Tie susvect annexune(s) | PAGES HOURS chemical Process Design Piles 9 Age s cove pate marks | 1000 © P0330 & CPOS00S s7enwary20r1 | 190 | 190° — ‘ Cape Peninsula University of Technology FACULTY OF ENGINEERING DEPARTMENT OF CHEMICAL ENGINEERING: CAPE TOWN CAMPUS Course: National Diploma: Chemical Engineering FINAL ASSESSMENT: SEMESTER TWO EXAMINER MODERATOR (INTERNAL) MODERATOR (EXTERNAL) SPECIAL INSTRUCTIONS 2 Answer ALL questions 3 Place Answer Sheet inside the Script whn handing in. 3 Calculator ae alowed REQUIREMENTS + ANSWER BOOKS + GRAPH PAPER + CALCULATORS + ANNEXURE A: 2 ANNEXURE 8: DO NOT TURN THE PAGE BEFORE THE STARTING TIMEPage 1 of § pages ‘Chemical Process Design 3 (cPps30¢ a cPD3008) 4.1. Give any 5 reasons why a plant would require retrofitting io} 1.2. Give four strategies for reducing isk 4 1.3. Explain what a heat exchanger network for maximum energy recovery implies with regard to capital cost, energy cost, and environmental cost 8 1.4 a) What do the abbreviation LDss and TLV stand for? fa |) b) What type of hazard are the terms associated with? ra 1.5 a) Define fixed capital cost and working capital cost and give one [4] ‘examples of each, | b) Between fixed capital cost and working capital cost, state which one of the two is usually recovered atthe end of a project. 2 ‘Question 2: Process Analysis (20 Marks) The simplified block diagram showing the basic steps for the production of hydrogen from natural gas is shown in Annexure 2. ‘The sour gas fed into the desulphuriser has the following composition: 83% CH, 10% COs, 5% 2% other S compounds The following reactions occur in the given reactors: Reformer CH, +H,04C0+3H, 4H= 208 KuMole CO+11,06C0.+H, — AH= 42 KJIMole Water-gas shift CO41,0.6 CO, +H, ‘AH = -42 KuiMolePage 2 of 5 pages Chemical Process Design 3 (cPo330¢ 8 cPD3005) hanstor CO-#3H, © CH, +H,0 AH =-205 K/Mole CO, +4H, ¢» CH, +20 aH = 169 Ki/Mole ‘and all reactors are filed with catalysts. Using the given information and the reactions equations, answor the following |} questions: 2.1. What compounds constitute streams § and 137 co} 2.2 Whatis the function ofthe desulphurizer and why do you think tis important? [4] 2.3 Why ie mono-ethanolamine (MEA) used in the CO, absorption-strpper system? a 2.4 What's the main function of the wator gas shift reactor? a 2.5. The main reaction in the reformer is endothermic with the energy required being obtained by buming fuel. A recent innovation has been to ad air into the reformer (auto-thermal reforming) to parialy combust the methane according tothe folowing reaction: 150 Ku/Mole CH, +050, »CO+2H, Provide a concise explanation of how you think this innovation affects the fuel consumption of the reformer? i) 2.6 Why oxygen isnot fed in excess? 2Page 3 of 5 pages ‘Chemical Process Design 3 (cPp330¢ & cPD3008) Consider the process flow sheet shown below, whero the dulies required for each hheat exchanger are given in MW: 13.4. The flow sheet calls for 990 MW to be removed by cooling water and 750 MW 10 be provided by steam. Its claimed that this process does not meet MER targets for ATmmn = 10°C, Verify or refute this claim using the table provided in the answer shoot 0) 3.2. Draw a plot of cost vs ATnin. Explain how capital, energy, and total cost vary With increasing ATeis and indicate on your plot where your optimum ATip Wil be located. (10)Page 4 of 5 pages Chemical Process Design 3 (cP0330C & CPD3008) Process Economics (20 Marks) 4.4 A storage tank is purged continuously with a stream of niogen. The purge stream leaving the tank Is saturated withthe product stored in the tank. A ‘major part ofthe product lst in the purge could be recovered by instaling fa scrubbing tower to absorb the product in a solvent. The recovered product and solvent could then be separated by distilation, and the solvent ‘cooled and recycled, A preliminary design of the purge recovery system hhas been made. It would consist of + An absorption