Professional Documents
Culture Documents
Ethanol 12
Ethanol 12
+
Where r
1
and r
2
are the forward and reverse rates, respectively. Experimental analysis of the
performance of this catalyst [1], gives the following expressions for these reaction rates:
( )
1
1 2
1
W E
W W E E A A
k p p
r
K p K p K p
=
+ + +
(2)
and
( )
2
2 2
1
A
W W E E A A
k p
r
K p K p K p
=
+ + +
(3)
where
3 2 -9
1
3 -2
2
1 -17
1 -4
91,130
[kmol/mcat/h/atm] 1.7723 10 exp
[K]
43,915
[kmol/mcat/h/atm] 1.3865 10 exp
[K]
162,730
[atm ] 1.2328 10 exp
[K]
35,368
[atm ] 2.0850 10 exp
[K]
W
E
k
RT
k
RT
K
RT
K
RT
=
=
=
=
and the activation energy is given in kJ /kmol, and p
i
is measured in atmospheres.
Under the conditions used in commercial reactors, the last term in the denominator is negligible and
may be ignored. Also note that the exponential terms in the numerator and denominator are all
positive. This is an artifact of the lumping together of reaction rate constants and adsorption
equilibrium constants in Equations (2)-(3). However, the net effect of temperature on the overall
12
forward and reverse reactions is that the overall rates increase with increasing temperature, which is
consistent with Arrhenius-type behavior.
Along with the desired, forward, reaction shown in Equation (1), ethanol can also dehydrate to form
diethyl ether as follows:
(4)
ether diethyl ethanol
O CH CH O H OH H C
2 2 3 2 5 2
) ( +
The catalyst used in the process of interest is zirconium tungstate, and it effectively suppresses the
diethyl ether reaction shown in Equation (4).
In addition, any in the ethylene feed may be converted to acetaldehyde, which is tolerable in the
final ethanol product at only very low concentrations (<1ppm).
(5)
de acetaldehy acetylene
CHO CH O H H C
r
3 2 2 2
3
+
The rate for this reaction is given by:
(6) atm] [ cat/h/atm] kmol/m [
3
3 3 Acet
p k r =
where
=
] RT[
kJ /kmol] [ 000 , 25
exp 10 1
4
3
K
k (7)
Reference
1. Momose, H., Kusumoto, K., Izumi, Y., and Y. Mizutani, Vapor-phase direct hydration of
ethylene over zirconium tungstate catalyst, J. Catalysis, 77, 23-31 (1982)
13
Appendix 3 Equipment Sizing Calculations
C-201 Flash-Gas Compressor
P =250 kPa
Q =13.5 m
3
/h (at inlet conditions)
37.7kg/h m = &
s
W
&
=1 kW
Positive displacement - Electric Drive
C-202 Recycle Compressor
P =4500 kPa
Q =2,794 m
3
/h (at inlet conditions)
16,455kg/h m = &
s
W
&
=1550 kW
Centrifugal - Electric Drive
Note: All overall heat transfer coefficients are taken from existing exchangers with similar services.
E-201 Reactor Feed Heater
T(C)
Q
85
229
254 Q =49,360 MJ /h
U =850 W/m
2
C
T
LM
=(229-85)/ln{(254-85)/(254-229)}=75.4C
A =49,36010
6
/(3600)/(850)/(75.4) =214 m
2
E-202 Reactor Effluent Cooler
T(C)
264
Q =57,210 MJ /h
50 40
U =425 W/m
2
C
T
LM
=(224-20)/ln{(224)/(20)}=84.4C
30
A =57,21010
6
/(3600)/(425)/(84.4) =442 m
2
Q
E-203 Ethanol Purification Tower Feed Vaporizer
T(C)
Q =46,300 MJ /h 160
123
U =950 W/m
2
C
T
LM
=(125-37)/ln{(125)/(37)}=72.3C
35
A =46,30010
6
/(3600)/(950)/(72.3) =187 m
2
Q
14
E-204 Ethanol Reboiler
T(C)
Q =6,516 MJ /h 160
127
U =1000 W/m
2
C
T
LM
=33C
A =6,51610
6
/(3600)/(1000)/(33) =55 m
2
Q
E-205 Ethanol Condenser
T(C)
99
Q =41,580 MJ /h
U =1100 W/m
2
C
40
T
LM
=(10)/ln{(69)/(59)}=63.9C
30
A =41,58010
6
/(3600)/(1100)/(63.9) =164 m
2
Q
E-206 Ethanol Product Condenser
T(C)
99
Q =4,014 MJ /h
U =1100 W/m
2
C
30
50
40
T
LM
=(59-20)/ln{(59)/(20)}=36.1C
A =4,00410
6
/(3600)/(1100)/(36.1) =28 m
2
Q
E-207 Waste water cooler
T(C)
127
Q =6,699 MJ /h
U =900 W/m
2
C
30
40
40
F =0.8
T
LM
=(87-10)/ln{(87)/(10)}=35.6C
A =6,69910
6
/(3600)/(900)/(36.1)/(0.8) =73 m
2
Q
P-201A/B Ethanol Reflux Pumps
Reflux rate =63.4 m
3
P
f
=50 ft of liquid =hg =(722)(50)(0.3048)(9.81) =108 kPa
Efficiency =65%
kW 1.9 W 1902
3600
) 000 , 108 )( 4 . 63 (
= = = = P Q W
s
&
15
R-201 Ethylene Reactor
Volume of Catalyst =100 m
3
Catalyst diameter =1 cm, voidage =0.5
L/D =10/1
2
(10 )
100 2.35m
4
D D
D
= =
L =23.5 m
assume P =50 kPa
T-201 Ethanol Absorber
Limiting condition at top of column
L =1837 kg/h, G =16,045 kg/h
L
=981 kg/m
3
G
=5.537 kg/m
3
(L/G)(
G
/
L
)
0.5
=0.0086
from flooding graph for 18 in tray spacing (P. Wankat, Separation Processes in Engineering, 2
nd
ed., Prentice Hall, 2007, p. 315.)
