Process Calculations
S3CH01
Dr. Sudhir Ranganath
Contact Hours/Week: 3 (Lecture) Credits: 4.0
Contact Hours/Week: 3 (Lecture) + 1 (Study Hour) Credits: 3.0
CIE Marks: 50
Total Lecture Hours: 39 CIE
SEE Marks:5050
Marks:
Total Hours: 42 (L) SEE Marks: 50
UNIT I
Introduction to Process Calculations
Units (Fundamental & derived) & Conversion of units
Dimensional consistency of equations
Conversion of empirical equations
Moles, mole fraction, composition of mixtures
Normality, molarity, ppm
Important Physical Quantities & Conversions
Volume: The amount of space that an object or substance occupies and
measured in cubic meters (m3) and in liters (SI units) and in gallons.
Conversions: 1 "# = 1000 &'()*+ = 1 ,'&-&'()*
1 . = 0.2199 2"3)*'4& 54&&-6
1 . = 0.2641 9: 54&&-6
Power: Work done “W” per unit time which is given by ; = = ⁄> and measured
in Watt or W (SI units). 1 = = 1 ?/+
1 metric horse power = 75 (m.kgf)/s = 0.7355 kW = 0.98633 hP
1 British horse power = 550 (ft.lbf)/s = 0.7457 kW
Heat: Form of energy & measured in Joule (SI units), kilocalorie (MKS),
calorie (CGS) and British Thermal Unit (FPS)
1 AB9 = 1055 ?
1 D4& = 4.184 ?
Important Physical Quantities & Conversions
Energy: Quantity that can be stored within the system and can be exchanged
between the system and the surroundings. The exchange of energy occurs
either as heat or as work.
Potential energy: Energy stored within the system due to its position above
some arbitrary reference plane. !" = $. &. '
Kinetic energy: Energy possessed by a body by virtue of its motion.
1
(" = $. +,
2
Units are Joule (SI units), Calorie (Metric system), erg (CGS system) and Btu
1 - = 1 .. $ = 1 /&. $, /1 ,
Conversion: 1 234 = 4.187 -
1 89& = 10;< -
1 =>+ = 1055 -
Important Physical Quantities & Conversions
Force: Product of mass and acceleration according to Newton’s second law.
! = #. %
Units are Dyne (CGS system), Newton (SI units), kgf (MKS system) and lbf
(AE system).
Dyne is defined as a force necessary to accelerate 1 gram mass at 1 cm/s2
Newton is defined as a force necessary to accelerate 1 kg mass at 1 m/s2
kgf is defined as a force necessary to accelerate 1 kg mass at 9.81 m/s2
lbf is defined as a force necessary to accelerate 1 lb mass at 32.174 ft/s2
Conversion: 1 '() = 9.807 .
1 /0) = 4.448 .
1 234 = 1056 .
Important Physical Quantities & Conversions
Weight: Force exerted on the object by gravitational attraction.
If an object of mass “m” is subjected to a gravitational force “W” and if this
object were falling freely, its acceleration would be “g”. They are related by:
! = #. %
% = 9.8066 #⁄+ , = 980.66 -#⁄+ , = 32.174 34⁄+ ,
Pressure: Force per unit area exerted by the fluid on a real or imaginary
boundary.
5 = 6/8
Units are N/m2 or Pa (SI unit), kgf/cm2 (MKS) and lbf/in or psi (FPS)
Conversion: 1 9:; = 10< 5: = 10< =⁄#, = 1.0197 >%? ⁄-#,
Important Physical Quantities & Conversions
Atmospheric Pressure: The pressure exerted by the atmosphere is called the
atmospheric pressure and it varies with location and elevation on the earth’s
surface.
One standard atmospheric pressure abbreviated as atm is used in all systems
of units as an empirical unit of pressure. It is the average pressure exerted by
the earth’s atmosphere at sea level, which is equal to 1.01325 x 105 N/m2 or
1.01325 bar.
In engineering practice, the pressure is usually reported as guage pressure.
Absolute pressure = Atmospheric pressure + Guage pressure
Pressures below atmospheric are:
Absolute pressure = Atmospheric Pressure - Vacuum
Pressure is also measured in terms of the height of the column of mercury,
which it will support at 273.15 K in a standard gravitational field. At standard
atmospheric pressure, this height is 0.76 m or 760 mm.
