Acetone Project Recovered

An- Najah National University
Faculty of Engineering
Chemical Engineering Department
Chemical plant design

Project 2: Acetone production plant
Prepared by:
Hussam Saleh (11820199)
Hala Badawi (11820211)
Nada Mahamid (11715951)
Syndia Abu Hardan (11820959)
Submitted to:
Dr. Shadi Sawalha
May 15th ,2022

Abstract
This project aims to implement a complete design of the acetone plant during the 2021-2022
semester according to the specifications and instructions specified by the teacher.
Initially, a design plan was prepared that includes all the steps and the roles of the group members
were assigned to each task. The beginning of this plan was from 14/2/2022 until the final
submission date, which is 15/5/2022 .The plant should produce acetone at an annual production
rate of 15,000 metric tons.
The teacher's instructions contain the suggested process for manufacturing acetone, but the
students were to conduct a literature search for the process selection task, and measure
performance among 3-5 selected processes .Several methods of producing acetone have been
found, and the best one had to be chosen between: Acetone-butanol-ethanol (ABE) fermentation,
Cumene method, Oxidation propylene to acetone, and Dehydrogenation of isopropyl alcohol
(IPA). A comparison was made between all previous processes, in it; many important factors such
as: purity, conversion, safety, Raw materials, Cost, Time needed and others were studied. The
results of this comparison were the adoption of the Dehydrogenation of isopropyl alcohol (IPA)
process as the best option for producing acetone inside the plant to be established.
Then the task of material balance was done, through it the contents of each stream, whether it was
inlet or outlet the equipment in the flow chart, was known. After that, work began on the task of
energy balance, the aim of this part is to see the total amount of energy used, conversion
efficiency, output and losses.
So here we are ready to go into the next task which is equipment design and sizing, starting with
the reactor: The type of reactor that was used is a fixed bed flow reactor. With a volume of 11.359
cubic meters, 192 number of tubes, zinc oxide and zirconium oxide combination as catalyst, and
all the details were taken into account and calculated. Second, design of separator: length,
diameter, thickness and others were calculated. 16.025m, 1.09 m, 4.023mm respectively. Then
to the Scrubber: Diameter, Total height, thickness, etc., it was found to be: 0.656 m, 9.112 m,
4.014 mm respectively. Finally with distillation: its calculations and equations were applied to
find its different dimensions: Hight, Plate spacing, Number of trays, and it was found to be: 21m,
0.46m, 37 respectively.
Also, we discussed safety. In this section, the HAZOP procedure was used to conduct a safety
and loss study for the fixed bed reactor and the distillation column: During the transfer of the
steam mixture to the reactor, we may encounter control failure and sudden valve shutdown, which
leads to loss of cooling and the possibility of leakage, so it was Install a filter with regular
maintenance. Also, the occupied problems encountered in distillation: are pipe blockage, closure
or failure of the control valve, leakage, and pump failure, possibly due to the drying of the column
or the occurrence of dangerous concentrations. We can bypass them by installing a low-level
alarm, checking maintenance procedures and schedules, and making an override line
To the economic department: By completing the cost task, and calculating: capital investment,
purchased cost, annual operating cost, production cost and cash flows. Found: 5,400,000$ by
Chilton, 500,600$, 16557566.82$, 8116347.811$ and 11215623.81$ at first year respectively.
II
Contents
Abstract ................................................................................................................................ II
Introduction ...........................................................................................................................1
Process selection ....................................................................................................................3
Material Balance ....................................................................................................................7
• Reactor .......................................................................................................................7
• Separation Vessel ........................................................................................................9
• Scrubber ................................................................................................................... 12
• Mixing point ............................................................................................................. 15
• Distillation ................................................................................................................ 16
Energy balance ..................................................................................................................... 18
Equipment design ................................................................................................................. 27
• Reactor design........................................................................................................... 27
• Two-Phase Separator Design ...................................................................................... 34
• Scrubber design ......................................................................................................... 40
• Distillation design...................................................................................................... 44
Economic study .................................................................................................................... 57
• Purchased cost........................................................................................................... 57
• Total Fixed Capital investment ................................................................................... 67
• Operating expenses.................................................................................................... 70
• Cash flow.................................................................................................................. 77
Hazard and Operability Analysis (HAZOP)............................................................................ 80
Plant location and Layout...................................................................................................... 88
Conclusion ........................................................................................................................... 94
References ........................................................................................................................... 95
III
Introduction
We present to you the final project of the factory and economy design course. By
completing this course, we can say that we have learned how to design a chemical plant
from A to Z, how to do a feasibility survey before setting up any project, and how to make
complete project cost calculations: capital investment, annual operating cost, and
production cost, cash flow.
The objective of the feasibility survey is to know the needs of the successful project in
terms of costs and resources and its success rate in the short and long term. The feasibility
study also helps to know the opportunity points for the project and the points of the
expected challenges and to develop plans to overcome them to reach the project for the
greatest success rate in the future.
Taking a look at the global acetone market: The acetone market is being negatively
affected by the COVID-19 pandemic. The global pandemic is crippling major acetone end -
user industries, such as automobiles, paints and coatings, cosmetics, and personal care.
However, it is expected to increase by over 3% during the forecast period (2022-2027).
The market has been dominated by the Asia Pacific region and is expected to dominate
during the forecast period due to increased consumption from countries like China and
India.
Figure 1: Acetone Market-Growth Rate by Region, 2022-2027 [1]
1
Some of the applications of acetone: Methyl Methacrylate (MMA), Bisphenol A (BPA),
Solvents, Methyl Isobutyl Ketone and Other Applications (Chemical Intermediates).
Figure 2: Acetone Market, Volume (%), by Application, Global,2021 [2]
2
Process selection
There are several ways to produce acetone, and we must choose the best, so we searched for
several ways to choose the best one, and the processes we found and compare:
1) Acetone–butanol–ethanol (ABE) fermentation
It is a method of producing acetone, n-Butanol, and ethanol from carbohydrates such as starch
and glucose by bacterial fermentation. In addition to the gases mentioned above, acetone-
butanol fermentation produces several other compounds. Isopropanol, formic acid, acetic acid,
butyric acid, acetyl methyl carbinol, and yellow oil, a mixture of higher alcohols and acids, are
among the most important industrial chemicals. It is estimated that energy cost was the second
highest production cost (occupying 14%) of biological ABE (conventional distillation is
energy-intensive), making it extremely costly. Because biobutanol is made by fermenting
acetone, butanol, and ethanol (ABE), the process contains numerous chemicals that can create
fires and explosions, as well as have significant environmental and health consequences. [3] [4]
Because it’s not a common process we can’t find a flowsheet for it
2) Dehydrogenation of isopropyl alcohol (IPA)
H2O
C3H8O C3H6O + H2
The isopropyl alcohol (C3H8O) and water (H2O) enter the process together at 25°C and 1 bar
pressure, resulting in the dehydrogenation of the isopropyl alcohol and an endothermic
reaction. The acetone production process has a high purity and conversion, is free of additives,
and is simple to separate because the by-product is hydrogen, which can be separated through
distillation. The raw materials are available and allowed to enter the country, but the materials
are hazardous and flammable.[5]
The flowsheet of the process:
3
Figure 3:Dehydrogenation of isopropyl alcohol process flowsheet
3) Cumene method
in this method, benzene (C6H6) reacts with propylene (C3H6) to form cumene (C9H12). After
the reaction, cumene is oxidized to form acetone (CH3) 2CO with phenol (C6H6O), as is
clarified in the equations below:
C6H6 + C3H6 + O2 → (CH3) 2CO + C6H6O
It has a high quantitative conversion of up to 90% or more and yields between 80% and 90%.
In addition, there is by-products are produced in this method such as mesityl oxide, α-methyl
styrene, acetophenone, and 2-phenyl-2-propanol, but as a by-product, is benzene lowers the
purity of acetone and increases production costs by separation. The raw materials are benzene
and propylene. The cumene process method is very expensive since it needs raw materials and
additional separation equipment to separate acetone from many different materials.[5] [6] [7]
The flowsheet of the process:
4
Figure 4:Cumene process flowsheet
4) Oxidation propylene to acetone.
A novel process for the preparation of acetone is reported by gas-phase oxidation of

