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chemical engineering design

Chemical Engineering Design 6th Edition Ray Sinnott, R.K. Sinnott, Sinnott Gavin Towler - Solutions

Design a vertical shell and tube condenser for the duty given in question 12.7. Use the same preferred tube size.Data from 12.7A condenser is required to condense n-propanol vapor leaving the top of a distillation column. The n-propanol is essentially pure and is a saturated vapors at a pressure
The reactor described in Example 12.15 is fitted with a flat blade disc turbine agitator 0.6 m diameter, running at 120rpm.The vessel is baffled and is constructed of stainless-steel plate 10 mm thick.The physical properties of the reactor contents are: ρ = 850kg/m3, μ = 80 mNm–2s, kf = 400 ×
A jacketed, agitated reactor consists of a vertical cylinder 1.5 m diameter, with a hemispherical base and a flat, flanged, top. The jacket is fitted to the cylindrical section only and extends to a height of 1 m. The spacing between the jacket and vessel walls is 75 mm. The jacket is fitted with a
Investigate the use of an air-cooled exchanger for the duty set out in Example 12.1. Determine the fan power consumption.Data from example 12.1Design an exchanger to sub-cool condensate from a methanol condenser from 95°C to 40°C. The flow-rate of methanol is 100,000kg/h. Brackish water will be
Investigate the use of a gasketed plate heat exchanger for the duty set out in Example 12.1: cooling methanol using brackish water as the coolant. Titanium plates are to be specified, to resist corrosion by the saline water.Data from example 12.1Design an exchanger to sub-cool condensate from a
Design a vaporizer to vaporize 5000kg/h n-butane at 5.84 bar. The minimum temperature of the feed (winter conditions) will be 0°C. Steam is available at 1.70 bar (10 psig). 90 145 H Tube O.D 30 mm D Tube outer limit dia. 420 mm 52 Tube holes 26 u-tubes Tube sheet layout, U-tubes, Example 12.9.
Make a preliminary design for a vertical thermosyphon reboiler for a debutanizer column that has the bottoms composition given below. Take the vapour rate required to be 36kmol/h.Bottoms composition: C3 0.001, iC4 0.001, nC4 0.02, iC5 0.34, nC5 0.64, kmol.Operating pressure 8.3 bar. Bubble point of
Make a preliminary design for a vertical thermosyphon for a column distilling crude aniline. The column will operate at atmospheric pressure and a vaporization rate of 6000 kg/h is required. Steam is available at 22 bar (300 psig). Take the column bottom pressure as 1.2 bar.
A fluid whose properties are essentially those of o-dichlorobenzene is vaporized in the tubes of a forced convection reboiler. Estimate the local heat-transfer coefficient at a point where 5 per cent of the liquid has been vaporized. The liquid velocity at the tube inlet is 2 m/s and the operating
Design a condenser for the following duty: 45,000kg/h of mixed light hydrocarbon vapours to be condensed. The condenser to operate at 10 bar. The vapour will enter the condenser saturated at 60°C and the condensation will be complete at 45°C. The average molecular weight of the vapours is 52. The
It is proposed to use an existing distillation column, which is fitted with a dephlegmator (reflux condenser) that has 200 vertical, 50 mm i.d., tubes, for separating benzene from a mixture of chlorobenzenes. The top product will be 2500kg/h benzene and the column will operate with a reflux ratio
Estimate the heat-transfer coefficient for the pool boiling of water at 2.1 bar, from a surface at 125°C. Check that the critical flux is not exceeded.
Estimate the heat-transfer coefficient for steam condensing on the outside, and on the inside, of a 25 mm o.d., 21 mm i.d. vertical tube 3.66 m long. The steam condensate rate is 0.015 kg/s per tube and condensation takes place at 3 bar. The steam will flow down the tube.
Optimize the design of Example 12.3 using commercial heat exchanger design software.Data from example 12.3Design a shell-and-tube exchanger for the following duty. 20,000kg/h of kerosene (42° API) leaves the base of a kerosene side-stripping column at 200°C and is to be cooled to 90°C by
Design a shell-and-tube exchanger for the following duty. 20,000kg/h of kerosene (42° API) leaves the base of a kerosene side-stripping column at 200°C and is to be cooled to 90°C by exchange with 70,000 kg/h light crude oil (34° API) coming from storage at 40°C. The kerosene enters the
Gas oil at 200°C is to be cooled to 40°C. The oil flow-rate is 22,500kg/h. Cooling water is available at 30°C and the temperature rise is to be limited to 20°C. The pressure drop allowance for each stream is 100 kN/m2. Design a suitable exchanger for this duty.
