IV-B. TECH.

I – SEM, INTERNAL EXAMINATION

PROCESS SIMULATION LABORATORY

Experiment 1: Simulation of Shell and Tube heat exchanger (UNISIM)

A gas stream containing 8.0 mol % CO and 92.0 mol % CO 2 at 500 oC and 1 bar is fed to a
waste heat boiler, a large metal shell containing a bundle of small diameter tubes. The hot
gas flows over the outside of the tubes. Liquid water at 25 oC and 5 bar is fed to the boiler
in the ratio of 0.2 kmol feed water per kmol of hot gas and flows inside the tubes. Heat is
transferred from the hot gas through the tube walls to the water, causing the gas to cool
and the water to heat to its boiling point and evaporate to saturated steam at 5.0 bar. The
gas leaving the boiler is flared and discharged to the atmosphere. The boiler operates
adiabatically. Simulate the shell and tube heat exchanger in UNISIM to calculate
exiting gas temperature and the performance.

Experiment 2: Simulation of CSTR (UNISIM)

The propylene oxide and water feed streams are combined in a mixer. The combined stream is
fed to a reactor of volume 280 ft3 and is 85% full, operating at atmospheric pressure, in which
propylene glycol is produced.
𝐻2 𝑂 + 𝐶3 𝐻6 𝑂 ⟶ 𝐶3 𝐻8 𝑂2
The pure propylene oxide entering at 75 oF & 1.1 atm at a flow rate of 150 lbmole/hr and the
pure water is fed at 75 oF & 16.17 psia at a flow rate of 11,000 lb/hr. The kinetic parameters
are A, the pre-exponential factor 1.7 × 1013 and E, the activation energy 3.24 ×
104 𝑏𝑡𝑢/𝑙𝑏𝑚𝑜𝑙𝑒. Simulate for temperature required for the product for the actual present
conversion in the 85 – 95% range.

Experiment 3: Simulation of Isothermal CSTR (MATLAB)

Simulate the following set of differential equations that describe isothermal CSTR by
Euler’s method in MATLAB programming.
dCA F
= (CA0 − CA ) − K1 CA − K 3 CA2
dt V
𝑑𝐶𝐵 𝐹
= (− ) 𝐶𝐵 + 𝐾1 CA − K 2 CB
𝑑𝑡 𝑉
The parameter values are K 1=5/6 min-1, K2=5/3 min-1, K3=1/6 mol/lt. min, CA0=10,
(F/V)=0.5714 . Take CA (0) = 2 and CB(0) = 1.117 with the step size of 0.1. Manually
solve the equations (minimum 3 iterations).

Experiment 4: Simulation of two tank liquid level non-interacting system (MATLAB)

Simulate the following set of differential equations that describe non interacting two
tank system by Runge Kutta fourth order Method.
𝒅𝒉𝟏
= 𝒒 − 𝒒𝟏
𝒅𝒕 Where, 𝑞1 =ℎ1 /𝑟1
𝒅𝒉𝟐 𝑞2 =ℎ2 /𝑟2 .
= 𝒒𝟏 − 𝒒𝟐
𝒅𝒕

The parameter values are q=5(𝑓𝑡 3 /min), 𝑟1 = (1ft/cfm), 𝑟2 =1ft/cfm, take ℎ1 (0) = 4.5 and
ℎ2 (0) = 4 with the step size of 0.1 and stopping criteria for time as 15. Manually solve
the equations (minimum 2 iterations).

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 Experiment 5: Simulation of Distillation column (UNISIM) and Two tank
interacting system(MATLAB)
a) A liquid mixture of benzene, toluene is fractionated at 101.3 kPa pressure. Feed is
entering at 100 kgmol/hr where 45% benzene and 55% toluene at 130 ºF, total
number of stages are 8, feed enters at 5th stage and reflux ratio of 4. Simulate the
distillation column assuming no pressure drop and pressure of distillate is 112 kPa
and reboiler pressure is 120 kPa with distillate of 43.1 kgmol/hr. Simulate the
distillation column using UNISIM and show the simulated results of top products,
bottom products, condenser duty and reboiler duty.
b) Simulate the following set of differential equations that describe two tank liquid level
non interacting system by ODE 45 solver in MATLAB.
dH1 H
= q − q1 where, 𝑞1 = 1
dt R1
dH2 H2
= q1 − q2 where, 𝑞2 =
dt R2
Where, q = 5 ft3 /min ; R1 = 1 ft/cfm ; R2 = 1 ft/cfm; Take H1(0)=4.96; H2(0)=4.94,
t=0 to 8 min with step size of 0.1. Manually solve the equations using Runge Kutta
fourth order Method (minimum 2 iterations).

Experiment 6: Simulation of two tank liquid level interacting system (MATLAB)

Simulate the following set of differential equations that describe interacting two tank
system by Euler’s Method
𝒅𝒉𝟏
= 𝒒 − 𝒒𝟏 Where, 𝑞1 = (ℎ1 -ℎ2 )/𝑟1
𝒅𝒕
𝒅𝒉𝟐
= 𝒒𝟏 − 𝒒𝟐 𝑞2 =ℎ2 /𝑟2
𝒅𝒕

The parameter values are q=5(𝑓𝑡 3 /min), 𝑟1 = (1ft/cfm), 𝑟2 =1ft/cfm, take ℎ1 (0) = 5 and
ℎ2 (0) = 1 with the step size of 0.1 and stopping criteria for time as 30.
Manually solve the equations (minimum 3 iterations).

