Transport Processes and Unit Operations, Third Edition.pdf

Transport Processes and Unit Operations

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CHRISTIE J. GEANKOPLIS University of Minnesota

Transport Processes and Unit Operations THIRD EDITION

Prentice-Hall International. Inc.

ISBN 0-13-045253-X

This edition may be sold only in those countries to which it is consigned by Prentice-Hall International. It is not to be re-exported and it is not for sale in the U.S.A., Mexico, or Canada.

© 1993, 1983, 1978 by P T R Prentice-Hall, Inc. A Simon & Schuster Company Englewood Cliffs, New Jersey 07632

All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.

Printed in the United States of America 10

9

ISBN 0-13-045253-X

Prentice-Hall International (UK) Limited, London Prentice-Hall of Australia Ply. Limited, Sydney Prentice-Hall Canada Inc., Toronto Prentice-Hall Hispanoamericana, S.A., Mexico Prentice-Hall of India Private Limited, New Delhi Prentice-Hall of Japan, Inc., Tokyo Simon & Schuster Asia Pte. Ltd., Singapore Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro Prentice-Hall, Inc., Englewood Cliffs, New Jersey

I

.;

Dedicated to the memory of my beloved mother, Helen, for her love and encouragement

Contents xi

Preface

PART 1 TRANSPORT PROCESSES: MOMENTUM, HEAT, AND MASS Chapter I 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Classification of Unit Operations and Transport Processes SI System of Basic Units Used in This Text and Other Systems Methods of Expressing Temperatures and Compositions Gas Laws and Vapor Pressure Conservation of Mass arid Material Balances Energy and Heat Units Conservation of Energy and Heat Balances Graphical, Numerical, and Mathematical Methods

Chapter 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11

Principles of Momentum Transfer and Overall Balances

Introduction Fluid Statics General Molecular Transport Equation for Momentum, Heat, and Mass Transfer Viscosity of Fluids Types of Fluid Flow and Reynolds Number OveraII Mass Balance and Continuity Equation Overall Energy Balance Overall Momentum Balance Shell Momentum Balance and Velocity Profile in Laminar Flow Design Equations for Laminar and Turbulent Flow in Pipes Compressible Flow of Gases -

Chapter 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11

Introduction to Engineering Principles and Units

Principles of Momentum Transfer and Applications

Flow Past Immersed Objects and Packed and Fluidized Beds Measurement of Flow of Fluids Pumps and Gas-Moving Equipment Agitation and Mixing of Fluids and Power Requirements Non-Newtonian Fluids Differential Equations of Continuity Differential Equations of Momentum Transfer or Motion Use of Differential Equations of Continuity and Motion Other Methods for Solution of Differential Equations of Motion Boundary-Layer Flow and Turbulence Dimensional Analysis in Momentum Transfer

1

1 3 5 7

9 14 19 23

31 31 32

39 43

47 50 56

69 78 83 lOl 114

114

127 133

140 153 164

170 175

184 190 202

vii

Chapter 4

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 1.10 4.11 4.12 4.13 4.14 4.15

Introduction and Mechanisms of Heat Transfer Conduction Heat Transfer Conduction Through Solids in Series Steady-State Conduction and Shape Factors Forced Convection Heat Transfer Inside Pipes Heat Transfer Outside Various Geometries in Forced Convection Natural Convection Heat Transfer Boiling and Condensation Heat Exchangers Introduction to Radiation Heat Transfer Advanced Radiation Heat-Transfer Principles Heat Transfer of Non-Newtonian Fluids Special Heat-Transfer Coefficients Dimensional Analysis in Heat Transfer Numerical Methods for Steady-State Conduction in Two Dimensions

Chapter 5

5.1 5.2 5.3 5.4 5.5 5.6 5.7

Principles of Steady-State Heat Transfer

Principles of Unsteady -State Heat Transfer

Derivation of Basic Equation Simplified Case for Systems with Negligible Internal Resistance Unsteady-State Heat Conduction in Various Geometries Numerical Finite-Difference Methods for Unsteady-State Conduction Chilling and Freezing of Food and BiolOgIcal Materials Differential Equation of Energy Change Boundary-Layer Flow and Turbulence in Heat Transfer

Chapter 6

Principles of Mass Transfer

6.1 Introduction to Mass Transfer and Diffusion 6.2 Molecular Diffusion in Gases 6.3 Molecular Diffusion in Liquids 6.4 Molecular Diffusion in Biological Solutions and Gels 6.5 Molecular Diffusion in Solids 6.6 ,_Nu~erical Methods for Steady-State Molecular Diffusion in Two Dimensions

Chapter 7

7.1 7.2 73

7.4 7.5 7.6 7.7 7.8 7.9 viii

Principles of Unsteady -State and Convective Mass Transfer

Unsteady-State Diffusion Convective Mass-Transfer Coefficients Mass-Transfer Coefficients for Various Geometries Mass Transfer to Suspensions of Small Particles Molecular Diffusion Plus Convection and Chemical Reaction Diffusion of Gases in Porous Solids and Capillaries Numerical Methods for Unsteady-State Molecular Diffusion Dimensional Analysis in Mass Transfer Boundary-Layer Flow and Turbulence in Mass Transfer

214 214 220 223 233

236 247 253 259 267 276 281 297 300

308 310

330 330 332

334 350 360

365 370

381 381 385 397 403 408 413

426 426 432 437 450

453 462 468 474

475 Contents

PART 2

UNIT OPERATIONS Chapter 8

8.1 8.2 8.3 8.4 85 8.6 8.7 8.8

Evap H 2 0

(1.5-10)

An accounting of the total moles of O 2 in the fuel gas is as follows: mol 02in fuel gas

(i)27.2(CO)

+ 5.6(C0 2) + 0.5(0 2 )

= 19.7 mol O 2

For all the Hz to be completely burned to H 20, we need from Eq. (1.5-10) mol O 2 for 1 mol H2 or 3.1(t) = 1.55 total mol O 2 , For completely burning the CO fwm Eq. 0.5-9), we need 27.2(~) = 13.6 mol O 2 , Hence, the amount of O 2 we must add is, theoretically, as follows:

i

mol O 2 theoretically needed = 1.55

+ 13.6 -

0.5 (in fuel gas)

1{65 mol O 2 For a 20"/" excess, we add 1.2(14.65), or 17.58 mol O 2 , Since air contains 79 mol % N z • the amount ofN2 added is (79/21)(17.58), or 66.1 mol N z . To calculate the moles in the final flue gas, all theH z gives H 20, or 3.1 mol H 2 0. For CO, 2.0% does not react. Hence, 0.02(27.2), or 0.54, mol CO will be unburned. A total carbon balance is as follows: inlet moles C = 27.2 + 5.6 = 32.8 mol C. In the outlet flue gas, 0.54 mol will be as CO and the remainder of 32.8 - 0.54, or 32.26, mol as CO 2 . For calculating the outlet mol O 2 , we make an overall O 2 balance. O 2 in O 2 out

=

19.7 (in fuel gas)

+ 17.58 (in

air)

=

37.28 mol O 2

(3.1/2) (in H 2 0) + (0.54/2) (in CO) + 32.26 (in CO 2) + free O 2

Equating inlet O 2 to outlet, the free remaining O 2 = 3.2 mol O 2 , For the N2 balance, the outlet = 63.6 (in fuel gas) + 66.1 (in air), or 129.70 mol N 2 . The outlet flue gas contains 3.10 mol H 2 0, 0.54 mol CO, 32.26 mol CO 2 , 3.20 mol O 2 , and 129.7 mol N 2 • In chemical reactions with several reactants, the limiting reactant component is defined as that compound which is present in an amount less than the amount necessary for it to react stoichiometrically with the other reactants. Then the percent completion df a reaction is the amount of this limiting reactant actually converted, divided by the amount originally present, times 100. Sec. 1.5

Conservation of Mass and Material Balances

13

1.6 1.6A

ENERGY AND HEAT UNITS

Joule, Calorie, and Btu

In a manner similar to that used in making material balances on chemical and biological processes, we can also make energy balances on a process. Often a large portion of the energy entering or leaving a system is in the form of heat. Before such energy or heat balances are made, we must understand the various types of energy and heat units. In the Sf system energy is given in joules (1) or kilojoules (kJ). Energy is also expressed in btu (British thermal unit) or cal (calorie). The g calorie (abbreviated cal) is defined as the amount of heat needed to heat 1.0 g water 1.0D C (from 14.5°C to 15.5°C). Also, 1 kcal (kilocalorie) 1000 cal. The btu is defined as the amount of heat needed to raise 1.0 lb water 1°F. Hence, from Appendix A.I, 1 btu

1.6B

252.16 cal

= 1.05506 kJ

(1.6-1)

Heat Capacity

The heat capacity of a substance is defined as the amount of heat necessary to increase the temperature by 1 degree. It can be expressed for I g, lib, 1 g mol, 1 kg mol, or I Ib mol of the substance. For example, a heat capacity is expressed in SI units as J/kg mol· K; in other u!1its as cal/g· dc. caljg mol, DC, kcal/kg mol· DC, btu/lb m • OF, or btu/lb mol· OF. It can be shown that the actual numerical value of a heat capacity is the same in mass units or in molar units. That is,

1.0 caljg' DC

=

1.0 btu/Ibm' OF

(1.6-2)

1.0 caljg mol· °C

=

1.0 btu/lb mol, OF

(1.6-3)

For example, to prove this, suppose that a substance has a heat capacity of 0.8 btu/Ibm' OF. The conversion is made using 1.8°F for PC or 1 K, 252.16 cal for 1 btu, and 453.6 g for 1 Ibm' as follows: cal ') heat capacity ( g 0c

btu )( cal)( 1 )( OF) ( 0.8 Ibm' OF 252.16 btu 453.6 g/lb 1.8 DC m

0.8

cal 0C g'

The heat capacities of gases (sometimes called specific heat) at constant pressure c p are functions of temperature and for engineering purposes can be assumed to be independent of pressure up to several atmospheres. I n most process engineering calculations, one is usually interested in the amount of heat needed to heat a gas from one temperature t I to another at 12 , Since the cp varies with temperature, an integration must be performed or a suitable mean cpm used. These mean values for gases have been obtained for Tl of 298 K or 25 c C (77°F) and various T2 values, and are tabulated in Table 1.6-1 at 101.325 kPa pressure or less as Cpm in kJ/kg mol, K at various values ofT2 in K or 0c. EXAMPLE 1.6-1. Heating ofN z Gas The gas N2 at 1 atm pressure absolute is being heated in a heat exchanger. Calculate the amount of heat needed in J to heat 3.0 g mol N z in the 14

Chap. }

Introduction to Engineering Principles and Units

TABLE

1.6-1.

Mean Molar Heat Capacities o/Gases Between 298 and TK (25 and roC) at 101.325 kPa or Less(SI Units: c p kJ/kg mol- K)

T(KI 298

25

373 473 573 673 773 873 973 1073 1173 1273 1473 1673

100 200 300 400 500 600 700 800 900 1000 1200 1400

H2

N2

co

Air

O2

H 20

CO 2

CH 4

S02

28.86 28.99 29.13 29.18 29.23 29.29 29.35 29.44 29.56 29,63 29,84 30,18 30.51

29.14 29.19 29.29 29,46 29.68 29.97 30.27 30.56 30,85 3U6 31.43 31.97 32.40

29.16' 29.24 29.38 29.60 29.88 30,19 30,52 30.84 31.16 31.49 31.77 32.30 32.73

29.19 29.29 29.40 29.61 29.94 30.25 30.56 30.87 31.18 31.48 31.79

29.38 29.66 30.07 30.53 31.01 31.46 31.89 32.26 32.62 32.97 33.25 33.78 34.19

33.59 33.85 34.24 34.39 35.21 35.75 36.33 36.91 37.53 38.14 38.71 39.88 40.90

37.20 38.73 40.62 42.32 43.80 45.12 46.28 47.32 48.27 49,15 49,91 51.29 52.34

35.8 37.6 40.3 43.1 45.9 48.8 51.4 54.0 56.4 58.8 61.0 64.9.

39.9 41.2 42,9 44.5 45.8 47.0 47.9 48.8 49.6 50.3 50.9 51.9

32.32 3276

Mean Molar Heat Capacities of Gases Between 25 and TOC at 1 atm Pressure or Less (English Units: cp = btu/lb mol· °F) T('C)

Hz

N,

CO

25 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 {700 1800 1900 2000 2100 2200

6.894 6.924 6.957 6.970 6.982 6.995 7.011 7.032 7.060 7.076 7.128 7.169 7.209 7.252 7.288 7,)26 7.386 7.421 7,467 7.505 7.548 7,588 7.624

6.961 6.972 6.996 7.036 7.089 7.159 7.229 7.298 7.369 7.443 7,507 7,574 7.635 7.692 7.738 7.786 7.844 7.879 7.924 7,957 7.994 8,028 8.054

6,965 6.983 7.017 7.070 7.136 7.210 7.289 7.365 7.44) 7.521 7.587 7,653 7.714 7,772 7.818 7,866 7,922 7,958 8.001 8.033 8.069 8.101 8.127

Air

O2

NO

6.972 7,017 7.134 6.996 7.083 7.144 7.021 7.181 7.224 7.073 7.293 7.252 7.152 7.406 7.301 7.225 7.515 7.389 7.299 7,616 7,470 7.374 7.706 7.549 7.447 7.792 7.630 7.520 7.874 7.708 7.593 7.941 7.773 7.660 8,009 7.839 7.719 8.068 7.898 7.778 8,123 7.952 7,824 8.166 7.994 7.873 8.203 8.039 7.929 8,269 8,092 7.965 8.305 8.124 8.010 8.349 8.164 8.043 8.383 8.192 8.081 8.423 8.225 8,115 8.460 8.255 8.144 8.491 8,277

H,O

CO,

8.024 8.084 8.177 8.215 8.409 8.539 8.678 8.816 8.963 9.109 9.246 9.389 9.524 9,66 9,77 9.89 9,95 10.13 10.24 10.34 10,43 10.52 10.61

8.884 9.251 9.701 10.108 10.462 10.776 11.053 11.303 11.53 11.74 11.92 12.10 12,25 12.39 12.50 12.69 12.75 12.70 12.94 13.01 13.10 13.17 13,24

HC! Cl 2 CH.

S02 C2 H. SO, C,H 6

6,96 6.97 6.98 7.00 7.02 7.06 7.10 7.15 7.21 7.27 7.33 7.39 7.45

9.54 9.85 10.25 1D.62 10.94 11.22 11.45 11.66 11.84 12.01 12.15 12.28 12.39

8:12 8.24 8.37 8,48 8.55 8.61 8.66 8.70 8.73 8.77 8.80 8.82 8.94

8.55 8.98 9.62 10.29 10.97 11.65 12.27 12.90 13.48 14.04 14.56 15.04 15.49

10,45 11.35 12.53 13.65 14.67 15.60 16.45 17.22 17.95 18.63 19.23 19.81 20.33

12.11 12.84 13.74 14.54 15.22 15.82 16.33 16.77 17.17 17.52 17.86 18.17 18.44

12.63 13.76 15.27 16.72 18.11 19.39 20.58 21.68 22.72 23.69 24.56 25.40 26.15

Source: O. A, Hougen, K. W. Watson, and R. A. Ragatz, Chemical Process Principles, Par! I, 2nd ed. New York: John Wiley & Sons, Inc" 1954. With pennission.

rollowing temperature ranges: (a) 298-673 K (25·400°C) (b) 298-1123 K (25-850°C) (c) 673-1123 K (400-850°C) Sec. 1.6

Energy and Heal Units

15

Solution:

For case (a), Table 1.6-1 gives c pm values at 1 atm pressure or less and can be used up to several atm pressures. For N z at 673 K,c pm = 29.68 kJ/kg mol· K or 29.68 J/g mol· K. This is the mean heat capacity for the range 298-673 K. heat required = M g mol

(c

pm

g

m~I' K}Tz- TdK

(1.6-4)

Substituting the known values, heat required

= (3.0)(29.68)(673 - 298) = 33390 J

For case (b), the cpm at 1123 K (obtained by linear interpolation between 1073 and 1173 K) is 3l.00 J /g mol· K. heat required

=

3.0(31.00)(1123 - 298)

=

76725 J

For case (c), there is no mean heat capacity for the interval 673-1123 K. However, we can use the heat required to heat the gas from 298 to 673 K in case (a) and subtract it from case (b), which includes the heat to go from 298 to 673 K plus 673 to 1123 K. heat required (673-1123 K)

=

heat required (298-1123 K) - heat required (298-673)

(1.6-5)

Substituting the proper values into Eq. (l.6-5), heat required

=

76725 - 33390

=

43 335 J

On heating a gas mixture, the total heat required is determined by first calculating the heat required for each individual component and then adding the results to obtain the total. The heat capacities of solids and liquids are also functions of temperature and independent of pressure. Data are given in Appendix Ac2, Physical Properties of Water; A.3, Physical Properties of Inorganic and Organic Compounds; and A.4, Physical Properties of Foods and Biological Materials. More data are available in (PI).

EXAMPLE 1.6-2.

Heating o/Milk

Rich cows' milk (4536 kg/h) at 4.4°C is being heated in a heat exchanger to 54.4°C by hot water. How much heat is needed?

Solution:

From Appendix A.4 the average heat capacity of rich cows' milk is 3.85 kJ/kg' K. Temperature rise, Ll T = (54.4 - 4.4 tC = 50 K. heat required

=

(4536 kgjh)(3.85 kJ/kg' K)(1/3600 h/s)(50 K)

=

242.5 kW

The enthalpy, H, of a substance in J/kg represents the sum of the internal energy plus the pressure-volume term. For no reaction and a constant-pressure process with a change in temperature, the heat change as computed from Eq. (1.6-4) is the difference in enthalpy, LlH, of the substance relative to a given temperature or base point. In other units, H = btu/Ibm or cal/g. 1.6C

Latent Heat and Steam Tables

Whenever a substance undergoes a change of phase, relatively large amounts of heat changes are involved at a constant temperature. For example, ice at oDe and 1 atm pressure can absorb 6013.4 kJ/kg mol. This enthalpy change is called the latent heat of fusion. Data for other compounds are available in various handbooks (PI, WI). 16

Chap. 1

Introduction to Engineering Principles and Units

When a liquid phase vaporizes to a vapor phase under its vapor pressure at constant temperature, an amount of heat called the latent heat oj vaporization must be added. Tabulations of latent heats of vaporization are given in various handbooks. For water at 25°e and a pressure of23.75 mm Hg, the latent heat is 44020 kJ/kg mol, and at 25°e and 760 mm Hg, 44045 kJ/kg mol. Hence, the effect of pressure can be neglected in engineering calculations. However, there is a large effect of temperature on the latent heat of water. Also, the effect of pressure on the heat capacity of liquid water is small and can be neglected. Since water is a very common chemical, the thermodynamic properties of it have been compiled in steam tables and are given in Appendix A.2 in SI and in English units.

EXAMPLE 1.6-3. UseoJSteam Tables Find the enthalpy change (i.e., how much heat must be added) for each of the following cases using SI and English units. (a) Heating 1 kg (Ibm) water from 2Llloe (70°F) to 60 e (140"F) at 101.325 kPa (1 atm) pressure. (b) Heating 1 kg (Ibm) water from 21.l1"e (70°F) to 115.6"e (24{rF) and vaporizing at 172.2 kPa (24.97 psi a). (c) Vaporizing 1 kg (Ibm) water at 115.6°e (240°F) and 172.2 kPa (24.97 psia). 0

Solution: For part (a), the effect of pressure on the enthalpy ofliquid water is negligible. From Appendix A.2, H at 21.11°e

88.60 kJ/kg

or

at

Hat 60 0 e

251.13 kJ/kg

or

at 140°F = 107.96 btu/Ibm

change in H = 6.H = 251.13

70"F

=

38.09 btu/Ibm

88.60 = 162.53 kJ/kg

= 107.96 - 38.09 = 69.87 btu/lb m

In part (b), the enthalpy at 115.6°e (240°F) and 172.2 kPa (24.97 psia) of the saturated vapor is 2699.9 kJ/kg or 1160.7 btu/Ibm. change in H

6.H

2699.9

88.60 = 2611.3 kJ/kg

1160.7

38.09 = 1122.6 btu/Ibm

The latent heat of water at 115.6°e (240°F) in part (c) is 2699.9

484.9 = 2215.0 kJ/kg

1160.7 - 208.44 = 952.26 btu/lb m

1.6D

Heat of Reaction

When chemical reactions occur, heat effects always accompany these reactions. This area where energy changes occur is often called thermochemistry. For example, when Hel is neutralized with NaOH, heat is given off and the reaction is exothermic. Heat is absorbed in an endothermic reaction. This heat of reaction is dependent on the chemical nature of each reacting material and product and on their physical states. For purposes of organizing data we define a standard heat of reaction 6.Ho as the change in enthalpy when 1 kg mol reacts under a pressure of 101.325 kPa at a temperSec. 1.6

Energy and Heat Units

17

ature of 298 K (25°C). For example, for the reaction (1.6-6) the !1Ho is - 285.840 x 10 3 kJjkg mol or 68.317 kcal/g mol. The reaction is exothermic and the value is negative since the reaction loses enthalpy. In this case, the H2 gas reacts with the O 2 gas to give liquid water, all at 298 K (25°C). Special names are given to !1Ho depending upon the type of reaction. When the product is formed from the elements, as in Eq. (1.6-6), we call the!1Ho, heat oJJormation of the product water, !1HJ . For the combustion ofCH", to form CO 2 and H 2 0, we call it heat oj combustion, !1H~ . Data are given in Appendix A.3 for various values of !1H~. EXAMPLE 1.6-4. Combustion oJCarbon A total of 10.0 g mol of carbon graphite is burned in a calorimeter held at 298 K and 1 atm. The combustion is incomplete and 90% of the C goes to CO 2 and 10% to CO. What is the total enthalpy change in kJ and kcal? Solution: From Appendix A.3 the !1H~ for carbon going to CO 2 is - 393.513 X 10 3 kJ/kg mol or - 94.0518 kcal/g mol, and for carbon going to CO is -110.523 X 10 3 kJ/kg mol or 26.4157 kcalfg moL Since 9 mol CO 2 and 1 mol CO are formed,

+ I( -110.523) 9(-94.0518) + I( 26.4157)

total !1H = 9( - 393.513)

- 3652 kJ 872.9 kcal

=

If a table of heats of formation, !1HJ, of compounds is available, the standard heat of the reaction, !1Ho, can be calculated by

!1HO

I

!1HJ (product,)

I

!1H f (react.nt,)

( 1.6-7)

In Appencix A.3, a short table of some values of 6.Hf is given. Other data are also available (HI, PI, SI). EXAMPLE 1.6-5. Reaction oJMethane For the following reaction of I kg mol ofCH", at 101.32 kPa and 298 K, CH 4 (g)

+

HzO(l)-+ CO(g)

+ 3H z(g)

calculate the standard heat of reaction 6.Ho at 298 K in kJ. Solution: From Appendix A.3, the following standard heats of formation are obtained at 298 K: M{~ (kJ/kg rna£)

- 74.848 X 10 3 285.840 X [03 110.523 x 10 3

CH 4 (g) HzO(l) CO(g) Hz(g)

o

Note that the !1HJ of all elements is, by definition, zero. Substituting into Eq. (1.6-7), Mlo

( =

18

110.523 x 10 3

+ 250.165

X

-

3(0)] - (

10 3 kJ/kg mol Chap. /

74.848

X

10 3

-

285.840

X

10 3)

(endothermic) Introduction to Engineering Principles and Units

1.7 1.7A

CONSERVATION OF ENERGY AND HEAT BALANCES Conservation of Energy

In making material balances we used the law of conservation of mass, which states that the mass entering is equal to the mass leaving plus the mass left in the process. In a similar manner, we can state the law of conservation of energy, which says that all energy entering a process is equal to that leaving plus that left in the process. In this section elementary heat balances will be made. More elaborate energy balances will be considered in Sections 2.7 and 5.6. Energy can appear in many forms. Some of the common forms are enthalpy, electrical energy, chemical energy (in terms of /j.f{ reaction), kinetic energy, potential energy, work, and heat inflow. In many cases in process engineering, which often takes place at constant pressure, electrical energy, kinetic energy, potential energy, and work either are not present or can be neglected. Then only the enthalpy of the materials (at constant pressure), the standard chemical reaction energy (/jHo) at 2YC, and the heat added or removed must be taken into account in the energy balance. This is generally caIIed a heat balance.

1.7B

Heat Balances

In making a heat balance at steady state we use methods similar to those used in making a material balance. The energy or heat coming into a process in the inlet materials plus any net energy added to the process is equal to the energy leaving in the materials. Expressed mathematically,

(1.7-1)

L

where H R IS the sum of enthalpies of all materials entering the reaction process relative to the reference state for the standard heat of reaction at 298 K and 101.32 kPa. If the standard heat of the inlet temperature is above 298 K, this sum will be positive. /jH~98 reaction at 298 K and to 1.32 k Pa. The reaction contributes heat to the process, so the negative of t1H~98 is taken to be positive input heat for an exothermic reaction. q = net energy or heat added to the system. If heat leaves the system, this item wiII be negative. H p = sum of enthalpies of all leaving materials referred to the standard reference state at 298 K (2S0C). Note that if the materials coming into a process are below 298 K, H R will be negative. Care must be taken not to confuse the signs of the items in Eq. (1.7-1). If no chemical reaction occurs, then simple heating, cooling, or phase change is occurring. Use of Eq. (1.7-1) will be illustrated by several examples. For convenience it is common practice to call the terms on the left-hand side of Eq. (1.7-1) input items, and those on the right, output items.

L

L

EXAMPLE 1.7-1. Heating of Fermentation Medium A liquid fermentation medium at 30°C is pumped at a rate of 2000 kg/h through a heater, where it is heated to 70°C under pressure. The waste heat water used to heat this medium enters at 95°C and leaves at 85°C. The average heat capacity of the fermentation medium is 4.06 kJ/kg' K, and that for water is 4.21 kJ/kg' K (Appendix A.2). The fermentation stream and the wastewater stream are separated by a metal surface through which heat is transferred and do not physically mix with each other. Make a complete heat. balance on the system. Calculate the water flow and the amount of heat added to the fermentation medium assuming no heat losses. The process flow is given in Fig. 1.7-1. Sec. 1.7

Conservation of Energy and Heat Balances

19

q heat added

2000 kg/h liquid

2000 kg/h liquid

30°C

70

0

e

W kg/h

W kgjh water

85 ° e

95

0

e

Process flow diagramfor Example 1.7-1.

FIGURE 1.7-1.

Solution: It is convenient to use the standard reference state of 298 K (25°C) as the datum to calculate the various enthalpies. From Eq. (1.7-1) the input items are as follows. 1nput items.

I

H R of the enthalpies of the two streams relative to 298 K

(25°C) (note that At

30 - 25°C = 5°C = 5 K):

H(Jiquid) = (2000 kg/h)(4.06 kJ/kg' K)(5 K)

H(water)

=

4.060 x 104 kJ/h

=

W(4.21)(95 - 25)

2.947 x 10 2 W kJ/h

(W

kg/h)

(since there is no chemical reaction) (there are no heat losses or additions) Output items.

I

Hp of the two streams relative to 298 K (25°C):

H(liquid) H(water)

=

2000(4.06X70 - 25) = 3.65 x 10 5 kJ/h W(4.21X85

25)

=

2.526 x 10 2 W kJjh

Equating input to output in Eq. (1.7-1) and solving for W, 4.060 x 10'4-

+ 2.947

X

10 2 W

W

3.654 =

X

10 5

+ 2.526

X

10 2 W

7720 kg/h water flow

The amount of heat added to the fermentation medium is simply the difference of the outlet and inlet liquid enthalpies. B(outlet liquid)

3.654 x 10 5

H(inlet liquid) =

3.248

X

-

4.060

X

104

10 5 kJjh (90.25 kW)

Note in this example that since the heat capacities were assumed constant, a simpler balance could have been written as follows: heat gained by liquid

= heat lost by water

2000(4.06)(70 - 30) = W(4.2IX95

85)

Then, solving, W = 7720 kg/h. This simple balance works well when c p is constant. However, when the c p varies with temperature and the material is a gas, cpm values are only available between 298 K (2YC) and t K and the simple method cannot be used without obtaining new c prn values over different temperature ranges. 20

Chap. 1

Introduction to Engineering Principles and Units

EXAMPLE 1.7-2 Heat and Material Balance in Combustion The waste gas from a process of 1000 g mol/h of CO at 473 K is burned at 1 atm pressure in a furnace using air at 373 K. The combustion is complete and 90% excess air is used. The flue gas leaves the furnace at 1273 K. Calculate the heat removed in the furnace. Solution: First the process flow diagram is drawn in Fig. 1.7-2 and then a material balance is made. CO(g)

+ -t02(g)-+ CO 2 (g)

LlH~98

= - 282.989

X

103 kJjkg mol

(from Appendix AJ) mol CO

1000 g mol/h

moles CO 2

1.00 kg mol/h

mol O 2 theoretically required

t(1.00) = 0.500 kg mol/h

mol O 2 actually added = 0.500(1.9) = 0.950 kg molfh 0.79 0.950 0.21 = 3.570 kg mol/h

mol N2 a dded air added

=

0.950

+ 3.570 = 4.520 kg mol/h

= A

O 2 in outlet flue gas = added - used =

CO 2 in outlet flue gas

N2 in outlet flue gas

0.450 kg mol/h

0.950 - 0.500 1.00 kg mol/h

3.570 kg mol/h

For the heat balanee relative to the standard state at 298 K, we follow Eq. (1.7-1). Jnput items

H (CO)

1.00(cp .J(473 - 298)

1.00(29.38X473 - 298) = 5142 kJjh

(The Cpm of CO of 29.38 kJjkg mol, K between 298 and 473 K is obtained from Table 1.6-1.) 11 (air) = 4.520(c pm )(373

298) = 4.52(\29.29)(373 - 298)

9929 kJ/h

q = heat added. kJjh

1000 g mol/h CO

473 K A g mol/h air

furnace

flue gas 1273 K

373 K

heat removed (- q) FIGURE

Sec. 1.7

1.7-2.

Processfiow diagramfor Example 1.7-2.

Conservation of Energy and Heat Balances

21

(This will give a negative value here, indicating that heat was removed.) dH~98

-(-282.989 X 10 3 kJ/kg mol)(1.00 kg moljh)

=

282990 kJ/h

Output items H(C0 2 ) = 1.00(c pm)(1273 - 298) = 1.00(49.91)(1273 - 298) H(02) = 0.450(cpl7l)(1273

H(N z)

0.450(33.25)(1273 - 298) = 14590 kJjh

298)

3.570(c pm )(1273 - 298)

48660 kJjh

3.570(31.43)(1273

=

298)

109400 kJjh

Equating input to output and solving for q, 5142

+ 9929 + q + 282990

48660 + 14590 + 109400 q = - 125411 kJjh

Hence, heat is removed: - 34 837 W. Often when chemical reactions occur in the process and the heat capacities vary with temperature, the solution in a heat balance can be trial and error if the final temperature is the unknown.

EXAMPLE 1.7-3. Oxidation of Lactose In many biochemical processes, lactose is used as a nutrient, which oxidized as follows:

lS

The heat of combustion I1H~ in Appendix A.3 at 25°C is - 5648.8. X 10 3 Jig mol. Calculate the heat of complete oxidation (combustion) at 3]oC, which is the temperature of many biochemical reactions. The cpm of solid lactose is 1.20 Jig' K, and the molecular weight is 342.3 g masslg moL

Solution: This can be treated as an ordinary heat-balance problem. First, the process flow diagram is drawn in Fig. 1.7-3. Next, the datum temperature of 25°C is selected and the input and output enthalpies calculated. The temperature difference dt = (37 - 25tC (37 25) K.

1 g mol lactose (s) 37°C

combustion 12 g mol 0z(g) II g mol H 20(l), 37°C 3:::-:7::;(o~C:;-,-;-I-a-:t-m---I-L---_-.-J 12 g mol CO 2 (g), 37° C FIGURE

22

1.7-3.

Process flow diagram for Example 1.7-3.

Chap. 1

Introduction to Engineering Principles and Units

Input items

H(1actose)

(342.3 g{ cpm

K}37 - 25) K = 342.3(1.20X37 - 25)

/

4929 J H(02 gas)

(l2 g mOI{C plII g l2(29.38)(37

m~I' ic}37 -

25)

25) K

= 4230 J

(The cpm of Oz was obtained from Table 1.6-1.) tlHg s

-( -5648.8 x 10 3 )

Output items

H(HzO liquid)

~

l1(l8.02 g{ cpm g K}37 - 25) K 11(18.02)(4.18)(37 - 25)

9943 J

(The c pm of liquid water was obtained from Appendix A.2.) H(CO z gas) = (l2 g mOl)(c pm =

J K)(37 g mol,

12(37.45X37 - 25)

25) K

5393 J

(The C pm of CO 2 is obtained from Table 1.6-1.) tlH 3TC : Setting input

output and solving,

4929 + 4230 + 5648.8 x 10 3 = 9943 + 5393 - tlH 37'C tlH 3rc

1.8

1.8A

= -5642.6 x 10 3

Jig mol

tlH 310K

GRAPHICAL, NUMERICAL, AND MATHEMATICAL METHODS

Graphical Integration

Often the mathematical function f(x) to be integrated is too complex and we are not able to integrate it analytically. Or in some cases the function is one that has been obtained from experimental data, and no mathematical equation is available to represent the data so that they can be integrated analytically. In these cases, we can use graphical integration. b can be represented graphically as Integration between the limits x = a to x shown in Fig. 1.8-1. Here a function y = J(x) has been plotted versus x. The area under the curve y =: J(x) between the limits x a to x == b is equal to the integral. This area is then equal to the sLIm of the areas of the rectangles as follows. (1.8-1)

Sec J.8

Graphical, Numerical, and lvfat/zematical Methods

23

y

r---------b--------~~l· FIGURE 1.8-1.

L8B

x

Graphical integra/ion of 1:;::: f(x) dx.

Numerical Integration and Simpson's Rule

Often it is desired or necessary to perform a numerical integration by computing the value of a definite integral from a set of numerical values of the integrand J(x). This, of course, can be done graphically, but if data are available in large quantities, numerical methods suitable for the digital computer are desired. The integral to be evaluated is as follows: (1.8-2)

where the interval is b - a. The most generally used numerical method is the parabolic rule often called Simpson's rule. This method divides the total interval b - a into an even number of subintervals m, where

m

b-a

(1.8-3)

h

The value of h, a constant, is the spacing in x used. Then, approximating I(x) by a parabola on each subinterval, Simpson's rule is

f.r=o

J.~a I(x) dx =

h

:3 [10 + 4{/l + 13 + Is + ... + 1m

1)

+ 2(/2 + I .. + 16 + ... + 1m2) + 1m]

(1.8-4)

where/o is the value ofJ(x) at x = a,fl the value of/(x) atx = Xl> ... ,f", the value of/(x) at x b. The reader should note that m must be an even number and the increments evenly spaced. This method is well suited for digital computation.

24

Chap. J

Introduction to Engineering Principles and Units

PROBLEMS 1.2-1. Temperature of a Chemical Process. The temperature of a chemical reaction was found to be 353.2 K. What is the temperature in of, °C, and OR? ADS. 176°F, 80°C, 636°R 1.2-2. Temperature for Smokehouse Processing of Meat. In smokehouse processing of sausage meat, a final temperature of 155°F inside the sausage is often used. Calculate this temperature in °C, K, and OR. 1.3-1. Molecular Weight of Air. For purposes of most engineering calculations, air is assumed to be composed of 21 mol % oxygen and 79 mol % nitrogen. Calculate the average molecular weight. . ADS. 28.9 g mass/g mol, lb mass/lb mol, or kg mass/kg mol 1.3-2. Oxidation of CO and Mole Units. The gas CO is being oxidized by a 2 to form CO 2 , How many kg of CO 2 will be formed from 56 kg of CO? Also, calculate the kg of O 2 theoretically needed for this reaction. (Hint: First write the balanced chemical equation to obtain the mol O 2 needed for 1.0 kg mol CO. Then calculate th:: kg mol of CO in 56 kg CO.) ADS. 88.0 kg CO 2 , 32.0 kg O 2 1.3-3. Composition ofa Gas Mixture. A gaseous mixture contains 20 g ofN 2 , 83 g of O 2 , and 45 g ofCO z . Calculate the composition in mole fraction and the average molecular weight of the mixt ure. ADS. Average mol wt = 34.2 g mass/g mol, 34.2 kg massfkg mol 1.3-4. Composition of a Protein Solution. A liquid solution contains 1.15 wt % of a protein, 0.27 wt % KCl, and the remainder water. The average molecular weight of the protein by gel permeation is 525000 g mass/g mol. Calculate the mole fraction of each component in solution. 1.3-5. Concentration of NaCI Solution. An aqueous solution of NaCl has a concentration of 24.0 wt % NaCl with a density of 1.118 g/cm 3 at 25°C. Calculate the following. (a) Mole fraction ofNaCI and water. (b) Concentration of NaCI as g molfliter, Ib,jft 3 , lb,jgal, and kg/m 3 • 1.4-1. Com'ersion of Pressure Measurements in Freeze Drying. In the experimental measurement of freeze drying of beef, an absolu te pressure of2.4 mm Hg was held in the chamber. Convert this pressure to atm, in. of water at 4oC, Jim of Hg, and Pa. (H inc: See Appendix A.I for conversion factors.) ADs. 3.16 x 10- 3 atm, 1.285 in. H 2 0, 2400 Jim Hg, 320 Pa 1.4-2. Compression and Cooling of Nitrogen Gas. A volume of 65.0 ftJ ofN 2 gas at 90°F and 29.0 psig is compressed to 15 psig and cooled to 65 F. Calculate the final volume in ft 3 and the final density in Ib,jft3. [Hint: Be sure to convert all pressures to psia first and then to atm. Substitute original conditions into Eq. (1.4-1) to obtain n, Ib mol.] 1.4-3. Gas Composition and Volume. A gas mixture of 0.13 g mol NH 3, 1.27 g mol N 2, and 0.025 g mol H 2 0 vapor is contained at a total pressure of 830 mm Hg and 323 K. Calculate the following. (a) Mole fraction of each component. (b) Partial pressure of each component in mm Hg. (c) Total volume of mixture in m 3 and ft 3. 1.4-4. Evaporation of a Heat-Sensitive Organic Liquid. An organic liquid is being evaporated from a liquid solution containing a few percent nonvolatile dissolved solids. Since it is heat-sensitive and may discolor at high temperatures, it will be evaporated under vacuum. If the lowest absolute pressure that can be obtained in the apparatus is 12.0 mm Hg, what will be the temperature of evaporation in K? It will be assumed that the small amount of solids does not affect the vapor Q

Chap. /

Problems

25

pressure, which is given as follows: log PA

-225~~) + 9.05

where PAis in mm Hg and Tin K. ADS. T = 282.3 K or9.1oC 1.5-1. Evaporation of Cane Sugar Solutions. An evaporator is used to concentrate cane sugar solutions. A feed of 10000 kgld of a solution containing 38 wt % sugar is evaporated, producing a 74 wt % solution. Calculate the weight of solution produced and amount of water removed. Ans. 5135 kgfd of 74 wt % solution, 4865 kgfd water 1.5-2. Processing of Fish Meal. Fish are processed into fish meal and used as a sup-

1.5-3.

1.5-4.

1.5-5.

1.5-6.

1.5-7.

26

plementary protein food. In the processing the oil is first extracted to produce wet fish. cake containing 80 wt % water and 20 wt % bone-dry cake. This wet cake feed is dried in rotary drum dryers to give a "dry" fish cake product containing 40 wt % water. Finally, the product is finely ground and packed. Calculate the kg/h of wet cake feed needed to produce 1000 kg/h of "dry" fish cake product. Ans. 3000 kg/h wet cake feed Drying of Lumber. A batch of 100 kg of wet lumber containing 11 wt % moisture is dried to a water content of 6.38 kg water/l.O kg bone-dry lumber. What is the weight or"dried" lumber and the amount of water removed? Processing of Paper Pulp. A wet paper pulp contains 68 wt % water. After the pulp was dried, it was found that 55% of the original water in the wet pulp was removed. Calculate the composition of the "dried" pulp and its weight for a feed of 1000 kg/min of wet pulp. Production oflam from Crushed Fruit in Two Stages. In a process producing jam (Cl), crushed fruit containing 14 wt% soluble solids is mixed in a mixer with sugar (1.22 kg sugar/l.OO kg crushed fruit) and pectin (0.0025 kg pectin/l.OO kg crushed fruit). The resultant mixture is then evaporated in a kettle to produce a jam containing 67 wt% soluble solids. For a feed of 1000 kg crushed fruit, calculate the kg mixture from the mixer, kg water evaporated, and kg jam produced, Ans. 2222.5 kg mixture, 189 kg water, 2033.5 kgjam Drying of Cassava (Tapioca) Root. Tapioca flour is used in many countries for bread and similar products. The flour is made by drying coarse granules of the cassava root containing 66 wt % moisture to 5% moisture and then grinding to produce a flour. How many kg of granules must be dried and how much water removed to produce 5000 kg/h of flour? Processing of Soybeans in Three Stages. A feed of 10000 kg of soybeans is processed in a sequence of three stages or steps (El). The feed contains 35 wt % protein, 27.1 wt % carbohydrate, 9.4 wt % fiber and ash, 10.5 wt % moisture, and 18.0 wt % oiL In the first stage the beans are crushed and pressed' to' remove oil, giving an expressed oil stream and a stream of pressed beans containing 6% oil. Assume no loss of other constituents with the oil stream. In the second step the pressed beans are extracted with hexane to produce an extracted meal stream containing 0,5 wt % oil and a hexane-oil stream. Assume no hexane in the extracted meal. Finally, in the last step the extracted meal is dried to give a dried meal of 8 wt % moisture. Calculate: (a) Kg of pressed beans from the first stage. (b) Kg of extracted meal from stage 2. (c) Kg offinal dried meal and the wt % protein in the dried meal. Ans. Ca) 8723 kg,(b) 8241 kg,(c) 7816 kg, 44,8 wt % protein

Chap. 1

Problems

1..5-8. Recycle in a Dryer. A solid material containing 15.0 wt % moisture is dried so that it contains 7.0 wt % water by blowing fresh warm air mixed with recycled air over the solid in the dryer. The inlet fresh air has a humidity of 0.01 kg water/kg dry air, the air from the drier that is recycled has a humidity of 0.1 kg water/kg dry air, and the mixed air to the dryer, 0.03 kg water/kg dry air. For a feed of 100 kg solid/h fed to the dryer, calculate the kg dry air/h in the fresh air, the kg dry air/h in the recycle air, and the kgfh of "dried product. Ans.95.6 kgfh dry air in fresh air, 27.3 kgfh dry air in recycle air, and 91.4 kg/h "dried" product 1.5-9. -Crystallization and Recycle. It is desired to produce 1000 kgfh of Na 3 P0 4 . 12H zO crystals from a feed solution containing 5.6 wt % Na 3P0 4 and traces of impurity. The original solution is first evaporated in an evaporator to a 35 wt% Na3P04 solution and then cooled to 293 K in a crystallizer, where the hydrated crystals and a mother liquor solution are removed. One out of every 10 kg of mother liquor is discarded to waste to get rid of the impurities, and the remaining mother liquor is recycled to the evaporator. The solubility ofNa 3 P0 4 at 293 K is 9.91 wt %. Calculate the kg/h of feed solution and kgfh of water evaporated. Ans. 7771 kgfh feed, 6739 kgfh water 1.5-10. Evaporation and Bypass in Orange Juice Concentration. In a process for concentrating 1000 kg of freshly extracted orange juice (Cl) containing 12.5 wt % solids, the juice is strained, yielding 800 kg of strained juice and 200 kg of pulpy juice. The strained juice is concentrated in a vacuum evaporator to give an evaporated juice of 58% solids. The 200 kg of pulpy juice is bypassed around the evaporator and mixed with the evaporated juice in a mixer to improve the flavor. This final concentrated juice contains 42 wt % solids. Calculate the concentration of solids in the strained juice, the kg of final concentrated juice, and the concentration of solids in the pulpy juice bypassed. (Hint: First, make a total balance and then a solids balance on the overall process. Next, make a balance on the evaporator. Finally, make a balance on the mixer.) .... Ans. 34.2 wt % solids in pulpy juice 1.5-11. Manufacture of Acetylene. For the making of 6000 fe of acetylene (CHCH) gas at 70°F and 750 mm Hg, solid calcium carbide (CaC z) which contains 97 wt % CaC z and 3 wt % solid inerts is used along with water. The reaction is n

CaC z + 2H 2 0

->

CHCH

+ Ca(OHh 1

The final lime slurry contains water, solid inerts, and Ca(O Hh lime. In this slurry the total wt % solids ofinerts plus Ca(OHh is 20%. How many lb of water must be added and how many lb of final lime slurry is produced? [Hint: Use a basis of 6000 ft3 and convert to lb mol. This gives 15.30 lb mol C 2 H z , 15.30 lb mol Ca(OHh, and 15.30 lb mol CaC z added. Convert lb mol CaC z feed to Ib and calculate Ib inerts added. The totallb solids in the slurry is then the sum of the Ca(OHh plus inerts. In calculating the water added, remember that some is consumed in the reaction.] Ans. 5200 lb water added (2359 kg), 5815lb lime slurry (2638 kg) 1.5-12. Combustion of Solid Fuel. A fuel analyzes 74.0 wt % C and 12.0% ash (inert). Air is added to burn the fuel, producing a flue gas of 12.4% CO 2 , 1.2% CO, 5.7% 2 , and 80.7% N z . Calculate the kg of fuel used for 100 kg mol of outlet flue gas and the kg mol of air used. (Hint: First calculate the mol O 2 added in the air, using the fact that the N 2 in the Hue gas equals the N z added in the air. Then make a carbon balance to obtain the total moles of C added.) 1.5-13. Burning of Coke. A furnace burns a coke containing 81.0 wt % C, 0.8% H, and the rest inert ash. The furnace uses 60% excess air (air over and above that needed to bum all C to CO 2 and H to H 2 0). Calculate the moles of aU components in the flue gas if only 95% of the carbon goes to CO 2 and 5% to CO.

°

Chap. 1

Problems

27

1.5-14. Production of Formaldehyde. Formaldehyde (CHzO) is made by the catalytic

oxidation of pure methanol vapor and air in a reactor. The moles from this reactor are 63.1 N z , 13A O 2 , 5.9 HzO, 4.1 CHzO, 12.3 CH 3 0H, and 1.2 HCOOH. The reaction is CH 3 0H

+ t02~ CHzO + HzO

A side reaction occurring is CHzO

1.6-1.

1.6-2.

1.6-3.

1.6-4.

1.6-5.

1.6-6.

1.6-7.

+ toz ~ HCOOH

Calculate the mol methanol feed, mol air feed, and percent conversion of methanol to formaldehyde. Ans. 17.6 mol CH 30H, 79.8 mol air, 23.3% conversion Heating of COl Gas. A total of 250 g ofCO z gas at 373 K is heated to 623 K at 101.32 kPa total pressure. Calculate the amount of heat needed in cal, btu, and kJ. Ans. 15050 cal, 59.7 btu, 62.98 kJ Heating a Gas Mixture. A mixture of 25 Ib mol N z and 75 Ib.mol CH 4 is being heated from 400°F to 800°F at I atm pressure. Calculate the total amount of heat needed in btu. Final Temperature in Heating Applesauce. A mixture of 454 kg of applesauce at 10°C is heated in a heat exchanger by adding 121300 kJ. Calculate the outlet temperature of the applesauce. (Hint: In Appendix AA a heat capacity for applesauce is given at 32.8°C. Assume that this is constant and use this as the average c pm ') Ans. 76SC Use of Steam Tahles. Using the steam tables, determine the enthalpy change for l'lb water foreach of the following cases. (a) Heating liquid water from 4QoF to 24QoF at 30 psia. (Note that the effect of total pressure on the enthalpy of liquid water can be neglected.) (b) Heating liquid water from 40°F to 240°F and vaporizing at 24QoF and 24.97 psia. (c) Cooling and condensing a saturated vapor at 212°F and 1 atm abs to a liquid at 60°F. . (d) Condensing a saturated vapor at 212°F and 1 atm abs. Ans. (a) 200.42 btu/Ibm , (b) 1152.7 btu/Ibm, (c) 1122.4 btu/Ibm, (d) - 970.3 btu/Ibm, 2256.9 kJ/kg Heating and Vaporization Using Steam Tables. A flow rate of 1000 kg/h of water at 21.l°C is heated to 110°C when the total pressure is 244.2 kPa in the first stage of a process. In the second stage at the same pressure the water is heated further, until it is all vaporized at its boiling point. Calculate the total enthalpy change in the first stage and in both stages. Combustion ofCN" and Hz. For 100 g mol of a gas mixture of 75 mol % CH 4 and 25% H 2 , calculate the total heat of combustion of the mixture at 298 K and 101.32 kPa, assuming that combustion is complete. Heat of Reactionfrom Heats of Formation. For the reaction 4NH3(g) +

50z{g)~

4NO(g) + 6H zO(g)

calculate the heat of reaction, DB, at 298 K and 101.32 kPa for 4 g mO'l ofNH 3 ";' reacting. Ans. 6.H, heat of reaction -904.7 kJ 1.7-1. Heat Balance and Cooling of Milk. In the processing of rich cows' milk, 4540

kg/h of milk is cooled from 60°C to 4.44°C by a refrigerant. Calculate the heat removed from the milk. Ans. Heat removed = 269.6 kW 28

Chap. I

Problems

1.7-2. Heating of Oil by Air. A flow of 2200 Ibmfh of hydrocarbon oil at 100°F enters a heat exchanger, where it is heated to 150°F by hot air. The hot air enters at 300°F and is to leave at 200°F. Calculate the total lb mol air/h needed. The mean heat capacity of the oil is 0.45 btu/lb m. of. AIlS. 70.11b mol air/h, 31.8 kg moljh 1.7-3. Combustion of Methane in a Furnace. A gas stream of 10 000 kg mol/h ofCH 4 at 101.32 kPa and 373 K is burned in a furnace using air at 313 K. The combustion is complete and 50% excess air is used. The flue gas leaves the furnace at 673 K. Calculate the heat removed in the furnace. (Hint: Use a datum of 298 K and liquid water at 298 K. The input items will be the following: the enthalpy of CH 4 at 373 K referred to 298 K; the enthalpy of the air at 313 K referred to 298 K; -!3.H~, the heat of combustion ofCH4- at 298 K which is referred to liquid water; and q, the heat added. The output items will include: the enthalpies of CO 2 , O 2 , N 2, and H 2 0 gases at 673 K referred to 298 K; and the latent heat of H 2 0 vapor at 298 K and 101.32 kPa from Appendix A.2. It is necessary to include this latent heat since the basis of the calculation and of the !3.H~ is liquid water.) 1.7-4. Preheating Air by Steam for Use in a Dryer. An air stream at 32.2°C is to be used in a dryer and is first preheated in a steam heater, where it is heated to 65.5°C. The air flow is 1000 kg mol/h. The steam enters the heater saturated at 148.9°C, is condensed and cooled, and leaves as a liquid at 137.8°C. Calculate the amount of steam used in kg/h. Ans. 450 kg steamjh 1.7-5. Cooling of Cans of Potato Soup After Thermal Processing. A total of 1500 cans of potato soup undergo thermal processing in a retort at 240°F. The cans are then cooled to 100°F in the retort before being removed from the retort by cooling water, which enters at 75°F and leaves at 85°F. Calculate the lb of cooling water needed. Each can of soup contains 1.0 lb of liquid soup and the empty metal can weighs 0.16Ib. The mean heat capacity of the soup is 0.94 btu/lbm • OF and that of the metal can is 0.12 btu/Ibm' OF. A metal rack or basket which is used to hold the cans in the retort weighs 350 Ib and has a heat capacity of 0.12 btu/lb m · OF. Assume that the metal rack is cooled from 240°F to 85°F, the temperature of the outlet water. The amount of heat removed from the retort walls in cooling from 240 to 100°F is 10000 btu. Radiation loss from the retort during cooling is estimated as 5000 btu. Ans. 21 320 lb water, 9670 kg 1.8-1. Graphical Integration and Numerical Integration Using Simpson's Method. The following experimental data of y = fix) were obtained. x

f(x)

x

f(x)

0 0.1 0.2 0.3

100 75 60.5 53.5

0.4 0.5 0.6

53 60 72.5

It is desired to determine the integral A

=

I

x

0.6

fix) dx

x=o

(a) Do this by a graphical integration. (b) Repeat using Simpson's numerical method. Ans. Chap. 1

Problems

(a) A

=

38.55; (b) A

=

38.45 29

1.8-2. Graphical and Numerical Integration to Obtain Wastewater Flow. The rate of flow of wastewater in an open channel has been measured and the following data obtained: Flow Time (min)

0

10 20 30 40 50 60

Flow

(m 3/min)

Time (min)

{ml/minJ

655 705 780 830 870 890 870

70 80 90 100 110 120

800 725 670 640 620 610

(a) Determine the total flow in m 3 for the first 60 -min and also the total for 120 min by graphical integration. (b) Determine the flow for 120 min using Simpson's numerical method. Ans. (a) 48460 m 3 for 60 min, 90 390m 3 for 120 m REFERENCES CHARM, S. E.·The Fundamentals of Food Engineering, 2nd ed. Westport, Conn.: Avi Publishing Co., Inc., 1971. EARLE, R. L. Unit Operations in Food Processing. Oxford: Pergamon Press, Inc., (E1) 1966. HOUGEN, O. A., WATSON, K. M., and RAGATZ, R. A. Chemical Process Principles, (H 1) Part 1, 2nd ed. New York: John Wiley & Sons, Inc., 1954. (01) OKOS, M. R. M.S. thesis. Ohio State University, Columbus, Ohio, 1972. PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6th cd. (PI) New York: McGraw-Hili Book Company, 1984. SOBER, H. A. Handbook 0/ Biochemistry, Selected Data/or Molecular Biology, 2nd (S 1) ed. Boca Raton, Fla.: Chemical Rubber Co., Inc., 1970. (WI) WEAST, R. C., and SELBY, S. M. Handbook o/Chemistry and Physics, 48th ed. Boca Raton, Fla.: Chemical Rubber Co., Inc., 1967-1968. (CI)

30

Chap. 1

References

CHAPTER 2

Principles of Momentum Transfer and Overall Balances

2.1

INTRODUCTION

The flow and behavior of fluids is important in many of the unit operations in process engineering. A fluid may be defined as a substance that does not permanently resist distortion and, hence, will change its shape. In this text gases, liquids, and vapors are considered to have the characteristics of fluids and to obey many of the same laws. In the process industries, many of the materials are in fluid form and must be stored, handled, pumped, and processed, so it is necessary that we become familiar with the principles that govern the flow of fluids and also with the equipment used. Typical fluids encountered include water, air, CO 2 , oil, slurries, and thick syrups. If a fluid is inappreciably affected by changes in pressure, it is said to be incompressible. Most liquids are incompressible. Gases are considered to be compressible fluids. However, if gases are subjected to small percentage changes in pressure and temperature, their density changes will be small and they can be considered to be incompressible. Like all physical matter, a fluid is composed of an extremely large number of molecules per unit volume. A theory such as the kinetic theory of gases or statistical mechanics treats the motions of molecules in terms of statistical groups and not in terms of i~dividual molecules. In engineering we are mainly concerned with the bulk or macroscopic beha vior of a fluid rather than with the individual molecular or microscopic behavior. In momentum transfer we treat the fluid as a continuous distribution of matter or as a "continuum n. This treatment as a continuum is valid when the smallest volume of fluid contains a large enough number of molecules so that a statistical average is meaningful and the macroscopic properties of the fluid such as density, pressure, and so on, vary smoothly or continuously from point to point The study of momentum transfer, or fluid mechanics as it is often called, can be divided into two branches: fluid statics, or fluids at rest, and fluid dynamics, or fluids in motion. In Section 2.2 we treat fluid statics; in the remaining sections of Chapter 2 and in Chapter J, fluid dynamics. Since in fluid dynamics momentum is being transferred, the term "momentum transfer" or "transport" is usually used. In Section 2.3 momentum transfer is related to heat and mass transfer. 31

2.2

2.2A

FLUID STATICS

Force, Units, and Dimensions

In a static fluid an important property is the pressure in the fluid. Pressure is familiar as a surface force exerted by a fluid against the walls of its container. Also, pressure exists at any point in a volume of a fluid. In order to understand pressure, which is defined as force exerted per unit area, we must first discuss a basic law of Newton's. This equation for calculation of the force exerted by a mass under the influence of gravity is

F=mg

(SI units) (2.2-1) (English units)

F

where in SI units F is the force exerted in newtons N(kg· m/s2), m the mass in kg, and 9 the standard acceleration of gravity, 9.80665 m/s2. In English units, F is in Ib r, m in Ibm' 9 is 32.1740 ft/s 2 , and ge (a gravitational conversion factor) is 32.174Ib m • ft/lb e · S2 . The use of the conversion factor gc means that g/ge has a value of 1.0 Ibrllbm and that I Ibm conveniently gives a force equal to I Ib e . Often when units of pressure are given, the word" force" is omitted, such as in Ib/in. 2 (psi) instead of Ibr/in. 2 • When the mass m is given in g mass, F is g force, 9 980.665 cm/s 2 , and gc = 980.665 g mass' cm/g force' S2. However, the units g force are seldom used. Another system of units sometimes used in Eq. (2.2-1) is that where the ge is omitted and the force (F mg) is given as Ibm' ft/S2, which is called poundals. Then llb m acted on by gravity will give a force of 32.174 poundals(lb m ' ft/s 2 ). Or if I g mass is used, the force (F = mg) is expressed in terms of dynes (g. cm/s 2 ). This is the centimeter-gram-second (cgs) systems of units. Conversion factors for different units of force and of force per unit area (pressure) are given in Appendix A.I. Note that always in the Sf system, and usually in the cgs system, the term ge is not used. EXAMPLE 2.2-1. Units and Dimensions of Force Calculate the force exerted by 3 Ib mass in terms of the following. (a) Lb force (English units). (b) Dynes'(cgs units). (c) Newtons (SI units). Solution:

For part (a), using Eq. (2.2-1), 3 Ib force (lb e)

For part (b), F

32

= mg

=

(3 Ib m{ 453.59 I:J(980.665

=

1.332

Chap. 2

X

10 6 g' cm S2

~~ )

1.332 x 10 6 dyn

Principles of Momentum Transfer and Overall Balances

As an alternative method for part (b). from Appendix A.l. I dyn = 2.248 [ x 1O- 6 1b r F

= (3

lb r{2.2481 x

1~-6Ibrldyn) = 1.332 x 106 dyn

To calculate newtons in part (c),

= (3 Ibm

F = mg

[3.32

X

2.2~~glbJ(9.8066S ~) . m = 13.32 N

As an alternative method, using values from Appendix A.I, g'cm kg· m 1 -z-(dyn) = 10- 5 --2-(newton)

s

F

2.2B

(1.332

s

X

10 6 dyn) (10- 5

ne~~n) =

13.32 N

Pressure in a Fluid

Since Eq. (2.2-1) gives the force exerted by a mass under the influence ofgravity, the force exerted by a mass of fluid on a supporting area or force/u nit area (pressure) also fOllo'ws from this equation. In Fig. 2.2-1 a stationary column of fluid of heighth z m and constant cross-sectional area A ml, where A = Ao Al A 2 , is shown. The pressure above the fluid is Po N/m 1; that is. this could be the pressure of the atmosphere above the fluid. The fluid at any point, say hi' must support all the fluid above it. It can be shown that the forces at any given point in a nonmoving or 'static fluid must be the same in all directions. Also, for a fluid at rest, the force/unit area or pressure is the same at all points with the same elevation. For example, at him from the top, the pressure is the same at all points shown on the cross-sectional area A I ' The lise of Eq. (2.2-1) will be shown in calculating the pressure at different vertical poi tl ts in Fig. 2.2-/. The total mass of f1 uid for h 1 m heigh t and density p kg/m 3 is (2.2-2)

Ffc;uKE

2.2-1.

Sec. 2.2

Pressure 111 (/ s[(IIIc/luid.

Fluid Statics

33

Substituting into Eq. (2.2-2), the total force F of the fluid on area A I due to the fluid only IS

'm

(N)

(2.2-3)

Pa

(2.2-4)

The pressure P is defined as force/unit area: F

P=-

1

(h2 Apg)

A

=

A

h2 pg N/m2

or

This is the pressure on A z due to the mass of the fluid above it. However, to get the total pressure P z on A z , the pressure Po on the top of the fluid must be added. (2.2-5) Equation (2.2-5) is the fundamental equation to calculate the pressure in a fluid at any depth. To calculate PI' PI

=

h1pg

+ Po

(2.2-6)

The pressure difference between points 2 and 1 is P2

PI

=

(h 2 pg

+

Po)

(hlpg

+

Po)

= (h2

hj)pg

(SI units) (2.2-7)

h1)p

JL

(English units)

gc

Since it is the vertical height of a fluid that determines the pressure in a fluid, the shape of the vessel does not affect the pressure. For example, in Fig. 2.2-2, the pressure Plat the bottom of all three vessels is the same and equal to h IPg + Po.

EXAMPLE 2.2-2. Pressure in Storage Tank A large storage tank contains oil having a density of 917 kg/m 3 (0.917 g/cm 3 ). The tank is 3.66 m (12.0 ft) tall and is vented (open) to the atmosphere of 1 atm abs at the top. The tank is filled with oil to a depth of 3.05 m (10 ft) and also contains 0.61 m (2.0 ft) of water in the bottom of the tank. Calculate the pressure in Pa and psia 3.05 m from the top of the tank and at the bottom. Also calculate the gage pressure at the tank bottom. Solution: First a sketch is made of the tank, as shown in Fig. 2.2-3. The pressure Po = 1 atm abs = 14.696 psia (from Appendix A.i). Also, •. ,

Po

1.01325

=

X

10 5 Pa

Po

Po

Po

r

hI

~ PI FIGURE

2.2-2.

PI

Pressure in vessels of various shapes. ,

34

Chap. 2

Principles of MomenLUm Transfer and Overall Balances

FIGURE

2.2-3.

Storage tank In Example 2.2-2.

I atm

h Al

_ hAl hTPB/PA 1 - PS/PA

-

(2.2-21)

This shows that the position of the interface or height hA I depends on the ratio of the densities of the two liquids and on the elevations hA2 and liT of the two overflow lines. Usually, the height h'l1 is movable so that the interface level can be adjusted.

2.3

2.3A

GENERAL MOLECULAR TRANSPORT EQUATION FOR MOMENTUM, HEAT, AND MASS TRANSFER General Molecular Transport Equation and General Property Balance

1. Introduction to transport processes. In molecular transport processes in general we are concerned with the transfer or movement of a given property or entity by molecular movement through a system or medium which can be a fluid (gas or liquid) or a solid. This property that is being transferred can be mass, thermal energy (heat), or momentum. Each molecule of a system has a given quantity of the property mass, thermal energy, or momentum associated with it. When a difference of concentration of the property exists for any of these properties from one region to an adjacent region, a net transport of this property occurs. In dilute fluids such as gases where the molecules are relatively far apart, the rate of transport of the property should be relatively fast since few molecules are present to block the transport or interact. In dense fluids such as liquids the molecules are close together and transport or diffusion pro cedes more slowly. The molecules in solids are even more close-packed than in liquids and molecular migration is even more restricted. Sec. 2.3

General Molecular Transport Equation

39

2. General molecular transport equation. All three of the molecular transport processes of momentum, heat or thermal energy, and mass are characterized in the elementary sense by the same general type of transport equation. First· we start by noting the following: . rate of a transfer process

driving force

= --.-"---

(2.3-1)

resistance

This states what is quite obvious-that we need a driving force to overcome a resistance in order to transport a property. This is similar to Ohm's law in electricity, where the rate of flow of electricity is proportional to the voltage drop (driving force) and inversely proportional to the resistance. We can formalize Eq. (2.3-1) by writing an equation as follows for molecular transport or diffusion of a property: di

-0dz

(2.3-2)

where", z is defined as the flux of the property as amount of property being transferred per unit time per unit cross-sectional area perpendicular to the z direction of flow in amount of property/s . m 2 , 0 is a proportionality constant called diffusivity in m2 /s, i is concentration of the property in amount of propertY/m3, and z is the distance in the direction of flow in m. If the process is at steady state, then the flux!/J z is constant. Rearranging Eq. (2.3-2) and integrating,

i

o

f2

di

(23-3)

f, ·(2.~)

A plot of the concentration i versus z is shown in Fig. 2.3-la and is a straight line. Since

the flux is in the direction 1 to 2 of decreasing concentration, the slope dildz is negative and the negative sign in Eq. (2.3-2) gives a positive flux in the direction 1 to 2. In Section 2.3B the specialized equations for momentum, heat, and mass transfer will be shown to be the same as Eq. (2.3-4) for the general property transfer.

unit area

in =

I/Izl z z

Distance,

Z

(a) FIGURE

40

2.3-1.

LlZ---j (b)

Molecular transport of a property: (aj pia! of concentration versus distancefor steady state, (b j unsteady-state general property balance.

Chap. 2

Principles of Momentum Transfer and Overall Balances

EXAMPLE 23-1. Molecular Transport ofa Property at Steady State A property is being transported by diffusion through a fluid at steady state. At a given point 1 the concentration is 1.37 x 10- 2 amount of property1m 3 and 0.72 x lO-2 at point 2 at a distance Zz 0.40 m. The diffusivity {j = 0.013 mZ/s and the cross-sectional area is constant. (a) Calculate the flux. (b) Derive the equation for r as a function of distance. (c) Calculate r at the midpoint of the path: Solution:

For part (a) substituting into Eq. (2.3-4), (0.013)(1.37 2.113

X

X

10- 2 - 0.72 x 10- 2) 0040 - 0

10- 4 amount of property/s'm 2

For part (b), integrating Eq. (2.3-2) between rearranging,

ifi z

{z

o {r

dz

Jr,

JZ 1

r1

and rand

dr

ZI

and

Z

and

(2.3-5) (2.3-6)

For part (c), using the midpoint Z

r

0.20 m and substituting into Eq. (2.3-6),

= 1.37 x 10- 2

+ 2.11~.~;0-4 (0 -

0.2)

1.045 x lO-2 amount of property/m 3

3. General property balance for unsteady state. In calculating the rates of transport in a system using the molecular transport equation (2.3-2), it is necessary to account for the amount of this property being transported in the entire system. This is done by writing a general property balance or conservation equation for the property (momentum, thermal energy, or mass) at unsteady state. We start by writing an equation for the z direction only, which accounts for all the property entering by molecular transport, leaving, being generated, and accumulating in a system shown in Fig. 2.3-lb, which is an element of volume Llz(l) m 3 fixed in space. rate of . ) ( property In

+ (rate

of generation) of property rate of ) ( property out

+ (rate

of accum) ulation of property

(2.3-7)

The rate of input is (t/I :Iz)' 1 amount of property/s and the rate of output is (t/lzlz+6z)'1, where the cross-sectional area is 1.0 m 2 • The rate of generation of the property is R(Llz' 1), where R is rate of generation of propertyIs . m 3 . The accumulation term is

.

ar (Llz . 1) at

rate of accumulatIOn of property = -

Sec. 2.3

General Molecular Transport Equation

(2.3-8)

41

Substituting the various tenns into Eq. (2.3-7),

(23-9) Dividing by Az and letting D.z go to zero,

or +-'=R 01/1, at az

(23-10)

Substituting Eq. (2.3-2) for ifJ z into (2.3-10) and assuming that b is constant,

or at

--b

a2 r

R

(2.3-11)

F or the case where no generation is present,

or at

(2.3-12)

This final equation relates the concentration of the property r to position z and time t. Equations (2.3-11) and (2.3-12) are general equations for the conservation of momentum, thermal energy, or mass and will be used in many sections of this text. The equations consider here only molecular transport occurring and the equations do not consider other transport mechanisms such as convection, and so on, which will be considered when·the specific conservation equations are derived in later sections of this text for momentum, energy, or mass.

2.38

Introduction to Molecular Transport

The kinetic theory of gases gives us a good physical interpretation of the motion of individual molecules in fluids. Because of their kinetic energy the molecules are in rapid random movement, often colliding with each other. Molecular transport or molecular diffusion of a property such as momentum, heat, or mass occurs in a fluid because of these random movements of individual molecules. Each individual molecule containing the property being transferred moves randomly in all directions and there are fluxes in all directions. Hence, if there is a concentration gradient of the property, there will be a net flux of the property from high to low concentration. This occurs because equal numbers of molecules diffuse in each direction between the high-concentration and lowconcentration regions. I. Momentum transport and Newton's law. When a fluid is flowing in the x direction parallel to a solid surface, a velocity gradient exists where the velocity Vx in the x direction decreases as we approach the surface in the z direction. The fluid has x-directed momentum and its concentration is VxP momentum/m 3, where the momentum has units of kg· m/s. Hence, the units of Vx P are (kg· m/s)/m3. By random diffusion of molecules there is an exchange of molecules in the z direction, an equal number moving in each direction ( + z and - z directions) between the faster-moving layer of molecules and the slower adjacent layer. Hence, the x-directed momentum has been transferred in the z direction from the faster- to the Slower-moving layer. The equation for this transport of 42

Chap. 2

Principles of Momentum Transfer and Overall Balances

momentum is similar to Eq; (2.3-2) and is Newton's law of viscosity written as follows for constant density p: (2.3-13) where r~x is flux of x-directed momentum in thez direction, (kg· m/s}/s· m 2 ; v is pip, the momentum diffusivity in m 2/s; z is the direction of transport or diffusion in m; p is the density in kg/m3; and p is the viscosity in kg/m . s. 2. Heat transport and Fourier's law. Fourier's law for molecular transport of heat or heat conduction in a fluid or solid can be written as follows for constant density p and heat capacity c p' q= = A

-'".1.

d(pc p dz

n

(2.3-14)

where q=IA is the heat flux in l/s· m 2, :x is the thermal diffusivity inm2/s, andpc p T is the concentration of heat or thermal energy in 1/m 3. When there is a temperature gradient in a fluid, equal numbers of molecules diffuse in each direction between the hot and the colder region. In this way energy is transferred in the z direction. 3. Mass transport and Fick's law. Fick's law for molecular transport of mass in a fluid or solid for constant total concentration in the fluid is

dC A

J*;_.=-D ~ AB dz

(2.3-15)

where J~= is the Rux of A in kg mol A/s' m 2, DAB is the molecular diffusivity of the molecule A in Bin m 2 /s, and C A is the concentration of A in kg moIA/m 3 • In a manner similar to momentum and heat transport, when there is a concentration gradient in a Ruid, equal numbers of molecules diffuse in each direction between the high- and the low-concentration region and a net flux of mass occurs. Hence, Eqs. (2.3-13), (2.3-14), and (2.3-15) for momentum, heat, and mass transfer are all similar to each other and to the general molecular transport equation (2.3-2). All equations have a Rux on the left-hand side of each equation, a diffusivity in m 2/s, and the derivative of the concentration with respect to distance. All three of the molecular transport equations are mathematically identical. Thus, we state we have an analogy or .' similarity among them. It should be emphasized, however, that even though there is a mathematical analogy, the actual physical mechanisms occurring can be totally different. For example, in mass transfer two components are often being transported by relative motion through one another. In heat transport in a solid, the molecules are relatively stationary and the transport is done mainly by the electrons. Transport of momentum can occur by several types of mechanisms. More detailed considerations of each of the transport processes of momentum, energy, and mass are presented in this and succeeding chapters.

2.4 2.4A

VISCOSITY OF FLUIDS Newton's Law and Viscosity

When a Ruid is Rowing through a closed channel such as a pipe or between two flat plates, either of two types of flow may occur, depending on the velocity of this fluid. At Sec. 2,4

Viscosity of Fluids

43

low velocities the fluid tends to flow without lateral mixing, and adjacent layers slide past one another like playing cards. There are no cross currents perpendicular to the direction of flow, nor eddies or swirls of fluid. This regime or type of flow is called laminar flow. At higher velocities eddies form, which leads to lateral mixing. This is called turbulent flow. The discussion in this section is limited to laminar flow. A fluid can be distinguished from a solid in this discussion of viscosity by its behavior when subjected to a stress (force per unit area) or applied force. An elastic solid deforms by an amount proportional to the applied stress. However, a fluid when subjected to a similar applied stress will continue to deform, i.e., to flow at a velocity that increases with increasing stress. A fluid exhibits resistance to this stress. Viscosity is that property of a fluid which gives rise to forces that resist the relative movement of adjacent layers in the fluid. These viscous forces arise from forces existing between the molecules in the fluid and are of similar character as the shear forces in solids. The ideas above can be clarified by a more quantitative discussion of viscosity. In Fig. 2.4-1 a fluid is contained between two infinite (very long and very wide) parallel plates. Suppose that the bottom plate is moving parallel to the top plate and at a constant velocity Av. m/s faster relative to the top plate because of a steady force F newtons being applied. This force is called the viscous drag, and it arises from the viscous forces in the fluid. The plates are Ay m apart. Each layer of liquid moves in the z direction. The layer immediately adjacent to the bottom plate is carried along at the velocity of this plate. The layer just above is at a slightly slower velocity, each layer moving at a slower velocity as we go up in the y direction. This velocity profile is linear, with y direction as shown in Fig. 2.4-1. An analogy to a fluid is a deck of playing cards, where, if the bottom card is moved, all the other cards above will slide to some extent. It has been found experimentally for many fluids that the force F in newtons is directly proportional to the velocity Av: in mis, to the area A in m 2 of the plate used, and inversely proportional to the distance Ay in m. Or, as given by Newton's law of viscosity when the flow is laminar, F

(2.4-1)

A

where J1 is a proportionality constant called the viscosity of the fluid, in Pa· s or kg/m s. If we let L'iy approach zero, then, Llsing the definition of the derivative,

dV - u -t , dy

(SI units)

(2.4-2)

where 'yz F/ A and is the shear stress or force per unit area in newtons/m 2 (N/m 2 ). In the egs system, F is in dynes, 11 in gjc:m' 5, v. incm/s, and yin c:m. We can also write

y

F force '------2

FIGURE

44

2.4- L

Chap. 2

Fluid shear between two parallel places.

Principles of Momentum Transfer and Overall Balances

Eq. (2.2-2) as (English units)

(2.4-3)

where ryz isin units oflbr/ft 2 • The. units of viscosity in the cgs system are gfcm· s, called poise or centipoise (cp). In the SI system, viscosity is given in Pa' s (N . s/m2 or kgfm· s). I cp

= 1 X 10- 3 kgfm's = 1 x 10- 3 Pa·s 1 cp

= 0.01

poise

1 x 10- 3 N.s/m 2 (SI)

= 0.01 gfcm· s

1 cp = 6.7197 x 1O- 4 Ib m /ft·s Other conversion factors for viscosity are given in Appendix A.I. Sometimes the viscosity is given as III p, kinematic viscosity, in m 21s or cm 2ls, where p is the density of the fluid.

EXAMPLE 2.4-1.

Calculation o/Shear Stress in a Liquid

Referring to Fig. 2.4-1, the distance between plates is ~y = 0.5 cm, ~vz = 10 cmls, and the fluid is ethyl alcohol at 273 K having a viscosity of 1.77 cp (0.0177 g/cm . s). (a) Calculate the shear stress ryx and the velocity gradient or shear rate dvJdy using cgs units. (b) Repeat, using Ib force, s, and ft units (English units). (c) Repeat, using SI units.

Solution:

We can substitute directly into Eq. (2.4-1) or we can integrate Eq. (2.4-2). Using the latter method, rearranging Eq. (2.4-2), calling the bottom plate point I, and integrating, .

r yz

[n=0.5 dy Jy, =0

= _ J1. [",=0

1,

dv

10

(2.4-4)

x

(2.4-5) Substituting the known values, J1. v -- = (0.0177 yz YI cm'

0.354 g' cmfs 2 cm

(10 - O)cm/s (0.5 - 0) cm

0.354 dyn cm 2

(2.4-6)

To calculate the shear rate dVzldy, since the velocity change is linear with y, shear rate

=

~v: (10 - 0) cmls dy = ~y = (0.5 0) cm

dv z

= 20.0 s

_I

(2.4-7)

For part (b), using Ib force units and the viscosity conversion factor from Appendix A.I, J1.

= 1.77 cp(6.7197 x 10- 4 Ibm 1ft .s)/cp = l.77(6.7197 x

Sec. 2.4

Viscosity of Fluids

10- 4 ) Ibm/ft·s 4S

Integrating Eq. (2.4-3), (2.4-8)

Substituting known values into Eq. (2.4-8) and converting~v% to ft/s and ~y to ft, Lyz = 7.39 x 1O- 4 Ibr/ft 2 . Also,dvJdy = 20s 1 • • For part (c), t.y 0.5/100 0.005 m, ~vr lO/l00 = 0.1 mis, and If. = 1.77 X lO-3 kg/m· S = 1.77 x 10 3 Pa' s. Substituting into Eq. (2.4-5), 3 !yz = (1.77 x 10- )(0.10)/0.005 0.0354 N/m2 The shear rate will be the same at 20.0s- 1 2.4B

Momentum Transfer in a Fluid

The shear stress! yz in Eqs. (2.4-1 )-(2.4-3) can also be interprl,:ted as a flux of z-directed momentum in the y direction, which is the rate of flow of momentum per unit area. The units of momentum are mass times velocity in kg· m/s. The shear stress can be written momentum

s

(2.4-9)

This gi ves an amount of momentum transferred per second per unit area. This can be shown by considering the interaction between two adjacent layers of a fluid in Fig. 2.4-1 which ha ve different velocities, and hence different momentum, in thez direction. The random motions of the molecules in the faster-moving layer send some of the molecules into the slower-moving layer, where they collide with the slower-moving molecules and tend to speed them up or increase their momentum in the z direction. Also, in the same fashion, molecules in the slower layer tend to retard those in the faster layer. This exchange of molecules between layers produces a transfer or flux of z-directed momentum from high-velocity to low-velocity layers. The negative sign in Eq. (2.4-2) indicates that momentum is transferred down the gradient from high- to low-velocity regions. This is similar to the transfer of heat from high- to low-tern perature regions.

2AC

Viscosities of Newtonian Fluids

Fluids that follow Newton's law of viscosity, Eqs. (2.4-IH2.4-3),are called Newtonian fluids. For a Newtonian fluid, there is a linear relation between the shear stress !yz and the velocity gradient dvJdy (rate of shear). This means that the viscosity JL is a constant and independent of the rate of shear. For non-Newtonian !bids, the relation between! yz and dVz/dy is not linear; i.e., the viscosity II does not remain constant but is a function of shear rate. Certain liquids do not obey this simple Newton's law. These are primarily pastes, slurries, high polymers, and emulsions. The science of the flow and deformation of fluids is often called rheology. A discussion of non-Newtonian fluids will not be given here but will be included in Section 3.5. The viscosity of gases, which are Newtonian fluids, increases with temperature and is approximately independent of pressure up to a pressure of about 1000 kPa. At higher pressures, the viscosity of gases increases with increase in pressure. For example, the viscosity of N 1 gas at 298 K approximately doubles in going from 100 kPa to about 5 x 10" kPa (Rl). In liquids, the viscosity decreases with increasing temperature. Since liquids are essentially incompressible, the viscosity is not affected by pressure. 46

Chap. 2

Principles of Momentum Transfer and Overall Balances

r ABLE 2.4-1.

Viscosities of Some Gases and Liquids at 10 132 kPa Pressure Gases

Liquids

Substance

K

Viscosity (Pa·s)103 or (kg/m's) 10 3

Air CO 2 CH 4

293 273 373 293

0.Oi813 0.01370 0.01828 0.01089

Nl R1 Rl Rl

SOz

373

0.01630

R1

Temp.,

Temp., Ref.

Substance

Water

K

Benzene

293 373 278

Glycerol Hg Olive oil

293 293 303

Viscosity (Pa,s)103 or (kg/m.s) 10 3

1.0019 0.2821 0.826 1069 1.55 84

Ref.

SI SI RI

L1 R2 E1

In Table 2.4·1 some experimental viscosity data are given for some typical pure. fluids at lO1.32 kPa. The viscosities for gases are the lowest and do not differ markedly from gas to gas, being about 5 x 10- 6 to 3 x 10- 5 Pa' s. The viscosities for liquids are much greater. The value for water at 293 K is about 1 x 10- 3 and for glycerol 1.069 Pa' s. Hence, there is a great difference between viscosities oJ liquids. More complete tables of viscosities are given for water in Appendix A.2, for inorganic and organic liquids and gases in Appendix A.3, and for biological and food liquids in Appendix AA. Extensive data are available in other references (PI, RI, WI, L1). Methods of estimating viscosities of gases and liquids when experimental data are not available are summarized elsewhere (RI). These estimation methods for gases at pressures below 100 kPa are reasonably accurate, with an error within about ± 5%, but the methods for liquids are often quite inaccurate. 2.5 2.5A

TYPES OF FLUID FLOW AND REYNOLDS NUMBER Introduction and Types of Fluid Flow

The principles of the statics of fluids, treated in Section are almost an exact science. On ,the other hand, the principles of the motions of fluids are quite complex. The basic relations describing the motions of a fluid are the equations for the overall balances of mass, energy, and momentum, which will be covered in the following sections. These overall or macroscopic balances will be applied to a finite enclosure or control volume fixed in space. We use the term" overall" because we wish to describe these balances from outside the enclosure. The changes inside the enclosure are determined in terms of the properties of the streams entering and leaving and the exchanges of energy between the enclosure and its surroundings. When making overall balances on mass, energy, and momentum we are not interested in the details of what occurs inside the enclosure. For example, in an overall balance average inlet and outlet velocities are considered. However, in a differential balance the velocity distribution inside an enclosure can be obtained with the use of Newton's law of viscosity. In this section we first discuss the two types of fluid flow that can occur: laminar and turbulent flow. Also, the Reynolds number used to characterize the regimes of flow is considered. Then in Sections 2.6, 2.7, and 2.8 the overall mass balance, energy balance, and momentum balance are covered together with a number of applications. Finally, a Sec. 2.5

Types of Fluid Flow and Reynolds Number

47

..

discussion is given in Section 2.9 on the methods of making a shell balance on an elemen t to obtain the velocity distribution in the element and pressure drop. 25B

Laminar and Turbulent Flow

The type of flow occurring in a fluid in a channel is important in fluid dynamics problems. When fluids move through a closed channel of any cross section, either of two distinct types of flow can be observed according to the conditions present. These two types of flow can be commonly seen in a flowing open stream or river. When the velocity of flow is slow, the flow patterns are smooth. However, when the velocity is quite high, an unstable pattern is observed in which eddies or small packets offluid particles are present moving in all directions and at all angles to the normal line of flow. The first type of flow at low velocities where the layers of fluid seem to slide by one another without eddies or swirls being present is called laminar flow and Newton's law of viscosity holds, as discussed in Section 2.4A. The second type of flow at higher velocities where eddies are present giving the fluid a fluctuating nature is called turbulentflow, The existence of laminar and turbulent flow is most easily visualized by the experiments of Reynolds. His experiments are shown in Fig. 2.5-1. Water was allowed to flow at steady state through a transparent pipe with the flow rate controlled by a valve at the end of the pipe. A fine steady stream of dye-colored water was introduced from a fine jet as shown and its flow pattern observed. At low rates of water flow, the dye pattern was regular and formed a single line or stream similar to a thread, as shown in Fig. 2.5-1 a. There was no lateral mixing of the fluid, and it flowed in streamlines down the tube. By putting in additional jets at other points in the pipe cross section, it was shown that there was no mixing in any parts of the tube and the fluid flowed in straight parallel lines. This type of flow is called laminar or viscous flow.

r

dye in wa ter

water r d y e streamline I 1

t (a)

(b) FIGURE

25-1.

Reynolds' experiment for different types offlow: (aj laminar flow. (b j turbulent flow. Chap. 2

Principles of Momentum Transfer and Overall Balances

As the velocity was increased, it was found that at a definite velocity the thread of dye became dispersed and the pattern was very erratic, as shown in Fig. 2.5-lb. This type of flow is known as turbulent flow. The velocity at which the flow changes is known as the critical velocity. 2.SC

Reynolds Number

Studies have shown that the transition from laminar to turbulent flow in tubes is not only a function of velocity but also of density and viscosity of the fluid and the tube diameter. These variables are combined into the Reynolds number, which is dimensionless. Dvp

NRc

=--

(2.5-1)

J1

where N Re is the Reynolds number, D the diameter in m, p the fluid density in kg/ml, J1 the fluid viscosity in Pa' s, and v the average velocity of the fluid in m/s (where average velocity is defined as the volumetric rate of flow divided by the cross-sectional area of the pipe). Units in the cgs system are D in em, p in gfcml, J1 in gfcm' s, and v in cm/s. In the English system D is in ft, p in Ibmlfe, J1 in Ibm /ft . s, and v in ft/s. The instability of the flow that leads to disturbed or turbulent flow is determined by the ratio of the kinetic or inertial forces to the viscous forces in the fluid stream. The inertial forces are proportional to pv 2 and the viscous forces to J1v/ D, and the ratio pv 2 /(J1v/D) is the Reynolds number Dvp/J1. Further explanation and derivation of dimensionless numbers is given in Section 3.11. For a straight circular pipe when the value of the Reynolds number is less than 2100, the flow is always laminar. When the value is over 4000, the flow will be turbulent, except in very special cases. In between, which is called the transition region, the flow can be viscous or turbulent, depending upon the apparatus details, which cannot be predicted. EXAMPLE 1.5-1 Reynolds Number in a Pipe Water at 303 K is flowing at the rate of 10 gal/min in a pipe having an inside diameter (ID)or 2.067 in. Calculate the Reynolds number using both English units and SI units. Solution: as

From AppendixA.l, 7.481 gal = 1 ft3. The flow rate is calculated

cross-sectional area of pipe velocity in pipe, v

71:(0. [72)2

4

(0.0223

0.0233 ft 2

r~J) (0.02~3 ft2) = 0.957 ft/s

From Appendix A.2 for water at 303 K (30°C), density, p viscosi ty, J1

0.996{62A3) Ibrn/ft3 =

(0.8007 cp) (6,7197 x 5.38 x 10 - 4 Ibm/ft· s

Sec. 2.5

Types of Fluid Flow and Reynolds Number

49

Substituting into Eq. (2.5-1),

Dvp (0.172 ft)(0.957 ft/s)(0.996 x 62.43 Ibm /ftl) NRe=-;;-= 5.38 X 10 4Ibm/ft·s = 1.905

X

104

Hence, the flow is turbulent. Using SI units, p = (0.996)(100 kg/m 3) = 996 kg/m 3

D = (2.067 in.)(1 ft/12 in.Xl m/3.2808 ft) = 0.0525 m

v= f.1. =

(0.957~) (1 m/3.2808 ft) =

(0.8007 cp)( 1

X

1O- l

0.2917 m/s

kg/m.s) cp

8.007 =

8.007

(0.0525 m)(0.2917 m/s)(996 kglm 8.007 x 10 4 kglm . s

2.6 2.6A

X

X 3

10- 4

~ m's

4

10- Pa' s

)

1.905

X

104

OVERALL MASS BALANCE AND CONTINUITY EQUA nON Introduction and Simple Mass Balances

In fluid dynamics fluids are in motion. Generally, they are moved from place to place by means of mechanical devices such as pumps or blowers, by gravity head, or by pressure, and flow through systems of piping and/or process equipment. The first step in the solution of flow problems is generally to apply the principles of the conservation of mass to the whole system or to any part of the system. First, we will consider an elementary balance on a simple geometry, and later we shall derive the general mass-balance equation. Simple mass or material balances were introduced in Section 1.5, where input

output

+ accumulation

(1.5-1)

Since, in fluid flow, we are usually working with rates of flow and usually at steady state, the rate of accumulation is zero and we obtain rate of input

= rate of output (steady state)

(2.6-1)

In Fig. 2.6-1 a simple flow system is shown where fluid enters section 1 with an

VI

PI---

process "-----1

FIGURE

so

2.6-1.

Chap. 2

M ass balance onjlow system.

Principles of Momentum Transfer and Overall Balances

average velocity VI m/s and density PI kg/m 3. The cross-sectional area is Al m Z• The fluid leaves section 2 with average velocity Vz. The mass balance, Eq. (2.6-1), becomes (2.6-2) where m = kg/so Often, vp is expressed as G = vp, where G is mass velocity or mass flux in kg/s' m 2 • In English units, v is in ft/s, p in Ibm /ft 3, A in ft 2 , m in lbm/s, and G in lbm/s· ftz . .

EXAMPLE 2.6-1. Flow o/Crude Oil and Mass Balance A petroleum crude oil having a density of 892 kg/m 3 is flowing through the piping arrangement shown in Fig. 2.6-2 at a total rate of 1.388 x 10- 3 m 3/s entering pipe 1. The flow divides equally in each of pipes 3. The steel pipes are schedule 40 pipe (see Appendix A.5 for actual dimensions). Calculate the following using SI units. (a) The total mass flow rate m in pipe I and pipes 3. (b) The average velocity V in 1 and 3. (c) The mass velocity Gin 1. Solution: From Appendix A.5, the dimensions of the pipes are as follows: 2-in. pipe: DI (10) = 2.067 in., cross-sectional area AI

=

@ rtt,

,,-,

0.02330 ft Z = 0.02330(0.0929) = 2.165 x 10- 3 m Z

H-in. pipe: D3(ID) = 1.610 in., cross-sectional area A3 = 0.01414 ftz = 0.01414(0.0929) = 1.313 x 10- 3 m 2

The total mass flow rate is the same through pipes 1 and 2 and is ml =(1.388 x 10- 3 kg/m3) = 1.238 kg/s

m3/sX89~

ml

m3

=2

1.238

= ~

.,/.f/' .IF~ &/,"f)o.r' 5" h 0

r{O

I

\

"\ .

= 0.619 kg/s

(J

j/ •

j .........

Since the flow divides equally in each of pipes 3,

f'....~O

,j' / ~ f

;.

.f"

.'

i'"d-

,/'

.~.

For part (b), using Eq. (2.6-2) and solving for v, mI VI

=

PIAl

V3

=

P3 A3

=

1.238 kg/s (892 kg/m 3){2.165 x 10-3 mZ)

=

0.619 (892)(1.313 x 10 3)

m3

=

0.528 m/s

3

2-in. pipe

0.641 m/s

=

/

2

1 1/2 -in. pipe

3-in. pipe

ll/z-in. pipe

3

FIGURE

Sec. 2.6

2.6-2.

Piping arrangemerlCfor Example 2.6-1.

Overall Mass Balance and Continuity Equation

51

/

Forpart(c),

ml Al

2.6B

L238 2.165 X 10- 3

Control Volume for Balances

The laws for the conservation of mass, energy, and momentum are all stated in terms of a system, and these laws give the interaction of a system with its surroundings. A system is defined as a collection of fluid of fixed identity. However, in flow of fluids, individual particles are not easily identifiable. As a result, attention is focused on a given space through which the fluid flows rather than to a given mass of fluid. The method used, which is more convenient, is to select a control volume, which is a region fixed in space through which the fluid flows. In Fig. 2.6-3 the case of a fluid flowing through a conduit is shown. The control surface shown as a dashed line is the surface surrounding the control volume. In most problems part of the control surface will coincide with some boundary, such as the wall of the conduit. The remaining part of the control surface is a hypothetical surface through which the fluid can flow, shown as point 1 and point 2 in Fig. 2.6-3. The control-volume representation is analogous to the open system of thermodynamics.

2.6C

Overall Mass-Balance Equation

In deriving the general equation for the overall balance of the property mass, the law of conservation of mass may be stated as follows for a control volume where no mass is being generated. rate of mass output) ( from control volume

+

(rate of mass input ) from control volume

rate of mass accumUlation) ( in control volume

o (rate of mass generation) (2.6-3)

We now consider the general control volume fixed in space and located in a fluid flow field, as shown in Fig. 2.6-4. For a small element of area dA m 2 on the control surface, the rate of mass emux from this element (pvXdA cos rx), where (dA cos IX) is the area dA projected in a direction normal to the velocity vector '1', Ct. is the angle between the velocity vector 'I' and the outward-directed unit normal vector n to dA, and p is the

control volume FIGURE

52

2.6-3. Control volume for flow through a conduit.

Chap. 2

Principles of Momentum Transfer and Overall Balances

streamlines of fluid stream control volume

normal to surface

conlm! ,mf.co FIGURE

2.6-4.

~

Flow through a differential area dA on a control surface.

density in kg/m J • The quantity pv has units of kg/s· m I and is called a flux or mass velocity G. From vector algebra we recognize that (pv)(dA cos a) is the scalar or dot product p(v. n) dA. If we now integrate this quantity over the entire control surface A we have the net outflow of mass across the control surface, or the net mass effiux in kg/s from the entire control volume V:

If

net mass efflux ) ( from control volume

vp cos

dA =

!X

If

p( v· n) dA

(2.6-4)

We should note that if mass is entering the control volume, i.e., flowing inward across the control surface, the net effiux of mass in Eq. (2.6-4) is negative since a> 90 0 and cos ex is negative. Hence, there is a net influx of mass. If !X < 90 there is a net effiux of mass. The rate of accumulation of mass within the control volume V can be expressed as follows. 0

,

rate of mass accumulation) ( in control volume

a at

=-

Iff

dM de

pdV=-

(2.6-5)

v

where M is the mass of fluid in the volume in kg. Substituting Eqs. (2.6-4) and (2.6-5) into (2.6-3), we obtain the general form of the overall mass balance.

ff

p(v·n) dA

+

:t fff

p dV

0

(2.6-6)

v

The use of Eq. (2.6-6) can be shown for a common situation for steady-state one-dimensional flow, where all the flow inward is normal to AI and outward normal to AI' as shown in Fig. 2.6-3. When the velocity V2 leaving (Fig. 2.6-3) is normal toA z , the 0 angle 0:2 between the normal to the control surface and the direction of the velocity is 0 and cos !x z = 1.0. Where VI is directed inward, a l > n12, and for the case in Fig. 2.6·3, 0 et 1 is 180 (cos a 1 l.0). Since a2 is 0° and a 1 is 180 0 , using Eq. (2.6-4),

ff

vp cos adA =

ff

vp cos a z dA

+

ff

vp cos a 1 dA

A

(2.6-7)

Sec. 2.6

Overall Mass Balance and Continuity Equation

S3

For steady state, dM/dt

0 in Eq. (2.6-5), and Eq. (2.6-6) becomes (2.6-2)

m = PI V1 Al = P2 V2 A2

which is Eq. (2.6-2), derived earlier. In Fig. 2.6-3 and Eqs. (2.6-3H2.6-7) we were not concerned with the composition of any of the streams. These equations can easily be extended to represent an overall mass balance for component i in a multicomponent system. For the case shown in Fig. 2.6-3 we combine Eqs. (2.6-5), (2.6-6), and (2.6-7), add a generation term, and obtain

m'2 -

m'l

I

•

dM· + __ "= dt

R·

(2.6-8)

I

where mi2 is the mass flow rate of component i leaving the control volume and R; is the rate of generation of component j in the control volume in kg per unit time. (Diffusion fluxes are neglected here or are assumed negligible.) In some cases, of course, R; 0 for no generation. Often it is more convenient to use Eq. (2.6-8) written in molar units. EXAMPLE 2.6-2. Overall Mass Balance in Stirred Tank Initially, a tank contains 500 kg of salt solution containing 10% salt. At point (1) in the control volume in Fig. 2.6-5, a stream enters at a constant flow rate of 10 kg/h containing 20% salt. A stream leaves at point (2) at a constant rate of 5 kgfh. The tank is well stirred. Derive an equation relating the weight fraction w A of the salt in the tank at any time t in hours. Solution: First we make a total mass balance using Eq. (2.6-7) for the net total mass effiux from the control volume.

ffvpcosadA=m2

mt

5 kg solution/h

510

(2.6-9)

A

From Eq. (2.6-5), where M is total kg of solution incontrol volume at time l, dM

(2.6-5)

dl

Substituting Eqs. (2.6-5) and (2.6-9) into (2.6-6), and then integrating, dM 5+- 0 elt M

r

JM~ 500

dM M

5f~odt

(2.6-10)

-

5t

+ 500

(2.6-11)

Equation (2.6-11) relates the total mass M in the tank at any time I. ----,

(I)

initial 500 kg salt solu tion (t 0, 10% salt)

10 kg/h (20% salt)

control volume

(2) 5 kg/h

FIGURE

54

2.6-5.

Control volumeJor flow in a stirred tankJor Example 2.6-2.

Chap. 2

Principles of Momentum Transfer and Overall Balances

Next, making a component A salt balance, let wA = weight fraction of salt in tank at time t and also the concentration in the stream ml leaving at time t. Again using Eq. (2.6-7) but for a salt balance,

I! Iff

vp cos

IX

dA

(5)rv A

-

10(0.20)

=

5w A

2 kg salt/h

(2.6-12)

A

Using Eq. (2.6-5) for a

a at

~alt

p dV

balance,

d (Mw A ) = dt

=

M dw A -d-t-

dM + W A Tt

kg saltfh

(2.6-13)

v

Substituting Eqs. (2.6-12) and (2.6-13) into (2.6-6), 5w A

2

-

+

M

dW A

dM

dt + wAde

(2.6-14)

= 0

Substituting the value for M from Eq. (2.6-11) into (2.6-14), separating variables, integrating, and solving for W A'

5w A

2

dWA

d(5oo + 5t) dt

2 + (500

+ 5t) dtA + 5w A

+ (500 + 5)t dt + W A

= 0

dW

l

0

WA

wA=O.lO

_ J.- In (2 10

2

dW A IOwA -

dt ,=0500 + 5t

1 I (500 + 5t) 5 n 500

IOWA)

1

WA

I'

= -0.1

100 ( tOO + t

)2 +

(2.6-15)

0.20 (2.6-16)

Note that Eq. (2.6-8) for component i could have been used for the salt balance with R; 0 (no generation). 2.6D

Average Velocity to Usc in Overall Mass Balance

In solving the case in Eq. (2.6-7) we assumed a constant velocity VI at section 1 and constant V2 at section 2. If the velocity is not constant but varies across the surface area, an average or bulk velocity is defined by

v,v = ~A fIv dA

(2.6-17)

A

for a surface over which v is normal to A and the density p is assumed constant.

EXAMPLE 2.6-3.

Variation of Velocity Across Control Surface and Average Velocity

For the case of imcompressible flow (p is constant) through a circular pipe of radius R, the velocity profile is parabolic for laminar flow as follows: (2.6-18)

Sec. 2.6

Overall Mass Balance and Con[inlli[y Equation

55

where Vmax is the maximum velocity at the center where r =.0 and v is the velocity at a radial distance r from the center. Derive an expression for the average or bulk velocity Va. to use in the overall mass-balance equation.

Solution: The average velocity is represented by Eq. (2.6-17). In Cartesian coordinates dA is dx dy. However, using polar coordinates which are more appropriate for a pipe, dA = r dr dO, where is the angle in polar coordinates. Substituting Eq. (2.6-18), dA r dr dO, and A = l'£R 2 into Eq. (2.6-17) and integrating,

e

Urn ..

nR 4

(2n _ 0)

(R42 _R4) 4

(2.6-19)

(2.6-20)

In this discussion overall or macroscopic mass balances were made because we wish to describe these balances from outside the enclosure. In this section on overall mass balances, some of the equations presented may have seemed quite obvious. However, the purpose was to develop the methods which should be helpful in the next sections~ Overall balances will also be made on energy and momentum in the next sections. These overall balances do not tell us the details of what happens inside. However, in Section 2.9 a shell momentum balance will be made to obtain these details, which will give us the velocity distribution and pressure drop. To further study these details of the processes occurring inside the enclosure, differential balances rather than shell balances can be written and these are discussed in other later Sections 3.6 to 3.9 on differential equations of continuity and momentum transfer, Sections 5.6 and 5.7 on differential equations of energy change and boundary-layer flow, and Section 7.5B on differential equations of continuity for a binary mixture.

2.7

2.7 A

OVERALL ENERGY BALANCE

Introduction

The second property to be considered in the overall balances on a control volume is energy. We shall apply the principle of the conservation of energy to a control volume fixed in space in much the same manner as the principle of conservation of mass was used to obtain the overall mass balance. The energy-conservation equation will then be combined with the first la w of thermodynamics to obtain the final overall energy-balance equation. We can write the first law of thermodynamics as t'1E = Q - W

(27-1)

where E is the total energy per unit mass of fluid, Q is the heat absorbed per unit mass of fluid, and W is the work of all kinds done per unit mass of fluid upon the surroundings. Chap. 2

Principles of Momentum Transfer and Overall Balances

In the calculations, each term in the equation must be expressed in the same units, such as J /kg (SI), btuflbm , or ft . lbfflb m (English). Since mass carries with it associated energy because of its position, motion, or physical state, we will find that each of these types of energy will appear in the energy balance. In addition, we can also traJ1sport energy across the boundary of the system without transferring mass.

2.7B

Derivation of Overall Energy-Balance Equation

The entity balance for a conserved quantity such as energy is sirnilar to Eq. (2.6-3) and is as follows for a control volume. rate of entity output - rate of entity input

+ rate

of entity accumulation

0

(2.7-2)

The energy Elresent within a system can be classified in three ways. 1. Potential energy zg of a unit mass of fluid is the energy present because of the position of the mass in a gravitational field g, where z is the relative height in meters from a . reference plane. The units for zg for the SI system are m' m/sz. Multiplying and dividing by kg mass, the units can be expressed as (kg· rn/s2). (m/kg), or J/kg. In English units the potential energy is zg/gc in ft· Ibrflb m • 2. Kinetic energy v Z/2 of a unit mass of fluid is the energy present because of translational or rotational motion of the mass, where v is the velocity in m/s relative to the boundary of the system at a given point. Again in the SI system the units of v 2 /2 are J/kg. In the English system the kinetic energy is v 2 /2gc in ft ·lbr/lb m • 3. Internal energy V of a unit mass of a fluid is all of the other energy present, such as rotational and vibrational energy in chemical bonds. Again the units are in J/kg or ft· lbr/lb m • The total energy of the fluid per unit mass is then V

E

=

V

Z

+ 2 + zg

(SI) (2.7-3) (English)

The rate of accumuhition of energy within the control volurne V in rate of energy accumUlation) . ( In control volume

Iff ( ct

= -c

V

2.6-4 is

Z

+ V + zg ) p dV 2

(2.7-4)

v

Next we consider the rate of energy input and output associated with mass in the control volume. The mass added or removed from the system carries internal, kinetic, and potential energy. In addition, energy is transferred when rnass flows into and out of the control volume. Net work is done by the fluid as it flows into and out of the control volume. This pressure-volume work per unit mass fluid is p V. The contribution of shear work is usually neglected. The pV term and U term are cornbined using the definition of enthalpy, H.

H

= U + pV

Hence, the total energy carried with a unit mass is (H Sec. 2.7

Overall Energy Balance

(2.7-5)

+ v 2 /2 + zg). 57

For a small area dA on the control·surface in Fig. 2.6-4, the rate of energy effiux is cos ;x), where (dA cos ;x) is the area dA projected in a direction normal to the velocity vector v and ':J. is the angle between the velocity vector v and the outward-directed unit normal vector D. We now integrate this quantity over the entire control surface to obtain

(H

+ r2/2 + zg){pv){dA

ff (

2

v H + -2 + zg) pv) cos

) net energy efflux ( from control volume

(1.

dA

(2.7-6)

A

Now we have accounted for all energy associated with mass in the system and moving across the boundary in the entity balance, Eq. (2.7-2). Next we take into account heat and work energy which transfers across the boundary and is not associated with mass. The term q is the heat transferred per unit time across the boundary to the fluid because of a temperature gradient. Heat absorbed by the system is positive by convention. The work W, which is energy per unit time, can be divided into Ws , purely mechanical shaft work identified with a rotating shaft crossing the control surface, and the pressure-volume work, which has been included in the enthalpy term H in Eq. (2.7-6). By convention, work done by the fluid upon the surroundings, i.e., work out of the system, is positive. To obtain the overall energy balance, we substitute Eqs. (2.7-4) and (2.7-6) into the entity balance Eq. (2.7-2) and equate the resulting equation to q

Ws.

ff (H

+

v; + Zg}PV) cos:x dA + :t fff (u + v; + Zg) P dV = q - ~Vs v

A

2.7C

(2.7-1)

Overall Energy Balance for Steady-State Flow System

A common special case of the overall or macroscopic energy balance is that of a steady-state system with one-dimensional flow across the boundaries, a single inlet, a single outlet, and negligible variation of height z, density p, and enthalpy H across either inlet or outlet area. This is shown in Fig. 2.7-\. Setting the accumulation term in Eq. (2.7-7) equal to zero and integrating.

(2.7-8) For steady state, m I is on a unit mass basis,

PIt; I HAl

nl2

=

m. Dividing through by m so that the equation

(SI)

(2.7-9)

The term (r 3 ),j(2t:,J can be replaced by u;J2:J., where ':J. is the kinetic-energy velocity correction factor and is equal to r:j(u 3 ).v. The term :x has been eva Iuated for various flows in pipes and is t for laminar flow and close to 1.0 for turbulent flow. (See Section 2.70.) Hence, Eq. (2.7-9) becomes (SI)

(2.7-10) (English)

58

Chap. 2

Principles of Mom etllll m Transfer and Ol'erall Balances

CDI I

'---_h_ea--;-~-er--.JT

pump or turbine

CD I I

Z2

__1__

reference plane FIGURE

2.7-1.

Steady-statejlow systemfor ajluid.

Some useful conversion factors to be used are as follows from Appendix A.I: I btu

=

778.17 ft· lb e = 1055.06 1

1 hp

=

550 ft· lbr/s

1 ft ·lbrllbm

0.7457 kW

2.9890 lfkg

11= 1 N'm

2.7D

=

1 kg·m 2/s 2

Kinetic-Energy Velocity Correction Factor:

1. Introduction. term,

1.05506 kJ

tJ.

In obtaining Eq. (2.7-8) it was necessary to integrate the kinetic-energy

kinetic energy

ff C;}PV)

cos :x dA

(2.7-11)

A

which appeared in Eq. (2.7-7). To do this we first take p as a constant and cos 'Y. = LO. Then mUltiplying the numerator and denomina tor by Vav A, where Vn is the bulk or average velocity and noting that m = PIJ. v A, Eq. (2.7-11) becomes (2.7-12)

Dividing through by m so that Eq. (2.7-12) is on a unit mass basis, (2.7-13)

where'Y. is defined as (2.7-14)

Sec. 2.7

Overall Energy Balance

59

and (v 3 ).v is defined as follows:

~

3

(v ).v =

ff

(v

3 )

(2.7-15)

dA

A

The locol velocity v varies across the cross-sectional area of a pipe. To evaluate(v 3 ).v and, hence, the value of~, we must ha ve an equation relating vasa function of position in the cross-sectional area.

2. Laminar flow. In order to determine the value of ex for laminar flow, we first combine Eqs. (2.6-18) and (2.6-20) for laminar flow to obtain vasa function of position r.

2v. [I - (~YJ

v=

(2.7-16)

v

Substituting Eq. (2.7-16) into (2.7-15) ,and noting that A Example 2.6-3), Eq. (2.7-15) becomes

r2 )J3

R2 (2n)23v31R (R 2 - r2)3 v . 2' 6 nR 0 R

r

dr =

r

It

R2 and dA

=

r dr dO (see

r2)3 r dr

(2.7-17)

dr dO

16v31R 2 f (R -

R

0

Integrating Eq. (2.7-17) and rearranging,

(2.7-18)

Substituting Eq. (2.7-18) into (2.7-14), (2.7-19) Hence, for laminar flow the value of 0: to use in the kinetic-energy term of Eq. (2.7-10) is 0.50. 3. Turbulent flow. For turbulent flow a relationship is needed between v and position. This can be approximated by the following expression: v

(2.7-20)

where r is the radial distance from the center. This Eq. (2.7-20) is substituted into Eq. (2.7-15) and the resultant integrated to obtain the value of (v 3 ).v. Next, Eq. (2.7-20) is substituted into Eq. (2.6-17) and this equation integrated to obtain Vav and (v.Y· Combining the results for (v 3 ).. and (v.Y into Eq. (2.7-14)., the value of (J. is 0.945. (See Problem 2.7-1 for solution.) The value of 0: for turbulent flow varies from about 0.90 to 0.99. In most cases (except for precise work) the value of (J. is taken to be 1.0. 60

Chap. 2

Principles of Momentum Transfer and Overall Balances

2.7E

Applications of Overall Energy-Balance Equation

The total energy balance, Eq. (2.7-10), in the fonn given is not often used when appreciable enthalpy changes occur or appreciable heat is added (or subtracted) since the kinetic- and potential-energy tenns are usually small and can be neglected. As a result, when appreciable heat is added or 'subtracte-d or large enthalpy changes occur, the methods of doing heat balances described in Section 1.7 are generally used. Examples will be given to illustrate this and other cases.

EXAMPLE 1.7-1.

Energy Balance on Steam Boiler

Water enters a boiler at 18.33°C and 137.9 kPa through a pipe at an average velocity of 1.52 m/s. Exit steam at a height of 15.2 m above the liquid inlet leaves at 137.9 kPa, 148.9"C, and 9.14 m/s in the outlet line. At steady state how much heat must be added per kg mass of steam? The flow in the two pipes is turbulent.

Solution: The process flow diagram is shown in Fig. 2.7-2. Rearranging Eq. (2.7-10) and setting 0: 1 for turbulent flow and W s = 0 (no external work), (2.7-21)

Q To solve for the kinetic-energy terms, (1.52)2

1.115 J/kg

= --

2

2

~ = (9.~4)2 = 41.77 J/kg Taking the datum height ZI at point 1, Z2 Zz

9

'15.2 m. Then,

(15.2)(9.80665) = 149.1 J/kg

From Appendix A.2, steam tables in SI units, HI at 18.33°C Hz of superheated steam at 148.9°C = 2771.4 kJ/kg, and H2

-

HI

2771.4 - 76.97

=

2694.4 kJ/kg

=

76.97 kJ/kg,

2.694 x 106 J/kg

Substituting these values into Eq. (2.7-21), Q

= (149.1

0)

+ (41.77

Q = 189.75 + 2.694

1.115) + 2.694 x 106

x' 106

= 2.6942

X

106 J/kg

Hence, the kinetic-energy and potential-energy terms totaling 189.75 J/kg are negligible compared to the enthalpy change of 2.694 x 10 6 J/kg. This 189.75 J/kg would raise the temperature of liquid water about O.0453°C, a negligible amount.

steam Q

J

15.2 m

water

v2==9.14m/s 148.9°e, 131.9 kPa

1.52 mts 18. 3°e, 131.9 kPa

VI

FIGURE

Sec. 2.7

2.7·2.

Overall Energy Balance

Process flow diagram/or Example 2.7-1. 61

rl

'0-1

cooler

i

Q

FIGURE

2.7-3.

Processfiow diagram for energy balancefor Example 2.7-2.

EXAMPLE 2.7-2.

Energy Balance on a Flow System with a Pump Water at 85.0°C is being stored in a large, insulated tank at atmospheric pressure as shown in Fig. 2.7-3. It is being pumped at steady state from this tank at point 1 by a pump at the rate of 0.567 m 3 /min. The motor driving the pump supplies energy at the rate of 7.45 k W. The water passes through a heat exchanger, where it gives up 1408 kW of heat. The cooled water is then delivered to a second, large open tank at point 2, which is 20 m above the first tank. Calculate the final temperature of the water delivered to the second tank. Neglect any kinetic-energy changes since the initial and final velocities in the tanks are essentially zero. Solution: From Appendix A.2, steam tables, HI (8YC) = 355.90 x 10 3 J/kg, PI = 1/0J}010325 = 968.5 kg/m J • Then, for steady state,

rnl = m l = (0.567){968.5)ao)

9.152 kg!s

Also, Zl = 0 and Z2 = 20 m. The work done by the fluid is Ws , but in this case work is done on the fluid and Ws is negative. Ws = -(7.45 X 10 3 J/s)(I/9.152 kg/s)

-0.8140 x 10 3 J/kg

The heat added to the fluid is also negative since it gives up heat and is

Q = -(1408 Setting (vi H2

vi)/2 355.90

X

10 3 J!s){1/9.152 kg/s)

153.8

X

10 3 J /kg

0 and substituting into Eq. (2.7-10), X

10 3

+ 0 + 9.80665(20 -

0)

(-153.8 x 10 3 )

-

(

0.814

X

10 3 )

Solving, H 2 = 202.71 X 10 3 J!kg. From the steam tables this corresponds to (2 = 48.41°C Note that in this example, Ws and g(Z2 Zt) are very small compared to Q.

EXAMPLE 2.7-3. Energy Balance in Flow Calorimeter A flow calorimeter is being used to measure the enthalpy of steam. The calorimeter, which is a horizontal insulated pipe, consists of an electric heater immersed in a fluid flowing at steady state. Liquid water at O°C at a rate of 0.3964 kg/min enters the calorimeter at point L The liquid is vaporized completely by the heater, where 19.63 kW is added and steam leaves point 2 at 250c C and 150 kPa absolute. Calculate the exit enthalpy H 2 of the steam if the liquid enthalpy at O°C is set arbitrarily as O. The 62

Chap. 2

Principles of Momentum Transfer and Overall Balances

kinetic-energy changes are smaIl and can be neglected. (It will be assumed that pressure has a negligible effect on the enthalpy of the liquid.)

Solution: For this case, Ws = 0 since there is no shaft work between points 1 and 2. Also, (v~/2:t vU2a) 0 and g(zz - zd = O. For steady state, m 1 = m2 = 0.3964/60 = 6.607 x 10- 3 kg/so Since heat is added to the system,

Q= The value of H 1

19.63 kJ/s 10- 3 kg/s

+ 6.607 x

2971 kJ/kg

O. Equation (2.7-10) becomes

Hz-H l +O+O=Q-O The final equation for the calorimeter is

H2

Q + HI

(2.7-22)

Substituting Q 2971 kJ/kg and HI 0 into Eq. (2.7-22), Hz = 2971 kJ/kg at 250°C and 150 kPa, which is close to the value from the steam table of 2972.7 kJ/kg.

