Production of 21,000 ethylene oxide

8/17/2019 Production of 21,000 ethylene oxide

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CONTENT

1•

Comparison between Simulation and Manual (Mass Energy Balance)

2 • Chapter 3 !eat "ntegration & #tilities

3 • Chapter $ %rocess Euipment Si'ing & %iping

$ • Chapter %rocess Control & Saety Studies

• Conclusion


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COMPUTER SIMULATION(MASS & ENERGY BALANCE


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MASS BALANCECOMPARISON

Str!"

M!#$!%('r)

A*+#('r) Err-r

1 23$*+,2 23$*3,+3 -*,*23..

2 23$*+,2 23$*3,+3 -*,*23..3 23$*+,2 23$*3,+3 -*,*23..$ 1/.0.,1 1/.0,+$ -*,*1$3. $1,*1 3/,++2 -*,*$0 $1,*1 3/,++2 -*,*$/ $1,*1 3/,++2 -*,*$. $1,*1 3/,++2 -*,*$+ 3**$,.1 3*12,+/. *,2/1121

1* 3**$,.1 3*12,+/. *,2/112111 3**$,.1 3*12,+/. *,2/112112 +3.2,.1 +.**,++ $,200$3313 +3.2,.1 +.**,++ $,200$331$ +3.0,**. +.**,/+2 $,2321$+1 +3.0,**. +.**,/+2 $,2321$+10 $0013,10 $0013,10 1,0E-1$1/ $0013,10 $002,20 *,*.3.211. **0,20/ $+/0,/03 -*,+2.

1+ *++2,+ 1$/0,2+ *,+3+*02* *++2,+ 1$/0,2+ *,+3+*0

Str!"

M!#$!%('r)

A*+#('r)

21 *++2,+* 1$/0,2+

22 *++2,+* 1$/0,2+23 32*0,+$ 32.2,$+2$ $//.2,.0 $.1+3,/$2 $//.2,.0 $.1+3,/$20 32*0,+$ 32.2,$+2/ 32*0,+$ 32.2,$+2. 2/**,110 2/*2,32+ *0,.2/ *.,$

3* *.2,10 *.0131 *.2,10 *.0132 *.2,10 *.0133 1*0.,2+/ 1*/,33$ $/+1,.. 23*,/03 $/+1,.. 23*,/030 $/+1,.. 23*,/03/ 2** 2**3. $/..,2/ $.2$,2$

3+ *2*3,30 *2*3,30$* 1*11,1/ 1*0$,2+

2 er age 1 3 er r or


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ENERGYBALANCE

COMPARISON

E.$/+"#tM!#$!%(r)

A*+#(r)

C-1 33*/0,10 30+33.1E-1 2*22/20,+ 23.2+141 2$$12,3/ 2.2/33,1C-2 /+13+.,/ +$21$1,$E-2 /+3*1,* /332+3

C-3 0++3*1,0 .*3/+E-3 11*.+.,11 13$/*21C-$ 21$+0,$2 00/.1M-1 *,** *E-$ 1**2*$1,*/ 111*+1*5-1 -$/.0/+23,33 -0,3E6*/ 2E- /12.*2,12 .3022+,0 1 7-1 2./2.**,** 30*****E-0 2+*3*0+,$/ 32.*3*$

%-2 //**,.. .23. 7-2 $*3++/**,** $.32***%-$ *.,.1 3$,. 7-3 /*0$23,** .+**** 2E-/ 1/$/2,1* 2*03.+,2 1 7-$ 0$.,** .**%-0 32+1,+* 30/$ 7- 323/$,.$ 3+/3 1

C- 21223,12 2$+0.,3.E-. 12/*+*,++ .*330 1

2 er age 1$3 er r or


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ASSUMPTIONS

T +%!#t /* -# t !*/* - 21,000 "tr/3 t-#* +r !r -+r!t

-$r* +r !r6

T/* +r-3** 7-* #-t 3-#*/7r t t/r7 r!3t/-#, !* /t /* *$ 8/#% 3%-r/7 (3!# /'#-r7 /# "!** !%!#3 !* t !"++")6

A%% t 3-"+-##t* /# t **t" !8 /# /7!% 3-#7/t/-

N- %-*** /# +/+* !#7 8**%* /# t **t"6

I#+$t 9 O$t+$t -r 3-"+r**-r, +$"+, "/:r !#7 !t :3!#'


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Chapter 3

Heat Integration & Utilities


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PINCH ANALYSISE.$/+"#t T"+r!t$r

- *-$r3(;C)

T"+r!t$r- t!r't (;C)

H!tD$t(12=T"/# 9 >56?4

> >


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E>?

