This document provides details for a design project involving the production of acetone. Students are tasked with designing a process to produce 15,000 metric tons per year of acetone via the reaction of isopropanol. The document outlines the process details including feed streams, equipment, costs, and economic analysis. It also specifies the deliverables which include a written report with process flow diagram and stream table, as well as an oral presentation.
This document outlines the procedures and results from an experiment on gas absorption using an absorption column. The experiment examined the air pressure drop across the column as air flow rate was increased for different fixed water flow rates. Pressure drop was recorded and plotted against air flow rate. The experimental flooding points where compared to theoretical calculations, with errors ranging from 11.1% to 20%. The results showed that pressure drop increased with air flow rate as expected, identifying the flooding points where liquid could no longer flow down the column.
The document provides design details for an acetic acid process plant with a capacity of 400,000 tonnes per year. It evaluates various process technologies for producing acetic acid and selects the methanol carbonylation process. The design includes piping and instrumentation diagrams and specifications for the main unit operations - reactor, flash tank, drying distillation column, heavy ends distillation column, absorption column, and storage tank. It also covers process control and instrumentation, safety, environmental, and economic aspects of the plant design.
The document presents an undergraduate design report for a plant to produce 10,000 tons per day of cumene from the reaction of propylene and benzene using an acid catalyst. It describes the chosen reactive distillation process route and provides justification. It includes the process description with flow diagram and block diagram. Results and discussion sections provide material and energy balances, equipment design details, and economic analysis showing a net profit and payback period of 2 years. Recommendations include considering a yearly design basis and using more realistic cost data.
Visbreaking and delayed coking are processes used in oil refineries. Visbreaking uses heat to crack large hydrocarbon molecules and reduce viscosity, producing gas, naphtha, and distillates. It occurs in either coil or soaker units. Delayed coking thermally cracks residual oil in parallel furnaces and drums, producing coker gas oil and petroleum coke while maximizing distillates and minimizing coke yield. Problems include fouling, coke formation, and asphaltene precipitation, which can be addressed using high pressure heat exchangers.
This document is a lecture on cost estimation that covers several topics:
1) It discusses capital costs including fixed capital and working capital.
2) It explains the breakdown of total product costs including manufacturing costs, general expenses, and their typical percentages.
3) It provides examples of cost estimation problems from referenced textbooks, showing calculations for direct costs, indirect costs, depreciation, taxes, net profit, and cash flow.
This document discusses options for distilling dilute ethanol to produce 99.5% ethanol. It analyzes pressure swing distillation versus azeotropic distillation, with benzene as a common entrainer. Preliminary simulations show pressure swing distillation yields the desired product composition with less ethanol loss. A three-column system is also considered but deemed too costly. The document outlines objectives of determining the optimal distillation method, finalizing a process flow diagram, performing safety and economic analyses, and achieving a 5% annual ROI.
Episode 43 : DESIGN of Rotary Vacuum Drum Filter
Theory of Separation
Rotary vacuum drum filter (RVDF) is one of the oldest filters used in the industrial liquid-solids separation .A rotary vacuum filter consists of a large rotating drum covered by a cloth. The drum is partially immersed in liquid/solids slurry with approximately up to (25-75) % of the screen area.
As the drum rotates into and out of the trough, the slurry is sucked on the surface of the cloth and rotated out of the liquid/solids suspension as a cake. When the cake is rotating out, it is dewatered in the drying zone. The cake is dry because the vacuum drum is continuously sucking the cake and taking the water out of it. At the final step of the separation, the cake is discharged as solids products and the drum rotates continuously to another separation cycle.
SAJJAD KHUDHUR ABBAS
Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Design of Methanol Water Distillation Column Rita EL Khoury
Methanol is an essential feed stock for the manufacture of many industrial products such as adhesives and paints and it is widely used as a solvent in many chemical reactions. Crude methanol is obtained from steam reforming of natural gas and then a purification process is needed since it contains smaller and larger degree of impurities.
The purification process consists of two steps: a topping column used to remove the low boiling impurity called the light ends; and the remaining water methanol mixture is transferred to another column called the refining column where it is constantly boiled until separation occurs. Methanol rises to the top while the water accumulates in the bottom.
This document focuses on methanol water separation. A detailed design study for the distillation column is conducted where the separation occurs at atmospheric pressure with a total condenser and a partial reboiler.
This document outlines the procedures and results from an experiment on gas absorption using an absorption column. The experiment examined the air pressure drop across the column as air flow rate was increased for different fixed water flow rates. Pressure drop was recorded and plotted against air flow rate. The experimental flooding points where compared to theoretical calculations, with errors ranging from 11.1% to 20%. The results showed that pressure drop increased with air flow rate as expected, identifying the flooding points where liquid could no longer flow down the column.
The document provides design details for an acetic acid process plant with a capacity of 400,000 tonnes per year. It evaluates various process technologies for producing acetic acid and selects the methanol carbonylation process. The design includes piping and instrumentation diagrams and specifications for the main unit operations - reactor, flash tank, drying distillation column, heavy ends distillation column, absorption column, and storage tank. It also covers process control and instrumentation, safety, environmental, and economic aspects of the plant design.
