Design of a Chemical Plant to Produce 80,000 Tons/year of Propylene from Methanol PDF Download

Author: Rusul Omar
Publisher:
ISBN:
Category :
Languages : en
Pages : 424

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Propylene is an important material chemical intermediary because it can be utilized in numerous applications like the electricity and many other, but the main application of propylene is to make it as polypropylene. There are many processes that produce propylene, but the propylene production is connected with methanol by Lurgi's MTP that involves the dehydration operations. The LURGI MTP technology produce more amount of propylene than the other processes. The objective of this capstone project is to produce 80, 000 tons per year of propylene from methanol. Moreover, nowadays, there are many processes that have been develops and improved to produce the propylene the recent one is for dehydration the methanol because it gives the high production conversion of propylene (yield) which is equals to 45.44% with applying some of zeolite catalysts to achieve this process. The process flow diagram was designed and detailed by using available literature and performing the material and energy balance for the entire process. The first step was to star this project was to analyze the required amount of methanol for the process was equals to be 1124269.182 kg/days or 1462.06 kmol/hr. In addition, the design section calculations were detailed for several units and the main equipment of the process that includes which are pump, Shell & tube Heat Exchanger, BPR reactor, multicomponent distillation column and compressor. The design involved many calculations for example diameter, height, area, and volume, also the required weight of the catalyst for the DME reactor. In addition, the analysis of economics was assembled which the plants results originate to be profitable and having a payback period, and the plant was found to be with a payback period of 1.71 years. Finally, the environmental impacts and ethical issues was discussed. Also, for the HAZOP was done and explained for all the equipment and units that designed.

Author: Alanoud Akram Albarri
Publisher:
ISBN:
Category :
Languages : en
Pages : 428

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Methanol is the simplest alcohol and it's an alternative source of fuel that provide energy. It is produced naturally as a byproduct of destructive distillation of wood that's why they call it wood alcohol. In addition, it could be synthesis on industry by catalytic process. The main characteristics of methanol is its highly toxicity, also it has essential properties such as its volatile, colorless. Methanol is used in a lot of application that requires fuels because it's cheaper to produce than other alternative fuels. However, it reacts violently with strong oxidants, causing a fire and explosion hazard. This project will explain the process of producing methanol from biomass, with the goal of producing 50, 000 tons per year from biomass. We have studied and simulated the biomass-to-methanol process in which biomass of woody origins is converted to liquid fuels for transportation and many other uses. In this study, methanol (MeOH) was considered mainly as a liquid fuel, however, other very useful applications for methanol can be taken into account as formaldehyde. This present study was designed, and the environmental analysis of the process was performed from the viewpoint of carbon dioxide emission. Methanol can be produced from biomass by means of gasification. There are other several ways to produce methanol that involves conventional, commercial and advanced technologies, but they are either under development, polluting, or expensive. Methanol production facilities typically contain of the next basic steps: 1. Pre-treatment. 2. Gasification. 3. Gas cleaning. 4. Reforming of higher hydrocarbons. 5. Shift to obtain appropriate H2:CO ratios. 6. Gas separation for methanol synthesis and purification.

Author: Sharyar Ahmed
Publisher: GRIN Verlag
ISBN: 3346195023
Category : Science
Languages : en
Pages : 81

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Project Report from the year 2016 in the subject Chemistry - Other, , language: English, abstract: This is a part two of the Advance Process design project. Part one was a group project in which we carried out a feasibility study of Methanol to Olefin (MTO) plant. The plant is an extension of an existing Coal-chemical complex in China, which produces 1,000,000 tonnes of methanol from coal each year. In order to become more competitive in the market, we studied alternative routes of MTO process and designed the most efficient, least pollutant and safest plant. The aim of this individual project is to cover a detailed design of the C2 splitter distillation column which is the final step in the MTO process where ethylene and ethane are separated. As ethylene is one of the most popular petrochemical product and the demand for the product is continuously increasing each year. Therefore, to meet the customers demand the column was designed with 99.4% purity. For the initial design calculation, the operating pressure of the column was chosen as 24bar. The diameter of the column was calculated to be around 1.66m for the stripping section, which was suitable for the sieve plate design. Using the AlChE method, the plate overall efficiency was obtained as 73%, which was in the range of the distillation column efficiencies, by using the plate efficiency the actual number of stages was obtained, 53 stages, with an overall height of the column as 35m. At 24bar the condenser duty of the column was calculated to be 2.66MW and reboiler duty 2.43MW. The design optimisation shows that as the pressure of the column increases, the capital cost of the column also increases due to the increase in a number of actual stages and the reflux ratio, mean taller and thicker column wall, will be required to meet the right specification and to handle the high pressure of the column. But, with the increasing pressure, the energy cost of the column decreases, as less energy will be required to condense the overhead vapour. The capital cost of the column outweighs the energy cost of the column. Therefore, the column total cost increases with the increase in column pressure. The optimum pressure, for the C2 splitter column, was chosen as 10bar. The reason being, low reflux ratio and less number of stages will be required, meaning the less capital cost of the column.

