Professional Development
Elements of Calculation Style
James Anthony,
Lockwood Greene
Style helps readers to understand,
and calculations to succeed.
T
he elements of style in calcu-
lations are the choices in com-
position that strengthen collab-
oration between writers and
readers by helping them meet
one anothers needs. The over-
riding need of both writers and readers is to not
have to keep track of too much new, unfamiliar
material at one time (1).
Elements of style include separate sections for
assumptions, data, calculations and summaries.
Each section can be prepared and read with a min-
imum of in-depth thought, yet each section moves
the solution forward and serves as a resource for
use with the later sections.
Elements of style at the formula level, which
are even more helpful, include conventional sym-
bols, reminders of variable definitions, reference
names and pages, reminders of values of depen-
dent variables, and equations that are visible, as
shown in Figure 1. These elements let writers and
readers understand and check formulas with a
minimum of cognitive strain.
Elements of style in calculations are elaborated
below and illustrated with a sample calculation on
pages 5253.
1. Use calculation software
Use software that displays the working formu-
las. The equations are the working parts of the
calculation. A calculation is easier to use if its
functions can be readily inferred by looking at
50 www.cepmagazine.org November 2001 CEP
the features visible to the user. Calculation soft-
ware packages, such as Mathcad and Calculation-
Center, display a calculations working formulas
and results together, and print them for conve-
nient writing and reading (3, 4). Spreadsheets
typically dont display formulas, so only simple
operations like totaling the numbers in a column
can be readily inferred by looking at a spread-
sheet. (Spreadsheets can be made to display for-
mulas and results together through the use of
named ranges (5) and user-defined functions, as
shown in Figure 2). Programming languages,
such as Visual Basic and FORTRAN, display and
print the working formulas and results separate
from each other, and often use coded syntax
(when referencing data objects, for example),
making calculations in these languages difficult
to read and document.
Use software that calculates units as well as
numbers. Calculation software like Mathcad and
CalculationCenter makes it possible to include di-
mensional units in values and formulas and have
the software perform unit conversions automatical-
ly, bypassing an otherwise major source of errors.
2. Set up for easy viewing
Make calculations read from top to bottom. Use
the approach that experts use when solving easy
problems work forward from the known data to
determine the unknown values that are needed (6).
Enter data before calculations, and summarize in-
puts before summarizing results. In the same man-
 Figure 1.
Formula blocks The effective interfacial areas per unit volume in the first and sec-
help readers to ond stage vessels, a1 and a2, are calculated from the gas holdups
understand and G1 and G2 and the Sauter-mean bubble diameters or bubble vol-
check formulas (2). ume-to-surface ratios dvs1 and dvs2 (Perrys pages 5-69 and 5-43):
G1 = 0.194676 and G2 = 0.196213
ner, provide reference materials before referring to them. dvs1 = 0.284573 in and dvs2 = 0.284552 in. 12 in = 1 ft.
Place the table of contents before the actual contents, list 6 6
a 1 : = G1 and a 2 : = G2 :
references before they are used, and list variable names be- d vs1 d vs2
fore they are mentioned. 2 2
a 1 = 49.255 ft and a 2 = 49.648 ft .
Use font, font size, and font style changes to help read- ft
3
ft
3

ers. Font changes can help readers distinguish equations

from text. Font size changes can improve readability of
equations. Both changes are performed automatically by
the calculation software used to prepare Figure 1 and the
sample calculation. A font style change to bold face for the
headings can help readers rapidly scan through a calcula-
tion, as shown in the sample calculation.
Use graphic lines mostly to convey information. When
graphic lines are used sparingly, the lines that are used
stand out better (7). Horizontal lines can be used as blanks
for user-supplied data. Vertical lines can be used as revision
bars. Blank space can serve the same function that graphics
lines are often used for in forms, providing separation be-
tween unrelated items of information and helping readers
read horizontally across rows of information in tables.
Include equipment number and page number at the
right on each page. Sets of calculations arranged by major
equipment number including letter prefix can be leafed
through easily to locate calculations that are of interest to
the reader.
Make formulas readable without comments. Help read-
ers be able to review formulas independent of the explana-
tory comments. Place formulas on separate lines from
comments. Center formulas on the page, or indent them.
Provide punctuation and text to allow the
resulting material to be read straight
through more easily than the formulas
alone could be read.
through it, and they proceed through it more quickly.
Sketch the system. Sketches with text help people un-
derstand problems more thoroughly and help people move
further toward solutions (9). The more useful diagrams
show spatial relationships, show key data at a glance, and
place information near the associated objects so that sym-
bolic labels are not needed (10). When solving a problem
that requires the use of formulas to interpret physical in-
formation, experts tend to insert an intermediate step re-
describing the problem qualitatively (11). Sketches can
capture some of an experts understanding of the problem
by emphasizing key considerations while leaving out sec-
ondary details. Unfortunately, people who have less trou-
ble proceeding with a problem tend to draw fewer sketch-
es. As a result, they miss out on opportunities to help
novices develop the skill of going beyond the literal fea-
tures clearly evident in problem statements to infer addi-
tional relationships that are important for constructing ef-
fective solutions, which is the skill that novices are usual-
ly most lacking (6).
State the approach, noting the key methods used. Name
the key method or methods used, and describe how they

3. Provide supporting information

Write clear sentences. Start by writing
what you would say aloud. Then remove
excessive words. Rearrange phrases to im-
prove clarity or eliminate ambiguity. Add
words wherever this will help readers un-
derstand without having to concentrate as
hard and without having to reread (8).
Reread the work yourself later and edit it
again, repeating these steps.
List the contents. Simple, descriptive
headings provide enough useful help to
readers to avoid the need for paragraphs of
explanatory text.
State the objective. Readers expect to
find the most important information at the
start, and if not there, then at the end.
They spend more time reading the infor-
mation at the start. When the key theme is
identified up front, readers understand the Figure 2. Current spreadsheets, such as Microsoft Excel, can display formulas and results together.
subsequent material better as they proceed

CEP November 2001 www.cepmagazine.org 51

 S A M P L E
page
Objectives 1
Approach 1
References 1
Symbols 1
Assumptions 1

Constants and Conversions 1

Hardware Data 1
Property Data 2
Operating Data 2

Calculations 2
Results 2
Objective
Estimate minimum recommended slurry velocities vs. pipe diameter.
Approach
Apply the Durand equation for the minimum transport velocity as recommended in Perrys and Heywood, adding a
reasonable margin to the velocity as recommended in Heywood.
References
Data Sheet World Minerals, Harborlite 2000 Technical Data Sheet, World Minerals, Lompoc, CA, 2000 (enclosed)
General Info World Minerals, Perlite General Information, World Minerals, Lompoc, CA, 2000 (enclosed)
Heywood Heywood, N.I., Stop Your Slurries from Stirring Up Trouble, Chemical Engineering Progress,
pp. 21-41, September 1999 (enclosed)
P & ID WRC, Filter Aid Storage/Delivery P&ID, Dwg. No. PR-001, Rev. A, Confidential Client, 2000
(in project master file)
Perrys Green, Don W., editor, Perrys Chemical Engineers Handbook - 7th Ed., McGraw-Hill, New York,
pages 6-30, 6-31, 10-72, and 10-73, 1997 (enclosed)
Symbols
Cs maximum volume fraction solids -

D pipe diameters in

d particle diameter mm

FL Durand factor for minimum suspension velocity -

ft
g gravitational acceleration
sec 2
s ratio of solid density to liquid density -

sgL specific gravity of liquid -

sgs specific gravity of solid -

ft
V minimum recommended slurry velocities sec
VM2 minimum transport velocities ft
sec
Ws maximum weight fraction solids -
lb
3
L density of liquid ft
lb
s density of solid 3
ft
Assumptions
Assume pipe is Schedule 40S.
Constants and Conversions
The gravitational acceleration g is:
g = 32.174 ft .
sec 2
Hardware Data
Consider several pipe diameters D (Perrys pages 10-72 and 10-73)
1.610
D: = 2.067 in.
3.068

52 www.cepmagazine.org November 2001 CEP

 C A L C U L A T I O N
Property Data
The specific gravity of the liquid, sgL, is (P&ID):
sgL := 1.0.
The specific gravity sgs and particle size d of the solid are (Data Sheet):
sgs := 2.3. d := 0.0431 mm.
Operating Data
The maximum weight fraction solids, Ws, is (General Info page 19):
Ws := 10%.
Calculations
The maximum volume fraction solids, Cs, follows from the maximum weight solids fraction Ws and the specific
gravities of the liquid and solid, sgL and sgs:
Ws = 10%, sgL = 1.0, and sgs = 2.3.
Ws
sgs
Cs: =
Ws 100% Ws
+
sgs sgL

Cs = 4.6%. Since 100% = 1, Cs = 0.046.

The Durand factor FL can be read from a chart given the particle size d and the maximum volume fraction solid, Cs
(Perrys page 6-31 Figure 6-33):
For d = 0.043 mm and Cs = 0.05, FL := 0.6.
The densities of the liquid and solid, L and s, follow from specific gravities sgL and sgs, within engineering accuracy:
sgL = 1.0 and sgs = 2.3.

L := sgL 62.45 lb3 ; L = 62.45 lb3 . s := sgs 62.45 lb3 ; s := 143.63 lb3 .
ft ft ft ft
s, the ratio of solid density s to liquid density L, is:

s = 143.63 lb3 . L = 62.45 lb3 .

ft ft
L
s := ; s = 2.3.
S

The minimum transport velocities VM2 as a function of the Durand factor FL, gravitational acceleration g, pipe
diameters, D, and ratio of liquid density to solid density, s (Perrys ):

FL = 0.6. g = 32.174 ft . s = 2.3.

sec 2

1.610 2.0
ft .
For D = 2.067 in, given that 12 in = 1 ft and VM2 := FL [2 g D (s1)]0.5, V M2 = 2.3 sec
3.068 2.8

The minimum slurry velocities V can be calculated given the minimum transport velocities VM2 vs. the pipe diameters
D (Heywood page 28):

1.610 2.5
For D = 2.067 in, V := 125% VM2 ; V = 2.8 ft .
sec
3.068 3.5

Results
Minimum slurry velocities V vs. pipe diameters D are:
1.610 2.5
For D = 2.067 in, V = 2.8 ft .
sec
3.068 3.5