1 "#$ = 1.01325 +", = 1.01325 × 10. /" = 760 $$ 23
Important Physical Quantities & Conversions
Density: Ratio of mass per unit volume having units "#⁄$% (or) &'⁄() % (or)
#⁄*$% , etc.
Density of solids and liquids do not change significantly with normal pressure
conditions, but change with temperature.
Specific Gravity: Ratio of density of substance A to that of the reference
substance B.
45⁄67 8 5⁄<67 8 =>⁄?@ 7 8
+,-*.(.* #/01.)2 = 45⁄67 9:;
= 5⁄<67 9:;
= =>⁄?@ 7 9:;
and so on
The reference for solids and liquids is water and for gases, it is air. Specific
gravity is stated always at the temperature at which each density is chosen.
EF°
For example, +,-*.(.* #/01.)2 = 0.73 can be interpreted as the specific
H°
gravity when the solution is at 20℃ and reference substance is at 4℃.
Important Physical Quantities & Conversions
Most processes involve the movement of material from one point to another -
sometimes between process units, production facility and a transportation
depot.
Mass flow rate: The rate at which a certain mass of a material is transported
through a process line is the mass flow rate of that material.
!"## $%&' (")* ,̇ = ,"##⁄)/,*
The units of mass flow rate are 01/#, 1/,/3, %4/ℎ, etc.
Volumetric flow rate: The rate at which a certain volume of a material is
transported through a process line is the volumetric flow rate of that material.
6&%7,*)(/8 $%&' (")* 6̇ = 9&%7,*⁄)/,*
The units of volumetric flow rate are ,: /#, ,;/,/3, $) : /ℎ, etc.
,̇ and 6̇ are related by density as: <*3#/)= = > = ,̇ ⁄6̇
Important Physical Quantities & Conversions
Temperature: A proportional measure of the average kinetic energy of the
random motions of the constituent microscopic particles in a system including
electrons, atoms, and molecules.
Units are ℃ (degree Celsius), ℉ (degree
Fahrenheit), # (Kelvin), °% (degree Rankine)
Conversions:
& °' = (1.8 × & ℃) + 32
& # = & ℃ + 273
& °% = & ℉ + 460
Important Physical Quantities & Conversions
On the temperature scale
(shown in the Figure), please
note that the unit temperature
difference on the Celsius
scale and Kelvin scale is
equal. On the same lines, the
unit temperature differences
are equal on the Fahrenheit
and Rankine scale.
If ∆℃ , ∆# , ∆℉ and ∆°& represent unit temperature differences in their
corresponding scales, then
∆℃ = ∆# and ∆℉ = ∆°&
Also, ∆℃ = 1.8∆℉ and ∆℃ = 1.8∆°&
Therefore, ∆℃ = ∆+ = ,. -∆℉ = ,. -∆°.
Conversion of Units
A measured quantity can be expressed in terms of units having the
appropriate dimension.
For example, velocity may be expressed in terms of feet per second, miles per
hour, centimeters per year, etc.
To convert a quantity from one unit to its equivalent in terms of another unit,
we need to multiply the given quantity by the conversion factor (new unit/old
unit).
Examples:
1. Convert 30 mg/s to its equivalent in kg/h
#$ ' ($ +,)) % ($
Answer: 30 × × = 0.11
% '),)),))) #$ '- -
2. Convert 30 lbm/s to its equivalent in kg/min
12 ' ($ ,) % ($
Answer: 30 3 × × = 816.3
% 4.4)5 123 ' #67 #67
Problems 1 & 2
Problem 1: Convert a volumetric flow rate of 2 m3/h to L/s
Solution: We know that 1 "# = 1000 & and. 1 ℎ = 3600 *
,- ,- 01 0.