propylene in the presence of H 2 and O 2 with Au-supported TS-1 catalyst (Au/TS-1). By
elevating the reaction temperature to 280 o C, Au/TS-1 catalyzes 11.6% propylene
generating acetone with 70.6% selectivity and 8.2% acetone in OnePass yield. Acetone is
originated from propylene oxide isomerization, which is mainly attributed to the surf ace of
the Lewis base and high reaction temperature. Furthermore, small Au nanoparticle size
promotes the reaction.[8]
The raw materials of this process have been available on the Palestinian markets. In
addition to that the process product acetone with good purity. Usually, there are no
byproducts in this reaction. And the time needed for completing the reaction is a little of
minutes. The cost of the raw material, which is propylene in this case is approximately
1,048 U.S. dollars per metric ton.[9]
TS-1
Propylene + H2 + O2 Acetone
5
Because it’s not a common process we can’t find a flowsheet for it
The table below has been described the optimum or best process to select for producing
acetone compound and we chose the important factors in our opinion and at the same time
the factors that we were able to collect for each process
Cumene IPA Oxidation of acetone-

method dehydration propylene butanol-ethanol
(reference) fermentation
Conversion - 0 - -
Purity - 0 0 -
Safety 0 0 0 +
Raw materials 0 0 0 +
Cost - 0 0 0
Byproducts - 0 0 -
Catalysts used 0 0 0 0
Time needed 0 0 0 -
Total score -4 0 -1 -2
Rank 4 1 2 3
According to the above data, the IPA dehydration process and oxidation of propylene
process were the best two processes. Therefore, to determine the best one the table below
shows the mechanism of that.
weight Oxidation of IPA dehydration

propylene
Purity 30% 3 3
Conversion 15% 2 3
Safety 30% 3 3
Raw materials 20% 4 3
Cost 25% 3 3
Byproducts 15% 2 3
Catalysts used 5% 3 3
Time needed 20% 3 3
Total score 4.7 4.8
Rank 2 1
The best process according to the data above was by dehydrogenation of the isopropyl
alcohol process
6
Material Balance
• Reactor
𝑚𝑜𝑙𝑒 𝑜𝑓 𝐼𝑃𝐴 𝑖𝑛 = 0.88 × 100 = 88𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

𝑚𝑜𝑙𝑒 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 = 0.12 × 100 = 12𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 ∶
𝑖𝑛 − 𝑜𝑢𝑡
𝑥= × 100%
𝑖𝑛
𝑓𝑜𝑟 𝐼𝑃𝐴:
𝑖𝑛 − 𝑜𝑢𝑡
𝑥= × 100%
𝑖𝑛
88 − 𝑜𝑢𝑡
90% = × 100%
88
𝑜𝑢𝑡 = 8.8 𝑚𝑜𝑙 𝐼𝑃𝐴
Therefore, moles of IPA reacted equal 88-8.8=79.2 mole