2.7F

Overall Mechanical-Energy Balance

A more useful type of energy balance for flowing fluids, especially liquids, is a modification of the total energy balance to deal with mechanical energy. Engineers are often concerned with this special type of energy, called mechanical energy, which includes the work term, kinetic energy, potential energy, and the flow work part of the enthalpy term. Mechanical energy is a form of energy that is either work or a form that can be directly converted into work. The other terms in the energy-balance equation (2.7-10), heat terms and internal energy, do not permit simple conversion into work because of the second law of thermodynamics and the efficiency of conversion, which depends on the temperatures. Mechanical-energy terms have no such limitation and can be converted almost completely into work. Energy converted to heat or internal energy is lost work or a loss in mechanical energy which is caused by frictional resistance to flow. It is convenient to write an energy balance in terms of this loss, I F, which is the sum of all frictional losses per unit mass. For the case of steady-state flow, when a unit mass of fluid passes from inlet to outlet, the batch work done by the fluid, W', is expressed as W'

rV2p dV -

Jv,

I

(I F > 0)

F

(2.7-23)

This work W' differs from the W of Eq. (2.7-1), which also includes kinetic- and potential-energy effects. Writing the first law of thermodynamics for this case, where llE becomes f..U, 6.U

Q

(2.7-24)

W'

The equation defining enthalpy, Eq. (2.7-5), can be written as

f..H

= f..U

+ 6.pV = llU +

l

v,

VI

Sec. 2.7

Overall Energy Balance

P dV +

iP2 V dp

(2.7-25)

PI

63

Substituting Eq. (2.7-23) into (2.7-24) and then combining the resultant with Eq. (2.7-25), we obtain (2.7-26)

Finally, we substitute Eq. (2.7-26) into (2.7-10) and l/p for V, to obtain the overall mechanical-energy-balance equation:

zd+

i

n dp

PI

-+2:F+Ws P

o

(2.7-27)

For English units the kinetic- and potential-energy terms of Eq. (2.7-27) are divided bygc' The value of the integral in Eq. (2.7-27) depends on the equation of state of the fluid and the path of the process. If the fluid is an incompressible liquid, the integral become.:; (P2 - Pl)/P and Eg. (2.7-27) becomes I ( 2~

2

2)

V 2av - V 1 .v +g(Z2- Z I

)

~ F + Ws=O + pz -. P1 +t... p

(2.7-28)

EXAMPLE 2.7-4. Mechanical-Energy Balance on Pumping System Water with a density of 998 kg/m 3 is flowing at a steady mass flow rate through a uniform-diameter pipe. The entrance pressure of the fluid is 68.9 kN/m2 abs in the pipe, which connects to a pump which actually supplies 155.4 lfkg of fluid flowing in the pipe. The exit pipe from the pump is the same diameter as the inlet pipe. The exit section of the pipe is 3.05 m higher than the entrance, and the exit pressure is 137.8 kN/m2 abs. The Reynolds number in the pipe is above 4000 in the system. Calculate the frictional loss I F in the pipe system. Solution: First a flow diagram is drawn of the system (Fig. 2.7-4), with 155.4 lfkg mechanical energy added to the fluid. Hence, Ws = -155.4, since the work done by the fluid is positive. Setting the datum height z 1 = 0, Z z 3.05 m. Since the pipe is of

;---.--- P2 == 137.8 kN/m2

3.05 m

v PI ==

68.9 kN/m2

FIGURE

64

2.7-4.

Chap. 2

Processjiow diagram/or Example 2.7-4.

Principles of Momentum Transfer and Overall Balances

constant diameter, V 1

V2'

Also, for turbulent flow 1

2(1)

2 V1)

(3.05 I)l)(9.806 m/s2)

9

Z2

2 (V2 -

0: =

1.0 and

o 29.91jkg

Since the liquid can be considered incompressible, Eq. (2.7-28) is used.

p

= 68.9

p

x 1000 998

= 690 1jk .

g

137.8 x 1000 = 138 0 1jk 998 . g

Using Eq. (2.7-28) and solving for L F, the frictional losses, (2.7-29) Substituting the known values, and solving for the frictional losses,

LF

155.4)

+0-

56.5 1jkg (18.9

EXAMPLE 2.7-5. .1

I I I I!

29.9

+ 69.0 -

138.0

ftl~~f)

Pump Horsepower in Flow System

A pump draws 69.1 gal/min of a liquid solution having a density of

114.8 Ib.Jft 3 from an open storage feed tank of large cross-sectional area through a 3.068-in.-ID suction line. The pump discharges its flow through a 2.067-in.-ID line to an open overhead tank. The end of the discharge line is 50 ft above the level of the liquid in the feed tank. The friction losses in the 10.0 ft-lb force/1bmass. What pressure must the piping system are L F pump develop and what is the horsepower of the pump if its efficiency is 65% (I] = 0.65)? The flow is turbulent.

Solution: First, a flow diagram of the system is drawn (Fig. 2.75). Equation (2.7-28) will be used. The term W, in Eq. (2.7-28) becomes (2.7-30) where - Ws

= mechanical

energy actually delivered to the fluid by the

T

50 ft

~

2.067 in.

FIGURE

Sec. 2.7

2.7-5.

Overall Energy Balance

Processfiow diagramfor Example 2.7-5.

65

pump or net mechanical work, 11 fractional efficiency, and Wp is the energy or shaft work delivered to the pump. From Appendix A.S, the cross-sectional area of the 3.068-in. pipe is 0.05134 ft2 and of the 2.067-in. pipe, 0.0233 ft2. The flow rate is flow rate

!:~) C6~~n) (7.418~t:al) = 0.1539 ft /s 3

= (69.1

(0.02~3 fe) = 6.61 ft/s

(0.1539 f:3)

V2

VI 0, since the tank is very large. Then d/2g c = O. The pressure 1 atm and pz 1 atm. Also, (t 1.0 since the flow is turbulent. Hence,

V~

PI

P2

p

p

=

= (6.61)2

29, U sing the datum of z 1

0, we have

Using Eq. (2.4-28), solving for

0 - 50.0

ftl~lbf m

(500) 32.174 . 32.174

=

0

0.678

2(32.174)

PI

ft· ·50.0 lb m

as, and su bstituting the known values,

+0

Using Eq. (2.7 -30) and solving for Jt;"

w=

as

p

-;;-

=

60.678 ft . = 93.3 ft· lbr Ibm Ibm

0:65

r: )(114.8 l~:;,) 3

mass flow rate = (0.1539

pump horsepower

= (17.65

17.65 s

l~m )(93.3 ftl~~r)(550 Ift~~brlS)

3.00 hp To calculate the pressure the pump must develop, Eq. (2.7-28) must be written over the pump itself between points 3 and 4 shown on the diagram.

as

V3 V..

= (0.1539 V2

=

r:3)(O.051~4 ft2) = 3.00 ft/s

6.61 ftls

~inc~ the difference in level between Z3 and z.. of the pump itself is negligible,

It 66

Will

be neglected. Rewriting Chap. 2

(2.7-28) between points 3 and 4 and

Principles of Momentum Transfer and Overall Balances

substituting known values (I F P4 - P3 -_ P

Z

3

fL gc

z4 fL gc

-

2

0- 0

2

+~ -

~

2gc

2gc

(3.00)2

=

= 0 since this is for the piping system),

+ 2(32.174) -

-

w.s - L " F

(6.61)2 2(32.174)

(2.7-31)

+ 60.678 -

0 ft ·Ib

= 0 - 0 + 0.140 - 0.678 + 60.678 = 60.14 ~ m

P4 - P3 = ( 60.14 =

2.7G

ft .Ib r ) ( Ib --u;;:114.8 fiT

m )(

1 ) 144 in.2/ft2

48.0 lb force/in. 2 (psia pressure developed by pump)

(331 kPa)

Bernoulli Equation for Mechanical-Energy Balance

In the special case where no mechanical energy is added

(Ws

=

0) and for no friction

CL:-F = 0), then Eq. (2.7-28) becomes the Bernoulli equation, Eq. (2.7-32), for turbulent flow, which is of sufficient importance to deserve further discussion. zig

vi PI v~ P2 +2" +p= Z2g +"2 +p

This equation covers many situations of practical importance and conjunction with the mass-balance equation (2.6-2) for steady state.

(2.7-32) IS

often used in (2.6-2)

Several examples of its use will be given. EXAMPLE 2.7-6. Rate of Flow from Pressure Measurements A liquid with a constant density p kg/m 3 is flowing at an unknown velocity VI m/s through a horizontal pipe of cross-sectional area A 1m2 at a pressure 2 PI N/m , and then it passes to a section of the pipe in which the area is reduced gradually to A2 m 2 and the pressure is P2' Assuming no friction losses, calculate the velocity v I and V2 if the pressure difference (P I - P2) is measured. Solution: In Fig. 2.7-6, the flow diagram is shown with pressure taps to measure PI and P2' From the mass-balance continuity equation (2.6-2), for constant p where p I = P2 = P, (2.7-33)

FIGURE

Sec. 2.7

2.7-6.

Overall Energy Balance

Processflow diagram for Example 2.7-6. 67

For the items in the Bernoulli equation (2.7-32), for a horizontal pipe, ZI

=

0

Z2

Then Eq. (2.7-32) becomes, after substituting Eq. (2.7-33) forv2,

O'+

viAilAi P2 +2 p

(2.7-34)

Rearranging,

PI

pvi[(A d A z)2 -

1J

(2.7-35)

2

PI - P2 2 P [(AdA2)2

(SI)

1J

(2.7-36) (English)

Performing the same derivation but in tenns of v2 , (2.7-37)

EXAMPLE 2.7-7. Rate of Flow from a Nozzle in a Tank A nozzle of cross-sectional area A2 is discharging to the atmosphere and is located in the side of a large tank, in which the open surface of the liquid in the tank is H m above the center line of the nozzle. Calculate the velocity V2 in the nozzle and the volumetric rate of discharge if no friction losses are assumed. Solution: The process flow is shown in Fig. 2.7-7, with point 1 taken in the liquid at the entrance to the nozzle and point 2 at the exit of the nozzle. Since A I is very,.large compared to A 2, VI ~ O. The pressure PI is greater than 1 atm (lO1.3 kN/m2) by the head of fluid of H m. The pressure P2, which is at the nozzle exit, is at 1 atm. Using point 2 as a datum,z2 = 0 and ZI 0 m. Rearranging Eq. (2.7-32), zig

vi vi + 2" + '-'--p--'-" = Z2 g + 2"

(2.7-38)

Substituting the known values, (2.7-39) ·Solving for

V2 ,

(2.7-40)

mls

FIGURE

2.7-7.

Nozzlejlow diagram for Example 2.7-7.

3

Hm

•

--e

L-__________ V_I~(

Chap. 2

1-

2

Principles of Momentum Transfer and Overall Balances

Since Pi - P3

= H pg and P3

=

P2 (both at 1 atm).

H

= Pi

P2

(2.7-41)

m

pg

where H is the head of liquid with density p. Then Eq. (2.4-40) becomes

-Jiiii

V2

(2.7-42)

. The volumetric flow rate is (2.7-43) To illustrate the fact that different points can be used in the balance, points 3 and 2 will be used. Writing Eq. (2.7-32), .

v~

z2g+T+ Since P2 = P3

1 atm,

D3

2.8A

p

0, and Z2

j2gz 3

D2

2.8

P2 - P3

v~

=z3g+T

(2.7-44)

J2gH

(2.7-45)

0, =

OVERALL MOMENTUM BALANCE Derivation of General Equation

A momentum balance can be written for the control volume shown in Fig. 2.6-3, which is somewhat similar to the overall mass-balance equation. Momentum. in contrast to mass and energy. is a vector quantity. The total linear momentum vector P of the total mass M of a moving fluid having a velocity of y is

P

= i'vfv

(2.8-1)

The term My is the momentum of this moving mass M enclosed at a particular instant in the control volume shown in Fig. 2.6-4. The units of My are kg· mls in the S1 system. Starting with Newton's second law we will develop the integral momentum-balance equation for linear momentum. Angular momentum will not be considered here. Newton's law may be stated: The time rate of change of momentum of a system is equal tothesummation of all forces acting on the system and takes place in the direction of the net force. dP

de

(2.8-2)

where F is force. In the SI system F is in newtons (N) and 1 N 1 kg· m/s2. Note that in the SI system g, is not needed, but it is needed in the English system. The equation for the conservation of momentum with respect to a control volume can be written as follows: sum of forces acting) (rate of momentum ) (rate of mOlJ1entum ) ( on control volume = out of control volume - into control volume

+ (:ate III

Sec. 2.8

of accumulation of momentum) control volume

Overall Momentum Balance

(2.8-3)

69

This is in the same form as the general mass-balance equation (2.6-3), with the sum of the forces as the generation rate term. Hence, momentum is not conserved, since it is generated by external forces on the system. If external forces are absent, momentum is conserved. Using the general control volume shown in Fig. 2.6-4, we shall evaluate the various terms in Eq. (2.8-3), using methods very similar to the development of the general mass balance. For a small element of area dA on the control surface, we write rate of momentum efflux

= Y\pvXdA cos a)

(2.8-4)

Note that the rate of mass effiux is (pvXdA cos ;x). Also, note that (dA cos a) is the area dA projected in a direction normal to the velocity vector v and Cl: is the angle between the velocity vector v and the outward-directed-normal vector n. From vector algebra the product in Eq. (2.8-4) becomes

v(pvXdA cos a) = pV(V'D) dA

(2.8-5)

Integrating over the entire control surface A, net momentum efflUX) ( from control vo Iume

=

If

Y\pv)cos a dA

=

ff

A

pv(v. n) dA

(2.8-6)

A

The net effiux represents the first two terms on the right-hand side of Eq. (2.8-3). Similarly to Eq. (2.6-5), the rate of accumulation of linear momentum within the control volume V is rate of accumulation of momentum) ( in control volume

-a at

fff

pvdV

(2.8-7)

v

Substituting Equations (2.8-2), (2.8-6), and (2.8-7) into (2.8-3), the overall linear momentum balance for a control volume becomes

ff

IF

pv(v. 0) dA

+

:t fff v

A

We should note that

I

(2.8-8)

pv dV

F in general may have a component in any direction, and the

F is the force the surroundings exert on the control-volume fluid. Since Eq. (2.8-8) is a vector equation, we may write the component scalar equations for the x, y, and z directions,

IF" =

ff

"',,,pu cos a ciA

+

:t fff pVx dV v

.4

ff ff ff

v"

P.. g"

v cos ;x dA

A

I

Fy =

vypu cos a ciA

+

F~ =

V,pu cos a ciA

~

ct

v

gc

Vx dV

(English)

pU y dV

(2.8-10)

+

pV; dV

(2.8-11)

v

A

70

flf fr fff :t fff

+

(2.8-9)

v

A

I

(SI)

Chap. 2

Principles of Momentum Transfer and Overall Balances

The force term are gi ven as follows.

L F;t: in Eq. (2.8-9) is composed of the sum of several forces. These

1. Body force. The body force F X9 is the x-directed force caused by gravity acting on the total mass M in the control volume. This force, F;Cg, is M gx. It is zero if the x direction is horizontal. 2. Pressure force. The force F xp is the x-directed force caused by the pressure forces acting on the surface of the fluid system. When the control surface cuts through the fluid, the pressure is taken ,to be directed inward and perpendicular to the surface. In some cases part of the control surface may be a solid, and this wall is included inside the control surface. Then there is a contribution to F xp from the pressure on the outside of this wall, which is typically atmospheric pressure. If gage pressure is used, the integral of the constant external pressure over the entire outer surface can be automatically ignored. 3. Friction force. When the fluid is flowing, an x-directed shear or friction force F;t:, is present, which is exerted on the fluid by a solid wall when the control surface cuts between the fluid and the solid wall. In some or many cases this frictional force may be negligible compared to the other forces and is neglected. 4. Solid surface force. In cases where the control surface cuts through a solid, there is present force R x , which is the x component of the resultant of the forces acting on the control volume at these points. This occurs in typical cases when the control volume includes a section of pipe and the fluid it contains. This is the force exerted by the solid surface on the fluid. The force terms of Eq. (2.8-9) can then be represented as (2.8-12) Similar equations can be writtel?-Jor the y and z directions. Then Eq. (2.8-9) becomes for the x direction,

=

SI

VX

pu cos

CI.

dA

:t ISS

+

(2.8-13)

dV

v

A

2.8B

pVx

Overall Momentum Balance in Flow System in One Direction

A quite common application of the overall momentum-balance equation is the case of a section of a conduit with its axis in the x direction. The fluid will be assumed to be flowing at steady state in the control volume shown in Fig. 2.6-3 and also shown in Fig. 2.8-1. Eq uation (2.8-! 3) for the x direction becomes as follows since IJ IJ x'

L Fx = Fxg + F;t:p+ F,s + R,

If

Vx pVx

cos

Cf.

dA

(2.8-14)

A

Integrating with cos

CI. =

± l.0 and pA

m/v ov '

(2.8-15)

Sec. 2.8

Overall Momentum Balance

71

FIGURE 2.8-1.

Flow·through a horizontal nozzle in the x direction only.

where if the velocity is not constant and varies across the surface area,

(v;)av

=

1II

(2.8-16)

v; dA

.-l

The ratio (v;)aJvxav is replaced by vxaJfJ, where fJ, which is the momentum velocity correction factor, has a value of 0.95 to 0.99 for turbulent flow and for laminar flow. For most applications in turbulent flow, (vx);Jv x av is replaced by Vx av' the average bulk velocity. Note that the subscript x on Vx and F x can be dropped since Vx = v and F x = F for one directional flow. The term F xp' which is the force caused by the pressures acting on the surface of the control volume, is

t

(2.8-17) The friction force will be neglected in Eq. (2.8-15), so Fxs = O. The body force F"9 = 0 since gra vi ty is acting only in the y direction. Substituting F xp from Eq. (2.8-17) into (2.8-15), replacing (v;).Jvx.v by vi f3 (where Vx av = v), setting f3 = 1.0, and solving for Rx in Eq. (2.8-15), (2.8-18) where Rx is the force exerted by the solid on the fluid. The force of the fluid on the solid (reaction force) is the nega tive of this or - Rx. EXAMPLE 2.B-l.

Momentum Velocity Correction Factor P for Laminar Flow The momentum velocity correction factor fJ is defined as follows for flow in one direction where the subscript x is dropped. 2

(v )a . . Vav

f3

=

=

Vav

fJ

(v~Y ( v-)JV

(2.8-19) (2.8-20)

Determine f3 for laminar flow in a tube. Solution:

Using Eq. (2.8-16),

1 (v 2 lav = A

72

Chap. 2

If

v 2 dA

(2.8-21)

Principles of Momentum Transfer and Overall Balances

Substituting Eq. (2.7-16) for laminar flow into Eq. (2.8-21) al!d noting that A nR2 and dA r dr de, we obtain (see Example 2.6-3)

2 = n~2 r~ IR [2Vav(1 - ~22)

I

(v )av

I

r Jo

_ {2n)22v;~ nR2

,

R

(R2 _ r2)2

R4

J

r drde

. r dr

(2.8-22)

Integrating Eq. (2.8-22) and rearranging,

\

(v

\

~v;J R6

l ) ••

= ~2 -

R6 2

Substituting Eq. (2.8-23) into (2.8-20), f3 =

I

EXAMPLE 2.8-2.

R 6)

+6

(2.8-23)

:to

Momentum Balance for Horizontal Nozzle

Water is flowing at a rate of 0.03154 m 3Is through a horizontal nozzle shown in Fig. 2.8-1 and discharges to the atmosphere at point 2. The nozzle is attadled at the upstream end at point 1 and frictional forces are considered negligible. The upstream ID is 0.0635 m and the downstream 0.0286 m. Calculate the resultant force on the nozzle. The density of the water is 1000 kg/m 3 •

i

Solution: First, the mass flow and average or bulk velocities at points I and 2 are calculated. The area at point 1 is Al = (n/4)(0.0635)2 = 3.167 x 10- 3 m 2 andA l = (n/4)(0.0286)2 = 6.424 x 10- 4 m l • Then, . mI

=

m = (0.03154)( 1000) = 31.54

m2

kg/s

0.03154/(3.167 x 10- 3 )

9.96 mls and m/s. To evaluate the upstream pressure PI we use the mechanical-energy balance equation (2.7-28) assuming no frictional losses and turbulent flow. (This can be checked by calculating the Reynolds number.) This equation then becomes, for a = LO,

The velocity at point 1 is Vl

0.03154/(6.424 x 10-

4

)

VI

= 49.1

(2..8-24)

Setting P2 0 gage pressure, p and solving for PI> 2

(1000)(49.1 2

9.96

2 )

1000 kg/m 3 ,

=

=

1.156

X

VI

= 9.96

106 N/m2

mis, V2

49.1

mis,

(gage pressure)

For the x direction, the momentum balance equation (2.S-IS) is used. Substituting the known values and solving for R x , Rx

31.54(49.10 - 9.96)

+0

(1.156 x 10 6 )(3.167 x 10- 3 )

2427 N{ - 546 Ibr)

Since the force is negative, it is acting in the negative x direction or to the left. This is the force of the nozzle on the fluid. The force of the fluid on the solid is -R", or +2427 N.

2.8e

Oyerall Momentum Balance in Two Directions

Another application of the overall momentum balance is shown in Fig. 2.S-2 for a flow system with fluid entering a conduit at point 1 inclined at an angle of a l relative to the Sec. 2.8

Overall Momentum Balance

73

y

Pl FIGURE

2.8-2.

Overall momentum balancefor flow system with fluid entering at point] and leaving at 2.

horizontal x direction and leaving a conduit at point 2 at an angleel 2 • The fluid will be assumed to be flowing at steady state and the frictional forceF"s will be neglected. Then Eq. (2.8-13) for the x direction becomes as follows for no accumulation: FXg

+ Fxp + Rx

=

If

(2.8-25)

vxpvcos ex dA

A

Integrating the surface (area) integral, FX9

(uD.v m --

+

cOS!X 2 -

m

V2av

The term (V 2).JV.v can again be replaced by v.vlP with IS the term

(vi).v

~-

cos

(2.8-26)

ell

V 1av

fJ being set at

2.8-2,

1.0. From

(2.8-27) Then Eq. (2.8-26) becomes as follows after solving for R, :

(2.8-28) The term F "9 = 0 in this case. For Ry the body force FY9 is in the negative y direction and Fyg m, is the total mass fluid in the control volume. Replacing cos ex by sin for the y direction becomes

!x,

- m, g, where the equation

EXAMPLE 2.8-3. Momentum Balance in a Pipe Bend Fluid is flowing at steady state through a reducing pipe bend, as shown in Fig. 2.8-3. Turbulent flow will be assumed with frictional forces negligible. The volumetric flow rate of the liquid and the pressure P2 at point'2 are known as are the pipe diameters at both ends. Derive the equations to calculate the forces on the bend. Assume that the density p is constant. Solution: The velocities VI and V2 can be obtained from the volumetric flow rate and the areas. Also, m = PlvlA I = P2 V2 A 2 • As in Example 2.8-2, the meChanical-energy balance equation (2.8-24) is used to obtain the upstream pressure, Pl' For the x direction Eq. (2.8-28) is used for the mo74

Chap. 2

Principles of Momenlllm Trar:sfer and Overall Balances

rz, pz

CD

FIGURE 2.8-3.

Flow through a reduCing bend in Example 2.8-3.

mentum balance. Since a l = 0°, cos

Ci l

=

1.0. Equation (2.8-28) becomes (SI)

(2.8-30)

(English) For the y direction the momentum balance Eq. (2.8-29) is used where sin

Ci l

o.

(SI)

(2.8-31)

where m, is total mass fluid in the pipe bend. The pressures at points 1 and 2 are gage pressures since the atmospheric pressures acting on all surfaces cancel. The magnitude of the resultant force of the bend acting on the control volume fluid is (2.8-32)

The angle this makes with the vertical is· 8 arctan (K,iR y ). Often the gra vity force F yg is small compared to the other terms in Eq. (2.8-31) and is neglected. EXAMPLE 2.8-4. Friction Loss in a Sudden Enlargement A mechanical-energy loss occurs when a fluid flows from a small pipe to a large pipe through an abrupt expansion, as shown in Fig. 2.8-4. Use the momentum balance and mechanical-energy balance to obtain an expression for the loss for a liquid. (Hint: Assume that Po PI and Vo VI. Make a mechanical-energy balance between points 0 and 2 and a momentum balance between points 1 and 2. It will be assumed that PI and pz are uniform over the cross-sectional area.) FIGURE 2.8-4.

Losses in expansionjlolV.

m

Sec. 2.8

Overall Momentum Balance

75

Solution: The control volume is selected so that it does not include the pipe wall, so Rx drops out. The boundaries selected are points 1 and 2. The flow through plane 1 occurs only through an area of AI). The frictional drag force will be neglected and all the loss is assumed to be from eddies in this volume. Making a momentum balance between points 1 and 2 using Eq.(2.8-18)andnotingthatpo=Pl,D 1 =vo,andA l Az,

(2.8-33) The mass-flow rate is m = fJo pAo and fJ2 = {AoIAz)vo. Substituting these terms into Eq. (2.8-33) and rearranging gives us

v5 Ao

Az

(1 _A

Ao) = Pz - PI p

z

(2.8-34)

Applying the mechanical-energy-balance equation (2.7-28) to points 1 and 2, (2.8-35) Finally, combining

(2.8-34) and (2.8-35), F

= fJ~ 2

2.80

(1 _

Ao)Z Az

(2.8-36)

Overall Momentum Balance for Free Jet Striking a Fixed Vane

When a free jet impinges on a fixed vane as in Fig. 2.8-5 the overall momentum balance can be applied to determine the force on the smooth vane. Since there are no changes in elevation or pressure before and after impact, there is no loss in energy and application of the Bernoulli equation shows that the magnitude of the velocity is unchanged. Losses due to impact are neglected. The frictional resistance between the jet and the smooth vane is also neglected. The velocity is assumed to be uniform throughout the jet upstream and downstream. Since the jet is open to the atmosphere, the pressure is the same at all ends of the vane. In making a momentum balance for the control volume shown for the curved vane in Fig. 2.8-5a, Eq. (2.8-28) is written as follows for steady state, where the pressure terms are zero, VI = fJZ,A 1 A 2 ,andm v 1 A 1 PI = vzAzpz: (2.8-37) Using Eq. (2.8-29) for the y direction and neglecting the body force, (2.8-38) Hence, Rx and Ry are the force components of the vane on the control volume fluid. The force components on the vane are - Rx and - R y • EXAMPLE 2.8-5. Force of Free Jet on a Curl'ed, Fixed Vane A jet of water having a velocity of 30.5 mls and a diameter of2.54 x 10 - 2 m is deflected by a smooth, curved vane as shown in 2.8-5a, where (Xl = 60°. What is the force of the jet on the vane? Assume that p = 1000 kg/m 3• 76

Chap. 2

Principles of Momentum Transfer and Overall Balances

p

2 \ .---:: /.

control volume \

/.

v::_ ~

~'-van,a,

lL -V'~~_ _ ~~y~~

jet~

,.:;

,

Lx

I

(a) fiGURE

2.8-5.

(b)

Free jet impinging on a fixed vane: (a) smooth, curved vane, (b) smooth, flat vane.

Solution: The cross-sectional area of the jet is Al = 1(2.54 x W- 2 )2/4 5.067 x W- 4 m 2 • Then, m = v1A1Pl = 30.5 x 5.067 x 10- 4 x 1000

15.45 kg/so Substituting into Eqs. (2.8-37) and (2.8-38), K"

15.45 x 30.5 (cos 60° - 1)

Ry

15.45 x 30.5 sin 60°

= 408.1

235.6 N(

52.97 Ib()

N(91.74 Ib r)

The force on the vane is -R" = +235.6 Nand -Ry = -408.1 N. The resultant force is calculated using Eq. (2.8-32). In Fig. 2.8-5b a free jet at velocity VI strikes a smooth, inclined flat plate and the flow divides into two separate streams whose velocities are all equal (VI = D2 = v) since there is no loss in energy. It is convenient to make a momentum balance in the p direction parallel to the plate. No force is exerted on the fluid by the flat plate in this direction; Le., there is no tangential force. Then, the initial momentum component in the p direction must equal the final momentum component in this direction. This means I Fp O. Writing an equation similar to Eq. (2.8-26), where m l is kg/s entering at I and m2 leaves at 2 and m) at 3, IFp=O=m2V2-mIVlcoS0:2

0=

m 2 VI -

miDI

cos

0:2

m)D) m) VI

(2.8-39)

By the continuity equation, (2.8-40) Combining and solving,

ml - (1

2

+ cos 0:,), -

(2.8-41)

The resultant force exerted by the plate on the fluid must be normal to it. This means the resultant force is simply miDI sin 0: 2 , Alternatively, the resultant force on the fluid can be Sec. 2.8

Overall Momemum Balance

77

calculated by determining Rx and Ry from Eqs. (2.8-28) and 2.8-29) and then using Eq. (2.8-32). The force on the bend is the opposite of this.

2.9 SHELL MOMENTUM BALANCE AND VELOCITY PROFILE IN LAMINAR FLOW 2.9A

Introduction

In Section 2.8 we analyzed momentum balances using an overall, macroscopic control volume. From this we obtained the total or overall changes in momentum crossing the control surface. This overall momentum balance did not tell us the details of what happens inside the control volume. In the present section we analyze a small control volume and then shrink this control volume to differential size. In doing this we make a shell momentum balance using the momentum-balance concepts of the preceding section, and then, using the equation for the definition of viscosity, we obtain an expression for the velocity profile inside the enclosure and the pressure drop. The equations are derived for flow systems of simple geometry in laminar flow at steady state. In many engineering problems a knowledge of the complete velocity profile is not needed, but a knowledge of the maximum velocity, average velocity, or the shear stress on a surface is needed. In this section we show how to obtain these quantities from the velocity profiles.

2.9B Shell Momentum Balance Inside a Pipe Engineers often deal with the flow of fluids inside a circular conduit or pipe. In Fig. 2.9-1 we have a horizontal section of pipe in which an incompressible Newtonian fluid is flowing in one-dimensional, steady-state, laminar flow:. The flow is fully developed; i.e., it is not influenced by entrance effects and the velocity profile does not vary along the axis of flow in the x direction. The cylindrical control volume is a shell with an inside radius r, thickness 6.r, and length 6.x. At steady state the conservation of momentum, (2.8-3), becomes as follows. sum of forces acting on control volume = rate of momentum out - rate of momentum into volume. The pressure forces become, from Eq. 17), pressure forces = pA Ix

pA 1.

FIGURE

84

;;.. ~

u 0

03 ;>

0.7

E :J E 0.6

2.10-2.

Ratio vav /v max as a function of Reynolds number for pipes. Chap. 2

Principles of Momentum Transfer and Overall Balances

cylindrical shell, the Hagen-Poiseuille equation (2.9-11) for laminar flow of a liquid in circular tubes was obtained. A derivation is also given in Section 3.6 using a differential momentum balance. This can be written as

(2.10-2) where PI is upstream pressure at point I, N/m2; P2' pressure at point 2; v is average velocity in tube, m/s; D is inside diameter, m; and (L2 - Ld or t..L is length of straight tube, m. For English units, the right-hand side ofEq. (2.10-2) is divided bygc' The quantity (Pi - P2)f or tlp f is the pressure loss due to skin friction. Then, for constant p, the friction loss F f is

Ff

=

(PI

P2)f

p

N'm --kg

or

J kg

(SI)

(2. 10-3} Ff

ft· Ib r Ibm

(English)

This is the mechanical-energy loss due to skin friction for the pipe in N· mjkg of fluid and is part of the L F term for frictional losses in the mechanical-energy-balance equation (2.7-28). This term (Pi - P2)f for skin friction loss is different from the (Pi - P2) term, owing to velocity head or potential head changes in Eq. (2.7-28). That part of F which arises from friction within the channel itself by laminar or turbulent flow is discussed in Sections 2.10B and in 2.1Oe. The part of friction loss due to fittings (valves, elbows, etc.), bends, and the like, which sometimes constitute a large part of the friction, is discussed in Section 2.1OF. Note that if Eq. (2.7-28) is applied to steady flow in a straight, horizontal tube, we obtain (Pi - pz)/ p L F. One of the uses of Eq. (2.10-2) is in the experimental measurement of the viscosity of a fluid by measuring the pressure drop and volumetric flow rate through a tube of known length and diameter. Slight 'corrections for kinetic energy and entrance effects are usually necessary in practice. Also, Eq. (2.10-2) is often used in the metering of small liquid flows.

L

EXAMPLE. 2.10-1.

Metering a/Small Liquid Flows

A small capillary with an inside diameter of 2.22 x 10-} m and a length 0.317 m is being used to continuously measure the flow ra te of a liquid having a density of 875 kg/m} and /.t = 1.l3 X 10- 3 Pa' s. The pressuredrop reading across the capillary during flow is 0.0655 m water (density 996 kg/m}). What is the flow rate in m 3 /s if end-effect corrections are neglected?

Solution:

Assuming that the flow is laminar, Eq. (2.10-2) will be used. First, to convert the height h of 0.0655 m water to a pressure drop using Eq. (2.2-4), tlpf = hpg

(0.0655 m{996

~~ )(9.80665 ~)

640 kg· m/s2 . m 2 = 640 N/m2 Substituting the following values in to Eq. (2.1 0-2) of /.t = 1.13 x 10- 3 Pa' $, Sec. 2.10

Design Equations for Laminar and Turbulent Flow in Pipes

85

L2 - Ll for v,

=

0.317 m, D

=

2.22

X

10- 3 m, and t.PJ

=

640 N/m2, and solving

(2.10-2) 640 = 32(1.13 x 10-3)(v)(0.317) (2.22 x 10 3)2 V

= 0.275 m/s

The volumetric rate is then

D2

volumetric flow rate = vn

0.275(n)(2.22 x 10- 3)2 4

4

1.066

X

10- 6 m3 /s

Since it was assumed that laminar flow is occurring, the Reynolds number will be calculated to check this. =

Jl

3

(2.22 x 1O- XO.275)(875) = 473 1.13 x 10- 3

Hence, the flow is laminar as assumed.

2. Use of friction factor for friction loss in laminar flow. A common parameter used in laminar and especially in turbulent flow is the Fanning friction factor,/, which is defined as the drag force per wetted surface unit area (shear stress at the surface) divided by the product of density times velocity head or t pv 2 • The force is t.p J times the cross-sectional area n:R2 and the wetted surface area is 2nR t.L. Hence, the relation between the pressure drop due to friction and/is as follows for laminar and turbulent flow.

"$

_,,__ t.PJrtR2jpv2 pv 2/2 - 2rtR t.L 2

f

(2.10-4)

Rearranging, this becomes

t.PJ

=

t.L v 2 4fp D 2

(SI) (2.10-5) (English)

4/

t.L v 2

-

D 2

(SI)

(2.10-6) (English) For laminar flow only, combining Eqs. (2.10-2) and (2.10-5),

f

16

16

Dvp/Jl

(2.10-7)

Equations (2.10-2), (2.10-5), (2.10-6), and (2.10-7) for laminar flow hold up to a Reynolds number of 2100. Beyond that at an N Re value above 2100, Eqs. (2.10-2) and (2.10-7) do not hold for turbulent flow. For turbulent flow Eqs. (2.10-5) and (2.10-6),

86

Chap. 2

Principles of Momentum Transfer and Overall Balances

however, are used extensively along with empirical methods of predicting the friction factor f, as discussed 'in the next section.

EXAMPLE 2.10-2.

Use of Friction Factorin Laminar Flow

Assume the same known conditions as in Example 2.10-1 except that the velocity of 0.275 m/s is known and the pressure drop !J.p f is to be predicted. Use the Fann'ing friction factor method.

Solution: The Reynolds number is, as before, N

_ Dvp Re -

Jl

(2.22 x 10- 3 m){0.275 m/s){875 kg/m 3 ) 1.13 x 10 3 kg/m· s

473

From Eq, (2.10-7) the friction factor lis

16·,

16

1= NRe = 473 = 0.0338 Using Eq. (2.10-5) with !J.L p = 875 kg/m 3 ,

0.317 m, v

(dimensionless) =

0.275 mis, D

2.22 x 10- 3 m,

4(0.03 38X8 75){0.317)(O.27 5)2 (2.22 x 10 - 3){2) This, of course, checks the value in Example 2.10-1. When the fluid is a gas and not a liquid, the Hagen-Poiseuille equation (2.10-2) can be written as follows for laminar flow:

m = 128(2R1)Jl(L

m=

2

_

L 1)

nD4gc M (pi - p~)

128(2R T)p( L2 - L I)

(SI) (2.10-8)

(English)

where m kg/s, M molecular weight in kg/kg mol, T = absolute temperature in K, and R 8314.3 N' m/kg mol· K, In English units, R 1545.3 ft ·Ibf/lb mol· OR.

2.10C

Pressure Drop and Friction Factor in Turbulent Flow

In turbulent flow, as in laminar flow, the friction factor also depends on the Reynolds number. However, it is not possible to predict theoretically the Fanning friction factor I for turbulent flow as it was done for laminar flow. The friction factor must be determined empirically (experimentally) and it not only depends upon the Reynolds number but also on surface roughness of the pipe. In laminar flow the roughness has essentially no effect. Dimensional analysis also shows the dependence of the friction factor on these factors. In Sections 3.11 and 4.14 methods of obtaining the dimensionless numbers and their importance are discussed. A large number of experimental data on fricti;n factors of smooth pipe and pipes of varying degrees of equivalent roughness have been obtained and the data correlated. For design purposes to predict the friction factor I and, hence, the frictional pressure drop of round pipe, the friction factor chart in Fig. 2.10-3 can be used. It is a log-log plot of I

Sec. 2./0

Design Equations for Laminar and Turbulent Flow in Pipes

87

1.0

OQ OQ

8

Material of construction

6

Equivalent roughness for new pipes, e (m)

0.5 3 2

"-.

0.1

.....u

8

..: 0

.... 0:1

;:::

,9 .....

4

OJ)

2

......;:::

1.5 X 10··

2.6 X

W~

1.8 X 10·' to 9 X 10-· 3 X I O· 4 to 3 X I 0- 3 9 X 10- 4 to 9 X 10- 3

6

3

....

4.6 X 10. 5 4.6 X 10. 5 1.2 X 10. 4

0.05

u

';:::

1.5 X 10- 6

Drawn tubing Commercial steel Wrough t iron Asphalted cast iron Galvanized iron Cast iron Wood stove Concrete Riveted steel

4

critical

I

relative roughness 'flD

I

turbulent flow

;:::

;::: 0:1

u... 0.01

laminar flow

8 6

0.005 4

3

smooth pipe

2

0. 001 1 10

2

2;

!~

5 ~ ,

8! I 10

2.1 ~ ~ ~ !

3

,

~!

I 10

2 4

~ ~ ~ ~ !

!8! I 10

2; ~ ~ ~ !

,

8' I

5

Dvp

Reynolds number, N Re :;: M FIGURE

2.10-3.

Friction/actors/or fluids inside pipes. [Based on L. F. Moody, Trans.

A.S.M.E., 66, 671, (1944),' Mech. Eng. 69, }O05 (1947). With permission.]

10

2

6

3

" 4 5, 6 8" I 10 7

versus N Re • This friction factorJis then used in Eqs. (2.10-5) and (2.10-6) to predict the friction loss ilpI or Fr.

ilL v2 4Jp-D 2

(SI) (2.10-5) (English)

(2.10-6) (English) For the region with a Reynolds,.number below 2100, the line is the same as Eq. (2.10- 7). For a Reynolds number above 4000 for turbulent flow, the lowest line in Fig. 2.10-3 repl'esents the friction factor line for smooth pipes and tubes, such as glass tubes, and drawn copper and brass tubes. The other lines for higher friction factors represent lines for different relative roughness factors, BID, where D is the inside pipe diameter in m and f, is a roughness parameter, which represents the average height in m of roughness projections from the wall (M1). On Fig. 2.10-3 values of the equivalent roughness for new pipes are given (Ml). The most common pipe, commercial steel, has a roughness of e 4.6 x 10- 5 m (1.5 x 10- 4 ft). The reader should be cautioned on using friction factors J from other sources. The Fanning friction factor ofJin Eq. (2.10-6) is the one used here. Others use a friction factor that may be 4 times larger. EXAMPLE 2.10-3. Use oj Friction Factor in Turbulent Flow A liquid is flowing through a horizontal straight commercial steel pipe at 4.57' m/s. The pipe used is commercial steel, schedule 40, 2-in. nominal diameter. The viscosity of the liquid is 4.46 cp and the densi ty 801 kg/m 3. Calculate the mechanical-energy friction loss FI in lfkg for a 36.6-m section of pipe.

Solution: The following data are given: From Appendix A.5, D 0.0525 m, v = 4.57 mis, p 801 kg/m 3 , ilL = 36.6 m, and /l =(4.46 cpX1 x 10- 3 )

4.46 x 10- 3 kg/m's

The Reynolds number is calculated as

N

_ Dvp Jl

Re -

0.0525(4.57X801) 4.46 x 10 3

= 43 •

0 1

X

104

Hence, the flow is turbulent. For commercial steel pipe from the table in Fig. 2.10-3, the equivalent roughness is 4.6 x 10- 5 m. e

D

4.6 X 10- 5 m 0.0525 m = 0.00088

For an NRc of4.310 x 104 , the friction factor from Fig. 2.10-3 isJ Substituting into Eq. (2.10-6), the friction loss is

4f AL v 2 D 2. Sec. 2./0

=

4(0.OO60X36.6X4.57)2 (0.0525X2)

0.0060.

J ( ft .lbr) 174.8 kg 58.5 Ibm'

Design Equations for Laminar and Turbulent Flow in Pipes

89

In problems involving the friction loss Ff in pipes, Ff is usually the unknown with the diameter D, velocity v, and pipe length I1L known. Then a direct solution is possible as in Example 2.1Q...3. However, in some cases, the friction loss F f is already set by the available head of liquid. Then if the volumetric flow rate and pipe length are set, the unknown to be calculated is the diameter. This solution is by trial and error since the velocity v appears in both NRc andf, which are unknown. In another case, with the F f being again already set, the diameter and pipe length are specified. This is also by trial and error, to calculate the velocity. Example 2.10-4 indicates the method to be used to calculate the pipe diameter with F f set. Others (M2) give a convenient chart to aid in these types of calculations.

EXAMPLE 2.10-4. Trial-and-Error Solution to Calculate Pipe Diameter Water at 4.4°C is to flow through a horizontal commercial steel pipe having a length of 305 m at the rate of 150 gal/min. A head of water of 6.1 m is a vail able to overcome the friction loss Ff ' Calculate the pipe diameter. Solution: From Appendix A.2 the density p = 1000 kg/m 3 and the viscosity fJ. is Jl = (1.55 cp}(l x 10- 3) = 1.55 x 10

friction loss F f

(6.1 m) 9 = (6.1}(9.80665)

3

kg/m· s

59.82 Jjkg

g~l)( 7.481 1 ft )(1 min)(0.028317 m3/ft3 ( 150 mm gal 60 s ) 3 3 9.46 X 10- m /s 3

flow rate =

area of pipe

rrD2

4

m2

(D is unknown)

. velOCIty v = ( 9.46 x 10

3

1 m ) = 0.01204 mIs m 3Is) ( nD2/4 2

The solution is by trial and error since v appears in D = 0.089 m for first trial.

NRc

andJ. Assume that

0.01204(1000) .. (0.089) (0.08W(l.55 x 10 3) = 8.730 x 10

NRc

For commercial steel pipe and using Fig. 2.1 0-3, e = 4.6 x 10- 5 m. Then, 4.6 x 10" 5 rn 0.089 rn = 0.00052

e D.

From Fig. 2.10-3 for NRe = 8.730 x 10" and s/D = 0.00052, Substituting into Eq. (2.10-6),

Ff

59.82

I1L

0

2

4f -D ...._ 1

f

0.0051.

4(0.OO51}(305) (0.01204)2 D(2) D4

Solving for D, D 0.0945 m. This docs not check the assumed value of 0.089 m. For the second trial D will be assumed as 0.0945 rn. 0.01204 1000 4 (0.0945) (0.0945)2 1.55 x 10 3 = 8.220 x 10

D 90

4.6 x 10 0.0945

Chap. 2

5

=

0.00049

Principles of Momentum Transfer alld Overall Balances

From Fig. 2.10-3,f = 0.0052. It can be seen that / does not change much with NRc in the turbulent region. F = 5982

=

4{0.OO52)(305) (0.01204)2 D(2)

f'

D4

Solving, D 0.0954 m or 3.75 in. Hence, the solution checks the assumed value of D closely.

2.10D

Pressure Drop and Friction Factor in Flow of Gases

The equations and methods discussed in this section for turbulent flow in pipes hold for incompressible liquids. They also hold for a gas if the density (or the pressure) changes less than 10%. Then an average density, Pay in kgjm 3 , should be used and the errors involved will be less than the uncertainty limits in the friction factor /. For gases, Eq. (2.10-5) can be rewritten as follows for laminar and turbulent flow: (2.10-9) where Pay is the density at Pay = (PI + pz)j2. Also, the NRc used is DG/Il, where G is kgjm Z • s and is a constant independent of the density and velocity variation for the gas. Equation (2.10-5) can also be written for gases as 2

2

PI - pz

pi -

=

4/ ilLG"l:RT DM

ilLG 2 RT

p~ = - ' - - - - -

gc DM

(SI) (2.10-10) (EngJish)

where R is 8314.3 J/kg mol· K or 1545.3 ft ·Ibr/lb mol· OR and M is molecular weight. The derivation of Eqs. (2.10-9) and (2.10-10) applies only to cases with gases where the relative pressure change is small enough so that large changes in velocity do not occur. Ir the exit velocity becomes large, the kinetic-energy term, which has been omitted, becomes important. For pressure changes above about 10%, compressible flow is occurring and the reader should refer to Section 2.11. In adiabatic flow in a uniform pipe, the velocity in the pipe cannot exceed the velocity of sound.

EXAMPLE 2.10-5. Flow o/Gas in Line and Pressure Drop Nitrogen gas at 25°C is flowing in a smooth tube 'having an inside diameter of 0.010 m at the rate of 9.0 kg/s' m 2 • The tube is 200 m long and the flow can be assumed to be isothermal. The pressure at the entrance to the tube is 2.0265 x 10 5 Pa. Calculate the outlet pressure. Solution: The viscosity of the gas from Appendix A.3 is 11 = 1.77 X 10- 5 Pa's at T = 298.15 K. Inlet gas pressure PI 2.0265 x 10 5 Pa, 2 G 9.0 kg/s' m , D 0.010 m, M = 28.02 kg/kg mol, ilL = 200 m, and R 8314.3 J/kg mol, K. Assuming that Eq. (2.10-10) holds for this case and that the pressure drop is less than 10%, the Reynolds number is N

- DG _ 0.010(9.0) 11 - L77 x 10 5

5085

Rc -

Hence, the flow is turbulent. Using Fig. 2.10-3,

:!s

Sec. 2.10

0.0090 for a smooth tube.

Design Equations for Laminar and Turbulent Flow in Pipes

91

Substituting into Eq. (2.10-tO), p~ - p~

(2.0265 x 10

4.1067 x 10 10

pz

4(0.0090)(200)(9.0)Z(8314.3)(298.15) 0.010(28.02)

pi =

0.5160 x 10 10

2 =

5)2 _

-

Solving, pz = 1.895 X 10 5 Pa. Hence, Eq. (2.10-10) can be used since the pressure drop is less than 10%.

2.10E

Effect of Heat Transfer on Friction Factor

The friction factor J given in Fig. 2.10-3 is ~ven for isothermal flow, i.e., no heat transfer. When a fluid is being heated or cooled, the temperature gradient wiU cause a change in physical prope 2100

(2.10-11)

(cooling)

NRe

> 2100

(2.10-12)

(heating)

NRe

< 2100

(2.10-13)

(cooling)

NRe

< 2100

(2.10-14)

lI

38

23

5. The final friction factor is obtained by dividing the

J from step 2 by the if; from step 4.

Hence, when the liquid is being heated, if; is greater than 1.0 and the finalJ decreases. The reverse occurs on cooling the liquid.

2.lOF

Friction Losses in Expansion, Contraction, and Pipe Fittings

Skin friction losses in flow through straight pipe are calculated by using the Fanning friction factor. However, if the velocity of the fluid is changed in direction or magnitude, additional friction losses occur. This results from additional turbulence which develops because of vortices and other factors. Methods to estimate these losses are discussed below.

I. Sudden enlargement losses. If the cross section of a pipe enlarges very gradually, very little or no extra losses are incurred. If the change is sudden, it results in additional losses 92

Chap. 2

Principles of Momentum Transfer and Overall Balances

due to eddies fonned by the jet expanding in the enlarged section. This friction loss can be calculated by the following for turbulent flow in both sections. This Eq. (2.8-36) was derived in Example 2.8-4. (2.10-15) where hex is the friction loss in J/kg, Kex is the expansion-loss coefficient and = (1 AI/A2)2, VI is the upstream velocity in the smaller area in mIs, V2 is the downstream velocity, and a. = 1.0. If the flow is laminar in both sections, the factor IX in the equation becomes t. For English units the right-hand side of Eq. (2.10-15) is divided by ge _ Aiso, h = ft - lbr/lb m •

2. Sudden contraction losses. When the cross section of the pipe is suddenly reduced, the stream cannot follow around the sharp corner, and additional frictional losses due to eddies occur. For turbulent flow, this is given by 0.55 ( 1 - -A2) -v~ Al 2et

= Kc

J 2et kg

(2.10-16)

where he is the friction loss, et 1.0 for turbulent flow, V 1 is the average velocity in the smaller or downstream section, and Ke is the contraction-loss coefficient (PI) and approximately equals 0.55 (1 A21 A I)' For laminar flow, the same equation can be used with a. = !(S2). For English units the right side is divided byge'

TABLE

2.10-1.

Friction LossJor Turbulent Flow Through Valves and Fittings

Type oj Fitting or Valve

Elbow, 45" Elbow, 90" Tee Return bend Coupling Union Gate valve Wide open Half open Globe valve Wide open Half open Angle valve, wide open Check valve Ball Swing Water meter, disk

Frictional Loss, Number oj Velocity Heads, K f

Frictional Loss, Equivalent Length oj Straight Pipe in Pipe Diameters, LjD

0.35 0.75 1 1.5 0.04 0.04

17 35 50 75 2 2

0.17 4.5

225

6.0 9.5 2.0

300 475 100

70.0 2.0 7.0

3500 100 350

9

Source: R. H. Perry and C. H. Chilton. Chemical Engineers' Handbook, 5th cd. New

York: McGraw-Hili Book Company. 1973. With permission.

s

Sec_ 2.10

Design Equations Jor Laminar and Turbulent Flow in Pipes

93

3. Losses in fittings and valves. Pipe fittings and valves also disturb the normal flow lines in a pipe and cause additional friction losses. In a short pipe with many fittings, the friction loss from these fittings could be greater than in the straight pipe. The friction loss for fittings and valves is given by the followingequation: (2.10-17) where K J is the loss factor for the fitting or valve and VI is the average velocity in the pipe leading to the fitting. Experimental values for K j are given in Table 2.10-1 for turbulent flow (PI) and in Table 2.10-2 for laminar flow. As an alternative method, some texts and references (B 1) give data for losses in fittings as an equivalent pipe length in pipe diameters. These data, also given in Table 2.10-1, are presented as L.ID, where L" is the equivalent length of straight pipe in m having the same frictional loss as the fitting,..and D is the inside pipe diameter in m. The K values in Eqs. (2.10-15) and (2.10-16) can be converted to LelD values by multiplying the K by 50 (PI). The L" values for 'the fittings are simply added to the length of the straight pipe to get the total length of equivalent straight pipe to use in Eq. (2.10-6).

4. Frictional losses in mechanical-energy-balance equation. The frictional losses from the friction in the straight pipe (Fanning friction), enlargement losses, contraction losses, and losses in fittings and valves are all incorporated in the F term of Eq. (2.7-28) for the mechanical-energy balance, so that

L

LF = If all the velocities, v, this special case,

VI'

and

I1L

4f Ii V2,

v vi 2: + Kex 2: + 2

Kc

vi vi 2: + K 2:

(2.10-18)

j

are the same, then factoring, Eq. (2.10-18) becomes, for

(2.W-19)

The use of the mechanical-energy-balance equation (2.7-28) along with Eq. (2.1 0-18) will be shown in the following examples.

EXAMPLE 2.10-6.

Friction Losses and Mechanical-Energy Balance

An elevated storage tank contains water at 82.2°C as shown in Fig. 2.10-4. It is desired to have a discharge rate at point 2 of 0.223 fto Is. What must be the height H in ft of the surface of the water in the tank relative to the TABLE 2.10-2.

Frictional Loss, Number of Velociry Heads, K f Reynolds Number

Type of Fiffing or Valve

Elbow, 90° Tee Globe valve Check valve, swing

94

Friction Loss for Laminar Flow Through Valves alld Fitlillgs (K J)

50

100

200

400

1000 Turbulenl

17 9 28

7 4.8 22

2.5 3.0

17

1.2 2.0 14

0.85 1.4 10

0.75 1.0 6.0

55

17

9

5.8

3.2

2.0

Chap. 2

Principles of Momentum Transfer and Overall Balances

~--~~--~

----------------------------------,-z\

~-.v_-4-in. pipe

f--50 I

ft--1 2-in. pipe

FIGURE 2.10-4.

Processjfow diagramJor Example 2.10-6.

discharge point? The pipe used is commercial steel pipe, schedule 40, and the lengths of the straight portions of pipe are shown. Solution: The mechanical-energy-balance equation (2.7-28) is written between points 1 and 2.

From Appendix A.2, for water, p = 0.970(62.43) 60.52 Ibmlft3 and II 0.347 cp = 0.347(6.7197 x 10- 4 ) = 2.33 x 10- 4 Ibmlft ·s. The diameters of the pipes are 4.026

For 4-in. pipe:

D3

= -12 -=

For 2-in. pipe:

D4

=

03353 ft , .

0.0884

2.067 ----u= 0.1722 ft,

0.02330 ftl

The velocities in the 4-in. and 2-in. pipe are = V3

V4

=

3 0.223 ft /s = 2523 fl 0.0884 ft2 . tS 0.223 0.02330

- f tis

= 9.)7

(4-in. pipe) (2-in. pipe)

The L F term for frictional losses in the system includes the following: (1) contraction loss at tank exit, (2) friction in the 4-in. straight pipe, (3) friction in 4-in. elbow, (4) contraction loss from 4-in. to 2-in. pipe, (5) friction in the 2-in. straight pipe, and (6) friction in the two 2-in. elbows. Calculations for the six items are as follows. I. Conlraclion loss al tank exit. Sec. 2./0

From Eq. (2.10..16) for contraction from

Design Equations Jor Laminar and Turbulent Flow in Pipes

9S

A! to A3 cross-sectional area since A 1 of the tank is very large compared to A3 ,

K<

~:) =

0.55(1 -

0.55(1 - 0) = 0.55

(2.523)2 0.55 2(32.174) = 0.054 ft· Ibr/lbm

2. Friction in the 4-in. pipe.

N

The Reynolds number is

D3 V3 P = 0.3353(2.523)(60.52) J.I. 2.3 3 x 10 4

= R.

=

10 5

2 193 x

•

Hence, the flow is turbulent. From Fig. 2.10-3, e = 4.6 x 10- 5 (1.5 x 10- 4 ft). 0.00015 0.3353

8

D3

0.000448

Then, for NRc = 219300, the Fanning friction factor tuting to Eq. (2.10-6) for !lL 20.0 ft of 4-in. pipe,

Ff

= 4J

!lL v2 D 2g<

20.0

= 4(0.0047) 0.3353

3. Friction in 4-in. elbow. ing into Eq. (2.10-17),

h =K f

f

(2.52W 2(32.174)

From Table 2.10-1, K f

v

2

m

J = 0.0047. Substi-

= 0.111

= 0.75.

ft· Ibm

Then, substitut-

= 0.75 (2.523)2

= 0074 ft· 2(32.174)' Ib",

29,

4. Contraction loss Jrom 4- to 2-in. pipe. Using Eq. (2.10-16) again for contraction from A3 to A4 cross-sectional area,

4)

(0.02330) Ke = 0.55 ( 1 - A A3 = 0.55 1 - 0.0884

0.405

ft· he = Ke 29, = 0.405 2(32.174) = 0.575 Ibm

5. Friction in the 2-in. pipe.

The Reynolds number is

_D 4 V4P - 0.1722(9.57)(60.52) J.I. 2.33 x 10 - 4

N

4.280 x 10 5

Re -

8

D

0.00015

= 0.1722 = 0.00087

The Fanning friction factor from Fig. 2.10-3 isJ 0.0048. The total length 125 + 10 + 50 185ft. Substituting into Eq.(2.10-6),

!lL

= Ff

4

!lL.!C =

J D 29,

185(9.57)2 4(0.0048) (0.1722){2)(32.l74)

6. Friction in the two 2-in. elbows.

.!C =

2K f

Chap. 2

29,

ft ·Ib r 29.4 Ibm

For a K f = 0.75 and two elbows,

2(0.75)(9.57)2 = 2 6 ft ·lbr 2(32.174) .13 Ibm

Principles of Momentum Transfer and Overall Balances

F is the sum of items (1) through (6).

The total frictional loss

L F = 0.054 + 0.111 + 0.074 + 0.575 + 29.4 + 2.136 =

32.35 ft ·lbr/lbm

Using as a datum level Z2, Z I = H ft, Z2 = O. Since turbulent flow exists, IX = 1.0. Also, VI = 0 and Vl V 4 = 9.57 ft/s. Since PI and pz are both at 1 atm abs pressure and PI = pz, PI _

=

P

Also, since no pump is used, Ws (2.10-20), H fL + 0 + 0 gc 0

0

P

O. Substituting these values into Eq. =

0

1(9.57)2

+ 2(32.174) + 32.35

"

Solving, H(g/gcl = 33.77 ft ·lbr/lbm (100.9 Jjkg) and H is 33.77 ft (10.3 m) height of water level above the discharge outlet. EXAMPLE 2.10-7.

Friction Losses with Pump in Mechanical-Energy Balance Water at 20 c C is being pumped from a tank to an elevated tank at the rate of 5.0 x 10- 3 m 3 /s. All of the piping in Fig. 2.10-5 is 4-in. schedule 40 pipe. The pump has an efficiency of 65%. Calculate the kW power needed for the pump. Solution: The mechanical-energy-balance equation (2.7-28) is written between points 1 and 2, with point 1 being the reference plane. 1 (V22 av 2 IX

-

2)

VI av

+ 9 (Z2

-

ZI

) + P2 - PI .

P

F+ +~ L,

ur

rrs

o

(2.7-28)

From Appendix A.2 for water, p 998.2 kg/m 3 , Ii 1.005 x 10- 3 Pa ·s. For 4-in. pipe from Appendix A.5, D = 0.1023 m and A = 8.219 X 10- 3 m 2 • The velocity in the pipe is V = 5.0 x 10- 3/(8.219 x 10- 3) 0.6083 m/s. The Reynolds number is 0.1023(0.6083)(998.2)

Dvp

N

Re

=

f.L

=

L005 x 10-

3

= 6. 18 I

4

x 10

Hence, the flow is turbulent.

15 m

I

1-- 5 m--l

_ttl Sf F!GURE

Sec. 2.10

«

2.10-5.

50

4-in. pipe

Processjlow diagramfor Example 2.10-7.

Design Equations for Laminar and Turbulent Flow in Pipes

97

The '[ F term for frictional losses includes the following: (I) contraction loss at tank exit, (2) friction in the straight pipe, (3) friction in the two elbows, and (4) expansion loss at the tank entrance. 1. Contraction loss at tank exit. large A 1 to a small A 2 ,

A2) = 0.55(1 -

~

kc = 0.55(1 he

v2

=

Ke 211

From Eq. (2.10-16) for contraction from a

= (0.55)

0) = 0.55

(0.608W 2(l.0) = 0.102 J/kg

2. Friction in the straight pipe. From Fig. 2.10-3, 6 4.6 x 10- 5 m and E/D = 4.6 x 10- 5/0.1023 0.00045. Then for N Re = 6.181 X 104 , / 0.0051. Substituting into Eq. (2.10-6) for l'lL = 5 + 50 + 15 + 100 = 170 m, t::.L v2 170 (0.6083)2 F f = 4/ D 2' = 4(0.0051) 0.1023 2 3. Friction in the two elbows. From Table 2.10-1, K f tuting into Eq. (2.10-7) for two elbows,

h = 2K f

f

VI

2

=

2(075) (0.6083)2

.

Kex hex

=

~

l.0

0.75. Then, substi-

Using Eq. (2.10-15),

Al)1 = (1 (1 - A2 Kex

6.272 Jfkg

0.278 J/kg

2

4. Expansion loss at the tallk entrance.

=

2

0) = l.0

(0.6~8W = 0.185 J/kg

The total frictional loss is I F.

IF = 0.102 + 6.272 + 0.278 + 0.185 = 6.837 Jjkg Substituting into Eq. (2.7-28), where(v~ -

vD

0 and(p2 - PI)

0,

0+ 9.806(15.0 - 0) + 0 + 6.837 + Ws = 0 Solving, Ws = -153.93 J/kg. The mass 10 3(998.2) 4.991 kg/so Using Eq. (2.7-30), Ws =

153.93

flow

rate

is

m

= 5.0

x

I]Wp

-0.65vy;,

Solving, Wp = 236.8 J/kg. The pump kW power is pump kW = mWp = 4.99/:6.8)

2.IOG

= 1.182 kW

Friction Loss in Noncircular Conduits

The friction loss in long straight channels or conduits of noncircular cross section can be estimated by using the same equations employed for circular pipes if the diameter in the Reynolds number and in the friction factor equation (2.10-6) is taken as the equivalent diameter. The equivalent diameter D is defined as four times the hydraulic radius rH The 98

Chap. 2

Principles of Momentum Transfer and Overall Balances

hydraulic radius is defined as the ratio of the cross-sectional area of the channel to the wetted perimeter of the channel for turbulent flow only. Hence, D

cross-sectional area of channel 'Yetted perimeter of channel

4rH = 4 - - - - - - - - - - - -

(2.1()"'21)

For example, for a circular tube,

F or an annular space with outside diameter D 1 and inside D 2, D

4{nDi/4 - nD~/4)

~---':.:......---=-...:.

nD I

+ nD 2

= DI

-

D2

(2. 1()"'22)

F or a rectangular duct of sides a and bTt, D

4{ab) 2a

2ab

+ 2b

a

(2.1 ()"'23)

+b

For open channels and partly filled ducts in turbulent flow, the equivalent diameter and Eq. (2.10-6) are also used (PI). For a rectangle with depth of liquid y and width b,

D=

(2. 1()"'24)

b + 2y

For a wide, shallow stream of depth y, D

(2. 1()"'25)

4y

For laminar flow in ducts running full and in open channels with various crosssectional shapes other than circular, equations are given elsewhere (Pl).

2.10H

Entrance Section of a Pipe

If the velocity profile at the entrance region of a tube is nat, a certain length of the tube is necessary for the velocity profile to be fully established. This length for the establishment of fully developed flow is called the transition length or entry length. This is shown in Fig. 2.10-6 for laminar flow. At the entrance the velocity profile is flat; i.e., the velocity is the same at all positions. As the fluid progresses down the tube, the boundary-layer thickness increases until finally they meet at the center of the pipe and the parabolic velocity profile is fully established.' The approximate entry length Le of a pipe having a diameter of D for a fully

velocity profile

boundary layer

e FIGURE

Sec. 2./0

2.10-6.. Velocity profiles near a pipe entrance for laminar flow.

Design Equations for Laminar and Turbulent Flow in Pipes

99

developed velocity profile to be formed in laminar flow is (L2)

Le

_

Ii = 0.0)75N Re

(2.10-26)

For turbulent flow, no relation is available to predict the entry length for a fully developed turbulent velocity profile to form. As an approximation, the entry length is nearly independent of the Reynolds number and is fully developed after 50 diameters downstream. EXAMPLE 2.10-8. Entry Length/or a Fluid in a Pipe Water at 200 is flowing through a tube having a diameter of 0.010 m at a velocity of 0.10 m/s. (a) Calculate the entry length. (b) Calculate the entry length for turbulent flow.

e

Solution: For part (a), from Appendix A.2, p 10-) Pa' s. The Reynolds number is N

0.0 10(0. lOX998.2) 1.005 x 10- 3

_Dvp Re -

998.2 kg/m), Jl

=

J1

1.005 x

993.2

Using Eq. (2.10-26) for laminar flow, D

O~OI

=

0.0575(993.2)

Hence, Lc 0.571 m. For turbulent flow in part (b), Le = 50(0.01)

57.1

= 0.50 m.

The pressure drop or friction factor in the entry length is greater than in fully developed flow. For laminar flow the friction factor is highest at the entrance (L2) and then decreases smoothly to the fully developed flow value. For turbulent flow there will be some portion of the entrance over which the boundary layer is laminar and the friction factor profile is difficult to express. As an approximation the friction factor for the entry length can be taken as two to three times the value of the friction factor in fully developed flow. 2.101

Selection of Pipe Sizes

10 large or complex process pipi ng systems, the optimum size of pipe to use for a specific situation depends upon the relative costs of capital investment, power, maintenance, and so 00. Charts are availa.ble for determining these optimum sizes (P 1). However, for small installations approximations are usually sufficiently accurate. A table of representative values of ranges of velocity in pipes are shown in Ta ble 2.10-3.

TABLE 2.10-3.

Representative Ranges of Velocities in Steel Pipes Velocity

Type of Fltlid

Nonviscous liquid Viscous liquid

Type of Flow

I nlet to Process Inlet to Process

Gas Steam

100

Chap. 2

pump line or pump discharge pump line or pump discharge

ftls

2-3 5-8 0.2-0.8 0.5-:-2 30-120 30-75

mls

0.6-0.9 1.5-2.5 0.06-0.25 0.15-0.6 9-36 9-23

Principles of Momenfllm Transfer and Overall Balances

2.11 2.11A

COMPRESSIBLE FLOW OF GASES Introduction and Basic Equation for Flow in Pipes

When pressure changes in gases occur which are greater than about 10%, the frictionloss equations (2.10-9) and (2.10-10) may be in error since compressible flow is occurring. Then the solution of the energy balance is more complicated because of the variation of the density or specific volume with changes in pressure. The field of compressible flow is very large and covers a very wide range of variations in geometry. pressure, velocity, and temperature. In this section we restrict our discussion to isothermal and adiabatic flow in uniform, straight pipes and do not cover flow in nozzles, which is discussed in some detail in other references (M2, PI). The general mechanical energy-balance equation (2.7-27) can be used as a starting point. Assuming turbulent flow, so that IX 1.0; no shaft work, so that Ws 0; and writing the equation for a differentiall.ength dL, Eq. (2.7-27) becomes

v dv

dp

+ 9 dz + - + dF

0

p

(2.11-1)

For a horizontal duct, dz = O. Using only the wall shear frictional term for dF and writing Eq. (2.10-6) in differential form, v dv + V dp +

= lip.

where V and

4Jv 2 dL 2D = 0

(2.11-2)

Assuming steady-state flow and a uniform pipe diameter, G is constant v

G

(2.11-3)

vp=V

(2.11-4)

dv=GdV. Substituting Eqs. (2.11-3) and (2.11-4) into (2.11-2) and rearranging, G2

2JG 2 +--dL

dV

-+ V

V

(2.I1-S)

0

D

This is the basic differential equation that is to be integrated. To do this the relation between V and p must be known so that the integral of dplV can be evaluated. This integral depends upon the nature of the flow and two important conditions used are isothermal and adiabatic flow in pipes.

2.11B

Isothermal Compressible Flow

To integrate Eq. (2.11-5) for isothermal flow, an ideal gas will be assumed where pV

1

=

(2.11-6)

M RT

Solving for V in Eg. (2.11-6) and substituting it into Eq. (2.11-5), and integrating assuming J is constant, G

2

1 2

1

dV +MV

12

RT

1

2

pdp+2J

G D

12

dL=O

(2.11-7)

1

(2.11-8)

Sec.2.11

Compressible Flow of Gases

101

Substituting PI/Pl for V1 /V1 and rearranging, 2

P1 =

4Jt:.LG 2 RT DM

+

2G 1 RT M

In

(2.11-9)

P2

where M = molecular weight in kg massJkg mol, R 8314.34 N· mJkg mol· K, and T temperature K. The quantity RT/M = p • ./Pa.' where Pay (PI + P2)/2 and Pav is the average density at T and Pav' In English units, R = 1545.3 ft ·lbr jlb mol· oR and the right-hand terms are divided by 9. 1000, which is called the Burke-Plummer equation, becomes

Ap = --'-'--'----

(3.1-19)

Dp

Adding Eq. (3.1-17) for laminar flow and Eq. (3.1-19) for turbulent flow, Ergun (El) proposed the following general equation for low, in termediate, and high Reynolds numbers which has been tested experimentally.

AL 1 - G ---'--'-D-'p--7

(3.1-20)

Rewriting Eq. (3.1-20) in terms of dimensionless groups, 150 NRc.

120

Chap. 3

+

1.75

(3.1-21)

p

Principles of Momentum Transfer and Applications

See also Eq. (3.1-33) for another fonn ofEq. (3.1-21). The Ergun equation (3.1-21) can be used for gases by using the density p of the gas as the arithmetic average of the inlet and outlet pressures. The velocity v' changes throughout the bed for a compressible fluid, but G' is a constant. At high values of N Re. p' Eqs. (3.1-20) and (3.1-21) reduce to Eq. (3.1-19) and to Eq. (3.1-17) fOT low values. For large pressure drops with gases, Eq. (3.1-20) can be written in differential fonn (PI). EXAMPLE 3.1-4.

Pressure Drop and Flow o/Gases in Packed Bed Air at 311 K is flowing through a packed bed of spheres having a diameter of 12.7 mm. The void fraction e of the bed is 0.38 and the bed has a diameter of 0.61 m and a height of 2.44 m. The air enters the bed at 1.10 atm abs at the rate of 0.358 kg/so Calculate the pressure drop of the air in the packed bed. The average molecular weight of air is 28.97. So'ution: From Appendix A.3 for air at 311 K,j1. = 1.90 X 10- 5 Pa· s. The cross-sectional area of the bed is A = (n:/4)D2 = (n:/4XO.61)2 = 0.2922 m 2. Hence, G' ~ 0.358/0.2922 = 1.225 kg/m 2 • s (based on empty cross section of container or bed). Dp = 0.0127 m, t'lL = 2.44 m, inlet pressure Pl = 1.1(1.01325 X 10 5 ) = 1.115 X 10 5 Pa. From Eq. (3.1-15), 0.0127(1.225) = 1321 (1- 0.38X1.90 x 10- 5 )

To use Eq. (3.1-21) for gases, the density p to use is the average at the inlet Pl and outlet pz pressures or at (Pl + pz)/2. This is trial and error since P2 is unknown. Assuming that t'lp 0.05 x 10 5 Pa, pz = 1.115 X 10 5 0.05 X 10 5 = 1.065 X 10 5 Pa. The average pressure is Pav = (Ll15 X 10 5 + 1.065 x 10 5 )/2 1.090 x 105 Pa. The average density to use is

M

P,v

(3.1-22)

= RT Pay 28.97( 1.090 x 10 8314.34(311)

5 )

=

1 221 kg/ :I . m

Substituting into Eq. (3.1-21) and solving for t'lp, t'lp(1.221) 0.0127 (0.38)3

(L22W

2.44

1 - 0.38

=

150 1321

1.75

+

Solving, t'lp 0.0497 x 10 5 Pa. This is close enough to the assumed value, so a second trial is not needed. 4. Shape factors. Many particles in packed beds are often irregular in shape. The equivalent diameter of a particle is defined as the diameter of a sphere having the same volume as this particle. The sphericity shape factor cPs of a particle is the ratio of the surface area of this sphere having the same volume as the particle to the actual surface area of the particle. For a sphere, the surface area Sp=7TD; and the volume is vp 7rD;/6. Hence, for any particle, cPs =7rD;IS p , where Sp is the actual surface area of the particle and D p is the diameter (equivalent diameter) of the sphere having the same volume as the particle. Then

vp Sec. 3.1

7rD~/cP s

6

7TD;/6

cP sD p

Flow Past Immersed Objects and Packed and Fluidized Beds

(3.1-23)

121

From Eq. (3.1-7),

6

(3.1·24)

Then Eq. (3.1-10) becomes (3.1-25)

For a sphere, 4>s = 1.0. For a cylinder where the diameter length, 4>s is calculated to be 0.874 and for a cube, 4>s is calculated as 0.806. For granular materials it is difficult to measure the actual volume and surface area to obtain the equivalent diameter. Hence, Dp is usually taken to be the nominal size from a screen analysis or visual length measurements. The surface area is determined by adsorption measurements or measurement of the pressure drop in a bed of particles. Then Eq. (3.1-23) is used to calculate 4>s (Table 3.1-0. Typical values for many crushed materials are between 0.6 and 0.7. For convenience for the cylinder and the cube, the nominal diameter is sometimes used (instead of the equivalent diameter) which then gives a shape factor of 1.0. 5. Mixtures of particles. For mixtures of particles of various sizes we can define a mean specific surface awn as (3.1-26)

where Xi is volume fraction. Combining Eqs. (3.1-24) and (3.1-26),

6

(3.1-27)

where Dpm is the effective mean diameter for the mixture. EXAMPLE 3.1-5.

Mean Diameter for a Particle Mixture

A mixture contains three sizes of particles: 25% by volume of 25 mm size, 40% of 50 mm, and 35% of 75 mm. The sphericity is 0.68. Calculate the

effective mean diameter.

TABLE

3.1-1.

Shape Factors (Sphericity) oJSome Materials

Material

Spheres Cubes Cylinders, Dp = h (length) Ber! saddles Raschig rings Coal dust, pulverized Sand, average Crushed glass

l22

Chap. 3

Shape Factor, CPs

ReJerence

1.0

0.81 0.87 0.3 0.3 0.73

0.75 0.65

(B4) (C2) (C2) (C2) (C2)

Principles oj Momenlllm TransJer and Applicalions

Solution: OAO, Dp2 27),

The following data are given: Xl = 0.25, Dpl 25 mm; Xz = = 0.35, Dp3 75; ¢s = 0.68. Substituting into Eq. (3.1-

= 50; X3

=

D pm

0.25/(0.68

X

25)

I

+ OAO/(0.68

X

50)

+ 0.35/(0.68

X

75)

30.0 mm

6. Darcy's empirical law for laminar jiow.

Equation (3.1-17) for laminar flow in packed beds shows that the flow rate is proportional to 4pand inversely proportional to the viscosity J1 and length 11L. This is the basis for Darcy's law as follows for purely viscous flow in consolidated porous media.

,

q'

v=-

A

(3.1-28)

where v' is superficial velocity based on the empty cross section in cm/s, q' is flow rate cm 3/s, A is empty cross section in cm 2 , J1 is-viscosity in cp, I1p is pressure drop in atm, I1L is length in cm, and k is permeability in (cm 3 flow/s)· (cp)' (cm length)/(cm 2 area)· (atm pressure drop). The units used for k of cm 2. cp/s· atm are often given in darcy or in miIlidarcy (1/1000 darcy). Hence, if a porous medium has a permeability of 1 darcy, a fluid of l-cp viscosity will flow at I cm 3 /s per 1 cm 2 cross section with a I1p of I atm per cm length. This equation is often used in measuring permeabilities of underground oil reservoirs.

3.1 D

Flow in Fluidized Ikds

1. Minimum velocity and porosity for fluidization. When a fluid flows upward through a packed bed of particles at low velocities, the particles remain stationary. As the fluid velocity is increased, the pressure drop increases according to the Ergun equation (3.1-20). Upon further increases in velocity, conditions finally occur where the force of the pressure drop times the cross-sectional area just equals the gravitational force on the mass of particles. Then the particles just begin to move, and this is the onset of fluidization or minimum fluidization. The fluid velocity at which fluidization begins is the minimum fluidization velocity v;"! in m/s based on the empty cross section of the tower (superficial velocity). The porosity of the bed when true fluidization occurs is the minimum porosity for fluidization and is Em!' Some typical values of em! for various materials are given in Table 3.1-2. The bed expands to this voidage or porosity before particle motion appears. This minimum voidage can be experimentally determined by subjecting the bed to a rising gas stream and measuring the height of the bed Lm! in m. Generally, it appears best to use gas as the fluid rather than a liquid since liquids give somewhat higher values of Em! . As stated earlier, the pressure drop increases as the gas velocity is increased until the onset of minimum fluidization. Then as the velocity is further increased, the pressure dror decreases very slightly and then remains practically unchanged as the bed continues to expand or increase in porosity with increases in velocity. The bed resembles a boiling liquid. As the bed expands with increase in velocity, the bed continues to retain its top horizontal surface. Eventually, as the velocity is increased much further, entrainment of particles from the actual fluidized bed becomes appreciable. The relation between bed height L and porosity e is as follows for a bed having a c:) is equal to the total volume uniform cross-sectional area A. Since the volume LA(1 Sec. 3.1

Flow Past Immersed Objects and Packed and Fluidized Beds

123

TABLE

3.1-2.

Void Fraction, emf' at Minimum Fluidization Conditions (L2) Particle Size, Dp (mm)

Type

of Particles

0.06

0.10

0.20

Void fraction,

Sharp sand (cPs = 0.67) Round sand (cPs = 0.86) Anthracite coal (cPs = 0.63)

0.58 0.48 0.60

0.60 0.53 0.61

0040 emf

0.53 0.43 0.56

0.49 (0.42) 0.52

of solids if they existed as one piece, (3.1-29) LI e2 - 1-- L2

(3.1-30)

1 - el

where Ll is height of bed with porosity el and L2 is height with porosity e2. 2. Pressure drop and minimumjluidizing velocity. As a first approximation, the pressure drop at the start of fluidization can be determined as follows. The force obtained from the pressure drop times the cross-sectional area must equal the gravitational force exerted by the mass of the particles minus the. buoyant force of the displaced fluid.

(3.1-31) Hence, JSI) (3.1-32) (English) Often we have irregular-shaped particles in the bed, and it is more convenient to use the paqicle size and shape factor in the equations. First we substitute for the effective mean diameter Dp the term cPs Dp where Dp now represents the particle size of a sphere having the same volume as the particle and cPs the shape factor. Often, the value of Dp is approximated by using the nominal size from a sieve analysis. Then Eq. 0.1-20) for pressure drop in a packed bed becomes l,p

150.uu' {l - e)2

-=--

L

cP~D~

e

3

+

1.75p(v')2 1 - e

cPsDp

- 3-

(3.1-33)

e

where l,L = L, bed length in m. Equation (3.1-33) can now be used by a smalI extrapolation for packed beds to calculate the minimum fluid velocity v'",f at which fluidization begins by substituting v;rif for v', emf for e, and Lmf for L and combining the result with Eq. (3.1-32) to give (3.1-34)

124

Chap. 3

Principles of Momentum Transfer and Applications

Defining a Reynolds number as (3.1-35) Eq. (3.1-34) becomes 1.7 5( N Rc. m!)2

+ _15_0(-,,-1_-:c~m!7)(:_N....:.:Rc::.:.c..:.;:.m!!.. C.)

a

¢~ c!!

¢sc!!

(3.1-36)

When N Rc • m ! < 20 (small particles), the first term of Eq. (3.1-36) can be dropped and when N Re. m! > 1000 (large particles), the second term drops out. If the terms Cm ! and/or ¢s are not known, Wen and Yu (W4) found for a variety of systems that (3.1-37) Substituting into Eq. (3.1-36), the following simplified eq uation is obtained. 33.7

(3.1-38)

This equation holds for a Reynolds number range of 0.001 to 4000 with an average deviation of ±25%. Alternative equations are available in the literature (Kl, W4) .

. EXAMPLE 3./-6. Minimum Velocity for Fluidization Solid particles having a size of 0.12 mm, a shape factor ¢s of 0.88, and a density of 1000 kg/m 3 are to be fluidized using air at 2.0 atm abs and 25°C. The voidage at minimum fluidizing conditions is 0.42. (a) If the cross section of the empty bed is 0.30 m 2 and the bed contains 300 kg of solid, calculate the minimum height of the fluidized bed. (b) Calculate the pressure drop at minimum fluidizing conditions. (c) Calculate the minimum velocity for fluidization. (d) Use Eq. (3.1-38) to calculate v:,,! assuming that data for ¢s andc m ! are not available.

....

:-'~

Solution: For part (a), the volume of solids 300 kg/(lOOO kg/m 3) 0.300 m 3 . The height the solids would occupy in the bed if e[ = 0 is L[ 0.300 m 3/(0.30 m 2 cross section) = 1.00 m. Using Eq. (3.1-30) and calling Lm! L2 and em! = C2 , ~ 1 - eml ..... 1 e[ Lm! 1.00 Lm!

1 - 0.42 1 -0

Solving, Lm! = 1.724 m. The physical properties of air at 2.0 atm and 25°C (Appendix A,3) are 5 Ji = 1.845 X 10- 5 Pa's, P I.l87 x 2 = 2.374 kg/m 3 , p 2.0265 x 10 3 Pa. For the particle, Dr 0.00012 m, pp = 1000 kg/m , ¢s 0.88, em! = 0.42. For part (b) using Eq. (3.1-32) to calculate D.p, D.p

= Lmf(l

- em! XP p

-

p)g

= 1.724(1 - 0.42)(1000

Sec. 3.1

2.374)(9.80665) = 0.0978 x 105 Pa

Flow Past Immersed Objects and Packed and Fluidized Beds

125

To calculate v~! for part (c), Eq. (3.1-36) is used. l.75(N Re • /H[)2 (0.88){0.42)3

+

150(1 - 0.42XN Re , m[) (0.88)2(0.42)3 0000 2)3 2.374(1000 2.374){9.80665) 1 (1.845 X 10- 5)2

(. Solving,

N Re • m !

=

0.07764

Dp v~J P _ P. -

0.00012(v~!){2.374)

1.845 x 10

5

0.005029 mls

v',.,!

Using the simplified Eq. P.l-38) for part (d), _ [( 37)2 0.0408(0.00012)3(2.374)(1000 - 2.374){9.80665)]11 N R•. m ! 3. + (1.845 x 10 5)2

2

33.7

0.Q7129 Solving, v',.,! = 0.004618 m/s.

3. Expansion of fluidized beds. For the case of small particles and where N Re .! Dpv'plp. < 20, we can estimate the variation of porosity or bed height L as follows. We assume that Eq. (3.1-36) applies over the whole range offl1.lid velocities with the first term being neglected. Then, solving for Vi, Vi

D~(pp - p)g4>i ~ _ K ~ 1 150p. 1 e 1 e

(3.1-39)

We find that all terms except e are constant for the parti~ular system and e depends upon Vi. This equation can be used with liquids to estimate e with e < 0.80. However, because of clumping and other factors, errors can occur when used for gases. The flow rate in a fluidized bed is limited on one hand by the minimum v~! and on the other by entrainment of solids from the bed proper. This maximum allowable velocity is approximated as the terminal settling velocity v; of the particles. (See Section 13.3 for methods to calculate this settling velocity.) Approximate equations to calculate the operating range are as follows (P2). For fine solids and N R • .r < 0.4,

v;

90

(3.1-40)

For la.rge,;;olids and N Re .! > 1000, 9

(3.1-41)

EXAMPLE 3.1-7. Expansion of Fluidized Bed Using the data from Example 3.1-6, estimate the maximum allowable velUsing an operating velocity of 3.0 times the minimum, estimate the ocity voidagc of the bed.

v;.

Solution: From Example 3.1-6, N Re. m! = 0.07764, v~! 0.005029 mis, f,m! = 0.42. Using Eq. (3.1-40), the maximum allowable velocity is

v;

126

90(v~!) =

Chap. 3

90(0.005029)

0.4526 mls

Principles of Momentum Transfer and Applications

Using an operating velocity v' of 3.0 times the minimum, v' = 10{v:"J) = 3.0(0.005029)

0.01509 mls

To determine the voidage at this new velocity, we substitute into Eq. JJ.1-39) using the known values at minimum fluidizing conditions to deter'mine K 1 . ~.

o005029 .

Solving, K I

=

= K

(0.42)3

!

1 - 0.42

0.03938. Then using the operating velocity in Eq. (3.1-39), 3

(0.03938) 1 ~

0.01509 Solving, the voidage of the bed

3.2

E.

E.

= 0.555 at the operating velocity.

MEASUREMENT OF FLOW OF FLUIDS

It is important to be able to measure and control the amount of material entering and leaving a chemical and other processing plants. Since many of the materials are in the form of fluids, they are flowing in pipes or conduits. Many different types of devices are used to measure the flow offluids. The most simple are those that measure directly the volume of the fluids, such as ordinary gas and water meters and positive-displacement pumps. Current meters make use of an element, such as a propeller or cups on a rotating arm, which rotates at a speed determined by the velocity of the fluid passing through it. Very widely used for fluid metering are the pitot tube, venturi meter, orifice meter, and open-channel weirs.

3.2A

Pitot Tube

The pitot tube is used to measure the local velocity at a given point in the flow stream and not the average velocity in the pipe or conduit. In Fig. 3.2-1a a sketch of this simple device is shown. One tube, the impact tube, has its opening normal to the direction of flow and the static tube has its opening parallel to the direction of flow.

'I. ...

--

-P-

____

-

e

impact

e

~tube

2

(

2~ _t

~-+

\

3.2-1.

b.h

-t

PA

(a)

Sec. 3.2

• •

D.h

static tube

FIGURE

---

(b)

Diagram afpilOl tube: (a) simple lUbe, (b) rube wilh static pressure holes.

Measurement of FlolV of Fluids

127

The fluid flows into the opening at point 2, pressure builds up, and then remains stationary at this point, called the stagnation point. The difference in the stagnation pressure at this point 2 and the static pressure measured by the static tube represents the pressure rise associated with the deceleration of the fluid. The manometer measures this small pressure rise. If the fluid is incompressible, we can write the Bernoulli equation (2.7-32) between point 1, where the velocity VI is undisturbed before the fluid decelerates, and point 2, where the velocity V2 is zero.

vi

+ PI

2 Setting

D2

2

- P2

=0

P

(3.2-1)

= 0 and solving for VI' (3.2-2)

where D is the velocity VI in the tube at point 1 in mIs, P2 is the stagnation pressure, p is the density of the flowing fluid at the static pressure Ph and C p is a dimensionless coefficient to take into account deviations from Eq. (3.2-1) and generally varies between about 0.98 to 1.0. For accurate use, the coefficient should be determined by calibration of the pitot tube. This equation applies to incompressible fluids but can be used to approximate the flow of gases at moderate velocities and pressure changes of about 10% or less of the total pressure. For gases the pressure change is often quite low and, hence, accurate measurement of velocities is difficult. The value of the pressure ~rop P2 - PI or t:.p in Pa is related to t:..h, the reading on the manometer, by Eq. (2.2-14) as follows: t:.p

= t:.h(PA

p)g

(3.2-3)

where PAis the density of the fluid in the manometer inkg/m 3 and t:..h is the manometer reading in m. In Fig. 3.2-lb, a more compact design is shown with concentric tubes. In the outer tube, static pressure holes are parallel to the direction of flow. Further details are given elsewhere (PI). Since the pitot tube measures velocity at one point only in the flow, several methods can be used to obtain the average velocity in the pipe. In the first method the velocity is measured at the exact center of the tube to obtain Vmax ' Then by using Fig. 2.10-2 the Vay can be obtained. Care should be taken to have the pitot tube at least 100 diameters downstream from any pipe obstruction. In the second method, readings are taken at several known positions in the pipe cross section and then using Eq. (2.6-17), a graphical or numerical integration is performed to obtain Dav . EXAMPLE 3.2-1." Flow Measurement Using a Pitot Tube A pitot tube similar to Fig. 3.2-1a is used to measure the airflow in a circular duct 600 mm in diameter. The flowing air temperature is 65.6°C. The pitot tube is placed at the center of the duct and the reading t:.h on the manometer is 10.7 mm of water. A static pressure measurement obtained at the pitot tube position is 205 mm of water above: atmospheric. The pitot tube coefficient C p = 0.98.

(a) Calculate the velocity at the center and the average velocity. (b) Calculate the volumetric flow rate of the flowing air in the duct. Solution: For part (a), the properties of air at 65.6°C from Appendix A.3 are II = 2.03 x 10- 5 Pa· s, P = 1.043 kg/m 3 (at 101.325 kPa). To calculate the absolute static pressure, the manometer reading t:.h = 0.205 m of water

128

Chap. 3

Principles of Momentum Transfer and Applications

indicates the pressure above 1 atm abs. Using Eq. (2.2-14), the water density as lOOO kg/m 3 , and assuming 1.043 kg/m 3 as the air density,

tJ.p = 0.205(1000 - 1.043)9.80665 = 2008 Pa Then the absolute static pressure PI 1.01325 x lO5 + 0.02008 X 10 5 1.0333 X 10 5 Pa: The correct air density in the flowing air is (1.0333 x 105 /1.01325 x 10 5 )(1.043) 1.063 kg/m 3 • This correct value when used instead of 1.043 would have a negligible effect on the recalculation of Pt. To calculate the dp for the pitot tube, Eq. (3.2-3) is used. dp = dh(PA

p)g

10.7

= 1000 (1000 -

1.063)(9.80665)

=

104.8 Pa

X

10 5

Using Eq. (3.2-2), the maximum velocity at the center is v = 0.98.

2(104.8) 1.063

=

13.76 m/s

The Reynolds number using the maximum velocity is 0.600(13.76)(1.063) 2.03 x 10 - 5

DVm .. P J1

=

4323 .

From Fig. 2.10-2, v.vlv m •• = 0.85. Then, Vav = 0.85(13.76) 11.70 m/s. To calculate the' flow rate for part (b), the cross-sectional area of the duct, A (n/4)(0.600)z = 0.2827 m Z• The flow rate = 0.2827(11.70) 3.308 m 3/s. 3.2B

Venturi Meter

A venturi meter is shown in Fig. 3.2-2 and is usually inserted directly into a pipeline. A manometer or other device is connected to the'two pressure taps shown and measures the pressure difference PI pz between points 1 and 2. The average velocity at point 1 where the diameter is Dim is v I mIs, and at point 2 or the throat the velocity is V2 and diameter D2 • Since the narrowing down from DI to D z and the expansion from D2 back to DI is gradual, little frictional loss due to contraction and expansion is incurred. To ded ve the equation for the venturi meter, friction is neglected and the pipe is assumed horizontaL Assuming turbulent flow and writing the mechanical-energybalance equation (2.7-28) between points 1 and 2 for an incompressible fluid,

+ pz

+

2

P

2

P

(3.2-4)

The continuity equation for constant pis nD~

nDt

v --

u -I

---

4

2

4

(3.2-5)

.2

il

P2

PI FIGURE

Sec. 3.2

3.2-2.

Venturi flow meIer.

Measurement of Flow of Fluids

129

Combining Eqs. (3.2-4) and (3.2-5) and eliminating V!,

J2(PI - pz)

1 V2 =

J1 _

(3.2-6)

P

(D2/Dd4

To account for the small friction loss an experimental coefficient C v is introduced to give

CV

Vz =

V2

Jl _ (D z/D I )4 Cv

Jl - (Dz/Dd

J2(PI - pz)

(SI)

P

(3.2-7)

J2gAPI 4

P2)

(English)

P

For many meters and a Reynolds number >10 4 at point 1, C v is about 0.98 for pipe diameters below 0.2 m and 0.99 for larger sizes. However, these coefficients can vary and individual calibration is recommended ifthe~manufacturer's calibration is not available. To calculate the volumetric flow rate, the velocity V 2 is multiplied by the area A z . flow rate

nD~ v -z 4

(3.2-8)

For the measurement pf compressible flow of gases, the adiabatic expansion fromp! to pz pressure must be allowed for in Eq. (3.2-7). A similar equation and the same coefficient C v are used along with the dimensionless expansion correction factor Y (shown in Fig. 3.2-3 for air) as follows: m

CvAzY

J1-

(D2/Dd

4.

J 2(p! -

(3.2-9)

P2)PI

where m is flow rate in kg/s, PI is density of the fluid upstream at point 1 in kg/m 3, and . A2 is cross-sectional area at point 2 in m 2 • The pressure difference P! - pz occurs because the velocity is increased from VI to V2' However, farther down the tube the velocity returns to its original value of VI for pz is not fully liquids. Because of some frictional losses, some of the difference PI

0.7

0.8

0.80 LL..LL.LJL-'--L...L...L...lWL1-L.L.JLL-L.1....lJl-L-L.L-'--\.~-L-J--' } venturi 0.7 0.9 0.8 1.0

Pressure ratio, P2/ P l fiGURE

130

3.2-3.

Expansion factor for air in venturi and orifice. [Calculaled from equa· tions and dara in references ( AZ, M2, S3).]

Chap. 3

Principles of Momentum Transfer and Applications

PI FIGURE

3.2-4.

P2

Orifice flow meter.

recovered. In a properly designed venturi meter, the permanent loss is about 10% of the differential PI - pz, and this represents power loss. A venturi meter is often used to measure flows in large lines, such as city water systems. 3.2C

Orifice Meter

For ordinary installations in a process plant the venturi meter has several disadvantages. It occupies considerable space and is expensive. Also, the throat diameter is fixed so that if the flow-rate range is changed considerably, inaccurate pressure differences may result. The orifice meter overcomes these objections but at the price of a much larger permanent head or power loss. A typical sharp-edged orifice is shown in Fig. 3.2-4. A machined and drilled plate having a hole of diameter Do is mounted between two flanges in a pipe of diameter D I • Pressure taps at point I upstream and 2 downstream measure PI pz- The exact positions of the two taps are somewhat arbitrary, and in one type of meter the taps are installed about I pipe diameter upstream and 0.3 to 0.8 pipe diameter downstream. The fluid stream, once past the orifice plate, forms a vena contracta or free-flowing jet. The equation for the orifice is similar to Eq. (3.2-7).

CO Vo

= Jl _ (DoIDI)4

J2(PI - P2) P

(3.2-10)

where Vo is the velocity in the orifice in mis, Do is the orifice diameter in m, and Co is the dimensionless orifice coefficient. The orifice coefficient Co is always determined experimentally. If the N R. at the orifice is above 20000 and Dol DI is less than about 0.5, the value of Co is approximately constant and it has the v::-.Iue of 0.61, which is adequate for design for liquids (M2, PI). Below 20000 the coefficient rises sharply and then drops and a correlation for Co is given elsewhere (P 1). As in the case of the venturi, for the measurement of compressible flow of gases in an orifice, a correction factor Y given in Fig. 3.2-3 for air is used as follows. (3.2-11) where m is flow rate in kgls, PI is upstream density in kg/m 3, and Ao is the cross-sectional area of the orifice. The permanent pressure loss is much higher than for a venturi because of the eddies formed when the jet expands below the vena contracta. This loss depends on Dol DI and Sec. 3.2

Measurement of Flow of Fluids

131

is 73% of PI (P 1).

P2 for Do/Dl = 0.5, 56% for Do/Dl = 0.65, and 38% for Do/Dl = 0.8

EXAMPLE 3.2-2. Metering Oil Flow by an Orifice A sharp-edged orifice having a diameter of 0.0566 m is installed in a 0.1541-m pipe through which oil having a density of 878 kg/m 3 and a viscosity of 4.1 cp is flowing. The measured pressure difference across the orifice is 93.2 kN/m 2 . Calculate the volumetric flow rate in m 3 Is. Assume that Co = 0.61. Solution:

PI Dl

= 0.1541

P2

93.2 kN/m2

= 9.32

Do = 0.0566 m

m

4

x 10 N/m2

Do = 0.0566 DI 0.1541

=

0.368

Substituting into Eq. (3.2-10). Co J2(Pl - pz) 4 Jl - (Do1Dd P 2(9.32 X 104 ) 878 Vo

'= 8.97 mls

. fi ow rate = vo 1umetnc

DO

4 = (8.97) (TC)(0.~566)2

= 0.02257 m 3 Is (0."97

ft3

The N Re is calculated to see if it is greater than 2 x 104 for Co J..I.

= 4.1 x 1 x 10 - 3 = 4.1 x 10 - 3 kg/m' S Do NRc

Vo

P

= --,,(-

=

0.0566{8,97)(878) 4.1 x 10 3

.

4.1 x 10 L087

X

3

Is) 0.6l.

Pa' s

10 5

Hence, the Reynolds number is above 2 x 104 . Other measuring devices for flow in closed conduits, such as rotameters, flow nozzles, and so on, are discussed elsewhere (P 1).

3.2D

Flow in Open Channels

am~

Weirs

In many instances in process engineering and in agriculture, liquids are flowing in open channels rather than closed conduits. To measure the flow rates, weir devices are often used. A weir is a dam over which the liquid flows. The two main types of weirs are the rectangular weir and the triangular weir shown in Fig. 3.2-5. The liquid flows over the weir and the height ho (weir head) in m is measured above the flat base or the notch as shown. This head should be measured at a distance of about 3h o m upstream of the weir by a level or float gage. The equation for the volumetric flow rate q in m 3 Is for a rectangular weir is given by q

0.415(L

0.2ho)h~·5 j2g

(3.2-12)

where L crest length in m, g = 9.80665 m/s2, and ho = weir head in m. This is called the modified Francis weir formula and it agrees with experimental values within 3% if 132

Chap.]

Principles of Momentum Transfer and Applications

(b)

FIGURE 3.2-5.

Types of weirs : (a) rectangular, (b) triangular.

L > 2ho , velocity upstream is < 0.6 mis, ho > 0.09 m, and the height of the crest above the bottom of the' channel is > 3h o . In English units Land h are in ft, q in ft 3 /s, and 9 = 32.174 ft/s2. For the triangular notch weir,

(3.2-13) Both Eqs. (3.2-12) and (3.2-13) apply only to water. For other liquids, see data given elsewhere (P 1).

3.3 3.3A

PUMPS AND GAS-MOVING EQUIPMENT Introduction

In order to make a fluid flow from one point to another in a closed conduit or pipe, it is necessary to have a driving force. Sometimes this force is supplied by gravity, where differences in elevation occur. Usually, the energy or driving force is supplied by a mechanical device such as a pump or blower, which increases the mechanical energy of the fluid. This energy may be used to increase the velocity (move the fluid), the pressure, or the elevation of the fluid, as seen in the mechanical-energy-balance equation (2.7-28), which relates v, p, p, and work. The most common methods of adding energy are by positive displacement or centrifugal action. Generally, the word" pump" designates a machine or device for moving an incompressible liquid. Fans, blowers, and compressors are devices for moving gas (usually air). Fans discharge large volumes of gas at low pressures of the order of several hundred mm of water. Blowers and compressors discharge gases at higher pressures. In pumps and fans the density of the fluid does not change appreciably, and incompressible flow can be assumed. Compressible flow theory is used for blowers and compressors.

3.3B

Pumps

f. Power and work required. Using the total mechanical-energy-balance equation (2.728) on a pump and piping system, the actual or theoretical mechanical energy itS J/kg added to the fluid by the pump can be calculated. Example 2.7-5 shows such a case. If IJ is the fractional efficiency and the shaft work delivered to the pump, Eq. (2.7-30) gives

w;,

Ws w=-P 7J Sec. 3.3

Pumps and Gas-Moving Equipment

(3.3-1)

133

The actual or brake power of a pump is as follows. brake kW

brake hp

= -Wm p- =

,Wsm

(SI)

' '1 x 1000

1000

(33-2)

w;,m _' Wsm

(English)

'1 x 550

550

where Wp is J(kg, m is the flow rate in kg/s, and 1000 is the conversion factor W (kW. In English units, Ws is in ft . Ibfflb m and m in Ibm/s. The theoretical or fluid power is theoretical power

(33-3)

(brake kW)(I1)

The mechanical energy Ws in J(kg added to the fluid is often expressed as the developed head H of the pump in m offluid being pumped, where

Ws = Hg' g

Ws=Hgc

(SI)

(33-4) (English)

To calculate the power of a fan where the pressure difference is of the order of a few hundred mm of water, a linear average density of the gas between the inlet and outlet of the fan is used to calculate Ws and brake kW or horsepower. Since most pumps are driven by electric motors, the efficiency of the electric motor must be taken into account to determine the total electric power input to the motor. Typical efficiencies 11. of electric motors are as follows: 75% fod-kW motors, 80% for 2 kW, 84% for 5 kW, 87%for,,15 kW, and about 93% for over 150c kW motors. Hence, the total electric power input equals the brake power divided by the electric motor drive efficiency 11 e . electric power input (kW)

brake kW 'I e

- Wsm l]l] e •

1000

(3.3-5)

2. Suction lift. The power calculated by Eq. (2.7-3) depends on the differences in pressures and not on the actual pressures being above or below atmospheric pressure. However, the lower limit of the absolute pressure in the suction (inlet) line to the pump is fixed by the vapor pressure of the liquid at the temperature of the liquid in the suction line. If the pressure on the liquid in the suction line drops to the vapor pressure, some of the liquid flashes into vapor (cavitation). Then no liquid can be drawn into the pump. For the special case where the liquid is nonvolatile, the friction in the suction line to the pump is negligible, and the liquid is being pumped from an open reservoir, the maximum possible vertical suction'lift which the pump can perform occurs. For cold water this would be about lOA m of water. Practically, however, because of friction, vapor pressure, dissolved gases, and the entrance loss, the actual value is much less. For details, see references elsewhere (P 1, M2). 3. Centrifugal pumps. Process industries commonly use centrifugal pumps. They are available in sizes of about 0.004 to 380 m 3 jmin (1 to 100000 galfmin) and for discharge pressures from a few m of head to 5000 kPa or so. A centrifugal pump in its simplest form consists of an impeller rotating inside a casing. Figure 3.3-1 shows a schematic diagram of a simple centrifugal pump. The liquid enters the pump axially at point 1 in the suction line and then enters the rotating eye of the impeller, where it spreads out radially. On spreading radially it enters 134

Chap. 3

Principles of Momentum Transfer and Applications

FIGURE 3.3- L

Simple centrifugal pump.

the channels between. the vanes at point 2 and flows through these channels to point 3 at the periphery of the impeller. From here it is collected in the volute chamber 4 and flows out the pump discharge at 5. The rotation of the impeller imparts a high-velocity head to the fluid, which is changed to a pressure head as the liquid passes into the volute chamber and out the discharge. Some pumps are also made as two-stage or even multistage pumps. Many complicating factors determine the actual efficiency and performance characteristics of a pump. Hence, the actual experimental performance of the pump is usually employed. The performance is usually expressed by the pump manufacturer by means of curves called characteristic curves and are usually for water. The head H in m produced . will be the same for any liquid of the same viscosity. The pressure produced, which is p H pg, will be in proportion to the density. Viscosities of less than 0.05 Pa' s (50 cp). have little effect on the head produced. The brake kW varies directly as the density. As rough approximations, the following can be used for a given pump. The capacity q I in m J /s is directly proportional to the rpm N I, or (3.3-6) The head HI is proportional to qi, or (3.3-7)

The power consumed WI is proportional to the product of HI q l' or WI

H

W2

H 2 q2

NJ

(3.3-8)

In most pumps, the speed is generally not varied. Characteristic curves for a typical single-stage centrifugal pump operating at a constant speed are given in Fig. 3.3-2. Most pumps are usually rated on the basis of head and capacity at the point of peak efficiency. The efficiency reaches a peak at about 50 gal/min flow rate. As the discharge rate in gal/min increases, the developed head drops. The brake hp increases, as expected, with flow rate.

EXAMPLE 33-1. Calculation oJ Brake Horsepower oJ a Pump In order to see how the brake-hp curve is determined, calculate the brake hp at 40 gal/min flow rate for the pump in Fig. 3.3-2. Sec. 33

Pumps and Gas-Moving Equipment

13S

50

---

+J .......

'-"

Speed 1750 rpm 40

80

1.6

60 >U

1.2

.....

'0

"" ::r:: 1000, since thef, is approximately constant, then t T N L/3 is constant. For some other mixers it has been shown that tTN is approximately constant. For scaling up from vessel 1 to another size vessel 2 with similar geometry and with the same power/unit volume in the turbulent region, the mixing times are related by t T2 -=

tTl

(D -

)11/18

az

(3.4-17)

Da l

Hence, the mixing time increases for the larger vessel. For scaling up keeping the same mixing time, the power/unit volume PIV increases markedly. (3.4-18)

Usually, in scaling up to large-size vessels, a somewhat larger mixing time is used so that the powerlunit volume does not increase markedly.

~ I-

.......

~

10

~

'---

II

~

1 1

II

t.

II

10

N' FIGURE

150

3.4-5.

I

~

d

I

105

2

NDaP

Rc=--1-1

Correlation of mixing time for miscible liquids using a turbine in a baffled tank (for a plain turbine, turbine with disk, and pitchedblade turbine). [From "Flow Patterns and Mixing Rates in Agitated Vessels" by K. W. Norwood and A. B. MetVler, A.l.Ch.E. i., 6, 432 (1960). Reproduced by permission of the American Institute of Chemical Engineers, 1960.J Chap. 3

Principles of Momentum Transfer and Applications

The mixing time for a helical-ribbon agitator is as follows for N Re < 20 (H2). NtT NtT

126

= 90

(agitator pitch/tank diameter = 1.0)

(3.4-19)

0.5)

(3.4-20)

(agitator pitch/tank diameter

For very viscous liquids the helical-ribbon mixer gives a much smaller mixing time than ~ turbine for the same power/unit volume (MS). For nonviscous liquids, however, it gives longer times. For a propellor agitator in a baffled tank, a mixing-time correlation is given by Biggs (BS) and that for an unbaffied tank by Fox and Gex (Fl).

3.4H

Flow Number and Circulation Rate in Agitation

An agitator acts like a centrifugal primp impeller without a casing and gives a flow at a certain pressure head. This circulation rate Q in m 3/s from the edge of the impeller is the flow rate perpendicular to the impeller discharge area. Fluid velocities have been measured in mixers and have been used to calculate the circulation rates. Data for baffled vessels have been correlated using the dimensionless flow number N Q (U 1). N Q =

Q

a

marine propeller (pitch

3.41

(3.4-21)

ND 3

diameter)

N Q =0.75

6 blade turbine with disk (W/ D a

t)

N Q = 0.5

6 blade turbine with disk (WlDa

t)

N Q = 0.75

pitched-blade turbine (WID a

=

~)

Special Agitation Systems

1. Suspension of solids. In some agitation systems a solid is suspended in the agitated liquid. Examples are where a finely dispersed solid is to be dissolved in the liquid, microorganisms are suspended in fermentation, a homogeneous liquid-solid mixture is to be produced for feed to a process, and a suspended solid is used as a catalyst to speed up a reaction. The suspension of solids is somewhat similar to a fluidized bed. In the agitated system circulation currents of the liquid keep the particles in suspension. The amount and type of agitation needed depends mainly on the terminal settling velocity of the particles, which can be calculated using the equations in Section 14.3. Empirical equations to predict the power required to suspend particles are given in references (M2, WI). 2. Dispersion of gases and liquids in liquids. 1n gas-liquid dispersion processes, the gas is introduced below the impeller, which chops the gas into very fine bubbles. The type and degree of agitation afrects the size of the bubbles and the total interfacial area. Typical of such processes are aeration in sewage treatment plants, hydrogenation of liquids by hydrogen gas in the presence of a catalyst, absorption of a solute from the gas by the Sec. 3.4

Agitation and Mixing of Fluids and Power Requirements

151

liquid, and fermentation. Correlations are available to predict the bubble size, holdup, and kW power needed (C3, Ll, Zl). For liquids dispersed in inmiscible liquids, see reference (Tl). The power required for the agitator in gas-liquid dispersion systems can be as much as 10 to 50% less than that required when no gas is present (C3, T2). 3. Motionless mixers. Mixing of two fluids can also be accomplished in motionless mixers with no moving parts. In such commercial devices stationary elements inside a pipe Succ!!ssively divide portions of the stream and then recombine these portions. In one type a sbort helical element divides the stream in two and rotates it 180°. The second el-;;ment set at 90° to the first again divides the stream in two. For each element there are 2 divisions and recombinations, or 2n for n elements in series. For 20 elements about 106 divisions occur. Other types are available which consist of bars or flat sheets placed lengthwise in a pipe. Low-pressure drops are characteristic of all of these types of mixers. Mixing of even highly viscous materials is quite good in these mixers.

3.4J Mixing of Powders, Viscous Material, and Pastes

In mixing of solid particles or powders it is necessary to displace parts of the powder mixture with respect to other parts. The simplest class of devices suitable for gentle blending is the tumbler. However, it is not usually used for breaking up agglomerates. A common type of tumbler used is the double-cone blender, in which two cones are mounted with their open ends fastened together and rotated as shown in Fig. 3.4-6a. Barnes can also be used internally. If an internal rotating device is also used in the double cone, agglomerates can also be broken up. Other geometries used are a cylin· drical drum with internal barnes or twin-shell V type. Tumblers used specifically for breaking up agglomerates are a rotating cylindrical or, conical shell charged with metal or porcelain steel balls or rods. Another class of devices for solids blending is the stationar y shell device, in which the container is stationary and the material displacement is accomplished by single or mUltiple rotating inner devices. In the ribbon mixer in Fig. 3.4-6b, a shaft with two open helical screws numbers 1 and 2 attached to it rotates. One screw is left-handed and one right-handed. As the shaft rotates, sections of powder move in opposite directions and mixing occurs. Other types of internal rotating devices are available for special situations (P 1). Also, in some devices both the shell and the internal device rotate. 1. Powders.

2. Dough, pastes, and viscous materials. In the mixing of dough, pastes, and viscous materials, large amounts of power are required so that the material is divided, folded, or recombined, and also different parts of the material should be displaced relative to each other so that fresh surfaces recombine as often as possible. Some machines may require jacketed cooling to remove the heat generated. The first class of device is somewhat similar to those for agitating fluids, with an impeller slowly rotating in a tank. The impeller can be a close-fitting anchor agitator as in Fig_ 3.4-6b, where the outer sweep assembly may have scraper blades. A gate impeller can also be used which has horizontal and vertical bars that cut the paste at various levels and at the wall, which may have stationary bars. A modified gate mixer is the shear-bar mixer, which contains vertical rotating bars or paddles passing between vertical stationary fingers. Other modifications of these types are those where the can or container will rotate as well as the bars and scrapers. These are called change-can mixers. The most commonly used mixer for heavy pastes and dough is the double-arm 152

Chap. 3

Principles of Momentum Transfer and Applications

(a) (b)

(c) FIGURE

3.4-6.

Mixers fo/ powders and pastes: (a) double-cone powder mixer, (b) ribbon powder mixer with two ribbons, (c) kneader mixer for pastes.

kneader mixer. The mixing action is bulk movement, smearing, stretching, dividing, fo~lding, and recombining. The most widely used design employs two contrarotating arms of sigmoid shape which may rotate at different speeds, as shown in 3.4-6c.

3.5 3.5A

NON-NEWTONIAN FLUIDS Types of Non-Newtonian Fluids

As discussed in Section 2.4, Newtonian fluids are those which follow Newton's law, Eq. (3.5-1 ). dv T= (SI) Ii dr (3.5-1) T=

!! dv gc dr

(English)

where!! is the viscosity and is a constant independent of shear rate. In 3.5-1 a plot is shown of shear stress T versus shear rate - dv/dr. The line for a Newtonian fluid is straight, the slope being!!. rr a fluid does not follow Eq. (3.5-1), it is a non-Newtonian fluid. Then a plot of T versus dv/dr is not linear through the origin for these fluids. Non-Newtonian fluids can be divided into two broad categories on the basis of their shear stress/shear rate behavior: those whose shear stress is independent of time or duration of shear (timeindependent) and those whose shear,stress is dependent on time or duration of shear (time-dependent). In addition to unusual shear-stress behavior, some non-Newtonian fluids also exhibit elastic (rubberlike) beha vior which is a function of time and results in Sec. 3.5

Non-Newtonian Fluids

153

their being called viscoelastic fluids. These fluids exhibit normal stresses perpendicular to the direction of flow in addition to the usual tangential stresses. Most of the emphasis will be put on the time-independent class, which includes the majority of non-Newtonian fluids.

3.5n

Time-Independent Fluids

I. Bingham plastiC fluids. These are the simplest because, as shown in Fig. 3.5-1, they differ from Newtonian only in that the linear relationship does not go through the origin. A finite shear stress 1: y (called yield stress) in N/m2 is needed to initiate flow. Some fluids have a finite yield (shear) stress 1: y ' but the plot of 1: versus -dv/dr is curved upward or downward. However, this departure from exact Bingham plasticity is often smaiL Examples of fluids with a yield stress are drillin~g muds, peat slurries, margarine, chocolate mixtures, greases, soap, grain-w~ter suspensions, toothpaste, paper pulp, and sewage sludge. 2. Pseudoplastic fluids. The majority of non-Newtonian fluids are in this category and include polymer solutions or melts, greases, starch suspensions, mayonnaise, biological fluids, detergent slurries, dispersion media in certain pharmaceuticals, and paints. The shape of the flow curve is shown in Fig. 3.5-1, and it generally can be represented by a power-law equation (sometimes called Ostwald-deWaele equation). (n < I)

(3.5-2)

where K is the consistency index in N· s"/m2 or Ibr . 's" /ft2, and n is the flow behavior index, dimensionless. The apparent viscosity, obtained from Eqs. (3.5-1) and (3.5-2), is }La = K(dvldr) ,,-1 and decreases with increasing shear rate.

Bingham plastic

""'

",-

'"... '1)

~

...'"

pseudoplastic Ty

'" '1)

..c;; Ul

Newtonian Shear rate,

FIGURE

154

3.5-1.

dv/dr

Shear diagram Jor Newtonian and time-independent non-Newtonian fluids.

Chap. 3

Principles of Momentum TransJer and Applicarions

3. Dilatant fluids. These fluids are far less common than pseudoplastic fluids and their flow behavior in Fig. 3.5-1 shows an increase in apparent viscosity with increasing shear rate. The power law equation (3.5-2) is often applicable, but with n > 1.

(n> 1)

(3.5-3)

For a Newtonian fluid, n 1. Solutions showing dilatancy are some corn flour-sugar solutions, wet beach sand, starch in water, potassium silicate in water, and some solutions containing high concentrations of powder in water. 3.5e

Time-Dependent Fluids

1. Thixotropicfluids. These fluids exhibit a reversible decrease in shear stress with time at a constant rate of shear. This shear~tress approaches a limiting value that depends on the shear rate. Examples include some polymer solutions, shortening, some food mat.{':rials, and paints. The theory for time-dependent fluids at present is still not completely developed.

These fluids are quite rare in occurrence and exhibit a reversible increase in shear stress with time at a constant rate of shear. Examples are bentonite clay suspensions, certain sols, and gypsum suspensions. In design procedures for thixotropic and rheopectic fluids for steady flow in pipes, the limiting flow-property values at a constant rate of shear are sometimes used (52, W3). 2. Rheopectic fluids.

