„TECHNICAL EQUIPMENT

(Chemical Process
Equipment)
SELECTION AND DESIGN”

Dr inż. Robert Kubica

BIBLIOGRAPHY
CONTENTS OF THE
LECTURE

PIPING

PUMPS

COMPRESSORS AND VACUUM
PUMPS

DRIVERS FOR MOVING
EQUIPMENT

CONVEYORS FOR PARTICULATE
SOLIDS
MASS RATE OF FLOW
.
m=F ⋅v ⋅ ρ [kg/s]

v = 0.5 ⋅ v max v = 0.8 ⋅ v max

VOLUME RATE OF FLOW

.
V = F ⋅v [m3/s]
 EQUATION OF CONTINUITY
. . .
m 1 = m 2 = m 3 = const
.
m 1 = F1 ⋅ v 1 ⋅ ρ1
.
m 2 = F2 ⋅ v 2 ⋅ ρ 2
.
m 3 = F3 ⋅ v 3 ⋅ ρ 3

if ρ 1 = ρ 2 = ρ 3 then F1 ⋅ v 1 = F2 ⋅ v 2 = F3 ⋅ v 3 = const
V =F ⋅v
 BERNOULLI EQUATION
E = Ek + Ep + Eh
2
m ⋅v
E k1 E k1 =
Ek = 2
G
G=m⋅g

KINETIC ENERGY m⋅v2 v2

Ek = =
UNIT MASS WEIGHT 2⋅m⋅g 2⋅g
 BERNOULLI EQUATION

E p1 E h1
Ep = Eh =
G G

E p1 = p ⋅ V E h1 = m ⋅ g ⋅ h

p ⋅V p m⋅g ⋅h
Ep = = Eh = =h
γ ⋅V γ m⋅g
BERNOULLI EQUATION
v2 p
E= + +h [m]
2⋅g γ
2 2
v1 p1 v2 p2
+ + h1 = + + h2 = const
2⋅g γ 2⋅g γ

2 2
v1 p1 v2 p2 2
+ + h1 = + + h 2 + ∑ h str
2⋅g γ1 2⋅g γ 2 1
PIPE RESISTANCE
l w2
∆p1 = λ ⋅ ⋅ ⋅ γ ⋅αo [Pa]
d 2g
2
l w
∆p1 = λ ⋅ ⋅ ⋅ ρ ⋅ αo [Pa]
d 2
l w2
∆h1 = λ ⋅ ⋅ ⋅ αo [m]
d 2g
λ = f(Re)
 COEFFICIENT OF FRICTION
w ⋅ρ⋅l w ⋅l
Re = =
η ν
Re<2320
64
λ=
Re
Re = 3000÷100000
0.3164
λ=
Re 0.25
Re = 3000÷100000
0.0221
λ = 0.0032 +
Re 0.237
LOCAL RESISTANCE OF FLOW

w2
∆p 2 = ξ ⋅ ⋅γ [Pa]
2g
w2
∆p 2 = ξ ⋅ ⋅ρ [Pa]
2
2
w
∆h 2 = ξ ⋅ [m]
2g
TOTAL RESISTANCE OF FLOW

w2  l 
∆p = ∆p1 + ∆p 2 = ⋅ ρ ⋅  ∑ λ ⋅ + ∑ ξ [Pa]
2  d 

Le w 2
∆p = λ ⋅ ⋅ρ
d 2 [Pa]

Le = l e 1 + l e 2 + ...+ l 1 + l 2 + ...
DRIVERS FOR MOVING
EQUIPMENT
Powered chemical processing equipment
includes pumps, compressors, agitators and
mixers, crushers and grinders, and conveyors.
Drivers are electric motors, steam or gas
turbines, and internal combustion engines.
Energy efficiencies vary widely with the size and
type of driver as shown in this table.
 DRIVERS AND POWER
RECOVERY EQUIPMENT
1. Efficiency is greater for larger machines.
2. Motors are 85-95%; steam turbines are 42-78%; gas engines and turbines are
28-38%.
3. For under 100 HP, electric motors are used almost exclusively.They are made
for up to 20,000 HP.
4. Induction motors are most popular. Synchronous motors are made for speeds
as low as 150 rpm and are thus suited for example for low speed reciprocating
compressors, but are not made smaller than 50HP. A variety of enclosures is
available, from weather-proof to explosion-proof.
5. Steam turbines are competitive above 1OOHP. They are speed controllable.
Frequently they are employed as spares in case of power failure.
6. Combustion engines and turbines are restricted to mobile and remote
locations.
7. Gas expanders for power recovery may be justified at capacities of several
hundred HP; otherwise any needed pressure reduction in process is effected
with throttling valves.
 FLUID TRANSPORT EQUIPMENT
PIPING

Standard pipe is made in a discrete number of sizes that are designated

by nominal diameters in inches, as “inches IPS (iron pipe size).”

