SI No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Calculation Heating time using hot water (Non Isothermal Heating Medium) Heating time using steam (Isothermal Heating Medium) Cooling time using non isothermal cooling medium Heating time using external Heat exchanger & Non Isothermal Heating Medium Heating time using external Heat exchanger & Isothermal Heating Medium Cooling time using external Heat exchanger & Non Isothermal Cooling Medium Cooling time using external Heat exchanger & Isothermal Cooling Medium Calculate the Heat Transfer coefficient for reactors based on different agitator types & utility flow rate Calculate the addition time required based on heat of the reaction, Type of agitator, MOC & utility flow rate in a semi batch reactor Scale up of reactor from lab to plant scale Calculate the vacuum pump flow rate based on air leakage rate Power required for pumping Pump affinity law Pipe flow distribution Pressure drop across pipe lines

Revision History Rev. 0

Issued to Downloads s

Issued to Downloads section on 5/5/2011

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Non Isothermal Heating Reactor Contents Mass M Initial temp t1 Final temp t2 Sp.Heat Cm Area A HTC U Heating Fluid Inlet temp Sp.Heat Flow rate

72500 120 200 1.05 150 180

lb F F Btu/ lb F ft2 BTU/hr ft2 F

T1 Cw W

230 F 1.2 Btu/ lb F 18000 lb/hr

Time required for heating

ln

T1 - t1 T1 - t2 = 3.4903 = e(UA/WC)

WCw MCm

K-1 K

xt

K K Time reqd

6.42 hrs

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Isothermal Heating Reactor Contents Mass M Initial temp t1 Final temp t2 Sp.Heat Cm Area A HTC U Heating Fluid Inlet temp

50000 68 257 0.5 100 150

lb F F Btu/ lb F ft2 BTU/hr ft2 F

T1

320 F

Time required for heating

ln

T1 - t1 T1 - t2

U A time MC

Time reqd

2.31 hrs

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Non Isothermal cooling Mass M Initial temp T1 Final temp T2 Sp.Heat Cm Area A HTC U Cooling Fluid Inlet temp Sp.Heat Flow rate

72500 200 82 1.05 150 110

lb F F Btu/ lb F ft2 BTU/hr ft2 F

t1 Cw W

72 F 1 Btu/ lb F 15500 lb/hr

Time required for cooling

ln

T1 - t1 T2 - t2

WCw MCm

K-1 K

xt

K K Time reqd

= 2.8994 = =

e(UA/WC)

19.11 hrs 1146.78 min

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Non Isothermal Heating Reactor Contents Mass M Mass Flow rate w Initial temp t1 Final temp t2 Sp.Heat c Area A HTC U Heating Fluid Inlet temp Sp.Heat Flow rate

72500 20000 82 200 1.05 150 210

lb lb/hr F F Btu/ lb F ft2 BTU/hr ft2 F

T1 C W

230 F 1.2 Btu/ lb F 15500 lb/hr

Time required for heating

ln

T1 - t1 T1 - t2 = 1.213548 = eUA*(1/WC-1/wc)

wWC x (K3wc-WC)

K3-1 M

xt

K3 K3 Time reqd

10.03

hrs

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Isothermal Heating Reactor Contents Mass Mass Flow rate Initial temp Final temp Sp.Heat Area HTC Heating Fluid Inlet temp

M w t1 t2 c A U

72500 20000 82 200 1.05 150 210

lb lb/hr F F Btu/ lb F ft2 BTU/hr ft2 F

T1

230 F

Time required for heating

ln

T1 - t1 T1 - t2 = 4.481689 = eUA/wc

wc Mc

K2-1 K2

xt

K2 K2 Time reqd

7.45

hrs

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Non Isothermal cooling Mass M Batch flow rate W Initial temp T1 Final temp T2 Sp.Heat C Area A HTC U Cooling Fluid Inlet temp Sp.Heat Flow rate

