ASSIGNMENT PROCESS SYNTHESIS (PAST YEAR TEST)

Question 1 (20 MARKS)

Product C is to be produced from A and B according to the reaction:

A + ½B → C + D

Some of C formed undergoes a secondary reaction in series to unwanted byproducts, E and F,

according to the reaction:
C ↔ E + F

Table 1: Properties of the components involved in the production of C

Normal Boiling point Inlet flow Outlet
Molecular Price
Component boiling point at 8 atm rate flow rate
Weight (RM/kg)
(oC) (oC) (kmol h-1) (kmol h-1)
A 32 65 111 1,337 311 5.10
B 32 -183 -132 955 442 1.50
C 30 -19 35 0 1,016 7.50
D 18 100 154 0 1,016 0
E* 28 -192 -140 4 14 0
F 2 -253 -199 4 14 2.30
*E is toxic and hazardous material

a) By considering only the main reaction, determine the economic potential to produce C (in
RM/kg).
(2 marks)

b) Synthesis a process flowsheet according to the 5 keys synthesis steps by Rudd, Power and
Sirola. Clearly label the equipment and the participating components. Assume:-
• The reaction takes place at 400 oC and 8 atm.

• The feed to the first separation system is at 25 oC and 8 atm.

• Reaction is highly exothermic
(10 marks)

c) Explain 4 heuristics that you consider when generating the process flowsheet.
(8 marks)
QUESTION 2 (25 MARKS)

(a) A company is producing ammonia using a process synthesis known as Haber-Bosch as shown
in Figure 1. The initial feed to the reactor comprises 74.25 mole% H2, 24.75 mole % N2, and
the remaining is inert. The remaining gases are recycled back to the feed stream. The joined
stream between initial feed and recycled is fed to a reactor where 25 percentages single-pass
conversion of nitrogen is accomplished. The product moves across a condenser in which all of
the ammonia liquid is removed. A purge stream (n7) is introduced in the process. The recycle
stream contains 12.5 mole% inert.
N2 + 3H2 → 2NH3

Figure 1. Ammonia production process

i. Evaluate the overall conversion of nitrogen, the ratio (moles purge gas/mole of gas
leaving the condenser), and the ratio (moles fresh feed/mole fed to the reactor). Use
basis of 10 mol fresh feed. (18 marks)
ii. Explain why purge system is introduced in the process. State two conditions required
for species to be purge from the process. (3 marks)
iii. Before N2 and H2 entering the reactor, these gases are to be sent to a heat exchanger to
heat the feed gas to reaction temperature of 450 °C. However, these gases are required
to be in the process operating pressure between 15 and 30 bar before being sent to a
heat exchanger. Determine the equipment needed to perform this pressure phase
change. (2 marks)
iv. The reactor effluent is required to be partially cooled to a temperature of 200 °C.
Determine the equipment needed to perform this temperature phase change. (2 marks)
QUESTION 3 (25 MARKS)

Chemical E is a highly sought feedstock in the manufacturing of specialty chemicals.

(a) Following are the possible routes to produce chemical E. Evaluate the most attractive
route from the viewpoint of gross profit. (6 marks)

(b) The plant manager has decided to choose Route #2 for the production of chemical E. The
conversion of the first reaction is 75%, while that of the second reaction is 55%. Using the
production basis of 10,000 kgmol/h of E, perform Step 2 of the key synthesis steps. Clearly
show the mass balance calculations and label the molar flow rate in each stream.
(10 marks)

(c) You have been assigned by the plant manager to design the best separation units for components
leaving Reactor 1 in Route #2 (reaction 1: 2A + 3B → 4C + W, conversion 75%) at operating
conditions of 600°C and 12 atm. The aims are to recover A, and to purify C as feed to Reactor
2. Using the chemical properties provided in the following table, perform Steps 3 and 4 of the
key synthesis steps to accomplish the separation. Justify the selection of separators. Clearly
label the separators, and the estimated values of temperature and pressure in each stream.

(9 marks)
QUESTION 4 (40 MARKS)

Styrene (a commodity chemical for producing polystyrene) is produced in two steps. First,
benzene and ethylene react at 450°C in the presence of catalyst 1 to form ethylbenzene:

Alkylation (450°C): C6H6 + CH2=CH2 → C6H5-CH2CH3 (Reaction 1)

The ethylbenzene is then dehydrogenated at 620°C in the presence of catalyst 2 to produce

styrene:

Dehydrogenation (620°C): C6H5-CH2CH3 → C6H5-CH=CH2 + H2 (Reaction 2)

Unfortunately, side reactions occur in both reactors. In the alkylation reactor, ethylbenzene
reacts with ethylene to form diethylbenzene:

Alkylation (450°C): C6H5-CH2CH3 + CH2=CH2 → C6H4(CH2CH3)2 (Reaction l-a)

