Scribd
Upload
56 views17 pages

Plant Design Procedure: Dr. M. Rizwan Department of Chemical Engineering University of Bahrain

Uploaded by

Ali Zbayel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
56 views17 pages

Plant Design Procedure: Dr. M. Rizwan Department of Chemical Engineering University of Bahrain

Uploaded by

Ali Zbayel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

Plant Design Procedure

Dr. M. Rizwan
Department of Chemical Engineering
University of Bahrain
[email protected]
Plant Design Procedure
1. Name of product, annual rate of production (tons/y), product
specification (purity as wt %), product price (e.g., $/ton), etc.

2. Is it produced via chemical and/or physical change? Chemistry:


main and side reactions, reaction rates, etc.

3. The physical and chemical properties of the chemical species


present.
Plant Design Procedure
4. Process variables
• Reactor conversion of limiting reactant.
• Molar ratios of reactants.
• Reactor temperature, and /or reactor pressure.
• Concentration of light reactant in gas stream and purge
5. Process description.
6. Draw the process flow sheet (block flow diagram)
7. Reduce the flow sheet to input-output structure.
Plant Design Procedure
8. Calculate the material balance for the input-output structure of
the flow sheet.
9. Calculate the Economic Potential 1 (EP1).
EP1 = Revenue – Cost of Raw materials
• IF EP1 > 0 → Decision: Proceed in design
• IF EP1 < 0 → Decision: Reject the process or look for
alternatives (e.g., recycle the un-reacted reactants, find cheaper
raw material, etc.)
How to Calculate EP1

Raw
material Product
Reactor Separator
Byproduct

• Cost of raw material


• Value of products and by products
Economic potential =
(value of product + byproduct) – (cost of raw material)
Plant Design Procedure

10. Perform energy balance and calculate the utilities (e.g., cooling
water, fuel, steam, electricity, etc).
11. Calculate the Economic Potential 2 (EP2).
EP2 = EP1 – Cost of utilities

• IF EP2 > 0 → Decision: Proceed in design


• IF EP2 < 0 → Decision: Reject the process or look for alternatives
(e.g., heat integration, look for cheaper fuel, etc.)
Plant Design Procedure

12. Estimate the total investment (Cost analysis).

13. Calculate the profit (Profitability analysis).

14. Consider the Environment, Safety& Health (determine the fate


of all waste streams – in air, water or land), safety and health
(toxicology analysis, hazard, probability analysis, risk analysis and
management) and ethical considerations.
HDA Process

Process description: The HDA process converts toluene to benzene


in the presence of a large excess of hydrogen.
A simplified approach considers two reactions:

Main reaction: Dealkylation of toluene to benzene and methane


C7H8 + H2 → C6H6 + CH4 (1)
Secondary reaction: Formation of diphenyl as by-product
2C6H6 = C12H10 + H2 (2)
14 15

2 6
3 4 5

1 13
10 8
7

11 9
12

HDA Process for benzene production: Non-integrated plant


Process Description
• The reaction, globally exothermic, takes place in an adiabatic
Plug Flow Reactor at pressures of 25 to 35 bars and
temperatures between 620 and 720oC.
• Large excess of hydrogen, to prevents the formation of coke.
• The reaction conversion is typically 60-80%, because at higher
value the selectivity drops rapidly.
• The process is presented in the simplified Process Flow
Diagram (PFD).
• In this process, benzene is formed by the reaction of toluene
with hydrogen.
Process Description
• The hydrogen feed stream has a purity of 97% (the rest is methane)
and mixed with a fresh inlet stream of toluene, a recycled stream
toluene and a recycled hydrogen stream.
• The feed mixture is heated in a furnace being fed to an adiabatic
reactor.
• The reactor effluent contains unreacted hydrogen, and toluene,
benzene (the desired product), diphenyl and methane. It is quenched
and subsequently cooled in a flash separator to condense the
aromatics from non-condensable hydrogen and methane.
• The vapor stream from the flash unit contains excess hydrogen and
methane that is recycled, a purge preventing the accumulation of
methane.
Process Description

• The liquid stream contains traces of hydrogen and methane that are
separated from the aromatics in a secondary flash unit.

• The liquid stream from the secondary flash unit consists of


benzene, diphenyl and toluene. It is separated in two distillation
columns.

• The first column, separates the product benzene, from diphenyl and
toluene, while the second column separates the diphenyl from
toluene. The toluene is recycled back into the reactor.
Fresh Fresh Toluene Reactor Reactor Separator
toluene hydrogen hydrogen inlet outlet gas out
mixing
feed
Stream Number 1 2 3 4 5 6

Temperature (oF) 86 86 86 1150 1263.2 113

Pressure (psi) 575 575 575 503 486 486

Mole Flow (Ibmol/h) 290.86 490.38 781.24 4382.5 4382.5 4156

Component mole
fraction
Hydrogen 0.0 0.97 0.6088 0.4291 0.3644 0.3992

Methane 0.0 0.03 0.0189 0.48 0.5463 0.5937

Benzene 0.0 0 0 0.0053 0.0685 0.0065

Toluene 1 0 0.3723 0.0856 0.0193 0.0006

Diphenyl 0.0 0 0 0 0.0015 0

R. Turton and J. A. Shaeiwitz - Copyright 2008


Stabilizer Stabilizer Stabilizer Benzene Product Diphenyl
feed gas bottoms Product bottoms product

Stream Number 7 8 9 10 11 12

Temperature (oF) 113 113 200* 211 283 559

Pressure (psi) 480 480 480 30 33 31

Mole Flow (Ibmol/h) 382.5 21.05 361.4 272.5 88.91 6.759

Component mole
fraction
Hydrogen 0.0 0.0 0.0 0.0 0.0 0.0

Methane 0.0516 0.9349 0.0 0.0 0.0 0.0

Benzene 0.7159 0.0651 0.7538 0.9997 0.0006 0.0

Toluene 0.2149 0.0 0.2275 0.0003 0.9234 0.00026

Diphenyl 0.0177 0.0 0.0187 0 0.0760 0.99974

R. Turton and J. A. Shaeiwitz - Copyright 2008


Toluene Separator Purge gas
recycle gas out
Stream Number 13 14 15

Temperature (oF) 272 113 115

Pressure (psi) 30 486 480

Mole Flow (Ibmol/h) 82.14 4156.0 480.88

Component mole fraction


Hydrogen 0.0 0.3992 0.3992

Methane 0.0 0.5937 0.5937

Benzene 0.00061 0.0065 0.0065

Toluene 0.99937 0.0006 0.0006

Diphenyl 0.00002 0.0 0.0

R. Turton and J. A. Shaeiwitz - Copyright 2008


Input/Output Structure

H2, CH4 Purge

H2
Separation C6H6
Toluene Reactor
system
C12H10

Toluene recycle

Calculate economic potential (1) EP1:


EP1 = Revenue – Cost of Raw materials
Is it economically feasible? If not, give suggestion.
P&ID

Thank you

R. Turton and J. A. Shaeiwitz - Copyright 2008

You might also like