Flowsheet of Acrylonitrile Process PDF

INTRODUCTION AND COURSE OBJECTIVES THROUGH MOTIVATING
EXAMPLES
MOTIVATING EXAMPLE #1: ACRYLONITRILE PROCESS

B FW Steam-Jet
Water Ejector
1.2 kg H2O/s Steam Condensate
5.0 kg AN/s 6.0 kg H2O/s Boiler 34 ppm NH3
O2 5.1 kg H2O/s 0.2 kg AN/s
+ Gases Tail Gases 1.2 kg H2O/s
NH3 to Disposal
Reactor Scrubber
C3H6
AN to
Sales
18 ppm NH3
4.6 kg AN/s 1ppm NH3
Off-Gas 10 ppm NH3
6.5 kg H2O/s 3.9kg AN/s
Condensate 4.2 kg AN/s
0.3 kg H2O/s
1.0 kg H2O/s Distillation
14 ppm NH3
Column
0.4 kg AN/s
Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.4 kg AN/s 0 ppm NH3
5.5 kg H2O/s 0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
Wastewater to Biotreatment
Flowsheet of Acrylonitrile Process

 Sold-out product with large profit/lb sold => need to expand. Biotreatment is a bottleneck
(cannot tolerate more throughput).
 Also, need to reduce fresh water consumption.
TWO PROCESS-DESIGN OBJECTIVES:
1. DEBOTTLENECK (ENABLE MORE THROUGHPUT FOR) THE PROCESS.
2. REDUCE FRESH WATER CONSUMPTION.
Let's brain storm for some alternative solutions.
1
B FW Steam-Jet
Water 1.2 kg H2O/s SteamEjector Condensate
Tail Gases
NH3 + Gases 1.2 kg H2O/s
Reactor Scrubber to Disposal
C 3H 6
AN to
18 ppm NH3 Sales
4.6 kg AN/s 10 ppm NH3 1ppm NH3
Off-Gas
3.9kg AN/s
Condensate 6.5 kg H2O/s 4.2 kg AN/s
1.0 kg H2O/sDistillation 0.3 kg H2O/s
14 ppm NH3
Column
0.4 kg AN/s Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
1.0 kg H2O/sDistillation 0.3 kg H 2O/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
2
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
6.5 kg H O/s 4.2 kg AN/s 3.9kg AN/s
Condensate 2
1.0 kg H2O/sDistillation 0.3 kg H 2O/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
Fresh Water
B FW
Water 1.2 kg H2O/s Steam Condensate
Tail Gases
C3H6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
14 ppm NH3
Column
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
6.5 kg H2O/s 4.2 kg AN/s 3.9kg AN/s
Condensate
14 ppm NH3
Column
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
New
Separation Wastewater to Biotreatment
3
B FW Steam-Jet
5.0 kg AN/s 6.0 kg H 2 O/s Boiler 34 ppm NH3
Tail Gases
Scrubber to Disposal
Reactor
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
6.5 kg H O/s 4.2 kg AN/s 3.9kg AN/s
Condensate 2
1.0 kg H2O/s Distillation 0.3 kg H 2O/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s New
Aqueous
Separation
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s New
Aqueous
Separation
New 25 ppm Layer
NH3 Bottoms
Separation 0.4 kg AN/s 0 ppm NH3
0.7 kg H2O/s
20 ppm NH3
New 1.1 kg AN/s
12.0kg H2O/s
Separation
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
14 ppm NH3
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Extraction
Aqueous
Layer
Stripping 25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
Ion 1.1 kg AN/s
12.0kg H2O/s
Exchange
4
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
14 ppm NH3 1.0 kg H2O/sDistillation 0.3 kg H2O/s
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Stripping
Aqueous
Ion Layer
25 ppm NH3 Bottoms
Exchange 0.4 kg AN/s 0 ppm NH3
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
Extraction 12.0kg H2O/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
Off-Gas
3.9kg AN/s
0.3 kg H2O/s
Stripping
14 ppm NH3 1.0 kg H2O/sDistillation
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Aqueous
Layer Ion
25 ppm NH3 Bottoms
0.4 kg AN/s 0 ppm NH3 Exchange
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
B FW Steam-Jet
Tail Gases
C 3H 6
AN to
18 ppm NH3 Sales
1ppm NH3 Ion
Off-Gas 4.6 kg AN/s 10 ppm NH3
3.9kg AN/s Exchange
14 ppm NH3 1.0 kg H2O/sDistillation 0.3 kg H2O/s
0.4 kg AN/s Column
Decanter
4.6 kg H2O/s
Aqueous
Layer Stripping
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
and so on …….. (infinite alternatives!)
5
And the optimum solution is ……
Tail Gases
5.0 kg AN/s to Disposal
O2 5.1 kg H2O/s Vacuum
+ Gases Tail Gases Pump
NH3 to Disposal
Reactor Scrubber
C3H6
AN to
Sales
23 ppm NH3
Off-Gas 21 ppm NH3
0.3 kg H2O/s
14 ppm NH3
Column
0.4 kg AN/s
Decanter
4.6 kg H2O/s
To Regeneration Resin Aqueous

Adsorption Layer
and Recycle Column 25 ppm NH3
0.4 kg AN/s Bottoms
10 ppm NH3 12 ppm NH3 4.8 kg H2O/s 0 ppm NH3
0.5 kg AN/s 0.4 kg AN/s
0.1 kg AN/s
5.3 kg H2O/s 4.6 kg H2O/s
0.7 kg H2O/s
Wastewater to 25 ppm NH3

Biotreatment 0.4 kg AN/s
4.8 kg H2O/s
Optimal Solution to the AN Case Study
How can we generate this optimum solution systematically?
What steps are needed to solve this problem?

