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CHEN 4401W
Unit Operations Laboratory
Section 003, Group 6
Section Instructor: Raul Caretta
September 17th, 2013
Planner: Alvaro de la Garza Musi
Experimenter: Chen Fang
Analyzer: Shaw Su
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Abstract
The Uni-Minn Corporation was asked to design a piping system to transport a dilute
guar-xanthan solution by a personal care products client. It was specified by the client
that a days solution should be transferred from a storage tank to a target tank 2000 ft.
away at a flow rate of 150 gallons/min. The specifications also included a height
difference between the tanks of 65 ft. Data was obtained from the Rheological Analysis
Equipment (RAE) and the Brookfield Viscometer, during to laboratory sessions at the
University of Minnesota pilot plant. The rheological constants calculated after were
transferred to construct the requested scale-up design. A comparative analysis between
the two test methods was also done to verify the values of the behavior and consistency
indexes, while also evaluating accuracy and precision. The effect of temperature on the
fluid was also studied.
The solution was analyzed at different Reeves pump settings and recycle stream valve
positions. A variation from 3 to 6.5 was done in the pump, and the recycle stream valve
was opened until there was almost no flow or closed completely to reach higher fluid
velocities. Similarly, the polymer solution was studied using the Rotational viscometer,
with RPM varying from 1 to 100.
Using the RAE, flow rates in the range of 0.15 to 0.65 0.06 kg/s were attained; the
pressure drops recorded at four different points spanned from 300 to 3,000 15 Pa.
Calculations resulted in a consistency index of 0.21 Nsn/m2 and a flow behavior index of
0.65. The Brookfield viscometer produced torque measurements ranging from 10 to 50
0.1 Nm, and apparent viscosities around 250 to 550 15 cp. Using this data the
consistency and flow behavior indexes were found to be 4.90 Nsn/m2 and 0.67
respectively. These values correspond to thinning behavior which indicates the power
law fluid lies in the pseudoplastic fluid region. Tests changing the temperature of the
polymer solution to 24, 25 and 27 0.2 C were done using a hot water bath and the
Brookfield viscometer. Viscosity was recorded and presented an exponential decreasing
behavior with increasing temperature. The consistency index was calculated at changing
temperatures and was found to be 3.6, 3.5, and 4.3 Nsn/m2 at 24, 25 and 27C
respectively. In addition, the flow behavior index was calculated to be 0.72, 0.73, and
0.68 at 24, 25 and 27 C. These values show a decreasing flow behavior index and
therefore increasing pseudoplastic behavior.
Density was measured to be 1090 10 during both lab periods using a 1L beaker. The
polymer content of the solution was obtained by drying the solution for two days in a
convection oven and was calculated to be 0.43 0.01wt%. The data could have been
improved on accuracy and precision by having one person run and record data for the
RAE and using a broader range of temperatures in the Brookfield viscometer tests.
The scale-up piping system was designed using the calculated values for the
consistency and the flow behavior indexes. Two open 190,290 gallon tanks, each with a
25.3 ft diameter, a 50.6 ft height and 20in freeboard were sized to hold a days supply for
the process. A 6-in diameter schedule 40 steel pipe was chosen for the piping in the
system to minimize cost. The Reynolds number was calculated to be 1,655 for the
polymer solution validating laminar flow. A Reynolds number of 197,000 was calculated
for water, indicating turbulent flow. A positive displacement 4HP pump is recommended
for its use in the transfer of the polymer solution from the storage tank to the receiving
tank. In case of water, vacuum pump with 3-HP motor can be used. A recycle stream is
also recommended to have more flexibility when it comes to fluid flow control if the
displacement pump does not offer many settings. The total cost for the design essentials
was calculated to be $1,710,000 not including the recycle stream, valves, fittings or
temperature gages and a rotameter.
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TABLE OF CONTENTS
1.
