Questions and Answers of Chemical Engineering Design

Consider the problem of separation, by ordinary distillation, of propane, A; isobutane, B; \(n\)-butane, \(\mathrm{C}\); isopentane, \(\mathrm{D}\); and \(n\)-pentane, \(\mathrm{E}\). Using the
Thermal cracking of naphtha yields a gas that is to be separated by a distillation train into the products indicated in Figure 9.52. If reasonably sharp separations are to be achieved, determine by
The effluent from a reactor contains a mixture of various chlorinated derivatives of the hydrocarbon \(\mathrm{RH}_{3}\), together with the hydrocarbon itself and \(\mathrm{HCl}\). Based on the
Investigators at the University of California at Berkeley have studied all 14 possible sequences for separating the following mixture at a flow rate of \(200 \mathrm{lbmol} / \mathrm{hr}\) into its
The following cost data, which include operating cost and depreciation of capital investment, pertain to Exercise 9.1. Determine by finding the total cost for each of the 14 possible sequences:(a)
The feed to a separation process consists of the following species:Notice that the addition of furfural causes n-Butane (4) to become more volatile than Butene-1 (3). Determine the number of possible
The following stream at \(100^{\circ} \mathrm{F}\) and 250 psia is to be separated into the four indicated products. Also, given is the cost of each of the unique separators. Determine:(a) The best
The following stream at \(100^{\circ} \mathrm{F}\) and 300 psia is to be separated into four essentially pure products. Also given is the cost of each unique separator. Determine the best sequence.
The following stream at \(100^{\circ} \mathrm{F}\) and \(20 \mathrm{psia}\) is to be separated into the four indicated products. Determine the best distillation sequence by the heuristics of Section
A hypothetical mixture of four species, A, B, C, and D, is to be separated into four separate components. Two different separator types are being considered, neither of which requires a mass
A multicomponent mixture is boiled in a flask at \(1 \mathrm{~atm}\). The vapors are condensed and recovered as a liquid product. It is desired to examine the mole fractions of the residual liquid in
Prepare residue-curve maps using a process simulation program for the following mixtures at \(1 \mathrm{~atm}\). Identify any distillation boundaries.(a) Acetone, n-heptane, toluene(b) Methanol,
For a mixture of \(70 \mathrm{~mol} \%\) chloroform, \(15 \mathrm{~mol} \%\) acetone, and \(15 \mathrm{~mol} \%\) ethanol at \(1 \mathrm{~atm}\), show on a residue curve map the feasible compositions
For the manufacture of di-tertiary-butyl peroxide in Example 9.7 synthesize an alternative process and show the flow rate and composition of each stream.Data From Example 9.7:- This example involves
For the pressure-swing dehydration of THF, determine the internal flow rates when the high-pressure column is at 5 bar.
Design a process for the separation of \(1,000 \mathrm{kgmol} / \mathrm{hr}\) of a mixture composed of \(50 \mathrm{~mol} \%\) acetone (A) and \(50 \mathrm{~mol} \%\) heptane (C) to highly pure
Design a process for the separation of \(1,000 \mathrm{kgmol} / \mathrm{hr}\) of a mixture comprising \(50 \mathrm{~mol} \%\) A and \(50 \mathrm{~mol} \% \mathrm{~B}\) to highly pure product streams
Design a process for the separation of \(1,000 \mathrm{kgmol} / \mathrm{hr}\) of a mixture composed of \(50 \mathrm{~mol} \% \mathrm{~A}\) and \(50 \mathrm{~mol} \% \mathrm{~B}\) (water) to product
In a process for the manufacture of \(\mathrm{C}\) from \(\mathrm{A}\) and \(\mathrm{B}\), streams of \(\mathrm{A}\) and \(\mathrm{B}\) are fed to a CSTR, where they undergo reversible reaction to
The invention and commercialization of a new chemical is a significant undertaking. An example is the invention of nylon in the laboratory and its transformation to a nylon stocking. Please read the
Show the main chemical reactions for producing polyvinyl butyral, assuming that ethylene, acetic acid, ethanol, and butyraldehyde are available as raw materials.
