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Tutorial

Conceptual Process Design

Synthesis of Reaction System

CCB 3024 Process Plant Design

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Question No 1
Given that the objective is to manufacture vinyl
chloride, there are at least three reaction paths
that can be readily exploited. The market values
and molar masses of the materials involved are
given in Table 5.1. Oxygen is considered to be
free at this stage, coming from the atmosphere.
Which reaction path makes most sense on the
basis of raw material costs, product and
byproduct values?

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Question No 2
What reactor conguration would you use to maximize the selectivity in
the following parallel reactions:
where R is the desired product and S is the undesired product

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Question No 3
The maximum allowable tensile strengths for a typical carbon steel and
stainless steel, at ambient temperature, 400C, and 550C are provided
below (Walas [1]). Determine the fractional decrease in the maximum
allowable tensile strength (relative to the strength at ambient conditions)
for the temperature intervals
(a) ambient to 400C
(b) 400C to 550C.
Tensile Strength of Material (bar)
Temperature
Carbon Steel (grade 70)
Stainless Steel (Type 302)

Ambient

400 C

550 C

1190
1290

970
1290

170
430

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Question No 4
The activation energy for the rate of reaction for the hydrodealkylation of
toluene is equal to 148.1 kJ/mol (Tarhan [2]). What is the reaction rate at
600C relative to that at 400C?

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Question No 5
In the manufacture of vinyl chloride (VC) by the pyrolysis of dichloroethane
(DCE), the reactor conversion is limited to 55 per cent to r educe carbon
formation, which fouls the reactor tubes. Calculate the quantity of DCE
needed to produce 5000 kg/h VC.
Assume the small loss of DCE to carbon and other products has been
neglected. All the DCE reacted has been assumed to be converted to VC.

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Question No 6
In the production of e thanol by the hydrolysis of ethylene, diethyl
ether is produced as a by-product. A typical feed stream composition
is: 55 per cent ethylene, 5 per cent inerts, 40 per cent water; and
product stream: 52.26 per cent ethylene, 5.49 per cent ethanol, 0.16
per cent ether, 36.81 per cent water, 5.28 per cent inerts. Calculate the
yield of ethanol and ether based on ethylene.

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Question No 7
Allyl alcohol can be produced by the hydrolysis of allyl chloride.
Together with the main product, allyl alcohol, di-ally ether is produced
as a by-product. The conversion of allyl chloride is typically 97 per cent
and the yield to alcohol 90 per cent, both on a molar basis. Assuming
that there a re no other signicant side reactions, calculate masses of
alcohol and ether produced, per 1000 kg of allyl chloride fed to the
reactor.

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Question No 8
Ethyl acetate can be produced by the esterication of acetic acid with ethanol in the
presence of a catalyst such as sulfuric acid or an ion-exchange resin according to the reaction:

Laboratory studies have been carried out to provide design data on the conversion. A
stoichiometric mixture of 60 g acetic acid and 45 g ethanol was reacted and held at constant
temperature until equilibrium was achieved. The reaction products were analyzed and found
to contain 63.62 g ethyl acetate.
a. Calculate the equilibrium conversion of acetic acid.
b. Estimate the effect of using a 50% and 100% excess of ethanol.
Assume the liquid mixture to be ideal and the molar masses of acetic acid and ethyl acetate
to be 60 kgkmol-1 and 88 kgkmol-1, respectively.

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