100 MTPD Acetic Acid Plant Design

Course No: MME 440

Materials Processing Plant Design

Submitted by,
Name: Mudasserul Islam (1811036)

Submission Date: 09-09-2023

Group NO: 09

Members:
1811036
1811039
1811050
1711018
1611024
Table of Contents
1. Literature Survey ................................................................................................................................ 5
1.1. Definition of the project .............................................................................................................. 5
1.2. Design Basis ................................................................................................................................. 5
1.2.1. Site Selection:....................................................................................................................... 6
1.2.2. Geological Data ................................................................................................................... 8
1.2.3. Climate Condition ............................................................................................................... 9
1.2.4. Raw Materials ................................................................................................................... 11
1.3. Product Specification ................................................................................................................ 13
2. Selection of Process & Process Description .................................................................................... 16
2.1. Description of available process............................................................................................... 16
2.1.1. Methanol Hydrocarboxylation Process ........................................................................... 16
2.1.2. Cativa Process ................................................................................................................... 16
2.1.3. Justification for the Selection of Hydrocarboxylation Process ..................................... 16
2.2. Selection of The Steam Reforming Process............................................................................. 17
2.2.1. Non-catalytic partial oxidation of methane (POX) ........................................................ 17
2.2.2. Catalytic partial oxidation (CPOX)................................................................................. 18
2.2.3. Methane Reforming in ATR ............................................................................................. 19
2.2.4. Justification for the Selection of ATR with Pre-reformer.............................................. 19
2.3. Process description.................................................................................................................... 20
2.3.1. Feed gas compression and Desulfurization ..................................................................... 21
2.3.2. Pre-Reforming ................................................................................................................... 22
2.3.3. Auto-Thermal Reformer (ATR): ..................................................................................... 22
2.3.4. Carbon Monoxide Shift Converter (HTS and LTS)....................................................... 23
2.3.5. Carbon Dioxide Separation: ............................................................................................ 23
2.3.6. Reactor ............................................................................................................................... 24
2.3.7. Acetic Acid Separation...................................................................................................... 24
3. Process Block Diagram ..................................................................................................................... 26
4. Process Flow Diagram ...................................................................................................................... 27
5. Material Balance ............................................................................................................................... 28
5.1. Desulphurizer Unit .................................................................................................................... 28
5.2. Pre-reformer Unit ..................................................................................................................... 28
5.3. Autothermal Reformer (ATR) ................................................................................................. 28
 5.4. High Temperature Shift Reactor (HTS) .................................................................................. 29
5.5. Low Temperature Shift Reactor (LTS) ................................................................................... 29
5.6. CO2 Absorber............................................................................................................................ 30
5.7. CO2 Desorber ............................................................................................................................ 30
5.8. Reactor ....................................................................................................................................... 30
5.9. Distillation Column 1 ................................................................................................................ 31
5.10. Distillation Column 2 ............................................................................................................ 31
5.11. Distillation Column-3................................................................................................................ 32
6. Energy Balance.................................................................................................................................. 33
6.1. Pre-reformer .............................................................................................................................. 33
6.2. Pre-reformer Convection Zone ................................................................................................ 34
6.3. Heat Recovery from Flue Gas .................................................................................................. 34
6.4. ATR ............................................................................................................................................ 35
6.5. Heat Recovery from ATR Outlet ............................................................................................. 35
7. Environment management plan....................................................................................................... 36
7.1. Air Pollution Control Systems and Equipment ...................................................................... 36
7.2. Water pollution and its mitigation plan .................................................................................. 40
7.3. Solid waste and its mitigation plant......................................................................................... 41
7.4. Dust and noise pollution and mitigation plan ......................................................................... 42
8. List of Equipment ............................................................................................................................. 45
8.1. List of major equipment: .......................................................................................................... 45
8.2. Compressors .............................................................................................................................. 46
8.3. Pumps ......................................................................................................................................... 46
8.4. Tanks .......................................................................................................................................... 47
8.5. Heat Exchangers ....................................................................................................................... 47
8.6. Mixer .......................................................................................................................................... 47
9. Process safety assessment of critical Equipment ............................................................................ 49
9.1. HAZOP study of Acetic acid storage Tank ............................................................................. 49
9.2. HAZOP study of Acetic acid Converter/reactor..................................................................... 50
9.3. HAZOP study of Absorber ....................................................................................................... 52
9.4. HAZOP study of ATR ............................................................................................................... 52
10. Plot Plan & Equipment Layout ................................................................................................... 54
10.1. Plot Plan ................................................................................................................................. 54
 10.2. Equipment Layout ................................................................................................................ 55
11. Cost Estimation & Economic Analysis ........................................................................................ 56
11.1. Estimation of Production Cost:................................................................................................ 57
12. Conclusion ..................................................................................................................................... 60
 1. Literature Survey

1.1. Definition of the project

An Acetic Acid Plant is to be set up at Bramhongon, Rupganj, Narayanganj in Bangladesh
having a capacity of 100MT of Acetic Acid per day, corresponding to 33000 MT of Acetic Acid
per year. Hydrogen will be produced at 8.78 MT per day as a byproduct. The plant includes all
offsite auxiliaries, utilities and supporting facilities using Natural Gas and Methanol as feedstock
and Natural Gas as fuel. Major specifications are given below,

• Plant location: Rupganj, Narayanganj

• Plant capacity: 100 MTPD
• No. of operating days: 330 days
• No. of shift per day: 3 (8 hours per shift)
• Raw materials: NG, water, air
• Raw material transportation: By Pipeline

1.2. Design Basis

Important aspects of the design basis are,
Geological data

• Climate conditions

• Utility conditions

• Raw materials

• Structural designs

• Others
 1.2.1. Site Selection:
The proposed 100MT/day acetic acid plant will be located on the flat land of Bramhongon,
Rupganj, Narayanganj with 6.74 acres area.
Latitude: 23.78841, Longitude: 90.53565

Figure 1.2.1: Proposed site location of 100MT/day Acetic acid plant

The proposed plant is in a city of industrial inland port which is in the central part of Bangladesh
and situated on the bank of the Shitalakshya River, where urban areas are expanding rapidly due
to the recent economic activity on industries and business of different kinds. Adamjee Export
Processing Zone is 12km south and Narayanganj river port is 26 km south of the proposed site
location which brings the great advantages of product marketing and transportation. The proposed
plant is approximately 8 m above the sea level. The groundwater flows from north to south. The
wastewater or sewage water from the area can be dumped into the pond located just beside the
plant after treatment.