Design an exchanger to sub-cool condensate from a methanol condenser from 95°C to 40°C. The flow-rate of methanol is 100,000kg/h. Brackish water will be used as the coolant, with a temperature rise from 25° to 40°C.
Acetone is to be extracted from a solution in water, using 1,1,2-trichloroethane. The feed concentration is 45.0 per cent w/w acetone. Determine the number of stages required to reduce the concentration of acetone to below 10 per cent, using 32 kg of extraction-solvent per 100 kg feed. The
Sulphur dioxide produced by the combustion of sulphur in air is absorbed in water. Pure SO2 is then recovered from the solution by steam stripping. Make a preliminary design for the absorption column. The feed will be 5000 kg/h of gas containing 8 per cent v/v SO2. The gas will be cooled to 20 °C.
Calculate the plate efficiency for the plate design considered in Examples 11.6 and 11.7, using Van Winkle’s correlation.Data from example 11.6 Design the plates for the column specified in Example 11.2. Take the minimum feed rate as 70 per cent of the maximum (maximum feed 10,000 kg/h). Use
For the plate design in Example 11.6, estimate the plate efficiency for the plate on which the concentration of acetone is 5 mol per cent. Use the AIChE method.Data from Example 11.6Design the plates for the column specified in Example 11.2. Take the minimum feed rate as 70 per cent of the maximum
Design the plates for the column specified in Example 11.2. Take the minimum feed rate as 70 per cent of the maximum (maximum feed 10,000 kg/h). Use sieve plates.Data from example 11.2Acetone is to be recovered from an aqueous waste stream by continuous distillation. The feed contains 10 mol%
Using O’Connell’s correlation, estimate the overall column efficiency and the number of real stages required for the separation given in Example 11.3, when the reflux ratio is 2.0.Data from example 11.3Estimate the minimum number of ideal stages needed in the butane-pentane splitter defined by
Estimate the position of the feed point for the separation considered in Example 11.3, for a reflux ratio of 3.Data from Example 11.3Estimate the minimum number of ideal stages needed in the butane-pentane splitter defined by the compositions given in the table below. The column will operate at a
Estimate the minimum number of ideal stages needed in the butane-pentane splitter defined by the compositions given in the table below. The column will operate at a pressure of 8.3 bar. Evaluate the effect of changes in reflux ratio on the number of stages required. This is an example of the
Acetone is to be recovered from an aqueous waste stream by continuous distillation. The feed contains 10 mol% acetone. Acetone of at least 95 mol% purity is wanted, and the aqueous effluent must not contain more than 1 mol% acetone. The feed will be a saturated liquid. Estimate the number of ideal
A feed to a column has the composition given in the table below and is at a pressure of 14 bar and a temperature of 60 °C. Calculate the flow and composition of the liquid and vapour phases. Take the equilibrium data from the Depriester charts given in Chapter 8. Feed ethane (C) propane (C3)
Design a cyclone to recover solids from a process gas stream. The anticipated particle size distribution in the inlet gas is given below. The density of the particles is 2500 kg/m3, and the gas is essentially nitrogen at 150°C. The stream volumetric flow-rate is 4000 m3/h, and the operation is at
Design a decanter to separate a light oil from water. The oil is the dispersed phase. Oil, flow rate 1000 kg/h, density 900 kg/m3, viscosity 3mN s/m2. Water, flow rate 5000 kg/h, density 1000 kg/m3, viscosity 1mN s/m2.
