Simulation Project Spring 2014

Lamar University, Beaumont, Texas

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CHEN- PROCESS SIMULATION






Modified Ketene Plant






Submitted by:
Vamsi Krishna Banda





Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 2

I. Objective
To modify the given ketene plant and make it more profitable
Figure 1 plant model

Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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II. Introduction
Developed a profitable plant using the conditions shown below


III. Measures taken to improve the profit
The following are the steps explaining the changes taken to improve the
profit


Step #1: Configurations of PFR
Conversion of Acetone is increased by changing the configuration of
PFR. By using the sensitivity analysis in the Model Analysis Tool, from
results we determined a better length and diameter for wish conversion
is acceptable.
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 4


Configuration of PFR1 is changed from the given value to a new value
LENGTH = 2.12105263 m Diameter = 25 mm NO OF TUBES = 1000
Amount of Acetone converted to its products is shown below :
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 5


Step #2: Adding new RadFrac Column
Before passing PFR-OUT stream directly to distillation column it is send
to a cooler to reduce the temperature of outlet stream and then stream is
send into a compressor upto pressure of 5bars. A RadFrac column is
added to which stream coming out from PFR is send into this column.
The main objective to send the PFR-OUT stream into this RadFrac
column is to separate the unconverted Acetone from the mixture stream.
If the entire outlet stream from PFR is send directly to second PFR the
Ketene that is produced in the first reactor does react again in the
second PFR and finally result in increase of production of Diketene.




Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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A design spec of mass purity is introduced in distillation column so that
the acetone coming out would be 99% pure and design spec of mole
recovery of ketene at top of the column is used.


Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 8


Acetone coming out from the bottom of distillation column is at 118C.The
conversion dose not carryon if we send to a second PFR. So bottom
product is send to a heat exchanger to raise temperature around 670C



Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 9

Split Fraction of the Rad-Ex shows the streams coming at the distillate
and bottom.


Step 3#: Introducing the Second PFR
PFRs in series are the same as one big PFR whose volume is equal
to the sum of the volume of all of the smaller PFRs. The conversion
is more if the PFRs are connected in series so that acetone is
completely converted into its products. Since the rate of conversion of
ketene to diketene is also a endothermic reaction the raise in
temperature converts ketene to diketene which is not a desired product.
Inorder to reduce the conversion of ketene we have separated using a
RadFrac column before sending it to second PFR.
There is no need of using recycle stream of Acetone by saving utility
cost while we are using two PFRs in series, helps in conversion of entire
acetone to its products which favors for the profitable Ketene Plant.
Conversion is shown below from PFR2-OUT
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 10


The concentrations of the final stream that is coming out from COOL
Contains
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 11


STEP 4# Design Spec in RADFRAC-1 :
A design spec of mass purity is introduced in distillation column so that
the diketene coming out would be 99%.
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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STEP 5# Change in RADFRAC-2 :
Using a SC-COL distillation column at same operating condition of
RADFRAC-2 column is operated at negative reflux ratio of -1.5. By using
sc-col at negative reflux ratio helps in finding the actual number of
stages, feed stage , minimum reflux ratio , actual reflux ratio which is
suitable for operating an radfrac column. From this we came to know the
operating conditions as shown below
The temperature in the condenser is at -38C so utility of condenser is
replaced with electricity.
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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To get maximum purity of IPA a design spec is introduced to get purity
around 0.995 mass purity.


STEP 6# Change in RADFRAC-3 :
Again by using a SC-COL distillation column at same operating condition
of RADFRAC-2 column is operated at negative reflux ratio of -1.5. By
using sc-col at negative reflux ratio helps in finding the actual number of
stages, feed stage , minimum reflux ratio , actual reflux ratio which is
suitable for operating an radfrac column. From this the we came to know
the better operating conditions as shown below

Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 15


The Ketene coming out at the bottom is at -11C so the utility in the HX-KET
is changed to HEAT instead of ELEC.


STEP 7# Change in RADFRAC-4 :
Again by using a SC-COL distillation column at same operating condition
of RADFRAC-2 column is operated at negative reflux ratio of -1.5. By
using sc-col at negative reflux ratio helps in finding the actual number of
stages, feed stage , minimum reflux ratio , actual reflux ratio which is
suitable for operating an radfrac column. From this the we came to know
the better operating conditions as shown below
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 16



A design spec of mass purity is introduced in distillation column so that
the ethylene coming out would be 99% and mass recovery of methane
99%.



Simulation Project Spring 2014

Lamar University, Beaumont, Texas
Page 17

STEP 8# Change in RADFRAC-5:
A design spec of mass purity is introduced in distillation column so that
the methane coming out would be 99% and mass recovery of methane
99%.


Another design spec of mass recovery of 99 percent at top of the
distillation column is used

Step #10:
Feed is sent to a heat exchangers in which energy heat is supplied from
the outlet for HX-COL. So Utility cost is reduced.

But from thermal zone due to cross over we can not use
integration for FEED-HT.
Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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Block B1 (HeatX) Thermal Results Zones
Zone
T
E
M
P
E
R
A
T
U
R
E

C
1.0 2.0
2
0
0
.
0
4
0
0
.
0
6
0
0
.
0
Hot-side Temp
Cold-side Temp



RESULT :
Final profit with around minimum of 99% purity of all the desired
products is


Simulation Project Spring 2014

Lamar University, Beaumont, Texas
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