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Code No: 07A70803

R07

Set No. 2

IV B.Tech I Semester Examinations,May/June 2012 CHEMICAL PROCESS EQUIPMENT DESIGN Chemical Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. Discuss the construction and functioning of falling lm evaporators with a neat diagram. [16] 2. (a) A double pipe heat exchanger is used to heat 1000 kg/h of oil from 30 0 C to 40 0 C using hot water at 90 0 Cin counter current ow. The hot water ows at a velocity of 2500 m/h through the annulus of the heat exchanger. The outer diameter of the inner pipe is 2.5cm and the inside diameter of outer pipe in 4.0 cm. The wall thickness of the inner pipe is 2mm. Neglect wall and scale resistances. Calculate the length of the heat exchanger. DATA: Properties Water Oil Cp (kJ/kgK) 4.2 1.9 K (W/mK) 0.7 0.14 3 (kg/m ) 1000 850 (m2 /s) 0.4 10 - 6 0.7 10 - 5 Heat Transfer coecients may be calculated using the equation appropriately. N u = 0.023 (N Re )0.8 (Npr )1/3 (b) Explain the salient features of the following heat exchangers with respect to their construction and limitations.

3. (a) What are the various types of stainless steel used as materials of construction? State their properties and applications as materials of construction. (b) State the purposes of lining chemical process equipment. Discuss the application of at least three types of lining used for process equipment. [8+8]

i. Double pipe heat exchangers ii. 1-1 Pass shell and tube heat exchanger.

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[10+6]

Discuss the features of the storage vessels for the following 4. (a) What do you understand wind girders? Explain their use in large storage (i) Storage of non-volatile liquids tanks. (ii) Storage of gases (b) Explain the meaning of ovalization of storage tank. (iii) Storage of volatile liquids (c) Explain How does occur? Write for theasalient features of tank a self - supported conical (b) the it design procedure horizontal storage with saddle supports. tank. [64] [6+10]
5. A mixture of benzene and toluene containing 40 percent benzene and 60 percent toluene is to be separated in fractionating column to give product (distillate) containing 96 percent benzene and a bottom product containing 95 percent toluene. Feed is a mixture of two third vapor and one third liquid. Find out the number of 1

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Code No: 07A70803

R07

Set No. 2

theoretical stages required if reux ratio of 1.5 times the minimum is used and if relative volatility is 2.5. [16] 6. The aqueous reaction A+B products with known kinetics -rA = (500lit/mol.min) CA CB is to take place in an experimental tubular reactor. Under the following conditions: Conversion desired =0.9, Volumetric ow rate V=0.05lit/min, concentration of reactants in feed, CA =CB =0.01mol/lit. Estimate the volume of the reactor Required. [16] 7. A constant pressure ltration test gave data that can t an expression, dt/dV = 9.3V + 8.5; (t in seconds, V in liters). If the resistance of the lter medium is assumed unaected with pressure drop and the compressibility coecient of the lter cake is 0.3, what will be the time taken for the collection of 3.5 liters of ltrate at a ltration pressure twice that used in the test? [16] 8. Explain the design procedure with required equations step wise to nd the size of the gasket and the number and size of the bolts for a non- standard ange joint. [16]

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Code No: 07A70803

R07

Set No. 4

IV B.Tech I Semester Examinations,May/June 2012 CHEMICAL PROCESS EQUIPMENT DESIGN Chemical Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. Derive the performance equation for Recycle reactors. In turn, give the equations for the extremes of negligible and innite recycle and name the ow types? [16]
2. Explain the following in the design of a sieves plate column. (a) Coning (b) Dumping (c) Weeping (d) Flooding.

3. (a) Draw a neat diagram of a 1 -1 shell and tube heat exchanger. Show all the parts including baes, tie rods, tube sheets and spacer tubes.

(b) A heat exchanger has to cool 50,000 kg/h of alcohol from 65 0 C to 40 0 C. using 35,000 kg/h of water entering at 30 0 C, calculate the surface area of the exchanger for: i. Parallel ow and ii. Counter ow of the uids. Explain why the surface required is less for counter current ow. DATA Overall heat transfer coecient based on outer tube =550 W/m K Specic heat alcohol = 3.76 kJ/kg K Specic heat of water = 4.2 kJ/kg K. [8+8]

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[16]

4. Derive an expression for calculating rate of heat transfer in single eect evaporator. [16] 5. A sludge forming a uniform non-compressible cake is ltered through a lter press out of which one frame is kept under study. At a constant pressure dierence of 2.8 kg/cm2 , a 10 cm cake is formed in one hour with a ltrate volume of 6000 liters. Three minutes are needed to drain liquor from lter. Two minutes are needed to ll the lter with water. Washing proceeds exactly as ltration using 1200 liters. Opening, dumping and closing take 6 minutes. Assume the ltrate has same properties of wash water and neglect the resistance oered by cloth and ow lines. How many liters of ltrate are produced in 24 hours on the average? [16] 6. (a) Explain, what do you understand by class 1, class 2 and class 3 types of Pressure Vessels.