E>@

E>4

E>2

E>1

E>

E>

E>5

INTEGRATION

OF THE HEAT

EXCHANGER

NET


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PROCESS FLO< DIAGRAM


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E-2E-E-3E-.E-/E-0E-$E-2E-$E-


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COMPARISON OF UTILITIES NEEDEDBEFORE & AFTER THE INTEGRATION

PROCESS

Ut/%/t

B-r

/#t'r!t/

-# (@ 100

2?2?

9

@4

@

Ut/%/t/* C-*t/#' -r %3tr/3/t

%ea< hours 5M*, 33/9= pea< 5M *,2*2

Electricity (pea< hours) *.** > 2

hr?yr)

Electricity (o= pea< hours) 22** >

hr?yr)

E#r'3-#*$"+t/-#

<

@hole plant 3021,01

“Tarif, E1 – Medium Voltage General InTNB (2014!


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Chapter 4

Process Equipment Sizing


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E.$/+"#t S+3/J3!t/-# St

"dentiAcation %ac


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**% S+3/J3!t/-#

Fessel weight (


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C-%$"# T>2 T>?

C-%$"# T>2


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7emperature• eed temperature at

saturated liuidcondition(GC)

• ;ew point (GC)• Bubble point (GC)

2*010+21*

1211*

1+/,

Column• M!tr/!% -

3-#*tr$3t/-#

• C-%$"# 7/!"tr, D3 (")

• Column cross-sectionalareaD c (m

2)

• C-%$"# /'t, t

(")

St!/#%**

St%

16

2,*1*..@6@1

St!/#%**

St%

160

*,/.@60

7rays• 7ray spacing (m)• Minimum number o

trays

• EIciency ()• A3t$!% #$"r -

tr!*• eed-plate location

(trays rom top)• 7ype

*,0***$,+J

3/,..0

2,3+*

Siee

*,0***,0J0

$$,./0$

12+,/0$3

Siee

5eKu• Minimum reKu ratio• ctual reKu ratio

0,02/2+,+$*/

*,2223*,333$

%roisional %late ;esign

• %late thic


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E.$/+"#t F$#3t/-#Storage 7an< o EthyleneD O-1 7o store the raw materialD Ethylene

Storage 7an< o @aterD O-2 7o store @ater used to absorb Ethylen

Ethylene 9ide absorber

Storage 7an< o %otassium Carbonate

solutionD O-0

7o store the %otassium Carbonate so

to absorb Carbon ;ioide in Carbo

absorber

Storage 7an< o Ethylene 9ideD O- 7o store the productD Ethylene 9ide

Storage 7an2 > >


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STORAGETANS

T!# >2 > >

Component to bestored

@ater2* %otassium

Carbonatesolution

Ethyle9ide

%ressure (bar) 1 1 3,umber o tan


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A*-rr* !#7 Str/++r

E.$/+"#t F$#3t/-#

Ethylene 9ide bsorber (7-1) 7o separate Ethylene 9ide rom other

componentsCarbon ;ioide bsorber (7-$) 7o separate Carbon ;ioide rom other

componentsCarbon ;ioide Stripper (7-) 7o separate Carbon ;ioide rom %otassiu

Carbonate

T>1 T>4 T> C-%$"# T>


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C-%$"# Et%#

O:/7

A*-rr

C!r-#

D/-:/7

A*-rr

C!r-#

D/-:/7

Str/++r@eir ;esign• @eir lengthD lw (m)

• @eir heightD hw (m)

• @eir liuid Cresti, MaimumD h

ow

(mm liuid) ii, MinimumD how

(mm liuid)

1*,/1$3*,***

03,$./

*,**$

12,2.*/*,***

01,*2+*

$.,113/

1*,/1$3*,***

2,3/+*

$1,2.$2

C-%$"#• M!tr/!% -

3-#*tr$3t/-#• C-%$"# 7/!"tr,

D3 (")

• Column cross-

sectional areaD c (m2)• C-%$"# /'t, t

(")

St!/#%**

St%065

*,$.260

St!/#%**

St%06

*,32.31260@

St!/#%**

St%160

*,+*$246@5

7rays• 7ray spacing (m)• EIciency ()• A3t$!% #$"r -

tr!*• T+

*,0*+*

S/8

*,0*/,+0

14S/8

*,20*

S/8

%roisional %late ;esign• %late thic


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!eat Echangers

T+ - E:3!#'r* S%% !#7 T$

H!t E:3!#'r

2 S%% P!**,

T$ P!**

S%% !#7 T$

H!t E:3!#'r

2 S%% P!**,

T$ P!**

S%% !#7 T$

H!t E:3!#'r

1 S%% P!**,

2 T$ P!**

S%% !#7 T

H!t

E:3!#'

