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Generally, the mass balance is every important equation in chemical plant to ensure
the flow rate and composition of materials at input is always equal to output for steady state
process. In this plant, the process assumed to ideal and at steady state. This known as law of
conversation of mass, which mention that the mass neither be created nor destroy but only
can transform to another form of energy. The chemical process can be classified into three
categories of processes which are batch, continuous and semi-batch. The batch process is
where a feed is charged into a vessel at the beginning of the process and vessel contents are
removed sometimes later after the process. No mass crosses the system boundaries between
the time the feed is charged and the time the product is removed. The continuous process
defines as the input and output flow continuously throughout the duration of the process. The
semi-batch process is neither batch nor continuous. For this plant, the process is based on
continuous process.
The values of the entire variable in this process (all temperature, pressure, flow rate
and volume) do not change over time, except possibly for minor fluctuation about constant
mean values, the process is said to be steady state. The balance on conserved quantity (total
mass flow rate, mass flow rate of particular species and energy) in this system (single process
unit, a collection of units or an overall balance process) is written in the following general
way as shown in equation below (Felder, Rousseau, & Bullard, n.d.);
Input + Generation Output Consumption = Accumulation
Where;
Input = enter through system boundary
Generation = produced within system
Output = leaves through system boundaries
Consumption = consumed within system
Accumulation = build up within system
The balance on continuous steady state process is where the accumulation term in
general balance equation is equal to zero and the equation simplifies as next equation
Input = Output
Law of conservation of mass stated that during a chemical reaction atoms are neither
created nor destroyed. The number of atoms remains constant throughout the reaction. Since
the number of atoms does not change, the mass must remain constant as well. The law of
conservation of mass is very important to the study and production of chemical reactions. If
scientists know the quantities and identities of reactants for a particular reaction, they can
predict the amounts of products that will be made. Chemical manufacturers can increase
efficiency by applying the law of conservation of mass to their laboratory practices. ("The
Law of Conservation of Mass: Definition, Equation & Examples - Video & Lesson Transcript
Study.com", 2016)
The conservation of mass principle for a control volume can be expressed as;
in - out = CV
For a steady state, steady flow process the conservation of mass principle becomes
in = out
where;
in = mass flowrate in
out= mass flowrate out
CV= mass flowrate in control volume
34246.57534658 kg/hours
320.0711193824 mol/hr
nC 2 H 4 + H 2 H ( C 2 H 4 ) nH
From the equation of polymerisation of polyethylene, it can be seen that one mole of
mLLDPE produce consume 1 mole of hydrogen.
[
106.99676812 kg mLLDPE 1000 g 2.01588 g H 2
mol
1 kg
mol ]
28.05316 g C2 H 4 / mol
3814 unit
3814 C 2 H 4 + H 2 H( C 2 H 4 )3814 H
1220751.24932441mol C 2 H 4 / hr
Since the conversion of polymerisation from ethylene to mLLDPE is 98%, therefore the
1220751.2493441mol C 2 H 4
number of mol of reactant feed=
0.98
=1245664.54012695 mol of C2 H 4 / hr
320.0711193824 mol H 2
number of mol of H 2 feed=
0.98
=326.6031830432 mol of H 2 / hr
Therefore,
mol mol
unreacted ethylene=1245664.54012695 122075102493441
hr hr
mol C 2 H 4
24913.290802539
hr
698.8965330102kg C 2 H 4 /hr
mol H 2
6.5320636609
hr
H 2 2.01588 g H 2 1 kg
6.532036609 mol
hr mol H 2 1000 g
0.0131678565 kg H 2 /hr
The ratio of ethylene to nitrogen is 52 vol.% ethylene to 48 vol.% nitrogen (Bergstra, 2004).
The amount of ethylene enter to the fluidise bed reactor
34944.8266505078 kg C2 H 4 /hr + 698.8965330102 kg C 2 H 4 /hr
35643.72318 kg C2 H 4 /hr
48
Nitrogen gas flow rate into the reactor 52 35643.72318kg /hr
32901.8983232473 kg N 2 /hr
The recycle stream of the nitrogen gas is control to be 50% of the inlet to the fluidised
reactor.
