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Design Of A Chemical Plant To Produce 40 000 Tons Year Formaldehyde Of High Purity From Methanol
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Book Synopsis Design of a Chemical Plant to Produce 40, 000 Tons/year Formaldehyde of High Purity from Methanol by : Sarah Al Shibah
Download or read book Design of a Chemical Plant to Produce 40, 000 Tons/year Formaldehyde of High Purity from Methanol written by Sarah Al Shibah and published by . This book was released on 2018 with total page 444 pages. Available in PDF, EPUB and Kindle. Book excerpt: The formaldehyde (formalin) is important compound, as its uses are too wide, like in polymers, urea formaldehyde production and sterilization in medical equipment. The focus of this project is on developing and designing a chemical plant for the production of 40, 000 tons per year of formaldehyde of 55% purity from methanol by partial oxidation using highly selective catalyst (iron-molybdate) process. Partial oxidation process was chosen among other alternatives including partial oxidation using silver catalyst, CO hydrogenation in gas phase and liquid phase.[sic] that has the most acceptable and easily provided operating conditions as well as the production of highest conversion and formaldehyde selectivity and purity. Detailed process flow diagrams of both reaction and absorption processes were developed. Subsequently, material and energy balances were performed on a basis of 1074 ton mol per year of methanol is needed in order to get the desired production of 40, 000 ton per year of formaldehyde. The three main equipment of the process, which are the steam reformer, heat exchanger and absorber were then designed in details. Cost was estimated for this three major equipment and the entire plant cost was analyzed. Moreover, ethical, safety, and environmental issues related to the selected process were investigated and HAZOP was studied for the designed equipment.
Book Synopsis A Chemical Plant for the Production of 55, 000 Tons/yr Formaldehyde of High Purity from Methanol by : Baseer Ul-Haq
Download or read book A Chemical Plant for the Production of 55, 000 Tons/yr Formaldehyde of High Purity from Methanol written by Baseer Ul-Haq and published by . This book was released on 2018 with total page 402 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant to Produce 80,000 Tons/year of Propylene from Methanol by : Rusul Omar
Download or read book Design of a Chemical Plant to Produce 80,000 Tons/year of Propylene from Methanol written by Rusul Omar and published by . This book was released on 2019 with total page 424 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant for the Production of 35,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Mohamed Adil
Download or read book Design of a Chemical Plant for the Production of 35,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Mohamed Adil and published by . This book was released on 2017 with total page 286 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant for the Production of 30,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Sana Eid
Download or read book Design of a Chemical Plant for the Production of 30,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Sana Eid and published by . This book was released on 2017 with total page 466 pages. Available in PDF, EPUB and Kindle. Book excerpt: There are increasing concerns regarding the carbon emissions resulting from the use of fossil fuel. Hence, alternative sources of energy are currently being examined; one of these sources being hydrogen. Hydrogen is considered very promising since 1 kg of hydrogen has the same energy as 3 kg of gasoline and is an infinite, safe, and clean source of energy.The best raw material for this process is glycerol since 1 kg of glycerol is generated per 10 kg of biodiesel, and 1 mole of glycerol produces 7 moles of of hydrogen. The aim of this project is to produce 30, 000 ton/year of high purity hydrogen from glycerol. It is noteworthy that a chemical plant for converting glycerol to hydrogen has not yet been done; however, a lot of research about the topic has been conducted resulting in having several methods to select from. The production of hydrogen from glycerol can be done using several methods such as steam reforming, and partial oxidation. Hence, after researching and comparing the different methods the process of steam reforming with Ni/Al2O3 catalyst at 700°C was selected as it produces 99% pure hydrogen. The Ni/AL2O3 catalyst was found by a study to give the highest hydrogen selectivity (80%) and glycerol conversion (71%). There are some challenges to this process such as by-products formation hindering the hydrogen production and its purity; however, there are viable options to overcome them such as using the in-situ adsorption process. After creating the PFD based on available literature and designing a heat exchanger, absorber and steam reformer we found that 507 kg of Ni/Al2O3 are needed to produce 30,000 tons per year of hydrogen. 350,000 tons per year of glycerol are required for producing 30,00 tons per year of hydrogen. Furthermore, the design process resulted in knowing the equipment's specifications. The designed shell and tube heat exchanger with 3/4" OD tubes (14 BWG) on a 1"square pitch, 25% segmental cut baffles and 90 tubes, with a shell diameter of 13.24", and a tube internal diameter of 0.584" has been made to cool down the outlet gas mixture. On the other hand, the absorber required to get rid of the CO2 present in the final gas mixture in order to achieve 99% pure hydrogen has been made with a cross sectional area of 1.54 m2 , a diameter of 1.4 m, a pressure drop of 418 Pa/m, and an overall packed bed height of 4.9 m. Cost is another important factor to be taken into consideration while designing a chemical plant. The total cost for the desired chemical plant was found to be approximately 94 million dollars. The cost of the individual three designed process units: heat exchanger, absorber, and steam reformer were found to be 27, 088 dollars, 272,541 dollars and 35, 458 dollars respectively.