Introduction, Theory and Technical Background
1.1 Introduction
1.2 Theory and Technical Background
1.3 Design Problem Theory
1.4 Error Analysis
2.
Description of Apparatus
2.1 Rheological Analysis Equipment
2.2 Brookfield Rotational Viscometer
3.
Experimental Procedure
3.1 Rheological Analysis Equipment
3.2 Brookfield Rotational Viscometer
4.
Results
4.1 Polymer Solution Characteristics Data
4.2 Rheological Analysis Equipment Data
4.3 Brookfield Rotational Viscometer Data
5.
Final Data and Results
5.1 Polymer Content and Density
5.2 RAE Results
5.3 Brookfield Rotational Viscometer Results
5.4 Temperature Effects
5.5 Comparison of RAE and Rotational Viscometer results
6.
Discussion of Results, Conclusions and Recommendations
6.1 Discussion of Results
6.2 Conclusions
6.3 Recommendations
7.
Design Problem
7.1 Introduction
7.2 Design Parameters
7.3 Design Calculations
7.4 Non-Newtonian and Water Comparative
8.
Nomenclature
9.
References
10. Appendices
A. Original Data Sheets
B. Sample Calculations
C. Design Problem Calculations
D. Error (Uncertainty) Analysis
E. Data Transfer Sheet
4
4
7
8
10
12
12
14
14
15
17
19
20
21
22
22
22
23
23
25
25
26
26
27
28
29
43
49
56
60
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(1.2.2)
Equation 1.2.2 above represents the power law equation where K is the consistency
index in
and n is the flow behavior index and its dimensionless. These two
rheological constants characterize a power law fluid. The apparent viscosity is
represented by the following equation.
(
(1.2.3)
For n<1 the apparent viscosity decreases as the shear rate increases, these are known
as shear thinning fluids. Non-Newtonian solutions rheological characteristics are
susceptible to bacterial, heat, enzyme and UV degradation.
Rheological Analysis Equipment
The RAE uses pipe flow and pressure changes to study non-Newtonian flow properties.
Shear stress and shear rate are calculated using the available measurements, and
logarithmic plots are used to find the rheological constants needed.
Shear stress can be calculated the following equation,
(
) ( )
(1.2.4)
)( )
(1.2.5)
This relation only holds for laminar flow, therefore low fluid velocities have to be
maintained. Finally using the results above the generalized viscosity coefficient is
calculated according to the following relation,
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(1.2.6)
(1.2.7)
[
) ]
Where
is the radius of the spindle,
is the radius of the outer cylinder, and is the
angular velocity of the spindle. The above relationship only holds for 0.5 <
< 0.99. To
calculate the angular velocity of the spindle and the torque required the below equations
are necessary,
(1.2.8)
Given that N is the revolutions per minute. And for torque in Nm,
(1.2.9)
The shear stress at the wall of the spindle is given by
(1.2.10)
Where T is the measured torque, and L is the length of the spindle. Equation 1.2.8 holds
for both Newtonian and non-Newtonian fluids.
Substituting equations 1.2.7 and 1.2.10 in the power-law equation results in the following
equation,
(1.2.11)
[
) )
Which after experimental data is obtained by measuring the torque at different angular
velocities can be used to evaluate flow-property constants. A log T versus log w results
in a linear fit with the parameter n as the slope and the intercept as
, the
consistency factor can be extracted easily from the intercept.
Effect of Temperature Changes
Non-Newtonian fluids apparent viscosity is very sensitive to temperature changes. As
temperature increases power law fluids present a reversible softening which translate to
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) ]
(1.3.1)
The above equation from Peters and Timmerhaus is based on economical and design
optimization parameters. It includes several costs which are essential to minimize in a
plant such as electricity, annual average fixed and maintenance costs, etc. The
description of the symbols used is found in the nomenclature section. (8)
Reynolds Number
To validate the use of the results obtained in lab for scale up, it has to be proven that the
fluid is flowing in the laminar region. The generalized Reynolds number equation can be
used for the analysis,
(
(1.3.2)
Where D is the pipe diameter, V is the linear velocity, is the fluids density, K and n are
flow indexes. The transition region to turbulent flow starts at
, so a flow lower
than that has to be attained.
