APOSTILA - Tópicos Especiais de EQ (Prof Delmiro)
APOSTILA - Tópicos Especiais de EQ (Prof Delmiro)
APOSTILA - Tópicos Especiais de EQ (Prof Delmiro)
DE ENGENHARIA
QUÍMICA
1
Aplicação do Metodo com Líquidos Viscosos
A Bomba Centrifuga possue duas significativas Perdas de Performance, causadas pelo Atrito do Liquido
e pela Fricção do Impelidor. Estas Perdas variam diretamente com a Viscosidade do Líquido sendo
bombeado, em que ambas a Altura Manométrica e a Energia Mecânica diferem quando se trabalha com
Água (baixa viscosidade) e um Líquido de Viscoso, maior que 440 cP. Nesta citada viscosidade a
eficiência da Bomba Centrífuga deteriora na relação Custo x Benefício. Nesta ordem de grandeza de
Viscosidade, já é recomendado a troca do tipo de Bomba, para Deslocamento Positivo.
Mas este efeito de Viscosidade na Performance de Bomba Centrífuga foi profundamente estudado pelo
Instituto de Hidráulica Americano, em que foi desenvolvido um Método específico para considerar estes
efeitos. Este Método é descrito abaixo.
Definições :
Fatores de correção :
Formulas :
Qvis = Qw x CQ
Hvis = Hw x CH
Nvis = Nw x CN
Todos os fatores serão obtidos das Figuras 71 (baixo fluxo de bombeamento) ou 72 (alto fluxo de bombeamento)
2
Figura 71 para Fluxo de 10 a 100 GPM
1.00
.90
CH
.80
CORRECTION FACTORS
.70
.60
.50
CQ
.40
.30
CE
.20
.10
CENTISTROKES
0
1320
1760
2200
132
176
220
330
440
660
880
4.5
7.4
10
15
20
32
45
66
88
0
40
0
30
0
20
0
15
0
10 0
8
60
40
30
20
18
10
8
6
10,0
00
8,00
0
400
30
0
6,00
HEAD IN FEET
0
200
1 5
0
0
100
4,00 ,000
8
60
0
40
3
30
20
18
2,00
10
8
0
1,00
6
150
600
40
50
80
300
200
400
800
60
100
VISCOSITY - SSU
1,50
0
10 15 20 25 30 40 50 60 70 80 90 100
0
3
Figura 72 para Fluxo de 100 a 10000 GPM
Para utilização do gráfico abaixo deve-se dividir o Fluxo utilizado por 100
1.00
.90 C
H
HEAD
-1.0 x Qnw
.60
-1.2 x Qnw
1.00
CAPACITY AND EFFICIENCY
.90
.80
C
.70 Q
.60 C
E
.50
.40
.30
880 66
176 132
3,3 200
1,3
2, 0
.20
1,7 0
00
330
CENTISTOKES
220
440
2
32
43
88
15
20
65
6
10
0
0 40
60 0
3 0 0 20
0 0 0
1 5 1
8 0 60
40
HEAD IN FEET
0
60
0 0 0
40 3 0
0 0 15
2
0 80
10 0
60 4
30 20
15,
100 80
800 60
60
4,0
2,0 0
200 15
1,5 1,
40
8,0
400 300
15
00010,00
00 3,00
00
0
0 0 6,00
0
0
000
0
0
1 2 4 6 8 10 15 20 40 60 80 100
Reprinted from the STANDARDS OF THE HYDRAULIC INSTITUTE, Tenth Edition.
Copyright 1955 by the Hydraulic Institute, 122 East 42nd St, New York 17 New York
4
5
6
EXERCÍCIOS DE APLICAÇÃO - Bomba Centrífuga com Líquidos Viscosos
. Selecione qual a melhor rotor para este serviço, considerando a curva característica fornecida
. Qual o head final, qual a rotaçào, qual o diâmetro do rotor selecionado,Qual a eficiência,NPSH
req,NPSH disponível,BHP
7
8
2. Resina é bombeada de um tanque de estocagem atmosférico para um reator. Este líquido
está a 65 C, pressão de vapor de 0,05 psia., fluxo de 17 m3/h. Considerar diâmetro de
sucção e descargas iguais.