Book Synopsis Design of a Chemical Plant for the Production of 70,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Eqbal Ahmed Amer
Download or read book Design of a Chemical Plant for the Production of 70,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Eqbal Ahmed Amer and published by . This book was released on 2017 with total page 480 pages. Available in PDF, EPUB and Kindle. Book excerpt: This project aims to utilize the by-product crude glycerol coming from the production of biodiesel and transform it into a form that is more environmental friendly and useful like hydrogen. The purpose of this project was to produce a 99% pure hydrogen from crude glycerol and with a capacity of 70, 000 tons/year. The process design was divided into two main processes, which are the purification of crude glycerol process and the hydrogen production process. A detailed process flow diagram was made for both processes. Mass and energy balance calculations were performed on both processes. The mass balance calculations showed that the final product stream contained 7910 kg/hr of hydrogen along with 79.9 kg/hr of impurity containing carbon dioxide. In addition, detailed design calculations were performed on three major pieces of equipment, which include the steam reforming reactor, the CO2 absorber, and a heat exchanger. The detailed design included calculations such as the height, diameter, volume and area, in addition to the catalyst weight for the steam reforming reactor. The total capital cost for this plant design was calculated and found to be approximately 43.4948 million dollars. Throughout this project, several programs were used that included mainly Microsoft Excel program, Aspen Hysys, and Polymath. In addition, there were several challenges faced in each step of the project that included difficulty in finding the desired information, and time limitation as this project was performed over the course of only one semester.
Book Synopsis Design of a Chemical Plant for the Production of 40, 000 Tons/yr. Styrene by : Amna Fahim
Download or read book Design of a Chemical Plant for the Production of 40, 000 Tons/yr. Styrene written by Amna Fahim and published by . This book was released on 2018 with total page 402 pages. Available in PDF, EPUB and Kindle. Book excerpt: Styrene monomer can be produced with the aid of various processes such as the catalytic dehyrogenation of ethyl benzene, oxidation of ethyl benzene and side-chain alkylation of toluene with methanol. These three processes were considered for commercial production among many other processes that are used to produce styrene. This project , however, focused on the catalytic dehydrogenation of ethyl benzene to produce styrene, since the latter is produced mostly using this method. In short, the aim of this project is to design a chemical plant for the production of styrene at a capacity of 40, 000 tons/year or equivalently 47.84 kmol/hour. This report gives a brief background on styrene, along with its uses, properties and different methods used to produce the monomer. In addition, it covers the process selection along with a detailed process flow diagram developed for the production. Material and Energy [sic] balances were performed for all different processes and corresponding units involved included in the plant. Detailed design calculations of the major equipment used were done, and a profitability analysis of the plant was conducted to know if the proposed design is economically feasible or not. The total manufacturing cost was calculated to be 77.8 Million [sic] dollars and the payback period was found to be 6 years. A Hazard and Operability (HAZOP) study was also conducted to address the safety of the various processes and their environmental impact. Throughout this project, several programs were used that included the use of Microsoft Excel in performing calculations for the energy balances, detailed design calculations and the profitability analysis. Aspen HYSYS was used to check the design of the three -phase separator, and Polymath software was used in the design of the isothermal packed bed reactor.
