ChBE Senior Design Presentation

8/12/2019 ChBE Senior Design Presentation

http://slidepdf.com/reader/full/chbe-senior-design-presentation 1/65

Design of an Ethylene ProductionPlant via Ethanol Dehydration

Team 06 – The Minions - Vedant Didwania, Luke Harris, Alia Khan, and Sarah Leung



Agenda

2

• Abstract• Project BackgroundExecutive Summary

• Reaction Scheme• Separation Scheme• Optimization

Optimum Design

• Projected Costs of Project• Market Pricing• Feasibility Simulation

Financial Analysis

• Environmental, Health, Safety Concerns• PotentialSustainability

• ConclusionFinal

Recommendations



BACKGROUND

Design of an Ethylene Production Plant via Ethanol Dehydration

3



Abstract

Assess the feasibility and sustainability of developingan ethylene production facility capable of producing

25,000 pounds per hour of 99.5% by weight ethylene

To be used in plastic production facility in the

Champaign-Urbana area 15-year project scope

350 production days per year

Currently: Plant is purchasing ethylene

4Background

ReactionScheme

SeparationScheme

Economics EHS Sustainability

Conclusions



Relevance of Ethylene

Most highly produced organic compound globally 141M tons of ethylene was produced last year,

Up by 3M from the previous year

Slated to increase by around 6M

Ethylene itself has no final use

Building block for a large array of chemical products

5Background

ReactionScheme

SeparationScheme

Economics EHS Sustainability

Conclusions



Innovation Map

6

EnvironmentallyF r ie n dl y

R e l ia b l e p r o d uc t i on f r o mn o n- f o s si l f u e l so u r ce

Polymer GradeE t h yl e n e

R e ne w a bl e LowerC a p it a l C o s t

S i m p le U n i tOperations

Produces Large

quantities of Product percracker

DehydrationReaction

C r a ck i n g

I n B r az i l In U S A

Ethanol fromS ug ar C an e

Ethanolf ro m C or n

Activated

AluminaCatalyst

SilicaC a t al y s t

SulfuricAcid

N a p h th a l e ne o r

o t h er F o s si lF u e l s o u rc e s

ABC ChemicalsV al u e

P r od u ct

Project Differences

Technology

R a w M at e r ia l



Ethanol Dehydration

Strengths: Simplicity

Environmentallyfriendly

Ethanol accessibility

Safer

Lower FCI than steam

cracking

Weaknesses: Higher raw material

cost

Smaller profit margin

7Background

ReactionScheme

SeparationScheme

Economics EHS Sustainability Conclusions



REACTOR SCHEME


8



Consists of feed pump, process heater, steam-injected reactorwith catalyst regenerator, two heat exchangers

Feed of 49473 lb/h of 95% ethanol and 4000 lb/h hps

Reaction Scheme

9Background

ReactionScheme

SeparationScheme




Feed Pump P-101

Centrifugal carbon steel0.242 hp pump

Feeds storage ethanolinto process heater

Provides pressuregradient for entiredownstream process

P-101 Flow (lbmol/h) 1157 Discharge Pressure (psig) 2 Temperature (F) 77 Driver Type Centrifugal Shaft Power (hp) 0.242 Material of Construction Carbon Steel Number of spares 1

10Background

ReactionScheme

SeparationScheme




Process Heater H-101

Stainless steel natural gasfed fired heater

Heats ethanol feed to720°F because reactor

cannot heat reactants Simulated by a electric

heater in ChemCAD

H-101 Type Fired Heater Tube Pressure (psig) 2

Tube Temperature 720 Duty (MJ/hr) 37300 Fuel Type Natural Gas Material of Construction Stainless Steel

