Chemical Process System Design
Chemical Process System Design
Design
Introduction
THE NATURE OF PROCESS DESIGN
A Creative Activity !
[ Example ]
CH3
+ H2 + CH4
Toluene
Figure 1.1 Block flow process diagram for the production of benzene
Toluene and hydrogen are converted in a reactor to produce benzene and methane. The
reaction does not go to completion, and excess toluene is required. The noncondensable
gases are separated and discharged. The benzene product and the unreacted toluene are
then separated by distillation. The toluene is then recycled back to the reactor and the
benzene removed in the product stream.
Table 1.1 Conventions and Format Recommended for Laying out a
Block Flow Process Diagram
1. major equipment;
2. principal flow route and control involved from raw
material feed to final product;
3. key temperature and pressure corresponding to
anticipated normal operation;
4. material flow rates and compositions;
5. design duties and sizes of major equipment.
Table 1.2 Conventions Used for Identifying Process Equipment
Parameter
structure
Process Synthesis
A design task where one conjectures the
building blocks and their interconnections to
create a structure which can meet the stated
design requirements.
IMPORTANCE OF PROCESS STRUCTURE
(1) Recycle? A→P
R or R S
A P A
P
(2)separation Sequence ?
A (propane) B (1-Butene) C(n-Butane)
A B A
AB
or
ABC ABC
C B
BC C
C
(3)Heat Recovery ?
or
H
Feed Product
Streams PROCESS ? Streams
(a) Process design starts with the synthesis of a process to convert raw
materials into desired products.
Feed Product
Streams PROCESS Streams ?
1 + H2 + CH4
Toluene Benzene
2 + H2
Benzene Diphenyl
A HIERARCHICAL APPROACH
compressor
Gas
Diphenyl
recycle
H2, feed
FIGURE 1.2-2
Hydrodealkylation of toluene; maximum energy recovery. Toluene
feed
ENERGY INTEGRATION
Vapor Recovery System
H2 Feed Purge
compressor
Reactor Flash
Toluene
Drum
Feed
Benzene
Toluene
Recycle
Benzene Col.
Toluene Col.
Stablizer
Diphenyl
Distillation Train
ALTERNATIVES OF DISTILLATION TRAIN
(1) Recycle Diphenyl
H2, CH4 Benzene
(2)
Feed
Toluene
(recycle)
Diphenyl
(3)
H2
CH4 Benzene Toluene
(recycle)
Diphenyl
ALTERNATIVES OF VAPOR RECOVERY
SYSTEM
(1) Condensation;
(2) Absorption;
(3) Adsorption;
(4) Membrane.
Vapor recovery Purge
system H2 , CH4
H2 , CH4
Reactor Phase
system split
Toluene
Benzene
Liquid separation
system
Dipheny1
Benzene
H2 , CH4 Reactor Separation
Toluene system system
Dipheny1
Toluene recycle
H2 , CH4 Benzene
Toluene Dipheny1