Book Synopsis Design of a Chemical Plant for the Production of 55,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Mirza Mustafa Baig
Download or read book Design of a Chemical Plant for the Production of 55,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Mirza Mustafa Baig and published by . This book was released on 2017 with total page 316 pages. Available in PDF, EPUB and Kindle. Book excerpt: The aim of this report was to design a chemical plant producing 55, 000 tons/year Hydrogen with 99% purity. The complete plant was designed from cradle to grave and detail explanation of every unit has been provided. The plant is mainly divided into two essential parts namely purification and reformer. At first crude glycerol goes under several process and attains purity of 99% and then pure glycerol undergoes numerous process under high pressure and temperature to produce Hydrogen and side product carbon dioxide. Designing was accomplished by using different software. Three equipment 's were designed namely Shell and tube heat exchanger, reformer and Absorber. The design of shell and tube heat exchanger added more information to our knowledge, the height, area, number of baffles, baffle spacing, number of tube, shell and tube diameter all these information were calculated using conventional calculation and using excel sheet. Secondly, reformer was designed using another software name polymath, this software helped us to solve multiple differential equations by which we were able to find the weight of the required catalyst Ni/Al2O3, to reach conversion of 95% with specified diameter and the length of the catalyst. Finally, the third equipment was designed by using conventional calculations and excels sheet formulas to ease calculation. The design gave us the results by providing us with the cross sectional area, overall height of transfer unit, and height of packed bed without allowance for end.
Book Synopsis Design of a Chemical Plant for the Production of 60, 000 Tons/year of Acrolein ( CɜH4O) by : Amal Radwan Jamal Eddin
Download or read book Design of a Chemical Plant for the Production of 60, 000 Tons/year of Acrolein ( CɜH4O) written by Amal Radwan Jamal Eddin and published by . This book was released on 2018 with total page 424 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant for the Production of 25,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Arij Ferzat Shekhani
Download or read book Design of a Chemical Plant for the Production of 25,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Arij Ferzat Shekhani and published by . This book was released on 2017 with total page 548 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant to Produce 65,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Hussain Jamal Al Nuumani
Download or read book Design of a Chemical Plant to Produce 65,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Hussain Jamal Al Nuumani and published by . This book was released on 2017 with total page 342 pages. Available in PDF, EPUB and Kindle. Book excerpt: This report describes the design of a chemical plant to produce high purity 99% hydrogen from glycerol through the steam reforming process using a nickel based catalyst It starts off with an introduction into the current energy situation and crisis which is the basis and motivation for finding alternative sources then moving on to the biodiesel production and its importance and the fact that it produces a high amount of glycerol that is the feedstock for our process.The glycerol is purified then run through the main steam reforming process to produce the needed hydrogen. a (sic) process flow diagram was designed based on previous existing work and modified based on the needs. Material and energy balances were performed on the processes or purification and steam reforming. the (sic) three of the equipment needed were signed which are the heat exchanger, steam reformer and absorber. Cost and feasibility analysis were then performed from the price of the feedstocks and the selling price of the final hydrogen product as well as the equipment and the plant. Then a safety analysis was performed based on what was learnt in the Chemical Process Safety course from industrial hygiene to HAZOP. The final parts are regarding project management and conclusion.
Book Synopsis Design of a Chemical Plant for the Production of 50, 000 Tons Per Year of Drying Oil of 99 Wt % Purity from Palmitic Acid by : Fatima Abdallah
Download or read book Design of a Chemical Plant for the Production of 50, 000 Tons Per Year of Drying Oil of 99 Wt % Purity from Palmitic Acid written by Fatima Abdallah and published by . This book was released on 2019 with total page 506 pages. Available in PDF, EPUB and Kindle. Book excerpt: Oils are generally chemicals that are used in various industries, especially in paints industries. There are three classification of oils, drying oils, non-drying oils, and semi-drying oils. They are classified by their ability to absorb iodine per 100 grams of oil-also known as the iodine value (IV). Drying oils are majorly used as additives to chemical paints and varnishes in order to aid in the drying processes of these chemicals when applied onto the surface as finishes. Drying oil can be produced from various sources such as acetylated castor oil. The feed was modelled as palmitic acid- or acetylated castor oil- for its availability and the ease of processing it into drying oil. The drying oil was modelled as 1 tetradecene. The aim of the project is to design a chemical plant that can produce 50, 000 tonnes of drying oil per year from Acetylated [sic] Castor [sic] Oil [sic] -also known as Palmitic [sic] Acid [sic]. For the production of drying oil, there are two main reactions. First decomposition of Palmitic [sic] Acid [sic] into Acetic [sic] Acid [sic] and 1-tetradecene. Second reaction produces gum (1-octacosene) as an[sic] by product. Moreover, recent developed process introduced the production of the drying oil (1-tetradecene) through the thermal cracking of acetylated castor oil. A lot of research has been done with different technology where it was decided in this project, the most beneficial reactor would be the continuous stirred tank reactor (CSTR) , where it has high conversion rate per reactor volume, best for large capacity processes and inexpensive to design and operate comparing with PFR. After the thermal cracking of acetylated castor produced drying oil and acetic acid and gum in CSTR. The mixture leaving the reactor and then enters a filtration where the gum is the solid product to be removed. The filtered liquid that contains acetic acid drying oil and unreacted ACO enters a distillation column where ACO is separated from the mixture of DO and AA, then it is recycled back into the feed. The DO and AA mixture enters another distillation column where they are both separated and stored. The product stored is of high purity, 99%, The [sic] reactor has 80% conversion [10], The [sic] conversion of acetylated castor oil to acetic acid is 0.245 at 330°C [34]. After designing the Process Flow Diagram (PFD) based on the literature reviews, it was that calculated that 67338 tonnes of acetylated castor oil per year is required to produce 50, 000 tonnes of drying oil per year.
