Reference no: EM132364477 , Length: 6

ASSESSMENT TASK: Special Assignment- Material Selection and Corrosion

PART A: RUDIMENTARY MASS AND ENERGY BALANCE FOR PFD

Complete the rudimentary mass and energy balance for your Process Flow Diagram (PFD) based on the sketch that is given to you. You are expected to do a rudimentary mass and energy calculation (both manual calculations and aspen plus simulation are acceptable) on all the streams given in the PFD.

This project is still at its conceptual design phase hence there is not a lot of information available to you (this includes clearly defined pressure and temperature for each stream), make appropriate assumptions to complete your rudimentary mass and energy balance. Clearly state all the assumptions you have made while performing your rudimentary mass and energy calculation. Tabulate your mass and heat energy balance in your main report. You may use the template given in Table 1 to tabulate the results of your mass and energy balance.

PART B: PRELIMINART MATERIAL SELECTION

Based on the mass and heat balance calculations/simulation, select materials for all the equipment and major pipelines (pipelines with stream number) shown on the PFD. Discuss why these materials are the most suitable materials for your process equipment and pipelines assuming that material cost is not a concern at this point of time.

You need to make your material selection data easy to read (wall of text is not a  good way to present your material selection results). Table 2 shows one of the many ways to make your material selection easy to read for the markers.

PART C: REVISIT THE MATERIAL SELECTION FOR PROCESS PIPELINES

You attended a quarterly meeting with the material specialists from Sustainable HC Pty Ltd (your clients). Your clients told you that the materials you have selected in PART B is too expensive and they want you to review the material selection you have done in PART B. You are instructed to minimize the material cost of your process pipelines without jeopardizing the safety of your plant.

You should propose another cheaper materials for your process pipelines (you need to show the price difference). Discuss the types of corrosions you expect to happen when you used these materials as your pipelines. In the event you choose polymer/composite pipes as the alternative material, you need to discuss how frequently you expect to replace the polymer/composite pipelines in your chemical plant.

You should also tabulate the corrosion rates/degradation rates of your selected materials (you need to cite your source clearly). Assume that all your pipelines have a size of DN100 (schedule 40) and a length of 1 km at this stage. Note that we have not cover equipment sizing at this stage, so leave your process equipment and instruments (vessels, tank, pumps, valves and heat exchanger) out of this section.

PART D: ECONOMIC ANALYSIS

You are instructed to perform an economic analysis to investigate which materials are the best (one from PART B and one from PART C) choice for your process pipelines. The process pipelines need to keep a minimum thickness equals to the thickness of schedule 40 pipelines throughout their service in the plant.

If you chose a material that undergo corrosion, you will need to add additional thickness (corrosion allowance) to the pipe. You will need to replace your pipes once the thickness of the pipes become lower than a schedule 40 pipes. Factor in the additional corrosion allowance into your purchasing costing and discuss which material is better for a plant with a design life of 30 years.

Attachment:- Reading for Assignment.rar