Material Balance

Basis: 10 tons/day
=416.68kg/hr
=9.47kmol/hr
Main Reaction
CH2=CH2 + ½ O2 CH3CHO
1 kmol of C2H4 = 0.5kmol of O2= 1 kmol of CH3CHO
9.47 kmol of C2H4 + 4.735 kmol of O2 9.47 kmol of CH3CHO
For 45% conversion,
Ethylene required = 9.47/0.45
= 21.044kmol
O2 required =0.5 mol of ethylene
= 0.5*21.044
= 10.522 kmol
Remaining moles of ethylene = 21.044 – 9.47
= 11.574 kmol
Remaining moles of oxygen = 10.522 – 4.735
= 5.765 kmol
Side Reaction
CH2=CH2 + O2 CH3COOH
1 kmol of C2H4 = 1 kmol of O2 = 1 kmol of CH3COOH
5.765 kmol of C2H4 + 5.765 kmol of O2 5.765 kmol of CH3COOH
Unreacted ethylene = 11.574 – 5.765
= 5.809 kmol

Ethylene= 589.232 kg/hr Acetaldehyde= 416.68 kg/hr

O2 = 336.704 kg/hr Acetic acid= 345.9 kg/hr

Un ethylene =162.652kg/hr
 Molar flow Mass flow Molar flow Mass flow
rate in rate in (kg/hr) rate out rate out
(kmol/hr) (kmol/hr) (kg/hr)
C2H4 21.044 589.232
O2 10.052 336.704
CH3CHO 9.47 416.68
CH3COOH 5.765 345.9
Unreacted 5.809 162.652
C2H4
Total 925.936 925.232

Degasifier Un ethylene= 162.652 kg/hr

Acetaldehyde= 416.68 kg/hr Acetaldehyde= 104.1684 kg/hr

Acetic acid= 345.9 kg/hr Acetic acid= 86.4766 kg/hr

Un ethylene =162.652kg/hr

Acetaldehyde= 416. 68 kg/hr

Acetic acid= 345.9 kg/hr

Outlet = Recycle+ Feed to distillation

Y = 0.2 Y +762.58
0.8Y = 762.58
Y = 953.225
953.225 = R + 762.58
R=190.645
Materials Mass in Moles in Top Bottom
kg/hr kmol/hr mass moles mass moles
Acetaldehyde 520.8484 11.8375 520.8484 11.8375
Acetic acid 432.3766 7.2062 432.3766 7.20625
Un ethylene 162.652 5.809 162.652 5.809
Total 1115.877 162.65 953.225
2

Distillation Column
Acetaldehyde=416.68kg/hr

Acetic acid= 345.9kg/hr

Acetic acid = 341.692kg/hr

Distillate = 416.68 kg/hr

Mass fraction of distillate = 0.99
D*0.99= 416.68
D= 420.888 kg/hr
Acetaldehyde = 416.68 kg/hr
Acetic acid in distillate= 420.888- 416.68
= 4.208 kg/hr
Residue= 341.692 kg/hr
Materials Mass in Moles in Top Bottom
kg/hr kmol/hr Mass Moles Mass Moles
Acetaldehyde 416.68 9.47 416.68 9.47
Acetic acid 345.9 5.809 4.208 0.0701 341.69 5.6994
2
Total 762.58 420.88 341.69
8 2

Energy balance
Preheater :
Feed enters at 250 C and reaction occurs at 1270C
∆Hfeed = ∆H400 – ∆H298
= (21.044*52.948)+(10.522*30.112)*(400-298)
=145969.77kg/hr
Steam required,
M = q/latent heat
= 145969.77/2260
 = 64.588kg/hr
Reactor
Heat of formation in KJ/mol
C2H4 52.47
O2 0
CH3CH0 -170.7
CH3COOH -483.52

Hrxn= -170.7-(52.47+0)
= -223.17KJ/mol
= -223.17*9.47
= -2113.4199KJ
The reaction is exothermic
Ein= mcp∆T
= ((21.044*52.948)+(10.522*30.112))*(127-25)
= 145969.7699KJ
Eout= mcp∆T
= 9.47*66.28*(127-25)
= 64022.5032KJ
Unreacted ethylene = 11.574*52.948*(127-25)
= 62507.6555KJ
Unreacted O2 = 5.765*30.112*(127-25)
= 17706.7594KJ
Total Eout = 64022.5032+ 62507.6555+ 17706.7594
= 144236.9181 KJ
Heat absorbed = Ein- Eout -H
= 145969.7699+2113.4199- 144236.9181
= 3846.2717 KJ
Heat absorbed = m*cp*∆T
 3846.2717 = m* 4.184*(50-25)
Steam required= 3846.2717/(4.184*25)
= 36.77 kg
Degasifier:
Heat in1 = (9.47*55.32)+(5.765*63.44)+(5.809*42.9)*(35-25)
= 11388.181
Heat in2 = (2.3658* 55.32)+(1.4412* 63.44)*(38.5-25)
= 4012. 7819
Total heat in = 11388.181 + 4012.7819
= 15400.962
Heat out1 = (5.809*42.9)*(38.5-25)
= 3364. 2824
Heat out2 = (9.47*55.32)+(5.765*63.44)*(38.5-25)
= 12036.6806
Total heat out = 3364.2824+ 12036.6806
= 15400.9629
Heat in = Heat out
Distillation column
Heat capacity
CH3CHO 55.32
CH3COOH 63.44
Feed temperature= 65
Distillate temperature= 30
Residue temperature= 120
Reflux ratio, R= 1.3
Distillate flow rate= 9.565 kmol/hr
R=L/D
L= R*D
 = 1.3 *9.565
= 12.4345 kmol/hr
Vapor flow rate= L+D
= 12.4345+9.565
= 21.9995kmol/hr
Condenser duty= (R+1)(m*latent heat)+(R+1)(mcpt)
Latent heat CH3CHO= 26.12 KJ/mol
Latent heat CH3COOH= 51.6 KJ/mol
=2.3*((9.47*26.12)+(0.095*51.6))
+2.3*((9.47*55.32)+(0.095*63.44))*(65-25)
= 49331.6567
Hf =m*cp*∆T
=(9.47*55.32)+(5.809*63.44)*(65-25)
= 35696.1344KJ
Hd = m*cp*∆T
= (9.47*55.32)+(0.095*63.44)*(30-25)
= 2649.536KJ
Hr= m*cp*∆T
=(5.714*63.44)*(120-25)
= 34437.1352 KJ
Reboiler duty= Hd+ Hr+Qc- Hf
= 2649.536+34437.1352+40752.2382-35696.1344
= 42142. 775 KJ
Steam required= 42142.775/ latent heat
= 42142.775/2260
=18.6472 kg