CH 07

CHAPTER 7 SOLUTIONS
7.1 Solutions are provided using ASPEN PLUS, HYSYS, and CHEMCAD.
ASPEN PLUS Solution
a. ASPEN PLUS Flowsheet – simulation results can be reproduced using the

file EXER7-1A.bkp in the ASPEN folder, under
Computer Solution Files, associated with the Solution
Manual on the Wiley web site for this book.
VP
FEED1 F1
M1
FEED2 S2
S5
S3
S4 LP
S1
P1
ASPEN PLUS Simulation Flowsheet
VP
FEED1 S2
M1 F1
FEED2 MIXER FLASH2
S5 S3
S4* S4 S1 LP
P1 $OLVER01
PUMP FSPLIT
SM-7-1
ASPEN PLUS Program
IN-UNITS ENG
DEF-STREAMS CONVEN ALL
DATABANKS PURE93 / AQUEOUS / SOLIDS / INORGANIC / &
NOASPENPCD
PROP-SOURCES PURE93 / AQUEOUS / SOLIDS / INORGANIC
COMPONENTS
METHANE CH4 METHANE /
ETHANE C2H6 ETHANE /
PROPANE C3H8 PROPANE /
N-BUTANE C4H10-1 N-BUTANE /
1-BUTENE C4H8-1 1-BUTENE /
1,3-BUTA C4H6-4 1,3-BUTA
FLOWSHEET
BLOCK M1 IN=S5 FEED2 FEED1 OUT=S2
BLOCK F1 IN=S2 OUT=VP S3
BLOCK S1 IN=S3 OUT=LP S4
BLOCK P1 IN=S4 OUT=S5
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL METHANE ETHANE -7.8000000E-3
BPVAL METHANE PROPANE 9.00000000E-3
BPVAL METHANE N-BUTANE 5.60000000E-3
BPVAL ETHANE PROPANE -2.2000000E-3
BPVAL ETHANE N-BUTANE 6.70000000E-3
BPVAL ETHANE METHANE -7.8000000E-3
BPVAL PROPANE ETHANE -2.2000000E-3
BPVAL PROPANE N-BUTANE 0.0
BPVAL PROPANE METHANE 9.00000000E-3
BPVAL N-BUTANE ETHANE 6.70000000E-3
BPVAL N-BUTANE PROPANE 0.0
BPVAL N-BUTANE METHANE 5.60000000E-3
BPVAL N-BUTANE 1-BUTENE -4.8000000E-3
BPVAL N-BUTANE 1,3-BUTA 8.10000000E-3
BPVAL 1-BUTENE N-BUTANE -4.8000000E-3
BPVAL 1-BUTENE 1,3-BUTA -4.4000000E-3
STREAM FEED1
SUBSTREAM MIXED TEMP=85 <C> PRES=100
MASS-FLOW METHANE 50 / ETHANE 100 / PROPANE 700
STREAM FEED2
SUBSTREAM MIXED TEMP=85 <C> PRES=100
MOLE-FLOW N-BUTANE 15 / 1-BUTENE 21 / 1,3-BUTA 95
BLOCK M1 MIXER
BLOCK S1 FSPLIT
FRAC S4 0.5
BLOCK F1 FLASH2
PARAM TEMP=5 <C> PRES=25
BLOCK P1 PUMP
PARAM PRES=100
Calculation Sequence
SEQUENCE USED WAS:
$OLVER01 P1 M1 F1 S1
(RETURN $OLVER01)
SM-7-2
Stream Variables
FEED1 FEED2 LP S2 S3
--------------------
STREAM ID FEED1 FEED2 LP S2 S3

FROM : ---- ---- S1 M1 F1
TO : M1 M1 ---- F1 S1
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR LIQUID MIXED LIQUID
COMPONENTS: LBMOL/HR
METHANE 3.1166 0.0 2.1961-02 3.1386 4.3923-02
ETHANE 3.3256 0.0 0.1616 3.4872 0.3232
PROPANE 15.8742 0.0 2.7989 18.6731 5.5978
N-BUTANE 0.0 15.0000 6.8587 21.8587 13.7175
1-BUTENE 0.0 21.0000 9.0466 30.0466 18.0932
1,3-BUTA 0.0 95.0000 41.5243 136.5243 83.0487
TOTAL FLOW:
LBMOL/HR 22.3165 131.0000 60.4122 213.7286 120.8245
LB/HR 850.0000 7188.8147 3280.9932 1.1320+04 6561.9864
CUFT/HR 1472.6295 8135.3222 84.7851 8814.7421 169.5702
STATE VARIABLES:
TEMP F 185.0000 185.0000 41.0000 126.7191 41.0000
PRES PSI 100.0000 100.0000 25.0000 100.0000 25.0000
VFRAC 1.0000 1.0000 0.0 0.7434 0.0
LFRAC 0.0 0.0 1.0000 0.2565 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -4.0234+04 2.9758+04 1.3635+04 1.7911+04 1.3635+04
BTU/LB -1056.3433 542.2708 251.0564 338.1758 251.0564
BTU/HR -8.9789+05 3.8983+06 8.2371+05 3.8281+06 1.6474+06
ENTROPY:
BTU/LBMOL-R -53.9876 -41.3689 -63.1321 -48.0510 -63.1321
BTU/LB-R -1.4174 -0.7538 -1.1624 -0.9072 -1.1624
DENSITY:
LBMOL/CUFT 1.5154-02 1.6103-02 0.7125 2.4247-02 0.7125
LB/CUFT 0.5772 0.8836 38.6977 1.2841 38.6977
AVG MW 38.0883 54.8764 54.3100 52.9634 54.3100
S4 S5 VP
--------
STREAM ID S4 S5 VP
FROM : S1 P1 F1
TO : P1 M1 ----
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID VAPOR
METHANE 2.1961-02 2.1961-02 3.0947
ETHANE 0.1616 0.1616 3.1639
PROPANE 2.7988 2.7988 13.0753
N-BUTANE 6.8587 6.8587 8.1411
1-BUTENE 9.0466 9.0466 11.9533
1,3-BUTA 41.5243 41.5243 53.4756
TOTAL FLOW:
LBMOL/HR 60.4121 60.4121 92.9041
LB/HR 3280.9860 3280.9860 4757.8142
CUFT/HR 84.7849 84.9629 1.9089+04
SM-7-3
STATE VARIABLES:
TEMP F 41.0000 42.9764 41.0000
PRES PSI 25.0000 100.0000 25.0000
VFRAC 0.0 0.0 1.0000
LFRAC 1.0000 1.0000 0.0
SFRAC 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.3635+04 1.3701+04 1.2859+04
BTU/LB 251.0555 252.2685 251.0950
BTU/HR 8.2371+05 8.2769+05 1.1947+06
ENTROPY:
BTU/LBMOL-R -63.1321 -63.0428 -44.6262
BTU/LB-R -1.1624 -1.1607 -0.8714
DENSITY:
LBMOL/CUFT 0.7125 0.7110 4.8669-03
LB/CUFT 38.6977 38.6166 0.2492
AVG MW 54.3100 54.3100 51.2120
Selected Process Unit Output
BLOCK: F1 MODEL: FLASH2

------------------------------
INLET STREAM: S2
OUTLET VAPOR STREAM: VP
OUTLET LIQUID STREAM: S3
PROPERTY OPTION SET: RK-SOAVE STANDARD RKS EQUATION OF STATE
*** MASS AND ENERGY BALANCE ***

IN OUT RELATIVE DIFF.
TOTAL BALANCE
MOLE(LBMOL/HR) 213.729 213.729 0.132980E-15
MASS(LB/HR ) 11319.8 11319.8 -0.299808E-10
ENTHALPY(BTU/HR ) 0.382808E+07 0.284209E+07 0.257568
*** INPUT DATA ***

TWO PHASE TP FLASH
SPECIFIED TEMPERATURE F 41.0000
SPECIFIED PRESSURE PSI 25.0000
MAXIMUM NO. ITERATIONS 30
CONVERGENCE TOLERANCE 0.00010000
*** RESULTS ***

OUTLET TEMPERATURE F 41.000
OUTLET PRESSURE PSI 25.000
HEAT DUTY BTU/HR -0.98599E+06
VAPOR FRACTION 0.43468
V-L PHASE EQUILIBRIUM :
COMP F(I) X(I) Y(I) K(I)

METHANE 0.14685E-01 0.36352E-03 0.33311E-01 91.633
ETHANE 0.16316E-01 0.26757E-02 0.34056E-01 12.728
PROPANE 0.87369E-01 0.46330E-01 0.14074 3.0378
N-BUTANE 0.10227 0.11353 0.87630E-01 0.77185
1-BUTENE 0.14058 0.14975 0.12866 0.85920
1,3-BUTA 0.63877 0.68735 0.57560 0.83742
SM-7-4
The results above are for Case 1 (50% bottoms recycle) in Figure 7.14. For
Cases 2 (25% bottoms recycle) and 3 (no recycle), the vapor and liquid product
streams are identical to those for Case 1. That is, the product streams and the
heat removed from the flash vessel are identical regardless of the amount of
recycle. This is because the vapor and liquid product streams are in phase
equilibrium at the conditions of the flash vessel.
Acyclic Simulation Flowsheet
Since the product streams do not change with recycle flow rate, they can be
computed at the conditions of the flash vessel. Then, given the recycle fraction,
the other streams can be computed. This is accomplished using the following
ASPEN PLUS simulation flowsheet.
MUL2 S3
MULT
VP
FEED1
MIX1 D1 F1 MUL1 S4 P1 S5 M1 S2
FEED2
MIXER S1 DUPL S1A FLASH2 MULT PUMP MIXER
LP
LPB
S1B D2
DUPL
LPA
Using this flowsheet, identical results are obtained.
SM-7-5
7.1 b. ASPEN PLUS Flowsheet – identical to that in Exer. 7.1a. The recycle flow rate
is zero.
Simulation results can be reproduced using the file EXER5-1B.bkp in the ASPEN
folder, under Computer Solution Files, associated with the Solution Manual on
the Wiley web site for this book.

850 lb/hr
FT
$OLVER02
VP
FEED1 S2 S2* T
M1 F1
$OLVER01 FLASH2
FEED2 MIXER
S5 S3
S4 S1 LP
P1
PUMP FSPLIT
ASPEN PLUS Program – identical to that in c with following change and

addition:
BLOCK S1 FSPLIT
FRAC S4 0
DESIGN-SPEC OVHD
DEFINE OVHD STREAM-VAR STREAM=VP SUBSTREAM=MIXED &
VARIABLE=MASS-FLOW
SPEC "OVHD" TO "850"
TOL-SPEC "0.01 "
VARY BLOCK-VAR BLOCK=F1 VARIABLE=TEMP SENTENCE=PARAM
LIMITS "0" "100"
SEQUENCE USED WAS:

$OLVER01 *P1 M1
| $OLVER02 F1
| (RETURN $OLVER02)
| S1
(RETURN $OLVER01)
SM-7-6
Stream Variables
FEED1 FEED2 LP S2 S3
--------------------
STREAM ID FEED1 FEED2 LP S2 S3

FROM : ---- ---- S1 M1 F1
TO : M1 M1 ---- F1 S1
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR LIQUID VAPOR LIQUID
METHANE 3.1166 0.0 0.2336 3.1166 0.2336
ETHANE 3.3256 0.0 1.3166 3.3256 1.3166
PROPANE 15.8742 0.0 11.8773 15.8742 11.8773
N-BUTANE 0.0 15.0000 13.9004 15.0000 13.9004
1-BUTENE 0.0 21.0000 19.2870 21.0000 19.2870
1,3-BUTA 0.0 95.0000 87.4743 95.0000 87.4743
TOTAL FLOW:
LBMOL/HR 22.3165 131.0000 134.0894 153.3165 134.0894
LB/HR 850.0000 7188.8147 7188.8082 8038.8147 7188.8082
CUFT/HR 1472.6295 8135.3222 184.0987 9621.0871 184.0987
STATE VARIABLES:
TEMP F 185.0000 185.0000 24.4944 184.7458 24.4944
PRES PSI 100.0000 100.0000 25.0000 100.0000 25.0000
VFRAC 1.0000 1.0000 0.0 1.0000 0.0
LFRAC 0.0 0.0 1.0000 0.0 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -4.0234+04 2.9758+04 1.0003+04 1.9570+04 1.0003+04
BTU/LB -1056.3433 542.2708 186.5833 373.2382 186.5833
BTU/HR -8.9789+05 3.8983+06 1.3413+06 3.0004+06 1.3413+06
ENTROPY:
BTU/LBMOL-R -53.9876 -41.3689 -64.4340 -42.3843 -64.4340
BTU/LB-R -1.4174 -0.7538 -1.2018 -0.8083 -1.2018
DENSITY:
LBMOL/CUFT 1.5154-02 1.6103-02 0.7283 1.5935-02 0.7283
LB/CUFT 0.5772 0.8836 39.0486 0.8355 39.0486
AVG MW 38.0883 54.8764 53.6120 52.4327 53.6120
S4 S5 VP
--------
STREAM ID S4 S5 VP
FROM : S1 P1 F1
TO : P1 M1 ----
SUBSTREAM: MIXED
PHASE: MISSING MISSING VAPOR
METHANE 0.0 0.0 2.8829
ETHANE 0.0 0.0 2.0090
PROPANE 0.0 0.0 3.9969
N-BUTANE 0.0 0.0 1.0995
1-BUTENE 0.0 0.0 1.7129
1,3-BUTA 0.0 0.0 7.5256
TOTAL FLOW:
LBMOL/HR 0.0 0.0 19.2270
LB/HR 0.0 0.0 850.0064
CUFT/HR 0.0 0.0 3852.4889
SM-7-7
STATE VARIABLES:
TEMP F MISSING MISSING 24.4944
PRES PSI MISSING 100.0000 25.0000
VFRAC MISSING MISSING 1.0000
LFRAC MISSING MISSING 0.0
SFRAC MISSING MISSING 0.0
ENTHALPY:
BTU/LBMOL MISSING MISSING -3598.6336
BTU/LB MISSING MISSING -81.4008
BTU/HR MISSING MISSING -6.9191+04
ENTROPY:
BTU/LBMOL-R MISSING MISSING -43.0246
BTU/LB-R MISSING MISSING -0.9732
DENSITY:
LBMOL/CUFT MISSING MISSING 4.9908-03
LB/CUFT MISSING MISSING 0.2206
AVG MW MISSING MISSING 44.2088

------------------------------
INLET STREAM: S2
OUTLET LIQUID STREAM: S3

TOTAL BALANCE
MOLE(LBMOL/HR) 153.317 153.317 -0.185379E-15
MASS(LB/HR ) 8038.81 8038.81 -0.138062E-11
*** INPUT DATA ***

TWO PHASE TP FLASH
*** RESULTS ***

HEAT DUTY BTU/HR -0.17283E+07

METHANE 0.20328E-01 0.17428E-02 0.14994 86.038
ETHANE 0.21691E-01 0.98189E-02 0.10449 10.641
PROPANE 0.10354 0.88578E-01 0.20788 2.3469
N-BUTANE 0.97837E-01 0.10367 0.57185E-01 0.55163
1-BUTENE 0.13697 0.14384 0.89091E-01 0.61939
1,3-BUTA 0.61963 0.65236 0.39141 0.60000
SM-7-8
HYSYS Solution
(a) The HYSYS PFD for this exercise is shown below. Table 1 below shows the obtained
results for 50% recycle in TEE-100. The bypass fraction has no effect on either the flow
rates or compositions of the Overhead and Product streams. Exer7_1A.hsc (in the
HYSYS folder, under Computer Solution Files, associated with the Solution Manual on
the Wiley web site for this book) can be used to reproduce these results.
(b) The amended PFD for this exercise is shown below. Note having determined that the
recycle stream has no impact of the effluent streams, it has been set to zero in this part.
The Adjust module is used to manipulate the temperature of the flash unit, and a value
of –4.4 oC brings the vapor flow rate to the desired value of 850 lb/hr. See Table 2.
Exer7_1A.hsc can be used to reproduce these results.
SM-7-9
Table 1. HYSYS-generated Stream Data for Exercise 7.1(a).
Name Feed R* R Mixed Feed Valve Eff Overhead Bottoms Product Recycle
Vapour Fraction 1 0 0 0.8336 0.9958 1 0 0 0
Temperature (C) 85 39.88 39.88 52.71 7.223 5 5 5 5
Pressure (psia) 100 100 100 100 25 25 25 25 25
Molar Flow (lbmole/hr) 153.1 54.47 54.47 207.6 207.6 98.61 108.9 54.47 54.47
Mass Flow (lb/hr) 8026 2960 2960 1.10E+04 1.10E+04 5066 5919 2960 2960
Liquid Volume Flow (barrel/day) 929.8 334.7 334.7 1265 1265 595.1 669.4 334.7 334.7
Heat Flow (Btu/hr) 3.04E+06 8.71E+05 8.71E+05 3.91E+06 3.91E+06 1.35E+06 1.53E+06 7.66E+05 7.66E+05
Comp Mass Flow (Methane) (lb/hr) 50 0.2928 0.2928 50.2928 50.2928 49.7072 0.5856 0.2928 0.2928
Comp Mass Flow (Ethane) (lb/hr) 100 4.0948 4.0948 104.0948 104.0948 95.9052 8.1895 4.0948 4.0948
Comp Mass Flow (Propane) (lb/hr) 700 107.11 107.11 807.11 807.11 592.89 214.22 107.11 107.11
Comp Mass Flow (n-Butane) (lb/hr) 870 361.992 361.992 1231.992 1231.992 508.008 723.9841 361.992 361.992
Comp Mass Flow (1-Butene) (lb/hr) 1176 456.2277 456.2277 1632.228 1632.228 719.7723 912.4554 456.2277 456.2277
Comp Mass Flow (13-Butadiene)
(lb/hr) 5130 2029.899 2029.899 7159.899 7159.899 3100.101 4059.797 2029.899 2029.899
Compositions
Name Feed R* Mixed Feed Overhead Bottoms Product Recycle R Valve Eff
Comp Mole Frac (Methane) 0.0204 0.0003 0.0151 0.0314 0.0003 0.0003 0.0003 0.0003 0.0151
Comp Mole Frac (Ethane) 0.0217 0.0025 0.0167 0.0323 0.0025 0.0025 0.0025 0.0025 0.0167
Comp Mole Frac (Propane) 0.1037 0.0446 0.0882 0.1363 0.0446 0.0446 0.0446 0.0446 0.0882
Comp Mole Frac (n-Butane) 0.0978 0.1143 0.1021 0.0886 0.1143 0.1143 0.1143 0.1143 0.1021
Comp Mole Frac (1-Butene) 0.1369 0.1493 0.1402 0.1301 0.1493 0.1493 0.1493 0.1493 0.1402
Comp Mole Frac (13-Butadiene) 0.6195 0.689 0.6377 0.5812 0.689 0.689 0.689 0.689 0.6377
Energy Streams
Name FLASH-DUTY Pump_Duty
Heat Flow (Btu/hr) -1.04E+06 1.05E+05
SM-7-10
Table 2. HYSYS-generated Stream Data for Exercise 7.1(b).
Name Feed R* R Mixed Feed Valve Eff Overhead Bottoms Product Recycle
Vapour Fraction 1 0 0 1 1 1 0 0 0
Temperature (C) 85 30.81 30.81 85 78.26 -4.446 -4.446 -4.446 -4.446
Pressure (psia) 100 100 100 100 25 25 25 25 25
Molar Flow (lbmole/hr) 153.1 0 0 153.1 153.1 19.24 133.8 133.8 0
Mass Flow (lb/hr) 8026 0 0 8026 8026 850 7176 7176 0
Liquid Volume Flow (barrel/day) 929.8 0 0 929.8 929.8 109.6 820.2 820.2 0
Heat Flow (Btu/hr) 3.04E+06 0 0 3.04E+06 3.04E+06 -6.74E+04 1.38E+06 1.38E+06 0
Comp Mass Flow (Methane) (lb/hr) 50 0 0 50 50 46.3338 3.6662 3.6662 0
Comp Mass Flow (Ethane) (lb/hr) 100 0 0 100 100 60.764 39.236 39.236 0
Comp Mass Flow (Propane) (lb/hr) 700 0 0 700 700 176.3363 523.6637 523.6637 0
Comp Mass Flow (n-Butane) (lb/hr) 870 0 0 870 870 63.5722 806.4278 806.4278 0
Comp Mass Flow (1-Butene) (lb/hr) 1176 0 0 1176 1176 96.6656 1079.334 1079.334 0
Comp Mass Flow (13-Butadiene) (lb/hr) 5130 0 0 5130 5130 406.3275 4723.673 4723.673 0
Compositions
Name Feed R* Mixed Feed Overhead Bottoms Product Recycle R Valve Eff
Comp Mole Frac (Methane) 0.0204 0.0017 0.0204 0.1501 0.0017 0.0017 0.0017 0.0017 0.0204
Comp Mole Frac (Ethane) 0.0217 0.0097 0.0217 0.1051 0.0097 0.0097 0.0097 0.0097 0.0217
Comp Mole Frac (Propane) 0.1037 0.0887 0.1037 0.2079 0.0887 0.0887 0.0887 0.0887 0.1037
Comp Mole Frac (n-Butane) 0.0978 0.1037 0.0978 0.0569 0.1037 0.1037 0.1037 0.1037 0.0978
Comp Mole Frac (1-Butene) 0.1369 0.1437 0.1369 0.0896 0.1437 0.1437 0.1437 0.1437 0.1369
Comp Mole Frac (13-Butadiene) 0.6195 0.6524 0.6195 0.3905 0.6524 0.6524 0.6524 0.6524 0.6195
Energy Streams
Name FLASH-DUTY Pump_Duty
Heat Flow (Btu/hr) -1.73E+06 0
SM-7-11
CHEMCAD 5.2.3 Solution
Exercise 7.1a – Flash with Recycle Page 1
Case 2, where recycle of bottoms from the flash drum is 25% is given in
detail, followed by a summary and comparison for the other two cases.
The tear (cut) stream is defaulted to stream 7.
Initial guess of the flow rates in the tear stream is zero.
Tolerance for the flow rates in the tear stream is increased from the default
of 10-3 to 10-5.
FLOWSHEET SUMMARY
Equipment Label Stream Numbers
1 MIXE 7 1 -2
2 FLAS 2 -3 -4
3 DIVI 4 -6 -5
4 PUMP 6 -7
STREAM CONNECTIONS
Stream Equipment Stream Equipment Stream Equipment
From To From To From To
1 1 4 2 3 7 4 1
2 1 2 5 3
3 2 6 3 4
Calculation mode : Sequential

Flash algorithm : Normal
Equipment Calculation Sequence

1 2 3 4
Equipment Recycle Sequence

1 2 3 4
Recycle Cut Streams

7
Recycle Convergence Method: Direct Substitution

Max. loop iterations 40
Recycle Convergence Tolerance
Flow rate 1.000E-005

Temperature 1.000E-003
Pressure 1.000E-003
Enthalpy 1.000E-003
Vapor frac. 1.000E-003
COMPONENTS
ID # Name
1 2 Methane
2 3 Ethane
3 4 Propane
4 6 N-Butane
5 24 1-Butene
6 28 1,3-Butadiene
SM-7-12
THERMODYNAMICS
K-value model : SRK

Enthalpy model : SRK
Liquid density : Library
Overall Mass Balance lbmol/h lb/h

Input Output Input Output
Methane 3.117 3.117 50.000 50.000
Ethane 3.326 3.326 100.000 100.000
Propane 15.874 15.874 700.000 700.000
N-Butane 14.968 14.968 870.000 870.000
1-Butene 20.960 20.960 1176.000 1176.000
1,3-Butadiene 94.838 94.838 5130.000 5130.001
Total 153.083 153.083 8026.000 8026.001
EQUIPMENT SUMMARIES
Mixer Summary
Equip. No. 1
Name
Output Pressure psia 100.0000
Flash Summary
Equip. No. 2
Name
Flash Mode 2
Param 1 5.0000
Param 2 25.0000
Heat duty MMBtu/h -1.0086
K values:
Methane 91.006
Ethane 12.692
Propane 3.044
N-Butane 0.733
1-Butene 0.897
1,3-Butadiene 0.831
Divider Summary
Equip. No. 3
Name
Output stream #1 0.2500
SM-7-13
Pump Summary
Equip. No. 4
Name
Output pressure psia 100.0000
Efficiency 1.0000
Calculated power hp 0.1592
Calculated Pout psia 100.0000
Head ft 277.4139
Vol. flow rate ft3/hr 29.1672
Mass flow rate lb/h 1135.5067
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name Fresh Combined Vapor Flash
feed feed product liquid
Temp C 85.0000 53.0367 5.0000 5.0000
Pres psia 100.0000 100.0000 25.0000 25.0000
Enth MMBtu/h 3.0356 3.3237 1.1642 1.1509
Vapor mass fraction 1.0000 0.98195 1.0000 0.00000
Total lb/h 8026.0000 9161.5078 4619.4814 4542.0269
Flowrates in lb/h
Methane 50.0000 50.1262 49.6214 0.5048
Ethane 100.0000 101.7289 94.8132 6.9157
Propane 700.0000 743.3376 569.9869 173.3507
N-Butane 870.0000 1011.1144 446.6582 564.4562
1-Butene 1176.0000 1347.0443 662.8683 684.1760
1,3-Butadiene 5130.0000 5908.1567 2795.5334 3112.6235
Stream No. 5 6 7
Stream Name Liquid Recycle Recycle
product to pump to feed
Temp C 5.0000 5.0000 5.1992
Pres psia 25.0000 25.0000 100.0000
Enth MMBtu/h 0.86319 0.28773 0.28814
Vapor mass fraction 0.00000 0.00000 0.00000
Total lb/h 3406.5203 1135.5067 1135.5067
Flowrates in lb/h
Methane 0.3786 0.1262 0.1262
Ethane 5.1868 1.7289 1.7289
Propane 130.0130 43.3377 43.3377
N-Butane 423.3421 141.1140 141.1140
1-Butene 513.1320 171.0440 171.0440
1,3-Butadiene 2334.4678 778.1559 778.1559
SM-7-14
Comparison of results from Cases 1, 2, and 3.
The only feed to the process is stream 1 (Fresh feed).

The only products from the process are streams 3 (Vapor product) and 5
(Liquid product).
The following is a comparison of the component and total flow rates for
stream 3 (Vapor product), which is the Overhead.
Flow rates in Vapor product (stream 3) in lb/hr:

Component: Case 1 Case 2 Case 3
50% recycle 25% recycle 0% recycle
Methane 49.62 49.62 49.62
Ethane 94.81 94.81 94.81
Propane 569.99 569.99 569.99
N-Butane 446.66 446.66 446.66
1-Butene 662.87 662.87 662.87
1,3-Butadiene 2,795.54 2,795.53 2,795.53
Total 4,619.49 4,619.48 4,619.48
The results show that the recycle ratio has no effect on the component flow
rates in the Vapor product. By material balance, this is also true for the
Liquid product. This result occurs because these two products are in phase
equilibrium at the same specified temperature and pressure for all three cases
with the same Fresh feed. Even if the vapor were recycled also, the component
flow rates in the Vapor product would be unchanged.
SM-7-15
Exercise 7.1b – Flash Temperature Page 1
Control of flash temperature to give a vapor product rate of 850 lb/hr.

Controller, CONT, used in feedback control mode.
Initial guess of flash temperature is 5oC.
CHEMCAD 5.2.3
FLOWSHEET SUMMARY
1 FLAS 1 -2 -3
2 CONT 2 -4
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1 2
3 1
4 2


1 2
COMPONENTS
ID # Name
1 2 Methane
2 3 Ethane
3 4 Propane
4 6 N-Butane
5 24 1-Butene
6 28 1,3-Butadiene
THERMODYNAMICS
K-value model : SRK


Methane 3.117 3.117 50.000 50.000
Ethane 3.326 3.326 100.000 100.000
Propane 15.874 15.874 700.000 700.000
N-Butane 14.968 14.968 870.000 870.000
1-Butene 20.960 20.960 1176.000 1176.000
1,3-Butadiene 94.838 94.838 5130.000 5130.000
Total 153.083 153.083 8026.000 8026.000
SM-7-16
Exercise 7.1b – Flash with Recycle Page 2
EQUIPMENT SUMMARIES
Flash Summary
Equip. No. 1
Name
Flash Mode 2
Param 1 -4.1090
Param 2 25.0000
Heat duty MMBtu/h -1.7306
K values:
Methane 85.386
Ethane 10.633
Propane 2.356
N-Butane 0.524
1-Butene 0.648
1,3-Butadiene 0.597
Controller Summary
Equip. No. 2
Name
Mode 2
Equip. no. adjusted 1
Variable No. 3
Minimum Value -50.0000
Maximum Value 50.0000
Unit of Min/Max values 2
Sign Flag 0
Measured variables:
Number 2
Variable 6
Constant 850.0000
Units 1
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name Feed Liquid Vapor
product product
Temp C 85.0000 -4.1090 -4.1090 -4.1090
Pres psia 100.0000 25.0000 25.0000 25.0000
Enth MMBtu/h 3.0356 -0.066288 1.3713 -0.066288
Vapor mass fraction 1.0000 1.0000 0.00000 1.0000
Total lb/h 8026.0000 850.1636 7175.8359 850.1636
Flowrates in lb/h
Methane 50.0000 46.2320 3.7680 46.2320
Ethane 100.0000 60.4415 39.5585 60.4415
Propane 700.0000 177.0210 522.9790 177.0210
N-Butane 870.0000 60.9174 809.0826 60.9174
1-Butene 1176.0000 100.2377 1075.7622 100.2377
1,3-Butadiene 5130.0000 405.3139 4724.6860 405.3139
SM-7-17
To the Instructor: Before assigning this exercise, please see Section 7.4 – Case
Studies – especially the case study on Hydrodealkylation of Toluene to Benzene.
ASPEN PLUS Solution
ASPEN PLUS Flowsheet - simulation results can be reproduced using the

file EXER7-2.bkp in the ASPEN folder, under Computer
Solution Files, associated with the Solution Manual on the
Wiley web site for this book.
FEED
M1
RECYCLE GAS-RECY
VP
CWIN
S1 H3 F1
H2 S7 S8
H1
S2
CWEX
S3
LPR
S6
P1
S4 S5
REC LP
M2
R1 S1
SM-7-18
FEED CWIN
100°F
F
$OLVER02
RECYCLE GAS-RECY
M1
MIXER VP
T
CWEX
S1 H3
S7 HEATX S8 F1
FLASH2
100°F
∆P=5 484psia
U=60 H1
∆P=5 HEATX
1000°F
1200°F H2 S2 S6*
HEATER LPR
∆P=70
1150°F
S3
$OLVER01 $OLVER03
T Recycle
S6 Fraction
LP
R1 S4 M2 S5 P1 REC S1
RSTOIC MIXER PUMP FSPLIT
1268°F
∆P=0
SM-7-19
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
H2 H2 H2 /
BENZENE C6H6 BENZENE /
TOLUENE C7H8 TOLUENE /
BIPHENYL C12H10 BIPHENYL /
WATER H2O WATER
FLOWSHEET
BLOCK M1 IN=GAS-RECY FEED RECYCLE OUT=S1
BLOCK H1 IN=S6 S1 OUT=S7 S2
BLOCK H2 IN=S2 OUT=S3
BLOCK R1 IN=S3 OUT=S4
BLOCK M2 IN=S4 S5 OUT=S6
BLOCK P1 IN=REC OUT=S5
BLOCK F1 IN=S8 OUT=VP LPR
BLOCK H3 IN=S7 CWIN OUT=S8 CWEX
BLOCK S1 IN=LPR OUT=REC LP
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL H2 METHANE -.0222000000
BPVAL H2 TOLUENE .3900000000
BPVAL METHANE TOLUENE .0978000000
BPVAL METHANE H2 -.0222000000
BPVAL METHANE BENZENE .0209000000
BPVAL BENZENE METHANE .0209000000
BPVAL TOLUENE METHANE .0978000000
BPVAL TOLUENE H2 .3900000000
STREAM CWIN
SUBSTREAM MIXED TEMP=90 PRES=50
MOLE-FLOW WATER 10000
STREAM FEED
MOLE-FLOW TOLUENE 274.2
STREAM GAS-RECY
MOLE-FLOW H2 2045.9 / METHANE 3020.8 / BENZENE 42.8 / &
TOLUENE 5.3
STREAM RECYCLE
MOLE-FLOW BENZENE 3.4 / TOLUENE 82.5 / BIPHENYL 1
BLOCK M1 MIXER
BLOCK M2 MIXER
BLOCK S1 FSPLIT
FRAC REC 0.5
BLOCK H2 HEATER
PARAM TEMP=1200 PRES=-70
BLOCK F1 FLASH2
PARAM TEMP=100 PRES=0
BLOCK H1 HEATX
PARAM T-COLD=1000 PRES-HOT=-5 PRES-COLD=-5 &
U-OPTION=CONSTANT
FEEDS HOT=S6 COLD=S1
PRODUCTS HOT=S7 COLD=S2
HEAT-TR-COEF U=60
BLOCK H3 HEATX
PARAM T-HOT=100 PRES-HOT=-5 PRES-COLD=-5 U-OPTION=CONSTANT
FEEDS HOT=S7 COLD=CWIN
SM-7-20
PRODUCTS HOT=S8 COLD=CWEX
HEAT-TR-COEF U=50
BLOCK R1 RSTOIC
PARAM TEMP=1268 PRES=0 SERIES=YES
STOIC 1 MIXED H2 -1 / TOLUENE -1 / METHANE 1 / &
BENZENE 1
STOIC 2 MIXED BENZENE -2 / H2 1 / BIPHENYL 1
CONV 1 MIXED TOLUENE 0.75
CONV 2 MIXED BENZENE 0.02
BLOCK P1 PUMP
PARAM PRES=494
DESIGN-SPEC CWFLOW
DEFINE TCWEX STREAM-VAR STREAM=CWEX SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TCWEX" TO "120"
TOL-SPEC "0.001"
VARY MOLE-FLOW STREAM=CWIN SUBSTREAM=MIXED COMPONENT=WATER
LIMITS "1000" "100000"
DESIGN-SPEC TEMPS6
DEFINE TEMPS6 STREAM-VAR STREAM=S6 SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TEMPS6" TO "1150"
TOL-SPEC "0.001"
VARY BLOCK-VAR BLOCK=S1 SENTENCE=FRAC VARIABLE=FRAC ID1=REC
LIMITS "0" "1"
SEQUENCE USED WAS:

M1
$OLVER01 H1
| $OLVER02 H3
| (RETURN $OLVER02)
| F1 H2 R1
| $OLVER03 S1 P1 M2
| (RETURN $OLVER03)
(RETURN $OLVER01)
SM-7-21
Stream Variables
CWEX CWIN FEED GAS-RECY LP

--------------------------
STREAM ID CWEX CWIN FEED GAS-RECY LP

FROM : H3 ---- ---- ---- S1
TO : ---- H3 M1 M1 ----
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID VAPOR LIQUID
H2 0.0 0.0 0.0 2045.9000 1.1782
METHANE 0.0 0.0 0.0 3020.8000 18.9580
BENZENE 0.0 0.0 0.0 42.8000 274.4741
TOLUENE 0.0 0.0 274.2000 5.3000 86.7403
BIPHENYL 0.0 0.0 0.0 0.0 4.1764
WATER 3.7339+04 3.7339+04 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 3.7339+04 3.7339+04 274.2000 5114.8000 385.5271
LB/HR 6.7268+05 6.7268+05 2.5265+04 5.6418+04 3.0383+04
CUFT/HR 1.1107+04 1.0922+04 468.8259 5.5971+04 577.8080
STATE VARIABLES:
TEMP F 120.0006 90.0000 75.0000 121.0000 100.0000
PRES PSI 45.0000 50.0000 569.0000 569.0000 484.0000
VFRAC 0.0 0.0 0.0 1.0000 0.0
LFRAC 1.0000 1.0000 1.0000 0.0 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -1.2337+05 -1.2399+05 5245.7431 -1.8339+04 1.6002+04
BTU/LB -6848.1123 -6882.6913 56.9319 -1662.5870 203.0428
BTU/HR -4.6066+09 -4.6298+09 1.4384+06 -9.3800+07 6.1691+06
ENTROPY:
BTU/LBMOL-R -39.2919 -40.3961 -81.8307 -17.0839 -61.2572
BTU/LB-R -2.1810 -2.2423 -0.8881 -1.5488 -0.7772
DENSITY:
LBMOL/CUFT 3.3619 3.4185 0.5848 9.1383-02 0.6672
LB/CUFT 60.5660 61.5866 53.8897 1.0079 52.5832
AVG MW 18.0152 18.0152 92.1405 11.0303 78.8090
LPR REC RECYCLE S1 S2

