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engineering
chemical engineering design
Questions and Answers of
Chemical Engineering Design
During the 2002 Winter Olympics in Salt Lake City, Utah, a local microbrewery received a rush order for 100 gallons of beer containing at least 4.0 volume \(\%\) alcohol. Although no \(4 \%\) beer
A batch distillation facility has a bank of columns of Type 1 and another bank of Type 2. Type 1 columns are available for processing \(6,000 \mathrm{hr} /\) week, and Type 2 columns are available
Willy Wonka has engaged your consultation services to assist in the recipe formulation of a new brand of chocolate bar, weighing \(100 \mathrm{~g}\), which he plans to name "Super-choc." Each
King Henry V of England has decided to wage war on France and has engaged your services to assist him to assemble an appropriate army, which can consist of four types of troops: cavalry, men at arms,
Using calculus, determine all maxima, \(m\) inima, and saddle points for the following unconstrained two-dimensional objective functions:(a) \(f\left\{x_{1} x_{2}\right\}=2 x_{1}^{3}+4 x_{1}
Use 10 steps of the golden-section search method to find the optimal dimensions for the cylindrical reactor vessel in Example 16.12. In that example, the dimensions of the vessel are given as the
As shown in the ASPEN PLUS simulation flowsheet in Fig. 21.15, liquid toluene is to be heated from 100 to \(350^{\circ} \mathrm{F}\) while liquid styrene is to be cooled from 300 to \(100^{\circ}
A process to separate propylene and propane to produce \(99 \mathrm{~mol} \%\) propylene and \(95 \mathrm{~mol} \%\) propane is shown in Figure 21.16. Because of the high product purities and the low
A process design for the disproportionation of toluene to benzene and the xylene isomers is being completed. Your assistance is needed on the design of the liquid separation section. It has been
In Example 22.2, derive the mass balances for the cell mass, penicillin, and substrate, and the overall mass balance.Data From Example 22.2:-Data From Exercise 22.2:-For the penicillin reactor in
For the penicillin reactor in Example 22.2, using repeated simulations, search for the optimal feed profile to maximize:\[0.025 P\{\tau\} V\{\tau\}-1.68 \tau-0.00085 \int_{0}^{\tau} F\{t\} d t\]where
For the batch distillation column in Example 22.3, devise a recipe that will decrease the batch time without reducing the amount of product recovered. Estimate the increase in the utility usage.Data
In Example 22.4, derive Eqs. (22.6) and (22.7). Then, graph the economic potential as a function of the reactor batch time for various values of the rate constant, \(k\), over the range \(0.4-0.6\)
In Example 22.5, derive Eqs. (22.9)-(22.11).Data From Example 22.5:-Equation 22.9 and 22.11:- Figure 22.8 shows an isothermal batch reactor in which the irreversible reactions A B C take place with
For the reactor-distillation process in Example 22.5, recompute the solution when the reactor and column volumes are decreased by \(20 \%\).Data From Example 22.5:-Equation 22.9 and 22.11:- Figure
Construct a Gantt chart for the general multipurpose plant in Figure 22.14, but with the unit assignments specified in Figure 22.13.Figure 22.13:-Figure 22.14:- Product A Product B Task 1 Task 2 Task
A batch process requires the following operations to be completed in sequence: \(3 \mathrm{hr}\) of mixing, \(5 \mathrm{hr}\) of heating, \(4 \mathrm{hr}\) of reaction, \(7 \mathrm{hr}\) of
Consider the hemodialysis device using the hollow-fiber module in Figure 24.1, operating \(12 \mathrm{hr} / \mathrm{wk}\) (3 days, \(4 \mathrm{hr} /\) day) at a dialysis center. As shown in Example
For the home hemodialysis device operating with a blood flow rate of \(133 \mathrm{~mL} / \mathrm{min}\) and a dialysate flow rate of \(300 \mathrm{~mL} / \mathrm{min}\), the fiber-side (blood-side)
Consider the hemodialysis device in Example 24.1. Examine the effect on the rate of urea removal of changing the hemodialyzer geometry, the blood and dialysate flow rates to the dialyzer, the rate of
Repeat Exercise 24.3 for a hemodialysis device designed for overnight home use. Assume that the device will be used 7 nights/ wk for \(6 \mathrm{hr} / \mathrm{night}\).Data From Exercise
Consider the home hemodialysis product.(a) Complete Exercise 24.4; that is, design a hemodialysis device that lowers the urea concentration in the blood to \(0.3 \mathrm{mg} / \mathrm{cm}^{3}\),
Data for the phosphorylation reaction, R1, are provided by Caliper Life Sciences, Inc., in Figure 25.15 at high [Pep] \(=1.5 \mu \mathrm{M}\) and in Figure 25.16 at high [ATP] \(=250 \mu
Consider the product concept in Figure 25.13 for the high throughput screening of kinase inhibitors. Two competitive concepts are proposed:(a) Use no bar codes; that is, use sequential generation of
Given the 1 -in. \(\times 3\)-in. glass slides upon which 1,000 aqueous drop/sec. are loaded into \(100 \times 10 \mu \mathrm{m}\) parallel channels, estimate the pressure drop. Is it sufficiently
Re-estimate the profitability measures in Section 25.3 as the price of \(\mathrm{IC}_{50}\) assays varies. Use a spreadsheet to increase and decrease the price from \(\$ 0.05 / \mathrm{IC}_{50}\)
The lab-on-a-chip product in Figure 25.13 incorporates the inventions in the innovation map of Figure 25.10. Carry out a patent search to determine whether all of the technological inventions in
Search the Internet to identify three or more companies marketing die attach adhesives. For example, check 3M and Henkel.