11Background Reaction

SchemeSeparation

SchemeEconomics EHS Sustainability Conclusions



Recycle/Feed Mixing Valve

Three way valve to combine feed ethanol with recyclestream

Recycle stream has higher pressure therefore flow isdriven without need of pump

Improves safety and costs less Recycle placement determined on heat duty

If placed before H-101 would increase duty by 9% or

$300,000/yr


SchemeSeparation




Reactor R-101

Catalyzed PFR coupled withcatalyst regenerator

Operated isothermally bysteam injection

Activated alumina ascatalyst

Simulated in ChemCAD asisothermal Kinetic Reactor

Jacketed Agitated IsothermalPFR in CAPCOST

R-101 Type Jacketed Agitated

(Isothermal PFR) Volume (ft3) 1630 Operating Temperature

(F) 720

Operating Pressure

(psia) 23

Pressure Drop (psi) 4 Specifications Steam Injected


SchemeSeparation




R-101 Optimization

Sensitivity studies from Volume, Pressure, and Temperatureversus product flow rates to maximum ethylene productionwith optimizing ethylene selectivity

81% ethylene selectivity

1630 ft2 Reactor operating at 23 psia and 720°F

Catalyst options

Replacement every 90 days

4 reactors operating in series at 25% 50% 75% and 100%

catalyst purities Catalyst regenerator

Catalyst regenerator the cheapest option

14



Heat Exchanger E-101

Passes recycle streamwith reactor exit stream

Optimized by HEN

Savings of $560,000/yr in

operating by using heatintegration

E-101 Type Floating Head Duty (MMBtu/hr) 3.9 Area (ft2) 599 Temperature of

Shell/Tube (F) 700/600

LMTD End Points (F) 130.83 Pressure of Shell/Tube

(psig) 4.3/6.3

Number of passes 1-shell/2-tube Material of Construction

Shell/Tube Stainless Steel/Stainless

Steel


SchemeSeparation




Heat Exchanger E-102

Cools reactor exit streamfurther to separation

600°F to 185°F

Uses cooling water

Cheap and easy wayto cool

Optimized via HEN

methodology

E-102

Type Floating Head

Duty (MMBtu/hr) 25.2

Area (ft2) 1150

Temperature of

Shell/Tube (F) 105/185

LMTD End Points (F) 242.39

Pressure of Shell/Tube

(psig) 5/5

Number of passes 1-shell/2-tube

Material of Construction

Shell/Tube Carbon Steel/Carbon

Steel


SchemeSeparation




SEPARATION SCHEME


17



Process Flow Diagram

EthanolRecycle

Background ReactionScheme

SeparationScheme

Economics EHS Sustainability Conclusions18



Flash Tanks

Removes excess water from process Two tanks with interstage cooling to reduce utilities usage

