Download - Production of 21,000 ethylene oxide
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CONTENT
1•
Comparison between Simulation and Manual (Mass Energy Balance)
2 • Chapter 3 !eat "ntegration & #tilities
3 • Chapter $ %rocess Euipment Si'ing & %iping
$ • Chapter %rocess Control & Saety Studies
• Conclusion
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COMPUTER SIMULATION(MASS & ENERGY BALANCE
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MASS BALANCECOMPARISON
Str!"
M!#$!%('r)
A*+#('r) Err-r
1 23$*+,2 23$*3,+3 -*,*23..
2 23$*+,2 23$*3,+3 -*,*23..3 23$*+,2 23$*3,+3 -*,*23..$ 1/.0.,1 1/.0,+$ -*,*1$3. $1,*1 3/,++2 -*,*$0 $1,*1 3/,++2 -*,*$/ $1,*1 3/,++2 -*,*$. $1,*1 3/,++2 -*,*$+ 3**$,.1 3*12,+/. *,2/1121
1* 3**$,.1 3*12,+/. *,2/112111 3**$,.1 3*12,+/. *,2/112112 +3.2,.1 +.**,++ $,200$3313 +3.2,.1 +.**,++ $,200$331$ +3.0,**. +.**,/+2 $,2321$+1 +3.0,**. +.**,/+2 $,2321$+10 $0013,10 $0013,10 1,0E-1$1/ $0013,10 $002,20 *,*.3.211. **0,20/ $+/0,/03 -*,+2.
1+ *++2,+ 1$/0,2+ *,+3+*02* *++2,+ 1$/0,2+ *,+3+*0
Str!"
M!#$!%('r)
A*+#('r)
21 *++2,+* 1$/0,2+
22 *++2,+* 1$/0,2+23 32*0,+$ 32.2,$+2$ $//.2,.0 $.1+3,/$2 $//.2,.0 $.1+3,/$20 32*0,+$ 32.2,$+2/ 32*0,+$ 32.2,$+2. 2/**,110 2/*2,32+ *0,.2/ *.,$
3* *.2,10 *.0131 *.2,10 *.0132 *.2,10 *.0133 1*0.,2+/ 1*/,33$ $/+1,.. 23*,/03 $/+1,.. 23*,/030 $/+1,.. 23*,/03/ 2** 2**3. $/..,2/ $.2$,2$
3+ *2*3,30 *2*3,30$* 1*11,1/ 1*0$,2+
2 er age 1 3 er r or
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ENERGYBALANCE
COMPARISON
E.$/+"#tM!#$!%(r)
A*+#(r)
C-1 33*/0,10 30+33.1E-1 2*22/20,+ 23.2+141 2$$12,3/ 2.2/33,1C-2 /+13+.,/ +$21$1,$E-2 /+3*1,* /332+3
C-3 0++3*1,0 .*3/+E-3 11*.+.,11 13$/*21C-$ 21$+0,$2 00/.1M-1 *,** *E-$ 1**2*$1,*/ 111*+1*5-1 -$/.0/+23,33 -0,3E6*/ 2E- /12.*2,12 .3022+,0 1 7-1 2./2.**,** 30*****E-0 2+*3*0+,$/ 32.*3*$
%-2 //**,.. .23. 7-2 $*3++/**,** $.32***%-$ *.,.1 3$,. 7-3 /*0$23,** .+**** 2E-/ 1/$/2,1* 2*03.+,2 1 7-$ 0$.,** .**%-0 32+1,+* 30/$ 7- 323/$,.$ 3+/3 1
C- 21223,12 2$+0.,3.E-. 12/*+*,++ .*330 1
2 er age 1$3 er r or
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ASSUMPTIONS
T +%!#t /* -# t !*/* - 21,000 "tr/3 t-#* +r !r -+r!t
-$r* +r !r6
T/* +r-3** 7-* #-t 3-#*/7r t t/r7 r!3t/-#, !* /t /* *$ 8/#% 3%-r/7 (3!# /'#-r7 /# "!** !%!#3 !* t !"++")6
A%% t 3-"+-##t* /# t **t" !8 /# /7!% 3-#7/t/-
N- %-*** /# +/+* !#7 8**%* /# t **t"6
I#+$t 9 O$t+$t -r 3-"+r**-r, +$"+, "/:r !#7 !t :3!#'
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Chapter 3
Heat Integration & Utilities
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PINCH ANALYSISE.$/+"#t T"+r!t$r
- *-$r3(;C)
T"+r!t$r- t!r't (;C)
H!tD$t(12=T"/# 9 >56?4
> >
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E>?
