EG-307

“Particulate Systems”

2017/2018

Problems

Level 3 Chemical/Environmental Engineering

Lecturer: Dr. Paolo Bertoncello

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 0
 Problems 2011

1. Question 1 was about diffusion and it is not anymore a topic in the module syllabus.

2. In a catalytic plant for the production of sulphuric acid, the secondary converter is a tray type
converter, 3.0 m in diameter with the catalyst arranged in five layers, each layer being 0.25 m
thick. The catalyst is constituted by spherical pellets 1 cm in diameter. The void fraction, e, is 0.4
and the gas flow rate is 0.75 kg/m2 s. The density of the gas is 0.6 kg/m3, while the viscosity is
0.028 mN s/m2.

a) State the general expression, valid for both streamline and turbulent flow conditions, for the
pressure drop through a granular bed, defining the terminology used.

b) Calculate the specific surface area, S, of the particles

c) Calculate the modified Reynolds number, Rel

d) Calculate the pressure drop through the converter

3. A slurry containing 30% by weight of solids is to be filtered using a rotary drum filter with a filter
area of 5 m2. The filter operates with an internal pressure which is 75 kN/m2 below atmospheric
and with 30% of its surface in contact with the slurry at any instant.

a) Assuming that the filter cake is incompressible and the filter cloth has a resistance equal to
that of 1 mm of cake, calculate the rate of production of filtrate and the thickness of the cake
when the rotary drum filter rotates at 0.0075 Hz.

b) It is desired to increase the rate of filtration by raising the speed of rotation of the drum. If the
thinnest cake that can be removed from the drum has a thickness of 3 mm, what is the maximum
rate of filtration which can be achieved?

c) What is speed of rotation of the drum required?

Data supplied:
The voidage, e, of the cake is 0.35
The specific resistance of the cake, r = 2 x 1012 m-2,
The density of the solids, ρs = 1750 kg/m3,
The density of filtrate, ρ = 1000 kg/m3,
The viscosity of filtrate, μ = 2 x 10-3 N s/m2

4. (a) Using appropriate equations and assumptions, describe the theory of sedimentation for a
spherical particle immersed in a fluid.

(b)Calculate the sedimentation velocity of a sphere of 0.04 mm diameter with a density of 1.5
kg/L, immersed in a liquid of density of 1.05 kg/L with a viscosity of 0.003 kg/m s.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 1
 (c) A slurry containing 5 kg of water/kg of solids is to be thickened to a sludge containing 1.3
kg of water/kg of solids in a continuous operation. Laboratory tests using five different
concentrations of the slurry yielded the following results:

Concentration, (Y) Water to overflow, (Y-U) Sedimentation rate, (uc)

kg water/kg solids kg water/kg solid mm/s
5.0 3.7 0.18
4.1 2.8 0.11
3.6 2.3 0.07
3.0 1.7 0.06
2.4 1.1 0.05

Calculate the minimum area of a thickener required to effect the separation of a flow of 0.8
kg/s of solids.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 2
 Problems 2012

1. (a) Consider the motion of 200 µm diameter spheres of graphite of density, ρs= 2300 kg/m3,
settling in an oil of density, ρ= 900 kg/m3, and viscosity, µ= 10 mN s/m2. For the
sedimentation of uniform coarse particles settling under the action of gravity, the relation
between the observed sedimentation velocity, uc, and the fractional volumetric
concentration C, is given by the following expression:

𝑈𝑐
= (1 − 𝐶)4.8
𝑈0

where u0 is the free falling velocity of the particles. By assuming that the relation between
resistance force, F on an isolated sphere is given by Stoke’s Law:

(i) State the Stokes’ Law and define the used variables.

(ii) Calculate the concentration at which the rate of deposition of particles per unit
area will be at maximum.

(iii) Calculate the free falling velocity, u0.

(iv) Calculate the maximum flux, Ψmax.

