Handbook Chemical rocessing Equipment Nicholas P. Cheremisinoff Handbook of Chemical Processing Equipment Nicholas P. Cheremisinoff, Ph.D. Boston Oxford Auckland Johannesburg Melbourne New Delhi Copyright 0 2000 by Butterworth-Heinemann A member of the Reed Elsevier group All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. @ Recognizing the importance of preserving what has been written, Butterworth-Heinemann prints its books on acid-free paper whenever possible. G.,, '"& ~20~1 Butterworth-Heinemann supports the efforts of American Forests and the Global ReLeaf program in its campaign for the betterment of trees, forests, and our environment. Library of Congress Cataloging-in-Publication Data Cheremisinoff, Nicholas P. Handbook of chemical processing equipment / Nicholas Cheremisinoff. Includes bibliographical references and index. ISBN 0-7506-7126-2 (alk. paper) 1. Chemical plants Equipment and supplies. I. Title. p. cm. TP155.5 .C52 2000 660'.283 d~21 00-037955 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. The publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Butterworth-Heinemann 225 Wildwood Avenue Woburn, MA 01801-2041 Tel: 781-904-2500 Fax: 78 1-904-2620 For information on all Butterworth-Heinemann publications available, contact our World Wide Web home page at: http://www.newnespress.com 109 87 65 43 2 1 Printed in the United States of America CONTENTS Preface About the Author Chapter 1. Heat Exchange Equipment Introduction, 1 General Concepts of Heat Transfer, 4 Air Cooled Heat Exchangers, 12 Shell and Tube Type Heat Exchangers, 24 Spiral-Plate Heat Exchangers, 36 Plate-and-Frame Exchangers, 41 Heat Exchanger Tube Rupture, 45 Condensers, 52 Steam-Driven Absorption Cooling, 60 Closure, 61 Nomenclature, 6 1 Suggested Readings, 62 Chapter 2. Evaporative Cooling Equipment Introduction, 65 Thermal Characteristics, 65 Design Configurations, 70 Components and Materials of Construction, 76 Use of Fans, Motors, and Drives, 80 Water Treatment Services, 86 Glossary ofTerms, 89 Suggested Readings, 93 Chapter 3. Evaporating and Drying Equipment Introduction, 94 Evaporators, 94 Drying Equipment, 124 Crystallization, 154 Suggested Readings, 161 Chapter 4. Distillation Equipment Introduction, 162 Overview of Distillation, 163 General Properties of Hydrocarbons, 18 1 Refinery Operations, 202 Products from Petroleum, 222 vii ix 1. 65 94 162 iii iv CONTENTS Spirits Production, 239 Closure and Recommended Web Sites, 241 Chapter 5. Mass Separation Equipment Introduction, 244 Absorption Equipment, 245 Adsorption Equipment, 276 Solvent Extraction, 320 Reverse Osmosis, 326 Suggested Readings, 330 Chapter 6. Mechanical Separation Equipment Introduction, 334 Filtration Equipment, 335 Sedimentation Equipment, 398 Centrifugal Separation Equipment, 416 Suggested Readings, 434 Chapter 7. Mixing Equipment Introduction, 435 Mechanical Mixing Equipment, 436 Design Practices, 453 Gas-Solids Contacting, 476 Suggested Readings, 487 Recommended Web Sites, 488 Chapter 8. Calculations for Select Operations Introduction, 489 Heat Capacity Ratios for Real Gases, 489 Sizing of Vapor-Liquid Separators, 489 Overall Efficiency of a Combination Boiler, 490 Pump Horsepower Calculations, 490 Pump Efficiency Calculations, 491 Lime Kiln Precoat Filter Estimation, 49 1 Steam Savings in Multiple Effect Evaporators, 493 Temperature and Latent Heat Estimation for Saturated Steam, 494 Estimating Condensate for Flash Tanks, 494 Linear Velocity of Air Through Ducts, 496 Thermal Conductivities of Gases, 496 Determining Pseudocritical Properties, 500 Estimating Heat Exchanger Temperatures, 501 Estimating the Viscosity of Gases, 503 Estimate for Mechanical Desuperheaters, 506 Estimating Pump Head with Negative Suction Pressure, 507 Calculations for Back-Pressure Turbines, 508 Tubeside Fouling Rates in Heat Exchangers, 5 10 Calculations for Pipe Flows, 5 11 244 334 435 489 CONTENTS V Recovery in Multicomponent Distillation, 5 17 Estimating Equilibrium Curves, 5 18 Estimating Evaporation Losses from Liquified Gases, 5 18 Combustion Air Calculations, 5 18 Estimating Temperature Profiles in Agitated Tanks, 5 19 Generalized Equations for Compressors, 520 Batch Distillation: Application of the Rayleigh Equation, 524 Index 527 PREFACE The chemical industry represents a 455-billion-dollar-a-year business, with products ranging from cosmetics, to fuel products, to plastics, to pharmaceuticals, health care products, food additives, and many others. It is diverse and dynamic, with market sectors rapidly expanding, and in turmoil in many parts of the world. Across these varied industry sectors, basic unit operations and equipment are applied on a daily basis, and indeed although there have been major technological innovations to processes, many pieces of equipment are based upon a foundation of engineering principles developed more than 50 years ago. The Handbook of Chemical Processing Equipment has been written as a basic reference for process engineers. It provides practical information on the working principles and engineering basis for major equipment commonly used throughout the chemical processing and allied industries. Although written largely with the chemical engineer in mind, the book's contents are general enough, with sufficient background and principles described, that other manufacturing and process engineers will find it useful. The handbook is organized into eight chapters. Chapters 1 through 3 deal with heat transfer equipment used in a variety of industry applications ranging from process heat exchange, to evaporative cooling, to drying and solvent recovery applications, humidity control, crystallization, and others. Chapters 4 and 5 cover stagewise mass transfer equipment. Specifically, Chapter 4 covers distillation, and Chapter 5 covers classical mass transfer equipment involving absorption, adsorption, extraction, and membrane technologies. Chapter 6 