Department of Chemical Engineering Process Integration 2023 - 2024 Coursework Introduction The purpose of the coursework is to provide you with an opportunity of demonstrating the application of knowledge acquired in the unit to a larger scale industrially related problem. You will make use of knowledge gained in lectures and problem solving and apply it to produce a feasible, validated heat exchanger network. You have a certain period of time to produce the coursework. You will also be expected to apply your own background skills as Chemical Engineers. You will be expected to produce an appropriately structured, written, and presented report, with a limited number of pages. You are provided with some guidance in relation to the structure of the report to be produced, but part of the assessment is to evaluate your skills in relation to reporting the work that you have performed, its validity, and relevance. - The coursework is group based with groups comprising three members. You are required to choose the members of the group and register the group and members in Blackboard. Marks are awarded for group contributions and for individual contributions. For group contributions, all members of the group are awarded the same mark. Individual contributions MUST be labelled with the member making the contribution (student ID). Introduction Stream data for a chemical process are given in Table 1.1. Table 1.1 Stream data Stream Ts (°C) TT (°C) CP(kW °C-1) HTC (kW m² K-1) Hot1 430 300 5 0.8 Hot2 285 40 1.4 0.8 Hot3 280 25 2.0 0.6 Hot4 230 70 11.0 0.6 Hot5 140 50 23 0.8 Hot6 120 35 30 0.8 Cold1 180 350 12 0.6 Cold2 110 210 12 0.8 Cold3 30 150 18 0.8 A Maximum Energy Recovery Heat Exchanger Network (MER HEN), using the Pinch Design method, is to be designed for this chemical process using a minimum approach temperature (AT MIN) of 20°C. The MER HEN is to be designed in three parts (above the utility pinch, above the process pinch, and below the process pinch). There are three utilities available to provide additional process heating and cooling (Table 1.2). The specific heat capacity of the hot oil is 1.5 kJ kg¯¹ K−¹. The final developed MER HEN and its component parts (above the utility pinch, above the process pinch, and below the process pinch) are required to be validated and tested for feasibility, by comparing their features with targeted values. Table 1.2 Utility data Utility Ts (°C) Hot Oil 390 TT (°C) 310 Cost (£/kWh) HTC (kW m² K-1) 0.6 1.5 MP Steam 241 Cooling Water 5 240 10 0.35 3.0 0.05 1.0 Task 1 (Group Task – 40 marks) Using a minimum approach temperature (ATMIN) of 20°C, determine the overall hot utility requirement (QHmin), overall cold utility requirement (Qcmin), and overall heat recovery (QREC) for the chemical process given in Table 1.1. These results should be supported by the appropriate graphical and tabular information. In addition, and making use of the utilities that are available for additional heating and cooling (Table 1.2), determine the duty of the hot oil to be provided (kW), the MP steam (kW), and the cooling water (kW). The use of two hot utilities (hot oil and MP steam) produces a utility pinch at shifted temperature of 231°C. Your results need to confirm this utility pinch shifted temperature value. (Note that MP steam will be used in preference to hot oil due to its lower cost of supply). Task 2 (Individual Task – Member 1 – 30 marks) Produce a feasible, validated Maximum Energy Recovery Heat Exchanger Network (MER HEN) for the Above Utility Pinch Design region using the Pinch Design method for the chemical process (Table 1.1), using a minimum approach temperature (AT MIN) of 20°C. In this design region you should be using only hot oil as a utility. The report should contain all the information required to demonstrate the Maximum Energy Recovery Heat Exchanger Network (MER HEN) for this design region using is feasible and validated. The report should contain a table of all of the heat exchangers used in this design region which includes the hot stream entry and exit temperatures, the cold stream entry and exit temperatures, and the duty of the heat exchangers. Task 3 (Individual Task - Member 2 - 30 marks) Produce a feasible, validated Maximum Energy Recovery Heat Exchanger Network (MER HEN) for the Above Process Pinch Design region (and below the utility pinch) using the Pinch Design method for the chemical process (Table 1.1), using a minimum approach temperature (AT MIN) of 20°C. In this design region