CLL703 Process Engineering

MAJOR EXAM
Time : 2 hrs ( ANSWER ALL QUESTIONS )
Max. Marks : 45 22. 11. 2021
Part A
[Be brief and relevant]

1. In what ways does recycle affect the process costs ? How do the I/O level and Reactor+Recycle level [2]
EPs change ?

2. In a process, reactant ‘R’ is converted to product ‘P’ in the reactor. However the conversion [2]
is not 100 %. The feed stream to the reactor is mainly the reactant but also has some impurity ‘I’
which can be tolerated by the reaction. Finally pure ‘P’ is required. Sketch the alternative
recycle structure flowsheets. Which of these can be taken as same at the I/O level ?

3. How do the utilities QHmin and QCmin vary with Tmin ? Assume that the total heat requirement of [2]
the cold streams is more than that available in the hot streams. Show also the capital, energy and
total costs variation for the above (on the same figure).

4. GCC carries the same information as the Hot/Cold composite curve diagram. ( T / F ) . [3]
If ΔTmin for a process is 20 °C, the hot stream temperature shown on the GCC is _____________ its
actual temperature.
On a GCC diagram, how will a distillation column with Qreb > Qcond look like ? What is the more usual
representation ?

5. Write the equation(s) for estimating the total Heat Exchanger Network area. State clearly what the [2]
variables in the equation are. What is the expression for the area when the overall heat transfer
coefficient U may be taken constant ?

6. What are the three main components of TPC (total production cost) which have to be evaluated [2]
as per the actuals ?
Which costs in Fixed Capital directly relates to the process flowsheet ?

7. What is the “Capital Charge Factor” (define) and how is it used ? What is its typical value and [2]
what may the value be for a high risk process ?

8. State the main component modules of a simulator such as ASPEN+ . What are 2 types [3]
of simulators (computation scheme-wise) & which one requires ‘stream tearing’ ?
 Part B

1. Acetone is made by dehydrogenation of iso-propyl alcohol (IPA) in a vapor phase high temperature reactor.

(CH3)2CHOH  (CH3)2CO + H2

The reactor product stream goes through a phase splitter to separate H2. Some acetone, IPA and H2O going
with H2 are absorbed by contacting with fresh (clean) water. Finally acetone, IPA+H2O azeotrope and water
(waste) are separated.

If the feed to the process is an IPA+H2O azeotrope (70 mol % IPA), draw the recycle structure flowsheet.
Show also the Input-output flowsheet and calculate the EP for a production rate of 100 mol/hr of acetone
at 50 % conversion of IPA in the reactor. Show all the streams clearly. Assume water needed for absorption
is 90 % of the flowrate of the condensables ( mol basis ) in the reactor exit stream.

Acetone price = Rs. 1150/mol, azeotrope feed cost = Rs. 700/mol, H2 fuel price = Rs. 35/mol,
clean H2O = Rs. 3/mol and H2O waste =  Rs. 1 /mol. [ 8]

2. Consider the flowsheet ( 2-stage reaction with separation ) in Fig. 1. For the 2 hot 2 cold stream system,
some heat recovery is shown to be taking place. Determine if there is scope for more heat recovery,
assuming Tmin = 10 C . Show the above pinch HEN for your answer.

If the heating requirement of the process is to be met by steam which is initially superheated at 220 C
but later becomes saturated during the heat transfer process, determine its mass flow rate required.
Show also the superheated/saturated steam lines clearly on the plot, using appropriate x-axis scale.

Data: Tsatd = 150 C ; hvap = 2100 kJ/kg ; Cp of Steam = 2.5 kJ/kg-K , assume const. in given T range. [12]

3. Estimated investment and cost figures ( all in 106 Rs. ) for a project are :
Fixed capital = 400 ; salvage value = 40 ; working capital = 60 ; operating expenses = 100/year ;
Plant life = 8 years ; class/tax life = 4 years.
Assuming straight line depreciation, bank interest rate of 12 % and tax rate of 40 %, find out what
should be the annual product sales (revenue) to make the project viable ? [7]
H = Hot Utility , C = Cold Utility