FYDP Slides Presentation

LOGO FINAL YEAR DESIGN PROJECT 1

10478 Chan Choon Hoong8142 Hafizah Binti Ahmad Afif8108 Muhamad Rahimi Bin Ali

8145 Jazli Izzuddin Bin Jamaludin8146 Muhammad Emil Hakim Bin Khudri

PRODUCTION OF VINYL ACETATE396,000 tonne/year

1200 tonne/day

PRODUCTION OF VINYL ACETATE396,000 tonne/year

1200 tonne/day

SUPERVISED BY: ASSOC PROF DR. HILMI BIN MUKHTAR

Introduction

This project is designed for students to apply all necessary knowledge acquired throughout the program to conceptually design a new appropriate plant and also to learn to work as a team in order to be a well rounded engineer in the future.

Students may also improve their skills in using the related computer software such as iCON, Sprint, and Microsoft Visio.

Background of Project

Produce VAM via vapor fixed-bed ethylene/ acetic acid technology The reaction path for production would be as follows:

1. C2H4 + CH3COOH + ½O2 → CH2=CHOCOCH3 + H2O (1)

2. C2H4 + 3O2 → 2CO2 +2H2O (2)

Both reactions are parallel in which the first reaction is where the main product is produced (i.e. vinyl acetate).

The second reaction is the undesired reaction producing the undesired product which is carbon dioxide. Both reactions produce same side product which is water.

Case Study TO DESIGN THE PRODUCTION PATH OF VAM

Product Market Study: Vinyl Acetate Market in United States

31% of the world’s total capacity is produced in the United States. World production capacity is expected to reach about 5.8 million tons per

year by 2010 and keep increasing up to 6.4 million tons per year in 2015. Based from track records, in 2004, world’s vinyl acetate consumption was

4.4 million tons. In North America and Western Europe, it is mainly used in the production

of vinyl acetate polyvinyl acetate. Demand expected is about to reach 5.38 million tons and 6.2 million tons

in 2010 and 2015 respectively.

Source: http://www.fjfdi.com

Product Market Study: Vinyl Acetate Market in Europe

VAM mainly is used in production of polyvinylacetate, bonding agents, acrylic fibres, and nonwoven fabric.

Total volume of supplies into Europe is estimated at 150 000 tons per year. The main exporter is the USA. The deliveries on a regular basis are also realised from the countries of Asia as well.

In 2008, many manufacturers increase production and capacities at plant as shown in table in the next slide

Source: http://business.export.by

Capacities of Basic Vinyl Acetate Producers in 2008 (Source: ICIS)

Company Capacities (K tons)

Acetex Chimse (France) 165

Achema (Lithuania) 20

Celenese (Bay City, USA) 300

Celenese (Clear Lake, USA) 310

Celenese Germany) 285

Celenese (Mexico) 115

Celenese (Spain) 200

Companhia Alccoiquimica Nacional (Brazil) 80

Doljchim (Romania) 20

Dom Chemical (USA) 365

Duront (USA) 335

INEOS (Great Britain) 250

LyondellBasell (USA) 380

Stavrlen (Russia) 60

SSME Azot Association (Ukraine) 30

Wacker Chemie (Germany) 200

3115 K tons of VAM in Europe

2008

Location Selection

The factors that should be taken into consideration of selecting a suitable site :- Raw materials availability Market Transportation facilities Utilities Land price and availability Climate Special incentives Waste disposal facilities

Location Selection

After conducting the feasibility and site survey, three (3) main locations have been short-listed

i) Tanjung Langsat Industrial Estate, Johorii) Gebeng Industrial Estates, Kuantan, Pahangiii)Kerteh Industrial Area, Terengganu

Location Selection

Based on the matrix comparison made, Gebeng Industrial Estate has been chosen as the site for the VAM plant.

Justifications : Gebeng industrial estate is situates at east coast of peninsular

Malaysia and it is only 25 km from Kuantan City and 5 km from Kuantan Port

Low land prices compared to other location, RM 5.65 – 38.00 per metre square.

Location Selection East Coast Highway Peninsular Gas Utilisation (PGU) Project Attractive incentives given by the Malaysia government

and local government which is :• Five-year exemption on import duty. • 5 % discount on monthly electrical bills for first 2 years.• 85% tax exemption on gross profit

Constant supply of utilities such as cooling water, power supply, steam and waste management.

