Append 8 Information fr the Preliminary Design of Fifteen Chemical Processes 8.5.3 Simulation (CHEMCAD) Hints ‘The CHEMCAD simulation used to generate the PFD shown in Figure B51 has several simplifications that are valid for this system, The removal of trace amounts of noncon- ddensables is achieved after the absorber using a component separator, which avoids prob- lems with column convergence downstream. The formation of maleic acid i simulated by "using a stoichiometric reactor and setting the conversion of water to 1 "Tower T-50, the maleic anhydride serubber, is simulated using the rigorous tower simulator, Tower 1-602, the dibuty! phthalate toveer is simulated using the Shortcut col ‘umn module. Currently, there is no experimental vapor pressure data for the components in this simulation. It appears thatthe vapor pressures ofthe components differ widely, and no azeotropes are known at this time. For this reason, the ideal vapor pressure _K-value option and the latent heat enthalpy option are used, Th order to simulate the temperature spike in the reactor, the reactor ie simulated as a cocurrent, packed-bed kinetic reactor, with a molten salt stream as the utility. This con- figuration provides a greater temperature differential at the front end of the reactor, ‘where the reaction rte is highest Countercurrent flow could be investigated as an alter” native. The Kinetics given above are used in the simulation. Dimensions of the reactor tubes are given in Section B5.2 B.5.4 References A. Felthouse,T-R, J-C. Burnet, B. Horcell, M.]. Mummey, and ¥-] Kuo, "Maleic Anhy- dride, Maleic Aci, and Fumaric Acid,” Kirk Other Encyclopei of Chena Technol- gy, anline version (New York: John Wiley and Sors, 2001). 2. "Maleic Acid and Anhydride,” Encyclopedia of Chemical Processing and Design, Vol. 28, ed. J.J. MeKetta (New York: Marcel Dekker, 1984), 35-55. 3. Wohlfahrt, Emig G, "Compare Maleic Anhydride Routes,” liytracarbon Processing, Jaane 1980, 83-80. ETHYLENE OXIDE PRODUCTION, UNIT 700 [Ethylene oxide is a chemical used to make ethylene glycol (the primary ingredient in an- tifreze). Ibis also ased to make polyethylene oxide, and both the law-moveculae-weight and high-molecular-weight polymers have many application including as detergent aci- tives. Beeause ethylene oxide i s0 reactive thas many other uses as a reactant. However, because ofits reactivity, danger of explosion, and toxicity, it «rarely shipped outside the _manufacturing facility but instead is often pumped directly toa nearby consumer. B.6.1 Process Description [1, 2] “The process flow diagram is shown in Figure B61. Ethylene feed (via pipeline from a neighboring plan) is mixed with recycled ethylene and mixed with comprested and dried Air (drying step not shown), heated, and then fed to the frst reactor. The reaction is ‘exothermic, and medisin-pressure steam is made in the reactor shell. Conversion inthe re- actor is kept low to enhance selectivity for the desired product. The reactor effluent is cooled, compressed, and sent to a scrubber, where ethylene oxide is absorbed by water. “The vapor from the scrubber is heated, theotled, and sent to a second reactor, followed by a secand series of cooling, compression, and scrubbing. A fraction ofthe unreacted vapor”oe Append 8 Information fr the Preliminary Design of Fifteen Chemical Processes Table 8.6.1 Stream Table for Unit 700 Stream Number 1 2 a 4 Temperature CO) 250 250 1592 60 Pressure (bt) 10 500 30 a Vapor mole faction 2.00 1.00 1.00 100 Powrste (kg/h) 509,900 aad 50000 0,000 west hal) 738145, mas 1738145173615 Component flowrates (kmel/h) lene oo ma > 09 Eubylene oxide oo oo 09 oo oxygen sess oo aaeas as Nitrogen 510008 09 1400091410008 Wiser a0 00 29 09 Stream Number 5 6 7 a Temperature CO) 0 1952 3 Pressure (bar) 87 9 m7 Vapor sole fxetion 1.00 1.00 1.00 Rowrate kg/h) seam Sone 2000 lweate aro) wssias 17381457291 Component flowrates (kmel/h) Fyne 20 0 0 ma Ebylene oxide oo oo 09 oo Carbon dioxide oo oo oo 00 Onygen was msgs aaas 09 Nitrogen 1410008 1410008 14,1008 oo Stream Number ° 10 u 2 Temperature °O) 28 1087) 20 