100 SOLVED

CHEMICAL
ENGINEERING
PROBLEMS
Using AVEVATM Process Simulation Software

Under the Mentorship of Dr. Pavan Kumar Veldandi

Busam Krishna Murthy | Surya Karla

Adithya Reddy Papaiahgari | Deepthi Chittalury
Vivikta Kona | Apoorva Dursheti

Osmania University College of Technology

Alumni Association (OUCTAA) Publication
 100 Solved Problems in
Chemical Engineering
using AVEVA Process Simulation Software
 100 Solved Problems in
Chemical Engineering
using AVEVA Process Simulation Software

Authors
Deepthi Chittalury
University College of Technology, Osmania University

Vivikta Kona
University College of Technology, Osmania University

Apoorva Dursheti
University College of Technology, Osmania University

Dr. Pavan Kumar Veldandi

Joint secretary, Osmania University College of Technology Alumni Association

Busam Krishna Murthy

University College of Technology, Osmania University

Adithya Reddy Papaiahgari

University College of Technology, Osmania University

Surya Karla
University College of Technology, Osmania University

Osmania University College of Technology

Alumni Association (OUCTAA) Publication
University College of Technology, Osmania University,
Hyderabad - 500007, Telangana, INDIA.
 100 Solved Problems in
Chemical Engineering
using AVEVA Process Simulation Software
by
Pavan Kumar Veldandi

Copyright © 2021 by Osmania University College of Technology

Alumni Association Publication, Inc. All rights reserved

First Edition 2021

Published by
Osmania University College of Technology Alumni Association Publication
University College of Technology, Osmania University, Hyderabad - 500007, Telangana, INDIA.

ISBN: 978-93-5493-292-2

Copyright © 2021 by Osmania University College of Technology Alumni Association Publication, Inc.
All rights reserved

Published by Osmania University College of Technology Alumni Association, No part of this

publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any
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While the publisher and authors have used their best efforts in preparing this book, they make no
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Contact information:
Dr. Pavan Kumar Veldandi: (+91) 9652396527
Krishna Murthy Busam (+91) 7893968254

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Contents
Author's Note

Preface

Acknowledgement

About Process Simulation

About AVEVA Process Simulation

1. FLUID MECHANICS 1

Problem number Problem address

1.1 Gavhane, problem 7.1 2

1.2 Gavhane, problem 7.30 5

1.3a McCabe and Smith, problem 5.1 7

1.3b McCabe and Smith, problem 5.1 9

1.4 McCabe and Smith, problem 5.8 11

1.5 G.K. Roy problem 16 14

1.6 McCabe and Smith 5.9 16

1.7 Gavhane 2.49 18

1.8 McCabe and Smith, problem 6.5 20

1.9 McCabe and Smith, problem 6.3 22

1.10 McCabe and Smith, problem 8.2 25

1.11 McCabe and Smith, problem 5.13 27

1.12 Cengel problem 8.6 29

1.13 Cengel problem 8.1 31

1.14 Industrial Problem 34

2. MATERIAL AND ENERGY BALANCE 36

Problem number Problem address

2.1 K.A. Gavhane, Problem 3.38 37

2.2 K.A. Gavhane, Problem 3.11 39

2.3 G.K Roy problem 6 42

2.4 Industrial Problem 44

2.5 Nptel Problem 47

2.6 K.A. Gavhane, Problem 4.47 51

2.7 K A Gavhane, Problem 4.7 54

2.8 K.A. Gavhane, Problem 5.14 57

2.9 Nptel Splitter problem 60

2.10 Himmelblau, 26.2 62

2.11 JM Smith 4.8 64

3. CHEMICAL ENGINEERING THERMODYNAMICS 67

Problem number Problem address

3.1 JM Smith, 4.2 68

3.2 JM Smith 3.33 70

3.3 JM smith 10.5 73

3.4 JM Smith 7.35a 76

3.5 JM Smith 7.34 78

3.6 JM Smith 7.47 a 80

3.7 JM Smith 7.47b 82

3.8 JM Smith 7.19 b 84

3.9 JM Smith 7.19 a 86

3.10 JM smith 7.18 88

3.11 JM smith 7.24 91

3.12 JM Smith 13.14 93

3.13 JM smith 7.59 95

3.14 JM smith 6.80 98

3.15 JM Smith 6.79 100

3.16 JM Smith 10.38 102

3.17 JM Smith 8.1 104

3.18 JM Smith 9.1 106

3.19 JM smith 13.12 108

Problem number Problem address

3.20 JM Smith figure 9.3 111

3.21 JM Smith 9.3 a 115

3.22 JM Smith 9.3 b 117

3.23 a JM smith 7.53 a 120

3.23 b JM smith 7.53 b 122

3.24 Jm smith 7.10 124

3.25 JM smith 6.30 126

3.26 nptel_thermodynamics 127

3.27 Industrial Problem 129

3.28 JM Smith 3.28 132

3.29 JM Smith 10.4 134

3.30 JM smith 13.6 136

3.31 JM smith 13.9 139

4. HEAT TRANSFER 142

Problem number Problem address

4.1 Mc Cabe 15.4 143

4.2 Cengel, Problem 13.4 146

4.3 Cengel Problem 13.3 148

4.4 Mc Cabe 11.5 150

4.5 Mc Cabe 11.5 153

4.6 Mc Cabe Problem 16.2 155

4.7 Industrial problem 158

4.8 Sukhatme 7.25 160

4.9 Industrial problem 162

4.10 Industrial problem 165

5. CHEMICAL REACTION ENGINEERING 167

Problem number Problem address

5.1 a Fogler 8-5 b 168

5.1 b Fogler 8-5 a 172

5.2 a Fogler 4-2 c 176

5.2.b Fogler 4-2 a 179

5.3 Fogler 4-3 182

5.4 Fogler P4-7A 185

5.5 Fogler 4-6 188

5.6 Fogler 4-7 example 191

5.7 Fogler 6-7 194

5.8 Fogler 6-10 197

5.9 Fogler 8-3a 200

5.10 Fogler 8-3b 203

5.11 Fogler 8-8 206

5.12 Industrial Problem 209

6. MASS TRANSFER OPERATIONS 212
Problem number Problem address
6.1 Treybal 8.3 a 213

6.2 Treybal 8.3 b 216

6.3 Mc Cabe 20.4 219

6.4 B.K Dutta 6.3 221

6.5 McCabe 20.2 224

6.6 MC Cabe and Smith 21.4 227

6.7 Treybal 8.12 230

6.8 HenlyandSeader_16.5 233

6.9 B.K Dutta 10.3 236

6.10 HenrgyKister 239

6.11 Treybal 9.4 242

6.12 Treybal 9.7 245

6.13 Mc Cabe and Smith 21.1 248

6.14 Mc Cabe and Smith 22.3 251

6.15 Mc Cabe and Smith 21.6 254

6.16 Gavhane 3.48 257

6.17 Industrial Problem 260

6.18 HenlyandSeader_15.30 263

Author's Note

This book has been brought in continuation of the book on PRO/II. In this book
we presented 100 solved problems in all the subjects of Chemical Engineering
using AVEVA(TM) Process Simulation(APS). APS is a next generation Process
Simulation software with emphasis on open ended process simulation
methodology.It gives flexibility to modify the equations used in modeling and
simulation.

I wish that this book motivates academia to pursue simulation as a class room
training course. Ultimately benefiting both Academia and Industry.
I would like to thank Pramod Kadangotte, Cal Depew, James Kattapuram and
Mihaela Hahne for their continuous support in all aspects for making this
publication possible.

I would like to thank my wife Anuradha for her continuous support throughout
the journey of this book

-Dr. Pavan Kumar Veldandi

Preface

This book provides the approach by which chemical engineering problems can be solved
using simulation software such as AVEVA Process Simulation (APS). I believe that this book
will help the students and faculty in understanding and practicing the simulation software,
therefore it improves the learning curve of readers. With the advent of the internet, artificial
intelligence, and the latest tools, it is important for the student to learn about these tools in a
short period of time and constantly keep updating his/her skill set. Students are often an
element of resource creation for the institution. They can provide value to the university and
build a win-win situation. They will make use of the faculty resources and do many
productive things by which the institution can benefit. Virtual experimentation is also
possible using simulation software such as APS. Students can carry out experiments on the
computer with minimal physical strain. They can play with various parameters related to the
experiment and get an in-depth understanding of the concepts. They can correlate theory
and experiment. It makes students industry-ready. For the students to do well and provide
value to the industry, it is essential that they are well versed with the tools being used in the
modern chemical industry.

The book comprises of 6 sections. Each section deals with solved problems based on the
concepts related to a particular chemical engineering subject. The authors have chosen the
example problems and exercise problems from standard core Chemical engineering
textbooks for the courses namely, Fluid Mechanics, Mechanical Unit Operations, Material
& Energy balances, Thermodynamics, Heat transfer, Chemical Reaction Engineering, and
Mass Transfer Operations.

Each problem consists of the statement, solution approach, input file, and the flow sheet with
results. The solution approach for the complex problems will help in understanding the
methodology and thought process for solving the problem using APS. The input file consists
of the input data given to the streams, unit operations, unit processes, and other tools in
APS. The flow sheets give the pictorial representation of the manner in which various unit
operations and processes are connected. Results are also displayed in the flow sheet. Graphs
and necessary sections of the simulation report are sometimes used to display the results.

In order to make the best use of this book, it is recommended to first solve the problems
manually, by hand calculation and then solve the same problems using APS. The results can
be compared and analyzed. I recommend this book to students where it provides a great way
of learning chemical engineering through simulation software.

-Prof. V. Venkata Basava Rao

Principal, University College of Technology, Osmania University
ACKNOWLEDGEMENT

We would like to thank AVEVA, Inc. for their support and cooperation. It should be
emphasized that screen images of AVEVA Process simulation (APS) are reprinted
with permission by AVEVA, Inc. APS simulation logo is the trademark of AVEVA, Inc.
All rights reserved. A soft- or hardcopy reproduction of any screen image appearing
in this textbook must be made with a prior permit from AVEVA, Inc. We would like to
express our gratitude to Prof. V.V. Basava Rao Garu (Principal OUCT), Prof. V.
Ramesh Kumar (HOD, Dept of Chem. Engg, OUCT), and the OUCT alumni for
providing modern learning tools and facilities such as PRO/II in our college. And we
would like to express our sincere thanks to Mr. K. V. Rameshwar Reddy (Chairman &
M.D, SURI Industries) for his support towards publication of the book. A book like
this cannot happen overnight. This book was possible because of the continuous
hard work and perseverance. It requires planning and a birds-eye for details. We are
very fortunate to be guided by Dr. Pavan Kumar Veldandi (Alumnus, OUCT). We are
grateful to him for his valuable time and sincere efforts in making this book
possible. His idea of sharing knowledge always inspires us. We would like to thank Y.
Sai Deepika Reddy for continuous support in designing the book. Finally, we would
like to thank our friends K.Nikhil, P. Rohith, and N. Lidvija for their persistent
support and encouragement.

Thank You Very Much!

-STUDENT AUTHORS
ABOUT PROCESS SIMULATION

A simulation is an approximate imitation of the operation of a process or system

that represents its operation over time. A simulation is the re-creation of a real-
world process in a controlled environment. It uses something called modelling to
figure out the result of the simulation. A model is a representation of an object or
process that describes and explains that phenomenon when it can't be experienced
directly.

Simulation is used in many contexts, such as simulation of technology for

performance tuning or optimizing, safety engineering etc. Often, computer
experiments are used to study simulation models. Simulation is also used with
scientific modelling of natural systems or human systems to gain insight into their
functioning, as in economics. Simulation can be used to show the eventual real
effects of alternative conditions and courses of action. Simulation is also used when
the real system cannot be engaged, because it may not be accessible, or it may be
dangerous or unacceptable to engage, or it is being designed but not yet built, or it
may simply not exist.

Process simulation is almost universally used to guide the design of new processes,
evaluates alternate plant configurations, troubleshoots and debottlenecks plant
process, etc. Process simulation programs perform rigorous mass and energy
balances for a wide range of chemical processes.
ABOUT AVEVA PROCESS SIMULATION
TM

AVEVA Process Simulation is an innovative, integrated platform covering the

entire process engineering lifecycle of design, simulation and training to
deliver the process side of the Digital Twin.

AVEVA Process Simulation is the first commercially available platform to take

advantage of developing web-based and cloud technologies to deliver an
enjoyable user experience so that engineers will be more productive,
collaborative, creative and inspired.
1
FLUID MECHANICS

Knowledge of fluid mechanics is essential for the chemical engineer because

the majority of chemical-processing operations are conducted either partly or
totally in the fluid phase. Examples of such operations abound in the
biochemical, chemical, energy, fermentation, materials, mining, petroleum,
pharmaceuticals, polymer, and waste-processing industries.

There are two principal reasons for placing such an emphasis on fluids. First, at
typical operating conditions, an enormous number of materials normally exist
as gases or liquids or can be transformed into such phases. Second, it is
usually more efficient and cost-effective to work with fluids in contrast to
solids. Knowledge of fluid mechanics is essential for plant design. It is
important for a chemical engineer to size the pump for the required load,
select the piping of suitable capacity and estimate the pressure drop for the
entire piping system.

