Questions and Answers of Analysis Synthesis And Design Of Chemical Processes

Repeat the process described in Problem 8.12 using a simple refrigeration loop to determine the cost of providing 1 GJ of refrigeration at –50°C using the following working
Estimate the cost of operating labor (COL), the cost of utilities (CUT), and the cost of manufacturing (COMd) for the formalin process given in Project B.7 of Appendix B. You must do Problem 7.27 in
Estimate the cost of operating labor (COL), the cost of utilities (CUT), and the cost of manufacturing (COMd) for the maleic anhydride process given in Project B.5 of Appendix B. You must do Problem
When is it appropriate to add a flag to a stream in a PFD rather than including the stream in the stream flow table?
Draw a section of a P&ID diagram for a vessel receiving a process liquid through an insulated 4-in schedule-40 pipe. The purpose of the vessel is to store approximately 5 minutes of liquid volume
A standard method for instrumenting a control valve is termed the “double block and bleed,” which is illustrated in Figure P1.22.Under normal conditions, valves a to c are open and valves d and e
Often, during the distillation of liquid mixtures, some noncondensable gases are dissolved in the feed to the tower. These noncondensables come out of solution when heated in the tower and may
Repeat Problem 1.23, but create the sketch as a P&ID to show all the instrumentation needed for this control loop.Problem 1.23Often, during the distillation of liquid mixtures, some noncondensable
With the information from Problem 1.28 and the topology given in Figure 1.5, accurately sketch a plant layout (plot plan) of the toluene HDA process using a grade-mounted, horizontal, in-line
Explain how each of the following statements might affect the layout of process equipment:A specific pump requires a large NPSH.The flow of liquid from an overhead condenser to the reflux drum is
Using the data from Table 1.7, estimate the footprints of all the equipment in the toluene HDA process. For the shell-and-tube exchangers, assume 12 ft, 1.25-in tubes on a 1.5-in square pitch, and
Estimate the footprint for a shell-and-tube heat exchanger from the following design data:Area = 145 m2Hot side temperatures: in at 300°C, out at 195°CCold side temperatures: bfw at 105°C, mps at
Make a sketch of a layout (plot plan only) of a process unit containing the following process equipment:3 reactors (vertical—diameter 1.3 m each)2 towers (1.3 and 2.1 m in diameter, respectively)4
A set of symbols seen on P&IDs are shown in Figure P1.30. Identify all the instrument types and instrument connections (electrical, pneumatic, capillary).
The P&ID shown in Figure P1.31 is for the feed section of a process in which a feed enters a tank and then is pumped through one of two pumps placed in parallel. The liquid then passes through a
What are the five elements of the hierarchy of process design?
What are the three types of recycle structures possible in a chemical process? Explain when each is used.
Give three criteria for choosing a batch process as opposed to a continuous process.
When would one purposely add an inert material to a feed stream? Illustrate this strategy with an example, and explain the advantages (and disadvantages) of doing this.
In general, when would one purify a material prior to feeding it to a process unit? Give at least one example for each case you state.
In modern integrated gasification combined cycle (IGCC) coal-fed power plants, oxygen is produced via cryogenic separation of air and is fed to the IGCC plant along with coal. The separation of
Most pharmaceutical products are manufactured using batch processes. Give at least three reasons why this is so.
Acetaldehyde is a colorless liquid with a pungent, fruity odor. It is primarily used as a chemical intermediate, principally for the production of acetic acid, pyridine and pyridine bases, peracetic
Consider three batch processes, producing products A, B, and C, as illustrated in Table E3.3. Each process uses the four pieces of equipment in the same sequence but for different times.Market demand
Consider the jobshop plant following the sequence shown in Figure 3.5(b) and described in Table E3.5. Construct the Gantt charts for overlapping single-product campaigns for products A, B, and C and
What are the two main methods for sequencing multiproduct processes?
Give one advantage and one disadvantage of using single-product campaigns in a multiproduct plant.
Consider the processes given in Examples 3.3 and 3.4. Determine the number of batches that can be produced in a month (500 h) using a multiproduct campaign strategy with the sequence ACBACBACB. Are
It is desired to produce the same number of batches of A, B, and C. Using information from Example 3.5, determine the total number of batches of each product that can be produced in an operating
Consider the processes given in Example 3.3. Determine the number of batches that can be produced in a month (500 h) using a series of single-product campaigns when the required number of batches for
What is the difference between a zero-wait and a uis process?
