BITS, PILANI, GOA CAMPUS, SECOND SEMESTER 2022 – 2023

MID-TERM TEST: PROCESS DESIGN PRINCIPLES - 2 (CLOSED BOOK)

COURSE CODE: CHE F343

DATE: 16/03/2023 TIME: 90 MINUTES MAX. MARKS: 30

(ALL QUESTIONS ARE COMPULSORY. MAKE SUITABLE ASSUMPTIONS WHEREVER

NECESSARY)

Question 1 [3 + 3 = 6 marks]

a. Ethanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene.
Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is
then condensed with a condenser to perform liquid ethylene. Hydrogenation of ethylene applies in
another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop BFD
for these processes.

b. Shown below is the BFD for a particular industrial process. Explain roughly in words the entire process
and what happens in each equipment.

Question 2 [6 + 3 + 3 = 12 marks]

a. A pump is 2.5 m above the water level in the sump and has a presence of –22 cm of mercury at the
suction side. The suction pipe is of 25 cm diameter and the delivery pipe is a short 30 cm diameter pipe
ending in a nozzle of 10 cm diameter. If the nozzle is directed vertically upwards at the elevation of 4.0
m above the sump water level, determine (i) the discharge, (ii) power input into the flow by the pump
and the (iii) elevation, above the sump water level, to which the jet would reach. (Neglect all losses).
b. Compare the cost of pumping fluid A between two points at the same volumetric flowrate in 10 cm and
15 cm diameter pipes having the same absolute roughness magnitude of 0.2 mm. The flow can be
assumed to be in a fully developed rough-turbulent regime. (Assume the pipes are horizontal).

c. A 300 mm diameter water supply sipe had a friction factor of 0.02 when freshly installed. After 10 years
of service the friction factor was found to be 0.025. What friction factor can be expected after another
15 years? The pipe can be assumed to be in rough-turbulent flow regime. The roughness magnitude
can be taken to increase linearly with age as ε1 = ε0+ αt) where is t is time in years.

Use [1/sqrt(f)] = 2log (r/) + 1.74 to compute the friction factor in the above two problems

Question 3 [6 + 3 + 3 = 12 marks]

a. A feed water heater which supplies hot water to a boiler comprises a shell and tube heat exchanger
with one-shell pass and two-tube passes. One hundred thin-walled tubes each of 20 mm diameter and
length of 2 m per pass are used. Under normal conditions, water enters the tubes at 10 kg/s and 17oC
and is heated by condensing saturated steam at 1 atm. on the outer surface of the tubes. The
convection coefficient of saturated steam is 10 kW/m2 oC. Determine the exit water temperature. Use
the following properties of water:
Cp = 4.18 kJ/kg.oC ; µ = 0.596 x 10−3 Ns/m2 ; k = 0.635 W/m.oC and Pr = 3.93.

b. A pump can deliver a discharge of 0.1 m3/s to a head of 30 m. The critical cavitation number defined as
the ration of minimum NPSH to the head required is 0.12. The pump is to be installed at a location of
where the barometric pressure is 96.0 kPa (abs) and the vapour pressure is 3 kPa (abs). Assuming an
intake pipe friction of 0.3 m, determine the maximum allowable elevation above the sump water surface
at which the pump can be installed?

c. Superheated steam is used to heat water at the rate of 10,500 kg/hr in a counter-flow tube in tube heat
exchanger. The steam enters the heat exchanger at 180 oC and leaves at 130 oC. The coolant water
inlet and exit temperatures are 30 and 80 oC. respectively. The overall heat transfer coefficient U from
steam to water is 814 W/m2.K. What would be the overall increase in area if the flow was parallel in this
heat exchanger? Take the specific heat of water and steam as 4.187 kJ/kg.K.

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