Chapter 1 EOC Problems

1. What are the three principle types of diagrams used by process engineers to
describe the flow of chemicals in a process? On which of these diagrams
would you expect to see the following items?
a. Temperature and pressure of a process stream: PFD
b. Overview of a multiple-unit process: BFD
c. Major Control Loop: PFD
d. Pressure Indicator: P&ID
e. Pressure-relief valve: P&ID
2. A problem has occurred in the measuring element of a level-indicating
controller in a batch reactor. To what principle diagram should you refer in
order to troubleshoot the problem? P&ID
3. Why is it important for a process engineer to be able to review a threedimensional model (actual or virtual/electronic) of the plant prior to the
construction phase of a project? To check for clearance, accessibility, layout
of equipment, piping, and instrumentation
4. Name five things that would affect the locations of different pieces of
equipment when determining the layout of equipment in a process unit.
a. Clearance for tube bundle removal on a heat exchanger
b. NPSH on a pump-affects the vertical separation of feed vessel and
pump inlet
c. Accessibility of an instrument for an operator
d. Separation between equipment for safety reasons
e. Crane access for removing equipment
f. Vertical position of equipment to allow for gravity flow of liquid
g. Hydrostatic head for thermosiphon reboiler-affects height of column
skirt
5. Why are accurate plant models (made of plastic parts) no longer made as
part of the design process? What function did these models play and how is
this function now achieved? No longer made because they are too expensive
and difficult to change/revise. The models have been replaced with virtual/Emodel using CAD. They allow revision of critical equipment and instrument
placement to ensure access, operability, and safety
6. In the context of process modeling tools, what does OTS and ITS stand for?
OTS-Operator Training Simulation; ITS-Immersive Training Simulation
7. What is augment reality? Give one example of it.
8. There are two common reasons for elevating the bottom of a tower by means
of skirt. One is to provide enough NPSH for the bottoms product pump to
avoid cavitation. What is the other reason? Provide enough hydrostatic head
driving force to operate a thermosiphon reboiler
9. What is the purpose of a pipe rack in a chemical process? Provides a clear
path for piping within and between processes. It keeps piping off the ground
to eliminate tripping hazards and elevates it above roads to allow vehicle
access
10.When would a structure-mounted vertical plant layout arrangement be
preferred over a grade-mounted, horizontal, in-line arrangement? When land
is at a premium and the process must have a small foot print. The

disadvantage is that it is more costly because of the additional structural

steel
11.Which of the principle diagrams should be used to do the following?
a. Number of trays in distillation column? PFD
b. Determine top and bottom temperatures in a distillation column? PFD
c. Validate the overall material balance for a process? PFD
d. Check the instrumentation for a given piece of equipment in a prestart-up review? P&ID
e. Determine the overall material balance for a whole chemical plant? All
BFD or PFD
12.A process that is being considered for construction has been through several
technical reviews; block flow, process flow, and piping and instrumentation
diagrams are available for the process. Explain the changes that would have
to be made to the following three principal diagrams if during a final
preconstruction review, the following changes were made:
a. The efficiency of a fired heater has been specified incorrectly as 92%
instead of 82%. PFD
b. It has been decided to add a second (backup) drive for an existing
compressor. P&ID
c. The locations of several control valves have been changed to allow for
better operator access. Plant Layout and Elevation
d. Pipes located at ground level present a tripping hazard. Pipe
isometrics
13.Explain how each of the following statements might affect the layout of
process equipment
a. A specific pump requires a large NPSH. Equipment should be elevated
above pump to allow enough NPSH for pump
b. The flow of liquid from an overhead condenser to the reflux drum is
gravity driven. Flow by gravity so condenser should be elevated above
reflux drum
c. Pumps and control valves should be located for easy access and
maintenance. Should be located for easy access on ground or on
accessible platforms
d. Shell-and-tube exchanges may require periodic cleaning and tube
bundle replacement. Should have enough space for cleaning and
replacement of bundle and crane movement
e.
14.

a.
b.
c.
d.
e.

PI
TR
Pressure Indicator
Temperature Recorder
Flow Indicator Controller
Level Alarm High
Pressure Alarm Low

FIC

LAH

PAL

15.

TI

PR

LIC

FAH

TAL

PAL

a.
b.
c.
d.
e.

Temperature Indicator
Pressure Recorder (panel)
Level Indicator Control
Flow Alarm High (panel)
Temperature Alarm Low

Chapter 2 EOC Problems

1.

2.

3.

4.

5.

What are the five elements of the hierarchy of process design?

