Prepare, in the form of a flowsheet, an outline showing the sequence of steps in the complete

de$.$ t for producing formaldehyde. A detailed analysis of the points to be co $142$ of $1006$ should be included. The outline should take the project from the initia tere the plant is in efficient operation.

A process for making a single product involves reacting two liquids in a continuously agitated reactor and distilling the resulting mixture. Unused reactants are recovered as overhead and are recycled. The product is obtained in sufficiently pure form as bottoms from the distillation tower.

a$.$ Prepare a qualitative flowsheet for the process, showing all pieces of equipment.

b$.$ With cross reference to the qualitative flowsheet, list each piece of equipment and tabulate for each the information needed concerning chemicals and the process, in order to design the equipment.

A search of the literature reveals many different processes for the production of acetylene. Select four different processes, prepare qualitative flowsheets for each, and discuss the essential differences between each process. When would one process be more desirable than the others? What are the main design problems which would require additional information? What approximations would be necessary if data were not available to resolve these questions?

Ethylene is produced commercially in a variety of different processes. Feedstocks for these various processes range from refinery gas, ethane, propane, butane, natural gasoline, light and heavy naphthas to gas and oil and heavier fractions. Prepare three different qualitative flowsheets to handle a majority of these feedstocks. What are the advantages and disadvantages of each selected process?

One of the ethylene processes using propane as a feedstock with front$-$end deethanization and front$-$end acetylene hydrogenation was presented as the preliminary design example in this chapter. For the product separation section for the base$-$case design, shown in Fig. $3-13,$ complete the material balance around each piece of equipment shown. The feed in $k\frac{g}{h}$ for the $C_2$ splitter and the depropanizer column are as follows:

$\backslash$table$[[$Component$,$Stream $533,$Stream $413,$Stream $416|],[$Methane$,2\mathrm{.}92,-,-],[$Acetylene$,0\mathrm{.}24,-,-],[$Ethylene$,62\mathrm{.}008,-,0\mathrm{.}005],[$Ethane$,11,953,-,1\mathrm{.}18],[$MAPD$,-,97\mathrm{.}5,458],[$Propylene$,2\mathrm{.}10,2,220,20,572],[$Propane$,0\mathrm{.}005,1,912,14,321],[$C ${?}_4$ S$-$C $6,-,8,734,4,776],[$Heavy gasoline,$-,1,858,0\mathrm{.}55]]$

CHAPTER $3$ Process Design Development

$3-7$ With the information developed in Prob. $3-6,$ prepare a quantitative energy balance for the separation section of the base$-$case ethylene process and size the equipment in sufficient detail for a preliminary cost estimate.

$3-8$ Figure P$3-8$ shows the series configuration hybrid system that was used to replace the $C_2$ splitter in the preliminary design outlined in this chapter. If the feed is $84\mathrm{.}75$mol percent ethylene, the product stream is $99\mathrm{.}9$mol percent ethylene, and both recycle streams are $99\mathrm{.}45$mol percent ethane, establish a material and energy balance around each piece of equipment of the hybrid system.