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    12 views37 pages

    Test 1

    Uploaded by

    RazzilGan
    for envi engineering review

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 37
    B. Joseph ChE 477 Fall 1998 Test 1 Time: 55 minutes Closed Book. One 8.5x11 sheet allowed 5% Bonus for neatness and clarity. There are 4 problems. Do all 4. Problem 1.( 15 paints) Cyclohexanone Process Description 10 Ibmoles/hr of fresh cyclohexanol raw material ie mixed with 10 Ibmoles/hr of recycled stream of unreacted cyclohexanol and fed to a continuous stirred tank reactor. Cyciohexanol reacts as follows: eyclohexanol{liq). ——Peyclohexanone (liq) + hydrogen (gas) cyclohexanol(liq) + cyclohexanone(liq) ——> highboiler (liq) ‘The He is removed as @ gas trom the reactor. Ine conversion ot cyclohexanol is 50% by mole. The liquid withdrawn from the reactor is fed to a flash drum where the highboiler is taken out as a liquid and most of the cyclohexanol and cyclohexanol are removed as vapor. The vapor product is fed to a distillation column where the cyclohexanone Product is removed as a distillate. The unreacted cyclohexanol is removed as the bottoms product from this distillation column. It is then split into two streams: 90% of the bottoms is recycled back to the reactor and 10% is taken off and sent to storage. (a) Draw a block flow (BFD) diagram of the process (3 points). (b) Draw a process flow diagram (PFD) using the standard equipment symbols shown in the attached figure. Label all streams and number all equipment. (6 points) (0) Draw an Aspen Simulation block diagram of the process using the standard Aspen Unit operation subroutines listed in the table. In this diagram, all streams must be labeled with stream IDs, the blocks must be labeled with block IDe and the unit subroutine used for each block must be identified also. (6 points) W Mixers and spliters Separators Flash drums ‘Approximate distillation Multistage separation (Equilbrium-based simulation) (Mass transfer simulation) Heat exchange Reactors Pampa, compressrs, and turbines Pipeline ‘Stream manipulators IXER FSPLIT SEP. SEP2 FLASH? FLASHS DsTWwU DISTL SCFRAC RADFRAC MULTIFRAC PETROFRAC ABSBR EXTRACT RATEFRAC HEATER HEATX MHEATX, RSTOIC RYIFLD RGIBBS REQUIL RCSTR RPLUG PUMP coMPR MCOMPR VALVE, PIPE PIPELINE MULT DUPL ce &) HEAT EXCHANGERS Z| —— FIRED HEATER Oo SR STORAGE TANKS fda PUMPS, TURBINES, COMPRESSORS (4) ASPEN PLUS (excluding solids-handling equipment-—see Table AV) ss Stream splitter Component separator multiple outhis ‘Component separator—two outlets ‘Two-outlt flash drums Three-outlet fash drums Winn-Underwood-Gilliland design ‘Edmster simulation Edmister simulation—complex columas ‘Two and three phases, with or without reaction Ditto—with interinked column sections Ditto—for petroteum refi Absorbers and Strippers Liquid-liquid extractors ‘Two phases—mass transfer model for staged or packed colurnns Heater or cooler ‘Two-stream heat exchanger Mulistream heat exchanger Extent of reaction specified Reaction yids specified Multiphase, chemical equilibrium ‘Two-phate, chemical equilibrium Continuous stirred tank reactor Plus-low tubular reactor Pump or hydraulic turbine Compressor or turbine Multistage compressor or turbine Control valves and pressure reducers Pressure drop in a pipe Pressure drop in a pipe Stream multiplies ‘Stream duplicator I TOWERS 02 VESSELS 288 REACTORS © rrocessivur DI vave QD rrocessoureut <> sraenununaen Ba comer