CHE 524

Principles of plant design II

3 Unit

3hours Contact Time per Week

Dr. Olagoke Oladokun

Dr. (Mrs) T.E. Oladimeji

Topic Weeks

General Engineering Design Consideration 1-2

Process design principles, Flow sheets 3

Sitting of Plants (Part1) 4

Sitting of Plants (Part 2) 5

Process services 6

Mid Semester Assessment 7

Material handling 8

Industrial hazards and environmental pollution (Part 1) 9

Industrial hazards and environmental pollution (Part 2) 10

Process Design methodology (Part 1) 11

Process Design methodology (Part 2) 12

Revision 13
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1

1 Chapter 1

General Engineering Design Consideration

1.1 Nature of Design

What is Engineering? It better to ask these two precursor questions. What is Science? and What is
Technology?

▪ Science is to understand a particular phenomenon.

▪ Technology is the application of Science.
▪ Engineering is the creation/design of solution(s) to a particular problem through science and
technology and the solution(s) subject to Safety, Ethics and Economics constraints.

Design is a creative activity, and as such can be one of the most rewarding and satisfying activities
undertaken by an engineer. It is the synthesis, the putting together, of ideas to achieve a desired
purpose. The design does not exist at the commencement of the project. The designer starts with
a specific objective in mind, a need, and by developing and evaluating possible designs, arrives at
what he considers the best way of achieving that objective; be it a better chair, a new bridge, or for
the chemical engineer, a new chemical product or a stage in the design of a production process.

In other for an engineer to create/design a solution he/she must go through basic design process
shown in Figure 1.1 and guided by constraints in Figure 1.2.

Table 1.1 Table Caption

Table 1.2

(1.1 )
Figure 1.1 The design processes.
 Figure 1.2 Design constraints

1.1.1 Objective or Formulation of Design Problems

Before a process design can be started, the design problem must be formulated. Formulation of the
design problem requires a product specification. If a well-defined chemical product is to be
manufactured, then the specification of the product might appear straight forward (e.g., A purity
specification). However, if a specialty product is to be manufactured, it is the functional properties
that are important, rather than the chemical properties, and this might require a product design
stage to specify the product (Seideretal.,2010; Cussler and Moggridge, 2011).

Many times, the failure of a process design project is ill defined problem. For example, in the
expansion of bio-hydrogen production. The question is do you expand the biomass drying unit or
do you purchase dry feedstock and eliminate the cost of drying.

Thus, from the initial ill-defined problem, the design team must create a series of very specific
options and these should then be compared on the basis of a common set of assumptions regarding,
for example, raw materials and product prices. Having specified an option, this gives the design
team a well-defined problem to which the methods of engineering and economic analysis can be
applied.

1.1.2 Collection of literatures, data and solutions

After formulating a well-defined formulated and clear objective, the designer must collect all the
relevant facts and data required. This includes existing design and solutions, for process designer
the process equipment performance, physical and chemical properties of chemicals involve. A
thorough search and collection of the information needed creates a foundation for successful
design. Remember progress is more rapid when there is foundation.
1.1.3 Synthesis and simulation

After the gathering of all the necessary information, the process of synthesizing and simulating the
solution(s) begins with sorting the available information. The sorting separates identifies existing
solutions which can readily be commission or deployed. Why change it if it is not broken? The
sorting can stimulate fresh ideas resulting in the synthesis of new design(s). But rarely is any design
novel, therefore, the best could be a hybrid design that improves on an old design by combining
with fresh ideas.

In a chemical process, the transformation of raw materials into desired chemical products usually
cannot be achieved in a single step. Instead, the overall transformation is broken down into several
steps that provide intermediate transformations. These are carried out through reaction,
separation, mixing, heating, cooling, pressure change, particle size reduction or enlargement for
solids. Once individual steps have been selected, they must be interconnected to carry out the
overall transformation. Thus, the synthesis of a chemical process involves two broad activities.
First, individual transformation steps are selected. Second, these individual transformations are
interconnected to form a complete process that achieves the required overall transformation. A
flowsheet or process flow diagram (PFD) is a diagrammatic representation of the process steps with
their interconnections.

