Appendix A: Design calculations

Belt conveyer:

Inlet = 2089 kg/day

After scale up = 2089 * 454.5 = 950 ton/day = 39.6 ton/hr

Specific gravity = 3.1

𝜌𝑜𝑟𝑒 =3100 𝑘𝑔 /𝑚 3

Width of conveyer = 50 cm = 20 in

At 20 in

50 (incline)

Speed = 100 ft/min= 6.39 ton/hr (capacity of conveyer) table 5.5, P79, [7]

𝑕𝑜𝑟𝑖𝑧𝑒𝑛𝑡𝑎𝑙 𝑙𝑒𝑛𝑔𝑡 𝑕 62
Length of conveyer = = = 62.3 𝑚 = 204.4 𝑓𝑡
𝐶𝑜𝑠 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑟𝑒𝑝𝑜𝑠𝑒 𝐶𝑜𝑠 5

Rise = 62*tan(5) = 5.4 m 17.72 ft

Speedmax = 425 ft/min table 5.5b , P79 , [7]

425
Corrected speed = 132 ∗ 100 = 322 𝑓𝑡/ min = 98 𝑚/𝑚𝑖𝑛

From chart 5.5-c (Walas)

425∗0.3
Pempty = = 1.275 𝑕𝑝
100

u = 322 ft/min

L1 = 204.4 ft

L2 = 2-3.4 ft

L3 = 17.72 ft
𝐿 𝐿2
HP = 0.001[(301 + 5)𝑢 + + 2𝐿3 𝑇] Eq5.26 , P81, [7]
16

HP = 35.13 hp = 26.2 kW

84: Appendix A
Main reactor:

 Rate of reaction

1.18 0.98
𝑚𝐶𝑎 𝐻2𝑃𝑂4 1.18
𝑚𝐻2𝑆𝑂4
−𝑟𝐴 = 𝐾 1−𝑥 ∗ (1 − 𝑥)0.98
𝑀𝑊𝐶𝑎 𝐻2𝑃𝑂4 𝑀𝑊𝐻2𝑆𝑂4

day 1.16
 Reaction rate constant (K) = 6.58 ∗ 10−6 koml 2.16 m 3

m (kg/day) MW(kg/kmol)
Ca(H2PO4)2 1035878.2 234
H2SO4 369690.3 98

kmol
 The value of the reaction rate −𝑟𝐴 = 7.02 m 3 day

 The design equation for the CSTR is

𝐹𝐴0 𝑋
𝑉=
−𝑟𝐴

𝑘𝑚𝑜𝑙
 From the mass balance: FA0 = 4426.8 𝑑𝑎𝑦

 The volume of the reactor is equal to

4426.8 ∗ 0.85
𝑉= = 535 𝑚3
7.02

 Assuming the effectiveness factor equal to 0.9

535
𝑉= = 594 𝑚3
0.9

85: Appendix A
 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑕𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 594 𝑚 3
 Resident tine for the main reactor 𝜏 = = 𝑚3
= 2.47 𝑕
𝑣𝑜𝑙𝑢𝑚𝑒𝑟𝑡𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 6367 .2
𝑑𝑎𝑦

 Assuming H=2D

𝜋 2
𝑉= 𝐷 𝐻
4

𝜋 3
𝑉= 𝐷
2

𝐷 = 7.5 𝑚

𝐻 = 15 𝑚

 Estimation the wall thickness of the reactor

 The head of the reactor is ellipsoidal head

 Material of construction: Carbon steel glass lined.

