Pumps, Compressors and Conveyors - Rev4

PUMPS, COMPRESSORS
AND CONVEYORS
PUMPS, COMPRESSORS
AND CONVEYORS
FLUORSPAR SILO TO BALL MILL
Type: Screw Conveyor

Design Requirements:
Conveyor Speed
Motor horsepower
Material Specification
Type of Material Metallurgical-Grade Flourspar

Mass Flowrate (
529.80
kg

hr
Particle Size 0.009
lb
Density ( 3
1794
ft
Volumetric flowrate of fluorspar:
kg
529.80
mass flow rate hr m3
qf = = =0.2953
density kg hr
1794 3
m
1
PUMPS, COMPRESSORS
AND CONVEYORS
From CEMC, the material code of fluorspar is 100 D36

100 = Density
D = Lumpy
3 = Average flowability
6 = Moderate abrasive
Determining capacity, conveyor size and speed

3
N=
Equivalent Capacity ( ) ft
hr
3
1 rpm capacity ( )
ft
hr
Note: A standard pitch screw conveyor will be used.
2
PUMPS, COMPRESSORS
AND CONVEYORS
3 3 3
m ft ft
Required capacity=0.2953 3
=10.428
h r ( 0.3048 m ) hr
Equivalent capacity=10.4281.001.001.08
ft 3
Equivalent capacity=11.262
hr
Referring to the Capacity table D for 45% loading, a 6-inch screw at maximum rpm will have more than
the equivalent capacity and will also have a capacity of 2.2 cubic feet per hour at RPM.
3
PUMPS, COMPRESSORS
AND CONVEYORS
11.262
Conveyor speed= =5.119rpm
2.2
Horsepower Requirement
Friction HP
ln F d F b
HP f =
1,000,000
Where;
L=total lengthof conveyor ,ft
N=operating speed ,rpm
Fd =conveyor diameter HP factor
Fb =hanger bearing HP factor
4
PUMPS, COMPRESSORS
AND CONVEYORS
( 55.77 ) ( 5.119 ) ( 18 ) ( 4.4 )

HP f = =0.0226
1,000,000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
C=capacity require ,
hr
lb
D=densityof material as conveyed ,
f t3
Fm =material factor
F f =flightingmodification HP factor
F p =Paddle HP factor
( 10.428 )( 55.77 )( 1794 )( 2.0 ) ( 1.0 ) (1.29 )

H P m= =2.69
1000000
5
PUMPS, COMPRESSORS
AND CONVEYORS
Total HP:
(H P f +H P m) F o
H Ptotal =
e
Where;
Fo =Overload HPfactor
e=Drive efficiency ( expressed asdecimal )
( H P f +H Pm )= ( 0.0226+2.69 )=2.7126
In this case,
If ( H P f +H Pm ) is 5.2 then Fo =1
If ( H P f +H Pm ) is 5.2 then Fo =ln ( H Pf +H Pm ) x (0.6115 )+2.024
Fo =ln ( 2.7126 ) x (0.6115 )+2.024=1.414
6
PUMPS, COMPRESSORS
AND CONVEYORS
Using Screw Conveyor Drive which is specially designed for screw conveyor, e = 0.88
( 2.7126 ) 1.414
H Ptotal = =4.36 hP
0.88
7
PUMPS, COMPRESSORS
AND CONVEYORS
BALL MILL TO CLASSIFIER

Conveyor Speed
Motor horsepower
Type of Material : Fluorspar
Mass Flowrate ( 768.21 (1690.06 lb/hr)
kg

hr
Particle Size 0.044mm
198.52
lb
Density (
ft 3
From plant layout, conveyor length should be 7.3 m (23.95 ft.)
lb
768.21 3
hr ft
q= =3.87
lb hr
198.52 3
ft
Material Code:
8
PUMPS, COMPRESSORS
AND CONVEYORS
From CEMC, the material code of fluorspar is 90B 36

90 - Density (90 lbs/ft^3)
B Fine No. 16 Sieve (1mm) and Under, size of material
3 Flowability (average)
6 Moderately Abrasive
30B Conveyor loading
2D Component Group
Material Factor ( F M =2.0
From screw conveyor capacities table the degree of through loading for fluorspar is 30%. For conveying
products horizontally or up slight inclines, use a standard pitch.
Single Cut-Flight, Standard Pitch

Screws are notched at regular intervals at outer edge. Afford mixing action and agitation of material in
transit, useful for moving materials which tends to pack.
9
PUMPS, COMPRESSORS
AND CONVEYORS
For a Cut flight standard pitch with conveyor loading of 30%
C F 1=1
C F 2=1.57
C F 3=1.08
f t3
(
Equivalent Capacity= 3.87
hr )
(1 x 1.57 x 1.08)
f t3
Equivalent Capacity=6.56
hr
f t3
For a capacity of 6.56 and 30%B through loading, a screw diameter of 9.36 inches should be
hr
used.
Maximum recommended speed = 54.4 rpm
The computed speed of conveyor should not exceed the maximum recommended speed.
10
PUMPS, COMPRESSORS
AND CONVEYORS
Equivalent Capacity 337.12

Conveyor Speed= = =51.39 rpm
1 rpm capacity 6.56
Thus, 51.39 rpm may be accepted since it is below the maximum recommended speed.
Calculation of Motor Horse power

Friction HP:
L NF d F b
H Pf=
1000000
Where;
For a screw diameter of 9.36 inches:
F
Conveyor diameter HP factor ( d )=33.16

11
PUMPS, COMPRESSORS
AND CONVEYORS
Fluorspar is in component group 2D. For this component group, chilled hard iron, hardened alloy sleeve or
stellite bearing hangers can be used. The chosen hanger bearing is stellite. Using ball bearing hanger
requires stellite inserts in a shaft, particularly desirable for use in extremely long conveyors or conveyors
operating at higher speeds.
Take Stellite as the bearing type.
Hanger bearing HP factor: Fb =4.4
12
PUMPS, COMPRESSORS
AND CONVEYORS
23.95 x 51.39 x 33.16 x 4.4
L NF d F b
H Pf= = =0.18
1000000 1000000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
D=densityof materia l as conveyed ,
f t3
Fm =material factor
13
PUMPS, COMPRESSORS
AND CONVEYORS
F
From material characteristics table the horsepower material factor ( m)=2.0

Density of fluorspar as conveyed = 198.52 lb/ft^3
CLD Fm F f F p ( 6.56 x 23.95 x 198.52 x 2 x 1.15 x 1.29 )

H P m= = =0.09
1000000 1000000
Total HP:
(H P f +H P m) F o
H Ptotal =
e
Where;
14
PUMPS, COMPRESSORS
AND CONVEYORS
( H P f +H Pm )= ( 0.18+0.09 )=0.27
In this case,
Fo =ln ( 0.27 ) x (0.6115 )+2.024=2.82
( 0.27 ) 2.82
H Ptotal = =0.87 hP
0.88
15
PUMPS, COMPRESSORS
AND CONVEYORS
CLASSIFIER TO FLOTATION CELLS
kg
2098.02
h
Mass flow rate
kg
0.58278
s
kg
Density 1056.16
m3
kg
Viscosity 0.000819619
ms
Solving for the volumetric flow rate:
kg
0.58278 3
mass flow rate s 4 m
qf = = =5.51791 10
density kg s
1056.16 3
m
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005), the
velocity of liquid inside the pipe should not exceed 1 to 3 m/s. Setting the fluid velocity to 0.5 m/s
16
PUMPS, COMPRESSORS
AND CONVEYORS
m3
5.51791 104
Volumetric Flow Rate s
Area= = =1.10358 103 m2
Velocity m
0.50
s

3
4 Area 4 1.10358 10
Diameter= = =0.03748 m

Diameter=1.47559.
The nominal pipe size to be used is 1 1/5 inch (Perry & Green, 2008).
1 1/5 in. Nominal Pipe Size SCH No. 40 ST
Inside Diameter 1.610 in. 0.04089 m
Outside Diameter 1.900 in. 0.04826 m
Wall Thickness 0.145 in. 0.003683 m
Calculating the fluid velocity:
0.04089 m

2

2
di
Area std = =
4
m3 4
5.51791 10
Volumetric flowrate s m
Velocity= = 3 2
=0.42019
Area 1.31318 10 m s
To solve for Reynolds number:
17
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
N =
vD
=
( 1056.16
m
3)( )
0.42019 ( 0.04089 m)
s
=22,140.148
kg
0.000819619
ms
Since Reynolds number obtained is greater than 2,100 therefore the fluid flow is turbulent (Geankoplis,
1995).
For turbulent flow, use Churchill equation to solve for the friction factor, :
[ ]
0.9
1 7
f
=4 log 0.27 +
( )( )
di N
[ ( ]
0.90
1 0.0000457 m 7
f
=4 log 0.27
0.04089 m
+
22,140.148 )( )
f =0.006964
To calculate frictional loss per meter:
FL 2 f v2
=
L gc d
2
m
FL
=
(
2 0.006964 0.42019
s ) 1056.16 kg 1 kPa
3
L kg m m N
1 0.04089 m 1,000 2
N s2 m
FL kPa
=0.06352
L m
Since pressure drop is less than 0.5 kPa/m, chosen pipe dimension is valid.
18
PUMPS, COMPRESSORS
AND CONVEYORS
FRICTION LOSSES DUE TO VALVES AND FITTINGS
The additional friction losses for laminar flows are given in the table below: page 6-18 (Perry & Green,
2008).
K fittings kf
o
90 elbows 0.75 2 1.5
Total 1.5
2
2 m
0.42019 2
s

1.5
k f v2
Ff= =
2 gc
FRICTION LOSS DUE TO PIPE LINE
L=10.8 m
2
m
0.42019 2
s2

2 0.006964 10.8 m
2 f Lv 2
F L= =
gc d i
N m
F L =0.6495
kg
FRICTION LOSS DUE TO SUDDEN CONTRACTION (Entrance Loss)
19
PUMPS, COMPRESSORS
AND CONVEYORS
A2 v 2
Fc =0.5 1
( )
A 1 2 gc
A2
0(negligible)
A1
2
( 0.42019 ) m2 2
v s Nm
Fc =0.5 =0.5 =0.04414
2 gc kgm kg
2 1 2
N s
FRICTION LOSS DUE TO SUDDEN ENLARGEMENT (Exit Loss)
2
( v 1v 2 )
Fe =
2 gc
2
( 00.42019 )2 m2
s Nm
Fe = =0.08828
kgm kg
2 1 2
Ns
Calculating the total frictional losses:
F=F L + F f +Fc +F e +F m
F=0.6495+0.13242+0.04414+0.08828
Nm
F=0.91434
kg
20
PUMPS, COMPRESSORS
AND CONVEYORS
CALCULATION OF KINETIC ENERGY
m
v 2=0.42019
s
v 1=0
m2
0.42019 2
s2

2 2
v v 1
KE= 2 =
2 gc
CALCULATION OF POTENTIAL ENERGY
m
( 2.09 m2.2 m) 9.81
( z2 z1 ) g s
2
PE= =
gc kg m
1
N s2
Nm
PE=1.0791
kg
OVERALL MECHANICAL ENERGY BALANCES
Substituting the values at the overall mechanical energy balance on pumping system with = 1 for laminar
flow (Geankoplis, 1995):
KE P
W S= +PE+ +F

21
PUMPS, COMPRESSORS
AND CONVEYORS
0.08828 N m
W S= ( 1
1.0791+0+0.91434
kg )
J 0.58278 kg
W S =0.07648
kg s
W S =0.0446 W 0.00005977 hp
Since the value of work is negative, pump is not required (Sinnot, 2005).
CLASSIFIER TO BALLMILL
(Recycle)

