PROJECT REPORTPROCESS SIMULATIONSpring-2011
Department of Chemical Engineering
Submitted ToDr. John L GossageSubmitted By
Mangesh Pate
LU ID: L20258949
Objective:To modify the ketene manufacturing plant to increase the operating profit.
Initial Flow Sheet:
Stream Result:
FEEDRECY.PFR-INPFR-OUTDIKETIPACOMETHETHYLKETEN
Temperature C2570.4967761.85757.3428109.187120.8413-123.159-73.1522.7797.6242
Pressure bar1.621.621.621.621.62560606060
Vapor Frac0.2180.5318611001010
Mole Flow kmol/hr15265.1013217.1448300.51831.2020738.9111132.309365.59832.14165.2559
Mass Flow kg/hr80003778.5911778.5911778.5386.75672320.323895.3791056.2907.7522733.52
Volume Flow cum/hr515.1613.09611534.5915893.760.104063.4838866.715366.360713.17987.49779
Enthalpy MMkcal/hr-7.65-3.5114-5.57176-3.71164-0.0749-2.62557-0.87948-1.2120.35802-0.666
Mass Flow kg/hr
CO4007.36E-07400882.615.38E-343.35E-31882.4870.10210.02092.34E-11
METHANE02.17E-052.17E-051070.8521.57E-302.43E-2712.89211047.310.70855.14E-06
ETHYLENE4000.00493400.0049883.36211.28E-248.93E-211.90E-078.8336854.65219.8712
KETENE012.024912.024882767.1738.15E-184.40E-131.91E-160.016642.37012712.76
ACETONE64003703.8610103.864225.5435.54E-07520.7979001.23E-110.88797
IPA80062.7066862.70661898.08935.85681799.525001.82E-180.0003
DIKETENE00050.8998450.89988.97E-080000
SODIUM0000000000
Cost of Feed and other Components on the Flow sheet:
No.ComponentCost ($/kg)
1FEED0.23
2Carbon Monoxide0.25
3Methane0.5
4Ethylene1
5Ketene2.7
6Acetone1.1
7Isopropyl Alcohol1.32
8Diketene0.2
Reaction and Kinetics:
Three first-order, irreversible, vapor-phase reactions occur simultaneously in the PFR.RxnPhaseStoichiometryk(S-1)E(MJ/kmol)T0(K)
1VaporAcetone ----> Methane + Ketene1.1252851000
2VaporAcetone ----> 0.5 IPA + 0.5 Ethylene + 0.5 CO0.53501000
3VaporAcetone ----> 0.5 Diketene0.11001000
Utilities:
Following three types of utilities are available:
No.UtilitiesEnergy/Purchase Price
1COOLCooling Water$0.1 /GJ
2ELECElectricity$0.1 /KWhr
3Heatgas$0.5/kg
The inlet and outlet temperatures of cooling water are 25oC and 50oC respectively.
Electricity is used both to run the compressors and to provide refrigeration for cooling to temperatures below 60oC.
Heating value of gas is 55687.5kJ/kg.
Constraints:1. The FEED stream composition and flow rate cannot be changed.
2. The NRTL property package must be used, and may not be modified.
3. The Reaction and Kinetics set may not be changed.
Profit of the Initial Case:The plant is making $29.18/hr for the initial conditions.
VariableValue readValue writtenUnits
FEED8000 KG/HR
WFCO0.9856015
FCO882.48698 KG/HR
WFMETH0.9915241
FMETH1047.2514 KG/HR
WFETH0.9415044
FETH854.65236 KG/HR
WFKET0.9924056
FKET2712.7616 KG/HR
WFIPA0.7755494
FIPA1799.5249 KG/HR
WFDIK0.5866965
FDIK50.899839 KG/HR
CCOOL-4.317738 $/HR
CHEAT1803.7601 $/HR
CELEC4281.1346 $/HR
PROFIT029.1805116$
UCOST06089.21239$
FCOST01840$
INCOME07958.3929$
Process Modification:Following sequence is used for the optimization of the process parameter:
1. Reactor
2. Separation and Recycle system3. Heat Integration1. Reactor Optimization:For initial condition of the reactor the following results are obtained:
Mass Flow(kg/hr)PFR-INPFR-OUTCOSTWORTH
CO400882.610.25220.653
METHANE2.17E-051070.8520.5535.426
ETHYLENE400.005883.36211883.362
KETENE12.02492767.1732.77471.37
IPA862.7071898.0891.322505.48
DIKETENE050.899840.210.18
TOTAL11626.5
Selectivity of ketene = (Desired product produced/Reactant consumed in the reactor)*
Stoichiometric factor.