vawve ©) mstromenr Fs pe (QLOBE_VALVE (MANUAL CONTROL) Figure 1.6, Symbols for buding process flow diagram Ww Problem 2 (10 points) Identify whether the following expenses are fixed capital costs, manufacturing costs or working capital costs. Fixed Capital Working Capital Cost of Manufacturing Raw Material Cost Contractor's fee paid for plant construction Land cost 4] es] so] Gales tax pald on purchase of equipment for plant 9 ‘Cost of transporting product to market &. Freight charges for delivery of equipment needed for plant construction 7. Royalty fees (Paid as % of sales each year) 8. Research and development costs ‘9. Sales tax paid on purchase of raw material 70. Construction cost for cooling tower 11. Cooling water costs 12. Cost of insulation put on steam piping 19, Labor cost for installing insulation on piping 14. Operating labor cost 15. Accounts receivable on product sales 16. Cost of building a tank to store raw materials 17. Cost of disposing waste by-product 18. Catalyst make-up charges (yearly cost) 19. Rent paid on land 20. Insurance on plant Teay off this sheet cmd Submet unth your solution Problem 3 (10 points) Attached figure shows the process flowsheet for a light gas separations unit. Estimate the annual operating labor cost required to run this plant in 1998. Use the attached table for labor cost estimates for each equipment, Additional data: a. Average operator's calary = $42,000/yr in 1903. b. Cost index table is attached. Problem 4 (15 points) ‘A.small manufacturer of pharmaceutical products currently produces its top-selling drug (SPRAIN) In a batch process. In order to meet the projected increase in sales over the next five years, the company has been considering an investment to upgrade its facility toa continuous process. The company estimates that this upgrade will require an investment of $5 milion dollars, and that the bank that they are dealing with will end them the money at an effective annual interest rate ot 10%. For the tollowing three repayment schemes, calculate the loan repayment schedule for the five years that the loan will be made. a. Repay the loan as a lump sum at the end of five years. b. Repay the loan in five equal payments at the end of each year. c. Repay the loan with 60 equal monthly payments. (Remember that the 10% p.a. is an effective annual interest rate.) Propane to Storage E-202 f “able 2.6 Values for the Chemical Engineering Plant ‘ost Index and the Marshall and Swift Equipment Cost dex from 1978 to 1996 Marshall & Swift Chemical Equipment Engineering Plant Year Cost Index Cost Index 1978 552 219 A979 a7 29 280 os 261 1981 ms 27 1982 ™ 34 1963 786 317 1984 806 33 1985 83 335 1986 7 318 1987 au 34 1988 852 38 1989 895 355 190 os 358 1991 931 361 1992 98 358 1983, 966 359 1994 93 368 1995 1028 301 1996 (mid year) 1037 382 (997 1057 ates 19938 1060 336-7 Ten E201, Bye v- 201 Depropanizer C3 Overhead C3 Rot Tower Condenser Pumps Drum g F201 Hydrocarbon Feed Problem 3 Process Equipment Evaporators 03 , | Vaporizers 05 Furnaces 05 | Fane 005 Blowers and Compressors* as, Heat Exchangers 01 Table, Opereter Require rents fey vavious uA eqspment a ® © Clohexand sh feck © Problem 1 Solutves Te Test 1 | Fart 1998 He oe Highbower —> cyclohexanone cyclohaxt To Stored Frite PRopy Fresh Feed maa FAME too sheers ~ AI Nate + EMUXeY Cckctot te Ww frock + paycte — Fsplr Uset te ptt c ohkean5 Nye % Ie. ‘6, do a. rCepiter — e.com ‘Orc ¢ ce Tze) Touser Cae p-201 Condenser oO} E2oinjg Pump O.0 (0) C3 - Rakgr Dre Oo E202 Redo. — ol Totek “SS Red, Operchs rasctact + = O54; Bshih, Bes day, B how ¢ Year Syke ony year See Seo 2 2aS™ ase spertes /yr 1 operator comm prowda = 40 hous U2 ule 1960 oe “yf Opersg Leber cost = 488 ops 942,d00 ro x : - geo er, ew 19928. foxes 03,18 2 eet, BB67_ s 199% é —— > eres, \t 1,000 75 Ics Problem a Tneestmewe = BS men lef = on Loan neferpyrent £chad& me 22 @ - a \ sos oe 6 fe = fs alin CP 4ST 14100 = %057,5srekee Ne te fe te 10 1 2 3 4 Pwd Annaty = 8 G44 (rote © 2 QE aera i Cayscon)y ° Swe R790 “Re #319987. ©) 6 ent Mmenthl, payne Compats vnonttly (lew nat eaivoten b © + yey =e Copp) le ote i fw ke l2, Le Chem 2 b OO'TS74} me (2) = 0079741 Avnunsey monty cet Ay >) Few Goppe tent = R c oo 7924) - ' (oP) “(S87 394192 6.007974) © 4AS3BR = OFS tt (eae | Peg © (05,199 /ementh yr Go rRenth: @ Joseph ChE 477 Test 1 Fall 1991 Open Text, Bound Copy of Lecture Notes Time: 55 Minutes 5K Reserved for Neatness, Clarity, etc. Problem 1 (152) Some of the coots associated with a plaut fur pruducing acetylene trom natural gas are given below. Classify each item as: a. Fixed capital cost. b. Working capital cost. e+ Operating coat. d. None of the above. Natural Gas. Steam. Steam Plane. 4, Electricity. 5. Solvent Inventory 6. Solvent Makeup. 7. Operating Labor. 8, Construction Labor. 9. Contractor's Fee for Plant Construction. 10, Real Estate Rent. 11, Real Estate Purchase. 12. Interest Payments on Borrowed Money. 13, Depreciation. 14, Royalties. 15, Waste Treatment Plant. Problem 2 (152) ‘The operating costs sccoctated with a sulfuric acid plant are given below. Fixed Capital Investment = $10 Million Working Capital $ 1 Million Annual Sales $ 5 Million/Year $ 3 Million/Year Annual Operating Coste (Excluding Depreciation) kstimated Life 10 Years Salvage Value - 0 Straight-line Method of Depreciation 1s Used. Tax Rate = 33% Compute the following: (/ix ) 1. Gross Profit. 2, Net Profit. 3. Net Profit After Tax 4. Total Cash Flow From the Project. Problem 3 (30%) An extoting pump has a book value of $0,000 and market value of $4,000. A new pump will cost $6,000, The new pump will reduce operating costs (excluding depreciation) by $500/year. The company expects 10% return on its investments after taxes. The tax rate is 332. a. Tf both the extoting pump and the new pump have a remaining 1ife of ten (10) years, should the replacement be made? Why or why not? b, IE the old pump has a life of five (5) years and the new pump has a life of ten (10) years, should a replacement be made? Why or why not? Problem 4 (252) ‘A company has $1 millim to invest. Two choices are available. Project 1, Required $700,000 total investment and will generate a cash flow of $200,000/year for five (5) years Project 2. Requires $800,000 total investment and will generate the following cash flows: Year Gash Flow 200,000 400,000 200.000 300,000 ‘The company earns an average of 10% return on its other investments. Should the company invest in any one of these projects? Which one? Why? Problem 5 (102) Aman deposits $1,000 in hie account at the bank which pays compound in~ terest (compounded daily). If at the end of one (1) year the account holds $1,060.00, what is the nominal and effective interest rates paid by the bank? SleApmn Te Test —Lrsblemt.. LONGUE Gas Cperaty Cub © Ae Stea eo . 