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Code No: 07A70803

R07

Set No. 4

(b) A pressure vessel is required to store a liquid at 18 kg/cm2 . The cylindrical shell of the vessel is closed at both ends by a 2:1 elliptical heads with 5 cm straightange. The maximum ratio of liquid height to vessel diameter is 2. The permissible stress of material of fabrication is 1150kg/cm2 . Welded jointeciency is 85%. Maximum diameter of the vessel could be 2.5m. Calculate The height of the vessel. [4+12] 7. (a) A high pressure vessel is to be designed to with stand a pressure of 150MN/m2 . The material of fabrication has a yield stress of 500 MN/m2 . Find the wall thickness required by maximum shear stress theory. The factor of safety is 1.8. (b) A thick cylindrical shell having an inside diameter of 3m is subjected to an internal pressure of 6 kg/cm2 . The permissible stress of the material is 1100 kg/cm2 . Calculate: i. The required thickness and ii. The corresponding deection.

8. (a) (a)What Discuss important characteristics to be considered for selecting a material are the various types of stainless steel used as materials of construction? State of construction. their properties and applications as materials of construction. (b) State theispurpose chemical equipment. Discuss the application (b) i. It desiredof tolining select a suitableprocess material of construction to transport theof atleast three types of lining in used for process equipment. [8+8] following materials a pipe at a pressure of 2 atmospheres. Suggest suitable material of construction for each of the following cases. A. 98 percent w/w sulfuric acid at 750 c B. 30 percent w/w hydrochloric acid at 600 c C. Concentrated aqueous sodium hydroxide solution at 500 c D. Boiling concentrated nitric acid E. 10 percent w/w hydrouoric acid. ii. Suggest suitable materials of construction for storing each of the following chemicals A. A 100m3 storage tank for storing nitric acid B. A 2m diameter, 20m high distillation column for distilling acrylonitrile. C. A tank for storing 30 percent w/w aqueous solution of sodium chloride D. A storage tank for toluene E. A packed absorption column for absorbing hydrochloric acid into water. [6+5+5]

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[8+8]

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Code No: 07A70803

R07

Set No. 1

IV B.Tech I Semester Examinations,May/June 2012 CHEMICAL PROCESS EQUIPMENT DESIGN Chemical Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. Explain with neat diagram the methods of feeding in multiple eect evaporators. [16] 2. An oil is to be stored in a horizontal circular tank fabricated from mild steel. The capacity of the tank is to be 25m3 . The tank covers with at plates. Calculate the maximum tensile bending stress and direct shear stress from the following data. [16] DATA: Density of oil = 920 kg/m3 Plate thickness = 8mm Density of steel = 800 kg/m3 Inside Diameter of tank = 3m Length of the tank = 5m

3. (a) Explain the merits and demerits of a xed tube sheet, U-tube and oating shell and tube heat exchangers. Draw their schematic diagrams also. (b) Explain the function and classication of baes in a heat exchanger along with the gures of the various baes. [8+8] 4. A distillation column is to be designed to separate A and B continuously. The feed is 35 % of A and 65% B at its dew point. The distillate and the residue compositions are 0.95 and 0.025 respectively. (a) Find the quantities of distillate and bottoms per hour. (b) Find the number of equilibrium stages required in the column if the reux ratio is 2.5 Assume the relative volatility as 2.5. [16] 5. Under appropriate conditions acetaldehyde vapor reacts to give methane and carbon monoxide by the reaction, CH3 CHO CH3 + CO 0.1kg / sec of acetaldehyde vapor is to be decomposed at 520 0 C and 1 atm, in a tubular reactor. The reaction is irreversible and second order with respect to acetaldehyde. Value of rate constant, K= 0.43m3 /kg mole sec. What will be the volume of the reactor for 35% and 90% decomposition of acetaldehyde? [16] 6. The output from a crystallizer is a 10% by volume slurry of crystals which have a density of 2.2 g/cm3 . The acceptable crystal loss from the centrifuge is such that 5

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Code No: 07A70803

R07

Set No. 1

it is necessary to retain a crystal size of 40. Obtain an estimate of the cost of the most suitable type of centrifuge. The eciency of centrifuge is 60%. [16] 7. A vessel is made of stainless steel and the shell thickness is 6mm. The shell and top head are connected by a anged joint. The ange of 1400nm diameter is used for which the design thickness of the shell is found to be 8mm. Design gasket size, bolt size and number of bolts from the following data: Specication of gasket: Gasket material : Asbestos Internal diameter of gasket = 1400mm External diameter =1460 mm Thickness = 3mm Gasket factor = 2 Design pressure = 0.4N/mm2 Permissible tensile stress in bolts = 60 N/mm2 . [16] 8. A distillation column is used to separate mixture of water and acetone. The feed consisting of 85 percent of water and 15 percent acetone enters the distillation column at the rate of 1200 kg/h. The feed temperature is 300 C. The top product contains 98 percent acetone and its temperature is 570 C. The bottom product contains 0.5 percent acetone and its temperature is 1000 C. The reux ratio is 10. Estimate the steam and cooling water required for the distillation. Dry saturated Steam is supplied at 25 psig, The rise in temperature of cooling water is limited to 250 C. DATA: Specic heat of acetone = 2.2kJ/kgK Specic heat of water = 4.2 kJ/kgK Boiling point of 98 percent = 570 C Latent heat of acetone at 570 c=320kJ/kg Latent heat of water at 570 c = 2500kJ/kg Latent heat of steam = 2174 kJ/kg. [16]

