Republic of the Philippines

BATANGAS STATE UNIVERSITY

The National Engineering University
Alangilan Campus
Golden Country Homes, Alangilan Batangas City, Batangas, Philippines 4200
Tel Nos.: (+63 43) 425-0139 local 2121 / 2221
E-mail Address: ceafa@g.batstate-u.edu.ph | Website Address: http://www.batstate-u.edu.ph

College of Engineering
Department of Chemical Engineering
Problem Set 1 | ChE 409 (2022-2023) | SEMESTER:
1ST

Directions: For your practice, try solving each problem. The answers are written in red after the question.
You are required to answer numbers 10 for Heat Exchangers, 3 and 10 for Evaporators, and 8 for
Crystallizers in an 8.5” x 11” Paper, typewritten. Submission is on Oct. 14, 2022.

HEAT EXCHANGERS

1. [G.G. Brown] The overall coefficient for a clean lean oil cooler with 1-in 16-gauge tubes is computed to be
260 BTU/hr·(ft2)OD·°F. Treated cooling water is used in the exchanger at 4 fps and leaves at 95°F. What
overall coefficient should be used for sizing the oil cooler? (143 BTU/hr·(ft2)OD·°F)

2. [McCabe] Methyl alcohol flowing in the inner pipe of a double-pipe exchanger is cooled with water
flowing in the jacket. The inner pipe is made from 1-in (25-mm) Sch 40 steel pipe. The thermal
conductivity of steel is 26 BTU/hr·ft·°F (45 W/m·K). The individual coefficients and fouling factors are
given below. What is the overall coefficient, based on the outside area of the inner pipe? (71.3
BTU/hr·(ft2)OD·°F)

3. [D. Prieve] A steel mill is considered whether to spare heat-exchanger will be able to cool off 3000 gal/hr
of a dilute acid from 250°F to 180°F using 5000 gal/hr of 80°F river water. You are asked to estimate: a)
the true-mean driving force, ∆Tm, and b) the shell-side coefficient, ℎ𝑜. (110°F, 363 BTU/hr·ft2·°F)

Description of available heat exchanger:

Type: 1-2
Tubes: 158-in, 14 BWG stainless tubes, 16 ft. long, stacked in 1.25 in square pitch Baffles: 25%
with 6 in pitch
Shell: 20 in inside diameter, mild steel

4. [Holman] A counterflow double-pipe heat exchanger operates with hot water flowing inside the inner pipe
and a polymer fluid flowing in the annular space between the two pipes. The water-flow rate is 2.0 kg/s and
it enters at a temperature of 90°C. The polymer enters at a temperature of 10°C and leaves at a temperature
of 50°C while the water leaves the exchanger at a temperature of 60°C. Calculate the value of the overall heat-
transfer coefficient expressed in W/m2·°C if the area for the heat exchanger is 20 m2. (282 W/m2·°C)

5. [Holman] Water at the rate of 230 kg/h at 35°C is available for use as a coolant in a double-pipe heat
exchanger whose total surface area is 1.4 m2. The water is to be used to cool oil [cp = 2.1 kJ/kg·°C] from an
initial temperature of 120°C. Because of other circumstances, an exit water temperature greater than 99°C
cannot be allowed. The exit temperature of the oil must not be below 60°C. The overall heat-transfer
coefficient is 280 W/m2·°C. Estimate the maximum flow rate of oil that may be cooled, assuming the flow
rate of water is fixed at 230 kg/h. (107.2°C)

6. [Holman] A small shell-and-tube exchanger with one tube pass [A = 4.64 m2 and U = 280 W/m2·°C] is to
be used to heat high-pressure water initially at 20°C with hot air initially at 260°C. If the exit water
temperature is not to exceed 93°C and the airflow rate is 0.45 kg/s, calculate the water-flow rate. (0.32 kg/s)

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7. [Holman] A shell-and-tube exchanger with one shell pass and two tube passes is used as a water- to-water
heat-transfer system with the hot fluid in the shell side. The hot water is cooled from 90 to 70°C, and the
cool fluid is heated from 5 to 60°C. Calculate the surface area for a heat transfer of 60 kW and a heat-
transfer coefficient of 1100 W/m2·°C. (1.49 m2)