Book Synopsis Design of a Chemical Plant for the Production of 100, 000 Tons/year of Cumene with 99.5% Purity by : Rawan Marwan El-Achkar
Download or read book Design of a Chemical Plant for the Production of 100, 000 Tons/year of Cumene with 99.5% Purity written by Rawan Marwan El-Achkar and published by . This book was released on 2018 with total page 470 pages. Available in PDF, EPUB and Kindle. Book excerpt: 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.
Book Synopsis Design of a Chemical Plant for the Production of 100, 000 Tons Per Year Phenol from Cumene by : Alaa Mohammed Mudheher
Download or read book Design of a Chemical Plant for the Production of 100, 000 Tons Per Year Phenol from Cumene written by Alaa Mohammed Mudheher and published by . This book was released on 2018 with total page 526 pages. Available in PDF, EPUB and Kindle. Book excerpt: Phenol is a vital chemical intermediate used in various material production such as the production of phenolic resins and polycarbonate via bisphenol A. The production of Phenol [sic] is interlinked with cumene under a process called Hock Process that comprises of two operations; oxidation and decomposition. The cumene is oxidized to produce cumene hydroperoxide where later on, it is decomposed by an acid catalyst to produce phenol and acetone. It is noteworthy to mention that Hock process [ sic] is considered as the optimum process for various reasons which are the production of large capacity of phenol and the production of an important by-product which is acetone. The aim of this project is to produce 100, 000 ton per year of phenol from fresh cumene. Moreover, recent developed processes were introduced to enhance the phenol production by examining different oxidizers for the oxidation process and catalysts for the decomposition operation. Extensive research has been conducted to select the best technology where our findings concluded to the choice of air as the efficient oxidizer and sulfuric acid for the catalyzation of cumene hydroperoxide. The air has been found as the optimum due to its availability and the sulfuric acid was considered the most efficient due to the large-scale production of phenol with the highest purity where the yield reaches up to 99%, selectivity of 99%, and conversion of cumene hydroperoxide of 98%. After designing the Process Flow Diagram (PFD) based on available literature, it was calculated that 300, 000 ton per year of fresh cumene is required to produce 100, 000 tons per year of phenol. In addition, detailed design was made for various units which are Bubble column reactor, LG separator, CSTR, Mixer, Shell & tube Heat Exchanger, and distillation column. In the design of the Bubble column reactor, it was found that the column diameter is 5 m, and the column height was obtained to be 5.09 m, besides the bubble size was found to be 3.83 mm. Moreover, for the distillation column design the obtained results were 8.8 m for the total height, 0.36 m for the diameter, 2.12 for the reflux ration; additionally, the number of theoretical stages was found to be 7 plates, and 10 plates is the actual number of stages.