---------------------
STREAM ID LPR REC RECYCLE S1 S2

FROM : F1 S1 ---- M1 H1
TO : S1 P1 M1 H1 H2
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID MIXED VAPOR
H2 1.7743 0.5961 0.0 2045.9000 2045.9000
METHANE 28.5508 9.5928 0.0 3020.8000 3020.8000
BENZENE 413.3583 138.8842 3.4000 46.2000 46.2000
TOLUENE 130.6310 43.8907 82.5000 362.0000 362.0000
BIPHENYL 6.2896 2.1132 1.0000 1.0000 1.0000
WATER 0.0 0.0 0.0 0.0 0.0
SM-7-22
TOTAL FLOW:
LBMOL/HR 580.6042 195.0771 86.9000 5475.9000 5475.9000
LB/HR 4.5757+04 1.5374+04 8021.3906 8.9704+04 8.9704+04
CUFT/HR 870.1796 292.3715 166.6175 5.6669+04 1.5426+05
STATE VARIABLES:
TEMP F 100.0000 100.0000 250.0000 124.8070 1000.0000
PRES PSI 484.0000 484.0000 569.0000 569.0000 564.0000
VFRAC 0.0 0.0 0.0 0.9267 1.0000
LFRAC 1.0000 1.0000 1.0000 7.3238-02 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.6002+04 1.6002+04 1.3401+04 -1.6654+04 -4555.0390
BTU/LB 203.0428 203.0428 145.1842 -1016.6376 -278.0576
BTU/HR 9.2906+06 3.1216+06 1.1646+06 -9.1197+07 -2.4943+07
ENTROPY:
BTU/LBMOL-R -61.2572 -61.2572 -69.5957 -21.1021 -8.3965
BTU/LB-R -0.7772 -0.7772 -0.7539 -1.2881 -0.5125
DENSITY:
LBMOL/CUFT 0.6672 0.6672 0.5215 9.6629-02 3.5497-02
LB/CUFT 52.5832 52.5832 48.1425 1.5829 0.5814
AVG MW 78.8090 78.8090 92.3059 16.3816 16.3816
S3 S4 S5 S6 S7
--------------
STREAM ID S3 S4 S5 S6 S7
FROM : H2 R1 P1 M2 H1
TO : R1 M2 M2 H1 H3
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR LIQUID VAPOR VAPOR
H2 2045.9000 1777.5770 0.5961 1778.1731 1778.1731
METHANE 3020.8000 3292.3000 9.5928 3301.8922 3301.8922
BENZENE 46.2000 311.3460 138.8842 450.2312 450.2312
TOLUENE 362.0000 90.5000 43.8907 134.3881 134.3881
BIPHENYL 1.0000 4.1770 2.1132 6.2901 6.2901
WATER 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 5475.9000 5475.9000 195.0771 5670.9749 5670.9749
LB/HR 8.9704+04 8.9704+04 1.5374+04 1.0508+05 1.0508+05
CUFT/HR 1.9978+05 2.0787+05 292.4023 2.0069+05 1.0115+05
STATE VARIABLES:
TEMP F 1200.0000 1268.0000 100.1610 1150.0000 354.1680
PRES PSI 494.0000 494.0000 494.0000 494.0000 489.0000
VFRAC 1.0000 1.0000 0.0 1.0000 1.0000
LFRAC 0.0 0.0 1.0000 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -1401.5925 -1343.6084 1.6009+04 -746.6996 -1.2430+04
BTU/LB -85.5587 -82.0192 203.1325 -40.2988 -670.8190
BTU/HR -7.6750+06 -7.3575+06 3.1229+06 -4.2345+06 -7.0488+07
ENTROPY:
BTU/LBMOL-R -6.1066 -5.5967 -61.2500 -6.6610 -16.4542
BTU/LB-R -0.3727 -0.3416 -0.7771 -0.3594 -0.8880
DENSITY:
LBMOL/CUFT 2.7410-02 2.6343-02 0.6671 2.8258-02 5.6067-02
LB/CUFT 0.4490 0.4315 52.5777 0.5235 1.0388
AVG MW 16.3816 16.3816 78.8090 18.5290 18.5290
SM-7-23
S8 VP
-----
STREAM ID S8 VP
FROM : H3 F1
TO : F1 ----
SUBSTREAM: MIXED
PHASE: MIXED VAPOR
H2 1778.1731 1776.3987
METHANE 3301.8922 3273.3413
BENZENE 450.2312 36.8729
TOLUENE 134.3881 3.7571
BIPHENYL 6.2901 5.1354-04
WATER 0.0 0.0
TOTAL FLOW:
LBMOL/HR 5670.9749 5090.3707
LB/HR 1.0508+05 5.9321+04
CUFT/HR 6.3560+04 6.2690+04
STATE VARIABLES:
TEMP F 100.0000 100.0000
PRES PSI 484.0000 484.0000
VFRAC 0.8976 1.0000
LFRAC 0.1023 0.0
SFRAC 0.0 0.0
ENTHALPY:
BTU/LBMOL -1.6531+04 -2.0242+04
BTU/LB -892.1841 -1736.9810
BTU/HR -9.3749+07 -1.0304+08
ENTROPY:
BTU/LBMOL-R -22.5002 -18.0796
BTU/LB-R -1.2143 -1.5514
DENSITY:
LBMOL/CUFT 8.9222-02 8.1199-02
LB/CUFT 1.6532 0.9462
AVG MW 18.5290 11.6535
BLOCK: R1 MODEL: RSTOIC

------------------------------
INLET STREAM: S3
OUTLET STREAM: S4

IN OUT GENERATION RELATIVE DIFF.
TOTAL BALANCE
MOLE(LBMOL/HR) 5475.90 5475.90 -0.112725E-12 -0.205856E-16
MASS(LB/HR ) 89704.2 89704.2 0.324442E-15
ENTHALPY(BTU/HR ) -0.767498E+07 -0.735747E+07 -0.413701E-01
*** INPUT DATA ***
SERIES REACTIONS
STOICHIOMETRY MATRIX:
REACTION # 1:
SUBSTREAM MIXED :
H2 -1.00 METHANE 1.00 BENZENE 1.00 TOLUENE -1.00
REACTION # 2:
SUBSTREAM MIXED :
H2 1.00 BENZENE -2.00 BIPHENYL 1.00
SM-7-24
REACTION CONVERSION SPECS: NUMBER= 2
REACTION # 1:
SUBSTREAM:MIXED KEY COMP:TOLUENE CONV FRAC: 0.7500
REACTION # 2:
SUBSTREAM:MIXED KEY COMP:BENZENE CONV FRAC: 0.2000E-01
TWO PHASE TP FLASH

SPECIFIED TEMPERATURE F 1,268.00
PRESSURE DROP PSI 0.0
*** RESULTS ***

HEAT DUTY BTU/HR 0.31752E+06
REACTION EXTENTS:
REACTION REACTION
NUMBER EXTENT
LBMOL/HR
1 271.50
2 3.1770

H2 0.32462 0.32462 0.32462 MISSING
METHANE 0.60123 0.60123 0.60123 MISSING
BENZENE 0.56858E-01 0.56858E-01 0.56858E-01 MISSING
TOLUENE 0.16527E-01 0.16527E-01 0.16527E-01 MISSING
BIPHENYL 0.76280E-03 0.76280E-03 0.76280E-03 MISSING
BLOCK: H1 MODEL: HEATX

-----------------------------
HOT SIDE:
---------
INLET STREAM: S6
OUTLET STREAM: S7
COLD SIDE:
----------
INLET STREAM: S1
OUTLET STREAM: S2

TOTAL BALANCE
MOLE(LBMOL/HR) 11146.9 11146.9 0.000000E+00
MASS(LB/HR ) 194782. 194782. 0.000000E+00
SM-7-25
*** INPUT DATA ***
FLASH SPECS FOR HOT SIDE:

TWO PHASE FLASH
FLASH SPECS FOR COLD SIDE:

TWO PHASE FLASH
FLOW DIRECTION AND SPECIFICATION:

COUNTERCURRENT HEAT EXCHANGER
SPECIFIED COLD OUTLET TEMP
SPECIFIED VALUE F 1000.0000
LMTD CORRECTION FACTOR 1.00000
PRESSURE SPECIFICATION:
HOT SIDE PRESSURE DROP PSI 5.0000
COLD SIDE PRESSURE DROP PSI 5.0000
HEAT TRANSFER COEFFICIENT SPECIFICATION:

OVERALL COEFFICIENT BTU/HR-SQFT-R 60.0000
*** OVERALL RESULTS ***
STREAMS:
--------------------------------------
| |
S6 ----->| HOT |-----> S7
T= 1.1500D+03 | | T= 3.5417D+02
P= 4.9400D+02 | | P= 4.8900D+02
V= 1.0000D+00 | | V= 1.0000D+00
| |
S2 <-----| COLD |<----- S1
T= 1.0000D+03 | | T= 1.2481D+02
P= 5.6400D+02 | | P= 5.6900D+02
V= 1.0000D+00 | | V= 9.2676D-01
--------------------------------------
DUTY AND AREA:

CALCULATED HEAT DUTY BTU/HR 66253716.1326
CALCULATED (REQUIRED) AREA SQFT 5908.7489
HEAT TRANSFER COEFFICIENT:

AVERAGE COEFFICIENT (DIRTY) BTU/HR-SQFT-R 60.0000
LOG-MEAN TEMPERATURE DIFFERENCE:

LMTD (CORRECTED) F 186.8803
PRESSURE DROP:
SHELLSIDE, TOTAL PSI 5.0000
TUBESIDE, TOTAL PSI 5.0000
SM-7-26
BLOCK: H3 MODEL: HEATX
-----------------------------
HOT SIDE:
---------
INLET STREAM: S7
OUTLET STREAM: S8
COLD SIDE:
----------
INLET STREAM: CWIN
OUTLET STREAM: CWEX

TOTAL BALANCE
MOLE(LBMOL/HR) 43010.3 43010.3 0.000000E+00
MASS(LB/HR ) 777756. 777756. 0.000000E+00
*** INPUT DATA ***
FLASH SPECS FOR HOT SIDE:

TWO PHASE FLASH
FLASH SPECS FOR COLD SIDE:

TWO PHASE FLASH
FLOW DIRECTION AND SPECIFICATION:

COUNTERCURRENT HEAT EXCHANGER
SPECIFIED HOT OUTLET TEMP
SPECIFIED VALUE F 100.0000
PRESSURE SPECIFICATION:
HOT SIDE PRESSURE DROP PSI 5.0000
COLD SIDE PRESSURE DROP PSI 5.0000
HEAT TRANSFER COEFFICIENT SPECIFICATION:

OVERALL COEFFICIENT BTU/HR-SQFT-R 50.0000
*** OVERALL RESULTS ***
STREAMS:
--------------------------------------
| |
S7 ----->| HOT |-----> S8
T= 3.5417D+02 | | T= 1.0000D+02
P= 4.8900D+02 | | P= 4.8400D+02
V= 1.0000D+00 | | V= 8.9762D-01
| |
CWEX <-----| COLD |<----- CWIN
T= 1.2000D+02 | | T= 9.0000D+01
P= 4.5000D+01 | | P= 5.0000D+01
V= 0.0000D+00 | | V= 0.0000D+00
--------------------------------------
SM-7-27
DUTY AND AREA:
CALCULATED HEAT DUTY BTU/HR 23260571.1267
CALCULATED (REQUIRED) AREA SQFT 6544.3049
HEAT TRANSFER COEFFICIENT:

AVERAGE COEFFICIENT (DIRTY) BTU/HR-SQFT-R 50.0000
LOG-MEAN TEMPERATURE DIFFERENCE:

LMTD (CORRECTED) F 71.0865
PRESSURE DROP:
SHELLSIDE, TOTAL PSI 5.0000
TUBESIDE, TOTAL PSI 5.0000

------------------------------
INLET STREAM: S8
OUTLET LIQUID STREAM: LPR

TOTAL BALANCE
MOLE(LBMOL/HR) 5670.97 5670.97 0.000000E+00
MASS(LB/HR ) 105078. 105078. 0.175809E-08
ENTHALPY(BTU/HR ) -0.937488E+08 -0.937488E+08 0.650080E-07
*** INPUT DATA ***

TWO PHASE TP FLASH
PRESSURE DROP PSI 0.0
*** RESULTS ***

HEAT DUTY BTU/HR -6.0944

H2 0.31356 0.30561E-02 0.34897 114.19
METHANE 0.58224 0.49174E-01 0.64305 13.077
BENZENE 0.79392E-01 0.71195 0.72437E-02 0.10174E-01
TOLUENE 0.23698E-01 0.22499 0.73809E-03 0.32805E-02
BIPHENYL 0.11092E-02 0.10833E-01 0.10089E-06 0.93128E-05
Acyclic Simulation Flowsheet
As illustrated in Exercise 7.1, because the vapor and liquid product streams are
at the equilibrium conditions of the flash vessel, the product streams are
independent of the amount recycled. Hence, recycle calculations can be
avoided by performing a single flash calculation to determine the product
streams. Then, the flow rate of the recycle stream, which has the same
composition as the liquid product stream, is adjusted until the temperature of
stream S6 is 1,150°F. This is accomplished using the following simulation
flowsheet:
SM-7-28
FEED
CWIN
100°F
RECYCLE GAS-RECY
M1 F
MIXER $OLVER02
S1
VP1
S1B T
D1
DUPL
CWEX
H3
S1A S7 HEATX F1
S8 100°F FLASH2
484psia
∆P=5
H1A U=60 H1B
HEATER ∆P=5 HEATX
1000°F LPR
S2B
1150°F
1200°F H2 S2A T
HEATER $OLVER01
S6
∆P=70
S3
R1 S4 D2 S4B M2 S5 P1 REC MUL2

RSTOIC 1268°F DUPL MIXER PUMP MULT
∆P=0
VP
S4A
FWR 100°F
FLASH2 484psia
Models entire
Flash with Recycle
process LP
Using this flowsheet, identical results are obtained.
SM-7-29
HYSYS Solution
The PFD for the reaction section of the toluene hydrodealkylation process, shown below, was set
up based on the information in Figure 7.31. A reaction set consisting of two conversion reactions
was set up, with 75% conversion of toluene to benzene and 2% conversion of benzene to biphenyl.
The fraction of flash liquid recycled (33.6%) was manipulated by the Adjust operation to bring the
temperature in stream S-5 to 1,150 oF. The results of the simulation are summarized in Table 1
below, and can be reproduced by running the file Exer7_2.hsc (in the HYSYS folder, under
Computer Solution Files, associated with the Solution Manual on the Wiley web site for this
textbook).
SM-7-30
Table 1. HYSYS-generated Stream Data for Exercise 7.2.
Name Feed Recycle Gas Recycle S-1 S-2 S-3 S-4 S-5
Vapour Fraction 0 0 1 0.9266 1 1 1 1
Temperature (F) 75 250 121 124.6 1000 1200 1268 1150
Pressure (psia) 569 569 569 569 564 494 494 494
Molar Flow (lbmole/hr) 274.2 86.9 5115 5476 5476 5476 5476 5671
Mass Flow (lb/hr) 2.53E+04 8021 5.64E+04 8.97E+04 8.97E+04 8.97E+04 8.97E+04 1.05E+05
Heat Flow (Btu/hr) 1.45E+06 1.17E+06 -9.43E+07 -9.17E+07 -2.57E+07 -8.45E+06 -8.04E+06 -4.95E+06
Comp Molar Flow (Hydrogen) (lbmole/hr) 0 0 2045.9 2045.9 2045.9 2045.9 1777.577 1778.1544
Comp Molar Flow (Methane) (lbmole/hr) 0 0 3020.8 3020.8 3020.8 3020.8 3292.3 3302.6618
Comp Molar Flow (Benzene) (lbmole/hr) 0 3.4 42.8 46.2 46.2 46.2 311.346 450.0067
Comp Molar Flow (Toluene) (lbmole/hr) 274.2 82.5 5.3 362 362 362 90.5 134.1688
Comp Molar Flow (BiPhenyl) (lbmole/hr) 0 1 0 1 1 1 4.177 6.2882
Name S-10* S-10 S-6 S-7 Vapor Product S-8 Liquid Product S-9
Vapour Fraction 0 0 1 0.8974 1 0 0 0
Temperature (F) 100.1 100.1 358 100 100 100 100 100
Pressure (psia) 494 494 489 484 484 484 484 484
Molar Flow (lbmole/hr) 195.4 195.4 5671 5671 5089 581.9 386.5 195.4
Mass Flow (lb/hr) 1.54E+04 1.54E+04 1.05E+05 1.05E+05 5.93E+04 4.57E+04 3.04E+04 1.54E+04
Heat Flow (Btu/hr) 3.10E+06 3.10E+06 -7.09E+07 -9.43E+07 -1.04E+08 9.22E+06 6.12E+06 3.10E+06
Comp Molar Flow (Hydrogen) (lbmole/hr) 0.5774 0.5774 1778.1544 1778.1544 1776.4347 1.7197 1.1423 0.5774
Comp Molar Flow (Methane) (lbmole/hr) 10.3618 10.3618 3302.6618 3302.6618 3271.8019 30.8599 20.4981 10.3618
Comp Molar Flow (Benzene) (lbmole/hr) 138.6607 138.6607 450.0067 450.0067 37.0437 412.963 274.3023 138.6607
Comp Molar Flow (Toluene) (lbmole/hr) 43.6688 43.6688 134.1688 134.1688 4.1133 130.0555 86.3867 43.6688
Comp Molar Flow (BiPhenyl) (lbmole/hr) 2.1112 2.1112 6.2882 6.2882 0.0006 6.2876 4.1764 2.1112
Energy Streams
Name Furnace_Duty R_Duty C-Duty Flsh_Duty P_Duty
Heat Flow (Btu/hr) 1.73E+07 4.10E+05 2.34E+07 -1.24E-08 717.4
SM-7-31
Table 1 (Cont’d). HYSYS-generated Composition and Unit Ops Data for Exercise 7.2.
Compositions
Name Feed RecycleGas Recycle S-1 S-2 S-3 S-4 S-5
Comp Mole Frac (Hydrogen) 0 0 0.4 0.3736 0.3736 0.3736 0.3246 0.3135
Comp Mole Frac (Methane) 0 0 0.5906 0.5517 0.5517 0.5517 0.6012 0.5823
Comp Mole Frac (Benzene) 0 0.0391 0.0084 0.0084 0.0084 0.0084 0.0569 0.0793
Comp Mole Frac (Toluene) 1 0.9494 0.001 0.0661 0.0661 0.0661 0.0165 0.0237
Comp Mole Frac (BiPhenyl) 0 0.0115 0 0.0002 0.0002 0.0002 0.0008 0.0011
Name S-10* S-10 S-6 S-7 Vapor Product S-8 Liquid Product S-9
Comp Mole Frac (Hydrogen) 0.003 0.003 0.3135 0.3135 0.349 0.003 0.003 0.003
Comp Mole Frac (Methane) 0.053 0.053 0.5823 0.5823 0.6429 0.053 0.053 0.053
Comp Mole Frac (Benzene) 0.7097 0.7097 0.0793 0.0793 0.0073 0.7097 0.7097 0.7097
Comp Mole Frac (Toluene) 0.2235 0.2235 0.0237 0.0237 0.0008 0.2235 0.2235 0.2235
Comp Mole Frac (BiPhenyl) 0.0108 0.0108 0.0011 0.0011 0 0.0108 0.0108 0.0108
Operation Name Operation Type Feeds Products Operation Name Operation Type Feeds Products
MIX-100 Mixer Gas Recycle S-1 V-100 Separator S-7 S-8
Recycle Flsh_Duty Vapor Product
Feed Flsh_Duty
MIX-101 Mixer S-4 S-5 TEE-100 Tee S-8 Liquid Product
S-10* S-9
E-100 Heat Exchanger S-1 S-2 P-100 Pump S-9 S-10
S-5 S-6 P_Duty
E-101 Heater S-2 S-3 RCY-1 Recycle S-10 S-10*
Furnace_Duty ADJ-1 Adjust
CRV-100 Conversion Reactor S-3 Dummy
R_Duty S-4
R_Duty
E-102 Cooler S-6 S-7
C-Duty
SM-7-32
Exercise 7.2 – Toluene hydrodealkylation process – reactor section Page 1
Two reactors are used in series, one for the main reaction, the other for the
side reaction.
A feedback controller, CONT, is used to adjust the quench flow rate to
achieve the temperature of 1150oF for the quenched reactor effluent. An
initial value of 160 lbmol/hr is used for the quench flow rate specified in
the divider, unit 9.
By default, stream 11, the quenched reactor effluent is used as the tear
(cut) stream, but an initial guess is not provided.
The cooling water rate in heat exchanger, unit 6, is initially set at 10,000
lbmol/hr. The correct value is computed from the converged heat duty.
CHEMCAD 5.2.3
FLOWSHEET SUMMARY
1 MIXE 3 2 1 -4
2 HTXR 4 11 -5 -12
3 FIRE 5 -6
4 REAC 6 -7
5 REAC 7 -8
6 HTXR 12 18 -13 -19
7 FLAS 13 -14 -15
8 PUMP 16 -9
9 DIVI 15 -16 -17
10 CONT 10 -11
11 MIXE 8 9 -10
STREAM CONNECTIONS
1 1 8 5 11 15 7 9
2 1 9 8 11 16 9 8
3 1 10 11 10 17 9
4 1 2 11 10 2 18 6
5 2 3 12 2 6 19 6
6 3 4 13 6 7
7 4 5 14 7


1 2 3 4 5 6 7 9 8 11 10

2 3 4 5 6 7 9 8 11 10
Recycle Cut Streams

11

SM-7-33

Pressure 1.000E-003
Enthalpy 1.000E-003
Recycle calculation has converged.
COMPONENTS
ID # Name
1 1 Hydrogen
2 2 Methane
3 40 Benzene
4 41 Toluene
5 194 Diphenyl
6 62 Water
THERMODYNAMICS
K-value model : SRK


Hydrogen 2045.900 1777.577 4124.125 3583.240
Methane 3020.800 3292.300 48462.693 52818.359
Benzene 46.200 311.346 3608.867 24320.486
Toluene 362.000 90.500 33355.042 8338.761
Diphenyl 1.000 4.177 154.211 644.139
Water 42969.922 42969.922 774103.116 774103.116
Total 48445.820 48445.820 863808.063 863808.125
EQUIPMENT SUMMARIES
Mixer Summary
Equip. No. 1 11
Name
Output Pressure psia 569.0000 494.0000
SM-7-34
Heat Exchanger Summary
Equip. No. 2 6
Name
Pressure drop 1 psi 5.0000 5.0000
T Out Str 1 F 1000.0001 100.0000
T Out Str 2 F 120.0000
Calc Ht Duty MMBtu/h 66.2639 23.2290
LMTD (End points) F 186.9719 71.1780
LMTD Corr Factor 1.0000 1.0000
Utility Option: 0 1
Calc U Btu/hr-ft2-F 60.0000 50.0000
Calc Area ft2 5906 6527
Str1 Pout psia 564.0000 484.0000
Str2 Pout psia 489.0000 45.0000
Fired Heater Summary
Equip. No. 3
Name
Pressure Drop psi 70.0000
Temperature Out F 1200.0000
Heat Absorbed MMBtu/h 17.2854
Fuel Usage(SCF) 25608.0645
Reactor Summary
Equip. No. 4 5
Name
Thermal mode 2 2
Temperature F 1268.0000 1268.0000
Heat duty MMBtu/h 0.2346 0.0367
Key Component 4 3
Frac. Conversion 0.7500 0.0200
Calc H of Reac. -18116.8672 2736.4453
(Btu/lbmol)
Stoichiometrics:
Hydrogen -1.000 1.000
Methane 1.000 0.000E+000
Benzene 1.000 -2.000
Toluene -1.000 0.000E+000
Diphenyl 0.000E+000 1.000
SM-7-35
Flash Summary
Equip. No. 7
Name
K values:
Hydrogen 90.658
Methane 11.066
Benzene 0.011
Toluene 3.668E-003
Diphenyl 8.725E-006
Water 0.037
Divider Summary
Equip. No. 9
Name
Split based on 1
Controller Summary
Equip. No. 10
Name
Mode 2
Equip. no. adjusted 9
Variable No. 3
Minimum Value 50.0000
Sign Flag 0
Measured variables:
Number 10
Variable 1
Constant 1150.0000
Units 2
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name Feed Recycle Gas Recycle Combined feed
Temp F 75.0000 250.0000 121.0000 124.4805
Pres psia 569.0000 569.0000 569.0000 569.0000
Enth MMBtu/h 1.4409 1.1644 -94.320 -91.715
Vapor mole fraction 0.00000 0.00000 1.0000 0.92589
Total lbmol/h 274.2000 86.9000 5114.7998 5475.9004
Flowrates in lbmol/h
Hydrogen 0.0000 0.0000 2045.9000 2045.9000
Methane 0.0000 0.0000 3020.8000 3020.7998
Benzene 0.0000 3.4000 42.8000 46.2000
Toluene 274.2000 82.5000 5.3000 362.0000
Diphenyl 0.0000 1.0000 0.0000 1.0000
Water 0.0000 0.0000 0.0000 0.0000
SM-7-36
Stream No. 5 6 7 8
Stream Name Heated feed Reactor feed 2nd reactor Reactor
feed effluent
Temp F 1000.0000 1200.0000 1268.0000 1268.0000
Pres psia 564.0000 494.0000 494.0000 494.0000
Enth MMBtu/h -25.451 -8.1652 -7.9306 -7.8939
Total lbmol/h 5475.9004 5475.8999 5475.8999 5475.8999
Hydrogen 2045.9000 2045.9000 1774.4000 1777.5770
Methane 3020.7998 3020.7998 3292.2998 3292.2998
Benzene 46.2000 46.2000 317.7000 311.3460
Toluene 362.0000 362.0000 90.5000 90.5000
Diphenyl 1.0000 1.0000 1.0000 4.1770
Water 0.0000 0.0000 0.0000 0.0000
Stream No. 9 10 11 12
Stream Name Quench Quenched Quenched Partially
effluent effluent cooled
effluent
Temp F 100.0273 1149.6009 1149.6009 354.5824
Pres psia 494.0000 494.0000 494.0000 489.0000
Enth MMBtu/h 3.0682 -4.8257 -4.8257 -71.090
Total lbmol/h 197.6563 5673.5562 5673.5562 5673.5566
Hydrogen 0.7610 1778.3380 1778.3380 1778.3380
Methane 11.4771 3303.7769 3303.7769 3303.7771
Benzene 139.2251 450.5711 450.5711 450.5711
Toluene 44.0617 134.5617 134.5617 134.5617
Diphenyl 2.1314 6.3084 6.3084 6.3084
Water 0.0000 0.0000 0.0000 0.0000
Stream No. 13 14 15 16
Stream Name Cooled Vapor Flash Quench to
effluent product liquid pump
Temp F 100.0000 100.0000 100.0000 100.0000
Pres psia 484.0000 484.0000 484.0000 484.0000
Enth MMBtu/h -94.319 -103.40 9.0788 3.0677
Total lbmol/h 5673.5566 5088.5898 584.9664 197.6563
Hydrogen 1778.3380 1776.0859 2.2521 0.7610
Methane 3303.7771 3269.8101 33.9666 11.4771
Benzene 450.5711 38.5327 412.0385 139.2251
Toluene 134.5617 4.1604 130.4013 44.0617
Diphenyl 6.3084 0.0005 6.3079 2.1314
Water 0.0000 0.0000 0.0000 0.0000
SM-7-37
Stream No. 17 18 19
Stream Name Liquid Water in Water out
product
Temp F 100.0000 90.0000 120.0000
Pres psia 484.0000 50.0000 45.0000
Enth MMBtu/h 6.0111 -5273.8 -5250.6
Vapor mole fraction 0.00000 0.00000 0.00000
Total lbmol/h 387.3101 42969.9219 42969.9219
Hydrogen 1.4911 0.0000 0.0000
Methane 22.4895 0.0000 0.0000
Benzene 272.8134 0.0000 0.0000
Toluene 86.3396 0.0000 0.0000
Diphenyl 4.1765 0.0000 0.0000
Water 0.0000 42969.9219 42969.9219
SM-7-38
ASPEN PLUS Solution

S4A
D1A S3A
D2A
S5A
S1A S2A
DUP
DUPL
S1B
S2B
D1B S4B
S3B D2B
S5B
T T
S3A 130°F S4A 130°F

$OLVER01 $OLVER03
PT PT
D1A PB D2A PB
FORTRAN FORTRAN
DSTWU DSTWU
PB = PT PB = PT
S1A
S2A S5A
S1 DUP
DUPL
T T
S2B 130°F S4B 130°F

$OLVER02 $OLVER04
S1B
PT PT
D1B PB D2B PB
FORTRAN DSTWU FORTRAN
DSTWU
PB = PT PB = PT
S3B S5B
SM-7-39
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
H2 H2 H2 /
BIPHENYL C12H10 BIPHENYL
FLOWSHEET
BLOCK D1A IN=S1A OUT=S3A S2A
BLOCK D1B IN=S1B OUT=S2B S3B
BLOCK D2A IN=S3A OUT=S4A S5A
BLOCK D2B IN=S3B OUT=S4B S5B
BLOCK DUP IN=S1 OUT=S1A S1B
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL H2 METHANE -.0222000000
BPVAL H2 TOLUENE .3900000000
BPVAL METHANE H2 -.0222000000
BPVAL TOLUENE H2 .3900000000
STREAM S1
MOLE-FLOW H2 1.5 / METHANE 19.3 / BENZENE 262.8 / &
TOLUENE 84.7 / BIPHENYL 5.1
BLOCK D1A DSTWU
PARAM LIGHTKEY=BENZENE RECOVL=0.98706 HEAVYKEY=TOLUENE &
RECOVH=0.00118 PTOP=200 PBOT=200 RDV=1 RR=-1.3
BLOCK D1B DSTWU
PARAM LIGHTKEY=METHANE RECOVL=0.99482 HEAVYKEY=BENZENE &
BLOCK D2A DSTWU
PARAM LIGHTKEY=METHANE RECOVL=0.99482 HEAVYKEY=BENZENE &
BLOCK D2B DSTWU
PARAM LIGHTKEY=BENZENE RECOVL=0.98700 HEAVYKEY=TOLUENE &
RECOVH=0.00118 PTOP=200 PBOT=200 RR=-1.3
BLOCK DUP DUPL
DESIGN-SPEC D1A
DEFINE TEMP3A STREAM-VAR STREAM=S3A SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TEMP3A" TO "130"
TOL-SPEC "0.01"
VARY BLOCK-VAR BLOCK=D1A VARIABLE=PTOP SENTENCE=PARAM
LIMITS "20" "484"
DESIGN-SPEC D1B
DEFINE TEMP2B STREAM-VAR STREAM=S2B SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TEMP2B" TO "130"
TOL-SPEC "0.01"
VARY BLOCK-VAR BLOCK=D1B VARIABLE=PTOP SENTENCE=PARAM
LIMITS "20" "484"
DESIGN-SPEC D2A
DEFINE TEMP4A STREAM-VAR STREAM=S4A SUBSTREAM=MIXED &
SM-7-40
VARIABLE=TEMP
SPEC "TEMP4A" TO "130"
TOL-SPEC "0.01"
VARY BLOCK-VAR BLOCK=D2A VARIABLE=PTOP SENTENCE=PARAM
LIMITS "20" "484"
DESIGN-SPEC D2B
DEFINE TEMP4B STREAM-VAR STREAM=S4B SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TEMP4B" TO "130"
TOL-SPEC "0.01"
VARY BLOCK-VAR BLOCK=D2B VARIABLE=PTOP SENTENCE=PARAM
LIMITS "20" "484"
FORTRAN D1A
DEFINE PTOPD1 BLOCK-VAR BLOCK=D1A VARIABLE=PTOP &
SENTENCE=PARAM
DEFINE PBOTD1 BLOCK-VAR BLOCK=D1A VARIABLE=PBOT &
SENTENCE=PARAM
F PBOTD1 = PTOPD1
EXECUTE BEFORE BLOCK D1A
FORTRAN D1B
DEFINE PTOPD1 BLOCK-VAR BLOCK=D1B VARIABLE=PTOP &
SENTENCE=PARAM
DEFINE PBOTD1 BLOCK-VAR BLOCK=D1B VARIABLE=PBOT &
SENTENCE=PARAM
F PBOTD1 = PTOPD1
EXECUTE BEFORE BLOCK D1B
FORTRAN D2A
DEFINE PTOPD2 BLOCK-VAR BLOCK=D2A VARIABLE=PTOP &
SENTENCE=PARAM
DEFINE PBOTD2 BLOCK-VAR BLOCK=D2A VARIABLE=PBOT &
SENTENCE=PARAM
F PBOTD2 = PTOPD2
EXECUTE BEFORE BLOCK D2A
FORTRAN D2B
DEFINE PTOPD2 BLOCK-VAR BLOCK=D2B VARIABLE=PTOP &
SENTENCE=PARAM
DEFINE PBOTD2 BLOCK-VAR BLOCK=D2B VARIABLE=PBOT &
SENTENCE=PARAM
F PBOTD2 = PTOPD2
EXECUTE BEFORE BLOCK D2B
SEQUENCE USED WAS:
DUP
*$OLVER01 D1A D1A
(RETURN *$OLVER01)
$OLVER03 D2A D2A
(RETURN $OLVER03)
$OLVER02 D1B *D1B
(RETURN $OLVER02)
*$OLVER04 D2B D2B
(RETURN *$OLVER04)
SM-7-41
Stream Variables
S1 S1A S1B S2A S2B

------------------
STREAM ID S1 S1A S1B S2A S2B

FROM : ---- DUP DUP D1A D1B
TO : DUP D1A D1B ---- ----
SUBSTREAM: MIXED
PHASE: MIXED MIXED MIXED LIQUID VAPOR
H2 1.5000 1.5000 1.5000 2.8711-14 1.4997
METHANE 19.3000 19.3000 19.3000 1.6590-31 19.2000
BENZENE 262.8000 262.8000 262.8000 3.4006 1.3008
TOLUENE 84.7000 84.7000 84.7000 84.6000 0.0
BIPHENYL 5.1000 5.1000 5.1000 5.1000 0.0
TOTAL FLOW:
LBMOL/HR 373.4000 373.4000 373.4000 93.1006 22.0005
LB/HR 2.9432+04 2.9432+04 2.9432+04 8847.2068 412.6595
CUFT/HR 573.2070 573.2070 573.2070 181.3581 1196.4929
STATE VARIABLES:
TEMP F 100.0000 100.0000 100.0000 254.9003 130.0000
PRES PSI 484.0000 484.0000 484.0000 20.0000 114.9047
VFRAC 3.1007-03 3.1007-03 3.1007-03 0.0 1.0000
LFRAC 0.9969 0.9969 0.9969 1.0000 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.5903+04 1.5903+04 1.5903+04 1.5491+04 -2.5422+04
BTU/LB 201.7570 201.7570 201.7570 163.0102 -1355.3383
BTU/HR 5.9381+06 5.9381+06 5.9381+06 1.4422+06 -5.5929+05
ENTROPY:
BTU/LBMOL-R -61.2698 -61.2698 -61.2698 -69.9205 -21.3698
BTU/LB-R -0.7773 -0.7773 -0.7773 -0.7357 -1.1393
DENSITY:
LBMOL/CUFT 0.6514 0.6514 0.6514 0.5133 1.8388-02
LB/CUFT 51.3456 51.3456 51.3456 48.7830 0.3448
AVG MW 78.8208 78.8208 78.8208 95.0283 18.7567
S3A S3B S4A S4B S5A