VALVES
Control of flow in lines and provision for isolation of equipment when needed
are accomplished with valves.
PIPING JOINT

Flanged joint. Conical flanged joint.

 FLUID TRANSPORT EQUIPMENT
VALVES

Control of flow in lines and provision for isolation of equipment when

needed are accomplished with valves.

(a) Gate valve, for the majority of applications.

(b) Globe valve, when tight shutoff is needed.
(c) Swing check valve to ensure flow in one direction only.
VALVES

Globe valve.
Gate valve.
 VALVES

Angle valve. Diaphragm valve. Plug cock.

VALVES

Ball valve Butterfly valve. Swing check valve.

 LIFT CHECK VALVES

Lift check valve, vertical. Lift check valve, globe.

EXPANSION JOINT

Hinged expansion joint. Slip-type expansion joint.

PUMPS
PUMP SELECTION
PUMP SELECTION
 CENTRIFUGAL PUMP

(a) Single-stage, single suction volute pump.

(b) Flow path in a volute pump.
CENTRIFUGAL PUMP
 CENTRIFUGAL PUMP

(c) Double suction for minimizing axial thrust.

(d) Horizontally split casing for ease of maintenance.
 CENTRIFUGAL PUMP

e) Diffuser pump: vanes V are fixed, impellers P rotate.

f) A related type, the turbine pump.
 CENTRIFUGAL PUMP

e) Some types of impellers for centrifugal pumps. (a) Open impeller. (b) Semiopen
impeller. (c) Shrouded
f) impeller. (d) Axial flow (propeller) type. (e) Combined axial and radial flow, open
type. (f) Shrouded mixed-flow
g) impeller. (g) Shrouded impeller (P) in a case with diffuser vanes (V). (h) Turbine
impeller.
CHARACTERISTIC CURVE OF A
CENTRIFUGAL PUMP
CHARACTERISTIC CURVE OF A
CENTRIFUGAL PUMP
CHARACTERISTIC CURVE OF A
CENTRIFUGAL PUMP OPERATING AT
A CONSTANT SPEED
CHARACTERISTIC CURVE OF A
CENTRIFUGAL PUMP
AT VARIOUS SPEEDS
 AFFINITY LAWS

1. Capacity V (Q) is proportional to impeller rotational speed .

2. Head H (h) varies as square of the impeller rotational speed.
3. Break horsepower N (BHP) varies as the cube of the impeller rotational
speed.
SCHEMATIC OF A PUMP, MOVING A
FLUID FROM TANK (A) TO TANK (B)
Typically,head and flow follow the following
relationship:
PUMP SYSTEM WITH A VALVE FULLY
AND PARTIALLY OPEN.
 SPECIFIC SPEED Ns

Specific speed is a parameter that defines the speed at

which impellers of geometrically similar design have to
be run to discharge one gallon per minute against a one-
foot head.
VALUES OF SPECIFIC SPEED Ns
RELATIONSHIPS BETWEEN SPECIFIC
SPEED, ROTATIVE SPEED, AND
IMPELLER PROPORTIONS
HORIZONTAL PROCESS PUMP
VERTICAL IN-LINE PROCESS PUMP
MULTISTAGE CENTRIFUGAL PUMP
CLOSE-COUPLED PUMP.
CANNED-MOTOR PUMP
VERTICAL PROCESS PUMP FOR DRY-
PIT MOUNTING
TWO-STAGE PUMP HAVING DOUBLE-
SUCTION IMPELLERS
CHARACTERISTIC CURVE OF AN
AXIAL-FLOW PUMP
POSITIVE-DISPLACEMENT PUMPS
DUPLEX SINGLE-ACTING PLUNGER
PUMP
DOUBLE-ACTING SINGLE PLUNGER
PUMP
PNEUMATICALLY ACTUATED
DIAPHRAGM PUMP FOR SLURRY
SERVICE
POSITIVE-DISPLACEMENT GEAR-
TYPE ROTARY PUMP.
POSITIVE-DISPLACEMENT LOBE-
TYPE ROTARY PUMP.
G-rotor ROTARY PUMP
Internal GEAR PUMP
TWO-ROTOR SCREW PUMP
TWO-ROTOR SCREW PUMP
SINGLE-ROTOR SCREW PUMP WITH
AN ELASTOMERIC LINING
SIMPLIFIED SKETCH OF AN AIR LIFT,
SHOWING SUBMERGENCE AND
TOTAL HEAD.
A FORM OF ACID EGG
SIMPLE EJECTOR
ELECTROMAGNETIC PUMP
 PUMP AND VALVE SEAL

