Plant Design and Economics

Saeed Eini
Department of Chemical and Petroleum Engineering
Sharif University of Technology

1401 ‫پاییز‬
http://che.sharif.edu/~ProSET
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology

Heuristics for Process Synthesis

Product and Process Design Principles, Analysis, Synthesis and Evaluation, Fourth edition, Seider et al., 2017.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Process design tasks
1- Information gathering 1- Eliminate differences in molecular types

2- Preliminary process synthesis 2- Distribute the chemicals by matching sources and sinks

3- Energy and mass balances 3- Eliminate differences in composition

4- Rigorous models 4- Eliminate differences in temperature, pressure, and phase

5- Heat and mass integration 5- Integrate tasks

6- Equipment sizing and costing

7- Economic evaluation

8- Environmental/sustainability/safety assessment

11- Controllability, Flexibility, …

10- Process optimization

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Heuristics in VCM case:
A pump and then an evaporator were used

It was assumed that because the reaction

is nearly complete at 110∘C, ethylene and
chlorine can be fed in stoichiometric
proportions
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Heuristics are used when generating the alternatives that make up the synthesis tree,
to generate base-case designs

• They are easy to apply and often they require little analysis

• Many heuristics have been suggested for each part of a chemical process
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 1: Raw materials and chemical reactions

Part 2: Distribution of chemicals

Part 3: Separations

Part 4: Heat removal from and addition to reactors

Part 5: Heat exchangers and furnaces

Part 6: Pumping, compression, pressure reduction, vacuum, and conveying of solids

Part 7: Changing the particle size of solids and size separation of particles

Part 8: Removal of particles from gases and liquids

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology

Part 1: Raw materials and chemical reactions

1 heuristic
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 1: Select raw materials and chemical reactions to avoid, or
reduce, the handling and storage of hazardous and toxic chemicals

• Bhopal disaster in India at 1984 focused worldwide attention on the need to reduce the
handling of highly reactive intermediates
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
 Bhopal disaster: The worst disaster in the history of the chemical industry
• at the Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh, India
• Owned by the Union Carbide Corporation (UCC)
• More than 2,000 killed and 200,000 injured

Trevor Kletz, What Went Wrong, 4th edition, 1999

Wikipedia
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 1: Select raw materials and chemical reactions to avoid, or
reduce, the handling and storage of hazardous and toxic chemicals

 Making the process inherently safer by:

1. Substitute
• Using different reaction paths
2. Minimize
• Integrating unit operations
• Removing intermediate storage
• Using a reliable/continuous supply chain to remove feed/product storages
3. Moderate
• Use less severe operating conditions
4. Simplify
• Use simple logics to avoid process malfunction

Kletz, T. A., & Amyotte, P. (2010). Process plants: A handbook for inherently safer design. CRC Press.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 1: Select raw materials and chemical reactions to avoid, or
reduce, the handling and storage of hazardous and toxic chemicals
• Example: the manufacturing of ethylene glycol

Alternative 1: Eliminate the storage tank(s)

Ethylene oxide Alternative 2: Use costly chlorine and caustic in a single reaction step

Alternative 3: Convert ethylene oxide to ethylene carbonate

ethylene glycol
1- highly exothermic
2- Eth. Ox + H2O ….
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology

Part 2: Distribution of chemicals

7 heuristics
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 2: Use an excess of one chemical reactant in a reaction operation
to consume completely a valuable, toxic, or hazardous chemical reactant.

• After the reaction operations are positioned, the sources of chemicals are distributed
among the sinks for chemicals

• The decisions in this step:

(1) the use of one chemical reactant in excess in a reaction operation

(2) the handling of inert species that enter in the feed streams

(3) the handling of undesired byproducts generated in side reactions

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 2: Use an excess of one chemical reactant in a reaction operation
to consume completely a valuable, toxic, or hazardous chemical reactant.
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 2: Use an excess of one chemical reactant in a reaction operation
to consume completely a valuable, toxic, or hazardous chemical reactant.

ethylene/chlorine ratio ????

 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 2: Use an excess of one chemical reactant in a reaction operation
to consume completely a valuable, toxic, or hazardous chemical reactant.

