TK19 Revised Assignment1

UNIVERSITAS INDONESIA
PRELIMINARY DESIGN OF ETHANEDIOL PLANT
Revised Assignment 1
GROUP TK19
GROUP PERSONNEL :
BADZLINA KHAIRUNIZZAHRAH 1606907972
FADHILA AZZAHRA PUTRI 1606871335
INDIRA OCTAFIONA DARUSSALAM 1606871373
KEMAS AKHMAD AINAN SALSABILA 1606908022
LULUS RIDHO PANGUDHI 1706104400
MUHAMAD FANDHI 1606871386
CHEMICAL ENGINEERING DEPARTMENT

FACULTY OF ENGINEERING
OCTOBER 2019
EXECUTIVE SUMMARY
Ethanediol or Ethylene Glycol (EG) is also interchangeably referred to as

monoethylene glycol (MEG). Ethylene glycol is the adduct of ethylene oxide
(EO) and water and is the simplest glycol, the first of a homologous series of three
dihydroxy alcohols, namely, mono-, di- and triethylene glycols (MEG, DEG and
TEG).
Ethylene glycol (EG) or ethanediol is one of the most highly demanded
raw materials in industrial applications. It is one of the chemical compounds
whose production amount has not yet meet the industrial demand in Indonesia.
PT. Polychem Indonesia Tbk. as the sole producer of ethylene glycol could only
produce 233,397 tons of ethylene glycol in 2018, which didn’t cover the demand
in Indonesia alone. Thus, 422,028.031 tons of ethylene glycol had to be imported
for the demand to be met. The current trend seems to show the ethylene glycol
consumption in Indonesia is going to continue to grow, so unless another ethylene
glycol plant is to be built, the remaining demand has to be imported from various
countries to be fulfilled. Ethylene glycol is commonly used as an ingredient in
antifreeze products. It also sees use as a de-icing solution on airplanes and boats,
solvent in paint and plastic industry, and hydraulic brake fluids.
Conventionally, ethylene oxide is produced from oxidizing ethylene with
oxygen and added ethyl chloride as a moderating substance to increase selectivity.
Ethylene oxide in turn is hydrolyzed to produce monoethylene glycol (MEG) with
by-products in forms of diethylene glycol (DEG) and triethylene glycol (TEG).
This process initially proceeded in the absence of any catalysts. The non-catalytic
hydration reaction is dominant in industry and generally proceeds at elevated
temperatures.
Based on several considerations, the best location that suited ethylene
glycol plant is in Cilegon, Banten. By looking at the needs, market opportunities
that exist, it is necessary to think about the establishment of an ethylene glycol
factory to reduce the amount of ethylene glycol imported that can save foreign
exchange. The ethylene glycol plant to be established is planned to be able to
meet 14% of the market vacancy in 2025 which is 78,836.7 tonne/year.
ii Universitas Indonesia
Process selection is conducted in the first step of designing the process.
The selection includes overall route selection. There are at least four suitable
routes, which are selected through several criteria, such as maturity, economic,
operability, selectivity and flexibility. In order to select one out of four routes
presented, a comprehensive scoring criteria must be build. The selected route is
non-catalytic hydrolysis of ethylene oxide.
There are three process stages in non-catalytic hydrolysis process that
consist of reactor, evaporator, and multistage vacuum distillation. Before entering
reactor, an aqueous solution of ethylene oxide is preheated to about 200C and fed
to a reactor. Literature shows that commercial reactors are operating at
temperature of 190 – 200C and pressure of 14 – 22 atm depending on the initial
concentration of ethylene oxide. In the reactor, ethylene oxide is hydrated to
produce monoethylene glycol (MEG) and small amounts of diethylene glycol
(DEG) and triethylene glycol (TEG) with respectively decreasing yield. After the
product passes through the reactor, it enters an evaporation system where it is fed
to the first stage of a multiple stage evaporator, which is reboiled using high
pressure steam. The remaining stages of the evaporator operate at successively
lower pressure, with the final stage normally under vacuum. Water is evaporated
from the glycol-water mixture. The evaporated water is recovered as a condensate
and recycled back to the glycol reaction feed mixing tank. The concentrated crude
glycol solution from the final evaporation stage is fed to a stripper where the
remaining water and light impurities are removed. The water-free solution is then
distilled in a series of vacuum distillation towers to separate MEG, DEG, and
TEG from heavier glycols.
Process design must be equipped with mass and energy balance
calculation for each equipment, to get the value of mass and energy efficiency.
For this process, the conversion efficiency of raw materials into useful products is
42.02%. The yield of MEG produced is 0.174 kg MEG/ kg ethylene by the basis
of ethylene. The energy consumption per unit product is calculated to be 240.627
MJ/ kg MEG.
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iv Universitas Indonesia
LIST OF CONTENT
EXECUTIVE SUMMARY...................................................................................ii
LIST OF CONTENT............................................................................................iv
LIST OF FIGURE................................................................................................vi
LIST OF TABLE.................................................................................................vii
CHAPTER 1:
INTRODUCTION..................................................................................................1
1.1. Background of Ideas..................................................................................1
1.2. Literature Review......................................................................................2
1.2.1. Nature of Ethanediol..........................................................................2
1.2.2. Overview of Ethanediol Production...................................................6
1.3. Analysis...................................................................................................11
1.3.1. Raw Material Analysis.....................................................................11
1.3.2. Market and Capacity Analysis.........................................................16
1.3.3. Plant Location Analysis...................................................................17
CHAPTER 2:
PROCESS SYNTHESIS, SELECTION, AND DESCRIPTION.....................20
2.1. Process Synthesis....................................................................................20
2.1.1. DuPont Formaldehyde Carbonylation.............................................20
2.1.2. Non-Catalytic Hydrolysis of Ethylene Oxide..................................21
2.1.3. Catalytic Hydrolysis of Ethylene Oxide..........................................23
2.1.4. Carbonation Process of Ethylene Oxide..........................................25
2.2. Process Selection.....................................................................................26
2.3. Process Description.................................................................................31
2.3.1. Ethylene to Ethylene Oxide.............................................................31
2.3.2. Ethylene Oxide to Ethylene Glycol.................................................32
2.4. Block Flow Diagram...............................................................................34
2.5. Process Flow Diagram.............................................................................35
CHAPTER 3:
MASS AND ENERGY BALANCE....................................................................42
3.1. Mass and Energy Balance for Each Process...........................................42
3.1.1. Mass Balance for Each Process.......................................................42
3.1.2. Energy Balance for Each Process....................................................55
3.2. Overall Mass and Energy Balance..........................................................57
3.2.1. Overall Mass Balance......................................................................57
3.2.2. Overall Energy Balance...................................................................60
3.3. Overall Mass Efficiency..........................................................................60
3.3.1. Product Conversion Efficiency........................................................60
3.3.2. Yield.................................................................................................60
3.4. Overall Energy Consumption..................................................................60
CHAPTER 4:
HEAT EXCHANGER NETWORK ANALYSIS..............................................61
4.1. Heat Exchanger Information...................................................................61
4.2. Determination of Energy Target..............................................................62
4.2.1. Composite Curve Method................................................................62
4.2.2. Problem Table Algorithm Method...................................................63
4.3. Heat Exchanger Network Design............................................................69
Universitas Indonesia
4.4. Process Flow Diagram After HEN..........................................................71
CHAPTER 5:
UTILITY...............................................................................................................78
5.1. Water Utility............................................................................................78
5.1.1. Water Treatment..............................................................................78
5.1.2. Cooling Water Requirement............................................................80
5.1.3. Boiler Feed Water............................................................................84
5.1.4. Total Water......................................................................................87
5.2. Electricity Utility.....................................................................................87
5.3. Air Utility................................................................................................88
5.4. Fuel Utility..............................................................................................88
5.5. Comparison of Pre-HEN and Post-Hen...................................................89
CHAPTER 6:
CONCLUSION.....................................................................................................90
REFERENCES.....................................................................................................91
LIST OF FIGURE
Figure 1.1 Vapor Pressure of Glycols.....................................................................3

Figure 1.2 Freezing Points of MEG, DEG and TEG Aqueous Solutions...............4
Figure 1.3 Synthetic Methodologies and Applications of EG................................7
Figure 1.4 Oxide Hydration Reaction Formation of Homologues EG...................9
Figure 1.5 Reaction Mechanisms for Hydrogenation of DMO...............................9
Figure 1.6 Synthesis of EG by Transesterification of EC with Methanol............10
Figure 1.7 Reaction Pathways for EG Synthesis from Formaldehyde..................10
Figure 1.8 Ethylene Glycol Imported to Indonesia...............................................17
Figure 1.9 Plant Location......................................................................................19
Figure 2.1 Block Flow Diagram of Ethylene Oxide Plant....................................34
Figure 2.2 Block Flow Diagram of Ethylene Glycol Plant...................................34
Figure 2.3 Process Flow Diagram of Ethylene Oxide Plant.................................35
Figure 2.4 Process Flow Diagram of Ethylene Glycol Plant................................39
Figure 4.1 Composite Curve of Hot and Cold Stream in EO Plant......................62
Figure 4.2 Composite Curve of Hot and Cold Stream in EG Plant......................63
Figure 4.3 Problem Table Cascade for Ethylene Oxide Plant..............................66
Figure 4.4 Problem Table Cascade for Ethylene Glycol Plant.............................68
Figure 4.5 Pinch Design for Ethylene Oxide Plant...............................................70
Figure 4.6 Pinch Design for Ethylene Glycol Plant..............................................71
Figure 4.7 Process Flow Diagram of Ethylene Oxide Plant Post-HEN................72
Figure 4.8 Process Flow Diagram of Ethylene Glycol Plant Post-HEN...............76
Figure 5.1 Process Flow Diagram of Water Treatment Plant...............................79
Figure 5.2 Process Flow Diagram of Cooling Water Unit....................................83
Figure 5.3 Process Diagram Flow of Steam Generation Plant..............................86
LIST OF TABLE
Tabel 1.1 Indonesia Ethylene Glycol Import..........................................................1

Table 1.2 Physical Properties of Ethylene Glycol...................................................3
Table 1.3 Manufacturing Composition Limits for Fiber Grade MEG....................6
Table 2.1 Catalytic Systems for Synthesis of EG by Hydration of EO.................24
Table 2.2 Scoring Criteria for Process Route Selection........................................27
Table 2.3 Parameter Comparison of Process Routes............................................28
Table 2.4 Scoring of Process Routes.....................................................................30
Table 2.5 Operating Conditions and Mass Balance Every Stream EO Plant........36
Table 2.6 Operating Conditions and Mass Balance Every Stream EG Plant........40
Table 3.1 Mass Balance of Compressor (K-101)..................................................42
Table 3.2 Mass Balance of Mixer (M-101)...........................................................42
Table 3.3 Mass Balance of Reactor (R-101).........................................................43
Table 3.4 Mass Balance of Exchanger (E-101).....................................................43
Table 3.5 Mass Balance of Absorber (T-101).......................................................44
Table 3.7 Mass Balance of Stripper (T-102).........................................................44
Table 3.9 Mass Balance of Flash Tank (S-101)....................................................45
Table 3.10 Mass Balance of Light End Column (T-105)......................................46
Table 3.11 Mass Balance of Purification Column (T-106)...................................46
Table 3.12 Mass Balance of Exchanger (E-104)...................................................46
Table 3.13 Mass Balance of Splitter (SP-101)......................................................47
Table 3.15 Mass Balance of Compressor (K-102)................................................48
Table 3.16 Mass Balance of Absorber (T-103).....................................................48
Table 3.18 Mass Balance of Stripper (T-104).......................................................49
Table 3.22 Mass Balance of Pump (P-201)...........................................................51
Table 3.23 Mass Balance of Mixer (M-201).........................................................51
Table 3.25 Mass Balance of Reactor (R-201).......................................................51
Table 3.26 Mass Balance of Evaporator (T-201)..................................................52
Table 3.31 Mass Balance of Separator (T-204)....................................................53
Table 3.32 Mass Balance of Compressor (K-201)................................................53
Table 3.33 Mass Balance of Mixer (M-202).........................................................53
Table 3.35 Mass Balance of Pump (P-202)...........................................................54
Table 3.37 Mass Balance of RadFrac Column (T-205)........................................54
Table 3.38 Mass Balance of RadFrac Column (T-206)........................................55
Table 3.39 Enthalpy Flow of Streams in EO Plant...............................................55
Table 3.40 Energy Balance of Equipment in EO Plant.........................................55
Table 3.41 Enthalpy Flow of Streams in EG Plant...............................................56
Table 3.42 Energy Balance of Equipment in EG Plant.........................................56
Table 3.43 Overall Mass Balance..........................................................................58
Table 4.1 Classification of Stream........................................................................61
Table 4.2 Shifted Temperature of Ethylene Oxide Plant......................................64
Table 4.3 Shifted Temperature of Ethylene Glycol Plant.....................................64
Table 4.4 Temperature Interval Balance for Ethylene Oxide Plant......................64
Table 4.5 Temperature Interval Balance for Ethylene Glycol Plant.....................67
Table 4.6 Minimum Hot and Cold Utility Requirement.......................................68
Table 4.7 Heat Exchanger Network Design Rule.................................................69
Table 4.8 After-HEN Heat Duty Calculation for Ethylene Oxide Plant...............69
Table 4.9 After-HEN Heat Duty Calculation for Ethylene Glycol Plant..............70
Table 4.10 Operating Condition and Flow Rate of Ethylene Oxide Plant............73
Table 4.11 Operating Condition and Flow Rate of Ethylene Glycol Plant...........77
Table 5.1 Process Water Requirement..................................................................78
Table 5.2 Cooling Water Requirement Before HEN............................................81
Table 5.3 Cooling Water Requirement After HEN...............................................81
Table 5.4 Steam Requirement in Plant Before HEN.............................................84
Table 5.5 Steam Requirement in Plant Before HEN.............................................84
Table 5.5 Electricity Requirement.........................................................................87
Table 5.6 Comparison of Process Before and After HEN....................................89
CHAPTER 1
INTRODUCTION
1.1. Background of Ideas

The need for raw materials and supporting materials in Indonesia is still
widely imported from abroad. If these raw materials and supporting materials can
be produced domestically, this will certainly save foreign exchange expenditure,
increase exports.
Ethylene glycol (EG) or ethanediol is one of the most highly demanded raw
materials in industrial applications. It is one of the chemical compounds whose
production amount has not yet meet the industrial demand in Indonesia. PT.
Polychem Indonesia Tbk. as the sole producer of ethylene glycol could only
produce 233,397 tons of ethylene glycol in 2018, which didn’t cover the demand
in Indonesia alone. Thus, 422,028.031 tons of ethylene glycol had to be imported
for the demand to be met. The current trend seems to show the ethylene glycol
consumption in Indonesia is going to continue to grow, so unless another ethylene
glycol plant is to be built, the remaining demand has to be imported from various
countries to be fulfilled. Ethylene glycol is commonly used as an ingredient in
antifreeze products. It also sees use as a de-icing solution on airplanes and boats,
solvent in paint and plastic industry, and hydraulic brake fluids.
Tabel 1.1 Indonesia Ethylene Glycol Import
Year Trade (USD) Weight (tons)
2009 214,039,538 319,940.264
2010 380,599,200 396,393.017
2011 492,749,822 386,041.895
2012 457,241,093 396,889.510
2013 471,949,079 406,995.402
2014 517,470,865 492,790.955
2015 423,972,766 475,208.611
2016 184,586,317 257,487.461
2017 386,488,060 400,591.208
2018 443,997,491 422,028.032
(Source: Commodity Trade Statistics Database, UN Statistics Division, 2019)
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Conventionally, ethylene oxide is produced from oxidizing ethylene with

oxygen and added ethyl chloride as a moderating substance to increase selectivity.
Ethylene oxide in turn is hydrolyzed to produce monoethylene glycol (MEG) with
by-products in forms of diethylene glycol (DEG) and triethylene glycol (TEG).
An efficient way to produce ethylene glycol is hydrolyzing ethylene oxide. This
process produces higher glycols, uses less steam and water, and generates less
waste.
1.2. Literature Review
1.2.1. Nature of Ethanediol
1.2.1.1. General
Ethanediol or Ethylene Glycol (EG) is also interchangeably referred to as
monoethylene glycol (MEG). Ethylene glycol is the adduct of ethylene oxide
(EO) and water and is the simplest glycol, the first of a homologous series of three
dihydroxy alcohols, namely, mono-, di- and triethylene glycols (MEG, DEG and
TEG). These glycols contain two hydroxyl groups attached to separate carbon
atoms in an aliphatic chain. Diethylene and triethylene glycols, and tetra-ethylene
glycols, are oligomers of ethylene glycol. Polyglycols are higher molecular weight
adducts of ethylene oxide distinguished by intervening ether linkages in the
hydrocarbon chain. Polyglycols are commercially important and have properties
that vary with molecular weight, are water soluble, hygroscopic, and undergo
reactions common to the lower molecular weight glycols.
The three glycols (mono-, di- and triethylene glycol) discussed are
composed solely of carbon, hydrogen and oxygen and have similar chemical
properties. They have applications that vary mainly with physical properties such
as viscosity, hygroscopicity and boiling point.
1.2.1.2. Physical Properties
Ethylene glycol is a colorless, odorless, relatively non-volatile, and
hygroscopic liquid with low viscosity (detailed physical properties are listed in
Table 1.2). It tastes sweet and imparts a warming sensation to the tongue upon
swallowing. It is completely miscible with many polar solvents (e.g., water,
alcohols, glycol ethers, and acetone) and only slightly soluble in non-polar
solvents such as benzene, toluene, dichloroethane, and chloroform. It is difficult
3
to crystallize. When it is cooled, it forms a highly viscous, super-cooled mass that

eventually solidifies to produce a glass-like substance.
Table 1.2 Physical Properties of Ethylene Glycol
Property Ethylene Glycol
Molecular weight 62.07
Boiling point@760 mmHg, 0C 197.6
Specific gravity@20/20 0C 1.1155
Density, kg/m3@40 0C 1099
Coefficient of expansion@20 0C per 0C 0.00059
Flash point, cleveland open cup, 0C 115
Freezing point at 760 mmHg, 0C -13.0
Refractive index, nD@20 0C 1.4318
Viscosity, @20 0C cp 20.9
Vapor pressure, mmHg@20 0C 0.06
Heat of vaporization@760 mmHg, cal/gm 191
Thermal conductivity, cal/(sec)(cm2) (0C/cm)@60 0C 0.000620
Surface tension, dynes/cm@20 0C 50.5
Specific heat, cal/gm/0C@20 0C 0.561
Water solubility complete
(Source: Shell Bull, 1993)
Vapor pressure curves for the ethylene glycols at various temperature are
illustrated in Figure 1.1. Another important property, ethylene glycols can reduce
the freezing point of water markedly as shown in Figure 1.2.
Figure 1.1 Vapor Pressure of Glycols

