SOLUTION TO HOMEWORK PROBLEMS FOR CHAPTER FIVE 5.1.

First, we establish wastewater discharge target:

Seal Pot Feed Water 0.15 kg/s

Tire-to-Fuel Plant

Seal Pot Wastewater 0.15 kg/s Decanter Wastewater 0.20 kg/s

Water Generation 0.08 kg/s Water-Jet Makeup 0.20 kg/s

Water with the Wet Cake 0.08 kg/s (a) Overall Water Balance Before Mass Integration

Tire-to-Fuel Plant
No Fresh Water

Seal Pot Feed Water 0.15 kg/s Water-Jet Makeup 0.20 kg/s Water Generation 0.08 kg/s

Seal Pot Wastewater 0.00 kg/s

Decanter Wastewater 0.00 kg/s

(b) Overall Water Balance After Mass Integration

Water with the Wet Cake 0.08 kg/s

Next, we represent the problem from a species viewpoint as shown in Fig. 5.2.

Flare Gas

Air Carbon

Resin

Decanter Wastewater

Seal Pot

Seal Pot Wastewater

Seal Pot Wastewater

Fresh Water

Waste Interception Network (WIN)

Water Jet Compression
To Compression

To Flare

Air Carbon Resin to To Regeneration Condensation and Recycle

Flowrate of a Source/Feed to a Sink, kg/s

0.25 0.20
0.18

Water Jet Compressor

Decanter Wastewater

0.15
Seal Pot Wastewater

Seal Pot

0.10

0.05 0.00

50

200 y, ppm Pollutant

400

500

600

Direct Recycle for Tire-to-Fuel Problem

150 Mass Exchanged 10-6 kg/s 120 90 60 30

50

R1
600 y, ppmw

0
150
135

100

200

300

400

500

120 Mass Exchanged 90 10-6 kg/s 60 30

50

Pinch Point

R1
100 200 200 300 400 500
550

600 y, ppmw x1, ppmw

x1out = 600

900

Flowrate of a Source/Feed to a Sink, kg/s

0.25 0.20
0.18

Water Jet Compressor

0.15

0.10 0.05 0.00

50

200 y, ppm Pollutant

400

500

600

C =
r j
r C2 =

Cj x x
t j s j

Therefore,

0. 001 1, 000 300

= $1. 43 x10 6 / kg pollu tan t removed

Similarly, and

r C3 = $105. 26 x10 6 / kg pollu tan t removed

r C4 = $68. 97 x10 6 / kg pollu tan t removed

Let us also examine the thermodynamic feasibility of the three external MSAs

Mass 150 Exchanged 135 10-6 kg/s

120 90 60 30 Pinch Point

R1
300 400 500 S2 S3 10 S4 20 600 200 300 600 y, ppmw x1, ppmw 1,000 x2, ppmw x3, ppmw x4, ppmw

0 14 48 50100 130 200

Fig. 3.3. Examining Thermodynamic Feasibility of the External MSAs (not to scale) From Fig. 3.3 it can be seen that S2 is not thermodynamically feasible to remove the remaining load. Therefore, S4 is the optimum external MSA with an annual operating cost of 30x10-6 x68.97x3600x8760 = $65,246/yr. Fixed cost of stripper = 270,000 (0.2)0.65 = $94,850

Condenser

Gaseous Fuel

To Atmosphere

Flare

Wastewater Decanter Reactor Off-Gases Tires Shredded Tires Pyrolysis Reactor Light Oil 0.20 kg/s 500 ppm

Seal Pot Flare Gas

Wastewater

Water-Jet Shredding Filtration

L iquid F uels

Separation

Finishing

Wet Cake (to Solid Waste Handling) 0.20 kg/s 50 ppm

Stripping Agent STRIPPER 0.20 kg/s 200 ppm

Compression

Payback period = 94,850/(110,000 - 65,246) = 2.1 yrs < 3 yrs (acceptable) p.s. For biotreatment, payback period = 240,000/ (110,000 - 60,000) = 4.8 yrs > 3 yrs (unacceptable)

5.2. Target of minimum fresh solvent usage of 0.011 kg/s

Fresh solvent 0.090 kg/s

Magnetic Tape Plant

Exhaust Gas leaving Coating 0.057 kg/s

Solvent Decomposition 0.011 kg/s Exhaust Gas leaving Drying 0.022kg/s

(a) Overall Solvent Balance Before Mass Integration

Fresh solvent 0.011 kg/s

Magnetic Tape Plant

Exhaust Gas leaving Coating 0.057 kg/s

0.079 kg solvent/s
Solvent Decomposition 0.011 kg/s Exhaust Gas leaving Drying 0.022kg/s

(b) Overall Solvent Balance After Mass Integration Including Recycling the Recovered Solvent

Maximum recovery of solvent entails reducing outlet composition of R1 and R2 to 2x10 -4 (corresponding to lowest inlet supply of S3).

0.077 kg solvent/s

Schematic (not to scale)

R1
0.039 kg/s

0.038 0.021
2x10-4
0.004 0.001

R2
0.006 0.012 0.016 0.019 0.032 S1 0.014 0.040

y x1

S3 0.001 0.010

S2 Infeasible x2 0.020 0.080 x3

C1r= 0.002/(0.040 - 0.014) = $0.077 kg C3r= 0.002/(0.010 - 0.001) = $0.220 kg Therefore, we use S1 to remove 0.039 kg/s then follow up with S3 to remove 0.038 kg/s. Total solvent recovered = 0.039 + 0.038 = 0.077 kg/s Value of recovered solvent = $0.80/kg*0.077kg/s*3600*8760 = $1.943 MM/yr Annual operating cost 0.220x0.038)x3600x8760 = (0.077x0.039 +

10

= $358,000/yr (compare to value of recovered solvent being $1.943 million/yr.) Annual savings = 1,943,000 - 358,000 = $1,585,000/yr

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Network Configuration
0.077 kg solvent/s Schematic (not to scale)

R1
0.039 kg/s

0.038 0.021
2x10-4
0.004 0.001

R2
0.006 0.012 0.016 0.019 0.032 S1 0.014 0.040

y x1

S3 0.001 0.010

S2 Infeasible x2 0.020 0.080 x3

R1 G1 = 3.0 kg/s y1s = 0.019 Ex1 S1 R1 G1 = 3.0 kg/s ypinch = 0.006 G = 8.5 kg/s Ex2 S3 R2 G2 = 5.5 kg/s y2s = 0.004

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To convert from annualized fixed cost to fixed cost, need to assume useful life period (e.g., 5 years) Fixed cost = 5*18,000 (Gas flowrate)0.65 Fixed cost of exchanger 1 = 90,000 (3.0) 0.65 = $184,000 and Fixed cost of exchanger 2 = 90,000 (8.5)0.65 = $362,000 Fixed cost = 184,000 + 362,000 = $546,000 Payback period = 546,000/1,585,000 = 0.34 year (` 4 months)

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