Chemical ProcessTechnology andSimulation

Srikumar Koyikkal

Chemical Process Technologyand Simulation

SRIKUMAR KOYIKKALProcess Design Consultant

Delhi-1100922013

CHEMICAL PROCESS TECHNOLOGY AND SIMULATIONSrikumar Koyikkal

© 2013 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher.

ISBN-978-81-203-4709-0

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111, Patparganj Industrial Estate, Delhi-110092 and Printed by Mohan Makhijani at Rekha Printers Private Limited, New Delhi-110020.

CONTENTS

iii

Preface ix

Chapter 1 INTRODUCTION 1–14 1.1 Technologies and Design 1 1.1.1 Development of New Technologies 2 1.2 Planning and Preparation 3 1.2.1 Approaches to Planning 3 1.2.2 Time Schedule Charts 4 1.2.3 Planning Software 5 1.2.4 Document Production Sequence 5 1.2.5 Environmental Planning and Statutes 6 1.3 Simulation and Design Tools 7 1.3.1 Conventional Methods 7 1.3.2 Process Simulation Software 8 1.3.3 Other Related Software (Multidisciplinary) 13 Review Questions 14

Chapter 2 NATURAL AND BIOPROCESS CHEMICALS 15–75 2.1 Cardanol from Cashew Nut Shell Liquid 15 2.2 Fermentation Products (Alcohol, Food and

Pharmaceuticals) 19 2.2.1 Alcohol from Molasses 19 2.2.2 Bakers’ Yeast 22 2.2.3 Citric Acid 23 2.2.4 Lactic Acid 25 2.2.5 Fructose (as High Fructose Corn Syrup) 26 2.2.6 Penicillin 27 2.2.7 Streptomycin 28 2.2.8 Ampicillin 29 2.2.9 L-ascorbic Acid (Vitamin C) 29

iv Contents

2.2.10 Vitamin B2 (Riboflavin C17H20N4O6) 30 2.2.11 Industrial Alcohol (Rectified Spirit) 30 2.3 Absolute Alcohol with Case Studies 33 2.3.1 Molecular Sieve Method 34 2.3.2 Azeotropic Distillation Method 36 2.4 Products from Sea—Agar and Agarose 39 2.4.1 Agar 39 2.4.2 Agarose 45 2.5 Coal and Coal Chemicals 47 2.5.1 Coal Gasification 48 2.5.2 IGCC (Integrated Gasification Combined Cycle) Plant 50 2.6 Sugar and Starch 51 2.6.1 Sugar 51 2.6.2 Starch 53 2.7 Pulp and Paper 54 2.7.1 Pulp 54 2.7.2 Paper 57 2.8 Soaps and Detergents 58 2.8.1 Soaps 58 2.8.2 Detergents 60 2.9 Rubber and Leather 61 2.9.1 Rubber 61 2.9.2 Leather 67 2.10 Oils and Their Hydrogenation 69 2.10.1 Vegetable Oils 69 2.10.2 Hydrogenation of Vegetable Oils 71 2.11 Biodiesel from Jatropha Seed Oil 72 2.11.1 Batch Process of Producing Biodiesel 73 2.11.2 Continuous Process Technologies 73 Review Questions 75

Chapter 3 ORGANIC CHEMICALS 76–129 3.1 Methanol, Phenol and Acetone 76 3.1.1 Methanol 76 3.1.2 Methanol Plant—A Case Study 84 3.1.3 Phenol and Acetone Coproduction 89 3.1.4 Solvent (Acetone) Recovery 92 3.2 LPG and Propylene from Cracked LPG 97 3.2.1 Liquified Petroleum Gas 97 3.2.2 LPG Production from Gas Processing Units 97 3.2.3 LPG Production from Refinery Gases 100 3.2.4 Propylene from Cracked LPG—A Case Study 101 3.3 Man-Made Fibres 105 3.3.1 Viscose Rayon 105 3.3.2 Nylons 107 3.3.3 Polyester 111 3.3.4 Acrylonitrile 112

