XAVIER UNIVERSITY – ATENEO DE CAGAYAN

COLLEGE OF ENGINEERING
CAGAYAN DE ORO CITY

Chemical Engineering Department

Equipment Design Report 1

GROUP NAME: Cascon 2

SUBMITTED BY: Libetario, Princess Gabrielle
CO-MEMBERS: Luyao, Ian Louie
Rico, Cyra Austin
Sialana, Shania Eve
DATE: 8 August 2020
COURSE & YEAR: BS Chemical Engineering - 5

Pumping and Piping Systems

Problem 12-3.

A condenser is to be supplied with 0.0095 m 3/s of cooling water at 25oC. What diameter of
schedule 40 pipe should be recommended for this application using the economic pipe
diameter?

Given:

Volumetric Flow Rate (V ) = 0.0095 m3/s

Temperature = 25oC
Schedule = 40

Required:

Optimum pipe diameter

Solution:

In order to calculate the diameter of the pipe, values such as density and viscosity should be
acquired from literature. From Table D-4, Timmerhaus:

kg
Density ( ρ ) at 25oC =997.053
m3
Viscosity ( μ) = 0.898 cp

Estimation of pipe diameter required:

From Table 12-3, Recommended economic velocities for sizing steel pipes for water at turbulent
flow the recommended velocity range is 1-3 m/s.

m
Typical velocity for liquids (υ ) = 2
s

m3
0.0095
V s
Area of Pipe (A) = = =4.75 x 10−3 m2
υ m
2
s

m❑=¿❑ ρA ¿

kg kg
m ❑=(997.053 )(4.75 x 1 0−3 m2 )=9.472
m 3
s

4 4
Diameter of Pipe (d) =
√ π √
A x = (4.75 x 1 0−3 )( )=0.078 m=78 mm
π

Pipe Diameter =78 mm

Pipe diameter formula (from Timmerhaus):
0.45
Eqn (12-15): d , optimum=0.363 mv ρ❑0.13

m 3 0.45 kg 0.13
d , optimum=0.363 (0.0095 ) (997.053 3 ) =0.1096 m=4.3140175∈¿
s m

m kg
.0 .1096(2 )(997 3 )
Dνρ s m
N ℜ= = =243,325.443, Turbulent Flow
μ kg
0.000898 2
m

Evaluating the schedule 40 steel dimensions using Table D-13, Timmerhaus. For a pipe
nominal size, 4in the inside diameter is 4.026 in, the 6in has 6.065, therefore we take the
nominal size as 4 in.

Using Nomograph:

Another way of solving the inside diameter of the pipe is using the nomograph. The basis of this
graph is the equation used earlier, Eqn (12-15). This can also be used to estimate the optimum
diameter of a steel pipe under normal process conditions.
d=0.1m
 m kg
0.1 m(2 )(997 , 053 3 )
Dνρ s m
N ℜ= = =222,060.8018, Turbulent Flow
μ kg
0.000898 2
m

Specifications Sheet:

Specification Sheet (Pipe)

Upstream U-101
Location
Downstream D-101
Fluid Use Cooling Water
Process Conditions
Fluid Water Flow Rate 9.5 L/s
Temperature 25℃ Specific Gravity 0.997
Flow Characteristic Turbulent Velocity 2m/s
Reynolds Number 243,325.44 Viscosity 0.898 cp
Pipe Specification
Material Steel OD, in. 4.50
Pipe roughness 4.6x10-4 ID, in 4.026
Flow Area Per Pipe,
Friction Factor 0.0047 12.7
in.2
Surface per linear ft,
Friction loss 0.040 J/kg⋅m 1.178
ft2, Outside
Nominal Pipe Size, Surface per linear ft,
4 1.055
in. ft2, Inside
Schedule No Weight Per Lin ft, lb
40 10.8
Steel
Diagram
3D Drawing:

Summary:

A 4in diameter of schedule 40 pipe is recommended for the application of a condenser to supply
0.0095 m3/s of cooling water at 25oC. This was calculated using the economic optimum pipe
diameter and using nomograph.
 Compression of Gases
Problem 12-8.

