Prilling Tower Design

Temperature of inlet air = 35C.

Temperature of outlet air = 65C
Temperature of inlet prill= 137C
Temperature of outlet prill = 70C

Heat transfer coefficient is given by :

Obj100

( Mcabe Smith Ed. 4 eq. 12.71)

Where, D= Diameter of particle = 0.002 m

k= Thermal conductivity of air = 0.027 W/mK
Re = particle Reynolds no.
Pr = Prandtl no.,

Cp (air) = 1087.32 J/kg

f (air) = 0.2 10-4 Ns/m2
kf (air) = 0.027W/mK
The Prandtl No. is given by

Obj101

Obj102

Or,
= 0.805
Now,
mair.Cp.Tair= murea. (Cp.Tpartticle + Hf)
Cp of particle = 1.8 J/ kg K
Cp of air = 1087.32 J/kg K
Hf = 241.6103 J/kg
Tair = 65-25 = 40C
T of particle = 137- 70
= 67C
So,
mair = 45833.33(1.867 + 241600)/(1087.3240)
= 254728.6 kg/hr
= 70.76 kg/s
The Reynolds No. is given by

Obj103

Re = 0.00270.76
0.210-4
= 7075.8
Hence,

Obj104

= 2.0 + 0.6(7075.8)0.5(0.805)0.33

And,

h = 48.980.027/0.002
= 661.28 W/m2C

Area of particle = Dp2/4

= (0.002)2/4
= 3.141610-6 m2
log mean temperature difference = (T)ln

Obj105

Or,
= 57.45 C
Now,

By applying heat balance on the prill.

t.hA(T)ln = mpCp(T)p + mpHf
Where,

t = time required by the particle to cool down

Mass of one particle = pp(Dp)3/6

pp =density (crystal) =1.335 gm/cm3 =1335 kg/m3
= 1335(0.002)3/ 6
mp = 5.5910-6 kg.

Or,
Therefore

t = 5.5910-6(1.867 + 241.6103)/(661.293.14110-657.45)
= 11.32 s
Now,

Obj106

For 1000 < NRe < 200000

pp = 1335kg/m3
pf = 1.28 kg/m3
g = 9.81 m/s2
Dp = 0.002 m

Obj107

Or,
ut = 7.91 m/s

Obj108

Now,

Obj109

= 1012.8
Hence the condition is satisfied.
Assuming Prilling Bucket Radius r = 0.18 m
Angular velocity ,

= 350 rpm

Now,
Horizontal distance traveled by the particle = rt
= 0.18(350/60)11.32
= 11.88 m
Taking clearance of 70 cms
Radius of the Prilling Tower R = 11.88 + 0.70

= 12.58 m

Diameter D = 212.58
= 25.172 m

Now,
The Cross section area is Ap = D2/4
= (25.172)2/4

= 497.3 m2
Air Flow rate G = 70.76 kg/s
And ,
The volumetric flow Rate = G/f
= 70.76/1.28 m3/s
Qair = 55.28 m3/s

Obj110

Cross Sectional velocity =

Obj111

=
vair = 0.111 m/s
Now,
Velocity of the prill relative to the ground = ut - vair
= 7.91 0.111
vrel = 7.799 m/s
Therefore,
Height of the tower required = vrel time of fall
= 7.799 11.32 m
= 88.28 m