Fluids/Solids Handling

OPTIMIZE PIPELINE DESIGN

FOR

NON-NEWTONIAN FLUIDS
Alejandro Anaya Durand, Cinthya Alejandra Aguilar Guerrero and Edgar Amaro Ronces, National Autonomous University of Mexico

Here is a graphical method for determining pipe diameter, fluid temperature and pressure drop for laminar and turbulent flow.

ngineers often encounter non-Newtonian uids as suspensions, viscous uids or polymer solutions, among others. Little information exists on how to optimize the design variables when handling these uids. This article offers a graphical procedure, given a set owrate, for determining the most economical diameter of a pipeline Dopt, as well as its optimum temperature topt; included is a method for calculating the pressure drop P. This procedure is based on the effect a given design variable has on costs. Therefore, an optimum value can be established for this variable at which the total costs will be at a minimum. For Newtonian fluids, the shear stress w is directly proportional to the shear rate. The proportionality constant is simply the Newtonian viscosity. For non-Newtonian fluids, the shear stress is proportional to the shear rate raised to a power n called the flow behavior index, and its value depends upon whether a fluid is pseudoplastic, Bingham plastic (for both n < 1) or dilatant (n >1). K is no longer the viscosity, and now is called the fluid consistency index. For non-Newtonian behavior, we can relate the Fanning friction factor f to the Reynolds number NRe by (1):

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Nomenclature
f = an/NRebn (1)
a an A, B b bn Ce Cp Cs CT D Dopt E FDi Fr FTi gc h K L n NRe p = = = = = = = = = = = = = = = = = = = = = = annual xed costs as a fraction of installed costs function of n (turbulent regime) empirical constants in Eq. 12 annual maintenance costs as a fraction of total installed costs function of n (turbulent regime) cost of electrical energy, $/kWh specic heat, Btu/lbmF heating (steam) cost, $/million Btu total annual cost/ft of pipe or total annual cost over whole pipe length, $ pipe dia., ft optimum pipe dia., ft efficiency of pump and motor correction factors to Dopt, dimensionless (i = 16; see Figures 24, 68) ratio of total costs for ttings and erection to total purchase cost of pipe correction factors to topt, dimensionless (i = 17; see Figures 1015, 17) gravitational constant, 32.174 lbm-ft/lbfs2 hours of operation/year consistency index, lbf-sn/ft2 pipe length, ft ow behavior index, dimensionless Reynolds number, dimensionless constant for each pipe material = slope of logarithmic plot of purchase cost of pipe/ft vs. 12D pressure drop, psi pressure drop per 100 ft, psi/ft volumetric owrate, ft3/s volumetric owrate at the end of laminar ow region, ft3/s specic gravity, dimensionless optimum pumping temperature, F uid temperature, F average linear ow velocity, ft/s cost of pipe/ft when 12D = 1 in., $/ft

where an and bn are dimensionless numbers that are functions of n. By knowing n, K, an and bn, a non-Newtonian can be characterized.

Optimization scheme The costs of a process can be classified in two types: capital and operating costs, f1(x) and f2(x), respectively, both a function of a design variable x. The total costs CT are the sum of both:
CT = f1(x) + f2(x) (2)

To obtain the minimum value of x, the rst derivative of Eq. 1 is set = 0; and to ensure that the optimized variable is a minimum, the second derivative must be positive.
dC T d f1(x) d f2(x) = + =0 dx dx dx

(3)

The fluid properties are set for each application, and we will show that x is a function of the flowrate Q, i.e., x = f(Q). Q is set by the particular process application. We will show that this will allow us to solve for Dopt and topt. The graphical method is based on the relationship x = f(Q). Plots are made with several values vs. Q using reference values for rheological parameters; this allows for specifying the rest of the variables. Correction factors are then applied to account for uids with properties that differ from the reference values used; these factors are also found from a series of plots.

