MODULE 1

Introduction to Design
-Design: Iterative process with the objective of producing a marketable product.
-Sustainable Process Design- Environment, Safety and Economics - must provide a net
social benefit, legal and social license
-Stage-Gate Work Process- 1) work, explore, decide and then move on to next step
-Conceptual Design- completing PFDs with sized equipment.
SustainabilityBLOCK FLOW DIAGRAMS

(a) No equipment details. (b) No line numbers. (c) Shows transformations NOT design detail. (d)
May show flow rates, or they may be expressed in written form (e) Normally do not show
heat transfer or fluid movers
(b) Left to right only critical instruments are shown, ex; separators and reactors horizontal
lines must stay the same and vertical lines are broken during cross
-Mass flow rates should be listed.
-Less volatile products on top and more volatile on bottom
-Must include figure number and title
-Include the reactions
COMMON MISTAKES- 1) Confusing flow paths (not left-right) 2) Complicated shapes (use
blocks) 3) Too many crossing lines (break the vertical one) 4) Incorrect mass balance 5) label
intermediate streams 6) Avoid acronyms
Le Chatelier's Law- For all gases---> Increasing the pressure causes the equilibrium to shift
towards more molecules, decreasing the pressure causes the equilibrium to shift towards less
molecules.
Endo/Exo - Endo has positive heats of rxn and Exo has negative heat of rxn.
BFDs to PFDs -1) Include Equipment List 2) Try to make the diagram go in a line 3) Label
the feeds and products, 4) Specify the equipment tag number 5) Feed and outlets should be
in proper boxes 6)
MODULE 2 Fluid Movers
Liquids Incompressible Pumps move liquids
Gases Compressible Compressors move gases
LIQUIDS
Cavitation- occurs when liquid is pulled into a pump and the local pressure falls
below the vapour pressure. Bubbles are formed which collapse violently and on
compression lead to cavitation. Can cause vibration, pitting, erosion and even
corrosion and impeller damage.
How to prevent Cavitation? - design pump to have NPSHA at least 1m above NPSHR.

What is the main selection criteria for a pump? -Capacity (Volumetric Flow rate) and Head
(pressure increase)
Types of pumps1) Centrifugal - imports KE into the fluid which is converted from velocity head to pressure
head. Deals with slurries as well. Max Capacity - 10m3/s
Advantages - 1) simple construction 2) high reliability 3) steady delivery 4) lower
maintenance costs 5) safe 6) inexpensive 7) Can handle slurries
Disadvantages - 1) Pressure increase per stage is limited 2) Operates at high efficiency
only for a limited range 3) Not self-priming 4) Viscous liquids cannot be handled efficiently 5)
Non-return valve must be provided because the liquid runs back through pump 6) May be
unsuitable for non-newtonian liquids
2) Positive Displacement- Liquid is forced from low to high pressure by moving mechanical
enclosure. Very high pressures can be obtained and very viscous liquids can be pumped.
a) Rotary positive displacement- gear, lobe and screw pumps 0.1 m3/s
b) Reciprocating positive displacement - diaphragm and piston pumps. Max:
0.03 m3/2
3) Momentum Transfer - No moving parts. Working fluid transfer its momentum to the fluid
being pumped. Ideal for corrosive fluids or pumping from inaccessible depths.
Pump Safety: Main objective in operating a pump is to operate a peak performance while
minimizing damages to the pump.
Common damage to pumps: 1) Cavitation 2) Deadhead 3) Hydraulic Surge
Deadhead- when a liquid filled pump is running with a blocked outlet piping. The
temperature will gradually rise and vaporize the liquid. Loss of seals, vibration,
disengagement of supports, rupture of pump casing. Causes: human errors, process control
failures
Indications: 1) low flow 2) high temp 3) low amperage/power 4) higher than normal vibration
5) higher pressure
Protection: Design and operate pump between 70-110% of best efficiency point and always
operate in that range. -Develop and follow operating procedure -Proactive unit monitoring
Hydraulic Surge- When a valve is closed instantly, transient pressure surges develop in
orders of magnitude.
Protection- Use slowly closing valves or increase closing time for existing installation. -Surge
relief valves. -consider using higher pressure rate piping and pump.
GAS
-Gas flows high to low
-Energy can be supplied in form of work to provide an increase in pressure and KE. (PE is
neglected)
-When gas is compressed, the temperature increases. For ideal gas, the temperature can be
calculated from absolute pressure The formula is given in the formula sheet
-Power required to adiabatically compress a gas requires change in volume and
temperature. Formula is given in formula sheet.

