Professional Documents
Culture Documents
EGE UNIVERSITY
Chemical Engineering Department
Submitted to:
Prof.Dr.Ferhan ATALAY
Prepared by;
Res.Assist.
Nilay GZL
Sezai ERDEM
Tuba GRMEN
05078901 rn ARDA
05068091 M.Serkan ACARSER
05068076 Mge METN
05078875 Sla Ezgi GNGR
05068052 Ali KK
March 2009
Bornova-ZMR
Date: 30.03.2009
SUMMARY
The process purpose is to produce acetone from isopropyl alcohol (IPA) at the
given conditions. This report is formed, some properties, manufacturing process of
acetone. In manufacturing process, feed drum, vaporizer, heater, reactor, furnace, cooler,
condenser, flash unit, scrubber, acetone and IPA columns are used.
INTRODUCTION
Including Acetone
Acetone
ii
TABLE OF CONTENTS:
Summary
Introduction
ii
2.0 Results
3.0 Discussion
4.0 Nomenclature
5.0 Appendix
5.1 Flowchart
5.2.1 Reactor
10
5.2.3 Scrubber
11
14
15
16
References
17
17
5.3.2 Vaporizer
18
19
5.3.4 Reactor
20
5.3.5 Cooler
22
5.3.6 Condenser
23
5.3.7 Scrubber
26
27
30
32
At the beginning of the process, feed including i-propyl alcohol and water, and recycle
stream are mixed in feed drum. From here, this mixture is send to vaporizer to change
streams phase as vapour. After vaporizer, mixture is heated to reaction temperature in the
heater. Reactor used is a tubular flow reactor. Acetone, hydrogen gas (H2) are produced and
water and i-propyl-alcohol are discharged. The mixture with acetone, hydrogen, water, ipropyl-alcohol are sent to cooler and then to condenser. After condenser the mixture is sent to
flash unit. Hydrogen, acetone, i-propyl-alcohol and water are obtained as top product. This
top product is sent to scrubber to remove hydrogen. The bottom product of flash unit which is
formed by acetone, water, i-propyl-alcohol are mixed with the bottom product of scrubber
before acetone column. In acetone column, acetone is obtained from top product with 99 wt%.
-propyl alcohol and water and also 0,1% of acetone is sent to i-propyl-alcohol column from
bottom product. The top product of this column is sent to feed drum and bottom product is
thrown away as waste water.
2.0 RESULTS
H2O
Acetone
IPA
H2
Molecular Weight(kg/kmol)
18,015
58,08
60,096
2,01
Freezing Point(C)
-95
-88,5
-259,2
Boling Point(C)
100
56,2
82,2
-252,8
647,3
508,1
508,3
33,2
220,5
47
47,6
13
0,056
0,209
0,220
0,065
Liquid Density(kg/m3)
998
790
786
71
Heat of Vaporization(J/mol)
40683
29140
39858
904
658,25
273,84
1139,70
13,82
283,16
131,63
323,44
5,39
-242,0
20,43
-272,60
-228,77
62,76
-173,5
32,243
3,710
32,427
27,143
1,923x10-3
2,345x10-1
1,886x10-1
2,73x10-3
1,055x10-5
-1,160x10-4
6,405x10-5
-1,380x10-5
-3,596x10-8
2,204x10-8
-9,261x10-8
7,645x10-9
11
-113
-259
168
-33
111
-248
-2-
Acetone
Basis:100kmol/h
ipropylalcohol
multipliedscalefactor
kg/h
Basis:100kmol/h
multipliedscalefactor
100
52644,1
100
90
6
7
Water
kg/h
multipliedscalefactor
kg/h
Basis:100kmol/h
multipliedscalefactor
90,937 47872,96 228,797 13749,785 120448,4 44,786 7067,741 112,682 2029,966 17782,44
kg/h
ton/year
52644,1
100
52644,1
10
5264,41
90
90
10
5264,41
90
90
10
5264,41
90
1,952
90
65,789 33472,18 165,525 9613,692 84216,01 9,194 4840,098 23,132 1390,141 12177,69 45,491 7178,998 114,455 2061,907 18062,36
1,952
9,387
169,107 1481,407
11
12
0,024
12,211
0,06
3,485
30,722
90
9,97 5248,616 25,085 1507,508 13205,52 653,263 103092,4 1643,61 29609,634 259380,4
0,907 477,482
15
0,089
45,281
0,224
13,010
113,928
9,063 4771,134 22,803 1370,369 12004,17 653,263 103092,4 1643,61 29609,634 259380,4
16
17
0,089
45,281
0,224
13,010
113,928
2,282
137,139 1201,345
Basis:100kmol/h
Hydrogen
704,47 11,231
202,326 1772,447
3.0 DISCUSSION
Feed drum is a kind of tank used for the mixing of the recycle stream and feed stream.
Recycle stream concentration was assumed to be same with the feed stream. The temperature
of the feed stream is assumed to be 250 C at 2 bar pressure, which is assumed to be constant.
The temperature of recycle stream was calculated as 111,50 C. The temperature of the leaving
stream was calculated as 32,890 C, by the energy balance around feed drum.
In the vaporizer molten salt was used for heating. The temperature at the entrance of
the unit is the temperature of the mixture leaving the feed drum, which is 32,890 C. And the
leaving temperature is the bubble point temperature of the mixture, which is 109,50 C. The
pressure is 2 bars, and assumed to be constant.
Since the temperature leaving the vaporizer is not enough for the reaction a pre-heater
was used. The unit is working at 2 bars, and assumed to be constant. The entrance and leaving
temperatures are 109,50 C and 3250 C.
The reactor was the starting point for the calculations. The temperature values for the
entering and leaving streams were found from literature, which are 3250 C and 3500 C,
respectively. The reaction taken place inside is endothermic, for this reason the reactor has to
be heated. For heating, molten salt was used. The pressure is 1,8 bar, and assumed to be
constant.
The entrance temperature of the cooler is 3500 C and leaving is 94,70 C. For cooling,
water was used. Instead of water a refrigerant may be used. Better results may get. But since it
costs too much, it wasnt chosen as the cooling material. From the temperature values its
easily seen that the load is on the cooler not on the condenser, for this process. But in reality
the unit cannot cool that much, and the load is mostly on the condenser. In this process, the
mixture cooled down to its dew point. The pressure is 1,5 bar, and assumed to be constant.
-4-
The temperature of the entering stream is the dew point and the leaving temperature is
the bubble point of the mixture. In the condenser water was used as cooling material. In the
calculation of the dew and bubble points Antoine Equation was used. Trial and error was used
with the help of Excel. The mixture includes acetone, i-propyl-alcohol, water and hydrogen.
But hydrogen was not taken into consideration in the calculations. Since the condensation
temperature of hydrogen is very low, it is not condense in the condenser. It stays in the for
this reasons it has no affect on bubble and dew point calculations. Also since it does not affect
the temperature calculations its not taken into consideration on mole and mass fraction
calculations. The leaving and entering temperatures are 94,70 C and 810 C, respectively. The
pressure is 1,5 bar, and assumed to be constant.
Flash unit was assumed to be isothermal, for this reason temperature was not changed.
It is 810 C in the entrance and exit. The pressure is 1,5 bar, and assumed to be constant. By
trial and error method, (V / F) value was found to be 0,2. The entrance temperature of the unit
is the bubble point of the mixture, but if it was its dew point the (V/F) value would be much
higher.
Scrubber was assumed to be adiabatic. The temperature of water entering the unit was
assumed to be 250 C. The temperature of the off gas, including hydrogen and a very little
amount of acetone, was assumed to 700 C. But this assumption is too high, a lower
temperature should have been assumed, since a lot of water is used in the unit. It should have
been around 400 C - 500 C. The temperature of the leaving stream was found to be 28.10 C.
The pressure of the unit is 1,5 bar, and assumed to be constant.
