Material Balance

Pre-heater:
Input to the pre-heater:(Unit ratios are obtained from literature)
The n-butane rich gas has to be heated to the reaction temperature before being sent into
the reactor.
Composition of the n-butane rich gas is,
Hydrogen

= 4 moles
= 4*2 = 8 kg/hr

Oxygen

= 2 moles
= 2*32 = 64kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 57.4 moles
= 57.4*58.12 = 3336.088 kg/hr

Water

= 28.6 moles
= 28.6* 18 = 514.8

Total input to the pre-heater = 4146.888 kg/hr

Output from the pre-heater:
No reaction takes place in the pre-heater, hence the output is,
Hydrogen

= 4 moles
= 4*2 = 8 kg/hr

Oxygen

= 2 moles
= 2*32 = 64kg/hr

Nitrogen

= 8 moles

= 8*28 = 224 kg/hr

Butane

= 57.4 moles
= 57.4*58.12 = 3336.088 kg/hr

Water

= 28.6 moles
= 28.6* 18 = 514.8

Total output from the pre-heater = 4146.888 kg/hr

Stream
Hydrogen
Oxygen
Nitrogen
Butane
Water
Total

Input (kg/hr)
8
64
224
3336.088
514.8
4146.888

Output (kg/hr)
8
64
224
3336.088
514.8
4146.888

Dehydrogenator:
Reactions:
C4H10 CH2=CH.CH=CH2 + 2CH2 + 2H2;
C4H10 C4H8 + H2

In the dehydrogenator, the above two reactions takes place, the n- butane rich gas may
get partially converted to butadiene and butenes. the probability of butadiene formation is very
less compared to the formation of butane.
Assumptions:
Reaction 1: Conversion of butane to butadiene is 10%.
Reaction 2: Conversion of butane to butene is 80%.
Input to the Dehydrogenator:
Hydrogen

= 4 moles
= 4*2 = 8 kg/hr

Oxygen

= 2 moles

= 2*32 = 64kg/hr
Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 57.4 moles
= 57.4*58.12 = 3336.088 kg/hr

Water

= 28.6 moles
= 28.6* 18 = 514.8

Total input to the Dehydrogenator = 4146.888 kg/hr

Output from the Dehydrogenator:
Conversion of butane takes place. Output from the dehydrogenator is,
Hydrogen

= 61.4 moles
= 61.4*2 = 122.8 kg/hr

Oxygen

= 2 moles
= 2*32 = 64 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 3336.088 - (3336.088*0.1) - (3336.088*0.8)

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 3336.088*0.8
= 45.92 moles
= 45.92*56.11 = 2576.571 kg/hr

1,3- butadiene = 3336.088*0.1

= 5.74 moles
= 5.74*54.09 = 310.4766 kg/hr
Total output from Dehydrogenator = 4146.257 kg/hr
Stream
Hydrogen
Oxygen

Input (kg/hr)
8
64

Ouput (kg/hr)
122.8
64

Nitrogen

224

224

Butane

3336.088

333.6088

Water

514.8

514.8

Butene

2576.571

1,3-butadiene

310.4766

4146.888

4146.257

Total

Oxydehydrogenator:
Reactions:
C4H8 CH2=CH.CH=CH2 + H2
In the oxy-dehydrogenator, butene is converted to 1,3-butadiene. The conversion in the
reactor is 90%. Additional oxygen is supplied to carry out the reaction.
Input to the oxy-dehydrogenator:
Hydrogen

= 61.4 moles
= 61.4*2 = 122.8 kg/hr

Oxygen

= 2 moles
= 2*32 = 64 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 45.92 moles
= 45.92*56.11 = 2576.571 kg/hr

1,3- butadiene = 5.74 moles

= 5.74*54.09 = 310.4766 kg/hr
Oxygen(additional) = 5 moles
= 5*32 =160 kg/hr
Total input to oxy-dehydrogenator = 4306.257 kg/hr
Output from the oxy-dehydrogenator:
Hydrogen

= 122.8 + (2576.571*0.9)
= 102.728 moles
= 102.728*2 = 205.456 kg/hr

Oxygen

= 7 moles
= 7*32 = 224 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 2576.571 (2576.571*0.9)
= 4.592 moles
= 4.592*56.11= 257.6571 kg/hr

1,3-butadiene = 310.4766 + (2576.571*0.9)

= 47.068 moles
= 47.068*54.09 = 2545.908 kg/hr
Total output from oxy-dehydrogenator = 4305.43 kg/hr
Stream

Input (kg/hr)

Output (kg/hr)

122.8
64

205.456
224

224
333.6088
514.8
2576.571
310.4766

224
333.6088
514.8
257.6571
2545.908

160

4306.257

4305.43

Hydrogen
Oxygen
Nitrogen
Butane
Water
Butene
1,3-butadiene
Oxygen (additional)
Total

Condenser:
The output gases from the reactor will be at a higher temperature. The temperature must
be reduced to be sent into the absorber. Hence the output is sent into a condenser.
Input to the condenser:
Hydrogen

= 102.728 moles
= 102.728*2 = 205.456 kg/hr

Oxygen

= 7 moles
= 7*32 = 224 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 4.592 moles
= 4.592*56.11= 257.6571 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
Total input to condenser = 4305.4299 kg/hr
Output from the condenser:
Hydrogen

= 102.728 moles
= 102.728*2 = 205.456 kg/hr

Oxygen

= 7 moles
= 7*32 = 224 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 4.592 moles
= 4,592*56.11= 257.6571 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
Total output from condenser = 4305.4299 kg/hr

Stream

Input (kg/hr)

Output (kg/hr)