Contents v

3.4 Petrochemicals 114 3.4.1 Steam Cracking Products 114 3.4.2 Vinyl Chloride and Vinyl Acetate 116 3.4.3 Phthalic Anhydride 119 3.5 Polymerization Products 120 3.5.1 HDPE, LDPE and LLDPE 121 3.5.2 Poly Vinyl Chloride and Poly Vinyl Acetate 124 3.5.3 Oxo-biodegradable Polyethylene 125 3.6 Pesticides 126 3.6.1 DDT and Dicofol 126 3.6.2 Malathion and Parathion 127 Review Questions 129

Chapter 4 INORGANIC CHEMICALS 130–201 4.1 Precipitated Calcium Carbonate 130 4.1.1 Process Description 131 4.1.2 Case Study — A Small Capacity Plant 133 4.2 Phosphorus 135 4.2.1 Electrochemical Process of Manufacture 135 4.3 Phosphoric Acid 136 4.3.1 Description of the Dihydrate Process 138 4.3.2 Simulation of the Phosphoric Acid Process 139 4.4 Hydrogen 141 4.4.1 Process Description 142 4.5 Ammonia 150 4.5.1 Process Description 150 4.5.2 Ammonia Plant—A Case Study 153 4.6 Soda Ash 154 4.6.1 Solvay Process 155 4.7 Glass 156 4.7.1 Glass-making Furnaces 157 4.7.2 Glass Blowing and Automation 157 4.7.3 Glass Rolling (for Plate and Float Glasses) 158 4.7.4 Annealing and Finishing 158 4.7.5 Other Types of Glasses 158 4.8 Caustic-Chlorine Products and Metals 159 4.8.1 Caustic Soda and Chlorine 159 4.8.2 Hydrogen Chloride and Hydrochloric Acid 162 4.8.3 Metals 162 4.9 Sulphur 172 4.9.1 Sulphur Production from Mines by Frasch Process 172 4.9.2 Sulphur Production from Hydrogen Sulphide by Modified Claus Process 173 4.10 Sulphuric Acid 174 4.10.1 DCDA Process 174 4.11 Nitric Acid 177 4.11.1 Process Description of Single Pressure Process 177 4.11.2 Dual Pressure Process 179

vi Contents

4.11.3 Concentration of Nitric Acid 179 4.11.4 Design and Simulation 179 4.12 Urea 180 4.12.1 Process Description 181 4.13 Hydrazine 181 4.13.1 Olin Raschig Process 182 4.14 Complex Fertilizer 182 4.14.1 NPK by Pipe Reactor Process 183 4.15 Cement 184 4.15.1 Designation of Components 185 4.15.2 Compounds in Cement 186 4.15.3 Beneficiation of Limestone 186 4.16 Lime 188 4.16.1 Process and Plant Description 189 4.17 Paints 190 4.17.1 Manufacture of Titanium Dioxide from Ilmenite 190 4.18 Varnishes 192 4.19 Water 193 4.19.1 Water for Municipal and Industrial Use 193 4.19.2 Potable Water from Sea Water 195 4.20 Uranium and Heavy Water 197 4.20.1 Uranium 198 4.20.2 Heavy Water 199 Review Questions 201

Chapter 5 REFINERY OPERATIONS 202–229 5.1 Crude Distillation 202 5.1.1 Atmospheric Distillation Column 203 5.1.2 Vacuum Distillation Column 209 5.2 Coking 211 5.2.1 Delayed Coking 211 5.3 Other Types of Coking 221 5.3.1 Fluid Coking 221 5.3.2 Flexi Coking 222 5.3.3 Contact Coking 222 5.3.4 Comparison of Methods of Coking 222 5.4 Catalytic Cracking 223 5.4.1 Fluid Catalytic Cracking Unit 223 5.4.2 Hydrocracking 226 5.4.3 Catalytic Reforming 227 Review Questions 229

Chapter 6 OIL AND GAS (UPSTREAM) 230–261 6.1 Phase Separation 230 6.1.1 Four Types of Reservoirs 230 6.1.2 Two-Phase Separators 231 6.1.3 Three-Phase Separators 232

Contents vii

6.1.4 Development of Separator Sizing 235 6.1.5 Free Water Knockouts 238 6.1.6 Three-Phase Separator—A Case Study 239 6.2 Natural Gas Transportation Network 248 6.2.1 Operation of Gas Pipelines 249 6.2.2 Methodology for Hydraulic Simulation 254 6.2.3 Pipeline Network—A Case Study 256 6.2.4 Shipping of Natural Gas 261 Review Questions 261