and unit sizes

Sensitivity study on ChemCAD utilized to determine

operating temperature


SeparationScheme


V-101 V-102 Height (ft) 6.6 6.6

Diameter (ft) 2.2 2.2 Orientation Vertical Vertical

Pressure (psig) 4 4 Temperature (F) 185 110

Material of Construction Carbon Steel Carbon Steel CBM $16,700 $16,700

19



Distillation Towers

3 Towers

ChemCAD used to simulate tower design

CAPCOST used to determine bare module unit costs

CBM includes vessel, pump, partial condenser, and kettlereboiler


SeparationScheme


T-101 T-102 T-103Function Ethylene

RecoveryEthanol Recycle α-Butylene

Purity 99.5% wt. fraction - 99.8% wt. fraction

Production 25,527 lb/h

Ethylene

4,121 lb/h Ethanol 1,457 lb/h

ButyleneCBM $379,600 $264,300 $301,400

20



T-101 Optimization

Vary feed tray location to minimize condenser/reboiler duties

Feed location of 3 out of 6 trays optimal


SeparationScheme


T-101 Height (ft) 34

Diameter (ft) 1.8 Pressure (psig) 5 Temperature (F) Top: -128

Bottom: 61 Number of Trays 6

Feed Location 3 Reflux Rate 325

Type of Trays Stainless Steel Sieve Material of

Construction Stainless Steel

21



T-102 Optimization


Large reduction in duties can be seen in figure above


SeparationScheme



Diameter (ft) 2 Pressure (psig) 5 Temperature (F) Top: 83

Bottom: 182

Number of Trays

8


Type of Trays Carbon Steel Sieve Material of

Construction Carbon Steel

22



T-103 Optimization


Not middle tray for the α-Butylene tower


SeparationScheme



Diameter (ft) 2.3 Pressure (psig) 6.5 Temperature (F) Top: 35

Bottom: 92 Number of Trays

10


Type of Trays Carbon Steel Sieve Material of

Construction Carbon Steel

23



Other Tower Equipment


SeparationScheme


E-105 E-106 E-107 E-108 E-109 E-110 Type Floating Head,

partial

condenser Floating Head,

partial

condenser Floating Head,

partial

condenser Kettle Reboiler Kettle Reboiler Kettle Reboiler

Duty (MMBtu/hr) -4.4 -0.63 -0.80 0.45 1.8 0.04 Area (ft2) 141 190 113 118 74.8 180

Temperature -128 83 35 61 182 92 Pressure of

Shell/Tube

(psig) 5/5 4/4 5.3/5.3 6.3/6.3 5.5/5.5 6.3/6.3

Number of

passes 1-shell/2-tube 1-shell/2-tube 1-shell/2-tube Single Pass Single Pass Single Pass

MOC

Shell/Tube Stainless

Steel/Stainless

Steel Carbon

Steel/Carbon

Steel Carbon

Steel/Carbon

Steel Carbon

Steel/Carbon

Steel Carbon

Steel/Carbon

Steel Carbon

Steel/Carbon

Steel P-102 P-103 P-104

Flow (lbmol/h) 930 63 32 Discharge Pressure (psig) 4.3 6.3 6.5

Temperature (F) -128 83 35 Driver Type Centrifugal Centrifugal Centrifugal

Shaft Power (hp) 0.5 0.7 0.7 Material of Construction Stainless Steel Carbon Steel Carbon Steel

Number of spares 1 1 1

Heat Exchangers:

Pumps:

24



Design Decisions

Flash Tanks with interstage coolingDistillation tower use

T-102

T-103Partial Condenser

Kettle Reboiler

HEN IntegrationSide-product use


SeparationScheme




ECONOMIC ANALYSIS


26



Financial Analysis


SeparationScheme


• Annual Cost of Ethanol: -$138 million• Annual Revenue from Ethylene: $130 million

• Bare Module Costs: -$5.6 million• Annual Utility Costs: -$5.92 million

• NPV: -200.58 million

Quick Overview

27



Economic Feasibility

Production life of 15 years

2 years construction time

60% FCI Year 1, 40% FCI Year 2

Year 1 Start-up: 60% of

full production capacity. 350 production days

Land cost: $250,000

7-year Modified Accelerated

Cost Recovery System (MACRS) Discount rate: 10%

Tax rate of 40%


SeparationScheme




Cost Estimations


SeparationScheme


Fixed Capital Investment – ($9.53 million) Grassroots basis

Bare Module Costs

Working Capital – ($15.28 million)

Non-depreciable amount Raw Material, FCI, Operating Labor

Cost of Manufacturing Per Year - ($186.43 million) Tertiary Wastewater system

FCI, Catalyst Costs, Operating Labor Costs, Utility Costs, RawMaterial Costs

Catalyst Costs – ($50k at $2.20/kg)



Cost Components - Equipment

Fired heater accounts for over 64% of total equipment costs& 66.7% of utility costs.


