INTRODUCTION
1.1 HISTORY:
Ethylene Glycol (1, 2 ethanediol), HOCH2CH2OH usually called glycol is the
simplest Diol. Diethylene glycol and Triethylene glycol are Oligomers of Mono
ethylene glycol.
Ethylene glycol was first prepared by Wurtz in 1859; treatment of 1,2 dibromoethane
with silver acetate yielding ethylene glycol diacetate via saponification with
potassium hydroxide and in 1860 from the hydration of ethylene oxide. There to have
been no commercial manufacture or application of ethylene glycol prior to World
War-I when it was synthesized from ethylene dichloride in Germany and used as
substituted for glycerol in the explosives industry and was first used industrially in
place of glycerol during World War I as an intermediate for explosives (ethylene
glycol dinitrate) but has since developed into a major industrial product.
The use of ethylene glycol as an antifreeze for water in automobile cooling systems
was patented in the United States in 1917, but this commercial application did not
start until the late 1920s. The first inhibited glycol antifreeze was put on the market in
1930 by National Carbon Co. (Now Union Carbide Corp.) under the brand name
prestone.
Carbide continued to be essentially the sole supplier until the late 1930s. In 1940
DuPont started up an ethylene glycol plant in Belle, West Virginia based on its new
formaldehyde methanol process. In 1937 Carbide started up the first plant based on
Leforts process for vapor phase oxidation of ethylene oxide.
The worldwide capacity for production of Ethylene Glycol via hydrolysis of ethylene
oxide is estimated to be 7106 ton/annum [1, 2].
1.2 CHEMISTRY:
Compound contains more than one oly group is called Polyhydric Alcohol (Dihydric
alcohol) or polyols (Diols). Diols are commonly known as Glycols, since they have a
sweet taste (Greek, glycys= Sweet).
Dihydric alcohols because compounds contain two OH groups on one carbon are
seldom encountered. This is because they are unstable and undergo spontaneous
decomposition to give corresponding carbonyl compound and water.
Figure-1[10]
According to IUPAC system of nomenclature, IUPAC name of glycol is obtained by
adding suffix Diol to the name of parent alkanes.
HO OH
H--C---C--H
H H
HO--C---C--OH
H
H H
H--C---C--H
HO
OH
1, 2 Glycol
1, 3 Glycol
1, 4 Glycol
(- Glycol)
(- Glycol)
(- Glycol)
Glycols are Diols. Compounds containing two hydroxyl groups attached to separate
carbon in an aliphatic chain. Although glycols may contain heteroatom can be
represented by the general formula C2nH4nOn-1(OH) 2. [3, 4]
Formula
Common name
IUPAC name
CH2OHCH2OH
Ethylene Glycol
Ethane-1, 2-Diol
1.3 USES:
The following is a summary of the major uses of ethylene glycol:
1.3.1 Antifreeze
engines. Solutions containing ethylene glycol have excellent heat transfer properties
and higher boiling points than pure water. Accordingly, there is an increasing
tendency to use glycol solutions as a year-round coolant. Ethylene glycol solutions are
2
Mixtures of ethylene glycol and propylene glycol are used for defrosting and
de-icing aircraft and preventing the formation of frost and ice on wings and fuselages
of aircraft while on the ground. Ethylene glycol-based formulations are also used to
de-ice airport runways and taxiways as de-icing agent.
against freezing, which would break the emulsion. Carbon dioxide pressurized fire
extinguishers and sprinkler systems often contain ethylene glycol to prevent freezing.
1.3.2 Explosives
sulfuric acid to form solutions of nitroglycerin in ethylene glycol dinitrate, which are
added to dynamite in amounts ranging from 25 to 50%.
1.3.3 Polyester Fibers
The use of ethylene glycol for fibers is becoming the most important consumer
of glycol worldwide. These fibers, marketed commercially under various trade names
like Dacron, Fortel, Kodel, Terylene etc are made by the polymerization of ethylene
glycol with BisHydroxyEthyl Terephthalate (BHET).
1.3.4 Resins
Polyester resins made from maleic and phthalic anhydrides, ethylene glycol,
automobile bodies, boat hulls, suitcases and aircraft parts. Alkyd-type resins are
produced by the reaction of ethylene glycol with a dibasic acid such as o-phthalic,
maleic or fumaric acid. These resins are used to modify synthetic rubbers, in
adhesives, and for other applications.
Alkyds made from ethylene glycol and phthalic anhydride is used with similar
Ethylene glycol is used in hydraulic, brake and shock absorber fluids to help
presses and die casting machines, and in airplane hydraulic systems because of their
relatively low viscosity at high pressure. An added advantage of primary importance
is that these hydro lubes are inflammable.
1.3.6 Capacitors
Ethylene glycol, which is of high purity (iron and chloride free), is used
because it has a low vapor pressure, is non-corrosive to aluminum and has excellent
electrical properties.
1.3.7 Other uses
Ethylene glycol derivatives mainly ether and ester are used as absorption
fluids, Diethylene Glycol is used as a softener (Cork, adhesives, and paper) dye
additive (Printing and stamping), deicing agent for runway & air craft, drying agent
for gases (natural gas).
Poly (ethylene glycol) with varying molecular masses and numerous uses in
CHAPTER II
PROPERTIES
2.1 PHYSICAL PROPERTIES:
Monoethylene glycol and its lower polyglycols are clear, odorless, colorless,
Its solubility is low however in non polar solvents, such as benzene, toluene,
Physical Properties
no.
1.
Molecular formula
C2H6O2
2.
Molecular weight
62
3.
1.1135
4.
197.60
5.
Freezing point oC
-13
6.
52.24
7.
19.07
8.
Critical Temp. oC
372
9.
6513.73
10.
0.1861
11.
Refractive index,
1.4318
12.
0.62 10-3
13.
19.83
14.
1.1135
15.
Flash point, oC
111
16.
410
17.
53
Lower
3.2
CH3CHO + H2O
(Ethylene Glycol)
(Acetaldehydes)
2.1.2 Oxidation
Ethylene glycol is easily oxidized to form a number of aldehydes and carboxylic acids
by oxygen, Nitric acid and other oxidizing agents.
[O]
HOCH2CHO
(Ethylene Glycol)
[O]
HOCH2CH2COOH
(Glycol aldehydes)
CHOCOOH
(Glycolic acid)
(Glyoxylic acid)
[O]
HOOC-COOH
(Oxylic acid)
[O]
HNO3
HOCH2CH2OH
[O]
HOCH2CHO
(Ethylene Glycol)
[O]
CHOCHO
(Glycol aldehydes)
CHOCOOH
(Glyoxal)
(Glyoxylic acid)
temperature is raised.
Na at 50 oC
Na at 160 oC
HOCH2CH2OH
HOCH2CH2ONa
NaOCH2CH2ONa
(Ethylene Glycol)
(Mono Alkoxide)
(Di Alkoxide)
HOCH2CH2Cl
(Ethylene Glycol)
PCl5
(Ethylene chlorohydrins)
ClCH2CH2Cl
(1, 2-Dicholorochlorohydrins)
HOCH2CH2OH
PBr3
HOCH2CH2Br
7
BrCH2CH2Br
(Ethylene Glycol)
(Ethylene Bromohydrins)
(1, 2-Dibromohydrins)
With HCl in two step reaction, form ethylene chlorohydrins at 160oC and
HOCH2CH2Cl
(Ethylene Glycol)
200 oC
ClCH2CH2Cl
(Ethylene chlorohydrins)
(1, 2-Dicholorochlorohydrins)
The largest commercial use of ethylene glycol is its reaction with dicarboxylic
acids (1) to form linear polyesters. Poly (Ethylene Terephthalate) (PET) (2) is
produced by esterification of teraphthalic acid to form BisHydroxyEthyl
Terephthalate (BHET) (3). BHET polymerizes in a transesterification reaction
catalyzed by antimony oxide to form PET.
2HOCH2CH2OH
+
HOOC
COOH
(2)
(1)
Sb2O3
H*
COOCH2CH2OH
HOCH2CH2OOC
OOC
*H
COOCH2CH2
+ HOCH2CH2OH
n
(3)
HOCH2CH2OCH2CH2OH
CH3NH2
CH3
+ 2H2O
(6)
Ketones and aldehydes react with ethylene glycol under acidic conditions to
O
+
HOCH2CH2OH
+ RCOR+
R'
+
R
H2O
(7)
Ethylene glycol reacts with ethylene oxide to form di, tri, tetra and
polyethylene glycols.
CHAPTER III
LITERATURE SURVEY
The literature survey has been done with an aim to obtain information concerning
Ethylene Glycol and its production from number of sources. Such information sources
include chemical abstracts, periodicals and books on chemical technology,
handbooks, encyclopedias and internet websites. The literature survey yielded a lot of
information on Ethylene Glycol. A brief review of information obtained from the
literature survey is presented hereafter.
During the project many Journals, Manuals and Hand book have been sited The
manufacturing process have been taken from Chemical Engineering Journal
107(2005), 199-204. The selectivity and other process parameters have been taken
from Chemical Engineering Journal 107(2005), 199-204. The demand growths,
Major producer in India & World have been taken from Internet.
3.1 DERIVATIVES OF MONO ETHYLENE GLYCOL:
In addition to Oligomers ethylene glycol dervative classes include monoethers,
diethers, esters, acetals, and ketals as well as numerous other organic and
organometalic molecules. These derivatives can be of ethylene glycol, Diethylene
glycol, or higher glycols and are commonly made with either the parent glycol or with
sequential addition of ethylene oxide to a glycol alcohol, or carboxylic acid forming
the required number of ethylene glycol submits.