CEP November 2001 www.cepmagazine.org 53

Professional Development
were located and chosen. Avoid describing the details of
the calculation in text form, since the actual formulas will
be displayed later when they are used and will be nearly
self-explanatory, while text descriptions of the formulas
would take extra effort and extra skill to write and would
be less clear and less helpful.
Name, list and enclose references. Identify convenient,
clear references for each formula used and data value en-
tered. Name each reference using a short descriptive name
such as the lead authors name. Give titles and page
ranges. Provide readers copies of references, so that they
can find out things for themselves right away, while they
are most interested.
Use conventional symbols. Match the conventional no-
tation in the area of interest for ready recognition. Use the
same main symbol for all variables of a given type, and use
subscripts to differentiate the family members from one
another. Greek letters and subscripts can be typed directly
into a calculation when calculation software like Mathcad
or CalculationCenter is used.
List complete symbols, including subscripts, and pro-
vide complete descriptions and standard units. Descrip-
tions that include subscripts can eliminate guesswork.
Standard units provide added descriptions of the symbols.
Promote alternative methods. Describe alternative ap-
proaches and possible outcomes. Present the alternatives
as positive possibilities, so they will be considered more
likely and will therefore more effectively counterbalance
the base case that is being presented positively. Consider-
ing alternatives reduces overconfidence. This promotes
progress on problems (12), improves decision-making,
and may improve self-checking by writers and error-
checking by readers.
4. Include text comments and equation-style
comments with the working formulas
Provide comments that supplement formulas but do not
describe them. The working formulas do the actual calcu-
lation. Writers and readers need to be helped to review
the formulas carefully, and need to not be lulled into a
false sense of security by comments that seem to tell a
complete story, and as a result, encourage them to skip
over the equations (13).
Repeat the description of each symbol each time it is
used in a formula. Provide the description and repeat the
symbol, including any subscript.
List a source for each formula. Identify a convenient
source that states the formula clearly. List the sources
short, descriptive name from the reference list, and identify
the page or pages where the formula is defined. Include the
formula number from the source, where helpful.
Repeat the value of each symbol used in standard units
each time it is used. Help people learn the relative magni-
tudes of terms and check the values of input data and inter-
mediate results at every opportunity they have to do so.
54 www.cepmagazine.org November 2001 CEP
Provide conversion factors each time they are used.
Conversion factors often help reassure readers of the rea-
sonableness of calculations and occasionally help writers
find mistakes. When calculation software is used, it takes
little effort to call up predefined conversion factors.
Check function definitions by calculating known values.
Check function definitions for temperature-dependent
properties, for instance, by evaluating the equations at tem-
peratures where the property values are known.
Show a formulas comments together with the formula
on the same page. Add a page break before an assembled
formula block if needed to keep the block together on a sin-
gle page. Self-contained formula definitions and evaluations
that can be seen together at a glance are easier to review.
5. Provide assumptions, inputs and calculations
Note assumptions. Assumptions can include notes on
how the mathematical models that are used oversimplify
the behavior that they describe. They can also include
notes on how the experimental approach underlying a
method differs from the particulars of the process that is
being analyzed. The assumptions that can be the most diffi-
cult to recognize are the underlying beliefs shared by pre-
vious workers, the writer, and the readers when they all are
from the same era and have similar backgrounds. Explain-
ing assumptions early, especially assumptions about factors
that cannot be changed by the writer or the readers, pro-
duces more realistic assessments about the reliability of re-
sults. Reducing overconfidence improves checking, which
improves accuracy.
Enter any assumed data values. Assumptions can also in-
clude reasonable guesses of data values that are not known
for certain. Provide an equation block for each assumed data
value, as shown in the sample calculation. Repeat the de-
scription and the symbol, including any subscripts. Display
the value in standard units for reasonability checking.
Enter the hardware data. Provide an equation block for
each hardware data value. Repeat the description and the
symbol, including any subscripts. Repeat the sources
name from the references and note the applicable page or
pages. Enter the data in the dimensional units that were
used in the source. Provide any conversion factors used, in
units that are as familiar as possible. Display the data in
standard units for reasonability checking.
Enter the property data. Provide an equation block for
each property data value. Repeat the description and the
symbol including any subscripts, the source of the data,
the data in the units used in the source, any conversion
factors, and the data in standard units. If a property is a
function of variables such as temperature, pressure or
composition, enter the property as a function that can be
evaluated later based on the values of the variables at that
point in the calculation.
Enter the operating data. Provide an equation block for
each operating data value. Provide the description and the
symbol including any subscripts, the source of the data, the
data in the units used in the source, any conversion factors,
and the data in standard units.
Enter the calculation formulas. Provide a formula
block, like that in Figure 1, for each calculation formula.
Provide text descriptions of the dependent variables and
the independent variables, and provide a reference source
for the formula. Then provide the values of the indepen-
dent variables in standard units, any conversion factors, the
formula, and the results.
6. Provide summary information
Repeat key assumptions. An assumption may be crucial,
and well worth highlighting again by including it in the
summary information at the end of a calculation.
Summarize the key input parameter values. Summariz-
ing key input parameters near the end of calculations high-
lights them for the writer as well as for the reader. Also,
sometimes it is convenient to set up a file containing a sin-
gle case and then change input parameters and save sepa-
rate files for new cases. In such situations, it is critical to
Literature Cited
1. Miller, G. A., The Magical Number Seven, Plus or Minus Two:
Some Limits on our Capacity for Processing Information, The Psy-
chological Review, 63 (2), pp. 8197 (1956).
2. Anthony, J., Chloroform Plan, available via http://www.cep-
magazine.org (2001).
3. Phillips, J. E., and J. D. Decicco, Choose the Right Mathematical
Software, Chem. Eng. Prog., 95 (7), pp. 69-74 (July 1999).
4. Sandler, S. I., Spreadsheets for Thermodynamics Instruction: An-
other Point of View, Chem. Eng. Edu., 31 (1), pp. 18-20 (Winter
1997).
5. Lira, Carl T., Advanced Spreadsheet Features for Chemical Engi-
neering Calculations, submitted to Chem. Eng. Edu.,
http://www.egr.msu.edu/~lira/spreadsheets.pdf (2000).
6. Chi, M. T. H., et al., Expertise in Problem Solving, in Sternberg,
R. J., Advances in the Psychology of Human Intelligence, Vol. 1,
Lawrence Erlbaum Associates, Publishers, Hillsdale, NJ, pp. 7-75;
see pp. 18, 19, 35, and 71 (1982).
7. Tufte, E. R., The Visual Display of Quantitative Information,
Graphics Press, Cheshire, CT, p. 96 (1983).
8. Cook, C. K., Line by Line: How to Improve Your Own Writing,
Houghton Mifflin, Boston (1985).
9. Mayer, R. E., Models for Understanding, Review of Educational
Research, 59 (1), pp. 43-64 (1989).
10. Larkin, J. H., and H. A. Simon, Why a Diagram is (Sometimes) Worth
Ten Thousand Words, Cognitive Science, 11 (1), pp. 65-99 (1987).
11. Larkin, J. H., Processing Information for Effective Problem Solv-
ing, Engineering Education, 70 (3), pp. 285-288 (December 1979).
12. Platt, J. R., Strong Inference, Science, 146 (3642), pp. 347-353
(1964).
13. Kernighan, D. W., and P. J. Plauger, The Elements of Program-
ming Style, 2nd ed., McGraw-Hill, New York, pp. 141-152 (1978).
14. Allwood, C. M., Error Detection Processes in Statistical Problem Solv-
ing, Cognitive Science, 8 (4), pp. 413-437; see pp. 419 and 431 (1984).
point out the values of the changed parameters to distin-
guish the cases from one another.
Summarize the results. Conclude by returning to the big
picture and recalling key intermediate results and final results
for the benefit of casual readers and careful readers alike.
7. Get calculations checked
Seek checking, whether by experts or by interested col-
leagues. Unless people get very detailed feedback on
their performance, they tend to be overconfident in their
own abilities. They do not perform nearly enough self-
checks on material they believe is correct (14). As a re-
sult, errors of omission are almost never identified and
corrected by the person who made them. With checking, a
fresh viewpoint enters the situation, and errors of omis-
sion can be corrected.
Calculations will get easier
The calculation approach shown here easily scales up to
handle tougher problems. An example of a more difficult
calculation is available at www.cepmagazine.org (2).
This approach produces accurate results, is easy to read,
and is easy to reuse. It is particularly helpful when experi-
mental data on a process are unavailable, data cannot be
obtained cheaply and quickly, and readily available calcu-
lation methods do not cover the process in question.
This list of uses barely hints at the broader roles that
could quickly develop for approaches like this. Affordable
calculation software already provides the capability to
embed subprograms and the capability to define graphical
symbols that have smart interconnections. Soon, such soft-
ware could provide the capability to embed subprograms in
smart symbols. Libraries of thermodynamic property cal-
culation routines and unit operations could emerge easily
from environments of friendly competition and sharing, in
academic settings and in industry. It could ultimately be
possible to simply connect components from reliable
sources and produce accurate and reliable process simula-
tions and other calculations.
Even wider impacts are imaginable. Calculation ap-
proaches developed for process applications could easily
be adapted to other uses in science and in education.
Much can get easier when collaboration is improved by
style in calculations. CEP
JAMES ANTHONY is a process engineer with Lockwood Greene, St. Louis,
MO (Phone: (314) 919-3208; Fax: (314) 919-3201; E-mail:
janthony@lg.com). He has process design experience with chemical,
pharmaceutical, and beverage applications, which have included the
manufacture of iodine products, abrasives, inorganic salts, alkyds,
polyesters, polyurethanes, synthetic pharmaceuticals, soy sauce, and
tea. He also has aerospace design experience developing jet engine air
inlets, piston-propeller systems, sensors, adhesive-bonded structures
and molded plastic parts. He has a BS in chemical engineering from the
Univ. of Missouri Rolla and an MS in mechanical engineering from
Washington Univ. He is a registered professional engineer.
CEP November 2001 www.cepmagazine.org 55
 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 1 of 37
Chloroform Effluent Plan Prep, Check, Appr: J Anthony, _________, _________

page

Objective 1
Approach 1
References 2
Symbols 3
Assumptions 6

Conversions and Constants 7

Hardware Data 8
Property Data 8
Operating Data 13

Steam Flows 14
Interfacial Areas 19
Mass Transfer Coefficients 27
Stripping and Dilution 29

Key Parameters Summary 34

Results Summary 35

Objective

Model the lime press effluent chloroform concentration after raffinate stripping, reslurrying using
stripper effluent, and reslurrying using four chloroform-free streams.

S team

FO FO Lim e P ress S olids

R affinate 1. S trip Liquor

2. Lim e Liquor
3. W ater
4. W ater
5. W ater

1st S tage 2nd S tage

Approach

Calculate restriction orifice flows using Benedict's general equation as suggested on Perry's page
10-16. Calculate sparger mass transfer per Perry's page 5-69, using bubble diameters calculated as
referenced on Perry's page 14-71 and interfacial areas calculated as referenced on Treybal page 144.
Calculate dilution using available data.

