COMPUTER AIDED DESIGN

OF
CHEMICAL EQUIPMENT LAB
(15CH1147)
Vision of the Department:

To evolve into a centre of higher learning in chemical engineering with experimental and
state-of-the art computational facilities for education and research.

Mission of the Department:

 To produce high quality chemical engineers with knowledge and skills suitable to the
needs of higher learning, industry and research organizations.
 To meet the technological needs of the economy, environment and society.
 To develop leadership qualities with good communication skills.

PEO Code Programme Educational Objectives (PEOs)

PEO1 Produce graduates to have basic knowledge in mathematics, science and

engineering for successful careers in and related to chemical
engineering with high morals and ethics.

PEO2 Analyse and design appropriate solutions for socially relevant problems
by using current engineering techniques and tools.

PEO3 Engage in professional development through effective communication,

team work and lifelong learning.

Program Outcomes:

1. Able to apply the knowledge of mathematics, science, engineering fundamentals

to solve complex chemical engineering problems.
2. Attain the capability to identify, formulate and analyse problems related to
chemical engineering and substantiate the conclusions
3. In a position to design solutions for chemical engineering problems and design
system components and processes that meet the specified needs with appropriate
consideration to public health and safety.
4. Able to perform analysis and interpretation of data by using research methods
such as design of experiments to synthesize the information and to provide valid
conclusions.
5. Able to select and apply appropriate techniques from the available resources and
modern chemical engineering and software tools, and will be able to predict and
model complex engineering activities with an understanding of the practical
limitations.
 6. Able to carry out their professional practice in chemical engineering by
appropriately considering and weighing the issues related to society and culture
and the consequent responsibilities.
7. Able to understand the impact of the professional engineering solutions on
environmental safety.
8. Transform into responsible citizens by resorting to professional ethics and norms
of the engineering practice.
9. Able to function effectively in individual capacity as well as a member in diverse
teams and in multidisciplinary streams.
10. Able to communicate fluently on complex engineering activities with the
engineering community and society, and will be able to prepare reports and make
presentations effectively.
11. Able to apply knowledge of engineering and management principles while
managing projects in multidisciplinary environments.
12. Engage in independent and life-long learning in their specialized areas of
chemical engineering.

COURSE OUTCOMES:
At the end of the course the student shall be able to

CO1: Review the standard flow sheet symbols and construct a flow sheet using the
symbols

CO2: Analyze a given situation, identify the type of heat exchanger, design and evaluate
the heat exchanger

CO3: Identify and design a suitable evaporator for evaporation process

CO4: Design a distillation column and absorber for a given problem

CO5: Apply PRO-II and simulate distillation column, heat exchanger and absorber
 Index
LIST OF EXPERIMENTS/PROGRAMMES:

1. Introduction of different basic symbols and drawing flow sheet

symbols.

2. Design of a Double Pipe Heat Exchanger

3. Design of a 1-2 shell & tube Heat Exchanger-Rating

4. Design of a 1-2 shell & tube Heat Exchanger-Sizing

5. Design of a Evaporator

6. Design of a Tray Distillation Column

7. Design of a Packed Distillation Column

8. Design of a Batch Reactor

9. Process simulation of Absorber using PRO-II

10. Process simulation of Distillation Column using PRO-II

11. Process simulation of LLE columns using PRO-II

 1. DOUBLE PIPE HEAT EXCHANGER (RATING)
Aim: To design a double pipe heat exchanger for the given data

Procedure:

The calculation consists simply of computing ho and hi to obtain UC. Allowing a reasonable
fouling resistance, a value of LMTD is calculated from which the surface can be found with the
use of the Fourier equation Q = UAΔT.

Usually the first problem is to determine which fluid should be placed in the annulus and which in
the inner pipe. This is expedited by establishing the relative sizes of the flow areas for both
streams. For equal allowable pressure drops on both the hot and cold streams, the decision rests in
the arrangement producing the most nearly equal mass velocities and pressure drops.

Process conditions required:

Hot fluid: T1, T2, W, c, s or ρ, μ, k, ΔP, Rdo or Rdi

Cold fluid: t1, t2, w, c, s or ρ, μ, k, ΔP, Rdi or Rdo

The diameter of the pipes must be given or assumed.

