CHEMICAL

ENGINEERING
DEPARTMENT
 Chemical Plant Design
(CH-414)
Teacher: Dr. Syed Ali Ammar Taqvi
Assignment

GROUP MEMBERS

• BAZIL AHMED KHAN (CH-17309)

Khan4001613@cloud.neduet.edu.pk

• TAIMOOR AHMED KHAN LODHI (CH-17040)

lodhi4001611@cloud.neduet.edu.pk

• DUAA YOUSUF (CH-17018)

yousuf4005452@cloud.neduet.edu.pk

• SYED SHAHAB SHAHNOOR (CH-15307)

shahnoor366540@cloud.neduet.edu.pk
 Question No. 1

Crude dichlorobenzene is pumped from a storage tank to a distillation column. The tank is
blanketed with nitrogen and the pressure above the liquid surface is held constant at 0.1 bar
gauge pressure. The minimum depth of liquid in the tank is 1 m. The distillation column
operates at a pressure of 500mmHg (500mm of mercury, absolute). The feed point to the
column is 12m above the base of the tank. The tank and column are connected by a 50 mm
internal diameter commercial steel pipe, 200m long. The pipe run from the tank to the
column contains the following valves and fittings: 20 standard radius 90o elbows; two gate
valves to isolate the pump (operated fully open); an orifice plate; and a flow-control valve. If
the maximum flow rate required is 20,000 kg/h, calculate the pump motor rating (power)
needed. Take the pump efficiency as 70% and allow for a pressure drop of 0.5 bar across the
control valve and a loss of 10 velocity heads across the orifice. Density of dichlorobenzene
1300 kg/m3, viscosity 1.4 cp.

SOLUTION:
Solution
Applying Bernoulli’s Equation on storage tank (1) and distillation column (2)

P1 v12 P2 v22
+ z1 + = + z2 + + hmajor + hminor − ha
ɤ 2g ɤ 2g

Area = πr2
= (π/4) (50x10-3)2
= 1.96 x 10-3 m2

Mass flowrate = 20000 Kg/h

= 5.56 Kg/sec

Velocity = flowrate/area
= (5.56)/ (1.96 x 10-3)
= 2.178 m/s
Reynold Number
ρDv
Re =
ɥ

μ = 0.0014 Pa.s

R e = (1300) (2.178) (50x10-3)/ (0.0014)

= 1x 105

Roughness
ε = 4.6 X 10-5m

ɛ 4.6 × 10−5
= = 0.0009
D 50 × 10−3

Friction factor from Colebrook’s Equation

ʄ = 0.023

Major loss

L v2
hmajor = ʄ
D 2g
= (0.023) (200) (2.178)2 / (50x10-3) (2) (9.8)
= 22.27m

Minor losses

v2
hminor = K
2g
2.1782 0.5 × 105
= × {(20 × 0.8) + (2 × 0.15) + (10) + ( )}
2 × 9.8 1300 × 9.8

= 7.32m
Pressure
P1 = 0.1 bar(gauge)
= 10000 Pa(gauge)

Pabsolute = Patm + Pgauge

= 101325 + 10000
= 111325 Pa

P2 = 500mm Hg
500 × 1 × 101325
=
760
= 66661.2 Pa

Put the values in Bernoulli’s equation, we get

ha = 37.08 m

Power = (Specific Weight) (Head) (Volumetric Flowrate)

