Conceptual Design Recycle Structure 2020

RECYCLE STRUCTURE OF THE FLOW SHEET
INTRODUCTION
Since wee have decided on the input-output structure of the
flowsheet, we want to add the next level of detail.
we know that the product distribution dominates the design,
and therefore we add the details of the reactor system.
Also, since gas compressors are the most expensive processing
equipment, we add the annualized capital and operating costs of any
compressors required.
However, at this level of the synthesis and analysis procedure, we
treat the separation system as just a blackbox, and we consider the
details of the separation system later.
J GOVHA (HIT) UNIT II: 42 / 97

DECISIONS FOR THE RECYCLE STRUCTURE
The decisions that fix the recycle structure of the flowsheet are listed
below
1 How many reactor systems are required? Is (here any separation
between the reactor systems?
2 How many recycle streams are required?
3 Do we want to use an excess of one reactant at the reactor inlet?
4 Is a gas compressor required? What are the costs?
5 Should the reactor be operated adiabatically, with direct heating or
cooling, or is a diluent or heat carrier required?
6 Do we want to shift the equilibrium conversion? How?
7 How do the reactor costs affect the economic potential?

NUMBER OF REACTOR SYSTEMS

If sets of reactions take place at different temperatures or pressures, or if
they require different catalysts, then we use different reactor systems for
these reaction sets.
Example, in the HDA process the reactions:
both take place at the same T and P without a catalyst. Only one reactor
required. In contrast, in the reaction system
first two reactions take place at a high temperature, whereas the third
reaction takes place at a lower temperature. Hence, two reactor
systems and we could call these Rl and R2.
NUMBER OF RECYCLE STREAMS

It has been discussed that we can associate reaction steps with a reactor
number. Then we can associate the feed streams with the reactor number
where that feed component reacts; e.g., in the anhydride process, acetone
would be fed to the first reactor, whereas acetic acid would be fed to the
second reactor.
Similarly, we can associate the components in recycle streams with the

reactor numbers where each component reacts; e.g., in the anhydride
process, acetone would be recycled to the first reactor, whereas acetic acid
would be recycled to the second reactor

Procedure for getting the number of recycle streams:

List all components leaving the reactor and order them by normal
boiling points.
List the reactor number as the destination code for each recycle
stream.
Group recycle components having neighboring boiling points if they
have the same reactor destination. Then the number of recycle
streams is merely the number of groups.
N.B: Do not separate two components and then remix them at a
reactor inlet.
Gas-recycle streams require compressors, which are expensive. We consider
a stream to be a gas-recycle stream if it boils at a lower temperature than
propylene.
Liquid-recycle streams require only pumps. In our initial design

calculations we do not include the costs of the pumps.
EXAMPLE PROBLEM:
Consider the following components whose destinations are given in order

of their normal boiling points. Find the number of recycle streams.
A. Waste by-product
B. Waste by-product
C. Reactant — recycle to Rl
D. Fuel by-product
E. Fuel by-product
F. Primary product
G. Reactant — recycle to R 2
H. Reactant — recycle to R 2
I. Reactant — recycle to R I
J. Valuable by-product

SOLUTION
There are four product streams which are:

A + B, D + E, F and J and
There are three recycle streams which are:

(C and I) go to reactor 1,G + H (go to R2),

EXAMPLE PROBLEM:
The components and their destinations for HDA process are given in table
below. Determine
(i) The number of product streams.
(ii) The number of recycle streams.
(ii) Draw the recycle flowsheet.

SOLUTION
(i) 3 product streams
Purge; Benzene; Diphenyl
(ii) 2 recycle streams

H2 and CH4 ; Toluene
(iii) Recycle flowsheet for HDA process

EXAMPLE PROBLEM:
The components and their destinations codes for anhydride process are
given in table below. Determine
(i) The number of product streams.
(ii) The number of recycle streams.
(ii) Draw the recycle flowsheet.

