Name: Syed Muhammad Haider Abbas Rizvi

Seat No: B-1533039

Subject: Simulation
Instructor: Sir Hasan
Class: Final Year
Batch no: 2016-2019
Department: Chemical Engineering
Institute: University of Karachi
OBJECT TITLE SIGNATURE
No
1. Pump.

2. Compressor.

3. Expander.

4. Heat Exchanger.

5. Flash Separator.

6. Conversion Reaction.

7. Equilibrium Reaction.

8. Continuous Stirred Tank Reactor (C.S.T.R).

9. Absorber.

10. Separation Column.

11. Process involving Reaction and Separation.

12. Modification of process for the Improvement.

13. Use of Compressor, Cooler and Separation

Column
14. Refrigerated Gas Plant.

15. Propane Refrigeration Loop.

16. Distillation Column.

OBJECT: 1
Problem Statement:

Pumps are used to move liquids. The pump increases the pressure of the liquid. Water at 120oC and 3
bar is fed into a pump that has only 10% efficiency. The flowrate of the water is 100 kgmole/h and its
outlet pressure from the pump is 84 bar. Using Peng-Robinson equation of state as a fluid package,
determine the outlet temperature of the water.

Property Package: Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:

Unit Ops:
Result:

The outlet temperature of the water is 138.1oC.

Further Study:

Q: If the outlet temperature is 200oC, what is the efficiency of the pump?

The efficiency of the pump is 2.33 %.

OBJECT: 2
Problem Statement:

Compressors are used to move gases. The compressor increases the pressure of the gases. A mixture of
natural gas (C1, C2, C3, i-C4, n-C4, i-C5, n-C5, n-C6, C7+) at 100oC and 1 bar is fed into a compressor that
has only 30% efficiency. The flowrate of the natural gas is 100 kgmole/h and its outlet pressure from the
compressor is 5 bar. Using Peng-Robinson equation of state as a fluid package, determine the outlet
temperature of the natural gas.

Property Package:

Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:
Compositions:

Energy Streams:

Unit Ops:

Result:

The outlet temperature is 265.8oC.

Further Study:

Q: If the outlet temperature is 400oC, what is the efficiency of the compressor?

The efficiency of the compressor 14.944 %.

OBJECT:3
Problem Statement:

The Expander operation is used to decrease the pressure of a high pressure inlet gas stream to produce
an outlet stream with low pressure and high velocity. A mixture of natural gas (methane, ethane and
propane) at 25oC and 20 bar is fed into an expander that has only 30% efficiency. The flowrate of the
natural gas is 100 kgmole/h and its outlet pressure from the compressor is 5 bar. Using Peng-Robinson
equation of state as a fluid package, determine the outlet temperature of the natural gas.

Property Package:

Peng-Robinson
Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:

Unit Ops:

Result:

The outlet temperature of the natural gas -6.190oC.

Further Study:

Q: If the outlet temperature is -30oC, what is the efficiency of the expander?

The efficiency of the expander is 70.730 %.

OBJECT: 4
Problem Statement:

Hot water at 250°C and 1000 psig is used to heat a cold stream of water in a shell and tube heat
exchanger. The inlet temperature and pressure of the cold stream is 25°C and 130 psig, respectively. The
outlet temperatures of the cold and hot streams are 150°C and 190°C, respectively. If the flow rate of
the hot stream is 100 kg/h, determine the flow rate of the cold stream passing through the exchanger.

Property Package:

Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Compositions:

Conditions:

Unit Ops:

Result:

The flowrate of the cold stream passing through the exchanger (shell side) is 3.074kgmol/hr
(55.38kg/hr).
Further Study:

Q: If the flow rate of the cold stream is 100 kg/h, determine the flow rate of the hot stream passing
through the exchanger. What is amount of heat transferred from the hot stream to the cold stream?

The flowrate of the hot stream is 180.6 kg/hr and the heat transferred form hot to cold stream is
54733.3399 KJ/hr.

OBJECT: 5
Problem Statement:

We have a stream containing 15% ethane, 20% propane, 60% i-butane and 5% n-butane at 50oF and
atmospheric pressure, and a flowrate of 100 lbmole/hr. This stream is to be compressed to 50 psia, and
then cooled to 32oF. The resulting vapour and liquid are to be separated as the two product streams.
What are the flowrates and compositions of these two streams?

Property Package:

Peng-Robinson:

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:
Compositions:

Energy Streams:

Unit Ops:

Result:

The flowrates and the composition of the vapor and liquid streams can be seen from the conditions and
compositions table.

Further Study:

Q: If the Cool Gas temperature is 10oF, what are the new flowrates and compositions of these two
streams?

