COURSE: CHE 341 – INDUSTRIAL PROCESS CALCULATIONS
(3 credits /Compulsory).
Course Duration: Three hours per week for 15 weeks
As taught in 2011/2012 session
LECTURERS:
1
OGUNLEYE,Oladipupo Olaosebikan
Ph.D ,MSc.,B.Tech. Reg. Engr.(COREN), MNSChE,MAIChE,MSIAM.
E-mail: ooogunleye@yahoo.com
Office Location: – Rm 5, Ground Floor,Department of Chemical Engineering Building
Consultation Hours: 11.00-1.00pm Mondays and Wednesdays.
2
ELETTA,Omodele Abiodun A.
Ph. D,MSc., B.Sc,MNSE, MCSN, MNSChE, R.Engr (COREN)
E-mail: modeletta@unilorin.edu.ng ,modwale@yahoo.com,
Office Location: Rm 6, Ground Floor,Department of Chemical Engineering Building.
Consultation Hours: 11.00-1.00pm Mondays and Wednesdays.
Developer: Dr OGUNLEYE,Oladipupo Olaosebikan
Course Content:
Introduction to equipment of chemical plants; Equipment for movement and storage of material.
Heat transfer equipment, Mass transfer equipment and equipment for physical processes. The
Chemical equation and stoichiometry: limiting reaction, excess reactant, conversion, selectivity
and yield. Material balances. Calculations for steady state systems involving inerts recycle, by
pass and purges. Energy balances: Forms of energy and overall energy balance for a chemical
system. Heat capacities. Calculation of enthalpy changes: heat of fusion, vaporization, reaction,
formation and combustion, solution and mixing. Combined material and energy balances.
Enthalpy concentration charts application and construction.
45h (T) PR CHM212 C
Course Description:
The course is intended to serve as an introduction to the principles and techniques used in the
field of chemical, petroleum and environmental engineering. It lays a foundation of relevant
information and skills that can be repeatedly employed in subsequent courses at higher levels as
well as in professional life. The course presents systematic problem solving skills ,what material
balances are and how to apply them;what energy balances are and how to apply them. It also
1
presents background information on units and measurements of physical properties, basic laws
about the behaviour of gas, liquids and solids and some basic mathematical tools.
Course Justification:
Foundations are crucial to the stability and durability
of every building.This statement
describes the
importance of the Industrial Process Calculation in the
training
of Chemical Engineers. Every Chemical
Engineers should be able to develop a process from
conception
to
commissioning
along
with
other
professionals . This task will become difficult if not
impossible without the knowledge of basic calculation
procedures that are crucial for equipment design and
sizing which is his sole responsibility in the team.
We are also in the computer age
where process
designs are computer aided. However, a good
understanding of the basic principles and procedures of
industrial calculation will enhance the Engineer’s
mastery of the computer aided design softwares as well
as the interpretation of the output from such
computations.
Course Objectives:
The objective of this course as an integral part for the award of B. Eng. Chemical
Engineering is for the students
to have an understanding of the fundamental principles
underlying the management of materials and energy in a chemical plant. It is also aimed at
describing the unit operations available for chemical processing.
Course Requirements:
This is a compulsory course for all students studying Engineering In view of this, students
are expected to participate in all the course activities and have minimum of 75% attendance
to be able to write the final examination.
Methods of grading:
No
1.
Item
Assignment/ Quiz / Monthly Test
2
Score %
10
2.
3.
Mid Semester Test
Examination
Total
20
70
100
Course Delivery Strategies:
The lecture will be delivered through face-to-face method, lecture guide (lecture note) will be
provided during lectures. Students will be encouraged and required to read around the topics.
The delivery strategies will also be supported by tutorial sessions.
LECTURES
Week 1 : Introduction to Engineering Calculations
Objective:
The students should have an understanding of the fundamentals of Industrial
calculations.