A convenient order of calculation follows:

(1) From T1, T2, t1, t2 check the heat balance, Q, using C at T(mean) and t(mean).

Q=W*C*(T1-T2) =w*c*(t2-t1)

Radiation losses from the exchanger are usually insignificant compared with the heat load
transferred in the exchanger.

(2) LMTD, assuming counter flow.

(3) Tc and tc: If the liquid is neither a petroleum fraction nor a hydrocarbon the caloric
temperatures cannot be determined through the use of Fig. 17

Instead, the calculation of UC must be performed for the hot and cold terminals giving Uh and
U from which one may obtain L. Fc is then obtained from Fig17.

If neither of the liquids is very viscous at the cold terminal, say not more than 1.0 centipoise,
if the temperature ranges do not exceed 50 to 100°F, and if the temperature difference is less
than 50°F, the arithmetic means of T1 and T2 and t1 and t2 may be used in place of Tc and tc
for evaluating the physical properties.

For non-viscous fluids φ may be taken as 1.0 as assumed below.

Inner pipe:

(4) Flow area, Ap = Π*D2/4, ft2

(5) Mass velocity, Gp = w/Ap, lb/(hr)(ft2)

(6) Obtain μ at T. or t. depending upon which flows through the inner pipe.

μ lb/(ft)(hr) = μ centi-poise * 2.42

From D, Gp, μ, obtain the Reynolds number, Rep = D*Gp/μ

(7) From Fig.24, a plot of jH v/s Re, obtain jH.

(4') Flow area, Aa= (D22-D12)/4, ft2

Equivalent diameter, De = (4 X flow area)/ (wetted perimeter)

= (D22-D12)/D1, ft

(5) Mass velocity, Ga = w/Aa, lb/(hr*ft2)

(6) Obtain μ at T. or t. depending upon which flows through the inner pipe.

μ lb/ (ft*hr) = μ centi-poise*2.42

From De, Ga, μ, obtain the Reynolds number, Rea = De*Ga/μ

(8)Calculate c (Btu/(lb)*( )), μ (lb/(ft)(hr)), k ( tu/hr)(ft )(f/ft)), all at Tc or tc.

(9) To obtain hi, multiply jH by (k/D)*(c*μ/k)0.3333 for (φ = 1.0)

(10) Convert hi to hi to hio = hi*(Ai/A) = hi*(ID/OD).

Annulus:

(7) From Fig. 24; of jH v/s Rea, obtain jH

(8)Calculate c, Btu/(lb*°F), μ, lb/ (ft*hr), k, (Btu/hr*ft2(oF/ft)), all at Tc or tc

(9) To obtain ho, multiply jH by (k/D)*(c*μ/k) 0.333 for (φ = 1.0)

Overall coefficients:

(11) Compute UC = hio*h0/ (hio + ho), Btu/ (hr*ft2*°F).

(12) Compute UD from (1/UD) = (1/UC) +Rd

(13) Compute A from Q = (U*LMTD*A)

From which may be translated into length. If the length should not correspond to an
integral number of hairs pins, a change in the dirt factor will result. The recalculated dirt
factor should equal or exceed the required dirt factor by using the next larger integral number
of hairpins.

Calculation of ΔP:

This requires the knowledge of the total length of path satisfying the heat-transfer
requirements.

Inner pipe:

(1) For Re, in (6) above obtain f from Eq.

f = 0.0035+0.262/ (Re0.42)

( ) Δ p= 4*f*G2*L/ ( *g*ρ2*D), ft.

(3)Δ p*ρ/144 = ΔPp, psi.

Annulus:

(1’) Obtain De’= (D2 - D1).

Compute the frictional Reynolds number, Rea’= De*Ga/μ. rom Re obtain f from Eq.

f= 0.0035 + 0.262/ (Re^0.42)

( ') Δ a = (4*f*G2*L)/ (2*g*ρ2*De), ft.

