L3-/T-II/CHE Date: 30/01/2025

BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY, DHAKA

L-3/T-II [Link]. Engineering Examinations 2022-2023
Sub: CHE 429 (Sustainable Process Engineering)
Full Marks: 210 Time: 3 Hours
The figures in the margin indicate full marks.
The symbols have their usual meanings if not explained.
USE SEPARATE SCRIPTS FOR EACH SECTION

SECTION – A
There are FOUR questions in this section. Question No. 1 is COMPULSORY.
Answer any TWO from the THREE questions.

1. (a) Define the Functional Unit and System Boundary in the context of Life Cycle Assessment
(LCA). Draw a block diagram showing the four interdependent phases of the LCA methodology
according to the ISO 14040 framework. (15)
(b) Numerical Problem: Land Use Change (LUC) is a controversial issue in biofuel sustainabil-
ity. Table 1 shows the default values for the Global Warming Potential (GWP) impact of LUC
over a 20-year period.

Table 1: GWP from LUC for Bioethanol (g CO2 -eq./MJ biofuel)

Feedstock Origin Land originally covered by
Cropland Forestland Grassland
Wheat Canada 0 977 126
Sugar cane Brazil 0 319 88

It is proposed to convert a Brazilian rainforest to sugar cane for bioethanol production. The
GWP for producing and using sugar cane ethanol (excluding LUC) is 24.1 g CO2 -eq/MJ, while
the GWP for conventional petrol is 84.8 g CO2 -eq/MJ.
(i) Calculate the total GWP footprint incurred over a 20-year period solely due to the Land
Use Change.
(ii) Calculate the annual GHG savings achieved by switching from petrol to Brazilian sugar
cane ethanol.
(iii) Calculate the payback time (in years) required to offset the carbon debt incurred by the
Land Use Change. Based on your result, comment on the sustainability of this specific
biofuel initiative.
(20)

2. (a) Numerical Problem: The Atom Utilization metric is a key indicator of inherently cleaner
chemistry. Ethylene oxide (C2 H4 O) can be manufactured via two routes. The overall stoichio-
metric equations are:
Route A (Direct Oxidation):
C2 H4 + 21 O2 −→ C2 H4 O
Route B (Chlorohydrin process):
C2 H4 + Cl2 + Ca(OH)2 −→ C2 H4 O + CaCl2 + H2 O
(Molecular weights: C2 H4 = 28, O2 = 32, Cl2 = 71, Ca(OH)2 = 74, C2 H4 O = 44, CaCl2 =
111, H2 O = 18)

1
 Calculate the atom utilization (as a %) for both routes. If the chlorohydrin route is used,
propose two industrial ecology strategies to manage the CaCl2 by-product to prevent it from
becoming an environmental burden. (15)
(b) What is “Industrial Symbiosis”? Draw a simplified network diagram mapping the resource
exchanges (e.g., steam, fly ash, waste heat) between the Asnaesvaerket power station, Statoil
refinery, and the Gyproc plasterboard plant at the Kalundborg Eco-industrial Park. (20)

3. (a) Numerical Problem: Much of the electric power generated for industrial use is obtained
from black coal using steam power cycles. Consider a power station supplied with black coal
of the following mass composition: 10.0% water, 16.7% ash, 0.5% sulfur, 60.0% carbon.
The efficiency of power generation is 36%, corresponding to a heating value of 24 GJ per tonne
of coal. (1 MWh = 3600 MJ).
(i) Calculate the total mass of coal consumed (in kg) to generate 1 MWh of electricity.
(ii) Assuming 100% combustion of carbon and sulfur, calculate the mass of CO2 and SO2
emitted (in kg) per MWh of electricity generated.
(20)
(b) Define “Environmental Externalities”. With reference to the unit damage costs associated with
power generation or landfill disposal, explain how emission taxes (e.g., carbon tax) act as an
economic policy instrument to internalize these external costs. (15)

4. (a) Explain the “Triple Bottom Line” (TBL) approach to sustainability. What specific indicators
are monitored to assess the Social sustainability of a chemical process plant? (15)
(b) Differentiate between “Classification” and “Characterisation” in the Impact Assessment phase
of an LCA. (10)
(c) Analytical Problem: A chemical plant emits 1500 kg of CO2 , 50 kg of Methane (CH4 ),
and 10 kg of Nitrous Oxide (N2 O) daily. Using the IPCC 100-year Global Warming Potential
(GWP) equivalency factors (CO2 = 1, CH4 = 21, N2 O = 310), calculate the total daily Global
Warming Impact score for the plant expressed in kg CO2 -equivalent. (10)

