Example 1: Stream

A stream has 20 mol% methane, 30 mol% ethylene & 50 mol% propane at 50 PSIA pressure and
flowrate of 10 T/hr. Determine Boiling point, dew point & molecular weight of the mixture. What is
the molar density & mass heat capacity of the mixture
Determine the vapor fraction of the mixture at 100F.
Example 2: Add following Assay data (TBP Curve) & a hypothetical component.
Add a component of molecular structure C10H21-(COOCH3)
Assay Percent
0
8.5
45
83.8
100

Temperature [C]
26.6666667
176.666667
343.333333
500
760

Example 3: Flash
A stream at 40 PSIA & -120F, has following molar composition
Methane 20%, Ethylene-10%, Propane-30%, Water-20%, Toluene-20%
This stream is flashed in a 2 phase separator, Calculate vapor & liquid stream rates &
composition. Repeat this exercise for a 3 phase separator.
Example 4: Pump
Compare the pump power to pressurize the stream from 1 bar to 5 bar at 30C and mass flow
100 T/hr, in the following cases
a)100% water b) 100% Benzene c) 50% Water & 50% Benzene
Example 5: Compressor & Turbine
Calculate the compressor power & efficiency to pressurize the hydrocarbon stream from 20 PSIA
to 50 PSIA at inlet temperature 80F, outlet temperature 200F & mass flowrate of 2,20,000 Lb/hr
for following composition of the stream (All compositions are in mol%)
H2-5, Methane5, Ethane-40, Ethylene-30, Propane-5, 1,3-Butadiene-10, Benzene 5
Using same compressor efficiency and inlet conditions, calculate compressor power to pressurize
the stream to 50 PSIA for the following stream composition
(All compositions are in mol%)
Methane 20, Ethane-10, Ethylene-20, Propane-30, 1,3-Butadiene-20
For both the cases, transfer compressor power to a steam turbine. Steam inlet to turbine is
20,000 kg/hr, at 2000 KPa, 300C. For turbine efficiency 75%, calculate liquid fraction at turbine
outlet and also calculate total condenser duty to condense the steam at turbine outlet.
For the second case composition, calculate total compression power to pressurize the stream
from 20 to 150 PSIA in a 3-stage compressor with intercoolers between the stages (assume the
same compressor efficiency). Outlet pressures for stage-1 & stage-2 are 50 & 80 PSIA,
intercooler outlet temperature 100F, deltaP for intercoolers is 5 psi.
Example 6: Rigorous HX
A heat exchanger for following conditions.
Tube side
Mass flow kg/hr
Temperature [C]
Pressure [kPa]
Component
Ethane
Methane

Inlet
25000
10
3000
Mole Fractions
0.8
0.2

Shell side
Mass flow kg/hr
Component
Steam (Saturated)
Inlet pressure

Inlet
4000
Mole fraction
1
500 KPa

Calculate Heat duty, LMTD, U-value & outlet stream conditions of the exchanger.

Evaluate the effect of tube side fouling on exchanger performance

Example 7: Benzene Recovery Column (elaborate with spreadsheet)

For the conditions given in the above diagram, determine the following:
What is the top temperature?
What is the purity of Benzene in distillate?
What is the Benzene loss in bottoms?
What is Condenser duty & Reboiler duty?
What is the column diameter?
For the reboiler duty calculated for the above case, determine reflux ratio, condenser duty and
distillate rate to achieve 98% Benzene purity
Example 8: Reactors
A stream has following inlet conditions
Stream Name
Temperature [C]
Pressure [kPa]
Mass Flow [kg/h]

1
40
1000
5000

Acetylene
Ethane
Ethylene
Hydrogen

Mole Fractions
0.1
0.2
0.4
0.3

Reactions:

C2H2 + H2
C2H4 (50% Conversion)
C2H2 + 2H2
C2H6
(50% Conversion)
Calculate the reactor outlet temperature.
Calculate heat removal rate to achieve 80C at the reactor outlet temperature
Hydrolysis of propylene oxide (C3H6O) to propylene glycol (C3H8O2) in a 5 m3 CSTR. Inlet
stream conditions: T-25C, P-1 ATM, C3H6O & water 50 mole% each. Total mass flow 5000 kg/hr.
Reaction temperature at 40C.
Arrhenius constant: 1.7e13 hr-1, Activation energy: 75362 KJ/kgmole. Calculate heat removal
rate.
Example 9: Flowsheet & Subflowsheet

