design of a plant for production of 36- annie
TRANSCRIPT
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DESIGN OF A PLANT FOR PRODUCTION OF 36,000kg/day OF METHYL ETHYLKETONE BY VAPOUR PHASE CATALYTIC DEHYDROGENATION OF 2-BUTANOL
A
DESIGN PROJECT
Presented to
The Department of Chemical Engineering
Covenant University, Canaan Land, Ota, Ogun State, Nigeria
BY
OKOYE CHIOMA CHIDIMMA
(11CF011991)
MEMBER OF TEAM COVENANT
In Partial Fulfilment of the requirements for the Degree
Bachelor of Engineering (Honours) in Chemical Engineering
Covenant University, Canaan Land, Ota, Ogun State, Nigeria
MARCH 2016
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CERTIFICATION
This is to certify that the design project entitled “DESIGN OF A PLANT FOR PRODUCTION
OF 36,000kg/day OF METHYL ETHYL KETONE BY VAPOUR PHASE CATALYTIC
DEHYDROGEN OF 2- BUTANOL”submitted to the Department of ChemicalEngineering,Covenant University,Canaaland,Ota ,Ogun State,Nigeria,is a record of the original
design carried out by Group “Covenant” Members in the Depa rtment of Chemical Engineering.
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DEDICATION
First of all, I dedicate this report to the Almighty God who kept and sustained me throughout this
period of this project. I would also like to dedicate this report to the staff of Chemical
Engineering Department for their guidance and support throughout this project. Lastly, this
report is also dedicated to my family, Mr. Sunday Okoye ,Mrs.Chioma Okoye,Onyinye Okoye
and Chinonye Okoye, my friends and loved ones who provided me with support throughout this
experience.
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Department of Chemical Engineering,
Covenant University,
Canaan Land, Ota,
Ogun State,
Nigeria.
November 10, 2015.
The Head,
Department of Chemical Engineering,
Covenant University,
Canaan Land, Ota,
Ogun State,
Nigeria.
Dear Sir,
LETTER OF TRANSMITTAL
In accordance with the regulations of the Department of Chemical Engineering, School of chemical &Petroleum Engineering, College of Engineering and Covenant University, Canaan Land, Ota, Ogun State,Nigeria , we the members of group “COVEANANT”, do hereby submit a Design Project entitled “DESIGNOF A PLANT FOR THE PRODUCTION OF 36,000KG/DAY OF METHYL ETHYL KETONE BY VAPOUR PHASECATALYTIC DEHYDROGENATION OF 2-BUTANOL”in partial fulfilment of the requirements for the awardof the Bachelor of Engineering (Honours) Degree in Chemical Engineering at Covenant University,Canaan Land, ota, Ogun State, Nigeria.
Yours faithfully,
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ACKNOWLEDGEMENT
The Design project on the preparation of MEK from DEHYDROGENATION of 2-Butanol was
a great chance for learning and professional development. I consider myself as a very lucky
individual as I was provided with an opportunity to be part of a team that designs a plant for the
preparation of MEK from Dehydrogenation of 2-Butanol.
I want to use this opportunity to express my deepest gratitude and special thanks to my
Supervisor Engr.Ojewumi,Miss Babatunde and the Covenant Team whose support, guidance
and encouragement was a source of inspiration throughout the execution of this project.
I give absolute thanks to God Almighty, whose glory and honor, brought me to the successful
conclusion of this project and for keeping me safe through all the difficult times, for granting me
wisdom and for always being faithful in my times of need, I give Him all the glory
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TABLE OF CONTENTS
CONTENTS PAGE
TITLE PAGE i
CERTIFICATION ii
DEDICATION iii
LETTER OF TRANSMITTAL iv
ACKNOWLEDGEMENT v
TABLE OF CONTENTS vi
LIST OF TABLES vii
LIST OF FIGURES viii
LIST OF SYMBOLS ix
LIST OF APPENDICES x
ABSTRACT xi
CHAPTER ONE 13
1.0 INTRODUCTION 13
1.1 BACKGROUND OF STUDY 13
1.1.1 PHYSICAL AND CHEMICAL PROPERTIES OF 2-BUTANOL 16
1.1.2 PHYSICAL AND CHEMICAL PROPERTIES OF MEK 18
1.1.3 INDUSTRIAL APPLICATION OF MEK 21
1.2 AIM AND OBJECTIVE OF WORK 22
1.3 SIGNIFICANCE OF WORK 23
1.4 SCOPE OF WORK 23
1.5 LIMITATION OF WORK 24
CHAPTER TWO 25
2.0 THEORETICAL PRINCIPLES AND LITERATURE REVIEW 25
2.1 THEORETICAL PRINCIPLES 25
2.1.1 PRINCIPLE OF DISTILLATION 25
2.1.2 COMPRESSORS 27
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2.1.3 LIQUID LIQUID EXTRACTION 29
2.1.4 SEPARATOR 31
2.1.5 VAPOUR PRESSURE 32
2.1.6 PRINCIPLE OF ABSORPTION 33
2.1.7 PRINCIPLE OF VAPOURISATION 34
2.1.8 CATALYSIS 36
2.1.9 HEAT TRANSFER 36
2.1.10 CONDENSATION 38
2.2 LITERATURE REVIEW 39
2.2.1 SELECTION OF PROCESS ROUTE 39
2.2.2 REVIEW OF PAST WORKS ON MEK PRODUCTION FROM
DEHYDROGENATION OF 2-BUTANOL. 42
CHAPTER THREE 43
3.0 MATERIAL BALANCES FOR THE PLANT 43
3.1 INTRODUCTION 43
3.2 DESCRIPTION OF THE PROCESS 43
3.3 ASSUMPTION MADE 47
3.4 MATERIAL BALANCE 48
CHAPTER FOUR 54
4.0 ENERGY BALANCE FOR THE PLANT 54
4.1 INTRODUCTION 54
4.2 ENERGY BALANCE 56
REFERENCES 62
APPENDICES 64
A: MATERIAL BALANCES 64
B: ENERGY BALANCE 73
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LIST OF TABLES
Table Name Page
Table 1.1- Physical Properties of MEK 19 Table 1.2 – Industrial application of MEK 22 Table 3.1 – Material Balance across Reactor 48
Table 3.2 – Material Balance across Partial Condenser 49 Table 3.3 – Material Balance across Absorption Column 50 Table 3.4 – Material Balance across Extraction Column 52 Table 3.5 – Material Balance across Solvent Recovery Unit 52 Table 3.6 – Material Balance across Distillation Column 53 Table 4.1 – Energy Balance across Preheater 56 Table 4.2 – Energy Balance across Vaporizer 57
Table 4.3 – Energy Balance across Superheater 1 57 Table 4.4 – Energy Balance across Compressor 57 Table 4.5 – Energy Balance across Superheater 2 58 Table 4.6 – Energy Balance across Reactor 58 Table 4.7 – Energy Balance across Condenser 59 Table 4.8 – Energy Balance across Absorber 60 Table 4.9 – Energy Balance across Solvent Recovery Unit 60
Table 4.10 – Energy Balance across Distillation Column 61 Table 4.11 – Energy Balance across Cooler system 61
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LIST OF FIGURES
Figure 1.1: Molecular Structure of MEK 15
Figure 1.2: Structure of 2-butanol 16
Figure 1.3: Chemical reaction of 2-butanol to give butane. 17
Figure 1.4: oxidation reaction of 2-butanol using KMnO 4 as oxidizing agent. 17
Figure 1.5: Chemical reaction of MEK 19
Figure 1.6: Reaction of MEK with ammonia and hydrogen 20
Figure 1.7: Reaction of MEK with acetylene. 20
Figure 1.8: Halo form 20
Figure 1.9: Chemical reaction of MEK with hydrogen peroxide 21
Figure 2.1: Diagram of a Distillation Column 26
Figure 2.2: liquid liquid extraction column 29
Figure 2.3: A vapour liquid separator 32
Figure 2.4: A boiling point diagram shows how the equilibrium compositions of the components
in a liquid mixture vary with temperature at a fixed pressure. 33
Figure 2.5: Heat exchanger 38
Figure 2.6: Dehydrogenation of 2-Butanol 40
Figure 3.1: Block flow Diagram of MEK production 40
Figure 3.2: Process Flow Diagram for production of MEK 46
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LIST OF SYMBOLSSymbols Meaning
λ Heat of Vaporization
α Relative Volatility
R Reflux Ratio
H Enthalpy
Cp Heat Capacity
D Distillate rate
B Bottoms rate
F Feed rate
M Mass flow
T Temperature
Qc Condenser heat
Q R Reboiler heat
Q Heat
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LIST OF APPENDICES
APPENDIX A: MATERIAL BALANCES CALCULATIONS 64
APPENDIX B: ENERGY BALANCES CALCULATIONS 73
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ABSTRACT
This project was performed in order to design a plant required for the production of Methyl
Ethyl Ketone of 99.9% purity at a continuous rate of 36,000 kg/day. The design shows all the
processes involved and the unit operations required to achieve the product by converting the raw
material 2-Butanol to Methyl Ethyl Ketone. Both material and energy balances was carried out
across the various unit operations for the process.
