Mass Integration

CHEN 4470 – Process Design Practice

Dr. Mario Richard Eden

Department of Chemical Engineering
Auburn University

Lecture No. 9 – Synthesis of Mass Exchange Networks II

February 7, 2013
 The Pinch Diagram 1:6

• Amount of Mass Transferred by Rich Streams

M R i  G i ( y is  y it ) , i  1, 2 , ...., N R

Mass
Exchanged

R2
MR2

MR1
R1
y1t y2t y1s y2s y
 The Pinch Diagram 2:6

• Constructing Rich Composite using Superposition

Mass
Exchanged

MR2 R2

MR1 R1

y1t y2t y1s y2s y

 The Pinch Diagram 3:6

• Amount of Mass Accepted by Process MSA’s

M S j  LCj ( x tj  x sj ) , j  1, 2, ...., N SP
Mass
Exchanged

MS2 S2

MS1
S1

y
y  b1
x1s x1t x1  1
m1
x2s x2t y  b2
x2  2
m2
 The Pinch Diagram 4:6

• Constructing Lean Composite using Superposition

Mass
Exchanged

MS2 S2

MS1
S1

y
y  b1
x1s x1t x1  1
m1
x2s x2t y  b2
x2  2
m2
 The Pinch Diagram 5:6

• Constructing the Pinch Diagram

– Plot the two composite curves on the same diagram

Mass Excess Capacity

Exchanged Lean Composite of Process MSA’s
Stream
Pinch Point Pinch
Integrated
Point
Mass Exchange
Move the lean
composite vertically Load to be
until the entire Removed Rich Composite
Stream
stream exists above by External
MSA’s
the rich composite.
The point closest to y
the rich composite is x1 
y  b1
1
the Pinch. m1
y  b2
x2  2
m2
 The Pinch Diagram 6:6

• Decomposing the Synthesis Problem

– Creates two subregions, i.e. a rich end and a lean end

• Above the Pinch

– Mass exchange between rich and lean process streams
– No external MSA’s required

• Below the Pinch

– Both process and external MSA’s are used
– If mass is transferred across the pinch, the lean
composite moves upward, thus:

DON’T TRANSFER MASS ACROSS THE PINCH!

 Example No. 2 1:17

• Dephenolization of Aqueous Wastes

To regen- To phenol
To final eration & condens-
finishing recycle ation
S1 S2 S3 S4 S5
Light Gases
R1 R1
Waste Gas Mass
Gas Oil Deashing Atmospheric Oil Exchange
and
R2
Stripping
Demetallization Distillation R2 Network

Steam S1 Air S5
Waste Gas
Lube Oil Oil
Deashing Vacuum Ion Exchange
and Distillat- Resin S4
Demetallization
ion

Dewaxing Activated
and Carbon S3
Lube Oil
Deasph- Stripping Lube Oil S2
alting
Steam
 Example No. 2 2:17

• Rich Stream Data

Supply Target
Stream Description Flowrate Composition Composition
Gi, kg/s yis yit

Condensate
R1 from first 2 0.050 0.010
stripper
Condensate
R2 from second 1 0.030 0.006
stripper

• Candidate MSA’s
– Two process MSA’s
– Three external MSA’s
 Example No. 2 3:17

• Process MSA Data

Upper Bound on Supply Target

Stream Description Flowrate Composition, Composition,

Ljc, kg/s xjs xjt

S1 Gas oil 5 0.005 0.015

S2 lube oil 3 0.010 0.030

• External MSA’s
– Absorption using activated carbon (S3)
– Ion exchange using a polymeric resin (S4)
– Stripping using air (S5)
 Example No. 2 4:17

• Equilibrium Data
– General equation for transferring phenol to the j’th lean
stream
 m1  2.00
 m  1.53
 2
y  mj  xj ,  m3  0.02
 m  0.09
 4
 m5  0.04

– Minimum allowable composition difference

 j  0.001 kgkg phenol

M SA , i  1, 2, 3, 4, 5
 Example No. 2 5:17

• The Pinch Diagram

0.140 Excess Capacity of
Mass Exchanged,
kg phenol/s 0.1224
Process MSA’s
0.120 Excess Capacity
of Process MSA’s
0.1040 0.1224 – 0.1040
0.100

