Green Tutorial 2

Production of Para Xylene
BFD of PARA-XYLENE PRODUCTION

Environmental Performance - Recycle of Effluent and
Waste
 In vessel-2, the wastewater stream of WASTE-2 contains of toluene, water and para-xylene.
 Therefore, WASTE-2 can be stored in a storage tank and sold to other companies.
 The main chemical use of toluene is to make benzene and xylenes using a number of
technologies. E.g.:
1. Hydro-dealkylation (HAD) process: Toluene and hydrogen are reacted to produce benzene.
2. Toluene disproportionation (TDP/ STDP) plant: Convert toluene to benzene and xylenes.
3. Trans-alkylation (TA) process: Convert toluene and C9 aromatics to xylenes.
Economic Performance – Secondary Grade Toluene
 Demand of secondary grade toluene:
 CMAI (2008) points out that West Europe is the largest user of toluene which 30% is
using in HAD plants; 30% is using in STDP and TDP plants; and the remaining demand
including solvent and gasoline blending is about 25%.
 In 2007, out of 58% of toluene (1.38m tonnes) were converted to benzene and
xylenes.
 In Asia, solvent were the largest end use followed by toluene trans-alkylation process,
STDP, HAD and TDI plants.
 Since WASTE-2 effluent stream can be sold to these chemical plants, extra profit can
be made.
Economic Performance – Secondary Grade Toluene
Price of toluene in 2018: $80/tonne – 673/tonne

Raw profit per annum: 553,466 kg/annum of toluene; $44,000/
annuum
CARBON DIOXIDE
CATEGORIES:
 Environmental Performance
 Economic Performance
CARBON CAPTURE & STORAGE
TECHNOLOGY
POST COMBUSTION CAPTURE
 Carbon dioxide from a gas stream is weakly absorbed by the solvent under
conditions of high pressure and released when the pressure is reduced to
allow solvent regeneration.
 Physical Solvent: Cold methanol (Rectisol)
 Physical solvent scrubbing is best applied to pressurised gas streams
containing high concentrations of carbon dioxide
 The absorbed CO2 is liberated from the solvent and is compressed for
transportation and storage.
 Carbon dioxide is stored in cylinders as a compressed liquefied gas and any
increase in temperature will cause an increase in pressure.
THE USE OF CARBON DIOXIDE
 Kelington was founded in 2000 to provide Ultra High Purity (UHP) gas delivery
solutions to the electronics and semiconductor industry.
 Kelington Group Bhd will be purchasing over 50,000 tonnes of carbon dioxide
waste gas per year.
 Projected 30% to 40% gross profit margin from the segment.
 This is significantly higher than the group’s overall gross profit margin of 10%
to 15%, currently.
 The carbon dioxide waste gas will then be purified to produce liquid gas to be
sold to the end users
THE USE OF CARBON DIOXIDE
 Carbon dioxide gas is commonly used across a wide variety of industries, with
the food and beverages sector being the largest consumer in Malaysia.
 The carbon dioxide in carbonated drinks is the same carbon dioxide that is
spewed from tailpipes and power plants.
 Valser, one of the many brands bottled by Coca-Cola in Switzerland, has
started carbonating its sparkling mineral water using captured carbon dioxide.
 Switzerland is capturing CO2 to sell to a neighboring greenhouse which uses
the product to make its vegetables grow faster.
COST OF CARBON DIOXIDE
 The forecasts of carbon dioxide price in 2020 is expected to be at $25 per

ton, and increases to approximately $53 in 2030 and $120 in 2050,
representing a $52 per ton levelized price over the period 2020‐2050.
 Amount of carbon dioxide produced: 83 000 kg/annum
 252 kg/day
 Raw profit per annum: $ 13 104
 $ 4 324 320
Catalyst Modification
• Conventional Toluene Alkylation Method uses Modernite
(Zeolite Mineral) as catalyst which operating temperature
of 600 to 800 degree Celsius
• In our manufacturing process, Boron Modified Zeolite
Socony Mobil-5 (B-ZSM-5) is used. Reducing the operating
temperature to 440 degree Celsius (University of
Pennysylvania, 2009)
 Effectiveness of catalyst can be increased by surface passivation and pore size

control (Advances in Nanoporous Materials, 2010)
i)Pore size control by silanization with TEOS (Tetraethyl orthosilicate)

