Académique Documents
Professionnel Documents
Culture Documents
Authors:
Daniel Du, Aditya Limaye, Jonathan Melville, and Giulio Zhou
Emails:
du.daniel.x@berkeley.edu, amlimaye@berkeley.edu, jmelville@berkeley.edu, gzhou123@berkeley.edu
Instructor:
Clayton Radke
Contents
1 Introduction
2 Design Approach
3 Results
4 Recommended Design
Appendices
A Equations
A.1 Constants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.1 Expressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Derivations
10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
C Graphs
11
11
11
12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D MATLAB Code
13
Introduction
In this project, our aim was to provide specifications for a plant for the polymerization of polystyrene
from styrene in terms of single-pass conversion, with the ultimate goal of optimizing the total cost of
the reactor in terms of the single-pass conversion. As such, we divided our work into two major
phases:
First, to define several characteristics of the reactorincluding volume, flow rate, total conversion,
and pressure dropin terms of the single-pass conversion of the reactor, and
Second, to minimize the cost of the reactor (which we can calculate in terms of the variables from
the previous phase) in terms of the single-pass conversion of the reactor.
The overarching goal of these two phases was to find the optimal reactor design such as to minimize
the necessary capital required, as if in an industry environment.
Design Approach
We began with a process flow diagram of the plant, as seen in Figure 1. A constant feed of styrene
(F) is mixed with a small amount of initiator (I) and fed into a plug-flow reactor (PFR). The reactor
output is fed into an evaporator, which separates an amount of styrene into a recycle feed (R)
necessary to satisfy a given recycle ratio, while the remainder is released in an output stream (P)
containing polystyrene product, unreacted styrene, and trace amounts of unused initiator.
(1)
dXM
rM
=
dV
nsty,in
(2)
dP
0.079 2v 2
=
dV
A Re1/4
(3)
(Derivations for these equations are provided in Appendices B.3.1 and B.3.2, on page 9.)
3
The given cost per cubic meter of PFR was $200. The given cost per Watt was $15 105 . The
cost of the monomer feed was $70 per kg/hr of feed into the system. We used these cost values to find
the total cost of each reactor and to obtain the minimum total cost reactor. The total cost is the sum
of the costs of feed into the system, power, and reactor volume (Equation 4):
Costtotal = $200 V + $70 (F + I) + $15 105 P ower
(4)
We found the reactor values pertaining to this particular PFR and these values are stated in the
following results section. Graphs of reactor cost vs. conversion, feed, and volume can be found in
Appendix C on page 11, and the MATLAB code used to generate these graphs can be found in
Appendix D on page 13.
Results
By implementing the design equations, we obtain a graph (Figure 2) representing total cost as a
function of single-pass monomer conversion, with a minimum cost of $107,087.10 at 37.5% conversion
(Figure 2). From our cost analysis, we know that the total capital and operating costs depend on the
volume, feed, and power costs. The volume cost scales directly with monomer conversion, but factors
minimally into the total cost and is thus negligible. The minimum cost, therefore, depends on how the
feed and power costs scale with increasing conversion. While higher single-pass conversion rates
decrease feed requirements, they lead to higher mixture viscosities, increasing the pressure drop across
the reactor and the power required to pump the mixture. As a result, the overall cost is minimized
when the sum of the feed and power costs is at a minimum.
Figure 2: The relative costs of production of a reactor in relation to the constraints of the problem and
the single-pass conversion of the reactor is shown. We see a minimum at 37.5% styrene conversion.
Recommended Design
Based on the previous calculations, we recommend constructing a polystyrene plant that utilizes a
PFR operating at a monomer conversion of 37.5%, requiring a reactor volume of 36.05 cubic meters.
Given a reactor diameter of 0.1 meters, the reactor length must be 4.6 kilometers. This is a
reasonable length because the volume of a PFR may be arranged in any fashion, meaning the reactor
tube may be coiled in order to save space.