The ratio between IPA and Acetone in the equation is 1:1, so moles of Acetone produced
=79.2 mol, the same thing for Hydrogen, so moles of Hydrogen produced =79.2 mol
Moles H 2 O in = moles H 2 O out = 12 mole
The statements required to produce 15000 tons acetone/year which means 1250tons
acetone/month.
Therefore: 100 𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ → 79.2 𝑚𝑜𝑙𝑒 𝑎𝑐𝑒𝑡𝑜𝑛𝑒/𝑚𝑜𝑛𝑡ℎ → 0.00461 ton/month
To produce 15000ton/year → 1250 tons/month needed

The actual amount must be pumped to the reactor:
1250
𝑚𝑜𝑙𝑒 𝑜𝑓 𝑎𝑐𝑒𝑡𝑜𝑛𝑒 𝑚𝑢𝑠𝑡 𝑏𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑚𝑜𝑛𝑡ℎ𝑙𝑦 = = 21.478 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
58.2
7
Known that the molar mass of acetone, IPA, water, and H2 were 58.2, 60.1, 18, and 2
respectively.
To calculate the actual moles which must be pumped monthly;
100 ∗ 21.477
𝑛𝑎𝑐𝑡 = = 27.117𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
79.2
Mole and masses produced from each product;
27.117
𝐴𝑐𝑒𝑡𝑜𝑛𝑒 = ∗ 79.2 = 21.477 𝑀𝑚𝑜𝑙𝑒𝐴𝑐𝑒𝑡𝑜𝑛𝑒/𝑚𝑜𝑛𝑡ℎ = 1250𝑡𝑜𝑛/𝑚𝑜𝑛𝑡ℎ
100
𝐻2 = 21.477 𝑀𝑚𝑜𝑙𝑒 𝐻𝑦𝑑𝑟𝑜𝑔𝑒𝑛/𝑚𝑜𝑛𝑡ℎ = 42.953𝑡𝑜𝑛/𝑚𝑜𝑛𝑡ℎ
𝐻2 𝑂 = 3.254 𝑀𝑚𝑜𝑙𝑒 𝑤𝑎𝑡𝑒𝑟/𝑚𝑜𝑛𝑡ℎ → 58.573𝑡𝑜𝑛/𝑚𝑜𝑛𝑡ℎ
𝐼𝑃𝐴 = 2.386𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ = 143.416 𝑡𝑜𝑛 𝐼𝑃𝐴/𝑚𝑜𝑛𝑡ℎ
8
• Separation Vessel
To find the bubble pressure:

By Raoul’s law
𝑠𝑢𝑝𝑝𝑜𝑠𝑒 𝑋𝑖 = 𝑍𝑖
𝑓𝑜𝑟 𝑎𝑐𝑒𝑡𝑜𝑛𝑒(𝐴): 𝑋𝐴 𝑃𝐴𝑠𝑎𝑡 = 𝑌𝐴 𝑃
𝑓𝑜𝑟 𝐼𝑃𝐴(𝐼): 𝑋𝐼 𝑃𝐼𝑠𝑎𝑡 = 𝑌𝐼 𝑃
𝑓𝑜𝑟 𝑤𝑎𝑡𝑒𝑟(𝑤): 𝑋𝑤 𝑃𝑤𝑠𝑎𝑡 = 𝑌𝑤 𝑃
𝑋𝐴 𝑃𝐴𝑠𝑎𝑡 +𝑋𝐼 𝑃𝐼𝑠𝑎𝑡 +𝑋𝑤 𝑃𝑤𝑠𝑎𝑡 = 𝑝 (1)
Using acetone equation to find 𝑃𝐴𝑠𝑎𝑡 and𝑃𝐼𝑠𝑎𝑡

𝐵
𝑙𝑛𝑃 𝑠𝑎𝑡 = 𝐴 −
𝑇 −𝐶
A, B, C from the statement
At T=45o C =318.15K
𝑃𝑤𝑠𝑎𝑡 = 9.5898𝑘𝑝𝑎
𝑃𝐴𝑠𝑎𝑡 = 68.354𝑘𝑝𝑎
𝑃𝐼𝑠𝑎𝑡 = 18.867𝑘𝑝𝑎
𝑝 = 56.945𝑘𝑝𝑎 (𝑎𝑓𝑡𝑒𝑟 𝑠𝑢𝑏𝑠𝑡𝑖𝑡𝑢𝑡𝑒 𝑖𝑛 𝑒𝑝𝑢𝑎𝑡𝑖𝑜𝑛 1)
9
Mass balance equations:
𝐴: 𝑋𝐴 × 68.354 = 𝑌𝐴 × 56.945
𝐼: 𝑋𝐼 × 18.817 = 𝑌𝐼 × 56.945
𝑊: 𝑋𝑤 9.5898 = 𝑌𝑤 × 56.945
𝑋𝐴 + 𝑋𝐼 + 𝑋𝑤 = 1
𝑌𝐴 + 𝑌𝐼 + 𝑌𝑤 = 1
𝐴: 0.792 × 27.117 = 𝑋𝐴 × 𝐿 + 𝑌𝐴 × 𝑉
𝐼: 0.0879 × 27.117 = 𝑋𝐼 × 𝐿 + 𝑌𝐼 × 𝑉
𝑊: 0.12 × 27.117 = 𝑋𝑊 × 𝐿 + 𝑌𝑊 × 𝑉
Know that:
𝐿 = 𝑆8 , 𝑉 = 𝑆7 , 27.117 = 𝑆6
These equations have been solved by EES, and the results were:
𝑆8 = 27.09𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑆7 = 0.0193 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑋𝐴 = 0.792 , 𝑌𝐴 = 0.9506
𝑋𝐼 = 0.0879 , 𝑌𝐼 = 0.02914
𝑋𝑊 = 0.12 , 𝑌𝑊 = 0.02022
𝑛𝐴𝐿 = 21.45528𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ , 𝑛𝐴𝑣 = 0.01834658𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