Chapter 7 NANOTECHNOLOGIES 262–277 7.1 Polysilicon 262 7.2 Polysilicon by Trichlorosilane Route 263 7.2.1 Production of MG-Si 263 7.2.2 Production of Polysilicon from MG-Si 263 7.3 Alternative Routes 267 7.3.1 Polysilicon from Magnesium Silicide 267 7.3.2 Silicon Production from Hydrosilisic Acid Produced from Superphosphate Plant 268 7.4 Pilot Plant and Mini Plants 269 7.4.1 Pilot Plant 269 7.4.2 Mini Plants 271 7.5 Semiconductors and Solar Panels 271 7.5.1 Semiconductors 271 7.5.2 Solar Panels 276 Review Questions 277

Chapter 8 MODELLING AND SIMULATION 278–298 8.1 Reformer Modelling 278 8.1.1 Equations for Model 278 8.1.2 Development of Model 284 8.2 Dynamic Modelling 292 Review Questions 298

Chapter 9 USER-WRITTEN PROGRAM EXAMPLE 299–316 9.1 Introduction 299 9.2 Terrace-Walled Reformer Simulation Program 299 Review Questions 316

Chapter 10 COST ESTIMATION EXAMPLES 317–329 10.1 Introduction 317 10.2 Cardanol Distillation Unit 318 10.2.1 Reactor (Distillation Vessel) 318 10.2.2 Condenser 320 10.2.3 Cooler 321 10.2.4 Receiving Vessels 321

viii Contents

10.3 Industrial Alcohol Distillation Unit 323 10.3.1 Wash Column (Main material of construction—deoxidized copper) 323 10.3.2 Rectifying Column 324 10.3.3 Wash Preheater 326 10.3.4 Final Condenser 326 10.3.5 Vent Condensers 327 10.3.6 Product Cooler 328 10.3.7 Reflux Tank 328 10.3.8 Rectified Spirit Plant (Plant and Machinery)—Cost Summary 328

Appendix 331

References 333–336

Index 337–345

This book is written to build an understanding of chemical technology processes, as used in the modern chemical industries, classified in the book as natural and bioprocess products, organic chemicals, inorganic chemicals, petrochemicals, polymers, metals, refinery operations, oil and gas operations, and nanotechnology products. A technology is a result of a good and feasible design. In this book, I have, therefore, related technologies to design and cost aspects as well. This approach makes us go much deeper and helps us in understanding the logic behind various operating techniques and parameters that we otherwise take for granted. The book has been developed primarily to fulfil the curriculum needs of the courses on Chemical Technology, prescribed for the undergraduate students of chemical engineering. Chemical products have been grouped and subgrouped in this book as per the groupings followed in industry. A common structure is followed for each topic. However, some examples of computer process simulations, case studies, mechanical designs, costing procedures and safety aspects (only one or two of a type) have been added to make the book more useful and informative. I have been environmentally conscious, too. The book includes the technologies of hydrogen and methanol, which are the clean fuels of the future. The book also includes biodiesel which is a carbon neutral fuel, solar panels as a supplier of clean energy, and biodegradable polymers. It is to be noted that the subject ‘Chemical Technology’ is well integrated nowadays with the subject of ‘Process Simulation Software’, and hence the latter also finds a place in this book. The discussion on simulation consists of two parts, with practical examples.

1. Overall process flow simulations using the commercial computer software. 2. Complex or ‘out of the ordinary’ equipment simulations using equipment modelling.

Pilot plants and miniplants have also been discussed. Chemical engineers have to translate new ideas into new plants. An ability to make a quick cost estimate of the process plant will be very beneficial for this purpose and hence the book has included two mechanical design and cost estimation examples as well. The intention in this book is only to show the method of cost estimation.

PREFACE

ix

Chemical Process Technology AndSimulation

Publisher : PHI Learning ISBN : 9788120347090 Author : KOYIKKAL,SRIKUMAR

Type the URL : http://www.kopykitab.com/product/7551

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