CL 451 Chemical Process Design Spring 2024

Process design problems

Q 1. Consider the hydro dealkylation of toluene (HDA) process to produce benzene. The desired
production rate for benzene is 265 kmol/h. Toluene feed is pure, but the feed gas contains
95% hydrogen and 5% methane. The following reactions take place.
T oluene + H2 → Benzene + CH4 (1)
2Benzene ⇌ Diphenyl + H2 (2)
Based on intrinsic kinetics, the selectivity for benzene (S) is related to toluene conversion (x)
0.0036
as S = 1 − (1−x) 1.544 . In order to avoid selectivity loss to diphenyl, it is decided to recycle the

diphenyl back into the reactor (rather than taking as byproduct). The equilibrium constant
for reaction (2) is 0.24. For this design alternative,

(a) Draw the corresponding level 2 and level 3 process flowsheets. Briefly justify elements
in these flowsheets.
(b) Consider reactor conversion of 0.75 and mole fraction of hydrogen in purge as 0.4. Also
consider that hydrogen to toluene ratio of 5:1 (mol to mol) is maintained at the reactor
inlet. Perform appropriate material balance and compute level 2 economic potential.
(c) The reactor exit stream is vapor and is cooled to 100 F to obtain vapor-liquid split.
Using approximate flash calculations, estimate the value of benzene lost through purge.

You can use the following data for calculations.

Component K value Price ($/kmol) Fuel value (MMBtu/kmol)

Hydrogen 99.07 1.14⋆ 0.123
Methane 20.00 N/A 0.383
Benzene 0.0104 9.04 N/A
Toluene 0.00363 6.40 N/A
Diphenyl 0.00008 5.38 N/A
Fuel N/A $2/MMBtu N/A
⋆
This is the cost of feed gas with 95% hydrogen in it.
Q 2. Consider the hydro dealkylation of toluene (HDA) process to produce benzene. The desired
production rate for benzene is 265 kmol/h. Toluene feed is pure, but the feed gas contains
95% hydrogen and 5% methane. The following reactions take place.
T oluene + H2 → Benzene + CH4 (3)
2Benzene ⇌ Diphenyl + H2 (4)
Based on intrinsic kinetics, the selectivity for benzene (S) is related to toluene conversion (x)
0.0036
as S = 1 − (1−x) 1.544 . In order to reduce the excess hydrogen feed, it is decided to separate the

recycle gas (instead of simple recycle and purge). To this end, a membrane separation unit
is installed which takes the flash vapor and separates it into 95% hydrogen enriched stream
(similar to feed gas) and purge stream of pure methane. For this design alternative,

1
 (a) Consider that reactor conversion is 0.7 and hydrogen to toluene ratio of 5:1 (mol to mol)
is maintained at the reactor inlet. Perform appropriate material balance and compute
level 2 economic potential.
(b) The reactor outlet temperature has a maximum limit of 1300 F. Assess the feasibility
of adiabatic operation. Heat of reaction (1) is -21530 Btu/mol. Assume negligible heat
effects for reaction (2). Consider that reactor inlet temperature is 1150 F.

You can use the following data for calculations.

Component Cp (Btu/mol/F) Price ($/kmol) Fuel value (MMBtu/kmol)

Hydrogen 7.0 1.14⋆ 0.123
Methane 10.1 N/A 0.383
Benzene 38.7 9.04 N/A
Toluene 48.7 6.40 N/A
Diphenyl 181.7 5.38 N/A
Fuel N/A $2/MMBtu N/A

⋆
This is the cost of feed gas with 95% hydrogen in it.

Q 3. Consider the dehydrogenation of isopropyl alcohol (IPA) process to produce acetone. The
following reaction takes place.
IP A → Acetone + H2

The reaction is carried out at 572 F and 1 atm pressure (vapor phase process). In petrochemi-
cal complexes, IPA is produced by hydration of propylene. IPA forms an azeotrope with water
(70 mol% IPA). For the above acetone manufacturing process, this azeotropic mixture is used
as a feedstream. Similarly, any recycle IPA is also an azeotropic mixture (there is no need to
undertake azeotrope separation). Co-product hydrogen is used as a fuel in the manufacturing
complex.
Consider that the desired production rate for acetone is 50 mol/h. Also consider that the
reactor conversion is 0.75. For this process,

(a) Develop Level 2, 3 and 4 flowsheets for the process. You are required to discuss the
relevant decisions leading to these flowsheets.
(b) Perform appropriate material balance and compute level 2 economic potential.
(c) Consider reactor inlet temperature of 572 F. The heat of reaction is 25800 Btu/mol and
cp of the azeotropic feed is 22 Btu/mol/F. What heat transfer policy should be used
(adiabatic/isothermal/external diluent)?
(d) If no vapor recovery system is implemented, compute the loss of product acetone leaving
with fuel hydrogen. You can use short-cut calculations.

You can use the following data for calculations.

2
 Component Value ($/mol) K
Hydrogen 0.5 1650
Acetone 15.5 0.37
IPA azeotrope 9.5 0.08
⋆
Water -0.01 0.04
⋆
This is the cost of wastewater treatment.

Q 4. We are interested in designing a process to manufacture styrene from ethylbenzene (EB). The
following significant reactions take place.

Ethylbenzene ⇌ Styrene + Hydrogen (5)

Ethylbenzene → Benzene + Ethylene (6)
Ethylbenzene + Hydrogen → T oluene + M ethane (7)

The primary reaction is typically equilibrium limited. The reaction is carried out in the
presence of steam as an inert. The reaction temperature is 875 K and the pressure is 0.9 bar.
Reaction kinetic and thermodynamic data is given below:
ystyrene yhydrogen P
Keq = (8)
yethylbenzene
14852.6
ln (Keq ) = 15.5408 − (9)
T
fB = 0.333S − 0.215S 2 + 2.547S 3 (10)
fT = 0.084S − 0.264S 2 + 2.638S 3 (11)

where Keq is the equilibrium constant for the first reaction, T is reaction temperature in K,
P is reactor pressure in bar, yi is mol fraction of species i, S is selectivity towards styrene,
fB is mol of benzene produced per mol of styrene and fT is mol of toluene produced per mol
of styrene. We are interested in producing 120 kmol/h of polymer-grade styrene monomer
(99.95% purity). Raw material ethylbenzene contains small impurities of benzene (1% of EB)
and Toluene (1% of EB). For this system,

(a) Draw level 2 process flowsheet. You will need to justify elements of the flowsheet with
the help of level 2 design decisions.
(b) Draw level 3 process flowsheet. You will need to justify elements of the flowsheet with
the help of level 3 design decisions.
(c) The two key design variables are reactor conversion (x) and steam to aromatics ratio (M)
at the reactor inlet. Perform relevant level 2 and level 3 material balances to compute
inlet and outlet flows for the process. Assess profitability of the design using level 2
economic potential. Consider x = 0.6 and M = 10.
(d) As the main reaction is equilibrium limited, we cannot arbitrarily select conversion and
expect that it will be less than the equilibrium conversion. However, we can check if the
selected conversion is feasible or not. Using the material flows computed earlier, check
if the selected conversion is thermodynamically feasible or not.

