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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. 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?
3 ) Should we use a gas recycle and purge stream?
4 ) Should we not bother to recover and recycle some reactants?
5 ) How many product streams will there be?
6 ) What are the design variables for the input/output structure?
What economic trade-offs are associated with these variables?
Products
&
PROCESS
Feeds
By products
OR
Feeds
PROCESS
Purge
Products
&
By products
Heat
Compressor
H2, CH4
H2
CH4
1150 ~ 1300
Reactor
Toluene
Coolant
Heat
H2, CH4
Benzene
Product
Toluene
Flash
500 psia
Recycle
Heat
95F
Dipheny1
Toluene
Stabilizer
Heat
Purge
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
should be minimized
By-products to waste treatment
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
Toluene
Purge
H2 , CH4
3
Process
Benzene
Diphenyl
1
FH2
FM
0
0
0
100
550
0
0
PB/S
0
100
15
0
PB
0
0
100
15
FIGURE 5.2-1
.
5
FE
0
FM + PB/S
0
0
0
0
PB(1 - S)/(2S) 0
100
100
15
465
Stream table
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
STOICHIOMETRIC FACTOR
(SF)
The stoichiometric moles of reactant
required per mole of product
Toluene
converted
x mole
recycl
e
Benzene
produced
Sx mole
Diphenyl
produced
(1-S)x / 2
Gas recycle
Purge
H2 , CH4
Toluene 1 x
Benzene
Sx
H2 , CH4
Toluene
Reactor
system
1
2
Diphenyl (1 S) x
Benzene
Separation
system
Sx
Dipheny1
1 x
Toluene recycle
1
(1 S ) x
2
If excess reactants are used, due to reactant not recovered or gas recycle and purge, then
the excess amount is another design variable.
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
P
FFT( mol/hr ) = toluene feed to process ( limiting reactant ) = PB/S
PR , CH4
PD
design
variable
F
Let FEE = excess amount of H2 in purge stream= PH2
y
( PB/S ) - [( PB/S )( 1 - S )/2]
FHFG
y
FE +
= FHFG
purge rate
of H2
disapp. in reaction
where
FH
= mole fraction of H2 in FG
( known )
methane in feed
FH2
design
variable
PH
Known :
S (yFH - yPH)
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,
S(x)
PB/S
FFT
FFT(1-S)/2
PD
PB[1-(1- yPH)(1-S)/2
PH
S(yFH - yPH)
FCH4
FH2
1- yPH
FCH4+PB/S
PCH4
FE+PB(1+S)/2S
FE
(PH2)
FH2
PG
FG
FG+(PB/S)(1-S)/2
PG yPH
PH
0.1
0.3
0.5
0.1
PH
0.1
0.7
0.9