SECTION 2

BASIC PROCESS DESIGN

SUPERVISOR: MISS NONHLANHLA MGUNI
GROUP 5
EMMANUEL P. MAWERE
N01519446Y
SECTION 2: BASIC PROCESS DESIGN

Chapter 1: Process Flow Diagram

Chapter 2: Equipment List

Chapter 3: Material Balance

Chapter 4: Energy Balance

Table of Content

List of Figures............................................................................................................................................iv

List of Tables...............................................................................................................................................v

1.0 Process Flow Diagram...........................................................................................................................1

1.1 Introduction.......................................................................................................................................1

1.2 Process description............................................................................................................................1

1.2.1 Isopropyl alcohol (IPA) Receiving tank......................................................................................1

1.2.2 Feed drum...................................................................................................................................1

1.2.3 Preheater.....................................................................................................................................1

1.2.4 Reactor........................................................................................................................................2

1.2.5 Boiler..........................................................................................................................................3

1.2.6 Condenser...................................................................................................................................3

1.2.7 Flash Column..............................................................................................................................3

1.2.8 Liquefaction................................................................................................................................3

1.2.9 Mixing drum...............................................................................................................................4

1.2.10 Heater.......................................................................................................................................4

1.2.11 Acetone Column.......................................................................................................................4

1.2.12 IPA column...............................................................................................................................4

1.2.13 Storage tanks.............................................................................................................................5

2.0 Equipment list........................................................................................................................................8

2.1 Introduction.......................................................................................................................................8

2.2 List of equipment not shown on the plant flow diagram..................................................................10

3.0 Material balance..................................................................................................................................12

3.1 Introduction.....................................................................................................................................12

3.2 Conservation of mass.......................................................................................................................12

i
 3.3 Mass balance on Packed bed Reactor..............................................................................................13

3.3.1 Assumptions.............................................................................................................................13

3.3.2 Operating conditions.................................................................................................................13

3.4 Mass balance on the Flash Column..................................................................................................15

3.4.1 Assumptions.............................................................................................................................15

3.5 Mass balance on the liquefaction plant: The Separation drum.........................................................18

3.5.1 Assumptions.............................................................................................................................18

3.5.2 Operating Conditions................................................................................................................18

3.6 Mass balance on the Mixing Drum..................................................................................................22

3.6.1 Assumptions.............................................................................................................................22

3.7 Mass balance on the Acetone Column.............................................................................................23

3.7.1 Assumptions.............................................................................................................................23

3.8 Mass balance on the IPA Column....................................................................................................25

3.8.1 Assumptions.............................................................................................................................25

3.9 Mass balance on the Feed Drum......................................................................................................27

3.9.1 Assumptions.............................................................................................................................27

4.0 Energy balance....................................................................................................................................28

4.1 Introduction.....................................................................................................................................28

4.1.1 Conservation of Energy............................................................................................................28

4.2 Energy balance on the Preheater......................................................................................................31

4.2.1 Assumptions.............................................................................................................................31

4.2.2 Operating conditions.................................................................................................................31

4.3 Energy balance on the Reactor.........................................................................................................33

4.3.1 Assumptions.............................................................................................................................33

4.3.2 Operating conditions.................................................................................................................33

4.4 Energy balance on the Condenser....................................................................................................35

4.4.1 Assumptions.............................................................................................................................35

ii
 4.5 Energy balance on the Flash column...............................................................................................37

4.5.1 Assumptions.............................................................................................................................37

4.6 Energy balance on the liquefaction plant.........................................................................................38

4.6.1 Assumptions.............................................................................................................................38

4.6.2 Operating conditions.................................................................................................................38

4.7 Mixing Drum...................................................................................................................................40

4.7.1 Assumptions.............................................................................................................................40

4.7.2 Operating conditions.................................................................................................................40

4.8 Energy balance on the Heater..........................................................................................................42

4.8.1 Assumptions.............................................................................................................................42

4.8.2 Operating conditions.................................................................................................................42

4.9 Energy balance on the Acetone distillation column.........................................................................44

4.9.1 Assumptions.............................................................................................................................44

4.10 Energy balance on the IPA distillation column..............................................................................48

4.10.1 Assumptions...........................................................................................................................48

4.11 Feed Drum.....................................................................................................................................51

4.11.1 Assumptions...........................................................................................................................51

4.11.2 Operating conditions...............................................................................................................51

References.................................................................................................................................................53

iii
List of Figures
Figure 1: Process flow diagram for the acetone plant..................................................................................6
Figure 2: Mass balance of a reactor...........................................................................................................14
Figure 3: Mass balance of a flash column..................................................................................................17
Figure 4: Mass balance of the liquefaction plant.......................................................................................21
Figure 5: Mass balance of the mixing drum...............................................................................................22
Figure 6: Mass balance on the acetone column..........................................................................................24
Figure 7: Mass balance on the IPA column...............................................................................................26
Figure 8: Mass balance on the feed drum..................................................................................................27
Figure 9: Energy balance of preheater.......................................................................................................32
Figure 10: Energy balance of a reactor......................................................................................................34
Figure 11: Energy balance of a condenser.................................................................................................36
Figure 12: Energy balance of the liquefaction plant..................................................................................39
Figure 13: Energy balance on the liquefaction plant..................................................................................41
Figure 14: Energy balance of acetone column preheater...........................................................................43
Figure 15: Energy balance of acetone column...........................................................................................47
Figure 16: Energy balance of IPA column.................................................................................................50

iv
List of Tables
Table 1: Conditions of the streams..............................................................................................................7
Table 2: Equipment list of Section 100........................................................................................................8
Table 3: Equipment list of Section 200........................................................................................................9
Table 4: Equipment list of Section 300........................................................................................................9
Table 5: Equipment list of Section 400......................................................................................................10
Table 6: Equipment list of Section 500......................................................................................................10
Table 7: Equipment not included on the PFD............................................................................................11
Table 8: Antoine coefficients.....................................................................................................................15
Table 9: Specific heat capacities of liquid components (Engineering Toolbox, 2018)..............................29
Table 10: Ideal gas heat capacity coefficients (Sinnot, 2005)....................................................................29
Table 11: Stream enthalpies and latent heat for Preheater.........................................................................31
Table 12: Stream enthalpies and latent heat for Reactor............................................................................33
Table 13: Stream enthalpies and latent heat for Condenser.......................................................................35
Table 14: Stream enthalpies and latent heat for the liquefaction plant.......................................................38
Table 15: Stream enthalpies for the Mixed drum.......................................................................................40
Table 16: Stream enthalpies for the Heater................................................................................................42
Table 17: Specification of the Distillate stream for Acetone and IPA.......................................................44
Table 18: Specification of the Bottoms stream for Acetone, IPA and Water.............................................44
Table 19: Stream ethalpies for Acetone distillation column......................................................................46
Table 20: Specification of the distillate stream for IPA, Water and Acetone for the IPA column.............48
Table 21: Specification of the bottoms stream for IPA and Water for IPA column...................................48
Table 22: Stream enthalpies for IPA distillation column...........................................................................49
Table 23: Stream enthalpies for the Feed drum.........................................................................................51

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

1.0 Process Flow Diagram

1.1 Introduction
This section gives detail description of the selected route of acetone isopropyl alcohol which
includes mass and energy balances. The process flow diagram shows the main units involved in
producing acetone in their sequence. The process flow diagram displayes major equipment
excluding small details such as piping.