Chloroform Plan.mcd NOT CHECKED

 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 2 of 37

References

Akita Akita, K., and F. Yoshida, "Gas Holdup and Volumetric Mass Transfer Coefficient
in Bubble Columns", Industrial and Engineering Chemistry Process Design and
Development, 12(1), pp. 76-80, 1973 (enclosed)

Baseline Anthony, J., "Confidential Client Lime Press Chloroform Effluent Baseline", [
Chloroform Baseline].mcd, Lockwood Greene, St. Louis, MO, 2000 (enclosed)

Benedict Benedict, R. P., "Loss Coefficients for Fluid Meters", Journal of Fluids
Engineering, 99(1), pp. 245-248, 1977 (enclosed)

Calderbank Calderbank, P. H., and M. B. Moo-Young, "The Continuous Phase Heat and
Mass-Transfer Properties of Dispersions", Chemical Engineering Science, 16, pp.
39-54, 1961 (enclosed);
Calderbank, P. H., in Uhl, V. and J. Grey, Editors, "Mixing", Volume 2, Chapter 6,
Academic Press, New York, 1967 (source of small bubble-size mass transfer
correlation listed in Perry's page 5-69, per Perry's page 5-8 reference 109, Kirwan
1987) (not enclosed; not available at Washington University until 9/18 or later)

Cussler Cussler, E. L., "Diffusion, Mass Transfer in Fluid Systems", page 251, Cambridge
University Press, 1984 (enclosed)

DIPPR Daubert, T. E., R. P. Danner, H. M. Sibul, and C. C. Stebbins, "Physical and

Thermodynamic Properties of Pure Chemicals: Data Compilation", chloroform's
fixed properties, vapor pressure, and surface tension; water's fixed properties,
vapor pressure, ideal gas heat capacity, second virial coefficient, vapor viscosity,
and surface tension, Taylor & Francis, Bristol, PA, extant 1994 (enclosed)

Geankoplis Geankoplis, C. J., "Transport Processes and Unit Operations", 3rd Ed., pp.
450-453, PTR Prentice Hall, Englewood Cliffs, NJ, 1993 (enclosed)

Godbole Godbole, S. P., and Y. T. Shah, "Design and Operation of Bubble Column
Reactors", in Cheremisinoff, N. P., "Encyclopedia of Fluid Mechanics" Vol. 3, pp.
1216-1239, Gulf Publishing, Houston, TX, 1986 (enclosed)

Grace Grace, H. P., and C. E. Lapple, "Discharge Coefficients of Small-Diameter Orifices

and Flow Nozzles", Transactions of the ASME, 73, pp. 639-647, 1951 (enclosed)

JH Anthony, J., Notes from phone call, 6/22/00 (enclosed)

Hwang Hwang, Y.-L., J. D. Olson, and G. E. Keller II, "Steam Stripping for Removal of
Organic Pollutants from Water. 2. Vapor-Liquid Equilibrium Data", Industrial and
Engineering Chemistry Research, 31, pp. 1759-1768, 1992 (enclosed)

Kumar Kumar, A., T. E. Degaleesan, G. S. Laddha, and H. E. Hoelscher, "Bubble Swarm

Characteristics in Bubble Columns", The Canadian Journal of Chemical
Engineering, 54, pp. 503-508, December 1976 (enclosed)

Manual SS, Confidential Company, "Confidential Client Raffinate Stripping System

Project A-7819 Operating Manual", Sparging Hole Requirements, Confidential
Client, 11/11/99 (enclosed)

Mathcad Help Mathsoft, Mathcad 2000 Solve Block help, Mathsoft, Cambridge, MA, 2000;
Mathsoft, Resource Center: Polynomial Regression, Mathsoft, Cambridge, MA,
2000 (enclosed)

P&ID SS, Confidential Company, "Raffinate Stripper P&ID", Dwg. 0000-102-001, Rev. 8,

Chloroform Plan.mcd NOT CHECKED

 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 3 of 37
y g
Confidential Client, 11-8-99 (enclosed)

Perry's Green, Don W., editor, "Perry's Chemical Engineers' Handbook", 7th Ed., pages
1-18, 1-19, 2-355, 4-7, 5-7, 5-8, 5-56, 5-69, 6-49, 6-50, 10-4, 10-14, 10-16, 10-72,
10-140, 14-70, 14-71, and 14-74, McGraw-Hill, New York, 1997 (enclosed)

Pfaudler Pfaudler, "30 Gal. (20 I.D. x 24 3/4 Dp.) POWCT VR-30 Gl. Stl. "P" Tank", Dwg.
CE279-0863-65, Pfaudler, Rochester, NY, 11/27/79;
Pfaudler, "50 Gal. (24" I.D. x 28 3/4" Dp.) JOWCT Glasteel Vacuum Receiver",
Dwg. CE279-0860, Pfaudler, Rochester, NY, 12/3/79;
Pfaudler, "Chemstor/Storage Tank", Pfaudler, Rochester, NY, 4/97 (enclosed)

Pipe Spec SS, Confidential Company, "Raffinate Stripper Piping Material Specifications",
Dwg. 0007-702-004, Rev. 0, Confidential Client, 5/28/99 (enclosed)

PQ Data SS, Confidential Company, "Chloroform Concentration in Raffinate Stripper",

Confidential Client, 11/01/00 (enclosed)

PQ Report Keeler, R., "Amendment to Process Qualification Protocol of the Raffinate

Stripper", Confidential Client, 1/5/00 (enclosed)

SS Anthony, J., Notes from meeting, 7/26/00 (enclosed)

Treybal Treybal, R. E., "Mass-Transfer Operations", 3rd Ed., pp. 143-144 and 211-217,
McGraw-Hill, New York, 1980 (enclosed)

Wilkinson Wilkinson, P. M., and L. L. van Dierendonck, "A Theoretical Model for the
Influence of Gas Properties and Pressure on Single-Bubble Formation at an
Orifice", Chemical Engineering Science, 49(9), pp. 1429-1438, 1994 (enclosed)

Wright Wright, D. A., S. I. Sandler, and D. DeVoll, "Infinite Dilution Activity Coefficients
and Solubilities of Halogenated Hydrocarbons in Water at Ambient
Temperatures", Environmental Science and Technology, 26(9), pp. 1828-1831,
1992 (enclosed)

Yaws Yaws, C. L., "Handbook of Transport Property Data", pp. 141-145, Gulf Publishing,
Houston, TX, 1995 (enclosed)
Symbols

2
A1 and A2 cross-sectional areas of first and second stage vessels ft
2
ft
a1 and a2 effective interfacial area per unit volume of vessels
3
ft
2
aT1 and aT2 total hole areas of first and second stage spargers ft
3
ft
Bw second virial coefficient of water vapor
lbmole
joule
CPgw ideal gas heat capacity of water vapor
kgmole K
D1 and D2 diameters of first and second stage restriction orifices in
2
ft
Dc0w diffusivity of chloroform in infinite dilution in water
sec
Dv1 and Dv2 diameters of stripper first and second stage vessels in
dN1 and dN2 hole diameters of first and second stage spargers in

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inertial_force
Fr1 and Fr2 Froude numbers, , of first and second stage vessels -
gravity_force
Frgc1 and Frgc2 Froude numbers for transition to foaming flow -
lbmole
GM1 and GM2 gas-phase molar fluxes based on vessel cross-sectional areas
2
hr ft
Gr1 and Gr2 Grashof numbers of first and second stage vessels -
ID1 and ID2 piping inside diameters of restriction orifices in
K1 and K2 loss coefficients of first and second stage restriction orifices -
Kc1 and Kc2 vapor-liquid equilibrium ratios of chloroform at infinite dilution -
in water in the first and second stage vessels
ft
KL1 and KL2 overall liquid-phase mass-transfer coefficients in vessels
hr
ft
kL1 and kL2 individual liquid-phase mass-transfer coefficients in vessels
hr
kw heat capacity ratio of water vapor -
lbmole
LM1 and LM2 liquid-phase molar fluxes based on vessel cross-sectional areas
2
hr ft
Lover1 and Lover2
level of clear liquid at overflow of first and second stage vessels %
lb
Mw and Mc molecular weight of water and of chloroform
lbmole
lbmole
NA1 and NA2 molar fluxes based on interfacial areas in vessels
2
hr ft
n1 and n2 hole counts of first and second stage spargers -
P0 absolute pressure upstream of the restriction orifices psi
Pv absolute pressure in first and second stage vessels psi
Pvc vapor pressure of chloroform psi
Pvw vapor pressure of water psi
gal
qr volumetric flow of raffinate
min
joule
Rg universal gas constant
mole K
r pressure ratios of the orifices -
rc1 and rc2 critical pressure ratios of restriction orifices -
inertial_force
ReN1 and ReN2 Reynolds numbers, , of spargers -
viscous_force
Sc1 and Sc2 Schmidt numbers of first and second stage vessels -
Sh1 and Sh2 Sherwood numbers of first and second stage vessels -
T absolute temperature K
T0 absolute temperature upstream of the restriction orifices K
TF magnitude of the temperature in degrees F -
Tref absolute temperature reference value K

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Tv1 and Tv2 absolute temperatures in first and second stage vessels K
ft
uN1 and uN2 superficial velocities based on hole areas of spargers
sec
ft
V1 and V2 velocities in first and second stage restriction orifices
sec
Vcap1 and Vcap2
rated capacities of first and second stage vessels gal
Voper1 and Voper2
operating volumes of first and second stage vessels gal
lb
W1 and W2 mass flows in first and second stage restriction orifices
hr
lb
WT total mass flow of steam
hr
wcr weight fraction chloroform in raffinate -
wcs weight fraction chloroform in stripped liquid -
wcs_adj weight fraction chloroform in stripped liquid, adjusted -
inertial_force
Weg1 and Weg2 Weber numbers, , of spargers -
surface_tension_force
x1v1 and y1v1 liquid and vapor mole fractions chloroform -
at bottom - position 1 - of first stage vessel
x2v1 and y2v1 liquid and vapor mole fractions chloroform -
at top - position 2 - of first stage vessel
x1v2 and y1v2 liquid and vapor mole fractions chloroform -
at bottom - position 1 - of second stage vessel
x2v2 and y2v2 liquid and vapor mole fractions chloroform -
at top - position 2 - of second stage vessel
1 and 2 diameter ratios of first and second stage restriction orifices -
G1 and G2 gas holdups in first and second stage vessels -
c activity coefficient of chloroform at infinite dilution in water -
lw liquid viscosity of water cP
lb
vw vapor viscosity of water
ft sec
lb
0 vapor density upstream of the restriction orifices
3
ft
lb
lw liquid density of water
3
ft
lb
v vapor density in first and second stage vessels
3
ft
newton
w surface tension of water
m

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Assumptions

The levels of clear liquid at overflow of the first and second stage vessels, Lover1 and Lover2 , are
taken to be (initial design, 100% : SS):

Lover1 := 60% and Lover2 := 60% .

