DESIGN OF 1,000 TONS OF HERBICIDES PER ANNUM PLANT FROM PROPYLENE

AND SYNTHESIS GAS

MATERIAL BALANCE
(HYDROGENATION CHAMBER)

BY

GODWIN ARCHIBONG
15/EG/CE/686

(GROUP SIX)

SUBMITTED TO

THE COURSE LECTURER

CHE522 (PLANT DESIGN 111)

PROF. I. O. OBOH

DEPARTMENT OF CHEMICAL ENGINEERING,

FACULTY OF ENGINEERING,

UNIVERSITY OF UYO, UYO, AKWA IBOM STATE, NIGERIA

IN PARTIAL FULFILMENT OF THE REQUIREMENTS OF THE AWARD OF

BACHELOR OF ENGINEERING (B. ENG) DEGREE IN CHEMICAL ENGINEERING

JANUARY, 2023
 MATERIAL BALANCE

5.1 Preliminary Data for Material Balance

Species Chemical Formula Molar Mass

2- Ethylhexanol C8H180 130.23
2- Ethylhexanal C8H16O 128.215
n- butyl aldehyde C4H8O 72.107
Iso- butyladehyde C4H8O 72.107
Propylene C3H6 42.08
CO CO 28.01
H2 H2 2
n-Butanol C4H10O 74.12
Iso-Butanol C4H10O 74.12
CH4 CH4 16
N2 N2 28
 Propylene C3H6 44.1
Table 5.1: Preliminary data for material balances

5.2 Simplified Flow Sheet

The material balance will be computed based on the Block Flow Diagram in Figure 4.1

5.3 Fundamentals of Material Balance

Material balance is the fundamental of process design. A material balance taken over the

entire process will be used to calculate the quantities of raw materials required and produced.

Material balances including inflow, outflow, reaction rates mixing effect are considered in

material balance calculation. Material balance is an expression of the generalized law of

conservation of mass. It accounts for all the materials in a process.

 Individual (component) and overall material balances may be carried out as a system

selected for analysis by the engineer, material balances and plant managers in their daily

operating decision. The loss of mass associated with the production of energy is significant only

in nuclear reactions. Energy and matter are always considered to be separately conserved in

chemical reaction which led to the law of conservation of mass. The general conservation

equation for any process system can be written as;

Material out = material in + generation – consumption - accumulation.

That is; accumulation = material- material+ generation- consumption in and out.

5.4 General Assumptions

i. The system is a steady state.

ii. 1 year (8760 hours) is dedicated for a skeletal production.

iii. The process is continuous

Given: To design 1,000 metric tons per 8760-hour capacity of 2-EH plant

The calculation is based on:

Basis: 1tonne of 2-ethylhexanol produced per day

The following equipment will be considered for material balance calculation;

i. Oxo Reactor

ii. Distillation Column

iii. Stripper Column

iv. Aldol condensation Reactor

v. Hydrogenation Chamber

The following data were given;

Molecular weight of 2-ethylhexanol = 130.23Kg/Kmol

Conversion of propylene gas (vapour) = 95%

Synthesis gas to propylene ratio = 2:1

Production per annum of 2-ethylhexanol = 1,000 tons/year

Assumptions

Conversion efficiency of Aldol reactor = 90%

Conversion efficiency of hydrogenation chamber = 99%

Operating period/annum = 8000hours

Downtime period/annum = 736hours

Material Balance around the Hydrogenation Chamber

Hydrogenation Chamber

Feed into the hydrogenation unit is the 2-ethylhexenal product from the dehydration

chamber which is the same as produced in the aldol reactor ¿ 35.96 kmol /hr

Equation of Reaction

C 8 H 14 O H C 8 H 16 O H C 8 H 18 O
→ →

C 8 H 14 O+4 H ¿ C 8 H 18 O
→

By stoichiometry: 1 kmol/hr of 2-ethylhexenal produces 1 mole of 2-ethylhexanol

2-etylhexanol produced (Q3) ¿ 0.99 ×33.78=33.44 Kmol/hr (5.54)

Amount of Hydrogen required in the excess of 100% is;

From the stoichiometry equation: 1 mole of 2-ethylhexenal require 4 moles of Hydrogen

4 × 33.78
33.78Kmol/hr of 2-ethylhexanal require ¿ =135.12kmol /hr (5.55)
1
 2-ethylhexenal 2-ethylhexanol