1.2 Process description

The plant being designed for acetone production has a capacity of 220 tonnes per day of raw
material which is isopropyl alcohol (IPA). The plant will have the following equipment which is
described its use in detail as given below.

1.2.1 Isopropyl alcohol (IPA) Receiving tank

IPA receiving tank acts as a reservior for IPA to be used as feed for the plant. IPA is received as
an azeotrope from Sasol (ZA) in the mole ratio of 67mol% IPA and 33mol% water (about 87wt
% IPA and 33wt% water) using either rail or road transport and stored at ambient
temperature[ CITATION Sas17 \l 12297 ]. The tank is made of low carbon steel. From the Receiving
tank, isopropyl alcohol is pumped to the feed drum.

1.2.2 Feed drum

This drum serves a main purpose of receiving the liquid from the IPA storage tank mixing it with
the recycle stream from the IPA distillation column which is received at a temperature of
86.68℃. This drum also equalises the temperature of the liquid from the recycle stream and the
temperature of the feed which is at ambient temperature becomes a uniform temperature of
35.25℃ upon exit. The outlet is pumped at about 2.8bars to the preheater.

1.2.3 Preheater
The preheater changes the feed temperature from 40 °C to a temperature of 185 °C which
becomes a superheated vapour feed to the reactor. The temperature increase is also accompanied
by a phase change from liquid to gaseous state of the reactor feed occurring at the dew point
temperatures of the respective feed constituents. The changes in the preheater are only physical
as the pressure and absence of catalyst does not promote the reaction of IPA to form acetone and
hydrogen.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

1.2.4 Reactor
The feed to the reactor consisting of isopropyl alcohol and water is injected as a superheated gas
at 185 °C. The feed is converted by a chemical reaction catalysed by a CuO-NiO 2 to yield
products which comprise of acetone and hydrogen as well as unreacted isopropyl alcohol. The
reactor is operated at 200℃ and pressure of 2.8 bars. To maintain this temperature, the reactor is
jacketed where steam is used to supply heat energy to maintain a temperature of 200℃. Below is
the dehydrogenation reaction that occurs to produce isopropyl alcohol and hydrogen [CITATION
eta16 \l 12297 ].

IPA Copper oxide−nickel oxide Acetone + Hydrogen

→

CH 3 CHOH CH 3 CuO−NiO CH 3 COCH 3 + H 2

→

A number of reactions involving isopropyl alcohol can occur at various conditions using CuO-
NiO2. At a temperature less than 175°C where methyl isobutyl alcohol (MIBK) is produced from
isopropyl alcohol as a further reaction from acetone. This continued reaction of acetone to form
MIBK has a conversion of 99.9% and a selectivity of 99.3% at those temperatures. The reaction
can occur in two ways; thus a single step and a formation of an intermediate complex
ion[CITATION eta16 \l 12297 ].

One step reaction

Multi stage reaction

The complex formed MO is called mesityl oxide

At temperatures above 200 °C the selectivity of propylene starts to increase whilst the selectivity
of acetone decreases.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Two isopropyl alcohol molecules can react together to give di-isopropyl ether (DE) and a water
molecule. The selectivity and yield of DE increases with increase in time of contact at
temperatures in the absence of catalyst.

1.2.5 Boiler
Boiler is a very crucial instrument which aid by supplying high pressurised steam and hot water for
process heating. Combustion air is supplied by forced draught fans and the flue gases are drawn out by
the induced draught fans. The fuel used for this boiler is coal.

1.2.6 Condenser
The condenser is operated at 200kPa or 2 bars where the products of the reactor are condensed
into a liquid. Therefore, the condenser cools the gas and condenses from a temperature of 200℃
or 473.15K to 80℃ or 353.15K.

1.2.7 Flash Column

The flash column is operated at 80℃ and 1.8bars where flashing of volatile components occurs.
All of the hydrogen gas in the feed is flashed and some of the acetone, isopropyl alcohol and
water. The flash column has two exits the vapour to the liquefaction plant and the bottoms to the
mixing drum.

1.2.8 Liquefaction
The liquefaction plant recovers acetone, IPA and water from the vapour from the flash Column,
moreover the plant produces hydrogen of high purity without any other chemical components.

Feed to the plant is a vapour just above its dew point it enters the cooler which cools and
condenses this feed to a sub-cooled liquid state at 10˚C at a pressure of 150kPa. The condensing
and the cooling effect is caused by liquefied refrigerant in the shell side of the cooler which

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

extracts the heat from the vapour as it changes its state from liquid to gas at 10 bars of pressure.
The liquefied components enter the separation drum where hydrogen gas escapes through the top
of the tank to the hydrogen storage tank whereas the liquid mixture flows downwards and settle
in the tank. The liquid in the tank is then pumped to the mixing tank using a centrifugal pump at
1 atmospheres of pressure.

1.2.9 Mixing drum

This drum serves a main purpose of receiving the liquid from the liquefaction plant and flash
column bottoms. This drum also equalises the pressure in the feeds and the temperature of the
liquid from the liquefaction plant and the temperature of the bottoms of the flash column
becomes a uniform temperature of 48.71℃ upon exit.

1.2.10 Heater
The feed enters the heater at the exit temperature of the mixing drum at 1.013bars. The heater
uses steam to heat the liquid with acetone as the main component raising the temperature to
67.71℃ so that the feed enters the acetone distillation temperature near the bubble point
temperature.

1.2.11 Acetone Column

The acetone column main purpose is to separate acetone from a mixture constitute of isopropyl
alcohol and water. The feed enters the column as a liquid with a temperature of 67℃. The
column is operated at atmospheric pressure.