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Figure 1.2 Freezing Points of MEG, DEG and TEG Aqueous Solutions
1.2.1.3. Toxicology
None of these glycols as liquids are highly initiating to human skin.
Laboratory studies have shown that ethylene glycol penetrates animal skin slowly
and that absorption through human skin takes place even more slowly. This slow-
rate of absorption prevents high concentrations of ethylene glycol and its toxic
breakdown products from accumulating in the bloodstream. A splash of glycol
liquids in the eyes many cause temporary discomfort or irritation, but permanent
damage is not likely.
In contrast, monoethylene and diethylene glycols are regarded as toxic for
applications where there is a possibility of ingestion. In general, no treatment is
necessary in the case of triethylene glycol ingestion unless large quantities are
swallowed. In any event, medical advice should be sought.
Due to their low vapor pressures, inhalation of the vapors of these glycols
appears to present no significant health hazard in ordinary applications. Yet
human experience and animal test data served at one time as a sufficiently
convincing basis for the U.S. Office of Safety and Health Administration (OSHA)
to set in 1989 an interim permissible atmospheric exposure limit (PEL) for
monoethylene and diethylene glycols of 50 ppm(m) and a value of 10 mg/m 3 of
ethylene glycol as particulate matter such as mist.
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1.2.1.4. Safety
Due to the relatively high flash point 115 0C (240 0F), 143 0C (290 0F) and
165 0C (330 0F) for mono-, di- and triethylene glycols, respectively, these glycols
are not readily ignited but can burn when exposed to heat and flames.
In the case of an accidental release, protective measures include: 1)
eliminate potential sources of ignition (no smoking, flares, sparks or flames in the
immediate area); 2) prevent all bodily contact with all spilled material; and 3)
wear appropriate personal protective equipment when responding to spills.
Personal protective equipment selections vary based on potential exposure
conditions such as handling practices, concentration and ventilation.
1.2.1.5. Applications
Ethylene glycol is ubiquitously used as a major component of antifreeze,
coolant and heat transfer fluids in automobiles, aircraft anti-icing or deicing
materials, chilled water air conditioning systems, and heat transport through
geothermal heat pumps. Pure ethylene glycol should not be used as an engine
coolant or antifreeze in most cases due to the low specific heat capacity and heat
transfer efficiency. Nevertheless, physical properties of ethylene glycol–water
mixtures vary significantly. For instance, the depressed freezing points as well as
elevated boiling points were attained with increasing the percentage of ethylene
glycol in a water solution, which makes mixtures with high antifreeze capabilities.
The minimum freezing point was -55 0C when the percentage of ethylene glycol is
about 70%.
The largest consumption, polyester fibers, was 34.5% in 1998 vs. 27% in
1983. PET (polyethylene terephthalate) bottles, film and packaging products were
31.0% in 1998 vs. 18.5% in 1983. Miscellaneous industrial uses for 1998 vs.
1983, were 7.5% and 12.5%, respectively. The attractiveness of ethylene glycol
usage for polyester fiber is that the polyester product imparts wrinkle resistance,
strength, durability and stain resistance when combined with natural fibers to
produce apparel, home furnishing fabrics, and carpeting. Polyester strength is an
asset in industrial products such as tire cord, seat belts and rope.
Polyester containers are widely preferred for packaging soft drinks, food,
personal care and other consumer products where water resistance and
6
recyclability are important. Special manufactures derived from ethylene glycol are
container resin products and thermally-formed cups. The strength of polyester
film makes the material ideal for the production of audio, computer and
videotapes as well as a number of film-wrapped products [Kirk-Othmer; 1994].
1.2.1.6. Product Specifications Requirement
Mono-, di- and triethylene glycols are colorless, essentially odorless stable
liquids with high boiling points. The three have many similar chemical properties.
Differences in their applications are due chiefly to variations in physical
properties such as viscosity, hygroscopicity and boiling points.
Monoethylene Glycol (MEG) is by far the largest volume of the glycol
products sold by the industry and is normally sold in three grades: fiber grade,
industrial grade, and antifreeze grade. Each of these grades can be distinguished
by their glycol and water contents. Fiber grade MEG is typically 99.9% (w)
minimum MEG. Industrial grade is 99.0% (w) minimum MEG, and antifreeze
grade is 95.0% (w) minimum MEG.
For a number of users, fiber grade MEG must also meet specific ultra
violet (UV) light transmittance requirements. For example, a 98% minimum UV
transmittance at 350 nanometers is set forth in some sales contacts [Dye, 1966].
Table 1.3 Manufacturing Composition Limits for Fiber Grade MEG
Component Composition
MEG, % (w) min 99.9
DEG, % (w) max 0.05
Water, % (w) max 0.03
Iron (as Fe), ppm (w) max 0.08
Aldehyde (as acetaldehyde), ppm (w) 10
max
(Source: Dye, 1966)
1.2.2. Overview of Ethanediol Production
Ethylene glycol (EG)—the simplest diol—was first developed in 1859 by
a French chemist—Charles-Adolphe Wurtz—via saponification of ethylene glycol
diacetate with potassium hydroxide. In the early stages, though ethylene glycol
was produced on a very small scale, its development created a considerable
revolution in coolant and explosives industries during World War I. As the state-
of-the-art invention by the Carbide Company of vapor-phase oxidation of ethylene
to ethylene oxide (EO)—a precursor for ethylene glycol synthesis via hydration—
7
became cheaply available, the industrial production of ethylene glycol has been
widespread since 1953. Currently, the global production and consumption of
ethylene glycol are about 20 million metric tons in 2010 with an estimated
increase of 5–10% per year. Ethylene glycol underpins almost every aspect of
everyday life, particularly associated with energy, chemicals, automotive, textiles,
transportation, and manufacturing technologies. Hence, it has attracted intense
research interest across interdisciplinary fields.
In view of various synthetic methodologies of ethylene glycol in
conventional industries and modern technologies (Figure 1.3), great efforts have
been undertaken in order to improve synthetic processes, enhance catalytic
performance, and reduce cost of investment. At present, the technology of
hydration of ethylene oxidation accounts for the major market share. Ethylene
oxide is commercially produced from ethylene via hydrocarbons obtained from
cracking petroleum; however, with the depletion of fossil-fuel resources and
increasing environmental concerns, it is imperative to develop alternative
economical and energy-efficient processes. Of particular interest is an indirect
synthetic route from syngas. This process is a two-step reaction and
conventionally uses noble metals as catalysts in homogenous systems. The high
operational cost and problems of product–catalyst separation spur the
development of a toxic base-metal heterogeneous catalysts. Additionally,
technologies for conversion of biomass-derived materials (e.g., cellulose and
glycerol) to ethylene glycol have become significant, and have been regarded as
promising and environmental alternatives.
Figure 1.3 Synthetic Methodologies and Applications of EG

(Source: Chem. Soc. Rev., 2012)
8
At present, the industrial approach to produce ethylene is hydration of

ethylene oxidation. Owing to the constantly increasing demand for ethylene
glycol, alternative routes for synthesis of ethylene glycol from syngas have
become very significant and attracted much interest. A promising indirect
synthetic process is an integrated technology based on oxidative carbonylation of
methanol to dimethyl oxalate (DMO) and subsequent hydrogenation to ethylene
glycol. In addition, increased attention has been paid to the development of
approaches based on the conversion of biomass-derived glycerol, and cellulose.
Other synthetic methods include conversion of formaldehyde or its derivatives,
trans-esterification of ethylene carbonate, etc.
1.2.2.1. Hydration of Ethylene Oxide
Hydration of ethylene oxide is a conventional thermal process for
industrial production of ethylene glycol, which was established in 1937 by the
Union Carbide Corporation (UCC). This process initially proceeded in the
absence of any catalysts and catalytic processes were developed later on in order
to obtain a higher selectivity of EG.
The non-catalytic hydration reaction is dominant in industry and generally
proceeds at elevated temperatures. The reaction follows a serial-to-parallel route
with formation of homologues of ethylene glycol (Figure 1.4). A carbon atom in
the protonated ethylene oxide (EOH+) can be attacked by H2O to produce
ethylene glycol with the release of a proton. The formed EOH+ can also be
attacked by an un-protonated ethylene oxide resulting in the creation of diethylene
glycol (DEG). Similarly, triethylene glycol (TEG) and polymerized ethylene
glycols can be generated as by-products. Note that diethylene glycol and
triethylene glycol are mainly used for unsaturated polyesters and solvents and
demands for both compounds are fairly steady. In order to obtain high selectivity
to EG (e.g., 88–89%), a large excess amount of water (20–25 molar ratio of
water/EO) must be used. However, higher water to ethylene oxide ratio lowers
ethylene glycol concentration in the reaction mass, thus increasing capital
investment for unit operations (e.g., remove excess water).
9
Figure 1.4 Oxide Hydration Reaction Formation of Homologues EG

Catalysts for the catalytic hydration of ethylene oxide to ethylene glycol
primarily include anions of salts (such as bicarbonate, bisulfate, and formate)
immobilized on an ion-exchange resins (IER), quaternary phosphonium halides,
polymeric organosilane ammonium salts, supported metal oxides, and zeolites.
1.2.2.2. Hydrogenation of Dimethyl Oxalate
Hydrogenation of Dimethyl Oxalate (DMO) is one of the key steps in the
synthesis of ethylene glycol from syngas (e.g., derived from coal, natural gas, and
biomass). The reaction proceeds via two steps—formation of methyl glycolate
(MG) and hydrogenation of methyl glycolate to ethylene glycol (Figure 1.5). The
reaction can be carried out in both homogeneous and heterogeneous systems
based on base- and noble-metal catalysts, such as Ru, Ag, and Cu.
Figure 1.5 Reaction Mechanisms for Hydrogenation of DMO.

1.2.2.3. From Biomass
Cellulose is the most abundant source of biomass. Since it comes mainly
from grass and agricultural and wood wastes, direct conversion into useful organic
compounds, including sugars and alcohols, is one of the most attractive routes for
industrial utilizations of cellulose. This process can be generally divided into two
steps, including selective hydrolysis into glucose and further transformation into
fuels and chemicals. However, unlike other water-soluble polysaccharides,
cellulose has a highly crystalline structure composed of b-1,4-glycosidic bonds of
D-glucose and is therefore difficult to hydrolyze. Up to now, the hydrolysis of
cellulose with enzymes, mineral acids and bases, and supercritical water still
suffers from a series of problems such as separation of products and catalysts and
corrosion hazards.
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1.2.2.4. Transesterification of Ethylene Carbonate and Methanol

Ethylene glycol can also be synthesized concurrently with dimethyl
carbonate (DMC) by a transesterification reaction between ethylene carbonate and
methanol (Figure 1.6). As Ethylene carbonate is generally synthesized via the
reaction of carbon dioxide (an abundantly available greenhouse gas) and ethylene
oxide, the transesterification for ethylene glycol synthesis is useful from the
viewpoint of green chemistry and sustainable development.
Figure 1.6 Synthesis of EG by Transesterification of EC with Methanol.

1.2.2.5. From Formaldehyde
Carbonylation of formaldehyde or its derivatives has been investigated for
producing glycolic acid and its esters/ethers, which can be converted readily into
ethylene glycol. Overall reaction pathways are shown in Figure 1.7.
Figure 1.7 Reaction Pathways for EG Synthesis from Formaldehyde.

1.2.2.6. From Ethylene and Hydrogen Peroxide
Direct synthesis of ethylene glycol from ethylene and hydrogen peroxide is
a green technology consisting of a coupling process, namely, epoxidation of
ethylene and sequential hydrolysis of ethylene oxide.
1.2.2.7. Carbonation Process
Ethylene glycol can be produced by reacting ethylene oxide with carbon
dioxide to form ethylene carbonate which is then hydrolyzed to ethylene glycol.
The ethylene oxidation unit by the direct process produces ethylene oxide which
11
is then absorbed by an absorbent solution before entering the carbonation unit.

The output from the absorption tower is reacted with carbon dioxide and then
converted to ethylene carbonate which then enters the hydrolysis unit to make
ethylene glycol (Kawabe et al., 1998). The most significant advantage in this
process is the almost perfect conversion of ethylene oxide to ethylene glycol
where only about 1% is produced by diethylene glycol and other glycol
compounds (Kirk & Othmer, 1990).
1.3. Analysis
1.3.1. Raw Material Analysis
1.3.1.1. Carbon Monoxide
Carbon monoxide (CO) is a poisonous, colorless, odorless, non-irritating,
and tasteless gas that is ubiquitous in the atmosphere. The gas is made up of
carbon and oxygen. CO is common industrial hazard resulting from the
incomplete burning of material containing carbon such as natural gas, gasoline,
kerosene, oil, propane, coal, or wood. Carbon monoxide is also produced
indirectly from the photochemical oxidation of methane and other volatile organic
compounds (VOCs) in the atmosphere. Volcanic activity is an additional natural
source of carbon monoxide in the atmosphere. Carbon monoxide is used for the
production of glycolic acid or its derivatives from formaldehyde comprising
reacting formaldehyde with carbon monoxide and water in the presence of a
catalyst. The reaction process is listed below.
CO + CH2O + H2O → HOCH2COOH
1.3.1.2. Formaldehyde
Formaldehyde (systematic name methanal) is a naturally occurring organic
compound with the formula CH2O (H-CHO). Formaldehyde is an important
precursor to many other materials and chemical compounds. It’s a colorless,
strong-smelling gas used in making building materials and many household
products. It is used in pressed-wood products, glues and adhesives, permanent-
press fabrics, paper product coatings, and certain insulation materials.
Formaldehyde is used for the production of glycolic acid by reacting it with
carbon monoxide and water with the process called DuPont process for ethylene
glycol synthesis.
12
Formaldehyde is produced industrially by the catalytic oxidation of