H2O
m-Xylene
Methane
Propane
1-Butene
K-100 Outlet pressure (KPa)
E-100 duty (MMBTU/hr)
K-101 outlet pressure

Mole Fractions
0.2
0.1
0.2
0.4
0.1
2000
1
500 KPa

Stream Name
Temperature [C]
Pressure [KPa]
Mass Flow [kg/h]

1
-5
1000
50000

Set mixout stream pressure same as expout pressure

Insert a subflowsheet & get streams expout, mixout in the
subflowsheet & flash the streams. Mix the vapor streams .
What is methane in mixed vapor stream

Feed the mixed vapor stream to a 10-stage distillation column at stage 5. Column top & bottom
pressures are 55 & 60 psig respectively. Column specs are, methane in bottoms 0.1 mol% &
propane in vapor distillate 0.1 mol%. What is condenser & reboiler duty, reflux ratio.
Mix the two liquid streams from the two flash drums and feed to a 3-phase separator. Feed the
light liquid stream from the separator to a 30-stage distillation column at stage 10. Column top &
bottom pressures are 50 & 55 psig respectively. Column specs are propane in bottoms 0.1 mol%
& butene in vapor distillate 0.05 mol%. What is condenser & reboiler duty, reflux ratio.
Generate report for this PFD
Example 10: Chilling train performance
Simulate following PFD in HYSYS

What is amount of ethylene recovered in liq stream? Check Sensitivity of pressure drop across
E-100 on ethylene recovery. Use of adjust block.

Stream Name
Temperature [F]
Pressure [psia]
Mass Flow [lb/hr]
Hydrogen
Methane
Acetylene
Ethylene
Ethane
Propene
1-Heptene

1
-30
450
225000
Mole Fractions
0.35
8.00E-02
3.00E-02
0.3
0.15
5.00E-02
4.00E-02

TEE-100
split1
split2
Coolers
E100
E101
E102
E103
E100
E101
E103

Flow Ratios
0.4
0.6
Duty (MMBTU/hr)
10
5
1.72
8
DeltaP (PSI)
10
10
10

Example 11: Pipe network

Simulate the following piping PFD in HYSYS (Component- Water)
Stream 1- T 50C, P 10bar, Flow 50 T/hr, Pipe length for all pipes 50 m
Nominal diameter: PIPE-100: 101.6 mm, PIPE-101 &101-2: 50.8 mm, for rest of the pipes 38.1
mm. Adjust split for TEE-100 such that deltaP across PIPE-101 is 50 KPa. Elevation change for
PIPE-102 & PIPE-102-2 is 10 m.

Example 12: Liquid-Liquid Extractor

T e m p C
P re s s u re , K P a
F lo w ra te , K g /h r
C o m p o s it io n , m o l%
A c e to n e
W a te r
M IB K
N u m b e r o f S ta g e s

Feed
25
100
3600

S o lv e n t
25
100
3600

40
0
60
0
0
100
F in d O p t im u m

Example 13: C2-Splitter Case study

Calculate HP product rate, Reboiler & Condenser duty, Bottoms rate

Stream Name
Temperature [F]
Pressure [psia]
Mass Flow [lb/hr]
Hydrogen
Methane
Ethylene
Ethane
Propene
Propane

Frac_feed
21
275
190000
Mass Fractions
2.31E-04
1.45E-03
0.641355976
0.350597512
5.72E-03
6.05E-04

Column input & Specs

Number of stages
Tray1-7 Efficiency
Tray8-178 Efficiency
Top stage pressure
Bottom stage pressure
Ethane+Methane in HP Product
Ethylene loss in Bottoms Ethane
Pumparound duty
Pumparound rate
LP product rate

178
80%
75%
265 PSIA
280 PSIA
1000 PPM
0.5 mol%
15 MMBTU/hr
500 MLb/hr
25000 Lb/hr

Example 14: Ethylene refrigeration loop

Calculate total compression power & condenser E-100 duty
Repeat this exercise for propylene

Ethylene
Stage1 inlet pressure
Stage2 inlet pressure
Stage3 inlet pressure
Stage3 outlet pressure

20 PSIA
50 PSIA
120 PSIA
415 PSIA

E-103 duty
E101 Duty
Total ethylene flow in loop
DeltaP for all exchangers

5 MMBTU/hr
15 MMBTU/hr
250 MLb/hr
5 PSI