Problem Statement Analysis of Chemical Heat Pump Analysis of Cooling Tower Analysis of Boiler

Flash tank Heat exchanger Exothermic reactor Distillation column endo reactor Flash tank H2 Acetone 2-Propanol H2 condenser MIXED Acetone H2 Acetone 2-prop Compressor 1 Pump 1 Compressor 2 Liquid gas Reduction valve water Hot air Cool air Pump 2 Air 79 % N2 21 % O2 Natural gas Combustion gasses CO2, H2O, N2, O2 T= 375  F BFW SS CR BOILER reboiler Cooling tower Ambient air 85  F 80 % RH CWR 103  F Exit air Pump 3 CWS 75  F COOLING TOWER MOCS WORKING DIAGRAM PBL-7-98 WATER 2- prop & acetone

Given: Chemical Heat Pump Diameter of L1 = 6.35 mm Average Velocity = 10 m/sec Temperature L6 = 200  C Mole composition of L1=.97 2-Propanol Mole composition of L5=.02 2-Propanol

Given: Chemical Heat Pump (continued) Hot Air going into Endo 23.8  C Relative Humidity 80 % Cool Air coming out of Endo 15.5  C

Required: Chemical Heat Pump Energy Supplied into Endo Reactor (Q in ) Diameter of L6 Partial Pressures of L6 Amount of Water Condensed in Endo

Endo Reactor Q in Hot air Next page L 202 L 2 L 201 Acetone 2- Prop L 3 Condenser L 5 L 4 L 803 Water Cool air L 303 Pump 2 L 1L 101 H2 Re-boiler Reduction valve Acetone 2-Prop L 801 CWR Flash Tank 1 Distillation Column

Analysis: Chemical Heat Pump (Endo) Q in = Btu/ hr (29 ton unit) Water Condensed 168 lb/hr (21 gal/hr)

Exothermic Reactor L 202 L 203 Compressor 1 L 5 Pump 1 Exo Reactor L 6 L 501 Acetone Heat Exchanger L 7 L 802 L 801 Gas Compressor 2 L 8 L 804 H2 Acetone 2-Propanol Flash Tank 2 H2

Analysis: Exothermic Reactor Diameter of L6 = 29.0 mm Partial Pressure: 1.96 ATM Acetone 0.04 ATM 2-Propanol

Given: Cooling Tower Cold Water Return 39.4  C Cold Water Supply 23.8  C Input Ambient Air 29.4  C Relative Humidity 80 % (Ambient Air) Exit Air 30.5  C RH 90 %

Given: Cooling Tower (continued) Diameter for CWS and CWR: 0.05 m

Cooling Tower CWR 103  F Cooling Tower Ambient Air 85  F 80 % RH L 301 L 302 Exit Air Pump 3 Water L 303 CWS 75  F

Required: Cooling Tower Velocity for Cold Water Supply Velocity for Cold Water Return Pounds of Dry Air from Cooling Tower

Analysis: Cooling Tower Velocity of Cold Water Supply: m/hr Velocity of Cold Water Return: m/hr Pounds of Dry Air: 34,600 lb dry air/ hr

Given: Boiler Steam Supply 220 psig (q=1) Cold Return (q=0) Temperature of Exit Gas  C Combustion Gasses: CO 2, H 2 O, N 2, O 2 Excess Air 40 %

Given: Boiler (continued) Diameter for SS and CR:.05 m

Boiler Boiler Feed Water Boiler Combustion Gasses CO2,H20, N2,O2 L 901 L 903 CR SS Natural Gas Air 79 % N2 21 % O2 T= 375  F L 902

Required: Boiler Velocity of Steam Supply Velocity of Cold Return Flow Rate of Natural Gas Percent Composition of Exit Gasses

Analysis: Boiler Velocity Steam Supply: m/hr Velocity Cold Return: 36.7 m/hr Amount of Natural Gas: 3.51 tons/month

Analysis: Boiler (continued) Composition of Flue Gasses: CO 2 = 7.0 % H 2 0 = 13.9 % O 2 = 5.6 % N 2 = 73.5 %

Differential (Batch) Distillation Bryan Gipson John Usher November 12, 1997

Progress Familiarization with System 2 Runs Conducted –First Run Inconsistent –Second Run Okay Data Taken –Initial Volume: 14 liters –Time vs. Temperature –Rate of Distillation

Observations Temperature Change –Less than Predicted Rate of Distillation –Observed: Sporadic, ~94 ml/min –Theoretical: Decreasing, ml/min

Next Steps Resolve Inconsistencies Conduct More Data Runs Estimate Heat Losses Compare Column Performance to Predictions

Differential (Batch) Distillation Bryan Gipson John Usher November 12, 1997

Progress Familiarization with System 2 Runs Conducted –First Run Inconsistent –Second Run Okay Data Taken –Initial Volume: 14 liters –Time vs. Temperature –Rate of Distillation

Observations Temperature Change –Less than Predicted Rate of Distillation –Observed: Sporadic, ~94 ml/min –Theoretical: Decreasing, ml/min

