CHAPTER 7

ENERGY BALANCE

7.1 METHOD OF CALCULATION

7.1.1 Assumptions in Calculations

The assumption used for the calculations of the energy balance for all the streams are:

i. ii. iii. iv. v.

The system is an open system at steady state. There are no moving parts in the system. The linear velocities of all streams are the same All streams enter and leave the process at a single height. Heat obtained from the pressure differences are neglected because the effect of pressure difference to the energy balance is very small compared to the values contributed by the sensible heat and the heat of formation therefore, heat obtained from the pressure difference is assumed to be negligible.

7.1.2 Equations Used in Calculations

7.1.2.1 General Equations (7.1)

Based on the assumptions stated above, the work shaft, potential energy and kinetic energy can be neglected.

Hence,

107

Therefore, the equation can be reduced to: Q = H 7.1.2.2 Equation for Reactive Process (7.2)

( )

( )

(7.4) (7.3)

(7.5)

7.1.2.3 Equation for Process with Phase Changes

(7.6)

(7.7) 7.1.2.4 Equation for Non-reactive Process ( )

(7.8)

108 Or [ ]

7.1.2.5 Equation for Heat Capacity, Cp

(7.9) (7.10)

Hence for sensible heat,

(7.11)

7.1.2.6 Total Heat for the Energy Balance (for Non-reactive Process):

(7.12)

7.1.3 Reference Conditions and Data

Tref = 25C (298 K) Pref = 1 atm (101.3kPa)

Hence, when T = Tref there will be no sensible heat. Therefore, the sensible heat of the substances in standard condition is equal to zero and can be neglected.

The reference data such as Heat Capacity (Cp), Specific Heat of Formation (f), Heat of vaporization (Hv), physical properties and all the data used in the calculation is available in Appendix K-1.

109 7.2 ENERGY BALANCE CALCULATION

The calculation is done by using Microsoft Excel to make changes and calculationif in case the temperature or pressure in any equipment change during the design process to meet with the equipment needs.

This sectionshows the deatil calculation of energy balance at the hydrolysis reactor only, for detail calculation of all the equipment please refer to Appendix K-2.

7.2.1 Balance at Reactor

P-41

P-42

Stream 1 Temperature : 28.4 C Pressure :170 kPa

Stream 9 Temperature : 85 C Pressure :150 kPa

Stream 2

E-19

Temperature : 43.5 C Pressure :170 kPa

P-39

P-40

Stream 3 Temperature : 27 C Pressure :170 kPa

Stream 10 Temperature : 85 C Pressure :150 kPa

Figure 7.1: Inlet and Outlet Stream for Reactor

110 Table 7.1: Total Amount of Enthalphy at Reactor Hr (kJ/hr) 2.18E+7 H inlet (kJ/hr) 8.95E+06 Houtlet (kJ/hr) 1.48E+07 H (kJ/hr) 2.77E+7

111 Table 7.2: Inlet Stream Component Enthalphy for Reactor Inlet Stream Stream 1 Component ninlet (kmol/hr) CA MA HCl H2O NH4Cl AA MIBK CO2 H
inlet

Stream 2 HComponent (kJ/hr) ninlet (kmol/hr) inlet

Stream 3 HComponent (kJ/hr) ninlet (kmol/hr) 1.45E+02 inlet

HComponent (kJ/hr) 2.19E+04 2.19E+04

(kJ/kmol)

(kJ/kmol) -

(kJ/kmol) 1.51E+02 -

5.36E+01 6.25E+02 3.35E+04 3.35E+04

7.15E+01 1.24E+05 8.90E+06 8.90E+06

112 Table 7.3: Outlet Stream Component Enthalphy for Reactor

Outlet Stream

Component noutlet (kmol/hr) CA MA HCl H2O NH4Cl AA MIBK CO2 H 1.75E+01 3.47E+01 3.49E+01 7.22E+01 3.55E+01 8.16E-01 -

Stream 10
outlet

Stream 9 HComponent (kJ/hr) 1.93E+05 2.66E+05 1.41E+07 3.27E+05 1.93E+05 6.52E+03 1.51E+07 noutlet (kmol/hr) 8.16E-01
outlet

HComponent (kJ/hr) -3.62E+05 -3.62E+05

(kJ/kmol) 1.10E+04 7.66E+03 4.05E+05 4.52E+03 5.42E+03 7.98E+03 -

(kJ/kmol) -4.43E+05

113 7.2.1.1 Balance for Stream 1

Cyanoacetic acid; Where, And;