Description: The course outline will be introduced with emphasis on the objectives and delivery
strategies, Units and dimensions, the mole units, methods of analysis and
measurements, basis, physical and chemical properties of compounds and mixtures
and techniques of problem solving.
Study Questions:
1. What is a force of 2kg.m/s2 equivalent to in newtons?
2. If the acceleration due to gravity at a point is g=9.8m/s2 and an object is resting on the
ground at this point,is this object accelerating at a rate of 9.8m/s2
3. Convert 38.9kg of NaCl per 100kg of water to kilogram mole of NaCl per kilogram mole
of water.
4. One pound mole of CH4 per minute is fed to a heat exchanger.How many kilogram is this
per seconds?
5. What are the three questions you should ask yourself in selecting a basis?
Reading List:
1 Himmeblau4, D.M. (1996). Supplementary problems for
Basic principles and
Calculations in Chemical Engineering,Sixth Edition, Prentice Hall Inc. ,Englewood
Cliffs,New Jersey (pp 1-23)
2 Himmeblau4, D.M. & Riggs, J.B. (1989). Basic principles and Calculations in Chemical
Engineering, Fifth Edition. Prentice Hall Inc. ,Englewood Cliffs,New Jersey.(pp 4-60 )
.ISBN 0-13-066572-X
3 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp 7-30 ) .ISBN 0- 471-68757-X.
3
Week 2:
Introduction to Equipment of Chemical Plants
Objective:
Students should be able to identify and distinguish various equipment available for
chemical processing.
Description: Equipment for movement and storage of material, Heat transfer equipment, Mass
transfer equipment and equipment for physical processes.
Study Questions: Briefly explain the following terms:
(i)
Distillation (ii) Extraction (iii) Absorption (iv) Adsorption (v) Leaching
Reading List
McCabe1,W. L., Smith,J.C. & Harriott, P.(1993). Unit Operations of Chemical
Engineering. Fifth Edition. McGraw Hill Co. Singapore. .(pp.501-1076 ).ISBN 0-07112738-0
2 Coulson1, J.M. ,Richardson, J.F., Backhurst,J.R. & Harker, J.H. (2001). Chemical
Engineering Volume 2, Sixth Edition, Butterworth Heinmann Inc. Oxford. . ISBN 0 7506
4444 1
3 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp 7-30 ) .ISBN 0- 471-68757-X
1
Week 3:
The Chemical Equation and Stoichiometry.
Objective: This is to describe various sitations of chemicals under various reaction
mechanisms.
Description: Limiting reaction, excess reactant, conversion, selectivity and yield.
Study Questions:
1 Define the following terms:
(i) Limiting reactant
(ii) excess reactant
(iii) conversion,
(iv) Selectivity
(v)Yield
(vi) Stoichiometry
2 Calcium oxide (CaO) is formed by decomposing limestone (pure CaCO3).In one
kiln,the reaction gies to 70% completion.
(a) What is the compositon of the solid product withdrawn from the kiln?
(b) What is the yield in terms of pounds of CO2 produced per pound of limestone
charged?
3 The electrolyte manufacture of chlorine gas from a sodium chloride solution is carried
out by the following reaction:
4
How many kilograms of Cl2 can one produce from 10m3 of brine solution containing 5%
by weight of sodium chloride? The specific gravity of the solution relative to water at
40C is 1.07.
4 Consider the reaction :C4H8+6O2
6CO2+4H2O
(i)
Is the stoichiomeric equation balanced?
(ii)
What is the stochiometry coeffeicnt of CO2?
(iii)
How many lb-moles of O2 reacts to form 400lb-mole of CO2
(iv)
One hundred mol/min of C4H8 is fed into a reactor, and 50%
reacts.At what rate is wter formed?