3
 You can use the following data for calculations.

Component NBP (C) Price ($/kmol) Fuel value (MMBtu/kmol)

Styrene 145 23 N/A
Ethylbenzene 136 16 N/A
Benzene 80 9 1.41
Toluene 111 8.5 1.68
Hydrogen -253 N/A 0.123
Methane -161 N/A 0.383
Ethylene -104 N/A 0.596
Steam 100 0.07 N/A
Fuel N/A $4/MMBtu N/A

Q 5. Cumene (isopropyl benzene) is an important petrochemical as it is a raw material for the

production of phenol. Cumene is manufactured by reaction of benzene and propylene. Unfor-
tunately, cumene can get alkylated further to produce undesired p-diisopropyl benzene which
has only fuel value. In order to selectively get cumene, excess benzene is used in the reactor.
The following gas phase exothermic reactions are of interest (temperature around 350-450 C,
pressure 25 bar).

Benzene + propylene → Cumene (12)

Cumene + propylene → p − diisopropylbenzene (13)

You are tasked to explore economic feasibility of this process. Consider that the desired
production rate for cumene is 100 kmol/h. Benzene feed is pure, however, propylene feed has
5% propane as impurity. Consider that the reactor propylene conversion is 0.8. Mol fraction
of propylene in purge can be taken as 0.1. Ratio of benzene to propylene at the reactor inlet
is 2. For this process,

(a) Develop level 2 and level 3 flowsheets for the process. You are required to discuss pros
and cons of the relevant decisions leading to these flowsheets with respect to this process.
(b) Perform appropriate material balance and compute level 2 economic potential.

You can use the following data for calculations.

Component Value ($/kmol) Fuel potential (GJ/kmol) Boiling point (C)

Propylene 34.3⋆ 1.74 -47.6
Propane - 1.82 -42.0
Benzene 68.6 4.65 80.1
Cumene 132.5 4.44 152.4
p-diisopropyl benzene - 6.09 209.8
Fuel $6/GJ - -

4
 ⋆
This is the cost of propylene feed gas with propane impurity.
The selectivity for cumene (S) as a function of propylene conversion (x) is given by

S = 1 − 0.0171x − 0.0114x2 (14)

Q 6. You are a process engineer in a petrochemical complex. Your complex has 2.5× 106 kmol/yr of
an ethylene-rich stream (96% ethylene, 3% propylene and 1% methane). As such (relatively)
impure ethylene stream cannot be put into ethylene pipeline (which requires more than 99.99%
purity), the company is exploring a possibility of valorization of this stream. One option is to
convert it into ethanol using the following reaction:

Ethylene + W ater ⇌ Ethanol (15)

The chemist working on this reaction reported that the reaction is carried out at high tem-
perature (535-575 K) and pressure (68-69 bar). The reactor ethylene conversion is typically
7%. Furthermore, there is a possibility of subsequent condensation of 2 ethanol molecules to
get diethyl ether via the following reaction:

2Ethanol ⇌ Diethylether + W ater (16)

The chemist reported that for every 100 molecules of ethanol produced by reaction (42),
10 molecules undergo such condensation via reaction (43). Furthermore, under the reaction
conditions, propylene can also react with water to produce isopropyl alcohol via the following
reaction:
P ropylene + W ater ⇌ Isopropyl alcohol (17)
Typical propylene conversion for reaction (17) is 1%. Equilibrium constants for reactions (42),
(43) and (17) are 1.1 bar−1 , 0.7 and 0.3 bar−1 , respectively. Furthermore, the chemist advised
to keep the methane mole fraction at reactor inlet to be less than 10% to prevent coking. As
ethanol forms azeotrope with water, the company is planning sell this ethanol-water azeotrope
(190 proof ethanol) with 85.44% mol ethanol and 14.56% mol water. You are tasked to explore
economic feasibility of this process. For this process,

(a) Develop level 3 flowsheet for the given conditions and constraints. You are required to
justify the relevant decisions leading to this flowsheet.
(b) Perform appropriate material balance and compute level 2 economic potential. If re-
quired, you can assume appropriate values of design variables. [Hint: There will be 2
such design variables]

You can use the following data for calculations.

5
 Component Value ($/kmol) Fuel potential (GJ/kmol) Boiling point (C)
Methane - 0.404 -161.5
Ethylene 18.72 ⋆ 0.596 -103.7
Propylene - 1.74 -47.6
Ethanol-water azeotrope 38.35 - 78.2
Diethyl ether 9.38 - 34.6
Isopropyl alcohol 43.36 - 82.4
Feed water 0.001 - 100
Effluent water -0.0005 - 100
Fuel $6/GJ - -

⋆
This is the cost of ethylene feed gas with above-mentioned impurities.

Q 7. Ethylbenzene is an important petrochemical as it is a raw material for the production of

styrene. Ethylbenzene is manufactured by reaction of benzene and ethylene. Ethylbenzene
can get alkylated further to produce undesired diethylbenzene which has only fuel value. For-
tunately, diethylbenzene can react with benzene to product ethylbenzene through transalky-
lation reaction. The following gas phase exothermic reactions are of interest (temperature
around 400 C, pressure 20 bar).

Benzene + Ethylene → Ethylbenzene (18)

Ethylbenzene + Ethylene → Diethylbenzene (19)
Diethylbenzene + Benzene ⇌ 2 Ethylbenzene (20)

Consider that the desired production rate for Ethylbenzene is 90 kmol/h. Ethylene feed has
7% Ethane as impurity. Benzene feed contains 2% toluene impurity. Toluene can react with
Ethylene, at the reaction conditions, to give Ethylbenzene by the following reaction.

T oluene + 2 Ethylene → Ethylbenzene + P ropylene (21)

For this process,

(a) Develop level 2 flowsheet for the process. You are required to discuss pros and cons of
the relevant decisions leading to the flowsheet with respect to this process.
(b) Set up material balance to compute all the input and output flows. Based on these
equations, identify key design variables at level 2.
(c) Develop level 3 flowsheet for the process. You are required to discuss pros and cons of
the relevant decisions leading to the flowsheet with respect to this process.

Q 8. Ethylbenzene (EB) is an important petrochemical intermediate, predominantly used for

styrene production. It is producted by catalytic ethylation of benzene (B) at 300 psig and
820 F. The following reactions take place in the reactor.

6
 B + Et → EB (22)
EB + Et → DEB (23)
DEB + Et ⇌ T EB (24)
2EB ⇌ DEB + B (25)

where Et, DEB and T EB refer to ethylene, diethylbenzene and triethylbenzene, respectively.
In order to improve ethylbenzene selectivity, the reactor is fed with excess benzene. The
ethylene feed contains 0.94% ethane (En) impurity. The benzene feed contains 0.28% water
(W ) impurity. The normal boiling points and cost/value for each of the components is given
in the table below.

Component Cost/value ($/kmol) Boiling point (C)

EB 16 136
B 9 80
Et 1.8 -104
En - -89
W −0.3 100
DEB 3 184
T EB 4 215

For this system, develop & draw a level 2 flowsheet. You are required to discuss pros and
cons of the relevant decisions leading to the flowsheet with respect to this process.

Q 9. Acetic anhydride is an important petrochemical as it is used for acetylation of a variety of

organic molecules. One of the traditional methods for its manufacture involves a two-step
process. Initially, acetone is pyrolysed to get a highly reactive intermediate ketene. However,
ketene can undergo decomposition to give CO and ethylene. In the next step, ketene reacts
with acetic acid to form acetic anhydride. The following reactions are of interest.