The choice of this site is made only after considering the cost and benefits of different alternative
sites. The plant site is chosen based on where the cost of the product is kept to a minimum, with a
large market share, the least risk, and maximum social gain where maximum net advantages or
which gives the lowest unit cost of production and distribution. The site was chosen due to:

1. Raw materials availability- process and utility natural gas is supplied from Titas Gas
Transmission and Distribution Company Limited (TGTDCL) and distributed from
Dighibarabo Town Border Distribution through a 5km 16-inch pipeline.
2. Easier Transportation and Shipping: The proposed location is only 1.3 km west of the
Shitalakshya River. So necessary materials, equipment, or raw materials (methanol if
needed) and the final product can be transported by ships or river barges. Also, transport
costs in obtaining raw materials and distribution or marketing finished products to the
ultimate users within a relatively short time to the ultimate users.
3. Water source: The Shitalakshya River is located just 1.3km west of the proposed plant
site. It has a mean value of turbidity is 50.57 ftu, an average pH of 7.47, an average DO of
2.88 mg/l, an average TDS of 519.89 mg/l, a mean hardness of 107.21 mg/l an average
BOD of 4.9 mg/l. So, pollution parameters are not so intense, treatment costs will be much
lower, and can be safely utilized as a process and utility water source. So, for cooling,
industrial, and housing purposes, water can be pumped from the river.
4. Highway: The proposed site is just along the Bhulta highway, and it can be used for
transportation of products for near-sight distribution by big trucks and lorries.
5. Meteorological and geographic condition: The proposed plant area is blessed with a
geographical location as soil due to its ideal combination of silt, sand, and clay. It combines
the best of all their qualities into the ideal balance for supporting a foundation. Clay textures
are often more stable than sand textures. And soil plant location soil is comprised mostly
of clay texture. Also, the area is not at risk of frequent earthquakes. So, tall structures with
appropriate support of up to 200 feet can be built here. From the meteorological data we
can see that temperature, and pressure is favorable for cooling tower operation and
fluctuation of this parameter is not that high. There is seldom a chance of heavy rainfall to
flood the plant area. Wind speed and direction influence the surface area and the
development of seiches and storms. Wind speed is moderate and draws heated air from the
cooling tower in the direction of the south, less populated area.
6. Nearer to the capital of the country: It is only almost 18 km far from the capital by road.
So, it has one of the highest advantages of top-level marketing, advertising, and dealing
with industrial priorities with structured management.
7. Availability of skilled and non-skilled labor: Skilled labor and technically qualified and
trained managers are quite available as the site is surrounded with other industrial plants
like ASM chemicals, Eskayef Pharmaceuticals, Wata Chemicals Ltd., and Pran RFL
Company Limited.
 8. Banking and financial institutions: Sonali Bank, Dutch Bangla Bank, Pubali Bank, and
Ria Money Exchange are at close distance. Thus, the company can easily deal with
financial and monetary transactions such as deposits, loans, investments, and currency
exchange with vendors, contractors, and manufacturing tender.

Also, the availability of link roads to develop industrial areas or business centers results in savings
and cost reductions in transport overheads, miscellaneous expenses, Narayanganj river ports,
public utilities, civil amenities, and means of communication making this proposed site most
suitable.

1.2.2. Geological Data

• Soil type: The area lies on the edge of the Madhupur tract and Holocene floodplain deposits
and is located in the middle part of the Bangle Basin. The top layers of the soil have been
encountered with cohesive soils of medium to low plasticity, very soft to soft clay, little to
trace slit, and sand extending roughly up to the depth of 9 feet measured from the existing
ground surface. The subsequent deep layers are non-plastic soils of very loose to lose slit
with clay, trace to some sand extending up to depth of 18’. The underlying soils are also
non-plastic and non-cohesive soils of medium-dense state extending up to the final depth
of boredom.

• Seismic conditions: Based on the distribution of earthquake epicenters and

morphotectonic behavior of different tectonic blocks, Bangladesh has been divided into
three generalized seismic zones. Zone II consists of the regions of recent uplifted
Pleistocene blocks of the Barind and Madhupur and the western extension of the folded
belt and the Bask coefficient for this zone is 0.05. The proposed site location is in zone II
seismic region where an earthquake intensity of VIII of the modified Mercall Scale is
possible. The horizontal seismic code coefficient = 0.15g. The BNBC code for are available
for earthquake resistance buildings is available to ensure that structures are available to
respond to shocks of moderate intensities without structural damage. This code is meant
only for normal buildings with a height of no more than 200ft. In the case of taller
 buildings, a dynamic analysis must be performed, with the ground accelerating on inputs
appropriate for the probable maximum intensity for a particular zone.

1.2.3. Climate Condition

a. Design conditions for equipment or facility:

Cooling tower
Maximum dry bulb temp in summer =340 C
Maximum wet bulb temp in winter = 250 C
Maximum dry bulb temp in winter = 280 C
Maximum wet bulb temp= 210 C

b. Design condition for building: (HVAC)

Maximum dry bulb temperature in summer=340 C
Maximum relative humidity (RH) in summer= 60%
Minimum dry bulb temp in winter = 200 C
Maximum relative humidity (RH) in summer= 50%

c. Meteorological conditions:
i. Ambient temperature

Maximum= 340 C
Average daily maximum temperature= 29.50 C
Average monthly maximum temperature= 340 C (April)
Average temperature=240 C
Average daily minimum temperature=22.50 C
Average monthly minimum temperature=250 C (December)
Minimum temperature= 140 C
 Figure 1.2.2: Monthly temperature statistics of Bhulta, Narayanganj

ii. Humidity:
Average relative humidity (RH) = 66%
Maximum monthly relative humidity=80% (during monsoon season)

iii. Rainfall:
Average annual = 100.025 mm
Maximum monthly =280.2 mm (July)
Minimum monthly=3.2 mm (January)
Maximum daily = 320 mm
Maximum in one hour = 78.6 mm
Maximum intensity = 82.3 mm/hr
Approximately 80% of the annual average rainfall occurs between May and
September.

Figure 1.2.3: Monthly rainfall statistics of Bhulta, Narayanganj.

iv. Barometric pressure

 Minimum pressure=1001.5 mb or 752.47 mmHg (June)

Figure 1.2.4: Monthly average pressure statistics of Bhulta, Narayanganj.

v. Wind
Maximum wind speed in Summer: 25.4 kmph
Maximum wind speed in Winter: 10 kmph

Figure 1.2.5: Monthly wind velocity statistics of Bhulta, Narayanganj.

1.2.4. Raw Materials

The main raw materials for this plant are methanol, natural gas, and MDEA.
I. Methanol-methanol was brought from and supplied at the rate of 1800 kg mole/hr with
the following specifications-

Table 1.2.1: Process Methanol Specification

 Gas composition Mole fraction
H2 0.0161
CO 0.0072
CO2 0.0059
H2O 0.0078
CH4 0.0030
CH3OH 0.960

II. Natural gas- Industrial natural gas is distributed at Dighibarabo Town Border Station
supplied by Titas Gas Transmission and Distribution Company Limited (TGTDCL)
through the 16-inch pipeline at a 1971 mole/hr rate in 1 bar.

Table 1.2.2: Process natural gas specification

Gas Composition Mole fraction

C1 0.9648

C2 0.0160

C3 0.0035

i-C4 0.0010

n-C4 0.0008

i-C5 0.0005

n-C5 0.0004

C6 0.0005

C7 0.0019

N2 0.0034
 H2S 0.0002

CO2 0.0070

1.3. Product Specification

Acetic Acid:

The main product of the plant is acetic acid in liquid form. Acetic acid is an essential organic acid
also known as ethanoic acid, ethylic acid, vinegar acid, or methane carboxylic acid. Acetic acid is
a colorless substance having a pungent or strong vinegar-like odor. Acetic acid is highly soluble in
water and also miscible with alcohol, glycerol, ether, and carbon tetrachloride. It is practically
insoluble in carbon disulfide. Its physical and chemical properties are given below.

Table1.3.1: Physical and chemical properties of acetic acid

Name of the property Value

Chemical formula CH3COOH

Molar mass 60.052 g.mol-1

Appearance Colorless

Physical state Liquid

Odor Pungent

Odor threshold 0.48 to 1.0 ppm

Density 1.049 g/cm3 (liquid); 1.27 g/cm3 (solid)

Melting point 16 to 17 ºC

Boiling point 118 to 119 ºC

Solubility in water Infinitely Miscible

Vapor pressure 11.6 mmHg (20 ºC)

 pH 2.4

Dissociation constant (pKa ) 4.76

Flash point 40ºC

Autoignition temperature 427 ºC

Explosion limits 4-16%

Surface Tension 0.027 N/m

Hydrogen:

Hydrogen is the byproduct of the plant in gaseous form. It is a clean fuel. It is the lightest element.
It is non-toxic and highly combustible. Hydrogen is also used in many industries such as in the
production of Ammonia, Methanol, Oil refining, etc. Its physical and chemical properties are given
below.