Consider the multiproduct batch plant described in Table P3.8.It is required to produce the same number of batches of each product. Determine the number of batches that can be produced in a 500 h
Consider the process given in Problem 3.8. Assuming that a single-product campaign strategy is used over a 500 h operating period and further assuming that the production rates (for a year = 6000 h)
Using the data from Tables P3.10(a) and (b), and following the methodology given in Section 3.6, determine the number of batches and limiting reactor size for each product. Table P3.10(a) Production
Referring to the batch production of amino acids described in Project 8 in Appendix B, the batch reaction times and product filtration times are given in Table P3.11.Includes 5 h for filling,
Referring to Problem 3.11, by how much would yearly production change if the following applied?The reaction times for L-aspartic acid and L-phenylalanine were reduced by 5 h each. Use the same
It is desired to produce three different products, A, B, and C, using the same equipment in a batch processing plant. Each production method uses the same equipment in the same order for the times
A batch chemical plant is to be used to produce three chemical products (A, B, and C) using a flowshop plant. The times for each product in each piece of equipment (in hours) are shown in Table
Four products (A-D) are made in a batch processing plant. The times (in hours) required for each piece of equipment for each product are shown in Table P3.15.Using the information in Table P3.15,
Consider the problem of batch scheduling three products (A, B, C). The number of batches of B required in a given time is twice the number of batches of A and of C. One possible scheduling plan is
Using the data in Example 3.3, answer the following problems:A campaign for 500 h is to be run using the following sequence of products: AABCCCAABCCCAABCCC…. Draw an accurate Gantt chart that
Batches of 4 (A-D) products are produced (in a flowshop plant) using the equipment processing times in Table P3.18 (all times are given in hours).It is decided to operate using a campaign time of 600
Two products are to be produced in a jobshop plant. The scheduling for each piece of equipment for the two products is given in Table P3.19.The market demand requires that 3 times the amount of
Consider the problem of batch scheduling two products (A, B). The number of batches of B required in a given time is twice the number of batches of A. One possible scheduling plan is shown in the
A batch chemical plant is to be used to produce four chemical products (A, B, C, and D) using the same equipment and in the same order, that is, using a flowshop plant. The times for each product in
Zebra mussels are mollusks that have been known to infest the water intake pipes of water treatment and electric power plants. Entire towns have been shut down because the infestation of zebra
Maintaining a swimming pool, either at home or in a public facility, is both expensive and time consuming. The water must be tested often, particularly for chlorine. The chlorine additive to a
Identify the main reactant and product process streams for the following:The ethylbenzene process shown in Figure B.2.1, Appendix B Table B.2.1 Stream Table for Unit
Research is under way to develop a magnetic refrigerator. This refrigerator operates by using magnetocaloric materials, which are materials that change temperature when exposed to a changing magnetic
With the advent of portable electric devices such as laptop computers, cellular phones, personal digital assistants, MP3 players, and so on, the length of time they can run before recharging and/or
Suggest some ideas for the zebra mussel problem in Example 4.1.Example 4.1Zebra mussels are mollusks that have been known to infest the water intake pipes of water treatment and electric power
Suggest some ideas for a power source for laptop computers, as discussed in Example 4.4.Example 4.4With the advent of portable electric devices such as laptop computers, cellular phones, personal
For the toluene hydrodealkylation process, establish the primary flow pathway for1. Toluene between the feed (Stream 1) and the reactor2. Benzene between the reactor and the product (Stream 15) Refer
This is a continuation of Example 10.4.1. Determine the NPV and the DCFROR for each increment of investment.2. Recommend the best option.Example 10.4A company is seeking to invest approximately $120
In the final design stage of a project, the question has arisen as to whether to use a water-cooled exchanger or an air-cooled exchanger in the overhead condenser loop of a distillation tower. The
During the design of a new project, a decision must be made regarding which type of pump should be used for a corrosive service. The options are as follows:Assume a discount rate of 8% p.a. Carbon
Compare the stainless steel and carbon steel pumps in Example 10.7 using the EAOC method.Example 10.7During the design of a new project, a decision must be made regarding which type of pump should be
Compare the two pumps given in Example 10.7 using the common denominator method. The discrete cash flow diagrams for the two pumps are shown in Figure E10.9. The minimum time over which the
For the following problems, unless stated otherwise, you may assume that the cost of land, L, and the salvage value, S, of the plant are both zero.Repeat Problem 10.8 using a straight-line
A circulating heating loop for an endothermic reactor has been in operation for several years. Due to an oversight in the design phase, a certain portion of the heating loop piping was left
For the following problems, unless stated otherwise, you may assume that the cost of land, L, and the salvage value, S, of the plant are both zero.In reviewing current operating processes, the
Which of the options in Example 10.10 is the best based on the nondiscounted ROROII of 15%?Example 10.10A circulating heating loop for an endothermic reactor has been in operation for several years.
Repeat the comparison of options in Example 10.10 using a nondiscounted incremental payback period of 6.67 years.Example 10.10A circulating heating loop for an endothermic reactor has been in
For the following problems, unless stated otherwise, you may assume that the cost of land, L, and the salvage value, S, of the plant are both zero.In reviewing current operating processes, the
Consider the maleic anhydride process shown in Appendix B.5. Estimate the profit margin for this process using the costs of raw materials and products from Table 8.4.Figure B.5.1 Table 8.4 Costs of
Based on the information provided in Example 10.10 for an acceptable internal interest rate of 15% and time n = 5 y, determine the most attractive alternative, using the INPV criterion to compare
Repeat Example 10.13 using EAOC in place of NPV.Example 10.13Based on the information provided in Example 10.10 for an acceptable internal interest rate of 15% and time n = 5 y, determine the most
Two pieces of equipment are being considered for an identical service. The installed costs and yearly operating costs associated with each piece of equipment are as follows:If the internal hurdle
For the chemical process considered in Example 10.1, calculate the sensitivity of R, COM , and FCI and plot these sensitivities with respect to the NPV.Example 10.1A new chemical plant is going to be
Your company is considering modifying an existing distillation column. A new reboiler and condenser will be required, along with several other peripherals. The equipment lists are as follows:The
What is the change in the NPV for a 2% increase in revenue coupled with a 3% increase in FCIL?
