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Why did we waste your time with this course??

Learn the importance of process design in chemical industry, including stages, economics, and implementation. Discover the role it plays in plant capacity, efficiency, and cost reduction.

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Why did we waste your time with this course??

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  1. Why did we waste your time with this course?? Terry A. Ring ChE

  2. Where are M&E Balances used in the Chemical Industry?Process DesignIncreasing Plant CapacityProcess Trouble Shooting

  3. 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

  4. 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?

  5. How is Design Practiced Stage Gate Management • 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

  6. 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)

  7. 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)

  8. 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+ ½ O2  C2H3Cl +H2O • C2H2 + 2HCl + ½ O2C2H3Cl +2H2O (overall) • 5) C2H4 + Cl2 C2H4Cl2 • C2H2 + 2HCl + ½ O2 C2H4Cl2+ H2O • 2 C2H4Cl2 2C2H3Cl + 2HCl • 2C2H4 + Cl2 + ½ O2 2C2H3Cl + H2O (overall)

  9. Gross Profitability Analysis-1 • Start With Raw Material Costs and Product Prices

  10. 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

  11. 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

  12. Example of Market Information http://www.ceramics.org/ASSETS/574195312DA149928805FFEA1242FECF/MaterialsReview_08_08.pdf

  13. Process Synthesis-1 • Reaction 3 • Direct Chlorination • Pyrolysis • M&E Balances

  14. Consider Separations • VLE data • Boiling Points • Flash HCl from Rxn Products

  15. Process Synthesis-1 • Separation System • M&E Balances

  16. Process Synthesis-3 • Task Integration • Reactor & Condenser • Separations

  17. Onion Model of Process Design

  18. Overall Process

  19. Octane Reaction • 2C2H4 + C4H10 C8H18 • P= 5 psi, T=93C, X=98% Conversion

  20. Preliminary Flow Sheet Flash ΔP= 2 psi Distillation Purge Stream

  21. With Heat Integration Without Heat Integration

  22. 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?

  23. Onion Model of Process Design

  24. Many M&E Balances • All Done by Hand???? • No!!!

  25. Steady State Process Simulation AspenPlus ProMax ChemCad Hysis HySim ProSim CADSim OLI Process Simulator KemSimp Chemical Workbench Code Ascend IV Dynamic Process Simulation Aspen Dynamics CADSim Simulation Solutions, Inc. Process Simulation Software

  26. 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?

  27. 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

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