5.

ENERGYBALANCE
Basis:1Hr.Operation
ENERGYBALANCESACROSSTHEFEEDPREHEATINGEQUIPMENT:
Theheatingofcold2butanolfeedistobecompletedinthreestagesinorderto
avoidlargeheatlosses.Thecoldfeedisfirstpreheatedtoitsboilingpointusingsteam
asheatingmediumandthenvaporizedinathermosyphonreboilerutilizingtheheat
containedinthereactionproducts.Thevapor,whichhasentrainedliquidisremoved
fromtheknockoutdrum,andthenheatedtoreactiontemperatureusingfluegas.

COLDFEEDPREHEATER:
Totalfeed=132.3585+1200.3768kg
=1332.7353kg
1332.7353kgperhourof2butanolistobepreheatedfrom250Citboilingpoint990C.
Heatloadonpreheater,

Q=1332.7353x1.497(372288)

=167.588x103KJ
Theheatingmediumisusedisdrysaturatedsteamat420K
Steamrequirement=167.588x10

3
2123.4

=78.9247kg/hr
2BUTANOLVAPORIZER:
2butanolfeedisvaporizedat107.50Cusingreactionproducts.
Heatloadonvaporizeris,Q=Mx
= 1332.7353x557.43KJ
= 742.906x103KJ/hr
AverageCpofreactionproducts=2.304KJ/Kg0k
742.906x103=1332.7353x2.304(642T)

22
T=400K

FIRSTSUPERHEATER:
2butanolvaporsistobeheatedfrom380.5kto573k.usingfluegaswhichentersat
673k&coolsto423k.
Cp=2.038kj/kgk.
Heatloadonsuperheater,Q=MxCpx(T2T1)
=1332.7353x2.038(573380.5)
3
Q=522.852x10 KJ/hr
Massflowrateoffluegas=522.852x10

3
1.2 x(673423)
3
= 1.742x10 KJ/hr
SECONDSUPERHEATER:
Itraisesthetemperatureofvaporfrom573to773k.usingfluegaswhichentersat
873kandcoolsto623k
Cp=2.674KJ/KgK
HeatloadonsuperheaterQ=MxCpx(T2T1)
= 1332.7353x2.674(773573)
= 13.9144x106KJ/hr
Fluegasrequirement,

=13.9144x10

6
1.195x(873623)
=4.6575x103kg/hr

ENERGYBALANCEACROSSTHEREACTOR:
Thefeedentersthereactorat773kandleavesat663k.Theconversionobtainedin
thereactoris90%.Theheatbalanceincludestwotermsi.e,sensibleheatchangedueto
coolingofreactionmixtureandheatconsumeduetoreaction.
Q=MxCpx(T2T1)+MxH
MeanCp=2.68KJ/kgk

23

H=73900KJ/kgmol

Cpmix

Total2butanolfeed=1332.7353kg/hr
= 18.0099kmol/hr
Q=1332.7353x2.68x(663773)+18.0099x0.9x73900=804.948x103KJ/hr
Itisassumethatafluegasisavailableat800k&leaving750k.
Cp=1.195KJ/kgk
Fluegasrequirement,

804.948x103
1.195x(800750)
=13.471x103kg/hr
=

ENERGYBALANCEACROSSTHECONDENSER:
4.3.1.1 Cooler condenser

Compone
nt
MEK
2
Butanol
H2
Total

Mass
1161.2
53
132.62
37
32.227
57
1326.1
05

Coolercondenser

%
87.568
76

Condensate

10.001
2.4302
43
100

Condensate

Componen
t

MEK
2-Butanol
H2

Compone
nt
MEK
2Butanol
H2

QR

xF
Mass
%
0.735 975.44 88.882
5
76
18
122.01 11.117
0.092
38
82
0
0
1097.4
Total
61
100

Mass
%
975.44 88.882
76
18
122.01 11.117
38
82
0
1097.4
61

0
100

The temperature at which the products of the reactor leave is 400 C.

The condenser cooler lowers cools the products to a temperature of

32 C. The energy balance is given as shown in the calculations

below.
Energy balance for MEK
Sensible heat to lower the temperature of the condensate MEK from
400 C to 79.6 C,

Sensible heat to lower the temperature of the incondensable MEK

from 400 C to 80 C,

Sensible heat to lower the temperature of the condensate MEK from

79.6 C to 32 C,

No of moles of MEK condensed

Latent heat of vaporization of MEK,

Total energy required for MEK cooling and condensation,

Energy balance for 2-butanol

Sensible heat to be removed to lower the temperature of 2-butamol
from 400 C to 99 C is determined as follows,

To condense the 2-butanol,

Total heat to be removed from 2-butanol,

Total heat to be removed from the cooler condenser,

ENERGYBALANCEACROSSTHEABSORBER:
HeatofcondensationofMEK

=3707.072x 443.14
=1.643x106 kj/hr

Heatofcondensationofalcoholis =233.488x560
=0.1308x106kj/hr
Heatofsolution

=(3707.072 +233.488)x0.35
=0.001379x106kj/hr

Heatlossincoolinggassesfrom62.7to270C
=(74.98x1.47+8.392x1.53+624.723x14.65)(62.7
27)
=0.3311x106kj/hr
6
Totalheatreleased=2.1063x10kj/hr

Heatremovedbywatervapor=(204.045x2437.9)
=0.49744x106kj/hr
Heatgainedbyirrigatingliquor
a) Water:31980.6816x4.186(T300)
b) MEK:3707.072x2.299x(T300)
c) Alcohol:233.488x2.429x(T300)
6
6
Totalheatgained=0.49744x10+0.142961x10

(T

300)kj/hr
Heatreleased=heatgained
=>

2.1063x10 =0.49744x10 +0.14296x10 (T300)

25

=>

T=311.25k

ENERGYBALANCEACROSSTHEEXTRACTIONCOLUMN:
Itisassumethattheextractionprocessisisothermal.Allthatstreamscomeat270C
andleavesat270C.