Conduct a competitive analysis by collecting information on the product specifications of one of the DAA products from each of the companies identified in Exercise 26.1. Specifically, the data should
Search the Internet to identify market segments other than HB-LED that use die attach adhesives. Identify the different products in those market segments.
A business model evolves over time. Given the information in this chapter and elsewhere, fill out a business model canvas for DAA as completely as possible.
Many models of a composite's effective thermal conductivity are available in the literature (Wang and Pan, 2008). Even if a model cannot accurately predict the DAA product performance, physical
It is desired to develop a day cream with sun-blocking, antioxidant, and moisturizing functions. The cream has to be transparent because it is used indoors. The skin has a variety of antioxidants
Figure 26.8 shows that the thermal conductivity of \(\mathrm{S} 3\) and \(\mathrm{S} 4\) increased by \(30.25 \%\) and \(111.37 \%\) by adding \(5 \mathrm{wt} \%\) and \(10 \mathrm{wt} \%\) of silver
Sketch the composition-temperature trajectory for the proposed ammonia converter shown in Figure 27.7 and use it to explain why it performs poorly. On the same plot, sketch the
Consider the effect on the reductions of \(\mathrm{CO}_{2}\) emissions of introducing a preheater to exchange heat from the effluent of the reformer with the reformer feed. What would be the impact
Consider the effect on profitability of introducing a heat-mass exchanger into the ammonia synthesis loop operating at \(90 \mathrm{bar}\). What is the optimal operating temperature of the flash
Carry out a formal pinch analysis of the process design presented as Step 8, using the UniSim \({ }^{\circledR}\) Design file NH3_PROCESS_4E_STEP_8 opt_V3.usc:(a) Compute the MER targets assuming
As part of an \(\mathrm{NH}_{3}\)-product life cycle assessment, evaluate the danger of an ammonia release from a missile attack from a 12,000 ton storage tank. Note that the existing facility is a
As part of an \(\mathrm{NH}_{3}\)-product life cycle assessment, consider the alternative of converting ammonia to urea by reaction with \(\mathrm{CO}_{2}\) as a vehicle for curbing the release of
For the ammonia product, carry out the development stage of the SGPDP as suggested in Section 27.3.