-------------------
STREAM ID S3A S3B S4A S4B S5A

FROM : D1A D1B D2A D2B D2A
TO : D2A D2B ---- ---- ----
SUBSTREAM: MIXED
PHASE: VAPOR LIQUID VAPOR LIQUID LIQUID
H2 1.5000 2.9563-04 1.4997 2.9563-04 2.7011-04
METHANE 19.3000 9.9974-02 19.2000 9.9974-02 9.9974-02
BENZENE 259.3993 261.4991 1.2995 258.0996 258.0997
TOLUENE 9.9946-02 84.7000 0.0 9.9946-02 9.9946-02
BIPHENYL 0.0 5.1000 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 280.2993 351.3994 21.9993 258.2998 258.2999
LB/HR 2.0584+04 2.9019+04 412.5604 2.0172+04 2.0172+04
CUFT/HR 9.4714+04 656.3770 1195.1884 399.1746 453.5498
STATE VARIABLES:
TEMP F 190.8710 344.1268 130.0000 187.2835 328.3152
PRES PSI 20.0000 114.9047 115.0228 20.0000 115.0228
VFRAC 1.0000 0.0 1.0000 0.0 0.0
LFRAC 0.0 1.0000 0.0 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
SM-7-42
ENTHALPY:
BTU/LBMOL 3.3071+04 2.7990+04 -2.5425+04 2.4726+04 3.0188+04
BTU/LB 450.3256 338.9329 -1355.7789 316.6149 386.5512
BTU/HR 9.2697+06 9.8355+06 -5.5934+05 6.3867+06 7.7975+06
ENTROPY:
BTU/LBMOL-R -32.0828 -49.5680 -21.3711 -54.1542 -46.5867
BTU/LB-R -0.4368 -0.6002 -1.1396 -0.6934 -0.5965
DENSITY:
LBMOL/CUFT 2.9594-03 0.5353 1.8407-02 0.6470 0.5695
LB/CUFT 0.2173 44.2109 0.3451 50.5340 44.4756
AVG MW 73.4375 82.5813 18.7533 78.0949 78.0949
S5B
---
STREAM ID S5B
FROM : D2B
TO : ----
SUBSTREAM: MIXED
PHASE: LIQUID
H2 1.0656-14
METHANE 7.9453-34
BENZENE 3.3994
TOLUENE 84.6000
BIPHENYL 5.1000
TOTAL FLOW:
LBMOL/HR 93.0995
LB/HR 8847.1175
CUFT/HR 181.1721
STATE VARIABLES:
TEMP F 255.1149
PRES PSI 20.0000
VFRAC 0.0
LFRAC 1.0000
SFRAC 0.0
ENTHALPY:
BTU/LBMOL 1.5643+04
BTU/LB 164.6160
BTU/HR 1.4564+06
ENTROPY:
BTU/LBMOL-R -69.8229
BTU/LB-R -0.7347
DENSITY:
LBMOL/CUFT 0.5138
LB/CUFT 48.8326
AVG MW 95.0285
BLOCK: D1A MODEL: DSTWU

-----------------------------
INLET STREAM: S1A
CONDENSER OUTLET: S3A
REBOILER OUTLET: S2A
SM-7-43
TOTAL BALANCE
MOLE(LBMOL/HR) 373.400 373.400 0.000000E+00
MASS(LB/HR ) 29431.7 29431.7 0.123608E-15
ENTHALPY(BTU/HR ) 0.593805E+07 0.107119E+08 -0.445659
*** INPUT DATA ***

HEAVY KEY COMPONENT TOLUENE
RECOVERY FOR HEAVY KEY 0.0011800
LIGHT KEY COMPONENT BENZENE
RECOVERY FOR LIGHT KEY 0.98706
TOP STAGE PRESSURE (PSI ) 20.0000
BOTTOM STAGE PRESSURE (PSI ) 20.0000
REFLUX RATIO -1.30000
DISTILLATE VAPOR FRACTION 1.00000
*** RESULTS ***

DISTILLATE TEMP. (F ) 190.871
BOTTOM TEMP. (F ) 254.900
MINIMUM REFLUX RATIO 0.96037
ACTUAL REFLUX RATIO 1.24848
MINIMUM STAGES 11.5755
ACTUAL EQUILIBRIUM STAGES 22.6508
NUMBER OF ACTUAL STAGES ABOVE FEED 12.5211
DIST. VS FEED 0.75067
CONDENSER COOLING REQUIRED (BTU/HR ) 6,042,040.
NET CONDENSER DUTY (BTU/HR ) -6,042,040.
REBOILER HEATING REQUIRED (BTU/HR ) 0.108159+08
NET REBOILER DUTY (BTU/HR ) 0.108159+08
BLOCK: D2A MODEL: DSTWU

-----------------------------
INLET STREAM: S3A
CONDENSER OUTLET: S4A
REBOILER OUTLET: S5A

TOTAL BALANCE
MOLE(LBMOL/HR) 280.299 280.299 0.000000E+00
MASS(LB/HR ) 20584.5 20584.5 0.000000E+00
*** INPUT DATA ***

HEAVY KEY COMPONENT BENZENE
LIGHT KEY COMPONENT METHANE
*** RESULTS ***

SM-7-44
REBOILER HEATING REQUIRED (BTU/HR ) 528,688.
NET REBOILER DUTY (BTU/HR ) -528,688.
BLOCK: D1B MODEL: DSTWU

-----------------------------
INLET STREAM: S1B
CONDENSER OUTLET: S2B
REBOILER OUTLET: S3B
***********************************************************************
* *
* ERRORS IN BLOCK CALCULATIONS *
* *
* MINIMUM REFLUX IS LESS THAN 0. RESET TO .1 *
* *
***********************************************************************

TOTAL BALANCE
MOLE(LBMOL/HR) 373.400 373.400 0.000000E+00
MASS(LB/HR ) 29431.7 29431.7 0.000000E+00
*** INPUT DATA ***

HEAVY KEY COMPONENT BENZENE
LIGHT KEY COMPONENT METHANE
*** RESULTS ***

REBOILER HEATING REQUIRED (BTU/HR ) 4,523,430.
NET REBOILER DUTY (BTU/HR ) 4,523,430.
BLOCK: D2B MODEL: DSTWU

-----------------------------
INLET STREAM: S3B
CONDENSER OUTLET: S4B
REBOILER OUTLET: S5B
SM-7-45
TOTAL BALANCE
MOLE(LBMOL/HR) 351.399 351.399 0.000000E+00
MASS(LB/HR ) 29019.0 29019.0 0.250731E-15
*** INPUT DATA ***

HEAVY KEY COMPONENT TOLUENE
*** RESULTS ***

When examining these results, note that the minimum reflux ratio is not computed
correctly for the column D1B. This mistake was observed after the DSTWU subroutine
was taken from the FLOWTRAN system and installed in ASPEN PLUS. A value less
than zero is computed, and consequently, DSTWU sets the minimum reflux ratio to
0.1.
Also, errors are reported in the results because the design specification of 130°F in the
condensers cannot be achieved with pressures greater than 20 psia when benzene is
being separated from toluene. Hence, the design specifications adjust the pressure to
the lower bound (20 psia) and the 130°F specification is not achieved. This is reported
as an error by ASPEN PLUS, although the results are as expected.
SM-7-46
HYSYS Solution
The PFD for the separation section of the toluene hydrodealkylation process in the direct sequence,
shown below, was set up based on the information in Figure 7.32. To obtain an initial estimate of
the column pressures, a dew-point pressure calculation is made on Product 1 and a bubble-point
pressure calculation is made on Product 2, both at a temperature of 130oF. The results are 121.4
psia and 8.6 psia, respectively. Accordingly, column 1 is set at 120 psia and column 2 at 20 psia.
An attempt at computing estimates for the number of trays and the feed tray location using the
FUG method as implemented in HYSYS’ Shortcut column module failed. Instead, the estimate
obtained with CHEMCAD is applied. Accordingly, column T-101 was designed as a reboiled
stripper of three stages, no condenser, and feed to the top stage. The single degree-of-freedom, the
draw rate of the Fuel Gas, was manipulated to maintain the benzene loss in the stream at the desired
1.3 lbmol/hr. A shown above, the FUG method as employed to estimate the reflux ratio, Nmin, N
and the feed location for the second column, T-102. The table below summarizes the results
obtained:
Shortcut Column: T-100 Component Mole Fraction

Light Key Benzene 3.65E-02
Heavy Key Toluene 3.87E-04
Pressures (psia) Reflux Ratios
Condenser Pressure 20 External Reflux Ratio 1.565
Reboiler Pressure 20 Minimum Reflux Ratio 1.204
Trays / Temperatures Flows
Minimum # of Trays 14.96 Rectify Vapour (lbmole/hr) 662.5
Actual # of Trays 31.8 Rectify Liquid (lbmole/hr) 404.2
Optimal Feed Stage 25.67 Stripping Vapour (lbmole/hr) 662.5
Condenser Temperature (F) 187.5 Stripping Liquid (lbmole/hr) 755.6
Reboiler Temperature (F) 251.7 Condenser Duty (Btu/hr) -8.87E+06
Reboiler Duty (Btu/hr) 6.81E+06
Note that the FUG method indicates a minimum reflux ratio of 1.20, which assuming a 1.3 factor,
SM-7-47
gives a reflux ratio to implement of 1.565. For this reflux ratio, the column will require 32 trays,
with the feed inserted at the 26th tray. Accordingly, T-102 was implemented as a 32-tray column,
with the feed at the 26th tray. Thus separates the actual bottoms product of T-101, which is slightly
different from the specification given in Figure 7.32. The two degrees-of-freedom were
manipulated to limit the benzene in the bottoms toluene recycle stream to 3.4 lbmol/hr, and to
reduce the toluene in the overhead benzene product to 0.1 lbmol/hr. These specifications can be
achieved with a reflux ratio of only 1.41. The composition profiles for column T-102 is shown
below, were it is noted that high purity of the benzene product is ensured.
The results of the simulation are summarized in Table 1, and can be reproduced by running the file
EXER7_3.hsc (in the HYSYS folder, under Computer Solution Files, associated with the Solution
Manual on the Wiley web site for this book).
SM-7-48
Table 1. HYSYS-generated Stream Data for Exercise 7.3
Name Bottoms - Specs D1 B1 Feed Stream Fuel Gas Bottoms Benzene Product Toluene Recycle
Vapour Fraction 0.0 0.0 0.0 0.0 1.0 0.0 0.0 0.0
Temperature (F) 347.3 187.5 251.7 100.0 145.7 348.7 195.3 251.7
Pressure (psia) 120.0 20.0 20.0 120.0 120.0 120.0 20.0 20.0
Molar Flow (lbmole/hr) 351.4 258.3 93.1 373.4 22.3 351.2 258.2 93.0
Mass Flow (lb/hr) 29,020.0 20,170.0 8,847.0 29,430.0 428.1 29,000.0 20,170.0 8,833.0
Liquid Volume Flow (barrel/day) 2252.0 1566.0 686.4 2334.0 82.7 2251.0 1566.0 685.3
Heat Flow (Btu/hr) 9.92E+06 6.39E+06 1.47E+06 5.94E+06 -5.59E+05 9.94E+06 6.47E+06 1.47E+06
Compositions
Name Bottoms - Specs D1 B1 Feed Stream Fuel Gas Bottoms Benzene Product Toluene Recycle
Comp Mole Frac (BiPhenyl) 0.0145 0.0000 0.0548 0.0137 0.0000 0.0145 0.0000 0.0549
Energy Streams
Name R_Duty_1 C1_DUTY R1_DUTY C_Duty_2 R_Duty_2
Heat Flow (Btu/hr) 3.44E+06 -8.87E+06 6.81E+06 8.15E+06 6.15E+06
SM-7-49
Exercise 7.3 – Separation Section of the Toluene Process Page 1
Only the solution to the first (direct) sequence is given here. The solution
to the indirect sequence is obtained in a similar manner.
To obtain an initial estimate of the column pressures, a dew-point pressure
calculation is made on Product 1 (using a partial condenser) and a bubble-
point pressure calculation is made on Product 2 (using a total condenser),
both at a temperature of 130oF. The results are 121.4 psia and 8.6 psia,
respectively. Accordingly, column 1 is set at 120 psia and column 2 at 20
psia.
The FUG shortcut method is then applied to each column using the SHOR module.
For column 1, for which Product 1 is the distillate, the result (not given in
detail here) is N min = 2.0 and R min = a very small value. Thus, a reboiled
stripper is indicated with about 3-4 stages, no condenser, and feed to the
top stage.
For column 2, for which Product 2 is the distillate, the result (not given in
detail here) is N min = 14.4 stages, R min = 1.22, R = 1.59, N = 29.5, and
feed stage at 18 from the top. Thus, for an initial rigorous calculation,
use N = 30 and R = 1.6, with a feed stage near the middle.
The following results are obtained using the SCDS module for the first column
and the TOWR module for the second column.
CHEMCAD 5.2.3
FLOWSHEET SUMMARY
3 SCDS 6 -7 -8
4 TOWR 8 -9 -10
STREAM CONNECTIONS
Stream Equipment
From To
6 3
7 3
8 3 4
9 4
10 4

3 4
No recycle loops in the flowsheet.
COMPONENTS
ID # Name
1 1 Hydrogen
2 2 Methane
3 40 Benzene
4 41 Toluene
5 194 Diphenyl
SM-7-50
THERMODYNAMICS
K-value model : Peng-Robinson

Enthalpy model : Peng-Robinson

Hydrogen 1.500 1.500 3.024 3.024
Methane 19.300 19.300 309.630 309.630
Benzene 262.800 262.800 20528.358 20528.348
Toluene 84.700 84.700 7804.342 7804.343
Diphenyl 5.100 5.100 786.476 786.476
Total 373.400 373.400 29431.830 29431.822
EQUIPMENT SUMMARIES
Scds Rigorous Distillation Summary
Equip. No. 3
Name
No. of stages 3
1st feed stage 1
Condenser spec. 130.0000
Reboiler mode 4
Reboiler spec. 351.3000
Est. dist. rate 22.1000
(lbmol/h)
Est. reflux rate 373.0000
(lbmol/h)
Est. stage 1 T F 130.0000
Est. bottom T F 230.0000
Est. stage n -1 T F 220.0000
Top pressure psia 120.0000
Reblr duty MMBtu/h 3.3385
Reflux mole lbmol/h 384.7802
Reflux mass lb/h 31242.4648
Towr Rigorous Distillation Summary
Equip. No. 4
Name
No. of stages 30
1st feed stage 15
Top pressure psia 20.0000
Condenser mode 5
Cond. comp i 4
Reboiler mode 5
Rebl. comp i 3
Calc cond duty -9.2337
(MMBtu/h)
Calc rebr duty 7.2153
SM-7-51
Towr Rigorous Distillation Summary (continued)
(MMBtu/h)
Est. dist. rate 258.0000
(lbmol/h)
Est. reflux rate 413.0000
(lbmol/h)
Est. bottom T F 230.0000
Reflux ratio 1.7368
FLOW SUMMARIES
Stream No. 6 7 8 9
Stream Name Feed to 1 Distillate Feed to 2 Distillate
from 1 from 2
Temp F 100.0000 141.3739 349.2164 188.7599
Pres psia 484.0000 120.0000 120.0000 20.0000
Enth MMBtu/h 6.0395 -0.56005 9.9381 6.4652
Total lbmol/h 373.4000 22.1000 351.3000 258.3401
Hydrogen 1.5000 1.4987 0.0013 0.0013
Methane 19.3000 19.2289 0.0711 0.0711
Benzene 262.8000 1.2321 261.5679 258.1678
Toluene 84.7000 0.1403 84.5597 0.1000
Diphenyl 5.1000 0.0000 5.1000 0.0000
Stream No. 10
Stream Name Bottoms
from 2
Temp F 252.5761
Pres psia 20.0000
Enth MMBtu/h 1.4544
Vapor mole fraction 0.00000
Total lbmol/h 92.9598
Hydrogen 0.0000
Methane 0.0000
Benzene 3.4000
Toluene 84.4598
Diphenyl 5.1000
SM-7-52
DISTILLATION PROFILE
Unit type : SCDS Unit name: Eqp # 3
* Net Flows *
Temp Pres Liquid Vapor Feeds Product Duties
Stg F psia lbmol/h lbmol/h lbmol/h lbmol/h MMBtu/h
1 141.4 120.00 384.78 373.40 22.10
2 322.5 120.00 595.87 33.48
3 349.2 120.00 244.57 351.30 3.339
Unit type : TOWR Unit name: Eqp # 4
* Net Flows *
1 188.8 20.00 448.69 258.34 -9.234
2 194.8 20.00 455.71 707.03
3 194.9 20.00 455.65 714.05
4 194.9 20.00 455.52 713.99
5 195.0 20.00 455.32 713.86
6 195.1 20.00 455.00 713.66
7 195.3 20.00 454.55 713.34
8 195.6 20.00 453.87 712.89
9 196.0 20.00 452.88 712.21
10 196.6 20.00 451.66 711.22
11 197.4 20.00 449.65 710.00
12 198.6 20.00 447.11 707.99
13 200.2 20.00 443.95 705.45
14 202.2 20.00 439.55 702.29
15 205.0 20.00 634.85 697.89 351.30
16 205.1 20.00 634.81 541.89
17 205.1 20.00 634.70 541.85
18 205.2 20.00 634.49 541.74
19 205.4 20.00 634.08 541.53
20 205.7 20.00 633.30 541.12
21 206.4 20.00 631.81 540.34
22 207.7 20.00 629.27 538.85
23 210.1 20.00 624.78 536.31
24 214.2 20.00 618.48 531.82
25 220.2 20.00 611.77 525.52
26 227.7 20.00 606.28 518.81
27 235.4 20.00 603.46 513.33
28 241.8 20.00 602.70 510.50
29 246.4 20.00 599.07 509.74
30 252.6 20.00 506.11 92.96 7.215
Mole Reflux ratio 1.737
SM-7-53
ASPEN PLUS Solution

GAS-RECY PURGE
C1
H2-FEED
17 16
S1
1
TOL-FEED
M1 F1
HX1 H2
TOL-RECY H1 6 7
9
3
5
R1
P1
4 8 S2
M2 10
FUEL
D1
D2 11
BENZENE
P2
12
15 D3
14
C12PURGE
ASPEN PLUS Program

TITLE 'ENTIRE TOLUENE HYDRODEALKYLATION PROCESS'
IN-UNITS ENG
NOASPENPCD
COMPONENTS
HYDROGEN H2 HYDROGEN /
BIPHENYL C12H10 BIPHENYL /
WATER H2O WATER
SM-7-54
FLOWSHEET
BLOCK M1 IN=TOL-FEED GAS-RECY TOL-RECY H2-FEED OUT=1
BLOCK HX1 IN=5 1 OUT=6 2
BLOCK H1 IN=2 OUT=3
BLOCK R1 IN=3 OUT=4
BLOCK M2 IN=4 8 OUT=5
BLOCK F1 IN=7 OUT=16 9
BLOCK P1 IN=10 OUT=8
BLOCK S2 IN=9 OUT=10 11
BLOCK S1 IN=16 OUT=PURGE 17
BLOCK C1 IN=17 OUT=GAS-RECY
BLOCK D1 IN=11 OUT=FUEL 12
BLOCK D2 IN=12 OUT=BENZENE 14
BLOCK D3 IN=14 OUT=15 C12PURGE
BLOCK H2 IN=6 OUT=7
BLOCK P2 IN=15 OUT=TOL-RECY
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL HYDROGEN METHANE -.0222000000
BPVAL HYDROGEN TOLUENE .3900000000
BPVAL METHANE HYDROGEN -.0222000000
BPVAL TOLUENE HYDROGEN .3900000000
PROP-SET HEAT-VAL QVALGRS SUBSTREAM=MIXED PHASE=T
STREAM 5
MOLE-FLOW HYDROGEN 1752.434 / METHANE 3659.012 / BENZENE &
454.824 / TOLUENE 138.914 / BIPHENYL 4.863
STREAM 11
268.14 / TOLUENE 87.028 / BIPHENYL 3.14
STREAM GAS-RECY
SUBSTREAM MIXED TEMP=131.1 PRES=569
36.841 / TOLUENE 3.863
STREAM H2-FEED
MOLE-FLOW HYDROGEN 393.9 / METHANE 0
STREAM TOL-FEED
MOLE-FLOW TOLUENE 274.2
BLOCK M1 MIXER
BLOCK M2 MIXER
BLOCK S1 FSPLIT
FRAC PURGE .07
BLOCK S2 FSPLIT
FRAC 10 .3542
BLOCK H1 HEATER
BLOCK H2 HEATER
BLOCK F1 FLASH2
PARAM TEMP=100 PRES=0
BLOCK HX1 HEATX
PARAM T-COLD=1000 PRES-HOT=-5 PRES-COLD=-5 &
U-OPTION=CONSTANT
FEEDS HOT=5 COLD=1
PRODUCTS HOT=6 COLD=2
HEAT-TR-COEF U=60
SM-7-55
BLOCK D1 DISTL
PARAM NSTAGE=10 FEED-LOC=5 RR=.3545 PTOP=109.12 PBOT=109.12 &
D:F=.0573 COND-TYPE=PARTIAL
SIZE-DATA COND=YES REB=YES LIGHT-KEY=METHANE &
HEAVY-KEY=BENZENE
BLOCK D2 DISTL
PARAM NSTAGE=25 FEED-LOC=16 RR=1.345 PTOP=20 PBOT=20 &
D:F=.7375
SIZE-DATA COND=YES REB=YES LIGHT-KEY=BENZENE &
HEAVY-KEY=TOLUENE
BLOCK D3 DISTL
PARAM NSTAGE=10 FEED-LOC=5 RR=.15 PTOP=20 PBOT=20 &
D:F=.9635
SIZE-DATA COND=YES REB=YES LIGHT-KEY=TOLUENE &
HEAVY-KEY=BIPHENYL
BLOCK R1 RSTOIC
PARAM TEMP=1268 PRES=0 SERIES=YES
STOIC 1 MIXED TOLUENE -1 / HYDROGEN -1 / BENZENE 1 / &
METHANE 1
STOIC 2 MIXED BENZENE -2 / BIPHENYL 1 / HYDROGEN 1
CONV 1 MIXED TOLUENE .75
CONV 2 MIXED BENZENE .02
BLOCK P1 PUMP
PARAM PRES=494
BLOCK P2 PUMP
PARAM PRES=569
BLOCK C1 COMPR
PARAM TYPE=ISENTROPIC PRES=569
CONV-OPTIONS
WEGSTEIN MAXIT=200
TEAR
TEAR 5 / 11 / GAS-RECY
STREAM-REPOR MOLEFLOW MOLEFRAC PROPERTIES=HEAT-VAL
SEQUENCE USED WAS:
$OLVER01 D1 D2 D3 P2 M1 HX1 H2 F1 S1 C1 S2 P1 H1 R1 M2
(RETURN $OLVER01)
SM-7-56
Stream Variables
1 10 11 12 14
-------------
STREAM ID 1 10 11 12 14
FROM : M1 S2 S2 D1 D2
TO : HX1 P1 D1 D2 D3
SUBSTREAM: MIXED
PHASE: MIXED LIQUID LIQUID LIQUID LIQUID
HYDROGEN 2023.3858 0.5920 1.0793 1.8217-06 0.0
METHANE 3373.6325 10.6305 19.3828 4.4054-02 0.0
BENZENE 40.8677 147.1116 268.2234 266.9448 4.0185
TOLUENE 364.3479 47.6825 86.9378 86.9313 86.5688
BIPHENYL 4.0259-04 1.7228 3.1412 3.1412 3.1412
WATER 0.0 0.0 0.0 0.0 0.0
COMPONENTS: MOLE FRAC
HYDROGEN 0.3487 2.8497-03 2.8496-03 5.1018-09 0.0
METHANE 0.5814 5.1173-02 5.1174-02 1.2338-04 0.0
BENZENE 7.0434-03 0.7081 0.7081 0.7476 4.2875-02
TOLUENE 6.2794-02 0.2295 0.2295 0.2434 0.9236
BIPHENYL 6.9385-08 8.2934-03 8.2934-03 8.7975-03 3.3514-02
WATER 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 5802.2342 207.7396 378.7647 357.0614 93.7286
LB/HR 9.4965+04 1.6322+04 2.9760+04 2.9347+04 8774.8185
CUFT/HR 6.0500+04 310.9628 566.9674 662.9467 180.9942
STATE VARIABLES:
TEMP F 127.6225 100.0000 100.0000 339.4706 253.0963
PRES PSI 569.0000 484.0000 484.0000 109.1200 20.0000
VFRAC 0.9321 0.0 0.0 0.0 0.0
LFRAC 6.7854-02 1.0000 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -1.7644+04 1.5745+04 1.5745+04 2.7541+04 1.4589+04
BTU/LB -1078.0044 200.3966 200.3960 335.0874 155.8300
BTU/HR -1.0237+08 3.2709+06 5.9638+06 9.8338+06 1.3674+06
ENTROPY:
BTU/LBMOL-R -21.3228 -61.1931 -61.1930 -49.7011 -69.4522
BTU/LB-R -1.3028 -0.7788 -0.7788 -0.6047 -0.7418
DENSITY:
LBMOL/CUFT 9.5904-02 0.6680 0.6680 0.5386 0.5178
LB/CUFT 1.5696 52.4897 52.4897 44.2675 48.4811
AVG MW 16.3669 78.5711 78.5710 82.1904 93.6193
MIXED SUBSTREAM PROPERTIES:
*** ALL PHASES ***

QVALGRS BTU/LB 2.3275+04 1.8111+04 1.8111+04 1.8048+04 1.8190+04
15 16 17 2 3
------------
STREAM ID 15 16 17 2 3
FROM : D3 F1 S1 HX1 H1
TO : P2 S1 C1 H1 R1
SUBSTREAM: MIXED
PHASE: LIQUID VAPOR VAPOR VAPOR VAPOR
SM-7-57
HYDROGEN 0.0 1752.2076 1629.5531 2023.3858 2023.3858
METHANE 0.0 3627.4544 3373.5326 3373.6325 3373.6325
BENZENE 4.0184 39.6228 36.8492 40.8677 40.8677
TOLUENE 86.2892 4.1491 3.8587 364.3479 364.3479
BIPHENYL 9.5275-07 4.3186-04 4.0163-04 4.0259-04 4.0259-04
WATER 0.0 0.0 0.0 0.0 0.0
HYDROGEN 0.0 0.3230 0.3230 0.3487 0.3487
METHANE 0.0 0.6688 0.6688 0.5814 0.5814
BENZENE 4.4497-02 7.3059-03 7.3059-03 7.0434-03 7.0434-03
TOLUENE 0.9555 7.6505-04 7.6505-04 6.2794-02 6.2794-02
BIPHENYL 1.0550-08 7.9629-08 7.9629-08 6.9385-08 6.9385-08
WATER 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 90.3075 5423.4345 5043.7941 5802.2342 5802.2342
LB/HR 8264.6182 6.5204+04 6.0640+04 9.4965+04 9.4965+04
CUFT/HR 172.6395 6.6633+04 6.1968+04 1.6345+05 2.1168+05
STATE VARIABLES:
TEMP F 250.7152 100.0000 100.0000 1000.0000 1200.0000
PRES PSI 20.0000 484.0000 484.0000 564.0000 494.0000
VFRAC 0.0 1.0000 1.0000 1.0000 1.0000
LFRAC 1.0000 0.0 0.0 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.2842+04 -2.1073+04 -2.1073+04 -5667.4625 -2509.3787
BTU/LB 140.3267 -1752.7666 -1752.7666 -346.2748 -153.3198
BTU/HR 1.1597+06 -1.1429+08 -1.0629+08 -3.2884+07 -1.4560+07
ENTROPY:
BTU/LBMOL-R -69.1137 -18.6213 -18.6213 -8.7927 -6.4998
BTU/LB-R -0.7552 -1.5488 -1.5488 -0.5372 -0.3971
DENSITY:
LBMOL/CUFT 0.5231 8.1393-02 8.1393-02 3.5499-02 2.7411-02
LB/CUFT 47.8720 0.9785 0.9785 0.5810 0.4486
AVG MW 91.5163 12.0226 12.0226 16.3669 16.3669
*** ALL PHASES ***

QVALGRS BTU/LB 1.8234+04 2.5564+04 2.5564+04 2.3275+04 2.3275+04
4 5 6 7 8
---------
STREAM ID 4 5 6 7 8
FROM : R1 M2 HX1 H2 P1
TO : M2 HX1 H2 F1 M2
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR VAPOR MIXED LIQUID
HYDROGEN 1753.2661 1753.8790 1753.8790 1753.8790 0.5920
METHANE 3646.8935 3657.4674 3657.4674 3657.4674 10.6305
BENZENE 307.8461 454.9578 454.9578 454.9578 147.1116
TOLUENE 91.0870 138.7695 138.7695 138.7695 47.6825
BIPHENYL 3.1416 4.8645 4.8645 4.8645 1.7228
WATER 0.0 0.0 0.0 0.0 0.0
HYDROGEN 0.3021 0.2918 0.2918 0.2918 2.8497-03
METHANE 0.6285 0.6085 0.6085 0.6085 5.1173-02
BENZENE 5.3056-02 7.5701-02 7.5701-02 7.5701-02 0.7081
TOLUENE 1.5699-02 2.3090-02 2.3090-02 2.3090-02 0.2295
BIPHENYL 5.4146-04 8.0942-04 8.0942-04 8.0942-04 8.2934-03
WATER 0.0 0.0 0.0 0.0 0.0
SM-7-58
TOTAL FLOW:
LBMOL/HR 5802.2344 6009.9384 6009.9384 6009.9384 207.7396
LB/HR 9.4965+04 1.1129+05 1.1129+05 1.1129+05 1.6322+04
CUFT/HR 2.2025+05 2.1267+05 1.0856+05 6.7510+04 310.9947
STATE VARIABLES:
TEMP F 1268.0000 1149.9926 364.1975 100.0000 100.1561
PRES PSI 494.0000 494.0000 489.0000 484.0000 494.0000
VFRAC 1.0000 1.0000 1.0000 0.9024 0.0
LFRAC 0.0 0.0 0.0 9.7589-02 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -2396.1700 -1768.6772 -1.3331+04 -1.7480+04 1.5752+04
BTU/LB -146.4029 -95.5161 -719.9287 -943.9862 200.4843
BTU/HR -1.3903+07 -1.0630+07 -8.0118+07 -1.0505+08 3.2724+06
ENTROPY:
BTU/LBMOL-R -5.9877 -7.0397 -16.6832 -22.7759 -61.1862
BTU/LB-R -0.3658 -0.3801 -0.9009 -1.2300 -0.7787
DENSITY:
LBMOL/CUFT 2.6344-02 2.8259-02 5.5359-02 8.9022-02 0.6679
LB/CUFT 0.4311 0.5232 1.0250 1.6484 52.4843
AVG MW 16.3669 18.5170 18.5170 18.5170 78.5711
*** ALL PHASES ***

QVALGRS BTU/LB 2.3229+04 2.2478+04 2.2478+04 2.2478+04 1.8111+04
9 BENZENE C12PURGE FUEL GAS-RECY

--------------------------------
STREAM ID 9 BENZENE C12PURGE FUEL GAS-RECY

FROM : F1 D2 D3 D1 C1
TO : S2 ---- ---- ---- M1
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID VAPOR VAPOR
HYDROGEN 1.6713 1.8217-06 0.0 1.0793 1629.4858
METHANE 30.0129 4.4054-02 0.0 19.3388 3373.6325
BENZENE 415.3350 262.9263 1.3045-04 1.2785 36.8492
TOLUENE 134.6203 0.3625 0.2795 6.4916-03 3.8587
BIPHENYL 4.8641 0.0 3.1412 0.0 4.0163-04
WATER 0.0 0.0 0.0 0.0 0.0
HYDROGEN 2.8497-03 6.9177-09 0.0 4.9731-02 0.3230
METHANE 5.1173-02 1.6729-04 0.0 0.8910 0.6688
BENZENE 0.7081 0.9984 3.8130-05 5.8912-02 7.3058-03
TOLUENE 0.2295 1.3766-03 8.1719-02 2.9911-04 7.6504-04
BIPHENYL 8.2934-03 0.0 0.9182 0.0 7.9629-08
WATER 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 586.5038 263.3328 3.4211 21.7032 5043.8267
LB/HR 4.6082+04 2.0572+04 510.2081 412.8968 6.0641+04
CUFT/HR 877.9300 408.6478 9.5048 1238.8941 5.5872+04
STATE VARIABLES:
TEMP F 100.0000 192.3232 439.0385 128.1794 131.0561
PRES PSI 484.0000 20.0000 20.0000 109.1200 569.0000
VFRAC 0.0 0.0 0.0 1.0000 1.0000
LFRAC 1.0000 1.0000 1.0000 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.5745+04 2.4900+04 7.1136+04 -2.6026+04 -2.0821+04
BTU/LB 200.3966 318.7258 476.9845 -1367.9886 -1731.7602
BTU/HR 9.2347+06 6.5569+06 2.4336+05 -5.6484+05 -1.0502+08
SM-7-59
ENTROPY:
BTU/LBMOL-R -61.1931 -53.8976 -72.9039 -21.7495 -18.5011
BTU/LB-R -0.7788 -0.6899 -0.4888 -1.1432 -1.5388
DENSITY:
LBMOL/CUFT 0.6680 0.6444 0.3599 1.7518-02 9.0275-02
LB/CUFT 52.4897 50.3422 53.6787 0.3332 1.0853
AVG MW 78.5711 78.1225 149.1359 19.0246 12.0228
*** ALL PHASES ***

QVALGRS BTU/LB 1.8111+04 1.7987+04 1.7470+04 2.2632+04 2.5564+04
H2-FEED PURGE TOL-FEED TOL-RECY

-------------------------------
STREAM ID H2-FEED PURGE TOL-FEED TOL-RECY

FROM : ---- S1 ---- P2
TO : M1 ---- M1 M1
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR LIQUID LIQUID
HYDROGEN 393.9000 122.6545 0.0 0.0
METHANE 0.0 253.9218 0.0 0.0
BENZENE 0.0 2.7736 0.0 4.0184
TOLUENE 0.0 0.2904 274.2000 86.2892
BIPHENYL 0.0 3.0230-05 0.0 9.5275-07
WATER 0.0 0.0 0.0 0.0
HYDROGEN 1.0000 0.3230 0.0 0.0
METHANE 0.0 0.6688 0.0 0.0
BENZENE 0.0 7.3059-03 0.0 4.4497-02
TOLUENE 0.0 7.6505-04 1.0000 0.9555
BIPHENYL 0.0 7.9629-08 0.0 1.0550-08
WATER 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 393.9000 379.6404 274.2000 90.3075
LB/HR 794.0551 4564.2854 2.5265+04 8264.6182
CUFT/HR 4028.3965 4664.2751 468.8259 174.2857
STATE VARIABLES:
TEMP F 70.0000 100.0000 75.0000 262.6565
PRES PSI 569.0000 484.0000 569.0000 569.0000
VFRAC 1.0000 1.0000 0.0 0.0
LFRAC 0.0 0.0 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -29.2004 -2.1073+04 5245.7431 1.3473+04
BTU/LB -14.4852 -1752.7666 56.9319 147.2180
BTU/HR -1.1502+04 -8.0001+06 1.4384+06 1.2167+06
ENTROPY:
BTU/LBMOL-R -7.3625 -18.6213 -81.8307 -68.5413
BTU/LB-R -3.6522 -1.5488 -0.8881 -0.7489
DENSITY:
LBMOL/CUFT 9.7781-02 8.1393-02 0.5848 0.5181
LB/CUFT 0.1971 0.9785 53.8897 47.4199
AVG MW 2.0158 12.0226 92.1405 91.5163
*** ALL PHASES ***

