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EH/JAN 2013/CHE604

UNIVERSITI TEKNOLOGI MARA FINAL EXAMINATION

COURSE COURSE CODE EXAMINATION TIME

PLANT DESIGN AND ECONOMICS CHE604 JANUARY 2013 3 HOURS

INSTRUCTIONS TO CANDIDATES 1. 2. 3. This question paper consists of FIVE (5) questions. Answer ALL the questions only in the Answer Booklet. Start each answer on a new page. Do not bring any material into the examination room unless permission is given by the invigilator. Please check to make sure that this examination pack consists of: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) the Question Paper a one - page Appendix 1 a one - page Appendix 2 a one - page Appendix 3 a one - page Appendix 4 a three - page Appendix 5 a one - page Appendix 6 a one - page Appendix 7 a one - page Appendix 8 a one - page Appendix 9 a o n e - p a g e Appendix 10 an Answer Booklet - provided by the Faculty

4.

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of 5 printed pages
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CONFIDENTIAL QUESTION 1 (P01.P02, C01.C1.C4)

EH/JAN 2013/CHE604

a) The process flow diagram (PFD) contains the bulk of the chemical engineering data necessary for the design of a chemical process. For all of these diagrams, there is no universally accepted standard even though they convey very similar information. Describe the information that should be included in a typical commercial PFD (8 marks) b) A pipeline connecting a separator and a tank contain six standard radius elbow, a globe valve that is half open and a gate valve that is fully open. The line is made of commercial steel pipe with 30mm internal diameter and 130 m length. The viscosity of the fluid is 0.62 mNM"2 and density is 874 kg/m3. The steady state flow rate of the fluid in the pipeline is 4000 kg/h. i) Calculate the miscellaneous losses of the pipeline (9 marks) ii) Using the equivalent pipe diameters method, calculate the total pressure drop due to friction during the steady state condition (3 marks)

QUESTION 2 (P06, C 0 1 . C 0 2 , C3.C4)

A distillation column is to be designed to separate the chemical mixture, whose molar composition and relative volatilities are given in Table 1 below. The feed is at its boiling point. Propane, C3 and iso-pentane, i-C5 are identified as the light and heavy key components in the mixture. Table 1 Molar composition and relative volatilities of the chemical mixture Feed (moles) Propane Iso-butane N-butane Iso-pentane N-pentane 15 5 20 25 35 Distillate (moles) 15 5 1 24 0 Bottoms (moles) 0 0 19 1 35 Relative volatility 2.6 5 1 2 0.85

a) Determine the minimum number of stages required for the separation using Fenske equation. (3 marks) b) Evaluate minimum reflux ratio required using Underwood equation. (10 marks)
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EH/JAN 2013/CHE604

c) If the reflux ratio used is 4, then determine the number of stages by using Erbar-Maddox correlation. (3 marks) d) Using Kirkbride equation, determine the feed point location. (4 marks)

QUESTION 3 (P05, P06, C03, C5)

Perform a Problem-Table analysis to estimate pinch temperature and synthesize a heat exchanger network (HEN) for the Reactor-Separator system shown in Figure 1 such that the resulting heat exchanger network requires minimum hot and cold utilities. Assume the minimum approach temperature is 20C. The units for the CP values are in SI.

-HH Reactor feed

20C

CP = 50

160C

H)n
I"* % CP=40

Reactor

lSCC^-^ <4> Overhead product

120C Reactor effluent

<3)-J
CP = 55

280C

Bottoms product

Figure 1 Reactor-Separator system

(20 marks)