𝑃𝑟 𝑖
𝑡 = 𝑆𝐸 + 𝐶𝐶 Table 12-10, [8]
𝑗 −0.6𝑃

101.325 ∗ 7.5
𝑡= + 0.05 = 0.075 𝑚 = 7.5 𝑐𝑚
(1.3 ∗ 104 ∗ 0.85) − (0.6 ∗ 101.325)

 The design for the jacket of the reactor

From material balance the amount of heat should be removed is 5894.9 KW

The amount of water needed for cooling is given by the following equation

𝑄 = 𝑚𝐶𝑃 ∆𝑇

5894.9 𝑘𝐽/𝑠
𝑚= = 21.6 𝑘𝑔/𝑠
𝑘𝐽
4.18 ∗ (90 − 25)
𝑘𝑔 𝐶

86: Appendix A
For water inter at 25 °C and exit at 90°C, the area needed for heat transfer is given

by the following equation:

𝑇 −𝑡 𝑈𝐴𝜃
𝑙𝑛 𝑡 1 −𝑡 1 = 𝑚 𝐶 [2]
2 1 𝑝

𝑈 = 133 W/m2 k

98 − 25
21.6 ∗ 4.18 ∗ 𝑙𝑛
𝐴= 90 − 25 = 362.8 𝑚2
133 ∗ 0.0053

87: Appendix A
Reslurry reaction tank

 Rate of reaction:

-rA = KG [𝑋𝐶𝑎 𝑃𝑂 4 𝐹3 𝑋𝐻3 𝑃𝑂4 ][𝛾𝐶𝑎 𝑃𝑂 4 𝐹3 𝛾𝐻3 𝑃𝑂4 ][1-X]

KG=K*KCS

 From the mass balance

𝑋𝐶𝑎 𝑃𝑂 4 𝐹3 = 0.107

𝑋𝐻3 𝑃𝑂4 = 0.306

𝛾𝐶𝑎 𝑃𝑂 4 𝐹3 = 0.51

𝛾𝐻3 𝑃𝑂4 = 0.72

𝐾𝑚𝑜𝑙
KCS= 4.8𝑚 3 𝑑𝑎𝑦

K =7.1

𝐾𝑚𝑜𝑙
-rA = 1.86 𝑚 3 𝑑𝑎𝑦

 The design equation for CSTR is given by the following equation

𝐹𝐴0 𝑋
𝑉=
−𝑟𝐴

 From the mass balance

FA0 = 904.5 kmol/day

88: Appendix A
 The volume of the reslurry reaction tank is equal to

904.5 ∗ 0.85
𝑉= = 413 𝑚3
1.86

 Assuming the effectiveness factor equal to 0.9

413
𝑉= = 459 𝑚3
0.9

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑕𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 459 𝑚 3

 Resident tine for the main reactor 𝜏 = = 𝑚3
= 2.51 𝑕
𝑣𝑜𝑙𝑢𝑚𝑒𝑟𝑡𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 4386 .7
𝑑𝑎𝑦

 Assuming H=2D

𝜋 2
𝑉= 𝐷 𝐻
4

𝜋 3
𝑉= 𝐷
2

𝐷 = 6.6 𝑚

𝐻 = 13.2 𝑚

 Estimation the wall thickness of the reactor

 Material of construction: carbon steel glass lined.

𝑃𝑟 𝑖
𝑡 = 𝑆𝐸 + 𝐶𝐶 Table 12-10, [8]
𝑗 −0.6𝑃

101.325 ∗ 6.6
𝑡= + 0.05 = 0.065 𝑚 = 6.4 𝑐𝑚
(1.3 ∗ 104 ∗ 0.85) − (0.6 ∗ 101.325)

89: Appendix A
 Crystallizer Design:
 Crystallization kinetics:

 Nucleation rate

j
B° = KRMT Gi

 Nuclei population density

B° j
n° = = KRMT Gi−1
G

 Population density
−L
n = n° e Gτ

 Growth rate
1
1−j i−1
13.5 M T
G=
f v ρc K R L 4d

 Residence time
Ld
τ=
3G
1
L d f v ρ c K R L 4d i−1
τ=
3 13.5 M 1−j
T

 The crystallizer volume

V=τQ
Where: Q is the Slurry volumetric flow rate [m3/hr]
τ is the residence time [hr]

90: Appendix A
 Crystal characteristics:

 Median crystal size, Ld = 40 µm.

kg
 Crystal density, ρc = 2320 m3

π
 Volume shape factor, fv = 4

 Kinetic equation for B°

B° = 8.59×1033 G3.2, [Crystallization kinetics from MSMPR crystallizers, John Garside and

Mukund B. shah, Ind. Eng. Chem. Process Des. Dev. 1980, 19, 509-514]

o KR = 8.58×1033
o j=0
o i = 3.2
o MT = 10 kg/m3
 Calculations:
1
3.2−1
13.5×10
 G= 4
𝜋
4
×2320×8.59×1033 × 4×10−5

G = 1.143 × 10-8 m/s

𝐿𝑑
τ=
3G

4×10−5
τ= = 1167 second
3×1.143×10−8

τ = 0.32 hr
The calculated residence time is not close to the actual one that is used in the industry,

thus; the residence time will be choose from Crystallization Technology Handbook.

