Project
Project
Project
FACULTY OF ENGINEERING
CHEMICAL ENGINEERING DEPARTMENT
PRODUCTION OF ACETALDEHYDE
1 INTRODUCTION 2 USES OF
ACETALDEHYDE
EQUAPMINT 6 COST
5
DESIGN
7 CONCLUSION
INTRODUCTION
•It is found in a variety of foods, including coffee, bread, and ripe fruit.
Acetic Acetaldehyd
Acetic acid
anhydride e ammonia
Dyes and
Paraldehyde butadiene_1,3
drugs
Rate equation:
Where:
W is the weight of the catalyst
F_{Ao} is the flow rate of ethanol
-r_{A} is the rate of the reaction
K is the rate constant (0.040788531 )
C_{Ao} is the ethanol concentration
X_{A} is the conversion
ε is
Equipment design
The reactor design was based on the performance and rate equations for a plug flow
reactor. The results show that the reactor meets the design criteria for a fixed bed
plug flow reactor:
• Weight of catalyst = 47178.86 kg
• Volume of catalyst bed = 13.12 m3
• Space velocity = 17.74 kg·hr/m3
• Catalyst particles size = 5 mm
• Reactor volume = 23.855 m3
• Number of tubes = 40
• Tube length = 10.24 m
• Tube diameter = 300 mm
• Shell diameter = 3.0988 m
• Shell thickness = 12 mm
• Head type = Tori spherical
• = BracLength to diameter ratio = 3.304 Support type
• kets Pressure drop = 0.74359 bar < 8.4 bar operating pressure:
Equipment design
Distillation column design T-101
Design Parameters:
• Separate acetaldehyde from water and unreacted ethanol.
• Feed stream contains acetaldehyde, water and ethanol
at 5.47 bar and 108.89 °C .
• Column operates at 5.47 bar with reflux ratio of 2.5.
• Use UNIQUAC-Ideal Thermodynamics property method.
Equipment design
Design Results:
• 8
Theoretical stages
• Total height: 4.8768 m
• Total pressure drop:68.84029222 mbar
Condenser:
• Temperature: 72.6585 °C
• Pressure: 5.4 bar
• Duty: 4134917.866 kcal/hr
Reboiler:
• Temperature: 151.024 °C
• Pressure: 5.47 bar
• Duty: 6601365.592 kcal/hr
Distillation Column Specifications:
• Section 1:
• Diameter: 1.6349 m
• Height: 2.4384 m
• Section 2:
• Diameter: 1.2949 m
• Height: 2.4384 m
Equipment design
Heat Exchanger (E-103) Design
Type: Shell and Tube
Software Used: Aspen Exchanger Design and Rating Shell & Tube V11
The design of the heat exchanger is as follows:
• The equation used in the design is the following: Q = UA(ΔT) where
Q is the heat transfer rate, U is the heat transfer coefficient, A is the surface area,
and ΔT is the temperature difference.
• The shell is made of carbon steel.
• The tubes are made of stainless steel.
• The tubes are arranged in a U-shape.
• The shell side fluid is water.
• The tube side fluid is acetaldehyde.
• The heat exchanger is insulated with fiberglass.
• The heat exchanger is designed to operate at a pressure of 10 bar and
temperature of 150°C.
Equipment design
Design Calculations:
• Thermal Load (Q) = 3968.9847 kW
• Heat Transfer Coefficient (U) = 417965.5360 kJ/C-h
• Number of Tubes = 367
• Tube Length = 5.85 m
• Tube OD = 0.0191 m
• Tube Thickness = 0.0021 m
• Tube ID = 0.0148 m
Utility Fluid:
• Water Utility Flow Rate = 39633.2211 kg/h
• ΔT = 28.3827°C
• Pressure Drop (Tube Side) = 0.0443 bar
• Pressure Drop (Shell Side) = 0.2706 bar
Key Results:
• Heat Transfer Area = 126.7 m2
• Matches required thermal load of 3968.9847 kW
• Acceptable pressure drops on tube and shell side
Design Cost of Acetaldehyde Production
Here is a summary slide on the design cost of acetaldehyde production:
Design Cost of Acetaldehyde Production
- Acetaldehyde produced by dehydrogenation of ethanol
- Reaction: CH3CH2OH → CH3CHO + H2
- Catalyst: Copper on silica support Design Elements:
- 3Plug flow reactors in series
- Distillation column T-101 to purify acetaldehyde
- Heat exchangers for heating and cooling
Equipment Cost:
- Reactors - $535,600
- Distillation column - $210,000
- Heat exchangers - $65,000
- Other equipment - $656,000
Total Capital Cost: $2,935,960
Design Cost of Acetaldehyde Production
Summary of Capital Cost obtained by Aspen Hysys V.11
Summary