P = ɤha Q
= (1300) (9.8) (37.08) (4.27x10-3)
= 2.02 KW

𝐏
𝐏𝐫𝐞𝐪 =
𝛈
= 2.02/ 0.7 = 2.957 KW
Question No. 2

A liquid is contained in a reactor vessel at 115 bar absolute pressure. It is transferred to a

storage vessel through a 50mm internal diameter commercial steel pipe. The storage vessel is
nitrogen blanketed, and pressure above the liquid surface is kept constant at 1500 N/m 2
gauge. The total run of pipe between the two vessels is 200 m. The miscellaneous losses due
to entry and exit losses, fittings, valves, etc. amount to 800 equivalent pipe diameters. The
liquid level in the storage vessel is at an elevation 20m below the level in the reactor. A
turbine is fitted in the pipeline to recover the excess Energy that is available, over that
required to transfer the liquid from one vessel to the other. Estimate the power that can be
taken from the turbine, when the liquid transfer rate is 5000 kg/h. Take the efficiency of the
turbine as 70%. The properties of the fluid are density 895 kg/m3, viscosity 0.76 mNm2s.

SOLUTION:
P1=115 bar(abs)=115×105 Pa

ID=50mm=50x10 -3m.
𝐾𝑔
Mass flow rate=m=5,000 ℎ

Efficiency=ⴄ=70%
Length =200
𝐿
= 800
𝐷
Total length = 200+(800×50×10-3) = 240m
 𝐾𝑔 𝑚𝑁𝑠 𝑁𝑠
𝜌 = 895 𝑚3 ,𝜇 = 0.76 = 0.76 × 10−3
𝑚2 𝑚2

Work produced by turbine=shaft work=Ws

Power required =P =?

SOLUTION:

Turbine provide shaft work (WS), minor losses are neglected, major losses are considered due
to friction in the pipe. The datum line is taken at the bottom of the reactor vessel i.e. (z1=0).
𝑃1 𝑉12 𝑃2 𝑉22
+ 𝑍1 + = + 𝑍2 + +ℎ =𝑊
Υ 2𝑔 Υ 2𝑔
𝛾 =𝜌×𝑔
𝑉12 𝑉22
= 2𝑔 = 0 (Velocity head) and Z1=0
2𝑔

𝑃1 𝑃2
𝑊= − − 𝑍2 − ℎ --------------------→ eq#01
Υ Υ

To calculate velocity and major loss

VELOCITY:
𝜋 𝜋
Area=4 D2 = 4 (50×10-3) =1.963×10-3 m2

Volumetric flow rate:

5000 𝐾𝑔 1 ℎ𝑟 1𝑚3 𝑚3
× 3600 𝑠𝑒𝑐 × 895 𝐾𝑔 = 1.55 × 10−3
ℎ𝑟 𝑠

𝑚3
1.55×10−3 𝑚
𝑠
Velocity=V=1.963×10−3 m2 = 0.7896 𝑠

MAJOR LOSS (hL(major)):

𝜌 × 𝐷 × 𝑉 895 × 50 × 10−3 × 0.896
Re= = = 46.56 × 103 = 4.56 × 104
𝜇 0.6 × 10−3
∈ 0.045𝑚𝑚
= = 9 × 10−4
𝑫 50𝑚𝑚
FROM MOODY’S GRAPH
f=0.023
𝑓𝐿𝑣 2 0.023×240×(0.789)2
Now 𝒉 = = = 3.506 𝑚
2𝑔 2×9.8

Equation #01 becomes

115×105 −10285
W s= − 20 − 3.506 = 1295.90𝑚
894×9.8

𝑷 = 𝛾 × Ws × Q = 895 × 9.8 × 125.90 × 1.55−3 = 1.34𝐾𝑊

𝑃 17.34𝐾𝑊
Preq= 𝜂 = = 24.7 𝐾𝑊
70%

Question No. 3

Estimate the shaft work required to pump 65 gals/min of sugar solution in water (specific
gravity = 1.05) if the pump inlet pressure is 25 psig and the outlet pressure required is 155
psig.