column: 0.5 m diameter, 4m high, packed with 25 mm ccoramic saddles, packed height 3 m, operating pressure 2 bar. + Recovery column: diameter 1 m, vessel height 20 m, 90 sieve plates, and ‘operating pressure 1 bar. = Reboiler: forced convection type, fixed tubo sheets, area 20 m?, and ‘operating pressure 1 bar. Condenser: fixed tube sheots, area 30 m’, and operating pressure 1 bar. Recycle solvent cooler: U-tubes, area 10 m, and operating pressure 6 bar. ‘+ Assmall storage tank forthe solution, 5 m® capacity and cone roc. 1+ The necessary pipe work, pump, and instrumentation All materials of construction are carbon steel. ‘Assume the working capital to bo 5% of the fixed capital Investment. Use the CGetaled Factorial method to wsliniale Une tolal capital investment required for this project in Rands (ZAR) for the year 2003, Assume the currency conversion for 2003 as £1 = R145, (Do your calculations to the nearest Rand ie. No decimal places). |] Note: The data given are for 1998, 119) 4.2. Draw a fully labelod typical cumulative cash flow diagram which shows the ‘cumulative cash flow during the life of a project. ro)Page $ of 5 pages Chemical Process Design 3 (ePps30¢ 8 cPD3008) Question Process Safety (10 Marks) Consider the PFD for the production of cumene (Annexure 3). Unit H-801 heats up the misture of benzene and ethylene gases from 240°C to the required temperature ‘of 350°C at the entry to the reactor. You are required to perform a HAZOP study on | the fired heater H-801 The node under analysis is the point of exit of the process stream 7 from the fired heater. ‘Complete the HAZOP table below by filing in the appropriate deviation, cause, ‘consequence and action Parameter] Guide Word] Deviation | Cause | Consequence | Action | [Composition | Other tian | 64 32 [Ss 3a Flow aie | Loss oF se |S? | 8 Flowrate [Reverso | 59 310 | a 312 10) | Total: 15asmw 95-08) ebay z prise Tepes He 0. Bo0s, Tagan [avo we aang soso | SL cs :SWYNUNS ® SWYN, “1 NWN INZONLS 1) gunaNNy:SIWYNUNS @ 3WYN AygaWNN LNaGNLS ZV aunxaNNYaus = sie zaunxannyANNEXURE 3ANNEXURE 1000. 100, 10. Equipment cost, £1000 aa ‘Shell and tube heat exchangers Time base Mid 1998 o | | 1000 Heat transter area, sqm (2) Pounds sterling Materials ‘Shel Tubes @ Carbon Ocs. Ocs. @ss. steel Carbon steel Brass Stainless sto! 33 Pressure factors 4-10 bar 10-20 20-30 30-50 50-70 10 a4 1.25 13 1000.0 Type factors Floating head Fixed tube sheet Utube Kettie 10 08 08s, 13ANNEXURE 42 Vertical pressure vessels. Time base mid-1998, ‘Time base Mid 1998 1000.0 © s000] g § 100 5 10 J 19 100 1000 Vessel height, m (2) Pounds sterling Diameter, m Material factors @-0s @-20 GS —« 10 SS. x20 @-10 O30 Mone x 34 SS. dad x15 Monel x21 clad Cost of column packing. Cost basis mid 1998 Con Elm B/mr) Size, mm 25 38 50 Saddles, stoneware 840 (1400) 620 (1020) 580 (960) Pall rings, polypropylene 650 (1080) 400. (650) 250 (400) Pall rings, stainless steel 1500 (2500) 1500 (2500) 830 (1360)ANNEXURE 4.3 10000, Cost per plate, £ Type ® Sieve @ valve Bubbie cap 1000.0} 0 ‘Column plates. Time base mid-1998 _ Time base Mid 1998 10 Plate diameter. m (@) Pound sterling Material factors CS.x10 SS.x17 Purchase cost of miscellaneous equipment, cost factors for use in equation 6-7 Cost basis mid 1998 Equipment Tanks Process vervcal fonzontat Storage Boating roof cone rool Sive Conant range ce cs capacity, a 1-50 14502400 to-100 17500 50-8000 1700 2900 50-8000 002300, Trex 0 00 ass. oss. ‘Comment atmos. pes carbon 860 x25 ferANNEXURE 4.4 PE index 410. 400 370 240. 19% 1997 1998 1999 2000 2001 2002 2003 2008 Yoar ‘Typical factors for estimation of project fixed capital cost tem Ff) Equipment erection A> Piping: Ff, Instrumentation. 