𝑛𝐼𝐿 = 2.3825655𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ , 𝑛𝐼𝑣 = 0.00056240 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑛𝑤𝐿 = 3.253509𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ , 𝑛𝑤𝑣 = 0.00039𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
10
Figure 5:equations of separator in EES
Figure 6:EES equation result for separator
11
• Scrubber
P = 56.945 kpa = 0.562atm, T= 45 °C, 𝑆 7 =0.0193𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ,
IPA = 0.00039𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ, A = 0.018346𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
W =0.0006𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ, H 2 = 21.477𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
Suppose 𝑠9 = 2.5*𝑆1 =67.7925 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
3598
exp (10.92− )
45+273.15
m=
0.562
m=1.2057
67.7925
A = 1.2057 ×48.594 = 1.157
𝑦𝑠𝑡𝑟𝑒𝑎𝑚11 1−𝐴
=
𝑦𝑠𝑡𝑟𝑒𝑎𝑚7 1 − 𝐴6
𝑦𝑠𝑡𝑟𝑒𝑎𝑚11
= 0.1122
𝑦𝑠𝑡𝑟𝑒𝑎𝑚7
𝑦𝑠𝑡𝑟𝑒𝑎𝑚11 = 0.1122 × 𝑦𝑠𝑡𝑟𝑒𝑎𝑚7
0.018346
𝑦𝑠𝑡𝑟𝑒𝑎𝑚7 = = 8.535 ∗ 10−4
0.0193 + 21.477
𝑦𝑠𝑡𝑟𝑒𝑎𝑚11 = 0.1122 ∗ 8.535 ∗ 10−4 = 9.576 × 10-5
nA11
= 9.576 × 10-5
S11
12
Mass balance equations:
For Acetone
0.018346= (9.576 × 10-5 ) + (𝑋𝐴 × 𝑆10 )
For IPA
0.0005624 = (𝑋𝐼 × 𝑆10 )
For H 2 O
67.79289 = (𝑌𝑊 × 𝑆11 ) + (𝑋𝑊 × 𝑆10 )
For H 2
21.477 = Y H × 𝑆11
𝑋𝐴 + 𝑋𝐼 + 𝑋𝑊 = 1
𝑌𝐻 + 𝑌𝑊 + 9.576 × 10-5 = 1
𝑌𝑊 × 𝑆11 = 3.3896
The EES software was used to solve the equations, and these results that we obtained:
𝑆10 = 64.42 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ 𝑆11 = 24.87 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑋𝐴 =0.0002478 𝑌𝐴 = 9.576 × 10-5
𝑋𝐼 = 0.000008731
𝑋𝑊 = 0.000008731 𝑌𝑊 = 0.1364
𝑌𝐻 = 0.8635
Figure 7:equations of scrubber in EES
13
Figure 8:EES equation result for scrubber
14
• Mixing point
𝑆12 = 𝑆10 + 𝑆8
𝑆12 = 64.42 + 27.09 = 91.51 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝐴𝑐𝑒𝑡𝑜𝑛𝑒: 𝑛𝐴 = 𝑥𝐴𝑆10 + 𝑧𝐴 𝑆8 = 0.0002478 × 64.42 + 0.792 × 27.09

= 21.47𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝐼𝑃𝐴: 𝑛𝐼𝑃𝐴 = 𝑥1 𝑆10 + 𝑧1 𝑆8 = 0.000008731 × 64.42 + 0.08795 × 27.09

𝑊𝑎𝑡𝑒𝑟: 𝑛𝑊 = 𝑥 𝑤𝑆10 + 𝑧𝑤 𝑆8 = 0.9997 × 64.42 + 0.1201 × 27.09
15
• Distillation
Make total material balance
Assume that all amount of water has been gone away from stream 14
91.51 = 𝑆13 + 𝑆14

0.995 × 21.47 = 0.999 × 𝑆13
0.005 × 21.47 = 𝑋𝐴 × 𝑆14
𝐼𝑃𝐴: 2.383 = 𝑋𝐼 × 𝑆14 + 𝑌𝐼 × 𝑆13
𝐻2 𝑂: 67.654 = 𝑋𝑊 × 𝑆14
𝑋𝐴 + 𝑋𝐼 + 𝑋𝑤 = 1
𝑌𝐼 + 0.999 = 1
These equations have been solved by EES, and the result was:
𝑆14 = 70.126 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ 𝑆13 = 21.384 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑋𝐴 = 0.001574 𝑋𝐼 = 0.03368 ,
𝑌𝐼 = 0.001 𝑋𝑊 = 0.9647
𝑛𝐼𝐿 = 2.3618𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ 𝑛𝐼𝑉 = 0.02138 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
𝑛𝑤𝐿 = 15.8146𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ 𝑛𝑤𝑉 = 0
𝑛𝐴𝐿 = 0.1104𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ 𝑛𝐴𝑉 = 21.3626𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ
mass of acetone that has been produced monthly;
16
𝑚 = 𝑀 ∗ 𝑛 = 58.2 ∗ 21.3626 = 1243.3𝑡𝑜𝑛/𝑚𝑜𝑛𝑡ℎ
Annual output from acetone is = 1243.3 ∗ 12 = 14919.64 𝑡𝑜𝑛/𝑦𝑒𝑎𝑟
According to the results, observed that the mole fraction of acetone and IPA in the bottom
of the distillation column is less than 0.04 which means there is no need for a treatment
process therefore, the cost of this process has been reduced.
Note: in this case, we suppose that the acetone produced from the reactor is 15000ton/year
not produced from the distillation column.
Note: To make the final amount of acetone in the process equal to 15000ton/year, all input
streams must be multiplied with the constant C = 15000/14919.64 = 1.005386
Figure 9:equations and result of distillation in EES
17
Energy balance
In this system, energy is one of most important cases which must be studied and controlled
according to its relation with the cost. Kinetic and potential energy have been neglected.
The focus in this process was on thermal energy only.
Heat exchanging in this process have been happened in five equipment which were heat
exchangers (E-401, E-402, E-403, E-404) in addition to the reactor, because the process
was endothermic process.
Results for heat exchangers were;
Table 1: results of energy balance on heat exchangers
E-401 E-402 E-403 E-404