Flowrates:

3 Liquid Vapor
Compositions:

OBJECT:6
Problem Statement:

The interest in production of hydrogen from hydrocarbons has grown significantly in the last decade.
Efficient production of hydrogen is an enabling technology, directly related to the fuel cell energy
conversion device. The conversion of fuels to hydrogen can be carried out by the partial oxidation. The
partial oxidation method relies on the reaction of the fuel for example methane with air in order to
produce carbon oxides and hydrogen.

Develop a model that represents partial oxidation of methane to produce hydrogen.

Property Package:

Peng Robinson

Schematic Diagram:
Inlet and Outlet Streams:

Conditions:

Compositions:

Unit Ops:

Result:

Molar flow of the components are as follows:

In Ox-Vap Stream;
OBJECT:7
Problem Statement:

The new application of hydrogen as a raw material for fuel cells for mobile power sources (PEM fuel
cells) requires that the anode inlet gas have a CO concentration lower than 10-20 ppm. Otherwise, the
anode is poisoned and the cell efficiency abruptly drops. Hence, if the hydrogen is produced from
hydrocarbon or alcohol reforming, purification is required in order to reduce the CO levels to cell
requirements. The most technologically feasible purification train consists of a water gas shift reaction
(WGS). The reaction;

has been employed for 40 years in the industrial process for H2 production from liquid and gaseous
hydrocarbons. The role of the WGS reaction is to increase the H2 yield and decrease the CO
concentration, which is a poison for some catalysts used. Develop a model that represents the water gas
shift reaction.

Property Package:

Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:
Compositions:

Unit Ops:

Result:

The molar flow of the components are as follows;

In WGS_Vap;

In WGS_Liq;
OBJECT:8
Problem Statement:

To calculate the reactor temperature and the actual % of a continuous stirred tank reactor (C.S.T.R). The
propylene oxide(75oF, 1.1atm, 150lbmol/hr) and water feed(75oF, 16.17psia, 11000lb/hr) is pre-mixed
by a mixer and then reacted in a C.S.T.R to produce propylene glycol using the reaction:

Property Package:

UNIQUAC

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:
Energy Streams:

Unit Ops:

Result:

Reactor Temperature= 75oC.

Actual % Conversion= 40.30%

OBJECT:9
Problem Statement:

CO2 is absorbed into propylene carbonate in a packed column. The inlet gas stream is 20 mol% CO2 and
80 mol% methane. The gas stream flows at a rate of 2 m3/s and the column operates at 60oC and 60.1
atm. The inlet solvent flow is 2000 kmol/h. Use Aspen HYSYS to determine the concentration of CO2
(mole%) in the exit gas stream, the column height (m) and the column diameter (m).

Property Package:

SOUR PR

Schematic Diagram:
Inlet and Outlet Streams:

Conditions:

Compositions:

Unit Ops:

Result:

Conc. of CO2 in exit gas stream= 0%

Column Diameter= 1.5m.

Case Study:

Changing trays to packed column:

OBJECT:10
Problem Statement:

Two feeds of different compositions of carbon dioxide, nitrogen, methane, ethane, propane, normal and
iso butane, normal and iso pentane, hexane, heptane and octane are feed into a reboiled absorber and
then the bottom liquid is pumped into a distillation column. The bottom from distillation column is the
feed into another distillation column using a valve.

Property Package:

Peng-Robinson
Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:
Energy Streams:

Unit Ops:

Result:

Flowrate of Overhead product of DC-1 Column= 1338kgmol/hr.

Flowrate of C2 in DC-2 Column= 308.7606kgmol/hr.

Flowrate of C3 in DC-2 Column= 129.3352kgmol/hr.

Flowrate of DC-2 Overhead= 320kgmol/hr.

Mol. Fraction of C3 in overhead of DC-3 column= 91.0245kgmol/hr.

Mol. Fraction of C3 in bottom of DC-3 column= 26.0709kgmol/hr.

OBJECT:11
Problem Statement:

Toluene is produced from n-heptane by dehydrogenation over a Cr2O3 catalyst:

The toluene production process is started by heating n-heptane from 65 to 800 oF in a heater. It is fed to
a catalytic reactor, which operates isothermally and converts 15 mol% of the n-heptane to toluene. Its
effluent is cooled to 65 oF and fed to a separator (flash). Assuming that all of the units operated at
atmospheric pressure, determine the species flow rates in every stream.

Property Package:

Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:
Compositions:

Energy Streams:

Unit Ops:

Result:

The species flowrate in every streams are as follows:

In feed: In R-feed:

In R-Btm In R-prod:
S-feed: Vapor:

Liquid:

OBJECT:12
Problem Statement:

Inspection of the calculation results of object 11 shows that the cooling duty is comparable to the
heating duty, suggesting that the utility load can be reduced by preheating the feed stream with hot
reactor product. Modify the process by adding a heat exchanger.

