Solution Manual For Analysis, Synthesis And Design Of Chemical Processes, 4th Edition

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Solutions Manual forAnalysis, Synthesis,and Design of ChemicalProcessesFourth EditionRichard TurtonRichard C. BailieWallace B. WhitingJoseph A. ShaeiwitzDebangsu Bhattacharyya

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1-1Chapter 11.1Block 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 model prior tothe construction phase to check for clearance, accessibility, and layout of equipment,piping, and instrumentation.1.4(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.1.5Plastic models are no longer made because they are too expensive and difficult tochange/revise. These models have been replaced with virtual/E-model using 3-D CAD.Both types of model allow revision of critical equipment and instrument placement toensure access, operability, and safety.1.6OTS = Operator Training SimulatorITS = Immersive Training Simulator1.7Augmented reality refers to a feature of an immersive training system (ITS) where by anoperator can obtain additional information about equipment by “peeling back” the wall of avessel, etc., and looking inside the equipment.

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1-21.8Another reason to elevate the bottom of a tower is to provide enough hydrostatic headdriving force to operate a thermosiphon reboiler1.9(a)PFD or P&ID(b)PFD(c)PFD(d)P&ID(e)BFD (or all PFDs)1.10A pipe rack provides a clear path for piping within and between processes. It keeps pipingoff the ground to eliminate tripping hazards and elevates it above roads to allow vehicleaccess.1.11A structure – mounted vertical plant layout is preferred when land is at a premium and theprocess must have a small foot print. The disadvantage is that it is more costly because ofthe additional structural steel.1.12 (a)BFD– No changePFD– Efficiency changed on fired heater, resize any heat exchanger used to extractheat from the flue gas (economizer)P&ID– Resize fuel and combustion air lines and instrumentation for utilities to firedheater. 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 diagram1.13(a) A new vessel number need not be used, but it would be good practice to add a letter todonate a new vessel, e.g. V-203→V-203N. This will enable an engineer to locate thenew process vessel sheet and vendor information.(b)P&ID definitelyPFD change/add the identifying letter.

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1-31.14

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1-41.15(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 we loosethe ability to control the flow of process fluid during the maintenance operation.(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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1-51.161.17

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1-61.18 (a)For a pump with a large NPSH – the vertical distance between the feed vessel and thepump inlet must be large in order to provide the static head required to avoid cavitating thepump.b)Place the overhead condenser vertically above the reflux drum – the bottom shelloutlet on the condenser should feed directly into the vertical drum.c)Pumps and control valves should always be placed either at ground level (always forpumps) or near a platform (sometimes control valves) to allow access for maintenance.d)Arrange shell and tube exchangers so that no other equipment or structural steelimpedes the removal of the bundle.e)This is why we have pipe racks – never have pipe runs on the ground. Always elevatepipes and place on rack.f)Locate plant to the east of major communities.

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1-71.19 HT area of 1 tube =πDL=π112⎛⎝⎜⎞⎠⎟12 ft()=3.142ft2Number of tubes =(145 m2)⋅3.2808 ftm⎛⎝⎜⎞⎠⎟213.142 ft2⎛⎝⎜⎞⎠⎟ =497tubesUse a 1 1/4 inch square pitch⇒Fractional area of the tubes =π41 m1.25 in⎛⎝⎜⎞⎠⎟2=0.5027 min⎛⎝⎜⎞⎠⎟2AVAP=3 ALIQ∴CSASHELL=4 ALIQALIQ=4970.5027⎛⎝⎜⎞⎠⎟inm⎛⎝⎜⎞⎠⎟2π4⎛⎝⎜⎞⎠⎟1 m()2=777in2CSASHELL=4( )777()=3108 in2⇒π4 D2SHELL=3108 in2DSHELL=4( )3108 in2()π=62.9 in=1.598 mLength of Heat Exchanger =(2+12+2) ft=16 ft=4.877 mFoot Print=1.598×4.877 m

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1-81.20From Table 1.11 towers and reactors should have a minimum separation of 15 feet or 4.6meters. No other restrictions apply. See sketch for details.

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1-91.21

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1-101.22

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1-111.23(a)A temperature (sensing) element (TE) in the plant is connected via a capillary line toa temperature transmitter (TT) also located in the plant. The TT sends an electricalsignal to a temperature indicator controller (TIC) located on the front of a panel in thecontrol room.(b)A pressure switch (PS) located in the plant sends an electrical signal to …(c)A pressure control valve (PCV) located in the plant is connected by a pneumatic (air)line to the valve stem.(d)A low pressure alarm (PAL) located on the front of a panel in the control roomreceives an electrical signal from …(e)A high level alarm (LAH) located on the front of a panel in the control room receivesa signal via a capillary line.

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1-121.24LELTLICPALLAHLY1322P-401P-402V-3022” sch 40 CS4” sch 40 CS2” sch 40 CSTo wastewater treatmentTo chemical sewerVent to flare123LELTLICLALLAHLY3222P-401AP-401BV-3022” sch 40 CS2” sch 40 CS4” sch 40 CSTo wastewater treatmentTo chemical sewerVent to flare123= ErrorList of Errors1.Pipe inlet always larger than pipe outlet due to NPSHissues2.Drains to chemical sewer and vent to flare3.Double-block and bleed needed on control valve4.Arrows must be consistent with flow of liquid throughpumps5.Pumps in parallel have A and B designation6.Pneumatic actuation of valve stem on cv is usual7.Level alarm low not pressure alarm lowCorrectedP&ID

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2-1Chapter 22.1The five elements of the Hierarchy of Process Design are:a.Batch or continuous processb.Input – output structure of processc.Recycle structure of processd.General separation structure of processe.Heat-exchanger network/process energy recovery2.2a.Separate/purify unreacted feed and recycle – use when separation is feasible.b.Recycle without separation but with purge – when separation of unused reactants isinfeasible/uneconomic. Purge is needed to stop build up of product or inerts.c.Recycle without separation or purge – product/byproduct must react further throughequilibrium reaction.2.3Batch preferred over continuous when: small quantities required, batch-to-batchaccountabilities required, seasonal demand for product or feed stock availability, need toproduce 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 reaction and toforce the equilibrium towards styrene product. In the acrylic acid example, steam is addedto the feed of propylene and air to act as thermal ballast (absorb the heat of reaction andregulate the temperature), and it also serves as an anti-coking agent – preventing cokingreactions 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 impurity foul or poison a catalyst used in the process.e.g. Remove trace sulfur compounds in natural gas prior to sending to the steamreforming reactor to produce hydrogen.CH4+H20→CO+3H2b.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 the impurityrather than having to size all the down stream equipment to handle the large flow ofinert material.e.g. One example is suing oxygen rather than air to fire a combustion or gasificationprocesses. Removing nitrogen reduces equipment size and makes the removal of CO2and H2S much easier because these species are more concentrated.2.6IGCCH2O+CaHbScOdNe+O2→pCO2+qH2+rH2O+sCO+tNH3+uH2SIn modern IGCC plants, coal is partially oxidized (gasified) to produce synthesis gas CO+ H2and other compounds. Prior to combusting the synthesis gas in a turbine, it must be“cleaned” or H2S and CO2(if carbon capture is to be employed.) Both H2S and CO2areacid gases that are removed by one of a variety of physical or chemical absorptionschemes. By removing nitrogen from the air, the raw synthesis gas stream is much smallermaking the acid gas removal much easier. In fact, when CO2removal is required IGCC isthe preferred technology, i.e. the cheapest.Remove trace sulfurPlatinum catalyst v. susceptible tosulfur poisoningCoal

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