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DESIGN EXERCISE
DEPARTMENT OF CHEMICAL ENGINEERING
UNIVERSITY OF MALAYA
SESSION 2014/2015, SEMESTER 2
GROUP: 6
LECTURER: DR. BRAHIM SI ALI
NAME OF GROUP MEMBERS
MATRICS NO.
ARUNAN MOHANAN
KEK 120023
NG SAU WEI
KEK 120037
KEK 120038
KEK 120049
KEK 120064
1.0 INTRODUCTION
Chlorine is a very important raw material in the industry to produce large amount of
chlorine-based products. It is commonly used it the production of plastics, solvents for
dry cleaning and metal degreasing, textiles, insecticides, household cleaning products
and others. In the industry, chlorine is usually produced by the electrolysis of NACl, with
co-product of caustic soda. However, surplus of alkali and deficit of chlorine are the
common problems in the current world. The byproduct, HCl that usually produced from
the process also cause disposal problem to the environment. Thus, many methods have
been proposed in the industry to recover chlorine from hydrogen chloride such as
electrolysis, direct oxidation and Deacon Process. For electrolysis process, there is
always a limitation where the equipment investment and energy consumption are very
high. For direct oxidation, the conversion of HCl is not so efficient and more waste need
to be disposed. As the result, Deacon process become the preferable choice in the
industry.
Deacon process is a catalytic oxidation process, in which HCl is oxidized by
oxygen or air in the presence of CuCl2 catalyst at about 400C to produce chlorine as the
final product. Deacon process usually involves two steps of reaction which are oxidation
and chloridation. The chemical reactions are as follow:
H = -28.8 kcal/mol
H = 15.0kcal/mol
2.0 OBJECTIVES
To come up with mass and energy balances for the reaction.
To generate process flow diagram (PFD) by using software such as AutoCAD,
AspenTech etc.
To design the unit operations that have been chosen for the process in terms
of
a. Chemical Engineering design
b. Mechanical Engineering design
18.00
71.00
36.50
32.00
28.00
98.08
kmol/kg
kmol/kg
kmol/kg
kmol/kg
kmol/kg
kmol/kg
Name
CAS #
Hydrogen chloride 7647-01-0
Water
7732-18-5
% by Weight
20-38
62-80
3.4 Standards
Code of professional conduct is followed before and while designing this plant.
Hold paramount the safety, health and welfare of the public and protect
the environment in performance of the professional duties.
Accept responsibility for the actions, seek and heed critical review of their
work and offer objective criticism of the work of others.
Issue statements or present information only in an objective and truthful
manner.
No heat loss
Isothermal condition
2(
2(
( )
2:
2:
38.67 kmol/h
1411.46 kg/h
1.0000
1.0000
HCl(g)
Molar rate
Mass rate
Mole frac
Mass frac
11.02 kmol/h
352.64 kg/h
0.2100
0.2099
N2 (g)
Molar rate
Mass rate
Mole frac
Mass frac
47.40 kmol/h
1327.76 kg/h
0.7900
0.7901
Molar rate
Mass rate
Mole frac
Mass frac
O2
(g)
Molar rate
Mass rate
Mole frac
Mass frac
Molar rate
Mass rate
Mole frac
38.67 kmol/h
1411.46 kg/h
0.3983
0.4566
11.02 kmol/h
352.64 kg/h
0.1135
58.44 kmol/h
1680.40 kg/h
1.0000
1.0000
H2O
(g)
Molar rate
35.42 kmol/h
Mass rate 1292.83 kg/h
Mole frac 0.9747
Mass frac 0.9762
Molar rate
Mass rate
Mole frac
1.00 kmol/h
18.00 kg/h
0.0200
Mass frac
N2 (g)
Molar rate
Mass rate
Mole frac
Mass frac
0.1141
47.40 kmol/h
1327.20 kg/h
0.4882
0.4293
1.0000
1.0000
HCl(g)
H2O
(g)
Molar rate
74.09 kmol/h
Mass rate 2704.30 kg/h
Mole frac 0.5553
Mass frac 0.6124
Mass frac
Cl2
(g)
Molar rate
Mass rate
Mole frac
Mass frac
0.0136
0.19 kmol/h
13.49 kg/h
0.0052
0.0100
H2O
(g)
Molar rate
38.83 kmol/h
Mass rate 1417.30 kg/h
Mole frac 0.3100
Mass frac 0.3205
Molar rate
Mass rate
Mole frac
Mass frac
1.00 kmol/h
18.00 kg/h
0.0055
0.0041
Molar rate
Mass rate
Mole frac
Mass frac
18.97 kmol/h
341.46 kg/h
0.1515
0.0772
Cl2 (g)
Molar rate
Mass rate
Mole frac
Mass frac
0.19 kmol/h
13.49 kg/h
0.0014
0.0031
Cl2 (g)
Molar rate
17.82 kmol/h
Mass rate 1265.22 kg/h
Mole frac 0.1423
Mass frac 0.2861
N2(g)
Molar rate
Mass rate
Mole frac
47.4 kmol/h
1327.2 kg/h
0.3552
N2(g)
Molar rate
Mass rate
Mole frac
47.4 kmol/h
1327.2 kg/h
0.3785
Mass frac
O2(g)
Molar rate
Mass rate
Mole frac
Mass frac
0.3006
11.02 kmol/h
352.64 kg/h
0.0824
0.0799
Mass frac
O2(g)
Molar rate
Mass rate
Mole frac
Mass frac
0.3001
2.22 kmol/h
71.04 kg/h
0.0177
0.0161
H2O (l)
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
kmol/h
kg/h
Concentration
37.76
1378.09
0.2170
0.3598
845.45
4.47E02
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
136.23
2452.22
0.7830
0.6402
2.46
55.4444
kmol/h
kg/h
(STREAM 10)
ACID FRESH FEED before recycle
Total molar rate=
Total mass rate=
Total mole fraction=
Total mass fraction=
HCl(l)
m3/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
mol/L
Concentration
4.47E-02 mol/L
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
46.41
835.46
0.9913
0.9826
0.84
55.4444
H2O
(l)
m3/h
mol/L
(STREAM 7)
GAS INLET FROM REACTOR
Total molar rate=
Total mass rate=
Total mole fraction=
Total mass fraction=
HCl(g)
H2O (g)
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
Molar rate
Mass rate
0.41 kmol/h
14.81 kg/h
0.0087
0.0174
9.09 m3/h
kmol/h
kg/h
m3/h
mol/L
(STREAM 13)
GAS OUTLET TO 2ND ABSORBER
125.24 kmol/h
4386.76 kg/h
1.0000
1.0000
38.83
1417.44
0.3101
0.3231
1762.99
0.0220
46.82 kmol/h
850.27 kg/h
1.0000
1.0000
kmol/h
kg/h
m3/h
mol/L
18.97 kmol/h
341.38 kg/h
H2O (g)
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
Molar rate
Mass rate
87.28 kmol/h
3250.18 kg/h
1.0000
1.0000
14.34
523.25
0.1643
0.1610
342.44
0.0419
kmol/h
kg/h
m3/h
mol/L
5.50 kmol/h
98.99 kg/h
Mole frac
Mass frac
Volume rate
Concentration
Cl2 (g)
N2(g)
O2(g)
0.1514
0.0778
424.60 m3/h
0.0447 mol/L
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
17.82
1265.22
0.1423
0.2884
422.59
0.0422
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
47.4
1327.2
0.3785
0.3025
1061.25
0.0447
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
2.22
35.52
0.0177
0.0081
24.86
0.0893
kmol/h
kg/h
HCl(l)
H2O (l)
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
Molar rate
N2(g)
m3/h
mol/L
m3/h
mol/L
211.95 kmol/h
4966.73 kg/h
1.0000
1.0000
62.25
2272.13
0.2937
0.4575
1393.94
0.0447
Cl2 (g)
m3/h
mol/L
(STREAM 8)
LIQ OUTLET FROM BOTTOM
Total molar rate=
Total mass rate=
Total mole fraction=
Total mass fraction=
Mole frac
Mass frac
Volume rate
Concentration
kmol/h
kg/h
m3/h
mol/L
149.70 kmol/h
O2(g)
0.0630
0.0305
123.13 m3/h
0.0447 mol/L
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
17.82
1265.22
0.2042
0.3893
422.59
0.0422
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
47.4
1327.2
0.5431
0.4083
1061.25
0.0447
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
2.22
35.52
0.0254
0.0109
24.86
0.0893
kmol/h
kg/h
m3/h
mol/L
m3/h
mol/L
m3/h
mol/L
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
2694.60 kg/h
0.7063
0.5425
2.70 m3/h
55.4444 mol/L
(STREAM 15)
PURGE TO EXPELLER
Total molar rate=
Total mass rate=
Total mole fraction=
Total mass fraction=
HCl(l)
H2O (l)
(STREAM 9)
RECYCLE BACK TO SCRUBBER
84.78 kmol/h
1986.69 kg/h
1.0000
1.0000
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
24.90
908.85
0.2937
0.4575
557.58
0.0447
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
59.88
1077.84
0.7063
0.5425
1.08
55.4444
kmol/h
kg/h
m3/h
mol/L
m3/h
mol/L
H2O (l)
127.17 kmol/h
2980.04 kg/h
1.0000
1.0000
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
37.35
1363.28
0.2937
0.4575
836.37
0.0447
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
Mass frac
Volume rate
Concentration
89.82
1616.76
0.7063
0.5425
1.62
55.4444
kmol/h
kg/h
m3/h
mol/L
m3/h
mol/L
(STREAM 23)
IN FROM RECYCLE ( 36%HCL)
Total molar rate=
169 kmol/h
Total mass rate=
3741 kg/h
Cl2 (g)
HCl(aq)
H2O (l)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
25
909
0.2937
60
1078
0.7063
kmol/h
kg/h
HCl(aq)
kmol/h
kg/h