SeparationScheme


Heat Exchanger

Fired Heater

Pumps

Reactors

Towers

Flash Tank



Profitability Analysis

(250,000,000.00)

(200,000,000.00)

(150,000,000.00)

(100,000,000.00)

(50,000,000.00)

-0 2 4 6 8 10 12 14 16

P r o j e c t V a l u e ,

$

Project Life, Years

Discounted Cumulative Cash Flow, Current Position

NPV: -200.58 million


SeparationScheme




Profitability Analysis


SeparationScheme




Fluctuating Nature - Ethylene


SeparationScheme


Price of the product can vary from -50% to 20% in a typicalanalysis



Fluctuating Nature - Ethanol


SeparationScheme


Raw material availability and pricing can fluctuate from adynamic range of -25% to 50%



Break Even Points: NPV

Price of Ethylene ($/lb) 0.670 0.680 0.690 0.700 0.710

Price of Ethanol ($/lb) Net Present Value ($, millions) 0.305 -63.16 -55.62 -48.08 -40.54 -33.01 0.300 -54.49 -46.95 -39.41 -31.87 -24.34 0.295 -45.82 -38.28 -30.74 -23.21 -15.67 0.290 -37.16 -29.62 -22.08 -14.54 -7.00 0.285 -28.49 -20.95 -13.41 -5.87 1.67 0.280 -19.82 -12.28 -4.74 2.80 10.34


SeparationScheme


Break even point: $0.283/lb ethanol and $0.695/lbethylene



Cash Flow Diagrams

36

CFD Scenarios

Ethylene($/lb)

Ethanol ($/lb) NPV PaybackPeriod

Current MarketPrice

0.61 0.35 -200.58M N/A

Increase in

Ethylene Price

0.892 0.35 +3.019M 2.9

Decrease inEthanol Price

0.61 0.237 +3.53M 2.8

Increase inEthylene andDecrease inEthanol Prices

0.710 0.280 +$2.84M 3.4


SeparationScheme




EH&S


37



Health and Safety Concerns

Importance of Safety

Based on decisions made by administrators

Legal and moral responsibility to employees and public

EH&S Concerns

Daily safety for plant operation Recommend tested pilot scale process

Thermal impact jacket to prevent heat buildup from reactorT&P

Transportation and storage of chemicals Endothermic reaction to avoid potential runaway


SeparationScheme





SeparationScheme


R-101 P&ID

39




SeparationScheme


T-101 P&ID

40



Environmental Considerations

Environmental Compliance - EPA Regulation

LDAR – Leak Detection And Response

MON – Miscellaneous Organic chemical NESHAP

HON – Hazardous Organic chemical NESHAP

NESHAP – National Emission Standards for Hazardous AirPollutants

Waste facility auditing

MSDS Reports

Purging Storage


SeparationScheme




SUSTAINABILITY


42



Corporate Culture

Process Safety Management Plan

Avenue for education and understanding of safety needs

Comprehensive management and advisory board

Emphasis on integrating safe technology and SOPs

Monthly meetings to discuss various incidents and share ideas

Safety awareness courses for all employees and administrators

Preventative first-aid proficiency courses

Industrial Recycling

Growing global market for scrapping and industrial recycling

Bureau of Industrial Recycling (BIR)

Possible to attain a higher salvage value for equipment and sideproducts


SchemeSeparation




Sustainability

Factors to Consider

Long term feasibility of operating the plant

Role of materials and products

Economic, societal and environmental impacts

Value proposition for the future

Price Sensitivity

Selling price of 1 lb ethylene vs purchase price of 1.84 lb ethanol

Operate when ethanol price is low, ethylene price high

Current prices are not favorable

Fluctuations in upstream product prices


SeparationScheme




Ethanol Price Trends


SchemeSeparation




Ethylene Price Trends


SeparationScheme




Economic Considerations

Economic Considerations

NPV target prices: $0.283/lb ethanol and $0.695/lbethylene

Current prices: $0.35/lb ethanol and $0.61/lb ethylene

Decreasing fossil fuel supply leading to increased crackingprices

Growing market for alternative fuel sources and moreefficient production methods

Realistic to expect these prices in the future

Background ReactionScheme SeparationScheme Economics EHS Sustainability Conclusions47



Accessibility

Location Factors

Transportation infrastructure and plant accessibility

Necessary to be able to access site to build and operate

Personnel movement and access to nearby amenities

Cost of transportation of raw materials and products Regional bioethanol and ethylene




Societal Considerations

Societal Considerations

Quality of workforce and access to research anddevelopment

Employee benefits with competitive wages, good morale

Accelerated job creation and downstream growth of localeconomy

Improved quality of life with strong community culture

49Background ReactionScheme SeparationScheme Economics EHS Sustainability Conclusions





Renewable ‘green’ bioethanol feedstock

Lower carbon emissions

Not a finite resource

Important to maintain reserves of natural resources Rising crude prices for cracking lead to higher ethylene

prices since this is the most common choice of technology

Governmental tax and infrastructure benefits




CONCLUSION


51



Final Recommendations

Profitability controlled by volatile fluctuations in ethanol and

ethylene prices

Self-production of ethylene vs outright purchase

Advantages

Downstream societal and environmental effects of design

Disadvantages

High utility and heating costs in addition to changing prices

Short term recommendation

Not to pursue

Long term recommendation

Assess market dynamics




APPENDIX SLIDES


53

R ti D t



Reaction Data

54

T a bl e 1 : K i ne ti c D a ta w i th A ct i va te d A lu mi n a C at a ly s t

Reaction A j (mole atm-1

kgcat-1

s-1

)

Ea ( kJ m ol e-

1)

k j R at e L aw

C2H5OH→C2H4 + H2O 5.41 x 106

147.7 k1 r1 = k1P C2H5O H

2 C2H5OH→(C2H5)2O +H2O

9.55 x 107 101.0 k2 r2 = k2P 2 C2H5O H

(C2H5)2O→ 2C2H4 + H2O 2.79 x 1010

135.0 k3 r3 = k3P (C2H5)2O

C2H5OH→ C2H4O + H2 2.78 x 108

138.4 k4 r4 = k4P C2H5O H

2C2H4→ C4H8 1.45 x 107

113.7 k5 r5 = k5P2

C2H4



EH&S

Reactor HAZOP

55Background ReactionScheme SeparationScheme Economics EHS Sustainability Conclusions



Background ReactionScheme SeparationScheme Economics EHS Sustainability Conclusions

EH&S

Tower T-101 HAZOP

56

R t S T bl



Reactor Summary Tables

57

Table 1: Process Heater Equipment Summary Table

H-101

Type Fired Heater

T u be P r es s ur e ( p si g ) 2

Tube Temperature 700

Duty (MJ/hr) 37300

Fuel Type Natural Gas

M a t e ri a l o f Co n s tr u c t io n S t a i nl e s s S t e e l

T a b le 2 : R e ac t o r E q u i p me n t S u m ma r y T a b l e

R-101

Type Jacketed Agitated (Isothermal PFR)

Volume (ft3

) 1630Opera ting Tempera ture (F) 720

Operating Pressure (psia) 23

Press ure Dr op (psi) 4

Specifications Steam Injected

H t E h S T bl



Heat Exchanger Summary Table

58

T a b le 1 : P r o ce s s H e at E x c ha n g er s E q u i pm e n t S u m ma r y T a b le

E-101 E-102 E- 103 E-104

Type Floating Head Floating Head Floating Head Floating Head

Duty

(MMBtu/hr)

3.9 25.2 12.4 1.8

A re a ( ft2

) 599 1150 3030 224

Temperature of

Shell/Tube (F)

700/600 105/185 110/115 87/80

LMTD End Points

(F)

130.83 242.39 45.21 89.78

Pressure of

Shell/Tube (psig)

4.3/6.3 5/5 5/5 5/5

N um be r o f

passes

1-shell/2-tube 1-shell/2-tube 1-shell/2-tube 1-shell/2-tube

M a te r ia l o f

Construction

Shell/Tube

Stainless

Steel/Stainless

Steel

Carbon

Steel/Carbon

Steel

Carbon

Steel/Carbon

Steel

Stainless

Steel/Stainless

Steel

S ti E i t T bl



Separation Equipment Table

59

T a bl e 1 : F l as h T a nk E q u ip m en t S u m m ar y T a b l e

V-101 V-102

Heigh t ( ft) 6.6 6.6

Diameter (ft) 2.2 2.2

Orientation Vertical Vertical

Pressure (psig) 4 4

Temperature (F) 185 110

Material of Construction Carbon Steel Carbon Steel

T a b l e 2 : D i s t il l a t io n T o w e r Eq u i p me n t S u m ma r y T a b le

T -101 T-102 T-103

Heigh t ( ft) 34 38 42

Diameter (ft) 1.8 2 2.3

Pressure (psig) 5 5 6.5

T e mp e ra t ur e ( F ) T o p: - 1 28

B o tt om : 6 1

T op : 8 3

B ot to m: 1 82

T op : 3 5

B o tt o m: 9 2Number of Trays 6 8 10

Feed Location 3 4 8

Reflux Rate 325 62 42

Type of Trays Stain less Steel Sieve Carbon Steel Sieve Carbon Steel Si eve

M a te r ia l o f

Construction

Stainless Steel Carbon Steel Carbon Steel

T S T bl



Tower Summary Table

60

T a b le 1: Dist illa t ion T ow er Hea t Exch a n g ers Eq u ip men t S u mma ry T ab le

E-10 5 E-1 06 E -107 E-1 08 E-109 E-110

Type Flo atingHead, partial

c o ndenser

Flo atingHead,

partial

c o ndenser

Flo atingHead,

partial

c o ndenser

KettleRebo iler

KettleR e b oi l er

KettleRebo iler

Duty

( M M B tu/hr

)

-4. 4 -0. 63 -0 .80 0.45 1. 8 0.0 4

A r ea ( f t2

) 141 1 90 1 13 118 74 .8 180

Temperatu

re

-128 8 3 3 5 61 18 2 92

Pressure o f

Shell/Tube( psig)

5/ 5 4 /4 5 . 3/5. 3 6.3/ 6. 3 5. 5/5 .5 6.3 /6 .3

N u m be r o f

passes

1-shell/2-

tube

1-shell/2-

tube

1-shell/2-

t u b e

Single

Pass

Single Pass Single

Pass

M a t e r ia l o f

Co nstruc ti

o n

Shell/Tube

Stainless

Steel/Stainle

ss Steel

Carbo n

Steel/Carbo

n Steel

Carbo n

Steel/Carbo

n Steel

Carbo n

Steel/Carb

o n Steel

Carbo n

Steel/Carb

o n Steel

Carbo n

Steel/Carb

o n Steel

T a b le 2 : P u m p s E q u i p m en t S u m ma r y T a b le

P-101 P-102 P-103 P-10 4Flo w ( lbmo l/ h) 11 57 9 30 63 3 2

Disc harge

Pressure ( psig)

2 4 .3 6. 3 6 .5

Tem perat ure ( F) 77 -128 83 3 5

D ri ve r T yp e C en tr if ug al C en tr if ug al C en tr if ug al C en tr if ug al

Shaft Pow er (h p) 0. 242 0 .5 0. 7 0 .7

M a t e r ia l o f

Co nstruc tio n

Car bon Steel Stainless Steel Carbo n St eel Carbo n Steel

N u m be r o f

spares

1 1 1 1

R ti P St T bl



Reaction Process Steam Table

61

S ti P St T bl



Separation Process Stream Table

62

Distillation Process Stream Table



Distillation Process Stream Table

63

Appendix CAPCOST



Appendix - CAPCOST


Appendix Utility Costs



Appendix – Utility Costs

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