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    Process Design and Economics Assignment Development of PFD and Process Concept Diagram

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    shailaja chowdhury
    The document discusses the production of acetaldehyde from ethanol. Ethanol undergoes dehydrogenation reactions in a packed bed reactor using a copper-based catalyst to produce acetaldehyde, ethyl acetate, butanol, and acetic acid. The stream is separated in a flash vessel and distillation columns. Three alternatives are proposed: 1) Using hydrogen as fuel in the process heater to improve efficiency. 2) Adding an additional distillation column to obtain higher purity acetaldehyde. 3) Changing the catalyst to silver pellets to increase single-pass conversion from 60% to 75-80%.

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    Process Design and Economics Assignment Development of PFD and Process Concept Diagram

    Uploaded by

    shailaja chowdhury
    454 views9 pages
    The document discusses the production of acetaldehyde from ethanol. Ethanol undergoes dehydrogenation reactions in a packed bed reactor using a copper-based catalyst to produce acetaldehyde, ethyl acetate, butanol, and acetic acid. The stream is separated in a flash vessel and distillation columns. Three alternatives are proposed: 1) Using hydrogen as fuel in the process heater to improve efficiency. 2) Adding an additional distillation column to obtain higher purity acetaldehyde. 3) Changing the catalyst to silver pellets to increase single-pass conversion from 60% to 75-80%.

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    The document discusses the production of acetaldehyde from ethanol. Ethanol undergoes dehydrogenation reactions in a packed bed reactor using a copper-based catalyst to produce acetaldehyde, ethyl acetate, butanol, and acetic acid. The stream is separated in a flash vessel and distillation columns. Three alternatives are proposed: 1) Using hydrogen as fuel in the process heater to improve efficiency. 2) Adding an additional distillation column to obtain higher purity acetaldehyde. 3) Changing the catalyst to silver pellets to increase single-pass conversion from 60% to 75-80%.

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    © All Rights Reserved
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    Download as pdf or txt
    454 views9 pages

    Process Design and Economics Assignment Development of PFD and Process Concept Diagram

    Uploaded by

    shailaja chowdhury
    The document discusses the production of acetaldehyde from ethanol. Ethanol undergoes dehydrogenation reactions in a packed bed reactor using a copper-based catalyst to produce acetaldehyde, ethyl acetate, butanol, and acetic acid. The stream is separated in a flash vessel and distillation columns. Three alternatives are proposed: 1) Using hydrogen as fuel in the process heater to improve efficiency. 2) Adding an additional distillation column to obtain higher purity acetaldehyde. 3) Changing the catalyst to silver pellets to increase single-pass conversion from 60% to 75-80%.

    Copyright:

    © All Rights Reserved
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    of 9

    PROCESS DESIGN AND ECONOMICS

    ASSIGNMENT
    Development of PFD and Process Concept Diagram

    Name: Shailaja Ujjal Chowdhury


    Enrollment Number: BT18CME076

    Question:

    Acetaldehyde is a colorless liquid with a pungent, fruity odor. It is primarily used as a


    chemical intermediate, principally for the production of acetic acid, pyridine and pyridine
    bases, peracetic acid, pentaerythritol, butylene glycol, and chloral. Acetaldehyde is a volatile
    and flammable liquid that is miscible in water, alcohol, ether, benzene, gasoline, and other
    common organic solvents. In this problem, the synthesis of acetaldehyde via the
    dehydrogenation of ethanol is to be considered. The following reactions occur during the
    dehydrogenation of ethanol:
    CH3CH2OH CH3CHO + H2 (1)
    2CH3CH2OH CH3COOC2H5 + 2H2 (2)
    2CH3CH2OH CH3(CH2)3OH + H2O (3)
    CH3CH2OH + H2O CH3COOH + 2H2 (4)
    The single-pass conversion of ethanol is typically 60%. The yields for each reaction are
    approximately:

     Acetaldehyde 92%
     Ethyl acetate 4%
     Butanol 2%
     Acetic acid 2%
    Part 1:
    Draw concept diagram and PFD
    Part 2:
    Suggest two alternatives for PFD based on recycle/ separation with proper justification
    Solution:

    Acetaldehyde
    CH3CH2OH CH3CHO + H2
    Ethanol Ethyl acetate
    2CH3CH2OH CH3COOC2H5 + 2H2
    Butanol
    Water
    2CH3CH2OH CH3(CH2)3OH + H2O
    Acetic acid
    CH3CH2OH + H2O CH3COOH + 2H2

    Figure 1: Process Concept Diagram for the Process of Production of Acetaldehyde from
    Ethanol

    Figure 2: Block Flow Diagram


    Process Description:
    Ethanol along with water is heated to 626 °F and pressurized to 100 psi, then fed into an
    isothermal, catalytic packed bed reactor in which dehydrogenation of ethanol takes place. A
    copper-based catalyst is used for this process. The resultant two-phase stream is separated
    in a flash vessel. The vapor stream is contacted with water which absorbs the acetaldehyde
    and ethanol from the vapor stream. The vapor resulting from the distillation column can be
    used to further extract valuable compound like hydrogen. The liquid from the distillation
    column is further sent for purification. Crude acetaldehyde can be obtained by further
    distillation. The bottom is sent to subsequent distillation column, here ethanol is separated
    from butanol, ethyl acetate, and most of water. The distillate consists of ethanol solution
    which is recycled back.