In the case of water a different equation for Reynolds number is needed,
(1.3.3)
Here the laminar region ends after a Reynolds number higher than 2,000.
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Pump
Pump sizing starts with a mechanical energy balance including potential energy,
pressure drop, kinetic energy, and the summation of the friction losses. It is given by the
following equation,
(1.3.4)
Here
is the velocity correction factor, approximated to be 0.5 for laminar flow in
Newtonian fluids. In non-Newtonian fluids is given by,
(1.3.5)
The pressure drop due to friction (p) in the mechanical energy balance is found using
the following equation,
(1.3.6)
This equation applies to laminar flow and requires the fanning friction factor
The total frictional loss in the pipe (F) is calculated adding all the expansion losses
(hex), contraction losses (Kc), and losses in fittings and valves (Kf). It is given by the
following relation,
(1.3.7)
Solving for the shaft work in the mechanical energy balance, and adding the average
pump efficiency of 75% (4) the work required by the pump is calculated using the relation
below,
(1.3.8)
Finally, the work required can be translated to Break horse power with the following
equation,
(1.3.9)
From here the electric power input can be determined with the next relation,
(1.3.10)
(1.4.1)
Where ep is propagated absolute error and e1 through en are absolute errors of the
measurements subtracted or added. Error of measurements in multiplication and division
propagates like:
(1.4.2)
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Where %ep is the percentage error propagated and e1 through en are the percentage
errors of the different measurements multiplied or divided.
Error associated with logarithms is determined using the following formula:
( )
(1.4.3)
To calculate the error associated to the mean of a value pool, the Students t test must
be applied to a 95% confidence interval. The first standard deviation Sp is computed as,
(
(1.4.4)
where xi is the value of the measurement, xavg is the average of the experimental values,
and n is the number of measurements made. The desired value for t to approach a
confidence interval is determined from students t table. Using this value, the error limit
can be determined for the sample mean value, as follows.
(1.4.5)
Hence the final result accounting for errors is expressed in the form xavg and it is
based on the degrees of freedom and a particular confidence level.
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2. Description of Apparatus
In this experiment, two sets of equipment, a Rheological Analysis Equipment (RAE) and
a Brookfield Rotational Viscometer were used to evaluate rheological properties of a
solution containing a blend of 97% guar and 3% xanthan. Results obtained with RAE
were compared with Brookfield Viscometer to see if the information could be obtained
with a much smaller and simpler instrument.
2.1 Rheological Analysis Equipment
A process flow diagram for the rheological analysis equipment was shown as follows.
Recycle line
P4
P3
P1
P2
Bypass line
2.9m
Drain
MOYNO Pump
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3. Experimental Procedure
3.1 Rheological Analysis Equipment
Start up
To start up, the main power switch located at the back of the panel was turned on. The
tank mixer was also turned on to mix the solution. The motor was started then the
Reeves Drive pump speed set to 3 for a start-up setting.
Steady state
For a certain Reeves Drive pump speed setting and bypass line valve position, whether
pressure reading was stable was used to determine if steady state was reached. For a
new run, when the pump speed or the bypass valve was set, it was observed that it took
a few seconds for the fluid inside the manometers to reach a new level and stay stable.
When the pressure reading was stable, the steady state was reached and the
measurements were taken after.
Measurements
For all measurement, flow rate was controlled by both the Reeves Drive pump speed
and the position of the bypass line valve. Measurements were taken after both the pump
speed and the valve position were fixed and the system reached steady state. For a
certain run, time and mass for the weight tank and pressure at four tags were measured.
