Sheet flow

Flow models Flow number FLOWPACK Flow patterns Flow-sheet models FlowSorb 2300 FLOWIRAN... 

Fig. 1. (a) Process flow sheet for human insulin production, recovery, and purification (12) (b) corresponding steps in recovery of biosynthetic human... 

At this time over 95% of all new urea plants are Hcensed by Snamprogetti, Stamicarbon, or Toyo Engineering. SNAM utilizes thermal stripping while STAC (Stamicarbon) and Toyo use CO2 stripping. Only these three processes are, therefore, covered in detail. Process flow sheets are included for others at the end of this section. 

Other Processes. Flow sheets for typical partial-recycle process and typical once-through urea process are given in Figures 9 and 10, respectively. 

The subject has been reviewed (37,38). Water may be added to the feed to suppress methyl acetate formation, but is probably not when operating on an industrial scale. Water increase methanol conversion, but it is involved in the unavoidable loss of carbon monoxide. A typical methanol carbonylation flow sheet is given in Figure 2. 

Fig. 1. Flow sheet for methyl acetate manufacture. To convert kPa to psi multiply by 0.145.

The unit has virtually the same flow sheet (see Fig. 2) as that of methanol carbonylation to acetic acid (qv). Any water present in the methyl acetate feed is destroyed by recycle anhydride. Water impairs the catalyst. Carbonylation occurs in a sparged reactor, fitted with baffles to diminish entrainment of the catalyst-rich Hquid. Carbon monoxide is introduced at about 15—18 MPa from centrifugal, multistage compressors. Gaseous dimethyl ether from the reactor is recycled with the CO and occasional injections of methyl iodide and methyl acetate may be introduced. Near the end of the life of a catalyst charge, additional rhodium chloride, with or without a ligand, can be put into the system to increase anhydride production based on net noble metal introduced. The reaction is exothermic, thus no heat need be added and surplus heat can be recovered as low pressure steam. 

Oxidation Step. A review of mechanistic studies of partial oxidation of propylene has appeared (58). The oxidation process flow sheet (Fig. 2) shows equipment and typical operating conditions. The reactors are of the fixed-bed shell-and-tube type (about 3—5 mlong and 2.5 cm in diameter) with a molten salt coolant on the shell side. The tubes are packed with catalyst, a small amount of inert material at the top serving as a preheater section for the feed gases. Vaporized propylene is mixed with steam and ak and fed to the first-stage reactor. The feed composition is typically 5—7% propylene, 10—30%... 

Acrylic Acid Recovery. The process flow sheet (Fig. 3) shows equipment and conditions for the separations step. The acryUc acid is extracted from the absorber effluent with a solvent, such as butyl acetate, xylene, diisobutyl ketone, or mixtures, chosen for high selectivity for acryUc acid and low solubihty for water and by-products. The extraction is performed using 5—10 theoretical stages in a tower or centrifiigal extractor (46,61—65). 

Esterifica.tlon. The process flow sheet (Fig. 4) outlines the process and equipment of the esterification step in the manufacture of the lower acryflc esters (methyl, ethyl, or butyl). For typical art, see References 69—74. The part of the flow sheet containing the dotted lines is appropriate only for butyl acrylate, since the lower alcohols, methanol and ethanol, are removed in the wash column. Since the butanol is not removed by a water or dilute caustic wash, it is removed in the a2eotrope column as the butyl acrylate a2eotrope this material is recycled to the reactor. 

Flow Sheet. Most purge-swing appHcations use two fixed-bed adsorbers to provide a continuous flow of feed and product (Fig. 16). Single beds are used when the flow to be treated is intermittent or cycHc. Because the purge flow is invariably greater than that of adsorption, purge is carried out in the down-flow direction to prevent bed lifting, and adsorption is up-flow. 

An extraction plant should operate at steady state in accordance with the flow-sheet design for the process. However, fluctuation in feed streams can cause changes in product quaUty unless a sophisticated system of feed-forward control is used (103). Upsets of operation caused by flooding in the column always force shutdowns. Therefore, interface control could be of utmost importance. The plant design should be based on (/) process control (qv) decisions made by trained technical personnel, (2) off-line analysis or limited on-line automatic analysis, and (J) control panels equipped with manual and automatic control for motor speed, flow, interface level, pressure, temperature, etc. 