Consider the tubular reactor to saponify ethyl acetate with sodium hydroxide in Example 15.1.(a) Assuming plug flow and perfect radial mixing, determine the length of the reactor to convert \(50 \%\)
For the saponification of ethyl acetate with sodium hydroxide in a tubular reactor with fully developed laminar flow at \(75^{\circ} \mathrm{C}\), use COMSOL to account for radial diffusion. Estimate
Revisit the helical flow reactor in Example 15.4.(a) Increase the mandrel radius to \(50 \mathrm{~cm}\) and increase the volumetric flow rate to achieve the same residence time. Determine the
Consider the mixing of ethyl acetate and sodium hydroxide in a confined jet tubular reactor as shown in the following figure. In thissystem, ethyl acetate is fed through the confined jet tube while
Rework Example 15.6, assuming convective heat transfer to cooling water that surrounds the tube. Let the heat-transfer coefficient be \(h_{\mathrm{o}}=100 \mathrm{Btu} /
On the Internet, find a recent annual report for the company Merck \& Co., Inc. Based on information in that report, determine the following:(a) The nature of the business of Merck.(b) The new
At the beginning of the year 2013, Company XYZ had an inventory of 8,000 widgets with a unit cost of \(\$ 6.00\). During that year, the following purchases of widgets were made:At the end of 2013,
Based upon the following data for the reactors, compressors/expanders, and distillation columns of a plant to produce 1,500 metric ton/day of methanol with an operating factor of 0.95 , estimate by
The feed to a sieve-tray distillation column operating at \(1 \mathrm{~atm}\) is \(700 \mathrm{lbmol} / \mathrm{hr}\) of \(45 \mathrm{~mol} \%\) benzene and \(55 \mathrm{~mol} \%\) toluene at \(1
The following are the major units in a chemical plant. Evaluate the bare-module cost for each unit and for the entire process. Assuming no allocated costs for the utilities and related facilities,
Determine the total bare-module cost for the flowsheet in Figure 16.21 at ambient temperature and pressure. Use \(\mathrm{CE}=600\).Design Specifications Pumps: reciprocating, motor driven, 25 psia
A chemical plant contains the following equipment:(a) Two gas-fired heaters, each with a heat duty of \(20,000,000 \mathrm{Btu} / \mathrm{hr}\). The tubes are carbon steel and the heaters operate at
Estimate the total bare-module cost for installation of nine \(600-\mathrm{Hp}\) centrifugal compressors of carbon steel with explosion-proof electric motors, a stainless steel direct-heat rotary
A plant contains 2 centrifugal compressors of carbon steel and \(500-\mathrm{kW}\) rating with explosion-proof electric motors 1 jaw crusher at \(10 \mathrm{~kg} / \mathrm{s}\) capacity 3
Consider a 1-2, shell-and-tube heat exchanger:The cold stream has a heat-capacity flow rate \(C=40,000 \mathrm{Btu} / \mathrm{hr}-{ }^{\circ} \mathrm{F}\). Its heat-transfer coefficients are
A chemical plant contains 3 drum dryers of nickel alloy, each containing \(540 \mathrm{ft}^{2}\).40 kettle reboilers with a carbon-steel shell and copper tubes at \(1,450 \mathrm{psia}\), each
Figure 16.20 shows a system designed to recover argon from the purge stream in an ammonia synthesis plant. Estimate the total bare-module cost associated with the addition of this argon recovery
In the design of a chemical plant, the following costs and revenues (in the third year of production) are projected:Total depreciable capital, excluding allocated \(\$ 10,000,000\) power Allocated
For Exercise 17.1, the return on investment desired by the chemical company is 20%. Determine the venture profit.
It is desired to have \($9,000\) available 12 yr from now. If \($5,000\) is available for investment at the present time, what discrete annual rate of compound interest on the investment would be
What will be the total amount available 10 yr from nowif \($2,000\) is deposited at the present time with nominal interest at the rate of 6%compounded semi-annually?
An original loan of \($2,000\) was made at 6% simple interest per year for 4 yr. At the end of this time, no interest had been paid and the loan was extended for 6 yr more at a new effective compound
A concern borrows \($50,000\) at an annual effective compound interest rate of 10%. The concern wishes to pay off the debt in 5 yr by making equal payments at the end of each year. How much will each
How many years are required for money to double when invested at a nominal interest rate of 14% compounded semiannually?Determine the shortest time in years, allowing any number of compounding
A person at age 30 is planning for retirement at age 60. He projects that he will need \($100,000\) a year until age 80. Determine the uniform annual contribution (by him and his company) needed to
A heat exchanger has been designed for use in a chemical process.A standard type of heat exchanger with a negligible scrap value costs \(\$ 4,000\) and will have a useful life of \(6 \mathrm{yr}\).
Two machines, each with a service life of \(5 \mathrm{yr}\), have the following cost comparison. If the effective interest rate is \(10 \% / \mathrm{yr}\), which machine is more economical? A B First
Two pumps are being considered for purchase:Determine the service life, \(n_{\mathrm{y}}\), at which the two pumps are competitive. The annual effective interest rate is \(10 \%\). A Initial cost
Two heat exchangers are being considered for installation in a chemical plant. It is projected that:For an effective interest rate of \(10 \%\), determine the uniform end-of-year maintenance for heat
Consider the following two alternatives for the installation of a pump:The effective annual interest rate is \(10 \%\). Determine the salvage value for pump A when the two pumps are competitive.
