses due to entry and exit
losses, fittings, valves, etc., amount to 800 equivalent pipe diameters. The liquid level in the
storage vessel is at an elevation 20 m below the level in the reactor. A turbine is fitted in the
pipeline to recover the excess energy that is available, over that required to transfer the liquid
from one vessel to the other. Estimate the power that can be taken from the turbine, when the
liquid transfer rate is 5000 kg/h. Take the efficiency of the turbine as 70%.

The properties of the fluid are: density 895 kg/m3, viscosity 0.76 mNm-2s.

GIVEN

Pipeline Diameter (D) = 50 mm = 0.05 m

𝛑𝑫𝟐 (3.14)(0.05𝑚)2
Cross sectional area of pipe (A) = 4
= 4
= 0.00196𝑚2

𝑘𝑔
liquid mass flow rate (m) = 5000 ℎ

𝑘𝑔
Density of liquid (ρ) = 895 𝑚3

SOLUTION
𝑘𝑔
𝑚 5000 𝑚
ℎ
liquid velocity in pipe (v) = ρA = 𝑘𝑔 𝑠𝑒𝑐 = 0.792 𝑠𝑒𝑐
(895 3 )(0.00196𝑚2 )(3600 )
𝑚 ℎ

Liquid viscosity (μ) = 0.76 mNm-2s

𝑘𝑔 𝑚
ρDv (895 3 )(0.792 )(0.05 m)
𝑚 𝑠𝑒𝑐
Reynolds number NRe = μ
= 0.76 𝑥 10−3 mPa.s
= 46634.2

Absolute roughness of commercial steel pipe r = 0.046 mm

𝑟 0.046 mm
Relative roughness rr = 𝐷 = 50 mm
= 0.00092

Friction factor (f) for the above Re and rr is 0.003. This value is obtained from Moody Chart
relating these values.

Total length of pipeline including miscellaneous losses L = 200𝑚 + (800𝑚 𝑥 0.05m) = 240𝑚
 𝑘𝑔 𝑚 2
8𝑓𝐿ρ𝑣 2 (8)(0.003)(240𝑚)(895 3 )(0.792 ) 𝑁
𝑚 𝑠𝑒𝑐
Friction loss in pipeline ΔPf = 2D
= 2(0.05 m)
= = 32336.7 𝑚2

The liquid level in the storage vessel is at an elevation 20 m below the level in the reactor.

Difference in elevation ΔZ= 20 m

𝑁
Pressure P1 = 115 bar = 1.15 𝑥 107 𝑚2

𝑁
Pressure P2 = 1500 𝑚2

𝑁 𝑁
Pressure difference ΔP= P1 - P2 = (1.15 𝑥 107 − 1500) 𝑚2 = 11498500 𝑚2

Energy balance

𝚫P 𝚫Pf
𝑔𝚫Z + − −𝑊 =0
ρ ρ

𝑚
g - acceleration due to gravity 9.81 𝑠2

𝐽
W - Work done 𝑘𝑔

𝑁 𝑁
𝑚 11498500 2 32336.7 2
(9.81 2 ) (20𝑚) + 𝑚 − 𝑚 −𝑊 =0
𝑠 𝑘𝑔 𝑘𝑔
895 3 895 3
𝑚 𝑚
𝐽
W = 13007.556 𝑘𝑔

Power = 𝑊𝑚η

η is efficiency = 70% = 0.7

𝐽 𝑘𝑔
(13007.556 )(5000 )(0.7)
𝑘𝑔 ℎ
Power = 𝑠 = 12646.235𝑊 = 12.65 𝑘𝑊
(3600 )
ℎ
PROBLEM 5.4

A process fluid is pumped from the bottom of one distillation column to another, using a centrifugal
pump. The line is standard commercial steel pipe 75 mm internal diameter. From the column to
the pump inlet the line is 25 m long and contains six standard elbows and a fully open gate valve.
From the pump outlet to the second column the line is 250 m long and contains ten standard
elbows, four gate valves (operated fully open) and a flow-control valve. The fluid level in the first
column is 4 m above the pump inlet. The feed point of the second column is 6 m above the pump
inlet. The operating pressure in the first column is 1.05 bara and that of the second column 0.3
barg.