At the start of a run, initial mass on the electronic balance of the weight tank was
recorded, a period of time (most frequently 60s) was recorded by a stop watch and the
final mass on the balance was recorded. The recycle line valve was closed during the
entire run and opened at the end of a run to recycle the fluid in the weight tank back to
the mixer tank. In the meantime while flow rate was measured, pressure measurement
was recorded. Both the weight tank-and-stopwatch and pressure measurements were
taken 3 times for each run to get the experimental errors and reduce random errors.
In order to get a volumetric flow rate from the mass flow rate, mass of the sample was
measurement along with volume of the sample using a 1000 mL graduated cylinder. 5
samples were taken to get a more accurate density measurement.
The polymer content of the solution was determined by placing a measured amount of
polymer solution inside a petri dish with lid on and put in an oven. After two days, the
mass of the dried polymer was measured again to get the polymer content of the
material.
Run conditions and range of variables
The Reeves Drive pump was started at a setting of 3, and increased in a 0.5 interval to a
setting of 6.5. In order to obtain results at very low flow rates to compare with the
Brookfield Viscometer, 7 sets of flow rate were obtained at a pump setting 3 during 2nd
week, from the bypass line valve widely open (where the flow was very narrow and
slow), closed a little bit to the bypass valve completely closed. Lowest flow rate was
obtained with Reeves Drive Pump setting at 3 and bypass valve widely open, highest
flow rate was obtained with Reeves Drive Pump setting at 6.5 and bypass valve closed.
Range of flow rate from 0.01 gal/min to 8.21 gal/min was obtained.
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Shutdown
Recycle line was opened to empty the remaining solution in the weight tank to the mixer
tank. The level of polymer solution in tank was checked to be about 3 to 4 inches below
top of barrel. The mixer was turned off. The Reeves Drive was returned to the setting of
3 and then the motor was stopped. The main power switch was finally turned off.
Precautions
The guar-xanthan solution has been determined to be nonhazardous by the Metropolitan
Waste Control Commission and the University Department of Environment Health and
Safety. The solution has a BOD5 (biological oxygen demand) equal to 6.51g/L and a
COD(chemical oxygen demand) of 8.14g/L and can be discharged to the sewer weekly
by the shop personnel because it is biodegradable.(2)
3.2 Brookfield Rotational Viscometer
Start up
First, check that the viscometer is level. The two leveling screws on the base were
adjusted to keep the viscometer level if necessary. The power switch on the real panel of
the viscometer was then turned on with no spindle attached. The DV-I+ then begins its
Autozero. The spindle (or the UL Adapter) was then taken out from the case and
screwed to the lower shaft of the viscometer and the S01 or S02 was shown on the
display corresponding to the spindle attached.
Measurements
A 1000mL flask containing the polymer solution was placed under the spindle. The
Brookfield viscometer was lowered so that the water line level mark on spindle was at
the same height of the polymer solution level in the flask. Once the rotational speed was
set, it took less than 30 seconds for the system to come to steady state and the reading
to be stabilized. The stability of reading was used to confirm that the system has
reached steady state. The torque in % and viscosity in cp were then displayed and
recorded. The rotational speed was varied from 5 RPM to 100 RPM for the range of
variables. Thermometer was used to measure the polymer solution temperature in the
flask, and was determined to be 21 .
Temperature effect on the rheological properties of the fluid was studied using the
Brookfield UL Adapter during the 2nd lab period. The 1000 mL flask containing the
polymer fluid was immersed in a 4L water bath containing the hot water from the tap.
The system was equilibrated and the temperature was measured. The same sets of
measurements as above were taken at the new temperature. The temperature for the
water bath and solution system decreased slowly to near the room temperature and
there is enough time for measurement at a certain temperature. And during the process
the same sets of measurements were taken at the intermediate temperature.
Shut down
The viscometer motor was turned off. The spindle or the UL Adapter was taken out of
the polymer solution. The spindle and the UL Adapter were cleaned up. The flask was
cleaned.