91: Appendix A
 τ = 5 hr, [Table A2.1 Data of Large-Scale Industrial Crystallizers]

 Nuclei Population density:

B°
n° = = 8.59 × 1033 G3.2-1
G

8.59×10 33 × 1.143×10 −8 3.2

n° =
1.143×10 −8

n° = 2.9 × 1013 nuclei/mm.L

 Population density

n = n° 𝑒 −𝐿/(𝐺𝜏 )

−4×10 −5
13
n = 2.9 × 10 × 𝑒 1.143 ×10 −8 ×18000

n = 2.4 × 1013 crystal/mm.L

 Slurry density

ρ𝑠𝑙𝑢𝑟𝑟𝑦 = 𝜈𝐻𝐻 𝜌𝐻𝐻 + 𝜈𝐻3 𝑃𝑂4 𝜌𝐻3 𝑃𝑂4 + 𝜈𝐻2 𝑂 𝜌𝐻2 𝑂

2866 1623 671
ρ𝑠𝑙𝑢𝑟𝑟𝑦 = × 2320 + × 2300 + × 1000
5160 5160 5160

kg
ρ𝑠𝑙𝑢𝑟𝑟𝑦 = 2145
m3

 Slurry volumetric flow rate

5160𝑘𝑔 𝑠𝑙𝑢𝑟𝑟𝑦 1 𝑑𝑎𝑦 1 𝑚3
Q= × × ×454.5
𝑑𝑎𝑦 24 𝑕𝑟 2145 𝑘𝑔 𝑠𝑙𝑢𝑟𝑟𝑦

92: Appendix A
 m3
Q = 45
hr

 The crystallizer volume:

m3
V = 5 hr × 45
hr

V = 225 m3

 As a rule of thumb
H
The diameter of the crystallizer is half the height, D =
2

𝜋
V= 𝐷2 𝐻
4

𝜋
V= 𝐷2 (2𝐷)
4

𝜋
225 = 𝐷3
2

D =5.23m,

Height = 11m

 Material of construction:Stainless Steel 316

 Wall thickness

𝑃 𝑟𝑖
t= + 𝐶𝑐 Joint efficiency: EJ = 1, spot examined
𝑆 𝐸𝐽 −0.6𝑃

70× 5.5
t= + 0.004 Working Stress: S =128000 kPa
128000 ×1 −(0.6×70 )

t = 0.0342 m Allowance for corrosion: Cc = 0.004 m

t = 3.42 cm Inside radius of shell: ri = 5.5 m

t = 1.35 in. Pressure: P = 70 kPa

93: Appendix A
 To insure a safe design let wall thickness equal to 2 inches.

Figure 28: scanning electron micrograph of solid hemihydrates crystals at 500 times magnification

Figure 29: scanning electron micrograph of solid hemihydrates crystals at 2000 times magnification.

94: Appendix A
Condenser design:

 Condenser heat load:

q = -13.23 kW, from energy balance.

