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Chemical Plant Design Guide

1. The document outlines the design of a plant to manufacture acetaldehyde via the catalytic oxidation of ethylene with copper chloride and palladium chloride catalysts. 2. It involves a vertical reactor where ethylene, oxygen and recycled gases contact the catalyst solution. The reacted gases are scrubbed and the acetaldehyde solution is distilled. Tail gases are recycled after inert removal. 3. It provides details to develop a material balance and flow sheet for a plant producing 7800 kg/h of acetaldehyde with 90% operating factor and 95% ethylene yield. Energy balances around equipment and the whole process are also required.

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643 views1 page

Chemical Plant Design Guide

1. The document outlines the design of a plant to manufacture acetaldehyde via the catalytic oxidation of ethylene with copper chloride and palladium chloride catalysts. 2. It involves a vertical reactor where ethylene, oxygen and recycled gases contact the catalyst solution. The reacted gases are scrubbed and the acetaldehyde solution is distilled. Tail gases are recycled after inert removal. 3. It provides details to develop a material balance and flow sheet for a plant producing 7800 kg/h of acetaldehyde with 90% operating factor and 95% ethylene yield. Energy balances around equipment and the whole process are also required.

Uploaded by

amitiffco
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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(A) Statement Of The Problem Design a plant to manufacturing of ACETALDEHYDE One method of preparing acetaldehyde is by the direct oxidation

of ethylene. The process employs a catalytic solution of copper chloride containing small quanti ties of palladium chloride. The reaction may be summarized as follows: C2H4 +2CuCl2 +H2O (PdCl2) CH3CHO +2HCl+2CuCl 2CuCl+2HCl+1\2O2 2CuCl2 +H2O In the reaction PdCl2 is reduced to elemental palladium and HCl, and is reoxidiz ed by PdCl2 .During catalyst regeneration the CuCl is reoxidized with oxygen. Th e reaction and regeneration steps can be conducted separately or together. In the process 99.8% ethylene, 99.5% oxygen and recycle gas are directe d to a vertical reactor and are contacted with the catalyst solution under sligh t pressure. The water evaporated during the reaction absorbs the exothermic heat evolved, and make up water is fed as necessary to maintain the catalytic soluti on concentration. The reacted gases are water scrubbed and the resulting acetald ehyde solution is fed to a distillation column. The tail gas from the scrubber i s recycled to the reactor. Inerts are eliminated from the recycle gas in a bleed stream which flows to an auxiliary reactor for additional ethylene conversion. Prepare a design report consisting of the following: 1Literature Survey 2Prepare in the form of a flow sheet, the sequence of steps in the develo pment of a plant to produce acetaldehyde by this process. An analysis of the poi nts to be considered as each step should be included. 3Prepare a material balance and a qualitative flow sheet for the producti on of 7800 kg/h of acetaldehyde. Assume an operating factor of 90% and a 95 % yield on the ethylene feed. Both ethylene and oxygen enter the process at 930 kpa. 4Using the information developed in part-3 make a basic energy balance ar ound each piece of equipment and for the entire process. Prepare a quantitative flow sheet to outline the results of the basic energy balance. 5Design including mechanical details of packed bed catalytic reactor. 6Design including mechanical details of fractionation column to separate acetaldehyde. 7Instrumentation and process control of the reactor. 8Safety and pollution abatement aspects. 9Cost estimation. 10List the additional information that will be needed to complete the prel iminary design evaluation. Suggested References: 1-Dryden C E, Outlines of chemical Technology, East- West Press Pvt. Ltd. New Delh i, 2nd Edition (1973). 2- Austin G T, Shreves Chemical Process Industries, McGraw Hill Book Company, New D elhi 5th Edition (1986). 3-Shukla S D and Pandey G N, A text book of Chemical Technology Vol I and II, Vika s Publishing House Pvt. Ltd. New Delhi. 4- Encyclopedia of Chemical Technology by Kirk- Othmer, 4th ed. John Willey New York. 5-Plant Design and Economics in Chemical Engineering by M.S.Peters.K.D.Temmerhou se, 4th ed. McGraw Hill International. 6- Process Plant: A Handbook for inherently safer design by Trevor AKlev, Taylor and Francis 1998 7- Elements of Chemical Reaction Engineering, By H. Scott Fogler and M. Nihas cu rmen,4th ed. Premice Hall of India Pvt. Ltd.2008. 8- Hydrocarbon Process,60(11),121(1931)

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