2.

0 Fundamental of Mass Balance

The process of production of Linear Low Density of Polyethylene (LLDPE) from

ethylene consists of two main sections which are mixing section and reaction section. In this
chapter, all material balance of the process will discuss based on those sections. Then, stream
tables for each section and overall process were constructing based on the calculation of mass
balance and process flow diagram (PFD). The comparison between HYSYS simulation and
manual calculation also been discussed.

Generally, the mass balance is every important equation in chemical plant to ensure
the flow rate and composition of materials at input is always equal to output for steady state
process. In this plant, the process assumed to ideal and at steady state. This known as law of
conversation of mass, which mention that the mass neither be created nor destroy but only
can transform to another form of energy. The chemical process can be classified into three
categories of processes which are batch, continuous and semi-batch. The batch process is
where a feed is charged into a vessel at the beginning of the process and vessel contents are
removed sometimes later after the process. No mass crosses the system boundaries between
the time the feed is charged and the time the product is removed. The continuous process
defines as the input and output flow continuously throughout the duration of the process. The
semi-batch process is neither batch nor continuous. For this plant, the process is based on
continuous process.

The values of the entire variable in this process (all temperature, pressure, flow rate
and volume) do not change over time, except possibly for minor fluctuation about constant
mean values, the process is said to be steady state. The balance on conserved quantity (total
mass flow rate, mass flow rate of particular species and energy) in this system (single process
unit, a collection of units or an overall balance process) is written in the following general
way as shown in equation below (Felder, Rousseau, & Bullard, n.d.);
 Input + Generation Output Consumption = Accumulation
Where;
Input = enter through system boundary
Generation = produced within system
Output = leaves through system boundaries
Consumption = consumed within system
Accumulation = build up within system

The balance on continuous steady state process is where the accumulation term in
general balance equation is equal to zero and the equation simplifies as next equation

Input + Generation = Output + Consumption

If the balance is on a non-reactive species or on total mass, the generation and

consumption term is equal to zero and the equation reduces as equation below.

Input = Output

Law of conservation of mass stated that during a chemical reaction atoms are neither
created nor destroyed. The number of atoms remains constant throughout the reaction. Since
the number of atoms does not change, the mass must remain constant as well. The law of
conservation of mass is very important to the study and production of chemical reactions. If
scientists know the quantities and identities of reactants for a particular reaction, they can
predict the amounts of products that will be made. Chemical manufacturers can increase
efficiency by applying the law of conservation of mass to their laboratory practices. ("The
Law of Conservation of Mass: Definition, Equation & Examples - Video & Lesson Transcript
Study.com", 2016)
The conservation of mass principle for a control volume can be expressed as;
in - out = CV

For a steady state, steady flow process the conservation of mass principle becomes
in = out
where;
in = mass flowrate in
out= mass flowrate out
CV= mass flowrate in control volume

2.1 Mass Balance of Each Component in process plant

Component Molar mass g/mol Source

Ethylene, C2H4 28.05316 Convertunit, 2017
Hydrogen gas , H2 2.01588 Convertunit, 2017
mLLDPE 106996.7681 Convertunit, 2017
Nitrogen gas, N2 28.013 Convertunit, 2017
Metallocene 392.44 Amalia, 2014
MAO 174.05 ChemicalBook, 2016
Table 2.1.1: Molar mass of each component

Productivity of mLLDPE = 300,000 ton/year

Amount of mLLDPE produce per hours

300,000 ton 1000 kg 1 year 1 days

year 1 ton 365 days 24 hours

34246.57534658 kg/hours

Number of mole of mLLDPE produce per hour

34246.57534658 kg 1 mol 1000 g

1hours 106996.7681 g 1 kg

320.0711193824 mol/hr
 nC 2 H 4 + H 2 H ( C 2 H 4 ) nH

From the equation of polymerisation of polyethylene, it can be seen that one mole of
mLLDPE produce consume 1 mole of hydrogen.