SOLUTION:
Bernoulli’s equation is:

P1 v12 P2 v22
+ z1 + + W + Q = + z2 + + hL
ɤ 2g ɤ 2g

Now applying Bernoulli’s equation at pump section and pump discharge and

so our equation becomes;

P2 P1
W= −
ɤ ɤ
Density of the Sugar Solution = (Density of Water @15oC) (Specific Gravity)
Density of the Sugar Solution = (1000) (1.05)

Density of the Sugar Solution = 1050 kg/m3

P1 = 25 psig = 172369 Pa

P2 = 155 psig = 1.069 x 106 Pa

Substituting the values, we get

𝑊 = 87.14 𝑚

𝑄 = 4.1 × 10−3 𝑚3/𝑠

∵ 𝑃 = ɤ𝑊𝑄

𝑃 = 1050 × 9.8 × 87.14 × 4.1 × 10−3

P=3.676kw

Question No. 4
Design an exchanger to sub cool condensate from a methanol condenser from 95°C to 40°C.
Flow rate of methanol 100,000 kg/h. Brackish water will be used as the coolant, with a
temperature rise from 25°C to 40°C. Simulate the same example on Aspen EDR and generate
TEMA Sheet.

Solution:
1. Heat balance:
100,000
Methanol: Q = w Cp ∆T = * 2.84 * (95-40) = 4339 kW
3600
Q 4338.88
Water: w =Cp ∆ T = 4.2∗(40−25) = 68.87 kg/s

2. ∆𝐭:
(95−40)−(40−25)
LMTD = (95−40) = 31 ℃
ln
(40−25)

Use one shell pass and two tube passes:

95−40 40−25
R = 40−25 = 3.667 ; S = 95−25 = 𝟎. 𝟐𝟏

From fig:
Ft = 0.85
∆𝐭 = 0.85 * 31 = 26 ℃

From fig:
U = 600 W/ m2 ℃
For Area:
Q 4339∗10^3
A= = = 278 m2
U ∆t 600∗26
3
Choose 20 mm OD, 16 mm ID, 4.88-m long tubes (4 in × 16ft ), cuprous-nickel. Allowing for
tube-sheet thickness, take
L=4.83 m
Area of one tube = 4.83× 20 × 10−3 π = 0.303 m2
 278
Number of tubes = 0.303 = 𝟗𝟏𝟖

As the shell-side fluid is relatively clean, use 1.25 triangular pitch.

1
918
Bundle diameter Db = 20 (0.249)2.207 = 𝟖𝟐𝟔 𝐦𝐦

Use a split-ring floating-head type. From Figure, bundle diametrical clearance= 68 mm, shell
diameter, Ds =826 + 68= 894 mm

TUBE SIDE COEFFICIENT:

45+25
Mean water temperature= = 𝟑𝟑℃
2
π
Tube cross-sectional area = 4 × 162 = 201 mm2
918
Tube per pass = = 𝟒𝟓𝟗
2

Total flow area = 459 × 201 × 10-6 = 0.092 m2

68.87
Water mass velocity = 0.092 = 𝟕𝟓𝟕 kg / m2 s

Density water = 995 Kg / m3

757 𝐦
Water linear velocity = 995 = 𝟎. 𝟕𝟔 𝐬

4200 (1.35+0.02 ×33)×0.750.8

hi = = 𝟑𝟖𝟓𝟐 𝐰/𝐦𝟐 ℃
160.2

The coefficient can also be calculated using equation; this is done to illustrate use of this
method.
hi di μ 0.14
= jh Re Pr 0.33 ( )
k μw
Viscosity of water = 0.8 mNs/m2
Thermal conductivity = 0.59 W/m℃
ρ∗v∗d 995 ×0.76 ×16 ×10−3
Re = = = 14925
μ 0.8 ×10−3

Cp μ 4.2 ×103 ×0.8 ×10−3

Pr = = = 5.7
k 0.59

μ
Neglect (μw)

L 4.83 ×103
= = 302
di 16
 From Fig, jh = 3.9 × 𝟏𝟎−𝟑
0.59
hi = 16 ×10−3 × 3.9 × 10−3 × 14925 × 5.70.33 = 𝟑𝟖𝟏𝟐 𝐰/𝐦𝟐 ℃

