1.

0 INTRODUCTION

The purpose of this project is to design a plant that efficiently converts liquid ethanol
into high purity ethylene gas via catalytic dehydration. Ethylene is currently the most
consumed intermediate product in the world. Global ethylene production was 107 million
tonnes in 2005, 109 million tonnes in 2006. In 2009, the world demand in ethylene was over
140 million tons per year that has estimated with an approximate yearly increase of 3.5%
(Cameron Gregory, 2012). Also the production of ethylene is 138 million tonnes in 2010 and
141 million tonnes in 2011. By 2013 ethylene was produced by at least 117 companies in 32
countries. To meet the ever increasing demand for ethylene, sharp increases in production
facilities are added globally, particularly in the Mideast and in China.

As we know, Ethylene or the IUPAC name is ethane has the hydrocarbon formula
C2H4. Ethylene is an extremely simple gas which is a colourless flammable gas at room
temperature and pressure and melting point at 169C, boiling point at 104C. It is has a faint
sweet and musky odour when it is pure. Ethylene is a non-polar molecule, soluble in non-
polar solvent and insoluble in polar solvents like water. The reactive site is at the double bond
which readily undergoes addition reaction, for example reacts with bromine water (red-
brown) to produce colourless 1,2-dibromoethane.

PRODUCTION OF ETHYLENE

Ethylene can be produced either by extraction from natural gas using fractional
distillation followed by steam cracking (750-900C) of the naphtha or gas-oil fractions
followed by liquefaction of the gas (-100C) and then further fractional distillation. It is also
can be extraction from natural gas using fractional distillation by steam cracking (alkanes to
alkenes) (750-900C) followed by liquefaction of the gas (-100C) and also undergoes further
fractional distillation. The cracking process typically involves endothermic equilibrium
reactions. So, to maximize the rate of cracking reactions the temperature can be increased so
that the gas particles move more quickly and collide more often, and also increase the
pressure which forces the gas particles closer together and collide more often.
 However, increasingly stricter environmental regulations also with the increasing
global demand for hydrocarbon the process for ethylene production has proven to become
very costly. Therefore, a cheaper process of creating ethylene is highly sought in todays
economy and the original production method of ethanol dehydration is being reconsidered.

REACTION INVOLVING ETHYLENE

Addition of Bromine CH2=CH2 + Br2 > CH2BrCH2Br

1,2-dibromoethane

(AlCl3)
Addition of Chlorine CH2=CH2 + Cl2 > CH2ClCH2Cl
1,2-dicholoethane
(AlCl3)
Addition of Hydrogen bromide CH2=CH2 + HBr > CH3CH2Br chloroethane

(AlCl3)
Addition of Hydrogen chloride CH2=CH2 + HCl > CH3CH2Cl chlorooethane

(Ni, 500C)
Addition of hydrogen CH2 = CH2 + H2 > CH3CH3 ethane

Addition of water (H3PO4, 300C)

CH2 = CH2 + 3O2 > 2CO2 + 2H2O
(excess air)
Combustion CH2 = CH2 + 3O2 > 2CO2 + 2H2O
USES

As we know that ethylene is the raw material used in the manufacture of polymers
such as polyethylene (PE), polystyrene (PS) and one of the most important uses of ethylene is
the production of polyvinyl chloride (PVC). PVC currently serves over 70% of the
construction market. This is include plastics, dominating pipe and fittings, widows, siding,
decking and fencing. In addition, PVC serves 60% of the wire and cable plastics market and
25% of the coatings market and as well as used in variety of industrial such as the packaging,
transportation.

PLANT LOCATION

The production of ethylene is located at Pengerang which is a mukim in KotaTinggi

District, Johor, Malaysia. The site selection of the plant chosen based on the geographical
matter. Considerable care must be exercised in selecting the plant site, and many different
factors must be considered. Primarily the plant must be located where the minimum cost of
production and transportation can be obtained but other factors such as room for expansion
and safe living conditions for plant operation as well as the surrounding are also important.
The choice of the final site should be based on completed survey on the advantages and
disadvantages of the various geographical area and also the safety around the area.

SAFETY

Both ethanol and ethylene are potentially dangerous materials if handled incorrectly.
All the detailed of safety are consider and MSDS report for all material handled in this
process are supplied.