Therefore 320.0711193824 mole of mLLDPE produce required 320.0711193824 mole of

hydrogen

Number of repeating unit of ethylene in mLLDPE

[
106.99676812 kg mLLDPE 1000 g 2.01588 g H 2
mol

1 kg

mol ]
28.05316 g C2 H 4 / mol

3814 unit

3814 C 2 H 4 + H 2 H( C 2 H 4 )3814 H

To produce 320.0711193824 mol mLLDPE/ hours

The number of mole of C2H4 required
320.0711193824 mol mLLDPE 3814 mol C2 H 4

hours 1 mol mLLDPE

1220751.24932441mol C 2 H 4 / hr

Since the conversion of polymerisation from ethylene to mLLDPE is 98%, therefore the

amount of C2 H 4 feed are calculated as below.

number of mol of reactant feednumber of mol of reactant exit

conversion=
number of mol of reactant feed

number of reactan t reacted

number of mol of reactant feed
Therefore, for 98% of conversion
1220751.2493441 mol C 2 H 4 react
100 =98
number of mol of C2 H 4 feed

1220751.2493441mol C 2 H 4
number of mol of reactant feed=
0.98

=1245664.54012695 mol of C2 H 4 / hr

The amount of hydrogen gas required for 98% conversion

320.0711193824 mol H 2 react
100 =98
number of mol H 2 feed

320.0711193824 mol H 2
number of mol of H 2 feed=
0.98

=326.6031830432 mol of H 2 / hr

Therefore,
mol mol
unreacted ethylene=1245664.54012695 122075102493441
hr hr
mol C 2 H 4
24913.290802539
hr

mass of unreacted ethylene

mol C 2 H 4 28.05316 g C 2 H 4 1kg
24913.290802539
hours mol C 2 H 4 1000 g

698.8965330102kg C 2 H 4 /hr

698.90 kg C 2 H 4 /hr 2.d.p

 mol H 2 mol H 2
unreacted hydrogen gas=326.6031830432 320.0711193824
hr hr

mol H 2
6.5320636609
hr

mass of unreacted ethylene

H 2 2.01588 g H 2 1 kg
6.532036609 mol
hr mol H 2 1000 g

0.0131678565 kg H 2 /hr

1.32 102 kg H 2 /hr 2.d.p

The ratio of ethylene to nitrogen is 52 vol.% ethylene to 48 vol.% nitrogen (Bergstra, 2004).
The amount of ethylene enter to the fluidise bed reactor
34944.8266505078 kg C2 H 4 /hr + 698.8965330102 kg C 2 H 4 /hr

35643.72318 kg C2 H 4 /hr

35643.72 kg C2 H 4 /hr 2 d.p

Therefore the amount of nitrogen enter into the reactor

48 N 2 nitrogen gas flow rate
=
52 C 2 H 4 35643.72318

48
Nitrogen gas flow rate into the reactor 52 35643.72318kg /hr

32901.8983232473 kg N 2 /hr

The recycle stream of the nitrogen gas is control to be 50% of the inlet to the fluidised
reactor.
 32901.8983232473 kg N 2 /hr
Therefore the amount of nitrogen gas feed
2

16450.9491616237 kg N 2 /hr

16450.95 kg N 2 /hr 2 d.p

The amount catalyst needed for polymerisation:-

The catalytic activity reported is 0.88 kg mLLDPE/g catalyst.hours
Therefore the amount of catalyst needed
34246.57534658 kg mLLDPE /hours 1 kg

mLLDPE 1000 g
0.88 kg catalyst . hours
g

38.9165628892kg active catalyst /hours

38.92 kg active catalyst /hr 2 d.p

It is reported by (Bergstra, 2004), the molar ratio of Al/Zr is 108. Therefore the active catalyst
is compose of 36 mol of MAO and one mole of metallocene.
One mole of active catalyst is
36 molar mass of MAO+1 metallocene

36 174.05 g /mol+1 392.44 g /mol

6658.24 g active catalyt /mol

2.2 Mass balance of the process plant of each individual unit

Mass balance of compressor (C-100)

S1 = 16450.95 kg/hr C-100 S2 = 16450.95 kg/hr

100% N2 100% N2
25C
25C
Figure 2.2.1: Mass balance of compressor (C-100)

Strea Componen Mass Mass Molar Mass Total

m t flow rate flow flow rate composition mass
 (kg/h) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
input S1 Nitrogen 16450.95 16.45 587.26 100 16450.95
Outpu S2 Nitrogen 16450.95 16.45 587.26 100 16450.95
t
Table 2.2.1: Input-Output of compressor (C-100)

Molar flowrate for component of Nitrogen was calculated using this formula:

Mass Flowrate
Molar Flowrate = Molar Mass

kg kg
Molar Flowrate = 16450.95 hr 28.013
kmol

kmol
= 587.26 hr

The following molar flow rate of nitrogen in other stream will be calculated using this
approach.