Dados :
Queda de pressão por atrito na tubulação
Sucção : 1 mcl
Descarga : 24 mcl
Trocador : 10 psi
Válvula de Controle : 5 psi
Medidor de Fluxo : 5 psi
Filtro tipo Manga : 5 psi
Altura de alimentação no reator : 6m
Altura de sucção à bomba : 2m
Pressão reinante no Reator : 70 psi
. Selecione qual a melhor rotor para este serviço, considerando a curva característica fornecida, e
responda os items abaixo :
. Qual o head final,Qual o diâmetro do rotor selecionado,Qual a eficiência,NPSH req,NPSH
disponível,BHP
9
3. Propileno Glicol 100% WT é bombeado de um Vaso de Processo para um reator. Está a 10 C, com
as propriedades listadas abaixo. O fluxo de projeto é de 20 m3/h . Considerar diâmetro de sucção e
descarga de de 4” sch40.
Sucção : 2 mcl
Descarga : 20 mcl
Trocador : 1 Bar
Válvula de Controle : 1 Bar
Medidor de Fluxo : 0.5 Bar
Filtro tipo Manga : 0.4 Bar
Altura de alimentação no reator : 20 m
Altura de sucção à bomba : 2m
Pressão no Vaso de Processo : 1 Bar
Pressão reinante no Reator : 2 Bar
• Tendo como referencia o Catalogo de Seleção da Goulds, 3196, selecione qual a melhor Bomba
para este serviço, e forneça os dados abaixo :
a. AMT em m
b. NPSHa
c. Coeficientes de Correção de Viscoso x Água
d. Modelo da Bomba Centrifuga Selecionado
e. RPM
f. Rotor selecionado em in
g. Eficiencia deste serviço em %
h. NPSHr em m
i. BHP em KW
j. Motor Recomendado em HP
10
11
TOPICS
• Steam Refresh
- Basics
- Pressure x Temperature
• Quality
- Free of Condensate and Incondensables
- Thermostatic
- Thermodynamics
- Float
- Inverted Bulk
• Condensate Recovery
- Flash Steam
- Piping Return
• Energy Conservation
12
13
14
15
16
17
18
19
20
Thermodynamic Trap – Performance Charts &
Design
Vendors Methods
There are reliable Methods from Armstrong, Spirax-Sarco and Flowserve
(Gestra), available at Internet.
Care should be taken not to oversize a thermodynamic trap as this can
increase cycle times and induce wear. Mains drainage applications often
only need to be fitted with low capacity versions, providing proper
consideration is given to siting the drain pockets correctly.
21
Condensate Load – Examples -
Armstrong
22
STEAM TRAPS - HEAT EXCHANGERS
Steam Trap has so important to keep Chemical Plant running accordingly needed
demand, that assure the correct use of Steam Latent Heat to the Exchanger Cold
Side.
Let’s assume a Falling Film Vaporizer . A Bad design, small Condensate drainage,
flooding Vaporizer, working only with Sensible Heat, reducing drastically Heat
Transfer and thermal performance.
Consequence : Plant Capacity reduction , destruction of Profit, no Value
aggregated to the Business.
A reliable and accuracy Process Data Treatment must be done, a rigorous Mass &
Energy balance around the Heater or Vaporizer involved in this case or design.
. Manual calculation, closing a Balance around Exchanger Cold and Hot Streams,
based on Inlet and Outlet enthalpies.
23
Main Traps applied at Temperature Control
24
Float Trap – Typical Performance Charts x
Design
25
Main Applied Traps associated with Temperature
Control
Inverted Bucket mechanical steam
traps : How It Works
1. As condensate reaches the trap it forms a
waterseal inside the body. The weight of the
bucket keeps the valve off its seat. Condensate
can then flow around the bottom of the bucket
and out of the trap.
2. When steam enters the underside of the
bucket it gives it buoyancy and the bucket rises.
This positions the lever mechanism such that
the main valve 'snaps' shut due to flow forces.
3. The bucket will lose its buoyancy as the
enclosed steam condenses due to radiation
losses and steam escapes through the vent
hole. Once this happens the weight of the
bucket will pull the valve off its seat and the
cycle is then repeated.
4. Any air reaching the trap will also give the
bucket buoyancy and close the valve
preventing condensate flow. The small vent
hole positioned at the top of the bucket will
bleed air into the top of the trap.
Because the vent hole at the top of the bucket
is small in diameter it will vent air very slowly.
Consequently a separate external air vent may
therefore be required to ensure speedy and
efficient start-up of steam plant.
26
Inverted Bucket Trap – Typical Performance Charts x
Design
27
Steam Traps – Selection Tables from Main
Suppliers
28
Steam Traps – Selection Tables from Main
Suppliers
Armstrong
29
Steam Traps – Safety Factors for Right Sizing & Design
SAFETY FACTORS
. Recommended safety factors and steam trap sizing guidelines are listed below for a
variety of conditions:
. Estimated Condensate Load must be direct multiplied by Safety Factor, where with
Pressure Drop, is possible to sizing and select the right Trap, using Performance
Charts according the select Model.