• Excess flowrate of a reactant governs the costs of separation and recirculation, and often
plays a key role in the process economics

• How to adjust the excess amount? It is treated as a design variable

• The application of excess reactant has more benefits:

o For exothermic reactions, the excess chemical often serves the useful function of
absorbing the heat of reaction and thereby maintaining more moderate temperatures

o An excess of one chemical reactant is also used to increase conversion of the other
(limiting) reactant when the extent of reaction is limited by equilibrium.

o Side reactions can be minimized by using an excess of one reactant

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactors for handling large values of adiabatic temperature change
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Economics and operational aspects determine whether an impurity should be separated
(when?) or not

o Ease of separation:
 Distillation: relative volatilities are assessed
 Crystallization: freezing points are examined

o Reactor size

o Heat absorption
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: MTBE production

Methyl tertiary-butyl ether

 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: MTBE production

Purchased in- house production (mixed C4 stream)

• Should we separate the impurities before the reactor of after that?

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: MTBE production

α=Pi/PMTBE at 200 oF

i α
1-butane 5.13
1,3-butadiene 4.116
Isobutene 4.04
MTBE 1
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: MTBE production

i α
1-butane 5.13
α=Pi/PMTBE at 200 oF 1,3-butadiene 4.116
Isobutene 4.04
MTBE 1

• relative volatilities
• impact on the catalyst
• the volumes of the reactors and distillation towers
• the temperature levels in the exothermic reactors
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: isomerization of n-butane to iso-butane

• Feed stream: 80% n-C4 and 20% i-C4

• What are the alternatives for positioning the reaction and distillation operations?
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: isomerization of n-butane to iso-butane
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 3: When nearly pure products are required, eliminate inert species before the reaction
operations when the separations are easily accomplished and when the catalyst is adversely
affected by the inert, but not when a large exothermic heat of reaction must be removed.
• Example: isomerization of n-butane to iso-butane
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 4: Introduce purge streams to provide exits for species that enter the process as
impurities in the feed or are formed in irreversible side reactions, when these species are
in trace quantities and/or are difficult to separate from the other chemicals.

• In order to avoid the accumulation of small trace of inert chemicals, purge streams are
considered

• Because the reaction or separation of species in low concentration is usually costly, purge
streams are used when the species are nontoxic and have little impact on the environment

• Purge streams are also used for removing species present in larger amounts when their
separation from the other chemicals in the mixture is difficult
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 4: Introduce purge streams to provide exits for species that enter the process as
impurities in the feed or are formed in irreversible side reactions, when these species are
in trace quantities and/or are difficult to separate from the other chemicals.

• Example: Ammonia process

???
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 4: Introduce purge streams to provide exits for species that enter the process as
impurities in the feed or are formed in irreversible side reactions, when these species are
in trace quantities and/or are difficult to separate from the other chemicals.

• Example: Ammonia process

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 4: Introduce purge streams to provide exits for species that enter the process as
impurities in the feed or are formed in irreversible side reactions, when these species are
in trace quantities and/or are difficult to separate from the other chemicals.

• Example: Ammonia process

a sink for the argon and methane

Purge/recycle NH3 production

ratio (lbmol/h)
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production toluene benzene

HydroDeAlkylation (HDA)

biphenyl

• without a catalyst at temperatures in the range of 1,200–1,270∘F with approximately 75 mol% of

the toluene converted to benzene and approximately 2 mol% of the benzene produced in the
hydrodealkylation reaction converted to biphenyl
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production

• EP: 1.4 cent$/lb C6H6
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production

1,268∘F , 494 psia

Conversion 75%
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production Excess H2 to

(1) prevent carbon deposition and
(2) absorb much of the heat of the
exothermic hydrodealkylation reaction

1,268∘F , 494 psia

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Example: Benzene production
Heuristics for Process Synthesis
to avoid an expensive separation of the
product methane from the hydrogen
gas, a purge stream is utilized in which
methane leaves the process
????
1,268∘F , 494 psia
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production

1,268∘F , 494 psia

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Example: Benzene production

1,268∘F , 494 psia

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 5: Do not purge valuable species or species that are toxic and hazardous,
even in small concentrations (see the MSDSs). Add separators to recover valuable
species. Add reactors to eliminate, if possible, toxic and hazardous species

• Example: combustion effluents

CO
H2O
NOx
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 5: Do not purge valuable species or species that are toxic and hazardous,
even in small concentrations (see the MSDSs). Add separators to recover valuable
species. Add reactors to eliminate, if possible, toxic and hazardous species

• Example: combustion effluents

CO
H2O
NOx
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 6: Byproducts that are produced in small quantities in
reversible reactions are usually not recovered in separators or
purged. Instead, they are usually recycled to extinction.

• Recall the Benzene production process

What will happen if we don’t

separate/purge biphenyl?