The streams leaving the scrubber and flash unit are mixed together before entering the
acetone column. The temperature leaving the flash unit and scrubber are 810 C and 28.10 C,
respectively. The temperature of the mixture was found to be 450 C. This result was getting by
using energy balance around the mixing point.
-5-
The acetone column is used to separate the acetone from the mixture. The entrance
temperature is 450 C. The leaving temperatures for the top and bottom product are 102,3 and
105, respectively, which are the bubble and dew points. Top product of the unit includes
acetone i-propyl-alcohol and 99wt% of the product is acetone. This amount is assumed to be
the desired acetone production rate, which is 115000 ton/year. From the bottom i-propylalcohol, water and a very little amount of, 0,1 %, acetone is discharged. The pressure is 1,1
bar, and assumed to be constant.
In the distillation column, i-propyl-alcohol and water are separated. The entrance
temperature is 1050 C. The leaving temperatures of the top and bottom products are both
111,50 C. The top product is recycled to the feed drum. For this reason its assumed to have
the same concentration with the feed stream. But in reality a very little amount of acetone
exists in the stream. Its calculated but neglected on the recycle stream calculations. The
bottom product is assumed to be pure water and its thrown away. Since its temperature is
very high it cannot be recycled to the scrubber. But if a cooler is used, a recycle can be used.
The pressure is 1,1 bar, and assumed to be constant.
In the calculations one year is assumed to be 360 working day and 8600 hours. If it
was 300 working day and 7200 hours, the results may be higher.
Since approximated values are used in the calculations, some errors may occur. The
values were taken in three decimal digits. If four or more decimal digits were taken, more
accurate results would get. Also during the calculations of the specific heats, approximated
values used.
-6-
4.0 NOMENCLATURE
MW=MolecularWeight[kg/kmol]
n=mole[mol/h]
y=molormassfractionofgasstream
x=molormassfractionofliquidstream
PT=TotalPressure[bar]
Pi*=VapourPressureofComponent[bar]
Pv*=VapourPressure[bar]
F=FeedFlowRate[kmol/h]
V=FlowRateofVapour[kmol/h]
L=FlowRateofLiquid[kmol/h]
T=Temperature[C]
Hvap=LatentHeatofVaporisation[kJ/kg]
TC=CriticalTemperature[C]
PC=CriticalPressure[bar]
Tb=NormalBoilingPoint[C]
Q=Heat[kJ]
m=MassFlowRate[kg/h]
-7-
12
STACK GAS
OFF GAS
H2
WATER
FURNACE
11
SCRUBBER
NATURAL GAS
AIR
14
ACETONE
17
MOLTEN SALT
13
IPA COLUMN
CONDERSER
ACETONE COLUMN