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EH/JAN 2013/CHE604

QUESTION 4 (P01.P05, P06, C01.C4) a) Determine the bare module cost for a long tube evaporator with the following operating conditions for the year 2012. Maximum operating pressure (tube side) = 40 barg Maximum operating pressure (shell side) = 5 barg Material of construction = stainless steel Heat exchange area = 200 m2 (15 marks) b) Explain the difference between direct costs, fixed costs and general expenses. Give one example of each. (5 marks) QUESTION 5 (P01.P02, C04, C4, C6)

a) The annual variable production costs of a vinyl chloride plant is RM980,000. This plant currently operates at 85% of full capacity. On top of that, the sum of annual fixed charges, overhead costs and general expenses is RM700,000 and considered not to change with the production rate. Total annual sales of the plant are RM1.96 million and the product sell for RM14,000 per tonne. i) Calculate the break-even point (8 marks) ii) Determine the gross annual profit with depreciation (2 marks) iii) Determine the net annual profit at 100% capacity if the income tax rate is 25% of gross profit. (2 marks) b) A consultant company just finished with few alternative designs of processes to produce formaldehyde from methanol. Cost data for these alternatives are shown in Table 2. For all parts of this problem, assume that the required before-tax return on investment is 15% per annum and the equipment life is considered to be 12 years. i) As the person-in-charge of doing the evaluation, do you recommend the construction of this plant using the base case design? (4 marks)

ii) There are two (2) alternative processes that require more expensive equipments, as indicated in Table 2. Recommend whether these two (2) alternatives profitable or not by using incremental analysis. (4 marks)
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5 Table 2 Details on projects considered

EH/JAN 2013/CHE604

Base Case Design (USD 106/year) Capital investment Additional investment Annual product revenue Annual raw material costs All other annual operating costs 11.9
-

Project B (USD 106/year)

-

Project C (USD 106/year)

-

1.02 11.1 3.16 0.206

0.5 11.1 3.16 0.258

11.1 3.16 0.299

END OF QUESTION PAPER

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APPENDIX 1

EH/JAN 2013/CHE604

TABLE 1.0 UNIT CONVERSION TABLE

Quantity ' Mass Length

Equivalent Values t k g =* lOOOg = 0.QQ1 metric ton 22046215^= 35;27392oz llbfa = 16 pz .*=. 5 X l&f4. ton = 453j593ig = 0.453593 kg l m = 100 cm: 1000mm'== 106microns (fun) #= 101angstroms (A) = 3937 in. = 3.2808 ft - 1.0936 yd: = O.0O06214mile 1ft = l 2 l m = l / 3 y d = 0304801 = 3048011 l m 3 = 1000 L = M^cm 3 = 10 6 mL = 35.3145 ft3 = 220.83 imperial gaflons= 264.17 gal = 1056.68 qt 1 ft3 - 1728 in.3 = 7.4805 gal = 0.028317 m3 = 28317 L = 28,317cm3 I N = 1 kg-m/s2 = 10s dynes - 105g-cm/s2 = 0.22481 lbf 1 lb f = 32.174 Ibm-ft/s2 - 4A482.K = 4.4482 X W dynes 1 arm = 1.01325 X 105 N/m2 (Pa) = 101325 kPa = 1.01325 bar = 1M325X:10s dynes/cm2 - 760 mm Hg at 0C (torr) = = 10333 m H a O at 4C = 14696 Ibf/in^ (m) = 33.9 ft H 2 0 at 4C = 29.921in, Hg at 0C 1 J = lN-m = 107ergs = lQ7dyne'Cm 2.778 X 10~7kW-h = 023901 cal = 0.7376 ft4bf = 9.486 X10^ 4 Btu 1 W = 1 J/s = 0.23901 cal/s = 0.7376 ft-lbf/a = 9.486 X id* 4 Btu/s = 1.341 X 10~3 hp
' .

Volume

Force Pressure

Energy

Power

*=

c *

_.