1,268∘F , 494 psia

biphenyl

or

Irreversible reaction?????
Reversible reaction?????
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 7: For competing reactions, both in series and parallel, adjust the temperature,
pressure, and catalyst to obtain high yields of the desired products. In the initial
distribution of chemicals, assume that these conditions can be satisfied. Before
developing a base-case design, obtain kinetics data and check this assumption.

• When chemical reactions compete in the formation of a desired chemical, the reaction conditions
must be set carefully to obtain a desirable distribution of chemicals
• When selectivity is the key to the success of a process design, it is not uncommon to carry out an
extensive analysis of the reactor alone, before distributing the chemicals, and proceeding with the
synthesis of the flowsheet
• Often, adequate selectivity cannot be achieved by simply adjusting the temperature and pressure of
the reactions. In these cases, the field of catalysis plays a crucial role
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 7: For competing reactions, both in series and parallel, adjust the temperature,
pressure, and catalyst to obtain high yields of the desired products. In the initial
distribution of chemicals, assume that these conditions can be satisfied. Before
developing a base-case design, obtain kinetics data and check this assumption.
• Example: Selectivity of the Allyl Chloride Reactions

~1020 R
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 8: For reversible reactions especially, consider conducting them in a separation
device capable of removing the products and hence driving the reactions to the right. Such
reaction-separation operations lead to very different distributions of chemicals

• In conventional processing, when a reversible reaction operation is followed by a distillation column,

it is common to use an excess of a feed chemical to drive the reaction forward. Alternatively, when
the reaction takes place in the gas phase, the pressure is raised or lowered, depending on whether
the summation of the stoichiometric coefficients is negative or positive.

• The strategy of first positioning the reaction operation and then separation operation, does not lead
to effective combinations of reaction and separation operations for reversible reactions

• As an advanced alternative, a combined reaction-separation (reactive distillation) operation can be

placed in the flowsheet before chemicals are distributed

• Reactive distillation is used commonly when the chemical reaction is reversible and there is a
significant difference in the relative volatilities of the chemicals at the conditions of temperature
and pressure suitable for the reaction
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 8: For reversible reactions especially, consider conducting them in a separation
device capable of removing the products and hence driving the reactions to the right. Such
reaction-separation operations lead to very different distributions of chemicals

• Example: the production of methyl acetate

methanol acetic acid methyl acetate

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Just a hint: The optimal conversion may not be complete conversion. Instead, an
economic balance between a high reactor section cost at high conversion and a
high separation section cost at low conversion determines the optimum.

Products

Products
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 3: Separations
13 heuristics
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

• A feed separation system may be required to purify the reactor feed(s) by removing catalyst
poisons and inert species, especially if they are present as a significant percentage of the feed.

• An effluent separation system, which follows the reactor system and is almost always required,
recovers unconverted reactants (in gas, liquid, and/or solid phases) for recycle to the reactor
system and separates and purifies products and byproducts.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Reaction Phase creation

section Homogeneous (change T/P) Heterogeneous
mixture mixture
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Separation techniques:

o Second phase creation by heat transfer, shaft work, or pressure reduction

No other chemicals are added to the feed mixture and the separation is achieved by an
energy-separating agent (ESA), usually heat transfer, which causes the formation of a
second phase. The components are separated by differences in volatility, thus causing each
species to favor one phase over another.
o The introduction into the system of a second fluid phase
A second phase is added to the separation unit in the form of a solvent as a mass-
separating agent (MSA) that selectively (i) dissolves or (ii) alters the volatility of certain
species of the mixture. An additional separation step is usually required to recover the
solvent for recycle.
o The addition of a solid phase on which selective adsorption can occur
This method involves the addition of solid particles that selectively adsorb certain species
of the mixture. Subsequently, the particles must be treated by another separation method to
recover the adsorbed species and regenerate the adsorbent for further use.
o The placement of a selective membrane barrier
This technique imposes a barrier that allows the permeation of some species over others. A
mechanical energy loss accompanies the permeation. Thus, this technique involves an ESA.
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Common Industrial Separation Methods
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Synthesis of separation systems

o Separation methods

o ESAs and/or MSAs

o Separation equipment

o The optimal arrangement or sequencing of the equipment

o The optimal operating conditions of temperature and pressure for the equipment
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• For a binary mixture:
o When the process feed is a binary mixture and the task is to separate that mixture into two
products, a single separation device may suffice if an ESA is used
o If an MSA is necessary, an additional separation device will be required to recover the MSA
for recycle.