methanol. The most common catalyst is silver metal or a mixture of an iron and
molybdenum or vanadium oxides. In the commonly used formox process,
methanol and oxygen react at 250 – 400C in presence of iron oxide in
combination with molybdenum and/or vanadium to produce formaldehyde
according to this chemical reaction below.
2 CH3OH + O2 → 2 CH2O + 2H2O
The silver-based catalyst usually operates at a higher temperature, about 650C.
Formaldehyde also can be produced by the dehydrogenation reaction below.
CH3OH → CH2O + H2
The two chemical reactions on it simultaneously produce formaldehyde. In
principle, formaldehyde could be generated by oxidation of methane, but this
route is not industrially viable because the methanol is more easily oxidized than
methane.
1.3.1.3. Methanol
Methanol, also known as methyl alcohol, is the simplest alcohol consisting
of a methyl group linked to a hydroxyl group with the formula CH 3OH. It is a
light, volatile, colorless, flammable liquid with a distinctive odor similar to that of
ethanol. Methanol is made from the destructive distillation of wood and is chiefly
synthesized from carbon monoxide and hydrogen. Its principal uses are in organic
synthesis, as a fuel, solvent, and antifreeze. The chemical is also used to produce
biodiesel via trans-esterification reaction. Because methanol has toxic properties,
it is frequently used as a denaturant additive for ethanol manufactured for
industrial purposes. Methanol is used for the esterification process of the glycolic
acid followed by hydrogenation of the ester to produce ethylene glycol. The
esterification reaction of the glycolic acid with methanol to produce methyl
glycolate is listed below.
HOCH2COOH + CH3OH → HOCH2COOCH3 + H2O
Methanol is produced naturally in the anaerobic metabolism of many
varieties of bacteria and is commonly present in small amounts in the
environment. As a result, the atmosphere contains a small amount of methanol
vapor. Atmospheric methanol is oxidized by air in sunlight to carbon dioxide and
13
water over the course of days. Methanol also can be produced from synthesis gas.
Carbon monoxide and hydrogen reacts over a catalyst to produce methanol with
the reaction below.
CO + 2 H2 → CH3OH
1.3.1.4. Hydrogen
Hydrogen is the smallest chemical element because it consists of only one
proton in its nucleus. Its symbol is H, and its atomic number is 1. Hydrogen is the
most abundant chemical substance in the universe. However, monoatomic
hydrogen is rare on Earth due to its propensity to form covalent bonds with most
elements. At standard temperature and pressure, hydrogen is a nontoxic,
nonmetallic, odorless, tasteless, colorless, and highly combustible diatomic gas
with the molecular formula H2. Hydrogen is produced in chemistry and biology
laboratories, often as a by-product of other reactions, in industry for the
hydrogenation of unsaturated substrates, and in nature as a means of expelling
reducing equivalents in biochemical reactions.
Large quantities of H2 are needed in the petroleum and chemical industries.
H2 has several other important uses, it is used as a hydrogenating agent,
production of methanol, reducing agent of metallic ores, used as a tracer gas for
minute leak detection, used in power stations as a coolant in generators, etc.
Hydrogen also used in hydrogenation process of methyl glycolate to produce
ethylene glycol with the reaction below.
HOCH2COOCH3 + 2H2 → C2H6O2 + CH3OH
1.3.1.5. Ethylene
Ethylene (IUPAC name: ethane) is the simplest of the organic compounds
alkene which has the formula C2H4 (H2C=CH2). Ethylene appears as a colorless
gas with a sweet taste and odor. It is lighter than air. It is easily ignited and a
flame can easily flash back to the source of the leak. Under prolonged exposure to
fire or intense heat, the containers may rupture violently.
Ethylene is an important industrial organic chemical. It is produced from
the cracking of fraction obtained from distillation of natural gas and oil. The
processes are steam cracking of ethane and propane (from natural gas and from
crude oil), steam cracking of naphtha from crude oil, and the catalytic cracking of
14
gas oil from crude oil. The choice of feedstock depends on the availability, price
(which can vary considerably), and what other products from cracking are needed.
The vast majority of ethylene is produced by steam cracking.
Major industrial reactions of ethylene include polymerization, oxidation,
halogenation and hydrohalogenation, alkylation, hydration, oligomerization, and
hydroformylation. Ethylene is oxidixed to produce ethylene oxide, a key raw
material in the production of surfactants and detergents by ethoxylation. Ethylene
oxide is also hydrolyzed to produce ethylene glycol, widely used as an automotive
antifreeze as well as higher molecular weight glycols, glycol ethers and
polyethylene terephthalate. The oxidation reaction mechanism of ethylene to
produce ethylene oxide is listed below.
C2H4 + ½ O2 → C2H4O
1.3.1.6. Oxygen
Oxygen is an important part of the atmosphere and is necessary to sustain
terrestrial life. Oxygen is a gaseous chemical element in group VA of the periodic
table. The chemical symbol for atomic oxygen is O, its atomic number is 8, and its
atomic weight is 15.9994. Elemental oxygen is known principally in the gaseous
form as the diatomic molecule, which makes up 20.94% by volume or 23% by
weight of the air we breathe. Diatomic oxygen is colorless, odorless, and tasteless.
Oxygen reacts vigorously with combustible materials, especially in its pure
state, releasing heat in the reaction process. Many reactions require the presence
of water or are accelerated by a catalyst. Oxygen has a low boiling/condensing
point: -297.3°F (-183°C). The gas is approximately 1.1 times heavier than air and
is slightly soluble in water and alcohol. Below its boiling point, oxygen is a pale
blue liquid slightly heavier than water.
Oxygen as the second-largest volume industrial gas. Aside from its
chemical name O2, may be referred to as GOX or GO when produced and
delivered in gaseous form, or as LOX or LO when in its cryogenic liquid form.
Oxygen is produced in large quantities and at high purity as a gas or liquid by
cryogenic distillation and as a lower purity gas (typically about 93%) by
adsorption technologies (pressure swing adsorption, abbreviated as PSA, or
vacuum-pressure swing adsorption, abbreviated as VPSA or more simply, VSA).
15
Oxygen is valued for its reactivity and is commonly used, with or instead of air, to
increase the amount of oxygen available for combustion or biological activity.
This increases reaction rates and leads to greater throughput in existing equipment
and smaller sizes for new equipment.
In term of chemical, pharmaceuticals, and petroleum industry, Oxygen is
used as a raw material in many oxidation processes, including the manufacturing
of ethylene oxide. All ethylene oxide direct oxidation plants are based on the
original process chemistry discovered by Lefort in 1931. The important reaction
that occurs is listed below.
C2H4 + ½ O2 → C2H4O
1.3.1.7. Carbon Dioxide
Carbon dioxide (CO2), is a colorless gas having a faint, sharp, odor, and a
sour taste. It is formed in combustion of carbon-containing materials, in
fermentation, and in respiration of animals and employed by plants in the
photosynthesis of carbohydrates. The presence of the gas in the atmosphere keeps
some of the radiant energy received by Earth from being returned to space, thus
producing the so-called greenhouse effect. Industrially, it is recovered for
numerous diverse applications from flue gases, as a by-product of the preparation
of hydrogen for synthesis of ammonia, from limekilns, and from other sources.
According to “IPCC Special Report on Carbon Dioxide Capture and
Storage,” carbon dioxide gas is involved in the production of refrigeration
systems, welding systems, water treatment processes (to stabilize the pH of water)
and carbonated beverages. It is also used in the metals industry to enhance the
hardness of casting molds and as a soldering agent. There has been recent patent
activity with respect to a process whereby ethylene oxide is converted to ethylene
glycol by reaction with CO2 to form ethylene carbonate, which is in turn
hydrolyzed to glycol. Ethylene carbonate is produced by the reaction between
ethylene oxide and carbon dioxide. Here’s the reaction that occur in forming
ethylene carbonate process.
C2H4O + CO2 → C3H4O3
1.3.1.8. Water
16
Water is an oxygen hydride consisting of an oxygen atom that is

covalently bonded to two hydrogen atoms. Water appears as a clear, nontoxic
liquid composed of hydrogen and oxygen, essential for life and the most widely
used solvent. Include water in a mixture to learn how it could react with other
chemicals in the mixture. It is a conjugate base of an oxonium, also it is a
conjugate acid of a hydroxide.
In many industries, water is used in hydrolysis process. Hydrolysis is a
chemical decomposition process that uses water to split chemical bonds of
substances. Thus hydrolysis adds water to break down the reaction. These routes
are used in the manufacture of alcohols (ethanol), glycol (ethylene glycol), and
propylene oxide. Here’s the reaction that occur in the hydrolysis process of
ethylene oxide and hydrolysis of ethylene carbonate.
C2H4O + H2O → C2H6O2
C3H4O3 + H2O → CO2 + C2H6O2
1.3.2. Market and Capacity Analysis
Ethanediol or ethylene glycol is used for various purpose in various fields.
Most of the use of ethylene glycol is as raw material for textile industry
(polyester). Polyester is a thermoplastic polymer compound used as a raw material
in textile and plastic industry. Other usages of ethylene glycol are as non-volatile
antifreeze in vehicle engine coolants, as additives in paints, heat transfer fluids in
aircraft, dehydrating agents for natural gas, and as additives in inks and pesticides.
High purity ethylene glycol can be used as a solvent and a suspension medium on
ammonium perborate.
The need for ethylene glycol in making those products above continues to
increase throughout the years and most of these needs are met by importing
ethylene glycol from other countries. To determine the market capacity of the
product, it is needed to know about ethylene glycol demand and production. In
2018, the amount of imports of ethylene glycol in Indonesia reached 422,028
tons/year. There is only one ethylene glycol producer in Indonesia, PT Polychem
Tbk, which produces ethylene glycol 192,645.9 tons/year
(www.polychemindo.com, 2018).
17
The need of ethylene glycol in Indonesia can be seen from the number of
imports that tend to increase throughout the years. Based on data obtained from
the Central Statistics Agency, the projection of an upward trend in the need of
ethylene glycol can be seen from Table 1.1 (BPS, 2009 – 2018).
Amount of Ethylene Glycol Imported (2009 - 2018)

600000
500000
EG Imported (tons)
400000
300000
200000
100000
0
2008 2010 2012 2014 2016 2018 2020
Years
Figure 1.8 Ethylene Glycol Imported to Indonesia

(Source: Badan Pusat Statistik 2009 – 2013)
From Table 1.1 and Figure 1.8, it can be seen that the imports of ethylene
glycol in Indonesia from 2009 to 2018 increased by average of 6.78%. With an
average increase of 6.78%, the need of ethylene glycol imports in Indonesia in
2025 can be predicted at 571,357 tons. By 2025, the needs of ethylene glycol will
be fulfilled by 33.7%, by existing ethylene glycol factory, PT Polychem Tbk with
production capacity of 192,645.9 tons/year while the rest are market vacancy.
Based on the description above, by looking at the needs, market opportunities that
exist, it is necessary to think about the establishment of an ethylene glycol factory
to reduce the amount of ethylene glycol imported that can save foreign exchange.
The ethylene glycol plant to be established is planned to be able to meet 14% of
the market vacancy in 2025 which is 78,836.7 tons/year.
1.3.3. Plant Location Analysis
Plant location is an important strategic level decision making for an
organization. It refers to the choice of the region where men, materials, money,
machinery, and equipment are brought together for setting up a business. In order
to selecting plant location, organization need to consider various factors such as
18
availability of men, materials, money, machinery, and equipment. Those factors

should be considered carefully because a large investment is made. Identifying an
ideal location is very crucial, an improper location of plant may lead to waste of
all the investments made in building, machinery, and equipment. Here’s several
factors that should be considered in order to choose plant location.
1) Availability of raw material
Availability of raw materials is the most important factor in plant location
decisions. Usually, manufacturing units where there is the conversion of
raw materials into finished goods is the main task then such organizations
should be located in a place where the raw materials availability is
maximum and cheap.
2) Nearness to the market
Nearness of market for the finished goods not only reduces the
transportation costs, but it can render quick services to the customers. If
the plant is located far away from the markets then the chances of spoiling
and breakage become high during transport. If the industry is nearer to the
market then it can grasp the market share by offering quick services.
3) Availability of labor
Another most important factor which influences the plant location
decisions is the availability of labor. The combination of the adequate
number of labor with suitable skills and reasonable labor wages can highly
benefit the firm. However, labor-intensive firms should select the plant
location which is nearer to the source of manpower.
4) Transport facilities
In order to bring the raw materials to the firm or to carrying the finished
goods to the market, transport facilities are very important. Depending on
the size of the finished goods or raw materials a suitable transportation is
necessary such as roads, water, rail, and air. Here the transportation costs
highly increase the cost of production, such organizations can not
complete with the rival firms. Here the point considered is transportation
costs must be kept low.
19
Based on the consideration above, the best location that suited ethanediol
or ethylene glycol plant is in Cilegon, Banten. Cilegon is chosen as plant location
because of several reasons such as:
 Ethylene glycol can be made from ethylene or syngas, the location is
known as industrial area where many petrochemical industries are located
there. Some of petrochemical industry that located in Cilegon produce
ethylene so it makes raw material supply much easier.
 Product will be distributed to market, in so many case ethylene glycol is
used as raw material of polyester industry. This location is near market
target because there are so many polyester industries that are located in
Cilegon.
 Cilegon is an industrial area, so facilities such as road access and electrical
installations are easy to obtain. This location also close to Merak Port,
making it easier to distribute products out of the island.
 The map view of the plant location can be seen in Figure 1.9.
Figure 1.9 Plant Location

(Source: www.maps.google.com)
20
CHAPTER 2
PROCESS SYNTHESIS, SELECTION, AND DESCRIPTION
2.1. Process Synthesis

According to the literature, there are plenty of alternative routes to produce
ethylene glycol. Ethylene glycol can be produced by hydration of ethylene oxide,
hydrogenation of dimethyl oxalate, from biomass, from formaldehyde, etc. In
general, there are four routes available which is widely used for manufacturing
process of ethylene glycol:
 DuPont Formaldehyde Carbonylation
 Non-Catalytic Hydrolysis of Ethylene Oxide
 Catalytic Hydrolysis of Ethylene Oxide
 Ethylene Oxide Carbonation
These routes are evaluated based on the specified criteria, and the best one
will be chosen. All of these aforementioned routes will be described in the
following section.
2.1.1. DuPont Formaldehyde Carbonylation
The reaction to form ethylene glycol by hydrogenation of derivatives of
glycolic acid was first disclosed by DuPont in Patent No. US2285448. It is
developed from a previous patent for reaction to form glycolic acid, also patented
by DuPont. The formation of glycolic acid is achieved by dissolving
formaldehyde in water, preferably in the presence of strong acidic catalyst. The
process subjected the solution to heat and pressure which obtained glycolic acid
according to this reaction.
CO + CH2O + H2O → HOCH2COOH
This preparation of glycolic acid which comprises of reacting formaldehyde with
CO and water using strong acidic catalyst is taking place at a temperature between
140 and 200°C and pressure of 900 atmospheres.
HOCH2COOH + CH3OH → HOCH2COOCH3 + H2O
The next process involves the catalytic hydrogenation of glycolic acid and its
derivatives to ethylene glycol. Glycolic acid, as an intermediate to monoethylene
22
glycol (MEG), is esterified with methanol to methyl glycolate (MG), and then
hydrogenated in the final step to yield monoethylene glycol (MEG).
HOCH2COOCH3 + 2 H2 → HOCH2CH2OH + CH3OH
This process was practiced commercially by DuPont with a yield of
ethylene glycol higher than 96% using H2SO4 as a catalyst. However, this
manufacturing method of producing ethylene glycol suffers from a few
disadvantages. The reaction was carried out under reaction conditions of 900
atmospheres of CO and temperatures between 140 and 200°C. The resultant high
corrosion reaction conditions due to use of mineral acid led to discontinuation of
the technology in 1968.
The high operating pressure condition and low selectivity, and highly
corrosive mixture and the difficulty of separating the homogenous acidic catalyst
from the final product became of the few setbacks of this method. A few solutions
have been proposed in order to address these problems. But, this manufacturing
method of ethylene glycol became obsolete and abandoned in favor of a more
efficient manufacturing method, hydrolysis of ethylene glycol is one of them. The
aforementioned method will be explained in the following sections.
2.1.2. Non-Catalytic Hydrolysis of Ethylene Oxide
Non-catalytic hydrolysis of ethylene oxide process is the conventional way
to manufacture monoethylene glycol by hydrolysis of ethylene oxide. It is the
most widely used method for production of monoethylene glycol with other
heavier glycol as by-products. It is reliable and can be used in plants that
manufacture ethylene oxide and glycol together.
The process occurs at neutral pH at high temperature and pressure in the
presence of large excess of water, increases the selectivity of ethylene glycol to 89
– 99%. The ratio for water/EO is normally 25/1 to prevent side reactions. Large
excess water that used in non-catalytic hydrolysis leads to high energy
consumption during the distillation process. The primary product of non-catalytic
hydrolysis process is monoethylene glycol (MEG) with higher glycols such as di-
and triethylene glycols that formed in smaller amount as the reaction proceed
through series of consecutive-parallel reaction. The series of parallel reactions of
non-catalytic hydrolysis of ethylene oxide are listed below.
23
 MEG formation: Desired reaction

 DEG formation: Side reaction
C2H4O + C3H4O3 → C4H10O3
 TEG formation: Undesired reaction
C2H4O + C4H10O3 → C6H14O4
There are three process stages in non-catalytic hydrolysis process that
consist of reactor, evaporator, and multistage vacuum distillation. Before entering
reactor, an aqueous solution of ethylene oxide is preheated to about 200C and fed
to a reactor. Literature shows that commercial reactors are operating at
temperature of 190 – 200C and pressure of 14 – 22 atm depending on the initial
concentration of ethylene oxide. In the reactor, ethylene oxide is hydrated to
produce monoethylene glycol (MEG) and small amounts of diethylene glycol
(DEG) and triethylene glycol (TEG) with respectively decreasing yield. The
formation of higher homologues, diethylene glycol and triethylene glycol, is
inevitable because ethylene oxide reacts with ethylene glycol faster than with
water.
After the product passes through the reactor, it enters an evaporation
system where it is fed to the first stage of a multiple stage evaporator, which is
reboiled using high pressure steam. The remaining stages of the evaporator
operate at successively lower pressure, with the final stage normally under
vacuum. Water is evaporated from the glycol-water mixture. The evaporated
water is recovered as a condensate and recycled back to the glycol reaction feed
mixing tank. The concentrated crude glycol solution from the final evaporation
stage is fed to a stripper where the remaining water and light impurities are
removed. The water-free solution is then distilled in a series of vacuum distillation
towers to separate MEG, DEG, and TEG from heavier glycols.
The heat liberated in the reactor is used to heat the distillation columns.
The shape of the reactor affects the selectivity of the reaction. Plug flow reactors
are superior to both agitator – stirred tanks and column reactors. Selectivity to the
different glycols is controlled by varying the ratio of water to ethylene oxide with
a large excess of water promoting ethylene glycol selectivity. Removing the
24
excess water is energy intensive and requires capital investment in evaporators.