2
 SECTION – B
There are FOUR questions in this section. Answer any THREE questions.

5. (a) Numerical Problem: A recirculated cooling water system utilizes an evaporative cooling
tower. Based on mass balances, the make-up water requirement (M ) must compensate for
Evaporation (E), Drift (D), and Blowdown/Purge (B). The overall and component solids
balances are:

M =B+E+D
xM · M = xB · B + xD · D + E × 0

Where xM and xB are the total dissolved solids (TDS) in the make-up and blowdown streams
respectively. Drift (D) has the same concentration as the blowdown (xD = xB ).
Given that E = 3.0% of the circulation rate (C), and D = 0.2% of C. The make-up water
contains 40 ppm TDS, and the recirculated cooling water must be maintained at a maximum
of 200 ppm TDS. Calculate:
(i) The required Blowdown rate (B) as a percentage of the circulation rate (C).
(ii) The required Make-up rate (M ) as a percentage of the circulation rate (C).
(20)
(b) What is the primary purpose of “Blowdown” in boilers? Discuss the mechanical and chemical
methods (e.g., Hydrazine addition) used to treat Boiler Feed Water (BFW) before it enters the
steam drum. (15)

6. (a) Numerical Problem: A gas compressor in an ethylene plant is required to compress 250 m3 /h
of methane supplied at 25◦ C (298 K) and 1.0 bar absolute to a delivery pressure of 3.0 bar
absolute. Assuming single-stage adiabatic compression, the theoretical work W (in kW) and
discharge temperature T2 are given by:
  "  γ−1 #   γ−1
γ P1 V 1 P2 γ P2 γ
W = −1 and T2 = T1
γ − 1 3600 P1 P1

Where P1 is in kPa (1 bar = 100 kPa), V1 is in m3 /h. Given the heat capacity ratio for methane
γ = 1.31:
(i) Calculate the theoretical power requirement in kW.
(ii) Calculate the discharge temperature T2 in ◦ C.
(iii) If the combined mechanical and electrical efficiency of the compressor and motor is 71%,
determine the actual absorbed power.
(20)
(b) Graphical Analysis: Figure 1 shows the typical performance curves for process gas compres-
sors.
Explain the fundamental difference between positive displacement (reciprocating) and aero-
dynamic (centrifugal/axial) compressors using the provided graph. What does the point ’S’
(Surge point) represent? (15)

7. (a) Numerical Problem: An economic viability study is being conducted for a proposed chemical
plant. The estimated data are as follows:
- Total Fixed Capital Investment: $100 million
- Working Capital: $10 million
- Annual Sales Revenue: $90 million/year

3
 Compression ratio
S S

Axial flow
Centrifugal

Reciprocating
Volumetric capacity (m3 /h)

Figure 1: Compressor Performance Curves

- Total Annual Operating Cost (excluding depreciation): $40 million/year

- Plant life: 10 years (with zero salvage value)
- Tax Depreciation: Straight-line over 10 years (10% of Fixed Capital per year)
- Corporate Tax Rate: 30%
Construct a cash flow table to calculate the Net Cash Flow After Tax for Year 1 of plant
operation. Clearly show your calculation for Depreciation, Taxable Income, and Tax Payment.
(20)
(b) Discuss the concept of “Economies of Scale” in plant capital costs, represented by the equation
I = kQb . Why does the capacity exponent b generally differ between single-stream plants
(0.5 − 0.6) and parallel-stream plants (0.8 − 0.9)? (15)

8. (a) Analytical Problem: Fault Tree Analysis (FTA) is used to investigate the probability of
major incidents. Figure 2 illustrates a Fault Tree for the total loss of cooling water (CW)
pumping capacity in a plant equipped with two 50% capacity pumps. Pump A is steam-turbine
driven, and Pump B is electric-motor driven.

STEAM
FAIL

LOSS OF CW TURBINE
OR
FROM PUMP A FAIL

PUMP A
TOTAL LOSS
FAIL
OF CW AND
ELECTRIC
CAPACITY
FAIL

LOSS OF CW MOTOR
OR
FROM PUMP B FAIL

PUMP B
FAIL

Figure 2: Fault Tree for Loss of Cooling Water Pumping Capacity

The historical annual failure probabilities for the basic events are given as: Steam Fail = 0.05,
Turbine Fail = 0.02, Pump A Fail = 0.01, Electric Fail = 0.04, Motor Fail = 0.03, Pump B
Fail = 0.01.

4
 Using Boolean approximation methods for small probabilities (POR ≈ P1 + P2 + P3 ), calculate
the probability of the Top Event occurring in a given year. (20)
(b) Define “Inherent Safety” in process plant design. Briefly elaborate on the four principles of
inherently safer design (Substitute, Minimise, Simplify, Moderate) using relevant examples
from chemical engineering. (15)