SHELL SIDE COEFFICIENT:

Ds 890
Choose baffle spacing = = = 𝟏𝟕𝟖𝐦𝐦
5 5

Tube Pitch = 1.25×20 =25 mm

(25−20)
Cross flow area A = 890 × 178 × 10−6 = 𝟎. 𝟎𝟑𝟐𝐦𝐦
25
100,000 1
Mass Velocity, Gs = × 0.032 = 𝟖𝟔𝟖 𝐤𝐠/𝐦𝟐𝐬
3600
1.1
Equivalent Diameter de = 20 (252 − 0.917 × 202 ) = 𝟏𝟒. 𝟒𝐦𝐦
95+40
Mean shell side temperature = = 𝟔𝟖℃
2

Methanol density = 750 kg / m3

Viscosity = 0.34 mNs/m2
Heat capacity = 2.84 kJ / kg℃
Thermal conductivity = 0.19 W/m℃
Gs de 868×14.4×10−3
Re = = = 𝟑𝟔𝟕𝟔𝟐
μ 0.34×10−3

Cp μ 2.84×103 ×0.34×10−3
Pr = = = 𝟓. 𝟏
k 0.19

Choose 25% baffle cut, from fig

Jh =3.3× 𝟏𝟎−𝟑
Without the viscosity correction term
1
0.19 𝐖
hs =14.4×10−3 × 3.3 × 10−3 × 36762 × 5.13 = 𝟐𝟕𝟒𝟎 𝐦𝟐 ℃

Estimate wall temperature

Mean temperature difference = 68 – 33 = 35℃ across all resistance
U 600
Across methanol film=ho × ∆T = 2740 × 35 = 𝟖℃

Mean wall temperature = 68-8=60℃

𝐦𝐍𝐬
𝛍𝐰 = 𝟎. 𝟑𝟕
𝐦𝟐
 μ 0.14
( ) = 𝟎. 𝟗𝟗
μw

Overall Coefficient:
Thermal conductivity of cuprous-nickel alloys = 50 W/m℃
Take fouling coefficient from table, Methanol (light organic) 5000 w/m2℃, Brackish water (sea
water), take highest value, 3000 W/m2℃
20
1 1 1 20 × 10−3 ln 16 20 1 20 1
= + + + × + ×
Uo 2740 5000 2 × 50 16 3600 16 38.12
Uo =738 W/m2℃
Well above assumed value of 600 W/m2℃
Pressure Drop:
Tube Side:
From fig, for Re = 14,925

Jf = 4.3 × 𝟏𝟎−𝟑
Neglecting the viscosity correction term
4.83×103 995×0.762
∆Pt = 2(8× 4.3 × 10−3 ( ) + 2.5)
16 2

=7211 N/m2 = 7.2 kPa (1.1 psi)

Shell Side:
Gs 868 𝐦
Linear velocity = = = 750 = 𝟏. 𝟏𝟔
ρ 𝐬

From fig, for Re = 36762

Jf = 4 × 𝟏𝟎−𝟐
Neglecting the viscosity correction term
4.83×103 894 750×1.162
∆Pt = 2×8× 4 × 10−2 ( ) (14.4)
178 2

=272,072 N/m^2 = 272 kPa (39 psi) too high

Could be reduced by increasing the baffle pitch. Doubling the pitch halves the shell side
velocity, which reduces the pressure drop by a factor of approximately (1/2)2
 𝟐𝟕𝟐
∆𝐏𝐬 = = 𝟔𝟖𝐊𝐏𝐚 (𝟏𝟎𝐏𝐬𝐢), 𝐚𝐜𝐜𝐞𝐩𝐭𝐚𝐛𝐥𝐞
𝟒
This will reduce the shell-side heat transfer coefficient by a factor of (1/2)0.8 (ho∝ Re0.8 ∝ μ0.8)
1 0.8
Ho= 2740 × (2) =1573 W/m2℃