Precautions
Both guar and xanthan are irritants materials and gloves were worn at all times when
handling the solution using the Brookfield viscometer.
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During the 2nd week, 5 samples were taken to get measurement uncertainty, with each
the mass and volume of the sample measured. Density was calculated as shown below
and in the Final Data and Results section. Density measurement if necessary to get
volumetric flow rate from the mass flow rate measured and hence get velocity for
calculation of rheological constant using RAE.
Table 4.1.2 Measurement of density of the polymer solution
Run sample
1
2
3
4
5
Mass of
sample(kg)
1.10
1.08
1.08
1.08
1.10
Volume of
sample(mL)
1000
1000
1000
1000
1000
Density of
sample(
)
1100
1080
1080
1080
1100
Average
density of
polymer
(
)
1088 14
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Table 4.2.1 Rheological Analysis Equipment results for the 1st week
Run
1-1-(1,2,3)
1-2-(1,2,3)
1-3-(1,2,3)
1-4-(1,2,3)
1-5-(1,2,3)
1-6-(1,2,3)
1-7-(1,2,3)
1-8-(1,2,3)
Flow rate
(lbs/s)*10
1.09 0.02
0.02 0
0.62 0.02
3.4 0.06
7.40 0.06
9.14 0.04
2.33 0.03
2.79 0.03
Velocity(kg/s)*10
0.94
0.01
5.36
2.94
6.39
7.90
2.01
2.41
0.02
0
0.06
0.06
0.08
0.09
0.04
0.03
(1-2)
(Pascal)
1513.5 21.3
519.8 48.7
3654.6 47.6
2762.2 35.4
3961.9 50.2
4426.1 56.8
2239.2 31.3
2406.0 32.0
(3-4)
(Pascal)
1493.9 12.7
483.8 26.6
3671.0 45.2
2817.8 36.2
4011.0 51.3
4527.4 58.5
2239.2 33.5
2402.6 32.2
For the run number notation, the 1st number 2 indicated the 2nd week, the 2nd number 1
was used for the rheological analysis equipment. Same quantities were calculated as
below.
Table 4.2.2 Rheological Analysis Equipment results for the 2nd week
Run
Flow rate
Velocity(kg/s)*10
(1-2)
(3-4)
(lbs/s)*10
(Pascal)
(Pascal)
2-1-1
5.93 0
5.04 0.07
2987.5 38.4
3094.2 39.8
2-1-2
0.40 0
0.34 0
558.4 15.5
553.0 15.2
2-1-3
1.03 0. 03
0.88 0.03
992.3 15.5
985.2 14.1
2-1-4
0.37 0
0.31 0
496.1 8.3
492.6 9.4
2-1-5
0.29 0.02
0.25 0.02
361.0 8.3
366.3 10.8
2-1-7
0.41 0.02
0.35 0.02
503.3 10.4
497.9 12.8
2-1-8
6.32 0.05
5.37 0.07
3083.5 42.5
3133.3 40.8
2-1-9
7.21 0. 11
6.12 0.11
3279.1 44.0
3353.8 44.0
2-1-10
8.03 0.07
6.82 0.09
3478.3 45.0
3581.4 46.5
2-1-11
9.09 0.05
7.72 0.09
3693.5 48.0
3844.6 50.0
2-1-12
10.11 0.04
8.59 0.10
3930.0 52.0
4143.4 53.7
2-1-13
11.33 0
9.63 0.10
4203.8 57.0
4445.7 58.5
2-1-14
12.42 0.48
10.55 0.42
4442.1 57.8
4712.4 61.9
2-1-14
0.98 0. 02
0.83 0.02
928.3 14.8
917.6 14.7
2-1-15
0.51
0.43 0.02
576.2
583.3 9.7
2-1-16
1.64
0.14 0.02
1298.1 20.8
1280.4 19.6
2-1-17
1.03 0
0.88 0.01
967.4 17.5
935.4 14.9
Certain parameters of the RAE would be needed to calculate the results as indicated in
the final results section. The parameters noted were as follows:
Table 4.2.3 Parameter used for calculation of the Rheological Analysis Equipment
Parameter of the RAE
Value
Diameter of the pipe(d)(m)
0.025m
Distance between pressure taps(L)(m)
2.9m
For the run number notation, during 1st week, only two numbers were used. For easy
reference here, a first number 1 was added. So the Run number below 1-2-1 correspond
to the run number 2-1 on the original data sheet of the 1st week S3N6 NNF Week 1