The document presents an undergraduate design report for a plant to produce 10,000 tons per day of cumene from the reaction of propylene and benzene using an acid catalyst. It describes the chosen reactive distillation process route and provides justification. It includes the process description with flow diagram and block diagram. Results and discussion sections provide material and energy balances, equipment design details, and economic analysis showing a net profit and payback period of 2 years. Recommendations include considering a yearly design basis and using more realistic cost data.
Visbreaking and delayed coking are processes used in oil refineries. Visbreaking uses heat to crack large hydrocarbon molecules and reduce viscosity, producing gas, naphtha, and distillates. It occurs in either coil or soaker units. Delayed coking thermally cracks residual oil in parallel furnaces and drums, producing coker gas oil and petroleum coke while maximizing distillates and minimizing coke yield. Problems include fouling, coke formation, and asphaltene precipitation, which can be addressed using high pressure heat exchangers.
This document is a lecture on cost estimation that covers several topics:
1) It discusses capital costs including fixed capital and working capital.
2) It explains the breakdown of total product costs including manufacturing costs, general expenses, and their typical percentages.
3) It provides examples of cost estimation problems from referenced textbooks, showing calculations for direct costs, indirect costs, depreciation, taxes, net profit, and cash flow.
This document discusses options for distilling dilute ethanol to produce 99.5% ethanol. It analyzes pressure swing distillation versus azeotropic distillation, with benzene as a common entrainer. Preliminary simulations show pressure swing distillation yields the desired product composition with less ethanol loss. A three-column system is also considered but deemed too costly. The document outlines objectives of determining the optimal distillation method, finalizing a process flow diagram, performing safety and economic analyses, and achieving a 5% annual ROI.
Episode 43 : DESIGN of Rotary Vacuum Drum Filter
Theory of Separation
Rotary vacuum drum filter (RVDF) is one of the oldest filters used in the industrial liquid-solids separation .A rotary vacuum filter consists of a large rotating drum covered by a cloth. The drum is partially immersed in liquid/solids slurry with approximately up to (25-75) % of the screen area.
As the drum rotates into and out of the trough, the slurry is sucked on the surface of the cloth and rotated out of the liquid/solids suspension as a cake. When the cake is rotating out, it is dewatered in the drying zone. The cake is dry because the vacuum drum is continuously sucking the cake and taking the water out of it. At the final step of the separation, the cake is discharged as solids products and the drum rotates continuously to another separation cycle.
SAJJAD KHUDHUR ABBAS
Ceo , Founder & Head of SHacademy
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Design of Methanol Water Distillation Column Rita EL Khoury
Methanol is an essential feed stock for the manufacture of many industrial products such as adhesives and paints and it is widely used as a solvent in many chemical reactions. Crude methanol is obtained from steam reforming of natural gas and then a purification process is needed since it contains smaller and larger degree of impurities.
The purification process consists of two steps: a topping column used to remove the low boiling impurity called the light ends; and the remaining water methanol mixture is transferred to another column called the refining column where it is constantly boiled until separation occurs. Methanol rises to the top while the water accumulates in the bottom.
This document focuses on methanol water separation. A detailed design study for the distillation column is conducted where the separation occurs at atmospheric pressure with a total condenser and a partial reboiler.
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
This document discusses an experiment on agitation and determining the relationship between speed of rotation, impeller diameter, and power requirement for baffled tanks. It also examines the relationship between power number and Reynold's number. The experiment used a baffled tank and found that power requirement increased with speed. While it could not directly compare baffled and unbaffled tanks, literature shows power numbers are higher for baffled tanks as Reynold's number increases. Greater impeller diameters also require more power.
The document describes the design of a batch stirred tank reactor for producing industrial alcohol through fermentation. Key details include:
- The reactor will be a jacketed, stirred tank reactor with a volume of 377m3, 10m height, 6.8m diameter, and carbon steel construction.
- It will operate at 32°C and 1.8 atm with a 52 hour batch time and use a torispherical head.
- Cooling will be provided by a 17m2 jacket using 33 tons/hr of cooling water from 20-28°C.
- Agitation will be from three 6-bladed impellers 2.2m in diameter running at 44 RPM and requiring 60
Distillation is the basic and oldest chemical separation process used in the chemical industries and petroleum refining.
Let's recognize the difference between Packed and Plate columns in industry and the comparison of their usage!
Slides for the eLearning course Separation and purification processes in biorefineries (https://open-learn.xamk.fi) in IMPRESS project (https://www.spire2030.eu/impress).
Section: Distillation
Subject: 1.2 Flash distillation.
The document discusses surface kinetics and pore diffusion resistance in solid catalyzed reactions. It presents the following key points:
1. Surface kinetics models assume reactions occur on active sites through adsorption, reaction, and desorption steps. Rate equations can be derived from different proposed mechanisms.
2. For a single cylindrical pore with first-order reaction, a material balance relates the diffusion and reaction terms. This yields a differential equation relating concentration to position.