3.1.1 Diethylene Glycol:
Physical properties of Diethylene glycol are listed in Table. Diethylene glycol is
similar in many respects to ethylene glycol, but contains an ether group. It was
originally synthesized at about the same time by both Lourenco and Wurtz in 1859,
and was first marketed, by Union Carbide in 1928. It is a co product (9 - 10%) of
ethylene glycol produced by ethylene oxide hydrolysis. It can be made directly by the
reaction of ethylene glycol with ethylene oxide, but this route is rarely used because
more than an adequate supply is available from the hydrolysis reaction.
Manufacture of unsaturated polyester resins and polyols for polyurethanes consumes
45% of the Diethylene glycol. Approximately 14% is blended into antifreeze.
Triethylene glycol from the ethylene oxide hydrolysis does not meet market
10
requirements, which leads to 12% of the Diethylene glycol being converted with
ethylene oxide to meet this market need. About 10% of Diethylene glycol is converted
to morpholine. Another significant use is natural gas dehydration, which uses 6%. The
remaining 13% is used in such applications as plasticizers for paper, fiber finishes,
and compatiblizers for dye and printing ink components, latex paint, antifreeze, and
lubricants in a number of applications.
3.1.2 Triethylene Glycol:
Triethylene glycol is a colorless, water-soluble liquid with chemical properties
essentially identical to those of Diethylene glycol. It is a co product of ethylene glycol
produced via ethylene oxide hydrolysis. Significant commercial quantities are also
produced directly by the reaction of ethylene oxide with the lower glycols.
Triethylene glycol is an efficient hygroscopicity agent with low volatility, and about
45% is used as a liquid drying agent for natural gas. Its use in small packaged plants
located at the gas wellhead eliminates the need for line heaters in field gathering
systems as a solvent (11 %) Triethylene glycol is used in resin impregnants and other
additives, steam-set printing inks, aromatic and paraffinic hydrocarbon separations,
cleaning compounds, and cleaning poly (ethylene Terephthalate) production
equipment. The freezing point depression property of Triethylene glycol is the basis
for its use in heat-transfer fluids.
Approximately 13% Triethylene glycol is used in some form as a vinyl plasticizer.
Triethylene glycol esters are important plasticizers for poly (vinyl butyral) resins,
Nitrocellulose lacquers, vinyl and poly (vinyl chloride) resins, poly (vinyl acetate) and
synthetic rubber compounds and cellulose esters. The fatty acid derivatives of
Triethylene glycol are used as emulsifiers, emulsifiers, and lubricants. Polyesters
derived from Triethylene glycol are useful as low pressure laminates for glass fibers,
asbestos, cloth, or paper. Triethylene glycol is used in the manufacture of alkyd resins
used as laminating agents and adhesives.
3.1.3 Tetra ethylene Glycol:
Tetra ethylene glycol has properties similar to Diethylene and Triethylene glycols and
may be used preferentially in applications requiring a higher boiling point, higher
molecular weight, or lower hygroscopicity.
11
Tetra ethylene glycol is miscible with water and many organic solvents. It is a
humectants that, although less hygroscopic than the lower members of the glycol
series, may find limited application in the dehydration of natural gases. Other
possibilities are in moisturizing and plasticizing cork, adhesives, and other substances.
Tetra ethylene glycol may be used directly as a plasticizer or modified by
esterification with fatty acids to produce plasticizers. Tetra ethylene glycol is used
directly to plasticize separation membranes, such as silicone rubber, poly (Vinyl
acetate), and cellulose triacetate. Ceramic materials utilize tetra- ethylene glycol as
plasticizing agents in resistant refractory plastics and molded ceramics. It is also
employed to improve the physical properties of cyanoacrylate and polyacrylonitrile
adhesives, and is chemically modified to form Polyisocyanate, polymethacrylate, and
to contain silicone compounds used for adhesives.
Tetra ethylene glycol has found application in the separation of aromatic
hydrocarbons from nonromantic hydrocarbons (BTX extraction). In general, the
critical solution temperature of a binary system, consisting of a given alkyl-substituted
aromatic hydrocarbon and tetra ethylene glycol, is lower than the critical solution
temperature of the same hydrocarbon with Triethylene glycol and is considerably
lower than the critical solution temperature of the same hydrocarbon with Diethylene
glycol. Hence, at a given temperature, tetra ethylene glycol tends to exact the higher
alkyl benzenes at a greater capacity than a lower polyglycols.
3.2 STORAGE AND TRANSPORTATION:
Pure anhydrous ethylene glycol is not aggressive toward most metals and plastics.
Since ethylene glycol also has a low vapor pressure and is non caustic. It can be
handled with out any problems: it is transported in railroad tank cars, tank trucks, and
tank ships. Tanks are usually made of steel: high grade materials are only required for
special quality requirements. Nitrogen blanketing can protect ethylene glycol against
oxidation.
At ambient temperature, aluminum is resistant to pure glycol. Corrosion occurs,
however, above 100oC and hydrogen is evolved. Water air and acid producing
impurities (aldehydes) accelerate this reaction. Great care should be taken when
phenolic resins are involved, since they are not resistance to ethylene glycol.
12
9.29 lb
0.00065
260F
13
CHAPTER IV
MARKET SURVEY
4.1 ECONOMIC ASPECTS:
Ethylene glycol is one of the major products of the chemical industry. Its economic
importance is founded on its two major commercial uses as antifreeze and for fiber
production. Since Ethylene glycol is currently produced exclusively from ethylene
oxide production plant are always located close to plant that produce ethylene oxide.
The proportion of ethylene oxide that is converted to Ethylene glycol depends on
local condition, such as market situation and transport facilities. About 60% of total
world production is converted to ethylene glycol.
About 50% of the ethylene glycol that is used as antifreeze. Another 40% is used in
fiber industry. Consequently the ethylene glycol demand is closely connected to the
development of these two sectors In view of the increasing price of crude oil,
alternative production method based on synthesis gas is likely to become more
important and increasing competitive.
4.2 LEADING PRODUCERS IN WORLD:
NOCIL, Thane.
Year
Month
Price(US$/MT)
1.
2004
November
1095
December
988
January
1045
4.
February
1095
5.
March
1095
6.
April
971
7.
May
734
8.
June
736
9.
July
808
10.
August
836
11.
September
883
12.
October
883
1st week
830
2nd week
822
2.
2005
3.
13.
November
14.
2002
2003
2004
2005
2006
Capacity
590
615
654
830
830
Production
548
647
691
833
830
Imports
11
64
106
103
90
Exports
29
104
133
60
Demand
551
682
750
803
860
24%
10%
7%
7%
Demand Growth %
15
DESCRIPTION
FIBER GRADE
INDUSTRIAL GRADE
10
Suspended matter
Substantially free
Substantially free
0.08
0.6
0.005
0.02
0.005
0.005
0.08
0.3
0.07
0.05
IBP, C min
196
196
DP, C max
200
199
max
Odor
Practically none
70
250 nm
70
90
275 nm
90
95
350 nm
98
99
1.1151-1.1156
1.1151-1.1156
Completely miscible
16
CHAPTER V
PROCESS SELECTION AND DESCRIPTION
5.1 MANUFACTURING PROCESSES:
Up to the end of 1981, only two processes for manufacturing ethylene glycol have
been commercialized. The first, the hydration of ethylene oxide, is by far the most
important, and from 1968 through 1981 has been the basis for all of the ethylene
glycol production.
Manufacturing process involves laboratory methods and industrial methods.
5.1.1 Laboratory methods: [3, 4]
sodium carbonate solution. This reaction mixture is refluxed till an oily globule of
ethylene bromide disappears. The resulting solution is evaporated on a water bath and
semi solid residue is extracted with ether-alcohol mixture. Glycol is recovered from
solution by distillation. The best yield of glycol (83-84%) can be obtained by heating
ethylene bromide with potassium acetate in Glacial acetic acid.
formaldehyde.
simple, and can be summarized as follows: ethylene oxide reacts with water to form
glycol, and then further reacts with ethylene glycol and higher homologues in a series
of consecutive reactions as shown in the following equations.
17
H2C
O
O
O
H
H
Ethylene Glycol
Ethylene Oxide
CH2
H2C
CH2
+ H2C
CH2
H2C
+ H2C
CH2
O
H
O
H
H2C
O
H
CH2
Diethylene Glycol
CH2
CH2
O
H
O
H
CH2
CH2
H2C
O
H
O
H
CH2
H2C
+ H2O
CH2
CH2
CH2
CH2
CH2
CH2
O
H
Triethylene Glycol
Ethylene oxide hydrolysis proceeds with either acid or base catalysis or uncatalyzed
in neutral medium. Acid-catalyzed hydrolysis activates the ethylene oxide by
protonation for the reaction with water. Base-catalyzed hydrolysis results in
considerably lower selectivity to ethylene glycol. The yield of higher glycol products
is substantially increased since anions of the first reaction products effectively
compete with hydroxide ion for ethylene oxide. Neutral hydrolysis (pH 6-10),
conducted in the presence of a large excess of water at high temperatures and
pressures, increases the selectivity of ethylene glycol to 89-91%. In all these ethylene
oxide hydrolysis processes the principal byproduct is Diethylene glycol. The higher
glycols, i.e., Triethylene and Triethylene glycols, account for the remainder.
Although catalytic hydration of ethylene oxide to maximize ethylene glycol
production has been studied by a number of companies with numerous materials
patented as catalysts, there has been no reported industrial manufacture of ethylene
glycol via catalytic ethylene oxide hydrolysis. Studied catalyst include sulfonic acids,
carboxylic acids and salts, cation-exchange resins, acidic zeolites, halides, anion-
18
exchange resins, metals, metal oxide and metal salts. Carbon dioxide as a co catalyst
with many of the same materials has also received extensive study.