Experiment 7: Simulation of Flash Distillation column (UNISIM) and two tank

liquid level non-interacting system (MATLAB)
A stream containing 15 % ethane, 20% propane, 60% i-butane and 5% n-butane at 50oF
and atmospheric pressure, and a flow rate of 100 lb mol/hr. This stream is to be
compressed to 50 psia and then cooled to 32 oF. The resulting vapor and liquid are to be
separated as the two product streams. Simulate the flash distillation column UNISIM and
show the simulated results of the flowrates and compositions of the two exit streams.

Experiment 8: Simulation of PFR Performance (MATLAB)

A homogeneous gas phase reaction A ⟶ 3R has a reported rate at 2150 C ,
−𝑟𝐴 = 10−2 √𝐶𝐴 mol/lt.sec.
Write the MATLAB code to find the space time required for 80% conversion of A. 50%
inert ,PFR operating at 2150 C and 5 atm and CA0 = 0.0625 mol/lt. Show the manual
calculations also.

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Experiment 9: Simulation of counter-current multi stage absorber (MATLAB)
It is desired to absorb 95% acetone by water from a mixture of acetone and nitrogen containing
1.5% of the component in a counter current tray tower as shown in figure 6.1.Total gas input
is 30 kmol/hr and water enters at a rate of 90 kmol/hr. The tower operates at27 0C and 1 atm.
The equilibrium relation is 𝑌 = 2.53𝑋. Simulate for number of ideal stages necessary for
separation by MATLAB programming using graphical method.
Experiment 10: Simulation of Conversion Reactor and Reactions (UNISIM)
The conversion of fuels to hydrogen can be carried out by the partial oxidation. The
partial oxidation method relies on the reaction of the fuel for example methane with air
in order to produce carbon dioxide and water.
1
𝐶𝐻4 + 𝑂2 ⟶ 𝐶𝑂 + 2𝐻2
2
𝐶𝐻4 + 𝑂2 ⟶ 𝐶𝑂2 + 2𝐻2
Simulate the above set of reactions in UNISIM to estimate the molar flowrates of each
component with the composition in the product stream.
Data: Feed conditions
Name Methane Air
Temperature 25 oC 25 oC
Pressure 2 bar 2 bar
Molar flow 100 kgmol/hr 260 kgmol/hr
Component mole fraction 1.000 0.790 𝑁2 + 0.210 𝑂2

Experiment 11: Isothermal CSTR system(MATLAB)

Simulate the following set of differential equations that describe isothermal CSTR by
ODE45 method using MATLAB
𝑑𝐶𝐴 𝐹
= (𝐶𝐴0 − 𝐶𝐴 ) − 𝐾1 𝐶𝐴 − 𝐾3 𝐶𝐴2
𝑑𝑡 𝑉
𝑑𝐶𝐵 𝐹
= (− ) 𝐶𝐵 + 𝐾1 𝐶𝐴 − 𝐾2 𝐶𝐵
𝑑𝑡 𝑉
The parameter values are K 1=5/6 min-1, K2=5/3 min-1, K3=1/6 mol/lt. min, CA0=10,
(F/V)=(4/7). Take CA (0) = 2 and CB(0) = 1.117 with the step size of 0.1.
Manually solve the equations using Runge Kutta fourth order Method (minimum
2 iterations).

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Experiment 12: Simulation of Non-isothermal CSTR system
Simulate the following set of nonlinear differential equations that describe non-isothermal
CSTR system as shown in Figure 4.1 and Table 4.1 gives the parameter values and steady state
conditions, using ODE 45 solver by MATLAB programming:
𝑑𝑉
= 𝐹0 − 𝐹
𝑑𝑡
𝑑(𝑉𝐶𝐴 )
= 𝐹0 𝐶𝐴0 − 𝐹𝐶𝐴 − 𝑉𝑘𝐶𝐴
𝑑𝑡
𝑑(𝑉𝑇) 𝜆𝑉𝑘𝐶𝐴 𝑈𝐴𝐻
= 𝐹0 𝑇0 − 𝐹𝑇 − − (𝑇 − 𝑇𝐽 )
𝑑𝑡 𝜌𝐶𝑃 𝜌𝐶𝑃
𝐹
𝑑𝑇𝐽 𝐽(𝑇𝐽0 −𝑇𝐽 ) 𝑈𝐴𝐻
= + (𝑇 − 𝑇𝐽 )
𝑑𝑡 𝑉𝐽 𝜌𝐽𝑉𝐽 𝐶𝐽
𝑑𝐹 𝑑𝑉
𝐹 = 40 − 10(48 − 𝑉 ); = 10 𝑘
𝑑𝑡 𝑑𝑡
𝐴→ 𝐵
𝑑𝐹𝐽 𝑑𝑇
𝐹𝐽 = 49.9 − 𝐾𝑐 (600 − 𝑇 ); = 𝐾𝑐 Figure 4.1 Nonisothermal CSTR system
𝑑𝑡 𝑑𝑡

Where, 𝑘 = 𝛼𝑒 (−𝐸⁄𝑅𝑇); 𝐶𝐴0 = 0.55 𝑙𝑏 𝑚𝑜𝑙𝐴 ⁄𝑓𝑡 3 , t=0 to 4 min with 0.2 interval.

Table 4.1 Nonisothermal CSTR parameter values

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