Chemical Process Simulation

Task 7

Pipe
Problem 1: Water at 25 °C and 2 atm inlet pressure flows through an isothermal horizontal
1 in nominal diameter schedule 40, 10 m long smooth pipe. Average velocity of water in the
pipe is 4 m/s. Calculate the discharge pressure at the outlet of the pipe.

Problem 2: Waters enters a 5000 ft long 6 in diameter schedule 40 commercial steel pipe at
60 F and 150 psig and discharges to an open tank located 300 ft above the inlet point. Calculate
the discharge water flow rate. Assume no heat loss from the pipe.

Problem 3: Problem 2, make a plot of water flow rate vs pressure drop (100-200 psi)

Problem 4: Water at 20 °C is being pumped from a tank to an elevated tank at the rate of 5 ⤫ 10-
3 m3/s . All of the piping is 4 in schedule 40 pipe. The pump has an efficiency of 65%. Calculate the
pump power requirement (kW).

Problem 5: Water at 60 °F is being transformed at a flow rate of 65 gpm from an open

reservoir to another open reservoir with a 75v % efficient pump. All the piping in the network
is scheduled for 40 steel pipe. Calculate the required pump horsepower.

Problem 6: This problem is a continuation (reverse version) of Example 5. Water at 60 °F is

being transferred from an open reservoir to another open reservoir with a 2 hp, 75% efficient
pump. Calculate the volumetric flow rate of water discharged to the open reservoir (GPM).

Problem 7: This problem is a continuation (reverse version) of Example 4. Water at 60 °F is

being transferred from an open reservoir to another open reservoir with a 2 hp, 75% efficient
pump. Calculate the volumetric flow rate of water discharged to the open reservoir (GPM).
 Task 8

Pipe
Problem 1 (Conversion Reactor): Toluene is produced from n-heptane by
dehydrogenation over Cr2O3 catalyst. The toluene production process requires heating 100
kmol/h of n-heptane at atmospheric pressure from 20 to 425 C in a heater. The preheated feed
enters a catalytic reactor, which operates at 425 C and atmospheric pressure and converts 15
mol% of the n-heptane to toluene. The reactor effluent is cooled to 20C and subsequently
enters a flesh separator. Assuming that all units are operated at atmospheric pressure,
determine the species flow rates, temperature and composition of each stream. Use Peng-
Robinson EOS.

Problem 2: Now modify the process described in Problem 1 by preheating the feed stream to
315 °c with hot reactor product before entering the reactor. Assume negligible pressure drop
in both the tube and shell side of the preheater. Compare the energy requirements between
Problem 1 and Problem 2.
Problem 3: Sulfur dioxide is oxidized to sulfur trioxide (SO2 + ½ 02 ➔ SO3) in a small pilot

plant reactor. so2 and 100 % excess air are fed to the reactor maintained at 450 C and 1 atm.
The production rate of SO3 is 100 kmol/min. Feed SO2 and air streams enter the reactor at

450 °C and 1 atm. The reaction proceeds to a 65% SO2 conversion and the products emerge

from the reactor at 550 oC.

The reactor is surrounded by a water jacket into which water enters at 25 oC and exits at 40.
Use the Peng-Robinson equation of state.

Calculate the heat of reaction

Calculate the product composition and molar flow rate of each component

Calculate the flow rate of cooling water if the temperature rise of cooling water is to be
kept below 15 C (1.e. at 40 °C).

Problem 4: Styrene is an important commercial monomer and is the feedstock for a large
number of polymeric materials. It is commercially produced by catalytic dehydrogenation of
ethylbenzene. i either adiabatic or isothermal reactor over promoted iron-based catalyst. The
reaction is highly endothermic equilibrium limited.

Simulate a styrene reactor as (a) an adiabatic reactor and (b) an isothermal reactor maintained
at 250 C. The stream is pure ethylbenzene, 217 kmol/s at 880K and 1.378 bar. Assume 80%
conversion in the reactor. Use Peng-Robinosn equation of state.

1) For the adiabatic reactor, calculate the product temperature (229.7 C)

2) (ii) For the isothermal reactor, calculate the heating load on the reactor
3) {iii) For the adiabatic reactor, make a plot between feed temperature (200 C-800
C)and reactor temperature
4) iv) For the isothermal reactor, make a plot between conversion (0-100%) and heating
load on the reactor. ( f Recator-CRVlOO:Variables: Rxn: Spec Conv% [C0] and Heat
Load in Databook)