1.1.4 Design selection subject to constraints

The three (3) sorted and synthesized categories of solutions are subject to constraints for selection.

1.1.5 Failed Design goes back to drawing board.

The designs that fail the constraints are sent back to the drawing board specifically for collection of
more information to fix the identified area of failure then they are run through the cycle again.
Design is a continuous cycle.

1.1.6 Passed design(s) become feasible design(s) or solution(s)

The designs that pass the constraints are final or feasible designs. Sometimes the many designs
could pass the initial constraint. In other to get the final design more and/or stringent constraints
could be introduced.

1.2 Chemical Process Design Consideration

The development of a complete plant design requires consideration of many different factors such
as:

i. Process flow diagram (PFD)

ii. Plant location
iii. Site and plant layout
iv. Plant operation and control
 v. Utilities
vi. Storage
vii. Waste disposal
viii. Health and safety
ix. Materials handling

1.2.1 Process Flow Diagram (PFD)

This is the diagrammatic representation of the unit operation and their interconnection in the
production of the chemical.

1.2.2 Plant Location and Site Selection

The geographical location of the final plant can have strong influence on the success of an industrial
venture. Considerable care must be exercised in selecting the plant site, and many different factors
must be considered. Primarily, the plant should be located where the minimum cost of production
and distribution can be obtained, but other factors, such as room for expansion and safe living
conditions for plant operation as well as the surrounding community, are also important.

The major factors in the selection of most plant sites are:

i. Marketing Area
ii. Raw Materials
iii. Transportation Facilities
iv. Availability of Labors
v. Water supply
vi. Energy Availability (power and fuel)
vii. Climate

1.2.3 Site and plant layout

The process units and ancillary buildings should be laid out to give the most economical flow of
materials and personnel around the site. Hazardous processes must be located at a safe distance
from other buildings. Consideration must also be given to the future expansion of the site.

The principal factors to be considered in making plant layout are:

i. Economic considerations: construction and operating costs;

ii. The process requirements.
iii. Convenience of operation.
iv. Convenience of maintenance.
v. Safety.
vi. Future expansion.
1.2.4 Plant operation and control

In the design of an industrial plant, the methods which will be used for plant operation and control
help determine many of the design variables. For example, the extent of instrumentation can be a
factor in choosing the type of process and setting the labor requirements.

1.2.5 Utilities

The word utility is used for the ancillary services needed in the operation of any production process.
These services are normally supplied from a central site facility and include:

i. Electricity.
ii. Steam, for process heating.
iii. Cooling water.
iv. Water for general use.
v. Demineralized water.
vi. Refrigeration.
vii. Compressed air.
viii. Inert-gas supplies;

1.2.6 Storage

Storage facilities are required for:

i. Raw materials
ii. Intermediate products
iii. Final products
iv. Recycle materials.
v. Off-grade materials
vi. Fuels

1.2.7 Waste disposal

Adequate plan must be made from the design stage of a plant on the disposal of waste generated
during the chemical production. Waste may be hazardous or non-hazardous but generally they are
nuisance. It could be through third party agent or a department setup internally.

1.2.8 Health and safety

For every plant or factory, the slogan is “safety first”.

Health and safety is paramount for the process plant community this include plant personnel,
people, animals and vegetation living around the process plant and the process plant (facility) itself.
The design team should give priority for health and safety in site location, identify possible hazard
units and develop programs and training to highlight importance. Furthermore, regular assessment
of risk should be carried out.

The three major hazards in process plant are:

i. Fire
ii. Explosion
iii. Toxic release

1.2.9 Materials handling

The process design team should consider all the flow of materials in, within and out of the process
plant and review subject to:

i. Toxicity
ii. Flammability
iii. Reactivity
iv. Transportation
2
2

2 Chapter 2

Process Design Principles, Flow Sheets

1.3 Introduction

Process flow-sheet is the key document in process design.