Vessel appurtenances - sparger pipes, level elements, etc. - are neglected in calculating vessel
cross-sectional areas.

The flows upstream of the restriction orifices are taken to be saturated vapor.

The absolute pressures downstream of the restriction orifices are taken to equal those of the first
and second stage vessels. For critical flow through thick-plate orifices, the flow increases only about 2% as
the pressure ratio is decreased to well below the critical pressure ratio (Grace pages 645 and 640).

The weight fraction chloroform in the raffinate, wcr , is taken to be (PQ Data from 7/7/99):

3926 3581 3760

+ +
6 6 6
10 10 10 1
wcr := : wcr = 3756 .
3 6
10

The absolute pressures and temperatures in the first and second stage spargers are taken to be
those of the vessels, not those of the restriction orifices. Bubbles reach pressure equilibrium with the vessel
before they disengage from the sparger, which is reasonable since the flow through the sparger orifices is
subsonic. Bubbles reach thermal equilibrium with the vessel before they disengage from the sparger, which
is reasonable given the experimental observation that the gas-phase mass transfer resistance is negligible
(Perry's page 5-69 Table 5-25 Condition Z).

The absolute pressures and temperatures in the first and second stage vessels, Pv , Tv1 , and Tv2 ,
are taken to be the following values at all points in the vessels, neglecting the small liquid heads at the
sparger holes and the small pressure drops in the vapor discharge piping and condenser (PQ Data from
10/5/99):

Pv := 14.696psi .
91 + 92 + 91 + 91 + 94
Tv1 := + 273.15 K and Tv2 := ( 100 + 273.15)K :
5
Tv1 = 364.95 K and Tv2 = 373.15 K .

The vapor densities and vapor viscosities in the first and second stage vessels are taken to be
those of water at the conditions in the second stage vessel. The liquid densities and surface tensions in the
first and second stage vessels are taken to be those of water at the conditions in the vessels. Changes in
properties due to chloroform and tar present are neglected.

The volumetric flow of raffinate, qr , is taken to be (PQ Data from 9/17/99):

gal gal
4.7 + 3.67
min min gal
qr := ; qr = 4.185 .
2 min

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The bubble diameter correlation (Kumar) is for spargers mounted horizontally, while the spargers
are mounted vertically, which may increase bubble coalescence, reducing interfacial area and mass
transfer.
The gas holdup correlation (Akita) and mass transfer correlation (Perry's page 5-69, Calderbank) is
for bubbles uniformly distributed throughout the cross-section of the vessel. The spargers, on the other
hand, are vertical pipes with holes every 90 degrees around (Manual), and the spargers are mounted on
off-center nozzles. The nonuniform bubble distributions may reduce mass transfer.

Conversions and Constants

The centipoise cP is defined as follows:

2
cP := 10 poise .

The millinewton mN is defined as follows:

3
mN := 10 newton .

The amount of substance kgmole is defined as follows:

kg = 1000 gm , so kgmole := 1000mole .

The amount of substance lbmole is defined as follows:

lb = 453.592370 gm , so lbmole := 453.592370mole .

The reference temperature, Tref , where the temperature-dependent property values listed in the
DIPPR fixed properties list are calculated, is:

Tref := 298.15K .

The magnitude of the temperature in degrees F, TF , as a function of the absolute temperature T is

(Perry's page 1-19):

T
TF ( T) := 1.8 459.69 .
K
Tref = 298.15 K : TF ( Tref ) = 76.980 .

The universal gas constant Rg is (Perry's page 1-19):

3
joule psi ft
Rg := 8.3144 . Alternatively, Rg = 10.73 .
mole K lbmole R

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Hardware Data

The restriction orifice diameters of the first and second stages, D1 and D2 , are (Baseline: JH):

16 19
D1 := in and D2 := in :
64 64
D1 = 0.250 in and D2 = 0.297 in .

The pipe inside diameters of the first and second stage restriction orifices, ID1 and ID2 , are (P&ID,
Pipe Spec, Perry's page 10-72):

ID1 := 1.049in and ID2 := ID1 .

The sparger hole diameters of the first and second stages, dN1 and dN2 , and hole counts n1 and
n2 are (Baseline: Manual Sparging Hole Requirements):

11 13
dN1 := in and dN2 := in . 12in = 1 ft .
64 64
n1 := 16 + 4 + 2 and n2 := n1 .

The vessel diameters of the first and second stages, Dv1 and Dv2 , are (Pfaudler):

Dv1 := 20in and Dv2 := 24in .

The rated capacities of the first and second stage vessels, Vcap1 and Vcap2 , are (Pfaudler
Chemstor/Storage Tank):

Vcap1 := 32gal and Vcap2 := 52gal .

These equal the straight side capacity plus the bottom head capacity, based on a check using the standard
formula for the capacity of an ellipsoidal head with a given height, using data for a Pfaudler VR-50 (Perry's
page 10-140 and Pfaudler).

Property Data

The molecular weight of water, Mw , is (DIPPR):

kg gm lb
Mw := 18.015 ; Mw = 18.015 ; Mw = 18.015 .
kgmole mole lbmole

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The liquid density of water, lw , as a function of the absolute temperature T is defined by the liquid
molar density as a function of the absolute temperature and the molecular weight of water Mw (DIPPR):

lw ( T) := ( 273.16 K T) ( T 333.15 K) kgmole M ; M = 18.015 kg .

5.4590
... w w
0.0810 3 kgmole
T
m
K
1 + 1

0.3054 647.13

+ ( 333.15 K < T) ( T 403.15 K) 4.9669
...
T
0.18740

1 + 1
K

647.13
0.27788
4.3910
+ ( 403.15 K < T) ( T 647.13 K) 0.25340
T
K
1 + 1
647.13
0.24870

Tref = 298.15 K :
lw ( Tref ) kgmole
= 55.239 .
Mw 3
m
kg
lw ( Tref ) = 995.122 . 1kg = 2.204623 lb . 1ft = 0.304800 m .
3
m
lb
lw ( Tref ) = 62.123 .
3
ft

The vapor pressure of water, Pvw , as a function of the absolute temperature T is (DIPPR):

7258.2
+ 7.3037 ln ... Pa .
T
Pvw ( T) := ( 273.16 K T) ( T 647.13 K) exp 73.649 +
T
K
K
2.0000
+ 4.1653 10 6
T

K

Tref = 298.15 K :
Pvw ( Tref ) = 3170 Pa . 1Pa = 0.000145038 psi .
Pvw ( Tref ) = 0.4598 psi .

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The ideal gas heat capacity of water, CPgw , as a function of the absolute temperature T is (DIPPR):

CPgw ( T) := ( 100.00K T) ( T 2273.1K) 3.3363 10 ...

4
joule .
2 kgmole K
2610.5

T
K
+ 2.6790 10
4
2610.5 ...
sinh T

K
2
1169.0

T
K
+ 8896.0
1169.0
cosh
T

K

Tref = 298.15 K :
joule joule BTU
CPgw ( Tref ) = 33578 . 1 = 0.000238851 .
kgmole K kgmole K lbmole R
BTU
CPgw ( Tref ) = 8.020 .
lbmole R
lb
Mw = 18.015 .
lbmole
CPgw ( Tref ) BTU
= 0.445193 .
Mw lb R

The heat capacity ratio of water vapor, kw , as a function of the ideal gas heat capacity of water
vapor Cpw ( T) and the universal gas constant Rg is (Perry's page 4-7):

CPgw ( T)
kw ( T) := .
CPgw ( T) Rg

Tref = 298.15 K :
joule joule
CPgw ( Tref ) = 33578 . Rg = 8314 .
kgmole K kgmole K
kw ( Tref ) = 1.329106 .

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The second virial coefficient of water vapor, Bw , as a function of the absolute temperature T is
(DIPPR):

26.38 1.675 10
7
m
3
Bw ( T) := ( 273.15 K T) ( T 2273.1 K) 0.0222 + + ... .
T
T
3
kgmole
K
K
19 21
+ 3.894 10 + 3.133 10
T
8
T
9

K K

Tref = 298.15 K :
3
m
Bw ( Tref ) = 1.1536 . 1m = 3.280840 ft . 1lbmole = 0.453592 kgmole .
kgmole
3
ft
Bw ( Tref ) = 18.479 .
lbmole

The liquid viscosity of water, lw , as a function of the absolute temperature T is (DIPPR):

lw ( T) := ( 273.16 K T) ( T 646.15 K) exp 52.843 + + 5.8660 ln ... Pa sec .

3703.6 T
T
K
K
10.000
+ 5.8790 10 29
T

K

Tref = 298.15 K :
lw ( Tref ) = 0.0009 Pa sec . 1Pa sec = 999.978174 cP .
lw ( Tref ) = 0.912511 cP .

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The vapor viscosity of water, vw , as a function of the absolute temperature T is (DIPPR):

0.6778

7 T
6.1839 10
vw ( T) := ( 273.16K T) ( T 1073.2K) K Pa sec .
4
847.23 7.3930 10
1+ +
T 2
T
K
K

Tref = 298.15 K :
lb
vw ( Tref ) = 9.7696 10
6
Pa sec . 1Pa sec = 0.671969 .
ft sec
lb
vw ( Tref ) = 6.564835 10
6
.
ft sec

The surface tension of water, w , as a function of the absolute temperature T is (DIPPR):

2
T T
K K
2.7170+ 3.5540 + 2.0470
647.13 647.13
T

K newton
w ( T) := ( 273.16 K T) ( T 647.13 K) 0.1855 1 .
647.13 m

Tref = 298.15 K :
newton
w ( Tref ) = 0.072825 . 1newton = 1000 mN .
m
mN
w ( Tref ) = 72.825 .
m
newton
w ( Tref ) = 0.072825 . 1newton = 0.224814 lbf . 1ft = 0.304800 m .
m
lbf
w ( Tref ) = 0.004990185 .
ft

The molecular weight of chloroform, Mc , is (DIPPR):

kg gm lb
Mc := 119.38 ; Mc = 119.38 ; Mc = 119.38 .
kgmole mole lbmole

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The vapor pressure of chloroform, Pvc , as a function of the absolute temperature T is (DIPPR):

7792.3
Pvc ( T) := ( 207.15 K T) ( T 536.40 K) exp 146.43 + + 20.614 ln ... Pa .
T

T K

K

T
1.0000

+ 0.0246
K

Tref = 298.15 K :
Pvc ( Tref ) = 26337 Pa . 1Pa = 0.000145038 psi .
Pvc ( Tref ) = 3.8199 psi .