Conveyor Speed
Motor horsepower
Type of Material : Fluorspar
22
PUMPS, COMPRESSORS
AND CONVEYORS
kg

hr
Particle Size Greater than 0.044mm
lb 198.52
Density (
ft 3
lb
238.41
hr f t3
q= =1.20
lb hr
198.52 3
ft
Material Code:
From CEMC, the material code of fluorspar is 100 D36

D Lumpy, containing lumps over 12 mesh
2D Component Group
23
PUMPS, COMPRESSORS
AND CONVEYORS

C F 1=1
C F 2=1.57
C F 3=1
f t3
Equivalent Capacity= 1.20(hr )
(1 x 1.57 x 1)
24
PUMPS, COMPRESSORS
AND CONVEYORS
f t3
hr
For a capacity of 1.88

f t 3 and 30%B through loading, a screw diameter of 6 inches should be used.
hr
Maximum recommended speed = 60 rpm

1 rpm capacity 1.5
25
PUMPS, COMPRESSORS
AND CONVEYORS

Friction HP:
L NF d F b
H Pf=
1000000
Where;
N=operatingspeed ,rpm
F
Conveyor diameter HP factor ( d )=18

26
PUMPS, COMPRESSORS
AND CONVEYORS
L NF d F b 23.2 x 1.25 x 18 x 4.4

H Pf= = =0.0023
1000000 1000000
27
PUMPS, COMPRESSORS
AND CONVEYORS
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
D=densityof materia l as conveyed ,
f t3
Fm =material factor
28
PUMPS, COMPRESSORS
AND CONVEYORS
F

Density of fluorspar as conveyed = 100 lb/ft^3
CLD Fm F f F p ( 1.88 x 23.2 x 100 x 2 x 1.15 x 1 )

H P m= = =0.01
1000000 1000000
Total HP:
(H P f +H P m) F o
H Ptotal =
e
Where;
( H P f +H Pm )= ( 0.0023+0.01 )=0.0123
In this case,
29
PUMPS, COMPRESSORS
AND CONVEYORS
Fo =ln ( 0.0123 ) x (0.6115 )+2.024=4.71
( 0.0123 ) 4.71
H Ptotal = =0.066 hP
0.88
Since the power requirement is very small, conveyor is not required.
BRANCHING
Water Tank to Classifier & Water Scrubber
(1) To Classifier Mass 0.4356 kg/s

Flow Rate
(2) To Water Scrubber 0.00025 kg/s
Mass Flow Rate
30
PUMPS, COMPRESSORS
AND CONVEYORS
Density 994.67 kg/m3
Viscosity 0.0008 kg/m-s
m=
m 1 + m 2
kg
(0.4356+ 0.00025)
Total mass flow rate s m3
4
qf = = =4.38 10
density kg s
994.67
m3
Calculating the relationship between v 1 and v2 with the following equal standard pipe sizing for the two
branches:
Properties of Steel Pipe (Perry & Green, 2008)

1 in. Nominal Pipe Size SCH No. 10S
Wall Thickness 0.109 in. 2.7686x10-3 m
f1f 2
v 1 2 L1 v 2 2 L2
=
d1 d2
31
PUMPS, COMPRESSORS
AND CONVEYORS
=

v 1 L2
=
126 m
v 2 L1 75.3 m
=1.2936
v 1=1.2936 v 2
Using the continuity equation
q f = A 1 v 1 + A2 v 2
3
m
4.38 10
4
( 2 2
)
= 0.0366 m (1.2936 v 2 +v 2)
s 4
m
v 2=0.18
s
Solving for v1 ,
m m
(
v 1=1.2936 0.18
s )
=0.23
s
Solving the Reynolds number of the branches:
kg m
994.67 0.0366 m 0.18
Dv 1 m
3
s
1= = =8152
kg
0.0008
m s
32
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
994.67 0.0366 m 0.23
Dv2 m3
s
2= = =10416
kg
0.0008
m s
Since Reynolds numbers obtained is greater than 4,200 therefore the fluid flow is turbulent (Geankoplis,
1995).
For turbulent flow, use Churchill equation to solve the friction factor, f:
2
1
f=
( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
1.442
0.0018

0.27 +( ( )] 7 0.9
8152
1
=0.0087
4 log [ )2

f 1=
1.442
0.0018

]
0.9
0.27 +
( ( 7
10416 )
1
=0.0087
4 log [ )2

f 2=
f 1=f 2
33
PUMPS, COMPRESSORS
AND CONVEYORS
Pipeline Before Split Point (A)
Continuity equation,
m A= m 1 + m 2
A A v A A= A 1 v 1 1 + A 2 v 2 2
For a constant cross-sectional area,
v A =v1 +v 2
m m
v A =0.18 +0.23
s s
m
v A =0.41
s
Reynolds Number,
kg m
994.67 0.0366 m0.41
Dv m
3
s
A = = =18658
kg
0.0008
m s
2
1
f=
( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=0.0018 for wrought iron
34
PUMPS, COMPRESSORS
AND CONVEYORS
1.44
0.0018

]
0.9
( (
0.27 +
7
18658 )
1
2
=0.0073
4 log [ )

f =
Before Split Point (A)
2
2 m
0.41 2
s

2 0.0073
FL 2 f v2
= =
L gc di
35
PUMPS, COMPRESSORS
AND CONVEYORS
Fittings and valves

Quantity Quantity Quantity
k kf kf kf
A 1 2
Tee
1 1 1 0 0 0 0
Branch
90o elbow 0.75 0 0 1 0.75 3 2.25
Globe
6 0 0 1 6 1 6
valve
Check
2 0 0 1 2 1 2
valve
TOTAL 1 8.75 10.25
Point (1)
2
2 m
0.18 2
s

2 0.0087
FL 2 f v2
= =
L gc di
Point (2)
2
2 m
0.23 2
s

2 0.0087
FL 2 f v2
= =
L gc di
36
PUMPS, COMPRESSORS
AND CONVEYORS
Nm kg 1kPa
( 0.0670+0.0154+ 0.0251 ) 994.67 3
Total Friction loss = kg m 1000 N
2
m
kPa
Total Frictionloss=0.107
m
Since the friction loss per meter is below 0.50 kPa/m, the chosen pipe dimensions are valid.
FRICTION LOSS DUE TO VALVES AND FITTINGS
The additional friction losses for laminar flows are given in the table below (Perry & Green, 2008).
Ff= f ( )
k v
2 gc A ,1,2
m2 2 2
( )( )( )
2m 2m
1 (0.41)2 2
8.75 (0.18) 2
10.25(0.23) 2
s s s N m
Ff= + + =0.4969
kgm kgm kgm kg
2 1 2
2 1 2
2 1 2
N s N s Ns
L A=7.97 m
L1=75.3 m
L2=126 m
37
PUMPS, COMPRESSORS
AND CONVEYORS
FL
F L= ( L
L ) A ,1,2
kPa kPa kPa

(
F L = 7.97 m 0.6670
m )(
+ 75.3 m0.1532
m )(
+ 126 m 0.2502
m )
N
3 2
1000
m m N m
F L =48.38 kPa =48.64
994.67 kg 1 kPa kg
FRICTION LOSS DUE TO FLOW METERING DEVICE
Orifice Meter
2 4
v (1 )
Fm = (Wilkes)
2C
The throat diameter of orifice meter is generally 20% to 80% of the pipe diameter (Rules of Thumb for
Chemical Engineers, 2012). Setting the throat diameter to 20% of pipe diameter,
D2 0.2 D
= = =0.2
D1 D
Discharge coefficient ,C=0.60(for orifice)

Before Split Point (A)
2 4
(0.41 m) (10.2 ) Nm
FmA = =0.14
2 0.60 kg
38
PUMPS, COMPRESSORS
AND CONVEYORS
Point (1)
2 4
(0.18 m) (10.2 ) Nm
Fm 1 = =0.03
2 0.60 kg
Point (2)
2 4
(0.23 m) (10.2 ) N m
Fm2 = =0.04
2 0.60 kg
Nm
FmTOTAL =0.14+0.03+0.04=0.21
kg
A2 v 2
Fc =0.5 1 ( ) A 1 2 gc
A2
0(negligible)
A1
Point (A)
39
PUMPS, COMPRESSORS
AND CONVEYORS
0.41

m2
2 2
s

FcA =0.5
Point (1)
0.18

m2
2 2
s

Fc 1=0.5
Point (2)
0.23

m2
2 2
s

Fc 2=0.5
Nm
FcTOTAL =0.04+0.008+0.01=0.058
kg
2
v
Fe =
2 gc
40
PUMPS, COMPRESSORS
AND CONVEYORS
Point (A)
0.41

m2
2 2
s

F e =
Point (1)
0.18

2
m
2 2
s

F e =
Point (2)
41
PUMPS, COMPRESSORS
AND CONVEYORS
0.23

m2
2 2
s

F e =
N m
FeTOTAL =0.08+0.02+0.03=0.13
kg
F=F L + F f +F M +Fc +F e
N m
F=( 48.64+0.50+0.21+0.058+0.13 )
kg
N m
F=49.54
kg
m
v A =0.41
s
42
PUMPS, COMPRESSORS
AND CONVEYORS
m
v 0 =0
s
m
v 2=0.23
s
m
v 1=0.18
s
m 2 2 m2 2 2 2 2
KE=
( 0.41
s2
2
0
s2
+
)(
0.23
2 m
s2
0.41
2 m
s2 )(
+
0.18
2 m
s2
0.41
2 m
s2 )
kgm kgm kgm
21 2
21 2
2 1
N s Ns Ns 2
N m
KE=0.04
kg
z A=2m
z 0=11m
z 1=2m
z 2=5m
( z2 z1 ) g
PE=
gc
43
PUMPS, COMPRESSORS
AND CONVEYORS
m m m
( 211 ) m 9.81 2
( 22 ) m 9.81 2 ( 52 ) m 9.81 2
s s s
PE= + +
kgm kgm kgm
1 1 1
N s 2 N s2
N s2
Nm
PE=58.86
kg
CALCULATION OF PRESSURE HEAD
P 101.325 kPa101.325 kPa

= =0
kg
994.67 3
m
Substituting the values at the overall mechanical energy balance on pumping system with = 1 for
turbulent flow (Geankoplis, 1995):
KE P
W S= +PE+ +F

Nm kg
W S= ( 0.04
1
58.86+0+49.54
kg )
0.5628
s
W S =9.36 Watts
Since the work is negative, pump is not required (Sinnot, 2005)
OLEIC ACID TANK TO FLOTATION CELLS
44
PUMPS, COMPRESSORS
AND CONVEYORS
Mass flow rate 0.09441 kg
h
kg
0.000026225
s
Density kg
881.7
m3
Viscosity
kg
0.02793
ms
kg
0.000026225
mass flow rate s m3
qf = = =2.9744 108
density kg s
881.7
m3
From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth Edition, 2005), the velocity of liquid
inside the pipe should not exceed 1 to 3 m/s. Setting the fluid velocity to 0.5 m/s
3
8 m
2.9744 10
Volumetric Flow Rate s 8 2
Area= = =5.9488 10 m
Velocity m
0.50
s

8
4 Area 4 5.9488 10
Diameter= = =2.7521 104 m

Diameter=0.0108.
The nominal pipe size to be used is 1/8 inch (Perry & Green, 2008).
45
PUMPS, COMPRESSORS
AND CONVEYORS
1/8 in. Nominal Pipe Size SCH No. 40 ST
0.0068326 m