Therefore, 2 =2 × × = 0.5555 &/*
. . 023- ,- #422 5
Problem 2: Convert 100 ℃ to :, ℉ and °=
Solution: We know that:
> °? = (1.8 × > ℃) + 32 = (1.8 × 100) + 32 = 212 ℉
> : = > ℃ + 273 = 100 + 273 = 373 :
> °= = > ℉ + 460 = 212 + 460 = 672 °=
Problem 3
Convert the size of a 20 nm nanoparticle to m, dm and in
Solution: We know that 1 "# = 10&' #, 1 "# = 10&( )# and
1 "# = 10&' # = 39.37 × 10&' /"
1234 5
Therefore, 20 "# = 20 "# × = 20 × 10&' #
1 65
10&( )#
20 "# × = 20 × 10&( )#
1 "#
39.37 × 10&' /"
20 "# × = 787.4 × 10&' /" = 7.874 × 10&9 /"
1 "#
Problem 4
Convert 0.6 $% &'(/(&+) &-. to (/ &'(/ 01 2 345
Solution: We know that 1 $% &'( = 1089 %&'( = 1089 × 2.203×1082 (/&'(
1 &+ = 1082 +, 1 + = 1082 &2 , 1 &2 = 35.31 01 2 , so, 1 + = 35.31 × 1082 01 2
1
1 &-. = 345
60 × 24
Therefore,
$% &'(
0.6
(&+) &-.
$% &'( 1089 ×2.203×1082 (/ &'( 1000 &+
= 0.6 × ×
(&+) &-. 1 $% &'( 1+
1+ 60 &-. 24 ℎ DE FGD
× × × = @. @ABC
35.31 × 1082 01 2 1ℎ 1 345 (HIB ) JKL
Problems 5 & 6
Problem 5: Convert 30 $⁄%& to '() ⁄*+ &
Solution:
$ $ 0.2248 '() 0.3048& %& 789
30 & = 30 & × × & = 3. 4546 5
% % 1$ 1 *+ 9:
Problem 6: Convert 25 <=>? to <=>@
Solution: We know that
Absolute pressure = Guage pressure + Atmospheric pressure
A(=B'C+D <ED==CED = 25 <=>? + 14.696 <=> = IJ. 4J4 KLMN
Problems 7 & 8
Problem 7: Show that 1.987 '() ⁄(+,-). .) is equivalent to
82.06 ',3 . (4,⁄(+,-). .)
Solution:
7 3 = 4.187 × 9.98 × 10:; (4, × 100 3
1 '() = 4.187 7. , = 4.187 . , ',3
,8
= 41.28 ',3 . (4,
'() '() 41.28 ',3 . (4, +,-). .
1.987 = 1.987 × ×
+,-). . +,-). . 1 '() +,-). .
',3 . (4,
= 82.06
+,-). .
Problem 8: Convert 20 <( vacuum to absolute pressure in atm.a
Solution: @AB. CDEBBFDE = @4,. CDEBBFDE − H('FF,
1 (4,
@AB CD = 1 (4, − 20 <( × = 1 − 0.000197 = 0.999 (4,. (
101325 <(
Problem 9
In an evaporator, vacuum is maintained at 475 torr. Find the absolute pressure
in kPa, bar and psi.
Solution: We know that 1 "#$$ = 1 && '(
For vacuum, )*+#,-". /$.++-$. = )"& /$.++-$. − 123--& /$.++-$.
Therefore, )*+#,-". /$.++-$. = 760 − 475 = 285 && '(
1.013 *2$
285 "#$$ = 285 && '( = 285 && '(× = 0.38 *2$
760 && '(
101.3 >?2
285 "#$$ = 285 && '( = 285 && '(× = 37.98 >?2
760 && '(
14.696 /+A
285 "#$$ = 285 && '( = 285 && '(× = 5.51 /+A
760 && '(
Problem 10
Volumetric flow rate of kerosene in an 80 mm nominal diameter pipe is 75
imperial gallon/min. Taking density of kerosene as 0.8 kg/dm3, find the mass
flow rate in kg/s.
Solution:
./0012 ./0012 1 38 108 >38 1 342 >38
75 = 75 × × 8 × = 5.683
342 342 219.96 ./0012 13 60 ? ?
Given: B = 0.8 D.⁄>38
D.
E/?? F01G H/IJ = K10L3JIH4M F01G H/IJ × NJ2?4IO = 5.683 × 0.8 = 4.546
?
Thank you