One can follow the developments in the chemical industry in trade magazines such as the Chemical \& Engineering News. Answer the following questions after reading the article, "Global Top 50 " for
The companies involved in the chemical product chain (Figure 1.1) can be categorized by product type. Gas, oil, chemical, pharmaceutical, mineral processing, and consumer goods companies have been
DuPont's Web site (www.dupont.com) shows 13 market sectors in which DuPont sells its products. Prepare a table similar to Table 1.2 in which the chemical products are classified by industrial sector
3M markets a wide variety of consumer goods. Visit its Web site (www.3M.com) and identify the attributes of the following \(3 \mathrm{M}\) products:(a) Ultrathon insect repellent(b) Filtrete air
Visit the Unilever Web site (www.unilever.com) and the Procter and Gamble Web site (www.pg.com). Name some of their brands for the following consumer goods products:(a) Soap(b) Skin cream(c)
A list of the typical attributes of creams and pastes is given in Example 1.2. Identify two sunscreen lotion products from two different companies. Compare them based on the four product attributes
The use of nano zinc oxide in sunscreen lotions is discussed in Example 1.4. The innovation map calls for an investigation of other nano inorganic oxides. Complete Figure 1.10 for the following
Use Google Advanced Patent Search to determine the number of skin care-related patents owned by the following cosmetic companies:(a) Avon(b) Kanebo(c) L'Oreal(d) Revlon(e) Shiseido
Product quality is of paramount importance in chemical product design. Explore the following quality improvement methodologies on the Internet:(a) Fishbone diagram(b) Pareto analysis(c) Process
Instead of the conventional unit operations, many B2C chemical products are manufactured using unconventional processing techniques such as etching, physical vapor deposition, and calendering.
For an equimolar solution of \(n\)-pentane and \(n\)-hexane, compute:(a) The dew-point pressure at \(120^{\circ} \mathrm{F}\)(b) The bubble-point temperature at \(1 \mathrm{~atm}\)(c) The vapor
Consider a stream at \(400 \mathrm{~K}\) containing \(34 \mathrm{~mol} \%\) n-pentane and \(66 \mathrm{~mol} \% \mathrm{n}\)-hexane.(a) What is the bubble point pressure?(b) What are the mole
For the manufacture of vinyl chloride, assemble a preliminary database. This should include thermophysical property data, MSDSs for each chemical giving toxicity and flammability data, and the
For the vinyl-chloride process, using heats of formation, heat capacities, and latent heats, carry-out energy balances to determine the heats liberated and absorbed in the two reaction operations.
Consider the flowsheet for the manufacture of vinyl chloride in Figure 2.6.(a) If the pyrolysis furnace and distillation towers are operated at low pressure \((1.5 \mathrm{~atm})\), what are the
(a) To generate steam at \(60 \mathrm{~atm}\), two processes are proposed:(1) Vaporize water at \(1 \mathrm{~atm}\) and compress the steam at \(60 \mathrm{~atm}\).(2) Pump water to \(60
Synthesize a flowsheet for the manufacture of vinyl chloride that corresponds to one of the other branches in the synthesis tree in Figure 2.7. It should begin with reaction path 4 or 5 .Figure 2.7:-
Using the chemical engineering literature, complete the detailed database for the detailed design of the base-case process in Figure 2.17. When appropriate, indicate the kind of data needed from a
Consider the tPA process reactor (cultivation) section in Figure 2.14 (a):(a) For the third cultivator, change the reaction time to three days. To obtain a cell concentration of \(3 \times 10^{6}
In 2000, when the tPA process in Example 2.3 was synthesized using Chinese hamster ovary cells, data could not be located for the second reaction path using E-coli bacterial cells. Search the
Regarding the recent advances in drilling technologies that permit natural gas to be recovered from shale deposits cost competitively, present arguments from an environmental perspective in favor and
Two serious environmental problems have received considerable attention over the past three decades:(a) The serious depletion of ozone in the Earth's stratosphere, especially over the North and South
Design teams are confronted with "multiobjective" decision making. Is it possible for objectives to lead to conflicting designs? Give an example(s).
Consider the flammability limits of a mixture of methane and ethane in Example 3.2 exposed to air at 5 volume percent. Use inert nitrogen gas to prevent combustion. What volume percent of nitrogen is
Using Table 3.2, discuss potential safety issues associated with the usage of hydrogen as a fuel for automobiles running on fuel cells in comparison with those associated with vehicles running on
The P\&ID reproduced in the next page shows an arrangement for the cooling of a hot effluent stream using cooling water. Unfortunately, the P\&ID includes a number of errors that could lead
The P\&ID reproduced below shows the coolant circuit for the batch reactor, \(\mathrm{R}-100\), in which a highly exothermic reaction occurs. The coolant circuit is intended to maintain the
Refer to the event tree in Figure 3.10 and the data in Table 3.6. Suppose the company operating this CSTR decides to hire an expert operator in response to the runaway reaction in April. This
You are an engineering manager and have been asked to work with the Public Relations Department in writing a press release about a new product that did not turn out quite as well as promised in
You are the plant manager in charge of creating the budget report that goes to the board of directors of your company. Just before the next meeting, the president asks you to leave something negative
You have received a job offer from a startup company headed by \(\mathrm{PhD}\) chemists to be their chief (and only) process engineer, responsible to move their process for a novel solid adhesive
The Bhopal disaster was caused by a gas leak incident in India, considered one of the world's worst industrial disasters. It occurred on the night of 2-3 December 1984 at the Union Carbide India
On March 23, 2005, a hydrocarbon vapor cloud explosion occurred at the isomerization process unit at BP's Texas City Refinery in Texas City, Texas, killing 15 workers and injuring more than 170
The Chernobyl disaster was a catastrophic nuclear accident that occurred on April 26, 1986, at the Chernobyl Nuclear Power Plant in Ukraine, which was under the direct jurisdiction of the central
Given the basis sets of groups Set- \(1\left\{\mathrm{CH}_{3} ; \mathrm{CH}_{2} ; \mathrm{CH} ; \mathrm{C}\right\} ;\) Set- \(2\left\{\mathrm{OH} ; \mathrm{CH}_{3} \mathrm{CO} ; \mathrm{CH}_{3}
For 2-ethylpentanoic acid [CCCC \((\mathrm{CC}) \mathrm{C}(=\) O)O; 020225-24-5], hardly any data are available in the database. To evaluate this molecule, \(T_{\mathrm{b}}, T_{\mathrm{m}}, \Delta
Using the basis set in Example 4.10 and the group-contribution methods in Table 4.6, find the polymer repeat unit that has a glass-transition temperature of \(383 \mathrm{~K}\), density
Fibers play an important role in the textile industries, with natural fibers usually having low tensile strength, high moisture absorption, variable quality, low durability, and so on. Synthetic
Repeat the azeotrope formation case study for cyclic (naphthenic) and cyclic (aromatic) compounds that form azeotropes with ethanol. Also, repeat the azeotrope formation case study to identify all
An identified chemical product to serve as an API (active pharmaceutical ingredient) in a drug is synthesized through a multistage reaction scheme. The key reaction step is hydrophobic, and so all of
The drug barbiturate is well known. It has different forms-mostly different types of barbituric acid. Consider the following list of barbituric acids: \{Candidate 1: 000077-02-1; Candidate 2:
Design a binary liquid mixture that is partially miscible with water, but totally miscible with each other. The binary mixture needs to have the following properties:\[\begin{array}{ll}\text { Normal
For a specific paint application, a mixture of solvents is needed. The mixture will be identified by its ability to mix with water (total miscibility), its normal boiling point (determines the
Some of the mathematical steps in Example 5.2 are omitted. Derive Eqs. (5.14), (5.17), and (5.18).Data From Example 5.2:-Figure 5.10:-Data From Eqs. 5.14 , 5.17, and 5.18:- Herbicides such as
The home appliance company decides to perform additional design work on the proposed air purifier.(a) The \(\mathrm{PtTiO}_{2}\) coated HEPA filter is expected to be easily clogged by particulates in
A home appliances company decides to produce an all-in-one water treatment system for treating tap water. It contains a filter to remove suspended solids, a reverse osmosis (RO) membrane unit to
A household goods company decides to produce a faucet mount water filter for removing organic and metallic contaminants from tap water. The filter is made up of activated carbon and ionexchange
A home supplies company decides to produce a reusable moisture absorber product for removing the water content in air in an enclosed space. A reduction in humidity is expected to help inhibit the
A food processing company is designing the packaging for a new product line of potato chips. The expected shelf life of the potato chips is 10 months. The bag has to hold \(200 \mathrm{~g}\) of
A tennis ball is a rubber hollow sphere covered by a thin layer of fabric usually yellow in color. It has a diameter of \(6.54-6.86 \mathrm{~cm}\) and weighs \(56.0-59.4 \mathrm{~g}\). The internal
A healthcare company decides to produce a medicated transdermal patch to relieve the pain caused by soft tissue injuries. This product with a brand name of nanoPatch is based on a traditional herbal
A healthcare company decides to market a hand warmer. It is basically a palm-size plastic pouch containing a supersaturated aqueous salt solution; that is, the amount of dissolved salt exceeds its
One of the tasks in a product development project is to source the ingredients. Identify a supplier and the cost for the following ingredients:(a) Zinc oxide nanoparticles under the trade name
Example 5.5 shows how to determine the rotor rotation speed and its gap width to produce emulsion particles \(5 \mu \mathrm{m}\) in diameter. If it is decided that the emulsion particle diameter
Many consumers, particularly those in developing countries, are concerned about the cleanliness of municipal water for human consumption. For this reason, distilled water is widely available at work,
Many coastal cities such as Hong Kong can be very humid, particularly in spring and summer with a mean relative humidity above \(80 \%\). Dehumidifiers remove the moisture from air to provide a more
For the production of ethylene glycol, how much is the economic potential per pound of ethylene glycol reduced when chlorine and caustic are used to avoid the production of ethylene oxide?
Consider ethyl-tertiary-butyl-ether (ETBE) as an alternative gasoline oxygenate to MTBE. Although the latter appears to have the best combination of properties such as oxygen content, octane number,
For the ammonia process in Example 6.4, consider operation of the reactor at \(932^{\circ} \mathrm{F}\) and \(400 \mathrm{~atm}\). Use a simulator to show how the product, recycle, and purge flow
Revamp of a toluene hydrodealkylation process. This problem considers some waste-minimization concepts involving recycle to extinction - a heuristic for process synthesis. However, in this exercise,
For the reaction system:\[\begin{aligned}& \mathrm{A}+\mathrm{B} \xrightarrow{k_{1}} \mathrm{C}+\mathrm{A} \xrightarrow{k_{3}} \mathrm{E} \\& \bigvee_{2} \mathrm{D}+\mathrm{A}
Propylene glycol mono-methyl-ether acetate (PMA) is produced by the esterification of propylene glycol mono-methyl ether (PM) in acetic acid (HOAc):Conventionally, the reaction takes place in a
For the following reactions, determine the maximum or minimum temperatures of the reactor effluents assuming:(a) Complete conversion(b) Equilibrium conversion The reactants are available in
For Example 6.9, use a simulator to graph the effluent temperature of the methanol reactor as a function of the \(\mathrm{H}_{2} / \mathrm{CO}\) ratio.Data From Example 6.9:-Data From Example 6.8:-
For Example 6.10, use a simulator to graph the effluent temperature of the methanol reactor as a function of the dodecane flow rate.Data From Example 6.10:-Data From Example 6.8:- Returning to
Divide the methanol reaction operation in Example 6.6 into five consecutive stages in series. Feed the \(\mathrm{CO}\) reactant entirely into the first operation at \(25^{\circ} \mathrm{C}\) and \(1
Repeat Exercise 6.10 using intercoolers instead of cold shots and an unknown number of reaction stages. The feed to the first reactor is at \(25^{\circ} \mathrm{C}\) and \(1 \mathrm{~atm}\).
A process under design requires that \(100 \mathrm{1bmol} / \mathrm{hr}\) of toluene at \(70^{\circ} \mathrm{F}\) and \(20 \mathrm{psia}\) be brought to \(450^{\circ} \mathrm{F}\) and 75 psia.
The fermentation of cane sugar to ethanol was introduced in problem 4.3, and typical yields were given. Design the reactor system for a plant that produces 500,000 metric tons per year of ethanol
The reaction of Example 15.5 can be carried out in a heat-exchanger reactor, using boiling water as coolant. Design and size a reactor to produce 40,000 metric tons per year of cyclohexane.
In the acrolein process introduced in problem 15.1, the catalyst is packed in tubes and the reactor is cooled using a circulating molten salt. The molten salt rejects heat to boiling steam in a
Riboflavin (vitamin B2) is a nutrient that is used as a food additive (mainly in animal feed, but also in breakfast cereal). It can be produced by fermentation of glucose using strains of the yeast
The specification for of a sieve plate column is given below. Make a preliminary mechanical design for the column. Your design should include:(a) Column wall thickness.(b) Selection and sizing of
Make a preliminary mechanical design for the vertical thermosyphon reboiler for which the thermal design was given in Example 12.10 in Chapter 12. The inlet liquid nozzle and the steam connections
The thermal design of a heat exchanger to recover heat from a kerosene stream by transfer to a crude oil stream was carried in Chapter 12, Examples 12.3 and 12.4. Make a preliminary mechanical design
Make a preliminary estimate of the plate thickness required for the distillation column specified below: Height, between tangent lines Diameter Hemispherical head Skirt support, height 100 sieve
Design a skirt support for the column specified in Example 13.2.Data from example 13.2 Height, between tangent lines Diameter Hemispherical head Skirt support, height 100 sieve plates, equally spaced
Estimate the thickness required for the component parts of the vessel shown in the diagram. The vessel is to operate at a pressure of 14 bar (absolute) and temperature of 260°C. The material of
Design an air cooler to cool 30,000 kg/h of diesel oil from 120 °C to 50 °C. The highest ambient temperature that is exceeded for 40 h/yr on average is 40 °C. Physical properties of diesel oil

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