QVALGRS BTU/LB 6.0956+04 2.5564+04 1.8244+04 1.8234+04
SM-7-60
HYSYS Solution
The complete process for hydrodealkylation of toluene involves three recycle loops and the
estimation of the hydrogen makeup stream flow rate. It is best assembled in the following
sequence, as shown in the PFD in Fig. 1:
a) Begin with the reactor section, as solved in Exercise 7.2. The vapor product stream from the
flash vessel, V-100, S-11, is split into a purge stream and the gas recycle stream, S-12, which
needs to be compressed to 569 psia, in stream S-13. At this stage, do not close the gas recycle
loop.
b) Add the separation section, as solved in Exercise 7.3, but installing an additional separation
device to reduce the biphenyl flow rate in the overhead toluene recycle stream to 1 lbmol/hr
and withdrawing a biphenyl product stream as bottoms. Since this is equivalent to 35%
biphenyl in the overhead toluene-rich vapor stream, it is easy to show that this separation can
be accomplished using a single-stage flash unit, V-101, operating at 20 psia. The operating
temperature of the flash is manipulated using Adjust object ADJ-2 to maintain the biphenyl
molar flow rate in the toluene recycle, S-18, at the 1 lbmol/hr target, achieved with a
temperature of 285.5 oF. Since the overhead vapor stream needs to be compressed to 569 psia,
this is best achieved by first cooling the stream to below the dew point to fully condense it in
stream S-19 (using E-103), followed by the installation of a pump, P-102, to product stream
S-20. At this stage, do not close the toluene recycle loop.
c) Fix the hydrogen feed flow rate arbitrarily at some value above the 549 lb/hr lower limit (say
700 lb/hr). Then, install a spreadsheet in which calculations are performed, as shown below.
Note that the spreadsheet tracks: (1) the estimated total hydrogen flow that needs to be fed to
account for losses in the purge and fuel gas streams [in cells B1-B4]; (2) a calculation of the
methane accumulation in the process, accounting for the estimated total hydrogen flow that
needs to be fed to account for losses in the purge [cell B6] and fuel gas streams [cell B7] and
net methane production [B9 - B8] – i.e., cell B10 should be zero for no accumulation of
methane; (c) Calculation the H2:Toluene molar ratio in the reactor feed [in cell D3].
d) Since the purge stream flow rate has to be large enough to ensure that methane does not
accumulate in the system, Adjust object ADJ-3 is installed to manipulate the purge fraction
in TEE-101 so that the CH4 balance is maintained at zero, and the second recycle loop is
closed by installing RCY-2.
e) Finally, the third recycle loop is closed by installing RCY-3. The hydrogen feed rate is
manipulated manually to a value of 600 lb/hr, to obtain a H2:Toluene ratio in the reactor
feed close to four.
SM-7-61
The results of the simulation are summarized in Table 1, and can be reproduced by running the file EXER7_4.hsc (in the HYSYS folder, under
Computer Solution Files, associated with the Solution Manual on the Wiley web site for this book).
Figure 1. HYSYS PFD for the complete process for hydrodealkylation of toluene.
SM-7-62
Name Toluene_Feed H2_Feed S-20* S-13* S-1 S-2 S-3 S-4

Vapour Fraction 0.0 1.0 0.0 1.0 1.0 1.0 1.0 1.0
Temperature (F) 75.0 100.0 243.5 128.5 126.7 1000.0 1200.0 1268.0
Pressure (psia) 569.0 569.0 569.0 569.0 569.0 564.0 494.0 494.0
Molar Flow (lbmole/hr) 274.2 297.6 79.7 10,010.0 10,660.0 10,660.0 10,660.0 10,660.0
Mass Flow (lb/hr) 25,270.0 600.0 7353.0 150,100.0 183,300.0 183,300.0 183,300.0 183,300.0
Liquid Volume Flow (barrel/day) 1988.0 588.1 576.6 34990.0 38140.0 38140.0 38140.0 38280.0
Heat Flow (Btu/hr) 1.45E+06 5.30E+04 1.06E+06 -2.77E+08 -2.74E+08 -1.49E+08 -1.14E+08 -1.07E+08
Comp Molar Flow (Hydrogen) (lbmole/hr) 0.0 297.6 0.0 1,154.3 1,451.9 1,451.9 1,451.9 1,186.5
Comp Molar Flow (Methane) (lbmole/hr) 0.0 0.0 0.0 8,762.7 8,762.7 8,762.7 8,762.7 9,031.6
Name S-10* S-5 S-6 S-7 S-8 S-9 S-10 S-11
Vapour Fraction 0.0 1.0 1.0 0.9 0.0 0.0 0.0 1.0
Temperature (F) 100.1 1193.0 440.2 100.0 100.0 100.0 100.1 100.0
Pressure (psia) 494.0 494.0 489.0 484.0 484.0 484.0 494.0 484.0
Mass Flow (lb/hr) 19,300.0 202,600.0 202,600.0 202,600.0 48,370.0 19,300.0 19,300.0 154,200.0
Liquid Volume Flow (barrel/day) 1,542.0 39,820.0 39,820.0 39,820.0 3,866.0 1,542.0 1,542.0 35,960.0
Heat Flow (Btu/hr) 3.73E+06 -1.04E+08 -2.28E+08 -2.77E+08 9.36E+06 3.73E+06 3.73E+06 -2.87E+08
SM-7-63
Table 1. HYSYS-generated Stream Data for Exercise 7.4 (Cont’d).
Name S-12 Purge S-13 S-14 Fuel Gas S-15 Benzene Prod S-17
Vapour Fraction 1.0 1.0 1.0 0.0 1.0 0.0 0.0 0.0
Temperature (F) 100.0 100.0 128.5 100.0 131.1 348.0 195.2 251.3
Pressure (psia) 484.0 484.0 569.0 484.0 120.0 120.0 20.0 20.0
Molar Flow (lbmole/hr) 10,010.0 276.0 10,010.0 375.5 29.1 346.4 258.3 88.1
Mass Flow (lb/hr) 150,100.0 4,139.0 150,100.0 29,080.0 553.0 28,530.0 20,180.0 8,347.0
Liquid Volume Flow (barrel/day) 34,990.0 965.0 34,990.0 2,324.0 109.8 2,214.0 1,566.0 648.2
Heat Flow (Btu/hr) -2.79E+08 -7.69E+06 -2.77E+08 5.62E+06 -8.16E+05 9.81E+06 6.47E+06 1.38E+06
Name S-18 Biphenyl Prod S-19 S-20
Vapour Fraction 1.0 0.0 0.0 0.0
Temperature (F) 285.5 285.5 240.0 243.5
Pressure (psia) 20.0 20.0 20.0 569.0
Molar Flow (lbmole/hr) 79.7 8.4 79.7 79.7
Mass Flow (lb/hr) 7,353.0 994.0 7,353.0 7,353.0
Liquid Volume Flow (barrel/day) 576.6 71.6 576.6 576.6
Heat Flow (Btu/hr) 2.30E+06 3.22E+05 1.03E+06 1.06E+06
Comp Molar Flow (Hydrogen) (lbmole/hr) 0.0 0.0 0.0 0.0
Comp Molar Flow (Methane) (lbmole/hr) 0.0 0.0 0.0 0.0
Comp Molar Flow (Benzene) (lbmole/hr) 3.3 0.1 3.3 3.3
Comp Molar Flow (Toluene) (lbmole/hr) 75.4 4.8 75.4 75.4
Comp Molar Flow (BiPhenyl) (lbmole/hr) 1.0 3.5 1.0 1.0
SM-7-64
Table 1. HYSYS-generated Stream Data for Exercise 7.4 (Cont’d).
Compositions
Name Toluene_Feed H2_Feed S-20* S-13* S-1 S-2 S-3 S-4
Comp Mole Frac (Hydrogen) 0 1 0 0.1153 0.1362 0.1362 0.1362 0.1113
Comp Mole Frac (Methane) 0 0 0 0.8756 0.8221 0.8221 0.8221 0.8473
Comp Mole Frac (Benzene) 0 0 0.0414 0.0082 0.008 0.008 0.008 0.0325
Comp Mole Frac (Toluene) 1 0 0.9464 0.0009 0.0336 0.0336 0.0336 0.0084
Comp Mole Frac (BiPhenyl) 0 0 0.0122 0 0.0001 0.0001 0.0001 0.0004
Name S-10* S-5 S-6 S-7 S-8 S-9 S-10 S-11
Comp Mole Frac (BiPhenyl) 0.012 0.0007 0.0007 0.0007 0.012 0.012 0.012 0
Name S-12 Purge S-13 S-14 Fuel Gas S-15 Benzene Product S-17
Comp Mole Frac (Hydrogen) 0.1153 0.1153 0.1153 0.001 0.0132 0 0 0
Comp Mole Frac (Methane) 0.8756 0.8756 0.8756 0.0727 0.9373 0 0 0
Comp Mole Frac (BiPhenyl) 0 0 0 0.012 0 0.013 0 0.0512
Name S-18 Biphenyl Product S-19 S-20
Comp Mole Frac (Hydrogen) 0 0 0 0
Comp Mole Frac (Methane) 0 0 0 0
Comp Mole Frac (Benzene) 0.0414 0.0122 0.0414 0.0414
Comp Mole Frac (Toluene) 0.9464 0.5676 0.9464 0.9464
Comp Mole Frac (BiPhenyl) 0.0122 0.4202 0.0122 0.0122
Energy Streams
Name E101_Duty R_Duty E102_Duty V100_Duty P100_Duty T100_Duty
Heat Flow (Btu/hr) 3.51E+07 6.84E+06 4.90E+07 -2.48E-08 908.2 3.37E+06
Name T101_CDuty T101_RDuty K100_Duty V101_Duty P101_Duty E103_Duty
Heat Flow (Btu/hr) 8.05E+06 6.08E+06 2.37E+06 1.25E+06 2.05E+04 1.27E+06
SM-7-65
Exercise 7.4 – Hydrodealkylation Process Page 1
For a process, such as this, that involves three recycle streams and an unknown flow rate for the
makeup hydrogen feed, it is best to first obtain a good initial estimate of the material balance.
This is done here by using perfect separations with simple split fraction models for the three
distillation columns. Also, the preheater that heats the combined reactor feed to 1,000oF by heat
exchange with the quenched reactor effluent is replaced by two one-sided heat exchangers to
simplify convergence. To avoid carbon deposition in the reactor, a hydrogen-to-toluene ratio of
4 is used for the combined reactor feed. This ratio is achieved by controlling the make-up
hydrogen flow rate. Two reactor models are used to handle the two reactions. The 1,150oF
quench temperature is achieved by controlling the split ratio in the divider on the flash liquid.
The tear (cut) streams and the calculation sequence must be selected carefully to avoid
convergence problems of both the cut streams and the controllers. The initial guesses for the
three cut streams and the make-up hydrogen stream are as follows:
Stream 25 Stream 3 Stream 16 Stream 27

Tol recycle Gas recycle Flash liquid Make-up H2
Temp, oF 250 120 100 70
Pres, psia 569 569 484 569
Flows,
Lbmol/hr:
H2 0 916 0 548
CH4 0 916 0 0
Benzene 0 0 364 0
Toluene 92 0 122 0
Diphenyl 0 0 0 0
FLOWSHEET SUMMARY
1 MIXE 26 1 25 -5
2 HTXR 5 -9
3 FIRE 9 -7
4 REAC 28 -6
5 REAC 6 -8
6 HTXR 4 -14
7 FLAS 14 -19 -16
8 PUMP 13 -12
9 DIVI 16 -13 -17
10 MIXE 8 12 -11
11 CONT 11 -4
12 COMP 15 -3
SM-7-66
13 DIVI 19 -15 -18

14 CSEP 17 -20 -21
15 CSEP 21 -22 -23
16 CSEP 23 -2 -24
17 PUMP 2 -25
18 MIXE 27 3 -26
19 CONT 7 -28
Stream Connections

1 1 11 10 11 20 14
2 16 17 12 8 10 21 14 15
3 12 18 13 9 8 22 15
4 11 6 14 6 7 23 15 16
5 1 2 15 13 12 24 16
6 4 5 16 7 9 25 17 1
7 3 19 17 9 14 26 18 1
8 5 10 18 13 27 18
9 2 3 19 7 13 28 19 4

18 9 8 14 15 16 17 1 2 3 19 4 5 10 11 6 7 13
12

18 9 8 14 15 16 17 1 2 3 19 4 5 10 11 6 7 13
12
Recycle Cut Streams

3 25 16
Recycle Convergence Method: Wegstein
Wegstein lower bound -5.00 Wegstein upper bound 0.00

Acceleration frequency 4

Pressure 1.000E-003
Enthalpy 1.000E-003
SM-7-67
COMPONENTS
ID # Name
1 1 Hydrogen
2 2 Methane
3 40 Benzene
4 41 Toluene
5 194 Diphenyl
THERMODYNAMICS
K-value model : Grayson Streed

Enthalpy model : Lee-Kesler

Hydrogen 510.197 239.434 1028.455 482.652
Methane 0.000 273.669 0.000 4390.471
Benzene 0.000 267.872 0.000 20924.532
Toluene 274.200 0.527 25265.063 48.516
Diphenyl 0.000 2.901 0.000 447.377
Total 784.397 784.403 26293.518 26293.547
EQUIPMENT SUMMARIES
Mixer Summary
Equip. No. 1 10 18
Name
Output Pressure psia 569.0000 494.0000
Equip. No. 2 6
Name
Pressure drop 2 psi 5.0000
T Out Str 1 F 1000.0001 100.0000
Calc Ht Duty MMBtu/h 40.2604 -55.0091
LMTD (End points) F 190.3567
Str1 Pout psia 564.0000 484.0000
Str2 Pout psia 479.0000
Fired Heater Summary
Equip. No. 3
Name
Pressure Drop psi 70.0000
Temperature Out F 1200.0000
Heat Absorbed MMBtu/h 9.8172
Fuel Usage(SCF) 14544.0400
SM-7-68
Reactor Summary
Equip. No. 4 5
Name
Thermal mode 1 1
Temperature F 1317.4574 1316.7316
Key Component 4 3
Reactor Pressure psia 494.0000 494.0000
Calc H of Reac. -18116.8672 2736.4453
(Btu/lbmol)
Stoichiometrics:
Hydrogen -1.000 1.000
Methane 1.000 0.000E+000
Benzene 1.000 -2.000
Toluene -1.000 0.000E+000
Diphenyl 0.000E+000 1.000
EQUIPMENT SUMMARIES
Flash Summary
Equip. No. 7
Name
K values:
Hydrogen 84.722
Methane 11.251
Benzene 0.012
Toluene 4.465E-003
Diphenyl 3.185E-005
Pump Summary
Equip. No. 8 17
Name
Output pressure psia 494.0000 569.0000
Efficiency 0.7000 1.0000
Calculated power hp 0.2511 6.8088
Calculated Pout psia 494.0000 569.0000
Head ft 28.0226 1650.4027
Vol. flow rate ft3/hr 241.5509 170.4132
Mass flow rate lb/h 12412.6006 8162.9697
Divider Summary
Equip. No. 9 13
Name
Split based on 1 0
Output stream #1 157.6102 0.8000
SM-7-69
Controller Summary
Equip. No. 11 19
Name
Mode 2 2
Equip. no. adjusted 9 0
Stream no. adjusted 0 27
Variable No. 3 5
Sign Flag 0 2
Tolerance 1.0000e-005
Iterations 100 0
Measured variables:
Number 11 7
Variable 1 -1
Operator 0 4
Number 0 7
Variable 0 -4
Constant 1150.0000 4.0000
Units 2 0
Compressor Summary
Equip. No. 12
Name
Pressure out psia 569.0000
Type of Compressor 1
Efficiency 1.0000
Actual power hp 144.4753
Cp/Cv 1.3683
Theoretical power hp 144.4753
Ideal Cp/Cv 1.3240
Calc Pout psia 569.0000
Calc. mass flowrate 19854
(lb/h)
Component Separator Summary
Equip. No. 14 15 16
Name
Pressure Out psia 100.0000 20.0000 20.0000
Top Temp Mode 0 1 1
Top Temp Spec 100.0000
Bottom Temp Mode 1 1 1
Component No. 1 1.0000 1.0000 1.0000
Component No. 2 1.0000 1.0000 1.0000
Component No. 3 1.0000 1.0000
Component No. 4 1.0000
SM-7-70
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name Feed Toluene recy Gas recycle Mixed feed
Temp F 75.0000 252.9280 123.6960 1150.0000
Pres psia 569.0000 20.0000 569.0000 494.0000
Enth MMBtu/h 1.4000 1.0967 -31.781 23.303
Total lbmol/h 274.2000 88.5922 1994.0187 3024.6233
Hydrogen 0.0000 0.0000 949.3198 1189.6398
Methane 0.0000 0.0000 1026.1588 1307.0370
Benzene 0.0000 0.0000 16.4334 395.3141
Toluene 274.2000 88.5922 2.1061 128.5101
Diphenyl 0.0000 0.0000 0.0005 4.1225
Stream No. 5 6 7 8
Stream Name Preheated fe R feed 2 R feed 1 Reactor effl
Temp F 117.1819 1317.4574 1200.0000 1316.7316
Pres psia 569.0000 494.0000 494.0000 494.0000
Enth MMBtu/h -29.287 20.790 20.790 20.790
Total lbmol/h 2867.0129 2867.0132 2867.0129 2867.0132
Hydrogen 1459.5267 1185.8530 1459.5267 1188.7542
Methane 1026.1541 1299.8279 1026.1541 1299.8279
Benzene 16.4334 290.1071 16.4334 284.3050
Toluene 364.8984 91.2246 364.8984 91.2246
Diphenyl 0.0005 0.0005 0.0005 2.9016
Stream No. 9 11 12 13
Stream Name Part cooled Quenched eff Pumped quenc Recycle quen
Temp F 1000.0000 1150.0000 100.0726 100.0000
Pres psia 564.0000 494.0000 494.0000 484.0000
Enth MMBtu/h 10.973 23.303 2.5124 2.5117
Total lbmol/h 2867.0129 3024.6233 157.6102 157.6102
Hydrogen 1459.5267 1189.6398 0.8857 0.8857
Methane 1026.1541 1307.0370 7.2091 7.2091
Benzene 16.4334 395.3141 111.0091 111.0091
Toluene 364.8984 128.5101 37.2854 37.2854
Diphenyl 0.0005 4.1225 1.2209 1.2209
SM-7-71
FLOW SUMMARIES
Stream No. 14 15 16 17
Stream Name Cooled effl Recycle vapo Flash liquid Sep Sys feed
Temp F 100.0000 100.0000 100.0000 100.0000
Pres psia 484.0000 484.0000 484.0000 484.0000
Enth MMBtu/h -31.706 -32.149 8.4797 5.9680
Total lbmol/h 3024.6233 1994.0187 532.1002 374.4901
Hydrogen 1189.6398 949.3198 2.9901 2.1044
Methane 1307.0370 1026.1588 24.3385 17.1292
Benzene 395.3141 16.4334 374.7723 263.7634
Toluene 128.5101 2.1061 125.8773 88.5922
Diphenyl 4.1225 0.0005 4.1219 2.9009
Stream No. 18 19 20 21
Stream Name Gas purge Flash vapor Light gas C-1 bottoms
Temp F 100.0000 100.0000 100.0000 335.2795
Pres psia 484.0000 484.0000 100.0000 100.0000
Enth MMBtu/h -8.0372 -40.186 -0.54809 9.6614
Total lbmol/h 498.5047 2492.5232 19.2336 355.2565
Hydrogen 237.3300 1186.6498 2.1044 0.0000
Methane 256.5397 1282.6985 17.1292 0.0000
Benzene 4.1083 20.5417 0.0000 263.7634
Toluene 0.5265 2.6327 0.0000 88.5922
Diphenyl 0.0001 0.0006 0.0000 2.9009
Stream No. 22 23 24 25
Stream Name Benzene prod C-2 bottoms Diphenyl pro Pumped Tol r
Temp F 195.9982 255.2597 522.3394 255.3508
Pres psia 20.0000 20.0000 20.0000 569.0000
Enth MMBtu/h 6.6430 1.2811 0.23438 1.1140
Total lbmol/h 263.7634 91.4931 2.9009 88.5922
Hydrogen 0.0000 0.0000 0.0000 0.0000
Methane 0.0000 0.0000 0.0000 0.0000
Benzene 263.7634 0.0000 0.0000 0.0000
Toluene 0.0000 88.5922 0.0000 88.5922
Diphenyl 0.0000 2.9009 2.9009 0.0000
SM-7-72
FLOW SUMMARIES
Stream No. 26 27 28
Stream Name Combined H2 Fresh H2 Reactor feed
Temp F 113.3660 70.0000 1200.0000
Pres psia 569.0000 569.0000 494.0000
Enth MMBtu/h -31.801 -0.020194 20.790
Total lbmol/h 2504.2209 510.1971 2867.0129
Hydrogen 1459.5269 510.1971 1459.5267
Methane 1026.1541 0.0000 1026.1541
Benzene 16.4334 0.0000 16.4334
Toluene 2.1062 0.0000 364.8984
Diphenyl 0.0005 0.0000 0.0005
The results show that considerable hydrogen is lost to the purge. An economic study should be
made to determine the optimal purge ratio, but should consider adding a vapor separation system
to separate hydrogen from methane by adsorption or membranes.
SM-7-73
Studies
ASPEN PLUS Solution

CL2
R1
S1 M1 P1 H1 R2 H2 H3
S2 S3 S4 S5 S6
RSTOIC
MIXER PUMP HEATER RSTOIC HEATER HEATER
C2H4
S7
RECYCOLD
HCL VC
D1 D2
SEP2 DSTWU
S8
C1
HEATER
RECY
ASPEN PLUS Program
TITLE 'Vinyl Chloride Process Simulation'

IN-UNITS ENG
DESCRIPTION "General Simulation with English Units :
F, psi, lb/hr, lbmol/hr, Btu/hr, cuft/hr.
Property Method: None
Flow basis for input: Mole
Stream report composition: Mole flow"
NOASPENPCD
COMPONENTS
CL2 CL2 /
HCL HCL /
C2H4 C2H4 /
C2H3CL C2H3CL /
C2H4CL2 C2H4CL2-2
FLOWSHEET
BLOCK R1 IN=CL2 C2H4 OUT=S1
BLOCK M1 IN=S1 RECYCOLD OUT=S2
BLOCK P1 IN=S2 OUT=S3
BLOCK R2 IN=S4 OUT=S5
BLOCK D2 IN=S8 OUT=VC RECY
BLOCK D1 IN=S7 OUT=HCL S8
BLOCK C1 IN=RECY OUT=RECYCOLD
SM-7-74
PROPERTIES UNIQUAC
PROPERTIES UNIFAC
PROP-DATA UNIQ-1
IN-UNITS ENG
PROP-LIST UNIQ
BPVAL HCL C2H3CL -2.380400000 655.2858548 0.0 0.0 &
-113.2599951 -113.2599951
BPVAL C2H3CL HCL -16.47000000 5827.908193 0.0 0.0 &
-113.2599951 -113.2599951
BPVAL C2H3CL C2H4CL2 0.0 56.84975955 0.0 0.0 50.00000360 &
131.0000030
BPVAL C2H4CL2 C2H3CL 0.0 -15.91469987 0.0 0.0 50.00000360 &
131.0000030
STREAM C2H4
SUBSTREAM MIXED TEMP=25. <C> PRES=1.5 <atm> MOLE-FLOW=1600.
MOLE-FRAC C2H4 1.
STREAM CL2
SUBSTREAM MIXED TEMP=25. <C> PRES=1.5 <atm> MOLE-FLOW=1600.
MOLE-FRAC CL2 1.
BLOCK M1 MIXER
PARAM PRES=1.5 <atm>
BLOCK D1 SEP2
FRAC STREAM=S8 SUBSTREAM=MIXED COMPS=CL2 HCL C2H4 C2H3CL &
C2H4CL2 FRACS=0. 0.001 0. 1. 1.
BLOCK C1 HEATER
PARAM TEMP=90. PRES=1.5 <atm>
BLOCK H1 HEATER
PARAM PRES=26. <atm> VFRAC=1.
BLOCK H2 HEATER
BLOCK H3 HEATER
BLOCK D2 DSTWU
PARAM LIGHTKEY=C2H3CL RECOVL=0.99 HEAVYKEY=C2H4CL2 &
RECOVH=0.01 PTOP=4.8 <atm> PBOT=4.8 <atm> RR=-1.3
BLOCK R1 RSTOIC
PARAM TEMP=90. <C> PRES=1.5 <atm>
STOIC 1 MIXED C2H4 -1. / CL2 -1. / C2H4CL2 1.
CONV 1 MIXED C2H4 1.
BLOCK R2 RSTOIC
PARAM TEMP=500. <C> PRES=26. <atm>
STOIC 1 MIXED C2H4CL2 -1. / C2H3CL 1. / HCL 1.
CONV 1 MIXED C2H4CL2 0.6
BLOCK P1 PUMP
PARAM PRES=26. <atm>
STREAM-REPOR MOLEFLOW MASSFLOW
Stream Variables
Note that these results were obtained using the UNIQUAC option set. The vapor-liquid
equilibrium calculations for the streams involving HCl are inaccurate. It is
recommended that experimental data, and possibly an improved option set, be utilized
to improve these results. Given an improved VLE model, the DSTWU subroutine can
replace the SEP2 subroutine for the unit D1.
SM-7-75
C2H4 CL2 HCL RECY RECYCOLD
--------------------------
STREAM ID C2H4 CL2 HCL RECY RECYCOLD

FROM : ---- ---- D1 D2 C1
TO : R1 R1 ---- C1 M1
MAX CONV. ERROR: 0.0 0.0 0.0 0.0 -6.4160-05

SUBSTREAM: MIXED
PHASE: VAPOR VAPOR VAPOR LIQUID LIQUID
CL2 0.0 1600.0000 0.0 0.0 0.0
HCL 0.0 0.0 1587.8146 1.8505-07 1.8506-07
C2H4 1600.0000 0.0 0.0 0.0 0.0
C2H3CL 0.0 0.0 0.0 16.0546 16.0546
C2H4CL2 0.0 0.0 0.0 1049.0066 1049.0066
COMPONENTS: LB/HR
CL2 0.0 1.1345+05 0.0 0.0 0.0
HCL 0.0 0.0 5.7893+04 6.7471-06 6.7475-06
C2H4 4.4886+04 0.0 0.0 0.0 0.0
C2H3CL 0.0 0.0 0.0 1003.3878 1003.3878
C2H4CL2 0.0 0.0 0.0 1.0381+05 1.0381+05
TOTAL FLOW:
LBMOL/HR 1600.0000 1600.0000 1587.8146 1065.0612 1065.0612
LB/HR 4.4886+04 1.1345+05 5.7893+04 1.0481+05 1.0481+05
CUFT/HR 4.1802+05 4.1802+05 4.5141+04 1586.5893 1361.9008
STATE VARIABLES:
TEMP F 77.0000 77.0000 7.5192 282.5860 90.0000
PRES PSI 22.0439 22.0439 176.3514 70.5406 22.0439
VFRAC 1.0000 1.0000 1.0000 0.0 0.0
LFRAC 0.0 0.0 0.0 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 2.2575+04 8.0079-13 -4.0170+04 -6.2864+04 -6.9369+04
BTU/LB 804.7134 1.1294-14 -1101.7294 -638.7965 -704.9026
BTU/HR 3.6120+07 1.2813-09 -6.3782+07 -6.6954+07 -7.3882+07
ENTROPY:
BTU/LBMOL-R -13.5666 -0.8052 -3.5044 -57.0087 -66.9021
BTU/LB-R -0.4836 -1.1356-02 -9.6114-02 -0.5793 -0.6798
DENSITY:
LBMOL/CUFT 3.8276-03 3.8276-03 3.5175-02 0.6713 0.7820
LB/CUFT 0.1074 0.2714 1.2825 66.0613 76.9602
AVG MW 28.0538 70.9054 36.4606 98.4096 98.4096
S1 S2 S3 S4 S5
--------------
FROM : R1 M1 P1 H1 R2
TO : M1 P1 H1 R2 H2
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID VAPOR VAPOR
CL2 0.0 0.0 0.0 0.0 0.0
HCL 0.0 1.8506-07 1.8506-07 1.8506-07 1589.4040
C2H4 0.0 0.0 0.0 0.0 0.0
C2H3CL 0.0 16.0546 16.0546 16.0546 1605.4586
C2H4CL2 1600.0000 2649.0066 2649.0066 2649.0066 1059.6026
SM-7-76
COMPONENTS: LB/HR
CL2 0.0 0.0 0.0 0.0 0.0
HCL 0.0 6.7475-06 6.7475-06 6.7475-06 5.7951+04
C2H4 0.0 0.0 0.0 0.0 0.0
C2H3CL 0.0 1003.3878 1003.3878 1003.3878 1.0034+05
C2H4CL2 1.5833+05 2.6214+05 2.6214+05 2.6214+05 1.0486+05
TOTAL FLOW:
LBMOL/HR 1600.0000 2665.0612 2665.0612 2665.0612 4254.4652
LB/HR 1.5833+05 2.6315+05 2.6315+05 2.6315+05 2.6315+05
CUFT/HR 2209.1848 3567.0757 3577.3963 6.8878+04 1.6629+05
STATE VARIABLES:
TEMP F 194.0000 153.9902 157.9219 460.5425 932.0000
PRES PSI 22.0439 22.0439 382.0947 382.0947 382.0947
VFRAC 0.0 0.0 0.0 1.0000 1.0000
LFRAC 1.0000 1.0000 1.0000 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -6.7184+04 -6.8057+04 -6.7930+04 -4.6967+04 -1.0598+04
BTU/LB -678.9039 -689.2593 -687.9733 -475.6694 -171.3421
BTU/HR -1.0749+08 -1.8138+08 -1.8104+08 -1.2517+08 -4.5088+07
ENTROPY:
BTU/LBMOL-R -62.1852 -63.9392 -63.7349 -39.2551 -4.0981
BTU/LB-R -0.6284 -0.6476 -0.6455 -0.3976 -6.6256-02
DENSITY:
LBMOL/CUFT 0.7242 0.7471 0.7450 3.8692-02 2.5585-02
LB/CUFT 71.6711 73.7710 73.5582 3.8205 1.5825
AVG MW 98.9592 98.7395 98.7395 98.7395 61.8519
S6 S7 S8 VC
-----------
STREAM ID S6 S7 S8 VC
FROM : H2 H3 D1 D2
TO : H3 D1 D2 ----
SUBSTREAM: MIXED
PHASE: VAPOR LIQUID LIQUID LIQUID
CL2 0.0 0.0 0.0 0.0
HCL 1589.4040 1589.4040 1.5894 1.5894
C2H4 0.0 0.0 0.0 0.0
C2H3CL 1605.4586 1605.4586 1605.4586 1589.4040
C2H4CL2 1059.6026 1059.6026 1059.6026 10.5960
COMPONENTS: LB/HR
CL2 0.0 0.0 0.0 0.0
HCL 5.7951+04 5.7951+04 57.9507 57.9507
C2H4 0.0 0.0 0.0 0.0
C2H3CL 1.0034+05 1.0034+05 1.0034+05 9.9335+04
C2H4CL2 1.0486+05 1.0486+05 1.0486+05 1048.5739
TOTAL FLOW:
LBMOL/HR 4254.4652 4254.4652 2666.6506 1601.5894
LB/HR 2.6315+05 2.6315+05 2.0525+05 1.0044+05
CUFT/HR 9.5055+04 3791.5554 2932.1701 1677.9267
STATE VARIABLES:
TEMP F 335.8379 7.5192 7.5192 30.0079
PRES PSI 382.0947 176.3514 176.3514 70.5406
VFRAC 1.0000 0.0 0.0 0.0
LFRAC 0.0 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -2.0647+04 -3.4726+04 -2.8006+04 1726.6942
BTU/LB -333.8116 -561.4351 -363.8543 27.5329
BTU/HR -8.7841+07 -1.4774+08 -7.4683+07 2.7655+06
ENTROPY:
BTU/LBMOL-R -13.4211 -35.2101 -47.4074 -32.2668
BTU/LB-R -0.2170 -0.5693 -0.6159 -0.5145
SM-7-77
DENSITY:
LBMOL/CUFT 4.4758-02 1.1221 0.9094 0.9545
LB/CUFT 2.7684 69.4034 70.0008 59.8607
AVG MW 61.8519 61.8519 76.9708 62.7139
SM-7-78
HYSYS Solution
(a) The process for the manufacture of vinyl chloride from ethylene and chlorine, as given in
the flowsheet in Fig. 2.17 is simulated in HYSYS. The extended NRL method was adopted
for property predictions – this uses UNIFAC for VLE estimation and assumes ideal gas for
the vapor phase. Perfect separation and isobaric conditions are assumed in the two columns.
Fig.1 gives the PFD for the process, while Table 1 summarizes the stream data obtained,
which can be reproduced by running the file EXER7_5A.hsc (in the HYSYS folder, under
Computer Solution Files, associated with the Solution Manual on the Wiley web site for
this book).
(b) Much of the heat integration possible in this system relies on the exploitation of the
considerable heat sources and sinks associated with the two columns. However, having
modeled them as component splitters prevents these being considered for heat integration.
Instead, a very simple heat-integrated configuration has been implemented in Fig. 2, in
which the hot furnace effluent is used to preheat the furnace feed, noting that the sum of
the heating requirements of the units E-101, F-100 and R-101 in Fig. 1 sum to 138×106
Btu/hr, while the cooling requirements of the units E-102 and E-103 sum to 92.5×106
Btu/hr. This policy assumes that the carbon formation rate is insignificant. The new
exchanger, E-100, has been designed to ensure a minimum temperature approach of 10 oC,
with the temperature profiles in the exchanger shown in the plot below.
The above figure shows temperature profiles in exchanger E-100 in the heat-
integrated flowsheet for VC maufacture. Note the closest temperature approach of 10
o
C.
The heating train duty requirements are reduced by 39% to 84.1×106 Btu/hr, while the
cooling train duty requirements are reduced by 58% to 38.5×106 Btu/hr. Stream data are
given in Table 2, and details of the design for E-100 are given in Table 3. These results can
be reproduced by running the file EXER7_5B.hsc.
SM-7-79
Figure 1. HYSYS PFD for the original process for VC manufacture.
SM-7-80
Table 1. HYSYS-generated Stream Data for Exercise 7.5(a)
Material Streams
Name 1 2 3 16* 4 5 6A 6B 7
Vapour Fraction 1.0 1.0 0.0 0.0 0.0 0.0 1.0 1.0 1.0
Temperature (C) 25.0 25.0 90.0 90.0 90.0 92.1 239.4 500.0 500.0
Pressure (atm) 1.5 1.5 1.5 4.8 1.5 26.0 26.0 26.0 26.0
Molar Flow (lbmole/hr) 1,600.0 1,600.0 1,600.0 1,067.0 2,667.0 2,667.0 2,667.0 2,667.0 4,267.0
Mass Flow (lb/hr) 44,890.0 113,400.0 158,300.0 105,600.0 263,900.0 263,900.0 263,900.0 263,900.0 263,900.0
Heat Flow (Btu/hr) 3.60E+07 0 -1.08E+08 -7.18E+07 -1.80E+08 -1.79E+08 -1.26E+08 -9.08E+07 -4.11E+07
Comp Molar Flow (Ethylene) (lbmole/hr) 1,600.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (Cl2) (lbmole/hr) 0.0 1,600.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (12-ClC2) (lbmole/hr) 0.0 0.0 1,600.0 1,066.7 2,666.7 2,666.7 2,666.7 2,666.7 1,066.7
Comp Molar Flow (VinylCl) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1,600.0
Comp Molar Flow (HCl) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1,600.0
Name 8 9 10 11 12 13 14 15 16
Vapour Fraction 1.0 0.0 0.2 1.0 0.0 0.2 1.0 0.0 0.0
Temperature (C) 170.0 38.3 17.2 -26.0 94.5 59.9 32.8 143.4 90.0
Pressure (atm) 26.0 26.0 12.0 12.0 12.0 4.8 4.8 4.8 4.8
Mass Flow (lb/hr) 263,900.0 263,900.0 263,900.0 58,340.0 205,500.0 205,500.0 99,990.0 105,600.0 105,600.0
Heat Flow (Btu/hr) -8.39E+07 -1.34E+08 -1.34E+08 -6.46E+07 -5.58E+07 -5.58E+07 2.45E+07 -6.84E+07 -7.18E+07
Comp Molar Flow (Ethylene) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (Cl2) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (12-ClC2) (lbmole/hr) 1,066.7 1,066.7 1,066.7 0.0 1,066.7 1,066.7 0.0 1,066.7 1,066.7
Comp Molar Flow (VinylCl) (lbmole/hr) 1,600.0 1,600.0 1,600.0 0.0 1,600.0 1,600.0 1,600.0 0.0 0.0
Comp Molar Flow (HCl) (lbmole/hr) 1,600.0 1,600.0 1,600.0 1,600.0 0.0 0.0 0.0 0.0 0.0
Energy Streams
Name R100_Duty P100_Duty E101_Duty F100_Duty R101_Duty
Heat Flow (Btu/hr) -1.44E+08 3.30E+05 5.31E+07 3.53E+07 4.97E+07
Name E102_Duty E103_Duty T100_Duty T101_Duty E108_Duty
SM-7-81
Heat Flow (Btu/hr) 4.28E+07 4.97E+07 1.32E+07 1.19E+07 3.46E+06
Figure 2. HYSYS PFD for the heat-integrated process for VC manufacture.
SM-7-82
Table 2. HYSYS-generated Stream Data for Exercise 7.5(b)
Material Streams
Name 1 2 3 16* 4 5 6A 6B 7
Vapour Fraction 1.0 1.0 0.0 0.0 0.0 0.0 1.0 1.0 1.0
Temperature (C) 25.0 25.0 90.0 90.0 90.0 92.1 246.8 500.0 500.0
Pressure (atm) 1.5 1.5 1.5 4.8 1.5 26.0 26.0 26.0 26.0
Mass Flow (lb/hr) 44,890.0 113,400.0 158,300.0 105,600.0 263,900.0 263,900.0 263,900.0 263,900.0 263,900.0
Heat Flow (Btu/hr) 3.60E+07 0 -1.08E+08 -7.18E+07 -1.80E+08 -1.79E+08 -1.25E+08 -9.08E+07 -4.11E+07
Comp Molar Flow (Ethylene) (lbmole/hr) 1,600.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (Cl2) (lbmole/hr) 0.0 1,600.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (12-ClC2) (lbmole/hr) 0.0 0.0 1,600.0 1,066.7 2,666.7 2,666.7 2,666.7 2,666.7 1,066.7
Comp Molar Flow (VinylCl) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1,600.0
Comp Molar Flow (HCl) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1,600.0
Name 8 9 10 11 12 13 14 15 16
Vapour Fraction 0.8 0.0 0.2 1.0 0.0 0.2 1.0 0.0 0.0
Temperature (C) 146.0 38.3 17.2 -26.0 94.5 59.9 32.8 143.4 90.0
Pressure (atm) 26.0 26.0 12.0 12.0 12.0 4.8 4.8 4.8 4.8
Mass Flow (lb/hr) 263,900.0 263,900.0 263,900.0 58,340.0 205,500.0 205,500.0 99,990.0 105,600.0 105,600.0
Heat Flow (Btu/hr) -9.51E+07 -1.34E+08 -1.34E+08 -6.46E+07 -5.58E+07 -5.58E+07 2.45E+07 -6.84E+07 -7.18E+07
Comp Molar Flow (Ethylene) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (Cl2) (lbmole/hr) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Comp Molar Flow (12-ClC2) (lbmole/hr) 1,066.7 1,066.7 1,066.7 0.0 1,066.7 1,066.7 0.0 1,066.7 1,066.7
Comp Molar Flow (VinylCl) (lbmole/hr) 1,600.0 1,600.0 1,600.0 0.0 1,600.0 1,600.0 1,600.0 0.0 0.0
Comp Molar Flow (HCl) (lbmole/hr) 1,600.0 1,600.0 1,600.0 1,600.0 0.0 0.0 0.0 0.0 0.0
Energy Streams
Name R100_Duty P100_Duty F100_Duty R101_Duty E103_Duty T100_Duty T101_Duty E108_Duty
Heat Flow (Btu/hr) -1.44E+08 3.30E+05 3.44E+07 4.97E+07 3.85E+07 1.32E+07 1.19E+07 3.46E+06
SM-7-83
Table 3. Design for E-100 in Exercise 7.5(b)
Tube Side Shell Side
Inlet Outlet Inlet Outlet