H2O (l)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
0.1897
13
0.0011
37
1354
0.2192
132
2374
0.7797
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
(STREAM 16)
MIXED OUTLET
Total molar rate=
Total mass rate=
Cl2 (g)
HCl(aq)
H2O (l)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
254 kmol/h
5728 kg/h
0.1897
13
0.0007
62
2262
0.2441
192
3452
0.7552
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
EXPELLER
(STREAM 16)
LIQUID FEED
Total molar rate=
254 kmol/h
Total mass rate=
5728 kg/h
Cl2 (g)
Molar
rate
Mass rate
0.1897 kmol/h
13 kg/h
(STREAM 14)
STEAM IN
Total molar rate=
Total mass rate=
Steam at 200psig
19 kmol/h
335 kg/h
HCl(aq)
H2O (l)
Mole frac
Molar
rate
Mass rate
0.0007
Mole frac
Molar
rate
Mass rate
Mole frac
0.2441
62 kmol/h
2262 kg/h
192 kmol/h
3452 kg/h
0.7552
(STREAM 19)
OUT, LIQUID (EFFLUENT)
Total molar rate=
218 kmol/h
Total mass rate=
4409 kg/h
Molar rate
Mass rate
Mole frac
27 kmol/h
970 kg/h
0.1221
H2O (l)
Molar rate
Mass rate
Mole frac
191 kmol/h
3439 kg/h
0.8779
2791
kJ/kg
842
kJ/kg
(STREAM 17)
OUT, VAPOR ( RECYCLE)
Total molar rate=
51 kmol/h
Total mass rate=
1589 kg/h
Cl2 (g)
HCl(aq)
198 C
1949 kJ/kg
HCl(g)
H2O
(g)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
0.1858
13
0.0036
35
1293
0.6899
kmol/h
kg/h
Molar rate
Mass rate
Mole frac
16 kmol/h
283 kg/h
0.3065
kmol/h
kg/h
From Scrubber
(Stream 20)
Total = 24
= m*x
= m*y
= 26.57
2 = m*z
2
m*a
)2
=0
2 = 191.06
HCl Absorber
=0
=0
From Scrubber
(Stream 13)
To Splitter 2
(Stream 21)
= 17.82
= 0.2064
= 14.34
= 40.89
2 = 5.5
2 = 146.56
= 47.4
=0
= 2.22
=0
Assumptions
1. Absorption is a non-reactive process, no generation of mass occurs.
2. No consumption of mass and accumulation of mass.
3. Only physical absorption occurs in the packed column HCl absorber
The overall mass balance has been reduced to the simplified form of:
In the process,
13
20
24
24
24
17.82 =
24
24
x = 0.1502
HCl:
14.34 + 26.5735 =
24
24
y = 0.000015
21
5.5 + 191.0641 =
24
24
z = 0.4265
47.4 =
24
24
a = 0.4043
2.22 =
24
Total =
24
= 117.2353kmol/hr
= 17.6136 kmol/hr
= 0.001712 kmol/hr
2
= 50 kmol/hr
= 47.4 kmol/hr
= 2.22 kmol/hr
At Inlet:
HCL ABSORBER
INLET(FROM SCRUBBER)
STREAM 13
INLET(FROM COOLER 2)
STREAM 20
Cl2
18
1276
0.2042
kmol/hr
kg/h
Cl2
0
0
0
kmol/hr
kg/h
HCL
14
523
0.1643
kmol/hr
kg/h
HCL
27
969
0.1221
kmol/hr
kg/h
H2O
6
99
0.063
kmol/hr
kg/h
H2O
191
3439
0.8779
kmol/hr
kg/h
N2
47
1327
0.5431
kmol/hr
kg/h
N2
0
0
0
kmol/hr
kg/h
O2
2
71.025
0.0254
kmol/hr
kg/h
O2
0
0
0
kmol/hr
kg/h
Total
87
3296
kmol/hr
kg/h
Total
218
4408
kmol/hr
kg/h
At outlet:
HCL ABSORBER
OUTLET(BOTTOM)
STREAM 21
OUTLET(TOP)
STREAM 24
Cl2
0.21
15
0.0011
kmol/hr
kg/h
Cl2
18
1249
0.1502
kmol/hr
kg/h
HCL
41
1490
0.2179
kmol/hr
kg/h
HCL
0
0.06
0
kmol/hr
kg/h
H2O
147
2638
0.781
kmol/hr
kg/h
H2O
50
900
0.4265
kmol/hr
kg/h
N2
0
0
0
kmol/hr
kg/h
N2
47
1422
0.4043
kmol/hr
kg/h
O2
0
0
0
kmol/hr
kg/h
O2
2
71
0.0189
kmol/hr
kg/h
Total
188
4143
kmol/hr
kg/h
Total
117
2149
kmol/hr
kg/h
OUTLET(RECYCLE)
STREAM 23
Cl2
0.21
15
0.219
kmol/hr
kg/h
Cl2
0.2
3.34
0.0011
kmol/hr
kg/h
HCL
kmol/hr
kg/h
HCL
37
1341
0.2179
kmol/hr
kg/h
H2O
147
2638
0.781
kmol/hr
kg/h
H2O
132
2374
0.781
kmol/hr
kg/h
N2
0
0
0
kmol/hr
kg/h
N2
0
0
0
kmol/hr
kg/h
O2
0
0
0
kmol/hr
kg/h
O2
0
0
0
kmol/hr
kg/h
Total
188
kmol/hr
Total
169
kmol/hr
4143
kg/h
At outlet:
Splitter 2
Outlet(Product)
Stream 22
Cl2 Molar Flow Rate
0
Mass Flow Rate
0
Mole Fraction
0.0011
kmol/hr
kg/h
4
149
0.2179
kmol/hr
kg/h
15
264
0.781
kmol/hr
kg/h
0
0
0
kmol/hr
kg/h
0
0
0
kmol/hr
kg/h
19
414
kmol/hr
kg/h
3716
kg/h
5.1.4 Dryer
COOLER
IN
OUT(TO DRYER)
3558.97 kg/hr
117.37 kmol/hr
3558.97 kg/hr
117.69 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.43
H2O
Mass rate =
Mole rate=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.42
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.22 kmol/hr
0.02
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.02
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
DRYER
IN(COOLER)
OUT(SULFURIC ACID)
30% H2SO4
Total mass rate= 1297.00 kg/hr
Total mole rate=
54.41 kmol/hr
3558.97 kg/hr
117.69 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.42
H2O
Mass rate =
Mole rate=
Mole fraction=
907.90 kg/hr
50.44 kmol/hr
0.93
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
HCl
Mass rate =
Mole rate=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.07
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.02
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
OUT(Cl2)
Total mass rate=
Total mole rate=
2817.82 kg/hr
76.52 kmol/hr
HCl
Mass rate =
Mole rate=
Mole fraction=
166.76 kg/hr
9.26 kmol/hr
0.70
H2O
Mass rate =
Mole rate=
Mole fraction=
158.86 kg/hr
8.83 kmol/hr
0.12
H2O
Mass rate =
Mole rate=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.30
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.23
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.03
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.62
Mass rate =
389.10 kg/hr
H2O
Mass rate =
0.04 kg/hr
H2O
Mole rate=
Mole fraction=
3.97 kmol/hr
0.90
Mass rate =
Mole rate=
Mole fraction=
7.94 kg/hr
0.44 kmol/hr
0.10
Mole rate=
Mole fraction=
0.00 kmol/hr
0.00
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.23
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.04
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.62
LIQUEFACTION /COMPRESSION
INLET
Total mass rate=
Total mole rate=
2659.01 kg/hr
67.69 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
0.04 kg/hr
0.00 kmol/hr
0.00
Cl2
Mass rate =
Mole rate=
Mole fraction=
HCl
OUTLET
TO LIQUID Cl2 (0.00005% RESIDUE)
Total mass rate= 1261.00 kg/hr
Total mole rate=
17.76 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
1260.87 kg/hr
17.76 kmol/hr
0.26
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
1.00
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
HCl
Mass rate =
Mole rate=
Mole fraction=
0.05 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.04
O2
Mass rate =
Mole rate=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.70
N2
Mass rate =
Mole rate=
Mole fraction=
0.07 kg/hr
0.00 kmol/hr
0.00
TO SNIFF GAS
Total mass rate=
Total mole rate=
1398.01 kg/hr
49.93 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
0.04 kg/hr
0.00 kmol/hr
0.00
Cl2
Mass rate =
Mole rate=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
HCl
Mass rate =
Mole rate=
Mole fraction=
0.01 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.05
N2
Mass rate =
Mole rate=
Mole fraction=
1326.92 kg/hr
47.39 kmol/hr
0.95
a
0.02913
0.0336
0.03346
0.0291
0.029
b
-1.34E-06
1.37E-05
6.88E-06
1.16E-05
2.20E-06
c
9.72E-09
-1.61E-08
7.60E-09
-6.08E-09
5.72E-09
d
-4.34E-12
6.47E-12
-3.59E-12
1.31E-12
-2.87E-12
At mixer:
Stream 1
25
Stream 2
25
20
,2
Stream 3
,2
25
25
20
25
,2
20
25
,2
At reactor:
Reactants
Tref (C)
molar flow
rate, kmol/h
Enthalpy,
kJ/kmol
32
32
32
32
32
25
25
25
25
25
74.09
0.19
1
11.02
47.4
194.1
226.5
224.3
196.2
193.4
Heat of
reactant,
kJ/h
14380.87
43.04
163.74
2162.12
9167.16
25916.93
Temperature,
(C)
Tref (C)
molar flow
rate, kmol/h
Enthalpy,
kJ/kmol
350
350
350
350
350
25
25
25
25
25
38.83
17.82
18.97
2.22
47.4
8029.4
9718.9
9570
8470
8120
311781.6
173190.8
181542.9
18803.4
384888
1070206.7
molar flow
rate,
kmol/h
Enthalpy,
kJ/kmol
Heat of
cool in, kJ/h
38.83
17.82
18.97
2.22
47.4
8029.4
9718.9
9570
8470
8120
311781.6
173190.8
181542.9
18803.4
384888
HCl
Cl2
H2O
O2
N2
total
Temperature,
(C)
HCl
H2O
O2
N2
TOTAL
Products
17.61(-29340)
= -516677.4
Heat of
product,
kJ/h
kJ/h
(
=
527612.37 kJ/h
At Cooler 1:
COOL IN
HCl
Cl2
H2O
O2
N2
Temperature,
(C)
Tref (C)
350
350
350
350
350
25
25
25
25
25
TOTAL
COOL OUT
HCl
Cl2
H2O
O2
N2
TOTAL
1070206.7
Temperature,
(C)
Tref (C)
molar flow
rate,
kmol/h
Enthalpy,
kJ/kmol
65
65
65
65
65
25
25
25
25
25
38.83
17.82
18.97
2.22
47.4
3054
3628
3575
3145
3067
1070206.7
Cooling water is used as the coolant, which is at 24C and flows at 25 kg/h.
