Flotation Cells to Thickener

2026.04 kg/hr
Mass flow rate
0.5628 kg/s
Density 1180.89 kg/m3
Viscosity 0.0012 kg/m-s

Solving for the volumetric flow rate:

kg
0.5628 3
mass flow rate s 4 m
qf = = =4.77 10
density kg s
1180.89 3
m

m
The velocity of slurry inside the pipe is less than 1.1887 s . (Poirier)

m
Setting the velocity to 1 s ,

3
m 4
4.77 10
Volumetric Flow Rate s
Area= = =4.77 104 m2
Velocity m
1
s

Diameter=
4 Area

=
4 4.77 104

=0.0246 m

Diameter=0.97 .

The nominal pipe size to be used is 3/8 inch (Perry & Green, 2008).
1 in. Nominal Pipe Size Sch No. 80 S
Inside Diameter 1.278 in. 0.0325 m
Outside Diameter 1.66 in. 0.0422 m
Wall Thickness 0.191 in. 4.8514x10-3 m
Calculating the fluid velocity:
 0.0325 m


2

d i2
Area std = =
4

3
m
4.77 104
Volumetric flowrate s m
Velocity= = 4 2
=0.575
Area 8.2958 10 m s

To solve for Reynolds number:

kg m
1180.89 0.575 0.0325 m
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

 1.278
0.0018

]
0.9

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

To calculate frictional loss due to meter:

2
2 m
0.575 2
s

2 0.0074
FL 2 f v2
= =
L gc di

kPa
0.18
m

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).
Quantit
k kf
y
90o elbows 0.75 2 1.5
Ball valve 70 1 70
Total 71.5
2
2m
0.575 2
s

71.5
k f v2
Ff= =
2 gc
FRICTION LOSS DUE TO PIPE LINE
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

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)

Substituting values to the equation,

m2
0.575 2 (10.24 )
2

s


F m =
FRICTION LOSS DUE TO SUDDEN CONTRACTION (Entrance Loss)
A2 v 2
Fc =0.5 1 ( )
A 1 2 gc

A2
0(negligible)
A1

2
m
0.575 2
s2


v2
Fc =0.5 =0.5
2 gc

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT (Exit Loss)

v2
Fe =
2 gc

m2
0.575 2
s2


F e =

Calculating the total frictional losses:

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

CALCULATION OF KINETIC ENERGY

 m
v 2=0.575
s

m
v 1=0.575
s

KE=0

CALCULATION OF POTENTIAL ENERGY

m
( 2.5 m1.5 m ) 9.81
( z 2z 1 ) g s2
PE= =
gc kg m
1
N s2

Nm
PE=9.81
kg

CALCULATION OF PRESSURE HEAD

P 101.325 kPa101.325 kPa
= =0
kg
1180.89 3
m

OVERALL MECHANICAL ENERGY BALANCES

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

W S= ( 01 +9.81+0+ 15.68) Nkgm 0.5628 kgs =14.3458Watts

Since the work is very small, pump is not required.
 Branching
Water Tank to Classifier & Water Scrubber
(1) To Classifier
0.4356 kg/s
Mass Flow Rate
(2) To Water
Scrubber Mass Flow 0.00025 kg/s
Rate
Density 994.67 kg/m3
Viscosity 0.0008 kg/m-s

m=
m 1 +m
2

Solving for the volumetric flow rate:

kg
(0.4356+ 0.00025) 3
Total mass flow rate s 4 m
qf = = =4.38 10
density kg s
994.67 3
m

Calculating the relationship between v1 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
Inside Diameter 1.442 in. 0.0366 m
Outside Diameter 1.660 in. 0.0422 m
Wall Thickness 0.109 in. 2.7686x10-3 m

f1f 2

v 1 2 L1 v 2 2 L 2
=
d1 d2

v1
v2
L
= 2=
L1
126 m
75.3 m
=1.2936

v 1=1.2936 v 2

Using the continuity equation

q f = A 1 v 1 + A2 v 2

m3
4.38 104
s 4 ( )
= 0.03662 m2 (1.2936 v 2 + v 2)

m
v 2=0.18
s

Solving for v 1 ,

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
 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

( ( )]
0.9
7
0.27 +
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

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

1.44
0.0018

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

f =

To calculate frictional loss per meter:

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

2 0.0073
FL 2 f v2
= =
L gc di

Point (1)
2
2 m
0.18 2
s

2 0.0087
FL 2 f v2
= =
L gc di

Point (2)
m2
0.23 2
s2

2 0.0087
FL 2 f v2
= =
L gc di

N m kg 1kPa
( 0.0670+0.0154+ 0.0251 ) 994.67 3
Total Friction loss = kg m 1000 N
m2

kPa
Total Friction loss=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).
Fittings and valves
 k Quantit kf Quantit kf Quantit kf
yA y1 y2
Tee Branch 1 1 1 0 0 0 0
90o elbow 0.75 0 0 1 0.75 3 2.25
Globe valve 6 0 0 1 6 1 6
Check valve 2 0 0 1 2 1 2
TOTAL 1 8.75 10.25

kf v2
Ff= ( )
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
kg m kg m kg m kg
2 1 2
21 2
2 1 2
N s N s N s

FRICTION LOSS DUE TO PIPE LINE

L A=7.97 m

L1=75.3 m

L2=126 m

F L= ( FL 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
v 2 (1 4 )
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

Point (1)
(0.18 m)2 (10.24 ) Nm
Fm 1 = =0.03
2 0.60 kg

Point (2)
2 4
(0.23 m) (10.2 ) N m
Fm 2 = =0.04
2 0.60 kg

Nm
FmTOTAL =0.14+0.03+ 0.04=0.21
kg

FRICTION LOSS DUE TO SUDDEN CONTRACTION (Entrance Loss)

A2 v 2
Fc =0.5 1 ( )
A 1 2 gc

A2
0(negligible)
A1

Point (A)
 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

FRICTION LOSS DUE TO SUDDEN ENLARGEMENT (Exit Loss)

v2
Fe =
2 gc

Point (A)
 0.41


m2
2 2
s

F e =

Point (1)
0.18


m2
2 2
s

F e =

Point (2)
0.23


m2
2 2
s

F e =

N m
FeTOTAL =0.08+0.02+ 0.03=0.13
kg

Calculating the total frictional losses:

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

CALCULATION OF KINETIC ENERGY

 m
v A =0.41
s

m
v 0 =0
s

m
v 2=0.23
s

m
v 1=0.18
s

2 2 2 2 2 2

KE=
( m
0.41 2 02 2
s
2 m
s
+
m
)(
0.232 2 0.412 2
s
m
s
+
m
)(
0.182 2 0.412 2
s
m
s )
kg m kg m kg m
2 1 2
2 1 2
2 1
Ns Ns N s2

Nm
KE=0.04
kg

CALCULATION OF POTENTIAL ENERGY

z A=2 m

z 0=11 m

z 1=2 m

z 2=5 m

( z 2z 1 ) g
PE=
gc

m m m
( 211 ) m9.81 2
( 22 ) m9.81 2 ( 52 ) m9.81 2
s s s
PE= + +
kg m kg m kg m
1 1 1
N s2 2
N s N s2
 N m
PE=58.86
kg

CALCULATION OF PRESSURE HEAD

P 101.325 kPa101.325 kPa
= =0
kg
994.67 3
m

OVERALL MECHANICAL ENERGY BALANCES

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).

Acid Scrubber to Water Scrubber

7.86 kg/hr
Mass flow rate
0.0022 kg/s
Density 3.0986 kg/m3
Viscosity 0.00002 kg/m-s

Solving for the volumetric flow rate:

 kg
0.0022 3
mass flow rate s 4 m
qf= = =7.1 10
density kg s
3.0986 3
m

From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth
Edition, 2005), the 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
4 m
7.1 10
Volumetric Flow Rate s 5 2
Area= = =4.73 10 m
Velocity m
15
s

Diameter=
4 Area

=
4 4.73 105 m2

=7.76 103 m

Diameter=0.3056.

