Beruflich Dokumente
Kultur Dokumente
PROCESS ENGINEERING
PRRE4001/6003
MODULE 1: Do-it-Yourself
Flowsheets
Why would you do it yourself?
Flowsheet
Metallurgical flowsheets
Unit Processes
1. Mixing 2 or more input streams are combined to form a single
output stream
2. Splitting an input stream is divided into 2 or more output
streams of identical composition (or size distribution, for
solids)
3. Separation an input stream is divided into 2 or more output
streams of different composition (or size distribution for
solids)
4. Reaction refers to alteration of minerals and other materials
by chemical reaction
5. Material transfer mostly involves the movement of liquids,
gases and slurries through pipes, etc.
6. Energy transfer heating, cooling, heat recovery and recycling
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Flowsheet Features
IMPORTANT TERMS:
Input stream
Feed stream
Product and waste streams tailings, concentrate
Recycle and bypass streams
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Flowsheet
A process flowsheet summarising the steps taken in the treatment of bauxite ore to
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produce aluminium metal (Hayes, P. , 1993, pp 9)
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Numbered Flowsheet
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Stream
Characteristics
Stream Information:
Species
uniquely distinguishable
material entity within a
stream
Examples:
Furnace gas: SO2, O2, CO,
CO2, N2
Slurry: water, solids
Matte: Cu2S, FeS
Note: Stream unknowns; Assignment of stream unknowns (pp 11-12)
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Units:
Standard Cubic Metre, Nm3 a cubic metre of ideal gas at STP (O0C and 1
atmosphere pressure)
1 mole (STP) 22.4 x 10-3 Nm3 (22.4 L)
vol % = mol% for ideal gases
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Sensible Heat
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Heat of Reaction
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Sensible Heat
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Stream Characteristics
Mass and Mole Balances
Heat Balances
Unit Process Characteristics
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Important Definitions
o Process Components
o Common Stream Variables
o Active Components
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Process Components
Stream species represent all of the physically distinguishable
elements, compounds or materials which collectively constitute a
given stream.
Process components represent the minimum number of
independently distinguishable physical entities present amongst
the species of a unit process, from which all input and output species
can be assembled, taking into account all intrinsic relationships
which exist amongst the species, such as stoichiometric linkages
and chemical reactions.
Note: A determination of the number of components for a unit process is fundamentally
important knowledge for a material balance since one independent material balance can
be written for each component within the unit process.
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Active Components
The number of components for which a
material balance equation can still be written
after the assignment of flow unknowns is the
number of active components
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MIXER
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SPLITTER
SFj = 1, SF = OS-1
Write SE = Cactive(OS-1) splitter equations
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Splitter Equations
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Splitter Equations
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Splitter Analysis
C=S
Write one material balance for each Active
Component
(OS-1) independent split fractions
Create an unknown for each undefined split fraction
Write SE splitter equations where:
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SEPARATOR
SCB2 = 0
SCC2 =0.15
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Example: Cactive = 1
Separator Analysis
C=S
Write one material balance for each Active Component
Total Independent Separation Coefficients SC = S(OS-1)
Use Common Variable for each SC = 1
Write SCE independent separator equations, where:
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REACTOR
Key Parameter:
R = Number of independent reactions
C = (SR R) + S
Write one material balance for each component
C<S
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CO + 2H2 CH4 + O
(1A)
Unchanged:
H 2 + O H 2O
(2)
Eliminate O
(1A) + (2)
(2) + (3A)
(1B)
(2B)
Or
(4)-(1)-2x(2)
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Neutral Species:
N2 (S = 1)
Reaction Species:
H2, O2, H2O (SR = 3)
Independent Reactions:
H2 + 0.5O2 H2O (R = 1)
Neutral Components:
N2 (1)
Reaction Element Components:
C = (SR R) = (3-1) = 2
Example: pp 38
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So far
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Example: pp 44
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(R1)
(R2)
(R3)
(R4)
(R5)
Soln
113.869
Nair
NOffGas 119.922
nN2
90.100
nCO2
6.010
nH2O
11.821
Flowsheet Analysis
Method for Flowsheet Analysis:
1. Sketch and annotate an input/output diagram for
the flowsheet
2. Analyse each unit process separately within the
flowsheet, using the established method
3. Summarise the number of unknowns, active
components, restrictions, DOF, and other
operating parameters
4. Solve the total flowsheet
5. Finally, verify the flowsheet balance (total mass
balance, element and neutral species balances)
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Hematite Reduction
Linear Equations
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Hematite Reduction
Non-Linear Equations
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Sensitivity Analysis
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NiO Reduction
mole and heat balance
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Flowsheet Annotation
Solve mole and heat balances
to find T, T4 and all flows.
Basis 1 kg mol NiO
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Thermodynamic Table
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Heat Balance
Fluid Bed
Reactor
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Heat Balance
Fluid Bed
Reactor
1 Equation
4 Unknowns
nH2, nH2(5), T, T4
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