Feed :

Assume propylene flow rate of 4004.419 kg/hr.

**Propylene:

Propene = Propylene = 4004.419 kg/hr = 95.16205 kmol/hr

Propane:

The molar ratio of propene/propane = 95/5 = 19

Propene = 19 * propane

Propene/19 = Propane = = 95.16205 / 19 = 5.00852 kmol/hr of propane = 44.1 * 5.00852 = 220.8757

kg/hr

Hydrogen Peroxide:

The molar ratio of propene/H2O2 = 0.9 to 2.5 or 1 to 2 or 1.05 to 1.5

Propene/H2O2 = 1.5

Propene = 1.5*H2O2

H2O2 = propene / 1.5 = 95.16205 / 1.5 = 63.4413 kmol/hr

Water:

The molar ratio of H2O2/water = 0.4 to 17 or 0.6 to 6

H2O2/water = 6

H2O2 = 6*water

Water = H2O2/6 = 63.4413/6 = 10.57355 kmol/hr

Methanol:

The amount of methanol solvent depend upon H2O2.

There molar ratio fo H2O2/Methanol = 1.56.

H2O2 = Methanol*1.56

H2O2/1.56 = Methanol = 63.4413/1.56 = 40.6675 kmol/hr.

Balance On Reactor:

Recycle Propene Stream:

The molar ratio of fresh propene feed / recycle propene = 2 to 5 or 1 to 10.

Propene Fresh / Propene Recycle = 5

Propene Recycle = Propene fresh / 5 = 95.16205 / 5 = 19.03241 kmol/hr

Propene Recycle Stream = 19.03241 kmol/hr.

Total recycle flow = ?

Recycle Methanol Stream:

Methanol = 63.4413/1.56 = 40.6675 kmol/hr (All methanol will come back to mixer)

Total recycle flow = ?

1–A

2-B

3–C

A+B+C=E

28 – R1 (propene recycle)

49 - R2 (methanol recycle)

8–D

In = Out

E + R1 + R2 = D

E= A + B + C = 214.85292 kmol/hr = Fresh feed flow rate

Combined feed flow = ?

90% propylene

E + R1 = D

Recycle Stream R1:

Propene in recycle = 19.03241 kmol/hr.

19.03241 = 0.9*R1

R1 = 19.03241 / 0.9 = 21.147122 kmol/hr

Recycle Stream R1 = 21.147122 kmol/hr

Propylene = 19.03241 / 21.14722 = 89.9999 = 90%

Remaining 10% is propane, PO.

Recycle Stream 2:

As we know the flow rate of methanol in recycle stream. Now we will calculate total flowrate of recycle
stream.

40.6675 kmol/hr = 0.9999*R2

R2 = 40.6675 / 0.9999 = 40.67156 kmol/hr

Let’s check out balance

Feed In = Product Out

E + R1 + R2 = D

40.67156 + 21.147122 + 214.85292 = D

D is stream 8 = 276.6716 kmol/hr.

Checking:

276.616 – 21.147122 – 40.67156 = 214.85 (OK)

Mass In to Reactor = Mass Out in Reactor

276.6716 = 276.6716

In composition is not equal to out composition only flow rates will remains same.

Combined feed flow = 276.6716 kmol/hr (with recycle)

While Fresh feed flow = 214.85 kmol/hr (without recycle)

Reactor Parameters: T = 50◦C P = 23 bar.

Reactor Outlet Composition (Weight Composition):

C3H6 = 0.5%

C3H8 = 2.168%

MeOH = 75%

H2O = 20%

PO = 2%

H2O2 = 0.332%

TOTAL = 100%

Total Flow Rate = 276.6716 kmol/hr

Average molecular weight:

1/MW = 0.005 / MW + 0.02168 / MW + 0.75/MW + 0.2/MW + 0.02/MW + 0.00332 / MW

1/MW = 0.005 / 42.02 + 0.02168 / 44.1 + 0.75/32.04 + 0.2/18 + 0.02/58.079 + 0.00332/34.0147

1/MW = 0.00011899 + 0.00049160 + 0.0234 + 0.0111 + 0.00034435 + 0.000097604 = 0.035552

MW (Avg) = 1/0.035552 = 28.1278 kg/kmol.

Total Rate = 276.6716*28.1278 = 7782.16343 kg/hr

C3H6 = 0.005*7782.16343 = 38.9 kg/hr

C3H8 = 0.02168*7782.16343 = 168.7173 kg/hr

MeOH = 0.75*7782.16343 = 5836.622 kg/hr

H2O = 0.2*7782.16343 = 1556.43268 kg/hr

*PO = 0.02*7782.16343= 155.6432 kg/hr

H2O2 = 0.00332*7782.16343 = 25.836 kg/hr

Material Balance On FL-1:

Stream In = Steam 7

Stream out = Stream 8 + Stream 13

7–D
8–F

13 – G

Input = Output

Overall Material Balance:

D=F+G

276.6716 = F + G

Composition of Stream D

C3H6 = 0.005*7782.16343 = 38.9 kg/hr

C3H8 = 0.02168*7782.16343 = 168.7173 kg/hr

MeOH = 0.75*7782.16343 = 5836.622 kg/hr

H2O = 0.2*7782.16343 = 1556.43268 kg/hr

*PO = 0.02*7782.16343= 155.6432 kg/hr

H2O2 = 0.00332*7782.16343 = 25.836 kg/hr

Total Flow of D = 7782.16343 kg/hr = 276.6716 kmol/hr

Find Steam G & F ?

Steam G (Stream 8) Composition:

Mass Fraction of Stream 8

C3H6 = 0.0440

C3H8 = 0.1581

PO = 0.0181

H2O2 = 0.0001

MeOH = 0.6042

H2O = 0.1754
Mass Fraction of Stream 13

C3H6 = 0.0027

C3H8 = 0.0117

PO = 0.0096

H2O2 = 0.0028

MeOH = 0.6590

H2O = 0.3142

Apply Balance on Propylene:

D=G+F

7782.16343 = G + F

7782.16343 – G = F

38.9 kg/hr = 0.0440G + 0.0027F

38.9 = 0.0440G + 0.0027 (7782.16343 – G)

38.9 = 0.0440G + 21.01184 – 0.0027G

38.19 – 21.01184 = 0.0440 – 0.0027G

17.17816 = 0.0413G

G = 415.9360 kg/hr

D=F+G

F = D – G = 7782.163 – 415.9360 = 7366.227 kg/hr

Material Balance On PG-1: