CHAPTER 5

Optimum Design and Design Strategy

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An optimum design is based on the best or most favorable
conditions. In almost every case, these optimum conditions can
ultimately be reduced to a consideration of costs or profits. Thus,
an optimum economic design could be based on conditions giving
the least cost per unit of time or the maximum profit per unit of
production. When one design variable is changed, it is often found
that some costs increase and others decrease. Under these
conditions, the total cost may go through a minimum at one value
of the particular design variable, and this value would be
considered as an optimum. An example illustrating the principles
of an optimum economic design is presented in Fig. 11-1. In this
simple case, the problem is to determine the optimum thickness of
insulation for a given steam-pipe installation. As the insulation
thickness is increased, the annual fixed costs increase, the cost of
heat loss decreases, and all other costs remain constant.
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5.1 A multiple-effect evaporator is to be used for evaporating
400,000 lb of water per day from a salt solution. The total initial
cost for the first effect is $18,000, and each additional effect costs
$15,000. The life period is estimated to be 10 years, and the salvage
or scrap value at the end of the life period may be assumed to be
zero. The straight-line depreciation method is used. Fixed charges
minus depreciation are 15 percent yearly based on the first cost of
the equipment. Steam costs $1.50 per 1000 lb. Annual maintenance
charges are 5 percent of the initial equipment cost. All other costs
are independent of the number of effects. The unit will operate 300
days per year. If the pounds of water evaporated per pound of steam
equals 0.85 x number of effects, determine the optimum number of
effects for minimum annual cost.

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5.1 V1 +V2+ V3+…..+ Vn = 400,000 lb of water / day
total initial cost for 1st effect = $ 18,000
additional effect = $ 15000
n = 10 yrs , salvage value = 0
operating day = 300 day / yr
fixed charges – depreciation = 15 % first cost of equipment
steam cost = $ 1.5 / 1000 lb
annual maintenance charges = 5 % initial equipment cost
= 0.85
optimum no of effect for min annual cost = ?
=0 , n=?
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let no of effect = n
evaporator cost = (18,000 + (n - 1) 15000)$
annual fixed change = 15% 1st cost 0f equipment
(excluding depreciation)
annual fixed charges = 0.15 (180000 + (n – 1 ) 15000) $/yr
depreciation cost = +
= 0.1 (18000 + (n – 1 ) 15000) $/ yr
annual maintenance charge = 5 % initial equipment cost
= 0.05 (18000 + ( n – 1 ) 15000)

lb of steam used = (given)

lb of H2O evaporated = 400,000 lb of H2O /day × 300 day /yr

= 12 × 107 lb of H2O evaporated / yr
lb of steam used =

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annual steam cost = ×

= $/ yr
Total annual cost = fixed cost /yr + depreciation cost/yr +
maintenance charges / yr + steam cost/yr

= 0.15 (18000 + (n - 1) 15000) + 0.1 (18000+ (n-1)

15000)+ 0.05(18000 + ( n - 1) 15000) +
CT = 5400 + ( n -1 ) 4500 +
= 4500 - = 0 (at optimum condition)
n = 6.86
n7
optimum number of effect = 7

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5.3 An absorption tower containing wooden grids is to be used for
absorbing SO2, in a sodium sulfite solution. A mixture of air and SO 2,
will enter the tower at a rate of 70,000 ft3/min, temperature of 25 ̊F, and
pressure of 1.1 atm. The concentration of SO 2, in the entering gas is
specified, and a given fraction of the entering SO 2 , must be removed in
the absorption tower. The molecular weight of the entering gas mixture
may be assumed to be 29.1. Under the specified design conditions, the
number of transfer units necessary varies with the superficial gas
velocity as follows:
Number of transfer units = 0.32Gs0.18
where Gs, is the entering gas velocity as lb/(hr ft 2) based on the cross-
sectional area of the empty tower.The height of a transfer unit is constant
at 15 ft. The cost for the installed tower is $1 per cubic foot of inside
volume, and annual fixed charges amount to 20 percent of the initial
cost. Variable operating charges for the absorbent, blower power, and
pumping power are represented by the following equation:
Total variable operating costs as $/h = 1.8Gs2 × 10-8 + +
The unit is to operate 8000 h/year. Determine the height and diameter of
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the absorption tower at conditions of minimum annual cost.
5.3 70000 ft 3 / min
250 ̊ F
molecular wt = 29.1
no of transfer unit = 0.32 Gs 0.18

Gs = gas velocity (lb /hr ft2 )

heigh transfer unit = 15 ft / unit
installed tower cost = $ 1/ft3 (inside volume)
annual fixed changes = 20 % of initial cost
total variable operating cost = (1.8 Gs 2 × 10 -8 + ) $/yr

8000 hr /yr
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5.3

= 0.062 lb /ft3

m ̊ = 70,000 ft 3 /min × 60 min/hr × 0.062 lb/ ft3

= 260,400 lb/hr

A = = 260,400 × = ft 2

no of transfer unit = 0.32 Gs 0.18

height of transfer unit = 1.5 ft / unit

height of tower = 1.5 × 0.32 Gs 0.18 ft

= 4.8 Gs0.18 ft
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volume of tower = A × height of tower
= 260400 ft2 × 4.8 Gs0.18 ft
= ft 3

cost for installed tower = initial cost = 1 $ /ft3 × volume

= 1 $ /ft3 × ft 3

= $

annual fixed charges = 20 % initial cost (given)

= 0.2 × $/yr
= $/yr

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variable operating cost = (1.8 Gs 2 × 10 -8 + + ) $/hr × 8000 hr/yr
= (14400 G s 2 × 10 - 8 + + ) $ / yr

total annual cost = annual fixed charges + variable operating cost

= ( + 14400 Gs2 ×10-8 + + ) $/yr

-0.82 -4 -0.8
annual cost =( 249984 Gs + 1.44×10 Gs2 + 648000Gs-1+ 38400 Gs )
(annual cost) = 249984(-0.82) Gs-1.82 + 1.44×10- 4 Gs2 + 648000(-1) Gs-2
-1.8
+ 38400 (- 0.8) Gs ) = 0
G s = 1760.67

A = d2 = =

d = 13.7 ft

height of tower = 4.8 G s 0.18

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= 18.43 ft