INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY

AUTUMN SEMESTER - END-SEMESTER EXAMINATION

2010-2011 SESSION

Programme: B.Tecb/Dual Degree Branch: Chemical Engineering

Course No. : CL 415 Course Name: Process Equipment Design & Economics
Day & Date: Tuesday, November 16, 2010 Weightage 50%

PART-SG and PART-RKM should be answered in separate answerbooks

Note: This is a No Book - No Notes Examination. Answer all questions. All parts of a
question must be answered together. Please do not raise any queries with the invigilators.
In case of insufficient information, if any, make and mention suitable assumptions and
proceed further.
BEGIN PART-SG

Question-1 [10]

A double pipe heat exchanger made up of a 3" steel outer pipe and 2" steel core pipe is to
be designed for the following service:

Annulus side Core pipe side

Pipe size 3", nominal 2", nominal
Pipe OD, mm 88.9 60.4
Pipe ID, mm 77.9 52.5
Fluid Mineral oil Cooling water
Flow rate, tons/h 15
Temperature in, ° C 80 35
Temperature out, ° C 50 45
Physical properties at mean temperature of: 65°C 40°C
Density, kg/m"3 1040 970
Viscosity, mPa.s 2.7 0.7
Thermal conductivity, W/(m.K) 0.138 0.676
Specific heat, J/kg.K 1550 4190

Determine the following:

Overall heat transfer coefficient for a new exchanger (no dirt)
Annulus side pressure drop
Total length of the heat exchanger

Assumptions:
Thermal conductivity of steel: 60 W/(m.K)
Friction factor is 30% greater than that predicted by the Blasius formula
Entrance and exit pressure losses are ignored
All fluid properties can be calculated at mean temperatures
The liquid viscosities are not temperature sensitive in the operating range
 Question-2 [10]

A shell and tube heat exchanger has the following geometry:

Shell inside diameter 25 ( >S-:

No. of tubes 470 ~-,0.
/ Tube OD 0.75 l'f ()S
I

Tube pitch, 30° triangular 1.25 times tube OD 'l._; , grl.. )

Baffle spacing 0.2 times shell ID 17-7
Tube length 120 ~ oi, !?
No. of tube passes One
No. of shell passes One

Note: All dimensions are in inch; 1inch=25.4 mm

For the liquid flowing on the shell side as detailed below, using the Kem method,
determine,
Flow area at centre line
Equivalent diameter
Shell side Reynolds No.
Total shell side pressure drop

Fluid flow data:

Flow rate, m"3/h 40
Liquid density, kg/m"3 800
Liquid viscosity, mPa.s 0.4

For the given flow take Fanning friction factor= 0.07

Question-3 [10]

Answer the following:

No Question Marks
1. What is the function of sealing strips in a shell and tube heat exchanger? 1
2. In horizontal shell side boiling in a shell and tube exchanger, what is the 1
function of baffles?
3. What is the minimum spacing allowed for baffles in TEMA standards? 1
4. Why are 'U' tubes not preferred for cooling water service? 1
5. When would you use a 90° square pitch for tubes? 1
6. What is the default pitch for a triangular layout? 1
7. A heat exchanger is designed to operate with saturated steam at 10 bara 1
(Saturation temperature, 179.88°C). Accidentally 10 bara superheated
steam at a temperature of 300 ° C is piped to the exchanger. What can
you say about the performance of the exchanger?

2
 8. A horizontal thermosyphon reboiler is designed for a setting depth of 1
3000 mm. If in operation the setting depth increases to 4000 mm, with
the other parameters being the same, what can you say about the
performance of the exchanger?
Note: Setting depth is the elevation difference between the bottom of the
shell and the level of liouid in the sump.
9. An exchanger is designed with a 30 ° triangular pitch. By mistake the 1
exchanger is fabricated with a 60 ° triangular layout. What can you say
of the performance of the exchanger?
10 On the shell side, as compared to the Kem method, does the Bell 1
Delaware method predict a higher or lower pressure drop? Give reasons.

END OF PART-SG

BEGINPART-RKM

Question-1 [10]

(a) A company borrows Rs 35,00,000 from a bank at 10.5% interest to purchase a

multicone cyclone rated at 2,000 m3/mfu.. If the company makes monthly payments of
Rs 32,500 (at the end of the month), how many payments will be required to pay off
the loan, and what is the amount of last payment? You must use the discrete
compounding/discounting concept.

(b) It is desired to determine the most advantageous method for depreciation for income-
tax purposes of a chemical plant investment. The three methods that are being
considered are the Straignt Line Method (SLM), Double Declining Balance Method
(DDBM), and the Sum-of-the-year's-digits Method (SYDM). It may be assumed that
the economic life of the plant is 5 years, and that the company's earning rate is
constant at 10%. Make your recommendation on the most advantageous method if it
is assumed that the salvage value is negligible at the end of economic life. What
percentage of initial investment remains unrecovered in the case of DDBM?

Question-2 [10]

(a) For the process design of a distillation column, setting column pressure is one of the
most important steps in design. In this connection, state whether the following effects
are True or False. In each case, provide very precise supporting arguments to get
credit. No credit will be given for correct answers if proper supporting arguments
are missing.
3
Raising column pressure,

1. Lowers relative volatility and increases separation difficulty. This raises reflux
and stage requirements and reboiler and condenser duties.
2. Reduces column bottom temperature. This decreases chemical degradation,
increases
polymerization, and fouling.
3. For super-atmospheric separations, it increases leakage, and if process materials
are inflammable or toxic, also the hazard potential.
4. For a given heating medium in the reboiler, it increases the reboiler area
requirement.
5. For a given cooling medium in condenser, it reduces the condenser area
requirement.
reduce
6. Increases the size Jr vapor pipes and valves.
reduces
7. Below 1 atm, increases air leakage into the system.
8. Increases vapor density and therefore vapor handling capacity.
9. Increases the column diameter and capital costs of columns.
10. Below 1 atm, reduces the costs of creating and maintaining a vacuum.

(b) For design of a multi-component distillation column, state the heuristics that relate:

1. Actual reflux with minimum reflux Economically

.
optimum reflux ratio is about 1.2 times the minimum reflux ratio Rm

2. Actual stages with minimum stages optimum number of trays is near 2 the minimum value Nm (Found with Fenske Underwod eq.
3. Pressure drop with stages Pressure drop is 0.1 in per stage
4. Top temperature with cooling medium

(c) For process design of distillation columns, how does one decide whether a partial
condenser, or a total condenser, will be required? Give examples.
The composition of the distillate is same as the vapor leaving the top tray

END OF PAPER Distillate is the vapor stream which is

equilibrium with Reflux,condensate,
providing an extra ideal separation
stage i.e distillate and reflux are in
equilibrium