Professional Documents
Culture Documents
STUDENT LABORATORY
GUIDE
NAME OF COURSE:
CHEMICAL ENGINEERING TECHNOLOGY( IIIA)
NQF
LEVEL
NQF
CREDITS
CHEMICAL
COURSE CODE
(CET33AT)
All rights reserved. Apart from any reasonable quotations for the purposes
of research criticism or review as permitted under the Copyright Act, no part
of this book may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy and recording, without
permission in writing from the publisher.
Contact Details.............................................................................................................8
2.2
Staff availability............................................................................................................8
4. ..........................................................................................................................Code of conduct
....................................................................................................................................................12
Safety..........................................................................................................................................12
B. Laboratory Format and Procedures.................................................................................12
4.1
Attendance..................................................................................................................15
4.2
4.3
Responsibilities of students........................................................................................16
5. Assessment..............................................................................................................................17
5.1
5.2
Assessment rules.........................................................................................................17
5.3
Marking system..........................................................................................................17
5.4
predicate/Year mark....................................................................................................18
5.5
Moderation..................................................................................................................19
5.6
Promotion requirements.............................................................................................20
6.1
6.2
6.3
7. Glossary of terms....................................................................................................................22
7.1.Assessment Records.............................................................................................................22
7.2
31
SECTION
ORGANISATIONAL COMPONENT
1. WELCOME
Welcome to laboratory session of Chemical Engineering Technology IIIA. This part of the
course provides an introduction and represents advanced knowledge in unity operation and is
offered via experimental work, problem-based work or project-based work over 8 weeks. The
course is structured in such a way as to master theoretical concepts and principles and various
practical skills to provide a sound foundation for the study of Load Losses, Test bench pumps
and Heat transfer to complement the major courses in the qualification and pave the way for
more advanced learning in B-Tech in Chemical engineering. We trust you will enjoy the
course, and find it interesting and informative.
2. LABORATORY STAFF
2.1
CONTACT DETAILS
NAME
CAMPUS
ROOM NO
Mr M.S
Ranyaoa
Pretoria
B3 R 707
Mr M.
Mosesane
Pretoria
2.2
CONSULTATI
ON TIME
ACADEMIC
FUNCTION
Lecturer
ranyaoams@tut.
ac.za
B2 R127
9h00
16h00
Technologist
STAFF AVAILABILITY
If, after attending class and making every effort from your side to master content, you still have
problems with understanding key concepts or principles or their application, lecturers are
available for consultation.
To consult your lecturer, make an appointment by calling his office or see/ call the secretary at
(012) 382 3550/3514 for an appointment.
To consult your technologist, make an appointment by calling his office at 012 382 4655 or
call the secretary at (012) 382 3514.
The following tables indicate what literature and other resources are essential for successful
completion of this course. You are strongly advised to acquire all the prescribed resources.
PRESCRIBED RESOURCES
CATEGORY
DESCRIPTION
WHERE TO FIND
CALCULATOR
Scientific
Bookstore
COMPUTER
HARDWARE
SOFTWARE
Soshanguve,
Arcadia
Pretoria campuses
and
COST
LEVY
EQUIPMEN
T
COMPONENTS
3.1.2
RECOMMENDED RESOURCES
The following recommend resources will enhance your understanding and knowledge in this
course, and you are encouraged to use the following additional resources.
RECOMMENDED RESOURCES
CATEGORY
AUTHOR
NAME
BOOKS
Library books
MANUALS
Laboratory
manual
Online
GUIDES
Study guides
Online
PUBLISHER
ISBN NO
CD
DVD
WEBSITES
myTUTor
tut4life.tut.ac.za
4. CODE OF CONDUCT
Please take note of the following regulations. These regulations are in addition to the standard
rules and regulations as determined by the TUT. Please familiarise yourself with the TUT rules
and regulations as set out in the student diaries received on registration.
Safety
Laboratory safety is the top priority and this requires all people in the lab to be observing safe
practices at all times!
Safety glasses must always be worn by everyone in the laboratory.
Make sure you understand how the experimental apparatus works and what all
4. Session 3
The laboratory will be open to gather additional data if needed. The lecturer will be available
for consultations during the first hour of the laboratory period. During this session
examination of the experimental apparatus for the next assigned project should be performed
by each group.
5. Final Technical Report .
The final Technical report is due at the beginning of the next scheduled laboratory period
following Session 3. There are no exceptions to this deadline. The reports are to be
submitted to one of the department secretaries in the Chemical Engineering office or to the
Technician. During the week following the day on which the final report was submitted, the
group should schedule a meeting with the lecturer for the discussion of the written report. Each
member of the group should be prepared to defend and/or discuss any part of the final report.
