CHAPTER NO.

5 Energy Balance

ENERGY BALANCE

5.1 Energy Balance around Compressor K-100:

Inlet Conditions:

Air enters at 30oC and 101Kpa

Outlet conditions:

Compressed air leaves at 202Kpa

Mass flow rate of Air = 66445.5 kg of Air/hr = 0.638 kgmole of Air/sec

Inlet volumetric flow rate:

nRT
V=
P

Where,

T = 303 K, P = 1atm, R = 0.0821 m3 atm /kgmole K

= 0.638 x 0.0821 x 303 = 15.85 m3/sec

From Coulson and Richardson vol. 6 for given flow rate at suction conditions

Approximate poly-tropic efficiency η= 76%

Outlet temperature for poly-tropic flow:

45
CHAPTER NO. 5 Energy Balance

m
P2 γ −1
T 2=T 1 ( )
P1 Where m= γ E
P
( )
For Air (diatomic gases) 𝛾 = 1.4

m= ( 1.41.4−1
X 0.76 )
= 0.376

0.376
2
So T 2=303 () 1
= 393.21K = 120oC

Work per mole for poly-tropic flow:

n−1
n Zi R T 1 P2
w= ( )
n−1 M [( ) ]
P1
n
−1

1 1
Where, n=
1−m
¿
1−0.376
= 1.60

General Gas constant R = 8.314 KJ / kgmole K

Compressibility factor Zi = 1
Average Air molecular mass M = 29.09
kg/kgmole

1.6−1
1.6 8.314 X 303 2
w= ( 1.6−1) 29.09 [( ) 1
1.6
−1 ]
W = 68.55 KJ/kgmole

Power Requirement:

Ideal work
Actual work=
Efficiency

Actual work = 68.55/0.76 = 90.20 KJ/kgmole

Power requirement= ṁW actual

46
CHAPTER NO. 5 Energy Balance

Power requirement = 1.09 x 90.20 = 98.32 KW

5.2 Energy Balance around Air Pre-heater E-101:

Inlet conditions: Air enters at 120oC and 202Kpa

Outlet conditions: Air stream leaves at 380oC and 202Kpa

Taking 120oC as reference temperature

As air contains 64 kgmole of moisture so

Heat taken by Air = (m Cp dry air + m Cp moisture) (T6 – T5)

= (2295.5 x 30.55 + 64 x 35.83) (380 – 120)

= 1.88 x 107 kJ/hr

5.3 Energy Balance around Benzene Pre-heater E-100:

Inlet conditions: Benzene enters at 30oC and 202Kpa

Outlet conditions: Benzene leaves at 110oC and 202Kpa

Taking 30oC as reference temperature

Boiling point of benzene at 202Kpa = 104.7oC

47
CHAPTER NO. 5 Energy Balance

So heat duty of benzene preheater

= m {Cpℓ (104.7 – T2) + Cpg (T3 – 104.7) + λ}

= 35.44{138.5(104.7 – 30) + 108.4(110 – 104.7) + 2.96x104}

= 1.44x106 kJ/hr

5.4 Energy Balance around Feed Mixer MIX-100:

Let reference temperature = 110oC

Q mix =Q Air + Q Benzene

[ mC p Air +mC p Benzene ] ( T mix−110 )=mC p Air (380−110)

Assuming Tmix = 350oC

So average temperature = (350 + 110)/2 = 230oC

m (kgmole/hr) Cp (kJ/kgmole oC) m Cp

Air 2359.8 30.57 72139.1

Benzene 35.44 138.4 4904.9

Temperature is found by making energy balance,

T mix = 363oC

48
CHAPTER NO. 5 Energy Balance

5.5 Energy Balance around Reactor PFR-100:

Chemical Reactions:

C6H6 + 4.5O2 C4H2O3 + 2CO2 + 2H2O (R1)

∆H = -1.86x106 KJ/kgmole

C6H6 + 7.5O2 CO2 + 3H2O (R2)

∆H = -3.20x106 KJ/kgmole

C6H6 + 1.5O2 C6H4O2 + H20 (R3)

