Scale-Up in Chemical Engineering, Second, Completely Revised and Extended Edition

277 Pages·2.144 MB·English

by  Prof. Dr.?Ing. Marko Zlokarnik(auth.)

MarkoZlokarnik
Scale-UpinChemical
Engineering
Scale-UpinChemicalEngineering.2ndEdition.M.Zlokarnik
Copyright(cid:1)2006WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:3-527-31421-0
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Marko Zlokarnik
Scale-Up in Chemical Engineering
Second,CompletelyRevisedandExtendedEdition
Author 1stEdition2002
2nd,CompletelyRevisedandExtendedEdition2006
Prof.Dr.-Ing.MarkoZlokarnik
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ISBN-13: 978-3-527-31421-5
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This book is dedicated to my friend and teacher
Dr. phil. Dr.-Ing. h.c. Juri Pawlowski
VII
Contents
Prefacetothe1stEdition XIII
Prefacetothe2ndEdition XV
Symbols XVII
1 Introduction 1
2 DimensionalAnalysis 3
2.1 TheFundamentalPrinciple 3
2.2 WhatisaDimension? 3
2.3 WhatisaPhysicalQuantity? 3
2.4 BaseandDerivedQuantities,DimensionalConstants 4
2.5 DimensionalSystems 5
2.6 DimensionalHomogeneityofaPhysicalContent 7
Example1: Whatdeterminestheperiodofoscillationofapendulum? 7
Example2: Whatdeterminesthedurationoffallhofabodyinahomogeneous
gravitationalfield(LawofFreeFall)?Whatdeterminesthespeedv
ofaliquiddischargeoutofavesselwithanopening?(Torricelli’s
formula) 9
Example3: Correlationbetweenmeatsizeandroastingtime 12
2.7 ThePiTheorem 14
3 GenerationofPi-setsbyMatrixTransformation 17
Example4: Thepressuredropofahomogeneousfluidinastraight,smoothpipe
(ignoringtheinleteffects) 17
4 ScaleInvarianceofthePi-space–theFoundationoftheScale-up 25
Example5: Heattransferfromaheatedwiretoanairstream 27
Scale-UpinChemicalEngineering.2ndEdition.M.Zlokarnik
Copyright(cid:1)2006WILEY-VCHVerlagGmbH&Co.KGaA,Weinheim
ISBN:3-527-31421-0
VIII Contents
5 ImportantTipsConcerningtheCompilationoftheProblemRelevance
List 31
5.1 TreatmentofUniversalPhysicalConstants 31
5.2 IntroductionofIntermediateQuantities 31
Example6: Homogenizationofliquidmixtureswithdifferentdensitiesand
viscosities 33
Example7: Dissolvedairflotationprocess 34
6 ImportantAspectsConcerningtheScale-up 39
6.1 Scale-upProcedureforUnavailabilityofModelMaterialSystems 39
Example8: Scale-upofmechanicalfoambreakers 39
6.2 Scale-upUnderConditionsofPartialSimilarity 42
Example9: Dragresistanceofaship’shull 43
Example10:Rulesofthumbforscalingupchemicalreactors:Volume-related
mixingpowerandthesuperficialvelocityasdesigncriteriaformixing
vesselsandbubblecolumns 47
7 PreliminarySummaryoftheScale-upEssentials 51
7.1 TheAdvantagesofUsingDimensionalAnalysis 51
7.2 ScopeofApplicabilityofDimensionalAnalysis 52
7.3 ExperimentalTechniquesforScale-up 53
7.4 CarryingoutExperimentsUnderChangesofScale 54
8 TreatmentofPhysicalPropertiesbyDimensionalAnalysis 57
8.1 WhyisthisConsiderationImportant? 57
8.2 DimensionlessRepresentationofaMaterialFunction 59
Example11:Standardrepresentationofthetemperaturedependenceoftheviscos-
ity 59
Example12:Standardrepresentationofthetemperaturedependenceofden-
sity 63
Example13:Standardrepresentationoftheparticlestrengthfordifferentmateri-
alsindependenceontheparticlediameter 64
Example14:Dryingawetpolymericmass.Reference-invariantrepresentationof
thematerialfunctionD(T,F) 66
8.3 Reference-invariantRepresentationofaMaterialFunction 68
8.4 Pi-spaceforVariablePhysicalProperties 69
Example15:Considerationofthedependencel(T)usingthel /lterm 70
w
Example16:Considerationofthedependence(cid:1)(T)bytheGrashofnumberGr 72
8.5 RheologicalStandardizationFunctionsandProcessEquationsin
Non-NewtonianFluids 72
8.5.1 RheologicalStandardizationFunctions 73
8.5.1.1 FlowBehaviorofNon-NewtonianPseudoplasticFluids 73
8.5.1.2 FlowBehaviorofNon-NewtonianViscoelasticFluids 76
8.5.1.3 Dimensional-analyticalDiscussionofViscoelasticfluids 78
8.5.1.4 ElaborationofRheologicalStandardizationFunctions 80
Contents IX
Example17:Dimensional-analyticaltreatmentofWeissenberg’sphenomenon–
InstructionsforaPhDthesis 81
8.5.2 ProcessEquationsforNon-NewtonianFluids 85
8.5.2.1 ConceptoftheEffectiveViscosityl AccordingtoMetzner–Otto 86
eff
8.5.2.2 ProcessEquationsforMechanicalProcesseswithNon-Newtonian
Fluids 87
Example18:Powercharacteristicsofastirrer 87
Example19:Homogenizationcharacteristicsofastirrer 90
8.5.2.3 ProcessEquationsforThermalProcessesinAssociationwith
Non-NewtonianFluids 91
