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complexity Optimal
Flowsheet: + design
rational evaluation results
𝑚𝑜𝑠𝑡 𝑝𝑟𝑜𝑓𝑖𝑡𝑎𝑏𝑙𝑒
𝑚𝑜𝑠𝑡 𝑜𝑝𝑡𝑖𝑚𝑎𝑙 = 𝑠𝑎𝑓𝑒
𝑒𝑛𝑣𝑖𝑟𝑜𝑛𝑚𝑒𝑛𝑡𝑎𝑙𝑙𝑦 𝑠𝑜𝑢𝑛𝑑 𝑑𝑒𝑠𝑖𝑔𝑛
Procedures of constructing flow sheet
2
2. Algorithmic method
Utilizes mathematical programming procedures that
includes optimization technique
Hierarchical
Method
3
4
General Procedures in hierarchical methods
5
1. Process information
Conduct a search of the technical and patent literature
Study market condition and pricing
6
3. Function Diagram
7
8
4. Operations diagram
9
10
5. Flowsheet
11
Shows
Detailed separation steps
Detailed reaction sections
Detailed processes such as reaction, separation,
mixing….etc are shown
Final flowsheet
12
6. Base case design
13
∗ 𝑦𝑖𝑒𝑙𝑑
𝑓𝑎𝑐𝑡𝑜𝑟𝑠 𝑡ℎ𝑎𝑡 𝑚𝑎𝑘𝑒𝑠 𝑎𝑠𝑠𝑒𝑠𝑠𝑚𝑒𝑛𝑡 𝑜𝑓
∗ 𝑏𝑦 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑒 𝑠𝑦𝑛𝑡ℎ𝑒𝑠𝑖𝑠 𝑑𝑖𝑓𝑓𝑖𝑐𝑢𝑙𝑡
∗ 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝𝑠
In most cases it is difficult and very expensive to start with simple species.
Benzyl acetate
Rules of thump (continues)
20
Given:
Capacity = 500000 t/yr
Answer
Mode of operation = continuous (large production
1. Acetylene hydrochlorination
Preprocessing
Heating or cooling the raw material
Reduce impurities to acceptable levels.
Remove harmful materials as complete as possible
Remove (reduce) impurities if they affect the
economics of the plant
Do not separate inert if they are not harmful to the
plant
Functions Diagram (continues)
44
Reactions
Show data needed for each main reactor
Recycle
Functions Diagram (continues)
45
Rules:
Recycle raw material that appears in the product
(output streams)
Mixtures of components that need to be recycled
should not be separated (do not separate mixtures
that will be mixed again)
Generally there is an optimum recycle/purge ratio
Intermediate:
Intermediate
C2H4 + Cl2 ==== C2H4Cl2
Waste
Functions Diagram (continues)
48
Separations
Guidelines:
Reactor products (product, co-product, by-product,
with Q
Functions Diagram (continues)
49
2 C2H4Cl2↔2C2H3Cl + 2HCl
C2H4Cl2
EDC is pure
C2H4Cl2
The reaction occurs at 475oC < T <
525oC
C2H3Cl
Reactor # 2 (R-2) C2H4Cl2 Separator C2H3Cl
The reaction is endothermic
Pyrolysis reactor HCL
Reaction pressure ranges from 1.5-3 S-2
T=475 – 525oC
Mpa P=1.5 – 3 MPa
Endothermic
Conversion is 53 to 63% Q
Q HCL
Residence time 2 – 30 s to prevent
VC from decaying
C2H4 + 2HCl + ½ O2 ↔
C2H4 Cl2 + H2O
2 C2H4Cl2↔2C2H3Cl + 2HCl
C2H4Cl2
EDC is pure
C2H4Cl2
The reaction occurs at 475oC < T <
525oC
C2H3Cl
Reactor # 2 (R-2) C2H4Cl2 Separator C2H3Cl
The reaction is endothermic
Pyrolysis reactor HCL
Reaction pressure ranges from 1.5-3 S-2
T=475 – 525oC
Mpa P=1.5 – 3 MPa
Endothermic
Conversion is 53 to 63% Q
Q HCL
Residence time 2 – 30 s to prevent
VC from decaying
Preprocessing:
Heating, cooling, purification, conditioning,
Operations Diagram (Reactors)
56
Q = -90 kJ
Reactor # 1 (R-1)
Chlorination reactor C2H4Cl2
T=65 – 200oC 183oC
P=.15 – 12 MPa 1MPa
exothermic
Cooling
1. Coil
2. Jacket
3. External
C2H4 + Cl2
Separator
64
Impurities
Reactor #2
65
Fuel + air
Separator
66
HCl to R3
Chemical Boiling point
HCl -32oC
VC 58oC Q
Separator#1
VC
EDC 183oC
EDC
Q
HCl EDC to the
VC Pyrolysis
250oC
Separator#2
reactor
EDC
Q
Impurities
Reactor #3
67
Highly exothermic
CuCl2 pellets
220<T<300 260oC
0.25<P<1.5 1MPa
Exothermic HCl
Catalyst: CUCl2 O2C2H4
Possible reactors
Fluidized bed EDC
Water
Packed as HE
Cooling Media C2H4
HCl
O2
Reactor#3 product treatment
68
Conversion is 98 to 99.5%
for HCl
HCl
Conversion of O2 is 100% O2
C2H4
EDC yield is 94 – 97%
Reactor#3
output
EDC
Water
Cooling
HCl
EDC should C2H4
Not have
EDC+Water
More than To
10 ppm water separation
70
Operation diagram of VC production
Process Flow Sheet
71
Reactor
A given conversion, yield is assumed. This will improve
mass and energy balance. Appropriate equilibrium, mass
transfer and kinetic models are used to size the reactor to
achieve the selected conversion. The assumed variables (x,
T, P are then optimized to achieve final design.
Mass and Energy Balance
72
Separation Train
To separate a mixture containing m component you
need m-1 separation unit
Need not to be of the same technology
Rules of Thumb
73
76