205.456

205.456

Oxygen

224

224

Nitrogen

224

224

Butane

333.6088

333.6088

Water

514.8

514.8

Butene

257.6571

257.6571

1,3-butadiene

2545.908

2545.908

Total

4305.43

4305.43

Hydrogen

Absorber 1:
The butadiene so formed contains high volatile components like hydrogen, oxygen, etc.
they have to be removed. Hence the product from the oxy-dehydrogenator is sent into a absorber.
The solvent used in the removal of these high volatile gases is N-Methylpyrrolidone. The solvent
absorbs butane, butene and 1,3-butadiene.
Input to the Absorber 1:
Hydrogen

= 102.728 moles
= 102.728*2 = 205.456 kg/hr

Oxygen

= 7 moles
= 7*32 = 224 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 4.592 moles
= 4,592*56.11= 257.6571 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
N-Methylpyrrolidone = 55.5 moles
= 55.5*99.13 = 5501.715 kg/hr
Total input to absorber 1 = 9807.145 kg/hr
Output from absorber 1:
Top product:
Hydrogen

= 102.728 moles
= 102.728*2 = 205.456 kg/hr

Oxygen

= 7 moles
= 7*32 = 224 kg/hr

Nitrogen

= 8 moles
= 8*28 = 224 kg/hr

Water

= 28.6 moles
= 28.6*18 = 514.8 kg/hr

Butene

= 0.04592 moles
= 0.04592*56.11 = 2.576571 kg/hr

Total output from top product = 1170.833 kg/hr

Bottom product:
Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Butene

= 4.54608 moles
= 4.54608*56.11 = 255.0805 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
N-Methylpyrrolidone = 55.5 moles
= 55.5*99.13 = 5501.715 kg/hr
Total output from bottom product = 8636.312 kg/hr
Total output from absorber 1 = 9807.145 kg/hr
Stream

Input (kg/hr)

Output (kg/hr)
Top product

Bottom product

205.456

205.456

Oxygen

224

224

Nitrogen

224

224

Butane

333.6088

333.6088

Water

514.8

514.8

Butene

257.6571

2.576571

255.0805

1,3-butadiene

2545.908

2545.908

N-Methylpyrrolidone

5501.715

5501.715

Total

9807.145

1170.833

8636.312

Hydrogen

Stripper 1:
Input to stripper 1:
Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Butene

= 4.54608 moles
= 4.54608*56.11 = 255.0805 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr

N-Methylpyrrolidone = 55.5 moles
= 55.5*99.13 = 5501.715 kg/hr
Total input to stripper 1 = 8636.312 kg/hr

Output from stripper 1:

Top product:
Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Butene

= 4.54608 moles
= 4.54608*56.11 = 255.0805 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
Total output from top product = 3134.5973 kg/hr
Bottom product:
N-Methylpyrrolidone = 55.5 moles
= 55.5*99.13 = 5501.715 kg/hr
Total output from bottom product = 5501.715 kg/hr
Total output from stripper 1 = 8636.312 kg/hr

Stream

Input (kg/hr)

Output (kg/hr)
Top product

Bottom product

Butane

333.6088

333.6088

Butene

255.0805

255.0805

1,3-butadiene

2545.908

2545.908

N-Methylpyrrolidone

5501.715

5501.715

Total

8636.312

3134.5973

5501.715

Absorber 2:
1,3-butadiene has to be separated from the top product from stripper 1. So absorber 2 is
made use of to absorb 1,3-butadiene using sulfolane as a solvent.
Input to absorber 2:
Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Butene

= 4.54608 moles
= 4.54608*56.11 = 255.0805 kg/hr

1,3-butadiene = 47.068 moles

= 47.068*54.09 = 2545.908 kg/hr
Sulfolane

= 50 moles
= 50*120.17 = 6008.5 kg/hr

Total input to absorber 2 = 9143.097 kg/hr

Output from absorber 2:
Top product:
Butane

= 5.74 moles
= 5.74*58.12 = 333.6088 kg/hr

Butene

= 4.54608 moles
= 4.54608*56.11 = 255.0805 kg/hr

1,3-butadiene = .001*47.068 = 0.047068 moles

= .047068*54.09 = 2.545908 kg/hr
Total output from top product = 359.3852 kg/hr
Bottom product:
1,3-butadiene = 47.068 0.047068 = 47.02093 moles
= 2543.362 kg/hr
Sulfolane

= 50 moles
= 50*120.17 = 6008.5 kg/hr

Total output from bottom product = 8551.862 kg/hr

Total output from absorber 2 = 8911.247 kg/hr
Stream

Butene

Input (kg/hr)

255.0805

Output (kg/hr)
Top product

Bottom product

255.0805

Butane

333.6088

333.6088

1,3-butadiene

2545.908

2.545908

2543.362

6008.5

6008.5

9143.097

591.2353

8551.862

Sulfolane
Total

Stripper 2:
Input to stripper 2:
1,3-butadiene = 47.068 0.047068 = 47.02093 moles
= 2543.362 kg/hr
Sulfolane

= 50 moles

= 50*120.17 = 6008.5 kg/hr

Total input to stripper 2 = 8551.862 kg/hr
Output from stripper 2:
Top product:
1,3-butadiene = 47.068 0.047068 = 47.02093 moles
= 2543.362 kg/hr
Bottom product:
Sulfolane

= 50 moles
= 50*120.17 = 6008.5 kg/hr

Total output from stripper = 8551.862 kg/hr

Stream

1,3-butadiene
Sulfolane
Total

Input (kg/hr)

Output (kg/hr)
Top product

Bottom product

2543.362

2543.362

6008.5

6008.5

8551.862

2543.362

6008.5