These factor limit the amount of excess water which can be used for control of the
selectivity to the ethylene glycol.
2.1.3. Catalytic Hydrolysis of Ethylene Oxide
The processes used in catalytic hydrolysis of ethylene oxide is more or less
the same with the processes used in non-catalytic hydrolysis of ethylene oxide
which has three major stages that consists of reactor, evaporator, and distillation.
The only difference between the two processes is the reactor stage which in this
process the catalyst is being used. Heterogeneous catalytic hydrolysis processed in
a fixed bed reactor while the homogeneous catalysts hydrolysis can be done with
the same reactors used in non-catalytic hydrolysis process. The following reaction
is a catalytic hydrolysis of ethylene oxide.
Usage of appropriate catalysts is an alternative and simple way to attain
high selectivity of ethylene glycol. Catalysts for the catalytic hydrolysis of
ethylene oxide to ethylene glycol primarily include anions of salts (such as
bicarbonate, bisulfate, and formate) immobilized on an ion-exchange resins (IER),
quarternary phosphonium halides, polymeric organosilane ammonium salts,
supported metal oxides, and zeolites.
Both homogeneous and heterogeneous catalysts exhibited excellent
activity for ethylene oxide hydration. Low-cost soluble salts were reported active
for this reaction. The difference in selectivity of ethylene glycol over these
catalysts can be ascribed to the different electron density of acidic anions. The pH
value also plays a key role in determining ethylene glycol selectivity since it could
control the formation rate of EOH+ by changing the concentration of H3O+. The
optimal pH value for high ethylene glycol selectivity are from weakly acidic (3.0
– 6.0) to weakly basic (7.5 – 10.0). Although both strong acidic or basic catalysts
can accelerate the reaction rate of the hydration, a low ethylene glycol selectivity
was obtained. Strong acidity may accelerate the rate of EOH + formation, but the
un-ionized anion species predominantly exist in the solution at low pH values,
which results in low ethylene glycol selectivity. On the other hand, if the basicity
is too strong, the rate of EOH+ formation would be low owing to the low
25
concentration of H3O+; consequently, a large amount of unprotonated ethylene

oxide would favor the oligomerization to form by-products. Therefore, catalysts
with adjustable pH ranges and suitable esterification capability would be desirable
to enhance ethylene glycol selectivity in homogeneous system.
It is noted that a significant amount of work on hydration of ethylene oxide
was carried out in heterogeneous catalytic systems. Heterogeneous catalysts have
advantages that they could effectively eliminate the corrosive environment and be
easily removed from the reaction mixture by decantation and filtration. Transition
metal oxides are catethylene glycolorized as promising catalysts for ethylene
oxide hydration. Niobic acid (Nb2O5.nH2O) possesses high acidity and structural
stability and has been utilized for the reaction. Niobic acid catalyst (Nb 2O5/α-
Al2O3) exhibited an ethylene glycol yield of 89% and this catalyst shows stability
in 1000 h test. To reduce the water feeding, the addition of hydrophilic species
(e.g. SnO2) to this catalyst could significantly improve the water adsorption
capacity and thereby result in a significant increase in ethylene glycol selectivity.
Different catalysts used for the hydrolysis process need different operating
condition and H2O/EO ratio and resulting different ethylene oxide conversion and
ethylene glycol selectivity. Some catalysts are shown on the table below.
Table 2.1 Catalytic Systems for Synthesis of EG by Hydration of EO
Reaction EG
EO
temperatur H2O/EO selectivit
Catalyst conversion ref
e (mol mol-1) y
(%)
(C) (%)
HZSM-5 (Si/Al = 61.2) 150 22 98 76 41
Nb2O5nH2O 150 22 100 83 41
Ethylenediamine (EDA) 100 4 100 92 43
Na4EDTAa 100 4 100 86 43
N,N0 0-
Bis(salicylidene)ethylenediamin 100 4 100 66 43
e
R1R2R3R4P+Xb 50 ~2 n/a 499 44
Sn-10wt%Nb2O5/a-Al2O3 150 22 99.7 94 45
Amberjet 4200/HCO3 85 5 n/a 94 47
Lewatit MonoPlus M500/HCO3 85 5 n/a 94.3 47
Tributylmethylphosphonium
150 2 98 81.8 68
iodide
Carboxylate 120 10 B100 96 70
Phosphate 120 10 B100 86 70
Carbonate 120 10 B100 95 70
Sulfite 120 10 B100 67 70
26
Table 2.1 Catalytic Systems for Synthesis of EG by Hydration of EO (Continued)

Reaction EG
EO
temperatur H2O/EO selectivit
Catalyst conversion ref
e (mol mol-1) y
(%)
(C) (%)
HxK1xNb3O8 ( x = 0 - 1) 110 8 499 495 71
NaHCO3/LEWATIT M 500 WS 60 5 72.2 95.3 74
NaHCO3/DELOXAN AMP I-1 60 5 64.8 95 74
HCOONa/DELOXAN AMP I-1 60 5 49.7 93.1 74
NaOH/DELOXAN AMP I-1 60 5 37.5 95.4 74
Na2MO4/DELOXAN AMP I-1 60 5 46 93.6 74
10%Nb2O5/a-Al2O3 150 22 99.8 89 75
10%Nb2O5/2.23%MgAl2O4/a-
150 22 99.8 90.6 76
Al2O3
PS-DVB/MWNT IER 85–105 8 99.2 95.6 77
Yield =
Amberlite IR 120 127–193 n/a n/a 78
70 - 90
Nafion XR (6%)/SiO2 50–110 10 94 94 78
AlPO4-Cu(NO3)2 266 n/a 90 57 78
H2SO4 50–70 n/a n/a 90 78
(Source: Hairong Yue, 2011)
2.1.4. Carbonation Process of Ethylene Oxide
A new process for the production of ethylene glycol was developed by
Mitsubishi Chemical Corporation (MCC) to meet its growing demand in the
world. This process is called Only MEG Advantage (OMEGA) process, which
involves two reaction steps for high selectivity (99.3 – 99.8%) monoethylene
glycol from ethylene oxide. The first step is based on initial conversion of
ethylene oxide (EO) to ethylene carbonate (EC) via its reaction with CO 2. This
new process consist of two steps reaction system as follows.
 1st step: Carbonation Reaction
C2H4O + CO2 → C3H4O3
 2nd step: Hydrolysis Reaction
C3H4O3 + H2O → C2H6O2 + CO2
At start-up, the CO2 is supplied from liquid storage and then recovered in
the ethylene oxide plant. In the second reactor, ethylene carbonate is hydrolyzed
to monoethylene glycol. The released CO2 is recycled back to the first reactor,
resulting in no overall CO2 consumption. The ethylene carbonate reaction is
27
exothermic and the ethylene carbonate hydrolysis reaction is endothermic. So,

both the reaction takes place in the liquid phase using homogeneous catalyst like
phosponium halide (potassium iodide). Dehydrator removes water after the
reaction and then the catalyst is separated. The recovered catalyst is then recycled
to the carbonation reactor. The monoethylene glycol is flashed off in the
distillation column and recovered at the top with diethylene glycol traces in the
bottom. The process mentioned has been exclusively licensed to Shell and has
plants in Middle East and Asia.
The advantages of this process are ethylene glycol can be produced in a
simplified way, can save a lot of energy consumption and construction cost, also
the overall selectivity reaches more than 99%. As a consequence of the higher
selectivity, it is possible to reduce the scale of the ethylene oxide production unit
by more than 10% compared to the conventional process to produce the same
amount of ethylene glycol. Construction cost also can be reduced by 10%
compared to the conventional process.
2.2. Process Selection
There are several routes that can be followed to produce ethylene glycol
from ethylene oxide and ethylene as raw materials. One routes consist of several
processes which connect one to another. Four alternatives routes for process
pathways are listed below.
A. DuPont Formaldehyde Carbonylation
(Formaldehyde → Glycolic Acid → Alkyl Glycolate → Ethylene Glycol)
B. Non-Catalytic Hydrolysis of Ethylene Oxide
(Ethylene → Ethylene Oxide → Ethylene Glycol)
C. Catalytic Hydrolysis of Ethylene Oxide
(Ethylene → Ethylene Oxide → Ethylene Glycol)
D. Ethylene Oxide Carbonation
(Ethylene → Ethylene Oxide → Ethylene Carbonate → Ethylene Glycol)
In order to select one out of four routes presented, a comprehensive scoring
criteria must be build. The scoring criteria, together with the weight percentage
are listed in the following Table 2.2
28
27
Table 2.2 Scoring Criteria for Process Route Selection

Weight Scoring Criteria
Parameter
(%) 1 2 3 4 5
some stages have all stages have been
All stages are still some stages are all stages have been
Maturity 25 been applied applied as a whole
on research still on research applied industrially
industrially industrially
Very high energy High energy Moderate energy Low energy Very low energy
Economic 25
consumption consumption consumption consumption consumption
Very complex, >8 Compact, <4 major
Operability 20 >5 major stages 5 major stages 4 major stages
major stages stages
Very low Low selectivity to High selectivity to High selectivity to High selectivity to
selectivity to ethylene glycol, ethylene glycol, 86- ethylene glycol, 91- ethylene glycol, 96-
Selectivity 20
ethylene glycol, 81-85%, lots of by- 90%, lots of by- 95%, little by- 100%, little by-
<80% products products products products
No possible step Little possible step
Little possible step Several possible step Many possible step
improvements, improvements, not
improvements, improvements., improvements, highly
not applied for applied for
Flexibility 10 applied for different applied for different applied for different
different raw different raw
raw materials or raw materials or raw materials or
materials or materials or
catalysts catalysts catalysts
catalysts catalysts
Table 2.3 Parameter Comparison of Process Routes

Parameter Process Routes Comparison
28
DuPont Has been applied in the industry but has been left behind because it is considered inefficient
Non-Catalytic Has been widely applied in the present industry
Maturity Catalytic Not too often applied in the industry
Already three world wide scale commercial plants were constructed and operated smoothly in Korea, Saudi
Carbonation
Arabia and Singapore, but not yet in Indonesia
DuPont Has many stages with very high operating conditions
Has less stages but the process occurs at neutral pH at high temperature and pressure in the presence of large
Non-Catalytic excess of water (the ratio for water/EO is normally 20/1 to prevent side reactions), so it leads to high energy
consumption during the distillation process
Economic
Catalytic Has less stages, but the operating conditions are still high
The reaction system does not need high temperature. Thus, high pressure steam for the raw materials preheat is
Carbonation unnecessary. This section is much simpler due to the low water concentration, so it is possible to reduce energy
consumption and construction cost, as well as to improve operability.
DuPont >5 stages
Operability
Non-Catalytic 3 stages
Catalytic 3 stages
Carbonation 5 stages
Table 2.3 Parameter Comparison of Process Routes (Continued)
Parameter Process Routes Comparison

DuPont 65% selectivity
Selectivity
Non-Catalytic 91% selectivity
29
Catalytic 92% selectivity

Carbonation 95% selectivity
DuPont Does not have many improvements but has a large selection of raw materials
Does not use any catalyst, but the selectivity to the different glycols is can be controlled by varying the
Non-Catalytic
ratio of water to ethylene oxide with a large excess of water promoting ethylene glycol selectivity
Flexibility There are many choices of catalysts. Catalysts with adjustable pH ranges and suitable esterification
Catalytic
capability would be desirable to enhance ethylene glycol selectivity in homogeneous system.
There are many choices of catalysts and it also can use 2 types of absorbing solution. Additional water
Carbonation
feed to the process is preferable to accelerate the reaction
Table 2.4 Scoring of Process Routes

DuPont Non-Catalytic Catalytic Carbonation
Parameter Weight (%)
Rating Score Rating Score Rating Score Rating Score
Maturity 25 5 1,25 5 1,25 4 1 4 1
Economic 25 1 0,25 2 0,5 2 0,5 4 1
Operability 20 2 0,4 5 1 5 1 3 0,6
Selectivity 20 1 0,2 4 0,8 4 0,8 4 0,8
Flexibility 10 3 0,3 3 0,3 4 0,4 4 0,4
30
Total 2,4 3,85 3,7 3,8

Rank 4 1 3 2
31
2.3. Process Description

2.3.1. Ethylene to Ethylene Oxide
The technology used for the manufacturing of ethylene oxide is the direct
vapor phase oxidation of ethylene over a silver containing catalyst at elevated
temperatures. The manufacturing of ethylene oxide involves these reactions
below.
C2H4 + ½ O2 → C2H4O
k: 9.547e+09 ; E: 28 kcal/mol
C2H4 + 3 O2 → 2 CO2 + 2 H2O
k: 1.593e+11 ; E: 31 kcal/mol
The by-products formed from this process carbon dioxide and water according to
this reaction.
The process flowsheet can be divided into two sections: (1) oxidation
section and (2) purification section. Oxygen will be utilized for the oxidation
process of ethylene. Ethylene is fed along with oxygen and recycle ethylene
stream by using a mixing nozzle. Methane is also added into the system as a
diluent. This gas mixture rich of ethylene and oxygen will then be pre-heated and
fed into the multi-tube reactor where the reaction to ethylene oxide along with its
by-products, with the aid of silver as a catalyst, takes place at a temperature
around 200-300°C. Heat from the reaction is removed by a cooler afterwards. The
ethylene oxide formed in the reactor is then recovered by absorption in water in
the absorber. The ethylene oxide is then stripped from its absorbent in the
ethylene oxide stripper. The ethylene oxide stream from the ethylene oxide
absorber is sent to the ethylene oxide purification section to remove the light ends,
water, and aldehydes. The bottom stream of the stripper contains H 2O which gets
recycled back into the ethylene oxide absorber. The EO-rich overhead stripper
stream gets purified further in the purification section consisting of separator and
in the end produces ethylene oxide as the final overhead separator stream.
Meanwhile, the absorber overhead stream is sent to a compressor and
subsequently the CO2 absorber, where the CO2 is removed by absorption in a
MEA solution, and the CO2 absorber overhead stream is sent back to the ethylene
oxide absorber as a recycle stream. MEA solution that has absorbed CO 2 is then
32
sent to the CO2 stripper to separate the CO2 from its absorbent, while the lean
MEA solution is recycled back to the CO2 absorber.
The ethylene oxide formation reaction is exothermic. Since the reactor
operates isothermally, it must be considered that the heat of reaction has to be
removed. The lower the temperatures, the better the selectivity to ethylene oxide
is, but at the cost of slower reaction time.
2.3.2. Ethylene Oxide to Ethylene Glycol
The chosen process routes were the non-catalytic hydrolysis of ethylene
oxide. This process flowsheet consists of three sections: (1) pre-treatment and
reactor section, (2) evaporator section and (3) distillation section.
Finished (purified) ethylene oxide (EO) or an EO:water mixture is the
principal feed to the process. This feed is mixed with recycled water, e.g.,
condensates from reboilers on evaporators. Subsequently, the pressure is boosted
on this feed via a high head pump, and it is then heated to reaction conditions. The
ethylene glycol reactor has a tubular shaped, usually arranged in a vertical
serpentine-like layout for reasons of space and heat insulation. The tube diameter
is such that assures fully-developed turbulent flow is established through the
reactor and back mixing is avoided. Reactor length is set to provide three minutes’
residence time, which allows 99.99% of ethylene oxide to be reacted.
The glycols-forming reactions are highly exothermic and the reactor is
operated adiabatically, no external heating or cooling source is required. The
reactor model was developed using the reaction kinetics outlined from Altiokka
and Akyalkin (2009). The activation energy (E) was derived from the studies
around the non-catalytic hydrolysis reaction between water and ethylene oxide
(EO). The equation used to determine the activation energies (E) at reference
temperature of 338F mentioned below.
k1/[L/(mol*min)] = exp(13.62 – 8220/T)
k: 822415 ; E: 28374.8 Btu/lbmol
k2/[L/(mol*min)] = exp(15.57 – 8700/T)
k: 6000000 ; E: 31095.8 Btu/lbmol
k3/[L/(mol*min)] = exp(16.06 – 8900/T)
k: 90000000 ; E: 31809.9 Btu/lbmol
33
Excess water (some water is consumed in the hydrolysis reaction) in the

