Raymond A.

Adomaitis

March 7, 2012 To be covered: Class syllabus (http://www.isr.umd.edu/ adomaiti/ench446), grading Team selection (4 members per team) Initial project description Approximate schedule for year
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 1 / 29

What you should know from ENCH444

Flowsheet synthesis, simple material and energy balances, rapid evaluation of design alternatives Shortcut distillation, absorber column, and ash drum calculations Reactor vessel, distillation/absorber column, heat exchanger, pump, and compressor sizing and costing Return on investment, discounted cash ow calculations, project value ChemCAD simulation, detailed designs, elements of process optimization Process utility calculations, heat exchanger networks, pinch design Separation sequences using simplied distillation columns

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

2 / 29

This semester
Two major chemical process design projects, both addressing current topics in energy engineering:
1

Design of the ethanol purication section of a fuel-grade ethanol plant

Corn is fermented to produce ethanol Focus will be on comparative analysis of alternative separation methods Intended to reinforce basic process design and economic analysis methods

Evaluation of shale gas processing systems

Appropriate for use in western Maryland Minimize environmental impact of these processing systems Project objectives are less well-dened

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

3 / 29

Project 1 overview

From 16. Optimal Peschel A, Grossmann I, Martin M, Martinson W, per Zullo FigureKaruppiah R, design of bioethanol plant producing 61.29 M gal and year. L, Energy optimization for the design of corn-based ethanol plants,the online issue, which is available at www.interscience.wiley.com.] [Color gure can be viewed in AIChE J., 2008 54 1499-1525. Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 4 / 29

Project 1 goals, by week

Purication process overall material balance; non-ChemCAD design of beer and rectication columns (individual projects) ChemCAD design of beer and rectication columns; summary of utilities; basis for economic analysis Design of molecular sieve absorbers as the nal step in producing fuel-grade ethanol; operation and regeneration of absorbers Energy integration and economic analysis of complete separation system Analysis of multieect distillation to reduce energy consumption in the beer and rectication columns Safety issues, nal report, group presentation

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

5 / 29

Subproject 1.1
Design basis for the ethanol purication system 60 106 gal/yr ethanol plant (see http://www.neo.ne.gov/statshtml/122.htm for representative plant capacities) All calculations are to be done and reported in SI units (m, kg, s, K, etc. with stream compositions given as mole fractions) Overall ethanol recovery: 99.5% (molar) Karuppiah et al. report the fermentor euent as approximately 11% ethanol and 35% solids by weight. After the mechanical press, we estimate the feed to the beer column to consist of 17% ethanol by weight and the remainder water. The stream is at 1 atm pressure and 30o C.

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

6 / 29

Subproject 1.1

Design basis, continued For the initial design calculations, assume the entire purication process operates at 1 atm Use the following initial values for column distillate and product stream compositions
1 2

Beer column distillate 72% ethanol by weight Rectifying column distillate is as close to the azeotrope as possible Absorber euent is 99.9% ethanol by weight

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

7 / 29

Subproject 1.1
Report (individual assignment)
1 2

Convert project specications to SI units Compute an overall material balance for the ethanol and water components, including the molecular sieve absorbers Appropriate shortcut or McCabe-Thiele design of beer column - report reux ratio, number of trays, feed tray location, condenser and reboiler operating temperatures McCabe-Thiele design of the rectication column, reporting the same quantities Typewritten report summarizing the design basis and preliminary design Validation of VCL usage

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

8 / 29

Binary distillation review

Basic assumption: yn and xn are at equilibrium at stage (tray) n of N. A material balance around the top of the column and between stages n and n + 1 gives the top (rectifying, enriching) section operating equation: Vn+1 yn+1 = Ln xn + DxD D Ln xn + xD yn+1 = Vn+1 Vn+1 where xD is the distillate concentration of the lower-boiling component.

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

9 / 29

Binary distillation review - continued

Likewise, a material balance around the bottom of the column and between stages m and m + 1 gives the bottom (stripping) section operating equation: Lm xm = Vm+1 ym+1 + BxB Lm B ym+1 = xm xB Vm+1 Vm+1 where xB is the bottoms concentration of the lower-boiling component.