A reciprocating compressor has been selected to compress 0.085 m3/s of 25°C methane gas
from 100 to 6200 kPa. Assume that the heat capacity remains constant at 2433 J/(kg-K) over
the temperature range of compression and that the ratio of Cp/Cv remains constant at 1.31.How
many stages of compression should be used? What is the power requirement if the compressor
exhibits an efficiency of 80 percent? What is the exit temperature of the gas at the exit from the
first stage? If the temperature of the cooling water can only increase by 15°C, how much water
is required for the intercoolers and aftercooler to ensure that the compressed gas from each
stage after cooling is again returned to 25°C?

Given:

V = 0.085 m3/s
T = 25°C
P1 = 100 kPa
P2 = 6200 kPa
Cp = 2433 J/(kg-K)
Ratio = 1.31

Required:

Number of Stages
Power requirement at 80% efficiency
T at 1st stage exit
Mass flow rate at 15°C, returned to 25°C

Solution:

Number of Stages:

In order to calculate for the number of stages, it is necessary to review the following from the
Rules of Thumb:
 ● Compression should be about the same in each stage of a multi unit, ratio =
(pn/p1)1/n, with n stages.
● Efficiency of reciprocating compressors 80-85% at compression ratio of 3-6.

So, by trial and error using the formula ¿, the calculated stages are as follows:

For n=2:

¿, compression ratio is larger than the maximum ratio for a reciprocating

compressors with 80% efficiency

Using n=3:

¿, since it’s within the 3-6 compression ratio we can say that it is valid

Furthermore, when n=4:

¿, ratio is less than the minimum range for a reciprocating compressors with
80% efficiency

We can say that increasing the number of stages will lead to a lesser compression ratio which is
out of range in the 3-6 as mentioned in the Rules of Thumb. Therefore, the number of stages in
this problem is equal to 3, with a compression ratio of 3.957.

Number of Stages = 3

Power requirement at 80% efficiency:

The power requirement for a single-stage is obtained using Eqn (12-22b), justifying that the
power required for the compression is equal to the product of the adiabatic head and the mass
flow rate of gas handled.

−4 k
Eqn (12-22b) Pad =2.78 x 1 0 m v ,1 p1 ( )¿
k−1
T1 = 298.15 K
k = 1.31
P1 = 100 kPa
P2 = 6200 kPa
m=ρv=(0.657)(0.085)=0.055845kg /s
ρ=0.657 kg /m³

3600 1.31
Pad =2.78 x 1 0−4 ((0.085)( ))( 10000) ( )¿
h ❑ 1.31−1

Pad =17.2906 kW

Since the calculated value is for single-stage and in this problem there are 3 stages,
multiplying the calculated power requirements to 3 we get:
 Pad , 3=( 3)(17.2906)=51.87 kW

Outlet Temperature:

In order to calculate for the exit temperature of the gas at the exit from the first stage, from
Rules of Thumb we have, for an outlet temperature T2=T1(P2/P1)ɑ, ɑ=(k-1)/k.

where;

T1 = 298.15 K
k = 1.31
ɑ=0.2366
P2/P1 = 3.957

Calculating using the formula and values provided we get:

T 2=(298.15)¿

Mass flow rate:

To obtain how much water is required for the intercoolers and aftercooler to ensure that the
compressed gas from each stage after cooling is again returned to 25°C involves a heat
balance.
q=m C P ΔT

Where;
m=ρv=(0.657)(0.085)=0.055845 (methane gas)
C P =2.40741kJ /kg ⋅ K (from Figure D-3, Timmerhaus)
ΔT =412.87−298.15=114.72
q=m C P ΔT =(0.055845)( 2.4074)(114.72)=15.423 kJ /s

For three stages, we just simply multiply by 3, this total to 46.2694 kJ/s. Therefore, we can now
calculate the cooling water required.

q 46.2964
m= = =0.738 kg /s
C P ΔT 4.18(15)
Specifications Sheet:

Specification Sheet (Compressor, C-101)

Type Reciprocating Cooling Type Water
Stages 3 Efficiency 80%
Per Stage 3.957
Compression Ratio
Overall 62
Process Conditions
Fluid Methane Flow Rate 0.085 m/s
Inlet Temperature 25℃ Suction Pressure 100 kPa
Outlet Temperature 25℃ Discharge Pressure 6200 kPa
Specific Gravity, Inlet 0.5537 Brake Power 51.87 kW
Vapor Pressure, Inlet 62.12 MPa Heat Capacity 2.433 kJ/kg K
Viscosity 0.01107 cp
Cooling Data
Cooling Water Flow
Number of Coolers 3 0.738 kg/s
Rate
Inlet Temperature 139.72℃ Outlet Temperature 25℃
Heat Removal Rate 46.2694 kJ/s
Cooling Data

3D Drawing:

Single stage (grab from Jeff Larson)

Summary:

A multistage reciprocating compressor with 3 stages has been selected to compress 0.085
m3/s of 25°C methane gas from 100 to 6200 kPa. For an 80% efficiency, the power requirement
is 51.87 kW. To reduce the outlet temperature from 139.72°C returned to 25°C a two
intercoolers and an aftercooler that removes a total of 46.2694 kJ/s is needed. The total amount
of cooling water that is required for the entire compression process is 0.738 kg/s.

Agitation and Mixing

End of PPT

In a batch process, there is a need to prepare 40% NaOH solution by mixing 50% NaOH stock
solution with water. If the process requirement is 500 kg of the 40% NaOH solution per batch,
design and specify a mixing tank for the process. Include in the specification the motor drive for
mixing. Specify all assumptions/heuristics used in the design calculations.

Given:

Feed 1:
 = 50% NaOH (400 kg)
= 200 kg NaOH
= 200 kg Water
Feed 2:
= 100 kg Water
Product:
= 40% NaOH (500 kg)
= 100 kg NaOH
= 200 kg Water
Required:

Design and specify a mixing tank

Specification of the motor drive mixing
Solution:
Material Balance:

The above diagram shows the material balance of the process.

Energy Balance:

To calculate the energy balance, the following values are obtained from Perry’s:
Heat of Dilution = 42 550 kJ/kmol (at infinite dilution)
Molar weight of NaOH = 40 kg/kmol
Heat Capacity of 50% NaOH = 3.29 kJ/kg-K
Heat Capacity of 40% NaOH = 3.31 kJ/kg-K
Heat Capacity of water = 4.18 kJ/kg-K

It is also important to state the assumptions made before calculating. Assumptions are:
Entering species are at normal temperature, T = 25℃
Enthalpy balance is conducted at T = 0℃ as reference temperature
No heat loss to the surrounding
Neglect potential and kinetic energy
All enthalpy is retained by the final product
Since, there is a generation of heat as sodium hydroxide interacts with water molecules. We
calculate for the heat generated by NaOH.
Total heat generated = (Heat of Dilution)(Amount of NaOH)
Amount of NaOH = (200 kg)/(40 kg/kmol) = 50 kmol
Total generated = (42 550 kJ/kmol)(50 kmol) = 2 127 500 kJ
Enthalpy of entering species (HF)= HNaOH + HH2O = mcpTNaOH + mcpTH2O
HF = (400)(3.29)(25) + (100)(4.18)(25) = 43 350 kJ
Enthalpy of leaving species (HP) = 43 350 kJ + 2 127 500 kJ = 2 170 850 kJ
Final Temperature at complete dilution, TF = H/cpm
 TF = 2 170 850 kJ/ (3.31)(500) = 1 311.6918 ℃

From the calculations above, we can see a large increase in temperature. Since it is
undesirable, due to its potential hazards it is necessary to apply cooling water to control the
temperature. We need to calculate for the cooling having the maximum design temperature at
50℃.
Thus,
Retained H = (500)(3.13)(50) = 82 750 kJ
Cooling duty = 2 170 850 kJ - 82 750 kJ = 2 088 100 kJ
For a cooling water supply, we assume that the allowable increase in temperature is 25℃
Thus,
Mass of cooling water = (2 088 100 kJ) / (4.18)(25) = 19 981.82 kg

The cooling water required on a site generally uses natural and forced-draft cooling towers.

