College of Engineering and Petroleum
Chemical Engineering Department
Plant Design (ChE 491)
Hysys Task
Production of Ethanol
Group Members:
Khalid al-Sulaili
204215889
Mosleh Mohammed
207217019
Omar Ali
205112892
Yousef bahbahani
207111495
Eid Ali
206113669
Presented by:
Prof. Mohamed A. Fahim
Eng. Yusuf Ismail Ali
1
TABLE OF CONTENTS :
Page
Abstract
2
Table of contents
3
List of Tables
4
Introduction
5
Hysys simulation program
6-11
Process Description
7-44
Process Equipments
Material Balance
45-48
49
2
LIST OF TABLES :
Contents
Table-1 : the change of conversion for each reaction in the
first reactor
Page
21
Table-2 : Summary of columns
45
Table-3: Summary of reactors
46
Table-4:Summary of Heat Exchanger,Heaters and coolers
46
Table-5:Summary of Compressors
46
Table-4:Summary of Heat Exchanger,Heaters and coolers
46
Table-6: Summary of separator
47
Table-7: Summary of energy streams
Table-8: Mass flow for inlet and outlet streams
47
48
3
ABSTRACT :
In this report we used the simulation software hysys to
simulate ethanol production from syngas by completed
material balance, and we will mention in detail about all
equipment we used. Various data were recovered from
different resources and assumptions have been made to
simplify the simulation process.
4
5
INTRODUCTION :
Our Process is Ethanol Production From Syngas
Ethanol considered as renewable fuel which has received attention in recent years
for its use in automobiles and as a potential source of hydrogen for fuel cells .
Ethanol synthesis involves the reaction between CO and H2 ( syngas) under high
pressure = 1640 psia and temperature = 617 F
The main reactions are:
2CO(g) + 4H2(g) → C2H5OH(g) + H2O(g)
There are several other side reactions that produce : acetaldehyde,acetic acid and
ethyl acetate.
It is a catalytic reaction and the catalyst used in the reaction is Rhodium over silica
gel Rh/SiO2 catalyst.
6
HYSYS Simulation Description:
Objectives :
- To describe the how to use HYSYS simulator
-To be able to design Chemical plant using HYSYS simulator
-To introduce some other chemical design simulators.
Introduction:
HYSYS is a powerful engineering simulation tool , has been uniquely created with
respect to the program architecture ,interface design , engineering capabilities , and interactive
operation . The integrated steady state and dynamics modeling capabilities , where the same
model can be evaluated from either perspective with full sharing of process information ,
represent a significant advancement in the engineering software
industry . the various
components that comprise HYSYS provide an extremely powerful approach to steady state
modeling .At a fundamental level , the comprehensive selection of the operations and property
methods allow you to model a wide range of processes with confidence .
To comprehend why HYSYS is such a powerful engineering simulation tool, you need look no
further than
its
strong thermodynamics
foundation .The inherent flexibility contributed
through its design ,combined with the un paralleled accuracy and robustness provided by its
property package calculation leads to the presentation of a more realistic model .HYSYS is
widely used in universities and colleges in introductory and advanced courses especially in
chemical engineering .In industry , the software is used in research , development ,modeling and
design .
Getting Started:
With windows, the installation process creates a shortcut to HYSYS :
Click the icon to start HYSYS
Or
1-click on the Start menu
2-Move from Programs to Hyprotech to HYSYS
3- Select HYSYS .
7
Fig 2.1:HYSYS starting window
Setting your Session Preferences :
1- To start a new simulation case , do one of the following :
-
From the File menu, select New Case.
-
Click the New Case icon and the simulation basis manager will appear

Creating a fluid Package
The next step is to create a fluid Package .As a minimum , a Fluid Package contains the
Components and property method (for example , an Equation of State )HYSYS will use in its
calculations for a particular flow sheet . Depending on what is required in a specific flow sheet ,
a fluid Package may also contain other information such as reactions and interaction parameters .
1- On the Simulation Basis Manager view , click the fluid Pkgs tab.
2- Click the Add button , and the property view for your Fluid Package appears
8
Fig 2.2 :Specify the fluid Package
Select a Fluid Package and HYSYS will find the match to your input
We choose UNIQUAC as a fluid package because the activity coefficients can be used to predict
simple phase equilibria (vapour–liquid, liquid–liquid, solid–liquid), or to estimate other physical properties.
