MATERIAL BALANCE

CHAPTER No.3
MATERIAL BALANCE
3.1 FLUIDIZED BED REACTOR :Basis:
400 ton/day Acrylonitrile production.
Feed Ratio = Propene / ammonia / air =1/ 1.2 /9.5
1 hr operation

22

Production of Acrylonitrile

MATERIAL BALANCE

INPUT STREAM:
Components
Propylene
Air
Ammonia
Total

Weight
(kg/hr)
14280
93024
6936
114240

Weight%
12.5
81.4
6.1
100

Moles
(kmol/hr)
340
3230
408
3978

Mole%
8.5
81.2
10.3
100

COMPOSITION OF COMPONENTS IN GASEOUS LEAVING

COMPONENT

AMOUNT

MOLECULAR

AMOUNT

MOLE %
(Kgmoles)
WEIGHT
(Kg)
Propylene
5.78
42
242.67
0.138
Oxygen
26.35
32
843.2
0.629
Nitrogen
2584
28
72352
61.8
Ammonia
97.41
17
1655.97
2.33
Carbon dioxide
109.14
44
4802.16
2.6
HCN
27.55
27
743.58
0.66
AN
272.33
53.1
14461.25
6.5
Acrolein
9.18
56.1
514.99
0.219
Acetonitrile
10.705
41.1
444.18
0.256
Water
1041.22
18
18742.14
24.88
TOTAL AMOUNT OF GASEOUS LEAVING = 114240 Kg/hr

Total Material in

= 114240 kg / hr

Total Material out

= 114240 kg / hr

3.2 QUENCHER:-

23

Production of Acrylonitrile

MATERIAL BALANCE

COMPOSITION OF COMPONENTS IN GASEOUS FEED

COMPONENT

AMOUNT MOLECULAR
(Kgmoles)

WEIGHT

AMOUNT
(Kg)

MOLE %
24

Production of Acrylonitrile

MATERIAL BALANCE

Propene
Oxygen
Nitrogen
Ammonia
Carbon dioxide
HCN
AN
Acrolein
Acetonitrile
Water

5.78
26.35
2584
97.41
109.14
27.55
272.33
9.18
10.705
1041.22

42
32
28
17
44
27
53.1
56.1
41.1
18

242.67
843.2
72352
1655.97
4802.16
743.58
14461.25
514.99
444.18
18742.14

0.138
0.629
61.8
2.33
2.6
0.66
6.5
0.219
0.256
24.88

TOTAL AMOUNT OF GASEOUS FEED ENTERING = 114240 Kg/hr

COMPOSITION OF QUENCHING MEDIA (30% H2SO4) ENTERING

COMPONENT

AMOUNT MOLECULAR AMOUNT

MOLE %
(Kgmoles)
WEIGHT..
(Kg)
Water
743.72
18
13386.6
92.7
Sulfuric Acid
58.54
98
5737.4
7.3
TOTAL AMOUNT OF QUENCHING MEDIA = 19124 Kg/hr
Total quenching media (30% H2SO4) entering = 19124 kg/hr
Total input

= 19124 + 114240
= 133364 kg/hr

COMPOSITION OF COMPONENTS LEAVING AT THE TOP

COMPONENT
Propene
Oxygen

AMOUNT

MOLECULAR

AMOUNT

(Kgmoles)
5.78
26.35

WEIGHT
42
32

(Kg)
242.76
843.20

MOLE %
0.19
0.85
25

Production of Acrylonitrile

MATERIAL BALANCE

Nitrogen
Carbon dioxide
HCN
AN
Acrolein
Acetonitrile
Water

2584
109.14
27.26
269.62
9.09
10.61
41.22

28
44
27
53.1
56.1
41.1
18

72352
4802.16
736.14
14316.64
509.84
435.78
18742.14

TOTAL AMOUNT OF GASEOUS COMPONENT LEAVING

83.8
3.54
0.88
8.74
0.29
0.34
1.34

= 112979 Kg/hr

COMPOSITON OF COMPONENTS LEAVING AT THE BOTTOM

COMPONENT
HCN
Sulfuric Acid
Ammonium Sulfate
AN
Acrolein
Acetonitrile
Water

AMOUNT

MOLECULAR

AMOUNT

MOLE

(Kgmoles)
0.255
9.76
48.78
2.73
0.094
0.107
743.7

WEIGHT
27
98
132
53.1
56.1
41.1
18

(Kg)
7.43
956.2
6439.1
144.61
5.15
4.4
13386.6

%
0.032
1.2
6.06
0.39
0.012
0.013
92.34

TOTAL AMOUNTS OF COMPONENTS LEAVING AT THE BOTTOM= 20385 Kg/hr

Material Entering

= 133364 kg / hr
26

Production of Acrylonitrile

MATERIAL BALANCE

Material Leaving

= 133364 kg / hr

27

Production of Acrylonitrile

MATERIAL BALANCE

3.3 ABSORBER:-

28

Production of Acrylonitrile

MATERIAL BALANCE

Total water entering for absorption

= 90195 kg / hr

Total input

= 90195 + 94035
= 185110 kg/hr

COMPOSITION OF COMPONENTS IN GASEOUS FEED

COMPONENT

AMOUNT MOLECULAR AMOUNT

(Kgmoles)
Propene
5.78
Oxygen
26.35
Nitrogen
2584
Carbondioxide
109.14
HCN
24.54
AN
134.81
Acrolein
4.54
Acetonitrile
5.30
Water
416.74

