5.

ENERGYBALANCE
Basis:1Hr.Operation
ENERGYBALANCESACROSSTHEFEEDPREHEATINGEQUIPMENT:
Theheatingofcold2butanolfeedistobecompletedinthreestagesinorderto
avoidlargeheatlosses.Thecoldfeedisfirstpreheatedtoitsboilingpointusingsteam
asheatingmediumandthenvaporizedinathermosyphonreboilerutilizingtheheat
containedinthereactionproducts.Thevapor,whichhasentrainedliquidisremoved
fromtheknockoutdrum,andthenheatedtoreactiontemperatureusingfluegas.

COLDFEEDPREHEATER:
Totalfeed=23412.14+2605.77kg
=26017.91kg
26017.91kgperhourof2butanolistobepreheatedfrom250Citboilingpoint107.50C.
Heatloadonpreheater,

Q=26017.91x1.497(380.5288)

=3.603x106KJ
Theheatingmediumisusedisdrysaturatedsteamat420K
6

Steamrequirement=3.603x10

2123.4

=1696.8kg/hr
2BUTANOLVAPORIZER:
2butanolfeedisvaporizedat107.50Cusingreactionproducts.
Heatloadonvaporizeris,Q=Mx
1=
26017.91x557.43kj
2=

14.5032x106kj/hr

AverageCpofreactionproducts=2.3KJ/Kg0k
14.5032x106=26017.91x2.304(642T)

22

T=400K

FIRSTSUPERHEATER:
2butanolvaporsistobeheat4edfrom380.5kto573k.usingfluegaswhichenters
at673k&coolsto423k.
Cp=2.038kj/kgk.
Heatloadonsuperheater,Q=MxCpx(T2T1)
=26017.91x2.038(573380.5)
6
Q=10.207x10 kj/hr
Massflowrateoffluegas=10.2072x10

6
1.2 x(673423)
2=3.4024x104kg/hr
SECONDSUPERHEATER:
Itraisesthetemperatureofvaporfrom573to773k.usingfluegaswhichentersat
873kabdcoolsto623k
Cp=2.674kj/kgk
HeatloadonsuperheaterQ=MxCpx(T2T1)
1=
26017.91x2.674(773573)
2=
13.9144x106kj/hr
Fluegasrequirement,

=13.9144x10

6
1.195x(873623)
=4.6575x103kg/hr

ENERGYBALANCEACROSSTHEREACTOR:
Thefeedentersthereactorat773kandleavesat663k.Theconversionobtainedin
thereactoris89.1%.Theheatbalanceincludestwotermsi.e,sensibleheatchangedue
tocoolingofreactionmixtureandheatconsumeduetoreaction.
Q=MxCpx(T2T1)+MxH
MeanCp=2.68kj/kgk

23

H=73900kj/kgmol
Total2butanolfeed=23412.14+2579.71kg
1=
25991.85kg/hr
2=
351.24kmol/hr
Q=26017.91x2.68x(663773)+351.24x.891x73900
=15.457x106
Itisassumethatafluegasisavailableat800k&leaving750k.
Cp=1.195kj/kgk
Fluegasrequirement,

15.457x106
1.195x(800750)
=25.869x104kg/hr
=

ENERGYBALANCEACROSSTHECONDENSER:
Thevaporenterscondenserat1270C(400k)at1barpressure.
Liquidandthevaporleavingthecondenserisinequilibrium.Atthemoremolefraction
x=0.88ofthecondensatewegetbothliquidandvaportemperaturefromtheTxy
diagramandtemperatureare
299.6k.=liquidtemperature.,335.7k=vaportemperature
Wetakecoolingwaterentersat240Candleavingat420C
CpH2=14650J/kgk
Cpalcohol=1760J/kgk
CpMEK=1664J/kgk
Cpmix
=0.867x1664+0.1089x1760+0.0241x14650
=1987.42J/kg.
Heatlosstoreductioninvaportemperaturefrom400kto335.7k
Q1=26017.91x1.98742(400335.7)
=3.325x106kj/hr
Heatlossduetocondensation
Q2=2591.34x689.19+18931.44x486.11
=10.989x106kj/hr
Heatlossduetofurthercoolingofapartofvaporis
Q3=21522.78x1.987x(335.7299.6)

2
4

=1.544x106kj/hr
Totalheatlost=Q=Q1+Q2+Q3
1=
2=

(3.325+10.989+1.544)x106kj/hr
15.858x106kj/hr
6
= 15.858x10
4.187x(4224)
5
= 2.104x10 kg/hr

Massflowofcoolingwater

ENERGYBALANCEACROSSTHEABSORBER:
HeatofcondensationofMEK

=3707.072x 443.14
=1.643x106 kj/hr

Heatofcondensationofalcoholis =233.488x560
=0.1308x106kj/hr
Heatofsolution

=(3707.072 +233.488)x0.35
=0.001379x106kj/hr

Heatlossincoolinggassesfrom62.7to270C
=(74.98x1.47+8.392x1.53+624.723x14.65)(62.7
27)
=0.3311x106kj/hr
6
Totalheatreleased=2.1063x10kj/hr

Heatremovedbywatervapor=(204.045x2437.9)
=0.49744x106kj/hr
Heatgainedbyirrigatingliquor
1) Water:31980.6816x4.186(T300)
2) MEK:3707.072x2.299x(T300)
3) Alcohol:233.488x2.429x(T300)
6
6
Totalheatgained=0.49744x10+0.142961x10

(T

300)kj/hr
Heatreleased=heatgained
=>

2.1063x10 =0.49744x10 +0.14296x10 (T300)

2
5

=>

T=311.25k

ENERGYBALANCEACROSSTHEEXTRACTIONCOLUMN:
Itisassumethattheextractionprocessisisothermal.Allthatstreamscomeat270C
andleavesat270C.

ENERGYBALANCEACROSSTHESOLVENTRECOVERY&UNIT:
Feedisnotsaturatedliquiditissubcoolliquid.Saturationtemperatureis
930CFromxydiagramwegetRm=0.38.
R=2Rm=0.76
Feed:
Alcohol=233.48=3.155kmol/hr
74
MEK=3577.639=49.689kmol/hr72
TCE=14992.191=112.3kmol/hr
133.5
Water=26.3613=1.465kmol/hr18
Total=166.609kmol/hr
MolefractionofMEK
XMEK=49.689=0.2982
166.609
Feedtemperature=270C
F.HF=3.155x170.058(270)+49.689x165.726x27+112.3x148.56x27+
1.465x75.36x27
F.HF=0.69025x106kj/hr

26

Distillate:
Alcohol=233.488=3.1552kmol/hr
74
MEK=(3577.63921.3454)=49.39kmol/hr
72
Water=(26.361325.9195)=0.0246kmol/hr
18
TCE=2.5098=0.0188
kmol/hr133.5
Total=52.5886
kmol/hrD=52.5886kmol/hr
MolefractionofMEK,XMEK=49.39=0.94
52.5886
fromTxydiagramdistillatetemperature=80.40C
CpMEK=170kj/kmolk
Cpalcohol=228kj/kmolk
Cpwater=75.37kj/molk
CpTCE=148.56kj/molk
4. HD=3.1552x228+49.39x170+0.4421x75.37+0.0188x148.56(80.4)
1=

0.7358x106kj/hr

Residue:
MEK=21.2454kg=0.2965kmol/hr
TCE=15199.421kmol=113.85kmol/hr
133.5
Water=25.9195=1.4399kmol/hr
18
Total=115.5864kmol/hr
XMEK
=0.2965=0.0026
115.5864
FromTxydiagramthetemoerature
obtained.T=1120C=385k(residue)
CpMEK=175kj/molk
Cpalcohol=260kj/kmolk
Cpwater=75.37kj/kmolk

2
7

CpTCE=148.56kj/kmolk

23. Hw=0.2965x175+113.85x148.56+1.4399x75.37x(112)
1=

1.9123x106kj/hr

Condenser:
VHv=D.HD+L.HL+Qc.
VHv=(D+L).HL+Qc
Qc=Vx(HvHL)
Qc=Vx
V=(1+R)xD
D=52.5886kmole/hr
V=(1+0.76)x52.5886=92.556kmole/hr.
Vx=92.556x3.18445x104
=2.9474x106kj/hr
Qc=2.9474x106kj/hr
Coolingwaterrequirement=2.9474x10

6
4.187x(4224)
=3.911x104kg/hr
Reboiler:
Overallheatbalance
F.HF+QB=Qc+D.HD+WHw
QB=Qc+D.HD+WHwF.HF
QB=DHD=WHw+QcFHF
QB=0.7358x106+1.9123x106+2.9474x1060.69025x106
QB=4.90525x106kj/hr
Steamisavailableat3.302barsteamtemperature=410k

2
8

Steamrequirementis=4.90525x10

2153.4

=2277.91kg/hr
Onecoolerisattachedtocooltheresidue.
Residueentersthecoolerat1120Candleavesat270C
So,coolingwaterrequirement=1.451299x10

6
4.187(4224)
=1.92567x104kg/hr
Onemoreheatexchangerisusedtoraisethetemperatureofthemixedliquor
ofcondensateandthedistillatefromthesolventrecoverycolumnto820C
2591.3424x170.058+18931.435x165.726(26.6)
74
72
+212.9726x260+3367.511x175
74
72
+QB=2804.315x260
74

+2.5098x148.56
133.5

+22298.946x165.726+2.5098x148.56(82)
72
133.5

QB=2.981x106KJ/hr
Steamisavailableat3.302bar,steamtemperature=410
K.Steamrequirement=2.981x10

6
2153.4
=1384.32Kg/hr
ENERGYBALANCEACROSSTHEDISTILLATIONCOLUMN:
Condenser:
Qc=Vx
Qc=Vx=541.261x3.1x107+5.4673x4.5x107
=17.025x106
So,massflowrateofcoolingwater=17.025x10

29

4.187x(4224)
=2.25899x106kg/hr
Reboiler:
QB=DHD+WHw+QcFHF
FHF=2804.315x260+22298.946x165.726+2.5098x148.56
74
72
133.5

(82)

=5.01696x106kj/hr
DHD=225.0x228+22275.0x170
74
72
6
=4.2896x10 kj/hr
WHw=2579.7131
74

(80.5)

x260+23.9731 x175+2.0846x148.65 x(107)

72
133.5

=0.97632x106kj/hr
QB=17.274kj/hr
Steamavailableat=3.302bar.Steamtemperature=410k
6

Steamrequirement=17.274x10

2153.4
=8021.733kg/hr.

Distillate&theresiduebothhastobecooled
Heatloadtocoolthedistillatefrom80.5to300C=225x228+22275x170(80.530)
74
72
6
=2.69099x10 kj/hr.
So,coolingwaterrequirement,

=2.69099x10

6
4.187x(4224)
4
=3.57056x10 kg/hr

Recycle2butanolis107to270C
3
0

Heatload=2579.7131 x260+239731x175+ 2.0846x148.65(10727)

74
72
133.5
=0.72996x106kj/hr
6

Coolingwaterrequirement=0.72996x10

4.187x(4224)
=9685.52kg/hr.

31