3 BodyPart

Table of Contents
1.0 Problem
Statement ............................................................................................................... 13
1.1
Background ...................................................................................................................
... 1.1.1
13
School of Chemical Engineering
Introduction ...............................................................................................................
1.1.2
13
EKC 451 Plant Designs 2018/2019
Application ................................................................................................................
1.2 14Importance of Propylene Glycol from Malaysia point of
view ....................................... 16 FULL REPORT
1.2.1
Demand ......................................................................................................................
1.2.2
16
Supply ........................................................................................................................
1.3 19Letter of
Transmittal......................................................................................................... 21
1.4 Scope of
Project ............................................................................................................... 24
1.5 Gantt
Chart ....................................................................................................................... 25
2.0 Process
Alternatives ............................................................................................................. 26
2.1 Discussion of the process
alternatives .............................................................................. 26
Plant
2.1.1 Design
Production for theglycol
of propylene Production
from glycerol ofin Propylene
Escherichia Glycol
coli. ........................... 26
2.1.2 Hydrogenolysis of glycerol to propylene glycol using Cu-ZnO
GROUPcatalyst. ................. 28: 17
2.1.3 Hydrogenation of biomass derived lactic acid to propylene glycol over a
GROUPcarbon-
MEMBERS :
supported ruthenium
2.2 1.Comparison
catalyst. MARYbetween Process
JOAN .............................................................................................
A/P PATRICK GEORGE (129073) 30
Alternatives ...................................................................... 34
2.32.Choice
LOW YING of KAI (131602)
3. NUR
Process .............................................................................................................
AMNI BINTI MD ANUAR (129109) 38
2.44.Current related problem of the plant to the environment and
society
5. NURUL..............................
AFINI BINTI FUAD 38 (129121)
3.0 Critical Assessment of the Process Chosen 3.1 Capacity of
SHERRINE A/P ARULDASS
Plant ...................................... 38 (129129)
3.1.1 Plant
Capacity ............................................................................................................ 38
SUPERVISOR
3.1.2 Location of the designed : DR. FADZIL NOOR GUNAWAN
plant...................................................................................
: 19th DECEMBER 2018 40
DATE OF SUBMISSION
3.1.3 Complete Process
Description ................................................................................... 42
3.2 Process Chemistry, Reactions, Kinetics, Thermodynamics Data & Other Physical
and
Chemical Properties
Data3.2.1
.......................................................................................................
Process 43
Chemistry ..................................................................................................... 43
3.2.2
Reactions ...................................................................................................................
44
1
3.2.3 Reaction
kinetics........................................................................................................ 44
3.3 Advantages and Disadvantages of
Process ...................................................................... 46
3.4 Environmental (disposal of waste, if any), Safety and Health
Concerns ......................... 47
3.5 Similar Plant with Plant Capacity and Total Capital
Investment ..................................... 48
3.6 Projected Demands/Supply for Next 10
Years ................................................................ 49
4.0 Process Synthesis Structure and
Analysis............................................................................ 50
4.1 Input-Output Structure with Feed and Specifications, Price of all product, By-
product
and Raw
Materials.
4.1.1 Input-Output
.................................................................................................................
Structure with Feed and 50
Specifications ............................................... 50
4.1.2 Feed and product
specification .................................................................................. 54
4.1.3 Price of all product, by product and raw
materials .................................................... 55
4.2 Destination of Codes and Component Classification,
Utilities ........................................ 56
4.2.1 Destination of Codes and Component
Classification ................................................ 56
4.2.2
Utilities ......................................................................................................................
5.0 Process
58 Flow Diagram
(PFD) .............................................................................................. 59
5.1 Block
Diagram ................................................................................................................. 59
5.2 Process Synthesis Flow
Sheet .......................................................................................... 60
5.3 Innovation approach of Process
Design ........................................................................... 60
5.4 Process Flow Diagram
(PFD) .......................................................................................... 61
6.0 Process
Analysis ............................................................................................................. 62
6.1 Process
Description ..................................................................................................... 62
6.2 Justification of Each Equipment
Chosen .................................................................... 62
6.2.1 Heat
Exchanger ....................................................................................................
6.2.2 Reboiler
63 .........................................................................................................
....... 67
6.2.3 Compressor ...................................................................................................
....... 69
6.2.4 Distillation
column............................................................................................... 70
6.2.5 Packed Bed
Reactor ............................................................................................. 73
6.2.6 Pumps............................................................................................................
....... 75
2
6.2.7 Reflux
drum ......................................................................................................... 77
6.2.8 Flash
Drum...........................................................................................................
6.2.9 79
Condenser ..................................................................................................................
6.2.10
80
Expander ..................................................................................................................
6.2.11
83 Number of Equipment Units
Required .................................................................... 85
6.3 Code
Justification ............................................................................................................. 85
6.4 Economical
Potential................................................................................................... 85
6.4.1 Prices of Raw Material and
Product .................................................................... 85
6.4.2 Input and Output Structure without
Recycle ....................................................... 86
6.5 Separation Operations Used in Production in Production of Propylene
Glycol ......... 90
7.0 Material and Energy
Balance .......................................................................................... 92
7.1 Mass Balance
Theory .................................................................................................. 92
7.2 Stream
Table .................................................................................................................... 93
7.3 Energy Balance
Theory .................................................................................................... 94
7.4 Aspen
Simulation ........................................................................................................
7.4.195 Aspen Flow
Sheet ................................................................................................ 95
7.4.2 Aspen Simulation
Result...................................................................................... 95
7.4.3 Table of comparison between Microsoft Excel Calculation and ASPEN PLUS
Simulation...................................................................................................................
........ 97
8.0 Utilities.....................................................................................................................
..... 101
8.1. Utilities
Summary ..................................................................................................... 101
8.2 Electricity .............................................................................................................
..... 103
8.3 Waste
Generation ......................................................................................................
8.3.1103 Solid Waste
Quantity ............................................................................................... 103
8.3.2 Liquid Waste
Quantity............................................................................................. 104
8.3.3 Gaseous Waste
Quantity.......................................................................................... 105
9.0 Mass Transfer Equipment
Design ................................................................................. 106
9.1 Distillation Column, V-
201 ....................................................................................... 108
3
301 ....................................................................................... 111
401 ....................................................................................... 113
10.0 Heat Transfer Equipment
Design.................................................................................. 117
10.1 Heat Exchanger, E-
101 ............................................................................................. 119
102 ............................................................................................. 122
104 ............................................................................................. 125
201 ............................................................................................. 128
301 ............................................................................................. 131
401 ............................................................................................. 134
10.7 Condenser, E-
103 ...................................................................................................... 137
10.8 Condenser, E-
202 ...................................................................................................... 140
10.9 Condenser, E-
302 ...................................................................................................... 143
10.10 Condenser, E-
402 ...................................................................................................... 146
10.11 Reboiler, E-
203 .......................................................................................................... 149
10.12 Reboiler, E-
303 .......................................................................................................... 150
10.13 Reboiler, E-
403 .......................................................................................................... 151
11.0 Reactor
Design .............................................................................................................. 152
11.1 Packed Bed Reactor, R-
101 ...................................................................................... 152
12.0 Auxiliary Equipment
Design ........................................................................................ 156
12.1
Pump.............................................................................................................................
12.1.1 Pump, P-
156
101 .......................................................................................................... 156
12.1.2 Pump, P-
301 .......................................................................................................... 157
12.1.3 Pump, P-
401 .......................................................................................................... 158
12.2
Compressor...................................................................................................................
12.2.1 Compressor, C-
159
101 ................................................................................................ 159
12.3 Flash
Drum ................................................................................................................... 160
12.3.1 Flash Drum, V-
101 ................................................................................................ 160
4
12.4
Expander.......................................................................................................................
16112.4.1 Expander, D-
101 .................................................................................................... 161
12.5 Reflux
Drum................................................................................................................. 163
12.5.1 Reflux Drum, V-
202 .............................................................................................. 163
302 .............................................................................................. 164
402 .............................................................................................. 165
13.0
References .......................................................................................................................
.Appendix
166 A: Thermodynamic
Data ......................................................................................... 176
Appendix B: Material Safety Data
Sheet ................................................................................. 179
B.1 Material Safety Datasheet of Propylene Glycol [76]
....................................................... 179
B.2 Material Safety Datasheet of Glycerol [78]
..................................................................... 184
B.3 Material Safety Datasheet of Hydrogen [79]
................................................................... 188
B.4 Material Safety Datasheet of Methanol
[80].................................................................... 197
B.5 Material Safety Datasheet of Water [81]
......................................................................... 201
B.6 Material Safety Datasheet of Ethylene Glycol [82]
......................................................... 204
B.7 Material Safety Datasheet of Acetol [83]
........................................................................ 209
Appendix C: Mass Balance on Individual
Unit ....................................................................... 214
C.1 Pump (P-
101) ............................................................................................................. 214
C.2 Heat Exchanger (E-
101) ............................................................................................ 215
C.3 Compressor (C-
101)................................................................................................... 216
C.4 Mixing
Point .............................................................................................................. 217
102) ............................................................................................ 218
C.6 Packed Bed Reactor (R-
101) ..................................................................................... 219
C.7 Condenser (E-
103) ..................................................................................................... 220
104) ............................................................................................ 221
C.9 Flash Drum (V-
101) ................................................................................................... 222
C.10 Splitting
Point .......................................................................................................... 223
5
C.11 Expander (D-
101) .................................................................................................... 224
201) .......................................................................................... 225
C.13 Distillation Column (V-
201) .................................................................................... 226
C.14 Condenser (E-
202) ................................................................................................... 227
C.15 Reflux Drum (V-
202) .............................................................................................. 228
C.16 Reboiler (E-
203) ...................................................................................................... 229
C.17 Pump (P-
301) ........................................................................................................... 230
301) .......................................................................................... 231
301) .................................................................................... 232
C.20 Condenser (E-
302) ................................................................................................... 233
C.21 Reflux Drum (V-
302) .............................................................................................. 234
C.22 Reboiler (E-
303) ...................................................................................................... 235
C.23 Pump (P-
401) ........................................................................................................... 236
401) .......................................................................................... 237
401) .................................................................................... 238
C.26 Condenser (E-
402) ................................................................................................... 239
C.27 Reflux drum (V-
402) ............................................................................................... 240
C.28 Reboiler (E-
403) ...................................................................................................... 241
C.29 Overall Mass Balance of
Streams ............................................................................ 242
Appendix D: Energy Balance on Individual
Equipment ......................................................... 246
D.1 Pump (P-
101)......................................................................................................... 246
F.2 Heat Exchanger (E-
101) ........................................................................................ 247
D.3 Compressor (C-
101) .............................................................................................. 248
D.4 Mixing
Point .......................................................................................................... 249
D.5 Heat Exchanger (E-
102) ........................................................................................ 250
D.6 Packed Bed Reactor (R-
101) ................................................................................. 251
D.7 Condenser (E-
103) ................................................................................................. 252
104) ........................................................................................ 253
6
D.9 Flash Drum (V-
101) .............................................................................................. 254
D.10 Splitting
Point ........................................................................................................ 255
D.11 Expander (D-
101) .................................................................................................. 256
201) ........................................................................................ 257
D.13 Distillation Column (V-
201) ................................................................................. 258
D.14 Condenser (E-
202) ................................................................................................. 259
D.15 Reflux Drum (V-
202) ............................................................................................ 260
D.16 Reboiler (E-
203) .................................................................................................... 261
D.17 Pump (P-
301)......................................................................................................... 262
301) ........................................................................................ 263
301) ................................................................................. 264
D.20 Condenser (E-
302) ................................................................................................. 265
302) ............................................................................................ 266
D.22 Reboiler (E-
303) .................................................................................................... 267
D.23 Pump (P-
401)......................................................................................................... 268
401) ........................................................................................ 269
401) ................................................................................. 270
D.26 Condenser (E-
402) ................................................................................................. 271
402) ............................................................................................ 272
D.28 Reboiler (E-
403) .................................................................................................... 273
D.29 Overall Energy Balance Followed Stream
Number........................................... 274
D.30 Heat Capacity Constants and Heat of Formation for
Components.......................... 276
Appendix E:
Utilities ............................................................................................................... 277
E.1 Utility Stream
Balance .............................................................................................. 277
Appendix F: Mass Transfer Equipment
Design....................................................................... 282
F.1 Distillation Column, V-
201 ........................................................................................... 282
301 ........................................................................................... 299
401 ........................................................................................... 315
7
Appendix G: Heat Transfer Equipment
Design ....................................................................... 332
G.1 Heat Exchanger, E-
101.................................................................................................. 332
G.2 Condenser, E-
103 .......................................................................................................... 341
G.3 Reboiler, E-
203 ............................................................................................................. 353
Appendix H: Reactor
Design ................................................................................................... 362
H.1 Packed Bed Reactor, R-
101........................................................................................... 362
Appendix I: Auxiliary Equipment
Design ............................................................................... 381
I.1 Pump, P-
101 .................................................................................................................... 381
I.2 Pump, P-
301 .................................................................................................................... 385
I.3 Pump, P-
401 .................................................................................................................... 389
I.4 Compressor, C-
101 ......................................................................................................... 393
I.5 Flash Drum, V-
101 ......................................................................................................... 397
I.6 Expander, D-
101 ............................................................................................................. 407
I.7 Reflux Drum, V-
202 ....................................................................................................... 409
I.8 Reflux Drum, V-
302 ....................................................................................................... 411
I.9 Reflux Drum, V-
402 ....................................................................................................... 412
Appendix J: Minutes of
Meeting ............................................................................................. 414
8
Table 1: Gantt
Chart ............................................................................................................... 25
Table 2: Comparison table between 3 process
alternatives ................................................. 34
Table 3: Rough calculation for plant capacity for production of propylene glycol. ..........
40
Table 4: Palm oil plantation area in Malaysia List of Tableby state (2016). [36]
...................................... 41
Table 5: Advantages and disadvantage of hydrogenolysis of propylene glycol from
glycerol .............................................................................................................................
.. 46
Table 6: Environmental, Safety and Health
Concerns ......................................................... 47
Table 7: Similar Plant with Plant Capacity and Total Capital Investment .......................
48
Table 8: Input-Output
Structure. .......................................................................................... 51
Table 9: Feed and Product
Specification. .............................................................................. 54
Table 10: Price of Raw Materials, By Products and Products ............................................
55
Table 11: Basis and cost calculation for the designed
plant. ............................................... 55
Table 12: Destination of Codes and Component
Classification........................................... 57
Table 13 Justification on the Heat Exchanger and Material of Construction ...................
64
Table 14 Justification on the Reboiler and Material Construction .....................................
67
Table 15 Justification on the Compressor and Material Construction ..............................
70
Table 16 Justification on the Distillation Column and Material Construction ..................
71
Table 17 Justification on the Packed Bed Reactor and Material Construction .................
74
Table 18 Justification on the Centrifugal Pump and Material Construction ....................
76
Table 19 Justification on the Reflux Drum and Material Construction .............................
78
Table 20 Justification on the Flash Drum and Material Construction ...............................
80
Table 21 Justification on the Condenser and Material Construction .................................
81
Table 22 Justification on the Expander and Material Construction ..................................
84
Table 23 Number of equipment units
required ..................................................................... 85
Table 24 Prices of Raw Materials and
Product..................................................................... 85
Table 25 Economics Potential of Production Plant of Propylene Glycol at Different
Conversion without Recycle
Stream ............................................................................... 86
Recycle
Percentages .......................................................................................................... 88
Table 27 Separation of Operations Used in the
Production ................................................ 90
Table 28 Molecular Weight of 9
Components .......................................................................... 92
Table 29 Conversion of reactions takes place in the
plant ................................................... 92
Table 30 Overall Stream Table for Mass Balance (Stream 1-Stream 19) ..........................
Table 38 Justification table between Microsoft Excel Calculation and ASPEN Plus
Simulation.........................................................................................................................
. 99
Table 39 Amount of steam required for heating
utilities ................................................... 101
Table 40 Amount of steam required for cooling utilities ...................................................
102
Table 41 Electrical energy required for pump, compressor and expander......................
103
Table 42 Quantity of waste produced per
hour .................................................................. 104
Table 43 Specification Sheet of Distillation Column V-201 ...............................................
108
111
114
Table 46 Specification Sheet of Heat Exchanger E-
101 ..................................................... 119
102 ..................................................... 122
104 ..................................................... 125
201 ..................................................... 128
301 ..................................................... 131
401 ..................................................... 134
Table 52 Specification Sheet of Condenser E-
103............................................................... 137
Table 53 Specification Sheet for Condenser E-
202 ............................................................. 140
302............................................................... 143
402............................................................... 146
Table 56 Specification Sheet of Reboiler E-
203 .................................................................. 149
203 .................................................................. 150
403 .................................................................. 151
Table 59 Specification Sheet of Packed Bed Reactor R-
101 .............................................. 153
Table 60 Specification Sheet of Pump P-
101 ....................................................................... 156
301 ....................................................................... 157
401 ....................................................................... 158
Table 63 Specification Sheet of Compressor C-
101 ............................................................ 159
Table 64 Specification Sheet of Flash Drum V-
101 ............................................................ 161
Table 65 Specification Sheet of Expander D-
101 ................................................................ 162
Table 66 Specification Sheet of Reflux Drum V- 10
202 .......................................................... 163
Table 67 Specification Sheet of Reflux Drum V-
302 .......................................................... 164
Table 68 Specification Sheet of Reflux Drum V-
Table 80 Amount of heating fluid for Heat Exchanger (E-104) ........................................
278
278
Table 82 Amount of cooling fluid for Condenser (E-202) ..................................................
278
Table 83 Amount of heating fluid for Reboiler (E-203) .....................................................
279
279
279
280
280
280
281
Table 90 Amount of heating fluid for Packed Bed Reactor Jacket ...................................
281
Table 91: Chemical and Physical Properties ..............................Error! Bookmark not
defined.
11
Figure 1: Chemical structure of propylene glycol. [2]
........................................................... 13
Figure 2: World consumption of propylene glycol in 2016. [7]
............................................. 17
Figure 3: Global Propylene Glycol Market in 2017, by End-Use Industry. [9] ...................
18
Figure 4: Global Propylene Glycol Market, List ofBy Figure
Application, 2014-2024. [10]......................
18
Figure 5: Import of Propylene glycol to Malaysia. [11]
.......................................................... 19
Figure 6: The E. coli pathways involved in the synthesis of propylene glycol through
fermentation of glycerol. [17]
............................................................................................. 27
Figure 7: The basic flow of fermentation of
glycerol. ........................................................... 28
Figure 8: Hydrogenolysis of glycerol to propylene glycol.
[19].............................................. 28
Figure 9: Basic block flow diagram for conversion of glycerol to propylene glycol using
Cu-ZnO
catalyst. ............................................................................................................... 29
Figure 10: Basic Process Flow Diagram for Conversion of glycerol to propylene glycol
using Cu-ZnO
catalyst...................................................................................................... 30
Figure 11: Conversion of biomass derived lactic acid to propylene glycol.
[22]................... 30
Figure 12: Process Flow Diagram for Conversion of lactic acid to propylene glycol. .......
31
Figure 13: Propylene glycol: world capacity broken down by region, 2013 [32] ..................
39
Figure 14: Location of the designed
plant ............................................................................. 40
Figure 15: Global Propylene Glycol Market Forecast (2018-2018) ....................................
50
Figure 16: Block Diagram for Production of Propylene Glycol ..........................................
59
Figure 17: Process Synthesis Flow Sheet for Production of Propylene Glycol ..................
60
Figure 18: Process Flow Diagram for Production of Propylene Glycol .............................
61
Figure 19 Heat Exchanger
[88]. ................................................................................................ 63
Figure 20: Reboiler
[90]. ............................................................................................................ 67
Figure 21: Compressor
[92]....................................................................................................... 69
Figure 22: Basic distillation column that used in industry
[94]. ............................................ 70
Figure 23: Basic Packed Bed Reactor that used in industry
[97]. ......................................... 73
Figure 24: Pump
[103]. ............................................................................................................... 75
Figure 25: Reflux drum
[108]. ................................................................................................... 77
Figure 26: Flash drum
[109]. ..................................................................................................... 79
Figure 27: Condenser
[113]. ....................................................................................................... 80
Figure 28: Expander
[116].......................................................................................................... 83 12
Figure 29: Input-Output
Structure ........................................................................................ 86
Figure 30: Graph of Economics Potential of Production Plant of Propylene Glycol against
as
1.0aProblem
heat transfer medium to decrease the freezing point of a liquid. Hence, it provides
Statement
a
The following report discusses about the plant design for the production of propylene
prevention
glycol. from pressure burst, corrosion, overheating and freezing. In the
pharmaceutical
industry, it is used as an excipient, a non-active enabling agent. It helps to enhance
1.1 Background
solubility,
The following section describes about the plant design of propylene
reduce viscosity and provides long term stabilization. Propylene glycol is used in the
glycol.
food
1.1.1 Introduction
industry to enhance the flavour of food, to maintain moisture in food and to retain a
good taste.
Asia Pacific is one of the major regional market of global propylene glycol
market with
approximately 40% of the market share. The growing demand for environment-friendly
coatings and the accelerating demand from the automotive sector are the dominant
drivers for
the propylene glycol market.[75] The largest end use of propylene glycol is unsaturated
polyester resins as it has contributed about 41% of consumption in the major world
regions.
Other than that, propylene glycol is also used as functional fluids, polyurethanes,
paints and
coatings and miscellaneous applications. According to research, it is reported that in
2016, the Figure 1: Chemical structure of propylene glycol. [2]
consumption of propylene glycol is reported to be 30% of consumption in the major
world Figure 1 shows the chemical structure of propylene glycol. Propylene glycol is an
regions.
organic compound with chemical formula of C3H8O2. It IUPAC name is 1,2-propanediol
and it Currently, the demand for propylene glycol is increasing and is expected to grow
has asymmetrical
in the carbon atom. Thus, it can exist in two enantiomers. In some cases,
this
upcoming years with a growth rate of 3%
compound is known as α-propylene glycol. Propylene glycol is a viscous, colourless and
annually.
odourless
1.1.2 liquid and has a sweet taste. It is chemically categorized as a diol and is
Application
miscible
Propylene glycol is often being used as raw material in numerous manufacturing
with various solvents such as acetone, chloroform and
water.
industries. It is commonly used as an organic solvent and diluent in pharmaceuticals
[2]
and manyPropylene glycol is traditionally produced via hydration of propylene This
other industrial applications. The industrial applications are discussed as
oxide.
below.
propylene oxide is derived from petroleum product. The propylene glycol market is
under
1.1.2.1
pressure Used
due intoPaints & Coatings
increase in oil and natural gas price. Hence, the price of propylene
glycol is
increasing. Now, we
Propylene need
glycol to to
help bepreserve
a pioneersurfaces,
of new alternatives to produce
protect buildings this
against product
weather
withoutchange
depending
and protecton theoilpower
and natural
of paints and varnishes. Propylene glycol is used in paints since
gas.
it can
control the flexibility and hardness of the coatings. It will extend the drying time that
Propylene glycol is used as an antifreeze when there is a possibility for leakage
helps the
surfacewhich
from drying because propylene glycol has a slower evaporation rate than
may cause contact with food in the chemical, pharmaceutical and food industries. It is
water. For
also
latex-based architectural paints, it will provide freeze and thaw stability which makes it
utilized to produce smoke or fog for firefighting training. Propylene glycol is also used
easier
in storage, transportation and handling. These low VOC paint does not cause danger
for
paints and coatings to maintain surface and protect buildings from weather change.
to human
Moreover,
and environment. Besides, some process requires UV-radiation for manufacturing,
it is used in liquid detergents as a stabilizer to remove dirt from washing materials and
printing
aid inpaints or coatings, usage of propylene glycol in the paint is very important since it
inks,
maintaining the properties of detergent even at low temperatures. Propylene glycol is
[3]
also used low emission and also increases energy
produces
efficiency.
13
14
1.1.2.2 Used in Liquid Detergents
Most of the liquid detergents require a homogenous distribution within the liquid
for an
active and effective cleaning. Propylene glycol function as a stabilizer in removing dirt
of the
washing materials and help to retain these properties even at low temperature. This
causes the
cleaning liquids to always remain clear when used at normal temperature. This makes
the
liquid detergent products containing propylene glycol is safer to use and an efficient
cleaning
agent. [4]
1.1.2.3 Heat Transfer Fluids
Propylene glycol is used as heat transfer medium where it can reduce the
freezing point
of a liquid. Thus, this gives a protection against pressure burst, corrosion, overheating
and
freezing. Propylene glycol have higher boiling point that can lower the vapour pressure.
A
water-propylene glycol mixture becomes cooler and this prevent additional pressure
inside the
pipe or vessels. Hence, it is an ideal solution that help to protect pipe, engine and
cooling
system.
Propylene glycol plays a vital role in industrial applications such as solar panel
systems, marine transportations, Temperature-Sensitive used with engines or under
extreme
conditions and pipes and tubes
[5]
1.1.2.4 Pharmaceutical Uses
Propylene glycol are used as an excipient, a non-active enabling agent in

pharmaceutical products. It is used for long term stabilization, reduce viscosity and
enhancing
solubility. Personal care products consisting this chemical are always soft, moist and
kept
consistent. The properties as an excipient enable personal care items to stabilize foam.
For
instance, hand sanitizer contains propylene glycol that will help to prevent the skin
from
drying. For medicinal intake, this chemical acts as a carrier of active ingredient found
in cough
syrup and gel capsules. It is used as a solvent in three different ways; injectable, oral
and
topical. There are no adverse effects found with normal dosage of propylene
glycol. [2]
15
1.1.2.5 Food
Propylene glycol is a chemical that often used in food industries. Propylene

glycol are
used in edible food items since it helps to enhance flavouring and retain a good taste.
It is used
in coffee-based drinks, ice-cream, whipped dairy products, soda and liquid sweeteners.
However, it is rarely listed in the nutrition label. It also uses to maintain the moisture
content in
food. It is widely used in food industries because propylene glycol is a good solvent
rather than
water as it helps to dissolves colours and flavours. The toxicity of propylene glycol is
low and
there are no reported cases of it adverse and toxicity in
food. [6]
1.2 Importance of Propylene Glycol from Malaysia point of view
The chemical manufacturing industry is one of the leading industries in Malaysia
and
has increased from year to year. Some of the examples of chemical products that
produced in
Malaysia are raw materials for the manufacturing of plastic, food and drinks, electronic,
pharmaceuticals, cosmetics and textiles. Propylene glycol is one of the chemicals that
being
used to produce flavours and fragrance, plasticisers, cosmetics and personal care
product and
other products. The supply and demand of propylene glycol in Malaysian Chemical
Industry
point of view are discussed below. There is a rising demand from the automotive
industry for
propylene glycol to be used as coolants and also in pharmaceutical
industries.
1.2.1 Demand
Propylene glycol is utilized in an extensive range of applications, including
unsaturated
polyester resins, cosmetics and personal care products, functional fluids and
antifreezes, liquid
detergents, and dog food.
[7]
In 2021, the propylene glycol market is most likely to reach at a CAGR of 5.8% in
the
global propylene glycol market.[8] Based on the CAGR, it is expected that CAGR of 2.8%
growth between 2016 to 2018 and a CAGR of 3.42% from 2018 to 2021. This massive
growth
is mainly contributed by the increasing demand for propylene glycol for the use in
automotive [8]
coolant and also the production of eco-friendly bio-based propylene glycol. Over the
forecast period; from 2018 to 2021, the consumption of propylene glycol is expected to
grow at
a rate of 3% annually. It is reported that in 2016, the largest end use of propylene
glycol is
unsaturated polyester resins as it has contributed about 41% of consumption in the
major world
regions. Other than that, propylene glycol is also used as functional fluids,
polyurethanes,
16
paints and coatings and miscellaneous applications. It is also reported that in 2016, the
consumption of propylene glycol is reported to be 30% of consumption in the major
world
regions.
Figure 2 illustrates the world consumption of propylene glycol in 2016. Based on

Figure 2, the major consumers of propylene glycol are United States and Western
Europe. One
of the significant applications of propylene glycol in United States and Western Europe
is to be
used as a solvent for liquid detergents. In the United States, propylene glycol is also
used in
paints and coatings, functional fluids and personal care products. In Western Europe,
the
growth prospects are mainly contributed by the food, personal care and
pharmaceutical sector.
The major sectors that utilize propylene glycol in China include the personal care and
pharmaceutical segments.
[7]
Figure 2: World consumption of propylene glycol in 2016. [7]
Figure 3 illustrates the global propylene glycol market in 2017, by end-use

industry.
There has been a continuously rising demand for propylene glycol from the food,
pharmaceuticals and cosmetics industry as consumers are becoming more health
conscious and
desire a healthier lifestyle. Moreover, current day consumers have higher living
standards
which causes them to prefer quality cosmetic products which are more expensive. In
addition,
there is also a rising demand for propylene glycol in the transportation industry where
it is used
in automotive coolants, hydraulic and brake fluids, aircraft de-icing fluids and power
cruisers.
17
It is also employed in the antifreeze market. Besides that, propylene glycol is also used
as a
solvent in liquid detergent due to its neutral
property.
Figure 3: Global Propylene Glycol Market in 2017, by End-Use Industry. [9]
Figure 4 illustrates the global propylene glycol market by application from 2014-
2024.
From the graph, it is observed that the demand for propylene glycol is expected to
increase in
the years to come. For Malaysia, due to the growth of personal care, food and
pharmaceutical
products manufacturing industries, the demand of propylene glycol increased yearly.
The
import of propylene glycol to Malaysia increased since
1990.
Figure 4: Global Propylene Glycol Market, By Application, 2014-2024. [10]
18
urbanization, rising disposable income, changing lifestyle, growing health awareness
and
relaxed investment norms.
[9]
Currently, the market is led by The Dow Chemical Company (U.S) LyondellBasell
Industries N.V. (Netherlands), BASF SE (Germany), Archer Daniels Midland Company
(U.S.),
Global Bio-chem Technology Group Co., Ltd. (China), DuPont Tate & Lyle Bio Products
Company, LLC (U.S.), Huntsman Corporation (U.S.), SKC Co., Ltd. (South Korea), Temix
International S.R.L. (Italy), and Ineos Oxide (Switzerland).
[13]
In 2016, the global exports of propylene glycol reached $589.6M (RM 2.43705
billion)
resulting in propylene glycol being the 1844th most popularly exported product out of
4717
product groups. Over 27 countries export propylene glycol with the top 5 exporting
countries
accounting for $586.9 M (51.8%) of all exports. During this period 49 countries
imported these
products. The largest markets for these products are Denmark ($2.8M), Croatia
($594.8K), Figure ($963.5K),
5: Import of Propylene glycol to Malaysia. [11]
India ($1.6M), Australia and Germany ($299.4M).
[14]
Figure
There is5a shows the import
continuous of propylene
increase glycol
in the supply ofto Malaysia glycol
propylene from 1995 to 2020.
to cater the
From
needs of
the
the graph,
variousitsectors.
is observed that expected
It is also the import of propylene
that the supplyglycol has been
will increase increasing
in years to come to
steadily
meet over
the The current import of propylene glycol in 2018 is 4,445,000 kg. The
the years.
demands of the industry. Propylene glycol plant is yet to be built in Malaysia. Hence,
predicted
there is quantity of propylene glycol in 2025 is about 5 288 000 kg. Hence, the import
imported
no export of propylene glycol from Malaysia. In 2017, The Dow Chemical Company
for
proposed
propylene glycol in Malaysia is expected to Phut,
increase. Thus,which
Malaysia
to build a propylene glycol plant in Map Ta Thailand, haswould be a
a production
potential
capacity of
producer for propylene glycol. If the supply of propylene glycol can be obtained from a
up to 150KTA. This investment will immensely bolster the customers of The Dow
local
Chemical
manufacturer,
Company in thethe cost
Asia of production
Pacific region. can be reduced because export expenses can be
reduced.
[15]
Moreover, the feedstock for the manufacturer is readily available and does not need to
be The current global production of propylene glycol is 2.18 million tons per year
imported so, is
which the expenses for obtaining feedstock can be reduced. Hence, the effect of
mainly
local produced from propylene oxide and sold at $1.0–2.2 per kg. The world’s PG
supply
market will
is help in reducing the production cost of propylene glycol and also reduce the
flow
growing at a rate of 4.5% per annum and is expected to increase
reach 2.56
of Malaysian currency to international market as well as themillion tonsincome
country’s by
2017.
because
Malaysia evolve to become a potential exporter of propylene
glycol.
1.2.2 Supply
The prominent regions for propylene glycol market are North America, Europe
and
Asia Pacific. [12] Asia-Pacific is expected to be growing in the highest rate in the market
for
propylene glycol in the period of 1995 to 2025 due to the rapid industrialization and
19
20
3. Propylene
1.3 Letter glycol manufacturing industry could be a prospering and well
of Transmittal
developed
industry in Malaysia which significantly help to boost the country’s economic
development.
Currently, Asia Pacific
JAJAS Chemical dominated propylene glycol market since propylene glycol is
Sdn. Bhd
consumed in large
Process Design scale
Team for various
Group 17, application. From global perspective, Dow Chemical
Company and Lyondell
Process Design Basell industries are the two dominant players in the propylene
and Analysis
Department,
glycol
Tanjungindustry.
LangsatLyondell Basell
Industrial Area,anticipates to build world largest propylene oxide plant
in
Texas, US that
81700 Pasir will produce 470,000 tonnes of Propylene oxide each year. Due to the
Gudang,
continuous
Johor Darul consumption
Takzim. of propylene glycol based products, propylene glycol is a
potential
industry to be developed in Malaysia. Hence, we are planning to build a plant in
___________________________________________________________________________
Malaysia to
meet the demand of propylene glycol. With the establishment of this chemical plant in
Dr. Fadzil we
Malaysia, Noor Gunawan
can increase economic growth and create new jobs in the effort to help
reduce
Plant Manager,
unemployment.
JAJAS Chemical Sdn.Bhd. 12th September
4. The targeted location of our proposed Propylene glycol plant was set at Tanjung
2018.
Langsat Industrial Area, Johor Bahru. Tanjung Langsat Industrial Area have all the
essential
features to become a strategic location for our plant production. This location was
confirmed
Dear considering
after Sir, several aspects such as convenient transportation, easy accessibility
of raw
materials, topography, road network, ecology and human health. Tanjung Langsat
Plant Design for the Production of Propylene Glycol
Industrial
Area is located near YTL power generation stations and surrounded by all the utilities
such as
With reference to the above matter, we attached the initial planning of plant design for
water
the supply, sewage management system and port facilities. There are no residential
areas
production of Propylene glycol. Since there is no plant that produces Propylene Glycol in
within 2 km radius from the plant and this will not affect human health. Besides that,
this
Malaysia, this plant design was proposed to build in Malaysia to fulfil the demand and
location
supply is very well connected to Johor Bahru through a four lane Lebuhraya Pasir
Gudang,
required by various type of industrial application. The expected production capacity of
JB East Coast Highway and a trunk road. This strategic location enables us to deliver our
this
plant design will be approximately 60,000 tonnes per year of Propylene glycol. The plant
products efficiently and operate our plant successfully without any
issues.
design for the production of Propylene glycol is mainly from glycerol as a raw material.
5. The production of Propylene Glycol plant is from hydrogenolysis of glycerol using
Besides, the by-products from the productions of Propylene Glycol can be sold to other
Cu-
ZnO as a catalyst after thorough comparison studies of the 3 process alternative that
industry which could help to generate side income for the .
are
company.
available. The glycerol used for this process is pure and it is abundantly available in
2. Propylene glycol is a synthetic organic compound which is stable, colourless and
Malaysia. This process is chosen because it reduces usage of non-renewable resources
and it
odourless. It is known as an excellent solvent because it is freely miscible with water.
is an environmental friendly process.
Propylene glycol has been used for over 50 years in a large variety of applications. It is
6. Our design project included choosing the most suitable alternative process after
generally regarded as a safe chemical by the Food and Drug Administration (FDA). Thus,
considering the aspect of health, safety, environment (HSE) and profitability. The
Propylene glycol can be considered as a versatile product as it is used in a wide range of
deliverables of this project include production cost, mass balance, energy balance,
consumer products, including food products, pharmaceuticals additive, animal feed and
process
flow diagram, operating condition, reactor sizing and process and equipment
moisturizer in cosmetic products.
optimization.
21
22
Other than that, several criteria were also taken into account such as sustainability,
green
chemistry, proper waste management and less environmental impact. The first half of
this
project consists of three tasks and expected to be completed by the end of December.
Hereby,
we attached a Gantt chart that clearly illustrate our project’s interactive
planning.
7. If there is any doubt, regarding this proposed Propylene Glycol production plant,
please
feel free to contact us. We are very delighted to entertain your enquiries and we hope
that this
design of production Propylene Glycol can meet your expectation. Thank you very much
for
your cooperation and we are eagerly looking forward to hear from you
soon.
Thank You.
Sincerely,
_________________________________ _____________________________
(JOAN MARY A/P PATRICK GEORGE) (SHERRINE A/P ARULDASS)
PLANT DESIGN LEADER TASK 1 PLANT DESIGN MEMBER
H/P NO: 016-4666935 H/P NO: 012-3679508
EMAIL: joan.eicc @gmail.com EMAIL: [email protected]
_____________________________ _____________________________
(NURUL AFINI BINTI FUAD) (LOW YING KAI)
PLANT DESIGN MEMBER PLANT DESIGN MEMBER
H/P NO: 019-4367208 H/P NO: 018-2351268
EMAIL: [email protected] EMAIL: [email protected]
_____________________________
(NUR AMNI BINTI MD ANUAR)

PLANT DESIGN MEMBER
H/P NO: 017-5246394
EMAIL: [email protected]
23
1.4 Scope of Project
The plant project is to design a plant that produces propylene glycol in the most
efficient way in terms of safety and environment, economical indicator, market analysis
as
well as flexibility and controllability of the process. Besides that, this project also aims to
design a profitable propylene glycol plant that imposes minimal environmental
impacts.
The method which are used to produce propylene glycol for this plant is by
hydrogenolysis of glycerol using Cu-ZnO catalyst. The deliverables of this process
includes
the selection of the best process alternative for the production of propylene glycol, the
cost of
production and process flow diagram.
The process of the designated plant is chosen based on a few aspects. Firstly, the
raw
material for the process is chosen, the reaction of raw materials in the reactor,
production of
desired product and by-product, separation of product and waste water management
process.
Other than that, we described the chosen process of alternatives in terms of
green
chemistry and sustainability, environmental impact, energy consumption, flexibility of
operation, safety factors, waste management, environment and society. In addition, the
plant
is designed by considering cost saving, environmental issues, public issues, market
analysis,
flexibility and controllability. We also studied and predicted the demand and supply of
the
plant for the next 10 years.
Moreover, we characterized the capacity of plant and stated the estimated

completion
date. We also studied the quantity and suitable materials for feed and product
specifications
in order to buy the raw materials needed from the supplier so that a good quality
product can
be produced. Lastly, we estimated the production cost of propylene glycol and the
selling
price through the price of all products, by product and raw materials used in the
production.
24
1.5 Gantt Chart
Below shows the planning for this
project:
Project Name : Plant Design for the Production of Propylene Glycol
Company Name : JAJAS Chemical Sdn Bhd
Project Manager : Joan Mary a/p Patrick George
Table 1: Gantt Chart
WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Task 1
Problem Statement
Process Alternatives
Critical Assessment of the
Process Chosen
Process Synthesis Structure
and Analysis
Process Flow Diagram (PFD)
Task 2
Process Analysis
Material Balances
Energy Balances
Utilities and Wastes
Task 3
Mass Transfer Equipment
Design
Heat Transfer Equipment
Design
Reaction Equipment Design
Auxiliary Equipment Design
25
2.0 Process Alternatives
2.1 Discussion of the process alternatives
The 3 different alternatives of the process scheme for the production of propylene glycol
are
listed as below:
Alternative 1: Production of propylene glycol from glycerol in Escherichia

Coli.
Alternative 2: Hydrogenolysis of glycerol to propylene glycol using Cu-ZnO
catalyst.
Alternative 3: Hydrogenation of biomass derived lactic acid to propylene glycol over a
carbon-supported ruthenium
catalyst.
The alternative processes were discussed in terms of green chemistry and

sustainability where the propylene glycol is a non-toxic chemical to human health,
safety and
environment. For example, the three alternative process uses renewable feedstock
material to
produce propylene glycol in an economical and environmental friendly manner. Besides,
the
waste generated from all these processes were treated properly and disposed according
to the
law enforced by the authorities. There are also some waste which can be recycled into
the
system where this act will help to minimize the waste formation. Other than that, less
energy
consumption is very significant since it produces less negative impact to the
environment as
well as reduce the cost to operate the plant. Safety factor is also an important measure
because the production of propylene glycol plant must comply with all OSHA standards
where it does not risk the health and safety of people surrounding the plant. Hence, the
detailed comparison of each of the alternative processes is summarized and tabulated
in the
table 2 below. Although every alternative process has its own advantages and
disadvantages,
further study and analyses are needed to choose the most suitable process scheme for
the
plant.
2.1.1 Production of propylene glycol from glycerol in Escherichia coli.
Fermentation is an anaerobic metabolic process that occurs in microorganism.

Products such as propylene glycol can be produced through the fermentation of glycerol
in
Escherichia coli (E. coli). [16] The anaerobic metabolic process is a complex biochemical
reaction that consists of a few steps. E. coli undergoes metabolic engineering process
that
manipulates the gene of the E. coli strain. This is to increase the yield of the propylene
glycol
through the fermentation process. The genetically engineered E. coli is also able to
ferment
the crude glycerol that is produced from the production of biofuels.
[17]
26
Firstly, the glycerol undergoes dehydrogenation process. The hydrogen atoms
are
removed from the glycerol which is catalysed by the enzyme, glycerol dehydrogenase
(glyDH) and dihydroxyacetone produced. The dihydroxyacetone is then catalysed by the
dihydroxyacetone kinase (DHAK) to form dihydroxyacetone phosphate by receiving
[17]
phosphate group from the
phosphoenolpyruvate.
The dihydroxyacetone phosphate is then converted to methylglyoxal by the
action of
methylglyoxal synthase. The conversion of methylglyoxal into propylene glycol occurs
through 2 alternate pathways, one with acetol as intermediate through the reaction of
aldehyde oxidoreductase and glycerol dehydrogenase and the other alternative is with
lactaldehyde as intermediate mediated by glyDH and propylene glycol
reductase. [17]
Figure 6: The E. coli pathways involved in the synthesis of propylene glycol through
fermentation of glycerol. [17]
Process scheme
In this process, the crude glycerol that produced as by-product from the
production of
biofuels is used as the raw material. The crude glycerol is used as the substrate for the
fermentation process to produce propylene glycol. The fermentation is a single batch
process.
The substrate is mixed with genetically engineered E. coli and filled into a digester with
culture medium and operated under airtight condition. Prior to inoculation, oxygen in
the [17]
culture medium is removed by autoclaving to speed up the fermentation The
process.
fermentation is operated at temperature in between 30˚C to 42˚C. [17] The pH of the
culture
27
Crude glycerol from
Mixed with genetic
production of
engineered E. coli
biofuel
medium is controlled to pH 7.5 with NaOH and H2SO4 to ensure that the microorganisms
work at their optimal condition. [18] glycerol
Mixed with genetic
Filled into digester
fromCrude production of with culture
engineered E. coli medium
biofuel
At the end of the fermentation process, the fermented material is removed from
the
digester. The yield of the propylene glycol is 21.3%. [17] Other chemicals such as
succinate, Crude glycerol from Filled into digester
Fermentation
ethanol, lactateand acetate are Mixed with by-products theprocessfermentation
geneticproduced as fromwith culture process.
Further purification is needed to recover the propylene medium
production of
glycol. engineered E. coli
biofuel
Crude glycerol from Filled into digester Fermentation
Mixed with genetic Propylene glycol
production of with culture process
engineered E. coli produced
biofuel medium
Figure 7: The basic flow of fermentation of glycerol.

Filled into digester Propylene glycol
Mixed with geneticFermentation produced
with culture catalyst.
engineered E. coliprocess glycol using Cu-ZnO
2.1.2 Hydrogenolysis of glycerol to propylene
medium
One of applicable alternatives to produce propylene glycol is by hydrogenolysis of
Filled into digester
Fermentation Propylene glycol. [19] glycol year to year, the supply of crude oil
with cultureproduce seems toFrom
propyleneglycerol
deplete and the price to gradually increases
produced due to limited supply. Therefore, the
production of process
propylene
medium glycol from crude oil is no longer relevant. A route to produce propylene
glycol isPropyleneFermentation
from process
glycerol.
process Recently,
promoted glycol conventional
by governmental industries
policies cametoout
that leads with bio-based
expanding of biofuels
economymany
industries, [20]
resulting in huge amount of glycerol being generated as by-
produced Therefore, the by-
product.
Propylene glycolproduct that have been purified are used to produce high value
produced
propylene glycol.
In this process, the feed stock; pure glycerol is purchased from supplier. The use
of
pure glycerol is crucial to achieve high yield and selectivity of propylene glycol up to
80%
and 83.6% respectively. [19] [21] Copper-Zinc Oxide is used as a catalyst in this
process.
Figure 8: Hydrogenolysis of glycerol to propylene glycol. [19]
Process Scheme
Hydrogenolysis of propylene glycol from glycerol involve two reaction steps.