E>@
E>4
E>2
E>1
E>
E>
E>5
INTEGRATION
OF THE HEAT
EXCHANGER
NET
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PROCESS FLO< DIAGRAM
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E-2E-E-3E-.E-/E-0E-$E-2E-$E-
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COMPARISON OF UTILITIES NEEDEDBEFORE & AFTER THE INTEGRATION
PROCESS
Ut/%/t
B-r
/#t'r!t/
-# (@ 100
2?2?
9
@4
@
Ut/%/t/* C-*t/#' -r %3tr/3/t
%ea< hours 5M*, 33/9= pea< 5M *,2*2
Electricity (pea< hours) *.** > 2
hr?yr)
Electricity (o= pea< hours) 22** >
hr?yr)
E#r'3-#*$"+t/-#
<
@hole plant 3021,01
“Tarif, E1 – Medium Voltage General InTNB (2014!
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Chapter 4
Process Equipment Sizing
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E.$/+"#t S+3/J3!t/-# St
"dentiAcation %ac
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**% S+3/J3!t/-#
Fessel weight (
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C-%$"# T>2 T>?
C-%$"# T>2
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7emperature• eed temperature at
saturated liuidcondition(GC)
• ;ew point (GC)• Bubble point (GC)
2*010+21*
1211*
1+/,
Column• M!tr/!% -
3-#*tr$3t/-#
• C-%$"# 7/!"tr, D3 (")
• Column cross-sectionalareaD c (m
2)
• C-%$"# /'t, t
(")
St!/#%**
St%
16
2,*1*..@6@1
St!/#%**
St%
160
*,/.@60
7rays• 7ray spacing (m)• Minimum number o
trays
• EIciency ()• A3t$!% #$"r -
tr!*• eed-plate location
(trays rom top)• 7ype
*,0***$,+J
3/,..0
2,3+*
Siee
*,0***,0J0
$$,./0$
12+,/0$3
Siee
5eKu• Minimum reKu ratio• ctual reKu ratio
0,02/2+,+$*/
*,2223*,333$
%roisional %late ;esign
• %late thic
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E.$/+"#t F$#3t/-#Storage 7an< o EthyleneD O-1 7o store the raw materialD Ethylene
Storage 7an< o @aterD O-2 7o store @ater used to absorb Ethylen
Ethylene 9ide absorber
Storage 7an< o %otassium Carbonate
solutionD O-0
7o store the %otassium Carbonate so
to absorb Carbon ;ioide in Carbo
absorber
Storage 7an< o Ethylene 9ideD O- 7o store the productD Ethylene 9ide
Storage 7an2 > >
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STORAGETANS
T!# >2 > >
Component to bestored
@ater2* %otassium
Carbonatesolution
Ethyle9ide
%ressure (bar) 1 1 3,umber o tan
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A*-rr* !#7 Str/++r
E.$/+"#t F$#3t/-#
Ethylene 9ide bsorber (7-1) 7o separate Ethylene 9ide rom other
componentsCarbon ;ioide bsorber (7-$) 7o separate Carbon ;ioide rom other
componentsCarbon ;ioide Stripper (7-) 7o separate Carbon ;ioide rom %otassiu
Carbonate
T>1 T>4 T> C-%$"# T>
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C-%$"# Et%#
O:/7
A*-rr
C!r-#
D/-:/7
A*-rr
C!r-#
D/-:/7
Str/++r@eir ;esign• @eir lengthD lw (m)
• @eir heightD hw (m)
• @eir liuid Cresti, MaimumD h
ow
(mm liuid) ii, MinimumD how
(mm liuid)
1*,/1$3*,***
03,$./
*,**$
12,2.*/*,***
01,*2+*
$.,113/
1*,/1$3*,***
2,3/+*
$1,2.$2
C-%$"#• M!tr/!% -
3-#*tr$3t/-#• C-%$"# 7/!"tr,
D3 (")
• Column cross-
sectional areaD c (m2)• C-%$"# /'t, t
(")
St!/#%**
St%065
*,$.260
St!/#%**
St%06
*,32.31260@
St!/#%**
St%160
*,+*$246@5
7rays• 7ray spacing (m)• EIciency ()• A3t$!% #$"r -
tr!*• T+
*,0*+*
S/8
*,0*/,+0
14S/8
*,20*
S/8
%roisional %late ;esign• %late thic
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!eat Echangers
T+ - E:3!#'r* S%% !#7 T$
H!t E:3!#'r
2 S%% P!**,
T$ P!**
S%% !#7 T$
H!t E:3!#'r
2 S%% P!**,
T$ P!**
S%% !#7 T$
H!t E:3!#'r
1 S%% P!**,
2 T$ P!**
S%% !#7 T
H!t
E:3!#'
1 S%% P!*
2 T$ P!"tem o, E-1 E-2 E- E-0
unction Cooling Cooling Cooling Cooling
M!tr/!% O
C-#*tr$3t/-#
C!r-# St% C!r-# St% C!r-# St% C!r-# St
C--%!#t F%$/7 C-%7
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T+ - E:3!#'r* S%% !#7 T$
H!t
E:3!#'r
1 S%% P!**,
4 T$ P!**
S%% !#7 T$
H!t
E:3!#'r
1 S%% P!**,
2 T$ P!**
S%% !#
T$ H!