32901.8983232473 kg N 2 /hr
Therefore the amount of nitrogen gas feed
2
16450.9491616237 kg N 2 /hr
It is reported by (Bergstra, 2004), the molar ratio of Al/Zr is 108. Therefore the active catalyst
is compose of 36 mol of MAO and one mole of metallocene.
One mole of active catalyst is
36 molar mass of MAO+1 metallocene
Molar flowrate for component of Nitrogen was calculated using this formula:
Mass Flowrate
Molar Flowrate = Molar Mass
kg kg
Molar Flowrate = 16450.95 hr 28.013
kmol
kmol
= 587.26 hr
The following molar flow rate of nitrogen in other stream will be calculated using this
approach.
1 ton
Mass flow rate in ton/hr = 16450.95 kg/hr 1000 kg
=16.45095 ton/hr
=16.45 ton/hr 2d.p
The following conversion unit from kg/hr to ton/hr is calculate using this approach
S3 = 38.92 kg/hr
100% active catalyst
25C
S4 = 16489.87 kg/hr
m N = 16450.95 kg/hr
S2 = 16450.95 kg/hr 2
100% N2 m
a .c = 38.92 kg/hr
25C
1
2.36 10 active catalyst
99.76% N2
Figure 2.2.2: Mass Balance for nitrogen carried active catalyst
Catalyst
Outpu S4 Nitrogen 16450.95 16.45 587.26 99.76 16489.87
t Active 38.92 3.89 10 5.84 10 2.36
2 3
Catalyst 101
Table 2.2.1: Input-Output of nitrogen carried active catalyst
S 2+ S 3=S 4
kg kg kg
16450.95 +38.92 =16489.87
hr hr hr
16450.95
Mass composition of nitrogen in S4 16489.87 100
=99.76%
38.92
Mass composition of active catalyst in S4 16489.87 100
1
=2.36 10
Molar flowrate for component of Active Catalyst was calculated using this formula:
Mass Flowrate
Molar Flowrate = Molar Mass
kg kg
Molar Flowrate = 38.92 hr 6658.24 kmol
kmol
= 5.84 10-3 hr
The following molar flowrate of active catalyst in other stream will be calculated
using this approach.
Molar flowrate for component of Ethylene was calculated using this formula:
Mass Flowrate
Molar Flowrate = Molar Mass
kg kg
Molar Flowrate = 34944.83 hr 28.05316
kmol
kmol
= 1245.66 hr
The following molar flowrate of ethylene in other stream will be calculated using this
approach.
S7= 6.58
1
S8= 6.58
10 kg/hr 101 kg/hr
100% H2 C-102
100% H2
T= 25C
T= 25C
Molar flowrate for component of Hydrogen was calculated using this formula:
Mass Flowrate
Molar Flowrate = Molar Mass
1 kg kg
Molar Flowrate = 6.58 10 hr 2.01588
kmol
kmol
= 3.2710-1 hr
The following molar flowrate of hydrogen in other stream will be calculated using this
approach.