They are commonly used in process simulation programs to predict the phase behavior of
multicomponent chemical mixtures.
Selecting Components :
Now that you have chosen the property Package to be used in the simulation , the next step is to
select the components .
1- On the component List Selection drop-down , select Component List -1, if it is not already
existed
2- Click the view button , the Component List View appear
9
There are number of way to select components for your simulation . One method is to use the
matching feature . Each component is listed in three ways on the selected tab :

Sim Name : The name appearing within the simulation .

Full Name :IUPAC name (or similar ), and synonyms for many components

Formula : The chemical formula of the component .
At the top of each of these three columns is a corresponding radio button. Based on the selected
radio button ,HYSYS will locate the component(s) that best matches the input in the match cell
.
3- Select component and add pure
4- For other that is not exist in HYSYS , is added by the user ,Click to Add HYPO , create your
new material and fill the new material properties
Fig 2.3 : Selecting Components
10
Selecting Reactions
Then we select reactions to set the reactions we have in the process:
-We put to sets because we have to reactors:
1-First reactor
 has the main reaction and 3 side reaction:
The main reaction : ( in the gas phase)
carbon monoxide + hydrogen  ethanol + water
2CO(g) + 4H2(g) → C2H5OH(g) + H2O(g)
The side reactions :
Ethanol  Acetaldehyde + hydrogen
C2h5OH  CH3CHO + H2
Ethanol + water  acetic acid + hydrogen
C2H5OH + H2O  CH3COOH + H2
Ethanol + acetic acid  Ethyl acetate + water
C2h5OH + CH3COOH  CH3COOCH2CH3 + H2O
2- Second reactor  has one side reaction:
11
Ethyl acetate + water  ethanol + acetic acid
CH3COOCH2CH3 + H2O  C2h5OH + CH3COOH
Entering the simulation Environment :
To leave the Basis environment and enter the Simulation environment
To leave the Basis environment and enter the simulation , do one of the following :

Click the enter Simulation Environment button on the Simulation Basis Manager view

Click the Enter Simulation Environment icon on the tool bar
When you enter the Simulation environment , the initial view is the PFD (HYSYS default
setting )
12
Process Description:
A feed stream 1 of syngas which contain hydrogen and carbon monoxide at 100 F and 300 psia is
fed to compressor K-100 to raise the pressure to 1038 psia in the outlet stream 1* and raise the
temperature to 420 F.
Table 1: Mass flow of compressor inlet feed:
Components
Mass flow( Ib/hr )
Hydrogen
18743
Carbon monoxide
153280
13
The outlet stream 1* from compressor will enter the mixer and will mix with the
recycled stream came from the absorber by MIX-100
14
The outlet stream 2 from mixer is fed to heat exchanger E-100 with the steam at
662 F and 2397 psia in which it heated stream 2 to 592 F as in stream 2* by
exchange the the heat with a steam stream with temperature = 662 F
and a molar flow = 39000 kgmole/h.
The effluent stream 2* from heat exchanger is fed to heater E-101 which it heated
the stream 2** to 617 F and 1640 psia which is the appropriate condition for the
reaction in the reactor.
15
The stream 2** enter the first reactor with a temperature = 617 F and a pressure =
1640 psia and mass fraction of :
16
17
Reactor 1 :
- The reactor is a conversion reactor.( packed bed reactor)
- The feed enter in the gas phase and also the reactions in the gas phase.
- The reactor is isobaric reactor.
- The main reaction is exothermic so the outlet stream are high temperature.
- We choose set 1 in the reaction where it has 4 reactions : 1 main and 3 side
reactions.
The side reacions:
18
Fig( )
Fig( )
19
Fig( )
Fig( )
20
After we solved the reactor the amount of ethanol that produced from the reactor is small and
under our desired amount, so we have tried to change the conversion of each reaction to get our
desired amount or approximately equal.
Table-1: explains the change of conversion for each reaction
Reactions
First Estimation
Second Estimation
Third Estimation
Rxn 1
80
70
60
Rxn 2
40
35
20
Rxn 3
40
35
20
Rxn 4
40
35
20
There are two outlet streams from the reactor:
- 2*** stream with zero flow rate because the reactions are in the vapor phase ,
since the conversion reactor gives us two streams : liquid and vapor.