Reading List:
1 Himmeblau4, D.M. (1996). Supplementary problems for
Basic principles and
Calculations in Chemical Engineering,Sixth Edition, Prentice Hall Inc. ,Englewood
Cliffs,New Jersey
2 Himmeblau4, D.M. & Riggs, J.B. (1989). Basic principles and Calculations in Chemical
Engineering, Fifth Edition. Prentice Hall Inc. ,Englewood Cliffs,New Jersey.(pp 64-76)
.ISBN 0-13-066572-X
3 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp 116 -121 ) .ISBN 0- 471-68757X
Week 4 - 7:
Material balances.
Objectives: This is to introduce students to quantitative combination of reactants to form
products.
Description: Calculations for steady state systems involving inerts recycle, by pass and purges.
Student will also be assessed on the topics covered so far through a short Monthly
Quiz.
Study Questions:
1. Explain each of the following terms : (i) recycle (ii) Bye pass (iii) Purge.
2. Differentiate between an orsat gas and a stack gas
3. An aqueous solution of sodium hydroxide contains 30.0% NaOH by mass. It is desired to
produce a 12% NaOH solution by diluting a stream of the 30.0% solution with a stream
of pure water. Calculate the ratio (litres H20/kg feed solution) and (kg product solution
/kg feed solution).
4. Fuel for motor vehicles other than gasoline are being eyed because they generate lower
level of pollutant than does gasoline. Compressed propane has been suggested as a source
of economic power for vehicles. Suppose that in a test 20 lb of C3H8 is burned with 400
lb of air to produce 44 lb of C02 and 12 lb of CO. What was the percent excess air?
5. A distillation column separates 10,000kg/hr of a 50% benzene -50% toluene mixture. The
product D recovered from condenser at the top of the column contains 95% benzene, and
the bottom W from the column contains 96% toluene. The vapour V entering the
condenser from the top of the column is 8000kg/hr. A portion of the product from the
condenser is returned to the column as reflux, and the rest is withdrawn for use
elsewhere. Assume that the compositions of the streams at the top of the column V, the
5
product withdrawn D and the reflux R are identical because the V stream is condensed
completely. Find the ratio of the amount refluxed R to the product withdrawn D
Reading List:
1 Himmeblau4, D.M. (1996). Supplementary problems for
Basic principles and
Calculations in Chemical Engineering,Sixth Edition, Prentice Hall Inc. ,Englewood
Cliffs,New Jersey (pp 29 -70)
2 Himmeblau4, D.M. & Riggs, J.B. (1989). Basic principles and Calculations in Chemical
Engineering, Fifth Edition. Prentice Hall Inc. ,Englewood Cliffs,New Jersey.(pp 102190) .ISBN 0-13-066572-X
3 Felder4, R.M. & Rousseau,R.W.(2005). .Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp 83-186 ) .ISBN 0- 471-68757-X.
4
Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition Solution . John Wiley & Sons,Inc. New York . (pp 4:1 – 4:80 )
Week 8 - 11 : Energy Balances
Objectives: This is to introduce students to the energy transformations that accompany the
quantitative combination of reactants to form products.
Description:
Forms of energy and overall energy balance for a chemical system.
Heat
capacities. Calculation of enthalpy changes, heat of fusion, vaporization, reaction,
formation and combustion, solution and mixing.
Study Questions:
1 List the three basic forms of energy.
2 Explain the following terms: (i) heat (ii) work.
3 Suppose that an ideal gas at 300K and 200kPa is enclosed in a cylinder by frictionless
piston, and the gas slowly forces the piston up so that the volume of gas expands from 0.1
to 0.2m3. Calculate the work done by the gas on the piston if two different paths are used
to go from the initial state to the final state:
Path A : expansion occurs at contant pressure (p=200kPa)
Path B: expansion occurs at contant temperature (T=300K)
4 The standard heat of the reaction :
ˆ O  69.36kJ / mol .
is ΔH
r
(i)
Is the reaction exothermic or endothermic at 200C?
(ii) Would you have to heat or cool the recator to keep the temperature constant?
(iii) What would happen to the temperature if the reactor ran adiabatically?