• For a multicomponent feed:

o Not only must these devices be selected but also an optimal arrangement of the devices must
be sought
o In a multicomponent separation process, each separation operation generally separates between
two components in which case the minimum number of operations is one less than the number
of products (usually Nsep,min=Nprod-1)
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1)
Phase condition
of the feed

Separation Criterion (2)

Methods Selection Separation
Criteria factor

Criterion (3)
Reason for the
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Vapor feeds
Criterion (1)
Phase condition Liquid feeds
of the feed
Slurries, Wet Cakes, and Dry Solids
Criterion (2)
Selection of
Separation
separation methods
factor

Criterion (3)
Reason for the
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

(1) partial condensation

Vapor feeds
(2) cryogenic distillation
Criterion (1)
Liquid feeds (3) gas absorption
Phase condition
(4) gas adsorption
of the feed
Slurries, Wet Cakes, and Dry Solids (5) membrane
(6) desublimation
Criterion (2)
Selection of
Separation
separation methods
factor

Criterion (3)
Reason for the
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

(1) flash or partial vaporization

Vapor feeds
(2) (ordinary) distillation
Criterion (1)
Liquid feeds (3) stripping
Phase condition
(4) extractive distillation
of the feed
Slurries, Wet Cakes, and Dry Solids (5) azeotropic distillation
(6) liquid–liquid extraction
Criterion (2) (7) Crystallization
Selection of
Separation (8) liquid adsorption
separation methods
factor (9) dialysis, reverse osmosis,
ultrafiltration, and pervaporation
Criterion (3) with membrane,
Reason for the (10) supercritical extraction
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Vapor feeds
Criterion (1)
Phase condition Liquid feeds
of the feed
Slurries, Wet Cakes, and Dry Solids Slurry feeds are generally
separated first by filtration or
Criterion (2)
Selection of centrifugation to obtain a wet
Separation
separation methods cake, which is then separated
factor
into a vapor and a dry solid by
drying. Feeds consisting of dry
Criterion (3) solids can be leached with a
Reason for the selective solvent to separate
separation the components.
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1) If phase I is to be rich in component 1 and phase II is to be

Phase condition rich in component 2, then SF must be large
of the feed

Criterion (2)
Selection of Distillation
Separation
separation methods
factor

Criterion (3)
Extractive distillation
Reason for the
separation

Liquid–liquid extraction
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1)
Phase condition 59
of the feed
99% Propylene
100 1% Propane
Criterion (2)
Selection of 60% Propylene 290
Separation 40% Propane psi
separation methods
factor
41
Criterion (3)
5% Propylene
Reason for the 95% Propane
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1)
Phase condition 59

of the feed 61% Propylene

100 39% Propane
290
Criterion (2) 60% Propylene psi
Selection of 40% Propane SF=1.66
Separation 51.4oC
separation methods
factor
41
Criterion (3) 49% Propylene
Reason for the 51% Propane

separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

a column with 200 stages and a reflux ratio of 15.9

Criterion (1)
Phase condition
of the feed 59
99% Propylene
1% Propane
100
Criterion (2)
Selection of
Separation 60% Propylene
separation methods 40% Propane
factor

Criterion (3) 41
Reason for the
separation 5% Propylene
95% Propane
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
a column with 200 stages and a reflux ratio of 15.9

• Single-stage operations (e.g., partial vaporization or

partial condensation with the use of an ESA) are utilized
Criterion (1) only if SF between the two key components is very large.
Phase condition For example, if SF=10,000, a mixture containing equimolar
of the feed
parts of components 1 and 2 could be partially vaporized to
give a vapor containing 99 mol%of component 1 and a liquid
Criterion (2)
Selection of
Separation
containing 99 mol%of component 2.
separation methods
factor
• At low values of SF, lower than 1.10 but greater than
Criterion (3) 1.05, ordinary distillation may still be the most economical
Reason for the choice.
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1)
Phase condition
of the feed

Criterion (2)
Selection of
Separation
separation methods
factor

Criterion (3)
Reason for the
separation
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Criterion (1)
Phase condition
of the feed The use of an MSA method may avoid
exposure with an ESA method to high
temperatures that may cause
Criterion (2)
Selection of (1) purification of a species decomposition
Separation
separation methods or group of species
factor
In some cases, removal of
Criterion (3) (2) removal of undesirable undesirable species together with a
Reason for the constituents modest amount of desirable species
separation may be economically acceptable
(3) recovery of constituents
for subsequent processing or Likewise, in the recovery of
removal. constituents for recycle, a high degree
of separation from the product(s) may
not be necessary.
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Sequencing of ordinary distillation columns
o Separation of A/B/C/D into four products, how many columns?

