H

Chapter 10
Equipment design

Production of High-Quality Paper from Sugarcane Bagasse via Kraft Chemical Pulping
Process

Submitted by:
Austria, Diana May
Bañares, Gian
De Mesa, Kharl Angelo
Martinez, Erol
Villanueva, Dan
Villanueva, Matthew

Submitted to:
Prof. Evelyn R. Laurito, Ph.D.
Prof. Lola Domnina B. Pestaño, Ph.D
H

Chapter 10
Equipment design

CHAPTER 10
EQUIPMENT DESIGN

This chapter provides detailed equipment design of five (5) selected major equipment
involved in the production of high-quality paper from sugarcane bagasse via kraft chemical
pulping process. For each equipment the complete operating conditons and specifications,
theoretical calculations, and rendered 3D diagram are shown. Moreover, an optimization in
the thickness of the insulation for the steam outlet pipe of the boiler was done and the
minimum total cost was calculated. Table 1 summarizes the five selected equipment.

Table 1. Selected Equipment

Equipment Specification Theoretical 3D Optimization
Sheet Calculations Diagram
Boiler ✓ ✓ ✓ ✓

Pulper ✓ ✓ ✓

Vibrating Screen ✓ ✓ ✓

Dryer ✓ ✓ ✓

Bleaching Tower ✓ ✓ ✓
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Chapter 10
Equipment design
BOILER

SPECIFICATION SHEET
EQUIPMENT : Boiler
EQUIPMENT CODE : BL – 001

Furnace
Oxygen Required 52.21 MT/hr
Air Supplied 55.178 MT/hr
Flue Gas Flow Rate 60.66 MT/hr
Heat Supplied by Furnace 15733.84 KJ/s
Flue Gas Temperature in Furnace Outlet 1100°C
Length 6.77 m
Width 2.2 m
Height 1.5 m
Heat Exchanger
Water Tube Externally Fired Horizontal
Equipment Design
Boiler
Process Fluid Water
Mass Rate 18.1899 MT/hr
Inlet: 30°C
Temperatures
Outlet: 200°C
Vessel Properties
Tubes 2.5 in. Sch 40 steel pipes
Tube Arrangement Square pitch
Number of Tubes 183
Pitch 0.10125 m
Tube Length 4.1 m
Shell Diameter 1.8115 m
Shell Thickness 0.2496 m
Baffle Spacing 0.3623 m
Baffle Cut 25%
Head Flat
Head Material Steel
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Chapter 10
Equipment design

Head Thickness 0.4828 m

Maximum Allowable Pressure 9019.996 kPa
Design Temperature 1100°C
Tube Side Heat Transfer Coefficient 536.50 W/m2 K
Shell Side Heat Transfer Coefficient 305.42 W/m2 K
Overall Heat Transfer Coefficient 157.21 W/m K

THEORETICAL CALCULATIONS
I. Material & Energy Balance Summary

Operating Conditions Steam = 18.1899 MT/hr

T = 200°C
P = 973 kPa
Maximum T = 1100°C
Max P = 9019.996 kPa
Superheated Steam H = 2829.86 KJ/kg
Cp = 2.41059 KJ/kg K
Lv (30°C) = 274.115 KJ/kg
Dry Bagasse Fuel 47% C
6.5% H
44% O
2.5% ash
H

Chapter 10
Equipment design
Flue gas compositions (mole %) 63.1% N2
6.3% O2
14.3% H2O
16.3% CO2
GCV = 13602 KJ/kg
Heat Balance Q=UA ∆T
Q=m water (c p ∆ T + L v )
Q= (18.1899 ×1000 ) [ ( 2.41059 ) ( 473−303 ) + ( 2704.115 ) ]
KJ
Q=15733.84
s

Flue Gas Rate Cp (flue gas) = 1.245 KJ/kg K

Q=mc p ∆ T
15733.84=m(1.245)(1373−623)
kg MT
m ( flue gas ) =16.85 =60.66
s hr

Solid Fuel Rate 100 kg bagasse x kg bagasse

=
37.6 mol FG 2061.16 mol FG
kg MT
x=5481.81 =5.482 bagasse
hr hr
Energy Input Q input=m× GCV

