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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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    63

    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