A (light) B
B
C
D (heavy) C

D
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Sequencing of ordinary distillation columns
Products are distillates

Products are bottom products

 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Sequencing of ordinary distillation columns

o The number of different sequences for P products

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 9: Separate liquid mixtures using distillation, stripping, enhanced (extractive,

azeotropic, reactive) distillation, liquid–liquid extraction, crystallization, and/or adsorption

Distillation
Stripping
Enhanced distillation
LL extraction
Crystallization
Adsorption
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 10: Attempt to condense or partially condense vapor mixtures with cooling water
or a refrigerant. Separate vapor mixtures using partial condensation, cryogenic distillation,
absorption, adsorption, membrane separation, and/or desublimation.

Partial condensation
Cryogenic distillation
Absorption
Adsorption
Membrane separation
Desublimation
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 11: Sequencing of ordinary distillation columns …

11-1) Remove thermally unstable, corrosive, or chemically reactive components early in the sequence.

11-2) Remove final products one-by-one as distillates (the direct sequence).

11-3) Remove, early in the sequence, those components of greatest molar percentage in the feed.

11-4) Remove the products in the order of decreasing relative volatility so that the most difficult splits are made in the
absence of the other components.

11-5) Sequence separation points to leave last those separations that give the highest purity products.

11-6) Sequence separation points that favor near equimolar amounts of distillate and bottoms in each column
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

benzene

1,268∘F , 494 psia

biphenyl

toluene
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

1,268∘F , 494 psia

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

Vapor phase

1,268∘F , 494 psia

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

Benzene Toluene Biphenyl

50

45
Component NBP (oC) Tc (oC)
40

35 P=34 bar (490 psi) H2 -253 -240

Vapor Pressure (bar)

30
CH4 -161 -82
25
T=35 oC (100 oF)
20
C6H6 80 289
15
C7H8 111 319
10

5 C12H10 255 516

0
0 100 200 300 400 500 600
Temperature (Deg C)
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

Liquid Separation
System
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

Liquid Separation
System
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process

Stream Component
H2
A
CH4
B C6H6
C C7H8
D C12H10
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The Benzene production process
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Distillation system considerations

o The relative volatility between the two selected key components for the separation in each
column is greater than 1.05

o The reboiler duty is not excessive. An example of an excessive duty occurs in the distillation of a
mixture with a low relative volatility between the two key components where the light key
component is water, which has a very high heat of vaporization.

o The tower pressure does not cause the mixture to approach its critical temperature

o The overhead vapor can be at least partially condensed at the column pressure to provide reflux
without excessive refrigeration requirements

o The bottoms temperature at the tower pressure is not so high that chemical decomposition
occurs and it must be far from auto ignition temperature at the column pressure

o Azeotropes do not prevent the desired separation

o Column pressure drop is tolerable, particularly if operation is under vacuum

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Distillation system considerations
D
F xDi
zi

B
xBi
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation

o Most chemical processes involve two important operations (reaction and separation) that are
typically carried out in different sections of the plant and use different equipment

Products
o Recycle streams are used to:
 improve conversion and yield
 minimize the production of undesirable byproducts
 improve energy efficiency
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation

o Process intensification: process innovations which lead to smaller inventories of chemical

materials and higher energy efficiency

o Reactive distillation is an excellent example of process intensification

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation

o Reactive distillation provides simultaneous production and removal of products.

o For reversible chemical reactions, the removal of the product components drives the reaction
toward the product side. Thus, the chemical equilibrium constraint on conversion can be
overcome and high conversions can be achieved, even in cases with small chemical equilibrium
constants.

o The relative volatilities among the reactants and the products must be such that the products
can be fairly easily removed from the region in the column where the reaction is occurring and
reactants are not lost from this region.

o The column configuration depends on the relative volatility of the reactants and products
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation

o Consider :
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation

o Consider :
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Reactive distillation
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 4: Heat removal from and addition to

reactors
2 heuristics
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 12: To control temperature for a highly exothermic/endothermic heat of
reaction, consider the use of (i) excess reactant, (ii) an inert diluent, or (iii) cold/hot shots.
These affect the distribution of chemicals and should be inserted early in process synthesis

excess reactant

Affecting
the inert diluent
distribution
of chemicals

B (cold/hot feed)

Cold/hot shots
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Heuristic 13: For less exothermic/endothermic heats of reaction, (i) circulate reactor fluid
to an external cooler/heater or (ii) use a jacketed vessel or (iii) cooling/heating coils. Also,
consider the use of intercoolers/interheaters between adiabatic reaction stages.