The diffusivity of chloroform in infinite dilution in water, Dc0w , as a function of the absolute
temperature T is (Yaws):

1051.706
1.4389+
T
K 2
Dc0w ( T) := ( 274 K T) ( T 394 K) 10
cm
. 2.54cm = 1 in .
sec
2
5 cm
Dc0w [ ( 25 + 273.15)K] = 1.08 10 .
sec
2
5 cm
Dc0w [ ( 100 + 273.15)K] = 5.53 10 .
sec

The activity coefficient of chloroform at infinite dilution in water, c , as a function of the absolute
temperature T is (Wright, Mathcad Polynomial Regression):

20.0 + 273.15 818 20.0 + 273.15 818

c ( T) := interp regress 35.0 + 273.15 , 847 , 2 , 35.0 + 273.15 K , 847 , T ;
50.0 + 273.15 862 50.0 + 273.15 862

c [ ( 20.0 + 273.15)K] = 818 .

c [ ( 35.0 + 273.15)K] = 847 .
c [ ( 50.0 + 273.15)K] = 862 .
c [ ( 100.0 + 273.15)K] = 811 .

Operating Data

The absolute pressure upstream of the orifices, P0 , is (P&ID):

P0 := 30psi + 14.7psi : P0 = 44.7 psi .

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Steam Flows

The pressure ratio of the restriction orifices, r , depends on the absolute pressure upstream P0 and
the absolute pressure downstream Pv :
P0 = 44.7 psi . Pv = 14.7 psi .
Pv
r := : r = 0.328770 .
P0

The diameter ratios of the first and second stage restriction orifices, 1 and 2 , are calculated from
the orifice diameters D1 and D2 and the orifice pipe inside diameters ID1 and ID2 (Perry's page 10-4):

D1 D2
1 := and 2 := :
ID1 ID2

1 = 0.238322 and 2 = 0.283008 .

The absolute temperature upstream of the restriction orifices, T0 , is calculated iteratively from the
absolute pressure upstream P0 using the water vapor pressure as a function of the absolute temperature,
Pvw ( T) (Mathcad Help for Solve Block):

Start with T0 := Tref . Tref = 298.15 K , so T0 = 298.15 K .

Given P0 = Pvw ( T0 ) , calculate T0 := Find ( T0 ) :
T0 = 407.67 K . [ TF ( T0 ) = 274.11 .]

The critical pressure ratios of the first and second stage restriction orifices, rc1 and rc2 , are
calculated iteratively from the heat capacity ratio of the water vapor at the upstream absolute temperature,
kw ( T0 ) , and the diameter ratios of the orifices 1 and 2 (Perry's page 10-14):

T0 = 407.67 K . [ TF ( T0 ) = 274.11 .] kw ( T0 ) = 1.319786 .

1 = 0.238322 and 2 = 0.283008 .
Start with rc1 := 1 and rc2 := 1 .
1 kw( T0) 2
kw( T0) kw ( T0) 1 kw( T0) kw ( T 0 ) + 1
Given ( rc1) ( 1) ( rc1)
4
+ = and
2 2
1 kw( T0) 2
kw( T0) kw ( T0) 1 kw( T0) kw ( T0 ) + 1
(rc2) ( 2) ( rc2)
4
+ = ,
2 2
rc1
calculate := Find ( rc1 , rc2) :
rc2
rc1 = 0.542571 and rc2 = 0.542962 .

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The restriction orifices are in critical flow if their pressure ratios r are smaller than their critical
pressure ratios rc1 and rc2 (Perry's page 10-14):

r = 0.329 . rc1 = 0.543 and rc2 = 0.543 .

flow1 := if ( r rc1 , "critical" , "not critical" ) and flow2 := if ( r rc2 , "critical" , "not critical" ) :
flow1 = "critical" and flow2 = "critical" .

The loss coefficients of the first and second stage restriction orifices, K1 and K2 , can be estimated
from the orifice diameter ratios 1 and 2 alone (Benedict page 247 equation 22):

3 3

(
K1 := 1 1 )
2 2
+
1
2
( )
2
(
1 1 + 1.41 1 1 )
2 2
and K2 := 1 2( )
2 2
+
1
2
( )
2
(
1 2 + 1.41 1 2
2 2
: )
K1 = 2.653 and K2 = 2.550 .

The vapor density upstream of the restriction orifices, 0 , is calculated iteratively from the absolute
pressure upstream P0 , universal gas constant Rg , molecular weight of water vapor Mw , absolute
temperature upstream T0 , and second virial coefficient of water upstream Bw ( T0 ) (Perry's page 2-355):

lb
P0 = 44.7 psi . Mw = 18.015 .
lbmole
3 3
psi ft ft
Rg = 10.73 . K = 1.8 R . T0 = 407.67 K . [ TF ( T0 ) = 274.11 .] Bw ( T0 ) = 5.297421 .
lbmole R lbmole
lb
Start with 0 := 0.1 .
3
ft
P0 0
Given that
0
= 1 + B w ( T0 )
Mw
, calculate 0 := Find 0 : ( )
Rg T0
Mw
lb
0 = 0.105532 .
3
ft

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The velocities in the first and second stage restriction orifices, V1 and V2 , are calculated from the
absolute pressure upstream P0 , the critical pressure ratios of the orifices rc1 and rc2 , the loss coefficients
of the orifices K1 and K2 , and the vapor density upstream 0 (Benedict page 245 equation 1):

lbf ft 2 2
P0 = 44.7 . rc1 = 0.542571 and rc2 = 0.542962 . 1 lbf = 32.174 lb . 144in = 1 ft .
2 2
in sec
lb
K1 = 2.652828 and K2 = 2.550223 . 0 = 0.105532 .
3
ft
2 2
V1 := (P0 rc1 P0) K and V2 := (P0 rc2 P0) K :
1 0 2 0
ft ft
V1 = 822.655 and V2 = 838.683 .
sec sec

The mass flows in the first and second stage restriction orifices, W1 and W2 , and the total mass
flow of steam WT are calculated from the vapor density upstream 0 , the pipe diameters D1 and D2 , and
the velocities in the orifices V1 and V2 (Benedict page 245 equation 3):

lb ft 2 2
0 = 0.105532 . = 3.141593 . D1 = 0.25 in . V1 = 822.655 . 144in = 1 ft .
3 sec
ft
ft
D2 = 0.296875 in . V2 = 838.683 .
sec
2 2
D1 D2
W1 := 0 V1 and W2 := 0 V2 :
2 2
lb lb
W1 = 106.540 and W2 = 153.165 .
hr hr
lb
WT := W1 + W2 : WT = 260 .
hr

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The vapor density at the vessels, v , is calculated iteratively from the absolute pressure at the
spargers Pv , the universal gas constant Rg , the molecular weight of water vapor Mw , the absolute
temperature of the second stage vessel Tv2 (as noted in the assumptions), and the second virial coefficient
of water Bw ( Tv2) (Perry's page 2-355):

lb
Pv = 14.696 psi . Mw = 18.015 .
lbmole
3 3
psi ft ft
Rg = 10.73 . K = 1.8 R . Tv1 = 364.95 K . [ TF ( Tv2) = 211.98 .] Bw ( Tv2) = 7.242413 .
lbmole R lbmole
lb
Start with v := 0.1 .
3
ft
Pv v
Given that
v
= 1 + Bw ( Tv2)
Mw
, calculate v := Find v : ( )
Rg Tv2
Mw
lb
v = 0.037288 .
3
ft

The cross-sectional areas of the first and second stage vessels, A1 and A2 are calculated from the
vessel diameters Dv1 and Dv2 (neglecting vessel appurtenances as noted in the assumptions):

= 3.141593 . Dv1 = 20 in and Dv2 = 24 in . 12in = 1 ft .

2 2
Dv1 Dv2
A1 := and A2 := :
2 2
2 2
A1 = 2.182 ft and A2 = 3.142 ft .

The superficial velocities in the first and second stage vessels, UG1 and UG2 , are calculated from
the mass flows W1 and W2 , vapor density v , and vessel cross-sectional areas A1 and A2 :

lb lb
W1 = 106.540 and W2 = 153.165 . 3600sec = 1 hr .
hr hr
lb 2 2
v = 0.037288 . A1 = 2.182 ft and A2 = 3.142 ft .
3
ft
W1 W2
UG1 := and UG2 := :
v A1 v A2
ft ft
UG1 = 0.363794 and UG2 = 0.363195 . 1ft = 0.304800 m .
sec sec
m m
UG1 = 0.110884 and UG2 = 0.110702 .
sec sec

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The vessel velocity regimes indicated by the vessel superficial velocities UG1 and UG2 are (Perry's
page 14-74):

ft ft
UG1 = 0.36 and UG2 = 0.36 .
sec sec

Vessel_Gas_Velocity1 := if UG1 0.15 , "Quiescent" , "" and

ft
sec
Vessel_Gas_Velocity2 := if UG2 0.15 , "Quiescent" , "" ;
ft
sec

Vessel_Gas_Velocity1 := if 0.15
ft
< UG1 UG1 < 0.20
ft
, "Quiescent or Turbulent" , Vessel_Gas_Velocity1 a
sec sec
Vessel_Gas_Velocity2 := if 0.15 < UG2 UG2 < 0.20
ft ft
, "Quiescent or Turbulent" , Vessel_Gas_Velocity2
sec sec
Vessel_Gas_Velocity1 := if 0.20 UG1 , "Turbulent" , Vessel_Gas_Velocity1 and
ft
sec
Vessel_Gas_Velocity2 := if 0.20 UG2 , "Turbulent" , Vessel_Gas_Velocity2 :
ft
sec
Vessel_Gas_Velocity1 = "Turbulent" and Vessel_Gas_Velocity2 = "Turbulent" .

UG1
Vessel_Quiescence_vs_Max1 := . 1 = 100 % .
ft
0.15
sec
UG2
Vessel_Quiescence_vs_Max2 := . 1 = 100 % :
ft
0.15
sec
Vessel_Quiescence_vs_Max1 = 243 % and
Vessel_Quiescence_vs_Max2 = 242 % .

UG1
Vessel_Turbulence_vs_Min1 := . 1 = 100 % .
ft
0.20
sec
UG2
Vessel_Turbulence_vs_Min2 := . 1 = 100 % :
ft
0.20
sec
Vessel_Turbulence_vs_Min1 = 182 % and
Vessel_Turbulence_vs_Min2 = 182 % .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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Interfacial Areas

The total hole areas of the first and second stage spargers, aT1 and aT2 , are calculated from the
hole diameters dN1 and dN2 and hole counts n1 and n2 :

dN1 = 0.171875 in and dN2 = 0.203125 in . 12in = 1 ft . n1 = 22 and n2 = 22 .

2 2
dN1 dN2
aT1 := n1 and aT2 := n2 :
2 2
2 2
aT1 = 0.003545 ft and aT2 = 0.004951 ft .