Q input= ( 5.4823600
×1000
) ( 13602 )=20,712.82 KJs
O2 Requirement theoO2 =at C +at H −at O
2576.45 356.32 2412
theo O 2 = + − =228.41 kg mol O 2
12 4 32
O 2 ¿ air=228.41 ( 1.5 )=342.615 kg mol O 2

N 2 ¿ air=342.615 ( 7921 )=1288.885 kg mol N 2

O2 supplied=1631.5 kg mol O2

II. Design Calculations & Heuristics

H

Heat Transfer Area Chapter 10

Equipment design
( 350−30 )−(1100−200)
∆ Tlm= =561℃
350−30
ln (
1100−200 )
1100−350
R= =4.41
200−30
200−30
S= =0.159
1100−30

Check using the equation and the graph from PHB:

1−S
Ft =
√ R 2+ 1 ln [ 1−RS ]
2−S ( R+1− √ R2 +1 )
(R−1) ln
[ 2−S ( R+1+ √ R2 +1 ) ]
Ft =0.93

Q=UA ∆TlmFt

Note: U = 30-100 W/m2 K from Coulson and Richardson

15733.84(1000)=(65) A (561)( 0.93)
A=463.95 m 2

Tube side:
Assume that the length of the tube is 10 m
Do = 0.081 m
Di = 0.062 m
X = 5.23 mm

A=π ( 0.081 ) ( 10 )=2.54 m2

463.95
no . of tubes= =183 tubes
2.54
tube pitch=1.25 Do=1.25 ( 0.081 )=0.10125 m
clearance=0.25 Do=0.25 ( 0.081 )=0.02025 m
200+30
Bulk T ∨Tmean= =115 ℃
2
π ( 0.062 )2
Tube CSA = =0.003019 m2
4

tube 183
= =9 2
pass 2
Total Flow A=92 ( 0.003019 )=0.278 m 2
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Chapter 10
Equipment design
mass flow rate 5.05275 kg
Water mass velocity= = =18.175 2
total flow A 0.278 m s
18.175 m
Water linear velocity= =0.019 2
947.03 s
Tube side coefficient:
T(mean) = 115°C
Di = 0.062 m
Density = 997.199 kg/m3
µ = 2.4 x 10-4 Pa s
Cp = 4239.18 J/kg K
K = 0.6825 W/m K

Dvρ ( 0.062 )( 0.019 )( 947.199 )

ℜ= = =4649.17
μ ( 2.4 ×10−4 )
−4
Cpμ (4239.18)(2.4 ×10 )
Pr= = =1.491
k 0.6825
1 1
Nu=2+0.6 R e 2 Pr 3 =48.737
hi(0.062)
48.737=
0.6825
W
hi=536.50 2
m K

Pressure drop at the tube side: (from ChE Design by Towler and Sinnott)
Jf = 5.8 x 10-3
m = 0.14 (non-viscous)
ρ u2
−m
L μ
[
∆ Pt =Np 8 j f ( )( )
Di μw
+2.5
] 2
∆ Pt =2.56 kPa

Shell side:
Kern’s Method
Ds ( shell diameter ) =D b +2C=1.8115 m
1.8115
Baffle spacing= =0.3623 m
5
0.10125−0.081
Cross flow A= ×1.8115 ×0.3623=0.1313 m2
0.10125
1.27
Equivalent Diameter ( De )= ( ( 0.10125 )2−0.785 ( 0.081 )2 ) =0.07998 m
0.081
16.85 kg
Flue gas mass velocity= =128.33 2
0.1313 m s

Shell side coefficient:

T(mean) = 725°C
H

Chapter 10
The following properties are determined using the flue gas calculator:
Equipment design
Density = 0.359 kg/m3

µ = 4.04 x 10-5 Pa s
Cp = 1272.79 J/kg K
K = 0.0669 W/m K

DG ( 0.07998 ) (128.33)
ℜ= = =254055
μ ( 4.04 ×10−5 )
Cpμ
Pr= =0.7686
k
Nu=279
Jn = 2.5 x 10-3
1 0.14
De μ
ho
k
= j n ℜ Pr 3
μw ( )
W
ho=305.42 2
m K

