Energy Balance
Energy Balance
Energy Balance
PROJECT SUPERVISORS
Ms. RABIA SABIR
Ms. AASIA FARUKH
2
Production of 120 Kiloton per year of HDPE
Exhaust Gases
Exhaust Gases
93.5°C
1 2 3 4 5 30.5 bar
Feed 8
400°C 292°C
25.7°C 400°C 199.6°C 41.62 bar 40.32 bar
25 °C F-101 43.35 bar F-102 R-102
P-101 43.35 bar R-101 41.62 bar
1.01 bar K-201 Coolant in 100°C Freon Coolant in
44.3 bar K-202
6
Air, Natural Gas Air, Natural Gas
301°C 7 FL-201 10
45 bar E-201
105°C
Coolant out 98°C Waste Water E-202
9 35 bar
37.42 bar
18°C Freon Coolant out
34.3 bar
11
Ethylene Gas
Recycle n-hexane Condenser
12 28
25°C n-hexane
15°C 25°C Vapors
20 8.08 bar Cooler E-104
34.31 bar 25°C 25°C 1.01 bar 110°C
8.08 bar 8.08 bar 18 E-104 27 1.01 bar
19
n-hexane 24 85°C
E-101 CW in CW out 25°C 1.01 bar
FL-
14 8.08 bar CW in CW out
202 25°C
13 25
1.01 bar R-103 22 85°C
Aqueous Waste n-hexane R-104 To Recovery N2 Gas
15°C 7.4 bar
34.31 bar 16 DC-1 Section
17 15 85°C
TiCl4 +(C2H5)3Al 25°C 85°C 8.4 bar 23
21 26 29
1.01 bar 8.08 bar Pure HDPE
H2 Gas 85°C 85°C Powder
E-103
P-103 1.01 bar FD-1
MX-1
P-102 N2 Gas
Energy Balance:
1 2 1 2
∑outlet(Hi+gZi+ Vi )Fi-∑inlet(Hj+gZj+ Vj )Fj= Q-W
2 2
• Potential and kinetic energy are relatively small in chemical
process application.
• Expect Pump, turbine and compressor most chemical process
do not involve work.
• Energy balance equation reduce to
∑ outlet(Hi Fi)- ∑ inlet(Hj Fj)=Q
• Specific enthalpy is calculate by the by equation
𝑇
Hi= 𝑓𝑒𝑟𝑇Cpidt
• The heat capacity is usually calculate by that
equation as a function of Temperature is
Cpi= a+b.T+c.T2+d.T3
• The final form of equation to calculate Specific
enthalpy is:
𝑇
𝑏 𝑐 𝑑
Hi = a. T + . T2 + . T3 + . T4
2 3 4 𝑇𝑟𝑒𝑓
𝑏 2 2 𝑐 3 3 𝑑 4 4
Hi=a(T-Tref)+ (T -𝑇𝑟𝑒𝑓 )+ (T -𝑇𝑟𝑒𝑓 )+ (T -𝑇𝑟𝑒𝑓 )
2 3 4
Reactor (R-101):
Heat of formation for components:
Δ Hf° for C2H5OH = -234.96 KJ/mols
Δ Hf° for H2O = -242 KJ/mols
Δ Hf° for C2H4 = 52.33 KJ/mols
298 𝑇𝑥𝑟𝑛
σ( 𝐶 𝑛𝑥𝑟𝑇pidT) σ(298 𝐶 pidT)
298 𝑇𝑥𝑟𝑛
∆Hr=∑react ( 𝐶 𝑛𝑥𝑟𝑇pidT) + ∆𝐻𝑟° + ∑prod(298 𝐶 pidT)
Δ Hr at reaction temperature:
𝑟𝑒𝑓 𝑇𝑥𝑛
Δ Hr = σ𝑟𝑒𝑎𝑐𝑡( )𝑡𝑑 𝑖𝑝𝐶 𝑛𝑥𝑇+ Δ Hr° σ𝑝𝑟𝑜𝑑𝑢𝑐𝑡()𝑡𝑑 𝑖𝑝𝐶 𝑓𝑒𝑟𝑇
𝐽 𝐽 𝐽
= −3.46 × 104 + 4.52 × 104 + 1.15 × 104
𝑚𝑜𝑙 𝑚𝑜𝑙 𝑚𝑜𝑙
4 𝐽 𝑘𝑗
= 2.58 × 10 or 25.8
𝑚𝑜𝑙 𝑚𝑜𝑙
10 𝐽
∑ inlet(Hj Fj) = 1.97 × 10
ℎ𝑟
𝐽
∑ outlet(Hi Fi) = 8.35 × 109
ℎ𝑟
rΔ Hr 9.21 × 10 9 𝐽
= ℎ𝑟
9 𝐽 10 𝐽 9 𝐽
Q= 8.35 × 10 − 1.97 × 10 +9.21 × 10
ℎ𝑟 ℎ𝑟 ℎ𝑟
𝐽 𝑘𝐽
Q= 4.35 × 109 or 4.35 × 106
ℎ𝑟 ℎ𝑟
Input Output
Temperature = 400 °C Temperature = 200 °C
Pressure = 4335Kpa Pressure = 4162Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
10 𝐽
∑ inlet(Hj Fj) = 2.00 × 10
ℎ𝑟
𝐽
∑ outlet(Hi Fi) = 1.42 × 1010
ℎ𝑟
r ΔHr 4.91 × 10 9 𝐽
= ℎ𝑟
∑ outlet(Hi Fi)- ∑ inlet(Hj Fj)=Q- rΔ Hr
𝐽 𝐽 𝐽
Q =1.42 × 1010 − 2.00 × 1010 +9.21 × 109
ℎ𝑟 ℎ𝑟 ℎ𝑟
9 𝐽 6 𝑘𝐽
Q =3.86 × 10 or 3.86 × 10
ℎ𝑟 ℎ𝑟
Input Output
Temperature = 400 °C Temperature = 292 °C
Pressure = 4462Kpa Pressure = 4032Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
Ethanol 193.72 6.69E+06 Ethanol 193.72 1.04E+06
Water 422.26 5.70E+06 Water 422.26 5.32E+06
Ethylene 346.33 7.68E+06 Ethylene 346.33 7.32E+06
Hin 2.00E+07 Hout 1.42E+07
Fired Heater(F-101)
Input Output
7 𝑘𝐽 3 𝑘𝐽
Q = 1.97 × 10 - 3.79 × 10
ℎ𝑟 ℎ𝑟
7 𝑘𝐽
= 1.97251 × 10
ℎ𝑟
7 𝑘𝐽
So 1.97 × 10 of heat is required to heat the feed in the
ℎ𝑟
first Fired heater.
Fired Heater(F-102)
Input Output
Temperature = 200 °C Temperature = 400 °C
Pressure = 4193Kpa Pressure = 4162Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
Ethanol 193.72 2.70E+06 Ethanol 193.72 6.69E+06
Water 422.26 2.56E+06 Water 422.26 5.70E+06
Ethylene 346.33 3.12E+06 Ethylene 346.33 7.68E+06
Hin 8.40E+06 Hout 2.00E+07
𝐻𝑂𝑢𝑡 − 𝐻𝐼𝑛 = 𝑄
6 𝑘𝐽
∑ inlet(H.F) = 8.04 × 10
ℎ𝑟
7 𝑘𝐽
∑ outlet(H.F) = 2.00 × 10
ℎ𝑟
7 𝑘𝐽 6 𝑘𝐽
Q = 2.00 × 10 - 2.00 × 10
ℎ𝑟 ℎ𝑟
7 𝑘𝐽
= 1.16 × 10
ℎ𝑟
7 𝑘𝐽
So 1.16 × 10 of heat is required to heat the feed in the
ℎ𝑟
first Fired heater.
Compressor (K-201)
𝑝𝑣 = 𝑛𝑅𝑇
𝑚
𝑝𝑣 = 𝑅𝑇
𝑀
𝑷𝑴
𝓹=
𝑹𝑻
4500 × 46 𝑘𝑔
𝓅𝐶2𝐻5𝑂𝐻 = 𝓅𝐶2𝐻5𝑂𝐻 = 48.712
8.314 × 515 𝑚3
Components Mass Flow Rate Mole Fraction Density kg/m3
(kg/hr)
Ethanol 2096.3 0.08 48.713
Water 10221.5 0.39 27.21
Ethylene 13890.8 0.53 17.5
𝑘𝑔
𝓅𝐴𝑣𝑎 = 23.46 𝑚3
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
26209
= 23.46
𝑚3
= 1117.18 ℎ𝑟
We know that,
Work done by compressor = 𝑣. ΔP
= 𝑣 × (𝑃2 − 𝑃1 )
= 1117.18 × 4500 − 4162
= 377606.8 kj/hr
377606.8 × 1ℎ𝑟
=
3600 𝑠
= 104.89 𝐾𝑊
Now,
𝐻𝑂𝑢𝑡 − 𝐻𝐼𝑛 = 𝑄 − 𝑊
𝐾𝐽
Hin= 4.56*109
ℎ𝑟
Hout= 9
4.82*10 kj/hr
So.
Q = 4.82*109 - 4.56*109 + 3.77*105
Q = 2.60*108 kj/hr
Compressor(K-202)
Input Output
Temperature = 301 °C Temperature = 100 °C
Pressure = 4500Kpa Pressure = 4430Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
Ethanol 45.58 1.08E+06 Ethanol 45.58 1.38E+04
Water 567.86 5.51E+06 Water 567.86 6.05E+03
Ethylene 496.1 7620698 Ethylene 496.1 9.02E+03
Hin 1.42E+07 Hout 3.44E+06
𝐻𝑂𝑢𝑡 − 𝐻𝐼𝑛 = 𝑄
𝑘𝐽
∑ inlet(Hj Fj) = 1.42 × 107
ℎ𝑟
6 𝑘𝐽
∑ outlet(Hi Fi) = 3.44 × 10
ℎ𝑟
7 𝑘𝐽
Q = −1.08 × 10
ℎ𝑟
Q= m Cp ΔT
1.08 × 107 = m ( 4.18× 25 )
m = 105719 kg/hr
Heat Exchanger (E201)
Input Output
Temperature = 105°C Temperature = 30 °C
Pressure = 3500Kpa Pressure = 3430Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
Ethanol 7.9 4.53E+04 Ethanol 7.9 2.60E+03
Water 20.3 5.54E+04 Water 20.3 3.43E+03
Ethylene 496.1 1.87E+06 Ethylene 496.1 1.07E+05
Hin 1.97E+06 Hout 1.13E+05
𝐻𝑂𝑢𝑡 − 𝐻𝐼𝑛 = 𝑄
𝑘𝐽
∑ inlet(Hj Fj) = 1.97 × 106
ℎ𝑟
5 𝑘𝐽
∑ outlet(Hi Fi) = 1.13 × 10
ℎ𝑟
6 𝑘𝐽
Q = −1.86 × 10
ℎ𝑟
Q= m Cp ΔT
1.86 × 106 = m ( 4.18× 25 )
m = 14815 kg/hr
ENERGY BALANCE ON POLYMERIZATION
SECTION
• REACTOR (R-103):
• Exothermic reaction
• 𝐶2 𝐻4 → (𝐶2 𝐻4 )35
∆𝐻
𝑇𝑅𝐸𝐹𝐸𝑅𝐸𝑁𝐶𝐸
=න 𝐶𝑃 . 𝑑𝑡
𝑇
∆𝑯𝑹𝑬𝑨𝑪𝑻𝑨𝑵𝑻𝑺
𝑩 2
𝑪 3
= 𝑨 𝑻𝑹𝑬𝑭𝑬𝑹𝑬𝑵𝑪𝑬 − 𝑻 + 𝑻 −𝑻 + 𝑻𝑹𝑬𝑭𝑬𝑹𝑬𝑵𝑪𝑬 − 𝑻
2 𝑹𝑬𝑭𝑬𝑹𝑬𝑵𝑪𝑬 3
𝑫
+ 𝑻𝑹𝑬𝑭𝑬𝑹𝑬𝑵𝑪𝑬 − 𝑻 4
4
Reactor (R-104)
∆𝑯85°𝑪 = ∆𝑯𝑹𝒆𝒂𝒄𝒕𝒂𝒏𝒕𝒔 + ∆𝑯𝑷𝒓𝒐𝒅𝒖𝒄𝒕𝒔 + ∆𝑯𝑹𝒆𝒇𝒆𝒓𝒏𝒄𝒆
Input Output
Temperature = 85 °C Temperature = 85 °C
Pressure = 808Kpa Pressure = 808Kpa
Components kmol/hr Enthalpy(kj/hr) Components kmol/hr Enthalpy(kj/hr)
Ethylene 489.14 1.60E+14 Ethylene 78.26 2.50E+13
n-Hexane 2.39 0.00E+00 n-Hexane 2.39 3.20E+09
Polyethylene 0.00 0.00E+00 Polyethylene 821[B] 4.75E+15
Hin 1.60E+14 Hout 4.78E+15
• Heat removed through N-Hexane:
joule
= −2.66471E + 12 × 0.60
seconds
= 1.59846𝐸 + 12
= 2.66471𝐸 + 12 − (1.59846𝐸 + 12)
=1.065274𝐸 + 12
Q=
𝑄 = 𝑚. 𝜆
• Heat Requirements:
Two types of heat requirements:
I. Heat required to raise the product temperature at discharge
temperature
II. Heat required to remove the n-hexane contents from HDPE
powder
Component Inlet Temperature(K) Outlet Temperature (K)
𝑸𝟐 = 𝒎𝒉 [𝑪𝒑𝒍𝑻 + + 𝑪𝒑𝒗𝑻]
Q2=35 ×[2.430555 ×(383-358) + 0.25578 + 1.96759 ×(388-383)]
Q2=2480.016175 W
• Total heat required: 𝑸𝒕 = 𝑸𝟏 + 𝑸𝟐
= 687257.7166 + 2480.016175
=689737.7328 W
689737.7326
𝑚= ×(398 − 388)]
1.0491
m=32872.83065 kg/hr