Excellent transportation link by railway, road and airport Good pipeline connection between Kerteh and Gebeng

Location Selection

Proposed plant location for VAM plant

Conceptual Design Analysis

Level 1 : Batch or Continuous

Level 2 : Input – Output Structure

Level 3 : Reactor Design & Network Synthesis

Level 4 : Separation System Synthesis

Level 5 :

Heat Integration

Hierarchy of Decisions(Douglas 1988)

1. Process operating mode2. Input-output structure of the flow sheet3. Reactor design and network synthesis4. Separation system synthesis

Separation of impurities Separation and purification of products

5. Heat-exchanger network

Level 1: Process Operating Mode

Criteria Requirement Current design Decision

Production rate

Batch if less than 1 X 106 lb/annum

Continuous if greater than 10 x 106 lb/annum

Production capacity ≈ 727.5 lb/annum Continuous process

Multiproduct plantsPlant is used for production of other product

Production is based on single product which is vinyl acetate

Continuous process

Seasonal production Product generated is of seasonal production

Has been a continuous demand daily for vinyl acetate

Continuous process

Short product lifetime The production is within limited time

Lifespan of the design plant is 20 years Continuous process

Level 2: Input-Output Structure

Decision : Should we purify the feed stream before they enter the

process? Should we remove or recycle a reversible by-product? Should we use a gas recycle and purge stream? Should we not bother to recover and recycle some reactants? How many product streams will there be? What are the design variables for the input-output structure,

and what economic trade-offs are associated with these variables?

Mixer

C2H4

C2H6

ReactionVaporization

HAc

O2

Separation

CO2 Removal

Purification VAM

HAcH2O

O2

HAcC2H4

C2H6

VAMH2OCO2

O2

C2H4

C2H6

Level 2: Input-Output Structure

Level 3: Reactor Design and Network Synthesis

Reactor Design : Selection criteria Reaction path Catalyst Size Operating conditions (Temp & Press) Phase Feed conditions (Temp & Conc.)

Multi Tubular Fixed Bed Reactor

Temperature : 140OC – 160OC (148.5OC)

Pressure : 8 bar – 10 bar (8.7 bar)

Phase : Vapor

Limiting Conditions

Oxygen concentration must not exceed 8 vol % to avoid gas mixtures capable of igniting

Reactor inlet temperature must > 1300C to prevent condensation in the reactor.

The peak reactor temperature along the length of the tube must remain below 2000C, avoid catalyst ageing

An excess of ethylene over acetic acid (3:1) must be guaranteed

The heat of reaction is removed by generating vapor in the shell section of the tubes. This vapor is used in other part of the process

Characteristics

Characteristics Multi tubular Fixed-Bed Reactor

Energy Transfer Mechanism

Shell and tube heat exchanger configuration with tubes packed with catalyst

Conversion Plug flow behavior ensures high conversion per unit mass of catalyst.

Operation Continuous operation

Maintenances

Fixed-bed device will have to be taken offline to regenerate the catalyst by means of shutting down the plant or using standby reactor. Not suitable for frequent catalyst regeneration.

Temperature Control Temperature control with liquid, gaseous or boiling heat transfer agent in shell side space.

Suitability for heterogeneous catalytic gas phase reaction

Catalyst attrition negligible.

Catalyst Lifetime For catalyst that is deactivated slowly

Selection Criteria

Selection criteria for catalysts: High durability High selectivity High production rates per unit volume of catalyst Low cost

Comparison Between Few Alternative

Technologies Phase Catalyst Features

A LiquidPdCl2 / CuCl2

Corrosion problem

B Gas Pd Highly undesired secondary reaction

C Gas Pd / Au Selectivity may reach 94% based on ethylene and 98-99% based on acetic acid

Mass Balance Around Reactor

C2H4 + CH3COOH + ½O2 → CH2=CHOCOCH3 + H2O (1)

C2H4 + 3O2 → 2CO2 +2H2O (2)

ReactionReactionn1 kmol/hr C2H4

n2 kmol/hr C2H6

n3 kmol/hr O2

n4 kmol/hr

CH3COOH

580.79 kmol/hr CH2=CHOCOCH3

n5 kmol/hr CO2

n6 kmol/hr H2O

n7 kmol/hr C2H4

n8 kmol/hr C2H6

n9 kmol/hr O2

n10 kmol/hr CH3COOH

The MEB around reactor as follows:

ξ1 = 580.79 kmol/hr CH2=CHOCOCH3

n5 kmol/hr CO2 = 2ξ2

n6 kmol/hr H2O = ξ1 + 2ξ2

n7 kmol/hr C2H4 = n2 kmol/hr C2H6 – (ξ1 + ξ2)

n8 kmol/hr C2H6 = n2 kmol/hr C2H6

n9 kmol/hr O2 = n3 kmol/hr O2 - (0.5ξ1 + 3ξ2)

n10 kmol/hr CH3COOH = n4 kmol/hr CH3COOH - ξ1


Component Reactor inlet (kmol/hr)

Reactor outlet

(kmol/hr)

Reactant consumed (kmol/hr)

Product produced (kmol/hr)

Ethylene 6178.6 5560.74 617.86 -

Oxygen 489.83 147.16 342.67 -

Acetic acid 1935.97 1355.18 580.79 -

Vinyl acetate 0 580.79 - 580.79

Carbon Dioxide 0 34.85 - 34.85

Water 0 615.64 - 615.64


Level 4: Separation System Synthesis

A. Distillation

Heuristic guidelines (Douglas 1988)

1. Separations in which the relative volatility of the key components is close to unity or which exhibit azeotropic behavior should be performed in the absence of non key components. In other words, perform the most difficult separation last.

2. Sequences that remove the lightest components alone one by one in column overheads should be favored. In other words favor the direct sequence.

3. A component composing a large fraction of the feed should be removed first. 4. Favor near-equimolar splits between top and bottom products in individual

columns.

Possible Sequence

A: Vinyl Acetate B: Water C: Acetic acid

SEQUENCE 1 SEQUENCE 2C

B

A B

A

A B C

B C

A B C

A

B

C

Separation

B. Phase separation Liquid-Vapor Separation System

Liquid-Liquid Separation System

Separation

Carbon Dioxide Removal Unit

Amine Treatment Unit Membrane Technology

Usually used to remove small amount of acid gas.

Usually used to remove bulk quantity of acid gas (more than

30%).

Need large amount of spaces usually area near the sea side.

Take only small amount of spaces which usually used in remote area.

Low transportation and maintenance cost.

High maintenance and transportation cost since it is

remote area.

Amine Treatment Unit

Amine solution

C2H6 + C2H4 + O2 + CO2

C2H6 + C2H4 + O2

Amine solution + CO2

Process Flow Diagram

Material Energy BalancesStream 1 2 3

Component Simulated (kgmol/hr)

Manual (kgmol/hr)

Deviation (%)

Simulated (kgmol/hr)

Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)

O2 616.36 489.83 20.53 148.06 147.16 0.61 148.06 147.16 0.61

HAc 1789.39 1935.97 -8.19 1333.17 1355.18 -1.65 1333.17 1355.18 -1.65

C2H4 6477.61 6178.60 4.62 5763.95 5560.74 3.53 5763.95 5560.74 3.53

C2H6 777.42 777.60 -0.02 738.96 777.60 -5.23 738.96 777.60 -5.23

VAM 1.88 0.00 100.00 594.25 580.79 2.27 594.24 580.79 2.26

H2O 49.44 0.00 100.00 738.84 615.64 16.67 738.84 615.64 16.67

CO2 10.46 0.00 100.00 109.22 34.85 68.09 109.22 34.85 68.09

Stream 4 5 6


Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)

O2 147.84 147.16 0.46 0.02 0.00 100.00 0.00 0.00 100.00

HAc 60.54 0.00 100.00 53.26 0.00 100.00 0.00 0.00 100.00

C2H4 5724.46 5560.74 2.86 6.24 0.00 100.00 0.00 0.00 100.00

C2H6 732.64 777.60 -6.14 1.14 0.00 100.00 0.00 0.00 100.00

VAM 209.20 145.20 30.59 65.22 145.20 -122.63 0.00 0.00 100.00

H2O 167.04 307.82 -84.28 7.85 0.00 100.00 117.17 307.82 -162.71

CO2 107.58 34.85 67.61 0.20 0.00 100.00 0.01 0.00 100.00



Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)

O2 147.82 147.16 0.45 147.82 147.16 0.45 147.68 147.16 0.35

HAc 10.55 0.00 100.00 10.55 0.00 100.00 19.20 0.00 100.00

C2H4 5717.98 5560.74 2.75 5717.98 5560.74 2.75 5682.15 5560.74 2.14

C2H6 731.45 777.60 -6.31 731.45 777.60 -6.31 725.06 777.60 -7.25

VAM 139.52 0.00 100.00 139.52 0.00 100.00 0.32 0.00 100.00

H2O 42.28 0.00 100.00 42.28 0.00 100.00 0.02 0.00 100.00

CO2 107.36 34.85 67.54 107.36 34.85 67.54 105.95 34.85 67.11

Stream 10 11 12


Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)