Equipment Design
Maximum Outlet Temperature rule of thumb
a) <200C - absolute max
b) <150 C- typical max
c) For oxygen compressors, use a lower max outlet temperature
d) Typically between 120-135C
If P2/P1 > 4, then one would have to cool the gas down before compressing the gas further.
-Compression Ratio per stage: (Pin/Pout) or rp
-The number of compression ratios require to obtain the overall compression ratio Pd/Ps is
calculated from compression ratio per stage. (formula sheet)
Design for real gases- 1) k is no longer constant. Use equation of state 2) Use a process
simulator 3) Use enthalpy data if available 4) The work and change in temperature for
isentropic (adiabatic) compression is more than that for non-ideal compression and
assuming adiabatic compression will yield conservative values.
Actual Power Consumption- To calculate the operating costs, calculate driving efficiency.
Condensation - During compression or interstage cooling, condensation may occur. This is
baaaad. Include liquid knockout drums or vessels in the design to remove condensation
products after cooling.
Surging- There is a minimum capacity below which operation becomes unstable and surging
happens. When the flow rate drops below the surging point, the pressure increase that is
produced by the compressor decreases. The pressure in the discharge line is them higher
than the pressure produced by the compressor and gas flow reverses momentarily until the
compressor can develop pressure to match the surging line.
Equipment Selection: Main Selection Criteria: Capacity and Pressure at outlet
Types of gas movers; 2 classifications
BASED ON COMPRESSION AND ROTATIONAL SPEED
1) Fans- P < 15 kPa, near atmospheric operation, maximum speed <1000
rpm.
2) Blowers- low end compressors with mechanically less demanding fabrications
. Max speed < 3000 rpm
3) Compressors - high compression ratios possible depending on the
compressor.
4) Ejectors - vacuum service
BASED ON PRINCIPLE OF OPERATION
1) Centrifugal - fans, blowers, some compressors
a) Fans- high capacity 500m3/s b) Radial Blowers and compressors -80m3/s c)
Axial centrifugal blowers and compressors - 300 m3/s
2) Positive Displacement- some compressors ---> a) rotary - 20m3/s b)
reciprocating - 20 m3/s

3) Momentum transfer Ejectors 500m3/s

MODULE 3
HEAT EXCHANGER
Heat addition and removal is important becauses 1) Chemical transformations 2) physical
transformations 3) thermal separations
Why is it important to have a good design? - Cost reductions and reduction of greenhouse
gas emissions
What do baffles do? They optimize velocity and avoid short circuiting so baffles are added to
the shell side.
HEX EQUIPMENT TYPES AND SELECTION p194, Table 4.12
1) Double pipe- a) provides true co-current or counter current flow b) handles
high pressures c) small hex area d) difficult to clean e) low heat transfer area per unit
volume
2) Shell and Tube - a) large heat transfer area per unit volume b) many possible
flow arrangements (counter, co, cross, multiple pass) c) might need correction factor
3) U-tube - a) combination of co and counter current. b) Requires correction
factor. c) can accommodate large heat transfer area.
4) Floating Head - a) required correction factor b) large heat transfer surface
area.
Design assumptions - Slide 37 HEX
Minimum Design Ft - 0.75

What causes fouling? When heat transfer is reduced because of build up of additional heat
transfer resistance. Ex; scaling, particles, chemical reaction, corrosion, biological,
solidification
-Low velocity can increase fouling.
-Fouling Resistance Table on Slide 68.
CHOICE OF UTILITIES
Heating- steam
a) LP ~400 kpag, 150 c
b) MP ~2400 kpag 225C
c) ~4000 kpag, 255C
Combustion Gases can be used for heating above 240 C
Cooling- a) cooling water b) salt water c) river water d) Air e) refrigerants
Water return temperature is restricted to 45-50C to limit water loss during evaporation. Max
outlet T for air is 100C

CONCEPTUAL DESIGN
1. Determine the duty required for the process stream: Q = m CP T + phase
change or other contributions
2. Select an initial utility/stream
3. Estimate U from Table 14-15 in U&V, pages 205-2101
4. Apply fouling correction to U, as needed
5. Assume initial geometry
6. Apply cross flow correction to U, if needed, and find Tlm
7. Estimate A from Q=UATlm
8. Finalize the choice of exchanger geometry
9. Verify choices of utility/stream, U and Tlm calculations
10. Find cost
MODULE 4
What does a reactor do?
1) Mixing managment
2) Heat Management
3) Mass Transfer Management
4) Reaction Kinetic Management
HEAT MANAGEMENT
-Reaction Rate and selectivity are strongly influenced by T
STEP1 :Determine the conversion chemistry
- Reaction network should contain main reaction and side reactions
- Reaction threshold T
STEP 2: Determine the heat release
- Heat of rxn = Hproducts H feed
- Magnitude ~ T adiabatic Hr /Cp
- Heat capacity depends on T and Composition
STEP 3: Evaluate strategies to deal with heat release
- Heat exchange with a utility stream
- Feed dilution with an inert material
- Staged hot/cold feed addition
- Per pass conversion limited
- Allow phase change
1)
2)
3)
4)
5)
6)

Pure Adiabatic Operation

Jacketed Heat Exchange
Direct Contact Heat Exchange
Internal Heat Exchange
External Heat Exchange
Multi-Tubular Heat Exchange

CATALYST PROPERTIES
1) Phase- Homogenous catalysts are liquids and heterogenous are solids

2) Size- small particles can be dispersed into the process fluid but larger
particles need to be in a bed
3) Strength- crushing strength of packed beds affect the handling in the reactor.
4) Deactivation rate- overtime
-Cycle length vs. Lifetime
DEACTIVATION
a) Poisoning - chemisorption of species in the feed material on the active sites
b) Chemical Transformation- active catalyst is chemically altered with the feed
material
c) Reactive Material Loss- when catalyst is not inert to the feed. Leeching into
the liquid phase or formation of volatile compunds lost to gas phase
d) Fouling - material deposition onto the catalyst
e) Mechanical Degradation - loss of mechanical integrity. Crushing of catalyst
into fine particles
f) Thermal degradation- structural change caused by elevated temperature