We have focused on problems relating to pressure drop and capacity for

incompressible flow, flow through pipe fittings such as U-bends, sudden
contractions and expansions. Problems on pump sizing based on frictional
losses and elevation changes also have been solved. Problems on steady state
gas flow equipment such as fans and compressors have been considered.

1
1.1) A crude oil of viscosity 0.9 poise and relative density of 0.9 is flowing through a
horizontal pipe of 120 mm and length 12 m. Calculate the difference in pressure at the
two ends of the pipe, if 785 N weight of the oil is collected in a tank in 25 s.

SOLUTION:-

Step-1:-The UOM is set to SI units and The units are to be selected from this window
which is shown in figure 1.1.1.

Figure 1.1.1

Step-2 :- Create a new fluid and Components and Thermodynamic methods are to be
selected from this window. Here in this problem, Decandiol is used as the component
and the ideal thermodynamic model is used which is shown in Figures 1.1.2 and 1.1.3

Figure 1.1.2

2
 Figure 1.1.3

Step-3:-Flowsheet is drawn in the Simulation Palette which is shown in the figure 1.1.4

Figure 1.1.4

3
Step-4:-Input data for streams and Pipe Operation Data need to be specified as
follows which is shown in the figure 1.1.5 and 1.1.6, Subsequently the output
data is shown in the figure 1.1.7

Figure 1.1.7

Figure 1.1.5

Figure 1.1.6

4
1.2) Find the size of the pipe in mm through which an oil of viscosity 0.9 cP and specific
gravity 0.8 is flowing with a velocity of 3 m/s.
SOLUTION:
Solved the problem by taking the water as the flowing liquid (the type of liquid is immaterial) and
specified the velocity as 3m/s. By giving these specifications, it has calculated the size of the pipe
(diameter). The input file, flowsheet and the results are shown in the figures 1.2.1, 1.2.2 and 1.2.3

Figure 1.2.1 Input

5
Figure 1.2.2 Flowsheet

Figure 1.2.3 Results

6
1.3) Water is flowing at 50o F through a long horizontal plastic pipe, 3 inch inside
diameter, at a velocity of 8ft/s.
a) Calculate the pressure drop per 100 ft of pipe.

SOLUTION:
The pipe unit operation is used. the velocity is specified as 8 ft/s. The pressure drop is calculated.
The input file, flowsheet and the result are as shown in the figure as 1.3.a.1, 1.3.a.2, and 1.3.a.3

Figure 1.3.a.1 Input

7
Figure 1.3.a.2 Flowsheet

Figure 1.3.a.3 Results

8
1.3) Water is flowing at 50o F through a long horizontal plastic pipe, 3 inch inside
diameter, at a velocity of 8ft/s.
b) If the pressure drop must be limited to 2 psi per 100 ft of pipe what is the maximum
allowable velocity of the water?
SOLUTION:
The pipe unit operation is used. For the second part, Here the pressure drop of 2 psi is specified.
The average velocity is calculated and displayed in the result table as shown in the figure 1.3.b.3
Input file is as shown in the figure 1.3.b.1 and the flowsheet is as shown in figure 1.3.b.2

Figure 1.3.b.1 Input

9
Figure 1.3.b.2 Flowsheet

Figure 1.3.b.3 Results

10
1.4) A steel pipe 2ft in diameter carries water at about 15ft/s. If a pipe has a roughness
of 0.0003ft, can the capacity be increased by inserting a smooth plastic liner that
reduces the inside diameter to 1.9ft? Calculate the change in pressure drop for the same
flow and the change in capacity for a fixed pressure drop.

SOLUTION:
.The pressure drop and the flow rate for the pipe without lining is calculated. The roughness value
is entered. The fixed pressure drop and fixed capacity calculations are performed on the smooth
pipe. The input file, flowsheet are shown in figures 1.4.1, 1.4.2 and results are shown in figure
1.4.3, 1.4.4, 1.4.5

Figure 1.4.1 Input file

11
 Figure 1.4.2 Flowsheet

Figure 1.4.3 Results of Pipe_1

12
Figure 1.4.4 Results of Pipe_2

Figure 1.4.5 Results of Pipe_3

13
1.5) Calculate the power required and the pressure which should be developed by a
pump of 70% efficiency in order to send 60 kg/min of 98% sulphuric acid at 25 degree C
from a tank at atmospheric pressure through 300 meters of 5min i.d., steel pipe to a
tank of 2.0 kg/cm^2 pressure, where the level is 3 meters above that in the lower tank.

SOLUTION:
The pump and pipe unit operations are used. The STREM_TABLE is used to display the pump
work. Since the water level in the discharge is at a higher level than the supply tank, the elevation
is taken as 150 feet. The input file, flowsheet and results are shown in figures 1.5.1, 1.5.2 & 1.5.3.

Figure 1.5.1 Input

14
Figure 1.5.2 Flowsheet

Figure 1.5.3 Results

15
1.6) Water at 600 F is pumped from a reservoir to the top of a mountain through a 6-in
schedule 120 pipe at an average velocity of 12 ft/s. The pipe discharges into the
atmosphere, 300 ft above the level in the reservoir. The pipeline used is 4500 ft long. If
the overall pump efficiency is 70%, calculate the shaft work.

SOLUTION:
The pipe unit operation with roughness and elevation change specified is used to calculate the
pressure drop. A pump is used to calculate the shaft work required to overcome this pressure
drop. The input file is shown in the figure 1.6.1, The flowsheet and the results are as shown in the
figure 1.6.2. and 1.6.3.

Figure1.6.1 Input

16
Figure1.6.2 Flowsheet

Figure1.6.3 Results

17
1.7) 15 kg of carbon dioxide is compressed at a temperature of 303 Kelvin to a volume of
0.5 m3. Calculate the pressure required for given duty. Assume ideal gas law is
applicable.

SOLUTION:
Calculated the pressure required by using compressor controlled by a controller at given
specifications. Input file, Flowsheet and the results are as shown in figures 1.7.1,1.7.2 and 1.7.3

Figure1.7.1 Input

18
Figure1.7.2 Flowsheet

Figure1.7.3 Results

19
1.8) Air at 25 Degree Celsius enters a section of 2-inch Schedule 40 steel pipe
at a gauge pressure of 310 kN/m2 and a flow rate of 1200 kg/h. Assuming
isothermal flow, what is the pressure drop in 60m of pipe?

SOLUTION
Problem is solved by giving isothermal condition in the heat transfer section in
selecting the conditions for the flow the pipe, along with the other data is also
provided. This input data is shown in the figure 1.8.1. The stream results are
displayed in the figure 1.8.2.

Figure 1.8.1 Flowsheet

20
Figure 1.8.2 Stream Results

21
1.9) Air at 1.7 atm gauge and 15 degrees Celsius enters a horizontal 75-mm steel pipe
(relative roughness = 0.00061) that is 70 mm long. The flow rate of the entering air is
0.265 m3/s. Assuming isothermal flow, what is the pressure at the discharge end of the
pipe?

SOLUTION:
Pipe with fittings unit operation is used to simulate the problem. The Input file, Flowsheet, Pipe
Specifications and Results and Stream results are shown in Figure 1.9.1, 1.9.2, 1.9.3 and 1.9.4
repsectively.

Figure 1.9.1 Input file

22
 Figure 1.9.2 Flowsheet

Figure 1.9.3 Pipe Specifications and Results

23
Figure 1.9.4 Stream Data and Results

24
1.10) A Centrifugal fan is used to take flue gas at rest and at a pressure of 29.0 in Hg (737
mm Hg) and temperature of 200 degree F (93.3 degree C) and discharges it at a pressure
30.1 in Hg (765 mm Hg) and velocity of 150 ft/s (45.7 m/s). Calculate the power needed to
move 10,000 std. ft^3/min (14.53 lb/s) of gas using standard conditions of 29.92 in Hg and
32 degree F. The efficiency of the fan is 65 % and molecular weight of the gas is 31.3.

SOLUTION:
The compressor unit operation is used. Here the fluid is flue gas which is with the following
compositions as shown in the input file. The input file, the flowsheet and the results are shown in
the figures 1.10.1, 1.10.2 and 1.10.3

Figure 1.10.1 Input

25
Figure 1.10.2 Flowsheet

Figure 1.10.3 Results

26
1.11) A centrifugal pump takes water from the bottom of a supply tank and delivers it
into the bottom of another tank. The water level in the discharge tank is 150 feet above
the supply tank. The line between the tanks is 600 feet of 4-in-Schedule 40 pipe. The flow
rate is 400gal/min. In the line, there are two gate valves, four standard tees and four
ells. If the overall efficiency of the motor is 60%, calculate the pump work.

SOLUTION:
The pump and pipe unit operations are used. The STREM_TABLE is used to display the pump
work. Since the water level in the discharge is at a higher level than the supply tank, the elevation
is taken as 150 feet. The input file, flowsheet and results are shown in figure 1.11.1, 1.11.2 and
1.11.3.

Figure 1.11.1 Input file

27
Figure 1.11.2 Flowsheet

Figure 1.11.3 Results

28
1.12) A 6-cm-diameter horizontal water pipe expands gradually to a 9-cm-diameter
pipe. The walls of the expansion section are angled 30° from the horizontal. The
average velocity and pressure of water before the expansion section are 7 m/s and 150
kPa, respectively. Determine the head loss in the expansion section and the pressure in
the larger-diameter pipe.
SOLUTION
A fluid with water as the component has been specified.. Ideal thermodynamic method was
chosen as shown in figure1.12.1. The enlarger unit operation was used by specifying the
diameters of both the sections and the expansion angle as shown in figure.1.12.2 The head loss
was calculated as shown in figure 1.12.3

Figure 1.12.1 Input

29
Figure 1.12.2 Flowsheet

Figure 1.12.3 Results

30
1.13)he flow rate of methanol at 20°C through a 4-cm-diameter pipe is to be measured
with a 3-cm-diameter orifice meter equipped with a mercury manometer across the orifice
place. If the differential height of the manometer is read to be 11 cm, determine the flow
rate of methanol through the pipe and the average flow velocity.

SOLUTION
A fluid is created with water as the component as shown in the figure.1.131.1. The orifice unit
operation was selected and the data in the problem was input. The pressure drop is calculated in Pa
using the equation. This pressure drop along with bore and beta were given as inputs to the orifice.
The velocity and flowrate was calculated. The flowsheet and the orifice specifications are as as shown
in the figures 1.13.2 and 1.13.3.

Figure 1.13.1 Input

31
Figure 1.13.2 Flowsheet

Figure 1.13.3 Orifice Specification

32
Figure 1.13.4 Results

33
1.14)Air flowing at 24.85 C and 1 atm, flowing at 1kg/sec is to be compressed to 2 atm
using a reciprocating compressor. If the isentropic efficiency is 0.8 determine the outlet
temperature and power requirement.

SOLUTION
A Reciprocating compressor is used which is to be compressed to 2 atm. The input file, flowsheet
and Results are as shown in the figures 1.14.1, 1.14.2, and 1.14.3.

Figure 1.14.1 Input

34
Figure 1.14.2 Flowsheet

Figure 1.14.3 Results

35
2
MATERIAL AND ENERGY BALANCE

Every chemical processing plant deals with many physical and chemical
processes. It handles lot of raw materials required to supply the input for a
process. Not only materials, it involves in the energy/ heat supply to maintain
particular reaction temperature, energy changes during the chemical reactions.
So, in order to deal with processes involving such material and energy balances,
we take help of the principles of "Process calculations".

Material and energy balance also called process calculations and are is one of the
fundamental subjects that is usually taught in the second year of Chemical
Engineering. The process calculations can be further divided into two sections i.e.,
1. Material and energy balance without chemical reactions
2. Material and energy balance with chemical reactions

The subject name itself suggests that it is useful in the first part deals with
calculations of the material and energy balances involving unit operations like
mixing/blending, extraction, separation, absorption, drying, distillation,
crystallization, etc. In this type of unit of operations, no chemical reaction occurs,
whereas the latter part deals with the unit processes involving chemical reactions
like combustion, the formation of various chemical compounds.

All the processes that we consider to solve in PRO/II must be a steady-state

process, i.e.,
Input = output, there is no accumulation.

36
2.1) A feed containing 50% benzene and 50% toluene is fed to the distillation
column at the rate of 5000kg/hr. The top product contains 95% benzene and the
bottom product contains 92% toluene by weight. Calculate
(a) The mass flow rates of the top and bottom products and
(b) The percent recovery of benzene

SOLUTION
Problem is solved by specifying the outlet compositions for the distillation column. The input
data to the Flowsheet can be interpreted from the figure 2.1.1. The results were displayed
using stream
property table (in output bar) as shown in Fig. 2.1.2.

Figure 2.1.1 Input file

37
Figure 2.1.2 Flowsheet

Figure 2.1.3 Results

38
2.2) It is desired to have a mixed acid containing 40% HNO3, 43% H2SO4, and
17% H2O by weight. Sulphuric acid of 98% by weight is readily available.
Calculate (a) strength of HNO3 (b) the weight ratios of sulphuric acid to nitric
acid.
SOLUTION
Calculations were done for a 100 kg/s mixed acid basis. Flow sheet is shown
in Figure 2.2.1. Specifications are as shown in Figure 2.2.2 The results were
displayed using stream property table (in output bar) as shown in figure 2.2.3.
The strength of Nitric Acid is shown in Figure 2.2.4

Figure 2.2.1 Flowsheet

Figure 2.2.2 Specifications

39
Figure 2.2.3 Results

40
Figure 2.2.4 Strength of Nitric acid

41
2.3) Two process streams are mixed to form single stream. A soluble salt is added to one
of the original streams at a steady state. Samples taken of this stream show it to be
4.76% salt by weight. Another original stream does not contain any salt. Samples from
the mixed stream show 0.63% salt by weight. What is the ratio of flows in the two
streams?

SOLUTION
A Mixer is used with the the streams with salt and without. The input file is shown in the figure 2.3.1
Flowsheet and result is as shown in the figure 2.3.3

Figure 2.3.1 Input

42
Figure 2.3.2 Flowsheet and results

43
2.4)In an ammonia reactor loop, the feed consisting of NITROGEN 24 lbmol/hr,
HYDROGEN 74.3 lbmol/hr, ARGON, 0.6 lbmol/hr and METHANE 1.1 lbmol/hr enters a
reactor at 77 °F and 200 atm. The reactor (Modeled as Equilibrium reactor with zero
degree temperature approach) is operating at 200 atm and 500 °C. The vapor and liquid
product streams from the reactor are mixed and cooled to -28 °F and 2000 psi then
admitted into a flash column. The flash column is operating at -28 °F and 2000 psi. The
liquid stream from the flash column is withdrawn as product and the vapor stream is
partially purged and then compressed to the reactor pressure of 200 atm. Simulate and
report the conversion obtained in the reactor along with the product and recycle flow
rates.
SOLUTION
Nitrogen and hydrogen are mixed in a mixer and sent to equilibrium reactor with reactor pressure
of 200 atm. The vapor and liquid product streams from the reactor are mixed and cooled to -28 °F
and 2000 psi then admitted into a flash column operating at -28 F and 2000psi. The input data and
reaction model can be interpreted from the figure 2.4.1 and 2.4.2. The flowsheet and the results
are shown in the figure 2.4.3 and 2.4.4.

Figure 2.4.1 Input

44
Figure 2.4.2 Reaction model

45
Figure 2.4.3 Flowsheet

Figure 2.4.4 Results

46
2.5)To find the effect of pressure on reactor conversion in Ammonia process.
Given conditions and data:
Reactor operating temperature and pressure 600K and 70 atm. The separator coolant is
maintained at 25°C.
A = -32.975
B = 22930.4 at T(°R), P(psig)

SOLUTION
The flowsheet is built and the reaction model is defined with the given equilibrium data. Nitrogen
and hydrogen is fed at NTP (1atm, 25°C) and then compressed to 70 atm which is fed to a Gibbs
Reactor which is defined with temperature and pressure of 600K and 70 atm respectively. The
coolant in flash is maintained at 25°C and parameters are defined at different pressures and a
profile is plotted to see the effect of pressure on reactor conversion. From profile 1, it is observed
that reactor conversion increases with the increase in reactor pressure. The input file, Model,
Flowsheet, Result and Profile are as shown in the figures 2.5.1, 2.5.2, 2.5.3, 2.5.4, 2.5.5

Figure 2.5.1 Input

47
Figure 2.5.2 Reaction model

48
Figure 2.5.3 Flowsheet

Figure 2.5.4 results

49
Figure 2.5.5 Profile

50
2.6) The reaction between ethylene and hydrogen bromide to form ethylene bromide
carried out in a continuous reactor. The product stream is analyzed and found to contain
50 mole% ethyl bromide and 33% hydrogen bromide. The fed to the reactor contains only
ethylene and hydrogen bromide. Calculate the fractional conversion of the limiting
reactant and the percentage in which the other reactant is in excess.

SOLUTION
A Mixer and CSTR is used with the the streams with Ethylene and HBR. Product Specifications are
given with 50 mole% ethyl bromide and 33 mole % hydrogen bromide. The input file and reactor
model are shown in the figure 2.6.1 and 2.6.2. Flowsheet and results are shown in the figure 2.6.3
and 2.6.4.

Figure 2.6.1 Input

51
Figure 2.6.2 Reaction Model

52
Figure 2.6.3 Flowsheet

Figure 2.6.4 Results

53
2.7) Ethylene oxide is prepared by oxidation of ethylene. 100 kmol of ethylene and 100
kmol of water are charged into a reactor. The percentage conversion of ethylene is 85
and the percentage yield of Ethylene oxide is 94.12. Calculate the composition of the
product stream leaving the reactor. The reactions taking place are:

SOLUTION
A Mixer and Conversion is used with the the streams with Ethylene and water. Specifications are
conversion of ethylene is given as 0.85. The input file and reactor model are shown in the figure
2.7.1 and 2.7.2. Flowsheet and results are shown in the figure 2.7.3 and 2.7.4.

Figure 2.7.1 Input

54
Figure 2.7.2 Reaction Model

55
Figure 2.7.3 Flowsheet

Figure 2.7.4 Results

56
2.8) The fresh feed to a methanol synthesis unit contains 32 mole % CO, 64 mole % H2,
and 4 mole% N2 and flows at the rate of 100 Kmol/h. The fresh feed is mixed with recycle
feed flowing at the rate of 400Kmol/h to produce a reactor feed containing 13 mole% N2.
The product stream leaving the condenser after the reactor contains only liquid
methanol. For preventing a build-up of nitrogen in the stream, a purge system is
withdrawn from the gas stream leaving the condenser. The gases not purged constitute
the stream recycled to the reactor. Compute the production rate of methanol, the molar
flow rate and composition of the purge gas and per pass conversion and the overall
conversion.
SOLUTION
The conversion reactor in APS is used and the initial estimate of 0.1 is given for the reaction
conversion. The user-supplied arbitrary K-values were used so that methanol is in the liquid
phase only. The results were displayed using a equation approach. The input data and
reaction model can be interpreted from the figure 2.8.1 and 2.8.2. The flowsheet and the
results are shown in the figure 2.8.3 and 2.8.4.

Figure 2.8.1 Input

57
Figure 2.8.2 Reaction Model

58
Figure 2.8.3 Flowsheet

Figure 2.8.4 Results

59
2.9) Part of a plant-wide environmental control facility (ECE) is a system for diverting
aqueous waste fluids from a discharge point based on the concentration levels of volatile
organic compounds (VOCs). If the composition of the VOCs exceed 20 parts per billion,
the stream is to be diverted to the second outlet of the splitter. Otherwise, the stream is
to be diverted to the first outlet. Test with the following potential feed Methanol and
water.

SOLUTION
The Splitter in APS is used and the initial estimate of split fraction of 0.5 is given. The input
data can be interpreted from the figure 2.9.1. The flowsheet and the results are shown in
the figure 2.9.2 and 2.9.3.

Figure 2.9.1 Input

60
Figure 2.9.2 Flowsheet

Figure 2.9.3 Results

61
2.10) Calculate the theoretical flame temperature for CO gas burnt at constant pressure
with 100% excess Air, when the reactants enter at 100ºC and one atm.

SOLUTION
In this problem, a conversion reactor is used with complete conversion specified for CO.
The reactor specification is given as zero pressure drop and zero heat duty. The outlet
temperature of the gas is the Adiabatic Flame Temperature. The input file is as shown in the
figure 2.10.1. For representing Air component O2 and N2 components are defined
separately. The theoretical flame temperature is displayed in the figure 2.10.2 and the
reaction model is shown in figure 2.10.3

Figure 2.10.1 Input

62
 Figure 2.10.2 Flowsheet

Figure 2.10.3 Reaction model

63
2.11) In the manufacture of synthesis gas, the reactants are supplied in the ratio 2 mol
steam to 1 mol methane, and if heat is supplied to the reactor such that the products
reach a temperature of 1300K, the methane is completely converted and the product
stream contains 17.4 mole % CO. Assuming that the reactants to be preheated to 600 K,
calculate the heat requirement for the reactor.
CH4+H2 → CO+3H2O
CO + H2O → CO2 + H2
SOLUTION
A suitable feed basis is chosen and the reaction data is entered in the input section. A
conversion reactor is used. The conversion factor is set as 1 for the first reaction. Since
17.4% of C remains unreacted, the remaining 82.6% has been converted. This is entered as
the conversion for the second reaction. The temperature rise is used as the thermal
specification. This input data and reaction model can be interpreted using the figures
2.11.1, and 2.11.2. The flowsheet and the results are displayed in the figure 2.11.3 and
2.11.4.

Figure 2.11.1 Input

64
Figure 2.11.2 Reaction Model

65
Figure 2.11.3 Flowsheet

Figure 2.11.4 Results

66
3
CHEMICAL ENGINEERING
THERMODYNAMICS

Thermodynamics, one of the central subjects of science is based on the laws of

universal applicability. One of the reasons why the study of thermodynamics is
so valuable to the students of chemical engineering is that it is a theory which
can be developed in its entirety, without gaps in the argument, on the basis of
only a moderate knowledge of mathematics. It is therefore a self-contained
logical structure, and much benefit and incidentally much pleasure may be
obtained from its study.

The first and second laws of thermodynamics are the basis for flow processes
such as compressors, expanders, throttle valves and pumps which are used
extensively in the process industry for fluid flow operations. The equations of
state and generalized correlations have been developed to calculate the
thermodynamic properties of pure species and they can also be extended to
mixtures. The analysis of various steady flow processes such as refrigeration
cycle, power generation cycle and liquefaction process are possible.

Solution thermodynamics is of utmost importance for chemical engineers. We

deal with mixtures all the time. Solution thermodynamics lays a theoretical
foundation for application of thermodynamics to gas mixtures and liquid
solutions. For example, in chemical, petroleum and pharmaceutical industries,
multicomponent gases and liquids undergo constant composition changes
brought about by mixing and separation processes, the transfer of species from
one phase to another and chemical reactions.

We have solved problems on steady flow devices, application of EOS and

correlations to calculate properties, analysis of power cycle, refrigeration cycle,
liquefaction, VLE, LLE and VLLE tools such as P-T-x-y graphs, regression of
experimental data using activity coefficient models and calculations on reaction
equilibrium composition.

67
3.1) Calculate the heat required to raise the temperature of 1 mol of methane from 260 C
to 600 C in a steady flow process at a pressure sufficiently low that methane may be
considered an ideal gas.

SOLUTION
Methane is selected from the fluid section of the model library. The ideal thermodynamic method is
used. A simple heat exchanger unit operation is used with the cold side outlet temperature
specification to calculate the heat duty. The flowsheet and results were displayed as shown in
figure 3.1.2 and 3.1.3.. The input file is shown in figure 3.1.1.

Figure 3.1.1 Input

68
Figure 3.1.2 Flowsheet

Figure 3.1.3 Results

69
3.2) Calculate Q for ethane at 500C and 15 Bar by the following equations:
a) Ideal gas b) Peng Robinson c) Soave Redlich Kwong

SOLUTION
1 Kmol/hr of ethane is taken as the basis and various thermodynamic methods are used to
calculate Q. Ethane is selected from the fluid section of the model library. Displayed volumetric flow
rate results are shown in figure 3.2.4. The input files are shown in figure 3.2.1, 3.2.2 and 3.2.3 and
the Flowsheet is displayed in 3.2.4.

Figure 3.2.1 Input 1

70
Figure 3.2.2 Input 2

Figure 3.2.3 Input 3

71
Figure 3.2.4 Flowsheet

Figure 3.2.5 Results

72
3.3) Estimate the maximum conversion of ethylene to ethanol by vapor-phase hydration
at 250 deg C and 35 bars for an initial steam to ethylene ratio of 5

SOLUTION:
The fluid is defined by selecting the components given in the question and the Peng Robinson
thermodynamic method was chosen as shown in figure 3.3.1. The Equilibrium reactor is used to
calculate the maximum conversion The flowsheet, reaction model, and results are shown in
figure 3.3.2., 3.3.3 and 3.3.4

Figure 3.3.1 Input

73
 Figure 3.3.2 Flowsheet

Figure 3.3.3 Reaction Model

74
Figure 3.3.4 Results

75
3.4) Compressor operates adiabatically with air T1 and P1 with a molar flow rate n. The
discharge pressure is P2 and the compressor efficiency is ε. Estimate the power
requirement of the compressor and the temperature of the discharge stream if
T1=298.15 K, P1=101.33 kPa, n =0.1 kmol/s, P2=375 kPa, Efficiency (ε) =0.75

SOLUTION
A compressor unit operation with the given specifications is setup. The outlet pressure, adiabatic
efficiency and the shaft work is displayed using the unit operations property table. The input file is
shown in figure 3.4.1. The flowsheet and results are shown in figure 3.4.2 and 3.4.3.

Figure 3.4.1 Input

76
Figure 3.4.2 Flowsheet

Figure 3.4.3 Results

77
3.5) Saturated steam at 125 kPa is compressed adiabatically in a centrifugal compressor
to 700 kPa at the rate of 2.5 Kg/s. The compressor efficiency is 78%. What is the power
requirement of the compressor and what are the enthalpy and entropy of the steam in
the outlet stream.

SOLUTION
Similar to the previous problem, a compressor unit operation is used. A user defined stream
property list is created to display enthalpy and entropy of outlet stream. The input file is shown in
figure 3.5.1. The flowsheet and results are shown in figures 3.5.2 and 3.5.3.