P = P100 = Q = Qc = Sg = topt = T = V = Xp =

Optimum pipe diameter The capital costs are assumed to be only those of the piping, and the operating costs are assumed to be the energy of pumping and, if needed, of heating the uid. Obviously, larger-diameter pipes require higher investments, but

Greek letters = gcK8(n 1) = viscosity, lbm/fts e = effective viscosity, lbm/fts = density, lbm/ft3 w = shear stress, lbf/in.2

D opt =

4.184 10 10 1 + 3n C ehK p a + b Fr + 1 X p 12
p

Q 4.05 10 5

1 p + 1 + 3n

(4)

1 p + 5 + b n(3n 4)

2 1.0463 10 10 5 4b n + 3b nn g cK 8 D opt = g c p a + b Fr + 1 X p 12
p

n 1

bn

a nC eQh

bn 1

Q 3.24 10 6

2 b n(2 n)

(5)

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Fluids/Solids Handling

10.0 Optimum Dia., in. Optimum Dia., in.

10.0

1.0

Pseudoplastic Dilatant Bingham Plastic Newtonian

1.0

Pseudoplastic Dilatant Bingham Plastic Newtonian

0.1 1 10 100 1,000 Volumetric Flowrate, gpm

0.1 1 10 100 1,000 Volumetric Flowrate, gpm

s Figure 1. Laminar ow optimum pipe diameter.

s Figure 2. Turbulent ow optimum diameter.

Correction Factor for Specific Gravity, FD1

1.5 1.3 1.1 0.9 0.7 0.3

Correction Factor for K', FD2

1.7

2.0

1.5

1.0

0.5

0.5

0.7

0.9

1.1

1.3

1.5

1.7

1.9 2.1

0.0 10-5

10-4

10-3

10-2

10-1

Specific Gravity

K', lbf-sn'/ft2

s Figure 3. Laminar ow FD1, correction factor for specic gravity Sg.

s Figure 4. Laminar ow FD2, correction factor for consistency index K. require less power to pump, so optimizing will determine the pipe diameter that is the minimum of the xed and variable costs. Thus, f1 represents the cost per feet of pipeline for a given diameter, and f2 the energy needed for a section of pipeline. CT takes two forms depending on the ow regime; therefore there are separate equations for the optimum diameter, Eq. 4 for laminar ow and Eq. 5 for turbulent ow (2) (see the box on the previous page). Plotting Dopt vs. Q, and keeping the rest of the variables at the reference values generates Figure 1 for laminar flow and Figure 2 for turbulent flow. Each curve represents the most typical non-Newtonian time-independent fluids with typical rheological properties (K, n, an and bn). The reference

Table. Reference values used to construct the figures. Variable Ce Xp p' a Variable Reference Value 62.37 lb/ft3 0.076 /kWh $6/ft 1.35 0.15 Pseudoplastic 0.85 0.05 0.077 0.258 Dilatant 1.5 0.05 0.081 0.228 Variable Reference Value 0.05 1.1 0.7 7,920 h/yr Bingham 0.67 0.05 0.07 0.27 Newtonian 1 0.05 0.078 0.25

b Fr E h

n' K an bn

Note: an and bn are necessary in turbulent flow.

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Correction Factor for (a + b), FD3

1.3 1.2 1.1 1.0 0.9 0.8 0.05 Correction Factor for K', FD5 0.15 0.25 (a + b) 0.35 0.45 1.1

0.9

0.7 10-5

10-4

10-3

10-2

10-1

K', lbf-sn'/ft2

s Figure 5. Laminar ow FD3, correction factor for (a + b).

s Figure 7. Turbulent ow FD5, correction factor for consistency

index K.
Correction Factor for (a + b), FD6

1.3 1.2 1.1 1.0 0.9 0.8 0.05

1.5 Correction Factor for Specific Gravity, FD4 1.3 1.1 0.9 0.7 0.25

0.55

0.85

1.15

1.45

1.75

2.05

0.15

0.25 (a + b)