The final temperature of the cooling water,
(
)(
Heat of
cool out,
kJ/h
118586.8
64651
67817.8
6981.9
145375.8
403413.3
HCl (g)
2.91E-02
-1.34E-06
C
D
9.72E-09
-4.34E-12
H2O (l)
7.540E-02
H2O (g)
3.346E-02
6.880E-06
Cl2 (g)
3.360E-02
1.367E-05
N2 (g)
2.900E-02
2.199E-06
7.604E-09
-3.593E-12
-1.607E-08
6.473E-12
5.723E-09
-2.871E-12
3
O2 (g)
2.910E-02
1.158E-05
-6.076E09
1.311E-12
Source: Felder, R. & Rousseau, R. Elementary Principles of Chemical Processes (3rd ed.).
, ( )
Stream
T(C)
12
7
8
13
20
65
45
50
Specific heat capacity values for HCl acid at varying compositions & temperature:
Streams
12
8
T(C)
20
45
Mol% HCl
20
30
kJ/kg
-12.36372
52
Tc
T1
T2
Hv(T1)
Hv(T2)
647.4
373
338
2257
2362.34
(1 )
K
K
K
kJ/kg
kJ/kg
2
1
0 38
Tc
T1
T2
Hv(T1)
Hv(T2)
647.4
373
323
2257
2405.23
K
K
K
kJ/kg
kJ/kg
H2O (g)
HCl (g)
N2 (g)
O2 (g)
Cl2 (g)
A
3.55959
4.57389
3.7362
3.9523
4.28814
B
643.748
868.358
264.651
340.024
969.992
C
-198.043
1.754
-6.788
-4.144
-12.791
Psat
0.152832
117.7305
899.703
902.0824
23.43327
y
0.1514
0.3101
0.3785
0.0177
0.1423
1
P * yi / Pi(sat) +=
1.0000
So, stream 7 can be at any temperature above 55 C (dew point) to remain in gas phase.
It is decided that Stream 7 will operate at 65 C.
H2O (g)
HCl (g)
N2 (g)
O2 (g)
Cl2 (g)
A
3.55959
4.57389
3.7362
3.9523
4.28814
B
C
Psat
643.748 -198.043 0.063878
868.358
1.754 96.23644
264.651
-6.788 843.3884
340.024
-4.144 831.2791
969.992 -12.791 18.3285
P * yi / Pi(sat) +=
y
0.0630
0.1643
0.5431
0.0254
0.2042
1
1.0000
So, Stream 13 can be operated at any temperature above 40 C (dew point) to remain in gas
phase.
It is decided that Stream 13 will be operated at 55C.
Initially, it is assumed that the packed column scrubber is ADIABATIC. So the energy balance
equation is reduced to:
H2O (l)
Mass rate
Enthalpy
Molar rate
Enthalpy
20 C
1378.09 kg/hr
-17038.29 kJ/hr
-4.73286 kW
136.23 kmol/h
-0.05136 kJ/hr
-0.00001 kW
Temperature=
65 C
HCl(g)
Molar rate
Enthalpy
38.834 kmol/h
0.04519 kJ/hr
1.255E-05 kW
H2O (g)
Mass rate
Molar rate
Enthalpy
341.38
18.97
8.065E+05
224.01549
Cl2 (g)
Molar rate
Enthalpy
17.82 kmol/hr
0.02436 kJ/hr
6.768E-06 kW
N2(g)
Molar rate
Enthalpy
47.40 kmol/hr
5.519E-02 kJ/hr
1.533E-05 kW
kg/h
kmol/hr
kJ/hr
kW
O2(g)
Molar rate
Enthalpy
2.22 kmol/hr
0.00263 kJ/hr
7.303E-07 kW
)
;5
;6
H2O (g)
Molar rate
5.50
Mass rate
98.99
Enthalpy 238100.31
66.14
Cl2 (g)
Molar rate
Enthalpy
17.82 kmol/h
0.02 kJ/hr
4.219E-06 kW
N2(g)
Molar rate
Enthalpy
47.40 kmol/h
0.03 kJ/hr
9.576E-06 kW
O2(g)
Molar rate
Enthalpy
2.22 kmol/h
1.639E-03 kJ/hr
4.552E-07 kW
14.34 kmol/h
0.01 kJ/hr
2.897E-06 kW
kmol/h
kg/h
kJ/hr
kW
;6
Temperature=
HCl(l)
Mass rate
Enthalpy
H2O (l)
Molar rate
Enthalpy
;6
;5
;7
50 C
HCl(g)
;5
45 C
2272.13 kg/h
118150.50 kJ/hr
32.82 kW
149.70 kmol/h
2.257E-01 kJ/hr
6.271E-05 kW
;6
;7
This is the amount of heat needed to be removed from the HCl absorber.
HCl(l)
Mass rate
Enthalpy
H2O
(l)
6
7
Molar rate
Enthalpy
45 C
Temperature=
1363.28 kg/h
70890.30 kJ/hr
19.69 kW
;5
)
(
HCl(l)
;6
)
6
7
1
Mass rate
Enthalpy
Molar rate
Enthalpy
20 C
14.81 kg/hr
370.32 kJ/hr
0.10287 kW
46.41 kmol/h
-0.01750 kJ/hr
-4.86E-06 kW
A
B
C
D
HCl (g)
2.91E-02
-1.34E-06
9.72E-09
-4.34E-12
H2O (l)
7.540E-02
H2O (g)
3.346E-02
6.880E-06
7.604E-09
-3.593E-12
Cl2 (g)
3.360E-02
1.367E-05
-1.607E-08
6.473E-12
Stream 15
45
20
45
25
,2
Stream 23
53 5
20
53 5
20
53 5
,2
20
,2
Stream 3
,
20
,2
20
,2
20
MIXER 3
(STREAM 15)
IN FROM SPLITTER
Temperature =
(STREAM 23)
IN FROM RECYCLE (36%HCl)
45C
85
1987
kmol/h
kg/h
Cl2 (g)
HCl(aq)
H2O (l)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
25
909
0.2937
60
1078
kmol/h
kg/h
HCl(aq)
kmol/h
kg/h
H2O (l)
Temperature =
53.5C
169
kmol/h
3741
kg/h
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
0.1897
13
0.0011
37
1354
0.2192
132
2374
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
Mole frac
0.7063
Mole frac
Qin = 11279538kJ/hr
HCl(aq)
H2O (l)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Q= 14212359 kJ/h
49.00 C
254 kmol/h
5728 kg/h
0.1897
13
0.0007
62
2262
0.2441
192
3452
0.7552
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
0.7797
EXPELLER
(STREAM 16)
LIQUID FEED
Total molar rate=
Total mass rate=
Cl2 (g)
HCl(aq)
H2O (l)
Qin=
(STREAM 14)
STEAM IN
254 kmol/h
5728 kg/h
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
0.1897
13
0.0007
62
2262
kmol/h
kg/h
Mole frac
0.2441
Molar rate
Mass rate
Mole frac
192 kmol/h
3452 kg/h
0.7552
kmol/h
kg/h
Steam at 200psig
From steam table:
Temp of Sat. Steam
Latent Heat of Steam
Specific Enthalpy of Sat.
