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Hierarchy of decisions
1. Batch versus continuous
2. Input-output structure of the flowsheet
3. Recycle structure of the flowsheet
4. General structure of the separation system
a. Vapor recovery system
b. Liquid recovery system
5. Heat-exchanger network Ch.6, Ch.7, Ch.16
Ch. 4
Ch.5
1106
lb/yr (usually)
c ) multi-product plants
2. Market force
a ) seasonal production
b) short production lifetime
3. Scale-up problems
a ) very long reaction times
b ) handling slurries at low flow rates
c ) rapidly fouling materials.
Hierarchy of decisions
1. Batch versus continuous
2. Input-output structure of the flowsheet
3. Recycle structure of the flowsheet
4. General structure of the separation system
a. Vapor recovery system
b. Liquid recovery system
5. Heat-exchanger network Ch.6, Ch.7, Ch.16
Ch. 4
Ch.5
Heuristics:
Recover more than 99% of all valuable materials.
assume
(1)
Feed streams
(2)
Feed streams
Products
by-products
no reactants
Process
Purge
Process
Products
By-Products
reasons:
a. inexpensive reactants, e.g. Air, Water.
b. gaseous reactants + (inert gaseous feed impurity or inert gaseous
reaction by-product)
LEVEL 2 DECISIONS:
1 ) Should we purify the feed streams before they enter the process?
2 ) Should we remove or recycle a reversible by-product?
PROCESS
Products
&
By products
OR
Feeds
PROCESS
Purge
Products
&
By products
remove it.
2 ) If a feed impurity is present in large amount, remove it.
3 ) If a feed impurity is catalyst poison, remove it.
4 ) If a feed impurity is present in a gas feed, as a first guess, process the
impurity.
Heat
Compressor
H2, CH4
Heat
Purge
H2
CH4
1150 ~1300
Reactor
Toluene
Coolant
Heat
Benzene
Product
Toluene
Flash
500 psia
Recycle
Heat
95F
Dipheny1
Toluene
H2, CH4
product boil lower than propylene (-55F), use a gas recycle and purge
stream.
Lower boiling components normally cannot be condensed at high pressure
with cooling water.
A HIERARCHICAL APPROACH
4.None
5.Excess - vent
6.Excess - vent
7.Primary product
8.Fuel
9.Waste
Component classifications
Gaseous by-products and feed impurities
Gaseous reactants plus inert gases and/or gaseous by-products
Reactants
Reaction intermediates
Azeotropes with reactants (sometimes)
Reversible by-products (sometimes)
Reactants-if complete conversion or unstable reaction intermediates
Gaseous reactant not recovered or recycles
Liquid reactant not recovered or recycled
Primary product
By-products to fuel
By-products to waste treatment
should be minimized
A ) List all the components that are expected to leave the reactor. This list includes all
the components in feed streams, and all reactants and products that appear in every
reaction.
B ) Classify each component in the list according to Table 5.1-3 and assign a destination
code to each.
C ) Order the components by their normal boiling points and group them with
neighboring destinations.
D ) The number of groups of all but the recycle streams is then considered to be the
number of product streams.
EXAMPLE
b.p.
A
B
C
D
E
F
G
H
I
J
Waste
Waste
Recycle
Fuel
Fuel
Primary product
Recycle
Recycle
Valuable By-product
Fuel
A + B to waste
D + E to fuel stream # 1
F
to primary product
(storage for sale)
I
to valuable by-product (storage for sale)
J to fuel stream # 2
EXAMPLE
b.p.
-253C
-161
80
111
253
H2
CH4
Benzene
Toluene
Diphenyl
Purge : H , CH
2
4
H2 , CH4
Toluene
Process
Benzene
Diphenyl
5
H2 , CH4
1
Purge
H2 , CH4
3
Process
Toluene
Benzene
Diphenyl
H2
FH2
0
CH4
FM
0
Benzene
0
0
Toluene
0
PB/S
Diphenyl
0
0
Temperature
100
100
Pressure
550
15
Stream table
where S = 1 - 0.0036/(1 -x)1.544
4
0
FE
0
0
FM + PB/S
PB
0
0
0
0
0
0
PB(1 - S)/(2S) 0
100
100
100
15
15
465
FH2 = FE + PB(1 + S)/2S
FG = FH2 + FE
REACTOR PERFORMANCE
Conversion (x)
= (reactant consumed in the
reactor)/(reactant fed to the reactor)
Selectivity (S)
=[(desired product produced)/(reactant
consumed in the reactor)]*SF
Reactor Yield (Y)
=[(desired product produced)/(reactant fed to
the reactor)]*SF
Toluene
unconverted
(1-x) mole
Toluene
feed
(1 mole)
Toluene
converted
x mole
recycle
Benzene
produced
Sx mole
Diphenyl
produced
(1-S)x / 2
Gas recycle
Toluene
Benzene
H2 , CH4
Reactor
system
Toluene
Purge
H2 , CH4
1 x
Sx
1
Diphenyl (1 S) x
2
Separation
system
Benzene
Sx
Dipheny1
1 x
Toluene recycle
1
(1 S) x
2
EXAMPLE
Purge ; H2 , CH4 , PG
FG , H2 , CH4
FFT , Toluene
relation
known
Benzene , PB
Diphenyl , PD
Process
design variable
given
SS( x )
= selectivity = given
PBB( mol/hr ) = production rate of Benzene =given
FFT( mol/hr ) = toluene feed to process ( limiting reactant ) = PB/S
PR , CH4
= methane produced in reaction = FFT = PB/S
PD
design
variable
y FF
= yFH
FH GG
of H2
where
FG = make-up gas stream flowrate (unknown)
y
FH =
mole fraction of H2 in FG
( known )
FH2
PH =
design
variable
Known :
S (yFH - yPH)
design variable
Design Variable :
S (x)
FH
PB
PB/S
(PB/S)[(1-S)/2]
FE
PCH4
FCH4+PB/S
PCH4+FE
PG
FN2+FCH4
FFT
FG
FE+[PB(1+S)/2S]
PD
Known : yFH
PB
Design Variables :
x, yPH
S(x)
PB/S
FFT
FFT(1-S)/2
PD
PB[1-(1- yPH)(1-S)/2
S(yFH - yPH)
FCH4
FCH4+PB/S
FE+PB(1+S)/2S
1- y
PH
PH
FH2
FH2
FE
(PH2)
PG yPH
PG
FG
FG+(PB/S)(1-S)/2
PCH4
6 ) ECONOMIC POTENTIAL AT LEVEL 2
EP2 = Annual profit if capital costs and utility costs are excluded
= Product Value + By-product Value - Raw-Material Costs
[EXAMPLE] HDA process
4 10^6
2 10^6
$/yr
-2 10^6
-4 10^6
0.1
0.3 0.5
PH
0.1
0.1
0.7
0.9