Selectivity of ketene = 0.650393
Sensitivity Analysis: To increase the ketene production i.e. the selectivity of ketene
No.VaryRangeIncrement
1Length of tube (m)1.0 to 3.50.001
2Temperature of Feed Streem(oC)400 to 75010
3Pressure of Feed Streem(bar)1 to 3.00.1
New Conditions:No.New Parameter
1Length of tube (m)2.398
2Temperature of Feed Streem(oC)660
3Pressure of Feed Streem(bar)2.2
Mass Flow kg/hrPFR-INPFR-OUTCOSTWORTH
CO400892.5034620.25223.126
METHANE2.61E-071197.881570.5598.941
ETHYLENE400.0003893.2661561893.266
KETENE3.062271643062.262232.78268.11
IPA809.3290531865.988321.322463.1
DIKETENE5.51E-3579.64167750.215.9283
TOTAL12462.5
Selectivity of ketene = 0.6632415722. Separation of PFR-OUT Stream: Strategy used for separation:
Design specifications for distillation columns:
Following design specifications are used for to achieve the purity of product and bi-product.
RF1: Component for Design Specifications: ketene(Dist) and acetone (Btm)
RF2: Component for Design Specifications: IPA (Dist) and diketene (Btm)
RF3: Component for Design Specifications: acetone (Dist) and IPA (Btm)
RF4: Component for Design Specifications: methane (Dist) and ethylene (Btm)
RF5: Component for Design Specifications: CO (Dist) and methane (Btm)
RF6: Component for Design Specifications: Ethylene (Dist) and ketene (Btm)
3. Heat Integration:
PFR-OUT stream is cooled from 755 oC to 75oC and heat duty of cooler is -4.157324 Gcal/hr.
On the other hand, Feed stream is heated from 29oC to 660oC and it required 4.477743 Gcal/hr. So heat removed from cool is fed to feed stream through new heat exchanger F-HT.
This Heat Integration saves approximately $160.00.New Flow Sheet:
FEEDACETONE1PFR-INPFR-OUTDIKETENEIPACOMETHANEETHYLENEKETENE
Temperature C25.00080.729660.000754.531153.148102.735-181.731-151.408-88.945-32.262
Pressure bar1.6202.2002.2002.2002.2002.2002.2002.2002.2002.200
Vapor Frac0.2181.0001.0001.0000.0000.0001.0000.0001.0000.000
Mole Flow kmol/hr152.04459.955211.999303.3020.95031.19232.07674.41231.90572.813
Mass Flow kg/hr8000.0003481.34911481.34911481.34979.8201873.899894.0111196.056894.6673061.620
Volume Flow cum/hr515.077801.8387476.34811779.8290.0882.702110.8222.934222.1084.001
Enthalpy MMkcal/hr-7.654-3.025-6.192-3.403-0.049-2.247-0.890-1.5700.364-1.191
Mass Flow kg/hr
CO400.0000.000400.000892.5030.0000.000888.0284.4620.0130.000
METHANE0.0000.0000.0001197.8820.0000.0005.9831190.7001.1980.000
ETHYLENE400.0000.000400.000893.2660.0000.0000.0000.893891.9260.446
KETENE0.0003.0623.0623062.2620.0000.0000.0000.0001.5303057.670
ACETONE6400.0003468.9579868.9573489.8050.00017.4310.0000.0000.0003.490
IPA800.0009.329809.3291865.9880.1871856.4590.0000.0000.0000.014
DIKETENE0.0000.0000.00079.64279.6340.0080.0000.0000.0000.000
SODIUM0.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
Mass Frac
CO0.0500.0000.0350.0780.0000.0000.9930.0040.0000.000
METHANE0.0000.0000.0000.1040.0000.0000.0070.9960.0010.000
ETHYLENE0.0500.0000.0350.0780.0000.0000.0000.0010.9970.000
KETENE0.0000.0010.0000.2670.0000.0000.0000.0000.0020.999
ACETONE0.8000.9960.8600.3040.0000.0090.0000.0000.0000.001
IPA0.1000.0030.0700.1630.0020.9910.0000.0000.0000.000
DIKETENE0.0000.0000.0000.0070.9980.0000.0000.0000.0000.000
SODIUM0.0000.0000.0000.0000.0000.0000.0000.0000.0000.000
Stream Result
RESULT:Final Profit: $10121.962
VariableValue readValue writtenUnits
FEED8000 KG/HR
WFCO0.99330723
FCO888.027869 KG/HR
WFMETH0.99552219
FMETH1190.70027 KG/HR
WFETH0.9969367
FETH891.926403 KG/HR
WFKET0.99870991
FKET3057.67038 KG/HR
WFIPA0.99069368
FIPA1856.45947 KG/HR
WFDIK0.99766037
FDIK79.6336826 KG/HR
CCOOL-2.43803 $/HR
CHEAT213.477265 $/HR
CELEC253.569473 $/HR
PROFIT010121.962$
UCOST0469.484768$
FCOST01840$
INCOME012431.4468$
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