30
31
Condensate Recovery – Return without
US$ Destruction
To have an efficient and Economic Steam Generation System, it must have a strong return of
Condensate. To achieve this, a very well designed Return Piping is mandatory. This rule will assure
directly the Plant Asset Capability, without bottlenecks at Heaters or Vaporizers.
All saturated or SubCooled Condensate suffer a Pressure Drop throughout the Trap, an expansiont.
This is usually called of “FLASH”, at this point there is a Saturation State, with Steam plus Condensate.
Energy remains constant, according First Law of Thermo “Principle of Energy Conservation”, specific
streams enthalpy are the same. See example at right side.
At this Outlet, Two phase-flow exists and piping from Traps to Steam System MUST BE designed
considering specific methods described at literature or recommended from Manufacturers. Pressure Drop
for Two Phase-Flow is very Higher in comparison of Single-Phase, in front of Phases Moments Transfer
at differents Velocities inside the Piping.
32
Steam Traps – How to keep it “Healthly”
33
Free References from Internet – Very Helpful
Armstrong International
http://www.youtube.com/watch?v=nQIQzEuGaMw
http://www.youtube.com/watch?v=x4c6UN8IqOc&feature=rel
ated
http://www.armstronginternational.com/college-of-steam-and-
condensate-systems
Flowserve-Gestra
http://www.youtube.com/watch?v=WehoU4Sh4Xc&feature=re
lated
http://www.gestra.com/academy/akademytv.php
Spirax-Sarco
http://www.spiraxsarco.com/
TLV
http://www.tlv.com/global/US/product-operation/
34
Cálculo e Seleção de Purgadores
Dados do Orgânico :
Pergunta-se :
1.1 Quanto será a quantidade de Vapor d’água necessária (em kg/h) para a vaporização
do Orgânico em questão ? (Valor 2,0)
1.2 Selecionar qual o purgador e o respectivo diâmetro (em polegadas) para drenar o
condensado gerado na questão acima (considerando um fator de segurança) ? justifique
a sua escolha. (Valor 3,0)
1.3 Na saída do purgador, ocorrerá um “flash” devido a mudança da condição de
Temperatura x Pressão.Qual é a fração em peso de Vapor d’água obtida ? (2,0)
35
2. Uma corrente de composto orgânico será aquecida em um trocador tipo casco tubo,
vertical. A alimentação de orgânico é de 140 GPM (US), numa temperatura de 25 C e
deseja-se atingir a temperatura final de 90 C, . O aquecimento deste orgânico será feito
por Vapor d’água, numa pressão de 215 psig, saturado e em seguida sofre uma redução
de pressão para 115 psig, alimentando o trocador. Este Vapor d’água sofrerá
condensação considerando a pressão constante ao longo dos tubos, com a respectiva
temperatura de saturação correspondente a pressão de trabalho. O condensado gerado
sofre um sub-resfiramento de 5C, onde será drenado por um purgador de vapor, para
um tubo coletor que está a pressão de 15 psig.
Dados do Orgânico :
Pergunta-se :
1.1Quanto será a quantidade de Condensado (em kg/h) que é drenado pelo Purgador?
1.2Qual a quantidade de Vapor após o purgador ?
1.3Qual a Energia Trocada no Vaporizador ?
1.4Qual o purgador selecionado
36
Spirax-Sarco Ball Float FT-20
37
38
39
40
MISTURA DE LÍQUIDOS – IMPELLER DESIGN
41
Flow Regimes in a Stirred Tank
2
Impeller Reynolds number, Re = D N /
(Equação 1)
42
Q
Pumping number, Nq = --------------- = Pumping number (Equação 2)
ND3
BHP
Power number, Np = --------------- = Power number (Equação 3)
n N3 D5
Shaft Power = BHP [W] Required motor power = 1.35 BHP [W]
n = impeller number
43
Mecanismos
Axial
Radial
44
Exemplos :
Position away from wall away from wall away from wall
Typical impellers Propeller Pitched blade turbine Flat blade disk turbine
Impeller shape
Flow pattern
h 3 /d 2 0.3 to 3 0.3 To 3
u [m/s] 3 to 15 3 to 15 3 to 7
[mPa s] to 8,000 to 20,000 to 10,000
Number of stages 1 1 1
Number of baffles 3 2/3/4 2/(4)
45
Procedimento para Cálculo de Agitadores para Mistura de Líquidos
4. Selecionar qual o grau de mistura desejado (escala de agitação=Scale of agitation), pela Table I
abaixo.