(b) Calculate the terminal velocity of a spherical nickel particle, with diameter d= 350 µm,
settling in an oil of density, ρ= 820 kg/m3 and viscosity µ= 10 mN s/m2. The density of
steel, ρs= 8900 kg/m3. Use Table 3.4 as appropriate.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 3
 2. A catalytic reaction is employed to produce ammonia, and the converter is a tray type converter,
4 m in diameter with the catalyst arranged in four layers, each layer being 0.30 m thick. The
catalyst is constituted by spherical pellets 8 mm in diameter and 8 mm long. The void fraction, e,
is 0.3 and the gas flow rate is 0.9 kg/m2 s. The density of the gas is ρg= 0.7 kg/m3, and the
viscosity is µ= 0.025 mN s/m2. No specifications are given regarding the flow conditions.

(a) State an expression to evaluate the pressure drop (-ΔP) through a granular bed and
define the used variables.

(b) Calculate the specific surface area of catalyst particles.

(c) Calculate the modified Reynolds number, Rel

(d) Calculate the pressure drop through the converter

3. A rotary drum with a filter area of 10 m2 operates with an internal pressure of 80 kN/m2 below
atmospheric and with 25% of its surface submerged in the slurry at any instant.

(a) State the general expression for filtration operation for incompressible cakes and explain the
used variables

(b) Calculate the rate of production of filtrate and the thickness of the cake when the rotary drum filter
rotates at 0.0060 Hz. The filter cake is incompressible and the filter cloth has a resistance
corresponding to that of 2 mm cake.

(c) Calculate the maximum rate of filtration that can be achieved if the minimum thickness of cake
that can be removed from the drum is 1 cm.

(d) Calculate the speed of rotation of the drum required, using the same thickness of cake as in (c).
Data supplied:

The voidage, e, of the cake is 0.30

The specific resistance of the cake, r = 3  1012 m-2,

The density of the solids, ρs = 1900 kg/m3,

The density of filtrate, ρ = 1000 kg/m3,

The viscosity of filtrate, μ = 10-3 N s/m2

EG-307 “Particulate Systems” 2017/2018 Swansea University
(Dr. Paolo Bertoncello)
Page 4
 4. (a) Using appropriate equations and assumptions, describe the basic principle of
centrifugation operations for a spherical particle immersed in a fluid.

(b) In a test on a centrifuge, the particles of a mineral of density, ρs= 1500 kg/m3and of size
equivalent spherical diameter, d= 4 µm, were separated from a suspension in water fed at
a volumetric throughput rate Q= 0.5 m3/s.

(i) Calculate the value of the capacity factor, Σ.

(ii) Assuming that the Stokes’ Law is applicable, what will be the corresponding size cut
for a suspension of coal particles in oil fed at rate Q= 0.1 m3/s? The density of coal and oil
are ρs= 1400 kg/m3 and ρ= 700 kg/m3, respectively. The viscosity of oil is µ= 10 mN s/m2.

(c) 1000 kg of an aqueous solution containing 32.5% by weight of solids of Na2SO4 is cooled
slowly at T=27°C to form crystals of Na2SO4•10H2O. The solubility of crystals is 31 kg/
100 kg of water. Using the attached Periodic table, calculate:

(i) The molecular weight of both anhydrous and hydrate solid.

(ii) The water of crystallisation.

(iii) The crystal yield.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 5
 Problems 2013

1. (a) Two spheres of equal terminal velocity, u0, settle in acetone starting from rest at the same
horizontal level. The diameter of one sphere is 15 μm and its density is 2500 kg/m 3. The
density of the second sphere is 8240 kg/m3. The density and viscosity of acetone are 785
kg/m3 and 0.3 mN·s/m2, respectively. It may be assumed that Stokes’ law is valid and this
assumption should be checked.

(i) State Stokes’ law and define the used variable.

(ii) Derive an expression for the terminal falling velocity u0 valid under Stokes’ law conditions.

(iii) Calculate the terminal falling velocity, u0, of the spheres above.

(iv) Calculate the diameter for the second sphere.

(v) Verify the hypothesis that Stokes’ law is valid for both spheres.

b) A slurry containing 8 kg of water per kg of solids is to be thickened to a sludge containing 2

kg of water per kg of solids in a continuous operation. Laboratory tests using seven different
concentrations of the slurry yielded the following results:

Concentration, (Y) Water to overflow, (Y-U) Sedimentation rate, (uc)

kg water/kg solids kg water/kg solid mm/s

8.0 6.0 0.25

7.4 5.4 0.22

6.5 4.5 0.18

5.9 3.9 0.15

4.6 2.6 0.10

3.4 1.4 0.07

2.8 0.8 0.04

Calculate the minimum area of the thickener required to effect the separation of a flow of 1.8
kg/s of solids. The density of water is 1000 kg/m3.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 6
 2. A packed bed consisting of uniform spherical particles of diameter 2 mm and density 4500 kg/m 3,
is fluidised by means of a liquid of viscosity 1 mN·s/m2 and density 1400 kg/m3.

