Design For Accessibility: Getting it right from the start
Design and balance : Styrene Oxide Production
1. A Project Report on
Design A Plant To Manufacture
50000 TPA Of
Styrene Oxide
By
UJJWAL BAJPAI (1071110009)
ARITRA MUKHERJEE (1071110029)
Under the guidance of
Dr. K. Tamilarasan
Professor, Chemical Engineering
7. ΔHrxn1 48.62 KJ/mole
Heat released by reaction 1 1.37E+06 KJ/hr
ΔHrxn2 -35.19 KJ/mole
Heat released by reaction 2 -8.81E+05 KJ/hr
Heat released by reaction =
Moles Of Products formed*ΔHrxn
Q(heat transfer rate)=Enthalpy of outlet Stream - Enthalpy of inlet Stream
+ Heat released by reaction 1 + Heat released by reaction 2
= 1.606E+06 -1.46E+06 +1.37E+06 -8.81E+05
= 3.47E+5 KJ/hr (heat lost)
Thus We need to use a steam Jacket
Steam at 1 atm enters the jacket and leaves out of the jacket as water(liquid) at 100°C
Latent Heat of Vaporization of steam(λs)= 2676 KJ/Kg
Mass flowrate of Steam =(Q/ λs)= 96.21 Kg/hr
8. Energy Balance for Distillation Column
Mole fraction of low boiler in feed =0.1542
Mole fraction of low boiler in Top Product =0.97
Mole fraction of low boiler in Bottom Product =0.01
Pressure 60 mm of Hg
Temperature 90.5°C
60.8°C Styrene
101.8°C Styrene
Oxide
Using Clayeperon equation
find x,y
Temperature °C P1sat mm of Hg P2sat mm of Hg x1 y1
60.80 60.00 12.37 1.00 1.00
63.73 66.95 14.02 0.87 0.97
66.66 74.56 15.86 0.75 0.93
69.58 82.89 17.91 0.65 0.89
72.51 91.99 20.18 0.55 0.85
75.44 101.90 22.69 0.47 0.80
78.37 112.69 25.46 0.40 0.74
81.30 124.41 28.51 0.33 0.68
84.23 137.13 31.88 0.27 0.61
87.16 150.91 35.57 0.21 0.53
90.08 165.82 39.63 0.16 0.45
93.01 181.93 44.07 0.12 0.35
95.94 199.31 48.92 0.07 0.24
98.87 218.03 54.22 0.04 0.13
101.80 238.19 60.00 0.00 0.00
9. Condenser Duty
Vapor Formed=(R+1)*D=34.40 Kmoles/hr
Since q=1 feed is saturated
λ Styrene 35008.00 KJ/Kmole
λ Styrene Oxide 40101.00 KJ/Kmole
mole fraction of top product 0.97
λ Effective 35160.79 KJ/Kmole
Where λ is latent
heat of
vaporization
Energy Required= V * λ Effective
= 1.210E+06 KJ/hr
Specific heat capacity of water=4.18KJ/KgK
Inlet and outlet temperature of condenser cooling water=25°C and 50°C
Q=mCpΔT
Mass flowrate of water= 5252.63 Kg/hr
10. Reboiler Duty
Vapor Formed in reboiler(V’)=Vapor from the top of the column= D=34.40 Kmoles/hr
Since q=1 feed is saturated
λ Styrene 35008.00 KJ/Kmole
λ Styrene Oxide 40101.00 KJ/Kmole
mole fraction of top product 0.01
λ Effective 40050.07 KJ/Kmole
Where λ is latent
heat of
vaporization
Energy Required= V’ * λ Effective
= 1.378E+06 KJ/hr
Latent heat of Steam= λs=2676 KJ/hr
Mass flowrate of steam required = (V’ * λ Effective)/ λs=514.874 Kg/hr
11. Reactor Design
Let 1-Styrene Chlorohydrin
2-Styrene Dichloride
Order 2 Order 2
Since pH has to be maintained 12 thus OH- will
be in excess and both of the reactions will
behave as pseudo order 1 reaction