Table1.3.2: Physical and chemical properties of Hydrogen

Name of the property Value

Chemical formula H2

Molar mass 2.016 g.mol-1

Appearance Colorless

Physical state Gas

Odor Odorless

Odor threshold Not applicable

Density 0.08375 g/cm3 @NTP

Melting point -259.16 ºC

Boiling point -252.879 ºC

Solubility in water 0.00016 g/100g @20 ºC

Vapor pressure 31.8 mmHg (30 ºC)

pH 7

Dissociation constant (pKa ) 7

Flash point Not applicable

Autoignition temperature 500 ºC

Explosion limits 18.3-59%

Surface tension Not applicable

 2. Selection of Process & Process Description

2.1. Description of available process

Acetic acid is an essential bulk chemical that can be produced by various methods industrially as
well as experimentally. The most established two processes are the Synthesis of acetic acid by
methanol hydrocarboxylation process with CO2 and H2 and the Cativa process.

2.1.1. Methanol Hydrocarboxylation Process

Synthesis of acetic acid from renewable and cheap CO2 is of great importance, but state-of-the-art
routes encounter difficulties, especially in reaction selectivity and activity. In this process, acetic
acid can be produced from CO2, methanol, and H2. The reaction can be efficiently catalyzed by
Ru–Rh bimetallic catalyst using imidazole as the ligand and LiI as the promoter in 1,3-dimethyl-
2-imidazolidinone (DMI) solvent. It is confirmed that methanol is hydrocarboxylated into acetic
acid by CO2 and H2, which accounts for the outstanding reaction results.

2.1.2. Cativa Process

The Cativa process is a method to produce acetic acid by the carbonylation of methanol. The
technology, which is similar to the Monsanto process, was developed by BP Chemicals. The
process is based on an iridium-containing catalyst.

2.1.3. Justification for the Selection of Hydrocarboxylation Process

The hydrocarboxylation with CO2 and H2 is selected to produce Acetic acid. Because this process
is cheaper and has more sophisticated units than the Cativa process. In the Cativa process, the
desulphurization, pre-reformer, and autothermal reformer units are the same as in the
hydrocarboxylation process. But membrane separation units, reverse shift reactors, etc. are more
expensive and complex. The membrane separation unit is more expensive and more complex to
design. The hydrocarboxylation process is simple and cheaper. Here, most of the units are the same
as the urea-ammonia plant. Pre-reformer, auto thermal reformer, high-temperature shift reactor,
low-temperature shift reactor, CO2 absorption unit, and desorption unit are the main units that are
sophisticated in the chemical industries.

On the other hand, the creative process includes carbon monoxide which is an extremely
flammable gas. In a fire or if heated, a pressure increase will occur, and the container may burst,
with the risk of a subsequent explosion. The hydrocarboxylation with CO2 and H2 process helps
to capture carbon dioxide. CO2 is a greenhouse gas and its fixation into value-added chemicals is
highly desirable for a sustainable society.

2.2. Selection of The Steam Reforming Process

2.2.1. Non-catalytic partial oxidation of methane (POX)
In the non-catalytic POX, similarly to ATR, a mixture of oxygen and natural gas is preheated,
mixed, and ignited in a burner at the top of the reactor. In the absence of a catalyst, the reactor
temperature must be high enough to reach complete CH4 conversion. Combustion products like
CO2 and H2O are also formed to a certain extent. Subsequently, endothermal reactions like steam
reforming are also involved, which determine the outlet temperature in the order of 1300–1500 K

Catalyst: None

Reactor outlet temperature: The reformer is operated in the temperature range of 1473-1773K

to produce the maximum syngas yield with desired compositions (CO, CO2, and H2).

Reactor shape & size: Typically, the reformer is a cylindrical, top-down pressure vessel (>6.0MPa
of pressure) with a spherical/elliptical dome.

Reactor feed: Preheated natural gas (CH4 97–99%) and the oxidizer (O2 and H2O) are injected
into the vessel through a two-way gas burner on the top of the dome. A small amount of high-
pressure steam (7.0 MPa) is injected into the reformer with oxygen to protect the burner and reduce
the formation of soot.

Conversion rate: By controlling the O2/CH4 ratio of feeding gases, the reformer is operated in
the temperature range 1473–1773K to produce the maximum syngas yield with desired
compositions (CO, CO2, and H2). However, at high CH4 conversion, the reaction was prone to
thermal runaway and thus the highest CH4 conversion reported was 17%, but conversion increased
rapidly above this 395-temperature reaching 87% and 100% respectively at 1773 K.

The advantage of this noncatalytic process is that it can work at high pressures required by the

downstream synthesis, thereby saving costly compressors.

In recent years, this technology has become increasingly attractive due to the rapid increase in oil
prices.

Basic Reactions.

(a) It will be assumed for the sake of illustration that the sour feed gas consists mainly of CH4, to
represents natural gas, and H2S/CO2, to represents acidic gases.

(b) The main reactions for the partial oxidation of methane are given by:

CH4 + 1/2O2 ----- CO + 2H2 (1)

CH4 + O2 ---------CO + H2O + H2 (2)

(c) The reaction given by eq 1 is considered to proceed in two well-defined steps: first, a complete
reaction of the oxygen with some of the methane to give water and carbon dioxide, followed by a
slower reaction of the carbon dioxide and the water with the excess of methane to give mixtures
of carbon monoxide and hydrogen, so that the total of the reactions occurring is

CH4 + 2O2 -------- CO2 + 2H2O

followed by:

CH4 + CO2 ----------2CO + 2H2

2.2.2. Catalytic partial oxidation (CPOX)

Catalytic partial oxidation (CPOX) is an attractive option to produce H2 and CO from hydrocarbon
fuels for fuel cell applications. In particular, CPOX is suitable for compact or mobile fuel-
processing systems integrated with solid oxide fuel cells (SOFCs) due to the similarity of operating
conditions and the utilization of currently available infrastructure fuels. CPOX can also be
followed by the water gas shift (WGS) reaction to produce a pure H2 and CO stream.
CPOX has the advantage of inherently rapid reforming kinetics with quick light-off characteristics
and response to transients. Since there is no need to feed water, as in steam reforming (SR) and
oxidative-steam reforming (OSR), CPOX reactors are smaller and more easily integrated into
transportation-based, onboard fuel reforming systems, as well as remote and distributed power
applications. Additionally, the exothermic nature of this process reduces the heat needed to be
supplied to the system, making it ideal for integration with high-temperature fuel cells. Typical
operating conditions provided are the temperature range of 700–1000 °C, atmospheric pressure,
and oxygen-to-carbon (O/C) ratio = 1.2.

The reactions occurring in the CPOX of hydrocarbons are complex. The overall CPOX reaction
can be,

CH4 + (1/2) O2 CO + H2

2.2.3. Methane Reforming in ATR

ATR is a newly developed technology in this era. Nowadays, it has been used in most industries.
In ATR, firstly natural gas is partially oxidized, and combustion reaction is given below:

CH4 + (1/2) O2 CO + 2H2O

From this above reaction, heat is produced, and it will be used to reform methane with steam from
the following reaction,

CH4 + H2O CO + 3H2

very simple operation

well-proven technology used in the Topsoe ammonia plant.