Firstly,
dehydration of glycerol to acetol. Dehydration is a process that involve the removal of
water.
Glycerol and catalyst are fed in the reactor that operates at 200[19] Catalyst used in this
℃.
28
process is Cu-ZnO which provides 93.4% selectivity of propylene glycol at given
operating
condition. Dehydration process will take place on ZnO support. During dehydration
process,
intermediates such as acetol will be dehydrated and water is released as by-product.
Second
step is hydrogenation process which is the addition of hydrogen gas. Hydrogen at a
pressure
of 4.2 MPa will be fed in the reactor and react with glycerol and catalyst. [19] This step
involves the hydrogenation of acetol to propylene glycol. Hydrogenation of acetol occurs
on
copper surface. In this step the desired product which is propylene glycol is formed.
Some
by-product such as ethylene glycol and methanol will also being released as the glycerol
reacts with hydrogen.
For this alternative, the optimum temperature is at 200 ℃ because at this

temperature,
the selectivity and conversion will be at highest value. Increasing in temperature will
favour [21]
the desorption and breaking of C-C and C-O bond. This will cause over hydrogenolysis
products, which is increasing in selectivity of ethylene glycol as by product. The by-
product
of hydrogenolysis of glycerol to propylene glycol are ethylene glycol, methanol, acetol
and
water. The product then undergoes a series of separation and purification process to
obtain
the desired product; propylene
glycol.
Figure 9: Basic block flow diagram for conversion of glycerol to propylene glycol using
Cu-ZnO catalyst.
29
Figure 10: Basic Process Flow Diagram for Conversion of glycerol to propylene glycol
using Cu-ZnO catalyst.
2.1.3 Hydrogenation of biomass derived lactic acid to propylene glycol over a carbon-
supported ruthenium catalyst.
Lactic acid production from biomass resources is a cheap raw material and it is
commonly produced by fermentation. In 1930s, production of propylene glycol from
lactic
acid was considered to be a viable method. [22] However, it is not viable in today’s world
as it
required high temperature and pressure which leads to high cost. The hydrogenation of
lactic
acid to propylene glycol produces other by-products such as ethylene glycol. [23] These
by-
products will reduce the yield of propylene glycol and contaminate the
product.
The biomass derived lactic acid undergoes hydrogenation to produce propylene
glycol
over a carbon-supported ruthenium catalyst.[24] Hydrogen atoms are introduced during
hydrogenation process.
Figure 11: Conversion of biomass derived lactic acid to propylene glycol. [22]
Process Scheme
Preparing and characterizing supported ruthenium

catalyst
30
resultingThe
hydrogen
preparation
stream
of supported
is pressurized
ruthenium
by a compressor.
catalyst involves
Optionally,
several
the
important
feedstock
streamsteps.
Firstly,
and hydrogen
immersestream
all carbon
are heated
supportinovernight
a preheater in atostirred
the desired
mixture
temperature
of HNO 3 andand
H2then
SO4 with
a
passed
volume ratio
through of 3:1. [25]
the reactor bedPlace
in anthe
upward
supports
or downward
in an ovenmanner
at 100°C
to increase
and leavethe
overnight
contact then,
with
catalyst.
wash the The
resultant
gas flow
carbon
can either
in warmbedistilled
concurrent
water
or several
counter-current
times. Thewith
ruthenium
the feedstock
catalyst
on
flow.
various carbons were prepared using incipient wetness impregnation method followed
by The passivated catalyst is introduced into the reactor and re-reduced with
drying hydrogen
at 100°C. The Ru loading is set at 5wt% for all catalyst. [25] The dried powder was
stream without the feedstock stream for about 1 hour under a pressure of about 1.7MPa
calcined at 500°C for a duration of 4hours. Before being exposed to air, the catalysts
(250psig).
are then To ensure complete catalyst reduction, a volume of hydrogen (STP) equal to
50
passivated in N2 for a duration of 30minutes after cooling. Detail analyses were carried
times
out onvolume catalyst is used. The re-reduction of catalyst takes place in the reactor.
After
all there-
synthesized catalysts. Using X-ray diffraction analysis, the crystallinity of the
reduction, the reactor is allowed to cool to below 150°C and vented to low pressure. [24]
Then,
synthesized samples was analysed. To examine the surface morphologies and Ru
the feed stream is introduced in mixture with hydrogen stream into the reactor. The rate
particle
of
sizes, a transmission electron microscope was used. Using BET method, the surface area
feed
of stream is adjusted so that it gives a weight hourly space velocity of approximately
0.5g-
the synthesized catalyst was determined, and the pore volumes and average pore sizes
5g
werelactic acid per gram catalyst per hour. The molar ratio of hydrogen to lactic acid feed
is
calculated using BJH model.
preferably about 4.2:1. The temperature of reaction is preferably around 150 to 700°C.
The
hydrogen pressure is increased to a desired value; preferably between 3.4MPA to
10.3MPa
(500 to 1500 psig). [23]
After the reaction, the reactor effluent stream is cooled to below 40°C in a heat
exchanger against a suitable fluid such as water and/or other process stream that needs
heating. For instance, a process hydrogen stream. The cooled effluent stream is passed
through a gas-liquid separator where the fluid is separated into an overhead gas stream
a
bottom liquid stream. In the overhead stream consists mainly of hydrogen and some
methane.
After passing through the gas-liquid separator, the overhead stream undergoes pressure
reduction and is passed through a hydrogen purification unit where the gas is purified to
about 90% volume hydrogen and recycled back to the reactor through a
Figure 12: [24]
compressor. Process Flow Diagram for Conversion of lactic acid to propylene glycol.
In a typical separation to recover propylene glycol, the bottom liquid stream is

preheated and12passed
Figure showsto a low
the pressure
process separatorfor
flow diagram where the overhead
the conversion wateracid
of lactic vapour
to is
withdrawn. The liquid
propylene glycol is then passed
in a continuous flowthrough
reactor. aThe
water distillation
process column
consists that removes
a three-phase
water
reactor
from
whichthe liquid
is run as product. Finally,
a trickle bed andthe liquid product
contains from
a fixed bed ofthe water Lactic
catalyst. column is fed
acid to a
is supplied
as a
propylene glycol
water solution. recovery
The column
“unrefined” where
lactate propylene
which glycol is from lignocellulosic biomass
was produced
recovered.
is
mixed with sulphuric acid. The preferable ratio of lactic acid to hydrogen ion solution is
The bottom liquid stream may contain monohydroxide alcohols, especially when
1:1.
the
The resulting solution is mixed in a tank. It is then pressurized and the stream is mixed
starting material consists of starting polyols produced in sugar conversion reactions.
with
Hence,
hydrogen from the hydrogen pre-saturator before being fed to the reactor. The
in an optional step, the bottom liquid stream is passed to an alcohol separation column
hydrogen is
at
optionally passed through a pre-saturator before mixing with the feed stream solution.
about atmosphere pressure where monohydroxide alcohols are removed before passing
The
to low
31
32
pressure separator. In some cases, the bottom liquid stream may need to be
demineralized
especially when the feedstock is a fermentate where lactate salt has been converted to
lactic
acid by sulphuric acid. Thus, in an optional step, the bottom liquid stream is
demineralized
with cationic resins to get rid of ions before being supplied to low pressure separator or
[26]
alcohol separation column.
33
2.2 Comparison between Process Alternatives
Table 2: Comparison table between 3 process alternatives
Hydrogenation of biomass derived lactic

Alternative Production of Propylene Glycol from Hydrogenolysis of glycerol to propylene
acid to propylene glycol over a carbon-
glycerol in Escherichia coliglycol using Cu-ZnO catalyst
supported
Green Chemistry ruthenium catalyst
and Sustainability
Raw Material  Crude Glycerol[16]  Pure glycerol[19]  Biomass derived lactic acid[23]
 Available abundantly as by-
Raw Material product from biodiesel  Available abundantly as biomass
 Highly available
Availability production waste is abundant
Inoculation of culture medium
 needed.[16]  Purification of biomass derived
Pre-treatment  N/A
lactic acid needed.
Reaction
Reactor  Batch[17]  Continuous  Continuous

Operating  Temperature : 30 - 42°C  Temperature: 200°C  Temperature: 300°C
Condition Pressure : 1 Bar[16]  Pressure:4.2MPa[20]  Pressure: 5.3 MPa[24]
Microorganism Escherichia Coli (E. coli)  N/A  N/A
  
Catalyst N/A Cu-ZnO Ruthenium
  
Ethanol,Lactate,Acetate, Ethylene glycol, Water, Ethylene glycol, Water, Acetol,

Succinate[16] Methanol[19][20] Acetol, Methanol, Formic acid[23][24]
By Product N/A 93.40%[40] 80.00%[23]
96 hours[17] Few minutes[19][20] Few minutes[24]
Selectivity   
Retention time   
34
Purity of 
Propylene Glycol N/A (Depends on separation
method)
Yield of Propylene   
21.30%[16] 80.00%[40] 74.00%
Glycol
Energy Consumption
 High energy consumption: For
Energy  Low energy consumption: For  High energy consumption: The pre-treatment and purification
consumption for production of propylene glycol. process takes place at high of
reaction to  High energy consumption: For temperature. lactic acid feedstock and
occurred inoculation of culture medium. process
occurs at high temperature and
pressure
Flexibility and Controllability
 Temperature flexibility: The
 Temperature flexibility: No  Temperature flexibility: No reaction is carried out at a
temperature flexibility as the temperature flexibility as the temperature preferably between
process takes place at specific process about 150 to 350° C.[24]
temperature. High temperature takes place at specific temperature  Pressure flexibility: The hydrogen
will cease the microorganism to pressure is increased to a desired
Flexibility and value, usually 3.4 to 16.5 MPa (500
activity  achieve high yield of the desired
controllability of PSIG to 2,400 PSIG), and
Pressure flexibility: The product.
reaction 
pressure must be low. Pressure flexibility: No pressure preferably between 3.4 MPa to
Output flexibility: The process flexibility as the process takes place 10.3
 produced other useful by- at specific pressure to achieve high MPa (500 to 1,500 PSIG) to obtain
products.  yield of the desired product. desired yield of the product. [24]
Output flexibility: The process  Output flexibility: The process
produced other useful by-products. produces other useful by-products.
Environmental Impacts
 Providing alternative route to  Providing alternative route to  Providing alternative route to
Positive impacts sustainable production of sustainable production of propylene sustainable production of
propylene glycol as the raw glycol as the raw material is supplied propylene
glycol as the raw material is
35
material is supplied by by- by by-product of the production of biomass derived.
product of the production of biodiesel.  There are no greenhouse
biodiesel.  There are no greenhouse gasses gasses
 No metallic catalyst used in the being released to environment being released to environment
process. through the process. through the process.
 There are no greenhouse
gasses
being released to environment
through the process.
 Large amountsofchemical
 Large amounts of chemical might
 Fermentation fluid might leak effluents used to control pH (e.g.
leak from the reactor to the
Negative impacts from the bioreactor and cause calcium sulphate) produced and
surrounding and cause water
water pollution. might leak to environment and
pollution.
cause water pollution. [23]
Safety Factors
 Lactic acid is very hazardous in
case of skin contact since it causes
irritation, burning sensation and
 Reactor operate under high blistering. [22]
 Reactor operate under low Under high temperature, lactic acid
temperature that might cause fire 
temperature and pressure that may be combustible.
incident to happen.
Hazard/Health prevent explosion incident. Ruthenium is highly toxic and can
 Reactor operate under high 
Issue  Proper handling of inoculation increase risk of cancer as it is
pressure
process to prevent hazard carcinogenic. [25]
that might cause explosion incident
happened on workers. Reactor operate under high
to happen.
 temperature and pressure that
might
cause fire and explosion incident to
happen.
Waste Management
 Water  Calcium Sulphate
Waste produced   Water 
Culture medium waste Water
36
 Use a shovel to dispose the waste
 and dispose it into a convenient
Wastewater treatment plant waste disposal container.
2.3 Choice of Process
needed to treat the  Keep away the waste from static
wastewater  Wastewater treatment plant discharge since calcium sulphate
Waste handling before releasing
2.4 Current related problemto the of the plant to the environment and
needed is
environment.
society  Culture medium waste must to treat the wastewater before
releasing to theand
environment.
slightly explosive when there is
Propylene glycol is highly
send for treatment before soluble in water, is readily metabolized

presence ofby microbes
heat. [25]
Wastewater treatment plant
and dispose to the environment. needed
other higher[27]
organisms when emancipated to the environment. The biodegradation
to treat the wastewater before
process releasing to the environment.
requires oxygen. Hence, dissolved oxygen concentration in receiving water may be
adversely
affected following a glycol release. Rapid glycol biodegradation may cause a bacterial
biomass
build-up around solid particles.
[30]
Moreover, propylene glycol does not volatilize readily into air from water as it has
high
solubility and low vapour pressure. When released into the atmosphere while at high
temperatures, propylene glycol exists as vapour phase and undergoes photochemical
oxidation
rapidly. The estimated lifetime for this reaction is about 20-32
hours. [30]
Despite the fact that the direct toxicity of propylene glycol is relatively low, it can
affect
aquatic life periphrastically because propylene glycols need oxygen to biodegrade. This
may
increase aquatic toxicity as a consequence of the anaerobic conditions at warm water
conditions.
[30]
37
Propylene glycol which is widely used cosmetic, food and pharmaceutical products
aids
the body to absorb chemicals more effectively. Propylene glycol is not a bioaccumulative
chemical. Hence, under typical dosage or exposure levels, propylene glycol breaks down
in the
body within a time span of 48 hours in individuals with kidneys and liver with good
condition
and does not build-up in the body to create toxicity in the body. Propylene glycol is used
in many
intravenous medications, including Lorazepam; a medication used to treat anxiety and
seizure
treatment. Lorazepam is often prescribed to patients with substantial burns as a
tranquilizer
during treatment or to patients with mental illness. Over a long period of time; in large
doses, it
can develop kidney problems in humans.
[31]
3.0 Critical Assessment of the Process Chosen

3.1 Capacity of Plant
3.1.1 Plant Capacity

The capacity of plant for the production of propylene glycol will be 60,000 tonnes
per
year. The capacity of the plant is decided based on the global demand of the propylene
glycol
38
and the available supply of the feedstock. According to research, the global propylene
glycol
production was around 2.18 million tonnes in 2013. [32] The production of propylene
glycol at
Asia Pacific called for almost 40% of the total capacity.[32] The overall propylene glycol
market
is anticipated to grow around 4.5% per year in the upcoming
years. [33]
Figure 13: Propylene glycol: world capacity broken down by region,

2013[32]
Malaysia is the second largest producer and exporter of palm oil in the world and
accounts for 40% of total palm oil produced annually. Due to the rising of action in
searching for
fossil fuel substitution, the production of biodiesel increases. In 2011, the total biodiesel
[34]
production in Malaysia was 170,000 tonnes. It is estimated that approximately for every
[35]
100kg of biodiesel produced, 10 kg of glycerol generated as a by-product. The refined
glycerol is then supplied to the plant to be used as the raw material for the production of
propylene glycol.
Since production of propylene glycol plant is yet to be found in Malaysia, the

production
of propylene glycol in Malaysia is predicted to contribute 2% of the total capacity of the
global
production. Hence the capacity of the plant is set with a reasonable amount which is
60,000
tonnes per year (2% of 2.93 million tonnes per year global production at 2018). Rough
calculation can be done to justify the feasibility of the
plant.
39
Table 3: Rough calculation for plant capacity for production of propylene
glycol.
Proposed plant capacity = 60,000 tonnes per year
Proposed plant output rate = 7.10 tonnes per hour
Number of working days per year = 352 days (13 days annual
Number of working hours per day maintenance)
Number of working hours per shift= 24 hours
= 12 hours
From table 4, it shows that the proposed plant capacity is feasible when the
production
run in 2 shifts per day and each shift is 12 hours working hour. The number of working
days per
year is 352 days excluding 13 days annual
maintenance.
3.1.2 Location of the designed plant
The location of the plant is important and must fulfil certain requirement before
being
established. Those criteria including the availability and accessibility of the raw material,
logistics and transportation, utilities supply, environmental considerations and also
product
output marketing. Tanjung Langsat Industrial Area is located near YTL power generation
stations and surrounded by all the utilities such as water supply, sewage management
system and
port facilities. There are no residential areas within 2 km radius from the plant and this
will not
affect human health. After deep consideration, the location of the plant for the
production of
propylene glycol will be established at Tanjung Langsat Industrial Area,
Johor.
Plant Location
Figure 14: Location of the designed plant
40
Table
The State 4: Palm oil of
Government plantation
Johor setarea in Malaysia
up centre by Johor
such as state State
(2016).Investment
Centre[36]
(JSIC) that facilitates and provides services for investor to invest in the board sector of
Palm oil plantation area in Malaysia by state (2016)
industries.[39] This mayPlantation
contribute areaPercentage of totalPercentage
for the production of state
plant future development. Besides,
State the (hectares)plantation area (%)area (%)
utilities supply such as 1electricity supply which provided by Tenaga Nasional Berhad
551 71427.021.1
(TNB)Sabah 1 506 76926.312.1
whileSarawak
the water supply which provided by the Syarikat Air Johor Berhad (SAJ) are readily
745 63013.038.8
Johor 732 05212.820.3
available at Tanjung Langsat Industrial
Pahang 397 9086.918.9
Area.
Perak 178 transportation,
9583.126.8
NegeriFor Sembilan
the logistics and Tanjung Langsat Industrial area is
approximately 171
2.1 9433.013.2
Terengganu
km away from the Tanjung155 Langsat
4582.710.3
Port (TLP). The TLP is a port that provide accessibility
to Kelantan 138 8312.417.1
Selangor
the centre of distribution87for7861.533.7
the finished goods from the plant. The finished goods can be
easilyKedah 56 1491.013.5
distributed
Melakato all parts of14 Malaysia and event export to other
countries. 1350.29.2
Penang 6520.00.8
3.1.3 Complete
Perlis Process Description
The chosen process for the production of propylene glycol is the hydrogenolysis of
glycerol to propylene glycol using Cu-ZnO catalyst. The production plant using the
process
mainlyAccording
involves dehydration,
to the data, hydrogenation,
the state of Johor vapor-liquid
comprisedseparation
of 745,630and distillation.
hectares of oil The
palm
process
plantationusing
area. refined
38.8%glycerol as raw
of the state material
land of the
are being production.
occupied Hence,
as the no plantation
oil palm pre-
treatment
area. Due to of raw
material neededoftooilbe
the abundance carried
palm out. Thecompany
plantation, raw material
that can be obtained
process directly from the
and manufacture
supplier.
oleochemical can
The process
be easily found proposed
in Johor.are discussed
These companyin such as Pacific Oleochemicals Sdn. Bhd. and
detail.
Vance
Bioenergy Sdn. Bhd. refine and supply refined glycerol. According to Vance Bioenergy
I. Dehydration of glycerol
Sdn.
Bhd., the company has two of the largest single standing glycerol refineries in Asia
production
The raw material, glycerol is fed into a packed [37] bed reactor which packed with Cu-
40,000 metric tons of refined glycerol per annum. The refined glycerol is the major raw
ZnO
catalyst. The reactor operated at temperature of 200˚C and pressure of 4.2MPa. The
material
pressure foris the production of propylene glycol plant. The Tanjung Langsat Industrial
Area is
built up by flowing hydrogen gas into the reactor. The glycerol will be dehydrated to
within the vicinity of the companies that supply the refined glycerol. Hence the raw
acetol
material for
(hydroxyacetone) and water will be produced as by-product. The acetol is an
the production plant is readily
intermediate of the
available.
hydrogenolysis process of glycerol to form propylene
glycol. As Johor state has abundant of food manufacturing companies which have larger
II. Hydrogenation of Acetol
production such as Kinos Food Industries (M) Sdn. Bhd., Bumi Hijau Food Industries Sdn.
Bhd.
and Frezfruta
The acetol Food inIndustries
the packed Sdn.
bedBhd., theare
reactor finished goods ofundergoes
then quickly the production of
hydrogenation in
propylene
the
glycol
reactor.plant
The can be suppliedprocess
hydrogenation to the companies.
is catalysedThe by propylene
the Cu-ZnO glycol is often
catalyst in theused to
reactor. As
maintain
the the
moisture
dehydration in prepared
of glycerol foods
and and also in foodof acetol occurred in the same reactor, the
hydrogenation
colouring.
operating [38]
temperature and pressure of the reactor is the same which is 200˚C and 4.2MPa. The
hydrogen
gas that used to build up the pressure in the reactor are now acted as the source of
hydrogen atom
41
42
to the hydrogenation of acetol. The acetol molecules reacted with the hydrogen gas to
form
propylene glycol.
A mixture of unreacted glycerol, hydrogen gas, methanol, ethylene glycol,

propylene
glycol, acetol and water are formed as the product stream. The pressure and
temperature of the
product stream is adjusted before sending it to vapor-liquid
separator.
III. Vapor-Liquid separation
The product mixture from reactor is feed into the flash drum to separate the vapor
and
liquid in the product mixture. The flash drum with operating temperature of 336˚C and
operating
pressure of 40 bar. The flash drum is to separate the unreacted hydrogen gas from the
product
mixture from the reactor. The leftover product mixture then transfers to a series of
distillation
columns.
IV. Purification of propylene glycol
The product mixture from the flash drum undergoes a series of distillation
columns to
purify out the propylene glycol with purity of >98.0wt%. Other by-product such as
ethylene
glycol, methanol, acetol, water and unreacted glycerol are separated out from the
product
mixture through the distillation
columns.
3.2 Process Chemistry, Reactions, Kinetics, Thermodynamics Data & Other Physical
and
Chemical Properties Data
3.2.1 Process Chemistry

The production of Propylene Glycol can be achieved through a two-step
mechanism for
hydrogenolysis of glycerol to propylene glycol using Cu-ZnO catalysts in continuous
reactor.
The glycerol is first undergoes dehydration to form intermediate acetol. The acetol
produced is
then undergoes hydrogenation to form propylene glycol. In the reaction, by-products
such as
ethylene glycol, methanol and water are produced. The reaction mechanism is discussed
as
following. The main steps to produce Propylene
Glycol:
I. Dehydration of glycerol to acetol
Glycerol and Cu-ZnO catalyst are fed into the reactor which operating
temperature is
200℃.. The catalyst will be packed in the reactor and catalysed the dehydration of
glycerol.
43
Large amount of hydrogen gas will be fed into the reactor to build up the operating
pressure to
4.2MPa. The glycerol will be dehydrated to produce acetol and water in this
reaction.
CH2OH-CHOH-CH2OH (l) → CH2OH-CO-CH3 (l) + H2O (l)
II. Hydrogenation of acetol to propylene glycol
In the same reactor, the acetol produced from the dehydration of glycerol will
undergoes
hydrogenation to form propylene glycol. The acetol will react with hydrogen to form
propylene
glycol. The reactor operated under same operating temperature and pressure which are
200˚C
and 4.2MPa. Some of the unreacted glycerol will undergoes hydrogenation to form
ethylene
glycol and methanol. The ethylene glycol and methanol are the by-product of the
process.
CH2OH-CO-CH3 (l) + H2 (g) → CH2OH-CHOH-CH3 (l)
3.2.2 Reactions
Mechanism of hydrogenolysis of glycerol to propylene
glycol
I. Dehydration of glycerol to acetol
II. Hydrogenation of acetol to propylene glycol

Side reaction:
CH2OH-CHOH-CH2OH (l) + H2 (g) → CH2OH-CH2OH (l) + CH3OH (l)
Rate of reaction for the main

process:
-rC3H6O2= k C3H6O2CC3H8O3 Where:
-rC3H8O2 = k C3H8O2C C3H6O2CH2 CC3H8O3 = Concentration of Glycerol
C C3H6O2 = Concentration of Acetol
CH2 = Concentration of Hydrogen
3.2.3 Reaction kinetics

The two-site Langmuir-Hinshelwood kinetics model was proposed by researcher to
[40]
model the glycerol hydrogenolysis The organic molecules will adsorb on one type
reaction. of
44
the active site of the catalyst while the hydrogen will adsorb on the other type of the
active site of
the catalyst. The organic molecules are glycerol, acetol and propylene
glycol.
The θ1 denote the active sites for hydrogen adsorption while θ2 denote the active
sites for
organic molecules adsorption. The bH, bG, bA and bp are the adsorption constants of
hydrogen,
glycerol, acetol and propylene glycol respectively. [1] The rate constants of glycerol
dehydration
to acteol is denoted as k1 while the rate constant of acetol hydrogenation to propylene
glycol is
denoted as k2[40]
. By assuming steady-state condition for the adsorbed intermediates, the
rate
expression for the dehydration of glycerol, r1 and hydrogenation of acetol, r2 can be
derived.
The cG is the molar concentration of glycerol while cA is the molar concentration of

acetol. The cP is the molar concentration of propylene glycol. The PH in the equation is the
hydrogen pressure.[40] Furthermore, the temperature dependence of rate constants and
equilibrium constants are then can be expressed. The activation energy of the reaction is
denoted
as Ei and the adsorption activation energy of species
j. [40]
The kinetic model can be used as the basis for the design of the reactor for the
hydrogenolysis of glycerol to propylene
glycol.
45
3.3 Advantages and Disadvantages of
Process
For designing this plant, we choose Alternative 2 as the main route for the
production of
propylene glycol. This is because we considered the advantages and disadvantages
criteria of this
alternative based on literature review. The criteria are considered in terms of raw
material,
catalyst, reaction, by-product and purification. Raw material is very important when
designing
our plant because it will reflect the yield that we can obtain from the process selected. A
pure
glycerol is chosen as our raw material. Besides, choosing the right type of catalyst is
crucial
since catalyst will affect the conversion and selectivity of the reaction. In addition, the
formation
of by-product in the chosen process also can be sold to other company since most of the
by-
product formed have its own function in industrial applications. Moreover, purification
process
by using distillation column as a unit operation in this process enables us to produce
propylene
glycol with higher purity.
However, there are also some disadvantages for the chosen process. But, the
advantages
outweigh the disadvantages. Thus, the table 8 below shows the criteria that we had
consider for
the production of propylene glycol from
glycerol.
Table 5: Advantages and disadvantage of hydrogenolysis of propylene glycol from
glycerol
No. Aspect AdvantagesDisadvantages
Raw High yield by using highly pure
1. material High cost for high purity glycerol.
glycerol.
The solid catalyst does not mix with
2. Cu: ZnO ratio must be at 1: 1 to
Catalystany reactants or product; thus, no
achieve high selectivity.
catalyst separation is required.
3. Further increase in temperature will
Water content in glycerol will not
cause excessive hydrogenolysis
[62]
Reactionaffect the catalyst. No water
which will increase the production of
4. content is required at feed.
by-product.
The by-product produced such as
ethylene glycol can be selling to other
The methanol is hazardous while the
4. company. Acetol is a good
By-productwastewater needs to be treated before
intermediate which will be use as
discharge or reuse the wastewater.
monomer in polyols manufactured
46
industry.
The unit operation such as distillation
Purification column is needed to produce highly The equipment capital cost is high.
purified product.
3.4 Environmental (disposal of waste, if any), Safety and Health
Concerns
In this propylene glycol production plant, environmental, safety and health
concerns as
well as waste management are the most important aspect. These aspect are important
to be
considered since governments and regulatory agencies have tighten the environmental
regulations recently. Propylene glycol is generally regarded as a safe chemical by U.S.
Food and
Drug Administration (FDA). Hence, there are no major threat to all living and non-living
things
in this environment by the production of this plant. For environmental aspect, proper
waste
management and 3R’s (Reduce, Reuse and Recycle) elements must be considered so
that it does
give a negative impact to the environment. Besides, safety is very crucial in designing a
plant
because human loss and suffering is immeasurable. All the employees must follow the
Standard
Operating Procedures (SOP) of the production plant. Hence, it is important to consider all
these
aspect so that a safe working environment is created and this could help to minimize the
hazard
which can result in illness and injury. The table 9 below shows the environmental, safety
and
health concerns and waste management of the propylene glycol
plant.
Table 6: Environmental, Safety and Health Concerns
Aspect Concern
 There are no greenhouse gases released from the process chosen.

Hence, there is no significant impact to the environment.
 Propylene glycol have been recognized as a safe chemical by U.S.
Food
 and Drug Administration (FDA). Thus, it rarely causes toxic effect.
The water released as by-product from this process is non-toxic
Environmental and

does not affect the environment.
Usage of pure glycerol as a raw material help to reduce the
 dependency
on fossil fuel sources which are not renewable.
 Planting more trees near the chemical plant area to ensure that
ozone
 level can be reduced.
High temperature is required for this reaction. Due to this, well-
Usage of equipment
ventilated which
area will be fixedproduces
to make less noise.
the environment cooler. The
employees will be provided personal protective equipment.
Safety and  Propylene glycol have minor exposure of hazard to human health;
Health Inhalation: May cause respiratory tract infection
Concerns Ingestion: May cause nausea and vomiting.
Skin Contact: Minor allergic reactions may occur.
Eye Contact: Slight transient injury.
47
3.6 Projected Demands/Supply
Due to allfor Next
this 10 Years
hazard, the plant will be equipped with eye wash
facility,
The Dow Chemical safety showerand
Company andLyondellBasell
the employeesIndustries
will be given
are personal
the most protective
influential
equipment.
players in the propylene glycol
Plant industry
manager willwith
taketheir propylene-oxide
in charge of educating based capacity
the employees
accounting for regarding
approximately 29% and 15% of world capacity. There are Dow plants in the United
States,  nature of chemical exposed and how to conduct first aid measures
western Europe, Brazil, inAustralia and Thailand and a new joint venture in Saudi Arabia
while case of any emergency.
there a LyondellBasell plants in United States and Western
Glycerol used as raw material in this process is flammable. It may
Europe. [63]
be
The most significant end useatofhigh
 combustible propylene glycol is
temperature. unsaturated
Hence, polyester
appropriate resins;
firefighting
mainly Hydrogen
equipmentgas andused in thissupply
firewater process
willisbe
lowprepared.
pressure Employees
and it will bemust
in China and other developing
recycled
wear countries.
back to the Instream.
2016, this segment has contributed almost
41% of  By-product waste such as methanol generated should be handled
Waste
consumption personal
in the major protective
worldandregions. equipment
The demand throughout
ofcompanies.
propylene the plantisoperation.
glycol mostly due
properly can be sold to other
Management
to the
regional construction Water which
 industry is produced
trends as waste
and the overall canof
health belocal
dispose of easilyItsince
economies. is it
expected that is a
the propylene glycol market
benignwill rate at a rate of 3% annually for this segment.
product.
According to the
forecast, it is expected that high growth rates are to occur in China, Asia and Central and
Eastern
3.5 Similar Plant with Plant Capacity and Total Capital Investment
Europe.
Currently, there are no propylene glycol plant available in Malaysia. But,
Propylene
productionglycol
of is also used as functional fluids, polyurethanes, paints and
Propylene Glycol is active in international regions such as Texas, Germany, Japan,
coatings
which contribute about 30% of usage in the major world regions in 2016. For this
Singapore
and manythe
segment, more. Propylene glycol is a colorless and odorless liquid and it does not cause
growth
major rate is expected to grow about 2.0%
threat to human health and environment. Because of this unique properties, propylene
annually.
glycol is
used inAlthough
a varietyonly for a small percentage,
of applications in industrial the antifreeze
scale. marketIndustries
LyondellBasell which comprises
N.V is a of
engine
coolants and de-icing
multinational chemicalfluids. Propylene
company which glycol is alsoproducer
is a leading used in North Americaglycol
of propylene and Western
and it is
Europe
as a solvent for in
headquartered liquid
Houston, Texas. High quality of propylene glycol are being produced by
detergent
this
company to meet the demand of this product. The capacity of their plant is 250,000
Other additional minor uses of propylene glycol display differing degrees of
tonnes per
growth.
year and In
their total capital investment to build the plant is 20,000,000 USD. Besides,
the United States, the markets with the most influential growth prospect are paints and
Dow
coatings,
Chemical Company is also another plant that produces propylene glycol at its Stade
functional fluids, and personal care products. In Western Europe, the growth prospect is
plant in
Germany by 280,000 tonnes per year with a total capital investment of more than
promising for food, personal care, and pharmaceutical
24,000,000
usage.
USD.
The demand is greatly affected by the current economy. For instance, the
utilization
Table 7: of
Similar Plant with Plant Capacity and Total Capital Investment
propylene glycol for the production of unsaturated polyester resins dwindled by 22% per
year in Capacity (tonne/ Total Investment
the United
Company States and 7% in Western
Plant LocationEurope as a consequence of the depreciation in the
year) Cost (USD)
construction
Dow Chemical and industrial markets during 2008-
2009. Stade, Germany. 280,000 24,750,000 USD
Company
LyondellBasell
Industries N.V Houston, Texas 250,000 20,000,000 USD
48
49
According to research, it is reported that the global propylene glycol production
was
around 2.18 million in 2013 and the overall propylene glycol market is expected to grow
at a rate
of 4.5% per year in the forecast period.
[64]
Figure 15: Global Propylene Glycol Market Forecast (2018-2018)
4.0 Process Synthesis Structure and Analysis
4.1 Input-Output Structure with Feed and Specifications, Price of all product, By-product
and Raw Materials.
4.1.1 Input-Output Structure with Feed and Specifications
The input-output structure shows the flow of the feedstock into the unit operations
in the
production plant. It also shows the products flow in the production plant and also the
operating
details of the unit
operations.
50
Table 8: Input-Output Structure.
Input Operation Output
51
Operating details of the unit
operation
Feed Product
Packed bed Reactor Unreacted Glycerol
Glycerol (Cu-ZnO catalyst) Unreacted Hydrogen
Hydrogen 200˚C , 4.2MPa Propylene Glycol
Ethylene Glycol
Methanol
Water
The pH adjusted glycerol is then feed into the packed bed reactor which packed
with Cu-
ZnO as the catalyst. Excess hydrogen gas is supply into the reactor. The reactor
operates with
200˚C and 4.2MPa. This is because the high operating temperature will favour the
adsorption
and transformation of the reaction intermediates and hence increases the propylene
glycol
selectivity.[19][20] The high operating pressure is built up by feeding hydrogen gas. The
fresh Cu-
ZnO catalyst will be pre-reduced by the hydrogen stream to avoid the water effects on
the
aggregation of Cu particles in situ formed in the reaction solution. [19] The product
produced are
the propylene glycol, ethylene glycol, methanol and water. The unreacted glycerol and
hydrogen
gas are being discharged together with the product
stream.
Feed Product
Unreacted Glycerol Flash Drum Unreacted Glycerol
Unreacted Hydrogen 336˚C, 40 Bar Propylene Glycol
Propylene Glycol Ethylene Glycol
Ethylene Glycol Methanol
Methanol Water
Water
Unreacted Hydrogen
The effluent of the packed bed reactor which consist of unreacted glycerol,
unreacted
hydrogen, propylene glycol, ethylene glycol, methanol and water are then fed into flash
drum.
The flash drum is used to separate the liquid mixture and the unreacted hydrogen gas at
operating
temperature of 336˚C and 40 bar. Before selecting the operating condition, the phase
diagram of
52
every components in the product mixture are studied. [50][41][54][41][56][58][49] At this
operating
condition, only hydrogen remain in gas phase while other components are in liquid
phase. The
effluent product mixture of the flash drum is then left with unreacted glycerol, propylene
glycol,
methanol and water.
Feed Product
Unreacted Glycerol Distillation Column 1 Unreacted Glycerol
Propylene Glycol 147˚C, 1 bar Propylene Glycol
Ethylene Glycol Ethylene Glycol
Methanol
Water
Methanol
Water
Acetol
The liquid mixture from flash drum is then fed into distillation column that operate
at
147˚C and 1 bar. At 1 bar, the boiling point of the methanol, water and acetol are lower
than 147
˚C.[56][50][49] This is to separate out methanol and water from the liquid mixture. The
distillate that
consist methanol and water are then transfer to another distillation column for further
separation.
Feed Product
Unreacted Glycerol Distillation Column Propylene Glycol
2
Propylene Glycol 198˚C, 1 bar
Ethylene Glycol
Ethylene Glycol
Unreacted Glycerol
The liquid mixture with unreacted glycerol, propylene glycol and ethylene glycol is
then
fed into distillation column that operate at 198˚C and 1 bar. At 1 bar, the boiling point of
the
propylene glycol and ethylene glycol are lower than198˚C.[59][41] The unreacted glycerol
is
53
separated out from the mixture as bottom product. The unreacted glycerol is collected
and
transferred to company that able to refine
glycerol.
Feed Product
Propylene Glycol Distillation Column Propylene Glycol
3
Ethylene Glycol
189˚C, 1 bar
Ethylene Glycol
The mixture of propylene glycol and ethylene glycol will not form azeotrope. [65]
The
propylene glycol and ethylene glycol mixture is fed into distillation column that operate
at 189˚C
and 1 bar. At 1 bar, the boiling point of propylene glycol is lower than189˚C.[59]
Separation of
the propylene glycol from ethylene glycol take place and the propylene glycol with lower
boiling
point will be collected as the
distillate.
4.1.2 Feed and product
specification
The feed and product specification shows the details of the components
in table.
Table 9: Feed and Product Specification.
Components Phase Specification

Raw Materials
Pure glycerol Liquid >99.7wt%
Hydrogen Gas 99.99%
By Product
Liquid
Ethylene Glycol Liquid >99.5wt%
Methanol Liquid >99.5wt%
Water Product -
Liquid
Propylene Glycol Catalyst >98.0%
Cu:ZnO
Cu-ZnO Solid
1:1
54
4.1.3 Price of all product, by product and raw materials
The price of all raw material, by products and products are stated in the table
below:
Table 10: Price of Raw Materials, By Products and Products
Price Price
Raw Materials
(USD/Metric Tonnes) (RM/Metric Tonnes)
Refined glycerol 950[66] 3800
Hydrogen* 530[84] 2120
Price Price
By Product
Ethylene Glycol 1200[67] 4800
Acetol 1100[68] 4400
[69]
Methanol 1980
495
Water 9.04
2.26
Price
Price
Product
Propylene Glycol 1550[70] 6200
Price Price
Catalyst (USD/Metric Tonnes) (RM/Metric Tonnes)
900[71] 3600
Cu-ZnO
*Hydrogen is sell in compressed
liquid.
Plant Economic Potential
The plant economic potential show the calculation of gross profit margin of the
production plant.
Table 11: Basis and cost calculation for the designed
plant.
BasisPriceTotal Cost
Component
(MT/year)(USD/MT)(USD/year)
Glycerol89118.50950.0084662576.69
hydrogen2000.00530.001060000.00
Acetol750.591100.00825649.97
Propylene Glycol60000.001550.0093000000.00
Ethylene Glycol1414.971200.001697958.29
Methanol730.30495.00361500.80
Water14210.53
* Basis of calculation: Overall yield of 81.5% of propylene glycol which is 60000 MT/year.
No
revenue generated from water as water are not sold out. Catalyst price, plant
construction cost,
operational cost and maintenance cost are
omitted.
55
Estimated Annual Cost of = USD 825649.97/year + USD
93000000.00/year
Products + USD 1697958.29/year + USD
361500.80/year
= USD 95885109.05/year
Estimated Annual Cost of Raw= USD 84662576.69/year + USD

1060000.00/year
Materials
= USD 85722576.69/year
Estimated Annual Gross Profit= USD 95885109.05/year – USD

85722576.69/year
= USD 10162532.37/year
Gross Profit Margin
= 10.60%
The gross profit margin of the production plant is 10.60%. The gross profit margin of the
plant
fall in the range of profit margins of the chemicals sector. The range of the profit margin
in the
chemicals sector is between 9% and 14% and the average profit margin is
approximately 12%.[73
4.2 Destination of Codes and Component Classification, Utilities

This section discusses about destination code and utilities of the
production plant.
4.2.1 Destination of Codes and Component Classification
56
Table 12: Destination of Codes and Component Classification
Component Classification Destination Destination Code

Reactant Heat Exchanger E-101
Reactant Packed bed Reactor R-101
Unreacted reactant Heat Exchanger E-104
Unreacted reactant Flash Drum V-101
Glycerol Unreacted reactant Distillation Column 1 V-201
Unreacted reactant Distillation Column 2 V-301
Unreacted reactant Condenser E-103
Reactant Packed bed Reactor R-101
Reactant Heat Exchanger E-102
Reactant Compressor C-101
Unreacted reactant Heat Exchanger E-104
Unreacted reactant Flash Drum V-101
Hydrogen Unreacted reactant Condenser E-103
Flash Drum V-101
Distillation Column 1 V-201
Reflux Drum V-302
Reflux Drum V-402
Condenser E-103
Heat Exchanger E-104
Reboiler E-203
Condenser E-302
Condenser E-402
Propylene Packed bed reactor R-101
Product Expander D-101
Glycol
Pump P-301
Pump P-401
Flash Drum V-101
Reflux Drum V-302
Packed bed reactor R-101
Expander D-101
Pump P-301
Ethylene
By Product
Glycol
57
Pump P-401
Reboiler E-203
Reboiler E-403
Condenser E-302
Condenser E-103
Flash Drum V-101
Reflux Drum V-201
Acetol By Product
Expander D-101
Flash Drum V-101
Reflux Drum V-202
Condenser E-103
Condenser E-202
Expander D-101
Methanol By Product Flash Drum V-101
Reflux Drum V-202
Condenser E-103
Condenser E-202
Expander D-101
Water By Product
4.2.2 Utilities
Utilities are required by any chemical plant to ensure the processes are carried out
smoothly.
Utilities are neither reactants nor products; they are required for sustaining suitable
conditions
of a manufacturing unit.
The utilities required in the propylene glycol plant

are:
58
i. Electricity
Electricity is the most significant utility for the propylene glycol production
plant
as electricity is needed to run pumps such as P-101, P-301 and P-401. It is
also
used for maintenance and to control the system if the process. The plant also
makes use of many high voltage equipment for production such as V-201, V-
301
and V-401 which operated at high temperature. A backup electricity generator
station which can supply 2000kW is installed for emergency
use.
ii. Water
Water which is a cheap, used in heat exchangers as a coolant due to its good
cooling properties and abundance. Since water is one of the by-products of
the
process, it can be recycled from the plant to the operating equipment. It is
non-
hazardous, thus making it able to be disposed without any further
treatment.
iii. Steam
Steam is used for heating in the process in heat exchanger(E-101, E-102, E-
104,
E-201, E-301, E-401) Steam is also used to heat the incoming glycerol and
hydrogen streams to the reactor, R-101 inlet temperature and the reboiler for
distillation column
5.0 Process Flow Diagram (PFD)
The block diagram, process synthesis flow sheet and process flow diagram give better
picture
on the flow of the production of propylene
glycol.
5.1 Block Diagram
Figure 16: Block Diagram for Production of Propylene Glycol
59
5.2 Process Synthesis Flow Sheet
Figure 17: Process Synthesis Flow Sheet for Production of Propylene Glycol
5.3 Innovation approach of Process Design
i. Water produced is used as Heating Medium
product.
heating
the
office
Hence,
supply.
and
From
The
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isThis
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water
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reused
transfer
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heat
absorb
electricity
renewable
gases.
administration
cell
from
as
system
asunlight and generate electricity which then stored for backup purpose. 60
5.4 Process Flow Diagram (PFD)
6.0 Process Analysis
6.1 Process Description

The main steps to produce propylene glycol is as follows. Firstly,
dehydration
of glycerol to acetol. Glycerol and Cu-ZnO catalyst are fed into the reactor which
operates at 473K and 40 bar. Cu-ZnO serves as a catalyst in this reaction. The
catalyst
will be packed in the reactor and catalyzed the dehydration of glycerol. Large
amount
of hydrogen gas will be fed into the reactor to build up the operating pressure to
40
bar. The glycerol will be dehydrated to produce acetol and water in this
reaction.
Next, hydrogenation of acetol to propylene glycol. Acetol produced from

the
dehydration of glycerol will undergoes hydrogenation to form propylene glycol in
the
reactor. Acetol reacts with hydrogen to form propylene glycol. The reactor
operated
under same operating temperature and pressure which are 473K and 40 bar.
Figure 18: Process Flow Diagram for Production of Propylene Glycol
Some of
the unreacted glycerol will undergo hydrogenation to form ethylene glycol and
61
methanol. Ethylene glycol and methanol are the by-product of the
process.
6.2 Justification of Each Equipment Chosen

For the production of our propylene glycol plant, we have decided to use
stainless steel mostly as the material of construction for our equipment. Stainless
steel
seems to be the more suitable material for the equipment compared to carbon
steel.
The significant properties of stainless steel causes it to be the most important
materials to build the equipment of our
plant.
Stainless steel is a corrosion resistant alloy steels made up of 10.5 % or
more
chromium and other alloying materials. Having chromium in stainless steel is
significant since it produces a thin layer of oxide on the surface of the stainless
steel
which helps to prevent corrosion[87]. A higher amount of chromium gives a higher
amount of resistance to corrosion.
There are many reasons to choose stainless steel as the material of

construction for our equipment because it is corrosion resistance, have high and
low
temperature resistance, good mechanical strength, low cost maintenance and
high
durability and toughness. Our proposed plant has a reaction that occurs at high
temperature. Hence, using stainless steel can help to resist scaling and maintain
high
62
strength at elevated temperatures. These properties will help to conserve our
equipment in the plant and ensure good quality of propylene glycol
produced.
Apart from that, stainless steel is divided into 5 types that are, ferritic,
austenitic, martensitic, duplex and precipitation hardening (PH). In this plant, we
mostly used austenitic type of stainless steel, 304 and 316. These steels are most
common because they are capable of working to a high strength while retaining
its
level of ductility as well as toughness. Eventhough the price of stainless steel are
higher than carbon steel, it requires less maintenance cost. Thus, the cost for
purchasing stainless steel is not a major problem as it benefits us during the
maintenance of the
equipment.
Justification of each equipment chosen in the production of this propylene
glycol plant as well as the operating conditions (temperature and pressure),
properties
of materials, usage, phase involved and number of units are shown in the table
below.
6.2.1 Heat Exchanger
Figure 19 Heat Exchanger [88].
There is a total of 6 heat exchangers are used in the proposed propylene

glycol
production plant. This equipment are used to achieve desired temperature for the
dehydration and hydrogenation process. Heat exchangers are responsible to
transfer
heat from one fluid to another [89]. They can be used as a heating or cooling
equipment. In this process, shell and tube heat exchanger will be chosen because
it of
its flexibility in design that allow to be used for wide range of temperature and
pressure. Besides, shell and tube heat exchanger are widely and most commonly
used [89]
heat exchange equipment . Two fluids of different temperature flows through the
63
heat exchanger where one flow through the tube wall and another from tube side
to
shell side. All the heat exchanger which are required for this plant must undergo
consistent maintenance and cleaning to prevent tubes fouling. The heat
exchanger is
placed in horizontal position so that the coils from can be easily drawn out for
cleaning process. This will help to reduce the maintenance cost as well as save
space
in the plant.
Table 13 Justification on the Heat Exchanger and Material of Construction
64
65
66
6.2.2 Reboiler
Figure 20: Reboiler [90].
There are reboilers used in this plant since we have distillation columns. A
kettle type reboiler are used because they are very reliable and easy to maintain.
[90]
Reboiler is used to provide heat at the bottom of industrial distillation column .
Liquid from the distillation column are passed into the shell consist of horizontal
tube
bundle where boiling takes place outside of the bundle. Any vapor produced are
passed back to the column and the liquid by-product drops to the bottom of the
kettle
reboiler. Steam will flow through the tube bundle and exits as condensate while
the [91]
liquid from the bottom of the tower flows through the shell side . Moreover, the
separation efficiency of this reboiler approaches one theoretical stage and it very
stable in operation. This is very significant as its role as a reboiler at distillation
column
Table 14 Justification on the Reboiler and Material Construction
67
68
6.2.3 Compressor
Figure 21: Compressor [92].
A compressor is used in this plant to increase the pressure of gas by

reducing
volume [93]. In propylene glycol plant, hydrogen gas (feedstock) are compressed
from
1 bar to 40 bar before it enters the packed-bed reactor. Air compressor are used
because it is safe, flexible, and ease of
maintenance.
69
Table 15 Justification on the Compressor and Material Construction
6.2.4 Distillation column
Figure 22: Basic distillation column that used in industry [94].
Distillation is one of the separation process that commonly used in

chemical
plant. The distillation operations that are carried out in columns which is
cylindrical
vessel with large height to diameter rations are often used to separate
components in
chemical plant [95]. In a distillation column, the liquid enters at the top as reflux
and
somewhere along the column as feed while the ascending vapor that enters the
70
column from bottom. The main purpose of distillation equipment is to establish
an
intimate contact between ascending vapor and descending liquid and hence the
mass
transfer occurs [95]. In the production of propylene glycol from glycerol, the
distillation column is used to separate the propylene glycol from other by-
products.
The figure 4 show the basic distillation column that used in
industry.
Table 16 Justification on the Distillation Column and Material Construction
71
72
6.2.5 Packed Bed Reactor
Figure 23: Basic Packed Bed Reactor that used in industry [97].
Packed bed reactor is one of the most common reactors used in industry
due to
their high conversion rate per catalyst weight compared to other catalytic
reactors [98].
Multiphase reactions such as three-phase reaction which gas and liquid phases in
contacted with solid catalyst can be operated in packed bed reactor. The solid
catalyst
is packed in the reactor while the raw material is fed into the reactor. In the
production of propylene glycol, the hydrogenolysis of glycerol involved 2 phases
of
raw material which the glycerol is in liquid phase and the hydrogen is in gas
phase.
The solid Cu-ZnO catalyst is packed in the reactor. The figure 5 shows the basic
packed bed reactor that used in
industry.
73
Table 17 Justification on the Packed Bed Reactor and Material Construction
74
6.2.6 Pumps
Figure 24: Pump [103].
In this plant, there are 4 pumps in total that we use to transfer fluids. The
type
of pump that be used in this plant is centrifugal pump. Centrifugal pumps are the
most
common type of pump being used in industry as they are compact, inexpensive,
[104]
robust, and available in a wide range of . A shaft connects the impeller
materials
to a power source such as an electric motor or steam turbine, which causes the
impeller to rotate at high speed. The motor in the casing will act on the liquid to
produce high velocity head that will converted to pressure when the liquid leaves
the [105]
pump . The design is less expensive and more suitable to use with impeller of
different size. This equipment needs to be sealed to avoid leakage. It also needed
where a rotating shaft passes through the wall of a vessel or casing of a pump.
We use
mechanical seal as a smooth metal surface is slide on each other. Centrifugal
pump is [105]
widely being use as it is simple in construction . Figure 7 shows centrifugal pump
that usually being used in
industry.
75
Table 18 Justification on the Centrifugal Pump and Material Construction
76
6.2.7 Reflux drum
Figure 25: Reflux drum [108].
In this plant, reflux drum is use in distillation column. Liquid drum is placed
horizontally at the distillation column and its role is to hold he condensed liquid
coming from condenser [105]. Reflux drum is also known as receiver (from
condenser).
Some of the liquid will be recycle back to the top of distillation column and some
may
leave as condensate. However, the amount of reflux that will return to the
distillation
column is one of our main concern. Therefore, the control of drum level is
important
to avoid unwanted consequence during operating the reflux drum such as
product
degradation or expensive maintenance. Figure 7 shows the illustration of reflux
drum.
77
Table 19 Justification on the Reflux Drum and Material Construction
78
6.2.8 Flash Drum
Figure 26: Flash drum [109].
In chemical plant, flash drum is one of the simplest operation processes

that
used to separate liquid and vapor phase. At certain temperature and pressure,
several
components in the liquid streams is partially vaporized which resulted two phase
occurs in a flash drum. The vapor generated from the flash drum will condensed
as a
less volatile component which enriched in liquid phase while more volatile
[110]
components enriched in vapor phase . A vertical flash drum was chosen as the
liquid and vapor mixture is separated by gravity force. This is because the liquid
components fall to the bottom of flash drum while the vapor components exit at
the
top of the flash drum. Besides, vertical flash drum is more economical compared
to
79
horizontal flash drum[111]. Figure 8 shows the flash drum that usually used in the
chemical plant industry.
Table 20 Justification on the Flash Drum and Material Construction
304
6.2.9 Condenser
Figure 27: Condenser [113].
80
In the distillation column, the vapor generated at the top of distillation
column
returned as liquid form into the column because the condenser will remove heat
to [114]
convert from vapor phase to liquid phase by cooling it down . The condenser is
designed to be in horizontal orientation because it gives higher heat transfer rate
between the fluids. Therefore, condenser with horizontal orientation is chosen in
the
chemical plant production [115].
Table 21 Justification on the Condenser and Material Construction
81
82
6.2.10 Expander
Figure 28: Expander [116].
An expander can help to expand a high pressure gas to a lower pressure

gas.
Expander converts kinetic energy to electrical energy by using turbines and
electrical
generators. The high pressure gas will flow into the expander and capable of
spinning
the turbine. Hence, work will be produced to drive the compressor or generator
[116].
83
Table 22 Justification on the Expander and Material Construction
84
6.2.11 Number of Equipment Units Required
Table 23 Number of equipment units required
Unit No of units required Unit Code