(3') Entrance and exit losses, one velocity head per hairpin:

Δ 1 = V2/ (2*g), ft/hairpin

 (Δ a+ Δ 1)*ρ/144 = ΔPa, psi

Sample calculation:
Exercise Problems:

6.11: 13,000 lb/hr of 26°API gas oil (see Example 6.3 in text for viscosities) is cooled from
450 to 350°F by heating 57oAPI gasoline under pressure from 220 to 230°F in as many 3- by
2-in. IPS double pipe 20-ft hairpins as are required. Pressure drops of 10 psi are permitted
along with a minimum dirt factor of 0.004. (a) How many hairpins are required? (b) How
shall they be arranged? (c) What is the final dirt factor? 6.12. 100,000 lb/hr of nitrobenzene is
to be cooled from 325 to 275°F by benzene heated from 100 to 430°F. Twenty-foot hairpins
of 4-by3-in. IPS double pipe will be emp1oy2d, and pressure drops of 10 psi are permissible.
A minimum dirt factor of 0.004 is required. (a) How many hairpins are required? (b) How
shall they be arranged? (r) What is the final dirt factor?
 2. DESIGN OF SHELL AND TUBE HEAT EXCHANGER
(RATING)

Aim: To design a shell and tube heat exchanger for the given data

Procedure:

Process conditions required are

 3. DESIGN OF SHELL AND TUBE HEAT EXCHANGER
(SIZING)

Aim: To design a shell and tube heat exchanger with the given data

Procedure:
1. Define the duty: heat-transfer rate, fluid flow-rates, and temperatures.
2. Collect together the fluid physical properties required: density, viscosity, thermal
conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient, U.
5. Calculate the mean temperature difference, ΔTm.
6. Calculate the area required from equation
Q=UA Δ*Tm
7. Decide the exchanger layout.
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value. If the calculated value
differs significantly from the estimated value, substitute the calculated for the estimated value
and return to step 6.
10. Calculate the exchanger pressure drop; if unsatisfactory return to steps 7 or 4 or 3, in that
order of preference.
11. Optimise the design: repeat steps 4 to 10, as necessary, to determine the cheapest
exchanger that will satisfy the duty. Usually this will be the one with the smallest area.
Example 12.2
Gas oil at 200C is to be cooled to 40C. The oil flow-rate is 22,500 kg/h. Cooling water is
available at 30C and the temperature rise is to be limited to 20C. The pressure drop allowance
for each stream is 100kN/m2. Design a suitable exchanger for this duty.
Solution
Only the thermal design will be carried out, to illustrate the calculation procedure for a heat
exchanger with a divided shell.
 4. DESIGN OF A SINGLE EFFECT EVAPORATOR
Aim: To design a single effect evaporator for the following duty

Problem Statement:***

A single effect evaporator is to concentrate is to 20,000 lb/hr of a 20%

solution of sodium hydroxide to 50% of solids. The gauge pressure of the system is to be 20
lbf/in2. The absolute pressure in the vapour phase is to be 100mmHg (1.93 lbf/in2). The
overall coefficient is estimated to be 250 Btu/ft2-hr-0F.The feed temperature is 1000F.

Data:

a) Boiling Point of the water at 100mmHg = 1240F

b) Boiling Point of the solution (50% of solids) = 1970F
c) Enthalpy of superheated vapour at 1970F and 1.93 lbf/inch2=1149 Btu/lb
d) Latent heat of vaporisation of the steam at 20 lbf/inch2 = 939 Btu/lb
e) Condensation temperature of the steam at 20 lbf/inch2 =2590F

Design data:

Tubes of 1.25 inch and 10 BWG are used

Length of the tube =1000mm, Triangular pitch of tubes

Material:

 Evaporators – Low carbon steel

 Drum- Low carbon steel
 Tubes-Brass
 Permissible stress for low carbon steel=9.8*106 N/m2
 Modulus of elasticity for low carbon steel =19*1010 N/m2
 Modulus elasticity for brass = 9.5*1010N/m2

Solution:

Given that F =20,000lb/hr

XF = 0.2 XL = 0.5 XV = 0

Overall Material Balance:

F= L+ V

Component Balance:

F* XF = L* XL +V* XV

20000*0.2 = L*0.5
 L = 8000 lb/hr

V=F - L= 20000-8000=12000 lb/hr

Enthalpy Balance:

qs + F*HF = L*HL + V*HV

qs – Rate of heat transfer through heating surface from steam = S* s

HF – Specific enthalpy of feed or thin liquor (20% of solids at 1000F) =55 Btu/lb

HL – Specific enthalpy of thick liquor (%0% of solids at 1970F) =221 Btu/lb

HF – Enthalpy of vapour =1149 Btu/lb

S* s + F*HF = L*HL + V*HV

S*939 + 20000*55 = 8000*221 + 12000*1149

S=15395 lb/hr

qs = S* s = 15395*939= 14456000 Btu/hr

qs = q= u*A*(t2-t1)

14456000=250*A*(259-197)

A=935.65 ft2 = 86.65 m2

Mechanical Design:

1) Inner diameter of the tubes =1.25 inches = 32 mm

Tube thickness = 0.134 inch (from 10 BWG) = 3.3 mm

do= outer diameter of tube = 1.25 + 2*0.134 = 1.518 inch = 38.55 mm

l = length of the tube = 1000mm

Number of tubes required (N) = (Heat transfer area)/ ( * do*L)

N= 86.65/ ((3.14*38.55*10-3)*(1000*10-3))

N=715 tubes

Pitch of the tubes (triangular) Pt = 1.25* do = 1.25*38.55*103

= 0.0482mm

= 48.19mm
2) Area required by the tubes a = N*(0.866)*Pt2/

= proportionality factor = 0.8 to 1

a = (715*0.866*.0482)/0.95 = 1.514 m2

3) Down take area = 30-40% of cross sectional-area

= 0.35*715*( /4)*(32*10-3)2

= 0.201 m2

Diameter of the down taker = ( /4)*(dd2) =0.2

dd = 0.506m 500mm

4) Total are of the tube sheet = Area of the tubes + area of the down taker = 1.5142 + 0.201

= 1.7152 m2

Diameter of the tube sheet = 1.7152= ( /4)*(dt2)

dt= 1.48 m 1.5 m

Therefore the tube sheet diameter (dt) = 1500mm (allowed)

5) Calendria sheet thickness

Design pressure P = 1.1* internal pressure

Internal pressure = Steam pressure
= 20+14.7=34.7 psi
=34.7/14.7 = 2.36 atm
Design pressure P = 1.1*2.36 = 2.596 atm
= 2.596*101325= 2.6*105 N/m2
Calendria sheet thickness is given by
ts = (P* dt)/ (2fJ – P)
= (2.6*105*1.5)/ ((2*0.85*98*106)-(2.6*105))
= 2.35*10-3m= 2.35mm
Give some corrosive allowance ts= 2.35+7.65= 10mm
6) Tube sheet thickness
 Effective tube sheet thickness t = F*G*((0.25*P)/f)0.5
P (Design Pressure) = 2.6*105 N/m2
G- Tube sheet diameter = 1.5 m
f=allowable stress = 98*106 N/m2
.5
F= )

k= Es*ts*(dt- ts)/ (Et* N* tt*(do- tt))

Es- modulus of elasticity of the shell = 19*104 N/mm2
ts- Calendria sheet thickness = 10mm
dt- tube sheet diameter = 1500mm
Et – modulus of elasticity of tube = 9.5*104 N/mm2
tt =Tube thickness = 3.3mm
do= outer diameter of tube = 38.55 mm
N = Number of tubes required = 715
k= (19*104*10*(1500-10))/ (9.5*104*715*3.3*(38.55-3.3))
=0.36
.5
F= ) =0.34

Thickness t = F*G*((0.25*P)/f).5

t= 0.34*1.5*((0.25*2.6*105)/ (98*106).5

Tube thickness is t = 13.13 mm

With common allowance, the thickness taken as 20mm

Result:

PARTS MEASURMENTS
1)Tube Inner Diameter = 32mm
Outer Diameter= 38.5mm
2) Tube sheet Thickness = 20mm
Inner Diameter = 1500mm
3) Calendria Thickness =10mm
4) Drum Height = 1500mm
Inner Diameter= 1500mm
Thickness= 10mm
5) Down take Diameter = 500mm
 Height = 1000mm
6) Nozzles Diameter = 40mm thickness=8mm
 5. DESIGN OF A TRIPLE EFFECT EVAPORATOR
Aim: To design a triple effect evaporator for the given conditions