2a Steam Plant Fe a] to SLeumces ou < 5b Solent Le Wwe b 6 6 Scent Mater CC < 2e yp lehbev ec 6 50% Crylnrcke leber Fe a Ta Coxntrechys Fee Fe a bbe Reatk Oc c hay Ree Ghee Ayer FC a fle Cutest oc e Ize PRepre oc c lye Re gets oc < |e Was Tree Part FC e Pablo a Fez = 40,000 & we - 4) oce a Sat, ~ ¥ Se00 Ryy o Op: cor _ 9 oe Zeck F/g~ = ee ° Tae a oa a Net Popa = oe % 2000 ky oats t Tax o> : 4 330 ee NP DT = £70 Kye) < Mer Cash Flo ~ (Were ar | Prev. 2 23) Capita Naat = Cesk ees 7 Meet Oetine A, Ryo = eo0s oo Se Sigs peor 2 A500 /y> Tremere < Tepes | tee = teoo re > Pere fgr ¢ Fong a | =F aoe Tances C33) - faa Jo. ao ae RET alley Fenen = #201 fae %ceso mote = soos % © vw, enpta CD See beens Cocco Life rere By Bente (cbs oe oe a Pasblem 3 4 Compare eet Bet Precet Werth Bthev weltve bo Ne Trveshe nt New. Flooo Phternekce NPW= 4300 kK) A Lake inked Cw) 4+ Seco 2S _ [ere 7 a O = =* ose) EY —— F2ce 6 Ane k Peek "a0: oe Cre te)* Ger yt = Seo e (8/81 + B3-S7 F 0-2, g Tt 20¢-Go =. 7 1067-54 & Cheoe Thterrerre 2 ohoen Preninaye, NP) iz @® Posble nO Bu nued PWleettoe Tuten (hts Va = * o60 —F toe yew ? lar = 6% @ Nomse=2 Cater nee ee 36S A+ leofesd = 4 Cex, aes An (4 byes) = Le Cie veg) Ur2 S227 re ChE 477 TEST 1 Fall 1994 B. Joseph TIME: 55 MINUTES There are 5 problems. Answer all questions. Start each problem on a new page. 5% bonus for neatness, clarity and legibility of solution Problem 1 (10 points) Consider the following process for producing cyclohexanone. Draw an Aspen+ block diagram for simulating the process. Identify and label all streams and blocks. Identify unit operation models used. Fuel > Gas (Mostly H,) Product Cyclohexanone = : LA Flash fresh F ba Separation cyclohexanol 7 Distillation Unit Recycle Cyclohexanol Liquia Purge ‘Stream Show Flowsheet Connectivity Table below: Block ‘Model Name Inlet Streams == Ouilet Streams 6) Problem (10 points) A flash block was used to remove a high boiling compound C, from low boiling compounds A and B. ‘The block diagram for the Aspen + simulation is shown below: -——_ Vapor Mostly A,B Block: Fl — FLASH 2 TT | oP 187 si Cyclohexanol (A): 24.1 Cyclohexnone (RB): 28.5 Tbmole/hr High boiler (C): 0.5 Ibmole/hr Liquid Mostly High Boiler, C In order to determine the temperature required to remove most of the high boiler, a Design Specification was added to the simulation. The design specification was set up as follows Vary: temperature of Block F1 from 0 to 1000 °F Spec: mole fraction of C in vapor stream is 1% Tolerance: +.001 ‘The simulation terminated abnormally because the design specifications failed to converge. Examine the problem specifications to determine why Aspen + cannot meet the design specifications by varying the flash teuperature, ‘Suggest how you might set up the correct design specification to calculate the temperature at which most of the C is removed in the bottoms stream and most of A and B is removed at the top in the vapor phase. @ (2B Problem 3 (10 points) Acetone (C2H¢CO) is made from Isopropanol, IPA, (C2H6CHOH) by the vapor phase catalytic reaction, GH.CHOH > C:H.CO +H: (96% conversion) Reaction is carried at 570 °F, 1 atm. It is desired to design a plant to manufacture 50 Ibmole/hr of acetone. Assume plant operates 340 days/year. Raw material used is an azeotropic mixture of 70 mole % IPA and 30 mole % water. Water is an acceptable impurity in the reactor. Costs Raw material (70% IPA, 30% H20) = $10.08/bmole of mixture Acetone = $15.66/lbmole Hydrogen = $ 08/bmole Water = negligible cost (@) Draw an inpuvoutput structure of the flow sheet. Show the flow of all material into and out of the blackbox representing the plant (in Ibmoles/hr). (b) Calcutate the economic potential of the plant in $/year assuming all of the unreacted IPA is recycled back to the reactor. Problem 4 ‘The following mixture is to be separated into pure components using distillation: NBP.