/'

3.5D

Viscoelastic Fluids

Viscoelastic fluids exhibit elastic recovery from the deformations that occur during flow. They show both viscous and elastic properties. Part of the deformation is recovered upon removal of the stress. Examples are flour dough, napalm, polymer melts, and bitumens. J.5E

Laminar Flow of Time-Independent Non-Newtonian Fluids

1, Flow properties of a fluid. In determining the flow properties of a time-independent non-Newtonian fluid, a capillary-tube viscometer is often used. The pressure drop I1P N/m2 for a given flow rate q m 3 /s is measured in a straight tube of length L and diameter D m. This is rep.eated for different flow rates or average velocities V m/s. H the fluid is time-independent, these flow data can be used to predict the flow in any other pipe size. A plot of D I1pI4L, which is t w , the shear stress at the wall in N/m2, versus 8VID, which is proportional to the shear rate at the wall, is shown in Fig. 3.5-2 for a power-law fluid following Eq. (3.5-4).

m

= DI1p

T IV

4L

K' (8 V) D

n'

(3.5-4)

where n' is the slope of the line when the data are plotted on logarithmic coordinates and K' has units of N . s"'/m 2 For n' 1, the fluid is Newtonian; for n' < 1, pseudoplastic, or Bingham plastic if the curve does not go through the origin; and for n' > I, dilatant. The Sec. 3.5

Non-Newtonian Fluids

155

FIGURE

3.5-2

General flow curve for a power-law fluid in laminar flow in a rube.

8V

K', the consistency index in Eq. (3.S-4), is the value of D !J.p/4L for 8V/D rate at the wall, ( dvldr)w, is

(

_dV) dr w

(3n' + 1)(8V) 4n'

1. The shear

(3.5-5)

D

Also, K' = 1L for Newtonian fluids. Equation (3.5-4) is simply another statement of the power-law model of (3.5-2) applied to flow in round tubes, and is more convenient to use for pipe-flow situations (D2). Hence, Eq. (3.5-4) defines the flow characteristics just as completely as (3.5-2). It has been found experimentally (M3) that for most fluids K' and n' are constant over wide ranges of 8 V/D or D /::;p/4L. For some fluids this is not the case, and K' and n' vary. Then the particular values of K' and n' used must be valid for the actual or /::;PI4L with which one is dealing in a design problem. This method using flow in a pipe or tube is often used to determine the flow properties of a non-Newtonian fluid. In many cases the flow properties of a fluid are determined using a rotational viscometer. The flow properties K and n in (3.5-2) are determined in this manner. A discussion of the rotational viscometer is given in Section 3.51. When the flow properties are constant over a range of shear stresses which occurs for many fluids, the following equations hold (M3):

8VID D

/1'

=

(3.5-6)

n

1)"'

3d + K'=K ( 4n'

(3.5-7)

Often a generalized viscosity coefficient y is defined as

y = K8"'

1

(SI)

(3.5-8) y

gc K'8",-1

(English)

where y has units ofN' s"'/m1 orlb.Jft· 5 2 -., Typical flow-property constants (rheological constants) for some fl uids are given in Table 3.5-1. Some data give y values instead of K' values, but Eq. (3.5-8) can be used to con vert these values if necessary. In some cases in the literature, K or K' values are given

156

Chap. 3

Principles of Momentum Transfer and Applications

TABLE

3.5-1.

Flow-Property ConstantsJor Non-Newtonian Fluids Flow-Property Constants

Fluid

n'

1.5% carboxymethylcellulose in water 3.0% CMC in water 4% paper pulp in water 14.3% clay in water 10% napalm in kerosene 25% clay in water Applesauce, brand A (297 K), density = 1.10 g/cm l / Banana puree, brand A (297 K), density 0.977 gJcm l Honey (297 K) Cream, 30% fat (276 K) Tomato concentrate, 5.8% total solids (305 K)

0.554 0.566 0.575 0.350 0.520 0.185 0.645

Ref.

(St) (Sl) (AI) (W2) (Sl) (W2)

1.369 4.17 9.12 0.0512 1.756 0.3036 0.500

(C1)

0.458

6.51

(Cl)

l.00 1.0 0.59

5.61 0.01379 0.2226

(CI) (M4) (HI)

as dyn' s"'/cm 2 or Ib r · s·,/ft 2 • From Appendix A.I, the conversion factors are

2. Equations Jor flow in a tube. In order to predict the frictional pressure drop t:.p in laminar flow in a tube, Eq. (3.5-4) is solved for t:.p. t:.p

K;L

(8:r

(3.5-9)

If the average velocity is desired, Eq. (3.5-4) can be rearranged to give V = D (t:.PD)I/"' 8 K'4L

(35-10)

If the equations are desired in terms of K instead of K', Eqs. (3.5-6) and (3.5-7) can be substituted into (3.5-9) and (3.5-10). The flow must be laminar and the generalized Reynolds number has been defined as Dn,v 2

N Re. gen

= ---'-y

K8"-1 (3n

1)" 4n

(SI)

(35-11)

+

3. Frictionfactor method. Alternatively, using the Fanning friction factor method given in Eqs. (2.10-5) to (2.10-7) for Newtonian fluids, but using the generalized Reynolds numbers, Sec. 3.5

Non-Newtonian Fluids

157

16

(3.5-12)

NRc. gen

L y2 Ap = 4fp D

(SI) (3.5-13)

L y2 4fp-D 2gc

Ap

(English)

EXAMPLE 3.5-1. Pressure Drop ofPower-Law Fluid in Laminar Flow A power-law fluid having a density of 1041 kg/m 3 is Howing through 14.9 m of a tubing having an inside diameter of 0.0524 m 'at an average velocity of 0.0728 m/s. The rheological or flow properties of the fluid are K' 15.23 N· s"/m2 (0.318Ib(· s"/ft 2 ) and n' OAO. (a) Calculate the pressure drop and friction loss using Eq. (3.5-9) for laminar flow. Check the generalized Reynolds number to make sure that the flow is laminar. (b) Repeat part (a) but use the friction factor method. Solution: The known data are as follows: K' = 15.23, n 0.40, D = 0.0524 m, V = 0.0728 mis, L = 14.9 m, and p = 1041 kg/m 3 . For part (a), using Eq. (3.5-9),

A = K'4L (8 V)., P D D

= 15.23(4)(14-9) (8 0.0524

x 0.0728)0.4 0.0524

45390 N/m2

Also, to calculate the friction loss, 45390 1041

_Ap FfP

=

43.60 Jjkg

Using Eq. (3.5-11), N Re. gen

D n 'V 2 = K'gn'

(0.0524)°..-1°(0.0728) 1.60( 1041) = 1.106 15.23(8)-0.6

Hence, the flow is laminar. For part (b), using Eq. (3.5-12), 16

16

-,

14.44

Substituting into Eq. (3.5-13), A P

= 4r ~

2

V JP D 2

=

4(14.44X1041)

= 45.39 kN (946

~ (0.0728)2 0.0524

2

~~;)

To calculate the pressure drop for a Bingham plastic fluid with a yield stress, methods are available for laminar flow and are discussed in detail elsewhere (C1, PI, S2).

158

Chap. 3

Principles of Momentum Transfer and Applications

3.5F Friction Losses in Contractions, Expansions, and Fittings in Laminar Flow Since non-Newtonian power-law fluids flowing in conduits are often in laminar flow because of their usually high effective viscosity, losses in sudden changes of velocity and fittings are important in laminar flow:,

1. Kinetic energy in laminar flow. In application of the total mechanical-energy balance in Eq. (2.7-28), the average kinetic energy per unit mass of fluid is needed. For fluids, this is (S2)

V2

average kinetic energy/kg = -

(3.5-14)

2et

For Newtonian fluids, Ct. =

t for laminar flow. /(2n

ex=

For example, if n 0.50, Ct. = 0.585. If n and non-Newtonian flow, Ct. l.0 (0 I).

For power-law non-Newtonian fluids,

+

I)(5n + 3) 3(3n + 1)2

= l.00, et

(3.5-1S)

t. For turbulent flow for Newtonian

2. Losses in contractions alldfittings. Skelland (S2) and Dodge and Metzner (02) state that when a fluid leaves a tank and flows through a sudden contraction to a pipe of diameter D2 or flows from a pipe of diameter DI through a sudden contraction to a pipe of Db a vena contracta is usually formed downstream from the contraction. General indications are that the frictional pressure losses for pseudoplastic and Bingham plastic fluids are very similar to those for Newtonian fluids at the same generalized Reynolds numbers in laminar and turbulent flow for contractions and also for fittings and valves. F or contraction losses, Eq. (2.1 0-16) can be used where Ct. = 1.0 for turbulent flow and for laminar flow Eq. (3.5-15) can be used to d'etermine Ct., since n is not 1.00. For fittings and valves, frictional losses should be determined using Eq. (2.10-17) and values from Table 2.10-1. 3. Losses ill stldden expansion. For the frictional loss for a non-Newtonian fluid in laminar flow through a sudden expansion from DI to D2 diameter, Skelland (S2) gives

hex

311 + 1 = 211 + 1

2[2(5nn ++33) (Dl)4 D2 -

VI

(DI)2 D2

+

3(3n 2(5n

+ I)J + 3)

(3.5-16)

where hex is the frictional loss in J/kg. In English units Eq. (3.5-16) is divided by gc and hex is in ft ·lbr/lbm. Equation (2.10-15) for laminar flow with ex t for a Newtonian fluid gives values reasonably close to those of Eq. (3.5-16) for n 1 (Newtonian fluid). For turbulent flow the frictional loss can be approximated by Eq. (2.10-15), with Ct. = 1.0 for non-Newtonian fluids (S2),

3.SG

Turbulent Flow and Generalized Friction Factors

In turbulent flow of time-independent fluids the Reynolds number at which turbulent flow occurs varies with the flow properties of the non-Newtonian fluid. Dodge and Metzner (02) in a comprehensive study derived a theoretical equation for turbulent flow of non-Newtonian fluids through smooth round tubes. The final equation is plotted in Fig. 3,5-3, where the Fanning friction factor is plotted versus the generalized Reynolds

Sec. 3.5

Non-Newtonian Fluids

159

....... .....~

0 ..... Q

.....c:\1 ~

0.02

n

0.01

0 ...... .....

.~ ..:::

2.0 1.4 l.0 0.8 0.6 0.4 0.3 0.2

0.005

b.()

~

'8 ~

u..'"

0.002

0.00 I

FIGURE

3.5-3.

I

5

10

3

2

5

10

4

2

5

lOs

Fanning friction factor versus generalized Reynolds number for timeindependent non-Newtonian and Newtonian fluids flowing in smooth tubes. [From D. W. Dodge and A. B. Metzner, A.l.Ch.E. J., 5, 189 ( 1959). With permission.]

number, N Re, geo' given in Eq. (3,5 c ll). Power-law fluids with flow-behavior indexes n' between 0.36 and 1.0 were experimentally studied at Reynolds numbers up to 3.5 X 10 4 and confirmed the derivation. The curves for different n' values break off from the laminar line at different Reynolds numbers to enter the transition region. For n' = 1.0 (Newtonian), the transition region starts at N Re • geo = 2100. Since many non-Newtonian power-law fluids have high effective viscosities, they are often in laminar flow. The correlation for a smooth tube also holds for a rough pipe in laminar flow. For rough commercial pipes with various values of roughness e/D, Fig. 3.5-3 cannot be used for turbulent flow, since it is derived for smooth tubes. The functional dependence of the roughness values c/D on n' requires expe'rimental data which are not yet available. Metzner and Reed (M3, S3) recommend use of the existing relationship, Fig. 2.10-3, for Newtonian fluids in rough tubes using the generalized Reynolds number N Re • gen' This is somewhat conservative since preliminary data indicate that friction factors for pseudoplastic fluids may be slightly s'maller than for Newtonian fluids. This is also consistent with Fig. 3.5-3 for smooth tubes that indicate lower f values for fluids with II' below 1.0 (S2).

EXAMPLE 35-2. Turbulent Flow of Power-Law Fluid A pseudoplastic fluid that follows the power law, having a density of 961 kg/m 3 , is flowing through a smooth circular tube having an inside diameter of 0.0508 m at an average velocity of 6.10 m/s. The flow properties of the fluid are n' = 0.30 and K' = 2.744 N· sm/m2. Calculate the frictional pressure drop for a tubing 30.5 m long. The data are as follows: K' 2.744, n' = 0.30, D = 0.0508' m, V = 6.10 mis, p = 961 kg/m 3 , and L 30.5 m. Using the general Reynolds-

Solution:

160

Chap. 3

Principles of Momentum Transfer and Applications

number equation (3.5-11), N Re, gen

D n,v 2 - n,p (0.0508)0.3(6.10)1.7(961) = K'8n'- 1 = 2.744{8 - 0.7)

= 1.328

X

104

Hence, the flow is turbulent. Using Fig. 3.5-3 for n' = 0.30, f = 0.0032. Substituting into Eq. (3.5-l3),

NRe.g en

= 1.328

X

104 and

Ll = 4 ~ L V2 4{0 0032 961)( 30.5 ) (6.10)2 X 0.0508 P :J P D 2 ' 2 137.4 kN/m2 (2870 Ibr/ft 2 )

3.5H Velocity Profiles for Non-Newtonian Fluids Starting with Eq. (3.5-2) written as T rx

(

dvx)n

K -dr

(35-17)

the following equation can be derived relating the velocity Vx with the radial position r, which is the distance from the center. (See Problem 2.9-3 for this derivation.) (35-18)

At r

0, Vx

Vx max

and Eq. (3.5-18) becomes

Vx max

[1

_ (~)(n+ Il/nj Ro

(35-19)

The velocity profile can be calculated for laminar flow of a non-Newtonian fluid to show that the velocity profile for a Newtonian fluid given in Eq. (2.9-9) can differ greatly from that of a non-Newtonian fluid. For pseudoplastic fluids (n < 1), a relatively flat velocity profile is obtained compared to the parabolic profile for a Newtonian fluid. For n = 0, rodlike flow is obtained. For dilitant fluids (n > 1), a much sharper profile is obtained and for n = 00, the velocity is a linear function of the radius. 3.5I Determination of Flow Properties of Non-Newtonian Fluids Using Rotational Viscometer The flow-property or rheological constants of non-Newtonian fluids can be measured using pipe flow as discussed in Section 3.5E. Another, more important method for measuring flow properties is by use of a rotating concentric-cylinder viscometer. This was first described by Couette in 1890. In this device a concentric rotating cylinder (spindle) spins at a constant rotational speed inside another cylinder. Generally, there is a very small gap between the walls. This annulus is filled with the fluid. The torque needed to maintain this constant rotation rate of the inner spindle is measured by a torsion wire from which the spindle is suspended. A typical commercial instrument of this type is the Brookfield viscometer. Some types rotate the outer cylinder.

Sec. 3.5

Non-Newtonian Fluids

161

The shear stress at the wall of the bob or spindle is given by

T 27rR~L

(3.5-20)

where T w is the shear stress at the wall, Nlm 2 or kg/s 2 • m; T is the measured torque, kg· m 2 /s2; Rb is the radius of the spindle, m; and L is the effective length of the spindle, m. Note that Eq. (3.5-20) holds for Newtonian and non-Newtonian fluids. The shear rate at the surface of the spindle for non-Newtonian fluids is as follows (M6) for 0.5 < RblRc < 0.99: 2w n[l

(3.5-21)

where Rc is the radius of the outer cylinder or container, m; and w is the angular velocity of the spindle, rad/s. Also, w=27rNI60, when N is the RPM. Results calculated using Eq. (3.5-21) give values very close to those using the more complicated equation of Krieger and Maron (K2), also given in (P4, 52). The power-law equation is given as T

.

where K gives

=

=

K(- dv)n dr

(3.5-2)

N· sn 1m 2 , kg· sn- 2 /m. Substituting Eqs. (3.5-20) and (3.5-21) into (3.5-2)

(3.5-22) Or,

(3.5-23) where,

(3.5-24)

A

Experimental data are obtained by measuring the torque T at different values of w for a given fluid. The flow property constants may be evaluated by plotting log T versus log (li. The parameter, n, is the slope of the straight line and the intercept isJog A. The consistency factor K is now easily evaluated from Eq. (3.5-24). Variolls special cases can be derived for Eq. (3.5-21). L Newtonian fluid.

(n

I).

2eu

(3.5-25)

< 0.1). This is the case of a spindle immersed in a large beaker of test fluid. Equation (3.5-21) becomes

2. Very large gap (RbiRc

2w n

162

Chap. 3

(3.5-26)

Principles of Momentum Transfer and Applications

Substituting Eqs. (3.5-20) and (3.5-26) into (3.5-2)

T 27TR~LK(~r w =

n

(3.5-27)

.~

Again, as before, the flow property constants can be evaluated by plotting log T versus log w. 3. Very narrow gap (RblRc > 0.99). This is similar to flow between parallel plates. Taking the shear rate at radius (Rb + Rc)l2, (3.5-28)

This equation, then, is the same as Eq. (3.5-25). 3.5J Power Requirements in Agitation and Mixing of Non-Newtonian Fluids For correlating the power requirements in agitation and mixing of non-Newtonian fluids the power number N p is defined by Eq. (3.4-2), which is also the same equation used for Newtonian fluids. However, the definition of the Reynolds number is much more complicated than for Newtonian fluids since the apparent viscosity is not constant for non-Newtonian fluids and varies with the shear rates or velocity gradients in the vessel. Several investigators (G I, MI) have used an average apparent viscosity JLo' which is used in the Reynolds number as follows:

, D;Np N Ren = - · . JLa'

(3.5-29)

The average apparent viscosity can be related to the average shear rate or average velocity gradien t by the following method. For a power-I a w fluid, T

=

K(- dv)n dy av

(3.5-30)

Ila(- dydV)

(3.5-31)

For a Newtonian fluid, T =

av

Combining Eqs. (3.5-30) and (3.5-31)

K(dv)n dy av

I

(3.5-32)

Metzner and others (Gl, Ml) found experimentally that the average shear rate (dv/dy) .. for pseudoplastic liquids (n < 1) varies approximately as follows with the rotational speed: = liN (3.5-33) dy av

(dV)

Hence, combining Eqs. (3.5-32) and (3.5-33) JLa Sec. 3.5

Non·Newtonian Fluids

= (11 Nt - I K

(3.5-34) 163

non-Newtonian 100r-------~-------1----_,

60 40 Q'" 20 ~ ~ 10 II

6. 4



1 ap

(} a

ap

1

r sin 0 a

2 cos (} avo)

(} a

(3.7-44)

+ pgq,

(3.7-45)

where in the three equations above.

'12

=

1

a (r2 -a) +

-

ar

ar

~)+

- ' (Sin (} 1 sin 0 ae ao

(}

(a~2)

(3.7-46)

Significant advantages and uses arise in the transformation from rectangular coordinates to cylindrical coordinates. For example, in Eq. (3.7-40) the term pv~/r is the centrifugal force. This gives the force in the r direction (radial) resulting from the motion of the fluid in the 8 direction. Note that this term is obtained automatically from the transformation from rectangular to cylindrical coordinates. It does not have to be added to the equation on physical grounds. The Coriolis force pv rV 01 r also arises automatically in the transformation of coordinates in Eq. (3.7-41). It is the effective force in the (] direction when there is flow in both the r and the 0 directions, such as in the case of flow near a rotating disk. 3.8 3.8A

USE OF DIFFERENTIAL EQUATIONS OF CONTINUITY AND MOTION Introduction

The purpose and uses of the differential equations of motion and continuity, as mentioned previously, are to apply these equations to any viscous-flow problem. For a given specific problem, the terms that are zero or near zero are simply discarded and the remaining equations used in the solution to solve for the velocity, density, and pressure distributions. Of course, it is necessary to know the initial conditions and the boundary conditions to solve the equations. Several examples will be given to illustrate the general methods used. We will consider cases for flow in specific geometri{!s that can easily be described mathematically, such as for flow between parallel plates and in cylinders. 3.8B

Differential Equations of Continuity and Motion for Flow between Parallel Plates

Two examples will be considered, one for horizontal plates and one for vertical plates. EXAMPLE 3.8-1. Laminar Flow Between HorizonUlI Parallel Plates Derive the equation giving the velocity distribution at steady state for laminar flow of a constant-density fluid with constant viscosity which is flowing between two flat and parallel plates. The velocity profile desired is Sec. 3.8

Use of Differential Equations of Continuity and Motion

175

at a point far from the inlet or outlet of the channel. The two plates will be considered to be fixed and of infinite width, with the flow driven by the pressure gradient in the x direction.

Solution: Assuming that the channel is horizontal, Fig. 3.8-1 shows the axes selected with flow in the x direction and the width in the z direction. The velocities vr and vr are then zero. The plates are a distance2yo apart. The continuity equation (3.6-24) for constant density is au" ax Since Vy and

vr

+ !!!!.z + avz = 0 ay

(3.6-24)

az

are zero, Eq. (3.6-24) becomes

av" = 0 ax

(3.8-1)

(3.7-36) 2

Also, avjat 0 for steady state, Vy = 0, Vr = 0, 8vj8x 0, 8 vj8x 2 O. We can see that avj8z 0, ,since there is no change of Vx with z. Then a2 v;rJaz 2 O. Making these substitutions into Eq. (3.7-36), we obtain

ap

ax - pgx =

j1

8 2 v;c ay2

(3.8-2)

In fluid-flow problems we will be concerned with gravitational force only in the vertical direction for gx, which is g, the gravitational force, in mjs2. We shall combine the static pressure p and the gravitational force and call them simply p, as follows (note that g" = 0 for the present case of a horizontal pipe but is not zero for the general case of a nonhorizontal pipe): p = p

+ pgh

(3.8-3)

,>f'

/

t) / ' . I

top plate

2Y ()

Yo

/1

/'

/

/

z

/

--_to_x flow in --,.""'---_ x direction

Yo

bottom plate FIGURE

176

3.8-1. Flow between two parallel plates in Example 3.8-/. Chap. 3

Principles of Momentum Transfer and Applications

where h is the distance upward from any chosen reference plane (h is in the direction opposed to gravity). Then Eq. (3.8-2) becomes

(3.8-4) We can see that p is not a function of z. Also, assuming that 2yo is small, p is not a function of y. (Some references avoid this problem and simply use p as a dynamic pressure, which is rigorously correct since dynamic pressure gradients cause flow. In a fluid at rest the total pressure gradient is the hydrostatic pressure gradient and the dynamic pressure gradient is zero.) Also, iJp/ox is a constant in this problem since Vx is not a function of x. Then Eq. (3.8-4) becomes an ordinary differential equation.

_..!.

d2 v% dp _ dy2/- /1 dx

(3.8-5)

const

Integrating Eq. (3.8-5) once using the condition dvx/dy for symmetry,

dvx dy

__

(..!./1 dx dP)

Y

0 aty

=

0

(3.8-6)

Integrating again using Vx = 0 at y = Yo, 1 dp 2 2 v = - - ( y -y) x 2/1 dx 0

The maximum velocity in Eq. (3.8-7) occurs when y

V.x max

(3.8-7)

= 0, giving (3.8-8)

Combining Eqs. (3.8-7) and (3.8-8),

(3.8-9)

Hence, a parabolic velocity profile is obtained. This result was also obtained in Eq. (2.9-9) when using a shell momentum balance. The results obtained in Example 3.8-1 could also have been obtained by making a force balance on a differential element of fluid and using the symmetry of the system to omit certain terms.

EXAMPLE 3.8-2. Laminar Flow Between Vertical Plates with One PIau Moving A Newtonian fluid is confined between two parallel and vertical plates as shown in Fig. 3.8-2 (W6). The surface on the left is stationary and the other is moving vertically at a constant velocity Vo. Assuming that the flow is laminar, solve for the velocity profile. Sec. 3.8

Use of Differential Equations ofContinuiry alld MOlion

177

H

FIGURE

3.8-2.

Flow between vertical parallel plates in Example 3.8-2.

Solution: The equation to use is the Navier-Stokes equation for the y coordinate, Eq. (3.7-37). av y aVy avy av y) p -+v -+V -+V x ax Y a y ' Z az ( at

(3.7-37)

At steady state, aVylat = O. The velocities Vx and V z = O. Also, = 0 from the continuity equation, aVy/az 0, and pgy = pg. The partial derivatives become derivatives and Eq. (3.7-37) becomes aVyl ay

d 2v J.L

y

--7 -

d

x~

dp dy

-

pg

0

(3.8-10)

This is similar to Eq. (3.8-2) in Example 3.8-1. The pressure gradient dpl dy is constant. Integrating Eq. (3.8-10) once yields

P

dv y

x (d -. -+

dx

J.L . dy

pg

)

(3.8-11)

Integrating again gives (3.8-12)

The boundary conditions are at x = 0, Vy = 0 and at x H, Vy Solving for the constants, C 1 volH (HI2J.L)(dpldy + pg) and O. Hence, Eq. (3.8-12) becomes -

178

P )(Hx 1 (d-+pg

2J.L

dy

Chap. 3

Principles

0/ Momentum

Vo.

(3.8-13)

Trans/er and Applications

3.SC

Differential Equations of Continuity and Motion for Flow in Stationary and Rotating Cylinders .

Several examples will be given for flow in stationary and rotating cyli'nders. EXAMPLE 3.8-3. LAminar Flow in a Circular Tube Derive the equation for steady-state viscous flow in a horizontal tube of radius ro, where the fluid is far from the tube inlet. The fluid is incompressible and J1. is .a . . constanL The flow is driven in one direction by a constantpressure gradient. Solution: The fluid will be assumed to flow in the z direction in the tube, as shown in Fig. 3.8-3. The y direction is vertical and the x direction horizontal. Since v'" and Vy are zero, the continuity equation becomes 8vJ8z = O. For steady state av;Jat 0.> Then substituting into Eq. (3.7-38) for the z component, we obtain'

dp

(3.8-14)

dz

To solve Eq. (3.8-14) we can use cylindrical coordinates from Eq. (3.6-26), giving , Z=Z r =

X

r cos

e

y

e=

+

r

sin 0 (3.6-26)

tan

1

1::: x

Substituting these into Eq. (3.8-14), 1 ov: r or

+--~-+

(3.8-15)

The flow is symmetrical about the z axis so a2vl.lo02 is zero in Eq. (3.8-15). As before, dpldz is a constant, so Eq. (3.8-15) becomes

l ~~ =

const

y

!:r (r ~=)

~:~= + ~ dr

(3.8-16)

x

----'f---- z

direction of flow of fluid

FIGURE

Sec. 3.8

3.8-3. Horizontal flow in a tube in Example 3.8-3.

Use of Differential Equations of Continuity and Motion

179

Alternatively, Eq. (3.7-42) in cylindrical coordinates can be used for the

z component and the terms that are zero discarded. av z auz Ve au z av z) . ap p -+v + +V = ( at r ar r a8 z az oz (3.7-42)

As before, oV7.lat 0, a2ul.lo02 0, Vr = 0, aUl.la8 = 0, av/oz = O. Then Eq. (3.7-42) becomes identical to Eq. (3.8-16). The boundary conditions for the first integration are dVz/dr = 0 at r O. For the second integration, Vr 0 at r = ro (tube radius). The result is dfJ (r2 (3.8-17) 4Jl dz

J...

Converting to the maximum velocity as before, (3.8-18) If Eq. (3.8-17) is integrated over the pipe cross section using Eq. (2.9-10) to give the average velocity v l. av' r~ dp 8Jl dz

(3.8-19)

Integrating to obtain the pressure drop from z = 0 for P = Pl to P = P2 , we obtain

Z =

L for

(3.8-20) where D = 2r o . This is the Hagen-Poiseuille equation derived previously as Eq. (2.9-1 I}.

EXAMPLE 3.8-4. Laminar Flow in a Cylindrical Annulus Derive the equation for steady-state laminar flow inside the annulus between two concentric horizontal pipes. This type of flow occurs often in concentric pipe heat exchangers. Solution: In this case Eq. (3.8-16) also still holds. However, the velocity in the annulus will reach a maximum at some radius r = r max which is between rl and r2' as shown in Fig. 3.8-4. For the first integration of Eq. (3.8-16), the boundary conditions are dVzldr = 0 at r = r max' which gives

velocity profile C=~J-~-----+~I

FIGURE

180

3.8-4. Flow through a cylindrical annulus.

Chap. 3

Principles of Momentum Tran.lfer and Applications

r:;z = (~~~) (r; _r;u)

(3.8-21)

Also, for the second integration ofEq. (3.8-21), v giving 2 rm.~

Repeating the second integration but for r = r 2 , we obtain liz

=

(2)~~)

liz

C; - 2-

In-r)

(3.8-22)

r1

= 0 at the outer wall where

r2 max

In

;J

(3.8-23)

Combining Eqs. (3.8-22) and (3.8-23) and solving for r max r rna:\

In (r 2

) (d - ri)/2

(3.8-24)

In Fig. 3.8-4 the velocity profile predicted by Eq. (3.8-23) is plotted. For the case where rl = 0, r max in Eq. (3.8-24) becomes zero and Eq. (3.8-23) reduces to Eq. (3.8-17) for a single circular pipe. EXAMPLE 3.8-5.

Velocity Distribution/or Flew Between Coaxial Cylinders

Tangential laminar flow of a Newtonian fluid with constant density is occurring between two vertical coaxial cylinders in which the outer one is rotating (S4) with an angular velocity of was shown in Fig. 3.8-5. It can be assumed that end effects can be neglected. Determine the velocity and the shear stress distributions for this flow. Solution: On physical grounds the fluid moves in a circular motion and the velocity v r in the radial direction is zero and v z in the axial direction at steady state. There is no pressure gradient in is zero. Also, ap/at = the e direction. The equation of continuity in cylindrical coordinates as derived before is

°

ap

I a(prv r)

at

r

-+

ar

1 a(pve)

a(pv )

z + ---+--= 0 r

ae

(3.6-27)

dZ

outside cylinder rotates inside cylinder ~fixed

FIGURE

Sec. 3.8

3.8-5.

Laminar flow in the region between two coax.ial cylinders in Example 3.8-5.

Use of Differential Equations of Continuity and Motion

181

All tenns in this equation are ze(o. The equations of motion il.1 cyjindIical coordinates, Eqs. (3.7-40), (3.7-41), and (3.7-12J tedrl!€ to J~ folli>*ing, respectively: 2

'V9

iJp

r

iJr

-p-=

o 0=

d

(r-corriponent)

(~ d(r'V 9»)

dr

r

dr

iJp

+

iJz

pgz

(3.8-25)

«(J -component)

( z-component)

(3.8-26)

(3.8-27)

Integrating Eq. (3.8-26), (3.8-28)

To solve for the integration constants eland c 2, the following boundary conditions are used: at r = Rlt v£! = 0; at r = R z • ve = wR z . The final equation is v -

e-

(3.8·29)

(R~

Using the shear-stress component for Newtonian fluids in cylindrical coordinates, =

T

-11.

r£!

r

[r i)(volr) + dr

~ dV r ] r dO

(3.7-31)

The last term in Eq. (3.7-31) is zero. Substituting Eq. (3.8-29) into (3.7-31) and differentiating gives (3.8-30)

The torque T that is necessary to rotate the outer cylinder is the product of the force times the lever arm.

(3.8-31)

where H is the length of the cylinder. This type of device has been used to measure fluid viscosities from observations of angular velocities and torque and also has been used as a model for some friction bearings. 182

Chap. 3

Principles of Momentum Transfer and Applications

EXAMPLE 3.8-6. Rotating Liquid in a Cylindrical Container A Newtonian fluid of constant density is in a vertical cylinder of radius R (Fig. 3.8-6) with the cylinder rotating about its axis at angular velocity w (B2). At steady state find the shape of the free surface. Solution: The system can be described in cylindrical coordinates. As in Example 3.8-5, at steady state, v, t': = 0 and g, = glJ = O. The final equations in cylindrical coordinates given below are the same as Eqs. (3.8-25) to (3.8-27) for Example 3.8-5 except that g l -gin Eq. (3.8-27).

z

ap ar

V8 P r

o= ap az

(3.8-32)

p.,!!.. (~ a(rVIJ») . ar r

ar

(3.8-33)

(3.8-34)

= -pg

Integration of Eq. (3.8-33) gives the same equation as in Example 3.8-5.

V8

= C Jr

+

CZ

(3.8·28)

r

The constant C 2 must be zero since v B cannot be infinite .11t r= O. At r= R, the velocity v I) = R w. Hence, C 1 wand we obtain V(J

(3.8·35)

wr

Combining Eqs. (3.8-35) and (3.8-32)

ap ar

?

pw -r

(3.8-36)

p = Po at sw-face p

FIGURE

Sec. 3.8

3.8-6.

=p(r,Z)

Liquid being rotated in a container with a free surface in Example 3.8-6.

Use of Differential Equations of Continuity and Motion

183

Hence, we see that Eqs. (3.8-36) and (3.8-34) show that pressure depends upon r because of the centrifugal force and upon z because of the gravitational force. . (3.8-34) Since the term P is a function of position we can write the total differential of pressure as iJp

dp = -

iJr

dr +

ap az

dz

(3.8-37)

Combining E:qs. (3.8-34) and (3.8-36) with (3,8-37) and integrating, p

(3.8-38)

The constant of integration can be determined since p z ZOo The equation becomes

Po at r

= 0 and

pw 2 r2 P-Po

~+pg(zo

z)

(3.8-39)

The free surface consists of all points on this surface at p = PO' Hence,

}'"". .'

(3.8-40)

This shows that the free surface is in the shape of a parabola,

3.9

3.9A

OTHER METHODS FOR SOLUTION OF DIFFERENTIAL EQUATIONS OF MOTION Introduction

In Section 3,8 we considered examples where the Navier-Stokes differential equations of motion could be solved analytically. These cases were used where there was only one nonvanishing component of the velocity. To solve these equations for flows in two and three directions is quite complex. In this section we will consider some approximations that simplify the differential equations to allow us to obtain analytical solutions. Terms will be omitted which are quite small compared to the'terms retained. Three cases will be considered in this section: in viscid flow. potential flow, and creeping flow. The fourth case, for boundary-layer flow, will be considered in Section 3.10. The solution of these equations may be simplified by using a stream function IjI(x, y) and/or a velocity potential 1>(x, y) rather than the terms of the velocity components V X ' v Y ' and v z . 184

Chap.3.

Principles of Momentum Transfer and Applications

3.9B

Stream Function

The stream function !fJ(x, y) is a convenient parameter by which we can represent two-dimensional, steady, incompressible flow. This stream function, '" in m 2 /s, is related to the velocity components'J}x and Vy by

a",

v

v =-

:=o-

ay

X

y

a",

(3.9-1)

ax

These definitions of vx and Vy can then be used in the x and y components of the differential equation of motion, Eqs. (3.7-36) and (3.7-37), with V z 0 to obtain a differential equation for'" that is equivalent to the Navier-Stokes equation. Details are given elsewhere (B2). The stream function is very useful because its physical significance is that in steady flow lines defined by '" constant are streamlines which are the actual curves traced out by the particles of fluid. A stream function exists for all two-dimensional, steady, incompressible flow whether viscous or inviscid and whether rotational or irrotational. EXAMPLE 3.9-1. Stream Function and Streamlines The stream function rc:lationship is given as '" xy. Find the equations for the components of velocity. Also plot the streamlines for a constant", = 4 and", = 1. Solution:

Using Eq. (3.9-1), a!/J

a(xy)

v =x

--=x

ay

ay

a!/J

a(xy)

ax

ax

:=

xy, assume that

constant

To determine the streamline for !/J y 0.5 and solve for x. !/J

-y

xy

x(0.5)

Hence, x 2. Repeating, for y 1, x := 1; for y = 2, x = 0.5; for y = = 0.2, etc. DQing the same for'" = constant = 4, the streamlines for "!/J 1 and!/J 4 are plotted in Fig. 3.9-1. A possible flow model is flow around a comer.

5, x

3.9C

Differential Equations of Motion for Ideal Fluids (Inviscid Flow)

Special equations for ideal or inviscid fluids can be obtained for a fluid having a constant density and zero viscosity. These are called the Euler equations. Equations (3.7-36)-(3.7-39) for the x, y, and z components of momentum become

ap ax

Sec. 3.9

+ pgx

Other Methods for Solution of Differential Equations of Motion

(3.9-2)

185

J

y

o

2

1

3

5

4

x FIGURE

3.9·1. Plot of streamlilt~s for l/!

au y ( at

av y y ay

aUy ax

xy for Example 3.9-1.

auy) az

p -+u -+v -+v -

p

av l

~

( at

x

+ Vx

av z ' -

ax

+

av z

Vy -

ay

Z

+ Vz

av z)

~

az

(3.9-3)

ap -

az

+

pg

(3.9-4) l

At :very high Reynolds numbers the viscous forces are quite small compared to the inertia forces and the viscosity can be assumed as zero. These equations are useful in calculating pressure distribution at the outer edge of the thin boundary layer in flow past immersed bodies. Away from the surface outside the boundary layer this assumption of an ideal fluid is often valid. 3.9D

Potential Flow and Velocity Potential

The velocity potential or potential function problems and is defined as

a4>

v =x

ax

v

4>( x ,y)

04> = 'I ay

in m 2/s is useful in inviscid flow

a4>

oz

(3.9-5)

This potential exists only for a flow with zero angular velocity, or irrotationality. This type of flow of aI1Jdeal or inviscid fluid (p constant, fL = 0) is called potentialflo w . Additionally, the velocity potential exists for three-dimensional flows, whereas the stream function does not. The vorticity of a fluid is defined as follows: (3.9-6)

or, (3.9-7)

186

Chap. 3

Principles of Momentum Transfer and Applications

v

where 2wz is the vorticity and W z in s -I is angular velocity about the z axis. If 2 W z = 0, the flow is irrotational and a potential function exists. Using Eq. (3.6-24), the conservation of mass equation for flows in the x and the y direction is as follows for constant density:

(3.9-8) Differentiating Vx in Eq. (3.9-5) with respect to substituting into Eq. (3.9-8),

and

x

Vy

with respect to y and

(3.9-9) This is Laplace's equation in rectangular coordinates. If suitable boundary conditions exist or are known, Eq. (3.9-9) can be solved to give 4>(x, y). Then the velocity at any point can be obtained using Eq. (3.9-5). Techniques for solving this equation include using numerical analysis, conformal mapping, and functions of a complex variable and are given elsewhere (B2, S3). Euler's equations can then be used to find the pressure distribution. . When the flow is inviscid and irrotational a similar type of Laplace equation is obtained from Eq. (3.9-7) for the stream function.

(3.9-10) Lines of constant 4> are called equal potential lines and for potential flow are everywhere perpendicular (orthogonal) to lines of constant t/!. This can be proved as follows. A line of constant I/! would be such that the change in I/! is zero.

at/!

aI/!

ax

ay

-dx + -

o

dy

(3.9-11)

Then, substituting Eq. (3.9-1) into the above,

(:;)

~

(3.9-12) = constant

Also, for lines of constant , d =

a4>

ax

dx +

a

ay

dy

=

0

(~~) • " 00."""'

(3.9-13)

(3.9-14)

Hence,

(dyldx)tJt Sec. 3.9

(3.9-15) constant

Other i'vl ethods for Solution of Differential Equations of MOlion

187

An example of the use of the stream function is in obtaining the flow pattern for inviscid, irrotational flow past a cylinder of infinite length. The fluid approaching the cylinder has a steady and uniform velocity of v", in the x direction. Laplace's Equation (3.9-10) can be converted to cylindrical coordinates to give a 2 cjJ

1 acjJ"'

1 a 2 cjJ

r ar

r2 ae

+--+--=0 2

(3.9-16)

where the velocity components are given by 1 acjJ Vr

r

V£I

ao

(3.9 .. 17)

ar

Using four boundary conditions which are needed and the method of separation of variables, the stream function cjJ is obtain~d. Converting to rectangular coordinates .""

VOOY(l - 2R2 2) X +Y

(3.9-18)

where R is the cylinder radius. The streamlines and the constant velocity potential lines are plotted in Fig. 3.9-2 as a flow net. EXAMPLE 3.9-2. Stream FunctionJor a Flow Field The velocity components for a flow field are as follows: Vy =

-:2axy

Prove that it satisfies the conservation of mass and determine cjJ. Solution: First we determine av;,J ax 2ax and aVyl ay = 2ax. Substituting these values into Eq. (3.6-24), the conservation of mass for two-dimensional flow, aV x

-

ax

av y

+-

ay

0

or

2ax

2ax = 0

6:::: constant

FIGURE

3.9-2.

Streamlines (ifJ = constant) and constant velocity potential lines ( = constant) for the steady and irrotational flow of an inviscid and incompressible fluid about an infinite circular cylinder.

188

Chap. 3

Principles of Momentum Transfer and Applications

Then using Eq. (3.9-1),

v

x

aif! = -ay= ax 2

ay2

v·= Y

aif! --= ax

-2axy

Integrating Eq. (3.9-19) for vx

., ay3 ax-y 3

+ j(x)

(3.9-20)

Differentiating Eq. (3.9-20) with respect tox and equating it to Eq. (3.9-19), a!f;

- = 2axy

ax

0 + !'(x)

=

+2axy

(3.9-21)

Hence,!,(x)=0 andf(x)=C, a constant. Then Eq. (3.9-20) becomes ax 2y -

ay3 3

+C

(3.9-22)

To plot the stream function, the constant C can be set equal to zero before plotting. . In potential flow, the stream function and the potential function are used to represent the flow in the main body of the fluid. These ideal fluid solutions do not satisfy the condition that Vx = Vy = 0 on the wall surface. Near the wall we have viscous drag and we use boundary-layer theory where we obtain approximate solutions for the velocity profiles in this thin. boundary layer taking into account viscosity. This is discussed in Section 3.10. Then we splice this solution onto the ideal flow solution that describes flow outside the boundary layer. 3.9E

Differential Equations of Motion for Creeping Flow .

At very low Reynolds numbers below about 1, the term creeping flow is used to describe flow at very low velocities. This type of flow applies for the fall or settling of small particles through a fluid. Stokes' law is derived using this type of flow in problems of settling and sedimentation. In flow around a sphere, for example, the fluid changes velocity and direction in a complex manner. If the inertia effects in this case were important, it would be necessary to keep all the terms in the three Navier-Stokes equations. Experiments show that at a Reynolds number below about 1, the inertia effects are small and can be omitted. Hence, the equations of motion, Eqs. (3.7-36)-(3.7-39) for creeping flow of an incompressible fluid, become

2 2 2V iJ v iJ v ) Jl iJx: + iJi + iJ/

iJp ay

2 2 (iJ:::....::1'.+:::....::1'.+:::....::1'. V a v alv ) al iJl y z 2 2 a vz + __ a vz ) Jl (PV ---.!. + __ 2 iJx iJy2 iJ z 2

iJp az Sec. 3.9

C

iJp iJx

Jl ox ~l

Other Methods for Solution of Differential Equations of Motion

(3.9-23)

(3.9-24)

(3.9-25)

189

For flow past a sphere the stream function", can be used in the Navier-Stokes equation in spherical coordinates to obtain the equation for the stream function and the velocity distribution and the pressure distribution over the sphere. Then by integration over the whole sphere, the form drag, caused by the pressure distribution, and the skin friction or viscous drag, caused by the shear stress at the surface, can be summed to give the total orag. (SI) F D = 37rJlD p v (3.9-26) FD =

37rJ1D v

p _.'--L-

gc

(English)

where F D is total drag force in N, Dp is particle diameter in m, v is free stream velocity of fluid approaching the sphere in mis, and J1 is viscosity in kg/m· s. This is Stokes' equation for the drag force on a sphere. Often Eq. (3.9-26) is rewritten as fol~()ws: F D = CD

v2

"2 pA v2

FD=CD-pA

2gc

(SI) (3.9-27)

(English)

where CD is a drag coefficient, which is equal to 24/N Re for Stokes' law, and A is the projected area of the sphere, which is nD~ 14. This is discussed in more detail in Section 3.1 for flow past spheres.

3.10

3.lOA

BOUNDARY-LAYER FLOW ANI;> TURBULENCE Boundary-Layer Flow

In Sections 3.8 and 3.9 the Navier-Stokes equations were used to find relations that described laminar flow between flat plates and inside circular tubes, flow of ideal fluids, and creeping flow. In this section the flow of fluids around objects will be considered in more detail, with particular attention being given to the region close to the solid surface, called the boundary layer. In the boundary-layer region near the solid, the fluid motion is greatly affected by this solid surface. In the bulk of the fluid away from the boundary layer the flow can often be adequately described by the theory of ideal fluids with zero viscosity. However, in the thin boundary layer, viscosity is important. Since the region is thin, simplified solutions can be obtained for the boundary-layer region. Prandtl originally suggested this division of the problem into two parts, which has been used extensively in fluid dynamics. In order to help explain boundary layers, an example of boundary-layer formation in the steady-state flow of a fluid past a flat plate is given in Fig. 3.10-1. The velocity of the fluid upstream of the leading edge at x = 0 of the plate is uniform across the entire fluid stream and has the value Dx . The velocity of the fluid at the interface is zero and the velocity V;c in the x direction increases as one goes farther from the plate. The velocityv;c approaches asymptotically the velocity Vro of the bulk of the stream. The dashed line L is drawn so that the velocity at that point is 99% of the bulk velocity Vro' The layer or zone between the plate and the dashed line constitutes the boundary layer. When the flow is laminar, the thickness r5 of the boundary layer increases

190

Chap. 3

Principles of Momentum Transfer and Applications

x

o

laminar boundary layer FIGURE

transition zone

3.10-1. Boundary layer for flow past a flat plate.

Jx

with the as we move in the X/direction. The Reynolds number is defined as N Re. x xv"" pifl, where x is the distance downstream from the leading edge. When the Reynolds number is less than 2 x 10 5 the flow is laminar, as shown in Fig. 3.10-\. The transition from laminar to turbulent flow on a smooth plate occurs in the Reynolds number range 2 x 10 5 to 3 X 106 , as shown in Fig. 3.10-1. When the boundary layer is turbulent, a thin viscous sublayer persists next to the plate. The drag caused by the viscous shear in the boundary layers is called skin friction and it is the only drag present for flow past a flat plate. The type of drag occurring when fluid flows by a bluff or blunt shape such as a sphere or cylinder, which is mostly caused by a pressure difference, is termed form drag. This drag predominates in flow past such objects at all except low values of the Reynolds numbers, and often a wake is present. Skin friction and form drag both OCCllr in flow past a bluff shape, and the total drag is the sum of the skin friction and the form drag: (See also Section 3.IA). 3.10B

Boundary-Layer Separation and Formation of Wakes

We discussed the growth of the boundary layer at the leading edge of a plate as shown in Fig. 3.10-2. However, some important phenomena also occur at the trailing edge of this plate and other objects. At the trailing edge or rear edge of the flat plate, the boundary layers are present at the top and bottom sides of the plate. On leaving the plate, the boundary layers gradually intermingle and disappear.

=====:;~ ---:- ~i5)------FIGURE 3.10--2.

Sec. 3.10

Flow perpendicular to a flat plate a!ld boundary-layer separation.

Boundary-Layer Flow and Turbulence

191

If the direction of flow is at right angles to the plate as shown in Fig. 3.10-2, a boundary layer forms as before in the fluid that is flowing over the upstream face. Once at the edge of the plate, however, the momentum in the fluid prevents it from making the abrupt turn around the edge of the plate, and it separ;ates from the plate. A zone of decelerated fluid is present behind the plat~.and large eddies (vortices), called the wake, are f0rmed in this area. The eddies consume large amounts of mechanical energy. This separation of boundary layers occurs when the change in velocity of the fluid flowing by an object is too large in direction or magnitude for the fluid to adhere to tbe surface. Since formation of a wake causes large losses in mechanical energy, it is often necessary to minimize or prevent boundary-layer separation by streamlining the objects or by other means. This is also discussed in Section 3.1 A for flow past immersed objects. 3.1OC

Laminar Flow and Boundary-Layer Theory

1. Boundary-layer equations. When laminar flow is occurring in a boundary layer, certain terms in the Navier-Stokes equations become negligible and can be neglected. The thickness of the boundary layer 0 is arbitrarily taken as the distance away from the surface where the velocity reaches 99% of the free stream velocity_ The concept of a relatively thin boundary layer leads to some important simplifications of the NavierStokes equations. For two-dimensional laminar .flow in the x and y directions of a fluid having a constant density, Eqs. (3.7-36) and (3.7-37) become as follows for flow at steady state as shown in Figure 3.10-1 when we neglect the body forces g x and g y'

v av" + v av" = _! op + !!. (aZv"2 + aZvx ) x ax Y oy Pox P ox ay2 2 v ov + v au = _! op +!:!. (a v2 + olv " ox Y oy P ay P ax al y

y

y

y)

(3.10-1)

(3.10-2)

The continuity equation for two-dimensional flow becomes

-ou" + ~ =

ox

oy

(3.10-3)

0

In Eq. (3.10-1), the term ILl pea 2 vxl ax 2) is negligible in comparison with the other terms in the equation. Also, it can be shown that all the terms containing Vy and its derivatives are smaiL Hence, the final two boundary-layer equations to be solved are Eqs. (3.10-3) and (3.10-4).

au ax

x v,,-+ u y

av" oy

-=

1 p

dp dx

Jl p

a v" ay2 2

---+---

(3.10-4)

2. Solution for laminar boundary layer on a flat place. An important case in which an analytical solution has been obtained for the boundary-layer equations is for the laminar boundary layer on a flat plate in steady flow, as shown in Fig. 3.10-1. A further simplification can be made in Eq. (3.10-4) in that dpldx is zero since v", is constant. The final boundary-layer equations reduce to the equation of motion for the x direction and the continuity equation as follows: u"

au, au" Jl OlU" ax + Vy oy = P ol vv" + ~ = 0 ax oy

192

Chap. 3

(3.10-5)

(3.10-3)

Principles of Momentum Transfer and Applications

The bOlpl;da!u,onditions are Vx Vy = 0 at y = 0 (y is distance from plate), and Vx :. ... ...... .. aty =' cO.- .. The solution of this problem for laminar flow over a flat plate giving v" and Vy as a function of x and y was first obtained·by Blasius and later elaborated by Howarth (BI, B2, S3). The mathematical details of the solution are quite tedious and complex and will not be given here. The general proc:edure will be outlined. Blasius reduced the two equations to a single ordinary differential equation which is nonlinear. The equation could not be solved to give a closed form but a series solution was obtained. The results of the work by Blasius are given as follows. The boundary-layer thickness 0, where v, ;;;; 0.99voo, is given approximately by ~

"

'~

'

o=

= 5.0

5.0x

JN

J

flX

(3.10-6)

pVoo

Re • x

Jx.

where N Re. x = xv oop/p. Hence, the thij::kness 0 varies as The drag in flow past a flat plate"consists only of skin friction and is calculated from . the shear stress at the surface ~J y = 0 for any x as follows. ,

- p 0-

(-avay

x)

(3.10-7)

y;O

From the relation of v", as a function of x and y obtained from the series solution, Eq. (3.10-7) becomes '0 = 0.332pvoo

JPVpx

oo

(3.10-8)

The total drag is given by the following for a plate of length L and width b: FD

=b

1\0

(3.10-9)

dx

Substituting Eq. (3.10-8) into (3.10-9) and integrating, FD

The drag coefficient A bL is defined as

=

O.664bJ ppv;, L

(3.10-10)

related to the total drag on one side of the plate having an area

FD=C D 2 pA

(3.10-11)

Substituting the value for A and Eq. (3.10-10) into (3.10-11), CD = 1.328

1.328

(3.10-12)

1/ 2 N Re. L

where N Re. L = LVpllL. A form of Eq. (3.10-11) is used in Section 14.3 for particle movement through a fluid, The definition of CD in Eq. (3.10-12) is similar to the Fanning friction factor f for pipes. The equation derived for CD applies only to the laminar boundary layer for N Re • L less than about 5 x !O5. Also, the results are valid only for positions where x is sufficiently far from the leading edge so that x or L is much greater than o. Experimental results on the drag coefficient to a flat plate confirm the validity of Eq. (3.10-12). Boundary-layer flow past many other shapes has been successfully analyzed using similar methods. Sec. 3.10

Boundary-Layer Flow and Turbulence

193

3.10D Nature and Intensity of Tnrbulence I. Nature of turbulence. Since turbulent flow is important in many areas of engineering. the nature of turbulence has been extensively investigated. Measurements of the velocity fluctuations of the eddies in turbulent flow h~ve helped explain turbulence. For turbulent flow there are no exact solutions of flow problems as there are in laminar flow, since the approximate equations used depend on many assumptions. However, useful relations have been obtained by using a combination of experimental data and theory. Some of these relations will be discussed. Turbulence can be generated by contact of two layers of fluid moving at different velocities or by a flowing stream in contact with a solid boundary, such as a wall or sphere. When a jet of fluid from an orifice flows into a mass of fluid, turbulence can arise. In turbulent flow at a given place and time large eddies are continually being formed which break down into smaller eddies and which finally disappear. Eddies are as small as about 0.1 or 1 mm or so and as large as the smallest dimension of the turbulent stream. Flow inside an eddy is laminar because of its large size. In turbulent flow the velocity is fluctuating in aU directions. In Fig. 3.10-3 a typical plot of the variation of the instantaneous velcity Dx in the x direction at a given point in turbulent flow is shown. The velocity D~ is the deviation of the velocity from the mean velocity Ox in the x-direction of flow of the stream. Similar relations also hold for the y and z directions.

i.i = -1 x t

l' 0

(3.10-13) D

x

dt

(3.10-14)

where the mean velocity Ox is the time-averaged velocity for time t, Dx the instantaneous total velocity in the x direction, and v~ the instantaneous deviating or fluctuating velocity in the x direction. These fluctuations can also occur in the y and z directions. The value of v~ fluctuates about zero as an average and, hence, the time-averaged values ~ 0, 0, O. However, the values .of D~2•. V~2, and V~2 will not be zero. Similar expressions can also. be written for pressure. ;Vhich also fluctuates.

v;

v;

2. Intensity of turbulence. The time average Df the fluctuating components vanishes over a time period of a few seconds. However, the time average of the mean square of the fluctuating components is a pDsitive value. Since the fluctuations are random, the data have been analyzed by statistical methods. The level or intensity Df turbulence can be

OL----------L----------------------Time

FIGURE

194

3.10-3. Velocity jluclllatiolls in turbulent flow.

Chap. 3

Principles of ,"domentUf/l Transfer and ApplicatiollS

related to the sq uare root of the sum of the mean squares of the fluctuating components. This intensity of turbulence is an important parameter in testing of models and theory of boundary layers. The intensity of turbulence I can be defined mathematically as I = VJYiP ·3~ "

+ 112r + V'2) z u"

(3.10-15)

This parameter [ is quite important. Such factors as boundary-layer transition, separation, and heat- and mass-transfer coefficients depend upon the intensity of turbulence. Simulation of turbulent flows in testing of models requires that the Reynolds number and the intensity of turbulence be the same. One method used to measure intensity of turbulence is to utilize a hot-wire anemometer.

3.10E Turbulent Shear or Reynolds,Stresses In a fluid flowing in turbulent flow shear forces occur wherever, there is a velocity gradient across a shear plane and these are much larger than those occurring in laminar flow. The velocity fluctuations in Eq:(3.IO-13) give rise to turbulent shear stresses. The equations of motion and the continuity equation are still valid for turbulent flow. For an incompressible fluid having a constant density p and viscosity fL, the continuity equation 0.6-24) holds. au ox

5

ov.

-.x +. +--=0

(3.6-24)

oz

oy

Also, the x component of the equation of motion, Eq. (3.7-36), can be written as follows if Eq. (3.6-24) holds:

at

+ _-"-=~

u"

+

o(pu" v) o(pv" v=) = ~ , uy oz

(02

p

02 V,,) _

02V",

",

P.ox 2· + uy ~ 2 + " 2 uZ

;,

ux

+ pg"

(3.10-16)

We can rewrite the continuity equation (3.6-24) and Eq. (3.10-16) by replacing 15" + v~, Vy by iiy + v~, Vz by 15= + v:, and p by P+ p' .

Vx

by

(3.10-17) 8[p(v" + v~)] • ot

+ o[p{u" + u~){ux + v~)J +

ox

+

o[p(vx

-=~::"---"::":""'----L=

+ v~)(v= + v:n

az

oy

2 _

=

j1V (v"

,

+ vJ

a(p + p') + pg"

ax

(3.10-18)

Now we use the fact that the time-averaged value of the fluctuating velocities is zero v-:.' v~z are zero), and that the time-averaged product v~ v~ is not zero. Then Eqs. (3.10-17) and (3.10-18) become au" avy avo 0 (3.10-19)

(~,

-+-+-ax oy oz

8(pi5,,) iJ{pif. vv) __ + o{pv" if,,) + ' + o(pv" v.). at ax oy oz T

+ Sec. 3.10

[ O(pV~ax v~) + o(pv~oy v~) + O(P~)J OZ

Boundary-Layer Flow and Turbulence

-

ax + pg"

(3.10-20)

195

By comparing these two time-smoothed equations with Eqs. (3.6-24) and (3.10-16) we see that the time-smoothed values everywhere replace the instantaneous values. However, in Eq. (3.10-20) new terms arise in the set of brackets which are related to turbulent velocity fluctuations. For convenience we use the notation (3.10-21) These are the components of the turoulent momentum flux and are called Reynolds stresses. 3.10F

Prandtl Mixing Length

The equations derived for turbulent flow must be solved to obtain velocity profiles. To do this, more simplifications must be made before the expressions for the Reynolds stresses can be evaluated. A number of semiempirical equations have been used and the eddy diffusivity model of Boussinesq is one' early attempt to evaluate these stresses. By analogy to the equation for shear stres~ in laminar flow, TyX = - p.(dv,Jdy), the turbulent shear stress can be written as (3.10-22) where 1], is a turbulent or eddy viscosity, which is a strong function of position and flow. This equation can also be written as follows:

pc,

dy

(3.10-23)

where e, = I)'/p and e, is eddy diffusivity of momentum in mlls by analogy to the momentum diffusivity p.lp for laminar flow. Prandtl in his mixing-length model developed ;In expression to evaluate these stresses by assuming that eddies move in a fluid in a manner similar to the movement of molecules in a gas. The eddies move a distance called the mixing length L before they lose their identity. Actually, the moving eddy or "lump" of fluid will gradually lose its identity. However, in the definition of the Prandtl mixing-length L, this small packet of fluid is assumed to retain its identity while traveling the entire length L and then to lose its identity or be absorbed in the host region. Prandtl assumed that the velocity fluctuation v~ is due to a "lump" offiuid moving a distance L in the y direction and retaining its mean velocity. At point L, the lump of fluid will differ in mean velocity from the adjacent fluid by uxl y +L uxl Y ' Then, the value of v~IY is (3.10-24) The length L is small enough so that the velocity difference can be written as (3.10-25) Hence, v' x

196

Chap. 3

=L

dux dy

(3.10-26)

Principles of Momentum Transfer and Applications

Prandtl also assumed v~ ~ v~. Then the time average, v~ x~, is

"

_ Lzi dvx

I

dv", dy dy

Vx Vy

(3.10-27)

The minus sign and the absolute value were used to make the quantity v~ v~ agree with experimental data. Substituting Eq. (3.10-27) into (3.10-21), tof. Y'"

=

I

dux dux -p Lzi dy dy

(3.10-28)

Comparing with Eg. (3.10-23), (3.10·29)

3.1OG

Universal Velocity Distribution in Turbulent Flow

To determine the velocity distribution for turbulent flow at steady state inside a circular tube, we divide the fluid inside the pipe into two regions: a central core where the Reynolds stress approximately equals the shear stress; and a thin, viscous sublayer adjacent to the wall where the shear stress is due only to viscous shear and the turbulence effects are assumed negligible. Later we include a third region, the buffer zone, where both stresses are important. Dropping the subscripts and superscripts on the shear stresses and velocity, and considering the thin, viscous sublayer, we can write

dv dy

(3.10·30).

to = - Jl -

where to is assumed constant in this region. On integration, (3.10-31)

toY = JlV

Defining a friction velocity as follows and substituting into Eq. (3.10-31) v*

f:

v

yv·

v*

Jl/p

(3.10-32)

---

(3.10-33)

The dimensionless velocity ratio on the left can be written as

fP

v+ = v

(SI)

~~

(3.10-34) (English)

The dimensionless number on the right can be written as

y

(SI)

J1

(3.10·35) (English) J1

Sec. 3./0

Boundary-Layer Flow and Turbulence

197

where y is the distance from the wall of the tube. For a tube of radius ro, y = ro - r, where r is the distance from the center. Hence, for the viscous sublayer, the velocity distribution is (3.10-36)

Next, considering the turbulent core where any viscous stresses are neglected, Eq. (3.10-28) becomes

,= pe(:~y

(3.10-37)

where dv/dy is always positive and the absolute value sign is dropped. Prandtl assumed that the mixing length is proportional to the distance from the wall, or L= Ky

and that

T

=

TO

=

(3.10-38)

constant. Equation (3.10-37) now becomes (3.10-39)

Hence, dv v* = Kydy

(3.10-40)

Upon integration, v* In y = Kv where K 1 is a constant. The constant K small value of y, say Yo . v

-=

v*

1

+

(3.10-41)

Kl

can be found by assuming that v is zero at a

+ 1 y v =-InK Yo

(3.10-42)

Introducing the variable y+ by multiplying the numerator and the denominator of the we obtain term y/Yo by v*/v, where v =

pip,

v+

v

+

1 K

= -

=

(yv* In -

1 + -In y K

YOv*)

In - -

l!

(3.10-43)

l!

+ C1

(3.10-44)

;;':"0: A large amount of velocity distribution data by Nikuradse and others for a range of Reynolds numbers of 4000 to 3.2 x 10 6 have been obtained and the data fit Eq. (3.10-36) in the region up to y+ of 5 and also fit Eq. (3.10-44) above Y+ of30 with K and C 1 being universal constants. For the region of y + from 5 to 30, which is defined as the buffer region, an empirical equation of the form of Eq. (3.10-44) fits the data. In Fig. 3.10-4 the following relations which are valid are plotted to give a universal velocity profile for fluids flowing in smooth circular tubes.

v+ = y+

198

(0

< y+ < 5)

v+

= 5.0 In

v+

= 2.5 In y+ + 5.5

y+ - 3.05

Chap. 3

(3.10-45)

(5 < y+ < 30)

(3.10-46)

(30 < y+)

(3.10-47)

Principles of Momentum Transfer and Applications

20r--------r--------.-----------~

viscous sublayer

buffer layer

turbulent7""'-_Joi core

I

15 ' - Eq. (3.10-47)

' - Eq. (3.10-46)

5

01

I 2 34 5/10

20 30 50 100 200 400 y+

FIGURE

3.10-4. Universal velocity profile for turbulent flow in smooth circular tubes.

Three distinct regions are apparent in Fig. 3.10-4. The first region next to the wall is the viscous sublayer (historically called "laminar" sublayer), given by Eq. (3.10-45), where the velocity is proportional to the distance from the wall. The second region, called the buffer layer, is given by Eq. (3.10-46), which is a region of transition between the viscous sublayer with practically no eddy activity and the violent eddy activity in the turbulent core region given by Eq. (3.10-47). These equations can then be used and related to the Fanning friction factor discussed earlier in the chapter. They can also be used in solving turbulent boundary-layer problems. 3.10H

Integral Momentum Balance for Boundary-Layer Analysis

1. Introduction and derivation of integral expression. In the solution for the laminar boundary layer on a flat plate, the Blasius solution is quite restrictive, since it is for laminar flow over a flat plate. Other more complex systems cannot be solved by this method. An approximate method developed by von Karm{m can be used when the configuration is more complicated or the flow is turbulent. This is an approximate momentum integral analysis of the boundary layer using an empirical or assumed velocity distribution. t.: In order to derive the basic equation for a laminar or turbulent boundary layer, a small control volume in the boundary layer on a flat plate is used as shown in Fig. 3.10-5. The depth in the z direction is b. Flow is only through the surfacesA I andA z and also from the top curved surface at J. An overall integral momentum balance using Eq. (2.8-8) and overall integral mass balance using Eq. (2.6-6) are applied to the control volume inside the boundary layer at steady state and the final integral expression by von Karman is (B2, S3) (3.10-48) where TO is the shear stress at the surface y = 0 at point x along the plate. Also, J and TO are functions of x. Equation (3.10-48) is an expression whose solution requires knowledge of the velocity Sec. 3.10

Boundary-Layer Flow and Turbulence

199

Vx as a function of the distance from the surface, y. The accuracy of the results will, of course, depend on how closely the assumed velocity profile approaches the actual profile.

2. Integral momentum balance for laminar boundary layer.

Before we use Eq. (3.10-48) for the turbulent boundary layer, this equation will be applied to the laminar boundary layer over a flat plate so that the results can be compared with the exact Blasius solution in Eqs. (3.10-6)-(3.10-12). In this analysis' certain boundary conditions must be satisfied in the boundary layer. at y = 0

0

Ux =

::::::0 dy -

at y

= {)

at y

= {)

(3.10-49)

The conditions above are fulfilled in the following simple, assumed velocity profile.

:: =~~~~(~y

(3.10-50)

The shear stress!o at a given x can be obtained from

. "!

(dUX)

-p-

(3.10-51)

dy y~O

0-

Differentiating Eq. (3.IO-50) with respect to y and setting y

dUX) ( dy y=O

0, (3.10-52)

2{)

Substituting Eg. (3.10-52) into 0.10-51), !

y

3pu oo

(3.10-53)

---

0-

215

o and

Substituting Eq. (3.10-50) into Eq. 0.10-48) and integrating between y 0, we obtain db

280!o

dx

39 u~p

(3.10-54)

Combining Egs. (3.10-53) and (3.10-54) and integrating between 0 = 0 and 0 = 0, and x 0 and x = L,

y

z

/ b

oWo.::..------"----"'-----L..-L:.._x Xl FIGURE 3.IO-S.

200

x2

Control volume for integral analysis of the boundary-layer flow.

Chap. 3

Principles of Momentum Transfer and Applications I"

(5

4.64

J

(3.10-55)

J-lL pv""

where the length of plate is x = L. Proceeding in a manner similar to Eqs. (3.10-6)(3.10-12), the drag coefficient is (3.10-56)

A comparison of Eq. (3.10-6) with (3.10-55) and (3.10-12) with (3.10-56) shows the success of this method. Only the numerical constants differ slightly. This method can be used with reasonable accuracy for cases where an exact analysis is not feasible. 3. Integral momentum analysis for turbulent boundary layer. The procedures used for the integral momentum analysis for} laminar boundary layer can be applied to the turbulent boundary layer on a flat plate. A simple empirical velocity distribution for pipe flow which is valid up to a Reynolds number of lOS can be ad~pted for the boundary la yer on a flat plate,. to become (3.10-57)

This is the Blasius t-power law often used. Equation (3.10-57) is substituted into the integral relation equation (3.10-48). (3.10-58)

The power-law equation does not hold, as y goes to zero at the walL Another useful relation is the Blasius correlation for shear stress for pipe flow, which is consistent at the wall for the wall shear stress to' For boundary-layer flow over a flat plate, it becomes

~ = O.023(5V"" PV~

p)

114

(3.10-59)

Ii

Integrating Eq. (3.10-58), combining the result with Eq. (3.10-59), and integrating 15, and x = 0 and x L, between 0 == 0 and 0 (5

O.376(

LV;

p

r

115

L

0.376L

---;:;ti5 Re. L

(3.10-60)

Integration of the drag force as before gives 0.072 NtiS

(3.10-61)

Re.L

In this development the turbulent boundary layer was assumed to extend to x = O. Actually, a certain length at the front has a laminar boundary layer. Experimental data check Eq. (3.10-61) reasonably well from a Reynolds number of 5 x 10 5 to 101 . More accurate results at higher Reynolds numbers can be obtained by using a logarithmic velocity distribution, Eqs. (3.1 0-45H3. 10-47).

Sec. 3./0

Boundary-Layer Flow llnd Turbulence

201

3.11

3.11A

DIMENSIONAL ANALYSIS IN MOMENTUM TRANSFER Dimensional Analysis of Differential Equations /

In this chapter we have derived several differential equations describing various flow situations. Dimensional homogeneity requires that each term in a given equation have the same units. Then, the ratio of one term in the equation to another term is dimensionless. Knowing the physical meaning of each term in the equation, we are then able to give a physical interpretation to each of the dimensionless parameters or numbers formed. These dimensionless numbers, such as the Reynolds number and others, are useful in correlating and predicting transport phenomena in laminar and turbulent flow. Often it is not possible to integrate the differential equation describing a flow situation. However, we can use the equation to find out which dimensionless numbers can be used in correlating experimental data for this physical situation. An important example of this involves the use of the Navier-Stokes equation, w~ich often cannot be integrated for a given physical situation. To start, we use Eq. (3.7-36) for the x component of the Navier-Stokes equation. At steady state this becomes V;r

av. ax

+ Vy

av.

ay +

1 ap

Vr

az

)1.

(aZvx

azv x

Pax + p ax z + ay2

9. -

+

azv.) az 2

(3.11-1)

Each term in this equation has the units length/time 2 or(L/t Z ). In this equation each term has a physical significance. First we use a single characteristic velocity v and a single characteristic length L for all terms. Then the expression of each term in Eq. (3.11-1) is as follows. The left-hand side can be expressed as v 2 /L and the right-hand terms, respectively, as g, p/ pL, and )1.L'/ pLz. We then write

[~]

[g] -

[l:.] + [.!:!!!..] pL

pI3

(3.11-2)

This expresses a dimensional equality and not a numerical equality. Each term has dimensions L/t 2 • The left-hand term in Eq. (3.11-2) represents the inertia force and the terms on the right-hand side represent, respectively, the gravity force, pressure force, and viscolls force. Dividing each of the terms in Eq. (3.11-2) by the inertia force [v IlL], the following dimensionless groups or their reciprocals are obtained.

[v 2 / L] inertia force v2 --=-=NF gravity force gL r [g]

(Froude number)

(3.11-3)

[p/pL] force 2 [u / L] = inertia force

(Euler number)

(3.11-4)

(Reynolds number)

(3.11-5)

[v 2/L] [pv/pI3]

=

p pv

-2 =

N Eu

inertia force Lvp =-=NR viscous force J1e

Note that this method not only gives the various dimensionless groups for a differential equation but also gives physical meaning to these dimensionless groups. The length, velocity, etc., to be used in a given case will be that value which is most significant. For example, the length may be the diameter of a sphere, the length of a flat plate, and so on. Systems that are geometrically similar are said to be dynamically similar if the

202

Chap. 3

Principles of Momentum Transfer and Applications

parameters representing ratios of forces pertinent to the situation are equal. This means that the Reynolds, Euler, or Froude numbers must be equal between the two systems. This dynamic similarity is an importa~t requirement in obtaining experimental data on a small model and extending these data to scale up to the large prototype. Since experiments with full-scale prototypes would often be difficult andlor expensive, it is customary to study small models. This is done in the scaleup of chemical process equipment and in the design of ships and airplanes.

3.UB

Dimensional Analysis Using Buckingham Method

The method of obtaining the important dimensionless numbers from the blisic differential equations is generally the preferred method. In many cases, however, we are not able to formulate a differential equation which clearly applies. Then a more general procedure is required, which is known as the Buckingham method. In this method the listing of the important variables in the particular physical problem is done first. Then we determine the number of dimensionless parameters into which the variables may be combined by using the Buckingham pi theorem. The Buckingham theorem states that the functional relationship among q quantities or variables whose units may be given in terms of u fundamental units or dimensions may be written as (q - u) independent dimensionless groups, often called IT's. [This quantity u is actually the maximum nurri"ber of these variables which will not form a dimensionless group. However, only in a few cases is this u not equal to the number of fundamental units (Bl).] Let us consider the following example, to illustrate the use of this method. An incompressible fluid is flowing inside a circular tube of inside diameter D. The significant variables are pressure drop I1p, velocity v, diameter D, tube length L, viscosity p., and density p. The total number of variables is q = 6.. The fundamental units or dimensions are u = 3 and are mass M, length L, and time t. The units of the variables are as follows: I1p in M I Lt Z , v in Lit, D in L, L in L, p. in MILt, and p in MI13. The number of dimensionless groups or IT'S is q - u, or 6 - 3 = 3. Thus,

(3.11-6) Next, we must select a core group ofu (or 3) variables which will appear in each IT group and among them contain all the fundamental dimensions. Also, no two of the variables selected for the core can have the same dimensions. In choosing the core, the variable whoseeffect one desires to isolate is often excluded (for example, I1p). This leaves us with the variables v, D, jJ., and p to be used. (L and D have the same dimensions.) We will select D, v, and p to be the core variables common to all three groups. Then the three dimensionless groups are ITI

=

D"vbpC I1pl

(3.11-7)

ITz

=

Dd ve pi LI

(3.11-8)

IT3

= D9Vh

/p 1

(3.11-9)

To be dimensionless, the variables must be raised to certain exponents a, b, c, etc. First we consider the IT 1 group. (3.11-7)

Sec. 3.11

Dimensional Analysis in Momeflillm Transfer

203

"

To evaluate these exponents, we write Eq. (3.11-7) dimensionally by substituting the dimensions for each variable.

(L)b(M)C MLt =1=E-IJ -LtM o 0 0

(3.11-10)

2

t

Next we equate the exponents of L on both sides of this equation, of M, and finally of t.

+b-

(L)

0

a

(M)

0

c+ 1

(t)

0

=

-b

3c

(3.11-11)

2

Solving these eq uations, a = 0, b 2, and c = 1. Substituting these values into Eq. (3.11-7),

(3.11-12) Repeating this procedure for n 1 and n3,

(3.11-13)

Dvp

n3 = - -

(3.11-14)

NRc

{!

Finally, substituting

1T!, 1T2,

and

1T)

into Eq. (3.11-6),

J(~, DVP) D

(3.11-15)

JI

Combining (2.10-5) with the left-hand side ofEg. (3.11-15), the result obtained shows that the friction factor is a function of the Reynolds number (as was shown before in the empirical correlation of friction factor and Reynolds number) and of length/diameter ratio. In pipes with L/D» I or pipes with fully devcioped flow, the friction factor is found to be independent of L/ D. This type of analysis is useful in empirical correlations of data. However, it does not tell us the importance of each dimensionless group, which must be determined by experimentation, nor does it select the variables to be used.

~

PROBLEMS 3.1-1. Force on a Cylinder in a Wind Tunnel. Air at 101.3 kPa absolute and 25°C is flowing at a velocity of 10 m/s in a wind tunnel. A long cylinder having a diameter of 90 mm is placed in the tunnel and the axis of the cylinder is held perpendicular to the air flow. What is the force on the cylinder per meter length? Ans. CD 1.3, F D = 6.94 N 3.1-2. Wind Force on a Steam Boiler Stack. A cylindrical steam boiler stack has a diameter of LO m and is 30.0 m high. It is exposed to a wind at 25"C having a velocity of 50 miles/h. Calculate the force exerted on the boiler stack. Ans. CD 0.33, F D = 2935 N 3.1-3. Effect oj Velocity on Force on a Sphere and Stokes' Law. A sphere is held in a

204

Chap. 3

Problems

small wind tunnel where air at 37.8°C and 1 atm abs and various velocities is forced by the sphere having a diameter of 0.042 m. (a) Determine the drag coefficient and force on the sphere for a velocity of 2.30 x 10- 4 m/s. Use Stokes' law here if it is applicable. (b) Also determine the force for velocities of 2.30 x 10- 3, 2.30 X 10- 2 , 2.30 X 10- 1 , and 2.30 m/s. Make a'plot of F D versus velocity. 3.1-4. Drag Force on Bridge Pier in River. A cylindrical bridge pier 1.0 m in diameter is submerged to a depth of 10 m. Water in the river at 20°C is flowing past at a . velocity of 1.2 m/s. Calculate the force on the pier. 3.1-5. SurJace Area in a Packed Bed. A packed bed is composed of cubes 0.020 m on a side and the bulk density of the packed bed is 980 kg/m). The density of the solid cubes is 1500 kg/m). (a) Calculate e, effective diameter Dp' and a. (b) Repeat for the same conditions but for cylinders having a diameter of D = 0.02 m and a length h =).5D. Ans. (a) e = 0.3467, Dp = 0.020 m, a 196.0 m- 1 3.1-6. Derivation Jor Number oJ Particles in a Bed oJ Cylinders: For a packed bed containing cylinders where the diameter D of the cylinders is equal to the length h, do as follows for a bed havinga void fraction e. (a) Calculate the effective diameter. (b) Calculate the number, n, of cylinders in 1 m 3 of the bed. Ans. (a) Dp = D 3,1-7. Derivation oJ Dimensio;"less Equation Jor Packed Bed. Starting with Eq. (3.1-20), derive the dimensionless equation (3.1-21). Show all steps in the derivation. 3.1-8. Flow and Pressure Drop oJGases in Packed Bed. Air at 394.3 K flows through a packed bed of cylinders having a diameter of 0.0127 m and length the same as the diameter. The bed void fraction is OAO and the length of the packed bed is 3.66 m. The air enters the bed at 2.20 atm abs at the rate of 2.45 kg/m 2 • s based on the empty cross section of the bed. Calculate the pressure drop of air in the bed. , Ans. L'lp = 0.1547 X 10 5 Pa 3.1-9. Flow oJ Water in a Filter Bed. Water at 24°C is flowing by gravity through a filter bed of small particles having an equivalent diameter of 0.0060 m. The void fraction of the bed is measured as 0.42. The packed bed has a depth of 1.50 m. The liquid level of water above the bed is held constant at OAO m, What is the water velocity v' based on the empty cross section of the bed? 3.1-10. Mean Diameter oJ Particles in Packed Bed. A mixture of particles in a packed bed contains the following volume percent of particles and sizes: 15%, 10 mm; 25%,20 mm; 40%, 40 mm; 20%, 70 mm. Calculate the effective mean diameter, Dpm, if the shape factor is 0.74. Aras. Dpm = 18.34 mm 3.1-11. Permeability and Darcy's Law. A sample core of a porous rock obtained from an oil reservoir is 8 em long and has a diameter of 2.0 cm. It is placed in a core holder. With a pressure drop of 1.0 atm, the water flow at 20.2°C through the core was measured as 2.60 cm 3/s. What is the permeability in darcy? 3.1-12. Minimum Fluidization and Expansion oJFluid Bed. Particles having a size of 0.10 mm, a shape factor of 0.86, and a density of 1200 kg/m 3 are to be fluidized using air at 25 C and 202.65 kPa abs pressure. The void fraction at minimum fluidizing conditions is 0.43. The bed diameter is 0.60 m and the bed contains 350 kg of solids. (a) Calculate the minimum height of the fluidized bed. (b) Calculate the pressure drop at minimum fluidizing conditions. (c) Calculate the minimum velocity for fluidization. (d) Using 4.0 times the minimum velocity, estimate the porosity of the bed. D

Chap. 3

Problems

205

ADs.

(a)

Lmf

(c) v:"f

1.810 m, (b) dp = 0.1212 X 10 5 Pa, 0.004374 mis, (d) Ii = 0.604

3.1-13. Minimum Fluidization Velocity Using a Liquid. A tower having a diameter of 0.1524 m is being fluidized with water at 20.2°e. The uniform spherical beads in the tower bed have a diameter of 4.42 rom and a density of 1603 kglm 3 • Estimate the minimum fluidizing velocity and compare with the experimental value of 0.02307 mls of Wilhelm and K wauk (W 5). 3.1-14. Fluidization of a Sand Bed Filter. To clean a sand bed filter it is fluidized at minimum conditions using water at 24"C. The round sand particles have a density of 2550 kglm 3 and an average size of 0.40 mm. The sand has the properties given in Table 3.1-2. (a) The bed diameter is 0.40 m and the desired height of the bed at these minimum fluidizing conditions is 1.75 m. Calculate the amount of solids needed. (b) Calculate the pressure drop at these conditions and the minimum velocity for fluidization. (c) Using 4.0 times the minimum velocity, estimate the porosity and height of the expanded bed. 3.2-1. Flow Measurement Using a Pitot Tube. A pitot tube is used to measure the flow rate of water at 20°C in the center of a pipe having an inside diameter of 102.3 mm. The manometer reading is 78 mm of carbon tetrachloride at 20"e. The pitot tube coefficient is .0.98. (a) Calculate the velocity at the center and the average velocity. (b) Calculate the volumetric flow rate of the water. Ans. (a) Vmax = 0.9372 mis, V.V 0.773 mis, (b) 6.35 x 10 - 3 m 3 /s 3.2-2. Gas Flow Rate Using a Pitot Tube. The flow rate of air at 37.8"C is being~ measured at the center of a duct having a diameter of 800 mm by a pitot tube. The pressure difference reading on the manometer is 12.4 mm of water. At the pitot tube position, the static pressure reading is 275 mm of water above one atmosphere absolute. The pitot tube coefficient is 0.97. Calculate the velocity at the center and the volumetric flow rate of the air. 3.2-3. Pitot-Tube Traverse for Flow Rate l'vfeasurement. In a pitot tube traverse of a pipe having an inside diameter of 155.4 mm in which water at 20°C is flowing, the following data were obtained. Distance from Wall (mm)

26.9 52.3 77.7 103.1 128.5

Reading in Manometer (mm of Carbon Tetrachloride)

122 142 157 137 112

The pitot tube coefficient is 0.98. (a) Calculate the maximum velocity at the center. (b) Calculate the average velocity. [Hint: Use Eq. (2.6-17) and do a graphical integration.] 3.2-4. Metering Flow by a Venturi. A venturi meter having a throat diameter of 38.9 mm is installed in a line having an inside diameter of 102.3 mm. It meters water having a density of 999 kglm 3 • The measured pressure drop across the

206

Chap.]

Problems

, ,

venturi is 156.9 kPa. The venturi coefficient C v is 0.98. Calculate the gal/min and m 3/ S flow ra teo Ans. 330 gal/min, 0.0208 m 3 /s 3.2-5. Use of a Venturi to Meter Water Flow. Water at 20°C is 'flowing in a 2-in. schedule 40 steel pipe. Its flow rate is measured by a venturi meter having a throat diameter of 20 mm. The manometer reading is 214 mm of mercury. The venturi coefficient is 0.98. Calculate the flow rate. 3.2-6. Metering of Oil Flow by an Orifice. A heavy oil at 20°C having a density of 900 kg/m 3 and a viscosity of 6 cp is flowing in a 4-in. schedule 40 steel pipe. When the flow rate is 0.0174 m 3/s it is desired to have a pressure drop reading across the manometer equivalent to 0.93 x 10 5 Pa. What size orifice should be used if the orifice coefficient is assumed as 0.61? What is the permanent pressure loss? 3.2-7. Water Flow Rate in an Irrigation Ditch. Water is flowing in an open channel in an irrigation ditch. A rectangular weir having a crest length L = 1.75 ft is used. The weir head is measured as,ho = 0.47 f1. Calculate the flow rate in ft 3/s and

m3 /s.

3.3-1.

3.3-2.

3.3-3.

3.4-1.

Ans. Flow rate = '1.776 ft3/S, 0.0503 m 3/s Brake Horsepower of Centrifugal Pump. Using Fig. 3.3-2 and a flow rate of 60 gal/min, do as follows. (a) Calculate the brake hp of the pump using water with a density of 62.4lbm/ft 3 • Compare with the value from the curve. (b) Do the same for a nonviscous liquid having a density of 0.85 g/cm 3. Ans. (b) 0.69 brake hp (0.51 kW) k W-Power of a Fan. A centrifugal fan is to be used to take a flue gas at rest (zero velocity) and at a temperature of 352.6 K and a pressure of 749.3 mm Hg and to discharge this gas at a pressure of 800.1 mm Hg and a velocity of 38.1 m/s. The volume flow rate of gas is 56.6 std m3/m in of gas (at 294.3 K and 760 mm Hg). Calculate the brake kW of the fan if its efficiency is 65% and the gas has a molecular weight of30.7. Assume incompr,essible flow. Adiabatic Compression of Air. A compressor operating adiabatically is to compress 2.83 m 3/min of air at 29AoC and 102.7 kN/m2 to 311.6 kN/m2. Calculate the power required if the efficiency of the compressor is 75%. Also, calculate the outlet temperature. Power for Liquid Agitation. It is desired to agitate a liquid having a viscosity of 1.5 x 10- 3 Pa· s and a density of 969 kg/m 3 in a tank having a diameter of 0.91 m. The agitator will be a six-blade open turbine having a diameter of 0.305 moperating at 180 rpm. The tank has four vertical barnes each with a width J of 0.076 m. Also, W = 0.0381 m. Calculate the required kW. Use curve 2, Fig. 3.4-4. Ans. Nl' 2.5, power O.l72kW(0.23Ihp)

3.4-2. Power for Agitation and Scale-Up. A turbine agitator having six flat blades and a disk has a diameter of 0.203 m and 'is used in a tank having a diameter of 0.61 m and height of 0.61 m. The width W = 0.0405 m. Four barnes are used having a width of 0.051 m. The turbine operates at 275 rpm in a liquid having a density of 909 kg/m 3 and viscosity of 0.020 Pa . s. (a) Calculate the kW power ofthe turbine and kW/m 3 of volume. (b) Scale up this system to a vessel having a volume of 100 times the original for the case of equal mass transfer rates. Ans. (a) P = 0.1508 kW, P/V 0.845 kW/m3, (b) P 2 = 15.06 kW, PJV2 0.845 kW/m 3 3.4-3. Scale-Down of Process Agitation System. An existing agitation process operates using the same agitation system and fluid as described in Example 3.4-1a. It is desired to design a small pilot unit with a vessel volume of 2.0 liters so that effects Chap. 3

Problems

207

of various process variables on the system can be studied in the laboratory. The rates of mass transfer appear to be important in this system, so the scale-down should be on this basis. Design the new system specifying sizes, rpm, and kW power. 3.4-4. Anchor Agitation System. An anchor-type agitator similar to that described for Eq. (3.4-3) is to be used to agitate a fluid having a viscosity of 100 Pa· s and a density of 980 kg/m 3. The vessel size is D, = 0.90 m and H = 0.90 m. The rpm is 50. Calculate the power required. 3.4-5. Design oj Agitation System. An agitation system is to be designed for a fluid

having a density of 950 kg/m 3 and viscosity of 0.005 Pa' s. The vessel volume is 1.50 m 3 and a standard six-blade open turbine with blades at 45° (curve 3, Fig. 3.4-4) is to be used with DJW 8 and DJD, 0.35. For the preliminary design a power of 0.5 kW/m 3 volume is to be used. Calculate the dimensions of the agitation system, rpm, and k W power. /

3.4-6. Scale-Up oj Mixing Times Jor a Turbine. For scaling up a turbine-agitated

system, do as follows: (a) Derive Eq. (3.4-17) for the same power/unit volume. (b) Derive (3.4-18) for the same mixing times. 3.4-7. Mixing Time in a, Turbine-Agitated System. Do as follows:

(a) Predict the time of mixing for the turbine system in Example 3.4-la. (b) Using the same system as part (a) but with a tank having a volume 01 10.0 m 3 and the same power/unit volume, predict the new mixing time. 17.7 s Ans. (a)JI = 4.1, IT 3.5-1. Pressure Drop oj Power-Law Fluid, Banana Puree. A power-law biological fluid, banana puree, is flowing at 23.9°C, with a velocity of 1.018 mis, through a smooth tube 6.10 m long having an inside diameter of 0.01267 m. The flow properties of the fluid are K 6.00 N· SO.454/ m2 and n 0.454. The density of the fluid is 976 kg/m3. (a) Calculate the generalized Reynolds number and also the pressure drop using Eq. (3.5-9). Be sure to convert K to K' first. (b) Repeat part (a), but use the friction factor method.

Ans.

(a) N Re • gen

=

63.6, Ap

=

245.2 kN/m2 (5120 Ibr/ft 2 )

3.5-2. Pressure Drop oj Pseudoplastic Fluid. A pseudoplastic power-law fluid having a density of 63.2 Ib"jft 3 is flowing through 100 ft of a pipe having an inside diameter of 2.067 in. at an average velocity of 0.500 ft/s. The flow properties of the fluid are K = 0.280 lb r • sn/ft2 and n = 0.50. Calculate the generalized Reynolds number and also the pressure drop, using the friction factor method. 3.5-3. Turbulent Flow oj Non-Newtonian Fluid, Applesauce. Applesauce having the flow properties given in Table 3.5-1 is flowing in a smooth tube having an inside diameter of 50.8 mm and a length of 3.05 m at a velocity of 4.57 m/s. (a) Calculate the friction factor and the pressure drop in the smooth tube. (b) Repeat, but for a commercial pipe having the same inside diameter with a roughness ofe = 4.6 x 10- 5 m. Ans. (a) NRc.g cn 4855,J= 0.0073, (b) f= 0.0100

3.5-4. Agitation oj a Non-Newtonian Liquid. A pseudoplastic liquid having the following properties of n = 0.53, K 26.49 N· s'''/m2, and p 975 kg/m 3 is being agitated in a system such as in Fig. 3.5-4 where D, 0.304 m, D" = 0.151 m, and N = 5 revIs. Calculate J.i." , NRc. n' and the kW power for this system. ADS. jl" = 4.028 Pa' s, NRc. n = 27.60, N p = 3.1, P = 0.02966 kW

208

Chap. 3

Problems

3.5-5. Flow Properties of a Non-Newtonian Fluid from Rotational Viscometer Data. Following are data obtained on a fluid using a Brookfield rotational viscometer.

RPM 0.5 1 2.5 5 -T-o-rq-u-e-l---86-.-2--16-8-".9--4-02-.-:/ 754

10 1365

20 2379

50 4636

(dyn-cm) The diameter of the inner concentric rotating spindle is 25.15 mm, the outer cylinder diameter is 27 .62 mm, and the effective length is 92.39 mm. Determine the flow properties of this non-Newtonian fluid. Ans. II 0.870 3.6-1. Equation of Continuity in a Cylinder. Fluid having a constant density pis flowing in the z. direction through a circular pipe with axial symmetry. The radial direction is designated by r./ (a) Using a cylindrical sh~1J balance with dimensions dr and dz, derive the equation of continuity for this system. , (b) Use the equation of continuity in cylindrical coordinates to derive the equa~ tion. 3.6-2. Change of Coordinates for Continuity Equation. Using the general equation of continuity given in rectangular coordinates, convert it to Eq. (3.6-27), which is the equation of con!inuity in cylindrical coordinates. Use the relationships in Eg. (3.6-26) to do this. 3.7-1. Combining Equations of Continuity and Motion. Using the continuity equation and the equations of motion for the x, y, and z. components, derive Eq. (3.7-13). 3.8-1. Average Velocity in a Circuwr Tube. Using Eq. (3.8-17) for the velocity in a circular tube as a function of radius r, _ 1 dp ( 2 _ 2) ' r ro 4 /l d z'

(3.8-17)

derive Eg. (3.8-19) for the average velocity. (3.8-19)

3.8-2. Laminar Flow in a Cylindrical Annulus. Derive all the equations given in Example 3.8-4 showing all the steps. Also, derive the equation for the average velocity v z av' Finally, integrate to obtain the pressure drop from z. 0 for p = Po to z. = L for P PL'

3.8-3. Velocity Profile in Wetted-Wall Tower. In a vertical wetted-wall tower, the fluid flows down the inside as a thin film 8 m thick in laminar flow in the vertical z. direction. Derive the equation for the velocity profile v z as a function of x, the distance from the liquid surface toward the wall. The fluid is at a large distance from the entrance. Also, derive expressions for V z av and V z max' (Hint: At x 8, which is at the wall, v l = O. At x = 0, the surface of the flowing liquid, v z = V Z max.) Show all steps. , ADS. VI = (pglj2/2/l)[1 - (X/lj)2], Vr av = pglj2/3p" V. mu = pglj2/2J1

Chap. 3

Problems

209

3.8-4. Velocity Profile in Falling Film and Differential Momentum BaIo.nce. A Newtonian liquid is flowing as a falling film on an inclined flat surface. The surface makes an angle of f3 with the vertical. Assume that in this case the section being considered is sufficiently far from both ends that there are no end effects on the velocity profile. The thickness of the film is o. The apparatus is similar to Fig. 2.9-3 but is not vertical. Do/as follows. (a) Derive the equation for the velocity profile of v z as a function of x in this film using the differential momentum balance equation. (b) What are the maximum velocity and the average velocity? (c) What is the equation for the momentum flux distribution of Txz? [Hint: Can Eq. (3.7-19) be used here?] Ans. (a) Vz = (pgo2 cos f3I2JL)[1 - (X/o)2] (c) Txz pgx cos f3 3.8-5. Velocity Profiles for Flow Between Parallel Ploles. In Example 3.8-2 a fluid is flowing between vertical parallel plates with one plate moving. Do as follows. (a) Determine the average velocity';:md the maximum velocity. (b) Make a sketch of the velocity prol1le for three cases where the surface is moving upward, downward, and stationary. 3.8-6. Conversion of Shear Stresses in Terms of Fluid Motion. Starting with the x component of motion, Eq. (3.7-10), which is in terms of shear stresses, convert it to the equation of motion, Eq. (3.7-36), in terms of velocity gradients, for a Newtonian fluid with constant p and fL. Note that (V· v) = o in this case. Also, use of Eqs. (3.7-14) to (3.7-20) should be considered. 3.8-7. Derivatfun of Equation of Continuity in Cylindrical Coordinoles. By means of a mass balance over a stationary element whose volume is r I:1r 1:1 fJ I:1z, derive the equation of continuity in cylindrical coordinates. 3.8·8. Flow between Two Rotating Coaxial Cylinders. The geometry of two coaxial cylinders is the same as in Example 3.8-5. In this case, however, both cylinders are rotating with the inner rotating with an annular velocity of WI and the outer at Wz. Determine the velocity and the shear stress distributions using the differential equation of momentum.

Ans. Va 3.9-1. Potential Function. The potential function ¢ for a given flow situation is ¢ C(x 2 y2), where C is a constant. Check to see if it satisfies Laplace's

equation. Determine the velocity components V x and v y • Ans. Vx 2Cx, Vy = 2Cy(C = constant) 3.9-2. Determining the Velocities from the Potential Function. The potential function Ax + By, where A and B are constants. Determine for flow is given as ¢ "the velocities v x and vy3.9-3. Stream Function and Velocity Vector. Flow of a fluid in two dimensions is given by the stream function IjJ = Bxy, where B = 50 S·I and the units of x and yare in cm. Determine the value of v x' v y , and the velocity vector at x = 1 cm and y = 1 cm. Ans. v = 70.7 cmls 3.9-4. Stream Function and Potential Function. A liquid is flowing parallel to the x axis. The flow is uniform and is represented by Vx = U and Vy = O. (a) Find the stream function IjJ for this flow field and plot the streamlines. (b) Find the potential function and plot the potential lines. Ans. (a) IjJ = Uy + C (C = constant)

210

Chap. 3

Problems

3.9-5. Velocity Components and Stream Function. A liquid is flowing in a uniform manner at an angle of f3 with respect to the x axis. Its velocity components are Vr U cos f3 and Vy U sin f3. Find the stream function and the potentia]

function. Ans ... 1{l

Uy cos

f3

Ux sin

f3 + C (C

= constant)

3.9-6. Flow Field wah Concentric Streamlines. The flow of a fluid that has concentric streamlines has a stream function represented by I{l = 1/(x 2 + y2). Find the

components of velocity Vx and vy- Also, determine if the flow is rotational, and if so, determine the vorticity, 2w z • 3.9-7. Potential Function and Velocity Field. In Example 3.9-2 the velocity components were given. Show if a velocity potential exists and, if so, also determine 4>. Ans. 4> ax 3/3 - axy2 + e(C constant) 3.9-8. Euler's Equation o/Motion for an Jdeal Fluid. Using the Euler equations

(3.9-2}-(3.9-4) for ideal fluids with constant density and zero viscosity, obtain ' the following equation: Dv

p Dt

-Vp+pg

3.10-1. Laminar Boundary Layer on FlaJ Plate. Water at 20°C is flowing past a flat plate

at 0.914 mls. The plate is 0.305 m wide. (a) Calculate the Reynolds number 0.305 m from the leading edge to determine if the flow is laminar. (b) Calculate the boundary-layer thickness at x = 0.152 and x = 0.305 m from the leading edge. (c) Calculate the total drag on the 0.305-m-long plate. Ans. (a) NRd = 2.77 X 10 5, (b) b 0.0029 m at x = 0.305 m 3.10-2. Air Flow Past a Plate. Air at 294.3 K and 101.3 kPa is flowing past a flat plate

at 6.1 mls. Calculate the thickness of the boundary layer at a distance of 0.3 from theJeadingedge and the total drag for a 0.3-m-wide plate.

m

3.10-3. Boundary-Layer Flow Past a Plate. Water at 293 K is flowing past a flat plate at 0.5 mls. Do as follows.

(a) Calculate the boundary-layer thickness in m at a point 0.1 m from the leading edge. (b) At the same point, calculate the point shear stress To. Also calculate the total drag coefficient. 3.10-4. Transition Point to Turbulent Boundary Layer. Air at 101.3 kPa and 293 K is flowing past a smooth flat plate at 100 ft/s. The turbulence in the air stream is such that the transition from a laminar to a turbulent boundary layer occurs at 5 N Re, L 5 x 10 . (a) Calculate the distance from the leading edge where the transition occurs. (b) Calculate the boundary-layer thickness b at a distance of 0.5 ft and 3.0 ft from the leading edge. Also calculate the drag coefficient for both distances L 0.5 and 3.0 f1. 3.11-1. Dimensional Analysis for Flow Pasta Body. A fluid is flowing external to a solid body. The force F exerted on the body is a function of the fluid velocity v, fluid density p, fluid viscosity JL, and a dimension of the body L. By dimensional analysis, obtain the dimensionless groups formed from the variables given. (Note: Use the M, L, t system of units. The units of Fare MLlt 2 • Select v, p, and L as the core variables.) JLILvp

Chap. 3

Problems

211

3.11-2. DimenswnalA nalysisJor Bubble Formation. Dimensional analysi,s is to be used to correlate data on bubble size with the properties of the liquid when gas bubbles are formed by a gas issuing from a small orifice below the liquid surface. Assume that the significant variables are bubble diameter D; orifice diameter d, liquid density p, surface tension (J in N/m, liquid viscosity JL, and g. Select d, p, and 9 as the core variables. Ans. 1£1 Dld,1£2 = (Jlpd 2 g,Jl3 = Jl 21p 2 d 3 g

REFERENCES (AI) (A2) (Bl) (B2) (B3) (B4) (B5) (Cl) (C2) (C3) (D 1) (D2)

Allis Chalmers Mfg. Co. Bull. 1659. American Gas Association, "Orifice Metering of Natural Gas," Gas Measurement Rept. 3, New York, 1955. BENNETT, C. 0., and MYERS, J. E. M~mentum, Heat, and Mass Transfer, 3rd ed. New York: McGraw-Hill Book Company, 1982. BIRD, R. B., STEWART, W. E., and LIGHTFOOT, E. N. Transport Phenomena. New York: John Wilf" & Sons, Inc., 1960. . BATES, R. L., FONDY, P. L., and CORPSTEIN, R. R. 1.E.C. Proc. Des. Dev., 2, 310 (1963). BROWN, G. G., et al. Unit Operations. New York: John Wiley & Sons, Inc., 1950. BIGGS, R. D., A.l.Ch.E.J., 9,636 (1%3). CHARM, S. E. The Fundamentals of Food Engineering. 2nd ed. Westport, Conn.: Avi Publishing Co., Inc., 1971. CARMAN, P. C. Trans.1nst. Chern. Eng. (London), 15,150 (1937). CALDERBANK, P. H. In Mixing: Theory and Practice, Vol. 2, V. W. Uhl and J. B. Gray (eds.). New York: Academic Press, Inc." 1967. DREW, T. B., and HOOPES, J. W., Jr. Advances in Chemical Engineering. New York: Academic Press, Inc.,1956. DODGE, D. W., and METZNER, A. B. A.I.Ch.E.J., 5, 189 (1959).

ERGUN, S. Chern. Eng. Progr., 48,89 (1952). (Fl) Fox, E. A., and GEX, V. E. A.I.Ch.E.l., 2,539 (1956). (Gl) GODLESKI, E. S., and SMITH,J. C. A.1.Ch.E. J., 8,617 (1962). (HI) HARPER, J. c., and EL SAHRIGI. J. Food Sci., 30, 470 (1965). (H2) Ho, F. c., and KWONG, A. Chern. Eng., July 23, 94 (1973). (K I) KUNIl, D., and LEVENSPIEL, O. Fluidization Engineering. New York: John Wiley & Sons, Inc., 1969. (K2) KruEGER, 1. M., and MARON, S. H. 1. Appl. Phys., 25, 72 (1954). (LlL._Lr;AMY, G. H. Chern. Eng., Oct. 15, 115 (1973). LEVA, M., WEINTRAUB, M., GRUMMF.R, M., POLLCHIK, M., and STORCH, H. H. U.S. (L2) Bur. Mines Bull., 504 (1951). (M!) METZNER, A. B., FEEHS, R. H., RAMOS, H. L., OTTO, R. E., and TUTI-llLL, J. D. A.l.Ch.E. 1.,7,3 (1961). (M2) MCCABE, W. L., SMITH, J. C., and HARRIOTT, P. Unit Operations 01 Chemical Engineering, 4th ed. New York: McGraw-Hill Book Company, 1985. (M3) METZNER, A. B., and REED, J. C. A.l.Ch.E. J., 1,434 (1955). (M4) MOHSENIN, N. N. Physical Properties of Plant and Animal Materials, Vol. I, Part II. New York: Gordon & Breach, Inc., 1970. (M5) Moo-YUNG, TICHAR, M. K., and DULLIEN, F. A. L A.I.Ch.E. 1., 18,178 (1972). (El)

212

Chap. 3

References

(M6) (NI) (PI) (P2) (P3)

MCKELVEY, J. M. Polymer Processing, New York: John Wiley & Sons, Inc., 1962. NORWOOD, K. W., and METZNER, A. B. A.I.Ch.E. J., 6,432 (1960). PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6th ed. New York: McGraw-Hill J?ook Company, 1984. PINCHBECK, P. H., and POPPER, F. Chem. Eng. Sci., 6, 57 (1956). PATTERSON, W. 1., CARREAU, P. J., and YAP, C. Y. A.l.Ch.£. J., 25, 208 (1979).

(P4)

PERRY, R. H., and CHILTON, C. H. Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973.

(Rl)

RUSHTON, J. H., COSTICH, D. W., and EVERETT, H. J. Chem. Eng. Pro gr., 46, 395, 467 (1950). RAUTZEN, R. R., CORPSTEIN, R. R., and DICKEY, D. S. Chem. Eng., Oct. 25, 119 (1976). STEVENS, W. E. Ph.D. thesis, yniversity of Utah, 1953. SKELLAND, A. H. P. Non-N~wlOnian Flow and Heat Transfer. New York: John Wiley & Sons, Inc., 1967. STREETER, V. L. Ha/ldbook of Fluid Dynamics. New York: McGraw-Hill Book Company, 1961.

(R2) (SI) (S2) (S3) (S4)

SCHLICHTING, H. Boundary Layer Theory. New York: McGraw-Hili Book . Company, 1955.

(TI)

TREYBAL, R. E. Liquid Extraction. 2nd ed. New York: McGraw-Hill Book Company, 1953.

(TI)

TREYBAL, R. E. Mass Transfer Operations, 3rd ed. New York: McGraw-Hill Book Company, 1980. UHL, v. W., and GRAY, J. B. (eds.), Mixing: Theory and Practice, Vol. I. New York: Academic, 1969. WEISMAN, 1., and EFFERDING, L. E. A.l.Ch.E. J., 6, 419 (1960). WINl"ING, M. D. M.Sc. thesis, University of Alberta, 1948. WALTERS, K. Rheometry. London: Chapman & Hall Ltd., 1975. WEN, C. Y., and Yu, Y. H. A.l.Ch.E. 1.,12,610 (1966). WILHELM, R. H., and KWAUK, M. Chem. Eng. Progr., 44, 201 (1948).

(UI) (WI) (W2) (W3) (W4) (W5) (W6) (ZI)

WELTY, J. R., WICKS, C. E., and WILSON, R. E. Fundamentals of Momentum, Heat. and Mass Transfer, 3rd ed. New York: John Wiley & Sons, 1984. ZLOKARNIK, M., and JUDAT, H. Chem. Eng. Tech., 39,1163 (1967).

Chap. 3

References

213

CHAPTER 4

Principles of Steady-State Heat Transfer

4.1

4.1A

INTRODUCTION AND MECHANISMS OF HEAT TRANSFER

Introduction to_ Stcady-,State Heat Transfer

The transfer of energy in the form of heat occurs in many chemical and other types of processes. Heat transfer often occurs in combination with other unit operations, such as drying of lumber or foods, alcohol distillation, burning of fuel, and evaporation. The heat transfer occurs because of a temperature difference driving force and heat flows from the high- to the low-temperature region. In Section 2.3 we derived an equation for a general property balance of momentum, thermal energy, or mass at unsteady state by writing Eq. (2.3-7). Writing a similar equation but specifically for heat transfer, rate ( heat

~f) + (ra~e In

of gener-) = (rate of ) atlOn of heat heat out

+ (rat.e

of accumu-) latlOn of heat

(4.1-1)

Assuming tfie rate of transfer of heat occurs only by conduction, we can rewrite Eq. (2.3-14), which is Fourier's law, as

dT

kdx

(4.1-2)

Making an unsteady-state heat balance for the x direction only on the element of volume or control volume in Fig. 4.1-1 by using Eqs. (4.1-1) and (4.1-2) with the cross-sectional area being A m 2 ,

(4.1-3)

214

x + 6.x

x

1-6.x--1

FIGURE

4.1- L

U nstead y-slDte balance for heat transfer in concrol volume.

where q is rate of heat generated per unit volume. Assuming no heat generation and also assuming steady-state heat transfer where the rate of accumulation is zero, Eq. (4.1-3) becomes ,./ ( 4.1-4)

This means the rate of heat input by conduction = the rate of heat output by conduction; or qx is a constant with time for 'steady-state heat transfer. In this chapter we are concerned with a control volume where the rate of accumulation of heat is zero and we have steady-state heat transfer. The rate of heat transfer is then constant with time, ahd the temperatures at various points in the system do not change with time. To solve problems in steady-state heat transfer, various mechanistic expressions in the form of differential equations for the different modes of heat transfer such as Fourier's law are integrated. Expressions for the temperature profile and heat flux are then obtained in this chapter. In Chapter 5 the conservation-of-energy equations (2.7-2) and (4.1-3) will be used again when the rate of accumulation is not zero and unsteady-state heat transfer occurs. The mechanistic expression for Fourier's law in the form of a partial differential equation will be used where temperature at various points and the rate of heat transfer change with time. In Section 5.6 a general differential equation of energy change will be derived and integrated for v9-rious specific cases to determine the temperature profile and heat flux. 4.1 B

Basic Mechanisms of Heat Transfer

Heat transfer may occur by anyone or more of the three basic mechanisms of heat transfer: conduction, convection, or radiation. 1. Conduction. In conduction, heat can be conduced through solids, liquids, and gases. The heat is conducted by the transfer of the energy of motion between adjacent molecules. In a gas the "hotter" molecules, which have greater energy and motions, impart energy to the adjacent molecules at lower energy levels. This type of transfer is present to some extent in all solids, gases, or liquids in which a temperature gradient exists. In conduction, energy can also be transferred by free" electrons, which is quite important in metallic solids. Examples of heat transfer mainly by conduction are heat transfer through walls of exchangers or a refrigerator, heat treatment of steel forgings, freezing of the ground during the winter, and so on. U

The transfer of heat by convection implies the transfer of heat by bulk transport and mixing of macroscopic elements of warmer portions with cooler portions

2. Convection.

Sec. 4.1

Introduction and Mechanisms of Heat Transfer

215

of a gas or a liquid. It also often involves the energy exchange between a solid surface and a fluid. A distinction must be made between forced-convection heat transfer, where a fluid is forced to flow past a solid surface by a pump, fan, or other mechanical means, and natural or free convection, where warmer or cooler fluid next to the solid surface causes a circulation because of a density difference resulting from the temperature differences in the fluid. Examples of heat transfer by convection are loss of heat from a Ulr radiator where the air is being circulated by a fan, cooking of foods in a vessel being stirred, cooling of a hot cup of coffee by blowing over the surface, and so on.

3. Radiation. Radiation differs from heat transfer by conduction and convection in that no physical medium is needed for its propagation. Radiation is the transfer of energy through space by means of electromagnetic waves in much the same way as electromagnetic light waves transfer light The same laws which govern the transfer of light govern the radiant transfer of heat. Solids and liquids tend to absorb the radiation being transferred through it, so that radiation is ill}portant primarily in transfer through space or gases. The most important example of radiation is the transport of heat to the earth from the sun. Other examples are cooking of food when passed below red-hot electric heaters, heating of fluids in coils of tubing inside a combustion furnace, and so on. 4.1C

Fourier's Law of Heat Conduction

As discussed in Section 2.3 for the general molecular transport equation, all three main types of rate-transfer processes-momentum transfer, heat transfer, and mass transferare characterized by the same general type of equation. The transfer of electric current can also be included in this category. This basic equation is as follows: rate of a transfer process

force resistance

(2.3-1)

This equation states what we know intuitively: that in order to transfer a property such as heat or mass, we need a driving force to overcome a resistance. The transfer of heat by conduction also follows this basic equation and is written as Fourier's law for heat conduction in fluids or solids.

-k

dT

(4.1-2)

dx

where qx is the heat-transfer rate in the x direction in watts (W), A is the cross-sectional area normal to the direction of flow of heat in m 2, T is temperature in K, x is distance in m, and k is the thermal conductivity in W/m' K in the SI system. The quantityqjA is called the heat flux in W/m2. The quantity dT/dx is the temperature gradient in the x direction. The minus sign in Eq. (4.1-2) is required because if the heat flow is positive in a given direction, the temperature decreases in this direction. The units in Eq. (4.1-2) may also be expressed in the cgs system withqx in cal/s, A in cm 2 , kin cal/s· °e· cm, T in ce, and x in cm. In the English system,qx is in btu/h, A inft 2, T in OF, x in ft, k in btu/h· of· ft, and qjA in btu/h· ft2. From Appendix A.l, the conversion factors are, for thermal conductivity, 1 btu/h' ft· OF = 4.1365 x 10- 3 caljs' cm' °e 1 btu/h' ft· OF 216

1.73073 W 1m' K Chap. 4

(4.1-5) (4.1-6)

Principles of Steady-State Heat Transfer

For heat flux and power, 1 btufh· ft2 = 3.1546 W/m2 1 btufh

0.29307 W

(4.1-7) (4.1-8)

Fourier's law, Eq. (4.1-2), can be' integrated for the case of steady-state heat transfer through a flat wall of constant cross-sectional area A, where the inside temperature at point 1 is TI and T2 at point 2 a distance ofx 2 - Xl m away. Rearranging Eq. (4.1-2), (4.1-9) Integrating, assuming that k is constant and does not vary with temperature and dropping the subscript X on qx for convenience, (4.1-10)

EXAMPLE 4.1-1. Heat Loss Through an Insulating Wall Calculate the heat loss per m 2 • of surface area for an insulating wall composed of 25.4-mm-thick fiber insulating board, where the inside temperature is 352.7 K and the outside temperature is 297.1 K. Solution:

From Appendix A.3, the thermal conductivity of fiber insulating board is 0.048 W/m' K. The thickness X 2 - Xl = 0.0254 m. Substituting into Eq. (4.1-10),

:L _

k

A - x

_

XI

(7; - T1 )

0.048

_

= 0.0254 (3:>2.7

297.1)

2

105.1 W/ml = (105.1 W 1m2)

4.1D

1

2 2 = 33.30 btu/h· ftl (3.1546 Wlm )/(btu/h· ft )

Thermal Conductivity

The defining equation for thermal conductivity is given as Eq. (4.1-2), and with this definition, experimental measurements have been made to determine the thermal conductivity of different materials. In Table 4.1-1 thermal conductivities are given for a few materials for the purpose of comparison. More detailed data are given in Appendix A.3 for inorganic and organic materials and A.4 for food and biological materials. As seen in Table 4.1-1, gases have quite low values of thermal conductivity, liquids intermediate values, and solid metals very high values. 1. Gases. In gases the mechanism of thermal conduction is relatively simple. The molecules are in continuous random motion, colliding with one another and exchanging energy and momentum. If a molecule moves from a high-temperature region to a region of lower temperature, it transports kinetic energy to this region and gives up this energy through collisions with lower-energy molecules. Since smaller molecules move faster, gases such as hydrogen should have higher thermal conductivities, as shown in Table 4.1-1. Theories to predict thermal conductivities of gases are reasonably accurate and are given elsewhere (Rl). The thermal conductivity increases approximately as the square root of the absolute temperature and is independent of pressure up to a few atmospheres. At very low pressures (vacuum), however, the thermal conductivity approaches zero.

Sec. 4.1

Introduction and Mechanisms of Heat Transfer

217

,;...

2. Liquids. The physical mechanism of conduction of energy in liquids is somewhat similar to that of gases, where higher-energy molecules collide with lower-energy molecules. However, the molecules are packed so closely together that molecular force fields exert a strong effect on the energy exchange. Since an adequate molecular theory of liquids is not available, most correlatioqs· to predict the thermal conductivities are empirical. Reid et at. (Rl) discuss these in detail. The thermal conductivity of liquids varies moderately with temperature and often can be expressed as a linear variation, k = a

+ bT

(4.1-11)

where a ·and b are empirical constants. Thermal conductivities of liquids are essentially independent of pressure. Water has a high thermal conductivity compared to organic-type liquids such as benzene. As shown in Table 4.1-1, the thermal conductivities of most unfrozen foodstuffs, such as skim milk and applesauce, which co.ntain large amounts of water have thermal ,/ conductivities near that of pure water. 3. Solids. The thermal conductivity of homogeneous solids varies quite widely, as may be seen for some typical values in Table- 4.1-1. The metallic solids of copper and aluminum have very high thermal conductivities, and some insulating nonmetallic materials such as rock wool and corkboard ha ve very low conductivities. Heat or energy is conducted tJlrough solids by two mechanisms. In the first, which applies primarily to metallic solids, heat, like electricity, is conducted by free electrons which move through the metal lattice. In the second mechanism, present in all solids, heat is conducted by the transmission of energy of vibration between adjacent atoms. TABLE 4.1-1.