Manual (kgmol/hr)

Deviation (%)

O2 0.01 0.00 100.00 147.67 147.16 0.35 0.24 0.00 100.00

HAc 8.98 0.00 100.00 10.22 0.00 100.00 1325.89 1355.18 -2.21

C2H4 3.21 0.00 100.00 5678.93 5560.74 2.08 45.73 0.00 100.00

C2H6 0.28 0.00 100.00 724.79 777.60 -7.29 7.45 0.00 100.00

VAM 0.00 0.00 100.00 0.32 0.00 100.00 450.26 580.79 -28.99

H2O 1828.46 0.00 100.00 47.88 0.00 100.00 579.65 307.82 46.90

CO2 96.75 34.85 63.98 9.19 0.00 100.00 1.84 0.00 100.00



Manual (kgmol/hr) Deviation (%) Simulated

(kgmol/hr)Manual

(kgmol/hr) Deviation (%) Simulated (kgmol/hr)

Manual (kgmol/hr) Deviation (%)

O2 0.24 0.00 100.00 0.39 0.00 100.00 0.37 0.00 100.00

HAc 1325.89 1355.18 -2.21 0.03 0.00 100.00 0.00 0.00 100.00

C2H4 45.73 0.00 100.00 101.69 0.00 100.00 75.10 0.00 100.00

C2H6 7.45 0.00 100.00 18.64 0.00 100.00 12.24 0.00 100.00

VAM 450.26 580.79 -28.99 2354.38 580.79 75.33 16.53 0.00 100.00

H2O 579.65 307.82 46.90 698.00 307.82 55.90 3.31 0.00 100.00

CO2 1.84 0.00 100.00 4.35 0.00 100.00 2.88 0.00 100.00

Stream 16 17 18


Manual (kgmol/hr) Deviation (%) Simulated

(kgmol/hr)Manual

(kgmol/hr) Deviation (%) Simulated (kgmol/hr)

Manual (kgmol/hr) Deviation (%)

O2 0.02 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00

HAc 0.03 0.00 100.00 0.00 0.00 100.00 1707.83 1355.18 20.65

C2H4 26.59 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00

C2H6 6.40 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00

VAM 2337.85 580.79 75.16 16.53 0.00 100.00 1.71 0.00 100.00

H2O 100.84 0.00 100.00 593.94 698.00 -17.52 76.19 0.00 100.00

CO2 1.47 0.00 100.00 0.01 0.00 100.00 0.00 0.00 100.00

Economic Studies

To determine whether a project is feasible and attractive enough for investment.

Acceptable plant design must present a process that is capable of operating under conditions which will yield a profit (Peters M.S and Timmerhaus K.D., 1991).

Economic Studies

Economic Potential 1

EP1 = Revenue – Raw Material Compare between :

Recycle Stream NeglectedRecycle Stream Included

Recycle Stream Included gives a positive value of EP1

Sample calculation at the next page

Economic Studies

ComponentMass Flow Rate

(kg/hr)Price

RM/kg

Total Running Hours in Year

(Hrs)

Annual Value of Product RM/year

RAW MATERIALS

Acetic Acid 106,930.00 1.10 7920 931,574,160

Ethylene 211,880.00 1.95 7920 3,272,274,720

TOTAL RAW MATERIALS 4,203,848,880

PRODUCT

Vinyl Acetate

51,021.45 3.00 7920 1,212,269,652

TOTAL PRODUCT 1,212,269,652

Recycle Stream NEGLECTED

Economic Studies

Economic Potential 1 (EP1) calculation EP1 = Revenue – Raw Material EP1 = (Total VAM produced) – (Acetic Acid Cost + Ethylene

Cost) Assumptions:

Oxygen is obtained from atmosphere. Therefore, it is assumed that no raw material cost is incurred on oxygen feed.

So, before including recycle stream:EP 1 = RM 1,212,269,652 – RM 4,203,848,880 = - RM 2,991,579,228.00 (negative value)

Economic Studies

ComponentMass Flow

Rate (kg/hr)Price

RM/kg


(Hrs)


RAW MATERIALS

Acetic Acid 12,971.22 1.10 7920 113,005,268.60

Ethylene 15,189.02 1.95 7920 234,579,225.00

TOTAL RAW MATERIALS 347,584,493.60

PRODUCT

Vinyl Acetate

51,021.45 3.00 7920 1,212,269,652

TOTAL PRODUCT 1,212,269,652

Recycle Stream INCLUDED

Economic Studies

Economic Potential 1 (EP1) EP1 = Revenue – Raw Material

EP1 = (Total VAM produced) – (Acetic Acid Cost + Ethylene Cost)

Assumptions: Oxygen is obtained from atmosphere. Therefore, it is assumed that no raw material cost is incurred on oxygen feed.

So, by including recycle stream:EP 1 = RM 1,212,269,652 - RM 347,584,493.60 = RM 864,685,158.40 (positive value)

Economic Studies

Economic Potential 2

EP2 = [EP1 (Recycle Stream Included) + By Product] – (Waste Gas)

By product CO2 can be sold to the fertilizer plant and for oil & gas company which can be used for Enhanced Oil Recovery

Our target to achieve green plant technology Positive value of EP2 indicates that this project is feasible

Sample calculation at the next page

Economic Studies Waste Gas and By-product

Chemical InvolveMass flow rate

(kg/hr)Price

RM/kg


(Hrs)


Waste Gas (Stream 17)

Ethylene + Ethane 2474 1.95 7920 38,208,456

Acetic Acid 0 1.10 7920 0

Oxygen 11.84 0.50 7920 46,886

Vinyl Acetate 1423.33 3.00 7920 33,818,320

Carbon Dioxide 126.53 0.2 7920 200,423

TOTAL RM 72,274,085

By-products (Sub flow sheet 1_33)

Carbon Dioxide 4258 0.20 7920 6,744,672

Economic Studies

Since,EP2 = EP1 (Recycle Stream Included) + By Product – (Waste Gas)

Therefore, EP2 = (RM 864,685,158.40 + RM 6,744,672) – (RM 38,208,456

+ RM 46,886 + RM33,818,320 + RM 200,423) EP2 = RM 799,155,745 (positive value)

Economic Studies

Economic Potential 3 (EP3)

EP3 = EP2 – [(Installation Cost of Recycle Compressor 1 + Installation Cost of Recycle Compressor 2 + Installation Cost of Reactor 1)]

Based from EP3 , the value also indicates positive value which also means that the Vinyl Acetate production can be accepted

Sample calculation as per attached In the report

Economic Studies

Installation Costs Reactor 1 = RM 828,334.00 Compressor 1 = RM 22.5 million/year Compressor 2 = RM 2.71 million/year

Since,EP3 = EP2 – (Installation Cost of Recycle Compressor 1 + Installation Cost of Recycle Compressor 2 + Installation Cost of Reactor 1)

So, EP3 = (RM 799.2 million /year) – (RM 828,334.00/year + RM 22.5 million /year + RM 2.71 million /year)

≈ RM 773 million/year

Heat Integration

PURPOSE OF HEAT INTEGRATION The cost of the utilities and energy is one of the major costs

in a process plant. Hence, utilities and energy costs savings has become one of the major issues in plant design. Heat integration enables the plant to optimize the energy of utilities usage by exchanging heat using process stream instead of utilities or energy.

Pinch Technology Method

The amount of energy can be determined from the process plant by using the Pinch Technology Method.

The most common method to calculate the amount of energy recovered using the pinch technology are through plotting composite curve or using the problem table algorithm.

For our plant, the Problem Table Algorithm is used to calculate the energy recovery due to accuracy in the results as compared to the composite curve method.

Methodology of Heat Integration

Stream Data from Sprint

Composite Curve

Grand Composite Curve

Heat Integration

Design of HEN

C

C

C

C

C

DH: 2529.37T: 132.71

DH: 34147.102T: 42.51

DH: 295.698T: 42.51

DH: 4199.483T: 42.51

DH: 5081.95

DH: 5288.19

DH: 33341.6

DH: 1556.48

DH: 4984.8

CP: 378.068

CP:3.298

HDH: 38308.037

CP:161.894

CP:216.174

DH: 26.39T: 147.19

DH: 186.463T: 149.23

C

From Grid diagram generated using SPRINT, we can design the heat exchanger network. The table below shows the design of heat exchanger.

Cold 2

Cold 1

Cold 1

Heat Integration

THANK YOUQ & A SESSION

Plant Layout

referred to PTS 20.158B and PTS 20.152G

Site selectio

n

Site layout & develop

ment

Classification of hazardous areas

Safety distance

s

Documents

FYDP Slides Presentation