Pressure (bar) x0 268 165 Vapoe sole fation 1.00 1.00 1.00 iowrate eg) soya 13.980 1025980 lowest ero) 26029 a5439se a5 40859 Component flowrates (kmel/h) Ethylene mrss wren a8 Eubylene oxide eas sar a7 679 Carbon dioxide a7 si7t simi $956 Onyeen soos ame aaot Nitrogen som «28139 —-BMIP_—-28919Appendix 8 Information forthe Preliminary Design of Fifteen Chemical Processes Table 8.6.1 Stream Table for Unit 700 (Continued) Stream Number a 1 6 16 Temperature CO) 50 a7 350 wa Pressure (bt) 235 woz 3a x Vapor mole faction 1.00 1.00 ooo 100 Powrste (kg/h) 1om9s0—mn39s> sang 1015 668 west hal) asa 55539 20000 35,358, Component flowrates (kmel/h) lene sss07 53867 0 3796 Euhylene oxide 20679 20679 09 1545, oxygen enue anus oo canna Nitrogen 219139 28,191.39 oo 28,8872 Water 132 4882 0,000 am Stream Number v7 a 9 20 Temperature CO) sis 200 9 2400 Pressure (bat) 300 27 265 358 Vapor sole fstion oo 1.00 100 1.00 Fowrste kg/) Ses11 1015569 L015.568 1.015.568 lowest rol) Doisi7? 335765535766 3527747 Component flowrates (kmel/h) lene 70 s5796 5796 aM Ethylene oxide sist 55 sas 7588 Carbon dioxide 00) ws: 1955 as Oxygen us ann am ann Nitrogen 26s 2818872 2518872 24,188.72 onal) 991100 Append 8 Information fr the Preliminary Design of Fifteen Chemical Processes Table 8.6.1. Stream Table for Unit 700 (Continued) ‘Stream Number a m 3 % Temperature (0) 50 es 250 eat Precure (ox) Bs x02 300 sao ‘Vapor nae fraction 1.00 1.00 00 1.00 Total kg/h 015669 101566 693001908084 Total kmal/h SS277a7 3527747 200003808476 Component Flowrates (kmol/h) thylene ones ems oo eros Ethylene oxide 175.983 oo 129% Carbon dioxide eas sot a0 5 Oxygen si «1017 oo «1002s Nitrogen asss72 28,8872 no mss Stream Number 5 26 a eg “Temperature (0) ss 301 301 2s Prssure (om) 300 sao x00 x0 Vapor tole fexetion 0 1.00 20 1.00 Flowrate(kg/4) ssras soko Suga sug Fowrate (el) msn sar w7sara8 7 sar3s Component flowrates (kmol/h) thylene 057 sash ash 5808 Ethylene oxide 102.88 688 eas 68s Carbon dioxide oot a7 aim a7 Onygen sso aasoad asa Nitrogen 26s 4oso2 oer 408502 Miter ronsas mae ange saea0 Appendix 8 Information forthe Preliminary Design of Fifteen Chemical Processes Table 8.6.1 Stream Table for Unit 700 (Continued) Stream Number 2 30 n 2 Temperature CC) saa 50 50 wea Pressure (bt) a0 337 00 10 Vapor role faction oo ooo 000 oo Fowrate (eg/h) rasa97 AT TR6ZIB SSIS Foverte (als) Wo2ouss —anactas —agasies 35.8 Component flowrates (kmel/h) yen 2 1s 1a 00 Ethylene oxide sin wim sn {carbon dioxide on 2 one fi Oxygen 29 ass 249 oo Nitrogen 535 535 535 oo Water sop0074——sgo074 a0 74 038 Stream Number 2 4 Temperature CC) 13) sea Pressure (ba) 105, 00 Vapor mole fetetion am 100 Foverate(g/4) 0703 a8 verte (mal) sopans7 95 Component flowrates (kmel/h) lbylene oxide 2s 09 Carbon dioxide on oor Oxygen oo 288 Nitrogen oo 535102 Append 8 Information fr the Preliminary Design of Fifteen Chemical Processes Table 8.6.2 Utility Summary Table for Unit 700, e701 E702 e703 E706 ow ow wpe ow 1SOTSTORg/h 1985578 kg/h 87162 kg/® 5,008,727 kg/h £705, 5-706 e707 E708, oe oe oe hee 135789kg/h___ 4850860 kg/h —_—_SIB.697kg/h__I5BS7S E709) R701 R702 ow bem brome 29,608 kg/h 267B kg/h 0818 ig Table 8.6.3 Major Equipment Summary for Unit 700 ‘Compressors crm e708 Carbon steel Carbon steal Gentigal Centfagal Power=19 MW Power =55 MW [0 adiabatic efcieney 0% adiabatic efficiency Carbon steel Carbon steet Centrifugal Centntugal Power -25 MW Power 55.MW 0% adiabatic efficiency 0% adiabatic efficiency cms Eaton steel ential Power =315 MW ‘Note that all comprestorshave electric explosion proof drives witha backup. These unite re esignated D701 A/B through D705 A/B but are nat shown onthe PFD.Appendix 8 nformation forthe Peliminar Design of FteenChenical Processes 103 Table 8.6.3 aor Equipment Summary for Unit 70 (Continued) Twi Fechanges eer {ochagerfosinghed.ertended! —taeschang festng hn, bon te doconsneninabe Posesnsntin mbes Srna Per hee Teenage fosinghedartonsee —— Taenchnger Dxtng ha bon ste Paccnsetinnabe Pascnaetamnube oveanwn era Em Eee aehangerfosteghed.entonsed —taeathger Nain hen, sles oceans ote Eo Aa tenone dossnsntinaabe Passtantamtess ht ocmesorh orien Es 1-2 exchanger, loating head, carbon see = 229880 Mim Pump Poot Ae Centrigaletrie drive Siainlest ates] Power KW (atl) Fieticent R701 Rem Carbon steel, shell and-tube packed bed Carbon ses, shelhand tube packed bed Spheres sty pellet, 9 mmm abate Spherial estalyt pelt 9mm aiameter Void faction =O Void faction =O v0 v= 200m? 10m tall,738 em diameter tubes Om al, 933 cm diameter tubes sates 2834 tubes 100% filled with active catalyst. 100% fled with active catalyst. (= 33,01 MI/h (= 26,79 Mh ripe made nhl smps made in shell (Conte)104 Append 8 Information fr the Preliminary Design of Fifteen Chemical Processes Table 8.6.2 Major Equipment Summary fr Unit 700 (Continued) 170 703 Carbon steal Staines steal 2058 seve tays 7058 sieve ways plus reboller and condenser 25% efficient tay Beticent tye Feeds on teays and 20 Total condenser (709) ‘ain teay spacing Bin wert Feed on ty 36 Column 22m Reflux ratio - 089 Diameter= 56m ‘tray spacing, in welts Ten Column height 43m Diameter = 80m Carbon seat 20S seve tay 25% efficient ays Feeds on rays | and 20 Dein tay spacing, Sin weirs Column height “122 m Diameter= 56m Vessel Staines ste Honzontal D=30 stream is purged, with the remainder recycled to recover unreacted ethylene. The com- bined aqueous product streams are mixed, cooled, trotted, and distilled to produce the desired product The required purty specification i 9.9 wt ethylene oxige. Stream summary tables, utility summary tables, and major equipment specifications are shown in Tables B61-B63, 5.2 Reaction Kinetics ‘The pertinent reactions (adapted from Stoukides and Pavlou [3] areas follows: GH + 050,640 Gl, #30,-+200, + 24,0 GHO +250, +200, + 24,0 “The kinetic expressions are, respectively, 1.96 exp(-2400/87)p, T$ 000098 expC 200/RT Pyne 8.0836 exp(~ 6400/ Paine T+ 0.00096 exp(T200/RT Pyar 0.42768 exp(— 5200/R pate 1.000033 exp(21200/R TP 51) (652) 63) 54) 55) (655)Appendix 8 Information forthe Preliminary Design of Fifteen Chemical Processes 105 ‘The units for the reaction rates are moles/m’ s. The pressure unit is bar. The activation ‘energy numerator is in cal/mol. The catalyst used for this reaction is silver on an inert support. The support consists of 75 mm diameter spheres that have a bulk density of 1250 kg/m! and a void fraction of Ot 5.3. Simulation (CHEMCAD) Hints ‘The following thermodynamics packages are strongly recommended for simulation of this process. + Kevalues: Use a global model of PSRK but use UNIFAC as a local model for T-701 and 7702 + Enthalpy: Use SRK, B.6.4 References A. Dever, J.P, KF. George, W.C. Hoffman, and II. $00, “Fthylene Oxide,” Kin-Oth- smer Eneyelopedia of Chemsca! Tecrlagy, online version (New York: John Wiley and Sons, 2004). 2. "Ethylene Oxide,” Encyclopedia of Chemical Processing and Design, Vol. 20, ed. J ‘Meketta (New Yorke Marcel Dekker, 1984), 274 318, 3. Stoukides, M, and 5. Pavlou, "Fthylene Oxidation on Silver Catalysts: Flfet of Fth- ylene Oxide and of External Transfer Limitations,” Chem. Eng. Common. 44 (1985) 574 FORMALIN PRODUCTION, UNIT 800 Formalin is 9 37 wt solution of formaldehyde in wates, Formaldehyde and urea are used to make ureaformaldehyde resins that subsequently are used as adhesives and binders for particle boned and plywood, B.7.1. Process Description [1, 2] Unit $00 produces formalin (37 wes formaldehyde in water) from methanol using the sl ver catalyst process Figure B71 illustrates the process, Air is compressed and preheated, fresh and recycled methanol is pumped and pre~ Jheated, and these two streams are mixed to provide reactor feed. The feed mixture is bout 39 mol’ methanol in ait, which is greater than the upper flammability limit for ‘methanol. (For methanol, UE = 35 mol’; LEL = § mol?) In the reactor, the following, two reactions occur ciyont =4o,-+HcHO+H0 ally =—M3kelimle 73) int fig (CH,OH + HCHO + Hy AH yy = 20.3 keal/mole (B72) tons! formate ‘The reactor is a unique configuration, in which the silver catalyst isin the form of wire gauze, suspended above a heat exchanger tube bank Because the net reaction is very