FLUID MECHANICS, HEAT TRANSFER, AND MASS TRANSFER FLUID MECHANICS, HEAT TRANSFER, AND MASS TRANSFER Chemical Engineering Practice K. S. N. RAJU Copyright(cid:1)2011byJohnWiley&Sons,Inc.Allrightsreserved. PublishedbyJohnWiley&Sons,Inc.,Hoboken,NewJersey PublishedsimultaneouslyinCanada Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical, photocopying,recording,scanning,orotherwise,exceptaspermittedunderSection107or108ofthe1976UnitedStatesCopyrightAct,without eitherthepriorwrittenpermissionofthePublisher,orauthorizationthroughpaymentoftheappropriateper-copyfeetotheCopyrightClearanceCenter, Inc.,222RosewoodDrive,Danvers,MA01923,978-750-8400,fax978-750-4470,oronthewebatwww.copyright.com.RequeststothePublisher forpermissionshouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons,Inc.,111RiverStreet,Hoboken,NJ07030,201-748-6011, fax201-748-6008,oronlineathttp://www.wiley.com/go/permission. 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FormoreinformationaboutWileyproducts,visitourwebsiteatwww.wiley.com. LibraryofCongressCataloging-in-PublicationData: Raju,K.S.N. Fluidmechanics,heattransfer,andmasstransfer:chemicalengineeringpractice/K.S.N.Raju. p.cm. Includesindex. ISBN978-0-470-63774-6(cloth) 1. Chemicalengineering—Miscellanea.2. Fluidmechanics—Miscellanea.3. Thermodynamics—Miscellanea. 4. Masstransfer—Miscellanea. I.Title. TP155.R282010 660’.29–dc22 2010019512 PrintedinSingapore oBookISBN:978-0-470-90997-3 ePDFISBN:978-0-470-90996-6 ePubISBN:978-0-470-92292-7 10 9 8 7 6 5 4 3 2 1 Practice of Science is Engineering CONTENTS ix FOREWORD xi PREFACE xiii ACKNOWLEDGMENTS xv ABOUT THE AUTHOR xvii LISTOFFIGURES xxv LISTOFTABLES SECTION I FLUID MECHANICS 1 Fluid Mechanics Basics 3 2 Fluid Flow 21 3 Piping, Seals, and Valves 35 4 Flow Measurement 59 5 Pumps,Ejectors, Blowers, and Compressors 101 6 Mixing 163 7 Two-Phase Flow Systems 195 SECTION II HEATTRANSFER 8 Dimensionless Numbers, Temperature Measurement, and 225 ConductionHeatTransfer vii viii CONTENTS 9 Convective Heat TransferBasics 245 10 Shell and Tube Heat Exchangers 271 11 HeatTransfer Equipment Involving Phase Transfer 331 12 Refrigeration, Heat Pumps, Heat Tracing,Coiled and JacketedVessels, 371 Steam Traps, and ImmersionHeaters 13 Compact HeatExchangers,Regenerators, and Recuperators 395 14 RadiantHeatTransfer and Fired Heaters 425 SECTIONIII MASS TRANSFER 15 Mass TransferBasics 455 16 Mass TransferEquipment 475 17 Absorption,Distillation, and Extraction 527 18 Crystallization,Air–Water Operations, Drying, Adsorption, Membrane 613 Separations, and Other Mass Transfer Processes 717 INDEX FOREWORD Professor K. S. N. Raju has presented the technical com- applications(absorption,distillation,crystallization,adsorp- munitywithaninteresting,valuable,anduniquebookonthe tion),andequipment(trayandpackedcolumns,crystallizers, practiceofchemicalengineeringinthebroadareasoffluid dryers,andmembranemodules),andanticipatesandresolves mechanics,heattransfer,andmasstransfer.Baseduponhis operational issues (column flooding, liquid inclusion in five decades of experience as an educator, researcher, and crystals). It will be difficult to find an area in the chemical consultant, Professor Raju has chosen to adopt the processindustriesnotcoveredinthiscomprehensivebook! question–answer format. Whilethisbookiswideinscope,itisalsoquitedetailed. Consider,forexample,anengineerfacedwiththeanalysis Asanexample,anengineerwhodrillsdownintothechapter and design of a fired heater. This book on chemical engi- oncrystallizationwilllearnaboutthefactorsthatrestrictthe neeringpracticeimmediatelyanswersdesignquestionssuch productivity and purity of crystals (agglomeration, liquid ashowthetubesarearrangedinthefurnaceandhowmany impurities inside and outside the crystals, cavitation). rows are usually provided and also the rationale for the Professor Raju has structured his book in the question– optimumdesignchoice.Inaddition,thebookintroducesthe answer format, which he feels stimulates interest in the theoreticalbackgroundofradiantheattransferbyexplaining subject matter and focuses attention on specific topics. I conceptssuchasemissivityandabsorptivityandkeydesign completely agree. As I read the book, I found that it relationships like the Stefan–Boltzmann equation and precisely explained concepts and applications in areas Kirchoff’s law. Finally, this thorough book presents and where I have some expertise, and also sparked my interest resolves operational issues, for example, hot spots, high- and gave me new understanding in subjects outside my temperaturecreep,corrosion,andtubelife.ProfessorRaju’s specialization. bookequipsthepracticingengineerwiththetoolstodesigna Thestyle,structure,preciseness,andclarityofProfessor fired heater as well as to diagnose and resolve operational Raju’s book are a reflection of his five decades of experi- problems. ence as an educator, researcher, and consultant. As an RadiantHeatTransferisoneoftheeightchaptersinthe