PLANT DESIGN –

MATERIAL HANDLING
LIQUIDS & GASES
Dr. Aqeel Ahmad TAIMOOR
 Nomenclature

Failure Mode
Nomenclature
Standards for SYMBOLS
Common Symbols – Standard
Piping and Instrumentation Diagram
Newtonian and Non-Newtonian Fluids

u rt
g
yo

hu
p
/ 𝑑𝑦
tc 𝑑𝑉
Ke
τ =μ
ater
W

s tard
Cu
Piping Basics – Newtonian Fluids
𝐿 𝜌 𝑢2
 Pressure drop in pipes ∆ 𝑃=𝑓
𝐷 2
 For fanning film calculations we require:
 Reynolds number
 relative roughness, e = absolute roughness/pipe inside diameter

 For gases differential lengths of pipe with average density must be used
Pipe Fittings
 Pressure Drop in Fittings

 K – method
 Equivalent pipe length
Piping and Instrumentation Diagram
 Valves Selection

Gate valve, Plug valve, Ball valve, Globe valve, Diaphragm valve, Butterfly valve, Non-return valve
ASME B16 standards provides specifications for the valves
Example – Manual

A pipeline connecting two tanks contains four standard elbows, a globe valve that is
fully open and a gate valve that is half open. The line is commercial steel pipe, 25 mm
internal diameter, length 120 m.
The properties of the fluid are: viscosity 0.99 mNm-2 s, density 998 kg/m3. Calculate
the total pressure drop due to friction when the flow rate is 3500 kg/h.
 Example – Computer Aided Design
40 tons⋅h–1 of water is transported by a 205-m long pipe made from mild steel, with the
inside diameter of 100mm and the wall thickness of 5 mm. The pipe system contains
the following fittings: an open gate valve, a half open gate valve, two standard 90◦
elbows, a disk water meter, and an open globe valve, which are placed as shown in
Figure. The pipe inlet and outlet are in the same horizontal level. Water pressure at the
beginning of the pipe system is 5 bar, and its temperature is 25◦C. Average ambient
temperature is 20 ◦C, and the average value of the heat transfer coefficient is 20
W⋅m−2⋅K−1. Calculate the pressure drop, pressure, and temperature profile across the
length of the pipe.

5m
Correlations for Pressure drop
Correlations for Pressure drop
Correlations for Pressure drop
Correlations for Pressure drop
Correlations for Pressure drop
Typical velocities in Pipes
Optimum Pipe Diameter
Nomograph for estimation of
optimum pipe diameter
Pipe
Schedule
Number
Example – Manual

Estimate the optimum pipe diameter for a water flow rate of 10 kg/s, at 20°C. Carbon
steel pipe will be used. Density of water 1000 kg/m3.
Example – Manual

Estimate the optimum pipe diameter for a flow of HCl of 7000 kg/h at 5 bar, 15°C,
stainless steel pipe. Molar volume 22.4 m3/kmol, at 1 bar, 0°C.
Example – Manual
Calculate the line size and specify the pump required for the line shown in Figure;
material ortho-dichlorobenzene (ODCB), flow-rate 10,000 kg/h, temperature 20°C,
pipe material carbon steel.
Pump Types
Pumps
Pump Selection
Pump – Centrifugal

 Pump head H = ΔP/ρg

Pumps
Example – Manual

A tanker carrying toluene is unloaded, using the ship’s pumps, to an on-shore storage
tank. The pipeline is 225 mm internal diameter and 900 m long. Miscellaneous losses
due to fittings, valves, etc., amount to 600 equivalent pipe diameters. The maximum
liquid level in the storage tank is 30 m above the lowest level in the ship’s tanks. The
ship’s tanks are nitrogen blanketed and maintained at a pressure of 1.05 bar. The
storage tank has a floating roof, which exerts a pressure of 1.1 bar on the liquid.
The ship must unload 1000 metric tons within 5 hours to avoid demurrage charges.
Estimate the power required by the pump. Take the pump efficiency as 70 per cent.
Physical properties of toluene: density 874 kg/m3, viscosity 0.62 mNm2 s.
 Pump Characteristic Curves

impeller sizes (a) 250 mm

(b) 225 mm (c) 200 (d) 175
mm (e) 150 mm
Example – Manual

A process liquid is pumped from a storage tank to a distillation column, using a

centrifugal pump. The pipeline is 80 mm internal diameter commercial steel pipe, 100
m long. Miscellaneous losses are equivalent to 600 pipe diameters. The storage tank
operates at atmospheric pressure and the column at 1.7 bara. The lowest liquid level
in the tank will be 1.5 m above the pump inlet, and the feed point to the column is 3 m
above the pump inlet.
Plot the system curve on the pump characteristic given in Figure and determine the
operating point and pump efficiency. Properties of the fluid: density 900 kg/m3,
viscosity 1.36 mN m-2s.
Example – Manual

Liquid chlorine is unloaded from rail tankers into a storage vessel. To provide the
necessary NPSH, the transfer pump is placed in a pit below ground level. Given the
following information, calculate the NPSH available at the inlet to the pump, at a
maximum flow-rate of 16,000 kg/h. The total length of the pipeline from the rail
tanker outlet to the pump inlet is 50 m. The vertical distance from the tank outlet to
the pump inlet is 10 m. Commercial steel piping, 50 mm internal diameter, is used.
Miscellaneous friction losses due to the tanker outlet constriction and the pipe fittings
in the inlet piping are equivalent to 1000 equivalent pipe diameters. The vapor
pressure of chlorine at the maximum temperature reached at the pump is 685kN/m2
and its density and viscosity, 1286 kg/m3 and 0.364 mNm-2 s. The pressure in the
tanker is 7 bara.
Mechanical Design of Piping System
Example – Computer Aided Design

Forty tons per hour of water with the temperature of 20 ◦C has to be pressured from 1 to 6 bar.
a. Calculate the electricity requirement of the pump if its efficiency is 70%.
b. The pump characteristic curve H=f(Q) provided by the producer is given in Table considering
the same efficiency as in point a, calculate the discharge pressure, head developed, and NPSH
available.
Use Aspen Plus in this simulation.
Select Property
package as
described
Only for water
Compressors Selection
Compressors
Compressor Selection
Example – Computer Aided Design

A centrifugal compressor is used to cover the pressure drop during the transportation of natural
gas between two compressor stations. The inlet temperature of natural gas is 25◦C, inlet
pressure is 5.5MPa, and the compressor pressure ratio is 1.5. One million Nm3 per day of natural
gas with the composition given in Table is processed. Using Aspen HYSYS, calculate the
temperature of gas at the compressor outlet, polytropic fluid head, and the power required, if
polytropic efficiency of the compressor is 0.76.
Example – Computer Aided Design

Select an appropriate compressor type for the compressor used in previous example. Compare
the costs of suitable compressor types.
Comparison
Conveyers – Solid handling
Size reduction – Solids
 Equipment for Solid Handling

• hoppers • centrifuges
• belt conveyors • falling film evaporators
• elevators • moving bed reactors
• pipe conveyors • crushers and pulverizers
• screw conveyors • jet mills
• kneaders • ball mills
• extruders • agglomerators
• slurry pumps • granulators
• fluidized bed heaters • tableting presses
• fluidized bed reactors • paper machines
• washers • classifiers
• flocculators • electrostatic precipitators
• spray driers • homogenizers
• prill towers
• rotary driers
• rotary kilns
• belt driers