3. Boundary conditions of known concentration at the pore entrance and zero flux at the closed end allow solving the equation. The solution shows an exponential drop in concentration into the pore dependent on the Thiele modulus.
This document provides an overview of the polymerization process used in petroleum refining to produce high octane gasoline. Polymerization involves combining light olefin gases like ethylene and propylene into higher molecular weight hydrocarbons using a phosphoric acid catalyst. It was widely used in the 1930s-40s but replaced by alkylation after WWII before making a comeback due to leaded gasoline phase outs. Polymerization occurs at 300-450°F and 200-1200 psi to polymerize olefins into gasoline blending components with octane numbers of 83-97. Safety risks include fires and runaway reactions due to cooling water loss or corrosion from phosphoric acid exposure.
This document provides an overview of petrochemicals from the website ChemicalEngineeringGuy.com. It begins with definitions of petrochemicals and describes the petrochemical industry and various petrochemical products. It then covers petrochemical raw materials, groups by carbon number, processes, plants and facilities. The document aims to provide foundational knowledge about petrochemicals, including key terminology, production pathways, common intermediates and final products. It also references additional resources to learn more about specific topics in petrochemical engineering.
This document describes a senior design project to design an ethanolamines production facility. The facility would produce 103 million pounds per year of monoethanolamine, diethanolamine and triethanolamine at 99% purity. An economic analysis found the facility would generate $91.5 million in profit over 20 years, with $7 million annual profit. Sensitivity analysis showed that feedstock and product prices strongly affect profits. The project was found to be economically viable.
The document discusses the benefits of exercise for both physical and mental health. It notes that regular exercise can reduce the risk of diseases like heart disease and diabetes, improve mood, and reduce feelings of stress and anxiety. The document recommends that adults get at least 150 minutes of moderate exercise or 75 minutes of vigorous exercise per week to gain these benefits.
The document describes a process for producing acetic acid from methane using three steps. First, methane is oxidized in a reactor to produce methanol and acetic acid. The products are separated using flash distillation, yielding methanol and acetic acid. The methanol is then converted to additional acetic acid in a carbonylation reactor using a rhodium catalyst. Mass and energy balances were performed on the overall process. The reactors and separation equipment are also described.
This document discusses various methods for estimating capital costs for chemical engineering projects. It describes different types of cost estimates ranging from order-of-magnitude to detailed estimates. It also covers adjusting costs based on changes in equipment capacity and time. Methods like Lang factors, module cost approach, and total plant cost estimates are outlined. Factors like materials, pressure, and temperature that influence capital costs are also addressed.
Feed conditions in distillation column with respect to feed plate and refluxIhsan Wassan
This document discusses feed conditions in distillation columns with respect to the feed plate and reflux. It defines key terms like distillation, relative volatility, and reflux. It explains that the condition of the feed stream determines the relation between flows above and below the feed plate. The amount of saturated liquid versus vapor in the feed is quantified by a variable q. Feed can be saturated liquid/vapor or a mixture, determining the slope of the q-line. Feed plates help separate mixtures, and more reflux improves separation efficiency, allowing fewer plates for a given separation. Total reflux passes vapor and liquid without product removal, while minimum reflux is the lowest ratio enabling separation with infinite plates.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
1) Distillation is a method used to separate components of a liquid solution based on differences in how the components distribute between the vapor and liquid phases when heated to their boiling points.
2) Raoult's law describes vapor-liquid equilibrium for ideal solutions, relating the partial pressure of a component in vapor phase to its mole fraction in the liquid phase. Boiling point diagrams can be constructed using vapor pressure data.
3) Equilibrium or flash distillation involves heating a liquid mixture to partially vaporize it in a single stage, separating the vapor and liquid which approach equilibrium compositions.
Chemical reaction engineering involves designing chemical reactors to optimize reaction rates and yields. There are several factors that influence reaction rates, including concentration, temperature, and catalysts. Common reactor types include batch, continuous stirred-tank (CSTR), and plug flow reactors. Reactors can be run in series or parallel to improve conversion levels. Residence time distribution is important for understanding flow patterns within real reactors.
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
The experiment studied the effect of temperature on the saponification reaction of ethyl acetate and sodium hydroxide in a batch reactor. Calibration curves were plotted at different temperatures to determine conductivity and conversion levels. Reactants were added to a jacketed reactor and stirred at 30°C and 50°C, with conductivity readings recorded. The data showed lower temperatures resulted in higher conversions as evidenced by lower conductivity readings. Batch reactors are useful for small-scale testing but have high operating costs and variable product quality compared to continuous reactors.
The document discusses key concepts in multicomponent distillation including:
- Key components are chosen to indicate separation and are always distributed between products.
- The Fenske equation is used to determine minimum number of stages assuming constant relative volatility, while the Underwood method determines minimum reflux ratio.
- The Gilliland correlation estimates actual number of stages given operating reflux from minimum values.
Industrial production of chemical solvents “Acetone”Esam Yahya
This document discusses various types of chemical solvents including their classification and common uses. It focuses on acetone, describing its structure and various industrial production methods such as the cumene process, fermentation, and oxidation. Acetone is widely used as an industrial and laboratory solvent as well as in products like nail polish remover due to its ability to dissolve many compounds.