Acetone → Ketene + CH4 (700C, 1atm) (26)

Ketene → CO + 0.5C2 H4 (700C, 1atm) (27)
Ketene + Acetic acid → Acetic anhydride (80C, 1atm) (28)

4
Acetone recycle 9 Fuel
gas

Acetone 5 Reactor 6 7 Reactor 8

fresh Separation Acetic
System System
feed system Anhydride
1 2
1 3
Acetic acid
fresh
feed Acetic acid recycle 10
2

Figure 1: Acetic anhydride process

7
 The corresponding level 3 flowsheet is shown in figure 1. Consider that the desired production
rate for Acetic anhydride is 10 kmol/h. Acetone and acetic acid feed can be assumed to be
pure. The selectivity for ketene (S) is related to acetone conversion in the first reactor (x) as
S = 1 − 43 x. In order to minimize formation of non-valuable CO, conversion in reactor 1 is
kept at 0.25. In order to ensure complete consumption of ketene in reactor 2, at the inlet of
reactor 2, Acetic acid to Ketene is maintained at 5:1.
For this process, perform the necessary material balances and complete the following stream
summary table. All values should be kmol/h.

Component 1 2 3 4 5 6 7 8 9 10
CH4
C2 H4
CO
Ketene
Acetone
Acetic acid
Acetic anhydride

Q 10. Acetic anhydride is an important petrochemical as it is used for acetylation of a variety of

organic molecules. One of the traditional methods for its manufacture involves a two-step
process wherein each step is conducted in a separate reactor. Initially, acetone is pyrolysed to
get a highly reactive intermediate ketene. However, ketene can undergo decomposition to give
CO and ethylene. In the next step, ketene reacts with acetic acid to form acetic anhydride.
The following reactions are of interest.

Acetone → Ketene + M ethane (700C, 1atm) (29)

Ketene → CO + 0.5Ethylene (700C, 1atm) (30)
Ketene + Acetic acid → Acetic anhydride (80C, 1atm) (31)

The selectivity for ketene (S) is related to acetone conversion in the first reactor (x) as S =
1 − 1.3x. In order to ensure complete consumption of ketene in reactor 2, acetic acid to ketene
at the inlet of reactor 2 is maintained at 5:1. Considering that the plant will produce 15000
TPA (tonnes per annum) of acetic anhydride, compute the range of acetone conversion in
reactor 1 over which the plant will be profitable. You can use the following data.

Component Cost/value ($/kg) Molecular weight (g/mol)

Acetone 0.6 58
Ketene 0 42
M ethane 0 16
Ethylene 0 28
CO 0 28
Acetic acid 0.54 60
Acetic Anhydride 0.9 102

8
Q 11. Benzoic acid is manufactured from catalytic oxidation of toluene using air. Along with benzoic
acid, benzaldehyde and benzylic acid are produced as byproducts. Furthermore, some amount
of toluene is also oxidised completely. The following reactions take place in the reactor.

T oluene + 1.5 O2 → Benzoic acid (32)

T oluene + O2 ⇌ Benzaldehyde (33)
2 T oluene + 2.5 O2 ⇌ Benzylic acid (34)
T oluene + 9 O2 → 7 CO2 + 4 H2 O (35)

In order to improve selectivity towards benzoic acid, it has been decided to operate the reactor
at around 30% conversion and the byproducts benzaldehyde and benzylic acid are recycled to
extinction. You are required to develop level 3 flowsheet for this process. The following data
may be useful.

Component Boiling point (C)

Toluene 111
Oxygen -183
Benzoic acid 250
Nitrogen -196
CO2 -78
H2 O 100
Benzaldehyde 178
Benzylic acid 180

Q 12. Monochlorodecane (M CD) is to be produced from decane (D) and chlorine via reaction (1).
Unfortunately, M CD can undergo further chlorination to give a waste product dichlorodecane
(DCD) via reaction (2).

D + Cl2 → M CD + HCl (36)

M CD + Cl2 → DCD + HCl (37)

The side-product HCl can be sold to a neighboring plant. It is desired to produce (100 + RN )
tpd of M CD where RN represents the last two digits of your roll number. Decane and
chlorine feed can be considered pure streams. The relevant data is given in table below. For
this system,

(a) Develop level 2 flowsheet for the process. You are required to discuss pros and cons of
the relevant decisions leading to the flowsheet with respect to this process.
(b) Develop level 3 flowsheet for the process. You are required to discuss pros and cons of
the relevant decisions leading to the flowsheet with respect to this process.
(c) Set up material balance to compute all the input and output flows. Based on these
equations, obtain the bound on selectivity (of the limiting reactant) which ensures eco-
nomically feasible process.

9
 (d) There is an idea of valorizing HCl by converting it back into Cl2 via the following
reaction:
2HCl + 0.5O2 ⇌ Cl2 + H2 O (38)
In the light of this new development, recompute the bound on selectivity required to
ensure economic feasibility.

Component Value ($/kg) Mol wt (kg/kmol) Boiling point (K)

HCl 0.10 36 188
Cl2 0.21 71 239
D 0.27 142 447
M CD 0.45 176 488
DCD 0.00 211 514

Q 13. Mono-isopropyl amine (MIPA) is to be produced from Isopropyl alcohol (IPA) and Ammonia
(NH3 ) via reaction (1). Unfortunately, MIPA can undergo further reaction with IPA to give
undesirable byproduct di-isopropyl amine (DIPA) via reaction (2).

IPA + NH3 → MIPA + H2 O (39)

IPA + MIPA → DIPA + H2 O (40)

Lab-scale batch experimental data collected by the chemist indicated that the selectivity (S)
of MIPA with respect to IPA is a strong function of conversion (x) and can be represented
as S = 1 − x3 . The chemist indicated that the following reaction also occurs at these reaction
conditions.

DIPA + NH3 ⇌ 2MIPA (41)

with an equilibrium constant equal to 1. Armed with this new exciting information, the
process engineer decided to use excess NH3 and recycle DIPA to extinction in order to improve
MIPA selectivity. Briefly comment on the trade-offs associated with these decisions (5 points).
Subsequently, the engineer came up with the following level 3 flowsheet.
NH3 recycle

Fresh NH3 MIPA

Separation
Reactor
system H2O
Fresh IPA

DIPA recycle

Consider that NH3 :IPA ratio of 3:1 is used at the reactor inlet and complete conversion of
IPA takes place in the reactor. For the production rate of 100 kmol/h of MIPA, compute the
following:

10
 (a) Fresh feed rate of IPA
(b) Fresh feed rate of NH3
(c) Recycle flowrate of NH3
(d) Recycle flowrate of DIPA
(e) Effluent water flowrate

The process engineer next focused his/her attention to level 4 design. It was decided to cool
the reactor outlet to 40 C and use a phase separator. Compute loss of MIPA in the flash
vapor as well as NH3 slip in the flash liquid. You can use the following information.

Component NH3 MIPA DIPA IPA H2 O

K value 10 0.1 0.05 0.02 0.01

Q 14. You are a process engineer in a petrochemical complex manufacturing ethanol from ethylene.
The following reactions take place in the reactor.

Ethylene + W ater ⇌ Ethanol (42)

2Ethanol ⇌ Diethylether + W ater (43)

gas recycle Purge gas

Ethylene feed
(1% methane) Separation
Reactor 190 proof ethanol
Process system
(800 mol/h)
water

diethyl ether recycle Effluent water

Figure 2: Level 3 flowsheet for ethanol process

The product is 190 proof ethanol (85.44% mol ethanol and 14.56% mol water). Your chemist
friend informed you that during lab studies, the selectivity towards ethanol was found out
to be 90%. After going through the process plant, you sketched the level 3 flowsheet for the
plant as shown in Figure 2. Unfortunately, there was no flow measurement on the diethyl
ether recycle line. You are required to estimate the recycle flowrate of diethyl ether. The
following data may be useful.

