Design Draft for Chemical Reactor Optimization
Explore the redesign process of chemical reactions through various design drafts focusing on maximizing product value, reducing unit numbers, and minimizing unit sizes. The designs aim to achieve equilibrium mixtures efficiently and profitably, illustrated with detailed properties and reactions data.
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Exercise 2.35 Original created by Allie Pinterpe ('13), Remastered and reworked by Angela Tang ( 18), Finessed and fine tuned by Francis Ledesma ( 19), Appraised and altered by Michelle Quien ( 20), Scrutinized and streamlined by Drew Lazarow ( 21), Revised and renovated by Sarah Huang and Lucy Cadanau ( 22), Edited and embellished by Ailen Lao and Sanna Vedrine ( 23), Trimmed and tidied by Austin Vollweiler ( 24), Chat GPT'd by Dennis Wu
Design Goals 1. Maximize the total value of the product(s) 2. Minimize the number of units 3. Minimize the size of each unit
Reactions P Q A B X both reactions result in an in equimolar mixture of components A P Q X B A, P, or Q B or X reactor
Properties P Q A B X Melting pt ( C) 51 Boiling pt ( C) 147 Price ($/mol) 1 A B P Q X 51 147 20 -36 77 100 24 123 30 -12 95 3
Properties P Q A B X Melting pt ( C) 51 Boiling pt ( C) 147 Price ($/mol) 1 A B P Q X 51 147 20 -36 77 100 24 123 30 -12 95 3
Properties P Q A B X Melting pt ( C) 51 Boiling pt ( C) 147 Price ($/mol) 1 A B P Q X 51 147 20 -36 77 100 24 123 30 -12 95 3
Design Draft 1: single pass A (30) B (5) P (30) Q (30) X (5) 117 oC A A+P+Q B B+X P (30) X (5) A (90) B (10) Reactor Liquid Gas Separator 110 oC A (30) B (5) Q (30) 95C: separate P and A,B,Q,X 110C: separate P,X and A,B,Q
Design Draft 1: single pass A (30) B (5) P (30) Q (30) X (5) 117 oC A A+P+Q B B+X P (30) P (30) X (5) Liquid Gas Separator 85 oC A (90) B (10) Reactor Liquid Gas Separator 110 oC X (5) Q (30) A (30) B (5) Q (30) Liquid Gas Separator 135 oC A (30) B (5)
Design Draft 1: single pass A (30) B (5) P (30) Q (30) X (5) 117 oC A A+P+Q B B+X P (30) P (30) X (5) Liquid Gas Separator 85 oC A (90) B (10) Reactor Liquid Gas Separator 110 oC X (5) Q (30) A (30) B (5) Q (30) Liquid Gas Separator 135 oC Flow Rate (mol/min) 30 Price ($/mol) 100 Value ($/min) 3000 A (30) B (5) Product P X 5 3 15 Are we really maximizing the total value of the products in this process? Q 30 30 900 A + B 35 0 0 Not quite! By adding recycles we can push up the production of of P (= more $$$) $3915/min total
How to Improve? P (30) P (30) X (5) A (30) B (5) P (30) Q (30) X (5) Liquid Gas Separator 85 oC A (90) B (10) [100] A (90) B (10) Reactor 117 oC A A+P+Q B B+X X (5) Liquid Gas Separator 110oC Q (30) A (30) B (5) Q (30) Liquid Gas Separator 135 oC A B purge A (30) B (5) How much money are we making now? What are the flow rates in the process?
Iterate to Find Flow Rates at Steady State P (30) (40) (43) (44) (45) P (43) (44) (45) (40) (7.5) (9) (9) (10) P X P (30) X (5) [35] [47.5] [52] [53] [55] A (43) B (9) P (43) P (44) P (45) A (40) B (7.5) P (40) Q (40) Q (43) Q (44) Q (45) A (30) B (5) P (30) Q (30) X (5) X (7.5) X (9) X (9) X (10) A (44) B (9) B (10) A (45) Liquid Gas Separator 85 oC A (90) B (10) [100] A (120) A (130) A (133) A (134) A (135) A (90) B (10) B (15) B (17) B (19) B (20) B (20) Reactor 117 oC A A+P+Q B B+X X (5) (9) (10) X (7.5) (9) Liquid Gas Separator 110 oC [155] [135] [135] [147] [152] [154] [100] [100] [135] [147] [150] [155] Q (30) (40) (43) (44) (45) Q A B (43) (44) (45) A (30) B (5) Q (30) (40) (43) (44) (45) Q (40) (7.5) (9) (9) (10) A (43) A (44) A (45) A (40) B (7.5) B (9) B (9) B (10) A (30) B (5) [35] [47.5] [52] [53] [55] [87.5] [65] [95] [97] [100] Liquid Gas Separator 135 oC (43) (44) (45) A (30) B (5) [35] [47.5] [52] [53] [55] A B (40) (7.5) (9) (9) (10) purge Done!