Procedure:
Notation scheme:

cf = specific heat of feed, tu/(lb)(F)

tf =temperature of feed, F

wf = feed, lb/hr

Ts = saturation temperature of steam to first effect, °F

ws = steam to first effect, lb/hr

w1-3 ---- total water removed by evaporation, lb/hr

c1, c2, c3 = specific heat of liquor in effects 1 to 3, ( tu/lb)(F)

t1, t2, t3= boiling points of liquor in effects 1 to 3, 0F

w1, w2, w3 = water removed in effects 1 to 3, lb/hr

Assume that there are no chemical heat effects as a result of the concentration (i.e., negative
heats of solution) and that there is no BPR.
Forward feed

Heat balance on first effect:

Ws * λs+ (wf *cf *(tf-t1)) = w1*λ1

Heat balance on second effect:

w1*λ1 + ((wf – w1) *c1* (t1-t2)) = w2*λ2

Heat balance on third effect:

w2*λ2 + ((wf – w1- w2)* c2* (t2-t3)) = w3*λ3

Material balance:

w1-3 = w1 + w2 + w3

The surface requirements will be

A1 =Q/ (U1*ΔT) = (Ws * λs) / (U1* (Ts-t1))

A2= w1*λ1 / (U2* (t1-t2))

A3= w2*λ2 / (U3* (t2-t3))

Let A1 = A2 = A3
where U1, U2 and U3 are the design overall coefficients in the respective effects. From the
material balance and the heat balances there are four equations and four unknowns: Ws,
w1, w2 and w3. These may be solved simultaneously.
Problem:
 6. DESIGN OF A DISTILLATION COLUMN
Aim: To design a distillation column for the given system.

Procedure:

The design of a distillation column can be divided into the following steps.
(a) If the feed mixture contains more than two components, then select two key components from all
the components of feed mixture.
(b) Decide the operating pressure of distillation column. At the operating pressure, find the
vapor—liquid equilibrium data.
(c) Specify the degree of separation required. In case of a binary distillation, decide the top
(distillate) and the bottom (residue) product compositions. In case of multi-component
distillation, decide the distribution of key components in distillate and residue. Also, find the
distribution of non key components in the same. Complete the material balance.
(d) Determine the minimum reflux ratio Rm.
(e) Determine the optimum reflux ratio R and find the number of theoretical or equilibrium stages
required for the desired separation.
(f) Select the type of tower: tray tower or packed tower. Select the type of tray in tray tower
or type of packing in packed tower.
(g) Find tower diameter and pressure drop across the tower. Decide the top disengagement and
bottom disengagement spaces.
(h) Determine the tray efficiency and find the actual number of trays in case of tray tower or find
HETP (height equivalent to theoretical plate) and decide the height of packing in packed
tower. In case of packed tower, design the liquid distributor, re-distributor, packing support,
etc.
(i) Select the material of construction for all parts. Design the suitable insulation system.
(j) Design the condenser and re-boiler.
(k) Decide the control methodology for the distillation column, line sizes and locations of all
nozzles.

(l) Mechanical design of distillation column which also includes design of skirt
support for the distillation column. Calculation and equations for the first five
steps are different for binary and multi-component distillation.

Stepwise design of tray procedure:

The design is performed separately both above feed plate (top section) and below feed
plate (bottom section) for single feed two product distillation column.
Step 1: Determine the number of theoretical plate and vapor and liquid flow-rates
separately both in top and bottom sections.
Step 2: Obtain the physical properties of the system.
Step 3: Select a trial plate spacing.
Step 4: Estimate the column diameter based on flooding considerations.
Step 5: Decide the liquid flow arrangement (reverse, single-pass, or multiple-pass).
Step 6: Make a provisional tray layout including down comer area, active area, perforated
area, hole area and size, weir height, weir length.
Step 7: Check the weeping rate; if not satisfactory go back to step 6 and reselect tray
Layout.
Step 8: Check the plate pressure drop, if too high return to step 6.
Step 9: Check down-comer back-up, if too high go back to step 6 or 3.
Step 10: Decide plate layout including calming zones and un-perforated areas and check
the hole pitch, if unsatisfactory return to step 6.
Step 11: Recalculate the percentage of flooding based upon selected tower diameter.
Step 12: Check for entrainment, if too high then return to step 4.
Step 13: Optimize design: repeat steps 3 to 9 to find smallest diameter and plate spacing
acceptable to get the lowest cost for the specified application.
Step 14: Finalize design: draw up the plate specification and sketch the layout.
Design Problem:
 7. DESIGN OF PACKED TOWER TYPE ABSORBER
Aim: To design an absorber for the given system.

