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CHE 481-483: Process Design Final Design Project Presentation Chemical & Biological Engineering Department Drexel University Manufacture of Ethylene Glycol.

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Presentation on theme: "CHE 481-483: Process Design Final Design Project Presentation Chemical & Biological Engineering Department Drexel University Manufacture of Ethylene Glycol."— Presentation transcript:

1 CHE 481-483: Process Design Final Design Project Presentation Chemical & Biological Engineering Department Drexel University Manufacture of Ethylene Glycol Design Team: Academic Advisor: Dr. George Rowell Industrial Advisor: Mr. Steven Schon, P.E. NameTopics Covered in Presentation Chong McLarenProject Scope Nicholas MitchellProcess Description Timre SegearEconomic Feasibility Suroor ManzoorSafety & Environment Conclusions & Recommendations

2 Project Scope Chong McLaren

3 Ethylene Glycol  896 MM lbs/Yr  99.8% Purity (Polyester Fiber Grade) Diethylene Glycol (By-product)  2.2 MM lbs/Yr  99.6% Purity Raw Material  Ethylene: 484 MM lbs/Yr  Oxygen: 370 MM lbs/Yr at 99% Purity Size of Plant

4 Location Port Arthur, TX BASF/ATOFINA steam cracker Grass-Roots Site Self Sufficient Unit (Utilities & WWTP)

5 Production of EO Technology EO Reactor  Shell Technology vs. Chlorohydrin process Silver Catalyst Efficient & Environmentally friendly No unwanted byproduct Ethylene Conversion: 12.5%  Oxygen vs. Air Reduce quantities of inert gases into recycle Eliminate the need for a purge reactor system Higher selectivity: 65-75% vs. 85-90% Higher operating cost Higher risk of handling

6 Production of EG Technology EG Reactor  Ion Exchange Catalyst vs. No Catalyst Hydrolysis of EO Reduce operating temperature by 150 °F Reduce amount of excess water  Water:EO - 20:1 to 4:1 EO Conversion: 98% Higher MEG selectivity: 91% vs. 98%

7 Chemistry Ethylene Reaction:  C 2 H 4 +1/2 O 2 → C 2 H 4 O Side Reactions:  C 2 H 4 + 3 O 2 → 2 CO 2 + 2 H 2 O  C 2 H 4 O + 2 1/2 O 2 → 2 CO 2 + 2 H 2 O EO Reaction:  C 2 H 4 O + H 2 O → C 2 H 6 O 2  C 2 H 4 O + C 2 H 6 O 2 → C 4 H 10 O 3

8 Market Analysis EG Worldwide Production  31.2 Billion lbs/Yr  20% in US GLYDE: 896 MM lbs/Yr of EG Production  3% of World market  14% of US market Growth Rate  6%-7% globally per year between 2006 - 2010

9 Market Analysis Polyester Grade EG Demand for Derivatives Uses  Demand of EG ↑, Demand in End-Use Segments ↑ automobile coolant, antifreeze additive, fiber, film, PET bottles, solvent in printing ink

10 Process Description Nick Mitchell

11 Ethylene Oxygen Feed Prep OMS EO Absorber EO Stripper CO 2 Absorber CO 2 Stripper Flare EO Reactor EG Reactor EG Dehydration EG Purification CO 2 Purge EG DEG Section 300: CO 2 Removal Section Section 400: EG Reaction Section Section 500: EG Purification Section Block Flow Diagram Section 100: EO Reaction Section Ethylene Oxide Absorber Ethylene Oxide Stripper Carbon Dioxide Absorber Carbon Dioxide Stripper EG ReactorEG Dehydration EG Purification Ethylene Feed Prep Oxygen Mixing Station Ethylene Oxide Reactor Section 200: EO Absorption Section

12 Section 100: EO Reaction Recycle Compressor 8,600 cfm 2,900 HP 2 Stages Oxygen Mixing Station Safe Mixing of Oxygen Avoiding Flammability Range Reactor & Cooler  150 MM Btu/hr to Oil System

13 EO Absorber  D = 10 ft  Structured Packing  HETP = 24 in.  Packing H = 40 ft Section 200: EO Absorption EO Stripper  D = 10 ft  20 Trays  Feed @ 10  Required EO/Water Concentration

14 Section 300: CO 2 Removal CO 2 Absorber  D = 4 ft  Structured Packing  HETP = 24 in.  Packing H = 40 ft CO 2 Stripper  D = 4 ft  15 Trays  Feed @ 1 Absorber Vapor

15 Section 400: EG Reaction Stripper Distillate

16 Section 500: EG Purification

17 Key Process Assumptions Overall Heat Transfer Coefficients  150 Btu / hr sqft o F Boiling or Condensing Liquid/Liquid  50 Btu / hr sqft o F Elsewhere Gas/Liquid Gas/Gas EO Reactor Pressure Drop  15 psi in Packed Bed Reactors  6 psi in Heat Exchangers  < 3 psi in Vacuum Heat Exchangers  Pressure Drop in Columns Estimated by Aspen

