Solvent recovery
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Solvent recovery

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Solvent recovery Solvent recovery Presentation Transcript

  • SOLVENT RECOVERY -
  • CONTENT  Objective  Limitations  Methodology  Data Tabulation  Observations  Conclusions  Recommendations  Bibliography
  • OBJECTIVE :  TO IMPROVE THE SOLVENT RECOVERY  IMPROVE THE EFFICIENCY OF DISTILLER AND CONDENSOR  REDUCE THE RECOVERY TIME.
  • LIMITATIONS  Use of batch distillation - economical for small volume productions - flexible in accommodating changes - permits better product integrity  R & D controlled input parameters, can’t be altered
  • METHODOLOGY  Rayleigh equation for estimation of vapor amount and its composition  Mass and energy balance between reactor and jacket for time estimation  HTRI Xchanger suite 6.0 used to understand the heat exchanger  Property package named VGM Thermo used to model the equilibrium between liquid and vapor  Ideal liquid/Ideal package for water’s properties  NRTL and Uniquac thermodynamic models for heterogeneous azeotropic conditions  End to end calculations & tabulations made in MS EXCEL
  • PRESENT AVAILABLE DESIGN LOT - I LOT - II PROCESS CONDITIONS HE - 2101A HE - 2101B HE - 2101A HE - 2101B Flow rate , shell (kg/hr) 300 1372.3 420 1372.2 Flow rate , tube (kg/hr) 15640 55 15640 120 Inlet T, Shell (C) 65 -8 68 -8 Outlet T, Shell (C) 30 -1 30 4 Inlet Pressure Inlet T, Tube (C) 20 65 20 65 Outlet T, Tube (C) 23.1 30 23.5 30
  • PRESENT AVAILABLE DESIGN CONDENSER DESIGN Overdesign (%) 20 6 1 98.11 Overall U (W/m2-K) 171 103 174.79 350 Required U (W/m2-K) 142 97 174.5 176 Duty (Watts) 56800 9800 63863 18500 Shellside h (W/m2-K) 1425 505 1355 540 Tubeside h (W/m2-K) 1767 365 2274 2031 Shellside delta P (kPa) 0.331 9.5 0.7 9.5 Tubeside delta P (kPa) 4.2 0.03 5.2 0.157 EMTD (C) 30.9 65 30.8 66.2 Fouling 0.002 0.002 0.002 0.002 CONDENSATE COLLECTED (lit) 1660 330 1680 340 Time (Hr) 6 6 5 5
  • NEW DESIGN REMOVING FOULING CHILLED WATER MAX FLOW , COOLANT MAX TEMP PROCESS CONDITIONS HE - 2101A HE - 2101A HE - 2101A HE - 2101A HE - 2101A Flow rate , shell (kg/hr) 300 420 420 874.8 874.8 874.8 Flow rate , tube (kg/hr) 15640 15640 15640 15640 15640 15640 Inlet T, Shell (C) 65 65 68 68 68 68 Outlet T, Shell (C) 30 30 30 30 30 30 Inlet Pressure Inlet T, Tube (C) 20 20 8 20 20 20 Outlet T, Tube (C) 23 24.8 12.5 30 30 30
  • NEW DESIGN CONDENSER DESIGN Overdesign (%) 292 115 1 13 15 31 Overall U (W/m2-K) 581 593 180 151 728 317 Required U (W/m2-K) 149 274 178 134 635 242 Duty (Watts) 56800 65600 64000 160800 160800 161300 Shellside h (W/m2-K) 1613 1464 1881 1310 1646 1697 Tubeside h (W/m2-K) 1916 2045 1804 870 4135 3790 Shellside delta P (kPa) 0.317 0.54 0.7 0.7 1 3.1 Tubeside delta P (kPa) 4.6 4.7 5 4 12 22 EMTD (C) 30.3 25.3 41.6 24.8 24.4 29 Fouling 0.0002 0.0002 0.002 0.002 0.0002 0.001 CONDENSATE COLLECTED (lit) 1990 2020 2000 2000 2000 2000 Time (Hr) 6 5 5 3 3 3
  • DESIGN COMPARISON Fouling removed under LOT-II conditions Initial fouling – 0.002 New fouling factor – 0.0002 New recovery – 90%
  • DESIGN COMPARISON Using secondary condenser Primary condenser flow rate- 300kg/hr fouling – 0.002 Secondary condenser Flow rate – 50 kg/hr coolant – Brine new recovery – 90%
  • DESIGN COMPARISON Using chilled water
  • DESIGN COMPARISON Using series double shell configuration
  • OBSERVATIONS  total intake of 700 MT of fresh solvent amounting nearly 400 lakhs per annum  acetone intake of 84 MT costing about 63 lakhs with 70% present recovery  the fouling of present condenser which is about 10 times the designed one  recovery up to 90% if secondary condenser is functioning  recovery up to 90% in the primary condenser itself if chill water at 8˚ C is used instead of cooling water at around 17˚ C.
  • CONCLUSIONS  ineffectiveness of the utility  malfunctioning of primary condenser due to excessive fouling  no operation of the secondary condenser  limitations of use of batch distillation and unaltered input levels  Recovery can be enhanced to 90% after making appropriate changes
  • RECOMMENDATIONS  Removal of fouling through the standard reference given by National Association of Corrosion Engineers (NACE) which includes six steps, namely: water jetting, de-oiling, acid washing, neutralization, passivation and drying  If more than 30% carbon by weight is present in a sample of the oil deposit, chemical treatment will not be successful  The Brine Utility line has to be immediately checked & made operational, for the secondary condenser to be functional
  • RECOMMENDATIONS CONT’D  Installing properly designed distillation column  Installing Sub coolers in addition to present secondary condenser  Chilled water instead of cooling water should be circulated  Use of modern condensers such as plate type heat exchangers, corrugated tube heat exchangers, graphite heat exchangers that save money, save space, reduce maintenance & ensure flexibility
  • BIBLIOGRAPGHY  Coulson & Richardson's Chemical Engineering. Vol. 6, Chemical Engineering Design, 4th Ed  Handbook Chemical Engineers Perrys, 7Th Ed – 1999  Process Heat Transfer, by D. Q. Kern  Unit Operations of Chemical Engineering, 5th Ed, McCabe and Smith  www.wikipedia.co.in www.chemicalprocessing.com www.chemresources.com www.eng_tips.com