Determination

of TSSA Certified Pressure Pipe and Fittings to Transfer

Extruded Plastics from Extruder’s Adaptor Exit to the Reactor

Prepared by
Femi Solomon Olorunnaiye, EIT


Supervised by
Amit Parekh, P.Eng
Pressure Drop Calculation

There are many factors that go into calculating pressure drop in pipe and fittings, including
volumetric flow rate, temperature, pipe geometry (ID), and the interior smoothness of the
pipe. The pressure drop in pipes can be determined using several methods such as the
Darcy-Weisbach formula, equivalent length method, flow coefficient method, and the
resistance coefficient method (1,2). The resistance coefficient method is considered the
most effective method because it takes into account losses due to friction in pipe and
fittings. The method is industrially applicable in determine losses in small and large pipe
under lamina or turbulence flow (2).

Head loss in a pipe is the sum of elevation difference (hZ), Fitting losses (hL), and Friction
losses (hF) (2). This report is intended to determine a safe operating pressure to transfer
extruded plastics from extruder’s adaptor exit to the reactor entrance.

Fitting losses (hL)
Loss due to fittings can be obtained using the Resistance Coefficient (K) Method:
hL = (f*L/D + ΣK)*(V²/2g) 1.0
K = K1/Re + K∞ (1 + 1/D) (2-K method) 1.1
K = (1.2 + 160/Re1) ∗ [(D1/D2)4 − 1] ∗ (1.6 sin(θ/2) 1.2a
!
K = (0.6 + 0.48f1) * (D1/D2) ² * ((D1/D2) ² - 1)*(1.6sin( ! )) 1.2b

Equation 1.2a is apply for tapered reduction θ < 450 when Re < 2500 and equation 1.2b is
apply for tapered reduction θ < 450 when Re > 2500 (3)

𝐴 = (𝜋𝐷! )/4 1.3
𝑉 = 𝜈/𝐴 1.4
Re = (𝜌. 𝑉. 𝐷)/𝜇 1.5
Re = 16/f (Re< 2320) 1.6
𝑓 = 4 ∗ 𝑓𝑎𝑛𝑛𝑖𝑛𝑔 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 1.7

Friction losses (hF)
Loss due to friction in pipes is calculated as:
hF = f(L/D)(V²/2g) 2.0


Total head loss in a pipe is hTotal = hZ + hL + hF 3.0

Pressure drop (ΔP) due to head loss in pipe is calculated as:
𝚫𝐏 = 𝒉𝒕𝒐𝒕𝒂𝒍 ∗ 𝛒 ∗ 𝐠 4.0

Fig. 1: Cross sectional drawing of the Extruder (Obtained from GreenMantra Resource)


Fig. 2: Pipes and fittings drawing from the Extruder’s adaptor to the Reactor head


Table 1: Wax/ HDPE Parameters (Obtained from Engr. Amit Parekh)
System Properties

Plastic Flow rate in kg/hr 500

Plastic Flow rate in kg/s 0.139

Density of HDPE in kg/m3 920

Plastic Volumetric Flow rate in m3/s 0.000151

Dynamic Viscosity of HDPE in Pa.s 750

Kinematic Viscosity of HDPE in m2/s 0.8152

Moderately Corroded Carbon Steel Absolute Roughness (m) 0.00015

 Reynolds Number Calculation
Pipes and fittings Diameter Diameter CSA Velocity, V Reynolds
(in) (m) (m2) (m/s) Number
(Re)
Extruder 4.5 0.114 0.0103 0.014710243 0.002062494
4.5" Reduction to 1-5/8", 15ᵒ Taper 1.625 0.041 0.0013 0.112807541 0.005711521
1.5" Pipe, 17.75" 1.5 0.038 0.0011 0.132392184 0.006187481
1.5" Tee, Run through 11.625" 1.5 0.038 0.0011 0.132392184 0.006187481
2.0" Ball valve, full bore, 11.375" 2 0.051 0.0020 0.074470603 0.004640611
2.0" Pipe, 9.875" 2 0.051 0.0020 0.074470603 0.004640611
45ᵒ Elbow, Mitered 2 0.051 0.0020 0.074470603 0.004640611
2.0" Pipe, 62.625" 2 0.051 0.0020 0.074470603 0.004640611
45ᵒ Elbow, Mitered 2 0.051 0.0020 0.074470603 0.004640611
2.0" Pipe, 4.875" 2 0.051 0.0020 0.074470603 0.004640611

The CSA, Velocity (V) and Reynolds number calculations was done using equation 1.3, 1.4
and 1.5 respectively.