Author: Hossam Khaled Mostafa
Publisher:
ISBN:
Category :
Languages : en
Pages : 390

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This report presents the design of a plant to produce cumene of high purity 99.5% from alkalayation of benzene with propylene using zeolite based catalyst. The project begins with the increased demand of cumene in the past, present and future, which motivated us to design a plant which uses the resources efficiently and sustainably. A block flow diagram along with a process flow diagram were prepared based on current existing work and adjusted based on the demanding needs. Material balance was implemented on each part of the process flow diagram and the 4 main pieces equipment which were used to produce cumene were plug flow reactor, flash separator, distillation, column and heat exchanger. Finally, it is planned to complete the energy balance as soon as possible along with the design of each equipment , cost analysis of plant along with safety analysis are expected to be completed in CPD-2.

Author: Baseer Ul-Haq
Publisher:
ISBN:
Category :
Languages : en
Pages : 402

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Book Description
In this project a plant is being designed to produce 55,000 tons/yr of 37 wt % formaldehyde from methanol, where for the capstone design II the last five chapters regarding this topic has been completed. From the five chapters, chapter five Detailed design regarding the design using a software for the Heat Exchanger, Absorber, and Distillation column, while in the sixth chapter which is the Process Economics is the chapter which the costs of equipment, maintenance, depreciation and Total [sic] Manufacturing [sic] costs are done. The seventh chapter in this this[sic] report is the section where the Safety and Environmental issues are discussed. The other sections in this chapter include Toxicological [sic] information of chemicals used and HAZOP of the equipment are discussed. Next, is the chapter eight, this is the project [sic] management [sic] chapter. The problems faced, resources used, tasks and distribution of tasks amongst team members are discussed. Finally, the ninth chapter is the conclusion[sic] of the project [sic] where the restatement of the objectives and deliverables including the summary of the selected process are discussed.

Author: Mohamed Adil
Publisher:
ISBN:
Category :
Languages : en
Pages : 286

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Hydrogen is the first element in the periodic table and the most abundant element on earth. Also, around 75% of the universe's mass consists of it, moreover; it's one of the main factors in chemical industry as it's considered the starting brick in the manufacturing of ammonia, methanol and polymers. Around 50 million tons of hydrogen is produced every year in the world. it comes from different sources, some are really expensive like the Electrolysis of water and other unsafe methods that may raise some issues with the environmental laws. The biodiesel production process offers a huge amount of crude glycerol that can be used after purification to produces tons of hydrogen and at the same time it's considerably safe. Our goal is to design a chemical plant that produces hydrogen from crude glycerol at a rate of 35, 000 ton/yr with a purity of 99%. The method used in this project was steam reforming because of the many advantages of it among other methods like supercritical and auto-thermal , giving higher conversion and purity. Process Flow Diagram was created to be the first and the main fundamental block for this project, moreover; mass and energy balance calculations were done by starting with a 10,000 ton/yr of crude glycerol then performing a scale up to identify the real amount needed to produce the required hydrogen. Following this a design of three units: absorber, heat exchanger and the steam reformer reactor, then a cost estimation was done for the whole design and the design was done to meet the regulation of the environment by performing a safety and hazardous investigation.

Author: Rawan Marwan El-Achkar
Publisher:
ISBN:
Category :
Languages : en
Pages : 470

