Separation Process

PROCESS DESIGN PRINCIPLES I
CHE F314
BITS Pilani
Pilani Campus
Suresh Gupta
Department of Chemical Engineering

BITS-Pilani, Pilani Campus
CHE F314 Process Design Principles I
Tutorial Class
Saturday, 8-8:50 AM
Section-1
Room No. 6107
Mr. Subhajit Majumder
Section-2
Mr. Utkarsh Maheshwari
Room No. 6104
2
BITS Pilani, Pilani Campus
BITS Pilani
Pilani Campus
Lecture-1
Introduction
06-08-2015
Process Design..
It is a combination of science and art in a

creative activity that helps to make process
design such a fascinating challenge to an
engineer
Process
Design
5
PROCESS
Outputs
Inputs
Process
feed
products
DESIGN
Definition of Chemical Process Design
Raw Material
Chemical
Process
??
Chemical
Product
Chemical process design is about finding a

sustainable process that can convert the raw
materials to the desired chemical products
7
Creative Aspects of Process

Design
The Purpose of Engineering
to create new material wealth
This goal in Chemical Engineering is

accomplished
via the chemical transformation
and/or separation of materials
Creative Aspects of Process

Design
50% of the chemical products sold
were developed during the last decade or two (20 30
years)
Indication of tremendous success of engineering effort
Process and Plant Design

Creative activity whereby
Generate ideas, translate them into equation and
processes for producing new materials
or for significantly upgrading the value of existing
materials
Your role in the chemical

process
Process synthesis vs. Process analysis

??
10
Strategy for Process

Synthesis and Analysis
The goal of a conceptual design is:
To find the best process flow sheet
To estimate the optimum design conditions
There can be many process alternatives to be

considered
There are many possibilities to consider with only
a small chance of success
104 109 alternatives can be generated for a
single product plant (since design problems are
under-defined)
11
Contd..
In some cases it is possible to use design
guidelines (rules of thumb or heuristics)
to make some decisions about the structure of the flow
sheet and/or
to set the values of some of the design variables
In the absence of heuristics - Use shortcut design

methods
12
Problem Areas Synthesis and

Analysis
Design problems are underdefined
To supply this missing information, we must
make assumptions about
What type of process units should be used?
How are they interconnected?
What temperatures, pressures, flow rates are
required?
Synthesis Activity
13
Contd..
Synthesis is difficult because there are very
large number (104 109) of ways to
accomplish same goal
Hence design problems are very openended
14
Objective
We have to find the process alternative (out
of 104 109) possibilities
That has the lowest cost
Process is safe
Satisfy environmental constraints
Easy to start up and operate etc.
15
Need of Process Design

Principles
Because of the under defined and open-ended

nature of design problems, and because of the
lower success rates, it is useful to develop a
strategy for solving design problems
16
Hierarchy of Decisions
Level 1
Batch vs Continuous
Level 2
Input-Output Structure
Level 3
Recycle Structure of flowsheet

General Structure of Separation System
Level 4
Level 5
4a. VRS
4b. LSS
Energy Integration Analysis (EIA)

17
Input Information and Batch

vs Continuous
Decision on Operating mode
18
Level 1
Batch vs Continuous
Level 2
Level 3