Steam
Specific Enthalpy of Sat.
Water
12326352 kJ/h
Qin=
(STREAM 19)
OUT, LIQUID( EFFLUENT)
Temperature =
Total molar rate=
Total mass rate=
Molar rate
Mass rate
Temperature =
44.45 C
218 kmol/h
4409 kg/h
27 kmol/h
970 kg/h
198 C
1949 kJ/kg
2791
kJ/kg
842
kJ/kg
15527846 kJ/h
STREAM 17
OUT, VAPOR ( RECYCLE)
HCl(aq)
19 kmol/h
335 kg/h
HCl(g)
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
120C
51 kmol/h
1589 kg/h
0.1858
13
0.0036
35
1293
kmol/h
kg/h
kmol/h
kg/h
Mole frac
Molar rate
Mass rate
Mole frac
H2O (l)
Qout=
0.1221
191 kmol/h
3439 kg/h
0.8779
8873176 kJ/h
Mole frac
Molar rate
Mass rate
Mole frac
H2O (g)
Qout=
0.6899
16 kmol/h
283 kg/h
0.3065
18981023 kJ/h
COOLER CONDENSER
(STREAM 17)
VAPOR IN
Temperature = 120C
Total molar rate=
Total mass rate=
Cl2 (g)
HCl(g)
H2O (g)
Qin=
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
55 kmol/h
1654 kg/h
0.1858
13
0.0034
35
1293
0.6446
19
348
0.3521
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
16939830 kJ/h
Stream 18
water out
Temperature =
Total molar rate=
Total mass rate=
Stream 4
Out, vapor ( recycle)
80C
19 kmol/h
335 kg/h
Temperature =
80.0C
36
1319
0.1858
13
0.0051
35
1292.6494
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
Mole frac
Molar rate
Mass rate
Mole frac
H2O (g)
Qout=
4646435 kJ/h
Qout=
Total heat removed by the system = 8472533 kJ/h
0.9747
1 kmol/h
13 kg/h
0.0202
3820862 kJ/h
H2O (l)
Qin=
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
8874307 kJ/h
Stream 20
Temperature =
35.0C
218 kmol/h
4409 kg/h
27
970
0.1221
191
3439
0.8779
kmol/h
kg/h
HCl(aq)
kmol/h
kg/h
H2O (l)
Qout=
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
3283563 kJ/h
218 kmol/h
4409 kg/h
27
970
0.1221
191
3439
0.8779
kmol/h
kg/h
kmol/h
kg/h
At inlet:
HCL Absorber
STREAM 13 (From Scrubber)
Temperature=
HCl(g)
H2O (g)
Cl2 (g)
N2(g)
Mass rate
Enthalpy
50 C
522.70 kg/h
74356.73 kJ/hr
21 kW
HCl(l)
Molar rate
Enthalpy
Molar rate
Enthalpy
1.288
17820.00
15186.90
4.22
kW
mol/hr
kJ/hr
kW
O2(g)
Temperature=
Molar rate
Enthalpy
2220.00 mol/hr
1638.66 kJ/hr
0.46 kW
Molar rate
Enthalpy
35 C
26573.60 mol/hr
19328.06 kJ/hr
5.37 kW
Q1in = 36.19 kW
Q2in = 105.41 kW
At outlet:
(STREAM 24)
TO DRYER
Temperature=
(STREAM 21)
TO SPLITTER2
53.5 C
Temperature=
Molar rate
Enthlpy
HCl(g)
Molar rate
Enthalpy
H2O (g)
Molar rate
Enthalpy
Mass rate
Enthalpy
15.47 kW
Cl2 (g)
Molar rate
Enthalpy
17613.60 mol/hr
H2O (l)
604.85 kJ/hr
0.17 kW
N2(g)
Molar rate
Enthalpy
47400.00 mol/hr
45520.40 kJ/hr
12.64 kW
O2(g)
Molar rate
Enthalpy
2220.00 mol/hr
66.05 kJ/hr
0.02 kW
Q3out = 28.3 kW
53.5 C
206.40 mol/hr
7.09 kJ/hr
1.97E-03 kW
1490.44 kg/h
218191.53 kJ/hr
60.61 kW
Q4out = 63.68 kW
Energy Balance
Energy in + Energy generated -Energy Out -Energy Consumption = Energy Accumulated
Assumption:
(
(
)
)(
)
)(
)
(
At Splitter 2 inlet:
(STREAM 21)
FROM ABSORBER
Temperature =
53.5C
187.65 kmol/h
9097.21 kg/h
Cl2 (g)
Molar rate
Mass rate
Mole frac
0.21 kmol/h
14.65 kg/h
0.0011
7.077E+00 kJ/h
HCl(l)
Molar rate
Mass rate
Mole frac
40.89 kmol/h
1490.44 kg/h
0.2179
6.367E+04 kJ/h
H2O (l)
Molar rate
Mass rate
Mole frac
146.56 kmol/h
2638.05 kg/h
0.7810
5.912E+05 kJ/h
O2 (g)
Molar rate
Mass rate
Mole frac
0.00 kmol/h
0.00 kg/h
0.00
N2 (g)
Molar rate
Mass rate
Mole frac
0.00 kmol/h
0.00 kg/h
0.00
Enthalpy
At Splitter 2 outlet:
(STREAM 23)
OUTLET TO EXPELLER
(STREAM 22)
OUTLET EFFLUENT
Temperature = 53.5C
Temperature = 53.5C
HCl(l)
H2O (l)
O2
N2
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
168.89 kmol/h
3623.70 kg/h
0.1858
13.18
0.0011
36.80
1341.40
0.2179
131.90
2374.25
0.7810
0.00
0.00
0.00
0.00
0.00
0.00
kmol/h
kg/h
Cl2 (g)
kmol/h
kg/h
HCl(l)
kmol/h
kg/h
H2O (l)
kmol/h
kg/h
O2
kmol/h
kg/h
N2
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
Molar rate
Mass rate
Mole frac
18.77 kmol/h
5435.55 kg/h
0.0206
1.4646
0.0011
4.09
149.04
0.2179
14.66
263.81
0.7810
0.00
0.00
0.00
0.00
0.00
0.00
Change in Energy,
= Qin Qout
= Enthalpy at Stream 21 - (Enthalpy at Stream 22 and Stream 23)
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
kmol/h
kg/h
5.2.5 Dryer
At cooler:
COOLER
IN
OUT(TO DRYER)
3558.97 kg/hr
117.37 kmol/hr
3558.97 kg/hr
117.69 kmol/hr
H2O
Mass rate =
Mole rate=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.43
H2O
Mass rate =
Mole rate=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.42
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
Cl2
Mass rate =
Mole rate=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
HCl
Mass rate =
Mole rate=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.22 kmol/hr
0.02
O2
Mass rate =
Mole rate=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.02
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
N2
Mass rate =
Mole rate=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
Chill water can range from (2 to 7 C) while cooling water can range from (13 to 25 C).
Both can be used for cooling.