Process flow sheet diagrammatic model of the process.

Process flow-sheet consist of the followings:

• Equipment arrangement (Alphabet label)

• Stream connections (Numeric label)
• Stream flow-rates and compositions
• Operating conditions of equipment and streams

1.4 Tools of Process flow sheet

• Material balance
• Sizing of equipment
• Energy balance
• Service requirement
• Manual calculation
• Computer-aided (Aspen Plus, Hysys, PRO-II)
• Hybrid computation

1.5 Flow-Sheet Presentation

Flow-sheet is the working document of a process engineer, therefore, the presentation must be
clear, comprehensive, accurate and complete.

1.5.1 Type of presentation

• Block diagram
• Pictorial representation
• Presentation of stream flow-rates
1.5.1.1 Block Diagram

Figure 2.1 Process flow sheet Block diagram

1.5.1.2 Pictorial Representation

Figure 2.2 Process flow sheet Pictorial Representation

1.5.1.3 Presentation of stream flow (A)

Figure 2.3 Process flow sheet Presentation of Stream type A

1.5.1.4 Presentation of stream flow (B)

 Figure 2.4 Process flow sheet Presentation of Stream type B

1.5.1.5 Presentation of stream flow (C)

Figure 2.5 Process flow sheet Presentation of Stream type C

1.6 Mass and Energy Balance

We will use Workout or Class activity 2.1 to demonstrate Mass and Energy balance of a Process
Flow Diagram.

1.6.1 Workout 2.1

In the production of Acetic-anhydride two reactors were used. Acetone (1035K, 1.6 atm) achieved
75% conversion to Ketene and Methane in a plug flow reactor (operates adiabatically, length 3m,
diameter 1m) and the outlets stream was further separated in a rectifier to remove excess acetone
follow by a distillation column to separate ketene from methane. The ketene (25oC, 1 bar) was feed
into the second CSTR reactor (50oC, 0.2 bar, volume 20m3) where acetic acid (25oC, 1 bar) reacts
with Ketene to form the desired product. Assume all acetone are recycled back to the feed.

Latent heat of steam (Volume 1) = 2174 kJ/kg at 274 kN/m2

Water, 4.2 kJ/kg K, 20oC temperature rise.

Question

1. Basis 100 kmol/hr. of Acetone.

2. Identify the components in the process.
3. Tabulate the Formulae, Molecular Weight, Boiling Point, Heat of formation, Heat capacity
(A, B, C & D) of the components present in the process.

Compt1 Compt…N
Name
Formulae
MW
BP
Hf
CP A
B
C
D

4. Draw the flow sheet with stream labeled with numbers for the process described.
5. Draw the table and guess the components in each stream from the description.
6. Write and balance the chemical reaction(s) in the plug flow reactor.
7. Write and balance the chemical reaction(s) in the CSTR reactor.
8. Carryout material balance on the plug flow reactor.
9. Carryout material balance on the CSTR reactor.
10. Draw the stream material balance table in kmol and kg.
11. Determine the heat of reaction for the reactions.
12. Carryout energy balance for the CSTR reactor.
 13. Calculate the amount of steam or water to maintain the heat in the CSTR.

Solution

1.6.2 Basis 100 kmol/hr. of Acetone.

Basis: 100 kmol/hr Acetone fed

1.6.3 Identify the components in the process.

1. Acetic anhydride
2. Acetone
3. Ketene
4. Methane
5. Acetic acid

1.6.4 Tabulate the Formulae, Molecular Weight, Boiling Point, Heat of formation, Heat capacity
(A, B, C & D) of the components present in the process.