ethylene glycol reactor product is removed in the triple effects evaporator, with
final reduction of water content achieved in vacuum column, the dehydrator.
Vacuum column completes the recovery of the glycols. This column reduces the
water content of the crude glycols stream to less than 100 ppm (w). Overhead
losses of monoethylene glycol (MEG) from this column are, typically less than
0.01% of the feed to this final dehydration operation. Vacuum distillation columns
in turn, separate the monoethylene glycol (MEG) as the main product, also
diethylene glycol (DEG) and triethylene glycol (TEG) as the by-products.
34
2.4. Block Flow Diagram
Figure 2.1 Block Flow Diagram of Ethylene Oxide Plant
Figure 2.2 Block Flow Diagram of Ethylene Glycol Plant
35
2.5. Process Flow Diagram Before-HEN
Figure 2.3 Process Flow Diagram of Ethylene Oxide Plant Before-HEN
36
Table 2.5 Operating Conditions and Mass Flow Rate EO Plant Before-HEN
Stream No. 101 102 103 104 105 106 107 108 109 110 111 112
Properties
Temperature
30.00 30.00 30.00 97.74 55.92 205.00 271.00 80.00 69.59 80.00 163.47 45.00
(C)
Pressure (bar) 10.00 10.00 10.00 25.00 25.00 24.79 24.50 24.27 24.27 24.26 24.00 23.99
Conditions (kg/hr)
Ethylene 25248.38 0.00 0.00 25248.38 25248.38 25248.38 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 14863.07 0.00 14863.07 28798.92 28798.92 14378.48 14378.48 442.47 442.46 442.46 442.46
Ethylene Oxide 0.00 0.00 0.00 0.00 651.94 651.94 40289.51 40289.51 39637.57 39639.05 39639.00 39639.00
Carbon Dioxide 0.00 0.00 0.00 0.00 77.39 77.39 100.05 100.05 22.66 22.66 22.66 22.66
Water 0.00 0.00 0.00 0.00 912.81 912.81 922.09 922.09 329688.89 329689.57 11090.70 11090.70
Methane 0.00 0.00 12731.08 12731.08 211764.48 211764.48 211764.48 211764.48 12731.21 12731.02 12731.02 12731.02
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 25248.38 14863.07 12731.08 52842.53 267453.94 267453.94 267454.62 267454.62 382522.80 382524.77 63925.84 63925.84
37
Table 2.5 Operating Conditions and Mass Flow Rate EO Plant Before-HEN (Continued)
Stream No. 113 114 115 116 117 118 119 120 121 122 123 124
Properties
Temperature
47.07 130.26 30.00 30.63 45.90 48.19 221.88 45.00 45.01 44.53 65.51 47.07
(C)
Pressure (bar) 23.99 24.89 1.00 24.30 24.27 25.00 24.00 24.00 24.30 24.30 23.99 23.99
Conditions (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 33.49 0.00 0.00 0.00 13936.01 13936.01 0.00 0.00 0.00 0.00 33.49 442.46
35692.1 34056.0
Ethylene Oxide 0.00 0.00 651.99 651.99 0.05 0.05 0.05 0.05 1636.13 5582.92
4 1
Carbon Dioxide 15.98 0.01 0.00 0.00 77.39 77.39 0.00 0.00 0.00 0.00 15.97 22.65
11059.9 11037.9 11080.7 11080.7 318598.8 318598.8 318598.8 329679.6
Water 912.82 912.82 22.02 52.61
6 5 5 5 7 7 7 2
199033.2 199033.2 12731.1
Methane 1966.24 0.00 0.00 0.00 0.00 0.00 0.00 0.00 1966.24
8 8 2
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
48767.8 45093.9 11080.7 11080.7 214611.4 214611.4 318598.9 318598.9 318598.9 329679.6 18831.7
TOTAL 3673.85
1 6 5 5 9 9 2 2 2 8 6
38
39
Figure 2.4 Process Flow Diagram of Ethylene Glycol Plant Before-HEN
40
Table 2.6 Operating Conditions and Mass Flow Rate EG Plant Before-HEN
Stream No. 201 202 203 204 205 206 207 208 209 210 211
Properties
Temperature (C) 30.00 30.21 128.85 170.00 232.58 193.37 167.70 157.61 271.40 170.73 221.39
Pressure (bar) 1.00 24.89 25.00 25.00 25.00 13.00 7.00 5.00 5.00 0.44 0.44
Component (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 34056.01 34056.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.25 0.25 0.25 0.00 0.00 0.00 0.00 0.00 0.00
Water 47079.41 47079.41 278536.65 278536.65 268353.52 201667.75 124818.08 47931.04 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 4138.89 4138.89 28712.32 27754.20 26601.33 24573.34 24573.34 24531.38 41.96
DEG 0.00 0.00 382.27 382.27 14269.77 14170.58 14068.50 13887.50 13887.42 71.67 13815.75
TEG 0.00 0.00 3010.34 3010.34 8788.53 6744.55 6036.94 5778.19 5778.15 0.06 5778.09
TOTAL 47079.41 47079.41 320124.40 320124.40 320124.40 250337.08 171524.85 92170.08 44238.92 24603.11 19635.81
41
Table 2.6 Operating Conditions and Mass Flow Rate EG Plant Before-HEN (Continued)
Stream No. 212 213 214 215 216 217 218 219 220 221 222
Properties
Temperature (C) 173.17 206.21 151.23 193.37 194.47 167.70 175.28 157.61 152.33 151.08 151.41
Pressure (bar) 0.10 0.10 4.90 13.00 14.00 7.00 8.96 5.00 5.00 4.86 25.00
Component (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.24 0.24 0.00 0.00 0.00 0.24 0.24 0.24
Water 0.00 0.00 47931.04 66685.78 66685.78 76849.67 76849.67 76887.03 220419.29 220419.29 220419.29
Methane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 41.96 0.00 0.00 958.12 958.12 1152.87 1152.87 2027.99 4138.89 4138.89 4138.89
DEG 13687.15 128.60 0.07 99.19 99.19 102.08 102.08 181.01 382.27 382.27 382.27
TEG 80.47 5697.63 0.04 2043.98 2043.98 707.61 707.61 258.75 3010.34 3010.34 3010.34
TOTAL 13809.58 5826.23 47931.16 69787.32 69787.32 78812.23 78812.23 79354.78 227951.03 227951.03 227951.03
42
CHAPTER 3
MASS AND ENERGY BALANCE
3.1. Mass and Energy Balance for Each Process

3.1.1. Mass Balance for Each Process Before-HEN
Mass balance of each process is calculated by calculating mass flow of
each component in the stream that get into and get outside of each equipment.
Some material which may be shown as going in but does not leave the unit or
process (vice versa), or some component that does not go inside the unit but exist
in the out stream. In this case, the performance of the simulation program we are
using is involved.
3.1.1.1. Ethylene Oxide Plant
Table 3.1 Mass Balance of Compressor (K-101)
Mass Flow In (kg/h) Mass Flow Out (kg/h)
Components
101 102 103 104
Ethylene 25248.38 0.00 0.00 25248.38
Oxygen 0.00 14863.07 0.00 14863.07
Ethylene Oxide 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 0.00
Methane 0.00 0.00 12731.08 12731.08
MEA 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00
TOTAL 52842.53 52842.53
Table 3.2 Mass Balance of Mixer (M-101)
Components
104 118 105
Ethylene 25248.38 0.00 25248.38
Oxygen 14863.07 13936.01 28798.92
Ethylene Oxide 0.00 651.99 651.94
Carbon Dioxide 0.00 77.39 77.39
Water 0.00 912.82 912.81
Methane 12731.08 199033.28 211764.48
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 0.00 0.00 0.00
DEG 0.00 0.00 0.00
TEG 0.00 0.00 0.00
43
TOTAL 267454.03 267453.94

Table 3.3 Mass Balance of Heat Exchanger (E-101)
Components
105 106
Ethylene 25248.38 25248.38
Oxygen 28798.92 28798.92
Ethylene Oxide 651.94 651.94
Carbon Dioxide 77.39 77.39
Water 912.81 912.81
Methane 211764.48 211764.48
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 267453.94 267453.94
Table 3.4 Mass Balance of Reactor (R-101)
Components
106 107
Ethylene 25248.38 0.00
Oxygen 28798.92 14378.48
Water 912.81 922.09
Methane 211764.48 211764.48
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 267453.94 267454.62
Components
107 108
Ethylene 0.00 0.00
Oxygen 14378.48 14378.48
Water 922.09 922.09
Methane 211764.48 211764.48
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 267454.62 267454.62
44
Table 3.6 Mass Balance of Pump (P-101)

Components
115 116
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 11080.75 11080.75
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 11080.75 11080.75
Components
116 121 122
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Ethylene Oxide 0.00 0.05 0.05
Water 11080.75 318598.87 329679.62
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 0.00 0.00 0.00
DEG 0.00 0.00 0.00
TEG 0.00 0.00 0.00
TOTAL 329679.68 329679.68
Table 3.8 Mass Balance of EO Absorber Column (T-101)
Components
108 122 109 117
Ethylene 0.00 0.00 0.00 0.00
Oxygen 14378.48 0.00 442.47 13936.01
Ethylene Oxide 40289.51 0.05 39637.57 651.99
Carbon Dioxide 100.05 0.00 22.66 77.39
Water 922.09 329679.62 329688.89 912.82
Methane 211764.48 0.00 12731.21 199033.28
MEA 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00
TOTAL 597134.29 597134.29
45

Components
109 110
Ethylene 0.00 0.00
Oxygen 442.47 442.46
Water 329688.89 329689.57
Methane 12731.21 12731.02
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 382522.80 382524.77
Table 3.10 Mass Balance of EO Stripper Column (T-102)
Components
110 111 119
Ethylene 0.00 0.00 0.00
Oxygen 442.46 442.46 0.00
Ethylene Oxide 39639.05 39639.00 0.05
Water 329689.57 11090.70 318598.87
Methane 12731.02 12731.02 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 0.00 0.00 0.00
DEG 0.00 0.00 0.00
TEG 0.00 0.00 0.00
TOTAL 382524.77 382524.77
Components
119 120
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 318598.87 318598.87
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 318598.92 318598.92
46

Components
120 121
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 318598.87 318598.87
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 318598.92 318598.92
Components
111 112
Ethylene 0.00 0.00
Oxygen 442.46 442.46
Water 11090.70 11090.70
Methane 12731.02 12731.02
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 63925.84 63925.84
Table 3.14 Mass Balance of Flash Tank (S-101)
Components
112 123 113 124
Ethylene 0.00 0.00 0.00 0.00
Oxygen 442.46 33.49 33.49 442.46
Ethylene Oxide 39639.00 1636.13 35692.14 5582.92
Carbon Dioxide 22.66 15.97 15.98 22.65
Water 11090.70 22.02 11059.96 52.61
Methane 12731.02 1966.24 1966.24 12731.12
MEA 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00
TOTAL 67599.69 67599.57
47
Table 3.15 Mass Balance of Light-End Column (T-103)

Components
113 114 123
Ethylene 0.00 0.00 0.00
Oxygen 33.49 0.00 33.49
Ethylene Oxide 35692.14 34056.01 1636.13
Water 11059.96 11037.95 22.02
Methane 1966.24 0.00 1966.24
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 0.00 0.00 0.00
DEG 0.00 0.00 0.00
TEG 0.00 0.00 0.00
TOTAL 48767.81 48767.81
Table 3.16 Mass Balance of Compressor (K-102)
Components
117 118
Ethylene 0.00 0.00
Oxygen 13936.01 13936.01
Water 912.82 912.82
Methane 199033.28 199033.28
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 214611.49 214611.49
3.1.1.2. Ethylene Glycol Plant

Components
201 202
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 47079.41 47079.41
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
48
OH- 0.00 0.00

MEG 0.00 0.00
DEG 0.00 0.00
TEG 0.00 0.00
TOTAL 47079.41 47079.41
Components
114 202 222 203
Ethylene 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00
Ethylene Oxide 34056.01 0.00 0.00 34056.01
Carbon Dioxide 0.01 0.00 0.24 0.25
Water 11037.95 47079.41 220419.29 278536.65
Methane 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00
MEG 0.00 0.00 4138.89 4138.89
DEG 0.00 0.00 382.27 382.27
TEG 0.00 0.00 3010.34 3010.34
TOTAL 320124.40 320124.40
Components
203 204
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 278536.65 278536.65
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 4138.89 4138.89
DEG 382.27 382.27
TEG 3010.34 3010.34
TOTAL 320124.40 320124.40
Table 3.20 Mass Balance of Reactor (R-201)
Components
204 205
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 278536.65 268353.52
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
49
MEG 4138.89 28712.32

DEG 382.27 14269.77
TEG 3010.34 8788.53
TOTAL 320124.40 320124.40
Table 3.21 Mass Balance of Evaporator (T-201)
Components
205 206 215
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 268353.52 201667.75 66685.78
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 28712.32 27754.20 958.12
DEG 14269.77 14170.58 99.19
TEG 8788.53 6744.55 2043.98
TOTAL 320124.40 320124.40
Components
215 216
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 66685.78 66685.78
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 958.12 958.12
DEG 99.19 99.19
TEG 2043.98 2043.98
TOTAL 69787.32 69787.32
Components
206 207 217
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 201667.75 124818.08 76849.67
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 27754.20 26601.33 1152.87
50
DEG 14170.58 14068.50 102.08

TEG 6744.55 6036.94 707.61
TOTAL 250337.08 250337.08
Components
217 218
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 76849.67 76849.67
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 1152.87 1152.87
DEG 102.08 102.08
TEG 707.61 707.61
TOTAL 78812.23 78812.23
Components
207 208 219
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 124818.08 47931.04 76887.03
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 26601.33 24573.34 2027.99
DEG 14068.50 13887.50 181.01
TEG 6036.94 5778.19 258.75
TOTAL 171524.85 171524.85
Table 3.26 Mass Balance of Dehydration Column (T-204)
Components
208 209 214
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 47931.04 0.00 47931.04
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 24573.34 24573.34 0.00
DEG 13887.50 13887.42 0.07
51
TEG 5778.19 5778.15 0.04

TOTAL 92170.08 92170.08
Table 3.27 Mass Balance of MEG Distillation Column (T-205)
Components
209 210 211
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 0.00 0.00 0.00
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 24573.34 24531.38 41.96
DEG 13887.42 71.67 13815.75
TEG 5778.15 0.06 5778.09
TOTAL 44238.92 44238.92
Table 3.28 Mass Balance of DEG, TEG Distillation Column (T-206)
Components
211 212 213
Ethylene 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Water 0.00 0.00 0.00
Methane 0.00 0.00 0.00
MEA 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00
OH- 0.00 0.00 0.00
MEG 41.96 41.96 0.00
DEG 13815.75 13687.15 128.60
TEG 5778.09 80.47 5697.63
TOTAL 19635.81 19635.81
Components
216 218 219 220
Ethylene 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 0.00 0.00
Carbon Dioxide 0.24 0.00 0.00 0.24
Water 66685.78 76849.67 76887.03 220419.29
Methane 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00
MEG 958.12 1152.87 2027.99 4138.89
DEG 99.19 102.08 181.01 382.27
TEG 2043.98 707.61 258.75 3010.34
52
TOTAL 227954.33 227951.03

