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Problem 5 page 32 - Robin Smith , Chemical Process Design and Integration

Acetone is to be produced by the dehydrogenation of an aqueous solution of isopropanol

according to the reaction :

(CH3)2CHOH  CH3COCH3 + H2
Isopropanol Acetone Hydrogen

The effluent from the reactor enters a phase separator that separates vapor from liquid. The
liquid contains the bulk of the product, and the vapor is a waste stream. The vapor stream is at
a temperature of 30 oC and an absolute pressure of 1.1 bar.
The component flowrates in the vapor stream are given in table 2.13, together with their raw
material values and fuel values. Three options are to be considered :
a. Burn the vapor in a furnace
b. Recover the acetone by absorption in water recycled from elsewhere in the process with
the tail gas being burnt in a furnace. it is expected that 99% will be recovered by this
method at a cost of 1.8 $/kmol acetone recovered
c. recover the acetone by condensation using refrigerated coolant with the tail gas being
burnt in a furnace. It is anticipated that a temperature of -10 oC will need to be achieved in
the condenser. It can be assumed that the hydrogen is an inert that will not dissolve in the
liquid acetone. The vapor pressure of acetone is given by
2940.5
𝐿𝑛 𝑃 = 10.031 − ( )
𝑇 − 35.93

where P = pressure (bar)

T = absolute temperature (K)

The cost of refrigerant is $11.5 / GJ, the mean molal heat capacity of the vapor is 40
kJ/kmol.K and the latent heat of acetone is 29,100 kJ/kmol. Calculate the economic
potential of each option given the data in Table 2.13.

Table 2.13 Data for exercise 5

Flow rate in vapor Raw Material Fuel value

Component
(kmol/hour) Value ($/kmol) ($/kmol)

Hydrogen 51,1 0 0,99

Acetone 13,5 34,8 6,85
 SOLUTION

Calculate the economic potential of each option :

Waste vapor
T= 30 oC, P= 1.1 bar

reactor Phase
isopropanol separator
acetone
hydrogen

liquid vapor

(a) OPTION A : Burn the vapor in a furnace

Fuel value
Flow rate in vapor Raw Material Fuel value cost
Component
(kmol/hour) Value ($/kmol) ($/kmol) ($/hour)

Hydrogen 51,1 0 0,99 50,589

Acetone 13,5 34,8 6,85 92,475
Total
143,064
cost/hour

Fuel value Hydrogen cost = Flow rate Hydrogen in vapor (kmol/hour) * Fuel value Hydrogen ($/kmol)
= 51,1 kmol/hour * 0,99 $/kmol
= 50,589 $/hour

Fuel value Acetone cost = Flow rate Acetone in vapor (kmol/hour) * Fuel value Acetone ($/kmol)
= 13,5 kmol/hour * 6,85 $/kmol
= 92,475 $/hour

Total cost/hour = Fuel value Hydrogen cost + Fuel value Acetone cost
= 50,589 $/hour + 92,475 $/hour
= 143,064 $/hour
 (b) OPTION B : Recover the acetone by absorption in water recycled with expected 99%
recover rate (1,8 $/kmol)

Raw Fuel Acetone

Flow rate in product
Material Fuel value value Absorption Acetone Fuel Value
Component vapor value
Value ($/kmol) cost cost ($/hour) recovered cost ($/hour)
(kmol/hour) ($/hour)
($/kmol) ($/hour)
Hydrogen 51,1 0 0,99 50,589 91,98 50,59 0
Acetone 13,5 34,8 6,85 92,475 24,3 13,365 0,92 465,10
116,28 51,51 465,10

Know : absorption cost = 1,8 $/kmol

absorption rate = 99%

So :
 absorption cost
Absorpsion cost Hydrogen = Flow rate Hydrogen in vapor (kmol/hour) * absorption cost ($/kmol)
= 51,1 kmol/hour * 1,8 $/kmol
= 91,98 $/hour

Absorpsion cost Acetone = Flow rate Acetone in vapor (kmol/hour) * absorption cost ($/kmol)
= 13,5 kmol/hour * 1,8 $/kmol
= 24,3 $/hour

Total absorption cost = Absorpsion cost Hydrogen + Absorpsion cost Acetone

= 91,98 $/hour + 24,3 $/hour
= 116,28 $/hour

 acetone recovered
acetone recovered = Flow rate Acetone in vapor (kmol/hour) * absorption rate
= 13,5 kmol/hour * 99%
= 13,365 kmol/hour

 Fuel value cost

Fuel value Hydrogen cost = (Flow rate Hydrogen in vapor (kmol/hour) * Fuel value Hydrogen
($/kmol)
= 51,1 kmol/hour * 0,99 $/kmol
= 50,589 $/hour

Fuel value Acetone cost = (Flow rate Acetone in vapor (kmol/hour) – Acetone recovered ) *
Fuel value Acetone ($/kmol)
= (13,5 kmol/hour – 13,65 kmol/hour) * 6,85 $/kmol
= 0,92 $/hour

Fuel value cost/hour = Fuel value Hydrogen cost + Fuel value Acetone cost
= 50,589 $/hour + 0.92 $/hour
= 51,51 $/hour
  Acetone product value
Acetone product value = Raw Material Value ($/kmol) * Acetone recovered
= 34,8 $/kmol * 13,365 kmol/hour
= 465,10 $/hour