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

10 / 29

Binary distillation review - continued

Dening the external reux ratio r as r= L0 liquid returned to column = D distillate

we can nd by constant molal overow Ln r = Vn+1 r +1 Likewise, the external reboil ratio is s= VN+1 reboiler vapor returned to column = B bottoms Lm s +1 = Vm+1 s
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 11 / 29

and so by CMO

Binary distillation review - continued

This gives the top operating line as xD r xn + yn+1 = r +1 r +1 the bottom operating line ym+1 = s +1 xB xm s s

and the feed quality q dened by

L,sat V hF = qhF + (1 q)hF ,sat

to give LB LT = qF VB VT = (q 1)F q zF y= x q1 q1
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 12 / 29

MATLAB McCabe-Thiele

ethanolwater fractionation 1 temperature deg. C 0.8 6 0.6 ye 0.4 0.2 9 0 0 0.2 0.4 xe 0.6 8 VLE enriching stripping 0.8 1 7 2 43 1 100 95 90 85 80 75

stage temperature

4 stage

10

Results produced by column.m for r = s = 3

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

13 / 29

Project 1.1 - my results

Assume plant operates 350 days/year, 17% by wt ethanol to beer column, 99.5% (molar) overall ethanol recovery ethanol product ethanol to beer column water to beer column F xF 128.6 mol/s 129.3 mol/s 1614 mol/s 1743 mol/s 0.0742

Mechanical press product stream at 30o C and 101325 Pa.

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

14 / 29

Project 1.1 - my beer column

minimum external reux 0.5 = generally use 1.1 to 2rmin minimum stages: 3 at total reux
ethanolwater fractionation 0.6 temperature deg. C 0.5 0.4 ye 0.3 0.2 3 0.1 4 5 6 0 0 2 VLE enriching q stripping 0.2 xe 0.4 0.6 1 95 100 stage temperature

90

85

3 stage

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

15 / 29

Project 1.1 - my beer column summary

r q NT nF D xD Tc B xB Tr 2 1 (preheat feed to bubble point) 4 + partial reboiler + partial condenser 2 269.7 mol/s 0.4772 358 K (85o C) 1473 mol/s 0.00033 373 K (100o C)

Higher reux ratio to help oset higher-than-expected number of stages relative to literature.

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

16 / 29

Project 1.1 - my rectication column

minimum external reux 2.1 = generally use 1.1 to 2rmin minimum stages: 11 at total reux
ethanolwater fractionation 1 temperature deg. C 0.8 15 0.6 ye 17 0.4 0.2 18 0 19 20 0 0.2 0.4 xe 0.6 VLE enriching q stripping 0.8 1 16 1 2 53 64 97 10 118 12 1413 100 95 90 85 80 75 stage temperature

10 stage

15

20

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

17 / 29

Project 1.1 - my rectication column summary

r q NT nF D xD Tc B xB Tr 3 0 (vapor from beer column condenser) 18 + partial reboiler + partial condenser 16 151.3 mol/s 0.85 351 K (78o C) 118.3 mol/s 0.00034 373 K (100o C)

ethanol recovery:

0.85(151.3 mol/s) = 0.9951 (relax this constraint?) 129.3 mol/s

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

18 / 29

Subproject 1.2

Report (group assignment)

1

Cover page with team number, date, honor pledge, group members, member contributions, and summary of contents ChemCAD design of beer and rectication columns: single page process owsheet; single page stream summary; single page with summary of both column designs Single page of heating/cooling duties for feed preheat and both reboilers and condensers Single page summarizing economic basis: interest rate, process equipment cost factors, and estimate of steam, cooling, and electricity costs, all for 2012

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

19 / 29

Subproject 1.3
Objective Design of molecular sieve absorbers as the nal step in producing fuel-grade ethanol; operation and regeneration of absorbers Based on Karuppiah, Peschel, Grossmann, Martin, Martinson, and Zullo, Energy optimization for the design of corn-based ethanol plants, AIChE J., 2008 54 1499-1525, we consider a zeolite adsorption process with the following characteristics:
1

Adsorption and regeneration processes take place at 368 K and 101325 Pa Air for drying is available at 303 K and 70% relative humidity The adsorption potential of the zeolite is adsp = 0.08 kg water/kg zeolite The absorption process vessels are sized such that the saturation time is ts = 360 s
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 20 / 29