FLASH
VAPORIZER
REACTOR
FEED DRUM
10
COOLER
HEATER
17
WASTE
WATER
15
16
RECYCLE IPA
-8-
17
5.0 APPENDIX
5.1 MASS BALANCES
Production Rate : 115000 ton/year
5.1.1 REACTOR
I-propylalcohol=100 kmol/h
H2O = 49.25 kmol/h
R
E
A
C
T
O
R
acetone
H2
H2 O
i-propyl-alcohol
conversion = 90 %
nH O 5 = 49.25 kmol / h
2
90
= 0.376
239.25
90
yH 5 =
= 0.376
2
239.25
49.25
yH O 5 =
= 0.206
2
239.25
10
yi propylalcohol 5 =
= 0.042
239.25
yacetone5 =
-9-
acetone
H2
H 2O
i-propyl-alcohol
acetone = 90 kmol/h
H2 = 90 kmol/h
F
L
A
S
H
acetone
H 2O
i-propyl-alcohol
For acetone
1161
224 + 81
= 1651.6 mmHg
*
= 7.02447
log Pacetone
*
Pacetone
K acetone =
1651.6
= 1.467
((1.5 /1.013) *760)
For i-propyl-alcohol
*
= 8.37895
log PIPA
1788.02
227.438 + 81
*
PIPA
= 381.89 mmHg
K IPA =
381.89
= 0.339
1125.092
For water
1668.21
228 + 81
= 369.89 mmHg
PH* O
2
K H 2O =
369.89
= 0.328
1125.092
- 10 -
F=V+L
0.2 =
V
F
V = 29.85 kmol/h
L = 119.4 kmol/h
yv = K xL
F zF = V yv + L xL
For acetone
yv = 1.467 xL
90 = 29.85 yv + 119.4 xL
xL = 0.551
yv = 0.809
For i-propyl-alcohol
yv = 0,339 xL
10 = 29.85 yv + 119.4 xL
xL = 0.077
yv = 0.026
For water
yv = 0.328 xL
49.25 = 29.85 yv + 119.4 xL
xL = 0.381
yv = 0.125
At stream 8;
V = 29.85 kmol/h
yacetone = 0.809
yi-propyl-alcohol = 0.026
ywater = 0.125
At stream 9;
L = 119.4 kmol/h
xacetone = 0.551
xi-propyl-alcohol = 0.077
xwater = 0.381
12
5.1.3 SCRUBBER
OFF-GAS
H2=90 kmol/h
Acetone
11
H2 O
H2 = 90 kmol/h
H2O = 3.731 kmol/h
8
Acetone = 24.148 kmol/h
i-propyl-alcohol = 0.776 kmol/h
10
Acetone
H2 O
i-propyl-alcohol = 0.776 kmol/h
y acetone12 1 A
L
; A = 11
=
6
y acetone8 1 A
mV8
m=
3598
10.92
m=
3598
10.92
354.15
1.48
= 1.445
y acetone12 2.68*104
1 A
=
= 1.320*103 =
y acetone8
0.203
1 A6
- 13 -
14
acetone
i-propyl-alcohol
A
C
E
T
O
N
E
13
C
O
L
U
M
N
acetone
15
i-propyl-alcohol
water
nacetone 15 =
89.913
= 0.089 kmol/h
1000
n-propyl-alcohol 14 = 89.824
0.01
= 0.907 kmol/h
0.99
17
15
acetone
i-propyl-alcohol
water
C
I O
P L
A U
M
N
16
water
nwater 17 = 9.063
0.33
= 4.464 kmol/h (neglecting acetone composition)
0.67
- 15 -
i-propyl-alcohol
water
1
FEED
DRUM
i-propyl-alcohol=9.063 kmol/h
water=4.464 kmol/h
i-propyl-alcohol=100 kmol/h
water=49.25 kmol/h
17
Input = Output
n-propyl-alcohol 2 = ni-propyl-alcohol 1 + n-propyl-alcohol 17
n-propyl-alcohol 1 = 100 9.063 = 90.937 kmol/h
nwater 2 = nwater 1 + nwater 17
nwater 1 = 49.25 4.464 = 44.786 kmol/h
since 115000 tons/year acetone is wanted to produce, all of these calculations should be
58.08kg 1ton
8760h
= 45700.726ton / year
1kmol 1000kg 1year
Scale Factor:
115000 ton year
= 2.516
45700.726 ton year