Thermal Conductivities of Some Materials at 101.325 kPa (1 Atm) Pressure (k in W/m' K) Temp.

Subsrance

Gases Air H2 n-Butane Liquids Water Benzene Biological materials and foods Olive oil Lean beef Skim milk Applesauce Salmon

218

Temp.

(K)

k

Ref.

273 373 273 273

0.0242 0.0316 0.167 0.0135

(K2)

273 366 303 333

0.569 0.680 0.159 0.151

(PI)

(K2) (P2)

(PI)

Substance

Solids Ice Fire claybrick Paper Hard rubber Cork board Asbestos Rock wool Steel Copper

293 373 263 275 296 277 248

0.168 0.164 1.35 0.538 0.692 0.502 1.30

(PI)

Aluminum

(K)

k

Ref.

273 473

2.25 1.00 0.130 0.151 0.043 0.168 0.029 45.3 45 388 377 202

(Cl) (PI) (Ml) (Ml) (Ml) (M1) (KI) (PI)

273 303 311 266 291 373 273 373 273

(PI) (PI)

(Cl) (Cl) (CI) (CI)

Chap. 4

Principles of Steady-State Heat Transfer

Thermal conductivities of insulating materials such as rock wool approach that of air since the insulating materials contain large amounts of air trapped in void spaces. Superinsulations to insulate cryogenic materials such as liquid hydrogen are composed of multiple layers of highly reflective materials separated by evacuated insulating spacers. Values of thermal conductivity are c9nsiderably lower than for air alone. Ice has a thermal conductivity much greater than water. Hence, the thermal conductivities of frozen foods such as lean beef and salmon given in Table 4.1-1 are much higher than for unfrozen foods.

4.1 E

Convective-Heat-Transfer Coefficient

It is well known that a hot piece of material will cool faster when air is blown or forced by the object. When the fluid outside the solid surface is in forced or natural convective motion, we express the rate of heat transfer from the solid to the fluid, or vice versa, by the following equation: " (4.1-12) where q is the heat-transfer rate in W, A is the area in m 2 , is the temperature of the. solid surface in K, TJ is the average or bulk temperature of the fluid flowing by in K, and h is the convective heat-t~ansfer coefficient in W1m2. K. In English units, II is in btu/h . ft2 . o f . ' The coefficient 11 is a function of the system geometry, fluid properties, flow velocity, and temperature difference. In many cases, empirical correlations are available to predict this coefficient, since it often cannot be predicted theoretically. Since we know that when a fluid flows by a surface there is a thin, almost stationary layer or film of fluid adjacent to the wall which presents most of the resistance to heat transfer, we often call the coefficient h afilm coefficient. In Table 4.1-2 some order-of-magnitude values of h for different convective mechanisms of free or natural convection, forced convection, boiling, and condensation are given. Water gives the highest values of the heat-transfer coefficien ts. To convert the heat-transfer coefficient II from English to SI units, 1 btu/h· ft2. of = 5.6783 W/m 2 . K

TABLE 4.1-2.

Approximate Magnitude of Some Heat- Transfer Coefficients Range of Values of h

Mechanism

Condensing steam Condensing organics Boiling liquids Moving water Moving hydrocarbons Still air Moving air

Sec.4.i

bru/h 11. 1

,

of

1000-5000 200-500 300-5000 50-3000 10-300 0.5-4 2-10

introduction and Mechanisms of Heat Transfer

W/m 1 'K

5700-28000 1100-2800 1700-28000 280-17000 55-1700 2.8-23 11.3--55

219

4.2

CONDUCTION HEAT TRANSFER

4.2A

Conduction Through a Flat Slab or Wall

In this section Fourier's equation (4.1-2) will be used to obtain equations for onedimensional steady-state conduction of heat through some simple geometries. For a flat slab or wall where the cross-sectional area A and k in Eq. (4J~2) are constant, we obtained Eq. (4.1-10), which we rewrite as q

(4.2-1)

A

This is shown in Fig. 4.2-1, where L\x = X 2 XI' Equation (4.2-1) indicates that if T is substituted for T2 and X for x 2 , the temperature varies linearly with distance as shown in Fig. 4.2-1 b. If the thermal conductivity is not consta~t but varies linearly with temperature, then substituting Eq. (4.1-11) into Eq. (4.1-2) and integrating, . a

q

+b

TI

L\x

A

+2 T2 (TI - T2) = L\x (Tl - T2 )

where (4.2-3)

This means that the mean value of k (i.e., k m ) to use in Eq. (4.2-2) is the value of k evaluated at the linear average of Tl and T2 • As stated in the introduction in Eq. (2.3-1), the rate of a transfer process equals the driving force over the resistance. Equation (4.2-1) can be rewritten in that form. Tl - T2

q

R

driving force resistance

(4.2-4)

where R = L\x/kA and is the resistance in KfW or h· of/btu.

o

6x Distance, (b)

(a) FIGURE

4.2-1.

H eat

x(m)

conduction in a fiat wall: (a) geometry of wail, (b) temperature

plot.

220

Chap. 4

Principles of Steady-State Heat Transfer

dr

Heat conduction in a cylinder.

FIGURE 4.2-2.

4.2B

Conduction Through a Hollow Cylinder

In many instances in the process industries, heat is being transferred through the walls of a thick-walled cylinder as in a pipe that mayor may not be insulated. Consider the hollow cylinder in Fig. 4.2-2 with an inside radius ofrl' where the temperature is T l , an outside radius of r 2 having a temperature of T2 , and a length of L m. Heat is flowing radially from the inside surface to the outside. Rewriting F ouner's law, Eg. (4.1-2), with distance dr instead of dx,

dT kdr

q A

-=

(4.2-5)

The cross-sectional area normal to the heat flow is A

=

(4.2-6)

2nrL

Substituting Eq. (4.2-6) into (4.2-5), rearranging, and integrating,

I

T2

2nL "

dr

-k

r

q

i

Tl'

dT

(4.2-7)

T,

k

2nL

In (r 21r 1)

(Tl - T2 )

(4.2-8)

Multiplying numerator and denominator by(r2 - r 1 ), (4.2-9)

where (2nLr2) - (2nLr J )

In (2nLr 2/2nLr J R

~ kA lm

= In (r 2 Ir 1 ) 2nkL

(4.2-10)

(4.2-11)

The log mean area is AIm' In 'engineering practice, if All Al < 1.5/1, the linear mean area of (A 1 + A l )/2 is within 1.5% of the log mean ar~a. From Eq. (4.2-8), if r is substituted for r 2 and T for T2 , the temperature is seen to be a linear function of In r instead of r as in the case of a flat wall. If the thermal conductivity varies with temperature as in Eq. (4.1-10), it can be shown that the mean value to use in a cylinder is still k m ofEq. (4.2-3). Sec. 4.2

Conduction Heat Transfer

221

EXAMPLE 4.2-1. Length of Tubingfor Cooling Coil A thick-walled cylindrical tubing of hard rubber having an inside radius of 5 mm and an outside radius of 20 mm is being used as a temporary cooling coil in a bath. Ice water is flowing rapidly inside and the inside wall temperature is 274.9 K. The outside surface temperature is 297.1 K. A total of 14.65 W must be removed from the bath by the cooling coil. How many m of tubing are needed? Solution: From Appendix A.3, the thermal conductivity at O°C (273 K) is k 0.151 W/m' K. Since data at other temperatures are not available, this value will be used for the range of 274.9 to 297.1 K. 5 r1 1000

0.005 m

r2

20 = -1000 - = 002 m .

The calculation will be done first for a length of 1.0 m of tubing. Solving for theareasA 1 ,A 2 ,andA 1m in (4.2-1Q), Al

= 2nLr i = 2n(1.0)(0.005) = 0.0314

m2

0.1257 - 0.0314 2.303 log (0.1257/0.0314)

0.0680 m 2

Substituting into Eq. (4.2-9) and solving, q = kA lm

r

274.9

r 2

1

= 0.151(0.0682) ( 0.02

297.1) 0.005

= -15.2 W (51.9 btu/h) The negative sign indicates that the heat flow is from r2 on the outside to r 1 on the inside. Since 15.2 W is removed for a 1-m length, the needed length is length

14.65 W 15.2 W/m

0964' m .

=

Note that the thermal conductivity of rubber is quite small. Generally, metal cooling coils are used, since the thermal conductivity of metals is quite high. The liquid film resistances in this case are quite small and are neglected. 4.2C

Conduction Through a Hollow Sphere

Heat conduction through a hollow sphere is another case of one-dimensional conduction. Using Fourier's law for constant thermal conductivity with distance dr, where r is the radius of the sphere, q dT - = -k (4.2-5) A dr The cross-sectional area normal to the heat flow is

A

=

4nr2

(4.2-12)

Substituting Eq. (4.2-12) into (4.2-5), rearranging, and integrating,

i'2

q dr 2" 4n " r q

222

4nk(Tl - T2 ) l/ r l l/r2

= -k

iT2 dt

(4.2-13)

T,

(l/rj

Chap. 4

(4.2-14)

Principles of Steady-State Heat Transfer

q

FIGURE

403-1.

lIeatjlow through a multilayer wall. ,.'

It can be easily shown that the temperature varies hyperbolicaHy with the radius. (See Problem 4.2-5.)

4.3 4.3A

CONDUCTION THROUGH SOLIDS IN SERIES Plane Walls in Series "

In the case where there is a multilayer wall of more than one material present as shown in . Fig. 4.3- I, we proceed as follows. The temperature profiles in the three materials A, B, and C are shown. Since the heat flow q must be the same in each layer, we can write Fourier's equation for each layer as

q

k A

_,_4_

t:\x A

kcA A ( T} - T) 4

(Tl - T2 )

(4.3-1)

tiXc

Solving each equation for t:\ T, (4.3-2) Adding the equations for Tl - T2 , T}, and T} and T3 drop out and the final rearranged equation is

- T4

q= t:\xA/(k A A)

+ t:\xB/(kBA) + l1x c/(k c A)

, the internal temperatures T2

= ---"-----'---

RA

+ RB + Rc

(4.3-3)

where the resistance RA = t:\xA/kA A, and so on. Hence, the final equation is in terms of the overall temperature drop Tl - T4 and the total resistance, RA + RB + Rc·

EXAMPLE 43-1. Heat Flow Through an Insulated Wall o/a Cold Room A cold-storage room is constructed of an inner layer of 12.7 mm of pine, a middle layer of 101.6 mm of cork board, and an outer layer of 76.2 mm of concrete. The wall surface temperature is 255.4 K inside the cold room and 297,1 K at the outside surface of the concrete. Use conductivities from Appendix A.3 for pine, 0.151 ; for cork board, 0.0433; and for concrete, 0.762 W/m' K. Calculate the heat loss in W for 1 m 2 and the temperature at the interface between the wood and cork board. Sec. 4.3

Conduction Through Solids in Series

223

Solution: Calling T j = 255.4, T4 = 297.1 K, pine as material A, cork as B, and concrete as C, a tabulation of the properties and dimensions IS as follows:

= 0.151

kA

kB

= 0.0127

f..XA

f..xB =

= 0.0433

kc = 0.762

m

0.1016 m

f..xc = 0.0762 m

The resistances for each material are, from Eq. (4.3-3), for an area of

1 m 2, 0.0127

f..XA

RA

=

-kA A

= 0.1 5 1( 1) = 0.0841

f..xB 0.H516 Rn ~ kB A - 0.0433(1)

KfW

= 2.346

_ f..xc _ 0.0762 _ 0 00 Rc - kcA - 0.762(1) - .1

Substituting into Eq. (4.3-3),

q=

=

TJ

RA

T4

-

+ RB + Rc

-41.7 2.530

=

-

255.4 - 297.1 0.0841 + 2.346 + 0.100

16.48 W (- 56.23 btu/h)

Since the answer is negati ve, heat flows in from the outside. To calculate the temperature T2 at the interface between the pine wood and cork,

q=

TJ

-

T2

RA

Substituting the known values and solving, _ 16.4 8 = _25-c:5_.4--,--_T--=.2 0.0841

and

T2 = 256.79 K at the interface

An alternative procedure to use to calculate T2 is to use the fact that the temperature drop is proportional to the resistance.

Tj

-

T2

RA

= R + R + R (T ABC

j

-

T4 )

Substituting, 25 5.4

_

- 0.0841(255.4 - 297.1) - _ 39 K T2 2.530 1.

Hence, T2 = 256.79 K, as calculated before.

4.3B

Multilayer Cylinders

In the process industries, heat transfer often occurs through multilayers of cylinders, as for example when heat is being transferred through the walls of an insulated pipe. Figure 224

Chap. 4

Principles of Sleady-Slale Heal Transfer

FIGURE

4.3-2.

Radial heatflow through mulcipie cylinders in series.

c 4.3-2 shows a pipe with two layers of insulation around it, i.e., a total of three concentric hollow cylinders. The temperature drop is T\ - T2 across material A, T2 - T3 across B, and T j T4. across C. The heat-transfer rate q will, of course, be the same for each layer, since we-are at steady stzte. Writing an equation simil:if to Eq. (4.2-9) for each concentric cylinder, q

=

- T4.

= __...c::-._--=-__ (r2-r\)/(kAAAIm)

(r3-r2)/(kBABIm)

(r4

(4.3-5)

r))/(kcAclJ

where (4.3-6)

Using the same method to combine the equations to eliminate T2 and Tj as was done for the flat walls in series, the final equations are (4.3-7)

q

q

= -----'---RA

+

RB

+

(4.3-8)

Rc

Hence, the overall resistance is again the sum of the individual resistances in series.

EXAMPLE 43-2. Heat Loss/rom an Insulated Pipe A thick-walled tube of stainless steel (A) having a k = 21.63 W/m' K with dimensions of 0.0254 m ID and 0.0508 m OD is covered with a 0.0254-m layer of asbestos {B) insulation, k = 0.2423 W /m . K. The inside wall tempera lure of the pipe is 811 K and the ou tside surface of the insulation is at 310.8 K. For a 0.305-m length of pipe, calculate the heat loss and also the temperature at the interface between the metal and the insulation. Solution: Calling T\ dimensions are r

l

=

0.0~54

=

811 K T2 the interface, a'nd T) = 310.8 K, the

0.0127 m

The areas are as follows for L

0.0508

r2 = - 2 -

0.0254 m

r)

=

0.0508 m

0.305 m.

AI = 2nLr 1 = 2n(O.305)(O.0127) = 0.0243 m 2 A2 Sec. 4.3

2nLr 2

2n(0.305)(O.0254) = 0.0487 m2

Conduction Through Solids in Series

225

A3

2nLr3 = 2n(0.305)(0.0508) = 0.0974 m 2

From Eq. (4.3-6), the log mean areas for the stainless steel (A) and asbestos (B) are

A2 AI AA 1m = In (A 2 /A,) A3

0.0487 - 0.0243 In (0.0487/0.0243)

A2 = 0.0974 - 0.0487 In (0.0974/0.0487)

In (A 3 /A 2 )

0.0351 m2 =

00703 m 2 .

From Eq. (4.3-7) the resistances are 0.0127 21.63(0.0351 )

0.01673 K/W

0.0254 0.2423(0.0703)

1.491 KfW

Hence, the heat-transfer rate is

q

811 310.8 0.01673 + 1.491 = 331.7 W (1132 btu/h)

To calculate the temperature T2 , or

331.7

811-T2 0.01673

Solving, 811 - T2 = 5.5 K and T2 805.5 K. Only a small temperature drop occurs across the metal wall because of its high thermal conductivity. 4.3C

Conduction Through Materials in Parallel

Suppose that two plane solids A and B are placed side by side in parallel, and the direction of heat flow is perpendicular to the plane of the exposed surface of each solid. Then the total heat flow is the sum of the heat flow through solid A plus that through B. Writing Fourier's equation for each solid and summing, ( 4.3-9) where qy is total heat flow, T, and T2 are the front and rear surface temperatures of solid A; T3 and T4 , for solid B. If we assume that Tl = T3 (front temperatures the same for A and B) and T2 = T4 (equal rear temperatures), i ,"'"

10.""

•

(4.3-10) An example would be an insulated wall (A) of a brick oven where steel reinforcing members (B) are in parallel and penetrate the wall. Even though the area A B of the steel would be small compared to the insulated brick area AA' the higher conductivity of the metal (which could be several hundred times larger than that of the brick) could allow a large portion of the heat lost to be conducted by the steel. Another example is a method of increasing heat conduction to accelerate the freeze drying of meat. Spikes of metal in the frozen meat conduct heat more rapidly into the insides of the meat.

226

Chap. 4

PrinCiples of Steady-State Heat Transfer

It should be mentioned that in some cases some two-dimensional heat flow can occur if the thermal conductivities of the materials in parallel differ markedly. Then the results using Eq. (4.3-10) would be affected somewhat. 4.3D

Combined Convection and Conduction and Overall Coefficients

In many practical situations the surface temperatures (or boundary conditions at the surface) are not known, but there is a fluid on both sides of the solid surfaces. Consider the plane wall in Fig. 4.3-3a with a hot fluid at temperature Tl on the inside surface and a cold fluid at T4 on the outside surface. The outside convective coefficient is ho W/m 2 . K and hi on the inside. (Methods to predict the convective h will be given later in Section 4.4 of this chapter.) The heat-transfer rate using Eqs. (4.1-12) and (4.3-1) is given as q = hiA(Tl - T2 )

kAA

= --

tlxA

. (Tl - T3) = h.A(T3 '- T4 )

(4.3-11)

Expressing I/h i A, tlx Alk A A, and I/h"A as resistances and combining the equations as before, (4.3-12)

The overall heat transfer by combined conduction and convection is often expressed in terms of an overall heat-transfer coefficient U defined by q

where Ll TomaH = Tl

(4.3-13)

U All T overall

T4 and U is (4.3-14)

A more important application is heat transfer from a fluid outside a cylinder, through a metal wall, and to a fluid inside the tube, as often occurs in heat exchangers. In Fig. 4.3-3b, such a case is shown. A

q

(a) FIGURE

Sec. 4.3

4.3-3.

(b)

Heat flow with convective boundaries: (a) plane wall, (b) cylindrical wall.

Conduction Through Solids in Series

227

Using the same procedure as before, the overall heat-transfer rate through the cylinder is

q

l/h;A;

+ (ro

- rj}/kAAAlm ,.-

+

(43-15)

l/h oAQ

.

where Ai represents 2rrLr;. the inside area of the metal tube; AA 1m the log mean area of the metal tube; and Ao the outside area. The overall heat-transfer coefficient V for the cylinder may be based on the inside area Ai or the outside area A of the tube. Hence, Q

(43-16)

(43-17) (43-18) ,

V.

EXAMPLE 43-3. Heat Loss by Convection and Conduction and Overall U Saturated steam at 267°F is flowing inside a :i-in. steel pipe having an ID of 0.824 in. and an OD of l.Q50 in. The pipe is insulated with 1.5 in. of insulation on the outside. The convective coefficient for the inside steam surface of the pipe is estimated as hi = 1000 btu/h· ft2 . OF, and the convective coefficient on the outside of the lagging is estimated as ho 2 btu/h' ft2. OF. The mean thermal conductivity of the metal is 45 W/m' K or 26 btu/h· ft· OF and 0.064 W/m' K or 0.037 btu/h· ft· OF for the insulation. (a) Calculate the heat loss. for 1 ft of pipe using resistances if the surrounding air is at gO°F. (b) Repeat using the overall Vi based on the inside area Ai' Solution: Calling r i the inside radius of the steel pipe, r 1 the outside radius of the pipe, and r0 the outside radius of the lagging, then 0.525 f 12 t

0.412 f

12

t

2.025 f 12 t

For 1 ft of pipe, the areas are as follows. Ai

2nLr;

=

2n{1}(0.:~2) =

0.2157 ft2

2n(1{0.~~5)

0.2750 ft 2

Al ,52nLrI

A.

2nLr o

= 2n(1}e·~~5) =

1.060

fe

From Eg. (4.3-6) the log mean areas for the steel (A) pipe and lagging (B) are AA

1m =

A B1m

228

A In (AI/A;)

=

0.2750 - 0.2157 In (0.2750/0.2157) 1.060 - 0.27 50 In (1.060/0.2750)

Chap. 4

= 0.245 0.583

Principles of Steady-State Heal Transfer

From Eq. (4.3-15) the various resistances are

000(~.2157) = 0.00464

1 R

'1 -

_ rj ... - kA A ... 1m

=./

(0.525 - 0.412)/12 26(0.245)

0.00148

RB = ro r 1 = (2.025 - 0.525)/12 = 580 kB AB 1m 0.037(0.583) . 1 2( l.060) = OA 72 Using an equation similar to Eq. (4.3-15), 267

q

0:00464 =

80

+

(43-19)

267 - 80 6.278 = 29.8 btu/h

For part (b), the equation relating V j to q is Eq. (4.3-16), which can be equated to Eq. (4.3-19). /

q

(43-20)

Solving for V j,

(43-21) Substituting known values, 1 0.2157(6.278) = 0.738

btu

Then to calculate q,

q = VjAj(T; 4.3E

7;,)

0.738(0.2157X267 - 80) = 29.8 btu/h (8.73 W)

Conduction with Internal Heat Generation

In certain systems heat is generated inside the conducting medium; i.e., a uniformly distributed heat source is present. Examples of this are electric resistance heaters and nuclear fuel rods. Also, if a chemical reaction is occurring uniformly in a medium, a heat of reaction is given off. In the agricultural and sanitation fields, compost heaps and trash heaps in which biological activity is occurring will have heat given off. Other important examples are in food processing, where the heat of respiration of fresh fruits and vegetables is present. These heats of generation can be as high as 0.3 to 0.6 W /kg or 0.5 to I btu/h· Ibm' 1. Heat generation in plane wall. In Fig. 4.3-4 a plane wall is shown with internal heat generation. Heat is conducted only in the one x direction. The other walls are assumed to be insulated. The temperature T", in K at x = L and x L is held constant. The volumetric rate of heat generation is q W /m 3 and the thermal conductivity of the medium is kW/m' K.

er

Sec. 43

Conduction Through Solids in Series

229

To derive the equation for this case of heat generation at steady state, we start with Eq. (4.l-3) but drop the accumulation term. (43-22) where A is the cross-sectional area of the plate. Rearranging, dividing by llx, and Jetting llx approach zero, dq" (4.3-23) --+q'A =0

dx

Substituting Eq. (4.1-2) for qx' (43-24) Integration gives the following for

q constant: ,/

T=

(4.3-25)

where C l' and C 2 are integration constants. The boundary condition's are at x = L or - L, T = Tw , and at x = 0, T = To (center temperature). Then, the temperature profile is (43-26)

T= The center temperature is

qE

'7"'--+T 10 2k w

(4.3-27)

The total heat lost from the two faces at steady state is equal to the total heat generated, 4T,inW.

qT

(4.3-28)

4(2LA)

where A is the cross-sectional area (surface area at

TJ of the plate.

2. Heat generation in cylinder. In a similar manner an equation can be derived for a cylinder of radius R with uniformly distributed heat sources and constant thermal

(generation rate)

-x~----~----~----~----_x

o

FIGURE 4.3-4.

230

Plane wall wilh internal heat generation aI steady state.

Chap. 4

Principles of Steady-State Heat Transfer

conductivity. The heat is assumed to flow only radially; i.e., the ends are neglected or insulated. The final equation for the temperature profile is

(4.3-29)

T

where r is distance from the center. The center temperature To is

qR2 To

=

4k

+ T.",

(4.3-30)

EXAMPLE 43-4. Heat Generation in a Cylinder An electric current of 200 A is passed through a stainless steel wire having a radius R of 0.001268 m. The wire is L = 0.91 m long and has a resistance R of 0.126 Q. The outer surface temperature T.", is held at 422.1 K. The average thermal conductivity is k 22.5 W 1m' K. Calculate the center temperature. Solution: First the value of q must be calculated. Si~ce power = 11R, where I is current in amps and R is resistance in ohms,

/21\-= watts

=

qrrR2L

(4.3-31)

Substituting known values and solving, (200)2(0.126)

q

4rr(0.00 126W(0.91)

1.096

X

10 9 W/m3

Substituting into Eq. (4.3-30) and solving, To = 441.7 K.

4.3F

Critical Thickness of Insulation for a Cylinder

In Fig. 4.3-5 a layer of insulation is installed around the outside of a cylinder whose radius r l is fixed with a length L. The cylinder has a high thermal conductivity and the inner temperature TI at point r 1 outside the cylinder is fixed. An example is the case where the cylinder is a metal {:'ipe with saturated steam inside. The outer surface of the is exposed to an environment at To where convective heat transfer insulation at occurs. It is not obvious if adding more insulation with a thermal conductivity of k will decrease the heat transfer rate. At steady state the heat-transfer rate q through the cylinder and the insulation equals the rate of convection from the surface.

(4.3-32) As insulation is added, the outside area, which is A = 2rrr2 L, increases but T2 decreases.

FIGURE

4.3-5.

Sec. 4.3

Crilical radius for insular ion of cylinder or pipe.

Conduction Through Solids in Series

insulation

231

However, it is not apparent whether q increases or decreases. To determine this, an equation similar to Eq. (4.3-15) with the resistance of the insulation represented by Eq. (4.2-11) is written using the two resistances. q

2nL(TI

In (r;/r ) ----=---=-1 k

To)

+

(4.3-33)

r 2 ho

To determine the effect of the thickness of insulation on q, we take the derivative of q with respect to r 2 , equatethis result to zero, and obtain the following for maximum heat flow. (4.3-34)

./

Solving, (4.3-35) where (r 2 )"r is the value of the critical radius when the heat-transfer rate is a maximum. Hence, if the outer radius r 2 is less..-than the critical value, adding more insulation will actually increase the heat-transfer rate q. Also, if the outer radius is greater than the critical, adding more insulation will decrease the heat-transfer rate. Using typical values of k and he often encountered, the critical radius is only a few mm. As a result, adding insulation on small electrical wires could increase the heat loss. Adding insulation to large pipes decreases the heat-transfer rate. EXAMPLE 43-5. Insulating an Electrical Wire and Critical Radius An electric wire having a diameter of 1.5 mm and covered with a plastic insulation (thickness 2.5 mm) is exposed to air at 300 K and h" = 20 W /m 2 . K. The insulation has a k of 0.4 W /m . K. I t is assumed that the wire surface temperature is constant at 400 K and is not affected by the covering. (a) Calculate the value of the critical radius. (b) Calculate the heat loss per m of wire length with no insulation. (c) Repeat (b) for the insulation present. Solution: 'For part (a) using Eq. (4.3-35), (r 2 )"r =

k

h

0.4 20

0.020 m

20 mm

e

For part (b), L = 1.0 m, r2 = 1.5/(2 x 10(0) = 0.75 Substituting into Eq. (4.3-32),

q = he A(t 2

To)

X

10- 3 m, A

(20X2n x 0.75 x 10- 3 x lX400 - 3(0)

= 2nr2

L.

9.42 W 3

For part (c) with insulation, r 1 = 1.5/(2 x 1000) = 0.75 X 10- m, r2 (2.5 + 1.5/2)11000 = 3.25 x 10- 3 m. Substituting into Eq. (4.3-33);

q = -------::---'-'-'-----.,,----'-----In 1 --~------~--------~+--~-~~~ (3.25 x 10 3X20)

= 32.98

W

Hence, adding insulation greatly increases the heat loss. 232

Chap. 4

Principles of Steady-State Heat Transfer

4.3G

Contact Resistance at an Interface

In the equations derived in this section for conduction through solids in series (see Fig. 4.3-1) it has been assumed that the adjacent touching surfaces are at the same temperature; i.e., completely perfect contact is made between the surfaces. For many engineering designs in industry, this assumption is reasonably accurate. However, in cases such as in nuclear power plants where very high heat fluxes are present, a significant drop in temperature may be present at the interface. This interface resistance, called contact resistance, occurs when the two solids do not fit tightly together and a thin layer of stagnant fluid is trapped between the two surfaces. At some points the solids touch at peaks in the surfaces and at other points the fluid occupies the open space. This interface resistance is a complex function of the roughness of the two surfaces, the pressure applied to hold the surfaces in contact, the interface temperature, and the interface fluid. Heat transfer takes place by conduction, radiation, and convection across the trapped fluid and also by condu9tion through the points of contact of the solids. No completely reliable empirical correlations or theories are available to predict contact resistances for all types of materials. See references (C7, R2) for detailed discussions. The equation for the contact resistance is often given as follows: .

~.

q

(4.3-36)

where he is the contact rdJ"stance coefficient in W/m 2 • K, II T the temperature drop across the contact resistance in K, and Re the contact resistance. The contact resistance Re can be added with the other resistances in Eq. (4.3-3) to include this effect for solids in series. For contact between two ground metal surfaces he values of the order of magnitude of about 0.2 x 10 4 to 1 X 104 W/m 2 • K have been obtained. An approximation of the maximum contact resistance can be obtained if the maximum gap llx between the surfaces can be estimated. Then, assuming that the heat transfer across the gap is by conduction only through the stagnant fluid, he is estimated as h

= C

k llx

(4.3-37)

If any actual convection, radiation, or point-to-point contact is present, this will reduce this assumed resistance.

4.4 STEADY-STATE CONDUCTION AND SHAPE FACTORS 4.4A

Introduction and Graphical Method for Two-Dimensional Conduction

In previous sections of this chapter we discussed steady-state heat conduction in one direction. In many cases, however, steady-state heat conduction is occurring in two directions; two-dimensional conduction is occurring. The two-dimensional solutions are more involved and in most cases analytical solutions are not available. One important approximate method to solve such problems is to use a numerical method discussed in detail in Section 4.15. Another important approximate method is the graphical method, which is a simple method that can provide reasonably accurate answers for the heat-transfer rate. This method is particularly applicable to systems having isothermal boundaries. Sec. 4.4

Steady-Stare Conduction and Shape Factors

233

In the graphical method we first note that for one-dimensional heat conduction through a flat slab (see Fig. 4.2-1) the direction of the heat flux or flux lines is always perpendicular to the isotherms. The graphical method for two-dimensional conduction is also based on the requirement that the heat flux lines and the isotherm lines intersect each other at right angles while forming a n~twork of curvilinear squares. This means, as shown in Fig. 4.4-1, that we can sketch the isotherms and also the flux lines until they intersect at right angles (are perpendicular to each other). With care and experience we can obtain reasonably accurate results. General steps to use in this graphical method are as follows. 1. Draw a model to scale of the two-dimensional solid. Lable the isothermal boundaries. In Fig. 4.4-1, TI and T2 are isothermal boundaries.

2. Select a number N that is the number of equal temperature subdivisions between the isothermal boundaries. In Fig. 4.4-1, N 4 subdivisions between TI and T2 • Sketch in the isotherm lines and the heat flow ~rfiux lines so that they are perpendicular to each other at the intersections. Note that isotherms are perpendi9.dar to adiabatic (insulated) boundaries and also lines of symmetry. 3. Keep adjusting the isotherm and flux lines until for each curvilinear square the condition Ax Ay is satisfied. In order to calculate the heat flux using the results of the graphical plot, we first assume unit depth of the materiat The heat flow q' through the curvilinear section shown in Fig. 4.4-1 is given by Fou{ier's law.

q'

dT -kA dy

AT

= k(Ax'l)-

(4.4-1)

Ay

This heat flow q' will be the same through each curvilinear square within this heat-flow lane. Since Ax = Ay, each temperature subdivision AT is equal. This temperature subdivision can be expressed in terms of the overall temperature difference Tl - T2 and N, which is the number of equal subdivisions. AT

( 4.4-2)

N

0.25 m

I>!

T

0.1

ill

1

rTl

1 0.2

T2

q'

T+ I:::. T

ill

1 FIGURE

234

I:::.y \

4.4-1.

T

Graphical curvilinear-square method for two-dimensional heat conduction in a rectangular flue.

Chap. 4

Principles of Steady-State Heat Transfer

I

Also, the heat flow q' through each lane is the same since ilx = ily in the construction and in Eq. (4.4-1). Hence, the total heat transfer q through all of the lanes is

q

=

Mq'

Mk ilT

=

(4.4-3)

where M is the total number of heat-fl9w lanes as determined by the graphical procedure. Substituting Eg. (4.4-2) into (4.4-3), ' (4.4-4)

EXAMPLE 4.4-1. Two-Dimensional Conduction by Graphical Procedure Determine the total heat transfer through the walls of the flue shown in Fig. 4.4-1 if T] = 600 K, T2 = 400 K, k 0.90 W/m· K, and L (length offlue) = 5 m. Solution: In Fig. 4.4-1, N =",A temperature subdivisions and M 9.25. The total heat-transfer rate through the four identical sectjons with a depth or length L of 5 m is obtained by using Eg. (4.4-4).

q

=

4

[~ kL(T

7;)J = 4

j

[9.~5 (0.9 X5.0)(600-400)J

8325 W 4.4B

Shape Factors in COllduction

In Eq. (4.4-4) the factor MIN is calJed the conduction shape factor S, where'

M

(4.4-5) (4.4-6)

l

1 s

This shape factor S has units of m and is used in two-dimensional heat conduction where only two temperatures are involved. The shape factors for a number of geometries have been obtained and some are given in Table 4.4-l. F or a three-dimensional geometry such as a furnace, separate shape factors are used to obtain the heat flow through the edge and corner sections. When each of the interior dimensions is greater than one-fifth of the wall thickness, the shape factors are as follows for a uniform wall thickness Tw: A Sedge

= 0.54L

(4.4-7)

where A is the inside area of wall and L the length of inside edge. For a completely enclosed geometry, there are 6 wall sections, 12 edges, and 8 corners. Note that for a single flat wall, q = kS wall (Tl - T2 ) = k{AI1:"XTI T2 ), which is the same as Eg. (4.2-1) for conduction through a single flat slab. For a long hollow cylinder oflength L such as that in Fig. 4.2-2,

S

2nL In (rJr J )

(4.4-8)

For a hollow sphere from Eq. (4.2-14),

4nr 2 r l S=r2 - r1 :r

Sec. 4.4

Steady-State Conduction and Shape Factors

(4.4-9)

235

TABLE

4.4-1.

Conduction Shape Factorsforq = kS(TI

T 2 )*

==============================================-

-t

Cylinder of length L in a square

G 1

y

a

2rrL

S==----In(O.54 air))

rl

k

I------a

I I

2rrL

Horizontal'''ui'ed cylinder of length L

S

Two parallel cylinders of length E

s=--------

= .....:..----

(H>3rl)

In(2Hlr l)

2rrL

T

Sphere buried

(3;,

s

===================================================• The thermal conductivity of the medium is k.

4.5 4.5A

FORCED CONVECTION HEAT TRANSFER INSIDE PIPES Introduction and Dimensionless Numbers

In most situations involving a liquid or a gas in heat transfer, convective heat transfer usually occurs as well as conduction. In most industrial processes where heat transfer is occurring, heat is being transformed from one fluid through a solid wall to a second fluid. In Fig. 4.5-1 heat is being transferred from the hot flowing fluid to the cold flowing fluid. The temperature profile is shown. The velocity gradient, when the fluid is in turbulent flow, is very steep next to the wall in the thin viscous sublayer where turbulence is absent. Here the heat transfer is mainly by conduction with a large temperature difference of T2 - T3 in the warm fluid. 236

Chap. 4

Principles of Steady-State Ileat Transfer

metal cold fluid B

I I

I I I

Iwarm fluid A I q

FIGURE

\

4.5-1.

Temperature profile fOT heat transfer by convection from one fluid to arlother. /

As we move farther away from the wall, we approach the turbulent region, where rapidly moving eddies tend to equalize the tem'perature. Hence, the temperature gradient is less and the difference Tl - T2 is small. The average temperature of fluid A is slightly less than the peak value TI . A similar explanation can be given for the temperature profile in the cold fluid. / The convective coefficient for heat transfer through a fluid is given by

I

'i] I,

--------=='

(4.5-1) where h is the convective coefficient in W/m 2 . K, A is the area in m 2 , T is the bulk or average temperature of the fluid in K, Tw is the temperature of the wall in contact with the fluid in K, and q is the heat-transfer rate in W. In English units, q is in btu/h, h in btu/h· ft2. of, A in ft2, and T and T", in OF. The type of fluid flow, whether laminar or turbulent, of the individual fluid has a great effect on the heat-transfer coefficient h, which is often called a film coefficient, since most of the resistance to heat transfer is in a thin film close to the wall. The more turbulent the flow, the greater the heat-transfer coefficient. There are two main classifications of convective heat transfer. The first is free or natural convection, where the motion of the fluid results from the density changes in heat transfer. The buoyant effect produces a natural circulation of the fluid, so it moves past the solid surface. In the second type, forced convection, the fluid is forced to flow by pressure differences, a pump, a fan, and so on. Most of the correlations for predicting film coefficients hare semiempirical in nature and are affected by the physical properties of the fluid, the type and velocity of flow, the temperature difference, and by the geometry of the specific physical system. Some approximate values of convective coefficients were presented in Table 4.1-2. In the following correlations, Sl or English units can be used since the equations are dimensionless. To correlate these data for heat-transfer coefficients, dimensionless numbers such as the Reynolds and Prandtl numbers are used. The Prandtl number is the ratio of the shear component of diffusivity for momentum /l/p to the diffusivity for heat k/pc p and physically relates the relative thickness of the hydrodynamic layer and thermal boundary layer.

N p = /l/p = r k/pc p Sec. 4.5

k

Forced Convection Heat Transfer Inside Pipes

(4.5-2)

237

Values of the N Pr for gases are given in Appendix A.3 and range from about 0.5 to 1.0. Values for liquids range from about 2 to well over 104 • The dimensionless Nusselt number, NNu, is used to relate data for the heat-transfer coefficient h to the thermal cond uctivity k of the fluid and a characteristic dimension D. hD

(45-3)

k

For example, for flow inside a pipe, D is the diameter.

4.5B

Heat-Transfer Coefficient for Laminar Flow Inside a Pipe

Certainly, the most important convective heat-transfer process industrially is that of cooling or heating a fluid flowing inside a closed circular conduit or pipe. Different types of correlations for the convective coefficie'nt are needed for laminar flow (NRc below 2100), for fully turbulent flow (N Re above 60(0), and for the transition region (NRe between 2100 and 6000). ' For laminar flow of fluids inside horizontal tubes or pipes, the following equation of Sieder and Tatc (S I) can be used for NRc < 2100:

(45-4) where D = pipe diameter in m, L pipe length before mixing occurs in the pipe in m, = fluid viscosity at bulk average temperature in Pa· s, J1w = viscosity at the wall temperature, c p = heat capacity in J/kg' K, k thermal cOj1ductivity in W/m' K, h. average heat-transfer coefficient in W/m 2 • K, and NNu = dimensionless Nusselt number. All the.-physical properties are evaluated at the bulk fluid temperature except J1,... The Reynolds number is .

J1b

Dup

(45-5)

J1

and the Pr:mdtl number,

k

(45-6)

This equation holds for (NRc N p , D/ L) > 100. If used down to a(NRc N p, D/ L) > 10, it still holds to ± 20% (BI). For (N R. N p , D/L) < 100, another expression is available (P 1). In laminar flow the average coefficient ho depends strongly on heated length. The average (arithmetic mean) temperature drop 6. r;, is used in the equation to calculate the heat-transfer rate q.

(45-7) where T", is the wall temperature in K, 1";,i the inlet bulk fluid temperature, and Too the outlet bulk fluid temperature. F or large pipe diameters and large temperature differences 6. T between pipe wall and bulk fluid, natural convection effects can increase h(P1). Equations are also available for laminar flow in vertical tubes.

238

Chap. 4

Principles of Steady-State Heat Transfer

4.5C

Heat-Transfer Coefficient for Turbulent Flow Inside a Pi~

When the Reynolds number is above 2100, the flow is turbulent. Since the rate of heat transfer is greater in the turbulent region, many industrial heat-transfer processes are in the turbulent region. The followj~g equation has been found to hold for tubes but is also used for pipes. This holds for a N Re > 6000, a N Pr between 0.7 and 16000, and LID > 60.

o.8N 1/3 !.!:.!:. o. 027 N RE Pr (

0.14

J-Lw )

(4.5-8)

where hL is the heat-transfer coefficient based on the log mean driving force 6. Trm (see Section 4.SH). The fluid properties except for Jiw are evaluated at the mean bulk temperature. If the bulk fluid temperature varies from the inlet to the outlet of the pipe, the mean of the inlet and outlet temperatures is used. To correct for an LID < 60, where the entry is an abrupt contraction, an approximate correction is to mUltiply the right-hand side of Eq. (4.5-8) by a correction factor given in Section 4.SF. The use of Eq. (4.S-8) may be tria!and error, since the value of ilL must be known to evaluate Tw, and hence J.lw' at the wall temperature. Also, if the mean bulk temperature increases or decreases in the tube length L because of heat transfer, the bulk temperature at length L must be estimated in order to have a mean bulk temperature of the entrance and exit to use. The heat-transfer coefficient for turbulent flow is somewhat greater for a pipe than for a smooth tube. This effect is much less than in fluid friction, and it is usually. neglected in calculations. Also, for liquid metals that have Prandtl numbers « 1, other correlations must be used to predict the heat-transfer coefficient. (See Section 4.SG.) For shapes of tubes other than circular, the equivalent diameter can be used as discussed in Section 4.SE. For air at 1 atm total pressure, the following simplified equation holds for turbulent flow in pipes. 3.S2uo. s (SI) ilL Do. 2 (4.5-9) (English)

hL =

where D is in m, u in mIs, and ilL in W/ml K for SI units; and D' is in in., v, in fils, and hi, in btu/h' ft2. OF in English units. Water is often used in heat-transfer equipment. A simplified equation to use for a temperature range of T 4 to !Osee (40 - 220 0 F) is

ilL = 1429(1

+ O.OI46T"q

(SI) (4.5-10)

vo. s

ilL

ISO( 1 +

om 1T"F) (D:)O.2

(English)

A very simplified equation for organic liquids to use for approximations is as follows (P3):

Vo. s

ilL = 423

(SI) (4.5-11) (English)

Sec. 4.5

Forced Conveclion Heal Transfer Inside Pipes

239

F or flow inside helical coils and NRc above 10 4 , the predicted film coefficient for straight pipes should be increased by the factor (1 + 3.SDID coil)'

EXAMPLE 4.5-1. Heating of Air in Turbulent Flow Air at 206.8 kPa and an average of 477.6 K is being heated as it flows through a tube of 2S.4 mm inside diameter at a velocity of 7.62 m/s. The heating medium is 488.7 K steam cOIJdensing on the outside of the tube. Since the heat-transfer coefficient of condensing steam is several thousand W/m2 . K and the resistance of the metal wall is very small, it will be assumed Iha t the surface wall temperature of the metal in contact with the air is 488.7 K. Calculate the heat-transfer coefficient for an LID> 60 and also the hea t-transfer flux ql A. Solution: From Appendix A.3 for physical properties of air at 477.6 K (204.4°C), JJ.b 2.60 x 10 - 5 Pa' s, k = 0.03894 W 1m, N Pr = 0.686. At 488.7K(21SSC),JJ.w 2.64 x 10-5la · s. JJ.b

= 2.60 x 10 -.5 Pa' s = 2.60 x 10 -.5 kg/m· s

p=

(28.97{22.~14)( 12~1~~83 )(~~~:~)

1.509 kgjm

3

The Reynolds number calculated at the bulk fluid temperature of 477.6 K is

Dvp It

=

0.0254(7.62)(1.509) 2.6 x 10 .5

= 1.122

x 104

Hence, the flow is turbulent and Eg. (4.5-8) will be used. Substituting into Eg. (4.5-8), NNu =

h~D 0.027N~~8N~~3{::) 0.14

h L (O.0254)

- - - - = 0.027(1.122

.

('0.0260)" 0.14 10 4 )°8(0.686)1/3 - - 0.0264

X

0.03894

Solving, hL 63.2 Wlm 2. K (11.13 btulh . ft2 . OF). To solve for the flux q/ A,

q

A = hL(T w ~ T) = 701.1

4.5D

63.2(488.7 - 477.6)

Wlm 2 (222.2 btulh' ft 2)

Heat-Transfer Coefficient for Transition Flow Inside a Pipe

aN

In the transition region for Re between 2100 and 6000, the empirical equations are not well defined just as in the case of fluid friction factors. No simple equation exists for accomplishing a smooth transition from heat transfer in laminar flow to turbulent flow, i.e., a transition from Eq. (4.5-4) at a N Re = 2100 to Eq. (4.5-8) at a N Re = 6000. The plot in Fig. 4.5-2 represents an approximate relationship to use between the various heat-transfer parameters and the Reynolds number between 2100 and 6000. For below a N Re of2100, the curves represent Eq. (4.5-4) and above 10 4 , Eq. (4.5-8). The mean ATa of Eq. (4.5-7) should be used with the ha in Fig. 4.5-2. 240

Chap. 4

Principles of Steady-State Heat Transfer

!

o

~I-

a 0 a 0

'"

J-l FIGURE

4.SE

4.5-2.

Correlarion of heal-fransfer paramelers for franSilion region for Reynolds number,s befWeen 2100 and 6000. (From R. H. Perry and C H. Chilton, Chemical Engineers' Handl;ook, 5th ed. New York: McGraw-Hili Book Company, 1973. With permission.)

Heal-Transfer Coefficient for Noncircular Conduits

A heat-transfer system often used is that in which fluids flow at different temperatures in concentric pipes. The heat-transfer coefficient of the fluid in the annular space can be predicted using the same equations as for circular pipes. However, the equivalent diameter defined in Section 2.10G must be used. For an annular space,D. q is the ID of the outer' pipe Dl minus the OD of the inner pipe D 2 • For other geometries, an equivalent diameter can also be used.

EXAMPLE 4.5-2. Water Heated by Steam and Trial-and-Error Solution Water is flowing in a horizontal I-in. schedule 40 steel pipe at an average temperature of 65.6°C and a velocity of 2.44 m/s. It is being heated by condensing steam at !o7.8°C on the outside of the pipe wall. The steam side coefficient has been estimated as 110 = 10500 W/m 2 • K. (a) Calculate the convective coefficient hi for water inside the pipe. (b) Calculate the overall coefficient U i based on the inside surface area. (c) Calculate the heat-transfer rate q for 0.305 m of pipe with the water at an average temperature of 6S.6°C. Solution: From Appendix A.S the various dimensions are D, 0.0266 m and Do = 0.0334 m. For water at a bulk average temperature of 65.6°C from Appendix A,2, N Pr 2.72, P = 0.980(1000) = 980 kg/m 3 , k 0.633 W/m' K, and Jl 4.32 x !O-4 Pa' S = 4.32 X 10- 4 kg/m· s. The temperature of the inside metal wall is needed and will be assumed as about one third the way between 65.6 and 107.8 or 80°C = T", for the first trial. Hence, Jl", at 80°C 3.56 x 10 4 Pa . s. First, the Reynolds number of the water is calculated at the bulk average temperature. 0.0266(2.44)(980) 4.32 x 10 "

s

e

'r

1.473

X

10 5

Hence, the flow is turbulent. Using Eq. (4.5-8) and substituting known values,

Sec. 4.5

Forced Convecfion Heal Transfer Inside Pipes

241

h L (0.0266)

- - - - = 0.027(1.473

0.14

.

X

0.663

10 5 )°.8(2.72)113

Solving, hL = hi = 13 324 W/m 2 • K. For part (b), the various areas are as follows for 0.305-m pipe . ./

11D j L = 11(0.0266)(0.305) = 0.0255 m 2

Ai

+ ~.0334)0.305

Aim

=

11 (0.0266)

Ao

=

11(0.0334)(0.305) = 0.0320 m 2

=

0.0287 m 2

The k for steel is 45.0 W1m . K. The resistances are

1 R;

0.002943

(13 324)0.0255 ,/

0.0334

0.0266 _ _ _ _ = 0.002633 2

0.002976

(105OOXO.0320)

R

= 0.002943 + 0.002633 + 0.002976

The overall temperature difference is (107.8' The temperature drop across the water film is

R;

temperature drop

= 2:

R (42.2)

0.008552

65.6tC

0.002943) ( -0.-00-8-85-2 (42.2)

42.2°C = 42.2 K.

14SC

= 14.5 K

Hence, Tw = 65.6 + 14.5 30.l a e. This is quite close to the original estimate of 80°e. The only physical property changing in the second estimate would bej.Liv' This will have a negligible effecton-h-; and a second trial is not necessary. For part (b), the overall coefficient is, by Eq. (4.3-16),

7;) Vi

1

Ai

R

7

0.0255(0.008552)

= 4586 W/m- . K.

For part (c), with the water at an average temperature of 65.6°C,

T. q

4.5F

= V;AdTo

7; T i)

107.8

65.6 = 42.2°C

4586(0.0255)(42.2)

42.2 K 4935 W

Entrance-Region Effect on Heat-Transfer Coefficient

Near the entrance of a pipe where the fluid is being heated, the temperature profile is not fully developed and the local coefficient h is greater than the fully developed heat-transfer coefficient ilL for turbulent flow. At the entrance itself where no temperature gradient has been established, the value of h is infinite. The value of h drops rapidly and is approximately the same as ilL at LID ~ 60, where L is the entrance length. These relations for turbulent flow inside a pipe are as follows where the entrance is an abrupt contraction. 242

Chap. 4

Principles of Steady-State Heat Transfer

II

h

L 2 < - < 20 D

= 1 + (Dy.7 L

hL

ilL

= 1+ 6 /

(~)

(4.5-12)

L. 20 < - < 60 D

L

(4.5-13)

where h is the average value for a tube of finite length Land h L is the value for a very long tube.

4.SG

Liquid-Metals Heat-Transfer Coefficient

Liquid metals are sometimes used as a heat-transfer flui~ in cases where a fluid is needed over a wide temperature range at relatively low pressures. Liquid metals are often used in nuclear reactors and have high heat-transfer coefficients as well as a high heat capacity per unit volume. The high heat-transfer coefficients are due to the very high thermal conductivities and, hence, low Prandtl numbers. In liquid metals in pipes, the heat transfer by conduction is very important in the entire turbulent core because of the high thermal conductivity and is often more important than the convection effects. For fully developed turbulent flow in tubes with uniform heat flux the following equation can be used (Ll): (4.5-14)

NNu

where the Peclet number N re c:= N Re N pr . This holds for L/D > 60 and Nrc between 100 and 10 4 • For constant wall temperatures, NNu

5.0

+ 0.025N~~8

(4.5-15)

for LID> 60 and N re > 100. All physical properties are evaluated at the average bulk temperature.

EXAMPLE 4.5-3. Liquid-Metal Heat Transfer Inside a Tube A liquid metal flows at a rate of 4.00 kg/s through a tube having an inside diameter of 0.05 m. The liquid enters at 500 K and is heated to 505 K in the tube. The tube wall is maintained at a temperature of 30 K above the fluid bulk temperature and constant heat flux is maintained. Calculate the required tube length. The average physical properties are as follows: f1 7.1 x 1O- 4 Pa's,pc:=7400kg/m 3 ,c p 120J/kg'K,k 13W/m·K. The area is A nD2/4 n(0.05)2/4 1.963 x 10- 3 m 2 . Then 4.0/1.963 X 10- 3 2.038 X 10 3 kg/m 2 • s. The Reynolds number is

Solution: G

=

DG

= 0.05(2.038

II

N pr r

x ;0 7.1 x 10

3 )

= 1.435

x lOs

--'---1-3----'- = 0.00655

Using Eq. (4.5-14),

s

ilL

·r

= Dk

0.4 13 5 0.4 (O.625)N pe = 0.05 (O.625X1.435 x lO x 0.00655)

2512 W/m 2 ·K

Sec. 4.5

Forced Convection Heat Transfer Inside Pipes

Using a heat balance,

q = mc p I1T

(4.5-16)

= 4.00(120){505 -

500)

2400 W

Substituting into Eq. (4.5-1),

!l.. = 2400 A

A

hdT", -

n=

2512(30) = 75360 W/m2

Hence, A = 2400/75360 A = 3.185 x 10- 2 = nDL

n(0.05){L)

Solving, L = 0.203 m. 4.SH

Log Mean Temperature Difference and Varying Temperature Drop . /

Equations (4.5-1) and (4.3-12) as written apply only when the temperature drop(7; - 7;,) is constant for all parts of the heating surface. Hence, the equation (4.5-17) only holds at one point in the apparatus when the fluids are being heated or cooled. However, as the fluids travel through the heat exch.anger, they become heated or cooled and both 7; and 7;, or either 7; and 7;, vary. Then (7; - 7;,) or 11 T varies with position, and some mean 11 Tm must be used over the whole apparatus. In a typical heat exchanger a hot fluid inside a pipe is cooled from T'\ to T~ by a cold fluid which is flowing on the outside in a double pipe countercurrently (in the reverse direction) and is heated from T2 to T\ as shown in Fig. 4.5-3a. The 11 T shown is varying with distance. Hence, 11 T in Eq. (4.5-17) varies as the area A goes from 0 at the . inlet to A at the outlet of the exchanger. For countercurrent flow of the two fluids as in Fig. 4.5-3a, the heat-transfer rate is (4.5-18) where 11 Tm is a suitable mean temperature difference to be determined. For a dA area, a heat balance on the hot and the cold fluids gives

= mc p

dT

(4.5-19)

where m is flow rate in kg/so The values of m, m', c p ,

c~,

and U are assumed constant.

dq

_t_

-m'c~

dT

T

6.T 1

-t-

6.T2

244

6.T

6.T j

-t-

Distance (b)

Distance (a) 4.5-3.

~

~ T2

T2

FIGURE

t:o

r;

T~

Temperatllre profiles for one-pass double-pipe heal exchangers: (a) countercurrent flow; (b) COClirrent or parallel flow.

Chap. 4

Principles of Steady-State Heat Transfer

I . Also, dq -dq/m'c~

From Eq. (4.5-19),dT dT

U(T - T) dA

anddT = dq/mc p • Then,

1 ) dq ( -1 + m'c~ mc

d(T -.: T)

dT

(4.5-20)

(4.5-21)

p

Substituting Eq. (4.5-20) into (4.5-21), d(T - T)

T

T

_U(~ + _1_) dA m cp

mc p

(4.5-22)

Integrating between points 1 and 2,

(T~ -

T2)

\T1

Tl

In

-

(4.5-23)

Making a heat balance between the inlet and outlet, q

Solving for

m'c~

m'c~(T;

- TD

mC p (T2 - T t }

. (4.5-24) .

and mc p in Eq. (4.5-24) and substituting into Eq. (4.5-23),

T2)-

UA

(4.5-25)

Comparing Eqs. (4.5-18) and (4.5-25), we see that l::. Tm is the log mean temperature difference l::. 7;m' Hence, in the case where the overall heat-transfer coefficient U is constant throughout the equipment and the heat capacity of each fluid is constant, the proper temperature driving force to use over the entire apparatus is the log mean driving force, (4.5-26) q = UAl::.7;m where, (4.5-27) It can be also shown that for parallel flow as pictured in Fig. 4.5-3b, the log mean temperature difference should be used. In some cases where steam is condensing, T{ and T-i may be the same. The equations still hold for this case. When U varies with distance or other complicating factors occur, other references should be consulted (B2, P3, WI).

EXAMPLE 4.5-4.

Heat-Transfer Area and Log Mean Temperature Difference A heavy hydrocarbon oil which has a c prn = 2.30 kJ/kg' K is being cooled in a heat exchanger from 371.9 K to 349.7 K and flows inside the tube at a rate of 3630 kg/h. A flow of 1450 kg water/h enters at 288.6 K for cooling and flows outside the tu be. (a) Calculate the water outlet temperature and heat-transfer area if the 340 W /m2 . K and the streams are countercurrent. overall U i (b) Repeat for parallel flow. Solution: Assume a c prn = 4.187 kJ/kg' K for water. The water inlet T2 = 288.6 K, outlet T); oil inlet T; 37l.9, outlet 349.7 K. Calculating the heat lost by the oil, g q = (3630 k )( 2.30 h 185400 kJ/h Sec. 4.5

k:~ K)37l.9 or

349.7)K

51490 W (175700 btu/h)

Forced Convection Heat Transfer Inside Pipes

245

By a heat balance, the q must also equal the heat gained by the water.

q

g 185400 kJ/h = (1450 k )(4.187 h

k:~K}Tl -

288.6) K

Solving, Tl = 319.1 K. .' To solve for the log mean temperature difference, 6. T2 = T~ - T2 349.7 288.6 = 61 1 K, 6.T1 = T; Tl = 371.9 - 319.1 52.8 K. Substituting into Eq. (4.5-27), 61.1 - 52.8 6.'T;m = In (6.T2 /6.T1) = In .1/52.8) = 56.9 K Using

(4.5-26), 51 490

340{Aj)(56.9)

Solving, Ai 2.66m 2 • For part (b), the water outlet is still T j 319.1 K. Referring to Fig. 4.5-3b, 6. Tl = 371.9 - 288.6 83.3 K and 6. Tl = 349.7 - 319.1 = 30.6 K. Again, using Eq. (4.5-27) and solving, 6. 7;m 52.7 K. Substituting into Eq. (4.5-26), Ai = 2.87 ml. This is a larger area than for counterflow. This occurs because counterflow gives larger temperature driving forces and is usually preferred over parallel flow for this reason.

EXAMPLE 4.5-5.

Laminar Heat Transfer and Trial and Error

A hydrocarbon oil at 150°F enters inside a pipe with an inside diameter of 0.0303 ft and a length of 15 ft with a flow rate of 80 Ibm/h. The inside pipe surface is assumed constant at 350°F since steam is condensing outside the pipe wall and has a very large heat-transfer coefficient. The properties of the oil are c pm 0.50 btu/Ibm' of and k m = 0.083 btuth . ft . OF. The viscosity of the oil varies with temperature as follows: 150°F, 6.50 cp; 200 c F, 5.05 cp; 250°F, 3.80 cp; 300°F, 2.82 cp; 350°F, 1.95 cp.Predict the heat-transfer coefficient and the oil outlet temperature, Too'

Solution: This is a trial-and-error solution since the outlet temperature of the oil Tbo is unknown. The value of Too = 250°F will be assumed and checked later. The bulk mean temperature of the oil to use for the physical properties is (150 + 250)/2 or 200°F. The viscosity at 200°F is 5.05(2.4191)

Pb

12.23 Ibm ft'h

At the wall temperature of 350°F, /lw

=

1.95(2.4191)

= 4.72

·h

The cross-section area of the pipe A is A

rr(0.030W 4

4

80 Ib,jh

m G=

0.000722 ft2

A = 0.000722 ft

Ibm 2

= 111000 fe. h

The Reynolds number at the bulk mean temperature is

N R<

_ Djvp _ DiG -

Jl

-

Jl

0.0303(111 000) 12.23

Chap. 4

275.5

Principles of Steady-State Heat Transfer

The Prandtl number is

0.7. / ' (4.6-2)

where NRc. L Lvp/Jl. For the completely turbulent region at a N Re • Labove 3 x 10 5 (KI, K3) and N p , > 0.7, (4.6-3) However, turbulence can start at a N Re. L below 3 x 10 5 if the plate is rough (K3) and then Eq. (4.6-3) will hold and give aN Nu greater than by Eq. (4.6-2). Below about aN Re • L of 2 x 104, Eq. (4.6-2) gives the larger value of N Nu'

EXAMPLE 4.6-1.

Cooling a Copper Fin

A smooth, flat, thin fin of copper extending out from a tu be is 51 mm by 51 mm square. Its temperature is approximately uniform at 82.2°C. Cooling air at 15.6°C and 1 atm abs flows parallel to the fin at a velocity 0[12.2 m/s. (a) For laminar flow, calculate the heat-transfer coefficient, h. (b) If the leading edge of the fin is rough so that all of the boundary layer or film next to the fin is completely turbulent, calculate h.

Solution: The fluid properties will be evaluated at the film temperature Tf = (Tw + 7;,)/2. 82.2

+ 15.6 2

48.9°C (322.1 K)

The physical properties of air at 48.9°C from Appendix A.3 are k = 0.0280 W /m . K, p 1.097 kg/m 3, Jl 1.95 x 10 - 5 Pa· s, N Pr = 0.704. The Reynolds number is, for L = 0.051 m,