Level 4
Level 5
4a. VRS
4b. LSS

19
Level 1
Batch vs Continuous
Level 2
Level 3

Level 4
Level 5
4a. VRS
4b. LSS

20
Level 1
Batch vs Continuous
Level 2
Level 3

Level 4
Level 5
4a. VRS
4b. LSS

21
Level 1
Batch vs Continuous
Level 2
Level 3

Level 4
Level 5
4a. VRS
4b. LSS

22
Organization of Course
Module-I
Strategy for Process
Synthesis and Analysis
23
Module-II
Developing a Conceptual
Design and Finding the
Best Flowsheet
Batch vs
Continuous
Input-Output
24
Recycle
Separation
Heat
Exchanger
Network
Mass
Exchanger
Network
Handout
25
Evaluation Scheme
EC Evaluation
No component (EC)
.
Duratio Weightage
n
(300)
(Minute
s)
1 Mid-Semester Test
90
75
2 Tutorials/Surprise
70
Tests#
Date and time
3 Assignment*
To be
Open Book
announced in
the class in due
course of time
Closed Book
4 Comprehensive
Examination
26
35
180
120
Nature of
component
Closed Book
Open/Closed
Book
Prerequisite
Concepts of
Heat Transfer
Separation Process I & II
Chemical Process Calculations
Chemical Engineering Thermodynamics
Fluid Mechanics
27
Points to Remember
Being ONTIME is a good thing!
Be Interactive!
Share your idea and views
28
Outline
Hierarchical Approach to Conceptual Design: HDA
Case Study
Simplified flowsheet for the separation process

Recycle structure of flowsheet
Input-Output Structure of Flowsheet
29
Hierarchical Approach to
Conceptual Design
Example: Hydrodealkylation of toluene (HDA Process)
To produce benzene
C6 H 5CH 3 H 2 C6 H 6 CH 4
Rxn 1
2C6 H 6 2C6 H 5 H 2
Rxn 2
Reaction temperatures for homogeneous reactions: 1150 13000F
If T < 1150 0F
If T > 1300 0F
the reaction rate is very slow

a significant amount of hydrocracking
takes place
Pressure
500 psia ( 34 atm)
Excess hydrogen
(H2: aromatics = 5:1)
Reactor effluent gas must be rapidly quenched to 11500F
30
Boiling points
Boiling Point (F)

Diphenyl 491
Toluene 232
Benzene 176.2
Methane 258.68
Hydrogen - 423.182
31
Possible flow sheet

H2, CH4
Purge
H2, CH4
HEAT
COMPRESSOR
Recycle H2
HEAT
1150 1300
0F
H2, CH4
C6H6
REACTOR
HEAT
HEAT
Toluene (C6H5CH3)
Diphenyl (unwanted)
COOLANT
C6H5CH3,
Diphenyl
Recycle Toluene
R
E
C
Y
C
L
E
Partial
Condenser
P
R
O
D
U
C
T
C6H6
(Main Product)
C6H5CH3, (C6H5)2
Condensed
aromatics +
Light gases
Light Gases
H2, CH4
FLASH
H2, CH4
S
T
A
B
I
L
I
Z
E
R
Boiling Point (F)

Diphenyl 491
Toluene 232
Benzene 176.2
Methane 258.68
Hydrogen - 423.182
C6H6, C6H5CH3, C6H5
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Energy Integration
Is the process flow sheet very realistic?
In the last decade (1978), a new design procedure
has been developed
that makes possible to find the minimum heating and
cooling loads for a process
and the Heat Exchanger Network Synthesis (HENS)
that gives the Best energy integration
33
Energy Integrated Flow sheet
Fig. 2
34
Contd..
Energy Integration flow sheet is more complicated
many more interconnection
Moreover to apply the Energy Integration (HENS) analysis

we must know the flow rate and composition of every process
stream i.e. all the process heat loads including those of the
separation system as well as all the stream temperatures
Since we need to fix almost all the flow sheet before we can
design the Energy Integration system
since it adds the greatest complication to the process flow sheet
we consider the Energy Integration Analysis (HENS) as last step in
our process design procedure
35
Distillation Train
We could recover the benzene as overhead
Remove toluene as the side-stream (below the feed), and
recover the diphenyl as a bottom stream
Boiling Point (F)
H2, CH4
Benzene (C6H6)
Diphenyl 491
Toluene 232
Benzene 176.2
Methane 258.68
Hydrogen - 423.182
Feed
H2, CH4, C6H6,
C6H5CH3,C6H5
Toluene (C6H5CH3) +
Small amount of
(C6H5)2
C6H6, C6H5CH3,
C6H5
Diphenyl (C6H5)2
Fig. 3
Contd..
H2, CH4
Toluene (C6H5CH3)
Benzene (C6H6)
Feed
Boiling Point (F)