- 16 -
T=25o C
mi-propyl-alcohol = 13749.785 kg/h
mwater = 2029.966 kg/h
1
2
FEED DRUM
T=111.5o C
mi-propyl-alcohol = 1370.369 kg/h
mwater = 202.326 kg/h
T=32.89o C
mi-propyl-alcohol = 15120.154 kg/h
mwater = 2232.293 kg/h
17
- 17 -
5.2.2 VAPORIZER
T=32.83 o C
mi-propyl-alcohol = 15120.154 kg/h
mwater = 2232.293 kg/h
VAPORIZER
T=109.5 o C
mi-propyl-alcohol = 15120.154 kg/h
mwater = 2232.293 kg/h
At 32.83 oC
Cp i-propyl-alcohol = 145 kJ/kmol.K = 2.413 kJ /kg.K
Cp water = 4.179 kJ /kg.K
For Water:
TC = 508.3 K
Tb = 394.399 K
Hf = 39838 kJ/kmol
H vap,H O
2
T T
= H f c
Tc Tb
0,38
508.3K 382.5 K
H vap,H O = 39838
2
508.3 K 394.399 K
For IPA :
0.38
TC = 647.3 K
Tb = 375 K
Hf = 40683 kJ/kmol
H vap,IPA
647,3K 382,5 K
= 40683
647,3 K 375 K
0,38
- 18 -
Molten Salt :
Q = m Cp,molten salt T
9.652 106 kJ= 1,56 kJ /kg m (20)
m= 309.358 tons
5.2.3 PRE-HEATER
T=109.5 o C
mwater = 2232.293 kg/h
mi-propyl-alcohol = 15120.154 kg/h
T=325 o C
mi-propyl-alcohol = 15120.154 kg/h
mwater = 2232.293 kg/h
HEATER
Molten Salt :
We assume T = 150
Q = m Cp,molten salt T
1.845 106 kJ= 1,56 kJ /kg m (150)
m= 7.885 ton
- 19 -
5.2.4 REACTOR
Hf kJ/kmol
nout kmol/h
(CH3)2CHOH
251.6
-272.290
25.16
(CH3)2CO
-216.685
226.44
H2
226.44
4
T=325 o C
mi-propyl-alcohol = 15120.154 kg/h
mwater = 2232.293 kg/h
325
Hin ,
IPA = 272,29 +
R
E
A
C
T
O
R
( 32,427 +1,88610
T=350 o C
mi-propyl-alcohol = 1512.015 kg/h
mwater = 2232.293 kg/h
macetone = 13151.635 kg/h
mH2 = 455.144 kg/h
25
( 32,427 +1,88610
25
- 20 -
350
Hout,H =
2
( 28.8410
25
Q = out n i H i in n i H i + H r
Molten Salt :
Cp (molten salt between 360C 410C) = 1,56 kJ/kg
Q = m Cp,molten salt T
30521.67 kJ= 1,56 kJ /kg m (50)
m= 391.300 kg/h
- 21 -
5.2.5 COOLER
T=350 o C
mi-propyl-alcohol = 1512.015 kg/h
mwater = 2232.293 kg/h
macetone = 13151.635 kg/h
m H = 455.144 kg/h
5
COOLER
T=94.7o C
mi-propyl-alcohol = 1512.015 kg/h
mwater = 2232.293 kg/h
macetone = 13151.635 kg/h
m H = 455.144 kg/h
2
Tref=94.7 oC
Q= - 10.123 106 kJ
Water :
- 22 -
5.2.6 CONDENSER
T=94.7o C (Tdp)
mi-propyl-alcohol = 1512.015 kg/h
mwater = 2232.293 kg/h
macetone = 13151.635 kg/h
m H = 455.144 kg/h
CONDENSER
log P* = A
B
C + Tdp
T=81o C (Tbp)
mi-propyl-alcohol = 1512.015 kg/h
mwater = 2232.293 kg/h
macetone = 13151.635 kg/h
m H = 455.144 kg/h
2
; P* mm Hg
y i propyl alcohol PT
y acetone PT
y water PT
y PT
+
+
+ H* 2
=1
*
*
*
Pacetone Tdp Pwater Tdp Pi propyl alcohol Tdp PH 2 Tdp
From literature;
For acetone:
A=7.02447
B=1161
C=224
For water:
A=7.96681
Using;
B = 1668.21
yacetone =0.6
ywater=0.33
yi-propyl-alcohol= 0.07
C=228
B=1788.02
C=227.438
- 23 -
Using;