N Rc . L Substituting into

Jl

_ (0.051X12.2)(1.097) _ 9 04 1.95 x 10 5 -3.4 xl

(4.6-2), NNu

=

hL

T

~~~~~~; = Solving, h 248

0.664N~~\NW 0.664(3.49

X

1Q4)o.5(0.704)113

= 60.7 W /m2 . K (10.7 btufh . ft2 . OF). Chap. 4

Principles of Steady-Slate Heal Transfer

For part (b), substituting into

Eq.

(4.6-3) and

solving, h =

77.2 W/m2 . K (13.6 btu/h· fe . OF). 4.6C

Cylinder with Axis

Perpendicu~ar

to Flow

Often a cylinder containing a fluid inside is being heated or cooled by a fluid flowing perpendicular to its axis. The equation for predicting the average heat-transfer coefficient of the outside of the cylinder for gases and liquids is (K3, P3) (4.6-1) with C and m as given in Table 4.6-1. The NRc = Dup/J1, where D is the outside tube diameter and all physical properties are evaluated at the film temperature Tf . The velocity is the undisturbed free stream velocity approaching the cylinder. 4.6D

Flow Past Single Sphere ./

When a single sphere is being heated or cooled by a fluid flowing past it, the following equation can be used to predict the average heat-transfer coefficient for a'N Re DUP/J1 of 1 to 70 000 and a N Pr of 0.6 to 400. (4.6-4) The fluid properties are evaluated at the film ~emperature TJ • A somewhat more accurate correlation is available fer a NRc range 1-17 000 by others (S2), which takes into account the effects of natural convection at these lower Reynolds numbers.

EXAMPLE 4.6-2.

Cooling of a Sphere Using the same conditions as Example 4.6-1, where air at I atm abs pressure and IS.6°C is flowing at a velocity of 12.2 mis, predict the average heat- transfer coefficient for air flowing by a sphere having a diameter of 51 mm and an average surface temperature of 82.2°C. Compare this with the value of h 77.2 W/m 2 • K for the flat plate in turbulent flow.

I I

Solution:

The physical properties at the average film temperature of 48.9°C are the same as for Example 4.6-1. The NRc is NRc

Dvp _ (0.051)( 12.2)( 1.097) _ 3 4 J1 1.95 x 10 5 -.49 x 10

TABLE

4.6-1.

...

Constants for Use in Eq. (4.6-1)for Heat Transfer to Cylinders with Axis PerpendiclIlar to Flow (N pc > 0.6)

NRc

1-4 4-40 40-4 x IO J 4 x 10 3 -4 X 104 4 x 104.-2.5 X 10 5

Sec. 4.6

m

C

0.330 0.385 0.466 0.618 0.805

0.989 0.911 0.683 0.193 0.0266

Heat Transfer Outside Various Geometries in Forced Convection

249

Substituting into Eq. (4.6-4) for a sphere,

hD N Nu = T

=

h(0.051) 0.0280

2.0

+ 0.60N~·e5 N p1r!3

= 2.0 + (0.60)(3.49

A

X

4

10 )°.5(0.704)1/3

Solving, h = 56.1 W/m 2 • K (9.88 btujh· ft 2 • 0I:). This value is somewhat smaller than the value of h 77.2 W 1m2. K (13.6 btu/h' fe . OF) for a flat plate. 4.6E

Flow Past Banks of Tubes or Cylinders

Many types of commercial heat exchangers are constructed with multiple rows of tubes, where the fluid flows at right angles to the bank of tubes. An example is a gas heater in which a hot fluid inside the tubes heats a passing over the outside of the tubes. Another example is a cold liquid stream the tubes being heated by a hot fluid on the outside. / Figure 4.6-1 shows the arrangement for banks of tubes in-line and banks of tubes staggered where D is tube OD in m (ft), S. is distance m (ft) between the centers of the tubes normal to the flow, and Sp parallel to the flow. The open area to flow for in-line tubes is (S. - D) and (Sp - D), and for staggered tubes it is(S. - D) and(S~ - D). Values of C and m to be used in Eq. (4.6-1) for a Reynolds number range of 2000 to 40000 for heat transfer to banks of tubes containing more than 10 transverse rows in the direction of flow are given in Table 4.6-2. FOr less than 10 rows, Table 4.6-3 gives correction factors. For cases where SJD and SJD are not equal to each other, the reader should consult Grimison (G 1) for more data. In balled exchangers where there is normal leakage where all the fluid does not flow normal to the tubes, the average values of h obtained should be multiplied by about 0.6 (P3). The Reynolds number is calculated using the minimum area open to flow for the velocity. All physical properties are evaluated at T.r.

EXAMPLE 4.6-3. Heating Air by a Bank o/Tubes Air at 15.6°C and 1 atm abs flows across a bank of tubes containing four transverse rows in the direction of flow and 10 rows normal to the flow at a

(a) FIGURE

250

4.6-1.

Nomenclacurefor banks of tubes in Table 4.6-2: (a) in-line cube rows, (b) staggered tube rows. Chap. 4

Principles of Steady-State Heat Transfer

Vailles oj C and m To Be Used in Eq. (4.6-1) Jor Heat TransJer to Banks oj TlIbes Containing More Than 10 Transverse Rows

TABLE 4.6-2.

~ = ~ '~.25 D

D

=~

1.50

D

~ D

~

2.0

D

C

m

C

m

C

m

0.386 0.575

0.592 0.556

0.278 0.511

0.620 0.562

0.254 0.535

0.632 0.556

Arrangement

In-line Staggered

D

Source: E. D. Grimison. Trans. ASl',1 E. 59,583 (1937).

velocity of 7.62 mls as the air approaches the bank of tubes. The tube surfaces are maintained at 57.2°C. The outside diameter of the tubes is 25.4 mm and the tubes are in-line to the flow. The spacing Sn of the tubes normal to the flow is 38.1 mm' and also Sp is 38.1 mm parallel to the flow. For a 0.305 m length of the tube bank, calculate the heat-transfer rate. Solution:

Referring to Fig. 4.6-la,

Sn D

= 38.1

1.5

~

38.1

D

25.4

25.4

1.5

Since the air is heated in passing through the four transverse rows, an outlet bulk temperature of 2L1°C will be assumed. The average bulk temperature is then

1;, = 15.6 + 21.1.= 18.30C The average film temperature is 57.2

+

18.3

nrc

2 From Appendix A.3 for air at 37.rC,

k cp

0.02700 W 1m . K

TABLE 4.6-3.

1.90 x 10 -

5

0.705

1.137kg/m 3

p

l.0048kJ/kg·K J1

N Pr

Pa' S

Ratio oJhJor N Transverse Rows Deep to hJor 10 Transverse Rows Deep (Jor Use with Table 4.6-2) 2

3

4

5

6

7

8

9

10

0.68

0.75

0.83

0.89

0.92

0.95

0.97

0.98

0.99

1.00

0.64

0.80

0.87

0.90

0.92

0.94

0.96

0.98

0.99

1.00

N

Ratio for staggered tubes Ratio for in-line tubes

Source: W. M. Kays and R. K. Lo, Stanford Univ. Tech. Rept. 15, Navy Contract N6·0NR-251 T.O.5, 1952.

r

Sec. 4.6

Heat Transfer Outside Variolls Geometries in Forced Convection

251

(S"

The ratio of the minimum-flow area to the "total frontal area D)/S". The maximum velocity in the tube banks is then

urn.,

Sn

7.62(0.0381) (0.0381 0.Q254)

D

=

0.0254(22.86)(1.137) 1.90 x 10 5

IS

22.86 mls

= 347

X

10 4

.

For SJD SJD 1.5/1, the values of C and m from Table 4.6-2 are 0.278 and 0.620, respectively. Substituting into Eq. (4.6-1) and solving for h,

~ CN~e NW (0~~~;5~) (0.278X3.47 x 10 )°.62(0.705)1/3 4

h

171.8 W/m 2 . K This h is for 10 rows. For only four rows in the transverse direction, the h must be mUltiplied by 0.90, as given in Table 4.6-3. / Since there are lOx 4 or 40 tubes, the total heat-transfer area per 0.305 m length is

A

40nDL

0.973 m 2

40n(0.0254)(0.305)

The total heat-transfer rate q using an arithmetic average temperature difference between the wall and the bulk fluid is

q

=

hA(Tw

7;,)

(0.90 x 171.8XO.973)(57.2

18.3) = 5852 W

Next, a heat balance on the air is made to calculate its temperature rise Ii T using the calculated q. First the mass flow rate of air m must be calculated. The total frontal area of the tub~ bank assembly of 10 rows of tubes each 0.305 m long is A, IOS"(1.0) 1O(0.0381XO.305) = 0.1162 m 2 The density of the entering air at 15.6°e is p = 1.224 kg/m 3 . The mass flow rate m is m

vpA,(3600)

7.62{1.224XO. 11 62)

= 1.084 kgls

For the heat balance the mean cp of air at 18.3°e is 1.0048 kJ/kg' K and then

q

5852

mCpliT

1.084(1.0048 x 10 3 ) liT

Solving, Ii T 5.37°e. Hence, the calculated outlet bulk gas temperature is 15.6 + 5.37 = 20.97°C, whkh is close to the assumed value of 21.1 0e. If a second trial were to bt;.~lI(Je, the new average 7;, to use would be (15.6 + 20.97)/2 or 18.28°e.

4.6F

Heat Transfer for Flow in Packed Beds

Correlations for heat-transfer coefficients for packed beds are useful in designing fixedbed systems such as catalytic reactors, dryers for solids, and pebble-bed heat exchangers. rn Section 3.1 C the pressure drop in packed beds was considered and discussions of the geometry factors in these beds were given. For determining the rate of heat transfer in packed beds for a differential length dz in m, (4.6-5) 252

Chap. 4

Principles of Steady-State Heat Transfer

where a is the solid particle surface area per unit volume of bed in m - 1, S the empty cross-secIional area of bed in m 2 , TI the bulk gas temperature in K, and T2 the solid surface tempera ture. For the heat transfer of gases in beds of spheres (02, 03) and a Reynolds number range of 10-10000, 2.876 0.3023 (4.6-6) 35

N Re

+

NO. Re

where v' is the superficial velocity based on the cross section of the empty container in m/s [see Eq. (3.1-11)], e is the void fraction, N Re = Dp G'/J1.f, and G' = v'p is the superficial mass velocity in kg/m 2 • s. The subscriptfindicates properties evaluated at the film temperature with others at the bulk temperature. This correlation can also be used for a fluidized bed. An alternate equation to use in place of Eq. (4.6-6) for fixed and fluidized beds is Eq. (7.3-36) for a R(':ynolds number range of 10-4000. The term J H is called the Colburn J factor and is deflned as in Eq. (4.6-6) in terms of h. Equations for heat transfer to noncircular cylinders sucIi' as a hexagon, etc., are given elsewhere (HI, 11, P3).

4.7 4.7A

?,'

NATURAL CONVECTION HEAT TRANSFER Introduction

Natural convection heat transfer occurs when a solid surface is in contact with a gas or liquid which is at a different temperature from the surface. Density differences in the fluid arising from the heating process provide the buoyancy force required to move the fluid. Free or natural convection is observed as a result of the motion of the fluid. An example of heat transfer by natural convection is a hot radiator used for heating a room. Cold air encountering the radiator is heated and rises in natural convection because of buoyancy forces. The theoretical derivation of equations for natural convection heat-transfer coefficients requires the solution of motion and energy equations. An important heat-transfer system occurring in process engineering is that in which heat is being transferred from a hot vertical plate to a gas or liquid adjacent to it by natural convection. The fluid is not moving by forced convection but only by natural or free convection. In Fig. 4.7-1 the vertical flat plate is heated and the free-convection boundary layer is formed. The velocity profile differs from that in a forced-convection system in that the velocity at the waH is zero and also 'is zero at the other edge of the boundary layer since the free-stream velocity is zero for natural convection. The boundary layer initially is laminar as shown, but at some distance from the leading edge it starts .to become turbulent. The wall temperature is Tw K and the bulk temperature 1;,. The differential momentum balance equation is written for the x and y directions for the control volume (dx dy· 1). The driving force is the buoyancy force in the gravitational field and is due to the density difference of the fluid. The momentum balance becomes

oUx ( ox

OUx) oy

p v -+v x

y

(4.1-1)

where Pb is the density at the bulk temperature 1;, and P at T. The density difference can be expressed in terms of the volumetric coefficient of expansion p and substituted back into Eq. (4.7-1).

p

Sec. 4.7

p(T - 7;,)

Natural Convection Heal Transfer

(4.1-2)

253

For gases, P = liT. The energy-balance equation can be expressed as follows'

aT aT) a T ( v" ax + vYay .= k ai 2

pCp

(4.7-3)

The solutions of these equations have been obtained by using integral methods of analysis discussed in Section 3.10. Results for a vertical plate have been obtained, which is the most simple case and serves to introduce the dimensionless Grashof number discussed below. However, in other physical geometries the relations are too complex and empirical correlations have been obtained. These are discussed in the following sections.

4.7B

Natural Convection from Various Geometries

1. Natural COI1VeCCiOIl from tJertical planes pnd cylinders. For an isothermal vertical surface or plate with height L less than 1 m (P3), the average natyral convection heat-transfer coelTicient can be expressed by the following general eq uation: hL k

(4.7-4)

where a and In are constants from Table 4.7-1, N Gr the Grashof number, p density in kg/m 3 , !1 viscosity in kg/m' s, '" l' tl1e positive temperature difference between the wall and bulk fluid or vice versa in K, k the thermal conductivity in W /m K, cp the heat capacity in J/kg' K, P the volumetric coelTicient of expansion of the fluid inl/K [for gases p is l/(Tr K)], and 9 is 9.80665 m/s2. All the physical properties are evaluated at the film temperatureTj = (1'", + Yt,)/2. In general, for a vertical cylinder with length L m, the same equations can be used as for a vertical plate. In English units p is l/(1'/F + 460) in ItRandgis32.174 x (360Wft/h2. The Grashof number can be interpreted physically a dimensionless number that represents the ratio of the buoyancy forces to the viscous forces in free convection and plays a role similar to that of the Reynolds number in forced convection.

as

EXAMPLE 4.7-1. Natural COnl'ectionjrom Vertical Wall of an Oven A heated vertical wall 1.0 ft (0.305 m) high of an oven for baking food with the surface at 450°F (S05.4 K) is in contact with air at lOO°F (311 K). Calculate the heat-transfer coelTicient and the heat transfer/ft (0.305 m) width of wall. Note that heat transfer for radiation will not be considered. Use English and SI units.

FIGURE 4.7-1.

Boundary-layer velocity profile for nat!Jrai convection heat transfer from a heated, vertical plate.

x

254

Chap. 4

Principles of Steady-State Heat Transfer

TABLE 4.7-1.

Constants/or Use with Eq. (4.7-4) for Natural Convection

Physical Geometry

NG,N p ,

a

10 9

1.36 0.59 0.13

Ref

m

Vertical planes and cylind 109 Horizontal plates Upper surface of heated 10 5 -2 x 10 7 0.54 plates or lower surface 2 x 10 7 -3 X 10 10 0.14 of cooled plat~s 105 _10 11 Lower surface or heated 0.58 plates or upper surface of cooled plates r

1

5" 1

"4 1

"3

0 1

TI 1

TO I

!

1

"4 I

"3 I

"4 1

J

(P3) (MI) (Ml)

(P3) (P3) (P3) (P3) (Ml) (P3) (Ml) (Ml)

1

!

(F1)

The film temperature is

Solution:

450

+

100 = 2750F

505.4

2

+ 311 2

408.2 K

The physical properties of air at 275°F are k 0.0198 btu/h, ft . OF, 0.0343 W/m· K; p = 0.0541 Ibmlft 3, 0.867 kg/m3; Nf'r = 0.690; p = (0.0232 cp) x (2.4191) = 0.0562Ibmlft·h 2.32 x 1O- 5 Pa's;f)= 1/408.2 2.45 x 10- 3 K I, P 1/(460 + 275) = 1.36 x 10- 3 OR I; f,T = Tw - 4 450 100 = 350°F (194.4 K). The Grashof number is, in English units, (1.0)3(0.0541)2(32.174)(3600)2(1.36 x 10 3)(350) (0.0562)2

N Gr =

1.84

X

10 8

In SI units, V

_ (0.30W(0.867)2(9.806)(2.45 x 10- 3)(194.4) _ 84 x 08 (2.32 x 10 5)2 - L 1

1 Gr -

The Grashof numbers calculated using English and SI units must, of course, be the same as shown. N Gt N p, = (1.84 x 108 )(0.690) = 1.270 x 108

Hence, from Table 4.7-1, a

Sec. 4.7

=

0.59 and m

Natural Convection Heat Transfer

=

t

for use in Eq. (4.7-4).

25S

Solving for h in Eq. (4.7-4) and substituting known values, h

= ~ a(N Or N Pr)m

(O.~ .1~8 }0.59X1.270 X

II

= (0~~:0~}0.59)(1.27

X

Foral-ftwidthofwall,A q

hA(Tw

q

7.03(0.305

8

10 )1/47.03 W /m I

Tb ) X

10 8 ) 1/4 = 1.24 btu/h· ft 2 • of

X

I

2

•

1.0ft 2 (0.305

(1.24Xl.O)(450 0.305XI94.4)

K

100)

= 127.1

0.305m 2 ).Then

X

=

433 btujh

W

A considerable amount of heat will also be lost by radiation. This will be considered in Section 4.10. Simplified equations for the natural convection heat transfer from air to vertical planes and cylinders at I atm abs pressure are given in Table 4.7-2,·ln SI units the equation for the range of NGrN pr of 104 to 10 9 is the one usually encountered and this holds for (J! il T) values below about 4.7 m 3 . K and film temperatures between 255 and 533 K. To correct the value of h to pressures other than 1 atm, the values of h in Table

TABLE 4.7-2. Surfaces

Simplified Eq{wtions for Natural Convection from Various

Equation h = bw/h 1t 2 Physical Geometry

Vertical planes and cylinders Horizontal cylinders

Na,N p ,

Vertical planes and cylinders

256

h

of

=

Wjm 2 • K

L=m,f.T=K D= m

Air at 101.32 kPa (1 atm) abs pressure 10 4-10 9 h = 0.28(il T/L)1/4 h = 1.37(il T/L)I/4 >10 9 h=0.I8(ilT)I/3 h=1.24ilT I/3 3 9 10 -10 h = 0.27(ilT/D)I/4 h = 1.32(ilT/D)I/4 >109 h=0.I8(ilT)I/3 h=1.24ilT I/3

Horizontal plates Heated plate facing upward or cooled 2 plate facing downward Heated plate facing 3 downward or cooled plate facing upward Vertical planes and cylinders

•

L=jt,6T=oF D =jt

10 7

10 -3

X

h 10 10 h

X

10 5-3

X

10 10 h = 0.12(ilT/L)I/4 h

Water at 70°F (294 K) 104_10 9 h = 26(ilT/L)1/4 Organic liquids at 70°F (294 K) 104-10 9 h I2(i1T/L)1/4

Chap. 4

(PI) (PI) (MI) (MI)

= 0.27(ilT/L)I/4 h = 1.32(ilT/L)I/4 (MI) = 0.22(il T)I/3 h = 1.52 il T I /3 (MI)

X

X 7

Ref

= 0.59(ilT/L)I/4 (MI)

h = 127(ilT/L)I/4 (PI)

h = 59(ilT/L)1/4

(PI)

Principles of Steady-State Heat Transfer

4.7-2 can be multiplied by (p/l01.32)1/2 for N Gr N Pr 104 to 10 9 and by (P/101.32)2/3 for 9 NGrN pr > 10 , where p = pressure in kN/m2. In English units the range of NGrN pr of 4 9 10 to 10 is encountered when (IJ D. T) is less than about 300ft)· of. The value of h can be corrected to pressures other than 1.0 atm abs by mUltiplying the h at 1 atm bypl/2 for 4 9 9 NGrN pr of 10 to 10 and by plo for NGrN pr above 10 , where p atm abs pressure. Simplified equations are also given f~r water and organic liquids.

EXAMPLE 4.7-2.

Natllral Convections and Simplified Equation Repeat Example 4.7 -1 but use the simplified equation-.

Solution:

The film temperature of 408.2 K is in the range 255-533 K. Also,

JJ D. T

= (0.305)3(l94.4) = 5.~

This is slightly greater than the value of 4.7 given as the approximate maximum for use of the simplified equation. However, in Example 4.7-1 the value of N Gr N Pr is below 1O~;so the simplified equation from Table 4.7-2 witl be used. Ii

=

D.

T)1/4

1.37( 1;

137(194.4)1/4 . 0.305

The heat-transfer rate.q is

q

hA(Tw - Tb ) = 6.88(0.305 x 0.305}(194.4)

=

124.4 W (424 btu/h)

This value is reasonably close to the value of 127.1 W for Example 4.7-1.

2. Nall/ral convection from horizontal cylinders. For a horizontal cylinder with an outside diameter of D m, Eq. (4.7-4) is used with the constants being given in Table 4.7-1. The diameter D is used for L in the equation .. Simplified equations are given in Table 4.7-2. The usual case for pipes is for the NGrNPr range 10 4 to 10 9 (Ml). 3. Nail/Tal convectionfrom horizontal plates. For horizontal flat plates Eq. (4.7-4) is also used with the constants given in Table 4.7-1 and simplified equations in Table 4.7-2. The dimension L to be used is the length of a side of a square plate, the linear mean of the two dimensions for a rectangle, and 0.9 times the diameter of a circular disk. 4. Natural convection in enclosed spaces. Free convection in enclosed spaces occurs in a number of processing applications. One example is in an enclosed double window in which two layers of glass are separated by a layer of air for energy conservation. The flow phenomena inside these enclosed spaces are complex since a number of different types of flow patterns can occur. At low Grashof numbers the heat transfer is mainly by conduction across the fluid layer. As the Grashof number is increased, different flow regimes are encountered. The system for two vertical plates of height L m containing the fluid with a gap of b m js shown in 4.7-2, where the plate surfaces are at T J and Tl temperatures. The Grashof number is defined as (4.7-5)

N Gr • b The Nusselt number is defined as

hb

NNu. b

Sec. 4.7

Natural Convection Heat Transfer

k

(4.7-6)

257

The heat flux is calculated from (4.7-7) The physical properties are all evaluated- atihe mean temperature between the two plates. For gases enclosed between vertical plates and Lib> 3 (H I, 11, KI, PI),

ho

NN u.v,= k

(4.7-8)

N N )114 020 (. Gr.6 Pr . (Lib) 119

NNu.o

N Nu, J

1.0

= 0,073

(4.7-9)

(N Gr, 0 N pyo (Llb)119

(4.7-10)

For liquids in vertical plates, hi)

k N

Nu..

= 028

.

1.0

(4.7-11)

(N Gr. b N)114 1', (LI(5)114

(4.7-12)

For gases or liquids in a vertical annulus, the same equations hold as for vertical plates. For gases in horizontal plates with the lower plate hotter than the upper, N:'Iu.b =

0.21(NGr.JNpr)114

(7

NNu.J = 0.061(NGr.6Npr)113

X

10 3 < NGr,aNpr < 3

(Nor, ij N pr

>3 x

X

10 5 )

10 5 )

( 4.7-13) (4.7-14)

For liquids in horizontal plates with the lower plate hotter than the upper (G5),

EXAlv/PLE 4.7-3. Natural Convection in Enclosed Vertical Space Air at I atm abs pressure is enclosed between two vertical plates where L 0.6 m and 0 = 30 mm. The plates are 0.4 m wide. The plate temperatures are TI = 394.3 K and T2 = 366.5 K. Calculate the heat-transfer rate across the air gap. FIGURE 4.7-2. vertical space.

Natural convection in enclosed

q

;0

---I 258

Chap. 4

'/

0

1---

Principles of Steady-Slate Heal Transfer

Solution: The mean temperature between the plates is used to evaluate the physical properties. Tf = (TI + T 2 )/2 (394.3 + 366.5)/2 380.4 K. Also, (5 30/1000 = 0.030 m. From Appendix A.3, p = 0.9295 kgjm 3 , J1. = 2.21 X 10- 5 Pa's, k=0.03219 W/m'K, N pr =0.693, {1= 1/0= 1/380.4 = 2.629 x 10 - 3K - J.

N Gr . J =

(0.030)3(0.929W(9.806)(2.629 x 10- 3)(394.3 - 366.5) (2.21 x 10 5)2

= 3.423

X

104

Also, N Gr. ,) N p, = (3.423 x 104 )0.693 J _ 1 -

k (0.20)(N Gr • .lN p ,)1/4 J (L/O)119

=

2.372 x 104 • Using Eq. (4.7-9),

0.03219(0.20X2.352 X 104 )1/4 0.030(0.6/0.030)119

1.909 W/m 2 . K The area A

q

(0.6 x 0.4) Ivi(TI

=

0.241112. Substituting into Eq. (4.7-7),

T 2 ) = 1.909(0.24)(394.3 - 366.5) = 12.74 W

5. Nall/ral COil vecr iOI! from other shapes. For spheres, blocks, and other types of enclosed air spaces, references elsewhere (HI, KI, MI, PI, P3) should be consulted. In some cases when a fluid is forced over a heated surface at low velocity in the laminar region, combined forced-convection plus natural-convection heat transfer occurs. For further discussion of this, see (HI, Kl, MI).

4.8 4.8A

BOILING AND CONDENSATION Boiling

l. ,\c/echanisms afboiling. Heat transfer to a boiling liquid is very important in evaporation and distillation and also in other kinds of chemical and biological processing, such as petroleum processing, control of the temperature of chemical reactions, evaporation of liquid foods, and so on. The boiling liquid is usually contained in a vessel with a heating surface of tubes or vertical or horizontal plates which supply the heat for boiling. The heating surfaces can be heated electrically or by a hot or condensing fluid on the other side of the heated surface. In boiling the temperature of the liquid is the boiling point of this liquid at the pressure in the equipment. The heated surface is, of course, at a temperature above the boiling point. Bubbles of vapor are generated at the heated surface and rise through the mass of liquid. The vapor accumulates in a vapor space above the liquid level and is withdrawn. Boiling is a complex phenomenon. Suppose we consider a small heated horizontal tube or wire immersed in a vessel containing water boiling at 373.2 K (lOO°C). The heat flux is q/AW/m 2 , 6 T = T,,, - 373_2 K, where Tw is the tube or wire wall temperature and h is the heat-transfer coefficient in W /m 2. K. Starting with a low 6 T, the q/ A and h values are measured. This is repeated at higher values of 6 T and the data obtained are shown in Fig. 4.8-1 plotted as q/ A versus 6 T. In the first region A of the plot in Fig_ 4.8-1, at jow temperature drops, the mechanism of boiling is essentially that of heat transfer to a liquid in natural convection.

Sec. 4.8

Boiling and Condensation

259

The variation of h with t.. TO. lS is approximately the same as that for natural convection to horizontal plates or cylinders. The very few bubbles formed are released from the surface of the metal and rise and do not disturb appreciably the normal natural convection. In the region B of nucleate boiling for at.. Tof about 5 25 K (9 - 45°F), the ra te of bubble production increases so that the velocity of circulation of the liquid increases. The heat-transfer coefficient h increases rapidly and is proportional to t.. T2 to t.. T3 in this region. In the region C of transition boiling, many bubbles are formed so quickly that they tend to coalesce and form a layer of insulating vapor. Increasing the t.. T increases the thickness of this layer and the heat flux and h drop as t.. T is increased. In region D or film boiling, bubbles detach themselves regularly and rise upward. At higher t.. T values radiation through the vapor layer next to the surface helps increase the ql A and h. The curve of h versus t..T has approximately the same shape as Fig. 4.8-1. The values of h are quite large. At the beginning'of region B in Fig. 4.8-1 for nucleate boiling, h has a value of about 5700-11 400 W1m2. K, or 1000-2000 btulh . ft2 .O}-, and at the end of this region h has a peak value of almost 57000 W 1m2. K, or 10000 btu/hr' ft2 . OF. These values are quite high, and in most cases the percent resistance of the boiling film is only a few percent of the overall resistance to heat transfer. The regions of commercial interest are the nucleate and film-boiling regions (P3). Nucleate boiling occurs in kettle-tYJ~e and natural-circulation reboilers. 2. Nucleate boiling.

In the nucleate boiling region the heat flux is affected by t..T, pressure, nature and geometry of the surface and system, and physical properties of the vapor and liquid. Equations have been derived by Rohesenow et al. (PI). They apply to single tubes or flat surfaces and arc quite complex. Simplified empirical equations to estimate the boiling heat-transfer coefficients for water boiling on the outside of submerged surfaces at 1.0 atm abs pressure have been developed (12).

6.T K

10

A--t- B

I

-. which is constant. The convection coefficient h in W 1m 2 • K or btu/h· ft 2 • OF is present and is constant; i.e., a surface resistance is present. Hence, the temperature at the surface is not the same as TI • The solution of Eq. (5.1-10) for these conditions has been obtained (SI) and is

1- y

x

erfc' Co 2"';Cf.l

exp

hJai (x hFc)] erfc Jai + -k[-k-

(5.1-7)

where x is the distance into the solid from the surface in SI units in m, t = time in 5, = kl pc p in m 2 Is. In English units, x = ft, l = h, and Cf. ft 2/h. The function erfc is (l - ern, where erf is the error function and numerical values are tabulated in standard tables and texts (G 1, PI, S 1), Yis fraction of unaccomplished change (T j T)/(TI - To), and 1 - Y is fraction of change. Figure 5.3-3, calculated using Eq. (5.3-7), is a convenient plot used for unsteady-state heat conduction into a semiinfinite solid with surface convection. If conduction into the solid is slow enough or is very large, the top line with 00 is used. Cf.

h

IlFclk

EXAMPLE 53-1. Freezing Temperature in the Ground The depth in the soil of the earth at which freezing temperatures penetrate is often of importance in agriculture and construction. During a certain fall day, the temperature in the earth is constant at 15.6°C (60°F) to a depth of several meters. A cold wave suddenly reduces the air temperature from 15.6 to -17.8°C (0° F). The convective coefficient above the soil is 11.36 W1m 2 • K (2 btu/h . ft2 . OF). The soil properties can be, assumed as Cf. = 4.65 FIGURE 5.3-2.

Unsleady-slate conduction in a semiinfinile solid.

TS

"T "-

at t "" t

XT~a~=O

1----""" x

336

Chap. 5

Principles of Unsteady-StIlte Heat Transfer

7 2 X 10- mlls (0.018 ft /h) and k = 0.865 W1m' K (0.5 btufh· ft· Neglect any latent heat effects. Use SI and English units. (a) What is the surface temperature after 5 h? (b) To what depth in the soil will the freezing temperature ofOoe (32°F) penetrate in 5 h?

Solution: This is a case of unsteady-state conduction in a semiinfinite solid. For part (a), the value of x which is the distance from the surface is x = 0 m. Then the value of x/2.jW. is calculated as follows for 1 = 5 h, r.x ~ 4.65 x 10- 7 mlls, k = 0.865 W /m' °e, and h 11.36 W/m 2 • dc. Using SI and English units, 0 x 0 x --=

2J(4.65 x 10 7)(5 x 3600)

2fo

2JO.018(5)

2fo

Also,

~

~

k

k

1.2

2JO.018(5) 0.5 1.2

Using Fig. 5.3-3, for x/2fo = 0 and h.jW.lk 1.2, the value of 1 - Y = 0.63 is read off the curve. Converting temperatures to K, To = 15.6°e + 273.2 = 288.8 K (60°F) and Tl = 17.8°C + 273.2 255.4 K (O°F). Then T - 288.8 y = T = 0.63

Tj

To

1.00 0.80 0.60 0.40 0.30

0

h

0

0.20

h

I

h

0.10

:>-.-

0.08 0.06 0.04 0.03 0.02

0.4

0.8

1.2

1.6

x

FIGURE

Sec. 5.3

5.3-3.

Unsteady-state heal condllcted in a semiinjinite solid with Sllrface convection. Calclilatedfrom Eq. (5.3-7){SJ).

Unsteady-State Heat Condllction in VariOIlS Geometries

337

Solving for T at the surface after 5 h,

T = 267.76 K

or

-5.44°C (22.2°F)

For part (b), T = 273.2 K or O°C, and the distance x Substituting the known values,

T - To T) - To

=

2St

unknown.

273.2 - 288.8 = 0.467 255.4 - 288.8

From Fig. 5.3-3 for (T - To)/(T) - To) = 0.467 and hFat/k 0.16 is read off the curve for x/2Ft. Hence, _x_=

IS

x =0.16 2)(4.65 x 10 7X5 x 3600)

_x_=

2St

1.2, a value of

=

x

=0.16

2)0.018(5)

Solving for x, the distance the freezing temperature penetrates in 5 h, x = 0.0293 m (0.096 ft) S.3C

Unsteady-State Conduction in a Large Flat Plate

A geometry that often occurs in heat-conduction problems is a flat plate ofthickness2x) in the x direction and having large or infinite dimensions in the y and z directions, as shown in Fig. 5.3-4. Heat is being conducted only ffom the two flat and parallel surfaces in the x direction. The original uniform temperature of the plate is To, and at time I = 0, the solid is exposed to an environment at temperature T) and unsteady-state conduction occurs. A surface resistance is present. The numerical results of this ~ase are presented graphically in Figs. 5.3-5 and 5.3-6. Figure 5.3-5 by Gurney .and Lurie (G2) is a convenient chart for determining the temperatures at any position in the plate and at any time l. The dimensionless parameters used in these and subsequent unsteady-state charts in this section are given in Table 5.3-1 (x is the distance from the center of the flat plate, cylinder, or sphere. x) is one half the thickness of the fla t plate radius of cylinder, or radius of sphere. x = distance from the surface for a semiinfinite solid.) When n = 0, the position is at the center of the plate in Fig. 5.3-5. Often the temperature history at the center of the plate is quite important. A more accurate chart for determining only the center temperature is given in Fig. 5.3-6 in the Heisler (HI) chart. Heisler (H 1) has also prepared multiple charts for determining the temperatures at other positions.

EXAMPLE 5.3-2. Ileat Conduction in a Slab of Butter A rectangular slab of butter which is 46.2 mm thick at a temperature of 277.6 K (4.4°C) in a cooler is removed and placed in an environment at 297.1 K (23.9°C). The si,9~s and bottom of the butter container can be

FIGURE

338

5.3-4.

Unsteady-state conduction in a large fiat plate.

Chap. 5

Principles of Unsteady-Slate Heat Transfer

considered to be insulated by the con~ainer side walls. The fiat top surface of the butter is exposed to the environment.' The convective coefTicient is constant and is 8.52 W/m 1 . K. Calculate the temperature in the butter at the surface, at 25.4 mm below the surface, and at 46.2 mm below the surface at the insulated bottom after 5 h 0Fexposure.

Solution: The butter can be considered as a large fiat plate with conduction vertically in the x direction. Since heat is en tering only at the top face and the bottom face is insulated, the 46.2 mm of butter is equivalent to a half plate with thickness XI 46.2 mm. In a plate with two exposed surfaces as in Fig. 5.3-4, the center at X = 0 acts as an insulated surface and both halves are mirror images of each other. The physical properties of butter from Appendix A.4 are k 0.197 W/m' K, cp = 2.30 kJ/kg' K 2300 J/kg' K, and p = 998 kg/m 3 • The thermal diIfusivity is k 0.197 a = 8.58 x 10- 8 m 2 /s pCp 998(2300) Also, XI = 46.2/1000 0.0462 m. The parameters needed for use in Fig. 5.3-5 are k

0.197 8.52(0.0462) = 0.50

m=hXI

at' = (8.58 x 1O,c:. aX5 x 3600) = 072

x

(0.0462)2

For the top surface wherex

.

0.0462 m,

= Xl

0.0462 0.0462

n

1.0

Then using Fig. 5.3-5, y = 0.25

Solving, T TABLE 5.3-1.

T

---'---

TI - To

297.1 T 297.1 277.6

292.2 K (19.0°C). Dimensionless Parametersfor Use in Unsteady-State Conduction Charts

Y

y=

X

-T TI - To T T)

To

k

m=hXI

n=

X Xl

at

xi

SI units: 0: = m /s, T K, t = s, x = m, Xl m,k=W/m K,h=W/m 2 'K English units: a = fe /h, T = OF, t = h, X ft,XI = ft, k btufh· ft· OF, h = btu/h' ft 2 • OF cm, k = cal/s . em' °C, Cgsunits:o: cm 2 /s, T = °C,t s,X = cm,x) h = cal/s· cm 2 • °C 2

Sec. 5.3

Unsteady-State Heat Conduction in Various Geometries

339

hh

0.010

r--+--t-

, I

m"'O

~ n"'l

4.0

a.t

X, FIGURE

340

5.3-5.

xi

Unsteady-state heat conduction in a large flat plate. [From H. P. Gurney and J. Lurie, Ind. Eng. Chern., 15, 1170 (1923).]

Chap. 5

Principles of Unsteady-State Heat Transfer

",-f"'o;>"

1.0 0.8

'r/ .::::-

"-

----

/Z:.: ,

0) 0.2 0.1 0.08

hlh'

hi h-

0.04 0.02

0

~

0.01 0.008 0.004 0.002 0.001

0

4

2

FIGURE

~ .....

6

5.3-6.

81012141618

22

Charljor delermillillg letnperalure al lhe celller oj alargejlal plalejor ullsleadY-Slale heal collduclioll. [From H. P. Heisler, TrailS. A.S.M.E., 69,227 (1947). Will! permissioll.]

plate

At the point 25.4 mm from the top surface or 20.8 mm from the center, x = 0.0208 m, and n ..::. = 0.0208 = 045 0.0462

Xl

From Fig. 5.3-5, Y

- T'

0.45

Tl - To

.

297.1 T 297.1 - 277.6

Solving, T = 288.3 K (15.1 QC). For the bottom point or 0.0462 m from the top, x n

X

0

Xl

XI

0 and

-=-=0

Then, from Fig. 5.3-5,

Y

0.50

297.1 - T 297.1-

TI- T TI - To

Solving, T = 287.4 K (14.2°C). Alternatively, using Fig. 5.3-6, which is only for the center point, Y 0.53 and T = 286.8 K (13.6°C). 5.3D

Unsteady-State Conduction in a Long Cylinder

Here we consider unsteady-state conduction in a long cylinder where conduction occurs only in the radial direction. The cylinder is long so that conduction at the ends can be neglected or the ends are insulated. Charts for this case are presented in Fig. 5.3-7 for determining the temperatures at any position and Fig. 5.3-8 for the center temperature only. EXAMPLE 53-3. Transient Heat Conduction in a Can ofPeaPurie A cylindrical can of pea puree (C2) has a diameter of 68.1 mm and a height of 101.6 mm and is initially at a uniform temperature of 29.4°C. The cans are stacked vertically in a retort and steam at 115.6°C is admitted. For a heating time of 0.75 h at 115.6°C, calculate the temperature at the center of the can. Assume that the can is in the center of a vertical stack of cans and that it is insulated on its two ends by the other cans. The heat capacity of the metal wall of the can will be neglected. The heat-transfer coefficient of the steam is estimated as 4540 W/m 2 . K. Physical properties of puree are k = 0.830 W/m' K and IX 2.007 x 10- 7 m 2/s.

Solution: Since the can is insulated at the two ends we can consider it as a long cylinder. The radius is XI = 0.0681/2 = 0.03405 m. For the center with x = 0, X

0

Xl

Xt

n=-=-=O

Also, rn

x

k IXt

0.830 4540(0.03405)

= 0.00537

(2.007 x 10- 7 )(0.75 x 3600) (0.03405)2

0.468

Using Fig. 5.3-8 by Heisler for the center temperature, Y

Solving, T 342

=

0.13 = Tl - T T1-To

=

115.6 11

T

104.4°C. Chap. 5

Principles 0/ Unsteady-State Heat Transfer

n = 1.0 0.8

0.10

hh' I

h h-

0.00100~--~--OJ.-5---L---l~.LO-L~---IL.5--~---2~.~0--~---2~.-5~~L--3~.0--~--~3.5

FIGURE

5.3E

5.3-7.

Unsteady-stale heat COnduclion in a long cylinder. [From lI. P. Gurney and 1. Lurie, Ind. Eng. Chern., 15, 1170 (1923).J

Unsteady-State Conduction in a Spbere

In Fig. 5.3-9 a chart is given by Gurney and Lurie for determining the temperatures at any position in a sphere. In Fig. 5.3-10 a chart by Heisler is given for determining the center temperature only in a sphere. Sec. 5.3

Unsteady-State fleat Conduction in Various Geometries

343

t

1.0 I~ 0.8~~~ ..

0.4

-1--?linder

\..--\m\\-\\\",,~

II 0.1 0.08

hl~ I

~+~ I 'I..

0.04

1"....

I

t

"=oJ",

X--+

hi h0

0.02

>-.

0.01 0.008

0.004

0.002

0.001

0

ext X=2 Xl

FIGURE

5.3-8.

Chart for delermillillg temperature at the cellter of a 10llg cylillder for unsleady-slale heal COlldUClioll. [From H. P. Heisler, TrailS. A.S.M.E., 69,227 (1947). Wilh permissioll.]

".~

.....

,.,~,~,--.-~

..,....

~--. -.-~~-.,,".-:-

sphere

0.0 1 a t--..,..--t-HII----··- ...····

0.5

1.0

2.0

1.5

X, FIGURE

5.3F

5.3-9.

2.5

3.0

3.5

at

Unsteady-state heal conduction in a sphere. [From H. P. Gurney and 1. Lurie, Ind. Eng. Chem" 15, 1170 (/923).)

Unsteady-State Conduction in Twoand Three-Dimensional Systems

The heat-conduction problems considered so far have been limited to one dimension. However, many practical problems are involved with simultaneous unsteady-state COI1duction in two and three directions. We shall illustrate how to combine one-dimensional solutions to yield solutions for several-dimensional systems. Newman (NI) used the principle of superposition and showed mathematically how Sec. 5.3

Unsteady-State Heat Conduction in Various Geometries

345

1.0

*

0.8~-

-~... ~~---.---.--

-'f--t-.--t--+--t--tsphere

0.4

0.2

0.1 0.08

hlh' I

hi h0

:>-.

0.04

0.02

0.0] 0.008

0.004

0.0021

0.001

0

I

0.5

I

1.0

1.5

2.0

2.5

3

4

5

6

7

8

9

X

FIGURE

5.3-10.

]0

20

30

40

170

250

at

Chart for determining the temperature at the center of a sphere for unsteady-state h"at cOlldlU:lilm. rFrom 11. P. Heisier, Trails. A.S.M.E., 69, 227 (1947). Wjth

·-~-··'-·"",_,_ ........ ~,~ .. '-;">",~ .... ;..i>w.'".,."_,,,,.~.".,,

...; .• ~",_;",....;:...""~,.;c.:"."";,;;:,,,,:;,~W.;'i:;::';:;,,,'... ~;.,~'.r~i,l.J ..f";';";1.',.;t.

.;:.:

FIGURE 5.3-11.

Unsteady-state conduction in three directions in a rectangular block.

-1

1 to combine the solutions for one-dimensional heat conduction in the x, the y, and the z direction into an overall solution for simultaneous conduction in all three directions. For example, a rectangular block with dimensions 2x l , .7YI' and 2zt is shown in Fig. 5.3-11. For the Y value in the x direction, as before, y=Tt Yx .. Tl-To

(5.3-8)

where Yx is the temperature at time t and/position x distance from the center line, as before. Also, n = X/Xl' m k/hxl' and X x = ext/xi, as before. Then for the y direction,

and n = Y/YI' m

TI -

T,

TI

To

(5.3-9)

k/hYI and X y = C1.t/yi. Similarly, for the z direction,

Y = Z

7:1

. T.

•

(5.3-10)

TJ-To

Then, for the simultaneous transfer in all three directions,

TJ

-

Tl

T""y.z To

(5.3-11)

where Yx. Y. z is the temperature at the point x, y, z from the center of the rectangular block. The value of r,. for the two parallel faces is obtained from Figs. 5.3-5 and 5.3-6 for conduction in a flat plate. The values of Y, and Y. are similarly obtained from the same charts. For a short cylinder with radius Xl and length 2Yl' the following procedure is followed. First Yx for the radial conduction is obtained from the figures for a long cylinder. Then Y, for conduction between two parallel planes is obtained from Fig. 5.3-5 or 5.3-6 for conduction in a flat plate. Then, . (5.3-12)

EXAMPLE 53-4. Two-Dimensional Conduction in a Short Cylinder Repeat Example 5.3-3 for transient conduction in a can of pea puree but assume that conduction also occurs from the two flat ends. Solution: The can, which has a diameter of 68.1 mm and a height of 101.6 mm, is shown in Fig. 5.3-12. The given values from Example 5.3-3 are Sec. 5.3

Unsteady-State Heat Conduction in Various Geometries

347

FIGURE

5.3-12.

Two dimensional conduction in a short cylinder in Example 5.3-4.

= 0.03405 m, YI = 0.1016j2 = 0.0508 m, k = 0.830 W jm· K,C1. = 2.007 10- 7 mljs, h = 4540 Wjm l . K and t = 0.75(3600) = 2700 s. For conduction in the x (radial) direction as calculated previously,

XI

x 0 n=-=-=O XI

x

XI

X

k 0.830 m = hx I = 4540(0.03405) = 0.00537

'

= C1.; = (2.007 x

10 - 7~2700

=

0.468

(0.03405)

xI

From Fig. 5.3-8 for the center temperature, ... Yx = 0.13 For conduction in the y (axial) direction for the center temperature,

n=L=_O_=o 0.0508

YI

k m

0.830

= hYI = 4540(0.0508) = 0.00360

7 X = ~ = (2.007 x 10- )2700 = 0210 (0.050W .

Y;

Using Fig. 5.3-6 for the center of a large plate (two parallel opposed planes), Yy

=

0.80

Substituting into Eq. (5.3-12), Yx. y = (YxXYy) = 0.13(0.80)

=

0.104

Then, TI - T".y TI - To Tx • y

=

=

115.6 - T".y 115.6 - 29.4

=

0.104

106.6°C

This compares with l04.4°C obtained in Example 5.3-3 for only radial conduction.

53G

Charts for AYerage Temperature in a Plate, Cylinder, and Sphere with Negligible Surface Resistance

If the surface resistance is negligible, the curves given in Fig. 5.3-13 will give the total fraction of unaccomplished change, E, for slabs, cylinders, or spheres for unsteady-state 348

Chap. 5

Principles of Unsteady-State Heat Transfer

conduction. The value of E is

E=.....:..--

(5.3-13)

where To is the original uniform temperature, Tl is the environment temperature to which the solid is suddenly subjected, and Yav is the average temperature of the solid after t hours. The values of Ea, E b , and Ec are each used for conduction between a pair of parallel faces as in a plate. For example, for conduction in the a and b directions in a rectangular bar, (5.3-14) For conduction from all three sets of faces, (5.3-15) For conduction in a short cylinder 2c long and radius a, (5.3-16)

1.0 0.8 0.6

e17, L? , ::::!:'~L?,;. !:.l~6, \"\

~ _\ "-

0.4 0,3 0,2

\

"\~fC~ f'-rs (2; V;r + r1)' v, + r yz v.)

y

+ :z (rzxV;r + rzyV + rnv z ) ]

(5.6-8)

For further details of this derivation, see (B2). 366

Chap. 5

Principles of Unsteady-State Heat Transfer

Equation (5.6-8) is the final equation of energy change relative to a stationary point. However, it is not in a convenient form. We first combine Eq. (5.6-8} with the equation of continuity, Eq. (3.6-23), with the equation of motion, Eq. (3.7-13), and express the internal energy in terms of fluid temperature T and heat capacity. Then writing the resultant equation for a Newtonian fluid with constant thermal conductivity k, we obtain

pc DT v

Dc

= kV 2 T _ T(iJ P ) iJT

(V. v)

+ J1. PA2 and Pa2 > PEl' Molecules of A diffuse to the right and B to the left. Since the total pressure P is constant throughout, the net moles of A diffusing to the right must equal the net moles of B to the left. If this is not so, the total pressure would not remain constant. This means that (6.2-1) The subscript z is often dropped when the direction is obvious. Writing Fick's law for B for constant c, (6.2-2) Now since P =

PA

+ PB

constant, then (6.2-3)

Differentiating both sides, (6.2-4) Equating Eq. (6.1-3) to (6.2-2),

dC

DAB -dzA

J *A--

-J~

(6.2-S)

Substituting Eq. (6.2-4) into (6.2-5) and canceling like terms, (6.2-6) This shows that for a binary gas mixture of A and B the diffusivity coefficient D AE for A diffusing in B is the same as DBA for B diffusing into A. EXAIHPLE 6.2-1. Equimofar Counterdiffusion Ammonia gas (A) is diffusing through a uniform tube 0.10 m long containing N z gas (B) at 1.0132 x 10 5 Pa press and 298 K. The diagram is similar to Fig. 6.2-1. At point 1, PAl = 1.013 x 104 Pa and at point 2, PAl 0.507 4 x 10 Pa. The diffusivity D AE = 0.230 x 10 4 m 2 /s. (a) Calculate the flux J~ at steady sta teo (b) Repeat for

J:.

Zl

Equation (6./-13) can be used where P = 1.0132 X 10 5 Pa, 0.10 m, and T = 298 K. Substituting into Eq. (6.1 13) for part (a),

J* _

DAB(PAI -

Solution: Z2 -

A -

=

RT(Z2 - Zl)

4.70

X

(0.23 x 1O- 4 Xl.013 x 104 8314{298XO.lO

PA;) _

_

0.507 0)

X

10- 7 kg mol A/s·m 2

Rewriting Eq. (6.1-13) for component B for part (b) and noting that PEl P - p" I 1.0132 X 10 5 - 1.013 X 104 9.119 X 104 Pa and PBl P - P,12 = 1.0132 x lOs - 0.507

,,, _ J8 -

I!

10 4 )

X

4

10 = 9.625

X

10 Pa,

4

RT(Z2 - :1)

=

4

_ (0.23 x 10- )(9.119 x 104 8314{298X0.10

9.625 0)

X

10"')

-4.70 x 10- 7 kg mol B/s ·m 2 The negative value for 386

J; means the flux goes from point 2 to 1. Chup.6

Principles of Mass Trallsfer

6.2B

General Case for Diffusion of Gases A and B Plus Convection

Up to now we ha ve considered Fick's law for diffusion in a stationary fluid; i.e., there has been no net movement or convective flow of the entire phase of the binary mixture A and B. The diffusion flux J~ occurred because· of the concentration gradient. The rate at which moles of A passed a fixed point to the right, which will be taken as a positive flux, is J~ kg mol A/s' m 2 . This flux can be converted to a velocity of diffusion of A to the right by 2

J~ (kg mol Als· m ) =

VAdC A

(m kg mol A) m -;

3

(6.2-7)

where vAd is the diffusion veloci ty of A in m/s. Now let us consider what happens when the whole fluid is moving in bulk or convective flow to the right. The molar average velocity of the whole fluid relative to a stationary point is V.\j m/s. Component A is still diffusing to the right, but now its diffusion velocity VAd is ID{' Expressed mathematically, the velocity of A relative to the stationary point is the sum of the diffusion velocity and the average or convective velocity. (6.2-8) where VA is the velocity of A relative to a stationary point. Expressed pictorially,

Multiplying Eq. (6.2-8) by C A

,

(6.2-9) Each of the three terms represents a flux. The first term, C A v A, can be represented by the flux NA kg mol Als· m 2 • This is the total flux of A relative to the stationary point. The second term is J~ , the diffusion flux relative to the moving fluid. The third term is the convective flux of A relative to the stationary point. Hence, Eq. (6.2-9) becomes

(6.2-10) Let N be the total convective flux of the whole stream relative to the stationary point. Then, (6.2-11) Or, solving for

VM ,

(6.2-12) Substituting Eq. (6.2-12) into (6.2-10),

(6.2-13)

Sec. 6.2

Molecular Diffusion in Gases

387

Since J~ is Fick's law, Eq. (6.1-7), (6.2-14) Equation (6.2-14) is the final general equation for diffusion plus convection to use when the flux N A is used, which is relative to a stationary point. A similar equation can be written for N B . (6.2-15) To solve Eq. (6.2-14) or (6.2-15), the relation between the flux N A and N B must be known. Equa tions (6.2-14) and (6.2-15) hold for diffusion in a gas, liquid, or solid. For equimolar counterdiffusion,N A N B and the convective term in Eq. (6.2-14) N B -J; . becomes zero. Then, N A J~ 6.2C

Special Case for A Diffusing Through Stagnant, NonditTusing B'

The case of diffusion of A through stagnant or nondifTusing B at steady state often occurs. In this case one boundary at the end of the diffusion path is impermeable to component B, so it cannot pass through. One example shown in Fig. 6.2-2a is in evaporation of a pure liquid such as benzene (A) at the bottom of a narrow tube, where a large amount of inert or nondiffusing air (B) is passed over the top. The benzene vapor (A) diffuses through the air (B) in the tube. The boundary at the liquid surface at point 1 is impermeable to air, since air is insoluble in benzene liquid. Hence, air (B) cannot diffuse into or away from the surface. At point 2 the partial pressure PA2 = 0, since a large volume of air is passing by. Another example shown in Fig. 6.2-2b occurs in the absorption of NH3 (A) vapor which is in air (B) by water. The water surface is impermeable to the air, since air is only very slightly soluble in water. Thus, since B cannot difTuse,NB O. To derive the case for A diffusing III stagnant, nondiffusing B, N B O i s substituted into the general Eq. (6.2-14). N A = -cD AD i

(Z

11

C

+~(NA+O)

_ a i r (B) 2

Z2 -

21

I_LL,

1 is a constant and corrects for the fact the path is actually greater than 0 cm. In this method, discussed by Bidstrup and Geankoplis (B4), the effective diffusion length is obtained by calibrating with a solute such as KCI having a known diffusivity. Sec. 6.3

Molecular Diffusion in Liquids

399

V'

stirrer

I

C

-)

v c FIGURE

6.3- J.

DifJusion cell for delerminal ion of difJusivity in a liquid.

To derive the equation, quasi-steady-state diffusion in the membrane is assumed. c

NA

CDAB

c'

Kb

(6.3-6)

I

where c is the concentration in the lower chamber at a time t, c' is the concentration in the upper, and c is the fraction of area of the glass open to diffusion. Making a balance on solute A in the upper chamber, where the rate in rate out + rate of accumulation, making a similar balance on the lower chamber, using volume V = V', and combining and integrating the final equation is

2eA

In --'---- = - K tbV c c'

DAB

r

(6.3-7)

where 2eAJK t oV is a cell constant that can be determined using a solute of known diffusivity, such as KCl. The valuesc o and c~ are initial concentrations and c and c' final concentrations. 2. Experimental liquid diffilsiviry data. Experimental diffusivity data for binary mixtures in the liquid phase are given in Table 6.3-1. All the data are for dilute solutions of the diffusing solute in the solvent. In liquids the diffusivities often vary quite markedly with concentration. Hence, the values in Table 6.3-1 should be used with some caution when outside the dilute range. Additional data are given in (PI). Values for biological solutes in solution are given in the next section. As noted in the table, the ditfusivity values are quite small and in the range of about 0.5 X 10- 9 to 5 X 10- 9 m 2/s for relatively nonviscous liquids. Diffusivities in gases are larger by a factor of 10 4 to lOS.

6.3D

Prediction of Diffusivities in Liquids

The equations for predicting diffusivities of dilute solutes in liquids are by necessity semiempirical, since the theory for diffusion in liquids is not well established as yet. The Stokes-Einstein equation, one of the first theories, was derived for a very large spherical molecule (A) diffusing in a liquid solvent (B) of small molecules. Stokes' law was used to describe the drag on the moving solute molecule. Then the equation was modified by assuming that all molecules are alike and arranged in a cubic lattice and by expressing the molecular radius in terms of the molar volume (W5),

9.96 x 10- 16T DAB

400

=

J1

V I /3

(6.3-8)

A

Chap. 6

Principles of Mass Transfer

TABLE

6.3-1.

Diffusion Coefficients for Dilute Liquid Solut ions Temperature Solvent

°C

NH3

Water

O2

Water

12 15 18 25 25 25 15 10 25 15 25 9.7 25 25 10 10 25 25 25 12 25 25 25

Solute

CO 2 H2 Methyl alcohol Ethyl alcohol

Il-Propyl alcohol Formic acid Acetic acid Propionic acid H CI (9 g mOl/liter) (2.5 g mol/liter) Benzoic acid Acetone Acetic acid Urea Water KCI KCI

Water Water Water Water Water ' Water Water Water Water Water Water Benzene Ethanol Ethanol Water Ethylene glycol

K

Diffusivity [(m 1 js)10 9 or (cm 1 js)10']

285 288 291 298 298 298 288 283 298 288 298 282.7 298 298 283 283 298 298 298 285 298 298 298

1.64 1.77 1.98 2.41 2.00 4.8 1.26 0.84 1.24 0.87 1.52 0.769 1.26 1.01 3.3 2.5 1.21 1.28 2.09 0.54 1.13 1.870 0.119

Ref

(N2) (N2) (VI) (VI) (VI)

(11) (11)

(11) (11)

(B4) (B4) (B4) (B4) (N2) (N2) (C4) (A2) (C5) (N2) (H4) (P2) (P2)

where DAD is diJfusivity in m 2 js, T is temperature in K, J1 is viscosity of solution in Pa' s or kgjm . s, and VA is the solute molar volume at its normal boiling point in m 3(kg mol. This equation applies very well to very large unhydrated and spherical-like solute molecules of about 1000 molecular weight or greater (Rl), or where the V A is above about 0.500 m 3 /kg mol (W5) in aqueous solution. For smaller solute molar volumes, Eq. (6.3-8) does not hold. Several other theoretical derivations have been attempted, but the equations do not predict diJfusivities very accurately. Hence, a number of semitheoretical expressions have been developed (R 1). The Wilke-Chang (T3, W5) correlation can be used for most general purposes where the solute (A) is dilute in the solvent (B). D AB = 1.173 x 1O- 16 ( 1 and CLi > Cj, even though they are in equilibrium. Other cases are shown in Fig. 7.1-3c and d. This was also discussed in Section 6.6B. 2. Relation between mass- alld heat-transfer parameters. In order to use the unsteadystate heat-conduction charts in Chapter 5 for solving unsteady-state diffusion problems, the dimensionless variables or parameters for heat transfer must be related to those for mass transfer. In Table 7.1-1 the relations between these variables are tabulated. For K -=f. 1.0, whenever kc appears, it is given as Kk c ' and whenever C I appears, it is given as cl/K.

TABLE 7.1-1.

Relation Between Mass- and H eat- Transfer Parameters for Unsteady-State Diffusion* M ass Transfer

Heal Trallsfer

K

T - T

Y

c I -

I

'T1

1- Y

-

To T-T

C cI -

0

x-I

=

1.0

C

cI -

'TI - To

elt X, ---;;

cJc

=

Co

K

=

cIIK cIIK -

C Co

c-

Co Co

cJc -# 1.0

cJK -

DABt

DABt

X2 I

X2 I

Co

X

X

x

2.;-;1

2JD::i

2JD::i

k m, hXI

DAB kc

-h.;-;1 at k

-kcDAB

X 11,XI

DAB KkcXI

XI

JD::i DABt

Kkc -DAB

X

X

XI

XI

JD::i DABt

• x is the distance from the center of the slab, cylinder, or sphere; for a semiinfinite slab, x is the distance from the surface. Co is the original uniform concentration in the solid, c, the concentration in the fluid outside the slab, and c the concentration in the solid at position x and time t.

430

Chap. 7

Principles of Unsteady-State and Convective Mass Transfer

3. Charts for diffusion in various geometries. The various heat-transfer charts for unsteady-state conduction can be used for unsteady-state diffusion and (j.re as follows. 1. Semiinfinite solid, Fig. 5.3-3.

2. 3. 4. 5.

Flat plate, Figs. 5.3-5 and 5.3-6. Long cylinder, Figs. 5.3-7 and 5.3-8. Sphere, Figs. 5.3-9 anq 5.3-10. Average concentrations, zero convective resistance, Fig. 5.3-13.

EXAMPLE 7.1-1. Unsteady-State Diffusion in a Slab of Agar Gel A solid slab of 5.15 wt % agar gel at 278 K is 10.16 mm thick and contains a uniform concentration of urea of 0.1 kg mol/m 3 Diffusion is only in the x direction through two parallel flat surfaces 10.16 mm apart. The slab is suddenly immersed in pure turbulent water so that the surface resistance can be assumed to be negligible; i.e., the convective coefficien t k, is very large. The difTusivity of urea in the agar from Table 6.4-2 is 4.72 x 10- 10 m 2/s. (a) Calculate the concentration at the midpoint of the slab (5.08 mm from the surface) and 2.54 mm from the surface after 10 h. (b) If the thickness of the slab is halved, what would be the midpoint concentration in 10 h? Solution: For part (a), Co 0.10 kg mol/m\ C 1 = 0 for pure water, and c = concentration at distance x from center line and time t s. The equilibrium distribution coefficient K in Eq, (7.1-16) can be assumed to be 1.0, since the water in the aqueous solution in the gel and outside should be very similar in properties. From Table 7.1-1,

Y

ct/K -

Co

Also, XI 10.16/(1000 x 2) = 5.08 X 10- 3 m (half-slab thickness), x 0 (center), X = DABt/X; (4.72 x 1O- IO ){1O x 3600)/(5.08 x 10- 3 )2 0.658. The relative position n = x/x 1 0/5.08 x 10- 3 0 and relative resistance m = DAJKk, Xl 0, since kc is very large (zero resistance). From Fig. 5.3-5 for X 0.658, m = 0, and n = 0, Y

= 0.275

O-c

o -- 0.10

3

Solving, c = 0.0275 kg mol/m for x O. For the point 2.54 mm from the surface or 2.54 mm from center, x 2.54/1000 2.54 x 10- 3 m, X = 0.658, m = 0, n x/x! = 2.54 x 10- 3/5.08 x 10- 3 = 0.5. Then from Fig. 5.3-5, Y 0.172. Solving, c = 0.0172 kg mol/m 3 . For part (b) and half the thickness,X = 0.658/(0.5)2 2.632, n 0, and m O.Hence,Y 0.OO20andc 2.0xlO- 4 kgmol/m 3 •

EXAMPLE 7.1-1. Unsteady-State Diffusion in a Semiinfinite Slab A very thick slab has a uniform concentration of solute A of Co = 1.0 X 10- 2 kg mol A/m 3 , Suddenly, the front face of the slab is exposed to a flowing fluid having a concentration c! = 0.10 kg mol A/m 3 and a convective coefficient kc 2 x 10- 7 m/s. The equilibrium distribution coefficient K cdc; = 2.0. Assuming that the slab is a semiinfinite solid, calculate the concentration in the solid at the surface (x 0) and x = 0.01 m from the surface after t = 3 X 104 s. The diffusivity in the solid is DAB = 4 X 10- 9 m 2 /s.

Sec. 7.1

Unsteady-State Diffusion

431

To use Fig. S.3-3,

Solution:

For x = 0.01 m from the surface in the solid, x

_r===O=,=;O1:======:= = 0.4 57

2JD ABt From the chart, 1 - Y = 0.26. Then, substituting into the equation for Y) from Table 7.1-1 and solving,

(1

Y =_c_-,,-_ cIIK - Co

c For x

=

2.04

X

0.26

10- 2 kg mol/m 3

(for x

0.01 m)

0 m (i,e., at the surface of the solid),

0

x

2JD::c

From the chart, 1 - Y = 0.62. Solving, c = 3.48 X 10- 2 • This value is the same as c;, as shown in Fig. 7.1-3b. To calculate the concentrationc u in the liquid at the interface,

eLi =

Kc;

2.0(3.48 x 10- 2)

6.96 x 10- 2 kg mol/m 3

A plot of these values will be similar to Fig. 7.l-3b. 4. Unsteady-state diffusion in more than one direction. In Section 5.3F a method was given for unsteady-state heat conduction to combine the one-dimensional solutions to yield solutions for several-dimensional systems. The' same method can be used for unsteady-state diffusion in more than one direction. Rewriting Eq. (5.3-11) for diffusion in a rectangular block in the x, y, and z directions, (7.1-17)

where ex. y, z is the concentration at the point x, y, z from the center of the block. The value of Y., for the two parallel faces is obtained from Fig_ 5..3-5 or 5.3-6 for a flat plate in the x direction. The values of Yy and y. are similarly obtained from the same charts. For a short cylinder, an equation similar to Eq. (S.3-12) is used, and for average concentrations, ones similar to Eqs. (5.3-14), (5.3-1S), and (S.3-16) are used.

7.2 7.2A

CONVECTIVE MASS-TRANSFER COEFFICIENTS Introduction to COllvective Mass Transfer

In the previous sections of this chapter and Chapter 6 we have emphasized molecular diffusion in stagnant fluids or fluids in laminar flow. In many cases the rate of diffusion is slow, and more rapid transfer is desired. To do this. the fluid velocity is increased until turbulent mass transfer occurs. To have a fluid in convective flow usually requires the fluid to be flowing by another immiscible fluid or by a solid surface. An example is a fluid flowing in a pipe, where part 432

Chap. 7

Principles of Unsteady-State and Convective Mass Transfer

of the pipe wall is made by a slightly dissolving solid material such as benzoic acid. The benzoic acid dissolves and is transported perpendicular to the main stream from the wall. When a fluid is in turbulent flow and is flowing past a surface, the actual velocity of small particles of fluid cannot be described clearly as in laminar flow. In laminar flow the fluid flows in streamlines and its behavior can usually be described mathematically. However, in turbulent motion there are no streamlines, but there are large eddies or "chunks" offluid moving rapidly in seemingly random fashion. When a solute A is dissolving from a solid surface there is a high concentration of this solute in the fluid at the surface, and its concentration, in general, decreases as the distance from the wall increases. However, minute samples of fluid adjacent to each other do not always have concentrations close to each other. This occ;urs because eddies having solute in them move rapidly from one part of the fluid to another, transferring relatively large amounts of solute. This turbulent diffusion or eddy transfer is quite fast in comparison to molecular transfer. Three regions of mass transfer can be visualized. In the first, which is adjacent to the surface, a thin viscous sublayer film is present. Most of the mass transfer occurs by molecular diffusion. since few or no eddies are presenC A large concentration drop occurs across this film as a result oftbe slow diffusion rate. The transition or buffer region is adjacent to the first region. Some eddies are present and the mass transfer is the sum of turbulen t and molecular diffusion. There is a gradual transition in this region from the transfer by mainly molecular diffusion at the one end to mainly turbulent at the other end. In the turbulent region adjacent to the buffer region, most of the transfer is by turbulent diffusion, with a small amount by molecular diffusion. The concentration decrease is very small here since the eddies tend to keep the fluid concentration uniform. A more detailed discussion of these three regions is given in Section 3.100. A typical plot for the mass transfer of a dissolving solid from a surface to a turbulent ,fluid in a conduit is given in Fig, 7.2- L The concentration drop from CAl adjacent to the surface is very abrupt close to the surface and then levels off. This curve is very similar to the shapes found for heat and momentum transfer. The average or mixed concentration is shown and is slightly greater than the minimum C A2 • 7.2B

Types of Mass-Transfer Coefficients

1. Defillitioll of mass-transfer coefficient. Since our understanding of turbulent flow is incomplete, we attempt to write the equations for turbulent diffusion in a manner similar to that for molecular diffusion. For turDulent mass transfer for constant c, (6.1-6) is

FIGURE

7.2-1.

Concentration profile in turbulent mass rransfer from a surface to a fluid.

CA 1

---=--O~------------~Z

Distance from surface

Sec. 7.2

Convective Mass-Transfer Coefficients

433

written as J~

-(D AB

dC A

+ eM) dz

(7.2-1)

where DAB is the molecular diffusivity in m 2 /s and eM is the mass eddy diffusivity inm 2/s. The value of eM is a variable and is near zero at the interface or surface and increases as the distance from the wall increases. We then use an average value eM since the variation of eJi is not generally known. Integrating Eq. (7.2-1) between points 1 and 2, (7.2-2) The flux J~ I is based on the surface area A 1 since the cross-sectional area may vary. The value of Z 2 - Z I, the distance of the path, is often not known. Hence, Eq. (7.2-2) is simplified and is written using a convective mass-transfer coefJicient k~. (7.2-3) J~I

is the flux of A from tlle surface Al relative to the whole bulk phase, k; is - Z I) an experimental mass-transfer coefficient in kg mol/s· m 2 . (kg 3 mOl/m ) or simplified as mIs, and C ,-\2 is the concentration at point 2 in kg mol A/m 3 or more usually the average bulk concentration CA2 • This defining of a convective masstransfer coefficient k~ is quite similar to the convective heat-transfer coefficient h.

where (DAB

+ e\l)/(Z2

2. iHass-rransjer coefficient Jar equimolar counterdiffusion. Generally, we are interested in N A' the flux of A relative to stationary coordinates, We can start with the following, which is similar to that for molecular diffusion but the terme M is added. (7.2-4) For the case of equimolar counterdiffusion, whereN A steady state, calling k~ = (D All + [M)/(Z 2 Z 1),

N B, and integrating at

NA = k~(CAl - CA2 )

(7.2-5)

Equation (7.2-5) is the defining equation for the mass-transfer coefficient. Often, however, we define the concentration in terms of mole fraction if a liquid or gas or in terms of partial pressure if a gas, Hence, we can define the mass-transfer coefficient in several ways. If YA is mole fraction in a gas phase and x II in a liquid phase, then Eq. (7.2-5) can be written as follows for equimolar counterdiffusion:

= k;(c AI

Gases:

NA

Liquids:

NA = k~(CAI

CA2 )

k~(PAl - p,u)

CA2 ) = k~(CAI - CA2 }

=

k~(YAI

YA2)

(7.2-6)

k~(XAI

XA2)

(7.2-7)

All of these mass-transfer coefficients can be related to each other. For example, using C A dc and Y A2 = C A2/C into the equation, Eq. (7.2-6) and substituting YAI

k'(~C Y

Hence,

k' k'< =..1'

(7.2-9)

C

These relations among mass-transfer coefficients, and the various flux equations, are given in Table 7.2-1.

434

Chap. 7

Principles of Unsteady-State and Convective Mass Transfer

TABLE

7.2-1.

Flux Equations and Mass-Transfer Coefficients

Flux equations for equimolar counterdiffusion Gases:

Flux equations for A diffusing through stagnant, nondiffusing B

Conversions between mass-transfer coefficients Gases:

k~c = k~:T

kc

~;

k'c;P

=

kCPBM

=

kYYBM

=

k~

kcYBMC

kGYBM P

Liquids: k~c=k~c

kLxBMC

k~plM

k~=k"XBM

(where p is density of liquid and M is molecular weight)

U nits of mass-transfer coefficients Sl Units

mls

s·

mol . mol frac mol

s·

kg mol

s' ·Pa s·m 2 ·atm (preferred)

Cgs Units

English Units

cmls

ft/h

mol . mol frac mol

s'

'atm

h·

Ib mol . mol frac

lb mol h·

'atm

3. Mass-transfer coefficient for A diffusing through stagnant, nondiffusing B. For A diffusing through stagnant, nondiffusing B where N B = 0, Eq. (7.2-4) gives for steady state (7.2-10)

<

where the X 8M and its counterpart YBM are similar to Eq. (6.2-21) and kc is the masstransfer coefTicient for A diffusing through stagnant B. Also, (7.2-11) Rewriting Eq. (7.2-10) using other units, (Gases):

(7.2-12) (7.2-13)

Again all the mass-transfer coefficients can be related to each other and are given in Sec. 7.2

Convective Mass-Transfer Coejficienrs

435

Table 7.2- L For example, setting Eq. (7.2-10) equal to (7.2-13), (7.2-14) Hence, (7.2-15)

EXAMPLE 7.2-1. Vaporizing A and Convective Mass Transfer A large volume of pure gas B at 2 atm pressure is flowing over a surface from which pure A is vaporizing. The liquid A completely wets the surface, which is a blotting paper. Hence, the partial pressure of A at the surface is the vapor pressure of A at 298 K, which is 0.20 atm. The k~ has been estimated to be 6.78 x 10- 5 kg mol/s· m 2 . mol frac. Calculate N A, the vaporization rate, and also the value of ky and kG' Solution:

This is the case of A diffusing through B, where the flux of B normal to the surface is zero, since B is not soluble in liquid A. PAl 0.20 atmandpA2 OinthepuregasB. Also'YAI =PAI/P 0.20/2.0 0.10 and YA2 O. We can use Eq. (7.2-12) with mole fractions. (7.2-12) However, we have a value for k~ which is related to ky from Table 7.2-1 by kYYBM

k~

=

(7.2-16)

The term YaM is similar to X 8M and is, from Eq. (7.2-11), (7.2-11) YAI

YBI

1 - 0.10

o

= 0.90

1.0

Substituting in to Eq. (7.2-11), 1.0 - 0.90 YBM = In (1.0/0.90)

= 0.95

Then, from Eq. (7.2-16), 6.78 0~9~0- 5 = 7.138 x 10

5

kg moljs' m 2 . mol frac

Also, from Table 7.2-1, kGYBM P

(7.2-17)

kYYBM

Hence, solving for kG and substituting knowns,

P kG

P

7.138 x 10- 5 2 x 1.01325 X 105 Pa

= 3.522 x 10-

7.l~80 X

X

10

2

kg mol/s·m ·Pa

5

10. atm

= 3.569

10- 5 kg mOl/s·m 2 .atm

For the flux using Eq. (7.2-12), NA

436

kY(YAI

YA2)

=

Chap. 7

7.138 x 10- 5 (0.10

0)

7.138 x 10- 6 kg mOl/s·m 2

Principles of Unsteady-State and Convective Mass Transfer

Also, PAl

= 0.20 atm

=

0.20(1.01325 x 10 5) = 2.026

X

104 Pa

Using Eq. (7.2-12) again,

NA

= kG (P.ln

-

P A2) =

3.522 x 10 - 1°(2.026

= 7.138

N A = koCI? Ai

PA2) =

X

X

6

104

10- kg mOl/s· m

3.569 x 10- 5(0.20

0)

2

0)

7.138 x 10- 6 kg mol/s'm 2 Note that in this case, since the concentrations were dilute, YaM is close to LO and ky and k~ differ very little.

7.2C Methods to Determine Mass-Transfer Coefficients Many different experimental methods have been employed to experimentally obtain mass-transfer coefficients. In determining the mass-transfer coefficient to a sphere, Steele and Geankoplis (S3) used a solid sphere of benzoic acid held rigidly by a rear support in a pipe. Before the run the sphere was weighed. After flow of the fluid for a timed interval, the sphere was removed, dried, and weighed again to give the amount of mass transferred, which was small compared to the weight of the sphere. From the mass transferred and the area of the sphere, the flux N A was calculated. Then the driving force (CAS - 0) was used to calculate kL' where CAS is the solubility and the water contained no benzoic acid. Another method used is to flow gases over various geometries wet with evaporating liquids. For mass transfer from a flat plate, a porous blotter wet with the liquid serves as the plate.

7.3

7.3A

MASS-TRANSFER COEFFICIENTS FOR VARIOUS GEOMETRIES Dimensionless Numbers Used to Correlate Data

The experimental data for mass-transfer coefficients obtained using various kinds of fluids, different velocities, and different geometries are correlated using dimensionless numbers similar to those of heat and momentum transfer. Methods of dimensional analysis are discussed in Sections 3.11, 4.14, and 7.8. The most important dimensionless number is the Reynolds number N Re , which indicates degree of turbulence. Lvp N Re · = - ' -

(7.3-1)

J1

where L is diameter Dp for a sphere, diameter D for a pipe, or length L for a flat plate, The velocity v is the mass average velocity if in a pipe. In a packed bed the superficial velocity v' in the empty cross section is often used or sometimes v = v'je is used, where v is interstitial velocity and e void fraction of bed. The Schmidt number is (7.3-2)

Sec. 7.3

M ass-Transfer Coefficients for Various Geometries

437

The viscosity /-l and density p used are the actual flowing mixture of solute A and fluid B. If the mixture is dilute, properties of the pure fluid B can be used. The Prandtl number cp/-llk for heat transfer is analogous to the Schmidt number for mass transfer. The Schmidt number is the ratio of the shear component for diffusivity /-lIp to the diffusivity for mass transfer D liB' and it physically relates the relative thickness of the hydrodynamic layer and mass-transfer boundary layer. The Sherwood number, which is dimensionless, is

(7.3-3) Other substitutions from Table 7.2-1 can be made for k; in Eq. (7.3-3). The Stanton number occurs often and is

·k'

k'

Ns =..5-=_y , v GM

k~P

GM

(7.3-4)

Again,substitutionfork~

can be made. G M vPIMav = VC. Often the mass-transfer coefficient is correlated as a dimensionless J D factor which is related to k~ and NSh as follows.

(7.3-5) F or heat transfer a dimensionless J Ii factor is as follows:

~ (N Pc )2/3 Cp G

7.3B

(7.3-6)

Analogies Among Mass, Heat, and Momentum Transfer

1. Introduction. In molecular transport of momentum, heat, or mass there are many similarities, which were pointed out in Chapters 2 to 6. The molecular diffusion equations of Newton for momentum, Fourier for heat, and Fick for mass are very similar and we can say that we have analogies among these three molecular transport processes. There are also similarities in turbulent transport, as discussed in Sections 5.7C and 6.1A, where the flux equations were written using the turbulent eddy momentum diffusivity e" the turbulent eddy thermal diffusivity a" and the turbulent eddy mass dilTusivity SoH' However, these similarities are not as well defined mathematically or physically and are more difficult to relate to each other. A great deal of effort has been devoted in the literature to developing analogies among these three transport processes for turbulent transfer so as to allow prediction of one from any of the others. We discuss several next. 2. Reynolds analogy. Reynolds was the first to note similarities in transport processes and relate turbulent momentum and heat transfer. Since then, mass transfer has also been related to momentum and heat transfer. We derive this analogy from Eqs. (6.1-4}(6.1-6) for turbulent transport. For fluid How in a pipe for heat transfer from the fluid to the wall, Eq. (6.1-5) becomes as follows, where z is distance from the wall:

q A 438

Chap. 7

(7.3-7)

Principles of Unsteady-State and Convective Mass Transfer

For momentum transfer, Eq. (6.t-4) becomes

p(!:!. + 8,) dv Next we assume a and )l/p are negligible and that (7.3-8),

(-')c q/A

(7.3-8)

dz

p

CJ.,

= £,. Then dividing Eq. (7.3-7) by

dT = dv

(7.3-9)

p

If we assume that heat flux q/ A in a turbulent system is analogous to momentum flux r, the ratio r/(q/A) must be constant for all radial positions. We now integrate between conditions at the wall where T ~ and v 0 to some point in the fluid where T is the same as the bulk T and assume that the velocity at this point is the sameas vn , the bulk velocity. Also, q/ A is understood to be the flux at the wall, as is the shear· at the wall, written as". Hence,

qA / Also,substitutingq/A = h(T

cp(T -~)

Vav -

0

(7.3-10)

~) and 's =fv;v p/2 from Eq.(2.10-4) into Eq. (7.3-10),

f

h

h

2

(73-11)

In a similar manner using Eq. (6.1-6) for J~ and alsoJ~ = k~(CA CAi)' we can relate this to Eq. (7.3-8) for momentum transfer. Then, the complete Reynolds analogy is

f

h

k'c

2

(7.3--12)

Experimental data for gas streams agree approximately with Eg. (7.3-12) if the Schmidt and Prandtl numbers are near 1.0 and only skin friction is present in flow past a flat plate or inside a pipe. When liquids are present and/or form drag is present, the analogy is not valid. J. Other analogies. The Reynolds analogy assumes that the turbulent diffusivitiese" (1." and e,\/ are all equal and that the molecular diffusivities )l/ p, (1., and DAB are negligible compared to the turbulent diffusivities. When the Prandtl number ()l/p)/a is 1.0, then JI/ p = a; also, for Nsc = 1.0, )l/p DAB' Then, ()l/p + e,) = (a + a,) (D AB + £.\{) and the Reynolds analogy can be obtained with the molecular terms present. However, the analogy breaks down when the viscous sublayer becomes important since the eddy diffusivities diminish to zero and the molecular diffusivities become important. Prandtl modified the Reynolds analogy by writing the regular molecular diffusion equation for the viscous sublayer and a Reynolds-analogy equation for the turbulent core region. Then since these processes are in series, these equations were combined to pl'oduce an overall equation (GI). The results also are poor for fluids where the Prandtl and Schmidt numbers differ from 1.0. Von Karman further modified the Prandtl analogy by considering the buffer region in addition to the viscous sublayer and the turbulent core. These three regions are shown in the universal velocity profile in 3.10-4. Again, an equation is written for molecular diffusion in the viscous sublayer using only the molecular diffusivity and a Reynolds analogy equation for the turbulent core. Both the molecular and eddy diffusivity are used in an equation for the buffer layer, where the velocity in this layer is used to obtain an

Sec. 7.3

M ass- Transfer Coefficients for VariOlls Geometries

439

equation for the eddy dilfusivity. These three equations are then combined to give the von Karman analogy. Since then, numerous other analogies have appeared (PI, S4). 4. Chilton and Colburn J-factor analogy. The most successful and most widely used analogy is the Chilton and Colburn J-factor analogy (C2). This analogy is based on experimental data for gases and liquids in both the laminar and turbulent flow regions and is written as follows: (7.3-13) Although this is an equation based on experimental data for both laminar and turbulent flow, it can be shown to satisfy the exact solution derived from laminar flow over a flat plate in Sections 3.10 and 5.7. Equation (7.3-13) has been shown to be quite useful in correlating momentum, heat, and mass transfer data. It permits the prediction of an unknown transfer coefficient when one of the other coefficients is known. In momentum transfer the friction factor is obtained for the total drag or friction loss, which includes form drag or momentum losses due to blunt objects and also skin friction. For flow past a flat plate or in a pipe where no form drag is present,j72 J H = J D' When form drag is present, such as in flow in packed beds or past other blunt objects,J72 is greater than J II or J D and J II :;;;:; J D'

7.3C

Derivation of Mass-Transfer Coefficients in Laminar Flow

1. Introduction. When a fluid is flowing in laminar flow and mass transfer by molecular diffusion is occurring, the equations are very similar to those for heat transfer by conduction in laminar flow. The phenomena of heat and mass transfer are not always completely analogous since in mass transfer several components may be diffusing. Also, the flux of mass perpendicular to the direction of the flow must be small so as not to distort the laminar velocity profile. In theory it is not necessary to have experimental mass-transfer coefficients for laminar flow, since the equations for momentum transfer and for diffusion can be solved. However, in many actual cases it is difficult to describe mathematically the laminar flow for geometries, such as flow past a cylinder or in a packed bed. Hence, experimental mass-transfer coefficients are often obtained and correlated. A simplified theoretical derivation will be given for two cases in laminar flow. 2. Mass transfer in laminar flow in {l wbe. We consider the case of mass transfer from a tube wall to a fluid inside in laminar flow, where, for example, the wall is made of solid benzoic acid which is dissolving in water. This is similar to heat transfer from a wall to the flowing fluid where natural convection is negligible. For fully developed flow, the parabolic velocity derived as Eqs. (2.6-18) and (2.6-20) is (7.3-14)

where Vx is the velocity in the x direction at the distance r from the center. For steady-state diffusion in a cylinder, a mass balance can be made on a differential element where the rate in by convection plus diffusion equals the rate out radially by diffusion to gIve

v x

ac ax

Chap. 7

A

=

(~DC A +

D AB

r

ar

(7.3-15)

Principles of Unsteady-State and Convective Mass Tramfer

Then, a2 e ,.;ax 2 = 0 if the diffusion in the x direction is negligible compared to that by convection. Combining Eqs. (7.3-14) and (7.3-15), the final solution (S1) is a complex . series similar to the Graetz solution for heat transfer and a parabolic velocity profile. Hit is assumed that the velocity profile is flat as in rodlike flow, the solution is more easily obtained (S1). A third solution, called the approximate Leveque solution, has been obtained, where there is a linear velocity profile near the wall and the solute diffuses only a short distance from the wall into the fluid. This is similar to the parabolic velocity profile solution at high flow rates. Experimental design: equations are presented in Section 7.3D for this case. 3. Diffusion in a laminar falling film. In Section 2.9C we derived the equation for the velocity profile in a falling film shown in Fig. 7.3-1a. We will consider mass transfer of solute A into a laminar falling film, which is important in wetted-wall columns, in developing theories to explain mass transfer in stagnant pockets of fluids, and in turbulent mass transfer. The solute A in the gas is absorbed at the interface and then diffuses a distance into the liquid so that it has not penetrated the whole distance x bat the wall. At steady state the inlet concentration cA = O. At a point z distance from the inlet the concentration profile of e A is shown in Fig. 7.3-1a. A mass balance will be made on the element shown in Fig. 7.3-lb. For steady state, rate of input rate of output.

N AxiAl Az) + N Azl.(l Ax)

(7.3-16)

N Axlx+Ax(l Az) + N Azl= +Az(l Ax)

For a dilute solution the diffusion equation for A in the x direction is

N Ax =

OCA DAB -

ox + zero convection

(7.3-17)

For the z direction the diffusion is negligible. N A=

(7.3-18)

O+cAv z

gas

z N;tzlz /'""'0----7:'-::'--:--

velocity profile

!J6.x--1

L

r:----f~_ 0

z

0,

for r > 0

00,

for r > 0

Z

=

(7.5-38)

The solution by Danckwerts (D I) is =

1exp( -zjk'/D AB )'

crrc(

CAO

k k

2

+ 1 exp(zJk'/D AB) . crrc(

2

rD AB

tD AB

fo) + fo)

(7.5-39)

The total amount Q of A absorbed up to time t is

Q

= c,wjD AB/k'[(k't + 1)erf

fo + jk'c/ne-

k

"]

(7.5-40)

where Q is kg mol A absorbed/m2. Many actual cases are approximated by this case. The equatign is useful where absorption occurs at the surface of a stagnant fluid or a solid and unsteady-state diffusion and reaction occurs in the solid or fluid. The results can be used to measure the diffusivity of a gas in a solution, to determine reaction rate constants k' of dissolved gases, and to determine solubilities of gas in liquids with which they react. Details are given elsewhere (D3).

EXAMPLE 7S-3. Reaction and Unsteady-State Diffusion Pure CO 2 gas at 101.32 kPa pressure is absorbed into a dilute alkaline buffer solution containing a catalyst. The dilute, absorbed solute CO 2 undergoes a first-order reaction with k' 35 s 1 and DAB = 1.5 x 10- 9 460

Chap. 7

Principles of Umleady-Slale and Conveclive Mass Transfer

m 2 /s. The solubility of CO 2 is 2.961 X 10- 7 kg mol/m 3 ·Pa (D3). The'" surface is exposed to the gas for 0.010 s. Calculate the kg mol CO 2 absorbed/mz surface. For use in Eq. (7.5-40), k't 35(0.01) = 0.350. Also, c AO = 2.961 X 10- 7 (kg mOl/m 3 • Pa)(101.32 x 10 3 Pal = 3.00 x 10- 2 kg mol S02/m3.

Solution:

Q = (3.00 x 1O- 2 )j1.5 x 10- 9 /35[(0.35 + i)erf J035 + JO.35/n:e- O• 35 ] 1.458 x 10- 7 kg mol COz/m z

7.SF

Multicomponent Diffusion of Gases

The equations derived in this chapter have been for a binary system of A and B, which is probably the most important and most useful one. However, multicomponent diffusion sometimes occurs where three or more components A, B, C, ... , are present. The simplest case is for diffusion of A in a gas through a stagnant nondiffusing mixture of B, C, D, ... , at constan t total pressure. Hence, N B = 0, N c = 0, .... The final equation derived using the Stefan-Maxwell method (G 1) for steady-state diffusion is NA =

where PiM is the log mean of Pi I

P RT(Z2 -

P - PAl andpiz x~/D AB

where x~

mol B/mol inerts

(PAl

xB/{l

(7.5-41)

PAZ)

ZI)PiM

x A),

=P-

PAZ' Also, (7.5-42)

+ x~/D AC + ... x~ =

x A), ....

xc/{l

EXAMPLE 7.5-4. Diffusion of A Through NondijJusing Band C At 298 K and 1 atm total pressure, methane (A) is diffusing at steady state through nondiffusing argon (B) and helium (C). At Z I = 0, the partial pressures in atm are PAl = 004, PBt 004, PCI 0.2 and at Zl 0.005 m, PAl = 0.1, Pe2 = 0.6, and Po 0.3. The binary diffusivities from Table 6.2-1 are D,IB = 2.02 X 10- 5 ml/s, D AC = 6.75 X 10- 5 m 2 /s, and Dsc 7.29 x 10 - 5 m 2 /s. Calculate N A' At point 1, x~ xB/(l x A) = OA/{l - 0.4) = 0.667. At point 2, 0.6/(1 - 0.1) 0.667. The value of X'B is constant throughout the path. Also, x~ xc/( 1 - x A) = 0.2/( 1 - 004) 0.333. Substituting into Eq. (7.5·42),

Solution: x~ =

I DAm =

'/D ,.18

X8

2.635

+ Xc'/D AC 2 X 10- 5 m /s

For calculating Pi.OJ' Pit = P 1.0 0.1 = 0.90. Then,

p.~( I,

Sec. 7.5

= In (Pil/PiI)

0.667/2.02

PA 1

X

10-

1.0 - 0.4

0.6 atm, PiZ = P - PA2

0.90 0.60 In (0.90/0.60) = 0.740 atm

PA \

OA( LO 1325 x 10 5 )

= 4.053

PA2

0.1(1.01325 x 10 5 )

1.013

7.496

X

104 Pa

x 10 4 Pa X

10 4 Pa

Molecular Diffusion Plus Convection and Chemical Reaction

461 .

Substituting into Eq. (7.5-41),

N _ A -

DAmP (p RT(Z2 _ ZI)PiM AI (2.635

=

8.74

X

) PA2

1O- S Xl.01325 X lO SX4.053 - l.013X104 ) (8314X298XO.OO5 - 0X7.496 X 104 )

X

10- 5 kg mol A/s· m 2

Using atm pressure units,

DAmP (p RT{Z2 - ZdPiM Al

= 8.74

X

) PA2 =

(2.635 X 1O- 5Xl.0X0.4 (82.06 X 1O- 3X298XO.OO5

0.1)

OXO.740)

10- 5 kg mol A/s· m 2

A number of analytical solutions have been obtained for other cases such as for equimolar diffusion of three components, diffusion of components A and B through stagnant C, and the general case of two or more components diffusing in a multicomponent mixture. These are discussed in detail with examples by Geankoplis (G 1) and the reader is referred there for further details..

7.6

7.6A

DIFFUSION OF GASES IN POROUS SOLIDS AND CAPILLARIES

Introduction

In Section 6.5C diffusion in porous solids that depends on structure was discussed for liquids and for gases. For gases it was assumed that the pores were very large and Fickian-type diffusion occured. However, often the pores are small in diameter and the mechanism of diffusion is basically changed. Diffusion of gases in small pores occurs often in heterogeneous catalysis where gases diffuse through very small pores to react on the surface of the catalyst. In freeze drying of foods such as turkey meat, gaseous H 2 0 diffuses through very fine pores of the porous structure. Since the pores or capillaries of porous solids are often small, the diffusion of gases may depend upon the diameter of the pores. We first define a mean free path A.; which is the average distance a gas molecule travels before it collides with another gas molecule. ).=

3.2fl P

J -

RT

(7.6-1)

2nM

where ). is in m, fl is viscosity in Pa :s, P is pressure in N/m2, T is temperature in K, lvf = molecular weight in kg/kg mol, and R 8.3143 x 10 3 N· m/kg mol, K. Note that low pressures give large values of X For liquids, since), is so small, diffusion follows Fick's law. In the next sections we shall consider what happens to the basic mechanisms of diffusion in gases as the relative value of the mean free path compared to the pore diameter varies. The total pressure P in the system will be constant, but partial pressures of A and B may be dilTerent. Chap. 7

Principles of Unsteady-Scare and COrlveClive Mass Transfer

-r d

t (a) FIGURE

7.68

(c)

(b)

Types of diffusion of gases in small capillary tubes: (aj Knudsen gas diffusion. (b) molecular or Fick's gas diffusion. (c j transition gas diffusion.

7.6-1.

Knudsen Diffusion of Gases

In Fig. 7.6-1a a gas molecule A at partial pressure PAl at the entrance to a capillary is diffusing through the capillary having a diameter of d m. The total pressure P is constant throughout. The mean free path ), is large compared to the diameter d. As a result, the molecule collides with the wall and molecule-wall collisions are important. This type is called Knudsen diffusion. The Knudsen diffusi vity is independent of pressure P and is calculated from (7.6-2) where DKA is diffusivity in m2 /s, F is average pore radius in m, and VA is the average molecular velocity for component A in m/s. Using the kinetic theory of gases to evaluate VA the final equation for DKA is (7.6-3) .

DKA = 97.0\:J 1/2

where M A is molecular weight of A in kglkg mol and T is temperature in K.

EXAMPLE 7.6-1.

Knudsen Dijfusivity of Hydrogen

A H 2(A)-C 2 H6(B) gas mixture is diffusing in a pore of a nickel catalyst used for hydrogenation at 1.01325 x 10 5 Pa pressure and 373 K. The pore radius is 60 A (angstrom). Calculate the Knudsen diffusivity DKA of H 2 .

Solution: and T

Substituting into Eq. (7.6-3) for f= 6.0 x 10- 9 m, MA = 2.016, 373 K, DKA =

97.0{~J 1/2 =

= 7.92

X

97.0{6.0

X

1O-9{2~~~6}12

10- 6 ml/s

The flux equation for Knudsen diffusion in a pore is DKA dPA

---RT dz Integrating between

Zt

=O,PA

N

PAl andz 2 = L,PA

(7.6-4)

PA2,

DKA P - -RTL - ( x At

A-

(7.6-5)

The diffusion of A for Knudsen diffusion is completely independent of B, since A collides

Sec. 7.6

Diffusion of Gases in Porous Solids and Capillaries

463

with the walls of t~e pore and not with B. A similar equation can be written for component B. When the Knudsen number NKn defined as A.

= 21

NKn

(7.6-6)

is ~ lOll, the diffusion is primarily Knudsen and Eq. (7.6-5) predicts the flux to within about a 10% error. As N Kn gets larger, this error decreases, since the diffusion approaches the Knudsen type. 7.6C

Molecular Diffusion of Gases

As shown in Fig. 7.6-1 b when the mean free path A. is small compared to the pore diameter d or where N Kn ::; 1/100, molecule-molecule collisions predominate and molecule-wall collisions are few. Ordinary molecular or Fickian diffusion holds and Fick's law predicts the diffusion to within about 10%. The error diminishes as N Kn gets smaller since the diffusion approaches more closely the Fickian type. The equation for molecular diffusion given in previous sections is DAfJP dX A

RT

dz + xA(N + N A

B)

(7.6-7)

A flux ratio factor Cf. can be defined as

NB

(X=

1 +-

(7.6-8)

NA

Combining Eqs. (7.6-7) and (7.6-8) and integrating for a path length of L cm, D AfJP

1-

- - In -----"-'rxRTL 1 - aX Al

(7.6-9)

If the diffusion is equimolar, NA = NB and Eq. (7.6-7) becomes Fick's law. The molecular diffusivity D AS is inversely proportional to the total pressure P.

7.6D

Transition-Region Diffusion of Gases

As shown in Fig. 7.6-1c, when the mean free path A. and pore diameter are intermediate in siz.e between the two limits given for Knudsen and molecular diffusion, transition-type diffusion occurs where molecule-molecule and molecule-wall collisions are important in diffusion. The transition-region diffusion equation can be derived by adding the momentum loss due to molecule-wall collisions in Eq. (7.6-4) and that due to molecule-molecule collisions in Eq. (7.6-7) on a slice of capillary. No _cpemical reactions are occurring. The final differential equation is(Gl) . DNA P dX

- - -A

RT

dz

(7.6-10)

where (7.6-11)

Chap. 7

Principles of Unsteady-State and Convective Mass Transfer

This transition region diffusivity DNA depends slightly on concentrationx A • Integrating Eq. (7.6-10),

NA

=

DABP In 1 IXXA2 r:t.RTL 1 - aX Al

+ DAalDKA + DAalDKA

(7.6-12)

This equation has been shown experimentally to be valid over the entire transition region (Rl). It reduces to the Knudsen equation at low pressures and to the molecular diffusion equation at high pressures. An equation similar to Eq. (7.6-12) can also be written for component B. The term DABI DKA is proportional to lIP. Hence, a..rators

The basic equation for solving for the capacity of a single-effect evaporator is Eq. (8.2-1), which can be written as

q

(8.4-1)

UA 6.T

where 6. T K CF) is the difference in temperature between the condensing steam and the . _ boiling liquid in theevaporator, In order to solve Eq. (8.4-1) the value of q in W (btu/h) must be determined by making a heat and material balance on the evaporator shown in Fig. 8.4-1. The feed to the evaporator is F kg/h(lb.,jh) having a solids content OfXF mass fraction, temperature TF , and enthalpy hF J/kg (btu/Ibm). Coming out as a liquid is the concentrated liquid L kgJh (Ibmlh) having a solids content of XL' temperature T 1 , and enthalpy h L • The vapor V kgJh (Ib.,jh) is given ofT as pure solvent having a solids content of Yv = 0, temperature T 1 , and enthalpy fI v. Saturated steam entering is S kgJh (lb.Jh) and has a temperature of Ts and enthalpy of H s' The condensed s team lea ving of S kgJh is assumed usually to be at Ts , the saturation temperature, with an enthalpy ofh s . This 496

Chap. 8

Evaporation

means that the steam gives off only its latent heat, which is A., where A. = Hs

hs

(8.4-2)

Since the vapor V is in equilibrium with the liquid L, the temperatures of vapor and liquid are the same. Also, the pressure PI is the saturation vapor pressure of the liquid of composition XL at its boiling point T1 • (This assumes no boiling-point rise.) For the material balance since we are at steady state, the rate of mass in rate of mass out. Then, for a total balance,

(8.4-3) For a balance on the solute (solids) alone,

=

FXF

(8.4-4)

LXL

For the heat balance, since the total heat entering

+ heat

heat in feed

= heat in

= total heat leaving,

in steam

concentrated liquid

+ heat

in vapor

+ heat

in condensed steam

(8.4-5)

This assumes no heat lost by radiation or convection. Substituting into Eq. (8.4-5),

.

FhF

+ SHs

+ VHy + Shs

LhL

(8.4-6)

Substituting Eq. (8.4-2) into (8.4-6),

(8.4-7)

FhF+SA=Lh L + VHv The heat q transferred in the evaporator is then

q

=

S(Hs

hs ) = SA.

(8.4-8)

In Eq. (8.4-7) the latent heat A. of steam at the saturation temperature Ts can be obtained from the steam tables in Appendix A.2. However, the enthalpies of the feed and products are often not available. These enthalpy--concentration data are available for only a few substances in solution. Hence, some approximations are made in order to make a heat balance. These are as follows. 1. It can be demonstrated as an approximation that the latent heat of evaporation of

I kg mass of the water from an aqueous solution can be obtained from the steam tables using,the temperature of the boiling solution 1'. (exposed surface temperature) rather than the equilibrium temperature for pure water at PI' 2. If the heat capacities c pF of the liquid feed and CpL of the product are known, they can be used to calculate the enthalpies. (This neglects heats of dilution, which in most cases are not known.) FIGURE

8.4-1.

vapor V

Heat and mass balance for single-effect evaporator.

feed F

condensate S Ts,h s

concentrated liq uid L T1,xL,hL Sec. 8.4

Calculation Methods for Single-Effect Evaporators

497

EXAMPLE 8.4-1. Heat-Transfer Area in Single-Effect Evaporator A continuous single-effect evaporator concentrates 9072 kg/h of a LO wt % salt solution entering at 31 LO K (37.8°C) to a final concentration of 1.5 wt %. The vapor space of the evaporator is at 101.325 kPa (1.0 atm abs) and the steam supplied is saturated at 143.3 kPa. The overall coefficient U = 1704 W/m2 . K. Calculate the amounts of vapor and liquid product and the heat-transfer area required. Assume that, since it is dilute, the solution has the same boiling point as water. Solution: The flow diagram is the same as that in Fig. 8.4-1. For the material balance, substituting into Eq. (8.4-3), (8.4-3)

F=L+ V 9072

+

L

V

Substituting into Eq. (8.4-4) and solving, (8.4-4)

FXF = LXL 9072(0.01)

L(0.015)

L = 6048 kg/h of liquid

Substituting into Eq. (8.4-3) and solving,

"

V = 3024 kg/h of vapor

The heat capacity of the feed is assumed to be c pF = 4.14 kJ/kg' K. (Often, for feeds of inorganic salts in water, the c p can be assumed approximately as that of water alone.) To make a heat balance using Eq. (8.4-7), it is convenient to select the boiling point of the dilute solution in the evaporator, which is assumed to be that of water at 101.32 kPa, ~ = 373.2 K (100°C), as the datum temperature. Then JIv is simply the latent heat of water at 373.2 K, which from the steam tables in Appendix A.2 is 2257 kJ/kg (970.3 btu/Ibm). The latent heat ). of the steam at 143.3 kPa [saturation temperature 1S = 383.2 K (230°F)] is 2230 kJ/kg (958.8 btuflb,J. The enthalpy of the feed can be calculated from (8.4-9) Substituting into Eq. (S.4-7) with ilL 9072(4.14)(311.0

373.2) S

=

=

0, since it is at the datum of 373.2 K,

+ 5(2230)

=

6048(0)

+ 3024{2257)

4108 kg steamjh

The heat q transferred through the heating surface area A is, from Eq. (8.4-S), (8.4-8) q = 5(l) q = 4108(2230)(I000j36QO) = 2544000 W

Substituting into Eq. (8.4-1), wherell T q = 2544 000 = UA II T

Solving, A 8AB

=

=

IS - T 1,

= 1704(AX383.2

373.2)

149.3 m 2 •

Effects of Processing Variables on Evaporator Operation

The inlet temperature of the feed has a large effect on the operation of the evaporator. In Example S.4-1 the feed entering was at a cold temperJ. Effect offeed temperature.

498

Chap. 8

Evaporation

ature of 311.0 K compared to the boiling temperature of 373.2 K. About i of the steam used for heating was used to heat the cold feed to the boiling point. Hence, only about :i of the steam was left for vaporization of the feed. If the feed is under pressure and enters the evaporator at a temperature above the boiling point in the evaporator, additional vaporization is obtained by the flashing of part of the entering hot feed. Preheating the feed can reduce the size of evaporator heat-transfer area needed. 2. Effect of pressure. In Example 8.4-1 the pressure of 101.32 kPa abs was used in the vapor space of the evaporator. This set the boiling point of the solution at 373.2 K and gave a 6. T for use in Eq. (8.4- 1) of 383.2 373.2, or 10K. In many cases a larger 6. T is desirable, since, as the 6. T increases, the heating-surface area A and cost of evaporator decrease. To reduce the pressure below 101.32 kPa, Le., to be under vacuum, a condenser and vacuum pump can be used. For example, if the pressure were reduced to 41A kPa, the boiling point of water would be 349.9 K and the new 6. T would be 383.2 349.9, or 33.3 K. A large decrease in heating-surface area would be obtained.

3. Effect of steam pressure. Using higher pressure, saturated steam increases the 6. T, which decreases the size and cost of the evaporator. However, high-pressure steam .is more costly and also is often more valuable as a source of power elsewhere. Hence, overall economic balances are really needed to determine the optimum steam pressures.

SAC

Boiling-Point Rise of Solutions

In the majority of cases in evaporation the solutions are not such dilute solutions as those considered in Example 8.4-1. In most cases, the thermal properties of the solution being evaporated may differ considerably from those of water. The concentrations of the solutions are high enough so that the heat capacity and boiling point are quite different from that of water. . For strong solutions of dissolved solutes the boiling-point rise due to the solutes in the solution usually cannot be predicted. However, a useful empirical law known as Diihring's rule can be used. In this rule a straight line is obtained if the boiling point ofa solution in °C or OF is plotted against the boiling point of pure water at the same pressure for a given concentration at different pressures. A different straight line is obtained for each given concentration. In 8.4-2 such a Diihring line chart is given for solutions of sodium hydroxide in water. It is necessary to know the boiling point of a given solution at only two pressures to determine a line. EXAMPLE 8.4-1. Use of Diihring Chart for Boiling-Point Rise As an example of use of the chart, the pressure in an evaporator is given as 25.6 kPa (3.72 psia) and a solution of 30% NaOH is being boiled. Determine the boiling temperature of the NaOH solution and the boiling-point rise BPR of the .. . solution over that of water at the same pressure. Solution: From the steam tables in Appendix A.2, the boiling point of water at 25.6 kPa is 65.6°C. From Fig. 8.4-2 for 65.6°C (l50°F) and 30% NaOH, the boiling point of the NaOH solution is 79SC (l75°F). The boiling-point rise is 79.5 - 65.6 13.9°C (25°F).

In Perry and Green (P2) a chart is given to estimate the boiling-point rise of a large number of common aqueous solutions used in chemical and biological processes. In addition to the common salts and solutes, such as NaNO] , NaOH, NaCI, and H 2 S0 4 , the biological solutes sucrose, citric acid, kraft solution, and glycerol are g.iven. These Sec. 8.4

Calculation Methods for Single-Effect Evaporators

499

Boiling point of water (0C)

o

25

50

75

100

125

125

G

°

"-'

s::::

.9 ...... -+-+-t--if-t-+-"--i-.:r- 100

oen

;:l .

.s::::

E ;:t

:.ao

en

'-'

o

,

:

,

I

'-'

o

25

50

100

150

200

250

300

Boiling point of water (F) FIGURE

8.4-2.

Diihring linesfor aqueous solutions of sodium hydroxide.

biological solutes have quite small boiling-point-rise values compared to those of common salts.

8.40

Enthalpy-Concentration Charts of Solutions

If the heat of solution of the aqueous solution being concentrated in the evaporator is large, neglecting it could cause errors in the heat balances. This heat-of-solution phenomenon can be explained as follows. If pellets of NaOH are dissolved in a given amount of water, it is found that a considerable temperature rise occurs; i.e., heat is evolved, called heat oj solution. The amount of heat evolved depends on the type of substance and on the amount of water used. Also, if a strong solution of NaOH is diluted to a lower concentration, heat is liberated. Conversely, if a solution is concentrated from a low to a high concentration, heat must be added. In Fig. 8.4-3 an enthalpy-concentration chart for NaOH is given (MI) where the enthalpy is in kJ/kg (btu/Ibm) solution, temperature in °C (OF), and concentration in weight fraction NaOH in solution. Such enthalpy-concentration charts are usually not made for solutions having negligible heats of solution, since the heat capacities can be 500

Chap. 8

Evaporation

easily used to calculate enthalpies. Also, such charts are available for only a few solutions. The enthalpy of the liquid water in Fig. 8.4-3 is referred to the same datum or reference state as in the steam tables, i.e., liquid water at DoC (273 K). This means that enthalpies from the figure can be used with those in the steam tables. In Eq. (8.4-7) values for hF and hL can be taken from Fig. 8.4-3 and values for A and H y from the steam tables. The uses of Fig. 8.4-3 will be best understood in the following example.

EXAMPLE 8.4-3. Evaporation of an NaO H Solution An evaporator is used to concentrate 4536 kgfh (10000 Ib.Jh) of a 20% solution of NaOH in water entering at 60°C (140°F) to a product of 50% solids. The pressure of the saturated steam used is 172.4 kPa (25 psia) and the pressure in the vapor space of the evaporator is 11.7 kPa (1.7 psia). The overall heat-transfer coefficient is 1560 W 1m2. K (275 btu/h' ft2 . OF). Calculate the steam used, the steam economy in kg vaporized/kg steam used, and the heating surface area in m 2 • Solution:. The process flow diagram and nomenclature are the same as given in Fig. 8.4-1. The given variables are F 4536 kgfh, x F 0.20 wt fraction, TF 60°C, PI 11.7 kPa, steam pressure 172.4 kPa, and XL = 0.50 wt fraction. For the overall material balance, substituting into Eq. (8.4-3), F = 4536

L

+

V

(8.4-3)

600 r-.

500

i::

~g :::J

"0

'"

.....,

..;.: '-../

300

200

>.

..c: P< -; ..c: +-' i::

p:.:j

100

Concentration (wt fraction NaOH) FIGURE

Sec. 8.4

8.4-3.

Enchaipy-concencracion chartJor the system NaOH-water. [ReJerence slate: liquid water at O°C (273 K) or 32°F.] [From W. L. McCabe, Trans. A.l.Ch.E., 31, ! 29 (/935). With permission.]

Calculation Methods Jar Single-Effect Evaporators

501

Substituting into Eq. (8.4-4) and solving (8.4-3) and (8.4-4) simultaneously, (8.4-4) 4536(0.20)

=

L(0.50)

V

L = 1814 kg/h

2722 kg/h

To determine the boiling point Tl of the 50% concentrated solution, we first obtain the boiling point of pure water at 11.7 kPa from the steam tables, Appendix A.2, as 48.9°C (120°F). From the Diihring chart, Fig. 8.4-2, for a boiling point of water of 48.9°C and 50% NaOH, the boiling point of the solution is Tl = 89SC (l93°F). Hence, boiling-point rise = TI

48.9 = 89.5 - 48.9

40.6°C (73°F)

From the enthalpy-concentration chart (Fig. 8.4-3), for 20% NaOH at 60°C (l40°F), h, = 214 kJ/kg (92 btu/Ibm). For 50% NaOH at 89SC (193°F), hL = 505 kJ/kg (217 btuflb m). For the superheated vapor V at 89.5°C (193°F) and 11.7 kPa [superheated 40.6°C (73°F) since the boiling point of water is 48.9°C (l20°F) at 11.7 kPa], from the steam tables, H v 2667 kJ/kg (1147 btu/Ibm). An alternative method to use to calculate the H v is to first obtain the enthalpy of saturated vapor at 48.9°C (120°F) and 11.7 kPa of 2590 kJ /kg (1113.5 btu/Ibm)' Then using a heat capacity of 1.884 kJ/kg' K for superheated steam with the superheat of (89.5 48.9tC (89.5 - 48.9) K,

H v = 2590

+

1.884(89.5 - 48.9) = 2667 kJ/kg

For the saturated steam at 172.4 kPa, the saturation temperature from the steam tables is 115.6°C (240°F) and the latent heat is). 2214 kJ/kg (952 btu/Ibm). Substituting into Eq. (8.4-7) and solving for S,

Fil,

+ S;.

4535(214) + S(2214) S

=

LhL

+

(8.4-7)

VHv

= 1814(505) + 2722(2667)

3255 kg steam/h

Substituting into Eq. (S.4-S), q

S), =

1 3255{2214{36 00) = 2002 kW

Substituting into Eq. (SA-I) and solving, 2002(1000) Hence, A

8.5

8.5A

=

1560(A)(115.6

49.2 m 2 . Also, steam economy

89.5)

2722/3255

0.836.

CALCULATION METHODS FOR MULTIPLE-EFFECT EVAPORATORS Introduction

In evaporation of solutions in a single-effect evaporator, a major cost is the cost of the steam used to evaporate the water. A single-effect evaporator is wasteful of steam costs, 502

Chap. 8

Evaporation

since the latent heat of the vapor leaving the evaporator is usually not used. However, to reduce this cost, multiple-effect evaporators are used which recover the latent heat of the vapor leaving and reuse it. A three-effect evaporator, discussed briefly in Section S.2B, is shown in Fig. 8.2-3. In this system each effect in itself acts as a single-effect evaporator. In the first effect raw steam is used as the heating medium to this first effect, which is boiling at temperature Tl and pressure Pt. The vapor removed from the first effect is used as the heating medium, condensing in the second effect and vaporizing water at temperature T2 and pressure P z in this effect. To transfer heat from the condensing vapor to the boiling liquid in this second effect, the boiling temperature T2 must be less than the condensing temperature. This means that the pressure P 2 in the second effect is lower than PI in the first effect. In a similar manner, vapor from the second effect is condensed in heating the third effect. Hence, pressure p) is less than P 2' If the first effect is operating at 1 atm abs pressure, the second and third effects will be under vacuum. In the first effect, raw dilute feed is added and it is partly concentrated. Then this partly concentrated liquid (Fig. 8.2-3) flows to the second evaporator in series, where it is further concentrated. This liquid from the second effect flows to the third effect for final concentration. When a multiple-effect evaporator is at steady-state operation, the flow rates and rate of evaporation in each effect are constant. The pressures, temperatures. and internal flow rates are automatically kept constant by the steady-state operation of the process itself. To change the concentration in the final effect, the feed rate to the first effect must be changed. The overall material balance made over the whole system and over each evaporator itself must be satisfied. If the final solution is too concentrated, the feed rate is increased, and vice versa. Then the final solution will reach a new steady state at the desired concentration.

8.5B

Temperature Drops and Capacity of Multiple-Effect Evaporators

The amount of heat transferred per hour in the first effect of a triple-effect evaporator with forward feed as in Fig. 8.2-3 will be 1. Temperature drops in multiple-efFect evaporators.

(8.5-1)

where 6. TI is the difference between the condensing steam and the boiling point of the liquid. IS - Tlo Assuming that the solutions have no boiling-point rise and no heat of solution and neglecting the sensible heat necessary to heat the feed to the boiling point, approximately all the latent heat of the condensing stearn appears as latent heat in the vapor. This vapor then condenses in the second effect, giving up approximately the same amount or heat. (8.5-2)

This same reasoning holds for q). Then since ql

U1A1llT1

U 2 A2111;

qz

q), then, approximately,

U)A36. T3

(8.5-3)

Usually. in commercial practice the areas in all effects are equal and q

(8.5-4)

A

Sec. 8.5

Calculation Methods for Multiple-Effect Evaporators

503

Hence, the temperature drops ~ T in a multiple-effect evaporator are approximately inversely proportional to the values of U. Calling'L I1T as follows for no boiling-point rise, (8.5-5)

Note that ~ T\ °C IjU\, then

11 T\ K,

~ T2

°C

11 T2 K, and so on. Since

~

7J.

is proportional to

(8.5-6) Similar equations can be written for 11 Tz and 11 T).

2. Capacity of multiple-effect evaporators. A rough estimate of the capacity of a threeeffect evaporator compared to a single effect can be obtained by adding the value of q for each evaporator. (8.5-7)

If we make the assumption that the value of U is the same in each effect and the values of A are equal, Eq. (8.5-7) becomes (8.5-8)

L

where ~ T = ~ T = 11 T\ + ~ Tz + ~ T3 = Ts T) . If a single-effect evaporator is used with the same area A, the same value of U, and the same total temperature drop ~ T, then q

=

UA

~T

(8.5-9)

This, of course, gives the same capacity as for the multiple-effect evaporators, Hence, the increase in steam economy obtained by using multiple-effect evaporators is obtained at the expense of reduced capaci ty, 8.5C

Calculations for Multiple-Effect Evaporators

[n doing calculations for a multiple-effect evaporator system, the values to be obtained are usually the area of the heating surface in each effect, the kg of steam per hour to be supplied, and the amount of vapor leaving each effect, especially the last effect. The given or known values are usually as follows: (\) steam pressure to first effect, (2) final pressure in vapor space of the last effect, (3) feed conditions and flow to first effect, (4) the final concentration in the liquid leaving the last effect, (5) physical properties such as enthalpies andjor heat capacities of the liquid and vapors, and (6) the overall heat-transfer coefficients in each effect. Usually, the areas of each effect are assumed equal. The calculations are done using material balances, heat balances, and the capacity equations q = U A ~ T for each effect. A convenient way to solve these equations is by trial and error. The basic steps to follow are given as follows for a triple-effect evaporator. 85D

Step-by-Step Calculation Methods for Triple-Effect Evaporators

l. From the known outlet concentration and pressure in the last effect, determine the boiling point in the last effect. (If a boiling-point rise is present, this can be determined from a Duhring line plot.) 51)4

Chap. 8

Evaporalion

2. Determine the total amount of vapor evaporated by an overall material bala~ce. For this first trial apportion this total amount of vapor among the three effects. (Usually, equal vapor produced in each effect, so that VI = V2 = V3 is assumed for the first trial.) Make a total material balance on effects 1, 2, and 3 to obtain L 1 , L 2 , and L 3 • Then calculate the .solids concentration in each effect by a solids balance on each effect. 3. Using Eq. (8.5-6), estimate t,he temperature drops tl T1 , t'1 T z , and t'1 T3 in the three effects: Any effect that has an extra heating load, such as a cold feed, requires a proportionately larger t'1 T. Then calculate the boiling point in each effect. [If a boiling-point rise (BPR) in °C is present, estimate the pressure in effects 1 and 2 and determine the BPR in each of the three effects. Only a crude pressure estimate is needed since BPR is almost independent of pressure. Then the tl T available for heat transfer without the superheat is obtained by subtracting the sum of aU three BPRs from the overall t'1 T of Ts T3 (saturation). Using Eq. (8.5-6), estimate t'1 T 1 , t'1 T z , and tl T3 . Then calculate the boiling point in each effect.] 4. Using heat and material balances in each effect, calculate the amount vaporized and the flows of liquid in each effect. If the amounts vaporized differ appreciably from those assumed in step 2, then steps 2, 3, and 4 can be repeated using the amounts of evaporation just calculated. (In step 2 only the solids balance is repeated.) 5. Calculate the value of q transferred in each effect. Using the rate equation qUA t'1 T for each effect, calculate the areas A I' A 2' and A 3' Then calculate t he a verage value Am by

I

(8.5-10)

If these areas are reasonably close to each other, the calculations are complete and a second trial is not needed. If these areas are not nearly eq ual, a second trial should be performed as follows. 6. To start trial 2, use the new values of L 1, L 2 , L 3 , VI' V2 , and V3 calculated by the heat balances in step 4 and calculate the new solids concentrations in each effect by a solids balance on each effect. 7. Obtain new values of tl T 1 , t'1 T~, and t'1 T~ from (8.5-11)

I

The sum t'1 Tl + t'1 T~ + t'1 T~ must equal the original t'1 T. If not, proportionately readjust all t'1 T values so that this is so. Then calculate the boiling point in each effect. [If a boiling point rise is present, then using the new concentrations from step 6, determine the new BPRs in the th ree effects. This gives a new val ue of L t'1 T available for heat transfer by subtracting the sum of all three BPRs from the overall t'1 T. Calculate the new values of t'1T by Eq. (8.5-11). The sum of the t'1T values just calculated must be readjusted to this new t'1 T value. Then calculate the boiling point in each effect] Step 7 is essentially a repeat of step 3 but using Eq. (8.5-11) to obtain a better estimate of the t'1 T values. 8. Using the new t'1 T values from step 7, repeat the calculations starting with step 4. Two trials are usually sufficient so that the areas are reasonably close to being equal.

I

EXAMPLE 8.5-1.

Evaporation o/Sugar Solution in a Triple-Effect Evaporator A triple-effect forward-feed evaporator is being used to evaporate a sugar solution containing to wt % solids to a concentrated solution of 50%. The boiling-point rise of the solutions (independent of pressure) can be estimated Sec. 8.5

Calculation Methods for Multiple-Effect Evaporl1lors

505

from BPROC = 1.78x + 6.22x 2 (BPROF = 3.2x + 1 L2x 2), where x is. wt fraction of sugar in solution (KI). Saturated stearn at 205.5 kPa (29.8 psia) [12LlOC (250°F) saturation temperature] is beingused. The pressure in the vapor space of the third effect is 13.4 kPa (1.94 psia). The feed rate is 22680 kg/h (50000 lb,jh) at 26.7°C (80°F). The heat capacity of the liquid solutions is (Kl) cp = 4.19 - 2.35x kJ/kg' K (1.0 - 0.56x btujIb m' oF). The heat of solution is considered to be negligible. The coefficients of heat transfer have been estimated as U t 3123, U 2 = 1987, and'U 3 1136 W/m 2 • K or 550, 2 350, and 200 btu/h· ft • OF. If each effect has the same surface area, calculate the area, the steam rate used, and the steam economy. Solution: The process flow diagram is given in Fig. 8.5- 1. Following the eight steps outlined, the calculations are as follows. .

Step 1. For 13.4 kPa (1.94 psia), the saturation temperature is 5L6TC (125°F) from the steam tables. Using the equation for BPR for evaporator number 3 with x 0.5, BPR 3 = l.78x + 6.22x2 = 1.78(0.5) + 6.22(0.5)2 2.4SOe (4.4°F) T3 = 51.67 + 2.45 54.12°e (l29.4°F) Step 2. Making an overall and a solids balance to calculate the total amount vaporized (Vj + V1 + V3 ) and L 3 ,

= 22680

F

L3

22680(0.1) = L](O.5)

FXF

= 4536 kg/h

L3

+ (VI +

(VI

total vaporized

V2

+

V3 )

+ (Vj +

Vz + V)(O)

(10000 lbmfh)

+ Vz + V3 ) = 18 144 kg/h (40 000 Ib,jh)

Assuming equal amount vaporized in each effect, VI Vz = V3 = 6048 kg/h (13333 lb,jh). Making a total material balance on effects 1, 2, and 3 and solving, (1)

F = 22680 = VI

(2)

1.1

= 16632

=

(3)

1.2

= 10584

= V)

V1

+

6048 + L 1 ,

L!

16632kg/h(33667Ib,jh)

+ = 6048 + L 1 , + L) = 6048 + L),

1.2

10584(23334)

1.3

4536(10000)

Ll

Making a solids balance on effects 1,2, and 3 and solving for x,

F XF

= Ltx l

(1)

22680(0.1)

(2)

16632(0.136) =

22680 0.1, TF

=:

xz

26.7°C

S, 205.5 kPa =: 12Ll°C

(-l )

16632(xd,

Xl

0.136

10 584{x 2 ),

X2

= 0.214

X3

0.500

(check balance)

13.7 kPa (3)

TSI

TS3

L3 = 4536 X3

FIGURE

S06

8.5- L

= 0.5, T3

Flow diagramfor triple-effect evaporation for Example 85-1.

Chap. 8

Evaporation

Step 3.

The BPR in each effect is calculated as folIows:

= 1.78x 1 + 6.22xi = 1.78(0.136) + 6.22(0.136)2 = 0.36°C (O.rF) (2) BPR z = 1.78(0.214) + 6.22(0.214)2 = 0.65°C (1.2°F) (3) BPR 3 = 1.78(0.5) + 6.22(0.5)z = 2.4SOC (4.4°F) L t'l. T available 151 T3 (saturation) - (BPR 1+ BPR z + BPR 3 ) 121.1 ~ 51.67 ~ (0.36 + 0.65 + 2.45) = 65.97°C (118YF) (I) BPR 1

Using Eq. (8.5-6) for II TI and similar equations for t'l. Tz and t'l. T3 ,

=

t'l.Tj

'\ L t'l.T I/U 1

t'l. TI

+

IjU! I/U z

(65.97)(1/3123)

+ I/U 3

t'l. T z

12.40°C

+ (1/1987) + (1/1136)

(1/3123)

= 19.50°C

II T3 = 34.0rC

However, since a cold feed enters effect number I, this effect requires more heat. Increasing t'l. TI and lowering II T z and t'l. T3 proportionately as a first estimate, II Tl 15.56°C = 15.56 K llTz 18.34°C = 18.34 K II T) = 32.07°C = 32.07 K To calculate the actual boiling point of the solution in each effect, (1)

Tj

TSI

llTI

= 121.1 121.1 °C

TSI (2)

15.56 = 105.54°C

~ =

TI

BPR 1

= 105.54 TS2

(condensing temperature of saturated steam to effect 1)

0.36 - 18.34

BPR 1

TI

llTz

=

86.84°C

105.54 - 0.36

=

= 105.18°C (condensing temperature of steam to effect 2) (3)

T) = T z =

BPR 1

86.84

TS3 = Tl

llT3

-

32.07 = 54.12°C

0.65 BPR z

86.84 0.65 effect 3)

= 86.19°C

(condensing temperature of steam to

The temperatures in the three effects are as follows: Effect 1 Effect 2 Effect 3 151 = 121.l0~ 15z = 105.I~TS3 86.19 Tl = 105.54

Tz

= 86.84

T3

STS4

Condenser = 51.67

54.12

Step 4. The heat capacity of the liquid in each effect is calculated from the equation cp = 4.19 2.35x.

Sec. 8.5

F:

cp

=

4.19 - 2.35(0.1)

L 1:

cp

=

4.19 - 2.35(0.136)

3.869

L 2:

cp = 4.19 - 2.35(0.214)

3.684

L3:

cp

= 4.19 -

2.35(0.5)

3.955 kJ/kg' K

3.015

Calculation Methods for Multiple·Effect Evaporators

507

The v.alues of the enthalpy H of the various vapo('streams relative to water at ooe as a datum are obtained from the steam table as follows: Effect I: Tl

=

H t = H S2 (saturation enthalpy at 'fs2) = 2684 ;'SI

+

=

105.18 (221.3°F), BPR 1 = 0.36, TSI

105.54°e, T:n

+ 1.884 (0.36°e

12l.! (250°F)

superheat)

1.884{0.36) = 2685 kJ/kg

= HSI (vapor saturation enthalpy) - hSI (liquid enthalpy at (2708 - 508)

=

'fst)

2200 kJ/kg latent heat of condensation

Effect 2: T2

H2

=

H S3

= 86.84°e,

Tn = 86.19,

+

= 2654 + 1.884{O.65) 441 = 2244 kJ/kg

1.884{0.65)

)'S2 = HI - hS2

= 2685

BPR z

0.65 2655 kJ/kg

Effect 3: T3 = 54. 12°C, H 3 = HS4

;'S3 = H 1

+

1.884{2.45)

hS3

-

TS4

=

51.67,

= 2595 +

BPR 3

2.45

1.884{2.45)

2600 kJ/kg

2655 - 361 = 2294 kJ/kg

(Note that the superheat corrections in this example are small and could possibly have been neglected. However, the corrections were used to demonstrate the method of calculation.) Flow relations to be used in heat balances are VI = 22680

L 1,

V2

LI

L2,

V)

= L2

4536,

L3 = 4536

Write a heat balance on each effect. Use ooe as a datum since the values of H of the vapors are relative to ooe (3TF) and note that (TF - ote = (TF 0) K and (TI - ote (T1 - 0) K, (1)

Substituting the known values, 22680(3.955)(26.7 - 0)

+ S(2200)

L I(3.869)(105.54

0)

+ (22 680 - L 1)(2685) (2)

L1cp{TI

Ll{3.869)(105.54

(3)

L2 cp{T2 L2(3.684)(86.84

+ VI /' S2 = L2 Cp(Tl - 0) + V2 Hl 0) + (22680 - L 1 )(2244) = L2(3.684)(86.84 - 0)

0)

0)

+

V2 I. S) = L) cp(T)

0) + (L 1

-

+ (LI 0) + V3 H:;

L 2 )(2655)

L 2 )(2294) = 4536{3.015)(54.12 - 0)

+ (L 2

4536)(2600)

Solving the last two equations simultaneously for LI and L2 and substi· tuting into the first equation, L I =17078kg/h S = 8936 508

VI

5602

L 2 =11068 V1 = 6010

4536

L3 V3

6532 Chap. 8

Evaporation

The calculated values of VI' V2 , and V3 are close enough to the assumed values so that steps 2, 3, and 4 do not need to be repeated. If the calculation were repeated, the calculated values of VI' V2 , and V3 would be used starting with step 2 and a solids balance in each effect would be made. Step 5.

Solving for the values of q in each effect and area, ql

G~~}22oo x

= Si'SI

1000) = 5.460

q2

V\i' S2 =

G~~}2244 x

q3

Vz ;'S3 =

e~~}2294 x 1000)

6

10 W

X

1000) = 3.492 3.830

6

X

10 W

X

10 W

6

5.460 X 10 6 3123( 15.56) 7 3.492 x 10 6 1987(18.34) = 95.8 m-

_ 3.830 x 10 6 _ 1 2 1136(32.07) - .105. m

_ A3

-

U 3 t1 T) -

The average area Am' 104.4 m 2. The areas differ from the average value by less than 10% and a second trial is not really necessary. However, a second trial will be made starting with step 6 to indicate the calculation methods used. Step 6. Making a new solids balance on effects 1, 2, and 3 using the new L I = 17078, = 11 068, and L) 4536 and sol ving for x,

(1)

22680(0.1)

(2)

17078(0.133)

(3)

11 068(0.205)

Step 7.

The new BPR in each effect is then

BPR! = 1.78x!

(2)

BPR 2

(3)

BPR) t1 T

Xl

= 0.133

11 068(x 2)'

X2 =

0.205

4536(x 3 ),

x)

0.500 (check balance)

+ 6.22x; 1.78(0.133) + 6.22(0.133)2 1.78(0.205) + 6.22(O.20W 0.63°C = 1.78(0.5) + 6.22(0.W = 2.45 C available = 12Ll - 51.67 - (0.35 + 0.63 + 2.45)

(1)

I

=

17078(x 1 ),

0.35°C

C

66.00°C

The new values for t1 T are obtained using Eq. (8.5-11). 15.56(112.4) 104.4

=

1677 K .

16.77°C

t1 T z A2 = 18.34(95.8) = 16.86"C

Am

I on

Sec. 8.5

t1T

=

16.77

104.4

+

16.86 + 32.34

65.97°C

Calculation Methods for Multiple-Effect Evaporators

509

These /I.. T' values are readj usted so that /I.. T'l = 16.77, /I.. T~ = 16.87, /I.. T~ 32.36, and /I.. T = 16.77 + 16.87 + 32.36 = 66.00°C. To calculate the actual boiling point of the solution in each effect,

I

Tl

TSI

/l..T'1

(2)

Tz

Tl

BPR 1

= Tl (3)

153 Step 8. 4.19

/l..T~

-

= Tz

121.1°e

= 104.33 - 0.35 - 16.87 = 87.11°e

BPR 1 = 104.33 - 0.35

Tz - BPR z - /I.. T3

TJ

0il =

= 121.1 - 16.77 = 104.33°e,

(1)

=

103.98°e

87.11 - 0.63 - 32.36

=

54.l2°e

BPR z = 87.11 - 0.63 = 86.48°e

Following step 4, the heat capacity of the liquid 2.35x. F:

cp =3.955kJjkg·K

L1:

c p = 4.19 - 2.35(0.133)

L z : cp

L}:

= 4.19

- 2.35(0.205)

cp

IS

= 3.877 = 3.708

c p = 3.015

The new values of the enthalpy H are as follows in each effect. (1)

(2)

H 52

I'S t

HSI -

Hz

H53

i. 5z (3)

+

HI

=

1'53

= 2708 -

+

1.884(0.35)

2683 kJjkg

= 2200 kJjkg + 1.884(0.63) = 2654 + 1.884(0.63) = 2655 kJjkg hSI

508

hS2 = 2683 - 440 = 2243 kJjkg

HI

H} = H 54

1.884rC superheat) = 2682

+

Hz -

1.884(2.45)

hS3

= 2655

= 2595 + 1.884(2.45) = 2600 kJjkg - 362 = 2293 kJjkg

W ri ting a heat balance on each effect, (I)

22680(3.955)(26.7 - 0)

+ S(2200)

= L 1(3.877XI04.33

+ (22 680 (2)

L I(3.877){ 104.33 - 0) + (22680 - L I)(2243)

=

LIX2683)

L z(3.708)(S7.ll

+ (L I (3)

+ (LI -

L2(3.70S){S7.l1 - 0)

L z)(2293)

=

0)

L zX2655)

-

4536(3.015)(54.12

+ (L z -

0)

0)

4536)(2600)

Solving, LI

Lz

17005 kgfh

=

10952

5675

VI =

Vz

L3

= 4536 S

8960 (steam used)

= 6053

Note that these values from trial 2 differ very little from the trial I results. Following step 5, and solving for q in each effect and A,

S10

ql =

S).SI

qz =

VIAS Z

8960

6

= 3600 (2200 x 1000) = 5.476 x 10 W

.

5675

= 3600 (2243 x 1000)

3.539

X

10 6 W

Chap. 8

Evaporation

,

q3

= V2 AS3 =

6053 3600 (2293 x 1000)

= 3.855

6

x 10 W

5.476 X 106 2 3123(16.77) = 104.6 m

Az = A

u z AT~ q3

3=U 3 AT3

3.539 x 106 1987(16.87)

105.6 m 2

3.855 X 106 2 1136(32.36) = 104.9 m

The average area Am 105.0 m 2 to use in each effect. Note that this value of 105.0 m Z is quite close to the average value of 104.4 m 2 from the first trial. steam economy

8.6 8.6A

== v+v+v I ; 3

5675 + 6053 + 6416 = 2.025

CONDENSERS FOR EVAPORATORS Introduction

In multiple-effect evaporators the vapors from the last effect are usually leaving under vacuum, i.e., at less than atmospheric pressure. These vapors must be condensed and discharged as a liquid at atmospheric pressure. This is done by condensing the vapor's using cooling water. The condenser can be a surface condenser, where the vapor to be condensed and the cooling liquid are separated by a metal wall, or a direct contact condenser, where the vapor and cooling liquid are mixed directly. 8.68

Surface Condensers

Surface condensers are employed where actual mixing of the condensate with condenser cooling water is not desired. In general, they are shell and tube condensers with the vapor on the shell side and cooling water in multipass flow on the tube side. Noncondensable gases are usually present in the vapor stream. These can be air, CO 2 , N 2' or another gas which may have entered as dissolved gases in the liquid feed or occur because of decomposition in the solutions. These noncondensable gases may be vented from any well-cooled point in the condenser. If the vapor being condensed is below atmospheric pressure, the condensed liquid lea ving the surface condenser can be removed by pumping and the noncondensable gases by a vacuum pump. Surface condensers are much more expensive and use niore cooling water, so they are usually not used in cases where a direct-contact condenser is suitable.

8.6C

Direct-Contact Condensers

In direct-contact condensers cooling water directly contacts the vapors and condenses the vapors. One of the most common types of direct-contact condensers is the countercurrent barometric condenser shown in Fig. 8.6-1. The vapor enters the condenser and is condensed by rising upward against a shower of cooling water droplets. The condenser is located on top of a long discharge tail pipe. The condenser is high enough above the discharge point in the tail pipe so that the water column established in the pipe more than compensates for the difference in pressure between the low absolute pressure in the Sec. 8.6

Condensers for Evaporators

511

cold water K

Til

+ur=--noncondensables o

o 0 o

00

o 0 of. vapor inlet---

0

o 0

:/00

o

o

0

tailpipe

FIGURE

8.6-1.

Schematic of barometric condenser.

condenser and' the atmosphere. The water can then discharge by gravity through a seal pot at the bottom. A height of about lOA m (34 rt) is used. The barometric condenser is inexpensive and economical of water consumption. It can maintain a vacuum corresponding to a saturated vapor temperature within about 2.8 K (5°F) of the water temperature leaving the condenser. For example, if the discharge water is at 316.5 K (110°F), the pressure corresponding to 316.5 + 2.8 or 319.3 K is 10.1 kPa(1.47psia). The water consumption can be estimated by a simple heat balance for a barometric condenser. the vapor flow to the condenser is V kgfh at temperaty/e Ts and the water flow is W kgfh at an entering temperature of T[ and it leaving temperature of T2 , the deri vat ion is as follows.

rr

(8.6-1 )

where H s is the enthalpy from the steam tables of the vapor at Ts K and the pressure in the vapor stream. Solving, W

kg water

V

kg vapor

Hs -

C p(T2 Cp(T2

273.2)

(8.6-2)

- TIl

The noncondensable gases can be removed from the condenser by a vacuum pump. The vacuum pump used can be a mechanical pump or a steam-jet ejector. [n the ejector high-pressure stearn enters a nozzle at high speed and entrains the noncondensable gases from the space under vacuum. Another type of direct-contact condenser is the jet barometric condenser. Highvelocity jets of water act both as a vapor condenser and as an entrainer of the noncondensables out of the tail pipe. Jet condensers usually require more water than the more common barometric condensers and are more difficult to throttle at low vapor rates.

512

Chap.S

Evaporation

8.7

EVAPORATION OF BIOLOGICAL MATERIALS

8.7 A Introduction and Properties of Biological Materials The evaporation of many biological materials often differs from evaporation of inorganic materials such as NaCI and NaOH and organic materials such as ethanol and acetic acid. Biological materials such as pharmaceuticals, milk, citrus juices, and vegetable extracts are usually quite heat-sensitive and often contain fine particles of suspended matter in the solution. Also, because of problem~ due to bacteria growth, the equipment must be designed for easy cleaning. Many biological materials in solution exhibit only a small boiling-point rise when concentrated. This is due to the fact that suspended solids in a fine dispersed form and dissolved solutes of large molecular weight contribute little to this rise. The amount of degradation of biological materials on evaporation is a function of the temperature and the length of time. To keep the temperature low, the ~vaporation must be done under vacuum, which reduces the boiling point of the solution. To keep the time of contact low, the equipment must provide for a low holdup time (contact time) of the material being evaporated. Typical types of equipment used and some biological materials processed are given below. Detailed discussions of the equipment are given in Section 8.2. 1. Long-tube vertical evaporator. Condensed milk. 2. Falling-film evaporator. Fruit juices. 3. Agitated-film (wiped-film) evaporator. Rubber latex, gelatin, antibiotics, fruit juices. 4. Heat-pump cycle evaporator. Fruit juices, milk, pharmaceuticals.

s C

:r

e

n

J.

,r !s

8.7B

Fruit Juices

In evaporation of fruit juices such as orange juice the problems are quite different from evaporation of a typical salt such as NaCI. The fruit juices are heat-sensitive and the viscosity increases greatly as concentration increases. Also, solid suspended matter in fruit juices has a tendency to cling to the heating surface and thus causes overheating, leading to burning and spoilage of the matter (B2). To reduce this tendency to stick and to reduce residence time, high rates of circulation over the heat-transfer surface are necessary. Since the material is heatsensitive, low-temperature operation is also necessary. Hence, a fruit juice concentration plant usually employs a single and not a multiple evaporation unit. Vacuum is used to reduce the temperature of evaporation. A typical fruit juice evaporation system using the heat pump cycle is shown (P 1, C 1), which uses low-temperature ammonia as the heating fluid. A frozen concentrated citrus juice process is described by Charm (Cl). The process uses a multistage falling-film evaporator. A major fault of concentrated orange juice is a flat flavor due to the loss of volatile constituents during ev'aporation. To overcome this, a portion of the fresh pulpy juice bypasses the evaporation cycle and is blended with the evaporated concentrate.

1l-

Ie

8.7C

Sugar Solutions

Sugar (sucrose) is obtained primarily from the sugar cane and sugar beet. Sugar tends to caramelize if kept at high temperatures for long periods (B2). The general tendency is to

Sec. 8.7

Evaporation of Biological Materials

513

use short-tube evaporators of the natural circulation type. In the evaporation process of sugar solutions, the clear solution of sugar having a concentration of 10-13° Brix (IOn wt %) is evaporated to 40-60° Brix (K1, S1). The feed is first preheated by exhaust steam and then typically enters a six-effect forward-feed evaporator system. The first effect operates at a pressure in the vapor space of the evaporator of about 207 kPa (30 psia) [121.1 °C (2S0°F) saturation temperature] and the last effect under vacuum at about 24 kPa (63.9°C saturation). Examples of the relatively small boiling-point rise of sugar solutions and the heat capacity are given in Example 8.S- L 8.7D

Paper-Pulp Waste Liquors

In the maki!1g of paper pulp in the sulfate process, wood chips are digested or cooked and spent black liquor is obtained after washing the pUlp. This solution contains primarily sodium carbonate and organic sulfide compounds. This solution is concentrated by evaporation in a six-effect system (Kl, SI). 8.8. 8.8A

EVAPORATION USING VAPOR RECOMPRESSION Introduction

In the single-effect evaporator the vapor from the unit is generally condensed and discarded. In the multiple-effect evaporator, the pressure in each succeeding effect is lowered so that the boiling point of the liquid is lowered in each effect. Hence, there is a temperature difference created for the vapor from one effect to condense in the next effect and boil the liquid to form vapor. In a single-effect vapor recompression (sometimes called vapor compression) evaporator the vapor is compressed so that its condensing or saturation temperature is increased. This compressed vapor is returned back to the heater of steam chest and condenses so that vapor is formed in the evaporator (BS, WI, ZI). In this manner the latent heat of the vapor is used and not discarded. The two types of vapor recompression units are the mechanical and the thermal type. 8.SB