ENERGYBALANCEACROSSTHESOLVENTRECOVERY&UNIT:
Feedisnotsaturatedliquiditissubcoolliquid.Saturationtemperatureis
930CFromxydiagramwegetRm=0.38.
R=2Rm=0.76
Feed:
Alcohol=233.48=3.155kmol/hr
74
MEK=3577.639=49.689kmol/hr72
TCE=14992.191=112.3kmol/hr
133.5
Water=26.3613=1.465kmol/hr18
Total=166.609kmol/hr
MolefractionofMEK
XMEK=49.689=0.2982
166.609
Feedtemperature=270C
F.HF=3.155x170.058(270)+49.689x165.726x27+112.3x148.56x27+
1.465x75.36x27
F.HF=0.69025x106kj/hr

26

Distillate:

XMEK

Alcohol=233.488=3.1552kmol/hr
74
MEK=(3577.63921.3454)=49.39kmol/hr
72
Water=(26.361325.9195)=0.0246kmol/hr
18
TCE=2.5098=0.0188
kmol/hr133.5
Total=52.5886

kmol/hrD=52.5886kmol/hr
MolefractionofMEK,XMEK=49.39=0.94
52.5886
fromTxydiagramdistillatetemperature=80.40C
CpMEK=170kj/kmolk
Cpalcohol=228kj/kmolk
Cpwater=75.37kj/molk
CpTCE=148.56kj/molk
D. HD=3.1552x228+49.39x170+0.4421x75.37+0.0188x148.56(80.4)
6

= 0.7358x10 kj/hr

Residue:
MEK=21.2454kg=0.2965kmol/hr
TCE=15199.421kmol=113.85kmol/hr
133.5
Water=25.9195=1.4399kmol/hr
18
Total=115.5864kmol/hr
=0.2965=0.0026
115.5864
FromTxydiagramthetemoerature
obtained.T=1120C=385k(residue)
CpMEK=175kj/molk
Cpalcohol=260kj/kmolk
Cpwater=75.37kj/kmolk
27

CpTCE=148.56kj/kmolk

W. Hw=0.2965x175+113.85x148.56+1.4399x75.37x(112)
6

= 1.9123x10 kj/hr

Condenser:
VHv=D.HD+L.HL+Qc.
VHv=(D+L).HL+Qc
Qc=Vx(HvHL)
Qc=Vx
V=(1+R)xD
D=52.5886kmole/hr
V=(1+0.76)x52.5886=92.556kmole/hr.
Vx=92.556x3.18445x104
=2.9474x106kj/hr
Qc=2.9474x106kj/hr
Coolingwaterrequirement=2.9474x10

6
4.187x(4224)
=3.911x104kg/hr
Reboiler:
Overallheatbalance
F.HF+QB=Qc+D.HD+WHw
QB=Qc+D.HD+WHwF.HF
QB=DHD=WHw+QcFHF
QB=0.7358x106+1.9123x106+2.9474x1060.69025x106
QB=4.90525x106kj/hr
Steamisavailableat3.302barsteamtemperature=410k

28

Steamrequirementis=4.90525x10

2153.4

=2277.91kg/hr
Onecoolerisattachedtocooltheresidue.
Residueentersthecoolerat1120Candleavesat270C
So,coolingwaterrequirement=1.451299x10

6
4.187(4224)
=1.92567x104kg/hr
Onemoreheatexchangerisusedtoraisethetemperatureofthemixedliquor
ofcondensateandthedistillatefromthesolventrecoverycolumnto820C
2591.3424x170.058+18931.435x165.726(26.6)
74
72
+212.9726x260+3367.511x175
74
72
+QB=2804.315x260
74

+2.5098x148.56
133.5

+22298.946x165.726+2.5098x148.56(82)
72
133.5

QB=2.981x106KJ/hr
Steamisavailableat3.302bar,steamtemperature=410
K.Steamrequirement=2.981x10

6
2153.4
=1384.32Kg/hr
ENERGYBALANCEACROSSTHEDISTILLATIONCOLUMN:
Condenser:
Qc=Vx
Qc=Vx=541.261x3.1x107+5.4673x4.5x107
=17.025x106
So,massflowrateofcoolingwater=17.025x10

29

4.187x(4224)
=2.25899x106kg/hr
Reboiler:
QB=DHD+WHw+QcFHF
FHF=2804.315x260+22298.946x165.726+2.5098x148.56
74
72
133.5

(82)

=5.01696x106kj/hr
DHD=225.0x228+22275.0x170
74
72
6
=4.2896x10 kj/hr
WHw=2579.7131
74

(80.5)

x260+23.9731 x175+2.0846x148.65 x(107)

72
133.5

=0.97632x106kj/hr
QB=17.274kj/hr
Steamavailableat=3.302bar.Steamtemperature=410k
6

Steamrequirement=17.274x10

2153.4
=8021.733kg/hr.

Distillate&theresiduebothhastobecooled
Heatloadtocoolthedistillatefrom80.5to300C=225x228+22275x170(80.530)
74
72
6
=2.69099x10 kj/hr.
So,coolingwaterrequirement,

=2.69099x10

6
4.187x(4224)
4
=3.57056x10 kg/hr

Recycle2butanolis107to270C

30

Heatload=2579.7131 x260+239731x175+ 2.0846x148.65(10727)

74
72
133.5
=0.72996x106kj/hr
6

Coolingwaterrequirement=0.72996x10

4.187x(4224)
=9685.52kg/hr.

31