_ /2.204621bm\

Example: The factor to convert grams to lbm is _ ^

\ lOUQ g

1
y

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APPENDIX 2

EH/JAN 2013/CHE604

Table 1.1 Pipe roughness

Material Drawn tubing Commercial steel pipe Cast iron pipe Concrete pipe

Absolute roughness, mm 0,0015 0.046 0.26 0.3 to 3.0

Table 1.2 Pressure losses in pipe fittings and valves (for turbulent flow)

Fitting or valve 45 standard elbow 45 long radius elbow 90 standard radius elbow 90* standard long elbow 90" square elbow Tee-entry from leg Tee-entry into leg Union and coupling Sharp reduction (tank outlet) Sudden expansion (tank inlet) Gate valve fully open 1/4 open 1/2 open 3/4 open Globe valve, bevel seatfully open 1/2 open Plug valve - open

K, number of velocity heads 0.35 0.2 0.6-0.8 0.45 1.5 1.2 1.8 0.04 0,5 1.0 0.15 16 4 1 6 8.5 0.4

number of equivalent pipe diameters 15 10 30-40 23 75 60 90 2 25 50 7.5 800 200 40 300 450 IS

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9<W
III

p
;-, -.

o o z
T]

I
H <D O

III* "llll
0.0? AAA

r* m
\

~
--Z'l'.

XT" '..'.
:':'..::: :

mrrHT

t" 1

r i -t

'[' ^ 21

""-11

:..i

i.'l t II

o rn z

Uc ' Equation 5.J, A p , - of

i/2

'

\dl

004

-- - -

003

>

0.2
0.01S

_
0

0.01

tz

u
Z. 5M

s 8

-p pe roue hness /
e/dj |

00080 0.0075 0.0070 0.0065 00060 00055 00050 000S 0.0040

>
;

'O.M-5

Lanlina rf o w

^bs

B"l*r

m
4.J

1
A-1''
SSs;

===

il_

g
= = .

- 'ids'- 4 +H-1T -d02-|f -0 . 0 0 8 ' ff - i.m-7

TJ TJ

m z o
X w

0.0030' 0.00275 0.0025 0.00225 0.0020

\
i f -y

III 1 1

z:
*

>

5 b- ::= -"?-! 7" " " ""

(SuiQQthji8s

"Tnf
11 iM

- 0.000 m
- 0.0001 #

0.00125 0.001

n;
I

0.0005

. .J
4 5 6 7 8 01f)3

o o
m

10'

'10

7 8 9

n ' 11 0 "

3'

6 7 B 9 1n5

10

7 8 9<g6

7 8 9 .Q7

III

m i

Reynolds number Re = udp

> z
O W

k
Figure 5.7. Pipe friction versus Reynolds number and relative roughness

O X m

a> o

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APPENDIX 4

EH/JAN 2013/CHE604

too

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APPENDIX 5(1)

EH/JAN 2013/CHE604

USEFUL FORMULAE pM P = RT

is

m
if

AP,=8/
Divp

pu

Re

log Nmm
lOgOfLK

EfV* - ' a,- - 6 log AT,

+I

0.2061og

Class 1 estimate: +6% to -4% accurate 10. C = KA"

11.

Uv
V^W
(T \

12.
K*XJ

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APPENDIX 5(2)

EH/JAN 2013/CHE604

USEFUL FORMULAE
( A \ 0.6 ( T

C2 Cj

12. 13.
14. 15.

\Ab J

vAy

log10 FP=C,+ C2 log10 P + C3 (log10 P)2 Cm=CP[Bl+B2FPFu] log10 CP = Kx + K2 log10 A + K3(logw Af COMd = 0.180FC7 + 2.73COL + 1 . 2 3 ^ +CWT+CPM)

16. 17.
18.

DM7 = 0 ^ + ^ + 0 ^ . + 1.33COL + 0.069FCI + 0.03COMd FMC = 0.708COi + 0.068FC7 + depreciation .EL40C = (Capital Investment) x (, /, ne I + YOC G = 0.1 llCn , + 0.009 FCI + 0.16COM, '0Z,

19.
20.

21.

(i+0 n -i
F F = -FC7 + CF x , i,

22.

