FACULTY OF CHEMICAL & NATURAL RESOURCES ENGINEERING

Project
Material & Energy Balance (BKF2343)

Project Objective:
The aim of this project is to produce 5000 metric ton per annum of acrylic acid (AA). Your main
objective in this work is to generate a process flow diagram (PFD) and conduct the material and
energy balances for the production of AA.

Project Description:
Acrylic acid (AA) is used as a precursor for a wide variety of chemicals in the polymers and textile
industries. There are several chemical pathways to produce AA, but the most common one is via
the partial oxidation of propylene. The oxidation of propylene to AA is an endothermic reaction
and carried out in vapor phase with steam in a single reactor. The steam serves as diluent for
several functions: delivers heat for the reaction, keeps the catalyst in the appropriate oxidation
state, and prevents deactivation by coke formation. The major reaction for AA production is the
oxidation of propylene (C3H6) into AA (C3H4O2) and water (H2O):

3
Main reaction: 3 6 + 3 4 2 + 2
2 2

Among the side reactions that competing the main reaction is the production of acetic acid
(C2H4O2):
5
Side reaction: 3 6 + 2 2 4 2 + 2 + 2
2

The typical operating conditions in the reactor are in the temperature range of 250 330C. Above
330C, the catalyst starts to coke-up (carbon deposits on the surface of the catalysts causing it to
deactivate), and below 250C the rate of reaction drops off rapidly. Due to these effects, the
catalysts should never be operated outside of these temperature limits. It is recommended that the
steam-to-propylene ratio at the reactor inlet never be set less than 4:1 on a mole basis. This steam
is used to inhibit the formation of coke on the catalyst below temperatures of 330C. After reaction,
it is essential to cool the products (reactor effluent) quickly to avoid further homogeneous
oxidation reactions. The homogeneous combustion reactions will not take place so long as the
reactor effluent is cooled to below 100C immediately after the reactor. The products and the
diluent then undergo phase transition from vapor to liquid through a series of separation units (i.e.
phase separator, absorption, liquid-liquid extraction column and acid purification column). After
the separation, the unconverted propylene is then recycled if applicable.

Project Instruction:
1) Draw a process flow diagram (PFD) for the acrylic acid production.
2) Include appropriate compressor/pump and heater/cooler in your system.
3) State any assumption for your calculations.
4) Provide references for process variables (temperature, pressure, conversion, selectivity,
composition) used in your calculations.
5) Perform the material balance for every process unit involved.
6) Conduct the energy balance to evaluate amount of heat Q and/or W required/removed for
reactor, heater/cooler and separator available in the process.

Project Assessments:
This project will be evaluated based on the following distribution:
Report 70%
Interview 20%
Peer Evaluation 10%

Report format:
Report should contains the following:

Part 1 Introduction

Introduction of the product.

Application of the product.
Market survey Supply and demand of the product worldwide, major producers, prices.
Screening of synthesis route describe at least 2 possible synthesis routes for producing
the product. Discuss the feasibility of the route based on several factors: such as availability
of raw materials, complexity of the process, effectiveness/efficiency of the process,
preliminary safety and environmental issues.

Part 2: Material Balance and Energy Balance Calculations (Manual & Excel)

Draw the process flow diagram with all streams numbered.

Do the material and energy balances and show clearly all the manual calculations. State
any assumption you have made in your calculations.
Conduct the material and energy balance in MS Excel. Make sure that the calculations are
flexible for any value of basis.
Summarized all stream compositions in tables.
Reminder: A softcopy for MS Excel calculation must be submitted together with this
report.

Project due dates:

The final report to be submitted on the 13th week.
The interview session will be conducted in the 14th week (will be decided later)