2.2.4. Justification for the Selection of ATR with Pre-reformer

Non-catalytic partial oxidation, without any catalyst the reaction occurs but it needs high
temperature. So as a result, there produced CO2, CO, H2. The amount of CO and H2 is very small
compare to carbon dioxide. Also, to get high conversion of methane, we heated it at 3530 C,
pressure also quite high. So, it is very dangerous for environmental issues. So, to maintain this
high temperature, we need to cool the reactor, also to maintain pressure, overall it will be less cost
effective.
For catalytic partial oxidation, Challenges for the CPOX of hydrocarbons include catalyst
deactivation from high-temperature sintering, metal vaporization, support degradation, coke
formation, and poisoning from sulfur and other contaminants.

In the ATR process, we are producing syngas by steam reforming and as it is an endothermic
reaction, need heat, this heat is taken from the partial combustion of methane that is occurred in
the ATR also. The main advantages of ATR compared to two others given below:

1. Very simple operation

2. Easy to scale up to large capacities.

3. Most developed technology

4. The previous two processes are based on partial oxidation to produce syngas, so there is a huge
possibility to form carbon which will cause blockage of catalyst, sintering but in ATR, with the
help of heat addition, steam is reformed, and syngas is produced. Also, the size of ATR is quite
small compared to the other two processes. That’s why for economic feasibility, we are using ATR
in our desired acetic acid production process.

2.3. Process description

The acetic acid plant is based on methanol carbonylation process in which natural gas is reforming
and further some process, methanol is added to reformed gas. The plant is designed for 100 MTPD
acetic acid.

Here the compressors are centrifugal compressors. The feed gas and syngas compressors are driven
by steam turbines. The waste heat boiler is used to regenerate steam that is supplied to some units
where it is needed. Acetic acid storage tanks are motor driven.

The acetic acid process is shown on process flow diagrams PFD-

The process steps are given below:

1. Feed gas compression and Desulfurization

2. Pre-forming
3. Process air compression

4. Autothermal reforming

5. Carbon monoxide shift conversion (HTS & LTS)

6. Carbon dioxide and hydrogen gas separation (by absorber & desorber)

7. Acetic acid synthesis

8. Acetic acid separation process

9. Acetic acid product storage

10. Steam system

11. Cooling water system

12. Other facilities

Each of the process steps and systems are described in detail in the following paragraphs.

2.3.1. Feed gas compression and Desulfurization

Feed gas (natural gas) is first compressed at 35 bar and preheated to 4000C. Further natural gas is
desulfurized because sulfur contained natural gas while going to other process, it will damage
catalyst and replacement of catalyst is very expensive. So, desulfurization of natural gas is given
below:

In the first step, the heated gas flows through the hydrotreater which contains a cobalt-
molybdenum catalyst to convert organic sulfur compound to hydrogen sulfide as follows:

➢ RHS + H2 = H2S + RH

➢ COS + H2 = CO + H2S
In the second step, the hydrogen sulfide is removed in two zinc oxide columns operating in series
or in parallel. The hydrogen sulfide and zinc oxide react, resulting in zinc sulfide. The desulfurized
gas at the column outlet contains less than 0.1 ppm of sulfur. The reaction is given below:

➢ H2S + ZnO = ZnS + H2O

2.3.2. Pre-Reforming
Desulfurized natural gas at 35 bar is mixed with high pressure saturated steam at 35 bar which is
produced from waste heat boiler in the process that is going into pre-reformer. Before going to
reformer, the natural gas is pre-heated to 4000C. The following reaction occurs given below:

CH4 + H2O(steam) + heat CO + 3H2

The above reaction is an endothermic reaction. So, it needs heat to produce syngas. In the reformer,
heat is provided from the burner, and it is normally flowing through convective and radiative ways.
In the pre-reformer, on a fixed nickel catalyst bed, methane and steam reacted with the addition of
heat and produced a portion of carbon monoxide and hydrogen which brings more single
conversion. It is because of residual amount (more in percentage) of methane again passed through
the autothermal reactor.

2.3.3. Auto-Thermal Reformer (ATR):

The outlet of the pre-reformer contains CH4, CO, H2, H2O, CO2 at 5600C and at 34 bar pressure
which is then feed to the top of the Autothermal reformer (ATR). Pure O2 is also feed at 34 bar.
Before feeding to the ATR, O2 is preheated to 400 0C by heat recovery from ATR outlet stream.
ATR is a simple unit operation and well-proven technology in Topsoe ammonia plants. Partial
combustion of the hydrocarbon feed with Oxygen is followed by hydrocarbon conversion due to
the steam reforming reactions in the catalyst bed. The exit temperature from the ATR is typically
above 1189.240C and this ensures low CH4 concentration even at high pressure.

Combustion zone reaction

CH4 + 1.5 O2 CO + 2H2O

Thermal and catalytic zone

CH4 + H2O CO + 3H2

CO + H2O CO2 + H2

2.3.4. Carbon Monoxide Shift Converter (HTS and LTS)

Carbon monoxide conversion section is shown in flow diagram (FD). The downstream of LTS
effluent heat recovery section is also shown in flow diagram (FD).

ATR outlet is cooled to 400 0C and is feed to high temperature shift conversion reactor (HTS) and
then to the low temperature shift conversion (LTS) at 2700C. In shift conversion step, carbon
monoxide reacts with steam to produce (equal) amount of carbon dioxide and hydrogen. This shift
conversion reaction is reversable and exothermic compared to primary reformer. The CO to CO2
conversion rate is favored by high temperature whereas equilibrium CO to CO2 conversion is
favored by low temperature. That’s why we firstly do the shift conversion by HTS reactor which
gives high conversion at relatively low cost and durable (copper promoted iron-oxide catalyst)
with (70%) conversion. The effluent of shift converter contains (31%) of CO (dry basis). The
copper promoted surpasses an unwanted side reaction that could occur due to low steam to carbon
ratio. The HTS converter effluent is cooled by generating HP steam or boiling boiler feed water
(BFW). A bypass on the BFW side of (103-C1/C2) is provided to control inlet temperature to the
LTS at about (2700C).

The low shift conversion reactor goes near completion through a copper/Zinc catalyst bed. The
LTS reactor’s effluent contains (0.29%) of CO on a dry basis. The LTS shift catalyst permits a
considerable reduction in the quantity of steam in overall conversion.

2.3.5. Carbon Dioxide Separation:

Some fraction of the stream coming from the LTS is sent to the CO2 separation section to separate
CO2 from the other components and to isolate H2 byproduct. The gas stream first enters the bottom
section of the CO2 absorber where bulk of it’s carbon dioxide content is removed by absorption
into the semi-lean methyl-diethanolamine (MDEA) solution. The gas stream then flows to the top
section of the absorber where most of the remaining carbon dioxide is removed by absorption into
the lean solution. The gas stream leaving the top of the absorber mostly contains H2 by product
other components that is sent to H2 separation section.

The CO2 rich MDEA solution form the bottom of the absorber is then pumped and heated to the
top of the stripper at low pressure. Flashing at this low pressure removes most of the carbon dioxide
from the solution. The solution flows down through the packed section where it contacts with the
rising vapor from the CO2 and further flashes off. The overhead gas stream leaving the stripper is
nearly pure CO2 that is compressed and mixed with the Acetic Acid reactor feed stream to the
reactor. The MDEA solvent from the bottom of the stripper is cooled and recycled to the top of the
CO2 absorption tower. In this process around 90% of the CO2 feed to the absorber is separated
and fed to the reactor mixing with the reactor feed stream.