(a) State the expression for Ergun’s equation to evaluate the pressure drop (-ΔP) through a
bed of height l and voidage e as function of the superficial velocity and define the used
variables.

(b) Calculate the minimum fluidising velocity, umf, in terms of the settling velocity of the
particles in the bed. The value of e is taken as 0.48.

(c) Calculate the settling velocity u0 of the spherical particles above and verify your
assumptions using Figure 3 on Page 6.

(d) Calculate the ratio u0/umf.

3. An aqueous slurry is filtered using a plates and frame press. The frame press is fitted with three
frames and the total thickness is 75 mm. Each frame is 200 mm square, the filtration operates
with a pressure difference of 400 kN/m2, and the frames are filled in 1 h.

(a) State the general expression for a filtration operating at constant pressure difference
through the cloth and cake combined and explain the used variables.

(b) Calculate how long it will take to produce the same volume of filtrate as is obtained from a
single cycle when using a centrifuge with a perforated basket 400 mm diameter and 200
mm deep. The radius of the inner surface of the slurry is maintained constant at 75 mm
and the speed of rotation is 80 Hz (4800 rpm). It may be assumed that the filter cake is
incompressible, that the resistance of the cloth is equivalent to 4 mm of cake in both
cases, and that the liquid in the slurry has a density of 1000 kg/m3.

4. 300 kg of a solution containing 0.4 kg Na2CO3/kg solution is cooled slowly to 293 K to form
crystals of Na2CO3∙10H2O.

(a) Describe, with the aid of appropriate diagrams, the theory of crystallisation.

(b) Calculate the yield of crystals if the solubility of Na2CO3 at 293 K is 21 kg/100 kg water and
during cooling 4% of the original solution is lost by evaporation. The molecular weights of the
anhydrous and hydrate solids are 106 kg/kmol and 286 kg/kmol, respectively.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 7
 Problems 2014

1. Spherical particles of density 2000 kg/m3 and 1 mm diameter are fluidised by water in a tube of
15 mm diameter and 1 m length. Assume that the Carman-Kozeny equation is applicable and
that wall effects apply in this problem.

(i) Derive an expression for the Carman-Kozeny equation for the fluidisation.

(ii) Define the correction factor, fw.

(iii) Calculate the minimum fluidising velocity, umf, consider emf = 0.40.

2. In a contact catalytic plant, the secondary converter is a tray type converter, with the catalyst
arranged in 7 layers, each 0.15 m thick. The catalyst is in the form of spherical pellets, and the
catalytic reaction involves the partial oxidation of a gas. The specific surface area of the catalyst
particles, S, is 800 m2/m3. The gas flow rate is 0.80 kg/m2s. The gas density and viscosity are
0.70 kg/m3 and 0.035 mN s/m2, respectively, while the void fraction, e=0.33.

(i) State the Carman equation, valid for both laminar and turbulent flow conditions, for the
pressure drop through the contact catalytic plant and define the terminology used.

(ii) Calculate the diameter of the catalyst particles

(iii) Defined and calculate the modified Reynolds number, Rel.

(iv) Calculate the pressure drop (-ΔP) through the secondary converter.

3. An aqueous slurry is filtered using a plates and frame press. The frame press is fitted with four
frames and the total thickness is 100 mm. Each frame is 150 mm square, the filtration operates
with (-ΔP)= 600 kN/m2, and the frames are filled in 1 h.

(i) State the two general expressions for a filtration operating at constant rate and at constant
pressure difference through the cake, and explain the used variables.

(ii) Calculate how long it will take to produce the same volume of filtrate as is obtained from a
single cycle when using a centrifuge with a perforated basket 300 mm diameter and 150
mm deep. The radius of the inner surface of the slurry is maintained constant at 50 mm
and the speed of rotation is 100 Hz (6000 rpm). It may be assumed that the filter cake is

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 8
 incompressible, that the resistance of the cloth is equivalent to 3 mm of cake in both
cases, and that the liquid in the slurry has a density of 1000 kg/m3.

