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Lecture 3
First level:
we consider batch processes only if at least one of the following holds. We must get the process operational in a few months. The product is one where the first company to market wins an enormous competitive advantage. We need only a few days production for a year's supply. We have little design information and the process is sensitive to upsets and variations. The product will likely have a total lifetime of one to two years before some other product will come out that replaces it. The value of the product overwhelms the cost to 3 manufacture it.
level 2:
we consider the number of raw material and product streams and their overall relation to the process. We also consider the presence of by-products and inert components in the process and how they participate in the reaction chemistry. An important question is the recovery of these compounds. At this level, a process recycle may be needed for the reactor, and the designer needs to consider the addition of purge streams to avoid the buildup of inert components or byproducts.
4
Level 4 is
divided into two decision stages: vapor and liquid recovery. Raw materials from this step will be recycled to the reactor while products and byproducts are generally processed further and removed. In vapor recovery, the more expensive stage, we also need to consider the effect of purge streams and the removal of components based on their value and their effect on the reactor if they are recycled. In the liquid recovery stage, we prefer to use distillation, as this is often the least expensive separation. Design decisions at this stage include sequencing of the separators and determining their operating conditions.
6
BP (oC)
Water Ethyl alcohol Ethylene Di ethyl ether Methane Propylene Isopropyl alcohol M, E-M 100 78.4 -103.7 34.6 -161.5 -47.7 82.4 E, PL- E
Tcritical (oC)
374.4 243.1 9.6 193.8 -82.1 91.4 235.16
Pcritical (atm)
217.6 63.1 50.7 35.5 45.8 45.4 47.0
Absorber
Diethyl ether Water Compressor Reactor
Ethanol
Flash
DC
DC
DC
Ethylene
Water + waste
W
EL Sepn M PL EL M DEE EA W EL W REACTOR EL DEE EA W
EL W EA DEE
EL PL M W
EL PL M
Sepn
Sepn PL
EL M
REACTOR
Sepn
M EL W
EA DEE
W EL PL M
REACTOR
EL PL M DEE EA W
Sepn
EA DEE
M PL IPA
Step 5. Write out the chemical reactions involved for the main products and byproducts. Step 6. Note any other constraints, such as specified stream compositions, azeotropes, phase or reaction equilibrium, tie substances Step 7. Note any stream compositions and flows that can be approximated. Step 8. Check the number of conservation (and other) equations that can be written, and compare with the number of unknowns. Decide which variables are to be design variables; Step 9. Decide the basis of the calculation.