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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