*C Mole Flow © Xylene 144 30 Benzene 80 30 Tuluene 110 30 Using the Heuristic Rules of Nodgir and Liu, synthesize a distillation sequence to produce nearly pure Benzene, Tolene and O-xylene. Show a schematic of the synthesized flowsheet. Explain clearly how you arrived at your sequence. All components are equally corrosive and hazardous, Problem 5 (10 points) A process has the following heating and cooling requirement Stream Inlet‘E Outlet “F kot F 200 100 50 B 100 200 40 Assume a minimum approach temperature of 10 "F. What are the minimum heating and cooling tility requirements for this system? (tis not necessary to use temperature intervals diagram for solving this problem, although you may do so.) Fete ay @) - Solehe so ater | Problem 4 RECYCLE 5B blecks QW vcens Conn echuty Lester Outer Ma Mocegm Feed Reed Recycag a Reste Recep REPO Gz) Porshe “POD ae UQ pt RADPARL ue DisT pot i sh SPLIT Bot feeng Pok- @ —Peblen 2 Tha ole Aapcchinn 4 a. nw0&4 9 CONE BOC IEAM | Uleen ley \rRan lh Leper Pe Speeket ote dren SBP te hy Reccron Jye ow fGe Up eG 7. Weree ee ; Carne be met. (cannA> —— Ke belie cme rn a b heey IMA. recov AL a Ne —— Stace wn ov acini ten. Spec : méble rece a Ay Beet Hn aq %, va my PGI bap @ __Prvlern 2 The denen Spec conn’ be met becassze the milefraction sf Cin TH Eko only = _os 24)-+ 285408 = O.0CAAL = ONEK Even at ate Renee = veporipet by ars. tRe ce nyperaburs » the mele lyactien can ony ogk te SE, rn Reblen 3 > K yrange n Sb Oboe nr oS EV BD OSe~ Michie bo Arvada), Meabee 1 se Lorde ppp a ZY Borratafe HD 5 wt TG» D1 Lord Ws0 Free stotchio mel SD \hmele s f ae Reels. Pores Se Boreas A, EP A Were ba ~ Sv Unks. BO ide Hee = ZO reste TR = Qe Lerede fox Ryyetorogen (Provcect = 8 Sd Lode noe ch Cerne Wend Ege oon cos ies Lice? = olan + SOx O08 . Seeseesr /hs ~ B40 x24 bes cc) steer : = meee Cw es Prblenn 4 Mas dou ar cee 220 Benzere oe tol® S20 “Buene lic 3 S| Z03q O-rpbene lag? + 1 CES = ATHKS Bo Ge BAC sper fy ese Sos 60275 Cl= BO s CES = be IS~ oad t/x Spe f- Be .-=s0s~ eo 7 Ql< 34 Ces = eS17 Accordingly B/ HK hie Besar uo favors PPP one Meunsh ides: Qe me Faver atisheratsn Jokay Ree M2. AvwA Vecunn [ryote omy (ar Dr Fay 3 rrethoir hasct web. OE UY ee Roe BSL Renner Sone Bue Jaga din, maton ol (um So Peden Alpe spr lak. No Upeh Sepeae hans “tr @ wn He te Cts Rereve mealr Plennhe Comporente kev ay a ap * Roe C2. Far soho Xt Petje Avphesr ces kunt —{ a B= 40 (190-1 = BOK (AD B& = 727 ( y, 3. € Q.- Ke(2ev-ias)=400 ED k= 40 KeC = ao Quo= E( 128 -1US)= 1G¢o0 ehh m - Nd whe \aes B. JOSEPH CHE 477 FALL 1996 TEST #2 Time: 55 minutes Open: Text 1-2 points bonus for neatness, clarity, and organization. PROBLEM 1 (10 points) A heat exchanger is to be constructed by forming copper tubing into a coil and placing it inside an insulated stccl shell. If the following data apply, what should be the length of the coil? a) Water will flow inside the tubing, and a hydrocarbon vapor will coudeuse un the vutside of the tubing. b) ID of tubing = 0.5 in. ©) OD of tubing = 0.6 in, 4) Condensate rate = 1000 Ib/h. ©) Temperature of condensation = 190°F. ) Heat of vaporization of hydrocarbon at 190°F = 144 Brw/lb. 2) Overall heat-transfer coefficient for condensing vapor = 250 