0.35

0.45

Specific Gravity

s Figure 6. Turbulent ow FD4, correction factor for specic gravity Sg. values used to draw up those graphs are presented in the table below. Correction factors, FDi, are used to account for properties that differ from those used as reference values. In such cases, the optimum diameter can be found by applying the factors in Figures 35 for laminar flow and Figures 68 for turbulent flow. Thus, the optimum diameter Dopt is found by correcting the optimum reference diameter by multiplying by the appropriate factors:
D opt = D opt, ref

s Figure 8. Turbulent ow FD6, correction factor for (a + b). pipe such that the total annual cost of transporting the fluid is a minimum. Note: 1 yr = 7,920 h. Operating data: Specific heat = 1 Btu/ lbF; density = 61 lb/ft3; overall efficiency of pump and motor = 70%; n = 0.85; and K = 0.07 lbf-sn/ft2. Cost data: Steam heating Cs = $1/million Btu; electrical energy Ce = $0.076/kWh; purchase cost of new steel pipe per foot of pipe length Xp when 12D = 1 in. is $6/ft; p(a constant for each pipe material) is assumed to be 1.35 for new carbon steel pipe and 12Dopt = 1 in. p is the slope of a logarithmic plot of purchase cost of pipe/ft vs. 12D (2). The average annual interest rate a = 9% of installed costs and annual maintenance charges b = 1% of installed costs (thus, a + b = 0.09 + 0.01 = 0.1); the ratio of total cost for ttings, insulation and installation to the total purchase cost of new pipe Fr = 1.1 (this is a typical value used in many cost-estimation texts); the anticipated useful life = 10 yr. Straightline depreciation is assumed.

F
n i=1

Di

(6)

Example I A pseudoplastic fluid in a storage vessel will be transported at a flowrate of 50,000 lb/h to a production process 500 ft away. Determine the optimum diameter of the

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Optimum Pumping Temperature, F

220 200 180 160 140 120 100 80 60 40 1

Correction Factor for B, FT3

Pseudoplastic Dilatant Bingham Plastic Newtonian

2.0

1.0

10

100

1,000

0.0 0.015

0.035

0.055

0.075

0.095

Volumetric Flowrate, gpm

B,1/F

s Figure 9. Optimum pumping temperature topt.

s Figure 12. Optimum pumping temperature FT3, correction factor for B.

Correction Factor for Cp, FT1

1.2 1.0 0.8 0.6 0.4 0 0.5 1 1.5 2 Specific Heat, Btu/Flbm
Pseudoplastic Dilatant Bingham Plastic Newtonian

1.2 Correction Factor for SpecificGravity, FT4 1.0 0.8 0.6 0.4 0.1
Pseudoplastic Dilatant Bingham Plastic Newtonian

0.6

1.1 Specific Gravity

1.6

s Figure 10. Optimum pumping temperature FT1, correction factor for

specic heat Cp.

s Figure 13. Optimum pumping temperature FT4, correction factor for specic gravity Sg.

Correction Factor for A, FT2

3.0 Correction Factor for Pipe Dia., FT5 3.75 4.25 4.75
Pseudoplastic Dilatant Bingham Plastic Newtonian

3.0 2.5 2.0 1.5 1.0 0.5 0.0 0 2 4 6 8 10 12 14 16 18 Pipe Dia., in.

2.0

1.0

0.0 1.25

1.75 2.25

2.75 3.25

s Figure 11. Optimum pumping temperature FT2, correction factor for A.

s Figure 14. Optimum pumping temperature FT5, correction factor for pipe diameter D.