72500 20000 200 82 1.05 150 180

lb lb/hr F F Btu/ lb F ft2 BTU/hr ft2 F

t1 c w

72 F 1 Btu/ lb F 15500 lb/hr

Time required for cooling

ln

T1 - t1 T2 - t1

Wcw x (K4wc-WC)

K4-1 M

xt

K4 K4 Time reqd

= 0.6337 = =

eUA*(1/WC-1/wc)

18.19 hrs 1091.62 min

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Isothermal cooling Mass Batch flow rate Initial temp Final temp Sp.Heat Area HTC Cooling Fluid Inlet temp Sp.Heat Flow rate

M W T1 T2 C A U

72500 20000 200 82 1.05 150 180

lb lb/hr F F Btu/ lb F ft2 BTU/hr ft2 F

t1 c w

72 F 1 Btu/ lb F 15500 lb/hr

Time required for cooling

ln

T1 - t1 T2 - t1

WC MC

K1-1 K1

xt

K1 K1 Time reqd

= 3.6173 = =

eUA/WC

12.77 hrs 766.37 min

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Calculation of Heat transfer coefficient in reactor Reactor data Diameter of the tank Impeller speed Impeller Dia Impeller power Agitator Type Vessel jacket flow depth Height of liquid in cylindrical section Properties of batch side fluid Heat capacity Sp gravity Bulk Viscosity Viscosity at wall Thermal conductivity Properties of jacket side fluid Heat capacity Sp gravity Bulk Viscosity Viscosity at wall Thermal conductivity Liquid flow rate L Z 1 96 T N Da Hp 108 45 42 2 in rpm in Hp Anchor-1 in in 0.08 8 ft ft 9 2700 3.5 ft rph ft

Cp b w k Cp b w k Q Calculation

0.997 1.0028 0.536 1.45 0.368 1.01 65.2 1.45 1.45 0.335 0.22

Btu/lb F 1002.8 cp cp Btu/hr ft F Btu/lb F lb/ft3 cp cp Btu/hr ft F cu ft / sec 3.509 lb/hr ft 3.509 lb/hr ft 62.60 lb/ft3 1.2971 lb/hr ft

Batch Side calculation Agitated batch liquid reynolds number NRe Agitated batch liquid Prandlt number NPr /w Z/T Da/T a b M hb T / k = a x Nreb x NPr 1/3 x (/w)M Agitated liquid Heat Transfer coefficient,hb = = = = = = = = Da2 x N x b / 1596296 Cp x / k 3.51 0.370 0.889 0.389 1 0.67 0.18

709.84

Btu/hr ft2 F

Jacket Side calculation

Nu = A1 x NRe0.667 x NPr b x (u/uw)0.14 Nu = hj Dj / Kj Dj = Equivalent cross flow diameter of the jacket Nre = Dj V j / j Dj - Jacket cross flow diamater = 4 x Acs / Wetted Acs = L x W Wetted = L x 2 + W x 2 Dj Aequivalent Velocity (V = Q/A) NRe NPr For cooling A1 b Jacket side Heat transfer coefficient, hj = = = = = = = = = =

A1

0.0243 0.0265

0.4 0.3

0.667 16.167 0.165 0.021 10.300 113650.5 10.58

ft2 ft ft ft2 ft/sec 37082 ft/hr

0.0243 0.3 235.89 Btu / hr ft2 F

Overall heat transfer coefficient 1/U overall = 1/hJ + 1/hB + 1/hDM RDM = 1/hDM 1/U overall = = = 0.001 0.0066 150.42 Btu / hr ft2 F

Uoverall

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A reactor 2.0 KL capacity is used to carryout an exothermic reaction at 80C The reaction calorimetry shows heat of the reaction of 15000 BTU/mole of reagent 'Z'. If 5 mole of reagent Z is used calculate the addition rate Cooling water is available at 0C U A T Q Heat of rxn Addn Rate 55 BTU / hr sq F F 7 m2 80 C 147840 kcal / hr 1000 kcal/mole 29.568 lit/hr 264 kcal/hr m2 C

