EHCPB 3B – Chemical Engineering Design Principles
General: Handing in on time 2
All questions answered in self study project 3
How neat 2
TOTAL MARKS: 48
MEMO Study guide questions - CHPT 1 (CR6)
3.2 Discuss the two main phases a design project is organised into
Phase 1: Process design which covers the steps from the initial selection of the process to
be used, through to the issuing of the process flow-sheets; and includes the selection,
specification and chemical engineering design of equipment. In a typical organisation, this
phase is mainly done by chemical engineers. The process design group may also be
responsible for the preparation of the piping and instrumentation diagrams.
Phase 2: Plant design, including the detailed mechanical design of equipment, the
structural, civil and electrical design and the specification and design of the ancillary
services. These activities will be the responsibility of specialist design groups having
expertise in the whole range of engineering disciplines.
MEMO Study guide questions - CHPT 9 (CR6)
5.1 Explain what failure-mode analysis is
Failure-mode effect analysis is used to determine the relative importance of different component
failures within an overall system. It can be applied to analysis of chemical plant safety, as well
as to design of products and ever business plans and commercial projects. The method is
semi-quantitative. It assigns numerical rankings to different failure modes based on the
perceptions of the participants. The method is best used in the early stages of design as a
means of brainstorming for safety issues.
MEMO Study guide questions - CHPT 7 (CR6)
8.3 What are all the different materials classified as ceramics?
Ceramics are compounds of non-metallic elements that have a cross-linked structure that
makes them brittle and include the following materials used for chemical plants:
Glass, the borosilicate glasses (hard glass)
Stoneware
Acid-resistant bricks and tiles
Refractory materials
Cements and concrete
8.4 Do problems 7.3, 7.4 and 7.5 on pages 417
7.3.1
98% w/w sulphuric acid at 700C - High silicone iron (mild steel/low carbon steel)
7.4.2
A 5m3 tank for storing a 30% w/w aqueous solution of sodium chloride – Monel / Titanium /
plastic
MEMO Self Study Project - CHPT 1, 7 and 9 (CR6)
1 Look at diagram and description of the By-Product Coking Process and answer the following questions:
1.1 Chemical Engineering projects can be divided into three types, depending on the novelty involved under which of these types
would the design a by-product coking plant be classified?
Modifications and additions to an existing plant usually carried out by plant design group.
New production capacity to meet growing sales demand. Repetition of existing designs, with
minor design changes. Done by contractors.
1.2 What is the project documentation needed for this type of design project?
1.3 Identify the different stages of the Chemical Manufacturing Process, applying it to this process
1.4 Explain whether this is a continuous or a batch process. (You need to discuss you answers – start with the guide rules for batch
or continuous processes )
1.5 Is this an intrinsic or an extrinsic safe process? Clearly explain you answer.
1.6 List the hazards you will associate with this process and explain the preventative measures you would implement to ensure a safe
process.
1.7 Do an operability study on the quenching unit. (Figure 9.5 pg 515 steps 1 to 13)
Intention (vessel and lines) – Water cools the coke quickly and completely preventing any
danger or product loss due to coke reacting with air to burn
Intention (line) – Supplying water to the quenching unit
Deviation – No water
Less (Part of) water
More water
Water as well as air
Causes – blockage, valve failure, failure of water supply
Hazards – (No and Less and As well as) Ignition of the coke causing fire and loss of product
(More) not really a safety concern, might reduce the quality of
the final coke product a little
(any explanation that shows understanding)
1.8 Do you think any special materials of construction are needed, explain your answer? (Look at the guidelines for selecting
materials for corrosion resistance and apply these to the process in general.)
1.9 Recommend a suitable material for the overhead piping of the collecting main – discuss the problems you needed to consider and
the reasons for your choice.
The material must be able to handle
very high temperatures 12900C
slightly acidic environment because of the water vapour combining with coal dust
tar, light oils and heavy hydrocarbons which may include small quantities of organic
solvents
SOx, COX and NOX (quantities will depend of the grade of coal used), all corrosive when
combined with water
Inconel and Incoloy – high temperature, furnace gasses, but sulphur could be a problem
Stainless steel – high temperature corrosion resistant
(any explanation that shows understanding)
