A chemical company is producing acetylene (C2H2). The acetylene is produced by reacting methane (CH4) and oxygen (O2) according to the given reaction equations. Prior to the reaction, both CH4 and O2 at 25C are mixed (M) and heated (H) to 600C. The fed CH4 is in excess by the range of (100200)% excess. The heated reactants enter the Reactor (R), the fed O2 is completely consumed by the incomplete combustion reaction (reaction 1) and yield of C2H2 is 0.25. The product stream leaves the reactor at temperature range of (600700)C and immediately quenched or cooled in quenching tower (Q) to 40C by cooling liquid water. The cooling liquid water enters at 14C and leaves as steam at pressure of 5 bar. The water vapour from the incomplete combustion reaction is merged with the exit cooling water system during the quenching. The cooled products enter Separator 1, where CO and H2 were discarded while CH4 and C2H2 enter Separator 2. From Separator 2,CH4 is recycled to the mixer while the C2H2 is collected as final product. CH4(g)+23O2(g)CO(g)+2H2O(v)2CH4(g)C2H2(g)+3H2(g) a) Draw the process flow diagram and completely label each stream and unit operations. b) Report energy balance calculation of the reactor. A one (1) percentage of excess CH4 and a one (1) process condition (reactor outlet stream temperature) should be selected based on the given ranges. All assumptions in the calculation should be stated. Your company request to increase yield of the produce C2H2, give your comment and support with related reference. c) Amount of the cooling water enters the quenching tower should be determined. All assumptions in the calculation should be stated. Explain the important of immediate cooling or quenching in the process, support the explanation with reference. d) The report should consider the shut down plan (day maintenance) as to maintain customer demand. The maintenance duration should be set according to the current C2H2 in the storage tank (10,000kg). The minimum storage of C2H2 should not be less than 5000kg as to maintain the demand. Mathematical model which represent the demand is mdemand =0.23t, where t is the time in hour. note: please do answer every questions (a), (b), (c) and (d) with complete diagram, calculations and explanation. Thank you