CHILLING WATER
INLET
Outlet
13.00 Deg C
707.36 kg/hr
39.30 kmol/hr
Mass of water=
Mole=
Enthalpy =
980.20 kJ/kmol
38519.47 kJ/hr
45.00 Deg C
707.36 kg/hr
39.30 kmol/hr
Mass of water=
Mole=
Enthalpy =
3393.00 kJ/kmol
133336.62 kJ/hr
Source: http://pubs.acs.org/doi/pdf/10.1021/ja01486a014
Specific heat capacity of water in 98% sulfuric acid outlet (kJ/kmol) = 1508.00kJ/kmol
Specific heat capacity of water in 30% sulfuric acid outlet (kJ/kmol) = 7313.30kJ/kmol
Heat of Dilution due to Sulfuric acid(98% to 70%) = -65.00 Btu/lb = -151.19 kJ/kg
At 1st Dryer:
Temperature of aqueous sulfuric acid
Inlet = 20 oC
Tref = 0 oC
Outlet = 95 oC
Using the same specific heat capacity earlier, heat of dilution is calculated:
Specific heat capacity of water in 98% H2SO4 acid outlet (kJ/kmol) = 1508.00 kJ/kmol
Specific heat capacity of water in 30% H2SO4 acid outlet (kJ/kmol) = 7142.41 kJ/kmol
Heat of Dilution due to H2SO4 (70% to 30%) = -340 Btu/lb = -790.84 kJ/kg
555.86 kg/hr
13.23 kmol/hr
Total mass=
Total mole=
1297.00 kg/hr
54.41 kmol/hr
Mass H2SO4=
Mole=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.30
Mass H2SO4=
Mole=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.07
Mass H20=
Mole=
Mole fraction=
166.76 kg/hr
9.26 kmol/hr
0.70
Mass H20=
Mole=
Mole fraction=
907.90 kg/hr
50.44 kmol/hr
0.93
Total Enthalpy=
13972.15 kJ/hr
STREAM, 28 DEG C
Total Enthalpy=
52551.78 kJ/hr
STREAM,28 DEG C
Total mass=
Total mole=
3558.97 kg/hr
117.69 kmol/hr
Total mass=
Total mole=
2817.82 kg/hr
76.52 kmol/hr
Mass of water=
Mole=
Mole fraction=
900.00 kg/hr
50.00 kmol/hr
0.42
Mass of water=
Mole=
Mole fraction=
158.86 kg/hr
8.83 kmol/hr
0.12
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.15
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.23
Mass of HCl=
0.06 kg/hr
Mass of HCl=
0.06 kg/hr
Mole=
Mole fraction=
0.00 kmol/hr
0.00
Mole=
Mole fraction=
0.00 kmol/hr
0.00
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.02
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.03
Mass of N2=
Mole=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.40
Mass of N2=
Mole=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.62
Enthalpy=
104112.95 kJ/hr
Enthalpy=
65533.32 kJ/hr
At 2nd Dryer:
ENERGY BALANCE IN 2ND DRYER
INLET
OUTLET
SULFURIC ACID 98% , 20 C
Total mass=
Total mole=
397.04 kg/hr
4.41 kmol/hr
Total mass=
Total mole=
555.86 kg/hr
13.23 kmol/hr
Mass H2SO4=
Mole=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.90
Mass H2SO4=
Mole=
Mole fraction=
389.10 kg/hr
3.97 kmol/hr
0.30
Mass H20=
Mole=
Mole fraction=
7.94 kg/hr
0.44 kmol/hr
0.10
Mass H20=
Mole=
Mole fraction=
166.76 kg/hr
9.26 kmol/hr
0.70
Total Enthalpy=
666.37 kJ/hr
Total Enthalpy=
STREAM, 28 C
8933.43 kJ/hr
STREAM,28 C
Total mass=
Total mole=
2817.82 kg/hr
76.52 kmol/hr
Total mass=
Total mole=
2659.01 kg/hr
67.69 kmol/hr
Mass of water=
Mole=
Mole fraction=
158.86 kg/hr
8.83 kmol/hr
0.12
Mass of water=
Mole=
Mole fraction=
0.04 kg/hr
0.00 kmol/hr
0.00
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.23
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.26
Mass of HCl=
Mole=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
Mass of HCl=
Mole=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.03
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.04
Mass of N2=
Mole=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.62
Mass of N2=
Mole=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.70
Enthalpy=
65533.32 kJ/hr
Enthalpy=
57266.25 kJ/hr
At Liquefaction Section:
Liquid Chlorine
Boiling point of Chlorine =
-31.50 C
-20.00 C
2.00 bar
LIQUEFACTION/COMPRESSOR
INLET
FROM DRYER (28 C)
OUTLET
CHLORINE STORAGE(-20 C)
Total mass=
Total mole=
2659.01 kg/hr
67.69 kmol/hr
Total mass=
Total mole=
1261.00 kg/hr
17.76 kmol/hr
Mass of water=
Mole=
Mole fraction=
0.04 kg/hr
0.00 kmol/hr
0.00
Mass of water=
Mole=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
0.26
Mass of Cl2=
Mole=
Mole fraction=
1260.87 kg/hr
17.76 kmol/hr
1.00
Mass of HCl=
Mole=
Mole fraction=
0.06 kg/hr
0.00 kmol/hr
0.00
Mass of HCl=
Mole=
Mole fraction=
0.05 kg/hr
0.00 kmol/hr
0.00
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.04
Mass of O2=
Mole=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
Mass of N2=
Mole=
Mole fraction=
1326.99 kg/hr
47.39 kmol/hr
0.70
Mass of N2=
Mole=
Mole fraction=
0.07 kg/hr
0.00 kmol/hr
0.00
Enthalpy=
57266.25 kJ/hr
Enthalpy=
-11938.59 kJ/hr
Mass of water=
Mole=
Mole fraction=
0.04 kg/hr
0.00 kmol/hr
0.00
Mass of Cl2=
Mole=
Mole fraction=
0.00 kg/hr
0.00 kmol/hr
0.00
Mass of HCl=
Mole=
Mole fraction=
0.01 kg/hr
0.00 kmol/hr
0.00
Mass of O2=
Mole=
Mole fraction=
71.04 kg/hr
2.54 kmol/hr
0.05
Mass of N2=
Mole=
Mole fraction=
1326.92 kg/hr
47.39 kmol/hr
0.95
Enthalpy=
16714.03 kJ/hr
R-404A Refrigerant
Component
CHF2CF3
CH3CF3
CH2FCF3
a
11.70
1.37
4.64
b
0.02
0.08
0.06
c
0.00
0.00
0.00
d
0.00
0.00
0.00
composition
0.44
0.52
0.04
Tref = 0 OC
Specific enthalpy, H (kJ/kmol)
T(Deg C) CHF2CF3
CH3CF3
CH2FCF3
-40.00
-468.49
-56.41
-186.71
-20.00
-234.25
-28.21
-93.35
-5.00
-58.56
-7.05
-23.34
INLET(-40 C)
OUTLET(-5 C)
Total Mole=
243.75 kmol/hr
Total Mole=
243.75 kmol/hr
CHF2CF3
107.25 kmol/hr
CHF2CF3
107.25 kmol/hr
CH3CF3
126.75 kmol/hr
CH3CF3
55.77 kmol/hr
CH2FCF3
Enthalpy=
9.75 kmol/hr
CH2FCF3
-59216.90 kJ/hr
Enthalpy=
2.23 kmol/hr
-6726.08 kJ/hr
;5
3
2
% wt/wt
0
50 -100
100 -150
150 - 200
200 -250
250 - 300
300 - 350
>350
0.39
14.61
43
27
11.6
3.26
0.14
75
125
175
225
275
325
= 640 kg/m3
0.55
= 0.7
2)
Calculating the gas flow rate at minimum fluidization using Ergun equation,
(
3
(
2
)
3
)
3
)
2
Terminal velocity,
(
)(
)2 (
Expansion ratio, R
)(
(23% of the
)2
Number of holes, N
Diameter of holes, d = 6mm
Arranging the holes on a triangular pitch to get a uniform distribution of total hole
area
)0 5
50100
0.39
100150
15.00
150200
58.00
;4
50
200250
85.00
250300
96.60
300350
99.86
G(x)
50
50
100
150
200
250
300
Characteristic velocity,
Eu = Euler Number
pressure drop, Pa
density of gas inlet
characteristic velocity
Reactor product flow rate, (cyclone volumetric flow inlet)
Diameter of Cyclone, D
50
350
50
50
50
The calculated cut size value is almost the same with the cut size value obtained from
the grade efficiency graph
A
3.28
B
2.05
C
1.23
E
0.31
J
0.41
L
0.16
K
0.41
N
0.41
Diameter=
Bulk density=
Surface area=
Packing factor, Fp=
Corresponding column
diameter
Suitable packing height range=
Pressure drop, P >=
38
62.5
194
170
0.3-0.9
0.5-0.75
15-50
mm
kg/m3
m2/m3
m-1
m
m
mmH20/mm
4386.76 kg/h
3250.18
338
293
1
kg/h
K
K
atm
42
1179
1.1528
0.0018
mmH20/m packing
kg/m3
<---HCl 36 wt%, T =20 C
kg/m3
<---HCl gas, T=65 C
Pa.s
1
2
4 (
1 2
01
;3 0 1
Note: Vw = gas mass flow rate per unit column cross-sectional area, kg/m2.s
Cross-sectional area of column:
Diameter of column:
(
1
2 )
7975.93 kg/h
5909.42 kg/h
1.35
)2
Operating line
Top (2)
Bottom (1)
Liquid,x
0.157
0.523
Gas, y
0.354
0.800
1.2186
y = 1.2186x + 0.1627
y = 1.35x
Operating
Linear (Equilibrium)
Linear (Operating)
0
0.2
0.4
0.6
y1/y2
mGm/Lm
Equilibrium
2.26
1.6
0.8
0 75
01
;0 05
2 3
1 3
07
;0 5
1 3
04
( )
;2 0
( )
02
where K5=
Lw*=
Vw*=
aw=
a=
dp=
c=
L=
kG=
kL=
R=
where P=
Ct=
GM=
LM=
To find aw:
a=
194 m2/m3
c=
61 mN/m
L=
69 mN/m
v= 0.00001348 Pa.s
L=
0.00199 Pa.s
L=
1179 kg/m3
g=
9.81 m/s2
dp=
38 mm
Vw*=
2.2155 kg/m2.s
Lw*=
1.9345 kg/m2.s
01
0 75
;3
;3
02
;0 05
aw=
578.03
DL
Dv first.
To find kL and kgmust
find
and
;5
)(
To find DV:
Using Chapman-Enskog kinetic theory for gases:
Since inlet gas has five components, calculation for DV is based on multi-component mixtures.