(iv) What can you infer about the energy required to break the molecular bonds of the
reactants and that released when the product bonds form?
5 When 2.00g of MgO (MW=40.32) are formed by burning Mg in the air,the laboratory
reports that 31,780J were absorbed by the calorimeter.What is the heat of combustion of
Mg per g-mol?
6
Reading List:
1 Himmeblau4, D.M. (1996). Supplementary problems for
Basic principles and
Calculations in Chemical Engineering,Sixth Edition, Prentice Hall Inc. ,Englewood
Cliffs,New Jersey (pp 111 -163)
2 Himmeblau4, D.M. & Riggs, J.B. (1989). Basic principles and Calculations in Chemical
Engineering, Fifth Edition. Prentice Hall Inc. ,Englewood Cliffs,New Jersey.(pp 362535 ) .ISBN 0-13-066572-X
3 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp311-475 ) .ISBN 0- 471-68757X.
4 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition Solution . John Wiley & Sons,Inc. New York . (pp5:1-5:83 )
Week 12: Mid Semester Test
Objective: This is to assess the students mastery of the topic covered so far.
Description: Students will be tested on all the topics taken so far. This is to serve as a
preparation for the final examination at the end of the semster
Week 13 : Combined Material and Energy Balances.
Objective : This is to integrate the concept of materials and energy balances.
Description: Enthalpy concentration charts application and construction.
Study Questions:
1.
2.
3.
4
Hydrochloric acid is produced by absorbing gaseous HCl (Hydrogen chloride ) in
water. Calculate the heat that must be transferred to or from an absorption unit if HCl
(g) at 1000C and H20(l) at 250C are fed to produce 1000kg/h of 20.0 wt % HCl (aq) at
400C.
Saturated steam at 1 atm is discharged from a turbine at a rate of 1150kg/h.
Superheated steam at 3000C and 1 atm is needed as a feed to heat exchanger; to
produce it, the turbine discharge stream is mixed with superheated steam available
from a second source at 4000C and 1 atm. The mixing unit operates adiabatically.
Calculate the amount of the superheated steam at 3000C produced and the required
volumetric flow rate of the 4000C steam.
The standard heat of reaction for the oxidation of ammonia is given below:
One hundred mol NH3/s and 200mol O2/s at 250C are fed into a reactor in which the
ammonia is completely consumed.The product gas emerges at 3000C.Calculate the
rate at which heat must be transferred to or from the reactor,assuming operation at
approximately 1 atm.
A 5.0 wt% H2SO4 solution at 600F is to be concentrated to 40.0 wt % by evaporation
of water.The concentration solution and water vapour emerge from the evaporator at
1800F and 1 atm.Calculate the rate at which heat must be transferred to the evaporator
to process 1000lbm/h of the feed solution.
7
Air at 800F and 80% relative humidity is cooled to 510F at a constant pressure of
1atm.Use the psychrometric chart to calculate the fraction of the water that condenses
and the rate at which heat must be removed to deliver 1000ft3/min of humid air at the
final condition.
Reading List:
5
Himmeblau4, D.M. & Riggs, J.B. (1989). Basic principles and Calculations in
Chemical Engineering, Fifth Edition. Prentice Hall Inc. ,Englewood Cliffs,New
Jersey.(pp 537-626 ) .ISBN 0-13-066572-X
2 Felder4, R.M. & Rousseau,R.W.(2005). Elemetary Principles of Chemical Processes .
Third Edition . John Wiley & Sons,Inc. New York . (pp 311 -475 ) .ISBN 0- 471-68757X.
Week 14 - 15: Revision/ Tutorial Exercises
1
Objectives: This is meant to revise the whole course again before examination.
Description: A general overview of the course will be made. Students are expected to seek
explanation on any difficult concept or topic treated during the course.
LEGEND FOR LIST OF BOOKS:
1
- Available in the University Library
2
- Available in local bookshops
3
- Available on the Web
4
- Personal collection
5
- Departmental library
8