Pump 3 P-101, P-301,P-401
Heat Exchanger 6 E-101,E-102,E-104,E-201,E-301,E-401
Compressor 1 C-101
Packed bed reactor 1 R-101
Condenser 4 E-103,E-202,E-302,E-402
Flash Drum 1 V-101
Expander 1 D-101
Distillation Column 3 V-201,V-301,V-401
Reflux Drum 3 V-202,V-302,V-402
Reboiler 3 E-203,E-303,E-403
6.3 Code Justification
Code C: are used for compressor in our

plant.
Code D: This code are used for expander in our
plant.
Code E:All the heat exchangers, condenser and reboiler in our plant use this equipment
code.
Code P: All the pump present in our plant use this
code.
Code R: The reactor in the plant was coded as
R.
Code V: This code represents the column which is flash drum, reflux drum and
distillation
column.
6.4 Economical Potential
6.4.1 Prices of Raw Material and Product

Economics potential is the total capacity to produce goods and services.
From
the economics potential calculation, the capability of the production plant to give
positive profit to the company is identified. The table below shows the prices for
the
raw materials and products.
Table 24 Prices of Raw Materials and Product
Components Price (RM/ton)
Reactants Refined glycerol 3500
Hydrogen 2120
Product Propylene glycol 6200
85
6.4.2 Input and Output Structure without Recycle
Input: Production plant of Output:

propylene glycol
Refined glycerol Propylene
and hydrogen glycol
Figure 29: Input-Output Structure
The input output diagram without recycle stream is shown in the block
diagram above. The production plant of propylene glycol used refined glycerol
and
hydrogen as raw material to produce propylene glycol as the product of the
production plant. Throughout the production plant, the by-products such as
Ethylene
glycol, methanol, water and acetol are produced. However, the amount of by-
products
produced are relatively small when compared to the desired product, propylene
glycol. Hence, the calculation excluded the small amount of the by-products. The
economics potential of the production plant is calculated
as:
Economic Potential(RM/year) = [Total product(RM/year) + Total by-product(RM/year)] –
Total reactants(RM/year)

Conversion without Recycle Stream
Propylene
Glycerol Hydrogen Economics
Conversion glycol Total reactant Total product
feed feed Potential
(%) produced (RM/year) (RM/year)
(ton/year) (ton/year) (RM/hr)
(ton/year)
10.00 92759.04 10137.60 7349.76 346148352.00 45568512.00 -300579840.00
20.00 92759.04 10137.60 14699.52 346148352.00 91137024.00 -255011328.00
30.00 92759.04 10137.60 22049.28 346148352.00 136705536.00 -209442816.00
40.00 92759.04 10137.60 29399.04 346148352.00 182274048.00 -163874304.00
50.00 92759.04 10137.60 36833.28 346148352.00 228366336.00 -117782016.00
60.00 92759.04 10137.60 44183.04 346148352.00 273934848.00 -72213504.00
70.00 92759.04 10137.60 51532.80 346148352.00 319503360.00 -26644992.00
80.00 92759.04 10137.60 58882.56 346148352.00 365071872.00 18923520.00
81.50 92759.04 10137.60 60000.23 346148352.00 372001428.48 25853076.48
86
90.00 92759.04 10137.60 66232.32 346148352.00 410640384.00 64492032.00
100.00 92759.04 10137.60 73582.08 346148352.00 456208896.00 110060544.00
Figure 30: Graph of Economics Potential of Production Plant of Propylene Glycol

against Conversion
The economics potential calculation is done under condition which no

recycle
stream in the production plant. As shown in figure, the economics potential of the
production plant increased as the conversion increased. The economics potential
of
the plant are negative value when the conversion is below 75.0%. That means
the total
cost of the reactants will be higher than the total profit from the end product. The
production plant will have financial deficit if the conversion is below
75.0%.
The designed production plant of propylene glycol aimed to have
production
capacity of 60000 ton/year. From the data in table, when the conversion is
81.5%, the
amount of propylene glycol produced fulfilled the targeted production capacity
and
the economics potential of the plant is RM25853076.48/year. Hence, the
production
plant did not deficit when the conversion is
81.5%.
In order to increase the economics potential of the production plant of
propylene glycol, recycle stream of hydrogen gas can be introduced. The
economics
potential of the production plant at different recycle percentages are calculated
and
tabulated in table.
87
From figure
Table 26 Economics 31, as the
Potential recycle percentage
of Production increased,
Plant of Propylene the economics
Glycol at Different
potentialRecycle Percentages
of the production plant increased. In the production of propylene glycol, the
reactions
required hydrogen gas as rawPropylene
material and it is feed in excess amount into the
reactor.
RecycleUnreacted
Glycerol Hydrogen
hydrogen glycol
gas will be separated from the products and recycled Economics
back
into
Percentage feed However,
the reactor. feed it is impossible
produced Total reactant
to recycle Total
100.0% of the product
hydrogen Potential
gas,
some of
(%) (ton/year)
the hydrogen gas (ton/year)
will be purge(ton/year)
out from the(RM/year)
plant as purge(RM/year) (RM/hr)
gas. The recycle
0.00 92759.04
percentage 10137.60
is chose 60000.23
to be 40.0% 346148352.00
as the recycle 372001428.48
percentage 25853076.48
shall not more than
50.0%.
10.00 This is92759.04 9299.80
because the 60000.23
purity of the 344372216.00
recycle hydrogen 372001428.48
gas is not 27629212.48
that high and might
affect
20.00 92759.04
the reaction 8448.02
in reactor. Hence,60000.23
60.0% of the342566451.72
hydrogen gas372001428.48 29434976.76
is purge out from the
plant.
30.00 92759.04 7596.25 60000.23 340760681.93 372001428.48 31240746.55
From the table 26, the economics potential of the plant increased from
40.00 92759.04 6744.47 60000.23 338954912.14 372001428.48 33046516.34
RM25853076.48/year to RM33046516.34/year when 40.0% of the hydrogen gas
50.00 92759.04 5892.69 60000.23 337149142.36 372001428.48 34852286.12
recycled. The economics potential of the production plant increased when recycle
60.00 92759.04 5040.91 60000.23 335343372.57 372001428.48 36658055.91
stream is introduced.
70.00 92759.04 4189.13 60000.23 333537602.78 372001428.48 38463825.70
80.00 92759.04 3337.36 60000.23 331731832.99 372001428.48 40269595.49
90.00 92759.04 2485.58 60000.23 329926063.21 372001428.48 42075365.27
100.00 92759.04 1633.80 60000.23 328120293.42 372001428.48 43881135.06
Figure 31: Graph of Economics Potential of Production Plant of Propylene Glycol

against Recycle Percentage.
88
89
6.5 Separation Operations Used in Production in Production of Propylene Glycol
Table 27 Separation of Operations Used in the Production
Operating Condition
Separation Type of
Code Justification
Unit Phase Temperature Pressure
(K) (bar)
Based on the phase of the product, separation process occurs in the

flash
Liquid drum. The vapor is taken off overhead, while the liquid drains
Flash to the bottom of the drum, where it is withdrawn. This is because the
V-101 and 150 20
Drum vapor is less dense than liquid product. Unreacted hydrogen is taken
vapor
off
as overhead as it is more volatile while unreacted glycerol,
propylene
glycol, ethylene glycol, methanol, acetol and water drains to the
bottom
Distillation
of the drum, column
whereisit used to separate unreacted glycerol, propylene
is withdrawn.
glycol and ethylene glycol from methanol, acetol and water.
Methanol,
acetol and water which is produced as distillate is sent to
wastewater
treatment. Since methanol, acetol and water is lighter than
Liquid unreacted
Distillation
V-201 and 374.38 1 glycerol, propylene glycol and ethylene glycol; the light key
Column 1
vapor components
will evaporate and vaporize as overhead products. The light key
components will then leave from the top of the distillation column.
The
heavy key components will be withdrawn as bottom product.
Products
with boiling point higher than 374.38 K (unreacted glycerol,
propylene
Liquid glycol, ethylene glycol) will leave distillation column as bottom key
Distillation V-301 461.35 1
Distillation
components. column is used
A kettle to separate
reboiler unreacted
is used where glycerol
the bottom keyfrom
and
components
from the distillation column will be boiled to produce vapor, which is 90
then returned to the distillation column to enable the distillation
separation.
Column 2 vapor propylene glycol and ethylene glycol. Liquid mixture of unreacted
glycerol, propylene glycol and ethylene glycol is fed into the
distillation
column. At 461.35K, propylene glycol and ethylene glycol exists as
vapor phase and exits the distillation column as light key
components.
Unreacted glycerol has boiling point higher than 461.35K so, it
leaves
the distillation column as heavy key component. A kettle reboiler is
used
where the bottom key components from the column will be boiled to
produce vapor,
Distillation which
column is then
is used returned to
to separate the column
propylene to enable
glycol from the
distillation separation.
ethylene
glycol. Liquid mixture of propylene glycol and ethylene glycol is fed
Liquid into the distillation column. At 461.05K, propylene glycol exists as
Distillation vapor phase and exits the distillation column as light key
V-401 and 461.05 1
Column 3 component.
vapor
Ethylene glycol has boiling point higher than 461.05K hence, it
leaves
the distillation column as bottom key component. A kettle reboiler is
used where the bottom key components from the column will be
boiled
to produce vapor, which is then returned to the column to enable the
distillation separation.
91
7.0 Material and Energy Balance
The following section discusses about the mass balance of the process plant
for the
production of propylene glycol.
7.1 Mass Balance Theory

Mass balance is calculation that based on the conservation law of mass which
states that the mass can neither disappear nor be created. Mass balance
calculation is
used to design chemical reactors or equipment in a plant. The calculation can
later be
used to determine the size of the unit operations of the production
plant.
Input = Output + Accumulation
The mass balance is generally based on the equation above. The mass
that
enter a system as inlet must either leave the system as output or accumulate in
the
Components
system to obey the law of conservation of mass. Molecular Weight (ton/kmol)
For non-reactive process, the
Glycerol (C3H8O3) 0.0921
accumulation
Hydrogen (H2) term is equal to zero. The mass flow0.0020 rate, mole flow rate, mass
fraction
Propylene Glycol (C Conversion
3H8O2) 0.0761 Percentage
and mole fraction for each streams are calculated in Microsoft Excel. The
Ethylene Glycol Conversion
(C2H6O2) of Glycerol 0.0621 0.82
molecular
Methanol (CH OH)
Conversion of Acetol
weight of the components that used in the mass balance
3 0.0320 calculation
0.99 are shown in
Acetol production
(C3H6O2Degradation
) capacity of of Glycerol
propylene glycol is assumed 0.0741
to be 7.10
0.03
Table
Water 29
Table (H 28. Forand
assumption
tonne/hr.
2Conversion reactive
O)Selectivityof
Table
of process
condition
reactions
Propylene
28 that
Molecular
that
takes
Glycol
made takes
place
Weight
for place
in the
the in reactor,
of calculation
Components
plant R-101,
0.0180is shown the
0.92 in calculation
Table 29.92
The
7.2 Stream Table
Table 30 Overall Stream Table for Mass Balance (Stream 1-Stream 19)
Stream No. 1 2 3 4 5 6 7 8910 11 12 13 14 15 16 171819
Temperature (deg_C) 30.00 30.00 79.42 200.00 55.66 227.11 200.00 200.00336.00200.00 336.00 336.00 336.00 336.00 259.62 173.49 101.38 101.38 101.38
Pressure (bar) 1.00 1.00 40.00 40.00 40.00 40.00 40.00 40.0040.0040.00 40.00 40.00 40.00 40.00 1.00 1.00 1.001.001.00
Vapor Fraction 0.00 1.00 0.00 0.00 1.00 1.00 1.00 1.001.001.00 0.00 0.00 1.00 1.00 0.00 0.00 1.000.000.00
Mole Flow Rate (kmol/hr)
22.060.0022.06
500.18200.07500.18
Glycerol119.22 0.00 119.22 119.22 0.00 0.00 0.00 93.220.0093.22 22.06 22.06 0.00 0.00 22.06 22.06 0.000.00 0.00
Hydrogen0.00 396.05 0.00 0.00 396.05 596.12 596.12 2.720.002.72 500.18 0.00 500.18 300.11 0.00 0.00 0.000.00 0.00
Propylene Glycol0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.720.002.72 93.22 93.22 0.00 0.00 93.22 93.22 0.030.03 0.01
Ethylene Glycol0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.230.001.23 2.72 2.72 0.00 0.00 2.72 2.72 0.000.00 0.00
Methanol0.00 0.00 0.00 0.00 0.00 0.00 0.00 94.450.0094.45 2.72 2.72 0.00 0.00 2.72 2.72 3.253.25 0.53
Acetol0.00 0.00 0.00 0.00 0.00 0.00 0.00 1.23 1.23 0.00 0.00 1.23 1.23 1.461.46 0.24
Water0.00 0.00 0.00 0.00 0.00 0.00 0.00 94.45 94.45 0.00 0.00 94.45 94.45 112.67 112.67 18.23
Total Mole Flow Rate
(kmol/hr)119.22
Total Mass Flow Rate
(ton/hr)10.98
396.05 119.22 119.22 396.05 596.12 596.12 716.57 200.07 716.57 716.57 216.39 500.18 300.11 216.39 216.39 117.42 117.42 18.99
0.80 10.98 10.98 0.80 1.20 1.20 12.18 0.40 12.18 12.18 11.17 1.01 0.60 11.17 11.17 2.24 2.24 0.36
Table 31 Overall Stream Table for Mass Balance (Stream 20-Stream 41)
20 21 22 23 24 25 26 27 28 29 303132 33 34 35 36 37 38 39 40 41
101.38 194.65 194.65 194.65 269.25 285.00 188.35 188.35 188.35 188.35 262.39188.97188.05 188.05 188.05 188.05 197.44 197.44 197.44 285.45 285.45 285.45
1.00 1.00 1.00 1.00 1.01 1.01 1.00 1.00 1.00 1.00 1.011.011.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00
0.00 0.00 1.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 0.000.001.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 1.00 0.00
0.000.000.00
0.000.000.00
0.00 22.06 0.00 22.06 22.06 22.06 0.00 0.00 0.00 0.00 93.1993.19485.04 0.00 0.00 0.00 0.00 0.00 0.00 27.75 5.69 22.05
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2.722.720.85 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.03 226.44 133.25 93.19 93.19 93.19 104.65 104.65 11.45 93.19 0.000.000.00 485.04 391.86 93.17 0.02 0.00 0.02 0.00 0.00 0.00
0.00 6.61 3.89 2.72 2.72 2.72 3.05 3.05 0.33 2.72 0.000.000.00 0.85 0.69 0.16 2.92 0.37 2.56 0.00 0.00 0.00
2.72 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.23 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
94.45 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
98.42 255.11 137.14 117.97 117.97 117.97 107.70 107.70 11.79 95.91 95.91 95.91 485.89 485.89 392.55 93.34 2.95 0.37 2.58 27.75 5.69 22.05
1.88 19.67 10.38 9.29 9.29 9.29 8.15 8.15 0.89 7.26 7.26 7.26 36.96 36.96 29.86 7.10 0.18 0.02 0.16 2.56 0.52 2.03
93
7.3 Energy Balance Theory
Energy balance the calculation based on the law of conservation of energy

which is the first law of thermodynamics. The first law of thermodynamics states
that
the total energy of an isolated system is constant where the energy cannot be
created
or destroyed while it can be transformed from one form to another. From the
calculation of the energy balance, the heat duty and the power requirement for
the unit
operations can be determined. Then, the energy intensity of the production plant
can
be identified. The equation of energy balance is as
below:
△H = Q - W
where, △H = Enthalpy changes
Q = Heat transfer into the

system
W = Work done on the system
Ideal conditions is assumed for each unit with no shaft work involved. The
enthalpy of each stream is calculated based on specific heat and latent heat of
vaporization when phase change is involved. Theoretically, the specific heat is
affected by pressure. However, in the energy balance calculation, the specific
heat is
assumed to be independent on pressure under ideal
condition.
where, Hv = latent hear of vaporization (Data obtained from

ASPEN)
H(T) = enthalpy at temperature of
T
Cp = Specific heat capacity
The specific heat capacity can be calculated using the constants that is
shown
in Appendix F.30. There is only one equipment involve reactive process which is
the
packed bed reactor, R-101. The heat if formation is used to calculate the overall
enthalpy change.
94
7.4Aspen Simulation
7.4.1 Aspen Flow Sheet
Figure 32: Aspen Flow Sheet for Production of Propylene Glycol
7.4.2 Aspen Simulation Result
Table 32 Energy Balance of Overall Stream Balances (Stream 1-Stream 7)
95
96
7.4.3 Table of comparison between Microsoft Excel Calculation and ASPEN PLUS
Simulation
7.4.3.1 Comparison of Total Mass Flow (ton/hr)
Table 36 Comparison of total mass flow calculated in Microsoft Excel and in ASPEN
Plus Simulation
Overall Mass Flow (ton/hr)

Stream Microsoft ExcelASPEN Plus Error (%)
10.9810.98
1 0.800.80 0.00
2 10.9810.98 0.00
3 10.9810.98 0.00
4 0.800.80 0.00
5 1.201.20 0.00
6 1.201.20 0.00
7 12.1812.18 0.00
8 0.400.40 0.00
9 12.1812.18 0.00
10 12.1812.18 0.00
11.1711.17 0.00
11
1.011.01 0.00
12
0.600.61 0.00
13
11.1711.17 1.64
14 0.00
15 11.1711.17
1.885.59 0.00
16 66.37
20 9.295.59
9.295.59 66.19
23 66.19
24 9.295.59
7.262.79 66.19
25 160.22
7.262.79
29 160.22
7.262.79
30 160.22
7.101.40
31 0.161.40 407.14
35 2.032.79 88.57
38 27.24
41
97
Overall Heat Duty (MJ/hr)
7.4.3.2 Comparison
P-101 of Heat Duty Microsoft
(MJ/hr) ExcelASPEN Plus
E-101 0.0081.70
Table 37 Comparison
C-101 of heat duty calculated
2.052555.80in Microsoft Excel and in ASPEN Plus
MIXING POINT 0.0010378.76
Simulation
E-102 0.000.05
R-101 -0.11-528.29
E-103 -3198.16-5674.10
Unit Operation Error (%)
E-104 -2940.140.00
V-101 5198.678093.00
100.00
SPLITTING POINT 0.00-13878.50
99.92
D-101 0.000.05
100.00
E-201 0.00-0.40
100.00
V-201 -3003.93-2138.60
99.98
V-202 0.003276.50
43.64
E-202 -4510.80N/A
N/A
E-203 -N/A
35.76
P-301 0.00N/A
100.00
E-301 0.000.00
100.00
V-301 454.3590.70
100.00
E-302 0.00-1.79
40.46
V-302 -3690.32N/A
100.00
E-303 -N/A
P-401 0.00N/A
E-401 0.000.00
V-401 -1957.93-123.34 100.00
E-402 0.00125.60 N/A
Simulation. This
V-402
is due to the different-30.64N/A
boundary selection between manual
1487.42
400.93 calculation
Unitcompare
be
Microsoft
in operation
Excel
with
E-403
V-202,
and
Microsoft
in E-202,
ASPEN Excel
E-203,
PLUS
calculation
simulation.
E-302,
12.55N/A
V-302,
because
E-303,
it does
E-402,
not V-402
present
100.00
and
in E-403
ASPENcannot
PLUS
98
3.4.3.3 Justification between Microsoft Excel Calculation and ASPEN Plus
Table 38 Justification table between Microsoft Excel Calculation and ASPEN Plus Simulation
Unit Stream Deviation Justification
P-101 1,3 Heat duty The heat duty calculated using Excel and Simulation in ASPEN
are different. The heat duty calculated using ASPEN is 81.7
MJ/hr while using Excel is 0 MJ/hr. The error was 100%. In excel
calculation, the total energy flow differences between inlet
and
outlet is assumed to be the power required for the pump to
operate. No heat duty is generated or released from the
pump.
Therefore, the heat flow will be different compared to Aspen.
E-101, E-102, E- 3,4,7,6,8,10,10, Heat duty The value of total energy flow in heat exchanger does not
11,15,16,17,18,24,25,26, have
103, E-104, E-201, the same value in Excel calculation and ASPEN Plus. This is
27,30,31,32,33,21,22,23, may
E-202, E-301, E-
39,40,41,36,37,38 be due to the different value of specific heat capacity used in
302, E-401, E-402, Excel calculation and ASPEN Plus. Thus, the heat duty of two
different method also will be different.
E-203, E-303, E-403
C-101 2,5 Heat duty The value of heat duty of this unit operation is different in
Excel
D-101 12,15 calculation and ASPEN Simulation because there was a phase
change involve in the simulation while there is no phase
change
V-101 11,12,13 consideration
Temperature The in Excel
temperature calculation.
of flash drum calculated in Excel are different
with the temperature in ASPEN. This is because, Excel
calculation is assumed no temperature difference among the
inlet
and outlet stream.
V-201 16,17,18,19,20,21,22,23 Heat duty, The reflux ratio of V-201 calculated in Excel is 0.19 while the
99
reflux ratio value of reflux ratio simulates in ASPEN show minimum value
of
0.29. In Excel, the minimum reflux ratio is calculated using the
Underwood’s method while in ASPEN the DWSTU mode is used
to determine the value of reflux ratio. In addition, by using
Excel,
the calculation is based on the vapor pressure. To calculate
the
vapor pressure, the Antoine constant used might be different
in
ASPEN. Therefore, the value of reflux ratio is different. Due to
the difference in reflux ratio, the mass and energy flow of the
distillation column from Excel calculation and ASPEN
simulation
is deviated. The mass flow of stream 20 in ASPEN simulation is
5.59 ton/hr which is higher than value calculated in Excel
which
is 1.88 ton/hr. The error is about 66.37%. The simulation value
is
higher than the value calculated in excel due to the iteration
loop
caused by internal recycle loop of the distillation column.
Therefore, the unit operation placed after V-201 have different
V-301 25,26,27,28,29,39,40,41 Total mass The
valuevalue of reflux
of mass ratio calculated
flow compared in ASPEN
to value is different
calculated from
in Excel. The
flow, Heat imbalanced
the value calculated
of total mass
usingflow
Microsoft
for thisExcel
equipment
which arewill0.68
be carry
and
duty, reflux 0.12
forwardrespectively.
to the nextInunit
Excel, the minimum
operation refluxthe
throughout ratio is
process
ratio which
calculated
using the Underwood’s
are E-203, P-301, E-301,method
V-301, while
E-302,inV-302,
ASPENE-303,
the DWSTU
P-401, E-
401, V-401,
mode is usedE-402,
to determine
V-402, E-403.
the value of reflux ratio. In
addition,
by using Excel, the calculation is based on the vapor pressure.
To
calculate the vapor pressure, the Antoine constant used might
be
V-401 31,32,33,34,35,36,37,38 Total mass The valueinofASPEN.
different reflux ratio calculated
Therefore, in ASPEN
the value is 5.2
of reflux while
ratio is in
flow, Heat Excel is 4.21. In Excel, the minimum reflux ratio is calculated
different.
100
duty, reflux using the Underwood’s method while in ASPEN the DWSTU
ratio mode is used causing inaccurate value of reflux ratio. In
addition,
by using Excel, the calculation is based on the vapor pressure.
To
calculate the vapor pressure, the Antoine constant used might
be
different in ASPEN. Therefore, the value of reflux ratio is
different.
8.0 Utilities
8.1. Utilities Summary
Table 39 Amount of steam required for heating utilities
Heating
Heating Heating Heating
medium
medium inlet medium medium
Unit Code Heating Medium Heat Duty (MJ/hr) outlet
temperature required required
temperature
(K) (ton/hr) (ton/year)
(K)
E-101
Superheated Steam 20.50 523.00 473.00 0.20 1722.88
Heat E-104
Superheated Steam 5203.22 523.00 473.00 51.77 437381.02
Exchanger
E-301 Water 454.88 323.00 303.00 16775.99 141723524.44
E-203
Water 4471.22 523.00 473.00 44.49 375849.83
E-303
Reboiler Water 0.00 323.00 303.00 0.08 656.51
E-403
Water 12.55 323.00 303.00 462.70 3908910.63
101
Table 40 Amount of steam required for cooling utilities
Cooling water Cooling water

Cooling water Cooling water Cooling water
Cooling Duty inlet outlet
Unit Code required required required
(MJ/hr) temperature temperature
(kmol/hr) (ton/hr) (ton/year)
(K) (K)
E-102
0.11 298.00 323.00 0.06 3.32 28088.80
Heat E-201
3006.65 298.00 323.00 1597.70 88686.08 749219983.67
Exchanger
E-401
1957.93 298.00 323.00 1040.42 57752.27 487891159.03
E-103 2940.14 298.00 323.00 1562.36 86724.28 732646719.89

E-202
4510.80 298.00 323.00 2396.99 133053.54 1124036311.67
Condenser
E-302 3690.32 298.00 323.00 1960.99 108852.04 919581992.33
E-402 30.64 298.00 323.00 16.28 903.83 7635585.96
Packed Bed
R-101 3218.97 298.00 323.00 1710.52 94948.77 802127212.30
Reactor
102
8.2 Electricity
Plant Operation: 24 hr/day
Working days: 352 days
Table 41 Electrical energy required for pump, compressor and expander
Electrical Energy
Unit Code Power Required (kW)
(kWh/year)
0.20 1686.26
P-101
558.07 4714571.71
Pump P-301
548.21 4631247.96
P-401
27.35 231027.64
C-101
854.25 7216694.40
Compressor D-101
Expander
8.3 Waste Generation
For our proposed propylene glycol plant, there are solid, liquid and
gaseous
waste produced. All these waste requires proper waste treatment in accordance
with
applicable regional and local laws and regulations. This is to ensure the health
and
safety of the public and environment are protected. Improper waste management
treatment will cause pollution to the environment and give adverse health
effects.
Hence, all the waste produced in this plant must be treated and disposed
according to
rules and regulation of Environmental Quality (Sewage and Industrial Effluents)
Regulations 1979.
8.3.1 Solid Waste Quantity
In production of propylene glycol plant, copper zinc oxide catalyst is

needed
for the dehydration reaction in the reactor where the dehydration process will
take
place on ZnO support meanwhile the hydrogenation of acetol occurs at copper
surface. Hence, the copper zinc oxide, solid waste are required to be disposed
after
being separated from the product in the packed bed
reactor.
CuZnO is toxic by ingestion and may cause irritant to the respiratory
system.
It should be handled with care since it is a hazardous solid and flammable when it
is
kept near ignition sources. Besides, safety glasses or goggles must be provided
to all
103
keptworkers
the away from in the
heatplant
andwhen
sources
handling
of ignition.
the solid
It need
catalyst
to betoplaced
prevent
in an
eye contact.
The
appropriate
catalyst
waste disposal
should container
be sealedaccording
and labelled
to local
properly
regulations.
before disposing.
Besides, acetol
Hence,isthe
a
catalyst
flammable
must besolvent.
organic sent to aInhalation
proper wastewater
of acetol can
treatment
cause nerve
plantdamage
before disposing it to[117]
and possibly a .
secure
coma
landfill. itThe
Hence, need
catalyst
to be waste
treatedmust
before
be releasing
disposed in to accordance
the with federal, state
and
environment.
local environment regulation.
Apart from that, unreacted glycerol and ethylene glycol waste have
benefit
that can
8.3.2 Liquid Waste be used for other purposes. For instance, glycerol is used in food
Quantity
industry as a
solvent and sweetener that may help preserve foods. It is also mainly used in
There are several liquid waste being produced in this plant. The waste
medical
and personal care applications. Meanwhile, ethylene glycol is used as an
generated in the production of propylene glycol plant are methanol, acetol and
antifreeze
water
and coolant in automobile engines. Ethylene glycol also plays an important role
in stream 18, unreacted glycerol in stream 39 whereas ethylene glycol in stream
as
36.
precursor to polyester fibers and resins. Thus, it is important to send the waste to
For production of 36.91 ton/hr propylene glycol, 4.98 ton/hr wastewater is
generated.
waste water treatment plant before disposing
The amount of wastewater generated per year is calculated as
it.
below:
Lastly, the disposal of all these waste products must be in accordance with
applicable regional and local laws and regulations. The product waste must be
kept in
their original container and sealed tightly. All these waste must be managed
properly Table 42 Quantity of waste produced per hour
to conserve and preserve the
environment.
Component Mass Flow rate (ton/hr) Mass Fraction (%)
8.3.3 Gaseous Waste Quantity
Methanol 0.10 0.02
Acetol 0.11 0.022
Water 2.03 the gaseous waste from this
In this propylene glycol plant, 0.41plant is
Glycerol
hydrogen 2.56 0.51
gas. Excess
Ethylene hydrogen is released
Glycol as waste. Hydrogen is used0.036
0.18 in the reaction of
Total 4.98 1
conversion of acetol into propylene glycol and in the degradation of hydrogen
into
methanol and ethylene glycol. The unreacted hydrogen gas will be recycled back
to
the reactor and some of it will be purged out. The purge gas will be the gaseous
waste Hence, 42,071.04 ton of wastewater will be generated in one year when
generated from the plant. Hydrogen gas is highly explosive and it is a flammable
60,000.00 ton of propylene glycol are produced. The wastewater will be sent to
the
high-pressure gas. Hence, need to keep it away from heat sources and open
wastewater
flames. treatment plant for proper waste disposal. The wastewater contains
0.022
Therefore, the hydrogen gas must be stored appropriately where all electrical
wt% of acetol, 0.02 wt% of methanol, 0.51wt% of glycerol, 0.41 wt% of water and
equipment in storage areas must be explosion proof. Storage areas must meet
0.036
nationalwt% of ethylene glycol. The water, acetol and methanol produced from the
electrical codes for Class 1 hazardous areas. Safe disposal for hydrogen gas must
distillate
be of distillation column (V-201) will be sent to the wastewater treatment
plant
practiced. The amount of gaseous waste generated per year can be calculated as
for proper disposal. This is because the methanol and acetol produced is
hazardous in
below:
terms of ingestion, inhalation or skin contact. The water generated also cannot
be
directly discharged to the nearby river source without being treated since it is not
pure
water and have some mixture of acetol and methanol. Based on the material
data
sheet, methanol is a hazardous chemical because of its toxicity which can cause
death
when ingested or skin absorption. Methanol is a flammable liquid and it need to
be
104
105
Gaseous waste generated from reactor per year:
= Waste from reactor per day x Operation days per

year
Total gaseous waste from plant
= Waste from reactor
= 5068.8
9.0 Mass Transfer Equipment Design
Design Basis
Distillation Column is a multicomponent distillation used to separate mixture of

component
in the solution by means of boiling point difference and volatility of the components
of the
feed mixture.
Design Parameters
PLATE MECHANICAL
COMPONENT COLUMN
HYDRAULIC DESIGN
DISTRIBUTION SIZING
DESIGN
Tray
Number of Stages Active Area Design Pressure
Spacing
Flooding Design
Reflux Ratio Velocity Hole Area
Temperature
Number of Actual Material of
Stages Net Area Tray Thickness Construction
Column Wall
Downcomer Thickness
Tray Efficiency Hole Diameter
Area Column Head
Location of Feed Column Liquid Flow Design
Stage Diameter Arrangement
Column Column Pressure
Height Drop Insulation
Weeping checking
Downcomer Liquid Stress Analysis
Backup Column Support
Residence Time
Entrainment Nozzle Size
checking
Number of holes
106
Design Method
Fenske-Underwood-Gilliland shortcut method from Seader’s Separation Process
Principles,
Chemical and Biochemical Operations is used for component distribution calculation.
The
column sizing, plate hydraulic design and mechanical design of the distillation column
is
based on Coulson and Richardson’s Chemical Engineering
Design.
*Please refer to Appendix for detailed calculation.
Design Criteria
Distillation Column V-201

Inlet Outlet
Stream 1620 23
11 1
Pressure (bar)
121.0101.38 193.73
Temperature (°C)
Plate Column
Type of Column
Sieve Tray
Type of Tray
100%
Recovery of Light Key

Inlet Outlet
Stream 2529 41
11 1
Pressure (bar)
194.66188.35 285.45
Temperature (°C)
Type of Column Plate Column
Type of Tray Sieve Tray
Recovery of Light Key 100%

Inlet Outlet
Stream 3135 38
11 1
Pressure (bar)
188.27188.07 197.47
Temperature (°C)
Type of Column Plate Column
Type of Tray Sieve Tray
Recovery of Light Key 100%
Material of Construction
The material of construction chosen for the distillation is stainless steel type 316.
Stainless
steel was chosen as it can withstand operating temperature and have high mechanical
strength compare to carbon
steel.
107
9.1 Distillation Column, V-201
The basis values of feed used for the calculation are as
below;
Mass Flow Rate (ton/hr) 11.17
Volatility 5.385
Light Key Acetol
Heavy Key Propylene glycol
Table 43 Specification Sheet of Distillation Column V-201
DISTILLATION COLUMN, V-201

Identification: V-201Date: 9/12/2018
Item: Distillation ColumnBy: Sherrine Aruldass
No. of unit: 1
FUNCTION: To separate propylene glycol, ethylene glycol and glycerol from by-
products such
as methanol, acetol and water.
OPERATION: Continuous
OPERATING DATA
Material
FeedDistillateBottom
Handled:
Glycerol (ton/hr.)2.031250.002.03125
Propylene glycol
7.093400.002137.09127
(ton/hr.)
Ethylene glycol
0.168870.000.16887
(ton/hr.)
Methanol
0.087180.087180.00
(ton/hr.)
Acetol (ton/hr) 0.09095 0.09094 0.00002
Water (ton/hr) 1.70147 1.70147 0.00
Temperature (o C) 121 101.38 193.73
Pressure (bar) 1 1 1
OPERATIONAL DESIGN
Number of trays: 89Reflux ratio: 0.10
Feed stage from bottom: 67Tray spacing: 0.46 m
Column diameter: 1.4367 mFunctional Height: 42.207 m
Maximum vapour flow rate: 1.8008
Maximum liquid flow rate: 1.0740 kg/s
kg/s
Ratio of column height to diameter : 29.3769Overall tray efficiency (%): 32.86
PLATE HYDRAULIC DESIGN
Active area: 1.2321 m2Liquid flow arrangement : Cross
108
flow single pass
Type of tray: Sieve trayTray thickness: 5 mm
Hole diameter: 0.005mWeir length: 1.0919 m
Active holes: 6275Weir height: 0.05 m
Total plate pressure drop: 74.4275
Flow rate turndown: 70%
mm liquid per tray
Percentage flooding: 80%Entrainment: 0.085
Unperforated strip round plate edge:
Calming zone width: 50 mm
50 mm
MECHANICAL DESIGN
Design pressure: 1.1 barDesign temperature: 204 o C
Material of construction: Stainless steel Type
Column wall thickness: 5 mm
316L
Type of head: TorisphericalHead thickness: 0.54 mm
Insulation: Rock woolInsulation thickness: 75 mm
Vessel support: Conical skirtSkirt thickness: 13 mm
Feed inlet nozzle size: 2 inCorrosion allowance: 2 mm
Reflux inlet nozzle size: 0.3 inTop outlet nozzle size: 0.8 in
Boil up inlet nozzle size: 2 inBottom outlet nozzle size: 1.9 in
Welding joint factor : 0.85
Aspen Comparison
The following parameters were compared with the calculation based on Aspen and
Excel.
For the Aspen simulation, the simulation was done based on DSTWU distillation
model.
Variables Excel Aspen

Minimum reflux ratio 0.07 0.04
Actual reflux ratio 0.10 0.04
Minimum number of 9.88=10 stages 3.93= 4stages
stages
Number of actual stages
Feed stage 90 stages 88 stages
Number of actual stages 67 stages 19.19 = 19
above feed 66 stages 18.19 = 18stages
Reboiler heating
required 8.29E+06 kJ/hr 7.27E+06 kJ/hr
Condenser cooling
required
Distillate temperature 3.79E+06 kJ/hr 4.43 E+06 kJ/hr
Bottom temperature
101.38 oC 95.07 oC
193.73 oC 219.16 oC
From the Aspen simulation, it can be concluded that both excel and Aspen calculation
are
nearly the same with minimal deviation except for the minimum number of stages. This
is
109
because the no of stages are dependent on the relative volatility which is calculated
manually
in Excel meanwhile the minimum number of stages are calculated by using a short-cut
method in Aspen Plus (DSTWU).
AutoCAD Drawing of Designed Operation Unit
0.022
1.4367
0.00765
42.2070
0.05042
1.4367
0.05085
3.2
1.6
*Units of measurement in meters, m.
Distillation Column
Item Code V-201
Date 11/12/2018
Drawn By Sherrine Aruldass
110
9.2 Distillation Column, V-301
Design Basis

below;
Volatility 20.408
Light Key Ethylene Glycol
Heavy Key Glycerol

No. of unit: 1
FUNCTION: To separate glycerol from ethylene glycol and propylene glycol.
OPERATING DATA
Material
Handled:
Glycerol (ton/hr.)2.030.002.03
Propylene glycol
7.097.090.00
(ton/hr.)
Ethylene glycol
0.170.170.00
(ton/hr.)
Temperature (o C)194.66188.35285.45
OPERATIONAL DESIGN
kg/s
Liquid flow arrangement : Cross
2
Active area: 1.3735 m
flow single pass
mm liquid per tray
111
50 mm
MECHANICAL DESIGN
316L
Feed inlet nozzle size: 2.3 inCorrosion allowance: 2 mm
Boil up inlet nozzle size: 0.6 inBottom outlet nozzle size: 1.2 in
Aspen Comparison
Excel.
model.
Minimum number of 6.0087=6 stages 7.299=7stages
stages
Feed stage 66.89= 67stages 66 stages
Number of actual stages 44.85= 45stages 31.1994 = 31 stages
above feed 44 stages 30.1994 = 30 stages
Reboiler heating
required 1.83E+06 kJ/hr 8.02 E+06 kJ/hr
Condenser cooling
required
Distillate temperature 1.58E+06 kJ/hr 7.16 E+06 kJ/hr
Bottom temperature
188.35 oC 214.293 oC
285.45 oC 276.948 oC
are
nearly the same with minimal deviation except for the minimum reflux ratio and actual
reflux ratio. This is because the reflux ratio are calculated manually in excel by using
Underwood method meanwhile the reflux ratio are calculated by using a short-cut
method in
Aspen Plus (DSTWU).
112
0.05563
1.5169
0.01669
20.998
0.05784
1.5169
0.014
3.2
1.7
Distillation Column
Item Code V-301
Date 12/12/2018
9.3Distillation Column, V-401

Design Basis

below;
Volatility 22.991
Light Key Propylene Glycol
113
Heavy Key Ethylene Glycol

No. of unit: 1
FUNCTION: To separate propylene glycol from ethylene glycol.
OPERATING DATA
Material
Handled:
Propylene glycol
7.097.090.00
(ton/hr.)
Ethylene glycol
0.170.10.16
(ton/hr.)
Temperature (o C)188.27188.07197.47
OPERATIONAL DESIGN
kg/s
Liquid flow arrangement : Cross
2
Active area: 3.5665 m
flow single pass
mm liquid per tray
50 mm
MECHANICAL DESIGN
316L
Feed inlet nozzle size: 2.2 inCorrosion allowance: 2 mm
114
Boil up inlet nozzle size: 0.2 in Bottom outlet nozzle size: 0.4 in
Aspen Comparison
Excel.
model.

Minimum number of 38.22 = 38 stages 22.74=23 stages
stages
Feed stage 119.64 = 120 stages 29.18=29 stages
Number of actual stages 43.25 = 43 stages 11.51=12 stages
above feed 42 stages 10.51 = 11 stages
Reboiler heating
required 1.47E+05 kJ/hr 2.32E+08 kJ/hr
Condenser cooling
required
Distillate temperature 2.54E+07 kJ/hr 3.83E+08 kJ/hr
Bottom temperature
188.07 oC 179.99 oC
197.47 oC 192.79 oC
are
nearly the same with minimal deviation except for the minimum and actual number of
stages. This is because the no of stages are dependent on the relative volatility which
is
calculated manually in Excel meanwhile the minimum and actual number of stages are
calculated by using a short-cut method in Aspen Plus (DSTWU).
115
0.0555
2.44
0.0042
2
56.097
0.05607
2.44
0.00423
3.2
2.5
Distillation Column
Item Code V-401
Date 14/12/2018
116
10.0 Heat Transfer Equipment Design
Heat Exchanger
Design basis
In the process of producing propylene glycol from glycerol, we need to increase or

decrease
some of the temperature of component in process stream to the desired temperature.
The
increase and decrease of temperature are done by using heat exchanger. In this plant,
there
are six heat exchangers used. The heat exchanger used is shell and tube heat
exchanger
configure horizontally with split-ring floated head. In the production of propylene glycol
from glycerol, we need several condenser units to condense a vapor component from
specific
stream to liquid component. To condense the vapor, we use cooling water as our main
utilities. In our design, there are four condensers used. E-103 is used to condensed
vapor
component exits from R-101. However, E-202, E-302 and E-402 is attached to distillation
column to condense the vapor distillate. Feed stream into reboiler contains a mixture of
component from bottom of distillation column in liquid phase. The vapour product
leaves the
reboiler and returns as boilup inlet to the distillation column. Superheated steam is
supplied
in tube side for heating utilities and leaves the
reboiler.
Design parameter
1. Outside diameter, do and inside diameter, di of

tubes.
2. Number of tubes required
3. Number of tube and shell passes
4. Shell diameter, ds
5. Baffle spacing, lb
6. Overall heat transfer coefficient.
7. Pressure drops
When designing heat exchanger, the properties such as density, specific heat, viscosity
and
thermal conductivity of component and utility involved are determined at different
temperature and pressure. These properties are obtained using ASPEN
Plus.
Design method and assumption
The step and guidelines in designing heat exchanger are based on the steps provided in
Coulson Richardson’s Chemical Engineering. Vol 6 Chemical Engineering Design 4th Ed.
117
The calculation is shown in Appendix X. The assumption of all heat exchanger also is
provided in the same appendix.
Design Criteria
Below are design criteria of six heat

exchanger.
Heat Exchanger Design criteria
E-101 Before entering reactor, R-101 which operate at 473K, the glycerol
needs to be heat up from 352.42K to
473K.
E-102 The hydrogen from stream 3 also need to heat up from 352.42K to
473K before entering R-101.
E-104 E-104 will heat up glycerol, hydrogen, propylene glycol, ethylene

glycol, methanol, acetol and water from 473K to 609K before
entering
flash drum that operates at
609K.
E-201 E-201 is used to cooled down component that exits from bottom
part
of flash drum which are glycerol, propylene glycol, ethylene glycol,
methanol, acetol and water from 532.622K to
394K.
E-301 E-301 cooled down glycerol, propylene glycol and ethylene glycol
from reboiler E-203 from 542.245K to 467K.
E-104 E-401 will cooled down propylene glycol which is the main product
from 535.39K to 461.27K.
E-103 To condense the outlet vapor component from R-

101.
E-202 To condense the outlet distillate from V-201 contain mainly acetol,
methanol and water.
E-302 To condense the outlet distillate from V-301 contain propylene

glycol
and ethylene glycol.
E-402 To condense the outlet distillate from V-401 contain the main
product
which is propylene glycol
E-203 To heat up the component from bottom distillation column of V-

201
301
401
118
Material of construction
The material of construction used for all heat exchanger in this plant is Stainless Steel
316.
For condenser and reboiler, Stainless Steel 304 is chosen. Kettle type reboiler is chosen
because boiling takes place on tubes immersed in a pool of liquid and there is no need
of
liquid circulation through the
exchanger.
10.1 Heat Exchanger, E-101
Table 46 Specification Sheet of Heat Exchanger E-101
HEAT EXCHANGER, E-101
Item: Heater Date: 24 November 2018
Item Code: E-101 By: Nurul Afini binti Fuad
No of unit: 1
General
Function: Before entering reactor, R-101 which operate at 473K, the glycerol needs
to be
heat up from 352.42K to 473K.
Operation: Continuous
Type: Shell and tube
Orientation: Horizontal
OPERATING DATA
Fluid Tube Inlet Tube Outlet Shell Inlet Shell Outlet
Mass Flow Rate (kg/s) 3.050 3.050 0.006 0.006
Temperature (K) 352.42 473 523 473
Pressure (bar) 40 40 1 1
OPERATIONAL DESIGN
Heat Duty per unit: 5693.324W

2
Total heat transfer area: 0.880
m
Overall heat transfer coefficient: 91.263 W/m2.
K
Tube Shell
Outside diameter (m) 0.016 Bundle diameter (m) 0.12
Inside diameter (m) 0.012 Shell inside diameter 0.165

(m)
119
Thickness (m) 0.002 Number of shells 1
Length (m) 1.83 Shell clearance diameter 45

(mm)
Arrangement Triangular Baffle cut (%) 25
Pitch 0.02 Baffle spacing (m) 0.033
Number of tubes 8 Pressure drop (bar) 0.16
Number of passes 1
Pressure drop (bar) 0.353
MECHANICAL DESIGN
Design Temperature (K) Tube: 422.71
Shell: 508.0
Design pressure Tube: 4.4

(N/mm2)
Shell: 0.11
Material of construction: Stainless Steel

316
Type of head: Ellipsoidal Head
Insulation: Calcium Silicate Insulation thickness (mm): 50
Vessel support: Saddle
Nozzle size
Tube Shell
Inlet: 0.07m Inlet: 0.11m
Outlet: 0.07m Outlet: 0.11m
120
Item Code E-101
Date 15 December 2018
Drawn By Nurul Afini binti Fuad
Comparison table between ASPEN Plus Simulation and Microsoft Excel Calculation
Parameters ASPEN Plus Simulation Microsoft Excel calculation

Heat duty (W) 586 5693.324
Number of tubes 52 8
Length (m) 1.83 1.83
Shell inside diameter (m) 0.2135 0.165
Justification for differences in Microsoft Excel Calculation and ASPEN Plus Simulation
121
There is some difference of heat duty value in ASPEN Plus Simulation and Microsoft
Excel
Simulation. This is due to different calculation of specific enthalpy in both methods. In
Excel
calculation, we use constant to calculate the heat duty. The linearity of the value also
might
be different. The number of tubes present in E-101 also different when using simulation.
This
might be because of different surface area of tube causing different number of tubes
obtained.
The shell inside diameter are different but the difference is not too much. Since the heat
duty
obtained are different which is higher than in excel, the mass flow rate in shell side are
also
high. This cause the shell inside diameter to be slightly
different.
No of unit: 1
General
Function: The hydrogen from stream 3 also need to heat up from 352.42K to 473K
before
entering R-101.
Operation:
OPERATING DATA
Temperature (K) 500.11 473 298 323
OPERATIONAL DESIGN
Total heat transfer area:

118.115m2
Overall heat transfer coefficient: 46.499W/m2.
K
122
Tube Shell

(mm)
Number of passes 2
MECHANICAL DESIGN
Shell: 320.5

(N/mm2)
Shell: 0.11

316
Nozzle size
Tube Shell
123
Item Code E-102

Heat duty (W) 131631 31.312
Length (m) 3.66 3.66
124
The number of tubes is not much different in for both methods. The difference may be
due to
small difference of surface area of tube. However, the heat duty shows large difference.
This
is because, the calculation of specific enthalpy in ASPEN are different compared in
Excel
calculation. The constant used also caused the value to be different.
No of unit: 1
General
Function: E-104 will heat up glycerol, hydrogen, propylene glycol, ethylene glycol,
methanol, acetol and water from 473K to 609K before entering flash drum that
operates at
609K.
OPERATING DATA
Temperature (K) 473 609 773 769
OPERATIONAL DESIGN

2
2513.881m
2
Overall heat transfer coefficient: 337.863W/m .K
Tube Shell
Inside diameter (m) 0.016 Shell inside diameter (m) 1.815
125
(mm)
Number of passes 8
Pressure drop (bar) 0
MECHANICAL DESIGN
Shell: 781.0

(N/mm2)
Shell: 0.11

316
Nozzle size
Tube Shell
126
Item Code E-104

Heat duty (W) 1847169 266436441.325
Length (m) 6 7.32
The difference of enthalpy data in ASPEN and Excel contribute to the difference heat
duty
for both methods. There are also slightly different in the number of tube when we do
127
simulation in ASPEN. The difference in the number of tubes cause the shell inside
dimeter to
be different.
No of unit: 1
General
Function: E-201 is used to cooled down component that exits from bottom part of flash
drum
which are glycerol, propylene glycol, ethylene glycol, methanol, acetol and water from
532.622K to 394K.
OPERATING DATA
Temperature (K) 532.622 394 298 323
OPERATIONAL DESIGN

29.461m2
K
Tube Shell

(mm)
128
Number of passes 2
Pressure drop (bar) 0
MECHANICAL DESIGN
Shell: 320.5

(N/mm2)
Shell: 0.11

316
Nozzle size
Tube Shell
129
Item Code E-201

Heat duty (W) 3628056 1290482.35
Length (m) 1.83 1.83
Heat duty calculated in E-201 is also different in both different method of calculation.
This
may be due to different specific enthalpy values as the constant used is different.
However,
130
the difference in the number of tubes are small and brings no effect to the inside
diameter of
shell. The differences in the number of tubes is due to different surface are calculated
in
ASPEN and Excel.
No of unit: 1
General
Function: E-301 cooled down glycerol, propylene glycol and ethylene glycol from
reboiler
E-203 from 542.245K to 467K.
Operation:
OPERATING DATA
Temperature (K) 542.245 467.66 298 363
Pressure (bar) 1.01 1.01 1 1
OPERATIONAL DESIGN

6.124m2
K
Tube Shell

(mm)
131
Number of tubes 50 Pressure drop (bar) 0
Number of passes 8
MECHANICAL DESIGN
Shell: 340.5

