TA BL.

E 8-1
APPENDIX Stcleclh·il )' o r IInA prOCbS

.99
B ,
S

"
0985

.60
0971

07"
.97

.1>
F,OOD ,he 1%1 AJCII,E 51 .... 0 ' C_ 1C<t f'rohlt<l> Sec
'93
."
J J M.Kcu;o, ·Ea.:)~Jopc.b.. " Cbc......,.. 1"""""",, an.!
0.:."",,- , o1 _. o..H ••. New YOf~ 1 ~ 77, P U2
HDA
CAS E The 1967 AIChE Student Contest problem presents the selectiVity dala gl\<cn
STUDY InTable 8 -1. If we plot the dala as In(1 - S) versus 10(1 - .x), 50 thai we make the
data as sensitive as possible, we: ohlalll the results shown In Fig. 8 -1.
I. Now, If we fil an equallon (0 the data and rearrange the results. we obtain

0,0036
S = I - (I _ X)I ~« (" ·3)

Conditions : Gas phase, no cata lysl

o 10

The design of a process 10 produce: benzene by thc hydroalkylallon of toluene has

been d iscussed in numerous chaplers in Ihls leX!. The purpose of this appendiX is
simply to collect and present a SCI of sample calcula tions for th iS case stud), This
problem is a modified version of the 1967 AIChE Student Contcst problem .

LEVEL 0: INPUT INFORMATION

The definition of the p roblem was given 10 Example 4. 1-1. The infonnatlon of
importance IS as follows:
Reactions:

Toluene + Hz ...... Benzene + C II . (8-1) '\

2 Benzcnc;;::::Diphenyl + H2 (8·2)
.\
Reaction condllions: Reactor inlet temperature = 1150~ F (10 get a high
enough ra te) and reactor pressure = 500 psia
Selcctivity: Moles being produced per mole of toluene converled = S
o.0 1 \
0. 1 I0
I - x
• SC>£ J J McKell&, -EDCydopedi. of C,",mlCl' P,occssms and Des'sn,- .01 4, I:>':ILlc•• Nc:.. Vo rk ,
1917, p 182 nGe,u ; 8-1
Sclccmuy of the: Il [)A proc.=
518
 lEVEL 1 Ilf.OSlOliS IS'U1.()lf1"U1 fTIlUCTUIl£ 52 1

2. Producllon rate = 265 mol/hr of ben7ene TABU' 8-2

Component dfc'itinalinns
J. Product punty :
ComtM'W nl N8P.Gf 1}esIMuU;"'"
Xo ~ 0,9997
II . -.13 Gu .ccyck Bnd pU'lr
4. Raw materials: Pure toluene at ambienl condi tions; 95 o,~ Il l' 5 %('II. al IOO~ F. CII, 219 Gas l'tCyck: Bnd purlC
550 p~1a
5. ('on~tnllnt~· II z , aromatics = 5 at reactor inlet (10 pre\ent coking ); reactor
outlet temperature S 1100 1 (10 pre.'ent hydrocracking re:u:t.om), quench
9cnlcnr
Toh"' ....
l)'pI\cn)1
7762
.,.
HI 1
. Primary produc.
Recyck:
8) -1'.od...,'
reacto r emuenl 10 1150 F ( to pre\ent cok1l11!-)
6_ Other plant and Slle data are lP"en where needed 5, Number of product Slreams: The component boiling pollltsodand destinallon; :~e
gIven III Table 8 -2 The II I and C H .. are lumped as one pr uct stream. an e
benzene and diphen ~ 1 are t"'O additional product streams, T hus. the flowsheet IS
LEVEL- l DECI SION: HATCH VE RSUS gwen in fig. 5,1-2
CONTI NUOUS 6. Material balance~ and stream costs : Let
Choose a conlmuou<; pr<:l«SS, (8-4)
P" ..., 265 molfhr ben7ene x = 0,75 )' ,.H " 04

0.0036
S "" 1 - = 0.9694 (B-3)
LEVEL-2 IJ ECIS IONS: IN P UT-OUTPUT (I - x)
1 , . ..

STRUCTU RE
Fresh feed toluene
See Fxamplcs 51-2, 52-I. and 5.3-1
p. 265 ( 8 -<;)
F, - S = 0 _9694 = 273 4 mol lhr
I. Punfy feed strr:.am:;· The loluene feed strr:.am IS pure; do no! purify the hydrogen
feed stream because Ihe methane ImpuTlly IS small. Also. methane IS a by-
Dlphenyl produced
product of Ihe rr:.actions. and the separation of gases IS cxpensive.
2. Reversible by-products: Diphenyl is a by· product fonned by a reversible PD - P.,(I - S)/2S (0-6)
reaction. Thus, we can eilher recover diphenyl from the process or let it build up
10 ils equilibrium level in a recycle loop. Ir we remO\'e the diphenyl, we hne a _ 265(1 - 09694)/2(0.9694) = 4.18
selectl\ity loss of toluene to produce the dlphenyl. However. if we recycle the
diphenyl. we can avoid the selectivity loss. but we must o\·ersi7.e all of the
Extent 1 = 273.4 Extenl2 = 4. 18 (D-7)
equipment III the recycle loop to accommodate the recycle How of dlpheny!. We
guess that it is chr:.aper to reco\'er the diphenyl
Makeup gas:
3. Recycle and purge ; Since a reactant (hydrogen) and both a feed impuTlty
(methane) and a reaction by· product (methane) boil lower than propylene, we p. PJ"I - S) _ P (B-8)
WIll nttd a gas recycle and a purge stream; i.e., we want to recycle the hydrogen. YrRFG - S+ 2S - Y"H G

but Ihe methane will build up in the recycle loop so Ihat it must be purged. A
membrane separation process, which could be used to separate the hydrogen
and methane, might be less expensive than the leKS of hydr(lgen m a purge (I -YrH)f-G + p. = (I -}",." )PG (B-9)
stream. Unfortunately, however, no deSign procedure or cost correlation is
S
available for membrane separators. and so we base our fir~t design on a gas
Add the<;c expres~lOn~ 10 obll!.ln
recycle and purge ~trcam
4. Excess reactants: Sillce neilhe r 0 1 fro m air nor 11 10 is a reac tant thcre are no (8- 10)
e~ce~~ react"nt«
 I.Ht.1 J I>t.( 15I0t<) ~E":YltE SlIL"CT"U or TIll IW .... UUl 523