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10.0 1.5 Correction Factor for Pipe Length, FT6 P/100, psi/100 ft
Pseudoplastic Dilatant Bingham Plastic Newtonian Pseudoplastic Dilatant Bingham Plastic Newtonian

1.0

1.0

0.5 10

0.1 100 Pipe Length, ft 1,000 1 10 100 1,000 Volumetric Flowrate, gpm

s Figure 15. Optimum pumping temperature FT6, correction factor for pipe length L.
2.25 Correction Factor for n', FT7
Pseudoplastic Dilatant Bingham Plastic Newtonian

s Figure 17. Laminar ow pressure drop for optimum pipe diameter.

100
Pseudoplastic Dilatant Bingham Plastic Newtonian

1.25

P100, psi/100 ft 1 1.2 1.4 1.6 1.8 2

1.75

10

0.75

0.25 0.2 0.4 0.6 0.8

1 1 10 100 1,000

n'

Volumetric Flowrate, gpm

s Figure 16. Optimum pumping temperature FT7, correction factor for pipe length ow behavior index n. Note that piping length only affects the optimum temperature, not the optimum diameter. The variable p has an exponential effect on the diameter, and it is difficult to correct the diameter and temperature for values that differ from the refence value used. This method is limited to installations using carbon steel or other pipe materials with the same or close value of p .

s Figure 18. Turbulent ow pressure drop for optimum pipe diameter.

1.008 1.08 1.152 = 4.79 in., or Dopt 5 in.; the commercial diameter is 6 in.

Procedure The volumetric flowrate is 50,000 lb/h (1 ft3/ 61 lb) (1 gal/0.1337 ft3) (1 h/60 min) 100 gpm. From Figure 1, Dopt, ref = 3.82 in. With the known values of specific gravity = 61/62.37 = 0.978; K= 0.07 lbf-sn/ft2 and a + b = 0.10; we can obtain from Figures 3, 4 and 5, respectively: FD1 = 1.008; FD2 = 1.08; FD3 = 1.152. Therefore: Dopt = 3.82 in.

For turbulent flow From Figure 2 for the curve for pseudoplastic uids (n = 0.85) with a volumetric owrate of 100 gpm, a reference diameter in turbulent ow is obtained as: Dopt, ref = 2.76 in. With a specic gravity = 0.978; K= 0.07 lbf-sn/ft2 and a + b = 0.10; we obtain from Figures 6, 7 and 8, respectively: FD4 = 1.007; FD5 = 1.02; and FD6 = 1.123. Therefore: Dopt = (2.76 in. 1.007 1.02 1.123) = 3.18 in. 3 in. In the optimization of the diameter, the critical Reynolds number, NRe, crit, determines whether optimum conditions occur in laminar or turbulent ow (2). If NRe, crit is above 2,100, the transition from laminar to turbulent ow, the optimum diameter is for a pipe in turbulent ow. If it is below 2,100, the optimum diameter occurs in laminar ow.
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N Re , crit =

D nV 2 n g cK 8 n 1
1 2 n

= D n
crit

4Q C D 2

2 n

(7)

2,100 QC = 4

4 3n 2 n

(8)

Eq. 4, corresponding to laminar ow, may be substituted for D in Eq. 8. Substituting (M/)1+n for (3,600Qc)1+n and rearranging yields Eq. 9 (see the box). This equation depicts conditions just at the end of the laminar flow regime. To solve the problem: 1. Evaluate the right-hand side (RHS) of Eq. 9. This yields 6.2. 2. Substitute the proposed volumetric flowrate Q into the left-hand side (LHS) of Eq. 9. The conversion is: (100 gpm)(1 min/60 s)(1 ft3/7.48 gal) = 0.223 ft3/s. Using this and the values for n and p yields 8.463 102. 3. If the LHS is < the RHS, the ow will be laminar in the pipe of optimum diameter, which is then evaluated from Eq. 4. This is the case here, and laminar ow should be used. 4. If the LHS is > the RHS, the flow may be regarded as turbulent, which is evaluated from Eq. 5. 5. When n is < 1, substitute the corresponding value of NRe, crit from Eq. 7.