A reverse osmosis plant is to be designed to produce 50 kg/s of boiler feed water with less than 20 ppmw of NaCl starting from sea water that contains 3.5 wt% NaCl. The 40 m2 membrane modules operate at 60 atm and achieve a flux of 0.4 m3/m2.day when the permeate pressure is 2 atm. If each membrane
Estimate the size of hydro cyclone needed to separate 90 per cent of particles with a diameter greater than 20 μm, from 10 m3/h of a dilute slurry. Physical properties: solid density 2000 kg/m3, liquid density 1000 kg/m3, viscosity 1 mN s/m2
Yang et al. (1997) gives isotherm data for adsorption of methane on zeolite 5A in the presence of hydrogen:It has been determined that a four-bed PSA plant using this adsorbent can be used to purify a stream containing 40%CH4 in H2 to give 90% recovery of hydrogen at purity 99.99 mol%. The
A distillation column separates benzene from toluene using a control scheme similar to that shown in Figure 5.26c. Make a practice HAZOP study of the plant section and add any instrumentation that is needed to develop the full P and I diagram.Data from figure 5.26 FT FFC FT # FFV
Evaluate the Dow F & EI for the nitric acid plant illustrated in Chapter 4, Figure 4.2.Data from figure 4.2 Flows kg/h Pressures nominal Line no. Stream Component NH3 0 N NO NO HNO3 HO Total Press bar Temp. C 731.0 8 15 Air 20 1 1A 2 2A Ammonia Ammonia Filtered Oxidizer Feed Vapour Air Air 731.0
Using Lydersen’s method, estimate the critical constants for isobutanol. Compare your values with those given in Appendix C.Data from appendix c NO 1 2 3 4 5 Formula AR BCL3 BF3 BR2 CLNO CL2 CL3P CLASI 15 16 8 9 D2 10 D20 11 F2 12 F3N 13 F4SI 14 F6S HBR HCL 17 HF 18 H1 19 H2 20 H2O 21 H2S 22 H3N
For the compounds listed below, estimate the constants in the equation for ideal gas heat capacity, equation 3.19, using the method given in Section 8.9.2.1. 3-methyl thiophene.2. Nitrobenzene.3. 2-methyl-2-butanethiol.4. Methyl-t-butyl ether.Data from section 8.9.2The dependence of gas specific
Make a rough estimate of the viscosity of 2-butanol and aniline at their boiling points, using the modified Arrhenius equation. Compare your values with those given using the equation for viscosity in Appendix C.Data from appendix c LOG[viscosity] = [VISA] * [(1/T) - (1/VISB)], viscosity mNs/m, T
Estimate the diffusivity of phenol in ethanol at 20 °C (293 K).
Estimate the diffusivity of methanol in air at atmospheric pressure and 25 °C.
Estimate the latent heat of vaporization of acetic anhydride, C4H6O3, at its boiling point, 139.6 °C (412.7 K), and at 200 °C (473 K).
Estimate the specific heat capacity of isopropyl alcohol at 500 K.
Estimate the specific heat capacity of chlorobutadiene at 20 °C, using Chueh and Swanson’s method.
Using Chueh and Swanson’s method, estimate the specific heat capacity of ethyl bromide at 20 °C.
Estimate the specific heat capacity of urea, CH4N2O.
Estimate the thermal conductivity of ethane at 1 bar and 450 °C.
Estimate the thermal conductivity of benzene at 30 °C.
Estimate the viscosity of toluene at 80 °C, using the value at 20 °C given in Example 8.2.Data from Example 8.2Estimate the viscosity of toluene at 20 °C.
Estimate the viscosity of toluene at 20 °C.
