FILTRATION PROBLEMS –RICHARD COULSON 5TH EDITION t = 857 s

Example 7.1 −P = 2902 kN/m2

A slurry is filtered in a plate and frame press containing 12
frames, each 0.3 m square and 25 mm thick. During the first Example 7.4
180 s the pressure difference for filtration is slowly raised to A slurry containing 40 per cent by mass solid is to be filtered
the final value of 400 kN/m2 and, during this period, the rate on a rotary drum filter 2 m diameter and 2 m long which
of filtration is maintained constant. After the initial period, normally operates with 40 per cent of its surface immersed in
filtration is carried out at constant pressure and the cakes are the slurry and under a pressure of 17 kN/m2. A laboratory
completely formed in a further 900 s. The cakes are then test on a sample of the slurry using a leaf filter of area
washed with a pressure difference of 275 kN/m2 for 600 s 200 cm2 and covered with a similar cloth to that on the drum
using thorough washing (See the plate and frame press in produced 300 cm3 of filtrate in the first 60 s and 140 cm3 in
Section 7.4.4). What is the volume of filtrate collected the next 60 s, when the leaf was under an absolute pressure
per cycle and how much wash water is used? of 17 kN/m2. The bulk density of the dry cake was 1500
A sample of the slurry had previously been tested with a leaf kg/m3 and the density of the filtrate was 1000 kg/m3.
filter of 0.05 m2 filtering surface using a vacuum giving a The minimum thickness of cake which could be readily
pressure difference of 71.3 kN/m2. The volume of filtrate removed from the cloth was 5 mm. At what speed should the
collected in the first 300 s, was 250 cm3 and, after a further drum rotate for maximum throughput and what is this
300 s, an additional 150 cm3 was collected. It may be throughout in terms of the mass of the slurry fed to the unit
assumed that the cake is incompressible and that the cloth per unit time?
resistance is the same in the leaf as in the filter press.
speed = (1/67.3) = 0.015 Hz
total volume of filtrate collected: = 6.15 × 10−2 or 0.062 m3
mass of slurry = (1.66 × 2.11) = 3.5 kg/s
amount of wash-water passing in 600 s = (600 × 6.5 × 10−6)
= 3.9 × 10−3m3 or 0.004 m3 Example 7.5
A plate and frame press with a filtration area of 2.2 m2 is
Example 7.2 operated with a pressure drop of 413 kN/m2 and with a
A slurry containing 100 kg of whiting, of density 3000 kg/m3, downtime of 21.6 ks (6 h). In a test with a small leaf filter 0.05
per m3 of water, and, is filtered in a plate and frame press, m2 in area, operating with a pressure difference of 70 kN/m2,
which takes 900 s to dismantle, clean, and re-assemble. If the 0.00025 m3 of filtrate was obtained in 300 s and a total of
cake is incompressible and has a voidage of 0.4, what is the 0.00040 m3 in 600 s. Estimate the optimum filtration time for
optimum thickness of cake for a filtration pressure (−_P) of maximum throughput. If the operating cost during filtration is
1000 kN/m2? The density of the whiting is 3000 kg/m3. If the £10/ks and the cost of a shutdown is £100, what is the
cake is washed at 500 kN/m2 and the total volume of wash optimum filtration time for minimum cost?
water employed is 25 per cent of that of the filtrate, how is
the optimum thickness of the cake affected? The resistance t= 2.216 × 104 s or 22.2 ks (6.2 h)
of the filter medium may be neglected and the viscosity of
water is 1 mNs/m2. In an experiment, a pressure difference V/(t + t’) = 0.111/(2.216 × 104 + 21.6 × 103) = 2.54 × 10−6
of 165 kN/m2 produced a flow of water of 0.02 cm3/s m3/s
through a centimetre cube of filter cake.
t= 1.03 × 104 s or 10.3 ks (2.86 h)
optimum frame thickness = 70 mm
Example 7.6
Frame thickness = 59.2 ≈ 60 mm A slurry, containing 0.2 kg of solid per kilogram of water, is
fed to a rotary drum filter 0.6 m long and 0.6 m diameter. The
Example 7.3 drum rotates at one revolution in 360 s and 20 per cent of the
The relation between flow and head for a certain slurry pump filtering surface is in contact with the slurry at any instant. If
may be represented approximately by a straight line, the filtrate is produced at the rate of 0.125 kg/s and the cake has
maximum flow at zero head being 0.0015 m2/s and the a voidage of 0.5, what thickness of cake is produced when
maximum head at zero flow 760 m of liquid. Using this pump filtering with a pressure difference of 65 kN/m2? The density
to feed a particular slurry to a pressure leaf filter: of the solids is 3000 kg/m3. The rotary filter breaks down and
(a) How long will it take to produce 1 m3 of filtrate? the operation has to be carried out temporarily in a plate and
(b) What will be the pressure across the filter after this time? frame press with frames 0.3 m square. The press takes 120 s
A sample of the slurry was filtered at a constant rate of to dismantle and 120 s to reassemble and, in addition, 120 s