Fanning friction Calculation

Pipes and fittings Reynolds Fanning Friction
Number (Re) (f)
Extruder 0.002062494 7757.599441
4.5" Reduction to 1-5/8", 15ᵒ Taper 0.005711521 2801.355354
1.5" Pipe, 17.75" 0.006187481 2585.86648
1.5" Tee, Run through 11.625" 0.006187481 2585.86648
2.0" Ball valve, full bore, 11.375" 0.004640611 3447.821974
2.0" Pipe, 9.875" 0.004640611 3447.821974
45ᵒ Elbow, Mitered 0.004640611 3447.821974
2.0" Pipe, 62.625" 0.004640611 3447.821974
45ᵒ Elbow, Mitered 0.004640611 3447.821974
2.0" Pipe, 4.875" 0.004640611 3447.821974

The fanning friction factor calculation was done using equation 1.6

Ks Calculation
Fittings Diamet Diameter
er (in) (m) K1 K∞ K
4.5" Reduction to 1-5/8", 15ᵒ Taper 1.625 0.041275 53676.20
- -
1.5" Tee, Run through 11.625" 1.5 0.0381 150 0.05 24243.86
2.0" Ball valve, full bore, 11.375" 2 0.0508 300 0.017 28014.59
45ᵒ Elbow, Mitered 2 0.0508 500 0.25 107745.47
45ᵒ Elbow, Mitered 2 0.0508 500 0.25 107745.47
 The K value for the 4.5" reduction to 1-5/8", 15ᵒ taper’s calculation was done using
equation 1.2 and the constant K1 and K∞ values were obtained from literature (2,3). Also,
the 1.5" Tee run through 11.625", 2.0" Ball valve full bore 11.375", and 45ᵒ Elbow Mitered
Ks was calculated using equation 1.1.

Friction Loss Calculation, hf

Pipes D (in) D (m) V (m/s) Fanning Length Length Friction Loss (hF)
Friction (f) (in) (m) (m)
1.5" Pipe, 17.75" 1.5 0.038 0.132 2585.9 17.75 0.451
109.5
2.0" Pipe, 9.875" 2 0.051 0.074 3447.9 9.875 0.251
19.3
2.0" Pipe, 62.625" 2 0.051 0.074 3447.9 62.625 1.591
122.2
2.0" Pipe, 4.875" 2 0.051 0.074 3447.9 4.875 0.124
9.5

The friction loss in pipes was calculated using equation 2.0.

Head Loss Calculation, hL

Pipes and fittings D D V Fanning L K h L
(in) (m) (m/s) Friction (f) L (in) (m) (m)
4.5" Reduction to 1- 1.62 0.041 0.113 53676.20 61.7
5/8", 15ᵒ Taper 5 2801.4 6 0.15
1.5" Tee, Run through 1.5 0.038 0.132 11.62
11.625" 2585.9 5 0.30 24243.9 93.4
2.0" Ball valve, full bore, 2 0.051 0.074 11.32
11.375" 3447.8 5 0.29 28014.6 30.0
45ᵒ Elbow, Mitered 2 0.051 0.074
3447.8 - - 107745.5 30.5
45ᵒ Elbow, Mitered 2 0.051 0.074
3447.8 - - 107745.5 30.5

The head loss in pipes was calculated using equation 1.0

Total Losses (hT) from extruder’s adaptor exit to the reactor entrance
hT= (109.5 + 19.3+ 122.2 + 9.5) + (93.4 + 30 + 30.5 + 30.5) (equation 3.0)
=444. 79m

Pressure Drop (ΔP) from extruder’s adaptor exit to the reactor entrance

Pipes and fittings Head Loss Pressure Drop
(m) (Psi)
Extruder - -
4.5" Reduction to 1-5/8", 15ᵒ Taper 61.7 80.78
1.5" Pipe, 17.75" 109.5 143.278
1.5" Tee, Run through 11.625" 93.4 122.217
2.0" Ball valve, full bore, 11.375" 30.0 39.301
2.0" Pipe, 9.875" 19.3 25.221
45ᵒ Elbow, Mitered 30.5 39.907
2.0" Pipe, 62.625" 122.2 159.947
45ᵒ Elbow, Mitered 30.5 39.907
2.0" Pipe, 4.875" 9.5 12.451
Total 444.79 582.373

The total pressure drop (ΔP) in pipes and fittings was calculated using equation 4.0

Conclusion
I would recommend TSSA certified pressure pipes and fittings of 600 Psi to transfer
extruded materials from extruder’s adaptor exit to the reactor.

Glossary
K Resistance coefficient due to fittings
f Darcy’s pipe friction factor
D Pipe inside diameter
D1 Internal diameter of the extruder
D2 Internal diameter of the extruder’s adaptor
A cross sectional area
V Fluid velocity
𝜈 Fluid volumetric flow rate
Re Reynolds number
K1 Resistance Coefficient at Re=1
K∞ Resistance Coefficient for larger fittings at Re= ∞
K Resistance Coefficient
𝜃 Reduction angle
𝜇 Dynamic viscosity
g Acceleration due to gravity
f Darcy’s pipe friction factor=4*fanning friction factor
L Pipe length
ρ Fluid density
e Pipe roughness


References
1. https://neutrium.net/fluid_flow/pressure-loss-from-fittings-2k-method/
2. http://www.katmarsoftware.com/articles/pipe-fitting-pressure-drop.htm#kvalue
3. http://cheguide.com/tag/3-k-darby/