4. (a) Let us consider 1000 kg of a 15% solution (in mass) of KHCO3. 500 kg of solvent are
removed and the remaining solution is cooled down at 20°C. The solubility of KHCO3 at
20°C is 10.53% in mass.

(i) Calculate the mass of crystals of KHCO3, and explain the terminology used.

(ii) Calculate the crystallisation yield.

(b) A series of batch thickening tests on activated sludge have given the results plotted in
Figure 1, and a continuous circular thickener is to be designed to treat this sludge. The
influent flow rate is 25 m3/h, and the sludge is to be thickened from 5 kg/m3 to 15.7 kg/m3.

(i) Draw a smooth curve passing by the points in the graph (Figure 1).

(ii) Calculate the required area and diameter for the circular thickener.

(iii) Identify the limiting concentration.

(iv) If the solids loading increases by 50% after the thickener has been designed in (b)
(ii), calculate the maximum underflow concentration that can be achieved at
steady-state without losing excessive solids in the effluent flow.
6

5
Solid Flux (Kg/m2h)

0
0 5 10 15 20
Solid Concentrations (kg/m3)

FIGURE 1

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 9
 Problems 2015

1. Oil, of density 600 kg/m3 and viscosity 3 mNs/m2, is passed vertically upwards through a bed of
catalyst consisting of spherical particles of diameter 0.12 mm, density 2200 kg/m 3, and voidage
e=0.45.

(i) Derive an expression that relates the fluid velocity, Uc, pressure drop (-ΔP), and voidage,
e, for a fixed bed of spherical particles of diameter d. Assume the flow conditions within
the bed are laminar.

(ii) Calculate the mass rate of flow per unit area of bed under fluidisation of particles
condition.

(iii) Calculate the mass rate of flow per unit area of bed under transport of particles condition.

(iv) Calculate the ratio U0/Umf.

2. (a) Consider 1000 kg of a 22% solution in mass fraction of NaHCO3. 350 kg of solvent are
removed by evaporation and the remaining solution is cooled down to 22°C. The solubility of
NaHCO3 at 22°C is 12.5% in mass ratio relative to solvent.

(i) Calculate the mass of crystals of NaHCO3 formed, and explain the terminology used.
(ii) Calculate the crystallisation yield.

(b) A batch of 2000 kg of saturated LiCl solution is cooled from 340K to 270K in an unagitated
tank. The solubilities of LiCl are 45 kg/100 kg water and 27 kg/100 kg water, at 340K and
270K, respectively.

(i) Calculate the mass of crystals of LiCl

(ii) Calculate the yield of crystals. Assume the evaporation of water is negligible.

(c) Consider the motion of 0.05 mm diameter spheres of steel of density, ρs=2300 kg/m3, settling
in water of density 1000 kg/m3 and viscosity 1 mNs/m2. For the sedimentation of uniform
coarse particles settling under the action of gravity, the relation between the observed
sedimentation velocity, Uc, and the fractional volumetric concentration C, is given by the
following expression:

𝑈𝑐
= (1 − 𝐶)3.3
𝑈0

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 10
 where U0 is the free falling velocity of the particles. By assuming that the relation between
resistance force, F, on an isolated sphere is given by Stokes’ law:

(i) Derive an expression for the terminal falling velocity, U0, for spherical particles under
Stokes’ law conditions.

(ii) Calculate the concentration at which the rate of deposition of particles per unit area will be
at maximum.

(iii) Calculate the free falling velocity, U0.

(iv) Calculate the maximum flux, Ψmax.

3. (a) Consider the separation of solid particles using centrifugation.

(i) Derive an expression for the maximum radial velocity of deposition of solids. Assume that
Stokes’ law applies.
(ii) Express the radial velocity of deposition of solids as a function of the diameter of particles and
deduce an equation to determine the time that it takes a particle of diameter d to reach the
wall of a basket of radius R.

(b) In a test on a centrifuge, spherical particles of a mineral of density ρs=1700 kg/m3 and of size
equivalent spherical diameter, d=3μm, were separated from a suspension in water having
density ρ=1000 kg/m3, viscosity μ=1 mN s/m2, and fed at a volumetric throughput rate Q=0.8
m3/s.