0.00015 m3/s through a leaf filter covered with a similar filter is required to remove the cake from each frame. If filtration is
cloth but of one-tenth the area of the full-scale unit, and after to be carried out at the same overall rate as before, with an
625 s the pressure across the filter was 360 m of liquid. After operating pressure difference of 175 kN/m2, what is the
a further 480 s the pressure was 600 m of liquid. minimum number of frames that needs to be used and what
is the thickness of each? It may be assumed that the cakes PROBLEM 7.8
are incompressible and that the resistance of the filter Filtration is carried out in a plate and frame filter press, with
medium may be neglected. 20 frames 0.3 m square and 50 mm thick, and the rate of
filtration is maintained constant for the first 300 s. During this
Thickness of cake produced = (6.44 × 10−3)/(0.36π) = 5.7 × period, the pressure is raised to 350 kN/m2, and one-quarter
10−3 m or 5.7 mm of the total filtrate per cycle is obtained. At the end of the
constant rate period, filtration is continued at a constant
Example 7.7 pressure of 350 kN/m2 for a further 1800 s, after which the
A sludge is filtered in a plate and frame press fitted with 25 frames are full. The total volume of filtrate per cycle is 0.7 m3
mm frames. For the first 600 s the slurry pump runs at and dismantling and refitting of the press takes 500 s. It is
maximum capacity. During this period the pressure rises to decided to use a rotary drum filter, 1.5 m long and 2.2 m in
415 kN/m2 and 25 per cent of the total filtrate is obtained. diameter, in place of the filter press. Assuming that the
The filtration takes a further 3600 s to complete at resistance of the cloth is the same in the two plants and that
constant pressure and 900 s is required for emptying and the filter cake is incompressible, calculate the speed of
resetting the press. It is found that if the cloths are precoated rotation of the drum which will result in the same overall rate
with filter aid to a depth of 1.6 mm, the cloth resistance of filtration as was obtained with the filter press. The
is reduced to 25 per cent of its former value. What will be the filtration in the rotary filter is carried out at a constant
increase in the overall throughput of the press if the precoat pressure difference of 70 kN/m2, and the filter operates with
can be applied in 180 s? 25 per cent of the drum submerged in the slurry at any
instant.
Increase = [(0.000214 − 0.000196)V/ 0.000196V]× 100 = 9.1 speed = (1/580) = 0.002 Hz (0.12 rpm)
per cent
PROBLEM 7.9
PROBLEM 7.3 It is required to filter a slurry to produce 2.25 m3 of filtrate
A plate and frame press gave a total of 8 m3 of filtrate in per working day of 8 hours. The process is carried out in a
1800 s and 11.3 m3 in 3600 s when filtration was stopped. plate and frame filter press with 0.45 m square frames
Estimate the washing time if 3 m3 of wash water is used. and a working pressure difference of 348.7 kN/m2. The
The resistance of the cloth may be neglected and a constant pressure is built up slowly over a period of 300 s and, during
pressure is used throughout. this period, the rate of filtration is maintained constant.
When a sample of the slurry is filtered, using a pressure
time of washing = 3/(3.6 × 10−4) = 8400 s (2.3 h) difference of 66.3 kN/m2 on a single leaf filter of filtering area
0.05 m2, 400 cm3 of filtrate is collected in the first 300 s
PROBLEM 7.4 of filtration and a further 400 cm3 is collected during the
In the filtration of a sludge, the initial period is effected at a following 600 s. Assuming that the dismantling of the filter
constant rate with the feed pump at full capacity, until the press, the removal of the cakes and the setting up again of
pressure differences reaches 400 kN/m2. The pressure is the press takes an overall time of 300 s, plus an additional
then maintained at this value for a remainder of the filtration. 180 s for each cake produced, what is the minimum number
The constant rate operation requires 900 s and one-third of of frames that need be employed? The resistance of the
the total filtrate is obtained during this period. Neglecting the filter cloth may be taken as the same in the laboratory tests
resistance of the filter medium, determine (a) the total as on the plant.
filtration time and (b) the filtration cycle with the existing
pump for a maximum daily capacity, if the time for removing for the positive value, n = 13
the cake and reassembling the press is 1200 s. The cake is not
washed. PROBLEM 7.10
The relation between flow and head for a slurry pump may be
For the constant pressure period; represented approximately by a straight line, the maximum
total filtration time = (900 + 3600) = 4500 s flow at zero head being 0.0015 m3/s and the maximum
and: total cycle time = (4500 + 1200) = 5700 s head at zero flow 760 m of liquid. Using this pump to feed a
