Chemical Engineering Process Design Research Papers (original) (raw)

Chapter 1: Process Background & Selection
Chapter 2: Site Location
Chapter 3: Mass Balance
Chapter 4: Energy Balance
Chapter 5: Process Simulation
Chapter 6: Environmental and Waste Management
Chapter 7: Process Integration
Chapter 8: Process Control & Instrumentation
Chapter 9: Design of Major Equipment (Chemical & Mechanical)
Chapter 10: Economic Analysis
Chapter 11: Plant Safety & Layout

In this study, the optimization of parameters of the printing process was carried out. The aim is to minimize the size of color variation in prints. A factorial design was used to evaluate the effects and interactions of three factors, that is, impression pressure, alcohol %, and press speed. The color variation is gauged by variation in ink transfer, which is governed by color difference (?E). The optimal conditions obtained from the desirable response are impression pressure of 0.15 mm, alcohol percentage of 12.2 % and press speed of 8500 sheets per hour. Under these conditions, about 0.62 of color difference is obtained.

This is the first presentation for proposed Phosphoric Acid production.

Power Number and Flow number are very important to calculate power requirements for the agitated vessel in the process industries. The Excel sheet design program for the agitated vessel has been prepared and used by the author and is... more

- by Suryakant Randeri
- •
- Chemical Engineering Process Design

The upstream part of the production process does not do anything with the material itself, such as processing the material. The upstream stage of the production process involves searching for and extracting raw materials. This part of the process simply finds and extracts the raw material. For citric acid production, the upstream process involves starch hydrolysis with α-amylase which resulted dextrin formation. Also at upstream step, mineral nutrients and nitrogen sources prepared and sterilized. The downstream stage in the production process involves processing the materials collected during the upstream stage into a finished product. For citric acid production, the downstream process starts after fermentation. This stage involves biomass separation, which held by rotary filter and ultrafiltration.After filtration, the dilute solution of citric acid is passed through columns of activated charcoal and ion exchangers so as to remove colours and other impurities. Purified crystals of citric acid are obtained after evaporation of water. In order to evaporate water, the solution goes to crystallization. After this step, the mother liquid is separated from suspension with rotary vacuum filter. Separated crystals transfer to the fluidized bed dryer to dry with air.

- by Deniz Yılmaz
- •
- Bioengineering, Chemical Engineering Process Design

Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT

Design of an ammonia reactor was conceived as part of a series of item designs for an ammonia plant in Cyprus. The Chemical and Mechanical aspects of the design were considered. Optimization of these designs was studied, worked on, & discussed. The safety, environmental and legal regulations of relevant reactor regulations were followed in the design concerned.

- by Ibrahim Abo Elkheir and +1
- •
- Mechanical Engineering, Chemical Engineering, Cyprus Studies, Cyprus

The plant designed was primarily based on the Sulfur based effluents that are currently disposed from the Ceylon Petroleum Corporation refinery at 25 MTPD were to be completely regenerated in the form of Sulfuric acid by installing a manufacturing plant. The production was scaled up to correspond to 35 MTPD of Sulfur inputs, to account for future growth in demand for oil refining in Sri Lanka

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In this study, a novel mixed refrigerant cycle (MRC) integrated with NGL recovery process for small-scale LNG plant is proposed and optimized. The proposed process can be used to produce LNG and NGL with low energy consumption. Genetic algorithm is chosen as the optimization method for the proposed MRC-NGL process. The unit energy consumption as an objective function is optimized with key parameters. The optimization results show that the unit energy consumption and the molar flow rate of the mixed refrigerants can be reduced by 9.64% and 11.68%, respectively, compared with that of the base case. The effects of several key parameters on the process performance are also investigated and discussed based on the optimization results. Furthermore, the exergy analyses of the main equipment are also presented and analyzed. The economic analysis also shows that the proposed process has a good profitability and a short payback period.

- by Tianbiao He and +1
- •
- LNG, Chemical Engineering Process Design, LPG AND LNG

Petroleum products play an important role in different sectors of Bangladesh and Eastern Refinery Limited is the most renowned company to refine crude oil to produce different petroleum products. It produces almost 16 different petroleum products such as LPG, Naphtha, Kerosene, Diesel, AGO, Fuel gas. Though refining process consists of a wide variety of units the major part is done in Crude Distillation Unit (CDU). So, Simulation of Crude Distillation Unit of Eastern Refinery Limited Company was carried out using ‘Aspen Plus’ Process Simulator. The aim of the simulation was to compare the theoretical data with the simulated data. Design data have been taken from Eastern Refinery Limited. Aspen Plus model was developed and simulated data was validated. Different distillation curves obtained from the simulator was found similar to the expected.