Figure 3.5.1 Input

Figure 3.5.2 Flowsheet

78
Figure 3.5.3 Results

79
3.6) A pump operates adiabatically with liquid water entering T1 and P1 with mass flow
rate m. The discharge pressure is P2, and the efficiency is ε. For the following operating
conditions, determine the power requirement of the pump. T1=298 K, P1=100 kPa, m=20
kg/s, P2=2000 kPa, efficiency (ε) =0.7

SOLUTION:
A pump unit operation is used with the given specifications. The adiabatic efficiency and outlet
pressure are shown in figure 3.6.3 . The Input file, flowsheet and the results are shown in figure
3.6.1, 3.6.2 and 3.6.3.

Figure 3.6.1 Input

80
Figure 3.6.2 Flowsheet

Figure 3.6.3 Results

81
3.7)A pump operates adiabatically with liquid water entering T1 and P1 with mass flow
rate m. The discharge pressure is P2, and the efficiency is ε. For one of the following sets
of operating conditions, determine the power requirement of the pump and the
temperature of the water discharged from the pump. T1=363.15 K, P1=100 kPa,
m=30kg/s, P2=5000 kPa, efficiency (ε) =0.7

SOLUTION
A pump unit operation is used similar to the previous problem. A STREAM_TABLE is used to
display the outlet pressure which is slightly higher than inlet temperature due to flow
irreversibilities. The input file, the flowsheet and the results are shown in figure 3.7.1, 3.7.2 and
3.7.3.

Figure 3.7.1 Input

82
Figure 3.7.2 Flowsheet

Figure 3.7.3 Results

83
3.8) A turbine operates adiabatically with superheated steam entering at T1 and P1 with
a mass flow rate of m. The exhaust pressure is P2 and the efficiency is ε. For the
following operating conditions, determine the power output of the turbine. T1= 823.15 K,
P1= 9000 kPa, m = 90 kg/s, P2 = 20 kPa, efficiency (ε) = 0.77

SOLUTION
The expander unit operation is used for the turbine. The selected fluid is ‘Steam’ which is already
available in the fluid section of the model library. A STREAM_TABLE is used to display the outlet
pressure and adiabatic efficiency are specified. The input file is shown in the figure 3.8.1. The
flowsheet and results are shown in figure 3.8.2 and 3.8.3.

Figure 3.8.1 Input file

84
Figure 3.8.2 Flowsheet

Figure 3.8.2 Results

85
3.9) A turbine operates adiabatically with superheated steam entering at T1 and P1 with
a mass flow rate of m. The exhaust pressure is P2, and the efficiency is ε. For the
following operating conditions, determine the power output of the turbine and the
enthalpy and entropy of the exhaust stream. T1=723.15K, P1=8000 kPa, m =80kg/s, P2=30
kPa, efficiency (ε) =0.8.

SOLUTION:
The expander unit operation is used for the turbine. The selected fluid is ‘Steam’ which is already
available in the fluid section of the model library. A STREAM_TABLE is used to display the outlet
pressure and adiabatic efficiency are specified. The input file ,flowsheet and results are shown in
figure 3.9.1, 3.9.2 , and 3.9.3

Figure 3.9.1 Input file

86
Figure 3.9.2 Flowsheet

Figure 3.9.3 Results

87
3.10) A steam turbine operates adiabatically at a power level of 35000 W. Steam enters
the turbine at 2400 kPa and 773.15 K and exhausts from the turbine as a saturated
vapor at 20 kPa. What is the stream rate through the turbine, and what is the turbine
efficiency?
SOLUTION:
The expander unit operation is used for the turbine. The selected fluid is ‘WATER’ which is already
available in the fluid section of the model library. A STREAM_TABLE is used to display the outlet
flowrate and adiabatic efficiency are specified. The input file ,flowsheet and results are shown in
figure 3.10.1, 3.10.2 , and 3.10.3

Figure 3.10.1 Input

88
Figure 3.10.2 Flowsheet

89
Figure 3.10.3 Results
90
3.11) Carbon dioxide gas enters an adiabatic expander at 8 bar and 400 degrees celsius
and discharges at 1 bar. If the turbine efficiency is 0.75, what are the discharge
temperature and work output per mole? Assume ideal gas behaviour.

SOLUTION:
The ideal thermodynamic method is chosen. An expander with the given specifications is set up.
The input file is shown in figure 3.11.1. The flowsheet and results are shown in figure 3.11.2.

Figure 3.11.1 Input

91
Figure 3.11.2 Flowsheet and Results

92
3.12) Calculate the equilibrium compositions at 1000 K and 1 bar of a gas phase
system containing the species CH4, H2O, CO, CO2, and H2. In the unreacted state
there are present 2 mol of CH4 and 3 moles of H2O.

SOLUTION
The fluid is defined by selecting the components given in the question and the ideal
thermodynamic method was chosen as shown in figure 3.12.1. The Gibbs reactor is
used to calculate the equilibrium composition of the bas mixture by minimizing the
total Gibbs free energy as shown in figure 3.12.2. No reaction data is required. The
composition results are shown in figure 3.12.3.

Figure 3.12.1 Input file

93
Figure 3.12.2 Flowsheet

Figure 3.12.3 Results

94
3.13) Two schemes are proposed for the reduction in pressure of ethylene gas at 375 K
and 18 bar to 1.2 bar in a steady flow process: 1) Pass it through a throttle valve; 2) Send
it through an adiabatic expander of 70% efficiency For each proposal, find the
downstream temperature, and the rate of entropy generation. What is the power
output for the second process?
SOLUTION:
The process which has a lower rate of entropy generation will be the better process for the given
change of state. The rate of entropy generation was compared and displayed in flowsheet . It is
lower for the expander. So, the second scheme will be more efficient. The input file is shown in
figure 3.13.1, The flowsheet and results are shown in figure 3.13.2. and 3.13.3

Figure 3.13.1 Input

95
Figure 3.13.2 Flowsheet

96
Figure 3.13.3 Results

97
3.14) A stream of air at 12 Bar and 900 K is mixed with another stream of air at 2 Bar and
400 K with 2.5 times the mass flow rate. If the process were accomplished reversibly and
adiabatically, calculate the outlet temperature and pressure. Assume air to be an ideal
gas.
SOLUTION:
The ideal thermodynamic method is chosen. Since a reversible adiabatic process is isentropic, the
inlet and outlet entropies for the process should be equal. An equation solver is used to calculate
and display the inlet and outlet entropies. . The input file is shown in figure 3.14.1. The flowsheet
and results are shown in figure 3.14.2 and 3.14.3

Figure 3.14.1 Input

98
Figure 3.14.2 Flowsheet

Figure 3.14.3 Results

99
3.15) Superheated steam at 700 kPa and 553.15 K is mixed flowing at the rate of 50 Kg/s
is mixed with liquid water at 313.15 K to produce steam at 700 kPa and 200 degrees
Celsius. Assuming adiabatic operation, at what rate is water supplied to the mixer?

SOLUTION:
A mixer is used with the outlet pressure specification. A controller is used to vary the water flow
rate for the given outlet temperature. The input file is shown in figure 3.15.1 and 3.15.2. The
flowsheet and results are shown in figure 3.15.3.

Figure 3.15.1 Input file

100
Figure 3.15.2 Flowsheet

Figure 3.15.3 Results

101
3.16) 10 Kmol h-1 of cool flue gas at 1000C is further cooled to 250C. The pressure is
constant at 1 atm. What is the heat transfer for the process? The initial composition of
flue gas: y02 = 0.0387, yN2 = 0.7288, yCO2 = 0.0775, yH2O = 0.1550.

SOLUTION:
The input file is shown in figure 3.16.1. The flowsheet and results are shown in figure 3.16.2 and
3.16.3.

Figure 3.16.1 Input file

102
Figure 3.16.2 Flowsheet

Figure 3.16.3 Results

103
3.17) Steam generated in a power plant at a pressure of 8600 KPa and a temperature of
500 degrees C is fed to a turbine. Exhaust from the turbine enters a condenser at 10 KPa,
where it is condensed to a saturated liquid, which is then pumped to the boiler. What is
the thermal efficiency of a practical cycle operating at these conditions if the turbine
and pump efficiency are both 0.75? What should be the refrigerant flowrate for a power
rating of 80000 KW?

SOLUTION:
Rankine cycle is constructed and the equation is used to vary the water flow rate to meet the given
power rating. The input file is shown in figure 3.17.1 and 3.17.2. The flowsheet and results are
shown in figure 3.17.3.

Figure 3.17.1 Input file

104
Figure 3.17.1 Flowsheet

Figure 3.17.3 Results

105
3.18) Refrigerated space is maintained at 261.15 K and cooling water is available at 294.15
K. Refrigeration capacity is 35.2 KW. The evaporator and condenser are of sufficient size
that a 5.6 K minimum temperature difference for heat transfer can be realized in each.
The refrigerant is tetrafluoroethane (HFC-134a). Calculate COP and mass flow rate of
refrigerant for the vapor compression cycle if the compressor is 0.8.

SOLUTION
R143A is selected as the fluid component with Peng Robinson thermodynamic method as shown in
figure 3.18.1. A refrigeration cycle is constructed by using heat exchangers for evaporator and
condenser, compressor and a throttle valve as shown in figure 3.18.2. The flowrate required to
achieve the given refrigeration duty is calculated as shown in figure 3.18.3.

Figure 3.18.1 Input file

106
Figure 3.18.2 Flowsheet

Figure 3.18.3 Results

107
3.19) Feedstock of pure n-Butane is cracked at 750 K and 1.2 bar to produce olefins. Only
two reactions have favorable equilibrium conversions under these conditions.
C4H10 → C2H4 + C2H6 K = 3.856
→
C4H10 C3H6 + CH4 K = 268.4
If these reactions reach equilibrium, what is the product composition?

SOLUTION:
A new reaction set is created and the two reactions along with their equilibrium data were entered
as shown in figure 3.19.3. The equilibrium reactor unit operation is used to find out the multi-
reaction equilibrium composition. The input file is shown in figure 3.19.1. The flowsheet, Reaction
model and results are shown in figure 3.19.2, 3.19.3 and 3.19.4

Figure 3.19.1 Input

108
 Figure 3.19.2 Flowsheet

Figure 3.19.3 Reaction model

109
Figure 3.19.4 Results

110
3.20) In the cascade refrigeration cycle, the two cycles operate so that the heat
absorbed in the interchanger by the refrigerant of the higher-temperature cycle 2
serves to condense the refrigerant in the lower-temperature cycle 1. The two
refrigerants are chosen such that each cycle operates at a reasonable pressure. For
example, assume the following operating temperatures.TH = 30°C; TC ′ = −16°C; TH′ =
−10°C ,TC = −50°C. The refrigerant in cycle 1 is R32 and refrigerant in cycle 2 is R143A. If
the refrigeration capacity is 30 kW, calculate the necessary flow rates in the two
cycles, the COP, and the compressor pressure ratios.

SOLUTION
In the cascade refrigeration cycle, two fluids are to be created, one for the high temperature
cycle and another for the lower temperature cycle as shown in figure 3.20.1 and 3.30.2. Cycle 1
is constructed and the required flow rate for the given refrigeration capacity is calculated using
a controller. The compressor outlet pressure is calculated based on the condensation
temperature for the refrigerant. Cycle 2 is constructed next and the refrigerant flow rate is
calculated such that saturated vapor leaves the inter-heat exchanger in cycle 2. The calculated
COP, pressure ratios and flowrates are displayed. The flowsheet and results are shown in figure
3.20.3 and 3.20.4 respectively.

Figure 3.20.1 Input file

111
Figure 3.20.2 Input file

112
Figure 3.20.3 Flowsheet

113
 Figure 3.20.4 Results

114
3.21) Natural gas, assumed here to be pure methane, is liquefied by Linde process.
Compression is to 60 bar and precooling is to 300 K. The expander and the throttle exhaust
to a pressure of 1 bar. Recycle methane at this pressure leaves the exchanger system at 295
K. Assume no heat leaks to the surroundings. What fraction z of the methane is liquified.

SOLUTION
Linde liquefaction process involves compression, heat exchange at constant pressure, followed by
pressure reduction to produce a two-phase mixture. A fluid with ideal thermodynamic method and
methane as the component as shown in figure 3.21.1. The uncondensed vapor is used for heat
exchange and recycled. An equation is used to calculate the fraction liquefied. It is important to build
the flowsheet one operation after the other to diagnose the errors easily. The recycle stream should be
added at the end. The flowsheet and results are shown in figure 3.21.3.

Figure 3.21.1 Input file

115
Figure 3.21.2 Flowsheet

Figure 3.21.3 Results

116
3.22) Natural gas, assumed here to be pure methane, is liquefied by the Claude process.
Compression is to 60 bar and precooling is to 300 K. The expander a. A calculator was used
to calculate and display the fraction liquefied and the throttle exhaust to a pressure of 1
bar. Recycle methane at this pressure leaves the exchanger system at 295 K. Assume no
heat leaks to the surroundings and an expander efficiency of 75 percent and an expander
exhaust of saturated vapor. For a draw off to the expander of 25% of methane entering the
exchange system, what fraction z of the methane is liquified.
SOLUTION
Claude liquefaction process involves compression, heat exchange at constant pressure, followed by
pressure reduction to produce a two-phase mixture. A draw off the stream from the first exchanger
is used to extract work from a turbine and then this stream is used for heat exchanger. The input file
is shown in figure 3.22.1The flowsheet and results are shown in figure 3.22.2 and figure 3.22.3
respectively.