Components
220 221
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 220419.29 220419.29
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 4138.89 4138.89
DEG 382.27 382.27
TEG 3010.34 3010.34
TOTAL 227951.03 227951.03
Components
221 222
Ethylene 0.00 0.00
Oxygen 0.00 0.00
Water 220419.29 220419.29
Methane 0.00 0.00
MEA 0.00 0.00
H3O+ 0.00 0.00
MEACO-01 0.00 0.00
OH- 0.00 0.00
MEG 4138.89 4138.89
DEG 382.27 382.27
TEG 3010.34 3010.34
TOTAL 227951.03 227951.03
3.1.2. Energy Balance for Each Process Before-HEN

Energy balance can be calculated by multiplying mass flow with mass
enthalpy for each stream. This apply to either it is a stream in or stream out. But at
the simulation results.
3.1.2.1. Ethylene Oxide Plant
The enthalpy flow of each stream for ethylene oxide plant are listed below.
Table 3.32 Enthalpy Flow of Streams in EO Plant
Equipment Enthalpy Flow (MJ/h)
K-101 6100.971
E-101 92152.175
R-101 -49112.372
E-102 -124746.814
53
P-101 32.225
K-102 1128.269
E-103 16760.981
T-102 Reboiler 286130.564
E-105 -282148.927
P-102 12.293
E-104 -57031.431
T-103 Reboiler 13992.283
The energy balance of each equipment can be calculated too by calculating
total of enthalpy flow that get into the equipment and get outside of the
equipment.
Table 3.33 Energy Balance of Equipment in EO Plant
Enthalpy Enthalpy
Equipment Heat Duty (MJ/h) Power Loss (MJ/h)
Flow In (MJ/h) Flow Out (MJ/h)
47453.366
K-101 68.184 -5677.558 5795.922 0
-58995.030
E-101 -933177.287 -841025.112 92152.175 0
R-101 -841025.112 -890137.484 -49112.372 0
E-102 -890137.484 -1014884.298 -124746.814 0
P-101 -175559.846 -175530.844 29.002 0
K-102 -928570.946 -927499.090 1071.856 0
E-103 -5289683.471 -5272934.604 16748.867 0
-4745701.343 0
T-102 -5272934.604 286130.563
-241102.699 0
E-105 -4745701.343 -5027850.270 -282148.927 0
P-102 -5027850.270 -5027839.207 11.063 0
E-104 -241102.699 -298134.130 -57031.431 0
-11265.145 0
T-103 -243465.042 13992.309
-218207.587 0
TOTAL -24600681.582 -24697789.369 -97107.787 0
3.1.2.1. Ethylene Glycol Plant

The enthalpy flow of each stream for ethylene glycol plant are listed
below.
Table 3.34 Enthalpy Flow of Streams in EG Plant
Equipment Enthalpy Flow (MJ/h)
P-201 131.3512999
E-201 55165.46018
E-202 -130267.7205
E-203 -154529.3845
E-204 -184304.6183
P-202 597.0597876
T-204 Condenser 301125.3332
54
T-204 Reboiler 316561.1667

T-205 Condenser -44103.41123
T-205 Reboiler 33595.8828
T-206 Condenser -33898.16285
T-206 Reboiler 31820.64104
The energy balance of each equipment can be calculated too by calculating
total of enthalpy flow that get into the equipment and get outside of the
equipment.
Table 3.35 Energy Balance of Equipment in EG Plant
Enthalpy Enthalpy
Equipment Heat Duty (MJ/h) Power Loss (MJ/h)
Flow In (MJ/h) Flow Out (MJ/h)
P-201 -744580.231 -744455.447 124.784 0
E-201 -4389989.473 -4334824.013 55165.460 0
E-202 -897760.865 -1028028.586 -130267.721 0
E-203 -1028348.438 -1182877.822 -154529.384 0
E-204 -3243618.880 -3427923.498 -184304.618 0
P-202 -3427923.498 -3427326.438 597.060 0
-265463.814 0
T-204 -1015794.069 15435.834
-734894.422 0
-172325.938 0
T-205 -265463.814 -10507.545
-103645.421 0
-76539.801 0
T-206 -103645.421 -2077.519
-29183.140 0
TOTAL -15117124.689 -15527488.339 -410363.651 0
3.2. Overall Mass and Energy Balance Before-HEN

3.2.1. Overall Mass Balance Before-HEN
The plant’s overall mass balance before-HEN will be shown in the
following table.
55
Table 3.35 Overall Mass Balance Before-HEN

Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Stream Stream
Component Stream 101 Stream 115 Stream Stream Stream
102 103 Stream 201 Stream Stream
(Ethylene (Make Up 210 212 213
(Oxygen (Methane (Water In) 124 214
In) Water) (MEG) (DEG) (TEG)
In) In)
Ethylene 25248.38 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 14863.07 0.00 0.00 0.00 442.46 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 0.00 0.00 0.00 5582.92 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.00 0.00 22.65 0.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 11080.75 47079.41 52.61 47931.04 0.00 0.00 0.00
Methane 0.00 0.00 12731.08 0.00 0.00 12731.12 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 24531.38 41.96 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.07 71.67 13687.15 128.60
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.04 0.06 80.47 5697.63
TOTAL 25248.38 14863.07 12731.08 11080.75 47079.41 18831.76 47931.16 24603.11 13809.58 5826.23
TOTAL STREAM 111002.69 111001.84
3.2.2. Overall Energy Balance Before-HEN
The overall energy balance before-HEN is shown in the table below.
Table 3.36 Overall Energy Balance Before-HEN
Stream Enthalpy Flow In Enthalpy Flow Out Heat Duty Power Loss
Name (MJ/h) (MJ/h) (MJ/h) (MJ/h)
47453.366
K-101 68.184 -5677.558 5795.922 0
-58995.030
E-101 -933177.287 -841025.112 92152.175 0
R-101 -841025.112 -890137.484 -49112.372 0
E-102 -890137.484 -1014884.298 -124746.814 0
P-101 -175559.846 -175530.844 29.002 0
K-102 -928570.946 -927499.090 1071.856 0
E-103 -5289683.471 -5272934.604 16748.867 0
-4745701.343 0
T-102 -5272934.604 286130.563
-241102.699 0
E-105 -4745701.343 -5027850.270 -282148.927 0
P-102 -5027850.270 -5027839.207 11.063 0
E-104 -241102.699 -298134.130 -57031.431 0
-11265.145 0
T-103 -243465.042 13992.309
-218207.587 0
P-201 -744580.231 -744455.447 124.784 0
E-201 -4389989.473 -4334824.013 55165.460 0
E-202 -897760.865 -1028028.586 -130267.721 0
E-203 -1028348.438 -1182877.822 -154529.384 0
E-204 -3243618.880 -3427923.498 -184304.618 0
P-202 -3427923.498 -3427326.438 597.060 0
-265463.814 0
T-204 -1015794.069 15435.834
-734894.422 0
-172325.938 0
T-205 -265463.814 -10507.545
-103645.421 0
-76539.801 0
T-206 -103645.421 -2077.519
-29183.140 0
TOTAL -39717806.271 -40225277.709 -507471.437 0
Enthalpy ¿ −Enthalpy Out + Heat Duty∨Work =Power Loss

MJ MJ MJ MJ
−39717806.27
hr (
− −40225277.71
hr )(
+ 507471.4374
hr
=0.00
hr )
MJ MJ MJ
507471.4374
hr (
+ 507471.4374
hr
−0.00)hr
=0
3.3. Plant Efficiency

3.3.1. Product Conversion Efficiency
The product conversion efficiency is reviewed by how far the combination of
raw materials could produce usable product streams. In this process, it is calculated by
the amount of MEG produced per amount of Ethylene and O2 introduced.
57
ṁMEG + ṁ DEG+ ṁ TEG

Conversion Efficiency= x 100 %
ṁ Ethylene
8973.24+5048.5+7578.63
Conversion Efficiency= x 100 %
51488
Conversion Efficiency=42.02%
3.3.2. Yield
Yield is reviewed by how much MEG could be produced per amount of raw
material introduced.
ṁ MEG 8973.24 kg MEG
Yield MEG = = =0.174
Ethylene ṁEthylene 51488 kg Ethylene
ṁ DEG 7578.63 kg DEG
Yield DEG = = =0.142
Ethylene ṁ Ethylene 51488 kg Ethylene
ṁ TEG 5048.5 kg TEG
Yield TEG = = =0.098
Ethylene ṁ Ethylene 51488 kg Ethylene
3.3.3. Energy Consumption
The energy consumption per unit product can be calculated by the amount of
energy per amount of gasoline produced in the process.
Total Heat Duty
Energy Consumption=
ṁ MEG
2159202.979 MJ /h MJ
Energy Consumption= =240.627
8973.24 kg /h kg MEG
58
CHAPTER 4
HEAT EXCHANGER NETWORK ANALYSIS
4.1. Heat Exchanger Information

As a way to reduce energy losses due to temperature difference, an arrangement
of heat exchanger network must be made. A good heat recovery from a given process
can be achieved through effective use of heat exchangers. The basic aim is to
accomplish the exchanger duty by utilizing the process fluid while minimizing the
usage of utilities.
From equipment energy balance, classification of stream into hot and cold fluid
can be made as shown on the following table. The term hot fluid refers to fluid which
undergoes temperature decrease, or enthalpy decrease, or negative value of heat duty.
The hot fluid acts as the source of heat to the cold fluid. On the other hand, the term
cold fluid refers to fluid which undergoes temperature increase, or enthalpy increase,
or positive value of heat duty. It acts as the sink of heat.
Table 4.1 Classification of Stream
Ethylene Oxide Plant
Heat Duty
Equipment T Supply (C) T Target (C) Type
(kW)
E-101 55.92 205 25,598 COLD
E-102 271 80 -34,652 HOT
E-103 69.59 80 4,656 COLD
E-104 163.47 45 -15,842 HOT
E-105 221.88 45 -78,375 HOT
E-106 69.59 80 186.23 COLD
Ethylene Glycol Plant
Heat Duty
Equipment T Supply (C) T Target (C) Type
(kW)
E-201 128.85 170 15,323.7 COLD
Based on the table above, there are 3 hot streams and 4 cold streams. For
designing heat exchanger network, the value of minimum temperature approach for
heat transfer process is next to be considered. Actually the value of ΔTmin can
influence the effectiveness of the designed heat exchanger network. However,
determining the optimum value of ΔTmin is not included on this project. The
determination of ΔTmin follows Heuristic of Seider, et. al. (2003). It is stated that a
value of 50oF (10oC) is to be taken for process temperature above 300 oF (149 oC).
Since the process temperature is high, the minimum temperature approach of 10 oC is
taken.
59
4.2. Determination of Energy Target

The term ‘pinch’ was introduced by Linnhoff and Vredeveld to represent a new
set of thermodynamically based methods that guarantee minimum energy levels in
design of heat exchanger networks. There are two methods that can be used to
determine the ‘pinch’ from all heat exchanger in one plant; they are composite curve
and problem table cascade. The composite curve displays graphically the heat duty as
a function of temperature, while problem table cascade calculates the amount of
energy involved more precisely.
4.2.1. Composite Curve Method
This method plots the relation between temperature and enthalpy or heat of
both the cold and hot streams. Through the composite curve, the amount of heat
which can be exchanged through the process fluids can be visually analyzed. The hot
composite curve relies on heat availability in the process while the cold composite
curve shows the heat demand in the process. The composite curve for ethylene oxide
and ethylene glycol plant are shown below.
Figu
re 4.1 Composite Curve of Hot and Cold Stream
The red curve represents the hot streams and the blue curve represents the cold
streams. The left-end side denotes the minimum cold utility requirement (Qc min),
while the right-end side denotes the minimum hot utility requirement (Qhmin). The
composite curve showed an alignment at the hot end and indicating there is no longer
demand for hot utility. Therefore, only cold utility below threshold value required.
60
Through the generated curve, it can be inferred that the minimum cold utility
requirement is approximately 83,291.37 kW and the minimum hot utility requirement
is approximately 0 kW. This value is then validated by the problem table algorithm
method.
4.2.2. Problem Table Algorithm Method
Although composite curves can be used to set energy targets, they are
inconvenient since they are based on a graphical construction. To solve this, a
problem table show method of calculating energy targets directly without the
necessity of graphical construction can be developed. The basic approach can be
developed into a formal algorithm known as the problem table algorithm. The first
step is determined the shifted temperature intervals (T*) from actual supply and target
temperatures. Hot streams are shifted down in temperature by Tmin/2 and cold
streams up by Tmin/2. The shifted temperature is tabulated as follow.
Table 4.2 Shifted Temperature Table
Tin Tout T*in T*out
No Equipment Type
(C) (C) (C) (C)
1 E-101 COLD 55.92 205 60.9 210
2 E-102 HOT 271 80 266 75
3 E-103 COLD 69.59 80 74.6 85
4 E-104 HOT 163.47 45 158.5 40
5 E-105 HOT 221.88 45 216.9 40
6 E-106 COLD 69.59 80 74.6 85
7 E-201 COLD 128.85 170 133.9 175
The value of CP is defined as the product of mass flow rate and heat capacity.
CP calculated through the division of heat duty and temperature difference. The
calculation of CP of each stream is tabulated below.
Table 4.3 Calculation of CP
T Supply T Target Heat Duty CP
Equipment Type
(C) (C) (kW) (kW/C)
E-101 55.92 205 25,598 171.708 COLD
E-102 271 80 -34,652 181.423 HOT
E-103 69.59 80 4,656 429.286 COLD
E-104 163.47 45 -15,842 133.721 HOT
E-105 221.88 45 -78,375 443.087 HOT
E-106 69.59 80 186.23 17.889 COLD
E-201 128.85 170 15,323.7 372.383 COLD
After the shifted temperature calculated, in each shifted temperature interval a
simple energy balance is calculated as follow.
∆ H =( ∑ CP cold −∑ CP hot ) ∆ T
The heat balance within each shifted interval allows maximum heat recovery
within each interval. The ∆Hi is the heat balance for shifted temperature. If the cold
61
stream dominates the hot stream than the interval has a net surplus of heat and ∆H is
positive. If hot streams dominate cold stream, the interval has a net surplus of heat
and ∆H is negative. The temperature interval balance is shown in the following table.
Table 4.4 Temperature Interval Balance
Shift
T(i+1)-Ti CP H Surplus/
Temperature Interval
(C) (kW/C) (kW) Demand
(C)
266 PINCH
1 49.117 181.4236 8910.981 surplus
216.883
2 6.883 624.5114 4298.5117 surplus
210
3 35 452.8028 15848.0974 surplus
175
4 16.529 80.4188 1329.2427 surplus
158.471
5 24.621 214.1402 5272.3448 surplus
133.85
6 48.85 586.5241 28651.7031 surplus
85
7 10 139.3483 1393.4826 surplus
75
8 0.41 -42.0753 -17.2509 demand
74.59
9 0.001 -24.1858 -0.0242 demand
74.589
10 13.666 405.1006 5536.1042 surplus
60.923
11 20.923 576.8091 12068.5776 surplus
40
Now each stream has identified to have surplus and demand. The stream will
be cascaded from surplus heat down in temperature scale from interval to interval.
The cascade down would be possible because there is excess heat available from the
hot stream in interval is hot enough to supply a demand in cold stream in the next
interval down. The feasible cascade would be illustrated as follow.
Shift
Infeasible Feasible
Temperature
Cascade Cascade
(C)
Hot Utility
266 PINCH ▼ 0 ▼ 0
8910.981 8910.981
62
216.883 ▼ 8911 ▼ 8911

4298.512 4298.512
210 ▼ 13209 ▼ 13209
15848.1 15848.1
175 ▼ 29058 ▼ 29058
1329.243 1329.243
158.471 ▼ 30387 ▼ 30387
5272.345 5272.345
133.85 ▼ 35659 ▼ 35659
28651.7 28651.7
85 ▼ 64311 ▼ 64311
1393.483 1393.483
75 ▼ 65704 ▼ 65704
-17.25087 -17.25087
74.59 ▼ 65687 ▼ 65687
-0.024186 -0.024186
74.589 ▼ 65687 ▼ 65687
5536.104 5536.104
60.923 ▼ 71223 ▼ 71223
12068.58 12068.58
40 ▼ 83292 ▼ 83292
Cold Utility
Figure 4.2 Problem Table Cascade

