Reactor R-101 from the file attached is to be designed. The followings things need to be done:Chemical Engineering DesignMechanical Engineering DesignSafety, Health and Environmental factorsCost Analysis
KKEK4281 – Design Project Design Report Production of 2-Ethylhexanoic Acid (2-EHAcid) from Propylene and Syngas via Oxo Synthesis Group 11 Semester 2, 2016/2017 Group Members: 1) Goh Lee Mei KEK130015 2) Kaviarasan A/L Vijasangar KEK130017 3) Nur Najihah binti Roslee KEK130042 4) Wan Muhammad Faiz bin W Yusoff KEK130059 Facilitators: 1) Dr. Badrul Hisham bin Mohamad Jan 2) Prof. Ir. Dr. Mohd Azlan bin Hussain ES-1 Executive Summary Introduction Commonly associated as the product of oxo synthesis of propylene with syngas, 2-Ethylhexanoic Acid (2-EHAcid) is an important chemical intermediate used for various end products in today’s industry including in the production of plasticizers, lubricants and automotive coolants. With Malaysia having 409 oil and gas fields which is the second largest reserves in South East Asia as well as its strategic location at the centre of South East Asia located in between the growing markets of China and India, the production of 2-EHAcid based on propylene and syngas is seen as a good business opportunity as these major raw materials can be obtained from petrochemical hubs around Malaysia. Therefore, the objective of this plant is to produce 30,000 metric ton of 2- EHAcid annually from propylene and syngas for a plant life of 20 years. Market Analysis The global sales market of 2-EHAcid is 340,000 metric ton in 2015 and the market size is expected to expand by a compound annual growth rate (CAGR) of 5.19% from 2017 to 2022 in which the approximated demand in 2022 is around 460,000 metric ton. Currently, major producers of 2- EHAcid are from all over the world including OXEA and BASF from Germany, Eastman in USA and Perstorp in Sweden. It seems as a good opportunity for the proposed 2-EHAcid plant of 30,000 metric ton capacity per annum located in Malaysia to provide 2-EHAcid to customers worldwide. Technology Survey There are several ways in which 2-EHAcid can be produced but after thorough analysis from aspects such as conversion efficiency and availability of raw materials, production of 2-EHAcid via oxo synthesis from propylene and syngas has been chosen as the best pathway. The continuous process includes hydroformylation, aldolization, hydrogenation and oxidation processes with conversions ranging from 85.0-99.9%. Its benefits include good reaction time of approximately 4 hours, reusability of catalysts and elimination of highly toxic materials. Moreover, the pathway selected has the highest gross profit of RM9.06/kg 2-EHAcid among pathway compared, and with additional selling profit of by-products isobutanal, 3-heptanone and 3-heptanol, this pathway has an upper hand compared to other technologies analyzed. Another trump card of this pathway is ES-2 that most of its raw materials and catalysts are easily obtained at the proposed plant location in Pengerang Industrial Park, Johor. Process Description The process starts with liquid propylene of 99 wt% purity, stored at 13 atm and 30oC, being subjected to heating to produce gaseous propylene. The fresh feed is fed into the oxo reactor with recycled propylene and syngas, operating at 5 atm and 120oC with 85% conversion efficiency, using rhodium triphenylphosphine as catalyst, to produce isomers n & isobutanal at 10:1 molar ratio which is then distilled at 1.2 atm to separate isobutanal stream of 97.5 wt% as top product, the bottom product, n-butanal then undergoes aldol condensation in the aldol reactor, operating with 90% conversion efficiency, at 10 atm and 110oC employing aqueous NaOH as catalyst. 2- ethylhexen-2-al produced is then hydrogenated using palladium on alumina catalyst, in a two-loop packed-bed hydrogenator system, to obtain a conversion of 99.9% with maximum selectivity to produce pure 2-ethylhexanal. The reactors operate at 15 atm and 120oC and 110oC respectively. 2- ethylhexanal produced is then subjected to air oxidation in a gas bubble column reactor at 3 atm and 70oC, producing the desired end product, 2-EHAcid at a 95% conversion efficiency with 95% selectivity, using manganese acetate solution as catalyst. The products from the reactor, including 2-EHAcid, liquid catalyst, byproducts and unreacted 2-ethylhexanal is subjected to three distillation columns to recycle the unreacted 2-ethylhexanal and the liquid catalyst for subsequent oxidation process. Novelty associated with the process includes usage of high-boiling point solvent in the oxo reactor to eliminate the need for catalyst separation and the employment of two-loop hydrogenation system that is able to produce pure 2-ethylhexanal to eliminate another separation unit afterwards. Table ES.1 in Page 4 summarizes the yearly mass balance of the plant. Plant Location The plant is proposed to be situated at Pengerang, Johor. Pengerang can be easily accessed as it is located near major ports in South East Asia such as Johor Port, near Senai International Airport and is well connected to capital