ˆ Water to ethylene ratio at the reactor inlet is 2:1

ˆ Reactor conversion is 0.1
ˆ Equilibrium constant for reaction (43) is 0.2
ˆ Methane at reactor inlet is 10%

11
Q 15. Consider the dehydrogenation of isopropyl alcohol (IPA) process to produce acetone. The
following reaction takes place.
IP A → Acetone + H2

The reaction is carried out at 500-600 F and 1 atm pressure (vapor phase process). In
petrochemical complexes, IPA is produced by hydration of propylene. IPA forms an azeotrope
with water (70 mol% IPA). For the above acetone manufacturing process, this azeotropic
mixture is used as a feedstream. Similarly, any recycle IPA is also an azeotropic mixture
(with same composition). Co-product hydrogen is used as a fuel in the manufacturing complex.
Figure 3 shows the corresponding level 3 flowsheet.
Hydrogen

Azeotrope Separation
Reactor Acetone
fresh feed system

Azeotrope recycle
Effluent
water

Figure 3: Level 3 flowsheet for acetone process

Consider that the desired production rate for acetone is 50 mol/h. The reactor conversion
is 0.75. The reactor inlet temperature is 600 F. The heat of reaction is 25800 Btu/mol
(endothermic) and Cp of the IPA-water azeotrope is 22 Btu/mol/F. What heat management
policy should be used for the reactor system? (Hint: Typically for gas phase reactions, 6-8
MMBtu/h load can be handled by STHE reactor)

Q 16. Consider level 4 design of the vinyl acetate manufacturing process. The feed to the flash vessel
downstream of the reactor effluent has the following specifications.

Component Molar flow (kmol/h) K value

Oxygen 6 170
Ethane 194 83
Ethylene 99 83
Carbon dioxide 3 48
Vinyl acetate 60 0.06
Water 63 0.014
Acetic acid 259 0.009

In this context,

(a) Estimate the loss of vinyl acetate in the flash vapor.

(b) Estimate the amount of light ends in the flash liquid.

Q 17. Mono-isopropyl amine (MIPA) is to be produced from Isopropyl alcohol (IPA) and Ammonia
(NH3 ) via reaction (1). Unfortunately, MIPA can undergo further reaction with IPA to give

12
 undesirable byproduct di-isopropyl amine (DIPA) via reaction (2). Reaction (3) provides a
path for converting DIPA back into MIPA.

IPA + NH3 → MIPA + H2 O (44)

IPA + MIPA → DIPA + H2 O (45)
DIPA + NH3 ⇌ 2MIPA (46)

Reactor
317 F 349 F

Gas recycle
Fresh IPA 283 F Vaporizer
32 mol/h
100 mol/h H2:0.583
120 F FEHE
4.94 MMBtu/h NH3: 0.397
1.23 MMBtu/h MIPA: 0.018
DIPA: 0.001
Total NH3

300 mol/h

vessel
200 F

Flash
120 F
350 psia 120 F
Cooler

Vent
8.2 mol/h
2.03 MMBtu/h
H2:0.05
Fresh NH3 NH3: 0.95
449.3 mol/h
99.9 mol/h Recycle NH3 H2:0.001
120 F NH3: 0.463
200.1 mol/h MIPA: 0.223
NH3: 0.999

RC
DIPA recycle MIPA

41.1 mol/h 99.8 mol/h

IPA: 0.012 MIPA: 0.999
MIPA: 0.003
DIPA: 0.974
BPC PC
H2O: 0.010 141.2 mol/h
MIPA: 0.001 241.0 mol/h
NH3: 0.0005

Water
100.1 mol/h
H2O: 0.999

Figure 4: Level 5 flowsheet for MIPA process (values without unit represent mol fraction)

Figure 4 shows a level 5 flowsheet for this process. Justify various design decisions made while
obtaining this flowsheet using hierarchical design approach and discuss the associated trade-
offs. Note that hydrogen is not consumed/produced in the reaction system. It is circulated
in the system as it improves catalyst life and lowers dew point temperature. Normal boiling
points of various components are as follows: MIPA 34 C, IPA 82 C, NH3 −33 C, DIPA 84 C,
H2O 100 C, H2 −253 C.

Q 18. Consider a parallel reaction scheme of A → B and A → C with B being the desired product.
Consider that both the reactions are zeroth order with rate constants of kB = 4mol/L/s and

13
 kC = 1mol/L/s. Consider that the initial feed contains only A with CA0 = 1mol/L. Draw
the corresponding attainable region and shade the achievable concentration region (only 2-
d plots). Identify the components (reactor type and the corresponding residence time) of
superstructure spanning the feasible concentration space achievable for this system.

Q 19. Consider a parallel reaction scheme of A → B and A → C with B being the desired product.
The rate constant for production of B is 3s−1 and that for C is 2s−1 . Consider that the initial
feed contains only A with CA0 = 1mol/L. Draw the corresponding attainable regions and shade
the achievable concentration region (only 2-d plots). Identify the components (reactor type
and the corresponding residence time) of superstructure spanning the feasible concentration
space achievable for this system.

Q 20. Consider the following reaction system:

A → B kB = 2 s−1 (47)
A → C kC = 1 mol L−1 s−1 (48)
A → D kD = 1 L mol−1 s−1 (49)

where kB , kC and kD are the corresponding rate constants. The desired product is C. Consider
that the initial concentration is CA0 . For this system,

(a) Construct attainable region. You need to show all the major steps and use graph paper
to plot the responses.
(b) Identify the point/s of maximum selectivity and maximum yield. Also mention the
corresponding reactor type and residence time.
(c) Identify components of the reactor network superstructure and draw the superstructure.

Use CA0 = 2 mol L−1 .

Q 21. Consider the following reaction scheme

A→B→C (50)
where B is the desired product. The rate constant for the first reaction (A → B) is 0.5 s−1 ,
whereas the rate constant for the second reaction (B → C) is 0.1 mol.L−1 s−1 . For this system,

(a) Construct the attainable region when the feed is pure A with concentration of 1 mol.L−1 .
(b) Identify the points of maximum conversion, selectivity and yield.
(c) Draw the corresponding reactor network superstructure.

Q 22. We are interested in developing reactor network for a process. The following reactions take
place.

A⇌B (51)
A→C (52)

14
 Consider that each reaction follows first order kinetics and the corresponding rate constants
are k1f , k1r and k2 , respectively. Feed can be considered as pure A with concentration of CA0 .
For this system,

(a) We want to develop an attainable region. As the first step, we need to construct PFR
and CSTR trajectories. Develop the equations required to obtain these trajectories.
Specifically, you are required to give the final forms of equations and describe, in detail,
the procedure to solve these equations and obtain trajectories shown in Figure 5 (like a
pseudocode). You are not required to solve the equations.
(b) Figure 5 depicts the trajectories for PFR and CSTR. Let us consider that B is the
desired product. Draw the corresponding attainable region, show the points/regions
of maximum conversion, yield and selectivity. Finally draw the corresponding reactor
network superstructure which can be used to solve superstructure optimization problem.
(c) Let us now consider that C is the desired product. Repeat the tasks mentioned in part
(b) for this case.

