PROJECT REPORT
PROCESS SIMULATION
Spring-2011
Department of Chemical Engineering
Submitted To
Dr. John L Gossage
Submitted By
Mangesh Pate
LU ID: L20258949
1|Page
Objective:
To modify the ketene manufacturing plant to increase the operating profit.
Initial Flow Sheet:
2|Page
Stream Result:
PFROUT
FEED
RECY.
PFR-IN
25
1.62
0.218
70.4967
1.62
0.53186
757.3428
1.62
1
109.187
1.62
0
152
65.1013
300.5183
1.20207
Mass Flow kg/hr
8000
3778.59
11778.53
86.7567
Volume Flow cum/hr
Enthalpy MMkcal/hr
Mass Flow kg/hr
CO
METHANE
515.1
-7.65
613.096
-3.5114
761.85
1.62
1
217.144
8
11778.5
9
11534.5
9
-5.57176
15893.76
-3.71164
0.10406
-0.0749
IPA
120.841
3
5
0
38.9111
1
2320.32
3
3.48388
6
-2.62557
400
0
7.36E-07
2.17E-05
882.61
1070.852
5.38E-34
1.57E-30
400
0.00493
883.3621
12.0249
ACETONE
6400
3703.86
IPA
DIKETENE
SODIUM
800
0
0
62.7066
0
0
400
2.17E-05
400.004
9
12.0248
8
10103.8
6
862.706
6
0
0
Temperature C
Pressure bar
Vapor Frac
Mole Flow kmol/hr
ETHYLENE
KETENE
DIKET
CO
METH
ETHYL
-123.159
60
1
-73.15
60
0
22.77
60
1
97.6242
60
0
32.3093
65.598
32.141
65.2559
895.379
1056.2
907.752
2733.52
6.71536
-0.87948
6.3607
-1.212
13.1798
0.35802
7.49779
-0.666
3.35E-31
2.43E-27
882.487
12.8921
0.1021
1047.3
0.0209
10.7085
2.34E-11
5.14E-06
1.28E-24
8.93E-21
1.90E-07
8.8336
854.652
19.8712
2767.173
8.15E-18
1.91E-16
0.0166
42.3701
2712.76
4225.543
5.54E-07
1.23E-11
0.88797
1898.089
50.89984
0
35.8568
50.8998
0
4.40E-13
520.797
9
1799.52
5
8.97E-08
0
0
0
0
0
0
0
1.82E-18
0
0
0.0003
0
0
3|Page
KETEN
Cost of Feed and other Components on the Flow sheet:
No.
1
2
3
4
5
6
7
8
Component
FEED
Carbon Monoxide
Methane
Ethylene
Ketene
Acetone
Isopropyl Alcohol
Diketene
Cost ($/kg)
0.23
0.25
0.5
1
2.7
1.1
1.32
0.2
Reaction and Kinetics:
Three first-order, irreversible, vapor-phase reactions occur simultaneously in the PFR.
Rxn
Phase
Stoichiometry
k(S-1)
1
2
3
Vapor
Vapor
Vapor
Acetone ----> Methane + Ketene
Acetone ----> 0.5 IPA + 0.5 Ethylene + 0.5 CO
Acetone ----> 0.5 Diketene
1.125
0.5
0.1
E(MJ/kmol
)
285
350
100
T0(K)
1000
1000
1000
Utilities:
Following three types of utilities are available:
No.
1
2
3
Utilities
COOL Cooling Water
ELEC Electricity
Heat gas
Energy/Purchase
Price
$0.1 /GJ
$0.1 /KWhr
$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.
4|Page
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.
Variable
FEED
WFCO
FCO
WFMET
H
FMETH
WFETH
FETH
WFKET
FKET
WFIPA
FIPA
WFDIK
FDIK
CCOOL
Value
read
8000
0.985601
5
882.4869
8
0.991524
1
1047.251
4
0.941504
4
854.6523
6
0.992405
6
2712.761
6
0.775549
4
1799.524
9
0.586696
5
50.89983
9
4.317738
Value
written
Units
KG/HR
KG/HR
KG/HR
KG/HR
KG/HR
KG/HR
KG/HR
$/HR
5|Page
CHEAT
CELEC
1803.760
1
4281.134
6
$/HR
$/HR
PROFIT
UCOST
FCOST
INCOM
E
0
0
29.180511
6
6089.2123
9
1840
7958.3929
$
$
$
$
Process Modification:
Following sequence is used for the optimization of the process parameter:
1. Reactor
2. Separation and Recycle system
3. Heat Integration
1.
Reactor Optimization:
For initial condition of the reactor the following results are obtained:
Mass
Flow(kg/hr)
CO
METHANE
ETHYLENE
KETENE
IPA
DIKETENE
PFR-IN
400
2.17E-05
400.005
12.0249
862.707
0
PFR-OUT
882.61
1070.852
883.3621
2767.173
1898.089
50.89984
COST
0.25
0.5
1
2.7
1.32
0.2
TOTAL
WORTH
220.653
535.426
883.362
7471.37
2505.48
10.18
11626.5
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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.