Acetone Ketene Methane Acetic Acid Acetic anhydride

127 83 64 98 162
Name ACETONE KETENE METHANE ACETIC ACID ACETIC ANHYDRIDE
Formulae C3H6O C2H2O CH4 C2H4O2 C4H6O
MW 58.080 43.038 16.043 60.052 102.089
BP 56.2 -41.2 -161.5 117.9 138.8
Hf -217.71 -61.13 -74.86 -435.13 -576.10
CP A 6.301 6.385 19.251 4.840 -23.128
B 26.059E-2 16.383E-2 52.126E-3 25.485E-2 50.870E-2
C -1.253E-4 -1.084E-4 11.974E-6 -1.753E-4 -3.580E-4
D 20.377E-9 26.984E-9 -1.132E-8 49.488E-9 98.348E-9
1.6.5 Draw the flow sheet with stream labeled with numbers for the process described.

1.6.6 Draw the table and guess the components in each stream from the description.

(1) (2) (3) (4) (5) (6) (7) (8)

Acetone C3H6O 1 1 1
Ketene C2H2O 1 1 1 1
Methane CH4 1 1 1
Acetic Acid C2H4O2 1 1
Acetic anhydride C4H6O 1

1.6.7 Reactions

1.6.7.1 Write and balance the chemical reaction(s) in the plug flow reactor.

C3H6O → C2H2O + CH4 R1

1.6.7.2 Write and balance the chemical reaction(s) in the CSTR reactor.

C2H2O + C2H4O2 → C4H6O R2

1.6.8 Manual Maas calculation

1.6.8.1 Carryout material balance on the plug flow reactor.

 C3H6O in feed (1) = 100 kmol/hr

Amount of C3H6O converted in reaction = 100 x 0.75 = 75 kmol/hr

1 mole of C3H6O gives 1 mole of C2H2O and 1 mole of CH4

C2H2O produced from reaction = 75 kmol/hr

CH4 produced from reaction = 75 kmol/hr

1.6.8.2 Carryout material balance on the CSTR reactor.

C2H2O in (6) = 75 kmol/hr

Assume 100% conversion.

Amount of C2H2O converted in reaction R2 = 75 kmol/hr
1 mole of C2H2O reacts with 1 mole of C2H4O2 to produce 1 mole of C4H6O.

C4H6O produced from reaction = 75 kmol/hr

C2H4O2 used in reaction = 75 kmol/hr

1.6.8.3 Draw the stream material balance table in kmol and kg.
 (1) (2) (3) (4) (5) (6) (7) (8)
km k km k km k km k km k km k km k km k
ol g ol g ol g ol g ol g ol g ol g ol g
C3H6 100 25 25
O
C2H2 75 75 75
O
CH4 75 75 75
C2H4 75
O2
C4H6 75
O

1.6.9 Manual Energy Calculations

1.6.9.1 Determine the heat of reaction for the reactions.

∆𝐻𝑟 = ∑(𝑛 × 𝐻𝑓 )𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑(𝑛 × 𝐻𝑓 )𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡

C3H6O → C2H2O + CH4 R1

∆𝐻𝑟 = (-61.13 + -74.86) – (-217.71) = 81.72 kJ/mol

C2H2O + C2H4O2 → C4H6O R2

∆𝐻𝑟 = (-576.1) – (-61.13 + 435.13) = -79.84 kJ/mol

1.6.9.2 Carryout energy balance for the CSTR reactor.

𝑄𝑝 = 𝐻2 − 𝐻1 − 𝑄𝑠

𝐵(𝑇 2 − 𝑇𝑑2 ) 𝐶(𝑇 3 − 𝑇𝑑3 ) 𝐷(𝑇 4 − 𝑇𝑑4 )

𝐻 = 𝐴 (𝑇 − 𝑇𝑑 ) + + +
2 3 4

𝑄𝑠 = 𝑄𝑟 = ∑ −∆𝐻𝑟 × (𝑚𝑜𝑙 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑)

H1 = 0 kJ/kmol
H2 = 193661.084 kJ/kmol

Qs = 5988 kJ/kmol

Qp = 187673.08 kJ/kmol

1.6.9.3 Calculate the amount of steam or water to maintain the heat in the CSTR.

𝑄𝑝 = 𝑚𝐶𝑝 ∆𝑇 𝑘𝐽/ℎ

m = 1489.47 kg
1.7 Computer-Aided Flow-Sheeting

1.7.1 Information flow diagram

To present the process flow sheet problem to the computer, the basic process flow diagram,
showing the sequence of unit operations and the interconnected streams must be transformed into
an information flow diagram. Each block in an information flow diagram represents a calculation
module.

