Essay

1. What are the three principal types of flowsheets used in the chemical process industries?
Discuss briefly their characteristics.
5. Would you expect the process design to include more PFDs or P&IDs? Why?
6. Discuss briefly the cash flow for industrial operations. Illustrate their interrelationship with
each other.
PFD Design and Control
4. For the process described in problem 2, the flow of bottom product sent to Unit 400 is
controlled by a pneumatic valve that receives a signal from a liquid level indicator that senses the
level of accumulated liquid in the bottom of the column. Add this control loop to the PFD
developed in Problem 2.
PROBLEM SOLVING
3. Given the following streams:
Temperature, °C Cp ΔH
Stream
Inlet Target MW/K MW
1 190 50 0.25 35
2 190 50 0.35 49
3 40 140 0.3 -30
4 40 120 0.4 -32
5 40 140 0.1 -10
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ΔTmin = 20 K
a. Design a network which achieves maximum energy recovery.
b. It is required to raise low pressure saturated steam at 140 °C from boiler feed water supplied
at 30 °C. For the steam ΔHfg = 2100 kJ/kg and Cp = 4 kJ/kg∙K. Use the Grand Composite
Curve to determine the maximum flowrate of steam that can be generated from waste heat
from the above streams.
c. Design a network which produces the maximum amount of steam calculated in part (b).

4. The following data is taken from “Optimizing the Heat Recovery of Crude Units”, F. Huang
and R. Elshout, Chemical Engineering Progress:
Stream Temperature, °C Cp ΔH
 Inlet Target MW/K MW
Residue (1) 340 93 0.279 68.9
Gas Oil (2) 222 54 0.113 19.0
Kerosene PA
195 164 0.567 17.6
(3)
O/H Reflux (4) 147 102 0.814 36.6
Crude Oil (5) 43 190 0.498 -73.2
190 361 0.564 -87.9
Running this data though the problem table data gave the following results:
ΔTmin, °C Qh, MW Qc, MW Pinch, °C
0 41.7 22.7 195
10 46.9 27.9 195/185
20 51.9 32.9 195/175
30 56.9 37.8 195/165
40 61.8 42.8 195/155
When ΔTmin = 20 °C, the following is based on a HEN design in the paper:

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a. Why does the above design not achieve the utilities target for ΔTmin = 20 °C?
b. Identify where heat is transferred across pinch. How much heat is so transferred? How does it
compare with (Qh)actual - (Qh)min.
c. Design a MER network (also with 9 heat exchangers) which achievers the utilities target.
d. Can you achieve the utilities target without stream splitting?

16. The purchased cost of equipment for a solid processing plant is 500,000. The plant is to be
constructed as an addition to an existing plant. Estimate the total capital investment and the fixed
capital investment for the plant. What percentage and amount of the fixed capital investment for
the plant. What percentage and amount of the fixed capital invest are due to cost for engineering
and supervision, and what percentage and amount for the contractors fee?
20. A chemical processing unit has a capacity for producing 1 million kg of a product per year.
After the unit has been put into operation, it is found that only 500,000 kg of the product can be
sold per year. An analysis of the existing situation shows that all fixed and other invariant
charges, which must be paid whether or not the unit is operating, amount to 40 percent of the
total product cost when operating at full capacity. Raw material costs and other production cost
are directly proportional to