7.2.1.2

Balance for Stream 2

Hydrochloric Acid; Where, And;

7.2.1.3 For Water: Where,

Balance for Stream 3

114 And;

7.2.1.4

Balance for Stream 10

Cyanoacetic Acid;

Where, And;

Malonic Acid; Where,

Where, And;

115 Hydrochloric Acid;

Where, And;

For Water: Where, And;

Ammonium Chloride: Where, And;

116

Acetic Acid: Where,

And;

7.2.1.5

Balance for Stream 9

Carbon Dioxide: Where,

And;

117 7.2.1.6 Heat of Reaction

The heat of reaction can be calculated by modifying Equation 7.5:

and r can be calculated by refering to thestoichiometric equation of the reaction, for this process the stochiometric equation is as follows:

From equation 7.5: [ [ ] ]

Next to calculate , equation 7.6 was used: | | | |

118 Henceforth, Hr is:

7.2.1.7

Total Balance

The total overall energy balance from the reactor can be calculated by using Equation 7.4:

( )

( )

Where Hinlet and Houtlet is equal to:

119 ( ) ( )

120 7.2.2 Evaporator 1

P-60

Stream 11 Temperature : 110 C Pressure :130 kPa

Stream 10 Temperature : 85 C Pressure :150 kPa

E-22
P-5

Stream 12 Temperature : 110 C Pressure :130 kPa

Figure 7.2: Inlet and Outlet Stream for Evaporator 1

Table 7.4: Total Amount of Enthalphy at Evaporator 1 H inlet (kJ/hr) 1.44E+07 Houtlet (kJ/hr) 2.16E+07 H (kJ/hr) 7.19E+06

121 Table 7.5: Component Enthalphy for Evaporator 1 Inlet Stream Stream 10 Component ninlet (kmol/hr) CA MA HCl H2O NH4Cl AA MIBK CO2 H 1.75.E+01 3.47.E+01 3.32.E+01 7.22.E+01 3.55.E+01 8.16.E-01 inlet

Outlet Stream Stream 11 HComponent (kJ/hr) 1.93.E+05 2.66.E+05 1.34.E+07 3.27.E+05 1.93.E+05 6.52.E+03 1.44.E+07 noutlet (kmol/hr) 3.17.E+01 2.14.E+01 3.62.E-01 outlet

Stream 12 HComponent (kJ/hr) 1.85.E+07 9.99.E+05 1.30.E+04 1.95.E+07 noutlet (kmol/hr) 1.75.E+01 3.47.E+01 1.41.E+00 4.70.E+01 3.64.E+01 1.41.E+00 outlet

(kJ/kmol) 1.10.E+04 7.66.E+03 4.05.E+05 4.52.E+03 5.42.E+03 7.98.E+03 -

(kJ/kmol) 5.84.E+05 4.67.E+04 3.59.E+04 -

(kJ/kmol) 1.56.E+04 1.08.E+04 5.74.E+05 6.41.E+03 7.68.E+03 1.15.E+04 -

HComponent (kJ/hr) 2.74.E+05 3.76.E+05 8.12.E+05 3.01.E+05 2.80.E+05 1.61.E+04 2.06.E+06

122 7.2.3 Evaporator 2

P-60

Stream 15

Temperature : 140 C Pressure :130 kPa

Stream 14 Temperature : 110 C Pressure :150 kPa

E-22
P-5

Stream 16

Temperature : 140 C Pressure :130 kPa

Figure 7.3: Inlet and Outlet Stream for Evaporator 2

Table 7.6: Total Amount of Enthalphy at Evaporator 2

H inlet (kJ/hr) 2.06E+06

Houtlet (kJ/hr) 2.91E+06

H (kJ/hr) 8.49E+05

123 Table 7.7: Component Enthalphy for Evaporator 2

Inlet Stream Stream 14 Component ninlet (kmol/hr) CA MA HCl H2O NH4Cl AA MIBK CO2 H 1.75.E+01 3.47.E+01 1.41.E+00 4.70.E+01 3.64.E+01 1.41.E+00 inlet