Mechanical VaJWr Recompression EV3JWrator.

In a mechanical vapor recompression evaporator, a conventional single effect evaporator similar to that in Fig. 8.2-2 is used and is shown in Fig. 8.8-1. The cold feed is preheated by exchange with the hot outlet liquid product and then flows to the unit. The vapor coming overhead does not go to a condenser but is sent to a centrifugal or positive displacement compressor driven by an electric motor or steam. This compressed vapor or steam is 'sent back to the heat exchanger or steam chest. The cOfI1;pre.ssed vapor condenses ~t a higher temperature than the boiling point of the hot liquid in- the effect and a temperature differe'nce is set up. Vapor is again generated and the cycle repeated. Sometimes it is necessary to add a small amount of makeup steam to the vapor line before the compressor (B5, K2). Also; a small amount of condensate may be added to the compressed vapor to remove any superheat, if present. Vapor recompression units generally operate at low optimum temperature difference9 of S to lOoC. Hence, large heat transfer areas are needed. These units usually have higher capital costs than multiple-effect units because of the larger area and the 514

Chap. 8

Evaporation

makeup steam ---~I-""

vapor

vapor compressor

drive co neeD tra ted product

condensate (for desuperheating) feed beater FIGURE

8.B-1.

cold feed

Simplified process flow for mechanical vapor recompre ssion evaporator.

costs of the relatively expensive compressor and drive unit. The main advantage of vapor recompression units is in the lower energy costs. Using the steam equivalent of the power to drive the compressor, the steam economy is equivalent to a multipleeffect evaporator of up to 10 or more units (Zl). Some typical applications of mechanical vapor recompression units are evaporation of sea water to give distilled water, evaporation of kraft black liquor in the paper industry (L2), evaporation of heat-sensitive materials such as fruit juices, and crystallizing of salts having inverse solubility curves where the solubility decreases with increasing temperature (K2, M3). Falling-film evaporators are well suited for vapor recompression systems (W 1) because they operate at low-temperature-difference values and have very little entrained liquid which can cause problems in the compressor. Vapor recompression has been used in distillation towers where the overhead vapor is recompressed and used in the reboiler as the heating medium (M2).

8.8e

Thermal Vapor Recompression Evaporator

A steam jet can also be used to compress the vapor in a thermal vapor recompression unit. The main disadvantages are the low efficiency of the steamjet, necessitating the removal of this excess heat, and the lack of flexibility to changes in process variables (M3). Steam jets are cheaper and more durable than mechanical compressors and can more easily handle large volumes of low-pressure vapors.

PROBLEMS

8.4-1. Heat-Transfer Coefficient in Single-Effect El·aporator. A feed of 4535 kg/h of a 2.0 wt % salt solution at 311 K enters continuously a single-effect evaporator and is being concentrateq to 3.0%. The evaporation is at atmospheric pressure and the area of the evaporator is 69.7 m 2. SattIrated steam at 383.2 K is supplied for heating. Since the solution is dilute, it can be assumed to have the same boiling point as water. The heat capacity of the feed can be taken asc p = A.lO kJjkg' K. Calculate the amounts of vapor and liquid product and the overall heat-transfer coefficient U. Ans. U 1823 W/m 2 • K 8.4-2. Effects of Increased Feed Rate in Evaporator. Using the same area, value of U, steam pressure, evaporator pressure, and feed temperature as in Problem 8.4-1,

Chap. 8

Problems

515

calculate the amounts of liquid and vapor leaving and the liquid outlet concentration if the feed rate is increased to 6804 kgfh. ADS. V 1256 kgfh, L = 5548 kgfh, XL = 2.45% 8.4-3. Effect of Evaporator Pressure on Capacity and Product Composition.. Recalculate Example 8.4-1 but use an evaporator pressure of 41.4 kPa instead of 101.32 kPa abs. Use the same steam pressure, area A, and heat-transfer coefficient U in the calculations. (a) Do this to obtain the new capacity or feed rate under. these new conditions. The composition of the liquid product will be the same as before. (b) Do this to obtain the new product composition if the feed rate is increased to 18 144 kgfh. 8.4-4. Production of Distilled Water. An evaporator having an area of 83.6 m 2 and a U 2270 W/m 2 • K is used to produce distilled water for a boiler feed. Tap water having 400 ppm of dissolved solids at 15.6°C is fed to the evaporator operating at 1 atm pressure abs. Saturated steam at 115.6°C is available for use. Calculate the amount of distilled water produced per hour if the outlet liquid contains 800 ppm solids. 8.4-5. Boiling-Point Rise of NaOH Solutions. Determine the boiling temperature'of the solution and the boiling-point rise for the following cases. (a) A 30% NaOH solution boiling in an evaporator at a pressure of 172.4 kPa (25 psia). (b) A 60% NaOH solution boiling in an evaporator at a pressure of 3.45 kPa (0.50 psia). Ans. (a) Boiling point = 130.6°C, boiling point rise 15°C 8.4-6. Boiling-Point Rise of Biological Solutes in Solution. Determine the boiling-point rise for the following solutions of biological solutes in water. Use the figure in (PI), p. 11-31. (a) A 30 wt % solution of citric acid in water boiling at 220°F (104.4°C). (b) A 40 wt % solution of sucrose in water boiling at 220°F (1 04.4° C). Ans. (a) Boiling-point rise 2.2°F (L22°C) 8.4-7. Effect of Feed Temperature on Evaporating an NaOH Solution. A single-effect evaporator is concentrating a feed of 9072 kgjh of a 10 wt % solution of NaOH in water to a product of 50% solids. The pressure of the saturated steam used is 42 kPa (gage) and the pressure in the vapor space of the evaporator is 20 kPa (abs). The overall heat-transfer coefficient is 1988 W/m 2 . K. Calculate the steam used, the steam economy in kg vaporized/kg steam, and the area for the following feed conditions. (a) Feed temperature of288.8 K (l5.6°C). (b) Feed temperature of322.1 K (48.9°C). Ans. (a) S 8959kgjhofsteam,A 295.4m 2 8.4-8. Heat-Transfer Coefficient to Evaporate NaOH. In order to concentrate 4536 kgjh of an NaOH solution containing 10 wt % NaOH to a 20 wt % solution, a single-effect evaporator is being used with an area of 37.6m 2 • The feed enters at 21.1 °C (294.3 K). Saturated steam at 11 O°C (383.2 K) is used for heating and the pressure in the vapor space of the evaporator is 51.7 kPa. Calculate the and the overall heat-transfer coefficient. kgjh of steam

8.4-9. Throughput of a Single-Effect Evaporator. An evaporator is concentrating F kgjh at 311 K of a 20 wt % solution of NaOH to 50%. The saturated steam used for heating is at 399.3 K. The pressure in the vapor space of the evaporator is 13.3 kPa abs. The overall coefficient is 1420 W /m 2 . K and the area is 86.4m 1 • Calculate the feed rate F of the evaporator. ADS. F 9072 kgfh 8.4-10. Surface Area and Steam Consumption of an Evaporator. A single-effect evaporator is concentrating a feed solution of organic colloids from 5 to 50 wt %. The 516

Chap. 8

Problems

solution has a negligible boiling-point elevation. The heat capacity of the feed is cp = 4.06 kJjkg' K (0.97 btuflbm ' OF) and the feed enters at 15.6°C (60°F). Saturated steam at 101.32 kPa is available for heating, and the pressure in the vapor space of the evaporator is 15.3 kPa. A total of 4536 kg/h (10000lbmfh) of water is to be evaporated. The overall heat-transfer coefficient is 1988 W/m 2 • K (350 btu/h' ft2. OF). What is the required surface area in m Z and the steam consumption? 8.4-11. Evaporation of Tomato Juice Under Vacuum. Tomato juice having a concentration of 12 wt % solids is being concentrated to 25% solids in a film-type evaporator. The maximum allowable temperature for the tomato juice is 135°F, which will be the temperature of the product. The feed enters at 100°F. Saturated steam at 25 psia is used for heating. The overall heat-transfer coefficient U is 600 btufh· ftz. OF and the area A is 50 ft 2 • The heat capacity of the feed cp is estimated as 0.95 btuflb m ' OF. Neglect any boiling-point rise if present. Calculate the feed rate of tomato juice to the evaporator. 8.4-12. Concentration of Cane Sugar Solution. A single-effect evaporator is being used to concentrate a feed of 10000 lbmlh of a cane sugar solution at 80°F and containing a sugar content of 15° Brix (degrees Brix is wt % sugar) to 30° Brix for use in a food process. Saturated steam at 240°F is available for heating. The vapor space in the evaporator will be at 1 atm abs pressure. The overall U = 350 btu/h . ft2. OF and the heat capacity of the feed is Cp 0.91 btu/Ibm' OF. The boiling-point rise can be estimated from Example 8.5-1. The heat of solution can be considered negligible and neglected. Calculate the area required for the evaporator and the amount of steam used per hour. ADS. Boiling-point rise = 2.0°F (1.1 0q, A 667 ftZ (62.0 mZ) 8.5·1. Boiling Points in a Triple-Effect Evaporator. A solution with a negligible boilingpoint rise is being evaporated in a triple-effect evaporator using saturated steam at 12Ll°C (394.3 K). The pressure in the vapor of the last effect is 25.6 kPa abs. The heat-transfer coefficients are VI = 2840, V 2 == 1988, and V3 = 1420 W/m 2 • K and the areas are equal. Estimate the boiling point in each of the evaporators. AilS. Tl 108.6°C (381.8 K) 8.5·2. Evaporation of Sugar Solution in a Multiple-Effect Evaporator. A triple-effect evaporator with forward feed is evaporating a sugar solution with negligible boiling-point rise (less than 1.0 K, which will be neglected) and containing 5 wt % solids to 25% solids. Saturated steam at 205 kPa abs is being used. The pressure in the vapor space of the third effect is 13.65 kPa. The feed rate is 22 680 kglh and the temperature 299.9 K. The liquid heat capacity is c p 4.19 - 2.35 x, where c p is in kJlkg· K and x in wt fraction (Kl). The heat-transfer coefficients are U 1 = 3123, U 2 = 1987, and U 3 = 1136 W/m 2 • K. Calculate the surface area of each effect if each effect has the same area, and the steam rate. AilS. Area A = 99.1 m 2 , steam rate S = 8972 kg/h 8.5-3. Evaporation in Double-Effect J?everse-Feed Evaporators. A feed containing 2 wt % dissolved organic solids in water is fed to a double-effect evaporator with reverse feed. The feed enters at 100°F and is concentrated to 25% solids. The boiling-point rise can be considered negligible as well as the heat of '..:. .. solution. Each evaporator has a 1()(){)-ft2 surface area and the heat-transfer coefficients are VI = 500 and V z 700 btulh·ft Z 'OF. The feed enters evaporator number 2 and steam at 100 psia is fed to number I. The pressure in the vapor space of evaporator number 2 is 0.98 psia. Assume that the heat capacity of all liquid solutions is that of liquid water. Calculate the feed rate F and the product rate L I of a solution containing 25% solids. (Hint: Assume a feed rate of, say, F == 1000 Ibm/h. Calculate the area. Then calculate the actual feed rate by mUltiplying 1000 by lOOO/calculated area.) AilS. F = 133800 lbmlh (60 691 kg/h), L[ 10700 lb.,jh (4853 kg/h) Chap. 8

Problems

517

8.5-4. Concentration ofNaOH Solution in Triple-Effect Evaporator. A forced-circulation triple-effect evaporator using forward feed is to be used to concentrate a 10 wt % NaOH solution entering at 37.SoC to 50%. The steam used enters at 5S.6 kPa gage. The absolute pressure in the vapor space of the third effect is 6.76 kPa. The feed rate is 13 60S kglh. The heat -transfer coefficients are U I = 6246, U 2 2 = 3407, and U 3 = 2271 W/m • K. All effects have the same area. Calculate the surface area and steam consumption. AIlS. A = 97.3 m\ S = 5284 kg steamjh 8.5-5. Triple-Effect Evaporator with Reverse Feed. A feed rate of 20410 kglh of 10 wt % NaOH solution at 4S.9°C is being concentrated in a triple-effect reverse-feed evaporator to produce a 50% solution. Saturated steam at 17S.3°C is fed to the first evaporator and the pressure in the third effect is 10.34 kPa abs. The heat-transfer coefficient for each effect is assumed to be 2840 W/m 2 • K. Calculate the heat-transfer area and the steam consumption rate. 8.5-6. Evaporation of Sugar Solution in Double Effect Evaporator. A double-effect evaporator with reverse feed is used to concentrate 4536 kglh of a 10 wt % sugar solution to 50%. The feed enters the second effect at 37.8°C. Saturated steam at 115.6°C enters the first effect and the vapor from this effect is used to heat the second effect. The absolute pressure in the second effect is 13.65 kPa abs. The overall coefficients are U 1 2270 and U 2 = 1705 W1m 2 • K. The heating areas for both effects are equal. Use boiling-poi nt-rise and heat-capacity data from Example S.5-1. Calculate the area and steam consumption. 8.6-1. Water Consumption and Pressure in Barometric Condenser. The concentration of NaOH solution leaving the third effect of a triple-effect evaporator is 50 wt %. The vapor flow rate leaving is 5670 kglh and this vapor goes to a barometric condenser. The discharge water from the condenser leaves at 40.5°C. Assuming that the condenser can maintain a vacuum in the third effect corresponding to a saturated vapor pressure of 2.78°C above 40.5°C, calculate the pressure in the third effect and the cooling water flow to the condenser. The cooling water enters at 29.5°C. (Note: The vapor leaving the evaporator will be superheated because of the boiling-point rise.) 306200 kg waterjh Ans. Pressure = 8.80 k Pa abs, W

REFERENCES (Bl) (B2) (B3) (B4) (BS)

(CI) (Kl)

BADGER, W. L, and BANCHERO, J. T. IntroduClion to Chemical Engineering. New York: McGraw-Hili Book Company, 1955. BLAKEBROUGH, N. Biochemical and Biological Engineering Science, Vol. 2. New York: Academic Press, Inc., 1968. BADGER, W. L, and MCCABE, W. L Elements of Chemical Engineering, 2nd ed. New York' McGraw-Hili Book Company, 1936. BROWN, G. G., et aL Unil Operations. New York: John Wiley & Sons, Inc., 1950. BEESLEY, A. H. and RHINESMITH, R. D. Chern. Eng. Progr., 76(8),37 (1980). CHARM, S. E. The Fundamentals of Food Engineering, 2nd ed. Westport, Conn.: Avi Publishing Co., Inc., 1971. ... " KERN, D. Q. Process Heat Transfer. New York: McGraw-Hill Book Company, t

19S0.

(K2) (LJ) (Ll)

(Ml)

518

KING, R. J. Chern. Eng. Progr., 80(7), 63 (1984). LINDSEY, E. Chern. Eng., 60 (4),227 (1953). LOGSDON, 1. D. Chern. Eng. Progr., 79(9),36 (1983). MCCABE, W. L. Trans. A.l.Ch.E., 31, 129 (1935).

Chap. 8

References'

MElLI, A., and STUECHELl, A. Chem. Eng., 94 (F~b. 16), 133 (1987). MEHRA, D. K. Chem. Eng., 93(Feb. 3),56 (1986). (PI) PERRY, R. H., and CHILTON, C. H. Chemical Engineers' Handbook, 5th ed .. New York: McGraw-Hill Book Company, 1973. (P2) PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6th ed. New York: McGraw-Hill Book Company, 1984. (Sl) SHREVE, R. N., and BRINK, J. A., JR. Chemical Process Industries, 4th ed. New York: McGraw-Hill Book Company, 1977. (WI) WEIMER, L. D., DOLF, H. R., and AUSTIN, D. A. Chern. Eng. Progr., 76 (11), 70 (1980). (Zl) ZIMMER, A. Chem. Eng. Progr., 76(9),37 (1980).

(M2) (M3)

Chap. 8

References

519

CHAPTER 9

Drying of Process Materials

9.1 9.1A

INTRODUCTION AND METHODS OF DRYING Purposes of Drying

The discussions of drying in this chapter are concerned with the removal of water from process materials and other substances. The term drying is also used to refer to removal of other organic liquids, such as benzene or organic solvents, from solids. Many of the types of equipment and calculation methods discussed for removal of water can also be used for removal of organic liquids. Drying, in general, usually means removal of relatively small amounts of water from material. Evaporation refers to removal of relatively large amounts of water from material. In evaporation the water is removed as vapor at its boiling point. In drying the water is usually removed as a vapor by air. In some cases water may be removed mechanicaliy from solid materials by presses, centrifuging, and other methods. This is cheaper than drying by thermal means for removal of water, which will be discussed here. The moisture content of the final dried product varies depending upon the type of product. Dried salt contains about 0.5% water, coal about 4%, and many food products about 5%. Drying is usually the final processing step before packaging and makes many materials, such as soap powders and dyestuffs, more suitable for handling. Drying or dehydration of biological materials, especially foods, is used as a preservation technique. Microorganisms that cause food spoilage and decay cannot grow and mUltiply. in the absence of water. Also, many enzymes that cause chemical changes in food and other biological materials canijot function without water. When the water content is reduced below about 10 wt %, the microorganisms are not active. However, it is usually necessary to lower the moisture content below 5 wt % in foods to preserve flavor and nutrition. Dried foods can be stored for extended periods of time. Some biological materials and pharmaceuticals, which may not be heated for ordinary drying, may be freeze-dried as discussed in Section 9.11. Also, in Section 9.12, sterilization of foods and other biological materials is discussed, which is another method often employed to preserve such materials.

520

9.1B

General Methods of Drying

Drying methods and processes can be classified in several different ways. Drying processes can be classified as batch, where the material is inserted into the drying equipment and drying proceeds for a given period of time, or as continuous, where the material is continuously added to the dryer and dried material continuously removed. Drying processes can also be categorized according to the physical conditions used to add heat and remove water vapor: (1) in the first category, heat is added by direct contact with heated air at atmospheric pressure, and the water vapor formed is removed by the air; (2) in vacuum drying, the evaporation of water proceeds more rapidly at low" pressures, and the heat is added indirectly by contact with a metal wall or by radiation (low temperatures can also be used under vacuum for certain materials that may discolor or decompose at higher temperatures); and (3) in freeze drying, water is sublimed from the frozen material. 9.2 9.2A

EQUIPMENT FOR DRYING Tray Dryer

In tray dryers, which are also called shelf, cabinet, or compartment dryers, the material, which may be a lumpy solid or a pasty solid, is spread uniformly on a metal tray to a depth of 10 to 100 mm. Such a typical tray dryer, shown in Fig. 9.2-1, contains removable trays loaded in a cabinet. Steam-heated air is recirculated by a fan over and parallel to the surface of the trays. Electrical heat is also used, especially for low heating loads. About 10 to 20% of the air passing over the trays is fresh air, the remainder being recirculated air. After drying, the cabinet is opened and the trays are replaced with a new batch of trays. A modification.of this type is the tray-truck type, where trays are loaded on trucks which are pushed into the dryer. This saves considerable time, since the trucks can be loaded and unloaded outside the dryer. In the case of granular materials, the material can be loaded on screens which are the bottom of each tray. Then in this through-circulation dryer, heated air passes through the permeable bed, giving shorter drying times because of the greater surface area exposed to the air. 9.2B

Vacuum-Shelf Indirect Dryers

Vacuum-shelf dryers are indirectly heated batch dryers similar to tray dryers. Such a dryer consists of a cabinet made of cast-iron or steel plates fitted with tightly fitted doors

. . . . . "I

adjustable louvers

~I,L/

- a i r out

FiGURE

Sec. 9.2

Equipment For Drying

9.2-1.

~

fan

Tray or shelf dryer.

521

so that it can be operated under vacuum. Hollow shelves of steel are fastened permanently inside the chamber and are connected in parallel to inlet and outlet steam headers. The trays containing the solids to be dried rest upon ·the hollow shelves. The heat is conducted through the metal walls and added by radiation from the shelf above. For low-temperature operation, circulating warm water is used instead of steam for furnishing the heat to vaporize the moisture. The vapors usually pass to a condenser. These dryers are used to dry expensive, or temperature-sensitive, or easily oxidizable materials. They are useful for handling materials with toxic or valuable solvents.

9.2C

Continuous Tunnel Dryers

Continuous tunnel dryers are often batch truck or tray compartments operated in series, as shown in Fig. 9.2-2a. The solids are placed on trays or on trucks which move continuously through a tunnel with hot gases passing over the surface of each tray. The hot air flow can be countercurrent, cocurrent, or a combination. Many foods are dried in this way. When granular particles of solids are to be dried, perforated or screen-belt continuous conveyors are often used, as in Fig. 9.2-2b. The wet granular solids are conveyed as a layer 25 to about 150 mm deep on a screen or perforated apron while heated air is blown upward through the bed, or downward. The dryer consists of several sections in series, each with a fan and heating coils. A portion of the air is exhausted to the atmosphere by a fan. In some cases pasty materials can be preformed into cylinders and placed on the bed to be dried.

h

louv.ers~

blower

,--------------------------Z

Q.g

freshairin------:;: ,..,... ./ , °6heater °0

//1//

wet material---...-j

I

- - .......

---

~

~,

\

\

\\

"'--

f-----l~dry

t - '-1-" --.-l \

r-l

i

trucks enter

---- ----

material

I

'-----\------L_air out

trucks leave

atir~fan ayT~airfiOW

-

t t

I

I

I

°to,O °to °

Y- steam heaters

screen belt (b) FIGURE

522

9.2-2.

Cominuous tunnel dryers: (a) [[mnel dryer trucks with coumercurrent air flow, (b) through-circulation screen conveyor dryer.

Chap. 9

Drying of Process Materials

rer, ____

air

->

L.l...

~-~~

......-.------

-,

9.2D

-.........s- 0 .

0

» 0

~endvieW FIGURE

C_OilS~

he_at_in_g

9.2-3.

0

0 -+- __

~

I

air

Ij-r dry solids

Schematic drawing oj a direct-heat rotary dryer.

Rotary Dryers

A rotary dryer consists of a hollow cylinder which is rotated and usually slightly inclined toward the outlet. The wet granular solids are fed at the high end as shown in Fig. 9.2-3 and move through the shell as it rotates. The heating shown is by direct contact with hot gases in countercurrent flow. In some cases the heating is by indirect contact through the heated wall of the cylinder. The granular particles move forward slowly a short distance before they are showered downward through the hot gases as shown. Many other variations of this rotary dryer are available, and these are discussed elsewhere (Pi). 9.2E

11

Drum Dryers

A dnuil dryer consists of a heated metal roll shown in Fig. 9.2-4, on the outside of which a thin layer of liquid or slurry is evaporated to dryness. The final dry solid is scraped off the roll, which is revolving slowly. Drum dryers are suitable for handling slurries or pastes of solids in fine suspension and for solutions. The drum functions partly as an evaporator and also as a dryer. Other variations of the single-drum type are twin rotating drums with dip feeding or with top feeding to the two drums. Potato slurry is dried using drum dryers, to give potato flakes. 9.2F

Spray Dryers

In a spray dryer a liquid or slurry solution is sprayed into a hot gas srream in the form of a mist of fine droplets. The water is rapidly vaporized from the droplets, leaving particles

internally steamheated drum

film

spreader ---liquid or slurry feed

FIGURE

Sec. 9.2

Equipment For Drying

9.2-4.

Rotary-drum dryer.

523

cyclone separator hopper

-

screw conveyor FIGURE 9.2-5.

Processjlow diagram oj spray-drying apparatus.

of dry solid which are separated from the gas stream. The flow of gas and liquid in the spray chamber may be countercurrent, cocurrent, or a combination. The fine droplets are formed from the liquid feed by spray nozzles or high-speed rotating spray disks inside a cylindrical chamber, as in Fig. 9.2-5. It is necessary to ensure that the droplets or wet particles of solid do not strike and stick to solid surfaces before drying has taken place. Hence, large chambers are used. The dried solids leave at the bottom of the chamber through a screw conveyor. The exhaust gases flow through a cyclone separator to remove any fines. The particles produced are usually light and quite porous. Dried milk powder is made from spray-drying milk.

9.2G

Drying of Crops and Grains

In the drying of grain from a harvest, the grain contains about 30 to 35% moisture and for safe storage for about 1 year should be dried to about 13 wt % moisture (H 1). A typical continuous-flow dryer is shown in Fig. 9.2-6. In the drying bin the thickness of the layer of grain is 0.5 m or less, through which the hot air passes. Unheated air in the bottom section cools the dry grain before it leaves. Other types of crop dryers and storage bi ns are descri bed by Hall (H 1).

grain inlet I

I

.... heated air for drying

wire screen

.... cooling air

dry grain FIGURE

524

9.2-6.

Verlical conlinu()usjlow grain dryer.

Chap. 9

Drying oj Process Materials

9.3 9.3A

VAPOR PRESSURE OF WATER AND HUMIDITY Vapor Pressure of Water

1. Introduction. In a number of the unit operations and transport processes it is necessary to make calculations involving the properties of mixtures of water vapor and air. These calculations involve knowledge of the concentration of water vapor in air under various conditions of temperature and pressure, the thermal properties of these mixtures, and the changes occurring when this mixture is brought into contact with water or with wet solids in drying . . Humidification involves the transfer of water from the liquid phase into a gaseous mixture of air and water vapor. Dehumidification involves the reverse transfer, whereby water vapor is transferred from the vapor state to the liquid state. Humidification and dehumidification can also refer to vapor mixtures of materials such as benzene, but most practical applications occur with water. To better understand humidity, it is first necessary to discuss the vapor pressure of water.

2. Vapor pressure of water and physical states. Pure water can exist in three different physical states: solid ice, liquid, and vapor. The physical state in which it exists depends on the pressure and temperature. Figure 9.3-1 illustrates the various physical states of water and the pressuretemperature relationships at equilibrium. In Fig. 9.3-1 the regions of the solid, liquid, and vapor states are shown. Along the line AB, the phases liquid and vapor coexist. Along line AC, the phases ice and liquid coexist. Along line AD, ice and vapor coexist. If ice at point (1) is heated at constant pressure, the temperature rises and the physical condition is shown moving horizontally. As the line crosses AC, the solid melts, and on crossing AB the liquid vaporizes. Moving from point (3) to (4), ice sublimes (vaporizes) to a vapor without becoming a liquid. Liquid and vapor coexist in equilibrium along the line AB, which is the vaporpressure line of water. Boiling occurs when the vapor pressure of the water is equal to the total pressure above the water surface. For example, at 100°C (212°F) the vapor pressure of water is 101.3 kPa (1.0 atm), and hence it will boil at 1 atm pressure. At 65.6°C (150°F), from the steam tables in Appendix A.2, the vapor pressure of water is 25.7 kPa (3.72 psia). Hence, at 25.7 kPa and 65.6°C, water will boil. If a pan of water is held at 65.6°C in a room at 101.3 kPa abs pressure, the vapor pressure of water will again be 25.7 k Pa. This illustrates an important property of the solid region~--,,_c_~Jj:Uid region

(1)

(2) _--t-_vapor region, .

A

(3) -

---(4)

D

Temperature FIGURE

Sec. 9.3

9,3- L Phase diagram for warer.

Vapor Pressure of Water and Hi,midity

"

525

vapor pressure of water, which is not influenced by the presence of an inert gas such k



\:)

::.

0.07

i:l...

:::t::

.....

'"~ tl.Il

I::

0.06

..:.: '-'

~.

0.05

::t:

;"l ~

0.04 0.03 0.02

Jttt:f:::tj o

10

20

30

40

50

60

70

80

90

I I 13Jjt-f:tt1 100

110

120

0.01

I

110 130

o

Temperature ( C) FIGURE V1

N

'"

9.3-2.

Humidicy chart for mixctlres of air and water vapor at a total pressure oj 101.325 kPa (760 mm Hg). (From R. E. Treybal, Mass-TransJer Opcrarions, ]rd ed. New York: McGraw-Hili Book Company, 1980. With permission.)

Eq. (9.3-6), cs = 1.005 =

+ 1.88(0.0225)

1.047 kJ/kg dry air· K

or

1.047 x 10 3 J/kg' K

cs = 0.24 + 0.45(0.0225) = 0.250 btuJ1b m dry air· OF

(English)

The humid volume at 60°C (140°F), from Eq. (9.3-7), is Un

= (2.83 x 10- 3

+ 4.56

X

10- 3 x 0.0225X60 + 273)

= 0.977 m 3/kg dry air In English units, Un

9.JC

= (0.0252 + 0.0405 x 0.0225)(460

+

140)

15.67 ft 3 jlbm dry air

Adiabatic Saturation Temperatures

Consider the process shown in Fig. 9.3-3, where the entering gas of air-water vapor mixture is contacted with a spray of liquid water. The gas leaves having a different humidity and temperature and the process is adiabatic. The water is recirculated, with some makeup water added. The temperature of the water being recirculated reaches a steady-state temperature called the adiabatic saturation temperature, IS. If the entering gas at temperature T having a humidity of H is not saturated, Ts will be lower than T. If the contact between the entering gas and the spray of droplets is enough to bring the gas and liquid to equilibrium, the lea ving air is saturated at IS, having a humidity H s. Writing an enthalpy balance (heat balance) over the process, a datum of1s is used. The enthalpy of the makeup H 2 0 is then zero. This means that the total enthalpy of the entering gas mixture = enthalpy of the leaving gas mixture, or, using Eq. (9.3-8), (9.3-10) Or, rearranging, and using Eq. (9.3-6) for cs ,

H - Hs

Cs

-= )·s

T - Ts H -Us

0.24

T - Ts

1.005

+ 1.88H

(SI)

)·s

(9.3-11)

+ 0.45H

(English)

).S

Equation (9.3-11) is the equation of an adiabatic humidification curve when plotted

outlet gas.

inlet gas H, T

Hs. Ts

makeup H 2 0

Ts Ts FIGURE

S3{)

9.3-3.

Adiabalic air-waler vapor salurator.

Chap. 9

Drying of Process Materials

on Fig. 9.3-2, which passes through the point Hs andTs on the 100% saturation curve and other points of Hand T. These series of lines, running upward to the left, are called adiabatic humidification lines or adiabatic saturation lines. Since cs contains the term H, the adiabatic lines are not quite straight when plotted on the humidity chart. If a given gas mixture at Tl and HI is contacted for a sufficiently long time in an adiabatic saturator, it will leave saturated at HSl and TS1 ' The values orHSI and TSI are determined by following the adiabatic saturation line going through point Tj, HI until it intersects the 100% saturation line. If contact is not sufficient, the leaving mixture will be at a percentage saturation less than 100 but on the same line.

EXAMPLE 9.3-3.

Adiabatic Saturation of Air

An air stream at 87.8°C having a humidity H = 0.030 kg HzO/kg dry air is contacted in an adiabatic saturator with water. It is cooled and humidified to 90% saturation. (a) What are the final values of Hand T? (b) For 100% saturation, what would be the values of Hand T? For. part (a), the point H = 0.030 and T = 87.8°C is located on the humidity chart. The adiabatic saturation curve through this point is followed upward to the left until it intersects the 90% line at 42.5°C and H = 0.0500 kg H 2 0/kg dry air. For part (b), the same line is followed to 100% saturation, where T = 40SC and H 0.0505 kg H 2 0/kg dry air.

Solution:

9.3D

Wet Bulb Temperature

The adiabatic saturation temperature is the steady-state temperature attained when a large amount of water is contacted with the entering gas. The wet bulb temperature is the steady-state nonequilibrium temperature reached when a small amount of water is contacted under adiabatic conditions by a continuous stream of gas. Since the amount of liquid is small, the temperature and humidity of the gas are not changed, contrary to the adiabatic saturation case, where the temperature and humidity of the gas are changed. The method used to measure the wet bulb temperature is illustrated in Fig. 9.3-4, where a thermometer is covered by a wick or cloth. The wick is kept wet by water and is immersed in a flowing stream of air-water vapor having a temperature of T (dry bulb temperature) and humidity H. At steady state, water is evaporating to the gas stream. The wick and water are cooled to 7;1' and stay at this constant temperature. The latent heat of evaporation is exactly balanced by the convective heat flowing from the gas stream at T to the wick at a lower temperature 7;". thermometer reads Tw

Tw

FtGURE

Sec. 9.J

9.3-4.

Measurement o/wet bulb temperature.

Vapor Pressure of Water and Humidity

531

A heat balance on the wick can be made. The datum temperature is taken at Tw. The amount of heat lost by vaporization, neglecting the small sensible heat change oUhe vaporized liquid and radiation, is (9.3-12) where q is kW(kJ/s), M A is molecular weight of water, N A is kg mol H 2 0 evaporating; s· m 2 , A is surface area m 2 , and Aw is the latent heat of vaporization at Tw in kJ/kg H 2 0. In English units, q is btu/h,N A is lbmolfh· ft2, andAw is btuflblll H 20. The fluxN A is . (9.3-13) where k~is the mass-transfer coefficient in kg molls' m 2 • mol frac, X 8M is the log mean inert mole fraction of the air, Yw is the mole fraction of water vapor in the gas at the surface, and y is the mole fraction in the gas. For a dilute mixture X 8M 1.0 and k~ ~ k y • The relation between Hand y is. (9.3-14) where M 8 is the molecular weight of air and MAthe molecular weight of H 2 0. Since H is small, as an approximation,

HMB

(9.3-15)

y~-­

M,j

Substitu ting (9.3-12),

(9.3·1S) into (9.3-13) and then substituting the resultant into Eq.

(9.3-16) The rate of convective heat transfer from the gas stream at T to the wick at Tw is

q = h(T - Tw)A

(9.3-17)

where h is the heat-transfer coefficient in k W1m2. K (btu/h' ft2 . OF). Equating Eq. (9.3-16) to (9.3-17) and rearranging, H -Hw

(9.3-18)

T- Tw

Experimental data on the value of hiM Bky, called the psychrometric ratio, show that for water vapor-air mixtures, the value is approximately 0.96-1.005. Since this value is close to the value of Cs in (9.3-11), approximately l.OOS, Eqs. (9.3-18) and (9.3-11) are almost the same. This means that the adiabatic saturation lines can also be used for wet bulb lines with reasonable accuracy. (Note that this is only true for water vapor and not for others, such as benzene.) Hence, the wet bulb determination is often used to determine the humidity of an air-water vapor mixture.

EXAMPLE 93-4. Wet Bulb Temperature and Humidity A water vapor-air mixture having a dry bulb temperature of T 60°C is passed over a wet bulb as shown in Fig. 9.3-4, and the wet bulb temperature obtained is Tw 29.5°C. What is the humidity of the mixture? Solution: The wet bulb temperature of 29.SoC can be assumed to be the same as the adiabatic saturation temperature 7S, as discussed. Following the adiabatic saturation curve of 29.SoC until it reaches the dry bulb temperature of 60°C, the humidity is H = 0.0135 kgH 2 0/kg dry air. 532

Chap. 9

Drying of Process Materials

9.4 9.4A

EQUILIBRIUM MOISTURE CONTENT OF MATERIAlS Introduction

As in other transfer processes, such as mass transfer, the process of drying of materials must be approached from the viewpoint of the equilibrium relationships and also the rate relationships, In most of the drying apparatus discussed in Section 9.2, material is dried in contact with an air-water vapor mixture. The equilibrium relationships between the air-water vapor and the solid material will be discussed in this section. An important variable in the drying of materials is the humidity of the air in contact with a solid of given moisture content Suppose that a wet solid containing moisture is brought into contact with a stream of air ha ving a constant humidity H and temperature. A large excess of air is used, so its conditions remain constant. Eventually, after exposure of the solid sufficiently long for equilibrium to be reached, the solid will attain a definite moisture content This is known as the equilibrium moisture content of the material under the specified humidity and temperature of the air. The moisture content is usually expressed on a dry basis as kg of water per kg of moisture-free (bone-dry) solid or kg H 2 0/100 kg dry solid; in English units as lb HzO/lOO Ib dry solid. For some solids the value of the equilibrium moisture content depends on the direction from which equilibrium is approached. A different value of the equilibrium moisture content is obtained according to whether a wet sample is allowed to dry by desorption or whether a dry sample adsorbs moisture by adsorption. For drying calculations it is the desorption eq uilibrium that is the larger value and is of particular interest. 9.4B

Experimental Data of Equilibrium Moisture Content for Inorganic and Biological Materials

I. Typical dataJor various materials, If the material contains more moisture than its equilibrium value in contact with a gas of a given humidity and temperature, it will dry until it reaches its equilibrium value. If the material contains less moisture than its equilibrium value, it will adsorb water until it reaches its equilibrium value. For air having 0% humidity, the equilibrium moisture value of all materials is zero, The equilibrium moisture conten t varies greatly with the type of material for any given percent relative humidity, as shown in Fig. 9.4-1 for some typical materials at room temperature. Nonporous insoluble solids tend to have equilibrium moisture contents which are quite low, as shown for glass wool and kaolin, Certain spongy, cellular materials of organic and biological origin generally show large equilibrium moisture contents. Examples of this in Fig. 9.4-1 are wool, leather, and wood. 2, Typical Jood materials, In Fig. 9.4-2 the equilibrium moisture contents of some typical food materials are plotted versus percent relative humidity. These biological materials also show large values of equilibrium moisture contents. Data in this figure and in Fig. 9.4-1 for biological materials show that at high percent relative humidities of ... about 60 to 80%, the equilibrium moisture content increases very rapidly with increases of relative humidity, In general, at low relative humidities the equilibrium moisture content is greatest for food materials high in protein, starch, or other high-molecular-weight polymers and lower for food materials high in soluble solids. Crystalline salts and sugars and also fats generally adsorb small amounts of water. 3, Effect oj temperature,

.\'

Sec. 9.4

The equilibrium moisture content of a solid decreases some-

Equilibrium Moisture Content of Materials

533

28 1 Paper. newsprint

----

:8 "0 0 '" ;>.. .... ::r::'" "CJ

OJ)

OJ)

24

6 7

20

[ 1

0 0

....c ....c

8 9 [0

.;.; .;.;

~

2 3 4 5

12

Wool, worsted N itrocell ulose Silk Leather, tanned Kaolin Tobacco leaf Soap Glue, hide Wood Glass wool Cotton

16

Q)

0

0.6 are in error because of the curvature of line A.

EXAMPLE 9.9-2. Diffusion Coefficient in the Tapioca Root Tapioca flour is obtained from drying and then milling the tapioca root. Experimental data on drying thin slices of the tapioca root 3 mm thick on both sides in the falling-rate period under constant drying conditions are tabulated below. The time t = 0 is the start of the falling-rate period.

t

1.0 0.80 0.63

(h)

X/Xc

t

(h)

X/Xc

t

0.23 0.18

0.94 1.07

o

0.55

OAO

0.15 0.27

OAO

0.60 0.80

0.30

(h)

It has been determined that the data do not follow the capillary-flow equation but appear to follow the diffusion equation. Plot the data as X/Xc versus t on semilog coordinates and determine the average diffusivity of the moisture up to a value of X/Xc = 0.20.

Solution: In Fig. 9.9-2 the data are plotted as X/Xc on the log scale versus t on a linear scale and a smooth curve drawn through the data. At X/Xc = t (h) 1.00

0.2

0.4

0.6

0.8

1.0

1.2

1.4

0.8 ~

\.

0.6 0.4

~

I\.)

0.2

~

I

'"

~

.~

0.1 0.08

I

~i

I

~

1\ ~ \

-'-1\

0.06

\

0

,I

"""!".

(B~

0.04 0.03

-L

I

!

"'"

(A)-

'I

0.2

0.4

0.6

0.8

1.0

1.2

1.4

DLt

FlGURE

Sec. 9.9

9.9-1.

Pial of equalions for falling-rale period: (A) Eq. (9.9-4) for moisture movement by diffusion, (B) Eq. (9.9-/0) for moisture movement by capillary flow. (From R. H. Perry alld C. H. Chilton, Chemical, Engilleers Handbook, 5th ed. New York: McGraw-Hili Book Company, /973. With permission.)

Drying in Falling-Rate Period by Diffusion and Capillary Flow

555

1.0

Time t (h) FIGURE

9.9-2.

Plot of drying datafor Example 9.9-2.

0.20, a value of t 1.02 h is read olTthe plot. The value of Xl 3 mm/2 = 1(5mm for drying from both sides. From Fig. 9.9-1, line A, for X/Xc = 0.20, (IfL t/Xi)'heor 0.56. Then substituting into Eq. (9.9-12), '---'

D - (D L -

9.10

9.10A

L

t/x 2 )

1 .heor

2 XI -

2

0.56(1.5/1000) - 344 t 1.02 x 3600 - .

X

10- 10 m 2 /s

EQUATIONS FOR VARIOUS TYPES OF DRYERS Through Circulation Drying in Packed Bds

For through circulation drying where the drying gas passes upward or downward through a bed of wet granular solids, both a constant-rate period and a falling-rate period of drying may result. Often the granular solids are arranged on a screen so that the gas passes through the screen and through the open spaces or voids between the solid particles.

/. Derivation oj equations. To derive the equations for this case, no heat losses will be assumed, so the system is adiabatic. The drying will be for unbound moisture in the wet granular solids. We shall consider a bed of uniform cross-sectional area A m 2 , where a gas flow of G kg dry gas/h, m 2 cross section enters with a humidity of H I' By a material balance on the gas at a given time, the gas leaves the bed with a humidity H 2' The amount of water removed from the bed by the gas is equal to the rate of drying at this time. (9.10-1) where R = kg H 2 0/h. m 2 cross section and G kg dry air/h· m 1 cross section. In Fig. 9.10-1 the gas enters at TI and HI and leaves at T2 and H 2 • Hence, the temperature T and humidity H both vary through the bed. Making a heat balance over 556

Chap. 9

Drying of Process Materials

the short section dz m of the bed, dq

=

(9.10-2)

-GcsA dT

where A = m 2 cross-sectional area, q is the beat-transfer rate in W (J/s), and Cs is the humid heat of the air-water vapor mixture in- Eq. (9.3-6). Note that G in tbis equation is in kgfs' m 2 • The heat-transfer equation gives dq

= haA

(9.10-3)

dz(T - Tw)

where Tw = wet bulb temperature of solid, h is the heat-transfer coefficient in W/m 2 • K, and a is m 2 surface area of solids/m 3 bed volume. Equating Eq. (9.10-2) to (9.10-3), rearranging, and integrating, -.ha Gcs

1"dz

(9.10-4)

0

(9.10-5) where z bed thickness Xl m. For the constant-rate period of drying by air flowing parallel to a surface, Eq. (9.6-11) was derived. LS(XI - X 2 ) Ls .A. w (X 1 - X 2) t = -"----"--'--'---= (9.6-11) Ah(T - Tw) AkyMB(Hw H) ( VsU!g Eq. (9.9-9) and the definition of a, we obtain =

A

Ps a

(9.10-6)

Substituting Eq. (9.10-6) into (9.6-11) and settingX 2 = Xc for drying toX c , we obtain the equation for through circulation drying in the constant-rate period.

PSAW(X 1

XC>

ah(T - Tw)

(9.10-7)

akyMB(Hw - H)

In a similar manner, Eq. (9.7-8) for the falling-rate period, which assumes that R proportional to X, becomes, for through circulation drying, Ps).wXc In (XciX) ah(T - Tw) FIGURE

9.1O-L

PsXc In (Xc/X) akyMB(Hw-lf)

IS

(9.10-8)

Heat and material balances in a through circulation dryer in a packed bed.

~dz Tz

__t~~T~

H+dH

----r---

T, H

~ T I , HI

Sec. 9.10

Equations for Various Types of Dryers

557

Both Eqs. (9.10-7) and (9.10-8), however, hold only for one point in the bed in Fig. 9.10-1; since the temperature T of the gas varies throughout the bed. Hence, in a manner similar to the derivation in heat transfer, a log mean temperature difference can be used as an approximation for the whole bed in place ofT - Tw in Eqs. (9.10-7) and (9.10-8). T, - T 1

2

In [(7; - Tw)/(T2 - Tw)]

(9.10-9).

Substitpting Eq. (9.10-5) for the denominator of Eq. (9.10-9) and also substituting the value of T2 from Eq. (9.10-5) into (9.10-9), (T

TW)LM

= -------haz/Gcs

(9.10-10)

Substituting Eq. (9.10-10) into (9.10-7) for the constant-rate period and setting

t

PS,{WX1(X 1 Xc) = --'--=--"---'-'--'---:':.:......~

GCS(TI - Tw)(l - e

(9.10-11)

ha:q/GcS)

Similarly, for the falling-rate period an approximate equation is obtained. (9.10-12) A major difficulty with the use of Eq. (9.1 0-12) is that the critical moisture content is not easily estimated. Different forms of Eqs. (9.10-11) and (9.10-12) can also be derived, using . humidity instead of temperature (TI). 2. Heat-transfer coefficients. For through circulation drying, where the gases pass through a bed of wet granular solids, the following equations for estimating h for adiabatic evaporation of water can be used (G 1, WI).

GO. 59

h

= 0.151 D~.41

(SI)

p

h

0.11

(English)

G°.49

h

= 0.214 D~.Sl

(SI)

P

D G

_P_' > 350

0.15 D~.51

(English)

(9.10-13)

Jl

DG

- p- '

G°.49

h

I I

< 350

(9.10-14)

Jl

p

where II is in W/m 2 . K, Dp is diameter in m of a sphere having the same surface area as the particle in the bed, G, is the total mass velocity entering the bed in kg/h· m Z, and Jl is viscosity in kg/m· h. In English units, h is btu/h· ft l . OF, Dp is ft, G, is Ib,Jh' ftl, and J1. is Ib,Jft· h. 3. Geometry factors in a bed. To determine the value of a, a packed bed for spherical particles having a diameter Dp m, a

558

surfacearea/m 3 of bed, in

(9.10-15)

Chap. 9

Drying of Process Materials

where e is the void fraction in the bed. For cylindrical particles, (9.10-16) where Dc is diameter of cylinder in m and h is length of cylinder in m. The valueof Dp to use in Eqs. (9.10-13) and (9.10-14) for a cylinder is the diameter of a sphere having the same surface area as the cylinder, as follows: (9.10-17) 4. Equations Jor very fine particles. The equations derived for the constant- and falling- . rate periods in packed beds hold for particles of about 1-19 mm in diameter. in shallow beds about 10-65 mm thick (T1, M1). For very fine particles of 10-200 mesh (1.66--0.079 mm) and bed depth greater than 11 mm, the interfacial area a varies with the moisture content. Empirical expressions are available to estimate a and the mass-transfer coefficient (Tl, AI). EXAMPLE 9.10-1. Through Circulation Drying in a Bed A granular paste material is extruded into cylinders with a diameter of 6.35 mm and length of 25.4 mm. The initial total moisture content Xn 1.0 kg H 2 0/kg dry solid and the equilibrium moisture is X* = 0.01. The density of the dry solid is 1602 kg/m 3 (100 Ib.Jft 3 ). The cylinders are packed on a screen to a depth of Xl = 50.8 mm. The bulk density of the dry solid in the bed is Ps 641 kg/m 3 . The inlet air has a humidity HI = 0.04 kg H 2 0jkg dry air and a temperature Tl = 121.1 0c. The gas superficial velocity is 0.811 m/s and the gas passes through the bed. The total critical moisture content is X,c 0.50. Calculate the total time to dry the solids to X, = 0.10 kg H 2 0/kg dry solid.

For the solid,

Solution:

XI

XII - X* = 1.00

Xc

X,c - X*

X

X,

=

X*

0.01 = 0.99 kg H 2 0jkg dry solid

0.50 - 0.01 =

0.10 - 0.01

=

0.49 0.09

For the gas, T\ = 121.l°C and HI 0.04 kg H 2 0/kg dry air. The wet bulb temperature Tw 47.2°C and H w 0.074. The solid temperature is at Tw if radiation and conduction are neglected. The density of the entering air at 121.1 °C and 1 atm is as follows. (2.83 x 10- 3

VH

=

P=

+ 4.56

X

10- 3 x 0.04X273

+

121.1) (9.3-7)

1.187 m 3 /kg dry air 1.00 1.

+ 0.04 =

. 0.876 kg dry aIr

+ H 2 0/m

3

The mass y.elocity of the dry air is G=

vpC.o ~00.04) 0.811(3600){0.876{1.~) = 2459 kg dry airjh·m =

2

Since the inlet HI = 0.040 and the outlet will be less than 0.074, an approximate average H of 0.05 will be used to calculate the total average mass velocity. The approximate average G, is G,

's

Sec. 9./0

2459

+ 2459(0.05)

2582 kg air

Equations Jor Various Types oj Dryers

+ HzO/h . m 2 559

For the packed bed, the void fraction e is calculated as follows for 1 m 3 of bed containing solids plus voids. A total of 641 kg dry solid is present. The density of the dry solid is 1602 kg dry solid/m 3 solid. The volume of the solids in 1 m 3 of bed is then 641/1602, or 0.40 m 3 solid. Hence, e = 1 - 0.40 = 0.60. The solid cylinder length h = 0.0254 m. The diameter Dc 0.00635 m. Substituting into Eq. (9.10-16), a

+ O.5DJ

e)(h

4{1

4{1

= 283.5

0.6)[0.0254

+ 0.5(0.00635)]

~----~~~~~~--~~

Dc h

0.00635(0.0254)

m 2 surface area/m 3 bed volume

To calculate the diameter Dp of a sphere with the same area as the cylinder using Eq. (9.1 0-17), Dp ::{!?c,h+ 0.5D;)1/2

[0.00635 x 0.0254

+ O.5(0.0063W] 1/2

= {),0135 m The bed thickness XI = 50.8 mm 0.050.8 m. To calculate the heat-transfer coefficient, the Reynolds number is first calculated. Assuming an approximate average air temperature of93.3°C, the viscosity of air is 11 = 2.15 X 10- 5 kg/m' s 2.15 X 10- 5 (3600) = 7.74 x 10- 2 kg/m· h. The Reynolds number is

N Re

_ DpG, -

11

0.0135(2582) 7.74 x 10 2

450

Using Eq. (9.10-13), -~h =

0.151(2582)°·51 2 (0.0135)0,41 = 90.9 W /m . K

0.151

For T,v 47.2°C, ).w 2389 kJ/kg, or 2.389 x 10 6 J/kg (1027 btu/Ibm), from steam tables, The average humid heat, from Eq. (9,3-6), is Cs

= 1.005 + L88H = 1.005 + 1.88(0.05) = 1.099

X

1.099 kJ/kg dry air' K

10 3 J/kg' K

To calculate the time of drying for the constant-rate period using Eq. (9.10-11) and G = 2459/3600 = 0.6831 kg/s' m 2 , PS)'WXl(X 1 -

XC>

641 (2.389 x 10 6 )(0.0508)(0.99 - 0.49) 47.2)[1 e [90.9 x 283.5 x 0.050B)/{0.683 x 1.099 x 10))] (0.683)(1.099 x 103)(121.1 850 s

= 0.236 h

For the time of drying for the falling-rate period, using Eq. (9.10-12), ( =

=

In

-=-",-:,:::~-=--:,,-,---'---"i---'-:-r--:

Tw)(1

641(2.389 x 10 6 )(0.0508)(0.49) In (0.49/0.09) (0.6831)(1.099 x 10 3 )(121.1 _ 47.2)[1 e {90.9 x 283.5 x O.050B)/{0.683 x 1.099< 10 l )] 1412 s = 0.392 h total time t

560

= 0.236 + 0.392 = 0.628 h Chap. 9

Drying of Process Materials

9.10B Tray Dr)lng with Varying Air Conditions For drying in a compartmen£ 'or tray dryer where the air passes in parallel flow over the surface of the tray, the air conditions do not remain constant. Heat and material balances similar to those for through circulation must be made to determine the exit-gas temperature and humidity. In Fig. 9.10-2 air is shown passing over a tray. It enters having a temperature of TI and humidity HI and leaves at T2 and H 2 . The spacing between the trays is b m and dry air flow is G kg dry air/s· m 2 cross-sectional area. Writing a heat balance over a length dL, of tray for a section 1 m wide, dq = Gcs (1 x b) dT

(9.10-18)

dq = h(l x dL,XT - Tw)

(9.10-19)

The heat-transfer equation is

Rearranging and integrating,

hL,

(9.10-20)

Gcsb

Defining a log mean temperature difference similar to Eq. (9.10-10) and substituting into Eqs. (9.6-11) and (9.7-8), we obtain the following. For the constant-rate period, t=

xIPsL,),w(X , - XC> Gcsb(T, TwXl - e hL,/GcSb)

(9.10-21)

--...:.:...=--'--::....:...-:.---:-c~--:-

For the falling-rate period, an approximate equation is obtained. (9.10-22)

9.1 DC

Material and Heat Balances for Continuous Dryers

1. Simple heat and material balances. In Fig. 9.10-3 a flow diagram is given for a continuous-type dryer where the drying gas flows countercurrently to the solids flow. The solid enters at a rate of Ls kg dry solid/h, having a free moisture content X I and a

air

FIGURE

Sec. 9.10

...

9.10-2.

Heat and material balances in a tray dryer.

Equations for Various Types of Dryers

561

FIGURE

9.10-3.

Process flow Jor a countercurrent continuous dryer. gas TCI,

HI

solid

temperature Ts1 . It leaves at X 2 and IS2' The gas enters at a rate G kg dry air/h, having a humidity Hz kg HzO/kg dry air and a temperature ofT02 - The gas leaves at TOI andH l . For a material balance on the moisture, (9.10-23)

For a heat balance a datum of To °c is selected. A convenient temperature is ODC (32°F). The enthalpy of the wet solid is composed of the enthalpy of the dry solid plus that of the liquid as free moisture. The heat of wetting is usually neglected. The enthalpy of the gas H~ in kJ/kg dry air is ' H~ =

cs(TG

-

To)

+ H).o

(9.11)..24)

where;'o is the latent heat of water at To DC, 2501 kJ/kg (1075.4 btu/lb m ) at oDe, andc s is the humid heat, given as kJ/kg dry air' K. Cs

The enthalpy of the wet solid

H~

l.005

+ 1.88H

in kJ/kg dry solid, where(Ts

(9.3-6)

TotC = (IS - To) K, is

H's

(9.11)..25)

where cps is the heat capacity of the dry solid in kJ/kg dry solid, K and cpA. is the heat capacity of liquid moisture in kJ/kg H 2 0. K. The, heat of wetting or adsorption is neglected. A heat balance on the dryer is (9.11)..26)

where Q is the heat loss in the dryer in kJ/h. For an adiabatic process Q = 0, and if heat is added, Qis negative. EXAMPLE 9.10-2. Heat Balance on a Dryer A continuous countercurrent dryer is being used to dry 453.6 kg dry solid/h containing 0.04 kg total moisture/kg dry solid to a value of 0.002 kg total moisture/kg dry solid. The granular solid enters at 26.7°C and is to be discharged at 62.8°C. The dry solid has a heat capacity of l.465 kJ/kg' K, which is assumed constant. Heating air enters at 93.3"e, having a humidity of 0.010 kg H 2 0/kg dry air, and is to leave at 37.8°C. Calculate the air ftow rate and the outlet humidity, assuming no heat losses in the dryer. Solution: The flow diagram is given in Fig. 9.10-3. For the solid, Ls = 453.6 kg/h dry'soli

e-kyMea;Q/G)

9.10-3. Through Circulation Drying in the Constant-Ra1e Period. Spherical wet catalyst pellets having a diameter of 12.7 mm are being dried in a through circulation dryer. The pellets are in a bed 63.5 mm thick on a screen. The solids are being dried by air entering with a superficial velocity of 0.914 mls at 82.2°C and having a humidity H = 0.01 kg HzOlkg dry air. The dry solid density is determined as 1522 kg/m 3 , and the void fraction in the bed is 0.35. The initial free moisture content is 0.90 kg H 2 0lkg solid and the solids are to be dried to a free moisture content of O.4S, which is above the critical free moisture content. Calculate the time for drying in this constant-rate period. 9.10-4. MaJerinl and HeaJ Balo.nces on a Continuous Dryer. Repeat Example 9.10-2, making heat and material balances, but with the following changes. The solid enters at lS.6°C and leaves at 60°C. The gas enters at 87.8°C and leaves at 32.2°C, Heat losses from the dryer are estimated as 2931 W. 9.10-5. Drying in a Continuous Tunnel Dryer. A rate of feed of 700 Ibm dry solidlh containing a free moisture content of X I 004133 Ib HzOllb dry solid is to be dried to X z = 0.0374 lb H 2 0llb dry solid in a continuous counterflow tunnel dryer. A flow of 13 280 Ibm dry airlh enters at 203°F with an H,2 = 0.OS62 Ib HzOllb dry air. The stock enters at the, wet bulb temperature of 119°F and remains essentially constant in temperature in the dryer. The satuJ:"ation humidity at 119°F from the humidity chart is H w = 0.0786 Ib H 2 0llb dry air. The surface area available for drying is (AILs) = 0.30 ft211b m dry solid. A small batch experiment was performed using constant drying conditions, air velocity, and temperature of the solid approximately the same as in the continuous dryer. The equilibrium critical moisture content was found to be Xc = 0.09S91b H 20/lb dry solid, and the experimental value of ky M B was found as 30.1S Ibm airfh· ft2. In the falling-rate period, the drying rate was directly proportional to X. For the continuous dryer, calculate the time in the dryer in the constant-rate zone and in the falling-rate zone. ADS. He 0.OS93 Ib H 2 0/lb dry air, HI 0.0760 Ib H 2 0flb dry air, t = 4.24 h in the constant-rate zone, t = 0.47 h in the [alling-rate zone

r

9.10-6. Air Recirculo.tion in a Continuous Dryer. The wet feed material to a continuous dryer contains SO wt % water on a wet basis and is dried to 27 wt % by countercurrent air flow. The,dried product leaves at the rate of907.2 kglh. Fresh air to the ~ystem is at 2S.6°C and has a humidity of H = 0.007 kg H 20/kg dry air. The moist air leaves the dryer at 37.8°C and H 0.020 and part of it is recirculated and mixed with the fresh air before entering a heater. The heated mixed air enters the dryer at 6S.6°C and H = 0.010. The solid enters at 26.7°C and leaves at 26.7°C, Calculate the fresh-air flow, the percent air leaving the dryer that is recycled, the heat added in the heater, and the heat loss from the dryer. ADS. 32094 kg fresh dry airfh, 23.08% recycled, 440.6 kW in heater

s

Chap. 9

Problems

581

9.12-1. Sterilizing Canned Foods. In a sterilizing retort, cans of a given food were heated

and the average temperature in the center of a can is approximately 9B.9°C for the first 30 min. The average temperature for the next period is 110°C. If the F 0 for the spore organism is 2.50 min and l. 10°C, calculate the time of heating at 110°C to make the process safe. AIlS. 29.9 min 9.12-2. Temperature Effect on Decimal Reduction Time. Prove by combining Eqs. (9.12-6) and (9.12-8) that a plot of 10glO DT versus liT (T in degrees absolute) is a straight line. 9.12-3. Thenna! Process Time for Pea Puree. For cans of pea puree, the F 0 2,45 min and l. = 9.94°C (C2). Neglecting heat-up time, determine the process time for adequate sterilization at 112.BoC at the center of the can. Ans. t = 16.76 min 9.12-4. Process Time Jor Adequate Sterilization. The F 0 value for a given canned food is 2.BO min and l. is 18"F (lO°C). The center temperatures of a can of this food when heated in a retort were as follows for the time periods given: t! (0-10 min), Tl = 140°F; 12 (10-30 min), T2 185°F; 13 (30-50 min), T3 220°F; t4 (50-80 min), T4 230"F; 15 (80-100 min), T5 = 190"F. Detennine if adequate sterilization is obtained. 9.12-5. Process Time and Graphical Integration. The following time-temperature data were obtained for the heating, holding, and cooling of a canned food product in a retort, the temperature being measured in the center of the can. T(°F)

t(min)

0 20 40 60

110 165 205 228

t(min)

(43YC) (73.9) (96.1) (108.9)

BO

90 100

TrF)

232 (111.1) 225 (107.2) 160 (71.1)

The F 0 value used is 2.60 min and z is IBOF (lOcC). Calculate theF 0 value for this process and determine if the thermal processing is adequate. Use SI and English units. 9.12-6. Sterility Level of Fermentation Medium. The aqueous medium in a fermentor is being sterilized and the time-temperature data obtained are as follows. Time

(min)

Temperawre CC)

o

10

20

25

30

35

100

110

120

120

110

100

The reaction velocity constant k in min - 1 [or the contaminating bacterial spores can be represented as (A 1) k = 7.94 x 10 38 e--(68.7 x I03)/1.987T where T K. The contamination level No = I X 10 12 spores. Calculate the sterility level N at the end and 'V. 9.12-7. Time for Pasteurization of Milk. Calculate the time in min at 62.8°C for pasteurization of milk. The F 0 value to be used at 65.6°C is 9.0 min. The l. value is 5°C. Ans. t = 32.7 min

582

Chap. 9

Problems

j

9.12-8. Reduction in Number of Viable Cells in PasteuriZiltion. In a given: pasteurization process the reduction in the number of viable cells used is 10 15 and the F 0 value used is 9.0 min. If the reduction is to be increased to 10 16 because of increased contamination, what would be the new F 0 value?

[

REFERENCES ALLERTON, 1., BROWNELL, L. E., and KATZ, D. L. Chern. Eng. Progr., 45, 619 (1949). (A2) AlBA, S., HUMPHREY, A. E., and MILLIS, N. F. Biochemical Engineering, 2nd ed. New York: Academic Press, Inc., 1973. (BI) BLAKEBROUGH, N. Biochemical and Biological Engineering Science, VoL 2. New York: Academic Press, Inc., 1968. (B2) BATESON, R. N. Chern. Eng. Progr. Symp. Ser., 67 (108), 44 (1971). (CI) CRUESS, W. V. Commercial Fruit and Vegetable Products, 4th ed. New York: McGraw-Hill Book Company, 1958. (C2) CHARM, S. E. The Fundamentals of Food Engineering, 2nd ed. Westport, Conn.: Avi Publishing Co., Inc., 1971. (Dl) DIETRICH, W. C, BOGGS, M. M., NUTTING, M. D., and WEINSTEIN, N. E. Food T echnol., 14, 522 (1960). (E1) EARLE, R. L. Unit Operations in Food Processing. Oxford: Pergamon Press, Inc., 1966. (GI) GAMSON, B. W., THODOS, G., and HOUGEN, O. A. Trans. A.I.Ch.E., 39,1 (1943). (HI) HALL, C W. Processing Equipment for Agricultural Products. Westport, Conn.: Avi Publishing Co., Inc., 1972. (H2) HENDERSON, S. M. Agr. Eng., 330), 29 (1952). (Kl) KING, c. J. Freeze Drying of Foods. Boca Raton, Fla.: Chemical Rubber Co., Inc., 1971. (M 1) MARSHALL, W. R., JR., and HOUGEN, O. A. Trans. A.l.Ch.E., 38, 91 (1942). (PI) PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6th ed. New York: McGraw-Hill Book Company, 1984. (S1) SANDALL, O. c., KING, C. 1., and WILKE, CR. A.I.Ch.E. J., 13,428 (1967); Chem. Progr., 64{86), 43 (1968). (S2) STUMBO, C. R. Thermobacteriology in Food Processing, 2nd ed. New York: Academic Press, Inc., 1973. (T 1) TREYBAL, R. E. M ass Transfer Operations, 3rd ed. New York: McGraw-Hili Book Company, 1980. (W 1) WILKE, C. R., and HOUGEN, O. A. Trans. A.I.Ch.E., 41, 441 (1945).

(AI) [

s :I

o 4

e ..:i

n

IS

)[

Ie

s

References

583

CHAPTER 10

Stage and Continuous Gas-Liquid Separation Processes

10.1 10.lA

TYPES OF SEPARATION PROCESSES AND METHODS Introduction

Many chemical process materials and biological substances occur as mixtures of different components in the gas, liquid, or solid phase. In order to separate or remove one or more of the components from its original mixture, it must be contacted with another phase. The two phases are brought into more or less intimate contact with each other so that a solute or solutes can diffuse from one to the other. The two bulk phases are usually only somewhat miscible in each other. The two-phase pair can be gas-liquid, gas-solid, liquid-liquid, or liquid-solid. During the contact of the two phases the components of the original mixture redistribute themselves between the two phases. The phases are then separated by simple physical methods. By choosing the proper conditions and phases, one phase is enriched while the other is depleted in one or more components.

10.IB Types of Separation Processes I. Absorption. When the two contacting phases are a gas and a liquid, the unit operation is called absorption. A solute A or several solutes are absorbed from the gas phase into a liquid phase in absorption. This process involves molecular and turbulent diffusion or mass transfer of solute A through a stagnant nondiffusing gas B into a stagnant liquid C An example is absorption of ammonia A from air B by the liquid water C Usually, the exit ammonia-water solution is distilled to recover relatively pure ammonia. Another example is absorbing S02 from the flue gases by absorption in alkaline solutions. In the hydrogenation of edible oils in the food industry, hydrogen gas is bubbled into oil and absorbed. The hydrogen in solution then reacts with the oil in the presence of a catalyst. The reverse of absorption is called stripping or desorption, and the same theories and basic principles hold. An example is the steam stripping of nonvolatile

584

oils, in which the steam contacts the oil and small amounts of volatile components of the oil pass out with the steam. When the gas is pure air and the liquid is pure water, the process IS called humidification. Dehumidification involves removal of water vapor from air. 2, Distillation. In.the distil/ation process, a volatile vapor phase and a liquid phase that vaporizes are involved. An example is distillation of an ethanol-water solution, where the vapor contains a concentration of ethanol greater than in the liquid. Another example is distillation of an ammonia-water solution to produce a vapor richer in ammonia. In the distillation of crude petroleum, various fractions, such as gasoline, kerosene, and heating oils, are distilled off.

3. Liquid-liquid extraction. When the two phases are liquids, where a solute or solutes are removed from one liquid phase to another liquid phase, the process is called liquid-liquid extraction. One example is extraction of acetic acid from a water solution by isopropyl ether. In the pharmaceutical industry, antibiotics in an aqueous fermentation soLution are sometimes removed by extraction with an organic solvent. 4, Leaching. If a fluid is being used to extract a solute from a solid, the process is called leaching. Sometimes this process is also called extraction. Examples are leaching copper

from solid ores by sulfuric acid and leaching vegetable oils from solid soybeans by organic solvents such as hexane. Vegetable oils are also leached from other biological products, such as peanuts, rape seeds, and sunflower seeds. Soluble sucrose is leached by water extraction from sugar cane and beets. 5. Membrane processing. Separation of molecules by the use of membranes is a relatively new unit operation and is becoming more important. The relatively thin, solid membrane controls the rate of movement of molecules between two phases. It is used to remove salt from water, purify gases, in food processing, and so on. Y i,

If n ),

it

Solute components soluble in a solution can be removed from the solution by adjusting the conditions, such as temperature or concentration, so that the solubility of one or more solute components is exceeded and they crystallize out as a solid phase. Examples of this separation process are crysta!lization of sugar from solution and crystallization of metal salts in the processing of metal ore solutions.

6. Cryscal/izalion.

7. Adsorption. In an adsorption process one or more components of a liquid or gas stream are adsorbed on the surface or in the pores of a solid adsorbent and a separation is obtained. Examples include removal of organic compounds from polluted water, separation of paraffins from aromatics, and removal of solvents from air.

IS

It a :r ,'e

Ie is Ie Ie

IO.Ie

Processing Methoos

Several methods of processing are used in the separations discussed above. The two phases, such as gas and liquid, or liquid and liquid. can be mixed together in a vessel and then separated. This is a single-stage process. Often the phases are mixed in one stage, separated, and then contacted again in a multiple-stage process. These two methods can be carried out batchwise or continuously_ In still another general method. the two phases can be contacted continuously in a packed tower. In this chapter, humidification and absorption will be considered; in Chapter II, distillation; in Chapter 12, adsorption, liquid-liquid extraction,)eaching, and crystalSec. 10.1

Types of Separation Processes and Melhods

585

lization, and in Chapter 13, membrane processes. In:al! of these processes the equilibrium relations between the two phases being con~idered must be known. This is discussed for gas-liquid systems in Section 10.2 and for the other systems in Chapters II, 12, and 13.

10.2 1O.2A

EQUILIBRIUM RELATIONS BETWEEN PHASES Phase Rule and Equilibrium

In order to predict the concentration of a solute in each of two phases in equilibrium, experimental equilibrium data inust be available. Also, if the two phases are not at equilibrium, the rate of mass transfer is proportional to the driving force, which is the departure from equilibrium. In aU cases involving equilibria, two phases are involved, such as gas-liquid or liquid-liquid. The important variables affecting the equilibrium of a solute are temperature, pressure, and concentration. The equilibrium between two phases in a given situation is restricted by the phase rule: (10.2-1) F=C-P+2 where P is the number of phases at equilibrium, C the number of total components in the two phases when no chemical reactions are occurring, and F the number of variants or degrees of freedom of the system. For example, for the gas-liquid system of COz-air-water, there are two phases and three components (considering air as one inert component). Then, by Eq. (10.2.1),

F

C

P+2=3

2+2

3

This means that there are 3 degrees of freedom. If the total pressure and the temperature are set, only one variable is left that can be arbitrarily set. If the mole fraction composition x A of CO 2 (A) in the liquid phase is set, the mole fraction composition YA or pressure PAin the gas phase is automatically determined. The phase rule does not tell us the partial pressure PA in equilibrium with the selected X A • The value of PA must be determined experimentally. The two phases can, of course, be gas-liquid, liquid-solid, and so on. For example, the equilibrium distribution of acetic acid between a water phase and an isopropyl ether phase has been determined experimentally for various conditions. to.2B

Gas--Liquid Equilibrium

I. Gas-liquid equilibrium data. To illustrate the obtaining of experimental gas-liquid equilibrium data, the system SOz-air-water will be considered. An amount of gaseous S02' air, and water are put in a closed container and shaken repeatedly at a given temperature until equilibrium is reached. Samples of the gas and liquid are analyzed to give the partial pressure PA in atm of SOl (A) in the gas and mole fraction XA in the liquid. Figure 10.2·1 shows a plot of data from Appendix A.3 of the partial pressure PA of SOz in the vapor in equilibrium with the mole fraction X A of S02 in the liquid at 293 K (20°C).

2. Henry's law. Often the equilibrium relation between PA in the gas phase andx A can be expressed by a straight-line Henry's law equation at low concentrations. (10.2-2)

586

Chap. /0

Stage and ContilluOIiS Gas-Liquid Separation Processes

where H is the Henry's law constant in atm/mole fraction for the given system. If both sides of Eq. (10.2-2) are divided by total pressure Pin atm, (10.2-3) where H' is the Henry's law constant in mole frac gas/mole frac liquid and is equal to H/P. Note that H' depends on total pressure, whereas H does not. In Fig. 10.2-1 the data follow Henry's law up to a concentrationx A or about 0.005, where H 29.6 atm/mol frac. In general, up to a total pressure of about 5 x 105 Pa (5 atm) the value of H is independent of P. Data for some common gases with water are given in Appendix A.3.

EXAMPLE 10.1-1. Dissolved Oxygen Concentration in Water What will be the concentratibn of oxygen dissolved in water at 298 K when the solution is in equilibrium with air at 1 atm total pressure? The Henry's law constant is 4.38 x 104 atm/mol fraction. Solution: The partial pressure PA of oxygen (A) in air is 0.21 atm. Using Eq. (10.2-2),

\

0.21 = f

10.3

1O.3A

n

d

4.38

X

10 4 x,j

Solving, X,j = 4.80 X 10- 6 mol fraction. This means that 4.80 x 10- 6 mol O 2 is dissolved in 1.0 mol water plus oxygen or 0.000853 part O:JlOO parts water.

r

e )f

HXA =

SINGLE AND MULTIPLE EQUILIBRIUM CONT ACT STAGES Single-Stage Equilibrium Contact

In many operations of the chemical and other process industries, the transfer of mass from one phase to another occurs, usually accompanied by a separation of the components of the mixture, since one component will be transferred to a larger extent than will another component.

0.8

0.6

id IS

;n

0.4

~o

1e

of K

0.2

0.010

0.020

Mole fraction S02 in liquid phase, ·2)

ses

FIGURE 10.2-1.

Sec. 10.3

xA

Equilibrium plo/Jor SOcwater system at 293 K (20°C).

Single and Multiple Equilibrium Contact Stages

587

FIGURE

10.3-l.

Single-stage equilibrium process.

..Vt Lo

V:z

I'

.1

.

L1

A single-stage process can be defined as one in which two different phases are brought into intimate contact with each other and 'then are separated. During the time of contact, intimate mixing occurs and the various components diffuse and redistribute themselves between the two phases. If mixing time is long enough, the components are essentially at equilibrium in the two phases after separation and the process is considered a single equilibrium stage. A single equilibrium stage can be represented as in Fig. 10.3-1. The two entering phases, Lo and V2 , of known amounts and compositions, enter the stage, mixing and equilibration occur, and the two exit streams Ll and VI leave in equilibrium with each other. IVlaking a total mass balance, (10.3-1)

where L is kg (Ibm), V is kg, and M is total kg. Assuming that three components, A, B, and C, are present making a balance on A and C,

In

the streams and (10.3-2) (10.3-3)

An equation for B is not needed since X A + X B + Xc = 1.0. The mass fraction of A in the L stream is x Aand Y Ain the V stream. The mass fraction of A in the M stream isx AM' To solve the three equations, the equilibrium relations between the components must be known. In Section 1O.3B, this will be done for a gas-liquid system and in Chapter 11 for a vapor-liquid system. Note that Eqs. (10.3-1 )--{1O.3-3) can also be wri tten using mole units, with L and V having units of moles and x A and YA units of mole fraction. 10.3B

Single-Stage Equilibrium Contact for Gas-Liquid System

In the usual gas-liquid system the solute A is in the gas phase V, along with inert air B and in the liquid phase L along with inert water C. Assuming that air is essentially insoluble in the water phase and that water does not vaporize to the gas phase, the gas phase is a binary A-B and the liquid phase is a binary A-C. Using moles and mole fraction units, Eq. (10.3-1) holds for a single-stage process for the total material balance. Since component A is the only component that redistributes between the two phases, a balance on A can be written as follows.

cC XA;AJ v'C YA;AJ +

=

L'C XA~AJ + v'C YA~AJ

(10.3-4)

where L is moles inert water C and V' is moles inert air B. Both L and V' are constant and usually known. To solve Eq. (10.3-4), the relation between Y A I and X A I in equilibrium is given by Henry's law.

588

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

(10.3-5)

H'x,u

YAI

If the solution is not dilute, equilibrium data in the form of a plot of PA or YA versus x A must be available, such as in Fig. 10.2-1.

EXAMPLE 103-1. Equilibrium Stage Contact/or C01-Air-Water A gas mixture at 1.0 atm pressure abs containing air and CO 2 is contacted in a single-stage mixer continuously with pure water at 293 K. The two exit gas and liquid streams reach equilibrium. The inlet gas flow rate is 100 kg mol/h, with a mole fraction of COl of YA2 = 0.20. The liquid flow rate entering is 300 kg mol waterfh. Calculate the amounts and compositions of the two outlet phases. Assume that water does not vaporize to the gas phase.

Solution: The flow diagram is the same as given in Fig. 10.3-1. The inert water flow is 1'. = Lo = 300 kg molfh. The inert air flow V' is obtained from Eq. (10.3-6). V' = V(l -

(10.3-6)

YA)

Hence, the inert air flow is V' V2 ( 1 - YAl) = 1000 - 0.20) Substituting into Eq ..{10.3-4) to make a balance on COl (A),

3cd_O) + 8J \1- 0

,\1

0.20 ) 0.20

=

3w1

X

A1

\ 1 - x,41

)

+ 8J

= 80 kg molfh·

YAI

\1 -

)

(10.3-7)

YAI

At 293 K, the Henry's law constant from Appendix A.3 is H 0.142 X 104 atm/mol frac. Then H' H/P 0.142 x 10 4 /1.0 0.142 x 104 mol frac gas/mol frac liquid. Substituting into Eq. (10.3-5), (10.3-8) Substituting Eq. (10.3-8) into (10.3-7) and solving, 0.20. To calculate the total flow rates lea ving,

X A1

= 1.41

X 1O~4

and

YA! =

1'.

Ll =-1--x.-I!

V'

1-

~

YAI

300 1.41 x 80 1 _ 0.20

=

300 kg molfh

100 kg mol/h

In this case, since the liquid solution is so dilute, Lo IO.3C B

Y s e

a

I)

Lv

Countercurrent Multiple-Contact Stages

I. Derivation of general equation. In Section 10.3A we used single-stage contact to transfer the solute A between the V and L phases. In order to transfer more solute from, say, the VI stream, the single-stage contact can be repeated by again contacting the VI stream leaving the first stage with fresh Lo. This can be repeated using multiple stages. However, this is wasteful of the Lo stream and gives a dilute product in the outlet L I streams. To conserve use of the Lo stream and to get a more concentrated product, countercurrent multiple-stage contacting is generally used. This is somewhat similar to countercurrent heat transfer in- a heat exchanger, where the outlet heated stream approaches more closely the temperature of the inlet hot stream. The process flow diagram for a countercurrent stage process is shown in Fig. 10.3-2. The inlet L stream is La and the inlet V stream is VN + 1 instead of Vl as for a single-stage in Fig. 10.3-1. The outlet product streams are VI and LN and the total number of stages is N. The component A is being exchanged between the V and L streams. The V stream is Sec. 10.3

~es

~

Single and Multiple Equilibrium Contact Stages

589

Countercurrent multiple-stage process.

FIGURE 10.3-2.

composed mainly of component B and the L stream of component C. Components B and C mayor may not be somewhat miscible in each other. The two-phase system can be gas-liquid. vapor-liquid, liquid-liquid, or other. Making a total overall balance on all stages, (10.3-9) where VN+ I is moljh entering, LN is mol(h leaving the process, and M is the total flow. Note in Fig. 10.3-2 that any two streams leaving a stage are in equilibrium with each other. For example, in stage n, Vnand Ln are in equilibrium. For an overall component balance on A, B, or C, Loxo

+

VN+IYN+I

LNxN

+

VIYI

MXM

(l03-1O)

where x and yare mole fractions. Flows in kgfh (Ib.,jh) and mass fraction can also be used in these equations. Making a total balance over the first n stages,

Lo

+ v" + I

Ln

+

VI

(103-11)

Making a component balance over the first n stages,

Loxo

+ v" + IYn+ 1 =

(103-12)

I

(10.3-13)

Solving for Yn+ I in Eq. (10.3-12). Yn+

This is an important material-balance equation, often called an operating line. It relates the concentration Yn+ I in the V stream with Xn in the L stream passing it. The terms VI' Y!' L o , and Xo are constant and usually known or can be determined from Eqs. ([ OJ-9)-{ lOJ-12).

2. Countercurrent contact with immiscible streams. An important case where the solute A is being transferred occurs when the solvent stream V contains components A and B with no C and the solvent stream L contains A and C with no B. The two streams Land V are immiscible in each other with only A being transferred. When Eq. (10.3-13) is plotted on an xy plot (XA and YA of component A) as in Fig. 10.3-3, it is often curved, since the slope LJVn + I of the operating line varies if the L and V streams vary from stage to stage. In Fig. 10.3-3 is plotted the equilibrium line that relates the compositions of two streams leaving a stage in equilibrium with each other. To determine the number of ideal stages required to bring about a given separation or reduction of the concentration of A from YN + I to Y I' the calculation is oft~n done graphically. Starting at stage 1, YI and Xo are on the operating line, Eq. (10.3-13), plotted in the figure. The vapor YI leaving is in equilibrium with the leaving x I and both compositions are on the equilibrium line. Then Yl and XI are on the operating line and Y2 is in equilibrium with Xl' and so on. Each

590

Chap. 10

Stage and Continuolls Gas-Liquid Separation Processes

stage is represented by a step drawn on Fig. 10.3-3. The steps are continued on the graph until YN + 1 is reached. Alternatively, we can start at YN + 1 and draw the steps going to YI' If the streams L and V are dilute in component A, the streams are approximately constant and the slope L,Jv,,+ 1 of Eq. (10.3-13) is nearly constant. Hence, the operating line is essentially a straight line on an xy plot. In distillation, where only components A and B are present, Eq. (10.3-13) also holds for the operating line, and this will be covered in Chapter 11. Cases where A, E, and C are appreciably soluble in each other often occur in liquid-liquid extraction and will be discussed in Chapter 12.

EXAMPLE 10.3-2.

Absorption of Acetone in a Countercurrent Stage Tower It is desired to absorb 90% of the acetone in a gas containing LO mol % acetone in air in a countercurrent stage tower. The total inlet gas flow to the tower is 30.0 kg mol/h, and the total inlet pure water flow to be used to absorb the acetone is 90 kg mol H 2 0/h. The process is to operate isothermally at 300 K and a total pressure of 101.3 kPa. The equilibrium relation for the acetone (A) in the gas-liquid is YA 2.53x A' Determine the number of theoretical stages required for this separation. Solution: The process flow diagram is similar to Fig. 10.3-3. Given values are YAN+ 1 0.01, x AO = 0, VN + 1 = 30.0 kg mol/h, and Lo 90.0 kg mol/h. Making an acetone material balance, amount of entering acetone entering air

= YAN + 1 VN + 1 =

= (1

0.01(30.0) = 0.30 kg mpl/h

YAN+l)VN+l

(1-0.01)(30.0)

29.7 kg mol air/h acetone leaving in VI = 0.10(0.30) acetone leaving in LN

= 0.030

kg molfh

= 0.90(0.30) = 0.27 kg mol/h

YN+l

;...,

Y4

c;

~g

g ..::

Y3-

equilibrium line

0)

'0

::2

Y2

Yr

Mole fraction, x FIGURE

's

Sec. 10.3

10.3-3.

Number of stages in a countercurrent multiple-stage contact process.

Single and Multiple Equilibrium Contact Stages

591

~

;:....

0.012

.;~ YAN+l-

.S

operating line

0.008

0.004

'---+--equilibrium line

0.002

0.001

0.003

0.004

I I

XAN

Mole fraction acetone b water, XA FIGURE

10.3-4.

Theoretical stages for countercurrent absorption in Example 10.3-2.

VI = 29.7

+ 0.Q3

= 29.73 kg mol air

+ acetone/h

0.030 Y,,j1 = 29.73 ~ 0.00101 LN = 90.0 X AN

+ 0.27

90.27 kg mol water

+ acetone/h

0.27 90.27 = 0.00300

Since the flow of liquid varies only slightly from Lo = 90.0 at the inlet to LN 90.27 at the outlet and V from 30.0 to 29.73, the slope LjV.+ 1 of the operating line in Eq. (10.3-13) is essentially constant. This line is plotted in Fig. 10.3-4 and the equilibrium relation YA = 2.53x A is also plotted. Starting at point YA1' X AO , the stages are drawn as shown. About 5.2 theoretical stages are required. to.3D

Analytical Equations for Countercurrent Stage Contact

When the flow rates V and L in a countercurrent process are essentially constant, the operating-line equation (10.3-13) becomes straight. If the equilibrium line is also a straight line over the concentration range, simplified analytical expressions can be derived for the number of equilibrium stages in a countercurrent stage process. Referring again to Fig. 10.3-2, Eq. (10.3-14) is an overall component balance on component A. (10.3-14) Rearranging, (10.3-15) Making a component balance for A on the first n stages, (10.3-16) Rearranging, (10.3-17) 592

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

Eq uating Eq. (10.3-15) to (10.3-17), (10.3-18)

= LN =

Since the molar flows are constant, L. constant = V. Then Eq. (10.3-18) becomes

constant

Land

v" + 1 = VN+ I

=

(10.3-19) Since Yn+ I and X n + 1 are in equilibrium, and the equilibrium line is straight, Y.+ 1 mxn + l • Also YN+l mx N + 1• Substituting mX n + 1 for Yn+1 and calling A L/mV, Eq. (10.3-19) becomes (10.3-20)

Xn + I

where A is an absorption factor and is constant. All factors on the right-hand side of Eq. (l0.3-20) are constant. This equation is a linear first-order difference equation and can be solved by the calculus of finite-difference methods (G 1, M 1). The final derived equations are as follows. For transfer of solute A from phase L to V (stripping), (I/A)N+

1 -

(l/A)

(10.3-21)

I

(l/At+ -1

XO-(YN+I/m )

A) N

+A

J

log (l/A)

(10.3-22)

When A = 1, (10.3-23) For transfer of solute A from phase V to L (absorption), AN+ 1 YN+I

mxo

A

N

+

-

A

(I 0.3-24)

1

(10.3-25)

N

When A

1,

N

(10.3-26)

=

YI

mxo

Often the term A is called the absorptionjactor and S the strippingjactor, where S = 1/ A. These equations can be used with any consistent set of units such as mass flow and mass fraction or molar flow and mole fraction. Such series of equations are often called Kremser equations and are convenient to use. If A varies slightly from the inlet to the outlet, the geometric average of the two values can be used, with the value of m at the dilute end being used for both values of A.

EXAMPLE 10.3-3.

Numher oj Stages hy Analytical Equation.

Repeat Example 10.3-2 but use the Kremser analytical equations for countercurrent stage processes. Sec. 10.3

Single and Multiple Equilibrium Contact Stages

593

Solution: At one end of the process at stage 1, VI 29.73 kg mol/h, 0.00101, Lo = 90.0, and X AO = O. Also, the equilibrium relation is YA 2.53xA where m 2.53. Then, Y,tI

A = I

At stage N, VN + I

~

Lo mVI

=

mV

= 30.0, Y,-IN+ 1 AN

=

0.01, LN

~=

m

V.

N+ I

90.0 = 1.20 2.53 x 29.73

= 90.27, and XAN = 0.00300.

90.27 2.53 x 30.0

1.19

The geometric average A = j AlAN = j1.20 x 1.19 = 1.195. The acetone solute is transferred from the V to the L phase (absorption). Substituting into Eq. (10.3-25), 0.01 2.53(0) ( 1) 2.53(0) 1 -lJ9s log [ 0.00101 N = log (1.195)

1 ]

+ T:T95

= 5.04 stages

This compares closely with 5.2 stages obtained using the graphical method.

lOA 10AA

MASS TRANSFER BETWEEN PHASES Introduction and Equilibrium Relatiolls

1. Introduction to interphase mass transfer. In Chapter 7 we considered mass transfer from a fluid phase to another phase, which was primarily a solid phase. The solute A was usually transferred from the fluid phase by convective mass transfer and through the solid by diffusion. In the present section we shall be concerned with the mass transfer of solute A from one fluid phase by convection and then through a second fluid phase by convection. For example, the solute may diffuse through a gas phaSe and then diffuse through and be absorbed in an adjacent and immiscible liquid phase. This occurs in the case of absorption of ammonia from air by water. . The two phases are in direct contact with each other, such as in a packed, tray, or spray-type tower, and the interfacial area between the phases is usually not well defined. In two-phase mass transfer, a concentration gradient will exist in each phase, causing mass transfer to occur. At the interface between the two fluid phases, equilibrium exists in most cases. 2. Equilibrium relations. Even when mass transfer is occurring equilibrium relations are important to determine concentration profiles for predicting rates of mass transfer. In Section 10.2 the equilibrium relation in a gas-liquid system and Henry's law were discussed. In Section 7.1 C a discussion covered equilibrium distribution coefficients between two phases. These equilibrium relations will be used in discussion of mass transfer between phases in this section.

10AB

Concentration Profiles in Interphase Mass 'Transfer

In the majority of mass-transfer systems, two phases, which are essentially immiscible in each other, are present and also an interface between these two phases. Assuming the solute A is diffusing from the bulk gas phase G to the liquid phase L, it must pass through phase G, through the interface, and then into phase L in series. A concentration gradient 594

Chap. JO

Stage and Continuous Gas-Liquid Separation Processes

FIGURE

10.4- L Concentration profile of so/ute A diffusing through two phases.

liquid-phase solution: gas-phase mixture of A in liquid L I of A in gas G

x

::.A..!-____

A

~

YA"; NA

I

I

interface

distance from interface

"

must exist to cause this mass transfer through the resistances in each phase, as shown in Fig. 10.4-1. The average or bulk concentration of A in the gas phase in mole fraction units iSYAG' where YAG p,JP, andx AL in the bulk liquid phase in mole fraction units. The concen tration in the bulk gas phase YAO decreases to Y Ai at the in terface. The liquid concentration starts at XAi at the interface and falls to X AL• At the interface, since there would be no resistance to transfer across this interface, YAi and x Ai are in equilibrium and are related by the equilibrium distribution relation (10.4-1) where Y,il is a function of x Ai' They are related by an equilibrium plot such as Fig. 10.1-1. If the system follows Henry's law, YAP or PA and XA are related by Eq. (10.2-2) at the interface. Experimentally, the resistance at the interface has been shown to be negligible for most cases of mass transfer where chemical reactions do not occur, such as absorption of common gases from air to water and extraction of organic solutes from one phase to another. However, there are some exceptions. Certain surface-active~compounds may concentrate at the interface and cause an "interfacial resistance" that slows down the diffusion of solute molecules. Theories to predict when interfacial resistance may occur are still obscure and unreliable. lOAC

Mass Transfer Using Film Mass-Transfer Coefficients and Interface Concentrations

1. Equimolar counterdijJlI~ion. For equimolar counterdiffusion the concentrations of Fig. 10.4-1 can be plotted on an xy diagram in Fig. 10.4-2. Point P represents the bulk phase compositions X AC and X AL of the two phases and point M the interface concentrations Y,,jj and X,Ii' For A diffusing from the gas to liquid and B in equimolar counterdiffusion from liquid to gas,

(10.4-2) where k~ is the gas-phase mass-transfer coefficient in kg molls' m 2 . mol frac (g molls' em 2. mol frac, Ib mol/h' ft2 . mol frac) and k~ the liquid-phase mass-transfer coefficient in kg mol/s· m 2 . mol frac (g molls' cm 2 . mol frac, Ib mol/h' ft 2 . mol frac). Rearranging Eq. (10.4-2), (10.4-3) The driving force in the gas phase is (YAG - YAi) and in the liquid phase it is(X Ai XAtJ. The slope of the line PM is k'jk~. This means if the two film coefficients k~ and k~ are known, the interface compositions can be determined by drawing line PM with a slope -k'jk~ intersecting the equilibrium line. Sec. lOA

Mass Transfer Between Phases

595

equilibrium line

slope:::: m'',. I

I I

~

.>.~

~4-

b

IE

x* A FIGURE 10.4-2.

Concentration driving forces and interface concentrations in interphase mass transfer (equimolar counterdiffusion).

The bulk-phase concentrations Y..tG and x AL can be determined by simply sampling the mixed bulk gas phase and sampling the mixed bulk liquid phase. The interface concentrations are determined by Eq. (10.4-3). 2. DifJusion of A through stagnant or nondifJusing B. For the common case of A diffusing through a stagnant gas phase and then through a stagnant liquid phase, the concentrations are shown in Fig. 10.4-3, where P again represents bulk-phase compositions and M interface compositions. The equations for A diffusing through a stagnant gas and then through a stagnant liquid are (10.4-4)

Now, k = ----'-'---x (1 - XA)iM -k~/(I-XA )iM

slope

1- Y A )uW

YAG

eq uilibrium line

I

YAi I

m

1

~

,X/'

1,/

I /../.

4-

r;

I I I

I

I I

FIGURE 10.4-3.

596

(10.4-5)

M

I

_,I

I I

I I I

Concentration driving forces and interface concentrations in interphase mass transfer (A diffusing through stagnant B).

Chap. 10

Stage and COfltinuous Gas-Liquid Separation Processes

where (

(

1

_ -

Y.1)iM -

-

X

1

) A

(1 YAi) (1 In [(1 - Y Ai)/(l -

_ (1 xAJ-(l iM - In [(1 x A J/(1

YAG)

(10.4-6)

Y AG)]

XAj)

-

(10.4.. 7)

XAi)J

Then,

NA

k' (1 _

)

(YAG

YAi)

YA 1M

(1 -

x

(XAi

(1004..8)

X AL)

XA)iM

Note that (1 - Y A)iM is the same as Y BM of Eq. (7.2.. 11) bu t is written for the in terface, and (1 - x A)iM is the same as X BM of Eq. (7.2-11). Using Eq. (lOA.. 8) and rearranging,

x A bo1

- kj(1 k~/(1 -

YA)iM

YAG -

YAi

X AL -

XAi

(10.4-9)

The slope of the line PM in Fig. 10.4-3 to obtain the interface compositions is given by the left-hand side of Eq. (10.4-9). This differs from the slope of Eq. (10.4-3) for equimolar counterdiffusion by the terms (1 - YA)iM and (1 - XA)iM' When A is diffusing through stagnant B and the solutions are dilute, (1 - Y A)iM and (1 x A)iM are close to L A trial-and-error method is needed to use Eq. (10.4-9) to get the slope, since the left-hand side contains YAi and X Ai that are being sought. For the first trial (1 - Y A)iM and (1 - XA)iM are assumed to be 1.0 and Eq. (10.4-9) is used to get the slope andYAi andx Ai values. Then for the second trial, these values of YAi and X Ai are used . to calculate a new slope to get new values of YAi and X Ai . This is repeated until the interface compositions do not change. Three trials are usually sufficient.

EXAMPLE 10.4-1.

Interface Compositions in Interphase Mass Transfer

The solute A is being absorbed from a gas mixture of A and B in a wetted-wall tower with the liquid flowing as a film downward along the wall. At a certain point in the tower the bulk gas concentration YAG = 0.380 mol fraction and the bulk liquid concentration is X AL 0.100. The tower is operating at 298 K and 1.013 x 10 5 Pa and the equilibrium data are as follows: X ..

Y..

X..

Y..

0 0.05 0.10 0.15

0 0.022 0.052 0.087

0.20 0.25 030 0.35

0.131 0.187 0.265 0.385

The solute A diffuses through stagnant B in the gas phase and then through a nondiffusing liquid. Using correlations for dilute solutions in wetted-wall towers, the film mass-transfer coefficient for A in the gas phase is predicted as ky 1.465 x 10- 3 kg mol A/s· m 2 • mol frac (1.08 Ib moljh . ft2 . mol frac) and for 1.967 x 10- 3 kg mol A/s' m 2 . mol frac (1.45 lb the liquid phase as kx mol/h· ft 2 . mol frac). Calculate the interface concentrations Y Ai and x Ai and the flux N A'

Solution: Sec. 10.4

Since the correlations are for dilute solutions, (1 -

Mass Transfer ilerween Phases

YA)iM

and 597

0.4

YAG--1

I

0.3

1

I I I

I YAi---0.2 ----1-----

I I I I I

0.1

I

Yl---

0.1

0.2

I 0.4

I

I

I

xl

XAL FIGURE

10.4-4.

Location oJinterfaceconcentralionsJor Example 10.4-/.

X A)iM are approximately l.0 and the coefficients are the same as k~ and The equilibrium data are plotted in Fig. 10.4-4. Point P is plotted at YAG 0.380 and x AL = 0.1 00. For the first trial (I - YA)iM and (1 - X A)iM are assumed as 1.0 and the slope of line PM is, from Eq. (10.4-9),

(I k~.

_ k'f(1 - xAb ky/{I - YAb.f

= _ 1.967

x 1O-:/l.0 = -1.342 1.465 x 10- 11.0

A line through point P with a slope of 1.342 is plotted in Fig. 10.4-4 intersecting the equilibrium line at M l' where YAi =0.183 andx Ai = 0.247. For the second trial we use YAi and X Ai from the first trial to calculate the new slope. Substituting into Eqs. (10.4-6) and (10.4-7), (

(l

Y Ai)

-

(l

Y Ad

1 - Y Av = In [( 1 - YAJ/( 1 - Y AG)] (l - 0.183) - (l

0.380) _

7

In [(1 _ 0.183)/(1 _ 0.380)] - O. 15 (l-xAd-(I-xAJ In [(1 XAL)/(I - X Ai )]

(1 - 0.100) (I In [( 1 0.100)/( 1

0.247) 0.247)]

0.825

Substituting into Eq. (10.4-9) to obtain the new slope,

kJ(1

1.967 x 10- 3/0.825 1.465 x 10 3/0.715

xA);..,.f

k~/(1 - YJiM

-1.163

A line through point P with a slope of - 1.163 is plotted and intersects the equilibrium line at M, where YAi 0.197 and x Ai 0.257. Using these new values for the third trial, the following values are calculated: (1

(I - YA)iM = In [( 1

598

Chap. 10

0.197) (1 - 0.380) 0.197)/( 1 0.380)]

0.709

Swge and Cominllolls Gas-Liquid Separatioll Processes

_ (1 -

XA)iM -

(1 - 0.100) - (1 0.257) _ 2 In [(1 _ 0.100)/(1 _ 0.257)J -::.0.8 0 1.967 x 10- 3/0.820 - 1.465 x 10 3/0.709

k'j( 1 - X A)iM k~/( 1 - Y A)iM

1.160

=

This slope of -1.l60 is essentially the same as the slope of 1.163 for the second trial. Hence, the final values are YAj = 0.197 and x Ai 0.257 and are shown as point M. To calculate the flux, Eq. (lOA-8) is used. NA -

_ 1.465 X 10- 3 0.709 (0.380 - 0.197)

k~

_ (1

YA)iM (YAG -

= 3.78 x

YAi)

10- 4 kg molfs·m 2

1.08 0.709 (0.380 - 0.197)

NA

=

NA

= -_-=--).- (x Ai X A 1M

3.78

X

=

x AL) =

0.2785 Ib mol/h' ft

2

1.967 x 10- 3 0820 (0.257 .

0.1 00)

10- 4 kg molfs' m 1

Note that the flux N A through each phase is the same as in the other phase, which should be the case at steady state. lOAD

Overall Mass-Transfer Coefficients and Driving Forces

1. Introduction. Film or single-phase mass-transfer coefficients k~ and k~ or ky and k" are often difficult to measure experimentally, except in certain experiments designed so that the concentration difference across one phase is small and can be neglected. As a result, overall mass-transfer coefficients K~. and K~ are measured based on the gas phase or liquid phase. This method is used in heat transfer, where overall heat-transfer coefficients are measured based on inside or outside areas instead of film coefficients. The overall mass transfer K~ is defined as

IV A

= K~(YAG

- Y~)

(IOA-IO)

where K~ is based on the overall gas-phase driving force in kg mol/s . m 2. mol frae, and is the value that would be in equilibrium with XAL> as shown in Fig. 10.4-2. Also,K~ is defined as Y~

(lOA-II) where K~ is based on the overall liquid-phase driving rorce in kg molfs' m is the value that would be in equilibrium with YAG .

2

•

mol frae and

x~

2. Equimolar counterdifJusion and/or diffusion in dilule Solulions. Equation (10:4-2) holds for equimolar counterdiffusion, or when the solutions are dilute, (10.4-8) and (10.4-2) are identical.

(10.4-2) From Fig. 10.4-2, (1004-12) Sec. lOA

Mass Transfer Between Phases

599

Between the points E and M the slope m' can be given as (10.4-13)

m'

Solving Eq. (10.4-13) for (y Ai YAG

y~)

and substituting into Eq. (10.4-12),

Y~=(YAG-YA)+m'(xAi

xAJ

(10.4-14)

Then on substituting Eqs. (10.4-10) and (10A-2) into (10.4-14) and canceling out N A' 11m K~

=-+k~

(10.4-15)

k~

The left-hand side of Eq. (lOA-IS) is the total resistance based on the overall gas driving force and equals the gas film resistance I/k~ plus the liquid film resistancem'/k~. In a similar manner from 10.4-2, (10.4-16)

m"

A:.:..' = _Yx~A:.:..G=---_Y-' - x ,

(10.4-17)

A

Proceeding as before,

K~

I

1

m"k~

k~

=--+-

(10.4-18)

Several special cases of Eqs. (lOA-IS) and (1004-18) wiII now be discussed. The numerical values of k~ and k~ are very roughly similar. The values of the slopes m'or m" are very important. If m' is quite small, so that the equilibrium curve in Fig. 10.4-2 is almost horizontal, a small value of YA in the gas will give a large value of x A in equilibrium in the liquid. The gas solute A is then very soluble in the liquid phase, and hence the term m'/k~ in (10.4-15) is very smaIL Then, (10.4-19)

~

K'y = k'y

and the major resistance is in the gas phase, or the" gas phase is con trolling." The poin t M has moved down very close to E, so that (10.4-20)

Similarly, when m" is very large, the solute A is very insoluble in the liquid, I/(m"k~) becomes small, and K' "

=

(10.4-21)

k' .r

The" liquid phase is controlling" and X A • ~ x~. Systems for absorption of oxygen oreO z from air by water are similar to (10.4-21). 3. DifJusion orA through stagnant or nondifJusing B. For the case of A diffusing through nondiffusing B, Eqs. (lOA-8) and (10.4-14) hold and Fig. 10.4-3 is used. NA

{l

YA )iM

(YAO - Y Ai)

=

(1 _

)

XA iM

(x Ai

(l0.4-8) (1004-14)

600

Chap.

to

Stage and COlllinaolls Gas-Liquid Separation Processes

We must, however, define the equations for the flux using overall coefficients as follows:

NA

[{l

y~) = [(1 ~K;A).MJ (x~ -

KL)'MJ (YAG

xAJ

_ ..

(10.4-22)

The bracketed terms are often written as follows:

K,

(10.4-23)

where K, is the overall gas mass-transfer coefficient for A diffusing through stagnant B and K" the overall liquid mass-transfer coefficient. These two coefficients are concentration-dependent. Substituting Eqs. (lOA.. 8) and (lOA-22) into (10.4-14), we obtain 1 rn' (10.4-24) k'J( 1 - Y A)iM + k'xf( I - X A)iM K~/(I where (10.4-25) Similarly, for K'",

I

K'xf( 1

X A).M

= rn" k~/( 1 - YA)iM

where (1

1

+ k'xf( 1 -

(10.4-26) X A);M

(l-xAJ-(l-x~)

x~)J

XA).M = In [(1 - xAJ/(1 -

(10.4-27)

It should be noted that the relations derived here also hold for any two-phase system where Y stands for the one phase and x for the other phase. For example, for the extraction of the solute acetic acid (A) from water (y phase) by isopropyl ether (x phase), the same relations will hold.

EXAMPLE 10.4-2.

Overall Mass-Transfer Coefficients from Film Coefficients Using the same data as in Example lOA-I, calculate the overall masstransfer coefficient K~, the flux, and the percent resistance in the gas and liquid films. Do this for the case of A diffusing through stagnant B.

Solution: From Fig. 10.4-4, Y~ = 0.052, which is in equilibrium with the bulk liquid x At. 0.10. Also, Y AG = 0.380. The slope of chord m' between E and M from Eq. (1004-13) is, for YAi = 0.197 and X Ai = 0.257,

m'

..::....:.:.:....-.:-:.:.. = X Ai

XAL

0.197 - 0.052 0.257 - 0.100

= 0.923

From Example 10.4.. 1, k~

1.465 x 10- 3 (l

(I -

X

1.967 x 10- 3

A)iM

0.820

Using Eq. (10.4-25), (1

(1 y~) (1 - YAG) In [(1 - y~)f( 1 - Y AG)] (1 0.052) - (1 - 0.380) = 0.773 In [( 1 - 0.052)/( 1 - 0.380)]

Sec. lOA

Mass Transfer Between Phases

601

Then, using Eq. (10.4-24), 1 K~/O.773

0.923

1.465 x 10 3/0.709 484.0

+ 384.8

+ 1.967

x 10 3/0.820

868.8

Solving, K~ = 8.90 X 19- • The percent resistance in the gas film is (484.0/868.8)100 = 55.7% and 44.3%' in the liquid film. The flux is as follows, using Eq. (10.4-22): 4

N A

= (1

K~

4

YA).M

= 3.78

X

(y

*)

8.90

X

10- (0.380 _ 0.052)

AOYA

10- 4 kg molls' m 2

This, of course, is the same flux value as was calculated in Example 10.4-1 using the film equations.

4. Discussion of overall coefficients. If the two-phase system is such that the major resistance is in the gas phase as in (10.4-19), then to increase the overall rate of mass transfer, efforts should be centered on increasing the gas-phase turbulence, not the liquid-phase turbulence. For a two-phase system where the liquid film resistance is controlling, turbulence should be increased in this phase to increase rates of mass transfer. To design mass-transfer equipment, the overall mass-transfer coefficient is synthesized from the individual film coefficients, as discussed in this section.

10.5 lO.SA

CONTINUOUS HUMIDIFICATION PROCESSES Introduction and Types of Equipment for Humidification

i. introduction to gas-liquid contactors. When a relatively warm liquid is directly contacted with gas that is unsaturated, some of the liquid is vaporized. The liquid temperature will drop mainly because of the latent heat of evaporation. This direct contact of a gas with a pure liquid occurs most often in contacting air with water. This is done for the following purposes: humidifying air for control of the moisture content of air in drying or air conditioning; dehumidifying air, where cold water condenses some water vapor from warm air; and water cooling, where evaporation of water to the air cools warm water. In Chapter 9 the fundamentals of humidity and adiabatic humidification were discussed. In this section the performance and design of continuous air-water contactors is considered. The emphasis is on cooling of water, since this is the most important type of process in the process industries. There are many cases in industry in which warm water is discharged from heat exchangers and condensers when it would be more economical to cool and reuse it than to discard it. "'2. 'Fowers for }vater cooling. In a typical water-cooling tower, warm water flows countercurrently to an air stream. Typically, the warm water enters the top of a packed tower and cascades down through the packing, leaving at the bottom. Air enters at the bottom of the tower and flows upward through the descending water. The tower packing often consists of slats of wood or plastic or of a packed bed. The water is distributed by troughs and overflows to cascade over slat gratings or packing that provide large interfacial areas of contact between the water and air in the form of droplets and films 602

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

of water. The flow of air upward through the tower can be induced by the buoyancy of the warm air in the tower (natural draft) or by the action of a fan. Detailed descriptions of towers are given in other texts (Bl, Tl). The water cannot be cooled below the wet bulb temperature. The driving force for the evaporation of the water is approximately the vapor pressure of the water less the vapor pressure it would have at the wet bulb temperature. The water can be cooled only to the wet bulb temperature, and in practice it is cooled to about 3 K or more above this. Only a small amount of water is lost by evaporation in cooling water. Since the latent -heat of vaporization of water is about 2300 kJlkg, a typical change of about 8 K in water temperature corresponds to an evaporation loss of about 1.5%. Hence, the total flow of water is usually assumed to be constant in calculations of tower size. humidification and dehumidification, intimate contact between the gas phase and liquid phase is needed for large rates of mass transfer and heat transfer. The gas-phase resistance controls the rate_ of transfer. Spray or packed towers are used to give large interfacial areas and to promote turbulence in the gas phase.

-In

10.5B Theory and Calculation of Water-Cooling Towers l. Temperature and concentration profiles at interface. In Fig. 10.5-1 the temperature profile and the concentration profile in terms of humidity are shown at the water-gas interface. Water vapor diffuses from the interface to the bulk gas phase with a driving force in the gas phase of (Hi H G) kg H 2 0jkg dry air. There is no driving force for mass transfer in the liquid phase, since water is a pure liquid. The temperature driving force is TL - T; in the liquid phase and T; - TG K or °C in the gas phase. Sensible heat flows from the bulk liquid to the interface in the liquid. Sensible heat also flows from the interface to the gas phase. Latent heat also leaves the interface in the water vapor, diffusing to the gas phase. The sensible heat flow from the liquid to the interface equals the sensible heat flow in the gas plus the latent heat flow in the gas. The conditions in Fig. 10.5-1 occur at the upper part of the cooling tower. In the lower part of the cooling tower the temperature of the bulk water is higher than the wet bulb temperature of the air but may be below the dry bulb temperature. Then the direction of the sensible heat flow in Fig. 10.5-1 is reversed. 2. Rate equations for heat and mass transfer.

liquid water

We shall consider a packed water-cooling

___- ..-. interface air

HG humidity ---water vapor

T G temperature

------sensible ==-----; heat in liquid

latent heat in gas sensible heat in gas

FIGURE

Sec. /0.5

10.5-1.

Temperature and concencratiot! profiles in upper part of cooling tower.

Continuous Humidification Processes

603

tower with air flowing upward and water countercurrently downward in the tower. The total interfacial area between the air and water phases is unknown, since the surface area of the packing is not equal to the interfacial area between the water droplets and the air. Hence, we define a quantity a, defined as m 2 of interfacial area per m 3 volume of packed section, or m 2 /m 3 • This is combined with the gaS-phase mass-transfer coefficient kG in kg molls' m 2 • Pa or kg molls' m 2 • atm to give a volumetric coefficient kG a in kg moi/s· m 3 volume· Pa or kg moi/s· m 3 . atm (lb mol/h' ft3. atm). The process is carried out adiabatically and the various streams and conditions are shown in Fig. 10.5-2, where L

= water flow, kg waterls· m 2 (lb,jh' ft 2 )

TL = temperature of water, °e or K (oF)

o = dry air flow, kg/s' m 2 (lb,jh' ft2) TG

temperature of air, °e or K (OF)

H = hurnidity of air, kg water/kg dry air (lb water/lb dry air)

Hy

=

enthalpy of air-water vapor mixture, J/kg dry air (btu/lbm dry air)

The enthalpy H y as given in Eq. (9.3-8) is Hy = cs(T

To) + HAo

HJI = cs(T

To)

+ HAo

= (1.005 + 1.88H)103(T 0) + 2501 = (0.24 + O.4SH)(T - 32) + 1075.4H

x 106H

(SI) (English) (9.3-8)

The base temperature selected is ooe or 273 K (32°F). Note that(T Tore = (T - To) K. Making a total heat balance for the dashed-line box shown in Fig. 10.5-2, an operating line is obtained. FIGURE

10.5-2.

Continuous countercurrent adiabatic water cooling.

O2 TC2

H2

L2

TL2 water

.-'----......,

Hy2

G TG+dTc

H+dH fly+dfl y

r--I I I

G TG

fI Hy

I Gl~____-.~ I L.--TGI LI·--J I

au

fI 1

TL I

flYl

Chap. 10

Sfage and Continuous Gas-Liquid Separation Processes

(10.5-1)

This assumes that L is essentially constant, since only a small amount is evaporated. The heat capacity CL of the liquid is assumed constant at 4.181 x 10 3 lfkg· K (1.00 btuflb m ' OF). When plotted on a chart of Hy versus 7;., this Eq. (l0.5-1) is a straight line with a slope of LcJG. Making an overall heat balance over both ends of the tower, (10.5-2)

Again making a heat balance for the dz column height and neglecting sensible heat terms compared to the latent heat, (10.5-3)

The total sensible heat transfer from the bulk liquid to the interface is (refer to Fig. 10.5-1) (10.5-4) 3

where ilL a is the liquid-phase volumetric heat-transfer coefficient in W/m . K (btu/h' ft3 . OF) and 7; is the interface temperature. For adiabatic mass transfer the rate of heat transfer due to the latent heat in the water vapor being transferred can be obtained from Eq. (9.3-16) by rearranging and using a volumetric basis. (10.5-5)

where qJ A is in W1m 2 (btu/h' f(2), M B = molecular weight of air, kG a is a volumetric mass-transfer coefficient in the gas in kg moljs' m 3 . Pa, P = atm pressure in Pa, )'0 is the latent heat of water in lfkg water, Hi is the humidity of the gas at the interface in kg water/kg dry air, and HG is the humidity of th~ gas in the bulk gas phase in kg waterfkg dry air. The rate of sensible heat transfer in the gas is (10.5-6)

A

where qs/A is in W/m 1 and Ilea is a volumetric heat-transfer coefficient in the gas in W/m J • K. Now from Fig. 10.5-1, Eq. (10.5-4) must equal the sum ofEqs. (10.5-5) and (10.5-6).

GdH y

=

MBkGaPi'o(H i

He) dz

+ hGa(T; - Tel dz

(10.5-1)

Equation (9.3-18) states that (10.5-8) Substituting Pk e a for ky a, (10.5-9)

Substituting Eq. (10.5-9) into Eq. (10.5-1) and rearranging,

G dH y = Mgk e aP dz [(cs Ti + A 0 Hi) - (cs T G + A 0 H c)]

(10.5-10)

Adding and subtracting Cs To inside the brackets,

G dH y = MgkGaP dz{csCI; Sec. /0.5

To)

+ H),o

Continuous Humidification Processes

[cs(TG - To)

+ He J'oJ}

(10.5-11)

605

The terms inside the braces are (HYi G dHy

H), and

(10.5·11) becomes

MBkGaP dz(Hyj

(10.5-12)

Hy)

Integrating, the final equation to use to calculate the tower height is

rz dz

=

Jo

z=

r MBkG aP JH'l G

H

,2

~---"-_ H yj

(10.5-13)

Hy

If Eq. (10.54) is equated to Eq. (10.5·12) and the result rearranged, (10.5-14)

10.SC

Design of Water·Cooling Tower Using Film Mass-Transfer Coefficients

The tower design is done using the following

steps~

L The enthalpy of saturated air Hy; is plotted versus 7; on an H versus T plot as shown in Fig. 10.5-3. This enthalpy is calculated with Eq. (9.3-8) using the saturation humidity from the humidity chart for a given temperature, with O°C (273 K) as a base temperature. Calculated values are tabulated in Table 10.5-1. 2. Knowing the entering air conditions Tal and HI' the enthalpy of this air HYI is calculated from Eq. (9.3-8). The point HYI and TLI (desired leaving water temperature) is plotted in Fig. 10.5-3 as one point on the operating line. The operating line is plotted with a slope LedG and ends at point TL2 , which is the entering water temperature. This gives Hy2 ' Alternatively, HY2 can be calculated from Eq. (10.5-2). 3. Knowing h L a and kG a, lines with a slope of - hL a/kG aM B P are plotted as shown in Fig. 10.5-3. From Eq. (10.5-14) point P represents Hy and TL on the operating line, and point M represents Hy; and 7;, the interface conditions. Hence, line MS or H y, - Hy represents the driving force in Eq. (l0.5-13).

equilibrium line

flY2

H*y operating line, slope LeLIC slope =

-hLa

keaMBP

Liquid temperature (OC) FIGURE

606

10.5-3.

Temperature enthalpy diagram and operating line Jar water-cooling £Ower.

Chap. 10

Stage and Continuous Gas-Liquid Separation ProceSSeS

TABLE 10.5-1.

Enthalpies of Saturated Air-Water Vapor Mixtures (O°C Base Temperature) Hy

Hy J

btu

TL

OF

°C

60 80 85 90 95

15.6 26.7 29.4 32.2 35.0

btu

TL

Ib", dry air

kg dry air

of

°C

18.78 36.1 41.8 48.2 55.4

43.68 X 10 3 84.0 X 10 3 97.2 X 103 112.1 X 103 128.9 X 10 3

100 105 110 115 140

37.8 40.6 43.3 46.1 60.0

Ibm dry air

63.7 74.0 84.8 96.5 198.4

J kg dry air

148.2 172.1 197.2 224.5 461.5

X X X X X

103 103 103 103 103

4. The driving force lly; -c Hy is computed for various values ofTL between TL! and TL2 . Then by plotting 1/(HYi - Hy) versus lly from HYI to H y2 , agraphical integration is performed to obtain the value of the integral in Eq. (10.5-13). Finally, the height z is calculated from Eq.(10.5-13).

10.5D Design of Water-Cooling Tower Using Overall Mass-Transfer Coefficients Often, only an overall mass-transfer coefficient K ca in kg mol/s' m}' Pa or kg mol/s' m 3 • atm is available, and Eq. (l0.S-13) becomes

Z=

G MBKC aP

(H,' JH YI

dH y -fJ-;---'-H-y

(10.5-15)

The value of H; is determined by going vertically from the value of H y at point P up to the equilibrium line to give H; at point R, as shown in Fig. 10.5-3. In many cases the experimental film coefficients kea and hLa are not available. The few experimental data available indicate that h L a is quite large and the slope of the lines - II L at (keaMBP) in Eq. (10.S-14) would be very large and the value of Hyi would approach that of in Fig. 10.5-3. The tower design using the overall mass-transfer coefficient is done using the following steps.

H;

1. The enthalpy-temperature data from Table IO.S-1 are plotted as shown in Fig. 10.5-3. . 2. The operating line is calculated as in steps 1 and 2 for the film coefficients and plotted in Fig. 10.5-3. 3. In Fig. 10.5-3 point P represents H y and T L on the operating line and point R represents H; on the equilibrium line. Hence, the vertical line RP or H; fly represents the driving force in Eq. (1O.5-1S). 4. The ariving force H; Hy is computed for various values of T L between T Ll and h2' Then by plotting II(H; Hy) versus Hy from Hyl to JI y2 , a graphical integration is performed to obtain the value of the integral in Eq. (10.5-15). Finally, the height z is obtained from Eq. (10.5-15). If experimental cooling data in an actual run in a cooling tower with known height z are available, then using Eg. (l0.5-15), the experimental value of Kea can be obtained. Sec. 10.5

Continuous Humidification Processes

607

EXAMPLE 10.5-1. Design ojWaJer-Cooling Tower Using Film Coefficients A packed countercurrent water-cooling tower using a gas flow rate of G 1.356 kg dry air/s' m 2 and a water flow rate of L = 1.356 kg water/s' m 2 is to cool the water from TL2 = 43.3°C (110°F) to TLI = 29.4°C (85°F). The entering air at 29.4°C has a wet bulb temperature of 23.9°C. The mass-transfer coefficient kG a is estimated as 1.207 x 10- 7 kg molls' m 3 . Pa and hL a/kG aMBP as 4.187 x 104 Jjkg·K (1O.0btu/lb m ·°F). Calculate the height of packed tower z. The tower operates at a pressure of1.013 x 10 5 Pa. Solution: Following the steps outlined, the enthalpies from the saturated air-water vapor mixtures from Table 10.5-1 are plotted in Fig. 10.5-4. The inlet air at TGI = 29.4°C has a wet bulb temperature of 23.9°C. The humidity from the humidity chart is HI = 0.0165 kg HzOjkg dry air. Substituting into Eq. (9.3-8), noting that (29.4 - OtC = (29.4 - 0) K,

HYI

= (L005 + 1.88

x 0.0165)10 3 (29.4 - 0)

+ 2.501

x 106 (0.0165)

71.7 x 10 3 J/kg

= 29.4°C is plotted. Then sub~tituting

The point Hy, 71.7 x 10 3 and TL! into Eq. (10.5-2) and solving,

1.356(HY2 - 71.7 x 10 3 ) = 1.356(4.187 x 10 3 )(43.3 - 29.4) HY2 = 129.9 X 10 3 Jjkg dry air (55.8 btu/lbmJ. The point H yz 129.9 x 10 3 and TLl 43.3°C is also plotted, giving the operating line. Lines with slope hLa/kGaMBP -41.87 x 10 3 Jjkg'K are plotted giving Hy; and Hy values, which are tabulated in Table 10.5-2 along with derived values as shown. Values of 1/(Hy; - H y) are plotted versus Hy and the area under the curve from HYI = 71.7 X 10 3 to HY2 = 129.9 X 10 3 is

rfl'l

JH

y

,

Hy

.

,

,

200

= 1.82

dH y fIyi -

I 1 slope '=-41.87 X 10 3

180

-1--

r-·

-

-----

equilibrium line\ 160

I

140

- - --- .

80

/\

~

r V

60 28 \30

,

---

FIGURE

/

V

~

';I

II. \/

\

\

vz: ~

\

\

\

tv\

\

/'

~f/

~ I

~

1I

"-operating lin·e

I

1

,-

-

I I I

32

10.5·4.

Chap. 10

/'

I

I

I

TLI

608

/'

I

120 100

I

1/

I

I

34

36

38

40

LiquidtemperatureCC)

42

144

46

To

Graphical solution of Example 10.5-1.

Stage and Continuolls Gas-Liquid Separation Processes

Enthalpy Values for Solution to Example 10.5-1 (enthalpy in J/kg dry air)

i0.5-2.

TABLE

H, 94.4 108.4 124.4 141.8 162.1 184.7

X X X X X

X

10 3 10 3 10 3 103 103 10 3

71.7 83.5 94.9 106.5 118.4 129.9

l/(Hy; - Hy)

X

X

X

X X X

10 3 103 10 3 10 3 10 3 10 3

22.7 24.9 29.5 35.3 43.7 54.8

X

X

X

X X X

10 3 10 3 10 3 10 3 10 3 103

4.41 x 10 5 4.02 X 10- 5 3.39 X 10- 5 2.83 X 10- 5 2.29 X 10- 5 1.82 X 10- 5

Substituting into Eq. (10.5-13), Z

G

=

MB

= 6.98 IO.SE

aP

f

1.356

dRy

29(1.207 x 10 7}(1.013

Hyi - Hy

X

105) (1.82)

m (22.9 ft)

Minimum Value of Air Flow

Often the air flow G is not fixed but must be set for the design of the cooling tower. As shown in Fig. 10.5-5 for a minimum value ofG, the operating line MN is drawn through the point BYI and TLI with a slope that touches the equilibrium line at Tn.. point N. If the equilibrium line is quite curved. line MN could become tangent to the equilibrium line at a point farther down the equilibrium line than point N. For the actual tower, a value of G greater than G min must be used. Often, a value of G equal to 1.3 to 1.5 times G min is used. lO.SF

Design of Water-Cooling Tower Using Height of a Transfer Unit

Often another form of the film mass-transfer coefficient is used in Eq. (10.5-13): (10.5-16)

eq Uilibc:ne

. operating line for Gmin, slope LCL/G min operating line, "-----''--slope"" LCL/G

FIGURE

Sec. 10.5

10.5-5.

Operating-line construction for minimum 9as flow.

ContinuOlls Humidification Processes

609

G

Ho=---,

MBkOaP

(10.5-17)

where H 0 is the height of a gas enthalpy transfer unit in m and the integral term is called the number of transfer units. The term HG is often used since it is less dependent upon flow rates than.k o a. , Often another form of the overall mass-transfer coefficient Koa in kg molls' m 3 • Pa or kg molls' m 3 • atm is used and Eq. 00.5-15) becomes

(10.5-18) where H 00 is the height of an overall gas enthalpy transfer unit in m. The value of H: is determined by going vertically from the value of H)l up to the equilibrium line as shown in Fig. 10.5-3. This method should be used only when the equilibrium line is almost straight over the range used. However, the H 00 is often used even if the equilibrium line is somewhat curved because of the lack of film mass-transfer coefficient data.

10.5G

Temperature and Humidity of Air Stream in Tower

The procedures outlined above do not yield any information on the changes in temperature and humidity of the air-water vapor stream through the tower. If this information is of interest, a graphical method by Mickley (M2) is available. The equation used for the graphical method is derived by first setting Eq. (10.5-6) equal to Gcs dT o and combining it with Eqs. (10.5-12) and (10.5-9) to yield Eq. (10.5-19).

dHy dTG

10.5H

l:lyi - Hy T; - TG

(10.5-19)

Dehumidification Tower

For the cooling or humidification tower discussed, the operating line lies below the equilibrium line and water is cooled and air humidified. In a dehumidification tower cool water is used to reduce the humidity and temperature of the air that enters. In this case the operating line is above the equilibrium line. Similar calculation methods are used (Tl).

10.6 10.6A

ABSORPTION IN PLATE AND PACKED TOWERS Equipment for Absorption and Distillation

I. 1ntroduClion to absorption. As discussed briefly in Section 10.1 B, absorption is a ma'Ss-transfer process in whiCh a vapor solute A in a gas mixture is absorbed by means of a liquid in which the solute is more or less soluble. The gas mixture consists mainly of an inert gas and the solute. The liquid also is primarily immiscible in the gas phase; its vaporization into the gas phase is relatively slight. A typical example is absorption of the solute ammonia from an air-ammonia mixture by water. Subsequently, the solute is recovered from the solution by distillation. In the reverse process of desorption or stripping, the same principles and equations hold.

610

Chap. 10

Slage and Continuolls Gas-Liquid Separarion Processes

Equilibrium relations for gas-liquid systems in absorption were discussed in Section to.2, and such data are needed for design of absorption towers. Some data are tabulated in Appendix A.3: Other more extensive data are available in Perry and Green (Pl). 2. Various types of tray (plate) towers for absorption and distillation. In order to efficiently contact the vapor and liquid in absorption and distillation, tray (plate) towers are often used. A very common type of tray contacting device is the sieve tray, which is shown schematically in Fig. 1O.6-1a and in Section 11.4A for distillation.

Essentially. the same type of sieve tray is used in gas absorption and in distillation. In the sieve tray, vapor bubbles up through simple holes in the tray through the flowing liquid. Hole sizes range from 3 to 12 mm in diameter, with 5 mm a common size. The vapor area of the holes varies between 5 to 15% of the tray area. The liquid is maintained on the tray surface and prevented from flowing down through the holes by the kinetic energy of the gas or vapor. The depth of liquid on the tray is maintained by an overflow, outlet weir. The overflow liquid flows into the downspout to the next tray below. 2. Valve tray. A modification of the sieve tray is the valve tray. which consists of openings in the tray and a lift-valve cover for each opening, providing a variable open area which is varied by the vapor flow inhibiting leakage of liquid down the opening at low vapor rates. Hence, this type of tray can operate at a greater range of flow rates than the sieve tray, with a cost of only about 20% higher than a sieve tray. The valve tray is being increasingly used today. 3. Bubble-cap tray. Bubble-cap trays, shown in Fig. 10.6-1 b, have been used for over 100 years, but since 1950 they have been generally stlperseded by sieve-type or valve trays because of their cost, which is almost double that of sieve-type trays. In the bubble tray, the vapor or gas rises through the opening in the tray into the bubble caps. Then the gas flows through slots in the periphery of each cap and bubbles upward through the flowing liquid. Details and design procedures for many of these and other types of trays are given elsewhere (B2, PI, TI). The different types of tray efficiencies are discussed in Section 11.5.

1. Sieve tray.

~vapor

t/lvapor

1 liquid

liquid

(b)

(a) FIGURE

Sec. 10.6

10.6-1.

Tray carllac/ing devices.- (a) detail of sieve-tray tower, (b) detail of bubble-cap lOwer tray.

,,1bsorption in Plate and Packed Towers

611

3. Packed towers/or absorption and distillation. Packed towers are used for continuous count~rcurrent contacting of gas and liquid in absorption and also for vapor-liquid contacting in distillation. The tower in Fig. 10.6-2 consists of a cylindrical column containing a gas inlet and distributing space at the bottom, a liquid inlet and distributing device at the top, a gas outlet at the top, a liquid outlet at the bottom, and a packing or filling in the tower. The entering gas enters the distributing space below the packed section and rises upward through the openings or interstices in the packing and contacts the descending liquid flowing through the same openings. A large area of intimate contact between the liquid and gas is provided by the packing. Many different types of tower packing have been developed and a number are used quite commonly. Common types of packing which are dumped at random in the tower are shown in Fig. 10.6-3. Such packings and other commercial packings are available in sizes of 3 mm to about 75 mm. Most of the tower packing:; are made of inert and cheap materials such as clay, porcelain, graphite, or plastic. High void spaces of 60 to 90% are characteristic of good packings. The packings permit relatively large volumes of liquid to pass countercurrently to the gas flow through the openings with relatively low pressure drops for the gas. These same types of packing are also used in vapor-liquid separation processes of distillation. Stacked packing having sizes of 75 mm or so and larger is also used. The packing is stacked vertically, with open channels running uninterruptedly through the bed. The advantage of the lower pressure drop of the gas is offset in part by the poorer gas-liquid contact in stacked packings. Typical stacked packings are wood grids, drip-point grids, spiral partition rings, and others.

gas outlet

--'-----,1 ~ liquid distributor

packing

_ _ gas inlet

FIGURE

612

10.6-2.

Packed rower flows and characteristics Jar absorption.

Chap. 10

Slage and Continuous Gas-Liquid Separation Processes

(b)

(a)

(c)

(d)

Typical tower packings: (a) Raschig ring, (b) Lessing ring, (c) Berf saddle, (d) Pall ring:

FIGURE 10.6-3.

In a given packed tower with a given type and size of packing and with a definite flow of liquid, there is an upper limit to the rate of gas flow, called the flooding velocity. Above this gas velocity the tower cannot operate. At low gas velocities the liquid flows downward through the packing essentially uninfluenced by the upward gas flow. As the gas flow rate is increased at low gas velocities, the pressure drop is proportional to the flow rate to the 1.8 power. At a gas flow rate called the loading point, the gas starts to hinder the liquid downflow and local accumulations or pools ofliquid start to appear in the packing. The pressure drop of the gas starts to rise at a faster rate. As the gas flow rate is increased, the liquid holdup or accumulation increases. At the flooding point, the liquid can no longer flow down through the packing and is blown out with the gas. In an actual operating tower the gas velocity is well below flooding. The optimum economic gas velocity is about one half or so of the flooding velocity. It depends upon an economic balance between the cost of power and the fixed charges on the equipment cost (S 1). Detailed design methods for predicting the pressure drop in various types of packing are gi ven elsewhere (P 1, Lt, TI). 10.68

Design of Plate Absorption Towers

I. Operating-line derivation. A plate (tray) absorption tower has the same process flow diagram as the countercurrent multiple-stage process in Fig. 10.3-2 and is shown as a vertical tray tower in Fig. 10.6-4. In the case of solute A diffusing through a stagnant gas (B) and then into a stagnant fluid, as in the absorption of acetone (A) from air (8) by water, the moles of inert or stagnant air and inert water remain constant throughout the entire tower. If the rates are V' kg mol inert air/s and kg mol inert solvent water/s or in kg mol inert/s m 2 units (lb mol inert/h . ft 2 ), an overall material balance on component A in Fig. 10.6-4 is

r.

r.C ~OxJ + v'C YN;:+J r.C ~NxJ + v'C YlyJ

(10.6-1)

A balance around the dashed-line box gives

r.(~) + v'( I

Xo

Yn+

I

1 - Yn+ I

)

=

r.(~) + V'(_YI ) I

x.

1

(10.6-2)

YI

where x is the mole fraction A in the liquid, Y the mole fraction of A in the gas, Ln the total moles liquid/s, and v" + I the total moles gas/so The total flows/s of liquid and of gas vary throughout the tower. Equation (10.6-2) is the material balance or operating line for the absorption tower Sec. 10.6

Absorption in Plate and Packed Towers

613

and is similar to Eq. (10.3-13) for a countercurrent-stage process, except that the inert streams r.. and V' are used instead of the total flow rates Land V. Equation (10.6-2) relates the concentration Y.. + I in the gas stream with x" in the liquid stream passing it. The terms V', 1:., xo, and Yl are constant and usually known or can be detennined. 2. Graphical determination oj the number oj trays. A plot of the operating-line equation (10.6-2) as Y versus x will give a curved line. If x and yare very dilute, the denominators 1 - x and 1 y will be close to 1.0, and the line will be approximately straight, with a slope;;: 1:.jV'. The number of theoretical trays are determined by simply stepping off the number of trays, as done in Fig. 10.3-3 for a countercurrent multiple-stage process.

EXAMPLE 10.6-1. Absorption O/SOl in a Tray Tower A tray tower is to be designed to absorb SO:z from an air stream by using pure water at 293 K (68°F). The entering gas contains 20 mol % SOz and that leaving 2 mol % at a total pressure of 101.3 kPa. The inert air flow rate is 150 kg airjh· m 2 , and the entering water flow rate is 6000 kg waterjh· m 2 . Assuming an overall tray efficiency of 25%, how many theoretical trays and actual trays are needed? Assume that the tower operates at 293 K (20°C). Solution:

First calculating the molar flow rates, V'

1:.

=

= 150 29

5.18 kg mol inert airjh· m 2

~: = 333 kg mol inert waterjh· m 2

Referring to Fig. 10.6-4, Y/H I = 0.20, Yl into Eq. (10.6-1) and solving for Xli' 0) 333 ( 10

+ 5.18 (0.20) 1 _ 0.20

0.02, and Xo = O. Substituting

Xli) _ ( 0.02 ) 333 ( 1 _ xl' + ).18 1 - 0.02 0.00355

Substituting into Eq. (10.6-2), using V' and L as kg moljh· m 2 instead of

r

-)

I I I

I )

21-------i

I

I I

I

I L

Vn + l ,

Ln,

Yn+1

I X

n

- __

-1

n+l N-

11-------l

N

FIGURE

614

10.6-4.

Chap. 10

L...,---.,-J

Material balance in an absorption tray tower.

Stage and Continuous Gas-Liquid Separation Processes

kg molfs' m 2 ,

(Y.+ 1) = 333(X.) 1_ + 5.18(0.02)1 - 0.02

0 ) + 5.18 1 _ Y.+! 333 ( 10

X.

In order to plot the operating line, several intermediate points will be calculated. Setting Yn + 1 = 0.07 and substituting into the operating equation, 0+5.18 ( 1

X.)

0.07 ) 3 ( (0.02) 0.07 = 33 1 _ x. + 5.18 1 _ 0.02

Hence, x. = 0.000855. To calculate another intermediate point, we set 1 0.13, and X. is calculated as 0.00201. The two end points and the two intermediate points on the operating line are plotted in Fig. 10.6-5, as are the equilibrium data from Appendix A.3. The operating line is somewhat curved. The number of theoretical trays is determined by stepping off the steps to give 2.4 theoretical trays. The actual number of trays is 2.4/0.25 = 9.6 trays.

Y.+

lO.6C

Design of Packed Towers for Absorption

1. Operating-line derivation. For the case of solute A diffusing through a stagnant gas and then into a stagnant fluid, an overall material balance on component A in Fig. 10.6-6 for a packed absorption tower is

LC ~\J + v'C YIy) LC ~lX) + v'C ~2yJ =

(10.&·3)-

