((Units Operation))

Syllabus
 Sedimentation Separation
 Centrifuge Separation
 Filtration Process
 Humidification and Cooling Tower
 Drying

References
1-Transport Process and Unit Operation, by: Geankoplis

2-Unit Operation of Chemical Engineering, by: Mc. Cape W L, Smith J C,

3-Chemical Engineering Vol. 2, by: Coulson J M, Richardson J F,

 Mechanical Separation
Separation Types:
The chemical Separation
It depends on adding another chemical substance for dissociation the main materials or elements
from each other and its effected on the chemical properties of the materials.

The Physical separation

It depends on the variance of the physical properties and may be change the phase, for example
(distillation, absorption, extraction, evaporation, drying, humidification, etc)

The Mechanical Separation

It of particles from a fluid uses forces acting on these particles. So the separating action depends
on the character of the particle being separated and the forces on the particle which cause the
separation.
 The Velocity of Particles Moving in a Fluid
Under a constant force, for example the force of gravity, particles in a liquid accelerate for a
time and there after move at a uniform velocity. This maximum velocity which they reach is
called their terminal velocity (Vm).

It's depends upon the size, density and shape of the particles, and upon viscosity and density
of the fluid. When a particle moves steadily through a fluid, there are two principal forces acting
upon it .

1. The external force causing the motion (FS)

2. The drag force resisting motion which arises from frictional action of the fluid (FD).
Fs = V. g (ρp – ρc )
Fs : the net external accelerating force on the particle. Drag Force (FD)

V: the volume of the particle.

g : the gravity acceleration.
ρp and ρc : the density of the particle and fluid receptively.
The drag force on the particle (FD) is obtained by :
External Force (FS)

C: is the drag coefficient

Ap : the cross section area of the particle.
If these forces are acting on a spherical particle so that
Vp = π DP3/6 and AP = π DP 2/4,
D: diameter of the particle.
Then equating Fs and FD, in which case the velocity V becomes the terminal velocity Vm:
FS = FD
(π DP /6) g (ρp - ρc) = C ρc Vm2 π DP2/8
3
 The drag coefficient C has been found to be a function of the shape of the particle and Reynolds
number of the flowing of fluid. The Reynolds number is defined as:
Re=D pVt  c/
The curve shown in Figure below can be simplified into three sections from which curve-fit
approximations of the C vs Re curve can be derived. three settling laws are obtained as described
below.

1. Stok’s Law

At low Reynolds no. Re < 2 ( laminar flow) and small spherical particles so:

So the equation for the terminal velocity magnitude:

Stokes’ Law applies only to cases in which settling is free, that’s where;

 Reynolds no. of streamline flow less than 2 (Re < 2)

 Only to spherical particles.
 The size range of the particles is not much greater than 1:10
2. Intermediate Law
For Reynold’s numbers between 2 and 500, the Intermediate Law applies, and the terminal
settling law can be expressed as:

3. Newton’s Law
Newton’s Law is applicable for a Reynold’s number range of approximately 500 – 200,000.
The limiting drag coefficient is approximately as 0.44.

The following equations were based on the assumption that the settling of the particle is not
affected by other particles (free falling).

EXAMPLE.1:

Calculate the settling velocity of dust particles of (a) 60μm and (b) 10μm diameter in air at 21 oC
and 100 kPa pressure. Assume that the particles are spherical and of density 1280 kg/m3, and
that the viscosity of air = 1.8 x 10-5 Ns m-2 and density of air = 1.2 kgm-3.
 Sedimentation
A separation process uses gravitational forces to separate particulate material from fluid. It
is very often used in the industry for separating dirt and debris from incoming raw material,
crystals from their mother liquor and dust or product particles from air.

Sedimentation Types:
1. Batch Sedimentation
In a cylinder in which a uniform suspension is allowed to settle, various quite well defined
Zones appear as the settling proceeds. At the top is a zone of clear liquid. Below this is a zone
of more or less constant composition, constant because of the uniform settling velocity of all
sizes of particles. At the bottom of the cylinder is a zone of sediment with the larger particles.

A: Clear Liquid Zone, B: Homogeneous Zone, C: Transition Zone. D: Sediment Zone .

2. Continuous Sedimentation
In a continuous thickener, solids settle as the slurry flows through the unit. Clarified liquid is
removed from the top and sludge from the bottom, forming the same settling zones as in
batch settling.
 EXAMPLE 2:
A continuous separating tank is to be designed to follow after a water washing plant for
liquid oil. Estimate the necessary area for the tank if the oil, on leaving the washer, is in the
form of globules 5.1×10-5 m diameter, the feed concentration is 4 kg water to 1 kg oil, and the
leaving water is effectively oil free. The feed rate is 1000 kg/h, the density of the oil is 894
kg/m3 and the temperature of the oil and of the water is 38°C. Assume Stokes' Law. Viscosity
of water = 0.7×10-3 N s/m2 , Density of water = 1000 kg/m3

Solution
Vm= D2.g (ρp −ρc)/ 18µ
Vm = (5.1 x 10-5)2×9.81×(1000 - 894)/(18×0.7×10-3)
Vm = 2.15×10-4 m/s = 0.77 m/h
since F = 4 and U = 0,
Q = flow of minor component = 1000/5 = 200 kg/h
A = 4×200/(0.77×1000) = 1.0 m2

SEDIMENTATION EQUIPMENT
1. Simple Classifier
In the simple classifier, the design is similar to that of the straight gravity settling tank, except
that the bottom half is divided into several equal partitions. What happens is that instead of
just falling into a big mess on the bottom of the tank, the coarse particles get trapped in the
first chamber, the intermediates get trapped in the middle partitions, and the fine particles,
the dust, gets captured in the last section. Then, you can drain the sections from the bottom
and have a segregated sediment.

Simple Classifier
2. Thickeners
The slurry enters near the center below the surface. Clear liquid overflows from the top. A
rotating rake at the sloped bottom pushes settled sludge to the center for discharge. Particles
settle in a settling zone, then pass through a transition zone, and finally compress in a bottom
zone before removal.

Continuous thickener sedimentation

3. Multistage of Thickeners
The flow scheme for a three-stage CCD system is illustrated in flowing Figure. The feed
stream(F), is mixed with overflow Q2 (from thickener 2) before entering stage 1. The
overflow of concentrated solution, Q1, is withdrawn from the first stage. The underflow from
the first stage, U1, is mixed with third-stage overflow, Q3, and fed to the second stage.
Similarly, the second stage underflow, U2, is mixed with wash water and fed to thickener 3.
The washed solids are removed from the third stage as the final underflow U3.

Simplified flow scheme for a three-stage CCD system.

Flotation
In some cases, where it is not practicable to settle out fine particles, these can sometimes be
floated to the surface by the use of air bubbles. It depends upon the relative tendency of air
and water to adhere to the particle surface. The water at the particle surface must be displaced
by air. In some instances, the air bubbles remain round the solid particles and cause froths.
The greatest application of froth flotation is in the concentration of minerals.

Flotation