∆H = -4.50x105 KJ/kgmole

Making heat balance at reactor

At steady state

Heat input to reactor = Heat output from reactor

h eat ∈feead
h eat of reaction = h eat takenby h eat ¿ 400o C + h eat taken
( o
at 363 C )(
stream entering +
at 25o C ) (
products
¿
¿ ¿ by cooling
salt
)( )
Enthalpy of Reactants: ∆ H =m ( C p l ∆ T l +C pg ∆ T g+ λ )

 m  Cpℓ  ΔTℓ  CpℓΔTℓ  Cpg  ΔTg  Cpg∆Tg  λ ∆H

Air 2295 …. …. …. 32.21 338 10886.9  …. 2.4x107

Moistur 64.3 72.94 75 5470.5 35.65 263 9375.9 4.0x104 3.5x106

e 8
Benzene 35.4 133 53 7049 136.4 285 38874 2.9x104 1.6x106

Total Σ ∆H = 2.9 x 107 kJ/hr

49
CHAPTER NO. 5 Energy Balance

Enthalpy of products leaving at 400oC:

 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  Cpg∆Tg  λ ∆H

ℓ
Nitroge 1813 …. …. …. 30.16 375 11310  …. 2.0x107
n
Oxygen 318. …. …. …. 30.94 375 11606 …. 3.7x106
4
Water 134. 72.94 75 5471 35.83 300 10749 4.0x104 7.6x106
7
CO2 88.7 …. …. …. 43.87 375 16451 …. 1.5x106
5
MAN 25.8 158 177 27966 162.5 198 32175 4.7x104 2.8x106
7
Benzene 2.83 133 53 7049 140.4 322 45209 2.9x104 2.3x105

Quinone 0.56 182 155 28210 172.6 220 37972 4.4x104 6.2x104

Total Σ ∆H = 3.59 x 107 kJ/hr

Heat produced by reactions assuming reaction takes place at 25oC

By reaction (R1) = 1.86x106 x 25.87 = 4.81x107 kJ/hr

By reaction (R2) = 3.2x106 x 6.17 = 1.97x107 kJ/hr

By reaction (R4) = 4.5x105 x 0.57 = 2.57x105 kJ/hr

Total Heat of reaction at 25oC ΔHR = 6.81 x 107 KJ/hr

So, Making energy balance to calculate

Heat taken by cooling salt = 2.76 x 107 kJ/hr

50
CHAPTER NO. 5 Energy Balance

5.6 Energy Balance around Heat Exchanger E-102:

Product steam (8) from the reactor is cooled from 400oC to 76oC at 152Kpa. For energy
balance around Waste Heat Boiler assume 76 oC as reference temperature.

Heat Heat
( Heat
removed∈¿ E−102 ) ( )(
= carried by − carried by
(8) ( 9) )
Enthalpy of stream (8)

 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  Cpg∆T  λ ∆H

ℓ g
Nitroge 1813 …. …. …. 30.16 324 11310  …. 1.77x107
n
Oxygen 318. …. …. …. 30.94 324 11606 …. 3.19x106
4
Water 134. 72.94 24 1750 35.83 300 10749 4.0x104 1.72x106
7
CO2 88.7 …. …. …. 43.87 324 16451 …. 1.26x106
5
MAN 25.8 158 126 19908 162.5 198 32175 4.7x104 1.39x106
7
Benzene 2.83 133 4 532 140.4 320 44928 2.9x104 1.57x105

Quinone 0.56 182 104 18928 172.6 220 37972 4.4x104 7.58x104

Total Σ ∆H = 2.55 x 107 kJ/hr

So Heat removed in waste heat boiler = 2.57x107 KJ/hr

51
CHAPTER NO. 5 Energy Balance

5.7 Energy Balance around Pre-scrubber cooler E-103:

Stream(11) is cooled from 76.5oC to 50oC before it enters Gas Scrubber. For energy
balance assuming 50oC as reference temperature.