Btu/(h) (f12) (*F) (based on inside area). ‘h) Inlet water temperature = 5U'F. i) Outlet water temperature = 90°F. 4) Heat losses from the shell may be neglected. PROBLEM 2 (10 points) The sales income from a project is $1.1 milliow/year. The operating expenses (excluding depreciation) is $0.82 million/yr. The total capital investment in the project is $1.5 million out of which 20% is for working capital and 80% is for fixed capital investment. Part of the fixed capital is land costing $0.1 million. The estimated life of the plant is 10 years at which time the plant is estimated to have a salvage value of $0.2 million. The income tax rate is 40%. Compute the cash flow in S/year resulting from the plant operation. Assume straight-line depreciation. PROBLEM3 (10 points) ‘You win the Missouri Lotto Jackpot worth 20 million. You are given two choices A) $90 million paid in 20 inctallmente of $1 million each year. The first payment ie immediate and then on the anniversary date for every year thereafter. »)--$6 million in cash right now as one lump sum payment. Assume income tax rate is 37%. Your investments can be expected to give a return of 10% per year after taxes (effective annual interest rate on your savings). Which option would you select if you want to maximize your present worth. Neglect inflation. PROBLEM 4 (10 points) (Based on Aspen project work) It is desired to design a separation column using DSTWU mode! with the following stream as feed. Flow of cyclohexanol, A 10 Ibmoles/hr Flow of cyclohexanone, B 10 thmoles/he Flow of High Boiler, C 0.01 tomotesfhr ‘We would like to separate a product consisting of 95 mole% B and $% A. You may assume that 1% of B ‘entering the foed leaves with the recycle stream. Aspen DSTWU block requires the following specifications: Answer these questions. a) What is the light key component? b) What i the heavy key component? ©) What is recovery of light key component in distillate? 4) What is recovery of heavy key in distillate? ©) Bither actual reflux ratio ot the reflux ratio as multiple of the minimum reflux ratio. Which one will ‘you enter. What is a recommended value? Why? 4) After completing this run, the student includes a small amount of H dissolved in the foed and Aspen fails to complete normally, reporting a problem with DSTWU calculations. Why would adding a trace amount of 11 cause a problem? Will this change your column design significantly? How? &) Selerin Ket a Prrleen 2 aot Shh = AAA mpl nt asd Q= uAnere_ AT, = I1?7O- 50 = Ieolre Pa: flo~ Pa ~— (Or (m. - = bw (atfer) _ris.s- (8h) -E0d. 4* (ep s7)= A) 7 14667 Ma tome ooo o he = uA or A: iz D)L= 7 Cos) fee & Le 1a, govo Ste Kg, Bhai x //P 0 Fx OS) Ds Bhp EP CS @ hoe _friblem 2 FEF $ 00 bur FEZOK /yr Fes F1ISDD EL 200 & 300 k - 5 ey Ho 100K O¢o (PET kame — Sobisge iba £ S)200- # /epk ~ #2cvd Se 3 %o k/gr F100 k- Feowe — Sees, " Oress - Pr&t Net Priab « oe Aeprec = 20k M90e = T19Ck yy, RP Tans = NPx tax: Fito 40 Tre cy Mer Prt Pte Cre Finy ke foe 4, Net Gh Flas < Fikere Yeap Frgke Fok Bog Kfar Tl oe Ark the ennd-ly chhin , yor entl Fl mit x Cl: 37) = 163 My Pu eae kz oot es Gea és ee ~ SST mite Play 2 IBF rte. VE lec the eo. Pinnvisly oh 7 hos prs loa \s @ “One RX cz rol B=.) Ae? x we horc “Coren lO tloe OV se PH Oe 14% 20o-01= pPtx«ll Ptx = 19-9 Goiee =< los :9sPe <1 CF lOY~UH m= DERM Chect-—e tora @ A oh, Too ba O Recon A HE Ay Lae © pet & A = DaSé osxf > geal » Dio OS xP _ 9899 f)

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