99.99% Acetone is recovered as distillate the remaining being isopropyl alcohol as a mixture at
its dew point of 56℃. Latent heat of vapourisation is removed in a condenser before the liquid
being received into a reflux drum. Part of the liquid is recycled back into the column and the rest
exits and is stored in acetone storage tank. The bottoms of the consists of mainly isopropyl
alcohol and water enters the reboiler where a fraction is recycled as a vapour into the column the
rest leaves as a liquid at bubble point temperature of 93.33℃.

1.2.12 IPA column

IPA column serves a main purpose of producing an azeotropic stream of IPA and water at a ratio
67:33 which is recycled to the inlet where the fresh feed enters.

The feed of the column enters at atmospheric pressure and a temperature of 93.33℃ in liquid
state near bubble point temperature.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

99.99% of the IPA in the feed stream is recovered in the distillate together with other
components. All of the acetone in the feed goes to the distillate. The distillate is recovered from
the reflux drum at bubble point temperature of 86.68℃. The bottoms consist of mainly water and
a very small fraction of IPA which enters the reboiler where a fraction is vapourised and the rest
exists in the form of liquid at a temperature of 99.98℃.to waste water storage tanks.

1.2.13 Storage tanks

This is the final section where products of the process are stored. Storage tanks consists of the
Acetone storage tank, Hydrogen storage tank and the water storage tank. The acetone and
hydrogen tanks are made up of carbon steel and the water/ reservoir tank is made up of concrete
which contains water which is used for heating and cooling in the plant.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 1: Process flow diagram for the acetone plant

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 Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Temperature
(˚C) 25.00 86.68 25.00 185.00 200.00 80.00 80.00 80.00 10.00 10.00 10.00 48.71 67.71 56.33 93.33 99.98

Pressure (bars) 1.01 1.01 2.80 2.80 2.00 1.80 1.80 1.80 1.50 1.50 1.01 1.01 1.01 1.01 1.01 1.01

Mole flowrate
(kmol/h)  

IPA 133.11 26.56 159.67 159.67 26.62 26.62 18.79 7.83 7.83 0.00 7.83 26.62 26.62 0.01 26.61 0.05

Acetone 0.00 0.01 0.01 0.01 106.49 106.49 47.98 58.51 58.51 0.00 58.51 106.49 106.49 106.48 0.01 0.00

Water 65.56 13.11 78.67 78.67 65.56 65.56 46.63 18.93 18.93 0.00 18.93 65.56 65.56 0.00 65.56 52.45

Hydrogen 0.00 0.00 0.00 0.00 106.49 106.49 0.00 106.49 106.49 106.49 0.00 0.00 0.00 0.00 0.00 0.00

Total Mole
Flowrate
(kmol/h) 198.67 39.68 238.35 238.35 305.16 305.16 113.40 191.76 191.76 106.49 85.27 198.67 198.67 106.49 92.18 52.50

Total Mass 220000.0 220000.0 220000.0 220000.0 220000.0 113991.0 106008.9 106008.9 5111.4 100897.5 214888.6 214888.6 148230.6 66658.0
Flowrate (kg/hr) 0 43923.02 0 0 0 0 7 3 3 0 3 0 0 0 0 22734.98
Table 1: Conditions of the streams

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

2.0 Equipment list

2.1 Introduction
Basic equipment it is the main equipment in each section of the plant. This equipment determines
the capital cost of the plant. These sections include the following:

 Feed storage and heating.

 Reactor
 Flashing
 Acetone Removal
 IPA Recovery

The equipment list is structured in such a way to show the following:

Code – this is the equipment identification code as indicated on the plant flow diagram.

Equipment – the name of the equipment.

Description – the function of the equipment.

Material of construction – list of the fabrication material for the equipment.

Section 100: Feed Storage and

Heating
Code Equipment Description Material of Construction
Receives IPA in liquid form from
IPA storage suppliers and stores before it is Stainless steel 304 (ASTM
V101 tank required in the plant. A240)
IPA feed Pumps IPA from the storage tank Bronze internals and brass
PU101 pump to the feed drum. body
Mixing point of the recycle
stream and fresh feed from Stainless steel 304 (ASTM
MX101 Feed drum storage. A240)
Pumps the feed and creates
IPA feed pressure which is required in the Bronze internals and brass
PU102 pump reactor. body
 Heats the feed from sub-cooled
liquid until it becomes Stainless steel 304 (ASTM
HX101 Pre-heater superheated gas A240)

Table 2: Equipment list of Section 100

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Section 200: Reactor

Code Equipment Description Material of Construction
Throttling
TD201 device pressure regulation Low carbon steel
PBR20 Packed bed reaction of IPA to form acetone Stainless steel 304 (ASTM
1 reactor and hydrogen A240)
Provide additional energy
HX201 Boiler required in the reactor Low carbon Steel
Table 3: Equipment list of Section 200

Section 300: Flashing

Code Equipment Description Material of Construction
Throttling regulates pressure going into the Stainless steel 304 (ASTM
TD301 device condenser A240)
Adjust the temperature of the Low carbon steel body and
HX301 Condenser reactor output stream stainless steel tubes
separates hydrogen from the Stainless steel 304 (ASTM
FC301 Flash column liquid stream A240)
Condense the vapour from the Stainless steel 304 (ASTM
HX302 Feed cooler Flash Column A240)
Separation Separates the hydrogen gas and Stainless steel 304 (ASTM
SD301 drum the subcooled liquid A240)
Hydrogen Low carbon steel (ASTM
V301 storage tank Collects and stores hydrogen A815)
Pumps liquid out of separation Bronze internals and brass
PU301 Pump drum body
Refrigerant Receives the refrigerant from the Low carbon steel (ASTM
V302 tank Feed Cooler A815)
Refrigerant Compress the refrigerant to high Low carbon steel (ASTM
CM101 compressor pressure A815)
Refrigerant Low carbon steel (ASTM
HX303 cooler Cools the refrigerant A815)
Throttling Regulates pressure of the Low carbon steel (ASTM
TD302 device refrigerant A815)
Table 4: Equipment list of Section 300

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

    Section 400: Acetone Removal Section

Code Equipment Description Material of Construction
Mixing point of the liquid
product of liquefaction plant and Low carbon steel (ASTM
MX401 Mixing drum flash column bottoms. A815)
Mixing drum Stainless steel 304 (ASTM
PU402 product pump Pumps the mixed product A240)
Pre heats the mixture to lessen Low carbon steel body and
HX401 Heater load on column stainless steel tubes
Acetone Separates acetone as distillate Stainless steel 304 (ASTM
C401 column from the feed mixture A240)
Column Stainless steel 304 (ASTM
HX402 reboiler Vaporises the a part of bottoms A240)
Column Stainless steel 304 (ASTM
HX403 condenser Condenses the distillate vapour A240)
Column Distillate condensate temporary Stainless steel 304 (ASTM
RD401 reflux drum storage A240)
Acetone Low carbon steel (ASTM
V401 Storage Tank Stores the acetone product A815)
Table 5: Equipment list of Section 400