H2

Figure 5.7: The Hydrogenation Chamber

Table 5.6: Summary of the material balance around the Hydrogenation Chamber

Components INPUT OUTPUT

2-ethylhexenal 33.78kmol/hr 33.78kmol/hr

2-ethylhexanol 33.44kmol/hr

H2 135.12kmol/hr 135.12kmol/hr

Total 168.9kmol/hr 168.9kmol/hr

5.11 Scale Up

Scaling up the result of material balance using the information below;

Scaling up the result of material balance using the information below;

Production required: 1,000tons/yr = 1.0 ×103 kg / yr

Molecular weight of 2-ethylhexanol ¿ 130.23 kg /kmol

Operating period = 8000hours

3 kg
1.0× 10
yr
kmol/hr of 2-ethylhexanol ¿ =9.598 Kmol/hr (5.56)
hrs kg
8000 × 130.23
yr kmol

Amount of Propylene required is given as; Z kmol/hr

105.4 kmol 33.44 kmol

of Propylene → of 2−ethylhexanol
hr hr
Zkmol 9.598 kmol
of propylene → of 2−ethylhexanol
hr hr

105.4 ×9.598
Z¿ (5.57)
33.44

Z ¿ 30.252 Kmol /hr (5.58)

Amount of synthesis gas required is given as Y kmol/hr, feed ratio of syngas to propylene is 2:1.
Therefore,

Y =2× Z ,=2 ×30.252 (5.59)

Y =60.504 kmol /hr

Let the ratio of H2 to CO in the synthesis gas be 1:1

Then, the amount of CO required

1
¿ ×60.504=30.252 Kmol/ hr (5.60)
2

Then, the amount of H2 required ¿ 30.252 Kmol /hr

Assuming catalyst concentration is 1wt%

Let the amount of catalyst present be W kg/hr

weigth of catalyst
=concentration of catalyst (5.61)
weight of reactant

W
=¿ 0.01
( 30.252× 42 ) + ( 30.252× 28 ) + ( 30.252× 2 )+ W
(5.62)

Amount of catalyst required ¿ 22.001 kg/hr

5
Unreacted propylene is 5% of propylene; ×30.252=1.513 kmol/ hr (5.63)
100

Off gas¿ Y −Z ,60.504−30.252=30.252kmol /hr (5.64)

Amount of butanal (n-butanal and i-butanal) produced = conversion of propylene

¿ 0.95 ×30.252=28.739 kmol/hr (5.65)

4
n-butanal ¿ ×28.739=22.991 kmol/hr (5.66)
5

1
i-butanal ¿ ×28.739=5.748 kmol /hr (5.67)
5

Since 6% and 4% of n-butanal and i-butanal is converted to n-butanol and i-butanol respectively

n-butanol formed ¿ 0.06 ×22.991=1.379 kmol/hr (5.68)

i-butanol formed ¿ 0.04 × 5.748=0.229 kmol /hr (5.69)

New Amount of n-butanal ¿ 22.991−1.379=21.612 kmol/hr (5.70)

New Amount of i-butanal ¿ 5.748−0.229=5.519 kmol /hr (5.71)

Hydrogenation Chamber

Feed into the hydrogenation unit is the 2-ethylhexenal product from the dehydration

chamber which is the same as produced in the aldol reactor ¿ 8.805 kmol /hr

Equation of Reaction

C 8 H 14 O H C 8 H 16 O H C 8 H 18 O
→ →

C 8 H 14 O+4 H ¿ C 8 H 18 O
→

By stoichiometry: 1 kmol/hr of 2-ethylhexenal produces 1 mole of 2-ethylhexanol

2-etylhexanol produced (Q3) ¿ 0.99 ×8.805=8.717 Kmol/hr (5.88)

Amount of Hydrogen required in the excess of 100% is;

From the stoichiometry equation: 1 mole of 2-ethylhexenal require 4 mole of Hydrogen

 4 × 8.805
8.805Kmol/hr of 2-ethylhexanal require ¿ =35.220 kmol /hr (5.89)
1

2-ethylhexenal 2-ethylhexanol

H2
Figure 5.14: The Hydrogenation Chamber

Table 5.12: Summary of the material balance around the Hydrogenation Chamber

Components INPUT OUTPUT

2-ethylhexenal 8.805kmol/hr 0.088kmol/hr

2-ethylhexanol 8.717kmol/hr

H2 35.220kmol/hr 35.220kmol/hr

Total 44.025kmol/hr 44.025kmol/hr