SOLUTION
(i) 2 product streams
CH4 +CO+C2 H4 ; Anhydride
(ii) 2 Liquid recycle streams

Acetone ; Acetic acid
(iii) Recycle flowsheet for Anhydride process

EXCESS REACTANTS
Use of an excess reactant can be used to:

(a) Shift product distribution
Example: Simplified model for production of isooctane via butane
alkylation
Butene + Isobutane → Isooctane
Butene + Isooctane → C12
Excess of Isobutane leads to improved selectivity to produce Isooctane.
The larger the excess, the greater the selectivity, but the higher the cost
to recover and recycle Isobutane.
There must be an optimum value for excess Isobutane.
(b)force another component to be close to complete conversion
Example:Production of phosgene which is an intermediate in the
production of di-isocyanate,
CO + Cl2 → COCl2

The product must be free of Cl2 , an excess of CO will force the Cl2 to
almost complete conversion.
(c) Shift the equilibrium conversion.

Example: in the production of cyclohexane by the reaction
Benzene + 3 H2 Cyclohexane
Separation of benzene from cyclohexane in a distillation column is very
difficult (close B.P.). Hence we can shift the equilibrium conversion
to the right by using an excess of H2 .
The molar ratio of reactants at the rector inlet is often a design

variable.
Unfortunately there is no rule of thumb available to make a reasonable
guess of the optimum amount of excess.
We need to carry out our economic analysis in terms of this additional
design variable.

COMPRESSOR DESIGN AND COSTS
Whenever a gas-recycle stream is present, we will need a gas-recycle

compressor.
The design equation for the theoretical horsepower (hp) for a centrifugal
gas compressor is
−5
hp = ( 3.03xy10 )Pin Qin [( PPout
in
)y − 1]
Pin = inlet pressure (Ib/ft 2 )

Qin = Volumetric flow rate (ft 3 /min)
Cp
−1
y= Cv
Cp
Cv

The exit temperature from a compressor stage is: Tout

Tin = ( PPout
in
)y
Temperatures and pressures are absolute units
Values of y that can be used for first estimates of designs are given in
table below:

Efficiency
For first designs, we assume a compressor efficiency of 90% to account
for fluid friction in suction and discharge valves, ports, friction of moving
metal surfaces, fluid turbulence, etc. Also we assume a driver efficiency of
90% to account for the conversion of the input energy to shaft work.
Spares
Compressors are so expensive that spares are seldom provided for
centrifugal units (although reciprocating compressors may have spares
because of a lower service factor). In some instances two compressors may
be installed, with each providing 60% of the load, so that partial operation
of the plant can be maintained in case one compressor fails and additional
flexibility is available to respond to changes in process flows.

Multistage Compressors
It is common practice to use multistage compressors. The gas is cooled
to cooling- water temperatures (IOO 0 F ) between stages. Also knockout
drums are installed between stages to remove any condensate. It is
essential to ensure that no condensation takes place inside the compressor,
since liquid droplets condensing on the vanes which are rotating at very
high speeds might cause an imbalance and wild vibrations.
For a three-stage compressor with inter cooling, the work required is:
Work = MRTin [( PP21 )y + ( PP32 )y + ( PP34 )y − 1]
M= Molecular weight
R = Gas Constant
The compression ratios for each stage in a gas compressor should be equal.
Thus: PP21 = PP23 = PP43

Annualized Installed Cost

The brake horsepower (bph) is obtained by introducing the compressor
efficiency on the design equation for the theoretical horsepower (hp) for a
centrifugal gas compressor:
hp
bhp = 0.9
Then, Guthrie’s correlation or some equivalent correlation can be used to

calculate the installed cost for various types of compressors:
280 )(517.5)(bhp)
Installed cost =( M&S 0.82 (2.11 + F )
c
where Fc is correction factor given in table E.2-4 (Appendix) of J. M.

Douglas, conceptual design of chemical processes and M & S = Marshall
and Swift inflation index (which is published each month in Chemical
Engineering).