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Code No: 07A70803

R07

Set No. 3

IV B.Tech I Semester Examinations,May/June 2012 CHEMICAL PROCESS EQUIPMENT DESIGN Chemical Engineering Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. A continuous fractionating column is to be designed for separating 10,000 kg per hour of a liquid mixture containing 40 mole percent methanol and 60 mole percent water into an overhead product containing 97 mole percent methanol and a bottom product having 98 mole percent water. A mole reux ratio of 3 is used. Calculate: (a) Moles of overhead product obtained per hour and

(b) Number of ideal plates and location of the feed plate if the feed is at its bubble point. Equilibrium data:

X 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Y 0.417 0.579 0.669 0.729 0.78 0.825 0.871 0.915 0.959 Where, x= mole fraction of methanol in liquid Y= mole fraction of methanol in vapor.

2. (a) What are formed heads? Discuss the factors for their selection for a pressure vessel. (b) A vertical cylindrical vessel with hemispherical head is to be installed. The diameter and thickness of the vessel are 200mm and 12mm respectively. The tangent to tangent length is12m. The vessel contains oil of specic gravity of 900 kg/m3 . The vessel is lled to its 80 percent capacity. Determine the total longitudinal stress. [6+10]

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[16]

3. A PFR is to be used for carrying out a gas phase reaction. A 4R. The reactor operates at 2000 c and 4 atm. pressure. The conversion desired is 75%. Feed rate to the reactor is 2.6kmol/hr.Rateconstant is 0.05. min - 1 . Estimate the volume of PFR. [16] 4. (a) Acetone is synthesized by catalytic hydrogenation of isopropyl vapor in a reactor at 4000 C and 40 psig pressure. For this purpose, liquid isopropyl alcohol is vaporized, heated and fed to a reactor. The reactor exit gases including water, unconverted isopropyl alcohol and the products of the reaction are fed to a condenser in which most of the acetone, water and alcohol are condensed. The remaining traces of acetone and alcohol are removed in a water scrubber. The euent from the scrubber is combined with the condensate and sent to a distillation column to obtain pure acetone. The bottom product consisting of water and alcohol is sent to another distillation column. The top product is an azeotrope from the second distillation column and is recycled to the reactor. 7

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Code No: 07A70803

R07

Set No. 3

The convertion of alcohol per pass through the reactor is 85 percent. Draw a preliminary ow sheet of the process. (b) Write short notes on the following: i. Time basis for ow sheet preparation ii. Scaling factor for ow sheet calculations. [10+6]

5. (a) What are the types of condensers that are used in evaporator installations? (b) 3.78 kg/sec steam at 13.5 KN/m2 is to be condensed in a jet condenser using cooling water at 2880k. If the cooling water exit temperature is 3160 K and the steam is not super heated, what is the cooling water requirement? At 13.5 KN/m2 ,steam temperature =3250 K and latent heat = 2379 KJ/kg. [16] 6. Write the principle of operation of xed bed and moving bed centrifugal lters and briey the explain construction of any one type with neat diagrams. [16] 7. (a) A reaction mixture contained in a vessel is to be heated from 250 C to 900 C by steam owing through the coils having an area of 6m2 . Calculate the time required for heating the contents from the following data. DATA Weight of the mixture =200kg Cp of reaction mixture (kJ/kgk) =3.7 Overall heat transfer coecient (W/m2 0 K) = 650 Steam temperature = 1200 c (b) Ethylene glycol owing at the rate of 2000kg/h is to be cooled from 1000 C to 500 C in a concentric tubular heat exchanger using water available at 250 c and the exit temperature of water is to be limited to 400 C. Water ows through the annulus of the exchanger in counter current ow. Calculate the length of the exchanger from the following data. DATA: Inside diameter of outer pipe = 2.2 cm Out side dia of inner pipe = 1.2 cm Wall thickness of inner pipe = 1.5 mm

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Properties (kg/m3 ) (mN s/m2 ) Cp (J/kgK ) K(W/mK)

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Ethylene Water 1100 1000 3.2 0.85 2600 4200 0.26 0.61

Use the following in appropriate form for calculation of heat transfer coecients
hd k

= 0.023 (Re)0.8 (Pr)0.33 .

[6+10]

8. (a) A cylindrical vessel of diameter 50cm is subjected to an internal pressure of 800 kg/cm2 . Allowable tensile stress of the material is 1500 kg/cm2 . Assuming that the vessel is a thick walled cylinder nd: 8

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Code No: 07A70803

R07

Set No. 3

i. The minimum thickness of the vessel and ii. Maximum radial deection that occurs at the inner surface and iii. The percentage increase in thickness if the equation for a thin cylinder is used for calculation of thickness. (b) Discuss the fabrication of a high pressure vessel by ribbon winding. [12+4]

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