Solution Manual for Analysis, Synthesis, and Design of Chemical Processes, 5th Edition

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SolutionManualforAnalysis, Synthesis,and Design ofChemical ProcessesFifth EditionRichard TurtonJoseph A. ShaeiwitzDebangsu BhattacharyyaWallace B. Whiting

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1-1CHAPTER 1SHORT ANSWER QUESTIONS1.1Block Flow Diagram (BFD)Process Flow Diagram (PFD)Piping and Instrument Diagrams (P&ID)(a) PFD(b) BFD(c) PFD or P&ID(d) P&ID(e) P&ID1.2P&ID1.3It is important for a process engineer to be able to review a 3-dimensional modelprior to the construction phase to check for clearance, accessibility, and layout ofequipment, piping, and instrumentation.1.4Things that would affect the locations of different pieces of equipment whendetermining the layout of equipment in a process unit(1) Clearance for tube bundle removal on a heat exchanger.(2) NPSH on a pump affects the vertical separation of feed vessel and pump inlet.(3) Accessibility of an instrument for an operator must be able to read a PI orchange/move a valve.(4) Separation between equipment for safety reasons reactors and compressors.(5) Crane access for removing equipment.(6) Vertical positioning of equipment to allow for gravity flow of liquid.(7) Hydrostatic head for thermosiphon reboiler affects height of column skirt.1.5Why are accurate plant models (made of plastic parts) no longer made as part ofthe design process? What function did these models play and how is this functionnow achieved?Plastic models are no longer made because they are too expensive and difficult tochange/revise. These models have been replaced with virtual/e-models using 3-DCAD. Both types of model allow revision of critical equipment and instrumentplacement to ensure access, operability, and safety.1.6OTS = Operator Training Simulator ITS = Immersive Training Simulator

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1-21.7Augmented reality refers to a feature of an immersive training system (ITS) whereby anoperator can obtain additional information about equipment by “peelingback” the wall of a vessel, etc., and looking inside the equipment.1.8What are the two principle methods for the layout of process equipment in achemical plant?(a) Grade-Mounted, Horizontal, In-line Arrangement and (b) Structure-MountedVertical Arrangement1.9When is it appropriate to add a flag to a stream in a PFD rather than including thestream in the stream flow table?When only temperature or pressure changes in the equipment. So for example atthe outlet of a pump or the outlet of a heat exchanger. Flags should also beconsidered around critical equipment for example reactors.1.10What problems would you foresee in naming equipment in a process thathad a unit number of 10 (for example, pumps starting with P-11, P-12,etc.)?By having a unit number with only 2 digits (10, 20, 30, etc.), the maximumnumber of equipment items within an equipment class is 9. For example,pump 11 in unit 20 would become P-31, which could be in conflict withthe first pump of unit 30. By numbering units in the hundreds (200, 300,etc.), the maximum number of items in an equipment class is 99 so therewill never be a conflict of this type.1.11What diagram would you refer to in order to estimate the frictional lossthrough a certain piping run within a process?This would require a piping isometric(s) for the whole piping run.1.12In the vast majority of cases what is the final control element in a processcontrol loop?Nearly always, this control element will be a control valve.1.13What is the most effective way of communicating information about aprocess?Through the use of diagrams (or computer generated models)–but alwaysa visual representation.1.14Vessel V-307 is to be replaced in a plant with a vessel that is designed towithstand a higher pressure and which has a larger volume. Should thisvessel be numbered V-307 to correspond with the vessel it is replacing?Explain your answer.Generally, the answer is No. Unless the replacement equipment is essentiallyidentical in function and characteristics to the original equipment a new numbershouldbechosentoavoidconfusionwhenlocatinginformationabouttheequipment.For the case considered in this question, calling the vessel V-307Awould probably be ok.

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1-3PROBLEMS1.15There are two common reasons for elevating the bottom of a tower bymeans of a “skirt.” One reason is to provide enoughNPSHAfor bottomsproduct pumps to avoid cavitation. What is the other reason?Another reason to elevate the bottom of a tower is to provide enough hydrostatichead driving force to operate a thermosiphon reboiler1.16(a) PFD or P&ID(b) PFD(c) PFD(d) P&ID(e) BFD (or all PFDs)1.17A pipe rack provides a clear path for piping within and between processes. Itkeeps piping off the ground to eliminate tripping hazards and elevates it aboveroads to allow vehicle access.1.18A structure mounted vertical plant layout is preferred when land is at a premiumand the process must have a small foot print. The disadvantage is that it is morecostly because of the additional structural steel.1.19(a)BFD - No changePFD - Efficiency changed on fired heater, resize any heat exchanger used toextract heat from the flue gas (economizer)P&ID - Resize fuel and combustion air lines and instrumentation for utilitiesto fired heater. Changes for design changed of economizer (if present)(b)BFD - Change flow of waste stream in overall material balancePFD - Change stream tableP&ID Change pipe size and any instrumentation for this process line(c)BFD - No changePFD - Add a spare drive, e.g. D-301 → D-301 A/BP&ID - Add parallel drive(d)BFD - No changePFD - No changeP&ID - Note changes of valves on diagram1.20(a)A new vessel number need not be used, but it would be good practice to adda letter to donate a new vessel, e.g. V-203 → V-203N. This will enable anengineer to locate the new process vessel sheet and vendor information.(b)P&ID definitelyPFD change/add the identifying letter.