18 Purity of Raw Materials Ambient Temperature & Humidity  Wet Bulb Temperature for Cooling Water Operating Time  8,100 hrs/yr (~4 wks downtime) Key Process Assumptions

19 EO Reaction Kinetics  Shell Catalyst is Proprietary  Conversion & Selectivity EG Reaction Kinetics  Ion Exchange Resin only used in Lab Scale Pilot Plant Required to test BOTH Catalysts

20 Economic Feasibility Timre Segear

21 Economic Assumptions

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23 Fixed Costs

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25 Other Capital Costs Assumptions Five miles of piping uninstalled cost $1MM Cost factor of 5 for a total of $5 MM Oxygen Mixing Station uninstalled cost of $1 MM Cost factor of 4.44 for a total of $4.4 MM Seader, Seider and Lewin  600 MM lbs/yr in 1995  $80 MM  896 MM lbs/yr in 2006  $123 MM  Reassuring our capital cost ($175 MM) is reasonable

26 Total = 23.3 c/lb Total = 38 c/lb

27 Design Case 19% Hurdle Rate 12%

28 Design Case 19% Hurdle Rate 12% Capital Cost Capital Cost Sensitivity Capital Cost – 175 $MM

29 Design Case 88% EO 98% EG Increasing EG Selectivity Increasing EO Selectivity

30 Design Case 19% Hurdle Rate 12% Current Market Price Price/Capacity Sensitivity Ethylene Glycol - 896 MMlb/yr 0% 5% 10% 15% 20% 25% 30% 35% 40% $0.30$0.35$0.40$0.45$0.50 Price (2006) $0.38, $/lb DCF IRR, % 1000 MM lb/yr 896 MM lb/yr 600 MM lb/yr

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33 Economic Conclusions Total Capital Costs  $175 MM Raw Materials is major manufacturing cost Anticipated Internal Rate of Return: 19%  Hurdle rate: 12%  Break even period: 3 years Preliminary results lead us to believe this is an economically feasible process

34 Safety & Environment Conclusions & Recommendations Suroor Manzoor

35 Safety Safety Concerns  Ethylene Highly Explosive and Hazardous  Oxygen mixing station Potential Source of Explosion Located in Bunker  Ethylene Oxide Very Toxic Human Carcinogen

36 Safety Risk Management  Utilities Consideration Shut off Oxygen & Ethylene Supply Back up generator Shut Down  Fire Prevention Fire Suppression System Shut off all gas streams  Wrong Feed Ratios

37 Risk Management  Leaks and Spills Ventilate Area Isolate Area Spill Collected or Absorbed  Process Waste Flare Recycle and Blending  Plant Layout Safety

38 WASTE WATER PLANT MAIN ROAD ROAD RAILROAD SIDING UTILITIES 50 ft OXYGEN PLANT O2 MIXING STATION ETHYLENE PREP C-501 C-101 E-206 E-205 T-202 E-203 E-202A E-201 T-201 E-103 E-102 E-101 R-101 R-401 E-502A T-501 E-502B P-503 V-202 P-202B V-201 P-201 E-301 T-301 V-501 P-202A P-301A P-301B TK-101 TK-102 TK-103 TK-104 LOADING STATIONS ROAD WAREHOUSE SHIPPING & RECEIVING MAINTENANCE BLDG MACHINE SHOP N2 TANKS T-502 V-502 P-505 P-504 V-601 P-601 PIPE RACK E-503 E-504 PIPE RACK ROAD PARKING MAIN GATE CONTROL LAB FLARE SE PREVAILING WIND GATE OFFICE P-501 P-303 P-502 P-506 E-202B E-202C E-204A E-204B E-204C E-204E E-204D P-203B P-203A E-401 E-402A E-402B V-401 E-501A E-501B E-501C E-601 P-602 TK-105 South East

39 Environmental All raw materials/products biodegradable DEG byproduct Sold Waste Management  Streams recycled to optimize process  No process waste water  WWTP  Bottoms from EG Purification blended into MEG product stream  Emissions

40 Issues Economics  Ethylene price 1c/lb is a difference of $9 million/yr Technical  Reaction kinetics of silver catalyst proprietary  Glycol resin catalyst only tested on lab-scale Product  Purity of Ethylene Glycol The final price drops by 25% if purity is in the range 98-99.8%

41 Conclusions Capital investment: $175 million Production rate: 896 million lb/year EG Anticipated Internal Rate of Return: 19%  Break even period: 3 years  Hurdle rate: 12% Economically Feasible Process

42 Recommendations Lock Ethylene price Process Optimization  Heating, Cooling  CO 2  Catalyst

43 Acknowledgements Dr. George Rowell Mr. Steve Schon, P.E. Dr. Richard Cairncross Dr. Elihu Grossmann

44 Questions Timre ChongvsNick Suroor


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