 m  Cpℓ  ΔTℓ  CpℓΔTℓ  Cpg  ΔTg  Cpg∆Tg ∆H

Nitrogen 1813 …. …. …. 29.33 46.5 1363.5 2.3x106

Oxygen 318.4 …. …. …. 29.51 46.5 1372.2 4.0x105

Water 134.7 72.94 46.5 3384.2 …. …. …. 4.3x105

CO2 88.75 …. …. …. 39.25 46.5 1825 1.6x105

MAN 12.9 144 46.5 6714 …. …. …. 1.0x105

Benzene 2.83 133 46.5 6198 …. …. …. 1.7x104

Quinone 0.56 182 46.5 7765 …. …. …. 2.5x103

Total Σ ∆H = 3.60x106 kJ/hr

Enthalpy of stream (12)
 m  Cpℓ  ΔTℓ  CpℓΔTℓ  Cpg  ΔTg  Cpg∆Tg ∆H

Nitrogen 1813 …. …. …. 29.33 30 1363.5 1.35x106

Oxygen 318.4 …. …. …. 29.51 30 1372.2 2.88x105

Water 134.7 72.94 30 3384.2 …. …. …. 2.95x105

CO2 88.75 …. …. …. 39.25 30 1825 1.0x105

MAN 12.9 144 30 6714 …. …. …. 6.5x104

Benzene 2.83 133 30 6198 …. …. …. 1.0x104

Quinone 0.56 182 30 7765 …. …. …. 1.3x103

Total Σ ∆H = 2.35x106 kJ/hr

52
CHAPTER NO. 5 Energy Balance

Heat to be removed = enthalpy of stream (12) - enthalpy of stream (11)

= 1.25x106 kJ/hr

5.8 Energy Balance around Mixer MIX-101:

Pure water stream (16) is added to scrubbed liquid (13) to keep the concentration of
MAC solution up to 40%. Assuming water enters at 30 oC and 101Kpa while scrubbed
liquid is entering at 45oC. also stream (15) and (17) are leaving at same temperature. So
T15 = T17 = T

Energy balance around mixer MIX-101 is

Heat Heat Heat Heat

( )( )( )(
carried by + carried by = carried by + carried by
(13) (16) (15) (17) )
Enthalpy of stream (13), assuming 30oC as reference temperature

 m  Cpℓ  ΔTℓ  CpℓΔTℓ ∆H

Water 2832.4 77.8 15 1155 3.2x106

MAC 313.8 233.5 15 3498 1.1x106

Quinone 0.33 171.3 15 2565 8.4x102

Total Σ ∆H = 4.3x106 kJ/hr

53
CHAPTER NO. 5 Energy Balance

Enthalpy of stream (15)

 m  Cpℓ  ΔTℓ ∆H

Water 2913.1 77.8 (T-30) 2.2x105(T-30)

MAC 301.9 233.5 (T-30) 7.0x104(T-30)

Total Σ ∆H = 2.9x105(T-30)

Enthalpy of stream (17)

 m  Cpℓ  ΔTℓ ∆H

Water 2832.4 77.8 (T-30) 2.4x104(T-30)

MAC 317.8 233.5 (T-30) 6.6x105(T-30)

Quinone 0.33 171.3 (T-30) 5.6x101(T-30)

Total Σ ∆H = 6.8x105(T-30)

So energy balance across MIX-101

4.3x106 = 2.9x105(T-30) + 6.8x105(T-30)

T = 34.5oC

So temperature of T15 = T17 = T = 34.5oC

54
CHAPTER NO. 5 Energy Balance

55
CHAPTER NO. 5 Energy Balance

5.9 Energy Balance around Scrubber T-100:

MAN is absorbed in 40% solution of MAC entering at 45oC while the gases leaves from
the top of scrubber in vent stream (14).

For energy balance assuming 30oC as reference temperature

Then
h eat h eat h eat h eat
( (12) )(
carried by carried by
+
(15)
+
)(
h eat of =
reaction) ( )(
carried by carried by
(13)
+
(14) )
Reaction involved in scrubber

C4H2O3 + H2O C4H4O4

ΔH = -3.6x104 KJ/kgmole

= 5.4x105 Kj/hr

Enthalpy of stream (12)

m C Pl ∆Tl C Pl ∆ T l ∆H

Nitrogen 1813 29.33 30 879 1.6x106

Oxygen 318 29.51 30 885 2.9x105

56
CHAPTER NO. 5 Energy Balance

Water 133 72.78 30 2183 3.0x105

CO2 88 39.25 30 1177 1.0x105

MAN 13 144.4 30 4332 6.5x104

Benzene 2.83 133.3 30 3999 1.4x104

Quinone 0.33 167 30 5010 1.6x103

Total Σ ∆H = 2.3x106 kJ/hr

Enthalpy of stream (13)

m C Pl ∆Tl C Pl ∆ T l ∆H

Water 2832.4 72.8 15 1092 3.3x106

MAC 313.8 208.5 15 3098 9.8x105

Quinone 0.33 164.3 15 2464 8.1x102

Total Σ ∆H = 4.4x106 kJ/hr

Enthalpy of stream (15)

m C Pl ∆Tl C Pl ∆ T l ∆H

Water 2913.4 76 4.5 342 9.5x105

MAC 301.2 233 4.5 1048 3.0x105

Total Σ ∆H = 1.2x106 kJ/hr

Enthalpy of stream (14)

m C Pg ∆Tg ∆H

Nitrogen 1813 29.26 (T-30) 5.3x104(T-30)

Oxygen 319.2 29.48 (T-30) 9.6x103(T-30)

Water 201.1 72.79 (T-30) 1.4x104(T-30)

CO2 88.73 39.16 (T-30) 3.4x103(T-30)

MAN 0.25 144.4 (T-30) 3.7x101(T-30)

Benzene 2.83 131.2 (T-30) 3.7x102(T-30)

57
CHAPTER NO. 5 Energy Balance

Total Σ ∆H = 8.1x104(T-30)

So energy balance provides

2.3x106 + 5.4x105 + 1.3x106 = 4.4x106 + 8.1x104(T-30)

T = T14 = 37.8oC

5.9.1 Energy Balance around Dehydrator Feed Pre-Heater E-104:

Feed is heated from 44.2oC to 95oC in vapor phase before it enters the dehydrator.

Reference temperature is 30 oC

Energy balance across stream (17)

m CPl ∆Tl CPl ∆ T l ∆H

Water 142.5 73.1 14.2 1038 1.47x105

MAC 14.89 215.8 14.2 3064 4.53x104

Quinone 0.33 173.6 14.2 2465 8.13x102

Total Σ ∆H = 1.94x105

Energy balance across stream (18)

m CPl ∆Tl CPl ∆ T l ∆H

Water 142.5 73.1 65 4752 6.73x105

MAC 14.89 215.8 65 14027 2.08x105

Quinone 0.33 173.6 65 11284 3.79x103

Total Σ ∆H = 8.84x105

58
CHAPTER NO. 5 Energy Balance

So heat duty of Dehydrator feed preheater

Q = 8.84x105-1.94x105 KJ/hr

= 6.90x105KJ/hr

5.10 Energy Balance around Dehydrator T-101:

Operating conditions:

Top plate temperature = 55oC

Re-boiler temperature = 120 oC

Operating pressure = 15.2 kpa

Assuming 100oC as reference temperature

Reactions involved

C4H4O4 C4H2O3 + H20 (R1)

ΔH = 3.6x104 KJ/kgmole

C4H4O4 C4H4O4 (R2)

59
CHAPTER NO. 5 Energy Balance

ΔH = 3.9x103 KJ/kgmole

5.10.1 Energy Balance around Overhead condenser:

Overhead product is condensed from 55oC to 45oC at 15.2Kpa.

Boiling point of water at 15.2Kpa = 53.6oC
Boiling point of O-xylene at 15.2Kpa = 85.05oC
Taking 30oC as reference temperature
Enthalpy of stream (19)

 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  Cpg∆T  λ ∆H

ℓ g
Water 149 72.77 24 1819 33.8 1 33.8  4.3x104 6.7x106

Xylene 43 194.3 25 4857 …. …. …. …. 2.1x106

Total Σ ∆H = 6.9x106

Enthalpy of stream (20)

 m  Cpℓ  ΔTℓ  CpℓΔTℓ ∆H

Water 149 72.77 15 1091 1.6x105

Xylene 43 192.3 15 2884 2.1x106

Total Σ ∆H = 2.86x105

60
 CHAPTER NO. 5 Energy Balance

So heat duty of overhead condenser

(¿ hheadeatcondenser
duty of ent h alpy of − ent h alpy of
)=(entering stream ) ( leaving stream )