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Two assumptions - Power per unit volume is constant - Tip speed is constant Scale up (Lab scale data) Dt1 0.108 m H1 0.108 m Vol 0.001 m3 Da1 0.043 m N1 400 rpm Density 1300 kg/m3 Viscosity 1000 CP Scale up times

1.00 6.67 1.0000

Lit rps kg / m s

1000 times

Assumption, Power per unit volume is constant N2 = N1 x (1/R) power 2/3 Ratio 10 = V2 V1 N2 1.44 rps 86.2 rpm Np 5 (Assume) Da2 Dt2 V2 Nre P 0.433614 m 1.084035 m 1000.00 L 351.0687 295.2272 J/sec 0.515162 hp 0.30 KW (30 % Loss)

1/3

0.40

hp

Assuming Tip speed is constant N2 = N1 / R N2 0.666667 rps Nre P 162.9517 J/sec 29.52272 J/sec 0.051516 hp

40 rpm

0.03 KW (30 % Loss)

0.04

hp

- The assumption is also based on power per unit volume as constant

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Designing Based on pressure drop test

V Pi Pf t Po Q

= = = = = =

350 2 3 10 1

ft3 in Hg Abs in Hg Abs min in Hg Abs

Pump capacity required

(Rise in pressure) x System volume (V)

35

CFM

Designing Based on pump evacuation time

Pump capacity required

V x ln(Pi/Pf)
t

120.9

ACFM

Once the pump size is selected, we must recalculate the evacuation time by using that pump's average capacity.

Designing Based on Air Leakage Rate Assuming the inlet gas composition is only air at 75F
Fall in vacuum Total System volume Temperature Initial Pressure Operating Pressure Air Leakage rate 300 5000 75 760 100 2.348 mm Hg/hr lit F mm Hg Abs mm Hg Abs kg/hr

V T Pi Po

= = = =

The capacity in ACFM can be calculated using ACFM = ( m / Mwt ) x (379/60) x (Initial pressure / Operating Pressure) x (460+T/520) ACFM Correction factor Corrected capacity S Fc Sc = = = 8.82 0.85 10.37 ACFM ACFM

Based on this, from the pump manufacturer curve required CFM, hp & gpm of water for service can be obtained

Designing for air & solvent vapour

Fall in vacuum Total System volume Temperature Initial Pressure Operating Pressure Methanol vapour Water vapour Air Leakage rate Total Compound Methanol Water Air Calculating average molecular weight ACFM Correction factor Corrected capacity

V T Pi Po

= = = = = = = = Qty 15.0 5.0 2.2 =

300 5000 104 760 50 15 5 2.23 22.23 % weight 67.48 22.49 10.02 27.00 85.74 0.85 100.87

mm Hg/hr lit F mm Hg Abs mm Hg Abs kg/hr kg/hr kg/hr kg/hr Mwt 32.0 18.0 29.0

S Fc Sc

= = =

ACFM

ACFM

ystem volume (V)

erating pressure (Po)

at pump's average

0.4 5 296.9

atm m3 K

5.18

lb/hr

or service can be obtained

0.394737 atm 5 m3 313.0 K

4.91

lb/hr

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Power Required for pumping Flow rate Density Pump head required Pump efficiency Q 300 m3/hr 1000 kg/m3 25 m 0.75 0.0833 m3/sec 83.33 kg/sec

Power Required

2777.8 kg m / sec

37.04 hp

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Q, Flow H, Head P , Power

Affinity Laws Proportional Proportional Proportional Example

N N2 N3

Data Initial RPM Initial flow Initial Head Power

N1 Q1 H1 P1 By adjusting N2 Result Q2 H2 P2 6.67 12.89 18.70

1500 400 25 49.4

rpm m3/hr m hp

Final RPM

1400

rpm

Final flow Final Head Final Power By reducing rpm by Head reduced by Power reduced by

373 21.8 40.1 % % %

m3/hr m hp

Pipe flow distribution

Data Density Viscosity Flow rate Pipe Dia Acceleration, Calculation Area Velocity Reynolds Number Friction Factor