6. Laboratory Notebook
Part of the purpose of the chemical engineering laboratories is to learn good laboratory and
research practices. An important aspect of this is safety. Another important aspect is recordkeeping and documentation. In industry you will find that all experiments have to be carefully
recorded in an official laboratory notebook and signed by the investigator on a daily basis. To
help foster these professional practices, each group is required to keep a laboratory notebook
documenting the group's work. In the notebook should be kept a neat, labeled and dated record
of all work associated with the experiment, including a copy of the precis, all raw data, the
settings on the experimental controls, any problems encountered in the experiment and what
was done to fix them and why, all calculations, a copy of your progress report, etc. The
laboratory notebooks will be handed in at the end of the semester and will contribute to the
laboratory participation portion of your grade.
7. Student Responsibilities in the Laboratory
Condition of Working Area. Students are responsible for the condition of their working area
at the end of each laboratory period.
Checkout before Leaving Laboratory. The students must have their notebooks initialed by a
Technician prior to leaving at the end of the laboratory period. At that time the Technician will
check the working area and take information about any equipment or instrumentation
problems.
8. Grading/Marking
Report grading is done by the lecturers who are in charge of a given experiment. This grade
will be based on the written report, the oral defense and other pertinent factors (e.g., if you are
totally unprepared to do an experiment, you will be docked.) Grades for this course will be
determined by the grades on the three experiments as well as your laboratory participation.
The laboratory participation portion of your grade in will include how well you followed
laboratory safety guidelines (did you wear safety glasses at all times in the lab? did you follow
the special safety precautions required for each experiment?), attendance, tardiness,
participation, professionalism, how effective a group leader you were, and the quality of your
laboratory notebook. Both laboratory instructors and teaching assistants will contribute
towards this portion of your grade.
4.1
ATTENDANCE
4.2.1.
LABORATORY RULES
BASIC RULES
4.3
It is your responsibility to make a success of learning in this course. To this end you are
encouraged to attend practical class, write practical report and hand in your
assignments/projects on the set due dates.
SECTION
LEARNING COMPONENT
5. ASSESSMENT
5.1
Assessment of this laboratory course will include experimental work, problem-based work,
Project-based works and assignments, report writing. The purpose of assessment is to
determine whether you have achieved the learning outcomes. The various assessment methods
therefore will focus on criteria that will enable the lecturer(s) to determine whether you have
achieved the learning outcomes and mastered the required skills. The assessment criteria
relevant to each learning outcome are detailed in section 2.2.
5.2
ASSESSMENT RULES
The general rules of TUT regarding assessment apply. You are advised to familiarise yourself
with these rules, as they are applied stringently.
5.3
MARKING SYSTEM
SUBJECT
MAX
MA
RK
1.
TITLE PAGE
2.
ABSTRACT
3.
INTRODUCTION
4.
THEORETICAL
BACKGROUND
ACTUAL
MARK
5.
PROCEDURE
6.
RESULTS
7.
DISCUSSION OF RESULTS
10
8.
CONCLUSION
AND
RECOMMENDATIO
NS
9.
LITERATURE CITED
10.
NOMENCLATURE
11.
ORGANIZATION
NEATNESS
AND
Appendix
A1
Raw Data
A2
10
TOTAL
50
5.4
PREDICATE/YEAR MARK
MODERATION
The lecturer of the subject will be responsible to moderate all practical report.
1.6
PROMOTION REQUIREMENTS
The leaner has to obtain the minimum of 50% in the practical report in order to pass.
6. LABORATORY COURSE CONTENT AND SCHEDULE
This course comprises of an experimental component, problem-based component and a
project-based component. Your mastery of the required skills is assessed at regular intervals.
More importantly, the application of theory is assessed through problem-based- or projectbased assignments or projects.
The following outline provides an overview of the content to be covered in this course and the
ways in which your progress will be assessed.
6.1
EXPERIME
NTAL/
DURATION
THEME
PROBLEMBASED/
PROJECTBASED
Week 1-4
PRESSURE
Load Losses
(Learning Outcome 1)
DROP
PIPING
SYSTEMS
IN
COMPLE
TION
DATE*
Week 5-8
TEST
TEST BENCH
BENCH
(Learning Outcomes 2 )
It is expected that the students will be able
to
Week 9- 12
HEAT
TRANSFER
heat
transfer
LEARNING OUTCOME 1:
Load losses
Assessment criteria
Assessment method
Oral test
Written report
LEARNING OUTCOME 2:
Test bench pumps
Assessment criteria
Assessment method
Oral test
Task performance
Written report
LEARNING OUTCOME 3:
Heat exchanger
Assessment criteria
Assessment method
6.3
Written report
Communication skills
Sources used for the compilation of the glossary: Fluid flow for Chemical Engineers by H.