2.3.6. Reactor
Stream from the LTS mixes with several streams before entering the reactor. It is mixed with CO2
stream from the disorber, recycle stream and methanol stream. Methanol is added to the process at
this step. The mixed stream is then feed to the reactor at 2000C and 20 bar pressure. The targeted
reaction was catalyzed in the reactor with Ru-Rh catalyst (Ru3(CO)12, Rh2(OAc)4) using
imidazole as the ligand and LiI (lithium iodide) as the promoter in 1,3-dimethyl ether. The single
pass conversion of methanol into acetic acid is 70.3%. The ligand is crucial to catalytic
performance. Without ligand, the catalyst is unstable with much more selectivity.

2.3.7. Acetic Acid Separation

(i) Distillation column 1:

After the synthesis of acetic acid in the conversion reactor, there is not only produced desired
product but also many undesired products. Separation of other undesired products are necessary
to maximize or to meet up product specification. So, the outlet products from a reactor fed into a
distillation column-1 at 2100C and 10bar. The main basis of distillation column is to separate
components according to their boiling point. So, the light compounds will go to overhead chamber
and the heavy compounds go to the bottom chamber. But for getting maximum heavy products in
the bottom, must do trial and error of distillation column’s operating condition. For our acetic acid
plant, by operating the distillation column at specified condition (achieved by trial and error), the
maximum possible amounts of acetic acid, methanol and water is collected as bottom product and
it leaves at 1920C and 12 bar which further goes to the mixer.

(ii) Distillation column 2:

Distillation-1 overhead products stream shown, there is still significant amounts of acetic acid,
water and other compounds are left which is not economical feasible for our process plant if we
don’t recover that acetic acid, methanol and water. For this, we again fed the overhead product
stream of D-1 to another distillation column named D-2 at 134.30C and 12bar. By doing trial and
error of second distillation column’s operating condition, we are able to separate maximum
possible amounts of acetic acid, water and methanol products in the bottom and the stream leaves
at 182.50C and 11bar. The overhead stream of D-2 is recycled back to the reactor to maximize the
desired acetic acid production.

(iii) Distillation column 3:

From distillation column-2 and distillation column-1, two bottom products mixed in a mixer and
fed the stream into another distillation column named D-3. By doing trial and error, distillation
column operates at 11 bars. And thus, able to separate acetic acid and water as to get acetic acid
product. The distillate and bottom product’s operating condition are 182.20C, 11 bar and 203.70C,
11 bar.
3. Process Block Diagram
4. Process Flow Diagram
 5. Material Balance
5.1. Desulphurizer Unit
Stream – 42 Stream – 51
2076.734 kmol/day 2066.350 kmol/day

Desulpharizer
0.969 kmol CH4/kmol 0.974kmol CH4/kmol
0.0249 kmol H2O/kmol 0.0251kmol H2O/kmol
0.00249 kmol S /kmol

5.2. Pre-reformer Unit

Stream –51 Stream –4

2066.35 km/day 8512.533 kmol/day

Pre-Reformer
0.9749 kmol CH4/kmol 0.142kmol CH4/kmol
0.0251 kmol H2O/kmol 0.4791kmol H2O/kmol
0.095 kmol CO/kmol
0.284 kmol H2/kmol

Stream –3
4834.637 km H2O /day

5.3. Autothermal Reformer (ATR)

Stream – 4 Stream – 5
8512.533 kmol/day 11285.2 kmol/day

ATR
0.142kmol CH4/kmol 0.011 kmol CH4/kmol
0.4791kmol H2O/kmol 0.447 kmol H2O/kmol
0.095 kmol CO/kmol 0.168 kmol CO/kmol
0.284 kmol H2/kmo 0.374 kmol H2/kmol
Stream – 1
725.196 kmol O2 /day

5.4. High Temperature Shift Reactor (HTS)

Stream – 6 Stream – 7
11285.2 kmol/day 11285.2 kmol/day

HTS
0.011 kmol CH4/kmol 0.011 kmol CH4/kmol
0.447 kmol H2O/kmol 0.302 kmol H2O/kmol
0.168 kmol CO/kmo 0.022 kmol CO/kmol
0.52 kmol H2/kmol
0.146 kmol CO2/kmol

5.5. Low Temperature Shift Reactor (LTS)

Stream – 8 Stream – 9
11285.2 kmol/day 11285.2 kmol/day

LTS
0.011 kmol CH4/kmol 0.011 kmol CH4/kmol
0.302 kmol H2O/kmol 0.282 kmol H2O/kmol
0.022 kmol CO/kmol 0.0017 kmol CO/kmol
0.52 kmol H2/kmol 0.54 kmol H2/kmol
0.146 kmol CO2/kmol 0.166 kmol CO2/kmol
 5.6. CO2 Absorber

5.7. CO2 Desorber

5.8. Reactor

Stream – 52 Stream – 22
8961.29 Kmol/d 6268.42 Kmol/d

Reactor
0.078 kmol CH4/kmol
0.102 kmol H2O/kmol
0.0125 kmol CO/kmol
0.27 kmol H2/kmol
0.27 kmol CO2/kmol
0.268 kmol CH3COOH/kmol
0.112 kmol CH4/kmol
0.259 kmol H2O/kmol
0.018 kmol CO/kmol
0.115 kmol H2/kmol
 0.115 kmol CO2/kmol

5.9. Distillation Column 1

5.10. Distillation Column 2

5.11. Distillation Column-3
6. Energy Balance
6.1. Pre-reformer
6.2. Pre-reformer Convection Zone

6.3. Heat Recovery from Flue Gas

6.4. ATR

6.5. Heat Recovery from ATR Outlet

 7. Environment management plan
Chemical process plants are habitually subjected to the release of unwanted chemicals and wastes,
and this project is no different. The efficient and economically viable project with consideration
of environmental protection is the demand of clients. Therefore, focus on the environmental
protection is to ensure that only the minimal amount of hazardous waste and chemicals are
produced and released, if possible, all the waste streams and emissions must be neutralized before
disposal. Planned action should be taken to ensure acceptable and minimal amount disposal of
wastes and emissions while maintaining energy requirements have been integrated throughout the
chemical process.

7.1. Air Pollution Control Systems and Equipment

Some types of air pollution control equipment applied to industrial applications, and which utilize
one or more of the methods of air pollutant removal or reduction mentioned above include:

➢ Scrubbers
➢ Air Filters
➢ Cyclones
➢ Electrostatic Precipitators
➢ Mist Collectors
➢ Incinerators
➢ Catalytic Reactors
➢ Biofilters

Scrubbers

Industrial air scrubbers use a physical process to remove gases and particulates from industrial
emissions, such as smokestack exhaust (in the case of exhaust air scrubbers) before they are
released into the atmosphere. They are some of the most frequently used air pollution control
devices in manufacturing and processing facilities. Scrubbers can be divided into two primary
categories: dry scrubbers and wet scrubbers.
Air Filters

In order to capture and remove dry particles and contaminants from the air passing through them,
such as dust, pollen, microorganisms, chemicals, etc., air filters use a particular type of filtering
medium, such as cloth, sintered metal, ceramic, etc. To improve the air quality in the workplace
and eliminate contaminants from exhaust air, these devices are used in residential, commercial,
and industrial settings. HEPA filters, cloth filters, and cartridge dust collectors are just a few of the
air filters that are available for industrial applications.