Name 5 Name 6A Name 7 Name
From Op. P-100 Pump To Op. F-100 Heater From Op. R-101 To Op. E-103 Cooler
Temp 92.11 C Temp 246.82 C Temp 500.00 C Temp 145.97 C
PARAMETERS
Exchanger Design (Weighted)
Tube Side DeltaP: 0.0000 atm Shell Side DeltaP: 0.0000 atm UA: 6.787e+005 Btu/F-hr
Heat Leak/Loss: None Tolerance: 1.0000e-04
Individual Heat Curve Details
SPECS
Specified Value Current Value Relative Error Active Estimate
E-100 Heat Balance 0.0000 Btu/hr 2.793e-007 Btu/hr -8.19E-11 On Off
E-100 UA 6.787e+005 Btu/F-hr Off Off
E-100 ExchSpec 10.00 C 10.00 C -7.83E-04 On On
Detailed Specifications
E-100 Heat Balance
Type: Duty Pass: Error Spec Value: 0.0000 Btu/hr
E-100 UA
Type: UA Pass: Overall Spec Value:
E-100 ExchSpec
Type: Min Approach Pass: Overall Spec Value: 10.00 C
User Variables
DETAILS
Overall/Detailed Performance
Duty: 5.401e+07 Btu/hr UA: 6.787e+05 Btu/F-hr UA Curv. Error: 1.20e+02 Btu/F-hr Ft Factor:
Heat Leak: 0.000e-01 Btu/hr Min. Approach: 10.00 C Hot Pinch Temp: 170.6 C Uncorrected Lmtd:
Heat Loss: 0.000e-01 Btu/hr Lmtd: 44.21 C Cold Pinch Temp: 160.6 C
SM-7-84
Shell Side
Temperature (C) Pressure (atm) Heat Flow (Btu/hr) Enthalpy (Btu/lbmole) Molar Vap Frac Mass Vap Frac
145.97 26 0 -22280.3 0.8107 0.7305
156.55 26 4501158 -21225.35 0.8894 0.8394
160.98 26 6751737 -20697.88 0.9271 0.8933
165.1 26 9002316 -20170.4 0.9653 0.9489
167.04 26 10127606 -19906.67 0.9847 0.9774
167.98 26 10690251 -19774.8 0.9944 0.9917
170.64 26 11252895 -19642.93 1 1
190.36 26 13503475 -19115.46 1 1
209.68 26 15754054 -18587.98 1 1
228.64 26 18004633 -18060.51 1 1
265.61 26 22505791 -17005.56 1 1
301.46 26 27006949 -15950.61 1 1
336.35 26 31508107 -14895.66 1 1
370.4 26 36009265 -13840.71 1 1
436.38 26 45011582 -11730.82 1 1
500 26 54013898 -9620.92 1 1
Tube Side
92.11 26 0 -67196.76 0 0
106.37 26 2250579 -66352.81 0 0
120.36 26 4501158 -65508.85 0 0
147.51 26 9002316 -63820.93 0 0
160.64 26 11252895 -62976.97 0 0
167.1 26 12378185 -62554.99 0 0
173.47 26 13503475 -62133.01 0 0
185.97 26 15754054 -61289.05 0 0
198.13 26 18004633 -60445.1 0 0
208.99 26 20075831 -59668.4 0 0
219.5 26 22147029 -58891.71 0 0
229.65 26 24218227 -58115.02 0 0
239.4 26 26289425 -57338.33 0 0
239.4 26 36009265 -53693.43 0.3624 0.3624
239.4 26 53110551 -47280.51 1 1
246.82 26 54013898 -46941.76 1 1
SM-7-85
Exercise 7.5 – Vinyl Chloride Process Page 1
The following solution is for the flowsheet shown in Figure 2.6. The stream
numbers beginning with S in the material balance table correspond the to
stream numbers in Figure 2.17 and Table 2.7. The UNIQUAC-UNIFAC method is
used for K-values. The tear (cut) stream is 18 (S16) with an initial guess
of the flow rate for 1,2 dichloroethane of 1,067 lbmol/hr based on the 60%
conversion in the pyrolysis reactor. Perfect separations are assumed in the
two distillation columns.
FLOWSHEET SUMMARY
1 REAC 3 -8
2 MIXE 2 1 -3
3 MIXE 8 18 -4
4 PUMP 4 -5
5 HTXR 5 -6
6 HTXR 6 -7
7 HTXR 7 -9
8 REAC 9 -10
9 HTXR 10 -11
10 HTXR 11 -12
11 CSEP 12 -15 -13
12 CSEP 13 -16 -14
14 HTXR 14 -18
Stream Connections

1 2 7 6 7 13 11 12
2 2 8 1 3 14 12 14
3 2 1 9 7 8 15 11
4 3 4 10 8 9 16 12
5 4 5 11 9 10 18 14 3
6 5 6 12 10 11


2 1 3 4 5 6 7 8 9 10 11 12 14

3 4 5 6 7 8 9 10 11 12 14
Recycle Cut Streams

18
SM-7-86

Pressure 1.000E-003
Enthalpy 1.000E-003
COMPONENTS
ID # Name
1 22 Ethylene
2 105 Chlorine
3 127 1,2-DiCl-Ethane
4 122 Vinyl Chloride
5 104 HydrogenChloride
THERMODYNAMICS
K-value model : UNQC ( Uniquac with Unifac R and Q )

Enthalpy model : Latent Heat

Ethylene 1600.000 0.000 44886.401 0.000
Chlorine 1600.000 0.000 113449.597 0.000
1,2-DiCl-Ethane 0.000 0.000 0.000 0.000
Vinyl Chloride 0.000 1600.005 0.000 99998.714
HydrogenChloride 0.000 1600.005 0.000 58337.780
Total 3200.000 3200.010 158336.000 158336.484
SM-7-87
EQUIPMENT SUMMARIES
Reactor Summary
Equip. No. 1 8
Name
Thermal mode 2 2
Temperature C 90.0000 500.0000
Heat duty MMBtu/h -143.2618 41.8937
Key Component 2 3
Reactor Pressure atm 1.5000 26.0000
Calc H of Reac. -78276.9922 28348.1250
(Btu/lbmol)
Stoichiometrics:
Ethylene -1.000 0.000E+000
Chlorine -1.000 0.000E+000
1,2-DiCl-Ethane 1.000 -1.000
Vinyl Chloride 0.000E+000 1.000
HydrogenChlorid 0.000E+000 1.000
Mixer Summary
Equip. No. 2 3
Name
Output Pressure atm 1.5000 1.5000
Pump Summary
Equip. No. 4
Name
Output pressure atm 26.0000
Efficiency 1.0000
Calculated Pout atm 26.0000
Head ft 724.8973
SM-7-88
Equip. No. 5 6 7 9
Name
T Out Str 1 C 500.0000
VF Out Str 1 1.0000e-005 1.0000 1.0000
Calc Ht Duty MMBtu/h 27.7052 22.6007 35.4380 -42.9587
Str1 Pout atm 26.0000 26.0000 26.0000 26.0000
Equip. No. 10 14
Name
Pressure drop 1 atm 14.0000
T Out Str 1 C 90.0000
VF Out Str 1 1.0000e-005
Calc Ht Duty MMBtu/h -51.4202 -3.6540
Str1 Pout atm 12.0000 4.8000
Equip. No. 11 12
Name
Pressure Out atm 12.0000 4.8000
Top Temp Mode 2 1
Bottom Temp Mode 1 1
Component No. 1 1.0000 1.0000
Component No. 2 1.0000 1.0000
Component No. 5 1.0000 1.0000
Component No. 6 1.0000 1.0000
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name S1 S2 Mixed feed S4
Temp C 25.0000 25.0000 25.0000 90.0000
Pres atm 1.5000 1.5000 1.5000 1.5000
Enth MMBtu/h 35.930 -0.059972 35.870 -178.99
Total lbmol/h 1600.0000 1600.0000 3200.0000 2666.6753
Ethylene 1600.0000 0.0000 1600.0000 0.0000
Chlorine 0.0000 1600.0000 1600.0000 0.0000
1,2-DiCl-Ethane 0.0000 0.0000 0.0000 2666.6753
Vinyl Chloride 0.0000 0.0000 0.0000 0.0000
SM-7-89
Stream No. 5 6 7 8
Stream Name S5
Temp C 91.5272 238.4040 238.4040 90.0000
Pres atm 26.0000 26.0000 26.0000 1.5000
Enth MMBtu/h -178.74 -151.04 -128.44 -107.39
Vapor mole fraction 0.00000 1.0000E-005 0.99999 0.00000
Total lbmol/h 2666.6753 2666.6753 2666.6753 1600.0000
Ethylene 0.0000 0.0000 0.0000 0.0000
Chlorine 0.0000 0.0000 0.0000 0.0000
1,2-DiCl-Ethane 2666.6753 2666.6753 2666.6753 1600.0000
Vinyl Chloride 0.0000 0.0000 0.0000 0.0000
Stream No. 9 10 11 12
Stream Name S6 S7 S8 S9
Temp C 500.0000 500.0000 167.8330 6.5126
Pres atm 26.0000 26.0000 26.0000 12.0000
Enth MMBtu/h -92.997 -51.103 -94.062 -145.48
Vapor mole fraction 1.0000 1.0000 0.99999 1.0000E-005
Total lbmol/h 2666.6753 4266.6807 4266.6807 4266.6807
Ethylene 0.0000 0.0000 0.0000 0.0000
Chlorine 0.0000 0.0000 0.0000 0.0000
1,2-DiCl-Ethane 2666.6753 1066.6700 1066.6700 1066.6700
Vinyl Chloride 0.0000 1600.0052 1600.0052 1600.0052
Stream No. 13 14 15 16
Stream Name S12 S11 S14
Temp C 92.8497 144.0321 -25.9108 31.9764
Pres atm 12.0000 4.8000 12.0000 4.8000
Enth MMBtu/h -62.090 -67.941 -64.847 5.2172
Total lbmol/h 2666.6753 1066.6700 1600.0050 1600.0050
Ethylene 0.0000 0.0000 0.0000 0.0000
Chlorine 0.0000 0.0000 0.0000 0.0000
1,2-DiCl-Ethane 1066.6700 1066.6700 0.0000 0.0000
Vinyl Chloride 1600.0052 0.0000 0.0000 1600.0050
Stream No. 18
Stream Name S16
Temp C 90.0000
Pres atm 4.8000
Enth MMBtu/h -71.595
Ethylene 0.0000
Chlorine 0.0000
1,2-DiCl-Ethane 1066.6700
Vinyl Chloride 0.0000
HydrogenChloride 0.0000
SM-7-90
To the Instructor: Before assigning this exercise, please see Section 7.4 – Case Studies –
especially the case study on the Monochlorobenzene (MCB) Separation Process.
ASPEN PLUS Solution
ASPEN PLUS Flowsheet – see Figure 7.22 – simulation results can be reproduced
using the file EXER7-6.bkp in the ASPEN folder associated
with the Solution Manual on the Wiley web site for this book.
ASPEN PLUS Simulation Flowsheet – see Figure A-I.8 (ASPEN → Principles of

Flowsheet Simulation→Interpretation of Input and Output → Input)
ASPEN PLUS Program – see Figure A-I.9 (ASPEN → Principles of Flowsheet

Simulation→Interpretation of Input and Output → Input)
SEQUENCE USED WAS:
H1 F1
$OLVER02
| $OLVER01
| | $OLVER03 D1
| | (RETURN $OLVER03)
| | H2 S1 P1 A1 M1 T1
| (RETURN $OLVER01)
(RETURN $OLVER02)
Stream Variables
S01 S02 S03 S04 S05
-------------------
FROM : ---- H1 F1 F1 P1
TO : H1 F1 M1 A1 A1
SUBSTREAM: MIXED
PHASE: MIXED MIXED LIQUID VAPOR LIQUID
HCL 10.0000 10.0000 0.2373 9.7626 0.0
C6H6 40.0000 40.0000 17.3395 22.6604 2.5002-02
MCB 50.0000 50.0000 36.4989 13.5010 12.0555
H2O 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 100.0000 100.0000 54.0758 45.9241 12.0805
LB/HR 9117.0720 9117.0720 5471.3721 3645.6999 1358.9036
CUFT/HR 786.1917 5987.3724 95.6776 9895.3291 20.3022
STATE VARIABLES:
TEMP F 80.0000 250.0000 270.0000 270.0000 130.6089
PRES PSI 37.0000 35.0000 35.0000 35.0000 50.0000
VFRAC 4.1772-02 0.2781 0.0 1.0000 0.0
LFRAC 0.9582 0.7218 1.0000 0.0 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 6326.8001 1.4888+04 1.6729+04 1.9450+04 6215.1756
BTU/LB 69.3950 163.3032 165.3357 245.0028 55.2523
BTU/HR 6.3268+05 1.4888+06 9.0461+05 8.9321+05 7.5083+04
ENTROPY:
BTU/LBMOL-R -56.7886 -41.9038 -49.9782 -22.4478 -61.3807
BTU/LB-R -0.6228 -0.4596 -0.4939 -0.2827 -0.5456
SM-7-91
DENSITY:
LBMOL/CUFT 0.1272 1.6702-02 0.5651 4.6410-03 0.5950
LB/CUFT 11.5965 1.5227 57.1854 0.3684 66.9337
AVG MW 91.1707 91.1707 101.1796 79.3852 112.4871
S06 S07 S08 S09 S10

-------------------

FROM : A1 A1 M1 T1 T1
TO : ---- M1 T1 ---- D1
SUBSTREAM: MIXED
PHASE: VAPOR LIQUID MIXED VAPOR LIQUID
HCL 9.6926 6.9990-02 0.3073 0.3073 0.0
C6H6 17.3652 5.3202 22.6598 0.0 22.6578
MCB 13.7340 11.8225 48.3215 0.0 48.3221
H2O 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 40.7919 17.2127 71.2886 0.3073 70.9800
LB/HR 3255.7415 1748.8623 7220.2345 11.2051 7208.9510
CUFT/HR 9904.3432 30.3760 216.4086 74.5525 125.6919
STATE VARIABLES:
TEMP F 265.3772 264.6207 267.1446 267.1446 267.1446
PRES PSI 31.0000 32.0000 32.0000 32.0000 32.0000
VFRAC 1.0000 0.0 5.4391-03 1.0000 0.0
LFRAC 0.0 1.0000 0.9945 0.0 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 1.6843+04 1.6337+04 1.6634+04 -3.8384+04 1.6832+04
BTU/LB 211.0352 160.7978 164.2366 -1052.7560 165.7270
BTU/HR 6.8708+05 2.8121+05 1.1858+06 -1.1796+04 1.1947+06
ENTROPY:
BTU/LBMOL-R -21.3781 -50.3543 -50.0688 2.9423 -50.3863
BTU/LB-R -0.2678 -0.4956 -0.4943 8.0698-02 -0.4961
DENSITY:
LBMOL/CUFT 4.1186-03 0.5666 0.3294 4.1222-03 0.5647
LB/CUFT 0.3287 57.5737 33.3638 0.1503 57.3541
AVG MW 79.8134 101.6025 101.2817 36.4606 101.5631
S11 S12 S13 S14 S15

-------------------

FROM : D1 D1 H2 S1 S1
TO : ---- H2 S1 ---- P1
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID LIQUID LIQUID
HCL 0.0 0.0 0.0 0.0 0.0
C6H6 22.5578 0.1000 0.1000 7.5007-02 2.5002-02
MCB 0.1000 48.2221 48.2221 36.1665 12.0555
H2O 0.0 0.0 0.0 0.0 0.0
TOTAL FLOW:
LBMOL/HR 22.6579 48.3221 48.3221 36.2415 12.0805
LB/HR 1773.3361 5435.6145 5435.6145 4076.7109 1358.9036
CUFT/HR 35.5442 91.0959 81.1811 60.8858 20.2952
STATE VARIABLES:
TEMP F 205.0852 309.1877 130.0000 130.0000 130.0000
PRES PSI 23.0000 25.0000 23.0000 23.0000 23.0000
VFRAC 0.0 0.0 0.0 0.0 0.0
LFRAC 1.0000 1.0000 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
SM-7-92
ENTHALPY:
BTU/LBMOL 2.5495+04 1.3501+04 6186.7851 6186.7851 6186.7851
BTU/LB 325.7486 120.0259 54.9999 54.9999 54.9999
BTU/HR 5.7766+05 6.5241+05 2.9896+05 2.2422+05 7.4740+04
ENTROPY:
BTU/LBMOL-R -54.1162 -49.4738 -61.4114 -61.4114 -61.4114
BTU/LB-R -0.6914 -0.4398 -0.5459 -0.5459 -0.5459
DENSITY:
LBMOL/CUFT 0.6374 0.5304 0.5952 0.5952 0.5952
LB/CUFT 49.8909 59.6691 66.9566 66.9566 66.9566
AVG MW 78.2656 112.4871 112.4871 112.4871 112.4871
SM-7-93
HYSYS Solution
The “Extended NRTL” method was used to predict the thermo-physical properties for this process.
A modified version of the process (see Fig. 1) was simulated, in which the “treater” that selectively
(and perfectly) removes the traces of HCl not extracted in the absorber was eliminated, and
replaced by a small vapor purge stream in the column D1. Thus, the column, installed with only
15 ideal trays, has three product streams: the vapor purge, S09, the benzene-rich distillate, S11,
and the MCB-rich bottoms, S12. The column’s three degrees-of-freedom in the (reflux ratio, purge
flow rate, and distillate flow rate) are manipulated to meet the following specifications: (a) MCB
mole fraction in S12 at 0.98; (b) HCl recovery in the purge at 90%; (c) MCB molar flow rate in
the distillate at 0.1 lbmol/hr. The fraction of the MCB product in S13 recycled to the absorber was
set to 72% by experiment, to increase the HCl concentration in the absorber overhead vapor stream,
S06, to be greater than 96 mol %. The stream data as computed by HYSYS is given in Table 1.
Figure 2 shows the vapor composition profiles in the absorber, A1, and the liquid composition
profiles in the distillation column, D1.
Figure 1. HYSYS PFD for the MCB process.
(a) (b)
Figure 2. Composition Profiles: (a) absorber, A1; (b) distillation column, D1
These results can be reproduced by running the file EXER57_6.hsc (in the HYSYS folder, under
book).
SM-7-94
Material Streams
Name S01 S02 S03 S04 S05* S05 S06 S07
Vapour Fraction 0.05 0.62 0.00 1.00 0.00 0.00 1.00 0.00
Temperature (F) 80.00 270.00 270.00 270.00 120.10 120.10 132.80 261.70
Pressure (psia) 37.00 32.00 32.00 32.00 32.00 32.00 32.00 32.00
Mass Flow (lb/hr) 9,117.00 9,117.00 3,959.00 5,158.00 14,550.00 14,550.00 385.90 19,330.00
Liquid Volume Flow (barrel/day) 619.60 619.60 257.00 362.60 904.20 904.20 29.76 1,237.00
Heat Flow (Btu/hr) 658,800.00 2,037,000.00 606,900.00 1,431,000.00 803,400.00 803,400.00 -363,200.00 2,597,000.00
Comp Molar Flow (HCl) (lbmole/hr) 10.00 10.00 0.04 9.96 0.00 0.00 9.48 0.47
Comp Molar Flow (Cl-BZ) (lbmole/hr) 50.00 50.00 28.41 21.59 127.50 127.50 0.32 148.78
Name S08 S09 S11 S12 S13 S14 S15

Vapour Fraction 0.00 1.00 0.00 0.00 0.00 0.00 0.00
Temperature (F) 263.10 196.90 196.90 302.40 120.00 120.00 120.00
Pressure (psia) 32.00 25.00 25.00 25.00 20.00 20.00 20.00
Molar Flow (lbmole/hr) 220.20 3.23 36.32 180.70 180.70 50.59 130.10
Mass Flow (lb/hr) 23,280.00 232.60 2,838.00 20,210.00 20,210.00 5,660.00 14,550.00
Liquid Volume Flow (barrel/day) 1,494.00 18.07 220.10 1,256.00 1,256.00 351.60 904.20
Heat Flow (Btu/hr) 3,204,000.00 87,640.00 913,700.00 2,454,000.00 1,115,000.00 312,200.00 802,700.00
Comp Molar Flow (HCl) (lbmole/hr) 0.52 0.47 0.05 0.00 0.00 0.00 0.00
Comp Molar Flow (Benzene) (lbmole/hr) 42.54 2.76 36.17 3.61 3.61 1.01 2.60
Comp Molar Flow (Cl-BZ) (lbmole/hr) 177.18 0.00 0.10 177.08 177.08 49.58 127.50
SM-7-95
Table 1. HYSYS-generated Stream Data for Exercise 7.6 (Cont’d)
Compositions
Name S01 S02 S03 S04 S05* S05 S06 S07
Comp Mole Frac (HCl) 0.1000 0.1000 0.0011 0.1610 0.0000 0.0000 0.9619 0.0026
Comp Mole Frac (Cl-BZ) 0.5000 0.5000 0.7441 0.3493 0.9800 0.9800 0.0320 0.8172
Name S08 S09 S11 S12 S13 S14 S15

Comp Mole Frac (HCl) 0.0023 0.1442 0.0014 0.0000 0.0000 0.0000 0.0000
Comp Mole Frac (Benzene) 0.1932 0.8552 0.9958 0.0200 0.0200 0.0200 0.0200
Comp Mole Frac (Cl-BZ) 0.8045 0.0005 0.0028 0.9800 0.9800 0.9800 0.9800
Energy Streams
Name H1_Duty D1_R_Duty D1_C_Duty H2_Duty P1_Duty
Heat Flow (Btu/hr) 1.38E+06 2.92E+06 2.66E+06 1.34E+06 646.7
SM-7-96
Exercise 7.6 – Revised MCB Separation Process Page 1
The process flowsheet is shown in Figure 7.21. However, in

this revision, the following changes in specifications are made:
1. Only 25% of bottoms from the column is recycled
2. The recycle is cooled to 130oF.
3. The feed is preheated to 270oF.
4. The distillation tower contains only 15 theoretical stages.
The distillation column is still specified to (1) set the

distillate rate equal to the flow rate of benzene in the column
feed or equivalently, as done here, set the bottoms rate equal
to the MCB flow rate in the column feed (a feed-forward
controller, equipment 10 below, is used), and (2) set the flow
rate of MCB in the distillate to 0.1 lbmol/hr by adjusting the
reflux ratio (this is accomplished with a feedback controller,
equipment 11 below).
The tear (cut) stream is 13, for which an initial estimate is

provided: 130oF, 32 psia, and 0.333(50) = 16.65 lbmol/hr of MCB.
FLOWSHEET SUMMARY
1 HTXR 1 -2
2 FLAS 2 -14 -3
3 TOWR 13 14 -12 -4
4 CSEP 5 -15 -6
5 TOWR 16 -7 -8
6 HTXR 8 -9
7 DIVI 9 -10 -11
8 PUMP 10 -13
9 MIXE 4 3 -5
10 CONT 6 -16
11 CONT 7 -17
Stream Connections
1 1 7 5 11 13 8 3
2 1 2 8 5 6 14 2 3
3 2 9 9 6 7 15 4
4 3 9 10 7 8 16 10 5
5 9 4 11 7 17 11
6 4 10 12 3
SM-7-97

1 2 3 9 4 10 5 6 7 8 11

3 9 4 10 5 6 7 8
Recycle Cut Streams

13

Pressure 1.000E-003
Enthalpy 1.000E-003
COMPONENTS
ID # Name
1 104 HydrogenChloride
2 40 Benzene
3 172 Chlorobenzene
THERMODYNAMICS
K-value model : UNIFAC

No corrrection for vapor fugacity

Benzene 40.000 40.295 3124.560 3147.609
Chlorobenzene 50.000 49.744 5627.900 5599.087
Total 100.000 100.039 9117.070 9111.306
SM-7-98
EQUIPMENT SUMMARIES
Equip. No. 1 6
Name
T Out Str 1 F 250.0000 130.0000
Calc Ht Duty MMBtu/h 0.9765 -0.5220
Str1 Pout psia 32.0000 25.0000
Flash Summary
Equip. No. 2
Name
K values:
HydrogenChlorid 137.925
Benzene 1.419
Chlorobenzene 0.335
Towr Rigorous Distillation Summary
Equip. No. 3 5
Name
No. of stages 3 17
1st feed stage 1 9
2nd feed stage 3 0
Top pressure psia 32.0000 25.0000
Condenser mode 0 1
Reboiler mode 0 4
Calc cond duty -0.9802
(MMBtu/h)
Calc rebr duty 1.1822
(MMBtu/h)
Est. dist. rate 10.0000 40.0000
(lbmol/h)
Est. reflux rate 17.0000 120.0000
(lbmol/h)
Est. stage 1 T F 200.0000 200.0000
Est. bottom T F 200.0000 250.0000
Est. stage 2 T F 200.0000 200.0000
Reflux ratio 1.5740
SM-7-99
EQUIPMENT SUMMARIES
Equip. No. 4
Name
Pressure Out psia 32.0000
Top Temp Mode 2
Top Temp Spec 32.0000
Bottom Temp Mode 1
Bottom Temp Spec 32.0000
Divider Summary
Equip. No. 7
Name
Pump Summary
Equip. No. 8
Name
Output pressure psia 32.0000
Efficiency 1.0000
Calculated Pout psia 32.0000
Head ft 15.0978
Mixer Summary
Equip. No. 9
Name
Output Pressure psia 32.0000
Controller Summary
Equip. No. 10 11
Name
Mode 1 2
Equip. no. adjusted 5 5
Variable No. 22 17
Sign Flag 0 0
Measured variables:
Number 16 7
Variable -3 -3
Constant 0.1000
SM-7-100
FLOW SUMMARIES
Stream No. 1 2 3 4
Stream Name Feed Heated feed Flash liquid Absorber bot
Temp F 80.0000 250.0000 250.0000 252.2491
Pres psia 37.0000 32.0000 32.0000 32.0000
Enth MMBtu/h 0.68046 1.6570 1.1391 0.35541
Total lbmol/h 100.0000 100.0000 65.6069 20.7208
Benzene 40.0000 40.0000 22.9387 6.7936
Chlorobenzene 50.0000 50.0000 42.5318 13.8849
Stream No. 5 6 7 8
Stream Name Mixed feed Column feed Distillate Bottoms
Temp F 250.5443 243.2749 209.3484 306.9872
Pres psia 32.0000 32.0000 25.0000 25.0000
Enth MMBtu/h 1.4945 1.4704 0.76325 0.90921
Vapor mole fraction 3.5252E-006 0.00000 0.00000 0.00000
Total lbmol/h 86.3277 86.1490 29.7325 56.4165
Benzene 29.7323 29.7323 29.6325 0.0998
Chlorobenzene 56.4167 56.4167 0.1001 56.3166
Stream No. 9 10 11 12
Stream Name Cooled botto Recycle MCB MCB product HCl product
Temp F 130.0000 130.0000 130.0000 254.1784
Pres psia 25.0000 25.0000 25.0000 32.0000
Enth MMBtu/h 0.38718 0.096794 0.29038 0.26431
Total lbmol/h 56.4165 14.1041 42.3123 27.8155
Benzene 0.0998 0.0250 0.0749 10.5877
Chlorobenzene 56.3166 14.0792 42.2375 7.4065
Stream No. 13 14 15 16
Stream Name Pumped recyc Flash vapor Purge Column feed
Temp F 130.0582 250.0000 -62.2006 243.2749
Pres psia 32.0000 32.0000 32.0000 32.0000
Enth MMBtu/h 0.096825 0.51789 -0.0072715 1.4704
Total lbmol/h 14.1041 34.3931 0.1787 86.1490
Benzene 0.0250 17.0613 0.0000 29.7323
Chlorobenzene 14.0792 7.4682 0.0000 56.4167
SM-7-101
FLOW SUMMARIES
Stream No. 17
Stream Name Distillate C
Temp F 209.3484
Pres psia 25.0000
Enth MMBtu/h 0.76325
HydrogenChloride 0.0000
Benzene 29.6325
Chlorobenzene 0.1001
* Net Flows *
1 254.2 32.00 20.11 14.10 27.82
2 255.0 32.00 20.60 33.78
3 252.2 32.00 34.27 34.39 20.72
* Net Flows *
1 209.3 25.00 46.80 29.73 -0.9802
2 209.9 25.00 46.42 76.53
3 211.5 25.00 45.49 76.16
4 215.5 25.00 43.58 75.23
5 223.7 25.00 40.73 73.31
6 236.3 25.00 38.15 70.46
7 248.9 25.00 36.80 67.89
8 257.6 25.00 36.34 66.53
9 262.2 25.00 125.78 66.07 86.15
10 271.1 25.00 125.89 69.37
11 281.7 25.00 127.25 69.47
12 291.6 25.00 129.67 70.84
13 298.7 25.00 132.14 73.25
14 303.0 25.00 133.95 75.73
15 305.3 25.00 135.01 77.53
16 306.4 25.00 135.57 78.59
17 307.0 25.00 79.15 56.42 1.182
Mole Reflux ratio 1.574
SM-7-102
Discussion:
The calculations give the following results for the four products, noting that convergence
is not as accurate as desired.
Component HCl product Purge Benzene product MCB product
HCl 9.8 0.2 0 0

Benzene 10.6 0 29.6 0.1
MCB 7.4 0 0.1 19.6
The operating conditions for the process need to be improved because the HCl product contains
substantial amounts of benzene and monochlorobenzene. This can be achieved by reducing the
temperature of the feed leaving the preheater, reducing the temperature of the MCB recycle,
and/or increasing the MCB absorbent rate. For example, if the preheater temperature is reduced
to give just 12 lbmol/hr of vapor and the MCB recycle temperature is reduced to 100oF, the
following products are obtained:
Component HCl product Purge Benzene product MCB product
HCl 8.7 1.3 0 0

Benzene 0 0 39.9 0.1
MCB 0.2 0 0.1 49.7
Now, the recoveries of benzene and MCB are greatly improved, but at the expense of some
decrease in the recovery of HCl.
SM-7-103
Studies
ASPEN PLUS Solution