Mass balance of mixer (M-100)
S9 = 34945.49 kg/hr
m C 2 H 4 = 34944.83
S6 = 34944.83 kg/hr
100% C2H4 kg/hr
T= 25C M-100 mH2 = 6.58 10
1
kg/hr
S8= 6.58
99.99% C2H4
101 kg/hr 3
1.89 10 H2
100% H2
Figure 2.2.5: Mass balance of mixer (M-100)
T= 25C
1
10
Table 2.2.5: Input-Output of mixer (M-100)
S 6+ S 8=S 9
kg kg kg
34944.83 +6.58 101 =34945.49
hr hr hr
34944.83
Mass composition of Ethylene in S9 34945.49 100
=99.99%
6.58 101
Mass composition of Hydrogen gas in S9 100
34945.49
3
= 1.89 10
S18=16864.75 kg/hr
m H 2 O = 16864.75 kg/hr
100% H2O
T= 25C
3
1.89 10 H2 kg kg/hr
99.99% C2H4
3
1.89 10 H2
S19=16864.75 kg/hr
m H 2 O = 16864.75
kg/hr
100% H2O
Hydrogen 6.58 4
6.60 10 3.27 10
1
1.89 10
3
101
S18 Water 16864.75 16.86 936.93 100
1
10
kg
S19 Water 16864.75 16.86 936.93 100
Table 2.2.6: Input-Output of heat exchanger (E-100)
m
H 2 =1.32 10
2
kg/hr
m N = 16450.95 kg/hr
2
4.08% C2H4
95.92% N2
S15 = 51435.36 kg/hr
m mLLDPE = 34246.58
kg/hr
S4 = 16489.87 kg/hr R-100 m C 2 H 4 = 698.90 kg/hr
m N = 16450.95 kg/hr
2
m
H = 1.32 10
2
m
2
a .c = 38.92 kg/hr
1
kg/hr
2.36 10 active catalyst m N = 16450.95 kg/hr
2
99.76% N2 m
a .c = 38.92 kg/hr
S11 = 52095.35 kg/hr 66.58% mLLDPE
m C 2 H 4 = 35643.73 31.98% N2
kg/hr 1.36% C2H4
mH 2 = 0.67 kg/hr
m
N 2 = 16450.95 kg/hr
68.42% C2H4
3
Figure 2.2.7: Mass balance of fluid bed reactor (R-100)
Strea Componen Mass Mass Molar Mass Total
m t flow rate flow flow rate composition mass
(kg/hr) rate (kmol/hr) (mass %) flow rate
(ton/hr) (kg/hr)
Input S4 Nitrogen 16450.95 16.45 587.26 99.76 68585.22
Active 38.92 3.89 10 5.84 10 2.36
2 3
Catalyst 101
S11 Ethylene 35643.73 35.64 1270.58 68.42
Hydrogen 6.71 6.71 1043.33 1011.29
1 3
10 10
Nitrogen 16450.95 16.45 587.26 31.58
Outpu S12 Ethylene 698.90 6.99 1024.91
1
4.08 68585.22
t
Hydrogen 1.32 5
1.32 10 6.53 10
3
7.68 10
5
102
Nitrogen 16450.95 16.45 587.26 95.92
S15 mLLDPE 34246.58 34.25 3.20 10 66.58
1
2
10
Nitrogen 16450.95 16.45 587.26 31.98
Active 38.92 3.89 10 5.84 10 7.57 102
2 3
catalyst
Table 2.2.7: Input-Output of fluid bed reactor (R-100)
S 4+ S 11=S 12+ S 15
kg kg
S4 + S11 = 16489.87 h +52095.35 h
= 68585.22 kg/h
kg kg
S12 + S15 = 17149.86 +51435.36
h h
=68585.22 kg/h
698.90
Mass composition of ethylene in S12 17149.86 100
=4.08%
1.32 102
Mass composition of Hydrogen gas in S12 100
17149.86
5
= 7.68 10
16450.95
Mass composition of nitrogen gas in S12 17149.86 100
= 95.92
34246.58
Mass composition of mLLDPE gas in S15 51435.36 100
= 66.58
698.90
Mass composition of Ethylene gas in S15 51435.36 100
= 1.36
2
1.32 10
Mass composition of Hydrogen gas in S15 51435.36 100
5
= 2.56 10
16450.95
Mass composition of Nitrogen gas in S15 51435.36 100
= 31.98
38.92
Mass composition of Active Catalyst gas in S15 51435.36 100
2
=7.57 10
kmol kg
= (1270.5778309295 hr ) 2 12.0107 kmol
kg
= 30521.05831 hr of C element