To put the installed cost on an annualized basis, we introduce a capital

charge factor of 13 yr.
Operating Cost
By dividing the brake horsepower by the driver efficiency, we can
calculate the utility requirement.
hp
bhp = 0.9
Then from the utility cost and using 8I50hr/yr, we can calculate the
operating cost.
TAC = Annualized Capital Cost + Annual Operating Cost

ADIABATIC REACTOR WITH DIRECT HEATING OR

COOLING
In general, the reactor flows need to be available in order to evaluate the

reactor heat effects.
Thus a material balance of recycle flows has to be done in order to find
flow to the reactor.
RECYCLE MATERIAL BALANCES

The central issue in performing the material balance with recycles is the
behavior of the reaction system
The goal is to obtain a quick estimate of the recycle flows, rather than
rigorous calculations.
We have not specified any details of the separation system as yet, and
therefore we assume that greater than 99 % recoveries of reactants
are equivalent to 100% recoveries.

LIMITING REACTANT
First we make a balance on the limiting reactant.
Using HDA process given in figure below, let’s make FT be the toluene
entering reactor and x be the conversion.
Amt of toluene leaving reactor = FT (1 − x )

Balance at the mixing point before reactor:
Ft = FFT + FT (1 − x)
Ft = FFT
x

This same material balance is always valid for the limiting reactant when
there is complete recovery and recycle of the limiting reactant.
In some cases, some of the limiting reactant might leave the process in a
gas recycle and purge stream (ammonia synthesis), or it may leave with
the product (ethanol synthesis).

Consider a simplified version of the ethanol process, given by following

reactions
CH2 CH2 + H2 O CH3 CH2 OH
2 CH3 CH2 OH (CH3 CH2 )2 + H2 O
Suppose that we want to produce 783 mol/hr of an EtOH-H2 O
azeotrope that contains 85.4 mol% EtOH, from an ethylene feed stream
containing 4% CH4 and pure water: Determine
(i) Amount of ethanol in azeotrop
(ii) Amount of water in product stream
(iii)Feed rate of water, which is the limiting reactant

SOLUTION
Pazeo = 783 mol/hr

(i) PEtOH =yazeo Pazeo
PEtOH =0.854(783)=669 mol/hr EtOH
(ii) Amount of water in the product stream

PH2 O =Pazeo − PEtOH = 783-669=114 mol/hr H2 O
(iii) using stoichiometry of reaction the feed rate of water which is limiting
reagent is: Fresh feed water = water consumed by reaction 1 - water
released reaction 2 + water leaving with product
FH2 O = yazeo Pazeo + (1 − yazeo )Pazeo = 669 +114 =783 mol/hr

Suppose that we let the water leaving with the product be Fw ,P = 114
and the fresh feed water required for the reaction be Fw ,R .
Now, referring to the schematic above, for water let the amount entering
the reactor be Fw , the amount leaving the reactor be Fw (l — x), the
amount leaving with the product be Fw , P, and the amount recycled be
Fw (l — x) — Fw ,P .
Balance at the mixing point before the reactor gives:
(Fw ,p + Fw ,R ) + [Fw (1 − x ) − Fw ,P ]=Fw
F
Fw = wx,R
After we have estimated the flow of the limiting reactant, we use a
specification of the molar ratio at the reactor inlet to calculate the
recycle flows of the other components.
EXAMPLE PROBLEM:
Make a balance on the limiting reactant for the HDA process and
determine the recycle gas if x =0.75, PB =265 and FF T =273.

SOLUTION
Toluene:
FT = FxFT = PSxB = 0.75

273
=365
After estimating the flow of the limiting reactant, use specification of the
molar ratio at the reactor inlet to calculate the recycle flows of the other
components.
Recycle gas:
Total amount of hydrogen entering into reactor = Fresh feed hydrogen +
Recycle hydrogen
If we let the molar ratio of hydrogen to toluene at the reactor inlet be
MR we find that: yFH FG + RG = MR( FxFT )
yPH
or RG = SxyPH ( x
PB MR
− yFH −yPH ) = 0.694(0.4) ( 0.75
265 5
− 0.95−0.4 )=3376
0.95

REVERSIBLE BY-PRODUCTS
If we recycle a by-product formed by a reversible reaction and let the

component build up to its equilibrium level, such as the diphenyl in the
HDA process.
2 Benzene Diphenyl + H2
or the diethyleiher in ethanol synthesis, then we find the recycle flow by

using the equilibrium relationship at the reactor exit. That is, at the
reactor exit.
(Diphenyl)(H2 )
Keq = Benzene 2
However, the H2 and benzene flows have been determined by using the
first reaction and the purge calculations; so we can use the equilibrium
expression to calculate the diphenyl flow at the reactor exit.