This gives an overall coefficient of 615 W/m2℃—still above the assumed value of 600 W/m2℃.
Aspen Exchanger Design and Rating Shell & Tube V10

File: Printed: 29-

Dec-20 at 5:23:47 PM

TEMA Sheet

Heat Exchanger Specification Sheet

1 Company:

2 Location:

3 Service of Unit: Our Reference:

4 Item No.: Your Reference:

5 Date: Rev No.: Job No.:

6 Size : 940 - 6096 mm Type: AEL Horizontal Connected in: 1 parallel 1 series

7 Surf/unit(eff.) 314.9 m² Shells/unit 1 Surf/shell(eff.) 314.9 m²

8 PERFORMANCE OF ONE UNIT

9 Fluid allocation Shell Side Tube Side

10 Fluid name Methanol in->Methanol out Water in->Water out

11 Fluid quantity, Total kg/s 27.7778 87.5165

12 Vapor (In/Out) kg/s 0 0 0 0

13 Liquid kg/s 27.7778 27.7778 87.5165 87.5165

14 Noncondensable kg/s 0 0 0 0

15

16 Temperature (In/Out) °C 95 40 25 40

17 Bubble / Dew point °C 95 / 95 94.44 / 94.44 / /

18 Density Vapor/Liquid kg/m³ / 707.12 / 770.28 / 1007.34 / 995.95

19 Viscosity mPa-s / 0.2348 / 0.4448 / 0.8904 / 0.6514

20 Molecular wt, Vap

21 Molecular wt, NC

22 Specific heat kJ/(kg-K) / 3.892 / 3.559 / 4.313 / 4.316

23 Thermal conductivity W/(m-K) / 0.1493 / 0.1734 / 0.611 / 0.6315

24 Latent heat kJ/kg

25 Pressure (abs) bar 2.80783 2.75574 1.01325 0.92494

26 Velocity (Mean/Max) m/s 0.31 / 0.41 0.86 / 0.88

27 Pressure drop, allow./calc. bar 0.25855 0.05209 0.20684 0.08831

28 Fouling resistance (min) m²-K/W 0 0 0 Ao based

29 Heat exchanged 5662.9 kW MTD (corrected) 25.36 °C

30 Transfer rate, Service 709.2 Dirty 926 Clean 926 W/(m²-K)

31 CONSTRUCTION OF ONE SHELL Sketch

32 Shell Side Tube Side

33 Design/Vacuum/test pressure bar 3.44738 / / 3.44738 / /

34 Design temperature °C 132.22 76.67

35 Number passes per shell 1 2

36 Corrosion allowance mm 3.18 3.18

37 Connections In mm 1 254 / - 1 254 / -

38 Size/Rating Out 1 152.4 / - 1 254 / -

39 Nominal Intermediate / - / -
T2 S2 S1

T1

40 Tube #: 659 OD: 25.4 Tks. Average 2.77 mm Length: 6096 mm Pitch: 31.75 mm Tube pattern:30

41 Tube type: Plain Insert:None Fin#: #/m Material:Carbon Steel

42 Shell Carbon Steel ID 939.8 OD 962.02 mm Shell cover -

43 Channel or bonnet Carbon Steel Channel cover Carbon Steel

44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -

45 Floating head cover - Impingement protection None

46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 30.08 Hori Spacing: c/c 406.4 mm

47 Baffle-long - Seal Type Inlet 555.62 mm

48 Supports-tube U-bend 0 Type

49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(App.A 'i')

50 Expansion joint - Type None

51 RhoV2-Inlet nozzle 422 Bundle entrance 172 Bundle exit 158 kg/(m-s²)

52 Gaskets - Shell side - Tube side Flat Metal Jacket Fibe

53 Floating head -

54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service

55 Weight/Shell 10067.9 Filled with water 14206.2 Bundle 6924.9 kg

56 Remarks

57