-selectivity increases to above 85% and increases conversion to 28% (previous
conversion = 6.25%)
-Pore size from 1um-2um decrease to 0.2-0.4um
 Effectiveness of catalyst can be increased by surface

passivation and pore size control (Advances in Nanoporous
Materials, 2010)
ii) Surface Passivation with metal (boron, magnesium,
platinum and etc)- to reduce the operating temperature.
(Ahmed et all,Metal
Journal
Type of
andChinese
Amount Chemical
OperatingSociety, 2014)
Temperature
ZSM-5 with 0.2% platinum 437 degree Celsius
ZSM-5 without passivation 440 degree Celsius
Catalyst Modification-
Sustainability
Environmental Performance
 Material and Energy
-Reduce feedstock required as higher conversion, Lower operating temperature
 Effluent And Waste
-100% conversion of methanol
Economic Performance
-Reducing utilities and increase production rate
Social Performance
 Innovation and Knowledge Potential
-By modification on catalyst
Environmental Performance: Reusing
Waste Water From Vessel -1 (Decanter)
 One of the wastes produced from the production is water with traces of
Nitrogen content from the splitter
 It is being discharged at 40°C, 48691.7 kg per day and can be acted as coolant
to be used in cooling of reactor 1 and 2.
 Then, the steam produced from the jacketed reactor can be fed to the
reboiler at distillation column in order to heat up the bottom and boilup.
 Therefore, the utility required for purchashing steam can be reduced by
recycling the steam from the jacketed reactor.
Social Performances: Safety
 Process includes hazardous processes such as:

 Heating flammable materials to temperature exceeding their flashpoints
 High temperature reactors
 Storage of volatile substances
 Reactors temperature was kept below 440°C to ensure the design material does
not experience thermal fatigue or explosion. Piping which are involved in
transporting fluids higher than 70°C are insulated.
 Flammable materials such as toluene and methanol are heated way past their
flashpoints where it presents considerable explosion risk in an event of a
leakage. Thus, fired heater is used to prevent such risk. It is a high but necessary
cost.
 Due to its considerable volatility, a vapor pressure of 3.84 psia at 77°F, methanol
is stored in vertical cylindrical tanks with floating-head covers. This limits
extreme rises in pressure due to evaporation.
 Other ways to control temperature is by using engineering solutions such as :

 Using fans or air conditioning
 Use physical barriers that reduces exposure to radiant heat around the fired heater
 Providing mechanical aids to reduce work rate to regulate length of exposure
to hot environments.
 allowing employees to enter only when the temperature is below a set level or at
cooler times of the day
 issuing permit to work that specify how long your employees should work in
situations where there is a risk
 providing periodic rest breaks and rest facilities in cooler conditions
REFERENCES
 https://www.icis.com/explore/resources/news/2007/11/07/9076550/toluen
e-uses-and-market-data
 file:///C:/Users/user/Downloads/298948711-135-PERP0607-6-1-Benzene-
Toluene-Nexant.pdf
 https://www.digitalrefining.com/data/literature/file/367313690.pdf
 https://www.icis.com/explore/resources/news/2018/06/08/10229654/chemi
cal-profile-asia-toluene/
 https://hub.globalccsinstitute.com/publications/co2-capture-cement-
industry/34-types-co2-capture-technology
 http://www.ccsassociation.org/what-is-ccs/storage/

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Production of Para Xylene

BFD of PARA-XYLENE PRODUCTION

Price of toluene in 2018: $80/tonne – 673/tonne

 The forecasts of carbon dioxide price in 2020 is expected to be at $25 per

 Effectiveness of catalyst can be increased by surface passivation and pore size

i)Pore size control by silanization with TEOS (Tetraethyl orthosilicate)

 Effectiveness of catalyst can be increased by surface

 Process includes hazardous processes such as:

 Other ways to control temperature is by using engineering solutions such as :

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