REACTOR HEAT EFFECTS
It’s important to make a decision as to whether the reactor can be

operated adiabatically, with direct heating or cooling, or whether a
diluent or heat carrier is needed.
This decision should be made before any specification of separation
system because these diluents or heat carriers will affect the design of
separation system.
To make the decision concerning the reactor heat effects. First
estimate the reactor heat load and the adiabatic temperature change.

Reactor Heat Load
Single reaction: it is known that all fresh feed of the limiting reactant
usually gets converted in the process. Reactor heat load for single
reactions is given by:
Reactor Heat load = Heat of Reaction x Fresh Feed Rate.
QR = 4HR FFresh
NB: The heat of reaction is calculated at the reactor operating conditions.
For complex reactions, the extent of each reaction will depend on design
variables (conversion, molar ratio of reactants, temperature and or
pressure). So we need to find the extent of each reaction before then
calculate heat load

EXAMPLE PROBLEM:
Estimate the reactor heat load for HDA process in a case where x = 0.75,
PB = 265 mol/hr, and Fresh feed toluene FFT = 273 mol/hr, if heat of
reaction is -21 530Btu/mol. We might neglect the second reaction.

SOLUTION
given data: 4HR = 21530 Btu/hr; FFT =273 mol/hr
QR =4HR FFT =(-21 530)(273)= −5878x 106 Btu/hr
Heat is generated by exothermic reaction
Where 4HR is the heat of reaction at 1200o F and 500 psia and heat is
liberated by the reaction.

EXAMPLE PROBLEM:
Acetone can be produced by the dehydrogenation of isopropanol

(CH3 )2 CHOH → (CH3 )2 CO + H2
If we desire to produce 51.3 mol/hr of acetone then 51.3 mol/hr of IPA is

required. The heat of reaction at 299o C and 1 atm is 25,800 Btu/mol,
Determine reactor heat load.

SOLUTION
Given Data: 4HR =25 800 Btu/hr; FFT = 51.3 mol/hr
QR = 4HR FFT = (25 800)(51.3) = 1.324X 106 Btu/hr
Heat is consumed by the endothermic reaction

ADIABATIC TEMPERATURE CHANGE
Once the reactor heat load and flow rate through reactor is determined.
We can then estimate the adiabatic Temp. Change using the following
equation:
QR =FCp (TR,in − TR,out )

EXAMPLE PROBLEM:
The flow and heat capacities of the reactor feed stream for a case where x
= 0.75 and yPH =0.4 are given below. Calculate adiabatic temperature
change if inlet temperature is TR,in =1, 150o F

SOLUTION
QR = 4HR FFT = (-21 530)(273)= −5878x 106 Btu/hr
QR =FCp (TR,in − TR,out )
−5878x 106 Btu/hr =[(273+91)48.7 + 496(7.16) +

3371(8.86)](TR,in − TR,out )
TR,out =1150+115= 1265o F
This value is below the constraints on the reactor exit temperature of

1300o F see input information for HDA process.(Douglas, 1988). Thus, an
adiabatic reactor can be used.

EXAMPLE PROBLEM
CH3 )2 CHOH → (CH3 )2 CO + H2

If we design to produce 51.3 mol/hr of acetone, the feed stream to
acetone process is an IPA-H2O azeotrope (70% IPA) and we recycle an
azeotropic mixture, then it is easy to show that 22.0 mol/hr of water
enters with the feed. Also, for a conversion of x=0.96, the recycle flow will
be 2.1 mol/hr of IPA and 0.9 mol/hr of water. If the reactor inlet temp. is
572O F , find adiabatic Temp. change.