Rheological Constants using Brookfield Rotational Viscometer. The rotational speed
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was calculated, and the torque measured in % was converted to the absolute value
using the full torque for this model 7187.0 dyne-cm. Since the RPM measured has no
errors associated, the calculated has no errors. The results were as follows:
4.3 Brookfield Viscometer Data
Table 4.3.1 Brookfield Viscometer results for the 1st week
Run
Torque(NM)
*
( .0001)
1-2-1
16.5
5
0.5
1.5
1-2-2
16.5
10
1.0
2.8
1-2-3
16.5
20
2.1
4.8
1-2-4
16.5
50
5.2
9.2
1-2-5
16.5
100
10.5
14.4
1-2-6
16.5
30
3.1
6.3
1-2-7
16.5
60
6.3
10.3
Brookfield UL Adapter was used for the 2nd week to study the temperature effects. The
same quantities were calculated as below:
Temp. (
RPM( 1%)
(rad/s) ( 1%)
( .0001)
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Several parameters regarding the Brookfield viscometer were needed to calculate the
rheological constants as in the final results section. The parameters as shown as below:
Table 4.3.3 Parameter used for calculation of the Brookfield Viscometer
Parameter of the cylindrical spindle
Radius of
spindle(m)
0.00942
Radius of spindle(m)
0.0126
Length of
spindle(m)
0.0749
Radius of UL Adapter(m)
0.0138
Actual length(m)
0.0651
0.911
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The polymer solution is pumped through a capillary tube of 1 inch in diameter, where the
pressure drops across a 2.9 m straight section is measured by a manometer. The
Reynolds number at the highest flow rate is determined to be 930 40, which indicates
laminar flow. This condition is required for the power law model 1.2.2 used for analysis,
where the shear stress at the wall is plotted against shear rate in the logarithmic scale.
100
y = 0.2282x0.6551
R = 0.998
21 C
10
1
1
0.1
10
100
1000
Figure 5.2.1 log-log Flow curve of the guar-xanthan solution, where the shear stress w
is given by DP/4L, and the shear rate 8V/D. Note the small error bars.
The slope and the intercept are given as the exponent n and constant K respectively.
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n
0.6551
The errors in the above constants are from the regression analysis alone and are
approximated to be less than 1%. They are therefore ignored. The temperature under
which the RAE analysis was performed was 21 C.
5.3 Brookfield Rotational Viscometer Results
A cylindrical spindle attached to an electric motor is dipped into the polymer solution
where the angular velocity is controlled to shear the liquid. The torque needed to keep
the RPM constant is calculated and correlated to give the rheological constants in the
following figure.
1
Torque (Nm)
0.1
10
100
0.1
0.01
y = 0.0098x0.6778
R = 0.9992
21 C
0.001
Figure 5.3.1 log log plot of torque vs angular velocity, where the slope is the
exponent, and intercept the constant in the equation above.
The constant 0.0098 is used again to obtain the consistency factor K that relates shear
stress to shear rate. They are given in the table below.
Table 5.3.1 Rheological constants from rotational viscometer
A
0.0098
n
0.6778
K (Nsn/m2)
4.9019
There are ignorable errors from regression analysis for the constants above. The
temperature of the solution was 21 C.