The opportunity of heat integration

 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• The design team selects acceptable temperature levels and flow rates of the recirculating
fluids, considering:

o the rates of reaction to avoid thermal runaway or catalyst deterioration

o the materials of construction
o the temperature levels of the available cold process streams and utilities, such as cooling water

• It is common to assign temperatures on the basis of these factors early in process

synthesis. However, as optimization strategies are perfected, temperature levels are
varied within bounds.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 5: HEAT EXCHANGERS AND FURNACES

10 heuristics
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• Heat exchange methods in a process:

o Heat exchange between two process fluids using a double-pipe, shell-and-tube, or compact heat
exchanger.

o Heat exchange between a process fluid and a utility, such as cooling water or steam, using a
double-pipe, shell-and-tube, compact, or air-cooled heat exchanger.

o High-temperature heating of a process fluid using heat from the products of combustion in a
furnace (also called a fired heater).

o Heat exchange within a reactor or separator, rather than in an external heat-exchange device
such as a shell-and-tube heat exchanger or furnace.

o Direct heat exchange by mixing the two streams that are exchanging heat.

o Heat exchange involving solid particles.

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 14: Provide necessary heat exchange in an external shell-and-tube heat

exchanger using countercurrent flow.

400 oC
Heuristic 15: If a process stream requires heating above 750∘F, use a furnace

~6 oC ~ 11 oC
Heuristic 16: Consider appropriate MITA (<10oF for temperatures below ambient, 20oF for
temperatures at or above ambient up to 300oF, 50oF for high temperatures, 250 to 350oF in
a furnace) ~ 28 C ~ 140 to 200oC
o

Heuristic 17: When using cooling water to cool or condense a process stream, assume a
water inlet temperature ofo 90oF (from a cooling tower) and a maximum water outlet
32 C
temperature of 120oF.o
49 C
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Toluene Styrene
100oF and 90 psi 300oF and 50 psi
25000 lb/h 25000 lb/h
0.43 Btu/lb oF 0.44 Btu/lb oF

MITA: 20 oF

T= ??????? T= ???????
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Toluene Styrene
100oF and 90 psi 300oF and 50 psi
25000 lb/h 25000 lb/h
0.43 Btu/lb oF 0.44 Btu/lb oF

MITA: 20 oF
1 T out = 120 oF
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Toluene Styrene
100oF and 90 psi 300oF and 50 psi
25000 lb/h 25000 lb/h
0.43 Btu/lb oF 0.44 Btu/lb oF

MITA: 20 oF T out = 284oF

1 T out = 120 oF MITA: 16 oF
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Toluene Styrene
100oF and 90 psi 300oF and 50 psi
25000 lb/h 25000 lb/h
0.44 Btu/lb oF 0.44 Btu/lb oF

MITA: 20 oF T out = 284oF

1 T out = 120 oF MITA: 16 oF

MITA: 20 oF
T out = 280 oF 2
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Toluene Styrene
100oF and 90 psi 300oF and 50 psi
25000 lb/h 25000 lb/h
0.44 Btu/lb oF 0.44 Btu/lb oF

MITA: 20 oF T out = 284oF

1 T out = 120 oF MITA: 16 oF

T out = 124 oF MITA: 20 oF

MITA: 24 oF T out = 280 oF 2
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

MITA MITA

Temperature
Temperature

Enthalpy Enthalpy

(a) (b)
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 18: When cooling/heating a phase-changing-stream in a heat exchanger, a zone

analysis, should be made to make sure that the temperature difference between the hot
stream and the cold stream is equal to or greater than MITA.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 19: Boil a pure liquid or close-boiling liquid mixture in a separate heat exchanger,
using a maximum overall temperature driving force of 45oF to ensure nucleate boiling and
avoid undesirable film boiling.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 20: Use excess air to achieve complete combustion and give a maximum flue gas
temperature of 2,000 oF. Set the stack gas temperature in the range of 650–950oF to
1100 C
o
prevent condensation of corrosive components of the flue gas. 340-510 C
o

• Typically, a hydrocarbon gives an adiabatic flame temperature of approximately 3,500oF when

1900 oC
using the stoichiometric amount of air.

• Using stoichiometric amount of air, not only causes incomplete combustion, but it requires high
temperature resistance material for the furnace and tubes.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 21: Estimate heat exchanger pressure drop (1.5 psi for boiling and condensing, 3
psi for a gas, 5 psi for a low-viscosity liquid, 7–9 psi for a high-viscosity liquid, 20 psi for a
process fluid passing through a furnace)

620 oC
Heuristic 22: Quench a very hot process stream to at least 1,150oF before sending it to a
heat exchanger for additional cooling and/or condensation.