    Section 500: IPA Recovery Section

Code Equipment Description Material of Construction
IPA feed Pumping azeotropic IPA to the Bronze internals and brass
PU501 pump IPA column body
Remove excess water and
produces an azeotropic
composition of IPA and water as Stainless steel 304 (ASTM
C501 IPA column top product A240)
IPA column Stainless steel 304 (ASTM
HX501 reboiler Vaporises the a part of bottoms A240)
IPA column Cools the azeotropic vapour Stainless steel 304 (ASTM
HX502 condenser mixture to liquid phase A240)
Water
recovery Stores waters coming from the Low carbon steel (ASTM
RD501 drum reboiler A815)
IPA
circulating Pumping distillate to the feed Bronze internals and brass
PU502 pump drum body
Table 6: Equipment list of Section 500

2.2 List of equipment not shown on the plant flow diagram

Equipment which is not shown on the plant flow diagram mainly comprise valves which are
different depending with use. Examples of these valves are in the table below.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Equipment Description Material of Construction

Low carbon steel (ASTM
Control valve Regulates flow to the feed drum A815)
Non return Avoids backflow into the feed Low carbon steel (ASTM
valve drum A815)
Non return Avoids backflow of bottoms into Low carbon steel (ASTM
valve the flash column A815)
Regulates flow out of the Low carbon steel (ASTM
Control valve separation drum A815)
Non return Avoids backflow into the mixing Low carbon steel (ASTM
valve drum A815)
Non return Avoids backflow of bottoms into Low carbon steel (ASTM
valve the acetone column A815)
Table 7: Equipment not included on the PFD

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.0 Material balance

3.1 Introduction
Material balances are the foundation of process design. A material balance taken over the
complete process will determine the quantities of raw materials required and products produced.
Balances over individual process units set the process stream flows and compositions.

Material balances are also useful tools for the study of plant operation and trouble shooting. They
can be used to check performance against design; to extend the often limited data available from
the plant instrumentation; to check instrument calibrations; and to locate sources of material loss[
CITATION RKS05 \l 1033 ].

3.2 Conservation of mass

The general equation for the conservation of mass is as follows:

Mass out =Mass∈+Generation−Accumulation−Consumption

For steady state processes there is no accumulation[ CITATION RKS05 \l 12297 ]. Whenever a
chemical reaction occur chemical species are consumed and produced and if neither the case
occur the conservation of mass equation is reduced to the following:

Mass∈¿ Mass out

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.3 Mass balance on Packed bed Reactor

3.3.1 Assumptions
 No side reactions.
 Iso-propanol alcohol (IPA) single pass conversion of 80%.
 Feed of 67mol% of iso-propanol alcohol and 33mol% water[ CITATION Sas17 \l 12297 ].

3.3.2 Operating conditions

 Temperature of 200℃
 Pressure of 2.8 bars

Process chemical reaction

IPA Copper oxide−nickel oxide Acetone + Hydrogen

→

CH 3 CHOH CH 3 CuO−NiO CH 3 COCH 3 + H 2

→

Calculation

Mass∈¿ Mass out

67mol% gives 0.87 wt% of IPA in feed, therefore:

220000 kg
day 1day
Moles of IPA∈the feed=0.87 × ×
60 kg 24 hrs
kmol

= 133.11kmol/hr

Amount of IPA reacted =0.8 ×133.11

= 106.49kmol/hr

From the reaction above one mole of IPA produce one mole of Acetone and one mole of
Hydrogen therefore:

Amount of IPA reacted in kmol/hr = Amount of Acetone produced in kmol/hr

= Amount of Hydrogen produced in kmol/hr

Amount of IPA unreacted=0.2× 133.11

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

= 26.62kmol/hr

Figure 2: Mass balance of a reactor

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.4 Mass balance on the Flash Column

3.4.1 Assumptions
 Isothermal operation at 80˚C (353.15K).
 The top product contains all the hydrogen.
 Hydrogen is not included in the flash calculations.

Calculations

Overall mass balance

Mass∈¿ Mass out

z i F=x i L+ y i V ………………………………………… ..1

L V
1=L+V , where L= ∧V = ……………………. ..2
F F

Where zi if the mole fraction of component i in the feed, F is the total feed in moles, xi is the
mole fraction of component i in the liquid phase, L is the total amount of liquid from the flash
column, yi is the mole fraction of component i in the vapour phase and V is the total amount of
vapour from the flash column.

By using the UNIFAC method calculations of the following activity coefficients where obtained
at 353.15K (80℃) of the composition (mole fractions) of the feed below:

IPA (1) = 0.134, Acetone (2) = 0.536, Water (3) = 0.330

Ƴ1 = 1.33850, Ƴ2 = 1.25804, Ƴ3 = 2.08560.

A B C
IPA (1) 10.9237 3166.38 -80.15
Acetone (2) 10.0311 2940.46 -35.93
Water (3) 11.6834 3816.44 -46.13
Table 8: Antoine coefficients[ CITATION RKS05 \l 2057 ]

Where Pressure is expressed in bars and temperature in degree kelvins.

By using the Antoine equation the values of saturation pressures are found at a temperature of
3353.15K.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

B
lnP sat = A− … … … … … … … … … … … … … … … … .. 3
T +C

P1sat = 92.03kPa (0.9203bars)

P2sat = 215.47kPa (2.1547bars)

P3sat = 47.38kPa (0.4738bars)

By using an operating pressure P of 180kPa chosen between the bubble point pressure (Pb =
194.41kPa) and dew point pressure (Pd = 156.13kPa) the following equation is utilized to find the
K values.

γ 1 Pisat
K i= … … … … … … … … … … … … … … … … … … … … .4
ɸi P

But for low to moderate operating pressures the value of ɸ is unit which means equal to 1.
Therefore the equation remains as below:

γ 1 Pisat
K i= ……………………………………………………5
P

K1 = 0.68435, K2 = 1.50594, K3 = 0.54898.