So, we need to use Wilki approximation:
Lennard-Jones constants:
H2O
HCl
Cl2
N2
O2
T at gas inlet:
Interaction
1_2
1_3
1_4
1_5
Mw
(g/mol)
18
36.5
35.5
28
32
i
1
2
3
4
5
, (A)
2.649
3.305
4.115
3.681
3.433
/K (K)
y (gas inlet)
356
0.1514
360
0.3101
357
0.1423
91.5
0.3785
113
0.0177
338 K
1-i
8.862529
11.43792
10.01723
9.247681
AB/K
T/(AB/K)
357.99
0.94
356.50
0.95
180.48
1.87
200.57
1.69
AB
1.484
1.476
1.099
1.141
D1-i
1.029E-06
6.239E-07
1.141E-06
1.257E-06
;2
;2
;2
;2
;2
To find DL:
DL (H2O-HCl at T=25C) = 3.10E-05 cm2/s
*Source: Perry's Chemical Engineering Handbook (pg -259)
Since the value is given at 25 C, we need to extrapolate the value to the stream
temperature.
yi'
0.37
0.17
0.45
0.02
;5
<55
;5
;9
2 3
;0 5
;4
)0 4
;9
)
;6
07
;5
1 3
;5
;6 )
);2 0
;5
2
By using inlet gas flow rate & inlet liq flow and area of column, we get:
Gm
0.0633 kmol/m2.s
Lm
0.0879 kmol/m2.s
Substitute all values into the equations of HG and HL:
;5
The inlet stream consists of 2262kg/h of HCl, 3452kg/h of H2O and 0.0007kg/h of Cl2 is
fed at 322K to the column. The inlet steam consist of 335kg/h of saturated vapor which
fed at 470K . The steam works to heat up the liquid stream and strip out the HCl vapor
to the top of the column while the remaining solution been cool down and move to the
bottom of the column. The overall mass and energy balance have been shown in the
table presented before.
Given Data:
Liquid inlet temperature : 322K
Inlet steam temperature : 470K
Liquid outlet temperature : 317K
Vapor outlet temperature : 393K
Inlet liquid flow rate : 5728kg/h
Mass fraction : 0.6026 H2O, 0.3950 HCl, 0.0024 Cl2
Steam flow rate : 335kg/h
Outlet liquid flow rate : 4409kg/h
Mass fraction : 0.78 H2O, 0.22 HCl
Outlet vapor flow rate : 1589kg/h
Mass fraction : 0.1782 H2O, 0.8135 HCl, 0.0083 Cl2
For this stripper, we first assume the pressure drop to be 42mm water/m packing to
avoid flooding but smaller diameter to save cost.
( The standard for absorber and stripper will be 16-48mm water / m packing.)
( From topic 11.14.4, Coulson &Richardson)
From the graph, we can see that the corresponding K value is 1.4 while the
corresponding Kflooding value is 3.4
0 1)
05
= 1.1708kg/m2.s
= 0.3770m2
(
= 0.69m
)0 5
Verify the diameter of the column with the diameter of the packing which is 0.0508m
( )
1
)
298 15
From the graph, we can see there is 4 number of plate which is equivalent of HETP=4
The HETP value given for stripping column is 1.83m. ( By Henry Kister )
Height of packing = 1.83m*HETP
= 1.83m*4
= 7.32m
From the K value that we obtained from the Sherwood Correlation Graph, the
percentage of flooding can be estimated .
The flooding percentage is lower than 80% which mean the design is acceptable.
)
(
)0 1
)0 5
When K=1.4
07
= 3.62inch H2O/ ft
= 301.67mm H2O/m packing
Total pressure can be determined by the graph.
2
;3
Vapor outlet
Liquid inlet
TT
LC
LT
Steam inlet
Liquid outlet
Stripping Column
TC
Legend:
There are two controllers in the unit operation to achieve the two objectives mentioned
above. Firstly, the temperature sensor which located at the vapor outlet will measure
the outlet vapor temperature. It would send the signal to the temperature controller
and any fluctuation from the optimum temperature will trigger the control valve at the
steam inlet to manipulate the flow rate of steam entering the stripping column.
Secondly, the level detector which attached with the stripping column will measure the
liquid level in the stripping column. When the level of the liquid exceed the optimum
level, it would send signal to the level controller and trigger the valve at the liquid inlet.
By controlling the flow rate of liquid inlet, the level of the stripping column can be
controlled.
6.3.12 Design Summary
Unit Operation : Random Packed Stripping Column
Function : To strip HCL gas from HCL solution
Operation : Continuous
Total pressure drop = 3018Pa/m
Percentage of flooding = 64%
HETP = 4
Method 1:
Method 2:
Z = HOG * NOG
c) Determine the column diameter to handle liquid and vapor flow rates.
Raschig rings
Cascade rings
Berl saddle
Pall rings
Intalox Saddle
Intalox Saddle
Hence, in the design of a packed column HCl absorber, ceramic Intalox Saddle is chosen.
The reason of choosing the ceramic Intalox Saddle:
The advantages of using Ceramics Intalox Saddle:
Ceramic will not cause any significant pollution (best choice to handle
corrosive liquid. In this case is hydrochloric acid used as the solvent
which is a corrosive liquid.
Intalox saddle increase the free and improves the liquid distribution
characteristics.
High level of stability
Relatively low cost
Smooth surface impact with high chemical resistance
Design Data
Value
Size
Bulk Density
Surface Area
Packing factor, Fp
38mm
625 kg/m3
194m2/m3
170m-1
Xin = 0.1221
yout = ?
HCl Absorber
Xout = 0.2179
yin = 0.4
By component balance
Gin yin + Lin xin = Gout yout + Lout xout
87.28kmol/h (0.4) + 217.63kmol/h (0.1221) = 217.63kmol/h (yout ) + 187.65 kmol/h
(0.2179)
yout = 0.23
Plotting equilibrium
y= Kx
where
Hence
K=
()
At 326.5 K
Antoine's Constant are as follows:
Antoines Constant
Value
3.4531
1068.4
1.754
()
1 6
1
1.6* x
Equilibrium line
x
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
y
0.16
0.32
0.48
0.64
0.8
0.96
1.12
1.28
1.44
1.6
Operating line
For x
xin
xout
x
0.1221
0.2179
xin
xout
y
0.21
0.4
For y
Equilibrium data
Operating line
0.5
y = 1.6x
y = 1.8989x - 0.0102
0.4
0.3
0.2
0.1
0
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
Figure 1: y vs x for Operating line and Equilibrium line for HCl Absorption
87 28
1
3600
36 5
1
= 0.8849 kg/s
217 63
1
3600
= 2.2065 kg/s
b) Specifications of parameters:
36 5
1
Parameter
Value
;1
1.49
1.017
FLV =
x-axis :
( ) =
) = 3.01816
From Generalized Pressure Drop Correlation, when the value of x-axis (FLV ) =
3.01816, the value of correlated value of K4 is equal approximately 0.115
)
13 1(
y-axis:
13 1
=(
0.608 kg/m^2*s
13 1 170
0 8849
^2
4
Diameter =
= 1.36m
15
4
= 1.7671m
= 46.5
10
Flooding Velocity
b) Percentage flooding =
0.115
0.185
77.8%
to 80%)
07
07
= 4.188inch H2O/ ft
= 106.38mm H2O/m packing
Could consider reducing column diameter
Z = HTU x NTU
= 1.83m/theoretical plates * 4 theoretical plates
Z = 7.32m
* (
)0 1 * (
65 95
(1 017
0 0059
1 87
);0 05 * (
0 75
61
194
01
10
194
0 05589
1 017
) 02]
194 ;0 05
9 81
) 02]
2. Calculating HOG
2.1 For the liquid phase mass-transfer coefficient:
(
(1 87
1 017
)
9 81
10
;3 0 4
) =0.0051* (
=0.0051*
( 193 32
0 05589
1 87
10
(a
)0 4
1 87
10
1 017 0 2272
;6
kmol/sm^2 bar
* (
0 08314 326 5
194 2 272
10
07
0 8045
0 05589
07
194 0 05589
);2 0
(a
1 49 0 2272
;3 ;2 0
;5
0 8849
11
= 0.8045
0 8045
36 5
0 05589
36 5
= 0.02204
= 1.392 x 1
;3
0 02204
10
193 92 1 013
= 3.7974m
1 392
1
10
10
193 92
= 4.58m
= 4.58 m
3. Calculating NOG
Number of overall gas-phase transfer units,
Where
( 1)
2
= 0.4 0.19
= 0.21
= 0.23 0.19
= 0.04
0 21; 0 04
= 0.1024
0 4 0 23
0 1024
= 1.6582
= 4.58 * 1.6582
= 7.59 m
Compare the value with the value of packing of column height found from
Method 1 and Method 2
% error =
7 59 7 32
7 59
= 3.56 %
The toleration set is to be within 5% error. The small percentage error of 3.56%
which is lower than tolerance value of 5% shows that the height of packed
column is roughly about 7.5 m which proves the value accurate and trustable.
6.4.6 Packing support
The function of the packing support plate is to carry the weight of the wet packing,
while at the same time allowing free passage of the gas and liquid.