Next Steps Resolve Inconsistencies Conduct More Data Runs Estimate Heat Losses Compare Column Performance to Predictions

Distillation Column Design Project M. O. C. Project Engineering Department Team Members Michael Hobbs Michael McGann Marc Moss Brad Parr Brian Vandagriff

Topics of Discussion Problem Statement Recommended Design McCabe-Thiele Diagram Design Specifications Combined Flow Diagram

Topics, cont. Method of Design Raoult Method van Laars Method Sieve Tray Efficiency Optimum Reflux Ratio Conclusions

Problem Statement To design a new ethylene purification column to work with the advanced catalytic cracking operation that produces ethylene for manufacture of specialty products

PROCESS AREA B PROCESS AREA C PROCESS AREA C EAST AVENUE WEST AVENUE BROADWAY EMPLOYEE PARKING VISITOR PARKING OFFICE T1 T2 T3 T4 FS1 B2 B1 CT 1 CT 2 T5T6 COLUMN STREET 3 RD STREET 2 ND 1 ST DISTILLATE CWS SS

Recommended Design Design analysis included: number of trays tray diameter pipe diameter for each stream pump selection (if necessary)

McCabe-Thiele Diagram Fortran program “Distil.exe” was used to generate data that was plotted in Excel to give McCabe-Thiele Diagram. Diagram shows equilibrium line, operating line, feed line, separation line, and the stepped off stages.

Feed tray = 73

Design Specifications

Combined Flow Diagram Shows system diagram with both qualitative and quantitative information.

81 stages

Design Requirements feed : 220 M lb/hr of vapor, 85% ethylene product: 182 M lb/hr, 99.9% ethylene

Raoult Model Assumes ideal behavior System deviated slightly from ideality at low compositions

Actual Data Operating Line Equilibrium Line

van Laars Model Assumes all non-ideal behavior in the liquid Shows an improved correlation between model and actual data

Operating Line Equilibrium Line Actual Data

Sieve Tray Efficiency Sieve trays were chosen because they are cheaper, more efficient, and have a larger operating range than other types of tray designs

Fg = U t  g 1/2

Optimum Reflux Ratio The optimum reflux ratio was determined by calculating the annual operating costs for columns with varying reflux ratios. A plot of annual cost vs. reflux ratio was made; the optimum value is the one that corresponds to the minimum point on the curve.

Minimizing Annual Cost Three options each were given for heating the reboiler and cooling the condenser. Heating: steam at 20 psig ($1/1000lb) steam at 100 psig ($3/1000lb) electrical heating ($0.12/kWh) Cooling:cooling water ($0.50/1000gal) domestic water ($1.80/1000gal) refrigerant ($5/ton-day)

Minimizing Annual Cost Total annual costs (based on 7200 hr/yr) were calculated for each of the options. The lowest priced option for each was selected. heating: steam at 20 psig cooling: CWS

Conclusions The column designed contains 81 trays, with a diameter of 23.7 ft and 12 inch spacing between the trays. It will require an initial start-up cost of $3.01 million, and a present worth of $17.14 million over a projected 11 year operational life.

Ultimate Tennessee Corn whiskey Skip Pond, EI Michael McGann

Topics of Discussion Past Accomplishments (Section 200) Current Work (Section 300) Next Steps

Revised Problem Statement Basis: 500,000 gallons finished product Areas of focus –Section 200 (Cooking/Fermenting) –Section 300 (Distillation) –Section 900 (Boiler/Cooling Tower)

Revised Problem Statement Customer requirements –Operational Schedule Comparison –Automated Control Investigation –Onsite Boiler/Cooling Tower –Pre-Distillation Settling Tank Liquid Feed Column with Flash Tank

Section 200: Cooking/Fermenting

Equipment Specifications

Mash Tank Material Balance Inputs corn: 259 bushels rye: 44.3 bushels malt: 37.5 bushels H 2 O: gal. *1 bushel = 55 pounds Outputs spent grain: bushels H 2 O vap : 2500 gal. wort: 7500 gal.

Mash Cooking Energy Balance q convection  T, 132 o F qxqx qxqx q x + q convection= Btu/hr q water= Btu/hr 250psia Steam T=401 o F h= Btu/hr =25,823 lbs/hr 250psia Condensed Steam T=401 o F h = Btu/hr Heat Exchanger Coils

Operational Schedule

F=147 klb x F =0.0 7 B=13 klb x B =0.0 1 D=16 klb x D =0.5 5 V=3800 lbs/day L=1400 lbs/day Distillation Column

Distillate D = 16 klb x D = 0.55 Bottoms Product B = 13 klb x B = 0.01 Condenser Splitter Reboiler Cold Water Supply = T = Steam Supply = P = Cold Water Return T = Water Return L = V’= L’= V = Feed F = 147 klb x F = 0.07 f = 1 Tray Spacing = 12 in E M = 11 stages

Feed Tray Material Balance L’=R D *D + (1-f)*F V’=D*(R D +1) - f*F

Condenser Material Balance L=R D *D V=D*(R D +1)

Next Steps Post Distillation Flash Tank Boiler/Cooling Tower Section Final cost analysis and reporting