Calculate the density of a mixture of methanol and water at 20 °C, composition 40 per cent w/w methanol. Density of water at 20C Density of methanol at 20 C 998.2 kg/m 791.2 kg/m
The pipeline described in question 7.1 was used to carry wastewater to a hold-up tank.The effluent is not hazardous. A decision has to be made on what material to use to replacethe pipe. Three suggestions have been made:1. Replace with the same schedule carbon steel pipe and accept renewal at
Carry out a sensitivity analysis of the adipic acid project described in Examples 6.11 and 6.12.Data from example 6.11Adipic acid is used in the manufacture of nylon 6,6. It is made by hydrogenation of phenol to a mixture of cyclohexanol and cyclohexanone (known as KA oil – ketone and alcohol),
A preliminary (Class 4) estimate of the ISBL capital cost of building a 200,000 ton per year ethanol plant by corn dry milling has been stated as $130 MM -30% / +50%. The plant is to be built on a green-field site and offsite costs are estimated to be between $40 MM and $60 MM. Estimate a value for
A plant is producing 10,000 metric tons per year (10 kMTA) of a product. The overall yield is 70 per cent, on a mass basis (kg of product per kg raw material). The raw material costs $500/metric ton, and the product sells for $900/metric ton. A process modification has been devised that will
The adipic acid plant in Example 6.11 is built with 30% of the fixed investment in year 1 and 70% in year 2, and the plant operates at 50% of capacity in year 3 before reaching full capacity in year 4. The plant can be depreciated by the straightline method over ten years and profits can be assumed
Adipic acid is used in the manufacture of nylon 6,6. It is made by hydrogenation of phenol to a mixture of cyclohexanol and cyclohexanone (known as KA oil – ketone and alcohol), followed by oxidation with nitric acid. The overall reaction can be written approximately as: The actual process
A carbon steel heat exchanger that costs €140,000 is expected to have a service life of five years before it requires replacement. If type 304 stainless steel is used then the service life will be increased to 10 years. Which exchanger is the most economical if the cost of capital is 12%?
A chemical plant with a fixed capital investment of $100 million generates an annual gross profit of $50 million. Calculate the depreciation charge, taxes paid and after-tax cash flows for the first ten years of plant operation using straight-line depreciation over 10 years and using MACRS
The light naphtha isomerization process is more complex than the description given in Example 4.7. 1. Hydrogen is flowed through the plant to reduce catalyst deactivation. The hydrogen flow rate is typically about 2 moles per mole of hydrocarbon on a pure hydrogen basis. The hydrogen make-up gas
The autothermal reforming of methane to hydrogen was described in Example 4.2. The solution in the example was not optimized, and suggestions were given for how to improve the results. Optimize the process to minimize the cost of production of hydrogen, assuming: Data from example 4.2Steam
Methyl ethyl ketone (MEK) is manufactured by the dehydrogenation of 2-butanol. A simplified description of the process listing the various units used is given below: 1. A reactor in which the butanol is dehydrated to produce MEK and hydrogen, according to the reaction: The conversion of alcohol
The batch fermentation of glucose to glutamic acid using Brevibacterium divaricatum is described in detail in US patent 2,978,384. In Example I in the patent a 10.5 wt% glucose feed was fermented for 72 hours at 30 °C, giving 33.5 wt% glutamic acid yield on glucose. What annual production of
Light naphtha is a mixture produced by distillation of crude oil. Light naphtha primarily contains alkane compounds (paraffins) and it can be blended into gasoline. The octane value of methyl-substituted alkanes (iso-paraffins) is higher than that of straight-chain compounds (normal paraffins), so
Continuing the problem defined in Example 4.3, use a rigorous simulation to carry out tray sizing and estimate the required column diameter.Data from example 4.3This example provides more detail on the solution of the problem that was introduced as Example 1.1. The original problem statement was
In an ethanol plant, the mixture of water and ethanol from the beer column distillate contains about 40% ethanol (molar basis) in water, together with the fusel oils described in the previous problem. This mixture is distilled to give an azeotropic mixture of ethanol and water (89% ethanol)
This example provides more detail on the solution of the problem that was introduced as Example 1.1. The original problem statement was to optimize the design of a distillation column to separate 225 metric tons per hour of an equimolar mixture of benzene, toluene, ethylbenzene, paraxylene and
Hydrogen can be made by steam reforming of methane, which is a highly endothermic process: Steam reforming is usually carried out in fired tubular reactors, with catalyst packed inside the tubes and fuel fired on the outside of the tubes to provide the heat of reaction. The product gas mixture
When heavy oils are cracked in a catalytic or thermal cracking process, lighter hydrocarbon compounds are formed. Most cracking processes on heavy oil feeds form products with carbon numbers ranging from two to greater than twenty. How does the equilibrium distribution of hydrocarbon compounds with
If the gases leave the tower at 6 atm, 25°C, and are expanded to, say, 1.5 atm, calculate the turbine exit gas temperatures without preheat, and if the gases are preheated to 400°C with the reactor off-gas. Also, estimate the power recovered from the preheated gases. Consider the extraction of
Methane is compressed from 1 bar and 290 K to 10 bar. If the isentropic efficiency is 0.85, calculate the energy required to compress 10,000 kg/h. Estimate the exit gas temperature.
Calculate the standard heat of reaction for the following reaction: the hydrogenation of benzene to cyclohexane. (1) C6H6(g) + 3H₂(g) → C6H12(g) (2) C6H6(g) + 7 O₂(g) 6CO₂(g) + 3H₂O(1) AH-3287.4 kJ (3) C6H12(g) + 90₂ → 6CO₂(g) + 6H₂O(1) AH-3949.2 kJ CO₂(g) AH = -393.12 kJ (4)
Illustrates the manual calculation of a reactor heat balance.Vinyl chloride (VC) is manufactured by the pyrolysis of 1,2-dichloroethane (DCE). The reaction is endothermic. The flow-rates to produce 5000 kg/h at 55 per cent conversion are shown in the diagram (see Example 2.13). The reactor is a
Estimate the specific enthalpy of ethyl alcohol at 1 bar and 200 °C, taking the datum temperature as 0°C.Cp liquid 0°C 24.65 cal/mol°C100°C 37.96 cal/mol°C Boiling point of ethyl alcohol at 1 bar = 78.4°C.Latent heat of vaporization = 9.22 kcal/mol. Cp gas (t°C) 14.66+3.758 x 10-2-2.091
An alternative process for converting benzene to cyclohexane also uses a supported noble metal catalyst, but carries out the reaction in the liquid phase, at a temperature of 160 °C and pressure of 100 bara, in a slurry reactor. The catalyst has piece density 1100 kg/m3. Laboratory scale
Estimate the annual cost of providing refrigeration to a condenser with duty 1.2 MW operating at – 5°C. The refrigeration cycle rejects heat to cooling water that is available at 40 °C, and has an efficiency of 80% of the Carnot cycle efficiency. The plant operates for 8000 hours per year and
Estimate the NPV at a 12% interest rate and the DCFROR for the project described in Example 6.8, using the MACRS depreciation method.Data in example 6.8A chemical plant with a fixed capital investment of $100 million generates an annual gross profit of $50 million. Calculate the depreciation
A new process is being developed for converting benzene to cyclohexane by hydrogenation over a noble metal catalyst. The reaction is carried out at 50 bara, at a feed temperature of 220 °C, and the reactor contents should not exceed 300 °C, to minimize formation of methyl cyclopentane (MCP)
A gasoline surge drum has capacity 4 m3 (1060 gal) and is normally operated 50% full at 40°C (100°F) under 20 bar absolute pressure (280 psig) of hydrogen in the head space and using a level controlled outflow as shown in Figure 9.10a. Gasoline of specific gravity 0.7 is pumped into the surge
Laboratory test data for a trip system shows a failure rate of 0.2 per year. If the demand rate is once every two years and the test interval is six months, what is the hazard rate? Should a parallel system be installed?Hazard rate for single system, F = δ ϕ = 0.5 × 0.05 = 0.025, i.e., once in
This example illustrates how the techniques used in an operability study can be used to decide the instrumentation required for safe operation. Figure 9.6a shows the basic instrumentation and control systems required for the steady-state operation of the reactor section of the nitric acid process
Estimate the surface tension of pure methanol at 20 °C, density 791.7 kg/m3, molecular weight 32.04.
Estimate the critical constants for diphenylmethane using Lydersen’s method; normal boiling point 537.5 K, molecular mass 168.2, structural formula: HC H С H Н C. C Н H T c-С-С | H Н Н H C H CH
A precipitate is to be continuously separated from a slurry. The solids concentration is 5 per cent and the slurry feed rate5.5 m3/h. The relevant physical properties at the system operating temperature are: liquid density 1050 kg/m3, viscosity 4 cp (mNm–2s),solid density 2300 kg/m3,
Make a preliminary design for a separator to separate a mixture of steam and water; flow-rates: steam 2000 kg/h, water 1000 kg/h; operating pressure 4 bar.
Design a horizontal separator to separate 10,000 kg/h of liquid, density 962.0 kg/m3, from 12,500 kg/h of vapor, density 23.6 kg/m3. The vessel operating pressure will be 21 bar.
