CH4050 : CHEMICAL TECHNOLOGY AND EQUIPMENT DESIGN Group - 12 NAME ROLL NO. JENNE KUMAR SUNIL CH16B011 KAVITHA H CH16B041 NEEL KAPOOR CH16B046 SPHURTI AGARWAL CH16B066 Product: Acetic acid Location: Visakhapatnam Quantity: 320,000TPA Develop an optimized process. Submit a process diagram including all major items of equipment and their operating T & P Note: Warning from submission 2 have been rectified - as per suggestions given We have submitted the economic analysis excel workbook. The first sheet contains a summary of the economic analysis and the remaining sheets have been generated by aspen. The process description is exactly as that of the second submission. In this weeks submissions we have integrated a heat exchanger and cut down on utility requirements (an optimized flow sheet) Optimization Fig 1: Optimized Flow Sheet with heat exchanger Fig 2: Optimized Utility Use Fig 3: Unoptimized Flow Sheet Fig 4: Unoptimized Utility Use Thus by strategically utilizing a heat exchanger we were able to bring down our utility requirement from 5.42*107 to 4.08*107 cal/sec The major reduction in utility was because of two factors: 1. By using the heat exchanger, we use the high temperature syngas produced in the coal gasification process to heat up the feed to both the reactors (for coal gasification and methanol carbonylation. Here, instead of using separate heaters to first create steam from water in the feed for the coal gasification process, we use the hot syngas feed to heat the feed to 100 C0 so that water converts to steam. Also we heat up the feed to the second reactor to almost 180 by mixing hot CO to the other feed inputs 2. By optimizing the Distillation Columns by using proper utilities. Economic Analysis Cost Of Raw Materials ( As per our inputs) Cost/ton No. of kilo tonnes/year Total cost/year Reference HI 80,000 87.4599 699,67,92,000 https://www.indiamart.com/proddetail/hydrogen-iodid e-21448521555.html Methanol 25,000 184.668 461,67,00,000 https://dir.indiamart.com/search.mp?ss=methanol&cq =visakhapatnam Coal 5,000 140.984 70,49,20,000 https://dir.indiamart.com/visakhapatnam/coal.html Water 36 46.98844 16,91,583.84 https://www.thehindu.com/news/cities/Visakhapatna m/bulk-water-charges-to-industries-hiked/article7179 468.ece Product (Acetic acid) 50,000 336.362 1681,81,00,000 https://www.indiamart.com/proddetail/acetic-acid-419 6863591.html ₹449,79,96,416.16 Profit Transportation Cost Chemical Location Produced Distance from Vishakapatnam Cost/year Methanol Chennai 798 51,45,926.014 HI Hyderabad 618 35,23,443.012 Assuming price of trucking is 0.03 rupees/km/ton (http://www.truckbhada.com/) Water and coal is abundant in visakhapatnam thus there is no transportation cost From Aspen Operating Cost ₹ 1,48,96,94,400.00 Capital Cost ₹ 1,06,12,36,800.00 Net Profit Per Annum ₹ 1,54,15,32,647.13 As our net profit per annum is around 154 Crores per year, we can expect a break even point of around 1-1.5 years (as our capital cost is around 106 cr) Process description We have modelled a methyl carbonylation reaction to produce acetic acid on aspen. Our feed inputs to the reactor were Carbon Monoxide, Methanol and Water. We produce our own Carbon Monoxide by doing a coal gasification process (based on feedback provided) Thus the entire flowsheet can be broken down into two parts - the first is a coal gasification model to produce CO which is then used as an input for the methanol carbonylation process. Char Gasification: The ASPEN PLUS stoichiometric reactor, RSTOIC, performs char gasification by specifying the gasification reactions. Fig 8. RSTOIC Specification Fig 9. RSTOIC Specification Product Formation: In the Stoichiometric reactor, char gasification will take place. The principal product is synthesis gas i.e. H2 and CO along with the other components like H2O, N2, S, SO2, SO3, Cl2, HCl, CO2,CH4 and ash which needs to be separated. The product stream is the outlet stream of the RSTOIC i.e. RXOUT. The temperature is slightly lower becuase we are modelling a fluidized bed reactor CO-Feed Purity We get around 189 k tonnes/year of CO produce. High amount of N2 in the feed is because we used air to partially oxidize the coal. Fig 10. CO-FEED Methanol Carbonylation Process Description - with major component specifications We have a feed of CO (from the above process), Methanol, Water go into a RSTOIC reactor along with an iridium catalyst. 1. CH3OH + HI → CH3I + H2O 2. CH3I + CO → CH3COI 3. CH3COI + H2O → CH3COOH + HI We also have a water gas shift reaction. We put all the conversion and model these reactions in the reactor[2] Fig 12. Reactor Specification Fig 13. Reactor T&P The outlet is then passed through a flash column to recover the catalyst and then that is recycled back to the reactor (Recycle1). Fig 14. Flash Column Specification Fig 15. Recycle Stream 1 for catalyst regeneration The vapour is then sent to a distillation column (B3), here N2, H2, O2, CO2 are separated as vapour and HI plus CH3COOH is sent to another distillation column (B4). Fig 16. Distillation Columns B3 and B4 Fig 17. B3 Specifications Fig 18. B3 Specifications T&P Fig 19. B4 Specifications Fig 20. B4 Specifications T&P Here we separate CH3COOH and the HI as distillate is sent back as a recycle stream (Recycle2) Fig 21. Recycle Stream 2 to recycle HI back to the reactor Thus we recycle back 90% of the HI. A heater is used to get the recycle stream back to 300 C and 1 bar pressure (feed T&P). We get 320TPA of acetic acid with 99% purit Heat Exchanger Specification Fig 22. Product Stream Fig 23. Product Purity All Streams Fig 24. All feed + product streams HI (87.4599 k tonnes/year), CH3OH (184.668 k tonnes), Coal (140.984 k tonnes/ year), steam + water (47ktonnes/year) Fig 25. Recycle Streams Fig 26. Purge Stream Our Purge Streams are mostly Inert except for CO which can be oxidized to produce CO2
