P100 - Chemical Engineering Process Design ... - Discovery Press

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EngrI 1120 - Introduction to Chemical Engineering Design Competition - Fall 2012 - Part 1. Your company has decided to produce P by the reaction A → P. Unfortunately, there is a parallel reaction, A → X. Both reactions are irreversible and both reactions are incomplete. Reactant A is available only as a mixture with inert impurity I. A, I, and P have identical boiling points; we obtain pure P with a liquid-solid separator. But the solids A, I, and X retain some liquid P. A generic process is shown below. To produce and sell product P, you need only a reactor and a liquidsolid separator. You have three options for the A+I+P+X mixture in the liquid-solid separator bottoms stream: (1) you may discard the mixture by sending 100% of the stream to the purge, or (2) you may recycle some of the mixture, for example, by purging 50% and sending 50% through the recycle, or (3) you may purchase a second separator to separate and sell by-product X. If you wish to produce X, the bypass plus purge must be less than 100%. P (liquid) to market A and I recycle A, I, P, and X reactor A → P A → X A, I, P, and X liquid-solid separator gas-liquid separator tops A, I, P, and X A, I, P, and X A, I, and P bypass liquid-solid separator bottoms solids A, I, and X, wet with liquid P to market X gas-liquid separator purge A, I, P, and X There are two options for reactant purity. Grade 1 mixture is high purity A and is expensive. Grade 2 mixture is modest purity A and is less expensive. There are two options for the reactor. Reactor Type 1 has a high conversion of A but has modest selectivity for P over X. Reactor Type 2 has a lower conversion of A, but better selectivity for P over X. There are two options for the liquid-solid separator. Both options produce pure P, but differ by the amount of P retained by the solids. Liquid-solid separator Type 1 recovers more P. Liquid-solid separator Type 2 retains more P in the solids stream, but is less expensive to operate. Disposal of the purged stream requires special treatment and is expensive.
Engineering and Economic Data for Manufacturing P (and X) from A. Equipment specifications, equipment costs, operating costs, chemical costs, and disposal costs vary with Design League and Division. Identify your team’s League and Division and then download the data from the EngrI 1120 homepage - see “Design Competition.” Wednesday Design League: Thursday Design League: Keynes Division: Teams W1 - W7 Smith Division: Teams W8 - W13 Friedman Division: Teams R1 - R6 Galbraith Division: Teams R7 - R13 Reactor and separator prices are given by the formula price = k × (F T ) 0.6 , where k is a constant conversion factor, F T is the flow through the unit, in mol/day, and price is in $. For example, a reactor with double the capacity costs only 1.5 times as much. Operating costs for reactors and separators are given by the formula operating cost = c × F T ; the units of operating cost are $/year. All economic parameters - equipment prices, operating costs, chemical prices, and disposal cost - are constant. Equipment depreciation is calculated with straight-line formula, with a lifetime of 10 years. The process operates 365 days/year. Equipment purchase costs are paid at the beginning of the year. Operating costs are paid during the year. Revenue from sale of P (and perhaps, X) is received at the end of the year. _________________________________ Goal: Start with $10,000,000 and maximize the ROI for your process in the first year. You must decide what grade of reactant purity and what type of reactor and liquid-solid separator to purchase, and the capacity of each. You must decide if you wish to purchase a gas-liquid separator to purify and sell by-product X. You must specify the fraction of liquid-solid separator bottoms to be purged and the fraction to be recycled. You also must decide how much reactant to purchase. Annual Plans are due by 2:30 p.m. on the day of your Calculation Session, either October 17 or October 18. You will receive an Annual Report of your team’s results by Friday, October 19. If your team achieves a positive Return On Investment, your team will earn 25 homework points. If your ROI is greater than 0.2, your team will earn an additional 10 points. If your team has the highest Return On Investment in your Division, your team will be bestowed an additional 10 points. Hint: There are eight combinations of reactant grade, reactor type, and liquid-solid separator type. Every combination can be operated to produce a positive ROI. Half of the combinations can be operated to produce an ROI greater than 0.2.
Page 1 and 2: Chemical Engineering Process Design
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Page 9 and 10: Thursday Design League - Milton Fri
Page 11 and 12: EngrI 1120 - Introduction to Chemic

P100 - Chemical Engineering Process Design ... - Discovery Press

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