Devise a preliminary control scheme for the sections of the nitric acid plant described in Chapter 4, flow-sheet Figure 4.2, which are listed below. Make a practice HAZOP study of each section and revise your preliminary control scheme.1. Waste heat boiler (WHB)2. Condenser3. Absorption column
Develop a fault tree for events that could lead to release of benzene to the atmosphere for the distillation section designed in problem 9.5.Data from problem 9.5A distillation column separates benzene from toluene using a control scheme similar to that shown in Figure 5.26c. Make a practice HAZOP
Estimate the Dow Fire and Explosion Index, and determine the hazard rating, for the processes listed below. Use the process descriptions given in Appendix F and develop the designs, as needed, to estimate the index.1. Ethyl hexanol from propylene and synthesis gas, F.1.2. Chlorobenzenes from
It has been suggested that carbon dioxide can be recovered from flue as using a membrane process. The flue gas has composition: nitrogen 73.9 mol%, oxygen 3.1 mol%, carbon dioxide 7.7 mol%, water vapour 15.3 mol%. Using the data in Table 10.2, determine the best membrane material for this process.
An electronics plant uses an adsorption system to recover solvent from a vent gas stream and prevent volatile organic compound (VOC) emissions. The vent gas flow rate is 20 m3/s of dry air at 293 K, 1.5 atm. The initial solvent loading is 1.5 mol%, which must be reduced to 20 ppm to comply with
In the production of aniline by the hydrogenation of nitrobenzene, the reactor products are separated from unreacted hydrogen in a condenser. The condensate, which is mainly water and aniline, together with a small amount of unreacted nitrobenzene and cyclohexylamine, is fed to a decanter to
The product from a crystallizer is to be separated from the liquor using a centrifuge. The concentration of the crystals is 6.5 per cent and the slurry feed rate to the centrifuge will be 5.0 m3/h. The density of the liquor is 995 kg/m3 and that of the crystals 1500 kg/m3. The viscosity of the
At a pressure of 10 bar, determine the bubble and dew point of a mixture of hydrocarbons, composition, mol per cent: n-butane 21, n-pentane 48, n-hexane 31. The equilibrium K factors can be estimated using the De Priester charts in Chapter 8 or found using a process simulation program.
The feed to a distillation column has the following composition, mol per cent: propane 5.0, isobutane 15, n-butane 25, isopentane 20, n-pentane 35. The feed is preheated to a temperature of 90 °C, at 8.3 bar pressure. Estimate the proportion of the feed that is vapour.
In the manufacture of methyl ethyl ketone (MEK). The product MEK is extracted from a solution in water using 1,1,2 trichloroethane as the solvent.For a feed rate 2000 kg/h of solution, composition 30 per cent w/w MEK, determine the number of stages required to recover 95 per cent of the dissolved
A column is required to recover acetone from an aqueous solution. The feed contains 5 mol per cent acetone. A product purity of 99.5 per cent w/w is required and the effluent water must contain less than 100 ppm acetone.The feed temperature will range from 10 to 25 °C. The column will operate at
The heat duty of the jacketed vessel of Examples 12.15 and 12.16 can be estimated from the coolant flow rate and temperatures. What is the minimum temperature at which the reactor can operate using the jacket as designed? Does the choice of coolant make sense at this temperature? Propose a better
In the manufacture of methyl ethyl ketone (MEK) from 2-butanol, the reactor products are precooled and then partially condensed in a shell and tube exchanger. A typical analysis of the stream entering the condenser is, mol fractions: MEK 0.47, unreacted alcohol 0.06, hydrogen 0.47. Only 85 per cent
A stirred tank fermentation reactor has height 2 m, diameter 1.5 m and is filled with a fermentation broth that can be assumed to have the physical properties of water. The fermenter must be maintained at a temperature less than 42 °C to prevent damage to the cell culture. After allowing for
A storage tank is purged continuously with a stream of nitrogen. The purge stream leaving the tank is saturated with the product stored in the tank. A major part of the product lost in the purge could be recovered by installing a scrubbing tower to absorb the product in a solvent. The solution from
The production of methyl ethyl ketone (MEK) is described in Appendix F, problem F.3. A preliminary design has been made for a plant to produce 10,000 metric tons per year. The major equipment items required are listed below. The plant operating rate will be 8000 hours per year.Estimate the capital

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