Plant Design and Economics

Most of this course is from Sinnott and Towler (2009) or Coker (2011) and Peters, Timmerhaus, and West (2004).

Additionally the freely avail­able I.S. 4503-1967 for Indian Standard Specification for Shell and Tube Type Heat Exchangers is to be used.

Unit I

Introduction and Heat Exchangers

• Introduction to ba­sic de­sign pro­ce­dure and the­ory
• Heat ex­changer analy­sis:
  • The ef­fec­tive­ness NTU method
  • Overall heat-trans­fer co­ef­fi­cient
  • Fouling fac­tors (dirt fac­tors)
• Shell and tube ex­chang­ers:
  • Construction de­tails
  • Heat ex­changer stan­dards and codes
  • Tubes
  • Shells
  • Tube-sheet lay­out (tube count)
  • Shell types (passes)
  • Shell and tube des­ig­na­tion
  • Baffles
  • Support plates and tie rods
  • Tube sheets (plates)
  • Shell and header noz­zles (branches)
  • Flow in­duced tube vi­bra­tions
  • Mean tem­per­a­ture dif­fer­ence (temperature dri­ving force)
  • General de­sign con­sid­er­a­tions
  • Fluid al­lo­ca­tion
    • Shell
    • Tubes
  • Shell and tube fluid ve­loc­i­ties
  • Stream tem­per­a­tures
  • Pressure drop
  • Fluid phys­i­cal prop­er­ties
  • Tube-side:
    • Heat-transfer co­ef­fi­cient
    • Pressure drop (single phase)
  • Shell-side:
    • Heat-transfer co­ef­fi­cient
    • Pressure drop (single phase)
    • Flow pat­tern
  • Design meth­ods:
    • Kern’s method
    • Bell’s method
  • Shell and bun­dle geom­e­try
  • Effect of foul­ing on pres­sure drop
  • Pressure drop lim­i­ta­tions

Unit II

Condensers

• Heat-transfer fun­da­men­tals
• Condensation out­side hor­i­zon­tal tubes
• Condensation in­side and out­side ver­ti­cal tubes
• Condensation in­side hor­i­zon­tal tubes
• Condensation of steam
• Mean tem­per­a­ture dif­fer­ence
• Desuperheating and sub-cool­ing
• Condensation of mix­tures
• Pressure drop in con­densers
• Design of:
  • Forced cir­cu­la­tion re­boil­ers
  • Thermosyphon re­boil­ers
  • Kettle re­boil­ers
• Heat trans­fer to ves­sels
• Jacketed ves­sels
• Internal coils
• Agitated ves­sels

Unit III

Design meth­ods for bi­nary dis­til­la­tion sys­tems

• Basic equa­tions
• McCabe-Thiele method
• Low prod­uct con­cen­tra­tions
• The Smoker equa­tions
• Batch dis­til­la­tion
• Steam dis­til­la­tion
• Plate ef­fi­ciency
• Prediction of plate ef­fi­ciency:
  • O’Connell’s cor­re­la­tion
  • Van Winkle’s cor­re­la­tion
  • AIChE method
  • Entrainment
• Approximate col­umn siz­ing
• Plate con­tac­tors
• Selection of plate type
• Plate con­struc­tion
• Plate hy­draulic de­sign
• Plate-design pro­ce­dure
• Plate ar­eas
• Diameter
• Liquid-flow arrange­ment
• Entrainment
• Weep point
• Weir liq­uid crest
• Weir di­men­sions
• Perforated area
• Hole size
• Hole pitch
• Hydraulic gra­di­ent
• Liquid throw
• Plate pres­sure drop
• Downcomer de­sign [back-up]

Unit IV

Design of packed columns for ab­sorp­tion/​strip­ping

• Types of pack­ing
• Packed-bed height
• Prediction of the height of a trans­fer unit (HTU)
• Prediction of the num­ber of trans­fer units (NTU)
• Column di­am­e­ter (capacity)
• Column in­ter­nals
• Wetting rates
• Column aux­il­iaries

Unit V

Economics

Mainly from Peters, Timmerhaus, and West (2004).

• Analysis of Cost Estimates:
  • Factors af­fect­ing in­vest­ment and pro­duc­tion costs
  • Capital in­vest­ment
  • Types of cap­i­tal cost es­ti­mates:
    • Methods for es­ti­mat­ing cap­i­tal in­vest­ment
    • Estimation of Revenue
    • Estimation of to­tal prod­uct cost
• Gross Profit
• Net Profit
• Cash flow
• Simple and Compound in­ter­est
• Loan Payments
• Cash flow pat­terns:
  • Discrete
  • Continuous
• Profitability
• Alternative in­vest­ments by dif­fer­ent prof­itabil­ity meth­ods
• Effect of in­fla­tion on prof­itabil­ity analy­sis
• Methods of prof­itabil­ity eval­u­a­tion for re­place­ments
• Depreciation:
  • Straight line
  • Declining bal­ance
  • Double de­clin­ing bal­ance
  • Sum-of-digits
  • Sinking-fund
  • Accelerated cost re­cov­ery sys­tem
  • Modified ac­cel­er­ated cost re­cov­ery sys­tem

References