Figure 3.22.1 Input file 117

 Figure 3.22.2 Flowsheet

118
 Figure 3.22.3 Results

119
3.23) Liquid Benzene at 298.15 K and 1.2 bar is converted into vapor at 473.15 K and %
bar in a two-step process:
a) compression of the gas to 5 bar followed by vaporization in a counterflow heat
exchanger. Determine the power requirement of the pump and the duty of the heat
exchanger. Assume a pump efficiency of 70% and treat benzene vapor as ideal gas

SOLUTION:
The input file is shown in figure 3.23.a.1 . The flowsheet and results are shown in figure 3.23.a.2
and 3.23.a.3

Figure 3.23.a.1 Input

Figure 3.23.a.2 Flowsheet

120
Figure 3.23.a.3 Results

121
3.23) Liquid Benzene at 298.15 K and 1.2 bar is converted into vapor at 473.15 K and %
bar in a two-step process:
b) vaporization in a counterflow heat exchanger followed by compression of the gas to 5
bar. Assume a compressor efficiency of 75% and treat benzene vapor as an ideal gas.
Determine the power requirement of the compressor and the duty of the heat
exchanger

SOLUTION:
The input file is shown in figure 3.23.b.1 . The flowsheet and results are shown in figure 3.23.b.2
and 3.23.b.3

Figure 3.23.b.1 Input

Figure 3.23.b.2 Flowsheet

122
Figure 3.23.b.3 Results

123
3.24) Water at 45 deg C, and 10 KPa enters an adiabatic pump and is discharged at a
pressure of 8600kPa . Assume that the pump efficiency is 0.75. Calculate the work of the
pump, the temperature change of the water, and the entropy change of the water.

SOLUTION:
AN adiabatic pump is used with a discharge pressure as 8600 Kpa. The input file is shown in figure
3.24.1 . The flowsheet and The results are shown in figures 3.24.2.

Figure 3.24.1 Input

124
Figure 3.24.2 Flowsheet and Results

125
3.25) Superheated steam at 500kPa and 300 deg C expands isentropically to 50kPa , what
is its Final enthalpy

SOLUTION:
The input file is shown in figure 3.25.1 . The flowsheet and The results are shown in figures 3.25.2

Figure 3.25.1 Input

Figure 3.25.2 Flowsheet and Results

126
3.26) Calculate the entropy change for the following isenthalpic process. N-butane is
throttled from T1= 486.2 K, P1= 19.66 bar to P2 = 1 bar. Assume it is ideal gas at final
conditions.

SOLUTION
Calculated the entropy change by taking the throttle valve by providing the thermodynamic method
as Peng-Robinson. The input file is shown in figure 3..26.1. The flowsheet and results are shown in
figure 3.26.2 and 3.26.3

Figure 3.26.1 Input

127
Figure 3.26.2 Flowsheet

Figure 3.26.3 Results

128
3.27) A natural gas stream is compressed before entering a pipeline. The stream is first
compressed to 12 bar and then to 26 bar. Liquid condenses in the compressor aftercoolers
and is recycled back to the previous stage. The liquid product is removed from the feed
flash. Problem data is given in figure 3.27.1.
1. What are the amounts of liquid and vapor leaving the process?
2. What compressor work is required for each stage?
3. What are the aftercooler duties?

SOLUTION
All the hydrocarbons containing more than 7 carbon atoms are modeled as C-9. The PR
thermodynamic model is used to calculate the compressor works and aftercooler duties. The input
file is shown in figure 3.27.2. The flowsheet and results are shown in figure 3.27.3

Figure 3.27.1 Problem Data

129
Figure 3.27.2 Input

130
 Figure 3.27.3 Flowsheet and Results

131
3.28) Plot the T-x-y and x-y diagrams for the ethanol/toluene binary mixture at 101.325
Kpa

SOLUTION
The binary VLE tool is used to plot the T-x-y and x-y diagrams after selecting ethanol and toluene
as the components. A pressure of 101.325 Kpa was specified as shown in figures 3.28.1 and
3.28.2.

Figure 3.28.1

132
Figure 3.28.2

133
3.29) For a mixture of 10 mole % methane, 20 mole % ethane and 70 mole % propane at
100C, determine the: a) the dew point pressure and b) the bubble point pressure.

SOLUTION:
The Peng Robinson method is used with dew point and bubble point stream specifications. The
input file, the flowsheet and results are shown in figure 3.29.1, 3.29.2 and 3.29.3.

Figure 3.29.1 Input file

134
Figure 3.29.1 Flowsheet

Figure 3.29.1 Results

135
3.30) The system acetone/acetonitrile/nitromethane at 80 degrees Celsius and 110 kPa
has an overall composition z1 = 0.45, z2 = 0.35, z3 = 0.2. Assuming that Raoult’s law is
appropriate for this system, determine L, V, vapor, and liquid compositions.

SOLUTION:
The flash unit operation is used with a constant temperature specification. The compositions of
the vapor and liquid phases are obtained. The input file is shown in figure 3.30.1 The flowsheet
plots, and results are shown in figure 3.30.2 , 3.30.3 and 3.30.4

Figure 3.30.1 Input

136
Figure 3.30.2 Flowsheet

Figure 3.30.3 Plots

137
Figure 3.30.4 Results

138
3.31) The gas-phase adiabatic oxidation of SO2 to SO3 is carried out at a pressure of 1
bar with 20% excess air in an adiabatic reactor. Assuming that the reactants enter at
298.15 K and that equilibrium is attained at the exit, determine the composition and
temperature of the product stream from the reactor. Heat of reaction at 298 K = -98890
J/mol; Gibbs free energy of the reaction at 298 K = -70866 J/mol

SOLUTION:
In entering the equilibrium data for the reaction in the form ln(K) = A + B/T, the values of A and B
were calculated using the reaction data given above. The input file is shown in figure 3.31.1 The
flowsheet, reaction model and results are shown in figure 3.31.2 , 3.31.3 and 3.31.4

Figure 3.31.1 Input

139
Figure 3.31.2 Flowsheet

Figure 3.31.3 Reaction Model

140
Figure 3.31.4 Results

141
4
HEAT TRANSFER
Heat Transfer is a constituent of Transport Phenomena which deals with the
transfer of energy in the form of heat. It includes the generation, use,
conversion, and exchange of thermal energy (heat) between physical systems.
Heat transfer is classified into various mechanisms, such as thermal conduction,
thermal convection, thermal radiation, and transfer of energy by phase
changes.

We deal with Heat Transfer everyday right from cooking to the industrial
applications in the form of heating and boiling. A heat exchanger is used for
more efficient heat transfer or to dissipate heat. Heat exchangers are widely
used in refrigeration, air conditioning, space heating, power generation, and
chemical processing. One common example of a heat exchanger is a car's
radiator, in which the hot coolant fluid is cooled by the flow of air over the
radiator's surface. Also, heat transfer can be in different forms like
evaporators, boilers, condensers, thermal reactors etc. Having a deeper
understanding of the heat transfer applications and its various processes
would make chemical engineers more worthy and makes them more efficient in
process designing.

The following are problems that cover most of the heat transfer applications
and will be useful for a deeper understanding of the subject. The problems
discussed include the sizing and rating of heat exchangers, designing of a
rigorous heat exchanger, co-current and counter-current double pipe heat
exchanger and also problems on horizontal condensers and single effective
evaporators and an industrial problem on refrigeration process application.

142
4.1) A counter flow exchanger with 1 tube pass and one shell pass is used to
recover heat from an oil stream at 110oCelsius. Estimate outlet oil temperature.
U*A = 4.56 KW/C
mass flow rate of water = 2400 Kg/h Cp = 4180 J/kg C
mass flow water of oil = 3000 kg/h Cp = 2300 J/Kg C

SOLUTION
A heat exchanger unit is used and UA value is used as a specification. The input
,flowsheet, Heating curves and Stream results are shown in Fig 4.1.1,
Fig 4.1.2, Fig.4.1.3 and Fig. 4.1.4 repsectively

Figure 4.1.1 Input

143
Figure 4.1.2 Flowsheet

Figure 4.1.3 Heat Curves

144
Figure 4.1.4 RESULTS

145
4.2) A counter-flow double-pipe heat exchanger is to heat water from 20°C to
80°C at a rate of 1.2 kg/s. The heating is to be accomplished by geothermal
water available at 160°C at a mass flow rate of 2 kg/s. The inner tube is thin-
walled and has a diameter of 1.5 cm. If the overall heat transfer coefficient
of the heat exchanger is 640 W/m2 ·°C, determine the length of the heat
exchanger required to achieve the desired heating

SOLUTION
Fixing the cold product outlet temperature in heat exchanger specification by
giving the overall duty, the area of the heat exchanger is calculated and then
using standard equation, the length required is obtained. The flowsheet and
results are displayed in figure 4.2.1 and Figure 4.2.2 respectively

Figure 4.2.1 Flowsheet

146
Figure 4.2.2 Results

147
4.3) Steam in the condenser of a power plant is to be condensed at a
temperature of 30°C with cooling water from a nearby lake, which enters
the tubes of the condenser at 14°C and leaves at 22°C. The surface area of
the tubes is 45 m2, and the overall heat transfer coefficient is 2100
W/m2.°C. Determine the mass flow rate of the cooling water needed and
the rate of condensation of the steam in the condenser.

SOLUTION
This condensation problem is approached by using the utility stream in the
heat exchanger. The length of the heat exchanger is calculated using
standard formula using Equation tool.The calculated value is dispalyed on
flowsheet. The flowsheet and results are displayed in figure 4.3.1 and 4.3.2
respectiely

Figure 4.3.1 Flowsheet

148
Figure 4.3.2 Results

149
4.4) Carbon tetrachloride flowing at 19000 kg/hr is to be cooled from 85 C to 40 C
using 13500 kg /h of cooling water at 20 C. The film coefficient for carbon
tetrachloride is 1700 W/m2C. The wall resistance is negligible but the heat
transfer coefficient on the waterside including fouling factors is 11000 W/m2 C.
What is the area needed for counter-current flow heat exchanger?

SOLUTION
The simple heat exchanger is used. The overall heat transfer coefficient is
calculated using the calculator. The hot side outlet temperature is specified and
the counter-current arrangement is specified and the area is calculated. The
input file is shown in figure 4.4.1. The flowsheet and results are displayed in
figure 4.4.2 and figure 4.4.3

Figure 4.4.1 Input

150
Figure 4.4.2 Flowsheet

151
Figure 4.4.3 Results

152
4.5) Carbon tetrachloride flowing at 19000 kg/hr is to be cooled from 85 C to
40 C using 13500 kg /h of cooling water at 20 C. The film coefficient for
carbon tetrachloride is 1700 W/m2C. The wall resistance is negligible but the
heat transfer coefficient on the waterside including fouling factors is 11000
W/m2 C. What is the area needed for co-current flow heat exchanger?

SOLUTION
The simple heat exchanger is used. The overall heat transfer coefficient is
calculated using the calculator. The hot side outlet temperature is specified
and area is calculated. The flowsheet is shown in figure 4.5.1. The results are
displayed in figure 4.5.2.

Figure 4.5.1 Flowsheet

153
Figure 4.5.2 Results

154
4.6) A single-effect evaporator is to concentrate 20000 lb/h of a 20 percent solution of sodium
hydroxide to 50 percent solids. The gauge pressure of the steam is 1.37 atm. The absolute
pressure in the vapor space is 100 mm Hg. The overall coefficient is estimated to be 1400 W/m2
K. The feed temperature is 37.8 oC. Calculate the amount of steam consumed, the economy and
the heating surface required.
SOLUTION
The electrolyte NRTL thermodynamic method is selected because NaOH solution is ionic. Water and
NaOH were the compounds selected as shown in figure 4.6.1. The evaporator is modeled using a
throttle valve, heat exchanger and flash drum. The throttle valve is used to reduce the inlet stream to
the evaporator pressure. In the heat exchanger, the vapor fraction is specified as 1 and the tube
outlet temperature is specified as 91oC. The flash drum is used to separate the water vapor from the
concentrated liquid. The steam flow rate required to meet the outlet specifications was calculated.
Using the calculated heat duty and the overall heat transfer coefficient, the area of the heat
exchanger was calculated as shown in figure 4.6.2.

Figure 4.6.1 Input file

155
Figure 4.6.2 Input file

156
Figure 4.6.3 Flowsheet

Figure 4.6.4 Results

157
4.7) Consider a Shell and U-tube heat exchanger given below. Key dimensions
and flowrates are given as follows in figure 4.7.1
a) What is the overall heat transfer coefficient?
b) What will be the temperature of the toluene going out of the heat
exchanger?

SOLUTION
The U-tube heat exchanger can be modelled using the heat exchanger unit
operation. The flowsheet and results are shown in figures 4.7.2 and 4.7.3.

Figure 4.7.1 Problem Data

Figure 4.7.2 Flowsheet

158
Figure 4.7.3 Results

159
4.8) Heat is transferred from a hot water stream to a cold water stream in a counter flow
heat exchanger. Given mh=0.5 kg/s, Thi=90oC, mc=0.4 kg/s, Tci=15oC, U=2100 W/m2K, A=240
m2. Calculate the performance of the heat exchanger. How does this performance change if
the area is increased by 50%.