- by Sabrina Khan and +1
- •
- Industrial Design, Modeling and Simulation, Oil and gas, Petroleum geology

Propylene glycol monomethyl ether (PGME) and propylene glycol monomethyl ether acetate(PGMEA) are representative photoresistor thinners used extensively and generated as waste during the display and semiconductor material manufacturing processes. Although the waste thinner is normally retrieved by distillation, the azeotropes of these two thinner components with water limit the distillation performance. In this paper, an extensive design study of enhanced distillation processes was carried out to determine a favorable path for waste thinner recovery. Appropriate thermodynamic models for the design of a waste thinner recovery process were obtained through the regression and validation of experimental vapor-liquid-liquid equilibrium data. An optimal direct sequence using three conventional distillation columns with a decanter was introduced as a base design to overcome the distillation boundary by azeotropes. Several advanced distillation configurations were examined to further improve the energy efficiency of the conventional recovery process. A novel heterogeneous azeotropic dividing-wall column was developed based on process intensification and integration. The proposed enhanced recovery process reduced the energy requirement for waste thinner recovery significantly by 33.1%. The advanced distillation configuration can be an attractive option for improving the economic and environmental efficiency of the commercial waste thinner recovery and recycling processes.

En el trabajo proyectado se estudia la factibilidad técnico-económica y ambiental de la instalación de una planta productora de ácido nítrico de grado técnico. Se determina que la concentración a la cual será producido el ácido es del 69% en peso. Como materia prima se tendrán al amoniaco anhidro que será almacenado en forma líquida en un tanque a presión con refrigeración de agua, el aire que será tomado directamente de la atmósfera y agua pretratada. El amoniaco deberá ser importado ya que no se cuentan con fábricas productoras de amoniaco en el país. Como mercado se seleccionan el mercado nacional, el argentino y el uruguayo. Abarcando el 100% del mercado nacional, el 37% del mercado uruguayo y el 30% del mercado argentino para el año 2019. Se selecciona la capacidad de producción de 35 toneladas de ácido nítrico al 69% como capacidad instalada de la planta con el fin de cubrir el mercado seleccionado. Se arrancará la planta al 50% de su capacidad instalada y se irá aumentando gradualmente hasta alcanzar la capacidad instalada proyectada. Para la localización de la planta de
producción se selecciona un terreno de 6,4 há ubicado en el parque industrial sur de la ciudad de Villeta, el cual cuenta con servicio de agua pretratada. La superficie seleccionada prevé futuras ampliaciones de la capacidad de producción. Como proceso de producción se selecciona el método de Ostwald de una sola presión, con una presión de operación de 10 bar. Para la producción de las 35 toneladas diarias del producto terminado serán necesarios procesar, diariamente; 6,946 ton de amoniaco anhidro, 1,897 ton de agua desionizada y 131,340 ton de aire. Con esta entrada se producen 105,184 ton de gas de cola que se descargan a la atmósfera. Se realiza el estudio de las medidas a tomar con el fin de garantizar que la concentración de NOx descargado a la atmósfera se encuentre dentro de los reglamentos consultados. Se obtiene una puntuación de +1 para la evaluación con la utilización de la Matriz de Leopold, por lo que se concluye que el proyecto tendrá un impacto ambiental positivo. Para el proyecto, se obtiene un valor de VAN de 2.952.162,89 USD y una TIR del 21%, por lo que se concluye que el proyecto es económicamente viable para un horizonte de 12 años. Obteniéndose ganancias a partir del tercer año desde el arranque de la planta, teniendo un punto de nivelación del 39,56% de la capacidad instalada y un periodo de retorno de la inversión de 4,85 años.

Benzene is the simplest hydrocarbon that belongs to the class of organic compounds also known as aromatics. The chemical formula, C6H6, represents its ring-like structure, in which all six carbon atoms share the same number of electrons and the carbon-to - carbon connections are intermediate between single and double bonds (Carey, n.d.). Benzene is a colourless liquid that has the smell of 'sweet gasoline' at room temperature. Benzene boiling point and freezing point temperature is at 176.2 degrees Fahrenheit and 41.9 degrees Fahrenheit respectively. Benzene is a highly flammable and carcinogenic chemical. It occurs as a component of crude oil, naturally, and there are other several methods to produce it.