2

d i2
Area std = =
4
m3 8
2.9744 10
Volumetric flowrate s 4 m
Velocity= = 5 2
=8.112210
Area 3.66659 10 m s
kg 4 m
N =
vD
=
( 881.7
m )(
3
8.1122 10
s )
( 0.0068326 m )
=0.1749744
kg
0.02793
ms
Since Reynolds number obtained is lower than 2,100 therefore the fluid flow is laminar (Geankoplis, 1995).
For laminar flow, use the following equation to solve for the friction factor, f:
16 16
f= = =91.4419
N 0.1749744
46
PUMPS, COMPRESSORS
AND CONVEYORS
FL 2 f v2
=
L gc d
2
m
FL
=
(
2 91.4419 8.1122 104
s ) 881.7 kg 1 kPa
3
L kgm m N
1 0.0068326 m 1,000 2
Ns2 m
FL kPa
=0.0155
L m
The additional friction losses for laminar flows are given in the table below (Perry & Green, 2008).
K fittings kf
o
90 elbows 0.75 2 1.5
Total 1.5
2
m
8.1122104 2 2
s

1.5
2
kf v
Ff= =
2 gc
L=47.22m
47
PUMPS, COMPRESSORS
AND CONVEYORS
2
4 2 m
8.1122 10
s2

2 91.4419 47.22m
2 f Lv 2
F L= =
gc di
N m
F L =0.8317
kg
A2 v 2
Fc =0.5 1
( )
A 1 2 gc
A2
0(negligible)
A1
2
( 8.1122104 ) m2
2
v2 s 7 N m
Fc =0.5 =0.5 =1.6452 10
2 gc kgm kg
2 1 2
N s
2
( v 1v 2 )
Fe =
2 gc
48
PUMPS, COMPRESSORS
AND CONVEYORS
2
( 8.1122 104 ) m2
2
s N m
Fe = =3.2904 107
kgm kg
2 1
Ns 2
F=F L + F f +Fc +F e
7 7 7
F=0.8317+4.9356 10 +1.6452 10 +3.2904 10
Nm
F=0.8317
kg
4 m
v 2=8.112210
s
v 1=0
m2
8.1122104 2
s2

2 2
v 2 v1
KE= =
2 gc
49
PUMPS, COMPRESSORS
AND CONVEYORS
m
( 4.65 m2.5 m ) 9.81
( z 2z 1 ) g s
2
PE= =
gc kg m
1
N s2
Nm
PE=21.0915
kg
Substituting the values at the overall mechanical energy balance on pumping system with = 1 for laminar flow
(Geankoplis, 1995):
KE P
W S= + PE+ + F

W S=( 3.2904 107

1
+21.0915+0+0.8317
Nm
kg )
J 0.000026225 kg
W S =21.9232 =5.749 104 W
kg s
4
W s =5.749 10 W
7
7.7095 10 h p
Since the value is positive, a pump is required (Sinnot, 2005). However, the calculated value for power requirement is
in negligible amount, therefore pump is not needed.
According to (Sinnott, 2005), flow element and control valve has allowable pressure drop of 15 kPa and 140 kPa,
respectively.
50
PUMPS, COMPRESSORS
AND CONVEYORS
Line to Pump Suction
Suction Pressure = Upstream Pressure - Pressure Losses + Static Pressure
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 2 1.5 40
SUCTION LINE CALCULATION
Pressure Losses = Frictional Line Loss + Instrument Losses
5m to pump
1.5 ( 40 mm )
Linelengthsuction pump=10 m+ =10.6 m
1000mm
m
Line Loss=Fanning Pressure Drop x Lengthof Pipe
kPa
Line Loss=0.0155 10.6 m=0.1643 kPa
m
Pressure Losses=0.1643kPa
kg m
881.7 3
x 9.81 2 x 2.5 m
gh m s
static Pressure= = =21623.69 Pa 21.6237 kPa
gc kgm
1
N s 2
Suction Pressure=Upstream PressurePressure Losses+Static Pressure
( 101.3250.1643+21.6237 ) kPa
51
PUMPS, COMPRESSORS
AND CONVEYORS
Suction Pressure=122.7844 kPa

LINE FROM PUMP DISCHARGE
Discharge Pressure = Dynamic Loss + Equipment Operating Pressure + Static Pressure
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 2 1.5 40
( 1.5 ) ( 40 ) mm
Linelength the pump discharge=37.22 m+ =37.28 m
1000 mm
( 1m )
kPa
Line Loss=0.0155 37.28m=0.57784 kPa
m
Dynamic Loss = Pressure drop of instruments + Frictional Line Loss
Dynamic Loss=15kPa+140 kPa+0.57784 kPa=155.58kPa
Equipment Operating Pressure=101.325kPa
kg m
881.7 3
x 9.81 2 x 4.65 m
gh m s
Static Pressure= = =40.22 kPa
gc N
kgm m2
1 2
1000
N s kPa
Discharge Pressure=Dynamic Loss+Equipment Operating Pressure+Static Pressure
52
PUMPS, COMPRESSORS
AND CONVEYORS
Discharge Pressure=( 155.58+101.325+40.22 ) kPa
Discharge Pressure=297.125kPa
Differential Pressure=Discharge PressureSuction Pressure
Differential Pressure=( 297.125122.7844 ) kPa
Differential Pressure=174.34kPa
Vapor Pressure of solvent : PT =P A X A
101.325=P A ( 1 )
P A =101.325 kPa
Suction PressureVapor Pressure

NPSH available=
g
N
1000 2
( 122.7844101.325 ) kPa m kgm
NPSH available= x x1 2
kg m kPa N s
881.7 3 x 9.81 2
m s
NPSH available=2.48 Pa
53
PUMPS, COMPRESSORS
AND CONVEYORS
1000 Pa
174.34 kPa( )
Differential Pressure 1 kPa
Pump Head= = =20.16 m
( g) ( ) m kg
(
9.81 2 881.7 3
s m )
Shutoff Pressure=1.25 x Differential Pressure
Shutoff Pressure=1.25 x174.34kPa=217.925kPa
SODA ASH TANK TO FLOTATION CELLS

Conveyor Speed
Motor horsepower
Type of Material : Soda Ash
54
PUMPS, COMPRESSORS
AND CONVEYORS
kg

hr
Particle Size 0.075mm
lb
Density ( 157.29
ft 3
Volumetric flowrate of soda ash:
lb
5.68
hr f t3
q= =0.04
lb hr
157.29 3
ft
Material Code:
From CEMC, the material code of soda ash is 28 A 36Y

B Very Fine 100 mesh and under
55
PUMPS, COMPRESSORS
AND CONVEYORS
Y- Very light and fluffy
2D Component Group
From screw conveyor capacities table the degree of through loading for soda ash is 30%. For conveying

C F 1=1
56
PUMPS, COMPRESSORS
AND CONVEYORS
C F 2=1.57
C F 3=1.08
f t3
(
hr )(1 x 1.57 x 1.08)
f t3
hr

f t 3 and 30%B through loading, a screw diameter of 6 inches should be used.
hr
57
PUMPS, COMPRESSORS
AND CONVEYORS

Conveyor Speed= = =21.4 3 rpm
1 rpm capacity 0.07

Friction HP:
L NF d F b
H Pf=
1000000
Where;
L=total lengthof conveyor ,f t
N= ating speed ,rpm
For a screw diameter of 6 inches:
58
PUMPS, COMPRESSORS
AND CONVEYORS
F

Soda Ash is in component group 2D. For this component group, chilled hard iron, hardened alloy sleeve or
59
PUMPS, COMPRESSORS
AND CONVEYORS
189.50 x 21.43 x 18 x 4.4
L NF d F b
H Pf= = =0.32
1000000 1000000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
f t3
Fm =material factor
60
PUMPS, COMPRESSORS
AND CONVEYORS
F

Density of soda sh as conveyed = 198.52 lb/ft^3
CLD Fm F f F p ( 0.07 x 189.50 x 157.29 x 0.8 x 1.15 x 1.29 )

H P m= = =0.0025
1000000 1000000
Total HP:
(H P f +H P m) F o
H Ptotal =
e
61
PUMPS, COMPRESSORS
AND CONVEYORS
Where;
( H P f +H Pm )= ( 0.321+0.0025 )=0.32
In this case,
Fo =ln ( 0.32 ) x (0.6115 ) +2.024=2.72
( 0.32 ) 2.72
H Ptotal = =0.99 hP
0.88
62
PUMPS, COMPRESSORS
AND CONVEYORS
63
PUMPS, COMPRESSORS
AND CONVEYORS
SODIUM BISULFITE TANK TO FLOTATION CELLS

Conveyor Speed
Motor horsepower
Type of Material : Sodium Bisulfite
Mass Flowrate (
0.2628 (0.5771 lb/hr)

kg

hr
lb
Density ( 92
ft 3
From plant layout, conveyor length should be 167.65 ft
lb
0.5771
hr f t3
q= =0.0063
lb hr
92
f t3
Material Code:
64
PUMPS, COMPRESSORS
AND CONVEYORS
From CEMC, the material code of fluorspar is 96B 46 X 30B2 D

4 Sluggish
X- Packs Under Pressure
2D Component Group
From screw conveyor capacities table the degree of through loading for sodium bisulfite is 15%. For
conveying products horizontally or up slight inclines, use a standard pitch.
Cut-Flight, Standard Pitch
65
PUMPS, COMPRESSORS
AND CONVEYORS
C F 1=1
C F 2=1.95
C F 3=1
f t3
(
hr )
(1 x 1.95 x 1)
f t3
hr
f t3 and 15% trough loading, a screw diameter of 6 inches should be used.

hr
66
PUMPS, COMPRESSORS
AND CONVEYORS
3
ft
0.0122
Equivalent Capacity hr
1 rpm capacity 0.8 rpm

Friction HP:
L NF d F b
H Pf=
1000000
Where;
F

67
PUMPS, COMPRESSORS
AND CONVEYORS
68
PUMPS, COMPRESSORS
AND CONVEYORS
167.65 ft x 0.0153 rpm x 18 x 4.4
L NF d F b
H Pf= = =0.0002
1000000 1000000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
f t3
Fm =material factor
F p =Paddle HP facto r
69
PUMPS, COMPRESSORS
AND CONVEYORS
F

CLD Fm F f F p ( 0.0063 x 167.65 x 92 x 1.5 x 1.1 x 1 )

H P m= = =0.0002
1000000 1000000
Total HP:
( H P f +H P m) Fo
H Pt otal=
e
Where;
70
PUMPS, COMPRESSORS
AND CONVEYORS
( H P f +H Pm )= ( 0.0002+0.0002 )=0.0004
In this case,
Fo =ln ( 0.0004 ) x (0.6115 ) +2.024=6.87
( 0.0004 ) 6.87
H Ptotal = =0.0028 hP
0.88
Since the power requirement is very small, conveyor is not required.
71
PUMPS, COMPRESSORS
AND CONVEYORS
FLOTATION CELLS TO THICKENER

Mass flow rate 2026.04
kg
h
0.5628
kg
s
Density 1180.89 kg
m3
Viscosity 0.0012
kg
ms
kg
0.5628 3
qf = = =4.77 10
density kg s
1180.89 3
m
m
The velocity of slurry inside the pipe is less than 1.1887 . (Poirier)
s
72
PUMPS, COMPRESSORS
AND CONVEYORS
m
Setting the velocity to 1 ,
s
m3 4
4.77 10
Area= = =4.77 10 m
Velocity m
1
s
Diameter=

=

4 Area 4 4.77 104

=0.0246 m
Diameter=0.97 .
1 in. Nominal Pipe Size Sch No. 80 S
0.0325 m

2

d i2
Area std = =
4
m34
4.77 10
Velocity= = 4 2
=0.575
Area 8.2958 10 m s
73
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
1180.89 0.575 0.0325m
vD m 3
s
N = = =18389.90
kg
0.0012
ms
Since Reynolds number obtained is higher than 4,200, therefore the fluid flow is turbulent. (Perry & Green,
2008)
For turbulent flow, use the Churchill equation to solve for the friction factor, f :
2
1
f=
( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=0.0018.for commercial steel , from table 6-1, Perrys ChE HandBook
74
PUMPS, COMPRESSORS
AND CONVEYORS
1.278
0.0018