Outlet Stream Stream 15 HComponent (kJ/hr) 2.74.E+05 3.76.E+05 8.12.E+05 3.01.E+05 2.80.E+05 1.61.E+04 2.06.E+06 noutlet (kmol/hr) 1.23.E+00 9.09.E+00 1.60.E-01 outlet

Stream 16 HComponent (kJ/hr) 7.20.E+05 4.33.E+05 6.20.E+03 1.16.E+06 noutlet (kmol/hr) 1.75.E+01 3.47.E+01 1.82.E-01 3.79.E+01 3.64.E+01 1.25.E+00 outlet

(kJ/kmol) 1.56.E+04 1.08.E+04 5.74.E+05 6.41.E+03 7.68.E+03 1.15.E+04 -

(kJ/kmol) 5.85.E+05 4.77.E+04 3.87.E+04 -

(kJ/kmol) 2.11.E+04 1.47.E+04 7.78.E+05 8.67.E+03 1.04.E+04 1.58.E+04 -

HComponent (kJ/hr) 3.70.E+05 5.09.E+05 1.42.E+05 3.29.E+05 3.79.E+05 1.97.E+04 1.75.E+06

124 7.2.4 Balance on Heat Exchanger 1 (Condensor) Stream 11 Temperature : 110 C Pressure : 130 kPa Stream 13 Temperature : 60 C Pressure :152 kPa

Figure 7.4: Inlet and Outlet Stream for Heat Exchanger 1

Table 7.8: Total Amount of Enthalphy at Heat Exchanger 1

H inlet (kJ/hr) 1.42E+05

Houtlet (kJ/hr) -9.07E+06

H (kJ/hr) -9.22E+06

125 Table 7.9: Component Enthalphy for Heat Exchanger 1

Inlet Stream Stream 11 Component CA MA HCl H2O NH4Cl AA MIBK CO2 H ninlet (kmol/hr) 3.17.E+01 2.14.E+01 3.62.E-01 inlet

Outlet Stream Stream 13 HComponent (kJ/hr) 7.85.E+04 6.18.E+04 2.19.E+03 1.42E+05 noutlet (kmol/hr) 3.17.E+01 2.14.E+01 3.62.E-01 outlet

(kJ/kmol) 2.47.E+03 2.89.E+03 6.04.E+03 -

(kJ/kmol) -3.13.E+05 4.02.E+04 2.36.E+04 -

HComponent (kJ/hr) -9.94.E+06 8.60.E+05 8.53.E+03 -9.07E+06

126 7.2.5 Balance on Distillation Column

P-60

Stream 23

Temperature : 117 C Pressure :253.31 kPa

Stream 22 Temperature : 97 C Pressure : 263.45 kPa

P-6

Stream 24 Temperature : 161.6 C Pressure :273.58 kPa

Figure 7.5: Inlet and Outlet Stream for Distillation Column

Table 7.10: Total Amount of Enthalphy at Distillation Column

H inlet (kJ/hr) 1.91E+06

Houtlet (kJ/hr) 2.86E+06

H (kJ/hr) 9.44E+05

127 Table 7.11: Component Enthalphy for Distillation Column

Inlet Stream Stream 22 Component ninlet (kmol/hr) 1.75E+01 3.47E+01 1.82E-01 3.79E+01 1.25E+00 6.94E+01 inlet

Outlet Stream Stream 23 HComponent (kJ/hr) 2.32E+05 3.19E+05 8.85E+04 2.06E+05 1.20E+04 1.06E+06 1.91E+06 noutlet (kmol/hr) 1.82E-01 3.79E+01 1.04E+00 6.20E+01 outlet

Stream 24 HComponent (kJ/hr) 1.13E+05 2.63E+05 1.30E+04 1.21E+06 1.60E+06 noutlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 2.05E-01 7.35E+00 outlet

(kJ/kmol) 1.32E+04 9.19E+03 4.86E+05 5.43E+03 9.64E+03 1.53E+04 -

(kJ/kmol) 6.22E+05 6.94E+03 1.25E+04 1.95E+04 -

(kJ/kmol) 2.51E+04 1.74E+04 1.03E+04 1.90E+04 2.89E+04 -

HComponent (kJ/hr) 4.40E+05 6.05E+05 3.09E+01 3.90E+03 2.13E+05 1.26E+06

CA MA HCl H2O NH4Cl AA MIBK CO2 H

128 7.2.6 Balance on Heat Exchanger

Stream 26 Temperature : 259.31 C Pressure : 101.3 kPa

Stream 27 Temperature : 80 C Pressure : 131.72 kPa

Figure 7.6: Inlet and Outlet Stream for Heat Exchanger 2

Table 7.11: Total Amount of Enthalphy at Heat Exchanger 2 H inlet (kJ/hr) 1.26E+06 Houtlet (kJ/hr) 6.90E+05 H (kJ/hr) -5.68E+05