Randall
7. ASSESSMENT RECORDS
The following guideline for the preparation of report writing are attached to serve as examples
of the implementation of the assessment criteria and assessment method, as listed in the table
3.1, and you should be familiar with these examples to prepare and orientate yourself of how
the various assessment criteria are used and applied in the various assessment methods.
FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL
ENGINEERING
1. INTRODUCTION
The transport of fluid (liquid or gas) in closed conduits (commonly called pipe if it is of round
cross sectional area or duct if it is not round) is extremely important in our daily operations.
There is a variety of application of pipe flow with a range of very large constructed pipelines,
consider the pipelines carrying crude oil from oil rigs in the sea being pumped inland for
hundreds of kilometers, to a complex human beings blood and respiratory systems. (You can
think of many applications between the two extremes)
The flow of a fluid in a pipe may be laminar flow or it may be a turbulent flow. Osborne
Reynolds conducted a simple experiment of injecting a neutrally buoyant dye in a pipe of
diameter D carrying water with velocity V and observed the characteristics or behavior of the
fluid at very low flow rate, larger intermediate flow rate and large enough flow rate and later
denoted the three characteristics as laminar, transitional and turbulent flow, respectively. The
flow in a round pipe is laminar if Reynolds number is less than approximately 2100 and
turbulent if it is greater than 4000. For Reynolds numbers between the two limits, the flow is in
a transitional flow.
N RE
ud
NOTE: The drop in pressure, discharge coefficient and friction factor will calculated by using
the formulae:
i. P 10 5
fLu
2D
(bar)
where:
4Q
ii. d 2 2 g P
where:
= discharge coefficient
Q = volumetric flow rate
g = gravity
2P
iii. K u 2 10 5
where:
K = friction factor
4. PIPE DIMENSIONS
COMPONENT
S.S Pipe DN 15
d = 18.10
S.S Pipe DN 20
d = 23.70
Cal. Orifice DN 25
d = 20.65
Venturi tube DN 25
d = 16.00
U bends
d = 30.50
L bends
d = 30.50
Enlargement
d = 18.10
OUTER DIAMETER(mm)
D = 30.50
Contraction
D = 30.50
d = 18.10
The distance between the measure points for all the tubes is 800mm.
5. PROCEDURE
Set the pressure of the pilot plant at 1.4 bar (plants operational pressure).
Increase or decrease the flow rate by pressing the from control panel.
The pressure can be read either from the mercury manometer or from the computer,
depending on whether the plant is operated manually or automatically via the computer.
Depending on the plant operation again, the pump output can either be read off from
the control panel or the computer.
7. EMERGENCY STOP
8. PURPOSE
(d) To compare experimentally determined pressure drop with the calculated one from
equation.
Reference:
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Unit for the study of
load losses pilot plant
INTRODUCTION.
The liquid transfer and circulation in piping is a problem of main importance for normal civil
applications (e.g. waterworks) as well as for the industry. It follows that it is important to know
the mechanisms of fluid transfer.
The pump test bench plant (or any plant operated with multiple pumps) can be characterized by
the regulation of the following manipulated variables:
The efficiency ()
These variables are taken indirectly from the following controlled variables:
The formulae that gave us consent to detect, via the controlled variables, the manipulated
variables, have the following:
N fluid
(H Q )
in (kW)
102
(1)
Where:
N shaft
(2n)
C 9.81 in (W)
60
(2)
Where:
n is the rpm;
C is the torque given by: arm weight * length, expressed in kg.m.
(%)
N fluid
Nshaft
100
(3)
The measurement will be made by changing the pump speed, i.e. the rpm and, different
flow rate will be set for each constant speed value. The following variables will be
detected for each of these conditions:
Pump efficiency
Behavior of the efficiency (%) as a function of flow rate (Q in l/h) for fixed revolutions
per minute (e.g. 2800rpm).
Behaviour of the efficiency (%) as a function of flow rate (Q in l/h) for a range of
revolutions per minute (e.g. 29rpm 3000rpm).
Pressure developed (P in mH2O) as a function of flow rate (Q in l/h) for a range of
revolutions per minute (e.g 20rpm 3500rpm).
Pressure developed (P in mH2O) as a function of flow rate (Q in l/h) for fixed
revolutions per minute (2900rpm.
Pressure developed by pumps G1 and G2 in series versus pump G2 at constant speed of
2900rpm.