Following the scheme described by Eqs. 2 and 3, the optimum temperature in the pipeline can be obtained. When a heater must be installed at the pipeline inlet, it will be necessary to consider the fixed costs of the heater in the optimization analysis. If however, an adequate heater is already available, then there is no fixed cost, i.e., f1(x) = 0. Thus, f2(x) is relevant, and consideration must be given to the costs of the steam and of pumping the fluid. We will make the latter assumption here. Two equations are used: Eq. 10 for laminar flow and Eq. 11 for turbulent flow (2) (see the box). K and t are related by: K = (1/gc) 10(A Bt) Taking common logarithms: log(Kgc) = A Bt (13) (12)

In industry, optimizing the temperature at turbulent flow is infrequent, therefore, the graphical analysis will be limited to laminar flow. (Our own calculations for topt in turbulent flow indicated numerous times that such a temperature did not have a significant effect vs. flowrate; e.g., at 1 gpm, a typical value was 100F, and only 105F for 100 gpm.) In this case, topt is plotted vs. Q, with the rest of the variables at reference values. Thus, the optimum temperature of pumping will be:
t opt = t opt ref

Optimum pumping temperature If the temperature decreases, it will be more difficult to pump the fluid and the electric costs will increase. On the other hand, steam or another heating medium will be needed when the temperature must be increased, along with the associated costs.

F
n i=1

Ti

(14)

Where the FTi are correction factors, and the opti-

1 + n 4 3n

Q C 3,600Q C

2 n p + 1 + 3n

= 4

2,100 g cK 8

n 1

1 2 n

15.064 10 7 1 + 3n C ehK p a + b Fr + 1 X p12 pE 112.5

n

4 3n 2 n p + 1 + 3n

(9)

C pC sg cED 1 + 3n 4.05 10 5 t opt = 1 A log B Q 3.4625BC eL

(10)

C pC sg c b nED 5+ b n 3n 4 3.24 10 6 t opt = 1 A 1 log B Q bn 1.7343a nb nC eL8 b n n 1 B

2 b n 2 n

(11)

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mum temperature at reference conditions topt, ref is given in Figure 9 as a function of Q. The additional reference values that were used to draw up the graphs are: C p = 1 Btu/lb mF; D = 1 in.; L = 100 ft; Cs = $1/106 Btu; A = 2.5; and B = 0.05/F. Note that if D is not = 1 in., then it should be corrected by the factor FT5 . This optimization is independent of the diameter. Other references values (, Ce and E) are the same as in the first example.

f = an/NRebn

(19)

The effective viscosity of a non-Newtonian uid is: e = w/[8(V/D)] = Kgc8(n 1)V(n 1)D(1 n) Writing NRe for a non-Newtonian fluid as: NRe = DV/e = DnV(2 n)/gcK8(n 1) (21) (20)

Example II We will refer to the same example as before, and find topt. A pseudoplastic fluid in a storage vessel is pumped at 100 gpm to a production unit 500 ft away. The vessel is equipped with adequate heating facilities in the form of a steam jacket and heating coils. The vessel contents are at 60F before heating. Determine the optimum temperature of this system, so that the total annual cost of transporting the fluid is a minimum. Operating data: Cp = 0.85 Btu/lbmF; = 61 lb/ft3; L = 500 ft; E = 0.70; K at 60F = 0.063 lbf-sn/ft2; at 70F = 0.031; and at 75F = 0.021; n = 0.85. Cost data: Cs = $1/million Btu; Ce = $0.076/kWh; anticipated useful life = 10 yr. Solution Using Eq. 13 and fitting a linear relationship to the data yields A = 2.2079 and B = 3.1644 10-2/F. D = 6 in. from the first example. From Figure 9 for a pseudoplastic fluid, topt, ref = 113F. Figures 1016 are used to determine FT1FT7, respectively: FT1 = 0.968; FT2 = 0.818; FT3 = 0.938; FT4 = 0.996; FT5 = 2.24; FT6 = 0.69; and FT7 = 0.92. Therefore: topt =113F 0.968 0.818 0.938 0.996 2.24 0.69 0.92 = 118.8F. Pressure drop This method derives from Refs. 36. First, from a force balance, the relationship between shear stress w and P is:
w = DP/4L The friction factor is defined as: f = [wgc/(V2/2)] (16) (15)