where L is kg mol inert liquid/s or kg mol inertliquid/s' m 2 , V' is kg mol inert gas/s or kg mol inert gas/s' m 2 , and Y 1 and X I are mole fractions A in gas and liquid, respectively. operating line YN+l

0.20

0.18 0.16 0.14 0.12 eq uilibrium line

0.10

Y1 -0.02

0.002 0.004 0.006 0.008 I

I

XN

Mole fraction, FIGURE

Sec. 10.6

10.6-5.

X

Theoretical number oJtraysJorabsorplion OJS02 in Example 10.6-1.

Absorption in Plate and Packed Towers

615

-L dz

-,

I-I i I

I I I

I I

I

I

I

FIGURE

z

10.6-6.

Material balancefor a countercurrent packed absorption tower.

The flows L and V' are constant throughout the tower, but the total flows L and V are not constant A balance around the dashed-line box in Fig. 10.6-6 gives the operating-line equation.

L(_X)+V'(_Yl)=L(_XI)+v,(-y) I-x

l-YI

I-xI'

l-y

{I 0.6-4)

This equation, when plotted on yx coordinates, will give a curved line, as shown in Fig. 1O.6-7a. Equation (10.6-4) can also be written in termsofpartial pressure PI of A, where yd(l Yl) = pd(P PI), and so on. If x and yare very dilute, (l - x) and (1 y) can be taken as 1.0 and Eq. (10.6-4) becomes (10.6-5)

This has a slope LjV' and the operating line is essentially straight. When the solute is being transferred from the L to the V stream, the process is called stripping. The operating line is below the equilibrium line, as shown in Fig. 1O.6-7b. 2. Limiting and optimum L/V' ratios. .In the absorption process, the inlet gas flow VI (Fig. 10.6-6) and its composition YI are generally set. The exit concentration Y2 is also usually set by the designer and the concentration x 2 of the entering liquid is often fixed by process requirements. Hence, the amount of the entering liquid flow L2 or L is open to choice. In Fig. 10.6-8 the How VI and the concentrations Y2 , Xz , and Y I are set. When the operating line has a minimum slope and touches the equilibrium line at point P, the liq uid flow L is a minimum at L~in' The value of x I is a maximum at x I max when L is a minimum. At point P the driving forces Y y*, Y - Yi' x* x, or Xi x are all zero. To solve for L;"in, the values YI and XI max are substituted into the operating-line equation. In some cases if the equilibrium line is curved concavely downward, the minimum value of L is reached by the operating line becoming tangent to the equilibrium line instead of intersecting it. The choice of the optimum LjV' ratio to use in the design depends on an economic balance. In absorption, too high a value requires a large liquid flow, and hence a 616

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

equilibrium line

(tower bottom)

Y2t-----------

operating line equilibrium line

I

operating line (tower bottom)

I

Yl I

Mole fraction, x

Mole fraction,

(a) F,GURE

10_6-7.

I

Xl

Xl

X

(b)

Location of operating lines: (a) for absorption of A from V stream, (b)for stripping of A from L to V stream.

10

L

large-diameter tower. The cost of recovering the solute from the liquid by distillation will be high. A small liquid flow results in a high tower, which is costly. As an approximation, the optimum liquid flow is obtained by using a value of about 1.5 for the ratio of the average slope of the operating line to that of the equilibrium line for absorption. This factor can vary depending on the value of the solute and tower type. 3. Film and overall mass-transfer coefficients in packed towers. As discussed in Section 10.5; it is very difficult to measure experimenti:tlly the interfacial area A m 2 between phases Land V. Also, it is difficult to measure the film coefficients k~ and k~ and the overall coefficients K: and K~. Usually, experimental measurements in a packed tower yield a volumetric mass-transfer coefficient that combines the interfacial area and masstransfer coefficient. Defining a as interfacial area in m 2 per m 3 volume of packed section, the volume of

operating line for actual liquid flow

'----i-

operating line for minimum liquid flow

'----,--- equilibrium line

X 1 max

FIGURE

Sec. 10.6

10.6-8.

Minimum liquid/gas ratiofor absorption.

Absorption in Plate and Packed Towers

617

packing in a height dz m (Fig. 10.6-6) is S dz and

as dz

dA =

(10.6-6)

where S is m 2 cross-sectional area of tower. The volumetric film and overall masstransfer coefficients are then defined as k~a

K~a

kg mol s . m 3 packing· mol frae kg mol s· m 3 packing· mol frac lb mol packing· mol frae

k~a

k~a

=

K~a

=

k' a %

mol s· mol s'

= h·

lb mol packing· mol frae

(SI)

(SI)

(English)

4. Design method for packed towers. For absorption of A from stagnant B, the operating-line equation (10.6-4) holds. For the differential height of tower dz in Fig. (10.6-6), the moles of A leaving V equal the moles entering L. d(Vy)

=

(10.6-7)

d(Lx)

where V kg mol total gasls, L = kg mol totalliquid/s, and d(Vy) = d(Lx) = kg mol A transferred/s in height dz m. The kg mol A transferred/s from Eq. (10.6-7) must equal the kg mol A transferred/s from the mass-transfer equation for N A' Equation (10.4-8) gives the flux N A using the gas-film and liquid-film coefficients.

=

N A

(1 _

k~

)

YA iM

(YAG

_

YAJ

(10.4-8)

(l

where (l YA)iM and (l - x Abf are defined by Eqs. (10.4-6) and (10.4-7). Multiplying the left-hand side of Eq. (10.4-8) by dA and the two right-side terms by as dz from Eq. (10.6-6), (10.6-8) where N A dA = kg mol A transferred/s in height elz m (lb mol/h). Equating Eq. (10.6-7) to (10.6-8) and using YAG for the bulk gas phase and x AL for the bulk liquid phase, (10.6-9)

d(Lx AL ) Since V'

V(l

YAG) or V

k' a =

x

(1 - XA)iM

(X Ai

XA1JS

dz

(10.6-10)

= V'/(l - y,d, (10.6-11)

Substituting V for V'/(I (10.6-9),

y,d

in Eq. (10,6-11) and then equating Eq. (10.6-11) to

(10.6-12)

618

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

Repeating for Eq. (10.6-10) since L = L/(l - xAJ,

.' L dX AL l-xAL

=

a ( X A· (l-XA)iM •

(10.6-13)

Dropping the subscripts A, G, and L and integrating, the final equations are as follows using film coefficients:

z=

f

Y1

Y2

f

V---':...-_ __

____

as

Jy

-O--'-'-Y-)i-M (1 - y)(y - Yi)

_______ l _.:::..-as_ ~.'

dz =z

(10.6-14)

L_d_x______

xb..

(1 -

(1

(10.6-15)

XXXi - X)

In a similar manner, the final equations can be derived using overall coefficients.

z=

f

Yl

____ V_d-=.Y_ _ __

as

Jy

Y2

--'---

(1 - Y).M

z

(10.6-16)

(1 - yXy - Y·)

fX 1______L_d_x_ ___

as

J,

X2

_ - " -_ _

(10.6-17)

xXx. - x)

(1

(1 - X).M

In the general case, the equilibrium and the operating lines are usually curved and k~ a, k~ a, K~ a, and K~a vary somewhat with total gas and liquid flows. Then Eqs. (1O.6-l4)-{10.6-l7) must be integrated graphically. The methods to do this for concentrated mixtures will be discussed in Section 10.7. Methods for dilute gases will be considered below.

lO.6D

Simplified Design Methods for Absorption of Dilute Gas Mixtures in Packeil Towers

Since a considerable percentage of the absorption processes include absorption of a dilute gas A, these cases will be considered using a simplified design procedure. The concentrations can be considered dilute for engineering design purposes when the mole fractions y and x in the gas and liquid streams are less than about 0.10, i.e., 10%. The flows will vary by less than 10% and the mass-transfer coefficients by considerably less than this. As a result,the average values of the flows V and L and the mass-transfer coefficients at the top and bottom of the tower can be taken outside the integral. Likewise, the terms (I Y)iM/(I y), (l - Y).M/( I y), (l - x)iM/(1 - x), and (l - X).M/ (l - x) can be taken outside and average values of the values at the top and bottom of the tower used. (Often these terms are close to 1.0 and can be dropped out entirely.) Then Eqs. (l0.6-I4)-{1O.6-I7) become

z Z

=

V [ k~

as

[L

k~aS

Sec. 10.6

(I

p"

y)iM] I -

y

av JY2

(l-X)iM] 1 x av

Absorption in Plate and Packed Towers

fer,

Jx2

dy Y - Yi

dx Xi -

(10.6-18)

(10.6-19) X

619

z

Y).M] P'

V (1 [ K~ as 1 - Y

L

z= [

K~ as

av

(1 - X).M] 1 - x av

J12

dy Y

r

X1

J.2

y*

dx x* -

X

Since the solutions are dilute, the operating line will be essentially strai~ suming the equilibrium line is approximately straight over the range of concen~ used, (y Yi) varies linearly with Y and also with x.

1

Y

Yi

ky

,1

+b

(l~

where k and b are constants. Therefore, the integral of Eq. (10.6-18) can be give the following.

(YI

Jrl

inte~,

l l

Y-

(,m. "k

Yi

'1

where (y - Yi)M is the log mean driving force. (YI - Yil) - (Y2 - Yi2)

In [(YI - Yil)/(Yz - Yi2)]

,~

(W~

i

J

(~~ ~' If the term (1 - Y)iM/(1 - y) is considered 1.0, then substituting Eq. (1O,6-2:t~i= (10.6-18) and doing the same for Eqs. (1O.6-19HlO.6-21), the final results-are as fo~ ~c

V S (YI L S (Xl

Y2)

~

k~az(y

{~;

Yi)M

.~ X2) = k~ az(x i

.

~~,

X)M

.~.

t ((~

l

.i!

;!~.

f)'6$ ~:

.;

where the left side is the kg mol absorbed/s' m 2 (Ib mol/h· ft 2) by material balarcl: the right-hand side is the rate equation for mass transfer. The value of V is the .n~ (VI + V2 )/2 and of Lis (LI + L 2 )/2. Equations (10.6-26) to (10.6-29) can be used in slightly different ways. The!.~ steps to follow are discussed below and shown in Fig. 10.6-9.

i

1

1. The operating-line equation (10.6-4) is plotted as in Fig. 10.6-9 as a strai~ Calclliate VI' V2 .and Vav (VI + V2 )/2; also calculate L I• L 2 • and La. = (L I +Qf. 2. Average experimental values of the film coefficients k~a and k~a are availables.:

obtained from empirical correlations. The interface compositions Yil and Xil a~ Y I> X I in the tower are determined by plotting line PI M I whose slope is calc~. Eq. (10.6-30): .

/}

slope

620

Chap. 10

a

Stage and Continuous Gas-Liquid Separation ~

j

slope

~

k: al(l

Xl)

k~al(1

Yl)

(10.6-31)

If terms (1 X)iM and (1 - ytM are used, the procedure is trial and error, as in Example 10.4-1. However, since the solutions are dilute, the terms (1 - Xl) and (1 Yl) can be used in Eq. (10.6-31) without trial and error and with a small error in the slope. If the coefficients kya and kx a are available for the approximate concentration range, they can be used, since they include the terms (1 - Xbl and (1 Y)iM . For line P 2 M 2 at the other end of the tower, values of Yi2 and Xi2 are determined using Eq. (10.6-30) or (10.6-31) and Y2 and x 2 • 3. If the overall coefficient K~ a is being used, yt and y! are determined as shown in Fig. 10.6-9. If a is used, xi and xi are obtained. 4. Calculate the log mean driving force (y Yi)M by Eq. (10.6-24) if k~a is used. For K~ a, (y Y*)M is calculated by Eq. (10.6-25). Using the liquid coefficients, the appropriate driving forces are calculated. 5. Calculate the column height z m by substituting into the appropriate form of Eqs. ( 1O.6-26HlO·6-29).

K:

EXAMPLE 10.6-2. Absorption of Acetone in a Packed Tower Acetone is being absorbed by water in a packed tower having a crosssectional area of 0.186 m 2 at 293 K and 101.32 kPa (1 atm). The inlet air contains 2.6 mol % acetone and outlet 0.5%. The gas flow is 13.65 kg mol inert airjh (30.llb moljh). The pure water inlet flow is 45.36 kg mol waterlh (100 lb moljh). Film coefficients for the given flows in the tower are k~a 3.78)( 10- 2 kg mol/s· m 3 • mol frac (8.50 Ib mol/h· ft. 3 • mol frac) and a 6.16 x 10- 2 kg mol/s' m 3 . mol frac (13.85 lb moljh· ft3. mol frac). Equilibrium data are given in Appendix A.3. (a) Calculate the tower height using k~ a. (b) Repeat using k~ a. (c) Calculate K~ a and the tower height.

k:

Solution: From Appendix A.3 for acetone-water and X..t = 0.0333 mol frac, P..t 30/760 = 0.0395 atm or Y A 0.0395 mol frac. Hence, the equilibrium line is YA = mX A or 0.0395 m (0.0333). Then, Y = 1.186x. This equi-

operating line

--~--~-~" ---- - --+-

YI

_ _-:r"-_,,,I

---__

Ml I

I

~equilibrium line -k~al(l-x)iM

slope= k' 1(1- ). ya

Y 1M

e it

Y

))

?s

FIGURE

Sec. /0.6

[0.6-9.

Operaring-line and interface compositions in a packed lOwer for absorption of dilute gases.

Absorption ill Place and Packed Towers

621

librium line is plotted in Fig. 10.6-10. The given data are £. = 45.36 kg moljh, V' = 13.65 kg mol/h, YI = 0.026, Y2 = 0.005, andx 2 = O. Substituting into Eq. (10.6-3) for an overall material balance using flow rates as kg molfh instead of kg mol/s, 0 ) 45.36( 1 _ 0

) + 13.65( 1 _0.026 0.026

=

I) + (

( x 45.36 ~

13.65 1

0.005 ) 0.005

0.00648

XI

The points YI' X I and Y2, x 2 are plotted in Fig. 10.6-10 and a straight line is drawn for the operating line. Using Eq. (10.6-31) the approximate slope at YI, x I is

I

~

_ k~ al( 1 - x d ~ k~al(1 -

s ope =

YI) -

3.78 x 10 2/(1

0.00648) 0.026)

- 1.60

Plotting this line through YI' XI' the line intersects the equilibrium line at = 0.0154 and Xii = 0.0130. Also, yi 0.0077. Using Eq. (10.6-30) to calculate a more accurate slope, the preliminary values of Yil and Xii will be used in the trial-and-error solution. Substituting into Eq. (1004-6), Yil

(

(1 - Yil) (1 1 - Y)iM = In [(1 - Yil)/(1

YI)

YI)]

(1 0.0154) (1 In [( 1 0.0154)/(1

0.026) 0.020)] = 0.979

Using Eq. (10.4-7), (l-xI)-(1

Xii)

In [(1 - X1)/(1

(I

In [(1

x it )]

0.00648) - (1 0.00648)/(1

0.0130) 0.0130)] = 0.993

0.028 YI--I I

0.024 operating line 0.020

-1.62

I I

I I L __

Yil- 0.016

I

I I

0.012

I I

equilibrium line Yr0:004 Yi2- -

Y;---OO~~~0~;0~0-2--~-OJ.0-0-4~-O-.~OLO~6:~--0-.0~0-8--~-0-.OLI-O~--0~.0~1-2~~0~.~014 I

x2

I

FIGURE

622

X I

Xj2

10.6-10.

Localioll oj illlerJace composilions Jar Example 10.6-2.

Chap. 10

Stage and Continuous Gas-Liquid Separation Processes

Substituting into Eq. (10.6-30), sIope

= -

k~a/(l -

k~ a/(1

xb,{

6.16 x 3.78 x

=

- Y)iM

1.61

Hence, the approximate slope and interface values are accurate enough. For the slope at pointY2 ,x 2 , slope

~

k~a/(1 - x 2 )

k~a/(l

-

_ Y2)

= -

6.16 x 10- 2 /(1 - 0) 3.78 x 10 2/(1 0.005)

The slope changes little in the tower. Plotting this line, Y!Z 0.0018, and yi = O. Substituting into Eq. (10.6-24),

1.62

0.0020, X i2

( _ ) _ (Yt - Yil) (yz y;z) Y Yi M - In [(Yl - Yil)f{Y2 - YiZ)] (0.026 - 0.0154) (0.005 0.0154)/(0.005

0.0020) 0.0020)]

In [(0.026

0.00602

To calculate the total molar flow rates in kg mOl/s, V' 1 _ Yl

13.65/3600 1 _ 0.026

= 3.893

x

V' 13.65/3600 V2 = 1 _ Y2 = 1 _ 0.005

= 3.811

x 10

VI

=

=

3.893

X

10- 3

-3

10

kg mol/s _3

+ 3.811

kg mol/s

10- 3

X

2

45.36 3600

3.852 x 10 -

3

kg molls

1.260 x 10- 2 kg mOl/s

For part (a), substituting into Eq. (10.6-26) and solving,

~v (Yl

k~az(y

- Y2)

3.852 x 10- 3 0.186 (0.0260 - 0.005)

Yi)M

(3.78 x 10- 2)z(0.00602) 1.911 m (6.27 ft)

z

For part (b), using an equation similar to Eq. (10.6-24), ( Xi -

X)

.'f

(Xi! -

=

Xl) -

In [(Xi! -

X

(XiI -

l)/(X i l

-

Xl) Xl)]

(0.0130 - 0.00648) - (0.0018 - 0) 0)]

In [(0.0130 - 0.00648)/(0.0018

=

000368 .

Substituting into Eq. (10.6-27) and solving, 1.260 x 10- 2 0.186 (0.00648 - 0) z

= (6.16 =

x 10

-2

)z(O.00368)

1.936 m

This checks part (a) quite closely.

Sec. 10.6

Absorption in Plate and Packed Towers

623

For part (c), substituting into Eq. (10.4-25) for point Y l' X l' (1

Y).M

=

yf -

(1 In [(1

(1 - YI) yf)/(l - YI)]

(1 - 0.0077) (1 In [(1 - 0.0077)/(1

0.026) 0.026)] = 0.983

The overall mass-transfer coefficient K~ a at point Y I' XI is calculated by substituting into Eq. (10.4-24). K'y 1

1 3.78 x 10 2/0.979

K~a/0.983

K~

+ 6.16

1.186 x 10 2/0.993

a = 2.183 x 10 - 2 kg moljs· m 3. mol frae

Substituting into Eq. (10.6-25), (y _ Y*)M = (y 1 yi) - (h Y!) In [(YI yt)/(Y2 - y!)]

(0.0260 0.0077) - (0.0050 In [(0.0260 0.0077)/(0.0050

0) O)J = 0.01025

Finally substituting into Eq. (10.6-28), 3

3.852 x 10- (0'0260 0.186 .

0.0050)

(2.183 x 1O- 2 )z(0.01025)

z = 1.944 m

This checks parts (a) and (b). 10.6E

Design of Packed Towers Using Transfer Units

Another and in some ways a more useful design method of packed towers is the use of the transfer unit concept. For the most common case of A diffusing through stagnant and nondiffusing B, Eqs. (l0.6-14)-{10.6-17) can be rewritten as

l'" ix, l ix,

(l

YI

Z

HG

z

= HL

HOG

Y2

x,

z=

HOL

(10.6-32)

y;)

dx (I - XXXi - X)

Y'

Z

y)(y

(I

n

dy

(! -

(10.6-33)

(I

----~~~

(I

yXy - y*)

(1-

dx

(1 - xXx*

x)

(10.6-34)

(10.6-35)

where

v

V

(10.6-36)

(10.6-37)

624

Chap. ]0

Stage and Continuous Gas-Liquid Separation Processes

H

v

OG - K~aS

HOL

V K y a(l - Y).M S

L

--= K~aS

L

K;ra(1

X).MS

(10.6-38)

(10.6-39)

The units of H are in m (ft). The HG is the height ,of a tr:ansfer unit based on the gas film. The values of the heights of transfer units are more constant than the mass-transfer coefficients. For example, k~a is often proportional to VO. 7 , then Ha oc VL O/VO. 7 oc VO. 3 • The average values of the mass-transfer coefficients, (1 - Y)iM, (1 Y).M' (1 - X)iM, and (1 - X).M' must be used in Eqs. (1O.6-36HlO.6-39). The integrals on the right side of Eqs. (1O.6-32HlO.6-35) are the number of transfer units N G' N L, N OG, and N OL, respectively. The height of the packed tower is then (10.6-40) These equations are basically no different than those using mass-transfer coefficients. One still needs k~a and k:a to determine interface concentrations. Disregarding (1 - ybl/(l Y), which is near 1.0 in Eq. (10.6-32), the greater the amount of absorption (y 1 - Y2) or the smaller the driving force (y - y.), the larger the number of transfer units N G and the taller the tower. When the solulions are dilute with concentrations below 10%, the terms (1- Y)iM/ (1- y), (1 x),M/(l - x), (1 Y).M/(1 - Y), and (1 x).M/(1 - x) ca~ taken outside the integral and average values used. Often they are quite closlfo r and can be dropped out. The equations become " (10.6-41) (10.6-42) (10.6-43)

(10.6-44) If the operating and equilibrium lines are both straight and the solutions dilute, the integral shown in Eq. (10.6-23) is valid.

r

y

JY2

'

dy Y - Yi

(10.6-23) (y - Y;)M

This then can be substituted into Eq. (10.6-41) and similar expressions into Eqs. (10.642HlO.6-44).

EXAMPLE 10.6-3. Use of TrQnsfer Unitsfor Packed Tower Repeat Example 10.6-2 using transfer units and height of a transfer unit as follows. (a) Use HG and N G to calculate tower height. (b) Use HOG and N OG to calculate tower height. Solution:

Sec. 10.6

For part (a), k~a

3.78 x 10- 2 kg mOl/s·m 3 ·mol frac from

Absorption in Plate and Packed Towers

625

Example 10.6-2. From Eq. (10.6-36),

(10.6-36) The average V is 3.852 x 10- 3 kg molls and S = 0.186 m 2 • Substituting and solving, 3.852 x 10- 3 (3.78 x 10 2)(0.186)

= 0.548

m

Since the solution is dilute, the number of transfer units from Eq. (10.6-41) is

(1

Y)iM] 1- Y

[

.v

in YI

(10.6-45)

Y

The term in the brackets will be evaluated at point 1 and point 2. At point Yt 0.026, Yil = 0.0154 from Example 10.6-2. Also, from Eq. (1004-6) in Example 10.6-2, (l Y)iM = 0.979. Also, 1 - Y 1 0.026 = 0.974. Then at point 1, 0.979 0.974

1.005

~--"-.:..:.::.:.. -~-

Y At (l

point Y2 = 0.005, Yi2 = 0.002. Substituting into Eq. Y)iM = 0.997 and 1 - Y = 1 0.005 = 0.995. Then at point 2, '----..;;...;..:=

(10A-6),

= 0.997 = 1 002

0.995

Y

.

Hence, the average value of the term in the brackets in Eq. (10.6-45) is

[ Using

(1

1.005

Y)IM]

l-y

+

1.002.

1.003

2

av

(10.6-23), the integral is

i

Y1

dy

From Example 10.6-2, (y - Y;)M Eq. (10.6-45),

NG

(10.6-23) Y.)M

Y - Yi

Y2

0.00602. Substituting Eq. (1O.6-23) into

[(I -

Y}iM]

1- Y

Yl

.v (y

Y2

(10.6-46)

Y.)M

(10.6-46),

Substituting into NG

{1.003} (

Finally, substituting into

z

0.026 0.005) 0.00602

3 50 =.

f

.

trans er Untts

(10.6-40),

H G N G = (0.548X3.50) = 1.918 m

For part (b), using K~a = 2.183 x 10- 2 kg mol/s·m 3 ·mol frac from Example 10.6-2 and substituting into Eq. (10.6-38),

H

OG

626

V = K~aS

Chap. 10

3.852 x 10- 3 (2.183 xl 1

=~~m

and Confinuous Gas-Liquid Separation Processes

The number of transfer units in Eq. (10.6-43) becomes as follows when the integration similar to Eq. (10.6-23) is carried out.

NOG

= [(1

y).M] 1- Y

av

YI - ~2 (y Y)M

(10.6-47)

Substituting (y Y*)M = 0.01025 froIl} Example 10.6-2 and the other knowns into Eq. (10.6-47) and calling the bracketed term 1.0, (0 1.) (

N OG

0.026 - 0.0(5) . 0.01025 = 2.05 transfer umts

Finally by Eq. (10.6-40), Z=

HOG N OG = 0.949(2.05) = 1.945 m

Note that the number of transfer units N OG of 2.05 is not the same as N G of 3.50. 10.'7

ABSORPTION OF CONCENTRATED MIXTURES IN PACKED TOWERS

In Section 1O.6D simplified design methods were given for absorption of dilute gases in packed towers when the mole fractions in the gas and liquid streams were less than about 10%. Straight operating lines and approximately straight equilibrium lines are obtained. In concentrated gas mixtures the operating line and usually the equilibrium line will be substantially curved and k~ a and k~ a may vary with total flows. Then the design equations (1O.6-14H 10.6-17) must be integrated graphically or numerically.

fdZ

= Z

fl fl fl

(10.6-14)

Y2

f dZ f elZ

1

dz

o

Z

y)(y - y.)

(1

L dx

x,

z=

(I-x);.\.{

(1

(10.6-15) XXXi -

X)

(10.6-16)

Y2

y*)

L dx = Z = IXI - - - - ----Xl

as

_ - " -_ _

(1 _ xXx*

(l - x).,1.{

(10.6-17)

X)

The detailed general steps to follow are as follows: L The operating-line equation (10.6-4) and the equilibrium line are plotted. 2. The values of the film coelTicients k~ a and k~ a are obtained from empirical equations. These two film coelTicients are functions of G;, kg total gas/s' m 2 , and G~, kg total liquids/s·m 2 , where nand m are in the range 0.2-0.8. Using the operating-lineequation values, total V and L are calculated for different values of y and X in the tower and converted to G y and Gx ' Then values of k~ a and k: a are 1.0, as shown. The enriching and operating lines are plotted for the case of a feed of part liquid and part vapor and the two lines intersect on the q line. A convenient way to locate the stripping operating line is to first plot the enriching operating line and the q line. Then draw the stripping line between the intersection of the q line and enriching operating line and the point y = x Xw. 5. Location of the feed tray in a tower and number of trays. To determine the number of theoretical trays needed in a tower, the stripping and operating lines are drawn to intersect on the q line as shown in Fig. 11.4-8. Starting at the top at x D' the trays are stepped off. For trays 2 and 3, the steps can go to the enriching operating line, as shown

q = 1

I

enriching operating line

I

I I

I I

stripping operating line I

Xw

I

xp

Mole fraction in liquid, x FIGURE

Sec. 1l,4

11.4-7.

Location oj the q line Jor various Jeed conditions: liquid below boiling J), liquid + vapor point (q > J), liquid at boiling point (q (0 < q < 1), saturated vapor (q = 0).

Distillation With Reflux and McCabe-Thiele Method

655

in Fig. llA-8a. At step 4 the step goes to the stripping line. A total of about 4.6 theoretical steps are needed. The feed enters on tray 4. F or the correct method, the shift is made on step 2 to the stripping line, as shown in Fig. 11.4-8b. A total of only about 3.7 steps are needed with the feed on tray 2. To keep the number of trays to a minimum, the shift from the enriching to the stripping operating line should be made at the first opportunity after passing the operating-line intersection. In Fig. 11.4-8b the feed is part liquid and part vapor since 0 < q < 1. Hence, in adding the feed to tray 2, the vapor portion of the feed is separated and added beneath plate 2 and the liquid added to the liquid from above entering tray 2. If the feed is all liquid, it should be added to the liquid flowing to tray 2 from the tray above. If the feed is all vapor, it should be added below tray 2 and joins the vapor rising from the plate below. Since a reboiler is considered a theoretical step when the vapor Yw is in equilibrium with Xw as in Fig. 11.4-5b, the number of theoretical trays in a tower is equal to the number of theoretical steps minus one. EXAMPLE 11.4-1. Rectification ofa Benzene-Toluene Mixture A liquid mixture of benzene-toluene is to be distilled in a fractionating tower at 101.3 kPa pressure. The feed of 100 kg molfh is liquid and it contains 45 mol % benzene and 55 mol % toluene and enters at 327.6 K (130°F). A distillate containing 95 mol % benzene and 5 mol % toluene and a bottoms containing 10 mol % benzene and 90 mol % toluene are to be / obtained. The reflux ratio is 4: 1. The average heat capacity of the feed is 159 . kJ/kg mol, K (38 btuj1b mol, oF) and the average latent heat 32099 kJ/kg mol (13 800 btuj1b mol). Equilibrium data for this system are given in Table 11.1-1 and in Fig. 11.1·1. Calculate the kg moles per hour distillate, kg moles per hour bottoms, and the number of theoretical trays needed. Solution: The given data are F = 100 kg mol/h, x F 0045, X D 0.95, Xw = 0.10, and R = LJD = 4. For the overall material balance substituting into Eq. (llA·3), F

100

y

D+ W D

(11.4-3)

+W

y

(a) FIGURE 11.4-8.

656

(b)

Method of stepping off number of theoretical crays and location offeed place: (a) improper iocacion of feed on tray 4, (b) proper /ocflcion of feed on tray 2 co give minimum number of steps.

Chap. lJ

Vapor-Liquid Separation Processes

Substituting into Eq. (11.4-4) and solving for D and W,

+ WXw 100(0.45) = D{0.95) + (100 D)(0.10) D = 41.2 kg molfh W = 58.8 kg moljh FXF = DXD

(U.4-4)

F or the enriching operating line, using Eq. (11.4-8), 0.95

4

4

0.800x n

+ 1 xn + 4 +

+ 0.190

The equilibrium data from Table 11.1-1 and the enriching operating line above are plotted in Fig. 11.4-9. . Next, the value of q is calculated. From the boiling-point diagram, Fig. 11.1-1, for X F = 0.45, the boiling point of the feed is 93SC or 366.7 K (200.3°F). From Eq. (11.4-13), (11.4-13)

q The value of H v Eq. (11.4-13) is

H L = latent heat

= 32099 kJ/kg mol. The numerator of (11.4-20)

.

-' '

Also,

HL

HF = cpL(T8

-

TF)

(11.4-21)

where the heat capacity of the liquid feed c pL 159 kJjkg mol, K, TB = 366.7 K (boiling point of feed), and TF = 327.6 K (inlet feed temperature). Substituting Eqs. (11.4-20) and (11.4-21) into (11.4-13),

q

(Hv - H t)

+ c pL(T8 -

Tp)

Hv - HL

(I 1.4-22)

1.0

;:..., 0.8

-

....

0 0.

'"> .5 0.6 t::

0 ..... .....

u

........'"

0.4

v

-

y

I

,

I I

.S

enriching operating line

~ I:::

I

·3

I I I

0

o:!



!I

0.6

.5

steps for total reflux

t::

.S ...... u

I I

0.4

ro .........

I

£

0

~

I

0.2

I I I

xw Mole fraction in liquid, x FIGURE

Sec. 11.4

11.4-13.

Graphical solution for minimum reflux ratio Rm and total reflux/or Example 11.4-2.

Distillation With Reflux and McCabe-Thiele Method

661

r m + 1 !--,...---!--j

I

I I I I

I

1

I

I I L

(b)

(a) FIGURE

11.4-14.

Material balance and operating line for stripping tower: (a)fiows in tOIVer. (0) operaring and e'qui!iorium line'.

If the feed is saturated liquid. then Lm = F. If the feed is cold liquid below the boiling point. the q line should be used and q > 1. (11.4-26) In Fig. 11.4-14 the stripping operating-line equation (l1.4-25) is plotted and the q line, Eq, (11.4-19), is also shown for q 1.0. Starting at X F , the steps are drawn down the tower. EXAMPLE 11.4-3. Number of Trays in Stripping Tower A liq uid feed at the boiling point of 400 kg mol/h containing 70 mol % benzene (A) and 30 mol % toluene (8) is fed to a stripping tower at 101.3 kPa pressure. The bottoms product flow is to be 60 kg mol/h containing only 10 mol Oft, A and the rest B. Calculate the kg moljh overhead vapor, its composition, and the number of theoretical steps required. Solution: Referring to Fig. 11.4-14a, the known values are F = 400 kg mOl/h, X F = 0.70, W 60 kg mol/h, and XI+' 0.10. The equilibrium data from Table 11.1-1 are plotted in Fig. 11.4-15. Making an overall material balance, F= W

400 = 60

+ Vo

+

Vo

Solving, VD = 340 kg mol/h. Making a component A balance and solving, FXF

400(0.70)

=

WXw

+

VDYD

60(0.10) + 34O(y D)

Yo = 0.806

662

Chap. II

Vapor-Liquid Separation Processes

1.0 r--------------~ JD0.8

..... ....§

0.6

()

cd .... ......

v

o

op~rating line

0.4

I I

::E

I I I

0.2

ne

I

I

1.0

XF

XW

Mole fraction, x FIGURE

11.4-15.

Stripping tower for Example 11.4-3.

For a saturated liquid, the q line is vertical and is plotted in Fig. 11.4-15. The operating line is plotted through the point y = Xw = 0.10 and the intersection of YD 0.806 with the q line. Alternatively, Eq. (11.4-25) can be used 400/340. Stepping off the trays from the top, 5.3 with a slope of L,JVm+l theoretical steps or 4.3 theoretical trays plus a reboiler are needed. 2. Enriching-column distillatioll. Enriching towers 'are also sometimes used, where the feed enters the bottom of the tower as a vapor. The overhead distillate is produced in the same manner as in a complete fractionating tower and is usuaIly quite rich in the more volatile component A. The liquid bottoms is usually comparable to the feed in composition, being slightly leaner in c')mponent A. If the feed is saturated vapor, the vapor in the tower v" F. Enriching-line equation (l1.4-7) holds, as does the q-line equation (11.4-19). 3. Rectification with direct steam injection. Generally, the heat to a distillation tower is applied to one side of a heat exchanger (reboDer) and the steam does not directly contact the boiling solution, as shown in Fig. 11.4-5. However, when an aqueous solution of more volatile A and water B is being distilled, the heat required may be provided by the use of open steam injected directly at the bottom of the tower. The reboiler exchanger is then not needed. The steam is injected as small bubbles into the liquid in the tower bottom, as shown in Fig. 11.4-16a. The vapor leaving the liquid is then in equilibrium with the liquid if sufficient contact is obtained. Making an overall balance on the tower and a balance

onA, F+S=D+W

(11.4-27) (11.4-28)

where S = mol/h of steam and Ys = 0 = mole fraction of A in steam. The enriching operating-line equation is the same as for indirect steam. Sec. 11.4

Dislillation Wilh Reflux and McCabe-Thiele Melhod

663

For the stripping-line equation, an overall balance and a balance on component A are asfollows:

L", + S = V", + 1 + W Lmxm

+ S(O) =

Vm+ 1Ym+1

(11.4-29)

+ Wxw

(11.4-30)

Solving for Ym+ I in Eq. (11.4-30), (11.4-31)

Y",+I

For saturated steam entering, S = Vm + 1 and hence, by Eq. (11.4-29), Lm ing into Eq. (11.4-31), the stripping operating line is Ym+1

W -x

S

W. Substitut-

W m

S

(11.4-32)

Xw

When Y = 0, x Xw. Hence, the stripping line passes through the point Y = 0, x x w , as shown in Fig. 11.4-16b, and is con tinued to the x axis. Also, for the intersection of the stripping line with the 45° line, when Y x in Eq. (1 1.4-32), X = Wxw/(W - S). ' F or a given reflux ratio and overhead distillate composition, the use of open steam rather than closed requires an extra fraction of a stage, since the bottom step starts below the y = x line (Fig. 11.4-16b). The advantage of open steam lies in simpler construction of the heater, which is a sparger. 4. Rectification tower with side stream.

In certain situations, intermediate product or enriching operating line Y

equilibrium"'. line \

F YN

I I

-

I

stripping operating line I 45° line

Yw

I

steam S mol/h Ys = 0

xp

x (a) FlGURE

664

I I

11.4-16.

(b) Use of direct steam injection: (a) schematic of tower, (b) operating and equilibrium lines.

Chap. 11

Vapor-Liquid Separation Processes

x

side streams are removed from sections of the tower between the distillate and the bottoms. The side stream may be vapor or liquid and may be remov~d at a pgint above the feed entrance or below depending on the composition desired. The flows for a column with a liquid side stream removed above the feed inlet are shown in Fig. 11.4-17. The top enriching operating line above the liquid side stream and the stripping operating line below the feed are found in the usual way. The equation of the q line is also unaffected by the side stream and is found as before. The liquid side stream alters the liquid rate below it, and hence the material balance or operating line in the middle portion between the feed and liquid side stream plates. Making a total material balance on the top portion of the tower as shown in the dashed-line box in Fig. 1104-17, VS + 1

(11.4-33)

Ls+O+D

where 0 is mol/h saturated liquid removed as a side stream. Since the liquid side stream is saturated, (11.4-34) VS + 1 =

V:+I

(11.4-35)

Making a balance on the most volatile component, Vs+ IYS+

1

Lsxs

+ OXo + DXD

(11.4-36)

Solving for Ys+ I, the operating line for the region between the side stream and the feed is YS+I =

T7

YS+I

xs+

OXo

+ DXD

(11.4-37)

VS + 1

/

I

(n+l

t !Ln

I L __ t-~ IVS+l F,

XD

I

1o, Xo saturated liquid

XF

Vm + 1

X

ID, !

t ~Lm

W,xw

FIGURE

Sec. 11.4

11.4-17.

Process flow for a rectifiCGlion tower with a liquid side Slream.

Dislillalion Wilh Reflux and McCabe-Thiele Melhod

665

FIGURE 11.4-18.

McCabe-Thiele plot for a tower with a liquid side stream above thefeed.

y

The slope of this line is Ls/Vs+ I' The line can be located as shown in Fig. 11.4-18 by the q line, which determines the intersection of the stripping line and Eq. (11.4-37), or it may be fixed by the specification of x o , the side-stream composition. The step on the McCabeThiele diagram must actually be at the intersection of the two operating lines at Xo in an actual tower. If this does not occur, the reflux ratio can be altered slightly to change the steps. In a few cases it may be desired to remove the overhead distillate product as a vapor instead of a liquid. This can also occur when the low boiling point of the distillate makes complete condensation difficult. The liquid condensate in a partial condenser is returned to the tower as reflux and the vapor removed as product as shown in Fig. 11.4-19. If the time of 5=0ntact between the vapor product and the liquid is sufficient, the partial condenser is a theoretical stage. Then the composition x R of the liquid reflux is in XD' If the cooling in the equilibrium with the vapor composition YD' where YD condenser is rapid and the vapor and liquid do not reach equilibrium, only a partial stage separation is obtained.

5. Partial condensers.

1l.S

1L5A

DISTILLATION AND ABSORPTION TRAY EFFICIENCIES Introduction

In all the previous discussions on theoretical trays or stages in distillation, we assumed that the vapor leaving a tray was in equilibrium with the liquid leaving. However, if the time of contact and the degree of mixing on the tray is insufficient, the streams will not be in equilibrium. As a result the efficiency of the stage or tray is not 100%. This means that we must use more actual trays for a given separation than the theoretical number of trays determined by calculation. The discussions in this section apply to both absorption and distillation tray towers. Three types of tray or plate efficiency are used: overall tray efficiency Eo, Murphree tray efficiency EM' and point or local tray efficiency EMP (sometimes called Murphree point efficiency). These will be considered individually.

666

Chap. II

Vapor-Liquid Separation Processes

Yl

I

.

enriching line I I

I I

I

I

45° line

I

(b)

(a) FIGURE

11.5B

11.4-19.

Partial condenser where lhe vapor and liquid leave in equilibrium: (a) processflow diagram. (b) McCabe- Thiele plOl.

Types of Tray Efficiencies

f. Overall tray efficiellcy. The overall tray or plate efficiency Eo concerns the entire tower and is simple to use but is the least fundamental. It is defined as the ratio of the number of theoretical or ideal trays needed in an entire tower to the number of actual trays used.

number of ideal Eo = - - - - - - - - - - ' - number of actual trays

(11.5--1)

For example, if eight theoretical steps are needed and the overall efficiency is 60%, the number of theoretical trays is eight minus a reboiler, or seven trays. The actual number of trays is 7;0.60, or 11.7 trays. Two empirical correlations for absorption and distiJIation overall tray efficiencies in commercial towers are available for standard tray designs (01). For hydrocarbon distillation these values range from about 50 to 85% and for hydrocarbon absorption from about 10 to 50%. These correlations should only be used for approximate estimates. 2. Murphree tray efficiency.

The Murphree tray efficiency EM is defined as follows: EM

= :...:.:.--::..:.:...--=..

y:

Yn+

(11.5--2)

I

where Yn is the average actual concentration of the mixed vapor leaving the tray n shown in Fig. 11.5-1, Yn+ I the average actual concentration of tme mixed vapor entering tray n, and the concentration of the vapor that would be in equilibrium with the liquid of concentration Xn leaving the tray to the downcomer.

y:

Sec. 11.5

Distillation and Absorption Tray Efficiencies

667

The liquid entering the tray has a concentration ofxn l ' and as it travels across the tray, its concentration drops to x. at the outlet. Hence, there is a concentration gradient in the liquid as it flows across the tray. The vapor entering the tray contacts liquid of different concentrations, and the outlet vapor will not be uniform in concentration. 3. Point efficiency.

The point or local efficiency E MP on a tray is defined as

E MP

(l1.5-3)

=;;"'::"",-";"':':''''''':'

Yn

Y~+

I

y:

where is the concentration of the vapor at a specific point in plate n as shown in Fig. 11.5-1, y~+ 1 the concentration of the vapor entering the plate n at the same point, and y~* the concentration of the vapor that would be in equilibrium with x~ at the same point. Since y: cannot be greater than y~* , the local efficiency cannot be greater than 1.00 or 100%. In small-diameter towers the vapor flow sufficiently agitates the liquid so that it is uniform on the tray. Then the concentration of the liq uid leaving is the same as that on the tray. Then Y: Yn' y:+ 1 = Y.+ I' and y~* = y:. The point efficiency then equals the Murphree tray efficiency or EM = E MP ' In large-diameter columns incomplete mixing of the liquid occurs on the trays. Some vapor will contact the entering liquid xn [, which is richer in component A than X n • This will give a richer vapor at this point than at the exit point, where Xn leaves. Hence, the tray efficiency EM will be greater than the point efficiency E MP ' The value of EI,I can be related to E MP by the integration of E MP over the entire tray. 11.5C

Relationship Between Efficiencies

The relationship between E MP and EM can be derived mathematically if the amount of liquid mixing is specified and the amount of vapor mixing is also set. Derivations for three different sets of assumptions are given by Robinson and Gilliland (R 1). However, experimental data are usually needed to obtain amounts of mixing. Semitheoretical methods to predict E MP and EM are summarized in detail by Van Winkle (V 1). When the Murphree tray efficiency EM is known or can be predicted, the overall tray

inlet

Xn-l

;.~

,

~-----------~----~~----~ y

outlet

Xn

Yn+l

average

FIGURE

11.5- L

Vapor and liquid compositions on a sieve tray and [ray efficiency.

Chap. II

Vapor-Liquid Separation Processes

eq uilibrium line

I

I

I

Yn+l

I operating line I

y

I

I I reboiler step

I I

XF

x FIGURE

11.5-2.

Use oj Murphree plate efficiency 10 de/ermine accual number oJ trays.

efficiency Eo can be related to EM by several methoos. In the first method an analytical expression is as follows when the slope m of the equilibrium line is constant and also the slope L/V of the operating line: 1)] log [1 + E.\f(mV/L Eo = 10g(mV/L) (11.5-4) If the equilibrium and operating lines of the tower are not straight, a graphical method in the McCabe-Thiele diagram can be used to determine the actual number of trays when the Murphree tray efficiency is known. In Fig. 11.5-2 a diagram is given for an actual plate as compared with an ideal plate. The triangle acd represents an ideal plate and the smaller triangle abe the actual plate. For the case shown, the Murphree efficiency EM 0.60 ba/ca. The dashed line going through point b is drawn so that ba/ca for each tray is 0.60. The trays are stepped off using this efficiency, and the total number of steps gives the actual number of trays needed. The reboiler is considered to be one theoretical tray, so the true equilibrium curve is used for this tray as shown. In Fig. 1 6.0 actual trays plus a reboiler are obtained.

11.6 FRACTIONAL DISTILLATION USING ENTHALPY-CONCENTRATION METHOD 11.6A

Enthalpy-Concentration Data

1. Introduction. In Section II.4B the McCabe-Thiele method was used to calculate the number of theoretical steps or trays needed for a given separation of a binary mixture of A and B by rectification or fractional distillation. The main assumptions in the method are that the latent heats are equal, sensible heat differences are negligible, and constant molal overflow occurs in each section of the distillation tower. In this section we shall consider fractional distillation using enthalpy-concentration data where the molal overflow rates are not necessarily constant. The analysis will be made using enthalpy as well as material balances. Sec. 11.6

Fractional Distillation Using Efllhalpy-Concenlralion Method

669

2. Enthalpy-concentration data. An enthaipy-{;oncentration diagram for a binary vapor-liquid mixture of A and B takes into account latent heats, heats of solution or mixing, and sensible heats of the components of the mixture. The following data are needed to construct such a diagram at a constant pressure: (1) heat capacity of the liquid as a function of temperature, composition, and pressure; (2) heat of solution as a function of temperature and composition; (3) latent heats of vaporization as a function of composition and pressure or temperature; and (4) boiling point as a function of pressure, composition, and temperature. The diagram at a given constant pressure is based on arbitrary reference states of liquid and temperature, such a 273 K (32°F). The saturated liquid line in enthalpy h kJ/kg (btullb m ) or kJ/kg mol is calculated by (11.6-1) where x A is wt or mole fraction A, T is boiling point of the mixture in KeF) or °C, To is reference temperature, K, cpA is the liquid heat capacity of the component A in kJ/kg . K (btullb m • OF) or kJ/kg mol, K, C pB is heat capacity of B, and t:..H sol is heat of solution at To in kJ/kg (btullb m ) or kJ/kg mol. rfheat is evolved on mixing, the t:..H sol will be a negative value in Eq. 01.6-1). Often, the heats of solution are small, as in hydrocarbon mixtures, and are neglected. The saturated vapor enthalpy line of H kJ/kg (btullb m ) Or kJ/kg mol of a vapor composition Y A is calculated by (11.6-2)

where c PYA is the vapor heat capacity of A and C PYe for B. The latent heats AA and AB are the values at the reference temperature To. Generally, the latent heat is given as AAb at the normal boiling point T bA of the pure component A and ARb for B. Then to correct this to the reference temperature To to use in Eq. (11.6-2), (11.6-3) (11.6-4)

In Eq. (11.6-3) the pure liquid is heated from To {O T M, vaporized at T bA, and then cooled as a vapor to To. Similarly, Eq. (11.6-4) also holds for As. For convenience, the reference temperature To is often taken as equal to the boiling point of the lowerboiling component A. This means AA = AAb' Hence, only ARb must be corrected to A B · EXAMPLE 11.6-1. Enthalpy-Concentration Plot for Benzene-Toluene Prepare an enthalpy-concentration plot for benzene-toluene at I atm pressure. Equilibrium data are given in Table 11.1-1 and Figs. 11.1-1 and 11.1-2. Physical property data are given in Table 11.6-1. TABLE

11.6-1.

Benzene and Toluene Heat Capacity, (kJlkg mol, K)

Component

(OC)

Liquid

Vapor

Latent Heat of Vaporization (kJlkg mol)

Benzene (A) Toluene (B)

80.1 110.6

138.2 167.5

96.3 138.2

30820 33330

Chap. II

Vapor-Liquid Separation Processes

Boiling Point,

670

Solution: A reference temperature of To 80. IOc will be used for convenience so that the liquid enthalpy of pure benzene (XA = 1.0) at the boiling point will be zero. For the first point we will select pure toluene (x A = 0). For liquid toluene at the boiling point of I 10. 6°C using Eq. (11.6-1) with zero heat of solution and data from Table 11.6-1, h=XACpA(T

h

0+(1

80.l)+(l-XA)C pB(T

0)(167.5)(110.6

(11.6-5)

80.1)+0

80.1)=5109kJlkgmol

For the saturated vapor enthalpy line, Eq. (11.6-2) is used. However, we first must calculate AB at the reference temperature To = 80.l o e using Eq. (11.6-4). AB = cpB(T bB

To) + ASb - cpyB(TbB

(11.6-4)

To)

/

=

167.5(110.6 - 80.1) + 33 330

138.2(110.6 - 80.1)

34 224 k1lkg mol To calculate H, Eq. (11.6-2) is used and Y A = O. H

= Y A[A A =

+ cpyA(T - To)] + (I - YA)[A B +

0 + (1.0

C pyB(T

- To)]

(11.6-2)

0)[34224 + 138.2(110.6 - 80.1)]

= 38 439 kJ/kg mol Forpurebenzene,x A = 1.0andYA = 1.0. UsingEq. (11.6-5), since T = To 80.1, h = O. For the saturated vapor enthalpy, using Eq. (11.6-2) and T 80.1, H

1.0[30 820 + 96.3(80.1

80.1)] + 0

=

30 820

Selecting XA 0.50, the boiling point Tb = 92°C and the temperature of saturated vapor for Y A = 0.50 is 98.8°e from Fig. 11.1-1. Using Eq. (11.6-5) for the saturated liquid enthalpy at the boiling point, h

0.5(138.2)(92 - 80.1) + (I

0.5)(167.5)(92 - 80.1)

1820

Using Eq. (11.6-2) for y,\ = 0.5, the saturated vapor enthalpy at 98.8°e is

H

0.5[30 820 + 96.3(98.8

80.1)] + (1 - 0.5)[34 224

+ 138.2(98.8

80.1)] = 34 716

SelectingxA =0.30andYA 0.30,h = 2920andH 36268. Also, for XA 0.80 and Y A = 0.80, II 562 and H = 32380. These values are . tabulated in Table 11.6-2 and plotted in Fig. 11.6-1. Some properties of the enthalpy-concentration plot are as follows. The region in between the saturated vapor line and the saturated liquid line is the two-phase liquid-vapor region. From Table 11.1-1 for XA = 00411, the vapor in equilibrium is Y A = 0.632. These two points are plotted in Fig. 11.6-1 and this tie line represents the Sec. 1l.6

Fractional Distillation Using Enthalpy-Concentration Method

671

TABLE

11.6-2.

Enthalpy-Concentration Data for Benzene-Toluene Mixtures at Total Pressure 101325 kPa

Saturated Liquid Mole fraction,

XA

Saturated Vapor

Enthalpy, h, (kJlkg mol)

Mole fraction,

5109 2920 1820 562 0

0 0.30 0.50 0.80 1.00

YA

enthalpy, H, (kJlkg mol)

38439 36268 34716 32380 30820

0 0.30 0.50 0.80 1.00

enthalpies and compositions of the liquid and vapor phases in equilibrium. Other tie lines can be drawn in a similar manner. The region below the h versus x A line represents liquid below the boiling point.

1l.6B

Distillation in Enriching Section of Tower

To analyze the enriching section of a fractionating tower using enthalpy-concentration data, we make an overall and a component balance in Fig. 11.6-2.

(11.6-6) (11.6-7)

40000r------,-------.------.------.------~

H vs. YA (saturated vapor)

/

30000~-----+------+-----_4~----4-----~

I

Enthalpy of / tie line mixture, 20000 i'-----t-----+---+--ji'-----t----__j Horh, I I (kJ/kg mol I mixture) I 10000~-----+------__l_~----~----_4------__j

I

I I

h vs. XA (saturated liquid

0.4 0.6 0.8 Mole fraction benzene,YA or XA

0.2

FIGURE

672

11.6-1.

1.0

Enthalpy-concentration plot for benzene-toluene mixture at 1.0 atm abs. Chap. 11

Vapor-Liquid Separation Processes

l~----~~L~,lh~D~----,~Dn,lh~D-x~D~ 2 !--i---"'---i

I I l -

Xw Lw hn n+ II-T---'--l

FIGURE

11.6-2.

Enriching section oj distillation tower.

Equation (11.6-7) can be rearranged to give the enriching-section operating line. Ln Yn+l

=V

Xn n+1

+

DXD Vn+1

(11.6-8)

This is the same as Eq. (11.4-7) for the McCabe-Thiele method, but now the liquid and vapor flow rates V n+ 1 and Lit may vary throughout the tower and Eq. (11.6-8) will not be a straight line on an xy plot. Making an enthalpy balance, (11.6-9)

where q c is the condenser duty, kJIh or kW (btulh). An enthalpy balance can be made just around the condenser. (11.6·10)

By combining Eqs. (11.6-9) and (11.6-10) to eliminate qc' an alternative form is obtained. (11.6·11)

Substituting the value of Ln from Eq. (11.6-6) into (l 1.6-1 l), (11.6-12)

Equations (11.6-8) and (11.6-12) are the final working equations for the enriching section. In order to plot the operating line Eq. (11.6-8), the terms V n + 1 and Ln must be determined from Eq. (11.6-12). If the reflux ratio is set, Viand L are known. The values H I and h D can be determined by Eqs. (11.6-1) and (11.6-2) or from an Sec. 11.6

Fractional Distillation Using Enthalpy-Concentr.ation Method

673

enthalpy-concentration plot. If a value of x n" is selected, it is a trial-and-error solution to obtain H n+ 1 since Yn+ 1 is not known. The steps to follow are given below. I. Select a value of x n' Assume V n + 1 = VI = L + D and L n = L. Then using these values in Eq. (11.6-8), calculate an approximate value of Yn+ l ' This assumes a straight operating line. 2. Using this Yn+ 1, obtain H n + 1 and also obtain h n using x n' Substitute these values into Eq. (11.6-12) and solve for V n + l • Obtain Ln from Eq. (11.6-6). 3. Substitute into Eq. (11.6-8) and solve for Yn+ I' 4. If the calculated value of Yn + 1 does not equal the assumed value of Yn + I, repeat steps 2-3. Generally, a second trial is not needed. Assume another value of Xn and repeat steps 1-4. 5. Plot the curved operating line for the enriching section. Generally, only a few values of the flows L n and V n + 1 are needed to determine the operating line, which is slightly curved.

1l.6C

Distillation in Stripping Section of Tower

To analyze the stripping section of a distillation tower, an overall and a component material balance are made on Fig. 11.4-5a. Lm

=

(11.6-13)

W+ V m+ 1

(11.6-14)

Ym+1

WXw

Lm = -Vm + 1

(11.6-15)

Xm - - V m+1

Making an enthalpy balance with q R kJ/h or kW(btulh) entering the reboiler in Fig. 11.4-5a and substituting (Vm+ 1+ W) for Lm from Eq. (11.6-13), (11.6-16)

Making an overall enthalpy balance in Fig. 11.4-3, (11.6-17)

The final working equations to use are Eqs. (11.6-15)-(11.6-17). Using a method similar to that for the enriching section to solve the equations, select a value ofYm+1 and calculate an approximate value of Xm from Eq. (11.6-15) assuming constant molal overflow. Then calculate V m + 1 and L m from Eqs. (11.6-16) and (11.6-13). Then use Eq. (11.6-15) to determine X m . Compare this calculated value of x m with the assumed value. EXAMPLE 11.6-2.

Distillation Using Enthalpy-Concentration Method

A liquid mixture of benzene-toluene is being distilled using the same conditions as in Example 11.4-1 except that a reflux ratio of 1.5 times the minimum reflux ratio is to be used. The value of R m = 1.17 from Example 11.4-2 will be used. Use enthalpy balances to calculate the flow rates of the liquid and vapor at various points in the tower and plot the curved operating lines. Determine the number of theoretical stages needed.

674

Chap. J I

Vapor~Liquid

Separarion Processes

Solution: The given data are as follows: F = 100 kg mollh, XF ::: 0.45, Xv = 0.95,xw = O.lO,R = 1.5 Rm 1.5(1.17) 1.755,D = 41.2 kg mollh, W == 58.8 kg mollh. The feed enters at 54.4°C and q= 1.195. The Rows at the top of the tower are calculated as follows. L

-:=: 1.755; D

L = 1. 755(41. 2) = 72.3;

VI

L+D

72.3

+ 41.2 The saturation temp~rature at the top of the tower for Y I 0.95 is 82.3°C from Fig. 11.1-1. Using Eq. (11.6-2),

113.5

.xD

=

HI = 0.95(30 820 + 96.3(82.3 - 80.1)] + (1 - 0.95)[34 224

+ 138.2(82.3

80.1)]

31 206

This value of 31 206 could also have been obtained from the enthalpyconcentration plot, Fig. 11.6-1. The boiling point of the distillate D is obtained from Fig. lLl-1 and is 8LloC. Using Eq. (11.6-5), hD

0.95(138.2)(81.1 - 80.1) + (1 - 0.95)(167.5)(81.1 - 80.1)

139

Again this value could have been obtained from Fig. 11.6-1. Following the procedure outlined for the enriching section for step 1. a value of Xn =0.55 is selected. Assuming a straight operating line for Eq. (11.6-8), an approximate value of Y n+ I is obtained. 41.2

72.3 - - Xn

Yn+1

113.5

+ - - (0.95) = 0.637(x n ) + 0.345 113.5

0.}l:37(0.55) + 0.345

0.695

1l.6-1,forx n = 0.55,hn = 1590 and Starting with step 2 and using 0.695, Hn+1 = 33 240. Substituting into Eq. (11.6-12) and for Yn+l solving, V,,+1(33 240):=:

41.2)1590 + 113.5(31 206)

(Vn+I

72.3(139)

109.5

Vn+l

Using Eq. (1\.6-6),

109.5

Ln + 41.2

For step 3, substituting into Yn+l

=

or

L"

68.3

(I l.6-8) ,

4'1.2 (0.55) + - - (0.95) = 0.700 109.5 109.5 68.3

This calculated value of Y n+ 1=0.700 is sufficiently close to the approxi· mate value of 0.695 so that no further trials are needed. Sec. J J.6

Fractional Distillation Using Enthalpy-Concentration Method

675

Selecting another value for x nO. 70 and using Eq. (11.6-8), an approximate value of Yn+ I is calculated. 72.3

= 113.5

Yn+l

41.2 (0.70) + 113.5 (0.95)

= 0.791

Using Fig. 11.6-1 for xn 0.70, h n 1000, and for Yn+1 = 0.791, 32 500. Substituting into Eq. (11.6-12) and solving,

H n+ I

(Vn+I-41.2)1000+ 113.5(31206)

V n + I (32500) Vn + 1

72.3(139)

110.8

Using Eq. (11.6-6), Ln

= 110.8

41.2

69.6

=

Substituting into Eq. 11.6-8), Yn+!

69.6

41.2

110.8

110.8

= - - (0.70) +

(0.95)

= 0.793

In Fig. 11.6-3, the points for the curved operating line in the enriching section are plotted. This line is approximately straight and is very slightly above that for constant molal overflow. 1.0

,-----.,..----.,------r-----,------:""

0.81----1--

Mole fraction in vapor, y

0.6

1------+------,Io'-l-;;O

~

I

-0 ~

~

I

t>O

~

~

I

I I 1.1.- tie 'hne

I N

!-tie line I

I

I 0

1.0

0

1.0

VS. YA

II

I

fI I f

I

II

I J

I f f . I

N vs. XA

XA. YA

1.0

1.0

YA

YA

1.0 (b)

(a) FIGURE

12.9-1.

Several typical equilibrium diagrams: (a) case for verCical lie lines and y" = x", (b) case where y" oF x" for £fe lines.

balance equations are almost identical to Eqs. (12.5-12)-{12.5-14) for single-stage liquidliquid extraction and are as follows for a total solution balance (solute A + solvent C), a component balance on A, and a solids balance on B, respectively. Lo Lo Y.40

+

+

V2

LI

+

V2 XA2

LIYAI

+0

NIL I

B = NoLo

VI

=

M

+ VIX A 1 MXAM + 0 = N MM

(12.9-4) (12.9-5) (12.9-6)

where M is the total flow rate in A + C/h andx AM and NM are the coordinates of this point M. A balance on C is not needed, since XA + Xc 1.0 and YA + Yc = 1.0. As shown before, L 1 M VI must lie on a straigh t line and Lo M V2 must also lie on a straight line. This is shown in Fig. 12.9-2b. Also, LI and VI must lie on the vertical tie line. The point M is the intersection of the two lines. If Lo entering is the fresh solid feed to be leached with no solvent C present, it would be located above the N versus y line in Fig. 12.9-2b.

EXAMPLE 12.9-1. Single-Stage Leaching of Flaked Soybeans In a single-stage leaching of soybean oil from flaked soybeans with hexane, 100 kg of soybeans containing 20 wt % oil is leached with 100 kg of fresh hexane solvent. The value of N for the slurry underflow is essentially constant at 1.5 kg insoluble solid/kg solution retained. Calculate the amounts and compositions of the overflow VI and the underflow slurry LI lea ving the stage. Solution: The process flow diagram is the same as given in Fig. 12.9-2a. The known process variables are as follows. Sec. 12.9

Equilibrium Relations and Single-Stage Leaching

731

NVS'YA

I ~

Vb

V2 ,

Xl

I

X2

N

a

NM

slurry

slurry

L l • N 1 , y., B

L o• No. Yo. B

V2 XAM

(a)

YA,xA

(b) FIGURE

12.9-2.

Process flow and material balance for single-stage leaching: (a) process flow, (b) material balance.

The entering solvent flow V2 100 kg, X,12 = 0, xcz = 1.0. For the entering slurry stream, B 100(1.0 0.2) = 80 kg insoluble solid, Lo = 100(1.0 0.8) = 20 kg A, No 80/20 4.0 kg solid/kg solution, y,4O = 1.0. To calculate the location of M, substituting into Eqs. (12.9-4), (12.9-5), and (12.9-6) and solving,

+ V2 = 20 + 100 + VZx AZ = 20(1.0) + Lo

LOYAO

120 kg 100(0)

=

M 120x AM

Hence'X AM = 0.167.

B

NoLo

NM

0.667

4.0(20)

80

=. NM (120)

The point M is plotted in Fig. 12.9-3 along with Vz andL o . The vertical tie line is drawn locating Ll and VI in equilibrium with each other. Then N 1 = 1.5, YAI = 0.167, X A1 0.167. Substituting into Eqs. (12.9-4) and (12.9-6) and solving or using the lever-arm rule, Ll = 53.3 kg and Vt = 66.7 kg. 4.-----------------------~Lo

3

N

2

N vs. xA 1.0

FIGURE

732

12.9-3.

Graphical solution ofsingle-stage leachingfor Example 12.9-1.

Chap. 12

Liquid-Liquid and Fluid-Solid Separation Processes

II I

l

12.10 COUNTERCURRENT MULTISTAGE .LEACHING 12.10A

Introduction and Operati~g'iine for Countercurrent Leaching

A process flow sheet for countercurrent multistage leaching is shown in Fig. 12.10-1 and is similar to Fig. 12.7-1 for liquid-liquid extraction. The ideal stages are numbered in the direction of the solids or underflow stream. The solvent (C}-solute (A) phase or V phase is the liquid phase that overflows continuously from stage to stage countercurrently to the solid phase, and it dissolves solute as it moves along. The slurry phase L composed of inert solids (B) and a liquid phase of A and C is the continuous underflow from each stage. Note that the composition of the V phase is denoted by x and the composition of the L phase by y, which is the reverse of that for liquid-liquid extraction. It is assumed that the solid B is insoluble and is not lost in the liquid V phase. The flow rate of the solids is constant throughout the cascade of stages. As in the single-stage leaching V is kglh (lblT/h) of overflow solution and L is kgfh of liquid solution in the slurry retained by the solid. ' In order to derive the operating-line equation, an overall baJance and a component balance on solute A is made over the first n stages. (12.10-1) (12.10-2) Solving for x.+ I and eliminating

v" + [. (12.10-3)

The operating-line equation (12.10-3) when plotted on an xy plot passes through the terminal points Xl. Yo andx N + I' YN' In the leaching process, if the viscosity and density of the solution changes appreciably with the solute (A) concentration, the solids from the lower-numbered stages where solute concentrations are high may retain more liquid solution than the solids from the higher-numbered stages. where the solute concentration is dilute. Then L., the liquid retained in the solids underflow. will vary and the slope of Eq. (12.10-3) will vary from stage to stage. This condition of variable underflow will be considered first. The overflow will also vary. If the amount of solution Ln retained by the solid is constant and independent of concentration, then constant underflow occurs. This simplifies somewhat the stage-to-stage calculations. This case will be considered later. exit overflow

leaching solvent

V2

VI

V)

['

Xl

2

Yo, No Lo,Bo

LI feed solids

L2

VN

.D~n+l

Ln- 1

Ln

.1

V N +1 XN+l N

LN- 1

underflow stream FIGURE 12.1()...1.

Sec. 12.10

Vn

YN, NN LN,B

leached solids

Process flow Jor countercurrent multistage leaching.

Countercurrent Multistage Leaching

733

12.10B

Variable Underflow in Countercurrent Multistage Leaching

The methods in this section are very similar to those used in Section 12.7B for countercurrent solvent extraction, where the L and V flow rates varied from stage to stage. Making an overall total solution (solute A + solvent C) balance on the process of Fig. 12.10-1,

(12.10-4) + VN+ 1= LN + VI = M where M is the total mixture flow rate in kg A + C/h. Next making a component balance Lo

on A, (12.10-5) Making a total solids balance on B,

B = No Lo = N NLN

=

NM M

(12.10-6)

,

where N.1l and -'AM are the coordinates of point M shown in Fig. 12.10-2, which is the operating diagram for the process. As shown previously Lo MVN + I must lie on a straight line and VI M L", must be on a straight line. Usually the flows and compositions of Lo and V:... + I are known and the desired exit concentration Y AN is set. Then the coordinates N M and X AM can be calculated from Eqs. (12.1O-4}-{12.1O-6) and point M plotted. ThenL N , M, and VI must lie on one line as shown in Fig. 12.10-2. In order to go stage by stage on Fig. 12.1 0-2, we must derive the operating-poin t

FIGURE

734

12.10-2.

Number

0/ stages/or

Chap. 12

mllitistage countercurrent leaching.

Liquid-Liquid and Fluid-Solid Separation Processes

equation. Making a total balance on stage 1 and than on stage n, La

+ Vz

LI

+

(12.10-7)

VI

(12.10-8) Rearranging Eq. (12.1 0-7) for the difference flows Ll in kg/h, La

VI

(12.10-9)

LI - Vz = Ll

This val ue Ll is constant and also holds for Eq. (12.10-8) rearranged and for all stages. (12.10-10) This can also be written for a balance on solute A to give LOYAo

VIX AI

LNYAN

VN+IXAN+I

LN - VN + I

Lo - VI

(12.10-11)

where x A~ is the x coordinate of the operating point Ll. A balance given on solids gives

B

N~=---

Lo

VI

NoLo

Lo

(12.10-12)

VI

where N ~ is the N coordinate of the operating point Ll. As shown in Section 12.7B, Ll is the operating point. This point Ll is located graphically in Fig. 12JO-2 as the intersection of lines Lo VI and LN VN+ I' From Eq. (12.10-10) we see that VI is on a line between-Lo and Ll, Vz is on a line between LI and Ll, V,,+ I is on a line between L. and Ll, and so on. To graphically determine the number of stages, we start at Lo and draw line Lo Ll to locate VI' A tie line through VI locates L I. Line LI Ll is drawn given Vz . A tie line gives L z . This is continued until the desired LN is reached. In Fig. 12.10-2, about 3.5 stages are required.

EXAMPLE 12.10-1.

Countercurrent Leaching o/Oilfrom Meal

A continuous countercurrent multistage system is to be used to leach oil from meal by benzene solven t (il3). The process is to treat 2000 kg/h of inert solid meal (8) containing 800 kg oil (A) and also 50 kg benzene (C). The inlet flow per hour of fresh solvent mixture contains 13lO kg benzene and 20 kg oil. The leached solids are to contain 120 kg oil. Settling experiments similar to those in the actual extractor show that the solution retained depends upon the concentration of oil in the solution. The data (B3) are tabulated below as N kg inert solid 8jkg solution and YA kg oil Ajkg solution. N

YA

N

YA

2.00 1.98 1.94 1.89

0 0.1 0.2 0.3

1.82 1.75 1.68 1.61

0.4 0.5 0.6

0_7

Calculate the amounts and concentrations of the stream leaving the process and the number of stages required.

Solution: The underflow data from the table are plotted in Fig. 12.10-3 as N versus YA' For the inlet solution with the untreated solid, Lo = 800 + Sec. 12./0

Countercurrent Multistage Leaching

735

NVS'YA

3

-7 FIGURE

Graphical construction for number of stages for Example J2.10-1.

12.10-3.

50 = 850 kg,lh, YAO 800/(800 + 50) = 0.941, B = 2000 kgfh, No = 2000/(800 + 50) = 2.36. For the inlet leaching solvent, VN + I 1310 + 20 = 1330 kg,lh and X AN + I 20/1330 = 0.015. The points VN + I and Lo are plotted. The point LN lies on the N versus YA line in Fig. 12.10"3. Also for this point, the ratio N N/Y,J,N (kg solid/kg solution)/(kg oil/kg solution) = kg solid/kg oil = 2000/120 16.67. Hence, a dashed line through the origin at YA = 0 and N = 0 is plotted with a slope of 16.67, which intersects the N versus YA line at LN' The coordinates of LN at this intersection are N N = 1.95 kg solid/kg solution and YAN 0.118 kg oil/kg solution. Making an overall balance by substituting into Eq. (12.10-4) to determine point M,

Lo

+ V:V+ 1

850

+ 1330 =

2180 kg,lh

M

Substituting into Eq. (12.10-5) and solving, La YAO

+

VN +

lX AN

850(0.941)

+1

+ 1330(0.015)

2180x AM

0.376

X AM

Substituting into Eq. (12.10-6) and solving,

B

2000

NM M

=

N M (2180)

NM

0.918

The point M is plotted with the coordinates X AM = 0.376 and N M = 0.918 in Fig. 12.10-3. The line VN+IML o is drawn, as is line LNM, which intersects the abscissa at point VI where X A I = 0.600. The amounts of streams VI and LN are calculated by substituting into Eqs. (12.10-4) and (12.10-5), and solving simultaneously.

L.., YAN

LN+VI

M=2180

+

LN{O.l18)

VIX AI

+

V1(0.600)

2180(0.376)

Hence, LN = 1016 kg solution/h in the outlet underflow stream and VI = 1164 kg solutionfh in the exit overflow stream. Alternatively, the amoun'ts could have been calculated using the lever-arm rule. The operating point ,1 is obtained as the intersection of lines La VI and 736

Chap. 12

Liquid-Liquid and Fluid-Solid Separation Processes

LN VN+ I in Fig. 12.10-3. Its coordinates can also be calculated from Eqs. (12.10-11) and (12.10-12). The stages are stepped off as shown. The fourth stage for L4 is slightly past the desired LN' Hence, about 3.9 stages are required.

12.lOC

Constant Underflow in Countercurrent Multistage Leaching

In this case the liquid Ln retained in the underflow solids is constant from stage to stage. This means that a plot of N versus YA is a horizontal straight line and N is constant. Then the operating-line equation (12.10-3) is a straight line when plotted as YA versus x A' The equilibrium line can also be plotted on the same diagram. In many cases the equilibrium line may also be straight with YA x A • Special treatment must be given the first stage, however, since Lo is generally not equal to Ln, since it contains little or no solvent. A separate material and equilibrium balance is made on stage 1 to obtain L J and Vz (see Fig. 12.10-1). Then the straight operating line can be used and the McCabe-Thiele method used to step off the number of stages. Since this procedure for constant underflow requires almost as many calculations as the general case fo~ variable underflow, the general procedure can be used for constant underflow by simply using a horizontal line of N versus Y A in Fig. 12.10-2 and stepping off the stages with the 6 point.

12.11

12.llA

I !

I

INTRODUCfION AND EQUIPMENT FOR CRYSTALLIZATION Crystallization and Types of Crystals.

1. Introduction. Separation processes for gas-liquid and liquid-liquid systems have been treated in this and previous chapters. Also, the separation process of leaching was discussed for a solid-liquid system. Crystallization is also a solid-liquid separation process in which mass transfer occurs of a solute from the liquid solution to a pure solid crystalline phase. An important example is in the production of sucrose from sugar beet, where the sucrose is crystallized out from an aqueous solution. Crystallization is a process where solid particles are formed from a homogeneous phase. This process can occur in the freezing of water to form ice, in the formation of snow particles from a vapor, in the formation of solid particles from a liquid melt, or in the formation of solid crystals from a Jiq uid solution. The last process mentioned, crystallization from a solution, is the most important one commercially and will be treated in the present discussion. In crystallization the solution is concentrated and usually cooled until the solute concentration becomes greater than its solubility at that temperature. Then the solute comes out of the solution forming crystals of approximately pure solute. In commercial crystallization the yield and purity of crystals are not only important but also the sizes and shapes of the crystals. It is often desirable that crystals be uniform in size. Size uniformity is desirable to minimize caking in the package, for ease of pouring, for ease in washing and filtering, and for uniform behavior when used. Sometimes large crystals are requested by the purchaser, even though smaller crystals are just as useful. Also, crystals of a certain shape are sometimes required, such as needles rather than cubes. Sec. 12.Il

Introduction and Equipmenl for Crystalliz.ation

737

2. Types of crystal geometry. A crystal can be defined as a solid composed of atoms, ions, or molecules, which are arranged in an orderly and repetitive manner. It is a highly organized type of matter. The atoms, ions, or molecules are located in three-dimensional arrays or space lattices. The interatomic distances in a crystal between these imaginary planes or space lattices are measured by x-ray diffraction as are the angles between these planes. The pattern or arrangement of these space lattices is repeated in ail directions. Crystals appear as polyhedrons having flat faces and sharp corners. The relative sizes of the faces and edges of different crystals of the same material may differ greatly. However, the angles between the corresponding faces of all crystals of the same material are equal and are characteristic of that particular material. Crystals are thus classified on the basis of these interfacial angles. There are seven classes of crystals, depending upon the arrangement of the axes to which the angles are referred: 1. Cubic system. Three equal axes at right angles to each other. 2. Tetragonal system. Three axes at right angles to each other, one axis longer than the other two. 3. Orthorhombic system. Three axes at right angles to each other, all of different lengths. 4. Hexagonal system. Three equal axes in one plane at 60° to each other, and a fourth axis at right angles to this plane and not necessarily the same length. 5. Monoclinic system. Three unequal axes, two at right angles in a plane and a third at some angle to this plane. 6. Triclinic system. Three unequal axes at unequal angles to each other and not 30,60, or 90°. 7. Trigonal system. Three equal and equally inclined axes.

The relative development of different types of faces of a crystal may differ for a given solute crystallizing. Sodium chloride crystallizes from aqueous solutions with cubic faces only. In another case, if sodium chloride crystallizes fmm an aqueous solution with a given slight impurity present, the crystals will have octahedral faces. Both types of crystals are in the cubic system but differ in crystal habit. The crystallization in overall shapes of plates or needles has no relation to crystal habit or crystal system and usually depends upon the process conditions under which the crystals are grown.

n.ll B Equilibrium Solubility in Crystallization In crystallization equilibrium is attained when the solution or mother liquor is saturated. This is represented by a solubility curve. Solubility is dependent mainly upon temperature. Pressure has a negligible effect on solubility. Solubility data are given in the form of curves where solubilities in some convenient units are plotted versus temperature. Tables of solubilities are given in many chemical handbooks (P 1). Solubility curves for some typical salts in water were given in Fig. 8.1-1. In general, the solubilities of most salts increase slightly or markedly with increasing temperature. A very common type of curve is shown in Fig. 8.1-1 for KN0 3 , where the solubility increases markedly with temperature and there are no hydrates. Over the whole range of temperatures, the solid phase is KN0 3 • The solubility of NaCI is marked by its small change with temperature. In solubility plots the solubility data are ordinarily given as parts by weight of anhydrous material per 100 parts by weight of total solvent (i.e., water in many cases). In Fig. 1211-1 the solubility curve is shown for sodium thiosulfate, Na ZS Z 0 3 • The solubility increases rapidly with temperature, but there are definite breaks in the curve 738

Chap. 12

Liquid-Liquid and Fluid-Solid Separation Processes

which indicate different hydrates. The stable phase up to 4S.2°C is the pentahydrate Na Z SZ 0 3 • 5H 2 0. This means that at concentrations above the solubility line (up to 4S.2"C), the solid crystals formed are Na Z S 2 0 3 ' 5H 2 0. At concentrations below the solubility line, only a solution exists. From 48.2 to about 65°C,. the stable phase is Na ZS Z 0 3 • 2H zO. A half-hydrate is present between 65 to 70"C, and the anhydrous salt is the stable phase above 70°C. 12.llC

Yields and Ileat and Material Balances in Crystalliza tion

1. Yields and material balances in crystallization. In most of the industrial crystallization processes, the solution (mother liquor) and the solid crystals are in contact for a long enough time to reach equilibrium. Hence, the mother liquor is saturated at the final temperature of the process, and the final concentration of the solute in the solution can be obtained from the solubility curve. The yield of crystals from a crystallization process can then be calculated knowing the initial concentration of solute, the final temperature, and the solubility at this temperature. In some instances in commercial crystallization, the rate of crystal growth may be quite slow, due to a very viscous solution or a small surface of crystals exposed to the solution. Hence, some supersaturation may still exist, giving a lower yield of crystals than predicted. In making the material balances, the calculations are straightforward when the solute crystals are anhydrous. Simple water and solute material balances are made. When the crystals are hydrated, some of the water in the solution is removed with the crystals as a hydrate. EXAMPLE 12.11-1. Yield oJa Crystallization Process A salt solution weighing 10 000 kg with 30 wt % Na ZC0 3 is cooled to 293 K (20°C). The salt crystallizes as the decahydrate. What will be the yield of NazCO) . lOHzO crystals if the solubility is 21.5 kg anhydrous Na 2 C0 3 /lOO kg of total water? Do this for the following cases. (a) Assume that no water is evaporated. (b) Assume that 3% of the total weight of the solution IS lost by evaporation of water in cooling.

240

two-phase liquidsolid region

(/)

;:l"""

8 0N

NazSz 0 3 Na2 S2 0 3 .1/2 H2 0

200

'0

»:I:

..C!/){)

;;~

00 0

---

~o '-'

»

10 kg NaCI is in 1004 kg solution/m 3 (PI 1004). Then, 1004 - 10 = 994 kg HlO in 1 m 3 solution. Hence, in the feed solution where the molecular weight of NaCI = 58.45, (10.00 x 1000)/(994 x 58.45) = 0.1721g mol NaCI/kg H 2 0. From Table 13.9-1, 7TJ = 7.80 atm by linear interpolation. Substituting into Eq. (13.9-1), the predicted 7TJ = 8.39 atm, which is higher than the experimental value. For the product solution, 997 - 0.39 996.6 kg H 20. Hence, (0.39 x 1000)/(996.6 x 58.45) = 0.00670g mol NaCI{kg H 2 0. From Table 13.9-1,7T2 0.32atm.Then,t:..7T=7Tl 7T2 7.80-.0.32 = 7.48 atm and I1P = 54.42 atm. Substituting into Eq. (13.9-2), N w = 9.57

X

10- 3

I1n)

~w (54.42 -

7.48)

m

Solving (P.JL m ) = Aw tuting into Eq. (13.9-5),

=

N s =3.744x 10- 6

2.039

X

DsKs( ---r:-

10- 4 kg solvent/s·m 2 • atm. Substi-

CI -

C2

Solving,(DsKJLm) Sec. 13.9

As

---r:- .

) = DsKs(1000

m

0.39)

m

3.896 x 10- 7 m/s.

Reverse-Osmosis Membrane Processes

787

To calculate the solute- rejection R by substituting into Eq. (13.9-8), R

= ~C-l-=. = 1O·~0~0.39 = 0.961

Also substituting into Eq. (13.9-10) and then Eq. (13.9-9), 2.039 X 10- 4 (3.896 x 10 7)997 R

B(~P

1+

- ~n;) B(t.,P - ~7r)

0.5249 atm -

0.5249(54.42 - 7.48) 1 + 0.5249(54.42 - 7.48)

=

1

0.961

13.10 APPLICATIONS, EQUIPMENT, AND MODELS FOR REVERSE OSMOSIS 13.10A Effects of Operating Variables In many commercial units operating pressures in reverse osmosis range from about 1035 up to 10 350 kPa (150 up to 1500 psi). Comparison of Eq. (13.9-2) for solvent flux and Eq. (13.9-5) for solute flux shows that the solvent flux N w depends only on the net pressure difference, while the solute flux N. depends only on the concentration difference. Hence, as the feed pressure is increased, solvent or water flow through the membrane increases and the solute flow remains approximately constant, giving lower solute concentration in the product solution. At a constant applied pressure, increasing the feed solute concentration increases the product solute concentration. This is caused by the increase in the feed osmotic pressure, since as more solvent is extracted from the feed solution (as water recovery increases), the solute concentration becomes higher and the water flux decreases. Also, the amount of solute present in the product solution increases because of the higher feed concentration. If a reverse-osmosis unit has a large membrane area (as in a commercial unit), and the path between the feed inlet and outlet is long, the outlet feed concentration can be considerably higher than the inlet feed C I' Then the salt flux will be greater at the outlet feed compared to the inlet (K2). Many manufacturers use the feed solute or salt concentration average between inlet and outlet to calculate the solute or salt rejection R in Eq. (13.9-8). EXAMPLE 13.10-1.

Prediction of PeifoT7TlClnce in a Reverse-Osmosis Unit A reverse-osmosis membrane to be used at 25°C for a NaCl feed solution containing 2.5 g NaCI/L (2.5 kg NaCl/m 3 , P 999 kg/m 3 ) has a water permeability constant Aw = 4.81 X 10- 4 kg/s' m 2 • atm and a solute (NaCl) permeability constant As = 4.42 X 10- 7 m/s (A I). Calculate the water flux and solute flux through the membrane using a ~P 27.20 atm and the solute rejection R. Also calculate C 2 of the product solution. Solution: In the feed solution, C I = 2.5 kg NaCl/m 3 and PI = 999 kg solution/m 3 • Hence, for the feed, 999 2.5 = 996.5 kg H 2 0 in 1.0 m 3 solution; also for the feed, (2.50 x 1000)/(996.5 x 58.45) 0.04292 g mol NaClJkg H 2 0. From Table 13.9-1, 7T] 1.97 atm. Since the product solution C2 is unknown, a value of C 2 0.1 kg NaCl/m 3 will be assumed. Also, since this is quite dilute, Pz = 997 kg solution/m 3 and C~ 997kg solventlm 3 . Then for the product solution, (0.10 X 1000)1 (996.9 x 58.45) 0.00172 g mol NaCI/kg H 2 0 and 1[2 0.08 atm. Also, t.,7r 7r 1 - 7r 2 1.97 0.08 = 1.89 atm. 788

Chap. 13

Membrane Separation Processes

I

i

t I

I I

1!

!

Substituting into Eq. (13.9-2), Nw

Aw (liP - Lin) :;;: 4.81 x 10- 4 (27.20 - 1.89) = 1.217

x 10- 2 kg H 2 0/;'m 2

For calculation of R, substituting first into Eq. (13.9-1O), B=

4.81 x 10- 4

x 997

A,c w2

1.092 atm - 1

Next substituting into Eq. (13.9-9), R

=

B(LiP - Lin) 1 + B(LiP - Lin)

1.092(27.20 - 1.89) = 0.965 1 + 1.092(27.20 - 1.89)

Using this value of R in Eq. (13.9-8), R

0.965

2.50 - c 2 2.50

Solving, C 2 = 0.0875 kg NaCI/m 3 for the product solution. This is close enough to the assumed value of C 2 = 0.10 so that n 2 will not change significantly on a second triaL Hence, the final value of C 2 is 0.0875 kg NaCljm 3 (0.0875 g NaCljL}. Substituting into Eq. (13.9-5),

Ns

A,(c 1

c2)

= 4.42

x 10- 7 (2.50

0.0875)

= 1.066 x 10- kg NaCl/s' m 2 6

13.10B

1

!

Concentration Polarization in Reverse-Osmosis Diffusion Model

In desalination, localized concentrations of solute build up at the point where the solvent leaves the solution and enters the membrane. The solute accumulates in a relatively stable boundary layer (Fig. 13.9-3) next to the membrane. Concentration polarization, {3, is defined as the ratio of the salt concentration at the membrane surface to the salt concentration in the bulk feed stream c I' Concentration polarization causes the water flux to decrease since the osmotic pressure 1T1 increases as the boundary layer concentration increases and the overal! driving force (liP - !:::'1T) decreases. Also, the solute flux increases since the solute concentration increases at the boundary. Hence, often the !:::.P must be increased to compensate which gives higher power costs (K2). The effect of the concentration polarization {3 can be included approximately by modifying the value of !:::.1T in Eqs. (13.9-2) and (13.9-9) as follows (P6):

1

(13.10-1)

I

i 1

I

I

t

It is assumed that the osmotic pressure 1T1 is directly proportional to the concentration, which is approximately correct. Also, Eq. (13.9-5) can be modified as

(13.10-2) The usual concentration polarization ratio (K3) is 1.2 to 2.0, I.e., the concentration in the boundary layer is 1.2 to 2.0 times C I in the bulk feed solution. This ratio is often difficult to predict. In desalination of seawater using values of about 1000 psia = liP, n 1 can be large. Increasing this n 1 by a factor of 1.2 to 2.0 can appreciably reduce the Sec. 13./0

Applications, Equipment, and Models for Reverse Osmosis

189

solvent flux. For brackish waters contammg 2 to 10 gIL and using !sP values of 17 to 55 atm abs, the value of 11: 1 is low and concentration polarization is not important. The boundary layer can be reduced by increasing the turbulence using higher feed solution velocities. However, this extra flow results in a smaller ratio of product solution to feed. Also, screens can be put in the How path to induce turbulence. 13.10C

Permeability Constants of Reverse-Osmosis Membranes

Permeability constants for membranes must be determined experimentally for the particular type of membrane to be used. For cellulose acetate membranes, typical water permeability constants Aw range from about 1 x 10- 4 to 5 X 10- 4 kg solventsls ·m 2 ·atm (AI, M3, WI). Values for other types of membranes can differ widely. Generally, the water permeability constant for a particular membrane does not depend upon the solute present. For the solute permeability constants As of cellulose acetate membranes, some relative typical values are as follows, assuming a value of As 4 x 10-7 m/s for NaCl: 1.6 x 10- 7 mJs (BaCI 2), 2.2 x 10-7 (MgCl z), 2.4 x 10-7 (CaCI 2), 4.0 x 10- 7 (Na2S04)' 6.0 x 10-7 (KCl), 6.0 x 10- 7 (NH 4 CI) (Al). 13.10D Types of Equipment for Reverse Osmosis

The equipment fo~ reverse osmosis is quite simnar to that for gas permeation membrane processes described in Section 13.3C. In the plate-and-frame type unit, thin plastic support plates with thin grooves are covered on both sides with membranes as in a filter press. Pressurized feed solution flows between the closely spaced membranes (Ll). Solvent permeates through the membrane and flows in the grooves to an outlet. In the tubular-type unit, membranes in the form of tubes are inserted inside poroustube casings, which serve as a pressure vessel. These tubes are then arranged in bundles like a heat exchanger. ' In the spiral-wound type, a planar membrane is used and a flat, porous support material is sandwiched between the membranes. Then the membranes, support, and a mesh feed-side spacer are wrapped in a spiral around a tube, In the hollow-fiber type, fibers of 100 to 200 /-Lm diameter with walls about 25 /-Lm thick are arranged in a bundle similar to a heat exchanger (Ll, RI), B.IOE Complete-Mixing Model for Reverse Osmosis The process flow diagram for the complete-mixing model is shown in Fig. 13.10-1. The model is a simplified one for use with low concentrations of salt of about I% or so such

f eedin

reject out (exit fee d)

I co

c1

qf,cf

t

t

permeate out FIGURE 13.10-1. 790

t

t

c2

~

q2

t

ql

(1-0)

c1

8qf

Process flow for complete-mixing model for reverse osmosis. Chap. 13

Membrane Separation Processes

I

as occur in brackish waters. Also, a relatively low recovery of solvent occurs and the effects of concentration polarization are small. Since the concentration of the permeate is very low, the permeate side acts as though it were completely mixed. For the overall material balance for dilute solutions, (13.10-3)

where q, is volumetric flow rate of feed, m 3 /s; qz is flow rate of permeate, m 3 /s; and 3 ql is flow rate of residue or exit, m /s. Making a solute balance, (13.10-4)

Defining the cut or fraction of solvent recovered as 6

!

= qzlq"

Eq. (13.10-4) becomes (13.10-5)

The previous equations derived for the fluxes and rejection are useful in this case and are. as follows: N w == Az(LlP - Ll1T) (13.9-2) (13.9-5)

Ns == AAcl - cz) R

CI

c2

(13.9-8)

ci

R

B(LlP

1 + B(LlP

Ll1T ) Ll1T)

(13.9-9)

When the cut or fraction recovered, 6, is specified the solution is trial and error. Since the permeate and reject concentrations C I and C2 are unknown, a value of C2 is assumed. Then C I is calculated from Eq. (13.10-5). Next N w is obtained from Eq. (13.9-2) and c2 from Eqs. (13.9-8) and (13.9-9). If the calculated value of C2 does not equal the assumed value, the procedure is repeated. When concentration polarization effects are present an estimated value of f3 can be used to make an approximate correction for this effect. This is used in Eq. (13.IO-i) to obtain a value of t::..1T for use in Eqs. (13.9-2) and (13.9-9). Also, Eq. (13.10-2) will replace Eq. (13.9-5). A more detailed analysis of this complete mixing model is given by others (H [, K 1) in which the mass transfer coefficient in the concentration polarization boundary layer is used. The cross-flow model for reverse osmosis is similar to that for gas separation by membranes discussed in Section 13.6. Because of the small solute concentration, the penneate side acts as if completely mixed. Hence, even if the module is designed for countercurrent or cocurrent flow, the cross-flow model is valid. This is discussed in detail elsewhere (HI). 13.11

ULTRAFILTRATION MEMBRANE PROCESSES

13.11 A Introduction Ultrafiltration is a membrane process that is quite similar to reverse osmosis. It is a pressure-driven process where the solvent and, when present, small solute molecules pass through the membrane and are collected as a permeate. Larger solute molecules Sec. n.ll

Ultrafiltration Membrane Processes

791

do not pass through the membrane and are recovered in a concentrated solution. The solutes or molecules to be separated generally have molecular weights greater than 500 and up to 1 000 000 or more. such as macromolecules of proteins, polymers, and starches and also colloidal dispersions of clays, latex particles, and microorganisms. Unlike reverse osmosis, ultrafiltration membranes are too porous to be used for desalting. The rejection, often called retention, is also given by Eq. (13.9-8), which is defined for reverse osmosis. Ultrafiltration is also used to separate a mixture of different molecular weight proteins. The molecular weight cut-off of the membrane is defined as the molecular weight of globular proteins, which are 90% retained by the membrane. Ultrafiltration is used in many different processes at the present time. Some of these are separation of oil-water emulsions, concentration of latex particles, processing of blood and plasma, fractionation or separation of proteins, recovery of whey proteins in cheese manufacturing, removal of bacteria and other particles to sterilize wine, and clarification of fruit juices. Membranes for ultrafiltration are in general similar to those for reverse osmosis and are commonly asymmetric and more porous. The membrane consists of a very thin dense skin supported by a relatively porous layer for strength. Membranes are made from aromatic polyamides, cellulose acetate, cellulose nitrate, polycarbonate, polyimides, polysuifone, etc. (M2, P6, R 1). l3.11B

Types of Equipment for Ultrafiltration

The equipment for ultrafiltration is similar to that used for reverse osmosis and gas separation processes described in Sections 13.3C and 13.lOD. The tubular type unit is less prone to foul and is more easily cleaned than any of the other three types. However, this type is relatively costly. Flat sheet membranes in a plate-and-frame unit offer the greatest versatility but at the highest capital cost (P6). Membranes can easily be cleaned or replaced by disassembly of the unit. Spiral-wound modules provide relatively low costs per unit membrane area. These units are more prone to foul than tubular units but are more resistant to fouling than hollow-fiber units. Hollow-fiber modules are the least resistant to fouling when compared to the three other types. However, the hollow-fiber configuration has the highest ratio of membrane area per unit volume. l3.11e

Flux Equations for Ultrafiltration

The flux equation for diffusion of solvent through the membrane is the same as Eq. (13.9-2) for reverse osmosis: (13.9-2)

In ultrafiltration the membrane does not allow the passage of the solute, which is generally a macromolecule. The concentration in moleslliter of the large solute molecules is usually small. Hence, the osmotic pressure is very low and is neglected. Then Eq. (13.9-2) becomes (13.11-1)

Ultrafiltration units operate at about 5 to 100 psi pressure drop compared to 400 to 2000 for reverse osmosis. For low-pressure drops of, say, 5 to 10 psi and dilute solutions of 792

Chap. 13

Membrane Separation Processes

up to 1 wt % or so, Eq. (13.11-1) predicts the performance reasonably well for well-stirred systems. Since the solute is rejected by the membrane, it accumulates and starts to build up at the surface of the membrane. As pressure drop is increased and/or concentration of the solute is increased, concentration polarization occurs, which is much more severe than in reverse osmosis. This is shown in Fig. l3.II-la, where CI is the concentration of the solute in the bulk solution, kg solutelm 3 , and C s is the concentration of the solute at the surface of the membrane. As the pressure drop increases, this increases the solvent flux N IV to and through the membrane. This gives a higher convective transport of the solute to the membrane, i.e., the solvent carries with it more solute. The concentration C s increases and gives a larger back molecular diffusion of solute from the membrane to the bulk solution. At steady state the convective flux equals the diffusion flux,

(13.11-2)

p

where N wcl p [kg solventl(s· m 2)](kg solute/m 3 )1(kg solventlm 3 ) = kg solute/s' m 2; DAB is diffusivity of solute in solvent, m 2 Is; and x is distance, m. Integrating this equation between the limits of x 0 and c = c s and x = a and c cI,

(13.11-3) where kc is the mass-transfer coefficient, rn/s. Further increases in pressure drop increase the value of c s to a limiting concentration where the accumulated solute forms ~ semisolid gel where C s = c g , as shown in Fig. B.ll-Ib.

--

1/ Nwdp

,

Nwdp

,

~o

~o

boundary layer

boundary layer

(a) FIGURE

s

Sec. 13.11

solvent

1

13.11-1.

gel layer

(b) Concentralion polarization in ultrafiltration: (a) concentralion profile before gel formation, (b) concentration profile with a gel layer formed at membrane surface.

Ultrafiltration Membrane Processes

793

Still further increases in pressure drop do not change C g,and the membrane is said to be "gel polarized." Then Eq. (13.11-3) becomes (pI, P6, Rl) Nw p

- = kc

(C g) ,

In -

(13.11-4)

C,

With increases in pressure drop, the gel layer increases in thickness and this causes the solvent flux to decrease because of the added gel layer resistance. Finally. the net flux of solute by convective transfer becomes equal to the back diffusion of solute into the bulk solution because of the polarized concentration gradient as given by Eq. (13.11-4). The added gel layer resistance next to the membrane causes an increased resistance to solvent flux as given by !1P

. (13.11-5)

IIAw + Rg

where lIA'l' is the membrane resistance and Rg is the variable gel layer resistance, (s' m 2 • atm)lkg solvent. The solvent flux in this gel-polarized regime is independent of pressure difference and is determined by Eq. (l3.11-4) for back diffusion. Experimental data confirm the use of Eq. (13.11-4) for a large number of macromolecular solutions, such as proteins, etc., and colloidal suspensions, such as latex particles, etc. (PI, P6). 13.11D Effects of Processing Variables in tntrafiltration A plot of typical experimental data of flux versus pressure difference is shown in 13.11-2 (HI, P6). At low pressure differences and/or low solute concentrations the data typically follow Eq. (13.1 I-I). For a given bulk concentration, c" the flux approaches a constant value at high pressure differences as shown in Eq. (l3.11-4). Also, more dilute protein concentrations give higher flux rates a's expected from Eq. (13.11-4). Most commercial applications are flux limited by concentration polarization and operate in the region where the flux is approximately independent of pressure difference (Rl).

Eq. (13.11-1)

,.

,. ,.

,.

,.

,. ,.

0.5%

,. ".

1

4%

6% protein

FIGURE 13.11-2.

794

Effect of pressure difference on solvent flux. Chap. /3

Membrane Separation Processes

II ..~

Using experimental data, a plot of N wI p versus In C I is a straight line with the negative slope of ke> the mass-transfer coefficient, as shown by Eq. (13.11-4). These plots also give the value or- C g' the gel concentration. Data (P 1) show that the gel. concentration for many macromolecular solutions is about 25 wt %, with a range of 5 to 50%. For colloidal dispersions it is about 65 wt %, with a range of 50 to 75%. The concentration polarization effects for hollow fibers is often quite small because of the low solvent flux. Hence, Eq. (13.11-1) describes the flux. In order to increase the ultrafiltration solvent flux, cross-flow of fluid past the membrane can be used to sweep away part of the polarized layer, thereby increasing kc in Eq. (13.11-4). Higher velocities and other methods are used to increase turbulence, and hence, k c • In most cases the solvent flux is too small to operate in a single-pass mode. It is necessary to recirculate the feed by the membrane with recirculation rates of 1011 to 10011 often used. Methods to predict the mass-transfer coefficient kc in Eq. (13.11-4) are given by others (PI, P6) for known geometries such as channels, etc. Predictions of flux in known geometries using these methods and experimental values of c g in Eq. (13.11-4) in the gel polarization regime compare with experimental values for macromolecular solutions within about 25 to 30%. However, for colloidal dispersions the experimental flux is higher than the theoretical by factors of 20 to 30 for laminar flow and 8 to 1O.for turbulent flow. Hence, Eq. (13.11-4) is not useful for predicting the solvent flux accurately. Generally, for design of commercial units it is necessary to obtain experimental data on single modules. PROBLEMS 13.2-1. Diffusion Through Liquids and a Membrane. A membrane process is being designed to recover solute A from a dilute solution where C 1 = 2.0 x 10- 2 kg mol A/m 3 by dialysis through a membrane to a solution wherec 2 = 0.3 x 10- 2. The membrane thickness is 1.59 x 10- 5 m, the distribution coefficient K' = 0.75, DAB = 3.5 X 10- 11 m 2 /s in the membrane, the mass-transfer coefficient in the dilute solution is kcl = 3.5 x 10 - 5 mis, and kc2 = 2.1 x 10- 5. (a) Calculate the individual resistances, total resistance, and the total percent resistance of the two films. (b) Calculate the flux at steady state and the total area in m 2 for a transfer of 0.01 kg mol solute/h. (c) Increasing the velocity of both liquid phases flowing by the surface of the membrane will increase the mass-transfer coefficients, which are approximately proportional to VO. 6 , where I.J is velocity. If the velocities are doubled, calculate the total percent resistance of the two films and the percent increase in flux. Aus. (a) Total resistance 6.823 x 105 s/m, 11.17% resistance, 8 (b) NA = 2.492 X 10- kg mol A/s·m 2 , area = 111.5 m 2 13.2-2. Suitability of a Membrane for Hemodialysis. Experiments are being conducted to determine the suitability of a cellophane membrane 0.029 mm thick for use in an artificial kidney device. In an experiment at 37°C using NaCI as the diffusing solute, the membrane separates two components containing stirred aqueous solutions of NaCI, where C 1 1.0 x 10- 4 g mol/cm 3 (100 g mol/m 3 ) and 7 C 2 = 5.0 X 10- • The mass-transfer coefficients on either side of the membrane have been estimated as kcl = kc2 = 5.24 x 10- 5 m/s. Experimental data obtained gave a flux N A = 8.11 x 10- 4 g mol NaCl/s· m 2 at pseudo-steady-state conditions. (a) Calculate the permeability PM in m/s and DAB K' in m 2/S• (b) Calculate the percent resistance to diffusion in the liquid films. Chap. 13

Problems

795

13.3-1. Gas-Permeation Membrane for Oxygenation. To dete~ne the suitability of silicone rubber for its use as a membrane for a heart-lung machine to o~genate blood, an experimental value of the permhbility at 30°C of oxygen was obtained where Pit = 6.50 x 10 -7 cm3 O 2 (STP)/(s . em 2 . em Hgfmm). (a) Predict the maximum flux of0 2 in kgmol/s' m 2 with an0 2 pressure of 700 mm Hg on one side of the membrane and an equivalent pressure in the blood film side of 50 mm. The membrane is 0.165 mm thick. Since the gas film is pure oxygen, the gas film resistance is zero. Neglect the blood film resistance in this case. (b) Assuming a maximum requirement for an adult of 300 em 3 02 (STP) per minute, ca1culate the membrane surface area required in m 2 • (Note: The actual area needed should be considerably larger since the blood film resistance, which must be determined by experiment, can be apprecjable.) ADS.

(b) 1.953 m 2

13.4-1. Derivation afEquationfor Permeate Concentration. Derive Eq. (13.4-11) for Case 2 for complete mixing. Note that x 0 from Eq. (13.4-8) must first be substituted into Eq. (13.4-S) before multiplying out the equation and solving for y po 13.4-2. Use of Complete-Mixing Model for Membrane Design. A membrane having a thickness of 2 x 10 -), cm, a permeability P A : : : 400 x 10 10 cm 3(STP)·cml (s'cm 2' cm Hg), and an 0:* = lOis to be used to separate a gas mixture of A and B. The feed flow rate is qf = 2 x 10) cm3(STP)/s and its composition isxf = 0.413. The feed-side pressure is 80 cm Hg and the permeate-side pressure is 20 cm Hg. The reject composition is to be x 0 0.30. Using the complete-mixing model, calculate the permeate composition, the fraction of feed permeated, and the membrane area. Ans. yp = 0.678 13.4-3. Design Using Complete-Mixing Model. A gaseous feed stream having a compo-. sition xf = O.SO and a flow rate of 2 x 10) cm) (STP)/s is to be separated in a membrane unit. The feed-side pressure is 40· cm Hg and the permeate is 10 cm Hg. The membrane has a thickness of I.S x 10 -) cm, a permeability PA 40 x 10 10 cm 3 (STP)'cm!(s'cm 2 'cmHg), and an 0:* = 10. The fraction of feed permeated is 0.S29. (a) Use the complete-mixing model to calculate the permeate composition, the reject composition, and the membrane area. (b) Calculate the minimum reject concentration. (c) If the feed composition is increased to xf = 0.60, what is this new minimum reject concentration? Ans. (a) Am = 5.153 X 10 7 cm Z (C) xoM = 0.2478 13.4-4. Effect of Permeabilities on Minimum Reject Concentration. For the conditions of Problem 13.4-2, xf = 0.413,0:* = 10, PI = 20 cm Hg, Ph = 80 cm Hg, and Xo 0.30. Calculate the minimum reject concentration for the following cases. (a) Calculate x oM for the given conditions. (b) Calculate the effect on XoM if the permeability of B increases so that a* decreases to 5. (c) Calculate the limiting value of XoM when a* is lowered to its minimum value. Make a plot of XoM versus a* for these three cases. 13.4-5. Minimum Reject Concentration and Pressure Effect. For Example 13.4-2 for separation of air, do as follows. (a) Calculate the minimum reject concentration. (b) If the pressure on the feed side is reduced by one-half, calculate the effect on XoM' Ans. (b) XoM = 0.0624 7%

Chap. 13

Problems

13.5-1. Separation of Multicomponent Gas Mixtures. Using the same feed composition

I

13.5-2.

! l

13.6-1.

13.7·1.

13.7-2.

f

(0 ,

j

13.9-1.

n lr

and flow rate, pressures, and membrane as in Example 13 .5-1, do the following using the complete-mixing model. (a) Calculate the permeate composition, the reject composition, and the . membrane area for a fraction permeated of 0.50 instead of 0.25. (b) Repeat part (a) but for f) 0.90. (c) Make a plot of permeate composition YpAversus f) and also of·area Am versus f) using the calculated values for f) = 0.25, 0.50, and 0.90. Separation of Helium from Natural Gas. A typical composition of a natural gas (SI) is 0.5% He (A), 17.0% N2 (B), 76.5% CH 4 (C), and 6.0% higher hydrocarbons ~). The membrane proposed to separate helium has a thickness of2.54 x 10 - cm and the permeabilities are P A = 60 x 10 -10 cm 3 (STP)·cml (s' cm z . cm Hg), P B = 3.0 x 10 -10, and Pc 1.5 x 10 -10. It is assumed that the higher hydrocarbons are essentially non-permeable (Ph == 0). The feed flow rate is 2.0 x 10 5 cm 3 (STP)/s. The feed pressure Ph = 500 cm Hg and the permeate pressure PI=20 cm Hg. (a) For a fraction permeated of 0.2, calculate the permeate composition, the reject composition, and the membrane area using the complete mixing , model. (b) Use the permeate from part (a) as feed to a completely mixed second stage. 20 cm. For a fraction permeated The pressure Ph = 500 cm Hg and PI of 0.20, calculate the permeate composition and the membrane area. Design Using Cross-Flow Modelfor Membrane. Use the same conditions for the separation of an air stream as given in Example 13.6-1. These given values are xf = 0.209, a* 10, Ph 190 cm H~, PI ~ 19 cm H~, qf 1 x 10 6 10 3 cm (STP)/s, P A 500 x 10cm (STP)'crnl(s'cm 'cm Hg), and t =2.54 x 1O- 3 cm. Do as follows using the cross-flow model. (a) Calculate y p' x 0> and A m for e 0.40. (b) Calculate y p and x 0 for f) = o. . Ans. (a) yp = 0.452, Xo = 0.0303, Am 6.94 X 10 8 cm Z (S6) (b) Yp 0.655, Xo 0.209 Equations for Countercurrent-Flow Madel. For the derivation of the equations for countercurrent flow in a gas separation using a membrane do the following. (a) Obtain Eq. (13.7-5) from Eq. 03.7-4). (b) Show that Eq. (13.7-10) is valid. (c) Obtain Eq. (13.7-12). Design Using Countercurrent-Flow Model for Membrane. Use the same conditions as given in Example 13.6-1 for the separation of an air stream. The given valuesarexf 0.209,a* 10,Ph= 190cmHg,PI 19cmHg,Qf= I x 10 6 cm 3 (STP)/s, P A = 500 x IO -10 cm 3 (STP)' crn/(s' cm z . cm Hg), and t = 2.54 x 10 - 3 cm. Using the countercurrent-flow model, calculate y p , x and Am for e = 0.40. (Note that this problem involves a trial-and-error procedure along with the numerical solution of two differential equations.) Osmotic Pressure of Salt and Sugar Solutions. Calculate the osmotic pressure of the following solutions at 25°C and compare with the experimental values. (a) Solution of 0.50 g mol NaCljkg H 2 0. (See Table 13.9-1 for the experimental value.) (b) Solution of 1.0 g sucrose/kg H 2 0. (Experimental value = 0.0714 atm.) (c) Solution of 1.0 g MgCI 2 jkg H 2 0. (Experimental value = 0.660 atm).

(a) rr = 24.39 atm, (b) n 0.0713 atm, (c) n 0.768 atm 13.9-2. Determination of Permeability Constants for Reverse· Osmosis. A celluloseacetate membrane with an area of 4.0 x 10- 3 m2 is used at 25°C to determine AIlS..

:4 IS

Chap. 13

Problems

797

the permeability constants for reverse osmosis of a feed salt solution containing 12.0 kg NaCl/m 3 (p 1005.5 kg/m 3 ). The product solution has a concentration·' 3 of 0.468 kg NaCl/m (p = 997.3 kg/m 3 ). The measured product flow rate is 3.84 x 10 - 8 m 3/S and the pressure difference used is 56.0 atm. Calculate the permeability constants and the solute rejection R. Ans. Aw=2.013 x 1O- 4 kgsolvent/s·m 2 ·atm,R=0.961 13.9-3. Performance of a Laboratory Reverse-Osmosis Unit. A feed solution at 25°C contains 3500 mg NaCI/L (p = 999.5 kg/m 3 ). The permeability constant Aw = 3.50 X 10- 4 kg solvent/s· m 2 • atm. and A. = 2.50 X 10- 7 m/s. Using a tlP = 35.50 atm, calculate the fluxes, solute rejection R, and the product solution concentration in mg NaCI/L. Repeat, but using a feed solution of 3500 mg BaClz/L. Use the same value of Aw but A. = 1.00 X 10- 7 mls (A 1). 13.10-1. Effect of Pressure on Perfomulnce of Reverse-Osmosis Unit. Using the same conditions and permeability constants as in Example 13.10-1, calculate the fluxes, solute rejection R, and the product concentration C2 for I1P pressures of 17.20, 27.20, and 37.20 atm. (Note: The values for 27.20 atm have already been calculated.) Plot the fluxes, R, and Cz versus the pressure. 13.1()"2. Effect of Concentration Polarization on Reverse Osmosis. Repeat Example 13.10-1 but use a concentration polarization of 1.5. (Note: The flux equations and the solute rejection R should be calculated using this new value of Ct.) Ans. N w = 1.170 X 10- 2 kgsolvent/s·m 2 , Cz 0.1361 kg NaCI/m 3

13.10-3. Performance of a Complete-Mixing Model for Reverse Osmosis. Use the same feed conditions and pressures given in Example 13.10-1. Assume that the cut or fraction recovered of the solvent water will be 0.10 instead of the very low water recovery assumed in Example 13.10-1. Hence, the concentration of the entering feed solution and the exit feed will not be the same. The flow rate q3 of the permeate water solution is 100 gal/h. Calculate Cl and C2 in kg NaClIm and the membrane area in m 2 • Ans. ci 2.767 kg/m 3 , c2 ='0.0973 kg/m 3 , area 8.68 m 2 13.11-1. Flux for Ultrafiltration. A solution containing 0.9 wt % protein is to undergo ultrafiltration using a pressure difference of 5 psi. The membrane permeability is A IV = 1.37 x 10 - 2 krs' m 2 • atm. Assuming no effects of polarization, predict the flux in kg/s'm and in units of gallft 2 • day which are often used in industry. Ans. 9.88 gal/ft 2 • day 13.11-2. Timefor Ultrafiltration Using Recirculation. It is desired to use ultrafiltration for

800 kg of a solution containing 0.05 wt % of a protein to obtain a solution of 1.10 wt %. The feed is recirculated by the membrane with a surface area of 9.90 m 2 . The permeability of the membrane is Aw 2.50 X 10- 2 kg/s' m 2 • atm. Neglecting the effects of concentration polarization, if any, calculate the final amount of solution and the time to perform this using a pressure difference of 0.50 atm.

REFERENCES (AI) (B 1)

(B2) (B3) 798

AGRAWAL, 1. P., and SOURIRAJAN, S. Ind. Eng. Chern., 69(11),62 (1969). BLAISDELL, c. T., and KAMMERMEYER, K. Chern. Eng. Sci., 28, 1249 (1973). BASS, A. L., MAURER, C. 1., FRY, D. L., POPOVICH, R. P., and McKEE, R. E. Chern. Eng. Progr. Syrnp., 64(84), 59 (1968). BERRY, R. L Chem. Eng., 88(July 13),63 (1981) Chap. 13

References

(Cl)

CLARK, W. E. Science, 138, 148 (1962).

(HI)

HWANG, S. T., and KAMMERMEYER, K. Membranes in Separations. New York: John Wiley & Sons, Inc., 1975.

(Kl) (K2) (K3)

KIMURA, S., and SOURlRA1AN, S. A.I.Ch.E. I., 13,497 (1967). KAup, E. C. Chern. Eng., 80(Apr. 2),46 (1973). KURZ, J. E., and NARAYAN, R. S., "New Developments and Applications in Membrane Technology."

(Ll) (Ml) (M2)

LACEY, R. E. Chern. Eng., 79(Sept. 4), 57 (1972). MCCABE, W. L. Ind. Eng. Chern., 21, 112 (1929). MICHAELS, A. S. Chern. Eng. Progr., 64(12), 31 (1968).

(M3)

MERTEN, U. (ED.). Desalination by Reverse Osmosis. Cambridge, Mass.: The MIT Press, 1966.

(M4) (PI)

MAZUR, W. H., AND MARTIN, C. C. Chern, Eng. Progr., 78(10),38 (1982). PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6th ed. New York: McGraw-Hill Book Company, 1984.

(n)

PAN, C. Y. A.I.Ch.E. I., 29, 545 (1983). PER.'l.fASEP PERMEATORS, E. I. duPont Tech. Bull., 401, 403, 405 (1972).

(P3) (P4) (P5) (P6) (Rl) (SI) (S2) (S3)

PAN, C. Y., and HABGOOD, H. W. Ind. Eng. Chern. Fund., PAN, C. Y., and HABGOOD, H. W. Can. I. Chern. Eng., 56 PORTER, M. C. (ed.). Handbook of Industrial Membrane Ridge, N.J.: Noyes Publications, 1990. ROUSSEAU, R. W. (ed.). Handbook of Separation Process York: John Wiley & Sons, Inc., 1987. STElU'

qc

=

7.87

10- 7

X

(2410)2(1461 - 801)D~(2.747 x 10- 4 ) 18(0.100) In [2 x 0.02225/(0.00716 + 0.02225)]

Dpc

=

0.746

X

10- 6 m

or

0.746 Jlm

Substituting into Eq. (14.4-13) to obtain v t and then calculating the Reynolds number, the settling is in the Stokes' law range. 3. Sigma values and scale-up oj centrifuges. A useful physical characteristic of a tubularbowl centrifuge can be derived by mUltiplying and dividing Eq. (14.4-12) by 2g and then substituting Eq. (14.3-9) written for Dpc into Eq. (14.4-12) to obtain q c

where

Vr

=2

(pp - p)gD;c wZV 18 Jl 2g In [2rJ(r\

+ r 2 )]

=

2v ·I

(14.4-18)

,

is the terminal settling velocity of the particle in a gravitational field and w2[nb(r~

-

2g In [2r 2 /(r l

r;)] + r 2 )]

(14.4-19)

where I is a physical characteristic of the centrifuge and not of the fluid-particle system being separated. Using Eq. (14.4-17) fOI the special case for settling for a thin layer, I

=---=-

(14.4-20)

9

The value of L is really the area in m 2 of a gravitational settler that will have the same sedimentation characteristics as the centrifuge for the same feed rate. To scale up from a laboratory test of q 1 and II to qz (for Vi I = vr2 ), (14.4-21) II

This scale-up procedure is dependable for similar type the centrifugal forces are within a factor of 2 from each are used, efficiency factors E should be used where ficiencies are determined experimentally and values for given elsewhere (Fl, PI).

and geometry centrifuges and if other. If different configurations ql/IIEI qJI 2 E2 • These efdifferent types of centrifuges are

4. Separation oj liquids in a centrifuge. Liquid-liquid separations in which the liquids are immiscible but finely dispersed as an emulsion are common operations in the food and other industries. An example is the dairy industry, in which the emulsion of milk is separated into skim milk and cream. In these liquid-liquid separations, the position of the outlet overflow weir in the centrifuge is quite important, not only in controlling the volumetric holdup V in the centrifuge but also in determining whether a separation is actually made. In Fig. 14.4-3 a tubular-bowl centrifuge is shown in which the centrifuge is separating two liquid phg;Ses, one a heavy liquid with density PH kg/m 3 and the second a light liquid with density PL' The distances shown are as follows: r I is radius to surface of light liquid layer. r2 is radius to liquid-liquid interface, and r 4 is radius to surface of heavy liquid downstream. To locate the interface, a balance must be made of the pressures in the two layers.

834

Chap. 14

Mechanical-Physical Separation Processes

The force on the fluid at distance r is, by Eq. (14.4-2), (14.4-2) The differential force across a thickness dr is (14.4-22)

dmrw 2

dF c

But, (14.4-23)

dm = [(2nrb) dr]p

where b is the height of the bowl in m and (2nrb) dr is the volume of fluid. Substituting Eq. (14.4-23) in (14.4-22) and dividing both sides by the area A = 211" rb ,

dFc 2 dP = - = W pr dr A

(14.4-24)

where P is pressure in N/m2 (lbr/ft 2 ). Integrating Eq. (14.4-24) between rJ and r2' pw 2

-

2

(r2 _ r2) 2

I

(14.4-25)

Applying Eq. (14.4-25) to Fig. 14.4-3 and equating the pressure exerted by the light phase of thickness r 2 '1 to the pressure exerted by the heavy phase of thickness r 2 - r 4 at the liquid-liquid in terface at r 2 , (14.4-26) Solving for r~, the interface position, 2

'2 =

PHd - PL r ; PH

(14.4-27)

PL

The interface at r2 must be located at a radius smaller than r3 in Fig. 14.4-3.

___--heavy liquid, PH ~~;.q..

_ _ _ light liquid, PL

aL~1-___

liq uid-liquid interface

feed FIGURE

Sec. 14.4

14.4-3. Tubular bowl centrifugefor separating two liquid phases.

Centrifugal Separation Processes

835

EXAMPLE 14.4-3. Location of Interface in Centrifuge In a vegetable-oil-refining process, an aqueous phase is being separated from the oil phase in a centrifuge. The density of the oil is 919.5 kglm 3 and that of the aqueous phase is 980.3 kg/m 3 • The radius r 1 for overflow of the light liquid has been set at 10.160 mm and the outlet for the heavy liquid at 10.414 mm. Calculate the location of the interface in the centrifuge. Solution: The densities are PL = 919.5 and PH into Eq. 04.4-27) and solving for r2'

=

980.3 kglm 3 . Substituting

2 980.3(10.414? - 919.5(10.160)2 r2 = 980.3 919.5 r2

13.4D

13.75 mm

Centrifuge Equipment for Sedimentation

1. Tubular celZlrifuge. A schematic of a tubular bowl centrifuge is shown in Fig. 14.4-3. The bowl is tall and has a narrow diameter, 100 to 150 mm. Such centrifuges, known as supercentrijuges, develop a force about 13 ()(){) times the force of gravity. Some narrow centrifuges having a diameter of 75 mm and very high speeds of 60000 or so rev/min are known as uitracentrijitges. These supercentrifuges are often used to separate liquid-liquid emulsions. 2. Disk bowl centrifuge. The disk bowl centrifuge shown in Fig. 14.4-4 is often used in liquid-liquid separations. The feed enters the actual compartment at the bottom and travels upward through vertically spaced feed holes, fiJling the spaces between the disks. The holes divide the vertical assembly into an inner section, where mostly light liquid is present, and an outer section, where mainly heavy liquid is present. This dividing line is similar to an interface in a tubular centrifuge. ' The heavy liquid flows beneath the underside of a disk to the periphery of the bowl. The light liquid flows over the upper side of the disks and toward the inner outlet. Any

light

li~uid

feed

FIGURE 14.4-4.

836

Schematic of disk bowl centrifuge.

Chap. 14

Mechanical-Physical Separation Processes

'"1

small amount of heavy solids is thrown to the outer wall. Periodic cleaning is required to remove solids deposited. Disk bowl centrifuges are used in starch-gluten separation, concentration of rubber latex, and cream separation. Details are given elsewhere (PI, Ll). 14.4E

Centrifugal Filtration

J. T hear y for centrifugal filtration. Theoretical prediction of filtration rates in centrifugal filters have not been too successful. The filtration in centrifuges is more complicated than for ordinary filtration using pressure differences, since the area for flow and driving force increase with distance from the axis and the specific cake resistance may change markedly. Centrifuges for filtering are generally selected by scale-up from tests on a similar-type laboratory centrifuge using the slurry to be processed. The theory of constant-pressure filtration discussed in Section 14.2E can be modified and used where the centrifugal force causes the flow instead of the impressed pressure difference. The equation will be derived for the case where a cake has already been deposited as shown in Fig. 14.4-5. The inside radius of the basket is r2' ri is the inner radius of the face of the cake, and r 1 is the inner radius of the liquid surface. We will assume that the cake is nearly incompressible so that an average value of ct. can be used for the cake. Also, the flow is laminar. If we assume a thin cake in a large-diameter centrifuge, then the area A for flow is approximately constant. The velocity of the liquid IS

q dV -=--

v

A

(14.4-28)

A dt

where q is the filtrate flow rate in m 3/s and v the velocity. Substituting Eq. 04.4-28) into (14.2-8), (14.4-29)

where me = Cs V, mass of cake in kg deposited on the filter. For a hydraulic head of dz m, the pressure drop is dp = pg dz

(14.4-30)

In a centrifugal field, 9 is replaced by rw 2 from Eq. (14.4-1) and dz by dr. Then, dp

= prw 2

-,

(14.4-31)

dr

fllter medium fllter cake

b

1 FIGURE

Sec. 14.4

liquid

14.4-5.

Physical arrangement/or centrifugalfiltrarion.

Centrifugal Separation Processes

837

Integrating between r 1 and r 2,

to.p

pw2(r~ -

d)

2

(14.4-32)

Combining Eqs. (14.4-29) and (14.4-32) and solving for q,

(14.4-33)

For the case where the flow area A varies considerably with the radius, the following has been derived (Gl). pw2(r~

q

ri)

(14.4-34)

R m) 2p ( -=--=- + ALAa A2 mcry.

where A2 = 2nr2 b (area of filter medium), AL 2nb(r2 - rj)fln (r2/rj) (logarithmic cake area), and ita = (rj + r 2 )nb (arithmetic mean cake area). This equation holds for a cake of a given mass at a given time. It is not an integrated equation covering the whole filtra tion cycle. In a centrifugal filter, slurry is fed continuously to a rotating basket which has a perforated wall and is covered with a filter cloth. The cake builds up on the surface of the filter medium to the desired thickness. Then at the end of the filtration cycle, feed is stopped, and wash liquid is added or sprayed on to the cake. Then the wash liquid is stopped and the cake is spun as dry as possible. The motor is then shut off or slowed and the basked aUowed to rotate while the solids are discharged by a scraper knife so the solids drop through an opening in the basket floor. Finally, the filtyer medium is rinsed clean to complete the cycle. Usually, the batch cycle is completely automated. Automatic batch centrifugals have basket sizes up to about 1.2 m in diameter and usually rotate below 4000 rpm. Continuous centrifugal filters are available with capacities up to about 25000 kg solids/h. Intermittently, the cake deposited on the filter medium is removed by being pushed toward the discharge end by a pusher, which then retreats again, aJlowing the cake to build up once more. As the cake is being pushed, it passes through a wash region. The filtrate and wash liquid are kept separate by partitions in the collector. Details of different types of centrifugal filters are available (PI). 2. Equipment for centrifugal fillration.

14.4F

Gas-Solid Cyclone Separators

I. Inlroduclion and equipmenl. For separation of small solid particles or mist from gases, the most widely used type of equipment is the cyclone separator, shown in Fig. 14.4-6. The cyclone consists of a vertical cylinder with a conical bottom. The gas-solid particle mixture enters in a tangential inlet near the top. This gas-solid mixture enters in a rotating motion, and the·vortex formed develops centrifugal force which throws the particles radially toward the wall. On entering, the air in the cyclone flows downward in a spiral or vortex adjacent to the wall. When the air reaches near the bottom of the cone, it spirals upward in a smaller spiral in the center of the cone and cylinder. Hence, a double vortex is present. The downward and upward spirals are in the same direction. 838

Chap. 14

Mechanical-Physical Separarion Processes

The particles are thrown toward the wall and fall downward, leaving out the bottom of the cone. A cyclone is a settling device in which the outward force on the particles at high tangential velocities is many times the force of gravity. Hence, cyclones accomplish much more effective separation than gravity settling chambers. ' .. The centrifugal force in a cyclone ranges from about 5 times gravity in large, low-velocity units to 2500 times gravity in small, high-resistance units. These devices are used often in many applications, such as in spray drying of foods, where the dried particles are removed by cyclones; in cleaning dust-laden air; and in removing mist droplets from gases. Cyclones offer one of the least expensive means of gas-particle separation. They are generally applicable in removing particles over 5 pm in diameter from gases. For particles over 200 pm in size, gravity settling chambers are often used. Wet scrubber cyclones are sometimes used where water is sprayed 'inside, helping to remove the solids. 2. Theory for cyclone separators. It is assumed that particles on entering a cyclone quickly reach their tenninal settling velocities. Particle sizes are usually so small that Stokes' law is considered valid. For centrifugal motion, the tenninal radial velocity VIR is given by Eq. (14.4-8), with VIR being used for VI' w2rD;(pp - p)

(14.4-35)

18)1

Since

W

vlanlr, where

V tan

is tangential velocity of the particle at radius r, Eq.

(14.4-35) becomes Vt R

where

VI

=

_D..!:;.::..-g..:. (p--"p_..:. p. :. ) 18)1 gr

is the gravitational tenninal settling velocity

(14.4-36) VI

in Eq. (14.3-9).

gas out

t gas-solids i n ------,..--.+-1

,

/'

/

/

/

~

-

-

0-

---

I / /'

(b)

~

solids out (a) FIGURE

Sec. 14.4

14.4-6. Gas-solid cyclone separator: (a) side view, (b) top view.

Centri}ilgal Separation Processes

839

The higher the terminal velocity v., the greater the radial velocity V rR and the easier it should be to "settle" the particle at the walls. However, the evaluation of the radial velocity is difficult, since it is a function of gravitational terminal velocity, tangential velocity, and position radially and axially in the cyclone. Hence, the following empirical equation is often used (S2).

(14.4-37) where b i and n are empirical constants. 3. Efficiency of collection of cyclones. Smaller particles have smaller settling velocities by Eg. (14.4-37) and do not have time to reach the wall to be collected. Hence, they leave with the exit air in a cyclone. Larger particles are more readily collected. The efficiency of separation for a given particle diameter is defined as the mass fraction of the size particles that are collected. A typical collection efficiency plot for a cyclone shows that the efficiency rises rapidly with particle size. The cut diameter Dpe is the diameter for which one half of the mass of the entering particles is retained.

14.S 14.SA

MECHANICAL SIZE REDUCTION Introduction

Many solid materials occur in sizes that are too large to be used and must be reduced. Often the solids are reduced in size so that the separation of various ingredients can be carried out. In general, the terms crushing and grinding, are used to signify the subdividing of large solid particles to smaller particles. In the food processing industry, a large number of food products are subjected to size reduction. Roller mills are used to .grind wheat and rye to flour and corn. Soybeans are rolled, pressed, and ground to produce oil and flour. Hammer mills are often used to produce potato flour, tapioca, and other flours. Sugar is ground to a finer product. Grinding operations are very extensive in the ore processing and cement industries. Examples are copper ores, nickel and cobalt ores, and iron ores being ground before chemical processing. Limestone, marble, gypsum, and dolomite are ground to use as fillers in paper, paint, and rubber. Raw materials for the cement industry, such as lime, alumina, and silica, are ground on a very large scale. Solids may be reduced in size by a number of methods: Compression or crushing is generally used for reduction of hard solids to coarse sizes. Impact gives coarse, medium, or fine sizes. Attrition or rubbing yields fine products. Cutting is used to give definite sizes.

14.SB

Particle-Size Measurement

The feed· to-size reduction processes and the product are defined in terms of the particlesize distribution. One common way to plot particle sizes is to plot particle diameter (sieve opening in screen) in mm or pm versus the cumulative percent retained at that size. (Openings for various screen sizes are given in Appendix A.5.) Such a plot was given on arithmetic probability paper in Fig. 12.12-2. Often the plot is made, instead, as the cumulative amount as percent smaller than the stated size versus particle size as shown in Fig. 14.5-1 a. In Fig. 14.5-1 b the same data 840

Chap. 14

Mechanical-Physical Separation Processes

are plotted as a particle distribution curve. The ordinate is obtained by taking the slopes of the 5-flm intervals of Fig. 14.5-1a and converting to percent by weight per flm. Complete particle-size analysis is necessary for most comparisons and calculations. 14.SC

Energy and Power Required in Size Reduction

1. Introduction. In size reduction of solids, feed materials of solid are reduced to a smaller size by mechanical action. The materials are fractured. The particles of feed are first distorted and strained by the action of the size-reduction machine. This work to strain the particles is first stored temporarily in the solid as strain energy. As additional force is added to the stressed particles, the strain energy exceeds a certain level, and the material fractures into smaller pieces. When the material fractures, new surface area is created. Each new unit area of surface requires a certain amount of energy. Some of the energy added is used to create the new surface, but a large portion of it appears as heat. The energy required for fracture is a complicated function of the type of material, size, hardness, and other factors. The magnitude of the mechanical force applied; the duration; the type of force, such as compression, shear, and impact; and other factors affect the extent and efficiency of the size-reduction process. The important factors in the size-reduction process are the amount of energy or power used and the particle size and new surface formed. 2. Power required in size reduction. The various theories or laws proposed for predicting power requirements for size reduction of solids do not apply well in practice. The most important ones will be discussed briefly. Part of the problem in the theories is that of estimating the theoretical amount of energy required to fracture and create new surface area. Approximate calculations give actual efficiencies of about 0.1 to 2%. The theories derived depend upon the assumption that the energy E required to produce a change dX in a particle of size X is a power function of X.

6~--------------------~

100r-------------~----~

30 Particle size (pm) (a)

60

60

30 Particle size (pm) (b)

..,:.'

FIGURE 14.5-1.

Sec. 14.5

Particle-size-distriblllion curves: (a) cumulative percent versus particle size, (b) percent by weight versus particle size. (From R. H. Perry and C. H. Chilton, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973. With permission.)

Mechanical Size Reduction

841

c

dE

(14.5-1)

dX

where X is size or diameter of particle in mm, and nand C are constants depending upon type and size of material and type of machine. Rittinger proposed a law which states that the work in crushing is proportional to the new surface created. This leads to a value of n = 2 in Eq. (14.5-1), since area is proportional to length squared. Integrating Eq. (14.5-1),

E_~(_l

__ X'i-1

(14.5-2)

1 X;-I

-n

where X I is mean diameter of feed and X 2 is mean diameter of product. Since n Rittinger's equation, we obtain E = KR

(_1 __ 1) X Xl

2 for (14.5-3)

2

where E is work to reduce a'unit mass of feed fromX I toX 2 andK R is a constant. The law implies that the same amount of energy is needed to reduce a material from 100 mm to 50 mm as is needed to reduce the same material from 50 mm to 33.3 mm. It has been found experimentally that this Jaw has some validity in grinding fine powders. Kick assumed that the energy required to reduce a material in size was directly proportional to the size-reduction ratio. This implies n = 1 in Eq. (14.5-1), giving Xl Xl E = C In - = KK logX

X

2

(14.5-4)

2

where KK is a constant. This law implies that the same amount of energy is required to reduce a material from 100 mm to 50 mm as is needed to reduce the same material from 50 mm to 25 mm. Recent data by Bond (B3) on correlating extensive experimental data suggest that the work required using a large-size feed is proportional to the square root of the surface/volume ratio of the product. This corresponds to n = 1.5 in Eq. (14.5-1), giving

E

1

KB

r:v

(14.5-5)

yX2

where KB is a constant. To use Eq. (14.4-5), Bond proposed a work index E; as the work in kW· h/ton required to reduce a unit weight from a very large size to 80% passing a 100-pm screen. Then the work E is the gross work required to reduce a unit weight of feed with 80% passing a diameter X f /lm to a product with 80% passing X ppm. Bond's final equation in terms of English units is

P= 146E. ( -1T

.

'.jD;,

(14.5-6)

where P is hp, T is feed rate in tons/min,D f is size offeed in ft, and Dp is product size in f1. Typical values of E j for various types of materials are given in Perry and Green' (PI) and by Bond (B3). Some typical values are bauxite (E; = 9.45), coal (11.37), potash salt (8.23), shale (16.4), and granite (14.39). These values should be multiplied by 1.34 for dry grinding.

EXAMPLE 14.5-1. Power to Crush Iron Ore hy Bond's Theory It is desired to crush 10 ton/h of iron ore hematite. The size of the feed is 842

Chap. 14

Mechanical-Physical Separation Processes

\!

I

{ I

j,

such that 80% passes a 3-in. (76.2-mm) screen and 80% of the product is to pass a ii-in. (3.175-mm) screen. Calculate the gross power required. Use a work index E, for iron ore hematite of12.68 (PI). Solution: The feed size is DF = ti = 0.250 ft (76.2 mm) and the product size is Dp = t/12 = 0:0104 ft (3.175 mm). The feed rate is T = 10/60 = 0.167 ton/min. Substituting into Eq. (14.5-6) and solving for P, O. PI67

= (1.46XI2.68) (~ -

P

14.5D

0.0104

~) 0.250

24.1 hp (17.96 kW)

Equipment for Size Reduction

1. Introduction and classification. Size-reduction equipment may be classified according to the way the forces are applied as follows: between two surfaces, as in crushing and shearing; at one solid surface, as in impact; and by action of the surrounding medium~ as in a colloid mill. A more practical classification is to divide the equipment into crushers, grinders, fine grinders, and cutters. 2. Jaw crushers. Equipment for coarse reduction of large amounts of solids consists of slow-speed machines called crushers. Several types are in common use. In the first type, a jaw crusher, the material is fed between two heavy jaws or fiat plates. As shown in the Dodge crusher in Fig. 14.5-2a, one jaw is fixed and the other reciprocating and movable on a pivot point at the bottom. Thejaw swings back and forth, pivoting at the bottom of the V. The material is gradually worked down into a narrower space, being crushed as it moves. The Blake crusher in Fig. 14.5-2b is more commonly used, and the pivot point is at the top of the movable jaw. The reduction ratios average about 8 : 1 in the Blake crusher. Jaw crushers are used mainly for primary crushing of hard materials and are usually followed by other types of crushers.

feed fixed jaw

movable

pivot point

FIGURE 14.5-2.

movable jaw

fixed jaw (b)

(a)

Sec. 14.5

1

~jaw

fine product

pivot point

Types ofjaw crushers: (a) Dodge type, (b) Blake type.

Mechanical Size Reduction

843

3. Gyratory crushers. The gyratory crusher shown in Fig. 14.5-3a has taken over to a large extent in the field of large hard-ore and mineral crushing applications. Basically it is like a mortar-and-pestle crusher. The movable crushing head is shaped like an inverted truncated cone and is inside a truncated cone casing. The crushing head rotates eccentrically and the material being crushed is trapped between the outer fixed cone and the inner gyrating cone. 4. Roll crushers. In Fig. 14.5-3b a typical smooth roll crusher is shown. The rolls are rotated toward each other at the same or different speeds. Wear of the rolls is a serious problem. The reduction ratio varies from about 4: 1 to 2.5: 1. Single rolls are often used, rotating against a fixed surface, and corrugated and toothed rolls are also used. Many food products that are not hard materials, such as flour, soybeans, and starch, are ground on rolls. 5. Hammer mill grinders. Hammer mill devices are used to reduce intermediate-sized material to small sizes or powder. Often the product frum jaw and gyratory crushers is the feed to the hammer mill. In the hammer mill a high-speed rotor turns inside a cylindrical casing. Sets of hammers are attched to pivot points at the outside of the rotor. The feed enters the top of the casing and the particles are broken as they fall through the cylinder. The material is broken by the impact of the hammers and pulverized into powder between the hammers and casing. The powder then passes through a grate or screen at the discharge end. 6. Reuolring grinding mills. For intermediate and fine reduction of materials revaluing grinding mills are often used. In such mills a cylindrical or conical shell rotating on a horizontal axis is charged with a grinding medium such as steel, flint, or porcelain balls, or with steel rods. The size reduction is effected by the tumbling of the balls or rods on the material between them. In the revolving mill the grinding elements are carried up the side of the shell and fall on the particles underneath. These mills may operate wet or dry. Equipment for very fine grinding is very specialized. In some cases two flat disks are used where one or both disks rotate and grind the material caught between the disks (PI).

feed

0

!

crushing head