8.4.2.4 Scale-upinProcesseswithNon-NewtonianFluids 91
9 ReductionofthePi-space 93
9.1 TheRayleigh–RiabouchinskyControversy 93
Example20:Dimensional-analyticaltreatmentofBoussinesq’sproblem 95
Example21:Heattransfercharacteristicofastirringvessel 97
10 TypicalProblemsandMistakesintheUseofDimensionalAnalysis 101
10.1 ModelScaleandFlowConditions–Scale-upandMiniplants 101
10.1.1 TheSizeoftheLaboratoryDeviceandFluidDynamics 102
10.1.2 TheSizeoftheLaboratoryDeviceandthePi-space 103
10.1.3 MicroandMacroMixing 104
10.1.4 MicroMixingandtheSelectivityofComplexChemical
Reactions 105
10.1.5 MiniandMicroPlantsfromtheViewpointofScale-up 105
10.2 UnsatisfactorySensitivityoftheTargetQuantity 106
10.2.1 MixingTimeh 106
10.2.2 CompleteSuspensionofSolidsAccordingtothe1-sCriterion 106
10.3 ModelScaleandtheAccuracyofMeasurement 107
10.3.1 DeterminationoftheStirrerPower 108
10.3.2 MassTransferinSurfaceAeration 108
10.4 CompleteRecordingofthePi-setbyExperiment 109
10.5 CorrectProcedureintheApplicationofDimensionalAnalysis 111
10.5.1 PreparationofModelExperiments 111
10.5.2 ExecutionofModelExperiments 111
10.5.3 EvaluationofTestExperiments 111
11 OptimizationofProcessConditionsby
CombiningProcessCharacteristics 113
Example22:Determinationofstirringconditionsinordertocarryouta
homogenizationprocesswithminimummixingwork 113
Example23:Processcharacteristicsofaself-aspiratinghollowstirrerandthedeter-
minationofitsoptimumprocessconditions 118
Example24:Optimizationofstirrersforthemaximumremovalofreaction
heat 121
X Contents
12 SelectedExamplesoftheDimensional-analyticalTreatmentofProcesses
intheFieldofMechanicalUnitOperations 125
IntroductoryRemark 125
Example25:Powerconsumptioninagassedliquid.Designdataforstirrersand
modelexperimentsforscalingup 125
Example26:Scale-upofmixersformixingofsolids 131
Example27:Conveyingcharacteristicsofsingle-screwmachines 135
Example28:Dimensional-analyticaltreatmentofliquidatomization 140
Example29:Thehangingfilmphenomenon 143
Example30:Theproductionofliquid/liquidemulsions 146
Example31:Finegrindingofsolidsinstirredmediamills 150
Example32:Scale-upofflotationcellsforwastewaterpurification 156
Example33:Descriptionofthetemporalcourseofspindryingincentrifugal
filters 163
Example34:Descriptionofparticleseparationbymeansofinertialforces 166
Example35:Gashold-upinbubblecolumns 170
Example36:Dimensionalanalysisofthetabletingprocess 174
13 SelectedExamplesoftheDimensional-analyticalTreatmentofProcesses
intheFieldofThermalUnitOperations 181
13.1 IntroductoryRemarks 181
Example37:Steady-stateheattransferinmixingvessels 182
Example38:Steady-stateheattransferinpipes 184
Example39 Steady-stateheattransferinbubblecolumns 185
13.2 FoundationsoftheMassTransferinaGas/Liquid(G/L)System 189
AshortintroductiontoExamples40,41and42 189
Example40:Masstransferinsurfaceaeration 191
Example41:Masstransferinvolumeaerationinmixingvessels 193
Example42:MasstransferintheG/Lsysteminbubblecolumnswithinjectorsas
gasdistributors.Otimizationoftheprocessconditionswithrespectto
theefficiencyoftheoxygenuptakeE”G/RP 196
13.3 CoalescenceintheGas/LiquidSystem 203
Example43:Scalingupofdryers 205
14 SelectedExamplesfortheDimensional-analyticalTreatmentofProcesses
intheFieldofChemicalUnitOperations 211
IntroductoryRemark 211
Example44:Continuouschemicalreactionprocessinatubularreactor 212
Example45:Descriptionofthemassandheattransferinsolid-catalyzedgas
reactionsbydimensionalanalysis 218
Example46:Scale-upofreactorsforcatalyticprocessesinthepetrochemical
industry 226
Example47:Dimensioningofatubularreactor,equippedwithamixingnozzle,
designedforcarryingoutcompetitive-consecutivereactions 229
Contents XI
Example48:Masstransferlimitationofthereactionrateoffastchemicalreactions
intheheterogeneousmaterialgas/liquidsystem 233
15 SelectedExamplesfortheDimensional-analyticalTreatmentofProcesses
whithintheLivingWorld 237
IntroductoryRemark 237
Example49:Theconsiderationofrowingfromtheviewpointofdimensional
analysis 238
Example50:Whymostanimalsswimbeneaththewatersurface 240
Example51:WalkingontheMoon 241
Example52:Walkingandjumpingonwater 244
Example53:Whatmakessapascendupatree? 245
16 BriefHistoricSurveyonDimensionalAnalysisandScale-up 247
16.1 HistoricDevelopmentofDimensionalAnalysis 247
16.2 HistoricDevelopmentofScale-up 250
17 ExercisesonScale-upandSolutions 253
17.1 Exercises 253
17.2 Solutions 256
18 Listofimportant,namedpi-numbers 259
19 References 261
Index 269