V1
F1
FLASH2
V2 L1
F2
FEED
FLASH2
V3
L2
F3
FLASH2
V4 L3
F4
FLASH2
L4
ASPEN PLUS Program

IN-UNITS ENG
Property Method: None Flow basis for input: Mole
Stream report composition: Mole flow "
NOASPENPCD
COMPONENTS
NITROGEN N2 NITROGEN /
CO2 CO2 CO2 /
H2S H2S H2S /
SM-7-104
ETHANE C2H6 ETHANE /
PROPANE C3H8 PROPANE /
ISOBU-01 C4H10-2 ISOBU-01 /
N-BUT-01 C4H10-1 N-BUT-01 /
2-MET-01 C5H12-2 2-MET-01 /
N-PEN-01 C5H12-1 N-PEN-01 /
N-HEX-01 C6H14-1 N-HEX-01 /
N-HEP-01 C7H16-1 N-HEP-01 /
N-OCT-01 C8H18-1 N-OCT-01 /
N-NON-01 C9H20-1 N-NON-01 /
N-DEC-01 C10H22-1 N-DEC-01 /
N-DOD-01 C12H26 N-DOD-01
FLOWSHEET
BLOCK F1 IN=V2 OUT=V1 L1
BLOCK F2 IN=FEED L1 V3 OUT=V2 L2
BLOCK F3 IN=L2 V4 OUT=V3 L3
BLOCK F4 IN=L3 OUT=V4 L4
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL NITROGEN CO2 -.0315000000
BPVAL NITROGEN H2S .1696000000
BPVAL NITROGEN METHANE .0278000000
BPVAL NITROGEN ETHANE .0407000000
BPVAL NITROGEN PROPANE .0763000000
BPVAL NITROGEN ISOBU-01 .0944000000
BPVAL NITROGEN N-BUT-01 .0700000000
BPVAL NITROGEN 2-MET-01 .0867000000
BPVAL NITROGEN N-PEN-01 .0878000000
BPVAL NITROGEN N-HEX-01 .1496000000
BPVAL NITROGEN N-HEP-01 .1422000000
BPVAL NITROGEN N-OCT-01 -.4000000000
BPVAL CO2 H2S .0989000000
BPVAL CO2 METHANE .0933000000
BPVAL CO2 ETHANE .1363000000
BPVAL CO2 PROPANE .1289000000
BPVAL CO2 ISOBU-01 .1285000000
BPVAL CO2 N-BUT-01 .1430000000
BPVAL CO2 2-MET-01 .1307000000
BPVAL CO2 N-PEN-01 .1311000000
BPVAL CO2 N-HEX-01 .1178000000
BPVAL CO2 N-HEP-01 .1100000000
BPVAL CO2 NITROGEN -.0315000000
BPVAL H2S CO2 .0989000000
BPVAL H2S ETHANE .0852000000
BPVAL H2S PROPANE .0885000000
BPVAL H2S ISOBU-01 .0511000000
BPVAL H2S N-PEN-01 .0689000000
BPVAL H2S NITROGEN .1696000000
BPVAL METHANE CO2 .0933000000
BPVAL METHANE ETHANE -7.8000000E-3
BPVAL METHANE PROPANE 9.00000000E-3
BPVAL METHANE ISOBU-01 .0241000000
BPVAL METHANE N-BUT-01 5.60000000E-3
BPVAL METHANE 2-MET-01 -7.8000000E-3
BPVAL METHANE N-PEN-01 .0190000000
BPVAL METHANE N-HEX-01 .0374000000
BPVAL METHANE N-HEP-01 .0307000000
BPVAL METHANE N-OCT-01 .0448000000
BPVAL METHANE NITROGEN .0278000000
BPVAL METHANE N-NON-01 .0448000000
BPVAL ETHANE CO2 .1363000000
BPVAL ETHANE H2S .0852000000
BPVAL ETHANE METHANE -7.8000000E-3
BPVAL ETHANE PROPANE -2.2000000E-3
SM-7-105
BPVAL ETHANE ISOBU-01 -.0100000000
BPVAL ETHANE N-BUT-01 6.70000000E-3
BPVAL ETHANE N-PEN-01 5.60000000E-3
BPVAL ETHANE N-HEX-01 -.0156000000
BPVAL ETHANE N-HEP-01 4.10000000E-3
BPVAL ETHANE N-OCT-01 .0170000000
BPVAL ETHANE NITROGEN .0407000000
BPVAL PROPANE CO2 .1289000000
BPVAL PROPANE H2S .0885000000
BPVAL PROPANE METHANE 9.00000000E-3
BPVAL PROPANE ETHANE -2.2000000E-3
BPVAL PROPANE ISOBU-01 -.0100000000
BPVAL PROPANE N-BUT-01 0.0
BPVAL PROPANE 2-MET-01 7.80000000E-3
BPVAL PROPANE N-PEN-01 .0233000000
BPVAL PROPANE N-HEX-01 -2.2000000E-3
BPVAL PROPANE N-HEP-01 4.40000000E-3
BPVAL PROPANE NITROGEN .0763000000
BPVAL ISOBU-01 CO2 .1285000000
BPVAL ISOBU-01 H2S .0511000000
BPVAL ISOBU-01 METHANE .0241000000
BPVAL ISOBU-01 ETHANE -.0100000000
BPVAL ISOBU-01 PROPANE -.0100000000
BPVAL ISOBU-01 N-BUT-01 1.10000000E-3
BPVAL ISOBU-01 NITROGEN .0944000000
BPVAL N-BUT-01 CO2 .1430000000
BPVAL N-BUT-01 METHANE 5.60000000E-3
BPVAL N-BUT-01 ETHANE 6.70000000E-3
BPVAL N-BUT-01 PROPANE 0.0
BPVAL N-BUT-01 ISOBU-01 1.10000000E-3
BPVAL N-BUT-01 N-PEN-01 .0204000000
BPVAL N-BUT-01 N-HEX-01 -.0111000000
BPVAL N-BUT-01 N-HEP-01 -4.0000000E-4
BPVAL N-BUT-01 NITROGEN .0700000000
BPVAL 2-MET-01 CO2 .1307000000
BPVAL 2-MET-01 METHANE -7.8000000E-3
BPVAL 2-MET-01 PROPANE 7.80000000E-3
BPVAL 2-MET-01 N-PEN-01 0.0
BPVAL 2-MET-01 NITROGEN .0867000000
BPVAL N-PEN-01 CO2 .1311000000
BPVAL N-PEN-01 H2S .0689000000
BPVAL N-PEN-01 METHANE .0190000000
BPVAL N-PEN-01 ETHANE 5.60000000E-3
BPVAL N-PEN-01 PROPANE .0233000000
BPVAL N-PEN-01 N-BUT-01 .0204000000
BPVAL N-PEN-01 2-MET-01 0.0
BPVAL N-PEN-01 N-HEP-01 1.90000000E-3
BPVAL N-PEN-01 N-OCT-01 -2.2000000E-3
BPVAL N-PEN-01 NITROGEN .0878000000
BPVAL N-HEX-01 CO2 .1178000000
BPVAL N-HEX-01 METHANE .0374000000
BPVAL N-HEX-01 ETHANE -.0156000000
BPVAL N-HEX-01 PROPANE -2.2000000E-3
BPVAL N-HEX-01 N-BUT-01 -.0111000000
BPVAL N-HEX-01 N-HEP-01 -1.1000000E-3
BPVAL N-HEX-01 NITROGEN .1496000000
BPVAL N-HEP-01 CO2 .1100000000
BPVAL N-HEP-01 METHANE .0307000000
BPVAL N-HEP-01 ETHANE 4.10000000E-3
BPVAL N-HEP-01 PROPANE 4.40000000E-3
BPVAL N-HEP-01 N-BUT-01 -4.0000000E-4
BPVAL N-HEP-01 N-PEN-01 1.90000000E-3
BPVAL N-HEP-01 N-HEX-01 -1.1000000E-3
BPVAL N-HEP-01 NITROGEN .1422000000
BPVAL N-OCT-01 METHANE .0448000000
BPVAL N-OCT-01 ETHANE .0170000000
BPVAL N-OCT-01 N-PEN-01 -2.2000000E-3
SM-7-106
BPVAL N-OCT-01 NITROGEN -.4000000000
BPVAL N-NON-01 METHANE .0448000000
STREAM FEED
SUBSTREAM MIXED TEMP=120. PRES=284.7
MOLE-FLOW NITROGEN 358.2 / CO2 4965.6 / H2S 339.4 / &
METHANE 2995.5 / ETHANE 2395.5 / PROPANE 2291. / &
ISOBU-01 604.1 / N-BUT-01 1539.9 / 2-MET-01 790.4 / &
N-PEN-01 1129.9 / N-HEX-01 1764.7 / N-HEP-01 2606.7 / &
N-OCT-01 1844.5 / N-NON-01 1669. / N-DEC-01 831.7 / &
N-DOD-01 1214.5
BLOCK F1 FLASH2
PARAM TEMP=100. PRES=814.7
BLOCK F2 FLASH2
BLOCK F3 FLASH2
BLOCK F4 FLASH2
SEQUENCE USED WAS:

$OLVER01 F2 F1 F3 F4
(RETURN $OLVER01)
Stream Variables
FEED L1 L2 L3 L4
----------------
STREAM ID FEED L1 L2 L3 L4
FROM : ---- F1 F2 F3 F4
TO : F2 F2 F3 F4 ----
SUBSTREAM: MIXED
PHASE: MIXED LIQUID LIQUID LIQUID LIQUID
NITROGEN 358.2000 7.2105 22.8707 0.4965 1.7507-02
CO2 4965.6000 332.2386 1913.4766 309.4625 74.1176
H2S 339.4000 36.5041 290.1682 110.4444 52.4278
METHANE 2995.5000 116.1405 445.3504 24.4871 2.1453
ETHANE 2395.5000 237.2793 1510.5860 404.8408 145.5180
PROPANE 2291.0000 275.7346 2608.0792 1543.6508 1020.4873
ISOBU-01 604.1000 53.7814 701.2211 556.9299 461.9468
N-BUT-01 1539.9000 114.5864 1742.7375 1472.3644 1284.4581
2-MET-01 790.4000 37.2868 845.8587 785.7948 741.2558
N-PEN-01 1129.9000 44.8785 1191.6967 1125.5810 1077.0711
N-HEX-01 1764.7000 35.8039 1803.2644 1769.6980 1745.8170
N-HEP-01 2606.7000 24.9910 2628.7094 2611.1753 2599.6604
N-OCT-01 1844.5000 7.6824 1850.3056 1846.0705 1843.5053
N-NON-01 1669.0000 2.9719 1670.9576 1669.5788 1668.8073
N-DEC-01 831.7000 0.6467 832.0568 831.8028 831.6730
N-DOD-01 1214.5000 0.1750 1214.5759 1214.5223 1214.4983
TOTAL FLOW:
LBMOL/HR 2.7341+04 1327.9123 2.1272+04 1.6277+04 1.4763+04
LB/HR 1.8877+06 5.9910+04 1.7211+06 1.5183+06 1.4479+06
CUFT/HR 2.1582+05 1766.0410 4.4062+04 3.7357+04 3.4976+04
STATE VARIABLES:
TEMP F 120.0000 100.0000 120.0000 96.0000 85.0000
PRES PSI 284.7000 814.7000 284.7000 63.7000 27.7000
VFRAC 0.3191 0.0 0.0 0.0 0.0
LFRAC 0.6809 1.0000 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0 0.0 0.0
SM-7-107
ENTHALPY:
BTU/LBMOL -9.0812+04 -8.1807+04 -9.0021+04 -9.2361+04 -9.5063+04
BTU/LB -1315.3024 -1813.2724 -1112.5881 -990.1566 -969.2754
BTU/HR -2.4829+09 -1.0863+08 -1.9149+09 -1.5033+09 -1.4035+09
ENTROPY:
BTU/LBMOL-R -102.5609 -59.6746 -131.6561 -160.4215 -171.0890
BTU/LB-R -1.4854 -1.3227 -1.6271 -1.7198 -1.7444
DENSITY:
LBMOL/CUFT 0.1266 0.7519 0.4827 0.4357 0.4221
LB/CUFT 8.7464 33.9231 39.0618 40.6431 41.3986
AVG MW 69.0427 45.1156 80.9113 93.2790 98.0761
V1 V2 V3 V4
-----------
STREAM ID V1 V2 V3 V4
FROM : F1 F2 F3 F4
TO : ---- F1 F2 F3
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR VAPOR VAPOR
NITROGEN 358.1823 365.3929 22.8531 0.4790
CO2 4891.4779 5223.7206 1839.3587 235.3453
H2S 286.9707 323.4754 237.7394 58.0165
METHANE 2993.3523 3109.4945 443.2043 22.3418
ETHANE 2249.9775 2487.2597 1365.0663 259.3229
PROPANE 1270.4888 1546.2281 1587.5726 523.1608
ISOBU-01 142.1566 195.9392 239.2790 94.9836
N-BUT-01 255.4380 370.0255 458.2766 187.9059
2-MET-01 49.1434 86.4305 104.6024 44.5389
N-PEN-01 52.8281 97.7067 114.6249 48.5097
N-HEX-01 18.8826 54.6866 57.4472 23.8809
N-HEP-01 7.0393 32.0304 29.0488 11.5148
N-OCT-01 0.9946 8.6771 6.8003 2.5651
N-NON-01 0.1926 3.1645 2.1503 0.7715
N-DEC-01 2.6929-02 0.6736 0.3837 0.1297
N-DOD-01 1.6948-03 0.1767 7.7688-02 2.4046-02
TOTAL FLOW:
LBMOL/HR 1.2577+04 1.3905+04 6508.4859 1513.4910
LB/HR 4.3973+05 4.9964+05 2.7320+05 7.0356+04
CUFT/HR 6.5192+04 2.7614+05 5.8513+05 3.1096+05
STATE VARIABLES:
TEMP F 100.0000 120.0000 96.0000 85.0000
PRES PSI 814.7000 284.7000 63.7000 27.7000
VFRAC 1.0000 1.0000 1.0000 1.0000
LFRAC 0.0 0.0 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -8.8006+04 -8.5897+04 -7.7953+04 -6.5079+04
BTU/LB -2517.1525 -2390.5307 -1857.0901 -1399.9728
BTU/HR -1.1069+09 -1.1944+09 -5.0736+08 -9.8497+07
ENTROPY:
BTU/LBMOL-R -27.9154 -26.5798 -39.3918 -53.5736
BTU/LB-R -0.7984 -0.7397 -0.9384 -1.1524
DENSITY:
LBMOL/CUFT 0.1929 5.0355-02 1.1123-02 4.8671-03
LB/CUFT 6.7451 1.8093 0.4669 0.2262
AVG MW 34.9626 35.9322 41.9759 46.4861
SM-7-108
HYSYS Solution
The process involves four flash units, each operating at a distinct pressure and temperature. The
HYSYS simulation was developed using the so-called “Sour SRK” for property prediction, noting
that H2S is one of the components in the mixture. The PFD calls for the installation of compressors
and valves, as shown in Fig.1. Note that the compressors enable vapor transfer from a flash unit at
a lower pressure to one operating at a higher pressure, while the valves set the pressure drops in
the liquid traffic in the opposite direction. In addition, three recycle convergence control objects
need to be installed, to provide a means of converging the material and energy balances.
Figure 1. HYSYS PFD for the Cavett Problem.
These results can be reproduced by running the file EXER5_7.hsc (in the HYSYS folder, under
book).
SM-7-109
Name L1 L1* V1 L1_LP Feed L2 L2_LP V2 V2_HP

Vapour Fraction 0.0 0.0 1.0 0.4 0.3 0.0 0.2 1.0 1.0
Temperature (F) 100.0 100.0 100.0 49.3 120.0 120.0 94.7 120.0 267.5
Pressure (psia) 814.7 814.7 814.7 284.7 287.7 284.7 63.7 284.7 814.7
Mass Flow (lb/hr) 60,300.0 60,300.0 443,200.0 60,300.0 1,888,000.0 1,682,000.0 1,682,000.0 503,500.0 503,500.0
Liquid Volume Flow (barrel/day) 7,344.0 7,344.0 55,320.0 7,344.0 200,900.0 175,500.0 175,500.0 62,670.0 62,670.0
Heat Flow (Btu/hr) -1.08E+08 -1.08E+08 -1.12E+09 -1.08E+08 -2.48E+09 -1.82E+09 -1.82E+09 -1.20E+09 -1.18E+09
Comp Molar Flow (Nitrogen) (lbmole/hr) 7.2 7.2 358.2 7.2 358.2 19.7 19.7 365.4 365.4
Comp Molar Flow (CO2) (lbmole/hr) 325.8 325.8 4,919.6 325.8 4,965.6 1,511.8 1,511.8 5,245.4 5,245.4
Comp Molar Flow (H2S) (lbmole/hr) 35.4 35.4 303.0 35.4 339.4 239.8 239.8 338.4 338.4
Comp Molar Flow (Methane) (lbmole/hr) 116.2 116.2 2,993.0 116.2 2,995.5 424.9 424.9 3,109.2 3,109.2
Comp Molar Flow (Ethane) (lbmole/hr) 234.9 234.9 2,256.3 234.9 2,395.5 1,372.0 1,372.0 2,491.2 2,491.2
Comp Molar Flow (Propane) (lbmole/hr) 279.6 279.6 1,286.1 279.6 2,291.0 2,444.4 2,444.4 1,565.7 1,565.7
Comp Molar Flow (i-Butane) (lbmole/hr) 54.6 54.6 148.0 54.6 604.1 673.4 673.4 202.5 202.5
Comp Molar Flow (n-Butane) (lbmole/hr) 118.9 118.9 263.7 118.9 1,539.9 1,692.2 1,692.2 382.6 382.6
Comp Molar Flow (i-Pentane) (lbmole/hr) 37.3 37.3 47.1 37.3 790.4 831.4 831.4 84.4 84.4
Comp Molar Flow (n-Pentane) (lbmole/hr) 47.0 47.0 52.1 47.0 1,129.9 1,179.3 1,179.3 99.1 99.1
Comp Molar Flow (n-Hexane) (lbmole/hr) 36.6 36.6 20.7 36.6 1,764.7 1,795.7 1,795.7 57.2 57.2
Comp Molar Flow (n-Heptane) (lbmole/hr) 25.4 25.4 7.3 25.4 2,606.7 2,624.9 2,624.9 32.8 32.8
Comp Molar Flow (n-Octane) (lbmole/hr) 8.0 8.0 1.2 8.0 1,844.5 1,849.4 1,849.4 9.2 9.2
Comp Molar Flow (n-Nonane) (lbmole/hr) 3.1 3.1 0.3 3.1 1,669.0 1,670.7 1,670.7 3.3 3.3
Comp Molar Flow (n-Decane) (lbmole/hr) 0.7 0.7 0.0 0.7 831.7 832.0 832.0 0.7 0.7
Comp Molar Flow (n-C12) (lbmole/hr) 0.2 0.2 0.0 0.2 1,214.5 1,214.6 1,214.6 0.2 0.2
SM-7-110
Table 1. HYSYS-generated Stream Data for Exercise 7.7 (Cont’d)
Name L3 L3_LP V3 V3* V3_HP L4 V4 V4* V4_HP

Vapour Fraction 0.0 0.1 1.0 1.0 1.0 0.0 1.0 1.0 1.0
Temperature (F) 96.0 84.6 96.0 96.0 252.5 85.0 85.0 85.0 154.6
Pressure (psia) 63.7 27.7 63.7 63.7 284.7 27.7 27.7 27.7 63.7
Mass Flow (lb/hr) 1,509,000.0 1,509,000.0 237,800.0 237,800.0 237,800.0 1,444,000.0 64,250.0 64,250.0 64,250.0
Liquid Volume Flow (barrel/day) 153,700.0 153,700.0 29,950.0 29,950.0 29,950.0 145,600.0 8,139.0 8,139.0 8,139.0
Heat Flow (Btu/hr) -1.48E+09 -1.48E+09 -4.26E+08 -4.26E+08 -4.13E+08 -1.40E+09 -8.50E+07 -8.50E+07 -8.33E+07
Comp Molar Flow (Nitrogen) (lbmole/hr) 0.4 0.4 19.7 19.7 19.7 0.0 0.4 0.4 0.4
Comp Molar Flow (CO2) (lbmole/hr) 219.7 219.7 1,465.8 1,465.8 1,465.8 46.0 173.7 173.7 173.7
Comp Molar Flow (H2S) (lbmole/hr) 84.2 84.2 203.4 203.4 203.4 36.5 47.8 47.8 47.8
Comp Molar Flow (Methane) (lbmole/hr) 26.3 26.3 422.4 422.4 422.4 2.5 23.8 23.8 23.8
Comp Molar Flow (Ethane) (lbmole/hr) 385.2 385.2 1,232.9 1,232.9 1,232.9 139.2 246.0 246.0 246.0
Comp Molar Flow (Propane) (lbmole/hr) 1,505.2 1,505.2 1,439.5 1,439.5 1,439.5 1,004.9 500.3 500.3 500.3
Comp Molar Flow (i-Butane) (lbmole/hr) 546.6 546.6 217.3 217.3 217.3 456.1 90.5 90.5 90.5
Comp Molar Flow (n-Butane) (lbmole/hr) 1,455.3 1,455.3 415.9 415.9 415.9 1,276.2 179.0 179.0 179.0
Comp Molar Flow (i-Pentane) (lbmole/hr) 782.6 782.6 88.1 88.1 88.1 743.3 39.2 39.2 39.2
Comp Molar Flow (n-Pentane) (lbmole/hr) 1,123.0 1,123.0 101.5 101.5 101.5 1,077.8 45.1 45.1 45.1
Comp Molar Flow (n-Hexane) (lbmole/hr) 1,766.3 1,766.3 51.6 51.6 51.6 1,744.0 22.3 22.3 22.3
Comp Molar Flow (n-Heptane) (lbmole/hr) 2,609.9 2,609.9 25.6 25.6 25.6 2,599.4 10.5 10.5 10.5
Comp Molar Flow (n-Octane) (lbmole/hr) 1,845.7 1,845.7 6.2 6.2 6.2 1,843.3 2.4 2.4 2.4
Comp Molar Flow (n-Nonane) (lbmole/hr) 1,669.5 1,669.5 1.9 1.9 1.9 1,668.7 0.7 0.7 0.7
Comp Molar Flow (n-Decane) (lbmole/hr) 831.8 831.8 0.3 0.3 0.3 831.7 0.1 0.1 0.1
Comp Molar Flow (n-C12) (lbmole/hr) 1,214.5 1,214.5 0.1 0.1 0.1 1,214.5 0.0 0.0 0.0
SM-7-111
Exercise 7.7 – Cavett Problem Page

1
The exercise is solved with four flash modules (all isothermal mode), noting that the
module, FLAS, can have more than one feed. No initial guesses are given for the
three default tear (cut) streams and recycle convergence is achieved without
difficulty by the default successive substitution method. The tolerance on the flow
rates is changed from the default of 10-3 to 10-4 for better accuracy.
FLOWSHEET SUMMARY
1 FLAS 4 -2 -5
2 FLAS 1 5 6 -4 -8
3 FLAS 7 8 -6 -9
4 FLAS 9 -7 -3
STREAM CONNECTIONS
Stream Equipment Stream Equipment Stream

Equipment
From To From To From
To
1 2 4 2 1 7 4
3
2 1 5 1 2 8 2
3
3 4 6 3 2 9 3
4


1 2 3 4

1 2 3 4
Recycle Cut Streams

4 6 7

Pressure 1.000E-003
Enthalpy 1.000E-003
SM-7-112
SM-7-113
Exercise 5.7 – Cavett Problem
Page 2
COMPONENTS
ID # Name
1 46 Nitrogen
2 49 Carbon Dioxide
3 50 Hydrogen Sulfide
4 2 Methane
5 3 Ethane
6 4 Propane
7 5 I-Butane
8 6 N-Butane
9 7 I-Pentane
10 8 N-Pentane
11 10 N-Hexane
12 11 N-Heptane
13 12 N-Octane
14 13 N-Nonane
15 14 N-Decane
16 16 N-Dodecane
THERMODYNAMICS
K-value model : SRK


Nitrogen 358.200 358.200 10034.615 10034.604
Carbon Dioxide 4965.600 4965.574 218536.052 218535.000
Hydrogen Sulfide 339.400 339.392 11565.327 11565.038
Methane 2995.500 2995.493 48056.804 48056.691
Ethane 2395.500 2395.463 72032.684 72031.576
Propane 2291.000 2290.893 101024.000 101019.222
I-Butane 604.100 604.089 35112.104 35111.490
N-Butane 1539.900 1539.884 89503.611 89502.653
I-Pentane 790.400 790.397 57027.363 57027.165
N-Pentane 1129.900 1129.897 81522.288 81522.077
N-Hexane 1764.700 1764.698 152076.551 152076.393
N-Heptane 2606.700 2606.699 261202.000 261201.719
N-Octane 1844.500 1844.500 210699.085 210699.057
N-Nonane 1669.000 1669.000 214062.595 214062.563
N-Decane 831.700 831.700 118338.439 118338.439
N-Dodecane 1214.500 1214.500 206875.498 206875.477
Total 27340.598 27340.377 1887668.875 1887659.125
SM-7-114
Page 3
EQUIPMENT SUMMARIES
Flash Summary
Equip. No. 1 2 3
4
Name
Flash Mode 2 2 2
2
Param 1 100.0000 120.0000 96.0000
85.0000
Param 2 814.7000 284.7000 63.7000
27.7000
Heat duty MMBtu/h -21.6502 -10.6330 4.0074
1.5259
K values:
Nitrogen 5.167 25.290 120.442
280.645
Carbon Dioxide 1.495 4.000 14.125
29.356
Hydrogen Sulfide 0.873 1.890 6.091
12.322
Methane 2.672 9.983 41.667
92.886
Ethane 1.012 2.491 8.303
17.086
Propane 0.485 0.899 2.539
4.931
I-Butane 0.295 0.438 1.096
2.046
N-Butane 0.241 0.326 0.778
1.425
I-Pentane 0.139 0.154 0.324
0.570
N-Pentane 0.120 0.124 0.251
0.434
N-Hexane 0.054 0.047 0.083
0.137
N-Heptane 0.031 0.019 0.028
0.043
N-Octane 0.014 7.322E-003 9.405E-003
0.014
N-Nonane 7.093E-003 2.876E-003 3.142E-003 4.382E-
003
N-Decane 4.511E-003 1.233E-003 1.132E-003 1.492E-
003
N-Dodecane 9.954E-004 2.018E-004 1.404E-004 1.677E-
004
FLOW SUMMARIES
Stream No. 1 2 3
4
SM-7-115
Stream Name Feed V1 L4
V2
Temp F 120.0000 100.0000 85.0000
120.0000
Pres psia 284.7000 814.7000 27.7000
284.7000
Enth MMBtu/h -2484.1 -1105.3 -1405.6 -
1202.8
1.0000
Total lbmol/h 27340.5977 12565.3926 14774.9844
14004.9463
Nitrogen 358.2000 358.1848 0.0148
366.1266
Carbon Dioxide 4965.6000 4883.7910 81.7834
5258.1348
337.9337
Methane 2995.5000 2992.8936 2.5994
3121.2207
Ethane 2395.5000 2249.0410 146.4221
2503.7776
Propane 2291.0000 1261.6487 1029.2443
1559.6085
I-Butane 604.1000 145.7355 458.3539
202.3965
N-Butane 1539.9000 253.6980 1286.1855
374.0696
I-Pentane 790.4000 46.5399 743.8574
84.8965
N-Pentane 1129.9000 49.2562 1080.6409
96.2648
N-Hexane 1764.7000 17.8526 1746.8456
55.5319
N-Heptane 2606.7000 6.8783 2599.8210
32.2265
N-Octane 1844.5000 0.9544 1843.5454
8.8086
N-Nonane 1669.0000 0.1821 1668.8176
3.1240
N-Decane 831.7000 0.0253 831.6747
0.6671
N-Dodecane 1214.5000 0.0014 1214.4985
0.1593
SM-7-116
Page 4
FLOW SUMMARIES
Stream No. 5 6 7
8
Stream Name L1 V3 V4
L2
Temp F 100.0000 96.0000 85.0000
120.0000
Pres psia 814.7000 63.7000 27.7000
284.7000
Enth MMBtu/h -119.16 -531.52 -101.32 -
1942.7
0.00000
Total lbmol/h 1439.4447 6769.4854 1533.4969
21544.5000
Nitrogen 7.9413 22.2562 0.4304
22.2710
Carbon Dioxide 374.3209 1940.4545 249.1808
2022.2367
275.0920
Methane 128.3200 478.3910 25.0604
480.9902
Ethane 254.7132 1399.5138 259.6595
1545.9374
Propane 297.9195 1639.9225 526.7883
2669.1833
I-Butane 56.6580 252.9049 97.3262
711.2612
N-Butane 120.3669 476.8116 190.2328
1763.0013
I-Pentane 38.3560 106.1044 44.0328
849.9626
N-Pentane 47.0079 117.5126 48.6933
1198.1543
N-Hexane 37.6790 61.1968 24.8554
1808.0430
N-Heptane 25.3480 30.1598 11.6447
2629.9810
N-Octane 7.8541 7.2074 2.6557
1850.7528
N-Nonane 2.9419 2.1775 0.7590
1670.9952
N-Decane 0.6418 0.3909 0.1288
832.0656
N-Dodecane 0.1579 0.0708 0.0211
1214.5693
Stream No. 9
SM-7-117
Stream Name L3
Temp F 96.0000
Pres psia 63.7000
Enth MMBtu/h -1508.5
Nitrogen 0.4452
Carbon Dioxide 330.9643
Hydrogen Sulfide 92.7084
Methane 27.6599
Ethane 406.0816
Propane 1556.0326
I-Butane 555.6801
N-Butane 1476.4183
I-Pentane 787.8901
N-Pentane 1129.3342
N-Hexane 1771.7010
N-Heptane 2611.4658
N-Octane 1846.2012
N-Nonane 1669.5765
N-Decane 831.8035
N-Dodecane 1214.5197
SM-7-118
ASPEN PLUS Solution

file EXER7-8.bkp in the ASPEN folder, under
Computer Solution Files, associated with the Solution
Manual on the Wiley web site for this book.
C1
1 4
MCOMPR
C2
2 5
MCOMPR
C3
3 6
MCOMPR
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
HYDROGEN H2 HYDROGEN /
METHANE CH4 METHANE
FLOWSHEET
BLOCK C1 IN=1 OUT=4
BLOCK C2 IN=2 OUT=5
BLOCK C3 IN=3 OUT=6
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL HYDROGEN METHANE -.0222000000
STREAM 1
SUBSTREAM MIXED TEMP=100. PRES=30. MOLE-FLOW=440.
MOLE-FRAC HYDROGEN 0.95 / METHANE 0.05
STREAM 2
SM-7-119
STREAM 3
SM-7-120
BLOCK C1 MCOMPR
PARAM NSTAGE=2 TYPE=ISENTROPIC
FEEDS 1 1
PRODUCTS 4 2
COMPR-SPECS 1 PRES=100. SEFF=0.9 MEFF=0.98 / 2 PRES=569. &
SEFF=0.9 MEFF=0.98
COOLER-SPECS 1 TEMP=100.
BLOCK C2 MCOMPR
FEEDS 2 1
PRODUCTS 5 2
SEFF=0.9 MEFF=0.98
BLOCK C3 MCOMPR
FEEDS 3 1
PRODUCTS 6 2
SEFF=0.9 MEFF=0.98
Stream Variables
1 2 3 4 5
---------
STREAM ID 1 2 3 4 5
FROM : ---- ---- ---- C1 C2
TO : C1 C2 C3 ---- ----
SUBSTREAM: MIXED
PHASE: VAPOR VAPOR VAPOR VAPOR VAPOR
HYDROGEN 418.0000 418.0000 418.0000 418.0000 418.0000
METHANE 22.0000 22.0000 22.0000 22.0000 22.0000
TOTAL FLOW:
LBMOL/HR 440.0000 440.0000 440.0000 440.0000 440.0000
LB/HR 1195.5785 1195.5785 1195.5785 1195.5785 1195.5785
CUFT/HR 8.8195+04 8.8195+04 8.8195+04 4751.0275 4751.0275
STATE VARIABLES:
TEMP F 100.0000 100.0000 100.0000 100.0000 100.0000
PRES PSI 30.0000 30.0000 30.0000 569.0000 569.0000
VFRAC 1.0000 1.0000 1.0000 1.0000 1.0000
LFRAC 0.0 0.0 0.0 0.0 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -1440.7780 -1440.7780 -1440.7780 -1424.8211 -1424.8211
BTU/LB -530.2389 -530.2389 -530.2389 -524.3664 -524.3664
BTU/HR -6.3394+05 -6.3394+05 -6.3394+05 -6.2692+05 -6.2692+05
ENTROPY:
BTU/LBMOL-R -1.6939 -1.6939 -1.6939 -7.5522 -7.5522
BTU/LB-R -0.6234 -0.6234 -0.6234 -2.7793 -2.7793
DENSITY:
LBMOL/CUFT 4.9890-03 4.9890-03 4.9890-03 9.2612-02 9.2612-02
LB/CUFT 1.3556-02 1.3556-02 1.3556-02 0.2516 0.2516
AVG MW 2.7172 2.7172 2.7172 2.7172 2.7172
SM-7-121
6
-
STREAM ID 6
FROM : C3
TO : ----
SUBSTREAM: MIXED
PHASE: VAPOR
HYDROGEN 418.0000
METHANE 22.0000
TOTAL FLOW:
LBMOL/HR 440.0000
LB/HR 1195.5785
CUFT/HR 4751.0275
STATE VARIABLES:
TEMP F 100.0000
PRES PSI 569.0000
VFRAC 1.0000
LFRAC 0.0
SFRAC 0.0
ENTHALPY:
BTU/LBMOL -1424.8211
BTU/LB -524.3664
BTU/HR -6.2692+05
ENTROPY:
BTU/LBMOL-R -7.5522
BTU/LB-R -2.7793
DENSITY:
LBMOL/CUFT 9.2612-02
LB/CUFT 0.2516
AVG MW 2.7172
Process Unit Output
BLOCK: C1 MODEL: MCOMPR

------------------------------
INLET STREAMS: 1 TO STAGE 1
OUTLET STREAMS: 4 FROM STAGE 2

TOTAL BALANCE
MOLE(LBMOL/HR) 440.000 440.000 0.000000E+00
MASS(LB/HR ) 1195.58 1195.58 0.000000E+00
ENTHALPY(BTU/HR ) -633942. -626921. -0.110752E-01
*** INPUT DATA ***
ISENTROPIC CENTRIFUGAL COMPRESSOR

NUMBER OF STAGES 2
COMPRESSOR SPECIFICATIONS PER STAGE
STAGE PRESSURE MECHANICAL ISENTROPIC

NUMBER EFFICIENCY EFFICIENCY
PSI
1 100.0 0.9800 0.9000
2 569.0 0.9800 0.9000
SM-7-122
SM-7-123
COOLER SPECIFICATIONS PER STAGE
STAGE PRESSURE DROP TEMPERATURE

NUMBER PSI F
1 0.0000E+00 100.0
2 0.0000E+00 100.0
*** RESULTS ***
FINAL PRESSURE, PSI 569.000

TOTAL WORK REQUIRED, HP 805.784
TOTAL COOLING DUTY , BTU/HR -2,002,240.
*** PROFILE ***
COMPRESSOR PROFILE
STAGE OUTLET PRESSURE OUTLET

NUMBER PRESSURE RATIO TEMPERATURE
PSI F
1 100.0 3.333 349.9

2 569.0 5.690 488.4
STAGE INDICATED BRAKE

NUMBER HORSEPOWER HORSEPOWER
HP HP
1 306.8 313.0
2 482.9 492.8
COOLER PROFILE
STAGE OUTLET OUTLET COOLING VAPOR

NUMBER TEMPERATURE PRESSURE LOAD FRACTION
F PSI BTU/HR
1 100.0 100.0 -.7796E+06 1.000

2 100.0 569.0 -.1223E+07 1.000

------------------------------

TOTAL BALANCE
MOLE(LBMOL/HR) 440.000 440.000 0.000000E+00
MASS(LB/HR ) 1195.58 1195.58 0.000000E+00
ENTHALPY(BTU/HR ) -633942. -626921. -0.110752E-01
*** INPUT DATA ***

NUMBER OF STAGES 2
SM-7-124

PSI
1 130.0 0.9800 0.9000
2 569.0 0.9800 0.9000

NUMBER PSI F
1 0.0000E+00 100.0
2 0.0000E+00 100.0
*** RESULTS ***

*** PROFILE ***
COMPRESSOR PROFILE

PSI F
1 130.0 4.333 415.6

2 569.0 4.377 418.0

HP HP
1 388.5 396.5
2 394.8 402.8
COOLER PROFILE

F PSI BTU/HR
1 100.0 130.0 -.9873E+06 1.000

2 100.0 569.0 -.9987E+06 1.000

------------------------------

TOTAL BALANCE
MOLE(LBMOL/HR) 440.000 440.000 0.000000E+00
MASS(LB/HR ) 1195.58 1195.58 0.000000E+00
ENTHALPY(BTU/HR ) -633942. -626921. -0.110752E-01
SM-7-125
*** INPUT DATA ***

NUMBER OF STAGES 2

PSI
1 160.0 0.9800 0.9000
2 569.0 0.9800 0.9000

NUMBER PSI F
1 0.0000E+00 100.0
2 0.0000E+00 100.0
*** RESULTS ***

*** PROFILE ***
COMPRESSOR PROFILE

PSI F
1 160.0 5.333 470.8

2 569.0 3.556 365.6

HP HP
1 457.6 467.0
2 329.3 336.0
COOLER PROFILE

F PSI BTU/HR
1 100.0 160.0 -.1163E+07 1.000

2 100.0 569.0 -.8326E+06 1.000
SM-7-126
HYSYS Solution
The SRK method was used to predict the thermo-physical properties for this process. Fig.
1 shows the HYSYS PFD for the two-stage compressor, each stage of which is assumed to
have 90% adiabatic efficiency. Table 1 shows stream data for intermediate pressure of 130
psia. Table 2 summarizes the results for all three intermediate pressures. A case study was
carried out to track the effect of the selected value of intermediate pressure on the stage
and total duties, as summarized in Fig.2. Note that the minimum total duty is achieved by
selecting the intermediate pressure that approximately equalizes the two duties, 135 psia.
Figure 1. HYSYS PFD for the two-stage compressor.
(a) (b)
Figure 2. Effect of intermediate pressure on: (a) stage duties; (b) total duty.
These results can be reproduced by running the file EXER7_8.hsc (in the HYSYS folder,
under Computer Solution Files, associated with the Solution Manual on the Wiley web
site for this book).
SM-7-127
Material Streams
Name 1 2 3 4
Vapour Fraction 1.00 1.00 1.00 1.00
Temperature (F) 100.00 421.70 100.00 428.30
Pressure (psia) 30.00 130.00 128.00 569.00
Molar Flow (lbmole/hr) 440.00 440.00 440.00 440.00
Mass Flow (lb/hr) 1196.00 1196.00 1196.00 1196.00
Liquid Volume Flow (barrel/day) 906.70 906.70 906.70 906.70
Heat Flow (Btu/hr) -6.38E+05 3.54E+05 -6.37E+05 3.84E+05
Compositions
Name 1 2 3 4
Comp Mole Frac (Hydrogen) 0.9500 0.9500 0.9500 0.9500
Comp Mole Frac (Methane) 0.0500 0.0500 0.0500 0.0500
Energy Streams
Name K1_Duty E1_Duty K2_Duty
Heat Flow (Btu/hr) 9.92E+05 9.91E+05 1.02E+06
Table 2. Summary of Results for the Three Cases in Exercise 7.8
Case 1 Case 2 Case 3