]
0.9
( (
0.27 +
7
18389.90 )
1
2
=0.0074
4 log [ )

f =
To calculate frictional loss due to meter:
2
2 m
0.575 2
s

2 0.0074
FL 2 f v2
= =
L gc di
Since the friction loss per meter is below 0.50 kPa/m, the set velocity is valid.
FRICTION LOSS DUE TO VALVES AND FITTINGS
The additional friction losses for turbulent flows are given in the table below (Perry & Green, 2008).
k Quantity kf
o
90 elbows 0.75 2 1.5
Ball valve 70 1 70
Total 71.5
75
PUMPS, COMPRESSORS
AND CONVEYORS
2
2 m
0.575 2
s

71.5
k f v2
Ff= =
2 gc
L=22.16 m
2
2 m
0.575 2
s

2 0.0074 22.16 m
2 f Lv 2
F L= =
gc d i
N m
F L =3.34
kg
FRICTION LOSS DUE TO FLOW METERING DEVICE
Orifice Meter
2 4
v (1 )
Fm = (Wilkes)
2C
76
PUMPS, COMPRESSORS
AND CONVEYORS
D2 0.2 D
= = =0.2
D1 D
Substituting values to the equation,
2 m2 4
0.575 2
(10.2 )
s

F m =
A2 v 2
Fc =0.5 1
( )
A1 2 gc
A2
0(negligible)
A1
77
PUMPS, COMPRESSORS
AND CONVEYORS
2 m2
0.575
s2

2
v
Fc =0.5 =0.5
2 gc
2
v
Fe =
2 gc
2m2
0.575 2
s

F e =
F=F L + F f +F M +Fc +F e
Nm
F=( 3.34+11.82+0.2751+0.0826+0.1653 )
kg
N m
F=15.68
kg
78
PUMPS, COMPRESSORS
AND CONVEYORS
m
v 2=0.575
s
m
v 1=0.575
s
KE=0
m
( 2.5 m1.5 m ) 9.81
( z2 z1 ) g s
2
PE= =
gc kgm
1
Ns 2
N m
PE=9.81
kg
CALCULATION OF PRESSURE HEAD
P 101.325 kPa101.325 kPa

= =0
kg
1180.89 3
m
Substituting the values at the overall mechanical energy balance on pumping system with = 1 for
turbulent flow (Geankoplis, 1995):
79
PUMPS, COMPRESSORS
AND CONVEYORS
KE P
W S= +PE+ +F

0 N m kg
1(
W S = +9.81+0+15.68
kg )
0.5628 =14.3458Watts
s
Since the work is very small, pump is not required.
THICKENER TO ROTARY FILTER
kg
756.16
h
Mass flow rate
kg
0.21004
s
kg
Density 1234.20
m3
kg
Viscosity 0.000819619
ms
kg
0.21004 3
qf = = =1.70183 10
density kg s
1234.20 3
m
80
PUMPS, COMPRESSORS
AND CONVEYORS
m3 4
1.70183 10
Area= = =3.40366 104 m2
Velocity m
0.50
s

4
4 Area 4 3.40366 10
Diameter= = =0.02082 m

Diameter=0.81969.

0.02664 m

2

d 2
Area std = i =
4
3
m 4
1.70183 10
Velocity= = 4 2
=0.30532
Area 5.57389 10 m s
81
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
N =
vD
=
( 1234.20
m )(
3 )
0.30532 ( 0.02664 m )
s
=12,247.94
kg
0.000819619
ms
Since Reynolds number obtained is greater than 2,100 therefore the fluid flow is turbulent (Geankoplis, 1995).
[ ]
0.9
1 7
f
=4 log 0.27 +
di N ( )( )
[ ( ]
0.90
1 0.0000457 m 7
f
=4 log 0.27
0.02664 m
+
12,247.94 )( )
f =0.008102
FL 2 f v2
=
L gc d
2
m
FL
=
(
2 0.008102 0.30532
s ) 1234.20 kg 1 kPa
3
L kgm m N
1 0.02664 m 1,000 2
Ns2 m
FL kPa
=0.06998
L m
82
PUMPS, COMPRESSORS
AND CONVEYORS
The additional friction losses for laminar flows are given in the table below: page 6-18 (Perry & Green, 2008).
K fittings kf
90o elbows 0.75 3 2.25
Globe valve 9.5 1 9.5
Total 11.75
2
2 m
0.30532 2
s

11.75
k v2
F f = f =
2 gc
L=15.01 m
2
m2
0.30532 2
s

2 0.008102 15.01m
2 f Lv 2
F L= =
gc di
N m
F L =0.8511
kg
83
PUMPS, COMPRESSORS
AND CONVEYORS
A2 v 2
Fc =0.5 1
( )
A 1 2 gc
A2
0(negligible)
A1
2
( 0.30532 ) m2 2
v s Nm
Fc =0.5 =0.5 =0.02331
2 gc kgm kg
2 1 2
N s
2
( v 1v 2 )
Fe =
2 gc
2
( 00.30532 )2 m2
s N m
Fe = =0.04661
kgm kg
2 1 2
N s
F=F L + F f +Fc +F e
F=0.8511+0.54767+0.02331+0.04661
N m
F=1.46869
kg
84
PUMPS, COMPRESSORS
AND CONVEYORS
m
v 2=0.35320
s
v 1=0
2 m2
0.30532 2
s

v 22 v 12
KE= =
2 gc
m
( 6.81 m1 m ) 9.81
( z 2z 1 ) g s
2
PE= =
gc kg m
1
N s2
N m
PE=56.9961
kg
(Geankoplis, 1995):
KE P
W S= + PE+ + F

85
PUMPS, COMPRESSORS
AND CONVEYORS
0.04661 Nm
W S= ( 1
+56.9961+0+1.46869
kg )
J 0.21004 kg
W S =58.5114
kg s
W S =12.2897 W 0.01648 h p
respectively.
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 3 2.25 40
**2 m to pump
2.25 ( 40 mm )
1000 mm
m
kPa
Line Loss=0.06998 15.01 m=1.0504 kPa
m
86
PUMPS, COMPRESSORS
AND CONVEYORS
Pressure Losses=1.0504 kPa
kg m
1234.20 3
x 9.81 2 x 1 m
gh m s
static Pressure= = =12,107.50 Pa 12.1075 kPa
gc kgm
1
Ns 2
( 101.3251.0504+12.1075 ) kPa
Suction Pressure=112.3821kPa
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 3 2.25 40
( 2.25 ) ( 40 ) mm
1000 mm
( 1m )
kPa
Line Loss=0.06998 13.01 m=0.91044 kPa
m
Dynamic Loss=15kPa+140kPa+0.91044 kPa=155.9104 kPa
87
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
1234.20 3
x 9.81 2 x 6.81 m
gh m s
Static Pressure= = =82,452.09 Pa 82.4521kPa
gc kgm
1
Ns 2
Discharge Pressure=339.6875 kPa
Differential Pressure=227.3054 kPa
Vapor Pressure of solvent :0.200kPa

NPSH available=
g
N
1000 2
( 112.38210.200 ) kPa m kgm
kg m kPa N s
1234.20 3 x 9.81 2
m s
88
PUMPS, COMPRESSORS
AND CONVEYORS
NPSH available=9.266 m
1000 Pa
227.3054 kPa( )
( g) ( ) m kg
(
9.81 2 1234.20 3
s m)
Shutoff Pressure=1.25 x227.30546kPa=284.1318kPa
1000 Pa
227.3054 kPa( )
( g) ( ) m kg
(
9.81 2 1234.20 3
s m)
Shutoff Pressure=1.25 x227.30546kPa=284.1318 kPa
ROTARY FILTER TO ROTARY DRYER
89
PUMPS, COMPRESSORS
AND CONVEYORS

Conveyor Speed
Motor horsepower
Type of Material : Calcium Fluoride, Silicon dioxide and Water
Mass Flowrate (
482.66 (1061.85 lb/hr)

kg

hr
Particle Size 0.075 mm
lb
Density ( 175.27
ft 3
Volumetric flowrate:
lb
1061.85 3
hr ft
q= =6.06
lb hr
175.27 3
ft
Material Code:
90
PUMPS, COMPRESSORS
AND CONVEYORS
From CEMC, the material code of fluorspar is 90B 36 and for silicon dioxide is 75A27

A - Very Fine
B Fine No. 16 Sieve (1mm) and under, size of material
2 Free flowing
7 Extremely Abrasive
91
PUMPS, COMPRESSORS
AND CONVEYORS
15 and 30B Conveyor loading
2D and 3D Component Group
Material Factor ( F M =2.0 + 1.7 = 1.9
From screw conveyor capacities table the degree of through loading is 45%. For conveying products
horizontally or up slight inclines, use a standard pitch.

92
PUMPS, COMPRESSORS
AND CONVEYORS
C F 1=1
C F 2=1.43
C F 3=1.08
f t3
(
Equivalent Capa city= 6.06
hr ) (1 x 1.57 x 1.08)
f t3
hr
3
f t and 45% through loading, a screw diameter of 9.54 inches should be used.
hr
Maximum recommended speed = 153.8 rpm
93
PUMPS, COMPRESSORS
AND CONVEYORS
Equivalent Capacity 1400

1 rpm capacity 9.36
Friction HP:
L NF d F b
H Pf=
1000000
Where;
L=total lengthof conveyo r ,ft
F
Conveyor diameter HP factor ( d )=34.24

94
PUMPS, COMPRESSORS
AND CONVEYORS
Calcium fluoride and silicon dioxide is in component group 2D and 3D. For this component group, chilled
hard iron, hardened alloy sleeve or stellite bearing hangers can be used. The chosen hanger bearing is
stellite. Using ball bearing hanger requires stellite inserts in a shaft, particularly desirable for use in
extremely long conveyors or conveyors operating at higher speeds.
95
PUMPS, COMPRESSORS
AND CONVEYORS
L NF d F b (107.91 x 149.57 x 34.24 x 4.4)
H Pf= = =2.43
1000000 1000000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
D=densityof mater ial as conveyed ,
f t3
Fm =material factor
96
PUMPS, COMPRESSORS
AND CONVEYORS
F

Density of component as conveyed = 175.27 lb/ft^3
CLD Fm F f F p ( 9.36 x 107.91 x 175.27 x 1.9 x 1.2 x 1.29 )

H P m= = =0.52
1000000 1000000
Total HP:
(H P f +H P m) F o
H Ptotal =
e
Where;
97
PUMPS, COMPRESSORS
AND CONVEYORS
( H P f +H Pm )= ( 2.43+0.52 )=2.95
In this case,
Fo =ln ( 2.95 ) x (0.6115 ) +2.024=1.36
( 2.95 ) 1.36
H Ptotal = =4.56 hP
0.88
98
PUMPS, COMPRESSORS
AND CONVEYORS
ROTARY DRYER TO ROTARY KILN

Conveyor Speed
Motor horsepower
Type of Material : Acid-grade Fluorspar
Mass Flowrate ( 998.624 lb/hr
kg

hr
100
lb
Density ( 3
ft
From plant layout, conveyor length should be 119 ft
Volumetric flowrate of Fluorspar :
99
PUMPS, COMPRESSORS
AND CONVEYORS
lb
998.624
hr f t3
q= =9.99
lb hr
100
f t3
Material Code:
From CEMC, the material code of fluorspar is 90B 36

2D Component Group
100
PUMPS, COMPRESSORS
AND CONVEYORS
Cut-Flight, Standard Pitch

