Chapter 6 – Process Conditions

Chemical Engineering Department

West Virginia University

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 1
 Heuristics

• Temperature
< 40ºC > 250ºC > 400ºC
Require Require Special
Refrigeration Fired Heater M.O.C
• Pressure
< 1 atm > 10 atm
need Vacuum Thick Walls - $

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 2
 Temperature
• T < 40º C – Refrigeration
– Use as much cooling water as Possible

cw rw

– Operating Costs (Table 8.3)

• Cooling Water (30-40°C) $0.354/ GJ
• Refrigerated Water (5-15°C) $4.43/ GJ

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 3
 Temperature

40
35
Refrigeration (cw = 1)

30
Relative Cost of

25
20
15
10
5
0
-50 -30 -10 10 30 50
Temperature of Refrigerant

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 4
 Temperature
•  

Q  10 ,000 kW
U  1000 W/m 2 K
 T  30 C

A
10  10 
 333 m
6
2
10  30  3

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 5
 Temperature
– CBM
• Heat Exchanger = $ 1.70x105
• Fired Heater = $ 1.81x106
• T > 400C
– M.O.C. is very Important

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 6
 Why not use High-Pressure Steam?

P sat ( bar) T sat (ºC)

15.2 200
39.7 250
46.9 260
64.2 280
86.0 300
Graph of Saturated
74.5 290 Steam vs. Pressure
80.1 295
98.8 310
113.0 320

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 7
 Why not use High-Pressure Steam?
120
Tcrit

100
Pressure of Saturated

80
Steam, bar

60

40

20

0
0 50 100 150 200 250 300 350
Temperature of Saturated Steam, oC

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 8
 Pressure
• Vacuum
– Slightly Higher Cost due to Stiffening Rings
– Large Equipment
– Air Leaks
• High Pressure
– Thick Walls - $
– H2 Embrittlement
– Safety

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
9
 Minimum Wall Thickness
PR
t  CA
SE  0.6 P
Wall thickness, t = m , design pressure, P = bar , vessel radius,
R=m
S = Design Stress (Max Allowable Working Pressure, bar) this
is a function of material and temperature
E = Weld Efficiency( ~ 0.9)
CA = Corrosion Allowance ( 0.00315 to 0.00625 m)

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 10
 Minimum Wall Thickness
• Look at 36 inch Diameter Vessel with a CA of ¼
in made of CS with S = 13,700 psi
P t (m) t /CA
14.7 = 1 barg 0.0069 1.09
58.8 = 4 barg 0.0085 1.34
147 = 10 barg 0.0118 1.86
• As P > 10 then t >CA

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 11
 What About S vs. T ?
• Look at Several Steels in Graph
• For CS S as T > 400ºC
• Must use Stainless Steel and $
• For a given Pressure
– t as T

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 12
 13
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph
Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Material of Construction
1 m Diameter Vessel made of SA285 - Grade A Carbon Steel
10.0
CS @ 500 oC
Thickness of Vessel Wall, m

1.0

0.1 CS < 300 oC

0.0
0 100 200 300 400 500
Operating Pressure, bar

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 14
 Material of Construction
• Carbon Steel
– Cheap
• Stainless Steel
– Expensive
– Better Chemical/Thermal Resistance
• What About T = 700-900C?
– Insulate inside of Pipe
– Metal – Refraction Lining

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 15
 Conclusions
• T < 40C – Refrigeration
• T > 250C – Fired Heater or Furnace
• T > 400C – M.O.C. Issues
• P < 1 atm – Vacuum and Large Equipment
• P > 10 atm – Cost

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 16
 Operating Conditions
Wall Thickness Increases

10 atm
Requires Requires Requires
Refriger- Fired Special
ation Heater M.O.C.

1 atm

40º C 250º C 400º C

Vacuum – Large Equipment
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 17
 Do we ever operate outside these limits?

• Tables 6.1 – 6.3

– Reactors and Separators
• Table 6.4
– Other Equipment

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 18
 Examples

• Example 1 – Acrylic Acid

– Appendix B.9
– Why does T-305 Operate with the top pressure at 0.07 bar?
– Feed – 86.6 kmol/h Acrylic Acid – nbp =140°C
6.1 kmol/h Acetic Acid – nbp = 118°C
Table 6.2 – Reasons for using P < 1 atm
1. Obtain a gas phase for VLE
2. Temperature sensitive materials

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 19
 Examples
• Example 2 – Separation of Propane
– Typical depropanizer operates at 220 psig (16 bar)
– why?
Table 6.2 – reasons for using P > 10 bar
1. Obtain a liquid phase for VLE

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 20