A detailed work on the material and energy balance calculations is contained in this report
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CHAPTER ONE
1. INTRODUCTION
Process design can be the design of new facilities or it can be the modification orexpansion of existing facilities. The design starts at a conceptual level and ultimately ends in
the form of fabrication and construction plans. It is an innovation activity gaps in the
industrial world and provide lasting and innovative solutions to the gaps. The activity aimed
at providing the most economically feasible and effective procedure to either manufacture a
new or an existing product.in this case MEK (methyl Ethyl ketone),which is an important
industrial solvent. Chemical engineering has consistently been one of the highest paid
engineering professions. There is a demand for chemical engineers in many sectors of
industry, including the traditional processing industries: chemicals, polymers, fuels, foods,
pharmaceuticals, and paper, as well as other sectors such as electronic materials and devices,
consumer products, mining and metals extraction, biomedical implants, and power
generation. The reason that companies in such a diverse range of industries value chemical
engineers so highly is the following:
I. The creation of plans and specications and the prediction of the nancial outcome if
the plans were implemented is the activity of chemical engineering design. Design is
a creative activity, and as such can be one of the most rewarding and satisfying
activities undertaken by an engineer . The design does not exist at the start of the
project. The designer begins with a specic objective or customer need in mind and,
by developing and evaluating possible designs, arrives at the best way of achieving
that objective — be it a better chair, a new bridge, or for the chemical engineer, a new
chemical product or production process. When considering possible ways of
achieving the objective, the designer will be constrained by many factors, which will
narrow down the number of possible designsII. Starting from a vaguely dened problem statement such as a customer need or a set
of experimental results, chemical engineers can develop an understanding of the
important underlying physical science relevant to the problem and use this
understanding to cr eate a plan of action and set of detailed specications which, if
implemented, will lead to a predicted nancial outcome.
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III. Before the commencement of work, the designer is supposed to provide as complete,
and as simple, a statement of the necessities as possible. If in any case the
requirement (need) arises from outside the design group, from a customer or from
another department, then the designer will have to elucidate the real requirements
through discussion. When writing specifications for others, such as for the
mechanical design or purchase of a piece of equipment, the design engineer should be
aware of the restrictions (constraints) that are being placed on other designers. A
well-thought-out, comprehensive specification of the requirements for a piece of
equipment defines the external constraints within which the other designers must
work.
1.1 BACKGROUND OF STUDY
Methyl ethyl ketone (MEK), also known as 2-butanone, is a colorless organic liquid with an
acetone-like odor and has a low boiling point. It is miscible partially with water and many
conventional organic solvents and also forms azeotropes with a number of organic liquids. MEK
can be produced using dehydrogenation of secondary butyl alcohol and as a byproduct of butane
oxidation. For the purpose of this study, the dehydrogenation of secondary butyl alcohol will be
considered. (Arora & Sharma, November 2015)
MEK may be irriating to eyes,mucos membrances,and in high concentrations,narcotic .MEK is
similar to but more irritating than acetone.the vapor is irritating to mucos membrances and
conjunctiva.no serious poisonings were reported in man except for dermatitis.dermatitis can
result if excessive repeated prolonged skin contact occurs.Minor skin contacts have been shown
to cause no evidence of irritation .MEK can recognized at 25ppm by its odor,which is similar to
acetone but more irritating.the warning properties prevent inadvertent exposure to toxic levels.
MEK is used industrially as a solvent in the manufacture of adhesives, protective coatings,
inks and magnetic tapes. It is also the preferred extraction solvent for dewaxing lube oil. In
addition to industrial uses, methyl ethyl ketone is also used in various household products,
including paints, paint removers, varnishes and glues. Methyl ethyl ketone may enter the
environment during its production, transport and use. It may also be released from vehicle
exhausts, natural sources and during the breakdown of other chemicals. MEK is distinguished by
its exceptional solvency, which enables it to formulate higher-solids protective coatings. The
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molecular formula of methyl ethyl ketone is CH 3COCH 2CH 3; its molecular structure is given
as:
Figure 1.1: Molecular Structure of MEK (wikipedia, wikipedia/MEK-molecular-structure, 2015)
Because of MEK’s high reactivity, it is estimated to have a sh ort atmospheric lifetime ofapproximately eleven hours.
For the general population, exposure to methyl ethyl ketone can occur from cigarette
smoking. People may also breathe in small amounts when using household products that contain
methyl ethyl ketone. If exposed to methyl ethyl ketone, the potential adverse health effects that
may occur depend on the way people are exposed and the amount to which they are exposed.
Breathing in high levels of methyl ethyl ketone vapour can cause irritation of the nose, throat and
lungs and chest tightness. Ingestion may cause inflammation of the mouth and stomach upsets.Methyl ethyl ketone can be absorbed into the body following through inhalation, ingestion or
prolonged skin exposure causing headache, dizziness, tiredness, slurred speech, low temperature,
fitting and coma. Heart problems and high levels of blood sugar can also occur. (Arora &
Sharma, November 2015)
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1.1.1 PHYSICAL AND CHEMICAL PROPERTIES OF 2-BUTANOL
1.1.1.1 PHYSICAL PROPERTIES:
2-Butanol is a secondary alcohol with formula C 4H 7OH which is produced in a two (2)-step
process from hydration of butanes. It can also be manufactured industrially by the hydration of 1-
butene in the presence of sulphuric acid.
It is used as solvent for paints and resins, manufacture of industrial cleaners, perfumes; it
serves as a flavoring agent.
Physical properties are:
Colorless liquid
Strong alcoholic odour Flash point below 26 oC Boiling point at 99.5 oC Melting point: −115 °C Density: 0.808 g/mL at 25 °C Vapor density : 2.6 (vs air) Vapor pressure : 12.5 mm Hg ( 20 °C)
Refractive index: n20/D 1.397(lit.) Water Solubility : 12.5 g/100 mL (20 ºc) (wikipedia, 2-Butanol, 2015)
Figure 1.2: Structure of 2-butanol
https://en.wikipedia.org/wiki/Chemical_formulahttps://en.wikipedia.org/wiki/Carbonhttps://en.wikipedia.org/wiki/Carbonhttps://en.wikipedia.org/wiki/Carbonhttps://en.wikipedia.org/wiki/Chemical_formula
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1.1.1.2 CHEMICAL PROPERTIES
2-butanol which is a secondary alcohol has molecular formula of C 4H 10O and molecular mass
74.12 gmol -1. It can be easily oxidized as well as undergo elimination (dehydration) and
substitution reactions. 2-butanol is dehydrated (removal of H 2O) on heating with concentrated
sulphuric acid to give butane.
Figure 1.3: Chemical reaction of 2-butanol to give butane.
2-butanol are oxidized, by dehydrogenation, to form butanal and butanone respectively. Theoxidation can be achieved using oxidizing agents such as KMnO 4 or K 2Cr 207.The reactions
involve the loss of the -OH hydrogen together with a hydrogen atom from the adjacent alkyl
group.
Figure 1.4: oxidation reaction of 2-butanol using KMnO 4 as oxidizing agent.
2-butanol undergoes substitution reaction when reacted with sodium. The acidic part of the -
OH group shows up in their reaction with reactive metals (such as sodium) to liberate hydrogen
gas.
Specifically, in relation to our study, and the production of Methyl Ethyl Ketone. A notable
reaction undergone is the dehydration reaction which when carried out on the 2-butanol, an
elimination reaction in regards to the molecules present in the compound is observed. (wikipedia,
2-Butanol, 2015)
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1.1.2 PHYSICAL AND CHEMICAL PROPERTIES OF MEK
1.1.2.1 PHYSICAL PROPERTIES
MEK is a low boiling solvent with an atmospheric boiling point of 175.3 0F (79.6 0C).
Methyl Ethyl Ketone (MEK) is a chemically stable compound also known as 2-butanone. MEK
is a flammable, colorless liquid possessing a typical ketonic odor. It has very good solvent
properties, a fast evaporation rate, and is miscible with organic solvents. Some of the physical
properties are listed below.
Boiling point at 1 atm, 0C 79.6Azeotrope with water, bp, 0C 73.4Wt.% ketone in vapor 88.7Auto ignition temperature, 0C 515.6Coefficient of cubic expansion, per 0C 0.00119Critical pressure, atm 43Critical temperature , 0C 260Density, g/mL at 20 0C 0.8037Dielectric constant 18.51Dipole moment, debye units 2.74Electrical conductivity, mho 5.0 x 10 -8
Boiling point at 1 atm, 0C 79.6Azeotrope with water , bp, 0C 73.4Wt.% ketone in vapor 88.7Auto ignition temperature, 0C 515.6Coefficient of cubic expansion, per 0C 0.00119Critical pressure, atm 43Critical temperature , 0C 260Density, g/mL at 20 0C 0.8037Dielectric constant 18.51
Dipole moment, debye units 2.74Electrical conductivity, mho 5.0 x 10 -8 conductivity, mho 5.0 x 10 -8 Freezing point, 0C -86.3Heat of combustion, cal/g 8084Heat of fusion, cal/g 24.7Heat of vaporization, cal/g 106
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Molecular weight 72.104Refractive index nD 1.3791Ketone in water 26.3Water in ketone 11.8Solubility parameter 9.3Specific heat, cal/g 0C 0.549Surface tension, dyn/cm 24.6
Table 1.1: Physical properties of MEK (Arora & Sharma, November 2015)
1.1.2.2 CHEMICAL PROPERTIES
Methyl Ethyl ketone can be widely utilized in chemical synthesis. Its reactivity centers
around the carbonyl group and its adjacent hydrogen atoms. Condensation, ammonolysis,
halogenations, and oxidation can be carried out under the proper conditions. Some typical
reactions are described below.