1 ton
Mass flow rate in ton/hr = 16450.95 kg/hr 1000 kg

=16.45095 ton/hr
=16.45 ton/hr 2d.p

The following conversion unit from kg/hr to ton/hr is calculate using this approach

Mass Balance for nitrogen carried active catalyst

S3 = 38.92 kg/hr
100% active catalyst
25C
 S4 = 16489.87 kg/hr
m N = 16450.95 kg/hr
S2 = 16450.95 kg/hr 2

100% N2 m
a .c = 38.92 kg/hr
25C
1
2.36 10 active catalyst
99.76% N2
Figure 2.2.2: Mass Balance for nitrogen carried active catalyst

Strea Componen Mass Mass Molar Mass Total

m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S2 Nitrogen 16450.95 16.45 587.26 100 16489.87

S3 Active 38.92 3.89 10 5.84 10 100

2 3

Catalyst
Outpu S4 Nitrogen 16450.95 16.45 587.26 99.76 16489.87
t Active 38.92 3.89 10 5.84 10 2.36
2 3

Catalyst 101
Table 2.2.1: Input-Output of nitrogen carried active catalyst

Mass balance for nitrogen carried active catalyst:

Input = output

S 2+ S 3=S 4
kg kg kg
16450.95 +38.92 =16489.87
hr hr hr

16450.95
Mass composition of nitrogen in S4 16489.87 100

=99.76%

38.92
Mass composition of active catalyst in S4 16489.87 100
1
=2.36 10
 Molar flowrate for component of Active Catalyst was calculated using this formula:

Mass Flowrate
Molar Flowrate = Molar Mass

kg kg
Molar Flowrate = 38.92 hr 6658.24 kmol

kmol
= 5.84 10-3 hr

The following molar flowrate of active catalyst in other stream will be calculated
using this approach.

Mass balance of compressor (C-101)

S5 = 34944.83 kg/hr C-101 S6 = 34944.83 kg/hr

100% C2H4 100% C2H4
25C 25C

Figure 2.2.3: Mass balance of compressor (C-101)

Strea Componen Mass Mass Molar Mass Total

m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S5 Ethylene 34944.83 34.94 1245.66 100 34944.83
Outpu S6 Ethylene 34944.83 34.94 1245.66 100 34944.83
t
Table 2.2.3: Input-Output of compressor (C-101)

Molar flowrate for component of Ethylene was calculated using this formula:

Mass Flowrate
Molar Flowrate = Molar Mass

kg kg
Molar Flowrate = 34944.83 hr 28.05316
kmol
 kmol
= 1245.66 hr

The following molar flowrate of ethylene in other stream will be calculated using this
approach.

Mass balance of compressor (C-102)

S7= 6.58
1
S8= 6.58
10 kg/hr 101 kg/hr
100% H2 C-102
100% H2
T= 25C
T= 25C

Figure 2.2.4: Mass balance of compressor (C-102)

Strea Componen Mass Mass Molar Mass Total

m t flow flow rate flow rate composition mass
rate (ton/hr) (kmol/hr) (mass %) flow
(kg/hr) rate
(kg/hr)
Input S7 Hydrogen 6.58 6.58 104 3.27 101 1.89 103 6.58
101 101
Outpu S8 Hydrogen 6.58 6.58 104 3.27 101 1.89 103 6.58
t 10
1
10
1

Table 2.2.4: Input-Output of compressor (C-102)

Molar flowrate for component of Hydrogen was calculated using this formula:

Mass Flowrate
Molar Flowrate = Molar Mass

1 kg kg
Molar Flowrate = 6.58 10 hr 2.01588
kmol

kmol
= 3.2710-1 hr

The following molar flowrate of hydrogen in other stream will be calculated using this
approach.
Mass balance of mixer (M-100)
S9 = 34945.49 kg/hr
m C 2 H 4 = 34944.83
S6 = 34944.83 kg/hr
100% C2H4 kg/hr
T= 25C M-100 mH2 = 6.58 10
1

kg/hr
S8= 6.58
99.99% C2H4
101 kg/hr 3
1.89 10 H2
100% H2
Figure 2.2.5: Mass balance of mixer (M-100)
T= 25C

