PROBLEM

STATEMENT
To design a mono ethylene Glycol plant of
capacity 80,000 Tonnes per year from first
principle approach including material balance
and energy balance per equipment as well as for
the whole plant, cost analysis along with
designing and safety analysis. The project
includes the design details for the process, an
economic analysis, and recommendations and
predictions for the extent of its success.
INTRODUCTION
 A glycol is an alcohol with two hydroxyl groups on adjacent carbon atoms.
 Ethylene Glycol was first developed in 1859 by a French chemist—Charles-
Adolphe Wurtz—via saponification of ethylene glycol diacetate with
potassium hydroxide.
 It is the simplest member of the glycol family of organic compounds, with

the IUPAC name: ethane-1,2-diol and chemical formula (CH2oH2)

 The global production and consumption of ethylene glycol were about
30.2 million metric tons in 2021 with an estimated increase of 40.6 million Structure of Ethylene Glycol
metric tonnes by 2029.
 EG underpins almost every aspect of everyday life, particularly associated
with energy, chemicals, automotive, textiles, transportation, and
manufacturing technologies.
Literature Survey
 Basic introduction of mono ethylene glycol.
 Physical and chemical properties.
 Applications/Uses of mono ethylene glycol.
 Economic aspects.
 Major manufacturers of MEG in India and world.
 Manufacturing processes with their comparisons to choose out the efficient one.
 Equipment P(atm) T(°C)

Reactor 14.8 195

1st effect 0.8 142
2nd effect 0.58 123
3rd effect 0.35 101
Dryer 0.24 90
Refining column 0.20 160
Recovery column 1 190
MATERIAL BALANCE
Equipment Component Inlet Outlet
Liquid Vapour
Reactor EO 7230.77 kg/hr
H2o 59160.852 kg/hr 56281.572 kg/hr
MEG 0 9917.52 kg/hr
HG 0 188.40 kg/hr
Triple effect H2o 56281.572 kg/hr 8442.234 kg/hr 47839.338 kg/hr
evaporator 85%
MEG 9917.52 kg/hr 9731.52 kg/hr 186 kg/hr
HG 188.40 kg/hr 188.40 kg/hr 188.40 kg/hr
Drying column H2o 8442.234 kg/hr 8442.234 kg/hr
100%
MEG 9731.52 kg/hr 9669.52 kg/hr 62 kg/hr
HG 188.40 kg/hr 188.40 kg/hr
Refining column MEG 9669.52 kg/hr 96.1155 kg/hr 9572.825 kg/hr
99%
HG 188.40 kg/hr 172.78 kg/hr 16.382 kg/hr
Recovery Column H2o 56281.512 kg/hr 56.286 kg/hr 56252,286 kg/hr
95%
MEG 248 kg/hr 230.64 kg/hr 17.36 kg/hr
MATERIAL BALANCE

Reactor
REACTIONS-

Reactor EO + WATER MEG

EO+H2O T1 = 195°C MEG+ HG EO + MEG HG

P = 14.803atm

COMPO
NENTS INLET(kg/hr) Kmol/hr OUTLET(kg Kmol/hr
/hr) • Selectivity = 90%
• EO:H2O = 1:20
EO 7230 169 36 0.82 • Conversion = 99.5%
• Selectivity = Desired/Undesired
WATER 59160 5916 56281 3127 FA = FAo (1- XA)
•
MEG 0 0 9917 160
HG 0 0 188 1.77
EVAPORATOR(TRIPLE EFFECT)
H2O=13507 kg/hr
MEG=31 kg/hr
85% water is removed from all the three effects
collectively
MEG=9917 kg/hr MEG= 9886 kg/hr Total 3kmol/hr MEG is removed at top from evaporator,
H20 = 56281 kg/hr H20= 42774 kg/hr
HG = 188 kg/hr
Total water & MEG removed = 1719.98 kmol/hr
HG = 188 kg/hr
Overall Mass Balance- F=Y+L
3126=2657 +L
L= 469 kmol/hr
H2O=15398 kg/hr
MEG=62 kg/hr

MEG= 9886 kg/hr MEG=9824 kg/hr

H20= 42774 kg/hr H20= 27375 kg/hr
HG = 188 kg/hr HG = 188 kg/hr
Components Inlet(kg/hr) Outlet(kg/hr)
H2O=18933 kg/hr
MEG=93 kg/hr Liquid Vapor

Water 56281 8442 47839

MEG=9824 kg/hr MEG=9731 kg/hr
H20= 27375 kg/hr H20= 8442 kg/hr MEG 9917 9731 186
HG = 188 kg/hr HG = 188 kg/hr
DRYER

Water removal by dryer is 100%, Overall mass balance= F=Y+X

461.7959=303.99+X
Y=8504 kg/hr
Water removed=8442 kg/hr X=157.8059 kmol/hr
H2O=8442 kg/hr
MEG from top= 1 kmol/hr Amount of feed to MEG recovery column=2023.981kmol/hr
MEG= 62 kg/hr
Total MEG & water removed= 470 kmol/hr

F=18361 kg/hr
Dryer
MEG=9731 kg/hr X=9857 kg/hr
H2O= 8442 kg/hr
Removes 100% water MEG= 9669 kg/hr
HG=188 kg/hr
HG=188 kg/hr T= 90⁰C
P= 0.25atm
Refining Column
D=154.4 kmol/hr
MEG=9573 kg/hr
HG=16 kg/hr

99% recovery of MEG at top

F= 157.7 kg/hr P=155mm Hg Formula used:-
MEG= 9669 kg/hr
HG= 188 kg/hr
T= 155 -165 ⁰C Overall mass balance- F=D+W
Component mass balance= F*z f=Dxd+Wxw

W = 3.3 kmol/hr
MEG = 96kg/hr
HG = 172 kg/hr
Recovery column (MEG)
Water=56252 kg/hr
MEG=17 kg/hr

93% recovery of MEG at bottom,

99.9% water in feed is obtained from the distillate
Water= 56281 kg/hr
P=760 mm Hg
MEG= 248 kg/hr
T= 194 ⁰C Formula used:-
Overall mass balance- F=D+W
Component mass balance= F*z f=Dxd+Wxw

Water= 57/hr
MEG= 230 kg/hr
 ENERGY BALANCE

CALCULATIONS FOR REACTOR

Let’s take reference temperature=25
Enthalpy of formation of reaction (kJ/kmol)
------ For first reaction→ COMPONENT Cp (298K) (KJ/kmol)
At temp. 298 K
]=
-116,730*168 =-19.7*10⁶ kJ/hr
------ For second reaction→ Ethylene oxide -52640 43.71
]=
-121,660*168 =-20.5*10⁶ kJ/hr Water -285830 33.79
=(mCp)pT
Mono Ethylene
=22.2 x 10⁶ kJ/h -455200 149.6
Glycol
=+-= -18*10⁶ kJ/hr =0]

HG -629500 441
 ENERGY BALANCE

Enthalpy out Enthalpy out

Formula used:
Equipment P(atm) T(°C) from top from bottom
• Sensible heat = mCp∆T
10⁶ kJ/h 10⁶ kJ/h • Latent heat = mLv

Reactor 14.8 195 18 -

Dryer
0.24 90 21 1.98

Refining
0.20 160 3.8 0.14
column

Recovery
1 190 0.24 8.4x10 -4
column
EQUIPMENT DESIGN
REACTOR

MEG=160kmol/h PFR is selected because

EO = 169 kmol/hr  High conversion
H2O= 5916 kmol/hr REACTOR H20=3126 kmol/h  No back mixing
HG =1.78 kmol/h  Less volume than CSTR for
EO =0.8kmol/h same conversion
 Economical

Variable Values

Vmix 1.07 m³
Formula used (Process design): Formula used
rEO =kCEOCW CEO 2.563 kmol/h (Mechanical design)
• Pdesign = Pi * 1.05
But CW is in excess so pseudo first C water 51.3 kmol/h • t = Pi Di/(2f – Pi)
order reaction • V = πD²L/4
Residence time 17 min
rEO =kCEO • L/D = 30
Performance equation of PFR Reactor volume 18.16 m³
Π = -dCA/ rA D 2.48 m
CI =MI / VI
L 70.6 m

Thickness t 28.6mm
 Evaporator (Process design)
Pressure(atm) Steam or vapor Λs (kJ/kg)
Temperature(°C) FORMULA USED TO CALCULATE EVAPORATION RATES
STEAM
1st Effect- Ws λs + Wf (Tf – T1)Cp = W1 λ1
1 Effect
st
0.8 142 2138
2nd Effect- W1 λ1 + (Wf - W1)(T1 – T2)Cp = W2 λ2
2nd Effect 0.58 123 2194

3rd Effect 0.35 101 2254 3rd Effect- W2 λ2 + (Wf - W1- W2 )(T2 - T 3) Cp = W 3 λ 3

Formula used

HTC (U) calculation of heat transfer area

Area(m2) Evaporation
(W/m²°C) A= Q/U ΔT =Wλ/U ΔT
rate (W)
(kg/hr)
1st effecf 173 W1 =15204 2827

2nd effecf 190 W2 =16218 2553

3rd effect 200 W3 =16708 2268

Evaporator (Mechanical design)
Thickness Plastic Pressure
Formula used: (mm) failure (mN/m²)
(mN/m²)

• Do/Leff = 0.6 1st effect 5.98 0.19 0.08

• Elasticity Instability: 2nd effecf 4.25 0.16 0.058

P = KE(t/Do)m
3rd effect 3.27 0.11 0.035
• Plastic failure:
P = 2f(t/D o)/[1 + 1.5U(1 – 0.2D o/L)/100(t/D o)]

r k or R i = D o = 1.65m
D i = D o = 1.65m
r c or r i = 0.1* D o =0.165m
 References

• B. C. Bhattacharya, Mechanical aspects of Chemical engineering

• Rao, G.M. & Sittig, M. DRYDEN'S Outlines of Chemical Technology", Affiliated East-
West PressPrivate Limited, New Delhi.
• Smith, J.M. & Van Ness, H.C., "Introduction to Chemical Engineering
Thermodynamics",International Editions, Chemical Engineering Series, New York 6th
edition, McGrawHill
• https://www.icis.com/explore/resources/news/2008/08/18/9148176/shell-s-omega-
meg-process-kicks-off-in-south-korea/
• Heat transfer principles and applications by B.K. Dutta.Coulson J.M. & Richardson J.F.
“Chemical Engineering” Vol 6.
• Perry, Robert H.; Green, Don W. (2008). Perry's Chemical Engineers' Handbook, Eighth
Edition, McGrawHill
Thank you