By using the equation 7 below the value of V in equation 2 is found.

zi K i
= yi … … … … … … … … … … … … … … … … … 6
1+ V ( K i−1 )

zK
∑ 1+V i( K i−1 ) =1 … … … … … … … … … … … … … … … …7
i

V = 0.3789157

By using equation 6 the values of y are found:

y1 = 0.104, y2 = 0.677, y3 = 0.219

By using the equation (8) below the values of xi are found,

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

yi
K i= … … … … … … … … … … … … … … … … … … … … … … .8
xi

x1 = 0.152, x2 = 0.4496, x3 = 0.3984

Therefore, number of moles from the top of the column = V × Feed

= 0.3789157 × 198.671

= 75.2795kmol/hr (without hydrogen)

Moles in vapour from the top of the flash column with hydrogen = 75.2795 + 106.487

= 181.767kmol/hr

Moles in liquid from the bottom of the flash column = 198.671 – 75.2795

= 123.391kmol/hr

Figure 3: Mass balance of a flash column

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.5 Mass balance on the liquefaction plant: The Separation drum

3.5.1 Assumptions
 Hydrogen is the only component exiting as a gas.
 Acetone, IPA and water exit in liquid state.

3.5.2 Operating Conditions

 Temperature is 283.15K
 Pressure is 180kPa

Calculations

Mass∈¿ Mass out

Since there is need to liquefy other components except hydrogen there is to prove that these
components will exist as a sub cooled liquid at a temperature of 283.15K and pressure of
180kPa. To show that the components exist in the sub cooled region, dew point temperature and
bubble point temperature calculated at 130kPa should be higher than the operating temperature
of 283.15K and if otherwise the components will not exist as pure liquid but as both or as a
superheated vapour.

Dew point temperature calculation

Assuming a gaseous feed

Pressure = 130kPa (1.3 bars)

Composition,

IPA (1) = 0.104

Acetone (2) = 0.677

Water (3) = 0.219

By using the UNIFAC method calculations of the following activity coefficients where obtained
at 283.15K of the above composition:

19
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Ƴ1 = 1.470365,

Ƴ2 = 1.149075,

Ƴ3 = 2.458592.

By using the equations below and the antoine coefficients in table 1:

B
T sat = −C … … … … … … … … … … … … … … 9
A−lnP

B
lnP sat = A− … … … … … … … … … … … … … ..1 0
T +C

B
T= −C … … … … … … … … … … … … … …11
A−lnP sat

y k ɸk Psat
sat
P =∑
1
k
( ) i
Ƴ k Psat
k
… … … … … … … … … … … … 12

Psat
1 =P ¿

By using equation (1) the values of Tsat are calculated:

T1sat = 377.15K, T2sat = 336.94K, T3sat = 380.29K

T =∑ y k T sat
k ……………………………………… 14
k

By utilizing equation (6) the value of T = 350.62K

The value of T = 350.62K is utilized to find saturation pressures using equation (2) thus:

P1sat = 45.7kPa, P2sat = 198.8kPa, P3sat = 42.7kPa

The new value of P1sat is calculated using equation (5) where P = 130kPa therefore:

P1sat = 39.2kPa

The new value of P1sat is used to find the new value of dew point temperature using equation (3)
which is T = 347.13K.

20
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

The iteration is repeated until the value of dew point temperature becomes constant, in this case
dew point temperature becomes constant at Td = 346.5K.

Bubble point temperature calculation

Assumption

 Compositions of components are in liquid phase.

Using the values of Tsat for components from dew point calculation the value of T is calculated
from the equation below.

T =∑ x k T ksat…………………………………… 15
k

The value of T is found to be 350.62K and finding the saturation pressures using equation (2)
thus:

P1sat = 45.7kPa, P2sat = 198.8kPa, P3sat = 42.7kPa

The new value of P1sat is calculated using the equation (9) below where P = 130kPa therefore:

P
Psat
i =
x k Ƴ k Psat
k ………………………………….. 16
∑ ɸ k Pisat
k

But at low to moderate pressures ɸ is approximated to 1.

P
Psat
1 =
P2sat P3sat ………………………………….. 17
x 1 γ 1 + x 2 γ 2 sat + x 3 γ 3 sat
P1 P1

P1sat = 32.18kPa, and T is calculated using equation (3) and T = 342.76K is found, the iteration is
repeated until bubble point temperature is a constant value at Tb = 340.1K.

Therefore since dew point temperature Td = 346.5K and bubble point temperature Tb = 340.1K
are way greater than the operating temperature of the Knock out drum of 283.15K it means the
mixture of components exists as a sub-cooled liquid except hydrogen.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Mass balance of the liquefaction plant

Mass or moles in the liquefaction plant as vapour = mass or moles of hydrogen in vapour + mass
or moles of components in liquid state

Figure 4: Mass balance of the liquefaction plant

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.6 Mass balance on the Mixing Drum

3.6.1 Assumptions
 No reaction taking place in the Drum.

Calculations

Overall mass balance

Mass∈¿ Mass out

mass ¿ the FC bottoms+ mass ¿the LP=mass out of the MD

Where FC is the Flash Column, LP is the Liquefaction Plant and MD is the Mixed Drum.

Figure 5: Mass balance of the mixing drum

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.7 Mass balance on the Acetone Column

3.7.1 Assumptions
 Separation is between the key components which are acetone and IPA. Water is none
distributing.
 Top product contains 99.99% wt of Acetone in the feed making 99.99% wt of distillate.
 Assuming the bottoms contain 0.1% of Acetone.
 Water in the feed reports to the bottoms

Calculations

Overall mass balance

Basis: 1 day for mass

F=B+ D … … … … … … … … … … … … … … … … … … … … … . .18

Where F = mass flow rate of the feed, B = mass flow rate of bottom product, D = mass flow rate
of the distillate.

x f F=x b B+ x d D … … … … … … … … … … … … … … … … … … .19

xf is mass fraction of acetone in feed, xb is mass fraction of acetone in bottoms and xd is mass
fraction of acetone in distillate.

Since D contains 99.99% of acetone in the feed therefore:

Acetone∈distillate=0.9999 × x f F

¿ 0.9999 ×0.69 ×214888.6

¿ 148215.78 kg

IPA∈distillate=0.0001 × x f F

24
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

¿ 0.0001 ×0.69 ×214888.6

¿ 14.821578 kg

Distillate (D) = mass of IPA in distillate + mass of Acetone in distillate

D=148230.60 Kg

¿ eqn ( 19 ) B=66658 Kg

Individual masses are shown in the diagram below:

Figure 6: Mass balance on the acetone column

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.8 Mass balance on the IPA Column

3.8.1 Assumptions
 Separation is between the key components which are IPA and water. Acetone is none
distributing.
 Top product contains 99.99% wt of IPA in the feed.
 The distillate contains an azeotropic composition containing 67% mol IPA and 33% mol
water.
 Acetone in the feed goes to the distillate into the recycle stream.