After multiplying with scale up factor

q = -13.23 *454.5 = 6013 kW

 Surface Area of the condenser

𝑊
q = UAΔT U= 410𝑚 2 .𝐾 ,
applied process for chemical engineering, vol. 3, b third edition Table 10.15,

q 6013 ×1000
A= = = 201 m2
UΔT 410 ×(98−25)

3
 Using 20 mm outside diameter, 4.88 m tubes ( 4 in. × 16 ft)

 Area of one tube = π D L = π × (20 ×10−3 ) × 4.88 = 0.306 m2

201
 Number of tubes = 0.306 = 657

 Using one pass, square pitch configuration:

 Shell ID: 0.787 m , plant design and economics for chemical engineers, fifth edition

 Shell thickness: 0.0254 m

 Baffle height is 75 percent of the inside diameter of the shell

Baffle height = 0.75 × 0.787 = 0.59 m

 Baffle spacing is 25 percent of the inside diameter of the shell

Baffle spacing = 0.25 × 0.787 = 0.20 m

95: Appendix A
 tube length
 Number of baffles = baffle spacing

4.88
Number of baffles = = 25
0.2

 Material of construction: Stainless Steel 316

 A mist Eliminator was selected which is consisting of a packed fibered

between either two concentric screens or two flat parallel screens.

Figure 30: Mist eliminator

96: Appendix A
 Benefits of having such a mist eliminator in the crystallizer:

 Capture sub-micron mist particles 0.1 micron or smaller

 Reduce or eliminate visible stack gas plumes

 Provide unlimited turndown from design capacity

Crystallizer feed pump design:

 Material of construction: Stainless steel

 Type: Gear pump

 Drive: Electrical

 𝜌𝑠𝑙𝑢𝑟𝑟𝑦 = 𝑋𝑖 𝜌𝑖 = 𝑋𝐻2𝑂 𝜌𝐻2𝑂 + 𝑋𝐻𝐻 𝜌𝐻𝐻 + 𝑋𝐻3𝑃𝑂4 𝜌𝐻3𝑃𝑂4

XH2O = 0.33 𝜌H2O = 1000 kg.m3

XHH = 0.35 𝜌HH = 2320 kg/m3

XH3PO4 = 0.32 𝜌H3PO4 = 1830 kg/m3

𝜌slurry = (0.33 * 1000) + (0.35 * 2320) + (0.32 * 1830)

𝜌slurry = 1727.6 kg/m3

6216 .8 kg 1 day 1 hr 1 m3 𝑚3
 𝑚𝑣 = × × 3600 sec × ×454.5 = 0.0189 𝑠𝑒𝑐
day 24 hr 1727 .6 kg

 From figure 12-13, plant design, Peters

 At mv = 68.1 m3/hr

 H = 90 N.m/kg

 Power output

97: Appendix A
 𝐻 𝑚𝑣 𝜌
𝑊° =
103
90 ×0.0189 ×1727 .6
𝑊° = = 2.9 kW
10 3

 Power input
P out 2.9
𝑃𝑖𝑛 = = 0.65 = 4.46 kW
𝜂

 Material of construction:

Stainless Steel case, gears, and shaft

98: Appendix A
Scrubber:

Stream 1

GA1 = 17726 kg/day = 886 kmol/day

GB1 = 8863 kg/day = 147.7 kmol/day

GC1 = 227250 kg/day = 7836.3 kmol/day

GA2 , GB2 , GC2
886 886.3 L XA2 , XB2 , XC2
XA1 = 886+147.7+7836 .3 = = 0.1
8870 .3
3 2
147.7
XB1 = = 0.01665
8870

7836 .3 Scrubber
Scrubber
XC1 = = 0.883
8870

PA1 =XA1*PT Daltons law

P=1 atm
P=1 atm
PA1 = 0.1*101325 = 10132.5 Pa

Stream 2
T=98OOC
T=98 C
GA2 = 43.7 kmol/day

GB2 = 7.3 kmol/day

GC2 = 7836.3 kmol/day

43.7 43.7 4 1
XA2 = 43.7+7.3+7836 .3 = = 5.54 ∗ 10−3 E , GA , GB , L
*
GA1 , GB1 , GC1
7887 .3
XA1 , XB1 , XC1
7.3
XB2 = 7887 .3 = 9.25 ∗ 10−4

7836 .3
XC2 = 7887 .3 = 0.993

PA2= XA2*PT = 5.54 ∗ 10−3 ∗ 101325 = 561 Pa

Hatta number (to tell whether reaction is fast or slow)

𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 𝑘 1 𝐶𝐵 𝐷𝐴𝐿

MH = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 = Eq22, P550, levenspiel
𝑑𝑖𝑓𝑓𝑢𝑠𝑖𝑜𝑛𝑎𝑙 𝑡𝑟𝑎𝑛𝑠𝑝𝑜𝑟𝑡 𝑘 𝐴𝐿

−4980
Etching rate = 4.5*109 [HF] 𝑒𝑥𝑝 𝑇 (mol/min) Eq3-1,modeling for control of an etching
process
−4980
1- At T = 98C k1 = 4.5*109 [HF] 𝑒𝑥𝑝 371 = 6662 min-1

99: Appendix A
 𝑇
2- DAL = 1.173 * 10-16 (ф ML)0.5 µ 0.6 Eq6.3-9, transport processes, Geankoplis
𝐵 𝑉𝐴

VA= H+F = 0.0037+0.0087 = 0.0124 m3/kmol

Ф= 2.6 for water

ML= 18 kg/kmol

At T= 98C , µB = 2.899 * 10-4 Pa.s

371
DAL = 1.173 * 10-16 (2.6*18)0.5 2.899∗10 −4 ∗0.0124 0.6 = 1.43*10-8 m2/s

𝑃 0.0166 5
3- CB= 𝑅𝑇𝐵 = = 0.547 𝑚𝑜𝑙/𝑚3
8.2∗10 −5 ∗371

4- KAL= (DAL k1)0.5 Eq6.14-3, scaling analysis in modeling transport and

reaction

KAL = (1.43*10-8 * 6662)0.5 = 9.76*10-3 m/s

6662 ∗ 0.547∗ 1.43∗10 −8

5- MH = = 0.74 (intermediate reaction)
9.76∗10 −3

To find the volume

𝐹𝑔 𝑃𝐴 1 𝑑𝑃 𝐴
V= ∗ 𝑃𝐴 2 𝑟 𝐴 𝑎
Eq10,P563, levenspiel
𝛱

Fg = 8870 kmol/day = 6160 mol/min

a= 92 m2/m3 using 2in rasching rings, table10.6-1, Geankplis

−4980
rA = 4.5*109 * [A] 𝑒𝑥𝑝 𝑇 =

at T = 98C
𝑃 6662
rA = 6662 * 𝑅𝑇𝐴 = 8.314∗371 * 𝑃𝐴 = 2.16 * PA
rA.a = 2.16 * PA * 92 = 198 * PA

PA1 = 10132.5 Pa
PA2 = 561 Pa

100: Appendix A
substitute in Eq10

6160 10132 .5 𝑑𝑃𝐴

V= ∗ 561
= 9.908 * ln(10132.5/ 561) = 28.7 m3
3.14 199∗𝑃𝐴

Assume H=5D the commercial one, from Tri-Mer Packed bed Tower
scrubbers

V = 28.7 m3 = (𝛱/4)(D2)(H)

D = 1.94 m
H = 9.7 m

101: Appendix A
Filter

𝛼° × μ
𝐴 = 𝑚𝑐 ×
2 × c × ∆p1−s × g c × f × n

mc=mass flow rate for the cake (kg/s)

α̊̊=cake resistanceα

C= amount of dry cake per m3 slurry

∆p=pressure drop

f= fraction of submergence

n= 1/washing time

2866 .2∗454.5
mc= =15.077 Kg/s (from material balance)
24∗3600

𝑐𝑓
𝑐=
𝑚𝑓 𝑐𝑓
1 − 𝑚𝑐 − 1 × 𝜌

mass flow rate of solid

cF=volumetric (kg solid/m3 feed liquid)
flow rate of liquid feed

mf=mass flow rate of filtrate

mc=mass flow rate for the cake

ρL=Liquid feed density (kg liquid feed/m3)

102: Appendix A
 2866.2 × 454.5
𝑐𝑓 = = 1840
671 ∗ 454.5 1623 × 454.5
+
1000 1832

1840
𝑐= = 1381.8
2111 1840
1 − [2866.2 − 1] × 1462

7.1×10 7 ×12.1×10 −3
𝐴 = 15.077 × 1 = 493 m2
2×1831 .8×50000 .46 ×.6×
5×60

Width of filter = 3 m table 15-17, [8]

