ME505-MME505 Process Engineering

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Master of Engineering
(Industrial Automation)
(Mechanical)
Unit code
ME505-MME505
Unit name
Process Engineering
Assessment #
3
Paper #
B
Version #
2.2
Created by
Harisinh Parmar
Date
6 Feb 2018
Reviewed by
Harisinh Parmar
Date
30 Jan 2020
Reviewed and
updated by
Harisinh Parmar
Date
16 June 2020
Master of Engineering (Industrial Automation) and (Mechanical) 2
ME505-MME505_Assessment3_PaperB_v2.2
Assessment Instructions:
1. Please familiarise yourself with the EIT Academic Honesty and Misconduct Policy, in order to
understand your requirements and responsibilities as a student of EIT.
2. Please refer to our Assessment, Moderation and Student Progress Procedure for
information relating to extensions. Extension requests should be submitted to your LSO at
least 3 days prior to the due date.
3. Assessments submitted via email will not be accepted.
4. Assessments must be submitted through Turn-it-in (unless otherwise stated).
Your submission must:
a. Be a single document (Word or PDF only)
b. Include at least 20 words of machine-readable text, and
c. Not exceed 10MB.
5. You must use the provided assessment cover page available on your Moodle student
homepage. Submissions without a cover page will not be accepted.
6. You must correctly title your document/s. For example:
UNIT#_ASSESSMENT#_YOURNAME_DATE
E.g. ME501_Assessment2_SteveMackay_01Aug2019
7. You must reference all content used from other sources including course materials, slides,
diagrams, etc. Do not directly copy and paste from course materials or any other resources.
Refer to the referencing section of the EIT eLibrary on Moodle for referencing guides.
8. It is your responsibility to check that you have submitted the correct file, as revised
submissions are not permitted after the due date and time.
Important note: Failure to adhere to the above may result in academic penalties. Please refer to
the unit outline or EIT Policies and Procedures for further information.
Master of Engineering (Industrial Automation) and (Mechanical) 3
Unit code and name:
ME505-MME505: Process Engineering
Assessment #:
3B
Assessment type:
Practical
Weighting:
20%
Total marks:
100 marks
Please complete your answers on the assessment cover page document available on Moodle.
Clearly label your question numbers (there is no need to copy the full question over). Include all working
out.
You are to use the UniSim software program to answer the majority of the questions in this
assessment. This software is available on EIT’s Remote Labs. All students completing this unit have
been provided with access to this software.
An instructional pre-recording video has been created to assist you in using the UniSim software.
This video may be accessed on the Moodle page for this unit. The recommendation is that you view
this video prior to attempting to complete this assessment.
In the course of completing this assessment, you are required to provide screen shots at various
stages of the UniSim model in order to demonstrate your proficiency with using the software and
the attainment of the required level of knowledge for this assessment.
You are also required to submit your UniSim file (.usc) as a part of this assessment.
Problem statement:
Benzene, toluene and xylene are important precursors in the manufacture of petrochemicals. The
feedstock can be reformed naphtha.
You have been contracted to design the distillation column for the recovery of benzene.
You may assume that a constant flow of 150 metric tonnes per hour of feedstock is to be
processed.
Typically, a column will have a feed stream pumped at a certain temperature and pressure, a
vapour stream that is cooled by an overhead condenser, a reflux stream that is pumped back to the
column by a reflux pump, and a reboiler that adds heat to the process.
Data:
Master of Engineering (Industrial Automation) and (Mechanical) 4
ME505-MME505_Assessment3_PaperB_v2.2
Feed Composition:
Benzene
0.70
Toluene
0.26
p-xylene
0.02
o-xylene
0.01
m-xylene
0.01
Temperature and Pressure
You choose, but ensure that these parameters are suitable to comply with the client’s
specification. Note that some of the materials may need to be in a liquid state and that the
pressure needs to be at a level that will cause the benzene to flash when it enters the column.
Required Purity of Benzene
99 %
Data for Pump and Line Sizing
The base of the feed tank is vertically elevated 4 metres above ground. The pipe descends from
the base of the feed tank and, moving left to right, travels a distance of 2 metres laterally before
entering the feed pump.
The pipe exits the feed pump and travels 5 metres laterally before entering the heat exchanger.
The pipe then exits the heat exchanger and travels 3 metres laterally to a point below the
distillation column, the pipe then vertically ascends 8 metres to a bend, and continues 2 metres
laterally from the bend before entering the side of the distillation column.
The pipe carrying the distillate exits the side of the distillation column and descends to the
discharge pump which is located near the base of the distillation column. The pipe then exits the
discharge pump and travels 25 metres laterally to a point below a tank, it then vertically ascends
15 metres to a bend, and continues 1.5 metres laterally from the bend before entering the side of
the tank.
Another pipe exits the base of the distillation column and enters the bottoms pump. The pipe
then exits the bottoms pump and travels 90 metres laterally to a point below a vessel, it then
vertically ascends 8 metres to a bend, and continues 1.5 metres laterally from the bend before
entering the side of the vessel.
All pumps are at ground level.
You may assume that all piping will be Schedule 40 Mild Steel.
Recommended methodology:
Master of Engineering (Industrial Automation) and (Mechanical) 5
a) Review the instructional Pre-Recording video which has been created to assist you to use
UniSim software. This Pre-Recording may be accessed through the Moodle page for this unit at:
https://au.bbcollab.com/recording/f0c95d55926b4a43a971b7ddf9f9751f
The “Help” section (which may be accessed in the top bar of every window of the UniSim
software package) also provides a number of cases as examples.
b) Access the UniSim software package available on EIT’s Remote Labs.
c) Reflect that the distillate is the more volatile component and the bottoms should be the
component with the higher boiling point. A good starting basis is that the bottom is slightly
above the boiling point of the more volatile component and that the top is hotter than the
heavy component.
d) Consider using a fluid package (equation of state) appropriate for this system. [Hint: internet
search, research].
e) You may begin by using a short-cut distillation method which will allow you to determine key
parameters that can then be the input into the main column. Bear in mind that you do not
want to over-pressure the column and you do not want to have too high a reflux rate.
f) Once you have run a simulation which complies with the client’s specifications, you may obtain
a stream table with the flow rates and all process parameters from the UniSim model.
g) Line sizing: The lines need to be designed to suit this process.