0.6 1 1
PFR PFR PFR
CSTR CSTR CSTR
0.5
0.8 0.8

0.4
0.6 0.6
CB

CC

CC
0.3
0.4 0.4
0.2

0.2 0.2
0.1

0 0 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0 0.1 0.2 0.3 0.4 0.5 0.6
CA CA CB

(a) CA − CB view (b) CA − CC view (c) CB − CC view

Figure 5: CSTR and PFR trajectories

Q 23. Attainable region for methane steam reforming system is depicted in Figure 6.
Here, x-axis represents cCH4 /cCH4 ,0 and y-axis represents cCO /cCH4 ,0 . c represents concen-
tration and cCH4 ,0 is methane concentration in the feed. The corresponding reactions are as
follows.

CH4 + 2H2 O ⇌ CO2 + 4H2

CH4 + H2 O ⇌ CO + 3H2
CO + H2 O ⇌ CO2 + H2

Using this attainable region, answer the following.

(a) Depict the attainable region

(b) Identify the points with maximum CH4 conversion, maximum CO selectivity and max-
imum yield of CO. What reactor configuration is required to achieve each of these?

15
 Figure 6: Attainable region for methane steam reforming system

(c) Identify the components (reactor type only) of superstructure spanning the feasible con-
centration space achievable for this system.
(d) Draw the reactor superstructure and clearly specify under what conditions the various
components can be obtained.

Q 24. Consider the following reaction scheme in the context of reactor network design. We are
interested in developing a reactor superstrcture.

Consider that the feed contains only component A with concentration of 2 mol/L. The rate
constants are k1 = 10 mol/L/s, k2 = 2 mol/L/s, k3 = 5 mol/L/s and k4 = 3 mol/L/s. For
this system,

(a) Construct attainable region and show its projections in all the 2-d (CA − CB , CA − CC ,
CA − CD , CC − CB , CB − CD and CC − CD ) spaces. You NEED to shade the attainable
region and denote relevant values in the figure. Use graph paper.
(b) If B is the desired product, what is the maximum possible yield and selectivity? What
reactor (type and residence time) will be required to achieve each of these? Draw the
reactor superstructure for this case.
(c) If D is the desired product, what is the maximum possible yield and selectivity? What
reactor (type and residence time) will be required to achieve each of these? Draw the
reactor superstructure for this case.

16
Q 25. Ethylbenzene (EB) is an important petrochemical intermediate, predominantly used for
styrene production. It is produced by catalytic ethylation of benzene (B) at 300 psig and
820 F. The following reactions take place in the reactor.

B + Et → EB (53)
EB + Et → DEB (54)
2EB ⇌ DEB + B (55)
where Et and DEB refer to ethylene and diethylbenzene, respectively. We are interested in
synthesizing reactor network for this system. In this context,

(a) We want to develop attainable region for this system. As the first step, we need to
construct PFR and CSTR trajectories. Develop the equations required to obtain these
trajectories. Specifically, you are required to give the final forms of equations and describe
the procedure to solve these equations to obtain trajectories shown in Figure 7. You are
not required to solve the equations. You can assume the order of each reaction with
respect to each of its reactants to be 1.

0.5
PFR
CSTR
0.4
CEB/CE0

0.3

0.2

0.1

0
0 0.2 0.4 0.6 0.8 1
CE/CE0

Figure 7: PFR and CSTR trajectories for the ethylbenzene reaction system (CE and CEB refer to
concentration of ethylene and ethylbenzene respectively. CE0 refers to the initial feed concentration
of ethylene)

(b) Figure 7 depicts the trajectories for PFR and CSTR. Draw the corresponding attainable
region and show the points/regions of maximum conversion, yield and selectivity.

Q 26. Air separation by cryogenic distillation is one of most common methods to produce industrial
grade oxygen, nitrogen and argon. In conventional setup, this can be accomplished by direct
or indirect sequence of distillation columns. Using heuristic rules as well as marginal vapor
method, select and schematically draw the most appropriate sequence of distillation columns.
You can use the following data:

17
 Component NBP Relative volatility Feed mole fraction Desired purity
Nitrogen -196 3.1 0.78 99.00%
Argon -186 1.3 0.01 99.99%
Oxygen -183 1.0 0.21 98.50%
Column Minimum reflux ratio
Nitrogen/Argon-Oxygen 1.5
Nitrogen-Argon/Oxygen 2.1
Nitrogen/Argon 1.45
Argon/Oxygen 2.2

Q 27. Consider level 4 design of the styrene manufacturing process. The liquid from the flash vessel
downstream of the reactor effluent has the following composition.

Component Molar flow (kmol/h) Relative volatility

Benzene 8.9 14.8
Toluene 31.7 4.5
Ethylbenzene 105.0 1.5
Styrene 119.8 1

As benzene and toluene are byproducts, there is no stringent purity specification on them,
whereas styrene product purity spec is 99.95%. Ethylbenzene is recycled back to the reactor.
It should be noted that styrene has a tendency to polymerize. You are tasked to sequence the
distillation columns in the liquid separation system.

(a) List all the possible (simple) distillation column sequences. Use heuristic rules to select
your preferred sequence. Note that you need to explain the selection based on the rules.
(b) Use marginal vapor method to select the best distillation column sequence.

The following data will be useful.

Column Minimum reflux ratio

B/T-EB-S 3.93
B-T/EB-S 2.41
B-T-EB/S 2.84
T/EB-S 3.25
T-EB/S 3.04
B/T-EB 3.01
B-T/EB 1.66
B/T 1.81
T/EB 2.24
EB/S 4.01

Q 28. Cumene (isopropyl benzene) is an important petrochemical as it is a raw material for the
production of phenol. Cumene is manufactured by reaction of benzene and propylene. Un-
fortunately, cumene can get alkylated further to produce undesired p-diisopropyl benzene. In

18
 order to selectively get cumene, excess benzene is used in the reactor. The following gas phase
exothermic reactions take place.
Benzene + propylene → Cumene
Cumene + propylene → p − diisopropylbenzene
Consider that the desired production rate for cumene is PC with purity of xC,spec . Benzene feed
is pure, however, propylene feed mol fraction is yF P (rest propane as impurity). Consider that
selectivity to cumene is a function of conversion and benzene excess ratio. The corresponding
flowsheet (components present in a stream are shown in red across the corresponding arrow)
is given in Figure 8.
Purge gas
Pr, Py, B
Pr, Py, B
Pr, Py
Feed gas Pr, Py, B,

flash
Reactor
Fresh benzene C, D
B

Pr, Py, B,
C, D
Cumene Pr, Py, B, C

B, C, D

B, C, D
PC RC

p-diisopropyl B, C, D
benzene

C, D

Pr: Propane Py: Propylene B: Benzene C: Cumene D: p-diisopropyl benzene

Figure 8: Cumene process

For this system,

(a) Set up linear material balance equations (by introducing appropriate design variables)
and arrange it in explicit form. In other words, you can explain in what sequence these
equations should be solved to get key input and output flow rates (feed gas, purge gas,
feed benzene and p-diisopropyl benzene byproduct). For example, you would say eq. (x)
is used to get y and so on.
(b) For each of the independent design variables identified in the above balance equations,
discuss the associated trade off.

Q 29. Ethylbenzene (EB) is manufactured by reaction of benzene (B) and ethylene (Ey). EB can
get further alkylated to produce undesired diethylbenzene (DEB). Fortunately, DEB can react

19
 with B to produce EB via transalkylation. Furthermore, in order to selectively get EB, excess
benzene is used in the reactor. The following gas phase exothermic reactions are of interest.

B + Ey → EB (56)
EB + Ey → DIB (57)
B + DIB → 2EB (58)

Purge gas
Et, Ey, B Et, Ey, B
Et, Ey
Feed gas Et, Ey, B,

flash
Reactor
Fresh benzene EB, DEB
B
B, EB

Benzene
recycle

B, EB, DEB
Ethylbenzene

B, EB, DEB

B, EB, DEB
RC PC
DEB recycle
EB, DEB

B, EB, DEB

Et: Ethane Ey: Ethylene B: Benzene EB: Ethylbenzene DEB: Diethyl benzene

Figure 9: Ethylbenene process

Figure 9 shows level 4 flowsheet for this process highlighting the components present in each
stream. Using linear material balance, compute the fresh benzene and feed gas flow rate. You
can use the following data for calculations.

ˆ EB product specifications: 600 kmol/h at 99.9% purity

ˆ Feed: Benzene is pure, feed gas contains 1% ethane impurity
ˆ Excess reactant: At reactor inlet, benzene to ethylene ratio is 2:1
ˆ The selectivity for EB (S) as a function of Ethylene conversion (x) is given by

S = 1 − 0.2x (59)

ˆ Assume reasonable values for independent design variables.

Q 30. Polyvinyl chloride (PVC) is one of the widely used polymers. It is obtained by polymerization
of vinyl chloride monomer (VCM). This problem concerns process for VCM manufacturing.
VCM can be produced from ethylene via a 2-step process. In the first step, ethylene is
converted into ethylene dichloride (EDC) by direct chlorination or oxychlorination. In direct
chlorination, chlorine and ethylene react to form EDC.

C2 H4 + Cl2 → C2 H4 Cl2 (60)

20
 In oxychlorination, ethylene reacts with hydrogen chloride, in the presence of oxygen, to
product EDC.
1
C2 H4 + 2HCl + O2 → C2 H4 Cl2 + H2 O (61)
2
In the second step, the EDC is cracked to form vinyl chloride

C2 H4 Cl2 → C2 H3 Cl + HCl (62)

A simplified process for VCM manufacturing plant is shown in figure 10. A part of the total
ethylene feed is sent to direct chlorination reactor (R1). Ethylene is used in excess to force
complete conversion of chlorine. The reactor outlet is sent to flash vessel 1. The vapor phase
is recycled back to the reactor after taking out a small purge stream. The liquid phase is sent
to the pyrolysis (cracker) reactor (R3). In order to maintain selectivity, reactor R3 conversion
is kept to a low value. The outlet from R3 is sent to a recycle column, wherein HCl is
separated from VCM and EDC. The bottom stream from the recycle column is sent to the
product column wherein high purity VCM product is taken as distillate. The bottom stream
containing predominantly EDC is recycled back to the pyrolysis reactor. In order to improve
atom economy with respect to chlorine, the HCl generated is sent to oxychlorination reactor
(R2). The remaining ethylene fresh feed is also sent to R2, along with oxygen. In this reactor,
excess ethylene is used to force complete conversion of HCl. Due to the presence of oxygen, a
small amount of ethylene also combusts to form CO2 .

C2 H4 + 3O2 → 2CO2 + 2H2 O (63)

Accordingly, oxygen is also supplied in excess. The outlet from R2 is sent to flash vessel 2
to remove light gases. The liquid from flash vessel 2 is sent to the dewatering column to get
dehydrated EDC, which is then sent to the pyrolysis reactor. The components present in each
stream are indicated in the flowsheet.
Consider that the feed gas contains 99% ethylene and rest ethane. Chlorine and Oxygen feed
can be considered pure. Ethylene to Chlorine at R1 inlet is maintained at 2:1. Ethylene to
HCl at R2 inlet is maintained at 0.6:1. Oxygen to HCl at R2 inlet is maintained at 0.5:1.
Selectivity of EDC in R2 in terms of ethylene reacted is 0.9. Conversion in R3 is 0.4.
You are required to compute the flow rate of feed gas required to produce VCM at 100 kmol/h
with 99.5% purity. You can select appropriate values of any other design variables, as required.
Clearly state definition and selected value of any such design variable.

Q 31. Consider vinyl acetate monomer (V AM ) manufacturing process. The following high temper-
ature vapor phase catalytic reactions take place:
1
Et + AA + O2 → V AM + W (64)
2
Et + 3O2 → 2CO2 + 2W (65)

where Et, AA, O2, W and CO2 represent ethylene, acetic acid, oxygen, water and carbon
dioxide, respectively. It can be seen that undesirable combustion reaction converts valuable

21
 Ethylene recycle (C2, Et)
Purge gas
(C2, Et)
Furnace
Chlorine Direct Chlorination (C2, Et, Flash
fresh feed Reactor (R1) ECD) vessel 1
(CL2)

(EDC)
Feed gas (EDC, VCM,
Pyrolysis Reactor (R3)
(C2, Et, HCL)
(C2, Et) Vent gas
O2, CO2)
Recycle column

(C2, Et,
Oxygen Oxychlorination O2, CO2, Flash
VCM product
fresh feed

(EDC, VCM)
Reactor (R2) H2O, EDC, vessel 2
(EDC, VCM,
(O2) VCM)
HCL)

22
(EDC,
VCM,
HCL)

VCM)
Product column

(H2O, EDC,
Dewatering column
EDC recycle (EDC, VCM)

(H2O)

Waste water
HCL recycle (HCL, VCM)

Figure 10: VCM process (C2: ethane, Et: ethylene, VCM: vinyl chloride, EDC: ethylene dichloride)
 ethylene into CO2 . In order to improve selectivity towards V AM , excess AA is used. Un-
fortunately, too much (unreacted) acetic acid at the reactor outlet increases its dew point,
resulting in the formation of a liquid phase, which is detrimental to the process. Thus to lower
the dew point, excess Et is also used. The flowsheet at the end of level 4 design is depicted
in figure 11.
The reactor operates at 98% conversion (for the limiting reagent) at which the selectivity
towards VAM (reaction (1)) is 0.88. The reactor output is cooled and sent to a flash vessel.
To recover V AM lost in the vapor phase, it is absorbed in acetic acid. This absorbed V AM ,
as well as the flash liquid are then mixed and sent to the de-ethanizer column to remove the
light ends. The bottom stream from this column is sent to the product column, which is
an azeotropic distillation column. At the top of the column, a heterogeneous azeotrope is
formed, which splits into two phases upon condensation. The organic layer is rich in V AM
and taken as a product stream. The aqueous layer is rich in water, which is sent for effluent
treatment. The bottom of this column, which is rich in acetic acid, is partly used as a solvent
in the absorption column and the rest is recycled back to the reactor. The vapor leaving the
absorber is recycled back after taking out a purge stream. The light ends from the de-ethanizer
column are also recycled back to the reactor.
You are tasked to compute the fresh feed flow rate of oxygen to get 60 kmol/h of V AM
product with 99% purity. Use purge fraction of 0.1 and all the small split fractions as 0.01.

Q 32. Consider the hydro dealkylation of toluene (HDA) process to produce benzene. The desired
production rate for benzene is 265 kmol/h with purity of 99.97%. Toluene feed is pure, but
the feed gas contains 95% hydrogen and 5% methane. The following reactions take place.

T oluene + H2 → Benzene + CH4 (66)

2Benzene ⇌ Diphenyl + H2 (67)

Based on intrinsic kinetics, the selectivity for benzene (S) is related to toluene conversion (x)
0.0036
as S = 1 − (1−x) 1.544 . In order to avoid selectivity loss to diphenyl, it is decided to recycle the

diphenyl back into the reactor (rather than taking as byproduct). The equilibrium constant
for reaction (2) is 0.24. For this design alternative, the level 4 flowsheet is shown in Figure
12.
The following design variable values are selected.

