Final Year Project

Production of 30,000 MTPY Hydrogen Peroxide

(H2O2) From Methanol By Enzymatic Process
• Project Advisors:
Dr. Khalid Mahmood
Engr. Mudassar Hammed

• Group Members:
Sakhawat Ali 2014-CH-336
Ali Ahmed 2014-CH-306
M. Umar Rafi 2014-CH-352
Naeem Akram 2014-CH-338
Ali Afzal 2014-CH-321
 Introduction

• Hydrogen peroxide is a chemical compound with the formula H2O2.

• In its pure form, it is a colorless liquid, slightly more viscous than water.

• Hydrogen peroxide is the simplest peroxide.

• Use as a strong oxidizer, bleaching agent and disinfectant.

• Concentrated hydrogen peroxide has been used as a propellant in rocket.

 Uses

• Oxidant in paper, textile and cellulose bleaching

• Water Purification

• Organic Chemicals

• Detergents
 Production Process

There are four routes for the production of Hydrogen Peroxide:

• Barium Peroxide method

• Direct combination of Hydrogen and Oxygen

• Electrolytic method

• Ethyl-Anthraquinone process
Enzymatic Process for the Production of
Hydrogen Peroxide
 Process Flow Diagram
Oxygen
Recycle
T = 90.2 0 C
Vent Off
P = 11.15 Bar T = 68 0 C
T = 68 0 C
Compressor P = 0.29 Bar
P = 0.35 Bar Methanol
5 11
9 Recovery
0
T = -22 C 7
Methanol P = 11.15 Bar T = 64.8 0 C
(Fresh & Recycle)

Flash Column
P = 1.22 Bar Pump
T = 49.3 0 C 6
4 Enzyme Recovery 06

01
P = 11.49 Bar 4a
Mixer
1
T = 185 0 C T = 50 0 C
Reactor(CSTR)

Distillation Column
P = 11.49 Bar P = 11.15 Bar Vessel
Cooler T = -22 0 C
01
2 8

01
Water
3 Formalin(37%)
Ultra Filtration T = 68 0 C

Distillation Column
(Fresh & Recycle) Oxygen 9 T = 207.4 0 C
P = 0.35 Bar Vessel
T = 203.4 0 C (Fresh & Recycle) P = 19.97 Bar
T = 38.9 0 C 02 13
P = 11.49 Bar

02
P = 11.15 Bar R-134a
Pump
01

Pump
10 04
Vessel
T = 84.9 0 C

Distillation Column
03
P = 0.35 Bar Pump
12
02

03
T = 112.9 0 C
H202 P = 1.53 Bar Pump
05
Pump
07

T = 239.7 0 C
P = 20.36 Bar
14
H2O

Production of 30,000 MTPY Hydrogen Peroxide (H2O2) From Methanol By Enzymatic Process
Equipment Design
Reactor Design

CSTR Design
Contents

1. Selection of a Reactor

2. Residence Time

3. Volume of a Reactor

4. Diameter and Height of a Reactor

5. Impeller Design
6. Reactor Jacket Design
7. Specification Sheet
 Reaction
• Hydrogen peroxide formation reaction is:
𝐶𝐻3𝑂𝐻(aq) + 𝑂2(g) 𝐸𝑛𝑧𝑦𝑚𝑒 𝐻𝐶𝐻𝑂(aq) + 𝐻2𝑂2 (aq)

• This is exothermic reaction

ΔH = -1698 KJ/Kg
 Kinetics of Reaction
Rate of Reaction:
• The rate equation is:
𝑉𝑚 𝐶𝐴
𝑟𝑎 =
𝐾𝑚 +𝐶𝐴
Where
𝐾𝑚 = Michaelis Menten constant
= 0.4 mM
𝑉𝑚 = Maximum reaction rate (𝑘3 𝐸𝑜 )
= 0.3137 mM

“US Patent 005234827:Enzymatic process for manufacturing formaldehyde and hydrogen peroxide”.
 Selection of reactor

We selected continuous stirred tank reactor

 Material Balance around Reactor
Component Composition Kg/hr
CH3OH 0.32% 3.5
O2 99.68% 1044
Total 100.00% 1047.5

Component Composition Kg/hr

CH3OH 14% 8224
H2O 86% 50196 CSTR
Total 100.00% 58420 Component Composition Kg/hr
HCHO 5% 3060
CH3OH 8% 4960
H2O 81.36% 50184
Component Kg/hr H2O2 5.6% 3468
Oxygen 4384 O2 0.034% 21
Total 100.00% 61693
 Residence Time

From literature :

• Optimum condition of reaction;

Temperature = 37 °C
PH = 7.5
Residence time = 30 mint

“US Patent 4,920,055:Enzymatic process for manufacturing formaldehyde and hydrogen peroxide”.
 Volume of a Reactor
• Mass flow rate of Methanol solution = 58420 kg/hr

• Mass flow rate of oxygen = 4384 kg/hr

• Volumetric flow rate of entering stream (VFR) = 687 𝑚3 /hr

• If one reactor is used then it has very large dimension so we use 4 reactor
is parallel.
687
• VFR of every reactor = = 170 𝑚3 /hr
4
 Volume of a Reactor

• Volume = Residence time * VFR a Reactor

= 0.5 * 170
= 85 𝑚3

• From literature, 15% allowance

Actual Capacity = 98 𝑚3

Reference: Harry Silla, “Chemical Process Engineering Design and Economics”