Acetone is an organic compound with the formula (CH3)2CO. It is the simplest ketone. Acetone has a colorless, pungent odor and is miscible with water and many organic solvents. It is produced industrially via the cumene process, which involves oxidation of cumene. Other production methods include oxidation of isopropyl alcohol, hydrolysis of halogenated compounds, and fermentation. India's annual acetone production has increased in recent years and the country imports acetone to meet domestic demand. Major Indian producers include Reliance Industries and HPCL.
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
This document discusses an experiment on agitation and determining the relationship between speed of rotation, impeller diameter, and power requirement for baffled tanks. It also examines the relationship between power number and Reynold's number. The experiment used a baffled tank and found that power requirement increased with speed. While it could not directly compare baffled and unbaffled tanks, literature shows power numbers are higher for baffled tanks as Reynold's number increases. Greater impeller diameters also require more power.
The document describes the design of a batch stirred tank reactor for producing industrial alcohol through fermentation. Key details include:
- The reactor will be a jacketed, stirred tank reactor with a volume of 377m3, 10m height, 6.8m diameter, and carbon steel construction.
- It will operate at 32°C and 1.8 atm with a 52 hour batch time and use a torispherical head.
- Cooling will be provided by a 17m2 jacket using 33 tons/hr of cooling water from 20-28°C.
- Agitation will be from three 6-bladed impellers 2.2m in diameter running at 44 RPM and requiring 60
Distillation is the basic and oldest chemical separation process used in the chemical industries and petroleum refining.
Let's recognize the difference between Packed and Plate columns in industry and the comparison of their usage!
Slides for the eLearning course Separation and purification processes in biorefineries (https://open-learn.xamk.fi) in IMPRESS project (https://www.spire2030.eu/impress).
Section: Distillation
Subject: 1.2 Flash distillation.
The document discusses surface kinetics and pore diffusion resistance in solid catalyzed reactions. It presents the following key points:
1. Surface kinetics models assume reactions occur on active sites through adsorption, reaction, and desorption steps. Rate equations can be derived from different proposed mechanisms.
2. For a single cylindrical pore with first-order reaction, a material balance relates the diffusion and reaction terms. This yields a differential equation relating concentration to position.
3. Boundary conditions of known concentration at the pore entrance and zero flux at the closed end allow solving the equation. The solution shows an exponential drop in concentration into the pore dependent on the Thiele modulus.
This document provides an overview of the polymerization process used in petroleum refining to produce high octane gasoline. Polymerization involves combining light olefin gases like ethylene and propylene into higher molecular weight hydrocarbons using a phosphoric acid catalyst. It was widely used in the 1930s-40s but replaced by alkylation after WWII before making a comeback due to leaded gasoline phase outs. Polymerization occurs at 300-450°F and 200-1200 psi to polymerize olefins into gasoline blending components with octane numbers of 83-97. Safety risks include fires and runaway reactions due to cooling water loss or corrosion from phosphoric acid exposure.
This document provides an overview of petrochemicals from the website ChemicalEngineeringGuy.com. It begins with definitions of petrochemicals and describes the petrochemical industry and various petrochemical products. It then covers petrochemical raw materials, groups by carbon number, processes, plants and facilities. The document aims to provide foundational knowledge about petrochemicals, including key terminology, production pathways, common intermediates and final products. It also references additional resources to learn more about specific topics in petrochemical engineering.
This document describes a senior design project to design an ethanolamines production facility. The facility would produce 103 million pounds per year of monoethanolamine, diethanolamine and triethanolamine at 99% purity. An economic analysis found the facility would generate $91.5 million in profit over 20 years, with $7 million annual profit. Sensitivity analysis showed that feedstock and product prices strongly affect profits. The project was found to be economically viable.
The document discusses the benefits of exercise for both physical and mental health. It notes that regular exercise can reduce the risk of diseases like heart disease and diabetes, improve mood, and reduce feelings of stress and anxiety. The document recommends that adults get at least 150 minutes of moderate exercise or 75 minutes of vigorous exercise per week to gain these benefits.
The document describes a process for producing acetic acid from methane using three steps. First, methane is oxidized in a reactor to produce methanol and acetic acid. The products are separated using flash distillation, yielding methanol and acetic acid. The methanol is then converted to additional acetic acid in a carbonylation reactor using a rhodium catalyst. Mass and energy balances were performed on the overall process. The reactors and separation equipment are also described.
This document discusses various methods for estimating capital costs for chemical engineering projects. It describes different types of cost estimates ranging from order-of-magnitude to detailed estimates. It also covers adjusting costs based on changes in equipment capacity and time. Methods like Lang factors, module cost approach, and total plant cost estimates are outlined. Factors like materials, pressure, and temperature that influence capital costs are also addressed.