The nominal pipe size to be used is 3/8 inch (Perry & Green, 2008).
1 in. Nominal Pipe Size SCH No. 40 ST
Inside Diameter 0.307 in. 7.80x10-3 m
Outside Diameter 0.405 in. 0.0103 m
Wall Thickness 0.049 in. 1.2446x10-3 m
Calculating the fluid velocity:
3
7.80 x 10 m


2

d i2
Area std = =
4
3
m
7.1 104
Volumetric flowrate s m
Velocity= = 5 2
=14.87
Area 4.78 10 m s

To solve for Reynolds number:

 kg m
3.0986 14.87 7.80 x 103 m
vD m
3
s
N = = =17599.34
kg
0.00002
m s

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 :

0.307
0.0018

]
0.9

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

2
1
f=

( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=

To calculate frictional loss per meter:

4 f LG 2 G 2 P 1
P= + ln
2D P2

For the mass velocity:

Mass Flow Rate
G=
Crosssectional areaof pipe

kg
0.0022
s kg
G= 5 2
=46.0251
4.78 10 m s m2
The pressure drop should not exceed 11 kPa per 100m length of pipe (Norsok Standard
Process Design, 1997)
Calculating the pressure drop,
kg 2 kg 2
4 0.0092 100 m 46.0251 46.0251
s m2 s m2 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

Suction Pressure = Upstream Pressure Pressure Losses + Static Pressure

Pressure Losses = Frictional Line Loss + Instrument Losses

Line Length in pump suction = 2.3 m

2
4 f LG G
2
P
Line Loss= + ln 1
2D P2

Line Loss
2 2
kg kg
4 0.0092 2.3 m 46.0251 2
46.0251 2
sm 1 kPa sm 101.325 kPa
+ ln
kg N kg 101.325 kPa
2 7.80 x 103 3.0986 3 1000 2 3.0986 3
m m m
Line Loss=3.22 kPa

m 2
(14.87 )
s kg 1 kPa
Entrance Loss 0.5 3.0986 3 =0.1713 kPa
kg m m N
2 1 1000 2
N s2 m

Pressure Losses 3.22 kPa+ 0.1713=3.3939 kPa

Upstream Pressure = 101.325 kPa

 z=( 7.51 ) m=6.5 m

m kg
6.5 m 9.81 2
3.0986 3
s m 1 kPa
Static Pressure =0.1976 kPa
kg m N
1 1000 2
N s2 m

Suction Pressure (101.3253.3939+0.1976) kPa=98.1287 kPa

Suction Pressu =98.13 kPa

Line from Pump Discharge

Discharge Pressure = Dynamic Loss + Equipment Operating Pressure +Static Pressure

Quantit
Le /D
y
90o elbows 2 35

Dynamic Loss = Pressure Drop of Instruments + Frictional Line Loss

3
Le 7.80 x 10 m ( 2 35 )=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 line length
2 2
kg kg
4 0.009211.05 m(46.0251 2
) 46.0251 2
sm 1 kPa s m 101.3
Frictional Line Loss= + ln
kg N kg 101.3
27.80 x 103 3.0986 3 1000 2 3.0986 3
m m m
Frictional Line Loss=17.82 kPa

Frictional Loss due meter

Orifice Meter
v 2 (1 4 )
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)

Substituting values to the equation,

2
m
(14.87 ) (10.24 )
s kg 1 kPa
Fm = 3.0986 3 =0.57 kPa
2 0.60 m 1000 N
m2

Frictional Loss due sudden enlargement

v2
Fe =
2 gc

m 2
(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 (17.82+0.57+ 0.34) kPa=18.73 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 gc = =0.20 kPa
kg m N
1 1000
N s2 m2

Discharge Pressure 18.73 kPa+101.325 kPa+0.20 kPa

Discharge Pressure=120.26 kPa
 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,
=1.112
kJ
1.112 8.314 320 K 1.112
W '=
kmol K
1.1121 (( 120.26 kPa
98.13 kPa ) 1.1121
)
1
1 kmol
103.84 kg
0.0022
kg
s

W '=3.66 kW

The efficiency of compressor is 85% (Timmerhaus & Peters, 1991)

3.66 kW
W ' Actual = =4.30 kW
0.85

SELECTION OF COMPRESSOR

The discharge pressure is 275.15 kPa or 25.22 psi.

The capacity of compressor is
 kg
7.86
hr m3 ft 3
Capacity= =2.54 =1.50
kg hr hr
3.0986 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 1.50 cfm and
discharge pressure of 25.22 psi, metallic diaphragm compressor will be used.