Seal cage or lantern ring. External mechanical seal

OPERATING POINTS OF
CENTRIFUGAL PUMPS UNDER A
VARIETY OF CONDITIONS.
 COMPRESSORS AND
VACUUM PUMPS

Fans are used to raise the pressure about

3%
Blowers raise to less than 40 psig,
Compressors to higher pressures.
COMPRESSOR COVERAGE CHART BASED
ON THE NORMAL RANGE OF OPERATION
OF COMMERCIALLY
AVAILABLE TYPES SHOWN.
STRAIGHT-BLADE, OR STEEL-PLATE,
FAN.
FORWARD-CURVED BLADE, OR
“SCIROCCO”-TYPE, FAN.
BACKWARD-CURVED-BLADE FAN.
TWO-STAGE AXIAL-FLOW FAN.
APPROXIMATE CHARACTERISTIC
CURVES OF VARIOUS TYPES OF
FANS.
 COMPRESSORS
Compressors are used to handle large volumes of gas at pressure
increases from 10.32 kPa (1.5lbg/in 2 ) to several hundred kPa (lbg/in 2 ).
We can divide compressors into two major categories:
1. Continuous-flow compressors.
a. Centrifugal compressors
b. Axial flow compressors
2. Positive displacement compressors
a. Rotary compressors
b. Reciprocating compressors
AXIAL-FLOW COMPRESSOR.
TWO-IMPELLER TYPE OF ROTARY
POSITIVE-DISPLACEMENT BLOWER.
SCREW-TYPE ROTARY
COMPRESSOR.
SLIDING-VANE TYPE OF ROTARY
COMPRESSOR.
LIQUID-PISTON TYPE OF ROTARY
COMPRESSOR.
TYPICAL SINGLE-STAGE, DOUBLE-
ACTING WATER-COOLED
COMPRESSOR.
REAL PROCESSES AND GASES
VACUUM
EQUIPMENT.
VACUUM LEVELS ATTAINABLE WITH
VARIOUS TYPES OF EQUIPMENT.
TYPICAL DIFFUSION PUMP.
TRANSFER OF SOLIDS

Slurry Transport

Screw Conveyors

Belt Conveyors

Bucket Elevators

Pneumatic Conveying
 SLURRY TRANSPORT
The velocity at this condition is called a critical velocity of whichone
correlation is.

u, = critical flow velocity,

u, = terminal settling velocity of the particle, given by Figure
5.1,
C, = volume fraction of solids,
D = pipe diameter,
d = particle diameter,
s = ratio of densities of solid and liquid,
g = acceleration of gravity, 32.2 ft/sec’, or consistent units.
 SLURRY
TRANSPORT

Settling velocities of spheres as a function

of the ratio ot densities of the two phases.
Stokes law applies at diameters below
approximately 0.01 cm
CONVEYORS FOR BULK MATERIALS
FEEDERS FOR BULK MATERIALS
 CLASSIFICATION SYSTEM FOR BULK
SOLIDS

Example: A material which is granular, very free-flowing, mildly abrasive, and mildly corrosive
would fall in classes C, 1, 7, and P, making its classification C17P.
MATERIAL CLASSES A D BULK DE
SITIES
 MECHANICAL CONVEYORS
SCREW CONVEYORS

SCREW CONVEYORS are suited to transport of even sticky and abrasive

solids up inclines of 20°or so. They are limited to distances of 150ft or so
because of shaft torque strength. A 12in. dia conveyor can handle 1000-
3000cuft/hr, at speeds ranging from 40 to 60 rpm.
MECHANICAL CONVEYORS
SCREW CONVEYORS
 MECHANICAL CONVEYORS
SCREW

b) Standard shape with pitch equal to the diameter, the paddles retard the forward
movement and promote mixing.
c) Short pitch suited to transfer of material up inclines of as much as 20°.
d) Cut flight screws combine a moderate mixing action with forward movement,
used for light, fine, granular or flaky materials.
e) Ribbon flights are suited to sticky, gummy orviscous substances.
SCREW-COVEYOR CAPACITIES AND
LOADING CONDITIONS
SCREW-CONVEYOR DATA for 50-lb/ft
3
 MECHANICAL CONVEYORS
BELT CONVEYORS

BELT CONVEYORS are for high capacity and long distances (a mile or more,
but only several hundred feet in a plant), up inclines of 30°maximum. A 24in.
wide belt can carry 3000 cuft/hr at a speed of 100ft/min, but speeds up to 600
ft/min are suited to some materials. Power consumption is relatively low.
 MECHANICAL CONVEYORS
BELT CONVEYORS

(d) A flat belt idler, rubber cushion type.