Strea Componen Mass Mass Molar Mass Total

m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S6 Ethylene 34944.83 34.94 1245.66 100 34945.49

S8 Hydrogen 6.58 6.58 1043.27 101100

101
Outpu S9 Ethylene 34944.83 34.94 1245.66 99.99 34945.49
t Hydrogen 6.58 4
6.60 10 3.27 10 1
1.89 103

1
10
Table 2.2.5: Input-Output of mixer (M-100)

Mass balance for mixer (M-100):

Input = output

S 6+ S 8=S 9
 kg kg kg
34944.83 +6.58 101 =34945.49
hr hr hr

34944.83
Mass composition of Ethylene in S9 34945.49 100

=99.99%

6.58 101
Mass composition of Hydrogen gas in S9 100
34945.49
3
= 1.89 10

Mass balance of heat exchanger (E-100)

S18=16864.75 kg/hr
m H 2 O = 16864.75 kg/hr

100% H2O
T= 25C

S09 = 34945.49 kg/hr

m C 2 H 4 = 34944.83 kg/hr S10= 34945.49 kg/hr
m C 2 H 4 = 34944.83
m
H 2 = 6.58 10
1
kg E-100
kg/hr
kg/hr
mH = 6.58 10
1
99.99% C2H4 2

3
1.89 10 H2 kg kg/hr
99.99% C2H4
3
1.89 10 H2
S19=16864.75 kg/hr
m H 2 O = 16864.75

kg/hr
100% H2O

Figure 2.2.6: Mass balance of heat exchanger (E-100)

 Strea Componen Mass Mass Molar Mass Total
m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S09 Ethylene 34944.83 34.94 1245.66 99.99 51810.24

Hydrogen 6.58 4
6.60 10 3.27 10
1
1.89 10
3

101
S18 Water 16864.75 16.86 936.93 100

Outpu S10 Ethylene 34944.83 34.94 1245.66 99.99 51810.24

t Hydrogen 6.58 4
6.60 10 3.27 10 1
1.89 103

1
10
kg
S19 Water 16864.75 16.86 936.93 100
Table 2.2.6: Input-Output of heat exchanger (E-100)

Mass balance of fluid bed reactor (R-100)

S12 = 17149.86 kg/hr
m C 2 H 4 = 698.90 kg/hr

m
H 2 =1.32 10
2

kg/hr
m N = 16450.95 kg/hr
2

4.08% C2H4
95.92% N2
S15 = 51435.36 kg/hr
m mLLDPE = 34246.58

kg/hr
S4 = 16489.87 kg/hr R-100 m C 2 H 4 = 698.90 kg/hr
m N = 16450.95 kg/hr
2

m
H = 1.32 10
2
m
2
a .c = 38.92 kg/hr
1
kg/hr
2.36 10 active catalyst m N = 16450.95 kg/hr
2

99.76% N2 m
a .c = 38.92 kg/hr
S11 = 52095.35 kg/hr 66.58% mLLDPE
m C 2 H 4 = 35643.73 31.98% N2
kg/hr 1.36% C2H4
mH 2 = 0.67 kg/hr
m
N 2 = 16450.95 kg/hr
68.42% C2H4
3
 Figure 2.2.7: Mass balance of fluid bed reactor (R-100)
Strea Componen Mass Mass Molar Mass Total
m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S4 Nitrogen 16450.95 16.45 587.26 99.76 68585.22
Active 38.92 3.89 10 5.84 10 2.36
2 3

Catalyst 101
S11 Ethylene 35643.73 35.64 1270.58 68.42
Hydrogen 6.71 6.71 1043.33 1011.29
1 3
10 10
Nitrogen 16450.95 16.45 587.26 31.58
Outpu S12 Ethylene 698.90 6.99 1024.91
1
4.08 68585.22
t
Hydrogen 1.32 5
1.32 10 6.53 10
3
7.68 10
5

102
Nitrogen 16450.95 16.45 587.26 95.92
S15 mLLDPE 34246.58 34.25 3.20 10 66.58
1

Ethylene 698.90 6.99 1024.91

1
1.36
Hydrogen 1.32 5
1.32 10 6.53 10
3
2.56 10
5

2
10
Nitrogen 16450.95 16.45 587.26 31.98
Active 38.92 3.89 10 5.84 10 7.57 102
2 3

catalyst
Table 2.2.7: Input-Output of fluid bed reactor (R-100)