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Book Description
Cumene is an aromatic hydrocarbon with various applications in the industry. The main purpose of producing cumene is to use it as a raw material for the production of phenol. The raw materials for the production of cumene include benzene and propylene. After researching the different methods to produce cumene, it was found out that the classical method uses solid phosphoric acid (SPA) or aluminum trichloride (AlCl3) catalysts, yet the modern method is more efficient and utilizes various types of zeolites. In this design project the catalyst chosen is beta zeolite since it provides the highest selectivity /yield and is the most environmentally and health friendly catalyst in comparison to the other catalysts normally used in the classical method. Additionally, beta zeolite provides the highest cost efficiency. The aim of this design project is to fully design a chemical plant that yields 100, 000 tons/year of 99.5% purity cumene from benzene and propylene. This process will involve the usage of two reactors, an alkylation and a trans-alkylation reactor, which are originally fixed bed reactors; this type of reactor is chosen as it preserves the catalyst and boosts the exothermic reactions. In this design project, it was decided that the by-product, DIPB, is to be recycled in the trans-alkylation reactor in order to produce the maximum amount of cumene only. The benzene and propylene enter the alkylation reactor at a ratio of 4.71:1 respectively and a temperature of 180°C, whereas DIPB and the excess benzene enter the trans-alkylation reactor at a ratio of 4:1 respectively at a temperature of 240°C. The conversion of the first reactor is 100% with respect to propylene while the conversion of the second reactor is 45% of DIPB. Also, the overall selectivity of the process is 94%. In this design project, there were certain steps to follow. For instance, after selecting the desired process based on the one that results in the highest selectivity and yield of cumene, the process flow diagram (PFD) based on research and literature was created using Aspen HYSYS. Next, the design of the equipment was completed with the help of certain programs, such as polymath. In brief, for the Carbon Steel alkylation reactor, its volume, diameter, and length are 37.31m3 , 2.48 m, and 12.39 m respectively. Moreover, 3.73 x 104 kg of zeolite is required for the alkylation reactor. As for the Carbon Steel trans-alkylation reactor, the volume, diameter, length, and catalyst weight are 4.53 x 10ˉ3 m3, 0.17 m, 0.33 m, and 4.53 kg respectively. Other significant equipment that are noteworthy to mention are the heat exchanger, two distillation columns, and flash separator. For the heat exchanger placed before the alkylation reactor, it has been chosen in this report to utilize the huge amount of heat accompanied with the outlet stream of the reactor since the reaction is exothermic to heat the inlet of the same reactor. This would help in saving energy and cutting down costs. For this integrated shell and tube heat exchanger, the hot fluid was placed in the tube side, whereas the cold fluid was located in the shell side. For the tubes, there are 4 tube passes with 102 tubes per pass; the nominal pipe size is 3/8 the inner and outer diameters are 0.0125 m and 0.017 m respectively, and the length of the tube is calculated to be 7.315 m. Furthermore, the pitch type is identified to be 0.021 triangular. As for the shell, the heat transfer area, internal diameter, and the baffle cut are: 160.23 m2, 0.57 m, and 25% respectively. For the first distillation column, the benzene column, that intends to separate benzene from a mixture of benzene, cumene, and DIPB, has a minimum reflux ratio of 3.44, 21 actual stages , a diameter of 1.23 m, and a height of 12.01 m, and the feed enters the column starting from the top at the very first stage. As for the second distillation column, similar values were found. Moving on to the single stage flash separator, which separates propane from the rest of the mixture, its height and diameter are 3 m and 0.74 m respectively. In order to achieve this process successfully, estimation of the cost must be made, where it was found that the total manufacturing cost of the plant is 120, 863,690 US dollars. The payback period (PBP) was found to be 2.41 years and the rate of return of investment (ROROI) equal to 21.1%. At the end, a HAZOP study was done on different equipment of the plant to identify any environmental, health, and safety hazards. Not to forget to mention, certainly, there were problems faced, such as unavailability of data or uncertainty, while working on this project: nevertheless, the team members managed to resolve any conflicts.

Author: Amal Radwan Jamal Eddin
Publisher:
ISBN:
Category :
Languages : en
Pages : 424

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Book Description
Most of the industrial processes nowadays are accompanied by the usage of intermediate products in order to obtain the final desired product. Intermediate products are products that need to be further refined by the producer before they are sold to the target consumer. The idea of having an intermediate product is very useful for the industries, as these compounds are further processed rather than being directed into an incinerator or to waste treatment. Acrolein is one of the chemicals that are considered to be intermediate materials for the production of other materials used in day-to-day life.The aim of this project is to design a chemical plant that produces 60,000 tons/year capacity of acrolein with a high purity of approximately 98% from a raw material which was selected to be propylene. This final decision of the best raw material to select was taken after going through the general steps for selecting a raw material. Starting with the elimination based on yield, selectivity, and lack of practical foundation, followed by the elimination based on gross profit analysis, as well as the availability of the raw material in United Arab Emirates. Material balance calculations were done on a selected process flow diagram in order to know how much material should be fed to the process and at what flow rate does the product, by-product, and the unreacted materials leave and exit each single unit achieving the desired capacity material. In addition, energy balance calculations were done around around each piece of equipment installed in the process plant. Operating conditions were assumed based on different studies and sources and material and energy balance equations were applied properly. The process flow diagram was modified to overcome the challenges of the process where heat integration was applied on the reactor process since the reaction is extremely exothermic. In addition, a recycle stream was added in order to recycle all the raw material and reach 100% conversion of propylene, Moreover, since a huge amount of water was found leaving a process stream, it was suggested to treat the water and deionize it for the aim of it being used. From various equipment installed in the process plant, one from each of the main equipment were designed including, heat exchangers, reactors, fractionators, flash distillation columns, liquid-liquid extraction columns, pumps, and compressors. When designing each single equipment appropriate detailed design calculations were followed. The area of the shell and tube heat exchanger (E101) was found to be of 13430.5 ft2. The reactor (R101) diameter was found to be 0.385m with a length of 1.1553 m. The detailed design calculation of the extraction column (T101) shows that the height of the column is to be 45.88m. For, the fractionator (T103), the number of trays were found to be 11 stages. The diameter and length were 0.6 m and 9.4 respectively. The diameter and the length of the flash distillation column (T106) were found to be 15.1 m and 46 m respectively. Based on the head and flow rates, Pump (P101) type was selected to be centrifugal. The power out of the pump was found to be 36.98 hp while the power in to the pump was found to be 57.78 hp. A compressor (C104) was found to be of a type rotary compressor with a work of 290 kw. The number of compressor stages were found to be 2 stages. A process economic analysis was done on the constructed plant to determine whether the plant at hand is a good investment or not. The plant capital cost was found to be 40, 959, 756.7 US dollars, the manufacturing cost was found to be 207, 206, 460.6 US dollars a year. The revenue was found to be 219, 834, 000 US dollars. Based on the undiscounted analysis, the rate of return was found to be 14.7% and the payback period is approximately 4 years. Based on the discounted profitability analysis, the discounted rate was found to be 14.7%. The ethical, safety, and environmental issues related to the designed chemical plant of acrolein production were discussed in detail in this project.