5. Baseado na escala de agitação acima, achar a Velocidade de meio (Bulk velocity=Vb) em ft/min
9. Selecionar o tipo de Agitador , Exemplo : turbina de seis pás, Hélice, Alta eficiência
(Hydrofoil)…..
10. Assumir agitação em plena condição turbulenta (Re>10000) e do gráfico Nq x Re, coletar Nq
13. Tendo o Re e a relação D/T, retornar ao gráfico NqxRe e comparar o valor escolhido x calculado
14. Caso não batam, pegar o novo valor de Nq e retornar ao item 10 até que os valores coincidam
46
47
48
Regra para Número de Impelidores da Chemineer :
49
Prática :
50
Fluxo Bifásico – Líquido x Gás
51
2.2.1 Disperso.
2.2.2 Anular.
Quando o líquido forma um filme nas paredes da tubulação e o gás flui a alta
velocidade na região central.
2.2.3 Bolhas
2.2.4 Estratificado
52
2.2.3 Ondas
2.2.4 “Slug”
2.2.5 Plug
53
Critério de Determinação do Tipo de Fluxo Bifásico
54
Gt = Fluxo Massico Total / Area de Fluxo
55
56
Perda de Pressão devido a Elevação
Rl + Rv =1
Perda de Pressão Total
57
EXERCÍCIOS DE APLICAÇÃO
1. Calcular a queda de pressão por atrito de uma corrente de fluxo de duas fases,
consistindo de 39000 kg/h de um orgânico líquido mais 70000 kg/h de gás.
Considerar um trecho reto equivalente de 400 metros.
Dicas
58
Pneumatic Conveying Design
One of the most popular methods of moving solids in the chemical industry is pneumatic conveying.
Pneumatic conveying refers to the moving of solids suspended in or forced by a gas stream through
horizontal and/or vertical pipes. Pneumatic conveying can be used for particles ranging from fine
powders to pellets and bulk densities of 16 to 3200 kg/m3 (1 to 200 lb/ft 3).
The specifying engineer typically has four choice in specifying a pneumatic conveying system.
Vacuum systems allow multiple product inlets through the use of simple diverter valves. However, it
becomes costly to have multiple destinations because each must have its own filter receiver with
partial vacuum capability. Vacuum systems are also more "distance sensitive" than pressure systems
due to the maximum pressure differential of 5.5 to 6.0 psi. Dilute phase pressure systems can easily
achieve pressure differentials of 12 psi. Pressure-vacuum operation (utilizing both methods) are
sometimes ideal for a given conveying setup. A very common application is the unloading of a
standard railcar. Since the cars cannot be pressurized, air is pulled from the outside, through the car
(carrying solids with it) to a filter. Then after the filter, a blower can be used to forward the solids to
the final receiver.
The choice between dilute and dense phase operation is typically dependent on the solids properties.
For example, the lower velocity bulk phase operation is popular ofr highly abrasive products or for
those that degrade easily. For example, this method is popular in transporting kaolin clay.
59
Figure 1: Dilute Phase Pressure Conveying
60
Figure 3: Dilute Phase Pressure-Vacuum Conveying
Considering designing a pneumatic conveying system yourself? Probably not a good idea. There's as
much art involved as there is science and such a design should be left to professionals. Consider that
even different grades of the same material have been known to convey differently. Testing is a must
(as you'll see from the method below). Before you can even make any good judgements from the
method presented here, you need to know solid friction factor for your solids (which we'll discuss
later) and the minimum gas velocity required to move your particles. So, if you're involved in
designing a system from the ground up, seek assistance from reputatable people in the field of
conveying. If you're already familiar with your solids, the method below can be used to examine the
pressure loss expected in your system. The method presented here is very good and has been stood
the test of real systems over time.
The design method presented here is based on the work of Dr. F.A. Zenz and Dr. D.F. Othmer as
published in their book "Fluidized and Fluid Particle Systems" published in 1960 (see References).
This method was presented by A. T. Agarwal of Pneumatic Conveying Consulting Services LLC in
the January/February 2005 issue of Powder Handling and Processing. This method has been widely
used and is generally found to be within 10% of measured pressure losses.
Pressure losses experienced in pneumatic conveying systems are the result of the following forces:
Friction of the gas on the inside of the pipe, force required to move the solids through the pipe, forces
required to support the weight of the solid and the gases in vertical pipe runs, force required to
accelerate the solids, and friction between the solids and the inside of the pipe.
Friction losses as the result of the solids being in contact with the inside of the pipe are usually very
small and can be neglected when considering dilute phase transport.
61
Please be aware that using air as a carrier gas should be investigated thoroughly. When some powders
are mixed with oxygen, they form an explosive mixture!