A flow sheet of the basic TVA process for granular diammonium phosphate is given in Figure 12. The raw materials are wet-process phosphoric acid and anhydrous ammonia. Feed acid concentration of at least 40% P2 5 required to give a satisfactory water balance. This average concentration usually is provided by two separate feed streams, one of 54% P2 5 concentration and one of about 30% P2 5 arrangement shown, the 54% acid is... 

A flow sheet of a typical steam granulation plant is shown in Figure 16. Initial steps are cmshing, screening, proportioning, and blending of the dry... 

Fig. 10. Flow sheet for typical spunbond fabric manufacture.

Process Design and Machinery. Following the field work of geologists and mining engineers and analyses (assays) to estabhsh the grades (concentrations) of values in ores, a mineral concentration flow sheet is estabhshed on the basis of a number of preliminary tests. These include studies of... 

Fig. 12. Complex copper ore concentration flow sheet. Courtesy of Denver Equipment Co.

The basic flow sheet for the flotation-concentration of nonsulfide minerals is essentially the same as that for treating sulfides but the family of reagents used is different. The reagents utilized for nonsulfide mineral concentrations by flotation are usually fatty acids or their salts (RCOOH, RCOOM), sulfonates (RSO M), sulfates (RSO M), where M is usually Na or K, and R represents a linear, branched, or cycHc hydrocarbon chain and amines [R2N(R)3]A where R and R are hydrocarbon chains and A is an anion such as Cl or Br . Collectors for most nonsulfides can be selected on the basis of their isoelectric points. Thus at pH > pH p cationic surfactants are suitable collectors whereas at lower pH values anion-type collectors are selected as illustrated in Figure 10 (28). Figure 13 shows an iron ore flotation flow sheet as a representative of high volume oxide flotation practice. 

Fig. 13. Experimental iron ore flotation flow sheet (28) (-), forward flow (-----), return flow. Courtesy of USBM. Note the combination of flotation...

Fig. 14. Coal flotation flow sheet suggested for increased sulfur removal (29). Pyritic sulfur removal from coal makes it imperative to closely control pulp...

If equation 7 holds, then the soHd is exclusively in the aqueous phase equation 8 defines the condition at which the soHd resides in the oil phase whereas if equation 9 is satisfied then the soHd collects at the water—oil interfacial region. Figure 16 is the flow sheet of a bench-scale study that demonstrates the concept of two-Hquid flotation (40). 

Fig. 16. Two-hquid flotation flow sheet (39). The original ROM is kaolin (white clay) that contains 11% impurity in the form of mica, anatase, and siUca. Treatment produces high purity kaolin and a Ti02-rich fraction. A, Kaolin stockpile D, dispersant (sodium siUcate plus alkah) W, water K, kerosene C, collector (sodium oleate) RK, recycled kerosene S, screen M, inline mixer SPR, separator CFG, centrifuge P, product and T, to waste.

Eigure 4 preseats the equipmeat flow sheet for a 9-t/d fluorine plant. 

Fig. 4. Equipment flow sheet of elemental fluorine production and liquefaction plant, 9 t/d capacity. Step 1 purging residual F2 at rates indicated all but a trace of residual F2 is removed in 15min N2 purge is maintained for 1 h to remove last traces. Step 2 HF removal at rates indicated all but a trace of HF is...

Fig. 1. Simplified schematic flow sheet for the production of a moderate RDF, using trommel separation.

Fig. 2. Process flow sheet of (a) Sasol One and (b) the Sasol synfuel process for Sasol Two and Three (36). LPG is Hquefied petroleum gas other terms are...

Furthermore, 60—100 L (14—24 gal) oil, having sulfur content below 0.4 wt %, could be recovered per metric ton coal from pyrolysis at 427—517°C. The recovered oil was suitable as low sulfur fuel. Figure 15 is a flow sheet of the Rocky Flats pilot plant. Coal is fed from hoppers to a dilute-phase, fluid-bed preheater and transported to a pyrolysis dmm, where it is contacted by hot ceramic balls. Pyrolysis dmm effluent is passed over a trommel screen that permits char product to fall through. Product char is thereafter cooled and sent to storage. The ceramic balls are recycled and pyrolysis vapors are condensed and fractionated. 

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