E:3!#'
1 S%% P!
2 T$ P!
"tem o, E-3 E-$ E-.
unction !eating !eating !eating
M!tr/!% O
C-#*tr$3t/-#
St!/#%** St% C!r-# St% C!r-# St
H!t/#' F%$/7 H-t
7emperature 9utlet (C) 3 23* /*
N-6 - T$ 115 1? 4?@
Ar! ("2) 156 ?4 @
7ype o essel support Saddle Saddle Saddle
E*t/"!t7 C-*t (RM) ?56 4 5
d
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Compressors?Epander
I7#t/J3!t/-# C-"+r**-r C-"+r**-r C-"+r**-r E:+!#7r C-"+r"tem o C-1 C-2 C-3 C-$ C-unction Compress
pressureCompresspressure
Compresspressure
Epand pressure Comprpressu
T+ C#tr/$'!% C#tr/$'!% C#tr/$'!% C#tr/$'!% C#tr/M!tr/!% -C-#*tr$3t/-#
C!r-# St% C!r-# St% C!r-# St% C!r-# St% C!r-# S
lowrate (
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M/:r (M>1)
unction 7o ensured the ethylene streamD a
stream and recycle stream be in ostream beore entering the reacto1)
D*/'# H-r/Q-#t!% 3%/#7r/3!% 8**%
M!tr/!% - 3-#*tr$3t/-# St!/#%** *t%
7ype o essel support Saddle
O+r!t/#' 3-#7/t/-#*
9peratingtemperature () 1$ 9perating pressure(bar) 21
Molar Kowrate(1)
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MEMB5E SE%5795 (4-1)
F$#3t/-# 7o separate oygen and nitrogen g
T+ - ""r!# D/"t%*/%/3-# r$r
T+ - ""r!# *+!r!t-r H-%%- ""r!#T+ - *%% C!r-# *t%
M"r!# *$r!3 !r!, () ?
N$"r - "-7$%* 154
T+ - 8**% *$++-rt Saddle
O+r!t/#' 3-#7/t/-#*
9perating
temperature ()
.* 9perating %ressure
(bar)"nlet
9utlet
32
!ollow membrane;iameter (m):ength (m)
*,*12,+
Shell;iameter (m):ength (m)
*,23
E*t/"!t7 3-*t (RM)
1@@
F$#3t/-# 7o separate oygen and nitrogen g
T+ - ""r!# D/"t%*/%/3-# r$r
T+ - ""r!# *+!r!t-r H-%%- ""r!#T+ - *%% C!r-# *t%
?
N$"r - "-7$%* 154
T+ - 8**% *$++-rt Saddle
O+r!t/#' 3-#7/t/-#*
.* 9perating %ressure(bar)"nlet
9utlet
32
!ollow membrane;iameter (m):ength (m)
*,*12,+
Shell;iameter (m):ength (m)
*,23
E*t/"!t7 3-*t (RM)
1@@
E.$/+"#t*
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SUMMARY OFMAOR
EUIPMENTCOSTS
5eactor (5-1)
;istillation column 1 (7-2)
;istillation column 2 (7-3)
Ethylene oide storage tan< 1
Ethylene oide storage tan< 2
Ethylene storage tan< (O-1)
Ethylene storage tan< (O-1)
@ater storage tan<
%otassium carbonate storage tan<
n empty cylindricalD carbon steel essel
Ethylene oide absorber (7-1)
Carbon dioide absorber (7-$)
Carbon dioide stripper (7-)
!eaters (E-3D E-$D E-.)