Lean =
0.080 Composite
Stream 0.0184 kg phenol/s
0.060 Rich
Composite
Pinch Point Load to be
0.040 Removed by Stream
External MSA’s
y = 0.0168 0.020 Pinch
0.0124
Point External MSA
x1 = 0.0074 0.000
0.000 0.010 0.020 0.030 0.040 0.050 y Load
0.0168
x2 = 0.0100 0.004 0.009 0.014 0.019 0.0024
x1
0.0124 kg phenol/s
0.0074
x2
0.0055 0.0121 0.0186 0.0251 0.0317
0.0100
 Example No. 2 6:17

• Removing Excess Capacity of Process MSA’s

– Can be eliminated by lowering the flowrate and/or
outlet compositions of the process MSA’s.
– If elected to lower the flowrate of S2 then:

Excess
Lnew
L
old
 t
x j  x sj
j j

Excess 0.0184
Lnew
L
old
 t  3  2.08 kg/s
x2  x2 0.03  0.01
2 2 s
 Example No. 2 7:17

• Activated Carbon
– Adsorption isotherm is linear up to mass fraction 0.11
– Above 0.11 activated carbon becomes saturated
– Thus x3t is taken at 0.11
– Corresponding composition on y-scale:

y  0 .0 2 ( 0 .1 1  0 .0 0 1)  0 .0 0 2 2

– Less than supply compositions of R1 and R2

– Thus feasible to transfer phenol from both streams to S3
– Less than value of tail end of lean composite
– Hence S3 will not eliminate any phenol that can be
removed by the process MSA’s.
 Example No. 2 8:17

• Activated Carbon (Continued)

– Cost of using activated carbon

(A) C 3  0 .0 5  1 .6 0  2  5  1 0  3  x 3t  0 .0 8  0 .0 1  x 3t

– Amount of activated carbon required to remove 1 kg of

phenol can be calculated from a mass balance

(B1) 1 k g p h en o l rem o v ed  L 3 ( x 3t  0 )

kg activated carbon 1
(B2)  t
kg phenol x3
 Example No. 2 9:17

• Activated Carbon (Continued)

– Multiplying equations (A) and (B2) provides the cost of
removing 1 kg of phenol from the waste streams using
activated carbon
0.08
C  t  0.01
r
3
x3

– Substituting x3t = 0.11 kg phenol/kg activated carbon

into (A) and (B2)

C 3  $ 0 .0 8 1 / k g recircu latin g activ ated carb o n

C 3r  $ 0 .7 3 7 / k g o f rem o v ed p h en o l
 Example No. 2 10:17

• Ion Exchange
– Regeneration C 6 H 5O H  N a O H  C 6 H 5O N a  H 2O
– Cost of using ion exchange

(C) C 4  0 .0 5  3 .8 0  0 .4 6  0 .3 0  x 4t  0 .1 9  0 .1 2 8  x 4t

– Amount of activated carbon required to remove 1 kg of

phenol can be calculated from a mass balance

(D1) 1 k g p h en o l rem o v ed  L 4 ( x 4  0 )
t

kg ion exchange resin 1

(D2)  t
kg phenol x4
 Example No. 2 11:17

• Ion Exchange (Continued)

– Multiplying equations (C) and (D2) provides the cost of
removing 1 kg of phenol from the waste streams using
ion exchange t
The higher the value of x4 ,
the lower the removal cost.
0.19
(E) C  t  0.128
r
4 So what is the highest
x4 possible value of x4t that can
be used?