493
Length of filter = =165m
3

165 m
Speed of filter = = 0.55m/s
300 s

Filter media is Polypropylene

Polypropylene Fabrics Series, which made of polypropylene fiber (PP),

can be divided into PP staple fabrics, PP long thread fabrics, and PP

monofilament fabrics. These products possess the properties of acid-

resistance, alkali-resistance, small specific gravity, the melting point

142—146 degree, and normal working temperature maximum 90. They are mainly used

in the precision chemical, dye chemical, sugar, pharmaceutical, alumina industrial, for the

equipments of frame press filter, belt filter, blend belt filter, disc filter, drum filter etc.

The filtering precision can reach less than 1 micron.

103: Appendix A
Tanks:

H2SO4 tank:

Inlet before scale up = 813.4 kg/day

After scale up = 8.13.4 * 454.5 = 369690 kg/day

Storage for one week

Mass of H2SO4 369690*7 = 2587830 kg

Density of H2SO4 at T 25C = 1840 kg/m3

Volume of H2SO4 = volume of tank = (2587830 kg)/(1840 kg/m3) = 1406 m3

1406 = (𝛱/4)*(D2)*(H) for tank H = 2D

1406 = (𝛱/4)*(2D3)

D = 9.64 m , H = 19.28 m

The thickness of the tank

Material of construction is carbon steel table 10-9 [8]

At T = 25C, S = 1.35*105 kPa table 13-2, [6]

Optimum value of Ej = 0.85

𝑃𝑟 𝑖
t = 𝑆𝐸 + 𝐶𝐶 table 12-10, [8]
𝑗 −0.6𝑃

101.325∗4.82
t= + 0.05 = 0.054 𝑚 = 5.4 𝑐𝑚
(1.35∗10 5 ∗0.85)−(0.6∗101.325)

104: Appendix A
Water tank:

Inlet before scale up = 1535.4 kg/day

After scale up = 1535.4 * 454.5 = 697839 kg/day

Storage for one week

Mass of H2O = 697839*7 = 4884873 kg

volume of H2O = volume of tank = (4884873 kg)/(1000 kg/m3) = 4884.9 m3

divide this tank into two tanks = 4884.9 m3/2 = 2442.45 m3

2442.45 = (𝛱/4)*(D2)*(H) for tank H=2D

2442.45 = (𝛱/4)*(2D3)

D = 11.6 m , H = 23.2 m

The thickness of the tank

Material of construction is carbon steel

S = 1.35*105 kPa table 13-2, [6]

𝑃𝑟 𝑖 101.325∗5.8
t = 𝑆𝐸 + 𝐶𝐶 = + 0.03 = 0.035 𝑚 = 3.5 𝑐𝑚
𝑗 −0.6𝑃 1.35∗10 5 ∗0.85 − 0.6∗101.325

105: Appendix A
Filter feed tank:

Inlet before scale up = 5160.2 kg/day

After scale up = 5160.2 * 454.5 = 2345311 kg/day

Storage for one week

Mass of slurry = 2345311*7 = 16417177 kg

𝜌𝑎𝑣𝑔 = 𝑋𝑖 𝜌𝑖 = 𝑋𝐻3𝑃𝑂4 𝜌𝐻3𝑃𝑂4 + 𝑋𝐶𝑎𝑆𝑂 4 𝜌𝐶𝑎𝑆𝑂 4 + 𝑋𝐻2𝑂 𝜌𝐻2𝑂

737653 .5 737653 .5
XH3PO4 = 737653 .5+1302688 +304969 .5 = = 0.314
2345311

1302688
XCaSO4 = 2345311 = 0.556

304969 .5
XH2O = 2345311 = 0.13

At T = 25C

𝜌𝐻3𝑃𝑂4 = 1685 𝑘𝑔/𝑚3

𝑘𝑔
𝜌𝐶𝑎𝑆𝑂 4 = 2320
𝑚3
𝜌𝐻2𝑂 = 1000 𝑘𝑔/𝑚3

𝜌𝑎𝑣𝑔 = 0.314 ∗ 1685 + 0.556 ∗ 2320 + 0.13 ∗ 1000 = 1950 𝑘𝑔/𝑚3

Volume of slurry = volume of tank = (16417177 kg)/(1950 kg/m3) = 8419 m3

Divide this tank into three tanks = 8419 m3/3 = 2806 m3

2806 = (𝛱/4)*(D2*H) for tank H=2D

2806 = (𝛱/4)*(2D3)