The Information flow diagram rules

1. All process unit are blocks.

2. Remove all units in which no change of composition, or temperature or pressure.
3. Add other units not shown on the process flow diagram but with composition change such
as mixing and splitting tees.
4. Each outlet/product stream represent a block.
5. All reactors/or process units generating new component have pseudo fresh feed.

Figure 2.6 Process flow diagram

Transforming into information flow diagram

 Figure 2.7 Information block Diagram

1.7.2 Split Fraction Concept

The split fraction concept allow the information flow diagram be converted into calculation module
of system of linear equations that relate the outlet stream component flows to the inlet flows.

Figure 2.8 Split fraction of a Block Unit

 Figure 2.9 Reactor Unit
Conve ntional formulation
1. Develop the syste m of equati on.
∝𝑗,𝑖 ,𝑘 ∙ 𝜆𝑖 ,𝑘 = 𝑔𝑖 ,0.𝑘
2. Let rows of ∝𝑗,𝑖,𝑘 be, j that the stream inlet/enteri ng unit.
3. Let col umns of ∝𝑗,𝑖,𝑘 be, i, be the stream outlet/leaving unit.

Example 2.1

1 2 3 4 5 𝜆 g

1 (1 −∝11𝑘 ) −∝12𝑘 −∝13𝑘 −∝14𝑘 −∝14𝑘 𝜆1𝑘 𝑔10𝑘

j
2 −∝21𝑘 (1 −∝22𝑘 ) −∝23𝑘 −∝24𝑘 −∝24𝑘 𝜆2𝑘 𝑔20𝑘
3 −∝31𝑘 −∝32𝑘 (1 −∝33𝑘 ) −∝34𝑘 −∝34𝑘 𝜆3𝑘 = 𝑔30𝑘

4 −∝41𝑘 −∝42𝑘 −∝43𝑘 (1 −∝44𝑘 ) −∝45𝑘 𝜆4𝑘 𝑔40𝑘

5 −∝51𝑘 −∝52𝑘 −∝53𝑘 −∝54𝑘 (1 −∝55𝑘 ) 𝜆5𝑘 𝑔50𝑘

Simplify

1 2 3 4 5 𝜆 g

1 1 0 0 0 0 𝜆1𝑘 𝑔10𝑘

2 −∝21𝑘 1 0 0 0 𝜆2𝑘 𝑔20𝑘

j 3 0 −∝32𝑘 1 0 0 𝜆3𝑘 = 0

4 0 0 −∝43𝑘 1 0 𝜆4𝑘 𝑔40𝑘

5 0 0 0 −∝54𝑘 1 𝜆5𝑘 𝑔50𝑘

Table 2.1 Table of Split fraction Coefficient and Fresh feeds

k ∝21𝑘 ∝32𝑘 ∝43𝑘 ∝54𝑘 𝑔10𝑘 𝑔20𝑘 𝑔40𝑘 𝑔50𝑘

Acetone 1 0.25 0 0 0 100 0 0 0
Ketene 2 0 1 1 0 0 75 0 0
Methane 3 0 1 0 0 0 75 0 0

Acetic acid 4 0 0 0 0 0 0 75 0

Acetic Anhydride 5 0 0 0 0 0 0 0 75
Let’s solve manually for Acetone.
3
3

3 Chapter 3

Sitting of Plants (Part1)

1.8 Plant Location and Site Selection

The geographical location of the final plant can have strong influence on the success of an industrial
venture. Considerable care must be exercised in selecting the plant site, and many different factors
must be considered. Primarily, the plant should be located where the minimum cost of production
and distribution can be obtained, but other factors, such as room for expansion and safe living
conditions for plant operation as well as the surrounding community, are also important.