– No mass should be transferred across the pinch

– Optimum target composition of S4 is the pinch
composition y = 0.0168. Corresponding to:

0.0168
x 
t
4  0.001  0.186
0.09
 Example No. 2 12:17

• Ion Exchange (Continued)

– Substituting x4t = 0.186 kg phenol/kg ion exchange
resin into (C) and (E)

C 4  $ 0 .2 1 4 / k g recircu latin g resin

C 4r  $ 1 .1 5 0 / k g o f rem o v ed p h en o l
 Example No. 2 13:17

• Air Stripping
– Based on the cooling duty of the phenol condensation
unit, the cost of using air stripping is given as:

(F) C 5  $ 0 .0 6 / k g air

– The outlet composition should be 50% of the Lower

Flammability Limit (LFL) of 5.8 weight%:
Less than supply
(G) x 5t  0 .5  0 .0 5 8  0 .0 2 9 composition of rich streams
and pinch composition.
Thus thermodynamically
– Corresponding y-scale composition feasible!

y  m 5 ( x 5t   5 )  0 .0 4  (0 .0 2 9  0 .0 0 1)  0 .0 0 1 2
 Example No. 2 14:17

• Air Stripping (Continued)

– Since it is feasible to use air stripping for the phenol
removal, the removal cost can be calculated

C 5r  $ 2 .0 6 9 / k g o f rem o v ed p h en o l

• Summary
M SA Unit Cost ($/kg M SA) Removal Cost ($/kg phenol)
Activated Carbon (S 3 ) 0.081 0.737
Ion Exchange Resin (S 4 ) 0.214 1.150
Air S tripping (S 5 ) 0.060 2.069

And the winner is Activated Carbon!!!

 Example No. 2 15:17

• Summary (Continued)
– Flowrate of activated carbon

MS 3 0.0124 kg/s
L3  t   0.1127 kg/s
x3  x3
s
0.11  0
– Minimum Operating Cost Ahead of design!!!

MOC  $0.081
kg activated carbon  0.1127 kg activated carbon
s  3600
hr  yr
s 8760 hr

MOC  $288  10 3 / yr
MOC  $0.737
kg phenol removed  0.0124 kg phenol
s  hr  yr
removed 3600 s 8760 hr

MOC  $288  10 3 / yr
 Example No. 2 16:17

• Trading Off Fixed Vs. Operating Cost

– Minimum allowable composition differences can be used
to trade off fixed vs. operating cost.
– When waste streams are mixed, the number of mass
exchangers and, consequently, fixed cost decrease. On
the other hand, mixing various waste streams normally
increases the MOC of the system

– Waste stream data for mixing of waste streams

Supply Target Composition
Flowrate Composition (mass fraction)
Description Gi , kg/s yi t
Stream (mass fraction)
yis

Rmixed Mixed R1 and R2 3 0.0433 0.0087

 Example No. 2 17:17

• Trading Off Fixed Vs. Operating Cost (Continued)

– New Pinch Diagram for mixed waste streams
0.140
Mass Exchanged,
kg phenol/s 0.1224
0.120 Excess Capacity
of Process MSA’s
0.1040

Values Obtained
0.100

Lean
0.080 Composite Pinch location as well
Stream as external MSA load is
Rich
0.060
unchanged, i.e. so is
Composite
Load to be
Stream
the MOC.
0.040 Removed by
External MSA’s
0.020 Pinch
0.0124 MOC = $288,000/yr
Point
0.000
0.000 0.020 0.030 0.040 0.050 y
0.0087 0.0168 0.0433
x1
0.004 0.009 0.014 0.019 0.0024
0.0074
x2
0.0055 0.0121 0.0186 0.0251 0.0317
 Screening External MSA’s 1:3

• Questions
– How do we screen candidate external MSA’s?
– Is the cost of each MSA ($/kg recirculating MSA) a
proper screening criterion?

• Example - Refinery Hydrogen Removal

– Need to remove 10 kg H2/hr from refinery gasses
– Two candidate MSA’s
– Absorption on sand (Cost $10-4 /kg sand)
– Absorption on activated carbon (Cost $1.0 /kg carbon)
 Screening External MSA’s 2:3

• Example - Refinery Hydrogen Removal (Cont’d)

– 1 kg of sand can remove 10-9 kg of H2

MS sand 10 kg/hr
L sand  t  9
 10 10
kg sand/hr
x sand  x sand 10  0
s

C o st sa n d  1 0  4 $ / k g san d  1 0 1 0 k g san d /h r  $ 1 0 6 /h r

– 1 kg of activated carbon can remove 0.1 kg of H2

MS carbon 10 kg/hr
Lcarbon  t   100 kg carbon/hr
x carbon  x carbon
s
0.1  0

C o st ca rb o n  1 .0 $ / k g carb o n  1 0 0 k g carb o n /h r  $ 1 0 0 /h r
 Screening External MSA’s 3:3

• Proper Screening Criterion

– Removal cost: $/kg removed of targeted species

• Conversion to Removal Cost

– How to convert from $/kg MSA to $/kg removed?