discusses equipment used in mass separation based upon physical or mechanical means. This includes such equipment topics as sedimentation, centrifugal separation, filtrations methods. Chapter 7 covers mixing equipment and various continuous contacting devices such as gas-solids fluidized beds. Finally, Chapter 8 provides the reader with a compendium of short calculation methods for commonly encountered process operations. The calculation methods are readily set up on a personal computer's standard software spreadsheet. Select references are provided in each chapter for more in-depth coverage of an equipment subject, including key Web sites that offer vendor-specific information and equipment selection criteria. In a number of chapters, sample calculations are provided to guide the reader through the use of design and scale-up formulas that are useful in preparing equipment specifications or in establishing preliminary designs. Although the author has taken great care to ensure that the information presented in this volume is accurate, neither he nor the publisher will endorse or guarantee any designs based upon materials provided herein. The author wishes to thank Butterworth-Heinemann Publishers for their fine production of this volume. Nicholas P. Cherernisinofi Ph. D. vii [...]... for the design, applications, and operations of a major class of equipment that are used throughout the chemical process industries - heat exchange equipment, or heat exchangers There are many variations of these equipment and a multitude of 4 HANDBOOK OF CHEMICAL PROCESSING EQUIPMENT applications However, the design configurations for these equipment are universal, meaning that they generally are not... of heat required to raise the temperature of 1 pound of water 1 F and is equal to 252 calories 6 HANDBOOK OF CHEMICAL PROCESSING EQUIPMENT The term latent heat is also pertinent to our discussions The process of changing from solid to gas is referred to as sublimation; from solid to liquid, as melting; and from liquid to vapor, as vaporization The amount of heat required to produce such a change of. .. with the heated air, coming off the heat exchanger This situation gives a power advantage for the forced draft design The total pressure of the fan is the sum of the static pressure loss of the air flowing across the tube bundle, plus the velocity pressure of the air, moving 18 HANDBOOK OF CHEMICAL PROCESSING EQUIF'MENT through the fan Static pressure losses are of the order of 0.5 cm to 3 cm water gauge,... season of 4.8 "C to heat inside air at a mean temperature of 17.3 " C For each increase of the delta temperature of one of the heat exchangers by 1 "C, we need an extra F, /(17.3-4.8)/ 8 amount of electric power when the COP of a heat pump is 8 When we use the heat transfer and pressure drop equations in these functions for a heat exchanger of F, = lkW, the sum of the energy losses is: HEAT EXCHANGE EQUIPMENT. .. phase, but can contain any number of liquid and solid phases An alloy of copper and nickel, for example, contains two solid phases The rule makes possible the simple correlation of very large quantities of physical data and limited prediction of the behavior of chemical systems It is used particularly in alloy preparation, in chemical engineering, and in geology The subject of heat transfer refers to the... Eliminates high cost of water including expense of treating water Thermal or chemical pollution of water resources is avoided Installation is simplified due to elimination of coolant water piping Location of the air cooled heat exchangers is independent of water supply location Maintenance may be reduced due to elimination of water fouling characteristics which could require frequent cleaning of water cooled... with process fluids, cleanliness of the streams, and temperature approach This chapter provides an overview of the most commonly employed equipment Emphasis is given to practical features of these systems, and typical examples of industrial applications are discussed GENERAL CONCEPTS OF HEAT TRANSFER Before discussing typical equipment commonly used throughout the chemical processing industries, some general... cyclic machine can convert heat energy wholly into other forms of energy It is not possible to construct a cyclic machine that does nothing, but withdraw heat energy and convert it into mechanical energy The second law of thermodynamics implies the irreversibility 1 2 HANDBOOK OF CHEMICAL PROCESSING EQUIPMENT of certain processes - that of converting all heat into mechanical energy, although it is possible... billiard balls and bouncing off the surface of the container holding the gas The energy, associated with motion, is called Kinetic Energy and this kinetic approach to the behavior of ideal gases led to an interpretation of the concept of temperature on a microscopic scale The amount of kinetic energy each molecule has is a function of its velocity; for the large number of molecules in a gas (even at... freezing of the tube side fluid or formation of ice on the outside surface The movement of large volumes of coolmg air is accomplished by the rotation of large diameter fan blades rotating at high speeds As a result, noise due to air turbulence and high fan tip speed is generated 14 HANDBOOK OF CHEMICAL PROCESSING EQUIPMENT This bond may be mechanical or metallurgical in nature Metallurgical bonds are . Handbook Chemical rocessing Equipment Nicholas P. Cheremisinoff Handbook of Chemical Processing Equipment Nicholas P. Cheremisinoff, Ph.D. Boston Oxford. the chemical process industries - heat exchange equipment, or heat exchangers. There are many variations of these equipment and a multitude of 4 HANDBOOK OF CHEMICAL PROCESSING EQUIPMENT. processes, many pieces of equipment are based upon a foundation of engineering principles developed more than 50 years ago. The Handbook of Chemical Processing Equipment has been written