Process Engineering 2017

First period of examinations
Winter semester 2016/2017 II
Study Course: ___________________________________

Module Title: Fundamentals of Process Engineering
(Prof. Danjou / Prof. Gebel)
Written exam: 70 points

Duration: 110 min
Date: 01.02.2017
Family Name: ____________________ ___________________________
First Name: ____________________ Signature (Student)
Register No.: ____________________
The exam consists of 18 pages. First, check that your copy contains all pages and that the formulary
(one additional page) is attached.
All calculations and sketches should be done on the sheets provided for that purpose. If more than
one solution is given, mark clearly which one should be rated.
Please write legibly! Good luck!
FOR INTERNAL USE ONLY:
Written Home- Practical

Q1 Q2 Q3 Q4 Q5 Q6 Q7 exam work Training
Total
Max. Points 8 10 14 10 8 11 9 70 14 16 100
Achieved
≥ 36
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Graded by Checked by Final Grade
Regular grading key.
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Adjusted grading key.
(Please add the adjusted grading
key to the exam-results)
Page 1 of 18 page(s)
Register No.:
Question 1 … “What happens if ….?” Question session Points: 8
There is only one correct answer for each question.
1. What happens if the flow of water within a horizontal tube changes from laminar
to turbulent?
The pressure losses remain constant.
The pressure losses will increase.
The pressure losses will decrease.
2. Consider laminar flow of water under steady-state conditions. What happens if the
diameter of a horizontal tube smoothly increases?
The pressure will decrease and the velocity will increase.
Pressure and velocity remain constant.
Pressure and velocity will decrease.
The pressure will increase and the velocity will decrease.
3. Consider laminar flow of water under steady-state conditions through a horizontal

tube. What happens if the temperature of the water increases due to heating of
the tube?
The pressure remains constant.
4. Consider laminar flow of air under steady-state conditions through a horizontal

tube. What happens if the temperature of the air decreases due to cooling of the
tube?
The pressure remains constant.
5. What happens if two 5-cm-diameter spheres are falling through air at an initial
distance from each other of 50 cm?
The distance remains constant.
The distance becomes smaller.
The distance becomes longer.
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6. Consider a car moving at a velocity of 60 km/h. What happens if the car is imme-
diately accelerates to 120 km/h?
The drag force remains constant.
The drag force at 120 km/h is twice the drag at 60 km/h.
The drag force at 120 km/h is eight times bigger than the drag at 60 km/h.
No correct answer is given.
7. Plaice are bottom-living flatfish similar to flounder. At rest they constitute low,
rounded humps on smooth, sandy bottoms. What happens if the current passing
over the fish becomes stronger, i.e. higher flow velocity?
The flatfish is pressed on the ground.
The flatfish is lifted up into the current.
The flatfish remains quiescent.
8. A streamline is a line in the flow possessing the following property:

The velocity vector of each particle occupying a point on the streamline is
normal to the streamline.
The velocity vector of each particle occupying a point on the streamline is tan-
gent to the streamline.
The velocity vector of each particle occupying a point on the streamline is
shifted by 45° with respect to the streamline.
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Question 2 … Pressure loss for flow around a slider valve Points: 10
A Newtonian fluid flows around a slider valve. The geometrical data are given in the
sketch. The pressure difference between point 1 and point 2 can be measured by
Bourdon tubes.
p1 p2
v h h
d
a) Please explain what the Buckingham p-theorem states.
b) Define the set of variables the pressure difference ∆p depends on.
c) Identify appropriate repeating variables.
d) Form the p –terms by combining the repeating variables with each of the re-
maining variables.
e) Which well-known dimensionless numbers have you found? Please express

these numbers as ratio of different forces.
Register No.:
Answer sheet
Use this sheet for your answer only. Other notes will not be accepted.
Register No.:
Question 3 … Power demand of a pump Points: 14
A centrifugal pump is installed between two tanks. Both tanks are open to the atmos-
phere. The tanks are located at different levels within a building. The difference in
height is 15 m.
The total length of the 5-cm diameter stainless steel tube, which connects the pump
inlet and the pump exit with the respective tank, is 50 m.
a) Determine the total pressure losses of the system, in Pa.
b) Determine the power demand of the pump, in kW, if the internal efficiency of
the pump is 85%.
Given:
3
Volume flow  = 100 m
V
h
kg
Density of water ρ =1,000
m³
Ns
Viscosity @ 10°C =η 1.308 × 10 −3
m²
Roughness of the tube e = 0.002 mm
Loss coefficient of minor losses ζ =20
Moody diagram (see next page)
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Answer sheet
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Answer sheet
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Question 4 … Terminal velocity and drag Points: 10
Consider a 0.6-cm-diameter smooth glass sphere falling through a large vertical tube
filled with a highly concentrated sugar solution.
a) Provide an equation for the drag force FD acting on the sphere, which com-
prises solely the variables
- terminal velocity v∞,