– Research the velocity limits in pipes for hydrocarbons and ensure your design complies
with these limits.
– Use pipe sizing charts to determine the friction factor and other variables until you obtain
an acceptable pressure drop for your system.
– Whilst UniSim is useful as a first pass, you need to ensure that the line sizes in your model
are acceptable. It is, therefore, recommended that you create a Microsoft Excel spread
sheet or use hand calculations to calculate the various line sizes.
– Once you have sized the lines, you may then size the pumps.
h) Pump sizing: The pumps need to be carefully designed to suit this process.
– The critical requirement is to ensure that the pumps are designed with sufficient NPSH.
Drawing a sketch showing the various vessels, pipes, and discharges may assist you in
designing the pumps.
– Ensure you add up the losses and account for vapour pressure.
– Consider if you need sparing of pumps.
– Again, whilst UniSim is useful as a first pass, you need to ensure that the pump sizes in
your model are acceptable. It is, therefore, recommended that you create a Microsoft
Excel spread sheet or use hand calculations to calculate the various pump sizes.
Master of Engineering (Industrial Automation) and (Mechanical) 6
ME505-MME505_Assessment3_PaperB_v2.2
i) Drawings: Based on your UniSim model, you may obtain a process flow diagram (PFD) showing
the column, feed pump, condenser, reflux pump, distillate pump, reboiler, recycle pump and
bottoms pump.
– Using an appropriate software program (such as Microsoft Word’s Autoshapes, Microsoft’s
Paint, or other suitable program such as Visio), draw a P&ID of this chemical engineering
process.
– Ensure the drawing shows the line sizes and other relevant details.
– Show additional piping as required.
Requirements:
Using the UniSim software program, develop a PFD to successfully comply with the client’s
specification of designing a distillation column for the recovery of benzene. Once you have
completed this simulation furnish the following requirements:
a) Provide a PFD of this chemical engineering process showing the main equipment in this
process. Ensure that the PFD includes a shortcut distillation column, main distillation
column, feed pump, heat exchangers, reboiler, bottoms pump, and distillate pump.
(30 marks)
Note: You may obtain this PFD directly from the UniSim model environment by completing
the steps which are outlined below.
Exporting the PFD to Microsoft Word:
Position the PFD as per your requirements using the zoom and scrolling controls on UniSim.
The “Zoom All” button at the bottom left of the window is helpful for aligning the image.
The PFD will be copied exactly as it appears on the screen.
Right click on the PFD and select “Copy Pane to Clipboard” – “Scale by 100%”. Then paste
the image into the Microsoft Word document. This image is acceptable to be pasted into the
relevant section of your assignment. For instance, the PFD may be pasted into your
assignment sheet under section: 4. Requirements a).
b) Develop a stream table as a part of the PFD for all the major streams. Remember to go into
the Column environment for the overheads and reboiler information. (15 marks)
Note: You may obtain the stream table directly from the UniSim model environment by
completing the steps which are outlined below.
Adding stream tables to the PFD:
Right click on the PFD, select “Add Workbook Table” – “Materials Streams”. A stream table
will be added to the PFD. Right click on the created stream table to see some limited
Master of Engineering (Industrial Automation) and (Mechanical) 7
formatting options. There is also the option of creating “Compositions” and “Energy
Streams” tables.
c) Size the piping and pumps. (20 marks)
Ensure that you include the:
1. Feed pump.
2. Distillate discharge pump.
3. Bottoms pump.
Provide the detailed table for each pump. This can be obtained by right-clicking on the
pump and selecting “Show Table”.
Also provide a brief summary of your pipe sizing and pump sizing.
Note: You may obtain the required information for each pump from the UniSim model. You
may then paste a screen-shot of the details for each pump as your answer to this part of the
assessment. Again, follow the procedure which was previously described to do this.
d) Draw a P&ID from the feed pump to the discharge streams. This drawing requires you to
accurately size the lines and the pumps. (15 marks)
Note: You may use an appropriate software program (such as Microsoft Word’s AutoShapes,
Microsoft’s Paint, or another suitable program such as Visio) to draw the required P&ID.
e) Briefly discuss the research methodology and challenges which you adopted for sizing the
piping and pumps in your UniSim Model. Ensure that your answer includes a justification for
selecting the specific piping and pump sizing in your UniSim model. (5 marks)
f) Underline the importance of sustainable practices and environmental considerations in
chemical processes by providing a detailed discussion of the implications of these in the
system which you have designed. (15 marks)
Microsoft Word Document and UniSim Model Submission Process
Begin by following the process which is outlined in the “Assessment Task Instructions” at the
beginning of this assessment in order to submit your Word document file.
The UniSim model (.usc) file is to be labelled as follows:
ME505-MME505_Ass3-Pract_StudentNumber_StudentName.usc
Master of Engineering (Industrial Automation) and (Mechanical) 8
ME505-MME505_Assessment3_PaperB_v2.2
Please note that you must submit the UniSim model as an editable .usc file. PDFs or other formats
are not acceptable.
The Word document and the UniSim model are to be both uploaded into the assessment
submission box on Moodle, which may be accessed on the unit page.
This assessment is not to be uploaded onto TurnItIn.
END OF ASSESSMENT

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