m Cp T + mHf = Qtot
yacetone = 0.6
ywater= 0.33
yi-propyl-alcohol= 0.07
by trial and error Tbp = 81C
For Acetone:
T T
= H f c
Tc Tb
0,38
508.1K 354 K
= 29140*
508.1 K 341.5 K
0,38
For IPA:
T T
= H f c
Tc Tb
0,38
H vap
508,3K 354 K
= 39858*
= 41169,35kJ / kmol = 685,128kJ / kg
508,3 K 366,6 K
- 24 -
For Water :
Tc Tb
0,38
647,3K 354 K
= 40683*
647.3 K 385.186 K
0,38
For Hydrogen :
H2
m C
i
p,i
T = 410.677 *103 kJ ;
m H
i
vap,i
Water :
- 25 -
= 12.702*106 kJ
5.2.7 SCRUBBER
12
mwater = 27378.603 kg/h
T=70o C
macetone = 3.485 kg/h
m H = 455.144 kg/h
2
11
T=81o C
mi-propyl-alcohol = 117.307 kg/h
mwater = 169.107 kg/h
macetone = 3528.708 kg/h
m H = 455.144 kg/h
10
T=28.1o C
mi-propyl-alcohol = 117.307 kg/h
mwater = 27547.709 kg/h
macetone = 3525.224 kg/h
Qin = Qout
TRef = 25 oC ;
T = 28.1 oC
- 26 -
14
T=45o C
mi-propyl-alcohol = 1507.508 kg/h
mwater = 29609.634 kg/h
macetone = 13138.916 kg/h
A
C
E
T
O
N
E
13
C
O
L
U
M
N
T=105o C
mi-propyl-alcohol = 1370.369 kg/h
mwater = 29609.634 kg/h
macetone = 13.010 kg/h
15
H vap
T T
= H f c
Tc Tb
0,38
Before the application the formula boiling temperatures ( Tb ) for each of the
component must be find at 1,1 bar pressure.
B
T
will be used.
CONDENSER:
For acetone:
Pc = 47 bar
Tc = 508.1 K
P = 1.0133 bar
ln 1.0133 = A
B
329.2
ln 47 = A
B
508.1
- 27 -
ln 1.1 = 10.91
3587.3
Tb
Tb = 331.706 K
For i-propyl-alcohol
Pc = 47.6 bar
Tc = 508.3K
P = 1.0133 bar
ln 1.0133 = A
B
355.35
ln 47.6 = A
B
508.3
4546.375
Tb
Tb = 357.653 K
H acetone
508.1 375.3
= 29140
508.1 331.706
0,38
508.3 375.3
H IPA = 39858
508.3 357.653
0,38
- 28 -
For water:
Pc = 220.5 bar
Tc = 647.3 K
P = 1.0133 bar
ln 1.0133 = A
B
373.15
ln 220.5 = A
B
647.3
4743.39
Tb
Tb = 375.723 K
REBOILER:
508.1 378
H vap,acetone = 29140
508.1 331.706
0,38
For Water:
H vap,water
647.3 378
= 40683
647.1 375.723
0,38
508.3 378
H vap,i propylalcohol = 39858
508.3 357.653
0,38
Balance;
Q=mTHvap,mixture=30993.013672,945=20,86106 kJ
T=105o C
15
mwater = 29609.634 kg/h
macetone = 13.010 kg/h
mi-propyl-alcohol = 1370.369 kg/h
C
I O
P L
A U
M
N
16
T=111.5o C
mi-propyl-alcohol = 1370.369 kg/h
mwater = 202.326 kg/h
macetone = 13.010 kg/h
Q = 1.633*106 kJ
Reboiler:
H vap,WATER
647,3 384,5
= 40683
0,38
- 31 -
REFERENCES
Foust, A.S., Wenzel, L.A., Clump, C.W., Meus, L., Anderson, L.B., Principles of Unit
Operations, John Willey and Sons Inc, USA, 1960
Perry, R.H., Green, D., Perrys Chemical Engineers Handbook, 5th Edition, McGrawHill International Ed., 1984
McCabe, W.L., Smith, J.C., Horriott, P., Units Operations of Chemical Engineering,
McGraw-Hill International Edition, USA, 1993
32