you should be using only MP steam as a utility. The report should contain all the information required to demonstrate the Maximum Energy Recovery Heat Exchanger Network (MER HEN) for this design region using is feasible and validated. The report should contain a table of all of the heat exchangers used in this design region which includes the hot stream entry and exit temperatures, the cold stream entry and exit temperatures, and the duty of the heat exchangers. Task 4 (Individual Task - Member 3 - 30 marks) Produce a feasible, validated Maximum Energy Recovery Heat Exchanger Network (MER HEN) for the Below Process Pinch Design region using the Pinch Design method for the chemical process (Table 1.1), using a minimum approach temperature (ATMIN) of 20°C. In this design region you should be using only cooling water as a utility. The report should contain all the information required to demonstrate the Maximum Energy Recovery Heat Exchanger Network (MER HEN) for this design region using is feasible and validated. The report should contain a table of all of the heat exchangers used in this design region which includes the hot stream entry and exit temperatures, the cold stream entry and exit temperatures, and the duty of the heat exchangers. Task 5 (Group Task – 10 marks) Produce a feasible, validated Maximum Energy Recovery Heat Exchanger Network (MER HEN) using the Pinch Design method for the chemical process (Table 1.1), using a minimum approach temperature (ATMIN) of 20°C, and the utilities provided in Table 1.2. This is essentially the final MER HEN Design combining the designs from Region 1 (above the Utility Pinch), Region 2 (above the Process Pinch), and Region 3 (below the Process Pinch). You can refer to information that you have provided in Tasks 2,3, and 4, but you are required to comment and discuss the feasibility and validity of the final MER HEN. There will be help available from myself and Dr. Salman Shahid and the GTA's. However, this help is related to general guidance only. You are being assessed on your own ability to design the required Heat Exchanger Networks. Marking scheme and Report Submission It is up to you to decide the exact format of your report and what should be included to support the work you have done. A marking sheet and a marking scheme will be made available. However, the report should include the following sections; Task 1 (Group based - maximum 40 marks) Task 2 (Member 1 - maximum 30 marks) Task 3 (Member 2 - maximum 30 marks) Task 4 (Member 3 - maximum 30 marks) Task 5 (Group – maximum 10 marks) - Marks are also awarded for presentation of the report (Group based) – maximum 10 marks. Marks are also awarded to contribution from group members. This is done via Peer Assessment (method of awarding this mark will be released nearer to submission date). Maximum 10 marks. Total 100 marks maximum per group member As the space is limited, present information that you think is relevant and reflects the work that has been done and the points that you are attempting to make to an audience. Not all information can be presented as space is not sufficient. Part of the skill is deciding what is relevant and how to express it. DO NOT BE VERBOSE. The mark sheet to be used for assessment and the marking scheme will be available in separate documents. The report should be completed in MS Word, and should not contain more than 18 pages (which does not include a front page). Pages above this limit will be penalised by a reduction of 5% per additional page in your overall mark. Late submission of the coursework will also result in a penalty of a reduction in your overall mark. The later the submission the larger the reduction!!!! Late submission penalties are set by the Department. Mitigating circumstances can be submitted to support late submissions. Again, this has been set by the Department and further information can be found in the Student Handbook and Virtual Common Room. A pdf version of the report should be produced (CutePDFWriter is a good PDF production tool and is available online or on the CEAS computers), and this PDF should be uploaded into Blackboard. There will be an area in the Energy Systems Blackboard space for doing this and appropriate instructions a week prior to the submission date. The submitted report in Blackboard will be checked by TURNITINUK for plagiarism and collusion. BE WARNED!!!!!! If you are unsure of the meaning academic malpractice including plagiarism or collusion, please ask.