Designing:

The most important design variables for agitators and mixers are power consumption and
residence time which is the time required to accomplish the mixing process.

Sizing:

In order to calculate the tank size, it is necessary to convert the mass of materials into volume.
Since, it is expected that the mixture will go through changes in volume as the concentration
changes. To calculate for the volume we need the density of 40% NaOH at 40℃,which is equal
to 1 416.4 kg/m, from Perry’s.
Thus,
VP = m/𝜌 = 500/1 416.4 = 0.353 m3
However, for an agitated vessel a requirement of 80% is needed for the working volume
(Geankoplis, 2003).
Thus,
VActual = 0.353 m3 / 0.80 = 0.4413 m3

We can now then calculate the dimensions of the vessel.

D2 H D2 D D3
V =π =π =π
4 4 4
3
D
0.353 m3=π
4
D=0.766 m
D2 H
V =π
4
0.766 2 H
0.4413 m3=π
4
 H=0.9575m

From the heuristics, the proportions of a stirred tank relative to the diameter D: liquid level = D;
turbine impeller diameter = D/3; impeller level above bottom = D/3; impeller blade width = D/15;
four vertical baffles with width = D/10. We can calculate for the other dimensions and
components of the vessel.
Liquid level = D = 0.766 m
Impeller diameter = D/6 = 0.128 m
Impeller level above bottom = D/3 = 0.255 m
Impeller blade width (Geankoplis) = W/D = 1/5 = 0.026 m
Four vertical baffles with width = D/10 = 0.077 m
Length of the blades = L/D = ¼; L = 0.0319 m

From Sinnot, for a particular application the most suitable agitator will depend on the type of
mixing required, the capacity of the vessel, and the viscosity. From heuristics, propellers are
made a maximum of 18 in or 0.46 m and turbines to 9 ft or 2.74 m.

The selection chart given in Figure 10.57, from Sinnot (2005), is used to make a preliminary
selection of the agitator type, based on the liquid viscosity and tank volume. The viscosity of
40% NaOH at 40℃ is obtained from Covestro’s Caustic Soda Solution Data which is 12.0 cp or
0.012 N-s/m2. Plotting these values to Figure 10.57 below, we get a value for recommended
rotational speed of 1 750 rpm or 29.17 rps.
Power Consumption:

In order to calculate the power consumption, we need to calculate the impeller Reynold’s
number and use Figure 10.58 from Sinnot or solving using the generalised dimensionless
equation:
D 2 Nρ
N ℜ= =¿ ¿Turbulent
μ

P
N P=¿power number =
D N3 ρ
5

P
0.82=
(0.128)5 ¿ ¿
Power density = 0.9777/0.353 = 2.7677 kW/m3

From the calculated values we can see that the agitator speed from Figure 10.57 is the
maximum speed, rather than the optimum speed. We can use the equation below to calculate
for the power number. However, resources are limited and we do not have access to Rashtons
constants. Another way to calculate the desired power rate from the classification by Sinnot
shown in Table 10.14 is to reduce the agitator speed.

Eqn (10.11) from Sinnot:

N P=K Re b F r c
P
Where N P=¿power number =
D N3 ρ
5
 2
R E=¿ Reynolds number = D Nρ
μ
2
DN
Fr = Froude number =
g
P = shaft power, W
K = constant
𝜌 = density, kg/m3
Μ = viscosity, N-s/m2
N = agitator speed, rps
D = agitator diameter, m
g = gravitational acceleration, 9.81 m/s^2

Based on the table above we can decide for the application of the agitator. Since the calculated
power is greater than 2, and we know that the mixture is not slurry so we reduce the agitator
speed.
Thus, we have the adjusted values,
Rational speed = 23
Reynolds number = 44 247.9149
Power number = 0.82
Power rating = 0.479 kW
Power density = 1.36 kW/m3
Driver:

Table 4.1. (from Couper), identifies the kinds of motors that are being used successfully with
particular kinds of chemical process equipment with the help from electrical experts.
We can see for an agitator, for an AC motor type there are three choices which are a squirrel-
cage, constant speed at a) normal torque, normal starting current, b) normal torque, low starting
current, and a squirrel-cage, variable speed at constant torque. The torque-speed characteristic
of the motor must be matched against that of the equipment, for instance, the agitator. It was
also shown in Couper that motors in the range of 1-100 hP need to be provided with 220, 440,
and 550 V. Also, motors providing 10 kW and lower are usually have an efficiency of 85%.
Since the current agitator has a 0.479 kW power requirement, and taking efficiency into account
we have:
Power requirement = 0.479 kW, Efficiency = 0.85
Actual power required = 0.479/0.85 = 0.56 kW
Mixing Time:

A correlation of mixing time for a turbine agitator is shown below

Mixing factor is equal to 4, calculating for the mixing time using (fTH0.5D1.5 )/(NDa2)0.67g0.167 Da0.5
we get the value of 16 seconds.

Specifications Sheet:

Specification Sheet (Mixing Tank, M-101)

Operating Data
Type Top-loading Mounting Orientation Vertical
Vessel Volume 0.4413 m3 Type of Mixing Liquid-liquid mixing
3
Charge Volume 0.353 m Period of Mixing 16s
Cycle Batch
Vessel Data
Vessel Height 0.9575 m Working Pressure 1 atm
Working
Feed Height 0.9575 m 50℃
Temperature
Impeller Diameter 0.128 m Capacity 500 kg or 0.353 m3
Process Conditions
Liquid Liquid Solid or Gas
Material Information
50% NaOH Water -
Quantity 400 kg 100 kg -
Temperature 25℃ 25℃ -
Specific Gravity 1.522 0.997 -
Viscosity 75 cP 089 cP -
Mixture Characteristics Concentration 40% NaOH
Normal Temperature 25℃ Specific Gravity 1.4164 kg/L
Maximum
50℃ Viscosity 0.12
Temperature
Mechanical Design Data
Impeller Type Rushton Impeller Size 0.128 m
Shaft Length 0.690 m Speed 23 rps
Baffles 4 Width 0.026 m
Driver Data
Driver Type Squirrel-cage, constant speed at normal torque, normal starting
Current AC Voltage 220V
Efficiency 0.85 Power Rating 0.479 kW
Material of Construction
Vessel Carbon steel Impeller 316 Stainless Steel
Diagram
3D Drawing:

Summary:

For the batch process of the preparation of 40% NaOH solution by mixing 50% NaOH stock
solution with water, having a 500 kg of the 40% NaOH solution per batch the agitator design is
as follows has a vessel diameter of 0.766 m with a height of 0.9575 m. The impeller diameter is
0.128 m with a rotational speed of 23 rps. The power requirement and power density is 0.479
kW and 1.36 kW/m3, respectively. The driver used is an AC, squirrel-cage, constant speed at
normal torque, normal starting current at 220V. For the given design the time required to
accomplish the mixing process or the residence time is 16 s.
Thin-walled Vessels Under Internal Pressure
A horizontal, cylindrical, tank, with hemispherical ends, is used to store liquid chlorine at 10 bar.
The vessel is 4 m internal diameter and 20 m long. Estimate the minimum wall thickness
required to resist this pressure, for the cylindrical section and the heads. Take the design
pressure as 12 bar and the allowable design stress for the material as 110 MN/m2.

Given:
P = 10 bar
Di = 4m
Hv = 20m
Pi = 12 bar
f = 110 MN/m2

Required:
e (cylindrical section and the heads)

Solution:

Cylindrical Section:
Pi D i
Eqn 13.39 (Sinnot) e= =¿¿
2 f −P i
Heads:
Pi D i
Eqn 13.40 (Sinnot) e= =¿¿
4 f −P i
Pi D i
Eqn 13.41 (Sinnot) e= =¿ ¿
4 f −1.2 Pi

Specification Sheet:
Specification Sheet (Vessel, V-102)
Operating Data
Fluid Liquid Chlorine Mounting Orientation Horizontal
Shell Type Cylindrical Working Pressure 12 bar
Head Type Hemispherical Design Stress 110 MN/m2
Vessel Data
Vessel Height 20 m Shell Thickness 230.77 mm
Inside Diameter 4m Head Thickness 112.78 mm
Outside Diameter 4.23 m Capacity
Material of Construction
Vessel Fusion welded steel
Diagram