D = 12.1 m , H = 24.2 m

The thickness of the tank

S = 1.35*105 kPa
𝑃𝑟 𝑖 101.325∗6.05
t = 𝑆𝐸 + 𝐶𝐶 = + 0.06 = 0.065 𝑚 = 6.5 𝑐𝑚
𝑗 −0.6𝑃 1.35∗10 5 ∗0.85 − 0.6∗101.325

106: Appendix A
Ore Storage (feeder):

Inlet before scale up = 2089 kg /day

After scale up = 2089*454.5 = 949450.5 kg/day

Storage for one week

Mass of ore = 949450.5*7 = 6646153.5 kg

Volume of ore = volume of feeder = (6646153.5 kg)/(3100 kg/m3) = 2144 m3

2144 = (𝛱/4)*(D2*H) H=2D

D = 11 m , H = 22 m

The thickness of the feeder

t = [(Pri)/(SEj – 0.6P)] + CC = [(101.325*5.5)/((1.35*105*0.85) – (0.6*101.325))] + 0.05

t = 0.055 m = 5.5 cm

107: Appendix A
Crystallizer product and Filter feed pumps:

 Material of construction: Stainless steel

 Type: Gear pump

 Drive: Electrical
𝐻𝑚 𝑣 𝜌
 Wo = Eq12-20a, [6]
10 3

 𝜌𝑠𝑙𝑢𝑟𝑟𝑦 = 𝑋𝑖 𝜌𝑖 = 𝑋𝐻2𝑂 𝜌𝐻2𝑂 + 𝑋𝐻𝐻 𝜌𝐻𝐻 + 𝑋𝐻3𝑃𝑂4 𝜌𝐻3𝑃𝑂4

XH2O = 0.13 𝜌H2O = 1000 kg.m3

XHH = 0.55 𝜌HH = 2320 kg/m3

XH3PO4 = 0.32 𝜌H3PO4 = 1830 kg/m3

𝜌slurry = (0.13 * 1000) + (0.55 * 2320) + (0.32 * 1830)

𝜌slurry = 1991.6 kg/m3

 mv (m3/s)

mv = mm/ 𝜌slurry

mm = 5160.2 kg/day *454.5 = 12345311 kg/day = 97721.3 kg/hr = 27.15 kg/s

𝑘𝑔
27.15
𝑠 𝑚3
mv = 𝑘𝑔 = 0.0136
1991.6 3 𝑠
𝑚

 H (N.m/kg)
𝑘𝑔
97721 .3
𝑕𝑟 𝑚3
mv = 𝑘𝑔 = 49.1 𝑕𝑟
1991.6 3
𝑚

From figure 12-13, plant design, Peters

At mv = 49.1 m3/hr

H = 125 N.m/kg
𝐻𝑚 𝑣 𝜌 125∗0.014∗1991.6
Wo = = = 3.4 𝑘𝑊
10 3 10 3

108: Appendix A
 Power input
P out 3.4
𝑃𝑖𝑛 = = 0.65 = 5.23 kW
𝜂

 Material of construction: Stainless Steel case, gears, and shaft

109: Appendix A
Piping system:

 Sulfuric acid pipe line:

o Assume turbulent flow

o 𝜌H2SO4 = 1831 kg/m3

o 𝜇 = 15 𝑐𝑃

Di,opt = 0.365 ∗ m0.45

v ∗ ρ0.13

813.4 ∗ 454.5 𝑘𝑔 𝑚3 𝑑𝑎𝑦 𝑕𝑟 𝑚3

𝑚𝑣 = ∗ ∗ ∗ = 0.0023
𝑑𝑎𝑦 1831 𝑘𝑔 24 𝑕𝑟 3600 𝑠 𝑠

Di,opt = 0.365 ∗ 0.00230.45 ∗ 18310.13 = 0.148 m

From table D-13 peter

Nominal pipe size=6 in

For schedule number 40

OD = 6.625in ID = 6.065 in

Material of construction: carbon steel.