Diphenyl 491
Toluene 232
Benzene 176.2
Methane 258.68
Hydrogen - 423.182
H2, CH4, C6H6,

C6H5CH3,C6H5
C6H5CH3, C6H5
Diphenyl (C6H5)2
Fig. 4
Contd..
It might be cheaper than using the configuration shown in
the original flow sheet (Fig. 1)
The heurisitics (design guidelines) for separation systems
require
A knowledge of the feed composition of the stream entering the
distillation train
Thus before we consider the decisions associated with the

distillation train, we must specify the remainder of the flow
sheet and estimate the process flows
For this reason we consider the design of the distillation
train before we consider the design of the heat-exchanger
network
38
Vapor Recovery System (VRS)

Complete separation (of aromatics and light gases) in a
flash drum NOT POSSIBLE!
therefore that some of the aromatics will leave with the flash vapor
(H2 and CH4 lighter gases)
Moreover some of those aromatics will be lost in the purge

stream
It is possible to recover those aromatics by installing a VRS
either on the flash vapor stream or on the purge stream
39
Contd..
As a VRS, one of the following can be used
Condensation (high pressure or low temperature or both)

Absorption
Adsorption
A membrane process
To find out the economic feasibility of the VRS

we must estimate the flow rates of aromatics lost in the purge as well
as the H2 and CH4 flow in the purge
Hence before we consider the necessity and / or the design

of a VRS
we must specify the remainder of the flow sheet and we must
estimate the process flows
40
Contd..
When do we consider designing of VRS?
We consider the design of the VRS before that for the liquid
separation system
41
Simplified Flowsheet for the

Separation Systems
Our goal is to find a way of simplifying flowheets
It is obvious that Fig.1 is much simpler than the figure in
which energy integration (HENS) is included
because of which it was decided that the EIA be carried out at the
end (after distillation train is finalized)
Similarly, since we have to know that the process flow rates

to design the VRS and LRS
it was decided to consider these design problems just before the
energy integration
42
Contd..
The connections between the VRS and LRS shown in Fig. 5
VAPOR RECOVERY
SYSTEM
Gas Recycle
H2, CH4
Purge
H2, CH4
Light
Gases
H2, CH4
REACTOR
SYSTEM
Aromatics + Light Gases
PHASE
SPLIT
Toluene
Liquid
(aromatics)
Aromatics
Toluene
LIQUID SEPARATION
SYSTEM
Benzene
Diphenyl
Fig. 5
Recycle structure of the flow sheet

A simplified flow sheet for the process is shown in Fig. 6
Purge
H2, CH4
Gas Recycle
H2, CH4
H2, CH4
REACTOR
SYSTEM
Aromatics + Light Gases
Toluene
SEPARATION
SYSTEM
Benzene
Diphenyl
Toluene (Recycle)
Fig. 6
Contd..
Use this simple representation
to estimate the recycle flows
their effect on the reactor cost, and
the cost of gas recycle compressor, if any
For example, we can study:

1. The factors that determine the no. of recycle streams
2. Heat effects in the reactor
3. Equiliblrium limitations in the reactor, etc.
45
Can we still think of simplifying the flowsheet?
46
Input-Output structure of
the flowsheet
Since raw material costs normally fall in the range from 3385% of the total product costs
the overall material balance are the dominant factors in the design
Purge
H2, CH4
Gas Recycle
H2, CH4
H2, CH4
Benzene
PROCESS
Diphenyl
Toluene
Liquid Recycle
Is this structure of
flowsheet correct?
Fig. 7
Contd..
Also we do not want to spend any time investigating the
design variables in the ranges
where the products and by products are worth less than the raw
materials
Thus, we consider the Input-output structure of the flow

sheet and the decisions that affect this structure before we
consider any recycle streams
By successively simplifying a flowsheet, we can develop a
general procedure for attacking design problems
48
A systematic approach to process design by
reducing the design problem to a hierarchy of
decisions:
1.
2.
3.
4.
Batch vs Continuous
Input-Output structure of the flow sheet
General structure of the separation system
a) Vapor liquid system
b) Liquid separation system
5. Energy Integration Analysis (HENS)
49
Contd..
One great advantage of this approach to design is:
It allows us to calculate equipment cost
to estimate costs
Then if the potential profit becomes negative at some level

look for a process alternative or ,
terminate the design project without having to obtain a complete
solution to the problem
Another advantage of this procedure:

As we make about the structure of the flow sheet at various levels
We know that if we change these decisions, we will generate process
alternatives
The goal of a conceptual design is to find the best

alternative
50
Problem
Ethanol is produced by the hydration of ethylene. The primary reactions for

ethanol synthesis are given below:
Ethylene H 2 O Ethanol
2 Ethanol Diethylether H 2 O
Initially, the feed (90% ethylene, 8% ethane, and 2% methane) and water
are heated by passing through the primary heater. This heated feed is sent
to the reactor. The reaction takes place at 560 K and 69 bar. The fractional
conversion of ethylene in the reactor is 0.07. The reactants and products
are sent to the separator where gaseous and liquid products and reactants
are separated. All gaseous products and reactants are scrubbed in a
scrubber. Unconverted ethylene and inert gases (ethane and methane) are
recycled back. To avoid the accumulation of inert components, some
amount of recycled stream is purged. The liquid products and the bottom
products of scrubber are sent to the series of distillation columns where side
product diethyl ether and water are separated out. The diethyl ether is
recycled back and mixed with the feed stream. Ethanol-water azeotrope is
produced from the final distillation column.
51
Problem
Draw the following:
General structure of the flow sheet

Input-output structure of the flow sheet
52
Outline
Hierarchical Approach to Conceptual Design
IPA Case Study
Design of a solvent recovery system
53
Contd..
Draw the,
1. General structure of the Separation system.
2. Recycle structure of the flowsheet.
3. Input-output structure of the flowsheet.
54
55
BITS Pilani
Pilani Campus
Economic Decision Making
Outline
Design of A Solvent Recovery System (Ch. 3 of T2)
Problem Definition
Economic Potential
Process alternatives
Problem Definition
As a part of a process design problem
Assume that there is a stream
Containing 10.3 mol/hr of acetone and 687 mol/hr of air
That is being fed to a flare system (to avoid air pollution)
Economic Potential (EP)

Economic Potential (EP)
EP Product Value - Raw Material Cost

Since stream coming from the same process,
Raw material cost = 0
Therefore
EP Product Value - Raw M aterial Cost
Operating hours
Product Value - 0
Product Value
(10.3 mol/hr)(Rs .10.80/lb)( 58 lb/mol)(81 50 hr/yr)
Rs. 5.26 Cr/yr
Question 1
How to recover acetone?
60
General Considerations:
Process Alternatives
Solvent recovery alternatives
1. Condensation
a.
b.
c.
High Pressure
Low temperature
Combination of both
2. Absorption
3. Adsorption
4. A Membrane Separation System
5. A Reaction Process (Acetone as raw material for a new
product)
Question 2
Which is the cheapest
alternative?
62
General Considerations:
Process Alternatives
If solute concentration (mole fraction) in a gas < 5 %
Adsorption is the cheapest process
In the present case, it is 1.5 %
[10.3/(687+10.3) = 0.0147]
may opt for Adsorption

However, many petroleum companies prefer to use
Condensation or absorption process
63
Contd..
Judgment based on:
Concerning the use of technology where we have

great deal of experience
vs.
Using a technology where we have much less

experience (Relatively new technology)
64
Design of Gas Recovery

System: Flowsheet
Douglas, J. M. Conceptual Design of Chemical Processes, 1988
Alternate Flow sheet:

Recycling of solvent
Question 3
Whether discarding the process
water, as shown in Fig. 1 can
ever be justified even when a
pollution treatment facility is
available?
67
Contd..
Check the temperature of the process water
entering the gas absorber
Cooling water is available from the cooling towers
at 90 0F (32 0C) (on the hot summer day)
And that is must be returned to the cooling towers
at a temperature less than 120 0F (49 0C)
68
Contd..
69
Douglas, J. M. Conceptual Design of Chemical Processes, 1988, pp. 75

