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Copy of ACETALDEHYDE PRODUCTION PLANT DESIGN

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Makle Çiçek

on 23 April 2014

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Transcript of Copy of ACETALDEHYDE PRODUCTION PLANT DESIGN

Methodology
Results & Discussion
Introduction
Conclusion & Recommendations
ACETALDEHYDE PRODUCTION PLANT DESIGN
Reference List
References
Raw Material Source
Domestic Source
Capacity Selection
-Acetaldehyde demand in Turkey

-For making reasonable assumptions;

Countries such as India and China which are the major acetaldehyde producers in the world

Companies such as SEKAB, Naran Lala, Celanese and Jıangsu Kaımao Chemical Technology Co. Ltd.

-Between 30000-60000 tones/year


Marketing Area
Plant should be located close to the primary
market where acetaldehyde used as a raw material of other chemicals such as acetic acid

In an international market;

An area with preferential tariff


Transport Facilities
More than one transport option;

-Road
-Rail
-Waterway (canal or river)
-Seaport
-Airport (during start-up stage and
when the factory is running)

Lower transportation cost

Less delivery time

Availability of Labor
Availability of Utilities
Electrical power

Water supply

Plant should be located in the sea-side or close to the water resources

Availability of Suitable Land
The characteristics of soil;

Well drained

Suitable for load-bearing
be flat for future expansion of factory

Land should be far away from the
earthquake zone

Site Selection
Raw Materials
Availability and price of raw material

Plant should be located close to the source of
the raw material

-Ethylene
-Ethanol
-Acetylene
-Hydrocarbon

Environmental Impact & Effluent Disposal
Additional waste treatment facilities

Cost of disposal

The disposal of toxic and harmful effluents should be covered by local regulations

Local Community Considerations
New plant should provide adequate facilities for the plant personnel;

Schools
Banks
Housing
Cultural facilities
Safe location of the plant ( should not create risk for local community)

Political & Strategic Considerations
Political risks and governmental regulations

Inducements such as capital grants, tax concessions to the new investment areas.



Production from Ethyl Alcohol
Production from Acetylene
Production from Ethylene
Production from Carbon Source
Process Selection

Production from Ethyl Alcohol
Production of Acetylene
Production from Ethylene
Production from Carbon Source

Middle East Technical University
Northern Cyprus Campus
INTERIM REPORT I PRESENTATION

Group B

Gizem KARAGENÇ - 1663616
Gamze AKSOY - 1663418
Begüm Gökçe SAĞMANER - 1730258
Kaan ŞEN - 1730332
General Information of Acetaldehyde
Market Survey of
Acetaldehyde
Thank you for listening !

Unit 200
T-201
T- 203
T -202
T-204
Material Balance
Overall Yield of Process
Overall Process
Unit 100
R - 100
V-101
T -101
Material Balance
General Material Balance Eqn :
Material Balance are performed around major equipments of the process.
Material balance is examined into two parts:
Unit 100
Unit 200
Assumption:

V/F = 0.4
Assumption :
All
hydrogen
is recovered from top and
it's purity
is 95 mole% in there.
Pure water
is fed to column and
it's purity
is 98 mole% in the bottom product
Material balance is examined into two parts:
Unit 100
Unit 200
Overall Yield:

Assumptions:
Recovery
is 99 mole%
The aim is to separate
acetaldehyde and ethyl acetate
Purity of acetaldehyde
is 90 mole% in distillate
Assumptions:
Recovery
is 99 mole%
The aim is to obtain pure
acetaldehyde
as much as possible
Purity of acetaldehyde
is 99 mole% in distillate
Assumptions:
Recovery
is 99 mole% ethanol
The aim is to separate ethanol and recover the system
Purity of water
is 95 - 99 mole% in distillate (waste)
Assumptions:
Recovery
is 95 mole% ethanol due to azeotrope between ethanol & water.
The aim is to separate ethanol and recover the system
Purity of ethanol
is 85 wt.% in distillate (recovery)
Unit 100
Energy Balance
General Energy Balance Eqn. :
How the energy is calculated:
International Source
Skilled construction labors

Unskilled labor
Energy Balance Results
Energy Balance Results
Energy Balance Results
Results
Table 1.
Gross Margin Results for producing 1 kg acetaldehyde

Process Selection Result
Material Energy Balance Result
Table 2.
Material Balance Results

Figure 1.
Major equipment heat duties distribution for whole process

Table 5.
Heat Exchange Unit's Properties

Energy Balance Results
Table 6.
Heat Exchange Unit's Properties

Process Selection
Availability of raw material for each process

Safety & transportation

Gross margin calculations


Production from Ethylene
Production from Ethanol
Comparison between ethylene and ethanol processes
Gross margin of ethanol > gross margin of ethylene

In ethanol process, hydrogen is taken out as side-product which
can be used in other places such as generating heat

More conversion can be obtained in ethanol than ethylene
process

Ethylene in bulk quantities = petrochemical production
Ethanol in bulk quantities = petrochemical & biochemical production

Transportation of ethanol is easier than ethylene


Site Selection
Three cities were compared in terms of;

Transportation
Land prices
Government fundings
Utilities
Labor force


Discussion
Production from Acetylene
strongly exothermic, creates serious problems
in carrying out the reaction on a commercial scale.

some process difficulties may occur such as
loss of catalyst, selectivity and polymerization or oil formation.


Capacity Selection
Acetaldehyde markets of China, India and Usa were compared

Average capacity range is obtained from big companies in this area

Decision made based on the industry profile in Turkey and closest countries


Material & Energy Balances
Recovery & purity values were assumed in distillation column according to the literature

In energy balance, pressure range is set and pressure is distributed over the process

Cp values were calculated by interpolating known values


Production from Carbon Source
High fixed capital investments requirements

Risk of burning raw material during
combustion reaction

-Low gross margin

-Harsh safety & transportation conditions;

volatilizes rapidly and flaring problems

extra transportation costs due to high
pressure or very low temperature conditions

Oxidation
oxygen is an expensive chemical.

Dehydrogenation
Gross margin
Side-products
Supply of raw material
Safety, storage & transportation

Istanbul
Adana
Izmir
Earthquake zone
High land prices

Not in the first incentive areas that is determined by government

Government provides funding for the export and
import opportunities
Closeness to water resources and other utilities
Easy transportation of the raw material and other industrial equipment strong labor force

Conclusion
Dehydrogenation of ethanol as a process

Izmir Aliağa as site location

40000 tons/year as a capacity

138 tons/day ethanol supply

Overall yield value of 0.92

333 MJ/hr energy release from reactor as a major unit

Recommendation
By making use of the some simulation
programs such as ASPEN and ChemCAD, temperature values would be assumed more accurately

More accurate data would be obtained
by paid sources which are not provided for free use.

One Stage Method
Two Stage Method
Rhodium-catalyzed process is converting synthesis
gas into acetaldehyde in a single step.




Gasification
Direct combustion

PROJECT QUESTION
Acetaldehyde Production Plant
Feasibility
Market survey
Competition
Production Method
Plant Location and Layout
Technology And Pattent Issues

GANNT CHART
Unit 200
Material Balance are performed around major equipments of the process.
Material balance is examined into two parts:
Unit 100
Unit 200
Unit 100
Unit 200
Full transcript