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Overview of Process Design
Chapter 4
Terry A. Ring
ChE
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Where is Design used in Industry?
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Where is Design used in Industry?
• De Novo Designs• Known Plants but different location or
larger size• Plant Improvement
– Debottlenecking Plant– Increase Plant Capacity– Increase Plant Efficiency– Decrease Costs– Pollution Minimization
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Importance of Process Design
• In Preliminary Process Design– 98% Operating Costs Committed– 80% Capital Costs Committed
• Less than 10% $ Spent• Design is Very Important
• But why is this so?
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How is Design Practiced• Process Conception• Preliminary Design
– Process Concepts– Process Economics
• Management decision to go forward• Intermediate Design
– P&ID’s– Ask vendors for prices major pieces of equipment
• Reactor, Separators, HX, Utilities, tank farms– Process Economics
• Management decision to go forward• Detailed Design
– Mechanical Engineering• Equipment + Supports
– Where are all the nuts and bolts
– Piping elevation– Electrical/Power Engineering– Utilities– Process Economics
• Management decision to go forward
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Process Creation
• Chemical Reaction Routes
• Preliminary Database– MSDS – (Health and safety info.)
• Raw Materials• Reaction Products and Intermediates
– Thermo/phys properties (Expts and Predictions)
• Heats of Formation• VLE data, solubilities, etc.
– Chemical Prices (Chemical Market Reporter)
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Operating costs
• Selection of Raw Materials
• Selection of Reaction Path to Product
• Determine Gross Profitability of Process
• Examples– Vinyl Chloride Manufacture (part of PVC plant)
• Example in your book
– Octane Manufacture (part of refinery)
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Process Economics-I
• Macro View– Possible Reactions for vinyl chloride
• 1) C2H4 (ethylene) + Cl2 C2H3Cl (vinyl Chloride) + HCl• 2) C2H2 (acetylene) + HCl C2H3Cl• 3) C2H4 + Cl2 C2H4Cl2 C2H3Cl + HCl• 4) C2H2 + 2HCl + ½ O2 C2H4Cl2+H2O• C2H4Cl2 C2H3Cl +H2O• C2H2 + 2HCl + ½ O2C2H3Cl +H2O (overall)
• 5) C2H4 + Cl2 C2H4Cl2• C2H2 + 2HCl + ½ O2 C2H4Cl2+ H2O• 2 C2H4Cl2 2C2H3Cl + 2HCl• 2C2H4 + Cl2 + ½ O2 2C2H3Cl + H2O (overall)
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Gross Profitability Analysis-1
• Start With Raw Material Costs and Product Prices
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Gross Profitability Analysis-1
• For Each Reaction Determine the Profit to be made
• Gross Profit is – 22¢/lb(1) +18¢/lb (0.583)-18¢/lb(0.449)-11¢/lb(1.134)=11.94 ¢/lb
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Gross Profitability Analysis-2
• Overview of Various Reactions
• Reaction 3 is most profitable!• How much do we make? Market Volume?http://nexant.ecnext.com/coms2/summary_0255-3041_ITM
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Example of Market Information
http://www.ceramics.org/ASSETS/574195312DA149928805FFEA1242FECF/MaterialsReview_08_08.pdf
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Process Synthesis-1
• Reaction 3 – Direct Chlorination– Pyrolysis
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Consider Separations• VLE data
• Boiling Points
• Flash HCl from Rxn Products
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Process Synthesis-1
• Separation System
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Process Synthesis-3• Task Integration
– Reactor & Condenser
• Separations
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Onion Model of Process Design
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Overall Process
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Octane Reaction
• 2C2H4 + C4H10 C8H18
• P= 5 psi, T=93C, X=98% Conversion
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Preliminary Flow Sheet
Flash ΔP= 2 psi
Distillation
Purge Stream
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With Heat Integration
Without Heat Integration
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What else can be done?
• Where is the heat duty for the Flash vessel coming from?– Heat Exchanger coupling reactor feed to
reactor product.
• Do we really need the flash vessel?– Let distillation column do all the separation.
• Reactor heat duty– Exo or Endo reaction?– Where does it come from?
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Onion Model of Process Design
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Importance of Process Design
• In Preliminary Process Design– 98% Operating Costs Committed– 80% Capital Costs Committed
• Less than 10% $ Spent• Design is Very Important
• But why is this so?
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Why
• In Preliminary Design– Decide on Raw Materials Operating Costs
– Decide Process• Reactor System Capital Costs• Separation System Capital Costs• Recycle System Capital Costs• Heat Integration Scheme Capital Costs• Utilities Operating Costs