CH2
+ HOCl
+ NaOH
HOCH2CH2Cl
HOCH2CH2Cl
HOCH2CH2OH
(8)
NaCl
(9)
NaCl
(10)
O
HOCH2CH2Cl
Ca(OH)2
CH2
CH2
O
CH2
CH2
+ H2O
HOCH2CH2OH
(11)
methanol, hydrogen, and formaldehyde until 1968 at Belle, West Virginia. The
process consisted of the reaction of formaldehyde, water, and carbon monoxide with
an acid catalyst to form glycolic acid. The acid is esterified with methanol to produce
methyl glycolate. Subsequent reduction with hydrogen over a chromate catalyst yields
ethylene glycol and methanol. Methanol and formaldehyde were manufactured on site
from syngas.
CO
CH2O
HOOCCH2OH
CH3OOCCH2OH
H2O
H+
CH3OH
H2
HOOCCH2OH
CH3OOCCH2OH
Cr2O3
HOCH2CH2OH
+
+
+
NaCl
(12)
H2O
(13)
CH3OH
(14)
Coal was the original feedstock for syngas at Belle; thus ethylene glycol was
commercially manufactured from coal at one time. Ethylene glycol manufacture from
syngas continues to be pursued by a number of researchers.
19
oxygen, and ethylene react with a catalyst to form the glycol mono and diacetate.
Catalysts can be based on palladium, selenium, tellurium, or thallium. The esters are
hydrolyzed to ethylene glycol and acetic acid. The net reaction is ethylene plus water
plus oxygen to give ethylene glycol. This technology has several issues which have
limited its commercial use.
CH3COOH
+ CH2
CH2
O2
Te2Br2
CH3COOCH2CH2OH + CH3COOCH2CH2OOCCH3
CH3COOCH2OOCCH3
3 H2O
2 HOCH2CH2OH + 3 CH3COOH
(15)
(16)
The catalysts and acetic are highly corrosive, requiring expensive construction
materials. Trace amounts of ethylene glycol mono-and diacetates are difficult to
separate from ethylene glycol limiting the glycols value for polyester manufacturing.
This technology (Halcon license) was practiced by Oxirane in 1978 and j1979 but was
discontinued due to corrosion problems.
C
O
2 CH3OH
Zr2Cl4
HOCH2CH2OH
CO(CH3O)2
(18)
Selectivity to ethylene glycol are excellent with little Diethylene glycol or higher
glycols produced. A wide range of catalysts may be employed including ion exchange
resins, zirconium and titanium compounds, tin compounds, phosphines, acids and
bases. The process produces a large quantity of dimethyl carbonate which would
require a commercial outlet.
Oxalic acid produced from syngas can be esterified and reduced with
20
HOOCCOOH
ROOCCOOR
2 ROH
4 H2
ROOCCOOR
Cu
HOCH2CH2OH
2 H2O
2 ROH
(20)
(21)
The Teijin process, which has not been commercialized to date, produces
ethylene glycol by the reaction of ethylene with thallium salts in the presence of water
and chloride or bromide ions. The major by-product in the reaction is acetaldehyde.
A redox metal compound (such as copper) oxidizable with molecular oxygen is added
to the reaction medium to permit the regeneration of the thallium salt.
The DuPont process, based on feeds derived from synthesis gas (CO and
21
PROCESSES
PARAMETER
CATALYST
ADVANTAGES/DISA
NO
1.
DVANTAGES
Hydrolysis
of 1) Non- catalytic
Ethylene Oxide
Yield
1)Non
98% Catalytic
Selectivity: 98%
Temp:105oC
Pressure
1.5MPa
Carboxylic
2) catalytic:
Yield
which
95% Ion-exchange
2)
leads
High
to
yield
low
&
zeolites,
Pressure :
1-30 bar
oxide
Metal salts.
the
reaction
solution
highly corrosive.
2.
Non Catalytic
selectivity
very costly
chlorohydrins
3.
Temp: 200oC
CO,H2,CH3OH
Pressure:
&
100atm
High
Cromate
Catalyst
Discontinued now a
day
Low selectivity
halide Give high yield and
Alkali
from
or ammonium
carbonate
pressure
process
Formaldehyde
4.
Temp:180oC
salt.
selectivity
Utility saving
Extra
Pressure:13bar
cost
22
purification
5.
6.
Transesterificati
Low yield
Zirconium
& Produced
large
on of ethylene
titanium
amount
carbonate.
compound.
byproducts
Copper
catalyst
catalyst removal is
Reduction with
of
very difficult.
H2
7.
As
Rhodium
synthesis
catalyst
(Homogeneous
catalyst route.)
economical.
of Temp:
Pressure:
crude
prices
3400atm
pressure
Not prove to be
indirect route may
be viable or not.
Catalyst
sensitive
is
very
and
expensive.
8.
Hydrolysis
of Yield : 90%
Pd complexes
pdcl2+NaNO3
Temp: 160oC
Pressure:
2.4MPa
H2O+C2H4O
Ko
C2H4O + HOCH2CH2OH
HOCH2CH2OH
Ki
HO (CH2CH2O)2 H
23
---------------- (1)
---------------- (2)
Now all ethylene and propylene glycols is produced in industry by a non catalyzed
reaction. Product distribution in reaction (1) is regulated by the oxide/water ratio in
the initial reaction mixture. The distribution factor b = k1/k0 for a non catalyzed
reaction of ethylene oxide with water is in the range of 1.92.8. For this reason large
excess of water (up to 20 molar equiv.) is applied to increase the monoglycol yield on
the industrial scale. This results in a considerable power cost at the final product
isolation stage from dilute aqueous solutions. i.e. energy consumption for the
distillation of large amount of excess water is high. Also the selectivity of ethylene
oxide hydrolysis is low i.e. 10% is converted to Diethylene glycol and tri ethylene
glycol.
One of the ways of increasing the monoglycol selectivity and, therefore, of decreasing
water excess is the application of catalysts accelerating only the first step of the
reaction (1). There are much research has been carried out to improve this process.
The search for better catalyst is an objective for increase the selectivity and decrease
the excess water. As evident from the kinetic data the distribution factor b = k1/k0 is
reduced -0.10.2 at the concentration of some salts of about 0.5 mol/l. This enables to
produce monoethyleneglycol with high selectivity at waterethyleneoxide molar ratio
close to 10.
5.2.2 Catalyst:
A cross-linked styrenedivinylbenzene anion exchange resin (SBR) in the HCO3/
CO3- form, activated by anion exchanging with sodium bicarbonate solution used as
catalysts. (Dow Chemical produced anion-exchange resins: DOWEX SBR). The
ethylene oxide hydration process in a catalytic fixed-bed tube reactor was studied .The
properties of initial resins are summarized below:
Functional group
- [PhN (CH3)3] +
1.4
0.3-1.2
5.3.1
Ethylene oxides mixed with recycle water and pumped to glycol reactor where it is
reacted with water at 1050C &1.5 MPa in the presence of catalyst. The Reactor is
Catalytic Plug flow Fixed bed type. The reaction volume consists of two phase, the
liquid phase and ionite (catalyst) phase. The liquid streams through catalyst bed in a
plug flow regime. The catalytic and non catalytic ethylene oxide hydration takes place
in the ionite phase, and only non catalytic reaction takes place in the liquid phase. The
distribution of the components of the reaction mixture between liquid and ionite
phases is result of the rapid equilibrium. The glycol reactor operate at approximately
1.5MPa.pressure which is supplied by the reactor feed pump. The reactor effluent
goes to the evaporation unit for the evaporation of excess water.
5.3.2
pump to MEG refining column. Where the MEG is separated from the higher glycol,
Water vapors leaving the top of the drying column are fed to MEG recovery unit for
glycol recovery. (An inert gas line is provided at the base of the drying column for
breaking the vacuum).
5.3.4
Drying column bottoms essentially free of water are fed to the MEG refining column.
(PACKED COLUMN). About 15% of the feed to the MEG column enters as vapor
due to flashing. MEG product is withdrawn from the top of the column. Some MEG is
purged in the overhead to the vacuum jets to reduce the aldehydes in the product. The
MEG column bottoms primarily di-ethylene glycols are pumped from the column
bottom to the storage tank. The MEG column operates at a pressure of 10mmHg (A).
The vacuum is maintained by MEG column ejector system. The MEG column
condenser is mounted directly on the top of the MEG column.
5.3.5
The MEG leaving along with water from the Top of the multiple effect evaporator &
drying column are recovered in the MEG Recovery Column (PLATE COLUMN).
The column is operated under Atmospheric pressure.MEG leaving from the bottom of
the column and the water leaving from the top of the column are Recycle to reactor.
26
CHAPTER VI
MATERIAL BALANCE
Material balances are the basis of process design. A material balance taken over
complete process will determine the quantities of raw materials required and products
produced. Balances over Individual process until set the process stream flows and
compositions. The general conservation equation for any process can be written as
Material out = material in + accumulation
For a steady state process the accumulation term is zero. If a chemical reaction is
taking place a particular chemical species may be formed or consumed. But if there is
no chemical reaction, the steady state balance reduces to:
Material out = Material in
A balance equation can be written for each separately identifiable species present,
elements, compounds and for total material. [10]
6.1 BASIS:
Basis: 100000TPA
The process is planned and developed as a continuous process. A plant is operated for
24 Hours per day and 333 per year.
No of working days = 333days
Capacity =
1000000
333
= 300.3 T/days
= 201.47 Kmol/hr.
: 62
Water
: 18
: 44.01
Water [H2O]
: 18
Nitrogen [N2]
: 28
27
= 204.70 Kmol/hr.
6.3.1 Reactor:
REACTOR
Temp. = 100 0C
Water
= 37597.68 Kg
= 2088.76 Kmol
Conversion = 100 %
Higher glycol = 2.088 Kmol
= 221.328Kg
Pressure = 1.5-2MPa
C2H4O +
H2O
HOCH2CH2OH
--------- (1)
C2H4O + HOCH2CH2OH
(Higher Glycol)
As selectivity = 98%
Moles of undesired product formed =
204.70
98
= 2.088 Kmol
Moles of MEG to be produced from reactor = 206.788kmol
Moles of ethylene oxide reacted by reaction I
= 206.788 Kmol.
