Chemical Engineering Process Industries C Excel Spreadsheets

Process Industries C Develop a spreadsheet that calculates out for a range of Reynolds
numbers and relative roughness, the friction factor from Haaland, and the
Excel Spreadsheets one from Avci & Karagov. Calculate the percentage error (based on the
PROBLEM SET 2 Haaland equation) and show how this error changes with Reynolds
number for three test cases: a) e/d=0 (i.e. smooth wall pipe, e/d=0.0001,
Attempt all problems in the same workbook. Upload your completed Excel e/d=0.01).
spreadsheet onto Vision, when the assignment session becomes available.
Show the results by plotting a suitable graph or graphs.
1. In fluid mechanics calculating the friction factor is a key part of designing
pipelines. Rather than using the Moody chart, there are a number of References: A.Avci, I.Karagoz A Novel Explicit Equation for Friction
equations that different people propose to calculate f. Factor in Smooth and Rough Pipes J. Fluids Engineering June 2009,
Vol.131
The classic equation for friction factor in rough pipes is the Colebrook
equation, developed in 1939:
1 / 2.51 2. In thermodynamics, we often need to show processes such as those to
= 2.010 [( ) + ] generate power on a diagram; either a Pressure-Enthalpy diagram, or a
3.7 Temperature-Entropy diagram (you should know what these look like for a
pure substance). The spreadsheet that is attached to this problem sheet
With this equation being implicit in f, it is not easy to use. Next came contains the properties of saturated water as a liquid and vapour (a
the Haaland equation: section from Steam Tables). Using this data, generate the following:
1 / 1.11 6.9 a) A P-h plot showing both saturated vapour and liquid lines and hence
= 1.810 [( ) + ]
3.7 the two phase region.
b) A T-s plot, again showing the vapour and liquid curves.
Which gives f explicitly as a function of Reynolds number Re, and
roughness e and pipe diameter d. HTT
c) Draw the following process on the P-h diagram, using cells to contain
In a paper by Avci and Karagoz, (J.Fluids Eng.) May 2009, the friction the values of pressure and enthalpy to plot the lines.
factor through a pipeline at high Reynolds numbers has been quoted as:
100 kg of saturated water vapour at 100 kPa, is condensed to give
6.4 saturated liquid. The pressure of this liquid is suddenly dropped
= 2.4 across a throttling valve to 50 kPa and the resulting 2-phase mixture
passed into a gas-liquid separator. Calculate the mass of liquid and
(() (1 + 0.01 (1 + 10 ))) vapour coming from the separator.

Where f is the Darcy friction factor 3. A cylindrical storage tank with a conical bottom is used to store an
e is the absolute roughness aqueous solution of NaOH. To make up a desired volume and molarity of
d is the pipe diameter NaOH, operators first fill up the conical tank to a certain level H. They
Re is the Reynolds number then pump concentrated 47wt% solution NaOH from a IBC (Intermediate
Bulk Container) into the storage tank. Devise a spreadsheet that will
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Chemical Engineering
calculate the necessary volume of concentrated caustic that is needed to
make up a specified molarity of dilute caustic. Assume the tank and fresh
caustic are at 20C.
The tank and volume calculations of water are the same that you did in
the power point sessions you can re-use your spread sheet from that
exercise.
(You may will need to find a relationship between the density of the
caustic solution and mass % concentration the density of these
solutions vary with the NaOH added and cannot be assumed to be
constant)
HTT Adding a strong alkali, or acid to water releases heat. Why not
incorporate a feature in the spreadsheet that finds the temperature the
solution will reach after all the alkali has been added. Assume there are
no heat losses.
4. The flow diagram below shows a process to manufacture ethylene oxide.
Fresh ethylene is mixed with air and a recycle stream then passed into a
reactor. The single pass conversion of ethylene is typically 60 top 70%.
Alongside the main reaction, a side reaction where a portion of the
ethylene (4%) reacts with oxygen to produce CO2 and water:
2C2H4 + O2 -> 2C2H4O
C2H4 + 3O2 -> 2CO2 + 2H2O
The reactor product stream passes into a separation stage where first the
majority of the CO2, H2O and nitrogen are removed. The second
separation stage is designed to separate out unreacted ethylene and
ethylene oxide. Any remaining CO2 and nitrogen is likely to come off with
the ethylene. The ethylene rich product stream is recycled and a purge is
used to make sure that there is no build-up of nitrogen and water.
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27 November 2017
Process Industries C Excel Spreadsheets
The block diagram below, summarises the process.
Purge
Reactor CO2,H2O
Separator
Ethylene oxide
General specifications for the process are therefore:
The feed rate of fresh ethylene (in kg/hr)
The % excess air supplied (e.g. 30%), based on 100% conversion of
the ethylene supplied in the feed stream.
The single pass conversion of ethylene.
The selectivity of ethylene producing ethylene oxide, and the
ethylene that forms CO2.
Separation stages are assumed to be splitters, and should be
described in terms of the % of feed appearing in the top product
stream
The purge stream should be specified in terms of the % of the main
stream which is purged.
5. Using problem 4, develop a spread sheet that calculates the temperature of
the feed stream to the reactor, assuming there are no heat losses at the
mixing point between the feed and the recycle stream. Typically the fresh
feed will be at 20C and the recycle stream at 120C. Assume the gas
mixtures behave as an idea gas and there are no pressure effects on
specific heat capacity expressions.
Specific heat capacity of gaseous components can be expressed as:
= A + BT + C 2 + 2, T in K
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Chemical Engineering Process Industries C Excel Spreadsheets

A B C D
Multiplier 1 x103 x106 x10-5
C2H4 1.424 14.394 -4.392
C2H4O -0.385 23.463 -9.296
O2 3.639 0.506 -0.227
N2 3.28 0.593 0.04
CO2 5.457 1.045 -1.157
H2O 3.47 1.45 0.121

NB For unit conversions, you should refer to your copy of the UNIT
CONVERSION SHEET (also available from Vision). For other information, you
should use appropriate sources.

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