Heuristic 23: If possible, heat or cool a stream of solid particles by direct contact with a hot
gas or cold gas, respectively, using a rotary kiln, a fluidized bed, a multiple hearth, or a
flash/pneumatic conveyor. Otherwise, use a jacketed spiral conveyor.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 6: Pumping, compression, and

pressure reduction
13 heuristics
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

‫ تجهیزات انتقال سیاالت‬

‫ سیاالت تراکم پذیر‬o
‫ سیاالت تراکم ناپذیر‬o
‫‪Saeed Eini‬‬
‫‪Dep. of Chem. and Petrol. Eng.‬‬
‫‪Sharif Uni. of Technology‬‬
‫‪Heuristics for Process Synthesis‬‬

‫‪ ‬تجهیزات انتقال سیاالت تراکم پذیر (گازها)‬

‫‪ o‬برای جاری ساختن یا افزایش فشار سیاالت تراکم پذیر (گازها) از تجهیزات زیر استفاده می شود‪:‬‬
‫هواکش (‪ :)Fan‬برای جاری ساختن گازهای با فشار اتمسفری و افزایش فشار آن ها تا حدود ‪ 1/5‬پام‬ ‫•‬
‫دمنده (‪ :)Blower‬برای افزایش فشار گازها تا حدود ‪ 40‬پام‬ ‫•‬
‫کمپرسور (‪ :)Compressor‬برای افزایش فشار گازها بیش از ‪ 40‬پام‬ ‫•‬

‫‪Axial compressor‬‬ ‫‪Two-lobe blower‬‬ ‫‪Axial fan‬‬

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Compressor operating ranges

‫‪Saeed Eini‬‬
‫‪Dep. of Chem. and Petrol. Eng.‬‬
‫‪Sharif Uni. of Technology‬‬
‫‪Heuristics for Process Synthesis‬‬

‫‪ ‬تجهیزات انتقال سیاالت تراکم ناپذیر (مایعات)‬

‫‪ o‬برای جاری ساختن و افزایش فشار مایعات از پمپ (‪ )Pump‬استفاده می شود‪.‬‬
‫‪ o‬به طور کلی پمپ ها به دو دسته تقسیم می شوند‬
‫پمپ های جابجایی مثبت (‪)Positive displacement‬‬ ‫•‬
‫پمپ های دینامیکی‪/‬سانتریفیوژی (‪)Dynamic/Centrifugal‬‬ ‫•‬
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Pump Handbook, Karassik et al, 2001

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

)‫ تجهیزات انتقال سیاالت تراکم ناپذیر (مایعات‬

‌‫‌‌به‌دو‌دسته‌کلی‌رفت‌و‌برگشتی‬:)Positive displacement(‌‫پمپ‌های‌جابجایی‌مثبت‬ •
‫)‌تقسیم‌می‌شوند‬Rotary(‌‫)‌و‌دورانی‬reciprocating(

Single acting reciprocating pump Rotary (gear) pump

‫‪Saeed Eini‬‬
‫‪Dep. of Chem. and Petrol. Eng.‬‬
‫‪Sharif Uni. of Technology‬‬
‫‪Heuristics for Process Synthesis‬‬

‫‪ ‬تجهیزات انتقال سیاالت تراکم ناپذیر (مایعات)‬

‫پمپ‌های‌جابجایی‌مثبت‌(‪‌:)Positive displacement‬این‌پمپ‌ها‌برای‌سیاالت‌بسیار‌لزج‌یا‌برای‌‬ ‫•‬
‫شرایط‌با‌دبی‌کم‌کاربرد‌دارند‪‌.‬کاربردهای‌دیگر‌این‌پمپ‌ها‌در‌شرایطی‌است‌که‌فشار‌زیادی مورد‌نیاز‌‬
‫باشد‪‌.‬همچنین‌برای‌سیاالت‌حساس‌به‌تنش‌(مانند‌سیاالت‌غیرنیوتنی)‌به‌کار‌می‌روند‪‌.‬از‌طرف دیگر‌در‌‬
‫تجهیزاتی‌که‌اندازه‌گیری‌دبی‌دقیق‌جریان‌مهم‌است‌کاربرد‌دارد‪.‬‬
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

