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Procsses and Numerical Problems

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56 views

Procsses and Numerical Problems

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lipit83749
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PETROLEUM REFINERY

ENGINEERING AND
PETROCHEMICALS (ELECTIVE-II)
Class Note: Prof. Rajat Chakraborty; Jadavpur University

Chemicals from petroleum


hydrocarbons
Some useful
Definitions
Production of Vinyl Chloride

In the production of vinyl chloride (VC) by thermal cracking of dicholoroehane (DCE), the
reactor conversion is limited to 55% to reduce carbon formation (to control reactor
fouling). Compute the quantity of DCE fed to the reactor to produce 5000 kg/h VC.
Production dicholoroethane
Block flow diagram of balanced process for vinyl chloride
The HCl from the pyrolysis step is recycled to the oxyhydrochlorination step. The flow
of ethylene to the chlorination and oxyhydrochlorination reactors is adjusted so that the
production of HCl is in balance with the requirement. The conversion in the pyrolysis
reactor is limited to 55%, and the unreacted dichloroethane (DCE) is separated and
recycled. Using the yields given, and neglecting any other losses, calculate the flow of
ethylene to each reactor and the flow of DCE to the pyrolysis reactor, for a production
rate of 12,500 kg/h vinyl chloride (VC).
Purge
Production of Ethanol
Ethylene

Production of Ethanol through catalytic hydration of ethylene


Vinyl chloride(VC)is manufactured by the pyrolysis of 1,2-
dichloroethane(DCE). The reaction is endothermic. The flow rates to produce
5000kg/h at 55% conversion are shown in Figure. The reactor is a pipe reactor
heated with fuel gas, gross calorific value 33.5MJ/m3. Estimate the quantity of
fuel gas required considering 70% thermal efficiency of the reactor.

The small quantity of impurities, less than 1%, that would be present in the feed
have been neglected for the purposes of this example. Also, the selectivity for
VC has been taken as 100%. It would be in the region of 99% at 55%
conversion.
Heat capacity data, for vapor phase: Cp =a +bT +cT2 +dT3 kJ/kmol K

For liquid phase : DCE at 20 °C, Cp = 116kJ/kmol K, taken as constant over


temperature rise from 20 to 25 °C.
Latent heat of vaporization of DCE at 25°C =34.3 MJ/kmol. At 2 bar pressure the
change in Cp with pressure will be small and will be neglected.
Consider the base temperature as 25 °C (298K),the standard state for ΔHr° .

Enthalpy of feed =145.5 × 116(293 −298)= −84,390 J/h= −84.4 MJ/h


SELECTION OF REACTOR
The PFD for the EB process is shown in Figure B.2.1. A refinery cut of benzene is fed from storage to an on-
site process vessel (V-301), where it is mixed with the recycled benzene. From V-301, it is pumped to a
reaction pressure of approximately 2,000 kPa (20 atm) and sent to a fired heater (H-301) to bring it to
reaction temperature (approximately 400°C). The preheated benzene is mixed with feed ethylene just
prior to entering the first stage of a reactor system consisting of three adiabatic packed-bed reactors (R-
301 to R-303), with interstage feed addition and cooling. Reaction occurs in the gas phase and is
exothermic. The hot, partially converted reactor effluent leaves the first packed bed, is mixed with more
feed ethylene, and is fed to E-301, where the stream is cooled to 380°C prior to passing to the second
reactor (R-302), where further reaction takes place. High-pressure steam is produced in E-301, and this
steam is subsequently used in the styrene unit. The effluent stream from R-302 is similarly mixed with feed
ethylene and is cooled in E-302 (with generation of high-pressure steam) prior to entering the third and
final packed-bed reactor, R-303. The effluent stream leaving the reactor contains products, byproducts,
unreacted benzene, and small amounts of unreacted ethylene and other noncondensable gases.
The reactor effluent is cooled in two waste-heat boilers (E-303 and E-304), in which high-pressure and
low-pressure steam, respectively, is generated. This steam is also consumed in the styrene unit. The
twophase mixture leaving E-304 is sent to a trim cooler (E-305), where the stream is cooled to 80°C, and
then to a two-phase separator (V-302), where the light gases are separated and, because of the high
ethylene conversion, are sent overhead as fuel gas to be consumed in the fired heater. The condensed
liquid is then sent to the benzene tower, T-301, where the unreacted benzene is separated as the
overhead product and returned to the front end of the process. The bottoms product from the first
column is sent to
T-302, where product EB (at 99.8 mol% and containing less than 2 ppm diethylbenzene [DEB]) is taken as
the top product and is sent directly to the styrene unit. The bottoms product from T-302 contains all the
DEB and trace amounts of higher ethylbenzenes. This stream is mixed with recycle benzene and passes
through the fired heater (H-301) prior to being sent to a fourth packed-bed reactor (R-304), in which the
excess benzene is reacted with the DEB to produce EB and unreacted benzene. The effluent from this
reactor is mixed with the liquid stream entering the waste-heat boiler (E-303).
The production of ethylbenzene is described in Appendix B, project B.2. From the PFD
(Figure B.2.1) and accompanying stream table (Table B.2.1), determine the following:
a. The single-pass conversion of benzene
b. The single-pass conversion of ethylene
c. Overall conversion of benzene
d. Overall conversion of ethylene
Suggest two strategies to increase the overall conversion of ethylene and discuss their
merits.
Turton
solution
Catalyst Deactivation and Reactor configurations
Disproportionation of toluene
Hydrodealkylation of toluene
Overall Procedure for Flowsheet Synthesis

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