Author: Francois Vos
Publisher:
ISBN:
Category :
Languages : en
Pages : 0

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Final year report -- Chemiese Ingenieurswese.

Author: Arij Ferzat Shekhani
Publisher:
ISBN:
Category :
Languages : en
Pages : 548

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Designing a chemical plant for producing hydrogen from the raw crude glycerol through steam reforming method which plays significantly and effectively in most of the chemical industries for obtaining hydrogen was performed in the design thesis due to its significant role in the industry and various aspects in chemical processes. The main purpose of the project is to produce 25, 000 tons/yr. of hydrogen from steam reforming of crude glycerol with high purity of 99%. The process is based on two main processes which are the purification and production processes, in the purification step, 90% of methanol will be removed and production step is needed for obtaining 99% purified hydrogen. The design has been studied from different aspects through the process flow diagram, required considerations and calculations of the units, energy and mass balances, techniques and processes, process economics, operating conditions, and environmental , ethical, and safety considerations which have been fulfilled. The objectives of the design project are to create an advanced , environmentally safe, and techno-economical plant for the production of hydrogen due to its valuable and effective role as a promising renewable energy source. Secondly, to design the plant in lower prices and costs which will help in the utilize of the methods, involved materials, and the desired hydrogen since there is a huge demand in the past decades until now on it. Various calculations of detailed design were made for three main equipment which are heat exchanger in shell & tube type, steam reformer in a packed bed reactor, and the absorber. Polymath software program was involved in the calculations of the steam reformer, and the observable results showed that the required catalyst weight of Ni/Al2O3 catalyst is 424.7613 kg to reach 95% conversion and with a diameter of 0.531 m. length of 1.593 m, (sic) and unknown cross-sectional area to make the weight catalyst calculation simple. For the chemical absorber which is used to purify the hydrogen (H2) produced in the steam reforming plant to 99% by absorbing the carbon dioxide (CO2) with a 15% MEA solution, the calculated cross-sectional area of the column is 1.375m2, where the corresponding column diameter of 1.323 m . however, the column diameter used for design is 1.3 m. The height of the absorption column was calculated to be 4.865 m after a series of steps. Also, the pressure drop per unit height was found to be 382.952 Pa/m.For the heat exchanger design, it was found that the number of tubes is 76 having an outer diameter of 3⁄4 ", a wall thicknes (sic) of 14 BWG on 1" square pitch, an internal dimeter (sic) of 0.584 in, (sic) and a length of 16 ft. The required heat transfer area was calculated to be 232.4778 ft2 for the calculated number of tubes of 74.1 tubes, while the designed area was calculated to be 238.76 ft2 for the 76 tubes chosen for the design. The internal shell diameter was also found to be 12 in. The baffles, on the other hand was assumed to be 25% cut segmental baffles with a baffle spacing of half the shell ID. It was also paramount to find the cost of the equipment designed and the estimation of the whole plant. The cost of the three-designed equipment was 6143.700 dollars, 44495.120 dollars, 2539.980 dollars for the heat exchanger, absorber, and the pressurized vessel (steam reformer), respectively. The total manufacturing costs, on the other hand, were found to be approximately 34 million dollars.