Mass balance for fluidise bed reactor (R-100):

Input = output

S 4+ S 11=S 12+ S 15

kg kg
S4 + S11 = 16489.87 h +52095.35 h

= 68585.22 kg/h
 kg kg
S12 + S15 = 17149.86 +51435.36
h h
=68585.22 kg/h

698.90
Mass composition of ethylene in S12 17149.86 100

=4.08%

1.32 102
Mass composition of Hydrogen gas in S12 100
17149.86
5
= 7.68 10

16450.95
Mass composition of nitrogen gas in S12 17149.86 100

= 95.92

34246.58
Mass composition of mLLDPE gas in S15 51435.36 100

= 66.58

698.90
Mass composition of Ethylene gas in S15 51435.36 100

= 1.36

2
1.32 10
Mass composition of Hydrogen gas in S15 51435.36 100
5
= 2.56 10

16450.95
Mass composition of Nitrogen gas in S15 51435.36 100

= 31.98

38.92
Mass composition of Active Catalyst gas in S15 51435.36 100
2
=7.57 10

By doing element balance:

Mass balance for element C:

Input Stream 11

kmol kg
= (1270.5778309295 hr ) 2 12.0107 kmol
kg
= 30521.05831 hr of C element

Output Stream 12 and 15

kmol kg kmol
= [24.9132908025 hr 2 12.0107 kmol ] + [24.9132908025 h 212.017

kg kmol kg
3814 2 12.0107
kmol ] + [0.3200711194 hr kmol

kg
= 30521.05831 hr of C element

Mass balance for element H:

Input Stream 11

kmol kg kmol
= [1270.5778309295 hr 41.00794 kmol ] + [ 0.3331352467 hr 2

kg
1.00794 kmol ]

kg
= 5123.339436 hr of H element

Output @ Stream 12 and 15

kmol kg kmol
= [ 24.9132908025 hr 4 1.00794 kmol ] + [ 0.0065320637( hr ) 2

kg kmol kg
1.00794 kmol ] + [0.3200711194 hr (4 3814 + 2) 1.00794 kmol ] +
kmol kg kmol
[24.9132908025 hr 41.00794 kmol ] + [ 0.0065320637( hr ) 2 1.00794

kg
kmol ]
 kg
= 5124.691211 hr of H element

Mass balance for element N

Input Stream 4 and 11

kg kmol kg
[2 14.0067 kmol 587.2612416244 hr ] + [2 14.0067 kmol

kmol
587.2612416244 hr ]
= 32902.36813 kg/hr of N element

Output Stream 12 and 15

kg kmol kg
[2 14.0067 kmol 587.2612416244 hr ] + [2 14.0067 kmol

kmol
587.2612416244 hr ]
= 32902.36813 of N element

Molar flow rate for component of mLLDPE was calculated using this formula:

Mass Flowrate
Molar Flow rate = Molar Mass

kg kg
Molar Flow rate =34246.58 106996.7681
hr kmol

kmol
= 3.2010-1 hr of mLLDPE

The following molar flowrate of mLLDPE in other stream will be calculated using this
approach

S14 = 17149.86 kg/hr

m C 2 H 4 = 698.90 S11 = 52095.35 kg/hr
Mass balance of mixer (M-101) m C 2 H 4 = 35643.73
kg/hr
m H = 1.32 102
2
kg/hr
mH 2 = 6.71 10
1

kg/hr
m N = 16450.95
2
kg/hr
m N = 16450.95 kg/hr
2
kg/hr
4.08% C2H4 68.42% C2H4
 M-101

S10 = 34945.49 kg/hr

m C 2 H 4 = 34944.83

kg/hr
mH 2 = 6.58 10
1

kg/hr
99.99% C2H4
Figure 2.2.8: Mass balance of mixer (M-101)