kmol kg kmol
= [24.9132908025 hr 2 12.0107 kmol ] + [24.9132908025 h 212.017
kg kmol kg
3814 2 12.0107
kmol ] + [0.3200711194 hr kmol
kg
= 30521.05831 hr of C element
Input Stream 11
kmol kg kmol
= [1270.5778309295 hr 41.00794 kmol ] + [ 0.3331352467 hr 2
kg
1.00794 kmol ]
kg
= 5123.339436 hr of H element
kmol kg kmol
= [ 24.9132908025 hr 4 1.00794 kmol ] + [ 0.0065320637( hr ) 2
kg kmol kg
1.00794 kmol ] + [0.3200711194 hr (4 3814 + 2) 1.00794 kmol ] +
kmol kg kmol
[24.9132908025 hr 41.00794 kmol ] + [ 0.0065320637( hr ) 2 1.00794
kg
kmol ]
kg
= 5124.691211 hr of H element
kg kmol kg
[2 14.0067 kmol 587.2612416244 hr ] + [2 14.0067 kmol
kmol
587.2612416244 hr ]
= 32902.36813 kg/hr of N element
kg kmol kg
[2 14.0067 kmol 587.2612416244 hr ] + [2 14.0067 kmol
kmol
587.2612416244 hr ]
= 32902.36813 of N element
Molar flow rate for component of mLLDPE was calculated using this formula:
Mass Flowrate
Molar Flow rate = Molar Mass
kg kg
Molar Flow rate =34246.58 106996.7681
hr kmol
kmol
= 3.2010-1 hr of mLLDPE
The following molar flowrate of mLLDPE in other stream will be calculated using this
approach
kg/hr
m N = 16450.95
2
kg/hr
m N = 16450.95 kg/hr
2
kg/hr
4.08% C2H4 68.42% C2H4
M-101
kg/hr
mH 2 = 6.58 10
1
kg/hr
99.99% C2H4
Figure 2.2.8: Mass balance of mixer (M-101)
S 14+ S 10=S 11
kg kg kg
17149.86 +34944.49 =52095.35
hr hr hr
35643.73
Mass composition of ethylene in S11 52095.35 100
=68.42%
6.71 101
Mass composition of hydrogen in S11 100
52095.35
3
=1.29 10
16450.95
Mass composition of nitrogen in S11 52095.35 100
=31.58%
mH = 1.32 kg/hr
2
10 2 m N = 16450.95 kg/hr
kg/hr 2
m
N 2 = 16450.95 4.08% C2H4
95.92% N2
kg/hr
4.08% C2H4
Figure 2.2.9: Mass balance of compressor (C-103)
S20=9345.95 kg/hr
m H 2 O = 9345.95
kg/hr
100% water
S14 = 17149.86 kg/hr
m C 2 H 4 = 698.90 kg/hr
S13 = 17149.86 kg/hr
m C 2 H 4 = 698.90 kg/hr m
H 2
2 = 1.32 10 kg/hr
E-101
m
H = 1.32 10
2
m
N
2
2 = 16450.95 kg/hr
kg/hr 4.08% C2H4
m N = 16450.95 kg/hr
2 95.92% N2
5
4.08% C2H4 7.68 10 H2
95.92% N2
S21=9345.95 kg/hr
m H 2 O = 9345.95
kg/hr
100% water
Figure 2.2.10: Mass balance of heat exchanger (E-101)
102
Nitrogen 16450.9 16.45 587.26 95.92
5
S20 Water 9345.95 9.35 519.22 100 9345.95
output S14 Ethylene 698.90 6.99 1024.91
1
4.08 17149.8
6
Hydrogen 1.32 1.32 1056.53 103 7.68 105
102
Nitrogen 16450.9 16.45 587.26 95.92
5
S21 Water 9345.95 9.35 519.22 100 9345.95
Table 2.2.10: Input-Output of heat exchanger (E-101)
4.08% C2H4
m
H = 1.32 10
2
2
95.92% N2
5
kg/hr 7.68 10 H2 S16 = 34285.49 kg/hr
m N = 16450.95 kg/hr
2
m mLLDPE = 34246.58 kg/hr
m
a .c m
a .c = 38.92 kg/hr
= 38.92 kg/hr
66.58% mLLDPE 99.89% mLLDPE
31.98% N2 0.11% active catalyst
1.36% C2H4 T= 76C
5
2.56 10 % H2
TK-101
catalyst
Table 2.2.11: Input-Output of degassing tank (TK-101)
S 15=S 17+ S 16
kg kg kg
51435.36 =17149.86 + 34285.5
hr hr hr
698.90
Mass composition of ethylene in S17 17149.86 100
=4.08%
1.32 102
Mass composition of hydrogen in S17 100
17149.86
5
=7.68 10
16450.95
Mass composition of nitrogen in S17 17149.86 100
=95.92%
34246.58
Mass composition of mLLDPE in S16 34285.49 100
=99.89
38.92
Mass composition of active catalyst in S16 34285.49 100
=0.11%
Catalyst = 38.92
kg/hr
Ethylene = 34944.83
kg/hr LLDPE= 34285.49
kg/hr
Hydrogen= 6.58 x 10-1 Purge= 17149.86
kg/hr kg/hr
In this process, the reaction only take place in fluidized bed reactor where ethylene is
undergo polymerisation to form polyethylene, mLLDPE
mole reacted
Fractional conversion = mole feed
0.98
mole reacted
percentage of conversion= 100
mole feed
98
the process.
3814 C 2 H 4 + H 2 H( C 2 H 4 )3814 H
The hydrogen gas is used as reactant in calculation of yield, as the result will be more
significant compare to if ethylene is used. From the equation, it show that one mole of
hydrogen required in producing one mole of mLLDPE.
320.0711193824 mol/hr
326.6031830432 mol/hr
0.98
Since there is no undesired product form , where only have one produce form which is
mLLDPE from ethylene. Therefore the selectivity of the reaction is equal to 1.
2.4 Stream Table
Stream no. 1 2 3 4 5 6 7 8 9 10 11
Temperature (C) 25 25 25 25 25 25 25 25 25 44 44
Vapour fraction 1 1 0 1 1 1 1 1 1 1 1
Active 0 0 5.84 10 0
3
5.84 10
3 0 0 0 0 0 0
catalyst
mLLD 0 0 0 0 0 0 0 0 0 0 0
PE
Stream no. 12 13 14 15 16 17 18 19 20 21
Temperature (C) 76 76 44 76 76 76 25 40 25 40
Pressure (bar) 18.3 21.5 20.5 18.5 1 1 2 1.5 2 1.5
Vapour fraction 1 1 1 1 1 1 0 0 0 0
Mass flow rate (ton/h) 17.15 17.15 17.15 51.44 17.15 34.29 16.86 16.86 9.35 9.35
Mole flow rate 612.18 612.18 612.18 612.51 325.92 612.18 936.9 936.9 519.2 519.2
(kmol/h) 3 3 2 2
mLLDP 0 0 0 3.20 10 1
3.20 0 1
10 0 0 0 0
E
Felder, R., Rousseau, R., & Bullard, L. Elementary principles of chemical processes (1st ed.)
The Law of Conservation of Mass: Definition, Equation & Examples - Video & Lesson
Transcript | Study.com. (2017). Study.com. Retrieved 21 March 2017, from
http://study.com/academy/lesson/the-law-of-conservation-of-mass-definition-equation-
examples.html
http://www.chemicalbook.com/ChemicalProductProperty_EN_CB8193937.htm
https://tel.archives-ouvertes.fr/tel-01245076/file/RAPAKOUSLOU_AMALIA_2014.pdf
http://www.convertunits.com/molarmass
Metallocene catalysts in dissolved forms are unsuitable for the production of polyethylene or
isotactic polypropylene on an industrial scale. In order to use them in existing technical
processes (drop-in technology) by exchanging them for the conventional ZieglerNatta
catalysts, the metallocenes have to be applied to a powdery, insoluble substrate. One way to
do so is to support them on silica, alumina, magnesium dichloride or other supports.