Pharmaceutical corporations face rapidly rising process research and development (R&D) as well as production costs due to globalised competition. Batch production processes are
dominant in the pharmaceutical industry and have multiple advantages, including equipment flexibility, high-fidelity quality control and the ability to recall specific batches; they however suffer disadvantages such as limited heat transfer and mixing scalability and low operational asset efficiency. Continuous Pharmaceutical Manufacturing (CPM) has a documented
potential to reduce cost, as continuous production techniques can be easier to scale up and can be designed to be more efficient in terms of both solvent and energy use: therefore, it is both timely and important to explore the expanding feasibility limits of this emerging technology. The literature has been extensively surveyed in order to identify a series of candidate Active Pharmaceutical Ingredients (API) for flowsheet synthesis,
process modelling and mass balance simulation toward rapid assessment of CPM potential. Ibuprofen [2-(4-isobutylphenyl)propanoic acid], the widely used non-steroidal
anti-inflammatory drug (NSAID), has emerged as an ideal CPM candidate because it is in high global demand and can generate significant profit margins. The flowsheet is based on a published organic synthesis pathway and produces 50 kg of ibuprofen annually using three plug flow reactors (PFRs) in series,followed by a final separation for purification. Kinetic
and thermodynamic parameter estimation modelling has been employed in order to compute essential data for design, and all PFR reactors have been designed based on reported conversions of feed and intermediate organic molecules in the respective organic synthesis reactions. Theoretically computed reactor designs are in good agreement with experimental
prototypes constructed for the same organic synthesis, as well as in with previously reported CPM systems. The developed continuous final separation performs very well in accordance
with green chemistry principles, with relatively low environmental impact (E-factor = 25.4).

- by Hikaru Jolliffe and +1
- •
- Chemical Engineering, Process Modeling and Simulation, Pharmaceutical Technology, Chemical Engineering Process Design

References. Can be used for further discussion.

Full report on our proposed mini project, production of phosphoric acid.

Production of 50,000 Tons Per Year of Maleic Anhydride Via Oxidation of n-Butane

The pump is used as one of the most significant components in chemical industry so without its existence process may not be completed, because for any fluid to flow, initial driving force is required and it is fulfilled by the pump by consuming electrical energy and converting it to pressure energy. So, the selection of pump is very important in every field of section, depending on the property of process fluid. The Centrifugal pump is most demanding nowadays because it has simple design, less maintenance, can handle large quantities of fluids, and provides very high flow rates. The Centrifugal pump has mainly two components rotating components and stationary components. Shaft and impeller (open, semi-enclosed, and fully-enclosed) comes under the category of rotating components and casing (Volute, Vortex, and circular) comes under stationary components. Various parameters of process fluid like liquid viscosity, temperature, specific gravity, vapor pressure, concentration, shear sensitive and abrasive or non-abrasive, MOC, pump environment, pressure, flow rate, etc. are calculated to gain the desired efficiency and prevent a problem like cavitation if not properly handled. In this paper, a single-stage centrifugal pump is reviewed and studied how to increase performance and efficiency of centrifugal pump.

Chemical engineers develop, design, and operate processes that are vital to our society. Hardigg* states: "I consider engineering to be understandable by the general public by speaking about the four great ideas of engineering: structures, machines, networks, and processes." Processes are what distinguish chemical from other engineering disciplines. Nevertheless, designing chemical plants requires contributions from other branches of engineering. Before taking process design, students' thinking has been compartmentalized into several distinct subjects. Now, they must be trained to think more globally than before. This is not an easy transition. One of my students said that process design is a new way of thinking for him. I have found it informative to read employment ads to keep abreast of skills required of process engineers. An ad from General Dynamics* in San Diego, CA, states, "We are interested in chemical engineers with plant operations and/or process engineering experience because they develop the total process perspective and problem-solving skill we need."

Plant Design and Economics for Chemical Engineers Solutions Manual (Max s. peters)

This paper show how to find real roots of cubic equation by MATLAB Function. will help engineers in all sectors of engineering .

Compilation of my answers for tutorial.

