Cape Peninsula University of Technology

Chemical Process Design Principles 3

CPD300S

LECTURE 3
Dr.Yusuf Isa

PROCESS ANALYSIS
Study a case
Understand a case/problem
Check for errors
Take the best possible decision

Plastic bottle recycling

Finished bottles

Recycled empty
bottles
Dirty water

What is your say on this????????????

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Plastic bottle recycling

Water

Finished bottles

Recycled empty
bottles
Dirty water

There musty be a water source to get it exiting the process!

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Two mountain hikers

Two hikers are confronted by a hungry mountain LION

What is the problem here?

The space shuttle story

Situation : An issue arose during the development of the
manned space program in the early 1960s. A space capsule re
entering the Earths atmosphere is heated by air friction to
thousands of degrees. This is hazardous to the capsule
contents, such as its human passengers.
Possible problem: Find a material that can withstand the
extreme heat of re entry.
This problem was eventually solved, but not until 20 years of
manned space flight and the construction of the space shuttle.
This problem could not be solved with 1960s technology
Real Problem : Devising a way to protect the astronauts

Ammonia Synthesis
Design a process for the production of ammonia from Nitrogen and Hydrogen
H2, N2 recycle

H2
N2
Mixer

Reactor

Condenser
-35C

N2
H2

Conversion <1
NH3

Any other suggestions?

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Possible improvements to the Ammonia

synthesis process(previous slide)
Producing the raw material in house may be cheaper than obtaining them commercially

Nitrogen could come from air

Hydrogen could come from electrolysis of water

Ammonia synthesis with Nitrogen

production on site
Design a process for the production of ammonia from Nitrogen and Hydrogen
N2
H2

H2
N2

N2
Mixer

Mixer

Reactor

Conversion <1

H2

NH3

O2

Nitrogen produced from air

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Condenser
-35C

O2
N2

Condenser -160C

H2, N2 recycle

Ammonia synthesis with Nitrogen and

hydrogen produced on site
Nitrogen produced from air, hydrogen produced from water electrolysis

N2
H2

H2
N2

N2
Mixer

Mixer

Reactor

Condenser
-35C

O2
N2

Condenser -160C

H2, N2 recycle

Conversion <1

H2

NH3

O2

O2
Mixer

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Electrolytic reactor

H2O

Desulphurisation of Natural Gas

Desulphurization of Natural gas [Duncan and Reimer, 2002]

Reduce the H2S content of natural gas from 100 ppm to less than 0.1 ppm for use in
fuel cell.

Physical properties
Compound

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B.Pt @ 1 atm, oC

Solubility in water

CH4

-164

slightly

H2 S

-61

Very

Desulphurisation of Natural Gas

CH4
H2O

H2O

Absorber

Effluent poses a problem!

Foul smell
Poisonous
inflammable

CH4
H2S
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H2S
H2O

Desulphurisation of Natural Gas 2

H2O

CH4
H2O

CH4
H2S
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Distiller

Absorber

Water recycled
H2S sent for storage

H2S

H2S
H2O

H2O

Desulphurisation of Natural Gas 2

H2O

CH4
H2O

Distiller

Absorber

Water recycled
H2S sent for storage

H2S

H2S
H2O
CH4
H2S
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Make-up
H2O

H2O
Purge

Example
[Duncan and Reimer, 2002]:
A process for converting coal to diesel fuel is shown on the
simplified flow sheet (next slide)below. Coal has the generic formula
CxHySz
where x>y and z<<x, y. Coal also contains some inorganic matter,
called fly ash. Diesel fuel has the generic formula CaHb.
a) Identify the units of this process. If you are not sure about the
name of the unit, give it a name based on its function.
b) Write the overall reaction for this process.
c) Write the reactions that take place in each of the units you
identify as reactors.

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Conversion of coal to diesel flowsheet

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Example contd

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Solution continued

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Example 2 [Duncan and Reimer 2002]

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Example 2 Flowsheet

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Solution

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Solution continued

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Worth noting
In general, the process designs are evaluated on the following
criteria.
The

flowsheet

demonstrating

an

understanding

of

unit

operations and streams

The process accomplishing the stated goal.
Each unit having a viable basis of operation.
Intermediates are recovered and recycled.
The process is energy efficient. For example, using hot streams to heat
cold streams
Details stated in the exercises are not violated. The process
should not claim an insoluble substance can be dissolved,
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