1 kg of MSA (xt – xs) kg of targeted species is removed

xs per kg of the MSA

Cj
(3.30) C r IMPORTANT!!!
x tj  x sj
j

xt
 No Process MSA’s 1:2

• Screening the External MSA’s

Mass If C2r < C1r then eliminate S1 from the problem, as it

Exchanged
is thermodynamically and economically inferior to S2

If C2r < C3r retain both MSA’s

Rich Composite
Stream
Load to be
Removed by S2
Load to be
Removed
by S3
S1 y
x 1s y  b1
S2 x 1t x1  1
m1
x s2 x t2 y  b2
x2  2
S3 m2
x s3 x t3 y  b3
x3   3
m3

THERMODYNAMIC FEASIBILITY
 No Process MSA’s 2:2

• Constructing the Pinch Diagram

Mass
Exchanged

Pinch
Point
Rich Composite
Stream
Lean
Composite
Stream

S1 y
x 1s y  b1
S2 x 1t x1  1
m1
x s2 x t2 y  b2
x2  2
S3 m2
x s3 x t3 y  b3
x3   3
m3
 Example No. 3 1:4

• Toluene Removal from Wastewater

– Flowrate of wastestream: G = 10 kg/s
– Supply composition of toluene: ys = 500 ppmw
– Target composition of toluene: yt = 20 ppmw
– Three external MSA’s
• Air (S1) for stripping
• Activated carbon (S2) for adsorption
• Solvent (S3) for extraction
Stream Uppe r Supply Target mj  j Cj
bound composition composition ppmw $/kg
on flowrate
(ppmw) (ppmw) MSA
Removal Cost
C
L xjs
C1r = $0.38/kg
j
xjt
kg/s
S1  0 19,000 0.0084 6,000 7.2x10-3
C2r = $5.53/kg
S2  100 20,000 0.0012 15,000 0.11
C3r = $43.90/kg
S3  50 2,100 0.0040 10,000 0.09
 Example No. 3 2:4

• Screening the MSA’s

– S2 and S3 are capable of removing the entire toluene
load. S1 has limited removal capability
0.0050
Mass Exchanged, 0.0048
kg Toluene/s
0.0040
Air is least
expensive, thus S1
Rich
0.0030
Stream should be used to
remove all the load
0.0020 to its right, i.e.
0.0045 kg/s
Activated carbon is 0.0010
less expensive than
0.0003
the solvent, thus S2 0.000
0 20 50 100 200 300 400 500 y, ppmw
should be used to Air
x1, ppmw
remove the 0 19,000
Carbon
x2, ppmw
remaining load, i.e. 100 20,000

0.0003 kg/s
Extractant

50 2100
x3, ppmw
 Example No. 3 3:4

• Constructing the Pinch Diagram

0.0050
Mass Exchanged, 0.0048
kg Toluene/s
0.0040
Air
Rich
0.0030
Stream

0.0020 Activated
Carbon

0.0010
0.0003
0.000
0 20 50 100 200 300 400 500 y, ppmw
0 19,000 x1, ppmw

100 20,000 x2, ppmw

 Example No. 3 4:4

• Minimum Operating Cost (MOC) Solution

– Flowrate of air:

MS1 0.0045 kg/s

L1  t  6
 0.237 kg air/s
x1  x1 19, 000  10  0
s

– Flowrate of activated carbon:

MS2 0.0003 kg/s

L2  t  6
 0.015 kg carbon/s
x 2  x 2 (20, 000  100)  10
s

– Assuming 8000 hr/yr:

MOC  0.237 kg/s  $7.2  10  3 /kg  0.015 kg/s  $0.11/kg

MOC  0.00335 $/s  $96,700/yr
 Other Business

• Michelin Information Session – February 12

– Meet in McMillan Auditorium during regular lecture time

• Next Lecture – February 14

– Graphical mass integration techniques
– SSLW pp. 297-308