(i) Calculate the value of the capacity factor, Σ.

(ii) Assuming that Stokes’ law is applicable, what will be the corresponding size cut for a
suspension of Portland cement particles in oil fed at a rate Q=0.3 m3/s? The density of the
Portland cement particles and oil are ρs=1200 kg/m3 and ρ=600 kg/m3, respectively. The
viscosity of oil is μ=20 mN s/m2.

4. (a) A slurry, containing 20% kg of solid per kilogram of water is filtered using a rotary drum filter
60 cm diameter and 60 cm long. The specific weight of solid is γ= 3 g/cm3. The drum rotates at
one revolution in 6 minutes, and 20% of the filtering surface is in contact with the slurry at any
instant. The filtrate is produced at a rate of 450 kg/h and the cake has a voidage e=0.5.

(i) State the general equation of filtration and explain the terminology used.

(ii) Calculate the thickness of cake that is produced when filtering with a pressure difference
(-ΔP)= 6.6x103 N/m2.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 11
 (b) The rotary drum breaks down and the operation has to be carried out temporarily in a plate
and frame press with frames 30x30 cm. The press takes 2 minutes to dismantle, 2 minutes to
reassemble, and in addition, 2 minutes are required to remove the cake from each frame.
Assuming that the cakes are incompressible and that the resistance of the filter medium may be
neglected, if filtration is to be carried out at the same overall rate as in (a), with an operating
pressure difference (-ΔP)= 1.05x104 N/m2,

(i) Calculate the minimum number of frames that needs to be used.

(ii) Calculate the thickness of each frame.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 12
 Problems 2016

1. A secondary converter, tray type converter, is utilised in a catalytic plant for the production of
sulphuric acid. The tray is constituted by several layers of catalyst, each layer being 0.25 m thick.
The catalyst is in the form of spherical pellets, and the catalytic reaction involves the partial
oxidation of a gas. The specific surface area of the catalyst particles, S, is 1000 m2/m3. The
pressure drop through the secondary converter, (-ΔP), is 6000 N/m2, the modified Reynolds
number, Re1, is 40, while the density and viscosity of the gas are 0.7 kg/m3 and 0.025 mN s/m2,
respectively. The void fraction, e is 0.4.

(i) State and explain Carman’s equation.

(ii) Calculate the diameter of particles, d.
(iii) Calculate the specific surface of the bed, SB.
(iv) Calculate the equivalent diameter of pore spaces, d’m.
(v) Calculate the gas flow rate, G’.
(vi) Calculate the average fluid velocity, Uc.
(vii) Calculate the average fluid velocity in the pores, U1.
(viii) Calculate the modified friction factor, (R1/ρu12).
(ix) Calculate the number of catalyst layers, n

2. Spherical glass particles of 3 mm diameter are fluidised by water at a velocity, Uc, of 0.30 m/s.
The density of glass is 2700 kg/m3, the density of water is 1000 kg/m3, and the viscosity of water
is 1 mNs/m2.

(i) State the Galileo number, Ga, and define the used variables.
(ii) Calculate the Galileo number, Ga.
(iii) Calculate the Reynolds number, Re’0, using the expression:

Re’0 = (2.33Ga0.018 – 1.53Ga-0.016)13.3

(iv) Calculate the terminal velocity, U0.

(v) State and explain the Richardson’s expression for sedimentation or fluidisation of uniform
particles.
(vi) Calculate the value of the index, n, using the expression:

(4.8 − 𝑛)
= 0.043𝐺𝑎0.57
(𝑛 − 2.4)

(vii) Calculate the voidage, e.

(viii)

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 13
 3. A slurry is filtered using a plate and frame press containing 10 frames, each 0.5 m square and 25
mm thick. During the first 3 minutes, the pressure difference, (-ΔP), for filtration is slowly raised to
the final value of 500 kN/m2, and during this period, the rate of filtration is maintained constant.
After the initial period, filtration is carried out at constant pressure and the cakes are completely
formed in a further 15 minutes. The cakes are then washed with a pressure difference of 300
kN/m2 for 10 minutes using thorough washing.