SOLUTION
If the reactor inlet temperature is 572°F:

(51.3 / 0.7) × 0.3 = 22 mol/hr H2 O
51.3 × 0.04 = 2.1 mol/hr IPA (recycle)
(2.1 / 0.7) × 0.3 = 0.9 mol/hr H2 O (recycle)
QR =4HR FFT =(25 800)(51.3)= 1.324X 106 Btu/hr

QR = FCp (TR,in − TR,out )
1.324x 106 Btu/hr =[(51.3+22)+(2.1+0.9)] (22.0) (TR,in − TR,out )
TR,out = 572-788 =−2160 F
This is unreasonable result. Thus, instead of using an adiabatic reactor, we

attempt to achieve isothermal operation by supplying heat of the reaction
to the process. In particular, we might attempt to pack the tubes of a heat
exchanger with a catalyst.

HEAT LOADS
If adiabatic operation is not feasible then we attempt use of heating
or cooling. However, in many cases there is limit to the amount of
heat-transfer surface area that we can fit into a reactor.
To get some “feeling” for the magnitude of this area. We Consider
the case of a high Temperature. gas-phase reaction.
We let U=20 Btu/(hr .ft 2 .o F ) and 4T = 50o F ,Then for the heat
load 1x 106 Btu/hr
1×106
A = U4T
QR
= (20)(50) = 1000 ft 2
The maximum heat transfer area that fits into the shell of a
floating-head heat exchanger is in the ranger of 6000 to 8000ft 2 .
Thus to use a single heat exchanger as a reactor, when we are
attempting to remove or supply the heat of reaction by direct heating
or cooling the reactor heat loads are limited to the range of
6.0 to 8.0 × 106 Btu/hr.
EQUILIBRIUM CONVERSION
We can use our pervious procedure for calculating the process flows
as a fraction of the design variables.
Then we can substitute these flows into the equilibrium relationship
to see whether the conversion we selected is above or below the
equilibrium value. Of course, if it exceeds the equilibrium value the
result has no meaning.
In most of cases it is necessary to determine the exact value of
equilibrium conversion as a function of design variables. This normally
requires a trial and error solution.
In numerous industrial processes equilibrium limitations are important.

EXAMPLE PROBLEM:
Cyclohexane can be produced by the reaction

C6 H6 + 3 H2 C6 H12
We consider a case where we desire to produce 100 mol/hr of C6 H1 2
with a 99.9% purity. A pure benzene feed stream is available, and the
hydrogen makeup stream contains 97.5% H2 , 2% CH4 , 0.5% N2 . A flow
sheet for recycle structure is shown in below for a case where we recycle
some of the benzene (which is not necessarily the best flow sheet).

SOLUTION
Overall material balances. Assume no losses. Then
Production of C6 H12 : Pc = 100
Benzene fresh feed: FFB = Pc = 100
Assume we use a gas recycle and a purge stream. Let
FE = Excess H2 Fed to process
Total H2 Feed = 3Pc + FE = 0.975FG
Purge composition of H2 : yPH = F −E +0.025F
FE
G
1−yPH
Makeup gas rate = FG = 3Pc 0.975−y PH
Purge rate = PG = FE + 0.025FG
Recycle Balances:
Benzene feed to reactor: FB = Pxc
Let molar ratio of H2 to Benzene be MR. Then:
Recycle gas flow: RG = yPH ( x

1 MRPc
− 0.975FG )
Reactor Exit flows:

Cyclohexane = Pc
Benzene = Pc (1−x
x
)
; H2 = MRB − 3Pc = ( MR x − 3)Pc
Inerts = 0.025FG + (1 − yPH )RG = 1−y yPH ( x − 3)Pc
PH MR
Total flow = Pc [ x + ( x − 3) yPH ]

1 MR 1
Equilibrium relationship:
Kc = f fcf 3 = P 3 VV −Cy c
V 3y y3
; vH = 1 ; vvCB = 1.13
B H tot B H B H
Then: 1.13Ptot3 K = xc
c
1+MR−3xc
1−xc (MR−3xc )yPH
fi :fugacity of component; vi : fugacity coefficient of component i
Since benzene and cyclohexane are very close boilers, we would like to
avoid a benzene-cyclohexane distillation separation. This can be
accomplished by operating the reactor at a sufficiently high conversion
that we can leave any unconverted benzene as an impurity in the product.
However, to obtain high benzene conversions, we must force the
equilibrium conversion to be very close to unity.
HEAT CARRIERS
The adiabatic temperature change depends primarily on the flow through