Intermediate pressure, psia 100 130 160
Temperature of gas exiting comp. 1, oF 354.69 421.67 477.91
Comp. 1 actual hp 307.62 389.87 459.44
Intercooler duty, MMBtu/hr 0.781 0.991 1.167
Comp. 2 actual hp 491.93 401.17 334.17
Temperature of gas exiting comp. 2, oF 501.69 428.35 373.91
Total compressor power, hp 799.55 791.04 793.61
SM-7-128
Exercise 7.8 – Two-Stage Compression with Intercooler
Page 1
This exercise has three cases, each with a different intermediate

pressure, 100, 130, or 150 psia. Note that the optimal intermediate
pressure (the one giving nearly equal values of hp of the two
compressors) is close to 130 psia. Detailed results are given here for
case 1, followed by a summary of results for all three cases. Two
compressor modules plus a one-sided heat exchanger module are used.
Only the isentropic efficiency is applied.
FLOWSHEET SUMMARY
1 COMP 1 -2
2 HTXR 2 -3
3 COMP 3 -4
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1 2
3 2 3
4 3


1 2 3
COMPONENTS
ID # Name
1 1 Hydrogen
2 2 Methane
THERMODYNAMICS
K-value model : SRK

Hydrogen 418.000 418.000 842.604 842.604
Methane 22.000 22.000 352.946 352.946
Total 440.000 440.000 1195.5504 1195.5504
SM-7-129
Exercise 7.8 – Two-Stage Compression with Intercooler
Page 2
EQUIPMENT SUMMARIES
Compressor Summary
Equip. No. 1 3
Name
Pressure out psia 100.0000 569.0000
Type of Compressor 1 1
Efficiency 0.9000 0.9000
Actual power hp 306.7425 489.9954
Cp/Cv 1.3982 1.3993
Theoretical power hp 276.0683 440.9957
Ideal Cp/Cv 1.3977 1.3970
Calc Pout psia 100.0000 569.0000
Calc. mass flowrate 1196 1196
(lb/h)
Equip. No. 2
Name
T Out Str 1 F 100.0000
Calc Ht Duty MMBtu/h -0.7806
FLOW SUMMARIES
Stream No. 1 2 3
4
Stream Name Feed to Comp. 1 Feed to
Product
Comp. 1 exit Comp. 2
Temp F 100.0000 350.1166 100.0000
495.0912
Pres psia 30.0000 100.0000 98.0000
569.0000
Enth MMBtu/h -0.63738 0.143128 -0.63721
0.60958
1.0000
Total lbmol/h 440.0000 440.0000 440.0000
440.0000
Hydrogen 418.0000 418.0000 418.0000
418.0000
Methane 22.0000 22.0000 22.0000
22.0000
Summary of the three cases:

Case 1 Case 2 Case 3
Intermediate 100 130 160
pressure, psia
Temperature of gas 350.1 415.8 471.1
exiting comp. 1, oF
SM-7-130
Comp. 1 actual hp 306.7 388.5 457.6
Intercooler duty, -0.7086 -0.9882 -1.1642
MMBtu/hr
Comp. 2 actual hp 490.0 399.7 333.0
Temperature of gas 495.1 423.0 369.6
exiting comp. 2, oF
Note, that Case 2 gives nearly equal values of actual hp for the two
compressors.
SM-7-131
7.9 Simulation Flowsheet for Sequence Created by ASPEN PLUS
S11 S9 C2 S8 S1
$OLVER01 COMPR FSPLIT S7
S11* S9* S6
FEED M1 S1 C1 S2 M2 S3 R1 H1 F1
MIXER COMPR MIXER RSTOIC HEATER FLASH2
F2 S10
FLASH2
S12
SEQUENCE USED WAS:

$OLVER01 M1 C1 M2 R1 H1 F1 S1 C2 F2
(RETURN $OLVER01)
Alternate Simulation Flowsheet – S3 torn
S9 C2 S8 S1
COMPR FSPLIT S7
S6
FEED M1 S1 C1 S2 M2 S3 S3* R1 S4 H1 S5 F1
MIXER COMPR MIXER $OLVER01 RSTOIC HEATER FLASH2
S11
F2 S10
FLASH2
S12
SEQUENCE USED WAS:

$OLVER01 R1 H1 F1 S1 C2 F2 M1 C1 M2
SM-7-132
(RETURN $OLVER01)
Nested Simulation Flowsheet – S9 and S11 torn
S9 C2 S8 S1
CONV1 S7
COMP FSPLIT
S9* S6
FEED M1 S1 C1 S2 M2 S3 R1 S4 H1 S5 F1
MIXER COMP MIXER RSTOIC HEATER FLASH2
CONV2
S11* S11
F2 S10
FLASH2
S12
SEQUENCE USED WAS:

CONV2 M1 C1
 CONV1 M2 R1 H1 F1 S1 C2
 (RETURN CONV1)
 F2
(RETURN CONV2)
SM-7-133
7.10 a. Simulation Flowsheet
S1 H1 S2 R1
HEATER RSTOIC
S4 H2 S3
HEATER
SEQUENCE USED WAS:

H1 R1 H2
b. Simulation Flowsheet
S4
S1 H1 S2 S2* R1
$OLVER01
HEATX RSTOIC
S3
SEQUENCE USED WAS:

$OLVER01 R1 H1
(RETURN $OLVER01)
SM-7-134
7.11 a. Simulation Flowsheet
S8
S5
S1 A S2 B S3 C S4 S4* D S7 E
$OLVER01
MIXER RSTOIC MIXER DISTL DISTL
S9
SEQUENCE USED WAS:

$OLVER01 D E A B C
(RETURN $OLVER01)
b. Simulation Flowsheet
S11
S10
S1 A1 S2 R1 S3 A2 S4 S4* F1
$OLVER01
MIXER RSTOIC MIXER FLASH2
S5
R2 S6 F2
RSTOIC FLASH2
S8
S7
D1
DISTL
S9
SEQUENCE USED WAS:

$OLVER01 F1 R2 F2 D1 A1 R1 A2
(RETURN $OLVER01)
SM-7-135
c. Simulation Flowsheet
S12
U9 U8
U6 U5 S11
S13 S6
S7 S5
S1 S2 S3 S4 S4* S8 S9 S10
U1 U2 U3 $OLVER01 U4 U7 U10
SEQUENCE USED WAS:

U1
$OLVER01 U4 U5 U6 U2 U7 U8 U9 U3
(RETURN $OLVER01)
U10
SM-7-136
7.12 Solutions are provided using ASPEN PLUS and CHEMCAD.
ASPEN PLUS Solution
ASPEN PLUS Flowsheet - simulation results can be reproduced using the file
EXER7-12.bkp in the ASPEN folder, under Computer
Solution Files, associated with the Solution Manual on
VAPOR
M1
LIQUID EFFLUENT
MIXER

50°F
VAPOR
F
$OLVER01
T
M1
LIQUID EFFLUENT
MIXER
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
BENZENE C6H6 BENZENE
FLOWSHEET
BLOCK M1 IN=LIQUID VAPOR OUT=EFFLUENT
PROPERTIES RK-SOAVE
STREAM LIQUID
SUBSTREAM MIXED TEMP=25. PRES=1. <atm> MOLE-FLOW=100.
MASS-FRAC BENZENE 1.
SM-7-137
STREAM VAPOR
SUBSTREAM MIXED TEMP=176.2 PRES=1. <atm> MOLE-FLOW=30.
MASS-FRAC BENZENE 1.
BLOCK M1 MIXER
PARAM PRES=1. <atm>
DESIGN-SPEC DS-1
DEFINE TEMP STREAM-VAR STREAM=EFFLUENT SUBSTREAM=MIXED &
VARIABLE=TEMP
SPEC "TEMP" TO "50"
TOL-SPEC ".01"
VARY MOLE-FLOW STREAM=VAPOR SUBSTREAM=MIXED &
COMPONENT=BENZENE
LIMITS "1" "300"
SEQUENCE USED WAS:

$OLVER01 M1
(RETURN $OLVER01)
Stream Variables
EFFLUENT LIQUID VAPOR

---------------------
STREAM ID EFFLUENT LIQUID VAPOR

FROM : M1 ---- ----
TO : ---- M1 M1
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID
BENZENE 117.5776 100.0000 17.5776
TOTAL FLOW:
LBMOL/HR 117.5776 100.0000 17.5776
LB/HR 9184.4150 7811.3640 1373.0510
CUFT/HR 165.5540 138.7062 26.9520
STATE VARIABLES:
TEMP F 50.0000 25.0000 176.2000
PRES PSI 14.6959 14.6959 14.6959
VFRAC 0.0 0.0 0.0
LFRAC 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 2.0436+04 1.9746+04 2.4360+04
BTU/LB 261.6191 252.7897 311.8502
BTU/HR 2.4028+06 1.9746+06 4.2819+05
ENTROPY:
BTU/LBMOL-R -61.6362 -63.0235 -54.7824
BTU/LB-R -0.7890 -0.8068 -0.7013
DENSITY:
LBMOL/CUFT 0.7102 0.7209 0.6521
LB/CUFT 55.4768 56.3158 50.9441
AVG MW 78.1136 78.1136 78.1136
SM-7-138
Exercise 7.12 – Condensation of benzene vapor with benzene liquid
Page 1
A feedback controller, CONT, is used to determine the flow rate of

benzene vapor that can be condensed and cooled by liquid benzene. An
initial guess is needed for the flow rate of benzene vapor. Using the
given values of latent enthalpy of vaporization and specific heat
(assumed to be for the liquid phase), an enthalpy balance give 4.73
lbmol/hr for the benzene vapor, which is used for the initial guess.
FLOWSHEET SUMMARY
1 MIXE 2 1 -3
2 CONT 3 -4
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1
3 1 2
4 2


1 2
COMPONENTS
ID # Name
1 40 Benzene
THERMODYNAMICS
K-value model : UNIFAC

No corrrection for vapor fugacity

Benzene 104.504 104.504 8163.229 8163.229
Total 104.504 104.504 8163.229 8163.229
SM-7-139
Exercise 7.12 – Condensation of benzene vapor with benzene liquid
Page 2
EQUIPMENT SUMMARIES
Mixer Summary
Equip. No. 1
Name
Output Pressure atm 1.0000
Controller Summary
Equip. No. 2
Name
Mode 2
Stream no. adjusted 1
Variable No. 5
Unit of Min/Max values 1
Sign Flag 0
Tolerance 1.0000e-004
Measured variables:
Number 3
Variable 1
Constant 50.0000
Units 2
FLOW SUMMARIES
Stream No. 1 2 3
4
Stream Name Vapor feed Liquid feed Mix
Mix
Temp F 176.2345 25.0000 49.9968
49.9968
Pres atm 1.0000 1.0000 1.0000
1.0000
Enth MMBtu/h 0.17005 1.9461 2.1162
2.1162
0.00000
Total lbmol/h 4.5040 100.0000 104.5041
104.5041
Benzene 4.5040 100.0000 104.5041
104.5041
SM-7-140
ASPEN PLUS Solution
DIST
D1
FEED
DSTWU
BOT
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
STYRENE C8H8 STYRENE
FLOWSHEET
BLOCK D1 IN=FEED OUT=DIST BOT
PROPERTIES RK-SOAVE
STREAM FEED
SUBSTREAM MIXED TEMP=77. PRES=1. <atm> MOLE-FLOW=100.
MOLE-FRAC BENZENE 0.5 / STYRENE 0.5
BLOCK D1 DSTWU
PARAM LIGHTKEY=BENZENE RECOVL=0.95 HEAVYKEY=STYRENE &
RECOVH=0.0095 PTOP=1. <atm> PBOT=1. <atm> RR=-1.3
SM-7-141
Stream Variables
BOT DIST FEED

-------------
STREAM ID BOT DIST FEED
FROM : D1 D1 ----
TO : ---- ---- D1
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID
BENZENE 2.5000 47.5000 50.0000
STYRENE 49.9898 1.0200-02 50.0000
TOTAL FLOW:
LBMOL/HR 52.4898 47.5102 100.0000
LB/HR 5401.7977 3711.4602 9113.2580
CUFT/HR 111.8950 72.9057 167.2806
STATE VARIABLES:
TEMP F 282.5884 177.1558 77.0000
PRES PSI 14.6959 14.6959 14.6959
VFRAC 0.0 0.0 0.0
LFRAC 1.0000 1.0000 1.0000
SFRAC 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL 5.2851+04 2.4398+04 3.2931+04
BTU/LB 513.5563 312.3138 361.3532
BTU/HR 2.7741+06 1.1591+06 3.2931+06
ENTROPY:
BTU/LBMOL-R -62.7608 -54.7305 -68.0126
BTU/LB-R -0.6098 -0.7006 -0.7463
DENSITY:
LBMOL/CUFT 0.4691 0.6516 0.5978
LB/CUFT 48.2755 50.9076 54.4788
AVG MW 102.9113 78.1192 91.1325
Process Unit Output
BLOCK: D1 MODEL: DSTWU

-----------------------------
INLET STREAM: FEED
CONDENSER OUTLET: DIST
REBOILER OUTLET: BOT

TOTAL BALANCE
MOLE(LBMOL/HR) 100.000 100.000 0.000000E+00
MASS(LB/HR ) 9113.26 9113.26 0.000000E+00
*** INPUT DATA ***

HEAVY KEY COMPONENT STYRENE
SM-7-142
*** RESULTS ***
CONDENSER COOLING REQUIRED (BTU/HR ) 905,204.
NET CONDENSER DUTY (BTU/HR ) -905,204.
SM-7-143
Exercise 7.13 – Separation of Benzene-Styrene by the FUG Method Page 1
The SHOR (Shortcut) module is used with design option using the Fenske
equation for the feed-stage location. Pressure drop is ignored.
FLOWSHEET SUMMARY
1 SHOR 1 -2 -3
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1
3 1


1
COMPONENTS
ID # Name
1 40 Benzene
2 178 Styrene
THERMODYNAMICS
K-value model : SRK


Benzene 50.000 50.000 3905.700 3905.700
Styrene 50.000 50.000 5207.600 5207.600
Total 100.000 100.000 9113.300 9113.300
SM-7-144
Exercise 7.13 – Separation of Benzene-Styrene by the FUG Method Page 2
EQUIPMENT SUMMARIES
Shortcut Distillaton Summary
Equip. No. 1
Name
Mode 2
Light key component 1.0000
Light key split 0.9500
Heavy key component 2.0000
Heavy key split 0.0096
R/Rmin 1.3000
Number of stages 13.4678
Min. No. of stages 5.3387
Feed stage 8.5570
Condenser duty -0.8371
(MMBtu/h)
Reboiler duty MMBtu/h 1.4493
Colm pressure atm 1.0000
Reflux ratio, minimum 0.2344
Calc. Reflux ratio 0.3048
FLOW SUMMARIES
Stream No. 1 2 3
Stream Name Feed Distillate Bottoms
Temp F 77.0000 176.8845 278.9523
Pres atm 1.0000 1.0000 1.0000
Enth MMBtu/h 3.3459 1.1848 2.7734
Total lbmol/h 100.0000 47.9798 52.0202
Benzene 50.0000 47.5000 2.5000
Styrene 50.0000 0.4798 49.5202
SM-7-145
ASPEN PLUS Solution
H1
FEED EFFLUENT
HEATER
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
PROPA-01 C3H8 PROPA-01 /
N-BUT-01 C4H10-1 N-BUT-01 /
N-PEN-01 C5H12-1 N-PEN-01
FLOWSHEET
BLOCK H1 IN=FEED OUT=EFFLUENT
PROPERTIES RK-SOAVE
PROP-DATA RKSKIJ-1
IN-UNITS ENG
PROP-LIST RKSKIJ
BPVAL PROPA-01 N-BUT-01 0.0
BPVAL PROPA-01 N-PEN-01 .0233000000
BPVAL N-BUT-01 N-PEN-01 .0204000000
BPVAL N-BUT-01 PROPA-01 0.0
STREAM FEED
SUBSTREAM MIXED TEMP=150. PRES=202.
MOLE-FLOW PROPA-01 250. / N-BUT-01 400. / N-PEN-01 350.
BLOCK H1 HEATER
PARAM PRES=200. VFRAC=0.45
SM-7-146
Stream Variables
EFFLUENT FEED
-------------
STREAM ID EFFLUENT FEED

FROM : H1 ----
TO : ---- H1
SUBSTREAM: MIXED
PHASE: MIXED LIQUID
PROPA-01 250.0000 250.0000
N-BUT-01 400.0000 400.0000
N-PEN-01 350.0000 350.0000
TOTAL FLOW:
LBMOL/HR 1000.0000 1000.0000
LB/HR 5.9526+04 5.9526+04
CUFT/HR 1.3679+04 1808.2297
STATE VARIABLES:
TEMP F 204.1559 150.0000
PRES PSI 200.0000 202.0000
VFRAC 0.4500 0.0
LFRAC 0.5500 1.0000
SFRAC 0.0 0.0
ENTHALPY:
BTU/LBMOL -5.6593+04 -6.1760+04
BTU/LB -950.7233 -1037.5301
BTU/HR -5.6593+07 -6.1760+07
ENTROPY:
BTU/LBMOL-R -94.1471 -102.1370
BTU/LB-R -1.5816 -1.7158
DENSITY:
LBMOL/CUFT 7.3102-02 0.5530
LB/CUFT 4.3515 32.9195
AVG MW 59.5260 59.5260
Process Unit Output
BLOCK: H1 MODEL: HEATER

------------------------------
INLET STREAM: FEED
OUTLET STREAM: EFFLUENT

TOTAL BALANCE
MOLE(LBMOL/HR) 1000.00 1000.00 0.000000E+00
MASS(LB/HR ) 59526.1 59526.1 0.000000E+00
*** INPUT DATA ***

TWO PHASE PV FLASH
SM-7-147
*** RESULTS ***
HEAT DUTY BTU/HR 0.51673E+07
OUTLET VAPOR FRACTION 0.45000

PROPA-01 0.25000 0.16259 0.35683 2.1946
N-BUT-01 0.40000 0.39068 0.41139 1.0530
N-PEN-01 0.35000 0.44673 0.23178 0.51885
SM-7-148
Exercise 7.14 - Partial Vaporization

Page 1
A one-sided heat exchange is used with an HTXR module, which permits

the direct specification of mole fraction vaporized.
FLOWSHEET SUMMARY
1 HTXR 1 -2
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1


1
COMPONENTS
ID # Name
1 4 Propane
2 6 N-Butane
3 8 N-Pentane
THERMODYNAMICS
K-value model : SRK


Propane 250.000 250.000 11024.000 11024.000
N-Butane 400.000 400.000 23249.200 23249.200
N-Pentane 350.000 350.000 25252.501 25252.501
Total 1000.000 1000.000 59525.699 59525.699
SM-7-149
Exercise 7.14 - Partial Vaporization
Page 2
EQUIPMENT SUMMARIES
Equip. No. 1
Name
VF Out Str 1 0.4500
Calc Ht Duty MMBtu/h 5.3441
FLOW SUMMARIES
Stream No. 1 2
Stream Name Feed Product
Temp F 150.0000 207.6638
Pres psia 202.0000 200.0000
Enth MMBtu/h -61.832 -56.488
Vapor mole fraction 0.00000 0.45000
Total lbmol/h 1000.0000 1000.0000
Propane 250.0000 250.0000
N-Butane 400.0000 400.0000
N-Pentane 350.0000 350.0000
SM-7-150
ASPEN PLUS Solution
M1
BP S1
MIXER
M2
VF S2
MIXER
ASPEN PLUS Program
IN-UNITS ENG
NOASPENPCD
COMPONENTS
N-PEN-01 C5H12-1 N-PEN-01 /
N-HEX-01 C6H14-1 N-HEX-01
FLOWSHEET
BLOCK M1 IN=BP OUT=S1
BLOCK M2 IN=VF OUT=S2
PROPERTIES RK-SOAVE
STREAM BP
SUBSTREAM MIXED PRES=10. <atm> VFRAC=0. MOLE-FLOW=100.
MOLE-FRAC N-PEN-01 0.5 / N-HEX-01 0.5
STREAM VF
SUBSTREAM MIXED PRES=10. <atm> VFRAC=0.5 MOLE-FLOW=100.
MOLE-FRAC N-PEN-01 0.5 / N-HEX-01 0.5
BLOCK M1 MIXER
BLOCK M2 MIXER
SM-7-151
Stream Variables
BP S1 S2 VF
-----------
STREAM ID BP S1 S2 VF
FROM : ---- M1 M2 ----
TO : M1 ---- ---- M2
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID MIXED MIXED
N-PEN-01 50.0000 50.0000 50.0000 50.0000
N-HEX-01 50.0000 50.0000 50.0000 50.0000
TOTAL FLOW:
LBMOL/HR 100.0000 100.0000 100.0000 100.0000
LB/HR 7916.3720 7916.3720 7916.3720 7916.3720
CUFT/HR 250.1152 250.1153 2298.4746 2298.4583
STATE VARIABLES:
TEMP F 288.6534 288.6535 293.7120 293.7124
PRES PSI 146.9594 146.9594 146.9594 146.9594
VFRAC 0.0 0.0 0.5000 0.5000
LFRAC 1.0000 1.0000 0.5000 0.5000
SFRAC 0.0 0.0 0.0 0.0
ENTHALPY:
BTU/LBMOL -6.9527+04 -6.9527+04 -6.4951+04 -6.4951+04
BTU/LB -878.2728 -878.2728 -820.4585 -820.4585
BTU/HR -6.9527+06 -6.9527+06 -6.4951+06 -6.4951+06
ENTROPY:
BTU/LBMOL-R -125.9012 -125.9012 -119.8057 -119.8057
BTU/LB-R -1.5903 -1.5903 -1.5133 -1.5133
DENSITY:
LBMOL/CUFT 0.3998 0.3998 4.3507-02 4.3507-02
LB/CUFT 31.6509 31.6508 3.4441 3.4442
AVG MW 79.1637 79.1637 79.1637 79.1637
SM-7-152
Exercise 7.15 – Bubble-Point and Partial Vaporization
Page 1
A one-sided heat exchange is used with an HTXR module, which permits

the direct specification of mole fraction vaporized. A bubble-point
feed is specified to give the solution to Part (a) and the heat
exchanger is specified to give the solution to Part (b).
FLOWSHEET SUMMARY
1 HTXR 1 -2
STREAM CONNECTIONS
Stream Equipment
From To
1 1
2 1


1
COMPONENTS
ID # Name
1 8 N-Pentane
2 10 N-Hexane
THERMODYNAMICS
K-value model : SRK


N-Pentane 50.000 50.000 3607.500 3607.500
N-Hexane 50.000 50.000 4308.850 4308.850
Total 100.000 100.000 7916.350 7916.350
SM-7-153
EQUIPMENT SUMMARIES
Equip. No. 1
Name
VF Out Str 1 0.5000
Calc Ht Duty MMBtu/h 0.4559
Str1 Pout atm 10.0000
Exercise 7.15 – Bubble-Point and Partial Vaporization
Page 2
FLOW SUMMARIES
Stream No. 1 2
Stream Name Feed Product
Temp F 288.7792 293.9599
Pres atm 10.0000 10.0000
Enth MMBtu/h -6.9464 -6.4905
Vapor mole fraction 0.00000 0.50000
Total lbmol/h 100.0000 100.0000
N-Pentane 50.0000 50.0000
N-Hexane 50.0000 50.0000
7.16 No, because the vapor and liquid products (VP and LP) are not in phase
equilibrium.
SM-7-154
7.17 Flowsheet decomposition and calculation sequence
There are many ways to perform the flowsheet decomposition. Use of two methods is
highlighted here.
Method 1: Identifies the recycle-loops and from them determines how the flowsheet
can be decomposed.
Step 1: Identify the recycle-loops in the flowsheet (start from any stream and follow
the stram direction; if one returns to the same stream, then a recycle-loop has been
located). There are 3 recycle-loops
Recycle1: 12-13-20-11
Recycle2: 10-12-14-16-17-7-8
Recycle3: 7-8-10-12-14-16-18-21-19-2-4-6
Step 2: Identify partitions – since the recycle-loops are nested (two or more recycle
loops are nested if they have common streams), there are no partitions.
Step 3: Identify tear streams – normally, there should be 1 tear stream per recycle-loop.
However, for nested rcycle-loops, the number of tear streams depends on the number
of streams within the nested recycle-loops. Checking the streams in the recycle-loops,
it is seen that only stream-12 is common to all three recycle-loops. Therefore, stream-
12 is selected as the tear-stream.
Step 4: Identify the calculation order – with stream-12 as the tear stream, the calculation
sequence of the unit operations is as follows –
Known: All variables of stream 1; Guess: values for the needed variables in stream 12;
start the iterative calculation procedure from -
Separator 4 – reactor 2 – reactor 3 – separator 5 – separator 6 – reactor 4 – reactor 5 –
mixer 1 - separator 1 – separator 2 – mixer 2 – reactor 1 – separator 3 – mixer -3 (at
this point new values for stream 12 are obtained, based on them, repeat from separator
4, if necessary).
Method 2: Apply the method of Barkley and Motard (Barkley, R.W.; Motard, R.L.,
“Decomposition of Nets”, The Chemical Engineering Journal, 3, 265-275, 1972) – this
method is useful when not all the recycle-loops are nested. According to this method,
prepare a list of nodes and precursers; remove nodes (and precursers) with single
precursers; identify self-loops and/or two-way edges; cut a stream belonging to the self-
loop first; remove from the remaining nodes, those with single precursers (after cutting
the streams); repeat until there are no nodes with more than one precursor. The cut
streams are the tear streams. Table 1 gives the nodes, precursers for the given flowsheet
(note that input stream 1 and output streams 3, 5, 9 and 15 are not included in the list
below; that is, only streams connected to a unit operation on both sides are considered).
SM-7-155
Round 1 Round 2
Node Precurser
2 19
4 2
6 4
7 6, 17 12, 12
8 7
10 8
11 20
12 10, 11 7, 12 (cut 12)*
13 12
14 12
16 14
17 16
18 16
19 21
20 13
21 18
* stream 12 is cut because it signifies a self-loop (see the description in

Barkley & Motard).
After this initial cut, there are no remaining nodes with more than one
precursor. Therefore, stream 12 is the only tear-stream.
SM-7-156
7.18 Process Simulation with ASPEN PLUS
(Originally Exer. 7.19 in first printing of textbook – original Exer. 7.18 was deleted.)
ASPEN PLUS can be expected to select streams S10 or S11 as the tear stream
since they are common to both recycle loops. When S10 is selected the
simulation flowsheet is:
S16 S2 S14 A3 S15

FSPLIT MIXER
S13
S11 F2
FLASH2
R2
RSTOIC S9
S10*
S12
$OLVER01
S10
A2 S1
MIXER FSPLIT
S8
S5 S7
S1 A1 S2 R1 S3 F1 S4 D1
MIXER RSTOIC FLASH2 DISTL
S6
SEQUENCE USED WAS:

$OLVER01 R2 F2 S2 A1 R1 F1 D1 S1 A2
(RETURN $OLVER01)
A3
SM-7-157
Alternate Simulation Flowsheet
S16
S12
$OLVER01
S16* $OLVER02
S12*
Calculation Sequence – with the internal loop converged within the

external loop
SEQUENCE USED WAS:

$OLVER01 A1 R1 F1 D1 S1
 $OLVER02 A2 R2 F2
 (RETURN $OLVER02)
 S2
(RETURN $OLVER01)
A3
Another Simulation Flowsheet
S16 S12
$OLVER01
S16* S12*
SEQUENCE USED WAS:

$OLVER01 A1 R1 F1 D1 S1 A2 R2 F2 S2
(RETURN $OLVER01)
A3
SM-7-158
7.19 Mass balance model for MCB process from Figure 7.22
(Originally Exer. 7.20 in first printing of textbook.)
The flowsheet from Fig 7.22 is converted to a simple mass balance flowsheet consisting of
mixers, stream calculators (SC) and a divider (representing the purge unit) – see the figure
below.
Note that the absorber is represented by a combination of a mixer (mixer-1) and stream
calculator (SC-2), while, stream calculators (SC-1, SC-3, and SC-4) represent the flash unit,
the treater, and the distillation column, respectively. For a mass balance model, pumps,
compressors, heat exchangers are not necessary.
The list of equipment parameters for mass balances only is given in Table 7.1. For each of
the stream calculators, the component recoveries in one of the outlet streams corresponding
to the inlet stream needs to be specified. For the divider, the purge fraction corresponding to
the inlet stream to the divider needs to be specified. The list of specifications is given in the
table below. Use the simulated results from Exercise 7.6 to determine the values of the
variables to specify.
SM-7-159
Unit operation Variables to specify Remark
SC-1 f04,i/f01,i for i=1,2,3 Recovery of compound i in
stream S04
SC-2 f06,i/f04a,i for i=1,2,3 Recovery of compound i in
stream S06
stream 09
stream 11
Divider F15/F12 Purge fraction
Software file: 7-19-proii
SM-7-160
7.20 Simulation Task 2
(Originally Exer. 7.21 in first printing of textbook)
Benzene to cyclohexane process
Start with the reactor inlet conditions as the reaction data are usually available. So, S4 and S5
stream temperatures and pressures can be fixed. Since the reaction occurs in the gas phase,
the state of these streams is “vapor”. Stream S8 is the bottom product from the distillation
column and so it is at its bubble point. Since from the mass balance, the composition of the
stream is known, assuming a pressure (for example, the column pressure), the bubble point
temperature can be calculated. Streams S9, S10, and S3 (recycle) are at the same
temperature, pressure, and composition. Therefore, their state is unchanged. Stream S9 is a
distillate product and contains mainly unreacted hydrogen, methane and benzene. This
stream will be a vapor at its dew-point. Again, since the composition is known, assuming a
pressure (for example the column pressure), the dew-point temperature can be calculated.
Note that the above specifications do not take into account the change of temperature and
pressure of the feed streams, the inlet stream to the reactor, the inlet stream to the distillation
column and the recycle stream. These are taken into account in Task 3. For the vapor-liquid
equilibrium calculations (buuble-point and dew-point), a cubic equation of state, for example,
the SRK equation of state, should be selected.
Software file: 7-20a-proii
Ethanol from ethylene process (see Fig. 7.18 and Table 7.10)
(Originally HDA process in first printing of textbook.)
The mass balance flowsheet of the ethanol process (Fig. 7.18) is shown in the figure below:
Mass balance flowsheet showing the temperature-pressure

relationships for the ethanol process.
SM-7-161
As the reactor conditions are known, the reactor temperature and pressure are fixed at 575 K
and 68 atm, respectively. The reactor effluent is a vapor and by reducing the pressure and
temperature, a two-phase system is obtained at a temperature of 320 K and a pressure of 20
atm. For the three distillation columns, the pressures could be further reduced to around 2
atm. The temperatures for the distillate and bottoms product for each column can be
calculated from the known composition (using the mass balance) and the assumed pressure
as indicated in the figure above. Note that the unit operations needed to change the
temperature and/or pressure of the streams are not shown in the mass balance flow diagram.
These are added in the Task 3 simulation.
Software file: 7-20b-proii
SM-7-162
7.21 Design decisions
a) Heat exchanger design specification

Use the simple heat exchanger option where only the process stream needs to be
specified. Specify that the cold stream is to be heated to its dew point temperature
with the pressure fixed. In order to calculate the heat duty, specify the utility stream
condition (for example, steam at a specified pressure). The simulator will then
calculate the heat exchanger duty as well the required area of the heat exchanger for
an assumed value of the heat transfer coefficient.
Software file: 7-21a-proii
b) Distillation column design specification

In a conventional distillation column with one feed stream and two product streams, a
product close to the ethanol-water azeotrope will be obtained as the distillate product
and a bottom product containing mainly water (at its bubble point) will be obtained as
the bottom product.
To perform a simulation of the process, the distillation column will need to be

specified in terms of the following variables:
SM-7-163
N (number of stages)
NF (feed location)
Products (vapor or liquid distillate product; liquid bottom product)
Two specifications –
• for the top, one of the following: component recovery, distillate fraction,
distillate flow rate, or component composition (also, condenser duty or reflux
rate or ratio may be specified)
• for the bottom, one of the following: component recovery, bottoms fraction,
bottoms flow rate, or component composition (also, reboiler duty or reboil rate
or ratio may be specified)
In addition, the column pressure and pressure drop needs to be specified and the
property models for phase equilibrium, enthalpy, heat of vaporization, etc., also need
to be selected.
Software file: 7-21b-proii
c) Recovery of a reactor effluent
The temperature and pressure need to be reduced to obtain a two-phase system. The
temperature and pressure may be reduced by taking into account how much of a
specific compound in the reactor effluent should be recovered as, for example, a
vapor product? For the ethanol from ethylene process (see Example 7.5), it is desired
to recover approximately 50% of diethyl ether in the vapor product from the flash.
Thus, the temperature and pressure are adjusted until an approximate distribution os
obtained. The other compounds lighter than diethyl ether and heavier than diethyl
ether are distributed to the vapor and liquid products, respectively.
Note that the top product from the TP-flash represents a dew point, while at the same
temperature and pressure (but different composition), the bottom product represents a
bubble point.
For a simple mass balance, the compound recoveries in either the vapor or liquid
streams are specified and then using the mass balance results and an assumed
pressure, the bubble point and dew point temperatures are calculated.
SM-7-164
For the TP-flash, any two of the following specifications can be made (pressure,
temperature, heat duty, product fraction). One option is to take the results from the
mass balance and then by trial and error, find the pressure and temperature that
matches approximately the product distributions.
Software file: 7-21c-proii
d) Flash and absorber calculation
The process flow-diagram is shown below –
A temperature of approximately 320 K and a pressure of 20 atm will give the desired
distribution of diethyl ether in the TP-Flash. An important issue when considering the
flash temperature and pressure is the temperature of the absorber following it. For a
conventional solvent based physical absorption, the flash temperature should be close
to standard conditions for the solvent. Otherwise, the solvent may need to be pre-
heated. Thus, the temperature is reduced to bring the pressure as close as possible to
the solvent (liquid temperature). The key design variables that need to be specified
are for the vapor feed stream and the solvent inlet stream (the solvent flow rate is a
key factor), the height of the absorption column (or the number of stages or transfer
units) and the product specifications (one at the top and one at the bottom). This is not
very different than an extractive distillation column, except that the solvent based
physical absorber does not have a condenser or a reboiler. Isothermal operation may
be assumed. The use of the correct phase equilibria model is also very important.
Software file: 7-21d-proii
SM-7-165
7.22 Rigorous process simulation – design specification
To match the rigorous process simulation results given in Table 7.15 for the HDA
(hydrodealkylation of toluene process), the data needed by the simulator (select any) are
given in Table 7.14. The input stream details and the set of equipment parameters for each
unit operation in the flowsheet need to be specified. If the data in Table 7.14 are specified
correctly, the simulation results from the selected simulator should match the results in Table
7.15.
Note that the tear stream and calculation sequence are also given in Table 7.14. Perform the
simulations with the default tear streams found by the simulator and compare the simulation
times with the one given in Table 7.14.
Distillation columns can be specified in different ways – 2 variables need to be specified.