Moles of ethylene oxide reacted by reaction I I
28
= 2.088 Kmol.
Total Moles of ethylene oxide reacted = 206.788 + 2.088
= 208.876 Kmol.
As conversion = 100%
[6]
Moles of ethylene oxide charged = 208.876kmol
From the literature we know that the ratio of WATER TO ETHYLENE OXIDE =10
Amount of water fed to reactor = 2088.76 Kmol. (Including excess)
From the reaction moles of water reacted = 206.788 Kmol.
M.B.ON WATER:
Moles of water fed = Moles of water reacted + Moles of water unreacted
2088.76
M.B.ON MEG:
Moles of MEG in the product = 206.788 2.088
= 204.7 Kmol
Table 6.1 Material balance over reactor
Component
In, Kg
Out, kg
Ethylene oxide
9190.54
Water
37597.68
33875.496
12691.4
Higher Glycol
221.328
= 0.851881.972
= 1599.6762 Kmol.
= 28794.1715 Kg
= 28794.1716 kg.
Remaining 15% water are still in the bottom along with the MEG and Higher glycol.
Amount of water in the bottom
= 1881.972-1599.6762
= 282.2958 Kmol.
= 5081.324 Kg
There is some quantity of glycol carry over along with water from the top of
evaporator.
Amount of glycol carry over along with water from 1st effect
= 165.58 kg
W1= 8285.66kg
MEG = 165.58kg
H2O = 8120.08kg
F = 2088.76 Kmol
= (46788.224 kg)
M.E.G = 204.7Kmol
= 12691.4 Kg
Water =1881.972 Kmol
= 33875.496Kg
Pressure = 7 kg/cm2
Temp = 159 oC
Amount of glycol carry over along with water from IIst effect = 189.139kg
W2= 9689.31kg
MEG = 189.139kg
H2O = 9500.171kg
30
Amount of glycol carry over along with water from IIst effect = 335.064 kg
W3= 11508.96kg
MEG = 335.064kg
H2O = 11173.89kg
To MEG Refining
column
X = 477.9588
Kmol
In, Kg
Out, Kg
Liquid phase
Vapor phase
Water
33875.496
5081.355
28794.141
MEG
12691.4
12001.617
689.783
HG
221.328
221.328
31
F = 477.9588 kmol
Drying column
= 17304.2585 kg
MEG = 12001.606kg
H2O = 5081.324 kg
.
X = 188.306 Kmol
HG = 221.328kg.
= 11766.873 kg
MEG = 186.218kmol
= 115453545kg
HG = 2.088 Kmol
= 221.328kg
= 5018.324 Kgm
= 282.295 Kmol.
There is some quantity of glycol carry over along with water from the top of drying
column
Amount of glycol carry over along with water from drying column = 456.061kg
=7.3558 Kmol.
(Finding using VLE calculation)
Total quantity leaving from top of drying column
= (Amount of water +Amount of MEG)
= 282.295 +7.3558
= 289.65 Kmol.
TAKING OVERALL M.B
F =Y+X
477.9588 = 289.65 + X
X = 188.306 Kmol.
(Total quantity leaving from the bottom of drying column)
Now ,
Total amount of MEG leaving along with water during evaporation of water
32
In, Kg
Out, Kg
Liquid phase
Vapor phase
Water
5081.324
5081.324
MEG
12001.606
11545.3545
456.061
HG
221.328
221.328
D= 184.54 Kmol
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
F = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
HG = 0.18454kmol
Pressure = 10 mmHg
Temp = 93.2 oC
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
33
Assuming 99% recovery, of total MEG feed to distillation column, is obtained in the
distillate.
Kmol of Distillate
(D)
= 184.355 / 0.999
= 184.54 Kmol / hr.
= 184.54 x 62.04
= 11448.8618 kg / hr.
Amt. of HG in Distillate
= 184.54 x 0.001
= 0.18454 Kmol / hr.
= 0.18454 x 106
= 19.561 kg / hr.
= 0.4918 x 3.766
= 1.8521 Kmol / hr
Kmol of HG in Bottoms
= 0.5081 x 3.766
= 1.9135 Kmol / hr.
34
In, Kg
Out, Kg
Liquid phase
Vapor phase
MEG
11545.545
114.8426
11430.01
HG
221.328
202.8416
19.56124
D= 1881.97kmol
= 11766.873 kg
MEG =1.88kmol
H2O =1880.08kmol
F = 1900.451kmol
= 35021.339 kg
MEG = 18.481kmol
=1145.844kg
Plate column
H2O =1881.97kmol
= 33875.496kg.
W = 18.481kmol
=1205.55 kg
MEG = 17.122kmol
H2O = 1.3584kmol
= 1881.97 x 0.999
= 1880.08 Kmol / hr
Kmol of Distillate
(D)
= 1880.08 / 0.999
= 1881.97 Kmol / hr.
= 1881.97 x 18.044
35
= 33958.266 kg /hr
= 1881.97 x 0.001
= 1.88 Kmol / hr
= 1.88 x 62
= 116.56 kg/ hr.
Amount of feed ( F )
= 1900.451 Kmol/hr
= 35021.339 kg/hr.
= 18.481 x 0.9264
= 17.122 Kmol / hr
= 17.122 x 62
= 1061.56 kg/hr.
= 18.481 17.130
= 1.3584 Kmol / hr
= 1.3584 x 18
= 143.99 kg/ hr.
In, Kg
Out, Kg
Liquid phase
Vapor phase
Water
33875.496
24.4512
33841.44
MEG
1145.844
1061.546
116.56
36
Reactor
Triple
Component
In, kg
Out, Kg
Liquid phase
Vapor phase
Ethylene oxide
9190.54
Water
37597.68
33875.496
MEG
12691.4
HG
221.328
33875.496
5081.355
28794.141
MEG
12691.4
12001.617
689.783
HG
221.328
221.328
Water
5081.324
MEG
12001.606
11545.3545
456.061
HG
221.328
221.328
11545.545
114.8426
11430.01
221.328
202.8416
19.56124
33875.496
24.4512
33841.44
1145.844
1061.546
116.56
effect Water
evaporator
Drying column
5081.324
column
HG
MEG recovery Water
column
MEG
37
CHAPTER VII
ENERGY BALANCE
The first law of thermodynamics demands that energy be neither created nor
destroyed. The following is a systematic energy balance performed for each unit of
the process. The datum temperature for calculation is taken as 0C.
The different properties like specific heat, heat of reaction, heat of vaporization, etc.
are taken to be constant over the temperature range.
7.1 REACTOR: [9,11]
REACTOR
Ethylene Oxide = 9190.54 Kg
= 208.876 Kmols
Water
Temp. = 100 0C
Conversion = 100 %
= 37597.68 Kg
= 2088.76 Kmol
Pressure = 1.5-2MPa
H2O
HOCH2CH2OH
(Water)
C2H4O + HOCH2CH2OH
HOCH2CH2OH
IN
Ethylene oxide
Water
OUT
MonoEthyleneGlyocol
Di-EthyleneGlyocol
Water
(Higher Glycol)
kmol
C p ( kj
kmol k
99.106
75.673
-454800
-285831
-562570
75.673
189.39
441.602
------------ (2)
-77704
-285830
------------- (1)
H 0 f H 0 fp H 0 f R
38
H 0 f H 0 fp H 0
fR
H R0 H p H 0
H R
= m x Cp x T
= m x 75.79627 x 20
= 2.8394 x 103 Kg / hr (cooling rate) [9,11]
39
F = 2088.76 Kmol
= (46788.224 kg)
M.E.G = 204.7Kmol
= 12691.4 Kg
Water =1881.972 Kmol
= 33875.496Kg
H.G = 2.088
Kmol
Second
effect:
= 221.328Kg
Pressure = 7 kg/cm2
Temp = 159 oC
To 2nd
effect evaporator
To 3rd effect
evaporator
Third effect:
rd
From 3 effect
evaporator
40
To MEG Refining
column
X = 477.9588
Kmol
Steam or
, KJ/Kg
, KJ/Kg
e, KPa
vapor
(Steam)
(MEG)
temp. C
Steam chest, 1
st
1179.69
TS= 190.82
S = 2210.8
794.63
t1=175.17
1 = 2244.1
1 = 982.935
409.57
t2=152.585
2 = 2284.0
2 = 1001.15
24.53
t3= 106.155
3 = 2379.1
3 =1022.317
effect
Steam chest,
2nd effect
Steam chest,
3rd effect
Vapor to
condenser
w1 = 0.9787WS 6830.42
----------------------------- (1)
w1 + w2 + w3 = w1-3
0.9787WS 6830.42 +0.9022WS 4245.22 + 0.70WS 697.42 = 28794.1716 +
689.783
3
w1 = 8285.66 Kg/hr
w2 = 9689.31 Kg/hr
w3 = 11508.96 Kg/hr
Now , Enthalpy out from the bottom of the last effect,
Tbottom = 122oC
Trefrence = 25oC
T = 97oC.
Enthalpy out from Bottom = (mCpT )MEG + ( mCpT )WATER + ( mCpT )HG
= [(12001.606 x 3.077) + (5081.324 x 4.378) + (221.328 x 4.1032)] x 97
= 5.828 x 106 KJ / hr
42
F = 477.9588 kmol
= 17304.2585 kg
MEG = 12001.606kg
Drying column
Pressure = 0.21 kg/cm2
Temp = 87 oC
X = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
= 115453545kg
Toperating = 87 oC
Trefrence = 25 oC
HG = 2.088 Kmol
= 221.328kg
.