 Diameter and Height of a Reactor

•From rule of thumb

𝐻
=2
𝐷
• 𝑉𝑡 = 𝐴𝑟𝑒𝑎 ∗ 𝐻𝑒𝑖𝑔ℎ𝑡
𝞹 3 2𝑉𝑡
𝑉𝑡 = 𝐷2 ∗ 2𝐷 , 𝐷=
4 𝞹

• Putting value
D= 3.96 m
H= 7.92 m
Impeller Design
 Impeller selection

• Rushton impeller is used in;

o Gas-Liquid Reaction
o Fermentation reaction
• It is disk type radial flow-turbine impellers
• Commonly six-blades impeller is used
 Dimensions of turbine agitator:

• 𝐷𝑎 = Diameter of impeller
• 𝐷𝑡 = Diameter of tank
• H = Depth of liquid in tank
• J = Width of Baffle
• W = Width of impeller
• L = Length of impeller
• E = Distance from tank bottom
to impeller
 Standard Turbine Impeller

“Unit_Operations_Of_Chemical_Engineering__5th_Ed__McCabe_And_Smith, page-243”
 Impeller Design
𝐷𝑡
• Impeller diameter = 𝐷𝑎 = = 1.32 m
3

• Distance from tank bottom to impeller = E = 𝐷𝑎 = 1.32 m

𝐷𝑎
• Length of impeller = L = = 0.33 m
4

𝐷𝑎
• Width of impeller = W = = 0.26 m
5

• Liquid Depth = H = 𝐷𝑡 = 3.96 m

“Unit_Operations_Of_Chemical_Engineering__5th_Ed__McCabe_And_Smith, page-243”
 𝐷𝑡
• Width of baffle = J = = 0.33 m
12
𝐷𝑎
• Length of baffle = = 0.66 m
2

• Number of baffles = 4

• Number of blades = 6

• Number of impellers = 1

• Distance between 2 consecutive impellers = 𝐷𝑎 = 1.32 𝑚

“Chemical Process Equipment - Selection and Design (Walas), P-287”

 Shape Factor
𝐷𝑎 1
• 𝑆1 = = --------------- (1)
𝐷𝑡 3
𝐸 1
• 𝑆2 = = --------------- (2)
𝐷𝑡 3
𝐿 1
• 𝑆3 = = --------------- (3)
𝐷𝑎 4
𝑊 1
• 𝑆4 = = --------------- (4)
𝐷𝑎 5
𝐽 1
• 𝑆5 = = --------------- (5)
𝐷𝑡 12
𝐻
• 𝑆6 = = 1 --------------- (6)
𝐷𝑡
 Tip velocity & Agitator Speed
• From literature, take

Agitator speed = N = 84 RPM

• Tip Velocity = π*𝐷𝑎 ∗N

84
= 3.14 * 0.51 * ( )
60

= 5.8 m/s (19 ft/s)

For liquid-gas mixture, tip velocity is b/w 15 - 20 ft/s.

“Chemical Process Equipment-Selection and Design, page-292”

 Power Consumption
• Power =𝑁𝑃 ∗ 𝑁 3 ∗ 𝐷𝑎 5 ∗ 𝜌

𝜌 𝐷𝑎 2 𝑁
Reynold number =
𝜇
= 3× 106
Power number = 𝑁𝑃 = 5
(Fig 10.6, Chemical Engineering - Coulson and Richardson vol.6)

Power = 66 hp ( 1.5 HP/1000 gal )

Chemical Process Equipment - Selection and Design (Walas), P-292

 Reactor Jacket Design
Flow rate of Cooling Fluid:

• Cooling fluid used = water

• water inlet temperature = 25 C
• water outlet temperature = 40 C
• ΔT = 15 K
• 𝐶𝑃 = 4.18 KJ/Kg.k
• Heat removed by the water

Q = 420 kj/hr

• Mass flow rate of cooling fluid

Q = m 𝐶𝑃 ΔT
m = 7 Kg/hr
• Heat of reaction is -58.1 KJ/mole(- 9560 kj / hr
𝑘𝑗
• 𝐶𝑝 𝑣𝑎𝑙𝑢𝑒 𝑖𝑠 (76 + 30)
𝑘𝑚𝑜𝑙.𝑘
• Q = m 𝐶𝑃 ΔT
• 58.1* = 3138 kg/hr * 76 * ΔT
• ΔT = 1.2 k
 Jacket Area
𝐷2
• Jacket Area = 𝜋 + 𝜋DL
4
• D = 1.53 m
• L = 3.06 m

• Jacket Area = 16.25 𝑚2 (173 𝑓𝑡 2 )

• From Literature,
• Area = 155 𝑓𝑡 2

Ref: Chemical process Engineering Design & Economics

Silla, H.
 Specification Sheet
Item Fermenter
Type Cooling Jacketed Stirred Tank Reactor
Number of equipment
Operation Continuous
Residence Time
Volume of reactor
Diameter of reactor
Height of reactor
Operating temperature
Operating pressure
 Specification Sheet
Item Agitator
Type Three 6-Bladed Flat Turbine
Impeller Diameter
Impeller height above the Vessel Floor
Length of Impeller Blade
Width of Impeller Blade
Width of Baffle
Number of Impellers
Number of Impellers Blades
Distance b/w 2 Consecutive Impellers
Speed of Impeller RPM
 Specification Sheet
Item Cooling Jacket
Cooling Fluid R-134a
Inlet Temperature
Outlet Temperature
Refrigerant Flow Rate