1. Task Identifications: e.g. Stream rerouting (from where to where)? What
transformations are needed (e.g. separation, biotreatment, etc.)? For example, should
we use separations to clean up wastewater for reuse? To remove what? How much?
From which streams? Should we change operating conditions of some units? Which
units and which operating conditions?
2. Unit Selection: e.g., should we use extraction, stripping, ion exchange, or a combination
adsorption? Which solvents? What type of columns?
3. Generation of Alternatives: e.g. reroute + extraction, stripping and ion exchange, etc.
4. Interconnection of Alternatives
6
Till the late 80's, the available approaches were:
1. Brainstorming among experienced engineers
2. Copy the last design we or someone else did!
Limitations of This Traditional Approach:

 Cannot enumerate the infinite alternatives
 Time and money intensive
 Is not guaranteed to come close to optimum solutions (except for very simple cases or
extreme luck)
 Does not shed light on global insights and key characteristics of the process
 Severly limits groundbreaking and novel ideas.
State of the art:

Systematic, fundamental, and generally applicable techniques can be learned and applied
to synthesize optimal designs for improving process performance.
This is possible via Process Synthesis, Simulation, and Integration:
WHAT IS PROCESS SYNTHESIS?

Process synthesis is concerned with the activities in which the various process elements are
combined and the flowsheet of the system is generated so as to meet certain objectives. Hence, in
process synthesis we know process inputs and outputs and are required to revise the structure and
parameters of the flowsheet (for retrofitting design of an existing plant) or create a new flowsheet
(for grass-root design of a new plant).
7
Process
Process Process
Structure
Inputs Outputs
& Parameters
(Given) (Given)
(Unknown)
Process Synthesis Problems
Process synthesis involves the following activities:

1. Task Identifications
2. Unit Selection
3. Generation of Alternatives
4. Interconnection of Alternatives and selection from among the alternatives.
WHAT IS PROCESS ANALYSIS/SIMULATION?

Analysis is aimed at predicting how the synthesized process will perform. It involves the
decomposition of the process into its constituent elements (e.g. units) for individual study of
performance. Hence, once a process is synthesized, its detailed characteristics (e.g. flowrates,
compositions, temperature, pressure, etc.) are predicted using analysis techniques. These
techniques include mathematical models, empirical correlations and computer-aided process
simulation tools (e.g. ASPEN Plus). In addition, process analysis may involve the use of
experimental means to predict and validate performance. Therefore, in process simulation, we are
given the process inputs and flowsheet and are required to predict process outputs.
The lab will focus on ASPEN Plus.
Process
Process Process
Structure
Inputs Outputs
& Parameters
(Given) (Unknown)
(Given)
Process Simulation Problems
PROCESS DESIGN = PROCESS SYNTHESIS + PROCESS ANALYSIS
8
MOTIVATING EXAMPLE #2: REFINERY
H2 To flare
CH4 Steam Reforming Shift Conversion

CH4+ H2O = CO + 3H2 Amine
CO+ H2O = CO2 + H2 Separation
o
Exothermic @800 C o
Endothermic @350 C
Crude C2-C4 Steam

Atmospheric Distillation
Gasoline Steam
Oil
CO2
Naphtha
Gas Oil
Heavy Distillates
to Vacuum Distillation
Problem: Naphtha and gas oil contain objectionable materials (e.g. sulfur, nitrogen, oxygen,
halides) and unsaturated hydrocarbons (e.g. olefins and gum-forming unstable diolefins)
that should be converted to paraffins.
Design Objectives: Synthesize a revised process to remove sulfur (and other objectionable
materials) and stabilize olefins and diolefins.
Synthesis Activities: Example of a synthesized alternative:
1. Task Identifications: react naphtha and gas oil with hydrogen to remove objectionable
materials and stabilize (saturate) olefins and diolefins.
2. Unit Selection: Hydrotreating and hydrodesulfurization catalytic processes.
3. Generation and interconnection of Alternatives: Add hydrotreating/hydrodesulfurization to
each stream. Purchase fresh hydrogen and feed to units.
9
H2 To flare
CH4 Steam Reforming Shift Conversion

CH4+ H2O = CO + 3H2 Amine
CO+ H2O = CO2 + H2 Separation
Exothermic @800oC
Endothermic @350oC
Crude C2-C4 Steam

