CHEM 2002 – PROCESS SYSTEMS ANALYSIS - 2016-2017

Simulation Lab Problem-1

Methanol is manufactured in a “synthesis loop,” in which a mixture of carbon dioxide
and hydrogen is reacted to form the methonal product at high pressure:

The synthesis gas fed to the process, illustrated above, is largely composed of hydrogen
and carbon dioxide, but with traces of inert gases as in Table 1. Additional specifications
for the process are:
 SRK property predictions should be employed
 Pressure drops is all units can be neglected
 Converter feed temperature is set to 400 oC
 The converter can be approximated as a conversion reactor, operating
adiabatically.
 The reactor conversion depends of the operating pressure, according to Table 2.
 The reactor effluent is cooled to a temperature of TS using a cooler, and fed to a
flash unit, modeled by a separator.

Solve the material and energy balances for the flowsheet for a purge flow rate of 600
kg/h, and values for PS = 5 MPa , TS = 10 oC and CO2 conversion = 28.

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 CHEM 2002 – PROCESS SYSTEMS ANALYSIS - 2016-2017

Simulation Lab Problem-2

QUESTION ONE

Harber’s process:

N2 + 3H2 → 2NH3

is carried out at high temperature and pressure ( T=930 °F and P=200 atm ). In an
ammonia plant, the feed gas (74 % H2, 24.5 % N2, 1.2 % CH4, and 0.3 % Ar) at 300 °F is
catalytically reacted to produce NH3. 65 % of t he N2 is converted in the reactor. The
products of reaction are refrigerated to separate out 75 % of NH3 product per pass. The
remaining process stream is recycled back after being purged. Assume a total feed of 100
lbmol/hr and no pressure drop in the mixer. Simulate the process with Peng-Robinson
equation of state for the case when the purge fraction is 10 % .

QUESTION TWO

Assume a basis of 100 kmole/hr of n-heptane and the separator works adiabatically

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 CHEM 2002 – PROCESS SYSTEMS ANALYSIS - 2016-2017

Simulation Lab Problem Set-3

QUESTION ONE
A saturated vapor stream of alkenes (36% n- butane, 34% n- hexane, 30% n-octane in wt.
percent) enters to the shell of a heat exchanger at 1000 kPa with mass flow rate of 100
kg/ hr.
The cooling water at 20 °C and 1000 kPa is use to remove the heat from this stream ,
where its temperature should not be higher than 50 °C in outlet of the heat exchanger.
Calculate the minimum molar flow rate of cooling water so that the temperature of
alkenes stream to be 60 °C in the outlet of heat exchanger. Simulation with no pressure
drops in both sides (Thermodynamic package: Peng Robinson).

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 CHEM 2002 – PROCESS SYSTEMS ANALYSIS - 2016-2017

QUESTION TWO
The reactor section of a process shown in Figure 1 to produce benzene (C 6H6) by
hydrodealkylation of toluene (C7H8) is to be simulated using AspenHYSYS.

This example is typical of a model developed for preliminary flowsheet evaluation. Toluene
is to be converted thermally to benzene in a hydrodealkylation reactor. The main reaction is:
C7H8 + H2 → C6H6 + CH4
An unavoidable side reaction occurs that produces diphenyl as follows:
2C6H6 → C12H10 + H2
Conversion of toluene in the reactor is 75%, while 2% of the benzene present after the first
reaction occurs is converted to diphenyl. The conditions for the feed and the two recycle
streams are:

Develop a flowsheet simulation model to determine all product and intermediate stream
conditions and the performance of each major process unit. The important process conditions
are given in Figure 1. Use the NTRL for property calculations. Notes: ΔP = 5 psia applies to
both hot-side and cold-side of the heat exchanger.
Answer the following questions:
Flow rate of benzene product stream: _______________ lbmol/hr
Purity of benzene in the product stream: _____________ mole%

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 CHEM 2002 – PROCESS SYSTEMS ANALYSIS - 2016-2017

Simulation Lab Problem -4

QUESTION ONE
A process for the manufacture of bio-diesel using waste cooking oil at 60 0C and 101.3
kPa. The composition of the feed stream is:
TG 80.1 wt%
Methanol 18.4 wt%
NaOH 1.5 wt%

FAME (Fatty Acid Methyl Ester) Properties

The liquid density 880 kg/m3
Structure : CH3 1
CH-CH 2
CH2 12
COO 1

TG (Triacylglycerols ) Properties
The liquid density 926 kg/m3
Structure : CH3 3
CH-CH 6
CH2 38
COO 3
CH 1

TG + 3 CH3OH  3 FAME + GLYCEROL Conversion of TG is 95%

The reaction is isothermal. The outlet from reactor is sent to a separator where the
biodiesel (FAME) is completely separated from other constituents.
How much feed material mass flowrate needed for the production of of 1004.6 kg/hr of
biodiesel. Assume the pressure is constant throughout the process. Use NRTL as a fluid
package.

QUESTION TWO
Three streams of CS2, Pyridine (C5H5N) and H2O at a mass rate of 20, 30 and 5
respectively (at 25 0C and 100 kPa) are mixed together and then diluted with air (78% N2,
15% O2, 2% H2O and 5% CO2)(at 25 0C and 100 kPa). The resulting stream is
introduced to a conversion reactor (working at 200 C and 100 kPa) to proceed with the
following reaction :
CS2 + 3O2  2SO2 + CO2
The conversion of the reaction is 100% with respect to CS2
What is the mass-flowrate of dilution air needed to achieve a mass fraction of SO2 equal
to 0.1 in the reactor effluent. Use PRSV as a fluid package.

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