Property Package:

Peng-Robinson

Schematic Diagram:
Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:
Unit Ops:

Result:

The heat of the reactor product is utilized to heat the feed using a shell and tube heat exchanger which
can be observed from the schematic diagram.

OBJECT:13
Problem Statement:

We have a stream containing 15% ethane, 20% propane, 60% i-butane and 5% n-butane at 50°F and
atmospheric pressure, and a flow rate of 100lbmole/hr. This stream is to be compressed to 50 psia and
then cooled to 32°F. The resulting vapor and liquid are to be separated as the two product streams.
Neglect the pressure drop inside the condenser.

Property Package:

Peng-Robinson

Schematic Diagram:
Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:

Unit Ops:
Result:

Molar compositions of product streams are as follows:

Flowrate of product streams are as follows:

Case Study:

Create a case study to see the effect of changing temperature of the cooler out stream on the molar
flow of the liquid product stream.

Results of Case Study:

Plots:
OBJECT:14
Problem Statement:

The feed stream enters an inlet separator, which removes the free liquids. Overhead gas from the
Separator is fed to the Chiller where it is cooled to -20oC, which will be modeled simply as a Cooler
(Pressure Drop=35 kPa). The cold stream is then separated in a low-temperature separator (LTS).
Overhead gas from the LTS is fed to the heater (Pressure drop=5kPa) where it is heated to 10oC to meet
Sales Gas Specifications.

- Calculate the duty rejected from the chiller.

- Calculate the duty Absorbed inside the Heater.

Property Package:

Peng-Robinson
Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:
Unit Ops:

Results:

Duty rejected from the Chiller= 4.195e+006 KJ/hr.

Duty absorbed by the Heater= 2.285e+006 KJ/hr.

Case Study:

The design is modified to reduce the operating cost represented in Chiller & Heater duties, by adding a
Heat Exchanger before the Chiller where the overhead from the inlet separator is pre-cooled by already
refrigerated gas from LTS.

Heat Exchanger Design Specifications:

- Sales Gas Temperature= 10oC

- Tube side Pressure drop=35kPa

- Shell side Pressure drop= 5kPa

- No heat losses inside the heat exchanger.

- Choose Weighted Exchanger as Model

Modified Schematic Diagram:

Results:

Overall Heat Transfer Coefficient of Heat Exchanger= 2.780e+005

Heat rejected from Chiller= 1.88e+006 KJ/hr

OBJECT:15
Problem Statement:

A Refrigeration cycle utilizes propane as the working fluid is used in the liquefaction of the NG. Propane
is fed to an evaporator (Heater) the pressure drop=5 kPa, where it absorbed 1.50e+6 kJ/hr from the NG
and leaves at the dew point (Vapor Fraction=1.0) at T= -15oC. The output of the evaporator is then
compressed adiabatically with efficiency of 75%, and then it's condensed to reject heat. Inside the
Condenser there is a pressure drop of 30 kPa, and leaves as saturated liquid at 45oC. Finally, the
propane passes through a valve to return the pressure of the Evaporator.

Property Package:

Peng-Robinson

Schematic Diagram:

Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:

Unit Ops:

Result:

Pressure of the evaporator fed = 296.1 kPa

Valve pressure drop= 1243.34 kPa

Temperature of the valve outlet= -14.51oC

Compressor duty= 4.637e+005 KJ/hr

Condenser duty = 1.489e+006KJ/hr

Case Study:

To calculate C.O.P (Coefficient of Performance) using a spreadsheet:

COP= Evaporator Duty/ Compressor Power

Result:

OBJECT: 16
Problem Statement:

We need to separate a mixture of five paraffins into light and heavy fraction by using a distillation
column with 12 trays, a full reflux condenser, and a Kettle reboiler. The feed stream (1000 lbmol/hr)
consists of 3% (mole %) ethane, 20% propane, 37% n-butane, 35% n-pentane and 5% n-hexane at 225 oF
and 250 psia, which enters the column on the sixth tray, counting from the top. The condenser and
reboiler pressures are 248 and 252 psia, respectively. The preliminary design specifications require a
reflux ratio of 6.06 and a vapor overhead product of 226 lbmol/hr.

Property Package:

SRK.

Schematic Diagram:
Inlet and Outlet Streams:

Conditions:

Compositions:

Energy Streams:

Unit Ops:

Case Study:

Subsequently, the design is modified to ensure propane overhead flow of 191 lbmol/hr and n-butane
bottom flow of 365 lbmol/hr.

Calculate: The Condenser, the Reboiler Temperatures & the Reflux Ratio after modification
Result:

After modification the results are as followed:

Condenser Temp= 114.9oC.

Reboiler Temp= 263.8oC.

Reflux Ratio= 8.587.