Calculations

Overall mass balance

Basis: 1 day for mass

x f F=x b B+ x d D

From the above equation xf is mass fraction of IPA in feed, xb is mass fraction of IPA in bottoms
and xd is mass fraction of IPA in distillate.

Since B contains 0.01% of acetone in the feed therefore:

IPA∈distillate=0.9999 × x f F

¿ 0.9999 ×0.5749 ×66658

¿ 38316.15 kg

Since water will exist as an azeotrope in distillate in a mixture of 13wt% water and 87wt% IPA
therefore:

38316.15
Water∈distillate=0.13 ×
0.87

26
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

¿ 5674.94 kg

Distillate (D) = mass of IPA in distillate + mass of water in distillate + mass of Acetone in
distillate

D=44006.61 Kg

¿ eqn ( 19 ) B=22651.39 Kg

Individual masses are shown in the diagram below:

Figure 7: Mass balance on the IPA column

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

3.9 Mass balance on the Feed Drum

3.9.1 Assumptions
 No reaction taking place in the Drum.

Overall mass balance

mass ¿ the RS +mass ¿ the Feed=mass out of the FD

RS – Recycle Stream

FD – Feed Drum

Figure 8: Mass balance on the feed drum

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.0 Energy balance

4.1 Introduction
Material can change form, new molecular species can be formed by chemical reaction, but the
total mass flow into a process unit must be equal to the flow out at the steady state and it is the
same with energy. The total enthalpy of the outlet streams will not equal that of the inlet streams
if energy is generated or consumed in the processes; such as that due to heat of reaction. Energy
can exist in several forms: heat, mechanical energy, electrical energy, and it is the total energy
that is conserved[ CITATION RKS05 \l 1033 ].

In process design, energy balances are made to determine the energy requirements of the
process: the heating, cooling and power required. In plant operation, an energy balance on the
plant will show the pattern of energy usage, and suggest areas for conservation and savings.

4.1.1 Conservation of Energy

The same as for material balance, the conservation of energy can be written as:

Energy out =Energy∈+ generation−accumulation−consumption … … … … … .1

The above is the first law of thermodynamics. For processes involving chemical reactions,
energy generation results from an exothermic reaction and energy consumption from an
endothermic reaction. Energy accumulation occurs if the system is unsteady.

Calculation

All the energy calculations will be done using a temperature reference of 25 degree Celsius.
Sensible heat, Hs defined as the enthalpy that can be felt given for a specific point is contributed
to by the components from both liquid and gaseous states.

Sensible heat for the liquid phase, Hs (liquid) is given as the heat content of the liquid phase of
the component under scrutiny.

H liquid =C p ∆ T … … … … … … … … … … … … … … … … …2

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Where Cp is the liquid phase heat capacity of the component at constant pressure and ΔT is the
change in temperature. Below are the specific heat capacity of IPA, acetone and water.

Components Cp(kJ/kg.K)
IPA 2.37
Acetone 2.15
Water 4.19
Table 9: Specific heat capacities of liquid components[ CITATION Eng18 \l 2057 ]

Sensible heat for the gaseous phase Hs (gas) is given as the gaseous phase heat content of the
gaseous phase.

Tout
H gas = ∫ C p dT … … … … … … … … … … … … … … .3
Tin

C p= A+ BT +CT 2+ D T 3 … … … … … … … … … ….4

Where Cp is the heat capacity of the gas, A, B, C and D are constants in the ideal heat capacity.
In this case the values of the constants are in the following table.

A B C D
IPA 32.427 0.18862 0.000064058 -0.00000009261
Acetone 6.301 0.26059 -0.0001253 0.000000020377
Water 32.243 0.00192 0.0000106 -
0.000000003596
Hydrogen 27.143 0.00927 -0.00001381 0.00000000765
Table 10: Ideal gas heat capacity coefficients[ CITATION RKS05 \l 2057 ]

Enthalpy of vapourisation is the sum of latent heat of vapourisation and sensible heat of the
liquid. Latent heat of vapourisation is defined as follows:

H vapour =L v + H liquid … … … … … … … … … … … .5

Where Lv is the latent heat of vapourisation is determined using the Watson equation which is as
follows:

T c −T
Lv =L v
o
( )
T c −T b
… … … … … … … … … … … … … … .6

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Where Lov is the latent heat of vapourisation at standard conditions, T c is the critical temperature,
Tb is the boiling point of the component at the specific conditions and T is the bubble/dew point
temperature calculated using antoine equations and iterations.

B
T= −C … … … … … … … … … … … … … ….7
A−lnP

Where A, B and C are the Antoine constants for the components which are shown below for
IPA, Acetone and Water.

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.2 Energy balance on the Preheater

4.2.1 Assumptions
 No reaction occurring hence components under scrutiny are water and isopropyl alcohol.
 Single phase change from liquid to gas.
 No heat loss to the environment.
 Steady state.

4.2.2 Operating conditions

 Temperature change from 298.15K to 458.15K.
 Constant operating pressure of 1 atm

Calculation

Dew point calculation was calculated and iterated using the Antoine equations and the following
was found:

Td = 398.78

IPA Water Total

Hin (kJ/hr) 0 0 0
Hout (kJ/hr) 2851341.78 635026.13 3486367.91
Latent heat 5331.47 2690.33 8021.80
(kJ/hr)
Table 11: Stream enthalpies and latent heat for Preheater

∑ H out =∑ H ¿ +Q Preheater
Therefore:

QPreheater = 3494389.71kJ/hr

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 9: Energy balance of preheater

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.3 Energy balance on the Reactor

4.3.1 Assumptions
 No heat loss to the environment
 There are negligible pressure variations
 There is a uniform temperature profile from the feed to effluent sections of the reactor.
 The heat required to maintain the reactor operation temperature and that required to
sustain the reaction is supplied by the boiler
 Steady state conditions

4.3.2 Operating conditions

 Operating temperature of 473.15K
 Operating temperature of 2.8 bars

Calculation

Dew point calculation was calculated and iterated using the Antoine equations and the following
was found:

Td = 354.58K.