educator, he has taught graduate and undergraduate stu- sectiononHeatTransfer,whichcoverthetheoryandappli- dents, created and delivered on-site courses for industry, cationofheattransferintheprocessindustries.Inadditionto and developed and nurtured new chemical engineering Heat Transfer, the book has two other sections, Fluid departments. He has published over 90 papers in interna- Mechanics and Mass Transfer. Each section introduces the tionaljournals.Hisconsultancyhascoveredthechemical, theoreticalbackground,describestheapplicationsandequip- petroleum, petrochemical, and fertilizer industries and ment, and anticipates and resolves operational issues. The governmentorganizations.ProfessorRaju’sstudentsreport MassTransfersectionintroducesunderlyingconcepts(phase that his teaching style was always practical, focusing on equilibria,masstransfercoefficients,correlationsinvolving solving real-world problems rather than just teaching a dimensionless numbers, polymorphic structures), describes concept; he invariably used examples from his extensive ix x FOREWORD experiencetohelpstudentsunderstandchemicalengineer- plantokeepacopyhandyasareferencetounderstandand ing problems. That practical teaching style is clearly ev- resolvenewtechnical issues Iam confronted with. ident in this book. Fluid Mechanics, Heat Transfer, and Mass Transfer: PAUL.M. MATHIAS Chemical Engineering Practice is intended as a text book toundergraduateandgraduatestudentsandareferencebook FluorCorporation forpracticingengineersinthechemicalprocessindustries.I Irvine,California PREFACE Thebookisintendedforusebystudentsatundergraduateand students and others. It can be used as a textbook and/or a graduate levels, faculty in Chemical Engineering Depart- reference book. ments across the world, working and consulting engineers Inthemarket,thereisnosuchbookintheseareaslinking in areas such as petroleum refineries, petrochemical, gas theory with broad practical aspects and to this effect it is processing and fertilizer plants, design organizations, food originalinnaturewithalmostnocompetitorsonthesubject. andpharmaceuticalprocessing,environmentalengineering, Itavoidsreferringtoseveraltextandreferencebooks,toget and the like. The book is also useful to mechanical engi- informationon specifictopics/content. neeringstudents andfaculty. The vast literature available in the form of articles in Thebookiswrittenwithemphasisonpracticewithbrief chemical engineering magazines, monographs, and manu- theoreticalconceptsintheformofQuestionsandAnswers, facturersliteraturehasbeenusedinitspreparationalongwith bridgingthetwoareasoftheoryandpracticewithrespectto theactiveinteractionoftheauthorwithpracticingworldover the core areas ofchemical engineering. aperiod spanningnearlyfivedecades. Theauthorconsidersthatthequestion–answerapproach To summarize, features include emphasis on practical adoptedstimulatesinterestinthesubjectmatterandfocuses aspectsinthelearningprocessforstudentsandfacultyand attention to specific topics in a better and concise manner easeandconvenienceintheuseofthetheoreticalandpractical thanrunningmattergiveninnormaltextandreferencebooks. aspectsofthesubjectinthepracticeofprofessionalengineers. Theapproachwasusedbytheauthorintheclassroomfor Question–answerapproachfocusesonindividualtopicsin several years, spanning a period of over four decades. amoreeffectivewaythanthenormallyusedrunningmatter Feedback from faculty, students, alumni, and practicing in textbooks. Adds to learning process, creating better in- engineers in several institutions/organizations appreciated terest among students, faculty, and others for whom time this approach when the author used this approach during factor isimportant. continuingeducationandtrainingcourses,besidesclassroom Involves the core areas of chemical engineering and instruction.Thispromptedtheauthortoembarkuponwriting fulfillstheneedforasinglesource,avoidingtherequirement thisbook. of using several books, articles, and other sources for the Thebookisanattempttobridgethegapbetweentheory topics covered inthe book. andpracticeinabalancedmanner,sothatitwillbeeasyfor The core areas of fluid mechanics, heat transfer, mass studentsandacademicstogetagraspofpracticeandindustry transfer,andmembraneprocessesarecoveredinthebookina personnel to understand theoretical concepts necessary to balancedway,avoidingmakingthebookbulkyandunwieldy appreciate thegenesis involved inpractice. inits use. At the teaching level, the book is suitable for different Mostpartsofthebookareeasilyunderstandablebythose courses involving fluid mechanics, heat transfer, mass whoarenotexpertsinthefield.Forexample,itcoverstypes transfer, and membrane technology as well as design onpumps,valves,processequipment,membranes,andareas courses at both undergraduate and graduate levels. The of their use, their merits, and drawbacks and selection in a author considers it to be useful in design project work by simpleway. xi