Revenue from recover the acetone by absorption

= Acetone product value ($/hour) - Absorption cost ($/hour) - fuel value cost ($/hour)
= 465,10 $/hour - 116,28 $/hour - 51,51 $/hour
= 297,31 $/hour revenue

(c) OPTION C : recover acetone by condensation using refrigerated coolant with the tail gas
being burnt in a furnace

Data :
Feed temperature = 30 oC = 303,15 K
Coolant temperature = - 10 oC = 263,15 K
cost of refrigerant = $11.5 / GJ
mean molal heat of vapor = 40 KJ/kmol.K
latent heat acetone = 29100 KJ/kmol

vapor Pressure of acetone:

2940.5
𝐿𝑛 𝑃 = 10.031 − ( )
𝑇 − 35.93
2940,5
10.031−
𝑃 = 𝑒𝑥𝑝 𝑇−35,93
2940,5
10.031−
𝑃 = 𝑒𝑥𝑝 263,15−35,93

𝑃 = 0,05 𝑏𝑎𝑟

Flow Total Acetone Fuel Value Acetone product

Raw coolant latent
rate in Fuel coolant Cost of recovere cost ($/hour) value ($/hour)
Compon Material energy energy
vapor value energy refrigrant d
ent Value needed needed
(kmol/ho ($/kmol) needed (kJ / ($ / h)
($/kmol) (KJ/h) (KJ/h)
ur) h)
Hydro 0 81.760 0,94 50,59 0
51,1 0 0,99 81760
gen
Aceton 392,85 414.450 4,77 13,5 0 469,80
13,5 34,8 6,85 21600
e
496.210 5,71 50,59 469,80

 Coolant energy needed (KJ/h)

Coolant energy hydrogen = Flow rate Hydrogen in vapor (kmol/hour) * mean molal heat of vapor *
(Feed temperature – coolant temperature)
= 51,1 kmol/hr* 40 KJ/kmol.K * (303,15 K – 263,15 K)
= 81.760 KJ/hr

Coolant energy Acetone = Flow rate Acetone in vapor (kmol/hour) * mean molal heat of vapor *
(Feed temperature – coolant temperature)
= 13,5 kmol/hr * 40 KJ/kmol.K * (303,15 K – 263,15 K)
= 21.600 KJ/hr
 Latent energy needed
Latent energy needed = Flow rate Acetone in vapor (kmol/hour) * latent heat acetone
= 13,5 kmol/hr * 29100 KJ/kmol
= 392,85 KJ/hr

 Total coolant energy needed (KJ/h)

Total Coolant energy hydrogen = Coolant energy hydrogen (KJ/hr) + latent energy needed (KJ/hr)
= 81.760 KJ/hr + 0
= 81.760 KJ/hr

Total Coolant energy acetone = Coolant energy acetone (KJ/hr) + latent energy needed (KJ/hr)
= 21.600 KJ/hr + 392,85 KJ/hr
= 414.450 KJ/hr

Total coolant energy needed (KJ/h) = Total Coolant energy hydrogen + Total Coolant energy acetone
= 81.760 KJ/hr + 414.450 KJ/hr
= 496.210 KJ/hr

 Cost of refrigerant ($/h)

Cost of refrigerant hydrogen ($/h) = Total Coolant energy hydrogen * cost of refrigerant
= 81.760 KJ/hr *11,5 $/GJ*10-6 GJ/KJ
= 0,94 $/hr

Cost of refrigerant Acetone ($/h) = Total Coolant energy Acetone * cost of refrigerant
= 414.450 KJ/hr *11,5 $/GJ*10-6 GJ/KJ
= 4,77 $/hr

Cost of refrigerant ($/h) = Cost of refrigerant hydrogen ($/h) + Cost of refrigerant Acetone
($/h)
= 0,94 $/hr + 4,77 $/hr
= 5,71 $/hr

 Fuel Value cost ($/hr)

Fuel Value Cost hydrogen ($/h) = ( Flow rate Hydrogen in vapor (kmol/hour) – Acetone recovered ) *
Fuel value ($/kmol)
= ( 51,1 kmol/hr – 0 ) * 0,99 $/kmol
= 50,59 $/hr

Fuel Value Cost Acetone ($/h) = ( Flow rate Acetone in vapor (kmol/hour) – Acetone recovered ) *
Fuel value ($/kmol)
= ( 13,5 kmol/hr – 13,5 kmol/hr ) * 0,99 $/kmol
= 0

Fuel Value Cost ($/h) = Fuel Value Cost hydrogen ($/h) + Fuel Value Cost Acetone ($/h)
= 50,59 $/hr

 Acetone product value ($/hour)

Acetone product value ($/hour) = Raw Material Value Acetone ($/kmol) * Acetone recovered
= 34,8 $/kmol * 13,5 kmol/hr
= 469,80 $/ hr
Revenue from recover the acetone by condensation =
=acetone product value ($/hr) - cost of refrigrant ($/hr) - fuel value cost ($/hr)
= 469,80 $/ hr - 5,71 $/hr - 50,59 $/hr
= 413,50 $/hour revenue

SUMMARY
From of three options above (option A, B dan C), it can be concluded that option C
is the most economic by recover the acetone by condensation using refrigerated coolant with
the tail gas being burnt in the furnace