IPA Acetone Water Hydrogen Total

Hin (kJ/hr) 2856673.251 - 637716.4592 - 3494389.71
H (kJ/hr) 576114.7123 1936394.219 547987.3252 169618.637 3060496.25
7
Latent heat 1116.3733 3078.067 2817.279 - 7011.719
(kJ/hr)
Table 12: Stream enthalpies and latent heat for Reactor

Since there is a reaction occurring within the reactor the enthalpy of reaction is calculated as
follows:

H Reaction=H Formation ( products )−H Formation ( reactants)

Hreaction = 5921237.538kJ/hr

∑ H + H reaction=∑ H ¿ +Qreactor … … … … .. 8

34
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Qreactor = 5663974.44kJ/hr

Figure 10: Energy balance of a reactor

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.4 Energy balance on the Condenser

4.4.1 Assumptions
 No heat loss to the environment.
 Steady state.

Calculation

Dew point is the same as for the reactor since their operating pressure is nearly the same
therefore the temperature is as follows:

Td = 354.58K.

IPA Acetone Water Hydrogen Total

Hin (kJ/hr) 576114.712 1936394.219 547987.325 169618.637 3060496.25
3 7
H (kJ/hr) 208209.688 730344.531 271954.974 169618.640 1380127.83
0
Latent heat 1116.373 3078.067 2817.279 - 7011.719
(kJ/hr)
Table 13: Stream enthalpies and latent heat for Condenser

Since the inlet is gaseous feed the latent heat of vapourisation is added to the feed as below. The
outlet is a liquid.

∑ H +Q condenser =∑ H ¿ + L v … … … … … … … … … .9
Qcondenser = 2229506.71kJ/hr

By using water as a coolant and assuming the following.

Change in water temperature = 70K

Q=mC p ∆T

Where Cp = 4.19kJ/kgK

Mass of the water = 7601.45Kg/hr

Energy contributed by chemical components is shown below:

36
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 11: Energy balance of a condenser

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.5 Energy balance on the Flash column

4.5.1 Assumptions
 Isothermal operation
 Steady state conditions
 No energy lost to the environment

Due to the above assumptions for the flash column therefore:

Energy∈¿ Energy out

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.6 Energy balance on the liquefaction plant

4.6.1 Assumptions
 Energy lost to the environment is negligible

4.6.2 Operating conditions

 Pressure of 150kPa is assumed for the feed.
 CO2 is used as the refrigerant at a pressure of 10 bars.

Calculations

By using Antoine equations the bubble point temperature is found to be 351.72K.

IPA Acetone Water Hydrogen Total

Hin (kJ/hr) 5417.881 4368.012 1882.080 1609.400 3060496.257
H (kJ/hr) -16699.400 -109443.000 -21415.500 -46097.44 -193655.30
Latent heat 27696.5 2817.279 - 7011.719
(kJ/hr)
Table 14: Stream enthalpies and latent heat for the liquefaction plant

From equation 9:

Q+ ∑ Δ H out =∑ ∆ H ¿ +∑ Lv

Q=¿504997.9409+¿2727840.067¿−¿193655.2978¿ ¿

Q=3426493.31 kJ

Figure 12: Energy balance of the liquefaction plant

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.7 Mixing Drum

4.7.1 Assumptions
 No energy losses to the environment.

4.7.2 Operating conditions

 Pressure of 1.013bars

Calculations

Energy ¿ LP+ Energy ¿ FC =Energy out of MD

Where LP is Liquefaction Plant, FC is Flash Column and MD is the Mixed Drum.

40
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

IPA Acetone Water Total

Hin (kJ/hr)(FC) 146978.586 329053.696 193431.441 669463.723
Hin (kJ/hr)(LP) -16699.391 -109442.955 -21415.509 -193655.30
Hout (kJ/hr) 89768.718 314884.925 117252.225 521905.868
Table 15: Stream enthalpies for the Mixed drum

total Q out
T out = +298.15 K
(macetone C p ( acetone )+m IPA C p ( IPA) +mwater C p(water ))

Tout = 321.86K

Figure 13: Energy balance on the liquefaction plant

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.8 Energy balance on the Heater

4.8.1 Assumptions
 No heat loss to the environment.
 Steady state.
 The difference between stream enthalpies was considered the heat load of the Heater.

4.8.2 Operating conditions

 A temperature gain of 19℃.

Calculation

The outlet temperature of the heater is 340K therefore the enthalpies of individual components
are as follows:

IPA Acetone Water Total

Hin (kJ/hr) 89768.718 314884.925 117252.225 521905.868
Hout (kJ/hr) 161695.701 567185.763 211200.307 940081.771
Table 16: Stream enthalpies for the Heater

Since the inlet is gaseous feed the latent heat of vapourisation is added to the feed as below. The
outlet is a liquid.

∑ H ¿ +QHeater =∑ H out … … … … … … … … … … … ..11

Qheater = 418175.903kJ/hr

42
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 14: Energy balance of acetone column preheater

43
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.9 Energy balance on the Acetone distillation column

4.9.1 Assumptions
 Negligible heat loss to the environment.
 For heating and cooling, the difference between stream enthalpies was considered the
heat load of the equipment.

Calculation

Overall energy balance:

F ∆ H F + qr =D ∆ H D +W ∆ H w +q c … … … … … … … … … … ..1 2

Where Hf is enthalpy of feed, qr is reboiler duty, HD is enthalpy of distillate, qc is the condenser

duty and Hw is the enthalpy of the condensate.

The dew point temperature of the distillate and condensate was found using the trial and error
method until the total values of yi (kixi) equates to 1.

Distillate for dew point temperature = 329.48K:

Componen A B C P*(mmHg) Op ki xi kixi

t P(mmHg)
Acetone 16.651 2940.5 - 760.565877 760 1.00074457 0.99 0.99974383
3 6 35.93 6 6 9 1
IPA 18.692 3640.2 - 244.912680 760 0.32225352 0.00 0.00032225
9 53.54 2 7 1 4
                1.00006608
5
Table 17: Specification of the Distillate stream for Acetone and IPA

Bottoms for dew point temperature = 366.48K:

Componen A B C P*(mmHg) Op ki xi kixi

t P(mmHg)
Acetone 16.651 2940.5 - 2333.99979 760 3.07105235 0.000 0.00035475
3 6 35.93 1 7 1 8
IPA 18.692 3640.2 - 1165.18858 760 1.53314286 0.288 0.44258818
9 53.54 1 9 7 2
Water 18.303 3816.4 - 596.008674 760 0.78422194 0.711 0.55774190
6 4 46.13 1 2 4
                1.00068484

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4
Table 18: Specification of the Bottoms stream for Acetone, IPA and Water

k value of acetone∈distillate
α AB= … … … … … … … … … ..13
k value of IPA∈distillate

αAB = 3.105

By using the underwood’s equation the minimum reflux ratio was found:

1 x DA x DB
Rm = (
α AB−1 x FA
−α AB
x FB )
… … … … … … … … … … … .14

Rm = 0.874

But from literature the Reflux Ratio of a distillation column ranges at 1.2-2.0Rm

Therefore by selecting a multiplier value as 1.5 it gives the following:

R=1.5 R m … … … … … … … … … … … … … … … … … … … … … … … ..15

R = 1.311

L=R × D … … … … … … … … … … … … … … … … … … … … … … … … .16

Where L is the reflux and D is the distillate (106.49kmol/hr)

L = 139.64kmol/hr

V =L+ D … … … … … … … … … … … … … … … … … … … … … … … … ..17

Where V is the vapour from the distillation column to the condenser.

