Code No: R05410804 R05 Set No.

2
IV B.Tech I Semester Examinations,December 2011
CHEMICAL PROCESS EQUIPMENT DESIGN
Chemical Engineering
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A 1-4 shell and tube heat exchanger is to be designed to cool kerosene flowing at the
rate of 15,000 kg/h from a distillation column from 1900 C to 800 C using 60,000
kg/h of a crude oil available at 350 c. Allowance should be made for fouling factor
of 0.0003 m2 K/W. An initial estimate of overall heat transfer coefficient of 400
W/m2 K may be used for the design. Tubes of length of 4.8m, with 2cm outside
diameter and 1.5cm inside diameter laid on a triangular pitch of 1.25 times the
outside diameter of tube are to be used.
Find the

(a) Number of tubes

(b) Shell diameter. Neglect temperature effect on viscosity and other properties of
the fluids. Crude oil is on tube side. Check the assumed value of heat transfer
coefficient with the calculated value and comment on the result.

DATA

Property Kerosene Oil

Specific heat (kJ/kg0 C) 2.50 2.0
Thermal Conductivity (W/mK) 0.13 0.13
Density (kg/m3 ) 730 820
Viscosity (Ns/m2 ) 0.4 × 10−3 301×10−3
Correction factor for cross flow = 0.9
Corrlations:
Tube side: Nu = 0.027 Re0.8 Pr1/3
Shell side:
N t 1/2.2


Bundle diameter = do 0.25 ; do ; outside diameter of tube in mm.
Nt = Total number of tubes
Bundle clearance = 15 percent of bundle diameter
Baffle spacing = 20 percent of shell diameter.
 0.55
ho de
k
= 0.36 de Gs
µ
(Pr)1/3 . [16]

2. A distillation column is to be designed to separate A and B continuously. The

feed is 35 % of A and 65% B at its dew point. The distillate and the residue
compositions are 0.95 and 0.025 respectively.

(a) Find the quantities of distillate and bottoms per hour.

1
Code No: R05410804 R05 Set No. 2
(b) Find the number of equilibrium stages required in the column if the reflux
ratio is 2.5
Assume the relative volatility as 2.5. [16]

3. (a) What are the various types of stainless steel used as materials of construction?
State their properties and applications as materials of construction.
(b) State the purposes of lining chemical process equipment. Discuss the applica-
tion of at least three types of lining used for process equipment. [8+8]

4. (a) Discuss the use and features of the following supports with neat sketches
i. Saddle support
ii. Bracket support and
iii. Skirt support.
(b) Write short notes on the use of gaskets and gasket materials. [12+4]

5. A shell made of stainless steel with an internal diameter of 150mm is subjected to an

internal pressure 0.4 N/mm2 . The permissible stress of the material is 130N/mm2 .
It is fitted with a flanged and shallow dished head whose external diameter is 1400
mm. It has a crown radius of 1400 mm and a knuckle radius of 84mm. The wind
load is zero but the torque due to offset piping is 650Nm. The weight of the vessel
may be taken as 34000N. Find:

(a) The thickness of the shell.

(b) Combined stress on the vessel on the basis of shear strain energy theory and
(c) Thickness of dished head. [16]

6. A sludge forming a uniform non-compressible cake is filtered through a filter press

out of which one frame is kept under study. At a constant pressure difference of
2.8 kg/cm2 , a 10 cm cake is formed in one hour with a filtrate volume of 6000
liters. Three minutes are needed to drain liquor from filter. Two minutes are
needed to fill the filter with water. Washing proceeds exactly as filtration using
1200 liters. Opening, dumping and closing take 6 minutes. Assume the filtrate has
same properties of wash water and neglect the resistance offered by cloth and flow
lines. How many liters of filtrate are produced in 24 hours on the average? [16]

7. A solution of organic colloids is to be concentrated from 15 to 50 percent solids in

a vertical-tube evaporator. The solution has a negligible elevation in boiling point
and the specific heat of the feed is 0.92. saturated steam is available at 0.8 atm
abs, and the pressure in the condenser is 102 mm Hg abs. The feed enters at 18 0 C.
The overall coefficient is 2200 W/m2 . 0 C. The evaporator must evaporate 27,000
kg of water per hour. How many square meters of surface are required and what is
the steam consumption in kilogram per hour. [16]

8. 1 kg /s of A is to be decomposed at 700 K and 1 atm. pressure in a tubular plug

flow reactor irreversibly where the rate constant is 0.5 m3 / kg.mol.s. Calculate the
volume of the reactor required for 25 % decomposition of feed? [16]

2
Code No: R05410804 R05 Set No. 2
?????

3
Code No: R05410804 R05 Set No. 4
IV B.Tech I Semester Examinations,December 2011
CHEMICAL PROCESS EQUIPMENT DESIGN
Chemical Engineering
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A distillation column is to be designed to separate A and B continuously. The

feed is 35 % of A and 65% B at its dew point. The distillate and the residue
compositions are 0.95 and 0.025 respectively.