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0.1
10
100
0.1
y = 0.0089x0.6834
R = 0.9993
27 C
0.01
0.001
Torque (Nm)
0.1
10
100
0.1
y = 0.0083x0.7294
R = 0.9968
24 C
0.01
0.001
Torque (Nm)
0.1
10
100
0.1
y = 0.0081x0.7315
R = 0.9971
25 C
0.01
0.001
Figures 5.4.1-3 log log plot of torque vs angular velocity at their respective
temperatures, values of A and n given in the boxes
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The rheological constants at its respective temperature are given in the following
table. The associated uncertainties are again negligible and from regression alone.
Table 5.4.1 Rheological constants at 24, 25, and 27 C
Temperature (C)
24
25
27
A
0.0083
0.0081
0.0089
K (Nsn/m2)
3.6731
3.5668
4.3930
n
0.7294
0.7315
0.6834
The plot of effective viscosity vs shear rate is given below to demonstrate the effect of
temperature. The uncertainties are less than 1% and negligible.
3
(Pa s)
2.5
2
21 C
1.5
27C
25C
0.5
24C
0
0
50
100
150
1000
y = 4.9242x0.6778
R = 0.9992
Brookfield results
100
RAE results
10
Power (Brookfield
results)
1
1
0.1
10
100
1000
y = 0.2282x0.6551
R = 0.998
Figure 5.5.1 log log plot of shear stress vs shear rate from both the RAE and the
rotational viscometer results, values of K and n are given in previous tables
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6.2 Conclusions
The rheological constants obtained from both techniques indicate shear thinning nonNewtonian behavior in consistency with the theory. The difference in the consistency
factor K is the result of equipment scale and easiness to operate. These contributed to
the experimental and measurement uncertainties of the rheological properties. The
precision levels of both methods are equally high under the same temperature of 21 C.
The effect of temperature on the viscosity and rheological constants have shown
thinning of the solution with increased temperature. Due to the range of temperature
tested being from 21 to 27 C with only 6 C difference, the behavior of shear stress vs
shear rate are relatively close to each other. The rheological constants obtained from
both techniques have less than 1% of uncertainty and thereby not included their
corresponding values.
The RAE is a realistic model to perform testing for scaling up in bigger plants. It takes
into account the complexities of the bigger process where many equipments, bends,
valves and pumps are involved. These process components make the thermodynamic
steady state have sizable fluctuations, as well as taking longer to achieve. Therefore it is
necessary to use such model when the objective desires such.
The rotational viscometer is an economic and useful alternative for obtaining the generic
property information prior to doing testing on a bigger model like RAE. The results have
been consistently repeatable and precise. It did however produce a different correlation
for the rheology of the guar-xanthan solution than that of the RAE. Knowing the limitation
and the specifications of the design process are therefore the determining factor on
choosing the testing method. This method would also be suitable for processes that are
small and simple in scale.
6.3 Recommendations
For improvement on data accuracy and precision, its best to have a single person in
charge of running the RAE, verifying the steady state and taking measurements. The
same should be done for using the rotational viscometer as well. The third person can
be in charge of data analysis, recording experimental procedures, and giving
recommendations to the operations of either teammate.
To have a broader range of temperature effects on the rheology of the guar-xanthan
solution, ice bath can be used on the testing with the rotational viscometer. Making sure
the solution is thoroughly mixed before any testing is vital to the quality of data as well.
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7. Design Problem
7.1 Introduction
The Uni-Minn development corporation was asked to design an efficient piping system
for the transport of a 1% guar and xanthan blend to future use in the clients personal
care products. The client required for the solution to be transferred through 2000 feet of
piping at flow rate of 120 gallons/minute from an open storage tank to a target tank 65
feet above the initial tank. Some of the scale-up design specifications were optimal pipe
diameter, pump characteristics, and required instruments, valves or fittings. A process
flow diagram for the suggested piping system is shown below in figure 7.1.1.