Pressure developed by pumps G1 and G2 in parallel versus pump G2 at constant speed
of 2900rpm.
The power PE required in an ideal centrifugal pump can be expected to be a function of the
liquid density , the impeller diameter D and the rotational speed of the impeller N. The
relationship is assumed to be given by the equation:
PE C1 N 3 D 5
(4)
Where C1 is a constant which depends on the geometry of the system. The power PE is also
proportional to the product of the volumetric flow rate Q and the total head h developed by
the pump given by:
PE C 2 Qh
(5)
Using pump G2, prove that the two equations are consistent. What conclusions can you
make from your experiment? Keep the speed of pump constant at 2800rpm.
N 's
N Q
(6)
( gh) 3 / 4
Two pumps are said to be geometrically similar when the ratios of corresponding dimensions
in one pump are equal to those of the other pump. Geometrically similar pumps are said to be
homologous. A set of equations known as the affinity laws govern the performance of
homologous pumps at various speeds.
Affinity laws
Q1 N 1
Q2 N 2
and
D1
D2
(7)
h1 N 1
h2 N 2
D1
D2
(8)
Similarly:
PE1 N 1
PE 2 N 2
D1
D2
(9)
and by analogy with (8) the net positive suction heads for the two pumps can be related by the
equation;
NPSH 1 N 1
NPSH 2 N 2
D1
D2
(10)
A centrifugal pump with an impeller diameter 0.05m has the following performance data when
pumping water at the best efficiency point:
Impeller speed N
=2800rpm
Capacity Q
=10000l/hr
Total head h
=15.6m
=2m
Brake power PB
=8000W
Evaluate the performance characteristics of a homologous pump with the impeller diameter
operating at half the impeller speed.
START UP AND RUNNING.
PUMP G1.
PUMP G2.
STOP
Stop pump G1 and G2 pushing the relative red pushbutton.
Switch off the E.L.C.B
For long stop period, drain tank D1 and disconnect the plant from the electrical
supply.
EMERGENCY STOP.
Push the emergency pushbutton.
Reference:
Holland F.A and Bragg R. Fluid flow for Chemical Engineers 1995, 152 154
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Test bench
pump pilot plant
1. INTRODUCTION
Almost all operations of chemical engineering involve energy conversions, generating and
transferring heat. Therefore it is important to know how heat can be transferred between the
various systems.
In industry heat can be transferred from a fluid to another through various appliances: the most
important ones are heat exchangers; modern technology has developed several types of these
devices according to whether heat must be transferred between liquids, between liquids and
gases or vapour, or between gases.
2. HEAT TRANSFER
In thermodynamics, energy can be transferred between two bodies also as heat: this type of
transfer occurs thanks to a difference in temperature. The heat can be defined as the energy
which can be transferred due to difference in temperature between two bodies. This energy is
carried out through three distinct mechanisms, that is:
a. Heat conduction
b. Heat convection
c. Heat radiation
In the manual only heat of conduction and convection are treated because both these
phenomena need a material support, that is, they occur in the mass of a body.
3. HEAT CONDUCTION
Heat conduction is that type of heat transfer concerning heat exchangers without macroscopic
movement of matter. This phenomena absolutely occurs in solid bodies where there is no
relative movement of mass particles. The phenomena of heat conduction are regulated by
Fourier law.
Q
A(1 2 )
L
(1)
Where:
Q transferred
heat
1 temperature
2 = tempetature
A exchange surface
coefficient of thermal conductivity
m2
W/mC
4. HEAT CONVECTION
Heat convection is the type of heat transfer occurring particularly in liquids and gases. The
transport of thermal energy to the different points of the body occurs with a contemporary
movement of the mass particles forming the same body.
There are two types:
a. Natural convection: occurs when the movement of matter inside the mass of the
body is provoked by the transport of thermal energy.
b. Forced convection: occurring when the movement of matter inside the mass is
provoked by the external by the external factors (for example, by the difference of
pressure).
The phenomena of heat convection interesting this plant are those concerning the heat transfer
between a solid surface and a fluid skimming this surface. This manual will deal with forced
convection because only this type of heat transfer is developed in the heat exchangers of the
pilot plant SCTA.
The heat flow transferred between a surface and a fluid skimming it can be expressed by
Newtons law:
Q A( s f )
Where:
5. Tasks to be performed.
a. Spiral exchanger with counter-current flows.
Calculate dTmlg.
(2)
Connect the plant to the main water (valve FV2): max. consumption = 1000l/h, Pmax=2
bar.
