CHAPTER FOUR 4.0 MATFERIAL AND ENERGY BALANCE 4.1 MATERIAL BALANCE 4.1.1 Raw Material INPUT Component Mass flowrate (kg/hr) PET 630.6818 FLAKE Impurity 0.6313 Total 631.3131 Temperature: 25oC Pressure:100 kPa % Enthalpy 99.9 16240.05682 0.1 100 14.36237374 16254.41919 Size=10mm Cryogenic Ball Mill T= -196℃ Enthalpy, Liquid Nitrogen KJ/hr mass flow (kg/hr) 337.4250 -134916.0154 Temperature -196˚C Pressure 1 bar P= 1 bar Nitrogen Enthalpy gas Mass flow 337.4250 8773.050223 rate temperature 25℃ pressure 1 bar FEED OUT component PET Flake Impurity Total Temp=-196 ˚C sizes (mm) mass flow,kg/h 630.6818 0.6313 631.3131 Pressure = 1 bar 90% ≤ 0.25mm mass, % Enthalpy, KJ/hr 99.9 -127322.0455 0.1 -112.6010101 100 -127434.6465 Size = 10mm 10% > 0.25mm FEED OUT mass flow,kg/h mass, % Enthalpy, KJ/hr 630.6818 99.9 -127322.0455 0.6313 0.1 -112.6010101 631.3131 100 -127434.6465 Pressure = 1 bar Size = 10mm 90% ≤ 0.25mm 10% > 0.25mm component PET Flake Impurity Total Temp=-196 ˚C sizes (mm) component PET Flake Impurity Total Temp=-196 ˚C Screen (SN-1) T = -196˚C P = 1 bar SCREEN OVERSIZE mass Enthalpy, flow,kg/h mass, % KJ/hr 91.4489 99.9 -18461.69659 0.0915 0.1 -16.32714646 91.5404 100 -18478.02374 Pressure = 1 Size > bar 0.25mm SCREEN UNDERSIZE mass mass, Enthalpy, component flow,kg/h % KJ/hr PET Flake Impurity Total Temp=196 ˚C 99.9 108860.3489 0.5398 0.1 96.27386364 539.7727 100 108956.6227 Pressure Size ≤ = 1 bar 0.25mm 539.2330 component PET Flake Impurity Total Temp=-196 ˚C SCREEN UNDERSIZE mass flow,kg/h mass, % Enthalpy, KJ/hr 539.2330 99.9 -108860.3489 0.5398 0.1 -96.27386364 539.7727 100 -108956.6227 Pressure = 1 bar Size ≤ 0.25mm Screw Conveyor (SC-2) T = 25˚C P = 1 bar component Steam mass flow, Enthalpy, kg/hr mass, % KJ/hr steam 425.100869 100 1141395.833 Total 425.100869 100 1141395.833 Temperature Pressure = 105˚C = 1 bar SCREEN UNDERSIZE mass componen flow,kg/ mass, Enthalpy, t h % KJ/hr PET 539.233 13885.2485 Flake 0 99.9 8 12.2798295 Impurity 0.5398 0.1 5 539.772 13897.5284 Total 7 100 1 Size ≤ Temp=25 Pressure 0.25m ˚C = 1 bar m component Ethylene Glycol Water Total Temp=25 ˚C Reagent mass flow,kg/hr mass, % Enthalpy, KJ/hr 1335.9062 99.5 80488.34604 6.7131 0.5 701.5185605 1342.6193 100 81189.8646 Pressure = 1 bar Heat Exchanger 1 (HX-1) T = 190˚C P = 1 bar component Ethylene Glycol Water Total Reagent mass flow,kg/hr mass, % Enthalpy, KJ/hr 1335.9062 99.5 611711.4299 6.7131 0.5 5331.54106 1342.6193 100 617042.971 Temp=190 ˚C component Ethylene Glycol Water Total Temp=190 ˚C Pressure = 1 bar Reagent mass flow,kg/hr mass, % Enthalpy, KJ/hr 1335.9062 99.5 611711.4299 6.7131 0.5 5331.54106 1342.6193 100 617042.971 Pressure = 1 bar CATALYS T Component CSTR 1 (RT-1) T = 190˚C P = 1 bar component steam % Enthalpy 39.03266639 0.0030 99. 8 0.2 Total 1.4899 100 039.3440635 6 Temp =25℃ Pressure= 1 bar Sodium carbonate water Mass flow rate 1.4878 STEAM mass flow, Enthalpy, kg/hr mass, % KJ/hr 318.7813103 100 948055.6169 0.311397167 Total Temperature = 250˚C 318.7813103 100 Pressure = 1 bar compon ent steam CSTR 1 (RT-1) T = 190˚C P = 1 bar component Ethylene Glycol Total Temper ature = 105˚C Reactor 1 Effluent mass mass, flow,kg/h % 948055.6169 STEAM mass flow, mass, Enthalp kg/hr % y, KJ/hr 318.781 855927. 