8. [Holman] A cross-flow heat exchanger employs water in the tubes with h = 3000 W/m 2·°C and airflow
across the tubes with h = 190 W/m 2·°C. If the tube wall is copper having a thickness of 0.8 mm and outside
diameter of 25 mm, calculate the overall heat-transfer coefficient based on inside tube area. (190 W/m2·°C)

9. [Holman] A shell-and-tube heat exchanger employs a liquid in the shell that is heated from 30◦C to 55◦C by a
hot gas in the tubes that is cooled from 100◦C to 60◦C. Calculate the effectiveness of the heat exchanger.
(0.571)

10. A process simulation is given below where stream 1 enters the heat exchanger and leaves as stream 2. The
flow is parallel. Find the LMTD and the product of the area and overall-heat transfer coefficient. (32.37°C,
15446.40 W/K)
 Republic of the Philippines
BATANGAS STATE UNIVERSITY
The National Engineering University
Alangilan Campus
Golden Country Homes, Alangilan Batangas City, Batangas, Philippines 4200
Tel Nos.: (+63 43) 425-0139 local 2121 / 2221
E-mail Address: ceafa@g.batstate-u.edu.ph | Website Address: http://www.batstate-u.edu.ph

College of Engineering

EVAPORATORS

1. [Geankoplis] A feed of 4535 kg/hr of a 2.0 wt% salt solution at 311 K enters continuously a single- effect
evaporator and is being concentrated to 3.0%. The evaporation is at atmospheric pressure and the area of
the evaporator is 69.7 m2. Saturated steam at 383.2 K is suppled for heating. Since the solution is dilute, it
can be assumed to have the same boiling point as water. The heat capacity of the feed can be taken as cp =
4.10 kJ/kg·K. Calculate the overall heat-transfer coefficient U. (183 W/m2·K)

2. [Geankoplis] Using the same area of U, steam pressure, evaporator pressure, and feed temperature as in
Problem 1, calculate the amounts of liquid and vapor leaving and the liquid outlet concentration if the feed
rate is increased to 6804 kg/hr. (V = 1256 kg/hr, L = 5548 kg/hr, xL = 2.45%)

3. [Geankoplis] Determine the boiling point temperature of the solution and the BPR of the following case: A
30% NaOH solution boiling in an evaporator at a pressure of 172.4 kPa. (BPt. = 130.6°C, BPR = 15°C)

4. [Geankoplis] A single-effect evaporator is concentrating a feed at 9072 kg/hr of a 10 wt% solution of a

NaOH in water to a product of 50% solids. The pressure of the saturated steam used is 42 kPag and the
pressure in the vapor space of the evaporator is 20 kPa. The overall heat-transfer coefficient is 1988 W/m2K.
Calculate the steam used, the steam economy in kg V/kg S, and the area for a feed temperature of 288.8 K.
(S = 8959 kg/hr steam, V/S = ? A = 295.4 m2)

5. [Geankpolis] A triple-effect evaporator with forward feed is evaporating a sugar solution with negligible
boiling-point rise (less than 1.0 K) and containing 5 wt% solids to 25% solids. Saturated steam at 205 kPa
abs is being used. The pressure in the vapor space of the third effect is 13.65 kPa. The feed rate is 22,680
kg/hr and the temperature 299.9 K. The liquid heat capacity is cp =
4.19 – 2.35𝑥, where cp is in kJ/kg·K and 𝑥 in wt fraction. The heat-transfer coefficients are 𝑈1 = 3123, 𝑈2 =
1987, and 𝑈3 = 1136 W/m2·K. Calculate the surface area of each effect if each effect has the same area, and
the steam rate. (A = 99.1 m2, S = 8972 kg/hr)