Stream Componen Mass Mass Molar Mass Total

t flow rate flow flow rate compositio mass
(kg/hr) rate (kmol/hr n (mass %) flow rate
(ton/hr) ) (kg/hr)
Input S14 Ethylene 698.90 6.99 1024.91
1
4.08 52095.3
5
Hydrogen 1.32 5
1.32 10 6.53 10
3 5
7.68 10
102
Nitrogen 16450.9 16.45 587.26 95.92
5
S10 Ethylene 34944.8 34.94 1245.66 99.99
3
Hydrogen 6.58 4
6.58 10 3.27 10
1 3
1.89 10
101
output S11 Ethylene 35643.7 35.64 1270.58 68.42 52095.3
3 5
Hydrogen 6.71 6.71 1043.33 1011.29
101 103
Nitrogen 16450.9 16.45 587.26 31.58
5
Table 2.2.8: Input-Output of mixer (M-101)

Mass balance for mixer (M-101):

Input = output

S 14+ S 10=S 11
 kg kg kg
17149.86 +34944.49 =52095.35
hr hr hr

35643.73
Mass composition of ethylene in S11 52095.35 100

=68.42%

6.71 101
Mass composition of hydrogen in S11 100
52095.35
3
=1.29 10

16450.95
Mass composition of nitrogen in S11 52095.35 100

=31.58%

Mass balance of compressor (C-103)

S12 = 17149.86 kg/hr S13 = 17149.86 kg/hr

m C 2 H 4 = 698.90 m C 2 H 4 = 698.90 kg/hr
C-103
kg/hr m
H 2 = 1.32 10
2

mH = 1.32 kg/hr
2

10 2 m N = 16450.95 kg/hr
kg/hr 2

m
N 2 = 16450.95 4.08% C2H4
95.92% N2
kg/hr
4.08% C2H4
Figure 2.2.9: Mass balance of compressor (C-103)

Stream Componen Mass Mass Molar Mass Total

t flow rate flow flow rate compositio mass
(kg/hr) rate (kmol/hr n (mass %) flow rate
(ton/hr) ) (kg/hr)
Input S12 Ethylene 698.90 6.99 1024.91
1
4.08 17149.8
 Hydrogen 1.32 1.32 1056.53 103 7.68 105 6
2
10
Nitrogen 16450.9 16.45 587.26 95.92
5
output S13 Ethylene 698.90 6.99 1024.91
1
4.08 17149.8
6
Hydrogen 1.32 1.32 1056.53 103 7.68 105
102
Nitrogen 16450.9 16.45 587.26 95.92
5
Table 2.2.9: Input-Output of compressor (C-103)

Mass balance of heat exchanger(E-101)

S20=9345.95 kg/hr
m H 2 O = 9345.95

kg/hr
100% water
S14 = 17149.86 kg/hr
m C 2 H 4 = 698.90 kg/hr
S13 = 17149.86 kg/hr
m C 2 H 4 = 698.90 kg/hr m
H 2
2 = 1.32 10 kg/hr
E-101
m
H = 1.32 10
2
m
N
2
2 = 16450.95 kg/hr
kg/hr 4.08% C2H4
m N = 16450.95 kg/hr
2 95.92% N2
5
4.08% C2H4 7.68 10 H2
95.92% N2
S21=9345.95 kg/hr
m H 2 O = 9345.95

kg/hr
100% water
 Figure 2.2.10: Mass balance of heat exchanger (E-101)

Stream Componen Mass Mass Molar Mass Total

t flow rate flow flow rate compositio mass
(kg/hr) rate (kmol/hr n (mass %) flow rate
(ton/hr) ) (kg/hr)
Input S13 Ethylene 698.90 6.99 1024.91
1
4.08 17149.8
6
Hydrogen 1.32 5
1.32 10 6.53 10
3
7.68 10
5

102
Nitrogen 16450.9 16.45 587.26 95.92
5
S20 Water 9345.95 9.35 519.22 100 9345.95
output S14 Ethylene 698.90 6.99 1024.91
1
4.08 17149.8
6
Hydrogen 1.32 1.32 1056.53 103 7.68 105
102
Nitrogen 16450.9 16.45 587.26 95.92
5
S21 Water 9345.95 9.35 519.22 100 9345.95
Table 2.2.10: Input-Output of heat exchanger (E-101)

Mass balance of degassing tank (TK-101)

S17 = 17149.86 kg/hr

m C 2 H 4 = 698.90 kg/hr
S15 = 51435.36 kg/hr m
H 2
m mLLDPE = 34246.58 2 = 1.32 10
kg/hr
kg/hr m N = 16450.95 kg/hr
m C 2 H 4 = 698.90 kg/hr 2