Design of Gas Absorber:

Heuristic
This reasoning is the basis for a design heuristic
H1: If a raw material component is used
as the solvent (like water) in a gas absorber,
consider feeding the process through the gas absorber
70
Design of Gas Absorber

Considering the flow sheet shown in Fig. 1
because it is the simplest for further processing
Contd..
In addition, we must evaluate whether we really
want to use water as the solvent
We arbitrarily choose to consider the flow sheet
shown in Fig. 1 because it is the simplest for
further processing
72

Material Balances
Identify the components that will appear in every
stream
The inlet gas flow to the absorber
10.3 mol/hr of acetone + 687 mol/hr of air
If we use well water as solvent

inlet solvent stream is pure water (100%, solute
concentration is zero)
Contd..
Acetone

Contd..
The gas leaving the absorber (top) will contains
air, some acetone and some water
Since water is relatively inexpensive, neglecting this
solvent loss
Specify Acetone Amount for

Material Balance
Specify the product specification in distillate overhead
(2)
Specify amount of acetone leaving in the other two
streams (1 and 3)
Recovery of 90, or 99, or 99.9% of the acetone in the
gas absorber is possible?
Contd..
Of course we can recover 90, or 99, or 99.9% or
whatever of the acetone in the gas absorber
Adding more trays to the top of absorber
The cost of the gas absorber will continue to increase as
Increase the fractional recovery

but the value of the acetone lost to the flare system will
continue to decrease
There is a trade-off between these two, and

Thus there is an optimal fractional recovery
77
Contd..
Fig.: %Recovery vs. Cost in Gas Absorber

78
Contd..
There is optimum fractional recovery of bottoms
in the distillation column
As we add more & more plates in stripping
section (bottom of distillation) of this column,
the still cost increases, but the value of the acetone
lost to the sewer decreases
79
Contd..
Fig.: %Recovery vs. Cost in Distillation

80

Heuristics
H2: It is desirable to recover more than 99%

of all valuable materials
(we normally use 99.5% recovery as a first guess)
81

Heuristics
H3: For an isothermal, dilute absorber, choose the
solvent flow rate (L), such that L = 1.4mG
where, m = slope of equilibrium line, and G = gas molar
flow rate (mol/hr)
82
Material Balances
For the acetone-water system at 77oF (25oC) and
1 atm
Activity coefficient, s= 6.7
Vapour pressure of acetone in air, Pos = 229 mm Hg.
Air flow rate, G = 687 mol/hr
ys PT xs Pv
Vapor
pressure
ys P
6.Mol
7(229
)
fraction
2
.
02
Fugacitym
Mol
of760
solute in
Activity
xs pressure
P
coefficient fraction
T
ofcoefficient
solvent
o
s s
Total
solute
in gas
83
system
Contd..
Solvent flow rate (L) = 1.4 mG = 1.4 x 2.02 x 687
= 1943 mol/hr
For a 99.5% recovery of acetone in the gas
absorber,
The acetone lost from top of absorber = 0.005 (10.3) =
0.05 mol/hr
And the acetone flow to the distillation column,

0.995 (10.3) = 10.25 mol/hr
If 99.5% of acetone entering the still is recovered

overhead,
Then acetone as distillate = 0.995 (10.25) =10.20 mol/hr
Contd..
Also if the product composition of acetone is
specified to be 99%,
Then the amount of water in the product stream
(distillate) will be
1 0.99
(10.20) 0.10 mol/hr

0.99
Then the bottom flows of acetone and water are

Acetone: 0.005 (10.25) = 0.05 mol/hr
Water: 1943 - 0.1 = 1942.9 mol/hr
Material Balances: Flowsheet
Fig.: Stream compositions and flow rates