(N/mm2)
Shell: 0.11

316
Nozzle size
Tube Shell
132
Item Code E-301

Heat duty (W) 2423272 558024.397
Length (m) 2.44 2.44
As usual, the heat duty of E-301 also different in both methods. The heat duty
calculated in
Microsoft Excel calculation is high compared to in ASPEN Plus. This difference is due to
133
different constant used to calculate the specific enthalpy. There is also huge different in
the
number of tubes. This may be due to different value of heat transfer area for this heat
exchanger. The smaller the number of tubes, the smaller the bundle diameter. Thus,
shell
inside diameter is smaller
No of unit: 1
General
Function: E-401 will cooled down propylene glycol which is the main product from
535.39K
to 461.27K.
OPERATING DATA
Temperature (K) 535.394 461.27 298 323
Pressure (bar) 1.01 1.01 1 1
OPERATIONAL DESIGN

4.104m2
K
Tube Shell
134
(mm)
Number of passes 6
MECHANICAL DESIGN
Shell: 320.50

(N/mm2)
Shell: 0.11

316
Nozzle size
Tube Shell
135
Item Code E-401

Heat duty (W) 1892979 548749.23
Length (m) 1.83 1.83
136
The value of heat duty in Excel calculation is different compared to in ASPEN Plus. This
is
because, the value of specific enthalpy is different. However, the number of tubes is not
much
different cause the shell inside diameter to slightly
affected.
10.7 Condenser, E-103
Table 52 Specification Sheet of Condenser E-103
CONDENSER, E-103
Item Code: E-103 By: Nur Amni Bt Md Anuar
No of unit: 1
General
Function: To condense the vapor phase to liquid phase of the top product of distillation
column for reflux purpose and to cool down the components from distillation column.
OPERATING DATA
Temperature (K) 298 323 461.05 461.05
OPERATIONAL DESIGN
Heat Duty per unit: 290.136 W

m2
K
Tube Shell
137
(mm)
Number of passes 8
MECHANICAL DESIGN
Shell: 483.00

2
(N/mm ) Shell: 4.4

304
Nozzle size
Tube Shell
Inlet: 0.09 m Inlet: 0.02 m
Outlet: 0.09 m Outlet: 0.07 m
138
Item Code E-103
Drawn By Nur Amni Bt Md Anuar
Comparison between Aspen and manual

calculation
Parameters Aspen Calculation Manual Calculation
Number of tube 357 240
Heat duty (W) 579.193 290.136
Length (m) 86.61 2.44
Shell Inside Diameter (mm) 1115 1089
Justification Condenser E-103
Based on the comparison table above, it shown that there is major differences of heat
duty
between Aspen calculation and manual calculation. We calculated the value of heat duty
by
using the differences of enthalpy inlet and enthalpy outlet of the condenser which
resulted
heat duty for manual calculation is 290.136 W which is lower than the Aspen calculation.
Hence, the flow rate of shell is low. Besides, the number of tube for manual calculation
is 240
tubes while for Aspen calculation is 357 tubes. This is because heat duty value affected
the
number of tube needed to do the work and it also cause the difference of shell inside
diameter
between Aspen calculation and manual calculation. Aspen calculation have higher shell
139
inside diameter compared to manual calculation. In conclusion, heat duty affected the
number
of tube and shell inside diameter of the
condenser.
Table 53 Specification Sheet for Condenser E-202
CONDENSER, E-202
No of unit: 1
General
OPERATING DATA
Temperature (K) 298 323 374.38 374.38
OPERATIONAL DESIGN

m2
K
Tube Shell

(mm)
140
Number of passes 8
MECHANICAL DESIGN
Shell: 384.38

(N/mm2)
Shell: 0.11

304
Nozzle size
Tube Shell
Outlet: 0.119 m Outlet: 0032 m
141
Item Code E-202
Comparison between Aspen and manual

calculation
Heat duty (W) 439.088 541.857
Length (m) 7.32 2.44
Shell Inside Diameter (mm) 590.6 1089
Justification Condenser E-202
There is major differences in heat duty between Aspen calculation and manual
calculation
which affected the number of tube, shell inside diameter and length of the condenser.
The
manual calculation of heat duty of condenser is calculated by using the differences of
enthalpy inlet and enthalpy outlet of the condenser which resulted heat duty for manual
calculation is 541.857 W which is higher than the Aspen calculation. This cause the
number
of tube to do work for manual calculation is 120 tubes while for Aspen calculation is 212
tubes. Based on number of tubes for both calculation, it affect the length of condenser
and
shell inside diameter which resulted lebgth of condenser for Aspen calculation is lower
than
142
the manual calculation. Thus, higher heat duty cause the number of tube, length of
condenser
and shell inside diameter
affected.
CONDENSER, E-302
No of unit: 1
General
OPERATING DATA
Temperature (K) 298 323 461.35 461.35
OPERATIONAL DESIGN

m2
K
Tube Shell

(mm)
143
Number of passes 8
MECHANICAL DESIGN
Shell: 471.35

(N/mm2)
Shell: 0.11

304
Nozzle size
Tube Shell
Outlet: 0.079 m Outlet: 0058 m
144
Item Code E-302
Comparison Aspen and manual

calculation
Heat duty (W) 445.765 541.857
Length (m) 7.32 7.32
Shell Inside Diameter (mm) 590.6 565.1
Justification for Condenser E-302
Based on the comparison table above, it shown that there is major differences of heat
duty
between Aspen calculation and manual calculation. The value of heat duty is calculated
by
using the differences of enthalpy inlet and enthalpy outlet of the condenser which
resulted
heat duty for manual calculation is higher than the Aspen calculation. Heat duty for
manual
calculation is 541.857 W while Aspen calculation is 445.765 W. The heat duty of manual
calculation is higher due to mass flow rate in the shell. Moreover, value of heat duty
affected
the number of tubes needed to do work and cause difference shell inside diameter. The
number of tubes and shell inside diameter for Aspen calculation is higher than manual
145
calculation due to lower heat duty value. In conclusion, the higher heat duty gives low
value
of the number of tube and shell inside diameter of the
condenser.
CONDENSER, E-402
No of unit: 1
General
OPERATING DATA
Temperature (K) 298 323 461.05 461.05
OPERATIONAL DESIGN

m2
K
Tube Shell
Length (m) 7.32 Shell clearance diameter 69.55

(mm)
146
Number of passes 4
MECHANICAL DESIGN
Shell: 471.35

(N/mm2)
Shell: 0.11

304
Nozzle size
Tube Shell
Outlet: 0.276 m Outlet: 0.117 m
147
Item Code E-402
Comparison Aspen and manual

calculation
Heat duty (W) 7034.594 704.77
Length (m) 7.32 7.32
Shell Inside Diameter (mm) 978 977.9
Justification for Condenser E-402
Based on the comparison table above, major differences of heat duty between Aspen
calculation and manual calculation is shown. The heat duty value of Aspen calculation is
7034.594 W which is more higher compared to manual calculation. The value of heat
duty
for manual calculation is lower because it is calculated manually by using the
differences of
enthalpy inlet and enthalpy outlet of the condenser which resulted heat duty for manual
calculation is 704.77 W which is lower than the Aspen calculation. This cause lower flow
rate flow in the shell. Hence, it gives lower number of tubes needed to work. Number of
tubes
for manual calculation is 132 tubes which is lower compared to Aspen calculation. This
is
148
because heat duty of manual calculation is lower which resulted lower number of tube
needed
to do work. Besides, the value of shell inside diameter between Aspen calculation and
manual
calculation only have small differences 0f 0.1 m. In conclusion, the higher the heat duty,
the
higher the mass flow rate in the shell and the higher the number of tubes needed to
do work.
10.11 Reboiler, E-203
Table 56 Specification Sheet of Reboiler E-203
REBOILER (E-203)
Date: 14/12/2018
Identification: E-203
By: Joan Mary
Item: Reboiler
No. of unit: 1
Function: To heat up and vaporize the liquid residue in the bottom stream of
distillation
column and recycled the vapor back to the distillation column to improve
the
efficiency of distillation separation.
OPERATING DATA
Materials handled: Tube Inlet Tube Outlet Shell Shell Shell Liquid
Inlet Vapor Outlet
Outlet
Mass flow rate
(kmol/hr) 2396.99 2396.99 279.35 161.39 117.97
Temperature (K) 523.00 473.00 465.65 467.65 467.65
Pressure (bar) 1.00 1.00 1.00 1.00 1.00
OPERATIONAL DESIGN
Type: Kettle reboiler
Heat duty per unit: 2420042 W
Total heat transfer area: 145.4168717 m2
Overall heat transfer coefficient: 700 W/m2. K
Tubes:Shell:
Inside diameter (m):0.049996Inside diameter (mm):
Outside diameter (m):0.05Wall thickness (mm): 1.8674
Wall thickness (m):0.002Number of baffles: 1.0754
Length (m):6.1Equivalent diameter (m): 4
Pitch (mm):0.0625Baffle cut (%): 0.0494
Number of tubes needed:152Baffle spacing (m): 25
Number of tube passes:8Pressure drop (bar): 0.4668
Pressure drop (bar):178.5899 0.0098
MECHANICAL DESIGN
Design pressure (bar):Design temperature (K):
Tube1.10Tube
Shell1.10Shell
Materials of constructionStainless steel Corrosion allowance (mm): 508
304 476.65
2
149
Type of head: Torispherical Head thickness (mm): 1904.808033
head
Insulation: Mineral wool Insulation thickness (mm): 75
Vessel support: Saddle Shell inlet nozzle size (in): 4.00
Tube inlet nozzle size (in): 12.00 Shell vapor outlet nozzle size 6.00
(in):
Shell liquid outlet nozzle size
Tube outlet nozzle size (in): 12.00 (in): 3.00
* Aspen is not applicable to this equipment because kettle reboiler is used. Aspen
generates
result in vapour phase but our plant produces product in liquid phase.
REBOILER (E-303)
Date: 14/12/2018
By: Joan Mary
Item: Reboiler
No. of unit: 1
distillation
the
OPERATING DATA
Materials handled: Tube Inlet Tube OutletShell Shell Shell Liquid
Inlet Vapor Outlet
Outlet
Mass flow rate
(kmol/hr) 1217.98 1217.98 27.48 5.43 22.05
Temperature (K) 323.00 303.00 556.45 558.65 558.65
Pressure (bar) 1.00 1.00 1.00 1.00 1.00
OPERATIONAL DESIGN
Heat duty per unit: -518022 W
2
Total heat transfer area: 3.027431286 m
2
Overall heat transfer coefficient: 700 W/m . K
Tubes:Shell: 0.3913
Inside diameter (m):0.0299968Inside diameter (m): 0.2432
Outside diameter (m):0.03Wall thickness (mm): 4
Wall thickness (m):0.0016Number of baffles: 0.0296
Length (m):1.83Equivalent diameter (m): 25
Pitch:0.0375Baffle cut (%): 0.0978
Number of tubes needed:24Baffle spacing (m): 0.0045
Number of tube passes:8Pressure drop (bar):
Pressure drop (bar):656.9685
MECHANICAL DESIGN
150
Design pressure (bar): Design temperature (K):
Tube 1.10 Tube 323.00
Shell 1.10 Shell 567.55
Materials of construction Stainless steel Corrosion allowance (mm): 2
304
Torispherical
Type of head: head Head thickness (mm): 430.7556043
Mineral wool
Insulation: Saddle Insulation thickness (mm): 75
Vessel support: 16.00 Shell inlet nozzle size (in): 2.00
Tube inlet nozzle size (in): Shell vapor outlet nozzle size 2.00
(in):
Shell liquid outlet nozzle size
Tube outlet nozzle size (in): 15.00 (in): 2.00
generates
REBOILER (E-403)
Date: 14/12/2018
By: Joan Mary
Item: Reboiler
No. of unit: 1
distillation
the
OPERATING DATA
Materials handled: Tube Inlet Tube Outlet Shell Shell Shell Liquid
Inlet Vapor Outlet
Outlet
Mass flow rate
(kmol/hr) 97.43 97.43 487.41 394.07 93.34
Temperature (K) 323.00 303.00 468.44 470.44 470.44
Pressure (bar) 1.00 1.00 1.00 1.00 1.00
OPERATIONAL DESIGN
Heat duty per unit: -407333 W
Total heat transfer area: 3.72377615 m2
Overall heat transfer coefficient: 700 W/m2. K
Tubes:
Inside diameter (m):0.0299968 Shell:
Outside diameter (m):0.03 Inside diameter (m): 0.3580
Wall thickness (m):0.0016 Wall thickness (mm): 0.2077
Length (m):1.83 Number of baffles: 4
Equivalent diameter (m): 0.0296
151
Pitch: 0.0375Baffle cut (%): 25
Number of tubes needed: 24Baffle spacing (m): 0.0894
Number of tube passes: 6Pressure drop (bar): 0.000040
Pressure drop (bar): 2.9174
MECHANICAL DESIGN
Design temperature (K):
Design pressure (bar): 1.10Tube
Tube 1.10Shell 323.00
Shell Stainless steel Corrosion allowance (mm): 479.44
Materials of construction 304 2
Torispherical Head thickness (mm):
head
Type of head: 430.7556043
Mineral wool Insulation thickness (mm):
SaddleShell inlet nozzle size (in):
Insulation: 5.00Shell vapor outlet nozzle size 75
Vessel support: (in): 0.50
Tube inlet nozzle size (in): 5.00Shell liquid outlet nozzle size 0.30
(in):
Tube outlet nozzle size (in): 0.40
generates
11.0 Reactor Design
Chemical reaction of the production plant occurred in a reactor. The

reactor
design is crucial to ensure that the reactor vessel able to achieve the desired
reaction
rate and production capacity. Mechanical design of the reactor including
materials of
construction shell and support must be performed to ensure the reactor vessel
able to
withstand the stresses when the reactor is
operated.
11.1 Packed Bed Reactor, R-101
This reactor is designed to convert glycerol to propylene glycol in a packed

bubble-flow reactor with co-current gas-liquid upflow through the packed bed.
The
copper-zinc oxide catalyst (Cu/ZnO/Al2O3) is packed in the reactor and reactor is
operated at temperature of 200˚C and pressure of 40 bar. In order to he packed
bubble-flow reactor with co-current gas-liquid upflow through the packed bed is
used
as the design of the reactor as the upflow operation gives higher conversions
than the [1]
downflow operation under the same reaction . The co-current gas-liquid
condition
upflow operation provides complete catalyst wetting and fasten the transport of
the
reactants to the catalyst that packed in the [1]. The chemical reaction occurred in
bed
152
the reactor is the 2-step mechanism reactions, hydrogenolysis of glycerol to
propylene
glycol.
Design Parameters
The design parameters for the reactor are Inner diameter, mass of catalyst, pressure
drop,
reactor size, design temperature and pressure, material of construction, reactor wall
thickness, jacket thickness and nozzle
size.
Design method
POLYMATH is used to calculate the size of the reactor and the pressure drop due to the
complication caused by the 2-step mechanisms of the hydrogenolysis of glycerol to
propylene glycol. The reaction kinetics that applied in the calculation is referred to
study
done by Zhou et al. [2]. The design of the reactor is based on Coulson and Richardson’s
Chemical Engineering Design for mechanical design and the cooling jacket design is
based
on the J. P. Holman’s Heat transfer.
Material of construction
After the calculation of mechanical stresses of the reactor, the material of construction
is
chosen to be stainless steel type 316 as it withstand the stresses at the shell, head,
support
and openings. Besides, stainless steel type 316 has good corrosion-resistance and
heat-
resistance which is suitable to be used as the material of construction as the reactor
consist
high temperature water which possessed high corrosion
property.
Table 59 Specification Sheet of Packed Bed Reactor R-101
R-101, PACKED BED REACTOR

Date: 2 December
Identification: Item: Packed bed reactor 2018
Item No: R-101
No. Required: 1By: LOW YING KAI
To convert glycerol to propylene glycol
Function: Continuous
Operation: Packed bed reactor
Type: FLOW STREAM CONDITION
153
COMPONENTS INLET (kg/hr) OUTLET (kg/hr)
Glycerol 10979.72 2031.25
Hydrogen 1201.65 1008.26
Propylene Glycol 0 7093.40
Ethylene Glycol 0 168.87
Methanol 0 87.18
Acetol 0 90.95
Water 0 1701.47
GENERAL DESIGN DATA
Stainless steel type 316
3.15 m
1.38 m
Material of Construction: 1.45 m
Functional height: 2.90 m3
Diameter (internal): 0.18 bar
Diameter (external): 0.45
Reactor volume: Cu/ZnO/Al2O3 [ratio =
Pressure drop: 1:1:0.5]
Void fraction: 0.00034m
1050 kg/m3
1675 kg
Catalyst: Support grid
Catalyst diameter: UTILITY DESIGN
Catalyst density: 3218.97 MJ/hr
Mass of catalyst: 2.52 m
Catalyst support: 5.5 cm
Cooling water
30.89 ton/hr
MECHANICAL DESIGN
Cooling duty: 44 bar
Cooling jacket length: 210 C
Jacket thickness: Hemispherical head
Cooling medium: Conical skirt
Mass flow rate: 33 mm
22 mm
33 mm
Design Pressure:
Design Temperature:
Type of head:
Type of support:
Vessel wall thickness:
Head thickness:
Skirt thickness:
Glycerol inlet nozzle
size:
Hydrogen inlet nozzle
size: 2.5 in
Product outlet nozzle
size: 1.0 in
Cooling water inlet
nozzle size: 10.0 in
Cooling water outlet
nozzle size: 4.0 in
4.0 in
154
ASPEN Simulation
Cooling duty: 1100.14 MJ/hr
* The detailed design calculation steps are shown in

Appendix.
ASPEN simulation justification
The cooling duty that obtained from ASPEN simulation is 1100.14 MJ/hr which is lower
than the cooling duty that obtained from manual energy balance calculation. The
cooling
duty that obtained from the manual energy balance calculation is 3218.97 MJ/hr. The
difference of the cooling duty obtained from ASPEN simulation and manual energy
balance
calculation is due to the heat capacity constants that being used in both methods are
different. The manual energy balance calculation is based on the heat capacity
constants that
obtained from Perry’s Chemical Engineers’ Handbook (Sixth Edition). The calculation
method
AutoCADofDrawing
the ASPEN simulation
of Designed is “NRTL”.
Operation Unit
Item : Packed bed reactor Date : 10 December 2018
Code: R-101 Drawn by: Low Ying Kai
Material of construction: Stainless Steel 316 Drawing Millimetre (mm)

dimension:
155
12.0 Auxiliary Equipment Design
Auxiliary equipment play important role in a production plant. The auxiliary
equipment design provides the idea of how big the size of the equipment and
how
much power the equipment required in order for it to
operate.
12.1 Pump
Pump is used to transfer the raw material from its storage tank to a heat exchange
before
feeding into another unit operation. The power required for the pump to operate is
calculated.
Design Parameters
The design parameters for the pump are pipe diameter, total pump head, Net Pump
Suction
Head (NPSH), pump efficiency and power required.
Design method
The pump power design is based on the Bernoulli’s
Equation.
12.1.1 Pump, P-101

Table 60 Specification Sheet of Pump P-101
Pump, P-101
Item: Pump Date: 5 December 2018
Item No: P-101
Identification:
By: LOW YING KAI
No. Required: 1
Function: Used to pump fluid.
Type: Centrifugal Pump
FLOW STREAM CONDITION
INLET (kg/hr)OUTLET (kg/hr)
COMPONENTS 10979.7210979.72
Glycerol 00
Hydrogen 00
Propylene Glycol 00
Ethylene Glycol 00
Methanol 00
Acetol 00
Water GENERAL DESIGN DATA
1 bar
40 bar
Inlet Pressure:
Outlet Pressure:
156
Pipe diameter: 2.5 inch
Total Pump Head:319.94 m
NPSHA: 4.11 m
Pump Efficiency: 65%
Power required: 14.73 kW
Motor Power: 20 bhp
ASPEN Simulation
Pump Efficiency:40%
Power required:23.48 kW
Appendix.
The power required for the pump is 14.73kW when manually calculated while the power
required is 23.48kW using ASPEN simulation. The different in amount of power required
is
due to the pump efficiency that being used in manual calculation and ASPEN simulation
is
different.
12.1.2 Pump, P-301

Pump, P-301
Date: 5 December
Item: Pump 2018
Identification: Item No: P-301
No. Required: 1
By: LOW YING KAI
Used to pump fluid.
Operation: Centrifugal Pump
INLET (kg/hr)
2031.25
COMPONENTS 0 OUTLET (kg/hr)
Glycerol 7091.27 2031.25
Hydrogen 168.87 0
Methanol 0 0
Acetol GENERAL DESIGN DATA 0
Water 1 bar 0
1.01 bar
2.5 inch
2.35 m
3.75 m
Inlet Pressure:
Outlet Pressure:
Pipe diameter:
Total Pump Head:
NPSHA:
157
Pump Efficiency: 60%
Power required: 0.09 kW
Motor Power: 1 bhp
ASPEN Simulation
Pump Efficiency:43%
Appendix.
is
is
different.
12.1.3 Pump, P-401

Pump, P-401
Date: 5 December
Identification: Item: Pump 2018
Item No: P-401
No. Required: 1
By: LOW YING KAI
Used to pump fluid.
Operation: Centrifugal Pump
INLET (kg/hr)
0
COMPONENTS 0 OUTLET (kg/hr)
Glycerol 7091.27 0
Hydrogen 168.83 0
Methanol 0 0
Acetol GENERAL DESIGN DATA 0
Water 1 bar 0
1.01 bar
2.5 inch
1.93 m
4.17 m
Inlet Pressure: 60%
Outlet Pressure: 0.06 kW
Pipe diameter:
Total Pump Head:
NPSHA:
Pump Efficiency:
Power required:
158
Motor Power: 1 bhp
ASPEN Simulation
Pump Efficiency:40%
Appendix.
is
is
different.
12.2 Compressor
12.2.1 Compressor, C-101

Compressor, C-101 is used to compress the raw material hydrogen gas from its storage
tank
to before feeding into the reactor. The power required for the compressor to operate is
calculated.
Design Parameters
The design parameters for the compressor are compression ratio, number of
compression
stages, polytropic efficiency, motor efficiency and power
required.
Design method
The compressor design is based on Coulson and Richardson’s Chemical Engineering
Design.
Table 63 Specification Sheet of Compressor C-101
Compressor, C-101
Item: CompressorDate: 6 December 2018
Item No: C-101
Identification:
Used to compress hydrogen gas.
Operation: Centrifugal compressor
00
COMPONENTS 798.35798.35
Glycerol 00
Hydrogen 00
Propylene Glycol 00
Ethylene Glycol 00
Methanol
Acetol
159
Water 0 0
GENERAL DESIGN DATA
1 bar
Inlet Pressure:
40 bar
Outlet Pressure:
2 stages
Number of stages:
72%
Polytropic efficiency:
97%
Compressor efficiency:
11489.47 kW
Power required:
ASPEN Simulation
0.72
3165.96 kW
Power required:

Appendix.
The power required for the compressor is 11489.47 kW when manually calculated while
the
power required is 3165.96 kW using ASPEN simulation. The different in amount of power
required is due to the calculation model type that used in ASPEN is not multistage
compressor.
12.3 Flash Drum
12.3.1 Flash Drum, V-101

The flash drum V-101 is used to separate the hydrogen from the product mixture
before
entering the distillation column.
Design Parameters
The following design parameters were considered : Vessel Size, Inlet and Outlet Nozzle,
Vessel wall thickness, Vessel support, The flash drum V-101 is used to separate the
hydrogen
from the product mixture before entering the distillation
column.
Inlet Outlet (Top) Outlet (Bottom)
Molar Flowrate 716.57 500.18 216.39
(kmol/hr)
Mass Flowrate 12.18 1.01 11.17
(ton/hr)
Design Criteria
Vessel Mechanical
Velocity of Liquid Droplets Design Pressure
Vessel Diameter Design Temperature
Cross sectional Area of vessel Material of construction
160
Height of vapor section Vessel Thickness
Height of liquid section Vessel Head Design
Total height Vessel Support
Nozzle size
Note: Refer to Appendix for detailed calculation

Table 64 Specification Sheet of Flash Drum V-101
Flash Drum
Item : Flash drumDate : 5 December 2018
Item Code : V-101By : SHERRINE ARULDASS & JOAN MARY
No. Required :1
Function : Separate vapor by-product from liquid mixture
Orientation : Vertical
Operation : Continuous
Operating Data
FeedTopBottom
Temperature (°C)336383.29289.88
Pressure (bar)404040
Composition (ton/hr)
Glycerol 2.03125 0.00 2.03
Hydrogen 1.00826 1.01 0.00
Propylene glycol 7.09340 0.00 7.09
Ethylene glycol 0.16887 0.00 0.17
Methanol
0.08718 0.00 0.09
Acetol
0.09095 0.00 0.09
Water
1.70147 0.00 1.70
12.18138 1.01 11.17
Total
Design Data
Dimension type Cylinder Hold up time (min) 5
Internal diameter (m) 0.70 Liquid depth (m) 3.20
Outer diameter (m) 0.71 Demister pad area (m2) 0.39
Total height (m) 4.65 Demister pad thickness (mm) 100
Mechanical Design Data
Design Temperature (°C) 346.00 Pipe schedule no. 40

Design Pressure (bar) 44 Standard nominal pipe size
Wall thickness (m) 0.0177 Inlet Nozzle Diameter (in)
9
Material of Construction Stainless Steel 304Top outlet nozzle diameter (in)
10
Vessel's dead weight (kN) 6.70 Bottom outlet nozzle diameter
3
Design stress(bar) 1004 (in)
Plain flange rings
Corrsion allowance (mm) Base ring type
7
Head type 2 Base ring thickness
M24
Support type Standard bolt
Support thickness (mm) Torispherical Number of bolt
Support base diameter Conical skirt Maximum weight with load 13
(m) 9 17567.75
Support base angle (°) 0.75
88.09
12.4 Expander
12.4.1 Expander, D-101

Expander, D-101 is used to reduce the pressure the product mixture from flash drum
before
feeding into a heat exchanger. The power generated from the expander is
calculated.
Design Parameters
161
The design parameters for the compressor are expansion ratio, number of expansion
stages,
polytropic efficiency, motor efficiency and power
generated.
Design method
The expander design is based on Coulson and Richardson’s Chemical Engineering

Design.
Table 65 Specification Sheet of Expander D-101
Expander, D-101
Date: 6 December
Identification: Item: Expander 2018
Item No: D-101
Used to expand product mixture.
Operation: Turbine
2031.252031.25
COMPONENTS 00
Glycerol 7093.47093.4
Hydrogen 168.87168.87
Propylene Glycol 87.1887.18
Ethylene Glycol 90.9590.95
Methanol 1701.471701.47
Acetol GENERAL DESIGN DATA
Water 40 bar
1 bar
2 stages
61%
90%
Inlet Pressure: 22.61 kW
Outlet Pressure:
Number of stages:
Expander efficiency:
Power required:
162
12.5 Reflux Drum
Design Basis
Reflux drum is used to distribute the outlet of the condenser between the reflux
and the
distillate as a liquid product.
Design Parameters
Volumetric Flow Rate, Q ;Volume of Reflux Drum, V; Diameter of Reflux Drum, D; Length
of Reflux Drum
Design Criteria
Pressure (bar) & Temperature (K)
Design Method
The reflux drum calculation is based on Coulson and Richardson’s Chemical Engineering
Design. (*Please refer to Appendix for detailed calculation.)
Assumption
The assumption made is that the inlet is single phase, liquid after flowing through the
total
condenser.
Material of Construction
The material of construction chosen for the drum is Stainless Steel 316 as it has
high
resistance to corrosive chemicals considering that V-202 contains methanol which is
highly
corrosive.
12.5.1 Reflux Drum, V-202
Density(kg/m3) 948.319
Hold Up Time (min) 10
Table 66 Specification Sheet of Reflux Drum V-202
REFLUX DRUM, V-202

Item : Reflux DrumDate : 7th December 2018
Code : V-202By : Joan Mary
163
No.of unit : 1
GENERAL
Function : Distribution point for reflux and distillate for Distillation Column, V-201
Operation : ContinuousOrientation : Horizontal
Material of Construction : Stainless Steel 316
OPERATING DATA
Mass Flow Rate
Temperature (K)374.37631562.24
(ton/hr)
Pressure (bar)1
Volumetric Flow Rate (m 3/hr) 2.367172628
Density (kg/m3)948.319
OPERATIONAL DESIGN
Volume of Drum (m3)0.789Diameter of Drum (m)0.694
Length of Drum (m)2.083Hold Up Time (min)10
12.5.2 Reflux Drum, V-302
Hold Up Time (min) 10
Table 67 Specification Sheet of Reflux Drum V-302
REFLUX DRUM, V-302

Item : Reflux DrumDate : 7th December 2018
Code : V-302
By : Joan Mary
No.of unit : 1
GENERAL
Function : Distribution point for reflux and distillate for Distillation Column V-301
Operation : ContinuousOrientation : Horizontal
Material of Construction : Stainless Steel 316
OPERATING DATA
Mass Flow Rate
Temperature (K)461.34788438.15
(ton/hr)
Pressure (bar)1
Volumetric Flow Rate (m 3/h)
Density (kg/m3)948.319
OPERATIONAL DESIGN
Volume of Drum (m3)2.866Diameter of Drum (m)1.067
* Kindly refer to appendix for detailed calculation steps
164
12.5.3
13.0 Reflux Drum, V-402
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Appendix A: Thermodynamic Data
Table 69 Thermodynamic Data
Gibbs Heat of fusion Heat of

Tc(K) Heat of
Energy of at Melting Vaporization at Heat of formation Specific heat
combustion at
Compound formation, Pc(atm) point and 1 Boiling point at 25℃ and 1 atm capacity, Cp at
25℃ and 1 atm
ΔG atm and 1 atm ΔH (kJ/mole) 25℃ (kJ/kg.K)
ΔH (kJ/mole)
(kJ/mole) ΔH (kJ/mole) ΔH (kJ/mole)
[42]
Acetol
[43]
-291.36 589.06 5478.85 9.21 45.70 -370.06 -1490 0.11078 (g)
Ethylene
-451.5 (l) 145.20 (l)
[41]
Glycol -307.68 - - 9.11 56.9 -1179.5 (l)
[44]
-387.1 (g) 0.09975 (g)
[41]
Glycerol
[45]
-438.52 - - 12.27 - -665.9 (l) -1661.1 (l) 2.43 (l)
Hydrogen
[41] [46]
- 33.3 12.8 0.117 0.904 0 (g) -285.84 (g) 14.30 (g)
Methanol -238.6 (l) 726.6 (l) -726.50 (l)

[41] [47]
-179.28 513.20 78.50 2.43 35.27
-201.2 (g) -764.0 (g) -763.68 (g)
Propylene -501.00 (l) 0.1803 (l)

-301.70 614.38 5791.74 8.18 62.20 -1882.90 (l)
Glycol [48] -429.80 (g) 0.13547(g)
176
[41]
Water -237.2 (l) - -285.84 (l) 4.1852 (l)
647.4 218.3 6.0095 40.656 -
[49]
228.4(g) -241.83 (g) 1.8670 (g)
Table 70: Chemical and Physical Properties
Molecular Density Melting Boiling Vapor

Compound Formula
Weight Colour/Phase (g/L) at point point pressure Molecular Structure
(g/mole) 0℃ (℃) (℃) (kPa)
0.2552 at
Acetol [50] [51] C3H6O2 74.08 Colorless / Liquid 1.082 -17 145
25℃
Ethylene 0.00067 at
C2H6O2 62.07 Colorless / Liquid 1.113 -13 197.2
Glycol [41] [52] 20℃
Glycerol [41] 2.24x10-4 at

C3H8O3 92.09 Colorless / Liquid 1.260 18.20 290
[53] [54] 25℃
[41]
Hydrogen 320.59 at -
H2 2.016 Colorless / Gas - -259.19 -252.76 H-H
[55] 248.15℃
177
[41]
Methanol
CH3OH 32.04 Colorless / Liquid 0.792 -97.9 64.7 0.37 at 25℃
[56] [57]
Propylene 0.017 at
C3H8O2 76.095 Colorless / Liquid 1.0361 -59 188.2
Glycol [58] [59] 25℃
[41] [60]
Water
H 2O 18.016 Odorless / Liquid 1.000 0 100 3.17 at 25℃
[49]
178
Appendix B: Material Safety Data Sheet
Material Safety Data Sheet is important when handling the raw materials and reactants
in the
production plant. This is because it is useful for future reference for the workers and
employees especially if emergency occurs. Besides, MSDS were provided by Science
Lab.com, Chemicals and Laboratory Equipment that can be retrieved from online
website.
There are a total of eight components involved in the chosen process which are
classified into
reactant, product and by-product. Based on the MSDS below, methanol is the most
hazardous
components that contribute to health risk and environmental
impact.
B.1 Material Safety Datasheet of Propylene Glycol [76]
Details
a. Common Name 1,2-propanediol, 1,2-dihydroxypropane
b. Formula CH3CHOHCH2OH
Hazards Identification
a. Overview Odourless and colourless liquid, not flammable but

will cause burn, no specific hazards condition if
under specific condition.
b. Acute Potential Health Effects
Ingestion May cause gastrointestinal irritation with nausea,

vomiting and diarrhoea. Low hazard for usual
industrial handling. May cause hemoglobinuric
nephrosis. May cause changes in surface
EEG.
Eye May cause slight transient injury.
Skin May be absorbed through damaged or abraded

skin
in harmful amounts. Allergic reactions have been
reported. A single prolonged skin exposure is not
likely to result in the material being absorbed in
harmful amounts. Prolonged contact is essentially
non-irritating to skin. Repeated exposures may
cause problems. Negative results have consistently
been obtained in guinea pigs studies for
sensitization. 1,2-Propylene glycol is not
considered
an occupational skin sensitizer. (CHEMINFO)
179
Chronic Prolonged skin exposure has caused irritation in
16% of dermatitis patients. Irritation
seen in normal people appears to have been
caused
by local osmotic dehydration of skin
which disappeared rapidly after product
removed.
c. Potential Health Effects of Repeated Exposures
Route of Entry Ingestion, eye contact, skin contact,

inhalation
Symptoms Prolonged skin exposure has caused irritation in
16% of dermatitis patients. Irritation
seen in normal people appears to have been
caused
by local osmotic dehydration of skin
which disappeared rapidly after product
removed.
Target Organs Central nervous system
Medical Conditions Aggravated by May cause central nervous system

depression
Overexposure
Carcinogenicity CAS# 57-55-6: Not listed by ACGIH, IARC, NTP,

or CA Prop 65.
First Aid
Ingestion Do not induce vomiting unless directed to do so by

medical personnel. Never give anything by mouth
to
an unconscious person. If large quantities of this
material are swallowed, call a physician
immediately. Loosen tight clothing such as a
collar,
tie, belt or waistband.
Eye Check for and remove any contact lenses.

Immediately flush eyes with running water for at
least 15 minutes, keeping eyelids open. Cold water
may be used. Get medical
attention.
Skin In case of contact, immediately flush skin with
plenty of water. Cover the irritated skin with an
emollient. Remove contaminated clothing and
shoes. Cold water may be used. Wash clothing
before reuse. Thoroughly clean shoes before
reuse.
180
Get medical attention.
Inhalation If inhaled, remove to fresh air. If not breathing,

give
artificial respiration. If breathing is difficult, give
oxygen. Get medical
attention.
Fires and Explosion
Flash point Closed cup: 99°C (210.2°F)

Open cup : 107°C (224.6°F)
Autoignition 371°C (699.8°F)
Flammable limits 2.6 – 12.5 %
Extinguishing Media Small fire: Use DRY chemical powder.

Large fire: Use water spray, fog or foam. Do not
use
water jet.
Special firefighting procedures Fire fighters must wear SCBA
Unusual fire and explosion Fire hazards: Slightly flammable to flammable in

hazards presence of heat
Explosion hazards : Not available in presence of
mechanical impact
Hazardous combustion products Carbon monoxide and carbon dioxide
Accidental Release Measures
Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container. Finish cleaning by spreading water on the
contaminated surface and dispose of according to local and regional authority
requirements.
Large Spill:
Absorb with an inert material and put the spilled material in an appropriate waste
disposal. Finish cleaning by spreading water on the contaminated surface and allow
to
evacuate through the sanitary system. Be careful that the product is not present at a
concentration level above TLV. Check TLV on the MSDS and with local
authorities
181
Handling and Storage
Storage Hygroscopic. Keep container tightly closed. Keep

container in a cool, well-ventilated area. Do not
store above 23°C (73.4°F).
Handling Avoid skin and eye contact and breathing in

vapour.
Vapour may travel a considerable distance to
source
of ignition and flash back. Take precautionary
measures against static
discharges.
Personal Protection/Exposure Control
Engineering Measures Provide exhaust ventilation or other engineering

controls to keep the airborne concentrations of
vapours below their respective threshold limit
value.
Ensure that eyewash stations and safety showers
are
proximal to the work-station location.
Exposure Limits TWA: 10 (mg/m3) from AIHA Consult local

authorities for acceptable exposure
limits.
Body Protection Splash goggles. Lab coat. Vapour respirator. Be
sure
to use an approved/certified respirator or
equivalent.
Gloves.
Full Body Protection Splash goggles. Full suit. Vapour respirator. Boots.
Gloves. A self-contained breathing apparatus
should
be used to avoid inhalation of the product.
Suggested protective clothing might not be
sufficient; consult a specialist before handling this
product.
Other Protective Equipment Not available
Physical and Chemical Properties
Appearance Liquid. (Oily liquid)
Odour Practically odourless
Taste Practically tasteless
Molecular Weight 76.1 g/mole
Gas Density 2.62
Vapour Pressure 0 kPa at 20℃
182
Specific Gravity 1.036
Boiling Point 188℃ (370.4°F)
Melting Point -59°C (-74.2°F)
Solubility in Water Soluble in water
Stability and Reactivity
a. Stability: Stable under normal conditions.
Conditions to avoid Avoid exposure to heat, sources of ignition, and

open flame. Avoid temperatures above 40
°C.
Incompatibility (Materials to Incompatible with strong oxidizing agents , and
Avoid) strong acids
b. Reactivity: No reactivity hazards.
Hazardous Decomposition Carbon monoxide

Products
Hazardous Polymerization Will not occur
Toxicological Information
Routes of Entry Absorbed through skin and eye

contact
Toxicity to Animals Acute oral toxicity (LD50): 18500 mg/kg [Rabbit]
Acute dermal toxicity (LD50): 20800 mg/kg
[Rabbit]
Chronic toxicity May cause damage to the following organs :

Central
nervous system (CNS)
Carcinogenicity CAS# 57-55-6: Not listed by ACGIH, IARC, NTP,

or CA Prop 65.
Mutagenicity DNA Inhibition: Subcutaneous, mouse = 8000

mg/kg Cytogenetic Analysis: Subcutaneous, mouse
= 8000 mg/kg
Cytogenetic Analysis: Hamster, Fibroblast = 32
gm/L.
Reproductive hazards When propylene glycol was given at 30 percent in

the diet, it affected reproduction in rates in rats. It
has generally not affected fertility or reproduction,
except at very high doses where effects could be
attributed to nutritional deficiency.
183
Ecological Information
Ecotoxicity Ecotoxicity in water (LC50):

>5000 mg/l 24 hours [Goldfish]
>10000 mg/l 48 hours [guppy]
>10000 mg/l 48 hours [water flea]
BOD5 and COD Not available
Products of Biodegradation Possibly hazardous short term degradation

products
are not likely. However, long term degradation
products may arise.
Toxicity of the Products of The products of degradation are less toxic than the
Biodegradation product itself.
Special Remarks on the Products Not available

of Biodegradation
Disposal
Chemical waste generators must determine whether a discarded chemical is

classified as a
hazardous waste. US EPA guidelines for the classification determination are listed in
40
CFR Parts 261.3. Additionally, waste generators must consult state and local
hazardous
waste regulations to ensure complete and accurate
classification.
RCRA P-Series: None listed.
RCRA U-Series: None listed.
B.2 Material Safety Datasheet of Glycerol [78]
Details
a. Common name Glycerol, Glycerin and Glycyl alcohol.
b. Formula C3H8O3
a. Overview Glycerol is a colorless, odorless, viscous

liquid that is sweet tasting and non-toxic.
Glycerol is naturally occurring chemical. It is
generally regarded as a safe material and
does not required special handling
precautions. However, it is flammable.
184
Hence, need to practice appropriate
handling
precautions.
Inhalation Harmful if inhaled. May cause mucous

membrane and upper respiratory tract
irritation.
Ingestion No known critical hazard if swallowed
Eye Contact May cause eye irritation
Skin Contact May cause skin irritation
c. Potential Health Effects of Repeated

Exposures
Route of Entry Eye contact and absorbed through
skin
Symptoms Prolonged exposure causes nausea,
vomiting
and headache.
Target Organs Kidneys
Carcinogenicity No known carcinogenic chemicals in

glycerol.
First Aid
Inhalation Move to fresh air. If breathing difficulty

occurs, oxygen supply is required. Artificial
respiration is needed when breathing is not
sufficient.
Ingestion Wash mouth with water when the person is

conscious only and drink plenty of water.
Skin Contact Immediately flush skin with soap and a large

amount of water. Cover the irritated skin
area
with anti-bacterial cream and get medical
attention if symptoms occur.
Eye Contact Rinse eye immediately with plenty of water

including under the eyelids for at least 15
minutes. Seek medical attention.
Fire & Explosion
Flash Point 97°C
Auto ignition 400°C
185
Flammable Limits Not available
Extinguishing media Use water spray, fog or alcohol resistant

foam for large fire. Use dry chemical powder
for small fire. Use carbon dioxide.
Special firefighting procedures Wear self-contained breathing apparatus

and
protective clothing to avoid contact with skin
and clothing.
Hazardous combustion products Release irritating and toxic gases such as

carbon monoxide and carbon dioxide.
Place the glycerol in closed containers for

disposal.
Spill area is washed, absorbed with inert material and well
ventilated.
Use personal protective equipment and evacuate surrounding areas. No action shall be
taken
involving personal risk without proper instruction from safety
department.
Self-contained breathing apparatus need to be used when there is inadequate
ventilation.
Avoid disposal of waste and spilled material to nearby water source, drain and
sewer.
Inform the authorities and get licensed permission to dispose the harmful
waste.
Smoking or any ignition source is prohibited near the spillage
area.
Storage Hygroscopic.
Keep container tightly closed and in a cool
and well-ventilated area.
Handling Avoid contact with skin, eyes and clothing.

Avoid inhalation and prolonged exposure.
Special Precaution Keep away from any sources of ignition and

heat. Ground all equipment containing
glycerol. Do not store under direct
sunlight.
Personal Protection / Exposure Control
Personal Protection Use an air-purifying respirator for breathing.

The respirator must be properly
certified.
Gloves must be worn all the time when
handling chemical products. Inspect the
gloves before using it.
186
Lab coat must be worn when handling the
chemical products to prevent skin
exposure.
Long sleeved clothing which are chemical
resistant is significant when handling the
chemicals.
Engineering Controls Ensure eye wash and shower station are

nearer to the work source.
A well-ventilated area is required to ensure
that the exposure level to airborne
contaminants are always below the statutory
limits.
Mechanical exhaust are required in a
confined space.
Respiratory Protection Use appropriate certified respirators when

workers are overexposed to the
chemicals.
Eye Protection Wear safety glasses with side shields. Splash
goggles are also recommended to wear to
avoid dust, chemical splashes and gas
entering the eye.
Appearance, odor and state Viscous, Colorless liquid and no odor.
Molecular weight 104.11 g/mole
Gas Density 3.1
Vapor Pressure 0.003 mbar / 50°C
Boiling Point 194 °C
Freezing Point 17.9 °C
Solubility in water Miscible
a. Stability The product is stable
Materials to avoid Avoid strong oxidizing agents, excessive

heat
and open flames.
b. Reactivity Hygroscopic
187
Hazardous Decomposition Products Thermal decomposition release CO and CO2
Toxicity to Animals (LD 50) (ORAL) 8000 mg/kg (mouse) and 7750 mg/kg
(Guinea Pig).
(LD50) (DERMAL) 100 mg/kg (rat)
(LC 50) (INHALATION) Not applicable.
Product name is Glycerin

The product is water soluble and may absorb into water
systems.
The product degradation is not toxic.
Acute LC50 54000 mg/L Fish 96 hours.
Acute LC50 54 to 57 ml/L Fresh Water Fish – Rainbow trout, Donaldson trout –
Oncorhynchus mykiss – 0.9 g 96 hours
No adverse environmental effects.
Disposal
A licensed professional waste service should be contacted to dispose the

material.
Disposal should be in accordance with applicable regional, national and local laws and
regulations.
Do not reuse empty containers and disposes the container
properly.
Determine the proper waste identification and disposal
methods.
Classify the waste according to its hazardous and toxicity level and treat the waste
before
disposal.
Dissolve or mix the material with a combustible
solvent.
B.3 Material Safety Datasheet of Hydrogen [79]
Details
a. Common Name Hydrogen, Dihydrogen, Parahydrogen, Refrigerant

gas R702, Water gas
b. Formula H2
c. Overview Flammable high-pressure gas.

Can form explosive mixtures with air.
188
Burns with invisible flame.
May cause dizziness and drowsiness.
Self-contained breathing apparatus may be
required
by rescue workers.
Under ambient conditions, this is a colorless,
odorless, tasteless gas
d. Acute Potential Health Effects
Swallowed An unlikely route on exposure this product is a gas

at normal temperature and
pressure.
Eye Contact with rapidly expanding gas may cause
burns
or frostbite.
Skin Contact with rapidly expanding gas may cause

burns
or frostbite.
Inhaled Asphyxiant. Effects are due to lack of oxygen.

Moderate concentrations may cause headache,
drowsiness, dizziness, excitation, excess salivation,
vomiting and unconsciousness. Lack of oxygen can
kill.
Chronic No harm expected
e. Potential Health Effects of Repeated Exposures
Route of Entry
Symptoms
Concentration Symptoms of Exposure
12-16% Oxygen Breathing and pulse

rate increased, muscular
coordination slightly
disturbed
10-14% Oxygen Emotional upset,

abnormal fatigue,
disturbed respiration
6-10% Oxygen Nausea and vomiting,

collapse or loss of
189
consciousness
Below 6% Convulsive movements,

possible respiratory
collapse and death
In addition, inhalation of very high levels of this gas

may result in mild depression of the central
nervous
system. Symptoms can include headache, nausea,
dizziness, drowsiness, incoordination, and
confusion.
Target Organs Acute: Respiratory System.

Chronic: Heart, Central Nervous System.
Medical Conditions Aggravated The toxicology and the physical and chemical
by Overexposure properties of hydrogen suggest that overexposure
is
unlikely to aggravate existing medical
conditions.
Carcinogenicity This product is not listed by NTP, OSHA or IARC
First Aid
Swallowed An unlikely route of exposure. This product is a gas

at normal temperature and
pressure.
Eye Immediately flush eyes with plenty of water,
occasionally lifting the upper and lower eyelids.
Check for and remove any contact lenses. Continue
to rinse for at least 10 minutes. Get medical
attention
if irritation occurs.
Skin Flush contaminated skin with plenty of water.