Hence T = 62 C.
o
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
HG = 0.18454kmol
F = 188.306 Kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
Pressure = 10 mmHg
Temp = 93.2 oC
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
V=L+D
= 0.71D + D
= 0.71 x 184.355
V = 315.247 kmol / hr
Reflux L = 0.71D
= 0.71 x 184.355
L = 130.89 kmol / hr
Enthalpy out with vapor:
QV = latent heat + sensible heat associated with that vapor
= m + (mCpT)
MEG = 68.578 x 103 kJ / kmol
DEG = 72.067 x 103 kJ / kmol
AVEG = 68.58 x 103 kJ / kmol
QV = [(315.247 x 68.58 x 103) + (315.247 x 188.298 x 66.8)]
= 25.58 x 106 kJ / hr
Enthalpy out with Reflux:
QReflux = ( mCpT )Reflux
= [ 130.89 x 188.551 x 66.8 ]
= 1.6485 x106 kJ / hr
45
Condenser load, QC :
= QV ( QReflux + QD )
= [(25.58 x 106 ) (1.6485 x106 + 2.341 x 106 )]
= 21.595 x 106 kJ / hr
Assuming cooling water enters the condenser at 25oC & leave at 45oC
QC = (mCpT )cooling water
21.595 x 106 = m x 75.7962 x 20
m = 11.63 x 103 kg / hr (Rate of cooling water)
7.4.2 For bottom:
Tbottom = 94.6 oC
= 69.6 oC
21.794 x 106 kJ / hr
D= 184.54 Kmol
= 11448.8616 kg
MEG = 184.355kmol
(0.999.high purity)
F = 188.306 Kmol
HG = 0.18454kmol
= 11766.873 kg
Plate column
MEG = 186.218kmol
=11545.545kg
HG =2.088kmol
= 221.328kg
W = 3.766 Kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
Trefrence = 25oC
T = 169 oC
Poperating = 760 mmHg
Cpmean of MEG = 197.24 kJ / kmol oK
Cpmean of H2O
= 76.55 kJ / kmol oK
= 0.51 x 1881.97
V
= 2841.77kmol / hr
Reflux L = 0.71D
= 0.51 x 1881.97
L = 959.80 kmol / hr
Enthalpy out with vapor:
QV = latent heat + sensible heat associated with that vapor
= m + (mCpT)
MEG = 1023.184 kJ / Kg
H2O = 2231.8 kJ / Kg
48
Trefrence = 25oC
= 173 oC
Cpmean of H2O
= ( mCpT )feed
= [(18.481 x 187.97) MEG + (1881.97x 74.51) WATER] x 80
= 143.71x 103 kJ / hr
Reboiler load
QB = [( 603.39 x 103 + 172.12 x 106 + 24.40 x 106 ) (143.71x 103) ]
= 196.97 x 106 kJ / hr
Amount of steam required,
Consider the steam enter at 2 kg/cm2 & 118.719oC
steam =2037.51 kJ / kg
QB = m steam
196.97 x 106 = m x 2037.51
m = 97.67 x 10 3 kg / hr ( Rate of steam )
49
[9,11]
CHAPTER VIII
REACTIONS KINETICS & THERMODYNAMICS
REACTOR
E. O = 9190.54 Kg
= 208.876 Kmols
Temp. = 50 0C
Conversion = 100
Water = 37597.68 Kg
= 2088.76 Kmol
Here,
FAO
208.876 Kmol/hr
9190.544 Kg/hr
V0
10.649 m3/hr
FAO
= CAO V0
= 19.6136 Kmol/m3
= 19.6136 mol/lit
Similarly,
CBO
= 5.555 Kmol/m3
= 55.555 mol/lit
dt
Where,
Gyi
d (C2H4O)
= rA
dt
K0
T
where T = temperature o K
K0
= 1.5627 x 10-7
K0
L2
= 0.0005625
mol2. Sec
L2
mol2. hr
Kct
T
= 5.926 x 10-5
Kct
L2
= 0.21334
mol2. Sec
L2
mol2. hr
Now,
CAO XA
CBO XB
b
19.6136 XA
1
55.555 XB
1
XB = 0.3530 XA
- rA
- rA
51
0.1
654.5
0.005
0.2
532.40
0.3
424.57
0.4
330.131
0.5
248.286
0.6
0.7
178.2369 119.1836
0.8
70.31
0.9
30.86
0.98
53.60
0.0018
0.0023
0.00302
0.00402
0.00561
0.01
0.03
0.186
1
) & finding the area under he curve at
rA
Xa = 0.98
FAO
d XA
0
- rA
XA
d XA
0
0.0084
- rA
52
V
FAo
= 0.01227
= 2562.90 lit
= 2.56 m3
Now we have
Volume of Catalyst
Total bed Volume
1 =
Volume of Catalyst
2.56 m3
Consider = 0.6
Total Volume of Catalyst = 1.024 m3
8.2 THERMODYNAMICS
As we know the Gibbs free energy is given by following equation
G = -RT lnK
Where K = Kequ = (ka * kb)/ (kc * kd)
From reaction,
ka and kb are rate constants for the products.
Similarly kc and kd are rate constants for the reactants. But assuming reaction is
exothermic and irreversible; the values of kc and kd will not be in consideration to
finding out equilibrium rate constant.
Hence, Kequ is given by
Kequ = ka kb
Enthalpy, Gibbs free energy and specific heat data are below at reaction temperature
100 0C in the form of functional group. [11]
53
H2O
HOCH2CH2OH
G = [(-81.31)]-[(-23.12) + (-8.728)]
G = - 49.53 KJ/Kmol K
Ka = exp [-(-49.53) / (8314*373)]
Ka =1.00
ln(K2/K1)= E/R[(1/T1)-(1/T2)]
--------- (1)
[15]
ln(9.5/8)= E/8.314[(1/368)-(1/373)]
T2 reaction at 100 oC= 373K
T1 reaction at 95 oC=368K
0.26236 = 6.2382* E *10-6
E = 7.52*E*-7 J/mol
54
CHAPTER IX
MAJOR EQUIPMENT DESIGN
9.1
Consider the reactants are flow on tube side and cooling water are on shell side
Catalysts are fill inside the tube.
9.1.1 Process Design: [22]
Consider length of tube
Diameter of tube
= 4m
= 2.5 cm
(d)2 (L)
4
(2.5 x 10-2)2 (4)
4
1.9634 x 10-3 m3
=
=
=
Shell Side
(Water) (30oC )
5.1865 (KJ/Kg oK)
9 x 10-4 (Kg/m.Sec)
0.62 (w/m.oK)
995.40 (Kg/m3)
No. of tube
=
No. of tubes
Tube side
(Ethylene oxide + H2O) (65oC)
4.840 (KJ/Kg oK)
4.187 x 10-4 (Kg/m.Sec)
0.54 (w/m.oK)
973.09 (Kg/m3)
Volume of reactor
Volume of one tube
2.56
0.001963
= 1304 Nos.
=
=
Atp
(d) 2 (Ntp)
4
(2.5 x 10-2)2 (1304)
4
0.64 m2
Velocity:
m
U=
Atp
55
m = 12.996 Kg/Sec
12.996
U =
973.09 x0.64
U
= 0.02 m/sec
Now,
NRe
du
x(1 )
(2.5 x 10-2) x (0.02) x (973.09)
(4.187 x 10-4) x (1 -0.6)
2905.09
=
=
Now,
NRe
AO
=
=
=
AO
Nt x x d xL
(1304) x x (2.5 x 10-2) x (4)
409.66 m2
Shell diameter:
Ds
CL Aox ( PR 2 xdo)
0.637
L
Ctp
0.5
Ds
0.637
Ds
1.123 m
0.7
0.9
__(Ds)2
0.875 CTP
(PR)2 (d)2
CL
=
____(1.123)2
0.875 0.9
(1.25)2 (0.025)2
0.7
=
(hoxDe)
k
DexGs
= 0.36 x
0.55
Cpx
x
k
56
0.333
x b
w
0.14
0.5
De
3 PT2 d2
2
4
d
Pitch ratio
= PR
1.5=
De
PT
d
PT
0.0025
PT
= 0.03125 m
4
x 0.0025
De =
As
0.018 m
Gs =
m
As
DsxCxB
PT
=
=
=
PT do
0.03125 0.025
0.00625
=
=
=
0.4 Ds
0.4 x 1.125
0.45
As
As
= 0.101 m2
m
=
As
Gs
=
Gs
12.996
0.10
= 128.58 Kg/m2.sec
57
(hox0.018)
0.62
0.018 x128.58
0.36 x
9 x10 4
w
1825.04 20
m k
ho
0.55
x
0
.
62
0.333
x1
0.14
Nu
hixdi
k
= 0.023x(2905.09)0.8 x(
(Cp ) 0.4
)
k
672.163
w
m 20k
1
Uo
1
1
0.005
ho hi
1
1
0.005
1825.08 672.163
Uo = 142.133
w
m 20k
Now,
Total H.T area available = 409.66 m2
Rate of H.T. is given by
Q
= UAT
(1.1956 x 106) =
A
117.03 x A x 20
gc x ()3 x Dp x
150 (1 )
=
(1 ) (G)2
+ 1.75
Nre
150 x (0.4)
2905.09
58
+ 1.75
P
Z
Shell side P:
P
f x (Gs2) x (Nb + 1) x Ds
2 x x Dex s
f
= 0.3977
= 1
Nb
= L/B = 4 / 0.45
= 8.88 9
P =
P =
15 N / m2
Pd
D
C
2 f J Pd
1.575 x 1.123
+ 0.2
ts = 14 mm
59
D= 184.54 kmol
= 11448.8616 kg
D
I
S
T
I
L
L
A
T
I
O
N
F = 188.306 kmol
= 11766.873 kg
MEG = 186.218kmol
=11545.545kg
HG =2.088kmol
= 221.328kg.
