CH3028 Chemical Plant Design Syllabus:
CH3028 Chemical Plant Design Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
To understand the intricacies in equipment sizing and selection amongst options therein
To leverage lessons learnt in designing chemical process unit with safety as paramount
UNIT I ROTARY EQUIPMENT
Pumps: Various types: Centrifugal, Reciprocating& Other Positive displacement types – Plunger, Piston, Diaphragm, Gear, Screw, Lobe, Vane, etc.; Compressors: Various types: Axial, Centrifugal, Reciprocating, and other positive displacement type such as Rotary Screw, Scroll, etc. Further, compressors are classified into two namely Oil free and Oil flooded lubricated; Fans: Various types: Axial fans (including Propeller, Tube-axial, and Vane-axial) and Centrifugal fans. Further fans are classified as Induced draft and Forced draft types; Steam Turbines: : Various types: Back Pressure and Condensing Types with and without extraction, Impulse & Reaction types; Gas Turbines : Various types: Turbojet, Turboprop, Turbofan and Turboshaft Engines; Motor :Various types: AC motors (Synchronous & Asynchronous motors), DC motors (brushed and brushless), Variable Frequency and Variable Speed motors and Special purpose motors, Generator: Various types: AC and DC generator; Other Special Equipment: Various types: Power Recovery Turbines, Heat Pumps, Ejector pump, NASH vacuum pump Case Studies – From Industries on operations and maintenance aspects viz. Trouble shooting, Energy improvement, Capacity augmentation, Design tips, Equipment safety, Catastrophic incidents, etc.
UNIT II STATIC EQUIPMENT – HEAT TRANSFER EQUIPMENT
Heat Exchangers– Shell and Tube, Double Pipe, Plate &Frame type, Tube in tube Scraped surface, and Fin tube, Coolers, Condensers, Fin Fan Coolers; Fired Heaters& Boilers– With or without air preheaters, Balanced draft or simply natural draft or even only forced draft, With and without waste heat generation, Refrigeration& Air Conditioning– HVAC (Heating, Ventilation, and Air Conditioning); Miscellaneous – Chilled water system with vapour compression refrigeration, Ejector refrigeration system, direct contact heat exchanger (such as cooling towers, Jet condensers, direct contact feed), Incinerator. Case Studies – From Industries on operations and maintenance aspects viz. Fouling control, Pinch study for energy recovery, Capacity creep, Design tips, Equipment safety, Catastrophic incidents, etc.
UNIT III STATIC EQUIPMENT – MASS TRANSFER
Mass Transfer Operations: Multi Component Distillation columns, Extractive distillation, Reactive Distillation, Azeotropic distillation, Divided wall columns, Dryers, Adsorption Isotherm, Pressure Swing Adsorption, Importance of recycles and Optimization needs, Absorption processes & operating variables, Liquid – Liquid Solvent Extraction ; Humidification & dehumidification, Evaporation, Precipitation, Crystallizers, Membrane filtration; Reactors– CSTR, Slurry phase reactor, Tubular, Trickle Bed Reactor, etc., thermodynamically controlled reaction and kinetically controlled reaction, Reaction Kinetics, Importance of Reactor internals. Case Studies – From industries across life cycle such as Trouble shooting, enhance conversion & selectivity, IoT use, Debottlenecking, Design tips, Safety Incidents “Fit – For Purpose” Assessment, etc.
UNIT IV EQUIPMENT ANCILLARIES
Special equipment– Static Mixer, Agitators, Jet Mixing, Ejectors, Eductors, Structured Packing, Grid Packing and Random Packing, Demisters, Vortex Breaker, Calming Baffles, Schoepentoeter, Vapour horn device, Cyclone separators; Package units – Inert gas generators, Feed stream filters (Mechanical, Chemical), Scrubbers, Spray Nozzles, Guard beds, Flare stack, Ground Flare, Flame arrestors, Strainers, Spring supports, Expansion joints, Electrostatic Precipitators; Steam Traps – Thermodynamic, Inverted Bucket type, Thermostatic – Float, Bimetallic type, etc., Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting, Efficiency / Effectiveness tracking, Debottlenecking, Design tips, Safety & Environmental Incidents, etc.
UNIT V STATIC EQUIPMENT – PRESSURE VESSELS, INTERNALS &SAFETY VALVES
Pressure Vessels – Vertical / Horizontal, Knock Out Drums, Steam and Blow down drum, Cold & Hot Separators, Surge drum, Deaerators, Water Seal Pot, Molecular seals, Shock Absorbers, Pressure snubber, Silencer, Slug Catcher, Desalter, Coke drum; Vessel & Columns – associated structural accessories such as Platforms, Ladders, Staircase etc. Internals –Column internals such as Trays (Sieve, Valve, Bubble Cap, Baffle, Dual flow, Multi down comer, Chimney tray etc.), Packings (structured, grid, random, etc.), Packed tower internals – Bed support plates, Liquid distributors, Bed limiters etc.; Mist eliminators, Demisters, Coalescing pads, Vortex breakers etc. Safety Valves: Normal, balanced bellows, pilot operated, etc., Rupture Discs, and Design codes overning Safety valve design, Case Studies– From industrial operations & maintenance activities–ASME codes, Trouble shooting, Efficiency tracking, Use of IoT, Debottlenecking, and Design tips, Safety & Environmental Incidents, etc.
TOTAL: 45 PERIODS
OUTCOMES:
On completion of the course, the students will be able to
CO1 – understand the basic on designing chemical process unit for rotary equipment
CO2 – learn the operations of boilers, heat exchangers, refrigeration and air conditioners.
CO3 – knowledge on operations of reactors, humidifiers and mass transfer operations
CO4 – learn the different types of equipments in process industries
CO5 – understand the knowledge on usage of different valves such as pressure, safety and internal.
TEXTBOOKS
1. Chemical Engineering Handbook – Robert H. Perry; Don W. Green and James O. Maloney
2. Heat Transfer – D.Q. Kern
3. Mass Transfer Operations – Robert E. Treybal
4. Principles of Mass Transfer and separation Processes – BK Dutta
5. Fluid Mechanics, Heat Transfer, and Mass Transfer (Chemical Engineering Practice) – KSN Raju
REFERENCE BOOKS
1. Applied Process Design for Chemical and Petrochemical Plants – Ernest E. Ludwig