Remove contaminated clothing and shoes. To avoid
the risk of static discharges and gas ignition, soak
contaminated clothing thoroughly with water
before
removing it. Get medical attention if symptoms
occur. Wash clothing before reuse. Clean shoes
thoroughly before reuse.
Inhalation Remove to fresh air. If not breathing, give artificial

respiration. If breathing is difficult, qualified
190
personnel may give oxygen. Call a
physician.
Fires and Explosion
Flash point Not applicable
Autoignition 570°C
Flammable limits 4.0-75.0%
Extinguishing Media Extinguish fires of this gas by shutting-off the

source
of the gas. Use water spray to cool fire-exposed
structures and equipment.
Special firefighting procedures Structural fire-fighters must wear Self-Contained

Breathing Apparatus and full protective equipment.
The best fire-fighting technique may be simply to
let
the burning gas escape. Stop the leak before
extinguishing fire. If the fire is extinguished before
the leak is sealed, the still-leaking gas could
explosively re-ignite without warning and cause
extensive damage, injury, or fatality. In this case,
increase ventilation to prevent flammable or
explosive mixture formation. Evacuation may be
necessary.
Unusual fire and explosion An extreme explosion hazard exists in areas in

hazards which the gas has been released, but the material
has
not yet ignited. Hydrogen burns with an almost
invisible blue flame. DANGER! Fires impinging
(direct flame) on the outside surface of
unprotected
pressure storage vessels of Hydrogen can be very
dangerous. Direct flame exposure on the cylinder
wall can cause an explosion either by BLEVE
(Boiling Liquid Expanding Vapor Explosion. This is
a catastrophic failure of the vessel releasing the
contents into a massive fireball and explosion. The
resulting fire and explosion can result in severe
equipment damage and personnel injury or death
over a large area around the vessel. For massive
fires
191
in large areas, use unmanned hose holder or
monitor
nozzles; if this is not possible, withdraw from area
and allow fire to burn.
Hazardous combustion products None
Personal Precautions: Evacuate area. Consider the risk of potentially explosive

atmospheres. Wear self-contained breathing apparatus when entering area unless
atmosphere is proved to be safe. Eliminate ignition sources. Ensure adequate air
ventilation. Act in accordance with local emergency plan. Stay
upwind.
Environmental Precautions: As the gas is lighter than air, ensure that hydrogen gas
is not
trapped in confine space. Otherwise this could lead to the formation of a highly
explosive
gas-air mixture. Ventilate all confined area using forced draught if necessary. Ensure
that
all electrically powered equipment is
flameproof.
Methods for Containment and Clean Up: Ventilate

area
Storage Store and use with adequate

ventilation.
Store only where temperature will not exceed
125°F
(52°C). Separate hydrogen cylinders from oxygen,
chlorine, and other oxidizers by at least 20 ft (6.1
m),
or use a barricade of noncombustible material. This
barricade should be at least 5 ft (1.53 m) high and
have a fire resistance rating of at least 1⁄2 hour.
Always secure cylinders upright to keep them from

falling or being knocked over. Install valve
protection cap, if provided, firmly in place by hand
when the cylinder is not in use. Post “No Smoking
or
Open Flames” signs in storage and use areas.
There
must be no sources of ignition. All electrical
equipment in storage areas must be explosion-
proof.
Storage areas must meet national electric codes
for
Class 1 hazardous areas. Store full and empty
192
cylinders separately. Use a first-in, first-out
inventory system to prevent storing full cylinders
for
long periods.
Handling Keep away from heat, hot surfaces, sparks, open

flames and other ignition sources. No smoking. Use
only non-sparking tools. Use only explosion-proof
equipment. Wear leather safety gloves and safety
shoes when handling cylinders. Protect cylinders
from physical damage; do not drag, roll, slide or
drop. While moving cylinder, always keep in place
removable valve cover. Never attempt to lift a
cylinder by its cap; the cap is intended solely to
protect the valve. When moving cylinders, even for
short distances, use a cart (trolley, hand truck,
etc.)
designed to transport cylinders. Never insert an
object (e.g., wrench, screwdriver, pry bar) into cap
openings; doing so may damage the valve and
cause
a leak. Use an adjustable strap wrench to remove
over-tight or rusted caps. Slowly open the valve. If
the valve is hard to open, discontinue use and
contact your supplier. Close the container valve
after
each use; keep closed even when empty. Never
apply flame or localized heat directly to any part of
the container. High temperatures may damage the
container and could cause the pressure relief
device
to fail prematurely, venting the container
contents
Special Precaution Put on appropriate personal protective equipment.
Contains gas under pressure. Avoid breathing gas.
Use only with adequate ventilation. Wear
appropriate respirator when ventilation is
inadequate. Do not enter storage areas and
confined
spaces unless adequately ventilated. Do not
puncture
or incinerate container. Use equipment rated for
193
cylinder pressure. Close valve after each use and
when empty. Protect cylinders from physical
damage; do not drag, roll, slide, or drop. Use a
suitable hand truck for cylinder movement. Use
only
non-sparking tools. Avoid contact with eyes, skin
and clothing. Empty containers retain product
residue and can be hazardous. Store and use away
from heat, sparks, open flame or any other ignition
source. Use explosion-proof electrical (ventilating,
lighting and material handling)
equipment.
Engineering Measures Use only with adequate ventilation. Use process

enclosures, local exhaust ventilation or other
engineering controls to keep worker exposure to
airborne contaminants below any recommended or
statutory limits. The engineering controls also need
to keep gas, vapor or dust concentrations below
any
lower explosive limits. Use explosion-proof
ventilation equipment.
Respiratory Protection Based on the hazard and potential for exposure,

select a respirator that meets the appropriate
standard
or certification. Respirators must be used according
to a respiratory protection program to ensure
proper
fitting, training, and other important aspects of
use.
Respirator selection must be based on known or
anticipated exposure levels, the hazards of the
product and the safe working limits of the selected
respirator.
Eye Protection Safety eyewear complying with an approved

standard should be used when a risk assessment
indicates this is necessary to avoid exposure to
liquid
splashes, mists, gases or dusts. If contact is
possible,
the following protection should be worn, unless the
194
assessment indicates a higher degree of
protection:
safety glasses with sideshields.
Body Protection Personal protective equipment for the body should

be selected based on the task being performed and
the risks involved and should be approved by a
specialist before handling this product. When there
is a risk of ignition from static electricity, wear
antistatic protective clothing. For the greatest
protection from static discharges, clothing should
include anti-static overalls, boots and
gloves.
Hand Protection Chemical-resistant, impervious gloves complying
with an approved standard should be worn at all
times when handling chemical products if a risk
assessment indicates this is necessary. Considering
the parameters specified by the glove
manufacturer,
check during use that the gloves are still retaining
their protective properties. It should be noted that
the
time to breakthrough for any glove material may
be
different for different glove manufacturers. In the
case of mixtures, consisting of several substances,
the protection time of the gloves cannot be
accurately estimated.
Other Protective Equipment
Appearance Colorless
Odor Odorless
State Gas at normal temperature and

pressure
Molecular Weight 2.016 g/mol
Gas Density 0.08989g/ml (at 1 atm)
Vapor Pressure Not applicable
Specific Gravity 0.07 at 32°F (0°C)
Boiling Point -422.97°F (-252.76°C) at 1 atm
Freezing Point/Melting Point -434.56°F (-259.2°C) at 1 atm
195
Solubility in Water 0.019 vol/vol at 60°F (15.6°C)
a. Stability: Stable under normal conditions.
Conditions to avoid Overheating of cylinders. Keep sparks & flames

away from cylinders and under no circumstances
allow a torch flame to come into contact with any
part of the cylinder. Never test leaks with flame.
Use
soapy water when testing for leaks. Never use
cylinders as rollers or supports or for any other
purpose other than the storing of
hydrogen.
Incompatibility (Materials to Oxidizing agents. Lithium. Halogens.
Avoid)
b. Reactivity: No reactivity hazards.
Hazardous Decomposition No hazardous compounds are formed when

Products hydrogen/air mixture burn.
Hazardous Polymerization None
Acute Toxicity
Hydrogen, compressed (\f) 1333-74-0

LC50 inhalation rat >15000ppm/1h
(ppm)
Hydrogen (1333-74-0)
LC50 inhalation rat >15000ppm/1h

(ppm)
Skin and eye contact No known effect
Chronic toxicity No known effect
Carcinogenicity No known effect
Mutagenicity No known effect
Reproductive hazards No known effect
As hydrogen is lighter than air it will disperse rapidly in open areas. It does not pose
a
hazard to the ecology.
Disposal
196
Disposal Methods Small amounts may be blown to the atmosphere under controlled
conditions. No source of ignition should be in the vicinity. Large amounts should only
be
handled by the gas supplier. Disposal of Packaging The disposal of cylinders must
only
be handled by the gas supplier.
B.4 Material Safety Datasheet of Methanol [80]
Details
a. Common name Methanol, Methyl Hydrate and Methyl

alcohol.
b. Formula CH3OH
a. Overview Methanol is a simplest alcohol, light,

colorless and flammable liquid. Glycerol is
naturally occurring chemical. It is miscible
with water, ether, alcohol and other organic
solvents. It is a hazardous
chemical.
Inhalation Slight irritation of nose and eyes. Lack of

coordination and visual disturbance.
Ingestion Staggering, lack of coordination, mental

confusion and tiredness.
Eye Contact Methanol may seriously impair vision and

cause blindness. Irritation with painful
burning or stinging sensation.
Skin Contact Methanol is highly volatile and direct skin

contact can cause irritation, dermatitis,
erythema and scaling.
c. Potential Health Effects of Repeated

Exposures
Route of Entry Toxic by ingestion and skin absorption.
Symptoms Irritant and toxic if swallowed or inhaled.
Target Organs Eyes, Liver, Heart, Kidneys and Central

Nervous System.
197
Carcinogenicity No known carcinogenic chemicals in
methanol.
First Aid
Inhalation Move the person to fresh air if inhaled.

Remove contaminated clothing and
equipment. Provides artificial respiration
when breathing is not sufficient. Seek
medical attention immediately.
Ingestion Remove the victim from contaminated area

to a quiet, well-ventilated area. Call a posion
call center, to seek advice regarding the
chemical swallowed.
Skin Contact Immediately wash the affected area with

tepid water. Dry the skin gently with clean,
soft towel. Seek medical attention
immediately.
Eye Contact Gently rise the affected area of eye with

clean, lukewarm water for atleast 15
minutes.
Hold the eyelid(s) open and pour water
slowly over the eyeball(s) at the inner
corners, letting the water run out of the
outer
corners. Consult a physician if the victim
cannot tolerate the pain.
Fire & Explosion
Flash Point 12°C
Auto ignition 464°C
Flammable Limits LOWER: 6% and UPPER: 36.5%
Extinguishing media Use dry chemical alcohol foam, or carbon

dioxide; water spray may be ineffective as
an
extinguishing agent, but water should be
used
to keep fire-exposed containers
cool.
Special firefighting procedures Fire fighters should use self-contained
breathing apparatus and protective
clothing.
198
Hazardous combustion products Forms an explosive mixture with air due to
its low flash point It boils violently and
explodes. Release carbon oxides.
Methanol is a flammable liquid. Hence, keep it away from heat and sources of
ignition.
If small spill, dilute with water and mop up, or absorb with an inert dry material
and
Place in an appropriate waste disposal container according to local
regulations.
Use personal protective equipment and evacuate surrounding areas. No action shall be
taken
involving personal risk without proper instruction from safety
department.
Avoid breathing vapors, mist or gas. Self-contained breathing apparatus need to be
used
when there is inadequate
ventilation.
Inform the authorities and get licensed permission to dispose the harmful
waste.
Smoking or any ignition source is prohibited near the spillage
area.
Storage Keep container tightly closed in a dry and

well-ventilated place. Containers which are
opened must be carefully resealed and kept
upright to prevent leakage.
Handling Avoid contact with skin, eyes and clothing.

Avoid inhalation of vapor or mist and
prolonged exposure.
Keep away from sources of ignition – do not
smoke.
Take measures to prevent the buildup of
electrostatic charge.
Special Precaution Ground all equipment containing

material.
Keep away from incompatibles such as
oxidizing agents, metals, acids.
Personal Protection / Exposure Control
Personal Protection Use an air-purifying respirator for breathing.

The respirator must be properly
certified.
Appropriate protective clothing, including
gloves, aprons, suits, boots, and face shields
199
that are impervious to methyl alcohol should
be worn to prevent repeated or prolonged
skin contact.
Engineering Controls Provide exhaust ventilation or other

engineering controls to keep the airborne
concentrations of vapors below their
respective threshold limit value. Ensure that
eyewash stations and safety showers are
proximal to the work-station location
Respiratory Protection Supplied-air or self-contained breathing

apparatus operated in the positive pressure
mode.
Eye Protection Face shield and safety glasses Use

equipment
for eye protection tested and approved
under
appropriate government standards such as
NIOSH (US) or EN 166(EU).
Appearance, odor and state Clear, Colorless liquid and alcohol odor.
Molecular weight 32.04 g/mole
Gas Density 1.11
Vapor Pressure 12.3 kPa / 20°C
Boiling Point 64.5 °C
Freezing Point -97.6°C
Solubility in water Miscible
a. Stability The product is stable
Materials to avoid Avoid oxidizers, metals and acids.
b. Reactivity Hygroscopic and can ignite.
Hazardous Decomposition Products Hazardous decomposition products formed

under fire conditions. - Carbon oxides
Toxicity to Animals (LD 50) (ORAL) 5628 mg/kg (rat)
200
(LD50) (DERMAL) 15800 mg/kg (rabbit)
(LC 50) (INHALATION) 64000 4 hours (rat)
Eco toxicity in water (LC50): 29400 mg/l 96 hours.

Possibly hazardous short term degradation products are not
likely
The products of degradation are less toxic than the product
itself.
Low concentrations are biodegradable; therefore, long-term ecological effects are not
anticipated.
Disposal
Recycling/reuse of all methanol residuals is

recommended.
Consult state and local regulations regarding the proper disposal of the
material.
Burn in a chemical incinerator equipped with an afterburner and scrubber but be more
cautious when igniting as this material is highly
flammable.
Dispose of as unused product.
Offer surplus and non-recyclable solutions to a licensed disposal
company.
B.5 Material Safety Datasheet of Water [81]
Details
f. Common Name Water
g. Formula H2 O
h. Overview Colorless, Odorless, Tasteless
i. Acute Potential Health Effects
Ingestion Not applicable
Eye Not applicable
Skin Not applicable
Inhaled Not applicable
Chronic No harm expected
j. Potential Health Effects of Repeated Exposures
Route of Entry Absorb through skin, eye contact
Symptoms Not available
201
Target Organs Not available
Medical Conditions Aggravated by Non -corrosive for skin. Non-irritant for skin. Non-
Overexposure permeator by skin. Non-irritating to the eyes. Non-
hazardous in case of ingestion. Non-hazardous in
case of inhalation. Non-irritant for lungs. Non-
sensitizer for lungs.
Carcinogenicity Not available
First Aid
Ingestion Not applicable
Eye Not applicable
Skin Not applicable
Inhalation Not applicable
Fires and Explosion
Flash point Not applicable
Autoignition Not applicable
Flammable limits Not applicable
Extinguishing Media Not applicable
Special firefighting procedures Not applicable
Unusual fire and explosion hazards Not applicable
Hazardous combustion products Not applicable
Small Spill:
Mop up or absorb with an inert dry material and place in an appropriate waste disposal
container.
Large Spill:
Absorb with an inert material and put the spilled material in an appropriate waste
disposal.
Storage Not applicable
Handling No specific safety phrase has been found

applicable
for this product.
Engineering Measures Not applicable
202
Exposure Limits Not available
Body Protection Not applicable
Full Body Protection Safety glasses. Lab coat
Other Protective Equipment Not applicable
Appearance Liquid
Odor Odorless
State Gas at normal temperature and

pressure
Gas Density 0.62 g/ml (at 1 atm)
Vapor Pressure 2.3 kPa @ at 20℃
Specific Gravity 1
Boiling Point 212°F (100°C) at 1 atm
Freezing Point/Melting Point Not available
Solubility in Water Not applicable
c. Stability: Stable under normal conditions.
Conditions to avoid Not available
Incompatibility (Materials to Avoid) Not available
d. Reactivity: No reactivity hazards.
Hazardous Decomposition Products Not available
Routes of Entry Absorbed through skin. Eye contact.
Toxicity to Animals LD50: [Rat]-Route: oral; Dose:> 90 ml/kg LC50:

Not available
Chronic toxicity Not available
Carcinogenicity Not available
Mutagenicity Not available
Reproductive hazards Not available
203
Products of Biodegradation: Possibly hazardous short term degradation products are not
likely. However, long term degradation products may
arise.
Toxicity of the Products of Biodegradation: The product itself and its products of
degradation are not toxic.
Disposal
Waste must be disposed of in accordance with federal, state and local environmental
control
regulations.
B.6 Material Safety Datasheet of Ethylene Glycol [82]
Details
a. Common Name 1,2-Dihydroxyethane; 1,2-Ethanediol; 1,2-

Ethandiol; Ethylene dihydrate; Glycol alcohol;
Monoethylene glycol; Tescol
b. Formula HOCH2CH2OH
c. Overview Odorless, Colorless, Sweet-tasting, Viscous liquid
Ingestion Hazardous in case of ingestion.
Eye Hazardous in case of eye contact

(irritant).
Skin Slightly hazardous in case of skin contact (irritant,
permeator).
Inhaled Hazardous in case of inhalation.
Chronic Severe over-exposure can result in

death.
Route of Entry Absorbed through skin, ingestion
Symptoms When ingested early symptom mimic alcohol

inebriation and are followed by nausea, vomiting,
abdominal pain, weakness, muscle tenderness,
respiratory failure, convulsions, cardiovascular
204
collapse, pulmonary edema, hypocalcemic tetany,
and severe metabolic acidosis. Without treatment,
death may occur in 8 to 24 hours. Victim who
survive initial toxicity period usually develop renal
failure along with brain and liver damage.
Exposure
to and/or consumption of alcohol may increase
toxic
effect.
Target Organs Kidneys, liver, central nervous system (CNS).
Medical Conditions Aggravated by Person with pre-existing kidney, respiratory, eye, or

Overexposure neurological problems might be more sensitive to
Ethylene glycol.
Carcinogenicity A4 (Not classified for human or animal) by ACGIH
First Aid
Ingestion Do not induce vomiting unless directed to do so by

medical personnel. Never give anything by mouth
to
an unconscious person. If large quantities of this
material are swallowed, call a physician
immediately. Loosen tight clothing such as a collar,
tie, belt or waistband.
Eye Check for and remove any contact lenses.

Immediately flush eyes with running water for at
least 15 minutes, keeping eyelids open. Cold water
may be used. Get medical
attention.
Skin  In case of contact, wash with soap and
water.
Cover the irritated skin with emollient. Ge
medical attention if irritation develops. Cold
water may be used.
 Serious skin contact, not available.
Inhalation If inhaled, remove to fresh air. If not breathing,

give
artificial respiration. If breathing is difficult, give
oxygen. Get medical attention.
Fires and Explosion
Flash point CLOSED CUP: 111°C (231.8°F). (Tagliabue).
205
Autoignition 398°C (748.4°F)
Flammable limits Lower: 3.2%
Extinguishing Media Use dry chemical powder for small fire and use
water spray, fog or foam and do not use water jet
for
large fire.
Special firefighting procedures SMALL FIRE: Use DRY chemical powder.

LARGE FIRE: Use water spry, fog or foam. Do not
use water jet.
Unusual fire and explosion hazards Not available
Hazardous combustion products None
Small Spill:
Dilute with water and mop up or absorb with an inert dry material and place in an
appropriate
waste disposal container. Finish cleaning by spreading water on the contaminated
surface and
dispose of according to local and regional authority
requirements.
Large Spill:
Stop leak if without risk. Do not get water inside container. Do not touch spilled
material.
Use water spray to reduce vapors. Prevent entry into sewers, basements or confined
areas;
dike if needed. Eliminate all ignition source. Call for assistance on disposal. Finish
cleaning
by spreading water on the contaminated surface and allow to evacuate through the
sanitary
system. Be careful that the product is not present at a concentration level above TLV.
Check
TLV on the MSDS and with local authorities.
Storage Hygroscopic. Keep container tightly closed. Keep

container in a cool, well-ventilated
area.
Handling Keep away from heat. Keep away from sources of
ignition. Empty containers pose a fire risk,
evaporate the residue under a fume hood. Ground
all
equipment containing material. Do not ingest. Do
not breathe gas/fumes/ vapor/spray. Wear suitable
protective clothing. If ingested, seek medical
advice
immediately and show the container or the label.
206
Avoid contact with skin and eyes. Keep away from
incompatibles such as oxidizing agents, reducing
agents, acids, alkalis.
Engineering Measures Provide exhaust ventilation or other engineering

controls to keep the airborne concentrations of
vapors below their respective threshold limit value.
Ensure that eyewash stations and safety showers
are
proximal to the work-station location.
Exposure Limits STEL: 120(mg/m3) [Australia] TWA: 100 (mg/m3)

from ACGIH (TLV) [United State] CEIL: 125
(mg/m3) from OSHA (PEL) [ United State] CEIL:
50 (ppm) from OSHA (PEL) [United State] TWA:
52 STEL: 104 (mg/m3) [United Kingdom(UK)]
Inhalation TWA: 10 (mg/m3) [United
Kingdom(UK)] SKIN3 Consult local authorities for
acceptable exposure limits.
Body Protection Safety glasses. Synthetic apron. Gloves

(impervious). For most conditions, no respiratory
protection should need. However, if material is
heated or sprayed and if atmospheric levels
exceed
exposure guidelines, use an approved vapor (air
purifying) respirator.
Full Body Protection Splash googles. Full suit. Boots. Gloves. Suggested
protective clothing might not sufficient; consult a
specialist BEFORE handling this product.
Appearance Liquid (Syrupy)
Odor Odorless
State Liquid at normal temperature and

pressure
Gas Density 2.14 g/ml (at 1 atm)
207
Vapor Pressure 0.06 mmHg @ 20°C; 0.092 mmHg at 25°C
Boiling Point 387.7°F (197.6°C) at 1 atm
Freezing Point/Melting Point 8.6°F (-13°C) at 1 atm
Solubility in Water Soluble in cold water and hot water
f. Stability: Stable under normal conditions.
Conditions to avoid Excess heat, incompatible

materials.
Incompatibility (Materials to Avoid) Reactive with oxidizing agents, acids,
alkalis.
g. Reactivity: No reactivity hazards.
Hazardous Decomposition Products Explosive decomposition may occur if combined

with strong acids and strong bases and subjected
to
elevated temperatures.
Routes of Entry Absorbed through skin. Ingestion.
Toxicity to Animals Acute oral toxicity (LD50): 4700 mg/kg [Rat].

Acute toxicity of the vapor (LC50) :> 200 mg/m3 4
hours [Rat].
Chronic toxicity Hazardous in case of ingestion. Slightly hazardous

in case of skin contact (irritant, permeator), of
inhalation
Carcinogenicity A4 (Not classifiable for human or animal) by

ACGIH
Mutagenicity Mutagenic for mammalian somatic cell. Non-

mutagenic for bacteria and/or
yeast.
Reproductive hazards May cause adverse reproductive effects and birth
defects (teratogenic) based on animal test data.
No
human data reported this
time.
Ecotoxicity
Products of Biodegradation: Ecotoxicity in water (LC50): 41000mg/l 96 hours
Toxicity of the Products of [Fish (Trout)]. 46300 mg/l 48 hours [water flea].
208
Biodegradation: The products of 34250 mg/l 96 hours [fish (bluegill fish)]. 34250
degradation are less toxic than mg/l 72 hours [Fish (Goldfish)].
the
product itself.
Special Remarks on the Products of
Biodegradation: Not available.
BOD5 and COD Not available
Products of Biodegradation Possibly hazardous short-term degradation

products
are not likely. However, long term degradation
products may arise.
Disposal
Waste must be disposed of in accordance with federal, state and local environment
control
regulation.
B.7 Material Safety Datasheet of Acetol [83]
Details
a. Common Name Hydroxyacetone
b. Formula C3H6O2
c. Overview Classification under CHIP: -: R10

Classification under CLP: Flam. Liq. 3: H226
Most important adverse effects:
Flammable
Label elements under CLP:
Hazard statements: H226: Flammable liquid and
vapor. Signal words: Warning
Hazard pictograms: GHS02: Flame
209
Swallowed May result in nausea, vomiting and

diarrhea
Eye Mild irritant
Skin Mild irritant
Inhaled Does not present an inhalation

problem
Chronic Choline chloride is metabolized in the liver.
Prolonged or repeated exposure may lead to
symptoms of gastro-intestinal discomfort and
depression
Ingestion Mild irritant to the throat
Route of Entry Inhalation, ingestion, skin contact
Symptoms Breathing difficulties
Target Organs None
Medical Conditions Aggravated by Headache, dizziness, tiredness, nausea and vomiting

Overexposure
Carcinogenicity No information available
First Aid
Swallowed Rinse mouth with water. Give large quantities of

water or bland fluids to drink. DO NOT induce
vomiting. Seek medical attentions. Show this MSDS
to medical practitioner.
Eye Immediately flush eye with plenty of water for at

least 15 minutes.
Skin Wash skin with soap and water. Remove all

contaminated clothing.
210
Fires and Explosion
Flash point 56°C/132.8°F
Autoignition 280°C/536°F
Flammable limits Lower: 3%

Upper: 14.9%
Extinguishing Media Carbon dioxide, dry chemical powder, foam.

Suitable extinguishing media for the surrounding
media should be used.
Special firefighting procedures Advice for firefighters: Wear self-contained

breathing apparatus and full protective
suit
Unusual fire and explosion hazards
Hazardous combustion products Carbon dioxide and carbon dioxide
Personal Precautions: Use personal protective equipment. Remove all sources of

ignition.
Take precautionary measures against static
discharges.
Environmental Precautions: Should not be released into the

environment.
Methods for Containment and Clean Up: Soak with inert absorbent material. Keep in
suitable, closed containers for disposal. Remove all sources of ignition. Use spark-proof
tools
and explosion-proof equipment.
Storage Keep away from heat and sources of ignition. Keep

container tightly closed in a dry and well-ventilated
place. Keep refrigerated. Store under an inert
atmosphere. Flammables
area.
Handling Wear personal protective equipment. Ensure
adequate ventilation. Keep away from open
flames,
hot surfaces and sources of ignition. Take
precautionary measures against static discharges.
Use only non-sparking tools.
Special Precaution
211
Engineering Measures Ensure there is sufficient ventilation of the area.
Ensure lighting and electrical equipment are not a
source of ignition.
Respiratory Protection Respiratory protection not required.
Eye Protection Safety glasses. Ensure eye bath is to

hand.
Skin Protection Protective clothing.
Other Protective Equipment Protective gloves.
Appearance Colorless
Odor Characteristic
State Liquid
Molecular Weight 74.08
Gas Density No information available
Vapor Pressure 7.4 mbar (20°C)
Boiling Point 145 - 146 °C / 293 - 294.8 °F
Freezing Point/Melting Point -17 °C / 1.4 °F
pH 3.4 (50%)
Viscosity 1.592 mPas at 48C
Solubility in Water Miscible in all proportions
f. Stability: Stable under normal conditions. Stable at room

temperature.
Conditions to avoid Heat. Hot surfaces. Sources of ignition. Flames. Air.
Moist air. Humidity.
Incompatibility (Materials to Avoid) Strong oxidising agents. Strong acids.
g. Reactivity: Stable under recommended transport or storage

conditions.
Hazardous Decomposition Products In combustion emits toxic fumes of carbon
dioxide /
carbon monoxide.
Hazardous Polymerization Hazardous polymerization does not

occur.
LD50 (Oral) 2200mg/kg
LD50 (Dermal) >10000mg/l
212
Do not empty into drains
Component Freshwater Freshwater Fish Microtox Water Flea

Algae
Acetone Not listed Leusiscus idus: Not listed Not Listed

alcohol LC50: >4600
10000
mg/L/96H
Disposal
Chemical waste generators must determine whether a discarded chemical is classified

as a
hazardous waste. Chemical waste generators must also consult local, regional, and
national
hazardous waste regulations to ensure complete
and
213
Appendix C: Mass Balance on Individual Unit
C.1 Pump (P-101)
Pump (P-101)
Study Node
INLET OUTLET
Stream 1 3
303.00 352.42
Temperature (K)
1.00 40.00
Pressure (bar)
0.00 0.00
Vapor Fraction
Mass flow rate Mass flow rate
Mole fraction(ton/hr) Mole fraction(ton/hr)
Molar flow rate Molar flow rate
1.0010.98 1.0010.98
Components (kmol/hr) Mass fraction (kmol/hr) Mass fraction
0.000.00 0.000.00
Glycerol 119.22 1.00 119.22 1.00
0.000.00 0.000.00
Hydrogen 0.00 0.00 0.00 0.00
0.000.00 0.000.00
Propylene Glycol 0.00 0.00 0.00 0.00
0.000.00 0.000.00
Ethylene Glycol 0.00 0.00 0.00 0.00
0.000.00 0.000.00
Methanol 0.00 0.00 0.00 0.00
0.000.00 0.000.00
Acetol 0.00 0.00 0.00 0.00
1.0010.98 1.0010.98
Water 0.00 0.00 0.00 0.00
10.98 10.98
Total 119.22 1.00 119.22 1.00
Mass Balance (ton/hr)
214
C.2 Heat Exchanger (E-101)
215
C.3 Compressor (C-101)
Compressor (C-101)
Study Node
INLET OUTLET
Stream 2 5
303.00 328.66
Temperature (K)
1.00 40.00
Pressure (bar)
1.00 1.00
Vapor Fraction
Molar flow rate Mass flow rate Molar flow rate Mass flow rate
Components (kmol/hr) Mole fraction(ton/hr) Mass fraction (kmol/hr) Mole fraction(ton/hr) Mass fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 396.05 1.000.80 1.00 396.05 1.000.80 1.00
Propylene Glycol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 396.05 1.000.80 1.00 396.05 1.000.80 1.00
Mass Balance (ton/hr) 0.80 0.80
216
C.4 Mixing Point
Mixing Point
Study Node
INLET INLET OUTLET

Stream 5 9 6
328.66 609.00 500.11
Temperature (K) 40.00 40.00 40.00
Pressure (bar) 1.00 1.00 1.00
Vapor Fraction Mass flow rate Mass flow rate Mass flow rate
Mole fraction(ton/hr) Mole fraction(ton/hr) Mole fraction(ton/hr)
Molar flow rate Molar flow rate Molar flow rate
0.000.00 0.000.00 0.000.00
Components (kmol/hr) Mass fraction(kmol/hr) Mass fraction (kmol/hr) Mass fraction
1.000.80 1.000.40 1.001.20
Glycerol 0.00 0.000.00 0.00 0.00 0.00
0.000.00 0.000.00 0.000.00
Hydrogen 396.05 1.00200.07 1.00 596.12 1.00
0.000.00 0.000.00 0.000.00
Propylene Glycol 0.00 0.000.00 0.00 0.00 0.00
0.000.00 0.000.00 0.000.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.00
0.000.00 0.000.00 0.000.00
Methanol 0.00 0.000.00 0.00 0.00 0.00
0.000.00 0.000.00 0.000.00
Acetol 0.00 0.000.00 0.00 0.00 0.00
1.000.80 1.000.40 1.001.20
Water 0.00 0.000.00 0.00 0.00 0.00
1.20
Total 396.05 1.00200.07 1.00 596.12 1.00
Mass Balance (ton/hr) 1.20
217
Heat Exchanger (E-102)
Study Node
INLET OUTLET
Stream 6 7
500.11 473.00
Temperature (K)
40.00 40.00
Pressure (bar)
1.00 1.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 596.12 1.001.20 0.11 596.12 1.001.20 0.11
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 596.12 1.001.20 0.11 596.12 1.001.20 0.11
218
C.6 Packed Bed Reactor (R-101)
Assumption: Refer Table 18, Hydrogen to glycerol ratio =

5:1
Packed Bed Reactor (R-101)
Study Node
INLET INLET OUTLET

Stream 4 7 8
473.00 473.00 473.00
Temperature (K) 40.00 40.00 40.00
Pressure (bar) 0.00 1.00 1.00
Vapor Friction Mass flow rate Mass flow rate Mass flow rate
Molar flow rate Mole fraction(ton/hr) Molar flow rate Mole fraction(ton/hr) Molar flow rate Mole fraction(ton/hr)
(kmol/hr) 1.0010.98 Mass fraction(kmol/hr) 0.000.00 (kmol/hr) 0.032.03
Components 0.000.00 1.001.20 Mass fraction 0.701.01 Mass fraction
Glycerol 119.22 1.000.00 0.00 22.06 0.17
0.00 0.000.00 0.00596.12 0.000.00 500.18 0.137.09
Hydrogen 0.000.00 0.000.00 1.00 0.000.17 0.84
Propylene Glycol 0.00 0.000.00 0.00 93.22 5.90
0.00 0.000.00 0.000.00 0.000.00 2.72 0.000.09
Ethylene Glycol 0.000.00 0.000.00 0.00 0.000.09 0.14
Methanol 0.00 0.000.00 0.00 2.72 0.07
0.00 0.000.00 0.000.00 0.000.00 1.23 0.131.70
Acetol 1.0010.98 1.001.20 0.00 1.0012.18 0.08
Water 0.00 0.000.00 0.00 94.45 1.42
119.22 1.00596.12 716.57 12.18
Total 1.00 8.61
Mass Balance (ton/hr) 12.18
219
C.7 Condenser (E-103)
Condenser (E-103)
E-103
Study Node 8 710
COOLING WATER
INLET OUTLET
Stream 8 10
473.00 473.00
Temperature (K)
40.00 40.00
Pressure (bar)
1.00 1.00
Vapor Fraction
Mass flow rate Mass flow rate
Molar flow rate Mole fraction(ton/hr) Molar flow rate Mole fraction(ton/hr)
(kmol/hr) 0.032.03 (kmol/hr) 0.032.03
Components Mass fraction Mass fraction
22.06 0.701.01 22.06 0.701.01
Glycerol 0.17 0.17
500.18 0.137.09 500.18 0.137.09
Hydrogen 0.08 0.08
93.22 0.000.17 93.22 0.000.17
Propylene Glycol 0.58 0.58
2.72 0.000.09 2.72 0.000.09
Ethylene Glycol 0.01 0.01
2.72 0.000.09 2.72 0.000.09
Methanol 0.01 0.01
1.23 0.131.70 1.23 0.131.70
Acetol 0.01 0.01
94.45 1.0012.18 94.45 1.0012.18
Water 0.14 0.14
716.57 12.18 716.57 12.18
Total 1.00 1.00
Mass Balance (ton/hr)
220
Study Node
INLET OUTLET
Stream 10 11
473.00 609.00
Temperature (K)
40.00 40.00
Pressure (bar)
1.00 0.00
Vapor Fraction
Glycerol 22.06 0.032.03 0.19 22.06 0.032.03 0.19
Hydrogen 500.18 0.701.01 0.09 500.18 0.701.01 0.09
Ethylene Glycol 2.72 0.000.17 0.02 2.72 0.000.17 0.02
Methanol 2.72 0.000.09 0.01 2.72 0.000.09 0.01
Acetol 1.23 0.000.09 0.01 1.23 0.000.09 0.01
Water 94.45 0.131.70 0.15 94.45 0.131.70 0.15
Total 716.57 1.0012.18 1.11 716.57 1.0012.18 1.11
221
C.9 Flash Drum (V-101)
Assumption: As hydrogen gas is non-condensable, 100.0% hydrogen gas is

separated.
Flash Drum (V-101)
Study Node
INLET OUTLET OUTLET

Stream 11 13 12
609.00 609.00 609.00
Temperature (K) 40.00 40.00 40.00
Pressure (bar) 0.00 1.00 0.00
Vapor Fraction
Molar flow rate Mass flow rate Molar flow rate Mass flow rate Molar flow rate Mass flow rate
Components (kmol/hr) Mole fraction(ton/hr) Mass fraction (kmol/hr) Mole fraction (ton/hr) Mass fraction(kmol/hr) Mole fraction (ton/hr) Mass fraction
Glycerol 22.06 0.032.03 0.17 0.00 0.00 0.00 0.0022.06 0.10 2.03 0.18
Hydrogen 500.18 0.701.01 0.08 500.18 1.00 1.01 1.000.00 0.00 0.00 0.00
Propylene Glycol 93.22 0.137.09 0.58 0.00 0.00 0.00 0.0093.22 0.43 7.09 0.63
Ethylene Glycol 2.72 0.000.17 0.01 0.00 0.00 0.00 0.002.72 0.01 0.17 0.02
Methanol 2.72 0.000.09 0.01 0.00 0.00 0.00 0.002.72 0.01 0.09 0.01
Acetol 1.23 0.000.09 0.01 0.00 0.00 0.00 0.001.23 0.01 0.09 0.01
Water 94.45 0.131.70 0.14 0.00 0.00 0.00 0.0094.45 0.44 1.70 0.15
Total 716.57 1.0012.18 1.00 500.18 1.00 1.01 1.00216.39 1.00 11.17 1.00
222
C.10 Splitting Point
Assumption: Purge ratio = 0.60

Splitting Point
Study Node
INLET OUTLET OUTLET

Stream 13 9 14
609.00 609.00 609.00
Temperature (K) 40.00 40.00 40.00
Pressure (bar) 1 1.00 1.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 500.18 1.001.01 1.00 200.07 1.00 0.40 1.00300.11 1.00 0.60 1.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 500.18 1.001.01 1.00 200.07 1.00 0.40 1.00300.11 1.00 0.60 1.00
223
C.11 Expander (D-101)
Expander (D-101)
15
Study Node 12
D-101
INLET OUTLET
Stream 12 15
609.00 532.62
Temperature (K)
40.00 1.00
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 22.06 0.102.03 0.18 22.06 0.102.03 0.18
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.010.17 0.02 2.72 0.010.17 0.02
Methanol 2.72 0.010.09 0.01 2.72 0.010.09 0.01
Acetol 1.23 0.010.09 0.01 1.23 0.010.09 0.01
Water 94.45 0.441.70 0.15 94.45 0.441.70 0.15
Total 216.39 1.0011.17 1.00 216.39 1.0011.17 1.00
224
E-201
Study Node 15 16
STEAM
INLET OUTLET
Stream 15 16
532.62 446.49
Temperature (K)
1.00 1.00
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 22.06 0.102.03 0.18 22.06 0.102.03 0.18
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.010.17 0.02 2.72 0.010.17 0.02
Methanol 2.72 0.010.09 0.01 2.72 0.010.09 0.01
Acetol 1.23 0.010.09 0.01 1.23 0.010.09 0.01
Water 94.45 0.441.70 0.15 94.45 0.441.70 0.15
Total 216.39 1.0011.17 1.00 216.39 1.0011.17 1.00
225
C.13 Distillation Column (V-201)
Assumption: Recovery of Heavy Key (Propylene Glycol) = 0.0003
Recovery of Light Key (Acetol) = 0.9998

Distillation Column (V-201)
17 18
E-202
Cooling water
V-202
19 20
Study Node
16 V-201
22
E-203
23
21
INLET OUTLET
Stream 19
16 22 17 21
446.49 374.38 467.65 374.38 467.65
Temperature (K)
1.00 1.00 1.00 1.00 1.00
Pressure (bar)
0.00 0.00 1.00 1.00 0.00
Vapor Fraction
Molar flow rate Mass flow rate Molar flow rate Mass flow rate Molar flow rate Mass flow rate Molar flow rate Mass flow rate Molar flow rate Mass flow rate
Components (kmol/hr) Mole fraction (ton/hr) Mass fraction (kmol/hr) Mole fraction(ton/hr) Mass fraction (kmol/hr) Mole fraction (ton/hr) Mass fraction (kmol/hr) Mole fraction (ton/hr) Mass fraction(kmol/hr) Mole fraction (ton/hr) Mass fraction
Glycerol 22.06 0.10 2.03 0.18 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.0022.06 0.09 2.03 0.10
Hydrogen 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Propylene Glycol 93.22 0.43 7.09 0.63 0.01 0.000.00 0.00 133.25 0.97 10.14 0.98 0.03 0.00 0.00 0.00226.44 0.89 17.23 0.88
Ethylene Glycol 2.72 0.01 0.17 0.02 0.00 0.000.00 0.00 3.89 0.03 0.24 0.02 0.00 0.00 0.00 0.006.61 0.03 0.41 0.02
Methanol 2.72 0.01 0.09 0.01 0.53 0.030.02 0.05 0.00 0.00 0.00 0.00 3.25 0.03 0.10 0.050.00 0.00 0.00 0.00
Acetol 1.23 0.01 0.09 0.01 0.24 0.010.02 0.05 0.00 0.00 0.00 0.00 1.46 0.01 0.11 0.050.00 0.00 0.00 0.00
Water 94.45 0.44 1.70 0.15 18.23 0.960.33 0.90 0.00 0.00 0.00 0.00 112.67 0.96 2.03 0.900.00 0.00 0.00 0.00
Total 216.39 1.00 11.17 1.00 18.99 1.000.36 1.00 137.14 1.00 10.38 1.00 117.42 1.00 2.24 1.00255.11 1.00 19.67 1.00
226
Condenser (E-202)
Study Node
INLET OUTLET
Stream 17 18
374.38 374.38
Temperature (K)
1.00 1.00
Pressure (bar)
1.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Methanol 3.25 0.030.10 0.05 3.25 0.030.10 0.05
Acetol 1.46 0.010.11 0.05 1.46 0.010.11 0.05
Water 112.67 0.962.03 0.90 112.67 0.962.03 0.90
Total 117.42 1.002.24 1.00 117.42 1.002.24 1.00
227
C.15 Reflux Drum (V-202)
Assumption: Reflux ratio = 0.19

Reflux Drum (V-202)
Study Node
INLET OUTLET OUTLET

Stream 18 19 20
374.38 374.38 374.38
Temperature (K) 1.00 1.00 1.00
Pressure (bar) 0.00 0.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Methanol 3.25 0.030.10 0.05 0.53 0.03 0.02 0.052.72 0.03 0.09 0.05
Acetol 1.46 0.010.11 0.05 0.24 0.01 0.02 0.051.23 0.01 0.09 0.05
Water 112.67 0.962.03 0.90 18.23 0.96 0.33 0.9094.45 0.96 1.70 0.90
Total 117.42 1.002.24 1.00 18.99 1.00 0.36 1.0098.42 1.00 1.88 1.00
228
C.16 Reboiler (E-203)
Assumption: Boilup ratio = 1.43

Reboiler (E-203)
Study Node
INLET OUTLET OUTLET

Stream 21 22 23
467.65 467.65 467.65
Pressure (bar) 0.00 1.00 0.00
Vapor Fraction
Glycerol 22.06 0.092.03 0.10 0.00 0.00 0.00 0.0022.06 0.19 2.03 0.22
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 6.61 0.030.41 0.02 3.89 0.03 0.24 0.022.72 0.03 0.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 255.11 1.0019.67 1.00 137.14 1.00 10.38 1.00117.97 1.16 9.29 1.00
229
C.17 Pump (P-301)
Pump (P-301)
Study Node
INLET OUTLET
Stream 23 24
467.65 542.25
Temperature (K)
1.00 1.01
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 22.06 0.192.03 0.22 22.06 0.192.03 0.22
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.020.17 0.02 2.72 0.020.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 117.97 1.009.29 1.00 117.97 1.009.29 1.00
230
Study Node
INLET OUTLET
Stream 24 25
542.25 558.00
Temperature (K)
1.01 1.01
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 22.06 0.192.03 0.22 22.06 0.192.03 0.22
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.020.17 0.02 2.72 0.020.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 117.97 1.009.29 1.00 117.97 1.009.29 1.00
231
Assumption: Recovery of Heavy Key (Glycerol) = 0.0001
Recovery of Light Key (Ethylene Glycol) = 0.9998

Study Node
INLET OUTLET
Stream 28
25 40 26 39
558.00 461.35 558.45 461.35 558.45
Temperature (K)
1.01 1.00 1.00 1.00 1.00
Pressure (bar)
0.00 0.00 1.00 1.00 0.00
Vapor Fraction
Glycerol 22.06 0.19 2.03 0.22 0.00 0.000.00 0.00 5.69 1.00 0.52 1.00 0.00 0.00 0.00 0.0027.75 1.00 2.56 1.00
Hydrogen 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 2.72 0.02 0.17 0.02 0.33 0.030.02 0.02 0.00 0.00 0.00 0.00 3.05 0.03 0.19 0.020.00 0.00 0.00 0.00
Methanol 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 117.97 1.00 9.29 1.00 11.79 1.000.89 1.00 5.69 1.00 0.52 1.00 107.70 1.00 8.15 1.0027.75 1.00 2.56 1.00
232
Condenser (E-302)
Study Node
INLET OUTLET
Stream 26 27
461.35 461.35
Temperature (K)
1.00 1.00
Pressure (bar)
1.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 3.05 0.030.19 0.02 3.05 0.030.19 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 107.70 1.008.15 1.00 107.70 1.008.15 1.00
233
C.21 Reflux Drum (V-302)
Reflux Drum (V-302)
Study Node
INLET OUTLET OUTLET

Stream 27 28 29
461.35 461.35 461.35
Pressure (bar) 0.00 0.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 3.05 0.030.19 0.02 0.33 0.03 0.02 0.022.72 0.03 0.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 107.70 1.008.15 1.00 11.79 1.00 0.89 1.0095.91 1.00 7.26 1.00
234

Reboiler (E-303)
Study Node
INLET OUTLET OUTLET

Stream 39 40 41
558.45 558.45 558.45
Pressure (bar) 0.00 1.00 0.00
Vapor Friction
Glycerol 27.75 1.002.56 1.00 5.69 1.00 0.52 1.0022.05 1.00 2.03 0.22
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 27.75 1.002.56 1.00 5.69 1.00 0.52 1.0022.05 1.00 2.03 0.22
235
C.23 Pump (P-401)
Pump (P-401)
Study Node
INLET OUTLET
Stream 29 30
461.35 535.39
Temperature (K)
1.00 1.01
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.030.17 0.02 2.72 0.030.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 95.91 1.007.26 1.00 95.91 1.007.26 1.00
236
Study Node
INLET OUTLET
Stream 30 31
535.39 461.97
Temperature (K)
1.01 1.01
Pressure (bar)
0.00 0.00
Vapor Fraction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 2.72 0.030.17 0.02 2.72 0.030.17 0.02
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 95.91 1.007.26 1.00 95.91 1.007.26 1.00
237
Assumption: Recovery of Heavy Key (Ethylene Glycol) = 0.06
Recovery of Light Key (Propylene Glycol) = 0.9998

Study Node
INLET OUTLET
Stream 34
31 37 32 36
461.97 461.05 470.44 461.05 470.44
Temperature (K)
1.01 1.00 1.00 1.00 1.00
Pressure (bar)
0.00 0.00 1.00 1.00 0.00
Vapor Friction
Glycerol 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 2.72 0.03 0.17 0.02 0.69 0.000.04 0.00 0.37 0.99 0.02 0.99 0.85 0.00 0.05 0.002.92 0.99 0.18 0.99
Methanol 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 95.91 1.00 7.26 1.00 392.55 1.0029.86 1.00 0.37 1.00 0.02 1.00 485.89 1.00 36.96 1.002.95 1.00 0.18 1.00
238
Condenser (E-402)
Study Node
INLET OUTLET
Stream 32 33
461.05 461.05
Temperature (K)
1.00 1.00
Pressure (bar)
1.00 0.00
Vapor Friction
Glycerol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Ethylene Glycol 0.85 0.000.05 0.00 0.85 0.000.05 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.000.00 0.00
Total 485.89 1.0036.96 1.00 485.89 1.0036.96 1.00
239
C.27 Reflux drum (V-402)

Reflux Drum (V-402)
Study Node
INLET OUTLET OUTLET

Stream 33 34 35
461.05 461.05 461.05
Pressure (bar) 0.00 0.00 0.00
Vapor Friction
Glycerol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 0.85 0.000.05 0.00 0.69 0.00 0.04 0.000.16 0.00 0.01 0.00
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 485.89 1.0036.96 1.00 392.55 1.00 29.86 1.0093.34 1.00 7.10 1.00
240

Reboiler (E-403)
Study Node
INLET OUTLET OUTLET

Stream 36 37 38
470.44 470.44 470.44
Pressure (bar) 0.00 1.00 0.00
Vapor Friction
Glycerol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Hydrogen 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Ethylene Glycol 2.92 0.990.18 0.99 0.37 0.99 0.02 0.992.56 0.99 0.16 0.99
Methanol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Acetol 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Water 0.00 0.000.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00
Total 2.95 1.000.18 1.00 0.37 1.00 0.02 1.002.58 1.00 0.16 1.00
241
C.29 Overall Mass Balance of Streams
Table 71 Mass Balance of Overall Stream Balance (Stream 1-Stream 12)
Stream No. 1 2 3 4 5 6 7 8 9 10 11 12
Temperature
(deg_C) 30.00 30.00 79.42 200.00 55.66 227.11 200.00 200.00 336.00 200.00 336.00 336.00
Pressure (bar)
1.00 1.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00 40.00
Vapor Fraction
0.00 1.00 0.00 0.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00 0.00

Glycerol 119.22 0.00 119.22 119.220.000.000.00 22.06 0.00 22.06 22.06 22.06
Hydrogen 0.00 396.05 0.00 0.00396.05 596.12 596.12 500.18 200.07 500.18 500.18 0.00
Propylene Glycol 0.00 0.00 0.00 0.000.000.000.00 93.22 0.00 93.22 93.22 93.22
Ethylene Glycol 0.00 0.00 0.00 0.000.000.000.00 2.72 0.00 2.72 2.72 2.72
Methanol 0.00 0.00 0.00 0.000.000.000.00 2.72 0.00 2.72 2.72 2.72
Acetol 0.00 0.00 0.00 0.000.000.000.00 1.23 0.00 1.23 1.23 1.23
Water 0.00 0.00 0.00 0.000.000.000.00 94.45 0.00 94.45 94.45 94.45
Total Mole Flow 119.22 396.05 119.22 119.22 396.05 596.12 596.12 716.57 200.07 716.57 716.57 216.39
Rate (kmol/hr)
Total Mass Flow 10.98 0.80 10.98 10.98 0.80 1.20 1.20 12.18 0.40 12.18 12.18 11.17
Rate (ton/hr)
242
Stream No. 13 14 15 16 17 18 19 20 21 22 23 24
Temperature
(deg_C) 336.00 336.00 259.62 173.49 101.38 101.38 101.38 101.38 194.65 194.65 194.65 269.25
Pressure (bar)
40.00 40.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.01
Vapor Fraction
1.00 1.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00

Glycerol 0.00 0.00 22.06 22.060.000.000.00 0.00 22.06 0.00 22.06 22.06
Hydrogen 500.18 300.11 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Ethylene Glycol 0.00 0.00 2.72 2.720.000.000.00 0.00 6.61 3.89 2.72 2.72
Methanol 0.00 0.00 2.72 2.723.253.250.53 2.72 0.00 0.00 0.00 0.00
Acetol 0.00 0.00 1.23 1.231.461.460.24 1.23 0.00 0.00 0.00 0.00
Water 0.00 0.00 94.45 94.45112.67 112.6718.23 94.45 0.00 0.00 0.00 0.00
Total Mole Flow 500.18 300.11 216.39 216.39 117.42 117.42 18.99 98.42 255.11 137.14 117.97 117.97
Rate (kmol/hr)
Total Mass Flow 1.01 0.60 11.17 11.17 2.24 2.24 0.36 1.88 19.67 10.38 9.29 9.29
Rate (ton/hr)
243
Stream No. 25 26 27 28 29 30 31 32 33 34 35 36
Temperature
(deg_C) 285.00 188.35 188.35 188.35 188.35 262.39 188.97 188.05 188.05 188.05 188.05 197.44
Pressure (bar)
1.01 1.00 1.00 1.00 1.00 1.01 1.01 1.00 1.00 1.00 1.00 1.00
Vapor Fraction
0.00 1.00 0.00 0.00 0.00 0.00 0.00 1.00 0.00 0.00 0.00 0.00