You are offered two options to finance a compressor with a nominal interest rate at \(7.25 \%\) compounded monthly.(a) You pay \(\$ 590\) per month for 134 months.(b) You pay \(\$ 545\) per month for
Two pumps are under consideration:Determine the interest rate at which the two pumps are competitive. Installed cost Service life A $10,000 1 yr B $18,000 2 yr
A proposed chemical plant has the following projected costs and revenues in millions of dollars:Using an MACRS depreciation schedule having a class life of \(5 \mathrm{yr}\), (a) Compute the cash
An engineer in charge of the design of a plant must choose either a batch or a continuous system. The batch system offers a lower initial outlay but, owing to high labor requirements, exhibits a
The demand for styrene monomer continues to increase. Other companies produce styrene by alkylating benzene with ethylene to ethylbenzene, followed by dehydrogenation to styrene. Our chemists have
This assignment begins with a completed simulation of the toluene hydrodealkylation process in Figure 17.1 and involves the completion of an economic evaluation. Note that the simulation results for
A chemical plant constructed in 2007 began operating in 2008. In 2010 , the plant is projected to operate at \(90 \%\) of capacity, with(a) Calculate the return on investment (ROI) in 2010 given that
An oil company is offered a lease of a group of oil wells on which the primary reserves are close to exhaustion. The major condition of the purchase is that the oil company must agree to undertake a
For the manufacture of the hemodialysis device in Chapter 24,(a) Prepare a SIPOC.(b) Identify all of the sources of variance in the urea concentration in treated blood after a 4-hr treatment. Suggest
Photolithography is an important process in integrated circuit manufacture in which a circuit pattern is transferred from a mask onto a photosensitive polymer (the PR), ultimately replicating that
A company is considering a new three-year expansion project that requires an initial fixed investment of \(\$ 1.8 \mathrm{MM}\). The fixed asset is depreciated based on the five-year class life in
Calculate the net present value and investor's rate of return in Example 19.1 if the product life cycle is extended from three to five years. All other input data remain unchanged.Data From Example
Similarly, calculate the investor's rate of return in Example 19.2 with the following changes:(a) The product life cycle is extended from three to seven years.(b) In year 3, spend \(\$ 1
Regarding market share and government support, consider the following:(a) The product project team decides to seek a larger market share by lowering the price. Repeat Example 19.2 with the following
Regarding the innovation map for an air purifier, do the following:(a) The company decides to develop a long-term strategy for the development of air purifiers. HEPA filters are used to remove solid
Perform economic analysis for the water pitcher product development project in Exercise 5.12. Specifically, determine the investor's rate of return for this product. There is no correct answer to
Perform a degrees-of-freedom analysis for the noninteracting exothermic reactor shown in Figure 20.3a. Suggest an appropriate control structure. Carry out the same exercise for the heat-integrated
Consider the mixing vessel shown in Figure 20.19. The feed stream flow rate, \(F_{1}\), and composition, \(C_{1}\), are considered to be disturbance variables. The feed is mixed with a control stream
Consider the FS two-column configuration for the separation of methanol and water in Figure 20.2 and (a) determine the number of degrees of freedom for the overall system, (b) determine the number of
Repeat Exercise 20.3 for the LSF configuration in Figure 20.2.Data From Exercise 20.3:-Consider the FS two-column configuration for the separation of methanol and water in Figure 20.2 and (a)
A control system is suggested for the exothermic reactor in Figure 20.7. Suggest alternative configurations and compare them with the original configuration.Figure 20.7:- (CC) TC Ai F (TC h LC) To
Figure 12.20 shows a process for the isothermal production of \(\mathrm{C}\) from \(A\) and \(B(A+B \rightarrow C)\). The two reagents are fed to a CSTR, \(R-100\), where complete conversion of
Figure 20.21 shows the flowsheet for a reactive distillation column for the production of ethylene glycol (EG) from ethylene oxide (EO) and water (Al-Arfaj and Luyben,
Figure 20.22 shows the monochlorobenzene separation process introduced in Section 7.4. The process involves a flash vessel, V-100; an absorption column, T-100; a distillation column, T-101; a reflux
Figure 20.23 shows a heat-integrated process for the manufacture of vinyl chloride. This design sharply reduces the utilization of utilities in Figure 20.17 without requiring additional heat
How would the control configuration for the vinyl-chloride process in Figure 20.18 change if the primary control objective is to provide on-demand vinyl-chloride product?Figure 20.18:- Ethylene
Figure 20.24 shows the flowsheet for a process for the production of methanol from synthesis gas (a mixture of hydrogen, carbon monoxide, and carbon dioxide and a small quantity of residual methane,
Figure 20.25 shows the flowsheet for a process for the production of synthesis gas (a mixture of hydrogen, carbon monoxide, and carbon dioxide and a small quantity of unreacted residual methane) from
Figure 20.28 shows the flowsheet for the HDA process for the production of benzene from toluene and hydrogen. Feed streams of toluene (entering through valve V-1) and hydrogen (entering through valve
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