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Murphy's law
To estimate the time it takes to do a task, estimate the time you think
it should take, multiply by two, and change the unit of measure to the
next higher unit. Thus allocate 2 days to do a one-hour task.
Corollary:
1
Separation Tower Design
Distillation:
Absorption:
Extraction:
Adsorption:
Sizing Problem
# of stages
Type of column
Height, Diameter, Cost
Shell Thickness & weight
Utility requirements, Operating Cost
2
Types of Equipment
liquid vapor
vapor
liquid
6
5
4
3
2
1
3
Packed versus Plate Tower
Packed Tower
Diameter < 4 ft
Cannot handle dispersed solids in feed
No interstage cooling
Limited operating range
not suitable for large temperature variations
cheaper to construct
design database is poor
cheaper if corrosive fluids are involved
pressure drop is smaller (good in vacuum operation)
4
McCabe Thiele Diagrams
q=1
x
x xf
xd
L L x yF R x
Eqm line y
D 1 1 x
V D L y D xF R 1
xD yF
Rmin
yD xF
L R
V achial 1 R
5
Preliminary Design of Columns
[Assume 99%]
6
3. No. of stages (Fenske-Underwood-Gilliland Method)
Used in DSTWU
3. Penske equation
x x
log LK HK
x HK D x LK B
N min
log LK HK
4. Underwood Equation
i x Fi
1 q : solve for
i i
L i x Di
1 Compute minimum reflux ratio
D min i i
5. Gilliland Correlation
Tray Spacing = 24
Smaller for tall columns
Height = 24 x # of trays
7
5. Column Diameter
e v vapor density lb ft 3
L D
L+D L
F
(L+F)
L+D
F-D
6. Utility Requirements
8
Auxiliary Equipment Needed for column
reflux
5
4 coolant in
feed
condenser
1 reflux drum
reboiler
reflux pump
distillate
reboiler pump
bottoms
condensate
9
Absorbers & Strippers
Pure Gas
GGa Pure solvent, L lbmoles/hr
y0 x0
y = mx
G lbmoles/hr
Gas + Solute
Solvent + solute
yin xout
L
1.4 typical
mG
Kremser Equation
10
Packed Tower Design
11
Heat exchanger sizing
Problem:
Given: Flow rate and inlet and outlet temperature of the stream to be
heated or cooled
References:
12
Types of Heat Exchangers
13
Selection of Tubeside fluid
Corrosive fluids
Fluid with greater fouling tendency
Fluid at higher pressure
Less viscous fluid
14
Heat Exchanger Geometry
15
Utility Selection
16
Heating Medium
17
Short cut methods for HX design
18
Pipe Design
Factors:
Diameter of pipe
Wall thickness
Pipe diameter
v 22 v12
w z 2 z1 P2V2 P1V1 F
2 gc
19
Pipe Wall Thickness
Ps
Schedule # 1000
Ss
t
2000 m
Dm
20
Pumps: Pressure change in liquids
THP
Brake Horse Power = Efficiency
1. Centrifugal Pumps
15-5000 gpm
2. Axial Pumps
20-100,000 gpm
40 ft head
eg. Bike pumps
3. Rotary Pumps
1,500 gpm
50,000 ft head
4. Reciprocating Pump
10-10,000 gpm
1,000,000 ft head
21
Pressure change in gases
Fans
Blowers
Compressors
22
Pressure Vessels
PR
t C
SE GP
Flash Drums: H D 23
5 min holdup time (liquid)
Diameter based on gas velocity
23
Chemical Reactors
Specify
i) Volume of reactor
ii) geometry
iii) heat transfer
iv) agitation
v) material of construction
24
1. Homogenous Gas Phase
3. Hetero liquid/gas
- stirred vessels with baffles/agitation
- use gas velocity
0.2 ft/sec if gas is mostly absorbed
0.1 ft/sec if gas is 50% absorbed
0.05 ft/sec if gas is mostly not absorbed
4. Liquid/Solid
- well-stirred CSTR
- slurry reactors
5. Solid/gas
- packed types (solid not consumed)
- fluidized bed
- spouted bed
25
Materials of Construction
Stainless Steel
Type 302, 304, 316 common
Corrosion resistance
High temperature strength
Teflon:
Low temperature
26
Cost Factors
Relative
Material Cost Comments
27