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ENGINEERING
UNIVERSITY MALAYSIA PAHANG
BKF 3553
PROCESS SIMULATION & COMPUTER AIDED DESIGN
LECTURER: DR ING- RIZZA BIN OTHMAN
MINI PROJECT
PREPARED BY:
CHOO WEI CHUN
KE11037
KE11029
KA11206
KA11182
KA11178
DATE OF SUBMISSION:
27th MAY 2014
Table of Contents
1.0
INTRODUCTION ............................................................................................................3
1.0
INTRODUCTION
The first desired reaction is exothermic while the second is an endothermic reaction. The
projects target is to design a plant with a capacity of 50,000 metric ton formalin/annum
with the operating days of 49weeks/343 days in a year. This plant is to include three
major units; a reactor, an absorber and a distillation column. Also it includes pumps,
compressors and heat exchangers. All are to be designed and operated according to this
production capacity.
3
1.1.3 Objectives
1. To study an integrated design of a plant for formaldehyde production with
specified capacity in a point of view in chemical engineering.
2. To investigate the entire process unit design of the plant such as process flow
diagrams and operation parameters.
To apply knowledge of mass and heat transfer, fluid dynamics, unit operations,
Diagrams, design of the reactor, design of heat exchangers, design of the absorber
and distillation column and energy optimization in the project.
Figure 1.2.1 is a process of producing formalin (37 wt% formaldehyde in water) from
methanol using the silver catalyst process.
Air (0.21% Oxygen; 0.79% Nitrogen; 25 C; 1 atm) is compressed and mixed the
methanol (30 C; 1.2 bar) which has been preheated, fresh and recycled to provide
reactor feed. The feed mixture contains around 39 mol% methanol in air, which is more
than upper flammability limit for methanol. (For methanol, UFL= 36 mol%; LFL= 6
mol%).
In the PFR reactor, there are two reactions happen:
The reactor (length 0.347m and diameter 0.050799m) is using the silver catalyst (Bed
voidage 0.5 and particle density 1500 kg/cum), in the form of wire gauze, suspended
above a heat exchanger tube bank. It is a must to the remove the heat produced in the
adiabatic reactor section due to the net reaction is highly exothermic, thus the close
proximity of the heat exchanger tubes. Inside the heat exchanger, there is a pool of water
on the shell side. The set point on a level controller is adjusted when it detects the
temperature of the effluent is very high. The level controller will send signal to the
boiler so that to increase the feed water rate entering from the reboiler to the heat
exchanger to increase the water vaporization rate to remove more heat. In general, the
liquid-level controller on the boiler feed water is adjusted to keep the tube bundle fully
immersed. The reactor effluent enters an absorber in which most of the methanol and
formaldehyde are absorbed into water, with most of the remaining light gas purged into
the off-gas stream. The formaldehyde, the methanol, and water enter a distillation
column, in which the overhead product, methanol is recycled; the bottom product,
formaldehyde/ water mixture that contains <1 wt% methanol as an inhibitor. Due to
there are some batch downstream process, this mixture send to a storage tank after
cooling. A suitable amount of water is added inside the storage tank when the
downstream process draws from the storage tank because the composition in the storage
tank exceeds 37 wt% formaldehyde. The storage tank contents must be maintained
between 35C and 45C to prevent unfavourable conditions like polymerization and
formic acid formation from happening. Figure 1.2.2 shows the block flow diagram of
formalin production.
Where p is a partial pressure in atm, and m refers to methanol. The rate expression is
only valid when oxygen is present in excess. The constants are defined as:
Where T is in Kelvin, the rate data as follows for the side reaction:
Standard enthalpies of reaction (298 K, 1 atm) for the two reactions are given as:
10
2.0
11
Since CH2O and H2O has the same no. of mole of CH2(OH)2 produced, therefore, no. of
mole of CH2O and H2O feed is
Mole (kmol/yr)
Mass (MT/yr)
Formaldehyde
1041666.67
31280.00
Water
1041666.67
18720.00
Formalin
1041666.67
50,000.00
13
Pump
Heater 1
Compressor
Heater 2
Mixer 2
PFR
Chiller
Absorption Tower
Distillation
Column
Description
Mixing of pure methanol and recycled methanol.
Inlet and outlet temperature 30oC and pressure 1.5 bar.
Inlet and outlet flow rate 76.92 kmol/hr.
Outlet pressure of methanol at 3 bar.
To heat the reactant from 30 oC to 150 oC
To decrease pressure from 3 bar to 2.65 bar.
Vapour-liquid valid phase.
Compress air.
Inlet temperature and pressure are 25 oC and 1 atm.
Outlet temperature and pressure are 174 oC and 3 bar.
Inlet and outlet flow rate 145.94 mol/hr
Oxygen mole fraction: 0.21
Nitrogen mole fraction: 0.79
To heat the reactant from 174 oC to 200 oC
To decrease pressure from 3 bar to 2.65 abr.
Vapour-liquid valid phase.
To mix methanol and air.
Outlet temperature is 175 oC after mixing.
Operation set at 200 oC
Reactor length 0.347m and diameter 0.050799m
Catalyst present in the reactor
Bed voidage is 0.5
Particle density is 1500 kg/cum
Decrease temperature to 100 oC and pressure to 1.5 bar.
Vapour-liquid valid phase.
Rate-based calculation type
30 number of stages
Condenser pressure 1.5 bar
Feed streams above stage 1 (intermediate product)
Feed streams on stage 30 (water)
Equilibrium calculation type
31 number of stages
Total condenser
Reflux ratio of 37.34
Bottom rate is 1 kmol/hr
Condenser pressure 1.5 bar
Feed stream at 18th stages
14
n8 = 319.67 kmol/hr
xCH3OH = 0.240622
xO2 = 0.096041
xH2O = 0.302024
xN2 = 0.3613067
n9 = 356.46 kmol/hr
xCH3OH = 0.0825945
xO2 = 0.0561529
xCH2O = 0.1331915
xH2O = 0.3308004
xH2 = 0.0732467
xN2 = 0.3240139
Assumption:
Adiabatic
No pressure drop
Absorber
n11 = 143 kmol/hr
xH2O = 1
15
Distillation column
Assumption:
16
3.0
Substream: MIXED
Mole Flow kmol/hr
METHANOL
OXYGEN
FORMA-01
WATER
HYDROGEN
NITROGEN
Mole Frac
METHANOL
OXYGEN
FORMA-01
WATER
HYDROGEN
NITROGEN
Mass Flow kg/hr
METHANOL
OXYGEN
FORMA-01
WATER
HYDROGEN
NITROGEN
Mass Frac
METHANOL
OXYGEN
FORMA-01
WATER
HYDROGEN
NITROGEN
Total Flow kmol/hr
Total Flow kg/hr
Total Flow l/min
Temperature C
Pressure bar
Vapor Frac
Liquid Frac
Solid Frac
2
PUMP1
MIX1
LIQUID
3
HEATER1
PUMP1
LIQUID
4
MIX2
HEATER1
VAPOR
5
COM1
VAPOR
6
CHILLER1
COM1
VAPOR
7
MIX2
CHILLER1
VAPOR
8
PFR1
MIX2
VAPOR
9
CHILLER2
PFR1
VAPOR
10
ASB1
CHILLER2
VAPOR
11
12
ASB1
LIQUID
ASB1
VAPOR
13
DIST1
ASB1
LIQUID
14
MIX1
DIST1
LIQUID
15
DIST1
LIQUID
76.9200
0.0000
0.0000
0.0000
0.0000
0.0000
76.9200
0.0542
0.0000
96.5484
0.0019
0.2068
76.9200
0.0542
0.0000
96.5484
0.0019
0.2068
76.9200
0.0542
0.0000
96.5484
0.0019
0.2068
0.0000
30.6474
0.0000
0.0000
0.0000
115.2926
0.0000
30.6474
0.0000
0.0000
0.0000
115.2926
0.0000
30.6474
0.0000
0.0000
0.0000
115.2926
76.9200
30.7016
0.0000
96.5484
0.0019
115.4994
29.4420
20.0165
47.4780
117.9185
26.1098
115.4994
29.4420
20.0165
47.4780
117.9185
26.1098
115.4994
0.0000
0.0000
0.0000
143.0000
0.0000
0.0000
9.2637
19.9816
22.3521
134.7275
26.1084
115.3617
20.1783
0.0350
25.1260
126.1910
0.0015
0.1376
0.0000
0.0542
0.0000
96.5484
0.0019
0.2068
20.1783
0.0000
2.6307
126.1910
0.0000
0.0000
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.4428
0.0003
0.0000
0.5557
0.0000
0.0012
0.4428
0.0003
0.0000
0.5557
0.0000
0.0012
0.4428
0.0003
0.0000
0.5557
0.0000
0.0012
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
0.2406
0.0960
0.0000
0.3020
0.0000
0.3613
0.0826
0.0562
0.1332
0.3308
0.0732
0.3240
0.0826
0.0562
0.1332
0.3308
0.0732
0.3240
0.0000
0.0000
0.0000
1.0000
0.0000
0.0000
0.0283
0.0610
0.0682
0.4110
0.0796
0.3519
0.1175
0.0002
0.1464
0.7351
0.0000
0.0008
0.0000
0.0006
0.0000
0.9973
0.0000
0.0021
0.1354
0.0000
0.0177
0.8469
0.0000
0.0000
2464.6830
0.0000
0.0000
0.0000
0.0000
0.0000
2464.6830
1.7334
0.0000
1739.3460
0.0039
5.7923
2464.6830
1.7334
0.0000
1739.3460
0.0039
5.7923
2464.6830
1.7334
0.0000
1739.3460
0.0039
5.7923
0.0000
980.6800
0.0000
0.0000
0.0000
3229.7470
0.0000
980.6800
0.0000
0.0000
0.0000
3229.7470
0.0000
980.6800
0.0000
0.0000
0.0000
3229.7470
2464.6830
982.4134
0.0000
1739.3460
0.0039
3235.5390
943.3853
640.5046
1425.5880
2124.3350
52.6343
3235.5390
943.3853
640.5046
1425.5880
2124.3350
52.6343
3235.5390
0.0000
0.0000
0.0000
2576.1850
0.0000
0.0000
296.8288
639.3862
671.1491
2427.1530
52.6314
3231.6840
646.5566
1.1184
754.4387
2273.3660
0.0030
3.8556
0.0000 646.5565
1.7334
0.0000
0.0000
78.9901
1739.3460 2273.3660
0.0039
0.0000
5.7923
0.0000
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
76.9200
2464.6830
52.1992
30.0000
1.2000
0.0000
1.0000
0.0000
0.5852
0.0004
0.0000
0.4130