slurry to a pressure leaf filter, (a) how long will it take to
For the constant rate period: produce 1 m3 of filtrate, and (b) what will be the pressure
total cycle time = (2100 + 1200) = 3300 s
drop across the filter after this time? A sample of the slurry
PROBLEM 7.5 was filtered at a constant rate of 0.00015 m3/s through a leaf
A rotary filter, operating at 0.03 Hz, filters at the rate of filter covered with a similar filter cloth but of one-tenth the
0.0075 m3/s. Operating under the same vacuum and area of the full scale unit and after 625 s the pressure drop
neglecting the resistance of the filter cloth, at what speed across the filter was 360 m of liquid. After a further 480 s the
must the filter be operated to give a filtration rate of 0.0160 pressure drop was 600 m of liquid .t = 857 s
m3/s? N2 = 0.136 Hz (7.2 rpm)
(−_P) = 2902 kN/m2
PROBLEM 7.12 PROBLEM 7.15
A continuous rotary filter is required for an industrial process A slurry containing 50 per cent by mass of solids of density
for the filtration of a suspension to produce 0.002 m3/s of 2600 kg/m3 is to be filtered on a rotary drum filter, 2.25 m in
filtrate. A sample was tested on a small laboratory filter of diameter and 2.5 m long, which operates with 35 per cent
area 0.023 m2 to which it was fed by means of a slurry pump of its surface immersed in the slurry and under a vacuum of
to give filtrate at a constant rate of 0.0125 m3/s. The 600 mm Hg. A laboratory test on a sample of the slurry, using
pressure difference across the test filter increased from a leaf filter with an area of 100 cm2 and covered with a cloth
14 kN/m2 after 300 s filtration to 28 kN/m2 after 900 s, at similar to that used on the drum, produced 220 cm3 of
which time the cake thickness had reached 38 mm. What are filtrate in the first minute and 120 cm3 of filtrate in the next
suitable dimensions and operating conditions for the rotary minute when the leaf was under a vacuum of 550 mm Hg.
filter, assuming that the resistance of the cloth used is one- The bulk density of the wet cake was 1600 kg/m3 and the
half that on the test filter, and that the vacuum system is density of the filtrate was 1000 kg/m3. On the assumption
capable of maintaining a constant pressure difference of that the cake is incompressible and that 5 mm of cake is left
behind on the drum, determine the theoretical maximum
70 kN/m2 across the filter? Hence, the cake thickness on the
flowrate of filtrate obtainable. What drum speed will give a
drum, vV filtration rate of 80 per cent of the maximum?
/A = (0.078/11.7) = 0.0067 m or 6.7 mm
speed of rotation = (0.35 × 1.69) = 0.59 rpm (0.0099 Hz)
PROBLEM 7.13
PROBLEM 7.16
A rotary drum filter, 1.2 m diameter and 1.2 m long, handles
A rotary filter which operates at a fixed vacuum gives a
6.0 kg/s of slurry containing 10 per cent of solids when
desired rate of filtration of a slurry when rotating at 0.033 Hz.
rotated at 0.005 Hz. By increasing the speed to 0.008 Hz it is
By suitable treatment of the filter cloth with a filter aid, its
found that it can then handle 7.2 kg/s. What will be the
effective resistance is halved and the required filtration rate
percentage change in the amount of wash water which may
is now achieved at a rotational speed of 0.0167 Hz (1 rpm). If,
be applied to each kilogram of cake caused by the increased
by further treatment, it is possible to reduce the effective
speed of rotation of the drum, and what is the theoretical
cloth resistance to a quarter of the original value, what
maximum quantity of slurry which can be handled?
rotational speed is required? If the filter is now operated
per cent increase = [(0.625 − 0.6)/0.6] × 100 = 4.17 per cent
again at its original speed of 0.033 Hz, by what
factor will the filtration rate be increased?
Hence the limiting rate is three times the original rate,
that is: 18.0 kg/s
N = 0.0083 Hz (0.5 rpm)
F3/F1 = 2.0 in this way, the filtration rate will be doubled.
PROBLEM 7.14
A rotary drum with a filter area of 3 m3 operates with an
internal pressure of 71.3 kN/m2 below atmospheric and with
30 per cent of its surface submerged in the slurry. Calculate
the rate of production of filtrate and the thickness of cake
when it rotates at 0.0083 Hz, if the filter cake is
incompressible and the filter cloth has a resistance equal to
that of 1 mm of cake. It is desired to increase the rate of
filtration by raising the speed of rotation of the drum.
If the thinnest cake that can be removed from the drum has a
thickness of 5 mm, what is the maximum rate of filtration
which can be achieved and what speed of rotation of the
drum is required? The voidage of the cake = 0.4, the specific
resistance of cake = 2 × 1012 m−2 the density of solids = 2000
kg/m3, the density of filtrate = 1000 kg/m3, the viscosity of
filtrate = 10−3 N s/m2 and the slurry concentration = 20 per
cent by mass solids.