However, the effects of side Reaction l-a can be minimized (but not eliminated entirely) if an
excess of benzene is present, by Reaction l-b:

Alkylation (450°C): C6H4(CH2CH3)2 + nC6H6 → 2C6H5-CH2CH3 + (n - 1)C6H6

(Reaction l-b)

A nuisance in the dehydrogenation reactor is the reversal of reaction 1:

Dealkylation (620°C): C6H5-CH2CH3 → C6H6 + CH2=CH2. (Reaction 2-a)

None of the reactions go to completion. Reaction 1 is exothermic, whereas Reaction 2 is

endothermic. The energy to drive Reaction 2 is conveniently supplied by injecting super-heated
steam with the reactants. The steam does not affect any of the reactions and improves the
catalyst performance by removing residue. The properties of chemicals are shown in Table 1:
 Table 1: Physical properties at 1 atm

Chemical Chemical Nomenclature Melting Boiling Price

Species Name point (°C) point (°C) (RM/kg)
H2 Hydrogen H2 -259 -253 1.80
CH2=CH2 Ethylene E -169 -104 0.72
C6H6 Benzene B 6 80 2.00
H2O Water W 0 100 0
C6H5-CH2CH3 Ethylbenzene EB -95 136 0.61
C6H5-CH=CH2 Styrene S -31 145 0.80
C6H4(CH2CH3)2 Diethylbenzene DEB -84 182 1.81

You may assume that all species (B, E, EB, DEB, S, and H2) are insoluble in water and that
water does not dissolve in any of the species encountered in this process.

a) Calculate the economic potential for the production of styrene. (6 marks)

b) Design a process flowsheet according to the 5 keys synthesis steps by Rudd, Power and
Sirola up to Step 3. Use information below :-

1. Assume no other chemistry than the reactions given.

2. Maximize the product and minimize by-products.
3. Minimize the number of process units; then minimize the sizes of the process
units.
4. List the substances in every stream. No need to specify the flow rates or
compositions.
5. Label all units and the typical temperatures in each unit.
6. Neglect pumps, compressors, heat exchangers, heaters, and coolers.
(20 marks)

c) Explain 3 heuristics that you consider when generating the process flowsheet.
(6 marks)

d) Briefly explain the problem that may encounter in the separation system. How would
you propose to resolve the problem? (4 marks)

e) Suggest a way to increase the production yield without changing the flowsheet in (b).
(4 marks)
QUESTION 5 (25 MARKS)

Acetaldehyde is a colourless liquid with a pungent and fruity odour. It is primarily used as a chemical
intermediate for the production of acetic acid, pyridine and butylenes glycol. Acetaldehyde is a volatile
and flammable liquid that is miscible in water, alcohol, ether, benzene, gasoline, and other common
organic solvents. The synthesis of acetaldehydes using the dehydrogenation process of ethanol
(CH3CH2OH) occurs as the following reaction:

CH3CH2OH → CH3CHO + H2 (1)

Acetaldehyde

2CH3CH2OH → CH3COOC2H5 + 2H2 (2)

Ethyl acetate

2CH3CH2OH → CH3(CH2)3OH + H2O (3)

Butanol

CH3CH2OH + H2O → CH3COOH + 2H2 (4)

Acetic acid

The conversion of ethanol is typically 60%. The selectivity of ethanol to be converted to each reaction
are approximately as follows:

• Reaction (1) [Acetaldehyde]: 92%

• Reaction (2) [Ethyl acetate]: 4.3%
• Reaction (3) [Butanol]: 3.6%
• Reaction (4) [Acetic acid]: 0.1% (trace amount)

Table 1: Properties of the components in the dehydrogenation process of ethanol

Molecular Melting point Boiling Soluble in

Price
Components weight at 1 atm (°C) point at 1 water
(RM/kg)
atm (°C)
CH3CH2OH 1.50 46 -114 77 Yes
CH3CHO 3.20 44 -190 20 Yes
H2 1.30 2 -259 -252 No
CH3COOC2H5 2.40 88 -84 80 No
CH3(CH2)3OH 4.10 74 -33 118 No
CH3COOH 0.90 60 -107 78 Yes
H2O 0 18 0 100 Yes

i. Determine the economic potential for the production of acetaldehyde (in RM/kg
acetaldehyde). (5 Marks)

ii. Determine the mass flowrate of recycle stream containing ethanol to satisfy the
production of 1000 kg/h acetaldehyde. (6 Marks)

iii. Based on information given in Table 1, synthesis a flowsheet that containing reactor
and separators for the above process. Clearly label the equipment (including type of
 separator) and the participating components. You do not need to specify the
temperature and pressure. (10 Marks)

iv. Explain 2 heuristics that you consider when generating the process flowsheet.
(4 Marks)