23.

p . ^

(1+Q--l

.^
8j~sf
lS

J /! + /"
c
s

24. 25. 26. 27

oj

jT_coi-dj

i^=%a-eo
4f = % + d /

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APPENDIX 5(3)

EH/JAN 2013/CHE604

USEFUL FORMULAE

28. NPV = -FCIttcm + Net

Revemte(PfAri*n)

29. I1VP = Additional Investment

+ [Annual Operating Cost Base Armwd Operating Cost Jfl( / ^ Un)

30.
Year CEPCI 2011 585.7 2010 550.8 2009 521.9 2008 575.4 2007 525.4 2006 499.6 2005 468.2 2004 444.2 2003 402 2002 395.6 2001 394.3

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Table A . l

Equipment Cost Data to Be Used with Equation A.l {Continued)

Equipment Type Dust Collectors

Equipment Description Baghouse Cyclone scrubbers Electrostatic precipitator Venhiri scrubber Forced circulation (pumped) Falling film Agitated film (scraped wall) Short tube Long tube Centrifugal radial Backward curve Axial vane Axial tube Bent Cartridge Disc and drum Gravity Leaf Fan Plate and frame Table Tube Reformer furnace Pyrolysis furnace Nonreactive fired heater

K* 4.5007 3.6298 &629S 3.6298 5.0238 3.9119 5.0000 5,2366 46420 35391 33471 3.1761 3X1114 5,1055 33107 4.8123 4,2756 3.8187 48123 4,2756 5.1055 5.1055 3.0680 23859 73488

*z -0.5818 -04991 -0.4991 -0.4991 0.3475 0.8627 0.1490 -0.6S72 03698 -03533 -0.0734 -0.1373 -03375 -05001 -0.2403 -0.7142 -016480 -0.3765 -0.7142 -O.64S0 -03001 -0.5001 0.6597 0.9721 -L1666

Kt 0.0813 0.0411 0.04W 0.0411 0.0703 -0.0088 -0.0134 03500 0.0025 0,4477 03090 03414 0.4722 00001 0OO27 0.0420 0,0714 0.0176 0.0420 0.0714 0.0001 0.0001 0O194 -0O2O6 0.2028

Capacity, Units Volume, nv* Volume, m 3 Volume, m 3 Volume, m 3 Area, m2 Area,m 2 Area,m 2 Area,m J Area, in 1 Gas flowrate, m J /s Gas flowrate, m*/s Gas flowrate, m 3 /s Gas flowrate, mVs Area r m 2 Area, m2 Area,m* Area, m2 Arearm2 Area,m 2 Area,m 2 Area,m J Area,m 1 Duty,kW Duty,kW Duty,kW

Min Size 0-08 0.06 0.06 0.06 5 50

Max Size 350 200 200 200 1000 500 5 100 10,000 100 100 100 100 115 200 300 80 235 300 80 115 115 100,000 100,000 100,000 (continued) I

Evaporators

as
10 100 1 1 1 1 0.9 15 0.9 0,5 0,6 OS 05 0.9 0.9 3000 3000 1000

Fans

Fitters

>,

'*"

Furnaces

o o z
Table A.Z Pressure Factors for Process Equipment (Correlated from Data in Guthrie [ 1 , 2 } , and Ulrich [3])
Equipment Type Compressors Drives Equipment Description Centrifugal, axial, rotary, and reciprocating Gas turbine Intern, comb, engine Steam turbine Electricexplosion-proof Electrictotally enclosed Electricopen/drip-procrf Forced circulation (pumped), falling film, agitated film (scraped wall), short tube, and long tube Centrifugal radial, and centrifugal backward curve Axial vane and axial tube Fu rnaces Reformer furnace Pyrolysis furnace Nonreactivefiredheater Heat exchangers Scraped wail Q 0 0 0 0 0 0 0 0 0.1578 0 0 0 0 Q