Combine Eqs 0-8 and B-IO

proc(:» alternatl~e) .1) wc t1c~dop II d~lgn , II is easier to rcvi!! .... these decisions
I-a '" 1',(1 - (I - J/,,)(I - S)/2] after \Ie complete a base-(;<lSC deSign The altcrnati~es at Inel 2 are as follo ....'5.
( B· II )
S(YF" YI"")
_ 265[1 - ( I - 0.4XI - 0.9694)/ 2] I. Remo\'C the C II ~ from the:: II I feed ~lream This IS probably not dcslrable
- 0.969-l(0_95 _ 0.4) = 492 5 because .....e produce (, II ~ a) a by-produ..:! anyway
2. Re<.:}ck the dlphen)1 rdther th.1II removlIlg It Wuh this approa<.:h ....e a~oid
265{1 0_9694) an~ ~dccm'ny I n)~ of toluene to dtphcllyl, but \IoC must o,)\er~Jl': "II thc
P" :: 4925 + --- = 4967 (D-12)
2(0.9694) equipment m the Jlphen}'I-recyde loop to a<.:commOOate the eqUihbnum flow
Excess II I of Jlpncnyl
3. Reco\'er some II I from the purge stream We must determine \Iohether the 11 2
Fc= YI"" F G = 0.4(492.5) = 197.0 rcco\ery is Jusl1fied by determinmg the cost of the recove ry system
P, P,
II 1 Rcacled=S--2S(I-S) ( B·I3)
LEHL-3 DECISIQ S, REC YCLE
= 273.4 - 4. 18 = 2692 STRL·cr URE OF TilE FLOWSHEET
S tream costs ;

Va llie of Be nzene = SO.85/gal = S9.04/ mol =- ell (8 ·1 4) Design Decisions

Tolue ne - SO. SO/gal = S6 40/ mol = C r (8 -15) The deSign deCISIOn:. for the Icc yc1e structure were dl!>C ussed III Example 6. 1-2.
(ass uming II capllve internal price) Ther.c are bnt:fI) re, le\loed no ....

l-I l Feed = SI.J2/mol = C ( 8 - 16)

". J. Onl~ one reaClO1 I) lI:qUlred (the reactions lale place at the same temperature
Ileal values : and pressure)
H z = 0.123 x 10" Btu/ mol = t1 fJ c." 2_ There are two recycle streams- a gas recyle (and purge) or 11 2 + C H. and a
( B· 17)
bquld toluene-recycle stream
6
C H. = 0.383 x 10 Btu/mol = t1Hc II (B·18) 3. We mus t use a 5,1 h~drogen-to-aromallcs ratio OIl the reactor mlet accord 109 to
Benzene = 1.4 1 x 106 Bl u/mol = 6 H c .. (B·19) the problem sta tement
4. A gas· recycle compressor is required
Toluene - 1.68 )( 1()6 Btu/m ol = oH,., (8·20)
D ipheoyl _ 269 x 10' Bl u/ mol = t1l1c.o ( B·21) Before \Ioe can deCide on the reactor heat effects, we must calculate the recycle
( We ass ume Iha l the fuel va lue of diphenyl is $5.38/ mol.) matenal balances The recrde ftowshcct IS shown In Fig. 6.2-1.
Economic pOlent ial:

E P - C, P, - CT FF + C,'(t1 Hc.o P o + [t1 Hc." Y,,, + t1 Ho, ( I

- YI"H)]P G)
Recycle Material Balances
(B·22)
We can use this rela tionship and the expressIons above 10 p repare The recycle material balances were: developed as Eqs 6.2-2 and 6.2- 10.
Fig. 5.3- I. Toluene 10 reacto r :

( B-23)
uvel-2 Allernalives
We made several decisions concerOing the structure of the Rowshee t and If we had 265
made dl fTcre:n1 decislOlls, we would have changed the fl owsheet . If we Jist the - 0.9694(075) = 365
524 L!!VEL J DECHIQ~S "tncu! ""UClU"!! Of" THI! f"WW$H1!I!T l!!V!! .... J 0£Cl510J11 UCYCU: mucro"l! Of THI': noWSHEET 52.5

Recycle gas :
Also,
-
p _')' (SSS)"'"
_ _ _ 1.046
(T,)
__
(B-29)

Rc - p.
S)'I'H
(M - Y'.)
J. YrH ..1'1'''
(8-24)
( PIn 465 T,

and rOf our first design we assume tbat this value is constant. The gas density at
100°F and 465 psia. given an ideal gu, is
_ 265 ( _ '_ _ 0.95 ) = 3376
0.9694(0.4) 0.75 0.95 0.4
_ ( _1_ mOl) (460 + 32) 465 _ 0.0774 mol/ ft' (B-30)
P.. 3S9 rt) 460 + 100 1• .7
Reactor HCIII EH"f'Cts and the inlet pressure is
The reactor heat effects were dISCUSsed In Examples 6.3·1 and 6.3·3. The reacto r
(B-3 1)
heat load is
The volumetric now rate is
Ra(mol/h r) R,.
6
(B-25) ( B-32)
" 265 ) - 5.836 x 10 Btu/hr
2 1.53"\0.9694 Q;" = (P .. mo l/n 2X60 minjhr) - 6Op_

and tnc adiabatic exit temperature is given by Then since

p.
Q. = AU. S
273(
RG = - 5
-
0.4 0.75
- 0.9 5 ) - 3371 mol/hr
0.95 0.41
(B-33)

= p . 16F,. + (7YI'/I + 10,1(1 - "I'/I)]R G + 48.7F T HT•._, - 1150) 3371 .

(8 -J4)
Qlo "" 6O(0.0774} - 727 n' fmm
2 1,530P.I S
T,,_, - 115O+ -
. 7. 16F G + (10.1 3.1YI'/I )R G + 48.7P.f Sx
Also, hp = 3.0~.;5~0 - ' (6.70)( IO·X727XI.046 - I) = 267 (B-3' )
= 1150 + 2 1,530(265/0.9694)
7.16(492.5) + [10.1 - 3.1(0.4))3376 + 48.7(26')/[0.9694(0.75)]
and the brake horscpower is
= 1265 (B-26)
267
bhp '" - = 334 (B-36)
These resuhs are shown in Fig. 6.3-1, and we find that we expect that an adiabatic 0.8
reactor will be acoeptable.
Guthrie's correlation (Appendix EI) gives

M&S
Recyde Compressor Costs Install. Cost = 280 (517.5}(bhpt u (211 + FJ (B-37)
The reactor pressure is given as SOO psia. We guess that the pressure at the phase
splitter is 465 psia and that the recycle compressor must increase the pressure to U M&S .., 792 and Fe _ 1.0 (a ocDlrifugal compressor), and inlToducing a capital
555 psia This allows a pressure dropof90 psi though the gas-recycle loop. We need cbarge ractor of! yr to put the installed cost o n an annual basis. we find that
to assess the sensitivity of our design to changes in this guess..
The design equation for a gas compresso r is 792) 0.82(3. 11)
Compressor Cost = ( 280 (517.5)(334) 3 =S I77,800/ yr (B-38)

hp _
(
' .03 x 10
- - ') p . QI
Y ,..
[(P--)'- I J
PI.
(B-27)
For optimization calculations. we can write
Using Table 6.S- I, we can wri te
y - 0 .29YI'H + 0.23(1 - YI'/I) - 0.254 (B-28)
CompoCost .. ( 3371
R, )"" [(555/J465)'
.046
- IJ'" ( B-'9)
526 ~fiVH l PEeiSIONS UCYC U snUCTUIIE ot TIlE noWS't~£T

The operating cost is based on a motor efficicncy (comprcs~o r plu~ motor) of where T. =: (1150 + 1265) 2 '" 120.7_ from Eqs B·42 and B-43
08 and a power cost of SO.045/lwhr :
klli/l =: 6.] xIOU'(& mOI)"[( 1 ~ : mol )(28.32 L)J- l
I
.

Ann Cost - (334h P

08 )( Ikw )(0045)( h')
IJ41hp kwhr 8150 yr =SII4,OOO/ yr (8-40)
l 4541b mol ft l

mOIJ'"e;\p [-1.987(
52,000(1.8)J
We can also wnl~ tlus expr~ss'on as
)(
r04(O.0Z79) fll 1685) (B~46)

; 2522 x JO·[0 4(0 0279)O!exp 93600

, ] =0.0142s 1
[ 1987(1667)
Po"er COSI - 114,000 (3~;1) = S3].8IR G /yr (0-41 ) Thcn. from Eq. 8 -44,
v: _ (492.5 + 2048 + 364)(mol/hr) In (1 /( 1 - 0 _75)] _ l
(8-47)
Re.ll clor CoSI 11- (00142s - ' X3600sjhrXO.0279mol/ ft) -4090fl

The kin~tics for the primary reaction have been discussed by Silsby et al. ° and by Ifwc assume a cylindncal reaClor with L,,JD . ... 6, then
Zimmerman and York I Since Ihe amount of diphcnyl produced is "cry small, we ,0'' n ,
base the reactor design only on the primary reaction. (However, a kinetic model for I,c -- LII II< 4 (6DJI) ( B-48)
4
the by-produci reaction IS available in Hougen and Watson.') So
and thus, D II = 952ft LJI - 56.96 ft (B-49)
r = _ k(T)(H)l l l (8.42) c
The tolel and outlet temperatures for the reactor are 1150 F and 1265G F.
which is very high, and therefore we will add 6 In. of insulation on the inSIde of the
where k ... 6Jx 10,0 (g . mol 'L} - '!l(s - I) exp [ - 52,000 cal/(g · mOI)J (8-43) rcaclOr to try 10 Icttp Ihe inside walltempersture below 900°F. The addition of thIS
RT, Imulallon requires Ihat we add a nother fOOl 10 the diameter of our reactor shell,
and 10 be somewhat consenau\.-e Yoe lei
Smce there IS a la rgc execS!; of hydrogen, we assume Ihal IJ ul IS a constant
Also, lIo.e assume Ihal we can eSllmale the reaclOr ,·olume based on isolhermal LII - 60ft ( B-50)
operatio n, although "C wIll base the Isothermal reaclor temperature on a mean Then, from Guthrie's corrclallon for pressure vcssels,
value bel 'Ween the reactor lIl1c:t and out1c:1 temperatures T. = (II SO ... 1265)/2 -
1208 Thus, we write Ihe reaclor volume V. as Ann. Cost"" (792) (101.9XIOI OlioX600 11) 2. 18 ... 3.67 + 1.6
282 3
I' _ cF-'Clo"'[,-;I"
I(,- x"Jl
1 _-.. (8-44) = S239,254/yr (8 -51)
II kp",
We neglect the cost of the insulatIon in OUT first cstlmate of the reactor cost, hoptog
Ihat the additional cost associated wilh oversizing the reactor will compensale for
wherll the molar density at the reactor conditions (assuming an ideal gas) is
the Insulation.

+ 32)(500) ,
Po. - (359I mOIX460
fl] 460 + T. 14.7 ... 0.0279 mol/rt (B-45)
Economic Potential
By subuacting Ihe annualized reactor cost and both Ihe annualiz.ed capilal and the
operating cost of the com pressor from the st ream costs (i_c., the leveJ·2 economic
• R I SIt~byand E. W Sawycr; .1 App/ CIwm_, 6 341 (AulW;! 19S6); W D BeLl f." Poppcr.aod R [ potcntial, Eq. 8 ·22), we can calcu late Ihe economic potential at level 3 as
S;l$by • .1 App/ CMm . 7 4'17 (Scp!cmbcr 1'157) a function of the design variables (conversIon and purge composition): sec
'C. C. Z,mmmnan and R YOIl. ldf:.C 1"01: V~. On:_, 3 2501 (Ju[y 19(4) Fig 6.7-1. We note that there IS all o ptimum value for both con \·ersion and purge
lOA lI olllcn and K M Wal$On, CM",ocall'rocrn Pmlc,p/~. Pari III . I("""ru·. a..J C IJUJ/ ySIJ, WI[Cy, composition. or course, these optIma arc not the true oplima because we have not
New Vorl. t947, p 87S considered the: separallon co sts or the heat exchanger costs yel. However, we do
518 UVE1.. u,,,v.nON !YSf£)I U!vu. ... V"I'OII. U!COVl!.I.Y SYSTEM 529

cote that the range of the design variables where profitable operation IS possible plant group to run some additional experiments (which is why we want to
has been significantly reduced. Since the process is still profitable. we continue to undertake the conceptual design study very early in Ihe life of a project). The value
the next level. of the benzene in the flash vapor stream. assuming that all of it is losl. is

Potential Benzene Loss .., (29.6 mol/hrXS9.04/rnoIXBI50 hr/yr)

LEVEL 4 : SEPARATION SYSTEM
_ S2. IB x 1rJ>/ yr (B-55)
Now we add the details of the separation system. To determine the general
structure or [he separation system. we must decide which of the flowshee[s shown in which is very large. Thus, there is a great incenti\e fOf undertaking the experiments.
Figs. 7.1-2 through 7. 1-4 is applicable. The reactor emuen! is at 1265<>F and As an alternalive, we cou ld attempl to increase the pressure of the fla sh drum.
therefore is all vapor. Then, providing we obtain a phase split at 100°F and 465 Since PrY; = )',r:x j , .... e often can obtain a reasonable eslimale of the dTecl of
psia. the flowshect given in Fig. 7. 1-4 will be correct. pressure by using Ihe expression
We can usc either the Hadden and Grayson method given in Sec. C. I or a
FLOWTRAN program to find the K, values for the flash drum. The nash (8-56)
calculations were discussed in Sec. 7.1, and as shortcut expressions we use these '
so Ihat increasing the pressure will decrease the K value for benzene and will
Light components, K j > 10:
decrease the amount of benzene in the Hash vapor. Since tbe number of moles is
1- J,'L!' (B- 52)
conserved in the reactions, Eqs. B- 1 and 8-2, pressure docs Dot appear to affect the
,- KILl. reaction rate or the equilibrium. However, the possibility of coke formation or
hydrocracking rcaeliocs (both of which were mentioned as the causes of some
Heavy components. K J < 0.1: conslrainlS in Ihe problem fonnulation) again makes il essential to undertake

II ~f{ 1 - Kr.~J,)
additiona l eltpcriments before we undertake a design at a higher pressure.
(D-S]) Ralher Ihan gel bogcd down in details about the benzene.recycle loss or
pressure effects, we go ahead and complete a firsl design. In particular, if Ihe
With Ihese eltpressions. we calculate the vapor and liquid flows leaving the flash process is not profitable in any even I. so that we decide nOI to proceed to a final
drum (see Table B-3) design. then we do not wanl to waste money on experiments developing a data base
Lh "'" 1549 + 2]23 = 3872 i..fJ "" 26S + 91 + 4 = 360 (8. 54) ror a plant Ihat we are nOI going 10 build.

From Ihese results. we see tbal we obtain a re&SOnabk phase split. However,
a significant amount of benzene leaves wilh Ihe flash vapor. Some of this benzene
LEVEL 4a: VAPOR RECOVERY SYSTEM
will be lost in the purge stream, and the remainder will be recycled with the gas If we are going to include a vapor recovery system, we must decide on the location
stream. From the rcaclions in Eqs. B-1 and B-2, we would expect Ihal some of Ihis (flash vapor, purge stream, or gas recycle) and the type of recovery system
recycled benzene will be converted to diphenyl. However, OUT selectivity correla- (absorplioc, condensation, adsorption, o r membrace system). In the discussion
tion, Eq. 8·3, does not indicate that there will be any loss. above, we estimated the value of Ihe tolal amounl of benzene leaving in the flash
We suspect thai the dala given in Table 8 · 1 were for a pure loluene feed , so vapor. If it should be acocplable to recycle benzene, we slill must estimate the
that no loss would be appan:ct. Hence, from the information available it is nol benzeoe aod toluene loss in the purge stream, 10 see whether we should place a
possible to eslimale the benzene los$. and we should ask the chemist or Ihe pilol reco\'cry system 00 this purge stream. The flash vapor flows oC benzene and toluene
arc given in Table B-3, Ihe purge flow is given by Eq. B-IO, and the gas-recycle flow
IS gh'en by Eq. B-33. Thus, the fraction of Ihe flash vapor that leaves as purge is
TABLE 8-]
Flash takulations
Fraclion Purged _ PG 496
496 + 3376 - 0. 128 (8-57)
t. . II 1(' _"1 • PG + RG

.
Com..-

H,
" 99.07 ''') 2 The benzene and toluene losses are thert
.....
CH,
~
ToIliellC
2lll

'""•
20.00
0.GI04
0.00363
2312
29.'
)..
"
2U4
81.4 Benzene ill Purge = 0.128(29.6) = 3.79 mol/ht
Diphe:nyt 0.I10000I 0 • Toluene in Purge = 0.128(3.6) = 0.461
(8-58)
530 I..lVEI.. 41> I..IOUID 5i!1' ....... 00H usn ...

and the values of these streams Ire (sec Eq _ 8-54) T"'BU:~

Lo1'l-prtSsure Huh
Benzene Loss"" (S9.04/molX3.79 mol/hrX815O hr/ yr) = S279,200/ yr
(8-59) CDQlpcNII'li1 f. or fJ K, orK J •
Toluene Loss _ (S6,40/moIX0461 mol,11r)(815O hr/yr) = S24,OOOj yr
,
Now we must guess whether Ihe addition of a benzene and toluene recovery
system on the purge st ream can be justified lI o .... e\er, If the costs of the hqUid
II,
CII,
Bcnunc
II
2354
'"08'00906
'"
'"
0.8 5
00>
1.49
114 55
sepa rallon system and the heat-cxchanger networlo. arc ~uffiClcntly large that the
process loses money (and we decide not to bUild it). 'ftC do not want to spend much
rol~nc
Dlp"" .. )l ."• 00337
0,000074
011
0 ""
0

effon on the d esign of a \'apor recm'ery syStem. Thus, tentatively, we accept th iS

purge loss, although we might return 10 this problem later. (For example, we could
usc the lIadden and Grayson correlations given in Sec, C.l for such a large
use the toluene feed as the solvent in an absorber.)
pressure change). Thus, we obtain tbe K values and tbe component flows from
Table 8 -4 :
LEVEL 4b, LIQUID SEPARATION SYSTEM [k-" 2 + II = 13 [Ii = 23.5.4 + 81.4 + 4.0 = 326.8 ( 8-62)
From tbe results o f the flash calculalion (sec Table B-2), we have an estimate of Ibe Now if we recover all the H l • CH. , and benzene, we find that
amount of H 2 and C H. dissolved In the flash liquid. If we assume that we recover
all the benzene, then the feed 10 the liqUid separation system is 234.55
liD = - - = 0.9935 ( 8 -63)
Feed : H2 = 2 C H. = II Benzene .. 235.4 Toulene = 87.4
234.55 + 0.05 + 1.49
Diphenyl _ 4 moljhr (8-60) which IS SIIII less than our desired punty of X D = 0.9997 (even if we neglect the
toluene m Ihis stream). Moreover, there is a fa irly large benzene loss from Ihls low.
pressure Has h ; ie_, from Eq. 8 -.59
Le,el-4b Decisions
The decisions we must make concerning the liquid separalJon sySlem incl ude Benzene Loss - (S483,OOO/yr'\316 "'" SI09,200'yrJOS') ( 8-64)

I. H ow should Ihe light ends be removed If they might contaminate the producl'~ Hence, OU t eSlimates mdicate thai 'ftC probably will need a sta bilizer to obtam a
1. What IS the best deslinatlon of the light ends? product stream with the required puril)' (a pasteurization section on the produci
3. D o we recycle components that form azeotropes with the reactants? column might be acceptable, and we list this as an ahcrnali\·e),
4_ What separations can be made by distillation? If .....e recover the light ends ( H l and C H.) in a stabilizer, Ihen we would
S. Whal sequence of columns should we use? normally send Ihese lighl ends to the vapor recovery system to recover any benze ne
6. How should we accomplish separations if distillation IS nOI feasible ? or IOluene that leaves with this stream (or to any uni t that recovers and recycles
some of the hydroge n from the purge: stream). However, since we have nOllOciuded
We diSCUSS most of these decisions below. However, no azeotropcs arc a n~ units of this type (at least at this time), we would probably send the hght ends
formed with the reaclants and distillation separations are easy for all the to tbe fuel supply.
components, so Ihal ilems 2 and 6 arc not considered.
COLl.'MN SEQUENCING. To usc a slabl lizer column to rcmo\e the 1-11 and C H.
UGIIT ENDS. If we recovered all the benzene as well as the H 2 and CH. overhead from the benzene producl , we normally p~essurize this column 10 make il easier 10
in a product column, Ihe product purity would be condense the overhead and thereby to oblam an adequate amount of reflul:_That
15, the H, and C f-I. are remo\·ed as a vapor slream from Ihe rellux drum after a
x "'" 235.4 "'" 0.948 (8-61) panial condenser, but it is necessary to lake some benzene overhead 10 provide an
D 2+11+23.5.4
adequate amount of liquid reflux. From Table B-3 the K va lue nf bcn.lcnc is rairly
which is well below our product purity requirement of Xu = 0.9991. Of course, high at 50 psia, so that we might sct the stabilizer pressure at ISO psia, or so.
some toluene must leave In thiS stream. If we use a column sequefi(;c that docs not remove the light ends In the fi rst
If we attempt to drop the pressure to 50 psia and fla.sh off tbe I-i l and C H. , we column, then e ... ery column thallolally condensed the H J and CH. in the overhead
can obtam a rough esllmate of the K values by uSing Eq B·.56 (it would be better to .... ould ha\e 10 be opera ted at high pressure. Thus, the capital cost probahly would
 UVt:L", UQUID SEI'AlUl'IOtl SnfEM .533
be greater than if .....e had removed the light ends 10 the firsl column Sumlady. ICwe recover 99_5% of the toluene overhead and 99. 5~~ of the dlphenyl In the
Qperation of several columns at high pressure IIlcreases the bubble points of the bottoms. then we find that
botloms Slrcams. so Ihat a higher-pressure steam might be requi red to drive the
rebollers. For these. reasons, \I.e assume that il is cheapest to remove the hght ends d r = 0_995(87.4):= 87.1 do = 0.005(4) = 0.02 1 (8·67)
in the first column.
When we then consider Ihe separation of benzene (234.5 molfhr). toluene ,nd ,~_87.1 =09996 (D-68)
(87.4 molfhr). and d iphenyl (4 molfhr), almost at[ the hcurist lcs (i .e .. lightest firs!. o 87.1 + 0_021 .
most plentiful first . favor equlmolar sphls - but not the easiest first or save dlmcult. Also. "'r .." 0.005(87.4) = OA38 " '0 '" 0.995(4) = 0_-'98 (n·69)
high-purity splits until lasl). favor the dirc:ct sequence. Hence. for our base-ClIo;('
design .....e Will choose the hghtc.~1 first sequence to evaluate However. complc~ 0438
'nd '<. = 0.438
-- + 198
= 0.095 (8-70)
columns might provide a cheaper separation system.
Now we want to estimate the sizes and the costs of the columns. Since the
Assuming a saturated-liquid feed. Under ..... ood's equation for minimum reflux
rccycle column. I.e~ the toluene-diphenyl split, involves only a binary mixture, we
consider the design of this col umn first. Similarly. we consider the design of the
product column before we consider that of the stabilizer. We design both oC the
R _ _,_ ['. - '(' -
.. aI I Xr I
'0)]
Xr
(B-71)
recycle and product columns to operate at slightly above ambient press ure because
it is easy to condense both toluene and benzene with cooling water at this pressure R _ ' [0.9997 _ 25(1_ - 0.9997)J ( 8 -72)
.. 2S - I 0.956 I - 0_956
TOLUENE COLUMN. From a plo l of the vapor pressures of toluene and diphenyl,
,.,. h (1.0456 - 0227) = 0.0347 (8 -7])
we find that the slopes of the vapor-pressure curves for these two componenlS are
some..... hat dllTerent. This result, according to the Clausius-Clapeyron equation. .....hich is very low: the feed composition is very high. and II is very large. With a very
implies that the heats of vaporization of the Iwo compounds are different, whIch to lov. \'alue of reflux such as IhlS, we should also consider the usc of only a strippmg
turn implies that the common assumption of equal molal o\erflow in the coluOin column as an alternative. Hov.e\er, we contmue wilh Ihe design. and .....e let
will not be correct We could correct for this difference tn latent heats b)
introducing a fictitious molecular .....eight for one of the components and then UStng R ::::: 15R .. = 1. 5(0.0]47) = 0.Q5 ( D-74)
the McCabe·Thiele procedure to design the column. However, fo r our prelimmary According to Fenske's equation, the nlJOlmum number ofthcoretlcal trays at
calculations we Ignore thiS potential difficulty. tolal reflux needed for the separation is about
From the vapor-pressure data, we find that
, In [x oI( 1 - xo)][(1 - x.)/x,.] In[(O.9996jO.OOO4XO.905jO.095))
760 ,- -=. =3 13
...p - - (8·65) .. Inal 1025 '
7.4. , 102.1
( B-75)
This is a large vanation in Cl, as well as a very large temperature gradient across the We can obtalll an estimate of the number of theoretical trays required at the
colUmn, thaI is, 110.6°C _ 231°F at the top versus 254.9°C = 492°F al the bottom. operaling renu.x ratio by using Gilliland's approximation
Thus, we Cl:pect that some of the simplified design procedures. such as Fenske's
equation, Gilliland's correlation, or Smoker's equation, which ..... e often use to NT = 2N ..... 6.2 (8-76)
estimate column designs. may give misleading predictions. Nevertheless. we might
The o\'erall plate efficiency is given by O'Connell"s correlation, Eq A2-72. For a
be able to get some idea of the column design with these shortcut design procedures
quick esti mate we assume that JJr = 0.3, and .....e write that
if we choose a conservative estimate o f aI., . For this rea SOD we Jet aI = 25
Given no losses of aromatics anywhere in the process (which. of course, is not 0.5
really consistent with our other calculations. but the efTor is small). the reed rate to Eo!:l:: ~ 0 u ... 0.302
(0.3a1)
(8-77)
the toluene column is 87.4 mol{hr of toluene and 4 mol{hr o f diphenyl, so that
Then the actual number of required tray .. IS
x, = 87 _4/{R7A + 4) _ 0 _956 (B-66)
62
Thus, the feed composllion of toluene IS qUIte high ,.., ... .., 21.6 = 22 (n 7R)
0.30
 I. , ·t l 'b II<.,IUlD SErAl'.ATK)1'< SUl fM S3S

For a 2-fl tray spaclIIg and an additIOnal 15 ft at the ends, the tower height 15 The area then bc..:o melo
1/ ... 2(22) of 15 = 59::::: 60ft ( 8 -79) f2
A. _ 19,600(917) _
11 ,250 - ]60 I
(8-911
The lower cross-sectional area can be estimated by using Eq A 3-12
and the cost is
(8 -BO)
and we want to base Ihe design o n the bonom of the tower, i,e,t ht: dlphenyl, where ( B-9?)
At = 154 and r.
= 492wF The vapor rale is wrinen as
1'- L + D ... (R + I )D = 1.05(87.1 + 0.021) = 91.73 ( B-B I) The boiling paml of dlphen} 115 492' F, and 50 we must usc 10000psi stea m (or
and Ihe area becomes some high-pressure level} 11\ the reboller. Of course, we could usc 420-plol ste:l m If
we Clperaled the to wer under a \acuum, 50 Ihat the bollmg POint of dlphcnyl ..... as
A - 2124 x lO - ol J I54(492 + 460)(91.7) = 7.5 ft J (B-82) reduced 10 about 420~ F (w hlCh wo uld allow a 6 Tof 30"F} Il owever. since Ihe costs
associated with this column 3re reasonably small up to this point, we use lOOO-plol
The column diameter is steam Then the steam COSIS are
f4A = h')
D = ";7 27::::: 3 fI (B-83)
C (
Ann_ ost =
S2.25)[19,6OO(9J.7)lbJ(
IOOOlb 667,5 hr
960001
81SO yr =S4. yr
Now we can use Guthne's correla tIOn to find tbe cost (B-93)

Ann. Cost = 792) (101.9X31066X600.BOl {30IB)

(280 _
3'
S26 300/ yr
= (B-B4)
ThiS cost is fairly high, so that we might want to cxamllle some ahernallves later

BEl'"ZE;\"E COLUMN. Again assummg perfect separations and no losses, we Sec:

TOLUENE COLUMN CONDENSER AND COOLING WATER. A condenser heat that Ihe flow rale 10 the benzene column contams 235.4 mol 'he of benzene.
balance gives 874 mol 'hr of toluene, and 4 mol 'hr of dlphenyl. Since the diphe nyl flow rale is so
Qc - 1l1I 1, 1' = U c A c l1T.. = w,C,.{ 120 - 90) (8-85) small "'c assume thaI we could obtain a reasonable estlma le oflhe column design If
",e lump II together "lIh the to luene Then
and if AH. z: 14,400 Dtu/ mol, U = 100 81U/(hr · ft z .oF), and
c r. "" 231 °F,then
235.4
l1T. _ 120 - 90 ..,1250F ).F - 2354 + 914 = 0720 ( B·94)
(B-86)
.. In «231 - 90)/(231 - 120»
In addnion. our product Spcc1fiC81l0n for benzene requires that Ihe punly be
14,4001'.91.7) 1
Thus, (8-87) 9997~;" and we want 10 reco .. er 99_S~o of the benzene overhead. Wilh IheS(
Ac - 100(125) = 105 fI
restncllons
and the annual cost IS
d., _ 234.2 (I - 0.9997) = 0.Q7 (0 -95)
Ann. Cost = (792) (30")
280 (101.9)(I05° ") - 3- = S6500/yr (B-BB)
d. = 0.995(235.4) "" 234.2

w. =
0.9997
235.4 - 234.2 _ J.2 wr = (87.4 +4- 0.07) = 92.33
Also, the cooling-wa ler costs are
'0
Ann c 051_ ($0 06)( IB'I)[14,4OO(91.7)lbJ(
0

10000gai 8.34Jb 30 be 81SO

h') - S2600/ yr
)t.,. _ 0.013 ( B-96)
yr
(B-B9) From the vapor-pressure data we find that a •• ~ 2.5, and then Eq. 8-71 gives

TOLUENE COLUMN REDOILER ANfl STEAM. A heat balance for Ihe reboller I I
R",::::: = '"" 0.926 ( 13-97)
gives (a - I)x, (2.5 - 1)0.72
(8-90) Hence R ::::. L2R", _ L2(0.926) _ I II ( 8 -98)
S36 ll!Vf:l ... LIQUID U,,,lAllOtl SYSTEM Lf;Vf:L ..· LIQUID n' ....... ~ $YS'Tn' SJ7

Also. from Eq. D-75. Rnd the cost is

N.....
In [(O.9997ft100l3)(0.981/O.013)]
In 2.5 = 13.6 (8-99) Ann. Cost = G:~) (101 .3)(92806~{3.:9)
Then, by Gilliland's approximation "" S26,700/ yr ( 8 -109)

NT ~ 2N . ... 2(116) - 272 (8 - 100) Also. the cooling-water cost is

For a values in the range of 2 to 3. Eo IS insensitive to a (sec Eq A.2-72), and ~ ( S006 ) (~)[ll.JOO(494.7) Ib] (8150 h')
Ann. Cost 1000 gal. 8.341b 30 hr yr
therefore we can guess that Eo .. 0.5. Hence, the total number of trays required is
- S12,900/yr ( B- 1I0)
27.2
N ~ - = 54.4 :::: 55 (B-IOI)
0.5 BEI'IIZENE COLUMN RE80lLER ANI) STEAM COSTS. A reboiler heat balance
and the column height (allowing 15 n at the ends) is gives
Q. - Mlp P - U • .A..l!IT. _ n~M/$ ( B- III )
11 - 2(55)+ 15 - 125n ( B-102)
so that with l!IHr - 14.400, Ji' = V, and U.l!IT. = 11 .250. then
The cross-sectional area of the column is glyen by Eq. 8 -80, where we
evaluate the area at the bottom of the colum and V is given by Eq. B-81. Hence_ = 14,400(494.7) "" 708 n1 (B-112)
A. 11 ,250
.A. = (2. 124 )( 10 - "')J92(23 1 + 460) «1 . 11 + 1)(234.2 + 0.07) and the cost is
"" 19.73 ( B-103)
Ann Cost = G~) ( 10 1.3)(708° 6~)C·:9)
and the diameler is

D- cr I9 73
..J(4A11 ""..; 4 \.--;:--
,. - ) - 5.01 ft (B-I04)
= S20.800/yr

Morco'·er, the steam cost is given by

(8 - 113)

Then, fro m Guthrie. the cost is _ ( $1.65 ) [14,400(494.7) Ib] (8 150 hr)
Ann. Cost lOOl Ib 933.7 hr yr
Ann. Cost - G~) (101 .9)(1 251066)(5.01°.101) c.; 8) = SlOl,600/yr (B-1I4)

_ S8 1,3OO/yr (8-10') STABILIZER. The design of the stabilizer is not as simple as that for the other
columns. First, it is very difficult 10 find reliable thennodynamic data ·for mi.xtures
BENZENE COLUMN CONDENSER AND COOLING WATER. A heat balance of hydrogen and methane with aromatics. The variety of point! that could be used
o n the condenser gives o n the Hadden and Grayson charts (see Sec. C I) illustrates this d ifficulty_
In addition, the mixture o f hydrogen and methane that we desire to remove
Qc = 6.111' V "" Uc .A. c 11 T. "" wcC,(120 - 90) (B-I06)
from tbe top of the column is essentially noncondensible. so to obtain a sufficient
With 6HI' - 13,300, Uc = 100, and amount of liquid for reftuJl, we must allow some benzene to go o verhead. Howeyer,
as ....oe saw in the purge-loss calculation (Eq. 8 ·59). even small flows o f benzene are
120 - 90
;:In'''[('"17''7c-'i90;;;'')I(''1~77'-''12;n0'')1 ~ 10.9 (B-107) quite yaluable. Therefore, we want to pressurize the stabilizer oolumn. both to
6T. - minimize the benzene loss rrom the partial condenser and to be able to usc normal
we find that cooling water in this condenser. Of course, as we increase: the operating press ure.
we increase the capital costs of the column. or the condenser, and of the reboiler
13,300(1.1 1 + 1)(234.2 + 0.07) J because the wall thickness must be increased. lienee, we anticipate that there will
Ac - 100(70.9) - 928 ft ( D- IOS)
be an o ptimum opcnting pressure for the column.
 538 LEVEL'. LIQUID 51ol'AIlAllON SYSTUoI uVn 4b I MJUID SU·... UlION ~\SnM 539

To fix the operd lmg pressure of the slablllzer, we "ught start byexammlng We \,OIn ~m\plify the dOlgn cakul,UJolls If 'Ae lump all tho: arom3W.:S and
the behavior of the flash drum when K, < 0.1 for benzene For example, by conSider them to be benzene, so thai the benlene feed rate to the column bc:comes
considering the value lisled in Table B·3 for benzene. we might initially guess Iha l (sec Tabk 11· ') 235 4 + 1174 + 4 = 326.8 mol/hr. llence, the fccd rale I)
we want K. _ 0. 0.2 Then, from the "iadden and Grayson correla tion (Sec. C.I), the
F == 2 + II + 326.8 - 379 II mol/lir ( H· 124)
pressure of the nash drum has to be 280. psia 10 condense the: overhead al 100" " ,
and il is not even possibk to condense Ihe overhead at 1]0' F Similarly, if we Jet and the feed composlllon IS
K. = 0.05, we find that the pressure I) 80. pSia al 100°F ilnd 165 psia al IJD"F, so
AI" = 0.0055 A, = 0..961 (H-125)
the pressure calcula tion is \'ery sensitive.
Now, to determine the importance of choosing values of K, that are \·ery With thIS assumplion. the effluent from the bottom of the to"O:( 'Aill be
small, ie., in the range from 0..0.2 to o..o.S, we must eslima te the value of the benzene essenually pure benzene boiling at 150. psia Then from the Hadden and Grayson
that is lost with the vapor leaving the flash drum. We expect that the values of Klh correlat ions for K, = 1.0. and P _ ISO psia, we find thai the temperat ure IS 36o.~F
and K CH • will be very large compared to unity, and so we expect that the liquid In However, we expect that Ihe presence of the toluene and dlphenyJ 'A III mcrease IhlS
the flash drum will be essentially pure benzene. Then the equilibrium relationShip boiling pomt, thus we guess that the bolloms temperature is about 4OO' F. Also, at
when x.:::::: 1.0. gi ... es 150 psia and 4OQ°F, we find that
.Y, = K,x,::::: K/I (B-1 IS) K H , = 70. K CH , _ ]6 (8·126)

From Table B-3, we expect the hydrogen and methane flows leaving in the No'A, from Eqs. 8-119 and 8-125 we can estimate the II ... alues :
stabilizer overhead t~ be about 2 and II mol/llr, respecIIH:I), so ISS a," ___
36 900
Top ; aH, 0,04 - 4600 (8-127)
- • 0.,04
y, - K, 0;
'.
2+II+n/l
(8-116)
10 36
Bottom: all, = "I = 70 tlcu. = I :: 36
13K,
0' n,= - - - (B-1 17)
I - K. Clear!) to introduce an assumption of conSlanl rebtl\'e volatility would be
If K, = 0..0.5, then the benzene loss calculated from thiS expression IS about 0. 7 rather "5hal..y~ but all the shortcut design procedures rely on this ahumpllon
moljhr, and from Eq 8 ·59 the value of the benzene loss IS Hence, for our fir~1 design we as~ume Ihal :Xj IS conSlant, but we use the smallest
poSSible valUe, Eq. 8- 127 at the bollom, m our calculations.
Ann. Loss = 9,04(0..7)8150 = S51,600 lyr (8-IIS) Underwood'~ expression for the minimum reflux rales for binar)' separallons

which is fairly large. Of course, this loss is compensated, at least in pan, by the fuel should give us a conscrvath'e estimate for muillcomponent separation~. SO
value of the benzene in the overhead stream.
After examining the sensitivity of the benzene loss from the tiash drum o(the R ~ _ 1_ [X u .c , ~ tlc , XD.,] (8 -12S)
- (I( ~ I Xr.c, ,- )Cr.,
stabilizer. we decided to choose K, = 0.,04 with a condensing temperature of
II S"F, so that for OUf first design the operating pressure orthe stabilizer is 150 psia
At these conditions
I [O.SI2
-]6 ~ 1 0..0.324 ~ 3~\0.961
dOGO)] - 0.689 (8·129)

Kell • = 36 (B·1I9) Then, for an operating reflux, we choose

and the benzene loss is R ::::: 1.5(0. 689) ::::: 1.0.33 (B. I30)
I3(O.GO) We estimate the mimmum number of trays by uSing Fenske's equation, wliich we
n, = 1.0. 0.04'" 0.54 (B· I 20) wrile as
and Ann. Loss = 9.04(0.14)8150 = S39,SOO/yr (B·121) N .. In «xc,/x,)u (x,/x 1) .. ]
( 8 .13 1)
.. Inllc,_,
The distillate flows are then If (x, lxc,) .. - 10 -1>, then
dH • = 2 d, = 054 (B.122) In [(0.812/0,04)0,7 19/(6.62 x 10. ')]
N.~ 1,36 · - 3.' ( B·132)
so that XV.II, = 0.148 X O•CH • = 0..812 Xu., - 0.,040 (B·I23)
 S40 LEVEl. ... LlOUlO SEPA .... Tk),.. nSHM

Then, from Gilliland's apprmnmatlOn We let U c = 100 BIU/( hr ft l F), and we assume that AI/H. - 389 and dU ctl . -
3520 Btll mol lienee
NT = 2N.. - 6,8 ( B-133)
US1I1g Eq 8-19 to estimate the o\'erall plate efficIency (note that we are not eerlain (8 - 143)
that Jl f ". 0.3 centipoise at high pressures) g1\'ts

0.5 and the cost is

Eo = [03(36)]0 .i~ (8 -134)
'" 0.216
Ann COSI = 792)
(280 (10I,3)(41806~) (329)
-3- = S3600/ yr ( 11 - 144)
so that the total number of required trays is about
6.86 Also. the cost of coohng waler IS
N "'" 0.216 '" 24.6 (8-135)
Ann. Cost = SO' 06 ) ( ~~
1 •• 1 ) [ 83,600 -IbJ ( 8150 -''') _ S500/ yr( R_145)
and the column heigh I is ( 1000 gal 8J41b 1(100 9O)hr yr
II = 2(25) + 15 - 65 ft (8-136)
The vapor rate is STA BILI ZER REBOILER AND S rEAM. The reboiler heat balance is
QII '" l1HvV "" UtfA lI l1T,. = 1J~6 H' (8- 146)
V = (R + I)D ::::( 1.033 + 1)(2 + II + 0.54)::::27.5 (8-137)
and the tower diameter is (for an ideal gas) We assume that P= Vand 6Hp = l!H ., so that
A = 13,300(27,5) _ ]2.5 ft 2
A = 0.000214 [ 78(400 + 460'\150
j ")J'" (27.5) = 0.478 ( 8-138) II 11,250
(0- 147)

and the column diameter is and the cost is

J (79') (' 29) -=

4A
D= -;- = 0.8ft~ 1ft (8- 139) Ann Cost = ~ (101 ])(]2 SO u) - SJOOO/ Vf (8 -1 4R)
280 l -
Unfortunately, this diameter is less than Ihe allowable minimum value of The Ixulmg pomt of the bolloms is about 400 F. ~o 'A e U'iC 420-psla steam III 1he
1.5 fl, so we should consider the possibility of using a packed tower. lI owever. reboiler. Then, using the lalues in Sec. E.J. we find that the cost IS
clearly we have based our design on a number of questionable assumptions. so al
some poinl we mllst undertake a more careful analysis. Nevertheless, ollr primary Ann. Cost .. S2 ) [13,300(275)- IbJ ( 8150 -
~-
( 1000 Ib 775.6 hr yr
h')
- S7700/ yr (8-149)
focus at this time should be the processing costs of the lotal plant. ralher Ihan an
accurate design oC the stabilizer. and since we do not expect that the slabilizer 'Aill
be very expensive. we eSlimate Ihe cost LEVEL-4 ECONOMIC POTENTIAL. To calcula te the economic potential alle ..ei

Ann. Cost = G:~) ( 101.3)(65 1 066)(1°801) C· 18

; 1_15) = S5400/ yr ( 8 -140)
4, we sublract the annuahzed capital COSIS of the columns. condensers, and
feboilers. as well as the steam and coohng-water costs. from the values of the level -3
economic potential. In additIon, we must sublract the purge losses o f benzene and
toluene (as well as any recycle losses, but we may take fuel credll for the benzene
STABILIZER CONDENSER ANI) COOU NG WATER. A heal balance for the and loluene in the purge and the stabihzer overhead). The resulls are shown in Fig.
condenser gives 13-13. and we see that the range of the design variahlescorresponding to profitable
(8 - 141 ) operation has been dramaltcally reduced
Of course. with a dtfferr:nt process alternative. the profitabIlity mlghl be
Since we are tondensing the overhead at 11 5~ F, we cannOI allow the lemperature of Increased. However, we want to complete thr: design befOfe: we examine any
the cooling water to increase form 90 10 120 1- I hu~ , for our first deSign we as~ume alternat ll es.
thaI t.~, ,.
100°F. Then
100 - 90 UV .. I...... ALTnCNA11\ f'S. -) he re afe numerous illternatlles Ihat we could con-
AT = 19.6 ~ 2O"'F (1)- 142)
.. In nilS 90),( "5 - 100)] ~Ide r
al le \·el 4 A vapor rcco\"erysy~lem nl1ghl prove to be profitable on either the
fl ...sh vapor (if we U1(;ur ra:ycle losses) or the purge strc:am AbsorptIOn, condensa-
lion, adsorption, o r a membrane recovery system could be used as this vapor
recovery process
APPENDIX
There are also numerous alternatives for the distillation system Since the
renux ratios arc: so small for both the stabililer and the recycle column, we might be
able to use just stripping columns, I e .• no rectifYing sectiuns. Silnilarly, since both
the C I1 4 -benL.ene and the toluene-dlphenyl spillS are very easy, we should consider
C
the posslbhty of usmg pasteurization sections to decrease the number of columns.
However, we dder an attempt to evaluate the costs of these alternatives unlll we
have evaluated the heat-exchanger networl for our base-case dcslgn..
DESIGN
DATA
LEVEL 5: HEAT-EXCHANGER NETWORK
The procedure for designing a heal~xchanger network was presented in Chap. 8.
To develop the dala we need for this procedure, we mUSI calculate the temperature-
eothalpy curves for each process stream. We would recommend that normally this
IIlformalion be developed with the use of a CA D package such as FlOWTRAN,
particularly for processes where mixtures exhibit a phase change (i.e., a sct of flash
calculations is nceded along the length of an exchanger to calculate the T-II
profile). Similarly, [or cases where a phase change takes place at high pressures, II is
usually Simpler to use a CA D package to calculate the phYSical proJXrties reqUired
than it is to use handbooks and empirical corrclallons The use of FlOWTRA N
for these: calculations IS discussed in Chap 12 . CI HYDROCA RDO N VAPO R-LIQ UID
EQU ILIBRIA'
Use Figs Cl-J and C.1-2 for compouods wilh lower bolhng pomts than heptane,
and use Table c. J- J with the graphs ror compounds or cuts Wi th higher boiling
poims than heptane.

• Ta~eD from S T Hadden and II G G11I)'50n. wNcw Chani fOI lI),droca,bon VlPO' _Loq.oo
Eql.lllibna. ~ lIyJ'~tub P'DC" (J...J "mol R~fiMr . 40 91, 201 (s"pumbcr t961)

543