Material Balances: Acetone

Balances
Acetone entering Absorber = Acetone leaving
absorber (bottom) + Acetone lost from absorber
(top)
10.3 mol/hr = (10.25 + 0.05) mol/hr
Acetone leaving absorber (entering distillation

column) = Acetone in distillate + Acetone in bottom
10.25 mol/hr = (10.2 + 0.05 ) mol/hr
Material Balances: Water

Balances
Water entering Absorber = Water leaving absorber
= Water entering distillation
1943 mol/hr = 1943 mol/hr
Water entering distillation column = Water in

distillate + Water in bottom
1943 mol/hr = 10.2 (1-0.99)/0.99 + (1943 x)
x
= 0.10 + 1942.9 = 1943 mol/hr
Stream Cost Calculation:

Acetone-Water System
For acetone water system, with no recycling and
99.5 % recoveries
Acetone loss in absorber overhead (assume $0.27/lb of
Acetone
= ($0.27/lb)(58 lb/mol)(0.0515 mol/hr)(8150 hr/yr)
= $6600/yr
Acetone loss in still bottom
= ($0.27/lb)(58 lb/mol)(0.05 mol/hr)(8150 hr/yr)
= $6600/yr
Contd..
Pollution treatment cost (assume $0.25/lb BOD and 1 lb
acetone/lb BOD)
= ($0.25/lb BOD)(1 lb BOD/1 lb acetone)(58 lb/mol)
(0.05 mol/hr)(8150 hr/yr)
= $6100/yr
Sewer charges (assume $0.20/1000 gal)
= ($0.20/1000 gal)(1 gal/8.34 lb)(18 lb/mol)
(1942.9 mol/hr)(8150 hr/yr)
= $6800/yr
Contd..
Solvent water (assume $0.75/1000 gal)
=($0.75/1000 gal) (1 gal/8.34 lb) (18 lb/mol) (1943
mol/hr) (8150 hr/yr)
= $25,600/yr
Each of these costs all together

is essentially negligible compared to economic
potential of $1.315106/yr,
We want to continue developing the design
Solvent Loss Calculations:

Other than Water as Solvent
For a low pressure absorber, fugacity correction
factors are negligible
Vapor-liquid equilibrium relationship for the
solvent can be written as
PT ys P x
0
s s s
With greater than 99% recovery of the solute, xs 1
Alternate Flow sheet: Using Solvent

Recycle (Other than Water as solvent)
Fig.: Solvent Recycle to Gas-Absorber

Contd..
If a solvent is used that is in the homologous
series with the solute, then s = 1
Thus, from
P y P0 x
T
s s
0
s
P
ys
PT
Contd..
Homologous series
A series of chemical compounds of

(1) Uniform chemical type
(2) Showing a regular graduation in physical properties
and
(3) Capable of being represented by a general
molecular formula
e.g. alkanes: CnH2n+2 (CH4, C2H6, C3H8, etc.)
Ketone: CnH2nO (acetone, C3H6O, MIBK, C6H12O)
Solvent Loss Calculations:

Other than Water as Solvent
Contd..
Quick way to estimate the solvent loss
G G ' 1 ys
Where ys is the mole fraction of solute in solvent
Now, the amount of solvent lost

ms G ' y s
G
ys

1 ys
ys
G ys G

1 ys
Cost of Solvent Loss Using

MIBK as Solvent
Suppose we consider using MIBK (Methyl Isobutyl
Ketone) as a solvent and we recycle the MIBK
At 25oC, PT = 1 atm, Ps0 = 0.0237 atm
ys = Ps0 /PT = 0.0237 / 1 = 0.0237
Ps0 0.0237
ys
0.0237
PT
1
Therefore, solvent lost

ms ysG 0.0237 687 mol/hr 19.7169 mol/hr
Contd..
MIBK lost (assume $0.35/lb of MIBK = $35/mol of
MIBK)
($35/mol) (19.7169 mol/hr) (8150 hr/yr)
= $4.464106/yr
This value is much higher than E.P. ( = $1.315106)