- viscosity of sugar solution ηSuSo and
- diameter d of the sphere.
b) Determine the terminal velocity v∞, in m/s.
c) Determine the drag force FD, in N.
The drag coefficient cD can be expressed by Stokes’ drag formula:
24
cD =
Red
The terminal velocity can be expressed as:
g (ρGl − ρSuSo ) ⋅ d2
v∞ =
18 ηSuSo
Given:
kg
Density of sphere: ρGl =2,500
m³
kg
Density of sugar solution: ρSuSo =
1,260
m3
kg
Viscosity of sugar solution: ηSuSo =
1.47
sm
p 3
Volume of a sphere: VSphere = d
6
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Answer sheet
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Question 5 … Question session Points: 8
There is only one correct answer for each question.
1. A filtration process is generally defined by its filtration rate. What is the general
definition of the filtration rate?
resistance
filtration rate= driving force
specific surface of the filter cake
filtration rate= cycle time
driving force
filtration rate= resistance
resistance
filtration rate= filter cake area
2. In the case of cake filtration, what happens to the filtration rate if we increase the
porosity of the filtering medium?
The filtration rate remains constant.
The filtration rate will increase.
The filtration rate will decrease.
The filtration rate will first increase and then decrease.
3. A size reduction process by a hammer mill is given. What happens to the particle
size of the feed if we increase the power demand?
The particle size can be increased.
The particle size has to be decreased.
The particle size will not change.
The particle size has to be the same as the product size.
4. A ball mill is properly operated at a given angular velocity ω. What would be nec-
essary to change in the condition of operation in order to ensure proper running of
the mill if we would increase the drum diameter D?
The angular velocity ω would have to be increased too.
The angular velocity ω would have to be decreased.
The diameter d of the balls would have to be decreased.
There is no need for any change since the operation mode is independent
from the drum diameter D.
5. The shape of an individual particle is conveniently expressed in terms of spherici-

ty. What is the definition of sphericity ΦS ?
volume of a sphere with the same surface as the given particle
ΦS = actual volume of particle
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actual surface of a sphere

ΦS = surface of particle with the same surface as the given sphere
actual surface of particle

ΦS = surface of a sphere with the same volume as the given particle
surface of a sphere with the same volume as the given particle

ΦS = actual surface of particle
actual volume of particle

ΦS = volume of a sphere with the same surface as the given particle
6. The result of a sieve analysis is given as a smoothed frequency distribution curve.

What happens to the curve if we repeat the sieve analysis with a higher number
of sieves (same scales for plotting)?
Nothing. The shape of the curve is independent from the number of sieves.
The curve will get horizontally stretched.
The curve will approximate the ordinate.
The curve will get horizontally compressed.
The curve will approximate the abscissa.
7. For a given particle size distribution, which representation is necessary to graph-

ically determine the most frequent particle diameter?
The cumulative frequency distribution curve (residue).
The frequency density distribution curve based on particle numbers.
The cumulative frequency distribution curve (pass through).
The Tromp curve.
The frequency distribution curve based on particle mass.
8. The result of a sieve analysis is given as a frequency density distribution in form