Glycerol 22.06 0.00 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Ethylene Glycol 2.72 3.05 3.05 0.332.722.722.72 0.85 0.85 0.69 0.16 2.92
Methanol 0.00 0.00 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Acetol 0.00 0.00 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 0.000.000.000.00 0.00 0.00 0.00 0.00 0.00
Total Mole Flow 117.97 107.70 107.70 11.79 95.91 95.91 95.91 485.89 485.89 392.55 93.34 2.95
Rate (kmol/hr)
Total Mass Flow 9.29 8.15 8.15 0.89 7.26 7.26 7.26 36.96 36.96 29.86 7.10 0.18
Rate (ton/hr)
244
Stream No. 37 38 39 40 41
Temperature
(deg_C) 197.44 197.44 285.45 285.45 285.45
Pressure (bar)
Vapor Fraction 1.00 1.00 1.00 1.00 1.00
1.00 0.00 0.00 1.00 0.00

Glycerol 0.000.0027.75 5.69 22.05
Hydrogen 0.000.000.00 0.00 0.00
Propylene
Glycol 0.00 0.02 0.00 0.00 0.00
Ethylene
Glycol 0.37 2.56 0.00 0.00 0.00
Methanol
Acetol 0.00 0.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 0.00 0.00
Total Mole 0.00 0.00 0.00 0.00 0.00
Flow Rate
(kmol/hr)
Total Mass 0.37 2.58 27.75 5.69 22.05
Flow Rate
(ton/hr)
0.02 0.16 2.56 0.52 2.03 245
Appendix D: Energy Balance on Individual Equipment
D.1 Pump (P-101)

Pump (P-101)
3
Study Node 1
P-101
INLET OUTLET
Stream 1 3
Gamma Temperature (K)303.00 Temperature (K)352.42
1.36 Pressure (bar)1.00 Pressure (bar)40.00
Molar flowSpecific Molar flow
rateEnthalpyEnergy Flow rateSpecific Enthalpy Energy Flow
Components (kmol/hr)Mole fraction (MJ/kmol)(MJ/hr) (kmol/hr)Mole fraction (MJ/kmol)(MJ/hr)
119.221.00-665.90-79390.94 119.221.00-665.89-79390.23
0.000.000.030.00 0.000.000.030.00
Glycerol 0.000.00-500.040.00 0.000.00-489.960.00
Hydrogen 0.000.00-450.750.00 0.000.00-442.900.00
Propylene Glycol 0.000.00-238.190.00 0.000.00-233.840.00
Ethylene Glycol 0.000.00-369.300.00 0.000.00-361.290.00
Methanol 0.000.00-285.460.00 0.000.00-281.740.00
Acetol 119.221.00-2509.61-79390.94 119.221.00-2475.60-79390.23
Water -79390.94 -79390.23
Total -
Total Energy Flow (MJ/hr) 0.20
Heat duty (MJ/hr)
Power requirement (kW)
246
F.2 Heat Exchanger (E-101)
E-101
Study Node
3 4
STEAM
INLET OUTLET
Stream 3 4
352.42 473.00
Temperature (K) 40.00 40.00
Pressure (bar) Specific
Molar flow Enthalpy Molar flow
rate Mole fraction (MJ/kmol)
Components 1.00-665.89 Energy Flow rate Specific Enthalpy Energy Flow
(kmol/hr) (MJ/hr) (kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)
119.22 0.000.03 119.22
0.00-489.96 -79390.23 1.00-665.88-79388.18
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 0.00 0.00-442.90 0.00
0.00-233.84 0.00 0.00-460.800.00
Propylene Glycol 0.00 0.00 0.00 0.00-420.700.00
Ethylene Glycol 0.00 0.00-361.29 0.00
0.00-281.74 0.00 0.00-219.710.00
Methanol 0.00 0.00 0.00 0.00-336.150.00
Acetol 0.00 1.00-2475.60 0.00
-79390.23 0.00 0.00-272.390.00
Water 119.22 -79390.23 119.22 1.00-2375.61-79388.18
Total -79388.18
Total Energy Flow (MJ/hr)
Heat duty (MJ/hr)
2.05
-
247
D.3 Compressor (C-101)
Compressor (C-101)
Study Node 2 5
C-101
INLET OUTLET
Stream 2 5
0.000.00-665.900.00 0.000.00-665.900.00
396.051.000.0310.94 396.051.000.28109.39
Glycerol
0.000.00-500.040.00 0.000.00-494.940.00
Hydrogen
0.000.00-450.750.00 0.000.00-446.770.00
Propylene Glycol
0.000.00-238.190.00 0.000.00-236.010.00
Ethylene Glycol
0.000.00-369.300.00 0.000.00-365.260.00
Methanol
0.000.00-285.460.00 0.000.00-283.530.00
Acetol
396.051.00-2509.6110.94 396.051.00-2492.14109.39
Water
10.94 109.39
Total
-
27.35
Heat duty (MJ/hr)
248
D.4 Mixing Point
Mixing Point
Study Node
INLET INLET OUTLET

Stream 5 9 6
328.66 609.00 500.11
Temperature (K)
40.00 40.00 40.00
Pressure (bar)
Specific Specific
Molar flow Enthalpy Molar flow Molar flow Enthalpy
Components rate Mole fraction (MJ/kmol) Energy Flow rate Specific Enthalpy Energy Flow rate Mole fraction (MJ/kmol) Energy Flow
(kmol/hr) 0.00-665.90 (MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr) (kmol/hr) 0.00-665.87 (MJ/hr)
0.00 1.000.03 0.000.00 0.00-665.850.00 0.00 1.000.03 0.00
Glycerol 396.05 0.00-494.94 10.94200.07 596.12 0.00-453.35
1.000.035.78 16.72
Hydrogen 0.00 0.00-446.77 0.000.00 0.00 0.00-415.17
0.00-420.150.00 0.00
Propylene Glycol 0.00 0.00-236.01 0.000.00 0.00 0.00-215.60
0.00-391.130.00 0.00
Ethylene Glycol 0.00 0.00-365.26 0.000.00 0.00 0.00-328.97
0.00-194.440.00 0.00
Methanol 0.00 0.00-283.53 0.000.00 0.00 0.00-270.17
0.00-292.350.00 0.00
Acetol 0.00 1.00-2492.38 0.000.00 0.00 1.00-2349.10
0.00-259.640.00 0.00
Water 396.05 10.94200.07 596.12 16.72
1.00-2223.535.78 16.72
Total 16.72
Heat duty (MJ/hr)
-
-
249
D.5 Heat Exchanger (E-102)
E-102
Study Node 6 7
STEAM
INLET OUTLET
Stream 6 7
500.11 473.00
0.00 1.000.03 0.00
0.00-453.35 0.00 0.00-665.880.00
Glycerol 596.12 16.72 596.12 1.000.0316.61
Hydrogen 0.00 0.00-415.17 0.00
0.00-215.60 0.00 0.00-460.800.00
Propylene Glycol 0.00 0.00 0.00 0.00-420.700.00
Ethylene Glycol 0.00 0.00-328.97 0.00
0.00-270.17 0.00 0.00-219.710.00
Methanol 0.00 0.00 0.00 0.00-336.150.00
Acetol 0.00 1.00-2349.10 0.00
16.72 0.00 0.00-272.390.00
Water 596.12 16.72 596.12 1.00-2375.6116.61
Total 16.61
Heat duty (MJ/hr)
-0.11
-
250
D.6 Packed Bed Reactor (R-101)
Packed Bed Reactor (R-101)
Study Node
R-101
7 8
INLET INLET OUTLET

Stream 4 7 8
473.00 473.00 473.00
Temperature (K)
40.00 40.00 40.00
Pressure (bar)
Specific Specific
(kmol/hr) 1.00-665.88 (MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr) (kmol/hr) 0.03-665.88 (MJ/hr)
119.22 0.000.03 -79388.180.00 0.00-665.880.00 22.06 0.700.03 -14686.81
Glycerol 0.00 0.00-460.80 0.00596.12 500.18 0.13-460.80
1.000.0316.61 13.94
Hydrogen 0.00 0.00-420.70 0.000.00 93.22 0.00-420.70
0.00-460.800.00 -42955.37
Propylene Glycol 0.00 0.00-219.71 0.000.00 2.72 0.00-201.16
0.00-420.700.00 -1144.60
Ethylene Glycol 0.00 0.00-336.15 0.000.00 2.72 0.00-336.15
0.00-219.710.00 -547.29
Methanol 0.00 0.00-272.39 0.000.00 1.23 0.13-241.80
0.00-336.150.00 -412.73
Acetol 0.00 1.00-2375.61 0.000.00 94.45 1.00-2326.46
0.00-272.390.00 -22836.86
Water 119.22 -79388.18596.12 716.57 -82569.73
1.00-2375.6116.61 -82569.73
Total -79371.57
Heat duty (MJ/hr)
-3198.16
-
251
D.7 Condenser (E-103)
Condenser (E-103)
E-103
Study Node 710

8
COOLING WATER
INLET OUTLET
Stream 8 10
473.00 473.00
22.06 0.700.03 22.06
0.13-460.80 -14686.81 0.03-665.88-14686.81
Glycerol 500.18 13.94 500.18 0.700.0313.94
Hydrogen 93.22 0.00-420.70 93.22
0.00-201.16 -42955.37 0.13-460.80-42955.37
Propylene Glycol 2.72 -1144.60 2.72 0.00-420.70-1144.60
Ethylene Glycol 2.72 0.00-336.15 2.72
0.13-241.80 -547.29 0.00-219.71-597.76
Methanol 1.23 -412.73 1.23 0.00-336.15-412.73
Acetol 94.45 1.00-2326.46 94.45
-82569.73 -22836.86 0.13-272.39-25726.53
Water 716.57 -82569.73 716.57 1.00-2375.61-85509.87
Total -85509.87
Heat duty (MJ/hr)
-2940.14
-
252
E-104
Study Node 10 7
11
STEAM
INLET OUTLET
Stream 10 11
473.00 609.00
22.06 0.700.03 22.06
0.13-460.80 -14686.81 0.030.051.03
Glycerol 500.18 13.94 500.18 0.700.0314.46
Hydrogen 93.22 0.00-420.70 93.22
0.00-219.71 -42955.37 0.1380.857537.04
Propylene Glycol 2.72 -1144.60 2.72 0.0060.37164.24
Ethylene Glycol 2.72 0.00-336.15 2.72
0.13-272.39 -597.76 0.0044.16120.13
Methanol 1.23 -412.73 1.23 0.0077.7195.41
Acetol 94.45 1.00-2375.61 94.45
-85509.87 -25726.53 0.1326.202474.94
Water 716.57 -85509.87 716.57 1.00289.3710407.25
Total 10407.25
Heat duty (MJ/hr)
95917.12
-
253
D.9 Flash Drum (V-101)
Flash Drum (V-101)
13
Study Node 11 V-101
12
INLET INLET OUTLET

Stream 11 13 12
Temperature (K) Temperature (K)609.00 Temperature (K) 609.00 Temperature (K) 609.00
Pressure (bar) Pressure (bar)40.00 Pressure (bar) 40.00 Pressure (bar) 40.00
Molar flowSpecific Molar flow Molar flow
Specific
rateEnthalpyEnergy Flow rate Specific Enthalpy Energy Flow rate
Components Enthalpy Energy Flow
(kmol/hr)Mole fraction (MJ/kmol)(MJ/hr) (kmol/hr)Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr)Mole fraction
(MJ/kmol) (MJ/hr)
22.060.03-665.85-14686.31 0.000.00 -665.850.0022.060.10
-665.85 -14686.31
Glycerol 500.180.700.0314.46 500.181.00 0.0314.460.000.00
0.03 0.00
Hydrogen 93.220.13-420.15-39165.56 0.000.00 -420.150.0093.220.43
-420.15 -39165.56
Propylene Glycol 2.720.00-391.13-1064.14 0.000.00 -391.130.002.720.01
-391.13 -1064.14
Ethylene Glycol 2.720.00-194.44-529.02 0.000.00 -194.440.002.720.01
-194.44 -529.02
Methanol 1.230.00-292.35-358.95 0.000.00 -292.350.001.230.01
-292.35 -358.95
Acetol 94.450.13-259.64-24521.67 0.000.00 -259.640.0094.450.44
-259.64 -24521.67
Water 716.571.00-2223.53-80311.20 500.181.00 -2223.5314.46216.391.00
-2223.53 -80325.66
Total -80311.20 -80311.20
-
-
Heat duty (MJ/hr)

254
D.10 Splitting Point
Splitting Point
Study Node
INLET OUTLET OUTLET

Stream 13 9 14
609.00 609.00 609.00
Temperature (K)
40.00 40.00 40.00
Pressure (bar)
Specific Specific
(kmol/hr) 0.00-665.85 (MJ/hr) (kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) 0.00-665.85 (MJ/hr)
0.00 1.000.03 0.00 0.00 0.00-665.850.000.00 1.000.03 0.00
Glycerol 500.18 0.00-420.15 200.07 1.000.035.78300.11 0.00-420.15
14.46 8.67
Hydrogen 0.00 0.00-391.13 0.00 0.00-420.150.000.00 0.00-391.13
0.00 0.00
Propylene Glycol 0.00 0.00-194.44 0.00 0.00-391.130.000.00 0.00-194.44
0.00 0.00
Ethylene Glycol 0.00 0.00-292.35 0.00 0.00-194.440.000.00 0.00-292.35
0.00 0.00
Methanol 0.00 0.00-259.64 0.00 0.00-292.350.000.00 0.00-259.64
0.00 0.00
Acetol 0.00 1.00-2223.53 0.00 0.00-259.640.000.00 1.00-2223.53
0.00 0.00
Water 500.18 14.46 200.07 1.00-2223.535.78300.11
14.46 8.67
Total 14.46
Total Energy Flow (MJ/hr) -
Heat duty (MJ/hr) -
255
D.11 Expander (D-101)
Expander (D-101)
15
Study Note 12
D-101
INLET OUTLET
Stream 12 15
Gamma Temperature (K) 609.00 Temperature (K) 532.62
1.08 Pressure (bar) 40.00 Pressure (bar) 1.00
Molar flow Specific Molar flow

Components rate Enthalpy Energy Flow rate Specific Enthalpy Energy Flow
(kmol/hr) Mole fraction (MJ/kmol) (MJ/hr) (kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)
22.06 0.10-665.85 -14686.31 22.06 0.10-665.87-14686.60
Glycerol 0.00 0.000.03 0.00 0.00 0.000.030.00
Hydrogen 93.22 0.43-420.15 -39165.56 93.22 0.43-443.99-41388.43
Propylene Glycol 2.72 0.01-391.13 -1064.14 2.72 0.01-408.28-1110.80
Ethylene Glycol 2.72 0.01-194.44 -529.02 2.72 0.01-210.11-571.64
Methanol 1.23 0.01-292.35 -358.95 1.23 0.01-319.42-392.18
Acetol 94.45 0.44-259.64 -24521.67 94.45 0.44-267.36-25251.30
Water 216.39 1.00-2223.53 -80325.66 216.39 1.00-2315.00-83400.95
Total -80325.66 -83400.95
Heat duty (MJ/hr)
-
-854.25
256
E-201
Study Node
15 16
STEAM
INLET OUTLET
Stream 15 16
532.62 446.49
22.06 0.000.03 22.06
0.43-443.99 -14686.60 0.10-665.88-14686.90
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 93.22 0.01-408.28 93.22
0.01-210.11 -41388.43 0.43-467.77-43604.70
Ethylene Glycol 2.72 0.01-319.42 2.72
0.44-267.36 -571.64 0.01-223.36-607.69
Methanol 1.23 -392.18 1.23 0.01-342.56-420.59
Acetol 94.45 1.00-2315.00 94.45
-83400.95 -25251.30 0.44-274.51-25926.17
Water 216.39 -83400.95 216.39 1.00-2399.97-86404.88
Total -86404.88
Heat duty (MJ/hr)
-3003.93
-
257
D.13 Distillation Column (V-201)
17 18
E-202
Cooling water
V-202
19 20
Study Node
16 V-201
22
E-203
23
21
INLET OUTLET
Stream 19
16 22 17 21
446.49 374.38 467.65 374.38 467.65
Temperature (K) 1.00
Pressure (bar) 1.00 1.00 1.00 1.00
Specific Specific Specific Specific
Molar flow Enthalpy Molar flow Molar flow Enthalpy Molar flow Enthalpy Molar flow Enthalpy
Components rate Mole fraction (MJ/kmol) Energy Flow rate Specific Enthalpy Energy Flow rate Mole fraction (MJ/kmol) Energy Flow rate Mole fraction (MJ/kmol) Energy Flow rate Mole fraction (MJ/kmol) Energy Flow
(kmol/hr) 0.10-665.88 (MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) 0.00-665.88 (MJ/hr)(kmol/hr) 0.0000-665.89 (MJ/hr)(kmol/hr) 0.0865-665.88 (MJ/hr)
22.06 0.000.03 -14686.900.00 0.00-665.890.000.00 0.000.03 0.000.0000 0.00000.03 0.000022.0564 0.00000.03 -14686.8308
Glycerol 0.00 0.43-467.77 0.000.00 0.000.030.000.00 0.97-429.69 0.000.0000 0.0003-429.6074 0.00000.0000 0.8876-462.23 0.0000
Hydrogen 93.22 0.01-425.93 -43604.700.01 0.00-485.13-2.62133.25 0.03-357.37 -57256.910.0334 0.0000-439.1731 -14.3327226.4426 0.0259-421.77 -104668.9359
Propylene Glycol 2.72 0.01-223.36 -1158.830.00 0.00-439.170.003.89 0.00-201.16 -1390.280.0000 0.0276-201.1607 0.00006.6109 0.0000-220.48 -2788.3219
Ethylene Glycol 2.72 0.01-342.56 -607.690.53 0.03-231.69-121.640.00 0.00-291.29 0.003.2457 0.0125-291.2904 -652.90830.0000 0.0000-337.49 0.0000
Methanol 1.23 0.44-274.51 -420.590.24 0.01-357.39-84.660.00 0.00-272.82 -0.101.4644 0.9596-241.7966 -426.57940.0006 0.0000-272.82 -0.2014
Acetol 94.45 1.00-2399.97 -25926.1718.23 0.96-280.08-5104.600.00 1.00-2218.18 0.00112.6723 1.00-2268.89 -27243.78620.0000 1.00-2380.64 0.0000
Water 216.39 -86404.8818.99 1.00-2459.32-5313.52137.14 -58647.29117.42 -28337.61255.11 -122144.29
Total -150365.69 -150481.90
Heat duty (MJ/hr)
-
-
258
Condenser (E-202)
E-202
Study Node 17 18
COOLING WATER
INLET OUTLET
Stream 17 18
Temperature (K) Temperature (K)374.38Temperature (K)374.38
Pressure (bar) Pressure (bar)1.00Pressure (bar)1.00
Molar flowSpecificMolar flow
Components (kmol/hr)Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr)Mole fraction (MJ/kmol)(MJ/hr)
0.000.00-665.890.000.000.00-665.890.00
0.000.000.030.000.000.000.030.00
Glycerol
0.030.00-429.61-14.330.030.00-485.13-16.19
Hydrogen
0.000.00-439.170.000.000.00-439.170.00
Propylene Glycol
3.250.03-201.16-652.913.250.03-231.69-751.99
Ethylene Glycol
1.460.01-291.29-426.581.460.01-357.39-523.38
Methanol
112.670.96-241.80-27243.79112.670.96-280.08-31556.85
Acetol
117.421.00-2268.89-28337.61117.421.00-2459.32-32848.41
Water
-28337.61-32848.41
Total
-4510.80
-
Heat duty (MJ/hr)
259
D.15 Reflux Drum (V-202)
Reflux Drum (V-202)
18
Study Node V-202
19 20
INLET OUTLET OUTLET

Stream 18 19 20
374.38 374.38 374.38
Temperature (K)
1.00 1.00 1.00
Pressure (bar)
Specific Specific
0.00 0.000.03 0.00 0.00 0.00-665.890.000.00 0.000.03 0.00
Glycerol 0.00 0.00-485.13 0.00 0.000.030.000.00 0.00-485.13
0.00 0.00
Hydrogen 0.03 0.00-439.17 0.01 0.00-485.13-2.620.03 0.00-439.17
-16.19 -13.57
Propylene Glycol 0.00 0.03-231.69 0.00 0.00-439.170.000.00 0.03-231.69
0.00 0.00
Ethylene Glycol 3.25 0.01-357.39 0.53 0.03-231.69-121.642.72 0.01-357.39
-751.99 -630.35
Methanol 1.46 0.96-280.08 0.24 0.01-357.39-84.661.23 0.96-280.08
-523.38 -438.72
Acetol 112.67 1.00-2459.32 18.23 0.96-280.08-5104.6094.45 1.00-2459.32
-31556.85 -26452.25
Water 117.42 -32848.41 18.99 1.00-2459.32-5313.5298.42
-32848.41 -27534.89
Total -32848.41
Heat duty (MJ/hr) -
260
D.16 Reboiler (E-203)
Reboiler (E-203)
22
Study Node 21
E-203 23
INLET OUTLET OUTLET

Stream 21 22 23
467.65 467.65 467.65
Temperature (K)
1.00 1.00 1.00
Pressure (bar)
Specific Specific
22.06 0.000.03 -14686.83 0.00 0.00-665.880.0022.06 0.000.03 -14686.83
Glycerol 0.00 0.89-462.23 0.00 0.000.030.000.00 0.79-462.23
0.00 0.00
Hydrogen 226.44 0.03-421.77 133.25 0.97-429.69-57256.9193.19 0.02-421.77
-104668.94 -43075.74
Propylene Glycol 6.61 0.00-220.48 3.89 0.03-387.09-1505.882.72 0.00-220.48
-2788.32 -1147.51
Ethylene Glycol 0.00 0.00-337.49 0.00 0.00-220.480.000.00 0.00-337.49
0.00 0.00
Methanol 0.00 0.00-272.82 0.00 0.00-291.29-0.100.00 0.00-272.82
-0.20 -0.08
Acetol 0.00 1.00-2380.64 0.00 0.00-272.820.000.00 1.00-2380.64
0.00 0.00
Water 255.11 -122144.29 137.14 1.00-2267.22-58762.90117.97
-122144.29 -58910.17
Total -117673.07
Heat duty (MJ/hr) -
261
D.17 Pump (P-301)
Pump (P-301)
24
Study Node 23
P-301
INLET OUTLET
Stream 23 24
Gamma Temperature (K) 467.65 Temperature (K) 542.25
1.10 Pressure (bar) 1.00 Pressure (bar) 1.01
Molar flow Specific Molar flow

Components rate Enthalpy Energy Flow rate Specific Enthalpy Energy Flow
(kmol/hr) Mole fraction (MJ/kmol) (MJ/hr) (kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)
22.06 0.19-665.88 -14686.83 22.06 0.19-665.86-14686.56
Glycerol 0.00 0.000.03 0.00 0.00 0.000.030.00
Hydrogen 93.19 0.79-462.23 -43075.74 93.19 0.79-441.13-41109.35
Propylene Glycol 2.72 0.02-421.77 -1147.51 2.72 0.02-406.19-1105.13
Ethylene Glycol 0.00 0.00-220.48 0.00 0.00 0.00-208.360.00
Methanol 0.00 0.00-337.49 -0.08 0.00 0.00-316.38-0.08
Acetol 0.00 0.00-272.82 0.00 0.00 0.00-266.490.00
Water 117.97 1.00-2380.64 -58910.17 117.97 1.00-2304.39-56901.12
Total -58910.17 -56901.12
Heat duty (MJ/hr)
-
558.07
262
E-301
Study Node 24 25
STEAM
INLET OUTLET
Stream 24 25
542.25 558.00
22.06 0.000.03 22.06
0.79-441.13 -14686.56 0.19-665.86-14686.50
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 93.19 0.02-406.19 93.19
0.00-208.36 -41109.35 0.79-436.36-40664.49
Ethylene Glycol 0.00 0.00-316.38 0.00
0.00-266.49 0.00 0.00-205.360.00
Methanol 0.00 -0.08 0.00 0.00-311.19-0.08
Acetol 0.00 1.00-2304.39 0.00
-56901.12 0.00 0.00-265.020.00
Water 117.97 -56901.12 117.97 1.00-2286.48-56446.77
Total -56446.77
Heat duty (MJ/hr)
454.35
-
263
26 27
E-302
Cooling water
V-302
28 29
Study Node
25 V-301
40
E-303
39
INLET OUTLET
Stream 28
25 40 26 39
558.00 461.35 558.45 461.35 558.45
Temperature (K)
1.01 1.00 1.00 1.00 1.00
Pressure (bar)
Specific Specific SpecificMolar flow Specific
Molar flow Enthalpy Molar flow Molar flow Enthalpy Molar flow EnthalpyEnergy Flow rate EnthalpyEnergy Flow
Components rate Mole fraction (MJ/kmol) Energy Flow rate Specific Enthalpy Energy Flow rate Mole fraction (MJ/kmol) Energy Flow rate Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)
(kmol/hr) 0.19-665.86 (MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) 1.00-665.86 (MJ/hr)(kmol/hr) 0.0000-665.6801-1.648727.7487 1.0000-665.5219-18467.3748
22.06 0.000.03 -14686.500.00 0.00-665.88-0.185.69 0.000.03 -3791.780.0025 0.00000.02780.00000.0000 0.00000.02850.0000
Glycerol 0.00 0.000.00 0.000.030.000.00 0.000.0000
0.79-436.36 0.00-436.22 0.9716-429.6859-44964.59460.0000 0.0000-436.22010.0000
Hydrogen 93.19 -40664.4911.45 0.60-463.90-5313.740.00 0.00104.6453
0.02-402.73 0.00-387.08 0.0284-387.0909-1182.36240.0007 0.0000-402.6307-0.2757
Propylene Glycol 2.72 -1095.700.33 0.02-423.03-141.440.00 -0.053.0545
0.00-205.36 0.00-205.27 0.0000-221.35760.00000.0000 0.0000-205.26940.0000
Ethylene Glycol 0.00 0.000.00 0.00-221.360.000.00 0.000.0000
0.00-311.19 0.00-311.04 0.0000-291.2883-0.08030.0000 0.0000-311.03510.0000
Methanol 0.00 -0.080.00 0.00-339.04-0.010.00 0.000.0003
0.00-265.02 0.00-264.97 0.0000-273.32780.00000.0000 0.0000-264.97400.0000
Acetol 0.00 0.000.00 0.00-273.330.000.00 0.000.0000
1.00-2286.48 1.00-2270.41 1.0000-2268.4029 -46148.686027.7494 1.0000-2285.6227 -18467.6505
Water 117.97 -56446.7711.79 0.62-2386.50-5455.375.69 -3791.84107.7025 -64616.3365
Total -65693.98
Heat duty (MJ/hr)
-
-
264
Condenser (E-302)
E-302
Study Node 26 727
COOLING WATER
INLET OUTLET
Stream 26 27
461.35 461.35
0.00 0.000.03 0.00
0.97-429.69 -1.65 0.00-665.88-1.65
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 104.65 0.03-387.09 104.65
0.00-221.36 -44964.59 0.97-463.90-48545.14
Ethylene Glycol 0.00 0.00-291.29 0.00
0.00-273.33 0.00 0.00-221.360.00
Methanol 0.00 -0.08 0.00 0.00-339.04-0.09
Acetol 0.00 1.00-2268.60 0.00
-46148.69 0.00 0.00-273.330.00
Water 107.70 -46148.69 107.70 1.00-2386.50-49839.00
Total -49839.00
Heat duty (MJ/hr)
-3690.32
-
265
Reflux Drum (V-302)
Study Node
INLET OUTLET OUTLET

Stream 27 28 29
461.35 461.35 461.35
Temperature (K)
1.00 1.00 1.00
Pressure (bar)
Specific Specific
0.00 0.000.03 -1.65 0.00 0.00-665.88-0.180.00 0.000.03 -1.47
Glycerol 0.00 0.97-463.90 0.00 0.000.030.000.00 0.97-463.90
0.00 0.00
Hydrogen 104.65 0.03-423.03 11.45 0.97-463.90-5313.7493.19 0.03-423.03
-48545.14 -43231.39
-1292.13 -1150.69
Ethylene Glycol 0.00 0.00-339.04 0.00 0.00-221.360.000.00 0.00-339.04
0.00 0.00
Methanol 0.00 0.00-273.33 0.00 0.00-339.04-0.010.00 0.00-273.33
-0.09 -0.08
Acetol 0.00 1.00-2386.50 0.00 0.00-273.330.000.00 1.00-2386.50
0.00 0.00
Water 107.70 -49839.00 11.79 1.00-2386.50-5455.3795.91
-49839.00 -44383.63
Total -49839.00
Heat duty (MJ/hr) -
266
Reboiler (E-303)
40
Study Node 39
E-303 41
INLET OUTLET OUTLET

Stream 39 40 41
558.45 558.45 558.45
Temperature (K)
1.00 1.00 1.00
Pressure (bar)
Specific Specific
27.75 0.000.03 -18476.82 5.69 1.00-665.86-3791.7822.05 0.000.03 -14685.03
Glycerol 0.00 0.00-436.22 0.00 0.000.030.000.00 0.00-436.22
0.00 0.00
Hydrogen 0.00 0.00-402.63 0.00 0.00-436.220.000.00 0.00-402.63
0.00 0.00
-0.28 -0.22
Ethylene Glycol 0.00 0.00-311.04 0.00 0.00-205.270.000.00 0.00-311.04
0.00 0.00
Methanol 0.00 0.00-264.97 0.00 0.00-311.040.000.00 0.00-264.97
0.00 0.00
Acetol 0.00 1.00-2285.96 0.00 0.00-264.970.000.00 1.00-2285.96
0.00 0.00
Water 27.75 -18477.09 5.69 1.00-2270.41-3791.8422.05
-18477.09 -14685.25
Total -18477.09
Heat duty (MJ/hr) -
267
D.23 Pump (P-401)
Pump (P-401)
30
Study Node 29
P-401
INLET OUTLET
Stream 29 30
0.000.00-665.88-1.47 0.000.00-665.87-1.47
Glycerol 0.000.000.030.00 0.000.000.030.00
Hydrogen 93.190.79-463.90-43231.39 93.190.97-443.17-41299.59
Propylene Glycol 2.720.02-423.03-1150.69 2.720.03-407.68-1108.95
Ethylene Glycol 0.000.00-221.360.00 0.000.00-209.610.00
Methanol 0.000.00-339.04-0.08 0.000.00-318.55-0.08
Acetol 0.000.00-273.330.00 0.000.00-267.110.00
Water 95.910.81-2386.50-44383.63 95.911.00-2311.97-42410.09
Total -44383.63 -42410.09
Heat duty (MJ/hr) 548.21
268
E-401
Study Node 30 31
STEAM
INLET OUTLET
Stream 30 31
535.39 461.97
0.00 0.000.03 0.00
0.97-443.17 -1.47 0.00-665.88-1.47
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 93.19 0.03-407.68 93.19
0.00-209.61 -41299.59 0.97-463.74-43216.11
Ethylene Glycol 0.00 0.00-318.55 0.00
0.00-267.11 0.00 0.00-221.270.00
Methanol 0.00 -0.08 0.00 0.00-338.89-0.08
Acetol 0.00 1.00-2311.97 0.00
-42410.09 0.00 0.00-273.280.00
Water 95.91 -42410.09 95.91 1.00-2385.93-44368.02
Total -44368.02
Heat duty (MJ/hr)
-1957.93
-
269
32 33
E-402
Cooling water
V-402
34 35
Study Node
31 E-401
37
E-403
38
36
INLET OUTLET
Stream 34
31 37 32 36
461.97 461.05 470.44 461.05 470.44
Temperature (K) 1.00
Pressure (bar) 1.01 1.00 1.00 1.00
Specific Specific Specific Specific
Molar flow Enthalpy Molar flow Molar flow Enthalpy Molar flow Enthalpy Molar flow Enthalpy
Components rate Mole fraction (MJ/kmol) Energy Flow rate Specific Enthalpy Energy Flow rate Mole fraction (MJ/kmol) Energy Flow rate Mole fraction (MJ/kmol) Energy Flow rate Mole fraction (MJ/kmol) Energy Flow
(kmol/hr) 0.00-665.88 (MJ/hr)(kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) 0.00-665.88 (MJ/hr)(kmol/hr) 0.00-665.68 (MJ/hr)(kmol/hr) 0.00-665.67 (MJ/hr)
0.00 0.000.03 -1.470.00 0.00-665.880.000.00 0.000.03 -0.210.00 0.000.03 0.000.00 0.000.03 -1.68
Glycerol 0.00 0.97-463.74 0.000.00 0.000.030.000.00 0.01-461.49 0.000.00 1.00-463.98 0.000.00 0.01-461.49 0.00
Hydrogen 93.19 0.03-422.90 -43216.11391.86 1.00-463.98-181816.380.00 0.99-387.09 -1.24485.04 0.00-387.09 -225046.330.02 0.99-421.22 -9.84
Propylene Glycol 2.72 0.00-221.27 -1150.350.69 0.00-423.08-290.410.37 0.00-220.08 -142.300.85 0.00-221.40 -328.882.92 0.00-220.08 -1231.88
Ethylene Glycol 0.00 0.00-338.89 0.000.00 0.00-221.400.000.00 0.00-336.79 0.000.00 0.00-291.29 0.000.00 0.00-336.79 0.00
Methanol 0.00 0.00-273.28 -0.080.00 0.00-339.11-0.350.00 0.00-272.60 0.000.00 0.00-273.35 -0.370.00 0.00-272.60 0.00
Acetol 0.00 1.00-2385.93 0.000.00 0.00-273.350.000.00 1.00-2343.90 0.000.00 1.00-2302.76 0.000.00 1.00-2377.82 0.00
Water 95.91 -44368.02392.55 1.00-2386.77-182107.150.37 -143.75485.89 -225375.592.95 -1243.39
Total -226618.91 -226618.98
Heat duty (MJ/hr)
-
-
270
Condenser (E-402)
E-402
Study Node
32 733
COOLING WATER
INLET OUTLET
Stream 32 33
461.05 461.05
0.00 0.000.03 0.00
1.00-463.98 0.00 0.00-665.880.00
Glycerol 0.00 0.00 0.00 0.000.030.00
Hydrogen 485.04 0.00-387.09 485.04
0.00-221.40 -225046.33 1.00-463.98-225046.33
Ethylene Glycol 0.00 0.00-291.29 0.00
0.00-273.35 0.00 0.00-221.400.00
Methanol 0.00 -0.37 0.00 0.00-339.11-0.43
Acetol 0.00 1.00-2302.96 0.00
-225375.59 0.00 0.00-273.350.00
Water 485.89 -225375.59 485.89 1.00-2386.77-225406.23
Total -225406.23
Heat duty (MJ/hr)
-30.64
-
271
Reflux Drum (V-402)
33
Study Node V-402
34 35
INLET OUTLET OUTLET

Stream 33 34 35
461.05 461.05 461.05
Temperature (K)
1.00 1.00 1.00
Pressure (bar)
Specific Specific
0.00 0.000.03 0.00 0.00 0.00-665.880.000.00 0.000.03 0.00
Glycerol 0.00 1.00-463.98 0.00 0.000.030.000.00 1.00-463.98
0.00 0.00
Hydrogen 485.04 0.00-423.08 391.86 1.00-463.98-181816.3893.17 0.00-423.08
-225046.33 -43229.95
-359.46 -69.05
Ethylene Glycol 0.00 0.00-339.11 0.00 0.00-221.400.000.00 0.00-339.11
0.00 0.00
Methanol 0.00 0.00-273.35 0.00 0.00-339.11-0.350.00 0.00-273.35
-0.43 -0.08
Acetol 0.00 1.00-2386.77 0.00 0.00-273.350.000.00 1.00-2386.77
0.00 0.00
Water 485.89 -225406.23 392.55 1.00-2386.77-182107.1593.34
-225406.23 -43299.08
Total -225406.23
Heat duty (MJ/hr) -
272
Reboiler (E-403)
37
Study Node 36
E-403 38
INLET OUTLET OUTLET

Stream 36 37 38
470.44 470.44 470.44
Temperature (K)
Pressure (bar) 1.00 1.00 1.00
Molar flow Specific Molar flow Molar flow Specific
Components rate Enthalpy Energy Flow rate Specific Enthalpy Energy Flow rate Enthalpy Energy Flow
(kmol/hr) Mole fraction (MJ/kmol) (MJ/hr) (kmol/hr) Mole fraction (MJ/kmol)(MJ/hr)(kmol/hr) Mole fraction (MJ/kmol) (MJ/hr)
0.00 0.00-665.88 -1.68 0.00 0.00-665.88-0.210.00 0.00-665.88 -1.47
Glycerol 0.00 0.000.03 0.00 0.000.030.000.00 0.000.03
0.00 0.00
Hydrogen 0.02 0.01-461.49 0.00 0.01-461.49-1.240.02 0.01-461.49
-9.84 -8.60
-1231.88 -1077.03
Ethylene Glycol 0.00 0.00-220.08 0.00 0.00-220.080.000.00 0.00-220.08
0.00 0.00
Methanol 0.00 0.00-336.79 0.00 0.00-336.790.000.00 0.00-336.79
0.00 0.00
Acetol 0.00 0.00-272.60 0.00 0.00-272.600.000.00 0.00-272.60
0.00 0.00
Water 2.95 1.00-2378.03 0.37 1.00-2343.90-143.752.58 1.00-2378.03
-1243.39 -1087.10
Total -1243.39 -1230.85
Heat duty (MJ/hr) -
273
D.29 Overall Energy Balance Followed Stream Number
Specific Entalphy 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(MJ/kmol)
Glycerol
Hydrogen -665.90 -665.90 -665.89 -665.88 -665.90 -665.87 -665.88 -665.88 -665.85 -665.88 -665.85 -665.85 -665.85 -665.85 -665.87 -665.88
Propylene Glycol 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03
Ethylene Glycol -500.04 -500.04 -489.96 -460.80 -494.94 -453.35 -460.80 -460.80 -420.15 -460.80 -420.15 -420.15 -420.15 -420.15 -443.99 -467.77
Methanol -450.75 -450.75 -442.90 -420.70 -446.77 -415.17 -420.70 -420.70 -391.13 -420.70 -391.13 -391.13 -391.13 -391.13 -408.28 -425.93
Acetol -238.19 -238.19 -233.84 -219.71 -236.01 -215.60 -219.71 -201.16 -194.44 -219.71 -194.44 -194.44 -194.44 -194.44 -210.11 -223.36
Water -369.30 -369.30 -361.29 -336.15 -365.26 -328.97 -336.15 -336.15 -292.35 -336.15 -292.35 -292.35 -292.35 -292.35 -319.42 -342.56
TOTAL -285.46 -285.46 -281.74 -272.39 -283.53 -270.17 -272.39 -241.80 -259.64 -272.39 -259.64 -259.64 -259.64 -259.64 -267.36 -274.51
-2509.61 -2509.61 -2475.60 -2375.61 -2492.38 -2349.10 -2375.61 -2326.46 -2223.53 -2375.61 -2223.53 -2223.53 -2223.53 -2223.53 -2315.00 -2399.97
Energy Flow
(MJ/hr) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Glycerol
Hydrogen -79390.94 0.00 -79390.23 -79388.18 0.00 0.00 0.00 -14686.81 0.00 -14686.811.03 -14686.31 0.00 0.00 -14686.60 -14686.90
Propylene Glycol 0.00 10.94 0.000.00 10.94 16.72 16.61 13.94 5.78 13.9414.46 0.00 14.46 8.67 0.00 0.00
Ethylene Glycol 0.00 0.00 0.000.00 0.00 0.00 0.00 -42955.37 0.00 -42955.37 7537.04 -39165.56 0.00 0.00 -41388.43 -43604.70
Methanol 0.00 0.00 0.000.00 0.00 0.00 0.00 -1144.60 0.00 -1144.60164.24 -1064.14 0.00 0.00 -1110.80 -1158.83
Acetol 0.00 0.00 0.000.00 0.00 0.00 0.00 -547.29 0.00 -597.76120.13 -529.02 0.00 0.00 -571.64 -607.69
Water 0.00 0.00 0.000.00 0.00 0.00 0.00 -412.73 0.00 -412.7395.41 -358.95 0.00 0.00 -392.18 -420.59
TOTAL 0.00 0.00 0.000.00 0.00 0.00 0.00 -22836.86 0.00 -25726.53 2474.94 -24521.67 0.00 0.00 -25251.30 -25926.17
-79390.94 10.94 -79390.23 -79388.18 10.94 16.72 16.61 -82569.73 5.78 -85509.87 10407.25 -80325.66 14.46 8.67 -83400.95 -86404.88
274
Specific Entalphy 20 23 24 25 29 30 31 35 38 41
(MJ/kmol)
Glycerol
Hydrogen -665.89 -14686.83 -14686.56 -14686.50 -665.88 -665.87 -665.88 -665.88 -665.88 -665.86
Propylene Glycol 0.03 0.000.000.00 0.03 0.03 0.03 0.03 0.03 0.03
Ethylene Glycol -485.13 -43075.74 -41109.35 -40664.49 -463.90 -443.17 -463.74 -463.98 -461.49 -436.22
Methanol -439.17 -1147.51 -1105.13 -1095.70 -423.03 -407.68 -422.90 -423.08 -421.22 -402.63
Acetol -231.69 0.000.000.00 -221.36 -209.61 -221.27 -221.40 -220.08 -205.27
Water -357.39 -0.08-0.08-0.08 -339.04 -318.55 -338.89 -339.11 -336.79 -311.04
TOTAL -280.08 0.000.000.00 -273.33 -267.11 -273.28 -273.35 -272.60 -264.97
-2459.32 -58910.17 -56901.12 -56446.77 -2386.50 -2311.97 -2385.93 -2386.77 -2378.03 -2285.96
Energy Flow
(MJ/hr) 20232425293031353841
Glycerol 0.00 -14686.83 -14686.56 -14686.50-1.47-1.47-1.470.00-1.47 -14685.03
Hydrogen 0.000.000.000.000.000.000.000.000.000.00
Propylene Glycol -13.57 -43075.74 -41109.35 -40664.49 -43231.39 -41299.59 -43216.11 -43229.95-8.600.00
Ethylene Glycol 0.00 -1147.51 -1105.13 -1095.70 -1150.69 -1108.95 -1150.35-69.05 -1077.03-0.22
Methanol -630.350.000.000.000.000.000.000.000.000.00
Acetol -438.72-0.08-0.08-0.08-0.08-0.08-0.08-0.080.000.00
Water -26452.250.000.000.000.000.000.000.000.000.00
TOTAL -27534.89 -58910.17 -56901.12 -56446.77 -44383.63 -42410.09 -44368.02 -43299.08 -1087.10 -14685.25
275
D.30 Heat Capacity Constants and Heat of Formation for Components
Cp Constants (J/kmol.K) Hf
Components C1 C2 C3 C4 C5 (MJ/kmol)
Glycerol (C3H8O3)
[liquid] 8.4E+00 4.4E-01 -3.2E-04 9.4E-08 0.0E+00 -6.7E+02
Hydrogen (H2) [gas] 2.8E+04 9.6E+02 2.5E+03 3.8E+03 5.7E+02 0.0E+00
Propylene Glycol
(C3H8O2) [liquid] 5.8E+04 4.5E+02 0.0E+00 0.0E+00 0.0E+00 -5.0E+02
Propylene Glycol
(C3H8O2) [gas] 2.0E+05 8.1E+04 1.9E+03 -2.4E+05 2.8E+02 -4.3E+02
Ethylene Glycol
(C2H6O2) [liquid] 3.6E+04 4.4E+02 -1.8E-01 0.0E+00 0.0E+00 -4.5E+02
Ethylene Glycol
(C2H6O2) [gas] 8.2E+03 1.3E+04 1.7E+03 9.3E+04 -7.5E+02 -3.9E+02
Methanol (CH3OH)
[liquid] 1.1E+05 -3.6E+02 9.4E-01 0.0E+00 0.0E+00 -2.4E+02
Methanol (CH3OH)
[gas] 3.9E+04 8.8E+04 1.9E+03 5.4E+04 9.0E+02 -2.0E+02
Acetol (C3H6O2)
[liquid] 2.1E+05 -7.0E+02 1.7E+00 0.0E+00 0.0E+00 -3.7E+02
Acetol (C3H6O2) [gas] 7.0E+04 1.8E+05 1.7E+03 1.3E+05 -7.6E+02 -2.9E+02
Water (H2O) [liquid] 2.8E+05 -2.1E+03 8.1E+00 -1.4E-02 9.4E-06 -2.9E+02
Water (H2O) [gas] 3.3E+04 2.7E+04 2.6E+03 8.9E+03 1.2E+03 -2.4E+02
276
Appendix E: Utilities
E.1Utility Stream Balance
Table 77 Amount of heating fluid for Heat Exchanger (E-101)
UTILITY
INLET OUTLET
E-101 Steam_U 1 Stream_U 2
Heat Exchanger Temperature (K)473.00
Temperature (K)523.00 Pressure (bar)1.00
Pressure (bar)1.00 Mass flowSpecific
Mass flowSpecific rateMassEnthalpyEnergy Flow
rateMassEnthalpyEnergy Flow (ton/hr)fraction(MJ/ton)(MJ/hr)
(ton/hr)fraction(MJ/ton)(MJ/hr)Components 605.950.201.002870.72585.45
Superheated Steam0.201.002971.22 605.950.201.002870.72585.45
Total0.201.002971.22 585.45
Total Energy Flow (MJ/hr)605.95 -20.50
Heat duty (MJ/hr) -

UTILITY
INLET OUTLET
Pressure (bar)1.00 Molar flowSpecific
Molar flowSpecific rateMoleEnthalpyEnergy Flow
rateMoleEnthalpyEnergy Flow (kmol/hr)fraction(MJ/kmol) (MJ/hr)
(kmol/hr)fraction(MJ/kmol) (MJ/hr)Components 0.000.061.001.880.11
Water0.061.000.00 0.000.061.001.880.11
Total0.061.000.00 0.11
Total Energy Flow (MJ/hr)0.00
Heat duty (MJ/hr)
0.11
-
Table 79 Amount of cooling fluid for Condenser (E-103)

UTILITY
INLET OUTLET
Condenser Temperature (K)298.00 Temperature (K)323.00
Pressure (bar)1.00
Water1562.361.000.00 0.001562.361.001.882940.14
Total1562.361.000.00 2940.14
Total Energy Flow (MJ/hr)0.00 2940.14
Heat duty (MJ/hr) -
277
UTILITY
INLET OUTLET
Pressure (bar)1.00 Mass flowSpecific
Mass flowSpecific rateMassEnthalpyEnergy Flow
rateMassEnthalpyEnergy Flow (ton/hr)fraction(MJ/ton)(MJ/hr)
(ton/hr)fraction(MJ/ton)(MJ/hr)Components 153829.9351.771.002870.72 148626.71
Superheated Steam51.771.002971.22 153829.9351.771.002870.72 148626.71
Total51.771.002971.22 148626.71
Heat duty (MJ/hr) -

UTILITY
INLET OUTLET
Water1597.701.000.00 0.001597.701.001.883006.65
Total1597.701.000.00 3006.65
Heat duty (MJ/hr) -

UTILITY
INLET OUTLET
Condenser Temperature (K)298.00 Temperature (K)323.00
Pressure (bar)1.00
Water2396.991.000.00 0.002396.991.001.884510.80
Total2396.991.000.00 4510.80
Heat duty (MJ/hr) -
278
Table 83 Amount of heating fluid for Reboiler (E-203)
UTILITY
INLETOUTLET
E-203Steam_U 13Stream_U 14
ReboilerTemperature (K)523.00Temperature (K)473.00
Pressure (bar)1.00Pressure (bar)1.00
Mass flowSpecificSpecific
rateMassEnthalpyEnergy Flow Mass flow rateMassEnthalpyEnergy Flow
(ton/hr)fraction(MJ/ton)(MJ/hr)(ton/hr)fraction(MJ/ton)(MJ/hr)Components
Superheated Steam44.491.002971.22 132188.9844.491.002870.72 127717.76
Total44.491.002971.22 132188.9844.491.002870.72 127717.76
Total Energy Flow (MJ/hr)132188.98127717.76
Heat duty (MJ/hr)-4471.22
Power requirement (kW)-

UTILITY
INLET OUTLET
Water302.221.001.88 568.74302.221.000.38113.86
Total302.221.001.88 113.86
Heat duty (MJ/hr) -

UTILITY
INLET OUTLET
Condenser Temperature (K)323.00
Water1960.991.000.00 0.001960.991.001.883690.32
Total1960.991.000.00 3690.32
Heat duty (MJ/hr) -
279
UTILITY
INLETOUTLET
E-303Steam_U 19Stream_U 20
Molar flowSpecificSpecific
rateMoleEnthalpyEnergy Flow Molar flow rateMoleEnthalpyEnergy Flow
(kmol/hr)fraction(MJ/kmol) (MJ/hr)(kmol/hr)fraction(MJ/kmol) (MJ/hr)Components
Water0.001.001.880.000.001.000.380.00
Total0.001.001.880.000.001.000.380.00