3D Drawing:
Summary:

Jacketed Vessel
A jacketed vessel is to be used as a reactor. The vessel has an internal diameter of 2 m and is
fitted with a jacket over a straight section 1.5 m long. Both the vessel and jacket walls are 25
mm thick. The spacing between the vessel and jacket is 75 mm.
The vessel and jacket are made of carbon steel. The vessel will operate at atmospheric
pressure and the jacket will be supplied with steam at 20 bar. Check if the thickness of the
vessel and jacket is adequate for this duty.
Take the allowable design stress as 100 N/mm2 and the value of Young’s modulus at the
operating temperature as 180,000 N/mm2.
Given:
P = 10 bar
Di = 2m
Hv = 1.5m
e = 25mm
Space = 75mm
PV = 1 atm ≈ 1 bar
PJ = 20 bar
f = 100 N/mm2
E= 180,000 N/mm2
v = 0.3

Required:
Check if the thickness of the vessel and jacket is adequate for this duty.

Solution:

P = 20 barg - 1 barg = 19 barg

Do = Di + e = 2m + 2(25x10-3)m = 2.05m
Dj = Do + space = 2.05m + 2(75x10-3)m = 2.20m
Pi D i
Eqn 13.39 (Sinnot) e= =¿¿
2 f −P i
Eqn 13.51 (Sinnot) Pc =2.2 E ¿

Specification Sheet:
Specification Sheet (Jacketed Vessel, V-101)
Operating Data
Fluid Shell Type Cylindrical
Mounting Orientation Vertical Bottom Type Ellipsodial
Vessel Data
Vessel Height 1.5 m Working Pressure 19 bar
Shell thickness 25 mm Design Stress 180,000 N/mm2
Vesse Diameter 2m Young’s Modulus 100 N/mm2
Jacket Thickness 25 mm Space 75 mm
Heat Specification
Jacket Type Heating Heating Medium Steam
Material of Construction
Vessel Carbon steel
Diagram
3D Drawing (vessel and jacket only):
Summary:

Liquid Storage Tanks

A storage tank for concentrated nitric acid will be constructed from aluminium to resist corrosion.
The tank is to have an inside diameter of 6 m and a height of 17 m. The maximum liquid level in
the tank will be at 16 m. Estimate the plate thickness required at the base of the tank. Take the
allowable design stress for aluminium as 90 N/mm2.

Given:
Di = 6m
Hv = 17m
HL = 16m
ft = 90 N/mm2

Required:
es

Solution:
ρ L H L g D t ( ρ¿¿ L)(16 m)(9.81m/ s2 ) (6 m)
Eqn 13.130 (Sinnot) e s= = ¿
2 f t J 1 03 2(90 MN /m❑2 )(J ) 1 03
𝜌L = 1520 kg/m3 (From PubChem)
J = 0.7 (From Table 13.3, Sinnot)
(1520 kg/m 3)(16 m)(9.81 m/s 2) (6 m)
e s= =0.01136 m
2( 90 x 1 03 N /m2 )(0.7) 1 03

Specification Sheet:
 Specification Sheet (Vessel, V-102)
Operating Data
Concentrated Nitric
Fluid Mounting Orientation Vertical
Acid
Shell Type Cylindrical Design Stress 90 N/mm2
Head Type
Vessel Data
Vessel Height 17 m Thickness 11.36 mm
Liquid Height 16 m Capacity
Inside Diameter 6m
Material of Construction
Vessel Fusion welded steel
Diagram

3D Drawing:
Summary:

Plug-flow reactor
Normal butane 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 2010 selling price of n-butane was $0.44/kg, while the
trading price of isobutane was $0.68/kg. This elementary reversible 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. The feed enters at 330 K.
Calculate the PFR volume necessary to process 100,000 gal/day (163 kmol/h) at 70%
conversion of a mixture 90 mol % n-butane and 10 mol % i-pentane, which is considered an
inert.