1 S%% P!*

2 T$ P!"tem o, E-1 E-2 E- E-0

unction Cooling Cooling Cooling Cooling

M!tr/!% O

C-#*tr$3t/-#

C!r-# St% C!r-# St% C!r-# St% C!r-# St

C--%!#t F%$/7 C-%7


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T+ - E:3!#'r* S%% !#7 T$

H!t

E:3!#'r

1 S%% P!**,

4 T$ P!**

S%% !#7 T$

H!t

E:3!#'r

1 S%% P!**,

2 T$ P!**

S%% !#

T$ H!

E:3!#'

1 S%% P!

2 T$ P!

"tem o, E-3 E-$ E-.

unction !eating !eating !eating

M!tr/!% O

C-#*tr$3t/-#

St!/#%** St% C!r-# St% C!r-# St

H!t/#' F%$/7 H-t

7emperature 9utlet (C) 3 23* /*

N-6 - T$ 115 1? 4?@

Ar! ("2) 156 ?4 @

7ype o essel support Saddle Saddle Saddle

E*t/"!t7 C-*t (RM) ?56 4 5

d


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Compressors?Epander

I7#t/J3!t/-# C-"+r**-r C-"+r**-r C-"+r**-r E:+!#7r C-"+r"tem o C-1 C-2 C-3 C-$ C-unction Compress

pressureCompresspressure

Compresspressure

Epand pressure Comprpressu

T+ C#tr/$'!% C#tr/$'!% C#tr/$'!% C#tr/$'!% C#tr/M!tr/!% -C-#*tr$3t/-#

C!r-# St% C!r-# St% C!r-# St% C!r-# St% C!r-# S

lowrate (


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M/:r (M>1)

unction 7o ensured the ethylene streamD a

stream and recycle stream be in ostream beore entering the reacto1)

D*/'# H-r/Q-#t!% 3%/#7r/3!% 8**%

M!tr/!% - 3-#*tr$3t/-# St!/#%** *t%

7ype o essel support Saddle

O+r!t/#' 3-#7/t/-#*

9peratingtemperature () 1$ 9perating pressure(bar) 21

Molar Kowrate(1)


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MEMB5E SE%5795 (4-1)

F$#3t/-# 7o separate oygen and nitrogen g

T+ - ""r!# D/"t%*/%/3-# r$r

T+ - ""r!# *+!r!t-r H-%%- ""r!#T+ - *%% C!r-# *t%

M"r!# *$r!3 !r!, () ?

N$"r - "-7$%* 154

T+ - 8**% *$++-rt Saddle

O+r!t/#' 3-#7/t/-#*

9perating

temperature ()

.* 9perating %ressure

(bar)"nlet

9utlet

32

!ollow membrane;iameter (m):ength (m)

*,*12,+

Shell;iameter (m):ength (m)

*,23

E*t/"!t7 3-*t (RM)

1@@

F$#3t/-# 7o separate oygen and nitrogen g

T+ - ""r!# D/"t%*/%/3-# r$r

T+ - ""r!# *+!r!t-r H-%%- ""r!#T+ - *%% C!r-# *t%

?

N$"r - "-7$%* 154

T+ - 8**% *$++-rt Saddle

O+r!t/#' 3-#7/t/-#*

.* 9perating %ressure(bar)"nlet

9utlet

32

!ollow membrane;iameter (m):ength (m)

*,*12,+

Shell;iameter (m):ength (m)

*,23

E*t/"!t7 3-*t (RM)

1@@

E.$/+"#t*


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SUMMARY OFMAOR

EUIPMENTCOSTS

5eactor (5-1)

;istillation column 1 (7-2)

;istillation column 2 (7-3)

Ethylene oide storage tan< 1

Ethylene oide storage tan< 2

Ethylene storage tan< (O-1)

Ethylene storage tan< (O-1)

@ater storage tan<

%otassium carbonate storage tan<

n empty cylindricalD carbon steel essel

Ethylene oide absorber (7-1)

Carbon dioide absorber (7-$)

Carbon dioide stripper (7-)

!eaters (E-3D E-$D E-.)