UTILITY
INLET OUTLET
Heat ExchangerTemperature (K)298.00 Temperature (K)323.00
Pressure (bar)1.00
Water1040.421.000.00 0.001040.421.001.881957.93
Total1040.421.000.00 1957.93
Heat duty (MJ/hr) -

UTILITY
INLET OUTLET
Condenser Temperature (K)323.00
Water16.281.000.00 0.0016.281.001.8830.64
Total16.281.000.00 30.64
Heat duty (MJ/hr) -
280
UTILITY
INLETOUTLET
Steam_U 25Stream_U 26E-403
rateMoleEnthalpyEnergy Flow Molar flow rate MoleEnthalpyEnergy Flow
(kmol/hr)fraction(MJ/kmol) (MJ/hr)(kmol/hr)fraction(MJ/kmol) (MJ/hr)Components
Water8.341.001.8815.698.341.000.383.14
Total8.341.001.8815.698.341.000.383.14
Table 90 Amount of heating fluid for Packed Bed Reactor

Jacket
UTILITY
INLETOUTLET
Steam_U 27Stream_U 28Packed Bed Reactor
JacketTemperature (K)298.00Temperature (K)323.00
rateMoleEnthalpy Energy Flow Molar flow rateMoleEnthalpy Energy Flow
(kmol/hr)fraction(MJ/kmol)(MJ/hr)(kmol/hr)fraction(MJ/kmol)(MJ/hr)Components
Water1710.521.000.000.001710.521.001.883218.97
Total1710.521.000.000.001710.521.001.883218.97
Heat duty (MJ/hr)3218.97
281
Appendix F: Mass Transfer Equipment Design
F.1 Distillation Column, V-201
Component Distribution
Step 1: Identification of Light Key (LK) and Heavy Key (HK) Component
Acetol,C3H6O2 Light Key
Propylene Glycol,C3H8O2 Heavy Key
Step 2: Determination of partial vapor pressure and relative volatilities
From Raoult's Law and Dalton's Law, K=Psat/P
Psat is calculated based on Antoinne

Equation.
Components A B C
Glycerol 9.91 3821.36 253.81
Hydrogen 3.54 99.40 7.73
Propylene Glycol (HK) 9.19 2651.27 232.78
Ethylene Glycol 9.70 3147.10 264.25
Methanol 8.09 1582.91 239.10
Acetol (LK) 8.00 2193.00 272.69
Water 8.1402 1810.9400 244.4850
Dew point
Bubble point
282
Dew point 101.38˚C
Pressure (mmHg) 760.00
Components Psat (mmHg) K=(Psat/P) α = (Ki/K,HK)

Glycerol 0.14 0.00019 0.0079
428.66 0.56 23.91
Hydrogen
Propylene Glycol 17.93 0.02 1.00
Methanol 2767.58 3.64 154.39
Acetol 135.68 0.18 7.57
Water 801.97 1.06 44.74

1/P=∑yi/Psat 1.00
∑yi/Ki 1.00
Bubble point 193.73˚C

Glycerol 23.40 0.03 0.02
1121.40 1.48 1.20
Hydrogen
Methanol 27171.82 35.75 29.02
Acetol 1964.90 2.59 2.10
Water 10178.01 13.39 10.87

P=∑xi*Psat 1.00
∑xiKi 1.00
Relative volatility is calculated from the volatility of respective component,

which is
determined from the partial pressure of component and the system pressure.
Relative volatilities, α
283
KLK KHK LK,HK
Feed 0.350 0.065 5.385
Distillate 0.179 0.024 7.569
Bottom 2.585 1.232 2.098
Step 3: Minimum number of stages, Nmin
Average relative volatility,
= 3.985151065
Component αi
Glycerol 0.10 0.01
Hydrogen 0.00 11.95
Methanol 0.01 100.44
Acetol 0.01 5.38
Water 0.44 31.03
Underwood equation is used to find minimum reflux ratio,

Rmin
284
Feed condition saturated liquid
q 1.00
Vapor Fraction 0.00
Temperature (0C) 121
Pressure (mmHg) 760
The value is obtained such that the Underwood equation becomes equals to 1-q,
which in
this case is, equals to 0. Also the value compromises>θ >.
Therefore, for the obtainedvalue, minimum reflux ratio, Rmin is calculated according to
following equation, the
Step 5: Determination of actual reflux ratio, R
By rule of thumb, R = 1.5 Rmin
R = 1.5(0.07) = 0.10
Step 6: Overall tray efficiency, Eo

According to Coulson and Richardson’s Chemical Engineering Design, overall
tray
efficiency, Eo for preliminary design of distillation column can be calculate
using:
First, the total feed liquid viscosityis calculated.
Component C1 C2 C3 C4 C5 μ liq (cP) 𝜇,Favg
Propylene -804.54 30487.00 130.79 -1.54E-01 1.00 1.688437078 0.727359771

Glycol
Ethylene -20.515 2468.5000 1.2435E+00 2.4998E+12 -5 1.423131708 0.017893039
285
Glycol
Methanol -25.317 1.79E+03 2.069 - - 0.222448884 0.00279685
Water -52.84 3703.00 5.87 -5.88E-29 10.00 0.22654923 0.098880314
Only for Glycerol and Acetol, μ liq (cP) is taken from ASPEN at Feed Temperature = 394
K.
Component μ liq (cP) Mole frac 𝜇,Favg
Glycerol 7.8694 0.10193 0.802115152
Acetol 0.49851 0.00567 0.002828554
The average viscosity,

Σ (𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 × 𝑚𝑎𝑠𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑)
1.65187368
By using O'Connell's correlation of overall column efficiency,

Lockett,
=
= 32.85524412%
Step 7: Determination of actual number of theoretical stages
The actual number of theoretical

stage:
By Gilliland correlation,
X = 0.644293508
Therefore,29.57827466
Actual number of theoretical stages,

Nact
90.02603831
Number of trays by minus reboiler, N
N = 89 trays
Step 8: Feed point location
286
Number of stages = 89 trays
0.334108553
Nactual = NR + NS
Solving simultaneously gives, NR =
22.53922269
and NS = 67.46077731
Hence, NB = 67, NS = 67 (Round off)

Feed enters the column 67 stages above the bottom stage.
Number of stages/trays in rectifying section = 67
Number of stages in stripping section = 67
Number of trays in stripping section = 66 (Excluding partial
reboiler)
Column Sizing
The distillation column is sized based on the top condition and the bottom condition,
where
the dimensions of distillation column are finalized based on the larger diameter
calculated
either at the top or bottom condition. For column sizing, flow rate of and density at
top and
bottom condition. The data are presented below:
Density
Parameters top bottom
0.614388843 2.029686976
(kg/m3)
(kg/m3) 948.3188919 929.8525158
Mass Flow Rate

(kg/s) 195.4966611 3866.451107
(kg/s) 2077.20942 13157.85406
Other Calculated Parameters

0.056351927 0.021509925
ave (N/m)
Liquid-Vapor Flow 0.002395541 0.013728875
factor,
Note : Average density and average surface tension of mixture is calculated for
top and
bottom condition based on equations and constants obtained from Perry’s
Handbook.
Following forula is used to calculate FLV.
Step 1: Determination of vapor flooding velocity, Vnf
287
Assuming column diameter is less than 1 m, tray spacing of 0.46 m is typically
chosen.
  0 .2
  L  V  0 .5
Vnf  C sb   
To calculate Csb use this formula, 20   
V 

Top Condition Bottom Condition

Csb = 0.294015303 Csb= 0.289530788
Vnf = 3.568292949 m/s Vnf = 1.577736702 m/s
Step 2: Determination of actual vapour velocity, Vn
= 2.85463436 m/s = 1.262189362 m/s
Step 3: Determination of net column area, An

V _ dot
An 
Vn
V kmol/ hr Mr
kg / kmol  
V _ dot 
3600s
Top Condition 3 Bottom Condition
V_dot = v kg / m  V_dot =
0.939148919 hr 1.800750315
= 0.328990967 = 1.42668792
Step 4: Determination of cross sectional area, Ac
An
AC 
1  0.12
=0.373853372 = 1.621236273
288
Step 5: Determination of column diameter, Dc
 4 AC  0 .5
DC  
Top Condition 
0.689931373 m  Bottom Condition
Dc 1.436740714 m
Since limiting diameter occurs at bottom, the chosen diameter for the column is,
Dc =
1.436740714 m.
Rule of thumb:
Tray spacing is selected to minimize

entrainment.
Standard trays spacing for large diameter column of 0.46 m is
chosen.
Step 6: Height of Column
Tray spacing estimated, lt = 0.46

m
Plate thickness, tp = 0.003 m for stainless
steel
Column height, Hc
Where: Hs: tray spacing

∆H: Additional height required for column
operation
Ratio of column height to column

diameter:
Ratio = 29.37690817 (< 30, hence height and diameter of column is

valid)
Plate Hydraulic Design
Step 1: Liquid flow arrangement

Maximum liquid flow rate (occur at bottom condition), VLmax = and
0.001155037
Dc = 1.436740714 m
From Coulson and Richardson Chemical Engineering Design, Figure
11.28,
The liquid flow arrangement is selected to be cross flow, single pass.
289
Step 2: Provisional plate design
Column diameter,
Column area,
Downcomer area, Ad  AC  An
= 0.194548353 m2
Net area,
Active area,
 Assume all holes take 10% of active area,
Hole area,
From Coulson and Richardson’s Chemical Engineering Design, Figure
11.31,
When
Weir length, lw =1.091922942 m

Take weir height, hw = 50 mm = 0.05 m
 (taken the average of range, 40-50 mm is recommended for 1
atm.)
Take hole diameter, dh = 5 mm =
0.005m
 (Preferred size in design)
Take plate thickness = 3 mm = 0.003
m
 (Typical for stainless steel plate)
Step 3: Check weeping

Maximum liquid flow rate = 1.074014196 kg/s
Minimum liquid flow rate at 70% turndown = 0.70
0.751809937
(
Max 7.7863
Min 5.5817
11.30
At minimum liquid flow rate,55.5817
Weeping velocity, uh = 5.155225924
Maximum vapour flow rate=1.800750315

Minimum vapour flow rate at 70% turndown = 0.70
(
Actual minimum vapour velocity= 10.23037693
Since actual minimum vapour velocity (10.23037693 m/s) > weeping velocity
(5.155225924 m/s), the minimum operating liquid flow rate is well above weeping
point, the
design is satisfactory.
Step 4: Determination of plate pressure drop

Maximum vapour velocity through holes,
290
uh 14.61482419
Percentage of perforated and

area,

11.34
Orifice coefficient,0.74
Dry plate pressure drop, 5.402778171 mm liquid
Residual head pressure drop, 13.44299207

74.4275
Step 5: Down comer liquid backup

Taking average value range given by Coulson and Richardson’s Chemical
Engineering
Design
(5 to 10mm), height of bottom edge of the apron above the plate.
– 10 = 50 – 10 = 40 mm = 0.04 m
Clearance area under down comer, Aap = haplw = 0.043676918
As this is less than Ad = 0.194548353 m2, use Equation 11.92 to estimate the head
loss in
downcomer, hdc
0.108090121 mm
Downcomer backup, hb = (hw + how) + ht + hdc = 130.1172 mm
liquid
= 0.255 m
Hence, hb less than half of lt + hw, downcomer backup is acceptable for a safe design to
avoid
flooding.
Step 6: Downcomer residence time
Down comer residence time, 21.91625847
Since down comer residence time > 3 s, the design is
satisfactory.
Step 7: Check Entrainment
Actual vapour velocity (based on net
area),
1.262189362
Percentage Flooding = = 80 %
11.29
When FLV = 0.013728875
Fractional Entrainment, 𝜑 = 0.085
Since 𝜑 < 0.1, the efficiency of plate is not much affected, the design is
satisfactory
Step 8: Determination of perforated area

Allow calming zone width = 50 mm (Based on Coulson and
Richardson)
Take unperforated strip round plate edge = 50 mm
291
11.32
When
= 0.76, θc = 99°
Angle subtended at plate edge by unperforated strip = 180° - 99°

= 81° length, unperforated edge strips= (1.43647014 −
Mean = 1.960712695 m
0.05) ×
Area of unperforated edge strips = 0.098035635
m2
Mean length of calming zone = 1.14 m
Area of calming zone = 0.114192294 m2
Total area for perforations, Ap = 1.0199 m2
= 0.120808462

11.33
= 2.7
This ratio is between 2.5 and 4.0, hence the design is

satisfactory.
Step 9: Determination of number of holes
Area of one hole = 1.96375E-05
Number of holes = 6275
Mechanical Design
Step 1: Design Pressure
Safety margin of 10% is applied to the operating pressure of the column, which is
5 bar.
Step 2: Design temperature

Safety margin of 10 C is applied to the highest temperature of the column,
which is
204.00 C.
Design temperature = 193.7311 + 10 = 204 ℃
Step 3: Material of construction

Stainless steel 316 is chosen as the material of construction for this column because
there is
need for corrosion resistance for the column.
From Table 13.2 in Coulson and Richardson’s Chemical Engineering Design, stainless
steel
316 at T = 204.00 oC has design stress of about 119.5 N/mm2, which is much higher
than the
column design pressure. Hence, it is a suitable material of construction for this
distillation
column.
292
Step 4: Welded joint efficiency
A double welded butt type of welding is used to balance the tradeoff between higher
cost and
higher strength of weld joint. The welded joint factor, J is 0.85 using spot as the degree
of
radiography.
Step 5: Minimum Column Thickness
Internal diameter of column, Di = 1.43674014 m = 1436.74 mm
Wall thickness is calculated based on Coulson & Richardson’s Chemical Engineering
Design.
0.778516548 mm
Taking corrosion allowance of 2 mm.
So, fabrication thickness of column wall = 0.778516548 + 2 = 2.778516548 mm
For corrosion allowance of 2 mm from Coulson & Richardson’s Chemical
Engineering
Design,
Since the column diameter is 1.4367 m, thus the suggested minimum thickness
should be
used which is 7 mm because the calculated wall thickness is smaller.
The maximum allowable working pressure (MAWP) for this wall thickness is given
by:
293
Since the MAWP is greater than the operating pressure, the thickness of
column is
acceptable.
Step 6: Column Head Design
Due to low design pressure of the system, the type of head chosen is torispherical
head. For
torispherical head, the head thickness is designed as below:
Crown radius, Rc=Di = 1.4367 m
Knuckle radius, Rk=0.06Rc = 0.08622
Cs = 0.811237244t = e = 0.536687681
So, fabrication thickness of column wall = 0.536687681+ 2 = 2.536687681
mm
Engineering
Design,
should be
by:
Since the MAWP is greater than the operating pressure, the thickness of column is
acceptable
Step 7: Insulation Design
Rock wool is chosen as the insulation material as it can be used up to the temperature
of 659
oC. Rock wool has the density of 130 kg/m 3 and insulation thickness of 75 mm.
Step 8: Weight of Vessel

The total weight of the vessel consists of the column weight, tray weight and weight of
insulation. Each weight is calculated separately and totalled up to get the total weight
of
vessel which is required for stress analysis of the column. The weight of column is
calculated
based on formula in Coulson and Richardson’s Chemical Engineering Design:
294
Weight of Column
Take Cv = 1.15 as a factor to account for the weight of nozzle, manway, internal
support
1.443740714
= 123.802 kN
Weight of Trays
Weight of single tray = Plate area x Plate thickness x Stainless steel density
xg
= 0.633870178 kN
Weight of Trays= Weight of single tray x No. of trays

= 0.633870178 x 89 = 56.41444586 kN
Weight of Insulation
Volume of Insulation =14.28993743 m3
Weight of Insulation =g
= 130 x 14.28993743 x 9.81
= 18223.9572 N = 18.2239572 kN
Total weight of insulation = 2 x 18.2239572 kN
= 36.4479144 kN
Total weight of distillation column, W = 160.8838312

kN
Step 9: Stress Analysis
Stress analysis must be made to ensure that the column structure is strong and
safe. Stress
analysis is solely based on Coulson and Richardson’s Chemical Engineering Design.
Wind Loading
Typically, wind pressure = 1280 N/m2 for preliminary design.
1.604740714
1829590.152
Longitudinal stress, = 0.005644339 N/mm2
Circumferential stress, = 0.011288677 N/mm2
Dead weight stress, 6.18770856
Second moment area of the vessel about the plane of

bending,
= 1.56E+10 mm4
295
Bending stress,
85.29982594
Total longitudinal stress,
Since is compressive, hence it is

negative.
79.11776172
-91.48189016
Torsional shear stress needs not be considered in preliminary
design.
Under this condition, the 3 principal stresses and their difference are calculated as
shown:
From table, the greatest principle stress difference will be on the down-wind
side
Stress difference = = 91.49317884 N/mm2
This does not exceed the design stress for the material construction of this column
(119.5
N/mm2) hence the design is acceptable.
Critical buckling stress, 95.71074265

Maximum compressive where the vessel is not under pressure
=91.4875 N/mm2
Since critical buckling stress is smaller than maximum allowable design stress,
maximum
compressive stress (91.4875 N/mm2) less than critical buckling stress (95.7107
N/mm2).
Hence, the design is satisfactory.
Step 10: Vessel support
Type of support chosen: Conical Skirt
Take skirt bottom diameter,
Take skirt height, Hs = 3.2 m
This angle is between 80o and 90o hence the skirt base angle is
satisfactory.
The maximum dead weight load on the skirt will occur when the vessel is full of
water.
671361.5712 = 671.3615712 kN
Take skirt thickness, ts be 13 mm,
2117.534349
80.35012786
296
10.18996232
The skirt thickness should be such that under the worst combination of wind and dead-
weight
loading, 2 design criteria must be satisfied. Choosing the skirt material to be stainless
steel,
maximum allowable design stress at 20 oC is 145 N/mm2. The Young modulus of
stainless
2
101.5419676
steel type 316 is 197.5 kN/mm
203.0589432
Since both design criteria are satisfied, the skirt thickness is

acceptable.
Skirt thickness = 13 mm
Step 11: Base ring and anchor bolt design
Take pitch circle diameter,
Minimum bolt spacing is recommended at 600

mm
(Must be multiple of 4)
(from Coulson & Richardson’s Chemical Engineering
Design)
From Coulson & Richardson’s Chemical Engineering Design Figure 13.26, the bolt
type
selected is M 48 E as it is the closest standard size bolt larger than 38 mm. Its root
area is
1470 mm2.
Total compressive load on base ring, Fb
From Coulson and Richardson’s Chemical Engineering Design, maximum allowable

bearing
pressure on concrete foundation pad, fc = 5 N/mm2
Minimum base ring width,
From Figure 13.26 in Coulson and Richardson’s Chemical Engineering Design,

distance
from skirt edge to ring edge, Lr = 76 mm
297
Actual base ring width = Lr + ts + 50 = 76 + 7 + 50 = 133 mm
Actual bearing pressure on concrete foundation pad, = 8.159263197
N/mm2
Allowable design stress in ring material, fr = 140 N/mm2 (From Coulson and
Richardson’s
Chemical Engineering Design)
Step 12 : Nozzles design
W ρ Dopt D Standard D Schedule No of

Stream (kg/h) (kg/m 3) (mm) (in) (in) No. Nozzle
11173. 2329.46 50.42 1.99 2.0 40S
Feed inlet 12 1
Vapour 1881.7 2876.59 21.19 0.83 0.8 40S

top outlet 1 1
Reflux 195.50 2876.59 7.65 0.30 0.3 40S

inlet 1
Liq.
9291.4 2065.12 48.17 1.90 1.9 40S
bottom
0 1
outlet
Boilup 9605.9 1820.46 50.85 2.00 2.0 40S

inlet 8 1
The Harker equation (1978), modified for SI unit, for the optimum pipe (and
nozzle)
diameter:
Where W in kg/hr and in kg/m3
298
Ethylene Glycol, C2H6O2 Light Key
Glycerol, C3H8O3 Heavy Key

Equation.
Components A B C
Glycerol 6.19 1036.06 28.10
Dew point
Bubble point
Dew point 188.35˚C
299

Glycerol 25.02 0.03 1.00
1086.96 1.43 43.44
Hydrogen
Methanol 22770.57 29.96 910.04
Acetol 1731.57 2.28 69.20
Water 9120.96 12.00 364.52
1/P=∑yi/Psat 1.00
∑yi/Ki 1.00
Bubble point 285.45˚C

Glycerol 759.76 1.00 1.00
1599.96 2.11 2.11
Hydrogen
Methanol 104883.14 138.00 138.05
Acetol 11640.21 15.32 15.32
Water 52212.32 68.70 68.72

P=∑xi*Psat 1.00
∑xiKi 1.00

which is
300
KLK KHK LK,HK
Feed 0.918 0.045 20.408
Distillate 0.756 0.033 22.956
Bottom 8.656 15.316 0.565
= 14.09848722
Component αi
Glycerol 0.19 1.00

Rmin
301
q 1.00
Vapor Fraction 0.00
Temperature (0C) 194.66
Pressure (mmHg) 760
which in
R = 1.5(0.05) = 0.07

tray
using:
Propylene -804.54 30487.00 130.79 -1.54E-01 1.00 0.533978568 0.42182497

Glycol
Ethylene -20.515 2468.5000 1.2435E+00 2.4998E+12 -5 0.564187277 0.013011779

Glycol
Only for Glycerol, μ liq (cP) is taken from ASPEN at Feed Temperature = 467.66
K.
302
Component μ liq (cP) Mole frac 𝜇,Favg
Glycerol 1.61052 0.19 0.301117219

0.735953967

Lockett,
=
= 29.64467883%

stage:
X = 0.66352063
Therefore,19.8295

Nact
66.89071743
N = 66 trays
0.494148117
Nactual = NR + NS
303
22.15839478
and NS = 44.84160522

reboiler)
Column Sizing
where
calculated
top and
Density
(kg/m3) 1.973397829 1.983644088
887.2195531 1055.849857
(kg/m3)
Mass Flow Rate
(kg/s) 513.1315895 9804.534547
7773.46 11835.61
(kg/s)
0.077804548 0.03789347
ave (N/m)
factor,
top and
Handbook.

chosen.
  0 .2
  L  V  0 .5
Vnf  C sb   
 20   
304
V 

To calculate Csb use this formula,

Csb = 0.206289661 Csb= 0.19799853
Vnf = 1.440114959 m/s Vnf = 1.302655892 m/s
= 1.152091967 m/s = 1.042124713m/s

V _ dot
An 
Vn
V _ dot 
3600s
1.094200656 hr 1.657389276
= 0.949751138 = 1.590394369
An
AC 
1  0.12
= 1.079262656 = 1.807266328

0 .5
 4 AC 
DC  

305
1.172246158 m Dc 1.516932728 m
Since limiting diameter occurs at bottom, the chosen diameter for the column is,
Dc =
1.516932728 m.
Rule of thumb:

entrainment.
chosen.

m
steel
Column height, Hc

operation

diameter:

valid)

0.002579421
Dc = 1.516932728 m
11.28,
Column diameter,
Column area,
306
= 0.216871959 m2
Net area,
Active area,
Hole area,
11.31,
When

atm.)
0.005m
m

Minimum liquid flow rate at 70% turndown = 0.70
1.906437273
(2.723481819
Max 12.8299
Min 12.5419
11.30
Maximum vapour flow

rate=1.657389276
(1.657389276
Since actual minimum vapour velocity (8.446695046 m/s) > weeping velocity
(5.427717166 m/s), the minimum operating liquid flow rate is well above weeping
point, the
design is satisfactory.

uh 12.06670721

area,

11.34
307
Orifice coefficient, 0.74

79.5354

Engineering
Design
– 10 = 50 – 10 = 40 mm = 0.04 m
As this is less than Ad = 0.216871959 m2, use Equation 11.92 to estimate the head
loss in
downcomer, hdc
0.190699005 mm
liquid
= 0.175 m
avoid
flooding.
satisfactory.
area),
1.042124713
11.29
When FLV = 0.035905998
satisfactory.

Allow calming zone width = 50 mm (Based on Coulson and Richardson)
11.32
When
= 0.76, θc = 99°

= 81°
308
Mean length, unperforated edge strips= (1.5169 − = 2.074096184 m
0.05) ×
m2
= 0.11948549

11.33
= 2.7

satisfactory.
Mechanical Design

5 bar.

which is
296.00 C.

there is
steel
than the
distillation
column.
309
cost and
of
radiography.
Internal diameter of column, Di =m = 1516.93278 mm
Design.
0.889641201mm
So, fabrication thickness of column wall = 0.889641201 + 2 = 2.889641201 mm
Engineering
Design
should be
by:
310
column is
acceptable.

head. For
Cs = 0.81123t = e = 0.613280767
mm
Engineering
Design,
should be
by:
column is
acceptable.

of 659
311
of
calculated
Weight of Column
support
1.523932728
= 66.955 kN
Weight of Trays
xg
= 0.70660412 kN
Weight of Trays= Weight of single tray x No. of trays

= 0.70660412 x 66 = 46.63587189 kN
Volume of Insulation =7.50605 m3
= 130 x 7.50605 x 9.81
= 9572.470937 N = 9.5725 kN
= 19.1449 kN
Total weight of distillation column, W = 86.8066 kN

safe. Stress
Wind Loading
Typically, wind pressure = 1280 N/m2 for preliminary design.
1.680932728 m
2151.593891
474336.0904
Longitudinal stress, = 0.00596N/mm2
312

bending,
= 9.73E+09 mm4
Bending stress, 37.3157

negative.
34.73175226
-39.89963119
design.
shown:
side
Stress difference == 39.91154995 N/mm2
(110.4
N/mm2) hence the design is acceptable.
Critical buckling stress, 91.4475192
Maximum compressive where the vessel is not under
pressure
=39.90559057 N/mm2
maximum
compressive stress (39.90559057 N/mm2) less than critical buckling stress
(91.4475192
N/mm2). Hence, the design is satisfactory.
88.3501
o o
This angle is between 80 and 90 hence the skirt base angle is
satisfactory.
water.
= 372.3280628 kN
313
629.9255904
21.18329068
5.321313856
weight
steel,
maximum allowable design stress at 20 oC is 145 N/mm2. The Young modulus of
stainless
steel type 316 is 197.5 kN/mm2
1 93.80163342
191.0983079

acceptable.

mm
Design)
type
selected is M 24 F .

bearing
314
distance
Actual bearing pressure on concrete foundation pad, = 2.2089 N/mm 2
Allowable design stress in ring material, fr = 140 N/mm2 (From Coulson and
Richardson’s

Stream (kg/h) (kg/m 3) (mm) (in) (in) No. Nozzle
9291.4 1144.49 57.84 2.28 2.3 40S
Feed inlet 0 1
Vapour 7260.3 907.34 55.63 2.19 2.2 40S

top outlet 2 1
Reflux 500.04 907.34 16.69 0.66 0.7 40S

inlet 1
Liq.
2031.0 976.89 30.65 1.21 1.2 40S
bottom
8 1
outlet
Boilup
inlet 500.04 1601.13 14.00 0.55 0.6 40S
1
nozzle)
diameter:

Propylene Glycol, C3H8O2 Light Key
Ethylene Glycol, C2H6O2 Heavy Key
315

Equation.
Components A B C
Dew point
Bubble point
Dew point 188.07˚C

Glycerol 24.67 0.03 0.04
1085.18 1.43 1.91
Hydrogen
Methanol 22649.35 29.80 39.77
Acetol 1720.28 2.26 3.02
Water 9065.46 11.93 15.92

1/P=∑yi/Psat 1.00
∑yi/Ki 1.00
Bubble point 197.47 ˚C
316

Glycerol 39.07 0.05 0.05
1144.85 1.51 1.51
Hydrogen
Methanol 27071.66 35.62 35.64
Acetol 2141.55 2.82 2.82
Water 11115.88 14.63 14.64
P=∑xi*Psat 1.00
∑xiKi 1.00

which is
KLK KHK LK,HK
Feed 0.754 0.033 22.991
Distillate 0.749 0.032 23.081
Bottom 0.999 2.818 0.355
317
= 1.337274317
Component αi

Rmin
q 1.00
Vapor Fraction 0.00
Temperature (0C) 188.27
Pressure (mmHg) 760
which in
318
R = 1.5(2.81) = 4.22

tray
using:
Propylene -804.54 30487.00 130.79 -1.54E-01 1.00 0.584775793 0.568176392

Glycol
Ethylene -20.515 2468.5000 1.2435E+00 2.4998E+12 -5 0.601458925 0.017057596

Glycol

0.585233988

Lockett,
=
= 53.16498248 %

stage:
X = 0.3929
Therefore, 63.6071
319
Nact
119.64
N = 119 trays
1.774330824
Nactual = NR + NS
76.74632638
and NS = 43.25367362

reboiler)
Column Sizing
where
calculated
top and
320
Density
(kg/m3) 1.98429901 1.588098929
885.0554872 966.4397538
(kg/m3)
Mass Flow Rate
(kg/s) 29977.06581 37237.38974
37077.07 37397.71
(kg/s)
0.041843037 0.03942631
ave (N/m)
factor,
top and
Handbook.

chosen.
  0 .2
  L  V  0 .5
Vnf  C sb   
To calculate Csb use this formula, 20   
V 


Csb = 0.280000565 Csb= 0.279204698
Vnf = 1.719775855 m/s Vnf = 1.980001166 m/s
= 1.375820684 m/s = 1.584000933 m/s

V _ dot
An 
Vn
321
V _ dot 
3600s
5.190339206 hr 6.541314023
= 3.772540467 = 4.129615007
An
AC 
1  0.12
= 4.2870 = 4.6927
 4 AC  0 .5
DC  
Top Condition 
2.3363 m  Bottom Condition
Dc 2.4444 m
Since limiting diameter occurs at bottom, the chosen diameter for the column is, D c =
2.4444
m.
Rule of thumb:

entrainment.
chosen.

m
steel
Column height, Hc
322
operation

diameter:

valid)

0.010702912
Dc = 2.4444 m
11.28,
Column diameter,
Column area,
= 0.5631 m2
Net area,
Active area,
Hole area,
11.31,
When

atm.)
0.005m
m

323
Minimum liquid flow rate at 70% turndown = 0.70 7.2406
(10.3437
Max 24.1032
Min 36.7619
11.30
Maximum vapour flow rate= 6.5413

(6.5413
Since actual minimum vapour velocity (12.8387 m/s) > weeping velocity (6.2248 m/s),
the
minimum operating liquid flow rate is well above weeping point, the design is
satisfactory.
uh 18.34106343

area,

11.34
Orifice coefficient,0.74

105.6261

Engineering
Design
– 10 = 50 – 10 = 40 mm = 0.04 m
As this is less than Ad = 0.5631 m2, use Equation 11.92 to estimate the head loss
in
downcomer, hdc
0.332928289 mm
liquid
= 0.255 m
avoid
flooding.
324
satisfactory.
area),
1.5840
11.29
When FLV = 0.0404
satisfactory.

Allow calming zone width = 50 mm (Based on Coulson and Richardson)
11.32
When
= 0.76, θc = 99°

= 81° length, unperforated edge strips= (1.5169 −
Mean = 3.3854 m
0.05) ×
m2
= 0.1112

11.33
= 2.8

satisfactory.
Mechanical Design
5 bar.
325
which is
208.00 C.

there is
steel
than the
distillation
column.

cost and
of
radiography.
Internal diameter of column, Di =m = 2444.4 mm
Design.
1.32795 mm
So, fabrication thickness of column wall = 1.32795 + 2 = 3.32795
mm
326
Engineering
Design
should be
by:
column is
acceptable.

head. For
Cs = 0.8112t = e = 0.9155
mm
Engineering
Design,
327
should be
by:
column is
acceptable.

of 659

of
calculated
Weight of Column
support
= 362.1708 kN
Weight of Trays
xg
= 1.8348 kN
Weight of Trays= Weight of single tray x No. of

trays
= 1.8348 x 119 = 218.3373 kN
3
Volume of Insulation =32.3129 m
= 130 x 32.3129 x 9.81
328
= 41208.6256 N = 41.2086 kN
= 82.4173 kN
Total weight of distillation column, W = 446.4228 kN

safe. Stress
Wind Loading
Typically, wind pressure = 1280 N/m2 for preliminary
design.
2.6124 m
3343.8462
5261330.294
Longitudinal stress, = 0.005171N/mm2

bending,
= 7.58E+10 mm4
Bending stress, 85.7711

negative.
81.3286
-90.2135
design.
shown:
side
Stress difference == 90.2238 N/mm2
(119.2
2
Critical
N/mm ) buckling stress,
hence the design is acceptable. 105.2470
Maximum compressive where the vessel is not under
pressure
329
= 90.2186 N/mm2
maximum
compressive stress (90.2186 N/mm2) less than critical buckling stress (105.2470
N/mm2).
Hence, the design is satisfactory.

89.4905
This angle is between 80o and 90o hence the skirt base angle is
satisfactory.
water.
= 2582.8085 kN
5878.7060
91.6346
25.1623
weight
steel,
o2
maximum allowable design stress at 20 C is 145 N/mm . The Young modulus of
stainless
101.3162
steel type 316 is 197.5 kN/mm2
129.9951
330
acceptable.

mm
Design)
type
selected is M 64 F .

bearing

distance
Actual bearing pressure on concrete foundation pad, = 9.2922 N/mm 2
Allowable design stress in ring material, fr = 140 N/mm

2 (From Coulson and
Richardson’s

Stream (kg/h) (kg/m3) (mm) (in) (in) No. Nozzle
7260.3 884.70 56.07 2.21 2.2 40S
Feed inlet 2 1
Vapour 7100.0 884.90 55.50 2.19 2.2 40S

top outlet 0 1
Reflux 23.12 885.86 4.22 0.17 0.2 40S

inlet 1
Liq.
160.32 875.13 10.12 0.40 0.4 40S
bottom 1
331
outlet
Boilup 23.12 875.13 4.23 0.17 0.2 40S
inlet 1
nozzle)
diameter:
Appendix G: Heat Transfer Equipment Design

G.1 Heat Exchanger, E-101
The calculations for heat exchanger, E-101 is shown below. The rest of the heat
exchangers
are designed using the same method of calculations.
Step 1: Specification
Step 2: Physical Properties
Physical properties of the stream are determined at mean

temperature.
Physical Properties Tube Shell Unit
Mean temperature 412.71 498.00 K
Pressure 40 1 bar
Molecular weight 92.094 18.015 kg/kmol
Density 1178.04 0.44 kg/m3
Viscosity 0.01200 0.000017375 kg/m.s
Thermal Conductivity, K 0.293 0.0365 W/m.K
Heat Capacity, Cp 2.243 1.961 kJ/kg.K
332
Step 3: Mean temperature difference
For shell side (hot side), Th1 = 523K, Th2 = 473K,
For tube side (cold side), Tc1 = 352.422K, Tc2=

353K,
S= 0.707
Temperature correction factor, Ft:
True log mean temperature difference,

ΔTm:
Step 4: Total heat transfer area

By taking initial trial value of heat transfer coefficient, Uo = 100
W/m2.°K,
Step 5: Exchanger layout
Tube side
Taking, Tube outer diameter, do = 0.016

m
Wall thickness, t = 0.002m
Tube length, L = 1.830 m
333
Taking number of passes, Np = 1,
From Table 12.4 in Coulson and Richardson’s Chemical Engineering Design, for 1
tube
passes,
K1 = 0.037
n1 = 2.675
From Figure 12.12 in Coulson and Richardson’s Chemical Engineering Design, by

referring
the graph for split-ring floating head, Shell bundle clearance = 45mm = 0.045 m
Shell inside diameter = Shell bundle clearance + bundle
diameter
= 0.045 m + 0.120m
= 0.165 m
According to TEMA Standard, the maximum shell inside diameter is 1.52 m. Thus,
0.165 m
is acceptable.
Tube length to bundle diameter
ratio,
Step 6: Heat transfer coefficient
Tube side
From Figure 12.23 in Coulson and Richardson’s Chemical Engineering

Design,
334
Heat transfer factor, jh = 0.004
Shell side
By taking trial value of n = 5,
From Figure 12.29 in Coulson and Richardson’s Chemical Engineering Design, at buffer
cut
percent = 25% reasonable heat transfer coefficient without too large a pressure drop,
heat
transfer factor, jh = 0.009
Step 7: Overall heat transfer coefficient

From Table 12.2 in Coulson and Richardson’s Chemical Engineering
Design,
By taking steam as the fluid for the shell side and organic liquid for tube side, shell
side
fouling factor is, hod = 1500W/m2.K and tube side fouling factor, hid = 5000W/m2.K
respectively.
From Table 12.6, Thermal conductivity of stainless steel, kw = 16
W/m.K
Overall heat transfer coefficient, Uo:
335
Step 8: Pressure drop
Tube side
Design,
Friction factor, jf = 0.006
Shell side
Design,
Friction factor, jf = 0.0055,
MECHANICAL DESIGN
Shell and tube must be designed to withstand the maximum pressure to which it is
likely to
be subjected in operation.
Thus, safety margin of 10% is applied to the operating pressure of the

exchanger.
= 4.4N/mm2
336
The strength of metals decreases with increasing temperature, so the maximum
allowable
stress will depend on the material temperature.
Thus, safety margin of 10 K is applied to the operating temperature of the

exchanger.
Stainless steel 316 is chosen as the material of construction for this heat exchanger
because
the system contains methanol and steam which has tendency to corrode the heat
exchanger.
Stainless steel 316 can provide corrosion resistance for this exchanger where this kind
of
metal has low corrosion rate per year.
From Table 13.2 in Coulson and Richardson’s Chemical Engineering Design, Stainless
steel
type 316 for tube side (at 422.71K) and shell side (at 508K) has design stress of
517.11
N/mm2 and 206.844 N/mm2 respectively, which is much higher than the design
pressure.
Hence, it is a suitable material of construction for this exchanger.
A double welded butt type of welding is used for this exchanger to balance the
tradeoff
between higher cost and higher strength of weld joint. The welded joint efficiency, J of
this
weld joint is 0.85.
Step 5: Minimum Shell Wall Thickness

Design.
= 0.11 mm
Take corrosion allowance of 2 mm.
Fabrication thickness of shell wall = 0.11 + 2 =

2.11mm
by:
337
Since the MAWP is greater than the operating pressure, the thickness of shell is
acceptable.
Step 6: Weight of Exchanger
The total weight of the vessel consists of the exchanger shell weight, exchanger tubes
weight
and weight of insulation. Each weight is calculated separately and totalled up to get the
total
weight of exchanger which is required for support design. Since both the tubes and
shell are
in cylindrical shape and made of stainless steel, the weight is calculated based on
formula in
Coulson and Richardson’s Chemical Engineering Design:
Weight of Tubes
support
Length of the tube Hv = 1.83
Weight of tubes = Number of tubes x Weight of single

tube
= 8 x 0.02= 0.16N
Weight of Shell
support
Thicker insulation such as Calsium silicate is chosen as the material of insulation with
density
of 200 kg/m3 because can lower the surface temperature because the equivalent heat
loss is
spread over a larger surface.
1.97 N
Based on Coulson and Richardson’s Chemical Engineering

Design,
338
Weight of fittings are estimated by doubling the weight of insulation which is equal to
3.95
N.
Total weight of exchanger, W = 3.95 N +1.97 N + 0.13N + 0.19 N =

6.24 N
Step 8: Heat exchanger support
Type of support chosen: Saddle

Based on Figure 13.23 in Coulson and Richardson’s Chemical Engineering Design,
the
dimensions of standard steel saddles for the exchanger are stated as following:
By taking 50 mm as the insulation thickness,

ti
Actual exchanger diameter =
Support Design
Types of support Saddle
V (m) 0.48
Y (m) 0.15
C (m) 0.55
E (m) 0.24
J (m) 0.19
G (m) 0.095
t2 (mm) 6
t1 (mm) 5
Bolt diam. (mm) 20
Bolt holes (mm) 25
Step 9: Nozzles design
Tube Inlet
Q = Volumetric Flow Rate = m3/s
339
Minimum Nozzle Cross Sectional Area, A = m2
Minimum Nozzle Diameter = .0333m
Operating 2 times away from speed of sound, nozzle diameter = 2 x 0.033 m =

0.07 m
Tube Outlet
Minimum Nozzle Diameter = m

0.07 m
Shell Inlet

0.11 m
Shell Outlet

0.11 m
ASPEN Plus Simulation result for E-401
340
G.2 Condenser, E-103
The calculations for condenser, E-103 is shown below. The rest of the
condensers are
designed using the same method of calculations.
Design Procedure
From energy balance calculation,
Heat Duty = 290.136W x = 0.290136 kJ/s
Mass flow rate for tube side

= 9.9990xx
341
= 1.3887 kg/s
Mass flow rate for shell side

=
=
= 0.8459 kg/s

Mean temperature of process fluid at tube
side:
=
= 310.50 K
Mean temperature of steam at shell

side:
=
= 473 K
Physical properties of a mixture of gas (tube side), at T =

310.50 K
Density,  = 989.57 kg/m3
Viscosity,  = 0.00073604 Pa.s
Thermal conductivity, K = 0.62 W/m.K
Specific heat capacity, Cp = 4.53 kJ/kg.K
Physical properties cooling water (shell side), at T = 473

K
Density,  = 455.86 kg/m3
Viscosity,  = 0.00000599 Pa.s
Thermal conductivity, K = 0.16 W/m.K
Specific heat capacity, Cp = 11.348 kJ/kg.K
Step 3: Overall coefficient
The value of Uo is assumed based on Figure 12.1. To start with, the overall coefficient
(U) is
taken to be 700 W/m2. K.
Table 12.1: Typical overall coefficients
342
Figure 12.1 Overall coefficients
True mean temperature difference
343
R= = =0
S= = = 0.143
Using formula below, determine FT
FT = 1.000
 =
 =
 = 162.179 K
Step 5: Heat Transfer Area
Ao =
Ao =
Ao = 67.220 m2
*As first estimation, the heat transfer area needed lied in the normal area of a shell
and tube
exchanger, which are 3-1000m2, thus, a shell and tube exchanger is selected.
Step 6: Layout and Tube Size
Step 7: Number of Tubes

Area of one tube (neglecting thickness of tube
sheets)
= π x Tube Outer Diameter, do x Nominal

length
= π x 0.038 x 2.440
= 0.291 m2
344
Therefore,
Number of tubes, Nt = = 230.997 tubes ≈ 240

tubes
Number of passes, Np = 8
Total number of tubes per passes = = 28.875 ≈ 30

=
Inner Cross-sectional Area of Tube, Ai = = 0.0011 m2
with that,
Area per pass = Total number of tubes per passes x Inner Cross-sectional Area of
Tube, Ai
= 30 x 0.0011 m2
= 0.0340 m2
At mean temperature, the density of tube side is 989.567

kg/m3
Volumetric flow rate = = = 0.0014 m3/s
Number of central tube, Nr = x =x = 14.2645
Hence,
Tube side velocity, ut = = = 0.0413 m/s
Step 8: Bundle and Shell Diameter-triangular pitch

From Table 12.4 (Coulson & Richardson’s Chemical Engineering), for 8 tube
passes,
345
K1 = 0.037
n1 = 2.675
Bundle diameter, Db = do
Where,
Nt = number of tubes
do = tube outside diameter
Db = 0.038 = 1.016 m
Referring to Figure 12.10 (Coulson & Richardson’s Chemical

Engineering),
when Db = 1.016m, the shell inside diameter- bundle diameter, m (shell

clearance) is
0.073mm.
Hence, the shell inside diameter will
be:
Ds = Bundle diameter, Db + Shell inside diameter- bundle
diameter
Ds = = 1.089 m (1089mm)
TEMA standard Ds is max 1520 mm so, Ds is within the allowed

range.
Step 9: Tube-side heat transfer coefficient
Reynolds number, Re =
346
=
= 2107.469943
Prandtl number, Pr =
= 5.356
= = = 64
From Figure 12.23 (Coulson & Richardson’s Chemical

Engineering),
Nu = jh Re Pr 0.33 ( 0.14
Neglect ( ,
Nu = (0.0042) (2107.469943) (5.356)0.33 =

15.401
Nu =
2
hi = 4766.502 W/m .K
347
Step 10: Shell-side Heat Transfer Coefficient
For first trial, take n =4,
Baffle spacing, lb = = = 0.272
Tube pitch, pt = 1.25 x Tube outside diameter = 1.25 x 0.038m =

0.048m
Cross flow area, As = = = 0.059m2
For an equilateral triangular pitch arrangement, equivalent diameter can be

calculated using
the formula as below:
= ( 2 – 0.917 2)= (0.0482 – (0.917 x 0.0382)) = 0.0270
m
Shell slide mass velocity, Gs = = = 14.257 kg/m2.s
Reynolds number, Re = = = 64184.32667
Prandtl number, Pr = = = 0.430
Based on Figure 12.29 (Coulson & Richardson’s Chemical Engineering), a 15% baffle
cut is
chosen.
Nu = = jh Re Pr 0.33 = (0.0028)(2107.469943)(5.3560.33) =
136.070
348
Outside Fluid Film Coefficient, hs = = = 796.946
Step 11: Overall Coefficient
Where
Uo = overall coefficient based on the outside area of the

tube
ho = outside fluid film coefficient
hi = inside fluid film coefficient
hod= outside dirt coefficient (fouling

factor)
hid = inside dirt coefficient (fouling factor)
kw = thermal conductivity of the tube wall

material
di = tube inside diameter
do = tube outside diameter
Uo = 529.038 W/m2. K
x 100% = = 24.423%
Hence, Uo assume is between 0% – 30%. So, Uo=529.038 W/m2. K is

acceptable.
Tube side
240 tubes, 8 tube passes, tube di = 0.038m, ut =0.0413

m/s
Reynolds number, Re =
2107.469943
From Figure 12.24 (Coulson & Richardson’s Chemical
Engineering),
349
jf = 0.0071
For isothermal flow,
* 2.5 is the recommended value for the velocity heads per pass. Neglecting the
viscosity
correction term
 P = 0.000064 bar
This is within the specification with 0.8 bar.
Shell side
Re = 64184.32667,
The pressure drop in the shell side is predicted using Kern‟s
method.
Again, neglecting the viscosity correction
term;
From Figure 12.24,
jf = 0.050
 P = 0.00032 bar
350
This result is well within specification as the allowable pressure drop for this stream
is 0.8
bar.
Step 13: Mechanical Design
Tube plate design
General requirements (AS1210)

Tube pitch must be more than 25% larger than the tube diameter 
fulfilled.
Nozzles diameter
The Harker equation (1978), modified for SI units, for the optimum pipe (and
nozzle)
diameter is:
Where
Dopt = optimum diameter
W = mass flow rate, kg/hr

ρ = fluid density, kg/m3
Tube inlet diameter
Dopt = 8.41 ( ) = 89.4089 m = 0.3761 in
Tube outlet diameter
Dopt = 8.41 ( ) =89.697 m = 0.3705 in
Shell inlet diameter
Dopt = 8.41 ( ) =201.12 m = 1.27 in
Tube outlet diameter
Dopt = 8.41 ( ) =89.697 m = 0.3368 in
ASPEN Plus Simulation result for E-103
351
ASPEN
Plus
Simulation
result for E-
202
352
G.3 Reboiler, E-203
The calculations for reboiler, E-203 is shown below. The rest of the reboilers are
designed
using the same method of calculations.
Design Basis
TUBE SHELL
In Out In Out(22) Out(23)
353
Molar Flow Rate (kmol/hr) 2396.99 2396.99 279.35 161.39 117.97
Mass Flow Rate (ton/hr) 44.49 44.49 21.51 12.22 9.29
Design Parameters
TUBE SHELL MECHANICAL

Tube Size Shell inner diameter Design Pressure
Number of Tubes Baffle cut Design Temperature
Tube Configuration Baffle spacing Material of Construction
Heat Transfer Area Heat Transfer Area Shell Wall Thickness
Condensing Coefficient Nucleate Boiling Coefficient Exchanger Head Design
Pressure Drop Pressure Drop Insulation
Exchanger Support
Nozzle Size
Design Criteria
Type of Exchanger: Shell and Tube Heat Exchanger

Temperature (°C) Pressure
InletOutlet (bar)
Tube523.00473.00 1.00
Shell465.65467.65 1.00
Design Method
The heat exchanger design is based on Coulson and Richardson’s Chemical
Engineering
Design. For the properties of the components in stream, it is determined from
ASPEN
Database.
Heat Exchanger Design
Steam is supplied in tube side for heating utilities. From utilities

balance,

Physical properties of the stream are determined at mean
temperature.
Unit
Physical PropertiesShellTube
K
Mean temperature473.97489.64
354
Pressure 1.00 1.00 bar
Molecular weight 77.41 18.02 kg/kmol
909.9176 847.79
Density 2.46 0.45 kg/m3
0.0000547 0.000123
0.000011374 0.0000169
Viscosity 0.201 0.65 kg/m.s
0.029 0.04
Thermal 263.6684 95.41
Conductivity, k 143.3124 35.25 W/m.K
Heat Capacity, Cp kJ/kmol.K
Step 3: Mean temperature difference

For tube side (hot side), T1 = 523 K T2 = 473 K,
For shell side (cold side), t1 = 467.65 K, t2 = 465.65
K,
R = 25
S = 0.0349
Ft = 0.9626
Step 4: Total heat transfer area

By taking initial trial value of heat transfer coefficient, Uo = 700 W/m2.
K,
Step 5: Exchanger layout

Tube side
Taking tube outer diameter, do = 0.05 m, wall thickness, t = 0.002 m, tube length, L =
6.1 m,
Taking number of passes, Np = 8,
355
Shell side
Using square pitch
From Table 12.4 in Coulson and Richardson’s Chemical Engineering Design, for 8
tube
passes, K1= 0.0365, n1= 2.675,

Shell bundle clearance = 0.74 m
Shell inside diameter = Shell bundle clearance + bundle diameter = 0.74 m +
1.1274 m
= 1.8674 m
Tube length to bundle diameter

ratio,
is acceptable as it falls within 5 to 10 for optimum
range.
Step 6: Heat transfer coefficient

Shell side
Critical pressure, Pc = 47.2220 bar
Operating pressure, P = 1.00 bar
Since the mixture consists of different components with wide range of boiling
points, an
empirical correction factor is needed as the nucleate boiling coefficient is
overestimated.
Where Tbo and Tbi are the temperatures of the vapor leaving the reboiler and liquid
entering
the reboiler in K.
Tube side
Assume condensing coefficient of steam, hc = 629.8023 W/m2.
K
356
Step 7: Overall heat transfer coefficient
From table 12.2 in Coulson and Richardson’s Chemical Engineering Design,
By taking organic solution as the fluid in shell and steam condensate as the fluid in
tube,
Shell side fouling factor, hod = 5000W/m2. K
Tube side fouling factor, hid = 5000W/m2. K
From table 12.6, Thermal conductivity of stainless steel, kw = 14W/m. K
Overall heat transfer coefficient, Uo:
Uo is acceptable as it is close to the assumed Uo value and well

above it.