rate of filtration = (0.303/120.5) = 0.0025 m3/s .

cake thickness = (0.07/3) = 0.023 m or 23 mm

speed = 0.14 Hz (8.5 r.p.m)

Maximum filtrate rate = 0.065 m3 in 7.1 s

or: (0.065/7.1) = 0.009 m3/s
CRYSTALLIZATION -COULSON AND RICHARDSON’S Example 15.6
CHEMICAL ENGINEERING VOL 2 5TH ED An MSMPR crystalliser operates with a steady nucleation rate
of n◦ = 1013/m4, a growth rate, Gd = 10−8 m/s and a mixed-
Example 15.1 product removal rate, based on clear liquor of 0.00017 m3/s.
At 293 K, a supersaturated solution of sucrose contains 2.45 The volume of the vessel, again based on clear liquor, is 4 m3,
kg sucrose/kg water. If the equilibrium aturation value is 2.04 the crystal density is 2660 kg/m3 and the volumetric shape
kg/kg water, what is the supersaturation ratio in terms of factor is 0.7. Determine:
kg/kg water and kg/kg solution? (a) the solids content in the crystalliser
For concentrations in kg sucrose/kg water:S = c/c* = (b) the crystal production rate
(2.45/2.04) = 1.20 (c) the percent of nuclei removed in the discharge by the time
For concentrations in kg sucrose/kg solution: S= they have grown to 100 μm.
(0.710/0.671) = 1.06 (d) the liquor flowrate which passes through a trap which
removes 90 per cent of the original
Example 15.3 nuclei by the time they have grown to 100 μm
What is the theoretical yield of crystals which may be
obtained by cooling a solution containing 1000 kg of sodium (a) From a mass balance, the total mass of solids is: cs
sulphate (molecular mass = 142 kg/kmol) in 5000 kg water to = 343 kg/m3
283 K? The solubility of sodium sulphate at 283 K is 9 kg (b) The production rate = (343 × 0.00017) = 0.058 kg/s
anhydrous salt/100 kg water and the deposited crystals (200 kg/h)
will consist of the deca-hydrate (molecular mass = 322 (c) The crystal population decreases exponentially with
kg/kmol). It may be assumed that 2 per cent of the water will size, Thus: (100 − 66) = 34 per cent have been
be lost by evaporation during cooling. discharged by the time they reach 100 μm.
(d) (d) If (100 − 90) = 10 per cent of the nuclei remain
yield, y =1432 kg Na2SO4.10H2O and grow to >100 μm,
QF = 0.00075 m3/s (2.68 m3/h)
Example 15.4
What is the yield of sodium acetate crystals Example 15.7
(CH3COONa.3H2O) obtainable from a vacuum crystalliser The vapour pressures of naphthalene at 463 and 433 K are
operating at 1.33 kN/m2 when it is supplied with 0.56 kg/s of 0.780 and 0.220 kN/m2 respectively. If λ_v does not vary
a 40 per cent aqueous solution of the salt at 353 K? The greatly over the temperature range considered, what is the
boiling point elevation of the solution is 11.5 deg K. vapour pressure at 393 K? P = 30 kN/m2
Data:
Heat of crystallisation, q = 144 kJ/kg trihydrate Example 15.8
Heat capacity of the solution, Cp = 3.5 kJ/kg deg K Salicylic acid (Ms = 138 kg/kmol) is to be purified by entrainer
Latent heat of water at 1.33 kN/m2, λ = 2.46 MJ/kg sublimation with air (Mg = 29 kg/kmol) at 423 K. The vapour