Cyclone separators

Cyclone separators, commonly referred to as cyclone dust collectors, are air pollution control tools
that separate dry particulate matter from gaseous pollutants in a manner similar to air filters.
Cyclones, on the other hand, use centrifugal force to collect and remove particulates rather than
filtration medium. Gas streams enter a cyclone and move through the cylindrical chamber in a
spiral motion. Large particles are propelled against the chamber wall by the swirling motion, which
reduces their inertia and causes them to fall into the collection hopper below for additional
processing and disposal. Upward and out of the cyclone, the cleansed gas streams continue.

While cyclones are normally used for filtration applications involving particles with a diameter of
less than 50 m, some versions are capable of achieving better than 90% effectiveness for particles
with a diameter of 10 to 20 m. With larger or smaller particle sizes, efficiency rises or falls,
correspondingly. After cyclones in an air pollution control system, smaller particulates that were
not previously separated and collected from the gas stream by the cyclones are typically removed
using further filtering devices, such as baghouses.

Electrostatic Precipitators

Similar to air filters and cyclones, electrostatic precipitators (ESPs) are air pollution control tools
used to gather and remove particulate matter, such dust, from industrial emissions and exhaust. To
establish a large static electrical potential difference between the charging electrodes and the
collecting plates, ESPs use transformers. The introduction of an electrical charge to the particulates
when gas streams move between the two elements causes the particulates to become attracted to
the collecting plates. Similar to air filters, PM accumulation is routinely removed from the
collecting plates and dumped in a collection hopper below. This is accomplished either by
mechanically displacing the particulates or by adding water to rinse the particulates off. Wet ESPs
are ESPs that use the latter technique. ESPs frequently achieve efficiency of above 99% since they
frequently contain numerous collection plates.

Mist Collectors

In order to reduce air pollution, mist collectors, also known as mist or moisture eliminator filters—
remove moisture and vapor from gas streams, including smoke, oil, mist, and others. These devices
use tiny filters that resemble fine meshes to separate liquid droplets from gas and collect them in
a different chamber for processing and, possibly, recovery and reuse.

Mist collectors retain excellent filtering efficiencies for liquid particles as small as submicron, with
some versions providing 99.9% efficiency for particles as small as 0.3 mm. While mist collectors
are capable of processing acidic and corrosive gas streams, they cannot handle gas streams
containing large particulates, as they may cause an obstruction within the collector’s filter. They
also are not used in applications which have temperatures above 120 °F.

Incinerators

Incinerators are machines that use combustion techniques to convert pollutants into non-toxic by-
products. Even though these devices can be used to incinerate wastes in solid, liquid, and gaseous
form, they are primarily used in a wide range of industrial applications to maintain air quality and
control gas emissions by converting VOCs, hydrocarbons, and other hazardous air pollutants
(HAP) into harmless compounds like carbon dioxide, nitrogen, and oxygen. Scrubbers are
typically used in place of incinerators in an air pollution control system because they eliminate any
extra compounds created during burning. Depending on how the waste product is made,
incineration can either be self-sufficient or require additional fuel to enable complete combustion
of the waste chemicals. Furthermore, a few incinerator models are offered with regenerative and
recuperative capabilities and are appropriate for batch and continuous applications. Thermal
oxidizers and catalytic oxidizers are two of the different kinds of incinerators that are available.

Catalytic Reactors

Catalytic reactors, also referred to as selective catalytic reduction (SCR) systems, are air pollution
control devices widely used to mitigate nitrogen oxide (NOx) emissions produced by the burning
of fossil fuels in industrial applications. These devices first inject ammonia into the industrial
exhaust and emissions, which reacts with the NOx compounds to produce nitrogen and oxygen.
Similarly, to incinerators, these devices also employ other catalysts which enable some of the
remaining gaseous pollutants to undergo combustion for further processing and reduction. One
common application of catalytic reactors is in modern automobiles; the three-way catalytic
converter in a car’s exhaust system is used to reduce the amounts of NOx, CO, and other VOCs in
the engine emissions.

While for NOx reduction and removal, SCR systems can achieve more than 90% efficiencies, for
other gaseous pollutants these devices can achieve 99.99% efficiencies with lower energy
requirements compared to incinerators. Despite the high efficiencies possible, SCR systems are
not suitable for all gaseous pollutant reduction applications as the large amounts of catalyst
required are costly, and the systems cannot process emissions and exhaust containing particulate
matter.

Biofilters

Biofilters are air pollution control devices which employ microorganisms, such as bacteria and
fungi, to degrade and remove water-soluble compounds. Similarly, to incineration devices,
biofilters destroy the pollutants to reduce the amount present in industrial emissions and exhaust.
However, the microorganisms in biofilters absorb and metabolize gaseous pollutants, such as
VOCs and organic HAP, without generating by-products typically produced through combustion,
such as NOx and CO. These devices can achieve over 98% efficiencies.

Auxiliary Equipment

A complete air pollution control system refers not only to the equipment which destroys,
chemically changes, or collects the pollutants and emissions like, scrubbers, filters, ESPs,
incinerators, etc. but the components and equipment which make up the system’s infrastructure
and provide support to the control equipment as well. Some of the standard auxiliary components
and equipment includes:

➢ Monitoring and pollution control systems

➢ Fans and blowers
➢ Blade dampers
 ➢ Stacks
➢ Heat exchangers

7.2. Water pollution and its mitigation plan

The acetic acid industry can generate a few contaminants that can damage water sources if it is not
properly controlled. The following are some examples of typical water contaminants linked to the
acetic acid industry:

➢ Acetic Acid: Acetic acid manufacturing may result in its release into water sources. Acetic
acid can harm aquatic creatures by lowering the pH of water because it is a weak acid.
➢ Methanol: The manufacturing method for acetic acid includes the hazardous reactant
methanol. Methanol has the potential to taint sources of drinkable water and harm aquatic
organisms.
➢ Heavy Metals: Producing acetic acid can lead to the creation of wastewater that contains
heavy metals like lead, cadmium, and mercury. Due to their extreme toxicity, these metals
pose a serious risk to both human health and the environment.
➢ Organic Compounds: The production of acetic acid can lead to the production of
wastewater that contains organic substances such phenols and benzene. These substances
have the potential to be harmful, they can harm aquatic life, and they can taint water
sources.
➢ Suspended Solids: The manufacturing process may produce wastewater that contains
suspended solids, like pulp and fibre by-products. These substances can harm aquatic life
and clog water filtration systems

To reduce the amount of harmful pollutants released into water sources, protect the environment,
and promote public health, the acetic acid business must effectively manage and treat its effluent.
The following actions should be included in the strategy to reduce water pollution from an acetic
acid industry:

❖ Proper wastewater treatment: To eliminate pollutants from wastewater before it is

released into the environment, industries should establish an efficient wastewater
treatment procedure. The treatment procedure should be created to adhere to the industry's
regulatory standards.
 ❖ Best management practises implementation: To stop contaminants from ever entering
wastewater in the first place, the sector should implement best management practises
(BMPs). These BMPs could include actions like consistent equipment upkeep, safe
chemical handling and storage, and personnel training.
❖ Monitoring and reporting: To make sure that its wastewater output complies with legal
requirements, the industry needs frequently monitor it. The sector should also keep
thorough records of the way it treats its effluent and releases it.
❖ Recycling and reuse: To reduce the volume of wastewater that needs to be released, the
industry should think about recycling and reusing its effluent. Closed-loop systems can be
used to do this, which can assist cut down on water use and waste.
❖ Community involvement: The sector must get involved with the neighborhood
communities to resolve any issues or worries that may come up as well as to spread
awareness of its efforts to reduce water pollution.