Flash Tank to HF Condenser

171.35 kg/hr
Mass flow rate
0.0476 kg/s
Density 0.5904 kg/m3
Viscosity 0.00002 kg/m-s

Solving for the volumetric flow rate:

kg
0.0476 3
mass flow rate s m
qf = = =0.0806
density kg s
0.5904 3
m

From Table 5.4 (Coulson and Richardson's Chemical Engineering Design, Fourth
Edition, 2005), the 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
Volumetric Flow Rate s
Area= = =0.0054 m2
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
Inside Diameter 3.26 in. 0.0828 m
Outside Diameter 3.5 in. 0.0889 m
Wall Thickness 0.12 in. 3.048x10-3 m

Calculating the fluid velocity:

0.0828 m


2

d 2
Area std = i =
4

3
m
0.0806
Volumetric flowrate s m
Velocity= = 2
=14.97
Area 0.0054 m s

To solve for Reynolds number:

kg m
0.5904 14.97 0.0828 m
vD m
3
s
N = = =41948.85
kg
0.00002
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 :

3.26
0.0018

]
0.9

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

2
1
f=

( [ ( ) ( ) ])
4 log 0.27

di
+
7

0.9
=

To calculate frictional loss per meter:

4 f LG 2 G 2 P 1
P= + ln
2D P2

For the mass velocity:

Mass Flow Rate
G=
Crosssectional areaof pipe

kg
0.0476
s kg
G= 2
=8.84
0.0054 m s m2

The pressure drop should not exceed 11 kPa per 100m length of pipe (Norsok Standard
Process Design, 1997)
Calculating the pressure drop,
 kg
8.84 2
sm


2

kg 2
4 0.0059 100 m (8.84 )
s m2
P= +
kg
2 0.0828 m 0.5904 3
m

P=1877.67 Pa=1.8777 kPa

Line to Compressor Suction

Suction Pressure = Upstream Pressure Pressure Losses + Static Pressure

Pressure Losses = Frictional Line Loss + Instrument Losses

Quantit
Le /D
y
90o 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
Line Loss=0.1308 kPa
2
m
(14.97 )
s kg 1 kPa
Entrance Loss 0.5 kg m
0.5904 3
m 1000 N
=0.03 kPa
2 1
N s2 m2
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 kPa
kg m N
1 1000 2
N s2 m

Suction Pressure ( 101.3250.160.1976 ) kPa

Suction Pressure=101.15 kPa

Line from Pump Discharge

Discharge Pressure = Dynamic Loss + Equipment Operating Pressure +Static Pressure

Quantit
Le /D
y
Diaphragm
1 392
Valve

Dynamic Loss = Pressure Drop of Instruments + Frictional Line Loss

Le 0.0828 m ( 1 392 )=32.46 m
Line length from pump discharge = 4.5 m + 32.46 m = 36.92 m

Frictional Line Loss = Frictional Loss per meter Total line length
kg
8.84
s m2


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=0.71 kPa
 Frictional Loss due meter

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)

Substituting values to the equation,

m 2
(14.97 ) (10.24 )
s kg 1kPa
Fm = 0.5904 3 =0.11 kPa
2 0.60 m 1000 N
m2

Frictional Loss due sudden enlargement

v2
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 0.89 kPa+101.325 kPa+0 kPa
Discharge Pressure=102.22 kPa
 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 '=1.08 kW

The efficiency of compressor is 85% (Timmerhaus & Peters, 1991)

1.08 kW
W ' Actual = =1.27 kW
0.85
 SELECTION OF COMPRESSOR

The discharge pressure is 250.89 kPa or 21.70 psi.

The capacity of compressor is
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.

Sodium Bisulfite Tank to Flotation

Cells
Type: Screw Conveyor
Design Requirements:
Conveyor Speed
Motor horsepower

Material Specification
Type of Material : Sodium Bisulfite

Mass Flowrate ( 0.2628 (0.5771 lb/hr)

 kg

hr
lb 92

Density ( ft 3

From plant layout, conveyor length should be 167.65 ft

Volumetric flowrate of fluorspar:

lb
0.5771
hr f t3
q= =0.0063
lb hr
92
f t3

Material Code:

From CEMC, the material code of fluorspar is 96 B 46 X 3 0 B 2 D

96 - Density (90 lbs/ft^3)
B Fine No. 16 Sieve (1mm) and Under, size of material
4 Sluggish
6 Moderately Abrasive
X- Packs Under Pressure
30B Conveyor loading
2D Component Group
Material Factor ( F M =1.5

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

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.

