SIMULATION USING PLUG FLOW REACTOR
2013
ABSTRACT:
This laboratory is about the knowledge on how the simulation using the plug flow reactor and it totally different and easier than the other tasks. In this lab 5, it is about the comparison the result between the conversion with the different and varying length and diameter of the plug flow reactor. Firstly, the plug flow is used in order to produce the acetone from the reaction between ketene and methane. The flow rate of the feed that enter into the reactor is 8000kg/hr of acetone. This reactor is assumed to be adiabatic with the temperature is 1035K while the pressure is 1.6 atm. For the plug flow reactor, the state of fluid package is different compare to the Peng-Robinson and SRK because it used SYSOPO. The objective is to calculate the conversion of the production by varying the length and diameter of the tubes. For the starting, the length and diameter are assumed 3m and 1m respectively. Then, the result would come out and then we can calculate the conversion of the production based on the molar flow of the components in the reactor.
INTRODUCTION:
In this experiment, the acetone was enter undergo a reaction to separate into two components which are ketene and methane. The objective of this lab is known the conversion of the acetone to produced ketene and methane with the different diameter and length of the tubes. The feed that enter is 8000kg/hr thus what is the percentage conversion at the end of the product??. By using this simulation, the entire question can be answer easily.
OBJECTIVES:
1. To know the volume required for at least 20% conversion. 2. To know the percentage conversion of the product with the varying diameter and length.
SIMULATION USING PLUG FLOW REACTOR
2013
METHADOLOGY: CH3COCH3
CH2CO + CH4
The reaction is first order with respect to acetone. The fed condition is 8000 kg/hr of acetone to tubular reactor. The reactor is adiabatic, with inlet T is 1035K and the pressure is 1.6atm. 1. Use SYSOPO of state fluid package.(SI unit) 2. Reactor : ADIABATIC Length: Assume 3 m Diameter: Assume 1 m 3. Reaction type LHHW 4.
Kinetic: Vapour, k: 1.125, To 1000 K, E = 67999 cal/mol5.
5. Driving force: Term 1Reactant: acetone exponent to 1Products: ketene and methane exponent to 0. 6. Driving force: Term 2 All exponents and constant B, C, D = 0 Constant A = -10000007. 7. There length, diameter, number of tubes can be change to achieve specific goal
PROCEDURE:
1. Aspen plus V7.3.2 was started. 2. New, chemical processes and chemicals with metric unit were selected and click created. 1. The components were defined in the components, specifications and selection tab. For component name, ACETONE, KETENE and METHANE were entered. 2. Next, property method was defined by clicking on methods in the navigation pane. SYSOPO Equation of State was selected as the base method.
SIMULATION USING PLUG FLOW REACTOR
2013
3. After that, the flow sheet was constructed by clicked on simulation button at the bottom left of the screen. 4. The equipment that is used in this laboratory was selected by clicked to the model palette that have in the bottom of the screen. 5. The equipment that is only plug flow reactor. 6. The information that needed in the process such as flow rate, pressure, mole fraction, temperature, driving force and reaction type of the equipment were inserted in that equipment as in the question that provided in the lab manual. 7. The control panel was opened and the simulation was run.
APPARATUS:
List of equipment used in this process: 1. Plug flow reactor
PLUG PRODUCT
FEED
FIGURE 1:
PROCESS FLOW DIAGRAM
The process flow diagram above showed the equipment that had been used for the production of ketene and methane in the reactor. The process only used plug flow reactor. By setting up the data based on the specification stated, then the required information will be analysed and transformed into a data stream as in result.