Nomenclature
Vg Gas velocity [ft/s]
rg Gas density [lbs/ft3]
W Solids mass velocity [lbs/s ft2]
Vp Particle velocity [ft/s]
f Fanning friction factor
L Equivalent length of pipeline [ft]
D Pipe inside diameter [ft]
g Acceleration due to gravity [32.2 ft/s2]
gc Constant [32.174 ft-lb/lb s2]
K Friction multiplier for the solids conveyed
R Solids to gas mass flow ration [lb/lb]
Z Elevation change in pipe line [ft]
Early is their work, Zenz and Othmer used the following equations to described the pressure losses
in horizontal and vertical pipes:
It was later concluded that the term (fp Vp/f Vg) should be replaced by the constant K (friction
multiplier for the solids conveyed) because the term was dependent upon the physical properties of
the solids being conveyed. The value for K must be back-calculated from actual pressure drop data
from an existing system or it must be determined experimentally in plant tests. This lead to the
following equation for the pressure drop for the solids in the system.
62
Thus, the equation used for the total system pressure loss (Base Equation) is:
where:
63
The Base Equation is the basis for the following equations used in the pressure loss calculations. The
pressure loss is expressed in psi or lbs/in2 in the following equations:
Eq. (1)
Eq. (2)
Eq. (4)
Eq. (5)
In order to determine the fanning friction factor, f, the Reynolds Number must first be calculated:
Then, the friction factor is calculated from the following equation derived from pages A-23 and A-
24 of Crane's Technical Paper No. 410:
64
Where is the pipe roughness factor which can be estimated as 0.00015 for smooth pipes or 0.0005
for shot-peened pipes.
For straight pipe runs (either horizontal or vertical) use the actual length of the pipe. For bends and
other devices, use the table below as a guide:
Equivalent Length
Component
Bends,90°bend,long,radius 40 x diameter or 20 ft
(10 to 1 radius to diameter ratio) (whichever is larger)
Diverter Valves
45° divert angle 20 x diameter
30° divert angle 10 x diameter
Flexible Hoses
Stainless steel w/ lined interior 3 x pipe length
Rubber or vinyl hose 5 x pipe length
For bends that are less than 90°, use the following equivalent lengths:
65
Solids Velocity
Solids also move at a velocity lower than the gas velocity due to drag forces. The difference between
these velocities is called the slip factor. For most course or hard solids, the slip factor is around 0.80.
For fine powders, the solids velocity can be closer to the gas velocity and a factor of 0.90 may be
more appropriate. Depending on the size of the particles, the slip factor can range from 0.70 to 0.95.
For a 90° radius bend, the solids velocity at the exit of the bend (V p2) is around 0.80 times the solids
velocity at the inlet of the bend (Vp1). This factor can range from 0.60 to 0.90 depending of the
properties of the solids. For bends that are less than 90°, the exit velocity may be expressed as:
66
After leaving a 90° bend, use a nominal value of 20 pipe diameters for the length of pipe needed for
the particles to accelerate back to their original velocity at the inlet of the bend.
In the above, m is the the solids mass flow in lb/s and A is the pipe cross sectional area in
ft2. Remember that the gas density (and therefore velocity) will change throughout the system
When calculating the gas velocity, reduce the gas mass flow rate by 5% for pressure systems to
account for gas leakage through a rotary valve if such a valve is used to feed the solids.
As the carrier gas moves through the system and losses or gains pressure (depending on whether the
system is a pressure or vacuum system), it's density will increases or decrease accordingly thereby
changing the velocity of the gas. The gas pressure loss equation is shown in Equation 2 above. The
ideal gas law may be employed to calculate the density of the gas throughout the system.
The method presented here can easily be set up in a spreadsheet to show the performance of your
system. It is recommend the divide the entire system into 5 to 10 ft sections for such a
calculation. The exit conditions of from section become the inlet conditions for the next and so
on. Also, be sure to account for any gas losses that are known and for any extra gas inlet points in
the system. For pressure systems, start from the end of the conveying line and return to the solids
inlet point. For vacuum systems, start from the solids inlet point and end at the blower inlet.
67
References
1. Zenz and Othmer, "Fluidized and Fluid Particle Systems", Chapters 10 and 11, published by
Reinhold Publishing Corp, 1960
2. Agarwal, A.T., "Theory and Design of Dilute Phase Pneumatic Conveying Systems", Powder
Handling & Processing, Vol. 17, No. 1, January/February 2005
3. Kimbel, Kirk W., "Troublefree Pneumatic Conveying", Chemical Engineering Magazine,
April 1998, page 78
68