(e) Troughed belt idler for high loadings; usually available in 20”, 35”, and
45” side inclinations.
MECHANICAL CONVEYORS
BELT CONVEYORS
BELT-CONVEYOR DATA
 MECHANICAL CONVEYORS
CLOSED BELT CONVEYORS (ZIPPER)

Closed belt (zipper) for conveying in any direction

(a) Arrangement of pulley, feed hopper and open and closed belt regions.
MECHANICAL CONVEYORS
CLOSED BELT CONVEYORS (ZIPPER)

(b) The tubular belt

conveyor for
horizontal and
vertical transport; a
section of the
zippered closed belt
is shown.
(c) Showing how the
zipper closes (on
downward
movement of the
belt in this sketch)
or opens(on upward
movement of the
belt).
BUCKER ELEVATORS

BUCKER ELEVATORS are suited to vertical transport of sticky

and abrasive materials. With buckets 20 x 20 in. capacity can
reach 1000 cuft/hr at a speed of 100 ft/min, but speeds to 300
ft/min are used.
BUCKER ELEVATORS
 MECHANICAL CONVEYORS
DRUG-TYPE CONVEYORS

DRUG-TYPE CONVEYORS (Redler) are suited to short distances in any

direction and are completely enclosed. Units range in size from 3 in. square
to 19 in. square and may travel from 30 ft/min (flyash) to 250 ft/min (grains).
Power requirements are high.
APRON CONVEYORS
 MECHANICAL CONVEYORS
AND ELEVATORS
FEEDERS

(a) Bin discharge feeder.

(b) Rotary plate feeder with adjustable collar and speed.
(c) Flow controlled by an adjustable gate.
 MECHANICAL CONVEYORS
AND ELEVATORS
FEEDERS

(d) Rotary drum feeder, regulated by gate and speed.

(e) Rotary vane feeder, can be equipped with air lock for fine powders.
(f) Vane or pocket feeder.
 MECHANICAL CONVEYORS
AND ELEVATORS
FEEDERS

(g) Screw feeder.

(h) Apron conveyor feeder.
(i) Belt conveyor feeder.
 MECHANICAL CONVEYORS
AND ELEVATORS
FEEDERS

(j) Undercut gate feeder.

(k) Reciprocating plate feeder.
(l) Vibrating feeder,
 MECHANICAL CONVEYORS
AND ELEVATORS
FEEDERS

(n) Weighing belt feeder; unbalance ofthe weigh beam causes the material
flow rate onto the belt to change in the direction of restoring balance.
TYPICAL ARRANGEMENTS AND
APPLICATIONS FOR CONTINUOUS-
FLOW CONVEYORS.
 PNEUMATIC CONVEYING

PNEUMATIC CONVEYORS are for high capacity, short distance (400

ft) transport simultaneously from several sources to several
destinations. Either vacuum or low pressure (6-12psig) is employed
with a range of air velocities from 35 to 120ft/sec depending on the
material and pressure, air requirements from 1 to 7 cuft/cuft of solid
transferred.
PNEUMATIC CONVEYING
PNEUMATIC CONVEYING
PNEUMATIC CONVEYING
PNEUMATIC CONVEYING
PNEUMATIC CONVEYING
PNEUMATIC CONVEYING
 PNEUMATIC CONVEYING

Vacuum system with several sources and one destination, multiple

pickup;
 PNEUMATIC CONVEYING

pressure system with rotary valve feeder, one source and several
destinations, multiple discharge;
 PNEUMATIC CONVEYING
EQUIPMENT

Rotary positive displacement blower for pressure or vacuum.

A rotary airlock feeder for fine materials
PNEUMATIC CONVEYING
RECEIVERS

A four-compartment receiver-filter
A two-stagecyclone receiver
 PNEUMATIC CONVEYING
EGUIPMENT

The Fuller-Kinyon pump for cement and other fine powders. Powder
is fed into the aeration chamber with a screw and is fluidized with
compressed air
AIR VELOCITIES NEEDED TO CONVEY
SOLIDS
OF VARIOUS BULK