The major factors in the selection of most plant sites are:

1.8.1 Marketing Area

For materials that are produced in bulk quantities, such as cement, mineral acids, and fertilizers,
where the cost of the product per metric ton is relatively low and the cost of transport is a significant
fraction of the sales price, the plant should be located close to the primary market. This
consideration is much less important for low-volume production and high-priced products, such as
pharmaceuticals.

1.8.2 Raw Materials

The availability and price of suitable raw materials will often determine the site location. Plants that
produce bulk chemicals are best located close to the source of the major raw material, as long as
the costs of shipping product are not greater than the cost of shipping feed. For example, at the
time of writing much of the new ethylene capacity that is being added worldwide is being built in
the Middle East, close to supplies of cheap ethane from natural gas. Oil refineries, on the other
hand, tend to be located close to major population centers, as an oil refinery produces many grades
of fuel, which are expensive to ship separately.

1.8.3 Transportation Facilities

The transport of materials and products to and from the plant can be an overriding consideration
in site selection. If practicable, a site should be selected that is close to at least two major forms of
transport: road, rail, waterway (canal or river), or a sea port. Road transport is increasingly used
and is suitable for local distribution from a central warehouse. Rail transport is usually cheaper for
the long-distance transport of bulk chemicals. Air transport is convenient and efficient for the
movement of personnel and essential equipment and supplies, and the proximity of the site to a
major airport should be considered.

1.8.4 Availability of Labors

Labor will be needed for construction of the plant and its operation. Skilled construction workers
are usually brought in from outside the site area, but there should be an adequate pool of unskilled
labor available locally, and labor suitable for training to operate the plant. Skilled craft workers such
as electricians, welders, and pipe fitters will be needed for plant maintenance. Local labor laws,
trade union customs, and restrictive practices must be considered when assessing the availability
and suitability of the local labor for recruitment and training.

1.8.5 Water supply

Chemical processes invariably require large quantities of water for cooling, washing, steam
generation, and as a raw material, and the plant must be located near a source of water of suitable
quality. Process water may be drawn from a river, from wells, or purchased from a local authority.

1.8.6 Energy Availability (power and fuel)

Power and steam requirements are high in most industrial plants, and fuel is ordinarily required to
supply these utilities. Consequently, power and fuel can be combined as one major factor in the
choice of a plant site. If the plant requires large quantities of coal or oil, location near a source of
fuel supply may be essential for economic operation. The local cost of power can help determine
whether power should be purchased or self-generated.

Electrical power is needed at all sites. Electrochemical processes (for example, chlorine
manufacture or aluminum smelting) require large quantities of power and must be located close to
a cheap source of power.

A competitively priced fuel must be available on site for steam and power generation.

1.8.7 Climate

Adverse climatic conditions at a site will increase costs. Abnormally low temperatures require the
provision of additional insulation and special heating for equipment and pipe runs. Stronger
structures are needed at locations subject to high winds (cyclone/ hurricane areas) or earthquakes.
Corrosive environments will need strong protection for the plant equipment.
4
4

4 Chapter 4

Sitting of Plants (Part 2)

1.9
5
5

5 Chapter 5

Process Services

1.10
Mid Semester Assessment
6
6

6 Chapter 6

Material Handling

1.11

Material handling 8
7
7

7 Chapter 7

Industrial hazards and environmental pollution (Part 1)

1.12
8
8

8 Chapter 8

Industrial hazards and environmental pollution (Part 2)

1.13
9
9

9 Chapter 9

Process Design methodology (Part 1)

1.14
10
10

10 Chapter 10

Process Design methodology (Part 2)

1.15
Revision 13