4.08% C2H4
m
H = 1.32 10
2
2
95.92% N2
5
kg/hr 7.68 10 H2 S16 = 34285.49 kg/hr
m N = 16450.95 kg/hr
2
m mLLDPE = 34246.58 kg/hr

m
a .c m
a .c = 38.92 kg/hr
= 38.92 kg/hr
66.58% mLLDPE 99.89% mLLDPE
31.98% N2 0.11% active catalyst
1.36% C2H4 T= 76C
5
2.56 10 % H2
 TK-101

Figure 2.2.11: Mass balance of degassing tank (TK-101)

Stream Componen Mass Mass Molar Mass Total

t flow rate flow flow rate compositio mass
(kg/hr) rate (kmol/hr n (mass %) flow rate
(ton/hr) ) (kg/hr)
Input S15 mLLDPE 34246.5 34.25 3.20 10166.58 51435.3
8 6
Ethylene 698.90 6.99 1024.91
1
1.36
Hydrogen 1.32 1.32 1056.53 103 2.56 105
102
Nitrogen 16450.9 16.45 587.26 31.98
5
Active 38.92 3.89 1025.84 103 7.57 102
catalyst
output S17 Ethylene 698.90 6.99 1024.91
1
4.08 51435.3
6
Hydrogen 1.32 1.32 1056.53 103 7.68 105
102
Nitrogen 16450.9 16.45 587.26 95.92
5
S16 mLLDPE 34246.5 34.25 3.20 10199.89
8
Active 38.92 3.89 10 5.84 10 0.11
2 3

catalyst
Table 2.2.11: Input-Output of degassing tank (TK-101)

Mass balance for mixer (TK-101):

Input = output

S 15=S 17+ S 16
kg kg kg
51435.36 =17149.86 + 34285.5
hr hr hr
 698.90
Mass composition of ethylene in S17 17149.86 100

=4.08%

1.32 102
Mass composition of hydrogen in S17 100
17149.86
5
=7.68 10

16450.95
Mass composition of nitrogen in S17 17149.86 100

=95.92%

34246.58
Mass composition of mLLDPE in S16 34285.49 100

=99.89

38.92
Mass composition of active catalyst in S16 34285.49 100

=0.11%

Overall mass balance

Catalyst = 38.92
kg/hr

Ethylene = 34944.83
kg/hr LLDPE= 34285.49
kg/hr
Hydrogen= 6.58 x 10-1 Purge= 17149.86
kg/hr kg/hr

Nitrogen = 16450.95 kg/hr

Total Input value = Total Output value
Total Input value = 51435.358 kg/hr 2.2.12: Overall mass balance
Figure
Total Output value = 51435.35 kg/hr
The insignificant value between total input and total output value due to limitation of manual
calculation decimal places that have been rounded off to two decimal places.
2.3 Conversion, Selectivity and Yield of desired product

2.3.1 Conversion of reaction

Chemical reactions do not take place instantaneously and indeed often proceed rather
slowly. It is not practical to design the reactor for complete conversion, instead the reactor
effluent emerges with some of the reactant still present and is then usually subjected to
separation process to remove the unconverted reactant from the product. The separated
reactant is then recycle to the reactor inlet.

In this process, the reaction only take place in fluidized bed reactor where ethylene is
undergo polymerisation to form polyethylene, mLLDPE

The fractional conversion of a reactant is the ratio:

mole reacted
Fractional conversion = mole feed

1220751.25 mol /hr

1245664.54 mol /hr

0.98

mole reacted
percentage of conversion= 100
mole feed

1220751.25 mol /hr

100
1245664.54 mol /hr

98

2.3.2 Yield and Selectivity

The term yield and selectivity are used to describe the degree to which a desired reaction
predominates over competing side reactions.
moles of desired product formed
Yield=
moles that would have been formed if there were no side reactions
thelimiting reactant had reacted completely

moles of desired product f ormed

moles of reactant fed

moles of desired product formed

moles of reactant consumed

moles of desired product formed

In this calculation yield= moles of reactant fed , is use to calculate the yield of

the process.

3814 C 2 H 4 + H 2 H( C 2 H 4 )3814 H

The hydrogen gas is used as reactant in calculation of yield, as the result will be more
significant compare to if ethylene is used. From the equation, it show that one mole of
hydrogen required in producing one mole of mLLDPE.