And using Eqs. 1721, Figure 17 (laminar flow) and Figure 18 (turbulent flow) were created, which are used to determine the pressure drop for the Dopt for a given CEP volumetric flowrate.

Literature Cited
1. Dodge, D. W., and A. B. Metzner, Turbulent Flow of Non-Newtonian Systems, AIChE J., 5 (2), pp. 189204 (June, 1959). Errata: AIChE J., 8 (1), p. 143 (Mar. 1962). 2. Skelland, D. P., Non-Newtonian Flow and Heat Transfer, John Willey, New York, pp. 241269 (1967). 3. Anaya Durand, A., et al., Optimizacin de Sistemas de Manejo de Fludos No-Newtonianos en Tuberas, Memories of the XL National Convention of IMIQ [Mexican Institute of Chemical Engineers], Mxico City (Oct. 2000). 4. Metzner, A. B., Non-Newtonian Fluid Flow: Relationships between Recent Pressure-Drop Correlations, Ind. & Eng. Chem., 49 (9), pp. 14291432 (Sept. 1957). 5. Metzner, A. B., and J. C. Reed, Flow of Non-Newtonian Fluids: Correlation of the Laminar, Transition, and Turbulent Flow Regions, AIChE J., 1 (4), pp. 434440 (Dec. 1955). 6. Sultn, A. A., Sizing Pipe for Non-Newtonian Flow, Chem. Eng., 95, pp. 140146 (Dec. 19, 1988).

Substituting Eq. 15 into Eq. 16 and rearranging yields: P/L = 2f2/gcD (17)

ALEJANDRO ANAYA DURAND (Parque Espaa, St 15B Col. Condesa, Mxico, D.F:, Mxico, 06140; Phone and Fax: 5255- 5211-0385; E-mail: aanayadurand@hotmail.com) is a professor of chemical engineering at the National Autonomous University of Mexico (UNAM). He has been working as a process advisor to Bufete Industrial, S.A. (from 1998 until now) in Grupo Industrial Resistol S.A. de C.V. (from 1999 until now) and in Consultora Empresarial Ejecutiva, S.A. de C.V, He also advises TECHINT, S.A. He has 40 years of experience in process engineering, project engineering and equipment design. He retired from the Mexican Petroleum Institute after 30 years of holding several top-level positions. Anaya Durand has 37 years of experience as a professor of chemical engineering. He holds a masters in project enginering from UNAM. He is a Fellow of AIChE and, in 1997, he won the National Award in Chemistry. CINTHYA ALEJANDRA AGUILAR GUERRERO (Miguel Alemn 2a secc. 3-202 Lomas la Trinidad, Texcoco, Estado de Mxico, Mxico; Phone: 5259-59546722; E-mail: cinthyaaag@yahoo.com.mx or ephf@hotmail.com) is a ninthsemester chemical engineering honor student at UNAM. She is an active member of the Mexican Institute of Chemical Engineers (IMIQ). EDGAR AMARO RONCES (Isla Sn. Diego 3 Col. Jardines de Morelos Ecatepec, Estado de Mxico, Mxico; E-mail: edgaramaro@hotmail.com) is a ninthsemester chemical engineering honor student at UNAM. He is an active member of the Mexican Institute of Chemical Engineers (IMIQ).

In the case of the turbulent regime, the expressions developed by Dodge and Metzner (1) can be used: f = 16/Re We have already shown that: (18)

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