Coolers (E-1D E-2D E-D E-0D E-/)

Compressors and Epander (C-1D C-2D C-3D C-$D C-)

Mier (M-1)

Membrane Separator (4-1)

TOTAL ESTIMATED COST

3Te metods o% te)al)ulation %or eui+mentsi5ing and )osts are ta&en%rom Turton6s (2007 andinnot6s (2008 'ritings3


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Chapter 5

Process Control & SafetyStudies


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SS#M%7"9S

O# !/%$r !t ! t/"6

T **t" /* -+r!t7 !#7 "!/#t!/#7/# %/# /t 7*/'# /#t#t6

M-7* - -+r!t/-#K N-r"!% -+r!t/-#

G$/7-r7K N-, M-r, L**, H/', L-,R8r*

N-7K M!-r E.$/+"#t

HAOP -# R!3t-r (R>


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D8/!t/-#P-**/% 3!$** C-#*.$#3* R3-""P!r!"t

rG$/7-r

7

low tothe

reactor

o Kow tothe

reactor

Fale F-. ailclose,

o reaction occurs"nstall Kow mass alaChec< regularly the ale,

More Kowto thereactor

Fale F-. ailopen,

5unaway reaction"nstall Kow mass ala

7o chec< regularly thale,

:ess Kowto thereactor

%iping lea


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P & ID -r R!3t-r (R>

1)


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!N9% on ;istillationColumns

D8/!t/-#* P-**/% C!$** C-#*.$#3* R3-"P!r!"t G$/7


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r*

low on;istillation Column

o Kow to thedistillationcolumn

Control ale closed o operation

7emperature and pressureincreased in the pipe,

"nstall bac


34/54

.*

G$/7


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low on;istillate

;istillation

Column

o top product Kow todistillate distillation column

"nlet Kow bloc< :oss in product

o separation in column

9erKow o accumulator

%ump at the condenser brea


36/54

P!r!"tr* G$/7


37/54

P & ID -r D/*t/%%!t/-# 3-%$"#*


38/54

D8/!t/-#*P-**/% C!$** C-#*.$#3* R3

P!r!"tr* G$/7


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Et%# -:/7*t-r!'

Et%#, P-t!**3!r-#!t !#7 <

t!#*

P & ID -r St-r!' T!#*


40/54

D8/!t/-#* P-**/% 3!$** C-#*.$#3* RP!r!"tr* G$/7


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r*

low to theabsorbers

andstripper

o Kow to theabsorber and stripper,

Control ale ailclose,

o operation "nstall bac


42/54

P & ID -r A*-rr* !#7 Str/++


43/54

D8/!t/-#* P-**/%C!$**

C-#*.$#3* R3-""#7!t/-#*P!r!"tr

*G$/7


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% & "; or !eat Echangers

C--%r H!tr

!N9% 9n Compressor


45/54

D8/!t/-#*

P-**/% C!$** C-#*.$#3* R3-""#7!t/P!r!"tr*

G$/7


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% & "; or Compressorand Epander

!N9% on Mier (M 1)


47/54

D8/!t/-#*P-**/% C!$** C-#*.$#3* R3-""

P!r!"tr*

G$/7


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% & "; or Mier (M-1)

!N9% on membrane


49/54

separator (4-1)D8/!t/-#*

P-**/% C!$** C-#*.$#3* R3-"P!r!"tr* G$/7


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% & "; or MembraneSeparator

CONCLUSIONRECOMMENDATION


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CONCLUSIONRECOMMENDATIONFOR THE PROCESS SAFETY

•

Saety studies o all the nodes in the %; aresuccessully coered by the !N9% analysis,

• Saety "nterloc< Systems can be installed in caspossible seere conditions in the plant,

• 9ther saety studies such as the ailure Mode analysis (ME) and ault 7ree nalysis (7) cobe done in order to help oercoming the littledrawbac


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ECONOMIC POTENTIAL ATLEEL

*,2 *,3 *,$ *, *,0 *,/ *,. *,+ 1,* 1,1

-1*

*

1*

2*

3*

$*

*

E3-#-"/3 P-t#t/!%

C-#8r*/-#, X

E3-#-"/3 P-t#t/!% , EP (10@RMr)

At t -+3-#8r*/-# -

EP /* -t!

RM?5 "

C9C:#S"9


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M!** !#7 #r' !%!#3 rr-r!r %**r t!# !#7 ?0

r*+3t/8%6

@4 - -t $t/%/t/* !#7 @ - 3-%7 $t/%/t/* 3!# *!87

/#t'r!t7 HEN6

T t-t!% *t/"!t7 3-*t -rt "!-r .$/+"#t /* RM2@6

"/%%/-#6

P&ID /* *$33**$%% 78%-+7r-" t HAOP *t$7/*6

C9C:#S"9


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Documents

Production of 21,000 ethylene oxide