The superficial gas velocities based on total hole area of the first and second stage spargers, uN1
and uN2 , are calculated from the mass flows W1 and W2 , gas density v , and total hole areas aT1 and aT2 :

lb lb
W1 = 106.54 and W2 = 153.165 . 3600sec = 1 hr .
hr hr
lb 2 2
v = 0.037288 . aT1 = 0.003545 ft and aT2 = 0.004951 ft .
3
ft
W1 W2
uN1 := and uN2 := :
v aT1 v aT2
ft ft
uN1 = 223.907 and uN2 = 230.469 .
sec sec

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 20 of 37

The sparger hole superficial velocities uN1 and uN2 (for open-end pipe, perforated plate, or ring- or
cross-style perforated-pipe spargers in quiescent vessels) are considered (Perry's page 14-74):

ft
uN1 = 224 and
sec
ft
uN2 = 230
.
sec
Vessel_Gas_Velocity1 = "Turbulent" and
Vessel_Gas_Velocity2 = "Turbulent" .

Sparger_Velocity1 := if uN1 250 , "Not Excessive" , "" and

ft
sec
Sparger_Velocity2 := if uN2 250 , "Not Excessive" , "" ;
ft
sec
Sparger_Velocity1 := if 250 < uN1 uN1 < 300
ft ft
, "Possibly Excessive" , Sparger_Velocity1 and
sec sec
Sparger_Velocity2 := if 250 < uN2 uN2 < 300
ft ft
, "Possibly Excessive" , Sparger_Velocity2 ;
sec sec
Sparger_Velocity1 := if 300 uN1 , "Excessive" , Sparger_Velocity1 and
ft
sec

Sparger_Velocity2 := if 300
ft
uN2 , "Excessive" , Sparger_Velocity2 :
sec
Sparger_Velocity1 = "Not Excessive" and Sparger_Velocity2 = "Not Excessive" .

uN1
Sparger_Velocity_vs_Max_Okay1 := . 1 = 100 % .
ft
250
sec
uN2
Sparger_Velocity_vs_Max_Okay2 := . 1 = 100 % :
ft
250
sec
Sparger_Velocity_vs_Max_Okay1 = 90 % and
Sparger_Velocity_vs_Max_Okay2 = 92 % .

uN1
Sparger_Velocity_vs_Min_Excessive1 := . 1 = 100 % .
ft
300
sec
uN2
Sparger_Velocity_vs_Min_Excessive2 := . 1 = 100 % :
ft
300
sec
Sparger_Velocity_vs_Min_Excessive1 = 75 % and
Sparger_Velocity_vs_Min_Excessive2 = 77 % .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 21 of 37

inertial_force
The Reynolds numbers, (Perry's page 6-50), for the gas flows at the holes in the first
viscous_force
and second stage spargers, ReN1 and ReN2 , are calculated from the hole diameters dN1 and dN2 , hole
superficial gas velocities uN1 and uN2 , vapor density v , and vapor viscosity of water at the absolute
temperature in the second stage vessel (as noted in the assumptions) vw ( Tv2) (Kumar page 508
Nomenclature section):

ft ft lb
dN1 = 0.171875 in and dN2 = 0.203125 in . uN1 = 223.907 and uN2 = 230.469 . v = 0.037288 .
sec sec 3
ft
12in = 1 ft .
6 lb
Tv2 = 373.15 K . [ TF ( Tv2) = 211.98 .] vw ( Tv2) = 8.397656 10 .
ft sec
dN1 uN1 v dN2 uN2 v
ReN1 := and ReN2 := ;
vw ( Tv2) vw ( Tv2)
ReN1 = 14240 and ReN2 = 17322 .
The sparger flow regimes indicated by the sparger hole Reynolds numbers ReN1 and ReN2 are
(Perry's pages 14-70 and 14-71):

ReN1 = 14240 and

ReN2 = 17322 .
Sparger_Re_Regime1 := if ( ReN1 < 200 , "Single-Bubble" , "" ) and
Sparger_Re_Regime2 := if ( ReN2 < 200 , "Single-Bubble" , "" ) ;
Sparger_Re_Regime1 := if ( 200 ReN1) ( ReN1 2100) , "Intermediate" , Sparger_Re_Regime1 and
Sparger_Re_Regime2 := if ( 200 ReN2) ( ReN2 2100) , "Intermediate" , Sparger_Re_Regime2 ;
Sparger_Re_Regime1 := if ( 2100 < ReN1 , "Possibly Jet" , Sparger_Re_Regime1 ) and
Sparger_Re_Regime2 := if ( 2100 < ReN2 , "Possibly Jet" , Sparger_Re_Regime2 ) :
Sparger_Re_Regime1 = "Possibly Jet" and
Sparger_Re_Regime2 = "Possibly Jet" .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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inertial_force
The Weber numbers, (Perry's page 6-50), for the gas flows at the holes in the
surface_tension_force
first and second stage spargers, Weg1 and Weg2 , are calculated from the vapor density v , the hole
diameters dN1 and dN2 , the hole superficial gas velocities uN1 and uN2 , and the surface tensions of water
at the absolute temperatures in the vessels (as noted in the assumptions) w ( Tv1) and w ( Tv2) (Perry's
page 14-71):

lb ft ft
v = 0.037288 . dN1 = 0.171875 in and dN2 = 0.203125 in . uN1 = 223.907 and uN2 = 230.469 .
3 sec sec
ft
lbf lbft
Tv1 = 364.95 K . [ TF ( Tv1) = 197.22 .] w ( Tv1) = 0.004098 . 1lbf = 32.174 .
ft 2
sec
lbf lbft
Tv2 = 373.15 K . [ TF ( Tv2) = 211.98 .] w ( Tv2) = 0.003989 . 1lbf = 32.174 .
ft 2
sec

2 2
v dN1 uN1 v dN2 uN2
Weg1 := and Weg2 := :
w ( Tv1) w ( Tv2)
Weg1 = 203.062 and Weg2 = 261.198 .
The sparger flow jet regimes indicated by the sparger hole Weber numbers Weg1 and Weg2 are
(Perry's pages 14-70 and 14-71, and Wilkinson page 1433):

Weg1 = 203.062 and

Weg2 = 261.198 .
Sparger_We_Regime1 := if ( Weg1 > 2 , "Jet" , "Not Jet" ) and
Sparger_We_Regime2 := if ( Weg2 > 2 , "Jet" , "Not Jet" ) :
Sparger_We_Regime1 = "Jet" and
Sparger_We_Regime2 = "Jet" .

Weg1
Sparger_We_vs_Jet_Flow_We1 := . 1 = 100 % .
2
Weg2
Sparger_We_vs_Jet_Flow_We2 := . 1 = 100 % :
2
Sparger_We_vs_Jet_Flow_We1 = 10153 % and
Sparger_We_vs_Jet_Flow_We2 = 13060 % .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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The Sauter-mean bubble diameters or bubble volume-to-surface ratios of the first and second
stage spargers, dvs1 and dvs2 , are calculated from the Reynolds numbers for the gas flows at the holes
ReN1 and ReN2 , the hole diameters dN1 and dN2 , the surface tensions and liquid densities of water at the
absolute temperatures in the vessels w ( Tv1) , w ( Tv2) , lw ( Tv1) , and lw ( Tv2) (as noted in the
assumptions), the vapor density in the spargers v , and the gravitational acceleration g (Kumar page 504
equations 4 to 6):

ReN1 = 14240 and ReN2 = 17322 .

dN1 = 0.171875 in and dN2 = 0.203125 in . 12in = 1 ft .
Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
lbf lbf lbft
w ( Tv1) = 0.004098 and w ( Tv2) = 0.003989 . 1lbf = 32.174 .
ft ft 2
sec
lb lb lb ft
lw ( Tv1) = 60.155 and lw ( Tv2) = 59.793 . v = 0.037288 . g = 32.174 .
3 3 3 2
ft ft ft sec

Define interpolation functions f1 ( ReN1) and f2 ( ReN2) .

) + log( 100 4000 ) log( 0.32 2100 ) ( log( ReN1) log( 2100) )
0.4 0.425
(
log 0.32 2100
0.425

f1 ( ReN1) := 10 log( 4000) log( 2100) and

) + log( 100 4000 ) log( 0.32 2100 )

0.4 0.425
(
log 0.32 2100
0.425
( log( ReN2) log( 2100) )
f2 ( ReN2) := 10 log( 4000) log( 2100) :
0.425
f1 ( 2100) = 8.262 ; 0.32 2100 = 8.262 .
0.4
f1 ( 4000) = 3.624 ; 100 4000 = 3.624 .
f1 ( 3000) = 5.236 .
1
4
w ( Tv1) dN12
dvs1 := ( 1 < ReN1) ( ReN1 10) 1.56 ReN1

0.058
... . 1ft = 12 in .
( lw ( Tv1) v) g
+ ( 10 < ReN1) ( ReN1 2100) 0.32 ReN1 ...
0.425

+ ( 2100 < ReN1) ( ReN1 < 4000) f1 ( ReN1) ...

0.4
+ ( 4000 ReN1) ( ReN1 < 70000) 100 ReN1
1
4
w ( Tv2) dN22
dvs2 := ( 1 < ReN2) ( ReN2 10) 1.56 ReN2 ...
0.058
. 1ft = 12 in :
( lw ( Tv2) v) g
+ ( 10 < ReN2) ( ReN2 2100) 0.32 ReN2
0.425
...
+ ( 2100 < ReN2) ( ReN2 < 4000) f1 ( ReN2) ...
0.4
+ ( 4000 ReN2) ( ReN2 < 70000) 100 ReN2

dvs1 = 0.285 in and dvs2 = 0.285 in ;

dvs1 dvs2
= 166 % and = 140 % .
dN1 dN2

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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inertial_force
The Froude numbers, (Perry's page 6-49), in the first and second stage vessels, Fr1
gravity_force
and Fr2 , are calculated from the superficial velocities UG1 and UG2 , gravitational acceleration g , and
vessel diameters Dv1 and Dv2 (Godbole pages 1235-1236):

ft ft
UG1 = 0.363794 . UG2 = 0.363195 .
sec sec
ft
g = 32.174 . Dv1 = 20 in . Dv2 = 24 in . 12in = 1 ft .
2
sec
UG1 UG2
Fr1 := . Fr2 := .
g Dv1 g Dv2
Fr1 = 0.049680 . Fr2 = 0.045276 .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
Confidential Client Date, Page: 7/22/2001, 25 of 37

The gas holdups in the first and second stage vessels, G1 and G2 , are calculated iteratively from
the gravitational acceleration g , the vessel diameters Dv1 and Dv2 , the liquid densities, surface tensions,
and liquid viscosities of water at the absolute temperatures in the vessels (as noted in the assumptions)
lw ( Tv1) , lw ( Tv2) , w ( Tv1) , w ( Tv2) , lw ( Tv1) and lw ( Tv2) , and the superficial velocities UG1 and
UG2 (Akita page 78 equation 11):

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
ft lb lb
g = 32.174 . Dv1 = 20 in and Dv2 = 24 in . 12in = 1 ft . lw ( Tv1) = 60.155 and lw ( Tv2) = 59.793 .
2 3 3
sec ft ft
lbf 3 lbf lbft
w ( Tv1) = 4.098 10 and w ( Tv2) = 3.989 10
3
. 1lbf = 32.174 .
ft ft 2
sec
6 lb 6 lb
lw ( Tv1) = 206.177 10 and lw ( Tv2) = 187.815 10 .
ft sec ft sec
ft ft
UG1 = 0.363794 and UG2 = 0.363195 .
sec sec

Start with G1 := 10% and G2 := 10% .