C F 1=1
C F 2=1.43
C F 3=1
f t3
Equivalent Capacity= 9.99( hr )(1 x 1.43 x 1)
f t3
hr

f t3 and 45% trough loading, a screw diameter of 6 inches should be used.
hr
101
PUMPS, COMPRESSORS
AND CONVEYORS
Maximum recommended speed =165 rpm
3
ft
14.28
Equivalent Capacity hr
1 rpm capacity 2.2 rpm

Friction HP:
L NF d F b
H Pf=
1000000
Where;
102
PUMPS, COMPRESSORS
AND CONVEYORS
F

103
PUMPS, COMPRESSORS
AND CONVEYORS
119ft x 6.49rpm x 18 x 4.4

L NF d F b
H Pf= = =0.055 6
1000000 1000000
Material HP:
CLD Fm F f F p
H P m=
1000000
Where;
f t3
hr
lb
D=densityof m aterial as conveyed , 3
ft
104
PUMPS, COMPRESSORS
AND CONVEYORS
Fm =material factor
F

( 9.99 x 119 x 100 x 2 x 1.2 x 1 )

H P m= =0.2852
1000000
Total HP:
105
PUMPS, COMPRESSORS
AND CONVEYORS
(H P f +H Pm) F o
H Ptotal =
e
Where;
( H P f +H Pm )= ( 0.0556+0.2852 )=0.340 8
From the figure below Fo = 2.69
106
PUMPS, COMPRESSORS
AND CONVEYORS
107
PUMPS, COMPRESSORS
AND CONVEYORS
( 0.3408 ) 2.69
H Ptotal = =1.04 hP
0.88
108
PUMPS, COMPRESSORS
AND CONVEYORS
SULFURIC ACID TANK TO ROTARY KILN

h
0.1621
kg
s
Density 1840 kg
m3
Viscosity 0.019
kg
ms
q kg
0.1621
mass flow rate s m3
f= = =8.81 x 105
density kg s
1840 3
m
Table 5.4 (Towler & Sinnott, 2007)
Calculating the inside diameter of pipe with the assumed velocity of 1 m/s from preceding table:
5 m3
8.81 x 10
Volumetric Flow rate s 5 2
Area= = =8.81 x 10 m
Velocity m
1
s
109
PUMPS, COMPRESSORS
AND CONVEYORS
Diameter=

=

4 x Area 4 x 8.81 x 105 m2
=0.0106 m=0.4173
For standard pipe sizing

Table 10-22: Properties of Steel Pipe (Perry & Green, 2008)
Nominal Pipe Size 1

2
Schedule number 40S
Inside Diameter 0.622 in 0.0158 m
Outside Diameter 0.840 in 0.0213 m
Solving for the fluid velocity:

2
d i (0.0158m)2 2
Are a std = = =0.000196 m
4 4
m3 5
8.81 x 10
q s m
Velocity= f = =0.4496
A 0.000196 m 2
sec
Dv
N =

m kg
(0.0158 m)(0.4496 )(1840 3 )
sec m
N =
kg
0.019
msec
110
PUMPS, COMPRESSORS
AND CONVEYORS
N =687.92
Since Reynolds number obtained is lower than 2,100 therefore the fluid flow is laminar (Geankoplis, 1995)
For friction in Laminar Flow:
64 64
f= = =0.093
N 687.92
F M=
( dL ) = ( 0.093) (0.4496 )( 0.0158
f v2
i
2 48.67 m
m)
=28.95
N m
2g kgm kg
c
( Ns )
(2) 1 2
To calculate friction loss due to valves and fittings:
L
Description Equivalent Length in Pipe Diameter ( )
D
Globe Valve 0
90 Elbow (1)(30)
Total 30
111
PUMPS, COMPRESSORS
AND CONVEYORS
v

L
2 ( )
D
f
F L =
To calculate friction loss due to sudden contraction:
Kc = 0.5 (pipe entrance loss)

Inside diameter = 0.622 in
L
Using graph ( ) equivalent length for pipe
D
112
PUMPS, COMPRESSORS
AND CONVEYORS
v

Lc
2 ( )
D
f
F C =
To calculate friction loss due to sudden expansion:
Ke = 1.0 (pipe exit loss)

L
D
113
PUMPS, COMPRESSORS
AND CONVEYORS
v

Le
2 ( )
D
f
F E=
114
PUMPS, COMPRESSORS
AND CONVEYORS
Calculating the total Frictional Losses:
F=F M +F L +F C +F E
N m
F =(28.95+0.28+0.18+0.37)
kg
Nm
F =29.78
kg
To calculate kinetic energy:
m
v 1=0
s
m
v 2=0.4496
s
2
v v 1
KE= 2
2
=
2
( 0.4496 202 ) m2( ) s
=0.10
N m
2 gc Kgm kg
2 ( 1)
( Ns 2 )
To calculate potential energy:
z 1=5.3m
z 2=2.5m
115
PUMPS, COMPRESSORS
AND CONVEYORS
m
( 2.55.3 ) (9.81 )
( z 2z 1 ) g s
2
Nm
PE= = =27.47
gc kg
(1)
( Kgm
N s )
2
To calculate pressure head:
P ( 101,325101,325 ) Pa
= =0
kg
1840 3
m
Substituting the values at the overall mechanical energy balance on pumping system with
=0.5for laminar flow ( Geankoplis ,1995 ) .
KE P
W s= + PE+ +F

0.10 Nm kg
W s= ( 0.50
27.47+0+29.78
kg )
x 0.162 =0.4 1 W
s
Pump is not required (Sinnot, 2005)
116
PUMPS, COMPRESSORS
AND CONVEYORS
117
PUMPS, COMPRESSORS
AND CONVEYORS
ROTARY KILN TO ACID SCRUBBER

h
0.067233
kg
s
Density 0.6019 kg
m3
Viscosity 7.65310-6
kg
ms
kg
0.067233 3
mass flow rate s m
qf = = =0.11170
density kg s
0.6019 3
m
m3
0.11170
Volumetric Flow Rate s 2
Area= = =0.2234 m
Velocity m
0.50
s
Diameter=

=

4 Area 4 0.2234

=0.5333 m
Diameter=20.9961.
118
PUMPS, COMPRESSORS
AND CONVEYORS

The Inside Diameter 23.250 in. 0.59055 m nominal
Outside Diameter 24 in. 0.6096 m
pipe size to be used
(Perry & Green,
2008).
Calculating the velocity:
0.59055 m

2

d 2
Area std = i =
4
kg
0.067233
mass flowrate s kg
MassVelocity= = =0.24546 2
Area 0.27391 m
2
m s
m3
0.11170
Velocity= = 2
=0.407798
Area 0.27391m s
119
PUMPS, COMPRESSORS
AND CONVEYORS
kg
0.59055 m 0.24546
DG m2 s
N = = =18,941.12152
6kg
7.653 10
ms
[ ]
0.9
1 7
f
=4 log 0.27 +
( )( )
di N
[ ( ]
0.90
1 0.0000457 m 7
f
=4 log 0.27
0.59055 m
+
18,941.12152 )( )
f =0.0065966
FL 2 f v2
=
L gc d
m 2
FL
=
2 0.0065966 0.407798( s kg)
0.6019 3
1 kPa
L kg m m 1,000 N
1 2
0.59055 m 2
N s m
FL 6 kPa
=2.2362 10
L m
FOR COMPRESSIBLE FLUID
2
2 24 zRTfL G
P1 P2 =
g c DMW
Length of pipe = 77.72m
120
PUMPS, COMPRESSORS
AND CONVEYORS
Molecular weight = 22.7414 kg/kmol
3 2
2
101.325 P2 =
2
(
4 (1 ) 8.314
kPa m
kmol K ) ( kg
( 423.15 K ) ( 0.0065966 ) (77.72 m ) 0.24546 2
ms )
kg m kg 1000 N
( 1
N s )
2 (
( 0.59055 m ) 22.7414 )(
kmol kPam 3 )
P2=101.32kPa
For the Suction Line
To get the friction loss due to fittings to Suction
Number of Equivalent Pipe Diameter,

K Kf
fittings mm
90 elbow 0.75 2 0.75 40 (2)
Total 1.5 80 mm
1.5 ( 80 mm )
Linelengthsuction=77.72 m+ =77.84 m
1000 mm
m
From Equation 5.3, Coulson & Richardsons Chemical Engineering Design
4 f LG G P1
2 2
Line Loss= + ln
2 D P2
2
kg
2 (0.24546 2 )
4(0.0065966)(77.84 m)(0.24546) m s 101.325
Lineloss= + ln
kg kg 101.32
2(0.59055 m)(0.6019 3 ) 0.6019 3
m m
121
PUMPS, COMPRESSORS
AND CONVEYORS
Line Loss=0.289 Pa
Pressu Losses=Line Loss
Pressure Losses=0.289Pa
kg m
0.6019 3
x 9.81 2 x 2 m
gh m s
Static Pressure= =
gc kgm
1
Ns 2
Static Pressure=11.81 Pa
Pressureof Upstream Equipment=101325Pa
( 1013250.289+11.81 ) Pa
Suction Pressure=101336.52 P a
Pipeline from discharge of compressor
Linelengthdischarge compressor=50m
122
PUMPS, COMPRESSORS
AND CONVEYORS
4 f LG G P1
2 2
Line Loss= + ln
2 D P2
2
kg
2 (0.24546 2
)
4(0.0065966)(50 m)(0.24546) m s 101.325
+ ln
kg kg 101.32
2(0.59055 m)(0.6019 3 ) 0.6019 3
m m
Line Loss=0.227 Pa
kg m
0.6019 3
x 9.81 2 x 5 m
gh m s
Static Pressure= = =29.523
gc kgm
1
Ns 2
Dynamic Loss=0+0.227 Pa=0.112 Pa
Discharge Pressure=( 0.227+101325+29.523 ) Pa

COMPRESSOR
[( ) ]
1
RT P2
H ad= 1
1 P1
123
PUMPS, COMPRESSORS
AND CONVEYORS
[( ]
1.401
(1.40)(8.314)(423.15) 101.32
W=
( 1.40 ) 1 101.325 ) 1.40
1
J
W=0.1736
mol
mol
Molar Flowrate=11.86
s
J mol
H ad=0.1736 x11.86
mol s
H ad=2.059W
Assume 80% efficiency compressor (from Plant Design and Economics for ChE)
Calculating the compressor power:
2.059
Power Requirement= W
0.80
Power Requirement=2.57W 0.003446hp

Since the power requirement has a small value, therefore, compressor is not needed.
124
PUMPS, COMPRESSORS
AND CONVEYORS
125
PUMPS, COMPRESSORS
AND CONVEYORS
OLEUM TANK TO ACID SCRUBBER

h
0.06
kg
s
Density 1920 kg
m3
Viscosity 0.048
kg
ms
q kg
0.06
mass flow rate s m3
f= = =3.13 x10 5
density kg s
1920 3
m
Table 5.4 (Towler & Sinnott, 2007)
Calculating the inside diameter of pipe with the assumed velocity of 1 m/s from preceding table:
5 m3
3.13 x 10
Volumetric F low rate s 5 2
Area= = =3.13 x 10 m
Velocity m
1
s
126
PUMPS, COMPRESSORS
AND CONVEYORS
Diameter=

=

4 x Area 4 x 3.13 x 105 m2
=0.006 m=0.24
For standard pipe sizing
Table 10-22: Properties of Steel Pipe (Perry & Green, 2008)
1
Nominal Pipe Size
4
Schedule number 40S
Inside Diameter 0.364 in 0.009 m
Outside Diameter 0.540 in 0.014 m
Solving for the fluid velocity:

2
d i (0.009 m)2 5 2
Area std = = =6.36 x 10 m
4 4
m3 5
3.13 x 10
q s m
Velocity= f = =0.492
A 6.36 x 10 m
5 2
sec
Dv
N =

127
PUMPS, COMPRESSORS
AND CONVEYORS
m kg
(0.009 m)(0.492 )(1920 3 )
sec m
N =
kg
0.048
msec
N =177
Since Reynolds number obtained is lower than 2,100 therefore the fluid flow is laminar (Geankoplis, 1995)
For friction in Laminar Flow:
64 64
f 1= = =0.36
N 177
F M=
( dL ) = ( 0.36) (0.492 )( 0.009
f v2
i
87.9 m
2
m)
=425.55
Nm
2g kgm kg
c
( Ns )
(2) 1 2
To calculate friction loss due to valves and fittings:
L
D
Globe Valve (1)(145)
Check Valve (1)(135)
90 Elbow (2)(30)
Total 340
128
PUMPS, COMPRESSORS
AND CONVEYORS
v

L
2 ( )
D
f
F L =
To calculate friction loss due to sudden contraction:
Kc = 0.5 (pipe entrance loss)

L
D
129
PUMPS, COMPRESSORS
AND CONVEYORS
v

Lc
2 ( )
D
f
F C =
To calculate friction loss due to sudden expansion:
Ke = 1.0 (pipe exit loss)

L
D
130
PUMPS, COMPRESSORS
AND CONVEYORS
v

Lc
2 ( )
D
f
F E=
131
PUMPS, COMPRESSORS
AND CONVEYORS
Friction Loss due to flow metering device: Orifice Meter
v =C
2 gc H
1
4
The throat diameter of orifice meter is generally 20% to 80% of the pipe diameter (Rules of Thumb of
=1.0 ( liquid )
D2 0.2 D
= = =0.2
D1 D
C=0.61
Solving for velocity,
2 6 2
Area= x ( 0.2 x 0.009 m) =2.54 x10 m
4
m35
3.13 x 10
Volumetric Flow rate s m
v= = =12.30
Area 6 2
2.54 x 10 m s
132
PUMPS, COMPRESSORS
AND CONVEYORS

kgm
2(1 2
) H
m N s
12.30 =0.61(1.0)
s 10.2
4
Nm
H=202.97
kg
Calculating the friction loss,
F I= y H
2 (For orifice)
y=1
Nm Nm
(
F I =( 10.22 ) 202.97
kg )
=194.85
kg
Using mercury as the fluid in the differential manometer, the differential head is
m g
H=H m ( )
gc
133
PUMPS, COMPRESSORS
AND CONVEYORS
N m
202.97
H kg
H m= = =2.92m
m g 13,593 kg 9.81 m
( )
gc m
3
x
s
2
kg kgm
1,920 3 1 2
m Ns
H m=114.96 inHg
Calculating the total Frictional Losses:
F=F M +F L +F C +F E +F I
Nm
F =(425.55+14.81+0.74+1.53+194.85)
kg
Nm
F =637.48
kg
To calculate kinetic energy:
m
v 1=0
s
m
v 2=0.492
s
134
PUMPS, COMPRESSORS
AND CONVEYORS
2
v v 1
KE= 2
2
=
2
( 0.4922 02 ) m2 ( ) s
=0.12
Nm
2 gc kg
2 (1)
( Kgm
Ns )
2
To calculate potential energy:
z 1=2.15 m
z 2=7.0m
m
( 7.02.15 ) (9.81 )
( z 2z 1 ) g s
2
N m
PE= = =47.58
gc Kgm kg
(1)
( N s 2 )
To calculate pressure head:
P ( 101,325101,325 ) Pa
= =0
kg
895 3
m
Substituting the values at the overall mechanical energy balance on pumping system with
=0.5for laminar flow ( Geankoplis ,1995 ) .
KE P
W s= + PE+ +F

135
PUMPS, COMPRESSORS
AND CONVEYORS
L
D
90 Elbow (1)(30)
Total 30
W s= ( 0.12
0.50
+47.58+0+637.48 )
Nm
kg
x 0.06
kg
s
W s =41.12 W
Since the work is positive, pump is required (Sinnot, 2005)
Suction Pressure = Upstream Pressure Pressure Losses + Static Pressure

Line Length in Pump Suction = 11 m
11 m
Line Loss
( 0.36 ) ( 0.4922) ( 0.009m ) x 1840 mkg =97.99 KPa
3
kgm 1000 Pa
(
( 2) 1
N s
2 ) 1 KPa
136
PUMPS, COMPRESSORS
AND CONVEYORS
kg
2
1840
( 0.36 ) ( 0.492 ) ( 30 ) m
3
Loss due to fitting x =4.81 KPa

kgm 1000 Pa
(
(2) 1
N s
2 ) 1 KPa
Pressure Losses = 97.99 KPa+4.81KPa+0.74=103.54 KPa
Upstream Pressure = 101.325KPa
kg m
(1920 3
x 9.81 2 x 0.45 m)
gh m s
Static Pressure = =8.48 KPa
gc kgm
1 2
N s
Suction Pressure = 101.325KPa103.54 KPa+8.48 KPa=6.27 KPa
Line from Pump Discharge
Line Length from Pump Discharge = 11 m
137
PUMPS, COMPRESSORS
AND CONVEYORS
11m
Line Loss
( 0.36 ) ( 0.4922) ( 0.009m ) x 1840 mkg =97.99 KPa
3
kgm 1000 Pa
(
(2) 1
N s 2 ) 1 KPa
L
D
90 Elbow (1)(30)
Total 30
kg
2
1840
( 0.36 ) ( 0.492 ) ( 30 ) m3
Loss due to fitting x =4.81 KPa
kgm 1000 Pa
(2) 1
( N s 2 ) 1 KPa
Dynamic Loss 97.99 KPa+4.81KPa+1.53KPa+194.85=299.18KPa
Equipment Operating Pressure = 101.325KPa
kg m
(1920 3
x 9.81 2 x 2.5 m)
gh m s
Static Pressure = =4 7.09 KPa
gc kgm
1
Ns 2
Discharge Pressure = 299.18 KPa+101.325 KPa+ 47.09 KPa
138
PUMPS, COMPRESSORS
AND CONVEYORS
Discharge Pressure = 447.60 KPa
Differential Pressure = Discharge Pressure Suction Pressure
Differential Pressure = 447.60 KPa6.27 KPa=441.33 KPa

NPSH Available
g
30% Oleum at 30 has a vapor pressure of 0.001 KPa (Cornerstone Chemicals Company, 2010
6.27 KPa0.001 KPa 1000 Pa kgm

x x1
NPSH Available kg m 1 KPa N s 2
1920 3 x 9.81 2
m s
NPSH Available 0.33 m
Differential Pressure 441.33 KPa 1000 Pa kgm

= x x1
Pump Head = g kg m 1 KPa Ns2
1920 3 x 9.81 2
m s
Pump Head = 23.43m
Shut off Pressure = 1.25x Differential Pressure=1.25 x441.33 KPa
139
PUMPS, COMPRESSORS
AND CONVEYORS
Shut off Pressure = 551.66 KPa
SELECTION OF PUMP
The head of the fluid is 5.76 m the capacity is,
kg
216.01 3
h m gal
Capacity= =0.11 =0.48
kg h min
1920 3
m
From Figure 10-24 (Perrys Chemical Engineers Handbook, Eight Edition, 2008), the pump to be used is
multi stage centrifugal pump.
The efficiency of centrifugal pump is 75% (Sinnot, 2005),
140
PUMPS, COMPRESSORS
AND CONVEYORS
41.12
Pump Actual Work = =54.83W =0.07 hP
0.75
ACID SCRUBBER TO WATER SCRUBBER

Mass flow rate 7.86 kg/hr
0.0022 kg/s
Density 3.0986 kg/m3
Viscosity 0.00002 kg/m-s
kg
0.0022 3
qf= = =7.1 10
density kg s
3.0986 3
m
velocity of liquid inside the pipe is in the range of 15 to 30 m/s.
Setting the fluid velocity to 15 m/s,
3
m 4
7.1 10
Area= = =4.73 10 m
Velocity m
15
s
141
PUMPS, COMPRESSORS
AND CONVEYORS
Diameter=

=

4 Area 4 4.73 105 m2

=7.76 103 m
Diameter=0.3056.
1 in. Nominal Pipe Size SCH No. 40 ST
Inside Diameter 0.307 in. 7.80x10-3 m
7.80 x 103 m

2

d i2
Area std = =
4
3
m 4
7.1 10
Velocity= = 5 2
=14.87
Area 4.78 10 m s
kg m
3.0986 14.87 7.80 x 103 m
vD m
3
s
N = = =17599.34
kg
0.00002
ms
2008)
142
PUMPS, COMPRESSORS
AND CONVEYORS
0.307
0.0018

]
0.9
( (
0.27 +
7
17599.34 )
1
2
=0.0092
4 log [ )

2
1
f=
( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=
4 f LG G P 1
2 2
P= + ln
2 D P2
For the mass velocity:
Mass Flow Rate

G=
Crosssectional areaof pipe
kg
0.0022
s kg
G= 5 2
=46.0251 2
4.78 10 m s m
143
PUMPS, COMPRESSORS
AND CONVEYORS
The pressure drop should not exceed 11 kPa per 100m length of pipe (Norsok Standard Process Design,
1997)
Calculating the pressure drop,
2 2
kg kg
4 0.0092 100 m 46.0251 2
46.0251 2
sm sm 101.325 kPa
P= + ln
kg kg 101.325 kPa
2 7.80 x 103 m 3.0986 3 3.0986 3
m m
P=161133.57 Pa=161.1336 kPa
Line to Compressor Suction
Line Length in pump suction = 2.3 m
4 f LG G P1
2 2
Line Loss= + ln
2 D P2
2 2
kg kg
4 0.0092 2.3 m 46.0251 2
46.0251 2
sm 1 kPa s m 101.325 kPa
Line Loss + ln
kg N kg 101.325 kPa
2 7.80 x 103 3.0986 3 1000 2 3.0986 3
m m m
144
PUMPS, COMPRESSORS
AND CONVEYORS
Line Loss=3.22kPa
2
m
(14.87 )
s kg 1 kPa
Entrance Loss 0.5 3.0986 3 =0.1713 kPa
kgm m N
2 1 1000 2
N s 2 m
Pressure Losses 3.22kPa+0.1713=3.3939kPa
Upstream Pressure = 101.325 kPa
z=( 7.51 ) m=6.5m
m kg
6.5 m 9.81 2
3.0986 3
s m 1 kPa
Static Pressure =0.1976 kPa
kgm N
1 1000 2
Ns 2 m
Suction Pressure (101.3253.3939+0.1976)kPa=98.1287 kPa
Suction Pressure=98.13 kPa
145
PUMPS, COMPRESSORS
AND CONVEYORS
Discharge Pressure = Dynamic Loss + Equipment Operating Pressure +Static Pressure
Quantity Le /D
o
90 elbows 2 35
3
Le 7.80 x 10 m ( 235 )=0.546 m
Line length from pump discharge = 0.546 m + 10.5 m = 11.05 m
Frictional Line Loss = Frictional Loss per meter Total linelength
2 2
kg kg
4 0.009211.05 m 46.0251 2
46.0251 2
s m 1 kPa s m 250 kPa
Frictional Line Loss= + ln
kg N kg 101.325 kPa
2 7.80 x 103 3.0986 3 1000 2 3.0986 3
m m m
Frictional Line Loss=24.04kPa
146
PUMPS, COMPRESSORS
AND CONVEYORS
Frictional Loss duemeter