(a) Find the quantities of distillate and bottoms per hour.

(b) Find the number of equilibrium stages required in the column if the reflux
ratio is 2.5
Assume the relative volatility as 2.5. [16]

2. A sludge forming a uniform non-compressible cake is filtered through a filter press

out of which one frame is kept under study. At a constant pressure difference of
2.8 kg/cm2 , a 10 cm cake is formed in one hour with a filtrate volume of 6000
liters. Three minutes are needed to drain liquor from filter. Two minutes are
needed to fill the filter with water. Washing proceeds exactly as filtration using
1200 liters. Opening, dumping and closing take 6 minutes. Assume the filtrate has
same properties of wash water and neglect the resistance offered by cloth and flow
lines. How many liters of filtrate are produced in 24 hours on the average? [16]

3. 1 kg /s of A is to be decomposed at 700 K and 1 atm. pressure in a tubular plug

flow reactor irreversibly where the rate constant is 0.5 m3 / kg.mol.s. Calculate the
volume of the reactor required for 25 % decomposition of feed? [16]

4. (a) Discuss the use and features of the following supports with neat sketches
i. Saddle support
ii. Bracket support and
iii. Skirt support.
(b) Write short notes on the use of gaskets and gasket materials. [12+4]

5. A solution of organic colloids is to be concentrated from 15 to 50 percent solids in

a vertical-tube evaporator. The solution has a negligible elevation in boiling point
and the specific heat of the feed is 0.92. saturated steam is available at 0.8 atm
abs, and the pressure in the condenser is 102 mm Hg abs. The feed enters at 18 0 C.
The overall coefficient is 2200 W/m2 . 0 C. The evaporator must evaporate 27,000
kg of water per hour. How many square meters of surface are required and what is
the steam consumption in kilogram per hour. [16]

6. A 1-4 shell and tube heat exchanger is to be designed to cool kerosene flowing at the
rate of 15,000 kg/h from a distillation column from 1900 C to 800 C using 60,000

4
Code No: R05410804 R05 Set No. 4
kg/h of a crude oil available at 350 c. Allowance should be made for fouling factor
of 0.0003 m2 K/W. An initial estimate of overall heat transfer coefficient of 400
W/m2 K may be used for the design. Tubes of length of 4.8m, with 2cm outside
diameter and 1.5cm inside diameter laid on a triangular pitch of 1.25 times the
outside diameter of tube are to be used.
Find the
(a) Number of tubes
(b) Shell diameter. Neglect temperature effect on viscosity and other properties of
the fluids. Crude oil is on tube side. Check the assumed value of heat transfer
coefficient with the calculated value and comment on the result.
DATA

Property Kerosene Oil

Specific heat (kJ/kg0 C) 2.50 2.0
Thermal Conductivity (W/mK) 0.13 0.13
Density (kg/m3 ) 730 820
Viscosity (Ns/m2 ) 0.4 × 10−3 301×10−3
Correction factor for cross flow = 0.9
Corrlations:
Tube side: Nu = 0.027 Re0.8 Pr1/3
Shell side:
N t 1/2.2


Bundle diameter = do 0.25 ; do ; outside diameter of tube in mm.
Nt = Total number of tubes
Bundle clearance = 15 percent of bundle diameter
Baffle spacing = 20 percent of shell diameter.
 0.55
ho de
k
= 0.36 µde Gs
(Pr)1/3 . [16]

7. (a) What are the various types of stainless steel used as materials of construction?
State their properties and applications as materials of construction.
(b) State the purposes of lining chemical process equipment. Discuss the applica-
tion of at least three types of lining used for process equipment. [8+8]
8. A shell made of stainless steel with an internal diameter of 150mm is subjected to an
internal pressure 0.4 N/mm2 . The permissible stress of the material is 130N/mm2 .
It is fitted with a flanged and shallow dished head whose external diameter is 1400
mm. It has a crown radius of 1400 mm and a knuckle radius of 84mm. The wind
load is zero but the torque due to offset piping is 650Nm. The weight of the vessel
may be taken as 34000N. Find:
(a) The thickness of the shell.
(b) Combined stress on the vessel on the basis of shear strain energy theory and
(c) Thickness of dished head. [16]

?????

