Reference Prcedure EN-P-008

Calculation Face Sheet

Project: CORe FEL3 Study
Client: Vale
Discipline: Mechanical
Calc. Title: Blower Sizing Calculation
Description:

Project No.:

H335456

No. of Sheets:
Revision:

Preliminary

Calc. Doc. No.:

Blower duty calculations for new Rougher/Scavenger and Pyrrhotite Rougher /Scavenger floatation cells

Category of calculation verification required:

Level 5: Review by Lead Engineer (Preliminary Design)

Prepared by:

Date:

Aug 03, 2009

B. Perry

Print Name:

Date:

Preliminary review
by:
Print Name:

Can the calculation now be released for work?

No

To the Client?

No

Date:
Checked by:
Print Name:

Date:
Reviewed by:
Print Name:

Date:
Approved by:
Print Name:

General Notes:

Revision

Date

Superseded by Calculation No.:

Prepared

REVISIONS
Checked

Approved

Description

Date:

Reason voided:

ISO 9001
266953513.xls

Hatch 2009/07

Reference Prcedure EN-P-008

Calculation Face Sheet

Project: CORe FEL3 Study
Client: Vale
Discipline: Mechanical

Project No.:

H335456

No. of Sheets:
Revision:

ISO 9001
266953513.xls

Hatch 2009/07

SHEET NO.

CALCULATION SHEET
__1__
DESCRIPTION

PROJECT NO.

CORe Feasibility Study - Blower Sizing

MADE BY

H335456

B. Perry
DATE

Jul 27. 10

DATE

Assumptions:
1. Blower air will be distributed to the floatation plant via a single header with branches to each bank of cells
2. Nominal pipe sizing based on nominal air velocity of 65 ft/s
3. Pipe sizes based on ANSI B36.10 std wt pipe (final pipe spec will most likely use thinner wall)
4. Pipe absolute roughness coefficient for medium-smooth pipe:
5. Atmosphere assumed as standard air (64 F, 14.7 psi):

Density,

0.0003

ft

0.0753

lbm/ft3

6. Effect of moisture in air is negligible, Gas constant for dry air:

7. Compressibiliy effects on system losses is negligible
8. Temperature effects on system losses is negligible
9. Friction losses and dynamic losses in fittings are factored based on a design factor, df =

Floatation Cell Requirements:

Rougher/scavengers:

10 x Outotec XHD-100

Air required per cell:

883 Aft3/min

Pressure required at top of cell:

5.51 psig

Pyrrhotite rougher/scavengers:

10 x Outotec XHD-100

Air required per cell:

883 Aft3/min

Pressure required at top of cell:

5.51 psig

Assuming T1 = Tstd,

pstd / std.Tstd = p1 / 1.T1 = R

p = RT

Assuming an ideal gas

for

p1 =

1 = 0.10353 lbm/ft3

5.51 psig

For conservation of mass:

std.Qstd = 1.Q1

Standard air required per cell:

Qstd =

1213.9 std ft3/min

24278 std ft3/min

Total standard air requirement:

( 20 cells)

OF

CHECKED BY

1.5

__6__

SHEET NO.

CALCULATION SHEET
__2__
DESCRIPTION

PROJECT NO.

CORe Feasibility Study - Blower Sizing

MADE BY

H335456

B. Perry
DATE

Jul 27. 10

DATE

Main Air Header Size:

Total flow, for 20 cells:

Q=

20

17657 Aft3/min =

883 =

Ideal pipe area for 65 ft/s velocity:

Ap = Q / 65 =

Ideal pipe internal diamater,

Di = ( 4 * Ap / ) 1/2 =

Closest standard pipe size is 30 inch OD,

Aft3/s

294

4.5 ft2
2.40

ft =

28.81 in

Std wt wall thickness = 0.375 inch, Di =

29.25 in

Single Bank Air Header Size:

Flow:

Q = 5 x 883 =

Ideal pipe area for 65 ft/s velocity:

Ap = Q / 65 =

Ideal pipe internal diamater,

Di = ( 4 * Ap / )

Closest standard pipe size is 16 inch OD,

4414

Aft3/min =

73.6

Aft3/s

1.1 ft2
1/2

1.20

ft =

Std wt wall thickness = 0.375 inch, Di =

14.41

in

15.25

in

Single Cell Air Pipe Size:

Flow:

Q = 1 x 883 =

883 Aft3/min =

Ideal pipe area for 65 ft/s velocity:

Ap = Q / 65 =

0.2 ft2

Ideal pipe internal diamater,

Di = ( 4 * Ap / ) 1/2 =

Closest standard pipe size is 6 inch OD,

Std wt wall thickness = 0.280 inch, Di =

Assumed Configuration:

105'

20'
16''
18''
16'

6''

30''
16''

0.48

ft =

OF

CHECKED BY

14.7 Aft3/s

5.81 in
5.44 in

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SHEET NO.