Determine the operating point on the pump characteristic curve when the flow is such that the
𝑘𝑁
pressure drop across the control valve is 35 .
𝑚2

𝑘𝑔
The physical properties of the fluid are: density 875 , viscosity 1.46𝑚𝑁𝑚−2𝑠.
𝑚3

Also, determine the NPSH, at this flow-rate, if the vapor pressure of the fluid at the pump suction
𝑘𝑁
is 25𝑚2.

Pump characteristic

Flow 0.0 18.2 27.3 36.3 45.4 54.5 63.6

𝑚3
rate, ℎ
Head, m 32.0 31.4 30.8 29.0 26.5 23.2 18.3
of liquid

The Design Requirements

The problem requires the NPSH and the operating point on the pump characteristic curve.

GIVEN

D= 75 mm 𝑃1 = 1.05 bar absolute 𝑃2 = 0.03 bar gauge

𝑘𝑔
ρ= 875 𝑚3 µ= 1.46mPas
𝑧1 = 4𝑚 𝑧2 = 6𝑚
Length pump inlet: 25m
Length pump outlet: 250m
Miscellaneous Losses:
Type of Fitting or Valve Number of Velocity Heads, Equivalent Pipe Diameters,
K L/D
Entry 0.5 25
Elbows, 90° 0.8x(16) 40x(16)
Gate valve, fully open 0.15 x(5) 7.5x(5)
Exit 1.0 50
Total 15.05 752.5
Equivalength length of pipe = 752.5𝑥0.075𝑚 = 56.4375𝑚
Total length = 25𝑚 + 250𝑚 + 56.4375𝑚 = 331.4375𝑚

SOLUTION

Static Head
Difference in elevation ∆𝑧 = 6𝑚 − 4𝑚 = 2𝑚
1𝑎𝑡𝑚 101325𝑃𝑎
Difference in pressure, ∆𝑃 = [(. 03𝑏𝑎𝑟𝑔 + 1𝑏𝑎𝑟) − 1.05𝑏𝑎𝑟] ( )( )
1𝑏𝑎𝑟 1𝑎𝑡𝑚
= 25331.25 𝑃𝑎
25331.25 𝑃𝑎
As head of liquid= 𝑘𝑔 𝑚 = 2.95𝑚
875 3 𝑥9.8 2
𝑚 𝑠
Total Static Head= 2𝑚 + 2.95𝑚 = 4.95𝑚

Dynamic head
𝑚3
As an initial value, take initial flow rate: 36.3 ℎ𝑟
0.075𝑚 2
Cross-sectional area of pipe= 𝜋 ( 2
) = 4.418𝑥10−3 𝑚3
𝑚3 1 1ℎ𝑟 𝑚
Velocity, 𝑣 = 36.3 ℎ𝑟 𝑥 4.418𝑥10−3 𝑚3 𝑥 3600𝑠 = 2.282 𝑠
𝑚 𝑘𝑔
𝐷𝑣𝜌 (0.075𝑚)(2.282 )(875 3 )
𝑠 𝑚
Reynolds Number, 𝑁𝑅𝐸 = = 𝑚𝑁 1𝑃𝑎 𝑠 = 102,572.774
𝜇 1.46 2 𝑥
𝑚 𝑠 1000 𝑚𝑃𝑎 𝑠
−5
Commercial Steel Pipe, 𝜀 = 4.6𝑥10
𝜀 4.6𝑥10−5
Relative Roughness, 𝐷 = 0.075 = 0.0006
Friction factor form Figure 5.7, 𝑓 = 0.0025
𝑘𝑔 𝑚 2
𝐿 𝜌𝑣 2 331.4375 (875𝑚3 )(2.282 𝑠 )
Pressure Drop, ∆𝑃𝑓 = 8𝑓 𝐷 2 = 8(0.0025) ( 0.075 ) 2
2
= 201363.0192𝑁/𝑚
201363.0192𝑁
𝑚2
As liquid head= 𝑘𝑔 𝑚 = 23.48𝑚
875 3 𝑥9.8 2
𝑚 𝑠
𝑘𝑁
35 2 (1000)
𝑚
Pressure drop across control valve= 𝑘𝑔 𝑚 = 4.08𝑚
875 3 𝑥9.8 2
𝑚 𝑠
Total Static Head= 4.08𝑚+4.95𝑚 = 9𝑚
Total Head at this flow rate= 9𝑚+23.48𝑚 = 32.51𝑚