5
Code No: R05410804 R05 Set No. 1
IV B.Tech I Semester Examinations,December 2011
CHEMICAL PROCESS EQUIPMENT DESIGN
Chemical Engineering
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A 1-4 shell and tube heat exchanger is to be designed to cool kerosene flowing at the
rate of 15,000 kg/h from a distillation column from 1900 C to 800 C using 60,000
kg/h of a crude oil available at 350 c. Allowance should be made for fouling factor
of 0.0003 m2 K/W. An initial estimate of overall heat transfer coefficient of 400
W/m2 K may be used for the design. Tubes of length of 4.8m, with 2cm outside
diameter and 1.5cm inside diameter laid on a triangular pitch of 1.25 times the
outside diameter of tube are to be used.
Find the

(a) Number of tubes

(b) Shell diameter. Neglect temperature effect on viscosity and other properties of
the fluids. Crude oil is on tube side. Check the assumed value of heat transfer
coefficient with the calculated value and comment on the result.

DATA

Property Kerosene Oil

Specific heat (kJ/kg0 C) 2.50 2.0
Thermal Conductivity (W/mK) 0.13 0.13
Density (kg/m3 ) 730 820
Viscosity (Ns/m2 ) 0.4 × 10−3 301×10−3
Correction factor for cross flow = 0.9
Corrlations:
Tube side: Nu = 0.027 Re0.8 Pr1/3
Shell side:
N t 1/2.2


Bundle diameter = do 0.25 ; do ; outside diameter of tube in mm.
Nt = Total number of tubes
Bundle clearance = 15 percent of bundle diameter
Baffle spacing = 20 percent of shell diameter.
 0.55
ho de
k
= 0.36 µde Gs
(Pr)1/3 . [16]

2. (a) Discuss the use and features of the following supports with neat sketches
i. Saddle support
ii. Bracket support and
iii. Skirt support.
(b) Write short notes on the use of gaskets and gasket materials. [12+4]

6
Code No: R05410804 R05 Set No. 1
3. A distillation column is to be designed to separate A and B continuously. The
feed is 35 % of A and 65% B at its dew point. The distillate and the residue
compositions are 0.95 and 0.025 respectively.
(a) Find the quantities of distillate and bottoms per hour.
(b) Find the number of equilibrium stages required in the column if the reflux
ratio is 2.5
Assume the relative volatility as 2.5. [16]
4. A shell made of stainless steel with an internal diameter of 150mm is subjected to an
internal pressure 0.4 N/mm2 . The permissible stress of the material is 130N/mm2 .
It is fitted with a flanged and shallow dished head whose external diameter is 1400
mm. It has a crown radius of 1400 mm and a knuckle radius of 84mm. The wind
load is zero but the torque due to offset piping is 650Nm. The weight of the vessel
may be taken as 34000N. Find:
(a) The thickness of the shell.
(b) Combined stress on the vessel on the basis of shear strain energy theory and
(c) Thickness of dished head. [16]
5. 1 kg /s of A is to be decomposed at 700 K and 1 atm. pressure in a tubular plug
flow reactor irreversibly where the rate constant is 0.5 m3 / kg.mol.s. Calculate the
volume of the reactor required for 25 % decomposition of feed? [16]
6. A sludge forming a uniform non-compressible cake is filtered through a filter press
out of which one frame is kept under study. At a constant pressure difference of
2.8 kg/cm2 , a 10 cm cake is formed in one hour with a filtrate volume of 6000
liters. Three minutes are needed to drain liquor from filter. Two minutes are
needed to fill the filter with water. Washing proceeds exactly as filtration using
1200 liters. Opening, dumping and closing take 6 minutes. Assume the filtrate has
same properties of wash water and neglect the resistance offered by cloth and flow
lines. How many liters of filtrate are produced in 24 hours on the average? [16]
7. A solution of organic colloids is to be concentrated from 15 to 50 percent solids in
a vertical-tube evaporator. The solution has a negligible elevation in boiling point
and the specific heat of the feed is 0.92. saturated steam is available at 0.8 atm
abs, and the pressure in the condenser is 102 mm Hg abs. The feed enters at 18 0 C.
The overall coefficient is 2200 W/m2 . 0 C. The evaporator must evaporate 27,000
kg of water per hour. How many square meters of surface are required and what is
the steam consumption in kilogram per hour. [16]
8. (a) What are the various types of stainless steel used as materials of construction?
State their properties and applications as materials of construction.
(b) State the purposes of lining chemical process equipment. Discuss the applica-
tion of at least three types of lining used for process equipment. [8+8]

?????