In order to estimate both the volume of filtrate collected per cycle and the wash water, a sample
of the slurry had previously been tested with a leaf filter, of a 0.05 m 2 filtering surface using a
vacuum, giving a pressure difference of 75 kN/m2. The volume of filtrate collected in the first 5
minutes was 300 cm3, and after a further 5 minutes, an additional 180 cm3 was collected. It may
be assumed that the cake is incompressible and that the cloth resistance is the same in the leaf
as in the filter press. Assume the viscosity of filtrate and wash-water to be the same and the
washing rate to be ¼ of the final filtration rate.

(i) State the general expression for filtration at constant pressure and at constant rates, for
incompressible cakes and define the used variables.
(ii) Calculate the volume of filtrate, V1, collected during the constant rate period on the filter
press after 3 minutes.
(iii) Calculate the volume of filtrate, V, collected during the constant pressure period on the
filter press after 15 minutes.
(iv) Calculate the final rate of filtration.
(v) Calculate the rate of washing at 500 kN/m2 and at 300 kN/m2.
(vi) Calculate the amount of wash-water passing in 10 minutes.

4. (a) A solution containing 28% by mass of sodium phosphate, Na3PO4, is cooled down from 313 K
to 298 K in a Swenson-Walker crystalliser to form crystals of Na3PO4•12H2O. The solubility of
Na3PO4 at 298 K is 16 kg/100 kg water, and the required product rate of crystals is 0.1 kg/s. The
molecular mass of the anhydrous and hydrated salt is 164 kg/kmol and 380 kg/kmol, respectively.
The mean heat capacity of the solution is 3.5 kJ/kg K, and the heat of crystallisation is 150 kJ/kg.
The cooling water enters and leaves at 288 K and 293 K, respectively, and the overall coefficient
of heat transfer is 150 W/m2 deg K. Assume counter-current flow and that the evaporation is
negligible.

(i) State the general equation for the calculation of the crystal yield.
(ii) Calculate the crystal yield.
(iii) Calculate the required feed to produce 0.1 kg/s of crystals.
(iv) Calculate the heat required to cool the solution.
(v) Calculate the heat of crystallisation and the total heat required.
(vi) Calculate the required heat transfer area.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 14
 (b) In a test on a centrifuge, spherical particles with density 1350 kg/m3 and of size equivalent
spherical diameter 40 μm were separated from a suspension in water fed at volumetric
throughput rate of 0.35 m3/s. The density and viscosity values of water are 1000 kg/m3 and 1 mN
s/m2, respectively.

(i) Derive an expression for the terminal falling velocity of spherical particles under Stokes’
law conditions.
(ii) Calculate the value of the capacity factor, Σ, and check your hypothesis.
(iii) Calculate the corresponding size cut for a suspension of graphite particle in oil fed at
volumetric rate of 0.4 m3/s and verify your assumptions. The density of graphite and oil
are 1200 kg/m3 and 650 kg/m3, respectively. The viscosity of oil is 22 mN s/m2.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 15
 Problems 2017

1. 100 kg of a slurry containing 40% by mass of solids is to be filtered using a rotary drum filter
equipped with a filter area of 10 m2. The filter operates with an internal pressure of 100 kN/m2
below atmospheric and with 33% of its surface in contact with the slurry at any instant.

(a) From the Carman-Kozeny expression:

1 𝑒3 1 (−∆𝑃)
𝑢𝑐 = 2 2
𝐾′′ 𝑆 (1 − 𝑒) 𝜇 𝑙

Derive the general equation of filtration

𝑑𝑉 𝐴2 (−∆𝑃)
=
𝑑𝑡 𝒓𝜇𝑣𝑉

and explain the terminology used. You can assume that the cake is uniform and the voidage
is constant throughout filtration.

(b) Assuming that the filter cake is incompressible and the filter cloth has a resistance equivalent
to that of 1 mm of cake, calculate the rate of production of filtrate and the thickness of the
cake when the rotary drum filter rotates at 0.01 Hz.

(c) It is desired to increase the rate of filtration by raising the speed of rotation of the drum. If the
thinnest cake that can be removed from the drum has a thickness of 3 mm, calculate the
maximum rate of filtration that can be achieved and the speed of rotation of the drum.

Data supplied:
The voidage, e, of the cake is 0.45;
The specific resistance of the cake, r = 4x1012 m-2;
The density of the solids, ρs = 1800 kg/m3;
The density of filtrate, ρ = 1000 kg/m3;
The viscosity of filtrate, μ = 2 mN s/m2.