Boiling point of water at 1.33 kN/m2 = 290.7 K is fed at 101.5 kN/m2 to a series of condensers, the internal
Solubility of sodium acetate at 290.7 K, c2 = 0.539 kg/kg temperature and pressure of the last condenser being 313 K
water. and 100 kN/m2 respectively. The air flowrate is 0.56 kg/s and
y= 0.183 kg/s the pressure drop between the vaporiser and the last
condenser is 1.5 kN/m2. The vapour pressures of salicylic acid
Example 15.5 at 423 and 313 K are 1.44 and 0.0023 kN/m2 respectively.
A solution containing 23 per cent by mass of sodium What are the mass sublimation rates in the vaporiser and
phosphate is cooled from 313 to 298 K in a condenser?
Swenson-Walker crystalliser to form crystals of S_ = 0.56(138/29)(0.0023/(100 − 0.0023)) = 0.000061 kg/s
Na3PO4.12H2O. The solubility of Na3PO4 at 298 K (0.061 g/s)
is 15.5 kg/100 kg water, and the required product rate of
crystals is 0.063 kg/s. The mean heat capacity of the solution Example 15.9
is 3.2 kJ/kg deg K and the heat of crystallisation is 146.5 kJ/kg. Explain how fractional crystallisation may be applied to a
If cooling water enters and leaves at 288 and 293 K, mixture of sodium chloride and sodium nitrate given the
respectively, and the overall coefficient of heat transfer following data. At 293 K, the solubility of sodium chloride is
is 140 W/m2 deg K, what length of crystalliser is required? 36 kg/100 kg water and of sodium nitrate 88 kg/100 kg water.
Whilst at this temperature, a saturated solution comprising
The heat transfer area required, A both salts will contain 25 kg sodium chloride and 59 kg of
_ = Q/U_Tm = 18.5/(0.14 × 14.4) = 9.2 m2 sodium nitrate per 100 kg of water. At 373 K, these values,
Assuming that the area available is, typically, 1 m2/m length, again per 100 kg of water, are 40 and 176 and 17 and 160,
the length of exchanger required = 9.2 m. In practice 3 respectively.The amount of NaNO3 recovered from the
lengths, each of 3 m length would be specified. saturated solution at 373 K is:(92 × 100)/160 = 57.5%
yield of NaNO3 = (160 − 68.3) = 91.7 kg/100 kg water
PROBLEM 15.1 sections of crystalliser, each 3 m long, will be required to
A saturated solution containing 1500 kg of potassium chloride process 0.25 kg/s of the product? The solubilities of
at 360 K is cooled in an open tank to 290 K. If the density of anhydrous Na2SO4 in water are 40 and 14 kg/100 kg water at
the solution is 1200 kg/m3, the solubility of 300 K and 290 K respectively, the mean heat capacity of the
potassium chloride/100 parts of water by mass is 53.55 at liquor is 3.8 kJ/kgK and the heat of crystallisation is 230 kJ/kg.
360 K and 34.5 at 290 K calculate: For the crystalliser, the available heat transfer area is 3 m2/m
(a) the capacity of the tank required, and length, the overall coefficient of heat transfer is 0.15 kW/m2
(b) the mass of crystals obtained, neglecting any loss of water K and the molecular masses are Na2SO4.10H2O = 322
by evaporation. kg/kmol and Na2SO4 = 142 kg/kmol.