At these reactor specifications, 1.33 103 kilograms of styrene monomer1 and 2.94 grams of
azobisisobutyronitrile (AIBN) initiator must be fed every hour. Due to the changing viscosity of the
reaction mixture across the length of the PFR, the reactor must be outfitted to withstand a pressure
drop of 5.49 105 atmospheres. Such a large pressure drop across the reactor requires special safety
precautions, such as thick, reinforced walls and process control systems to prevent any catastrophic
reactor accidents.
Furthermore, in order to operate at a recycle ratio of 1, 1.33 103 kilograms of unconverted
styrene monomer must be recycled back into the feed stream from the reactor outlet. The final cost of
operating the reactor, considering the feed cost, reactor size, and pumping costs, totals to $1.07 105 .
1
Because approximately 1000 kgs of polystyrene come out for every 1,330 kg of reactant in, the resultant purity of the
1000
polystyrene product is about 1330
, which is approximately 75%.
Appendices
A
Equations
A.1
Constants
A.1.1
Rate Constants
Symbol
A.1.2
Value
kd
1
0.85 105 sec
kp
m
0.145 molsec
kt
m
5.8 104 molsec
Reactor Givens
Given
Symbol
A.1.3
Expression
22 mol
m3
CIO
Temperature
(60 + 273.15)K
0.1m
Area of a Plug
2
( D
2)
Other Givens
Given
Symbol
Expression
kg
(0.2778) sec
Density
kg
909.3 m
3
A.2
Mstyr
g
104.15 mol
A.2.1
Expressions
Parameter
Symbol
m
sty,in
n sty,in
Flowrate (Volumetric)
Expression
P kg
xM sec
m
sty,in mol
Mstyr sec
m
sty,in m3
sec
QIO
(CIO Q) mol
sec
CM O
n sty,in mol
Q m3
Q m
A sec
A.2.2
Initiator Concentration
CI
CIO (1 xI ) mol
m3
Monomer Concentration
CM
CM O (1 xM ) mol
m3
d
I
2R
kp
rI = kd CI
R + M RM
(5)
kp
RMn + M RMn+1
k
rM = kp (
t
Mi + Mj
Mi+j
2kd cI 1
) 2 cM
kt
(6)
Derivations
B.1
Necessary Conversions
Throughout the givens list, there are inconsistencies in units. This section is dedicated to converting
those to a single system of standards involving:
Volume: m3
Mass: kg
Moles: mol
Time: s
Temperature: K
Pressure: Pa
There are two exceptions to this rule, which are in the average molecular mass of the polymer chains
and the mass flowrate of the total feed into the system. The molecular mass term is calculated in
terms of g/mol. The mass flowrate term is calculated in terms of kg/hr.
B.1.1
Rate Constants
kd = 0.85 105 s1
1m3
1000L
L
107 mols
=
L
kp = 145 mols
m
= 0.145 molsec
kt = 5.8
5.8 107
B.1.2
1m3
1000L
m
= 5.8 104 molsec
1 hr
3600 s
0.2778 kgs1
1 kg
1000 g
= 0.10415 kgmol1
B.2
1000 L
1 m3
= 22 molm3
We assume that we are given a certain conversion wanted and label this conversion Xwant . We have
all the givens mentioned in the previous page.
2
Area of a Plug (A) = D
2
B.2.1
At any given moment, we know that the moles flowing out of any particular volume is equivalent to
the moles into that volume subtracting away the conversion of the moles in. In equation form, this
becomes: nout = nin nin X
If we multiply through by molar mass M , we get: mout = min min X
Solving for min , we find: min =
mout min
X
mconverted
,
X
particular species.