ˆ Reactor conversion (x) = 0.9

ˆ Purge fraction (fP ) = 0.1
ˆ Hydrogen to aromatics at reactor inlet (M ) = 5:1
ˆ Loss fraction of key component in distillation (fcolumn,component ) = 0.01
ˆ Loss fraction for benzene in flash vapor (fF V,B ) = 0.2

In this context,

(a) Compute the flow rate of fresh toluene

(b) Compute the flow rate of feed gas

23
 corresponding arrow)
Gas recycle Purge gas
Et, O2, CO2, VAM Et, O2, CO2, VAM

Solvent for absorption

AA, W

Absorber
Et, O2,

Et, VAM
CO2, VAM
Light ends

Et
Fresh Ethylene
O2 Et, O2, CO2,
Fresh Oxygen Reactor
VAM, AA, W

flash
AA
Fresh Acetic acid

24
VAM product

VAM, AA, W
Et, VAM, AA, W
Legend: Et: Ethylene

Et, VAM, AA, W

AA: Acetic Acid
O2: Oxygen Effluent water
VAM: Vinyl acetate VAM, AA, W

AA, W
W: Water

Liquid recycle
De-ethanizer

CO2: Carbon dioxide

Product column

Et, VAM, AA, W

Figure 11: VAM process flowsheet (components present in each stream are indicted across the
 Purge Gas recycle
Feed gas
H, M, B H, M, B H, M

H, M, B
vessel
Flash
Reactor
H, M, B, T, D
Cooler Heater

Fresh
Toluene
T
M, B, T, D

Light ends
M, B
Liquid recycle
Benzene
M, B, T B, T, D

SC PC

M, B, T, D

H: Hydrogen, M: Methane, B: Benzene, T: Toluene, D: Diphenyl

Figure 12: Level 4 flowsheet for HDA process (components present in a stream are shown across
the corresponding arrow)

Q 33. Consider ethylbenzene production process. The outlet of the reactor contains the following
components.

Component K value
Ethane 51.5
Ethylene 77.7
Benzene 0.25
Ethylbenzene 0.03
Diethylbenzene 0.004

During level 4 material balance, we need to estimate the split fractions for all the components
across the flash vessel. Considering that the flash vessel is designed for fractional loss of
ethylbenzene in the vapor stream (fF V,EB ) of 0.01, compute the corresponding loss  fractions

for the other components. (Hint: Component balance for any species gives VL = Ki vfii − 1
where fi and vi are the molar flowrate of component i in feed and vapor outlet, respectively.
L and V are the total liquid and vapor flowrate exiting the flash vessel.)

Q 34. We are interested in designing a heat exchanger network for a system. The stream details are
given in table 1. It has been decided to use ∆Tmin of 10 C. For this system,

25
 (a) Compute the heating and cooling utility required for the minimum utility design. Also
identify the pinch point temperatures.
(b) It was later realised that the hot utility is available at a relatively higher temperature
than required. It is proposed to insert a heat engine to extract some work from this hot
utility before it is sent to this heat exchanger network. Consider that the heat engine
efficiency is 10%. In the light of this scenario, compute the updated heating and cooling
utility required as well as the power generated by the engine. Draw the corresponding
combined heat cascade diagram.
(c) Using pinch design method, synthesize the corresponding heat exchanger network with
minimum utility requirement (as per part (a)).
(d) Depict the HEN using schematic diagram showing heat exchanger duties, outlet temper-
ature, stream split fractions if any, etc.

Table 1: Stream data for 3 hot 3 cold stream system

Stream F Cp (kW/K) Tin (C) Tout (C)
H1 23 170 88
H2 2 278 90
H3 5 354 100
C1 9 30 135
C2 20 130 205
C3 18 200 298

Q 35. You are in the process of designing a heat exchanger network for a process. The corresponding
hot and cold streams available are given in table 2. It has been decided to use ∆Tmin of 20
C. For this system,

(a) Compute the heating and cooling utility required for the minimum utility design. Also
identify the pinch point temperature.
(b) It was later realised that a distillation column needs to be integrated with this HEN.
The column has a requirement of condenser duty of 140 kW at 90 C and reboiler duty of
120 kW at 150 C. In the light of this scenario, compute the updated minimum heating
and cooling utility required. Also draw the corresponding heat cascade diagram.

Table 2: Stream data for 3 hot 3 cold stream system

Stream F Cp (kW/C) Tin (C) Tout (C)
H1 3 300 140
H2 4 230 120
H3 3 160 60
C1 2 40 230
C2 3 100 240
C3 3 230 300

26
Q 36. Consider a HEN design problem with the stream data given in table 3. It is desired to use
∆Tmin of 10C. In this case, the hot and cold-side pinch temperatures are 159C and 149C,
respectively. For this system,

(a) Design a minimum utility heat exchanger network using pinch design methodology. You
are required to schematically represent the corresponding HEN.
(b) It is desired to exploit the capital cost-operating cost trade-off. To this end, it is de-
cided to remove one process-to-process heat exchanger. Design the corresponding heat
exchanger network. You are required to schematically represent the corresponding HEN.

Table 3: Stream data for 3 hot 2 cold stream system

Stream F Cp (kW/K) Tsupply (C) Ttarget (C)
H1 2.285 159 77
H2 0.204 267 80
H3 0.538 343 90
C1 0.933 16 117
C2 1.961 118 265

Q 37. Consider the process stream data given in table 4. For this system,

(a) Compute the minimum hot and cold utility required if ∆Tmin of 20 C is selected.
(b) Design the heat exchanger network that achieves the above targets.

Table 4: Stream data for 2 hot 2 cold stream system

Stream Tin (C) Tout (C) FCp (kW/C)
1 175 45 10
2 125 65 40
3 20 155 20
4 40 112 15

Q 38. Consider the stream data given in Table 5. It is desired to synthesize a minimum utility HEN
for this system with ∆Tmin = 20 C. For this case,

(a) Obtain the minimum hot and cold utility targets.

(b) Design the HEN that achieves these targets

Q 39. Consider the stream data given in table 6. It is desired to synthesize a minimum utility HEN
for this system with ∆Tmin = 20 C. For this case,

(a) Estimate the minimum utility targets

(b) Design the HEN which achieves the minimum utility targets.

27
 Table 5: Stream data for 2 hot 2 cold stream system
Stream Tsupply (C) Ttarget (C) FCp (kW/K)
H1 500 110 2
H2 430 230 5
H3 400 110 3
C4 25 420 7

Table 6: Stream data for 2 hot 2 cold stream system

Stream Tsupply (C) Ttarget (C) FCp (kW/K)
H1 280 60 30
H2 180 20 45
C3 20 160 40
C4 120 260 60

(c) Relax this HEN by breaking all the loops in the network. Note that the ∆Tmin of the
final design should be equal to 20 C. [Hint: You may have to pass reduced load along a
path.]