7.3. Solid waste and its mitigation plant

Solid waste generated by an acetic acid production industry can include both hazardous and non-
hazardous waste materials. Some common examples of solid waste generated by the industry
include:

➢ Packaging waste: The industry may generate waste materials from the packaging of raw
materials and finished products.
➢ Plant residues: The production process can generate plant residues such as stems, leaves,
and other organic materials.
➢ Spent catalysts: The industry may generate waste catalysts that are no longer effective in
the production process.
➢ Sludge and filter cake: The production process may generate sludge and filter cake
materials from the treatment of wastewater and other process liquids.
➢ Scrap metals: The industry may generate scrap metals from equipment and machinery
maintenance and repair.
➢ Contaminated soil: Industry may generate contaminated soil from spills, leaks, and other
accidents.
 ➢ Chemical waste: The industry may generate chemical waste such as solvents, acids, and
other hazardous materials.

The mitigation plan for solid waste in an acetic acid production industry should include several
measures, including:

❖ Waste reduction: The industry should aim to reduce waste generation at the source by
implementing waste reduction measures, such as process modifications, material
substitutions, and recycling. By reducing waste generation, the industry can minimize the
amount of waste that needs to be managed and disposed of.
❖ Hazardous waste management: The industry should properly manage hazardous waste
through appropriate storage, handling, transportation, and disposal practices. The industry
should follow regulatory requirements for hazardous waste management, including proper
labelling, documentation, and reporting.
❖ Recycling and reuse: The industry should consider recycling and reusing waste materials,
such as waste solvents, to minimize waste generation and reduce disposal costs. The
industry should also consider the potential for recycling and reusing by-products generated
during the production process.
❖ Composting: Non-hazardous solid waste generated during the production process, such
as plant residues and other organic materials, can be composted to produce a valuable soil
amendment. Composting can also reduce the amount of waste that needs to be disposed
of in landfills.
❖ Landfill management: The industry should properly manage waste disposal in landfills,
including proper disposal methods and techniques to prevent environmental
contamination.

Overall, the mitigation plan for solid waste in an acetic acid production industry should prioritize
waste reduction, proper management of hazardous refuse, and the implementation of sustainable
waste management practises. The industry can reduce its environmental impact and contribute to
a more sustainable future by adopting these measures.

7.4. Dust and noise pollution and mitigation plan

Acetic acid production industry can generate both dust and noise pollution that can have negative
impacts on the environment and the health of surrounding communities.
Dust Pollution

When materials are handled and transported, as well as when products are mixed, ground, and
packaged, dust particles may be produced. These dust particles can land on neighbouring flora,
water supplies, and buildings, harming the environment, and they can also create breathing issues
for employees and nearby people. The industry should put in place suitable dust control measures,
such as employing dust suppression systems, covering conveyors and chutes, and using suitable
ventilation and filtration systems, to reduce dust pollution.

Noise Pollution

Pumps, compressors, and other gear used in the industrial process can produce noise pollution.
Hearing loss, sleep disruptions, and other health issues can result from the noise pollution, which
can also have an impact on the health and wellbeing of local communities and workers. The
industry should put in place noise reduction strategies such sound barriers, noise insulation, and
appropriate equipment maintenance and repair in order to reduce noise pollution.

Complying with all the regulations stipulated by the Department of Environment (DoE) related to
environmental pollution can be a complex and challenging task for industries. However, there are
several steps that an industry can take to ensure compliance with these regulations:

❖ Develop an environmental management plan: An environmental management plan

(EMP) is a comprehensive strategy for managing environmental impacts. The EMP should
include measures for monitoring, reporting, and mitigating the environmental impacts of
the industry's activities.
❖ Conduct regular environmental audits: Regular environmental audits can help to
identify any non-compliance issues and ensure that the industry is meeting its regulatory
requirements. Audits can also help to identify opportunities for improvement in
environmental performance.
❖ Implement pollution prevention measures: Pollution prevention measures can help to
minimize the environmental impact of the industry's activities. These measures can include
process modifications, waste reduction, and recycling programs.
 ❖ Provide regular training to employees: Providing regular training to employees can help
to ensure that they understand the regulations and are aware of their responsibilities for
environmental compliance.
❖ Maintain proper records: Maintaining accurate records of the industry's activities and
compliance with regulatory requirements is essential for demonstrating compliance and
responding to any inquiries or investigations.
❖ Report any non-compliance incidents: If the industry experiences any non-compliance
incidents, it should report them to the relevant regulatory authorities as soon as possible.

By following these steps, an industry can improve its environmental performance and comply with
all the regulations stipulated by the DoE related to environmental pollution.
 8. List of Equipment
8.1. List of major equipment:

Name of the Identification No. No of items Size

Equipment

T-100 D= 0.34m, Spacing = 0.5m, no

of stage = 18

Distillation T-101 3 D= 0.34m, Spacing = 0.46m,

Column no of stage = 17

T-102 D= 0.056m, Spacing = 0.46m,

no of stage = 17

PRF Reactor R-100 1 21.92 m3

ATR R-101 1 45.34 m3

HTS Reactor R-102 1 30.44 m3

LTS Reactor R-103 1 29.28 m3

Acetic acid R-104 1 33.24 m3

Converter

Pressure Swing A-101, 2 H =10m

Absorber
A-102 D =3m

Desorbing Column A-103 1 H =0.61m

D= 1.5m

Absorber Column A-104 1 H= 0.61m

 D= 1.5m

PRF Furnace H-100 1 144 MW

8.2. Compressors

Name of the Identification No. No of items Size

Equipment

Air Compressor C-100 1 234 kw

Recycle Compressor C-101 1 54 kw

NG Compressor C-102 1 185 kw

Methanol Compressor C-103 1 136 kw

8.3. Pumps

Name of the Identification No. No of items Size

Equipment

H2O Pump P-100 1 142.82 hp

Extract Pump P-101 1 45.78 hp

Solvent Recycle Pump P-102 1 78.97 hp

MDEA Pump P-103 1 1025.88 hp

 8.4. Tanks

Name of the Identification No. No of items Size

Equipment

N2 Storage Tank T-100 1 15319.30 m3

H2 Storage Tank T-101 1 3718.31 m3

Acetic Acid Storage T -102 1 2880 m3

Tank

8.5. Heat Exchangers

Name of the Equipment Identification No. No of items Size

ATR Heat Exchanger HE-100 1 75686.023 kW

MDEA Heat HE-101 1 510.88kW

Exchanger

8.6. Mixer

Name of the Identification No. No of items Size

Equipment

Bottom Product Mixer M-100 1 8.33 m3

Pre-reformer Reactant M-101 1 10.59 m3

Mixer

Fired Heater Reactant M-102 1 6.68 m3

Mixer
Acid Acid Reactant M-103 1 12.96 m3
Mixer

LTS Product Mixer M-104 1 9.16 m3

Flare Mixer M-105 1 4.91 m3

 9. Process safety assessment of critical Equipment

The characteristics of critical equipment of our plant is given bellow-

1. High Temperature

2. High pressure.

3. Corrosive liquid storage.

We have to do a safety assessment of these equipment otherwise these equipment may lead to
catastrophic disaster.

9.1. HAZOP study of Acetic acid storage Tank

• Consider the study node of storage tank is line from distillation column entering into the
tank from above PFD figure.
• Parameter of this study is flow through the line.