- stream 3 with a temperature = 767.14 F and pressure =1640 psia , and it has a
composition mass flow as in the figure :
21
The effluent stream 3 is fed to heat exchanger E-102 which it cooled the stream 3* to 140 F
by exchange the the heat with a water stream with temperature=77 F
and a molar flow = 30000 kgmole/h .
Stream 3 * then enter the separator (V-100) to seperate H2 and CO in the vapor phase (stream
v3) to recycle it . The liquid stream (L3) sent to absorber (T-100) to absorb all mono oxide to
recycle it . The advantage from recycling the unreacted feed:
-
To converge the syngas to get more ethanol and then high efficiency.
-
To have a constant ratio of 3:1 for H2:CO before entering the reactor.
22
Fig: Absorber
The number of stages we put was 10 stages and we put didn't put any specification because the
absorber doesn't need it.
23
The outlet streams of the absorber are :
1- The overhead Stream 4 where it has only CO and H2 :
Then stream 4 and stream v3 are mixed with (MIX-102) and sent to air compressor K101 to raise the outlet stream rec* temperature from 131 F to 154 F .
Then the stream is mixed with the feed stream 1* as we mentioned above.
24
The bottom stream 7 from the absorber will enter the first distilation that is called (acetaldehyde
column) .Seperation process will take place in this column. This column is used to separate
acetaldehyde (as a overhead) from other compounds.
First Ditillation (Acetaldehyde coloumn )
25
In the first column the specifaction we add to get converged:
- Total condenser distillation coloumn.
-number of stage =10
-reflux ratio of the condenser = 5
-Distillate rate to recover acetaldehyde in stream 8 = 21600 (Ib/h)
26
Mass flow rate of Stream 8:
27
The bottom stream contains mainly ethanol with other compounds in stream 9 which will
enter the second column (ethyl acetate column1).
Mass flow rate of Stream 9:
28
In this column is used to separate ethyl acetate in the over head product and the other
components will exist from the bottom stream 11 .
Second Distillation (ethyl acetate column1)
29
In the second column the specifaction we add to converged:
-number of stage = 10
-reflux ratio of the condenser = 2
-comp recovery for ethyl acetate in the upper stream=0.99
30
The recycled stream from the third distillation(ethyl acetate column 2) will mix with the
overhead product from the second distillation by (MIX-102) to enter the second reactor at
temperature = 81 F and pressure = 15 psia.
31
Reactor 2 :
32
-
The reactor is a conversion reactor. (Packed Bed Reactor)
-
The feed enter in the liquid phase and also the reactions in the liquid phase.
-
The reactor is isobaric reactor.
-
We choose set 2 which has 1 reaction :
Ethyl acetate + water  ethanol + acetic acid
The bottom liquid stream 13 from the reactor is sent to mixer (MIX-103) to enter the third
distillation with water( stream 14).
33
The third distillation ( ethyl acetate removal column)
34
The third distillation we put to recycle ethyl acetate by getting it from the upper head stream
because we need it as a feed with water in the second reactor
At the same time the bottom stream 11 from the second distillation will be mixed with the
bottom stream from the third distillation by mixer (MIX-104) to enter the fourth
distillation(ethanol column) to separate ethanol from other compounds.
In the third column the specifaction we add to get converged:
-number of stage =10
- Pressure of the condenser and the reboiler = 15 psia
-reflux ratio of the condenser = 1
- Mass flow of H2O in the top stream 15 = 20000 (Ib/h)
35
As we mentioned above the bottom streams of the second and the third distillations are
mixed together by a mixer MIX-104 to enter the fourth distillation ( Ethanol coloumn) to
separate ethanol from other components.
36
The fourth distillation ( Ethanol coloumn)
This coloumn we put to recover our main product ( ethanol) and separate it from acetic acid
which will be recovered by the fifth distillation.
In the fourth column the specifaction we add to get converged:
-number of stage =25
- Pressure of the condenser and the reboiler = 15 psia
-Coponent fraction of stream 18 = 0.94 for ethanol.