𝑣𝐷𝜌
Check Renold’s number: 𝑅𝑒 = 𝜇

v= 2 m/s table 12-3 peter

2∗0.148∗1831
𝑅𝑒 = = 36131
15∗10 −3

Re>2100, the assumption is correct

110: Appendix A
 Water pipe line:

o Assume turbulent flow

o 𝜌H2O = 1000 kg/m3

o 𝜇 = 0.218 𝑐𝑃

Di,opt = 0.365 ∗ m0.45

v ∗ ρ0.13

1535.4 ∗ 454.5 𝑘𝑔 𝑚3 𝑑𝑎𝑦 𝑕𝑟 𝑚3

𝑚𝑣 = ∗ ∗ ∗ = 0.0081
𝑑𝑎𝑦 1000 𝑘𝑔 24 𝑕𝑟 3600 𝑠 𝑠

Di,opt = 0.365 ∗ 0.00810.45 ∗ 10000.13 = 0.196 m

From table D-13 peter

Nominal pipe size=8 in

For schedule number 40

OD = 8.625in

ID = 7.981 in

Material of construction: cast iron

𝑣𝐷𝜌
Check renold’s number:𝑅𝑒 = 𝜇

v= 2 m/s table 12-3 peter

2∗0.196∗1000
𝑅𝑒 = = 139 ∗ 104
0.281∗10 −3

Re>2100, the assumption is correct

111: Appendix A
 Phosphoric acid pipe line

o Assume turbulent flow

o 𝜌H3PO4 = 1830 kg/m3

o 𝜇 = 2.4 𝑐𝑃

Di,opt = 0.365 ∗ m0.45

v ∗ ρ0.13

2111 ∗ 454.5 𝑘𝑔 𝑚3 𝑑𝑎𝑦 𝑕𝑟 𝑚3

𝑚𝑣 = ∗ ∗ ∗ = 0.0061
𝑑𝑎𝑦 1830 𝑘𝑔 24 𝑕𝑟 3600 𝑠 𝑠

Di,opt = 0.365 ∗ 0.00610.45 ∗ 18310.13 = 0.202 m

From table D-13 peter

Nominal pipe size=8 in

For schedule number 40

OD = 8.625in

ID = 7.981 in

Material of construction: carbon steel coated by polypropylene

𝑣𝐷𝜌
Check renold’s number:𝑅𝑒 = 𝜇

v= 2 m/s table 12-3 peter

2∗0.202∗1830
𝑅𝑒 = = 308 ∗ 105
2.4∗10 −3

Re>2100, the assumption is correct

112: Appendix A
 Slurry pipe line

o Assume turbulent flow

o 𝜌slurry = 2164 kg/m3

o 𝜇 = 1.3 𝑐𝑃

Di,opt = 0.365 ∗ m0.45

v ∗ ρ0.13

6216 ∗ 454.5 𝑘𝑔 𝑚3 𝑑𝑎𝑦 𝑕𝑟 𝑚3

𝑚𝑣 = ∗ ∗ ∗ = 0.015
𝑑𝑎𝑦 2164 𝑘𝑔 24 𝑕𝑟 3600 𝑠 𝑠

Di,opt = 0.365 ∗ 0.0150.45 ∗ 21640.13 = 0.371 m

From table D-13 peter

Nominal pipe size=16 in

For schedule number 30

OD = 16in

ID = 15.25 in

Material of construction: carbon steel coated by polypropylene

𝑣𝐷𝜌
Check renold’s number:𝑅𝑒 = 𝜇

v= 2 m/s table 12-3 peter

2∗0.371∗2164
𝑅𝑒 = = 1.2 ∗ 106
1.3∗10 −3

Re>2100, the assumption is correct.

113: Appendix A