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1-41.21Solution to Problem 1.211.22(a) (i) Open globe valve d(ii) Shut off gate valves a and c(iii) Open gate valve e and drain contents of isolated line to sewer(iv) Perform necessary maintenance on control valve b(v) Reconnect control valve b and close gate valve e(vi) Open gate valves a and c(vii) Close globe valve d(b)Drain from valve e can go to regular or oily water sewer.(c)Replacing valve d with a gate valve would not be a good idea because weloose the ability to control the flow of process fluid during the maintenanceoperation.(d)If valve d is eliminated then the process must be shut down every timemaintenance is required on the control valve.

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1-51.231.24Solution to Problem 1.23Solution to Problem 1.24

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1-61.25(a)For a pump with a large NPSH, the vertical distance between the feedvessel and the pump inlet must be large in order to provide the static headrequired to avoid cavitating the pump.(b)Place the overhead condenser vertically above the reflux drum, the bottomshell outlet on the condenser should feed directly into the vertical drum.(c)Pumps and control valves should always be placed either at ground level(always for pumps) or near a platform (sometimes for control valves) toallow access for maintenance.(d)Arrange shell and tube exchangers so that no other equipment or structuralsteel impedes the removal of the bundle.(e)This is why we have pipe racks never have pipe runs on the ground. Alwayselevate pipes and place on rack.(f)Locate plant to the east of major communities.

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1-71.26HT area of 1 tube21==()(12ft)=3.142ft12DLNumber of tubes2223.2808ft1=(145m )497m3.142ft    tubesUse a 1¼-inch square pitch⇒Fractional area of the tubes21==0.502741.25 222=(4)(777)=3108in=3108in4SHELLSHELLCSAD2(4)(3108in )62.9in1.598mSHELLDLength of Heat Exchanger = (2 + 12 + 2) ft = 16 ft = 4.877 mFoot Print = 1.598 × 4.877 m

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1-81.27From Table 1.11 towers and reactors should have a minimum separation of 15feet or 4.6 m and no other restrictions apply. See sketch for details.Solution to Problem 1.27

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1-91.28

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1-101.291.30(a)A temperature (sensing) element (TE) in the plant is connected via acapillary line to a temperature transmitter (TT) also located in the plant. TheTT sends an electrical signal to temperature high (TAH) and temperature low(TAL) alarms located on the front of a panel in the control room.(b)A level switch (LS) located in the plant sends an electrical signal to …(c)A pressure control valve (LCV) located in the plant is connected by apneumatic (air) line to the stem of a control valve.(d)A local flow indicator (FI) is attached to a flow orifice both instruments arelocated in the plant.(e)A safety (pressure) relief valve is shown attached to two process lines. Thetop process line appears to vent to atmosphere but could be attached to aflare system–there is not enough information to determine this based on thesketch provided.5 m

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1-111.311.32

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1-121.331.34

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2-1CHAPTER 2SHORT ANSWER PROBLEMS2.1The five elements of the Hierarchy of Process Design are:(a)Batch or continuous process(b)Input-output structure of process(c)Recycle structure of process(d)General separation structure of process e.Heat-exchanger network/processenergy recovery2.2(a)Separate/purify unreacted feed and recycle use when separation is feasible.(b)Recycle without separation but with purge when separation of unused reactantsis infeasible/uneconomic. Purge is needed to stop build-up of product or inerts.(c)Recycle without separation or purge product/byproduct must react furtherthrough equilibrium reaction.2.3Batch preferred over continuous when: small quantities required, batch-to-batchaccountabilities required, seasonal demand for product or feed stock availability, needto produce multiple products using the same equipment, very slow reactions, and highequipment fouling.2.4One example is the addition of steam to a catalytic reaction using hydrocarbon feeds.Examples are given in Appendix B (styrene, acrylic acid.) In the styrene process,superheated steam is added to provide energy for the desired endothermic reactionand to force the equilibrium towards styrene product. In the acrylic acid example,steam is added to the feed of propylene and air to act as thermal ballast (absorb theheat of reaction and regulate the temperature), and it also serves as an anti-cokingagent that prevents/supresses the coking reactions that deactivate the catalyst.

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2-22.5Reasons for purifying a feed material prior to feeding it to a process include:(a)If the impurity fouls or poisons a catalyst used in the process. e.g., remove tracesulfur compounds in natural gas prior to sending it to a steam reforming reactorto produce hydrogen.(b)If impurities react to form difficult-to-separate or hazardous products/byproducts.e.g. Production of isocyanates using phosgene. Production of phosgene isCO+Cl2→COCl2The carbon monoxide is formed via steam reforming of CH4to give CO + H2. H2mustbe removed from CO prior to reaction with Cl2to form HCl, which is highly corrosiveand causes many problems in the downstream processes.(c)If the impurity is present in large quantities then it may be better to remove theimpurity rather than having to size all the down stream equipment to handle thelarge flow of inert material.e.g. One example is using oxygen rather than air to fire a combustion orgasification processes. Removing nitrogen reduces equipment size and makes theremoval of CO2and H2S much easier because these species are more concentrated.

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