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Energy Balance and Heat Calculations

This document provides an energy balance for various unit operations in the production of potassium anthraquinone-1-sulfonate. It summarizes the heat supplied, heat removed, heat of reactions, and steam requirements for each unit. Key points include: - The preheater heats the feed stream from 25°C to 60°C requiring 3.25 kg/hr of steam. - The sulfonator reaction produces heat, with 4 kg/hr of steam needed to remove the heat. - The precipitator reaction absorbs heat, with 5 kg/hr of steam required to supply this heat. - Various coolers and neutralizers calculate heat removed or added via brine

Uploaded by

Bharat Vaaj
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© Attribution Non-Commercial (BY-NC)
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Download as DOCX, PDF, TXT or read online on Scribd
476 views11 pages

Energy Balance and Heat Calculations

This document provides an energy balance for various unit operations in the production of potassium anthraquinone-1-sulfonate. It summarizes the heat supplied, heat removed, heat of reactions, and steam requirements for each unit. Key points include: - The preheater heats the feed stream from 25°C to 60°C requiring 3.25 kg/hr of steam. - The sulfonator reaction produces heat, with 4 kg/hr of steam needed to remove the heat. - The precipitator reaction absorbs heat, with 5 kg/hr of steam required to supply this heat. - Various coolers and neutralizers calculate heat removed or added via brine

Uploaded by

Bharat Vaaj
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
  • Energy Balance: Details the initial energy balance including heat calculations and temperature settings for the process.
  • Sulfonator: Covers the sulfonation process, including thermal requirements and chemical equations involved.
  • Crystallizer: Describes the crystallization process with energy inputs, outputs, and associated thermal calculations.
  • Precipitator: Focuses on precipitation, detailing temperature and energy changes throughout the process.
  • Cooler: Outlines the cooling process including energy balance conditions and performance efficiency.
  • Neutralizer: Details the chemical neutralization process with equations and thermal data.
  • Recycle Heat Balances - Pan Dryer: Explains the recycle heat balance within the pan dryer and its effect on process efficiency.
  • Evaporator: Describes the evaporation stage, covering energy requirements and operational conditions.

ENERGY BALANCE

Reference temperature = 273 K

PRE-HEATER
Inlet temperature of solution

25C

Outlet temperature of solution

60C

Qf

mCp dT

Qf

[(111.1*1.429)+(4.187*2.268)]*(298-273)

168.258

Qf

4206.4504 kJ/hr

Qp

168.258

10095.48 kJ/hr

Heat carried in
by the feed stream

25

Heat carried out


by the product stream

60

Heat to be supplied,

Qp - Qf =

Steam requirement

5889.03

( Qp - Qf )/ s

(s=2260 kJ/kg)

2.60576 kg/hr

Assuming 80% heat transfer efficiency in the equipments


Actual steam requirement, S

Streams
Reactant stream
Product stream
Steam
Total

3.25 kg/hr

Energy inlet (kJ/hr)


4206.4504
5889.01
10095.46

Energy outlet (kJ/hr)


10095.48
10095.48

SULFONATOR

Qf

Qp

(235.8*1.17*30) + (10095.48) + [(228.2*1.3734)+(.437*4)] * 100

58128.25 kJ/hr

[(326.5*2.045) + (288.2*1.43136) + (4*.437) + (4.253*22.674)] *120

141524.46 kJ/hr

Heat of reaction:
No. of moles of anthraquinone taking part in the reaction = 1.13365 kmol/hr

C14H8O2

H2SO4

(in the presence of M)

HR

Hf

Hf

(Hf ASA + Hf W)

C14H8SO5 +

H2O

ASA

CpdT
-

(Hf A + Hf H)

Cp

CpdT
HR

Total heat

(-675320-285830) - (-58240-814000)

-88910 kJ/kmol

Cp Products

(588.96+76.554) (297.723+140.04)

228.474

228.474 * 95

-88910 + 21705.03 =

-76186.914 kJ/hr

Qp Qf + HR

7209.296 kJ/hr

Cp Reactants

21705.03 kJ/kmol
-67204.97 * 1.3365

Hence, heat should be supplied to get products at required temperature


Steam required,S

7209.296/2260

3.19 kg/hr

Assuming around 80% heat transfer efficiency in the equipments


Actual steam requirement, S

Streams
Reactant stream
Product stream
Heat of reaction
Steam
Total

4 kg/hr

Energy inlet (kJ/hr)


58128.25

Energy outlet (kJ/hr)


141524.46

76186.914
7209.4
141524.5

141524.46

CRYSTALLIZER
Qf

141524.46 + (15*4.187*25)

143094.6 kJ/hr

Qp

(326.5*2.045 + 288.2*1.311 + 4*.437 + 37.67*4.2) * 80

96448 kJ/hr

Heat to be removed =

Qp - Qf

-46646.6 kJ/hr

Brine water is to be supplied for this cooling purpose


Brine is available @ 288 K
Brine required

46646.6/(3.996*40)

179.6 kg/hr

Streams
Reactant stream
Product stream
Brine
Total

Energy inlet (kJ/hr)


143094.6
-

Energy outlet (kJ/hr)


96448
46646.6
143094.6

143094.6

Assuming 80% heat transfer efficiency, actual brine required = 225 kg/hr

PRECIPITATOR
Qf

= [(326.5*2.045 + 10*4.2) * 80] + [(34.63*.677 + 253.97*4.187) * 25]


= 84992.37 kJ/hr

Qp

= [ 151.53*3.5075 + (1.05*4.2)*280.97 + 192.63*2.045 ] * 85


= 183982.29 kJ/hr

Heat of reaction:
C14H8SO5 +
ASA

KCl

C14H7SO5K +
PAS

HCl
C

No. of moles of potassium anthraquinone-1-sulfonate formed = 0.4644 kmol

CpdT

HR

Hf

Hf

(Hf PAS + Hf C) -

(-1153981.62 167370) ( -675320 420680)

-225351.62 kJ/kmol

(Hf ASA + Hf P )

Cp

CpdT
HR

Total heat

Cp Products

(1144.357 + 25.8785) (588.96 + 50.485)

530.82 * 60

31849.23 kJ/kmol

-225351.62 + 31849.23

-193502.39 * 0.4644

-89862.76 kJ/hr

Qp Qf + HR

9127.157 kJ/hr

Steam required=

9127/2260

Cp Reactants

4.038 kg/hr

Assuming 80% efficiency, actual steam requirement = 5 kg/hr

Streams
Reactant stream
Product stream
Heat of reaction
Steam
Total

Energy inlet (kJ/hr)


84992.3725
89862.76
9127.01
183982.14

Energy outlet (kJ/hr)


183982.2896
183982.2

COOLER
Inlet temperature

85C

Outlet temperature =

25C

Qf

(133.5*3.5075 + 2.5*2.045 + .28*.709) * 85

40252.79 kJ/hr

11839.05 kJ/hr

Heat released

-28413.74 kJ/hr

Brine required

28413.74/(3.996*10)

Qp

711.05 kg/hr

Assuming 80% efficiency, actual brine requirement = 888 kg/hr

Streams
Reactant stream
Product stream
Brine
Total

Energy inlet (kJ/hr)


40252.79
-

Energy outlet (kJ/hr)


11839.05
28413.74
40252.79

40252.79

NEUTRALIZER
Qf

Qp

(11839.05 + 0.86*1.145*25)

11863.66 kJ/hr

(133.5*3.5075 + 0.45*.8645 + 4.326*2.7 + 0.14*4.187+.919*.35)*25

12030.7 kJ/hr

Heat of reaction:
Reaction 1:
2 C14H8SO5

Na2CO3

ASA

2 C14H7SO5Na +
NAS

CO2

CpdT

HR

Hf

Hf

(Hf NAS + Hf O + Hf W) - (Hf ASA + Hf S)

[-2*1091200 393500 285830] [-2*675320 1130770]

-380320 kJ/kmol

No. of moles of sodium carbonate reacted = 0.004355 kmol

CpdT

HR1 =
=

0
Hf
-1656.3 kJ/hr

H2O
W

Reaction 2:
2 HCl

Hf

Na2CO3
S

2 NaCl

CO2

H2O
W

(Hf N + Hf O + Hf W) - (Hf C + Hf S)

[-2*408760 393500 285830] [-2*167370 1130770]

-31340 kJ/kmol

No. of moles of sodium carbonate reacted = 0.003776 kmol


HR2 =

-118.33 kJ/hr

HR

HR1 +

1774.63 kJ/hr

HR2

Heat to be removed
+ HR

Qp - Qf

12030.7 11863.66 1774.63

-1607.6 kJ/hr

Brine required=
=

1607.6/(3.996*10)
40.23 kg/hr

Assuming 80% efficiency, actual brine requirement = 50 kg/hr

Streams
Reactant stream
Product stream
Heat of reaction
Brine
Total

Energy inlet (kJ/hr)


11863.66
1774.63
13638.3

Energy outlet (kJ/hr)


12030.7
1607.6
13638.3

RECYCLE HEAT BALANCES


PAN DRYER
Amount of solid to be dried

292.2 kg dry solid/hr

Inlet air temperature, Tg2

120C

Outlet air temperature, Tg1

85C

Inlet solids temperature, Ts1

85C

Outlet solids temperature, Ts2

100C

Assumptions:

@ 25C, humidity of air is 50% (which is available from flue gas)


Hence, absolute humidity of available air = 0.01 kgwater/kg dry air

Y2

The enthalpy of air entering the drier,HG2=

[(Cg + Y2Cv)(Tg2 To) + Y2]

Specific heat of air,

Cg

1.005 kJ/kgC

Specific heat of vapor,

Cv

1.884 kJ/kgC

Enthalpy of vapor,

2502.3 kJ/kg

HG2

147.882 kJ/kg

HG1

(1.005+1.884Y1)85 + 2502.3

85.425 + 2662.44 Y1

The enthalpy of the solid entering the drier,


Hs1

Cp(Ts1 To) + X1(Ts1 To) Cw

(1.311+ 0.077*4.187) * 80 kJ/kg

130.7014 kJ/kg

The enthalpy of the solid leaving the drier,


Hs2

1.369*100

136.9 kJ/kg

Assuming no heat loss due to radiation to the surroundings

Moisture balance:
Ss X1

Gs Y2

Ss X2

Ss(X1 X2)

Gs(Y1 + Y2)

292.2(0.077)

Gs(Y1 + 0.01)

Gs(Y1 0.01)

22.5

Gs HG2

Ss Hs2 +

Gs Y1

Enthalpy balance:
Ss Hs1 +
292.2*130.7 +

Gs(147.882)

Gs(62.458 2662Y1)

Gs HG1 +Q

= 292.2(136.9) + Gs(85.424 + 2662Y1) + 0


=

1837.78

By solving,
Gs

1724.13 kg dry air /hr

Y1

0.023

Heat source
Ss Hs1
Gs HG2
Ss Hs2
Gs HG1
Total

Heat in kJ/hr
38190.54
254964.34

293154.88

Heat out kJ/hr

40002.18
253151.17
293153.35

COOLER
Qf

Qp

Qp Qf

(172.63*2.045 + 13*0.709 + 229.97*4.2) * 85

112890.1448 kJ/hr

(172.63*2.045 + 13*0.709 + 229.97*4.2) * 25

33203 kJ/hr

-79687.14 kJ/hr

Brine required=
=

68533.856/(3.996*10)
1994.17 kg/hr

Streams
Feed stream
Product stream
Brine
Total

Energy inlet (kJ/hr)


112890.1448
112890.1448

Energy outlet (kJ/hr)


33203
79687.14
112890.14

NEUTRALIZER 2
Qp

Qp

(172.63*2.045 + 13*0.709 + 229.97*4.2 + (50.65*1.145)) * 25

34652.85 kJ/hr

(185.824*4.426 + 238.57*4.187 + 20.836*0.709 + 21.024*0.919)*25

46386.084 kJ/hr

Heat of reactions:
Same reactions as the previous neutralizer occur
HR1

-380320 kJ/kmol

No. of moles of sodium carbonate reacted = 0.6 kmol


HR2

-31340 kJ/kmol

No. of moles of sodium carbonate reacted = 0.356 kmol


Total heat of reactions=

Total heat

- 228192 - 11162.4

- 239354.4 kJ/hr

46386.084 34652.85 239354.4

Heat to be removed =

-227621.16 kJ/hr

Brine required

1.582 kg/s

Streams
Reactant stream
Product stream
Heat of reaction

Energy inlet (kJ/hr)


34652.85
239354.4

Energy outlet (kJ/hr)


46386.084
-

Brine
Total

274007.25

227621.16
274007.244

EVAPORATOR
Qf

46386.084 kJ/hr

Evaporator operated @ 120 C to completely vaporize water


Qp

(185.824*4.426 + 20.836*0.709 + 21.024*0.919)*120 + 2260*238.57

641954.29 kJ/hr

Qp Qf=

-595568.2125 kJ/hr

263.5 kg/hr

Assuming 80% efficiency in heat transfer equipments steam requirement is 330 kg/hr

Streams
Feed stream
Product stream
Steam
Total

Energy inlet (kJ/hr)


46386.084
595568.2125
641954.29

Energy outlet (kJ/hr)


641954.29
641954.29

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