Applying this result to the design problem, we see that the amount of styrene converted is the
amount of polymer exiting the reactor. Taking the conversion wanted, the mass of styrene going into
kg
1000
3600Xwant s
(7)
msty,in
Msty
(8)
msty,in m3
mixture s
(9)
nsty,in mol
Q m3
(10)
mol
s
(11)
Qm
A s
(12)
We first find the moles at any conversion constrained by the other variables affecting the PFR. We
take the earlier result: n = nin nin X
We divide by the flowrate in order to find the concentration:
n
nin nin X
=
Q
Q
Q
C = C0 C0 X
= C0 (1 X)
(13)
We apply this result to the initiator and the monomer concentrations and obtain:
B.3
B.3.1
CI = CIO (1 XI )
(14)
CM = CM O (1 XM )
(15)
Conversion as stated in the section title refers to the conversion at any point along the PFR
constrained by the wanted conversion and any other variables derived from it.
For the mass balance of a particular species along a single plug of the reactor, we have:
mout = min + M rdV , where M is the molar mass, r is the rate at which the mass of amount of
species changes as it is generated or consumed, and dV is the volume of the plug.
8
Dividing through by molar mass, we have a mole balance: nout = nin + rdV
By solving for r, we achieve the relation:
nout nin
dV
=r
If we take the plug to be a very thin slice, we obtain a differential of the change in moles with respect
to the change in volume of a single thin plug:
dn
dV
=r
Now we take the definition of moles along a plug in relation to conversion from our earlier results and
have n = nin nin X
By taking the derivative of this in relation to volume, we have:
dn
dV
= nin dX
dV
Relating the conversion differential and the rate differential, we have our final conversion differential
equation:
dX
dV
= nrin
When we apply this result to the initiator and the monomer, we have:
B.3.2
dXI
rI
=
dV
QI
(1)
dXM
rM
=
dV
nsty,in
(2)
(16)
where f is the friction factor within the PFR at any distance x, P is the pressure at any distance x,
and Re is the Reynolds number (defined later). The last part is the particular friction factor that
obeys the Blasius relation for a simple liquid in a circular pipe.
The Reynolds number is defined as:
Re =
Dv
,
(17)
2013
T
1K
Mw0.18 (3.915wp
5.437wp2
0.623 +
1387
T
1K
!
wp3
(18)
where Mw is the average molecular mass (in g/mol) of polymer at a certain point, wp is the mass
percentage of polymer in the mixture, and is measured in Pas.
The average molar mass of the polymer formed is
s
Mw =
2+3
!
2kt
(CM O CM ) Msty 1000 g/kg
kd CI
(19)
Looking at wp , we remember that the initiator is very dilute within the reaction mixture. Taking this
into account, we realize that the weight percentage of polystyrene is merely the converted amount of
styrene(XM ).
Rearranging the friction factor relation and dividing by area:
0.079 2v 2
dP
=
dV
A Re1/4
9
(3)
B.4
B.4.1
Determining Feed
The most important part of the system in determining the amount of cost required to run the reactor
is the amount of total feed entering the system. To calculate this, we need to take into account the
recycle stream, for which we have a recycle ratio to the amount of styrene coming into the system. If
we take the feed to be F , and the recycle to be R, then the recycle ratio is:
R
F
= Y . The fraction of
the total styrene feed entering the system is thus the reactor styrene feed times the following fraction:
1
Y +1 .
We must also take into account the amount of initiator entering the system. This term is:
minit,in = Minit QCIO , where Minit is the initiator molar mass in kg/mol.
Thus, the total amount of mass entering the system is:
F = msty,in
B.4.2
1
+ Minit QCIO
Y +1
(20)
Determining Power
dWork
dt
d(P V )
dt ,
d(P V )
dt
dP
dV
V +
P
dt
dt
dP
V
dt
V
P
dt
QP
(21)
where P is the overall pressure drop across the PFR and the second term in the second line
disappears since the volume of the reactor does not change over time.
B.5
We merely multiplied all the costs by their respective streams for multiple wanted conversions and
found the optimal (i.e. minimum) total cost.