Vary
1 Length of tube (m)
2 Temperature of Feed Streem(oC)
3 Pressure of Feed Streem(bar)
Range
1.0 to 3.5
400 to 750
1 to 3.0
Increment
0.001
10
0.1
7|Page
New Conditions:
No.
New Parameter
1 Length of tube (m)
2 Temperature of Feed Streem(oC)
3 Pressure of Feed Streem(bar)
Mass Flow kg/hr
CO
METHANE
ETHYLENE
KETENE
IPA
DIKETENE
PFR-IN
400
2.61E-07
400.0003
3.0622716
4
809.32905
3
5.51E-35
2.398
660
2.2
PFR-OUT
892.503462
1197.88157
893.266156
COST
0.25
0.5
1
WORTH
223.126
598.941
893.266
3062.26223
2.7
8268.11
1865.98832
79.6416775
1.32
0.2
2463.1
15.9283
8|Page
TOTAL
12462.5
Selectivity of ketene = 0.663241572
2. Separation of PFR-OUT Stream:
Strategy used for separation:
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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)
10 | P a g e
RF2: Component for Design Specifications: IPA (Dist) and diketene (Btm)
RF3: Component for Design Specifications: acetone (Dist) and IPA (Btm)
11 | P a g e
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)
12 | P a g e
3. Heat Integration:
13 | P a g e
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.
14 | P a g e
New Flow Sheet:
15 | P a g e
Stream Result
Temperature C
Pressure bar
Vapor Frac
Mole Flow kmol/hr
Mass Flow kg/hr
Volume Flow cum/hr
Enthalpy MMkcal/hr
Mass Flow kg/hr
CO
METHANE
ETHYLENE
KETENE
ACETONE
IPA
DIKETENE
SODIUM
Mass Frac
CO
METHANE
ETHYLENE
KETENE
ACETONE
IPA
DIKETENE
SODIUM
FEED
25.000
1.620
0.218
152.044
8000.00
0
ACETONE1
80.729
2.200
1.000
59.955
3481.349
PFR-IN
660.000
2.200
1.000
211.999
11481.34
9
DIKETENE
153.148
2.200
0.000
0.950
7476.348
-6.192
PFR-OUT
754.531
2.200
1.000
303.302
11481.34
9
11779.82
9
-3.403
CO
-181.731
2.200
1.000
32.076
METHANE
-151.408
2.200
0.000
74.412
ETHYLENE
-88.945
2.200
1.000
31.905
KETENE
-32.262
2.200
0.000
72.813
79.820
IPA
102.735
2.200
0.000
31.192
1873.89
9
894.011
1196.056
894.667
3061.620
515.077
-7.654
801.838
-3.025
0.088
-0.049
2.702
-2.247
110.822
-0.890
2.934
-1.570
222.108
0.364
4.001
-1.191
400.000
0.000
400.000
0.000
6400.00
0
0.000
0.000
0.000
3.062
400.000
0.000
400.000
3.062
892.503
1197.882
893.266
3062.262
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
888.028
5.983
0.000
0.000
4.462
1190.700
0.893
0.000
0.013
1.198
891.926
1.530
0.000
0.000
0.446
3057.670
3468.957
9868.957
3489.805
0.000
0.000
0.000
0.000
3.490
9.329
0.000
0.000
809.329
0.000
0.000
1865.988
79.642
0.000
0.187
79.634
0.000
17.431
1856.45
9
0.008
0.000
800.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.014
0.000
0.000
0.050
0.000
0.050
0.000
0.800
0.100
0.000
0.000
0.000
0.000
0.000
0.001
0.996
0.003
0.000
0.000
0.035
0.000
0.035
0.000
0.860
0.070
0.000
0.000
0.078
0.104
0.078
0.267
0.304
0.163
0.007
0.000
0.000
0.000
0.000
0.000
0.000
0.002
0.998
0.000
0.000
0.000
0.000
0.000
0.009
0.991
0.000
0.000
0.993
0.007
0.000
0.000
0.000
0.000
0.000
0.000
0.004
0.996
0.001
0.000
0.000
0.000
0.000
0.000
0.000
0.001
0.997
0.002
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.999
0.001
0.000
0.000
0.000
16 | P a g e
RESULT:
Final Profit: $10121.962
Variable
FEED
WFCO
FCO
WFMETH
FMETH
WFETH
FETH
WFKET
FKET
WFIPA
FIPA
WFDIK
FDIK
CCOOL
CHEAT
CELEC
PROFIT
UCOST
FCOST
INCOME
Value read
8000
0.99330723
888.027869
0.99552219
1190.70027
0.9969367
891.926403
0.99870991
3057.67038
0.99069368
1856.45947
0.99766037
79.6336826
-2.43803
213.477265
253.569473
0
0
0
0
Value written
Units
KG/HR
KG/HR
KG/HR
KG/HR
KG/HR
KG/HR
10121.962
469.484768
1840
12431.4468
KG/HR
$/HR
$/HR
$/HR
$
$
$
$
17 | P a g e