cities in Malaysia via North-South Expressway. Availability of all major materials as well as vast amount of land is seen as a plus point. Basic infrastructures such as electricity, water and telecommunications can be obtained at reasonable price since it is an upcoming petrochemical hub of Malaysia. Presence of new fires stations to accommodate any emergencies and also a state-of-the-art waste treatment area is seen as a plus point. Another trump ES-3 card for Pengerang is the fact that it is connected to one of the busiest international shipping route as well as the incentives provided by the government for petrochemical industries in the area. Safety, Health and Environmental (SHE) Considerations Safety, health and environmental (SHE) considerations are taken into account in the construction of 2-EHAcid plant to fulfill the PEAR concept which is to safeguard the People, protect the Environment, and protect the company’s Assets and Reputation. One of the main issue to highlight in this plant is that all the reactions are exothermic, safety tools must be used to identify the hazards associated with the chemicals and process involved and to assess its impact towards the PEAR. The safety tools used are Hazard and Operability (HAZOP) study, Hazard Identification (HAZID) analysis and the bowtie concept. Consequently, ways to reduce the hazards are introduced and it is based on the hierarchy of controls. The emergency response plan and emergency evacuation plan are designed to be used as the last line of defense in case of any emergency. In designing the 2-EHAcid plant, scrutinized decisions have to be taken in environmental considerations to ensure no harm is done towards the environment. Air emission is also considered since some of the materials used are hazardous flammable gaseous. Gases such as excess propylene and syngas are is recycled to be used as a fuel gas. Liquid wastes that consists of byproducts such as isobutanal is purified and sent for packaging to be sold, whereas other streams containing liquid catalysts and solvents are recovered as much as possible before being sent to the wastewater treatment plant for treatment before discharge. Mitigation steps are taken towards reducing the noise pollution induced by moving parts of equipment by isolating the noise generating equipment, introducing administrative control and by providing personal protective equipment (PPE) such as earplugs. Economic Analysis From the economic analysis, the payback period is approximately 5 years and with internal rate return (IRR) of 17.47%. This indicates that the project for production of 2-EHAcid is feasible. The summary of calculations is displayed in Table ES.2 in Page 4. Conclusion All in all, the production of 2-EHAcid via oxo synthesis from propylene and syngas is both technically and economically feasible with concerns towards the safety, health and environmental aspects have also been given thorough considerations. ES-4 Table ES.1: Summary of mass balance for the 2-EHAcid plant. Input Flow rate (MT/year) Purity (wt%) Output Flow rate (MT/year) Purity (wt%) Propylene 25,611.62 99.0 Off-gas 1 11,898.61 Syngas 25,443.00 Off-gas 2 267.80 NaOH catalyst 40.31 Off-gas 3 2,326.44 Hydrogen 633.60 Decanter (WWTP) 4,498.04 Air 19,686.86 Oxidation purge 853.03 Oxidation catalyst 821.60 Air 1,6243.02 Light-boilers 1,500.30 50.0 Isobutanal 3,424.23 97.5 2-EHAcid 31,225.52 99.5 TOTAL 72,236.99 TOTAL 72,236.99 Table ES.2: Summary of economic analysis for the 2-EHAcid plant. Item Value Construction period 2 years Plant lifespan 20 years Annual Revenue 243.12 million MYR Net profit 30.69 million MYR Payback period 5 years Return on investment (ROI) 19.80% Internal rate of return (IRR) 17.47% Table ES/3: Summary of raw materials and catalysts required and its potential supplier. Materials Usage Potential supplier Propylene Hydroformylation PETRONAS Pengerang Integrated Complex, Pengerang, Johor Syngas and Hydrogen Hydroformylation and hydrogenation Technip Group, Pengerang, Johor Rhodium triphenylphosphine Hydroformylation Shaanxi Rock New Materials Co., Ltd, China Sodium hydroxide Aldolization BIS Chemicals Sdn. Bhd., Shah Alam, Selangor Palladium Hydrogenation Ruizheng (Shanghai) Chemical Co. Ltd., China Manganese acetate Oxidation Foshan City Qiruide Additives Co., Ltd., China i Table of Contents Chapter 1: Introduction 1-1 1.1 Overview 1-1 1.2 The Product: 2-Ethylhexanoic Acid 1-1 1.3 References 1-2 Chapter 2: Market Analysis 2-1 2.1 Demand of 2-Ethylhexanoic Acid 2-1 2.2 References 2-5 Chapter 3: Technology Survey 3-1 3.1 Technology Survey 3-1 3.2 Raw Material Supply 3-1 3.3 Selection of Best Pathway 3-1 3.4 Novelty of Selected Pathway 3-4 3.5 Catalyst Survey 3-5 3.5.1 Catalyst Information 3-5 3.6 Reactor Selection 3-6 3.7 Summary 3-7 3.7.1 Raw Material and Catalyst Supply 3-7 3.7.2 Chosen Technology 3-8 3.7.3 Reactor Selection Summary 3-8 3.8 References 3-9 Chapter 4: Process Synthesis 4-1 4.1 Process Synthesis Steps 4-1 4.2 Process Description 4-3 4.3 References 4-5 Chapter 5: Mass and Energy Balance 5-1 5.1 Mass and Energy Balance 5-1 5.2 Mass Balance 5-1