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CHAPTER 2
2.1
Introduction
The process overview illustrates the urea plant process design. This diagram
is a layout of all units operation, which are needed in proper sequence to convert the
raw material to desired product, ethylene glycol.
The plant is to produce a total amount of 100,000 metric ton ethylene glycol
per annum. The operating day for this plant is 335 days per year and 24 hours a day.
The purity of the urea in the market is 99.8% for glycol industrial grades and 98%
for glycol antifreeze grade.
In this ethylene glycol plant design, several main synthesis and other process
will involve there are :-
Mixing section
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There are several ethylene glycol synthesis methods but those synthesis
methods have different raw material and yield different composition as well as the
product composition.
These are the synthesis methods that have been discussed in Chapter 1:
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In order to produce 203.58 kgmol/hr of Ethylene Glycol, the flow rate of the
reactant that we need to obtain the desired product is shown below :
Ethylene Glycol production rate = 203.58
= 230.73
= 2768.72
Hence, to produce 203.58 kmol per hour of Ethylene Glycol, we need 230.58
kmol per hour of Ethylene Oxide and 2768.72 kmol per hour of Water in the reactor
feed stream.
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2.2.3
According to the third synthesis step, there are several product stream components
which involves with separation process.
Flash Drum
Monoethylene
Glycol
Ethylene Oxide
Diethylene
Glycol
Triethylene
Glycol
Flash Drum
Monoethylene
Glycol
Ethylene Oxide
Water
Diethylene
Glycol
Triethylene
Glycol
Water
Monoethylene
Glycol
Water
Diethylene
Glycol
Triethylene
Glycol
Water
Evaporator
Monoethylene
Glycol
Diethylene
Glycol
Triethylene
Glycol
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Distillation Column
Monoethylene Glycol
Monoethylene
Glycol
Diethylene
Glycol
FC1
Triethylene
Glycol
Diethylene Glycol
Triethylene Glycol
MonoEthylene Glycol
197.0
DiEthylene Glycol
245.0
TriEthylene Glycol
288.0
Ethylene Oxide
10.7
Water
100.0
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2.2.4
From the figure 2.1, we can see that, to eliminate the difference between
temperature, pressure and phase, we are using temperature changer which is heat
exchanger and for pressure, we are using compressor and pump to change the
pressure.
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2.3
Process Description
2.3.1 Mixer
The multiple input streams are mixed well before they are entering reactor to
ensure that all the reactant is perfectly mix each other. The mixer helps to maximize
the reaction in Plug Flow Reactor on the next stage operation point. Feed to the
reactor is a fresh raw material and recycle stream of ethylene oxide and water.
50
The plug flow reactor model (PFR, sometimes called continuous tubular
reactor, CTR) is a model used to describe chemical reactions in continuous, flowing
systems of cylindrical geometry. It runs at steady state with continuous flow of
reactants and products.
51
Because the vapor and liquid are in such close contact up until the "flash"
occurs, the product liquid and vapor phases approach equilibrium. So it can separate
ethylene oxide from ethylene glycol and water of the stream S-7. One more flash
separator is operates to separate ethylene oxide and water from mono, di and
triethylene glycol of the stream S-20. The main advantage of flash drum is the
relatively low cost.
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2.3.5
Evaporator
While, the second effect unit evaporator evaporates the vapor ethylene oxide
and water which are not evaporate in EVA-01 and send to waste treatment system
via S-15. The boiling temperature of water decreases as pressure decreases, so the
vapor boiled off in first effect evaporator, EVA-01 is use to heat the second effect
evaporator, EVA-02.
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Same concepts apply to third effect evaporator EVA-03, the vapor boiled off
in EVA-02 is use to EVA-03 because multi-effect evaporator is a sequence of
vessels. The water vapor is evaporates in this unit and recycle back to S-16 before
entering mixer MIX-01. Then, the liquid components stream, S-13 entering the flash
column V-002.
2.3.6
Compressor
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2.3.7
Pump
This is isothermal pump increasing the pressure of stream S-13 from 0.0987
atm to 1 atm by moving the fluids. Pump is identical to compressor but differ only in
the phase involves. Pump is dealing only with liquid phase while compressor is only
for gas phase.
2.3.8
Heat Exchanger
Heat exchanger used to transfer heat into or from the stream to the process
fluid. In most chemical reaction process heat transfer is required to heat up or cool
down the stream of fluid.
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In this plant we used several heat exchanger shell and tube type such as
Heater (HX-01), (HX-05), (HX-06) and Cooler (HX-02), (HX-03), (HX-04).
Heater (HX-01): This is heater that increases the temperature of the stream S-4 to
120oC. Ethylene oxide and water stream S-4, change phase from liquid to vapor
before entering plug flow reactor R-001.
Cooler (HX-02): This is cooler that decrease the temperature of the ethylene glycol
stream S-6 to 98oC.
Cooler (HX-03): This is cooler that decreases the temperature of the recycle
ethylene oxide stream S-8 to 5oC. Ethylene oxide stream S-9, change phase from
vapor to liquid before entering mixer MIX-01.
Cooler (HX-04): This is cooler that decreases the temperature of the recycle water
stream S-17 to 5oC and fed to mixer MIX-01.
Heater (HX-05): This is heater that increases the temperature of the stream S-19 to
160oC.
Heater (HX-06): This is heater that increases the temperature of the stream S-22 to
197.3oC.
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2.4