Chemical Process Design: Principle III Main Examination 2007 December

VAAL UNIVERSITY OF TECHNOLOGY

FACULTY OF ENGINEERING & TECHNOLOGY

National Diploma: Chemical Engineering

SUBJECT: CHEMICAL PROCESS DESIGN: PRINCIPLES III [EHCPB 3B]
SUBJECT CODE: 080507303
DATE: DECEMBER 2007
DURATION: 3 HOURS

EXAMINER: S. TSIENYANE
MODERATOR: Mr. L KOEN

Answer all questions

Scientific calculator reqiured.

Please ensure that the following is provided

Formula sheet should be attached to the question paper

The examination department should supply a handout of appendices.
All the handouts (Appendices) should be handed back with the answer book provided.

INSTRUCTIONS

Answer all questions

Total Marks: 135
Full Marks: 143

THE PAPER CONSISTS OF 5 TYPED PAGES EXCLUDING COVER PAGE

AND FORMULA SHEETS

DO NOT TURN THE PAGE BEFORE PERMISSION IS GRANTED

 Chemical Process Design: Principle III Main Examination 2007 December

Question 2 [13]

2.0 Answer True or False

2.1 Flow induced vibration :

a) A very serious problem in the mechanical design of the heat exchanger is
the flow-induced vibration of tubes. (1)
b) Tube vibrations against the baffles eventually cause holes in tubes. (1)
c) Repeated stressing of the tubes at a rigid support such as tube sheet result
in fatigue cracking of the tubes and accelerated corrosion. (1)
d) Tube vibration is caused by repeated unbalanced forces being applied to
the tubes. (1)
e) One type of the unbalanced forces is eddying motion of fluid in the wake of
a tube as the fluid flows across the tube. (1)
f) The unbalanced forces occurrence is so frequent such that their magnitude
increases rapidly with increase in fluid velocity. (1)

2.2 Erosion :
g) Fluid flow with very high flow velocity can cause rapid removal of metal due
to the friction of the fluid flowing in or across the tube. (1)
h) Erosion occurs with an effect of corrosion by stripping off the protective film
formed on certain metals. (1)
i) Erosion rate depends upon the characteristics of metal (i.e. the harder the
metal, the lesser the erosion),
j) Erosion is more severe at the entrance of a tube, or in the bend of a U-tube. (1)

2.3 Costing of a Shell and Tube heat exchanger:

k) The cost of an exchanger is composed of the cost of individual components
such as shell, tubes, etc. plus the assembly cost. (1)
I) The cost of each component is the sum of the material cost plus fabrication
(e.g. rolling the shell) plus machining. (1)
n) In order to arrive at the most economical unit, it is necessary to consider the
effect of special requirements of the unit (e.g. fluid requires special alloy to
resist corrosion). (1)
 Chemical Process Design: Principle III Main Examination 2007 December

Question 3 [ 32]
In a preliminary design of a counter current heat exchanger; through which 42 kg/s of
methanol stream should cool down to 45 °C. It is required that the overall heat transfer
coefficient be determined, based on the following available information:

Cooling water with flow rate 60% higher than that of methanol, is available at 20 °C and
is to have an 18 °C temperature rise.
NB.: Determine the minimum tube length required.

TT

IAEOH trt
Splitting Floating Hssd Exchanger.

Additional Data
Equipment Details:
AGS: TEMA designation (Shell type G)
(Front: channel integral with tube sheet and removable cover; Back: Floating head with
backing device)
Pull-through floating head, 2:4 Shell and Tube exchanger
Chrome pipes (ID=14mm, 0D=18mm, Kw=45W/m°C)
Triangular pitch (1.25 d0)
Four Baffles with a 35% cut each.
Number of tubes = 1495

Table 1: Thermodvnamic properties of the Fluids

Shell side Tube side Units
(Methanol) Cooling water
Heat capacity (CD) 2.84 4.2 kJ/kg°C
Density (p) 800 996 Kg/m3
Viscosity (u) 0.3 - mNs/m
Thermal conductivity (kf) 0.24 - W/m°C
Fouling factors (hid, hod) 0.0002 0.0003 m z °C/W

NB.: No need to iterate the value of U.

 Chemical Process Design: Principle III Main Examination 2007 December

Question 4 [22]

4.1 Discuss the main consideration when selecting the column operating pressure. (5)
4.2 Explain how an optimum reflux ratio for a separation process is obtained. (5)
4.3 What is the difference between the vapor-liquid contact in a packed and plate
column. (2)
4.4 Name the two factors that dictate the choice of a packing type. (2)
4.5 Discuss the application of packed columns including their performance
dependencies. (4)
4.6 Identify the advantage(s) of a structured packing and its specific application
scenario. (4)

Question 5 [36]
In a project to design a sieve tray column operating at atmospheric pressure, for separating
methanol from an aqueous feed stream containing 40% methanol by weight.
The following information is available for a sieve plate distillation column:

Streams and properties:

Liquid rate, Lw 34 874 kg/h
Liquid density, pi 750 kg / m3
Surface tension, a 19E-3N/m
Vapour rate, Vw 26 100 kg/h
Vapour density, pv 28.15 kg/m3

Table 1: Preliminary column nomenclature and dimensions:

Nomenclature , Dimension Nomenckature Dimension
Column diameter,DG 1.3m Down comer area, Ad 12% Ac
Plate spacing, lt 0.6 m HolejDitch, lp 2.5 d h
Weir height, hw 50 mm Hole diameter, dh 5 mm
Weir lenqth, lw 77% Dc Hole Area, Ah 10% A ;
Plate thickness 5 mm Height of the bottom edge of down comer apron, hap 40 mm
NB.: Column must be able to handle 70% turn down.
5.1 Determine the following flow areas: Ac, Ad, An, Aa and Ah. (5)
5.2 Check if a satisfactory separation operation will be achieved, and advice
appropriately with respect to:
a) Weeping. (11)
b) Flooding. (11)
5.3 Determine whether the pressure drop would be acceptable. (11)
 Chemical Process Design: Principle III Main Examination 2007 December

Question 6 [ 20]

6.1 Discuss how the inherent toxicity of a material is measured. (10)

6.2 List at least ten basic safety and fire protective measures that should be included
in all chemical process designs, (based on the Dow Guide) (10)

ENJOY