The pinch temperature is marked with grey shading, with the value of 271 oC
for hot pinch and 261oC for cold pinch. Through the cascade, it is inferred that the
minimum hot and cold utility requirement are consecutively 0 kW and 83,291.77 kW.
It is noted that the value obtained through this method corresponds with the ones
approximated through composite curve method.
4.3. Heat Exchanger Network Design
After determining the energy targets, the next step is designing the network the
network based on pinch and design method. The general idea is to design the heat
transfer among fluids to achieve the minimum hot and cold utility requirement set
before. The design follows two basic rules, which are described below.
Table 4.5 Heat Exchanger Network Design Rule
Region CP S
Above Pinch CPH ≤ CPC SH ≤ S C
Below Pinch CPH ≥ CPC SH ≥ S C
(Source: Smith, 2005, reproduced)
In ethylene oxide and ethylene glycol plant, the original 7 heat exchangers
(heater or cooler) are to be replaced with 2 heat exchangers encountering heat
63
exchange of process fluids, and 5 other heat exchangers which use utilities. The heat
duty calculation of each exchanger is specified on the following table.
Table 4.6 After-HEN Heat Duty Calculation
HOT COLD
CP CP
Tin Tout Q Q Tin Tout
(kW/C (kW/C
(C) (C) (kW) (kW) (C) (C)
) )
1 271.00 135.00 188.22 25,598 25,598 171.71 55.92 205.00
2 221.88 213.80 553.11 4,469 4,469 429.29 69.59 80.00
C1 135.00 80.00 164.61 9,054 0
C2 213.80 45.00 437.82 73,904 0
C3 163.47 45.00 133.72 15,842 0
H1 0 186 17.89 69.59 80.00
128.8
H2 0 15,323 372.38 170
5
Figure 4.3 Pinch Design of Heat Exchangers

4.4. Process Flow Diagram After-HEN
The figure below shows the process flow diagram after heat exchanger network
design of each plant.
64
Figure 4.4 Process Flow Diagram of Ethylene Oxide Plant After-HEN

65
Table 4.7 Operating Condition and Mass Flow Rate EO Plant After-HEN
Stream No. 101 102 103 104 105 106 107 108 109 110
Properties
Temperature (C) 30.00 30.00 30.00 97.74 55.92 205.00 271.00 135.01 80.00 69.59
Pressure (bar) 10.00 10.00 10.00 25.00 25.00 25.00 24.50 24.50 24.30 24.27
Conditions (kg/hr)
Ethylene 25248.38 0.00 0.00 25248.38 25248.38 25248.38 0.00 0.00 0.00 0.00
Oxygen 0.00 14864.53 0.00 14864.53 28799.12 28799.12 14376.81 14376.81 14376.81 442.42
Ethylene Oxide 0.00 0.00 0.00 0.00 651.81 651.81 40293.34 40293.34 40293.34 39641.56
Carbon Dioxide 0.00 0.00 0.00 0.00 77.39 77.39 100.05 100.05 100.05 22.66
Water 0.00 0.00 0.00 0.00 912.74 912.74 921.97 921.97 921.97 329687.86
Methane 0.00 0.00 12731.22 12731.22 211764.35 211764.35 211764.48 211764.48 211764.48 12731.22
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 25248.38 14864.53 12731.22 52844.13 267453.79 267453.79 267456.65 267456.65 267456.65 382525.72
Table 4.7 Operating Condition and Mass Flow Rate EO Plant After-HEN (Continued)
66
Stream No. 111 112 113 114 115 116 117 118 119 120
Properties
Temperature (C) 69.59 80.00 69.59 80.00 80.00 163.57 45.00 47.08 130.27 30.00
Pressure (bar) 24.27 24.27 24.27 24.27 24.27 24.00 23.99 23.99 24.89 1.00
Conditions (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 424.74 424.74 17.70 17.70 442.43 442.43 442.43 33.53 0.00 0.00
Ethylene Oxide 38054.56 38054.56 1585.66 1585.49 39639.88 39639.83 39639.83 35697.16 34054.74 0.00
Carbon Dioxide 21.76 21.76 0.91 0.91 22.66 22.66 22.66 16.00 0.01 0.00
Water 316501.83 316501.83 13187.51 13187.56 329688.20 11130.95 11130.95 11100.84 11078.70 11121.36
Methane 12222.05 12222.05 509.25 509.25 12731.32 12731.32 12731.32 1968.51 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 367224.94 367224.94 15301.03 15300.90 382524.50 63967.20 63967.20 48816.04 45133.46 11121.36
67
Table 4.7 Operating Condition and Mass Flow Rate EO Plant After-HEN (Continued)
Stream No. 121 122 123 124 125 126 127 128 129 130
Properties
Temperature (C) 30.63 45.90 48.19 221.88 213.80 45.00 45.01 44.53 65.58 47.08
Pressure (bar) 24.30 24.27 25.00 24.00 24.00 24.00 24.30 24.30 23.99 23.99
Conditions (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 13934.39 13934.39 0.00 0.00 0.00 0.00 0.00 33.53 442.43
Ethylene Oxide 0.00 651.83 651.83 0.05 0.05 0.05 0.05 0.05 1642.42 5585.28
Carbon Dioxide 0.00 77.39 77.39 0.00 0.00 0.00 0.00 0.00 15.99 22.65
Water 11121.36 912.72 912.72 318557.25 318557.25 318557.25 318557.25 329678.61 22.14 52.65
Methane 0.00 199033.26 199033.26 0.00 0.00 0.00 0.00 0.00 1968.51 12731.37
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 11121.36 214609.59 214609.59 318557.30 318557.30 318557.30 318557.30 329678.66 3682.59 18834.38
68
Figure 4.5 Process Flow Diagram of Ethylene Glycol Plant After-HEN

69
Table 4.8 Operating Condition and Mass Flow Rate EG Plant After-HEN
Stream No. 201 202 203 204 205 206 207 208 209 210 211
Properties
Temperature
(C) 30.00 30.21 128.84 170.00 232.58 193.37 167.70 157.61 271.40 170.73 221.39
Pressure (bar) 1.00 24.89 25.00 25.00 25.00 13.00 7.00 5.00 5.00 0.44 0.44
Conditions (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 34054.74 34054.74 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.48 0.48 0.48 0.00 0.00 0.00 0.00 0.00 0.00
Water 47035.10 47035.10 278545.08 278545.08 268362.23 201678.38 124822.90 47930.15 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 4139.27 4139.27 28712.36 27754.30 26601.37 24573.20 24573.20 24531.25 41.95
DEG 0.00 0.00 382.30 382.30 14269.18 14170.00 14067.92 13886.90 13886.83 71.66 13815.17
TEG 0.00 0.00 3010.29 3010.29 8787.91 6744.03 6036.39 5777.63 5777.59 0.06 5777.53
TOTAL 47035.10 47035.10 320132.17 320132.17 320132.17 250346.71 171528.57 92167.89 44237.62 24602.97 19634.66
70
Table 4.8 Operating Condition and Mass Flow Rate EG Plant After-HEN (Continued)
Stream No. 212 213 214 215 216 217 218 219 220 221 222
Properties
Temperature
(C) 173.17 206.21 151.23 193.37 194.42 167.70 175.28 157.61 152.33 151.05 151.37
Pressure (bar) 0.10 0.10 4.90 13.00 14.00 7.00 8.96 5.00 5.00 4.86 25.00
Conditions (kg/hr)
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.48 0.48 0.00 0.00 0.00 0.47 0.47 0.47
Water 0.00 0.00 47930.14 66683.86 66683.86 76855.48 76855.48 76892.75 220431.28 220431.28 220431.28
Methane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 41.95 0.00 0.00 958.06 958.06 1152.93 1152.93 2028.17 4139.27 4139.27 4139.27
DEG 13686.59 128.58 0.07 99.18 99.18 102.08 102.08 181.02 382.30 382.30 382.30
TEG 80.46 5697.08 0.04 2043.87 2043.87 707.65 707.65 258.75 3010.29 3010.29 3010.29
TOTAL 13809.00 5825.66 47930.26 69785.46 69785.46 78818.14 78818.14 79360.69 227963.61 227963.61 227963.61
4.5. Overall Mass and Energy Balance After-HEN
4.5.1. Overall Mass Balance After-HEN
The plant’s overall mass balance after-HEN will be shown in the following
table.
Table 4.9 Overall Mass Balance After-HEN
Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Stream Stream Stream Stream
Stream Stream Stream Stream
Component 101 102 103 120 Stream Stream
201 210 212 213
(Ethylene (Oxygen (Methane (Make Up 130 214
(Water In) (MEG) (DEG) (TEG)
In) In) In) Water)
Ethylene 25248.38 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 14864.53 0.00 0.00 0.00 442.43 0.00 0.00 0.00 0.00
Ethylene Oxide 0.00 0.00 0.00 0.00 0.00 5585.28 0.00 0.00 0.00 0.00
Carbon Dioxide 0.00 0.00 0.00 0.00 0.00 22.65 0.00 0.00 0.00 0.00
Water 0.00 0.00 0.00 11121.36 47035.10 52.65 47930.14 0.00 0.00 0.00
Methane 0.00 0.00 12731.22 0.00 0.00 12731.37 0.00 0.00 0.00 0.00
MEA 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
H3O+ 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEACO-01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
OH- 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
MEG 0.00 0.00 0.00 0.00 0.00 0.00 0.00 24531.25 41.95 0.00
DEG 0.00 0.00 0.00 0.00 0.00 0.00 0.07 71.66 13686.59 128.58
TEG 0.00 0.00 0.00 0.00 0.00 0.00 0.04 0.06 80.46 5697.08
TOTAL 25248.38 14864.53 12731.22 11121.36 47035.10 18834.38 47930.26 24602.97 13809.00 5825.66
TOTAL STREAM 111000.60 111002.27
4.5.2. Overall Energy Balance After-HEN
The overall energy balance after-HEN is shown in the table below.
Table 4.10 Overall Energy Balance After-HEN
Stream Enthalpy Flow In Enthalpy Flow Out Heat Duty Power Loss
Name (MJ/h) (MJ/h) (MJ/h) (MJ/h)
47453.366 0
K-101 68.184 -5678.289 5795.951 0
-58995.790 0
-933177.369 -841025.485 0
E-101 0.000
-890136.848 -982288.733 0
R-101 -841025.485 -890136.848 -49111.363 0
E-102 -982288.733 -1014883.550 -32594.817 0
P-101 -175642.581 -175613.565 29.016 0
K-102 -928570.511 -927498.656 1071.855 0
E-106 -211587.340 -210916.914 670.427 0
-5078096.662 -5062006.540 0
E-103 0.000
-4745623.558 -4761713.680 0
E-105 -4761713.680 -5027767.861 -266054.181 0
P-102 -5027767.861 -5027756.799 11.062 0
-241140.304 0
T-102 -5272904.043 286140.181
-4745623.558 0
E-104 -241140.304 -298179.853 -57039.549 0
-218252.358 0
T-103 -243512.313 13993.534
-11266.421 0
P-201 -744566.074 -744441.293 124.781 0
E-201 -4389986.652 -4334821.809 55164.843 0
E-202 -897750.171 -1028016.331 -130266.160 0
E-203 -1028338.558 -1182866.445 -154527.887 0
E-204 -3243587.056 -3427890.055 -184302.999 0
P-202 -3427890.055 -3427293.001 597.054 0
-265459.594
T-204 -1015823.711 15435.582 0
-734928.535
-172324.767
T-205 -265459.594 -10507.253 0
-103642.079
-76537.912
T-206 -103642.079 -2077.425 0
-29181.592
TOTAL -45461705.479 -45969152.829 -507447.350 0
Enthalpy ¿ −Enthalpy Out + Heat Duty∨Work =Power Loss

MJ MJ MJ MJ
−45461705.479
hr (
− −45969152.829
hr )(
+ −507447.35
hr
=0.00
hr )
MJ MJ MJ
507447.35
hr (
+ −507447.35
hr
−0.00)hr
=0
CHAPTER 5
UTILITY
Plant utility is supporting facilities to running the process from the

beginning until the end of product. Utility unit is separated from the main process
unit and plays important role in the main process because it helps to maintain
proper process condition such as pressure and temperature. Ethylene glycol plant
required water, stream, electricity, and fuel utilities. This chapter only calculate
utilities requirement for main process.
5.1. Water Utility
5.1.1. Water Treatment
The water required for general purpose on a site usually taken from local
mains supply, unless a cheaper source of suitable quality water is available from a
river, lake, or well. Water utility for integrated ethylene glycol plant is supplied
from PDAM. Raw water is brought in to make up for losses in cooling water
system and is also treated to generate pure water for process and boiler feed water
use.
Water treatment with membrane is used to produced process feed and
boiler feed water. Membrane water treatment is a process that removes unwanted
constituents from water. A membrane is a barrier that allows certain substances to
pass through while blocking others. Osmosis is the naturally occurring tendency
for two solutions of differing salinities to want to neutralize. Reverse Osmosis
utilizes pressure to overcome the natural tendency and to force pure water through
a semi-permeable membrane while concentrating salts and other dissolved solids
on the feed side of the membrane. Total water requirement that has to be purified
for process is shown in table 5.1 below.
Table 5.1 Process Water Requirement
Water Requirement
No Code Equipment
(Kg/h)
1 M-102 Mixer 11,121.4
2 M-201 Mixer 47,035.1
Kg/h 58,156.5
Total
Ton/year 509,450.94
75
P-301 F-301 F-302 F-303 T-301 P-302 F-304 P-303 F-305 T-302
Raw Water Pump Multimedia Filter 100 µm Ultrafiltration UF Tank UF Pump 5 µm High Pressure Pump RO Device Middle Tank
Cartridge Filter Cartridge Filter (1st pass) (1st pass)
F-307 P-305 F-306 P-304

P-307 T-304 F-308 P-306 T-303
RO Device High Pressure Pump 1 µm Middle Pump
Product Pump Product Tank Mixed Bed RO Pump RO Tank
(2nd pass) (2nd pass) Cartridge Filter
305
303 307
309
301 302
Raw Water 308
F-302
306 F-304
P-301 F-301
304 P-303
310
F-305
T-301 P-302
F-303
321
Cooling Water
315
312
320
Boiler Feed Water

317
T-302
319 316 314 F-306
F-308 313 311
318
F-307
P-307 T-304 P-306

P-305 P-304
T-303
Stream No. 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321
Properties
Temperature C 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30
Pressure (bar) 1 3 2.999 2.998 2.997 2.996 7 7 15 14.998 14.996 15 14.998 25 24.9 24.9 25 24.99 24.99 40 2.999
Conditions (kg/hr) PROCESS FLOW DIAGRAM
PO43- 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
NO3- 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Cl- 0.1420 0.1420 0.0640 0.0640 0.0512 0.0512 0.0512 0.0512 0.0512 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0640
Na+ 0.1445 0.1445 0.0651 0.0651 0.0521 0.0521 0.0521 0.0521 0.0521 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0651
CHEMICAL ENGINEERING
SO42-
MG2+
0.3035
0.0853
0.3035
0.0853
0.1368
0.0384
0.1368
0.0384
0.1094
0.0307
0.1094
0.0307
0.1094
0.0307
0.1094
0.0307
0.1094
0.0307
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1368
0.0384 ENGINEERING FACULTY Boiler Feed Water Plant
CA2+ 0.5098 0.5098 0.2297 0.2297 0.1838 0.1838 0.1838 0.1838 0.1838 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.2297
K+ 0.0530 0.0530 0.0239 0.0239 0.0191 0.0191 0.0191 0.0191 0.0191 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0239
HCO3- 0.8788 0.8788 0.3960 0.3960 0.3168 0.3168 0.3168 0.3168 0.3168 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.3960
SR2+ 0.0008 0.0008 0.0003 0.0003 0.0003 0.0003 0.0003 0.0003 0.0003 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0003
PLANT DESIGN COURSE SIZE FSCM NO DWG NO 5 REV
Br- 0.0038 0.0038 0.0017 0.0017 0.0014 0.0014 0.0014 0.0014 0.0014 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0017
F- 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
H2O
Total
114124.4225 114124.4225 51350.0000 51350.0000 51350.0000 51350.0000 51350.0000 51350.0000 51350.0000 45425.0000 45425.0000 45425.0000 45425.0000 45425.0000
114126.544 114126.544 51350.95598 51350.95598 51350.765 51350.765 51350.76479 51350.765 51350.765 45425.00008 45425.00008 45425.00008 45425.00008 45425.00008
39500.0000
39500
39500.0000
39500
39500.0000
39500
39500.0000
39500
39500.0000
39500
39500.0000 62774.4225
39500 62775.379
GROUP TK-19 SCALE N/A SHEET 5 OF 7
Figure 5.1 Process Flow Diagram of Water Treatment Plant
76
5.1.2. Cooling Water Requirement