)‫ تجهیزات انتقال سیاالت تراکم ناپذیر (مایعات‬

)Dynamic/Centrifugal( ‫سانتریفیوژی‬/‫پمپ های دینامیکی‬ •
 ‫‪Saeed Eini‬‬
‫‪Dep. of Chem. and Petrol. Eng.‬‬
‫‪Sharif Uni. of Technology‬‬
‫‪Heuristics for Process Synthesis‬‬

‫‪ ‬تجهیزات انتقال سیاالت تراکم ناپذیر (مایعات)‬

‫پمپ های دینامیکی‪/‬سانتریفیوژی (‪ :)Dynamic/Centrifugal‬در صنایع عمدتا از این نوع پمپ ها استفاده‬ ‫•‬
‫می شود (‪ 70‬درصد کاربردها)‪ .‬مزایای این پمپ ها نسبت به دسته قبلی‪ :‬هزینه های پایین تر‪ ،‬عملیات ایمن تر و‬
‫ساده تر‪ ،‬عمر باالتر‪ ،‬شرایط عملیاتی کاربردی وسیع تر‬
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 24: Increase the pressure of gas streams as follows:

Fan: ∆P<1.5 psig , Blower: 1.5<∆P<30 psig , Compressor: ∆P>30 psig

Heuristic 25: For the case of a gas stream compression, preliminary, the assumption of a
single stage of reversible and adiabatic compression process may be considered.

THp = theoretical adiabatic horsepower

SCFM = standard cubic feet of gas per minute at 60oF and 1 atm (379 SCF∕lbmol)
T1 = gas inlet temperature in oR
P1 and P2= inlet and outlet absolute pressures
a=(k-1)/k where k = cp/cv

Heuristic 26: When using a compressor, the gas theoretical exit temperature should not
exceed approximately 375oF, the limit imposed by most compressor manufacturers. This
corresponds oto a compression ratio of 4 for k = 1.4 and T1 = 100oF.
190 C 38 oC
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 27: Optimal interstage pressures correspond to equal Hp for each compressor.
Therefore, estimate interstage pressures by using approximately the same compression
ratio for each stage with an intercooler pressure drop of 2 psi or 15 kPa.

Compression
30 psi 569 psi
100 oF
Compression ratio: 19
19 = (4)2.12  3 stages
19(1/3) = 2.7

30 psi 81 psi 79 psi 213 psi 211 psi 569 psi

100 oF 100 oF 100 oF
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 28: Select the type of pumping systems based on operating conditions.

H<3,200 ft and 10<Q<5,000 gpm use a centrifugal pump

H<20,000 ft and Q<500 gpm use a reciprocating pump
H<40 ft and 20<Q<100,000 gpm use a axial pump
H<3,000 ft and 1<Q<1,500 gpm use a rotary pump

Heuristic 29: The pump must overcome pressure drops in the system

For liquid flow:

o pipeline pressure drop of 2 psi∕100 ft
o control valve pressure drop of at least 10 psi
o pressure drop of 4 psi for each 10- ft rise in elevation

Heuristic 30: Estimate the theoretical horsepower (THp) for pumping a liquid using:
THp=(gpm)(Pressure increase, psi)/1714
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 31: Consider the use of an expander for reducing the pressure of a gas or a
pressure-recovery turbine for reducing the pressure of a liquid when more than 20 Hp and
150 Hp, respectively, can be recovered.

Heuristic 32: To increase the pressure of a stream, pump a liquid rather than compress a
gas unless refrigeration is needed.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Part 7: General considerations

4 heuristics
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Heuristic 33: To increase second-law efficiency and reduce energy consumption, avoid, if
possible, the mixing of streams of different temperatures, pressures, or compositions.

Heuristic 34: For a new process, determine how it differs from a similar conventional
process and pinpoint the advantages and disadvantages of the new process, making
changes where disadvantages are uncovered

Heuristic 35: Carefully examine the process flowsheet, looking for ways to eliminate
equipment by combining, rearranging, or replacing process steps.

Heuristic 36:Perform preliminary economic evaluations at different production rates and

corresponding plant sizes using simple scaling methods, noting that what is not
economical at a small size may be economical at a large size and vice versa
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis
• You may find more heuristics regarding the following issues in chapter 6 of the textbook:
o Separations involving solid particles
o Conveying granular solids
o Changing the pressure of granular solids
o Vacuum operations
o Changing the particle size of solids and size separation of particles
o Removal of particles from gases and liquids

• Refer to other references for more heuristics

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Heuristics for Process Synthesis

Workshop 2: Reporting

Workshop 3: Feasibility Study