capacity of the tank = (4301/1200) = 3.58 m3. Hence: Total length of unit required = (50.67/3) = 16.9 m
Thus: mass of crystals which has come out of solution = and 6 sections each of 3 m length would be specified.
(1500 − 966) = 534 kg
PROBLEM 15.8
PROBLEM 15.3 What is the evaporation rate and yield of the sodium acetate
10 Mg of a solution containing 0.3 kg Na2CO3/kg solution is hydrate CH3COONa.3H2O from a continuous evaporative
cooled slowly to 293 K to form crystals of Na2CO3.10H2O. crystalliser operating at 1 kN/m2 when it is fed with 1 kg/s
What is the yield of crystals if the solubility of Na2CO3 of a 50 per cent by mass aqueous solution of sodium acetate
at 293 K is 21.5 kg/100 kg water and during cooling 3 per cent hydrate at 350 K? The boiling point elevation of the solution
of the original solution is lost by evaporation? is 10 degK and the heat of crystallisation is 150 kJ/kg.
The mean heat capacity of the solution is 3.5 kJ/kgK and, at 1
Y = 6536 kg . kN/m2, water boils at 280 K at which temperature the latent
heat of vaporisation is 2.482 MJ/kg. Over the range 270–305
PROBLEM 15.4 K, the solubility of sodium acetate hydrate in water s at T (K)
The heat required when 1 kmol of MgSO4.7H2O is dissolved is given approximately by:
isothermally at 291 K in a large mass of water is 13.3 MJ. s = 0.61T − 132.4 kg/100 kg water
What is the heat of crystallisation per unit mass of the salt? Molecular masses: CH3COONa.3H2O = 136 kg/kmol,
CH3COONa = 82 kg/kmol.
heat of crystallisation= 53.9 kJ/kg
Therefore: Actual evaporation rate = (0.265 × 0.5) = 0.132
PROBLEM 15.5 kg/s
A solution of 500 kg of Na2SO4 in 2500 kg water is cooled y= 0.791 kg/s
from 333 K to 283 K in an agitated mild steel vessel of mass
750 kg. At 283 K, the solubility of the anhydrous salt
is 8.9 kg/100 kg water and the stable crystalline phase is
Na2SO4.10H2O. At 291 K, theheat of solution is −78.5
MJ/kmol and the specific heat capacities of the solution and
mild steel are 3.6 and 0.5 kJ/kg deg K respectively. If, during
cooling, 2 per cent of the water initially present is lost by
evaporation, estimate the heat which must be removed

net heat to be removed ≈ 615,000 kJ

PROBLEM 15.6
A batch of 1500 kg of saturated potassium chloride solution is
cooled from 360 K to 290 K in an unagitated tank. If the
solubilities of KCl are 53 and 34 kg/100 kg water at 360 K and
290 K respectively and water losses due to evaporation may
be neglected, what is the yield of crystals?

y=186 kg

PROBLEM 15.7
Glauber’s salt, Na2SO4.10H2O, is to be produced in a
Swenson–Walker crystalliser by cooling to 290 K a solution of
anhydrous Na2SO4 which saturates between 300 K and 290
K. If cooling water enters and leaves the unit at 280 K and 290
K respectively and evaporation is negligible, how many