Coolers (E-1D E-2D E-D E-0D E-/)
Compressors and Epander (C-1D C-2D C-3D C-$D C-)
Mier (M-1)
Membrane Separator (4-1)
TOTAL ESTIMATED COST
3Te metods o% te)al)ulation %or eui+mentsi5ing and )osts are ta&en%rom Turton6s (2007 andinnot6s (2008 'ritings3
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Chapter 5
Process Control & SafetyStudies
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SS#M%7"9S
O# !/%$r !t ! t/"6
T **t" /* -+r!t7 !#7 "!/#t!/#7/# %/# /t 7*/'# /#t#t6
M-7* - -+r!t/-#K N-r"!% -+r!t/-#
G$/7-r7K N-, M-r, L**, H/', L-,R8r*
N-7K M!-r E.$/+"#t
HAOP -# R!3t-r (R>
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D8/!t/-#P-**/% 3!$** C-#*.$#3* R3-""P!r!"t
rG$/7-r
7
low tothe
reactor
o Kow tothe
reactor
Fale F-. ailclose,
o reaction occurs"nstall Kow mass alaChec< regularly the ale,
More Kowto thereactor
Fale F-. ailopen,
5unaway reaction"nstall Kow mass ala
7o chec< regularly thale,
:ess Kowto thereactor
%iping lea
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P & ID -r R!3t-r (R>
1)
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!N9% on ;istillationColumns
D8/!t/-#* P-**/% C!$** C-#*.$#3* R3-"P!r!"t G$/7
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r*
low on;istillation Column
o Kow to thedistillationcolumn
Control ale closed o operation
7emperature and pressureincreased in the pipe,
"nstall bac
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.*
G$/7
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low on;istillate
;istillation
Column
o top product Kow todistillate distillation column
"nlet Kow bloc< :oss in product
o separation in column
9erKow o accumulator
%ump at the condenser brea
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P!r!"tr* G$/7
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P & ID -r D/*t/%%!t/-# 3-%$"#*
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D8/!t/-#*P-**/% C!$** C-#*.$#3* R3
P!r!"tr* G$/7
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Et%# -:/7*t-r!'
Et%#, P-t!**3!r-#!t !#7 <
t!#*
P & ID -r St-r!' T!#*
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D8/!t/-#* P-**/% 3!$** C-#*.$#3* RP!r!"tr* G$/7
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r*
low to theabsorbers
andstripper
o Kow to theabsorber and stripper,
Control ale ailclose,
o operation "nstall bac
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P & ID -r A*-rr* !#7 Str/++
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D8/!t/-#* P-**/%C!$**
C-#*.$#3* R3-""#7!t/-#*P!r!"tr
*G$/7
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% & "; or !eat Echangers
C--%r H!tr
!N9% 9n Compressor
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D8/!t/-#*
P-**/% C!$** C-#*.$#3* R3-""#7!t/P!r!"tr*
G$/7
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% & "; or Compressorand Epander
!N9% on Mier (M 1)
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D8/!t/-#*P-**/% C!$** C-#*.$#3* R3-""
P!r!"tr*
G$/7
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% & "; or Mier (M-1)
!N9% on membrane
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separator (4-1)D8/!t/-#*
P-**/% C!$** C-#*.$#3* R3-"P!r!"tr* G$/7
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% & "; or MembraneSeparator
CONCLUSIONRECOMMENDATION
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CONCLUSIONRECOMMENDATIONFOR THE PROCESS SAFETY
•
Saety studies o all the nodes in the %; aresuccessully coered by the !N9% analysis,
• Saety "nterloc< Systems can be installed in caspossible seere conditions in the plant,
• 9ther saety studies such as the ailure Mode analysis (ME) and ault 7ree nalysis (7) cobe done in order to help oercoming the littledrawbac
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ECONOMIC POTENTIAL ATLEEL
*,2 *,3 *,$ *, *,0 *,/ *,. *,+ 1,* 1,1
-1*
*
1*
2*
3*
$*
*
E3-#-"/3 P-t#t/!%
C-#8r*/-#, X
E3-#-"/3 P-t#t/!% , EP (10@RMr)
At t -+3-#8r*/-# -
EP /* -t!
RM?5 "
C9C:#S"9
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M!** !#7 #r' !%!#3 rr-r!r %**r t!# !#7 ?0
r*+3t/8%6
@4 - -t $t/%/t/* !#7 @ - 3-%7 $t/%/t/* 3!# *!87
/#t'r!t7 HEN6
T t-t!% *t/"!t7 3-*t -rt "!-r .$/+"#t /* RM2@6
"/%%/-#6
P&ID /* *$33**$%% 78%-+7r-" t HAOP *t$7/*6
C9C:#S"9
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