A small diameter simple grid & perforated support is chosen. There are two packing
supports in the packed column HCl absorber. One packing support is needed to carry
the weight of wet packing at the top while the other one is required at the bottom. The
height of one support are designed to be 0.5m each. Hence, two packing supports
contributed to 1.0m to the total height of the unit operation.
Height(m)
Packings
7.50
Liquid Distributor
0.8
Packing supports
1.0
3.9
Total
13.2
Vapor outlet
Liquid inlet
LT
LC
Absorption
Column
Vapor inlet
Liquid outlet
TC
TT
LTTTLCTC-
7.50m
13.2 m
Column Diameter
1.50m
Intalox Saddle-Ceramics
Packing support
Liquid Distributor
Level Controller
1.9m
6.5
Dryer
6.5.1 Introduction
Stream 30
2
2
2
2
2
2
2
2
=0.2623454
=2.529x10-5
=3.35x10-5
=0.0374804
=0.7001153
Stream 28
Liquid Feed (98% Sulfuric
Acid)
:
=0.232094
=2.237x10-5
=0.1153412
=0.0331585
=0.6193839
2 SO4 =0.8993
2 =0.1007
From stream 27
2
2
2
2
Stream 29
2 SO4 =0.29983
2 =0.70017
=0.1513
=1.5x10-5 :
=0.42599
=0.01891
=0.40378
2 SO4 =0.0729178
2 =0.9270822
27
3558.97
30
2659.01
V1
2817.82
117.69
67.69
76.52
Mass Of Water
Mole
Mole Fraction
900.00
50.00
0.42
0.04
2.27E-03
3.35E-05
158.86
8.83
0.12
Mass Of Cl2
Mole
Mole Fraction
1260.87
17.76
0.15
1260.87
17.76
0.26
1260.87
17.76
0.23
Mass Of HCl
Mole
Mole Fraction
0.06
1.71E-03
1.45E-05
0.06
1.71E-03
2.53E-05
0.06
1.71E-03
2.24E-05
Mass Of O2
Mole
Mole Fraction
71.04
2.54
0.02
71.04
2.54
0.04
71.04
2.54
0.03
Mass Of N2
Mole
Mole Fraction
1326.99
47.39
0.40
1326.99
47.39
0.70
1326.99
47.39
0.62
Stream
Total Mass(kg/hr)
Total Mole(kmol/hr)
28
397.04
4.41
29
1297.00
54.41
L1
555.86
13.23
Mass Of Water
Mole
Mole Fraction
389.10
3.97
0.90
907.90
50.44
0.93
166.76
9.26
0.70
7.94
0.44
0.10
389.10
3.97
0.07
389.10
3.97
0.30
Temperature(0C)
28.00
28.00
28.00
20.00
94.73
96.99
Pressure(bar)
1
1
1
1
1
1
Type of packing
size(mm)
packing factor, Fv
a(m2/m3)
Raschig rings
51
210
95
Using Generalised pressure drop correlation in Richardson and Coulson chart, the
Blue line-First
Column
Brown lineSecond
Column
30.696 kg/m3
)
01
2
)(
)(
)
01
37.410 kg/m3
)
01
2
)(
)(
(
)
01
Peters (2002) suggests that this same enrichment of the vapor will occur in a certain
height of packing, which is termed the height equivalent of a theoretical plate (HETP). In
practice, the HETP concept is used to convert empirically the number of theoretical
stages to packing height.
Table of HETP for Distillation Design by Henry Kister (McGraw-Hill, ISBN 0-07-034909-6)
Design Temperature, TD
As mentioned before, the maximum design temperature must be including a 10% safety
factor to cover uncertainties in temperature prediction due to the external factor such
as surrounding temperature influences.
Material of Construction
Selection of a suitable material is important as we need to consider the corrosive
properties of the stream as well as the sustainability and the compatibility of the
material with the process environment. The austenitic stainless steel 304 is chosen
since it is most common material used as the construction material.
Welded Joint Factor, J
The strength of a welded joint is relative to the type of joint and the quality of the
welding. Welded joint factor is taken as 1.0 which implies that the joint is equally as
strong as the virgin packing and plates.
Corrosion Allowance
The corrosion allowance is defined as the additional thickness of metal added to allow
for material lost by corrosion and erosion, rusting or scaling. The allowance is
determined based on the experience or from the literature review from the previous
hand on operation. For stainless steel, severe corrosion is not expected but certain
tolerance is needed to be consider as the operation involved sulphuric acid which is
highly corrosive, the corrosion allowance of 2.0 mm is used.
Design Stress, FD
Design stress are calculated to ensure that the material could be expected to withstand
maximum stress without failure under standard test conditions. The design stress factor
of 1.5 is chosen for austenitic stainless steel. Thus, the design stress at in this column is
2.115 N/mm2.
First Column
(
( ) (
Second Column
) (
)
(
( ) (
) (
)
First column
117.69
76.52
Second column
76.52
67.69
4.41
13.23
13.23
54.41
1.83
3.03
0.37
0.11
1
111.46
106.689
30.8
2.115
Raschigs Ring
austenitic stainless steel
304
1
2
0.37
10.013
1.83
3.03
0.34
0.09
1
111.46
106.689
30.8
2.115
Raschigs Ring
austenitic stainless
steel 304
1
2
0.34
9.2014
0.38
0.35
Appendix
Equlibrium data of the water-sulfuric acid binary system
x
0.62
0.64
0.66
0.68
0.70
0.72
0.74
0.76
0.78
0.80
y
0.269
0.354
0.450
0.550
0.646
0.731
0.802
0.858
0.900
0.931
x
0.82
0.84
0.86
0.88
0.90
0.92
0.94
0.96
0.98
1.00
y
0.953
0.968
0.978
0.985
0.990
0.993
0.996
0.997
0.998
0.999
1.400
1.200
y = 1.7693x - 0.6157
1.000
0.800
0.600
0.400
0.200
0.000
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
x
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
30.326 kg/kmol
28 oC
25 atm
30.696 kg/m3
8.825 kmol/hr
41.175 kmol/hr
Operating line
x
y
0.927
0.700
0.425
0.120
y
0.000
0.177
0.354
0.531
0.708
0.885
1.062
1.239
1.415
1.592
1.769
1.200
y = 0.5617x + 0.6328
1.000
0.800
0.600
0.400
0.200
0.000
0
0.1
0.2
0.3
0.4
-0.200
0.5
0.6
0.7
07
x
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
36.959 kg/kmol
28 oC
25 atm
37.410 kg/m3
0.002 kmol/hr
8.823 kmol/hr
Operating line
x
y
0.700
0.100
0.120
0.000
y
0.000
0.177
0.354
0.531
0.708
0.885
1.062
1.239
1.415
1.592
1.769
1.200
y = 0.5617x + 0.6328
1.000
0.800
0.600
0.400
0.200
0.000
0
0.1
0.2
0.3
0.4
-0.200
0.5
0.6
0.7
Overall Energy balance calculation for Two Steps Packed Column Dryer
Appendix G: Heat Capacity Equation
= a + b(T) + c(T)^2 +d(T)^3
dT
Component
HCl
0.02913
-1.341E-06
9.715E-09
-4.335E-12
Cl2
0.0336
0.00001367
-1.607E-08
6.473E-12
H2O(g)
0.03346
0.00000688
7.604E-09
-3.593E-12
N2
0.029
2.199E-06
5.723E-09
-2.871E-12
O2
0.0291
0.00001158
-6.076E-09
1.311E-12
H2O(l)
0.0754
, ( )
0.00
HCl
Cl2
H2O
N2
O2
H2O(l)
58.00
1689.50
1949.20
1940.88
1682.06
1688.14
4373.20
53.50
1558.42
1797.97
1790.29
1551.56
1557.16
4033.90
29.00
844.75
974.60
970.44
841.03
844.07
2186.60
28.00
815.62
940.99
936.98
812.03
814.96
2111.20
16.00
466.07
537.71
535.42
464.02
465.69
1206.40
10.00
291.29
336.07
334.63
290.01
291.06
754.00
-20.00
-582.59
-672.14
-669.27
-580.02
-582.12
-1508.00
fraction=
mass of HCl=
Mole=
Mole
fraction=
mass of O2=
Mole=
Mole
fraction=
mass of N2=
Mole=
Mole
fraction=
Enthalpy=
Total
Enthalpy=
fraction=
0.06 kg/hr
mass of HCl=
0.00 kmol/hr
Mole=
Mole
0.00
fraction=
71.04 kg/hr
mass of O2=
2.54 kmol/hr
Mole=
Mole
0.03
fraction=
1326.99 kg/hr
mass of N2=
47.39 kmol/hr
Mole=
Mole
0.62
fraction=
65533.32 kJ/hr
Enthalpy=
Total
66199.69 kJ/hr
Enthalpy=
Change of
Enthalpy=
0.00 kJ/hr
Intercooler Heat duty:
67759.86 kJ/hr
Temp Ref=
0.06 kg/hr
0.00 kmol/hr
0.00
71.04 kg/hr
2.54 kmol/hr
0.04
1326.99 kg/hr
47.39 kmol/hr
0.70
57266.25 kJ/hr
66199.69 kJ/hr
0.00 Deg C
Boiling point of
H2SO4
287 deg F
H2SO4=
Mole=
Mole
fraction=
Mass H20=
Mole=
Mole
fraction=
Total
Enthalpy=
3.97 kmol/hr
0.30
166.76 kg/hr
9.26 kmol/hr
0.70
H2SO4=
Mole=
3.97
Mole
fraction=
0.07
Mass H20=
907.90
Mole=
50.44
Mole
fraction=
0.93
Total
Enthalpy=
52551.78
stream,28 Deg C
total mass=
2817.82
total mole=
76.52
mass of
water=
158.86
Mole=
8.83
Mole
fraction=
0.12
mass of Cl2=
1260.87
Mole=
17.76
Mole
fraction=
0.23
mass of HCl=
0.06
Mole=
0.00
Mole
fraction=
0.00
mass of O2=
71.04
Mole=
2.54
Mole
fraction=
0.03
mass of N2=
1326.99
Mole=
47.39
Mole
fraction=
0.62
Enthalpy=
65533.32
Total
Enthalpy=
118085.10
13972.15 kJ/hr
stream, 28 Deg C
total mass=
3558.97 kg/hr
total mole=
117.69 kmol/hr
mass of
water=
900.00 kg/hr
Mole=
50.00 kmol/hr