SOLUTION
Water is selected as the component in the fluid as shown in figure 4.8.1. A heat exchanger with the
given specifications of U and A is selected. The input stream data was specified and the performance
of the heat exchanger was evaluated. In the second case, the area was increased by 50% and
performance was calculated. Flowsheet is as shown in the figure 4.8.2. Performance is quantified by
the heat duty and effectiveness as shown in figure 4.8.3

Figure 4.8.1 Input file

160
Figure 4.8.2 Flowsheet

Figure 4.8.3 Results

161
4.9)Water flowing at 1 Kg/ sec and with Temperature of 60 C is cooled in an air cooled
heat exchanger. Air is flowing at the rate of 5 kg/sec. Given over all heat transfer
coefficient as 15 W/m2-K. Determine the outlet temperature of the water if air is
maintained at the temperature of 10 deg C and Duty of ACHX?

SOLUTION
An Air cooled heat exchanger is used with U = 15 W/m2-K. Water is entered at 1 kg/sec and the Air
is entered at 5 Kg/sec. Outlet temperature and the duty of ACHX is calculated. The input file,
flowsheet and Results are as shown in the figures 4.9.1, 4.9.2 and 4.9.3.

Figure 4.9.1 Input

162
Figure 4.9.2 Flowsheet

163
Figure 4.9.3 Results

164
4.10)A cross flow heat exchanger is used to heat an oil in the tubes, c = 1.9 kJ/kg.0C from
15 0C to 85 0C. Blowing across the outside of the tubes is steam which enters at 130 0 C
and leaves at 110 C with mass flow of 5.2kg/sec. The overall heat transfer coefficient is
275 W/m2.0C and c for steam is 1.86 kJ/kg.0C. Calculate the surface area of the heat
exchanger?
SOLUTION
A Cross flow heat exchanger is used with U = 275 W/m2-K. Oil is entered at 5.2 kg/sec and the
steam is entered at 1.2 Kg/sec. The input file, flowsheet and Results are as shown in the figures
4.10.1, 4.10.2 and 4.10.3.

Figure 4.10.1 Input

165
Figure 4.10.2 Flowsheet

Figure 4.10.3 Results

166
5
CHEMICAL REACTION
ENGINEERING

Every chemical industry will aim to achieve high quality of products with
maximum possible conversion of reactants. For such industries selection of
reactor and its design is very important. Chemical Reaction Engineering
(CRE) is unique subject which concentrates on reactor design. Reactor
performance has vital significance. So, knowledge of drawbacks and
advantages of chemical reactor will be very important for chemical
process. In CRE, we study about kinetics and dynamics of chemical process.
It is one such subject which concentrates on improvement of present
processes and also concentrates on development of new processes.

It includes interaction of fluid mechanics, mass transfer, heat transfer,

thermodynamics as it would help in relating the operating condition with
that of reactor performance to feed composition.

We have solved problems particularly on batch reactor, packed bed

reactors, Continuous Stirred-Tank Reactor (CSTR), Plug Flow Reactor (PFR),
Microchannel PFR. We solved constant heat exchange, varied heat
exchange, isothermal and adiabatic process problems. We also
concentrated on solving problems with series reactions and multiple
reactions.

167
5.1 (a) Cracking of acetone to ketene and methane is one of the key
steps in the vapor phase manufacturing of acetic anhydride. It is first
order with respect to acetone and the specific rate constant can be
expressed as: ln(k) = 34.34 - 34222/T where K is the in reciprocal
seconds, T in Kelvin. The reactor consists of 1-inch schedule 40 tubes.
Plot the conversion and temperature profiles if the reactor is operated
adiabatically.
Heat of reaction at 298.15 K = 80.77 KJ/mol

SOLUTION
The PFR unit operation is used. and. 22% conversion occurs for a
volume of 0.17 ft3 which corresponds to a reactor length of 0.164 ft.
The input file and reaction model are as shown in the figure 5.1.a.1 and
5.1.a.2 Flowsheet is as shown in the figure 5.1.a.3, Plots and results are
shown in figure 5.a.1.4 and 5.1.a.5.

Figure 5.1.a.1 Input

168
Figure 5.1.a.2 Reaction Model

169
Figure 5.1.a.3 Flowsheet

Figure 5.1.a.4 Plots

170
Figure 5.1.a.5 Results

171
5.1 (b) Cracking of acetone to ketene and methane is one of the key steps in the vapor phase
manufacturing of acetic anhydride. It is first order with respect to acetone and the specific rate
constant can be expressed as: ln(k) = 34.34 - 34222/T where K is the in reciprocal seconds, T in
Kelvin. The reactor consists of 1-inch schedule 40 tubes. Plot the conversion and temperature
profiles if the reactor is operated adiabatically.
Heat of reaction at 298.15 K = 80.77 KJ/mol

SOLUTION
The PFR unit operation is used. and. 99% conversion occurs for a volume of 0.17 ft3
which corresponds to a reactor length of 0.164 ft. Here the utility operation is used
and the duties of reactor and heat exchanger are to be equalised. The input file and
reaction model are as shown in the figure 5.1.b.1 and 5.1.b.2 Flowsheet is as shown in
the figure 5.1.b.3, Plots and results are shown in figure 5.b.1.4 and 5.1.b.5.

Figure 5.1.b.1 Input

172
Figure 5.1.b.2 Reaction Model

173
Figure 5.1.b.3 Flowsheet

Figure 5.1.b.4 Plots

174
Figure 5.1.b.5 Results

175
5.2 a)It is desired to produce 200 million pounds per year of EG (Ethylene Glycol) using an isothermal
reactor. A 1 lbmol/ft3 solution of EO (Ethylene oxide) in water is fed to the reactor together with an
equal volumetric solution of water containing 0.9 wt.% of catalyst Sulphuric acid. The specific reaction
rate constant is 0.311 min-1. If two 800 gallons CSTRs are arranged in series, find the conversion.

SOLUTION
The input files and reaction models are as shown in the figure 5.2.a.1 and 5.2.a.2. Flowsheet is
as shown in the figure 5.2.a.3. and Results are shown in figure 5.2.a.4

Figure 5.2.a.1 Input

176
Figure 5.2.a.2 Reaction model

177
Figure 5.2.a.3 Flowsheet

Figure 5.2.a.4 Results

178
5.2 (b) It is desired to produce 200 million pounds per year of EG using an isothermal reactor. A 1
lbmol/ft3 solution of EO in water is fed to the reactor together with an equal volumetric solution of
water containing 0.9 wt.% of catalyst Sulphuric acid. The specific reaction rate constant is 0.311 min-1.
For a single CSTR of 1600 gallons, calculate the conversion achieved.

SOLUTION
The input files and reaction models are as shown in the figure 5.2.b.1 and 5.2.b.2. Flowsheet is
as shown in the figure 5.2.b.3. and Results are shown in figure 5.2.b.4

Figure 5.2.b.1 Input

179
Figure 5.2.b.2 Reaction model

180
Figure 5.2.b.3 Flowsheet

Figure 5.2.b.4 Results

181
5.3) Determine the volume of the PFR volume necessary to produce 300 million
pounds of ethylene a year from tracking a feed stream of pure ethane. The reaction
is irreversible and follows elementary rate law. We want to achieve 80% conversion
of ethane, operating the reactor isothermally at 1100K and a pressure of 6 atm.

SOLUTION
The PFR unit operation is used. The diameter is chosen as 2 in. and the length is
varied using a controller to get the required conversion. 80% conversion occurs
for a volume of 80.6 ft3 which corresponds to a reactor length of 46.19 ft. The
input file and reaction model are as shown in the figure 5.3.1. and 5.3.2
Flowsheet is as shown in the figure 5.3.3, Plots and results are shown in figure
5.3.4 and 5.3.5.

Figure 5.3.1.Input

182
Figure 5.3.2 Reaction Model

183
Figure 5.3.3 Flowsheet

Figure 5.3.4 Results

184
5.4) The elementary gas-phase reaction (CH3)3COO(CH3)3 → C2H6+ 2CH3COCH3 is
carried out isothermally in a flow reactor with no pressure drop. The specific
reaction rate at 50°C is 10-4 min-1 (from preciosity data) and the activation energy
is 85 kJ/mol. Pure di-tert-butyl peroxide enters the reactor at 10 atm and 127°C
and a molar flow rate of 2.5 mol/min. Calculate the reactor volume and space time
to achieve 90% conversion in: (a) a CSTR (b) a PFR

SOLUTION
Initially PFD is drawn and feed inputs and required Reactor data is given. .
In PFR, length is varied by maintaining diameter constant diameter. In
CSTR, volume is varied till 90% conversion is achieved in both reactors.
The input file and reaction model are as shown in the figure 5.4.1 and 5.4.2.
Flowsheet is as shown in the figure 5.4.3. The output file is as shown in the
figure 5.4.4.

Figure 5.4.1.Input

185
Figure 5.4.2 Reaction Model

186
Figure 5.4.3 Flowsheet

Figure 5.4.4 Results

187
5.5) Ethylene and Oxygen are fed in stoichiometric proportions operated
isothermally at 260 degrees Celsius. Ethylene is fed at the rate of 0.0003 lbmol/s
per tube. The tubes are 1.5 in. in diameter. The diameter of the catalyst is 120 lb/ft3
and the bed void fraction is 0.45. The rate law is -ra = k PA(1/3) PB(1/3) (lbmol/ lb
cat.h), k = 0.0141 (lb- mol/atm.lb cat. h) at 2600C.
Calculate the weight of the catalyst necessary to achieve 60% conversion.

SOLUTION
The PFR unit operation is chosen. The reaction kinetic data is entered in
terms of the partial pressures after converting the rate constant which was
based on the catalyst weight to reactor volume. The length of the reactor
for the required conversion is calculated using the controller. The weight of
the catalyst is calculated based on the length. The input files and Reaction
models are as shown in the figure 5.5.1 and 5.5.2. The flowsheet is as
shown in the figure 5.5.3. Results are shown in figure 5.5.4

Figure 5.5.1 Input

188
Figure 5.5.2 Reaction Model

189
Figure 5.5.3 Flowsheet

Figure 5.5.4 Results

190
5.6) The gas phase reaction 2NOCl → 2NO + Cl2 is carried out at 4250C and 1641 kPa.
Pure NOCl is to be fed and the reaction follows at an elementary rate law. It is
desired to produce 20 tons of NO per year in a microreactor system using a bank of
ten microreactors in parallel. Each microreactor has 100 channels with each channel
of diameter 0.2257 mm in square and 250 mm in length. Plot the conversion profile.
The rate constant at 281.6 dm3/mol*s at 4250C. To produce 20 tons per year of NO at
85% conversion would require a feed rate of 0.0226 mol/s of NOCl, or 2.26e-5 mol/s
per channel.

SOLUTION
The PFR unit operation was used and the reaction stoichiometry, kinetic data
and reactor dimensions were input. The case study feature was used to vary the
length, calculate conversion and plot it. The input file and reaction model are as
shown in the figure 5.6.1 and 5.6.2. Flowsheet is as shown in the figure 5.6.3.
The output graph is as shown in the figure 5.6.4.

Figure 5.6.1 Input

191
Figure 5.6.2 Reaction model

192
Figure 5.6.3 Flowsheet

Figure 5.6.4 Plots

193
5.7) The production of m-xylene by the hydrodealkylation of mesitylene over Houdry Detrol
catalyst involves the following reactions:
Mesitylene + Hydrogen → m-xylene + methane
m-xylene can also undergo hydrodealkylation to form toluene
M-xylene + hydrogen → toluene + methane
The second reaction is undesirable. We need to maximize the production of m-xylene
The hydrodealkylation is to be carried out isothermally at 1500 R and 35 atm in a packed
bed reactor to which the feed has a 66.7 mol% hydrogen and 33.3 mol % mesitylene. The
volumetric feed rate is 476 cubic feet per hour. And the reactor volume is 238 cubic feet.
The rate laws are:
-r1 = k1CMCH; k1 = 55.20 (ft3/lb.mol)0.5/h
-r2 = k2CXCH; k2 = 30.20 (ft3/lb.mol)0.5/h
M = mesitylene; X = meta-Xylene, T = toluene; H = hydrogen.
Compute the concentration profiles and calculate the optimum space-time.

SOLUTION
Since the rate laws are given in terms of reactor volume, the PBR can be modeled as a PFR.
The kinetic data for both the reactions are entered in the input reaction data. An optimizer is
used to maximize the xylene mole fraction in the output stream while varying the reactor
length.
The concentration profiles are obtained from the reactor results. The optimum space time
was calculated to be 0.2 hours. The input files and Reaction Models are as shown in the figure
5.7.1 and 5.7.2. Flowsheet is as shown in the figure 5.7.3 and Results are shown in figure 5.7.4

Figure 5.7.1.Input

194
Figure 5.7.2 Reaction Model

195
Figure 5.7.3 Flowsheet

Figure 5.7.4 Results

196
5.8) The following gas-phase reactions take place simultaneously on a metal
oxide-supported catalyst: 1. 4NH3 + 5O2 → 4NO + 6H2O
2. 2NH3 + 1.5O2 → N2 +3H20
3. 2NO + O2 → 2NO2
4. 4NH3 + 6NO → 5N2 + 6H2O

NH3, O2, NO, H2O, N2, NO2 are symbolically represented as A, B, C, D, E, F.

-r1A = k1A CA C2B k1A = 5 (m3/k. mol )2/min;
-r2A = k2A CA CB k2A = 2 m3/k. mol*min;
-r3B = k3B C2C CB k3B = 10 (m3/k. mol )2/min;
-r4C = k4C CC C2/3A k4C = 5 (m3/k. mol )2/3/min;
Determine the concentration of NO as a function of position (length) in a PFR.
Additional info: Feed rate = 10 dm3/min; Volume of reactor = 10 dm3; and
CA0 = CB0 = 1 mol/dm3, CT0 = 2 mol/dm3.