Feed conditions in distillation column with respect to feed plate and refluxIhsan Wassan
This document discusses feed conditions in distillation columns with respect to the feed plate and reflux. It defines key terms like distillation, relative volatility, and reflux. It explains that the condition of the feed stream determines the relation between flows above and below the feed plate. The amount of saturated liquid versus vapor in the feed is quantified by a variable q. Feed can be saturated liquid/vapor or a mixture, determining the slope of the q-line. Feed plates help separate mixtures, and more reflux improves separation efficiency, allowing fewer plates for a given separation. Total reflux passes vapor and liquid without product removal, while minimum reflux is the lowest ratio enabling separation with infinite plates.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
1) Distillation is a method used to separate components of a liquid solution based on differences in how the components distribute between the vapor and liquid phases when heated to their boiling points.
2) Raoult's law describes vapor-liquid equilibrium for ideal solutions, relating the partial pressure of a component in vapor phase to its mole fraction in the liquid phase. Boiling point diagrams can be constructed using vapor pressure data.
3) Equilibrium or flash distillation involves heating a liquid mixture to partially vaporize it in a single stage, separating the vapor and liquid which approach equilibrium compositions.
Chemical reaction engineering involves designing chemical reactors to optimize reaction rates and yields. There are several factors that influence reaction rates, including concentration, temperature, and catalysts. Common reactor types include batch, continuous stirred-tank (CSTR), and plug flow reactors. Reactors can be run in series or parallel to improve conversion levels. Residence time distribution is important for understanding flow patterns within real reactors.
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
The experiment studied the effect of temperature on the saponification reaction of ethyl acetate and sodium hydroxide in a batch reactor. Calibration curves were plotted at different temperatures to determine conductivity and conversion levels. Reactants were added to a jacketed reactor and stirred at 30°C and 50°C, with conductivity readings recorded. The data showed lower temperatures resulted in higher conversions as evidenced by lower conductivity readings. Batch reactors are useful for small-scale testing but have high operating costs and variable product quality compared to continuous reactors.
The document discusses key concepts in multicomponent distillation including:
- Key components are chosen to indicate separation and are always distributed between products.
- The Fenske equation is used to determine minimum number of stages assuming constant relative volatility, while the Underwood method determines minimum reflux ratio.
- The Gilliland correlation estimates actual number of stages given operating reflux from minimum values.
Industrial production of chemical solvents “Acetone”Esam Yahya
This document discusses various types of chemical solvents including their classification and common uses. It focuses on acetone, describing its structure and various industrial production methods such as the cumene process, fermentation, and oxidation. Acetone is widely used as an industrial and laboratory solvent as well as in products like nail polish remover due to its ability to dissolve many compounds.
Acetone is an organic compound with the formula (CH3)2CO. It is the simplest ketone. Acetone has a colorless, pungent odor and is miscible with water and many organic solvents. It is produced industrially via the cumene process, which involves oxidation of cumene. Other production methods include oxidation of isopropyl alcohol, hydrolysis of halogenated compounds, and fermentation. India's annual acetone production has increased in recent years and the country imports acetone to meet domestic demand. Major Indian producers include Reliance Industries and HPCL.
Industrial production of chemical solvents “Acetone” 2Esam Yahya
Acetone is produced industrially mainly through the cumene process, in which propylene and benzene are reacted to form cumene, which is then oxidized to form phenol and acetone. Other industrial production methods for acetone include the oxidation of isopropyl alcohol, hydrolysis of gem-dihalides, and reactions of alkane nitriles with Grignard reagents followed by hydrolysis. Acetone is widely used as a solvent in industries such as cleaning, paints, adhesives, and more. Strict laws regulate volatile organic compound emissions from industrial acetone production and use.
1. Acetone-butanol fermentation is a process that uses Clostridium bacteria to produce acetone and butanol from glucose through anaerobic fermentation.
2. Clostridium acetobutylicum and Clostridium beijerinckii are commonly used species that produce a 3:6:1 ratio of acetone, butanol, and ethanol.
3. Historically this fermentation process was used commercially until the 1970s to produce acetone and butanol, which are used as solvents and in producing synthetic rubbers, lacquers, and explosives.
1. Acetone is a colorless, flammable, and mobile liquid that is the simplest ketone. It is used as a solvent and fuel additive.
2. Acetone is produced commercially through two main processes - the cumene process and from isopropanol. The cumene process involves oxidizing cumene to form acetone and phenol. Production from isopropanol involves dehydrogenating isopropanol at high temperatures.
3. Acetone has a wide variety of applications including as a solvent for plastics, synthetic fibers, paints, adhesives, and varnishes. It is also used in cosmetics, laboratories, and as a miscellaneous solvent.
The consultants proposed increasing acetone production by 30% but their modeling had issues predicting separation at high concentrations. Their options were extractive distillation, purchasing acetone, or producing 97.6% purity. Extractive distillation was too costly. Purchasing acetone for $10.92 million annually was the best option to minimize losses compared to adding equipment for higher purity. The team recommends buying acetone but could improve their presentation by using informative headings and conclusions before recommendations.