WEIGHT
42
32
28
44
27
53.1
56.1
41.1
18

(Kg)
242.76
843.2
72352
4802.16
662.53
7158.32
254.92
217.89
7501.25

MOLE %
0.17
0.80
76.94
5.11
0.70
7.61
0.27
0.23
8.00

TOTAL AMOUNT OF GASEOUS FEED ENTERING = 94035 Kg/hr

COMPOSITION OF SOLVENT

COMPONENT

AMOUNT MOLECULAR AMOUNT

MOLE %
(Kgmoles)
WEIGHT..
(Kg)
Water
5010.82
18
90195
100
TOTAL AMOUNT OF SOLVENT ENTERING = 90195 Kg/hr
COMPOSITION OF COMPONENTS LEAVING AT THE TOP
COMPONENT
Propene
Oxygen

AMOUNT MOLECULAR AMOUNT

(Kgmoles)
5.78
26.35

WEIGHT
42
32

(Kg)
242.76
843.20

MOLE %
0.20
0.94
29

Production of Acrylonitrile

MATERIAL BALANCE

Nitrogen
Carbondioxide

2584
109.14

28
44

72352
4802.16

92.76
3.92

AN

0.67

53.1

35.79

0.02

Acrolein

2.74

56.1

153.90

0.1

Water

57.53

18

1035.58

2.06

TOTAL AMOUNT OF GASEOUS COMPONENT LEAVING

=79465Kg/hr

COMPOSITON OF COMPONENTS LEAVING AT THE BOTTOM

AMOUNT

MOLECULAR

AMOUNT

MOLE

HCN
AN
Acrolein

(Kgmoles)
24.54
134.13
1.80

WEIGHT
27
53.1
56.1

(Kg)
662.53
7122.53
101.02

%
0.44
2.42
0.03

Acetonitrile
Water

5.30
5370.03

41.1
18

217.89
96660.51

0.1
97

COMPONENT

TOTAL AMOUNTS OF COMPONENTS LEAVING AT THE BOTTOM=104765Kg/hr

Material Entering

= 185110 kg / hr

Material Leaving

= 185110 kg / hr

30

Production of Acrylonitrile

MATERIAL BALANCE

3.4 HCN RECOVERY

INPUT
STREAM
COMPONENTS

FROM

FROM

TOTAL ENTERING

ABSORBER DECANTER
AMOUNT

AMOUNT

AMOUNT WEIGHT AMOUNT MOLE

Kg/hr

Kg/hr

Kg/hr

Kmoles/hr

Acrylonitirle

7122.53

7158

14280.53

0.11

269.43

0.04

HCN

662.53

74

736.53

0.006

27.27

0.004

Acetonitrile

217.89

217

434.89

0.008

10.6

0.003

Acrolein

101.02

254

355.02

0.002

6.33

0.001

Water

96660.51

11241

107901.51

0.87

5994.53

0.94

Total

104763.95

18944

123707.59

6308.15

31

Production of Acrylonitrile

MATERIAL BALANCE

LOWER STREAM

wt %

wt (kg/hr)

kmol/hr

mol%

Acrylonitrile

11.6

14268

269.2

4.28

Acetonitrile

0.35

432.42

10.53

0.16

Acrolein

0.28

348.84

6.22

0.09

Water

87.8

107891.41

5993

95.44

TOTAL

100

122950.67

6278.95

100.00

UPPER
STREAM
Acrylonitrile

wt%

wt (kg/hr)

kmoles/hr

mol%

0.001

12

0.02

0.71

Acetonitrile

0.002

2.47

0.06

0.21

HCN

99.9

736.53

27.27

98.9

Water

ppm 9

10.1

0.56

0.4

Acrolein

0.005

6.18

0.111

0.39

Total

100

756.48

28.021

100

Material in = 123707.59 kg/hr

Material out = 123707.15 kg/hr

32

Production of Acrylonitrile

MATERIAL BALANCE

3.5 WATER RECOVERY

Since composition of upper stream is given in literature, so

Upper Stream

wt%

wt (kg/hr)

kmoles/hr

mol%

Acrylonitrile
LOWER STREAM
Acetonitrile

94.01
wt %
3.7

14024.57
wt (kg/hr)
402.32

264.61
kmol/hr
9.8

93.19
mol%
4.1

Water
Acrylonitrile
Acrolein
Acetonitrile

0.13 0.22
2.05 0.03

50.48
243.43
302.88
30.1

2.77
4.6
5.4
0.8

0.2
0.07
2.0
0.01

Acrolein
Total
Water

100 0.04
99.7

45.96
14780.25
107840.93

0.8
281.91
5992

0.01
100
99.8

TOTAL

100

108160.42

5998.2

100.00
33

Production of Acrylonitrile

MATERIAL BALANCE

Material in = 122950.67 kg/hr

Material out = 122940.58 kg/hr

3.6 ACRYLONITRILE RECOVERY

In literature, composition of Acrylonitrile and Acetonitrile is given

Top Product:Upper Stream

wt %

wt (kg/hr)

kmol/hr

mol%

Acrylonitrile

98.8

14011.88

264.18

97.90

Acetonitrile

0.04

10.51

0.25

0.004

Acrolein

1.01

288.31

5.14

2.01

Water

0.02

4.22

0.24

0.002
34

Production of Acrylonitrile

MATERIAL BALANCE

TOTAL

100

14314.92

269.81

100.00

Bottom Product:LOWER STREAM

wt%

wt (kg/hr)

kmoles/hr

mol%

Acrylonitrile

1.7

12.69

0.24

1.1

Acetonitrile

87.04

391.81

14.5

94.01

Water

9.8

45.79

2.54

5.01

Acrolein

2.13

14.57

0.21

0.5

Total

100

464.86

17.49

100

Material in = 147780 kg/hr

Material out = 14779.58 kg/hr

35

Production of Acrylonitrile