0.0000
0.0014
173.7313
4211.5590
82.3914
30.6548
1.2000
0.0000
1.0000
0.0000
0.5852
0.5852
0.0000
0.0000
0.0004
0.0004
0.2329
0.2329
0.0000
0.0000
0.0000
0.0000
0.4130
0.4130
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0014
0.0014
0.7671
0.7671
173.7313
173.7313
145.9400
145.9400
4211.5590 4211.5590 4210.4270 4210.4270
82.4082 37588.4600 59481.0300 30178.8500
30.8119
150.0000
25.0000
174.2000
3.0000
2.6500
1.0133
3.0000
0.0000
1.0000
1.0000
1.0000
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.2329
0.0000
0.0000
0.0000
0.7671
145.9400
4210.4270
36135.6900
200.0000
2.6500
1.0000
0.0000
0.0000
0.0000
0.0406
0.0000
0.0874
0.0000
0.0917
1.0000
0.3316
0.0000
0.0072
0.0000
0.4416
143.0000
327.7949
2576.1850
7318.8320
43.4087 108331.0000
30.0000
87.0727
1.5000
1.5000
0.0000
1.0000
1.0000
0.0000
0.0000
0.0000
0.1757
0.0003
0.2050
0.6179
0.0000
0.0010
171.6693
3679.3380
75.3443
87.3135
1.5000
0.0000
1.0000
0.0000
0.0000
0.2156
0.0010
0.0000
0.0000
0.0263
0.9957
0.7581
0.0000
0.0000
0.0033
0.0000
96.8113 149.0000
1746.8760 2998.9130
34.2124
59.1553
-43.3864 103.9483
1.5000
1.5000
0.0000
0.0000
1.0000
1.0000
0.0000
0.0000
0.2926
0.1120
0.1120
0.1166
0.0761
0.0761
0.0000
0.1693
0.1693
0.2065
0.2522
0.2522
0.0000
0.0062
0.0062
0.3842
0.3842
0.3842
319.6713
356.4642
356.4642
8421.9860 8421.9860
8421.9860
72856.2000 87930.6300 122158.0000
165.2305
200.0000
100.0000
2.6500
2.6500
1.5000
1.0000
1.0000
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
17
Discussion
We unable to solve the material for block DIST1 which is a rigorous distillation column
calculation. This is because the method used unable to model the behaviour of formaldehyde that
is provided by our reference. In Turton, formaldehyde is assume to follow the water but our
simulation method assume formaldehyde has very weak solubility in water and very volatile. KValue for formaldehyde/water/methanol system is provided in the Turtons reference, however
aspen does not feature that allow the use of this data. Furthermore, distillate of this block
supposedly to contain mostly methanol is recycled back which further complicate the calculation.
The complexities lead to the program unable to solve the calculation under a maximum 200
iteration.
From Turton reference, formaldehyde is able to be nearly fully absorbed by water with 99%
recovery at stream 13. However in our simulation, 47.07% of the formaldehyde is wasted at
stream 12 which is an off-gas stream. This suggests that the NRTL-HOC thermodynamic method
model the formaldehyde properties as more volatile and less soluble in water than it should in
experiment. We have tried more other thermodynamic properties such as NRTL-NTH, UNIFAC,
UNIQUAC but the result remains roughly the same.
Therefore, we recommend that aspen tech should add a feature whereby user is able to key in
experimental K-value data and the program is able to use the data to model the separation process.
18
19
References
Gerberich, H.R., and G.C. Seaman (2004). Formaldehyde, Kirk-Othmer Encyclopedia of
Chemical Technology, on-line version (New York: John Wiley & Sons).
H. Renon and J.M. Prausnitz, (1968). "Local Compositions in Thermodynamic Excess Functions
for Liquid Mixtures," AIChE J., Vol. 14, No. 1, pp. 135 144.
Ott, M., Schoenmakers, H. and Hasse, H. (2005). Distillation of formaldehyde containing
mixtures: laboratory experiments, equilibrium stage modeling and simulation. Chemical
Engineering and Processing: Process Intensification, 44(6), pp. 687--694.
Turton, R., Bailie, R., Whiting, W. and Shaeiwitz, J. (2009). Analysis, synthesis, and design of
chemical processes. 3rd ed. Upper Saddle River, N.J.: Prentice Hall PTR.
20