V-3
65 feet
2000 feet
T2
Storage Tank 2
Rotameter
P-9
Storage Tank 1
T1
15 feet
V-2
V-1
Positive displacement
Pump
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8. Nomenclature
Symbols listed in the order in which they appear.
:
Shear stress
: Shear rate
Viscosity
Consistency index
Flow behavior index
Apparent Viscosity
Pipe diameter
Pressure drop
Length of pipe
Pi
Fluid linear velocity
Generalized viscosity coefficient
Radius of spindle
Radius of outer cylinder
Angular velocity
Revolutions per minute
Torque
Length of spindle
Optimal pipe diameter
: Cost of electricity
Mass flow rate
Working hours a year
Annual fixed charges
Purchase cost of piping per feet of pipe
Constant for material determined for steel pipes
Pump efficiency
Density
Ratio of total cost of fittings and insulation bought per feet of pipe
Reynolds number
Velocity correction factor
Shaft work
Velocity
Height
Friction forces
Compressor efficiency
Generic loss due to friction
Real shaft work
Measured error
Standard deviation
Value of measurement
Average of experimental values
Error limit
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9. References
1.
3.
4.
Sept. 15 2013)
6.
Peters, M.S. and Timmerhous, K., Plant Design and Economics for Chemical
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D. Error Analysis
D.1 Sources of errors
All measurements were associated with errors. For all measurements, the true value
was unknown, so the true error was not known. Calibration was not performed in this
experiment and the systematic errors were not considered (calibration for the Brookfield
Viscometer might be needed but not a consideration for this lab). The most important
sources of error were from the random errors caused by time-varying phenomena in the
instrument, the surroundings and users, and the quantity being measured. The
instrument sources of errors were as follows:
Sources of errors, the errors in physical quantities measured in this lab included the
error in time, weight tank, pressure, Brookfield Viscometer, density and polymer content,
each discussed as follows.
The flow rate was measured using the stopwatch-weight tank method. Due to the
inaccuracy of human operating with stopwatch, the error in time measurement was 1s.
Due to the fluctuation of electronic scale during measurement, the error in weight
measurement was determined to be 0.4lbs. These two errors were accounted for by
the replications.
Pressure had an error of
by making replications.
0.5mm the fluid in the RAE. This error was also accounted for
The RPM had an error of 1%. The error on the reading torque was .1%, and the error on
viscosity varied with the value of the viscosity. The bigger the viscosity value, the bigger
the error.
Error in weight measurement was the fluctuation at the last digit of the scale: 0.0005g,
and was used to determine the error on polymer content. Error in density was accounted
for by replications.
D.2 Experimental uncertainties estimates with replications
In this experiment, most random errors, including error in flow rate, pressure, and
density were reduced by replication.
When multiple replications were obtained, the standard deviation was calculated.
Equation
was used in combination with students T table to get an estimate on the
true error.
For the density measurement, five values obtained were 1100, 1080, 1080, 1080, 1100.
to get
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%polymer=
For run 2-1-1 as in the original data sheet, in the 3 replications of time weight
measurement, flow rate were determined to be
,
and
0.269 0kg/s.
V=
So V=
For run 2-1-1, three replications of pressure measurements were the same, so
(650 0)-(370 ) =280
mm polymer fluid
So
)=2987.5
(1-2) =
pascal
All error for measurements on torque was determined to be .1%, which was
D..3 Propagation of error (calculated according to sample calculation)
For run 2-1-1
So
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Shear rate
Shear rate
(
The correlation between the shear stress and the shear rate are from plot of logarithmic
scale where the trend line is fitted to a power law behavior. The exponent n and the
constant K are obtained this way such that the uncertainties are from regression alone.
The regression analysis for the constants K and n are so small that are ignored as
discussed in the final results section. The above equation reduce to
For run 2-2-3 of the Brookfield viscometer, the rpm has an error of 1% of the reading
This error was ignored to the 1st digit after the digital point.
For the Reynolds number using run 2-1-14,
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, b=constant
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