2 3

Subproject 1.3
For this project, we further assume that 1 We cannot neglect the heat of adsorption during adsorption and desorption processes - for now, assume the heat of adsorption equals the latent heat of vaporization 2 No ethanol is adsorbed 3 Air leaving the absorber vessel during regeneration is at 368 K and 70 % relative humidity 4 We use two process vessels 5 Zeolite density is 1000 kg/m3 Report (group assignment)
1 2

Report the size of the process vessels Report the inlet/exit stream compositions and properties during the adsorption and regeneration phases of operation Propose an industrial zeolite for this process and estimate the cost of the absorber material
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 21 / 29

Subproject 1.4
Report (group assignment)
1

Revise your absorber design based on the practical constraints identied in your preliminary design calculations (e.g., increase switching time, increase regeneration air ow rate, etc.) Flowsheet of the complete separation system with no energy integration Capital and operating costs for base-case design; report as an annualized cost with a 20 year plant life, 10% interest rate Create a table of energy sources and sinks; develop a rigorous strategy for assessing the maximum reduction possible using energy integration assuming a 10o C minimum approach temperature Flowsheet and economic analysis of energy-integrated design

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

22 / 29

Subproject 1.5
Report (group assignment)
1

Examine your beer and rectication column designs after energy integration; which has the higher condenser/reboiler energy demands and why? Split the beer column feed stream into two equal ows; send one of the streams to a beer column with design specications (reux ratio, total trays, feed tray, etc) exactly the same as your energy-integrated design. Design a new, higher-pressure column for the remaining feed stream such that its condenser temperature 100o C + Tmin
atm hi P Re-adjust the two feed stream ows so that Qreb = Qcond

4 5

Compare the new process utility and capital equipment, and annualized costs to your previous optimized design.
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 23 / 29

Project 1 base case (0), energy integrated (1) costs

cap0 25 op0 cap1 op1 20

cost $106

15

10

4 5 6 randomized team number

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

24 / 29

Annualized costs
Our plant produces 60 106 gal/yr of anhydrous ethanol, currently valued at about $2.25/gal, resulting in RG = $135 106 /yr gross revenue so we compute the fractional cost of our separation process by computing the present worth of this annuity over the n = 20 year project life at i = 0.1 interest rate: PRG = RG (1 + i)n 1 i(1 + i)n

If PRO is the present worth of the annual operating costs, CF and CW the xed and working capital investments, Fractional sep cost = 100 CF + CW + PRO PRG
25 / 29

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

Subproject 1.6
Report (individual assignment) Using the information provided by the Safety and Chemical Engineering Education Website (www.SAChE.org), write a (max. 2 page) report outlining process design changes you can suggest to your group to improve the separation process safety. Be specic and concise. Group activities (no group report due next week) Note that nal report and (5 min.) presentation are due in two weeks. Finish overall design by considering
1 2 3

Reasonable pressure drops through columns Pumps and control valves Steam production on-site using natural gas; cooling towers for cooling water circuits Product storage
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 26 / 29

Project 1: costs after double-eect distillation

20 cap2 18 op2

16

14

cost $106

12

10

5 6 7 randomized team number

10

11

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

27 / 29

Subproject 1 nal report

Page limit: 10 including title page; not including references and appendices.
1

2 3 4 5

6 7 8 9 1

Title page, including title, team number, members, member contributions, date, project summary1 , honor pledge Process ow diagram Process stream summary Process equipment summary Project assumptions and basis, followed by a concise process description including energy integration strategy, justication for process assumptions/decisions, alternatives considered, etc. Safety and environmental issues Plant layout, geographical location, on-site storage Capital equipment summary Utilities, including on-site steam generation and cooling water

Project summary includes total capital cost, operating costs, separation system fractional cost, total fresh energy required/fuel energy produced
Raymond A. Adomaitis Spring 2012, ENCH446, Project 1 28 / 29

Subproject 1 group presentation

Time limit: 5 minutes with 3 minutes for questions and transitions

1 2

Use readable text and gures Do not spend time on motivation or the general process ow diagram: concentrate on your specic design choices and novel aspects of your design, such as energy integration Summarize costs on a single slide, similar to project summary Discuss safety and environmental aspects Absorber system operation Plant layout, integration with upstream processes

3 4 5 6

Raymond A. Adomaitis

Spring 2012, ENCH446, Project 1

29 / 29