MEG =
184.355kmol
(0.999.high purity)
HG = 0.18454kmol
W = 3.766 kmol
= 317.664 kg
MEG = 1.8523kmol
HG = 1.9136kmol
Steam
Condensate
PROCESS DESIGN:
Let ,
Mole fraction of MEG
XF= 0.9889
XD = 0.999
XW = 0.4918
top
So,
1.334 / 0.1333
= 10.077
Psat MEG = 1.4757 KPa
Now at bottom
So,
= 1.4757 / 0.1673
= 8.8174
Thus, average = { top x bottom }0.5
= {10.007 x 8.8174}0.5
average = 9.3933
Now we have the equation
Y = X / {1+ (-1)}
From the above eqn we can generate the vapor- liquid equilibrium data given as
follow.
Table-9.2 Vapor-Equilibrium data
X 1 0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Now plotting x-y diagram & Using McCabe Theile method for determining the
theoretical stages.
no. of theoretical stages = 18
9.2.2 Packed Column Diameter And Column Height:
The necessary data required is as follows :
Reflux Ratio
= 0.71
Feed
Kmol of Feed F
= 188.306 kmol
Kmol of Distillate D
= 184.54 kmol
Kmol of Bottom W
= 184.54 kmol
Liquid density L
= 954 Kg/m3
61
Vapor Density G
= 2.099Kg/m3
Liquid Viscosity
(375.5634 x 62.044)
(3600)
M g = 6.4726 Kg /s
Mass flow rate of liqid
Ml =
131.0234 x62.044
3600
M l = 2.2581 Kg /s
Flow parameter
X
Ml
Mg
g l
--------------------------- (2)
=2.099Kg/m3
l = Density of liquid
=954 Kg/m3
2.2581
6.4726
2.099
(954 2.099)
X = 0.01638
By using plot of flooding and Pressure drop.
62
g l
Ml
Mg
Y
V/S
G 2 f P l0.1
P
Take,
50
Z
m 2 ref.
m
We get Y = 0.0125
G 2 f P l0.1
----------------------------------------- (3)
Owing to its low-pressure drop, the metal pall ring is used as a packing for vacuum
distillation,
Pall Ring (Metal):
Size: 38 mm (1.499)
Packing Factor fp (m-1) = 131
Deigned H.E.T.P. (m) = 0.5425
= Viscosity of liquids = 2.2 x 10-3 Kg/m s
g = Density of gas = 2.099 kg / m3
l = Density of liquid = 954 kg / m3
G' in kg / m2. s
Y
G'2
G 2 f P l0.1
G'2 = 0.3515 kg / m2 s
G = 0.5929 kg / m2 s
Taking vapor mass velocity as 60% if flooding velocity.
Hence, Area of tower =
At
Mg
0.6 G
At
D2
= 18.19
10 + 2 + 2
= 14 m
MECHANICAL DESIGN [23, 24, 26]
9.2.3 Shell Design:
Shell Thickness (based on external pressure):
Diameter of tower = Di = 5m
Height of column = 14 m
Pressure inside column is vacuum.
Outside pressure is 1 atm = 0.1 MN /m2
Hence design pressure = Pd = 0.1 x 1.05
= 0.105 MN /m2
Shell is I.S. 2825-1969
Allowable stress = f = 98.1 MN /m2
Welding joint efficiency factor = J = 0.85
Thickness of shell,
The inside depth of the end can be calculated from the following correlation,
hi = Ri -
Ri Di / 2x( Ri Di / 2 2ri
64
Ri = 5m
Di = Do =5m (initial approximation)
ri = 0.1 x Ro
= 0.5m
hi = 5 -
(5 5 / 2) x(5 5 / 2 2 x0.5)
= 0.9686 m
Effective length of tower W/O stiffner = (Tangent to Tangent length + 2/3 x hi)
= 12 + 2/3x 0.9688
= 12.6459m
Do / L = 5/ 12.6459
= 0.3953
K value corresponding to this = 0.246 & m =2.43
Modulus of elasticity E = 1x 105 MN/m2
Corroded shell thickness,
P = KxE x (t/Do)m
0.105 = 0.246 x 1 x 105 (t/4)2.43
t = 0.02467 m
Take standard thickness = 26 m
t = 26 m
Checking for plastic deformation,
1
1 [1.5U (1 0.2 Do / l ) / 100 x(t / Do)]
P = 2x f x t/Do x
1
1 [1.5 x1.5(1 0.2 x0.3953 / 100 x0.00482)]
= 454.68 cm
Temperature = Td
= T + 50 oC
= 95 + 50
= 145 oC
Ro / t
Ro / 100t
Factor B
1.2
378.9
3.78
4400
0.7402
1.3
349.75
3.49
4500
0.8201
(assumed)
P=
factB
14.22 xRo / t
1.4
324.77
3.24
4800
0.9421
1.5
303.2
3.03
5000
1.051 Pdesign
th = 1.5 +0.2
th = 17 mm
Standard thickness available
th = 18 mm
s = 78480 N/m3
Insulation = Asbestos
in = 5.64*103 N/m3
tin =50 *10-3 m
Shell thickness without corrosion allowance = 26
= 0.026m
Do = 5.052m
Vessel is Located in non seismic zone
Determination Of Longitudinal Stresses:
p = P x Do / 4 x ts
= 1.05 x 5.052 / 4 x 0.026
= 51.005 MN/ m2
s x X
= 0.7848 X MN / m2
( b) Stress due to insulation in
in = tin x in x X/ ts
= 0.05 x ( 5.64*103 ) x X / 0.026
in = 0.01084 X MN / m2
(c ) Stress due to liquid and packing load in column
Volume of bed = x D2x H /4
= x 52 x 10
= 196.3495 m3
Consider void fraction for packing = 0.5
Liquid hold up = Vb x
= 196.3495 x 0.5
= 98.1747 m3
67
Weight of liquid = Vl x l
= 137.44 x 954
= 93658 kg
= 918.511 x 103 N
Total weight of packing = packed bed volume x density of packing
= x D2x H /4 x p
= x52x 10 /4 x 430
= 83.43 x 103 kg
= 824.08 x 103 N
l = Weight of (liquid + packing) / x D x ts
Weight of ( liquid + packing) =Weight of liquid + total weight of packing
= ( 918.511 x 103 + 824.08 x 103 )
= 1.7465MN
l = 1.7465 x X / x ( 5.052) x( 0.026 )
= 4.243 x X MN/m2
( d ) Stress due to attachments
Weight of head = /4 x D2 x thead x s
= 0.785 x ( 5.052 )2 x ( 0.018 ) x ( 784480 )
Whead =0.02831 MN
Weight of ladder + liq distributor = 1373.4 x X N
a = Whead + (Wladder & liquid distributor) / x Di x t
= 0.02831 + 0.0013734 x X / x ( 5 ) x (0.026)
a = 0.06931 + 0.003362 x X MN/m2
Total dead load stress
dead = s + in + l + a
= 0.7848 X + 0.01084 X + 4.243 X + 0.06931 + 0.003362 X
dead =0.06931 +4.3246 xX N/m2
Longitudinal Stress due to dynamic loads
The axial Stress due to wind load in self supporting tall vessel,
68
The total load due to wind acting on the bottom and upper part of thr vessel are
determined by
Pw = K1 x K2 x Pwindpress x H x Do ( insulated )
Where,
Pw = wind pressure = 1000 n/m2
K1 = coefficient depending upon the shape factor = 0.7 for cylindrical surface
K2 = coefficient depending upon the period of vibration of the vessel
= 1 if period of vibration is 0.5 sec or less
=2 if period of vibration is exceed 0.5
Do( insulated ) = Di + 2 tin
Period of Vibration is given by
T = 6.35 x 10-5 x ( H / D )1.5 x ( W / t ) 0.5
H = L + Skirt height
W = total weight
Now,
Weight of shell
Ws = x Dits x L x s
= (3.14) x (5) x (0.026) x ( 14 ) x (78480)
Ws = 0.4487 M N
Weight of insulation
Win = x D x tin x L x in
= ( 3.14 ) x ( 5 ) ( 0.05 ) x ( 14 ) x ( 5.64*103 )
Win = 0.06266 MN
Weight of ( liquid + packing) = 1.7465 MN
Weight of attachment = Weight of two heads + Weight of ladder, pipes, liq distributor
= 2 (0.02831) + 1.3734 x 10-3
Wa = 0.058 N
Total Weight = WS + Win + W (liquid + packing) + Wa
= 0.4487 + 0.06266 + 1.7465 + 0.058
W = 2315.86 KN
H = L + Skirt height
= 14 + 4
H = 18 m
a) Period of Vibration
T = 6.35 x 10-5 x ( H / D )1.5 x ( W / ts ) 0.5
69
K2 =1
K1 = 0.7 for cylindrical vessel
b) Wind load
Pw = K1 x K2 x Pwindpress x H x Do ( insulated )
Do( insulated ) = Di + 2 tin
= 5 + 2 (0.05)
Pw = ( 0.7 ) x ( 1 ) x ( 1000 ) x ( X ) x ( 5.1 )
Pw = 3.571 x X KN / m
Do = 5.1 m
Bending moment
i.e Wind moment at the base of the vessel due to wind load is given by
Mwind = { Pwmd x H }/2
= 3.571 x X x X /2
Mwind = 1.785 x X2 KN m
Resulting bending stress
i.e Wind Stress in axial direction is given by
wind = 4 x Mwind / x ts x D2
= 4 x ( 1.785 x X2) / 3.14 x ( 0.02 6) x ( 5.052 )2
wind
= 0.00349 x X2 MN/m2
PARAMETER
DESCRIPTION
Tower MOC
Tower ID
Tower OD
Shell thickness
Shell head thickness
Height of tower(Without support)
Height of packed Bed
Type of Head
No. of Beds of packing
P/Z Selected
Tower Support
Skirt MOC
Skirt Height
Skirt thickness
Type
MOC
Bulk Density
HETP
73
SS304
5m
5.052 m
26 mm
18mm
14m
10 m
Torrispherical
2 , each of height 5 m
50 N/M2/m
Skirt Support
SS304
4m
8 mm
Pall Ring
Metal (S S)
430 kg/m3
0.5425m
CHAPTER X
INSTRUMENTATION AND CONTROL
74
Depending on temperature and velocity condition the suitable meter is selected for
measurement of flow rates and velocity.