Orifice Meter
2 4
v (1 )
Fm = (Wilkes)
2C
D2 0.2 D
= = =0.2
D1 D
2
m 4
(14.87 ) (10.2 )
s kg 1 kPa
Fm = 3.0986 3 =0.57 kPa
2 0.60 m 1000 N
m2
FrictionalLoss duesudden enlargement

2
v
Fe =
2 gc
147
PUMPS, COMPRESSORS
AND CONVEYORS
2
m
(14.87 )
s kg 1 kPa
Fe = 3.0986 3 =0.34 kPa
kgm m N
2 1 1000 2
N s2 m
Dynamic Loss (24.04 +0.57+0.34 )kPa=24.95 kPa
Equipment Operating Pressure = 101.325 kPa
kg m
3.0986 3
9.81 2 6.5 m
gh m s 1 kPa
Static Pressure = =0.20 kPa
gc kg m N
1 1000 2
N s2 m
Discharge Pressure 24.95kPa+101.325kPa+0.20 kPa
CALCULATION OF POWER REQUIREMENT OF COMPRESSOR
148
PUMPS, COMPRESSORS
AND CONVEYORS
The power is calculated using the formula as follows assuming the system is adiabatic:
W '=
RT
1 ( ) )
P2
P1
1
1
From ASPEN HYSYS Version 8.6,
=1.112
kJ
1.1128.314 320 K 1.112
W '=
kmol K
1.1121 (( 126.48 kPa
98.13 kPa ) 1.1121
)
1
1 kmol
103.84 kg
0.0022
kg
s
W '=6.95kW
The efficiency of compressor is 85% (Timmerhaus & Peters, 1991)
6.95 kW
W ' Actual = =8.18 kW =10.97 hP
0.85
SELECTION OF COMPRESSOR
The discharge pressure is 275.15 kPa or 25.22 psi.
The capacity of compressor is
kg
7.86 3 3
hr m ft
Capacity= =2.54 =1.50
kg hr hr
3.0986 3
m
149
PUMPS, COMPRESSORS
AND CONVEYORS
From Figure 10-64 (Perry & Green, 2008), the type of compressor to be used can be rotary sliding vane
compressor, rotary-screw, piston-liquid or reciprocating-single cylinder compressor (overlapping regions).
Based on the capacity of 1.50 cfm and discharge pressure of 25.22 psi, metallic diaphragm compressor will
be used.
ACID SCRUBBER TO VAPORIZER
kg
450.18
h
Mass flow rate
kg
0.12505
s
kg
Density 1806
m3
kg
Viscosity 0.003046
ms
kg
0.12505
mass flow rate s m3
qf = = =6.9241 105
density kg s
1806 3
m
150
PUMPS, COMPRESSORS
AND CONVEYORS
m3
6.9241105
Area= = =1.3848 104 m2
Velocity m
0.50
s

4
4 Area 4 1.3848 10
Diameter= = =0.013278 m

Diameter=0.52278.
The nominal pipe size to be used is 1 inch (Perry & Green, 2008).

Wall Thickness 0.109in. 0.0027686 m
0.0157988 m

2

2
di
Area std = =
4
3
m
6.9241 105
Velocity= = 4 2
=0.35320
Area 1.960370163 10 m s
151
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
1806 0.35320 0.0157988 m
vD m3
s
N = = =3,308.5115
kg
0.003046
m s
Since Reynolds number obtained is greater than 2,100 therefore the fluid flow is turbulent (Geankoplis, 1995).
[ ]
0.9
1 7
f
=4 log 0.27 +
di N ( )( )
[ ( ]
0.90
1 0.0000457 m 7
f
=4 log 0.27 +
0.0157988 m 3,308.5115 )( )
f =0.011531
FL 2 f v2
=
L gc d
2
m
FL
=
2 0.011531 0.35320 ( s kg
1806 3
1 kPa )
L kgm m 1,000 N
1 2
0.0157988 m 2
Ns m
FL kPa
=0.3289
L m
152
PUMPS, COMPRESSORS
AND CONVEYORS
The additional friction losses for laminar flows are given in the table below: page 6-18 (Perry & Green, 2008).
K fittings kf
90o elbows 0.75 1 0.75
Globe valve 9.5 1 9.5
Check valve 2 1 2
Total 12.25
2
2m
0.35320 2
s

12.25
k f v2
Ff= =
2 gc
FRICTION LOSSES DUE TO METERING DEVICE
The throat diameter of orifice meter is generally 20% to 80% of the pipe diameter (Rules of Thumb of Chemical
Engineers, 2012). Setting the throat diameter to 20% of pipe diameter,
D2 0.2 D
= = =0.2
D1 D
D 2=0.20 ( 0.0157988 ) =0.00316 m
2 6 2
A o = ( 0.00316 m ) =7.8427 10 m
4
m3 5
qf 6.9241 10 s m
vo = = 6 2
=8.829
A o 7.8427 10 m s
153
PUMPS, COMPRESSORS
AND CONVEYORS
kg m
1806 8.829 0.00316 m
vo do m 3
s
N = = =16,541.94
kg
0.003046
ms
N =16,541.94
v o =C v
2 gc H
1
4
Venturi meter is used

kgm
m
8.829 =0.98
( )
( 2) 1
N s2
H
4
s 1( 0.2 )
J
H=40.52
kg
For venturi y=0.10
Fm = y H
Nm
Fm =0.10 40.52
kg
N m
Fm =4.052
kg
L=57.93m
154
PUMPS, COMPRESSORS
AND CONVEYORS
2
2 m
0.35320
s2

2 0.011531 57.93 m
2 f Lv 2
F L= =
gc d i
Nm
F L =10.549
kg
A2 v 2
Fc =0.5 1
( )
A 1 2 gc
A2
0(negligible)
A1
2
( 0.35320 )2 m2
v s Nm
Fc =0.5 =0.5 =0.031188
2 gc kgm kg
2 1 2
N s
2
( v 1v 2 )
Fe =
2 gc
155
PUMPS, COMPRESSORS
AND CONVEYORS
2
(0.35320 )2 m2
s Nm
Fe = =0.062375
kgm kg
2 1 2
Ns
F=F L + F f +Fc +F e +F m
F=10.549+0.7641+0.031188+0.062375+4.052
N m
F=15.459
kg
m
v 2=0.35320
s
v 1=0
2
2 m
0.35320 2
s

2 2
v 2 v 1
KE= =
2 gc
156
PUMPS, COMPRESSORS
AND CONVEYORS
m
( 3 m4 m ) 9.81
( z 2z 1 ) g s
2
PE= =
gc kg m
1
N s2
N m
PE=9.81
kg
(Geankoplis, 1995):
KE P
W S= + PE+ + F

W S=( 0.061952
1
9.81+0+15.459)
N m
kg
J 0.12505 kg
W S =5.71
kg s
W S =0.714 W 0.000958 h p
respectively.
157
PUMPS, COMPRESSORS
AND CONVEYORS
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 1 0.75 40
12 m to pump
0.75 ( 40 mm )
1000 mm
m
kPa
Line Loss=0.3289 12.03 m=3.9567 kPa
m
Pressure Losses=3.9567 kPa
kg m
1806 3
x 9.81 2 x 4 m
gh m s
static Pressure= = =70867.44 Pa 70.867 kPa
gc kgm
1 2
Ns
( 101.3253.9567+70.867 ) kPa
Suction Pressure=168.2353kPa
158
PUMPS, COMPRESSORS
AND CONVEYORS
Equivalent Pipe
K fittings kf
Diameter, mm
90o elbows 0.75 1 0.75 40
( 0.75 ) ( 40 ) mm
1000 mm
( 1m )
kPa
Line Loss=0.3289 45.96 m=15.116 kPa
m
Dynamic Loss=15kPa+140kPa+15.116kPa=170.116kPa
kg m
1806 3
x 9.81 2 x 3 m
gh m s
Static Pressure= = =53150.58 Pa 53.151kPa
gc kgm
1
Ns 2
159
PUMPS, COMPRESSORS
AND CONVEYORS
Differential Pressure=156.36kPa
Vapor Pressure of solvent :0.00191743 kPa

NPSH available=
g
N
1000 2
( 168.23530.00191743 ) kPa m kgm
kg m kPa Ns
1806 3 x 9.81 2
m s
NPSH available=9.50 Pa
1000 Pa
156.36 kPa( )
( g) ( ) m kg
(
9.81 2 1806 3
s m )
Shutoff Pressure=1.25 x156.36kPa=191.7 kPa
160
PUMPS, COMPRESSORS
AND CONVEYORS
VAPORIZER TO DISTILLATION COLUMN
kg
450.18
h
Mass flow rate
kg
0.12505
s
kg
Density 0.7105
m3
kg
Viscosity 1.088x10-5
ms
kg
0.12505
mass flow rate s m3
qf = = =0.1760
densit y kg s
0.7105 3
m
3
m
0.1760
Area= = =0.352m
Velocity m
0.50
s
161
PUMPS, COMPRESSORS
AND CONVEYORS
Diameter=

4 Area 4 0.352
=

=0.6695 m
Diameter=26.5783.
The nominal pipe size to be used (Perry & Green, 2008).

30 in. Nominal Pipe Size ST
Outside Diameter 30 in. 0.762 m
Calculating the velocity:
0.74295 m

2

d i2
Area std = =
4
kg
0.12505
mass flowrate s kg
MassVelocity ,G= = =0.28845 2
Area 0.43352 m
2
m s
m3
0.1760
Velocity= = 2
=0.406
Area 0.43352 m s
162
PUMPS, COMPRESSORS
AND CONVEYORS
kg
0.74295 m 0.28845
DG m2 s
N = = =19,697.05
kg
5
1.088 10
m s
[ ]
0.9
1 7
f
=4 log 0.27 +
( )( )
di N
[ ( ]
0.90
1 0.0000457 m 7
f
=4 log 0.27
0.74295 m
+
19,697.05 )( )
f =0.00652
FL 2 f v2
=
L gc d
m 2
FL
=
2 0.00652 0.406( s ) kg
0.7105 3
1 kPa
L kg m m 1,000 N
1 2
0.74295 m 2
N s m
FL 6 kPa
=2.056 10
L m
FOR COMPRESSIBLE FLUID
2
2 24 zRTfL G
P1 P2 =
g c DMW
Length of pipe =10.8 m
163
PUMPS, COMPRESSORS
AND CONVEYORS
Molecular weight = 59 kg/kmol
3 2
2
101.325 P2 =
2
(
4 (1 ) 8.314
kPam
kmolK ) ( kg
( 579.65 K )( 0.006521 ) ( 10.8 m) 0.28845 2
m s )
kg m kg 1000 N
( 0.74295m ) (59 )
( N s )
1 2
kmol ( kPam )
3
P2=100.824 kPa
For the Suction Line
To get the friction loss due to fittings to Suction
From Chemical Engineering Design by Coulson et.al, page 204 kf values and equivalent pipe diameters are
as follows:
Number of Equivalent Pipe Diameter,