of a histogram. What happens to the height of a bar if we split the corresponding
size class into two equal halves?
The height of the bar will get halved too.
The height of the bar will increase.
The height of the bar decreases proportional to the amount of particles.
The height of the bar will not change.
Register No.:
Question 6 … Particle size distribution Points: 11
The following table provides the result of a sieve analysis.
a) Complete the given table below by calculating the class width, the cumulative un-
dersize (residue) amounts and the cumulative oversize (pass through) amounts
for each sieve.
b) What is the amount of particles (in g) that would pass a 0.3 mm screen? Deter-
mine with the help of your calculated numbers and an appropriate PSD represen-
tation.
Note: Do not interpolate. Instead, use the provided diagram on the next page. Do
not change the axis labels.
c) Calculate the total average diameter for the given sample.
Mesh
Sieve Class width Residue
size 𝒙𝒙𝒊𝒊 𝑹𝑹(𝒙𝒙) [%] 𝑫𝑫(𝒙𝒙) [%]
# ∆𝒙𝒙𝒊𝒊 [mm] ∆𝒎𝒎𝒊𝒊 [g]
[mm]
1 0.71 13.9
2 0.5 71.1
3 0.355 120.1
4 0.25 116.7
5 0.18 76.3
6 0.125 50.0
7 0.071 34.6
8 0.045 10.3
Pan 0 7.0
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Question 7 … Energy demand of a cone crusher Points: 9
A cone crusher is fed with soft limestone having particles of 2 cm median equivalent
diameter and discharges a product consisting of particles of 0.5 cm median equiva-
lent diameter. The equipment operates at a capacity of 1.2 × 104 kg/h consuming a
power of 10 hp.
a) If the requirements of the process demand a ﬁner size of the product (0.4 cm of
median equivalent diameter) decreasing the capacity to 1.0 × 104 kg/h, calculate
the theoretical power consumption in kW under the new conditions. For this,
choose an appropriate calculation model.
1 hp = 0.7457 kW
b) While keeping the product size at 0.4 cm of median equivalent diameter, deter-
mine with the help of the following diagram the required feed size (in mm) if crush-
ing would operate at the original capacity and consume the original power.
kWh
50
t
cone crusher pebble mill
jaw breaker hammer mill
impact mill
roll crusher
10
Specific power demand
WZ
m
xα
1 n=
xω
0,5
0,1 1
0,1 0,5 1 5 10 50 100 500
cm
nn
xx´
ω
Register No.:
Answer sheet
Register No.:
Answer sheet
End of exam
Formulary „Fundamentals of Process Engineering”
P004-60-0000 Prof. Dr.-Ing. Joachim Gebel

Formulary Prof. Dr.-Ing. Stéphane Danjou
Version 2017-02-01 Process Engineering  WS 2016/17

Process Engineering 2017

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Process Engineering 2017

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First period of examinations

Winter semester 2016/2017 II

Study Course: ___________________________________

Written exam: 70 points

Please write legibly! Good luck!

FOR INTERNAL USE ONLY:

Written Home- Practical

Max. Points 8 10 14 10 8 11 9 70 14 16 100

Graded by Checked by Final Grade

Regular grading key.

Question 1 … “What happens if ….?” Question session Points: 8

There is only one correct answer for each question.

3. Consider laminar flow of water under steady-state conditions through a horizontal

4. Consider laminar flow of air under steady-state conditions through a horizontal

8. A streamline is a line in the flow possessing the following property:

Question 2 … Pressure loss for flow around a slider valve Points: 10

a) Please explain what the Buckingham p-theorem states.

b) Define the set of variables the pressure difference ∆p depends on.

c) Identify appropriate repeating variables.

e) Which well-known dimensionless numbers have you found? Please express

Question 3 … Power demand of a pump Points: 14

a) Determine the total pressure losses of the system, in Pa.

Roughness of the tube e = 0.002 mm

Loss coefficient of minor losses ζ =20

Moody diagram (see next page)

Question 4 … Terminal velocity and drag Points: 10

- terminal velocity v∞,

b) Determine the terminal velocity v∞, in m/s.

c) Determine the drag force FD, in N.

The drag coefficient cD can be expressed by Stokes’ drag formula:

The terminal velocity can be expressed as:

Question 5 … Question session Points: 8

There is only one correct answer for each question.

5. The shape of an individual particle is conveniently expressed in terms of spherici-

actual surface of a sphere

actual surface of particle

surface of a sphere with the same volume as the given particle

actual volume of particle

6. The result of a sieve analysis is given as a smoothed frequency distribution curve.

7. For a given particle size distribution, which representation is necessary to graph-

8. The result of a sieve analysis is given as a frequency density distribution in form

Question 6 … Particle size distribution Points: 11

The following table provides the result of a sieve analysis.

c) Calculate the total average diameter for the given sample.

Question 7 … Energy demand of a cone crusher Points: 9

P004-60-0000 Prof. Dr.-Ing. Joachim Gebel

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