the reactor. Hence, we can always moderate the temperature change by
increasing the flow through the reactor. To do this, we prefer to recycle
more of a reactant or byproduct or product. However, where this is not
possible, we may add an extraneous component. Of course, this will
complicate the separation task. Thus, we normally try to avoid this
situation.
In HDA process, the methane in the gas recycle stream (60%) acts as a
heat carrier. Thus, if we purify the hydrogen in the recycle stream we have
decreased the recycle gas flow but this will increase the exit temperature
of the reactor. If this exceeds the 1300°F limit we could no longer use an
adiabatic reactor. Instead, we would have to cool the reactor, increase the
recycle flow or introduce an extraneous component as a heat.

HEAT CARRIERS
A similar behavior happens in many oxidation reactions. If pure oxygen is

use as a reactant, the adiabatic temperature rise would be very large.
However, if air is used as the reactant, the presence of nitrogen moderate
the temperature change.

SEPARATOR REACTORS
If one of the products can be removed while the reaction is taking place,
then an apparently equilibrium-limited reaction can be forced to go to
complete conversion.
Example 1 - Acetone production
Isopropanol Acetone + H2
Acetone can be produced by the dehydrogenation of isopropanol In the

liquid phase as well as gas phase. At 300o F the equilibrium conversion for
the liquid phase process is about Xe q = 0.32 . By suspending the catalyst
in high boiling solvent and operating the reactor at a temperature above
the boiling point of the acetone, both H2 and acetone can be removed as
a vapor from the reactor. Thus, the equilibrium conversion is shifted to
the right. A series of three CSTRs with a pump-around loop containing a
heating system that supplies the endothermic heat can be used.

Example 2 - Production of ethyl acrylate

Acrylic Acid + Ethanol Ethyl Acrylate + H2 O
Both acrylic acid and ethyl acrylate are monomers, which tend to
polymerize in the reboilers of distillation column. We can eliminate a
column a column required to purify and recycle acrylic acid from the
process if we can force the equilibrium limited reaction to completion, say,
by removing the water. Hence, we use excess of ethanol to shift the
equilibrium to the right, and we carry out the reaction in reboiler of
rectifying column. With this approach, the ethanol, water and ethyl
acrylate are taken overhead, and the acrylic acid conversion approaches
unity.

Reversible Exothermic Reaction There are several important industrial

reactions that are reversible and exothermic. For example,
Sulfuric acid process: SO2 + 12 O2 SO3
In ammonia synthesis,
Water gas shift: CO + H2 O CO2 + H2

Amonia synthesis: N2 + 3 H2 2 NH3
High temperature (high reaction rate) corresponds to small reactor

volumes, but for these reactions the equilibrium conversion decreases as
the reactor temperature increases. Hence, these reactions are often carried
out in a series of adiabatic beds with either intermediate heat exchangers
to cool the gases or a bypass of cold feed to decrease the temperatures
between the beds. With this procedures we obtain a compromise between
high temperatures (small reactor volumes) and high equilibrium
Diluents From the discussion above we have found that the temperature,
pressure and molar ratio can all be used to shift the equilibrium
conversion. However, in some cases an extraneous component (a diluent)
is added which also shift the equilibrium conversion. For example, in
styrene process:
Ethylbenzene Styrene + H2
Ethylbenzene → Benzene + Ethylene
Ethylbenzene → Toluene + Methane
The addition of steam (or methane) at the reactor inlet lowers the partial
pressure of styrene an H2 and so decreases the reverse reaction rate. The
steam serves in part as a heat carrier to supply endothermic heat of
reaction.

Steam is often used as a diluent because water - hydrocarbon mixture

are usually immiscible after condensation. Hence, the separation of water
can be accomplished by a decanter (and usually stripper to recover the
hydrocarbons dissolved in the water, if the water is not recycled).

