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BITS Pilani: Module 2: Flowsheet Synthesis Lecture-4

This document discusses key input information and design aspects to consider when choosing between a batch and continuous process. [1] It lists input information needed initially like reaction conditions, production rate, purity requirements, kinetics, constraints, and costs. [2] Key factors in the decision include the scale of production, market characteristics, operational challenges, and flexibility needs. [3] Guidelines provided are that continuous processes are generally better for large scale production over 106 lb/hr, while batch may be preferred for seasonal, slow, or multi-product facilities.

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68 views

BITS Pilani: Module 2: Flowsheet Synthesis Lecture-4

This document discusses key input information and design aspects to consider when choosing between a batch and continuous process. [1] It lists input information needed initially like reaction conditions, production rate, purity requirements, kinetics, constraints, and costs. [2] Key factors in the decision include the scale of production, market characteristics, operational challenges, and flexibility needs. [3] Guidelines provided are that continuous processes are generally better for large scale production over 106 lb/hr, while batch may be preferred for seasonal, slow, or multi-product facilities.

Uploaded by

pulkit
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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BITS Pilani

Pilani Campus

Module 2: Flowsheet synthesis


Lecture-4
Input information and design aspects of Batch vs. Continuous
Course: Process Plant Design CE 1705/1701

Nandana Chakinala
Department of Chemical Engineering
Batch vs. Continuous process
• Input information required at initial stage of
design
• Reaction and reaction conditions
• Desired production rate
• Desired product purity
• Information of product vs purity
• Reaction kinetics, rate of catalyst deactivation
• Processing constraints
• Plant and site data
• Physical properties of all components
• Safety, toxicity, environmental impact of materials
involved in process
• Cost data
2
Contd..

• Reaction Information
– Chemistry of process
– Operating conditions
– Side reactions → By-products of the process should be
known precisely. Overlooking of side products can
adversely affect economy of the process
– Yield of reaction → condition corresponding to max yield
(might not be economic/optimum conditions)
– Eg: A→ B → C

3
Contd..

– Eg: A→ B → C

4
Contd..
– Eg: A→ B → C

P: Max yield of products


Q: Smaller conversion of A
(Negligible loss of raw
material to waste)

Trade off: Large amount of unconverted A, which needs to be


separated from B&C and recycled back to the reactor
corresponding to high recycle costs
5
Contd..

• Solution
– Work hand in hand with chemist for improvement of
process and optimization

• Selectivity = Moles of B obtained / Moles of A reacted


= Moles of B obtained / Moles of C obtained

6
Concept of selectivity
C6 H 5CH 3 + H 2 → C6 H 6 + CH 4
2C6 H 6  2C6 H 5 + H 2

• Selectivity = Moles of B obtained / Moles of A reacted

7
Concept of selectivity

• Flowsheet structure

8
Catalyst deactivation

– No or little knowledge of catalyst deactivation is an


uncertainty in design
– Sensitivity of total product cost to uncertainty in design
needs to be assessed
– Repeat calculations as soon as information available
regarding uncertainties

9
Production rate

– What should be the optimum production rate


– Whether the product is entirely new or several similar
products in the market
– Life of the product
– Access to market – whether the company can access
50% or higher market in country or only 5%
– Share in the market → what share of the market the
company access to is owned by the company

10
Economy of scale

– As production rate increases, unit production price


decreases
– Consider largest ever plant built for a product, if the
product is new
– Size of equipment – limit the volume of operation
– Market condition – the demand for product can fluctuate,
continuous market survey needed to decide optimum
production rate

11
Product purity

– Fixed by market consideration


– Production of a range of product with different purity
– As the purity of product increases, the operating cost
increases, as so does the cost of production

Raw materials
– Pure materials used by chemist
– On large scale, high purity raw material not available
– Whether impurity going to trigger side reactions, or is it
neutral

12
Processing constraints
– Safety, heat sensitivity
– For explosive mixtures, the concentration to be below
flammability limit
– Material under process heat sensitive or likely to
polymerize
– Coke formation, toxicity, corrosiveness of material

Plant and site data


– Location of the plant
– Access to location(connectivity)
– Local infrastructure

13
Batch vs Continuous
• Continuous process
– 24 hrs a day- 7 days a week
– 8000 hr/yr or 330 days
– Maintenance, shutdown and startup

• Batch Process
– Start up and shutdown frequently
– Small scale production

14
Guidelines for process selection
• Scale of process
– Plant capacity > 106 lb/hr → Continuous
– Plant capacity < 106 lb/hr → Batch
• Market of the product
− Products with seasonal market, batch process is suitable
• Operational problems (Batch process is suitable)
− Very slow
− 3 phase reactions
− Polymerization, fouling
Batch Process are more flexible and simpler. For companies making multiple
products, batch process is most suitable
Complete continuous or batch process is rare
15
Designs leading to choice of
process
• Continuous
– Selection of process units
– Sequence and interconnection
− Process alternatives
− List dominant design variables
− Optimum operating conditions
− List best few alternatives
• Batch
– Which units in batch mode/which continuous
– Which operation in single vessels
– Parallel batch units
– The extent of intermediate storage and location of these units

16
Thank You

17

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