C
sb
=0.295
u
fl
=3.92 ft/s
u
act
=0.897 m/s (75% of flooding)
if 75% active area
A =(G/3600)/[(0.75)(
G
)(u
act
)] =1.24 m
2
D =1.26 m
Efficiency from OConnell equation
2
log 1.597 0.199log 0.0896 log
L L L L
o
L L
KM KM
E
=
Where K =K-value for ethanol =0.159
M
L
=MW of liquid =19.3
L
=viscosity of liquid =0.72 cP
L
=density of liquid =59.5 lb/ft
3
( ) ( )
2
(0.159)(19.3)(.7)
0.0361
59.5
log 1.597 0.199log 0.0361 0.0896 log 0.0361 50%
L L
L
o
KM
E
= =
= =
Number of theoretical Stages =10
Number of actual Stages =20
Tray spacing =0.457 m (1.5 ft)
Tan-tan height =9.14 m
Column diameter =1.24 m
16
T-202 Ethanol Purification Column
Limiting condition at top of column
L =45,526 kg/h, G =49,319 kg/h
L
=723 kg/m
3
G
=3.262 kg/m
3
(L/G)(
G
/
L
)
0.5
=0.0620
from flooding graph for 24 in tray spacing (P. Wankat, Separation Processes in Engineering, 2
nd
ed., Prentice Hall, 2007, p. 315.)
C
sb
=0.355
u
fl
=5.27 ft/s
u
act
=1.204 m/s (75% of flooding)
if 75% active area
A =(G/3600)/[(0.75)(
G
)(u
act
)] =4.68 m
2
D =2.44 m
Efficiency from OConnell equation
2
log 1.597 0.199log 0.0896 log
L L L L
o
L L
KM KM
E
=
Where K =K-value for ethanol =3.77
M
L
=MW of liquid =42.7
L
=viscosity of liquid =0.659 cP
L
=density of liquid =47.48 lb/ft
3
( ) ( )
2
(3.77)(42.7)(.659)
2.234
(47.48)
log 1.597 0.199log 2.234 0.0896 log 2.234 33%
L L
L
o
KM
E
= =
= =
Number of theoretical Stages =34
Number of actual Stages =103
Tray spacing =0.609 m (2 ft)
Tan-tan height =63.1 m
Column diameter =2.44 m
V-201 High Pressure Separator
Liquid Flowrate =21.5 m
3
/h
Vertical
L/D =3/1
Liquid hold-up =10 mins
2
(3 ) 21.5
1.15m
4 6
D D
D
= =
L =3.45 m
17
V-202 Low Pressure Separator
Liquid Flowrate =21.3 m
3
/h
Vertical
L/D =3/1
Liquid hold-up =10 mins
2
(3 ) 21.3
1.15m
4 6
D D
D
= =
L =3.45 m
V-203 Ethanol Reflux Drum
Liquid Flowrate =63.4 m
3
/h
Vapor Flow =15202 m
3
/h
Horizontal
L/D =3/1
Liquid hold-up =10 mins
2
(3 ) 63.4
1.65m
4 6
D D
D
= =
L =5.0 m
Vapor Velocity =
15,202
0.51 m/s - OK
(1.65)(5)(3600)
=
V-204 Off-Gas Flash Vessel
Liquid Flowrate =4.94 m
3
/h
Vertical
L/D =3/1
Liquid hold-up =10 mins
2
(3 ) 4.94
0.70m
4 6
D D
D
= =
L =2.1 m
18