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Design process design gives an overview of the whole process in drafts, ideas and many other ways. This is very useful, it has made things easy for many industries; they are a lot of software’s that assist with process stimulation that are used industrially to make things easier for companies. Block flow diagram and process flow diagrams are useful as a start in process design.
Process design is a systematic series of steps that helps to define, plan and produce a product desired to be built.
It allows you to be efficient, transparent and focused on creating the best product possible. In Chemical engineering, a design process is used to help make sure we don’t miss a step or a part and sequencing of units for desired physical and chemical transformation of materials.
Process design can be the design of new facilities or it can be the modification or expansion of existing facilities.
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The design starts at a conceptual level and ultimately ends in the form of fabrication and construction plans. Process design is distinct from equipment design, which is closer in spirit to the design of unit operations. Processes often include many unit operations.
Now, new software can perform repetitive chemical engineering calculations in a fraction of the time it takes to execute them by hand. Simulation modelling solves real world problems safely and efficiently. It provides an important method of analysis which is easily verified, communicated and understood.
Across industries and disciplines, simulation modelling provides valuable solutions by giving clear insights into complex systems. Simulation enables experimentation on a valid digital representation of a system. Unlike physical modelling, such as making a scale copy of a building, simulation modelling is computer based and use algorithms and equations.
Faster Time To Market
Project time can be dramatically shortened if fabrication, assembly, and testing of the process system occur during any site civil and facilities construction. In a traditional project timeline, site civil and facilities must be completed before any process system work can begin. Since process systems are being assembled off-site into easily transportable skids, modular process system can be developed in parallel with civil and facilities construction. Start-up time is also minimized since systems can be fully assembled and tested before they ship, reducing the amount of on-site start-up time. Weather delays are eliminated during process system development since skids are assembled indoors.
Reduced Costs
Lower labor and operational costs are achieved due to a shorter project timeline, efficient use of material, and a smaller field crew. For multi-unit projects, higher capitol efficiency is achieved by designing once and building duplicates Off-site module construction does not interrupt or shut-down pre-existing operations.
Safety Benefits
Safety risks are reduced for modular process plant personnel with fewer onsite OSHA exposure hours and smaller crew sizes. Ideal construction conditions provided by an enclosed fabrication facility further reduce safety risk for fabricators. Full modular process system testing and checkout prior to shipment identifies and corrects any potential problems before the system is delivered on-site
Manual calculations
REACTIONS: C6H6 + Cl2 = C6H5Cl +HCl
C6H6 +Cl2 = C6H4Cl2 +2HCl
Basis: 100 kmol of benzene
Mol ratio of chlorine to benzene ratio = 0.9
Overall conversion of benzene = 55.3%
Yield of monochlorobenzene = 73.6%
Yield of dichlorobenzene = 27.3%
Molar mass of HCL = 36 kg/kmol
Molar mass of H2O = 18kg/kmol
The production of other chlorinated compounds are neglected.
Reactor inlet calculation
Chlorine feed to reactor = 100×0.9 = 90 kmol/h
Reactor outlet calculation
MCB produced =(55.3×73.6)/100 = 40.7 kmol/h
DCB produced = (55.3×27.3)/100= 15.1 kmol/h
Benzene = 100-55.3 = 44.7 kmol/h
HCl produced = 2(15.1)+40.7 = 70.9 kmol/h
Chlorine produced = 90-(2(15.1)+40.7) = 19.1 kmol/h
Total stream flow = 40.7+15.1+44.7+70.9+19.1 = 190.5kmol/h
Condenser feed stream calculation
Assumption: total condensation of chlorobenzenes and unreacted benzenes.
Condenser feed stream has the same flow as the reactor outlet
MCB fed = 40.7 kmol/h
DCB fed =15.1 kmol/h
Benzene fed = 44.7 kmol/h
HCl fed = 70.9 kmol/h
Chlorine fed =19.1kmol/h
Total stream flow = 40.7+15.1+44.7+70.9+19.1 = 190.5kmol/h
Condenser outlet stream calculation
At the condenser the is no reaction therefore the outlet stream of the condenser has equal compositions as the inlet stream.
Absorption feed stream calculation
All the HCl and Cl2 from separator is fed to the absorber
HCl fed = 70.9×36.5=2587.85 kg/h
Cl2 fed = 19.1kmol/h
Absorber Tops
98% of the chlorine fed to absorber is recycled
Chlorine recycled = 0.98×19.1 = 18.72 kmol/h
Absorber bottoms
Chlorine = 19.1-18.72 = 0.38 kmol/h
100% absorption of HCL is achieved
HCl = 70.1 kmol/h
H2O fed = H2O out =2587.85/0.3 = 8626.17kg
Distillation inlet stream
All the chlorobenzenes and unreacted benzene from separator is fed to the distillation column
MCB fed = 40.7 kmol/h
DCB fed = 15.1 kmol/h
Benzene fed = 44.7 kmol
Distillation overheads
95% of the benzene fed is recovered
Benzene recovery = 44.7×0.95 = 42.4 kmol/h
Distillation bottoms
MCB = 40.7 kmol/h
DCB = 15.1 kmol/h
Benzene = 44.7 -42.4=2.3 kmol/h
Reactor with recycle feeds
Benzene Fresh feed = recycle + feed
= 42.4 + 100
= 142.4 kmol/h
Chlorine fresh feed = recycle + feed
=18.9 + 90
= 108.9 kmol/h
Scaling Factor:
Product required=400000t.d-1 =400000/8760=45.66t/h
45.66/112.9=0.41
Fresh feed = 50.53
Produced = 40.7
Scaling flow = 0.41/40.7=0.01
Excel graph
Reactor In Out
Chlorine 90 kmol 19.1054 kmol
Benzene 100 kmol 44.7 kmol
MCB 0 kmol 40.7008 kmol
DCB 0 kmol 15.0969 kmol
HCl 0 kmol 70.8946 kmol
Condenser/Flush Drum In Vapour liquid
Chlorine 19.1054 kmol 19.1054 kmol 0 kmol
Benzene 44.7 kmol 0 kmol 44.7 kmol
MCB 40.7008 kmol 0 kmol 40.7008 kmol
DCB 15.0969 kmol 0 kmol 15.0969 kmol
HCl 70.8946 kmol 70.8946 kmol 0
Absorber In Tops Bottoms
Chlorine 19.1054 kmol 18.723292 kmol 0.382108 kmol
HCl 70.8946 kmol 0 70.8946 kmol
Distillation Column In Tops Bottoms
Benzene 44.7 kmol 42.465 kmol 2.235 kmol
MCB 40.7008 kmol 0 kmol 40.7008 kmol
DCB 15.0969 kmol 0 kmol 15.0969 kmol
The detailed process simulation and design for the production of Monochlorobenzene highlight the significance of simulation software in optimizing chemical engineering processes. By providing a clear visualization of process flows and enabling precise calculations of material balances, process simulation tools are indispensable in the efficient and safe design of chemical processes. The ability to predict process outcomes and refine designs through simulation leads to improved product quality, cost savings, and enhanced safety, underscoring the pivotal role of process design in modern chemical engineering practices.
Optimizing Chemical Process Design through Simulation. (2024, Feb 17). Retrieved from https://studymoose.com/document/optimizing-chemical-process-design-through-simulation
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