8
0 0 0 0 0 0 0 0 0.1413

Pressure Range (barg) P<10 10<F<150 AP<lkFa KAP<16kPa AP<lkP!a l<AP<4kPa P<10 10<P<20G P<10 10<P<200

o.
0 0 0 -0.2992

Evaporators

Fans*

Teflon tube

0 0 0 0.20899 -0.0328 G 0 0 0 0 0.20899 -0.0328 0 0 0 0.1405 -02698 0.1293 0 0 0 0.1017 -0.1957 0.09403 0 0 -P 0.1347 -02368 04021 0 0 o 0.6072 -0.9120 * 03327 13.1467 -12.6574 3.0705 0 0 0

p<io
10<P<200 P<40 40<P<100 100<P<300 P<15 (continued)

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APPENDIX 8

EH/JAN 2013/CHE604

Table A.5 Equations for Bare Module Cost for Equipment Not Covered by Tables A.3 aitdA.4 Equipment Type Compressors and blowers without drives Drives for compressors and blowers Evaporators and vaporizers Fans with electric drives Fired heaters and furnaces FTfe Qm saperheatisee&in jfcdorfarsteam laereCFr - 1 far fcheaJea^ and is given by FT - 1 + 0.0Q1MAT- 0.00000335(aT)1 where AT k the amount of supedwat in "C Power recovery equipmeitl Sieve trays, valve trays, and demister pads Equation for Bare Module Cost

Where W is Ihe number of toys and F, is a quantity factor far (rays oaky given fey -> -logu F U 0.4771 + 0.08516Iog3() N 0.l4730ogwN)Jf6rN<20 F^-lforNasSfl

Tower packing

20 30 40 50 Identification Number from Table AM

70

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Table A.6

Identification of Material Factors for Equipment Listed in Table A.5 to Be Used with Figure A.19 Equipment Type Compressors/blowers Equipment Description Centrifugal compressor or blower Centrifugal compressor or blower Centrifugal compressor or blower Axial compressor or blower Axial compressor or blower Axial compressor or blower Rotary compressor or blower Rotary compressor or blower Rotary compressor or blower Reciprocating compressor or blower Reciprocating compressor or blower Reciprocating compressor or blower Eiexmo"-*explosioxipjor Electrictotally enclosed Electricopen/dripproof Gas turbine Steam turbine Internal combustion engine Evaporatorforced circ> short or long tube Evaporatorforced arc, short or long tube Evaporator-^faroed circ, short or long tube Evaporatorforced circ, short or long tube Evaporatorforced circ short or long tube Evaporatorfalling film, scraped-wall Material of Construction CS SS * Ni alloy CS SS Ni alloy CS SS Ni alloy CS SS Ni alloy < CS Cu alloy SS "NiaJfloy Ti CS (continued)

Identification Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS 16 17 18 19 20 21 22 23 24

o o z T] o m
Z

>

"0 TJ

m z u x
to

Drives for compressors and blowers-

Evaporators arid vaporizers

m x > z
O W

' *"

*v"* -

O I

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APPENDIX 10

EH/JAN 2013/CHE604

Table 9.1

Commonly Used Factors for Cash Flow Diagram Calculations Symbol (P[P, i, n) (PIP, i, n) (F/A, i, n) (A/F,i,n) (AJP, i, n) (P/A, i, n) Common Name Single Payment Compound Amount Factor Single Payment Present Worth Factor Uniform Series Compound Amount Factor, Future Worth of Annuity Sinking Fund Factor Capital Recovery Factor Uniform Series Present Worth Factor, Present Worth of Annuity Eq. No.
(9.5) (9.6) (9.11) (9.12) (9.13) (9.14)

Conversion P to F F to P A to F FtoA P to A A to P

Formula
(1 + 0"
1

(l + 0" (1 + if - 1 i i (1 + 0" - 1 i(i + 0" . (i + 0" - 1 (l + 0" - 1

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