CALCULATION SHEET
__3__
DESCRIPTION

PROJECT NO.

CORe Feasibility Study - Blower Sizing

MADE BY

H335456

OF

__6__

CHECKED BY

B. Perry
DATE

Jul 27. 10

DATE

Approximate System Losses:

Formulae:
ref. ASHRAE Handbook 2009 ed.

Blower to Header:

Nominal pipe size = 18"

Pipe internal diameter = hydraulic diameter:
Pipe Area:

Ap = * (Dh / 2)

Flow:
Velocity:

V = Q / Ap

Approximate Pipe Length:

Dh =

17.25 in

Ap =

233.7 in2

Q =

4414 Aft3/min

V =

2720 Aft/min

L =

Approximate Reynolds number:

Re =

Friction factor:
pf =

Estimated total losses:

Header:

20 ft
3.99E+05
0.0200

Friction pressure loss:

1.62 ft2

Err:522

0.177 inch WG

0.00639 psi

0.266 inch WG

0.00959 psi

Nominal pipe size = 30"

Pipe internal diameter = hydraulic diameter:
Pipe Area:

Ap = * (Dh / 2)

Flow:
Velocity:

V = Q / Ap

Approximate Pipe Length:

Approximate Reynolds number:

Dh =

29.25 in

Ap =

672.0 in2

Q =

17657 Aft3/min

V =

3784 Aft/min

L =
Re =

Friction factor:
Friction pressure loss:

50 ft
9.41E+05
0.0200

pf =

4.67 ft2

0.505 inch WG

Err:522
=

0.01824 psi

pf . df =

Estimated total losses:

0.758 inch WG

0.02736 psi

SHEET NO.

CALCULATION SHEET
__4__
DESCRIPTION

PROJECT NO.

CORe Feasibility Study - Blower Sizing

MADE BY

H335456

Jul 27. 10

DATE

Nominal pipe size = 16"

Pipe internal diameter = hydraulic diameter:
Pipe Area:

Ap = * (Dh / 2) 2

Flow:
Velocity:

V = Q / Ap

Approximate Pipe Length:

Dh =

15.25 in

Ap =

182.7 in2

Q =

4414 Aft3/min

V =

3480 Aft/min

L =

Approximate Reynolds number:

Re =

4.51E+05
0.0200

pf =

Friction pressure loss:

pf . df =

Estimated total losses:

1.27 ft2

141 ft

Friction factor:

Cell Feed Line:

__6__

B. Perry
DATE

Header To Last Cell:

OF

CHECKED BY

Err:522

2.312 inch WG

0.08345 psi

3.468 inch WG

0.12517 psi

Nominal pipe size = 6"

Pipe internal diameter = hydraulic diameter:
Pipe Area:

Ap = * (Dh / 2)

Flow:
Velocity:

V = Q / Ap

Dh =

5.44 in

Ap =

23.2 in2

Q =

883 Aft3/min

V =

Approximate Pipe Length:

5470 Aft/min

L =

Approximate Reynolds number:

15 ft

Re =

2.53E+05

Friction factor:

0.0200
pf =

Friction pressure loss:

pf . df =

Estimated total losses:

Summation of System Losses =

7.05 inch WG

0.25

0.06148 psi

2.555 inch WG

0.09221 psi

psi

= pressure required at cell + system losses

=

5.51

5.77

psig

0.25
=

159.8

Err:522

1.703 inch WG

Blower Discharge Pressure

Estimated blower discharge pressure:

0.16 ft2

inch WG

SHEET NO.

CALCULATION SHEET
__5__
DESCRIPTION

PROJECT NO.

CORe Feasibility Study - Blower Sizing

MADE BY

H335456

B. Perry
DATE

Jul 27. 10

DATE

Blower Power

Blower power,

HP =

f =

Assuming total fan efficiency,

0.7

HPtotal =

Total blower power,

p in inch WG

Q.p / 6356.f

872

Estimated from curve

HP

HPea =

For four duty blowers, power for each,

217.9

HP

Recommend 250 HP drive motor.

Spencer Power Mizer Blower Size Selection

Total blower capacity, Qtotal =

For four duty blowers, Qea

Approximate blower total pressure,

24278 std ft3/min

6069.38 std ft3/min

pt =

159.8 inch WG

5.8 psig

OF

CHECKED BY

__6__

SHEET NO.

CALCULATION SHEET
__6__
DESCRIPTION

CORe Feasibility Study - Blower Sizing

PROJECT NO.

MADE BY

H335456

B. Perry
DATE

Spencer Power Mizer Series 6000 Blower Recommended

Jul 27. 10

OF

CHECKED BY

DATE

__6__