• If the flow of stream is very high, the following causes are responsible is given
below-
❖ Residence time become very high in the distillation column
❖ Flow indicator fails low.

• Due to this causes, following consequences are occurred is mentioned below-

❖ Acetic acid won’t be converted to the desired amount and more unconverted methanol is
entering into storage tank.
❖ Large concentration of methanol is very explosive. So, it may lead to a catastrophic
explosion.
❖ If the residence time of acetic acid is higher in storage tank, it leads to higher corrosion
rate of storage tank’s metal.
❖ In presence of metal, sometimes acetic undergo metal-hydrogen evaluation which is
increasing the risk of explosive.
❖ Methanol is more toxic for inhalation if it is overflowed due to the high flow rate of
entering stream.

• Safeguard
❖ is used as the desired acetic acid composition detector or AT.
❖ Maintenance the entering stream valve.

• Recommendation
❖ Adding an alarm for high flow rate of entering stream into the storage tank.
❖ Periodic maintenance of valve and storage tank.
❖ Adding venture in the storage tank
❖ Providing adequate insulation on the surface of metal to overcome the corrosion rate
over the useful life.

9.2. HAZOP study of Acetic acid Converter/reactor

• Consider cooling water line as study node from above figure.
• Parameter of this study is flow.
• Deviation of the parameter is no flow.
• Because of the deviation of parameter, the following causes are responsible-
❖ Control valve is failed close.
❖ Cooling water service failure.
❖ Plugged cooling coils.
❖ Leakage in the cooling water line.

• Consequence of this failure are –

❖ Loss of cooling and runaway reaction.
❖ Increasing pressure cause bursting of the vessel.
❖ Reaction rate increase and additional energy will be released.

• Safeguard-
 ❖ High temperature alarm
❖ Regular inspection of the control valve.
❖ Alternative maintenance valve should be used in case of closing of control valve.

• Recommendation-
❖ Select fail open control valve.
❖ Install filter with maintenance procedure.
❖ Install cooling water meter and low flow alarm.
❖ Check and monitor reliability of water service.

Again,

• Consider cooling water line as study node.

• Parameter of this study is flow.
• Deviation of the parameter is high flow.
• Because of the deviation of parameter, the following causes are responsible-
❖ Control valve is failed open.
❖ Controller fails and valve opens.

• Consequence of this failure are –

❖ Reactor cools
❖ Reactant concentration build up.
❖ Undesired products obtain.

• Safeguard-
❖ Low threshold temperature limit alarm
❖ Regular inspection of the control valve.

• Recommendation-
❖ Select fail close control valve.
❖ Place controller on critical instrumentation list.
❖ Install cooling water meter and high flow alarm.
❖ Check and monitor reliability of water service.

9.3. HAZOP study of Absorber

• Consider MDEA solvent line as study node.
• The parameter of this study node is flow.
• The deviation of the parameter is no flow.
• The causes of the deviation of parameter are given below-
❖ MDEA solvent line leakage.
❖ MDEA solvent storage service failure.
❖ Fail closed valve.
❖ High flow meter showing.

• The consequences of the causes are given below mentioned-

❖ Inefficient contacting.
❖ Causing high pressure.

• Safeguard-
❖ Low flow alarm.
❖ Maintenance of the control valve.
❖ Use PSV.

• Recommendation-
❖ Install gas/liquid ratio station valve.
❖ Regula inspection by the authority.
❖ Install alternative gate valve for maintenance.

9.4. HAZOP study of ATR

• Consider the Exothermic zone as a study node.
• The parameter of this node is temperature.
• The deviation of this parameter is high temperature.
• The causes of high temperature are given below-
❖ High flow rate inlet oxygen.
❖ Controller fails.
❖ Fails open valve.
❖ Low flow meter.

• The consequence of high temperature is described below-

❖ Catalyst bed damage and reaction rate becomes slower.
❖ High pressure causes bursting of this chamber.

• Safeguards-
❖ Use PSV.
❖ High temperature alarm.
❖ Maintenance.

• Required action-
❖ Install emergency alarm and shutdown.
❖ Regular inspection of control valve.
❖ Install fail close valve.
10. Plot Plan & Equipment Layout
10.1. Plot Plan
10.2. Equipment Layout
 11. Cost Estimation & Economic Analysis

Percent of delivered-equipment cost Cost in USD

Purchased equipment 100 6,411,382

delivered

Purchased equipment 47 3,013,349

Installation

Instrumentation and 36 2,308,097

controls

Piping(installed) 68 4,359,740

Electrical system 11 705,252

(installed)

Building (including 18 1,154,049

services)

Yard improvements 10 641,138

Service facilities 70 4,487,967

(installed)

Total direct plant cost 23,080,975

Engineering and 33 2,115,756

supervision

Construction 41 2,628,667
expenses
Legal expenses 4 256,455

Contractor's fee 22 1,410,504

Contingency 44 2,821,008

Total indirect plant cost 9,232,390

Fixed-capital investment 32,313,365

Working capital 89 5,706,130

Total capital investment without land 38,019,494

Land price = 2% of total capital investment = $755,908

Total Capital Investment = $38,019,494 + $755,908

= $38,795,402

11.1. Estimation of Production Cost:

Working day basis 330 days/year

Direct Production cost

Raw material

Natural gas: 33.5 MTPD

Cost: $132.7/MT

Annual cost for NG = $(33.5×132.7×330) = $1,466,998

Methanol: 55.68 MTPD

Cost: $350/MT
Annual cost for Methanol = $(54.4×350×330) = $6,431,040

MDEA: 2.38 MTPD

Cost: $1500/MT

Annual cost for MDEA = $(2.38×1500×330) = $1,178,100

Total annual raw material cost = $1,466,998 + $6,431,040 + $1,178,100

= $9,076,138

Operating labor cost = 15% of total raw material cost

= $1,361,421

Utility:

Cooling water: 9.011 MTPD

Cooling water cost: $0.08 /MT

Annual cooling water cost = $(9.011×0.08×330) = $ 238

Process water: 87.023 MTPD

Process water cost: $0.53 /MT

Annual cooling water cost = $(87.023×0.53×330) = $ 15220

Electricity cost: $0.045/kWh

Maintenance and repair: 5% of fixed capital investment = $1,615,668

Operating supplies: 10% of maintenance and repair cost = $161,567

Laboratory charges: 10% of operating labor cost = $136,142

Total direct annual production cost = $12,366,394 = 12.37 million USD

Fixed Charges:

Depreciation

Economic life = 20 years

FCI = $ 32,313,365

Salvage value =10% of FCI = $3,231,336

Depreciation per year = $ 32,313,365 −$3,231,33620

= $1,454,101

Insurance: 0.1% of FCI = $32,313

Plant overhead cost: 30% of operating labor, maintenance, and repair cost = 533,170

Total manufacturing cost = $14,385,978 = 14.39 million USD

Annual selling of the product = $27.35 million

Annual gross earning = $27,354,000- $16,897,778

= $10,456,222

Income tax = 25% of annual gross earning = $2,614,055

Net annual earning = $7,842,167 + $1,454,101

= $9,296,268 = $9.3 million

 12. Conclusion
Based on the chosen basis, the report shows that the proposed plant is economically viable. The
Methanol Hydro Carboxylation method was chosen to produce acetic acid. Catalysts like Ni,
Imidazole Lil, MDEA solvent, and other raw materials were assumed to be purchased. 1.95 acres
of land will be needed to set up the proposed plant. Given the need for acetic acid in Bangladesh,
it is logical to assume that the proposed plant will be profitable.