2. (a) Sedimentation is a physical process using gravity to remove suspended solids from a fluid.

(i) Derive an expression for the setting velocity of a spherical particle immersed in a fluid for (i)
streamline and (ii) turbulent conditions.

(ii) Derive an expression for the maximum settling velocity, 𝑈𝑚𝑎𝑥 , valid for both streamline and
turbulent conditions.

(iii) Estimate the value of the friction coefficient under streamline conditions.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 16
 (b) The results of batch settling tests performed in order to calculate the minimum area and
diameter of a thickener with circular basin to treat 0.2 m3/s of a slurry of a solids
concentration of 250 kg/m3, gave the following results:

Solid concentration, c Settling velocity, us

(kg/m3) (μm/s)
100 150
200 90
300 55
400 35
500 22
600 15
700 11
800 8
900 6
1000 4.5
1100 3.5
1200 3

(i) Calculate the settling rate of the solids, G’ (kg/m2 s) at each concentration of solids, plot the
solid concentration values, c, vs. the settling rate of the solids, G’, and estimate the value of G’
at point u = 0 and c = 1300 kg/m3.

(ii) Calculate the volumetric flow rate of underflow, considering that a value of 1300 kg/m 3 for the
underflow concentration was selected from a retention test.

(iii) Calculate the area and the diameter of the thickener.

3. Mineral oil, of density 800 kg/m3 and viscosity 4 mN s/m2, is passed vertically upwards through a
bed of catalyst consisting of spherical particles of diameter 0.15 mm, density 2000 kg/m 3 and
voidage e=0.45.

(a) Derive an expression for the minimum fluidising velocity, umf. Assume the flow conditions
within the bed are laminar.

(b) Explain how the expression derived in (a) evolves when the flow regime at the point of
incipient fluidisation is outside the range over which the Carman-Kozeny expression is
applicable.

(c) Calculate the mass flow rate of flow per unit area of bed under fluidisation of particles
conditions.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 17
 (d) Calculate the mass flow rate of flow per unit area of bed under transport of particles
conditions.

(e) Calculate the ratio u0/umf and verify your hypotheses.

4. (a) A solution containing 25% by mass of potassium alum, KAl(SO4)2 is cooled down from 313 K
to 298 K in a Swenson-Walker crystalliser to form crystals of KAl(SO4)212H2O. The solubility of
KAl(SO4)2 at 298 K is 14 kg/100 kg of water, and the required product rate of crystals is 0.3 kg/s.
The molecular mass of the anhydrous and hydrated salt is 258 kg/kmol and 474 kg/kmol,
respectively. The mean heat capacity Cp the solution is 4.5 kJ/(kg K), and the heat of
crystallisation is 200 kJ/kg. The cooling water enters and leaves at 288 K and 293 K,
respectively, and the overall coefficient of heat transfer is 200 W/m2 K. Assume counter-current
flow and that the 5% of the initial solution is evaporated.

(i) State the general equation for the calculation of the crystal yield and define the variables
used.

(ii) Calculate the crystal yield.

(iii) Calculate the required feed to produce 0.3 kg/s of crystals

(iv) Calculate the heat required to cool the solution.

(v) Calculate the heat of crystallisation and the total heat required.

(vi) Calculate the required heat transfer area.

(b) A solution saturated with both KCl and KF is made up at 333 K and fractional crystallisation is
utilised to separate the two salts. At 293 K, the solubility of KCl is 34 kg/100 kg water and of KF is
95 kg/100 kg water. At this temperature, a saturated solution comprising both of these salts will
contain 25 kg KCl and 60 kg KF per 100 kg of water. At 333 K, the solubility of KCl is 46 kg/100
kg water and of KF is 142 kg/100 kg water, whereas a saturated solution at this temperature will
contain 15 kg KCl and 130 kg KF per 100 kg water.

(i) Plot a solubility diagram of KF (x-axis) vs KCl (y-axis), calculate the concentration of KF, and
verify your calculation using the similar triangles rule.

(ii) Calculate the yield of KF at 293 K.

EG-307 “Particulate Systems” 2017/2018 Swansea University

(Dr. Paolo Bertoncello)
Page 18