Q D g

1000 0.8275 500 10 9.8

kg/m3 cp m3/hr in m/s2

0.00083 kg/m sec 3 0.13889 m /sec 0.254

A V NRe f

m2 0.05 2.74 m/s 841775.2 0.002988 Dia (m) 0.20 0.15 0.10 Length (m) 30 60 40

Flow rate A (m3/sec) 0.1389 Calculation Pipe AaB AbB AcB Solver Cons-1 Cons-2 Cons-3 0 Dia (m) Length(m) f V,m/s 0.20 30 0.00299 2.9536 0.15 60 0.00299 1.8087 0.10 40 0.00299 1.8087 hf 0.7980 0.7980 0.7980 Q (m3/sec) Q (m3/hr) 0.0927 333.88 0.0319 115.01 0.0142 51.11 500.00

0.00000 0.00000 0.00000

* Head loss across the pipe line is equal

Equations Used Equation of Continuity: Q_A = Q_a + Q_b + Q_c

Equality of Pressure drops: DelP due to friction in Pipe AaB = DelP due to friction in Pipe AbB DelP due to friction in Pipe AaB = DelP due to friction in Pipe AcB

Using these 3 sets of equations are formed; These equations are of non-

Equation of Continuity: Q_A = Q_a + Q_b + Q_c

Equality of Pressure drops: DelP due to friction in Pipe AaB = DelP due to friction in Pipe AbB DelP due to friction in Pipe AaB = DelP due to friction in Pipe AcB

Using these 3 sets of equations are formed; These equations are of nonlinear. To solve these, the solver add-in is being used.

This program will run with Macros. Set your macros setting to low and then proceed the calculation.

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A 35o API distillate is being transferred from a storage tank at 1 atm absolute pressure to a pressure vessel at 50 psig by means of the piping arrangements shown in figure. The liquid flows at the rate of 23100 lb/hr through 3 inch Schedule 40 steel pipe; the length of the straight pipe is 450 feet. Calculate the minimum horsepower input to the pump having an efficiency of 60 percent. The properties of the distillate are: viscosity = 3.4 cP, density = 52 lb/ft3. The following are the data for the pipe and fittings: For 3 inch Schedule 40 Nominal pipe, OD = 3.5 inch; Thickness = 0.216 inch Flow coefficients for the fittings (K) are: Gate valve = 0.25; 90o elbow = 0.9; Check valve = 10 Friction factor can be calculated from Blasius equation. Account for entry and exit losses also.

Conversion Factors 1 feet 1 lb 1 inch 1 centipoise 1 atm 1 atm g Data given: Mass flow rate Density Viscosity Pipe OD Pipe thickness Pipe length r m 23100 52 3.4 3.5 0.216 450 lb/hr lb/ft3 cP inch inch feet = = = 0.3048 0.454 0.0254 0.001 14.7 1.01E+05 9.812 m kg m kg/m.sec psi N/m2 m/sec2 Converted data: 2.913167 kg/sec 3 833.7087 kg/m 0.0034 kg/m.sec

137.16 m

Vertical height Pump efficiency (in fraction) Loss coefficient of Gate Valve Loss coefficient of elbow Loss coefficient of check valve Valve

z1-z2

70 feet 0.6 0.25 0.9 10

21.336 m

Pipe ID Pressure at 2 Calculations: Volumetric flow rate Velocity Reynolds Number Friction factor hf of pipe v2/2g hf of Gate valve hf of 2 number of elbows hf of Check valve hf of sudden contraction at inlet hf of sudden expansion at outlet Total frictional head Pump head Minimum power for the pump

D P2

3.068 inch 50 psig 3.401361

= =

0.077927 m 2 3.45E+05 N/m 34013.61

Q v NRe f

1.3985 m 0.02735 m 0.00684 m 0.04923 m 0.27351 m 0.01094 m 0.02735 m 1.76642 m 22.561 m 1074.81 Watt