This process involves upgrading waste streams from an existing plant to produce 189 MMlb/yr of acetone product. Two waste streams containing acetone and isopropanol will be fed to a new plant and processed using distillation columns and a reactor. In the reactor, isopropanol is converted to acetone over a copper-alumina catalyst. The overall process involves 7 distillation columns and separation of reactants and products to achieve >99.9% pure acetone product. Building this plant is not recommended due to its high capital costs and lower economic attractiveness compared to other company projects. Selling the waste streams is the best option economically.
This document discusses biobutanol as an alternative fuel. It is produced through fermentation of biomass using microbes. Biobutanol has advantages over bioethanol such as being non-hygroscopic and having a higher energy density. The fermentation and reactions involved in biobutanol production are explained. Properties of biobutanol like octane rating and heat of vaporization are compared to gasoline and other fuels. Modifications needed for gasoline engines to run on biobutanol include changes to the intake manifold, carburetor, and using a fuel pre-heater due to biobutanol's higher ignition temperature. Overall, biobutanol can be a safer and slightly lower power alternative
This document provides information about acetone, including its chemical and physical properties, major applications, producers in India, production and import/export trends. It notes that acetone is used as a solvent in pharmaceuticals and other industries, and as an intermediate in producing chemicals like bisphenol A and acrylic sheets. The two main Indian producers are Hindustan Organic Chemicals and SI Group India. While domestic production has increased in recent years, imports have grown substantially and now meet most of India's demand, which exceeded 200,000 tonnes in 2011-2012. Major export markets include the UAE, while India imports acetone primarily from Taiwan, Singapore, and other Asian countries.
biobutanol is an advanced biofuel, it has better properties than ethanol and gasoline .it can be transported via existing pipelines and can be used in current engines. ethanol plants can be easily converted to biobutanol plants.
O documento conta a história de um menino de 5 anos que perdeu sua irmã e mãe em um acidente de carro causado por um motorista bêbado. Ele queria comprar uma boneca para sua mãe levar para sua irmã no céu. Com a ajuda do narrador, o menino consegue comprar a boneca e uma rosa amarela para sua mãe.
The initial assessment of a trauma patient involves a primary survey consisting of a rapid assessment of the airway, breathing, circulation, disability, and exposure (ABCDE). For a 34-year-old male brought to the emergency room after a road traffic accident with hoarseness, low blood pressure and rapid heart rate and breathing, the primary steps would be to open and secure the airway, assess breathing for tension pneumothorax, control bleeding, check neurological status, and fully expose the patient for further examination and resuscitation efforts. A secondary survey would then obtain a full history and examine all body regions for potential injuries.
The document describes the purification of urease from sword bean for potential clinical use. Several issues were encountered with a previous purification method using an affinity matrix. The current study aimed to develop a simpler and lower cost purification process using solvent extraction followed by isoelectric focusing. Various parameters of the extraction process were optimized to address issues like inhibitor presence, activity loss, pH, and microbial growth. The purified urease was shown to retain activity and was stable for several weeks. It was used to prepare a low-cost urea test kit that demonstrated stability of results for over a month.
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Present at the Brooklyn Botanic Garden on October 11, 2015 as part of continuing education.
Presentation developed and presented by @Gil_Lopez
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This document provides details for a design project to produce acetone via a process involving isopropanol. The key steps are:
1) Isopropanol feed is heated, vaporized, and reacted in a reactor to produce acetone.
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3) Some acetone is recovered from the vapor stream by absorption, while the liquid stream is distilled to produce pure acetone and waste water, with economic and design specifications provided.
4) Students are tasked with developing an optimal process design using the specified equipment and costs, with
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- Rankine cycles, which are more practical vapor power cycles that use steam as the working fluid.
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Similar to Full design for acetone production (20)
1. Energy Balances, Numerical Methods
Design Project
Production of Acetone
Process Description
Figure 1 is a preliminary process flow diagram (PFD) for the acetone production process.
The raw material is isopropanol. The isopropanol (IPA) feed is a near azeotropic mixture with
water at 88 wt % IPA at 25°C and 1 atm. The feed is heated, vaporized, and superheated in a
heat exchanger (E-401), and it is then sent to the reactor (R-401) in which acetone is formed.
The reaction that occurs is shown below. The reactor effluent is cooled and partially condensed
in a heat exchanger (E-402), and it is then sent to a separation unit (V-401) in which all of the
light gas (hydrogen) enters Stream 7 while the remaining components (acetone, IPA, and water)
distribute according to Raoult’s Law. Some of the acetone in Stream 7 is recovered by absorbing
it into pure water in T-401. The liquid in Stream 12 is distilled to produce “pure” acetone in
Stream 13 and waste water (containing IPA) in Stream 14. The desired acetone production rate
is 15,000 metric tons/yr.
Process Details
Feed Streams
Stream 1: isopropyl alcohol, liquid, 88 wt % IPA, 12 wt % water, 1 atm, 25°C
Stream 9: distilled process water, 3 bar, 25°C
Effluent Streams
Stream 11: off-gas stream to incinerator, credit may be taken for LHV of fuel
Stream 13: acetone product, liquid, 99.9 mol% purity, must contain 99.5 mol% of acetone
in Stream 12
Stream 14: waste water stream, treatment cost $50.00/106 kg
must contain less than 0.04 mole fraction IPA and acetone
2.