4 Electrical fs Buildings. process Fo Utilities: 7) Stores ‘fa Site development Airy bings ‘Srp Design and Engineering Yar Contractor's fee Siz Contingency Process type Fluids Fluids ‘solids oa os, 030 070 05, 020 020 05, 0.10 010 0.10 0.10 os, 0.10 0.05 050 os 025 oas 020 025 ons 00s os ous 020 030 030 02s 020 005 0s 0.08 010 010 010‘Question 1 LA Any of the five: 8) To improve on energy usagev ») To cut down on pollution emission. v €) To add new technology 4) To improve on safety ané operabiliyy £8) Change of raw materialsv 1) Improve product specification eg. Purtyy 9) New productsy 1.2 Inherent, passive, active, and procedural svategieswwwv 112 Aheat exchanger network for maximum energy recovery implies: 12} Maximum capital cost o purchase the heat exchangers requiedv ') Minimum energy cost cue to maximum heat recaverywv ©) Maximum energy recovery means minimum fuel consumption and hence minimum ‘envrcrmental cost eg. pollutantsvy 4.4.8) Lethal dose 50 and Threshold Limit Valuovy b)Toxictywy 15 8) Fixed capital cost is cost incurred to supply required manufacturing and plant faites eg ining ve Working capital costs the cost incurred for the operation of the plant eg. Taxes payablevy 'b) Working capital is usually recovered at the end of a projectvy Question 2 2.41 Stream 5: CH, CO, CO, Hz, HsOvvwww ‘Stream 13: CH, Hs0, COpvw 2.2 The desulluriser removes all the HeS and sulfur compounds from the sour gas. tis an important process because suifur poisons the catalysts used in the reactor, thus ithas to be removed before the feed gas enter the reformer.wvwv 2.3 MEA Is used because CO>s highly soluble init. vw2.4 The main function of the water gas shift reactor Is to conver all he carbon monoxide to carbon ‘oxide and water. vwv 25 This innovation decreases the fuel consumption. The reason for this decrease Is thatthe paral ‘combustion of methane is an exothermic process, thus the energy needed forthe endothermic reforming reaction is therefore obtained from the heat given ff during the partial combustion of methane. vwvy 26 Orygen isnot fed in excess because feeding itn excess will promote the complete combustion of ‘methane. vv ‘Question 3 32 ww Cost oO @ atnin Optimum Capital cost decreases with increasing AT», because with increasing STanless energy is recovered, thus moaning loss heat exchangers are needed and hence the capital costs less.vv Energy cost increases with increasing ATww because with increasing ATme less energy is recovered meaning more utlly has tobe used to recover the required energy. vv Toa ost wih increasing ATx Because with increasing ATan 8s enray recovered tho mearang aes capital cost reued ad hence les il cost required. Tr 16 located where total cost is minimum, Question 4 4a ‘Absorption column: Bare vessel cost: £ 3,700vI2(cost: £3,700 1x £37002 coe Volume of packing: 22°, = 0:5) (5) wa. vi2 4 ‘Cost of packing :( £ 840/m*) (0.59m’ Total cost: £3,700 + £ 496 = £ 4.19602 ‘Recovery column are vessel cost: £16,7500/2 Cost: £16,750 1X1 =£ 16750v2 Cost of 1 plate: £ 100v72 Total cost of plate: £ 100% 30 = € 3.000912 Total cost of column = £16,750 +€ 3,000 = © 19,750v72 Reboior £ 4960/2 Bare vessel cost: £ 6,000v/2 Cost: £6,000 x 1X 0.8=£ 4,8000/2 Condenser Bare cost: £8,000v/2 Cost: £ 8,000 x 1X. Sooler Bare cost: £3,500v/2 Cost: £ 3500 X 1 X0.85= £2,975v/2 ‘Storage tank Cost = 1400 (5) = £3,999u/2 6400/2 ‘sorption column Recovery cotann Condenser Coote Storage tank ‘Tol PCE, Eaiswvi2 PPC =£41,514(140.4+0.7 +0.2+0.1) = £99,634vFixed capital = £99,634 (1 + 03+ 0.1 139,488" Working capital = € 199,488 X 0.05 = £ 6,974v Cost index in 1998 = 3800/2 Cost index in 2003 = 401v/2 Costin 2003 = £ 148,462 (401/380) = £ 150,980 a2‘Guide Word | Deviation | Cause ‘Consequence | Action ‘Composition | Oiherthan | $:7.The | 52. Pipa ‘33. Combustion — | 5 stall process fds | rapture in fred | gases may ignite in | safety alarm | Completely | heater causing | the fired heater, | that switches replaced | Combustion | causing explosion. | off uel by adiferent | gases to flow in |v suppl to the ‘hiv hater. heater. v Flow rate | Tass 35. The flow | 56, Pipeleak | 57. 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