Mole
fraction=
0.42
mass of Cl2=
1260.87 kg/hr
Mole=
17.76 kmol/hr
Mole
fraction=
0.15
mass of HCl=
0.06 kg/hr
Mole=
0.00 kmol/hr
Mole
fraction=
0.00
mass of O2=
71.04 kg/hr
Mole=
2.54 kmol/hr
Mole
fraction=
0.02
mass of N2=
1326.99 kg/hr
Mole=
47.39 kmol/hr
Mole
fraction=
0.40
Enthalpy=
104112.95 kJ/hr
Total
Enthalpy=
118085.10 kJ/hr
Change of
Enthalpy=
0.00 kJ/hr
Intercooler Heat duty:
360265.01 kJ/hr
kmol/hr
kg/hr
kmol/hr
kJ/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kJ/hr
kJ/hr
Overall Mass balance calculation for Two Steps Packed Column Dryer
1st Dryer Column
in(cooler)
total mass= 3558.97
total mole= 117.69
mass of water= 900.00
Mole=
50.00
Mole fraction=
0.42
kg/hr
kmol/hr
kg/hr
kmol/hr
out(sulfuric acid)
total mass= 1297.00
total mole=
54.41
mass of water= 907.90
Mole=
50.44
Mole fraction=
0.93
mass of sulfuric
acid= 389.10
Mole=
3.97
Mole fraction=
0.07
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
kg/hr
kmol/hr
6.6
6.6.1
Heat Exchanger
Calculation of Area
As we have calculated the mass flowrate and other required parameters from the mass
balance and also the energy balance.
COOLING WATER
T outlet(C)
T inlet(C)
COMPONENTS
20
13
T (C)inlet
T (C)outlet
Mass fraction
Cp(kJ/kmol C)
Density(kg/m^3)
Viscosity(Ns/m^2)
Thermal Conductivity
(W/m.K)
Mass flowrate(kg/h)
Mass flowrate(kg/h)
Cp(kJ/kmol C)
Density(kg/m^3)
Viscosity(Ns/m^2)
Thermal Conductivity
(W/m.K)
3558.9676
4.187000
1000.0000
0.001000
0.580000
53.5
28
H20
0.252882323
4.183000
1000.000000
0.001187
Cl2
0.354281
0.034286
2.994000
0.000015
HCl
0.000018
0.029085
1.528000
0.000018
O2
0.019961
0.029702
1.429000
0.000022
N2
0.372858
0.029134
1.250600
0.000019
0.580000
900.000000
0.008100
1260.874800
0.013000
0.062488
0.024000
71.040000
0.024000
1326.990336
0.0195
10
6.096
0.0122
Based on the fouling factor that we get from literature, we assume the fouling factor for
both inside and outside of the tubes
h,di
hdo
0.000159718
5.45934E-05
For this design, the material for construction is assumed to be the stainless steel which
has the thermal conductivity of 45 W/mC
From the temperatures that we have, we find the log mean temperature difference and
then we find the correction factor from the suitable graph. From this value that we have,
we find out that the correction factor is 0.95 from the graph of one shell pass and two or
more even tube passes.
T1 (C)
T2 (C)
Tm
(C)
33.5
15
23
R 0.274509804
P 0.62962963
Based on the graph , Ft
0.95
Then by using the Ft, we find the mean temperature difference given that
DTm = LMTD Ft
From this calculation, DTm value is 21.87C
Then provisional area is being calculated which is given
Therefore, A=29.75m
0.319
2.142
pt (m)
0.024375
Db (m) 0.256573584
We assume the heat exchanger having fixed and U-tube floating head.
Therefore,
Bundle diameter clearance, BDC (m)
Shell diameter, Ds (m)
Baffle spacing, Bs
0.01
0.27 m
0.11 m
21451.46Pa
Density
2.32176621
Viscosity 0.000633266
Cp,mix
1.081267036
Thermal
C
0.15896931
Prandlt and Reynolds number for fluids inside the tubes are 0.004307305 and 67186
respectively.
Since the flow is turbulent, therefore the heat transfer coefficient, hi = 3129.49
By using the equation for Ui and Uo, we get;
Ui
56.41857795
Uo
17.3587232
Therefore, U = 73.78 W/mC which is in between the values of 20-300 W/mC that
we have assumed for our design problem using gases as the hot fluid and water as the
cold fluid.
Therefore our P = 25145.95Pa
7.0 CONCLUSION
As a conclusion, a proper mass and energy balances have been constructed to each of
the unit operation and linked together as a whole process. Overall and component mass
balances of every species are done on the basic in which the inlet flow rate will equal to
the outlet flow rate and there is no accumulation in the unit operation. Energy balance is
done to determine the operating condition at each unit operation and helps us to
calculate the energy utility of the process. An organized and complete Process Flow
Sheet Diagram(PFD) has been generated by using computer software, Autocad. The PFD
consists of all unit operation and auxiliary equipment that labelled in a systematic way.
Finally, different students have designed different specific unit operation involved in the
process such as fluidized bed reactor, pack column absorber, pack column stripping
column and heat exchanger. The design fulfill both chemical and mechanical
engineering requirement. To sum up the conclusion, we can say that we have achieved
all objectives in this project.
Throughout this project, our groups have learned a lot of things aside from the project
and course objectives. We start to realize the importance and application of our
previous subjects and study in our future career especially when we are required to
design a real industrial unit operation. It is not a homework or project that we can copy
from seniors or friends but each of us have to really understand the design methodology
of different type of unit operation and come out with a specific design. We have to apply
our previous knowledge such as Chemical Process Principles, Thermodynamics and
Separation to extract our equilibrium data, construct mass and energy balance, and
design a specific unit operation. Besides, our group also trained to work in a group
instead of individual. Without the cooperation and hard work from every group
members, we are sure that we cannot complete this project on time. Each of us have
been sharing knowledge and idea throughout the whole project so that we can always
learn something news from other people. Furthermore, we found out that we should not
limit our source or reference in notes given by lecturer only but we should always
broaden our knowledge from all kind of source available in the internet or library. Study
and understand of others people work sometimes can give us a better guideline on how
to do our work especially in the design of our unit operation. Hereby, we also like to
deliver our highest gratitude to our mentor Dr. Brahim on guiding us throughout the
whole project. All of us are sure that without this proper guidance, we are unable to
work on the project. Thank you.
For the coming project, our groups feel that it would be much better to have more than
one mentor because we know it is really tiring and hard for only one mentor to guide all
the students. Each of the student is designing a different unit operation and it is
sometime hard for a mentor to assist all the student due to the time constraint. So, we
feel that more mentors that have been assigned to the students might help every
student to understand or master this subject better.
LC
LT
TT
TC
Intalox
SaddleCeramic
8.0 REFERENCES
1. Felder, R.M. & Rousseau, R.W.(2005). Elementary principles of chemical
processes.(3rd Eds.). United States of America: John Wiley & Sons, Inc.
2. Perry, R.H., Green, D.W. & Maloney, J.O.(1997).Perrys Chemical Engineers
Handbook. (8theds.). United States of America: The McGraw-Hill Companies, Inc.
3. Fasullo,Sulfuric Acid: Use and Handling, at p.304 (New York: McGraw-Hill Book
Company, 1965) Copyright Chas. S. Lewis & Company,St. Louis, MO.
4. Liquid-vapor equilibrium concentration sulfuric acid-water system,vapor at
1atm.pressure,General chemical
5. C.Gerrath, Recent Developments in Chlorine Processing, Krebs & Co. Ltd Zurich,
Switzerland.
6. V. F. Giauquee, . Yi'. Hornungj., E. Kunzlearn D T. R. Rubin(1959), The
Thermodynamic Properties of Aqueous Sulfuric Acid Solutions and Hydrates
from 15 to 3OO0K, Low Temperature Laboratory, Department of Chemistry and
Chemical Engineering. University of California, Berkelev
7. Brahim, Designing a randomly packed column, Department of Chemical
Engineering, University of Malaya