3. 3
Equipment
Heat Exchanger (E-401):
This unit heats, vaporizes, and superheats the feed to 235°C at 2.2 bar. A pump, which is
not shown and which you do not have to be concerned with this semester, increases the
pressure of the feed to the indicated pressure.
Reactor (R-401):
Following development of a new catalyst, only the following reaction occurs:
CH 3CHOHCH 3 → CH 3COCH 3 + H 2
(1)
IPA acetone
The reaction occurs at 350°C, and the conversion at this temperature is 90%. The reactor
exit pressure is 1.9 bar. The reaction is endothermic with heat being supplied by hot
molten salt.
Fired Heater (H-401):
This unit heats the molten salt that provides heat to the reactor. Energy is supplied by
combustion of natural gas, which may be assumed to be pure methane. The molten salt
enters the fired heater at 360°C (Stream 3) and leaves the fired heater at 410°C (Stream
4). The heat capacity of molten salt is 1.56 J/g K.
Heat Exchanger (E-402):
This unit cools and partially condenses the reactor effluent. None of the hydrogen
condenses. The exit pressure may be at any pressure below 1.6 bar and any temperature
below 50°C that can be achieved by using cooling water (cw) or refrigerated water (rw) is
possible.
Separation Vessel (V-401):
This unit disengages the vapor and liquid effluent from E-402. In this separator, all
hydrogen in the feed enters the vapor phase, Stream 7. All other components distribute
according to Raoult’s Law at the temperature and pressure of E-402. The combination of
E-402 and V-401 is often called a flash operation.
Absorber (T-401):
Here, additional acetone is recovered by absorption into pure process water. The
absorber operates at the same temperature and pressure as V-401 Stream 11 contains all
of the hydrogen and the acetone and water which are not in Stream 10. Stream 10
4. 4
contains all of the IPA in Stream 7, 95% of the water in Streams 7 and 9. The amount of
acetone in Stream 10 can be calculated from:
y stream 11 1− A
= (2)
ystream 7 1 − A6
where y is the mole fraction of acetone,
L
A= (3)
mV
L is the total molar flowrate of liquid in Stream 9, and V is the total molar flowrate of
liquid in Stream 7. The parameter m is an equilibrium constant that is a function of
temperature and pressure
3598
exp10.92 −
m= T
(4)
P
where T is in Kelvin and P is in atm.
Distillation Column (T-402):
In this distillation column, the acetone, IPA, and water in Stream 12 are separated. The
column operates at 1.4 bar. Specifications are as follows. The acetone must be 99.9
mol% pure and 99.5 mol% of the acetone in the feed must be recovered in Stream 13.
Stream 14 contains most of the water and IPA from Stream 12.
Heat Exchanger (E-403):
In this heat exchanger, the contents of Stream 13 are condensed from saturated vapor to
saturated liquid at a rate three times the flow of Stream 13. The cost is for the amount of
cooling water needed to remove the necessary energy.
Heat Exchanger (E-404):
In this heat exchanger, you may assume that one-half of the flow of Stream 14 is
vaporized from saturated liquid to saturated vapor at 1.4 bar and is returned to the
column. The cost is for the amount of low-pressure steam needed to supply the necessary
heat.
An additional distillation column (T-403):
You may choose to add an additional distillation column to process Stream 14 further.
This column can recover a near azeotropic mixture of water and IPA (88 wt% IPA – with
5. 5
all of the acetone remaining in Stream 14) out of the top, with residual water and IPA out
the bottom. If you choose to do this, you must recycle the IPA/water top product to the
beginning of the process. The bottom product goes to waste water treatment. This
distillation column needs two heat exchangers with similar energy specifications to E-403
and E-404. This distillation column operates at 1.2 bar. You should only include this
column if you decide it to be economically attractive
Other Equipment
It is required for two streams that mix to be at identical pressures. Pressure reduction may
be accomplished by adding a valve. These valves are not shown on the attached
flowsheet, and it may be assumed that additional valves can be added as needed at no cost.
Flow occurs from higher pressure to lower pressure. Pumps increase the pressure of
liquid streams, and compressors increase the pressure of gas streams. You may assume
that a pump exists where ever you need one. For this semester only, there is no cost for
pumps.
Equipment Costs
The equipment costs for the acetone plant are given below. Each cost is for an individual
piece of equipment, including installation.