~~~ (b)

fixed cone (a) FIGURE

844

14.5-3.

Types of size-reduction equipment: (a) gyratory crusher, (b) roll crusher.

Chap. 14

Mechanical-Physical Separation Processes

PROBLEMS 14.2-1 Constant-Pressure Filtration and Filtration Constants. Data for the filtration of CaC0 3 slurry in water at 298.2 K (25°C) are reported as follows (Rl, R2, Ml) at a constant pressure (-llp) of 46.2 kN/m2 (6.70 psi a). The area of the plate-andframe press was 0.0439 m 2 (0.473 ft2) and the slurry concentration was 23.47 kg solid/m 3 filtrate. Calculate the constants a and R",. Data are given as 1 = time in s and V = volume of filtrate collected in m 3 .

17.3 41.3

0.5 1.0

1.5

2.0

152.0 201.7

2.5 3.0

72.0 108.3

a = 1.106 x 10 11 mlkg 0.65 x lOll ftJlb m ), Rm = 6.40 X 10 10 m I (1.95 x 1010 ft I) 14.2-2. Filtration Constants for Constant-Pressure Filtration. Data for constant-

Ans.

pressure filtration at 194.4 kN/m 2 are reported for the same slurry and press as in Problem 14.2-1 as follows, where t is in s and V in m}:

vX

/0 3

V

0.5 1.0 1.5 2.0

6.3 14.0 24.2 37.0

X

V

/03

2.5 3.0 3.5 4.0

X

/0 3

4.5 5.0

51.7 69.0 88.8 110.0

134.0 160.0

Calculate the constants a and R",. Ans. a = 1.61 x 10 II mlkg 14.2-3. Compressibility of Filter Cake. Use the data for specific cake resistance a from Example 14.2-1 and Problems 14.2-1 and 14.2-2 and detennine the compressibility constant s in Eq. (14.2-11). Plot the In of ex versus the In of t:J.p and determine the slope s. 14.2-4. Prediction of FilJration Time and Washing Time. The slurry used in Problem 14.2-1 is to be filtered in a plate-and-frame press having 30 frames and 0.873 m 2 area per frame. The same pressure, 46.2 kN/m2, will be used in constantpressure filtration. Assume the same filter cake properties and filter cloth, and calculate the time to recover 2.26 m 3 of filtrate. At the end, using through washing and 0.283 m 3 of wash water, calculate the time of washing and the total filter cycle time if cleaning the press takes 30 min. 14.2-5. Constants in Constant-Pressure Filtration. McMillen and Webber (M2), using a filter press with an area of 0.0929 m 2 , performed constant-pressure filtration at 34.5 kPa of a 13.9 wt % CaC0 3 solids in water slurry at 300 K. The mass ratio of wet cake to dry cake was 1.59. The dry cake density was 1017 kg/m 3 . The data obtained are as follows, where W kg filtrate and t time in s:

w

w .D.91 1.81 2.72

24 71 146

3.63 4.54 5.44

W

244 372 524

6.35 7.26 8.16

690 888 1188

Calculate the values of a and Rm' Chap. 14

Problems

845

14.2-6. Constant-Pressure Filtration and Washing in a LeaJ Filter.

An experimental filter press having an area of 0.0414 m 2 (Rl) is used to filter an aqueous BaCO J slurry at a constant pressure of 267 k Pa. The filtration equation obtained was

where l is in s and V in m 3 . (a) If the same slurry and conditions are used in a leaf press having an area of 6.97 m 2 , how long will it take to obtain l.OOm 3 of filtrate ? (b) After the filtration the cake is to be washed with 0.100 m 3 of water. Calculate the time of washing. ADs. (a) I = 381.8 s 14.2-7. Constant-Rate Filtration oJ Incompressible Cake. The filtration equation for filtration at a constant pressure of 38.7 psia (266.8 k Pa) is l

V=6.10x 10

_5

V +0.01

where t is in s, I1p in psia, and V in liters. The specific resistance of the cake is independent of pressure. If the filtration is run at a constant rate of 10 liters/s, how long will it take to reach 50 psia? 14.2-8. Effect oj Filter Medium Resistance on Continuous Rotary-Drum Filler. Repeat Example 14.2-4 for the continuous rotary-drum vacuum filter but do not neglect the constant R m' which is the filter medium resistance to How. Compare with results of Example 14.2-4. Ans. A = 7.78 m 2

14.2-9. Throughput in Continuous Rotary Drum Filter. A rotary drum filter having an area 0[2.20 m 2 is to be used to filter the CaC0 3 slurry given in Example 14.2-4. The drum has a 28% submergence and the filter cycle time is 300 s. A pressure drop of 62.0 kN/m2 is to be used. Calculate the slurry feed rate in kg slurry/s for the following cases. (a) Neglect the filter medium resistance: (b) Do not neglect the value of B. 14.3-1. Settling Velocity oJ a Coffee Extract Particle. Solid spherical particles of coffee extract (FI) from a dryer having a diameter of 400 J1m are falling through air at a temperature of 422 K. The density of the particles is 1030 kgfm 3 • Calculate the terminal settling velocity and the distance of fall in 5 s. The pressure is 101.32 kPa. Ans. Vr = 1.49 mis, 7.45 m fall 14.3-2. Terminal Settling Velocity oJ Dust Particles. Calculate the terminal settling velocity of dust particles having a diameter of 60 J1m in air at 294.3 K and 101.32 kPa. The dust particles can be considered spherical with a density of 1280 kgfm 3 . Ans. Vr 0.1372 m/s 14.3-3. Settling Velocity oJ Liquid Particles. Oil droplets having a diameter of 200 pm are settling from still air at 294.3 K and 101.32 kPa. The density of the oil is 900 kgfm 3 • A settling chamber is 0.457 m high. Calculate the terminal settling velocity. How long will it take the particles to settle? (Note: If the Reynolds number is above about 100, the equations and form drag correlation for rigid spheres cannot be used.) 14.3-4. Settling Velocliy aJQuartz Particles in Water. Solid quartz particles having a diameter of 1000 pm are settling from water at 294.3 K. The density of the spherical particles is 2650 kgfm 3 • Calculate the terminal settling velocity of these particles. 846

Chap. 14

Problems

14.3-5. Hindered Settling oJ Solid Particles. Solid spherical particles ha ving a diameter of 0.090 mm and a solid density of 2002 kg/m 3 are settling in a solution of water at 26.7°C The volume fraction of the solids in the water is OA5. Calculate the settling velocity and the Reynolds number. 14.3-6. Settling oJ Quartz Particles in Hindered Settling. Particles of quartz having a diameter of 0.127 mm and a specific gravity of 2.65 are settling in water at 293.2 K. The volume fraction of the particles in the slurry mixture of quartz and water is 0.25. Calculate the hindered settling velocity and the Reynolds number. 14.3-7. Density Effect on Settling Velocity and Diameter. Calculate the terminal settling velocity of a glass sphere 0.080 mm in diameter having a density of 2469 kg/m 3 in air at 300 K and 101.32 kPa. Also calculate the diameter of a sphalerite sphere having a specific gravity of 4.00 with the same terminal settling velocity. 14.3-8. Differential Settling oJ Particles. Repeat Example 14.3-3 for particles ha ving a size range of 1.27 x 10- 2 mm to 5.08 x 10 2 mm. Calculate the size range of the various fractions obtained using free settling conditions. Also calculate the value of the largest Reynolds number occurring. 14.3-9. Separation by Settling. A mixture of galena and silica particles has a size range of 0.075-0.65 mm and is to be separated by a rising stream of water at 293.2 K. Use specific gravities from Example 14.3-3. (a) To obtain an uncontaminated product of galena, what velocity of water flow is needed and what is the size range of the pure product? (b) If another liquid, such as benzene, having a specific gravity of 0.85 and a viscosity of 6.50 x 10- 4 Pa' s is used, what velocity is needed and what is the size range of the pure product? 14.3-10. Separation by Sink-and-F1oat Method. Quartz ha ving a specific gravity of 2.65 and hematite having a specific gravity of 5.1 are present in a mixture of particles. It is desired to separate them by a sink-and-float method using a suspension of fine particles of ferrosilicon having a specific gravity of 6.7 in water. At what consistency in vol % ferrosilicon solids in water should the medium be maintained for the separation? 14.3-11. Batch Settling and Sedimentation Velocities. A batch settling test on a slurry gave the following results, where the height z in meters between the clear liquid and the suspended solids is given at time I hours.

t (h)

z (m)

t (h)

z (m)

t (h)

z (m)

o

0.360 0.285 0.211

1.75 3.00 5.00

0.150 0.125 0.113

12.0 20.0

0.102 0.090

0.50 1.00

The original slurry concentration is 250 kg/m 3 of slurry. Determine the velocities of settling and concentrations and make a plot of velocity versus concentration. 14.4-1. Comparison oJ Forces in Centrifuges. Two centrifuges rotate at the same peripheral velocity of 53.34 m/s. The first bowl has a radius of r I = 76.2 mm and the second r 2 = 305 mm. Calculate the rev/min and the centrifugal forces developed in each bowL .Ans. N 1 6684 rev/min, N 2 1670 rev/min, 3806 g's in bowl 1, 951 g's in bowl 2 14.4-2. Forces in a Centrifuge. A centrifuge bowl is spinning at a constant 2000 rev/min. What radius bowl is needed for the following?

Chap. 14

Problems

847

(a) A force of 455 9'S. (b) A force four times that in part (a). ADS. (a) r = 0.1017 m 14.4-3. Effect oj Varying Centrifuge Dimensions and Speed. Repeat Example 14.4-2 but with the following changes. (a) Reduce the rev/min to 10000 and double the outer-bowl radius r 2 to 0.0445 m, keeping r 1 = 0.00716 m. (b) Keep all variables as in Example 14.4-2 but double the throughput ADS. (b) Dp = 1.747 X 10- 6 m 14.4-4. Centrifuging to Remove Food Particles. A dilute slurry contains small solid food particles having a diameter of 5'x 10- 2 mm which are to be removed by centrifuging. The particle density is 1050 kg/m J and the solution density is 1000 kg/m 3 The viscosity of the liquid is 1.2 x 10- 3 Pa' s. A centrifuge at 3000 rev/min is to be used. The bowl dimensions are b = 100.1 mm,r! = 5.00 mm, and r 2 30.0 mm. Calculate the expected flow rate in m 3/s just to remove these particles. 14.4-5. Effect oJOil Density on InterJace Location. Repeat Example 14.4-3, but for the case where the vegetable oil density has been decreased to 914.7 kg/m 3 • 14.4-6. InterJace in Cream Separator. A cream separator centrifuge has an outlet discharge radius r I = 50.8 mm and outlet radius r 4 76.2 mm. The density of the skim milk is 1032 kg/m 3 and that of the cream is 865 kg/m) (EI). Calculate the radius of the interface neutral zone. Ans. r 2 = 150 mm 14.4-7. Scale-Up and 1: Values oj Centrifuges. For the conditions given in Example 14.4-2, do as follows. (a) Calculate the L value. (b) A new centrifuge having the following dimensions is to be used. r 2 = 0.0445 m, r 1 0.01432 m, b = 0.394 m, and N 26000 rev/min. Calculate the new L value and scale-up the flow rate using the same solution. Ans. (a) L = 196.3 m 2

14.4-8. Centrifugal Filtration Process. A batch centrifugal filter similar to Fig. 14.4-5 has a bowl height b = 0,457 m and r 2 0:381 m and operates at 33.33 rev/s at 25.0°C. The filtrate is essentially water. At a given time in the cycle the slurry and cake formed have the following properties. C s 60.0 kg solids/m) filtrate, E 0.82, Pp 2002 kg solids/m 3 , cake thickness 0.152 m, ':l = 6.38 X 10 10 m/kg, Rm 8.53 x 10 10 m - I, r I = 0.2032 m. Calculate the rate of filtrate flow. Ans. q = 6.11 X 10- 4 m 3/s 14.5-1. Change in Power Requirements in Crushing. In crushing a certain ore, the feed is such that 80'% is less than 50.8 mm in size and the product size is such that 80% is less than 6.35 mm. The power required is 89.5 kW. What will be the power required using the same feed so that 80% is less than 3.18 mm? Use the Bond equation. (Hint: The work index Ei is unknown, but it can be determined using the original experimental data in terms of T. In the equation for the new size, the same unknowns appear. Dividing one equation by the other will eliminate these unknowns.) Ans.

146.7 kW

14.5-2. Crushing oj Phosphate Rock. It is desired to crush 100 ton/h of phosphate rock from a feed size where 80% is less than 4 in. to a product where 80% is less than ~ in. The work index is 10.13 (PI). (a) Calculate the power required. (b) Calculate the power required to crus4-the product further where 80% is less than 1000 Jim. -~ . .

848

Chap. 14

Problems

REFERENCES (B1) (B2) (B3) (el) (El) (F 1) (F2) (GI) (H I) (KI) (LI) (L2) (M I) (M2) (NI) (PI) (P2) (Rl) (R2) (S I) (S2) (T I) (ZI)

BADGER, W. L, and BANCHERO, J. T. Introduction to Chemical Engineering. New York: McGraw-Hill Book Company, 1955. BECKER, H. A. Can. J. Chern. Eng., 37, 85 (1951). BOND, F. C. Trans. A.I.M.E., 193, 484 (1952). COULSON, J. M., and RICHARDSON, J. F. Chemical Engineering, Vol. 2, 3rd ed. New York: Pergamon Press, Inc., 1978. EARLE, R. L. Unit Operations in Food Processing. Oxford: Pergamon Press, Inc., 1966. FOUST, AS., el al. Principles of Unit Operations, 2nd ed. New York: John Wiley & Sons, Inc., 1980. FITCH, B. Ind. Eng. Chern., 58 (10), 18 (1966). GRACE, H. P. Chern. Eng. Progr., 46, 467 (1950); 49,303,367,427 (1953); A.I.Ch.E. J., 2, 307 (1956). HUGHES, R. R., and GILLILAND, E. R. Chern. Eng. Progr., 48, 497 (1952). KYNCH, G. J. Trans. Faraday Soc., 48,166 (1952). LARIAN, M. G. FUlldamelllais of Chemical Engineering Operations. Englewood Cliffs, N.J.: Prentice-Hall, Inc., 1958. LAPPLE, C. E., and SHEPHERD, C. B./nd. Eng. Chem., 32,605 (1940). MCCABE, W. L., and SMITH, J. C. Unit Operations of Chemical Engineering, 3rd ed. New York: McGraw-Hill Book Company, 1976. McMILLEN, E. L, and WEBBER, H. A. Trans. A.I.Ch.E., 34,213 (1938). NICKOLAUS, N., and DAHLSTROM, D. A Chern. Eng. Progr.,'52(3), 87M (1956). PERRY, R. H., and GREEN, D. Perry's Chemical Engineers' Handbook, 6lh ed. New York: McGraw-Hill Book Company, 1984. PERRY, R. H., and CHILTON, C. H. Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973. RUTH, B. F., and KEMPE, L L. Trans.A.I.Ch.E., 34, 213 (1938). RUTH, B. F. Ind. Eng. Chem., 25,157 (1933). STEINOUR, H. H. Ind. Eng. Chem., 36, 618, 840 (1944). SHEPHERD, C. B., and LAPPLE, C. E. Ind. Eng. Chem., 31, 972 (1939); 32, 1246 ( 1940). TALMAGE. W. P., and FITCH, E. B. Ind. Eng. Chern., 47(1),38 (1955). ZENZ, F. A, and OTHMER, D. F. Fluidization alld Fluid-Particle Systems. New York: Reinhold Publishing Co., Inc., 1960.

Chap. 14

References

849

APPENDIX A.1

Fundamental Constants and Conversion Factors

A.l-l

Gas Law Constant R

A.1-2

N lJmerical Va/lJe

Units

1.9872 1.9872 82.057 8314.34 82.057 X 10 - 3 8314.34 10.731 0.7302 1545.3 8314.34

g eal/g mol· K btu/Ib mol· oR em 3 . atm/g mol· K J/kg mol, K m 3 • atm/kg mol· K kg- m 2 /s 2 - kg mol· K ft 3 ·lbrJin. 2 ·Ib mol· oR ft 3 . atm/lb mol, oR ft ·Ibrllb mol, oR m 3 . Pa/kg mol· K

Volume and Density

I g mol ideal gas at O°C, 760mm Hg = 22.4140 liters 22414em 3 lib mol ideal gas at ooe, 760 mm Hg 359.05 ft3 1 kg mol ideal gas at ace, 760 mm Hg = 22.414m 3 Density of dry air at ooe, 760 mm Hg = 1.2929 gfliter 0.080711 Ibmlft3 Molecular weight of air 28.97 Ibm lib mol 28.97 gig mol 1 g/em 3 62.431bmlft 3 = 1000 kg/m 3 1 g/em 3 = 8.345IbmlU.S. gal 1 Ib.Jft 3 16.0185 kg/m 3 A.1-3

Length

1 in. 2.540 em 100 em = 1 m (meter) 850

1 micron = 10 - (, m = 10 - 4 cm 10 -:; mm 1 A (angstrom) = 10 10 m 10- 4 Ilm 1 mile = 5280 ft 1 m 3.2808 ft = 39.37 in.

A.l-4

1 pm (micrometer)

Mass

1 Ibm 453.59 g = 0.45359 kg 1 Jb m = 16 oz = 7000 grains 1 kg 1000 g = 2.2046 Ibm 1 ton (short) 2000 Ibm 1 ton (long) = 2240 Ibm 1 ton (metric) = 1000 kg A.1-5

Standard Acceleration of Gravity

g = 9.80665 m/s2 g 980.665 cm/s2 g 32.174 ft/S2 gc (gravitational conversion factor) = 32.1740 Ibm' ft/lb r ' S2 980.665 gm . cm/g! . S2 A.1-6

Volume

1 L (liter) 1000 cm:> 1 in.:; 16.387 em 3 1 ft 3 = 28.317 L (liter) 1 ft 3 = 0.028317 m 3 1 ft3 7.481 U.S. gal 1 m 3 = 264.17 U.S. gal A.1-7

1 m:; = 1000 L (liter) I U.S. gal 4 qt I U.S. gal = 3.7854 L (liter) 1 U.S. gal = 3785.4 cm 3 1 British gal 1.20094 U.S. gal 1 m3 35.313 ft 3

Force

1 g' cm/s2 (dyn) 10- 5 kg· m/s 2 = 10- 5 N (newton) 1 g' cm/s 2 7.2330 x 10- 5 Ibm' ft/S2 (poundal) 1 kg· m/5 2 = 1 N (newton) 1 Ib r = 4.4482 N 1g' cm/s2 = 2.2481 x 10- (,lb r

A.l-8

Pressure

1 bar = 1 x 10 5 Pa (pascal) 1 x 10 5 N/m2 2 1 psia = 1Ibr/in. 1 psia = 2.0360 in. Hg at ooe 1 psia 2.311 ft H 2 0 at 70°F I psia = 51.715 mm Hg at ooe (PHs = 13.5955 gjcm 3 ) 1 atm = 14.696 psia = 1.01325 x 10 5 N/m 2 = 1.01325 bar 1 atm 760 mm Hg at O°C 1.01325 x 10 5 Pa I atm = 29.921 in. Hg at ooe 1 atm = 33.90 ft H 2 0 at 4°C

AppenduA.l

851

1 psia = 6.89476 x 104 g/cm' S2 1 psia 6.89476 x W~ dyn/cm2 1 dyn/cm2 2.0886 x 10- 3 Ibrlft2 1 psia = 6.89476 x 10 3 Nlm 2 6.89476 x 10 3 Pa 2 1 Ibr/ft = 4.7880 x 102 dyn/cm2 = 47.880 N/i~12 1 mm Hg (O°C) 1.333224 x 10 2 N/m2 = 0.1333224 kPa

A.l-9

Power

1 hp = 0.74570 kW 1 hp = 550 ft ·Ibr/s I hp 0.7068 btu/s

A.I-IO

1 watt (W) 14.340 cal/min I btu/h = 0.29307 W (watt) I J/s (joule/s) 1W

Heat, Energy, Work

IJ=lN'm lkg·m 2 /s 2 2 2 1 kg· m /s 1 J (joule) = 10 7 g' cm 1 /s 1 (erg) 1 btu = 1055.06 J = 1.05506 kJ 1 btu = 252.16 cal (thermochemical) 1 kcal (thermochemical) 1000 cal 4.1840 kJ 1 cal (thermochemical) = 4.1840 J 1 cal (IT) = 4.1868 J 1 btu 251.996 cal (IT) 1 btu = 778.17 ft . Ib f Ihp'h 0.7457kW·h 1 hp . h = 2544.5 btu 1 ft· Ib f = 1.35582 J 1 ft ·Ibr/lb m = 2.9890 J/kg

A.l-ll

Thermal Conductivity

1 btu/h·ft·OF = 4.1365 x 10 3cal/s·cm "C 1 btu/h· ft· of 1.73073 W /m . K

A.l-12

Heat-Transfer Coefficient

1 btu/h' ft 2 . OF = 1.3571 x 10- 4 calls' cm 2 • °C 1 btu/h· ft l . OF 5.6783 x 10- 4 W/cm 2 . °C 1 btu/h· ft 2 . OF = 5.6783 W/m 2 • K 1 kcal/h' m 2 . OF 0.2048 btu/h· ft 2 . OF

A.1-13

Viscosity

I cp 10 2 g/cm . s (poise) 1 cp = 2.4191Ib.Jft· h 1 cp = 6.7197 x 1O- 4 Ib;;jft's lcp 1O- 3 Pa's=10 3kg/m's=1O- 3 N's/m 2 1 cp = 2.0886 x 10- 'lb e ' S/ft2 1 Pa' s = 1 N· s1m 2 = 1 kg/m· s 1000 cp 0.67197 Ib m lft· S

852

App. A.l

Fundamental Constants and Conversion Factors

A.I-I4

Diffusivity

1 cm 2 /s = 3.875 ft1lh 1 cm 2/s 10- 4 mlls 1 m 2 /h = 10.764 ftllh A.I-IS

1 m 2 /s = 3.875 x 104 fe/h 1 centistoke 10- 2 cm 2 /s

Mass Flux and Molar Flux

1 gls' cm 2 = 7.3734 x 10 3 1b"ih ' ft2 1 g molls' em 1 = 7.3734 x 10 3 1b mol/h· ft2 1 g mol/s' em 2 10 kg molls' m 1 = 1 x 104 g mol/s' m 1 lIb mol/h· ft2 = 1.3562 X 10- 3 kg molfs· m 2 A.I-I6

Heat Flux and Heat Flow

1 btu/h'

ft2

= 3.1546 W/m 2

1 btu/h = 0.29307 W 1 ealfh 1.1622 x 10- 3 W A.I-17

Heat Capacity and Enthalpy

1 btu/Ibm' OF = 4.1868 kJ/kg' K 1 btu/Ibm' cF = 1.000 cal/g . cC 1 btu/Ibm = 2326.0 J/kg 1 ft· Ibrllb m 2.9890 J/kg 1 cal (IT)/g' °c 4.1868 kJ/kg' K 1 keal/g mol = 4.1840 x 10 3 kJ/kg mol A.I-I8

Mass-Transfer Coefficient

1 kc em/s

= 10- 2 mis 1 kc ft/h 8.4668 x 10 - 5 m/s 1 k, g molls' em 2 • mol frac 10 kg molls' m 2 • mol frac 2 1 kx g moljs' em . mol frac 1 x 10 4 g moljs' m 2 . mol frae 2 I kx Ib mol/h' ft • mol frae = 1.3562 x 10- 3 kg molls' m 2 • mol frae 1 k< a Ib moljh . ft 3 . mol frac = 4.449 x 10 - 3 kg molls' m 3 • mol frae 1 kG kg molls' m 2 . atm 0.98692 x 10- 5 kg molls' m 2 • Pa 1 kG a kg molls' m 3 . atm 0.98692 x 10- 5 kg molls' m 3 . Pa

Appendix A.I

853

APPENDIX A.2

Physical Properties of Water

A.2-1

Latent Heat of Water at 273.15 K (O°C) Latent heat of fusion = 1436.3 cal/g mol 79.724 caljg =

2585.3 btu/lb mol 6013.4 kJ/kg mol

Source: O. A. Hougen. K. M. Watson. and R. A. Ragatz., Chemical Process Principles. Put I. 2nd cd. New York: John Wiley & Sons, Inc .• 1954.

Latent heat of vaporization at 298.15 K (2Ye) Pressure (mm Hg)

Laten! Heal

23.75 760

44 020 kJ/kg mol, 10.514 kcal/g mol, 18925 btu/lb mol 44 045 kJ/kg mol, 10.520 kcaljg mol, 18936 btuflb mol

Source: National Bureau of Standards. Circular 500.

A.2-2

Vapor Pressure of Water

T emperarure

K

273.15 283.15 293.15 298.15 303.15 313.15

cC

0 10 20 25 3040

Vapor Pressure kPa

0.611 1.228 2.338 3.168 4.242 7.375

T emperarure

mmHg

K

4.58 9.21 17.54 23.76 31.82 55.32

323.15 333.15 343.15 353.15 363.15 373.15

°C

50 60 70 80 90 100

Vapor Pressure kPa

12.333 19.92 31.16 47.34 70.10 . 101.325

mmHg

92.51 149.4 233.7 355.1 525.8 760.0

Source: Physikalish·technishe. Reichsansalt, Holborn. Scheel. and Henning, Warmetabellen. Brunswick. Germany: Friedrich Viewig and Son, 1909.

854

A.2-3

Density of

T emperalUre

Water T emperat lire

DensilY

Density

K

"C

g/cm 3

kg/m J

K

°C

g/cm J

273.15 277.15 283.15 293.15 298.15 303.15 313.15

0 4 10 20 25 30 40

0.99987 1.00000 0.99973 0.99823 0.99708 0.99568 0.99225

999.87 1000.00 999.73 998.23 997.08 995.68 992.25

323.15 333.15 343.15 353.15 363.15 373.15

50 60 70 80 90 100

0.98807 0.98324 0.97781 0.97183 0.96534 0.95838

kg/';lJ

988.07 983.24 977.81 971.83 965.34 958.38

Source: R. H. Perry and C. H. Chilton, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973. With permission.

A.2-4

Viscosity d Liquid Water

TemperalUre K

273.15 275.15 277.15 279.15 281.15 283.15 285.15 287:15 289.15 291.15 293.15 293.35 295.15 297.15 298.15 299.15 301.15 303.15 305.15 307.15 309.15 311.15 313.15 315.15 317.15 319.15 321.15

"C

0 2 4 6 8 10 12 14 16 18 20 20.2 22 24 25 26 28 30 32 34 36 38 40 42 44 46 48

ViscosilY [(Pa· s) 10 3 , (kg/m's) 10J, or cp]

1.7921 1.6728 1.5674 1.4728 1.3860 1.3077 1.2363 1.1709 1.111 1 1.0559 1.0050 1,0000 0.9579 0.9142 0.8937 0.8737 0.8360 0.8007 0.7679 0.7371 0.7085 0.6814 0.6560 0.6321 0.6097 0.5883 0.5683

T emperalllre

-

K

cC

323.15 325.15 327.15 329.15 331.15 333.15 335.15 337.15 339.15 341.15 343.15 345.15 347.15 349.15 351.15 353.15 355.15 357.15 359.15 361.15 363.15 365.15 367,15 369.15 371.15 373.15

50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94

96 98 100

ViscosilY [(Pa· s) J03, (kg/m s) 10 3 , or cp]

0.5494 0.5315 0.5146 0.4985 0.4832 0.4688 0.4550 0.4418 0.4293 0.4174 0.4061 0.3952 0.3849 0.3750 0.3655 0.3565 0.3478 0.3395 0.3315 0.3239 0.3165 0.3095 0.3027 0.2962 0.2899 0.2838

and Plasticity. New York: McGraw-Hill Book Com-

Appendix A.2

855

A.2-5

Heat Capacity of Liquid Water at 101.325 kPa (1 Atm) T emperalUre

Heat Capacity,c p

Tempera/llre

Heat Capacity, c p

°C

K

cal/g'oC

kJjkg' K

'C

K

cal/g'oC

kJjkg' K

0 10 20 25 30 40

273.15 283.15 293.15 298.15 303.15 313.15

1.0080 1.0019 0.9995 0.9989 0.9987 0.9987

4.220 4.195 4.185 4.182 4.181 4.181

50 60 70 80 90 100

323.15 333.15 343.15 353.15 363.15 373.15

0.9992 1.0001 1.0013 1.0029 1.0050 1.0076

4.183 4.187 4.192 4.199 4.208 4.219

Source: N. S. Osborne, H. F. Stimson, and D. C. Ginnings, Bur. SWlldards J. Res., 23, 197 (1939).

A.2-6

Thermal Conductivity of Liquid Water Temperature

Thermal Conductivity

°C

OF

K

bllljh '/t . =F

Wjm'K

0 37.8 93.3 148.9 215.6 326.7

32 100 200 300 420 620

273.15 311.0 366.5 422.1 588.8 599.9

0.329 0.363 0.393 0.395 0.376 0.275

0.569 0.628 0.680 0.684 0.651 0.476

Source: D. L. Timrot and N. B. Vargaflik, J. Tech. Phys, (U .S's.R.), 10, 1063(1940); 6th International Conference on the Properties or Steam, Paris, 1964.

A.2-7

Vapor Pressure of Saturated Ice-Water Vapor and Heat of Sublimation

Temperature

Heat of Sublimation

VapoT Pressure

K

OF

°C

kPa

273.2 266.5 261.0 255.4 249.9 244.3 238.8 233.2

32 20 10 0 -10 -20 30 -40

0 -6.7 12.2 -17.8 -23.3 28.9 -34.4 -40.0

6.1 07 X 10- 1 3.478 X 10- 1 2.128 X 10 1 1.275 X 10- t 7.411 X 10 2 '3.. 820 x 10- 2 2.372 X 10- 2 1.283 X 10- 2

psia

8.858 X 5.045 X 3.087 X 1.849 X 1.082 X 6.181 X 3.440 X 1.861 x

10- 2 10- 2 10- 2 10- 2 10- 2 10- 3 10- 3 10- 3

mmHg

btujlbm

kJjkg

4.581 2.609 1.596 0.9562 0.5596 0.3197 0.1779 0.09624

1218.6 1219.3 1219.7 1220.1 1220.3 1220.5 1220.5 1220.5

2834.5 2836.1 2837.0 2838.0 2838.4 2838.9 2838.9 2838.9

Source: ASH RAE, Handbook oj Fundamenzals. New Yor\(: ASHRAE, 1972.

856

App. A.2

Physical Properties of Waler

A.2·8

Heat Capacity of Ice cp

Temperawre

Temperature

of

K

bill/Ibm' F

kJ/kg' K

32 20 10 0

273.15 266.45 260.95 255.35

0.500 0,490 0.481 0.472

2.093 2.052 2.014 1.976

0

of

10 20 30

-40

cp

K

btu/Ibm .oF

kJ/kg'K

249.85 244.25 238.75 233.15

0,461 0.452 0.442 0,433

1.930 1.892 1.850 1.813

Source: Adapted from ASHRAE, Handbook of Fundamentals. New York: ASHRAE, 1972.

A.2-9

Properties of Saturated Steam and Water (Steam Table), SI Units S pecijic Va/ume

Temper. ature (0C)

~

0.01 3 6 9 12 15 18 21 24 25 27 30 33 36 40 45 50 55 60 65 70 75 80 '85 90 95 100

Vapor Pressure (kPa)

0.6113 0.7577 0.9349 1.1477 1.4022 1.7051 2.0640 2.487 2.985 3.169 3.567 4.246 5.034 5.947 7.384 9.593 12.349 15.758 19.940 25.03 31.19 38.58 47.39 57.83 70.14 84.55 101.35

Appendix A.2

(mJ/kg)

Enthalpy (kJjkg)

Liquid

Sa/'d Vapor

Uquid

0,0010002 0.0010001 0.0010001 0.0010003 0.0010005 0.0010009 0.0010014 0.0010020 0.0010027 0.0010029 0.0010035 0.0010043 0.0010053 0.0010063 0.0010078 0.0010099 0.0010121 0.0010146 0.0010172 0.0010199 0.0010228 0.0010259 0.0010291 0.0010325 0.0010360 0.0010397 0.0010435

206.136 168.132 137.734 113.386 93.784 77.926 65.038 54.514 45.883 43.360 38.774 32.894 28.011 23.940 19.523 15.258 12.032 9.568 7.671 6.197 5.042 4.131 3.407 2.828 2.361 1.9819 1.6729

0.00 12.57 25.20 37.80 50.41 62.99 75.58 88.14 100.70 104.89 113.25 125.79 138.33 150.86 167.57 188.45 209.33 230.23 251.13 272.06 292.98 313.93 334.91 355.90 376.92 397.96 419.04

Entropy (kJ/kg' K)

Sa/'d Vapor

Uquid

Sa/'d Vapor

2501.4 2506.9 2512.4 2517.9 2523.4 2528.9 2534.4 2539.9 2545.4 2547.2 2550.8 2556.3 2561.7 2567.1 2574.3 2583.2 2592.1 2600.9 2609.6 2618.3 2626.8 2635.3 2643.7 2651.9 2660.1 2668.1 2676.1

0.0000 0.0457 0.0912 0.1362 0.1806 0.2245 0.2679 0.3109 0.3534 0.3674 0.3954 0.4369 0.4781 0.5188 0.5725 0.6387 0.7038 0.7679 0.8312 0.8935 0.9549 1.0155 1.0753 1.1343 1.1925 1.2500 1.3069

9.1562 9.0773 9.0003 8.9253 8.8524 8.7814 8.7123 8.6450 8.5794 8.5580 8.5156 8.4533 8.3927 8.3336 8.2570 8.1648 8.0763 7.9913 7.9096 7.8310 7.7553 7.6824 7.6122 7.5445 7,4791 7.4159 7.3549 857

A.2-9 SI Units, Continued

Temper. ature (Oe)

105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 190 200 225 250 275 300

Vapor Pressure (kPa)

120.82 143.27 169.06 198.53 232.1 270.1 313.0 316.3 415.4 475~8

543.1 617.8 700.5 791.7 892.0 1002.1 1254.4 1553.8 2548 3973 5942 8581

¥

Specific Volume (ml/kg) ,

Liquid

0.0010475 0.0010516 0.0010559 0.0010603 0.0010649 0.0010697 0.0010746 0.0010797 0.0010850 0.0010905 0.0010961 0.0011020 0.0011080 0.0011143 0.0011207 0.0011274 0.0011414 0.0011565 0.0011992 0.0012512 0.0013168 0.0010436

Sa/'d Vapor

1.4194 1.2102 1.0366 0.8919 0.7706 0.6685 0.5822 0.5089 0.4463 0.3928 0.3468 0.3071 0.2727 0.2428 0.2168 0.19405 0.15654 0.12736 0.07849 0.05013 0.03279 0.02167

Enthalpy (kJjkg)

Entropy (kJ/kg' K)

Liquid

Sat'd Vapor

Liquid

Sat'd Vapor

440.15 461.30 482.48 503.71 524.99 546.31 567.69 589.13 610.63 632.20 653.84 675.55 697.34 719.21 741.17 763.22 807.62 852.45 966.78 1085.36 1210.07 1344.0

2683.8 2691.5 2699.0 2706.3 2713.5 2720.5 2727.3 2733.9 2740.3 2746.5 2752.4 2758.1 2763.5 2768.7 2773.6 2778.2 2786.4 2793.2 2803.3 2801.5 2785.0 2749.0

1.3630 1.4185 1.4734 1.5276 1.5813 1.6344 1.6870 1.7391 1.7907 1.8418 1.8925 1.9427 1.9925 2.0419 2.0909 2.1396 2.2359 2.3309 2.5639 2.7927 3.0208 3.2534

7.2958 7.2387 7.1833 7.1296 7.0775 7.0269 6.9777 6.9299 6.8833 6.8379 6.7935 6.7502 6.7078 6.6663 6.6256 6.5857 6.5079 6.4323 6.2503 6.0730 5.8938 5.7045

Source: Abridged from J. H. Keenan, F. G. Keyes, P. G. Hill, and 1. G. Moore, Steam Tables-Metric Units. New New York: John WlIey & Sons, Inc., 1%9. Reprinted by permission of John Wiley & Sons, Inc.

A.2-9 Properties of Saturated Steam and Water (Steam Table), English Units TemperalUre (OF)

32.02 35 40 45 50 55 858

Vapor Pressure (psia)

0.08866 0.09992 0.12166 0.14748 0.17803 0.2140

Specific Volume (ft3/Ib m ) Liquid

0.016022 0.016021 0.016020 0.016021 0.016024 0.016029

Sa/'J Vapor

3302 ,,2948 2445 2037 1704.2 1431.4

Enthalpy (bw/lb..J Liquid

Entropy (btullb m . 0 F)

Sar'd Vapor

Liquid

Sat'J Vapor

1075.4 1076.7 1078.9 1081.1 1083.3 1085.5

0.000 0.00607 0.01617 0.02618 0.03607 0.04586

2.1869 2.1764 2.1592 2.1423 2.1259 2.1099

0.00 3.00 8.02 13.04 18.06 23.07 .r1.pp. A.2

Physical Properties of Water

A.2-9

TemperaIUre (oF)

r

60 65 70 75 80 85 90 95 100 110 120 130 140 150 160 170 180 190 200 210 212 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390

400 410 450

English Units, Continued Specific Volume (ji3/1b"J

Enthalpy (btu/lbJ

Entropy (btu/Ibm' 0 F)

Vapor Pressure (psia)

Liquid

Sm'd Vapor

Liquid

'}at'd Vapor

Liquid

Sar'd Vapor

0.2563 0.3057 0.3622 0.4300 0.5073 0.5964 0.6988 0.8162 0.9503 1.2763 1.6945 2.225 2.892 3.722 4.745 5.996 7.515 9.343 11.529 14.125 14.698 17.188 20.78 24.97 29.82 35.42 41.85 49.18 57.33 66.98 77.64 89.60 103.00 117.93 134.53 152.92 173.23 195.60 220.2 247.1 276.5 422.1

0.016035 0.016042 0.016051 0.016061 0.016073 0.016085 0.016099 0.016114 0.016130 0.016166 0.016205 0.016247 0.016293 0.016343 0.016395 0.016450 0.016509 0.016570 0.016634 0.016702 0.016716 0.016772 0.016845 0.016922 0.017001 0.017084 0.017170 0.017259 0.017352 . 0.017448 0.017548 0.017652 0.Dl7760 0.017872 0.017988 0.018108 0.018233 0.018363 0.018498 0.018638 0.Dl8784 0.019433

1206.9 1021.5 867.7 739.7 632.8 543.1 467.7 404.0 350.0 265.1 203.0 157.17 122.88 96.99 77.23 62.02 50.20 40.95 33.63 27.82 26.80 23.15 19.386 16.327 13.826 11.768 10.066 8.650 7.467 6.472 5.632 4.919 4.312 3.792 3.346 2.961 2.628 2.339 2.087 1.8661 1.6726 1.1011

28.08 33.09 38.09 43.09 48.09 53.08 58.07 63.06 68.05 78.02 88.00 97.98 107.96 117.96 127.96 137.97 147.99 158.03 168.07 178.14 180.16 188:22 198.32 208.44 218.59 228.76 238.95 249.18 259.44 269.73 280.06 290.43 300.84 311.30 321.80 332.35 342.96 353.62 364.34 375.12 385.97 430.2

1087.7 1089.9 1092.0 1094.2 1096.4 1098.6 1100.7 11 02.9 1105.0 1109.3 1113.5 1117.8 1121.9 1126.1 1130.1 1134.2 1138.2 1142.1 1145.9 1149.7 1150.5 1153.5 1157.1 1160.7 1164.2 1167.6 1170.9 1174.1 1177.2 1180.2 1183.0 1185.8 1188.4 1190.8 1193.1 1195.2 1197.2 1199.0 1200.6 1202.0 1203.1 1205.6

0.05555 0.06514 0.07463 0.08402 0.09332 0.10252 0.11165 0.12068 0.12963 ,0.14730 0.16465 0.18172 0.19851 0.21503 0.23130 0.24732 0.26311 0.27866 0.29400 0.30913 0.31213 0.32406 0.33880 0.35335 0.36772 0.38193 0.39597 0.40986 0.42360 0.43720 0.45067 0.46400 0.47722 0.49031 0.50329 0.51617 0.52894. 0.54163 0.55422 0.56672 0.57916 0.6282

2.0943 2.0791 2.0642 2.0497 2.0356 2.0218 2.0083 1.9951 1.9822 1.9574 1.9336 1.9109 1.8892 1.8684 1.8484 1.8293 1.8109 1.7932 1.7762 1.7599 1.7567 1.7441 1.7289 1.7143 1.7001 1.6864 1.6731 1.6602 1.6477 1.6356 1.6238 1.6123 1.6010 1.5901 1.5793 1.5688 1.5585 1.5483 1.5383 1.5284 1.5187 1.4806

Source: Abridged from J. H. Keenan, F. G. Keyes, P. G. Hill, and J. G. Moore, Steam Tables-Eng/ish Units. New York: John Wiley & Sons, Inc., 1%9. Reprinted by pennission of John Wiley & Sons, Inc.

r

Appendix A.2

859

A.2-10

Properties of Superheated Steam (Steam Table), SI Units (v, specific volume, m 3 /kg; H, enthalpy, kJ/kg; s, entropy, kJ/kg· K)

Absolute Pressure, kPa Temperature (0C)

(Sat.

Temp., 0C)

JOO

150

200

250

300

360

420

500

V

10 (45.81)

17.196 H 2687.5 s 8,4479

19.512 2783.0 8.6882

21.825 2879.5 8,9038

24.136 2977.3 9.1002

26.445 3076.5 9.2813

29.216 3197.6 9,4821

31.986 3320.9 9.6682

35.679 3489.1 9.8978

V

50 (81.33)

3.418 H 2682.5 s 7.6947

3.889 2780.1 7.9401

4.356 2877.7 8.1580

4.820 2976.0 8.3556

5.284 3075.5 8.5373

5.839 3196.8 8.7385

6.394 3320,4 8.9249

7.134 3488.7 9.1546

V

75 (91.78)

2.270 H 2679.4 s 7.5009

2.587 2778.2 7.7496

2.900 2876.5 7.9690

3.211 2975.2 8.1673

' 3.520 3074.9 8.3493

3.891 3196,4 8.5508

4.262 3320.0 8.7374

4.755 3488.4 8.9672

V

100 (99.63)

1.6958 If 2672.2 s 7.3614

1.9364 2776.4 7.6134

2.172 2875.3 7.8343

2.406 2974.3 8.0333

2.639 3074.3 8.2158

2.917 3195.9 8,4175

3.195 3319.6 8.6042

3.565 3488.1 8.8342

v H

1.2853 2772.6 7,4193

1.4443 2872.9 7.6433

1.6012 2972.7 7.8438

1.7570 3073.1 8.0720

1.9432 3195.0 8.2293

2.129 3318.9 8,4163

2.376 3487.6 8.6466

V

0,4708 2752.8 6.9299

0.5342 2860.5 7.1706

0.5951 2964.2 7.3789

0.6548 3066.8 7.5662

0.7257 3190.3 7.7712

0.7960 3315.3 7.9598

0.8893 3484.9 8.1913

0.2999 2844.8 6.8865

0.3363 2953.6 7.1053

0.3714 3059.1 7.2979

0,4126 3184.7 7.5063

0,4533 3310.9 7.6968

0.5070 3481.7 7.9299

0.2060 2827.9 6.6940

0.2327 2942.6 6.9247

0.2579 3051.2 7.1229

0.2873 3178.9 7.3349

0.3162 3306.5 7.5275

0.3541 3478.5 7.7622

0.13248 2796.8 6.4546

0.15195 2923.3 6.7090

0.16966 3037.6 6.9179

0.18988 3.1692 7.1363

0.2095 3299.1 7.3323

0.2352 3473.1 7.5698

H 2000 (212,42) s

0.11144 2902.5 6.5453

0.12547 3023.5 6.7664

0.14113 3159.3 6.9917

0.15616 3291.6 7.1915

0.17568 3467.6 7,4317

v 2500 H (223.99) s

0.08700 2880.1 6.4085

0.09890 3008.8 6.6438

0.11186 3149.1 6.8767

0.12414 3284.0 7.0803

0.13998 3462.1 7.3234

0.07058 2855.8 6.2872

0.08114 2993.5 6.5390

0.09233 3138.7 6.7801

0.10279 3276.3 6.9878

0.11619 3456.5 7.2338

150 (111.37) s

400 H s (143.63) v H 700 (164.97) s V

H 1000 (179.91) s V

H 1500 ( 198.32) s V

V

H 3000. (233.90) s

Source: Abridged from 1. H. Keenan, F. G. Keyes, P. G. Hill, and 1. G. Moore, Sream Tables-Merrie Unirs. New York: John Wiley & Sons, Inc., 1%9. Reprinted by permission of John Wiley. & Sons, Inc.

860

App. A.2

Physical Properties of Water

A.2-10

Properties of Superheated Steam (Steam Table), English Units (v, specific volume, ft 3/lb",; H, enthalpy, btu/Ibm; s, entropy, btu/Ibm' OF)

Absolute Pressure, psia (Sat. Temp., oF)

Temperature (OF)

200

300

400

500

600

700

800

900

1000

v 392.5 452.3 511.9 571.5 631.1 690.7 750.3 809.9 869.5 1.0 H 1150.! 1195.7 1241.8 1288.5 1336.1 1384.5 1433.7 1483.8 1534.8 (101.70) s 2.0508 2.1150 2.1720 2.2235 2.2706 2.3142 2.3550 2.3932 2.4294 V

78.15

90.24 102.24 114.20 126.15 138.08 150.01 161.94 173.86

H 1148.6 1194.8 1241.2 1288.2 1335.8 1384.3 1433.5 1483.7 1534.7 (162.21) s 1.8715 1.9367 1.9941 2.0458 2.0930 2.1367 2.1775 2.2158 2.2520 5.0

v 38.85 44.99 51.03 57.04 63.03 69.01 74.98 80.95 86.91 H 1146.6 1193.7 1240.5 1287.7 1335.5 1384.0 1433.3 1483.5 1534.6 (193.19) s 1.7927 1.8592 1.9171 1.9690 2.0164 2.0601 2.1009 2.1393 2.1755 10.0

v H (211.99) s 14.696

v

H (227.96) s 20.0

V

H (292.73) s 60.0

V

H (327.86) s 100.0

V

150.0

f-I

(358.48) s V

H (381.86) s 200.0

V

250.0

H

(401.04) s V

300.0 H (417.43) s V

400 H (444.70) s ·hn

30.52 34.67 38.77 42.86 46.93 51.00 55.07 59.13 1192.6 1239.9 1287.3 1335.2 1383.8 1433.1 1483.4 1534.5 1.8157 1.8741 1.9263 1.9737 2.0175 2.0584 2.0967 2.1330 22.36 25.43 28.46 31.47 34.77 37.46 40.45 43.44 1191.5 1239.2 1286.8 1334.8 1383.5 1432.9 1483.2 1534.3 1.7805 1.8395 1.8919 1.9395 1.9834 2.0243 2.0627 2.0989 7.260 8.353 9.399 10.425 11.440 12.448 13.452 14.454 1181.9 1233.5 1283.0 1332.1 1381.4 1431.2 1481.8 1533.2 1.6496 1.7134 1.7678 1.8165 1.8609 1.9022 1.9408 1.9773 4.934 5.587 6.216 6.834 7.445 8.053 8.657 1227.5 1279.1 1329.3 1379.2 1429.6 1480.5 1532.1 1.6517 1.7085 1.7582 1.8033 1.8449 1.8838 1.9204 3.221 3.679 4.111 4.531 4.944 5.353 5.759 1219.5 1274.1 1325.7 1376.6 1427.5 1478.8 1530.7 1.5997 1.6598 1.7110 1.7568 1.7989 1.8381 1.8750 2.361 2.724 3.058 3.379 3.693 4.003 4.310 1210.8 1268.8 1322.1 1373.8 1425.3 1477.1 1529.3 1.5600 1.6239 1.6767 1.7234 1.7660 1.8055 1.8425 2.150 2.426 2.688 2.943 3.193 3.440 1263.3 1318.3 1371.1 1423.2 1475.3 1527.9 1.5948 1.6494 1.6970 1.7401 1.7799 1.8172 1.766 2.004 2.227 2.442 2.653 2.860 1257.5 1314.5 1368.3 1421.0 1473.6 1526.5 1.5701 1.6266 1.6751 1.7187 1.7589 1.7964 1.2843 1.4760 1.6503 1.8163 1.9776 2.136 1245.2 1306.6 1362.5 1416.6 1470.1 1523.6 1.5282 1.5892 1.6397 1.6884 1.7252 1.7632

Source: Abridged from J. H. Keenan, F. G. Keyes, P. G. Hill, and J. G. Moore. Sream Tables-Merric Units. New York: John Wiley & Sons, Inc., 1969. Reprinted by permission of John Wiley & Sons, Inc.

Appendi.x A.2

861

A.2-11

Heat-Transfer Properties of Liquid Water, SI Units Jl

T

(0C)

(K)

0 15.6 26.7 37.8 65.6 93.3 12l.! 148.9 204.4 260.0 315.6

273.2 288.8 299.9 311.0 338.8 366.5 394.3 422.1 477.6 5:>3.2 588.8

999.6 998.0 996.4 994.7 981.9 962.7 943.5 917.9 858.6 784.9 679.2

4.229 4.187 4.183 4.183 4.187 4.229 4.271 4.312 4.522 4.982 6.322

1.786 1.131 0.860 0.682 0.432 0.3066 0.2381 0:1935 0.1384 0.1042 0.0862

0.5694 0.5884 0.6109 0.6283 0.6629 0.6802 0.6836 0.6836 0.6611 0.6040 0.5071

(11K)

13.3 8.07 5.89 4.51 2.72 1.9\ 1.49 1.22 0.950 0.859 l.07

(gfJp2I p l) X 10- 8 (I/K ·m 3 )

0.630 10.93 1.44 30.70 2.34 3.24 68.0 '256.2 5.04 642 6.66 1300 8.46 2231 10.08 14.04 5308 11030 19.8 19260 31.5

Heat-Transfer Properties of Liquid Water, English Units p

cp

Jl X

10 3

T ("F)

G~) (~) U~:) Ibm·oF

32 60 80 100 150 200 250 300 400 500 600

62.4 62.3 62.2 62.1 61.3 60.1 58.9 57.3 53.6 49.0 42.4

862

p x 10"

k P Cp (Pa ·s, or (kg/m 3 ) (kJ/kg'K) kg/m's) (W/m'K) N p ,

T

A.2-11

x 10 3

1.01 1.00 0.999 0.999 1.00 1.01 1.02 1.03 1.08 1.19 1.51

1.20 0.760 0.578 0.458 0.290 0.206 0.160 0.130 0.0930 0.0700 0.0579

k (

btu ) hIt·oF

0.329 0.340 0.353 0.363 0.383 0.393 0.395 0.395 0.382 0.349 0.293

N p,

(ltR)

(gPp2Ipl) X 10- 6 (It R It 3)

13.3 8.07 5.89 4.51 2.72 1.91 1.49 1.22 0.950 0.859 1.07

-0.350 0.800 1.30 1.80 2.80 3.70 4.70 5.60 7.80 11.0 17.5

17.2 48.3 107 403 1010 2045 3510 8350 17350 30300

fJ X 104

App. A.2

Physical Properties of Water

. A.2-12

Heat-Transfer Properties of Water Vapor (Steam) at 101.32 kPa (l Atm Abs), SI Units p x

T (0C)

T (K)

100.0 148.9 204.4 260.0 315.6 371.1 426.7

373.2 422.1 477.6 533.2 588.8 644.3 699.9

A.2-12

k P Cp (Pa's,or (kg/m3) (kJ /kg· K) kglm' s) (Wlm·K) N pr

212 300 400 500 600 700 800

0.596 0.525 0.461 0.413 0.373 0.341 0.314

1.295 1.488 1.682 1.883 2.113 2.314 2.529

1.888 1.909 1.934 1.968 1.997 2.030 2.068

0.02510 0.02960 0.03462 0.03946 0.04448 0.04985 0.05556

fJ

0.96 0.95 0.94 0.94 0.94 0.93 0.92

x 10 3 (11K)

2.68 2.38 2.09 1.87 1.70 1.55 1.43

gf3p2/p2 (ilK m 3 )

0.557 0.292 0.154 0.0883 52.1 33.1 21.6

x x x x x x x

10 8 lOB lOB 10 8 10 5 10 5 10 5

Heat-Transfer Properties of Water Vapor (Steam) at 101.32 kPa (1 Atm Abs), English Units cp

p T (F)

10 5

('fb

m

l3

x 105

G~:)

)

0.0372 0.0328 0.0288 0.0258 0.0233 0.0213 0.0196

J-l.

0.451 0.456 0.462 0.470 0.477 0.485 0.494

0.870 1.000 1.130 1.265 1.420 1.555 1.700

k (

h-Jt·oF

N pr

fJ X 10 3 (JtR)

0.0145 0.0171 0.0200 0.0228 0.0257 0.0288 0.0321

0.96 0.95 0.94 0.94 0.94 0.93 0.92

1.49 1.32 1.16 1.04 0.943 0.862 0.794

bIll

)

gfJ p 2/ p 2 (itR .p)

0.877 0.459 0.243 0.139 82 52.1 34.0

x x x x x x x

10 6 10 6 10 6 10 6 10 3 10 3 10 3

Source: D. L Timrot and N. B. Vargaftik, J. Tech. Phys. (U.S.S.R.}, 10, 1063 (1940); R. H. Perry and C. H. Chilton, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hili Book Company, 1973; J. H. Keenan. F. G. Keyes, P. G. Hill, and J. G. Moore, Steam Tables. New York: John Wiley & Sons, Inc., 1969; National Research Council, International Critical Tables. New York: McGraw-Hill Book Company, 1929; L. S. Marks, Mechanical Engineers' Handbook, 5th ed. New York: McGraw. Hill Book Company, 1951.

r

Appendix A.2

863

APPENDIX A.3

Physical Properties of Inorganic and Organic Compounds

A.3-1 Standard Heats of Formation at 298.15 K (25°C) and 101.325 kPa (1 Atm Abs), (c) crystalline, (g) = gas, (I) = liquid flU; Compound

NH)(g) NO(g) H 2 O(l) H 2 O(y) HCN(y) HCI(y) H 2 S0 4 (1) H 3 P0 4 (C) NaCl(e) NH 4 CI(e)

flH;

(kJJk{1 moT)lO- J kealJg mol

-46.19 + 90.374 285.840 241.826 + 130.1 92.312 - 81 L32 -J28L1 411.003 315.39

-11.04 +21.600 -68.3174 57.7979 + 31.1 -22.063 -193.91 -306.2 98.232 75.38

Compound

CaCOJ(e). CaO(e) CO(g) CO 2 (y) CH 4 (y) C 1 H 6 (g) CJHs(Y) CH)OH(I) ·CH)CH)OH(l)

(kJ /kg mol)lO- 3 keal/g mol

1206.87 635.5 -110.523 - 393.513 -74.848 -84.667 103.847 238.66 277.61

288.45 151.9 26.4157 -94.0518 -17.889 -20.236 -24.820 57.04 66.35

Source: J. H. Perry and C. H. Chillon. Chemical Engineers' Handbook, 5th ed. New York: McGraw·HiII Book Company, 1973; and O. A. Hougen. K. M. Watson, and R. A. Ragalz, Chemical Process Principles, Pan I. 2nd cd. New York: John Wiley & Sons. Inc., 1954.

864

A.3-2

Standard Heats of Combustion at 298.15 K (2S°C) and 101.325 kPa (1 Atm Abs) (g) == gas, (I) == liquid, (s) = solid Mi~

Combustion Reaction

Compound C(s) CO(g) C(s) H 2(g) H 2(g) CH.,.(g) C Z H 6 (g) CJHa(g) d-Glucose (dextrose) C 6 H,206(S) Lactose (anhydrous) C, 2H220'l(S) Sucrose C'2 H 120,,(S)

C(s) + t02(g)-' CO(g) CO(g) + t02(g)-+ COl(g) C(s) + 02(g)-> CO 2(g) H 2(g) + t02(g) -, H 2 0 (1) H 2 (g) + i02(g)-' H 2 O(g) CH.(g) + 20 2 (g)-+ COl(g) + 2H 2O(1) C 2H 6 (g) + i02(g)-' 2C0 2 (g) + 3H 2O(1) C JHs(g) + 50 2(g)·_> 3C0 2 (g) + 4H 20(1)

-26.4157 - 67.6361 94.0518 - 68.3174 57.7979 -212.798 -372.820 - 530.605

+ 60 2 (g)-' 6C0 2 (y) + 6H 2 O(1)

C6H,206(S)

(J.:.J /kg mol)10- 3

kcai/g mol

-110.523 -282.989 - 393.513 -285.840 241.826 -890.346 -1559.879 2220.051

673

2816

ll (s)

+

120 2 (g)-> 12COAg)

+

IIH 20(l)

1350.1

-5648.8

C 1z H 22 0, ,(s)

+

120 2(g)-> 12C0 2(g)

+

IIH zO(1)

-1348.9

- 5643.8

C 12 H 12 0

SOl/ree: R. H. Perry and C. H. Chilton. Chemical Engineers' Handbook, 51h ed, New York: McGraw·HiII Book Company, 1973; and O. A. Hougen. K. M. Watson, and R. A. Ragatz, Chemical Process Principles, Part I. 2nd ed. New York: Jonn Wiley & Sons, Inc., 1954.

16 C2 H 6

J S03

fc J

/ II II / -~~ ~! 1//

~14

13

E c.

12

,... 0



N p,

0.720 0.715 0.713 0.705 0.702 0.694 0.692 0.689 0.687 0.686 0.684 0.680

3.92 3.65 3.53 3.22 2.95 2.74 2.54 2.38 2.21 2.09 1.98 1.87

2.79 2.04 1.72 1.12 0.775 0.534 0.386 0.289 0.214 0.168 0.130 0.104

x x x x x x x x x x x x

10 8 108 10 8 108 10 8 108 108 10 8 108 108 10 8 108

k

J1 (bW) ('bII)m) ( Ibm'bIU) F (cenripoise) h"/I" F

0.0861 0.0807 0.0778 0.Q710 0.0651 0.0602 0.0559 0.0523 0.0490 0.0462 0.0437 500 0.0413

0 32 50 100 150 200 250 300 350 400 450

1.379 1.293 1.246 1.137 1.043 0.964 0.895 0.838 0.785 0.740 0.700 0.662

X

(ilK)

C

0.240 0.240 0.240 0.240 0.241 0.241 0.242 0.243 0.244 0.245 0.246 0.247

0.0162 0.0172 0.0178 0.0190 0.0203 0.0215 0.0227 0.0237 0.0250 0.0260 0.0271 0.0280

0.0130 0.0140 0.0144 0.0156 0.0169 0.0180 0.0192 0.0204 0.0215 0.0225 0.0236 0.0246

{J

X

10 3

N p'

(J/"R)

0.720 0.715 0.713 0.705 0.702 0.694 0.692 0.689 0.687 0.686 0.674 0.680

2.18 2.03 1.96 1.79 1.64 1.52 1.41 1.32 1.23 L16

LlO 1.04

9{JP2/112

(l;oR "/t)

4.39 3.21 2.70 1.76 1.22 0.840 0.607 0.454 0.336 0.264 0.204 0.163

X X X X X X X X X X X X

10 6 10 6 10 6 10 6 10 6 10 6 106 10 6 10 6 10 6 10 6 10 6

Source: National Bureau of Standards, Circular 461C, 1947; 564, 1955; NBS-NACA, Tables of Thermal Propeflies of Gases, 1949; F. G. Keyes. Trans. A.S.M.E., 73,590,597 (1951); 74, 1303 (1952): D. D. Wagman, Selected Values of Chemical Thermodynamic Properties. Washinglon, D.C.: National Bureau of Standards., 1953.

866

App,A3

Physical Properties of Inorganic and Organic Compounds

A.3-4

Viscosity of Gases at 101315 kPa (1 Atm Abs) IViscosity in (Pa • s) 10 3 , (kg/m. s) 10\ orcp)

Temperalllre

K

of

°C

11 z

°2

N2

CO

CO 2

255.4 273.2 283.2 311.0 338.8 366.5 394.3 422.1 449.9 477.6 505.4 533.2

0 32 50 100 150 200 250 300 350 400 450 500

-17.8 0 10.0 37.8 65.6 93.3 121.1 148.9 176.7 204.4 232.2 260.0

0.00800 0.00840 0.00862 0.00915 0.00960 0.0101 0.0106 0.0111 0.0115 0.0119 0.0124 0.0128

0.0181 0.0192 0.0197 0.0213 0.0228 0.0241 0.0256 0.0267 0.0282 0.0293 0.0307 0.Q315

0.0158 0.0166 0.0171 0.0183 0.0196 0.0208 0.0220 0.0230 0.0240 0.0250 0.0260 0.0273

0.0156 0.0165 0.0169 0.0183 0.0195 0.0208 0.0220 0.0231 0.0242 0.0251 0.0264 0.0276

0.0128 0.0137 0.0141 0.0154 0.0167 0.0179 0.0191 0.0203 0.0215 0.0225 0.0236 0.0247

Source: National Bureau of Standards, Circular 461C, 1947; SM, 1955; NBS-NACA, Tables oj Thermal Properties oj Gases, 1949; F. G. Keyes, Trans. A.S.M.E., 73, 590, 597 (1951): 74. 1303 (1952); D. D. Wagman, Selecred Values oj Chemical Thermodynamic Properries. Washington, D.C.: National Bureau ofSlandards, 1953.

Appendix A.3

867

g; A.3-5

Thermal Conductivity of Gases at 101.325 kPa (I Atm Abs) H,

)..

~

CO

N,

0,

Telllpera/llre

)..

1....,

~ ~

.....,'"

~.

~ ..... ::s Cl

ci;l

;::,

::.

n' t:>

::.

K

"C

OF

W/m·K

h.!t of

W/m'K

II'!I·oF

W/m·K

h-ji·oF

W/m·K

h·!t·oF

255.4 273.2 283.2 311.0 338.8 366.5 394.3 422.1 449.9 477.6 505.4 533.2

-17.8 0 10.0 37.8 65.6 93.3 121.1 148.9 176.7 204.4 232.2 260.0

0 32 50 100 150 200 250 300 350 400 450 500

0.1592 0.1667 0.1720 0.1852 0.1990 0.2111 0.2233 0.2353 0.2458 0.2579 0.2683

0.0920 0.0963 0.0994 0.107 0.115 0.122 0.129 0.136 0.142 0.149 0.155 0.161

0.0228 0.0246 0.0253 0.0277 0.0299 0.0320 0.0343 0.0363 0.0382 0.0398 0.0422 0.0438

0.0132 0.0142 0.0146 0.0160 0.0173 0.0185 0.0198 0.0210 0.0221 0.0230 0.0244 0.0253

0.0228 0.0239 0.0248 0.0267 0.0287 0.0303 0.0329 0.0348 0.0365 0.0382 0.0400 0.0419

0.0132 0.0138 0.0143 0.0154 0.0166 0.0175 0.0190 0.0201 0.0211 0.0221 0.0231 0.0242

0.0222 0.0233 0.0239 0.0260 0.0279 0.0296 0.Q318 0.0338 0.0355 0.0369 0.0384 0.0407

0.0128 0.0135 0.0138 0.0150 0.0161 0.0171 0.0184 0.0195 0.0205 0.0213 0.0222 0.0235

Q.2786

0.0132 0.0145 0.0152 0.0173 0.0190 0.0216 0.0239 0.0260 0.0286 0.0308 0.0334 0.0355

0.0076 0.0084 0.0088 0.0100 0.0110 0.0125 0.0138 0.0150 0.0165 0.0178 0.0193 0.0205

1:1..

C ci;l

Source: National Bureau of Standards, Circular 461C. 1947; 564,1955; NBS-NACA, Table of Thermal Properties of Gases, 1949; F. O. Keyes, Trans. A.S.M.E., 73. 590, 597 (1951); 74, 1303 (1952); D. D. Wagman, Selecred Values of Chemical Thermodynamic Properries. Washington, D.C.: National Bureau of Standards. 1953.

;::,

::. i";'

~ ~Cl t:: ::.

!:}

a'Uk.t'i.~~i:..:.,i4"'''':',,:;,,,;.;.,,,,,;,,.'_''>'

, .. ~-'""~ .. ;;,,,.

~ 'I:l

;:, '"t).

>;. ~

l...

A.3-6

Heat Capacity of Gases at Constant Pressure at 10 1.325 kPa (l Atm Abs)

co

------

CO 2

K

"C

OF

kl/·K

Ib .OF

kg' K

Ib m. OF

kg'K

Ibm' OF

kJf kg· K

btu/ Ibm' OF

kJf kg· K

btu/ Ibm' OF

255.4 273.2 283.2 311.0 338.8 366.5 394.3 422.1 449.9 477.6 505.4 533.2

-17.8 0 10.0 37.8 65.6 93.3 12l.! 148.9 176.7 204.4 232.2 260.0

0 32 50 100 150 200 250 300 350 400 450 500

14.07 14.19 14.19 14.32 14.36 14.40 14.44 14.49 14.49 14.49 14.52 14.52

3.36 3.39 3.39 3.42 3.43 3.44 3.45 3.46 3.46 3.46 3.47 3.47

0.909 0.913 0.917 0.921 0.925 0.929 0.938 0.946 0.955 0.963 0.971 0.976

0.217 0.218 0.219 0.220 0.221 0.222 0.224 0.226 0.228 0.230 0.232 0.233

1.034 1.038 1.038 1.038 1.038 1.043 1.043 1.047 1.047 1.051 1.055 1.059

0.247 0.248 0.248 0.248 0.248 0.249 0.249 0.250 0.250 0.251 0.252 0.253

1.034 1.038 1.038 1.043 1.043 1.047 1.047 1.051 1.055 1.059 1.063 1.068

0.247 0.248 0.248 0.249 0.249 0.250 0.250 0.251 0.252 0.253 0.254 0.255

0.800 0.816 0.825 0.854 0.883 0.904 0.929 0.950 0.976 0.996 1.017 1.030

0.191 0.195 0.197 0.204 0.211 0.216 0.222 0.227 0.233 0.238. 0.243 0.246

or

S""rn:: National Bureau Sta",larcis. Cire"!,,, 46lC, 1947; 564, 1955; NBS-NACA, Tubles o/Thermal Proper/ies 0/ Guses, 1949; F. G. Kcy~s, Tru/lS. A.S.M .E., 73, 590, 5')7 (1951); 74, 130J (1952); D. D. Wagman, Sclecled Va/ues oj Chemku/ Thermudy,wmic ['ruperties. Washington, D.C.: Nationul13urcau or Standards, 1953.

~

A.3-7

Prandtl Number of Gases at 101325 kPa (1 Atm Abs) T emperat ure

°C

17.8 0 10.0 37.8 65.6 93.3 121.1 148.9 176.6 204.4 232.2 260.0

OF

K

H2

°2

0 32 50 100 150 200 250 300 350 400 450 500

255.4 273.2 283.2 311.0 338.8 366.5 394.3 422.1 449.9 477.6 505.4 533.2

0.720 0.715 0.710 0.700 0.700 0.694 0.688 0.683 0.677 0.670 0.668 0.666

0.720 0.711 0.710 0.707 0.706 0.703 0.703 0.703 0.704 0.706 0.702 0.700

N2

0.720 0.720 0.717 0.710 0.700 0.700 0.696 0.690 0.689 • 0.688 0.688 0.688

CO

CO 2

0.740 0.738 0.735 0.731 0.727 0.724 0.720 0.720 0.720 0.720 0.720 0.720

0.775 0.770 0.769 0.764 0.755 0.752 0.746 0.738 0.734 0.725 0.716 0.702

Source: National Bureau of Standards, Circular 461C. 1947; 564,1955; NB5-NACA, Taoles of Thermal Propenies of Gases, 1949; F. G. Keyes, Trans. A.S.M.E., 73,590,597 (1951); 74, 1303 (1952): D. D. Wagman, SeleCTed Values of Chemical Thermodynamic Properries. Washington, D.C.: National Bureau of Standards, 1953.

870

App. A.3

Physical Properties of Inorganic and Organic Compounds

Temperature ('C) (OP)

Viscosity [(kglm' s)10 3 or cp]

-100

0.1 0.09 -100

0.08 0.07 0.06

o o

0.05 30 100

28 26

t±

200

100

I

24 22

300 400

16 Y

300

600 700

14 12

I I ! i

900

500

1000 600

1100

700

1300

1200 1400 1500 1600 1700 1800

800

6

i

!

i

I

!

I

0.03

i

i i i

I I

I

0.02

! !

[

I :

!

i

I

I i

,

I

!

I I

! I

:

! I

! i

I

! i

!

i

10 8

I

I

400 800

i

,

!

18

500

#

i

20 200

0.04

!

:

i

i I

:

i

i :

I

I I

I

4

i I I II

2

1

-

ii- -

, 0.01

I

0.009 0.008 0.007

I 8

10

x

12

14

16

18

0.006

A.J-2.

Viscosities of gases at 101.325 kPa (l atm abs). (From R. H. Perry and C. H. Chilcon, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973. With permission.) See Table A.3-8 for coordinates for use with Fig. A.3-2.

Appendix A.3

871

FIGURE

A.3-8 No.

2 3 4 5

f> 7 8 9 10 II 12 13 14 15 16 17 1& 19 20 21 22 23 24 25 26 27 2&

872

Viscosities of Gases (Coordinates for Use with Fig. A.3-2) Gas

X

7.7 Acetic acid 8.9 Acetone Acetylene 9.8 . 11.0 Air Ammonia 8.4 Argon 10.5 Benzene 8.5 Bromine 8.9 Butene 9.2 Butylene 8.9 9.5 Carbon dioxide Carbon disulfide 8.0 Carbon monoxide 11.0 Chlorine 9.0 Chloroform 8.9 Cyanogen 9.2 Cyclohexane 9.2 Ethane 9.1 Ethyl acetate 8.5 9.2 Ethyl alcohol Ethyl chloride 8.5 Ethyl ether 8.9 Ethylene 9.5 Fluorine 7.3 Freon-II 10.6 Freon-12 11.1 Freon-21 10.8 Freon-22 10.1

App. A.3

Y

No.

14.3 13.0 14.9 20.0 16.0 22.4 13.2 19.2 13.7 13.0 18.7 16.0 20.0 18.4 15.7 15.2 12.0 14.5 13.2 14.2 15.6 13.0 15.1 23.8 15.1 16.0 15.3 17.0

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

Gas

X

Freon-I 13 11.3 Helium 10.9 Hexane 8.6 Hydrogen 11.2 11.2 3H 2 + IN2 Hydrogen bromide 8.8 Hydrogen chloride 8.8 Hydrogen cyanide 9.8 Hydrogen iodide 9.0 Hydrogen sulfide 8.6 Iodine 9.0 Mercury 5.3 Methane 9.9 Methyl alcohol 8.5 Nitric oxide 10.9 Nitrogen 10.6 Nitrosyl chloride 8.0 Nitrous' oxide 8.& Oxygen 11.0 Pentane 7.0 Propane 9.7 8,4 Propyl alcohol Propylene 9.0 Sulfur dioxide 9.6 Toluene 8.6 2,3,3·T rimeth yl butane 9.5 Water 8.0 Xenon 9.3

Y

14.0 20.5 11.8 12.4 17.2 20.9 18.7 14.9 21.3 18.0 18.4 22.9 15.5 15.6 20.5 20.0 17.6 19.0 21.3 12.8 12.9 13.4 13.8 17.0 12.4 10.5 16.0 23.0

Physical Properties of inorganic and Organic Compounds

cp = cal/g. °c = btu/Ibm. of

4.0 2

o

3.0

Temperature (0C) (OF)

2.0

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

3 0 40

5 6 0 9 0 o 11 1000

7 0 80

12 0 0 15

1.0

0.9 0.8

&13 14

0.7 0.6

016 017

0.5

17A

o

17C

17BOo

o

20

18

o

19

o

17D 22

o

21

0.4

0

0

230 240 26 28 o COg 25 27 29 30 32

o

'6

31

0.3

0.2

33 0 340 35 0

36 0

0.1 0.09 0.08 0.07 0.06 0.05

FIGURE

A.3:3.

Heal capacifY of gases at constant pressure at 101.325 kPa (1 aIm abs). (From R. H. Perry and C. lI. Chi/con, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973. Wilh permission.) See Table r1.3-9 for lise

with Fig. A3-3.

Appendix A.3

873

A.3-9 Heat Capacity of Gases at Constant Pressure (for Use with Fig. A.3-3) No.

10 15 16 27 12 14 18 24 26 32 34 3 9 8 4 11 13 17B 17C 17A 17D

2 35 30 20 36 19 21 5 6 7 25 28 26 23 29 33 22 31 17

874

Gas

Range (0C)

Acetylene Acetylene Acetylene Air Ammonia Ammonia Carbon dioxide Carbon dioxide Carbon monoxide , Chlorine Chlorine Ethane Ethane Ethane Ethylene Ethylene Ethylene Freon-ll (CCI 3 F) Freon-21 (CHClIF) Freon-22 (CHCIF 2) Freon-l13 (CCI2F~CCIF 2) Hydrogen Hydrogen Hydrogen bromide Hydrogen chloride Hydrogen fluoride Hydrogen iodide Hydrogen sulfide Hydrogen sulfide Methane Methane Methane Nitric oxide Nitric oxide Nitrogen Oxygen Oxygen Sulfur Sulfur dioxide Sulfur dioxide Water

0-200 200-400 400--1400 0-1400 0-600 600--1400 0-400 400--1400 0-1400 0-200 200--1400 0-200 200--600 600--1400 0-200 200--600 600--1400 0-150 0-150 0-150 0-150 0-600 600--1400 0-1400 0-1400 0-1400 0-1400 0-700 700--1400 0-300 300--700 700--1400 0-700 700--1400 0-1400 0-500 500--1400 300--1400 0-400 400-1400 0-1400

App. A.3

Physical Properties of Inorganic and Organic Compounds

A.3-10 Thermal Conductivities of Gases and Vaprs at 101.325 kPa (1 Atm Abs); k = W/m· K) K

Gas or Vapor.

Acetone(l)

Ammonia t2l

Butane(3) Carbon monoxidet2l

Chlorine(4)

k

Gas or Vapor

273 0.0099 319 0.0130 373 0.0171 457 0.0254 273 0.0218 373 0.0332 473 0.0484 273 0.0135 373 0.0234 173 0.0152 273 0.0232 373 0.0305 273 0.00744

K

Ethane's. 6)

239 273 373 Ethyl alcohol!l) 293 373 Ethyl ether(l) 273 319 373 Ethylene(6) 273 323 373 n-Hexane(3) 27: 293 Sulfur dioxide(7) 273 373

k

0.0149 0.0183 0.0303 0.0154 0.0215 0.0133 0.0171 0.0227 0.0175 0.0227 0.0279 0.0125 0.0138 0.0087 0.0119

Source: (I) Moser. dissertation, Berlin, 1913; (2) F. G. Keyes, Tech. Rep!. 37, Project Squid, Apr. 1. 1952; (3) W. B. Mann and B. G. Dickens. Proe. Roy. Soc. (London), A134, 77 (1931): (4) InrermHional Crilical Tables. New York: McGraw-Hili Book Company. 1929; (5) T. H. Chilton and R. P. Genereaux, personal communication. 1946; (6) A. Eucken, Physik, Z., 12. 1101 (1911); 14, 324 (1913); (7) B. G. Dickens, Proe. Roy. Soc. (London), At43, 517 (1934).

A.3-11

Heat Capacities of Liquids (c p = kJ /kg . K)

Liquid

Acetic acid

K

273 3 II 273 Acetone 293 Aniline 273 323 Benzene 293 333 Butane 273 i-Butyl alcohol 303 Ethyl alcohol 273 298 Formic acid 273 289 Glycerol 288 305 ....

cp

Liquid

K

cp

1.959 2.240 2.119 2.210 2.001 2.18 I 1.700 1.859 2.300 2.525 2.240 2.433 1.825 2.131 2.324 2.412

Hydrochloric acid (20 mol %)

273 293 293 293 313 283 303 363 293 330 293 273 323 303

2.43 2.474 0.01390 2.512 2.583 1.499 1.419 1.436 3.39 3.43 1.403 1.616 1.763 1.721

Mercury Methyl alcohol Nitrobenzene

Sodium chloride (9.1 mol %) Sulfuric acid (100%) Toluene o-Xylene

Source: N. A. Lange, Handbook ojChemislry. 10th ed. New York: McGraw-Hill Book Company, 1~67; National Rcs.:arch Council, Inlemlllional Crirical Tables, Vol. V. New York: McGraw-Hill Book Company, 1929; R. H. Perry and C. H. Chilton, Chemical Engineers' Handbook, 5th ed. New York: McGraw-Hill Book Company, 1973.

Appendix A3

875

Temperature (0C) (OF)

200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20

390 380 370 360 350 340 330 320 310 300 290 280 270 260 250 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 90 80 70 60

10

50

0

40 30 20

-10 -20

10 0 -10

30 FIGURE

876

Viscosity [(kg/m • S)]03 or cp] ~

F F f-

lf-

lft;-

rI'-

40

E--

30

i=-

f-

20

,

l-

I I

30

I

28

24

,I

I

i,

,I ii I ,

iFR

i

20

18

!

:~"

,

I '

14

10

,1

,

.!

I

I

, .

i

!

I

i

i I

,I

~-

,

,

I

I

i i

,

4

I

i

;

I i

r~

i

I

I

\

i

; I

i

I

,,

! 10

i

E--

I

r-- 0.2

!

I

I

I

\ I I

8

0.4

E-

0.3

i

I

!

l':--

--

i

!

I

,--

l=-

l-

I

I

0.9 0.8 0.7 0.6 0.5

l-

,

i

i

;

6

2

r

:

I

2

F--

J

i

;R=ffi

3

I i

!

i

2

F-

5

l:-

I ...

I

I

, -~

,

i

I : I

4

4

~

'!

6

f-

i

i

6

fl-

I,

!:

I

f-

10 9 8 7

I

i

I .

~

i

I

! i

,i

F

I

l-

·'1

i

f-f-;

8

o0

!

i

16

12

\

I

22

y

!

, i

I I

t

I ,

i

rl=-

._-

I

I I I

I

1 ,

I

26

12

14

16

l - I-

I-

18 20

x

- 20 A.3-4.

60 50

'--

0.1

Viscosities of liquids. (From R. H. Perry and C. H. Chilron, Chemical Engineers' Handbook,5lh ed. New York : McGraw-Hili Book Company, 1973. With permission.) See Table A.3-i2 for use with Fig. A.3-4.

App.A3

Physical Properties of inorganic and Organic Compounds

A.3-12

Viscosities of Liquids (Coordinates for Use with Fig. A.3-4) Liquid

Acetaldehyde Acetic acid, 100% Acetic acid, 70% Acetic anhydride Acetone, 100% Acetone, 35% Acetonitrile Acrylic acid Allyl alcohol Allyl bromide Allyl iodide Ammonia, 100% Ammonia, 26% Amyl acetate Amyl alcohol Aniline Anisole Arsenic trichloride Benzene Brine, CaCL 2 , 25% Brine, NaCI, 25% Bromine Bromotoluene Butyl acetate Butyl acrylate Butyl alcohol Butyric acid Carbon dioxide Carbon disulfide Carbon tetrachloride Chlorobenzene Chloroform Chlorosulfonic acid Chlorotoluene, ortho Chlorotoluene, meta Chlorotoiuene, para Cresol, meta

Appendix A3

X

Y

15.2 12.1 9.5 12.7 14.5 7.9 14.4 12.3 10.2 14.4 14.0 12.6 10.1 11.8 7.5 8.1 12.3 13.9 12.5 6.6 10.2 14.2 20.0 12.3 11.5 8.6 12.1 11.6 16.1 12.7 12.3 14.4 11.2 13.0 133 13.3 2.5

4.8 14.2 17.0 12.8 7.2 15.0 7.4 13.9 14.3 9.6 11.7 2.0 13.9 12.5 18.4 18.7 13.5 14.5 10.9 15.9 16.6 13.2 15.9 11.0 12.6 17.2 15.3 0.3 7.5 13.1 12.4 10.2 18.1 13.3 12.5 12.5 20.8

Liquid

Cyclohexanol Cyclohexane Dibromomethane Dichloroetha ne Dichloromethane Diethyl ketone Diethyl oxalate Diethylene glycol Diphenyl Dipropyl ether Dipropyl oxalate Ethyl acetate Ethyl acrylate Ethyl alcohol, 100% Ethyl alcohol, 95% Ethyl alcohol, 40% Ethyl benzene Ethyl bromide 2-Ethyl butyl acrylate Ethyl chloride Ethyl ether Ethyl formate 2-Ethyl hexyl acrylate Ethyl iodide Ethyl propionate Ethyl propyl ether Ethyl sulfide Ethylene bromide Ethylene chloride Ethylene glycol Ethylidene chloride FI uorobenzene Formic acid Freon-ll Freon-12 Freon-21 Freon-22

X

Y

2.9 9.8 12.7 13.2 14.6 13.5 11.0 5.0 12.0 13.2 10.3 13.7 12.7 10.5 9.8 6.5 13.2 14.5 11.2 14.8 14.5 14.2 9.0 14.7 13.2 14.0 13.8 11.9 12.7 6.0 14.1 13.7 10.7 14.4 16.8 15.7 17.2

24.3 12.9 15.8 12.2 8.9 9.2 16.4 24.7 18.3 8.6 17.7 9.1 lOA

13.8 14.3 16.6 11.5 8.1 14.0 6.0 5.3 8.4 15.0 10.3 9.9 7.0 8.9 15.7 12.2 23.6 '8.7 10.4 15.8 9.0 15.6 7.5 4.7

877

A.3-12

Viscosities of Liquids, Continued Liquid

X

Y

Liquid

Freon-113 Glycerol, 100% Glycerol, 50% Heptane Hexane Hydrochloric acid, 31.5% Iodobenzene Isobutyl alcohol Isobutyric acid Isopropyl alcohol Isopropyl bromide Isopropyl chloride Isopropyl iodide Kerosene Linseed oil, raw Mercury Methanol, 100% Methanol, 90% Methanol, 40% Methyl acetate Methyl acrylate Methyl i-butyrate Methyl n-butyrate Methyl chloride Methyl ethyl ketone Methyl formate Methyl iodide Methyl propionate Methyl propyl ketone Methyl sulfide Naphthalene Nitric acid, 95% Nitric acid, 60% Nitrobenzene Nitrogen dioxide Nitrotoluene Octane

12.5 2.0 6.9 14.1 14.7 13.0 12.8 7.1 12.2 8.2 14.1 13.9 13.7 10.2 7.5 18.4 12.4 12.3 7.8 14.2 13.0 12.3 13.2 15.0 13.9 14.2 14.3 13.5 14.3 15.3 7.9 12.8 10.8 10.6 12.9 11.0 13.7

11.4 30.0 19.6 8.4 7.0 16.6 15.9 18.0 14.4 16.0 9.2 7.1 11.2 16.9 27.2 16.4 10.5 11.8 15.5 8.2 9.5 9.7 10.3 3.8 8.6 7.5 9.3 9.0 9.5 6.4 18.1 13.8 17.0 16.2 8.6 17.0 10.0

Octyl alcohol Pentachloroethane Pentane Phenol Phosphorus tribromide Phosphorus trichloride Propionic acid Propyl acetate Propyl alcohol Propyl bromide Propyl chloride Propyl formate Propyl iodide Sodium Sodium hydroxide, 50% Stannic chloride Succinonitrile Sulfur dioxide Sulfuric acid, 110% Sulfuric acid, 100% Sulfuric acid, 98% Sulfuric acid, 60% Sulfuryl chloride Tetrachloroethane Thiophene Titanium tetrachloride Toluene Trichloroethylene Triethylene glycol Turpentine Vinyl acetate Vinyl toluene Water Xylene, ortho Xylene, meta Xylene, para

878

App. A.3

X

6.6 10.9 14.9 6.9 13.8 16.2 12.8 13.1 9.1 14.5 14.4 13.1 14.1 16.4 3.2 13.5 10.1 15.2 7.2 8.0 7.0 10.2 15.2 11.9 13.2 14.4 13.7 14.8 4.7 1l.5 14.0 13.4 10.2 13.5 13.9 13.9

Y

21.1 17.3 5.2 20.8 16.7 10.9 13.8 10.3 16.5 9.6 7.5 9.7 11.6 ~ 13.9 25.8 12.8 20.8 7.1 27.4 25.1 24.8 21.3 12.4 15.7 11.0 12.3 lOA

10.5 24.8 14.9 8.8 12.0 13.0 12.1 10.6 10.9

Physical Properties of Inorganic and Organic Compounds

Temperature (oC)

(oF)

1 2A 2 3 0 o 03A 4° 04A

200 No

Uqold

29 32

Acetic Acid 1 O~

"

Ammonl.a Amy. Alcohol

o· aO

B-enllW>.

20 ~ 50 ·70 - 50 ·50· 25 0·100 0·130 10· 60

10 49

Benzyl AlcoOo.I a..nzyl ChlotiOe

-20 .)0"

30 30

Bdne, 25--' CtCf2

,....CJ

.40·

20

44

Sd ..... 25% 1:3'1,.11)'1 Alcohol

-40· 20 0- 100

Ohuilio.

·100· 10·

Acetone

37 2'

Amyl Acet .. ,.

30 23 27

Aniline

,1

~tbon

2 3

c..rOOn latr.K;hlotlde Ch!otoo.nzen.

•

21

(')cc~ne

6A 5

Oic1llofOftth.lne

-30·

Ok;hlmometh.na

15

Olphenyl D'phenylm&thJlno CHph.nyt Oxide Oowthefm A Ethyl Acet .. to

-40· 50 eO'120 30·100

,.I.

22

24 42

4.

••

1

Senzene 8romid.

13

eh-torle'll!!

36

o

0.4

0- 200 25 80

20· 80 20 - BO 0- 1(}0 5· 25 ·30· 40

Ether

7

0.5 27

·100 - 25 0·100

lodld~

39

7

50 25 60

0- Zoo -50· 30·

AlCOhol 100')1.

95"

50 25

60

0- 100

Chlo'oform

Ethylene Glycol

°

-40 - 200

150

28_0 41 42

100

8

3 45

6

30°26

29Q)9~~34 32~

3&39

°

°

48

CD 44° 43 0 46 047

350 36

33 0.6

40

0 49 50

2A

6 4A 7A 3A 38 28

o

35 48

41 43 =434 dimensionless numbers for, 437-438 for equimolar counterdiffusion, 434435 914

experimental determination of, 437, 632 for falling film, 441-442 film and overall, 595--597, 599-601, 606-610, 632-633 for fiat plate, 444 for fluidized bed, 448 inside pipes, 440-443 introduction to, 385, 432-433 for liquid metals, 450 models for, 478-479 for packed bed, 447-449, 556-557 for packed tower, 632-633 to small particle suspensions, 450453 for sphere, 445--446 types of, 433-436 for wetted-wall tower, 441-443 Mass transfer fluxes, 453-454 Mass transfer between phases concentration profiles, 594-595 film coefficients, 595--597, 606-607 overall coefficients, 599-601, 607, 610, 617 Mass transfer models, 478-479 Mass units, 6 Mass velocity, 51 Material balances chemical reaction and, 12-13 for crystallization, 739 for evaporation, 496-497,504-505 methods of calculation, 10-11 overall,50-56 recycle and, II McCabe ilL Law of crystal growth, 745-746 McCabe-Thiele method, 651-666 Mean free path, 462 Mechanical energy balance, 63-67 Mechanical-physical separation processes (see also Centrifugal filtration; Centrifugal settling and sedimentation; Cyclones; Filtration; Mechanical size reduction; Settling and sedimentation) classification of, 800-801 methods of separation, 800-801 Mechanical size reduction equipment for Blake crusher, 843

Index

Dodge crusher, 843 gyratory crusher, 844 jaw crushers, 843 revolving grinding mill, 844 roll crusher, 844 particle size measurement, 840-841 power required for Bond's law, 842 general theory, 841-842 Kick's law, 842 Rittinger's law, 842 purpose of, 840 Membrane processes (see also Dialysis; Gas permeation membrane processes; Reverse osmosis; Ultrafiltration) equipment for, 758, 760-762, 790, 792 permeability in, 410-411, 756,785-786,790 series resistances in, 755--756, 759 types of, 585, 754-755 Metals, properties of, 883--884 Miers' theory, 744 Mixer-settlers, 715,728-729 Mixing (see also Agitation) discussion of, 140-141,152-153 equipment for, 152-153 with pastes, 152-153 with powders, 152 Mixing time (see Agitation) Moisture (see also Drying; Humidity) bound and unbound, 534-535 capillary flow of, 540, 553--555 diffusion of, 539-540, 551-555 equilibrium, for air-solids, 533--535 free moisture, 535 Molar volumes, 400-402 Molecular diffusion (see Diffusion) Molecular transport (see Diffusion) Mole units, 6 Momentum definition of, 46, 69-70 introduction to, 31 velocity correction factor for, 72-73 Momentum balance applications of, 175--184 for boundary layer, 192-193, 199201 .. in circular tube, 179-181 Coriolis force, 175

Index

differential equations for, 164-165, 170-175 Euler equations, 185--186 ideal fluids, 185--186 for jet striking a vane, 76-78 Laplace's equation in, 187 for Newtonian fluids, 172-175 overall, 69-78 between parallel plates, 175--178 potential flow, 186-189 in rotating cylinder, 181-184 shell, 78-82 stream function, 185 transfer of momentum, 46,79 Motionless mixers (see Agitation) Multicomponent diffusion, 402, 461462

Multicomponent distillation boiling point, 681-682 dew point, 682 distribution of other components, 684

equilibrium data for, 680-681 flash distillation, 682-683 introduction to, 679-680 key components, 683 minimum reflux (Underwood equation), 686-687 number of stages feed tray location, 687 by short-cut method, 687-688 number of towers in, 679 total reflux (Fenske equation), 683

N Natural convection heat transfer derivation of equation (vertical plate), 253--254 equations for various geometries, 254-259 introduction to, 253 Navier-Stokes equations, 173--175 Newtonian fluids, 46-47, 153--154 Newton's law of momentum transfer, 42-45 second law (momentum balance), 69-70 of settling, 817 of viscosity, 42-45 915

Non-Newtonian fluids agitation of, 163-164 flow-property constants, 156-157 friction loss in fittings, 159 heat transfer for, 297-299 laminar flow for, 155-159 rotational viscometer, 161-163 turbulent flow for, 159-160 types of, 153-155 velocity profiles for, 161 Notation, 895-903 Nucleation (see also Crystallization) primary, 744 secondary, 744 Number of transfer units for heat exchangers, 274 for humidifitation, 609-610 for mass transfer, 624-625 Numerical methods for integration, by Simpson's method,24 for steady-state conduction with other boundary conditions, 316-317 in two dimensions, 310-317 for steady-state diffusion with other boundary conditions, 414-416 in two dimensions, 413-414 for unsteady-state heat transfer boundary conditions, 351-353 in a cylinder, 358-359 implicit method, 359-360 Schmidt method, 351 in a slab, 350-353 for unsteady-state mass transfer boundary conditions, 470-471 Schmidt method, 469-470 in a slab, 468-471 Nusselt equation, 263-265 Nusselt number, 238

Overall energy balance (see Energy balances)

p Packed beds Darcy's law for flow in, 123 drying in, 556-559 heat transfer coefficients for, 252253,447-448,558-559 mass transfer coefficients for, 447448 mass transfer in, 448-449 tortuosity in, 412, 468 pressure drop in laminar flow, 118-120, 123 turbulent flow, 120-121 shape factors for particles, 121-122 surface area in, 118, 448, 558-559 Packed towers, 602-603, 612-613, 716 Packing, 612-613 Particle-size measurement in crystallization, 746-747 in mechanical size reduction, 840841 standard screens for, 894 Pasteurization, 576 Penetration theory, 442, 478-479 Permeability of solids, 410-411, 756, 760, 764-765, 785-786, 790 Phase rule, 586, 640, 648, 710 Physical properties of compounds, 854-891 Pipes dimensions of, 892-893 schedule number of, 83, 892 size selection of, 100 Pitot tube meter, 127-128 Planck's law, 281-282 Plate tower, 611, 715-716 Pohlhausen boundary layer relation, 372

o Operating lines (see Absorption; Distillation; Humidification processes; Leaching) Orifice meter, 131-132 Osmotic pressure, 783-784 916

Poiseuille equation (see HagenPoiseuille equation) Porous solids effective diffusivity of, 412, 468 introduction to, 408, 412-413, 462 Knudsen diffusion in, 463-464 molecular diffusion in, 412-413,464 transition diffusion in, 464-466 Index

Potential energy, 57 Potential flow, 186-189 Prandtl analogy, 439 Prandtl mixing length (see Turbulent flow) PrandtJ number definition of, 237-238 of gases, 866, 870 Pressure conversion factors for, 851-852 devices to measure, 36-39 head and, 35 units of, 7, 32-34 Pressure drop (see also Fluid friction) in compressible flow, 91, 101-104 in laminar flow, 84-87 in packed beds, J 18-121 in pipes, 84-94 in turbulent flow, 87-90 Pseudoplastic fluids, 154 Psychometric ratio, 532 Pumps centrifugal, 134-135 developed head of, 134-136 efficiency of, 133--136 positive displacement, 136- J37 power requirements for, 133-136 suction lift of, 134

between gray bodies, 292-293 Raoult's law, 640-641,680 Reflux ratio, 658-660, 686-687 Reiative volatility, 644-645, 681 Reverse osmosis complete-mixing model, 790-791 concentration polarization in, 789790 introduction to, 782-783 membranes in, 784 operating variables in, 788 osmotic pressure in, 783-784 solute rejection, 786 theory of, 785-786, 789-791 Reynolds analogy, 438-439 Reynolds number in agitation,' 144-145 for condensation, 265 definition of, 49, 202, 437 for flat plate, 191,193 for flow in tube, 49, 238, 437 for non-Newtonian fluids, 157 Reynolds stresses, 195-196 Rheopectic fluids, 155 Rittinger's crushing law, 842 Rotational viscometer, 161-163 Roughness in pipes, 87-89

s R Radiation heat transfer in absorbing gases, 293--296 absorptivity, 277 black body, 277-278 combined radiation and convection, 279-281 emissivity, 277-278, 283, 884 gray body, 278, 283-284 heat transfer coefficient, 279-280 introduction to, 216, 276-278,281 Kirchhoff's law, 277, 283 Planck's law for emissive power, 281-282 shields, 286 Stefan-Boltzmann law, 278, 283 to small object, 278-279 view factors between black bodies, 284-291 general equation for, 286-288 Index

Schmidt method for heat transfer, 351 for mass transfer, 469-470 Schmidt number, 396-397,437-438 Scraped-surface heat exchangers, 302303 Screen analyses in crystallization, 746-747 particle size measurement, 746 Tyler screen table, 894 Sedimentation (see Settling and sedimentation) Separation (see also Settling and sedimentation) by differential settling, 821-823, 826-827 of particles from gases, 838-840 of particles from liquids, 815-823, 831-834 of two liquids, 834-835 917

Separation processes, types of, 584585 Settlers (see also Settling and sedimentation) gravity chamber, 826 gravity classifier, 826-827 gravity tank, 826 Spitzkasten classifier, 827 thickener, 718, 728-729, 825-829 Settling and sedimentation (see also Centrifugal settling and sedimentation; Settlers; Thickeners) Brownian movement, 817-818 classification, 821-823, 826-827 differential settling, 821-827 drag coefficient for sphere, 816-8'19, 822-823 hindered settling, 820, 822 Newton's law, 817 purpose of, 815-816 sedimentation and thickening, 825828 Stoke's law, 116, 189-190,817 terminal settling velocity for sphere, 817 theory for rigid sphere, 816-819 wall effect, 821 Shape factors, in conduction, 235-236 Shape factors, for particles, 121-122, 124 Shear stress (see also Momentum balance) components of, 172-173 definition of, 44-45 Euler equations, 185-186 ideal fluids, 185-186 in laminar flow on flat plate, 193 in laminar flow in tube, 79 normal, 170 potential flow, 186-189 stream function, 185 Sherwood number, 438 Sieve (perforated) plate tower, 611, 667-668,716-717 Sigma value (centrifuge), 834 Simple batch or differential distillation, 646-647 Simpson's numerical integration method, 24 SI system of units, 3--4 918

Size reduction (see Mechanical size reduction) Skin friction, 114-115,440 Solid-liquid equilibrium, 729-731 Solids, properties of, 881-884 Solubility of gases in liquids, 586-587, 884-886 in solids, 409-411 Solubility of salts sodium thiosulfate, 738-739 typical solubility curves, 490 Solvent extraction (see Liquid-liquid extraction) Spheres diffusion to, 391-392 drag coefficient for, 114-117, 190 heat transfer to, 249 mass transfer to, 445-446, 450-453 Newton's law for, 817 settling velocity of, 817 Stoke's law for, 116, 190, 817 Spherical coordinates, 169, 368 Spitzkasten classifier, 827 Spray tower, 716 Stage processes (see also Absorption; Distillation; Liquid-liquid extraction; Leaching) absorption, 613--614 analytical equations for, 592-593 countercurrent multistage, 589-591 distillation, 649-688 leaching, 730-735, 737 liquid-liquid extraction, 715-722 single stage, 587-588, 642, 712-715, 730-731 Standard heat of combustion, 18,865 Standard heat of formation, 18, 864 Standard screen sizes, 894 Stanton number, 438 Steady-state diffusion (see also Diffusion; Diffusivity; Numerical methods) in biological solutions and gels, 403-407 in gases, 385-393 in liquids, 397-398 in two dimensions, 413--416 in solids, 408-413 Steady-state heat transfer (see Conduction heat transfer; Index

Convective heat transfer; Numerical methods) Steam distillation, 648-649 Steam table, 16-17,857-861 Stefan-Boltzmann radiation law, 278, 283 Sterilization of biological materials effects on food, 577 introduction to, 569-570 pasteurization, 576 thermal death rate kinetics, 570-571, 575-576 thermal process time, 571-574 Stoke's law, 116, 190,817 Stream function, 185 Streamlined body, 115 Stripping (see Absorption) Supersaturation, 741-746 (see also Crystallization) Suspensions, mass transfer to, 450453 Systeme International (SI) system of basic units, 3-4 table of values and conversion factors, 850-853

T Temperature scales, 5 Thermal conductivity de6nition of, 217-219 of foods, 891 of gases, 217-218,866, 868, 875 of liquids, 218, 880 of solids, 218-219,882-883 of water, 856, 862-863 Thickeners, 728-729, 825-828 (see also Settling and sedimentation) Thixotropic fluids, 155 Tortuosity factor, 412-413,468 Total energy, 56-57 Transfer unit method, 609-610,624625

Transition region diffusion, 464-466 ~Transport processes in boundary layers, 370-373 .classification of, 2 similarity of, 39-43, 381-382, 426, 430, 438-440 Tray efficiency 7

Index

. introduction to, 666 ~urphree,667-669

overall, 667-669 .. point, 668 Tray towers, 611, 613-614, 715-716 Triangular coordinates, 710-711 Tubes, sizes of, 893 (see also Circular pipes and tubes) Turboblowers, 138 Turbulence, 194-195 Turbulent flow (see also Boundary layers) boundary layer separation in, 191192 boundary layer theory for heat transfer, 373 mass transfer, 475-477 momentum transfer, 192-193, 199-201 deviating velocities in, 194-195 discussion of, 48-49, 194-195 on fiat plate, 190-191, 199-201 maximum velocity in, 83-84 Prandtl mixing length in heat transfer, 374-375 in mass transfer, 477-478 in momentum transfer, 196-197, 374-375 Reynolds number for, 49 in tubes, 49, 83-84, 87-89 turbulent shear in, 195-196 turbulent diffusion in, 382 velocity profile in, 83-84, 197-199 Two-dimensional conduction, 233-236 Tyler standard screens, 894

u Ul trafiltration comparison to reverse osmosis, 791792 concentration polarization in, 789791 equipment for, 792 introduction to, 791-792 membranes for, 792 processing variables in, 794-795 theory of,792-794 Unbound moisture, 534-535 919

Underwood, minimum reflux ratio, 686-687 Unit operations, classification of, 1-2 Units cgs system, 4 and dimensions, 5 English system, 4 SI system, 3-4 table of, 850-853 Universal velocity distribution, 197199 Unsteady-state diffusion (see also Numerical methods) analytical equations for flat plate, 428-429 basic equation for, 426-427 boundary conditions for, 428-430 charts for various geometries, 431 and chemical reaction, 460 in leaching, 724-726 mass and heat transfer parameters for, 430 in three directions, 432 Unsteady-state heat transfer (conduction) (see also Numerical methods) analytical equations for, 334-336 average temperature for, 348-349 in biological materials, 360-365 in cylinder, 342-344 derivation of equation for, 214-215, 330-332 to flat plate, 334-336, 338-341 heat and mass transfer parameters for, 339, 430 lumped capacity method for, 332334 method for negligible internal resistance, 332-334 . in semiinfinite solid, 336-337 in sphere, 343, 345-346 in three directions, 345, 347-349

v Valve trays, 611 Vapor-liquid eqUilibrium ... azeotropic mixtures, 642 benzene-toluene, 641-642 boiling point diagrams, 640-642 920

calculations using Raoult's law, 640-641 enthalpy-concentration, 669-672 ethanol-water, 887 n-heptane-ethylbenzene, 691 n-heptane-n-octane, 692 n-hexane-n-octane, 690 multicomponent, 680-682 n-pentane-n-heptane, 647 phase rule, 640, 648 water-benzene, 691 water-ethylaniline, 691 xy plots, 641-643 Vapor-liquid separation processes (see Distillation) Vapor pressure data for organic compounds, 642, 690-692 data for water, 525-526, 854,856859 discussion of, 9 Vapor recompression (see Evaporation) Vectors, 165-167 Velocity average, 55, 80, 82 interstitial, 437 maximum, 83-84 profile in laminar flow, 80, 82-84 profile in turbulent flow, 83-84 relation between velocities, 83-84 representative values in pipes, 100 superficial, 119,437 types of, in mass transfer, 387, 753754 universal, in pipes, 197-199 Venturi meter, 129-131 View factors in radiation, 284-293 Viscoelastic fluids, 155. Viscosity discussion of? 43-47 of foods, 891 of gases, 866-867, 871-872 of liquids, 876-878 Newton's law of, 43-45,381-382 of water, 855, 863 Void fraction (packed and fluidized beds), 118-119, 123-124,447 Von Karman analogy, 439-440

Index

w Washing (see Filtration; Leaching) Water physical states of, 525 properties of, 854-863 Water cooling (see Humidification processes)

Index

Weirs, 132-133 Wet-bulb temperature relation to adiabatic saturation temperature, 532 theory of, 531-532 Wilke-Change correlation, 401-402 Work, 57-58, 63 Work index for crushing, 842

921