Procedure: Process design of packed tower type absorbers involves two major steps;

(i) Determination of tower diameter and

(ii) Determination of height of packing.

Method for determining tower diameter is same for all types of packed tower absorbers. But

methods for finding the height of packing are different for the following cases.

(a) Physical absorption from dilute gas mixture in isothermal conditions

(b) Physical absorption from concentrated gas mixture in isothermal conditions

(c) Physical absorption in non-isothermal condition. Example: absorption of HCl or NH3 in

water

(d) Absorption with chemical reaction. Example: absorption of chlorine in sodium hydroxide
solution
-
 8.DESIGN OF A FLOW SHEET USING PRO-II
Aim: To draw a flow sheet using Pro-II

Process Description:

Production of Vinyl Chloride by Acetylene-HCl Reaction

Draw a flow sheet for production of vinyl chloride from the reaction of acetylene and
hydrochloric acid according to the description given below.

The reactants acetylene and hydrochloric acid are sent into a jet mixer where they are
thoroughly mixed and then they are sent into a catalytic reactor where they react to form
vinyl chloride and other products. A heating fluid is sent through bottom to maintain the
temperature of the reactor.

The product stream from the reactor is sent through a stripper where the un-reacted mixture
and the products are separated from the top and the required amount of un-reacted mixture
stream is recycled back and the other amount is purged out.

The product stream from the bottom is sent into flash distillation column where we get vinyl
chloride as the top product and the bottom stream which is the heavy residue is sent is stored
in a storage tank.

It is further distilled to get remaining vinyl chloride in the heavy residue which comes out as
the top product and aldehyde comes out as the bottom product.
9. DESIGN OF A DISTILLATION COLUMN USING PRO-II

Aim: To design the distillation column using the Pro-II

Problem Statement:

A tray tower is to be designed to continuously distill 450 lbmol/h (240 kmol/h) of a binary
mixture of 60 mol% benzene and 40 mol% toluene. A liquid distillate and a liquid bottoms
product of 95 mol% and 5 mol% benzene, respectively, are to be produced. The feed is
preheated so that it enters the column with a molar percent vaporization equal to the
distillate-to-feed ratio. Use the McCabe-Thiele method to compute the following, assuming a
uniform pressure of 1 atm (101.3 kPa) through the column:
(a) Minimum number of theoretical stages, Nmin;
(b) Minimum reflux ratio, Rmin; and
(c) Number of equilibrium stages N, for a reflux-to minimum reflux ratio, R/Rmin, of 1.3
and the optimal location of the feed stage.
Result:

Feed Conditions:

Distillate Details:
Residue Details:

Total Details:
 10. DESIGN OF A ABSORPTION COLUMN USING PRO-II

Aim: To design the absorption column using the Pro-II

Problem Statement:

When molasses is fermented to produce a liquor containing ethyl alcohol, a CO2-rich vapour
containing a small amount of ethyl alcohol is evolved. The alcohol can be recovered by
absorption with water in a sieve-tray tower. For the following; conditions, determine the
number of equilibrium stages required for counter-current flow of liquid and gas, assuming
isothermal, isobaric conditions in the tower and neglecting mass transfer of all components
except ethyl alcohol.

Entering gas: 180 kmo1/hr. 98% CO2. 2% ethyl alcohol: 30°C, 110 kPa

Entering liquid absorbent: 100% water. 30°C, 110 kPa

Required recovery (absorption) of ethyl alcohol: 97%

Results:

Water Details:

Feed Details:
Vapour Details:

Liquid Details:
Column Details: