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Rigorous Material Balances

The document describes the development of rigorous material balances for a process involving the separation of toluene and benzene. Equations are developed relating the component flows at each stage of the process, including the reactor, flash drum, stabilizer, product column, and recycle column. The goal is to use these balances to calculate flows and ensure they match the earlier approximate results, revising decisions if needed.

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Hritik Lal
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63 views15 pages

Rigorous Material Balances

The document describes the development of rigorous material balances for a process involving the separation of toluene and benzene. Equations are developed relating the component flows at each stage of the process, including the reactor, flash drum, stabilizer, product column, and recycle column. The goal is to use these balances to calculate flows and ensure they match the earlier approximate results, revising decisions if needed.

Uploaded by

Hritik Lal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Rigorous Material Balances

• After we have selected a liquid separation system, we


have completely fixed all the units in the flowsheet
where the component flow change
• These units include mixers, splitters, reactors, flash
drums, vapor recovery units, and liquid separation
systems.
• We can now develop a set of rigorous material balances
• If our rigorous balances differ significantly from our
earlier approximate results, then we will need to review
the decision that we made.
Rigorous Material Balances
• We could have revised the material balance calculations
at any stage of our development of the design, and
clearly there is a trade-off between the time required to
perform all the calculations and the accuracy of the
answer.
• Our goal is to complete the design as rapidly as possible,
providing that major errors are not introduced, and to
explore the alternatives using approximate calculations.
• Then after we have identified the best alternative, we
will use rigorous calculation procedures.
• However, it is not possible to make rigorous material
balances until we have completely defined the parts of a
flowsheet where the component flows change
Toluene balances :

• The toluene entering the reactor TOLR,in is the sum of


the fresh feed toluene TOLFF ,the toluene in the gas-
recycle stream TOLGR, and the toluene in the liquid-
recycle TOLLR :

TOLR,in = TOLFF + TOLGR + TOLLR (1)


• The toluene leaving the reactor TOLR,out is the toluene
that was not converted in the reactor :
• TOLR,out = TOLR,in ( 1 – x ) (2)
• If we let ƒTol,FV be the fraction of the toluene
leaving with the flash vapor TOLFV, then a fraction 1
- ƒTol,FV leave with the flash liquid TOLFL:

TOLFV = ƒTol,FV TOLR,out (3)

TOLFL = (1 - ƒTol,FV ) TOLR,out (4)

• If we let ƒPG be the fraction of toluene lost in the


purge TOLPG, then a fraction 1 – ƒPG of the toluene
will be the gas-recycle stream TOLGR :
TOLPG = ƒPG TOLFV (5)

TOLGR = ( 1 - ƒPG ) TOLFV (6)

• If we let ƒTOL,ST be the fraction of toluene that


leave with the stabilize distillate TOLST,D, then a
fraction 1 - ƒTOL,ST will leave with the stabilizer
bottoms TOLST,B :
• TOLST,D = ƒTOL,ST TOLFL (7)

• TOLST,B = ( 1 - ƒTOL,ST ) TOLFL (8)


• If a fraction ƒTOL,PR leave with benzene product
TOLPR,D, then a fraction 1 - ƒTOL,PR will leave the
product column in the bottoms TOLPR,B :
• TOLPR,D = ƒTOL,PR TOLST,B (9)

• TOLPR,B = ( 1 - ƒTOL,PR ) TOLST,B (10)

• Finally, if a fraction ƒTOL,RC is lost with the


diphenyl by product stream from the recycle
column TOLD, the a fractional 1 - ƒTOL,RC is recycled
to the reactor TOLLR :
• TOLD = ƒTOL,RC TOLPR,B (11)

• TOLLR = ( 1 - ƒTOL,RC ) TOLPR,B (12)

• We try to select the fractional recoveries in these


equation such that ƒi will be a small number.
However, the purge split ƒPG is the same for all
components in the flash drum are related to one
another.
• Now if we combine eq 6 , 3 and 2 to solve for the
gas recycle flow, we obtained

• TOLGR = TOLR,in ( 1 - ƒPG ) (ƒTOL,FV )( 1 – x) (13)


• Also, if we obtained eq 12, 10, 8, 4, and 2 to
calculate the liquid-recycle flow, we obtained

• TOLGR = TOLR,in ( 1 - ƒTOL,RC ) ( 1 - ƒTOL,PR ) (


1 - ƒTOL,ST ) ( 1 - ƒTOL,FV )(1 – x)
(14)

• Next we substitute eq 13 and 14 into eq 1 ,to


obtained
BENZENE BALANCE :
The balance for benzene are essentially the same, except
for the reactor equation. That is, at the reactor inlet we
obtain

BZR,in = BZFF + BZGR + BZLR = BZGR + BZLR (18)


• Where the fresh feed flow of benzene BZFF is equal to
zero.
• According to our selectivity correlation, a fraction S of
the toluene converted appears as benzene, although it
is important to remember that this correlation was
based on a pure toluene feed stream.
• Thus, we expect that some of the benzene recycled to
the reactor will be converted to diphenyl, and if the
benzene recycle flow is significant, we should revise
our correlation.
• Neglecting this discrepancy until we estimate the
benzene-recycle flow, we can write that the toluene
converted in the reactor is simply
Toluene converted = TOLR,inx (19)

• Where we can substitute Eq.16 for TOL R,in. Hence the


benzene leaving the reactor is the benzene produced
[xS(TOLR,in)] plus the benzene fed to the reactor:

BZR,out = BZR,in + xS(TOLR,in) (20)

• Letting fBZ,FV be the fraction of benzene going


overhead in the flash drum (which is related to f TOL,FV
by Eq.19) and fPG be the fraction of benzene lost in the
purge (which is the same for all component) we can
show that the gas recycle flow benzene is
BZGR = (1-fPG) fBZ,FV[BZR,in + xS(TOLR,in)] (21)

• Similarly , if we let fBZ,ST be the fraction of benzene


lost overhead in the stabilizer and fBZ,PR be the
fraction of benzene lost in the bottom of the product
column, and if we assume that all the benzene goes
overhead in the recycle column, then liquid recycle
flow of benzene is

BZLR = fBZ,PR (1-fBZ,ST)(1-fBZ,FV)[BZR,in + xS(TOLR,in)]


(22)
Substituting Eqs.21,22 into 18 gives

• BZR,in[ 1 – fBZ,FV (1 – fPG ) - fBZ,PR ( 1- fBZ,ST )

( 1 - fBZ,FV )] = xS(TOLR,in ) [ fBZ,FV ( 1 – fPG )

+ fBZ,PR ( 1 - fBZ,ST )( 1 - fBZ,FV ) ] (23)


There fore BZR,in can be found out from (23)
we can now use this result to calculate all the
other benzene flows

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