- by Wishal Kurnia
- •
- Chemical Engineering, Safety Engineering, Process Safety, Chemical Process Design

Ethanolamines are raw materials widely used in industry. Carbon dioxide and hydrogen sulfide absorption and the production of materials such as paint, rubber, adhesive, detergent, soap are the areas where ethanolamines are frequently used. With the formation of new industrial areas, the demand for ethanolamine is increasing every year.
Our design project aimed to produce mono-, di-, tri-ethanolamine of high purity and quality. In aqueous environment, ethanolamines are obtained by the serial reactions carried out by feeding ammonia and ethylene oxide into the plug flow reactor. This process runs on a continuous model. Compared with other alternatives, the selected process has more sensitivity to the environment. Production planning Turkey's industrial structure has been expected to establish a complex system. For this reason, it was decided to establish the facility in İzmir, Aliağa Industrial Zone. We take into account when determining the quality of our process is the most important factor in Turkey's foreign trade deficit ethanolamine field. Accordingly, our annual production capacity has been determined as 4440 tons.
Mass, energy and utility requirements values and some calculations were made using Chemcad® simulation software. The process flow chart and block diagram were drawn using Microsoft Visio 2013, and the process control charts of the equipment were drawn using Draw.io. Capcost 2012 was used in the economic analysis. Other calculations were made by manually.

In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H 2 is demineralized water and the hydrocarbons in the natural gas. The source of N 2 is the atmospheric air. The source of CO 2 is the hydrocarbons in the natural gas feed. Product ammonia and CO 2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.

- by Prem Baboo
- •
- Chemical Engineering Process Design, Material Balance, Ammonia Plants

The current increasing production of small volume, high added value products has called
attention to batch production technologies. Although batch distillation typically consumes more
energy than continuous distillation, it provides more flexibility and involves lower capital
investment. Thus, since energy costs are not too significant in the separation of small volume of
high profit products, batch distillation is often attractive.
Available batch distillation models have appeared in the literature, ranging from very simple
approaches to more detailed. Commercial software packages such as BATCHFRAC™ (Boston
et al. 1981), BASIS (Simulation Sciences Inc., 1989) and ProSimBatch, (1992) are available
only to model batch distillation operation.
Luyben W. (1992) implemented an inferential control using a rigorous quasi-dynamic model of
a batch distillation column. Recent progress in nonlinear model-based control techniques have
made the practical applicability of nonlinear controller a true. Many of these techniques use a
nonlinear dynamic process model directly in the control law development phase (which is
performed off-line). These features are very attractive for practical implementation. Henson
and Seborg (1997) list a number of simulation and experimental studies in which this
feedback controllers were used. In this context, a nonlinear model–based strategy implemented
with commercial software is analyzed here. Therefore BATCHFRAC™, HYSYS® and
CHEMCAD® performances were tested to evaluate whether their implementation in an
inferential control structure and /or soft sensor could be attractive.
Hence, using the worldwide commercial available tools, the dynamic behavior of a batch
distillation column was modeled.

- by Luis Alberto Toselli and +1
- •
- Chemical Engineering Process Design

The guideline is for selecting the TEMA type of HE shell and tube. I hope this paper helps you to select and design a heat exchanger.

- by Sathish Rajan
- •
- Chemical Engineering, Chemical Engineering Process Design

The efficiency of the bioremediation of a crude oil contaminated soil using Nutrients and a mixed microbial culture (Aspergillus niger and Pseudomonas aeruginosa) was investigated in this study. The efficacy was obtained using 6 cells (H1 through H6, control inclusive) by monitoring the pH of the soil, Residual Hydrocarbon Content (RHC) and Total Microbial Count (TMC) for 8 weeks. The pH of the samples were observed to increase (all within the range of 6 – 7.6). The RHC decreased for all samples with the highest percentage degradation observed for cell H6 (99.88 %), which incorporated a hybrid of both biostimulation and bioaugmentation. Cells H2, H3, H4 and H5 showed percentage degradation of 99.74, 99.67, 99.81 and 96.92 respectively. A fair percentage degradation (47.46 %) was observed for the Control, H1. The TMC for most sample followed the typically observed TMC profile. Conclusively, Bioremediation is an efficient process for environmental clean-up and its efficacy can be improved by employing a hybrid of biostimulation and bioaugmentation.

- by Ana Celaya
- •
- Chemical Engineering, Chemical Engineering Process Design

Process Control notes in bullet form.

Compilations of assignments and my answer.

The purpose of this handbook is to make readily available in a limited number of pages some of the more important chemical, biological, physical, safety, and mathematical data and concepts that are fundamental to the practice of the chemical engineering profession. With these principles you should be able to solve many chemical engineering problems.
Good Luck!

- by Ahmad Mukhtar
- •
- Chemical Engineering Process Design