Qc = 2.86x105– 66.9x106= 6.6x106 KJ/hr

Column operating conditions:

Top plate temperature = 55oC

Re-boiler temperature = 120oC

Reflux stream (21) is assumed as pure O-xylene at 45oC

Enthalpy of stream (18) entering at 95oC and 101Kpa

m C Pl ∆Tl C Pl ∆ T l ∆H

Water 142.30 72.9 65 4738 6.70x105

MAC 14.89 212.4 65 13806 2.05x105

Quinone 0.33 170.4 65 11076 3.65x103

Total Σ ∆H = 8.78x105

Enthalpy of stream (26) leaving at 120 oC and 15.2KPa

 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  Cpg∆Tg  λ ∆H

ℓ
Water 7.87 72.77 28.6 2081 34.03 61.4 2089 4.3x104 3.7x105

MAN 14.77 149.7 90 13473 …. …. …. …. 1.98x105

Xylene 2.29 200 60 12024 163.1 30 4.1x104 2.9x104 1.32x106

Fumaric 0.07 251 90 22590 …. …. …. …. 1.58x103

Acid
Quinone 0.33 173.8 90 15642 …. …. …. …. 5.13x103

Total Σ ∆H = 5.09x105

Enthalpy of reflux stream (21) = 75.79x192.3 (45-30)

= 2.91x105KJ/hr

Heat required by reaction (R1) = 3.6x104 x 14.77 = 5.31x105KJ/hr

61
 CHAPTER NO. 5 Energy Balance

Heat required by reaction (R2) = 3.19x103 x 0.07 = 4.68x102KJ/hr

Total heat required for reactions = 5.34x10 5KJ/hr

So heat duty of Re-boiler =

heat heat heat heat

( (26)
+
)(
carried by carried by
(19)
+
)(
heat of −
reactions )
carried by
(21) (
− carried by
(18) )( )
= 5.09x105+ 6.9x106+ 5.34x105- 2.91x105 - 8.78x105

= 6.7x106KJ/hr

5.11 Energy Balance around Mixer MIX-102:

Stream (27) entering at 120oC and 101Kpa is mixed with crude MAN stream (10).

heat heat heat

( )( )(
carried by + carried by = carried by
stream(27) stream(10) stream(28) )
Assuming 30oC as reference temperature so Enthalpy of stream (27)
 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  Cpg∆Tg  λ ∆H
ℓ
Water 9.55 72.77 75 54.57 34.42 15 516 4x104 4.39x105

MAN 25.57 149.7 90 13473 …. …. …. …. 3.42x105

Xylene 2.29 207 90 18630 …. …. …. …. 4.20x104

Fumaric 0.07 251 90 22590 …. …. …. …. 1.58x103

Acid
Quinone 0.33 173.8 90 15642 …. …. …. …. 5.13x103

Total Σ ∆H = 8.29x105

62
 CHAPTER NO. 5 Energy Balance

Enthalpy of stream (28)

 m  Cpℓ  ΔTℓ  CpℓΔT  Cpg  ΔTg  λ ∆H

ℓ
Water 9.55 73.12 75 5484 34.42 (T-100) 4x104 4.35x105

MAN 36.2 149.7 (T-30) …. …. …. …. 5422 (T-30)

2
Xylene 2.29 207 (T-30) …. …. …. …. 472(T-30)

Fumaric 0.07 251 (T-30) …. …. …. …. 18 (T-30)

Acid
Quinone 0.33 173.8 (T-30) …. …. …. …. 97 (T-30)

Total Σ ∆H = 4.35x105 + 328(T-100) + 6009(T-30)

Enthalpy of stream (10)

m CPl ∆Tl CPl ∆ T l ∆H

MAN 10.65 145.3 46.5 6756 7.19x104

Water 1.68 72.8 46.5 3385 5.68x103

Quinone 0.23 168.5 46.5 7835 1.8x103

Total Σ ∆H = 7.93x104

So enthalpy balance around mixer is

7.93x104 + 8.29x105 = 4.35x105 + 328(T-100) + 6009(T-30)