7
Code No: R05410804 R05 Set No. 3
IV B.Tech I Semester Examinations,December 2011
CHEMICAL PROCESS EQUIPMENT DESIGN
Chemical Engineering
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. (a) What are the various types of stainless steel used as materials of construction?
State their properties and applications as materials of construction.
(b) State the purposes of lining chemical process equipment. Discuss the applica-
tion of at least three types of lining used for process equipment. [8+8]

2. A sludge forming a uniform non-compressible cake is filtered through a filter press

out of which one frame is kept under study. At a constant pressure difference of
2.8 kg/cm2 , a 10 cm cake is formed in one hour with a filtrate volume of 6000
liters. Three minutes are needed to drain liquor from filter. Two minutes are
needed to fill the filter with water. Washing proceeds exactly as filtration using
1200 liters. Opening, dumping and closing take 6 minutes. Assume the filtrate has
same properties of wash water and neglect the resistance offered by cloth and flow
lines. How many liters of filtrate are produced in 24 hours on the average? [16]

3. A shell made of stainless steel with an internal diameter of 150mm is subjected to an

internal pressure 0.4 N/mm2 . The permissible stress of the material is 130N/mm2 .
It is fitted with a flanged and shallow dished head whose external diameter is 1400
mm. It has a crown radius of 1400 mm and a knuckle radius of 84mm. The wind
load is zero but the torque due to offset piping is 650Nm. The weight of the vessel
may be taken as 34000N. Find:

(a) The thickness of the shell.

(b) Combined stress on the vessel on the basis of shear strain energy theory and
(c) Thickness of dished head. [16]

4. A distillation column is to be designed to separate A and B continuously. The

feed is 35 % of A and 65% B at its dew point. The distillate and the residue
compositions are 0.95 and 0.025 respectively.

(a) Find the quantities of distillate and bottoms per hour.

(b) Find the number of equilibrium stages required in the column if the reflux
ratio is 2.5
Assume the relative volatility as 2.5. [16]

5. 1 kg /s of A is to be decomposed at 700 K and 1 atm. pressure in a tubular plug

flow reactor irreversibly where the rate constant is 0.5 m3 / kg.mol.s. Calculate the
volume of the reactor required for 25 % decomposition of feed? [16]

6. (a) Discuss the use and features of the following supports with neat sketches

8
Code No: R05410804 R05 Set No. 3
i. Saddle support
ii. Bracket support and
iii. Skirt support.
(b) Write short notes on the use of gaskets and gasket materials. [12+4]
7. A 1-4 shell and tube heat exchanger is to be designed to cool kerosene flowing at the
rate of 15,000 kg/h from a distillation column from 1900 C to 800 C using 60,000
kg/h of a crude oil available at 350 c. Allowance should be made for fouling factor
of 0.0003 m2 K/W. An initial estimate of overall heat transfer coefficient of 400
W/m2 K may be used for the design. Tubes of length of 4.8m, with 2cm outside
diameter and 1.5cm inside diameter laid on a triangular pitch of 1.25 times the
outside diameter of tube are to be used.
Find the
(a) Number of tubes
(b) Shell diameter. Neglect temperature effect on viscosity and other properties of
the fluids. Crude oil is on tube side. Check the assumed value of heat transfer
coefficient with the calculated value and comment on the result.
DATA

Property Kerosene Oil

Specific heat (kJ/kg0 C) 2.50 2.0
Thermal Conductivity (W/mK) 0.13 0.13
Density (kg/m3 ) 730 820
Viscosity (Ns/m2 ) 0.4 × 10−3 301×10−3
Correction factor for cross flow = 0.9
Corrlations:
Tube side: Nu = 0.027 Re0.8 Pr1/3
Shell side:
N t 1/2.2


Bundle diameter = do 0.25 ; do ; outside diameter of tube in mm.
Nt = Total number of tubes
Bundle clearance = 15 percent of bundle diameter
Baffle spacing = 20 percent of shell diameter.
 0.55
ho de
k
= 0.36 de Gs
µ
(Pr)1/3 . [16]

8. A solution of organic colloids is to be concentrated from 15 to 50 percent solids in

a vertical-tube evaporator. The solution has a negligible elevation in boiling point
and the specific heat of the feed is 0.92. saturated steam is available at 0.8 atm
abs, and the pressure in the condenser is 102 mm Hg abs. The feed enters at 18 0 C.
The overall coefficient is 2200 W/m2 . 0 C. The evaporator must evaporate 27,000
kg of water per hour. How many square meters of surface are required and what is
the steam consumption in kilogram per hour. [16]

?????