SOLUTION
Initially, The PFD is drawn. In the input section components are added, all
reactions are feed into reaction data and after referring different sources a
fixed temperature of 573K has been inputted in reactor data section.
Reactor length and diameter is calculated by taking specified reactor
volume. Here an optimizer is used to find out the maximum NO
concentration along the length of PFR by varying length of PFR from 0.5m
to 4m. Finally, the maximum NO concentration is obtained at 1 dm3.
The input files and reaction models are as shown in the figure 5.8.1 and
5.8.2. Flowsheet is as shown in the figure 5.8.3. and Results are shown in
figure 5.8.4

197
 Figure 5.8.1 Input

Figure 5.8.2 Reaction model

198
Figure 5.8.3 Flowsheet

Figure 5.8.4 Results

199
5.9) Normal Butane, C4H8, is to be isomerized to isobutane in a plug flow reactor. Isobutane is a
valuable product that is used in the manufacture of gasoline additives. For example, isobutane can be
further reacted to form iso-octane. The 2004 selling price of n-butane was 72 cents per gallon, while
the price of isobutane was 89 cents for gallon.
The reaction is to be carried out adiabatically in the liquid phase under high pressure using essentially
trace amounts of a liquid catalyst which gives a specific reaction rate of 31.1 h^-1 at 360 K. Calculate the
PFR volumes necessary to process 100000gal /day (163 kmol/h) at 70% conversion of a mixture 90
mol% n-butane and 10 mol% i-pentane, which is considered an inert. The feed enters at 330 K.
Additional Information :-
Kc= 3.03 at 60 C, Ca0 = 9.3 kmol/m3, Activation energy = 65.7 Kj/mol

SOLUTION
Initially, The PFD is drawn. In the input section components are added, all reactions are feed
into reaction data and after referring different sources a fixed temperature of 330K has been
inputted in reactor data section.
The input files and reaction models are as shown in the figure 5.9.1 and 5.9.2. Flowsheet is as
shown in the figure 5.9.3. and Results are shown in figure 5.9.4

Figure 5.9.1.Input

200
Figure 5.9.2 Reaction Model

201
Figure 5.9.3 Flowsheet

Figure 5.9.4 Results

202
5.10) Normal Butane, C4H8, is to be isomerized to isobutane in a plug flow reactor. Isobutane is a
valuable product that is used in the manufacture of gasoline additives. For example, isobutane can be
further reacted to form iso-octane. The 2004 selling price of n-butane was 72 cents per gallon, while
the price of isobutane was 89 cents for gallon.
The reaction is to be carried out adiabatically in the liquid phase under high pressure using essentially
trace amounts of a liquid catalyst which gives a specific reaction rate of 31.1 h^-1 at 360 K. Calculate the
CSTR volume necessary to process 100000gal /day (163 kmol/h) at 40% conversion of a mixture 90
mol% n-butane and 10 mol% i-pentane, which is considered an inert. The feed enters at 330 K.
Additional Information :-
Kc= 3.03 at 60 C, Ca0 = 9.3 kmol/m3, Activation energy = 65.7 Kj/mol

SOLUTION
Initially, The CSTR is drawn. In the input section components are added, all reactions are feed
into reaction data and after referring different sources a fixed temperature of 330K has been
inputted in reactor data section.
The input files and reaction models are as shown in the figure 5.10.1 and 5.10.2. Flowsheet is as
shown in the figure 5.10.3. and Results are shown in figure 5.10.4

Figure 5.10.1 Input

203
Figure 5.10.2 Reaction Model

204
Figure 5.10.3 Flowsheet

Figure 5.10.4 Results

205
5.11) Propylene glycol is manufactured using a 300-gallon adiabatic CSTR. The feed stream consists of:
1) Equi volumetric mixture of propylene oxide (46.63 ft3/hr) and methanol (46.63 ft3/hr) and 2) Water
containing 0.1% Sulphuric acid. The molar feed rate of water is 802.8 lb-mol/hr. The entering
temperature of all the feed streams is to be 750 Fahrenheit. The reaction is first order in PO and the
specific reaction rate constant is given as: K = 16.96e+12 exp(-32400/RT) hr-1. What will be the
conversion and the outlet stream temperature?
SOLUTION
The input files and reaction models are as shown in the figure 5.11.1 and 5.11.2. Flowsheet is as
shown in the figure 5.11.3. and Results are shown in figure 5.11.4

Figure 5.11.1.Input

206
Figure 5.11.2. Reaction Model

207
Figure 5.11.3. Flowsheet

Figure 5.11.4. Results

208
5.12) Ethylidene-Diacetate decomposes on heating to form acetic acid and methyl acrylate:-
CH3COOCH(CH3)COOCH3---->CH3COOH + CH2=CHCOOCH3
The pyrolysis closely approximate a first order irreversible reaction with
A= 7.8 x 10^9 and E =38200 cal/mol
Pure reactant enters at a temperature of 800K and a pressure of 5 atm with a equal flow rate of
1000lb/hr. If two perfectly mixed continuous stirred tank reactors of equal volume were to be in
series, What would be the minimum total volume of the two reactors in order to obtain a
conversion of 85%

SOLUTION
Two CSTR's are used with equal volume and the reaction is set up in reaction
model. Optimization setup is used to find the minimum total volume. The input and
reaction model are as shown in the figure 5.12.1 and 5.12.2 The flowsheet and the
results are shown in the figures 5.12.3 and 5.12.4

Figure 5.12.1 Input

209
Figure 5.12.2 Reaction Model

210
 Figure 5.12.3 Flowsheet

Figure 5.12.4 Optimization Results

211
6
MASS TRANSFER OPERATIONS

Mass transfer is one of the main pillars of chemical engineering. It deals with the
transport of species in a mixture in a single phase or across a phase boundary in
the presence of a concentration driving force. It is very much analogous to the
heat transfer.

Mass transfer occurs in many processes, such as absorption, evaporating, drying,

precipitation, membrane filtration and distillation. It is used by different scientific
disciplines for different processes and mechanisms. In industrial processes, mass
transfer operations include separation of chemical components in distillation
columns, absorbers such as scrubbers or stripping, adsorbers such as activated
carbon beds, and liquid-liquid extraction.

Mass transfer data is essential for determining the extraction time and the
capacities of pumps, compressors, and heat exchangers which in turn helps to
design the required equipment. The application of mass transfer in chemical
engineering is very extensive that it is used in reaction engineering, heat
transfer engineering, and separations engineering.

We have solved problems on absorption, stripping, humidification, cooling

towers, distillation, multi component distillation, tray designs, and extraction.

212
6.6) 6.1) A coal gas is to be freed of its light oil by scrubbing with wash oil as an
absorbent. Absorber gas in, 0.250 m3/s at 26degC, Pt=1.07*105N/m2(803 mmHg),
containing 2.0% by volume of light oil vapours. The light oil will be assumed to be
entirely benzene, and has an avg mol wt 260. An oil circulation rate of 1.5 times the
minimum is to be used. Wash oil-benzene solutions are ideal. The temperature will be
constant at 26degC.

SOLUTION
A Distillation column without reboiler and condenser is used as an absorber. Any heavy oil
with sufficiently large volatility can be used as the solvent. The ideal thermodynamic method
is used. The minimum liquid flow rate was calculated graphically as 0.00119 kmol/s of oil.
The liquid flowrate of 1.5 times this value is used. The number of stages in the column were
varied manually until the required outlet composition specs were met. 8 stages were
required. The input file is shown in figure 6.1.1 The flowsheet, Column Profiles and Results
are shown in figure 6.1.2, 6.1.3, and 6.1.4.

Figure 6.1.1 Input

213
 Figure 6.1.2 Flowsheet

Figure 6.1.3 Column Profiles

214
Figure 6.1.4 Results

215
6.2) The solution from the absorber in the previous problem is to be heated to 120deg
C and will enter the stripper at 1 std atm pressure. Stripping steam will be at standard
atmospheric pressure, superheated to 122deg C. The debenzolized oil, 0.005 mole
fraction benzene, is to be cooled to 26deg C and returned to the absorber. A steam
rate of 1.5 times the minimum is to be used. The temperature will be constant at
122deg C. Compute the oil-circulation rate and the steam rate required

SOLUTION
A Distillation column without condenser and reboiler is used as a stripping column. The
minimum steam rate is calculated from the graph and 1.5 times the minimum rate is used.
This is 0.0004526 kmol/s of steam. Any heavy oil with sufficiently large volatility can be used
as the solvent. The ideal thermodynamic method is used. The number of stages in the
column were varied manually until the required outlet composition specs were met. 6 stages
were required. The input file is shown in figure 6.2.1. The flowsheet, Column Profiles and
Results are shown in figure 6.2.2, 6.2.3, and 6.2.4.

Figure 6.1.1 Input

216
Figure 6.2.2 Flowsheet

Figure 6.2.3 Column Profiles

217
Figure 6.2.4 Results

218
6.3) If an ammonia absorber has 2% concentration of ammonia in the inlet gas
and no ammonia in the inlet water, what percentage of the ammonia could be
absorbed with an absorption factor of 0.9 and N = 5 and N = 10. At 260C m for
ammonia is 1.414.

SOLUTION
An arbitrary gas flow rate is selected and the corresponding water flow rate is
calculated using the definition of absorption factor. Two columns, one with 5
stages and the other with 10 stages were set up. A calculator was used to calculate
and display the percentage of ammonia absorbed. The input file is shown in figure
6.3.1. The flowsheet and results are shown in figure 6.3.2 and 6.3.3

Figure 6.3.1.Input

219
 Figure 6.3.2 Flowsheet and results for 5 stages

Figure 6.3.3 Flowsheet and results for 10 stages

220
6.4) A stream of waste gas contacting 0.6vol% ammonia in air is to be cleaned by removing 99.5% of
the ammonia before it can be discharged in the atmosphere. Removal of ammonia is to be done in
a packed tower. 1m2 in cross-section, in which the feed gas rate is 2000kg/h.m2 and the liquid (20%
H2SO4) is supplied at a rate of 2200kg/h.m2. the absorption is gas-film resistance controlled and
the overall volumetric mass transfer coefficient of NH3 on the gas phase basis KGa
=1350kg/h.m3.Δp.bar. although absorption of ammonia in a dilute acid is considered exothermic,
the temperature is assumed to be constant at 28-degree Celsius because of the low concentration
of ammonia. The total pressure in the column is 101.3kPa. the process starts with 1000 kg of the
20% acid solution in the storage tank for the scrubbing liquid, and the liquid is recirculated through
the column continuously. The concentration of the acid in the liquid gradually decreases as a
result. What total packed height is required to accomplish the separation if 0.3m dry packing is
provided above the liquid distributor in order to prevent entrainment of the liquid.

SOLUTION
A distillation column with 5 stages is taken with the given inputs. Assuming the
operation continues till the solution remains sufficiently acidic. As feed gas
concentration is very low, we can take y*=1; and the gas rate is constant. The
input file is shown in figure 6.4.1. The flowsheet, column profiles and results are
shown in figure 6.4.2, 6.4.3 and 6.4.4.

Figure 6.4.1 Input

221
 Figure 6.4.2 Flowsheet

Figure 6.4.3 Column profiles

222
Figure 6.4.4 Results
223
6.5) Ammonia is stripped from a dilute solution by counter current stripping
with air in a column containing 5 trays. The equilibrium relationship is y = 0.8x,
and when the molar flow rate of air is 1.5 times that of the solution, 90% of
ammonia is removed. a) How many ideal stages does the column have and what
is the stage efficiency? b) How much percentage removal would have been
obtained if the air rate were increased to 2 times the solution rate.
SOLUTION
A basis of 10.1 mol/hr of solution containing 0.1 moles of ammonia was
selected. The corresponding air flow rate for the first case is 15mol/hr. A
shortcut distillation column was used to find the number of ideal stages. For
part b of the question, a rigorous column with 5 stages was used. The water flow
rate was doubled and a calculator was used to calculate and display the stage
efficiency and percentage of ammonia absorbed. The input file is shown in figure
6.5.1. The flowsheet, Column Profiles and Results are shown in figure 6.5.2,
6.5.3, and 6.5.4.

Figure 6.5.1 Input

224
 Figure 6.5.2 Flowsheet

Figure 6.5.3 Column Profiles

225
Figure 6.5.4 Results

226
6.6) A mixture of 2 mol percent ethanol and 98 mol percent water is to be
stripped in a plate column to a bottom product containing not more than 0.01
mol percent ethanol. Steam admitted through an open coil in the liquid on the
bottom plate is to be used as a source of vapor. The feed is at its boiling point.
The steam flow is to be 0.2 mol per mol of feed. How many ideal plates are
required?

SOLUTION
Distillation column with specified composition and flow rate specs was used. For the
feed stream, bubble point condition was used. The Fenske index will give the
minimum number of ideal plates required. 9 ideal stages are required. The input file
is shown in figure 6.6.1. The flowsheet, Column Profile and Results are shown in
figure 6.6.2, 6.6.3 and 6.6.4.