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

C F 1=1
 C F 2=1.95

C F 3=1
3

(
Equivalent Capacity= 0.0063
ft
hr )
(1 x 1.95 x 1)

3
ft
Equivalent Capacity=0.0122
hr
3
ft
For a capacity of 0.0122 hr and 15% trough loading, a screw diameter of 6

inches should be used.

Maximum recommended speed = 60 rpm

The computed speed of conveyor should not exceed the maximum recommended
speed.
3
ft
0.0122
Equivalent Capacity hr
Conveyor Speed= = =0.0153 rpm
1 rpm capacity 0.8 rpm
Thus, 0.0153 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;
L=total lengthof conveyor , ft

N=operating speed , rpm

Fd =conveyor diameter H P factor

Fb =hanger bearing HP factor

For a screw diameter of 6 inches:
F
Conveyor diameter HP factor ( d )=18

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

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
C=capacity quire ,
hr

lb
D=density of material as conveyed ,
f t3

L=total lengthof conveyor , ft

Fm =material factor

F f =flighting modification HP fa ctor

 F p =Paddle HP factor

F
From material characteristics table the horsepower material factor ( m)=1.5

Density of fluorspar as conveyed = 92 lb/ft^3

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) F o
H Ptotal =
e

Where;
Fo =Overload HP factor

e=Drive efficiency ( expressed as decimal )

( H P f + H Pm )= ( 0.0002+ 0.0002 )=0.0004

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 ( 0.0004 ) x (0.6115 ) +2.024=6.87

Using Screw Conveyor Drive which is specially designed for screw conveyor, e = 0.88
 ( 0.0004 ) 6.87
H Ptotal = =0.0028 hP
0.88

Since the power requirement is very small, conveyor is not required.

Rotary Dryer to Rotary Kiln

Type: Screw Conveyor
Design Requirements:
Conveyor Speed
Motor horsepower

Material Specification
Type of Material : Acid-grade Fluorspar

Mass Flowrate ( 998.624 lb/hr

kg

hr
lb 100
Density ( ft 3

From plant layout, conveyor length should be 119 ft

Volumetric flowrate of fluorspar:

lb
998.624
hr f t3
q= =9.99
lb hr
100
f t3

Material Code:

From CEMC, the material code of fluorspar is 90 B 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
45%. For conveying products horizontally or up slight inclines, use a standard pitch.

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.

For a Cut flight standard pitch with conveyor loading of 45%

C F 1=1

C F 2=1.43

C F 3=1
3
Equivalent Capacity= 9.99
ft
hr( )
(1 x 1.43 x 1)

f t3
Equivalent Capacity=14.28
hr
 3
ft
For a capacity of 14.28 hr and 45% trough loading, a screw diameter of 6 inches

should be used.

Maximum recommended speed =165 rpm

The computed speed of conveyor should not exceed the maximum recommended
speed.
f t3
14.28
Equivalent Capacity hr
Conveyor Speed= = =6.49 rpm
1 rpm capacity 2.2 rpm
Thus, 6.49 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;
L=total lengthof co nveyor , ft

N=operating speed , rpm

Fd =conveyor diameter HP factor

Fb =hanger bearing HP factor

For a screw diameter of 6 inches:

F
Conveyor diameter HP factor ( d )=18

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

119 ft x 6.49rpm x 18 x 4.4

L NF d F b
H Pf= = =0.0 556
1000000 1000000

Material HP:
CLD Fm F f F p
H P m=
1000000

Where;
f t3
C=capacity require ,
hr

lb
D=density of material as conveyed ,
f t3

L=total lengthof conveyor , ft

Fm =material factor

F f =flighting modification HP factor

F p =Paddle HP factor

F
From material characteristics table the horsepower material factor ( m)=2.0

Density of fluorspar as conveyed = 100 lb/ft^3

 CLD Fm F f F p ( 9.99 x 119 x 100 x 2 x 1.2 x 1 )
H P m= = =0.2852
1000000 1000000

Total HP:
(H P f + H P m) F o
H Ptotal =
e

Where;
Fo =Overload HP factor

e=Drive eff iciency ( expressed as decimal )

( H P f + H Pm )= ( 0.0556+0.2852 )=0.3408

From the figure below Fo=2.69

Using Screw Conveyor Drive which is specially designed for screw conveyor, e = 0.88

( 0.3408 ) 2.69
H Ptotal = =1.0418 hP
0.88