SIMULATION USING PLUG FLOW REACTOR
RESULT/WORK BOOK:
There result that had been analysed:
Heat and Material Balance Table Stream ID
OUT
FEED
From
PFR
To
PFR
Phase
VAPOR
VAPOR
Substream: MIXED Mole Flow
kmol/hr
ACETONE
137.7410
109.4326
KETENE
0.0
28.30835
METHANE
0.0
28.30835
Total Flow
kmol/hr
137.7410
166.0493
Total Flow
kg/hr
8000.000
8000.000
Total Flow
l/min
1.21855E+5
1.29843E+5
Temperature
K
1035.000
914.8328
Pressure
atm
1.600000
1.600000
1.000000
1.000000
Vapor Frac Liquid Frac
0.0
0.0
Solid Frac
0.0
0.0
Enthalpy
cal/mol
-29235.24
-24251.17
Enthalpy
cal/gm
-503.3612
-503.3612
Enthalpy
cal/sec
-1.1186E+6
Entropy
cal/mol-K
-17.68577
-11.30441
Entropy
cal/gm-K
-.3045068
-.2346362
Density
mol/cc
1.88395E-5
2.13141E-5
Density
gm/cc
1.09420E-3
1.02688E-3
58.08004
48.17846
169.8718
190.3017
Average MW Liq Vol 60F
FIGURE 2: STREAM TABLES
l/min
-1.1186E+6
2013
SIMULATION USING PLUG FLOW REACTOR
2013
QUESTIONS:
1. What volume required for at least 20% conversion? 2. Fill he conversion below if configuration of reactor is set as below:
DIAMETER
LENGHT
CONVERSION %
2
1
18.91
1
2
21.69
2
2
24.39
1.5
1
17.72
1.8
1
20.65
0.9
1
15.59
ANSWER:
1. The volume required at least 20% conversion: The formula:
V= 4 xL At least 20% conversion, the specification od diameter and length as below: Diameter, D= 2.65m Length ,L = 1m
265 V= 4 x1 = 5.52
m
3
SIMULATION USING PLUG FLOW REACTOR
2013
2. The conversion of the following diameter and length: a) Diameter, D = 2m
; Length, L = 1m
Hea t and Material Balance Balance Table Str ea m I D
FEE D
P RODUCT
Fr o m
P LUG
To
P LUG
P hase
VAP OR
VAP OR
Su bstre am : MI XE D Mo le Flo w
km o l/hr
ACETO- 0 1
1 37. 74 10
1 11. 69 62
KE TEN- 0 1
0. 0
2 6. 044 79
0. 0
2 6. 044 79
T otal Flo w
M ET HA- 01 km o l/hr
1 37. 74 10
1 63. 78 57
T otal Flo w
kg/hr
8 000 .0 00
8 000 .0 00
T otal Fl Flo w
l/m in
1. 21 855 E+ 5
1.29 465 E+ 5
T em p er atur e
C
7 61. 85 00
6 51. 62 36
P r essur e
ba r
1 .6 212 00
1 .6 212 00
Vap or Fr ac
1 .0 000 00
1 .0 000 00
L iq uid Fr ac
0. 0
0. 0
So lid Fr a c
0. 0
0. 0
- 292 35. 24
- 245 86. 33
E nthalpy
ca l/m o l
E nthalpy
ca l/gm
- 503 .3 612
- 503 .3 612
E nthalpy
ca l/sec
- 1. 11 86E + 6
- 1.11 86E + 6
E ntropy
ca l/m o l- K
- 17. 68 577
- 11.66 140
E ntropy
ca l/gm - K
- .3 045 068
- .2 387 463
Den sity
m o l/cc
1.88 395 E- 5
2. 10 850 E- 5
Den sity
gm /c c
1.09 420 E- 3
1. 02 988 E- 3
5 8.080 04
4 8. 844 30
1 69. 87 18
1 88. 66 81
Ave r age M W L iq Vo l 60 F
l/m in
b) Diameter, D = 1m
; Length, L = 2m
Hea t an d M aterial Balance Ta b le S tr e am I D
F EED
P RO D U CT
Fr o m
P LU G
To
P LU G
P h a se
VA POR
VA POR
S u b s tr ea m : MI X E D Mo l e F lo w
k m o l /h r
A CE T O - 0 1
1 3 7 .7 4 1 0
1 0 7 .8 5 4 2
K E T EN - 0 1
0 .0
2 9 .8 8 6 7 5
ME T H A -0 1
The conversion: :