Connect the plant to the mod. SCT01/EV or to a hot water line through the black rubber
hose (valve FV1): max. consumption = 1000l/h, Pmax= 2 bar.
Connect the plant to the compressed air line: max. consumption = 10Nm3/h; Set the
pressure reducer under the switch board at P=1.4 bar.
Set the hot and cold water flow rates using the PID controllers:
a. Flow rate manual control.
Switch the loop of the controller n 1 (for the hot water) or n 2 (for the
cold water) in manual mode with the pushbutton.
Set the Out (proportional to the opening of valve FV1 or FV2) for example
at 50% with the pushbutton .
Adjust the flow rate varying the Out with the pushbutton .
Adjust the flow rate of hot and cold water in manual mode (see flow rate
manual control).
Set the value of set point with pushbutton for example at 60%, equal to
600l/h).
Switch the loop in automatic mode with the pushbutton M/A/C (green led
on).
i.
Close valves V2, V3, V6, V7, V10, V11, V12, V13, V14, V15, V16, V17
and V18.
Wait a few minutes until the temperatures TI1, TI2, TI3 and TI4 are
stabilized; take note of the experimental data.
Vary the flow rate of the fluids up to the desired value, wait some minutes
and take note of the experimental data.
Close the valves V1, V3, V6, V7, V8, V9, V12, V13, V14, V15, V16, V17
and V18.
Wait some minutes until the temperatures TI5, TI6, TI7 and TI8 are
stabilized; take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some
minutes and take note of the experimental data.
iii.
Close the valves V1, V2, V6, V7, V8, V9, V10, V11, V14, V15, V16, V17
and V18.
Wait some minutes until the temperatures TI9, TI0, TI1 and TI2 are
stabilized; take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some
minutes and take note of the experimental data.
iii. Connecting the spiral the spiral exchanger E1 with counter-current flows.
Close the valves V2, V3, V4, V5, V10, V11, V12, V13, V14, V15, V16, V17
and V18.
Wait some minutes until the temperatures TI1, TI2, TI3 and TI4 are stabilized;
take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some minutes
and take note of the experimental data.
iv. Connecting the shell-and-tube exchanger E2 with counter-current flows
Wait some minutes until the temperatures TI5, TI6, TI7 and TI8 are
stabilized; take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some
minutes and take note of the experimental data.
Close the valves V1, V2, V4, V5, V8, V9, V10, V11, V14, V15, V16, V17
and V18.
7.
8.
Wait some minutes until the temperatures TI9, TI0, TI1 and TI2 are
stabilized; take note of the experimental data.
Vary the flow rate of the two fluids up to the desired value, wait some
minutes and take note of the experimental data.
Connect the valves V14, V15, V16, V17 and V18 with a plastic hose to a
drain.
Drain the water of the exchangers opening the valves V14, V15, V16,
V17 and V18.
EMERGENCY STOP.
Reference
ElecttronicaVeneta & Inel Spa, 31045 Motta Di Livenza (Treviso) Italy. Heat transfer pilot
plant
5.2 RESPONSABILITIES
It is the students responsibility to make sure that she/he attends the practical sessions,
signs the attendance register, write practical report and submit on given due dates; as
this is crucial to succeed in this course.
Make sure that the engineering reports submitted are typed and binded.
6. OBJECTIVES
This practical experiment is to familiarize students with the operation of heat exchanger.
Students should be exposed to /or learn the following under the different operating conditions:
a) Heat transfer under parallel and counter flow.
b) Effect of different flow rates and temperature on rate of heat transfer.
c) Effect of different flow rates and temperatures on heat transfer coefficient.
54
Reference:
Essom Company Limited, 510/1 Taksin RD., SOI 22/1. Bukkalo Thonburi, Bankok 10600,
Thailand, Tel, +66(0)24760034 FAX +66(0)24761500
FACULTY OF ENGINEERING
Name: ________________________________________________________________________
Group: _______________________________________________________________________
Signature: ____________________________________________________________________
TSHWANEUNIVERSITY OF TECHNOLOGY
DEPARTMENT OF CHEMICAL AND METTALURGICAL ENGINEERING
REPORT GRADING FORM
Name of Student: ______________________________________________________________
Student Number: ______________________________________________________________
Title of Report: ________________________________________________________________
Term: ______________________________
DATE:______________________________
Subject
Max Mark
1.
Title Page
2.
Abstract
3.
Introduction
4.
Theoretical Background
5.
Procedure
6.
Results
7.
Discussion of Results
10
8.
9.
Literature Cited
10.
Nomenclature
11.
A1
A2
Appendix
Raw Data
Data analysis and Sample
Calculations
TOTAL
Actual Mark
2
10
50