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P2 workshop

Problem objectiveProcess costsProduct costs

+Class questionsFundamental Girls of CME

1 - Which column are we modeling in Chemcad? The large, industrial one, or the lab one? 

2 - Our final objective is to propose an experiment modeling this large industrial column, right?

3 - Which column are we doing the cost analysis for?

4 - Which column are we doing the innovation analysis for?

+Which column are we modeling in Chemcad? The large, industrial one, or the lab one? 

Q. Our understanding is that we are designing a large, industrial scale column. 

A. You are primarily modeling the big one, which has flows that should be within the typical range of the correlations for flooding, tray pressure drop, efficiencies, etc. When you have a solution that you like and think would be ‘stable’ in the lab, then transfer the conditions you have selected to a 30 ml/min flow, 8 tray column with a 5 cm diameter, sieve trays,..

+Our final objective is to propose an experiment modeling this large industrial column, right?

A. You have stated the primary objective well. We want to predict conditions for the lab experiment that the next student groups can check.

+Which column are we doing the cost analysis for?

Q. We will do the cost analysis on the large column to make sure it is a realistic and profitable column in real life. 

A. Cost analysis on the large column. This will inform the team with respect to what a commercial separation of the feed would cost. When you have a crude optimization of the large column case, you will understand better what some of the cost and operating constraints. This should help provide a more realistic scenario for students to replicate in lab.

+Which column are we doing the innovation analysis for?

Q. From this column we are designing a small scale experiment that students would do (for example, telling them what they are given, what their desired product is, details of the physical column, and suggestions on reflux ratios. From that point, they would determine the most efficient reflux ratios and costs of running their column as part of their experiment). We would then apply the innovation analysis to our experiment design?

A. The objective of designing the experiment before running it is to help students run the actual equipment. For example, with specified column operating conditions – feed condition, flows in and out, expected stage efficiencies – you will know the complete temperature profile at steady-state and how sensitive this might be to operating conditions changes (I.e., via a sensitivity analysis). Without a simulation, operators would have no idea what temperatures or flows to ‘hit’. If you were going to operate a piece of industrial equipment in a plant setting, the process engineer/plant manager should not let you touch a button until you can demonstrate that you know what will happen. Usually, this would extend to what to do in case of column flooding, a bad control valve, etc.

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Process costs

Approach Establish example material

balances for the stripping column, setting 4 of 6 variables

Run 3 to 4 trials changing one variable

Or

Sensitivity analysis for the same

Stripping column to generate a relatively pure 2PrOH bottoms stream

+Example trial:F = 100; xF = 0.5; xD = 0.95, 80% < %2-PrOH recovery < 90%

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Product costs

http://libguides.uky.edu/CME

Chemical pricing = http://libguides.uky.edu/c.php?g=222948&p=1476423

http://www.sigmaaldrich.com/united-states.html

Libguides.uky.edu/CME

+http://libguides.uky.edu/CME

+

+Click 1 = Select a yearClick 2 = search within this pub

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+What is the product cost for a year of operation?