−
x 100%
1377410−1676277 x 100% 1377410 : 21.69%
0 .0
2 9 .8 8 6 7 5
1 37 3 7 .7 41 41 0
1 67 6 7 .6 27 27 7
8 0 0 0 .0 0 0
8 0 0 0 .0 0 0
T o ta l F lo w
k m o l/ l/h r
T o ta l F lo w
k g /h r
T o ta l F lo w
l/ m in
T e m p e ra tu r e
C
7 6 1 .8 5 0 0
P r es s u re
b ar
1 .6 2 1 2 0 0
1 .6 2 1 2 0 0
V a p o r F r ac
1 .0 0 0 0 0 0
1 .0 0 0 0 0 0
L iq u i d F r ac
0 .0
0 .0
S o li d F r ac
0 .0
0 .0
1 .2 18 1 8 5 5 E+ E+ 51 .3 00 0 0 7 9 E+ E+ 5 6 3 4 .7 1 2 8
E n th a lp y
c al /m o l
E n th a lp y
c al /g m
- 5 0 3 .3 6 1 2 -5 - 5 0 3 .3 6 1 2
E n th al alp y
c al /s ec
- 1. 1 .1 18 1 8 6E 6 E + 6- 1. 1 .1 18 1 8 6E 6E+ 6
E n tr o p y
c al /m o ll-K - 1 7 .6 85 8 5 77 7 7 - 1 1 .0 65 6 5 98 98
E n tr op op y
c al /g m - K - .3 0 4 5 0 6 8 - .2 .2 3 1 8 7 0 6
D e n s ity
m o l /c c
1 .8 8 3 9 5 E - 52 .1 4 7 7 8 E - 5
D e n s ity
g m / cc
1 .0 9 4 2 0 E - 31 .0 2 5 0 2 E - 3
A v e r ag e M W L iq V o l 6 0 F
l/ m in
- 2 9 2 3 5 .2 4 -2 - 2 4 0 2 2 .8 2
5 8 .0 8 0 0 4
4 7 .7 2 4 8 1
1 6 9 .8 7 1 8
1 9 1 .4 4 0 9
SIMULATION USING PLUG FLOW REACTOR
c) Diameter, D = 2m
2013
; Length, L = 2m
Heat and Material Balance Table St re a m ID
FEE D
PRODUC T
Fr om
PLUG
To
PLUG
Pha se
VAPOR
VAPOR
Substr e a m : MIXED Mole Fl ow
The conversion: :
−
x 100%
1377410−1713292 1377410 x100%
km ol/ hr
ACET O- 01
137. 7410
KETE N- 01
0.0
33 33. 58827
MET HA- 01
0.0
33 33. 58827
Tot a l Fl ow
km ol/ hr
137. 7410
171. 3292
Tot a l Fl ow
kg/ hr
8000. 000
8000. 000
Tot a l Fl ow
l /m i n
Te m pe r a tur e
C
1. 21 21855E+5 1. 30 30539E+5 761. 8500
Pr e ssur e
ba r
1. 621200
1. 621200
1. 000000
1. 000000
Li qui d Fr a c
0.0
0.0
Sol id Fra c
0.0
0.0
-29235. 24
-23503. 81
-503. 3612
-503. 3612
Va por Fra c
:24.39%
618. 2406
Ent ha l py
c a l /m ol
Ent ha l py
c a l /gm
Ent ha l py
c a l /se c
Ent r opy
c a l /m ol -K
-17. 68577
-10. 53879
Ent r opy
c a l /gm -K
-. 3045068
-. 2257003
De nsi ty
m ol/ c c
1. 88395E-5 2. 18747E-5
De nsi ty
gm /c c
1. 09420E-3 1. 02141E-3
- 1.1186E +6 - 1.1186E +6
Ave ra ge MW Li q Vol 60F
d) Diameter, D = 1.5m
104. 1527
l /m i n
58. 08004
46. 69373
169. 8718
194. 1122
; Length, L = 1m
Hea t and Material Balance Balance Table Str e a m I D
FE E D
P RO D U CT
Fr o m
P LU G
To
P LU G
P h a se
VAP OR
VAP O R
Su bstr e a m : MI X E D Mo le F lo w
km o l/hr
A C E TO - 0 1
1 37. 74 10
1 13. 32 66
K E T EN - 0 1
0. 0
2 4. 414 31
M ET H A - 01
0. 0
2 4. 414 31
T ota l F lo w
km o l/hr
1 37. 74 10
1 62. 15 53
T ota l F lo w
kg/hr
8 000 .0 00
8 000 .0 00
T ota l F lo w
l/m in in
T e m p e r a tur e
C
7 61. 85 00
6 58. 74 51
P r e ssur e
ba r
1 .6 212 00
1 .6 212 00
V a p or Fr a c
1 .0 000 00
1 .0 000 00
L iq uid Fr a c
0. 0
0. 0
So lid Fr a c
0. 0
0. 0
1. 21 855 E+ 5 1. 29 163 E+ 5
E ntha lpy
c a l/m o l
- 292 35. 24
- 248 33. 54
E ntha lpy
c a l/gm
- 503 .3 612
- 503 .3 612
E ntha lpy
c a l/se c
E ntr opy
c a l/m o l- K
- 1. 11 86E + 6 - 1. 11 86E + 6 - 17. 68 577
- 11. 93 004
E ntr opy
c a l/gm -K -K
- .3 045 068
- .2 418 148
D e n sity
m o l/c c
1. 88 395 E- 5
2. 09 239 E- 5
D e n sity
gm /c c
1. 09 420 E- 3
1. 03 229 E- 3
5 8. 080 04
4 9. 335 43
1 69. 87 18
1 87. 49 14
A ve r a ge M W L iq V o l 60 F
l/m in
The conversion: :
−
x 100%
1377410−1621553 1377410 X 100%
:17.72%
SIMULATION USING PLUG FLOW REACTOR
e) Diameter, D = 1.8m
2013
; Length, L = 1m
Heat and Material Balance Table Str ea m I D
FEED
P RODUCT
Fr om
P LUG
To
P LUG
P hase
VAP OR
VAP OR
Su bstream : MI XED Mole Flo w
km ol/hr
ACETO-0 1
1 37.74 10
112. 2940
KETEN-0 1
0.0
25. 44694
0.0
25. 44694
Total Flow
METHA- 01 km ol/hr
1 37.74 10
163. 1879
Total Flow
kg/hr
8 000 .000
8000 .000
Total Fl Flow
l/m in
Tem per atur e
C
7 61.85 00
654. 2386
P r essur e
ba r
1 .621200
1.6 21200
1.21 855 E+ 5 1.29357E+ 5
Vapor Fr ac
1 .000000
1.0 00000
Liquid Fr ac
0.0
0.0
So lid Fr a c
0.0
0.0
Enthalpy
ca l/m ol
-292 35.24
- 24676.40
Enthalpy
ca l/gm
-503 .3612
- 503.3 612
Enthalpy
ca l/sec
-1.1186E+ 6
- 1.1186E+ 6
Entr opy
ca l/m ol- K
-17. 68577
- 11.75 876
Entr opy
ca l/gm - K
-.3 045068
- .2398 608
Density
m o l/cc
1.88 395E- 5
2. 10256 E- 5
Density
gm /c c
1.09 420E- 3
1. 03074 E- 3
5 8.080 04
49. 02324
1 69.87 18
188. 2367
Ave r age MW Liq Vo l 60 F
The conversion:
l/m in
f) Diameter, D = 0.9m
:
−
x 100%
1377410−1631879 X100% 1377410
:20.65 %
; Length, L = 1m
Heat and Material Balance Table Str ea m I D
FE E D
P RODUCT
Fr o m
P LUG
To
P LUG
P hase
VA P O R
VAP OR
Su bstr eam : MI XE D Mo le Flo w
km o l/hr
ACE TO- 0 1
The conversion:
−
x 100%
1 37. 74 10
1 16. 27 28
KET EN- 0 1
0.0
2 1.468 16
M ET HA- 01
0.0
2 1.468 16
1 37. 74 10
1 59. 20 91
8 000 .0 00
8 000 .0 00
Total Flo w
km o l/hr
Total Flo w
kg/hr
Total Flo w
l/m in in
Tem p er atur e
C
P r essur e
ba r
1.21 855 E+ 5 1. 28 556 E+ 5 7 61. 85 00
6 71. 53 21
1377410−1592091 : X100% 1377410
1 .6 212 00
1 .6 212 00
Vap or Fr ac
1 .0 000 00
1 .0 000 00
Liq uid Fr ac
0.0
0. 0
:15.59 %
Enthalpy
ca l/m o l
Enthalpy
ca l/gm
Enthalpy
ca l/sec
Entr opy
ca l/m o l- K
- 17. 68 577
Entr opy
ca l/gm - K
- .3 045 068
- .2 475 976
Den sity
m o l/cc
1.88 395 E- 5
2.06 407 E- 5
Den sity
gm /c c
1.09 420 E- 3
1.03 716 E- 3
So lid Fr a c
Ave r age M W Liq Vo l 60 F
l/m in
0.0
0. 0
- 292 35.24
- 252 93.09
- 503 .3 612
- 503 .3 612
- 1. 11 86E + 6 - 1. 11 86E + 6 - 12. 44 138
5 8.080 04
5 0.248 38
1 69. 87 18
1 85. 36 52
SIMULATION USING PLUG FLOW REACTOR
2013
THEORY: CH3COCH3
CH2CO + CH4
The reaction is first order with respect to acetone. The fed condition is 8000 kg/hr of acetone to tubular reactor. The reactor is adiabatic, with inlet T is 1035K and the pressure is 1.6atm. 1. Use SYSOPO of state fluid package.(SI unit) 2. Reactor : ADIABATIC Length: Assume 3 m Diameter: Assume 1 m 3. Reaction type LHHW 4.
Kinetic: Vapour, k: 1.125, To 1000 K, E = 67999 cal/mol5.
5. Driving force: Term 1Reactant: acetone exponent to 1Products: ketene and methane exponent to 0. 6. Driving force: Term 2 All exponents and constant B, C, D = 0 Constant A = -10000007. 7. There length, diameter, number of tubes can be change to achieve specific goal
A tubular reactor is a vessel through which flow is continuous, usually at steady state, and state, and configured so that conversion of the chemicals and other dependent variables are functions of position within the reactor rather than of time. In the ideal tubular reactor, the fluids flow as if they were solid plugs or pistons, and reaction time is the same for all flowing material at any given tube cross section. Tubular reactors resemble batch reactors in
SIMULATION USING PLUG FLOW REACTOR
2013
providing initially high driving forces, which diminish as the reactions progress down the tubes. Flow in tubular reactors can be laminar, laminar, as with viscous fluids in small-diameter tubes, and greatly deviate from ideal plug-flow behaviour, or turbulent, or turbulent, as with gases. Turbulent flow generally is preferred to laminar flow, because mixing and heat transfer are improved. For slow reactions and especially in small laboratory and pilot-plant reactors, establishing turbulent flow can result in inconveniently long reactors or may require unacceptably high feed rates. The plug flow reactor model (PFR, sometimes called continuous tubular reactor, CTR, or piston flow reactors) is a model used to describe chemical reactions in continuous, flowing systems of cylindrical geometry. The PFR model is used to predict the behaviour of chemical chemical reactors of such design, so that key reactor variables, such as the dimensions of the reactor, can be estimated. Fluid going through a PFR may be modelled as flowing through the reactor as a series of infinitely thin coherent "plugs", each with a uniform composition, traveling in the axial direction of the reactor, with each plug having a different composition from the ones before and after it. The key assumption is that as a plug flows through a PFR, the fluid is perfectly mixed in the radial direction but not in the axial direction (forwards or backwards). Each plug of differential volume is considered as a separate entity, effectively an infinitesimally small reactor, limiting to zero volume. As it flows down the tubular PFR, the residence time ( ) of the plug is a function of its position in the reactor. In the ideal PFR, the residence time distribution is therefore a Dirac a Dirac delta function with a value equal to .