Additional information:
Δ H O RX =−6900 J /mol n−butane
 Activation energy = 65.7 kJ/mol
KC = 3.03 at 60℃
CAO = 9.3 mol/dm3 = 9.3 kmol/m3
Butane
CP n-B = 141 J/mol•K
CP i-B = 141 J/mol•K = 141 kJ/kmol•K
i-Pentane
CP i-P = 161 J/mol•K
Solution
n-C4H10 ⇄ I-C4H10
A ⇄B

Given:
Selling price, n-butane = $0.44/kg
Selling price, isobutane = $0.68/kg
K = 31.1 h-1
T = 360 K
TF = 330 K
Feed = 100,000 gal/day (163 kmol/h)
Conversion = 70%
xn-butane = 90 mol%
xi-pentane = 10 mol %

Required:
VPFR

Solution:
Following the PFR algorithm (Fogler)
A) Mole Balance:
dX
F AO= =−r A
dV
B) Rate Law:
CB
−r A =k (C A − )
KC
where,
Eqn 11-3.3 k =k (T 1 )e ¿¿
Eqn 11-3.4 k =k (T 2 )e ¿¿
C) Stoichiometry:
CA = CAO(1-x)
CB = CAOX
D) Combining mole balance, rate law, and stoichiometry:
1
−r A =k C AO (1−(1+ )X )
KC
E) Energy balance:
Eqn 11-27 (Fogler)
Q−W s−F AO Σ Θ i C Pi(T −T o )−F AO X (Δ H o RX❑(T R )+ Δ C P (T −T R ))=0
For this problem:
Adiabatic: Q = 0
No work: W s= 0
ΔC P =C PB−C PA =141−141=0
Eqn 11-27 will become:
−F AO Σ Θ i C Pi (T −T o)−F AO X ( Δ H oRX ❑ (T R ))=0
ΣΘ i C Pi (T −T o)− X ( Δ H oRX❑ (T R))=0
ΣΘ i C Pi T =Σ Θ i C Pi T o + X (−Δ H oRX❑(T R))
Σ Θ i C Pi T o+ X (− Δ H oRX❑ (T R )) X (−Δ H oRX❑ )
T= =T o +
Σ Θ i C Pi Σ Θ i C Pi
X (−Δ H oRX❑ )
T =T o +
Σ Θ i C Pi
 F) Parameter evaluation:
FAO = 0.9 FTO = 0.9(163 kmol/h) = 146.7 kmol/h
0.1
ΣΘ i C Pi=C PA +Θ 1 C P 1=(141 J /mol • K )+( )(161 J / mol • K)
0.9
ΣΘ i C Pi=158.89 141 J /mol • K
X (−(−69000 J /mol))
T =330 K + =330 K + 43.4266 X
158.89 J /mol • K
Substitute to Eqn 11-3.3
65700 J / mol 1 1
Eqn 11-3.3 (Fogler) k =31.1 e( 8.314 J /mol • K ( 360 K − T ))
T −360 K
(7902.3334( ))
360 K T (K )
k =31.1 e
−6900 J /mol 1 1
( ( − ))
Eqn 11-3.4 k =3.03 e 8.314 J /mol • K 333.15 K T

T −33.3 .15 K
(−829.9254 ( ))
333.15 K T (K )
k =3.03 e
G) Equilibrium conversion:
At equilibrium, - rA = 0
1
−r A =k C AO (1−(1+ )X )
KC
1
0=k C AO (1−(1+ )X)
KC
X
X =k C AO (1−X + )
KC
X
X =k C AO −k C AO−X +
KC
X
X =−X +
KC
KC
X=
1+ K C
H) Calculation for x = 0 to x = 0.70

X T (K) k (h-1) Kc Xe -rA (kmol/m3 h) FAO/-rA (m3)