Book Synopsis Design of a Chemical Plant for the Production of 50,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol by : Salama Ali Al Katheeri
Download or read book Design of a Chemical Plant for the Production of 50,000 Tons/year Hydrogen (H2) of High Purity from Crude Glycerol written by Salama Ali Al Katheeri and published by . This book was released on 2017 with total page 426 pages. Available in PDF, EPUB and Kindle. Book excerpt: Energy is a significant part of people's lives now more than ever. Whether it is a small mobile phone, vehicle, pharmaceutical , plastic, air-conditioner, or water heater, energy plays an essential role. However, energy's benefits extend far beyond what people use individually at home, at work, and on the road. A variety of needed activities- including agriculture, manufacturing, construction, computing, and health and social services- depend on access to modern energy . Energy growth has always been directly linked to development and growth of our planet. There are more than seven billion people on Earth whose lives are dependent on energy. It is the human desire to improve the well - being of their families and communities that drives the energy demand. In order to make their lives richer, more productive, safer, and most important of all, healthier, new and clean technologies need to be developed. Changes in climate and depletion in fossil fuels have led countries everywhere to examine better options for energy, especially renewable energy sources. One major source of alternative fuels that produced from biomass, is biodiesel. This bio-based diesel can replace non-renewable petroleum-based diesel. Unfortunately, there are several weaknesses that need to be overcome before biodiesel production can be both economically and physically applicable. For instance, one of the major byproducts of biodiesel production is crude glycerol. Crude glycerol is expensive to refine. As the production of biodiesel increased, the market for pure glycerol became oversaturated and the price of crude oil dropped. Instead of purifying and selling crude glycerol, biodiesel plants were forced to pay to dispose of it. Consequently, biodiesel production costs rose. To make biodiesel production more cost-effective, it is necessary that a use for this crude glycerol is found. One possible method is using steam reforming technique to reform crude derived from biodiesel transesterification to produce hydrogen. Hydrogen is considered in many countries to be an important alternative energy vector and a bridge to a sustainable energy future. This project studies an effective method of producing hydrogen from crude glycerol using steam reforming. Also it conducts a simulation of a chemical plant including mass and energy balance, and sizing of the main equipment. Moreover, it evaluates the process economics such as feasibility study. and profitability analysis. Furthermore,it takes into consideration the ethical, safety, and environmental issues.
Book Synopsis Design of a Chemical Plant for the Production of 60, 000 Tons/yr Acrylic Acid of High Purity by : Sarah Muhammad Tasleem
Download or read book Design of a Chemical Plant for the Production of 60, 000 Tons/yr Acrylic Acid of High Purity written by Sarah Muhammad Tasleem and published by . This book was released on 2018 with total page 312 pages. Available in PDF, EPUB and Kindle. Book excerpt: This report was done with the core purpose of designing a plant which produces an annual amount of 60, 000 tons of acrylic acid. It follows a series of detailed description of the mentioned chemical compound and the pathways through which it can be synthesized.Based on several factors, one pathway along with the detailed analysis of the required industrial raw materials and equipments is introduced and demonstrated through a process flow diagram, and the mass and energy balance along each unit is then analysed. The selected pathway is through the two -step oxidation of propylene, and the process uses two catalysed reactors (the first for acrolein yield and the second for acrylic acid yield), a gas absorption column for removing the reactors' undesired by products using water as solvent, a liquid-liquid extraction unit to separate the desired acid from water using iso-propyl ether as the solvent, a solvent recovery unit and 2 more distillation units for further purification. Using the end product flow rate of 60, 000 tons/year and calculations based on conversions and stoichiometry, the inlet flow rates of the three streams are dtermined to be 110.64 kmol/hr of propylene, 790.286 kmol/hr of air, and 125.4 kmol/hr of steam . Energy balances around the elements of the entire process flow diagram was performed and the detailed design of each type of equipment was determined. Based on the parameters of the design , the costs and profitability of the proposed plant was analysed, and from the results obtained, the payback period is determined to be 6 years , and the rate of return on investment is 11.37%. Following the chapter of profitability analysis, ethical and safety issues of the project (such as HAZOP), and factors of project management are to be discussed in detail as well.
Book Synopsis Natural Gas Conversion VI by : T.H. Fleisch
Download or read book Natural Gas Conversion VI written by T.H. Fleisch and published by Elsevier. This book was released on 2001-06-01 with total page 577 pages. Available in PDF, EPUB and Kindle. Book excerpt: This volume contains peer-reviewed manuscripts describing the scientific and technological advances presented at the 6th Natural Gas Conversion Sumposium held in Alaska in June 2001. This symposium continues the tradition of excellence and the status as the premier technical meeting in this area established by previous meetings. The 6th Natural Gas Conversion Symposium is conducted under the overall direction of the Organizing Committee. The Program Committee was responsible for the review, selection, editing of most of the manuscripts included in this volum. A standing International Advisory Board has ensured the effective long-term planning and the continuity and technical excellence of these meetings.
