Chemical Engineering Plant Design

Course Code: CHE435

Course Cr. Hrs.: 3(3,0)

Course Instructor:
Dr. Muhammad Haris Hamayun
Assistant Professor,
Department of Chemical Engineering,
COMSATS University Islamabad, Lahore Campus.
Contact Email: [email protected]
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 Course Contents

Process design and development. General design consideration. Design codes,

standards and materials selection, optimum design. Health safety and environment, Fire and
explosion hazards: HAZID, HAZIN, HAZOP analysis. Lifecycle analysis. Vessel design: low,
medium and high pressure, storage and transportation vessels, cryogenic vessels. Hydraulic
design of tray and packed columns. Heat exchanger network design, piping and
pipeline design. Properties estimation. Design of mass transfer equipment, material
transport, material handling and heat transfer including furnaces and refrigeration units.
Basic concepts of cost indexing, estimation and optimization: optimization of unconstrained
functions; linear programming applications; non-linear programming with constraints.
Engineering Ethics; local, global impact analysis.
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 Course Learning Outcomes

• CLO # 1: Apply process design considerations and cost analysis on a chemical

engineering plant (C3, PLO1).

• CLO # 2: Apply optimization techniques on chemical engineering equipment/plant (C3,

PLO1).

• CLO # 3: Develop a solution that provides a feasible design of equipment used in the
process industry (C6, PLO3).

• CLO # 4: Develop safety protocols for on-site and surroundings and implement hazard
analysis (C6, PLO3).

• COMPLEX ENGINEERING ATTRIBUTES

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 Lecture # 10 (CLO # 1)

• Basic Concepts of Heat Exchange

• Temperature – Enthalpy Diagram

• Problem Table Approach

• Further Exercise

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 Basic Concept of Heat Exchange

• A chemical reactor, which will be treated at

present as a “black box”.

• Liquid is supplied to the reactor and needs to

be heated from near ambient temperature to
the operating temperature of the reactor.

• A hot liquid product from the separation

system needs to be cooled down to a lower
temperature.

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 Basic Concept of Heat Exchange

• Any flow which requires to be heated or cooled, but does not change in composition,
is defined as a stream.

• The feed, which starts cold and needs to be heated up, is known as a cold stream.

• The hot product which must be cooled down is called a hot stream.

• Conversely, the reaction process is not a stream, because it involves a change in

chemical composition; and the make up flow is not a stream, because it is not heated
or cooled.

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 Basic Concept of Heat Exchange

Heat
Specific Final
Mass capacity Initial
heat (Target) Heat Load
Stream flowrate flowrate, (Supply)
capacity temp (°C) (kW)
(kg/s) CP temp (°C)
(kJ/kg.K)
(kW/K)
Cold 0.25 4 1.0 20 200 +180

Hot 0.4 4.5 1.8 150 50 - 180

Important Question:

Can we reduce energy consumption?

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 Basic Concept of Heat Exchange

• Yes; if we can recover some heat from the hot stream and use it to heat the cold
stream in a heat exchanger, we will need less steam and water to satisfy the remaining
duties.

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Temperature – Enthalpy Diagram

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 210
200
180

150

120
Temp
(°C)
90

60
50
30
20
0
0 30 60 90 120 150 180 210 240 270 300

Heat Load 10
 Temperature – Enthalpy Diagram

• A helpful method of visualization is the temperature-heat content diagram, as illustrated.

The heat content or heat load of a stream (kW) is frequently called its enthalpy.

• For CP assumed to be constant for a stream i.e., which requires heating (cold stream)
from a supply temperature (Ts) to a target temperature (Tt), the total head added will be
equal to the stream enthalpy change.

• Note that the hot stream is represented by the line with the arrowhead pointing to the
left, and the cold stream vice versa. For feasible heat exchange between the two, the hot
stream must at all points be hotter than the cold stream, so it should be plotted above
the cold stream.
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Temperature – Enthalpy Diagram

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 210
200
180

150
20 °C
120
Temp
(°C)
90

60
50
30
20
0
70 kW 70 kW
0 30 60 90 120 150 180 210 240 270 300

Heat Load 13
 Temperature – Enthalpy Diagram

• From this analysis, two basic facts emerge:

▪ Correlation between the value of ΔTmin in the exchanger and the total utility load
on the system. This means that if we choose a value of ΔTmin, we have an energy
target for how much heating and cooling we should be using if we design our
heat exchanger correctly.

▪ Secondly, if the hot utility load is increased by any value α, the cold utility is
increased by α as well. More in, more out! As the stream heat loads are constant,
this also means that the heat exchanged falls by α

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 Problem Table Approach

• Set up shifted temperature intervals from the stream supply and target temperatures
by subtracting ΔTmin/2 from the hot streams and adding ΔTmin/2 to the cold streams.

• In each shifted temperature interval, calculate a simple energy balance from:

• If the cold streams dominate the hot streams in a temperature interval, then the
interval has a net deficit of heat, and ΔH is positive. If hot streams dominate cold
streams, the interval has a net surplus of heat, and ΔH is negative.

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 Problem Table Approach

Initial Final Shifted Shifted

Heat Load CP
Stream (Supply) (Target) Initial Final
(kW) (kW/K)
temp (°C) temp (°C) Temp (°C) Temp (°C)
Cold 20 200 30 210 +180 1.0

Hot 150 50 140 40 -180 1.8

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 T* interval Temperature (°C)

2
210

140

40

30
1

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 T*
Temp ΔTint. (ΣCPC – ΔHint. Surplus /
Interval (°C) ΣCPH) (kW) Deficit
(°C)
2
210

+70 +1.0 +70 Deficit

140

+100 -0.8 -80 Surplus

1.0 -1.8
40

+10 +1.0 +10 Deficit

30
1
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 T* kW T* kW
Temp Temp
Interval Interval
(°C) Hot Utility (°C) Hot Utility

210 +0 210 +70

ΔH = +70.0 ΔH = +70.0

140 -70 140 +0

ΔH = -80.0 ΔH = -80.0
40 +10 40 +80

ΔH = +10.0 ΔH = +10.0
30 +0 30 +70

Cold Utility Cold Utility

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 Results

• Pinch Temperature = 140 °C

• Hot Pinch Temperature = 140 + 10 = 150 °C

• Cold Pinch Temperature = 140 – 10 = 130 °C

• Hot Utility = 70 kW

• Cold Utility = 70 kW

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 Home-work Activity

Supply Target
Heat Load
Stream Temperature Temperature CP (MW/°C)
(MW)
(°C) (°C)

Cold 40.0 110.0 +14.0 ?

Hot 160.0 40.0 -12.0 ?

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