Cooling water is used to cool streams and usually circulated
between process heat exchangers and a cooling tower. Water is cooled
during downward motion by contact with air blown upwards.
Approximately 80% of the temperature reduction is due to evaporation of
the cooling water and heat transfer to the surrounding air. Water loss from
evaporation, drift loss, and blow down could exist. The numbers of
calculated water loss are the number of makeup water needed by the plant.
Water loss from evaporation is calculated by
W e =0.00085W c (∆ T )
Where,
W c = inlet water to cooling tower
W e = water loss from evaporation
∆ T = temperature difference between inlet and outlet water
Water loss from drift loss is usually 0.1 – 0.2% from the total inlet
cooling water and can be calculated by
W d =% drift loss ×W e
Water loss from blow down depend on the amount of cooling water
cycle, usually between 3 – 5 cycles and can be calculated by
We
W b=
C−1
Where,
W b = water losses from blow down
C = number of cycle
The total of required makeup cooling water can be calculated by
Makeup Cooling Water=W e +W d +W b
Integrated ethylene glycol plant consists of ethylene oxide and
ethylene glycol production. In ethylene oxide production, cooling water
system designed to provide cool stream before entering absorption column,
so the temperature of the feed suitable for the operation condition in the
absorption column. In ethylene glycol production, cooling water system
designed to condense stream from evaporator unit. This integrated
77
ethylene glycol plant assumed that Tin of cooling water is 30C and Tout
50C. The water loss in cooling water system assumed to have 0,2% drift
loss with 4 cooling water cycle. The calculation of cooling water
requirement before and after heat exchanger network shown in table 5.2
and 5.3 below.
Table 5.2 Cooling Water Requirement Before-HEN
Tin Tout
Equipment Q (kJ/h) Cp water mass flow
(C) (C)
E-102 30 50 1.25E+08 4.18 1492188.995
E-104 30 50 5.70E+07 4.18 682193.7799
E-105 30 50 2.82E+08 4.18 3374988.038
(Kg/h) 5549370.813
TOTAL
(Ton/h) 43951016.84
Makeup Cooling Water
Losses Number Amount (kg/h)
Water loss from evaporation (We) 20 C 94339.30383
Drift loss (Wd) 0.20% 188.6786077
Blowdown (Wb) 4 31446.43461
(Kg/h) 125974.417
TOTAL
(Ton/year) 1103535.893
TOTAL REQUIRED 1ST RUN (Kg/h) 5675345.23
Table 5.3 Cooling Water Requirement After-HEN

Tin Tout
Equipment Q (kJ/h) Cp water mass flow
(C) (C)
E-105 30 35 2.66E+08 4.18 3182093.301
(Kg/h) 3182093.301
TOTAL
(Ton/h) 27875137.32
Makeup Cooling Water
Losses Number Amount (kg/h)
Water loss from evaporation (We) 20 C 54095.58612
Drift loss (Wd) 0.20% 108.1911722
Blowdown (Wb) 4 18031.86204
(Kg/h) 72235.63934
TOTAL
(Ton/year) 632784.2006
TOTAL REQUIRED 1ST RUN (Kg/h) 3254328.941
From cooling water calculation above, it can be concluded that based

amount for continuous cooling tower system is 72,235.63934 kg/h. The
process flow diagram of cooling water circulation through the main
equipment of cooling tower is illustrated in figure 5.2 below.
78
CT-501 P-501
Cooling Tower Pump
Evaporation
Drift
506
505
504
Cooling Water
System
503
501 502
Makeup Water
P – 501
CT-501
507
Blowdown
Stream Number 501 502 503 504 505 506 507
Properties PROCESS FLOW DIAGRAM
Temperature C 30 20 20 50 30 30 30
Pressure (bar) 1,1 1,1 1,1 1,1 1 1 1
Compotition (kg/h) CHEMICAL ENGINEERING
H2O 72235,64 72235,64 72235,64 72235,64 54095,59 108,1912 18031,86 ENGINEERING FACULTY Cooling Tower
PLANT DESIGN COURSE SIZE FSCM NO DWG NO 5 REV
GROUP TK-19 SCALE N/A SHEET
Figure 5.2 Process Flow Diagram of Cooling Water Unit
79
5.1.3. Boiler Feed Water

Steam is required for process as the heating media. The steam will
be produced by boiler in utility plant and waste heat boiler in ethylene
oxide reactor. The steam that will be used are low pressure steam (4 bar
145 0C) and medium pressure steam (15 bar 198 0C) based on the stream
target temperature. The calculated steam requirement will be shown
below.
Table 5.4 Steam Requirement in Plant Before-HEN
Specific
Q Mass Flow
Equipment Code Latent Heat Note
(kJ/h) (kg/h)
(kJ/kg)
Heater E-101 1.25E+08 1904.5 6.55E+04 MP
Heater E-103 1,68E+07 2100.5 7.98E+03 LP
EO stripper reboiler E-106 2.86E+08 1904,5 1.50E+05 MP
EO purification reboiler E-107 1.40E+07 2100.5 6,66E+03 LP
Heater E-201 5.52E+07 2100.5 2,63E+04 LP
Dehydrator reboiler E-205 3.17E+08 1790.0 1,77E+05 HP
MEG purification
E-206 3.36E+07 1904.5 1.76E+04 MP
reboiler
DEG&TEG purification
E-207 3.18E+07 1904.5 1.67E+04 MP
reboiler
(Kg/h) 4.68E+05
TOTAL STEAM REQUIRED
(Ton/h) 3705340.987
After conducting HEN analysis, the steam requirement is calculated as
shown in the table below.
Table 5.5 Steam Requirement in Plant After-HEN
Specific
Q Mass Flow
Equipment Code Latent Heat Note
(kJ/h) (kg/h)
(kJ/kg)
Heater E-106 6.70E+05 2100.5 3.19E+02 LP
EO stripper reboiler E-107 2.87E+08 1904.5 1.51E+05 MP
EO purification reboiler E-108 1.40E+07 2100.5 6.67E+03 LP
Heater E-201 5.52E+07 2100.5 2.63E+04 LP
Dehydrator reboiler E-205 3.17E+08 1790.0 1.77E+05 HP
MEG purification
E-206 MP
reboiler 3.36E+07 1904.5 1.76E+04
DEG&TEG purification
E-207 MP
reboiler 3.18E+07 1904.5 1.67E+04
(Kg/h) 3.95E+05
TOTAL STEAM REQUIRED 3,129,101.34
(Ton/h)
3
By assuming that 90% of steam condensate can be circulated, the
makeup boiler feed water required can be calculated.
80
Makeup boiler feed water =0.1 x 395,000 kg/h=39,5 kg /h

The process diagram flow of steam generation plant shown in figure 5.3 below.
81
F-401 D-401 P-401 B-401

Air Screen Deaerator Boiler Feed Pump Boiler
P-402
Air Blower
401
Steam Condensate
408
HP Steam
D-401
E-2
409
405 MP Steam
406 407
402 P-401
Boiler Feed Water B-401 410
LP Steam
403
Fuel
404
Air
F-401 P-402
Stream No. 401 402 403 404 405 406 407 408 409 410
Properties
Temperature C 30 30 40 40 40 40 40 300 198 145
Pressure (bar) 1.1 40 1.2 1.2 1 40 40 40 15 4 PROCESS FLOW DIAGRAM
Conditions (kg/hr)
H2O 395000.00 39500.00 0.00 0.00 395000.00 395000.00 434500.00 434500.00 434500.00 434500.00 CHEMICAL ENGINEERING
ENGINEERING FACULTY Steam Generation Plant
N2 158.00 0.00 0.00 119782.79 0.00 0.00 0.00 0.00 0.00 0.00 UNIVERSITAS INDONESIA
O2 42.00 0.00 0.00 31841.00 0.00 0.00 0.00 0.00 0.00 0.00 SIZE FSCM NO DWG NO 6 REV
PLANT DESIGN COURSE
CH4 0.00 0.00 15920.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total 395200 39500 15920.5 151623.79 395000 395000 434500 434500 434500 434500 GROUP TK-19 SCALE N/A SHEET 6 OF 7
Figure 5.3 Process Diagram Flow of Steam Generation Plant

5.1.4. Total Water
Equation below is used to calculate required water utility for plant
start up.
kg
Total water req for start up( )=Feed process+ cooling water +boiler feed
h
Total water req for start up ( kgh )=58,156.5+2,828,086.3+395,000

kg
Total water req for start up( )=3,280,000
h
While for continuous process, it assumed that cooling water system
use produced water from process, so total water required for continuous
process can be calculated with equation bellow.
Total water req for continous process ( kgh )=Feed process+boiler feed
kg
Total water req for continous process ( ) =58,156.5+39,500
h
kg
Total water req for continous process ( )=97,656.5
h
5.2. Electricity Utility
Electricity demand of the process is mainly determined by the work required
for pumping, compression, air coolers and solid – handling operation. The power
required usually purchased from the local supply company. For this integrated
ethylene glycol plant, electricity is supplied from PT. PLN. Detailed amount of
electricity that are needed for integrated ethylene glycol process equipment are
listed in Table 5.5 below.
Table 5.5 Electricity Requirement
Usage Power
Equipment Code Power (kW)
Time (h) (kWh/day)
Feed Compressor K-101 24 1,694.76 40674.24
Recycle Feed Compressor K-102 24 313.405 7521.72
EO Absorber Feed Pump P-101 24 8.98415 215.6196
Recycle EO Absorberr
P-102 24 3.41376 81.93024
Feed Pump
EG Feed Pump P-201 24 36.4521 874.8504
Recycle EG Feed Pump P-202 24 165.853 3980.472
TOTAL 2,222.86801 53348,83224
Total Electricity Needed/year 17,605,114.64 kWh
Total Electricity Needed/year 17,605.11464 MWh
17,547,721,96
Total Electricity Cost/year IDR
5
5.3. Fuel Utility

The steam will be produced by both boilers in utility plant and waste
heat boiler in ethylene oxide reactor. The duty for steam generation will be
distributed between these two units kg/h. Steam required to be generated
by the boiler is 39,500 kg/h.
Given the heat of vaporization of steam is 1678 kJ/kg, the heat duty
required for the boiler is 738,711,127 kJ/h.
The fuel used for the burner in boiler is natural gas with net heating
value 46.4 MJ/kg or 33.5 MJ/Nm3. The fuel required is calculated below.
Total Heat Required
Rate of Fuel Gas=
NHV fuel
kg
Rate of Fuel Gas=15,920.5 =22,051.1 kg/ Nm3
h
5.4. Fuel Utility
Air is needed for combustion reaction of fuel gas with the
composition in table below. The combustion reactions that occur are:
CH4+2 O2 →CO2+2H2O
Assuming the combustion reaction, the molar flow rate of oxygen is
calculated below.
𝑛̇𝑂2𝑟𝑒𝑎𝑐𝑡𝑒𝑑=2×𝑛̇𝐶𝐻4
Meanwhile the molar flow rate of air is calculated below.
𝑛̇𝑎𝑖r=𝑛̇𝑂2×100%/21%
Therefore, air needed for boiler is 151,623.79 kg/h.
5.5. Comparison of Pre-HEN and Post-Hen
Calculation of required utility before and after HEN installation are
shown in table 5.6 below. After HEN installation, the system manages to
decrease the necessity around 42.7% for cold utility and 15.9% for cold
utility.
Table 5.6 Comparison of Process Before and After HEN
Utilit Mass (kg/h) Energy (Mj/h) Recovery (%)
Energ
y Before After Before After Mass
y
3254328,94 4,64E+0
cold 5675345,23 2,66E+08 42,7 42,7
1 8
3705340,98 3129101,34 8,79E+0
hot 7,39E+08 15,9 15,9
7 3 8
CHAPTER 6
CONCLUSION
Based on the design related to technology selection, process

description, flowsheeting, and mass and energy balance calculation,
several conclusions are listed as follows.
 Ethylene glycol (EG) or ethanediol is one of the most highly demanded
raw materials in industrial applications.
 The best location that best suited for ethanediol or ethylene glycol plant is
in the industrial area Cilegon, Banten with the main consideration of close
proximity of raw material, target market, and utilities.
 The ethylene glycol plant is planned to be able to meet 14% of the market
vacancy in 2025 which is 78,836.7 tons/year.
 The selected process route is the hydrolysis of ethylene oxide. This
process is the most mature technology and produces higher glycols, uses
less steam and water, and generates less waste.
 The production of Ethylene Glycol consists of five major steps, which are
ethylene oxide production, hydrolysis reaction, dehydration, product
separation.
 The produced ethylene glycol achieved fiber/polyester grade with 99.5%
purity
 The conversion efficiency of raw materials into useful products is 42.02%.
The yield of MEG produced is 0.174 kg MEG/kg ethylene by the basis of
ethylene.
 The energy consumption per unit product is calculated to be 240.627 MJ/
kg MEG.
REFERENCES
Akpa, J. G. and Onuorah, P. (2018) Simulation and Control of a Reactor for the
Non-catalytic Hydrolisis of Ethylene Oxide to Ethylene Glycol.
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American Chemistry Council, Arlington, VA, “Briefing Paper on Ethylene
Glycol,” Feb. (2000).
Celik, F. E., Lawrence, H., and Bell, A.T. (2008) Synthesis of Precursors to
Ethylene Glycol from Formaldehyde and Methyl Formate Catalyzed by
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288, pp. 87-96.
Choomwattana, C., et al. (2015) Evaluation of Dimethyl Carbonate and Ethylene
Glycol Production from Biomass. Bangkok: Chulalongkorn University.
Choomwattana, C., et al. (2016) Process Integration of Dimethyl Carbonate and
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Design. Bangkok: Chulalongkorn University.
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Bohemia
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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF ETHANEDIOL PLANT

CHEMICAL ENGINEERING DEPARTMENT

Ethanediol or Ethylene Glycol (EG) is also interchangeably referred to as

iii Universitas Indonesia

Figure 1.1 Vapor Pressure of Glycols.....................................................................3

Tabel 1.1 Indonesia Ethylene Glycol Import..........................................................1

1.1. Background of Ideas

Conventionally, ethylene oxide is produced from oxidizing ethylene with

to crystallize. When it is cooled, it forms a highly viscous, super-cooled mass that

Figure 1.1 Vapor Pressure of Glycols

Figure 1.3 Synthetic Methodologies and Applications of EG

At present, the industrial approach to produce ethylene is hydration of

Figure 1.4 Oxide Hydration Reaction Formation of Homologues EG

Figure 1.5 Reaction Mechanisms for Hydrogenation of DMO.

1.2.2.4. Transesterification of Ethylene Carbonate and Methanol

Figure 1.6 Synthesis of EG by Transesterification of EC with Methanol.

Figure 1.7 Reaction Pathways for EG Synthesis from Formaldehyde.

is then absorbed by an absorbent solution before entering the carbonation unit.

Formaldehyde is produced industrially by the catalytic oxidation of

Water is an oxygen hydride consisting of an oxygen atom that is

Amount of Ethylene Glycol Imported (2009 - 2018)

Figure 1.8 Ethylene Glycol Imported to Indonesia

availability of men, materials, money, machinery, and equipment. Those factors

Figure 1.9 Plant Location

2.1. Process Synthesis

 MEG formation: Desired reaction

excess water is energy intensive and requires capital investment in evaporators.

concentration of H3O+; consequently, a large amount of unprotonated ethylene

Table 2.1 Catalytic Systems for Synthesis of EG by Hydration of EO (Continued)

exothermic and the ethylene carbonate hydrolysis reaction is endothermic. So,

Table 2.2 Scoring Criteria for Process Route Selection

Table 2.3 Parameter Comparison of Process Routes

Table 2.3 Parameter Comparison of Process Routes (Continued)

Parameter Process Routes Comparison

Catalytic 92% selectivity

Table 2.4 Scoring of Process Routes

Total 2,4 3,85 3,7 3,8

2.3. Process Description

Excess water (some water is consumed in the hydrolysis reaction) in the

2.4. Block Flow Diagram

Figure 2.1 Block Flow Diagram of Ethylene Oxide Plant

Figure 2.2 Block Flow Diagram of Ethylene Glycol Plant

2.5. Process Flow Diagram Before-HEN

Figure 2.3 Process Flow Diagram of Ethylene Oxide Plant Before-HEN

Figure 2.4 Process Flow Diagram of Ethylene Glycol Plant Before-HEN

3.1. Mass and Energy Balance for Each Process

TOTAL 267454.03 267453.94

Table 3.6 Mass Balance of Pump (P-101)

Table 3.9 Mass Balance of Heat Exchanger (E-103)

Table 3.12 Mass Balance of Pump (P-102)

Table 3.15 Mass Balance of Light-End Column (T-103)

3.1.1.2. Ethylene Glycol Plant

OH- 0.00 0.00

MEG 4138.89 28712.32

DEG 14170.58 14068.50 102.08

TEG 5778.19 5778.15 0.04

TOTAL 227954.33 227951.03