So we drop any idea of using MIBK as solvent
Outline
Design of Gas Absorber
Energy Balances
Material Balances
Acetone

Energy Balances for the

Acetone Absorber
Since the inlet composition to the gas absorber is
quite dilute (10.3/687) (i.e. Acetone/Air)
assume that the absorber will operate isothermally
(constant temperature)
Contd..
Fig.: Stream Temperatures in Gas absorber

103
Contd..
Do not store our product stream (top product from
Distillation column, Acetone) at its boiling point
so install a product cooler.
the temperature of the product stream leaving the product
cooler will be 100 0F.
Acetone product (99 % pure) contains 1 % water.

guess that the temperature of the overhead is essentially
the same as the boiling point of acetone (56.5 0C or 135
0F)
104
Contd..
120oF
120F
90F
Fig.: Stream Temperatures in Still overhead

105
Contd..
Similarly, assume that the bottom stream from the
still is 2120F (i.e. B. P. of water = 1000C)
Cool this waste stream to 1000F (cooling water
temperature) prior to pollution treatment.
106
Contd..
Fig.: Stream Temperatures at Still bottom

107
Energy Integration Flowsheet
108
Energy Balances for the

Acetone Absorber
Must specify the temperature of the stream
entering the distillation column
109
Contd..
If we do not preheat the feed stream entering the
distillation column to close the saturated liquid
condition,
What will be consequences?

7
110
Contd..
Energy Balances
With the specified stream temperatures and estimated
stream flows, heat loads of various streams can be
calculated
Qi Fi CPi Tin Tout
Thus we can decide on HEN and calculate

The H.E. areas
Annualized H.E. capital costs and
The utility costs
111
Process Alternative
We noted that the still bottom was almost pure
water (0.05 mol acetone and 1943 mol of water)
For this case, the column reboiler uses 25-psia
(lps) at 276 degree F
As a process alternative, we could eliminate the
reboiler and feed live steam to the column
(alternative)
112
Do we have to face any problem in

this case?
113
Next Lecture
Design of Absorber
Determination of number of plates
Cause-and-effect relationship of design variables
Opportunities for simplification of unit operation
114
Outline
Equipment Design Consideration
Number of plates in gas absorber
Cause-and-effect relationship of process design
variables
Simplifying unit-operation models (Back-of-the-Envelop
design equation)
Rules of thumb: Liquid flow rate to absorber
Equipment Design
Consideration
Calculate the size & cost of the absorber and
distillation column
Need to understand the cause-and-effect
relationships (Input-output models) of the design
variables
System vs. Unit Approach
116
Gas Absorber
For isothermal dilute system, the Kremsers Eqn.
L
yin mxin
1
ln
1
mG
yo u t mxin
N 1
L
ln
mG
Pure water as the solvent,
xin 0
117
Contd..
From the rules of thumb, discussed earlier,
yout 1 0.99yin
yo u t
yin 1 0.99 0.01
L 1.4mG 1.4 P G
PT
118
Effect of Design Variables:

Column Pressure
If we double the column pressure (PT),

L decreases by a factor of 2,
P
but since L/mG = 1.4, i.e. constant L 1.4mG 1.4 P G
both L and m are = f(PT), decreases
The number of plates required in gas absorber does
not change.
L
y mx
T
1
ln
1
mG
yo u t mxin
N 1
L
ln
mG
in
119
in
Contd..
Lower values of L means
1. D.C. feed will be more concentrated
2. The reflux ratio decreases
3. The vapor rate in the still decreases
4. The column diameter decreases
5. Sizes of condenser and reboiler decreases (load
decreases)
6. Steam and cooling water requirement decreases
120
Is there any consequence of increasing

the pressure?
121
Effect Design Variables:

Solvent MIBK
For MIBK
= 1 in place of 6.7 in case of water
Liquid rate could be decreased as m will decrease
Decreases the D.C. cost
No. of plates in absorber will not change as L/mG is
constant
122
Effect of Design Variables:

Operating Temperatures
If we change the inlet water (solvent to absorber)
temperature to 400C (112 0F),
= 7.8 & Po = 421 mm Hg, Po T, T
Thus m increases , L increases ( So the D. C.
Cost increases)
But number of trays in absorber does not change

(L/mG = Const)
Simplifying unit-operation
models
Also called as Back-of-the-Envelope Design
equation
Significance and order of magnitude of various
terms in Kremsers Eqn.
L
yin m xin
1
ln
1
mG
yo u t m xin
N 1
L
ln
mG
Contd..
L
yin mxin
1
ln
1
mG
yo u t mxin
N 1
L
ln
mG
L.H.S. of Kremser Eqn.

= N +1
Assuming N @ =15-20 trays and 10% error is allowed
N + 1 N
L.H.S of Kremser Eqn. = N
125
Contd..
L
yin mxin
1
ln
1
mG
yo u t mxin
N 1
L
ln
mG
R.H.S.
For pure solvents, xin = 0
(Solute concentration in pure solvent = 0)
Numerator of R.H.S. of Kremser Eqn.
= L y
ln
1 1
in
mG
126
yout
Contd..
Rules of thumb indicate
yin
L
1.4 &
100
mG
yout
Thus
L
yin
1
1 40 1
mG yout
1<<40
127
Contd..
Applying the order of magnitude criteria
( 1 << 40)
L
L
yin
yin
ln
1
1 ln
1
mG yout
mG yout
The denominator of R.H.S. Kremser Eqn.

L
ln
ln 1
mG
From Taylor series expansion,
ln 1
128
Contd..
L
L
1 1.4 1 0.4 ln
0.4
mG
mG
With these, simplification and replacing ln by log

we get
129
Contd..
Approximation for a recovery of 99% gives 10 trays

instead of actual value of 10.1
For recovery of 99.9% gives 16 trays which is a very good

estimation
Rules of Thumb: Liquid Flow

Rate to gas Absorbers
For Isothermal, dilute gas absorbers
Kremser Eqn. can be used for calculating No. of trays
reqd. (N) for a specified recovery as a function of L/mG
L
yin mxin
1
ln
1
mG yout mxin
N 1
L
ln
mG
131
Contd..
Fig.: Liquid Flow Rate vs. Fractional Recovery : Kremser Eqn.

132
Contd..
L/mG < 1
INFINITE No. of trays are required for near
complete recovery (Infinite capital cost)
L/mG = 2
5 plates are required for complete recovery
(100 %)
Large L correspond to dilute feeds to the distillation
column
133
Contd..
L/mG > 2
We obtain tiny, inexpensive absorbers but very
expensive D.C.
Based on above arguments, 1 < L/mG < 2
L/mG = 1.5: Observe the shape of the curves near
L/mG
Better trade off (with high recoveries)
Decreasing no. of trays in absorber (capital cost Vs. Increasing
capital cost & operating cost of D.C.)
Common Rule of Thumb: By decreasing L ( such

that L/mG=1.4) almost 100 % recovery
134

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PROCESS DESIGN PRINCIPLES I

Department of Chemical Engineering

CHE F314 Process Design Principles I

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

It is a combination of science and art in a

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

Chemical process design is about finding a

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Creative Aspects of Process

This goal in Chemical Engineering is

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Process and Plant Design

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Your role in the chemical

Process synthesis vs. Process analysis

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Strategy for Process

There can be many process alternatives to be

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In the absence of heuristics - Use shortcut design

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Problem Areas Synthesis and

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BITS Pilani, Pilani Campus

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Need of Process Design

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Recycle Structure of flowsheet

Energy Integration Analysis (EIA)

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Input Information and Batch

Decision on Operating mode

BITS Pilani, Pilani Campus

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Recycle Structure of flowsheet

Energy Integration Analysis (EIA)

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

Recycle Structure of flowsheet

Energy Integration Analysis (EIA)

BITS Pilani, Pilani Campus

CHE F314 Process Design Principles I

Recycle Structure of flowsheet

Energy Integration Analysis (EIA)