Pressure (bar) 2.2 0.57 1.4 1.4
Boiling point 106.987 43.675 65.8 206.085
for the mixture
(deg.C)
Cold fluid IPA + water Water Water Water +
acetone + IPA
Tci (deg.C) 25 30 30 206.85
Tco (deg.C) 235 80 55 206.85
Hot fluid High IPA+ water+ Acetone + IPA High
pressurized acetone pressurized
saturated steam saturated steam
Thi (deg.C) 374.15 235 65.8 374.15
Tho (deg.C) 374.15 40 65.8 270
Total mass
flowrate of 2255.814 10895.1 9416.3 316.9
cold fluid
(kg/hr)
18
Total mass
flowrate of hot 782.053 2190.256 1876.9 98.695
fluid (kg/hr)
Cp IPA liquid 2.413 2.413 2.413 2.413
(j/g.K)
Cp IPA vapor 0.4845 0.485 0.607 0.528
(j/g.K)
Cp water 4.186 4.186 4.186 4.186
liquid
(j/g.K)
Cp water vapor 1.974 1.974 1.996 1.996
(j/g.K)
Cp acetone 2.144 2.144 2.144 2.144
liquid (j/g.K)
Cp acetone 0.618 0.625 1.29 1.291
vapor (j/g.K)
Cp hot at 2.789 2.143 ----
Liquid state ----
(j/g.K)
Cp cold at 2.625 4.186 4.186 4.123
Liquid state
(j/g.K)
Cp hot at 1.87 0.952 1.29 1.996
vapor state
(j/g.K)
Cp cold at 0.663 ---- ---- 1.945
vapor state
(j/g.K)
Latent heat for 391.375 1024.09 904.024 565.51
IPA (j/g)
19
Latent heat for 2707.76 3097.54 3284.558 2607.57
water (j/g)
Latent heat for 33.51 722.99 699.8 357.8
acetone (j/g)
heat for the 1087904.3 1859037.89 1313889.079 387946.64
mixture (j/g)
U (j/(m^2.K) 300 500 500 250
All of the above data were necessary for making the energy balance which determine the
total amount of heat gain or loss in this process.
However, for reactor;
Table 2: enthalpy of formation for each component
Enthalpy of Mass of Mass of

formation reactent product
at 25( Enthalpy of Enthalpy of
deg.C) reactent product enthalpy
compoun amount amount amount
d (kj/g) Kg/hr Kg/hr (kj/hr) (kj/hr) (Kj/hr)
- 36.0615 - -
4.34442595 6 3.60570 9415674.04 941450.610 8474223.43
IPA 7 9 4 8 3
- 4.91748 - -
15.8788888 6 4.91742 1405515.80 1405498.52
water 9 5 1 4 0
20
- - -
3.76205234 32.4559 7091617.26 7091617.26
acetone 2 0 1 0 8 8
hydrogen 32.4559
gas 0 0 1 0 0 0
SUM 1382606.16
5
the enthalpy of products and reactants have been shown in tables below;
Table 3: enthalpy of products for each component
Specific heat
capacity cp (j/g.K) Mass flowrate Enthalpy of product
compound (kg/hr) at 235 deg.C (kj/hr)
216.70311
IPA 0.484557362 53358.33483
88.513657
water 1.97378369 88777.26674
1885.0395
acetone 0.611709821 585946.33
1885.0395
hydrogen gas 14.51 478611.5617
SUM 1206693.493
21
Table 4: enthalpy of reactant for each component
Specific heat Mass flowrate Enthalpy of

capacity cp (j/g.K) (kg/hr) reactants at 235
compound deg.C ( kj/hr)
2167.2999
IPA 0.484557362 533649.543
88.514745
water 1.97378369 88777.26678
acetone 0.611709821 0 0
hydrogen gas 14.51 0 0
SUM 622426.8098
Enthalpy of reaction;
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = ∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡 + ∆𝐻𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 − ∆𝐻𝑟𝑒𝑎𝑐𝑡𝑒𝑛𝑡𝑠
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 1206693.493 + 1382606.16 − 622426.8098 = 1966872.848 kj/hr
For heater;
Table 5: enthalpy and mass needed from heater
Tin (deg.C) 360

Tout (deg.C) 410
cp for m.salt (j/g.K) 1.56
delta H reaction (kj/hr) 1966872.848
mass of molten salt pumped (kg) 25216.31857
22
Designing of heat exchangers
There are four heat exchangers for the process. First one was vaporizer for the feed before
reacting, second one was condenser for the product of the reaction. Third one was
condenser for the distilled vapor from distillation column. And forth one was reboilered
for boiling the bottom liquid product.
The main aim was to determine the surface area of the shell and tube heat exchangers in
the process in addition to the quantity of streams must be pumped.
The results have been shown below:
Table 6: designing heat exchangers
E-401 E-402 E-403 E-404