129 Table 7.12: Component Enthalphy for Heat Exchanger 2

Inlet Stream Stream 26 Component CA MA HCl H2O NH4Cl AA MIBK CO2 H ninlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 5.00E-03 7.35E+00 inlet

Outlet Stream Stream 27 HComponent (kJ/hr) 4.40E+05 6.05E+05 3.09E+01 9.51E+01 2.13E+05 1.26E+06 noutlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 5.00E-03 7.35E+00 outlet

(kJ/kmol) 2.51E+04 1.74E+04 1.03E+04 1.90E+04 2.89E+04 -

(kJ/kmol) 1.38E+04 9.56E+03 5.65E+03 1.01E+04 1.59E+04 -

HComponent (kJ/hr) 2.41E+05 3.32E+05 1.70E+01 5.03E+01 1.17E+05 6.90E+05

130 7.2.7 Crystalyzer

Stream 27 Temperature : 100 C Pressure : 131.72 kPa

Stream 28 Temperature : -17 C Pressure : 30.40 kPa

Figure 7.7: Inlet and Outlet Stream for Crystalyzer

Table 7.14: Total Amount of Enthalphy at Crystalyzer

H inlet (kJ/hr) 6.90E+05

Houtlet (kJ/hr) -3.87E+05

H (kJ/hr) -1.08E+06

131

Table 7.15: Component Enthalphy for Crystalyzer

Inlet Stream Stream 27 Component CA MA HCl H2O NH4Cl AA MIBK CO2 H ninlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 5.00E-03 7.35E+00 inlet

Outlet Stream Stream 28 HComponent (kJ/hr) 2.41E+05 3.32E+05 1.70E+01 5.03E+01 1.17E+05 6.90E+05 noutlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 5.00E-03 7.35E+00 outlet

(kJ/kmol) 1.38E+04 9.57E+03 5.66E+03 1.01E+04 1.59E+04 -

(kJ/kmol) -7.72E+03 -5.37E+03 -3.17E+03 -5.26E+03 -8.91E+03 -

HComponent (kJ/hr) -1.35E+05 -1.86E+05 -9.51E+00 -2.63E+01 -6.55E+04 -3.87E+05

132 7.2.8 Dryer

Stream 30 Temperature : 12.57 C Pressure :101.3 kPa

Steam 28 Temperature : -17 C Pressure :30.40 kPa

P-41

P-40

Stream 29 Temperature : 17 C Pressure :101.3 kPa

Figure 7.8: Inlet and Outlet Stream for Reactor

Table 7.15: Total Amount of Enthalphy at Dryer H inlet (kJ/hr) -3.86E+05 Houtlet (kJ/hr) -3.03E+05 H (kJ/hr) 8.30E+04

P-60

P-60

133
E-22
P-6 P-5

Table 7.16: Component Enthalphy for Dryer Inlet Stream Stream 28 Component ninlet (kmol/hr) 1.75E+01 3.47E+01 3.00E-03 5.00E-03 7.35E+00 inlet

Outlet Stream Stream 29 HComponent (kJ/hr) -1.35E+05 -1.86E+05 -9.50E+00 -2.63E+01 -6.54E+04 -3.86E+05 noutlet (kmol/hr) 3.47E+01 outlet

Stream 30 HComponent (kJ/hr) -1.46E+05 -1.46E+05 noutlet (kmol/hr) 1.75E+01 3.00E-03 5.00E-03 7.35E+00 outlet

(kJ/kmol) -7.72E+03 -5.36E+03 -3.17E+03 -5.26E+03 -8.90E+03 -

(kJ/kmol) -4.21E+03 -

(kJ/kmol) -6.06E+03 -2.49E+03 -4.15E+03 -6.98E+03 -

HComponent (kJ/hr) -1.06E+05 -7.46E+00 -2.08E+01 -5.13E+04 -1.57E+05

CA MA HCl H2O NH4Cl AA MIBK CO2 H