Where F1°= moles of feed Kmole/hr
V=Volume of reactor m3
13. Reactor Design
Area Under the curve = 0.264 m3/kmol
Residence time: 2.5 hours (From Literature)
Area Under the curve =
k (Rate Constant) = (Area Under the curve * C1°)/ Residence time
= 0.638 hr-1
Volume of liquid system = (Residence time * F1°)/C1°
= 12.328 m3
Actual Volume of liquid system will be calculated by giving 10% allowance=1.3893 m3
Weight of Catalyst =
=1929.405 kg /h
14. Actual Volume of Catalyst=1.1(Mass of Catalyst/ Density Of Catalyst)=1.3893 m3
Total Volume of reactor = Volume of Catalyst+Volume of liquid system= 14.950 m3
HEIGHT AND DIAMETER OF THE REACTOR:
Let us assume an ellipsoidal head at the top and at the bottom of the vessel
Taking H/D = 2,
Diameter of the reactor D: 2.013 m
Height of the reactor H =2* D
=4.026 m
Reactor Design
15. Distillation Column Design
Mole fraction of low boiler in feed =0.1542
Mole fraction of low boiler in Top Product =0.97
Mole fraction of low boiler in Bottom Product =0.01
Pressure 60 mm of Hg
Temperature 90.5°C
60.8°C Styrene
101.8°C Styrene
Oxide
Using Clayeperon equation
find x,y
Temperature °C P1sat mm of Hg P2sat mm of Hg x1 y1
60.80 60.00 12.37 1.00 1.00
63.73 66.95 14.02 0.87 0.97
66.66 74.56 15.86 0.75 0.93
69.58 82.89 17.91 0.65 0.89
72.51 91.99 20.18 0.55 0.85
75.44 101.90 22.69 0.47 0.80
78.37 112.69 25.46 0.40 0.74
81.30 124.41 28.51 0.33 0.68
84.23 137.13 31.88 0.27 0.61
87.16 150.91 35.57 0.21 0.53
90.08 165.82 39.63 0.16 0.45
93.01 181.93 44.07 0.12 0.35
95.94 199.31 48.92 0.07 0.24
98.87 218.03 54.22 0.04 0.13
101.80 238.19 60.00 0.00 0.00
17. Distillation Column Design
Plate Spacing (lt): 0.6 m (assumed)
ρl = Density of styrene in liquid phase = 859.41 kg/ m3 at 70oC and 60mm of Hg
ρv = Density of styrene in gaseous phase =0.2916 Kg/ m3 70oC and 60mm of Hg
Vapor Velocity
Molar flowrate of Vapors Formed=34.402 kmole/hr
Mass of Vapors formed Vm=
kmole/hr vapor formed*Molecular wt of styrene * /3600
=0.9938 Kg/s
18. Column Diameter=
Diameter of column=1.2231 m
From Graph,
Nm+ 1 = 12
Where Nm = Number of theoretical plates
Nm = 11
Tray Efficiency = 0.6
Actual Number of trays = 11 / 0.6 =19
COLUMN HEIGHT = (Actual number of trays – 1 )*Tray Spacing + Top and bottom allowance
= (19 – 1)* 0.6 + 2 * 0.6
= 12 m
COLUMN HEIGHT: 12 m
COLUMN DIAMETER: 1.223 m
19. Reference
I.L. Finar Organic Chemistry Volume 1 Sixth Edition Pearson page
380,616,89,569
David M.Himmelblau, Basic principles and calculations in chemical
engineering, edition 6, Prentice Hall of India, New Delhi, 1998.
George T. Austin Shreve’s Chemical Process Industries Fifth Edition page
661-687.
Citation No:US2582114 ,Filing Date: JULY 07,1949,Publishing,Date: JAN
08,1952,Title: U.S. Rubber Co.,(Styrene Oxide Synthesis).
M. Gopala Rao Marshall Sittig Dryden’s Outline of Chemical Technology
Third Edition East West Press page 518-525