Steam
Atmospheric Distillation
Gasoline
Oil
Naphtha CO2
Naphtha
Hydrotreating
and Hydrodesulfurization
Fresh (purchased) H2
Gas Oil
Gas Oil
Hydrotreating
and Hydrodesulfurization
Fresh (purchased) H2
Heavy Distillates
to Vacuum Distillation
What is wrong with this synthesized process from the hydrogen perspective?
No integration of mass (hydrogen)

MOTIVATING EXAMPLE #1 REVISITED
B FW Steam-Jet
Water Ejector
1.2 kg H2O/s Steam Condensate
+ Gases Tail Gases 1.2 kg H2O/s
NH3 to Disposal
Reactor Scrubber
C3H6
AN to
Sales
18 ppm NH3
Off-Gas 10 ppm NH3
6.5 kg H2O/s 3.9kg AN/s
0.3 kg H2O/s
14 ppm NH3
Column
0.4 kg AN/s
Decanter
4.6 kg H2O/s
Aqueous
Layer
25 ppm NH3 Bottoms
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0kg H2O/s
Flowsheet of Acrylonitrile Process
10
MOTIVATING EXAMPLE #3: PHARMACEUTICAL PROCESS
Need to cool to
330 K before recovery
Need to cool to
H1 300 K before storage
520 K
H2
C1 380 K C2
Adiabatic
Reactor 320 K
300 KNeed to heat
to 550 K before Need to heat to
reaction
Separation 380 K before washing
To
Finishing
Washing
Impurities
Purification
PROPOSED SOLUTION
Cooling utility
(water) Cooling utility
330 K To
(brine)
Recovery
Heating utility H1 300 K To
520 K Storage
(steam) H2
C1 380 K C2
Adiabatic
Reactor 320 K
300 K 550 K
Heating utility
Separation (steam)
380 K
To
Finishing
Washing
What is Wrong with

the Energy Usage Purification
Impurities
in this Synthesized
Flowsheet?
No integration of heat
11
WHAT IS PROCESS INTEGRATION?
Process integration is a holistic approach to process design, retrofitting and operation which
emphasizes the unity of the process.
Process integration = Energy Integration + Mass Integration.
Energy integration is a systematic methodology that provides a fundamental understanding of

energy utilization within the process and employs this understanding in identifying energy
targets and optimizing heat-recovery and energy-utility systems.
Mass integration is a systematic methodology that provides a fundamental understanding of the

global flow of mass within the process and employs this understanding in identifying performance
targets and optimizing the generation and routing of species throughout the process.
TARGETING APPROACH
OF PROCESS INTEGRATION
Performance targets for the whole system can be determined ahead of detailed design Big
Picture First
Using Fundamental Chemical Engineering,
Details Later!
We will learn process synthesis, integration, and simulation.
The lectures will focus on process synthesis and integration while the lab will focus on
ASPEN simulation.
We will learn:
 How to simulate complete flowsheets and predict their performance.
 How to identify best achievable performance targets for a process WITHOUT detailed
calculations.
12
 How to systematically enhance yield, maximize profit, maximize resource conservation,
reduce energy, and prevent pollution?
 How to debottleneck a process?
 How to choose units and screen their performance?
 How to understand the BIG picture of a process and use it to optimize any plant?
 And much more 
SUMMARY
 WHAT IS PROCESS ANALYSIS/SIMULATION?
Process
Process Process
Structure
Inputs Outputs
& Parameters
(Given) (Unknown)
(Given)
 WHAT IS PROCESS SYNTHESIS?
Process
Process Process
Structure
Inputs Outputs
& Parameters
(Given) (Given)
(Unknown)
 WHAT IS PROCESS INTEGRATION?

Holistic approach emphasizing unity of the process.
13

Flowsheet of Acrylonitrile Process PDF

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INTRODUCTION AND COURSE OBJECTIVES THROUGH MOTIVATING

MOTIVATING EXAMPLE #1: ACRYLONITRILE PROCESS

Flowsheet of Acrylonitrile Process

and so on …….. (infinite alternatives!)

To Regeneration Resin Aqueous

Wastewater to 25 ppm NH3

Optimal Solution to the AN Case Study

How can we generate this optimum solution systematically?

What steps are needed to solve this problem?

Limitations of This Traditional Approach:

State of the art:

This is possible via Process Synthesis, Simulation, and Integration:

WHAT IS PROCESS SYNTHESIS?

Process synthesis involves the following activities:

WHAT IS PROCESS ANALYSIS/SIMULATION?

CH4 Steam Reforming Shift Conversion

Crude C2-C4 Steam

CH4 Steam Reforming Shift Conversion

Crude C2-C4 Steam

No integration of mass (hydrogen)

Flowsheet of Acrylonitrile Process

What is Wrong with

emphasizes the unity of the process.

Process integration = Energy Integration + Mass Integration.

Energy integration is a systematic methodology that provides a fundamental understanding of

Mass integration is a systematic methodology that provides a fundamental understanding of the

We will learn process synthesis, integration, and simulation.

 WHAT IS PROCESS ANALYSIS/SIMULATION?

 WHAT IS PROCESS SYNTHESIS?

 WHAT IS PROCESS INTEGRATION?

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