T29 = T = 82.6oC

63
 CHAPTER NO. 5 Energy Balance

5.12 Energy Balance around Distillation Column T-102:

30

32

31
29

36

Operating conditions:
Top plate temperature = 1
Re-boiler temperature = 220 oC
Reflux temperature = 117oC
Operating pressure = 110 KPa
Assuming 25oC as reference temperature,
Enthalpy of feed stream (29) entering at 160C & 130KPa:
m Cpℓ ΔTℓ CpℓΔTℓ Cpg ΔTg Cpg∆Tg λ ∆H
Water 9.56 73.12 75 5484 34.38 60 2062.8 40000 454547.4
MAN 25.55 148.4 135 20034 …. …. …. …. 511868.7
O-Xylene 2.29 204.9 119 24383.1 235.2 16 3763.2 36330 147650.7
Fumaric 0.76 250.2 135 33777 …. …. …. …. 25670.52
Acid
Quinone 0.57 172 135 23220 …. …. …. …. 13235.4

Total Σ ∆H = 1.15x106 kJ/hr

64
CHAPTER NO. 5 Energy Balance

Enthalpy of stream (30) @ 137oC & 110KPa:

Components

Cpℓ

ΔTℓ

CpℓΔTℓ

Cpg

ΔTg

Cpg∆Tg

∆H

Water

62.34

73.12

75

5484

37

37

444

40000

2863152

MAN

5.6

148.4

112

65
CHAPTER NO. 5 Energy Balance

16620.8

….

….

….

….

93076.4

O-Xylene

16.04

204.9

112

22948.8

….

….

….

….

368098.8

Quinone

172

112

19264

….

….

….

….

66
CHAPTER NO. 5 Energy Balance

77056

Total

Σ ∆H = 3.4x106 kJ/hr

Enthalpy of stream (31) @117C & 110KPa:

Components
Cpℓ
ΔTℓ
CpℓΔTℓ
Cpg
ΔTg
Cpg∆Tg
λ
∆H

Water
73.12
75
5484
34.57
17
587.69
40000
2494782

67
CHAPTER NO. 5 Energy Balance

MAN
153.6
92
14131.2
….
….
….
….
67688.45

O-Xylene
212.3
92
19531.6
….
….
….
….
259184.3

68
CHAPTER NO. 5 Energy Balance

Quinone
179.1
92
16477.2
….
….
….
….
55857.71

Total
Σ ∆H = 2.9x107 kJ/hr

Enthalpy Of overhead product Stream (32) @117oC & 110 KPa:

m
Cpℓ
ΔTℓ
CpℓΔTℓ
Cpg

69
CHAPTER NO. 5 Energy Balance

ΔTg
Cpg∆Tg
λ
∆H

Water
8.9
73.12
75
5484
34.38
17
584.46
40000
410009.3

MAN
0.8
148.4
92
13652.8
….
….
….
….
10922.24

70
CHAPTER NO. 5 Energy Balance

O-Xylene
2.29
204.9
92
18850.8
….
….
….
….
43168.33

Quinone
0.57
172
92
15824
….
….
….
….
9019.68

Total
Σ ∆H = 4.7x105 kJ/hr

71
CHAPTER NO. 5 Energy Balance

Enthalpy of bottom product stream (36) @ 220C &160KPa:

Component m Cpℓ ΔTℓ CpℓΔT Cpg ΔTg Cpg∆T λ ∆H

s ℓ g
MAN 24.87 157.8 175 27615 …. …. …. …. 686978.4
7
Fumaric 0.76 256.6 175 44905 …. …. …. …. 34127.8
Acid
Quinone 0.035 181.9 155 28194.5 152.2 20 3044 46000 2703.348
Total Σ ∆H = 7.2x105 kJ/hr

Heat duty of condenser:

h eat h eat h eat

=
( carried by
stream(30))(
− carried by
stream(31) )(
− carried by
stream(32) )
= 5.08x105KJ/hr

Heat duty of re-boiler:

h eat h eat h eat h eat

=
( (29)
+
)(
carried by carried by
(31)
−
)(
carried by
(30)
−
)(
carried by
(36) )
= 3.30x106KJ/hr

72