10
C
C.1
Graphs
Cost vs. Monomer Conversion
Figure 2: The relative costs of production of a reactor in relation to the constraints of the problem and
the single-pass conversion of the reactor is shown. We see a minimum at 37.5% styrene conversion.
C.2
Figure 3: The relative costs of production of a reactor in relation to the constraints of the problem and
the feed of the reactors is shown. We see a minimum at 1330 kilograms per hour.
11
C.3
Figure 4: This graph shows the relative costs of production of a reactor in relation to the constraints
of the problem and the volumes of the reactors. We see a minimum occur at 36.05 meters cubed.
12
MATLAB Code
2
3
Y = 1;
%Recycle Ratio
VR = 0:0.05:50;
XI0 = 0;
XM0 = 0;
P0 = 0;
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
for i = 1:400
19
20
21
22
23
24
25
26
27
28
29
30
31
end
32
33
34
35
36
37
38
39
VReq(i) = V(index);
%Calculation for Power
dense = 909.3;
poly = 1000/3600;
sty m = poly./ConvWant;
Q = sty m./dense;
Power(i) = 1.*X(index,3).*Q;
40
41
42
43
44
45
46
%Next conversion.
ConvWant = ConvWant + .001;
47
48
49
50
51
M AIBN = 164.21;
CI0 = 22;
%Flowrate of Total Feed in kg/hr
MF(i) = (1000/ConvWant)*(1/(Y+1));
13
%g/mol
%mol/m3
52
53
54
55
end
56
57
58
59
60
61
%% Cost
VCost =
WCost =
FCost =
TotCost
Calculations
VReq.*200;
Power.*15*10(5);
F.*70;
= VCost+WCost+FCost;
62
63
64
65
66
Conversion = 1:400;
Conversion = Conversion.*.001+.099;
67
68
69
70
71
72
73
74
IdealConv = Conversion(MinIndex);
IdealVolume = VReq(MinIndex);
IdealFeed = F(MinIndex);
IdealMF = MF(MinIndex);
IdealIF = IF(MinIndex);
75
76
77
78
79
80
81
fprintf('Ideal
fprintf('Ideal
fprintf('Ideal
fprintf('Ideal
fprintf('Ideal
fprintf('Ideal
82
83
84
%% Plot
plotall(Conversion, VReq, F, TotCost, VCost, WCost, FCost, IdealConv, ...
IdealVolume, IdealFeed, MinCost);
85
86
%% Diffeq Function
87
88
89
90
91
92
%ddV(1) is dXIdV
%ddV(2) is dXMdV
%ddV(3) is dPdV
93
94
%%Constants
95
96
97
98
99
%Rate Constants
kd = 0.85*10(5);
kp = .145;
kt = 5.8*10(4);
100
101
%Given Constants
102
103
104
105
poly = 1000/3600;
dense = 909.3;
M sty = .10415;
%kg/s
%kg/m3
%kg/mol
14
CI0
T =
D =
A =
106
107
108
109
= 22;
60+273.15;
0.1;
pi*D2/4;
%mol/m3
%K
%m
%m3
110
111
112
113
114
115
116
117
118
%%VolumeDependent Variables
CI = CI0.*(1X(1));
%Concentration of I at Volume V mol/m3
CM = CM0.*(1X(2));
%Concentration of M at Volume V mol/m3
119
120
121
122
%%Rate Laws
ri = kd.*CI;
rm = kp.*(2.*kd.*CI./kt).(1/2).*CM;
123
124
125
126
%%Pressure Laws
Mw = (2+3.*(2.*kt./(kd.*CI)).(1/2).*(CM0CM)).* M sty. *1000;
wp = X(2);
mu = exp(13.04+2013./T+(Mw./1).(0.18).*...
(3.915.*wp5.437.*wp2+(0.623+1387./T).*wp3));
Re = D.*vel.*dense./mu;
127
128
129
130
131
132
133
134
135
136
137
138
end
139
140
%% Plotting Function
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
15
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
end
198
199
end
16