1 1
8 12
G1 g Dv12 lw ( Tv1) g Dv13 UG1 1.0
Given that = 0.20 and
( )
(1 G1)4 w T v1 lw ( Tv1)
2
g D v1

lw ( Tv1)
1 1
8 12
G2 g Dv2 lw ( Tv2) g Dv23 UG2 1.0
2
= 0.20 ,
w ( Tv2)
(1 G2)4 lw ( Tv2) g Dv2
2

lw ( Tv2)
G1
calculate := Find ( G1 , G2) :
G2

G1 = 19.468 % and G2 = 19.621 % .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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inertial_force
The critical values of the Froude number, (Perry's page 6-49), for transition to
gravity_force
foaming flow in the first and second stage vessels, Frgc1 and Frgc2 , are calculated from the gas holdups G1
and G2 , and the vessel foaming flow conditions are determined by comparing the calculated critical values
of the Froude number to the actual values Fr1 and Fr2 (Godbole page 1221):

G1 = 0.195 and G2 = 0.196 .

2 2
0.25 G1 0.25 G2
Frgc1 := and Frgc2 := .
3 3

(1 G1) 2 (1 G2) 2
Frgc1 = 0.013110 and Frgc2 = 0.013356 .

Fr1 = 0.049680 . Frgc1 = 0.013110 . Fr2 = 0.045276 . Frgc2 = 0.013356 .

Vessel_Fr_No1 := if ( Fr1 < Frgc1 , "Foaming Flow" , "Not Foaming Flow" ) and
Vessel_Fr_No2 := if ( Fr2 < Frgc2 , "Foaming Flow" , "Not Foaming Flow" ) :
Vessel_Fr_No1 = "Not Foaming Flow" and
Vessel_Fr_No1 = "Not Foaming Flow" .

Fr1
Vessel_Fr_vs_Min_Nonfoaming1 := . 1 = 100 % .
Frgc1
Fr2
Vessel_Fr_vs_Min_Nonfoaming2 := . 1 = 100 % :
Frgc2
Vessel_Fr_vs_Min_Nonfoaming1 = 379 % and
Vessel_Fr_vs_Min_Nonfoaming2 = 339 % .

The effective interfacial areas per unit volume in the first and second stage vessels, a1 and a2 , are
calculated from the gas holdups G1 and G2 and the Sauter-mean bubble diameters or bubble
volume-to-surface ratios dvs1 and dvs2 (Perry's pages 5-69 and 5-43):

G1 = 0.194676 and G2 = 0.196213 .

dvs1 = 0.284573 in and dvs2 = 0.284552 in . 12in = 1 ft .
6 G1 6 G2
a1 := and a2 := :
dvs1 dvs2
2 2
ft ft
a1 = 49.255 and a2 = 49.648 .
3 3
ft ft

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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Mass Transfer Coefficients

The Grashof numbers for the first and second stage vessels, Gr1 and Gr2 , are calculated from the
Sauter-mean bubble diameters or bubble volume-to-surface ratios dvs1 and dvs2 , the liquid densities and
liquid viscosities of water at the absolute temperatures in the vessels (as noted in the assumptions) lw ( Tv1)
, lw ( Tv2) , lw ( Tv1) , and lw ( Tv2) , the vapor density v , and the gravitational acceleration g (Calderbank
page 53):

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
lb lb ft
dvs1 = 0.284573 in . 12in = 1 ft . lw ( Tv1) = 60.155 . v = 0.037288 . g = 32.174 .
3 3 2
ft ft sec
lb
dvs2 = 0.284552 in . lw ( Tv2) = 59.793
3
ft
lb lb
lw ( Tv1) = 0.000206177 and lw ( Tv2) = 0.000187815 .
ft sec ft sec

Gr1 :=
3
(
dvs1 lw ( Tv1) lw ( Tv1) v g ) and Gr2 :=
(
dvs2 lw ( Tv2) lw ( Tv2) v g
3
) :
lw ( Tv1) lw ( Tv2)
2 2

6 6
Gr1 = 36.503 10 and Gr2 = 43.452 10 .

The Schmidt numbers for the first and second stage vessels, Sc1 and Sc2 , are calculated from the
liquid viscosities and liquid densities of water at the absolute temperatures in the vessels (as noted in the
assumptions) lw ( Tv1) , lw ( Tv2) , lw ( Tv1) , and lw ( Tv2) , and the diffusivities of chloroform at infinite
dilution in water at the absolute temperatures in the vessels Dc0w ( Tv1) and Dc0w ( Tv2) (Calderbank page 53):

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
lb lb
lw ( Tv1) = 0.000206177 and lw ( Tv2) = 0.000187815 .
ft sec ft sec
2
lb lb ft
lw ( Tv1) = 60.155 and lw ( Tv2) = 59.793 . Dc0w ( Tv1) = 51.439 10
9
and
3 3 sec
ft ft
2
ft
Dc0w ( Tv2) = 59.514 10
9
.
sec
lw ( Tv1) lw ( Tv2)
Sc1 := and Sc2 := :
lw ( Tv1) Dc0w ( Tv1) lw ( Tv2) Dc0w ( Tv2)
Sc1 = 66.632 and Sc2 = 52.780 .

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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The Sherwood numbers for the first and second stage vessels, Sh1 and Sh2 , are calculated from
the Grashof numbers Gr1 and Gr2 , Schmidt numbers Sc1 and Sc2 , and Sauter-mean bubble diameters or
bubble volume-to-surface ratios dvs1 and dvs2 (Perry's page 5-69):

6 6
Gr1 = 36.503 10 and Gr2 = 43.452 10 .
Sc1 = 66.632 and Sc2 = 52.780 .
dvs1 = 0.284573 in and dvs2 = 0.284552 in . 1in = 2.54 cm , so
dvs1 = 0.722814 cm and dvs2 = 0.722762 cm .
1 1 1 1

Sh1 := ( dvs1 < 0.25cm) 2 + 0.31 Gr1 Sc1 ... and Sh2 := ( dvs2 < 0.25cm) 2 + 0.31 Gr2 Sc2
3 3 3 3
... :
1 1 1 1

+ ( 0.25cm dvs1) 0.42 Gr1 Sc1 + ( 0.25cm dvs2) 0.42 Gr2 Sc2
3 2 3 2

Sh1 = 1554.180 and Sh2 = 1481.527 .

The individual liquid-phase mass-transfer coefficients in the first and second stage vessels, kL1
and kL2 , are calculated from the Sherwood numbers Sh1 and Sh2 , the diffusivities of chloroform at infinite
dilution in water at the absolute temperatures in the vessels Dc0w ( Tv1) and Dc0w ( Tv2) , and the
Sauter-mean bubble diameters or bubble volume-to-surface ratios dvs1 and dvs2 (Calderbank page 53):

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
2
ft
Sh1 = 1554.180 . Dc0w ( Tv1) = 51.439 10
9
. 1hr = 3600 sec .
sec
2
ft
Sh2 = 1481.527 . Dc0w ( Tv2) = 59.514 10
9
. 1hr = 3600 sec .
sec
dvs1 = 0.284573 in and dvs2 = 0.284552 in . 12in = 1 ft .
Sh1 Dc0w ( Tv1) Sh2 Dc0w ( Tv2)
kL1 := and kL2 := :
dvs1 dvs2
ft ft
kL1 = 12.136 and kL2 = 13.386 .
hr hr

The overall liquid-phase mass-transfer coefficients KL1 and KL2 are taken to equal the individual
liquid-phase mass-transfer coefficients kL1 and kL2 since the resistance is entirely in the liquid phase for
most gas-liquid mass transfer (Perry's page 5-69 Table 5-25 Condition Z, and page 5-56 equation 5-257):

ft ft
kL1 = 12.136 and kL2 = 13.386 .
hr hr
KL1 := kL1 and KL2 := kL2 :
ft ft
KL1 = 12.136 and KL2 = 13.386 .
hr hr

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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Stripping and Dilution

The operating volumes of the first and second stage vessels, Voper1 and Voper2 , are calculated
from the rated capacities Vcap1 and Vcap2 , the levels of clear liquid at overflow Lover1 and Lover2 , and the
gas holdups G1 and G2 (Akita page 76 equation 1):

Vcap1 = 32 gal and Vcap2 = 52 gal .

Lover1 = 60 % and Lover2 = 60 % .
G1 = 19.468 % and G2 = 19.621 % .
100% = 1 .
Lover1 Lover2
Voper1 := Vcap1 and Voper2 := Vcap2 :
100% G1 100% G2
Voper1 = 23.841 gal and Voper2 = 38.816 gal .