The amount of hydrogen gas feed= 326.6031830432 mol/hr

The amount of mLLDPE produce= 320.0711193824 mol/hr

320.0711193824 mol /hr

Yield=
326.6031830432 mol/hr

320.0711193824 mol/hr

326.6031830432 mol/hr

0.98

moles of desired product formed

Selectivity=
moles of undesired product formed

Since there is no undesired product form , where only have one produce form which is
mLLDPE from ethylene. Therefore the selectivity of the reaction is equal to 1.
2.4 Stream Table
Stream no. 1 2 3 4 5 6 7 8 9 10 11

Temperature (C) 25 25 25 25 25 25 25 25 25 44 44

Pressure (bar) 1 20 1 20 1 22 1 22 21.5 20.5 20

Vapour fraction 1 1 0 1 1 1 1 1 1 1 1

Mass flow rate 16.4 16.4 3.8916.49

10
2 34.94 34.94 6.58 10 34.95
4
6.58 10
4 34.95 34.95
(ton/h) 5 5

Mole flow rate 587. 587. 587.23

5.84 10 1245. 1245. 3.27 10 1 1245.1
3.27 10 1245. 1245.
(kmol/h) 26 26 7 66 66 99 99 99

Individu Ethylen 0 0 0 0 1245. 1245. 0 0 1245. 1245. 1270.

al e 66 66 66 66 58
compon
ent mole Hydrog 0 0 0 0 0 0 3.27 10 1
3.27 101
3.27 10 1
3.27 10 1
3.33 101
flow rate en
(kmol/h)
Nitroge 587. 587. 0 587.2 0 0 0 0 0 0 587.2
n 26 26 6 6

Active 0 0 5.84 10 0
3
5.84 10
3 0 0 0 0 0 0
catalyst

mLLD 0 0 0 0 0 0 0 0 0 0 0
PE
Stream no. 12 13 14 15 16 17 18 19 20 21

Temperature (C) 76 76 44 76 76 76 25 40 25 40
Pressure (bar) 18.3 21.5 20.5 18.5 1 1 2 1.5 2 1.5

Vapour fraction 1 1 1 1 1 1 0 0 0 0
Mass flow rate (ton/h) 17.15 17.15 17.15 51.44 17.15 34.29 16.86 16.86 9.35 9.35

Mole flow rate 612.18 612.18 612.18 612.51 325.92 612.18 936.9 936.9 519.2 519.2
(kmol/h) 3 3 2 2

Individual Ethylene 24.91 24.91 24.91 24.91 0 24.91 0 0 0 0

componen
t mole Hydroge 6.53 10
3
6.53 10
3
6.53 10 0
6.53 10
3 3 0
6.53 10
3 0 0 0
flow rate n
(kmol/h)
Nitrogen 587.26 587.26 587.26 587.26 0 587.26 0 0 0 0

Active 0 0 0 5.84 103

5.84 0 3
10 0 0 0 0
catalyst

mLLDP 0 0 0 3.20 10 1
3.20 0 1
10 0 0 0 0
E

Water 0 0 0 0 0 0 936.9 936.9 519.2 519.2

3 3 2 2

Table 2.4: Stream table

REFERENCE

Felder, R., Rousseau, R., & Bullard, L. Elementary principles of chemical processes (1st ed.)

The Law of Conservation of Mass: Definition, Equation & Examples - Video & Lesson
Transcript | Study.com. (2017). Study.com. Retrieved 21 March 2017, from
http://study.com/academy/lesson/the-law-of-conservation-of-mass-definition-equation-
examples.html

http://www.chemicalbook.com/ChemicalProductProperty_EN_CB8193937.htm

https://tel.archives-ouvertes.fr/tel-01245076/file/RAPAKOUSLOU_AMALIA_2014.pdf
http://www.convertunits.com/molarmass

Metallocene catalysts in dissolved forms are unsuitable for the production of polyethylene or
isotactic polypropylene on an industrial scale. In order to use them in existing technical
processes (drop-in technology) by exchanging them for the conventional ZieglerNatta
catalysts, the metallocenes have to be applied to a powdery, insoluble substrate. One way to
do so is to support them on silica, alumina, magnesium dichloride or other supports.