REACTOR DESIGN
At the very early stages in a new design, a kinetic model normally is not
available. Thus, we base our material balance calculations as correlation of
the product distribution.
Also we assume that we will use the same type of the reactor in the plant
that the chemist used in the laboratory and we often base a first estimate
of the reactor size on the reaction half-life measured by chemist.
For adiabatic reactors we might base the design on an isothermal

temperature which is the average of the inlet and out let temperature or
an average of the inlet and outlet rate constant. We estimate the costs of
plug flow reactors in the same way as we do for pressure vessels (Appendix
E.2) and we annualize the installed cost by introducing a capital charge
factor of 13 yr.

REACTOR CONFIGURATION
Since the product distribution can depend on the reactor configuration, we

need to determine the best configuration. A set of design guidelines has
been published by Levenspiel (Table 6.6-1). as this table indicates in some
cases we obtain complex reactor configurations; see Fig. 6.6-1


RECYCLE ECONOMIC EVALUATION
For HDA process, higher composition of hydrogen in the recycle stream

means higher raw material loss in purge stream but, lower cost of recycle
compressor, recycling less methane. Lower composition of hydrogen in the
recycle stream means lower raw material loss in purge stream but, higher
cost of recycle compressor, recycling more methane.
The value for optimum shown in Fig.below are not the true optimum
values because we have not consided any separation cost yet.

ECONOMIC POTENTIAL LEVEL -3

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RECYCLE STRUCTURE OF THE FLOW SHEET

J GOVHA (HIT) UNIT II: 42 / 97

DECISIONS FOR THE RECYCLE STRUCTURE

J GOVHA (HIT) UNIT II: 43 / 97

NUMBER OF REACTOR SYSTEMS

NUMBER OF RECYCLE STREAMS

Similarly, we can associate the components in recycle streams with the

J GOVHA (HIT) UNIT II: 45 / 97

Procedure for getting the number of recycle streams:

Liquid-recycle streams require only pumps. In our initial design

Consider the following components whose destinations are given in order

J GOVHA (HIT) UNIT II: 47 / 97

There are four product streams which are:

There are three recycle streams which are:

J GOVHA (HIT) UNIT II: 48 / 97

J GOVHA (HIT) UNIT II: 49 / 97

(ii) 2 recycle streams

(iii) Recycle flowsheet for HDA process

J GOVHA (HIT) UNIT II: 50 / 97

J GOVHA (HIT) UNIT II: 51 / 97

(ii) 2 Liquid recycle streams

(iii) Recycle flowsheet for Anhydride process

J GOVHA (HIT) UNIT II: 52 / 97

Use of an excess reactant can be used to:

J GOVHA (HIT) UNIT II: 53 / 97

(c) Shift the equilibrium conversion.

The molar ratio of reactants at the rector inlet is often a design

J GOVHA (HIT) UNIT II: 54 / 97

COMPRESSOR DESIGN AND COSTS

Whenever a gas-recycle stream is present, we will need a gas-recycle

Pin = inlet pressure (Ib/ft 2 )

J GOVHA (HIT) UNIT II: 55 / 97

The exit temperature from a compressor stage is: Tout

Temperatures and pressures are absolute units

J GOVHA (HIT) UNIT II: 56 / 97

J GOVHA (HIT) UNIT II: 57 / 97

J GOVHA (HIT) UNIT II: 58 / 97

Annualized Installed Cost

Then, Guthrie’s correlation or some equivalent correlation can be used to

where Fc is correction factor given in table E.2-4 (Appendix) of J. M.

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To put the installed cost on an annualized basis, we introduce a capital

TAC = Annualized Capital Cost + Annual Operating Cost

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ADIABATIC REACTOR WITH DIRECT HEATING OR

In general, the reactor flows need to be available in order to evaluate the

RECYCLE MATERIAL BALANCES

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Amt of toluene leaving reactor = FT (1 − x )

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Consider a simplified version of the ethanol process, given by following

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Pazeo = 783 mol/hr

(ii) Amount of water in the product stream

FH2 O = yazeo Pazeo + (1 − yazeo )Pazeo = 669 +114 =783 mol/hr

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FT = FxFT = PSxB = 0.75

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Sulfuric acid process: SO2 + 12 O2 SO3

Water gas shift: CO + H2 O CO2 + H2