Figure 2.5: Chemical reaction of MEK
Self-Condensation:
Aldol condensation of 2 moles of MEK yields a hydroxy ketone, which readily dehydrates to
an unsaturated ketone:
Condensation with other Compounds:Reaction with aldehydes gives higher ketones, as well as ketals and cyclic compounds,
depending on reaction conditions. β - ii ketones are produced by the condensation of MEK with
aliphatic esters. MEK condenses with glycols and organic oxides to give derivatives of
dioxolane. Sec-Butyl amine is formed by reacting MEK with aqueous ammonia and hydrogen:
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Figure 1.6: Reaction of MEK with ammonia and hydrogen.
An excess of MEK in this reaction will produce di-sec-butyl amine. Reacting MEK with
acetylene gives methyl pentynol, a hypnotic compound:
Figure 1.7: Reaction of MEK with acetylene. (Arora & Sharma, November 2015)
Halo form reaction :
This is a chemical reaction where a halo form (CHX 3, where X is a halogen) is produced by
the exhaustive halogenation of a methyl ketone (a molecule containing the R – CO – CH 3 group) in
the presence of a base. R may be alkyl or aryl. The reaction can be used to produce chloroform
(CHCl 3), bromoform (CHBr 3), or iodoform (CHI 3).
This reaction was traditionally used as a chemical test for qualitative organic analysis to
determine the presence of a methyl ketone, or a secondary alcohol oxidizable to a methyl ketone
through the iodoform test. In organic chemistry, this reaction may be used to convert a terminal
methyl ketone into the analogous carboxylic acid. (L. Cao, 2015)
Figure 1.8: Halo form reaction
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Miscellaneous Reactions
Oxidation of MEK with oxygen produces diacetyl, a flavoring material. Chlorination yields
mixtures of several monochloro and dichloride derivatives in various percentages depending onreaction conditions. The reaction of MEK with hydrogen peroxide gives a mixture of peroxides
and hydro peroxides which is used to cure polyester resins at room temperature:
Figure 1.9: Chemical reaction of MEK with hydrogen peroxide
MEK peroxides are widely used as catalysts for the polymerization of polyester resins at
room temperature. The condensation product of MEK and m-phenyl diamine is an efficient
curing agent for epoxy resins. MEK and cobalt acetate function together as a specific catalyst for
single-stage oxidation of p-xylene to terephthalic acid. Aliphatic monoketones, such as MEK
also function as catalysts in the polymerization of polyethylene terephthalate where, it is
claimed, they speed condensation times and cause less yellowing of the polymer than antimony
trioxide. MEK is also used in the preparation of complex catalysts used in the syndiotacic
polymerization of α - olefins such as propylene. Phenol, glyoxal, formaldehyde, acetaldehyde,
furfuraldehyde, and other chemicals can be reacted with MEK to form resins useful for
adhesives, coatings, molded products, and electrical insulation. MEK reacts with acrylonitrile to
produce a dinitrile, which upon hydrogenation produces amines. (Perona, 2004)
1.1.3 INDUSTRIAL APPLICATION OF METHYL ETHYL KETONE (MEK)
1.1.3.1 as a solvent:Butanone is an effective and common solvent and is used in processes involving gums,
resins, and cellulose acetate and nitrocellulose coatings and in vinyl films. For this reason it finds
use in the manufacture of plastics, textiles, in the production of paraffin wax, and in household
products such as lacquer, varnishes, paint remover, a denaturing agent for denatured alcohol,
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glues, and as a cleaning agent. It has similar solvent properties to acetone but has a significantly
slower evaporation rate. Butanone is also used in dry erase markers as the solvent of the erasable
dye. (wikipedia, industrial application of MEK, 2015)
1.1.3.2 as a welding agent:As butanone dissolves polystyrene, it is sold as "polystyrene cement" for use in connecting
together parts of scale model kits. Though often considered an adhesive, it is actually functioning
as a welding agent in this context. (wikipedia, industrial application of MEK, 2015)
MEK is consumed in large quantities in a variety of industries. Some industries and their
various application of MEK is listed below.
INDUSTRY APPLICATIONAdhesive manufacture Carpet adhesive solventsElectroplating Cold-cleaning solventsElectroplating Vapor degreasing solventsLaboratory chemicals Solvents-extractionMachinery manufacture and repair SolventsMetal degreasing SolventsPaint manufacture SolventsPaint stripping Solvents
Paper coating SolventsPesticide manufacturing (insecticides) SolventsPrinting Solvents for flexography and gravure printing
Table 1.2: industrial application of MEK (Arora & Sharma, November 2015)
1.2 AIM AND OBJECTIVES OF THE DESIGN PROJECT
The aim of this design is to design a plant with a capacity of 36,000kg/day that producesMethyl Ethyl Ketone (MEK) of 99.9% purity by vapour phase catalytic dehydrogenation of 2-
butanol.
The objectives of the design project are to:
Design a plant for the continuous production process of MEK;
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Use cost efficient and optimal energy methods for production; Obtain a high percentage purity of the product; Incorporate zinc-oxide brass as the reaction catalyst; Calculate the material and energy balances of the plant; Obtain mechanical and chemical design of the plant; and Perform HAZOP analysis of process equipment’s
1.3 SIGNIFICANCE OF WORK
Methyl Ethyl Ketone (MEK) is a highly useful and sought after solvent whose application
cut across so many industries such as paints,coating, printing and machinery industries. The
design project would to a large extent bring clearer insight on the use of vapour phase
dehydrogenation of 2-butanol to maximise the production of MEK.
1.4 SCOPE OF WORK
This Report tries to show how economics, safety, environmental considerations and
operability influence the choices taken in conveyig the task to fulfilment and also the various
contributions made by the various areas of study which includes;
• Process Design- this area involves a well detailed Process flow Diagrams (PFD), Detailed
Equipment lists, An estimated cost list for the equipment, a detailed material balance and an
overall Energy balance for all the plant items.
• Mechanical Design- Provision of recommendations on the mechanical design of the
secondary alcohol vaporizer, absorber, distillation column etc and preparation of mechanical
design specifications for key processes
• Chemical Engineering Design- Preparation of a detailed chemical Engineering design of
all items of equipment and a design specification sheet for all the items.
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1.5 LIMITATIONS OF WORK
The limitation of this design project is that one is limited to only use one process of
producing methyl ethyl ketone which is the vapor phase catalytic dehydrogenation of 2-
Butanol
MEK has come under fire due to some of its properties. It has been touted of being toxic
to the ozone layer thereby leading to global warming; it has also been linked to being
carcinogenic even though this has not been proved. Some countries have placed MEK on
their Hazard control lists.
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CHAPTER TWO
2. THEORETICAL PRINCIPLES AND LITERATURE REVIEW2.1 THEORETICAL PRINCIPLES
2.1.1PRINCIPLES OF DISTILLATION:
Distillation is separation process based on a strategy of isolating the constituents of mixture
(either a fluid or gaseous). It is a physical process and not a chemical process utilizing the
difference in the boiling temperatures of the constituents to separate them from the each other. In
this project, we are dealing with alcoholic distillation, a way of separating secondary alcohol, 2-
buatanol can be separated from Methyl ethyl ketone (MEK) based on the boiling points (79.64
°C (175.35 °F; 352.79 K) for MEK and 98 to 100 °C; 208 to 212 °F; 371 to 373 K for 2-butanol).
(wikipedia, 2-Butanol, 2015)
Distillation can take place either in pure components also known as a complete separation or in a
partial separation. Distillation in the production of methyl ethyl ketone for dehydrogenation of 2-
butanol as a separation process is inevitable. Also, distillation separation of components from a
liquid mixture depends on certain characteristics of the components such as differences in
boiling points of the individual components, concentrations of the components present, depends
on the vapour pressure characteristics of liquid mixtures, difference in volatility between the
components. (Tham, 2009)
3 Relative Volatility
Relative volatility is a measure comparing the vapor pressures of the components in a
liquid mixture of chemicals. (https://en.wikipedia.org/wiki/Relative_volatility, Retrieved October
2015). For a liquid mixture of two components (called a binary mixture) at a
given temperature and pressure, the relative volatility is defined as:
( ⁄ )( ⁄ ) ⁄ Where,
= the relative volatility of the more volatile component to the less volatile
component
https://en.wikipedia.org/wiki/Vapor_pressurehttps://en.wikipedia.org/wiki/Temperaturehttps://en.wikipedia.org/wiki/Pressurehttps://en.wikipedia.org/wiki/Pressurehttps://en.wikipedia.org/wiki/Temperaturehttps://en.wikipedia.org/wiki/Vapor_pressure
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= the vapor – liquid equilibrium concentration of component in the vapor phase
= the vapor – liquid equilibrium concentration of component in the liquid phase
= the vapor – liquid equilibrium concentration of component in the vapor phase
= the vapor – liquid equilibrium concentration of component in the liquid phase
= Henry's law constant (also called the K value or vapor-liquid distribution ratio )
of a component
Figure 2.1: Diagram of a Distillation Column
https://en.wikipedia.org/wiki/Vapor%E2%80%93liquid_equilibriumhttps://en.wikipedia.org/wiki/Vapor%E2%80%93liquid_equilibriumhttps://en.wikipedia.org/wiki/Vapor%E2%80%93liquid_equilibriumhttps://en.wikipedia.org/wiki/Henry%27s_lawhttps://en.wikipedia.org/wiki/Henry%27s_lawhttps://en.wikipedia.org/wiki/Vapor%E2%80%93liquid_equilibrium
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2.1.2 COMPRESSORS
Compressors are similar to pumps: both increase the pressure on a fluid and both can transport
the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a
gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids. (Perry et al , 2007)
2.1.2.2TYPES OF COMPRESSORS
2.1.2.3 CENRTIFUGAL COMPRESSORS
Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to
the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section
converts the velocity energy to pressure energy. They are primarily used for continuous,
stationary service in industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants. (Dixon, 1978) Their application can be from 100 horsepower (75
kW) to thousands of horsepower. With multiple staging, they can achieve high output pressures
greater than 10,000 psi (69 MPa).