Q 40. Consider a process wherein a raw material A is used to manufacture a valuable product B
using an exothermic A → B reaction. The main reactor operates at 66.67% conversion. The
reactor inlet is at 150 C, whereas the reactor outlet stream leaves at 200 C. The reactor outlet
is cooled to 60 C and sent to a distillation column. The column separates unreacted raw
material from the desired product. The condensation temperature and reboiler temperature
for the column are 50 C and 90 C, respectively. The corresponding condenser and reboiler
duties are 10000 kJ/h and 15000 kJ/h, respectively. You can assume perfect separation in
the distillation column. The distillate is recycled back to the reactor. The fresh feed of A
is available at 25 C and the product is cooled to 30 C before sending to the storage tank.
Consider that heat capacity of pure A is 5 kJ/kmol/C and that of pure B is 3 kJ/kmol/C.
For any other stream, heat capacity can be computed as weighted average of the individual
component heat capacities. The desired production rate is 100 kmol/h. For this process,

(a) Insert heaters and coolers at appropriate locations to satisfy temperature requirements
of the process. Accordingly, identify hot and cold streams, their source and target tem-
perature and compute total heating and cooling duty required by the process.
(b) Use problem table algorithm to identify pinch point and compute net heating and cooling
duty required by the process. Use ∆Tmin = 20 C
(c) Using pinch design methodology, design the heat exchanger network.

Q 41. We are interested in designing a heat exchanger network for a system with the following stream
details.

28
 Stream F Cp (kW/K) Tin (o C) Tout (o C)
H1 8 120 60
H2 10 160 40
C1 2 10 100
C2 60 80 115

For this system,

(a) Compute the minimum utility requirement for ∆Tmin = 20o C.

(b) Design a minimum utility heat exchanger network for ∆Tmin = 10o C. Note that the
corresponding pinch temperature is 85o C (shifted).

Q 42. We are interested in designing a heat exchanger network for a system with the following stream
details.

Stream F Cp (kW/K) Tin (o C) Tout (o C)

1 2 20 135
2 3 170 60
3 4 80 140
4 1.5 150 30

For this system, application of the problem table algorithm with ∆Tmin = 6o C gave pinch
temperature of 83o C (shifted). Using pinch design method, synthesize the corresponding heat
exchanger network with minimum utility requirement.

Q 43. Consider the process stream data given below. For this system, for ∆Tmin of 13 C, the pinch
temperatures are 112 C (cold) and 125 C (hot), and the minimum utility targets are 360 kW
(heating) and 280 kW (cooling). Design a heat exchanger network that achieves these targets.

Stream Tin (C) Tout (C) FCp (kW/C)

1 175 45 10
2 125 65 40
3 20 155 20
4 40 112 15

Q 44. Let us consider a batch fermentation process with the following recipe.

ˆ Pretreatment: Feed pre-treatment is done for 2h.

ˆ Reaction: Fermentation is carried out in a reactor and is completed in 12h.
ˆ Separation: Product purification is done using distillation and takes 4h.

For this system, we are interested in developing a production schedule to conduct 2 batches.
Consider that zero wait policy is to be implemented. For each of the following scenarios, draw
the production schedule, identify cycle time and compute makespan for completing 2 batches.

29
 (a) Each of the steps (pre-treatment, reaction and separation) are carried out in separate
equipment.
(b) Pre-treatment and reaction are carried out in a reactor, whereas separation is carried
out in a distillation column.
(c) Pre-treatment and separation are carried out in separate vessels and two reactors are
available to carry out the reaction step.

Q 45. Consider a multiproduct batch plant producing two products A and B. Each product has to
go through 3 processing units, S1, S2 and S3. The corresponding processing times (in h) are
given below:

Product S1 S2 S3
A 4 2 3
B 3 2 5

For this system,

(a) Consider production campaign of AAAABB with infinite intermediate storage policy.
Show the corresponding batch schedule using a gantt chart and compute makespan.
(b) Consider production campaign of AABAAB with zero wait policy. Show the correspond-
ing batch schedule using a gantt chart and compute makespan.

Q 46. Consider a multiproduct batch plant producing two products A and B. Each product has to
go through 3 processing units, S1, S2 and S3. The corresponding processing times (in h) are
given below:

Product S1 S2 S3
A 4 2 3
B 3 2 5

Every time there is a transition between different products, cleanup time of 1h is required
(applicable to all the processing units). It is desired to produce 2 batches of A and 2 batches
of B. For this system, compute the makespan for single product campaign as well as mixed
product campaign under zero wait policy. Which campaign is better? Draw the corresponding
gantt charts.

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 Answers
Q 1. (b) $419.2/h, (c) $32.9/h

Q 2. (b) $573.2/h, (c) Not feasible

Q 3. (b) $121.2/h, (c) Isothermal, (d) 9.71 mol/h

Q 4. (c) $34.8/h, (d) feasible

Q 5. (b) $2711.4/h

Q 6. (b) $60M/y (var 1: 1.5, var 2: 0.0026)

Q 7. (b) Feed gas flow, ethylene mol fr in purge, ethane mol fr in purge

Q 8. N/A

Q 9. Stream 8: (15, 2.5, 5, 0, 45, 40, 10)

Q 10. x ≤ 0.3185

Q 11. N/A

Q 12. (c) S ≥ 0.51, (d) S ≥ 0.44

Q 13. MIPA lost in vapor: 8 kmol/h, NH3 slip in liquid: 25 kmol/h

Q 14. 7.2 mol/h

Q 15. Isothermal

Q 16. (a) 2.85 kmol/h, (b) 4.59 kmol/h

Q 17. N/A

Q 18. Components: CSTR/PFR with bypass and τ = 0.2 s

Q 19. CSTR/PFR

Q 20. (b) Maximum selectivity: CSTR (τ = 2 s) with bypass, Maximum yield: CSTR (τ = 2 s)

Q 21. (b) Maximum conversion: CSTR/PFR (τ → ∞), maximum selectivity: PFR (τ → 0),
maximum yield: PFR (with CA ≈ 0.22)

Q 22. (b) Maximum conversion: CSTR/PFR (τ → ∞), maximum selectivity: PFR (τ → 0),
maximum yield: PFR (with CA ≈ 0.1)

Q 23. (b) Maximum conversion: point B, maximum selectivity: segment AC, maximum yield: point
D

Q 24. (c) Maximum selectivity: PFR/CSTR (0 ≤ τ ≤ 2/15), maximum yield: PFR/CSTR (τ =

2/15)

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Q 25. (b) Maximum conversion: CSTR/PFR (τ → ∞), maximum selectivity: PFR (τ → 0),
maximum yield: PFR (τ → ∞)

Q 26. Direct sequence

Q 27. (b) Indirect sequence

Q 28. N/A

Q 29. Fresh benzene flow: 613.9 kmol/h, Feed gas flow: 613.3 kmol/h

Q 30. Feed gas flow: 115.7 kmol/h

Q 31. 34.16 kmol/h

Q 32. (a) 274.7 kmol/h, (b) 462.6 kmol/h

Q 33. fF V,Benzene : 0.078, fF V,DEB : 0.001, fF L,Ethane : 0.055, fF L,Ethylene : 0.037

Q 34. (a) Heating 1528 kW, cooling 851 kW (b) power generated = 169.8 kW

Q 35. (a) Heating 130 kW, cooling 340 kW (b) Heating 130 kW, cooling 360 kW

Q 36. N/A

Q 37. (a) Heating 605 kW, cooling 525 kW

Q 38. (a) Heating 115 kW, cooling 0 kW

Q 39. (a) Heating 4000 kW, cooling 3800 kW

Q 40. (a) Heating 102500 kJ/h, cooling 105000 kJ/h, (b) Heating 14500 kJ/h, cooling 17000 kJ/h

Q 41. (a) Heating 1380 kW, cooling 780 kW

Q 42. N/A

Q 43. N/A

Q 44. (a) cycle time 12h, makespan 30h

Q 45. (a) 31 h, (b) 30 h

Q 46. Single product 24h, mixed product 25 h

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