Pressure drop at the shell side: (from ChE Design by Towler and Sinnott)
Jf = 2.9 x 10-2
m = 0.14 (non-viscous)
0.14
Ds L μ ρu 2
∆ Ps=8 j f( )( )( )
De LB μw 2
∆ Ps=20.88 kPa

Overall Heat Transfer Coefficient:

hod = 5000
hid = 5556
hi = 536.50
Do = 0.081 m
Di = 0.062 m
X = 5.23 mm
Kw = 50

1 1 1
(0.081)ln ( 0.081
0.062 ) 0.081 1 0.081 1
= +
Uo 305.42 5000
+
2(50)
+
[( )( )] [( )(
0.062 5556
+
0.062 536.50 )]
W
Uo=157.21
mK

Q=UA ∆TlmFt
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Chapter 10
15733.84(1000)=(157.21) A( 561)(0.93)
A=191.83 m2
L=4.1 m
Equipment design

Shell Thickness:
P = 9019996 kPa
R = 1.8115(0.5) = 0.90575 m
S = 3.8411 x 107 (ASME BPV of steel)
C = 0.002 m
E = 1 (fully radiographed)
PR
t= +C
SE−0.6 P
(9019996)(0.90575)
t= +0.002=0.2496 m
(3.8411 ×10 7)−0.6(9019996)
Head thickness: (flat)
0.3 P
t=2 R
√ S
+C

0.3 ( 9019996 )
√
t=2 ( 0.90575 )
3.8411×107
+0.002=0.4828 m

RENDERED 3D DIAGRAM

Figure 1. Boiler Internals

Figure 2. Boiler full side view

H

Chapter 10
Equipment design

OPTIMIZATION
It is important to provide an insulation for the pipe carrying the steam in order to prevent
hazards due to its high temperature. The steam carried by the pipe has a temperature of
about 200°C which will be supplied for the digestion process in the pulper. The required
surface temperature of insulation is 100°C according to sources.

Data ¿=200 ℃
KJ
λo=2704.115
kg
MT
Wo=18.1899
hr
200
bc=PhP
kg
Do=0.081 m=8.1 cm
Di=0.062 m
L=4.1 m
Hy=876 0
KJ
q=13663.22
s

Insulation (Firebrick) W
k =0.53
mK
1
Kf =
4
ε =0.8 8
ac=PhP 2537.4 6
Ts=25 ℃

0.5
Dso 14.4 bcHykπ ( ¿−Ts ) 1 200 k 200 k
ln
Do
=
[ λoKfac ( −
Dso ( hf +hr ) Ds o2 )] −
( hf +hr ) Dso

Dso=30.5 cm

C T min=C D +C F
H

3.6 bcHy
Chapter 10
2 πKL(¿−Ts) K f ac ( Dso−Do ) L
C T min=
λo
( Equipment design
ln
Dso
+
200 K
Do ( hf +hr ) Dso )
+
2

C T min=PhP 573,432

PULPER

SPECIFICATION SHEET
EQUIPMENT : Pulper
EQUIPMENT CODE : P – 001, P – 002, P – 003

Operating Conditions
Feed Rate
Feed Depithed Bagasse
Operating Temperature
Operating Pressure
Cooking Medium Saturated Steam
Steam Rate 11.821 MT/hr
Pulper Specifications
Material of Construction Stainless steel 316
Number required 3
Diameter 2.5 m
Height 2.92 m
Volume 14.23 m3
Total Surface Area 32.75 m2
Pulper cylinder thickness 2.6 mm
Working stress 62.5 MPa
Agitator
Agitator type Double Helical Ribbon
Impeller diameter 2.38 m
Ribbon width 0.28 m
Shaft length 2.43 m
Shaft diameter 0.1115 m
Torque 3204.91 N∙m
Maximum torsional shear stress 11.77 MPa
Power Requirement of Agitator 15.103 kW
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Chapter 10
Equipment design

THEORETICAL CALCULATIONS
I. Material & Energy Balance Summary

Overall Material Balance (OMB) OMB : D+W =C

MT MT
D=3.5361 W =9.0948
hr hr
MT
C=3.5361+9.0948=12.6309
hr

Specific Heat For the specific heat of the white liquor

solution:
c p= ( 0.0777 ) (1.488 )+ ( 0.1446 )( 1.6435 )+ ( 0.7778 )( 4.184 )
kJ
c p=3.6076
kg ∙ K

For the cP of the pulp:

c p= (3.6076 )( 0.72 ) + ( 1.76 )( 0.28 )
kJ
c p=3.09027
kg ∙ K

Heat Balance Q=mc p ∆ T (sludge )+ m λ v(¿liquor )

H

Chapter 10 9094.8 )( 3.09027 )( 443.15−298.15 ) +¿

Q= (3536.1+
Equipment design
(0.9212)(12630.9)(2325)
kJ
Q=32712504.56 =9086.81 kW
hr

Steam Requirement Q
Steamrequirement =
∆H
32712504.56
Steamrequirement =
2767.1
kg MT
Steamrequirement =11821.845 =11.821
h h

II. Design Calculations & Heuristics

Pulper Cylinder Sizing:

kg
Density of pulp ( ρ ¿=1172
m3

Volume of pulper (V r ¿:
1000 kg
12.6309 MT ×
m 1 MT
V c= = =10.78 m 3
ρ kg
1172 3
m
V r =V c + 0.32V c =10.78+0.32 (10.78 )=14.23 m3

Diameter of pulper (d):

V =π r 2 h
V 14.23
r=
√ √
πh
=
π ( 2.92 )
d=2 ( 1.25 ) =2.5 m
=1.25 m

Total Surface Area (A):

A=2 πr ( h+r ) =2 π ( 1.25 )( 2.92+1.25 ) =32.75 m2

Pulp cylinder thickness (t):

Pr
t=
δ allowable
H

δ yield Chapter 10
δ allowable=
n Equipment design
For the properties of steel, the allowable stress, δ yield , is 250 MPa (Howard and
Timothy, 1985). To accommodate forces arising from the cutting action of the
impeller, a safety factor (n) of 4 is used.

250 MPa
δ allowable= =62.5 MPa
4

kg m
P= ρgh=1000 3
× 9.81 2 ×2.92 m=28645.2 Pa
m s

( 101325+ 28645.2 ) Pa ×1.25 m

t= 6
=2.5994 ×10−3 m∨2.6 mm
62.5 ×10 Pa

Agitator: Double Helical Ribbon Impeller

For the calculation of the dimensions of the helical ribbon impeller, the following
relations were used:

Diameter (d):
DT
1.05=
d

Ribbon Width (wd):

d
wd=
8.5

Using the given relations, the dimensions of the impeller were calculated.
2.5 m
d= =2.38 m
1.05
2.38 m
wd= =0.28 m
8.5
5
Ls = ( 2.92 m ) =2.43 m
6
H

Chapter 10
With the dimensions of the double helical ribbon impeller calculated, the power
Equipment design
requirement was calculated using the relationship between the Reynold’s number
and the Power number.

Fluid viscosity (µ) = 0.15 Pa-s

Rotational Velocity (N) = 45 rpm

45
N =
ℜ
( 60 )
2
( 2.38 ) ( 1172 )
=33 , 193.38
0.15

Using the table of correlation between the Reynold’s number and the Power
number:

Figure 3. Correlation of Reynold’s Number and Power Number for Anchor and Helical Ribbon
Impellers

N P=0. 4
From the equation of the Power number, power requirement for the agitator was
computed.
P
0.4= 3
( 1172 ) 45 ( 2.38 )5
( )
60
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Chapter 10
P=15,102.76 J / s=15.103 kW=20.24 hp
Equipment design

For the dimensions of the shaft, the equations below were used:

 Shaft Length
5
Ls = h
6
 Shaft Diameter
T τ
=
J r

Where:
T = torque J = polar moment of inertia

τ = torsional shear stress r = shaft radius

π 4
J= (d )
32

P ( 60 ) ( 15102.76 )( 60 )
T= T= T =3204.91 N ∙ m
2 πN 2 ( π ) ( 45 )

The maximum torsional shear stress for C1045 Steel is computed by:

0.5 σ 0.5 (565 MPa )

τ m= =
24 24
3204.91 11770833
=
τ m=11.77 MPa π 4 d d s =0.1115 m=1115.13mm
(d )
32 2

RENDERED 3D DIAGRAM
H

Chapter 10
Equipment design

Figure 4. Pulper full outside view Figure 5. Pulper internals showing impeller

VIBRATING SCREEN

SPECIFICATION SHEET
EQUIPMENT : Vibrating Screen
EQUIPMENT CODE : VS – 001

Operating Conditions
Feed Rate 16.667 MT/hr
Feed Raw Bagasse
Vibrating Screen Specifications
Type Linear Drive Screen
Vibrator 3 Unbalance Exciters in Parallel Connected to Motor
Slope Range 20-25°
Stroke Length 3/16∈¿
Rotation Speed 1400 rpm
Vibration G-force 5.2
Screen Area 2
4.07 ft 2(top deck), 36.03 ft ( second deck )
Top Deck
Aperture Size 1/2in
Bed Depth 0.0071in
Second Deck
Aperture Size 0.0555in
Bed Depth 0.0072in
Mechanical design
Vibrating Screen Length 6.049ft
Vibrating Screen Height 5.629ft
Vibrating Screen Width 3.523ft
H

Side Plate Chapter 10

Low-Alloy Steel
Screen Deck Equipment design
High Carbon Steel
Bearing Spherical Roller type
Joint Huckbolt
Dampener Rubber Spring Coil
Driving Force Unbalance Exciter driven by motor

THEORETICAL CALCULATIONS
I. Material & Energy Balance Summary

Overall Material Balance F=B+ X

X =0.05 F
F=B+0.05 F
16.6667=B+ 0.05(16.6667)
MT
B=15.8333
hr
MT
X =0.8333
hr

Total static moment of counterweight mR= total vibrating weight (basket+ material
assemblies (mR)
load)× vibrating radius

907.185 kg
[(
¿ 15.8333 MT ×
1 MT ) ]
+180 kg ×2.5 cm

¿ 36359.3307 kgcm
Power Requirement mR (n)(1.25)
P=
97400( LRT )
H

Chapter 10
Equipment design
(36359.3307 kgcm)(3000 Hz ×
1 rpm
)(1.25)
1
Hz
60
P=
97400(2.0)
P=41996.15 kW ∨42 MW

II. Design Calculations & Heuristics

Feed conditions:
Feed: Raw Bagasse
Particle Size ranges from (1/2”) to (12 mesh)

Flow Diagram with Given

Desired stream is the fine fraction: (Have passed through the second deck)

=3.583 MT/hr
=10 MT/hr Feed (F) = 16.6667 MT/hr
=3.083 MT/hr
Fines (R)
Desired Stream (P)
1/2” aperture mesh
Fines (R) Stream (P) =0.207 MT/hr
s (R) =0 MT/hr
ed =0.205 MT/hr

Stream (S)

12 mesh Stream (Q) =0 MT/hr

=0.413 MT/hr
=0.008 MT/hr

Fines (R)
=5.425 MT/hr
=7.193 MT/hr
=3.215 MT/hr
H

Chapter 10
S1=F 1−P1= 3.376 MT/hr
Equipment design
S =F −P = 10 MT/hr
2 2 2

S3=F 3−P3 = 2.878 MT/hr

Screen Area [VSMA Vibrating Screens Handbook]

U
Screening Area= =Square Feet
A × B ×C × D× E × F ×G × H × J
Where:
U=Undersize Factor
A=Basic Capacity Factor
B=Oversize Factor
C=Halfsize Factor
D=Deck Location
E=wet factor (not needed as assumption of feed material is 0% moisture)
F=Material Weight Factor
G=Screen Surface Open Area Factor
H=Shape of Opening Factor
J=Efficiency Factor
H

Chapter 10
Equipment design

Figure 6. Factor Chart, from VSMA Vibrating Screens Handbook

16.254
Screening Area Top Deck= =4.07 ft 2
2.47 × 0.935× 1× 1×1.4 ×0.71 ×1 ×1.74
15.833
Screening Area Second Deck = =36.03 ft 2
0.58× 0.783 ×1× 0.9 ×1.25 ×0.61 ×1 ×1.41
Average Area of 2 Screen Decks:
A= 20.05 ft 2
H

Chapter 10
Equipment design

Figure 7. Stroke, Speed and Slope Selection for Inclined Screens, from VSMA Vibrating Screens
Handbook.

Discharge End Bed Depth [VSMA Vibrating Screens Handbook]

O×C
DBD= = inches of bed depth
5 ×T ×W
Where:
DBD= Discharge End Bed Depth
O= Oversize
C=Cubic feet per ton of material
T=Rate of Travel
W=Width of screening area in feet

Given:
At 1/2” aperture mesh, O=0.412
At 12 mesh, O=0.421
ft 3 1 lb 3
C= × =22.0462442 ft /ton
100lbs 0.000453592ton
H

T=1400 rpm = 72.917 fpm Chapter 10

W= 3.523 ft Equipment design
0.412 ×22.0462442
DBDTop Deck = =0.0071
5 ×72.917 ×3.523
0.421× 22.0462442
DBD Second Deck = =0.0072
5 ×72.917 × 3.523

The following are specifications of a vibrating screen used in the pulp and paper
industry (from Rotary vibrating screen specifications, Sinfonia Technology):

Screen speed (n)= 3000 Hz

Motor locked rotor torque (LRT)= 200% or 2.0
Weight of basket= 180 kg
Vibrating radius= 2.5 cm

Total static moment of counterweight assemblies (mR):

mR= total vibrating weight (basket+ material load)× vibrating radius
907.185 kg
[(
¿ 15.8333 MT ×
1 MT ) ]
+180 kg ×2.5 cm

¿ 36359.3307 kgcm

The following formula is used to determine the vibrating screen power requirement
(P):

mR (n)(1.25)
P=
97400( LRT )

1 rpm
(36359.3307 kgcm)(3000 Hz × )(1.25)
1
Hz
60
P=
97400(2.0)
P=41996.15 kW ∨42 MW

Vibrating Screens: Horizontal and inclined screening surfaces vibrated at high

frequencies (1000 to 7000 Hz). High-capacity units, with good separating efficiency,
which are used for wide range of particle sizes.
H

Chapter 10
Flat screens are vibrated, shaken, or impacted with bouncing balls. Inclined screens
Equipment design
vibrate at 600-7000 strokes/min and are used for down to 38μm, although capacity
drops off sharply below 200μm. Reciprocating screens operate in the range of 30-
1000strokes/min and handle sizes to 0.25mm at the higher speeds.

RENDERED 3D DIAGRAM

Figure 8. Vibrating screen

left side view

Figure 9. Vibrating screen

right side view

DRYER

SPECIFICATION SHEET
H

EQUIPMENT Chapter 10
: Dryer
EQUIPMENT CODE
Equipment design
: CD – 001

Operating Conditions
Dry bulb temperature 35°C
Wet bulb temperature 23°C
Entering air temperature 380°C
Exhaust air temperature 35°C
Humidity of air entering 0.012
Humidity of exhaust air 0.151
Feed Bagasse
Feed initial moisture 50%
Feed Final moisture 8%
Feed rate 40000 kg/hr
Specific heat of bagasse 1.055 kJ/Kg-K
Drying Air
Flow rate of air (Gs) 8.995x104 kg/hr
Air mass flowrate (G) Kg
8.388
m2 h
Heat transfer coefficient (Us) W
486.525
m3 K
Dryer Specifications
Length of transfer unit 19.968 m
Length of Dryer 86m
Thickness of dryer shell 0.001952m
Outer Diameter 2.029 m
Material of Construction Mild-steel

THEORETICAL CALCULATIONS
I. Material & Energy Balance Summary
H

Chapter 10
Equipment design

Overall Material Balance (OMB) OMB :W + A=D+ V

Water Balance Water Balance :w ( H 2−H 1 )=Fd ( X 1−X 2 )
w ( 0.60−0.30 ) =2.9859 ( 0.50−0.08 )
MT
w=4.1802
hr

Drying Air Properties w = 4.1802 MT/h

ia = 70.04 kJ/kg
i1 = 514.7517 kJ/kg
i2 = 298.1619 kJ/kg
Cpair = 1.005 kJ/kgK
Cpwater vapor = 1.884 kJ/kgK
Hv water = 2501 kJ/kg
Wet Paper Sheets Properties F = 5.9717 MT/h
Cpsolid = 1.055 kJ/kgK
Cpwater = 4.184 kJ/kgK
X1 = 30/70 kg water/kg dry air
X2 = 60/40 kg water/kg dry air
Heat Requirement for Pre-Heater 516.38 kW
Heat Requirement for Dryer 375.50 kW
Overall Heat Requirement 891.88 kW

II. Design Calculations & Heuristics

Data F = 40000
Ts1 = 25
Tg2 = 380
Y2 = 0.012
Cps = 1.055

Cpw = 1.055
50
X1= =1
100−50
H

Chapter 10 8
X = =0.87
Equipment design
100−8 2

Assumptions • Specific heat is constant

throughout the whole process
• Solid surface is at the wet bulb
temperature of the drying medium and
evaporation takes place at the surface
only.
• Heat is transferred mainly by
convection from the hot gasses entering
to the wetted surface of the material

Mass of dry solid:

M =Fx ( 1−0.50 )=2.2 x 10 4

Humidity of exhaust air and air flow rate:

Using moisture and enthalpy balance and solving simultaneously to solve for
humidity of exit air (Y1),
H

Y 1=0.151 Chapter 10
Equipment design
Computation for shell diameter

Heat transfer coefficient:

Gass mass flow rate:

W
Therefore, heat transfer coefficient id 486.525 .
m3 K
H

Chapter 10
Computation of length transfer unit:
Equipment design

Thickness of dryer shell

Outer diameter of the shell is 2.029m

Length of the Dryer is 86m

RENDERED 3D DIAGRAM

Figure 10. Dryer full view

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Chapter 10
BLEACHING TOWER Equipment design
SPECIFICATION SHEET
EQUIPMENT : Bleaching Tower
EQUIPMENT CODE : BLT – 001

Operating Conditions
Feed Rate 9476.4 kg/hr
Operating Temperature 25 OC
Operating Pressure 1 atm
Bleaching Agent Chlorine Dioxide
Bleaching Agent Rate 9476.4 kg/hr
Bleached Pulp Discharge Rate
Tower Specifications
Volume 5.15 m3
Diameter 1.29 m
Height 3.88 m
Freeboard 0.5 m
Leg Support (No.) 4
Leg Support Height 0.8 m
Feed Inlet Pipe
Discharge Pipe
Material of Construction (Bleaching Tank) Stainless Steel
Material of Construction (Leg Support) Carbon Steel
Discharge Scraper
Scraper Speed 80 rev/min
Scraper Torque 1.8 N-m
Power Requirement 15.07 kW
Scraper Length 1.15 m
Scraper Material of Construction Stainless Steel
Tower Pump
Suction Pressure 70 kPa
Discharge Pressure 1800 kPa
Power Requirement 740.05 kW
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Chapter 10
Equipment design
THEORETICAL CALCULATIONS
I. Material Balance & Energy Balance Summary

Overall Material Balance (OMB) OMB : P+ B=BP9.4764 +9.4764=BP

BP=18.9528
Bleached Pulp Mixture (BP) Composition MT
¿ Liquor =3.4907
hr
MT
Bleached Pulp=2.9860
hr
MT
Spent Bleach Solution=12.4764
hr
Pump Shaft Work 70.30758 kJ/kg
Pump Power Requirement 740.0458457 kW

II. Design Calculations & Heuristics

Tank Volume: Cylindrical Tank with Conical Bottom

π D2 π r2 h
V= h+
4 3

Total volume of the tower is based on the flowrate of the feed and bleaching
agent entering.

Basis: 1 hour of operation

18952.8 kg m3 m3
Q= x =4.5
hr 4211 kg hr
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Chapter 10
V =4.5 m3 Equipment design
According to available heuristics, a diameter to height ratio of 2:1 is generally
used for bleaching tower design.

h=2 D
π D2 π rD 2 ( 2 D )
V= (2 D )+ D=1.29 mh=2.58 m
4 12

Using a freeboard height of about 0.5 m, the volume of the tank (with freeboard)
is calculated as follows.

2
V T =Volume of tank+Volume of Freeboard V T =4.5+ π ( 1.29 ) ( 0.5 )=5.15 m 3
4
H T =height of tank+height offreeboard + height of leg support
H T =2.58+0.5+0.8=3.88 m

Discharge Scraper

Design scraper speed is based according to typical values provided by

established vendors.

rev
Scraper speed: N=80
min

Using a typical value of torque produced by the discharge scraper (1.8 N-m) and
the equation shown below, the power requirement of the discharge scraper can
be estimated.

60 P 60 ( P )
T= = =1.8 P=15.07 kW
2 πN 2 π ( 80 )

RENDERED 3D DIAGRAM
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Chapter 10
Equipment design

Figure 12. Bleaching tower internals showing

discharge scraper

Figure 11. Bleaching tower full view

References:
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Chapter 10
[1] Hugot, E, (1960). Handbook of Cane Sugar Engineering. New York: Elsevier
[2] Perry, R., and Green, Equipment design
D. (2008) Perry’s Chemical Engineer’s Handbook: 8th Ed
[3] Chemical Engineering Design by Coulson and Richardson, 4th Ed
[4] Unit Operations of Chemical Engineering, McCabe and Smith, 6th Edition
[5] HVAC Insulation. Retrieved from http://www.ashraeqatar.com/images/Insulation.pdf
[6] Manyuchi, Mercy. (2015). TECHNO-ECONOMIC ANALYSIS FOR VIRGIN PAPER
PRODUCTION FROM BAGASSE. 10.13140/RG.2.1.1226.1843.
[7] 2014 Minerals Yearbook - USGS Mineral Resources Program. (n.d.). Retrieved March
17, 2019 from https://minerals.usgs.gov/minerals/pubs/country/2014/myb3-2014-to.pdf
[8] Ore Separation by Screening. (n.d.). Retrieved March 17, 2019 from
https://www.researchgate.net/publication/315487165_ORE_SEPARATION_BY_SCREENIN
G
[9] Vibrating Screen. (n.d.). Retrieved March 17, 2019 from
https://es.scribd.com/document/333843974/Vibrating-Screen
[10] Metallurgist & Mineral Processing Engineer. (n.d.). Retrieved March 17, 2019 from
https://www.911metallurgist.com/
[11] 309674045-VSMA-Vibrating-Screens-Handbook.pdf. (n.d.). Retrieved March 17, 2019
from https://www.scribd.com/document/354560199/309674045-VSMA-Vibrating-Screens-
Handbook-pdf
[12] Bagasse. (2014). Chemistry, Manufacture and Applications of Natural Rubber.
[13] Battistelle, R., Bezzera, B., Valarelli, I., Lahr, A. (2015). Classification of cane bagasse
particle size in vibrating screen openings. Retrieved March 17, 2019 from
https://www.researchgate.net/figure/Classification-of-cane-bagasse-particle-size-in-vibrating-
screen-openings-from-127-to_tbl18_277003191
[14] Savalagi, P., & Chittappa, H.C. (2017).Flight Design for rotary bagasse dryers.
International Research Journal of Engineering and Technology. 4(8)

[15] (October, 2013). The 4th TSME International Conference on mechanical Engineering.
Pattaya, Banasode,A.,Valmiki, S., & Desai, V. (2017). Design and Anaysis of Bagasse Dryer
to Recover Energy of Water Tube Boiler in a Sugar Factory. International Journal of
Innovative Technology and Research.. 5( 4), 6645-6652. Chonbri.
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Chapter 10
[16] Banasode,A.,Valmiki, S., & Desai, V. (2017). Design and Anaysis of Bagasse Dryer to
Recover Energy of WaterEquipment design
Tube Boiler in a Sugar Factory. International Journal of Innovative
Technology and Research.. 5( 4), 6645-6652.

[17] Konidis, J. (1984). Design Of Direct Heated Rotary Dryers. Montreal, Qeubec.

[18] Peter, F. and Manfred, H. (2006). The Mathematical Model of Mechanical Pulp
Bleaching Process. IFAC Proceedings Volumes, 39(14), pp.70-75.