The liquid-phase molar flux in the first stage vessel, LM1 , is calculated from the volumetric flow of
raffinate, qr , the liquid density of water as a function of the absolute temperature in the vessel (neglecting
the chloroform present, as noted in the assumptions) lw ( Tv1) , the weight fraction chloroform in the
raffinate wcr , the molecular weights of water and chloroform Mw and Mc , and the cross-sectional area of
the vessel A1 (Cussler page 251):

Tv1 = 364.95 K . [ TF ( Tv1) = 197.22 .]

gal lb
. 1gal = 0.133681 ft . 1hr = 60 min . lw ( Tv1) = 60.155
3
qr = 4.185 .
min 3
ft
wcr = 0.003756 .
lb lb 2
Mw = 18.015 and Mc = 119.38 . A1 = 2.182 ft
lbmole lbmole

100lbwcr 100lb ( 1 wcr)

+
Mc Mw 1 lbmole
LM1 := qr lw ( Tv1) : LM1 = 51.213 .
100lb A1 2
hr ft

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 LOCKWOOD GREENE Job, Item: A7947 010704.01, CHCl3 Plan
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The liquid mole fraction chloroform at the top of the first stage vessel, x2v1 , is calculated from the
weight fraction chloroform in the raffinate wcr and the molecular weights of water and chloroform Mw and
Mc :

Basis: 100lb of raffinate.

wcr = 0.003756 .
lb lb
Mw = 18.015 . Mc = 119.38 .
lbmole lbmole

100lb wcr

x2v1 := Mc : x2v1 = 0.000569 .
100lbwcr 100lb ( 1 wcr)
+
Mc Mw

The gas-phase molar fluxes in the first and second stage vessels, GM1 and GM2 , are calculated
from the restriction orifice mass flows W1 and W2 , the molecular weight of water Mw , and the vessel
cross-sectional areas A1 and A2 (Cussler page 251):

lb
W1 = 106.540 .
hr
lb 2
Mw = 18.015 . A1 = 2.182 ft .
lbmole
W1 W2
GM1 := and GM2 := :
Mw A1 Mw A2
lbmole lbmole
GM1 = 2.711 and GM2 = 2.706 .
2 2
hr ft hr ft

The vapor-liquid equilibrium ratios of chloroform at infinite dilution in water in the first and second
stage vessels, Kc1 and Kc2 , are calculated from the vapor pressures of chloroform and the activity
coefficients of chloroform at infinite dilution in water, both evaluated at the absolute temperatures in the
vessels, Pvc ( Tv1) , Pvc ( Tv2) , c ( Tv1) , and c ( Tv2) , and from the total pressure in the vessels Pv (Hwang
page 1759 equation 1):

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
Pvc ( Tv1) = 36.595 psi and Pvc ( Tv2) = 45.276 psi . c ( Tv1) = 829.935 and c ( Tv2) = 810.889 .
Pv = 14.696 psi .
Pvc ( Tv1) c ( Tv1) Pvc ( Tv2) c ( Tv2)
Kc1 := and Kc2 := : Kc1 = 2067 and Kc2 = 2498 .
Pv Pv

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The remaining concentrations, molar fluxes based on interfacial areas, and molar fluxes based on
vessel cross-sectional areas, x1v1 , y2v1 , NA1 , x1v2 , x2v2 , y2v2 , NA2 , and LM2 , are calculated iteratively
from the interfacial areas per unit volume a1 and a2 , operating volumes Voper1 and Voper2 , liquid-phase
molar flux based on cross-sectional area of the first stage vessel LM1 , gas-phase molar fluxes based on
cross-sectional areas GM1 and GM2 , overall liquid-phase mass transfer coefficients KL1 and KL2 , liquid
densities of water at the vessel absolute temperatures (as noted in the assumptions) lw ( Tv1) and lw ( Tv2)
, molecular weight of water Mw , and vapor-liquid equilibrium ratios of chloroform at infinite dilution in water in
the vessels Kc1 and Kc2 (Geankoplis page 451 Example 7.4-1):

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x2v 1 y2v1 x2v 2 y2v2

x1v 1 y1v1 x1v 2 y1v2

Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]
2
ft lbmole 2
a1 = 49.255 . Voper1 = 23.841 gal . LM1 = 51.213 . A1 = 2.182 ft x2v1 = 0.000569 .
3 2
ft hr ft
lbmole ft lb lb
GM1 = 2.711 . KL1 = 12.136 . lw ( Tv1) = 60.155 . Mw = 18.015 . Kc1 = 2067 .
2 hr 3 lbmole
hr ft ft
2
ft 2 lbmole
a2 = 49.648 . Voper2 = 38.816 gal . A2 = 3.142 ft . GM2 = 2.706 .
3 2
ft hr ft
ft lb
KL2 = 13.386 . lw ( Tv2) = 59.793 . Kc2 = 2498
hr 3
ft

Note:
y1v1 := 0 . y1v2 := 0 .

Let:
lbmole
x1v1 := 0 . y2v1 := 0 . NA1 := 0 .
2
hr ft
lbmole
x1v2 := 0 . x2v2 := 0 . y2v2 := 0 . NA2 := 0 . LM2 := LM1 .
2
hr ft

Given
NA1 a1 Voper1 = LM1 A1 ( x2v1 x1v1) and NA2 a2 Voper2 = LM2 A2 ( x2v2 x1v2) .
NA1 a1 Voper1 = GM1 A1 ( y2v1 y1v1) and NA2 a2 Voper2 = GM2 A2 ( y2v2 y1v2) .
1 y2v1 1 y2v2
NA1 = KL1 lw ( Tv1) x1v1 and NA2 = KL2 lw ( Tv2) x1v2 .
Mw Kc1 Mw Kc2
LM2 A2 = LM1 A1 NA1 a1 Voper1 . x1v1 = x2v2 .

Calculate:

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x 1v1

y 2v1
N A1

x 1v2
:= Find ( x 1v1 , y 2v1 , N A1 , x 1v2 , x 2v2 , y 2v2 , N A2 , L M2) :
x 2v2
y 2v2

N A2

L M2
6 3 6 lbmole
x1v1 = 14.788 10 . y2v1 = 10.462 10 . NA1 = 394.136 10 .
2
hr ft
9 6 6
x1v2 = 218.741 10 . x2v2 = 14.788 10 . y2v2 = 191.357 10 .
6 lbmole lbmole
NA2 = 6.315 10 . LM2 = 35.545 .
2 2
hr ft hr ft

The weight fraction chloroform in the stripped liquid, wcs , is calculated from the mole fraction
chloroform in the stripped liquid x1v2 and the molecular weights of water and chloroform Mw and Mc :

Basis: 100lbmole of stripped liquid.

9
x1v2 = 218.741 10 .
lb lb
Mw = 18.015 . Mc = 119.38 .
lbmole lbmole

100lbmole x1v2 Mc 6
wcs := : wcs = 1.450 10 .
100lbmole x1v2 Mc + 100lbmole ( 1 x1v2) Mw

The weight fraction chloroform in the stripped liquid, adjusted based on Process Qualification data,
wcs_adj , is calculated from the weight fraction chloroform in the stripped liquid wcs based on PQ data
(Baseline calculation wcs , PQ Data from 10/5/99):

6
wcs = 1.450 10 .

125 + 125 + 115 + 115 + 70

wcs_adj := wcs 5 : w 6
cs_adj = 17.730 10 .
8.993

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The weight fraction chloroform in the final rinsate, wcf , is calculated from the adjusted weight
fraction chloroform in the stripped liquid wcs_adj based on PQ data (PQ Report):

6
wcs_adj = 17.730 10

0.19 + 0.22 + 0.08

wcf := wcs_adj 3 : wcf = 30.306 10
9
.
( 125 + 125 + 115) + ( 115 + 70 + 75) + ( 50 + 85 + 100)

9

Key Parameters Summary

The levels of clear liquid at overflow of the first and second stage vessels, Lover1 and Lover2 , are
taken to be:

Lover1 = 60 % and Lover2 = 60 % .

The volumetric flow of raffinate qr is taken to be:

gal
qr = 4.185 .
min

The absolute pressure upstream of the orifices, P0 , is:

P0 = 44.7 psi .

The absolute pressures and temperatures in the vessels, Pv , Tv1 , and Tv2 , are:

Pv = 14.7 psi .
Tv1 = 364.95 K and Tv2 = 373.15 K . [ TF ( Tv1) = 197.22 and TF ( Tv2) = 211.98 .]

The restriction orifice diameters of the first and second stages, D1 and D2 , are:

D1 = 0.250 in and D2 = 0.297 in .

The sparger total hole areas, aT1 and aT2 , are:

dN1 = 0.172 in and dN2 = 0.203 in .

n1 = 22 and n2 = 22 .
2 2
aT1 = 0.003545 ft and aT2 = 0.004951 ft .

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Results Summary

The mass flows in the first and second stage restriction orifices, W1 and W2 , and the total mass
flow of steam WT are:

lb lb lb
W1 = 106.540 and W2 = 153.165 . WT = 260 .
hr hr hr

The superficial velocities in the first and second stage vessels, UG1 and UG2 , are:

ft ft
UG1 = 0.363794 and UG2 = 0.363195 .
sec sec
m m
UG1 = 0.110884 and UG2 = 0.110702 .
sec sec

Wi
The vessel flow regimes indicated by the vessel superficial velocities are (Perry's
2
Dvi
4
2
page 14-74):

Vessel_Gas_Velocity1 = "Turbulent" and

Vessel_Gas_Velocity2 = "Turbulent" .

Vessel_Quiescence_vs_Max1 = 243 % and

Vessel_Quiescence_vs_Max2 = 242 % .

Vessel_Turbulence_vs_Min1 = 182 % and

Vessel_Turbulence_vs_Min2 = 182 % .

Wi
The sparger hole superficial velocities (for open-end pipe, perforated plate, or ring- or
0 aTi
cross-style perforated-pipe spargers in quiescent vessels) are considered (Perry's page 14-74:

Sparger_Velocity1 = "Not Excessive" and

Sparger_Velocity2 = "Not Excessive" .

Sparger_Velocity_vs_Max_Okay1 = 90 % and
Sparger_Velocity_vs_Max_Okay2 = 92 % .

Sparger_Velocity_vs_Min_Excessive1 = 75 % and
Sparger_Velocity_vs_Min_Excessive2 = 77 % .

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dNi uNi 4
The sparger flow regimes indicated by the sparger hole Reynolds numbers are (Perry's
vw ( T0 )
pages 14-70 and 14-71):

Sparger_Re_Regime1 = "Possibly Jet" and

Sparger_Re_Regime2 = "Possibly Jet" .

2
g dNi uNi
The sparger flow jet regimes indicated by the sparger hole Weber numbers are
w ( Ts)
(Perry's pages 14-70 and 14-71, and Wilkinson page 1433):

Sparger_We_Regime1 = "Jet" and

Sparger_We_Regime2 = "Jet" .

Sparger_We_vs_Jet_Flow_We1 = 10153 % and

Sparger_We_vs_Jet_Flow_We2 = 13060 % .

The Sauter-mean bubble diameters or bubble volume-to-surface ratios of the first and second
dvs1 dvs2
stage spargers, dvs1 and dvs2 , and the ratios of the bubble diameters to the hole diameters, and ,
dN1 dN2
are:

dvs1 = 0.285 in and dvs2 = 0.285 in .

dvs1 dvs2
= 166 % and = 140 % .
dN1 dN2

The gas volumetric holdups in the first and second stage vessels, G1 and G2 , are:

G1 = 19.5 % and G2 = 19.6 % .

UGi
The vessel foaming flow conditions indicated by the Froude numbers are (Perry's page
g Dvi
6-47, and Godbole page 1221):

Vessel_Fr_No1 = "Not Foaming Flow" and

Vessel_Fr_No1 = "Not Foaming Flow" .

Vessel_Fr_vs_Min_Nonfoaming1 = 379 % and

Vessel_Fr_vs_Min_Nonfoaming2 = 339 % .

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The weight fraction chloroform in the stripped liquid, wcs , is:

6
wcs = 1.450 10 .

The weight fraction chloroform in the stripped liquid, adjusted based on Process Qualification data,
wcs_adj , is:
6
wcs_adj = 17.730 10 .

The weight fraction chloroform in the final rinsate, wcf , is:

9
wcf = 30.306 10 .

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