0 330 4.227745745 3.102914228 0.7562708006 39.31803543 3.731112157
0.1 334.34266 5.770168135 3.003193599 0.7501994407 46.50945733 3.154197198
0.2 338.68532 7.812752458 2.909113653 0.7441875349 53.13163874 2.761066729
0.3 343.02798 10.49753208 2.820252747 0.7382372146 57.95400838 2.531317576
0.4 347.37064 14.00112357 2.73622767 0.7323503576 59.0912381 2.482601562
0.5 351.7133 18.5417153 2.656689563 0.7265286039 53.76543797 2.728518646
0.6 356.05596 24.38716309 2.581320316 0.7207733708 38.00289535 3.860232192
0.7 360.39862 31.86431432 2.509829405 0.7150858676 6.25172148 23.46553673
 V=2.77m3

Specification Sheet:
Specification Sheet (Reactor, R-101)
Operating Data
Type Plug-flow Reactor Mounting Orientation Vertical
n-butane, i-
Fluid Temperature Liquid-liquid mixing
pentane
Flowrate 0.353 m3 Reaction Isomerization
Vessel Data
Vessel Height 0.9575 m Packing Height 1 atm
Feed Height 0.9575 m Volume 50℃
Material of Construction
Vessel Carbon steel Packings
Diagram

3D Drawing:
Summary:

Heat Exchanger
A heat exchanger with two tube passes has been recommended for cooling distilled water from
33.9 to 29.4 °C. The proposed unit contains 160 tubes, each with a 0.0191-m outside diameter,
18 BWG, and 4.876-m in length. The tubes are laid out on a 0.0238-m triangular pitch within a
0.387-m inside diameter shell. Twenty-five percent cut segmental baffles, spaced 0.3 m apart,
are located within the shell. Cooling water at a temperature of 24°C and a flow rate of 2.0 m/s
will be used in the tubes to provide the cooling. Under these conditions, the fouling coefficients
for the distilled water and the cooling water can be assumed to be 11,360 and 5680 W/m2 -K,
respectively. The pressure drop on either the tube side or the shell side may not exceed 69 kPa.
Would the recommended design be adequate for cooling 22 kg/s of distilled water?

Solids Transport and Processing

An available crusher has been accepting hard rock with a volume-surface mean diameter of
0.069 m and providing a product with a volume-surface mean diameter of 5 x 10-3 m. The
power required for crushing 10,000 kg/h of this specific rock is 6.35 kW. What would be the
power consumption if the capacity were reduced to 9000 kg/h with the same feed characteristics
but with a reduction in the volume-surface mean diameter of the product to 4 x 10-3 m? Assume
that the mechanical efficiency of the unit will remain unchanged.

Multi-Comp Distillation
In a depropanizer described by King, a six-component feed at 96 °C and 2170 kPa has the
following composition: Note: K is a way to factor-in non-idealities of the mixture The feed is to be
separated in a sieve tray distillation column with a recovery of 98.4 percent of the propane in the
distillate product and 98.2 percent of the n-butane in the bottom product. The feed quality is 66
percent vapor. The column is equipped with a partial condenser. What are the minimum number
of stages and minimum reflux required for the separation? If a reflux ratio of 1.5 is selected, how
many theoretical stages are required, and where is the feed location?

Drying
A counterflow tunnel dryer is to be used to provide 227 kg/h product with a 1 percent moisture
content. The wet feed entering the dryer at 150C contains 1.5 kg of water/kg of dry product. The
dry bulk density is 560 kg/m3. The specific heat of the dry material is 1.25 kJ/kg-K. Tests show
that the critical moisture content of the material is about 0.4 kg of water/kg of dry product. The
inlet air to the dryer has a temperature of 149 °C, and the dried product leaves the dryer at
1430C. Since fresh air will be combined with recirculated air, the entering air will enter with a
moisture content of 0.03 kg of water/kg dry air. The air will leave the dryer at 60oC. The
maximum mass velocity of air that can be used with the solids being dried is 2.71 kg/s-m2.
Estimate the number of transfer units that will be required for the constant-rate section and the
falling-rate section of the dryer. What is the length of the dryer if the length of a transfer unit, in
meters, under these conditions is obtained from the empirical relation: Length of transfer unit =
12.11ttsG0.2 where tts is the spacing between drying trays (assumed in this case to be 0.0381
m) and G the mass velocity of the air in kg/s-m2 .