    Equipment Summary:

     E-101: Reactor Preheater


     E-102: Heat Exchanger
     E-103: Heat Exchanger
     E-104: Condenser
     E-105: Reboiler
     E-106: Condenser
     E-107: Reboiler
     E-108: Condenser
     E-109: Reboiler
     H-101: Fired Heater
     P-101: Feed Pump
     P-102: Dowtherm A Pump
     P-103: Reflux Pump
     P-104: Reflux Pump
     P-105: Reflux Pump
     R-101: Reactor
     T-101: Absorber
     T-102: Distillation Column
     V-101: Flash Vessel
     V-102: Reflux Vessel
     V-103: Reflux Vessel
     V-104: Reflux Vessel

    The next page contains the stream tables.


    Stream 1 2 3 4 5
    Temp. (F) 107.6 166 626 626 157
    Press. (psia) 14.7 14.7 96.2 96.2 95.1
    Vapor Fraction 0 0 1 1 0.4
    Total Flow (lbmol/h) 1037.9 1498.7 1498.7 2076 2076
    Component Flows
    (lbmole/h)
    Acetaldehyde NA 2.4 2.4 546.6 546.6
    Acetic Acid NA NA NA 11.8 11.8
    Butanol NA 2.3 2.3 15.8 15.8
    Water 336.8 464.6 464.6 466.3 466.3
    Ethanol 701.1 1028.9 1028.9 403.3 403.3
    Ethyl Acetate NA 0.4 0.4 21.7 21.7
    Hydrogen NA NA NA 610.4 610.4

    Stream 6 7 8 9 10
    Temp. (F) 107.3 107.3 209 152.2 173.8
    Press. (psia) 94.3 94.3 94.3 94.3 94.3
    Vapor Fraction 0 1 0 1 0
    Total Flow (lbmol/h) 1392.4 683.6 1392.4 638.1 5037.7
    Component Flows
    (lbmole/h)
    Acetaldehyde 483.2 63.4 483.2 62.5 545.7
    Acetic Acid 11.7 NA 11.7 NA 11.8
    Butanol 15.8 NA 15.8 NA 15.8
    Water 460.6 5.7 460.6 3578.9 4039.5
    Ethanol 400.1 3.2 400.1 3.2 403.3
    Ethyl Acetate 20.8 0.9 20.8 0.7 21.5
    Hydrogen NA 610.4 NA 0.2 NA

    Stream 11 12 13 14 15 16 17
    Temp. (F) 190.1 152.6 293.4 297.4 267.2 274.9 315.1
    Press. (psia) 94.3 94.3 94.3 94.3 94.3 94.3 94.3
    Vapor Fraction 0 0 0 0 0 0 0
    Total Flow (lbmol/h) 5037.7 3600.1 4435.1 4380.7 4435.1 460.7 3920
    Component Flows
    (lbmole/h)
    Acetaldehyde 545.7 NA 2.4 2.4 2.4 2.4 NA
    Acetic Acid 11.8 NA 11.7 11.7 11.7 NA 11.7
    Butanol 15.8 NA 15.8 15.8 15.8 2.4 13.4
    Water 4039.5 3600.1 3985 3973.7 3985 127.9 3845.8
    Ethanol 403.3 NA 400.9 376.8 400.9 327.8 49
    Ethyl Acetate 21.5 NA 19.4 0.4 19.4 0.4 NA
    Hydrogen NA NA NA NA NA NA NA
    Figure 3: Process Flow Diagram
    Alternative 1:

    As we can see from the process flow diagram that, the components in the reactors are being
    heated using a fire heater. Usually fuels such as Corex gas are used, however a huge amount
    of carbon dioxide is produced during this process. Hydrogen being a very efficient fuel can
    be used instead of carbon-based fuels. Along with it, the purification and transportation of
    hydrogen gas would have added to the capital costs. However, if we use it as a fuel for the
    heater, then it can be used efficiently. Hence the stream is redirected towards the heater.
    Depending upon the amount of hydrogen being produced, we can either store it in a vessel
    and regulate the flow using a valve or directly use it.
    Alternative 2:

    In the above process flow diagram, only one distillation column is used. Due to this, the
    acetaldehyde is not separated properly from the other compounds. Hence, the
    acetaldehyde obtained is not pure and can be used in processes where high purity is not
    required. To obtain high purity acetaldehyde (99.9%), we can add one more distillation
    column. It is shown in the following edited version of the process flow diagram.
    Alternative 3:

    The dehydrogenation of ethanol in the above process is done over Cu-catalyst which is
    either activated with Zn Co, or Cr. The single pass conversion or the above process is 60%. If
    we change the catalyst of the reaction to silver pellets and use a multitubular reactor, the
    catalytic reaction converts 75-80% of ethanol in a single pass. This would help us minimize
    the separation requirements, and affect both capital and operational cost.
    References:

     Acetaldehyde | Laboratory Preparation, Manufacture, Properties and Uses | »


    (genuinechemistry.com)
     Boosting the Single-Pass Conversion for Renewable Chemical Electrosynthesis -
    ScienceDirect
     Production of Acetaldehyde from Ethanol - Chempedia - LookChem
     Acetaldehyde production from ethanol - YouTube

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