Shell side
By taking trial value of number of baffles, n =
4

Design,
Using 25% baffle cut, friction factor, jf = 0.385,
**Viscosity correction neglected

Tube side
357
Design,
Friction factor, jf = 0.019
*Viscosity correction neglected
Mechanical Design

Safety margin of 10% is applied to the operating pressure of the
exchanger.

Safety margin of 10 oC is applied to the operating temperature of the
exchanger.

Stainless steel type 304 is chosen as the material of construction for this reboiler
because
there is a need to avoid corrosion and to reduce the maintenance cost . Stainless steel
type
304 can provide corrosion resistance for this exchanger. From Table 13.2 in Coulson and
Richardson’s Chemical Engineering Design, Take at average temperature of shell side
and
tube side, stainless steel type 304 has design stress of 145 N/mm 2 and 127N/mm2
respectively, which is much higher than the design pressure. Hence, it is a suitable
material of
Step 4: Welded
construction for joint efficiency
this exchanger.
A double welded butt type of welding is used for this exchanger to balance the
tradeoff
between higher cost and higher strength of weld joint. The welded join efficiency, J of
this
weld joint is 0.85.
Step 5: Minimum Shell Wall Thickness
Internal diameter of shell, Ds = 1.8674 m
Design.
m

Fabrication thickness of shell wall = 1.0754 + 2 = 3.0754
mm
358
Since the vessel diameter is less than 1m, thus the suggested minimum thickness
should be
used is 7mm as the calculated wall thickness is smaller.
by:
Since the MAWP is greater than the operating pressure, the thickness of shell is
acceptable.
Step 6: Exchanger Head Design
The type of head chosen is torispherical head. Based on Coulson and Richardson’s
Chemical
Engineering Design, it is proven ot be the most economical closure to use besides as
well as
its ability to withstand high pressure.

Fabrication thickness of exchanger head = 1904.808033 + 2 = 1906.808033
mm
Since the fabrication thickness of exchanger head calculated is less than the wall
thickness,
thus the exchanger head thickness should be chosen is 7 mm.
by:
Since the MAWP is greater than the operating pressure, the thickness of head is
acceptable.
Step 7: Weight of Exchanger
The total weight of the vessel consists of the exchanger shell weight, exchanger tubes
weight
and weight of insulation. Each weight is calculated separately and totalled up to get the
total
weight of exchanger which is required for support design. Since both the tubes and
shell are
in cylindrical shape and made of stainless steel, the weight is calculated based on
formula in
Weight of Shell
Coulson and Richardson’s Chemical Engineering Design:
support
359
= 0.0276 kN
Mineral wool is chosen as the material of insulation with thickness of 75mm and
density of
130kg/m3.
Based on Coulson and Richardson’s Chemical Engineering Design,

Weight of fittings are estimated by doubling the weight of insulation which is equal to
0.6413
kN.
Total weight of exchanger, W = 0.3207 kN + 0.6413 kN + 0.0276 kN + 0.0002 kN=

0.9898
kN
Step 8: Heat exchanger support
Type of support chosen: Saddle
Based on Figure 13.26 in Coulson and Richardson’s Chemical Engineering Design,
the
dimensions of standard steel saddles for the exchanger are stated as following:
Actual exchanger diameter =
Since the vessel diameter is smaller than 2 m, check from Figure

13.26(a)
Support Design
Types of supportSaddle
1.18
V (m)
Y (m) 0.2
C (m) 1.77
E (m) 0.8
J (m) 0.45
G (m) 0.14
t2 (mm) 12
t1 (mm) 10
Bolt diam. (mm) 24
Bolt holes (mm) 30

StreamT (K) P (bar) W (kg/hr) ρ (kg/m3) Dopt (mm) Dopt (in)
Shell inlet (L) 465.65 1.00 21507.69 914.6897 90.46245341 3.5615
360
Shell outlet (V) 467.65 1.00 12216.29 1.9792 - 5.5937
Shell outlet (L) 467.65 1.00 9291.40 938.5944 61.51264638 2.4218
Tube inlet (V) 523.00 1.00 44489.80 1.63 - 11.4262
Tube outlet (V) 473.00 1.00 44489.80 1.63 - 11.7168
Shell Outlet
W = Mass Flow Rate = 12216.2920 kg/hr
=m3
nozzle)
diameter:
Take the Schedule 40S pipe, the number of shell inlet nozzles required is one with the
pipe
size of 0.5 in. Same procedures are repeated for the shell outlet 1, shell outlet 2, tube
inlet and
tube outlet nozzle calculations.
361
For shell outlet (V)
W 12216.2920 kg/hr
Density 1.9792 kg/m3
Speed of sound at 465.65 K 432.57 m/s
Volumetric flowrate 1.7145 m3/s
Minimum Nozzle Cross Sectional Area, A 0.0040 m2

0.0710 m
Minimum Nozzle Diameter 2.7968 in
Operating 2 times away from speed

of 5.5937 in
sound, nozzle diameter
Appendix H: Reactor Design

H.1 Packed Bed Reactor, R-101
General
Type of reactor: Packed bed

reactor
Orientation: Vertical
Material of construction: Stainless steel

Temperature: 200˚C
Pressure: 40 bar
Mass flow rate: 12181.37 kg/hr
Catalyst: Cu/ZnO/Al2O3 [ratio = 1:1:0.5]
Catalyst density: 1050 kg/m3
Catalyst size: 0.00034m
Bed void fraction: 0.45
Reaction Kinetics and design equation
* The reaction kinetics is referred to kinetic study done by Z. Zhou et al.,

2010.
Reaction kinetics:
362
Design Equation:
Nomenclature
F = molar flow rate, mol.s-1
bj = adsorption rate constant for species j, m3.mol-1
bjo = preexponential factor of adsorption rate constant for species j,
m3.mol-1
c= molar concentration, mol.m-3
Ei = activation energy of the i-th reaction, mol.g-1.s-1
ki = rate constant of the i-th reation, mol-1.g-1.s-1
kio = preexponential factor of rate constant of the i-th reaction, mol-1.g-
1.s-1
W = mass of catalyst, g
P = pressure, MPa
Qj = adsorption activation energy of species j, kJ.mol-1
Rg = universal gas constant, kJ.mol-1.K-1
ri = rate of the ith reaction, mol.g-1.s-1
T = temperature, K
for subscripts
G = Glycerol
P = Propylene Glycol
A = Acetol
363
H=
# H=
Hydrogen
Hydrogen
# Mole Balance for the PBR

Pressure drop
d(FG)/d(W) correlation
= -r1
FG(0) = 33.12
d(FP)/d(W) = r2
FP(0) = 0
d(FA)/d(W) = r1
FA(0) = 0
d(FH)/d(W) = -r2
FH(0) = 165.59
# Rate of reaction
r1 = (k1 * bG * CG) / (1 + bG * CG + bA * CA + bP * CP)
Nomenclature
r2
Y ==pressure
(k2 * bA drop
* CA correlation,
* bH * PH) / Pa
((1 + bG * CG + bA * CA + bP * CP) * (1 + sqrt(bH * PH))
^ 2)
Ac = reactor cross sectional area
= catalyst density, kg.m-3
= reactor
# Rate bed void
constant
P o = inlet feed pressure, Pa
k1 = k1o * exp(-E1 / (Rg * T))
k2==inlet
k2o feed density,
* exp(-E2 kg.m-3
/ (Rg * T))
Dp = catalyst particle diameter, m
G = superficial mass velocity, kg.m-2.s-1
# Experimental data
k1o = 1.5E+04
k2o = 7.16E+03
E1 = 86.56
Step
E2 = 1: Weight of Catalyst
57.80
Design Assumption: The system is first assume to be operated under isobaric and
isothermal
bG = bGo * exp(QG / (Rg * T))
condition.
bA = bAo *The side reaction
exp(QA of glycerol is omitted as the degradation of glycerol is very
/ (Rg * T))
small
bP = bPo * exp(QP / (Rg * T))
(2.77%).
Using
bH Polymath:
= bHo * exp(QH / (Rg * T))
QH = 36.24# Nomenclature
bGo
#F= =molar
2.22E-03
flow rate, mol.s-1
bAo = 8.73E-03
# bj = adsorption rate constant for species j, m3.mol-1
bPo
# bjo==5.80E-03
preexponential factor of adsorption rate constant for species j,
bHo =
m3.mol-11.86E-05
QG
# C= = 36.42
molar concentration, mol.m-3
QA
# Ei =25.94
= activation energy of the i-th reaction, mol.g-1.s-1
QP
# ki==25.77
rate constant of the i-th reation, mol-1.g-1.s-1
# kio = preexponential factor of rate constant of the i-th reaction, mol-1.g-
1.s-1
# W = mass of catalyst, g
Rg
# P==0.008314
pressure, MPa
T
#=Qj473
= adsorption activation energy of species j, kJ.mol-1
Po =4
# Rg = universal gas constant, kJ.mol-1.K-1
# ri = rate of the ith reaction, mol.g-1.s-1
# T = temperature, K
# Initial Concentration
CTo = Po * 1000 / (Rg * T)
# for subscripts
# G = Glycerol
# Concentration
P = Propylene Glycol
FT
# A==FG + FA + FP + FH
Acetol
364
365
CG = CTo * FG / FT
CA = CTo * FA / FT
CP = CTo * FP / FT
CH = CTo * FH / FT
PH = CH * Rg * T / 1000
# Calculation Limit,g
W(0) = 0
W(f) = 1675000
Table 1: Calculated values of variables for weight of catalyst from

polymath.
366
367
# Ac = reactor cross sectional area
# denC = catalyst density, kg.m-3
# void = reactor bed void
# Po = inlet feed pressure, Pa
# denF = inlet feed density, kg.m-3
# dp = catalyst particle diameter, m
# Gv = superficial mass velocity, kg.m-2.s-
1
# m = mass flow rate of system, kg.s-1
# u = gas viscosity, kg.m-1.s-1
# Pressure drop correlation

d(Y)/d(W) = -alpha / 2 / Y * FT / FTo
Y(0) = 1
alpha = 2 * beta / Ac / denC / (1 - void) / Po
beta = Gv * (1 - void) / denF / dp / void ^ 3 * (150 * (1 - void) * u / dp + 1.75 *
Gv)
Figure
# 1: Graph of molar flow rate against weight of catalyst,
Constants
W.
denC = 1050
At weight
void of catalyst, W = 1675 kg, the molar flow rate of propylene glycol is
= 0.45
approximately
Ac = 1.5
25.89
denF =mol/s
29.4 which is near to the desired production capacity of the plant.
dp = 0.00034
u = 0.0000121
Step=2:198.7056
FTo Reactor bed sizing
FT = 199.0472
m = 3.378
Gv = m / Ac
Po = 4000000
# Weight of catalyst, kg
W(0) = 0
W(f) = 1675
For packed
Table bed reactor,
2: Calculated 3.0for
values ft variables
of quenchfor
zone and 1.0
pressure ft offrom
drop support grid are typical
included.
polymath.
Total height of the reactor, L = Lbed + Lquench +
Lsupport
= 1.93 + (3.0 x 0.3048) + (1.0 x
0.3048)
= 3.15 m
Step 3: Pressure drop in reactor
The pressure drop is correlated by the parameter Y in

Polymath.
# Nomenclature
# F = molar flow rate, mol.s-1
# W = mass of catalyst, kg
# T = temperature, K
# Y = pressure drop correlation,
Pa
368
369
Figure 2: Graph of Y against weight of catalyst,
W.
From Polymath calculation, at weight of catalyst, W= 1657 kg, Y =
0.9954615
P = Y x P0 = 0.9954615 x 40 = 39.82
bar
Pressure drop = 40.00 – 39.82 = 0.18
bar
Step 4: Cooling requirement Design
Cooling system is required for the reactor as the reaction that takes place in the reactor
is
exothermic reaction. Cooling water operating from 25˚C to 50˚C is used as the utility in
reactor shell side.
370
Properties of cooling water at average
temperature
Average temperature = 37.5˚C = 310.5
K
Density, ρ = 990.00 kg/m3
Viscosity, μ = 0.704 cP = 0.000704

kg/m.s
Thermal Conductivity, k = 0.623 W/m.K
Specific heat capacity, Cp = 4170.00 J/kg.K
From energy balance calculation, the cooling duty required is 3218.97

MJ/hr
Temperature of reactor wall, Tw = 200˚C = 473
K
Temperature of surrounding, = 37.5˚C = 310.5 K
For a vessel type reactor, cooling jacket length is typically 80% of reactor bed
length.
Ljacket = 0.80 x 3.15 = 2.52 m
The heat transfer system represent a cross flow system across a tube. The correlation of
heat
transfer across a tube bank is given as such: Nu = C(Re)nPr1/3
For large Nu value, the Re is expected to be large. From Heat Transfer by J. P. Holman,
for
high Re, C =0.0266, n = 0.805
371
Mechanical Design

According to Coulson Richardson’s Chemical Engineering Design (Chapter 13), safety
factor
of 10.0% is applied to the operating pressure of the reactor.
Operating pressure = 40 bar = 4.0
N/mm2
Design pressure, Pd = 1.10 x 4.0 = 4.4
N/mm2
Step 2: Design Temperature

Safety factor of 10˚C above the operating temperature will be applied to the reactor
design.
Design temperature, Td = Operating temperature + 10
˚C
= 200 + 10
= 210 ˚C
The material of construction for the packed bed reactor is stainless steel type 316 as it
has
good corrosion resistance properties. The reactor is operating at high temperature and
pressure. High temperature water will cause corrosion on the packed bed reactor.
Hence,
stainless steel type 316 with good corrosion resistance properties is chosen to be the
material
of construction for the reactor. From table 13.2 in Coulson and Richardson’s Chemical
2
Engineering Design, stainless steel type 316 has design stress, f of 120 N/mm at
temperature
of 200˚C which is higher than the reactor design pressure. Besides, the stainless steel
372
type
316 has good tensile strength which is 520 N/mm 2 which makes it suitable to be used
for the
material of construction for high operating temperature and pressure reactor.
A double welded butt type of welding is used for the reactor in order to balance the
tradeoff
between the higher cost and higher strength of weld joint. The welded joint efficiency, J
of
the double welded butt type of welding is 0.85 which shown in table 13.3 in Coulson and
Richardson’s Chemical Engineering Design.
Step 5: Wall Thickness

The minimum wall thickness is calculated based on Coulson and Richardson’s Chemical
Engineering Design.
Design pressure, Pd = 4.4 N/mm2
Internal diameter, Di = 1.38m = 1380

mm
Design stress, f = 120 N/mm2
Joint efficiency, J = 0.85
Corrosion allowance = 2.00 mm
Wall thickness, t = e + corrosion allowance = 30.46 + 2.00 = 32.46 mm

(Approximately to
33mm)
The Maximum Allowable Working Pressure (MAWP) is expected to be greater than
the
operating pressure to allow it to be used under safety concern.
Tensile strength of stainless steel type 316 = 520
N/mm2
Since the MAWP is greater than the operating pressure of 4.4 N/mm 2, the wall
thickness of
the reactor is acceptable.
Step 6: Reactor Vessel Head design
The type of head for the reactor is hemispherical head due to the high pressure of the
reactor.
According to Coulson and Richardson’s Chemical Engineering Design, the head
thickness for
hemispherical
Head thicknesshead
= 0.6is x0.6
t =times
0.6 xof
33the
mm reactor
= 19.8wall thickness.
mm
373
Corrosion allowance = 2.00 mm
Fabrication thickness of vessel head = 19.8 + 2 = 21.8 mm (Approximately to

22mm)
2
Since the MAWP is greater than the operating pressure of 4.4 N/mm , the thickness
of the
reactor head is acceptable.
Step 7: L/D ratio of reactor
Length of reactor, LR= 3150 mm = 3.15

m
Reactor shell outer diameter, Do = Di + 2 x t = 1380 + 2 x 33 = 1446 mm =
1.446 m
Since L/D ratio in between 2 to 5, the reactor size is

acceptable.
Step 8: Total weight of reactor

The weight of vessel is calculated based on Coulson and Richardson’s Chemical
Engineering
Design.
Let factor account for the weight of nozzle, Cv =
1.15,
Mean diameter of vessel, Dm = Di + t = 1380 + 33 = 1413 mm =
1.413 m
Weight of vessel, Wv = 240 Cv Dm ( HV + 0.8Dm) t
= 240 (1.15)(1.413)[3.15 + 0.8(1.413)]

(0.033)
= 54.29 kN
Weight of catalyst, W = 1675.00 x 9.81 = 16431.75 N = 16.43

kN
Total weight of reactor, WR = 54.29 + 16.43 = 70.72
kN

Stress analysis is conducted based on Coulson and Richardson’s Chemical
Engineering
Design to ensure the reactor structure is strong and safe against stresses.
For wind loading,
Let wind speed, uw = 160 km/hr
Wind pressure, Pw = 0.05 uw2 = 1280 N/m2
Wind loading per unit length of column, Fw = Pw Do = 1280 (1.446) = 1851.92

N/m
374
bending, Iv
Since is compressive, therefore is negative value.
(upwind) = 93.65 – 0.49 + 0.18 = 93.35

N/mm2
(downwind) = 93.65 – 0.49 - 0.18 = 92.98
N/mm2
No torsional shear stress is considered in preliminary
design.
The 3 principal stresses and their differences are calculated under this
condition.
Principal Stress (N/mm2) Upwind Downwind
46.83 46.83
93.35 92.98
2.2 2.2
-46.52 -46.15
44.63 44.63
91.15 90.78
From the calculation the greatest principal stress difference is 91.15

N/mm2
This does not exceed the design stress for the material construction of the reactor
which is
2
120 N/mm . Thus, the design is acceptable.
375
Maximum compressive where the vessel is not under = 0.49 + 0.18 =
pressure =
0.67 N/mm2
As the maximum allowable design stress is smaller than critical buckling stress, the
design is
satisfactory.
Step 10: Vessel Support
Type of support chosen: Conical skirt
Let skirt bottom diameter, Ds = 1.8 m
Let skirt height, Hs = 2.0 m
The skirt base angle is satisfactory as the angle is in between 80˚ and
90˚.
water.
Take skirt thickness, ts as the same as thickness of vessel

(33mm),
The skirt thickness should be such that under the worst combination of wind and dead
weight
loading. 2 design criteria must be satisfied:
376
The skirt material is chosen to be stainless steel 316 with maximum allowable design
stress at
ambient temperature is 175 N/mm2. The Young modulus, E of stainless steel type 316 is
197500 MPa.
fs = 175 N/mm2
J = 0.85
=82.17˚
E = 197500 MPa
ts = 45 mm
Ds = 2500 mm
[Satisfy]
[Satisfy]
Since both design criterial are satisfied, the skirt thickness is

acceptable.
Take pitch circle diameter, Db = 2.0 m
Circumference of bolt circle = 2000 x 3.142 = 6284.00

mm
Minimum bolt spacing is recommended at
600mm
Maximum allowable bolt stress, fb = 125

N/mm2
377
From Coulson & Richardson’s Chemical Engineering Design Figure 13.30, the bolt type
selected is M30 as it is the closest standard size bolt larger than 25.53mm. Its root area
is 561
mm2.
Maximum allowable bearing pressure on concrete foundation pad, fc = 72

N/mm
Using bolt M36 distance from skirt edge to ring edge, Lr =

76mm
Actual base ring width = Lr + ts + 50 = 76 + 33 + 50 = 159
mm
Allowable design stress in the ring material, fr = 140

N/mm2
Glycerol Feed Inlet
Calculated according to the Harker equation (1978), modified for SI unit, for the
optimum
pipe (and nozzle) diameter.
At temperature = 200˚C, pressure = 40
bar
W = Mass flow rate = 10979.72 kg/hr
ρ = 1130.00kg/m3
By referring to ASME B36. 10M and B36.19, the 2-1/2 in. stainless steel Sch. 80 is
used.
(OD = 73mm, wall thickness = 7.01 mm)
Hydrogen Feed Inlet

ρ = 2.05 kg/m
3
Since the feed inlet is a gas stream, the speed of sound is

considered.
378
bar
c = 1650 m/s
Operating 2 times away from speed of sound, nozzle diameter = 2 x 0.43

=0.86 in.
By referring to ASME B36. 10M and B36.19, the 1 in. stainless steel Sch. 80 is used.
(OD =
33.4 mm, wall thickness = 4.55 mm)
Product Outlet
optimum
bar
ρ = 21.40 kg/m3
(OD =
273.1mm, wall thickness = 12.70 mm)
Cooling water inlet
optimum
bar
ρ = 995.00 kg/m3
(OD =
379
Cooling water outlet
optimum
bar
ρ = 984.00 kg/m3
(OD =
Aspen simulation
Result summary for R-101 simulation.
380
Appendix I: Auxiliary Equipment Design
I.1 Pump, P-101
General
Mass flow rate = 10979.72 kg/hr

Density = 1250.00 kg/m3 (Mixture property obtained from
ASPEN)
Inlet pressure = 1.00 bar
Outlet pressure = 40.00 bar
Viscosity = 0.585 kg/s.m (Mixture property obtained from

ASPEN)
Pump design
Step 1: Inlet and outlet nozzle design
381
optimum
ρ = 1250.00kg/m3
used.
(OD = 73mm, wall thickness = 5.16 mm, ID = 62.68 mm )
Step 2: Velocity of Liquid
Step 3: Friction in pipe
The friction factor, f is determined through moody diagram with known Reynold
number, Re
and relative roughness, ε/D.
Using roughness of commercial steel pipe, ε =
0.046mm
382
From the moody diagram, the friction factor is
0.022
Let length of pipe = 10m
Step 4: Total Head

The total head is calculating using the Bernoulli’s
equation.
Step 5: Power required
Power required by the pump
Step 6: Net Pump Suction Head (NPSH)
NPSHA only involves the suction side.
383
From the graph, when the volumetric flow rate 8.78 m3/hr (38.66 GPM), NPSHR = 3.50
m.
NPSHA > NPSHR, no cavitation happened, the pump is
applicable.
Step 7: Actual motor power
The efficiency of the motor is determined in the previous graph. From the graph,
when the
volumetric flow rate 8.78 m3/hr (38.66 GPM) and total head of 319.94 m, the
efficiency is
65%.
Motor power that is chosen is 20 bhp.
ASPEN Simulation Result Summary
Pump
Name P-101
Property method NRTL
Henry's component list ID
Electrolyte chemistry ID
Use true species approach for
electrolytes YES
Free-water phase properties method STEAM-TA
Water solubility method 3
Model Type
Specified discharge pressure [bar]
Specified pressure increase [bar]
40
384
Specified pressure ratio
Specified power required [kW]
Pump efficiencies
Driver efficiencies
Suction area [sqm]
Hydraulic static head [m-kgf/kg]
Number of curves
Operating shaft speed [rpm]
Impeller diameter [meter]
EO Model components
Fluid power [kW]
Calculated brake power [kW]
Electricity [kW]
Volumetric flow rate [l/min] 9.37303472
Calculated discharge pressure [bar] 23.4845978
Calculated pressure change [bar] 23.4845978
Calculated pressure ratio 144.200534
NPSH available [m-kgf/kg] 40
NPSH required 39
Head developed [m-kgf/kg]
Pump efficiency used
Net work required [kW]
Specific speed, operating 8.03537229
Suction sp. speed, operating
Head coefficient
Flow coefficient 313.379646
Total feed stream CO2e flow [kg/hr] 0.399114125
Total product stream CO2e flow [kg/hr] 23.4845978
Net stream CO2e production [kg/hr]
Utility CO2e production [kg/hr]
Total CO2e production [kg/hr]
Utility usage
Utility cost
Utility ID
0
0
0
0
0
I.2 Pump, P-301

General

ASPEN)

ASPEN)
385
Pump design
optimum
ρ = 1079.00kg/m3
used.
number, Re
0.046mm
386
0.032
Step 4: Total Head

equation.
387
m.
applicable.
when the
volumetric flow rate 8.61 m3/hr (37.91GPM) and total head of 1.80 m, the efficiency
is
unable to determine. However, the efficiency of the pump is assumed to be 60%.
Pump
Name P-301
electrolytes YES
Model Type
1.01
388
Pump efficiencies
Driver efficiencies
Suction area [sqm]
Number of curves
EO Model components
Fluid power [kW]
Electricity [kW]
NPSH available [m-kgf/kg] 1.01
NPSH required 0.01
Head coefficient
Utility usage
Utility cost
Utility ID
0
0
0
0
0
I.3 Pump, P-401

General

ASPEN)

ASPEN)
389
Pump design
optimum
ρ = 1037.00kg/m3
used.
number, Re
0.046mm
390
0.032
Step 4: Total Head

equation.
391
m.
applicable.
when the
volumetric flow rate 7.00 m3/hr (30.82GPM) and total head of 1.93 m, the efficiency
is
unable to determine. However, the efficiency of the pump is assumed to be 60%.
Pump
Name P-401
electrolytes YES
Model Type
1.01
392
Pump efficiencies
Driver efficiencies
Suction area [sqm]
Number of curves
EO Model components
Fluid power [kW]
Electricity [kW]
NPSH available [m-kgf/kg] 1.01
NPSH required 0.01
Head coefficient
Utility usage
Utility cost
Utility ID
0
0
0
0
0
I.4 Compressor, C-101

General

ASPEN)
393
Design method
The compressor design is based on the calculation method in Coulson and
Richardson’s
Chemical Engineering Design.
Compressor Design
Step 1: Stages of compressor
The type of compressor used is centrifugal compressor. The typical value of

compression
ratio for centrifugal type of compressor is in between 6 to 8. Let the compression
ratio = 7.
The number of stages require is 2

stages.
Step 2: Power required for the compressor

Referring to Figure 3.6 in Coulson and Richardson’s Chemical Engineering Design,
the
polytropic efficiency can be determined based on the inlet volumetric flow rate.
394
3
From the figure, when the volumetric flow rate is 2.77 m /s, the E p =
72%
Step 3: Actual Power required
The efficiency of motor is based on table 3.1 in in Coulson and Richardson’s

Chemical
Engineering Design.
395
Since the power is >4000 kW, efficiency is
97%
Step 4: Number of compressor
In industrial, the common compressor power is 5000kW at maximum. Hence the

parallel
arrangement of compressor is required to compensate the power required.
3 units of compressors that arranged in parallel are

needed.
Compr
Name C-101
electrolytes YES
ASME-
POLYTROP
Model Type 40
Isentropic efficiency
Mechanical efficiency
Polytropic efficiency
EO Model components
Indicated horsepower [kW]
Calculated brake horsepower [kW]
Power loss [kW] 3165.96146
Efficiency (polytropic / isentropic) used 3165.96146
Calculated pressure change [bar] 0
Outlet temperature [C] 40
Isentropic outlet temperature [C] 39
Vapor fraction 40
995.141335
590.968286
1
396
Displacement
Volumetric efficiency
1048157.67
Isentropic power requirement [kW]
1810.19935
Inlet heat capacity ratio
1.40629496
Inlet volumetric flow rate [l/min]
166365.103
Outlet volumetric flow rate [l/min]
17400.5788
Inlet compressibility factor
1
Outlet compressibility factor
1
Compressor percent above surge
Percent below stonewall
Surge volume flow rate
Stonewall volume flow rate
Shaft speed
Specific speed
Inlet Mach number
Total feed stream CO2e flow [kg/hr]
Total product stream CO2e flow [kg/hr]
Total CO2e production [kg/hr] 0
Utility usage 0
Utility cost 0
Utility ID 0
0
I.5 Flash Drum, V-101
Step 1: Determine the liquid and vapour density of component
Component involved in flash drum,
Hydrogen Top (Vapour)
Propylene Glycol Bottom (Liquid)
Ethylene Glycol Bottom (Liquid)
Acetol Bottom (Liquid)
Methanol Bottom (Liquid)
397
Water Bottom (Liquid)
Glycerol Bottom (Liquid)
Calculate a liquid density of each component by using liquid density equation and
constant
for each component at desired
temperature:
………………………………………………. (Equation of liquid
density)
, T (K)
Top Bottom
383.29 289.88
656.29 562.88
Component A B n Tc T.range
723 291.33-723
Glycerol 0.3491 0.249 0.1541
Ethylene
Glycol 0.325 0.255 0.172 645 260.15-645
Water 0.3471 0.274 0.28571 647.13 273.16-647.13
Density of liquid calculated at bottom:
Bottom ρL(g/mL) ρL(kg/m3) mole ρL(kg/m3) * mole fraction

fraction
Glycerol 1.050958181 1050.958181 0.10 107.1224592
Ethylene glycol 0.847631752 847.6317523 0.01 10.65727636
Water 0.715273221 715.2732208 0.44 312.1901598
Density of Liquid for propylene glycol (Bottom) are calculated by using the formula
below
(Perry Handbook);
398
c1 c2 c3 c4
Propylene glycol 1.0923 0.26106 626 0.20459
ρL(kg/m3) of propylene glycol = 317.6524
Density of Liquid for methanol, acetol and hydrogen are calculated from
ASPEN;
Component (BOTTOM) Density (kg/m3) Mole frac ρL(kg/m3)TOTAL
Acetol 739.258 0.014.194562111
Methanol 275.643 0.013.465660198 7.660222309
Component (DISTILLATE) Density (kg/m3) Mole frac ρL(kg/m3)TOTAL

Hydrogen 1.46268 1.001.46268 1.46268
Use ideal gas law to calculate the vapour density of each

component:
PV = nRT…………………………………………………………………………………. (1)
= = ……………………………………………….. (2)
…………………………………………………………………….. (3)
Propylene Ethylene
Component Glycerol Hydrogen Glycol Glycol Methanol Acetol Water
MW 92.1 1 76.09 62.07 32.04 74.08 18.02
P 40 40 40 40 40 40 40
Distillate T 656.29
Bottom T
Vapor density 562.88 562.88 562.88 562.88 562.88 562.88
(distillate)
Vapor density 0.73309
(bottom)
8.02394716 28.01723752 0.667043393 0.344322061 0.35927327 6.72257044
Total of liquid density and vapour density at top and

bottom:
ρavg(kg/m3)
Top Bottom
1.46268 755.282502 378.3725908
ρL(kg/m3)
0.733089996 44.1343938 22.43374192
ρv (kg/m3)
Outlet liquid mass density = 755.2825015

kg/m3
399
Vapor Fraction = 1.00
Step 2: Determine the settling velocity (terminal velocity)
Average vapor MW = ……………. (Value from mass balance)
Average vapor MW = 2.0158 kg/mol
Liquid droplet settling velocity, ut:
ut = 0.07 [(ρL – ρv) / ρv)]½..…………………………………….............(Equation to find ut)
ut = 2.2458 m/s
Actual liquid droplet settling velocity, us:
us = 2.2458 m/s
Step 3: Determine the unit sizing of the flash drum
Figure shows dimension of flash drum
Orientation = vertical
Dimension type = cylinder
400
Vapor volumetric flow rate, Vv =
Vv = 1375.356623 m3/hr = 0.382043506

m3/s
Liquid volumetric flow rate, VL =
VL = 14.7933 m3/hr = 0.004109

m3/s
Minimum diameter of vessel, Dv (min) = ………… (Equation to calculate
Dv)
Dv = 0.4654 m = 4.4263 ft
Diameter of vessel, Dv or Di = 0.152
Diameter of vessel for calculation in SI unit, Dv or Di = 0.7

m
Demister pad's bottom to top head joint height = 0.4 m…………………….. (0.4m
minimum)
Inlet to demister pad height, vapor height, hv = similar to diameter of the vessel =
0.7 m
Liquid level to inlet height, flooding height, hf …........... (0.6m minimum or 1/2
Dv)
hf = ½ *(0.7) = 0.35 m
Holdup time = 300 s…………………………… (Typical: 5-10 min (Coulson Richardson
462))
Liquid volume holdup inside the vessel = (Liquid volumetric flow rate, VL x holdup
time)
Liquid volume holdup inside the vessel = 1.2328
m3
Liquid depth required, hL = = 3.2033 m
Liquid depth, hL = Liquid depth required + Extra space for level

controller
Extra space for level controller = 0.3
m
Liquid depth, hL = 3.2033 m
Total height =
401
Step 4: Determine the dimension of demister pad
Type of demister pad used in designing flash drum is Knitted mesh. Material used is
stainless
steel 304.
Standard thickness of demister pad for a flash drum = 100 mm =

0.1 m
Cross sectional area = = 0.3848451 m2
Step 5: Calculate the vessel mechanical design
Material of construction used for the flash vessel is stainless steel

304.
Pressure (bar) Temperature (C)

40 336
Operating Condition
Design temperature, Ti = 346.00 C……………………… (Plus 10 degree C from operating

T)
Design pressure, Pi = 44 bar = 4400000 Pa = 4.4 N/mm2………………… (1.1 x operating

P)
Design stress, f is calculated by interpolation of Table 13.2 (page 812), Coulson
Richardson
f = 100.4 N/mm2 = 100400000 Pa =1004
bar
Table shows typical design stresses for
plate
Welded joint efficiency, J = 0.85 obtained by;
Table 13.3 (page 813), Coulson Richardson Double welded butt, spot
radiography
402
Actual design stress, Jf = Welded joint efficiency, J + Design
stress, f
Jf = 0.85 × 1004 = 853.4 bar
Corrosion allowance = 2 mm = 0.002

m
Minimum wall thickness, e = 0.01568 m = 15.6823

mm
Wall thickness with corrosion allowance, t = Minimum wall thickness, e +
corrosion
allowance
Wall thickness with corrosion allowance, t = 17.6823 mm =
0.01768 m
Wall thickness with corrosion allowance (practical), t is obtained in Coulson Richardson
page
814;
Wall thickness with corrosion allowance (practical), t = 7 mm =
0.007 m
Vessel's mean diameter, Dm = Wall thickness with corrosion allowance (practical), t
+ Dv
Vessel's mean diameter, Dm = 0.707
m
Vessel's outer diameter, Do = Dv + 2(Wall thickness with corrosion allowance
(practical),t)
Vessel's outer diameter, Do = 0.714
m
Head type is torispherical
(conventional)
Min head thickness without corrosion allowance = 0.6 x Wall thickness with
corrosion
allowance (practical), t = 4.2 mm= 0.0042 m
Min head thickness with corrosion allowance = Min head thickness without
corrosion
allowance + Corrosion allowance :
Min head thickness with corrosion allowance = 4.2 + 2 = 6.2 mm =
0.0062 m
Approximate dead weight of vessel, Wv = 6694.7052 N = 6.6947

kN
Dynamic wind pressure, Pw calculated based on preliminary design, wind speed of
160km/h
Uw = 160 km/h
Wind loading per unit length, Fw is calculated based on this

equation:
403
Wind loading per unit length, Fw = 913.92
N/m
Bending moment, Mx is calculated by using this
equation:
Bending moment, Mx = 9894.6483 Nm
Step 6: Calculate the support design
Support type used is conical skirt (for vertical

column)
Support inside diameter at base, Ds = 0.75 (must bigger then
Dv)
Support height,Dh (Assume equal to Ds) =0.75
m
Θs = 1.5375 rad = 88.09° (*Satisfactory - between 80°-

90°)
Skirt thickness, ts = 0.007 mm = 7
m
Skirt thickness with corrosion allowance =7 m +2 m =9
m
Base angle at support, theta s =
88.0908°
Bending stress, sigma bs, Dead weight stress in support (test), sigma ws and Dead
weight
stress in support (operating), sigma ws is calculated by using this equation:
Bending stress, sigma bs, =

4274165.611N/m2
Dead weight stress in support (test), sigma ws = 1.4574
N/mm
Dead weight stress in support (operating), sigma ws = 0.4021
N/mm
Base ring type = Plain flange rings
Approximate bolt circle diameter, Db = 0.95

m
Minimum bolt required at minimum spacing = 4.974 (Minimum bolt pitch is 0.6
m)
Number of bolts, Nb =13 bolts
404
Bolt design stress, fb = 125 N/mm2 (Typical design
value)
Standard bolt used = M24
Root area = 353 mm2 (British standard BS 4190, Figure 13.30 Coulson
Richardson)
Per bolt diameter = 24 mm
Ring width from skirt, Lr = 76 mm
Compressive load on base ring, Fb:
Compressive load on base ring, Fb = 33039.7259 N/m = 33.0397

N/mm
Actual width of base ring = Ring width from skirt, Lr + Skirt thickness with
corrosion
allowance = 76 m +9 m = 85 m
Actual base ring thickness = 7 mm
Step 7: Calculate the nozzle design
Feed
Standard nominal pipe size = 9 in
Nozzle outer diameter = 9.69634 in =0.24629 m (based on table ASME

B36)
405
Schedule no = 40s
Max nozzle velocity, umax = 467.4464 ft/s = 142.4776

m/s
Min nozzle velocity, umin = 280.4678 ft/s = 85.4865
m/s
Bottom (liquid)
Standard nominal pipe size = 3 in
Nozzle outer diameter = 3.50266 in = 0.08897

m
Optimum inner nozzle diameter, Di,opt = 0.07249 m =

2.8538 in
Schedule no = 40s
Top (Vapour)
Number of nozzle needed = 1
Standard nominal pipe size =10 in
Nozzle outer diameter = 10.76014 in = 0.273307556

m
Schedule no = 40s
Step 8: Calculate the stress analysis
Horizontal Pressure Stress,
Longitudinal Pressure Stress,
Dead weight stress,
Second moment of area,
Bending stress,
Radial stress,
Resultant longitudinal stress

(upwind),
406
Resultant longitudinal stress
(downwind),
Upwind Downwind
220 220
σ1=σh
σ2=σz 111.0052923 103.7335273
σ3=0.5P 2.2 2.2
σ1-σ2 108.9947077 116.2664727
σ1-σ3 217.8 217.8000000
σ2-σ3 108.8052923 101.5335273
Difference in Principle Stresses = σh
Critical buckling stress,
Maximum compressive stress

=
I.6 Expander, D-101

General

ASPEN)
Design method
The expander design is based on Coulson and Richardson’s Chemical Engineering
Design.
407
Expander Design
Step 1: Stages of expander
The type of expander used is centrifugal expander. The typical value of expansion
ratio for
centrifugal type of expander is in between 6 to 8. Let the expansion ratio = 7.
The number of stages require is 2

stages.
Step 2: Power required for the expander

Referring to Figure 3.6 in Coulson and Richardson’s Chemical Engineering Design,
the
polytropic efficiency can be determined based on the inlet volumetric flow rate.
From the figure, when the volumetric flow rate is 0.0029 m3/s, the Ep =
61%
408
Step 3: Actual Power generated
The efficiency of motor is based on table 3.1 in in Coulson and Richardson’s

Chemical
Engineering Design.
Since the power is >15 kW, efficiency is 90%
I.7 Reflux Drum, V-202

Step 1 : Volumetric Flow Rate
409
Step 2 : Reflux Drum Volume
By referring to heuristics, the volume of liquid retained in the reflux drum is 50% of
the
reflux drum’s total volume.
Step 3 : Reflux Drum Length and Diameter
Volume of cylinder,
From general guide for length to diameter ratio in page 463 of Coulson and Richardson’s
Chemical Engineering Design,
For P = 1.00 bar
D=
410
L
the
Volume of cylinder,
411
For P = 1.00 bar
D=

Step 1: Volumetric Flow Rate
412
the
Volume of cylinder,
For P = 1.00 bar
D=
413
Appendix J: Minutes of Meeting
Minutes of meeting 1
Date: 20th September 2018 Time: 9.00 pm – 10.30 pm
Venue: Lembaran Cafeteria
Attendance:
1. Joan Mary A/P Patrick George
2. Low Ying Kai
3. Nur Amni binti Md Anuar
4. Nurul Afini binti Fuad
5. Sherrine A/P Aruldass
Activities:
1. Task segregation.
 Gantt chart – Amni
 Introduction, Importance – Afini
 Supply and demand – Joan
 Transmittal letter – Sherrine
 Review journal – Jeremy
2. The task needs to be complete before

23/9/2018.
414
Attendance:
2. Low Ying Kai
Activities:
1. Distribute journal to all group members. All members need to review

different
alternative based on different
journal.
 Description of process 1 – Jeremy
 Description of process 2 – Afini, Amni
 Description of process 3 – Joan, Sherrine
2. Find the MSDS for all chemicals involved.
3. In the meeting, we had drafted the comparison table of all three processes
that
we decide to choose. However, the description is not detailed enough. We
decide to edit the comparison table in google drive if any of us found
anything
suitable that should be added in the
table.
4. Decide one process to choose for production of propylene
glycol.
5. We decide to compile this task on 26/9/2018.
415
Attendance:
2. Low Ying Kai
Activities:
1. We discuss briefly about capacity of plant, current problem related to plant,

advantage and disadvantage of chosen process, and environmental
concern.
2. Through the discussion, we distribute the task o each of
us.
 Capacity of plant – Jeremy
 Current problem related to plant – Amni
 Advantage and disadvantage – Afini
 Choice of process – Joan
 Environmental, Safety and Health Concern –

Sherrine
3. After distributing the task, we update the comparison table with new
information and details.
4. We found that the choice of process needs to be edited as comparison table

is
updated.
5. The capacity of plant needs to include world demand, consumption and any
information related to Malaysia.
6. Find the chemical and kinetic reaction involves in the production of

propylene
glycol from glycerol.
416
Attendance:
2. Low Ying Kai
Activities:
1. We do the MSDS together during the meeting.
 Acetol and Hydrogen – Joan
 Ethylene glycol and Water – Afini
 Propylene glycol – Amni
 Glycerol and Methnol – Sherrine
2. During the meeting, we able to complete MSDS for all chemicals involved in
the process.
3. Discuss about task 4 which is input and output

structure.
4. Find the price for the raw material, by-product and product
involved.
Date: 3rd October 2018 Time: 9.00 pm – 11.00 pm
Attendance:
417
2. Low Ying Kai
Activities:
1. Discuss what equipment to use along the process from raw material until the
desired product.
2. Design the process flow and draw the block flow diagram
(BFD).
3. Find information on operating condition to be use in the
process.
4. Draw the process flow diagram (PFD) using Microsoft Visio.
5. We discuss and create the innovation part in the

PFD.
Date: 20th October 2018 Time: 9.00 am – 11.30 am
Attendance:
7. Low Ying Kai
418
Activities:
3. Task segregation for justification of chosen

equipment.
 Flash drum and condenser– Amni
 Reflux drum and pump– Afini
 Mixer and process description – Joan
 Heat Exchanger, reboiler & expander –

Sherrine
 Packed bed reactor and distillation column–
Jeremy
4. The task needs to be complete before
25/10/2018.
5. Discuss on method to select the material construction of equipment in
plant.
6. Discuss on the PFD of task 1.
Date: 25th October 2018 Time: 9.00 pm – 11.00 pm
Attendance:
6. Low Ying Kai
419
Activities:
6. Discussion on our latest PFD after evaluation.
7. Improve the modification in PFD and updated it.
8. Started on mass balance.
9. Define the economic potential.
10. Justification of each process

selected.
11. Discuss and completed the separation operations used in the
process.
Date: 2nd November 2018 Time: 2.00 pm – 5.00 pm
Attendance:
7. Low Ying Kai
Activities:
7. Prepared table for each of study node by referring to our

PFD.
8. Find information regarding mass flow of all streams into and out of the
unit.
9. Find chemical data on energy balance.
10. Calculated vapor pressure, dew point and bubble point by using Antione
Equation.
420
Date: 10th November 2018 Time: 6.30 pm – 11.30 pm
Attendance:
7. Low Ying Kai
Activities:
5. Done Aspen Calculation.
6. Prepared comparison table of Aspen and Excel.
7. List down all the heating and cooling utilities
8. Discussed on the amount of solid, liquid and gaseous waste

generated.
Attendance:
7. Low Ying Kai
421
Activities:
6. Finalized, Editing and Compiling of the Report.
7. Compilation of Mass Balance and Energy Balance.
8. Updated on PFD and utilities.
Attendance:
12. Low Ying Kai
Activities:
7. Task segregation.
a. Mass Transfer Equipment Design – Joan and Sherrine
b. Heat Transfer Equipment Design – Amni and Afini
c. Reactor Design - Jeremy
Date: 2nd December 2018 Time: 8.00 pm – 11.00 pm
Attendance:
422
10. Low Ying Kai
Activities:
12. Discuss any problems faced for equipment

design
13. Discuss group progress
14. Distribution of task for Auxiliary Equipment Design – Joan and

Jeremy
Date: 12th December 2018 Time: 8.00 pm – 11.00 pm
Attendance:
12. Low Ying Kai
Activities:
11. Discuss any problem faced
12. Discuss group progress
Date: 14th December 2018 Time: 8.30 pm – 11.30 pm
423
425
Attendance:
12. Low Ying Kai
Activities:
9. Task compilation
10. Checking of final report
424

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Table of Contents

1.1.2.3 Heat Transfer Fluids

1.1.2.4 Pharmaceutical Uses

Propylene glycol are used as an excipient, a non-active enabling agent in

Propylene glycol is a chemical that often used in food industries. Propylene

Figure 2 illustrates the world consumption of propylene glycol in 2016. Based on

Figure 2: World consumption of propylene glycol in 2016. [7]

Figure 3 illustrates the global propylene glycol market in 2017, by end-use

Figure 3: Global Propylene Glycol Market in 2017, by End-Use Industry. [9]

Figure 4: Global Propylene Glycol Market, By Application, 2014-2024. [10]

(NUR AMNI BINTI MD ANUAR)

Moreover, we characterized the capacity of plant and stated the estimated

Table 1: Gantt Chart

Alternative 1: Production of propylene glycol from glycerol in Escherichia

The alternative processes were discussed in terms of green chemistry and

2.1.1 Production of propylene glycol from glycerol in Escherichia coli.

Fermentation is an anaerobic metabolic process that occurs in microorganism.

Figure 7: The basic flow of fermentation of glycerol.

Figure 8: Hydrogenolysis of glycerol to propylene glycol. [19]

Hydrogenolysis of propylene glycol from glycerol involve two reaction steps.

For this alternative, the optimum temperature is at 200 ℃ because at this

Preparing and characterizing supported ruthenium

In a typical separation to recover propylene glycol, the bottom liquid stream is

Table 2: Comparison table between 3 process alternatives

Hydrogenation of biomass derived lactic

Reactor  Batch[17]  Continuous  Continuous

3.0 Critical Assessment of the Process Chosen

3.1.1 Plant Capacity

Figure 13: Propylene glycol: world capacity broken down by region,

Since production of propylene glycol plant is yet to be found in Malaysia, the

Figure 14: Location of the designed plant

A mixture of unreacted glycerol, hydrogen gas, methanol, ethylene glycol,

IV. Purification of propylene glycol

3.2.1 Process Chemistry

II. Hydrogenation of acetol to propylene glycol

CH2OH-CHOH-CH2OH (l) → CH2OH-CO-CH3 (l) + H2O (l)

II. Hydrogenation of acetol to propylene glycol

Rate of reaction for the main

-rC3H8O2 = k C3H8O2C C3H6O2CH2 CC3H8O3 = Concentration of Glycerol

C C3H6O2 = Concentration of Acetol

CH2 = Concentration of Hydrogen

3.2.3 Reaction kinetics

The cG is the molar concentration of glycerol while cA is the molar concentration of

 There are no greenhouse gases released from the process chosen.

Figure 15: Global Propylene Glycol Market Forecast (2018-2018)

4.0 Process Synthesis Structure and Analysis

4.1.1 Input-Output Structure with Feed and Specifications

Input Operation Output

Components Phase Specification

Estimated Annual Cost of Raw= USD 84662576.69/year + USD

Estimated Annual Gross Profit= USD 95885109.05/year – USD

Gross Profit Margin

4.2 Destination of Codes and Component Classification, Utilities

Component Classification Destination Destination Code

The utilities required in the propylene glycol plant

5.0 Process Flow Diagram (PFD)

5.1 Block Diagram

Figure 16: Block Diagram for Production of Propylene Glycol

5.3 Innovation approach of Process Design