When Things Go Wrong

William Josephson A.U. Chem. Eng. Jaya Krishnagopalan T.U. Chem. Eng. Dave Mills A.U. Chem. Eng.

2007 AIChE Annual Meeting Salt Lake City, Utah

Outline &
4 Experiments

Conduction Reynolds Number Friction factor Viscosity

What should occur What did occur Why it happened What was learned

For Each Experiment

Motivation

Conduction Heat Transfer

Objectives

To investigate Fouriers Law for the linear conduction of heat along a simple brass bar To determine the average thermal conductivity of brass in the temperature range studied To observe the effect of temperature on the thermal conductivity of brass in the range studied

Conduction Heat Transfer Apparatus

Conduction Heat Transfer

Conduction Heat Transfer

Conduction Experiment - Ideal Case
120 100

Temperature

80 60 40 20 0 0 10 20 30 40 Position 50 60 70 80

Conduction Heat Transfer

Conduction Experiment - Thermocouple Error
120 100

Temperature

80 60 40 20 0 0 10 20 30 40 Position 50 60 70 80

Conduction Heat Transfer

Conduction Experiment - Thermocouple Error plus T discrepancy across gaps
120 100

Temperature

80 60 40 20 0 0 10 20 30 40 Position 50 60 70 80

Conduction Heat Transfer

Told students of problem Let them devise workaround Most students made use of knowledge of sample material calculated 3 conductivities eliminated bad thermocouple

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Reynolds Number

Objectives

Compute Reynolds number Observe and quantify transitional flow

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Reynolds Number Apparatus

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Reynolds Number - Ideal Results

Re 500 Observations Parallel streamlines laminar flow

1000
1500 2000 2500

Laminar
Laminar Laminar Parallel & interacting streamlines transient flow

3000
3500 4000 4500 5000

Interacting streamlines - turbulent flow

Turbulent Turbulent Turbulent Turbulent

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Reynolds Number
The Problem

Mixing of streamlines at Re = 700 Occurred for all groups

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Reynolds Number Expected Reported Results

Re 500 600 650 700 800 1000 2000 3000 4000 5000 Observations Parallel streamlines laminar flow Laminar Parallel & interacting streamlines transient flow Turbulent flow Turbulent Turbulent Turbulent Turbulent Turbulent Turbulent
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Reynolds Number Actual Reported Results

Re 500 600 650 700 800 1000 2000 3000 4000 5000 Observations Parallel streamlines laminar flow Laminar Parallel & interacting streamlines laminar flow Interacting streamlines - laminar flow Interacting streamlines - laminar flow Interacting streamlines - laminar flow Interacting streamlines - laminar flow Interacting streamlines - transient flow Interacting streamlines - turbulent flow Turbulent

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Reynolds Number
Cause of the Problem (physical)
Nozzle at end of dye introduction pipe

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Reynolds Number
Cause of the Problem (mental)
Poor wording in handout: If the Reynolds number is less than 2100, the flow is considered laminar. If the Reynolds number is greater than 4000, the flow is considered turbulent.

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Piping

Objectives

To determine relationship between friction factor and Reynolds Number & roughness Friction losses in fittings (globe valve, elbows) Orifice meter

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Piping Apparatus
Direction of Flow

Pipe A

Pipe B Pipe C

Pipe D

Pipe E

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Piping What we want them to do

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Piping What we get (sometimes)

Fanning Friction Factor versus Reynolds Number
0.1 1000 10000 100000 1000000

Fanning Friction Factor, f

0.01

Pipe A Pipe B Pipe C Pipe D Pipe E

0.001

0.0001

Reynolds Number, NRe

Important! This is not the problem

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Piping What we get (other times)

0.01

Fanning Friction Factor

D - 29.0 E-04 E - 3.7 E-04 C - 2.9 E-04 B - 2.1 E-04 A - 1.6 E-04

0.001 10000 Re

100000

Important! This is the problem

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Piping

The Problem friction factors for SS Pipe below those of PVC Consideration of the Problem

Recheck the numbers A Lie in the handout?? (e.g., wrong info re pipe size) Deeper Thoughts is this an issue w/ the SS pipe or the PVC pipes? Or both?

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Viscosity

Objectives

To investigate rheology of several liquids

Confirm Newtonian fluids Determine if shear-thickening, shear-thinning or something else Temperature effect on a Newtonian fluid

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Viscosity

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Viscosity Apparatus

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Viscosity Ketchup Results

250000 200000

Viscosity (cP)

150000 100000 50000 0 0 -50000 Shear Rate (RPM) 10 20 30 40 50 60 70

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Viscosity Corn Starch Results

Cornstarch
2000 1800 1600

Viscosity (cP)

1400 1200 1000 800 600 400 200 0 0 0.5 1 1.5 2 2.5 3 3.5

Speed (RPM)
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Corn Starch Viscosity

The Problem data indicates shear thinning Consideration of the Problem

Recheck the numbers Try different concentrations Is corn starch really shear thickening?

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Corn Starch Viscosity

Is it really shear thickening??

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Corn Starch Viscosity

Consideration of the Problem (cont.)

Observe operation of viscometer esp. spindle interactions w/ fluid closely read literature

The Answer (& the solution)

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Viscosity Corn Starch Results w/ Vane

200 195 190 185

Viscosity (cP)

180 175 170 165 160 155 150 0 10 20 30 40 50 60

RPM

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What Went Wrong & What Happened

Conductivity Bad Sensor, students were told a priori Students derived workaround Reynolds Number Physical Setup Students re-examined their thinking (as did the instructor!) Piping Arguably, nothing went wrong Students have to think Viscosity Improper equipment Students had to think & observe

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A Sincere Thank You

To the students in CENG 320 Unit Operations Laboratory I T.U. & CHEN 3820 Chemical Engineering Laboratory I A.U.

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