Instead of IteratingWork Outside In (45) P (45) (10) [55] P X A A + P + Q A B P Q X [155] Pout = Qout = Ain / 2 = 45 (45) (10) (45) (45) (10) Liquid Gas Separator 85 oC mass balance Ain + Pin + Qin = Aout + Pout + Qout A (90) B (10) (135) (20) equimolar A B [155] Reactor 117 oC A A+P+Q B B+X (10) X Liquid Gas Separator 110 oC Pout = Qout solving (45) (10) (45) A B Q (45) (10) A B [55] (45) Q B B + X [100] Liquid Gas Separator 135 oC mass balance Bin + Xin = Bout + Xout A B [55] (45) (10) equimolar purge Bout = Xout Xout = 10 solving
Instead of IteratingWork Outside In (45) P (45) (10) [55] P X A B P Q X [155] (45) (10) (45) (45) (10) Liquid Gas Separator 85 oC A (90) B (10) [100] (135) (20) A B [155] Reactor 117 oC A A+P+Q B B+X (10) X Liquid Gas Separator 110 oC (45) (10) (45) A B Q (45) (10) A B [55] (45) Q [100] Liquid Gas Separator 135 oC A B [55] (45) (10) purge Same result as iterating! All reaction products leave the system
Now to evaluate our design P P (45) P (45) P X X (10) [55] A (45) B (10) P (45) Q (45) X (10) A B P Q X [155] Liquid Gas Separator 85 oC A (90) B (10) [100] A (135) A B B (20) [155] Reactor 117 oC A A+P+Q B B+X X X (10) Liquid Gas Separator 110 oC Q Q (45) A (45) B (10) A B Q Q (45) A (45) A B B (10) [55] [100] Liquid Gas Separator 135 oC A (45) A B B (10) [55] purge Flow Rate (mol/min) 45 10 45 Price ($/mol) 100 3 30 Value ($/min) 4500 30 1350 Are we really maximizing the total value of the products in this process? Product P X Q Total: $5880/min
Lets go back to see if weve met the design goals Maximize the total value of the product(s) Melting pt ( C) Boiling pt ( C) Price ($/mol) Focus on producing the most profitable products: P & B 51 147 1 A 51 147 20 B -36 77 100 P 24 123 30 Q How do we do this? -12 95 3 X
Focus on making P & B P P (45) A B P Q X X (10) A (45) B (10) P (45) Q (45) P (45) P X X (10) [55] Liquid Gas Separator 135 oC A (135) A B B (20) [155] A (90) B (10) [100] Reactor 117 oC A A+P+Q B B+X Liquid Gas Separator 85 oC X X (10) [155] Q Q (45) A B Q Q (50) A (50) B (10) [100] A (50) B (10) [60] Liquid Gas Separator 110 oC A (50) A B B (10) purge [60] Recycling Q will help us produce more P!
Focus on making P & B P P (90) A B P Q X X (10) [290] A (90) B (10) P (90) Q (90) P (90) P X X (10) [100] Liquid Gas Separator 135 oC A (180) B (20) A B Q (90) [290] A (90) B (10) [100] Reactor 117 oC A A+P+Q B B+X Liquid Gas Separator 85 oC X X(10) A (90) B (10) Q (90) A (90) B (10) A B Q Q (90) [190] [190] purge Are we really maximizing the total value of the products in this process? While we are now maximizing the value of P produced . we can still make more money by converting X to B
Focus on making P & B A (90) B (10) P (90) Q (90) X (10) 117 oC A A+P+Q B B+X P (90) P (90) X (10) [100] Liquid Gas Separator 135 oC A (180) B (20) Q (90) [290] A (90) B (10) [100] Reactor Liquid Gas Separator 110 oC X (10) [290] A (90) B (10) Q (90) A (90) B (10) Q (90) [190] [190] purge purge X X (10) X X (10) B (10) B X X (10) Liquid Gas Separator 117 oC Reactor 117 oC X B+X X X (20) B B (10) Flow Rate (mol/min) 90 10 Price ($/mol) 100 20 Value ($/min) 9000 200 Product Total: $9200/min P B
Chemical Process Recap Made a design that worked to isolate and maximize P and B Recycled unused reactants to increase product yield Utilized a second reactor to convert a less favorable product to a more favorable one
Our Process Recap (Takeaways) Check & prioritize your design goals May need to change design multiple times to make sure your top goal is accomplished! Recycle Loops Remember to purge Use to increase output of certain products Calculate flow rates by Iterating until numbers converge System mass balance, working outside in One input and one output stream per reactor
Calculation Session 3 Exercise 2.35 process design with informal, approximate flow rates. Assess your process: Does your process agree with an overall mass balance? Given Ain = 90 (A + P + Q)out = ? Given Bin = 10 (B + X)out = ? Does your process achieve the maximum P output? Exercises 3.4, 3.10, and 3.24 formal mass balances. 1. Draw system borders. 2. Describe system and state assumptions or write rate in = rate out Homework questions? Ask!
