Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Course Outline
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Course Outline
WEEK
TOPIC
Process Design Principles
Flow sheets,
Chemical Engineering Design of Mass and
Heat Transfer Equipment (Plate columns,
absorption towers, distillation columns, heat
exchangers, evaporators etc).
Mechanical Design of Equipments Pressure vessels, columns, storage tanks,
heat exchanger, etc.
Piping and instrumentation.
Costing and Project Evaluation
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Note:
Computer Applications are readily available to determine many of the
parameters and properties discussed in this course. However the basis and the
concepts are discussed to give a more complete understanding of the subject.
This ensures correct interpretation of computer generated results.
Furthermore, it provides foundation for students who may want to delve into
development of Computer-Aided Process applications in future
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Design Constraints
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Design Process
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Data collection
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Design selection
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Continuous processes
Designed to operate 24 hours a day, 7 days a
week, throughout the year.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Continuous processes
Production rate greater than 5 X 106 kg/h
Single product
No severe fouling
Good catalyst life
Proven processes design
Established market
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Batch Processes
Batch processes are designed to operate
intermittently. Some, or all, the process units
being frequently shut down and started up.
Batch processes are used where some
flexibility is wanted in production rate or
product specification.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Batch Processes
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Batch Processes
Production rate less than 5 X 106 kg/h
A range of products or product specifications
Severe fouling
Short catalyst life
New product
Uncertain design
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Project Documentation
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Project Documentation
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Factors of Safety
Avoid overdesign
(Preferred terminology: Design factor) Factor of safety historical
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Systems of Units
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Systems of Units
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Systems of Units
Note:
The electrical supply frequencies vary from one country to
another; 60 Hz in the US, 50 Hz in the UK and Nigeria. So a pump
specified running at 1750 rpm (revolutions per minute) in the US
would have its motor speed reduced to 1460 rpm in Nigeria and UK.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Degrees of freedom: The difference between the number of variables involved in a design
and the number of design relationships.
Nd= Nv- Nr
Nv = the number of possible variables in a design problem
Nr= the number of design relationships
Nd = Degrees of freedom
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Flash distillation
F = stream flow rate,
P = pressure,
T = temperature,
xi = concentration, component i,
q = heat input.
Suffixes, 1 = inlet, 2 = outlet vapour, 3 = outlet liquid.
Process Design Principles
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Variable
Streams 1
Still
Number
Stream1
C+2
Stream 2
C+2
Stream 3
C+2
Pressure
1
Temperature
1
Heat input
1
Nv(Total 3C+9
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Relationship
Number
C
1
C
4
2C+5
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Nd= Nv- Nr
Nd= (3C+9) - (2C+5) = C+4
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Optimization
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Optimization
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Optimization
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Optimization
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Stoichiometry
Write out and balance the overall equation for the manufacture of vinyl
chloride from ethylene, chlorine and oxygen
Write out the equation using letters for the unknown number of
molecules of each reactant and product. Make a balance on each
element. Solve the resulting set of equations.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Problem:
The feed stream to a reactor contains: ethylene 16 per cent, oxygen 9 per
cent, nitrogen 31 per cent, and hydrogen chloride. If the ethylene flow is 5000
kg/h, calculate the individual component flows and the total stream flow. All
percentages are by weight.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Solution:
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
General rule: the ratio of the flow of any component to the flow of any other
component is the same as the ratio of the compositions of the two components.
The flow of any component could have been calculated directly from the ratio of
the percentage to that of ethylene, and the ethylene flow.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Tie Component
Flow of any component is in the same ratio to the flow of any other component, as
the ratio of the concentrations of the two components.
If one component passes unchanged through a process unit it can be used to tie the
inlet and outlet compositions. (Nitrogen in combustion)
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Problem:
Carbon dioxide is added at a rate of 10 kg/h to an air stream and the air is
sampled at a sufficient distance downstream to ensure complete mixing. If the
analysis shows 0.45 per cent v/v CO2, calculate the air-flow rate.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Excess reagent
In industrial reactions the components are seldom fed to the reactor
in exact stoichiometric proportions.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Problem:
To ensure complete combustion, 20 per cent excess air is supplied to a
furnace burning natural gas. The gas composition (by volume) is
methane 95 per cent, ethane 5 per cent.
Calculate the mols of air required per mol of fuel.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Recycle Processes
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Problem
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Purge
A portion of a recycle stream bled off to prevent the build-up of unwanted material
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Problem:
In the production of ammonia from hydrogen and nitrogen the conversion, based on
either raw material, is limited to 15 per cent. The ammonia produced is condensed from
the reactor (converter) product stream and the unreacted material recycled. If the feed
contains 0.2 per cent argon (from the nitrogen separation process), calculate the purge
rate required to hold the argon in the recycle stream below 5.0 per cent. Percentages
are by volume.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
A flow stream divided and some part diverted (bypassed) around some units often used to control
stream composition or temperature.
Material balance calculations similar to those
involving recycle, except that the stream is fed forward
instead of backward
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
H= U+Pv
H2 - H1= Q - W
Q=H2-H1
Q=Qp +Qs
Qp =H2-H1-Qs
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Estimate the steam and the cooling water required for the distillation column
shown in the figure. Steam is available at 25 psig (274 kN/m2 abs), dry
saturated. The rise in cooling water temperature is limited to 300C. Column
operates at 1 bar.
Solution: Text Example 3.1
Process Design Principles
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
No Phase transition.
where
HT = specific enthalpy at temperature T,
Cp = specific heat capacity of the material, constant pressure,
Td = the datum temperature
Phase transition takes place.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
If Cp is represented by polynomial:
Then.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
For gases:
negligible heats of mixing
heat capacities and enthalpies can be taken as additive
For Liquids:
negligible heats of mixing not negligible
Heat of mixing considered in calculation of enthalpies .
For binary mixture.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.
Covenant University Department of Chemical Engineering . CHE 414: Principles of Plant Design - Daniel Ayo, PhD.