Three alternative pieces of equipment are being considered for solids separation from a liquid slurry:If the internal hurdle rate for this project is 11% p.a., which alternative do you recommend?
Because of corrosion, the feed pump to a batch reactor must be replaced every three years. What is the capitalized cost of the pump?Data:Purchased cost of pump = $35,000Installation cost = 75% of
Because you live in a southern, warm-weather climate, your electricity bill is very large for about eight months of the year due to the need for air conditioning. You have been approached by an
In considering investments in large capital projects, a company is deciding in which of the following projects it will invest:The company can always invest its money in stocks that are expected to
A change in air pollution control equipment is being considered. A baghouse filter is being considered to replace an existing electrostatic precipitator. Consider the costs and savings for the
You have been asked to evaluate several investment opportunities for the biotechnology company for which you work.These potential investments concern a new process to manufacture a new, genetically
Your company is considering investing in a process improvement that would require an initial capital investment of $500,000. The projected increases in revenue over the next seven years are as
During the design of a new process to manufacture nanocomposites, several alternative waste treatment processes are being considered. The base case is the main waste treatment process, and the
A process for the fabrication of microelectronic components has been designed. The required before-tax return on investment is 18% p.a., and the equipment life is assumed to be eight years.Do you
The installation of a new heat exchanger is proposed for the batch crystallization step in an existing pharmaceutical manufacturing process. The heat exchanger costs $49,600 (installed) and saves
A new pharmaceutical plant is expected to cost (FCI ) $25 million, and the revenue (R) from the sale of products is expected to be $10 million/y for the first four years of operation and $15
How much would you need to save annually to be willing to invest $1.75 million in a process improvement? The internal hurdle rate for process improvements is 18% before taxes over eight years.
How much would you be willing to invest in a process improvement to save $2.25 million/y? The internal hurdle rate for process improvements is 15% before taxes over six years.
You can invest $5.1 million in a process improvement to save $0.9 million/y. What internal hurdle rate would make this an attractive option? The assumed lifetime for these improvements is nine years.
You are considering two possible modifications to an existing microelectronics facility. The criterion for profitability is 18% p.a. over six years. All values are in $million.What do you recommend
Recommend whether your company should invest in the following process: The internal hurdle rate is 17% p.a., before taxes, over an operating lifetime of 12 years. The fixed capital investment is made
You are responsible for equipment selection for a new micro-fiber process. A batch blending tank is required for corrosive service. You are considering three alternatives:The after-tax internal
A new biotech plant is expected to cost (FCIL) $20 million, with $10 million paid at the beginning of the project and $10 million paid at the end of year 1. There is no land cost because the land is
In an already operational pharmaceutical plant, you are considering three alternative solvent-recovery systems to replace an existing combustion process. The internal hurdle rate is 15% after taxes
A condenser using refrigerated water is being considered for the recovery of a solvent used in a pharmaceutical coating operation. The amount of solvent recovered from the gas stream is a function of
For Problem 10.8, uncertainties associated with predicting the revenues and cost of manufacturing are estimated to be as follows: Revenue: Expected range of variation from base case, low = $45
Calculate the lowest and highest NPVs that are possible for Problem 10.38. Compare these values with the distribution of NPVs from Problem 10.38. What are the probabilities of getting an NPV within
Perform a Monte-Carlo analysis on Problem 10.10, using the following ranges for uncertain variables (all figures in $millions):What do you conclude?When using the CAPCOST program, set the equation
Perform a Monte-Carlo simulation on Example 10.1 for the following conditions. Show that the variation in the NPV is the same as shown in Figure 10.15. To which variable is the NPV more
You are considering buying a house with a mortgage of $250,000. The current interest rates for a mortgage loan for a 15- year period are 7.5% p.a. fixed or 6.75% p.a. variable. Based on historical
Three different products are manufactured in an existing batch process. The details are as follows:The cost of manufacturing is $0.95 million/y. The demand for these products is increasing, and the
A product is to be produced in a batch process. The estimated fixed capital investment is $5 million. The estimated raw materials cost is $100,000/batch, the estimated utility costs are
You are designing a new pharmaceutical facility. The criterion for profitability is 14% before taxes over ten years. The alternatives need not be included in the base design, but either one or both
A batch process runs on a zero-wait-time schedule. It has been determined that a 20% increase in capacity is possible if three equally sized storage tanks are purchased, and the processing schedule

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