6. [Geankoplis] A feed containing 2 wt% dissolved organic solids in water is fed to a double-effect evaporator
with reverse feed. The feed enters at 100°F and is concentrated to 25% solids. The BPR can be considered
negligible as well as the heat of solution. Each evaporator has 1000-ft 2 surface area, and the heat-transfer
coefficients are 𝑈1 = 500 and 𝑈2 = 700 BTU/hr·ft2·°F. The feed enters evaporator number 2 and steam at
100 psia is fed to number 1. The pressure in the vapor space of evaporator number 2 is 0.98 psia. Assume
that the heat capacity of all liquid solutions is that of liquid water. Calculate the feed rate 𝐹 and the product
rate 𝐿1 of a solution containing 25% solids. (F = 133800 lbm/hr, L1 = 10700 lbm/hr)

7. [Geankoplis] The concentration of NaOH solution leaving the third effect of a triple effect evaporator is 50
wt%., The vapor flow rate leaving is 5670 kg/hr and this vapor goes to a barometric condenser. The
discharge water from the condenser leaves at 40.5°C. Assuming that the condenser can maintain a vacuum
in the third effect corresponding to a saturated vapor pressure 2.78°C above 40.5°C, calculate the pressure
in the third effect and the cooling water flow to the condenser. The cooling water enters at 29.5°C. (Note:
The vapor leaving the evaporator will be superheated because of the BPR.) (P = 8.80 kPa abs, W = 306200
kg/hr)

8. [McCabe] A single-effect evaporator is to concentrate 20,000 lb/hr of a 20% NaOH to 50% solids. The
gauge pressure of the steam is to be 20 psi; the absolute pressure in the vapor space is to be 100 mm Hg.
The over-all coefficient is estimated to be 250 BTU/hr·ft2·°F. The feed temperature is 100°F. Calculate the
amount of steam consumed, the economy, and the heating surface required. (S = 15400 lb/hr, SE = 0.78, A
= 930 ft2)

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 9. [ChE Board Exam, May 1984] A 10% wt. NaOH at 80 °F is to be concentrated in a single effect evaporator
to 40% wt. Steam is supplied at 20 psig and the vacuum pressure of the barometric condenser is 26 in Hg.
100 gpm of water is fed to the condenser and the water leaving the condenser (including the condensate) is
at 100 °F. OHTC of evaporator is 200 BTU/h·ft 2·°F. Calculate the heating surface required for the
evaporator. (88.83 ft2)

10. Provided that saturated steam enters at 130°C, calculate the steam economy. (0.82)

CRYSTALLIZERS
1.
[ChE Series] A 20 weight % solution of Na 2SO4 at 200°F is pumped continuously to a vacuum crystallizer
from which the magma is pumped at 60°F. What is the composition of this magma, and what percentage
of Na2SO4 in the feed is recovered as Na2SO4·10H2O crystals after this magma is centrifuged? (C = 8.08%,
L = 91.91%, Rec = 17.83%)

2.
[ChE Series] A solution of 32.5% MgSO4 originally at 150°F is to be crystallized in a vacuum adiabatic
crystallizer to give a product containing 4,000 lb/h of MgSO 4·7H2O crystals from 10,000 lb/h of feed. The
solution boiling point rise is estimated at 10°F. Determine the product temperature, pressure and weight
ratio of mother liquor to crystalline product. (T = 60°F, OP = 0.18 psi, L/C = 1.32)

3.
[Che Board Exam, Jan. 1970] A plant produces 30,000 MT of anhydrous sulfate annually by crystallizing
sulfate brine at 0°C, yields of 95% and 90% in the crystallization and calcinations operations are obtained
respectively. How many metric tons of liquor are fed to the crystallizer daily? Note: 300 working days per
year. (5012.60 MT/day)