10.2.3 Temperature Measuring Devices:
Many devices are used to measure the temperature variations in the process such as
mercury in glass thermometer, bimetallic thermometer, pressure spring thermometer,
thermocouples,
resistance
thermocouples,
radiation
pyrometers
and
optical
Temp. Range C
-27 to 400
-40 to 540
-85 to 425
Resistance
-200 to 1700
Thermocouple
-250 to 1700
Thermister
Up to 300
Pyrometer
1300 to 2500
U Tube Manometer
Differential Manometer
Inclined Manometer
75
Bourdon Tube
Bellows
Diaphragm valve
Mc Leod gauge
Pirani gauge
77
In single loop control system failure of one controller affects only one control loop,
while case of DCS one component / card carries out lot of functions and hence failure
of it causes failure of many loops.
This calls for very high MTBF (Mean Time Between Failures) and high degree of
redundancy making such systems costly.
A limitation may be felt in operating number of control loops simultaneously in case
of emergency, if adequate numbers of CRT consoles are not installed.
personnel are required.
78
Skilled
CHAPTER XI
PLANT UTILITY
The utilities such as water, air, steam, electricity etc. are required for most of the
chemical process industries. These utilities are located at a certain distance from
processing area, from processing area hazardous and storage area etc, where a
separate utility department works to fulfill the utilities requirements.
Steam Generation
Cooling water
Water
Electricity
Compressed air
Balanced draft
In induced draft a fan is rotating at the bottom while in balanced draft fan is rotating
at the centre. In forced draft a fan rotating at top.
Cooling by sensible heat transfer
Cooling by evaporation
11.3 WATER:
A large reservoir has to be made which received water from nearby river. Storage also
must provide to such extent that turbidity is settling and then sent to raw water plant
for further treatment. Chlorine dose must be given to kill bacteria which prevent
organic matter. Then this water is sent to further treatment. To cooling tower, DM
plant, service water system, drinking water system, fire water system.
Cooling water is required for heat cooler, condenser etc. for cooling effect. Here in
cooling tower water is fall from high level and contacted with cross flow of air. Latent
heat of water is high that even a small amount of water evaporates produce large
cooling effect. The temp of CW is up to 25 to 30 C.
DM water is use for process . DM water is produced by removing impurities salts,
pass through anion exchanger.
11.4 ELECTRICITY:
It is required for motor drives , lighting and general use. It may be generated on site or
purchase from GEB & G.I.P.C.L. Transformers will be to step-down the supply
voltage to the voltage used on the site. A three-phase 415-volt system is used in
general industrial purposes and 240-volt single phase for lighting and other low power
requirements. For large motors, high voltage 600 to 1100 is used.
80
CHAPTER XII
SAFETY, HEALTH AND POLLUTION CONTROL
(2)
Control of hazards
(3)
(4)
MATERIAL NAME:
ETHYLENE OXIDE
USES:
Chemical intermediate
SYNONYMS:
Oxirane
HAZARDS IDENTIFICATION
burns of the skin and eye lesions. Onset of effects may be delayed for
several hours.
Skin Protection: Wear protective gloves and clean body-covering clothing.
Eye Contact: Couses burns
Eye Protection:
Use chemical safety goggles. Maintain eye wash fountain and quickdrench facilities in work area.
General Information:
Do not attempt to rescue the victim unless proper repiratory protection
is worn.
Inhalation:
Remove to fresh air. Do not attempt to rescue the victim unless proper
Expiratory protection is worn
Skin Contact:
Remove contaminated clothing. Flush exposed area with water and
follow by washing with soap if available
Eye Contact:
Immediately flush eyes with large amounts of water for at least 30
minutes while holding eyelids open. Transport to the nearest medical
facility for additional treatment.
Advice to Physician:
Contact a Poison Control Center or toxicologist for guidance.
Explosion
Extinguishing Media:
Shut off supply. If not possible and no risk to surroundings, let the fire
burn itself out.
Unsuitable:
Protective measures:
Avoid contact with spilled or released material. Isolate hazard area and
they deny entry to unnecessary or unprotected personnel. Stay unwinds
and keeps out of low areas. Extinguish ant make flames. Do not
smoke. Remove ignition sources. Avoid sparks.
Clean Up Methods:
Use water spray (fog) to reduce vapors or divert vapour cloud drift. Do
not use water in ajet. Alcohol foam applied to surface of liquid pools
may slow release of EO vapors into the atmosphere.
Handling:
Ventilate workplace in such a way that the Occupational Exposure
Limit (OEL) is not exceeded. The vapor is heavier than air spreads
along the ground and distant ignition is possible. Electrostatic charges
may be generated during pumping. Electrostatic discharge may cause
fire.
Storage:
Ethylene oxide (EO), an extremely flammable and toxic gas, and other
hazardous vapours may evolve and collect in the headspace of storage
tanks, transport vessels and other enclosed containers. Storage
Temperature: 30oC / 86oF maximum.
83
Product Transfer:
Electrostatic charges may be generate during pumping. Electrostatic
discharge may cause fire. Lines should be purged with nitrogen before
and after product transfer. Refer to supplier for further product transfer
instructions if required.
DISPOSAL CONSIDERATIONS:
Material Disposal:
PRODUCT NAME :
SYNONYMS:
1,2 - ethanediol
HAZARDS IDENTIFICATION:
Color:
Colorless
Physical State:
Liquid
Odor:
Sweet
Eye Contact:
May cause slight eye irritation. Corneal injury is unlikely. Vapor or
mist may cause eye irritation.
Skin Contact:
Brief contact is essentially nonirritating to skin
84
Skin Absorption:
Prolonged skin contact is unlikely to result in absorption of harmful
amounts.
Inhalation:
At room temperature, exposure to vapor is minimal due to low
volatility. With good ventilation, single exposure is not expected to
cause adverse effects.
Effects of Repeated Exposure:
Repeated excessive exposure may cause irritation of the upper
respiratory tract. In humans, effects have been reported on the
following organs: Central nervous system.
Birth Defects
Based on animal studies, ingestion of very large amounts of ethylene
glycol appears to be the major and possibly only route of exposure to
produce birth defects.
FIRST-AID MEASURES:
Eye Contact:
Flush eyes thoroughly with water for several minutes. Remove contact
lenses after the initial 1-2 minutes and continue flushing for several
additional minutes.
Skin Contact:
Wash skin with plenty of water.
Inhalation:
Move person to fresh air. If not breathing, give artificial respiration; if
by mouth to mouth use rescuer protection (pocket mask, etc).
Extinguishing Media:
Water fog or fine spray. Dry chemical fire extinguishers. Carbon
dioxide fire extinguishers. Foam. Do not use direct water stream. May
spread fire.
85
Handling:
Do not swallow. Avoid contact with eyes. Wash thoroughly after
handling. Spills of these organic materials on hot fibrous insulations
may lead to lowering of the autoignition temperatures possibly
resulting in spontaneous combustion.
Storage:
Do not store near food, foodstuffs, drugs or potable water supplies.
Additional storage and handling information on this product may be
obtained by calling your sales or customer service contact. Ask for a
product brochure.
PERSONAL PROTECTION:
Eye/Face Protection:
Use safety glasses. If exposure causes eye discomfort, use a full-face
respirator.
Skin Protection:
Use protective clothing chemically resistant to this material. Selection
of specific items such as face shield, boots, apron, or full body suit will
depend on the task. Remove contaminated clothing immediately.
Hand protection:
If hands are cut or scratched, use gloves chemically resistant to this
material even for brief exposures. Use gloves with insulation for
thermal protection, when needed. Examples of preferred glove barrier
materials include: Butyl rubber. Natural rubber
Stability/Instability:
Thermally stable at recommended temperatures and pressures.
Thermal Decomposition
86
TOXICOLOGICAL INFORMATION:
Acute Toxicity:
Ingestion
For ethylene glycol: Lethal Dose, Human, adult 3 Ounces LD50, Rat
6,000 - 13,000 mg/kg
Skin Absorption
LD50, Rabbit > 22,270 mg/kg
Inhalation
LC50, 7 h, Aerosol, Rat > 3.95 mg/l
ECOLOGICAL INFORMATION:
DISPOSAL CONSIDERATIONS:
87
Location of gauge glass - Gauge glass for reading level in the tank should be located
away from path where many people may be working.
Location of safety valve/ vent line - The vent pipe should not be located in a closed
area.
Location of flammable material - Storage should be away from any source of flame.
Smoking - Do not smoke in unauthorized area where flammable materials are likely to
be present.
Purging with inert atmosphere - Before entering a reactor or a distillation column
containing hazardous vapors, the equipment must be purged with air/inert gas for
sufficiently long time.
Machinery guards - Install guards on moving machinery parts.
Incompatible chemicals - Do not mix incompatible materials together.
Earthling of equipment - When two phase mixture is being separated into different
tanks, the tank should be earthed to avoid spark due to accumulation of static
electricity.
Explosion due to dust - In the operation of fine grinding, solid temperature increases
which can lead to dust explosion initiated by hot metal. It can be prevented by cooling
grinder with water or inert gas purging.