K Kf
fittings mm
90 elbow 0.75 2 1.5 40 (2)
Throttling valve 118 1 118 37
Needle valve 6 1 6 300
Total 125.5 417 mm
125.5 ( 417 mm )
Linelengthsuction due valvesfittings=10.8 m+ =63.13 m
1000 mm
m
From Equation 5.3, Coulson & Richardsons Chemical Engineering Design
4 f LG G P1
2 2
Line Loss= + ln
2 D P2
164
PUMPS, COMPRESSORS
AND CONVEYORS
2
kg
(0.28845 )
4(0.006521)(63.13 m)(0.28845)2 2
ms 101.325
Lineloss= + ln
kg kg 100.824
2(0.74295 m)(0.7105 3 ) 0.7105 3
m m
Line Loss=0.130 Pa
Pressure Losses=Line Loss
Pressure Losses=0.130Pa
kg m
0.7105 3
x 9.81 2 x 3 m
gh m s
Static Pressure= =
gc kgm
1
Ns 2
Static Pressure=20.91 Pa
Pressureof Upstream Equipment=101325Pa
( 1013250.130+20.91 ) Pa
Suction Pressure=101,345.78 Pa
Pipeline from discharge of compressor
165
PUMPS, COMPRESSORS
AND CONVEYORS
Linelengthdischarge compressor=5m
4 f LG 2 G 2 P1
Line Loss= + ln
2 D P2
2
kg
2 (0.28845 2 )
4(0.006521)(5 m)(0.28845) m s 101.325
+ ln
kg kg 100.824
2(0.74295 m)(0.7105 3 ) 0.7105 3
m m
5
Line Loss=0.01086 Pa 1.086 10 kPa
kg m
0.7105 3
x 9.81 2 x 1 m
gh m s
Static Pressure= = =6.97 Pa
gc kgm
1
Ns 2
5
Dynamic Loss=15kPa+140 kPa+1.086 10 kPa=155.0 kPa
Discharge Pressure=( 155103 +101325+6.97 ) Pa
Discharge Pressure=256,331.97 Pa
COMPRESSOR
166
PUMPS, COMPRESSORS
AND CONVEYORS
[( ) ]
1
RT P2
H ad= 1
1 P1
[( ]
1.401
(1.40)(8.314)(579.65) 100.824
W=
( 1.40 )1 101.325 ) 1.40
1
J
W=23.87
mol
mol
Molar Flowrate=13.0149
s
J mol
H ad=23.87 x 13.0149
mol s
H ad=310.67 W
Assume 80% efficiency compressor (from Plant Design and Economics for ChE)
Calculating the compressor power:
310.67
Power Requirement= W
0.80
Power Requirement=388.34 W 0.521 hp

Therefore, compressor is needed.
To limit heat loss insulation is to be given. Fiber glass is the recommended insulating material (Couper,
Penney, Fair, & Walas, 2012). The thermal conductivity of the fiberglass is 0.036 W/mK.
From energy balance:
167
PUMPS, COMPRESSORS
AND CONVEYORS
kJ 1000 J 1 hr
Q=270,796.02
hr 1 kJ 3600 s
Q=75,221.1167W
Di 0.74295
r i= = =0.3715 m
2 2
2 kL ( T 2T 1 )
Q=
r2
ln ()
r1
W
75,221.1167 W
=
(
2 0.036
mk )( 473140 )
10.8 m r2
ln(0.3715 m )
r2
ln ( 0.3715 m )
=0.010815
r 2=( 0.3715 ) ( e 0.010815 )
r 2=0.37554 m
insulationthickness=0.37554m0.3715m
insulationthickness=0.00404m 4.04mm
168
PUMPS, COMPRESSORS
AND CONVEYORS
DISTILLATION COLUMN TO HF CONDENSER

Mass flow rate 171.35
kg
h
0.0476
kg
s
169
PUMPS, COMPRESSORS
AND CONVEYORS
Density 0.5904 kg
m3
Viscosity 0.00002 kg
ms
kg
0.0476
mass flow rate s m3
qf = = =0.0806
density kg s
0.5904 3
m
velocity of liquid inside the pipe is in the range of 15 to 30 m/s.
Setting the fluid velocity to 15 m/s,
3
m
0.0806
Area= = =0.0054 m
Velocity m
15
s
Diameter=

=

4 Area 4 0.0054 m2
=0.0827 m
Diameter=3.26.
The nominal pipe size to be used is 3 inch (Perry & Green, 2008).
3 in. Nominal Pipe Size SCH No. 10S
170
PUMPS, COMPRESSORS
AND CONVEYORS
0.0828 m

2

d i2
Area std = =
4
m3
0.0806
Velocity= = 2
=14.97
Area 0.0054 m s
kg m
0.5904 14.97 0.0828 m
vD m
3
s
N = = =41948.85
kg
0.00002
ms
2008)
171
PUMPS, COMPRESSORS
AND CONVEYORS
3.26
0.0018

]
0.9
( (
0.27 +
7
41948.85 )
1
2
=0.0059
4 log [ )

2
1
f=
( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=
4 f LG 2 G 2 P 1
P= + ln
2 D P2
For the mass velocity:
Mass Flow Rate

G=
Crosssectional areaof pipe
kg
0.0476
s kg
G= 2
=8.84 2
0.0054 m s m
The pressure drop should not exceed 11 kPa per 100m length of pipe (Norsok Standard Process Design,
1997)
Calculating the pressure drop,
172
PUMPS, COMPRESSORS
AND CONVEYORS
kg
8.84 2
sm

2

2
kg
4 0.0059 100 m (8.84 )
s m2
P= +
kg
2 0.0828 m 0.5904 3
m
P=1877.67 Pa=1.8777kPa
Line to Compressor Suction
Quantity Le /D
o
90 elbows 1 35
Line Length in pump suction = 4.07 m + (35)(0.0828m)= 6.97 m
kg
8.84
s m2

2
Line Loss
kg 2
4 0.0059 6.97 m(8.84 )
s m2
+
kg
2 0.0828 m 0.5904 3
m
173
PUMPS, COMPRESSORS
AND CONVEYORS
Line Loss=0.1308 kPa

2
m
(14.97 )
s kg 1 kPa
Entrance Loss 0.5 0.5904 3 =0.03 kPa
kgm m N
2 1 1000 2
N s 2 m
Pressure Losses ( 0.1308+0.03 ) kPa=0.16 kPa
Upstream Pressure = 101.325 kPa
z=( 0.632 ) m=1.37 m
m kg
1.37 m 9.81 2
0.5904 3
s m 1 kPa
Static Pressure =0.0079 kP
kgm N
1 1000 2
Ns 2 m
Suction Pressure ( 101.3250.160.1976 ) kPa Suction Pressure=101.15kPa
Discharge Pressure = Dynamic Loss + Equipment Operating Pressure +Static Pressure
Quantity Le /D
Diaphragm Valve 1 392
Le 0.0828 m ( 1392 )=32.46m
174
PUMPS, COMPRESSORS
AND CONVEYORS
Line length from pump discharge = 4.5 m + 32.46 m = 36.92 m
Frictional Line Loss = Frictional Loss per meter Total linelength
kg
8.84 2
sm

2

kg 2
4 0.0059 36.92m ( 8.84 )
s m2
Frictional Line Loss= +
kg
2 0.0828 m 0.5904 3
m
Frictional Line Loss=0.71kPa
Frictional Loss duemeter

Orifice Meter
2 4
v (1 )
Fm = (Wilkes)
2C
D2 0.2 D
= = =0.2
D1 D
175
PUMPS, COMPRESSORS
AND CONVEYORS

2
m 4
(14.97 ) (10.2 )
s kg 1kPa
Fm = 0.5904 3 =0.11kPa
2 0.60 m 1000 N
m2
FrictionalLoss duesudden enlargement

2
v
Fe =
2 gc
2
m
(14.97 )
s kg 1 kPa
Fe = 0.5904 3 =0.07 kPa
kgm m N
2 1 1000 2
N s2 m
Dynamic Loss (0.71+0.11+0.07)kPa=0.89 kPa
Equipment Operating Pressure = 101.325 kPa
z=0
Static Pressure 0
Discharge Pressure 0.89kPa+101.325 kPa+0kPa
176
PUMPS, COMPRESSORS
AND CONVEYORS
CALCULATION OF POWER REQUIREMENT OF COMPRESSOR
The power is calculated using the formula as follows assuming the system is adiabatic:
W '=
RT
1 (( ) )
P2
P1
1
1
From ASPEN HYSYS Version 8.6,
=1.398
kJ
1.398 8.314 413.15 K 1.398
W= ' kmol K
1.3981 ((
102.22 kPa
101.15 kPa ) 1.3981
)
1
1 kmol
20 kg
0.0476
kg
s
W '=1.08kW
The efficiency of compressor is 85% (Timmerhaus & Peters, 1991)
1.08 kW
W ' Actual = =1.27 kW =1.70 hP
0.85
SELECTION OF COMPRESSOR
The discharge pressure is 250.89 kPa or 21.70 psi.
The capacity of compressor is
177
PUMPS, COMPRESSORS
AND CONVEYORS
kg
171.35
hr m3 ft 3
Capacity= =290.22 =170.83
kg hr hr
0.5904 3
m
From Figure 10-64 (Perry & Green, 2008), the type of compressor to be used can be rotary sliding vane
compressor, rotary-screw, piston-liquid or reciprocating-single cylinder compressor (overlapping regions).
Based on the capacity of 170.83 cfm and discharge pressure of 21.70 psi, Reciprocating single cylinder will
be used.
178

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PUMPS, COMPRESSORS

Type: Screw Conveyor

Type of Material Metallurgical-Grade Flourspar

Volumetric flowrate of fluorspar:

From CEMC, the material code of fluorspar is 100 D36

Determining capacity, conveyor size and speed

Note: A standard pitch screw conveyor will be used.

L=total lengthof conveyor ,ft

N=operating speed ,rpm

Fd =conveyor diameter HP factor

Fb =hanger bearing HP factor

( 55.77 ) ( 5.119 ) ( 18 ) ( 4.4 )

L=total lengthof conveyor ,ft

( 10.428 )( 55.77 )( 1794 )( 2.0 ) ( 1.0 ) (1.29 )

e=Drive efficiency ( expressed asdecimal )

If ( H P f +H Pm ) is 5.2 then Fo =ln ( H Pf +H Pm ) x (0.6115 )+2.024

Fo =ln ( 2.7126 ) x (0.6115 )+2.024=1.414

Type: Screw Conveyor

Volumetric flowrate of fluorspar:

From CEMC, the material code of fluorspar is 90B 36

Material Factor ( F M =2.0

Single Cut-Flight, Standard Pitch

Maximum recommended speed = 54.4 rpm

Equivalent Capacity 337.12

Calculation of Motor Horse power

L=total lengthof conveyor ,ft

N=operating speed ,rpm

Fd =conveyor diameter HP factor

Fb =hanger bearing HP factor

For a screw diameter of 9.36 inches:

Take Stellite as the bearing type.

Hanger bearing HP factor: Fb =4.4

L=total lengthof conveyor ,ft

Density of fluorspar as conveyed = 198.52 lb/ft^3

CLD Fm F f F p ( 6.56 x 23.95 x 198.52 x 2 x 1.15 x 1.29 )

e=Drive efficiency ( expressed asdecimal )

If ( H P f +H Pm ) is 5.2 then Fo =ln ( H Pf +H Pm ) x (0.6115 )+2.024

Fo =ln ( 0.27 ) x (0.6115 )+2.024=2.82

CLASSIFIER TO FLOTATION CELLS

Solving for the volumetric flow rate:

Calculating the fluid velocity:

To solve for Reynolds number:

FRICTION LOSS DUE TO PIPE LINE

FRICTION LOSS DUE TO SUDDEN CONTRACTION (Entrance Loss)

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT (Exit Loss)

Calculating the total frictional losses:

CALCULATION OF POTENTIAL ENERGY

OVERALL MECHANICAL ENERGY BALANCES

Type: Screw Conveyor

Volumetric flowrate of fluorspar:

From CEMC, the material code of fluorspar is 100 D36

Material Factor ( F M =2.0

Single Cut-Flight, Standard Pitch

For a Cut flight standard pitch with conveyor loading of 30%

For a capacity of 1.88

Maximum recommended speed = 60 rpm

Equivalent Capacity 1.88

Calculation of Motor Horse power

L=total lengthof conveyor ,ft

Fd =conveyor diameter HP factor

Fb =hanger bearing HP factor

For a screw diameter of 9.36 inches:

Take Stellite as the bearing type.