Figure 6.6.1 Input

227
Figure 6.6.2 Flowsheet

Figure 6.6.3 Column Profiles

228
Figure 6.6.4 Results

229
6.7)It is desired to reduce the ammonia content of 6000 ft3/hr (26.1 C, 1 atm)
of an air ammonia mixture from 5 to 0.04 % by volume by water scrubbing.
what water flow rate should be used? At this temperature, ammonia-water
solutions follow Henry’s law up to 5 mol% ammonia in the liquid, and
m=1.414.

SOLUTION
The inlet gas flow rate is approximately 7 kmol/h. A rigorous column with 8
stages was setup. The outlet composition was given as a column specification
and the water flow rate was varied. Since the number of trays is 8. The input file
is shown in figure 6.7.1. The flowsheet, column profiles and results are shown in
figure 6.7.2,6.7.3 and 6.7.4.

Figure 6.7.1 Input

230
 Figure 6.7.2 Flowsheet

Figure 6.7.3 Column profiles

231
Figure 6.7.4 Results

232
6.8) Air containing 1.6% sulphur dioxide by volume is being scrubbed with pure
water in a packed column 1.5 m2 in cross-sectional area and 3.5 m in height at a
pressure of 1 atm. Total gas flow rate is 0.062 kg-mole/sec, the liquid flow rate is 2.2
kg-mole/sec, and the outlet gas molar composition is 0.004. Determine the number
of theoretical stages required and HETP

SOLUTION
From the problem statement a rigorous distillation column with sieve trays
is setup to find the HETP. The input file is shown in figure 6.8.1. The
flowsheet, Column Profiles and results are shown in figure 6.8.2,6.8.3,
6.8.4.

Figure 6.8.1 Input

233
Figure 6.8.2 Flowsheet

Figure 6.8.3 Column Profiles

234
Figure 6.8.4 Results
235
6.9)Warm water of temperature 45 degrees is to be cooled by counter current
contact with air in a tower packed with wooden slats. Dry bulb temperature of air
is 31 degC, wet bulb temperature is 22 degrees. Mass flowrate of water is 6000
kg/m2.h and that of air is 3270kg/m2 h. Calculate the height of the cooling tower
and product purity for 4 stages?

SOLUTION
As we know dry bulb and wet bulb temperatures, we can find the humidity form the
psychometric chart. It is 0.01295kg/kg. A distillation column without condenser and
reboiler is taken with 4 trays. The input file is shown in figure 6.9.1. The flowsheet,
Column profiles and results are shown in figure 6.9.2, 6.9.3, and 6.9.4.

Figure 6.9.1 Input

236
 Figure 6.9.2 Flowsheet

Figure 6.9.3 Column Profiles

237
Figure 6.9.4 Results

238
6.10) It is required to separate 200 lb-mole/hr of a 40% Benzene and 60% Toluene
mixture into a top product containing 95% Benzene and Bottom product
containing 90% Toluene. The feed mixture is 25% vaporized. The reflux ratio is
3:1. And a total condenser is to be used. a). How many theoretical stages are
required? b). At what stage the feed be introduced.
SOLUTION
Distillation unit operation is used for simulating this problem. The specifications
are product purities as provided. The Inlet stream specification is defined as
25% Vaporized at 14.7 psia. A bubble temperature condenser is specified. The
input file is shown in figures 6.10.1.The flowsheet, Column Profile and results
are shown in figure 6.10.2, 6.10.3 and 6.10.4.

Figure 6.10.1 Input

239
Figure 6.10.2 Flowsheet

Figure 6.10.3 Column Profiles

240
Figure 6.10.4 Results

241
6.11) A liquid mixture containing 50 mol% n-heptane, 50 mol% n-octane, at 30 C
to be continuously flash vaporized at 1 std atm to vaporize 60 mol% of the feed.
What will be the composition of the vapor and liquid and the temperature in
the separator for an equilibrium stage?
SOLUTION
A suitable feed basis is selected. The flash drum unit operation is used with the
given product specification (60 mol% vapor). Adiabatic flash option is used. The
input file, The flowsheet, The results and The plots are shown in figures 6.11.1,
6.11.2, 6.11.3 and 6.11.4

Figure 6.11.1.Input

242
Figure 6.11.2.Flowsheet

243
Figure 6.11.3.Results

Figure 6.11.4.Plots

244
6.12) A liquid containing 50 mol% Benzene, 25 mol% Toluene, 25% o-Xylene is
differentially distilled at 1 atm, with vaporization of 32.5 mol% of the charge.
Raoult’s law applies. Compute the distillate and residue compositions.

SOLUTION
In the given problem four flash drums are used in series with the liquid from
each unit serving as the feed to the next unit. The total vapor product is equally
divided for each flash unit and it is used as the design specification. The vapor
streams from all the flash units are connected to a mixer and a single vapor
stream is withdrawn. The input file is shown in figures 6.12.1, The flowsheet and
results are shown in figure 6.12.2 and figure 6.12.3.

Figure 6.12.1 Input File

245
Figure 6.12.2 FLOWSHEET

246
Figure 6.12.3 RESULTS

247
6.13)A liquid containing 25 mol% toluene, 40 mol% ethylbenzene, and 35
mol % water is subjected to continuous flash distillation at a total pressure
of 0.5 atm. If 50% of the feed vaporizes, calculate the temperature and
compositions of the product streams.
SOLUTION
Since the given compounds for an immiscible mixture, the NRTL activity coefficient model
is used for the VLLE calculations. A flash drum with the given product specification is
used. The three product streams are for vapor, organic liquid and water. The input file is
shown in figure 6.13.1. The flowsheet and results are shown in figure 6.13.2 and 6.13.3
respectively

Figure 6.13.1 Input

248
Figure 6.13.2 Flowsheet

249
Figure 6.13.3 Results

250
6.14) A mixture with 33% n-hexane, 37% n-heptane, and 30 percent n-octane is
to be distilled to give a distillate product with 0.01 mole fraction of n-heptane
and a bottoms product with 0.02 mole fraction n-hexane. The column will
operate at 1.2 atm with 60 percent vaporized feed. Calculate the complete
product composition and the minimum number of ideal plates at infinite reflux.

SOLUTION
A Distillation column with the given specs is used to calculate the minimum
number of plates, which given the number of ideal stages at infinite reflux. The
input file is shown in figure 6.14.1. The flowsheet, Column profiles and results
are shown in figure 6.14.2. and 6.14.3

Figure 6.14.1 Input

251
 Figure 6.14.2 Flowsheet

Figure 6.14.3 Column Profiles

252
Figure 6.14.4 Results

253
6.15) A tower containing six ideal plates, a reboiler, and a total condenser is
used to separate partially, oxygen from the air at 65 psig. It is desired to
operate at a reflux ratio of 2.6 and to produce a bottom product containing
51 mole% oxygen. The air is fed to the column at 65 psig and 30 percent
vapor by mass. Compute the composition of the overhead.

SOLUTION
A rigorous column was used. The condenser and reboiler duties were varied to
get the desired reflux ratio and bottoms composition. The input file is shown in
figures 6.15.1. The flowsheet, column profiles and results are shown in figures
6.15.2, 6.15.3, and 6.15.4.

Figure 6.15.1 INPUT

254
 Figure 6.15.2 FLOWSHEET

Figure 6.15.3 Column profiles

255
Figure 6.15.4 Results

256
6.16) A continuous fractionating column is to be designed to separate 30000 Kg/h of a
mixture of 40% benzene and 60% toluene into an overhead product containing 97%
benzene and a bottom product containing 98% toluene. These percentages are by
weights. A molar reflux ratio of 3.5 is to be used. Calculate the moles of overhead
product and bottom product per hour. Determine the number of ideal plates and the
position of the feed for if the feed is - 1) liquid at its boiling point; 2) liquid at 20 degrees
Celsius; 3) feed is one-third liquid and two-thirds vapor.
SOLUTION
Distillation columns with the given composition specs and feed conditions were used along with
the minimum reflux and underwood calculations. For saturated liquid feed, 12 trays are required.
For subcooled liquid feed, 11 trays are needed. The partially vaporized feed requires the highest
number of trays (14 trays). The input file, Flowsheet, and the results are shown in the figures
6.16.1, 6.16.2, and 6.16.3

Figure 6.16.1 Input

257
Figure 6.16.2 Flowsheet

258
Figure 6.16.3 Results

259
6.17) Extractive distillation of ISO-PROPANOL and WATER using DMSO as an
Entrainer.

SOLUTION
Two distillation columns are used to separate three components (water,
isopropanol, and DMSO.
The input file is shown in figure 6.17.1. The flowsheet, Column Profiles and
Results are shown in figure 6.17.2, 6.17.3,6.17.4 and 6.17.5.

Figure 6.17.1 Input

260
 Figure 6.17.2 FLOWSHEET

Figure 6.17.3 TEMPERATURE PROFILES FOR COLUMN1 AND COLUMN2

261
Figure 6.17.4 COLUMN 1 AND COLUMN 2 PROFILES

Figure 6.17.5 RESULTS

262
6.18) Toluene and n-heptane are to be separated by extractive distillation with
phenol. The proposed specification for the operation is shown below in figure
6.18.1. If the design objective is to obtain a heptane purity of at least 99 mole%.
calculate the product compositions, stage temperatures, inter stage flow rates
and compositions, and condenser and reboiler duties

SOLUTION
The input file is shown in figure 6.18.1. The flowsheet, Column Profiles and
Results are shown in figure 6.18.2, 6.18.3, and 6.18.4.

Figure 6.18.1 Input

263
 Figure 6.18.2 Flowsheet

Figure 6.18.3 Column Profiles

264
Figure 6.18.4 Results

265
REFERENCES
1) Unit Operations of Chemical Engineering’ by McCabe, Smith and Harriot

(7thedition)

2) ‘Fluid Mechanics: Fundamentals and Applications’ by John Cimbala and

Yungus A. Cengel

3) ‘Unit Operations-1. Fluid flow and Mechanical unit operations by K. A. Gavhane

4) ‘Introduction to Process Calculations’ by K. A. Gavhane.

5) ‘Basic Principles and Calculations in Chemical Engineering (8th Edition) by

David M Himmelblau'.

6) 'Solved Problems in Chemical Engineering by Dr. G. K. Roy

7) 'Introduction to Chemical Engineering Thermodynamics. 7th Edition.

J M Smith, H C Van Ness, M M Abott

8) 'UNIT OPERATIONS OF CHEMICAL ENGINEERING, 5th Edition by Warren L. McCabe,

Julian C. Smith, Peter Harriott, published by McGraw-Hill, Inc.

9) PROCESS HEAT TRANSFER by Donald Q. Kern, published by

McGraw-Hill International Book Company.

10) Heat Transfer by Yunus A. Cengel

11) ‘Elements of Chemical Reaction Engineering’ by H. Scott Fogler (4rth Edition)

12) Principles of Mass Transfer and Separation Processes’ by Binay K.Dutta

13) ‘Mass Transfer Operations’ by Robert E. Treybal – 3rd edition

14) ‘Equilibrium stage separation operations in chemical engineering’ by

Ernest J. Henley and J.D. Seader

15) Distillation Design by Hengry Z. Kister

100 Problems

60 Days

6 Subjects

6 Students

1 Mentor

1 Disruptive Idea...!

Human nature and Society like disruptive ideas. The Education system has been the same for almost so years. With
the Internet, Software Revolution, and the advent of Artificial Intelligence, can Chemical Engineering be learned by a
different approach? YES!! We believe that our book is one such disruptive approach for learning Chemical
Engineering. We believe that this book has the capability to make a student industry-ready. In this book, we have
presented how Chemical Engineering problems from various subjects such as Fluid Mechanics, Material and Energy
Balance, Chemical Engineering Thermodynamics, Heat Transfer, Chemical Reaction Engineering and Mass Transfer
Operations can be solved using AVEVA" Process simulation (APS) software.

Salient features of the book

To make the book user friendly, one problem has been explained with a step by step procedure to introduce the
interface and features of APS.
Solution approach with the input data and the result has been explained for problems from standard Chemical.
Engineering textbooks and included industrial problems.
It allows readers to explore the problem solving approach for more difficult problems.
Problems have been solved on a variety of concepts from the core Chemical Engineering subjects.

A word from the Student Authors:

Being mentored by one great thinker, we adapted the much-required method for this generation, "Learn as we go Le
to attain the necessary capabilities for solving any kind of problem while solving it through different sources. We are
very motivated by the question, If we are not dreaming big, are we really living Learning from each other,
understanding a concept from its basics, going in Reverse Engineering pattern were our driving principles to move
forward as a student and come up with this book with a motive to inspire students and make them learn in a better
way.

Dr. Pavan Kamar Veldandi did his B.Tech. in Chemical Engineering from Osmania University College of Technology.
He completed M. Tech. in Chemical Plant Design from the National Institute of Technology Karnataka, Surathkal. He
holds a Ph.D. in Chemical Engineering from the Faculty of Technology, Osmania University. Ile has 15 years of
industrial experience in Modeling and Simulation of a variety of manufacturing processes. He started his career with
General Electric India development center, Bangalore, wherein he worked on the design of next-generation
integrated gasification and combined cycle power plants. Later he moved to Invensys India development center,
Hyderabad. Currently, he is working with Cognizant Technology Solutions, Hyderabad as a Principal Product
Assurance Engineer for the last 12 years, he has expertise in simulating process plants using simulators like PRO/II,
Dynsim, Spiral and Process Simulation, etc.

Also available as an e-book