Drying and ignition of flammable liquids - Keep air flow rate high so that air vapor
mixture is not near flammable limit.
Mixing - It should be effective to take care of exothermic heat of reaction.
Good house keeping - Do not store waste flammable materials near flame source.
Labeling of chemicals - Label the chemicals so that they do not get mixed up with
incompatible chemicals.
Pipetting - Do not suck with mouth, use rubber bulb.
Free excess energy exit - Do not store anything in passage way destructing free
movement in emergency.
88
2.
General Precautions:
Maintain good housekeeping. Follow the laid down procedure strictly.
Sampling and draining of hydrocarbon should be done under strict
supervision. Do not operate an equipment unauthorized. Use only approved
type of tools. Anticipate the hazards during vessel cleaning and take
prevention steps in advance.
3.
An emergency manual can be prepared to outline procedures and drills and detail
responsibilities of each individual involved.
Training
Valuable Check On The Adequacy and Condition of exits
and Alarm system
Instills a Sense of Security Among The Occupiers if Careful Plans Are Made.
Exits Drills
Plant Drills (Mock drills in plant area)
Mutual Aid Drills
On-Site / Off site Drills etc.
12.5 SAFETY IN PROCESS DESIGN:
Accidents are minimized by correct deign using scientific and performance data
without false economy.
12.5.1 Reactor:
The reactor is a heart of plant and vital for safety. Most reactions have hazard
potential. Here, reaction is exothermic and at higher pressure compared to
atmospheric pressure and also deals with the materials like Benzene and Cyclohexane
which are highly volatile.
12.5.2 Heat Transfer:
For safe operation,
Prevent mixing.
Provide different surface, for cleaning, insulation, expansion.
Prevent flame travel in furnace.
Use safety over design factor of 15 20 %.
89
Waste arises mainly as byproducts or unused reactants from the process, or as offspecification product produced through mis-operation. In emergency situations,
90
If the liquid effluent is flammable, it can be burnt in the incinerator. But as in this case
if it contains salts; acids and substantial amount of alkali it is to be subjected to
effluent treatment. Generally common effluent treatment plant (if the facility is
situated in and Industrial area with the CETP) serves the purpose. The level of
effluent treatment up to secondary treatment is sufficient for the effluent from the
plant like one on the hard.
12.6.3 SOLID WASTE:
The principle factors which determine the nature of an aqueous industrial effluent and
on which strict controls will be placed by responsible authority are:
pH
Suspended solids
Toxicity
Biological oxygen demand
For the present case pH of the effluent stream is expected to be alkaline and hence
addition of acids is recommended to neutralize the same. The suspended solids can be
removed by settling, using Chemical treatment may be given to remove some of the
chemicals.
Oxygen concentration in waste course must be maintained at a level sufficient to
support aquatic life. For this reason the biological oxygen of an effluent is of
paramount importance. Standard BOD 5 tests can be applied for the determination of
the same. The test measures the quantity of oxygen which a given volume of effluent
91
Noise can cause serious nuisance in the neighbourhood of a process plant. Care need
to be taken when selecting and specifying equipments such as compressors, air-cooler
fans, induced and force draft fans for furnaces, and other noisy plant. Excessive noise
can also be generated when venting through steam and other relief valves, and from
flare stacks. Such equipments should be fitted with silencers.Noisy equipments should
be as far away form the site boundary.
12.6.6 VISUAL IMPACT:
The appearance of the plant should be considered at the design stage. Few people
object to fairyland appearance of a process plant illuminated at the night, but it is
different scene at daytime. There is little that can be done to change the appearance of
modern style plant, where most of the equipment and piping will be outside and in full
view but some steps should be taken to minimize the visual impact.
12.6.7 ENVIRONMENTAL AUDITING:
92
NONE
DEVIATION
NO FLOW
POSSIBLE
CAUSE
1) No
EO/H2O
available at
the storage
tank
2) J1/J2 pump
fails (motor,
fault, loss of
drive, etc.)
3) Line valve
close (in error
or fail)
4) Line
fracture
MORE
OF
MORE FLOW
MORE PRES
MORE TEMP
Control
Valve fail to
open or LCV
by pass open
in error
1) V1. Valve
closed in error
with J1 and J2
pump
running.
2) Thermal
expansion in a
isolated
valved section
due to fire.
1) High
storage
temperature
2) cooling
water supply
to reactor
cooling
93
CONSEQUENCES
ACTION REQUIRED
Transfer line
subjected to full
pump delivery or
surge pressure.
Line fracture or
flange leak.
Install thermal
expansion relief on
valved section
High pressure in
transfer line
1) Check whether
there is adequate.
2) Warring of high
temperature at
storage, if not install.
1) Check design of
pumps and install a
stand by pump.
2) Install a kickback
system stop
LESS
OF
LESS FLOW
MORE
THAN
HIGH E.O
CONC IN
STREAM.
PART
OF
WATER
FLOW TO
REACTOR
OTHER
MAINT.
on pump.
3) Check proper
operation of cooling
water system.
1)
Leaking
flanges
of
valve stab not
blanked and
leaking.
2) Pump J2
fails or not
running
properly and
J1 running
well.
Valve V2-1,
and V2-2 are
not working
properly
Material loss to
adjacent area
Institute regular
patrolling and
inspection of transfer
line.
Formation of more
Higher glycol in the
reaction which will
affect the
product.(excess E.O
in reactor)
Leads to formation
of more higher
glycol
Leads to formation
of more higher
glycol
1) Install a stand by
pump.
2) Check design of
pump.
3) Install kickback on
pump.
1) Institute regular
inspection of valve.
2) Install by pass line
with standby
Valve.
1) Institute regular
inspection of valve.
2) Install by pass line
with standby valve.
Install low point
drain and N2 purge
point and N2 vent
line.
94
Line cannot be
completely
drainage or purge.
CHAPTER XIII
PLANT LOCATION AND LAY OUT
13.1.2 Markets
The location of markets or intermediates distribution centers can heavily affect the
cost of product distribution. Primarily to large market can be beneficial in the
following three ways:
95
13.1.5 Climate
Weather can have serious effect on the economic operating of the plant. Temperature
& humidity of weather should be favorable.
13.1.6 Transportation
The everyday products are always needed to be transported from the plant site to the
marked or other plants & the raw materials necessary from the sources to the plant.
Hence transportation holds a great deal in the final product cost. A plant should have
easy access to transport facilities. Not only that, the transport facilities available to the
plant should also be sufficient, quick & available at reasonable rates. Water, railway
& national high-ways are the most common means of transportation. These facilities
are very much necessary for the transfer of raw material & product transportation.
Luckily Baroda has all of these facilities.
96
97
13.1.15 Existence of hospitals, marketing centers, schools, banks, post offices, clubs
An ideal industry or organization is that which takes full care of its employees &
persons who are directly or indirectly involved with it. To cope up with the situation
of casualties or accidents pressure of a well-equipped hospital is a must. Other than
this a reputed school & the banking & postal facilities are the prime requirement of
the families of the employees.
3.1.17 Securities
The security of the plant site & the housing facility from the unsocial elements is
necessary & should be given equal attention.
The raw materials necessary are easily available from the nearby industrial
area & the industrial estate is always running with large number of chemical
industries, & hence getting skilled & experienced labor at reasonable rates is
not a problem.
99
100
CHAPTER XIV
COST ESTIMATION
A plant design obviously must present a process that is capable of operating under
conditions, which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that the chemical engineer be aware of many different types of
costs involved in manufacturing processes.
14.1 ESTIMATION CAPITAL COST:
14.1.1 Purchased Equipment Cost:
Table-14.1 Purchase Cost of equipments
Sr. No.
1
2
3
4
5
7
8
9
10
11
12
13
Equipment
MEG
STORAGE
TANK
HG STORAGE
TANK
ETHYLENE OXIDE
STORAGE
TANK
PLUG
FLOW
REACTOR
TRIPPLE
EFFECT
EVAPORATOR
VACUUM
DISTILLATION
COLUMN (PACKED
COLUMN)
DISTILLATION
COLUMN (PLATE
COLUMN)
DRYING COLUMN
CENTRIFUGAL
PUMP
HEAT EXCHANGER
BOILER
DM WATER
PLANT
COOLING
TOWER
No. of
EquipMents
Cost per
Unit (Rs.
Thusd)
Estimated
Cost
(Rs. Thusd)
200
400
200
200
200
400
500
500
85
85
70
70
75
75
1
6
50
10
50
60
7
2
20
50
140
100
25
25
10
20
101
Item
% of PEC
100
2125
40
850
15
318.75
Building cost
Yard improvement cost
60
12
18
10
1275
255
382.5
212.5
70
10
1487.5
212.5
Purchased Equipment
Delivered cost
Purchased
Equipment
Installation cost
Instrumentation & Control cost
(Installed)
Piping cost (Installed)
Electrical Installation cost
Item
% of PEC
Cost (Rs.
Thusd)
15
1067.81
Construction expenses
20
1423.75
Contractors Fees
355.93
Contingencies
10
711.875
Amount
Cost
Cost ( thuds
Rs)
Ethylene oxide
73450827.65 (Kg/Yr)
Styrene Divinylbenzene
anion exchange Resin
91491.47
1.024 M3
(Rs/m3)
(Catalyst)
thusd Rs.
103
30952.1787
0.9368
= 309.531 Thuds Rs
DIRECT PRODUCTION COSTS
Amount kg/year
MEG
99829190.88
60
Tax Paid
It is given by P.O.P
Fixed Capital Investment per year
P.O.P
11735.70 + 1067.8115
= 0.83 Years
RATE OF RETURN:
It is given by R.O.R
Net Profit
R.O.R =
11735.70
x100
12813.73
= 91.85 %
106
X 100
109