Consider specifying product purities or product fractions or product rates instead of the
suggested product recovery of specific compounds.
Exercies 7.2, 7.3 and 7.4 are related to this exercise.
SM-7-166
7.23 Simulation of a solvent-based extraction process
Before a conceptual flow-diagram can be made, additional data regarding the binary
azeotrope and the ternary mixture need to be generated.
The acetone-choloform binary azeotrope is high-boiling as shown by the T-xy diagram at 1

atm. The acetone boiling point is around 329 K and the chloroform boiling point is around
334 K.
A driving force diagram (absolute (y-x) versus x) diagram shows that any feed to the right of
the azeotrope point (zero driving force) will give a top product of acetone and bottom
product of the azeotrope while a feed to the left of the azeotrope point will give chloroform
as the top product and the azeotrope as the bottom product.
SM-7-167
Based on the above analysis, if a solvent could be found to break the azeotrope and sufficient
solvent is added to the extraction column, acetone will be obtained as the top product and the
solvent-chloroform mixture will be obtained as the bottom product. If the solvent is methyl-
n-pentyl ether, a ternary diagram with acetone and chloroform is shown below. The diagram
confirms that first a VLE extraction column where acetone of high purity can be the distillate
and the bottom product will be solvent plus chloroform.
Because of the distillation boundary, the bottom product will lie close to the solvent-
chloroform binary line. This bottom product now goes to the solvent recovery column, where
chloroform is obtained as the distillate and the solvent as the bottom, which is recycled. A
SM-7-168
very small amount of solvent may be lost with the acetone and chloroform products and so a
make-up solvent may be necessary.
A step by step approach to building up of the simulation file is recommended. First, simulate
and test the extraction column with the mixer with the binary azeotrope feed and the solvent
make-up stream (but using it as the main solvent feed). Then build and test the solvent
recovery column. Finally, connect the bottom product from the solvent recover column to the
mixer (as the solvent recycle) and change the solvent make-up stream to a low value
(consistent with the amount lost).
Note that the two distillation columns need to be carefully configured using the data from the
ternary diagram given above. It is better to specify product recoveries and not compositions
or flow rates.
A tutorial document with ICAS (integrated computer aided system) highlighting all the steps
can be downloaded from the Wiley web site for this book.
Tutorial file: 7-23.pdf

SM-7-169
7.24 Debottlenecking reactor train
Two ASPEN BATCH PROCESS DEVELOPER solutions are presented, the first
with a bottleneck, the second with the bottleneck removed. SUPERPRO DESIGNER
solutions are being prepared.
Bottleneck
In this simulation, just one holding tank and heat exchanger are used to feed the
three cultivators, which are fed in sequence, one after the other. After the holding tank is
charged, and the contents aged, Fermenter 1 is fed. Then, the holding tank remains idle for
several days before the feeding of Fermenter 2 begins. Again, the holding tank sits idle for
several more days before the feeding of Fermenter 3 begins. As shown in the results (from
which the recipe text and Gantt chart are shown on the next pages), the large occupancy
time of this vessel limits the batch time to 15 days, 15 hours. This means that the largest
bioreactor, Fermenter 3, sits idle over 1.5 day per batch, an inefficient use of process
equipment.
SM-7-170
Bottleneck Solution - Recipe
1. Reactor Growth Chain
1.1. Charge Mixing Tank with 458.3 kg of Media. The charge time is 1 h. Charge Mixing Tank with
3565 kg of WATER. The charge time is 1 h.
1.2. Cool unit Mixing Tank to 4 C. The cooling time is 1 day.
1.3. Age the contents of unit Mixing Tank for 2 day.
1.4. Microfilter the contents of Mixing Tank in Microfilter. The mode of operation is Batch
Concentration. Unspecified components go to the Permeate. The operation time is 2 h. The
permeate stream is sent to Holding Tank.
1.5. Charge Fermenter 1 with 1.2 kg of tPA-CHO Cells. The charge time is 1 h.
1.6. Transfer contents of unit Holding Tank to Fermenter 1 through heat exchanger Heat Exchanger.
The final stream temperature is 37 C. Transfer 21.2 kg of vessel contents. The transfer time is 0.5
day.
1.7. Ferment in unit Fermenter 1. The yield of tPA-CHO Cells in the Solid phase is 0.153, of
Endotoxin in the Liquid phase is 0.0001, of tPA in the Liquid phase is 0.0001, of WATER in the
Liquid phase is 0.847, of Media in the Liquid phase is 0, of Media in the Solid phase is 0 and of
tPA-CHO Cells in the Liquid phase is 0. The fermentation time is 5 day. Continuously add 0.02 kg
of CARBON-DIOXIDE. Continuously add 0.3 kg of AIR.
Start Parallel
Series
1.8. Transfer contents of unit Fermenter 1 to Fermenter 2. Transfer 100% of vessel contents.
The transfer time is 0.5 day.
1.9. Transfer contents of unit Holding Tank to Fermenter 2 through heat exchanger Heat
Exchanger. The final stream temperature is 37 C. Transfer 293.5 kg of vessel contents.
Endotoxin in the Liquid phase is 7.67e-6, of tPA in the Liquid phase is 0.00039, of
WATER in the Liquid phase is 0.883, of Media in the Solid phase is 0, of Media in the
Liquid phase is 0 and of tPA-CHO Cells in the Liquid phase is 0. The fermentation time
is 7 day. Continuously add 0.4 kg of CARBON-DIOXIDE. Continuously add 4.5 kg of
AIR.
Series
1.11. Clean unit Fermenter 1. Clean with 60 kg of WATER. The feed time is 1 min. Cleaning
time is 20 h.
1.12. Sterilize the contents of Fermenter 1. The sterilization temperature is 130 C. The heat-up
time is 1 h. Maintain the temperature for 2 h. The cool-down time is 1 h.
End Parallel
SM-7-171
2. Final Fermentation
Start Parallel
Series
2.2. Transfer contents of unit Holding Tank to Fermenter 3 through heat exchanger Heat
Exchanger. The final stream temperature is 37 C. Transfer 100% of vessel contents. The
transfer time is 1.5 day.
is 8 day. The final temperature is 37 C. Continuously add 70 kg of AIR. Continuously
add 5.5 kg of CARBON-DIOXIDE.
Series
2.4. Clean unit Fermenter 2. Clean with 600 kg of WATER. The feed time is 1 min. Cleaning time is
20 h.
2.5. Sterilize the contents of Fermenter 2. The sterilization temperature is 130 C. The heat-up time is 1
h. Maintain the temperature for 2 h. The cool-down time is 1 h.
End Parallel
2.6. Transfer contents of unit Fermenter 3 to Centrifuge Holding Tank through heat exchanger Cooler.
The final stream temperature is 4 C. Transfer 100% of vessel contents. The transfer time is 1 day.
68 h.
Bottleneck Solution – Gantt Chart
SM-7-172
Bottleneck Removed
To increase the yearly production of product, the bottleneck is removed by

investing in additional equipment, which is justified, given the high selling price of tPA.
This is achieved by adding Holding Tank 2, and its associated heat exchanger, Heat
Exchanger 2. The full load of media and water is charged to and aged in Holding Tank 1.
After Holding Tank 1 and Heat Exchanger 1 are used to fill Fermenters 1 and 2, the
remaining contents are transferred to Holding Tank 2. Fermenter 3 is subsequently fed
from this tank, through Heat Exchanger 2. With this transfer, Holding Tank 1 is free
substantially earlier, so that it can be charged and the mixture aged earlier for the next
batch. With this modification, as shown in the results that follow, the batch time is reduced
to 14 days, the uptime of Fermenter 3, a time savings of over 10%.
Note that other arrangements of holding tanks and heat exchangers can achieve a
batch time of 14 days.
SM-7-173
Solution Without Bottleneck – Recipe
1. Reactor Growth Chain

1.1. Charge Mixing Tank with 458.3 kg of Media. The charge time is 1 h. Charge Mixing Tank with
3565 kg of WATER. The charge time is 1 h.
1.2. Cool unit Mixing Tank to 4 C. The cooling time is 1 day.
1.3. Age the contents of unit Mixing Tank for 2 day.
1.4. Microfilter the contents of Mixing Tank in Microfilter. The mode of operation is Batch
Concentration. Unspecified components go to the Permeate. The operation time is 2 h. The
permeate stream is sent to Holding Tank 1.
1.5. Charge Fermenter 1 with 1.2 kg of tPA-CHO Cells. The charge time is 1 h.
1.6. Transfer contents of unit Holding Tank 1 to Fermenter 1 through heat exchanger Heat Exchanger
1. The final stream temperature is 37 C. Transfer 21.2 kg of vessel contents. The transfer time is
0.5 day.
Endotoxin in the Liquid phase is 0.0001, of tPA in the Liquid phase is 0.0001, of WATER in the
Liquid phase is 0.847, of Media in the Liquid phase is 0, of Media in the Solid phase is 0 and of
tPA-CHO Cells in the Liquid phase is 0. The fermentation time is 5 day. Continuously add 0.02 kg
of CARBON-DIOXIDE. Continuously add 0.3 kg of AIR.
Start Parallel
Series
1.9. Transfer contents of unit Holding Tank 1 to Fermenter 2 through heat exchanger Heat
Exchanger 1. The final stream temperature is 37 C. Transfer 293.5 kg of vessel contents.
is 7 day. Continuously add 0.4 kg of CARBON-DIOXIDE. Continuously add 4.5 kg of
AIR.
1.11. Transfer contents of unit Holding Tank 1 to Holding Tank 2.
Series
time is 20 h.
End Parallel
SM-7-174
2. Final Fermentation
Start Parallel
Series
2.2. Transfer contents of unit Holding Tank 2 to Fermenter 3 through heat exchanger Heat
Exchanger 2. The final stream temperature is 37 C. Transfer 100% of vessel contents.
is 8 day. Continuously add 70 kg of AIR. Continuously add 5.5 kg of CARBON-
DIOXIDE.
Series
time is 20 h.
End Parallel
2.6. Transfer contents of unit Fermenter 3 to Centrifuge Holding Tank through heat exchanger Cooler.
The final stream temperature is 4 C. The transfer time is 1 day.
68 h.
SM-7-175
Solution Without Bottleneck – ASPEN BATCH PROCESS DEVEL0PER Simulation Flowsheet
(43) 2.4. Clean
(33) 1.10. Ferment (60) 2.7. Clean
(25) 1.12. Clean
(42) 2.4. Clean (54) 2.6. Transfer-Through-Heat-Exchanger
(39) 2.1. Transfer
(21) 1.8. Transfer
(52) 2.3. Ferment
(59) 2.7. Clean
Fermenter 3
Fermenter 1 Fermenter 2 Cooler
(F-10000)
(F-10000) (F-10000) (HE-200)
(24) 1.12. Clean
(11) 1.5. Charge
(18) 1.7. Ferment (45) 2.2. Transfer-Through-Heat-Exchanger (55) 2.6. Transfer-Through-Heat-Exchanger
(27) 1.9. Transfer-Through-Heat-Exchanger
Heat Exchanger 1 Heat Exchanger 2

(13) 1.6. Transfer-Through-Heat-Exchanger (HE-200) (HE-200)
(2) 1.1. Charge (7) 1.4. Microfilter (44) 2.2. Transfer-Through-Heat-Exchanger
(6) 1.4. Microfilter Centrifuge Holding Tank

(ST-A)
(8) 1.4. Microfilter (36) 1.11. Transfer
Microfilter Holding Tank 1 Holding Tank 2

Mixing Tank (Microfilter 500) (ST-A) (ST-A)
(ST-A)
SM-7-176
Solution Without Bottleneck – Stream Variables
Step Stream Table

Process (Version): Reactor Growth Chain (1.0) Key Input Intermediate: Media
Step (Version): Step1 (1.0) Key Output Intermediate: tPA
Simulation Date: 12/18/01 13:26 Number of Batches: 1
Plan Quantity: 2.24 kg
BATCH PLUS Stream Label 1.1. Charge-1 1.1. Charge-2 1.4. Microfilter-6 1.4. Microfilter-7 1.4. Microfilter-8 1.5. Charge-11
Operation 1.1. Charge 1.1. Charge 1.4. Microfilter 1.4. Microfilter 1.4. Microfilter 1.5. Charge
Start Time (min) 0.00 0.00 4,380.00 4,380.00 4,380.00 4,500.00
End Time (min) 60.00 60.00 4,500.00 4,500.00 4,500.00 4,560.00
Total Time (min) 60.00 60.00 120.00 120.00 120.00 60.00
From Unit Mixing Tank Microfilter Microfilter
To Unit Mixing Tank Mixing Tank Microfilter Mixing Tank Holding Tank 1 Fermenter 1
Stream Type Input Input Intermediate Intermediate Intermediate Input
Mass - (kg) Per Batch Mol Wt

Total 458.3000 3,565.0000 4,023.3000 4,023.3000 4,023.3000 1.2000
Endotoxin 18.02
tPA 18.02
AIR 28.95
CARBON-DIOXIDE 44.01
WATER 18.02 3,565.0000 3,565.0000 3,565.0000 3,565.0000
Media 18.02 458.3000 458.3000 458.3000 458.3000
tPA-CHO Cells 18.02 1.2000
Total Mass (kg) 458.30 3,565.00 4,023.30 4,023.30 4,023.30 1.20

Total Volume (liter) 461.15 3,587.19 3,968.36 3,968.36 3,968.36 1.21
Mass Flowrate (kg/min) 7.64 59.42 33.53 33.53 33.53 0.02
Volume Flowrate (liter/h) 461.15 3,587.19 1,984.18 1,984.18 1,984.18 1.21
Composite Product Factor 204.44 1,590.30 1,794.74 1,794.74 1,794.74 0.54
Phase Liquid1 Liquid1 Liquid1 Liquid1 Liquid1 Liquid1
Temperature (C) 25.00 25.00 4.00 4.00 4.00 25.00
Average Density (kg/Cubic m) 993.81 993.81 1,013.84 1,013.84 1,013.84 993.81
Average Viscosity (cp) 0.92 0.92 1.53 1.53 1.53 0.92
Average Heat Capacity (kJ/kg-K) 4.18 4.18 4.21 4.21 4.21 4.18
Average Molecular Weight 18.02 18.02 18.02 18.02 18.02 18.02
SM-7-177
Solution Without Bottleneck – Stream Variables (Cont’d.)
Step Stream Table

1.6. Transfer-Through- 1.6. Transfer-Through-

BATCH PLUS Stream Label 1.7. Ferment-18 1.7. Ferment-19 1.8. Transfer-21 1.12. Clean-24
Heat-Exchanger-13 Heat-Exchanger-14
Operation 1.7. Ferment 1.7. Ferment 1.8. Transfer 1.12. Clean
Heat-Exchanger Heat-Exchanger
Start Time (min) 4,560.00 4,560.00 5,280.00 5,280.00 12,480.00 13,200.00
End Time (min) 5,280.00 5,280.00 5,280.30 5,286.76 13,200.00 13,201.00
Total Time (min) 720.00 720.00 0.30 6.76 720.00 1.00
From Unit Holding Tank 1 Heat Exchanger 1 Fermenter 1
To Unit Heat Exchanger 1 Fermenter 1 Fermenter 1 Fermenter 1 Fermenter 2 Fermenter 1
Stream Type Intermediate Intermediate Input Input Intermediate Input

Total 21.2000 21.2000 0.0200 0.3000 22.4000 60.0000
Endotoxin 18.02 0.0022
tPA 18.02 0.0022
AIR 28.95 0.3000
CARBON-DIOXIDE 44.01 0.0200
WATER 18.02 18.7851 18.7851 18.9690 60.0000
Media 18.02 2.4149 2.4149
Total Mass (kg) 21.20 21.20 0.02 0.30 22.40 60.00

Total Volume (liter) 20.91 21.58 11.12 253.53 22.73 60.37
Volume Flowrate (liter/h) 1.74 1.80 2,250.00 2,250.00 1.89 2,250.00
Composite Product Factor 9.46 9.46 0.01 0.13 9.99 26.77
Phase Liquid1 Liquid1 Gas Gas Liquid1+Solid Liquid1
Temperature (C) 4.01 37.00 25.00 25.00 36.31 25.00
Average Density (kg/Cubic m) 1,013.84 982.17 1.80 1.18 985.41 993.81
SM-7-178
Step Stream Table


BATCH PLUS Stream Label 1.12. Clean-25 1.10. Ferment-33 1.10. Ferment-34 1.11. Transfer-36
Operation 1.12. Clean 1.10. Ferment 1.10. Ferment 1.11. Transfer
Start Time (min) 14,401.00 13,200.00 13,200.00 13,920.00 13,920.00 24,000.00
End Time (min) 14,402.00 13,920.00 13,920.00 13,925.93 14,021.41 24,097.55
Total Time (min) 1.00 720.00 720.00 5.93 101.41 97.55
From Unit Fermenter 1 Holding Tank 1 Heat Exchanger 1 Holding Tank 1
To Unit Heat Exchanger 1 Fermenter 2 Fermenter 2 Fermenter 2 Holding Tank 2
Stream Type Output Intermediate Intermediate Input Input Intermediate

Total 60.0000 293.5000 293.5000 0.4000 4.5000 3,708.6000
Endotoxin 18.02
tPA 18.02
AIR 28.95 4.5000
WATER 18.02 60.0000 260.0670 260.0670 3,286.1479
Media 18.02 33.4330 33.4330 422.4521
tPA-CHO Cells 18.02
Total Mass (kg) 60.00 293.50 293.50 0.40 4.50 3,708.60

Total Volume (liter) 60.37 289.49 298.83 222.36 3,802.88 3,657.98
Volume Flowrate (liter/h) 2,250.00 24.12 24.90 2,250.00 2,250.00 2,250.00
Composite Product Factor 26.77 130.93 130.93 0.18 2.01 1,654.36
Phase Liquid1 Liquid1 Liquid1 Gas Gas Liquid1
Temperature (C) 25.00 4.01 37.00 25.00 25.00 4.01
Average Density (kg/Cubic m) 993.81 1,013.84 982.17 1.80 1.18 1,013.84
SM-7-179
Step Stream Table

Process (Version): Reactor Chain Debottlenecking (1.0) Key Input Intermediate: Media

BATCH PLUS Stream Label 1.11. Transfer-32 2.1. Transfer-35 2.3. Ferment-43
Operation 1.11. Transfer 2.1. Transfer 2.3. Ferment
Start Time (min) 24,000.00 24,097.59 24,817.59 24,817.59 26,977.59
End Time (min) 24,097.59 24,817.59 26,977.59 26,977.59 27,059.12
Total Time (min) 97.59 720.00 2,160.00 2,160.00 81.53
From Unit Holding Tank 1 Fermenter 2 Holding Tank 2 Heat Exchanger 2
To Unit Holding Tank 2 Fermenter 3 Heat Exchanger 2 Fermenter 3 Fermenter 3
Stream Type Intermediate Intermediate Intermediate Intermediate Input

Total 3,710.3000 315.9000 3,710.3000 3,710.3000 5.5000
tPA 18.02 0.1263
AIR 28.95
WATER 18.02 3,286.2657 277.8808 3,286.2657 3,286.2657
Media 18.02 424.0343 424.0343 424.0343
Total Mass (kg) 3,710.30 315.90 3,710.30 3,710.30 5.50

Total Volume (liter) 3,659.66 321.61 3,659.69 3,777.67 3,057.46
Mass Flowrate (kg/min) 38.02 0.44 1.72 1.72 0.07
Volume Flowrate (liter/h) 2,250.00 26.80 101.66 104.94 2,250.00
Composite Product Factor 1,844.00 157.00 1,844.00 1,844.00 2.73
Phase Liquid1 Liquid1 Liquid1 Liquid1 Gas
Temperature (C) 4.01 36.90 4.02 37.00 25.00
Average Density (kg/Cubic m) 1,013.84 982.26 1,013.83 982.17 1.80
Average Viscosity (cp) 1.53 0.72 1.53 0.71 0.01
Average Heat Capacity (kJ/kg-K) 4.21 4.17 4.21 4.17 0.85
Average Molecular Weight 18.02 18.02 18.02 18.02 44.01
SM-7-180
Solution Without Bottleneck – Stream Variables (Con’t)
Step Stream Table


BATCH PLUS Stream Label 2.1. Transfer-39 2.4. Clean-42 2.4. Clean-43 2.3. Ferment-51
Operation 2.1. Transfer 2.4. Clean 2.4. Clean 2.3. Ferment
Start Time (min) 24,097.55 24,817.55 26,018.55 24,817.55 24,817.55 26,977.55
End Time (min) 24,817.55 24,818.55 26,019.55 26,977.55 26,977.55 28,555.04
Total Time (min) 720.00 1.00 1.00 2,160.00 2,160.00 1,577.49
From Unit Fermenter 2 Fermenter 2 Holding Tank 2 Heat Exchanger 2
To Unit Fermenter 3 Fermenter 2 Heat Exchanger 2 Fermenter 3 Fermenter 3
Stream Type Intermediate Input Output Intermediate Intermediate Input

Total 315.9000 600.0000 600.0000 3,708.6000 3,708.6000 70.0000
tPA 18.02 0.1232
AIR 28.95 70.0000
CARBON-DIOXIDE 44.01
WATER 18.02 278.8288 600.0000 600.0000 3,286.1479 3,286.1479
Media 18.02 422.4521 422.4521
Total Mass (kg) 315.90 600.00 600.00 3,708.60 3,708.60 70.00

Total Volume (liter) 320.94 603.73 603.73 3,658.01 3,775.94 59,155.97
Volume Flowrate (liter/h) 26.75 2,250.00 2,250.00 101.61 104.89 2,250.00
Composite Product Factor 140.92 267.65 267.65 1,654.36 1,654.36 31.23
Phase Liquid1+Solid Liquid1 Liquid1 Liquid1 Liquid1 Gas
Temperature (C) 36.90 25.00 25.00 4.02 37.00 25.00
Average Density (kg/Cubic m) 984.29 993.81 993.81 1,013.83 982.17 1.18
SM-7-181
Solution Without Bottleneck – Stream Variables (Con’t)
Step Stream Table


BATCH PLUS Stream Label 2.3. Ferment-52 2.7. Clean-59 2.7. Clean-60
Operation 2.3. Ferment 2.7. Clean 2.7. Clean
Start Time (min) 26,977.55 38,497.55 38,497.55 39,937.55 44,018.55
End Time (min) 27,059.08 39,937.55 39,937.55 39,938.55 44,019.55
Total Time (min) 81.53 1,440.00 1,440.00 1.00 1.00
From Unit Fermenter 3 Cooler Fermenter 3
To Unit Fermenter 3 Cooler Centrifuge Holding Tank Fermenter 3
Stream Type Input Intermediate Intermediate Input Output

Total 5.5000 4,024.5000 4,024.5000 600.0000 600.0000
Endotoxin 18.02 0.0031 0.0031
tPA 18.02 2.2417 2.2417
AIR 28.95
WATER 18.02 3,565.0896 3,565.0896 600.0000 600.0000
Media 18.02
tPA-CHO Cells 18.02 457.1656 457.1656
Total Mass (kg) 5.50 4,024.50 4,024.50 600.00 600.00

Total Volume (liter) 3,057.46 4,089.08 3,975.82 603.73 603.73
Mass Flowrate (kg/min) 0.07 2.79 2.79 37.27 37.27
Volume Flowrate (liter/h) 2,250.00 170.38 165.66 2,250.00 2,250.00
Composite Product Factor 2.45 1,795.28 1,795.28 267.65 267.65
Phase Gas Liquid1+Solid Liquid1+Solid Liquid1 Liquid1
Temperature (C) 25.00 36.93 4.00 25.00 25.00
Average Density (kg/Cubic m) 1.80 984.21 1,012.24 993.81 993.81
Average Viscosity (cp) 0.01 0.63 1.36 0.92 0.92
Average Heat Capacity (kJ/kg-K) 0.85 4.17 4.21 4.18 4.18
Average Molecular Weight 44.01 18.02 18.02 18.02 18.02
SM-7-182
Solution Without Bottleneck – Mixing Tank Report
Step Equipment Contents

Mixing Tank
Operation START 1.1. Charge 1.2. Cool 1.3. Age 1.4. Microfilter
Time (min) 0.00 60.00 1,500.00 4,380.00 4,500.00
Mass - (kg) Mol Wt

Total 5.8957 4,024.4221 4,024.6086 4,024.6086 6.3424
WATER 18.02 3,565.0000 3,565.0000 3,565.0000
NITROGEN 28.01 4.5223 0.8607 1.0038 1.0038 4.8650
OXYGEN 32.00 1.3734 0.2614 0.3048 0.3048 1.4774
Media 18.02 458.3000 458.3000 458.3000
Liquid+Solid Mass (kg) 0.00 4,023.30 4,023.30 4,023.30 0.00

Liquid+Solid Volume (liter) 0.00 4,048.34 3,968.36 3,968.36 0.00
Phase Gas Gas+Liquid1 Gas+Liquid1 Gas+Liquid1 Gas
Temperature (C) 25.00 25.00 4.00 4.00 4.00
Pressure (kPa) 101.33 101.33 101.33 101.33 101.33
Average Liq+Sol Density (kg/Cubic m) 0.00 993.81 1,013.84 1,013.84 0.00
Average Liq+Sol Viscosity (cp) 0.00 0.92 1.53 1.53 0.00
Average Liq+Sol Heat Capacity (kJ/kg-K) 0.00 4.18 4.21 4.21 0.00
Average Liq+Sol Molecular Weight 0.00 18.02 18.02 18.02 0.00
Vessel Volume
6,000.00
Liquid+Solid Volume (liter)
5,000.00
4,000.00
3,000.00
2,000.00
1,000.00
0.00
0.00 1,000.00 2,000.00 3,000.00 4,000.00
Time (min)
Volume Maximum Design Volume
Minimum Design Volume
SM-7-183
Solution Without Bottleneck – Holding Tank 2 Report

Holding Tank 2
Operation START 1.11. Transfer 1.11. Transfer
Time (min) 0.00 24,000.00 24,097.55 24,817.55 26,977.55
Mass - (kg) Mol Wt

Total 5.8957 5.8957 3,710.3022 3,710.3022 6.3421
WATER 18.02 3,286.1479 3,286.1479
NITROGEN 28.01 4.5223 4.5223 1.3057 1.3057 4.8647
OXYGEN 32.00 1.3734 1.3734 0.3965 0.3965 1.4774
Media 18.02 422.4521 422.4521
Liquid+Solid Mass (kg) 0.00 0.00 3,708.60 3,708.60 0.00

Liquid+Solid Volume (liter) 0.00 0.00 3,658.01 3,658.01 0.00
Phase Gas Gas Gas+Liquid1 Gas+Liquid1 Gas
Temperature (C) 25.00 25.00 4.02 4.02 4.02
Pressure (kPa) 101.33 101.33 101.33 101.33 101.33
Average Liq+Sol Density (kg/Cubic m) 0.00 0.00 1,013.83 1,013.83 0.00
Average Liq+Sol Viscosity (cp) 0.00 0.00 1.53 1.53 0.00
Average Liq+Sol Heat Capacity (kJ/kg-K) 0.00 0.00 4.21 4.21 0.00
Average Liq+Sol Molecular Weight 0.00 0.00 18.02 18.02 0.00
Vessel Volume
6,000.00
5,000.00
4,000.00
3,000.00
2,000.00
1,000.00
0.00
0.00 5,000.00 10,000.0 15,000.0 20,000.0 25,000.0
0 Time (min)
0 0 0

Minimum Design Volume
SM-7-184
Solution Without Bottleneck – Fermenter 1 Report

Fermenter 1
1.6. Transfer-Through-
Operation START 1.5. Charge 1.5. Charge 1.7. Ferment 1.8. Transfer 1.12. Clean
Heat-Exchanger
Time (min) 0.00 4,500.00 4,560.00 5,280.00 12,480.00 13,200.00 14,402.00
Mass - (kg) Mol Wt

Total 0.0472 0.0472 1.2457 22.4195 22.4201 0.0459 0.0459
tPA 18.02 0.0022
AIR 28.95 0.0177 0.0177 0.0177
CARBON-DIOXIDE 44.01 0.0012 0.0012 0.0012
WATER 18.02 18.7851 18.9690
NITROGEN 28.01 0.0362 0.0362 0.0351 0.0150 0.0009 0.0207 0.0207
OXYGEN 32.00 0.0110 0.0110 0.0107 0.0046 0.0003 0.0063 0.0063
Media 18.02 2.4149
tPA-CHO Cells 18.02 1.2000 1.2000 3.4265
Liquid+Solid Mass (kg) 0.00 0.00 1.20 22.40 22.40 0.00 0.00
Liquid+Solid Volume (liter) 0.00 0.00 1.21 22.79 22.73 0.00 0.00
Phase Gas Gas Gas+Liquid1 Gas+Liquid1 Gas+Liquid1+Solid Gas Gas
Temperature (C) 25.00 25.00 25.00 36.35 36.31 36.31 36.31
Pressure (kPa) 101.33 101.33 101.33 101.33 101.33 101.32 101.32
Average Liq+Sol Density (kg/Cubic m) 0.00 0.00 993.81 982.80 985.41 0.00 0.00
Average Liq+Sol Viscosity (cp) 0.00 0.00 0.92 0.72 0.72 0.00 0.00
Average Liq+Sol Heat Capacity (kJ/kg-K) 0.00 0.00 4.18 4.17 4.17 0.00 0.00
Average Liq+Sol Molecular Weight 0.00 0.00 18.02 18.02 18.02 0.00 0.00
Vessel Volume
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
0.00 5,000.00 10,000.00
Time (min)
SM-7-185

Fermenter 2
1.9. Transfer-Through-
Operation START 1.8. Transfer 1.8. Transfer 1.10. Ferment 1.1. Transfer 1.1. Transfer 1.4. Clean
Heat-Exchanger
Time (min) 0.00 12,480.00 13,200.00 13,920.00 24,000.00 24,097.55 24,817.55 26,019.55
Mass - (kg) Mol Wt

Total 0.4717 0.4717 22.8287 315.9889 315.9925 315.9925 0.4564 0.4564
Endotoxin 18.02 0.0022 0.0022 0.0024 0.0024
tPA 18.02 0.0022 0.0022 0.1232 0.1232
AIR 28.95 0.0834 0.0834 0.0834 0.0834
CARBON-DIOXIDE 44.01 0.0074 0.0074 0.0074 0.0074
WATER 18.02 18.9690 279.0360 278.8288 278.8288
NITROGEN 28.01 0.3618 0.3618 0.3288 0.0682 0.0013 0.0013 0.2804 0.2804
OXYGEN 32.00 0.1099 0.1099 0.0999 0.0207 0.0004 0.0004 0.0852 0.0852
Media 18.02 33.4330
tPA-CHO Cells 18.02 3.4265 3.4265 36.9456 36.9456
Liquid+Solid Mass (kg) 0.00 0.00 22.40 315.90 315.90 315.90 0.00 0.00
Liquid+Solid Volume (liter) 0.00 0.00 22.73 321.56 320.94 320.94 0.00 0.00
Phase Gas Gas Gas+Liquid1+Solid Gas+Liquid1+Solid Gas+Liquid1+Solid Gas+Liquid1+Solid Gas Gas
Temperature (C) 25.00 25.00 36.26 36.95 36.90 36.90 36.90 36.90
Pressure (kPa) 101.33 101.33 101.33 101.33 101.33 101.33 101.33 101.33
Average Liq+Sol Density (kg/Cubic m) 0.00 0.00 985.46 982.41 984.29 984.29 0.00 0.00
Average Liq+Sol Viscosity (cp) 0.00 0.00 0.72 0.71 0.72 0.72 0.00 0.00
Average Liq+Sol Heat Capacity (kJ/kg-K) 0.00 0.00 4.17 4.17 4.17 4.17 0.00 0.00
Average Liq+Sol Molecular Weight 0.00 0.00 18.02 18.02 18.02 18.02 0.00 0.00
Vessel Volume
450.00
400.00
350.00
300.00
250.00
200.00
150.00
100.00
50.00
0.00
0.00 5,000.00 10,000.0 15,000.0 20,000.0 25,000.0
0 0 0 0
Time (min)
SM-7-186

Fermenter 3
Operation START 1.1. Transfer 1.1. Transfer 1.3. Ferment 1.7. Clean
Time (min) 0.00 24,097.55 24,817.55 26,977.55 38,497.55 39,937.55 44,019.55
Mass - (kg) Mol Wt

Total 5.8957 5.8957 321.2064 4,025.5238 4,025.5625 5.6985 5.6985
Endotoxin 18.02 0.0024 0.0024 0.0031
tPA 18.02 0.1232 0.1232 2.2417
AIR 28.95 0.9719 0.9719 0.9719
CARBON-DIOXIDE 44.01 0.0764 0.0764 0.0764
WATER 18.02 278.8288 3,564.9768 3,565.0896
NITROGEN 28.01 4.5223 4.5223 4.0703 0.7853 0.0109 3.5670 3.5670
OXYGEN 32.00 1.3734 1.3734 1.2361 0.2385 0.0033 1.0833 1.0833
Media 18.02 422.4521
tPA-CHO Cells 18.02 36.9456 36.9456 457.1656
Liquid+Solid Mass (kg) 0.00 0.00 315.90 4,024.50 4,024.50 0.00 0.00
Liquid+Solid Volume (liter) 0.00 0.00 320.93 4,096.86 4,089.08 0.00 0.00
Phase Gas Gas Gas+Liquid1+Solid Gas+Liquid1+Solid Gas+Liquid1+Solid Gas Gas
Temperature (C) 25.00 25.00 36.85 36.99 36.93 36.93 36.93
Pressure (kPa) 101.33 101.33 101.33 101.33 101.33 101.32 101.32
Average Liq+Sol Density (kg/Cubic m) 0.00 0.00 984.34 982.34 984.21 0.00 0.00
Average Liq+Sol Viscosity (cp) 0.00 0.00 0.72 0.71 0.72 0.00 0.00
Average Liq+Sol Heat Capacity (kJ/kg-K) 0.00 0.00 4.17 4.17 4.17 0.00 0.00
Average Liq+Sol Molecular Weight 0.00 0.00 18.02 18.02 18.02 0.00 0.00
Vessel Volume
6,000.00
5,000.00
4,000.00
3,000.00
2,000.00
1,000.00
0.00
0.00 10,000.00 20,000.00 30,000.00 40,000.00
Time (min)
SM-7-187
Solution Without Bottleneck – Multiple Batch Gantt Chart
SM-5-188
Solution Without Bottleneck – Single Batch Gantt Chart
SM-5-189

CH 07

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CHAPTER 7 SOLUTIONS

ASPEN PLUS Solution

a. ASPEN PLUS Flowsheet – simulation results can be reproduced using the

ASPEN PLUS Simulation Flowsheet

STREAM ID FEED1 FEED2 LP S2 S3

Selected Process Unit Output

BLOCK: F1 MODEL: FLASH2

*** MASS AND ENERGY BALANCE ***

*** INPUT DATA ***

*** RESULTS ***

V-L PHASE EQUILIBRIUM :

COMP F(I) X(I) Y(I) K(I)

Acyclic Simulation Flowsheet

Using this flowsheet, identical results are obtained.

ASPEN PLUS Simulation Flowsheet

ASPEN PLUS Program – identical to that in c with following change and

SEQUENCE USED WAS:

STREAM ID FEED1 FEED2 LP S2 S3

Selected Process Unit Output

BLOCK: F1 MODEL: FLASH2

*** MASS AND ENERGY BALANCE ***

*** INPUT DATA ***

*** RESULTS ***

V-L PHASE EQUILIBRIUM :

COMP F(I) X(I) Y(I) K(I)

Calculation mode : Sequential

Equipment Calculation Sequence

Equipment Recycle Sequence

Recycle Cut Streams

Recycle Convergence Method: Direct Substitution

Recycle Convergence Tolerance

Flow rate 1.000E-005

K-value model : SRK

Overall Mass Balance lbmol/h lb/h

Total 153.083 153.083 8026.000 8026.001

Comparison of results from Cases 1, 2, and 3.

The only feed to the process is stream 1 (Fresh feed).

Flow rates in Vapor product (stream 3) in lb/hr:

Total 4,619.49 4,619.48 4,619.48

Control of flash temperature to give a vapor product rate of 850 lb/hr.

Equipment Label Stream Numbers

Calculation mode : Sequential

Equipment Calculation Sequence

K-value model : SRK

Overall Mass Balance lbmol/h lb/h

Total 153.083 153.083 8026.000 8026.000

ASPEN PLUS Solution

ASPEN PLUS Flowsheet - simulation results can be reproduced using the

SEQUENCE USED WAS:

CWEX CWIN FEED GAS-RECY LP

STREAM ID CWEX CWIN FEED GAS-RECY LP

LPR REC RECYCLE S1 S2

STREAM ID LPR REC RECYCLE S1 S2

Selected Process Unit Output

BLOCK: R1 MODEL: RSTOIC

*** MASS AND ENERGY BALANCE ***

*** INPUT DATA ***

TWO PHASE TP FLASH

*** RESULTS ***

V-L PHASE EQUILIBRIUM :

COMP F(I) X(I) Y(I) K(I)

BLOCK: H1 MODEL: HEATX

*** MASS AND ENERGY BALANCE ***

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* MASS AND ENERGY BALANCE *

* OVERALL RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* OVERALL RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* INPUT DATA *

* RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* MASS AND ENERGY BALANCE *

* INPUT DATA *

* RESULTS *

* INPUT DATA *

* RESULTS *