3103 100 8182 318.781 855927. 3103 100 8182 Press ure = 1 bar Enthalpy, KJ/hr 1175.8757 62.4177 538433.4982 BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total Temperature = 190˚C 622.0063 33.0173 179635.4069 6.7161 0.3565 5333.907679 1.4870 43.1386 0.5398 34.1185 1883.8819 Pressure = 1 bar 0.0789 2.2899 0.0287 1.8111 100 296.6482646 8442.231136 93.32670455 10047.89432 742282.9133 Reactor 1 Effluent component Ethylene Glycol BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total Temperature = 190˚C mass flow,kg/h mass, % 1175.8757 62.4177 622.0063 33.0173 6.7161 0.3565 1.4870 0.0789 43.1386 2.2899 0.5398 0.0287 34.1185 1.8111 1883.8819 100 Pressure = 1 bar Enthalpy, KJ/hr 538433.4982 179635.4069 5333.907679 296.6482646 8442.231136 93.32670455 10047.89432 742282.9133 CSTR 2 (RT-2) T = 190˚C P = 1 bar STEAM componen mass flow, mass, Enthalpy, t kg/hr % KJ/hr 1.3166573 3535.225 steam 78 100 06 1.3166573 3535.225 Total 78 100 06 Pressu Temperatu re = 1 re = 105˚C bar STEAM mass flow, component kg/hr mass, % steam 1.316657378 100 Total 1.316657378 100 Temperature Pressure = 250˚C = 1 bar Enthalpy, KJ/hr 3915.739043 3915.739043 CSTR 2 (RT-2) T = 190˚C P = 1 bar Reactor 2 Effluent component Ethylene Glycol BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total mass flow,kg/h 1163.4769 669.9440 6.7161 1.4870 4.7021 0.5398 37.0161 1883.8819 mass, Enthalpy, % KJ/hr 61.7595 532756.0515 35.5619 193479.8395 0.3565 5333.907679 0.0789 296.6482646 0.2496 920.2031939 0.0287 93.32670455 1.9649 10901.24283 100 743781.2197 Temperature = 190˚C Pressure = 1 bar CSTR 3 (RT-3) component STEAM mass flow, Enthalpy, kg/hr mass, % KJ/hr steam 0.004167522 T = 190˚C P = 1 bar 100 11.18979582 Total 0.004167522 100 11.18979582 Temperature Pressure = 105˚C = 1 bar component STEAM mass flow, Enthalpy, kg/hr mass, % KJ/hr steam 0.004167522 100 12.3942096 Total 0.004167522 100 12.3942096 Temperature Pressure = 250˚C = 1 bar CSTR 3 (RT-3) T = 190˚C P = 1 bar component Ethylene Glycol BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total Temperature = 190˚C Reactor 3 Effluent mass flow,kg/h mass, % 1162.1299 61.6880 675.0357 35.8322 6.7161 0.3565 1.4870 0.0789 0.5266 0.027954856 0.5398 0.0287 37.4469 1.9877 1883.8819 100 Pressure = 1 bar Enthalpy, KJ/hr 532139.2934 194950.3095 5333.907679 296.6482646 103.0627577 93.32670455 11028.09793 743944.6463 component Ethylene Glycol BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total Temperature = 190˚C Reactor 3 Effluent mass flow,kg/h mass, % 1161.8975 6755.0357 6.7161 Enthalpy, KJ/hr 61.6880 532139.2934 35.8322 194950.3095 0.3565 5333.907679 1.4870 0.0789 296.6482646 0.5266 0.027954856 103.0627577 0.5398 0.0287 93.32670455 37.4469 1.9877 11028.09793 1883.8819 100 743944.6463 Pressure = 1 bar Rotary Drum Vacuum (FT-1) T = 190˚C P = 50kPa Cake from Filter 1 mass mass comp., component flow,kg/h % Sodium carbonate 1.4870 40.1521 Impurities 0.5398 14.5754 Ethylene glycol 0.2324 6.2762 Oligomers 0.7489 20.2234 BHET 0.1350 3.6456 Water 0.0336 0.9068 Unreacted PET 0.5266 14.2207 Total 3.7033 100 Pressure Temperature = 190˚C = 1 bar Enthalpy, KJ/hr 296.6482646 93.32670455 106.4278587 220.5619587 38.9900619 26.66953839 103.0627577 885.6871445 Rotary Drum Vacuum Filter (FT-1) T = 190˚C P = 50kPa component Filter 1 filtrate Effluent mass mass comp, flow,kg/h % Enthalpy, KJ/hr Ethylene Glycol 1161.8975 61.7972 532032.8656 BHET 674.9007 35.8956 194911.3194 Water 6.6825 0.3554 Oligomers 36.6979 1.9518 10807.53597 1880.1786 Pressure = 1 bar 100 743058.9591 Total Temperature = 190˚C 5307.23814 BHET Crystallizer (CR-1) T = 30˚C component Ethylene Glycol BHET Water Oligomers Total Temperature = 30˚C Crystallizer Outlet mass mass comp., flow,kg/h % P = 1 bar Enthalpy, KJ/hr 1161.8975 61.7972 84005.1893 674.9007 35.8956 30775.47149 6.6825 0.3554 837.9849695 36.6979 1.9518 1706.453049 1880.1786 100 117325.0988 Pressure = 1 bar Decanter Filter (FT-2) T = 25˚C component Ethylene Glycol BHET Water Oligomers Total P = 1 bar Temperature = 30˚C Filter 2 cake mass mass comp, flow,kg/h % Filter 2 filtrate mass mass comp, flow,kg/h % 987.6129 93.6803 28.6833 2.7208 6.0142 0.5705 31.9272 3.0285 1054.2376 100 Pressure = 1 bar Enthalpy, KJ/hr component Ethylene Glycol 174.2846 21.1013 12600.7784 BHET 646.2174 78.2401 29467.51395 Water 0.6682 0.0809 83.79849695 Oligomers 4.7707 0.5776 221.8388963 Total 825.9410 100 42373.92974 Temperature Pressure = 30˚C = 1 bar Vacuum Belt Dryer (DR-1) T = 80˚C P = 50kPa bar Vapour Product mass mass comp., flow,kg/h % component Ethylene Glycol 165.5703939 92.9025 Oligomers 3.578046715 2.0077 Water 0.6348 0.3562 Total 178.2195 95.26636708 Temperature Pressure = 1 = 80˚C bar Enthalpy, KJ/hr 31921.97194 443.6777926 212.2895256 32577.93925 Enthalpy, KJ/hr 71404.41091 1307.957538 754.1864726 1484.614152 74951.16907 Vacuum Belt Dryer (DR-1) T = 80˚C P = 50kPa bar Component BHET Dried Product mass flow, kg/hr mass comp, % 637.7812 98.4653 Enthalpy, KJ/hr 24235.6838 Ethylene Glycol 8.7142 1.3454 525.0324331 Oligomers 1.1927 0.1841 46.21643673 647.7215 Pressure = 1 bar 100 24806.93267 Total Temperature = 25˚C Mixing Temperature Reactor 1 Effluent component Ethylene Glycol BHET Water Sodium Carbonate Unreacted PET Impurities Oligomers Total Temperature = ˚C mass flow,kg/h mass, % Enthalpy, KJ/hr 1335.9062 0.0000 6.7161 0.7091 0.0000 0.0036 611711.4299 0 5331.852457 1.4870 539.2330 0.5398 0.0000 1883.8819 0.0008 0.2862 0.0003 0.0000 1 39.03266639 13885.24858 12.27982955 0 630979.8434 Pressure = 1 bar component STEAM mass flow, Enthalpy, kg/hr mass, % KJ/hr steam 1854.162998 100 5514280.756 Total 1854.162998 100 5514280.756 Temperature Pressure = 250˚C = 1 bar Heat Exchanger 1 (HX-1) T = 190˚C P = 1 bar component steam Total Temperature = 105˚C STEAM mass flow, kg/hr mass, % 1854.162998 100 1854.162998 100 Pressure = 1 bar Enthalpy, KJ/hr 4978427.649 4978427.649
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