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Huntsman Design Challenge

NPS14
by

Pedro Martín

on 3 November 2014

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Transcript of Huntsman Design Challenge

FEED

MDI: 25 wt%
MCB: 71 wt%
Phosgene: 3.5 wt%
HCl: 0.5 wt%
Introduction
Separation strategy
PFD
Operating Cost Analysis
Sustainability
Conclusions
Huntsman Design Challenge
NPS 2014
Pedro Martin-Salvador
Chaitanya Mogre
4-11-2014
Table of contents
Introduction
Operating cost analysis
Sustainability
HCl, COCl , MCB, N
Conclusions
Separation strategy
HCl
COCl
MCB
MDI
HCl
COCl
MCB
MDI
MCB
MDI
2
2
Boiling point difference
Corrosivity
Stripping section
Minimum operating costs
Minimum MCB losses
Gas/liquid distribution
N
Feed
MCB
MDI
HCl
COCl
N
2
2
2
Distillation & Crystallization
Feed 27% MDI
Hybrid system: Distillation
Hybrid: Crystallization
Continuous scrapped wall
Distillation
+300 C @1bar
200 C @ 0.01bar
Crystallization
-3 C @ 27% MDI
0
0
0
MDI decomposition
Heating medium
Energy intensive
MCB purity
Energy intensive
Hybrid system
Reboiler T
pictures taken from: Kiss et al., Towards energy efficient distillation technologies, Energy 47 (2012) 531-542
Mechanical Vapor Recompression (MVR)

No cooling water & steam needed

Instead,

Electricity for compression
Wash Columns
Variable cost break up
5.7 M€/yr
Installed cost break up
7.04 M€
Sensitivity Analysis

Cooling water , 25 C

Refrigeration Cycle

25 C
20 C
15 C
10 C
0
0
0
0
0
2
3
4
5
6
8
7
9
10
E-factor: 0,11
Electricity 0,5 t/h
Steam 0,4 t/h
CO emissions***
2
***assuming natural gas as fuel source
2
UTILITIES
WASTE STREAM
Composition:
E-factor*: 0,36
CO emission**: 0.5 t/h
2
* includes off-gas scrubbing system and 95% N2 & MCB recovery
Off-gas TREATMENT
2
Environmental
Economical
** from MCB incineration
Energy recoverable**: 1,5 MW
Electricity: future trends
EU agreement OCT-2014
7.6% electricity price
Data from: Union of Concerned Scientists.
2009. Clean power green jobs.
Fixed Costs: 7M€ Operating costs: 5.7 M€/yr

Atmospheric pressure process

Easy to accommodate MVR in existing columns

MDI decomposition is avoided

Electricity price Profitability

Advances in modular electric technology (acoustic heat pumps)

12
11
Picture from: Armstrong Chemtech group - http://www.rmarmstrong.com/
Introduction
Separation Strategy PFD Operating Cost Analysis Sustainability Conclusions


Introduction
Separation Strategy
PFD Operating Cost Analysis Sustainability Conclusions


Introduction
Separation Strategy
PFD Operating Cost Analysis Sustainability Conclusions


Introduction
Separation Strategy
PFD Operating Cost Analysis Sustainability Conclusions


Introduction
Separation Strategy
PFD Operating Cost Analysis Sustainability Conclusions


Introduction
Separation Strategy
PFD Operating Cost Analysis Sustainability Conclusions


Introduction Separation Strategy
PFD
Operating Cost Analysis Sustainability Conclusions


Introduction Separation Strategy PFD
Operating Cost Analysis
Sustainability Conclusions


Introduction Separation Strategy PFD Operating Cost Analysis
Sustainability
Conclusions


Introduction Separation Strategy PFD Operating Cost Analysis Sustainability
Conclusions



Picture from: Oord- Knol et al., Dynamic behavior of hydraulic wash columns, AIChE Journal, Vol. 48, No. 8, 2002
HCl, Phosgene: SS 316
MCB: Carbon steel
MDI: SS 304
Materials
Energy efficient
Modern technology
Well established

Safe
Minimum waste
Economical
Distillation vs Stripping
(Simple) distillations
MDI
< 10 ppm MCB
< 1 ppm phosgene
MCB
90% + recovery
< 10 ppm MDI
< 10 ppm phosgene
N
Feed
MCB
MDI
HCl
COCl
N
2
2
2
Feed
MCB
MDI
HCl
COCl
5% MCB
2
steam
water
Other heat pump technologies
Installed equipment cost
Refrigeration cycle
Refrigeration cycle
Without:
With:
Total: 652€/hr
HCl, PHOS

MCB
MDI
High/Low pressure
Low/High pressure
1 bar
vacuum
conventional
MVR
Renewable energy usage [%]
C
o
Full transcript