4.
[ChE Series] A Swenson-Walker crystallizer is to be used to produce 1 ton/h of copperas (FeSO4·7H2O)
crystals. The saturated solution enters the crystallizer at 120°F. The slurry leaving the crystallizer will be at
80°F. Cooling water enters the crystallizer jacket at 60°F and leaves at 70°F. It may be assumed that the U for
the crystallizer is 35 BTU/h·°F·ft2. There are 3.5 ft2 of cooling surface per ft of crystallizer length.
a) Estimate the cooling water required (52.14 gpm)
b) Determine the number of crystallizer section to be used. (7 units)
Data: specific heat of solution = 0.7 BTU/lb·°F; heat of solution = 4400 cal/gmol copperas; solubility at
120°F = 140 parts copperas/100 parts excess water; solubility at 80°F = 74 parts copperas/100 parts excess
water
 Republic of the Philippines
BATANGAS STATE UNIVERSITY
The National Engineering University
Alangilan Campus
Golden Country Homes, Alangilan Batangas City, Batangas, Philippines 4200
Tel Nos.: (+63 43) 425-0139 local 2121 / 2221
E-mail Address: ceafa@g.batstate-u.edu.ph | Website Address: http://www.batstate-
u.edu.ph

5.
[G.G. Brown] The solubility of sodium sulfate is 40 parts Na2SO4 per 100 parts of water at 30°C, and
13.5 parts at 15°C. The latent heat of crystallization (liberated when crystals form) is 18,000 g-cal per gmol
Na2SO4. Glauber’s salt (Na2SO4·10H2O) is to be made in a Swenson-Walker crystallizer by cooling a
solution, saturated at 30°C, to 15°C. Cooling water enters at 10°C and leaves at 20°C. The over-all heat
transfer coefficient in the crystallizer is 25 BTU/h·ft 2·°F and each foot of crystallizer has 3 sq ft of cooling
surface. How many 10-ft units of crystallizer will be required to produce 1 ton/h of Glauber’s Salt? (29
units)

6.
[Foust] Crystals of CaCl2·6H2O are to be obtained from a solution of 35 weight % CaCl2, 10 weight
% inert soluble impurity, and 55 weight % water in an Oslo crystallizer. The solution is fed to the
crystallizer at 100°F and receives 250 BTU/lb of feed from the external heater. Products are withdrawn
from the crystallizer at 40°F.
a.
What are the products from the crystallizer? (CaCl2·6H2O, H2O, inerts)
b.
The magma is centrifuged to a moisture content of 0.1 lb of liquid per lb of CaCl 2·6H2O crystals and
then dried in a conveyor drier. What is the purity of the final dried crystalline product? (92.01%)

7.
[ChE Series] Trisodium phosphate is to be recovered as Na 3PO4·12H2O from a 35 weight % solution originally
at 190°F by cooling and seeding in a Swenson-Walker crystallizer. From 20,000 lb/h feed, 7,000 lb/h of
product crystals in addition to the seed crystals are to be obtained. Seed crystals fed at a rate of 500 lb/h
have the following size range:

Weight Range Size Range, in

10% -0.0200 + 0.0100
20% -0.0100 + 0.0050
40% -0.0050 + 0.0025
30% -0.0025 + 0.0010

Latent heat of crystallization of trisodium phosphate is 27,500 BTU/lbmol. Specific heat for the
trisodium phosphate solution may be taken as 0.8 BTU/lb·°F.
a. Estimate the product particle size distribution.

Size Range, in Wt%

-0.0240 + 0.0140 1.41
- 0.0140 + 0.0090 5.00
- 0.0090 + 0.0065 23.99
- 0.0065 + 0.0050 69.60

b. To what temperature must the solution be cooled, and what will be the cooling duty in BTU/h? (T =
125.11°F, q = 1,508,634.74 BTU/hr)

Leading Innovations, Transforming

 8.
For every 28.5 grams of Na2CO3∙H2O, 1.5 gram impure (but soluble) substance is present. A certain amount
of this feed is sufficiently dissolved in water mixed with the recycled mother liquor to produce a saturated
solution at 30°C. It is then cooled to 10°C to produce 500 kg Na 2CO3∙10H2O with 5% of its dry weight as
adhered liquor and the remaining liquor is partly discarded and recycled. According to commercial
standards, the crystals must only contain 0.2% impurity and as dry as possible.
a. What amount of water is removed from the drying process? (21.327 kg)
b. What amount of feed is needed? (242.71 kg)
c. What is the ratio of the recycled mother liquor to that of the discarded? (7)

You may refer to the process flow diagram below.

Happy Solving!

Engr. Monroe H. de Guzman

Instructor, ChE 409