- Ethanol flow rate =74300 ( Ib/h)
37
We get ethanol mass flow in the upper stream = 74300 (Ib/h)
38
The bottom stream 19 enter the fifth distillation ( acetic acid coloumn) to recover acetic acid
in the upper stream and get rid of the waste in the bottom stream.
The Fifth distillation ( acetic acid coloumn)
39
In the fifth column the specifaction we add to get converged:
-number of stage =10
- Pressure of the condenser and the reboiler = 15 psia
-reflux ratio of the condenser = 2
- H2O recovery in the upper stream –since H2O boiling point is less than acetic acid- = 0.99
40
41
We get acetic acid flow rate = 24173(Ib/h)
The bottom stream is waste , so we get rid of it
42
Process Equipments:
- Several units are involved in this process. Reactors, columns, compressors, and heat
exchangers are examples of these units so each category will be discussed briefly.
1. Columns
Table-2 :Summary of columns
Column
Name
Number of
Stages
Top
Bottom
Temperature Temperature
( F)
( F)
Top
Pressure
(psia)
Bottom
Pressure(psia)
T-100
10
97.7
128.3
14.5
14.5
T-101
10
157
254
72
72
T-102
10
149
189.9
15
15
T-103
10
79.7
178.4
15
15
T-104
25
77
210
15
15
T-105
10
211
218
15
15
43
2. Reactors:
Table-3: Summary of reactors
Reactor
Temperature(F)
Pressure(psia)
CRV-100
617
1640
CRV-101
81
15
4. Heat Exchangers , Heater and coolers:
Table-4:Summary of Heat Exchanger,Heaters and coolers
Unit
ΔT (F)
E-100 (HE)
235
E-101 (Heater)
14
E-102 (Cooler)
350
5. Compressors:
Table-5:Summary of Compressors
Unit
ΔP(kpa)
K-100
5086
K-101
20
44
6. Separators:
Unit
V3(kg/h)
L3(kg/h)
V-100
316780
75789
- Energy Consumption:
Table-6: Summary of energy streams
Energy stream
Heat flow Q(KJ/h)
q1
3.446*107
q2
5.059*107
q3
4.366*107
q4
3.388*107
q5
5.142*107
q6
4.12*107
q7
3*107
q8
7*108
q9
7*108
q10
3.8109
q11
3.8*109
q12
1.72*108
q13
1.723*108
Material balance
45
The inlet streams are:
stream 1 + stream water1 + stream 14 = 186973.2 ( Ib/h )
The outlet streams are:
stream 8 + stream 18 + stream 20 + stream 21 = 186972.97 (lb/h)
Table-8: Mass flow for inlet and outlet streams
Mass
Stream
Flow (Ib/h)
1
Stream
Stream
Water 1
14
Stream
Stream
Stream
Stream
8
18
20
21
Co
153280
0
0
713.33
9.8368e26
1.2565e24
2.0157e-25
H2
18743
0
0
180.36
6.7105e27
8.5719e26
1.3751e-26
H20
0
992900
7000
1.3044
36424
51700
527
Ethanol
0
0
0
8.3246e-4
74259
795
2.1547e-6
Acetic acid
0
0
0
5.5774e-7
1623.1
24137
2192
Acetaldehyde 0
0
0
18390
757.51
1.2912e-4
3.3536e-18
Ethyl acetate
0
0
3.5955
1479.6
2.2356e-5
3.8835e-20
0
Error = 0.0%
46
75.7
110.47
388780
37.7
2068.4
Temp.(c)
Pressure
(kpa)
Flow rate 78030
(kg/h)
2
1
Stream
No #
388780
11307
408.41
3
276.8
100
42
4
0
100
60
5
311420
100
60
6
80970
100
57.7
7
9800.3
500
73.3
8
71170
500
123.6
9
22298
103.4
66
10
Table() :Stream information overall plant
47
48
27.3
103.4
55006
0
82
103.4
55006
0
Temp.(c)
Pressure
(kpa)
Flow rate
(kg/h)
12
11
Stream
No #
55006
0
103.4
25.2
13
3175.2
101.3
35
14
53054
0
103.4
29.55
15
22694
103.4
85.36
16
71565
103.4
83.557
17
35850
100
77.57
18
35715
100
98
19
34481
103.4
99
20
1233.9
103.4
103
21