Equipment Installed Cost
in millions of $
Reactor, R-401 1.5
Absorber, T-401 0.03
Acetone distillation column T- 2.8
402
including reboiler and
condenser
IPA distillation column T-403 0.1
(if added)
including reboiler and
condenser
Vessel, V-401 0.07
Any heat exchanger 0.05
Fired heater installed cost in dollars:
11× 10 x
where
x = 2.5 + 0.8 log10 Q
where Q is the heat duty in kW
6. 6
Utility Costs
Low-Pressure Steam (446 kPa, saturated) $5.00/1000 kg
Medium-Pressure Steam (1135 kPa, saturated) $7.31/1000 kg
High-Pressure Steam (4237 kPa, saturated) $8.65/1000 kg
Natural Gas or Fuel Gas (446 kPa, 25°C) $3.00/GJ
Electricity $0.05/kW h
Boiler Feed Water (at 549 kPa, 90°C) $2.54/1000 kg
Cooling Water $0.16/GJ
available at 516 kPa and 30°C
return pressure ≥ 308 kPa
return temperature should be no more than 15°C above the inlet temperature
Refrigerated Water $1.60/GJ
available at 516 kPa and 10°C
return pressure ≥ 308 kPa
return temperature is no higher than 20°C
Process Water $0.04/1000 kg
available at 300 kPa and 25°C
Data
Use data from Reference [1] or from any handbook (such as Reference [2]). The following
data are not readily available in these references.
Liquid Heat Capacity
For IPA: 145 J/mole K
Vapor Heat Capacity
for IPA: 27.87 + 0.176 + 2.12´10-4T 2 - 4.09´10-7T 3 J/mole K T (K)
Vapor Pressures – Antoine’s Equation constants
B
ln p* = A − (5)
T +C
(p* in mm Hg, T in K)
7. 7
A B C
IPA 17.664 3109.3 -73.546
acetone 16.732 2975.9 -34.523
Normal heat of vaporization
for IPA: 56,900 kJ/kmole
Economic Analysis
When evaluating alternative cases, the following objective function should be used. It is the
equivalent annual operating cost (EAOC), and is defined as
EAOC = -(product value - feed cost - other operating costs - capital cost annuity)
A negative EAOC means there is a profit. It is desirable to minimize the EAOC; i.e., a large
negative EAOC is very desirable.
The cost for acetone is $0.88/kg. The cost for IPA is $0.72/kg IPA in the feed solution. The
value for hydrogen is $35/1000 std m3.
Other operating costs are utilities, such as steam, cooling water, natural gas, and electricity.
The capital cost annuity is an annual cost (like a car payment) associated with the one-time,
fixed cost of plant construction. A list of capital costs for all pieces of equipment will be provided
by early March.
The capital cost annuity is defined as follows:
capital cost annuity = 0.2(capital cost)
Optimization
We will learn optimization methods in numerical methods class. The objective function
(EAOC) is defined above. It is your responsibility to define appropriate decision variables. If
there are too many decision variables to do a reasonable optimization, it is your responsibility to
determine, with appropriate justification, which ones most significantly affect the objective
function and focus on only those decision variables.
Other Information
You should assume that a year equals 8000 hours. This is about 330 days, which allows for
periodic shut-down and maintenance.
8. 8
Deliverables
Each group must deliver a report written using a word processor. The report should be clear
and concise. The format is explained in a separate document. Any report not containing a labeled
PFD and a stream table will be considered unacceptable. The stream table must include
temperature, pressure, phase, total mass flowrate, total molar flowrate, and component molar
flowrates. When presenting results for different cases, graphs are generally superior to tables.
The report appendix should contain details of calculations for the optimal case. These
calculations may be (neatly) hand-written. Calculations that can not be followed easily will lose
credit. Refer to the document entitled Written Design Reports for more information.
Each group will give an oral report in which the results of this project are presented in a
concise manner. The oral report should be no more than 15 minutes, and each group member
must speak. A 5-10 minute question-and-answer session will follow. Instructions for
presentation of oral reports will be provided in a separate document entitled Oral Reports.
However, the best way to learn how to present an oral report, other than actually presenting one,
is to make time to see some of the oral reports presented by the juniors the week before you are
to present your report. The presentations will most likely be on Wednesday, April 21, 1999,
between 11:00 a.m. and 3:00 p.m.
As mentioned in the cover memo, the written project report is due on Monday, April 26,
1999, at 1:00 p.m. The oral reports will be Monday, April 26, 1999 (ChE 38 class) and
Wednesday, April 28, 1999 (ChE 41 class). There will be a project review on Thursday, April 30,
1999 (ChE 38 class). In addition, everyone must attend the senior design presentation on
Tuesday, April 27, 1999, unless you have organic chemistry or physics lab at that time.
Furthermore, attendance is required of all students during their classmates’ presentations (this
means in the room, not in the hall or the lounge). Failure to attend any of the above required
sessions will result in a decrease in one letter grade (per occurrence) from your project grade in
both ChE 38 and ChE 41.
Anyone not participating in this project will automatically receive an F for ChE 38, regardless
of other grades earned in this classes.
Revisions
As with any open-ended problem; i.e., a problem with no single correct answer, the problem
statement above is deliberately vague. The possibility exists that as you work on this problem,
your questions will require revisions and/or clarifications of the problem statement. You should
be aware that these revisions/clarifications may be forthcoming.
9. 9
References
1. Felder, R. M. and R. W. Rousseau, Elementary Principles of Chemical Processes (2nd ed.),
Wiley, New York, 1986.
2. Perry, R. H. and D. Green, eds., Perry’s Chemical Engineering Handbook (7th ed.),
McGraw-Hill, New York, 1997.