𝑚3
Repeat calculations for flow rates: 18.2, 27.3, 45.4, 54.5 and 63.6 ℎ𝑟 .
Flow Rate Head of Liquid Static Head Dynamic Head Total Head
0 32 9 0 0
18.2 31.4 9 5.9 14.9
27.3 30.8 9 13.1 22.1
36.3 29 9 23.48 32.48
45.4 26.5 9 35.16 44.16
54.5 23.2 9 49.96 58.96
63.6 18.3 9 66.34 75.32
 70

60

LIQUID HEAD 50

40

30

20

10

0
0 10 20 30 40 50 60 70
FLOW RATE

By plotting operation curve on the pump characteristics, operating points is found to be

𝑚3
29.6m at 33 ℎ𝑟 .
Suction Head
Miscellaneous Losses= (25 + 6(40) + 7.5)(0.075𝑚) = 20.4375
Total length of inlet piping= 25𝑚 + 20.4375 = 45.4375𝑚
𝑚3 1 1ℎ𝑟 𝑚
Velocity, 𝑣 = 33 ℎ𝑟 𝑥 4.418𝑥10−3 𝑚3 𝑥 3600𝑠 = 2.075 𝑠
𝑘𝑔 𝑚 2
𝐿 𝜌𝑣 2 45.4375𝑚 (875 3 ) (2.075 )
𝑚 𝑠
∆𝑃𝑓 = 8𝑓 = 8(0.0025) ( ) = 22714.433 𝑃𝑎
𝐷 2 0.075𝑚 2
𝑘𝑁
Vapor pressure of the fluid at the pump suction= 25 2
𝑚
1𝑎𝑡𝑚 101325𝑃𝑎 𝑘𝑁
1.05𝑏𝑎𝑟)( )( ) 22714.433 𝑃𝑎 25 2 𝑥1000
1𝑏𝑎𝑟 1𝑎𝑡𝑚 𝑚
NPSH= 4𝑚 + ( 𝑘𝑔 𝑚 )−( 𝑘𝑔 𝑚 )− 𝑘𝑔 𝑚 = 10.84𝑚
875 3 𝑥9.8 2 875 3 𝑥9.8 2 875 3 𝑥9.8 2
𝑚 𝑠 𝑚 𝑠 𝑚 𝑠
PROBLEM 5.5

A polymer is produced by the emulsion polymerisation of acrylonitrile and methyl methacrylate in

a stirred vessel. The monomers and an aqueous solution of catalyst are fed to the polymerisation
reactor continuously. The product is withdrawn from the base of the vessel as a slurry. Devise a
control system for this reactor, and draw up a preliminary piping and instrument diagram. The
follow points need to be considered:

1. Close control of the reactor temperature is required.

2. The reactor runs 90 per cent full.

3. The water and monomers are fed to the reactor separately.

4. The emulsion is a 30 per cent mixture of monomers in water.

5. The flow of catalyst will be small compared with the water and monomer flows.

6. Accurate control of the catalyst flow is essential.