a. Batch or Continuous Process
b. Input-Output structure of Process
c. Recycle structure of process
d. General separation structure of process
e. Heat-exchanger network/process energy recover
What are the three types of recycle structures possible in a chemical process?
Explain when each is used.
a. Separate/purify unreacted feed and recycle-use when separation is
feasible
b. Recycle without separation but with purge-when separation of unused
reactants is infeasible/uneconomic. Purge is needed to stop build up of
product or inerts.
c. Recycle without separation or purge-product/byproduct must react further
through equilibrium reaction
Give three criteria for choosing a batch process as opposed to a continuous
process.
a. Small quantities required
b. Batch-to-batch accountabilities required
c. Seasonal demand for product or feed stock availability
d. Need to product multiple products using the same equipment
e. Slow reactions
f. High equipment fouling
g.
When would one purposely add an inert material to a feed stream? Illustrate this
strategy with an example, and explain the advantages (and disadvantages) of
doing this. Steam added to catalytic reaction using hydrocarbon feeds to provide
energy for the desired endothermic reaction and to force the equilibrium towards
styrene product.
In general, when would one purify a material prior to feeding it to a process unit?
Give at least one example for each case you state.
a. If the impurity foul or poison a catalyst used in the process. Remove trace
sulfur compounds in natural gas prior to sending them to the steam
reforming reactor to produce hydrogen
b. If impurities react to form difficult-to-separate or hazardous
products/byproducts. (Production of isocyanates using phosgene. CO is
formed via steam reforming of CH4 to give CO and H2. H2 must be
removed from CO prior to reaction with CL2 to form HCL)
c. Impurity is present in large quantities it may be better to remove the
impurity than having to size all the down stream equipment to handle the
large flow of the inert material. (Suing oxygen rather than air to fire a
combustion. Removing nitrogen reduces equipment size)

6. Pharmaceutical products are manufactured using batch process because:

a. they are usually required in small quantities
b. batch-to-batch accountability and tracking are required by the Food & Drug

Administration (FDA)
c. usually standardized equipment is used for many pharmaceutical products
and campaigns are run to produce each product this lends itself to batch
operation.

Chapter 6 EOC Problems

1. State two common criteria for setting the pressure of a distillation column.
a. Set based on the pressure required to condense the overhead steam
using cooling water
b. Set based on highest temperature of bottom product that avoids
decomposition or reaction
c. Set based on available highest hot utility for reboiler
2. Suggest two reasons each why distillation columns are run above or below
the ambient pressure.
Run a distillation column above ambient pressure because:
a. The components to be distilled have very high vapor pressures (very
light components) and the temperatures at which they can be
condensed at or below ambient pressure are <T cooling water. Thus,
we run the column at high pressure to avoid the use of refrigeration in
the condenser
b. The size of the column (diameter) reduces at the pressure decreases.
Although the separation is usually more difficult at higher pressures, it
may be more cost effective to run the column at or above atmospheric
pressure
Run a distillation column below ambient pressure
a. The components requiring separation have very low vapor pressures
(very heavy components) and if distilled at ambient pressure would
require excessively high temperatures to reboil
b. For thermally sensitive materials, e.g. foods, pharmaceuticals, and
some organics, the bottom temperature in an atmospheric column
might cause the material to decompose or react. For such systems, the
pressure is reduced below atmospheric to a point where the bottom
temperature does not cause thermal degradation of the product.
3. Suggest two reasons why reactors are run at elevated pressures and/or
temperatures.
Run reactions at elevated temperature because
a. The rate of reaction rate is faster. This results in a smaller reactor
and/or higher single-pass conversion
b. The reaction is endothermic and equilibrium limited and increasing the
temperature shifts the equilibrium to the right
Run reaction at elevated pressure because
c. The reaction is gas phase and the concentration and hence rate is
increased as the pressure is increased. This results in a smaller reactor
and/or higher conversion
d. The reaction is equilibrium limited and there are fewer product moles
than reactant moles. An increase in pressure shifts the equilibrium to
the right.
4. Give two reasons why operation of a process at greater than 250C is
undesirable. Give one reason each why one would operate a distillation
column and a reactor at a temperature greater than 250C.
a. In order to heat the streams to that temperature the use of a fired
heater is required, which is expensive
b. At temperatures in excess of 400C process equipment may require
more expensive materials of constructions

c. Examples for doing this for a reactor are to: increase the reaction rate
or improve equilibrium for an endothermic reactor. An example for
doing this for a distillation column is: to provide a vapor-liquid system
for a heavy (high boiling point) component
5. Define a condition of special concern. Define two such conditions, and state
one possible justification for each. A condition of special concern is a
process condition that deviates from an ideal or low-cost operating
conditions. Operating at pressures outside the range of 1-10 atm or
temperatures outside of the range 45-250C/4000C are examples of conditions
of special concern. Justification for operating at high temperatures and
pressure might be to increase the rate of a desired reaction.
6. In the food and drug industries, many processes used to produce new active
ingredients (drugs) or to separate and purify drugs and foods occur at
vacuum conditions and often at low temperatures (less than room
temperature). What is it about these types of products that requires that
these conditions of special concern be used? Many of these products are
thermally liable meaning that they degrade at quite low temperatures. The
use of vacuum conditions allows vapor-liquid equilibrium and vapor0solid
equilibrium (freeze drying or lyophilization) to occur at temperatures below
which thermal degradation occurs.
7. For the separation of a binary mixture in a distillation column, what will be
the effect of an increase in column pressure on the following variables?
a. Tendency to flood at a fixed reflux ratio. Will decrease because the
density of vapor will increase and hence the superficial velocity in the
tower will decrease thus moving away from flooding
b. Reflux ratio for a given top and bottom purity at a constant number of
stages. Will increase with pressure. This is because as pressure
increases, the separation becomes more difficult and the equilibrium
line moves closer to the xy line. The only way to compensate is
therefore to increase the reflux ration that in turn increases the internal
flows in the column-hence the vapor flow and velocity will increase and
move the column towards flooding.
c. Number of stages required for a given top and bottom purity at
constant reflux ratio. The number of stages will increase with pressure
for the same reason given in (b) above.
d. Overhead condenser temperature. As pressure increases, the condenser
temperature will increase- this is consistent with Antoines equation
that as temperature increases so does the vapor pressure.