Many large snowmaking operations (like ski resorts) use this type of compressor. They are also
used in internal combustion engines as superchargers and turbochargers. Centrifugal
compressors are used in small gas turbine engines or as the final compression stage of medium-
sized gas turbines. ( Aungier,2000)
2.1.2.4 DIAGONAL COMPRESSORS
Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial
and axial velocity component at the exit from the rotor. The diffuser is often used to turn
diagonal flow to an axial rather than radial direction.
2.1.2.5 RECIPROCATING COMPRESSORS
Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or
portable, can be single or multi-staged, and can be driven by electric motors or internal
combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are
commonly seen in automotive applications and are typically for intermittent duty. Larger
reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial
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and petroleum applications. Household, home workshop, and smaller job site compressors are
typically reciprocating compressors 1½ hp or less with an attached receiver tank. ( Bloch et al,
1996)
Other types of compressors include:
IONIC LIQUID PISTION COMPRESSORS ROTARY SCREW COMPRESSORS ROTARY VANE COMPRESSORS SCROLL COMPRESSORS DIAPHGRAM COMPRESSORS AIR BUBBLE COMPRESSOR
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2.1.3 LIQUID LIQUID EXTRACTION:
Liquid – liquid extraction (LLE) consists in transferring one (or more) solute(s) contained in a
feed solution to another immiscible liquid (solvent). The solvent that is enriched in solute(s) is
called extract. The feed solution that is depleted in solute(s) is called raffinate.
Figure 2.2: liquid liquid extraction column (wikipedia/liquid liquid extraction column, 2015)
Liquid – liquid extraction is a basic technique in chemical laboratories, where it is performed
using a variety of apparatus, from separatory funnels to countercurrent distribution
equipment.This type of process is commonly performed after a chemical reaction as part of the
work-up.
The term partitioning is commonly used to refer to the underlying chemical and physical
processes involved in liquid – liquid extraction, but on another reading may be fully synonymouswith it. The term solvent extraction can also refer to the separation of a substance from a mixture
by preferentially dissolving that substance in a suitable solvent. In that case, a soluble compound
is separated from an insoluble compound or a complex matrix. (chemwiki, 2015)
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Solvent extraction is used in nuclear reprocessing, ore processing, the production of fine
organic compounds, the processing of perfumes, the production of vegetable oils and biodiesel,
and other industries.
Liquid – liquid extraction is possible in non-aqueous systems: In a system consisting of amolten metal in contact with molten salts, metals can be extracted from one phase to the other.
This is related to a mercury electrode where a metal can be reduced, the metal will often then
dissolve in the mercury to form an amalgam that modifies its electrochemistry greatly. For
example, it is possible for sodium cations to be reduced at a mercury cathode to form sodium
amalgam, while at an inert electrode (such as platinum) the sodium cations are not reduced.
Instead, water is reduced to hydrogen. A detergent or fine solid can be used to stabilize an
emulsion, or third phase In solvent extraction, a distribution ratio is often quoted as a measure of
how well-extracted a species is. The distribution ratio (D) is equal to the concentration of a
solute in the organic phase divided by its concentration in the aqueous phase. Depending on the
system, the distribution ratio can be a function of temperature, the concentration of chemical
species in the system, and a large number of other parameters. Note that D is related to th e ΔG of
the extraction process.
In solvent extraction, two immiscible liquids are shaken together. The more polar solutes
dissolve preferentially in the more polar solvent, and the less polar solutes in the less polar
solvent.
After performing liquid-liquid extraction, a quantitative measure must be taken to determine
the ratio of the solution’s total concentration in each phase of the extractio n. This quantitative
measure is known as the distribution ratio or distribution coefficient. (chemwiki, 2015)
Separation factors:
The separation factor is one distribution ratio divided by another; it is a measure of the
ability of the system to separate two solutes. For instance, if the distribution ratio for nickel (D Ni)
is 10 and the distribution ratio for silver (D Ag) is 100, then the silver/nickel separation factor
(SF Ag/Ni ) is equal to D Ag/D Ni = SF Ag/Ni = 10. (chemwiki, 2015)
https://en.wikipedia.org/wiki/Nickelhttps://en.wikipedia.org/wiki/Silverhttps://en.wikipedia.org/wiki/Silverhttps://en.wikipedia.org/wiki/Nickel
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Decontamination factor:
This is used to express the ability of a process to remove a contaminant from a product. For
instance, if a process is fed with a mixture of 1:9 cadmium to indium, and the product is a 1:99
mixture of cadmium and indium, then the decontamination factor (for the removal of cadmium)of the process is 0.11 / 0.01 = 11 (chemwiki, 2015)
2.1.4 PRINCIPLES OF SEPARATION:
In chemistry and chemical engineering, a separation process , or a separation technique , or
simply a separation , is a method to achieve any mass transfer phenomenon that converts a
mixture of substances into two or more distinct product mixtures (which may be referred to as
fractions ) at least one of which is enriched in one or more of the mixture's constituents. In some
cases, a separation may fully divide the mixture into its pure constituents. Separations are carried
out based on differences in chemical properties or physical properties such as size, shape, mass,
density, or chemical affinity, between the constituents of a mixture. They are often classified
according to the particular differences they use to achieve separation. (wikipedia, 2015)
SEPARATOR:
A vapor – liquid separator is a device used in several industrial applications to separate a
vapor – liquid mixture. A vapor – liquid separator may also be referred to as a flash drum, knock-
out drum, knock-out pot, compressor suction drum or compressor inlet drum. When used to
remove suspended water droplets from streams of air, it is often called a demister.
Method of operation:
For the common variety, gravity is utilized in a vertical vessel to cause the liquid to settle to
the bottom of the vessel, where it is withdrawn.
In low gravity environments such as a space station, a common liquid separator will not
function because gravity is not usable as a separation mechanism. In this case, centrifugal force
needs to be utilized in a spinning centrifugal separator to drive liquid towards the outer edge of
the chamber for removal. Gaseous components migrate towards the center.
https://en.wikipedia.org/wiki/Contaminanthttps://en.wikipedia.org/wiki/Cadmiumhttps://en.wikipedia.org/wiki/Indiumhttps://en.wikipedia.org/wiki/Chemistryhttps://en.wikipedia.org/wiki/Chemical_engineeringhttps://en.wikipedia.org/wiki/Mass_transferhttps://en.wikipedia.org/wiki/Mixturehttps://en.wikipedia.org/wiki/Chemical_substancehttps://en.wikipedia.org/wiki/Chemical_substancehttps://en.wikipedia.org/wiki/Mixturehttps://en.wikipedia.org/wiki/Mass_transferhttps://en.wikipedia.org/wiki/Chemical_engineeringhttps://en.wikipedia.org/wiki/Chemistryhttps://en.wikipedia.org/wiki/Indiumhttps://en.wikipedia.org/wiki/Cadmiumhttps://en.wikipedia.org/wiki/Contaminant
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For both varieties of separator, the gas outlet may itself be surrounded by a spinning mesh
screen or grating, so that any liquid that does approach the outlet strikes the grating, is
accelerated, and thrown away from the outlet.
The vapor travels through the gas outlet at a design velocity which minimizes the
entrainment of any liquid droplets in the vapor as it exits the vessel. The feed to a vapor – liquid
separator may also be a liquid that is being partially or totally flashed into a vapor and liquid as it
enters the separator. (MIT, 2015)
Figure 2.3: A vapour liquid separator (wikipedia, 2015)
2.1.5 Vapor Pressure
The vapor pressure of a liquid at a particular temperature is the equilibrium pressure
exerted by molecules leaving and entering the liquid surface. (Tham, 2009) Special points
regarding vapor pressure are as follows:
Energy input raises vapor pressure Vapor pressure is related to boiling The ease with which a liquid boils depends on its volatility
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The vapor pressure and hence the boiling point of a liquid mixture depends on the relative
amounts of the components in the mixture.
Distillation occurs because of the differences in the volatility of the components in the
liquid mixture.
Boiling Point Diagram
Boiling point diagram shows how the equilibrium compositions of the components in a
liquid mixture vary with temperature at a fixed pressure.
Figure 2.4: A boiling point diagram shows how the equilibrium compositions of the componentsin a liquid mixture vary with temperature at a fixed pressure. (Tham, 2009)
The boiling point of A is that at which the mole fraction of A is 1. The boiling point of B is
that at which the mole fraction of A is 0. In this example, A is the more volatile component and
therefore has a lower boiling point than B. The upper curve in the diagram is called the dew-point
curve while the lower one is called the bubble-point curve. The dew-point is the temperature at
which the saturated vapour starts to condense. The bubble-point is the temperature at which the
liquid starts to boil. The region above the dew-point curve shows the equilibrium composition of
the superheated vapour while the region below the bubble-point curve shows the equilibrium
composition of the sub-cooled liquid. (Tham, 2009)
The difference between liquid and vapour compositions is the basis for distillation operations.
2.1.6 PRINCIPLES OF ABSORPTION:
Absorption, or gas absorption, is a unit operation used in the chemical industry to separate
gases by washing or scrubbing a gas mixture with a suitable liquid. The absorbent used for this
project is water.
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The fundamental physical principles underlying the process of gas absorption are the
solubility of the absorbed gas and the rate of mass transfer. One or more of the constituents of
the gas mixture dissolves or is absorbed in the liquid and can thus be removed from the mixture.
In some systems, this gaseous constituent forms a physical solution with the liquid or the solvent,
and in other cases, it reacts with the liquid chemically. (wikipedia, absorption_chemistry, 2015)
The purpose of such scrubbing operations may be any of the following: gas purification
(e.g., removal of air pollutants from exhausts gases or contaminants from gases that will be
further processed), product recovery, or production of solutions of gases for various purposes.
Gas absorption is usually carried out in vertical counter current columns. The solvent is fed
at the top of the absorber, whereas the gas mixture enters from the bottom .The absorbed
substance is washed out by the solvent and leaves the absorber at the bottom as a liquid solution .
The solvent is often recovered in a subsequent stripping or desorption operation. This second
step is essentially the reverse of absorption and involves counter current contacting of the liquid
loaded with solute using and inert gas or water vapor. (Terry, 2015)
The absorber may be a packed column, plate column, spray column , venturi scrubbers ,
bubble column , falling films , wet scrubbers ,stirred tanks. Tray absorbers are used in
applications where tall columns are required, because tall, random-type packed towers aresubject to channeling and maldistribution of the liquid streams. Plate towers can be more easily
cleaned. Plates are also preferred in applications having large heat effects since cooling coils are
more easily installed in plate towers and liquid can be withdrawn more easily from plates than
from packings for external cooling. Tray columns have got some disadvantage. These are slow
reaction rate processes, higher pressure drops than packed beds and plugging and fouling may be
occur. (Terry, 2015)
2.1.7 PRINCIPLES OF VAPOURIZATION:
A phase transition is the transformation of a thermodynamic system from one phase or state
of matter to another one by heat transfer. The term is most commonly used to describe transitions
between solid, liquid and gaseous states of matter, and, in rare cases, plasma. A phase of a
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thermodynamic system and the states of matter have uniform physical properties. The change
from liquid to gas is vapourization.
Vaporization happens at any boiling point. It occurs in two forms; Evaporation and Boiling.
It is a phase transition from the liquid phase to vapor (a state of substance below critical
temperature and critical pressure) that occurs at temperatures below the boiling temperature at a
given pressure. Evaporation usually occurs on the surface.
Evaporation may occur when the partial pressure of vapor of a substance is less than the
equilibrium vapour pressure.
We define the evaporation process as one that starts with a liquid product and ends up with a
more concentrated, but still liquid and still pumpable concentrate as the main product from the
process. It occurs at the liquid’s surface. (Adams, 1926)
The major requirement in the field of evaporation technology is to maintain the quality of
the liquid during evaporation and to avoid damage to the product. This may require the liquid to
be exposed to the lowest possible boiling temperature for the shortest period of time. The most
common types of evaporators are:
1. Falling Film Evaporators
2. Rising Film Evaporators
3. Forced Circulation Evaporators
4. Plate Evaporators
Boiling is a phase transition from the liquid phase to gas phase that occurs at or above the
boiling temperature. Boiling, as opposed to evaporation, occurs below the surface. Boiling is a
rapid vaporization that occurs at or above the boiling temperature and at or below the liquid's
surface.
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The boiling point corresponds to the temperature at which the vapour pressure of the liquid
equals the atmospheric pressure. If the liquid is open to the atmosphere (that is, not in a sealed
vessel), it is not possible to sustain a pressure greater than the atmospheric pressure, because the
vapour will simply expand until its pressure equals that of the atmosphere. For this reason,
boiling point varies with the pressure of the environment. Evaporation is a surface phenomenon
whereas boiling is a bulk phenomenon. (wikipedia, vapourization, 2015)
2.1.8 CATALYSIS:
Catalysts are substances that speed up a reaction but which are not consumed by it and do
not appear in the net reaction equation. In addition, catalysts affect the forward and reverse rates
equally; this means that catalysts have no effect on the equilibrium constant and thus on the
composition of the equilibrium state. (sciencezen, 2015)
Catalysts function by allowing the reaction to take place through an alternative mechanism
that requires a smaller activation energy. This change is brought about by a specific interaction
between the catalyst and the reaction components. Recall that the rate constacnt of a reaction is
an exponential function of the activation energy, so even a modest reduction of E a can yield an
impressive increase in the rate.
Catalysts are conventionally divided into two categories: homogeneous and heterogeneous.
Enzymes, natural biological catalysts, are often included in the former group, but because they
share some properties of both but exhibit some very special properties of their own they are
treated here as a third category. (chemwiki/catalysis, 2015)
2.1.9 HEAT TRANSFER
Basics of Heat Transfer
In the simplest of terms, the discipline of heat transfer is concerned with only two things:
temperature, and the flow of heat. Temperature represents the amount of thermal energy
available, whereas heat flow represents the movement of thermal energy from place to place.
(Efunda, 2015)
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and no net thermal energy is exchanged. The balance is upset when temperatures are not
uniform, and thermal energy is transported from surfaces of higher to surfaces of lower
temperature. (wikipedia, wikipedia/radiation, 2015)
Heat exchanger is a device built for heat transfer from one medium to another. Diagram of
a Heat exchanger is shown below.
Figure 2.5: Heat exchanger Heat exchanger ( Alaqua , 2015)
2.1.9 CONDENSATION:
Condensation is the change of the physical state of matter from gas phase into liquid phase. It
can also be defined as the change in the state of water vapor to liquid water when in contact with
a liquid or solid surface or cloud condensation nuclei within the atmosphere. When the transition
happens from the gaseous phase into the solid phase directly, the change is called deposition.
Condensation is deposition of a liquid or a solid from its vapour, generally upon a surface that is
cooler than the adjacent gas. A substance condenses when the pressure exerted by its vapour
exceeds the vapour pressure of the liquid or solid phase of the substance at the temperature of thesurface where condensation occurs. Heat is released when a vapour condenses. Unless this heat
is removed, the surface temperature will increase until it is equal to that of the surrounding
vapour.
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Partial condensation is a separation operation used when the feed mixture consists of different
chemical species that have different tendencies to condensate/evaporate (different boiling point).
By removing heat from a gas feed mixture, part of components will condensate, thus the partial
condensation. The liquid has the tendency to go on the bottom of the fraction column and thevapors will have the tendency to separate from the liquid and move to the top of the column.
The property that makes this separation possible is the volatility of the components. A
component with a higher volatility will evaporate faster, and thus has the tendency to move up to
the top of the column. The components with a lower volatility will remain on the bottom of the
column, as a liquid phase.
The main problem with this kind of separation is that usually, the components have a low
volatility range which means it is quite difficult to perform the operation of separation through
only one partial condensation/vaporization process. (WW2010, 2015)
2.2 LITERATURE REVIEW
2.2.1 SELECTION OF PROCESS ROUTE:
There are various ways in which MEK can be produced some of the methods are listed below
and emphasis made on the preferred one.
1. Vapor phase catalytic dehydrogenation of 2- Butanol.
2. Liquid phase oxidation of n-Butane.
3. Direct oxidation of n-Butanes, Hoechst-Wacker process.
4. Direct oxidation of n-Butanes, Maruzen process
Commercially, MEK is predominantly produced by the catalytic dehydrogenatio of SBA in
vapor phase over ZnO or Brass catalyst. It can, however be produced by the selective direct
oxidation of the olefin in a variety of processes, including the HoechstWacker-type process
employing a palladium(II) catalyst .
Most MEK (88%) is produced today by dehydrogenation of 2-butanol . 2-butanol can be easily
produced by the hydration of n-butenes(from petrochemically produced C4 raffinates). The
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remaining MEK is produced by process in which liquid butane is catalytically cracked giving
both acetic acid and MEK.
The vapor phase dehydrogenation process gives high conversion of 2-butanol and high
selectivity of MEK of about 95 mole%. Other advantages of this process include better yield,
longer catalyst life, simple production separation and lower energy consumption.
Of all the processes, it has been found that dehydrogenation of 2-butabol has more advantages
and is more economical compared to other processes, so this process has been selected for
design. The process is further explained below.
VAPOR PHASE DEHYDROGENTAION OF 2-BUTANOL:
MEK is prepared by vapor phase dehydrogenation of 2-butanol. A 2 step process from butanes ,
which are first hydrated to give 2-butanol, is used. The dehydrogenation of 2-butanol is an
exothermic reaction (51 KJ/Kgmol). The reaction is as follows.
Figure2.6: Dehydrogenation of 2-butanol.
The equilibrium constant for 2-butanol can be calculated as follows:
log Kp = -2790/T + 1.51*log T + 1.856
Where T = reaction temperature, K Kp= equilibrium constant, bar.
The MEK concentration in the reaction mixture increases and reaches its maximum at
approximately 3500C. Copper, Zinc or Bronze are used as catalysts in gas phase
dehydrogenation. Commercially used catalysts are reactivated by oxidation, after 3 to 6 months
use. They have a life expectance of several years.
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Sec-butyl alcohol is dehydrogenated in a multiple tube reactor, the reaction heat being supplied
by heat transfer oil. The reaction products leave the reactor as gas and are split into crude MEK
and hydrogen on cooling. The hydrogen is purified by further cooling. The crude MEK is
separated from uncreated reactants and by-products by distillation.
LIQUID PHASE OXIDATION OF n-BUTANE
MEK is produced as a by-product in the liquid phase oxidation of n-butane to acetic acid. Autoxidation
of n-butane takes place in the liquid phase according to the radical mechanism yielding MEK as an
intermediate and acetic acid as end-product with mass ratio 0.2:1.0 by non-catalyzed liquid phase
oxidation at 180 oC and 53 bars with remixing. Continuous oxidation under plug flow conditions at
150oC, 65 bars and a residence time of 2-7 minutes forms MEK and acetic acid at a mass ratio of 3:1.
DIRECT OXIDATION OF n-BUTENES (HOECHST-WACKER PROCESS)
In direct oxidation of n-butanes by Hoechst-Wacker process, oxygen is transferred in a
homogenous phase on to n-butenes using redox salt pair, PdCl 2 / CuCl 2. 95 per cent conversion of n-
butanes can be obtained with MEK selectivity of about 86 percent.
Disadvantages of the process are:
Formation of chlorinated butanone and n-butryaldehyde; and Causes corrosion due to free acids.
DIRECT OXIDATION OF n-BUTANES, MARUZEN PROCESS
The Maruzen process is similar to the Hoechst-Wacker process except that oxygen is transferred by an
aqueous solution of palladium sulphate and ferric sulphate. The process is commercially good to get
MEK via direct oxidation of n-butenes, but is generally not accepted due to formation of undesirable by
products. The process is patented and not much information is available.
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2.2.2 REVIEW OF PAST WORKS ON MEK PRODUCTION FROMDEHYDROGENATION OF 2-BUTANOL .
1. Dehydrogenation of Sec-Butanol to Methyl Ethyl Ketone over Cu-ZnO Catalysts
Prepared by Different Methods: Co-precipitation and Physical Mixing
Cu-ZnO catalysts prepared by co-precipitation and physical mixing methods were
characterized to investigate the roles of ZnO by X-ray diffraction (XRD), N 2O chemisorption
decomposition and evaluated for the vapour-phase dehydrogenation of sec-butanol (SBA) to
methyl ethyl ketone (MEK). ZnO not only could disperse Cu species, but also prevent Cu0
from sintering. Cu-ZnO catalyst by co-precipitation method exhibited excellent reactivity.
(Yun Feng Hu, 2013)
2. The production of methyl ethyl ketone from n-butene
In this preliminary design the production of methyl ethyl ketone (MEK) from normal butene,
with secondary butyl alcohol (SBA) as intermediate, is described. This design is split into
two parts. In the first part SBA is obtained from n-butene by absorption in sulphuric acid,
followed by hydrolysis with water. Sulphuric acid and SBA are separated in a stripper. The
sulphuric acid is reconcentrated and recycled to the absorber. The SBA is purified in an
azeotropic distillation unit, using di-isobutylene as entrained. In the second part of the design,
SBA is vaporized and fed to a multitubular, isothermal reactor, filled with a Cu/Ni on SiO 2
catalyst. The SBA is dehydrogenized; forming MEK and hydrogen. The hydrogen is purified
and sold as a valuable by-product. The MEK is purified in two fractionation columns and
obtained with a purity of 99.1 wt."-%. The capacity of the plant is 33,731 tons of MEK per
year. An economic evaluation shows that this plant can pay itself back within approximately
1.5 to 2 years. (A.H. Amer, 1988)
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CHAPTER 3
3.0 MATERIAL BALANCES FOR THE PROCESS
3.1 INTRODUCTION:
Material balances are the basis of process design. A material balance taken over the
complete process will determine the quantities of raw materials required and products produced.
Balances over individual process units set the process stream flows and compositions. Material
balances are also useful tools for the study of plant operation and trouble shooting. They can be
used to check performance against design; to extend the often limited data available from the
plant instrumentation; to check instrument calibrations; and to locate sources of material loss.
All mass/material balances are based on the principle of conservation of mass that is massr
can neither be created nor destroyed with an exception of nuclear processes according to
Einstein’s equation; E=mc 2.
The general conservation equation for any process system can be written as:
Material out Material in+Generation Con For a steady state process the accumulation term is zero and thus for a continuous steady
state process, the general balance equation for any substance involved in the process can be
written as:
Material in+Generation Material out If no chemical reaction takes place, material balance is computed on the basis of chemical
compounds mass basis that are used whereas if a chemical reaction occurs molar units are used.
Also it is worthwhile to note that when a reaction occurs an overall balance is not
appropriate but a reactant balance (a compound balance) is.
a. PROCESS DESCRIPTON Pre-Heater
In the dehydrogenation of 2-butanol, the cold feed of 2-Butanol is mixed with recycle stream and
then pumped from the feed tank to a steam heater and heated up to 373°K (stream1), the heating
medium being used is dry saturated steam at 140°C.
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Vaporizer
This Stream 1 is further fed to thermo-syphon vaporizer which is heated by the reactor vapor.
The heating medium in vaporizer is heated reaction products discharged from the reactor at
673°K i.e. (Stream 5) and itself gets cooled down to 425°K.
Knock-Out Drum
Stream 2 is further fed to knockout drum to remove entrained liquid which is recycled back to
the vaporizer. Knockout drum consists of a hollow vertical drum having inclined sieve plates
known as demister for the passage of clean gas. Separation in knock-out drum is based on the
principle of density difference of the liquid and the clean gas.
Super-Heater 1
The dry alcohol vapours are fed to the super-heater 1 where they are heated to increase the
temperature of the vapours to 573K. The vapours are heated with the help of flue gases at high
temperature of 813K.
Compressor
The superheated vapours are then compressed with the help of a compressor to increase the
pressure as well as increasing the temperature of the vapours.
Super-Heater 2
The compressed vapours are then fed to the super-heater 2 to increase the vapours temperature of
773K with the help of flue gases at 813K high temperature.
Reactor
The superheated vapours are fed to the reactor in which the butanol is dehydrated to produce
MEK and hydrogen, according to the reaction:
CH 3CH 2CH 3CHOH CH 3CH 2CH 3CO + H 2
The conversion of alcohol to MEK is 90 per cent and the yield is taken as 100 per cent. Initially,
preheated vapours of secondary-butyl alcohol are passed through a reactor (Step 1) containing a
catalytic bed of zinc oxide or brass (zinc-copper alloy) which is maintained between 400°C and
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500°C. A mean residence time of two to eight seconds at normal atmospheric pressures is
required for conversion from secondary-butyl alcohol to MEK.
Partial Condenser
The reaction product from the reactor are cooled to a suitable temperature in the vaporizer and
the cooled products are then fed to the condenser where almost 80% of the MEK and unreacted
2-butanol are condensed and sent to the distillation column while the non-condensable hydrogen
with the un-condensed MEK and unreacted 2-butanol are sent to the absorber.
Absorption Column
In the absorption column the uncondensed MEK and alcohol are absorbed in water. Around 98
per cent of the MEK and alcohol can be considered to be absorbed in this unit, giving a 10 per
cent w/w solution of MEK. The water feed to the absorber is recycled from the next unit, the
extractor. The vent stream from the absorber, containing mainly hydrogen, are dried and used as
a furnace fuel.
Extraction Column
In the extraction column the MEK and alcohol in the solution from the absorber are extracted
into tri-chloro-ethylane (TCE). The raffinate, water containing around 0.5 per cent w/w MEK, is
recycled to the absorption column. The extract, which contains around 20 per cent w/w MEK,
and a small amount of butanol and water, is fed to the solvent recovery.
Solvent Recovery
In the solvent recovery, the unit separates the MEK and alcohol from the solvent TCE. The
solvent containing a trace of MEK and water is recycled to the extraction column. The bottom
product is solvent, i.e. 1, 1, 2-trichloroethane and the distillate from this column (Stream 15) is
MEK and alcohol. The recovery of solvent is 99.9%. The solvent is first cooled down to room
temperature and then fed to the extraction column.
Distillation Column
The distillate from the solvent recovery column is fed to this distillation column along with the
condensate from partial condenser containing MEK and 2-Butanol, which is mixed first and then
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fed into the column. The distillate is MEK and the bottom product is 2-Butanol. The 2-Butanol
discharged from the bottom of the column will be sent back to the feed tank.
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Pump
Reactor
Partial Condenser
Liq-Liq Extraction Column
Solvent Recovery Column
Distillation Column
MEK Storage
Storage
FLOW SHEET FOR THE PRODUCTION OFMETHYL ETHYL KETONE
Separator
Separator
Make up water
Superheater 2
Cooler
Pre-heater
P-78
Absorber
Vaporizer
1
145KPa298 K
1'144KPa
373 K
2142KPa
373 K
3
133KPa
373 K
4
355KPa583 K
5353KPa
773 K
6169KPa
642 K
7163KPa
398 K
10156KPa
335 K
9299 K
13121KPa
300 K
11150KPa
300 K
12101KPa
310 K
14
300 K17
141KPa308
K
18101KPa
303 K
E-34
19
16
15
Superheater 1
Compressor
2-butanol feed
3'131KPa
573 K
13'
8
Figure 3.2 Process flow diagram for production of MEK
3.3 ASSUMPTIONS MADE
1. Material loss between the steam heater and the second super-heater is negligible.2. Only 98% of the MEK and 2-butanol entering the absorption column is absorbed.
3. MEK is 10% of the absorption product.
4. The raffinate from the extraction column contains 99.5% water, 0.5% MEK and no 2-
butanol.
5. The extract contains 20% MEK.
6. No spillage across any unit operation.
7.
Perfect separation in the absorption column8. Perfect separation of TCE in the extraction column
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K
2-Butanol = 0.02x
(kg/hr) (kg/hr)
MEK 1506.33 87.567
MEK
condensable 1205.07 70.054
MEK non-
condensable 301.27 17.514
2 Butanol 172.02 10
2 Butanol
condensable 137.62 8.000
2 Butanol
non-
condensable 34.4 1.999
H2 41.84 2.432 H 2 41.84 2.432
TOTAL 1720.2 100 TOTAL 1720.2 100
TABLE 3.2: MATERIAL BALANCE ACROSS PARTIAL CONDENSER
Absorption Column:
2
MATERIAL BALANCE ACROSS ABSORPTION COLUMN
IN OUT
Components Mass Flow % Components Mass Flow %
Absorptioncolumn
MEK 0.00803 H2O 1.597
MEK
0.17513
H2 0.024324
MEK 0.02(0.17513) Butanol 0.0004
H2=0.024324
MEK 0.1716 +0.00803 0.1796 H2O 1.597 and 2 0.0196
MEK=0.0035
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(kg/hr) (kg/hr)
MEK non-
condensable 301.27 9.599
MEK to
extraction
column 308.95 9.844
MEK
raffinate
stream 13.81 0.440 MEK to drier 6.02 0.192
2 Butanol
non-
condensable 34.4 1.096
2 Butanol to
extraction
column 33.716 1.074
2 Butanol to
drier 0.6881 0.022
H2 41.84 1.333 H 2 to drier 41.84 1.333
H2O raffinate
stream 2747.16 87.532
H2O to
extraction
column 2747.16 87.532
Negligible
losses 0.1059 0.003
TOTAL 3138.48 100 3138.48 100TABLE 3.3: MATERIAL BALANCE ACROSS ABSORPTION COLUMN
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ϑ
R- Recycle from next operation (TCE)
: MEK 0.00803 H2O 1.597
2-butanol= 0.0196x
Extraction column:
Raffinate
B
Q
R TC
MATERIAL BALANCE ACROSS EXTRACTION COLUMN
IN OUT
Components Mass Flow
(kg/hr)
% Components Mass Flow
(kg/hr)
%
MEK 308.95 7.291
MEK to
solvent
recovery 295.135 6.965MEK to
absorption
column 13.81 0.326
2 Butanol 33.716 0.7957
2 Butanol to
solvent
recovery 33.716 0.7957
H2O 2747.16 64.834 H 2O 2747.16 64.834
TCE from
recycle
stream 1147.4 27.079
TCE to
solvent
recovery 1147.4 27.079
Negligible
losses 0.005 0.0001
Extractor MEK 0.1796
H2O 1.597
MEK 0.17157 2-butanol 0.0196 TCE 0.667
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TOTAL 4237.226 100 4237.226 100
TABLE 3.4: MATERIAL BALANCE ACROSS EXTRACTION COLUMN
Solvent Recovery Unit :
2-Butanol = 0.0196x
MATERIAL BALANCE ACROSS SOLVENT RECOVERY UNIT (DISTILLATION
COLUMN 1)
IN OUT
Components Mass Flow
(kg/hr)
% Components Mass Flow
(kg/hr)
%
MEK 295.135 19.992 MEK 295.135 19.992
2 Butanol 33.716 2.284 2 Butanol 33.716 2.284
TCE 1147.4 77.724 TCE 1147.4 77.724
TOTAL 1476.251 100 TOTAL 1476.251 100
TABLE 3.5: MATERIAL BALANCE ACROSS SOLVENT RECOVERY UNIT
(DISTILLATION COLUMN 1)
SolventRecoveryUnit
TCE 0.667
MEK 0.17157
TCE 0.667
MEK 0.17157 2-Butanol 0.0196
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1500kg/hr. (flow rate as given)
Distillation Column:
MATERIAL BALANCE ACROSS DISTILLATION COLUMN
IN OUT
Components Mass Flow
(kg/hr)
% Components Mass Flow
(kg/hr)
%
MEK
condensable 1205.07 72.093
99.9% pure
MEK 1500.2 89.749
MEK from
solvent
recovery unit 295.135 17.656
2 Butanol
condensable 137.62 8.233
2 Butanol
back to
storage tank 171.33 10.249
2 Butanol
from solvent
recovery unit 33.716 2.017
Negligible
losses 0.011 0.00066
TOTAL 1671.541 100 TOTAL 1671.541 100
TABLE 3.6: MATERIAL BALANCE ACROSS DISTILLATION COLUMN
Detailed calculations are shown in Appendix B.
DistillationColumn
MEK (0.17157 +0.70054 )
0.872 2-Butanol 0.0196 +0.08
0.0996 2-Butanol (recycled back to the reactor )
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CHAPTER 4
a. ENERGY BALANCE FOR THE PLANT
4.1 INTRODUCTION
ENERGY BALANCES
As with mass, energy can be considered to be separately conserved in all but nuclear processes.
The conservation of energy, however, differs from that of mass in that energy can be generated
(or consumed) in a chemical process. Material can change form, new molecular species can be
formed by chemical reaction, but the total mass flow into a process unit must be equal to the
flow out at the steady state. The same is not true of energy. The total enthalpy of the outlet
streams will not equal that of the inlet streams if energy is generated or consumed in the
processes; such as that due to heat of reaction.
Energy can exist in several forms: heat, mechanical energy, electrical energy, and are the total
energy that is conserved.
In process design, energy balances are made to determine the energy requirements of the
process: the heating, cooling and power required. In plant operation, an energy balance (energy
audit) on the plant will show the pattern of energy usage, and suggest areas for conservation and
savings.
A general equation can be written for the conservation of energy:
Accumulation Energy In+Generation C This is a statement of the first law of thermodynamics. An energy balance can be written for any
process step. Chemical reaction will evolve energy (exothermic) or consume energy
(endothermic). For steady-state processes the accumulation of both mass and energy will be zero.
The energy balance was carried out around cooler condenser and the second distillation column.
In chemical processes the kinetic and potential energy terms are usually small compared with
heat and work terms, and can normally be neglected.
If the kinetic and potential energy terms are neglected the energy equation reduces to
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H H Q W For many processes the work term will be zero, or negligibly small, and equation above reduces
to the simple heat balance equation:
Q H H Where heat is generated in the system; for example in a chemical reactor:
Q QP + QS QS Heat generated in the system. If heat is evolved (exothermic processes) QS is taken as
positive, and if heat is absorbed (endothermic processes) it is taken as negative.
QP Process heat added to the system to maintain required system temperature.Hence:
QP H H QS H enthalpy of the exit stream
H enthalpy of the outlet stream.For a practical reactor, the heat added (or removed) Qp to maintain the design reactor
temperature will be given by:
QP= H H Q Where
H is the total enthalpy of the product streams, including unreacted materials and by- products, evaluated from a datum temperature of 25°C;H is the is the total enthalpy of the feed streams, including excess reagent and inerts,evaluated from a datum of 25°C;
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Qr is the total heat generated by the reactions taking place, evaluated from the standard heats of
reaction at 25°C (298 K).
This equation can be written in the form:
QP ∑∫ ncdT
∑∫ ncdT
∑[ ∆H° ]×mol of product f
C A+BT+CT +DT 4.2 ENERGY BALANCE ACROSS ALL UNIT OPERATIONS:
ENERGY BALANCE ACROSS COLD FEED PREHEATER
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost by
dry saturated
steam
335400 100 Heat load on
pre heater
335400 100
TOTAL 335400 100 335400 100TABLE 4.1: ENERGY BALANCE ACROSS COLD FEED PREHEATER
ENERGY BALANCE ACROSS VAPORIZER
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost by
reaction
products
958000 100 Heat gained
by 2-butanol
feed liquid
958000 100
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TOTAL 958000 100 958000 100
TABLE 4.2: ENERGY BALANCE ACROSS VAPORIZER
ENERGY BALANCE ACROSS SUPER HEATER 1
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost by
flue gas
538000 100 Heat gained
by 2-butanol
feed vapour
538000 100
TOTAL 538000 100 538000 100
TABLE 4.3: ENERGY BALANCE ACROSS SUPER HEATER 1
ENERGY BALANCE ACROSS COMPRESSORENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost by
compression
168650 100 Heat gained
by 2-butanol
feed vapour
168650 100
TOTAL 168650 100 168650 100
TABLE 4.4: ENERGY BALANCE ACROSS COMPRESSOR
ENERGY BALANCE ACROSS SUPER HEATER 2
Components HEAT LOST Component HEAT
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GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost by
flue gas
704000 100 Heat gained
by 2-butanol
feed vapour
704000 100
TOTAL 704000 100 704000 100
TABLE 4.5: ENERGY BALANCE ACROSS SUPER HEATER 2
ENERGY BALANCE ACROSS REACTORComponents HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost due
to reaction,
Qr
1160000 100 Heat gained
by reactor,
Qp
1160000 100
TOTAL 1160000 1160000 100
TABLE 4.6: ENERGY BALANCE ACROSS REACTOR
ENERGY BALANCE ACROSS CONDENSER
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat lost due 304000 26.32946475 Heat gained 1154600 100
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to reduction
in vapor
temperature,
Q1
by cooling
water
Heat lost due
to
condensation,
Q2
742000 64.26468041
Heat loss due
to further
cooling of
vapor, Q3
108600 9.405854842
TOTAL 1154600 100 1154600 100
TABLE 4.7: ENERGY BALANCE ACROSS CONDENSER
ENERGY BALANCE ACROSS ABSORBER
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat of
condensation
of MEK
137000 52.9120964 Heat gained
by water
242299.512 93.58084041
Heat of
condensation
of alcohol
22300 8.612698903 Heat gained
by MEK
13819.3335 5.337298586
Heat of
solution
120 Heat gained
by alcohol
1944.0519 0.750831106
Heat loss due 99500 38.42885833 negligible 857.1026 0.331029893
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to off gases losses
TOTAL 258920 100 258920 100
TABLE 4.8: ENERGY BALANCE ACROSS ABSORBER
ENERGY BALANCE ACROSS SOLVENT RECOVERY UNIT
Components HEAT LOST Component HEAT
GAINED
ENERGY
FLOW
(kJ/hr)
% ENERGY
FLOW
(kJ/hr)
%
Heat Lost byfeed
75000 15.46391753 Heat gained by
condensate
272000 56.08247423
Heat lost by
utility steam
410000 84.53608247 Heat gained
by distillate
52300 10.78350515
Heat gained
by bottom
product
160350 33.06185567
0 negligible
losses
350 0.072164948
TOTAL 485000 100 485000 100
TABLE 4.9: ENERGY BALANCE ACROSS SOLVENT RECOVERY UNIT
ENERGY BALANCE ACROSS DISTILLATION COLUMN
Components HEAT LOST Component HEAT
GAINED
Heat Lost by
feed
161000 5.768541741 Heat gained
by
condensate
2415000 86.46443179
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Heat lost by
utility steam
2630000 94.23145826 Heat gained
by distillate
340300 12.18378722
Heat gained
by bottom
product
37756 1.351780988
negligible
losses
2056 0.073665353 0
TOTAL 2791000 100 2793056 100
TABLE 4.10: ENERGY BALANCE ACROSS DISTILLATION COLUMN
ENERGY BALANCE ACROSS COOLER SYSTEMHeat lost by
distillate
233100 90.13921114 Heat gained
by cooling
water
258600 100
Heat lost by
bottoms
product
25500 9.860788863
TOTAL 258600 100 258600 100
TABLE 4.11: ENERGY BALANCE ACROSS COOLER SYSTEM
Detailed calculations are shown in Appendix B
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References
1. (2015, November 3). Retrieved from sciencezen: http://www.sciencezen.com/partial-
condensation
2. Alaqua. (2015). Heat Exchanger. (Alaqua Inc) Retrieved November 7, 2015, from AlaquaInc: http://www.alaquainc/heat_exchanger.com
3. Arora, D., & Sharma, M. (November 2015). Methyl Ethyl Ketone: A Techno-
Commercial Profile. Jaypee Institute of Engineering and Technology, Department of
chemical engineering.
4. britannica. (2015, November 5). Retrieved from condenser:
httption://www.britannica.com/condenser
5. catalysis. (2015, November 5). Retrieved from chemwiki:
http://www.chemwiki.ucdavis.edu/complex_reactions/catalysis
6. Davis, A. (2005). Reciprocating compressor basics. In A. Davis, Reciprocating
compressor basics. Noria corporation .
7. Efunda. (2015). Heat transfer:overview. Retrieved November 7, 2015, from Efunda:
http://www.efunda.com/formulae/heat_transfer/home/overview.cfm
8. https://en.wikipedia.org/wiki/2-Butanol. (October 2015). wikipedia/2-Butanol.
(wikipedia, Foundation Inc) Retrieved November 3, 2015, from wikipedia:
https://en.wikipedia.org/wiki/2-butanol
9. https://en.wikipedia.org/wiki/Relative_volatility. (Retrieved October 2015). Relative
Voaltility.
10. Perry, R.H & Green D.W. (2007). Perry chemical engineering handbook. Mc Graw Hill.
11. rhum-agricole. (Retrieved October,2015., October). Distillation.
12. S.L, D. (1978). compressors. In Fluid Mechanics, Thermodynamics of turbomachinery
(third ed). Pergamon Press.
13. Tham, M. T. (2009). Distillation. Distillation Principles.
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14. Treybal, R. .. (1981). Mass transfer operations. In R. .. Treybal, Mass transfer
operations/absorption (pp. 275,281,282). McGraw hill .
15. wikipedia. (2015, november 5). Retrieved from liquid liquid extraction column:
http://en.wikipedia.org
16. wikipedia. (2015, November 3). Retrieved from separators: http://www.wikipedia.org
17. wikipedia. (2015). wikipedia/convection. (wikipedia, foundation inc) Retrieved
November 6, 2015, from wikipedia: https://en.wikipedia.org/wiki/Convection
18. wikipedia. (2015, Novenmber 4th). wikipedia/MEK-molecular-structure. Retrieved from
Wikipedia: www.wikipedia.com
19. wikipedia. (2015). wikipedia/radiation. (wikipedia, foundation) Retrieved November 6,2015, from wikipedia: https://en.wikipedia.org/wiki/Radiation
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YieldsCH 3CH 2CH 3CHOH CH 3CH 2CH 3CO + H 2
X (kg)
XR
2-butanol X F
X (kg)
APPENDICES
A. MATERIAL BALANCE:
The material balance was done around the following units:
Reactor
RMM of 2-butanol =74
Moles of 2-butanol = ( ) 0.01351x Moles of the2-Butanol that reacted 0.90×0.01351x = 0.012162x From the equation:
Mole ratio for the reaction is 1:1
Hence moles of the MEK reacting is 1×(0.012162x) 0.012162x Mass of MEK then is 0.012162 x×72=0.875676 x Mass of 2-butanol is ×x 0.10x Mass of then H 2 is 0.012162 ×2=0.024324 x
Reactor
Reactor
MEK
2-butanol
H2
MEK = 0.87567
2-Butanol= 0.10 H2 =0.024324
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MEK 0.01369 2-Butanol 0.02
(Non-condensable )MEK =
2-Butanol= 012
All the components leaving the reactor are discharged directly into the cooler condenser for the
next operation.
Partial-condenser
Condensate (which is then directly sent to the final purification column) comprises:
80% MEK= 0.8 ×0.875676 x 0.70054x 80% 2-Butanol=0.80 ×0.10x 0.08x
Incondensable stream comprises:
20% MEK= 0.2 ×0.875676x 0.175135x 20% 2-Butanol 0.2×0.10x 0.02x
100% H 2=0.024324x
0.875676x
(Condensate )
MEK 0.70054x 2-butanol 0.08x
Partial-condenser
H2=0.024324 H2=0.024324
MEK =0.175135
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MEK 0.5% 0.005 H2O 99.5% 0.995
K
2-Butanol 0.02
J
MEK 0.98(0.175135) +0.005 0.1
Absorption column :
MEK
75
MEK balance around the absorption column
0.175135x +0.005K 0.02(0.175135X) +0.1J 0.175135x +0.005K 0.003503X +0.1J J 1.716x+0.05K
Overall balance
(0.024324x+0.02x+0.175135x)+K 1.716x+0.05k+(0.024320.003503x)
k 1.605x
Performing a new balance around the absorption column to express the k -value in terms of x inthe above equations gives the following values:
Absorptioncolumn 0.02(0.175135 )
2-Butanol 0.02(0.02 ) H2=0.024324
(Non-condensable )
MEK 0.175135
H2=0.024324
2-Butanol 0.98(0.02 ) H2O=?
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K
2-Butanol = 0.02x 2
Raffinate: MEK 0.005K 0.005(1.605x) 0.00803x H2O 0.995K 0.995(1.605x) 1.597x
Stream J: MEK 0.1J 0.1{1.716x+0.05(1.605x)} 0.1796x H2O 1.597x
2-butanol
0.0196x
Absorptioncolumn
MEK 0.00803 H2O 1.597
MEK 0.17513
H2 0.024324
MEK 0.02(0.17513) Butanol 0.0004 H2=0.024324
MEK 0.1716 +0.00803 0.1796
H2O 1.597 and 2 0.0196
MEK=0.0035
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ϑ
R- Recycle from next operation (TCE)
: MEK 0.00803 H2O 1.597
2-butanol= 0.0196x
Extraction column
Raffinate
B
Q
R TC
MEK Balance around the extractor
0.1796x 0.00803x+0.2 ϑ 0.858x
Overall balance
+ + 1.7962x+ 1.605x+0.858x
0.667x TCE 0.858x(0.17157x +0.0196x)
0.667x (Which is approximately = )
Extractor MEK 0.1796
H2O 1.597 MEK 0.17157
2-butanol 0.0196 TCE 0.667
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1500kg/hr (flow rate