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Few exact mathematical models or automated procedures Heat exchanger & separation networks are exceptions
Why is it critical? Preliminary design costs 15-20% of the entire project cost, but fixes about 80% of subsequent costs
Cyclohexane Manufacture - II
Purge Product Cooler Flash Recycle Compressor Reactor Steam Light Ends
Boiler Feed Water (335 psia, 570 F) Make-Up Hydrogen Feed Preheater Benzene Feed Pump Pump
Stabilizer 15 psia
Cyclohexane Product
What is the major difference from the previous process? How to select?
PFD (Process Flow Diagram) shows real processing equipment (physical units)
Heat exchanger, pump, distillation unit, reactor, etc. Often called process flowsheet
Boiler Feed Water (335 psia, 570 F) Make-Up Hydrogen Feed Preheater Benzene Feed Pump Pump
Stabilizer 15 psia
Cyclohexane Product
Purge 320 psia Condense 320 psia DPT-120 F Flash Expand 320 psia 15 psia 120 F Split 320 psia
Light Ends Purge
Cool 100 F
Distil 20 psia
Expand 20 psia
PFD?
Each stream (material/energy) has a state
(P, T, F, x, y, f, etc.)
Point A
Point B
P = 1 atm T = 30 C x, y, f
P = 1 atm T = 90 C x, y, f'
One single stream at two points in a process What must happen between A & B?
If we know state changes, we can know the operations If we know the operations, we can know the units Once we know the units, we can know the PFD!
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State 4
State 2 State 3
State 5
State 6
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c-changes?
x-changes?
Identify best intermediate states Recycle/purge materials, as & when needed Select & add operation to effect each state change
f-changes? P-changes?
T-changes? F-changes?
Add equipment for each operation
BFD
Copyright 2012 IA Karimi & Mukta Bansal
PFD
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MSDS maintained by OSHA (Occupational Safety & Health Agency) Cyclohexane: MW = 84.16, Density@20 C = 0.779, BP = 81 C,
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H = 266 kJ/mol
Cyclohexane is recycled to the reactor for heat removal What should be the limiting reactant?
or hazardous reactant
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Any c-change?
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Cyclohexane PFD
Heat
H2 (340 psia, 120 F) N2 H2 CH4 C6H12 C6H6
PFD1?
C6H6 (15 psia, 100 F)
PFD2?
Any more c-change? Any x-change? How to separate the reactor product to get C6H12 from PFD2?
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What is the state of mixture?
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PFD1?
C6H6 15 psia 100 F
PFD3?
Flash ?
PFD4?
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Liquefy completely? Two ways of condensing C6H6 and C6H12? Heuristic: Avoid compression.
Why restrict to 45 C?
Heuristic: For open-circuit system, use 45 C for CW outlet.
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Heat Exchanger
t2
T1
TR = T1 t2
Heuristic: Near-optimal min T-approaches are 10 F for below ambient, 20 F for up to 300 F (150 C), and 50 F for higher Heuristic: Near-optimal min T-approaches are 10 C for liquids (high heat transfer coefficient systems), 20 C for gases, and 5 C for refrigeration What should be flash temperature?
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PFD1?
C6H6 15 psia 100 F
PFD3?
N2+H2+CH4 C6H6+C6H12
C6H12+C6H6+gases
Any x-change? How to purify C6H12 in PFD4? State of the mixture? Recall heuristic. Is distillation easy for C6H6 & C6H12? Recall: Used excess H2 to consume most of C6H6!
Copyright 2012 IA Karimi & Mukta Bansal
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Add Distillation
H2 340 psia 120 F Heat N2 H2 CH4 C6H12 C6H6 H2+N2+CH4
PFD1?
C6H6 15 psia 100 F
PFD3?
PFD5? Distil P?
Top Product? C6H12+C6H6 15 psia 100 F
PFD6?
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PFD1?
PFD3?
From where to recycle C6H12? What are the two possible places? Does it need to be pure?
Distil 20 psia
PFD6?
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Recycle Cyclohexane
Heat H2 340 psia 120 F
PFD1?
PFD3?
C6H12+C6H6+gases
Light Ends
C6H12+C6H6 15 psia 100 F
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Mixing in PFD1
Fact: Mixing streams with very different viscosities is difficult
Fuel injection in car engine Hydrogen & benzene in the liquid-phase reactor for cyclohexane
Heuristic: Avoid mixing a gas with liquid
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PFD9?
PFD3?
PFD7?
L-Mix P?
PFD8?
What should be P & T of L-Mix? 15 psia? 320 psia? Intermediate? Which heuristic rule can you invoke?
Copyright 2012 IA Karimi & Mukta Bansal
PFD6?
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PFD9?
PFD3?
PFD7?
PFD8?
PFD6?
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Purge 320 psia Condense 320 psia DPT-120 F Flash Expand 320 psia 15 psia 120 F Split 320 psia
Light Ends Purge
Cool 100 F
Distil 20 psia
Expand 20 psia
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Cyclohexane PFD
Purge Product Cooler Flash Recycle Compressor Reactor Steam Light Ends
Boiler Feed Water (335 psia, 570 F) Make-Up Hydrogen Feed Preheater Benzene Feed Pump Pump
Stabilizer 15 psia
Cyclohexane Product
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Reading
Basics of PFD development - Vinyl Chloride (Ch 1) Heuristic rules for design & synthesis (Ch 5) References on synthesis (Ch 1, SSL) Handbooks, encyclopedias, Hydrocarbon Processing, etc.
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Practice Exercise
Formaldehyde (HCHO) is fully soluble in water, alcohols and other
polar solvents. However, aqueous formaldehyde is not a simple physical solution of formaldehyde in water, but a complex mixture of various hydrated chemical species. Develop a process to produce 40 wt% aqueous formaldehyde (1 atm, 40 C) using methanol (CH3OH, 2 atm, 40 C) and ambient air as raw materials via the following gas-phase, catalytic reactions at 1.5 atm and 600-650 C:
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Improving a PFD
Energy integration leads to alternate PFDs
Match hot streams with cold streams, under what conditions? Where can you conserve energy in this process?
Alternate reaction pathways, separation methods, etc.
Unit/stream conditions may change, but PFD largely unchanged Simulators handy in estimating properties and conditions (e.g. Flash,
BPs of Benzene and C6H12) On-line optimization using simulators
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Other Heuristics
1 psi for boiling & condensing 3 psi for a gas 5 psi for a low-viscosity liquid 7-9 psi for a high-viscosity liquid 20 psi for a fluid through furnace
Other units (reactors, columns, etc.) Flow velocities (gas & liquid)
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