V =246.13kmol/hr

Lmix =xi Lxi … … … … … … … … … … … … … … … … … … … … … … … … 18

Where Lmix is the latent heat mix of the distillate, xi is the mole fraction of the individual
components and Lxi is the latent heat of individual components.

Lmix = 29150.72J/mol

Qcondenser =V × L mix … … … … … … … … … … … … … … … … … … … … 19

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Qcondenser = 7174772.53kJ/hr

Assuming a temperature change (ΔT) of 50K/˚C of the coolant, mass of cooling water is found as
follows:

Qcondenser =mC p ∆T … … … … … … … … … … … … … … … … … … … … … 20

Mass of coolant = 34247.12kg/hr

IPA Acetone Water Total

Hin (kJ/hr)(Feed) 161695.701 567185.763 211200.307 940081.771
Hout (kJ/hr) 45.860 415989.200 - 416035.060
(Distillate)
Hout (kJ/hr)(Bottoms) 258572.125 90.735 337866.970 596529.831
Table 19: Stream ethalpies for Acetone distillation column

By using equation (12)

QReboiler = 7247255.653kJ/hr

Q reboiler =m Lsteam

Where Lsteam is the latent heat of steam.

Mass of steam required = 3206.75kg/hr

46
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 15: Energy balance of acetone column

4.10 Energy balance on the IPA distillation column

4.10.1 Assumptions
 Negligible heat loss to the environment.
 For heating and cooling, the difference between stream enthalpies was considered the
heat load of the equipment.

47
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Calculation

Overall energy balance from equation 12 is as follows:

F ∆ H F + qr =D ∆ H D +W ∆ H w +q c

Where Hf is enthalpy of feed, qr is reboiler duty, HD is enthalpy of distillate, qc is the condenser

duty and Hw is the enthalpy of the condensate.

The dew point temperature of the distillate and condensate was found using the trial and error
method until the total values of yi (kixi) equates to 1.

Distillate dew point temperature = 359.83K:

Componen A B C P*(mmHg) Op P(mmHg) ki xi kixi

t
IPA 18.692 3640.2 - 905.135770 760 1.19096811 0.66 0.796757672
9 53.54 8 9 9
Water 18.303 3816.4 - 462.991650 760 0.60919954 0.33 0.201035848
6 4 46.13 9 1
Acetone 16.651 2940.5 - 1944.37427 760 2.55838719 0.00 0.002558387
3 6 35.93 8 1
                1.000351908
Table 20: Specification of the distillate stream for IPA, Water and Acetone for the IPA column

Bottoms dew point temperature = 373.13K

Componen A B C P*(mmHg) Op P(mmHg) ki xi kixi

t
IPA 18.692 3640.2 -53.54 1484.27435 760 1.95299257 0.00 0.00195299
9 5 3 1 3
Water 18.303 3816.4 -46.13 759.400771 760 0.99921154 0.99 0.99821233
6 4 4 1 9
                1.00016532
2
Table 21: Specification of the bottoms stream for IPA and Water for IPA column

From equation 13 the following equation is rewritten:

k value of IPA ∈distillate

α AB=
k value of water ∈distillate

αAB = 1.955

48
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

By using the underwood’s equation from equation (14) the minimum reflux ratio was found:

Rm = 1.476

From equation (16) where the distillate (39.68kmol/hr)

L = 87.90kmol/hr

V =127.58kmol/hr, calculated using equation 17.

Lmix = 40119.53J/mol, calculated using equation 18.

Using equation 19 the following is found:

Qcondenser = 5118549.67kJ/hr

Assuming a temperature change (ΔT) of 50K/˚C of the coolant, mass of cooling water is found as
follows:

From equation 20 the mass of the coolant is found as:

Mass of coolant = 24432.22kg/hr

IPA Acetone Water Total

Hin (kJ/hr)(Feed) 258572.125 90.735 337866.970 596529.831
Hout (kJ/hr) 232940.600 99.570 60993.340 294033.510
(Distillate)
Hout (kJ/hr)(Bottoms) 567.474 - 296603.522 297171.000
Table 22: Stream enthalpies for IPA distillation column

By using equation (12)

QReboiler = 5113224.34kJ/hr

Qreboiler =m Lsteam

Where Lsteam is the latent heat of steam.

Mass of steam required = 2262.49kg/hr

49
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

Figure 16: Energy balance of IPA column

50
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

4.11 Feed Drum

4.11.1 Assumptions
 No energy losses to the environment.

4.11.2 Operating conditions

 Pressure of 1.013bars

Calculations

Energy ¿ Recycle+ Energy ¿ Feed=Energy out of FD

Where FD is the Feed Drum.

IPA Acetone Water Total

Hin (kJ/hr) 232940.60 81.905 60993.341 294015.846
(Recycle) 0
Hin (kJ/hr)(Feed) 0 0 0 0
Hout (kJ/hr) 233088.47 13.632 60913.735 294015.846
9
Table 23: Stream enthalpies for the Feed drum

total Q out
T out = +298.15 K
(macetone C p ( acetone )+m IPA C p ( IPA) +mwater C p(water ))

Tout = 308.42K

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Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

52
Chemical Engineering Design Project Acetone plant with IPA feed of 220 tpd

References
Engineering Toolbox, 2018. The Engineering Toolbox. [Online]
Available at: https://www.engineeringtoolbox.com
[Accessed 2018].

Koretsky, M. D., 2013. Engineering and Chemical Thermodynamics. 2nd ed. Oregon: Wiley.

Ness, J. V., 2005. Introduction to Chemical Engineering Thermodynamics. seventh ed. Boston: Mc-
Graw-Hill.

Said, A., 2016. Selective sythesis of acetone from isopropyl alcohol over active and stable CuO-NiO
nanocomposites at relatively low temperature. Egyption Journal of Basic and Applied Sciences, 1(3), pp.
357-365.

Sasol, 2017. Safety data sheet: Sasol. Sandton: Sasol.

Sinnot, R., 2005. Coulson and Richardson's Chemical Engineering Volume 6. Oxford: Elservier
Butterworth Heinemann.

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