12.

Prepare a material balance for the production of 7800 kg/h of acetaldehyde using the process described in
Prob. 8. However, because 99.5 percent oxygen is unavailable, it will be necessary to use 830%Pa air as one
of the raw materials. What steps of the process will be affected by this substitution in feed stocks? Assume
an operating factor of 90 percent and a 95 percent yield on the ethylene feed.
PdCl 2
C2H4 + 2CuCl2 + H2O CH3CHO + 2HCl + 2CuCl

2CuCl + 2HCl + 1/2O2 2CuCl2 + H2O

Reaction and regeneration :

The main considerations are the reaction kinetics, equilibrium relations, and heat of reaction. The relationship of
these factors will determine the reactor configuration and the cooling water requirements. Obviously, physical
and thermal data for all the flow streams will be needed. Catalyst activity with information on its decline with
time and reactivation time will be needed for regeneration design purposes.

Scrubbing :
The equilibrium relationship between the various reactor components and water will be the important design
factor in this unit. Physical and thermal data for all the flow streams will be needed. Build up of inerts is
controlled by a bleed stream. The composition of the latter must be known to determine the requirements for an
auxiliary reactor designed to complete the oxidation of unconverted ethylene.

Distillation :
The distillation unit requilibrium and vapor pressure data for the mass transfer calculations. Separation of key
components must be specified and separation efficiencies need to be established. Physical and thermal data for
all the flow streams will again be needed. Heat transfer coefficients will be required for the design of heat
exchangers, condenser, and reboiler.

Degassing :
This unit will require much of the same information that is required for the distillation unit only with different
composition and flows.

A simplified equipment flowsheet for the acetldehyde process is given in hydrocarbon process. Since this
aproprietary process only sketchy information is supplied with regards to temperature, pressure and stream
composition at each piece of equipment some of this information can be deduced from the information supplied
for the raw materials and utilities requirements per short ton of acetaldehyde.