U (j/(m^2. K) 300 500 500 250
∆𝑇𝑚 (K) 228.2734888 52.90348898 20.87005228 107.7268826
Total heat 490280.1906 633428.642 273726.8916 53881.47777

transferred
(W)
A (m^2) 7.159251434 23.94657344 26.23154824 2.000669711
Cp for the 1.8723 4.186 4.186 1.996

outside stream
(j/g.K)
Tin (deg.C) 374.15 30 30 374.15
Tout (deg.C) 374.15 80 55 270
Mass flowrate 7.159251434 10895.0937 9416.309696 78.69472445

of outside
stream (kg/hr)
23
Sample of calculations
for heat exchanger E-401;
at P = 2.2 bar
boiling point of the mixture was equal 106.987℃
𝑥 1 = 0.88 , 𝑥 2 = 0.12 , 𝑥3 = 0
IPA: 1 , water : 2 , acetone : 3.
All equations in energy balance have been taken from source [5].
For calculating the latent heat for the mixture, Riedel equation have been used;
1.092𝑅𝑇𝑛 ln (𝑃𝑐 − 1.013)

∆𝐻 =
0.93 − 𝑇𝑟𝑛
For IPA
Pc = 51.75 bar , Tc = 536.8 K , Tn = 355.65 K , T = 508.15 K
Tn T
𝑇𝑟𝑛 = = 0.663 , 𝑇𝑟 = = 0.947
𝑇𝑐 𝑇𝑐
𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝐼𝑃𝐴 𝑎𝑡 25℃ (∆𝐻) = 47403.99802 𝑗/𝑚𝑜𝑙
1 − 𝑇𝑟2 0.38
𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝐼𝑃𝐴 𝑎𝑡 235℃ (∆𝐻) = (∆𝐻)( ) = 23521.64877 𝑗/𝑚𝑜𝑙
1 − 𝑇𝑟1
23521.64877
𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝐼𝑃𝐴 = = 391.3751875 𝑗/𝑔
60.1
24
𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑛𝑒𝑒𝑑𝑒𝑑 = 𝑚̇ ∆𝐻 = 848227.414𝑘𝑗/ℎ𝑟
Then calculate the latent heat and heat needed for water by using same equations and
method. Therefore, the amount of latent heat heat needed was 239676.903 kj/hr.
For heating the mixture from 25℃ to 235℃ there are three steps. First one was a sensible
heat from 25℃ to 106.987 ℃ then latent heat and finally, a sensible heat from 106.987 ℃
to 235 ℃.
𝑠𝑒𝑛𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 ∆𝐻 = 𝑚̇ 𝐶𝑝(𝑇2 − 𝑇1 )
∆𝐻 = ∆𝐻𝑆1 + ∆𝐻𝑙𝑎𝑡𝑒𝑛𝑡 + ∆𝐻𝑆2
∆𝐻𝑆1 = 485571.4478 𝐾𝑗/ℎ𝑟 , ∆𝐻𝑆2 = 191532.9215 𝐾𝑗/ℎ𝑟
1
𝑘𝑗 𝑗 3600 ℎ𝑟
𝑡𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑛𝑒𝑒𝑑𝑒𝑑 (∆𝐻) = 1765008.686 ∗ 1000 ∗ = 490280.1906 𝑊
ℎ𝑟 𝑘𝑗 𝑠
The mixture have been heated by using high pressurized saturated steam at 374.15 ℃ with
specific heat capacity 1.8723 j/(m^2.K) and latent heat equal 2257 j/g.
For calculating the required surface are, energy balance has been done;
𝑄
𝑄 = 𝑈𝐴∆𝑇𝑚 −→ 𝐴= = 7.159251434 𝑚2
𝑈∆𝑇𝑚
For determining the required amount of steam must be pumped;
𝑡𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 (𝑄)(𝑗/𝑔) 490280.190 𝑗/𝑔 3600𝑠/ℎ𝑟

𝑚̇ = = ∗ = 782.015 𝑘𝑔/ℎ𝑟
𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑠𝑡𝑒𝑎𝑚 (𝑗/𝑠) 22257 𝑗/𝑠 1000𝑔/𝑘𝑔
This method with its equations and steps has been used for designing the other heat
exchangers.
for reactor;
25
the dehydrogenation of IPA is an endothermic reaction. So, heater must be used for
suppling the reactor with heat by pumping hot molten salt in the shell of the reactor. The
amount of heat must be transfer to the reactor will equal the heat of reaction. By making
energy balance;
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = ∆𝐻𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 + ∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 − ∆𝐻𝑟𝑒𝑎𝑐𝑡𝑒𝑛𝑡𝑠
∆𝐻𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 𝑎𝑡 25℃ = ∑ 𝑚̇ 𝑖 ∆𝐻𝑖𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 − ∑ 𝑚̇ 𝑖 ∆𝐻𝑖𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑛𝑡𝑠
∆𝐻𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 = 1382606.165 𝑘𝑗/ℎ𝑟
At 235℃;
𝑡ℎ𝑒 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 (∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 ) = ∑ 𝑚̇ 𝑖,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑐𝑝𝑖 ,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑇

= 1206693.493 𝑘𝑗/ℎ𝑟
𝑡ℎ𝑒 𝑒𝑛𝑡ℎ𝑎𝑙𝑝𝑦 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑒𝑛𝑡𝑠 (∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑠 ) = ∑ 𝑚̇ 𝑖,𝑟𝑒𝑎𝑐𝑡 𝑐𝑝𝑖,𝑟𝑒𝑎𝑐𝑡 𝑇

= 622426.8098 𝑘𝑗/ℎ𝑟
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 1382606.165 + 1206693.493 − 1206693.493 = 1966872.848 𝑘𝑗/ℎ𝑟
The amount of the enthalpy od reaction must equal the amount of heat absorbed from the
heater for ensuring the happening of the reaction. So, the amount of molten salt must be
pumped to the reactor is;
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 1966872.848
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 𝑚̇𝑐𝑝∆𝑇 → 𝑚̇ = = 25216.31857𝑘𝑔/ℎ𝑟
𝑐𝑝∆𝑇 1.56 ∗ (410 − 360)
The surface area for transferring energy in the reactor;

∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛
∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 𝑈𝐴∆𝑇𝑚 −→ 𝐴= = 14.4182594 𝑚2
𝑈∆𝑇𝑚
26
Equipment design
• Reactor design
Fixed bed reactors, moving bed reactors, and fluidized bed reactors all require changes to
the basic reactor design to use the catalyst.
Fixed bed reactors are employed in heterogeneous catalytic reactions and have a minor
pressure drop throughout the bed. Compared to moving bed and fluidized bed reactors,
the design of a fixed bed reactor is very simple. In comparison to other fluidized bed and
moving bed reactors, they are also relatively small. Because no energy is required to
fluidize or move the bed, the energy need is also low.
Fluidized bed reactors have a gas phase working fluid that requires gas flow around and
through the tiny particles.
Figure 10:fixed bed reactor.
• Catalyst type and its property
The catalyst used is zinc oxide and zirconium oxide combination (6%-12% ZrO), which
it worked very well over reaction temperatures from (300-400) o C with minimal
27
degradation. Metal catalysts such as copper were rejected because they are operated only
at temperatures exceeding 450o C, the reaction occurs at a temperature is 350 0 C with
activation energy Ea = 72380 KJ/Kmol and ko = 3.51 × 105 m3 gas/m3 bulk catalyst. S.
This catalyst is available in the form of cylindrical pellets 12 mm in length and 6 mm in
diameter, for these physical properties which are the density of this solid catalyst is =
2500 Kg/m3 and the void fraction of the cylindrical pellets. =0.5 [10]
Catalyst diameter = 6mm.
Catalyst density =2500kg/m3 .
Void fraction =0.5.
Ea = 72380 KJ/Kmol.
ko = 3.51 × 105 m3 gas/m3 bulk catalyst. S.
IPA conversion 90%.
The reactor used in the process is a fixed bed plug flow reactor.
• The performance equation for the fixed bed plug flow reactor is:
𝑋𝐴
𝑊 𝑑𝑋𝑎
= ∫ (1)
𝐹𝐴𝑜 −𝑟𝐴
0
Where:
W: is the weight of the catalyst.
FAo : is the flow rate of the isopropyl alcohol.
−𝑟𝐴 :is the rate of the reaction.
The weight of the catalyst is found in this performance equation.
Since the rate equation of reaction is:
−𝑟𝐼𝑃𝐴 = 𝐾 𝐶𝐼𝑃𝐴 (2)
28
In the form of conversion, the rate equation becomes:
1 − 𝑋𝐴
−𝑟𝐴 = 𝐾 𝐶𝐴𝑜 ( ) (3)
1 +∈𝐴 𝑋𝐴
Where:
−𝐸
𝐾 = 𝐾𝑜 𝑒𝑥𝑝 [ 𝑎 ] (4)
𝑅𝑇
By putting the values of conversion from 0 to 1 in rate equation we obtain the values of−𝑟𝐴 .
From this we find the values of 1/−𝑟𝐴 . Plot the graph between Xa and 1/−𝑟𝐴 , the weight of
catalyst can be calculated.
Table 7: Xa and -ra value
Xa (-ra) 1/-ra
0 0.001146 872.6049
0.1 0.000928 1077.29
0.2 0.00075 1333.146
0.3 0.000602 1662.105
0.4 0.000476 2100.715
0.5 0.000368 2714.771
0.6 0.000275 3635.854
0.7 0.000193 5170.992
0.8 0.000121 8241.268
0.9 5.73E-05 17452.1
1 0
29
The graph between Xa and -ra:
20000
y = 748278x6 - 2E+06x5 + 1E+06x4 - 538457x3 + 95901x2 - 3821.4x +
18000
879.65
16000 R² = 0.9999
14000
12000
1/-ra
10000
8000
6000
4000
2000
0
0 0.2 0.4 0.6 0.8 1
Xa
Figure 11:relation between Xa and -ra.
From this the area under the curve = 4382.454

So
𝑋𝐴
𝑑𝑋𝐴
∫ = 4382.454
−𝑟𝐴
0
Weight of catalyst = W = FAo × Area (5)
= 3.24× 4382.454= 14199.15kg

• To find the volume of the catalyst:
𝐾𝑔
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑐𝑜𝑝𝑝𝑒𝑟 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠 = 𝜌 = 2500
𝑚3
𝑊
𝑉𝑜𝑙𝑢𝑚𝑒𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑏𝑒𝑑 = 𝑉𝑐𝑎𝑡 = (6)
𝜌
14199.15
= = 5.67966 𝑚3
2500
From the general gas equation, the concentration of IPA = 𝐶𝐴𝑜 = 0.036682 𝑚𝑜𝑙/𝑚3
The time needed to treat the one reactor volume is called the space time.
30
𝑊𝐶𝐴𝑜
𝜏= (7)
𝐹𝐴𝑜
𝑘𝑔. ℎ𝑟
= 160.75
𝑚3
• To calculate the volume of reactor:

Void fraction=0.5
𝑉𝑐𝑎𝑡
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 𝑉𝑟 = (8)
1− 𝜑
5.67966
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 𝑉𝑟 = = 11.359 𝑚3
1 − 0.5
• To calculate number of tubes
The preferred lengths of the tubes (according to the TEMA standard) should be is 6ft, 8ft,
12ft, 16ft, 20ft and 24ft (7.32 m).
So assume that the Length of tube = 20 ft = 7.32 m
To calculate tube diameter
As we know that to prevent deviation from plug flow assumption
𝐷𝑡
⁄𝐷 > 15
𝑝
𝑊ℎ𝑒𝑟𝑒:
𝐷𝑡 ∶ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒 .
𝐷𝑝 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒
Assuming the Diameter of the tube = 101.6 mm(4 inches)
𝐷𝑡
⁄𝐷 = 101.6⁄6 = 16.93 > 15
𝑝
𝜋 2 𝜋
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒 = 𝐷 𝐿 = (0.1016)2 × 7.32 = 0.059 𝑚3
4 4
31
𝑇𝑜𝑡𝑎𝑙 𝑣𝑜𝑙𝑢𝑚𝑒 11.359
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = = 192 𝑡𝑢𝑏𝑒𝑠
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒 0.059
• To find the reactor shell hight:
Allowance of the reactor height is 20% - 50% of the shell height.
assuming the allowance for shell is 20% of the tube height.
So
𝑆ℎ𝑒𝑙𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 = 7.32 + 2 × 0.20(7.32) = 10.248 𝑚.
• To find the shell diameter (reactor diameter):
Diameter of the shell is calculated by using the Harvey equation. Harvey equation is:
[(𝐷𝑠 − 𝐾1 )2 ] − 𝑃𝑡 (𝐷𝑠 − 𝐾1 )(𝑛𝐾1 + 𝐾4 )

𝑁𝑇 =
1.23 (𝑃𝑡 )2
Where 𝑁𝑇 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 192
𝐷𝑠 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙
𝑃𝑇 = 𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 = 1.25 × 𝑇𝑢𝑏𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0.127
The tubes used in triangular form. For triangular form
𝐾1 = 1.08, 𝐾2 = −0.9, 𝐾3 = 0.69, 𝐾4 = −0.8
𝑛 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 1
By putting all these values in the Harvey and solving, we have
𝐷𝑠 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 4.8 𝑚.
32
Table 8:reactor summary table.
reactor
zinc oxide and zirconium
catalyst type oxide combination
catalyst mass(kg) 14199.15
tube diameter(mm) 101.6
shell diameter(m) 4.8
number of tubes 192
tube Hight (m) 7.32
shell Hight(m) 10.248
reactor volume (m3 ) 11.359
Thickness(mm) 12
33
• Two-Phase Separator Design
Selection of separator: Horizontal or Vertical
The separator can be installed in vertical or horizontal orientation.
Vertical orientation is preferred to horizontal orientation owing to the following

advantages:
• Bottom Land Area Required: The design area required is less when the vessel is
positioned vertically.
• The NPSH provides a higher pump, as the operating level is at a higher altitude.
• Provides better use of bowl size.
Based on the foregoing, it was selected.
Figure 12:Horizontal vs Vertical orientation [12].
Two-Phase (V/L) Separator Design
Depending on fluid phases the separators can be classified into two groups.
• Two-Phase Separator and

• Three-Phase separator
34
Two-phase separators handle two-phase fluids. One is a gas phase and the other is a
liquid phase, which is what was chosen.
Determining Separator Diameter
We must find the maximum allowable velocity or permitted velocity
𝜌 − 𝜌𝑉
𝑝𝑒𝑟𝑚𝑖𝑡𝑡𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝑘 √ 𝐿
𝜌𝑉
values of the proportionality constant k:
𝑊𝐿 𝜌𝑉
𝐹𝑙𝑣 = √
𝑊𝑉 𝜌𝐿
𝑊𝐿 = 40.6370 𝐾𝑚𝑜𝑙/ℎ𝑜𝑢𝑟
𝑊𝑉 = 32.24445 𝐾𝑚𝑜𝑙/ℎ𝑜𝑢𝑟
𝜌𝐿 = 816.9198 𝑘𝑔/𝑚3
𝜌𝑉 = 0.0761 𝑘𝑔/𝑚3
40.6370 0.0761
𝐹𝑙𝑣 = √
32.24445 816.9198
𝐹𝑙𝑣 = 0.0122
35
Figure 13:constant k chart.
Different values of the proportionality constant k are applied for the internals and
orientation of the separator: Vertical knock-out drums: Empty knock-out drum 0.08m/s,
Empty Compressor suction drums 0.04m/s, Flare knock out drum 0.07m/s.[11]
From the chart, it was taken as 0.35m/s.
816.9198 − 0.0761
𝑝𝑒𝑟𝑚𝑖𝑡𝑡𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 0.35√
0.0761
𝑚
𝑝𝑒𝑟𝑚𝑖𝑡𝑡𝑒𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 36.261
𝑠
4 4 𝑚𝑣
𝐷 = √ 𝐴𝐷 = √
𝜋 𝜋 𝑉𝑃 𝜌𝑉
𝑚3 𝑘𝑔
4 852.5910× 0.0761 3
ℎ𝑟 𝑚
𝐷 = √𝜋 × 𝑚 𝑠 𝑚𝑖𝑛 𝑘𝑔
36.261 × 60 × 60 × 0.0761 2
𝑠 𝑚𝑖𝑛 ℎ𝑟 𝑚3
𝐷 = 1.09 𝑚
36
Figure 14:Flash Drum Design.
1
ℎ 𝑉 = 36′′ + 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑓𝑒𝑒𝑑𝑙𝑖𝑛𝑒
2
𝑙𝑒𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑓𝑒𝑒𝑑𝑙𝑖𝑛𝑒 = 4"
1
ℎ 𝑉 = 36′′ + 4′′
2
ℎ 𝑉 = 38′′
= 38" × 0.0254
ℎ𝑣 = 0.9652𝑚
1
ℎ𝑓 = 12′′ + 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑓𝑒𝑒𝑑𝑙𝑖𝑛𝑒
2
ℎ𝑓 = 14′′ = 0.35𝑚
37
𝑉𝑝𝑜𝑜𝑙
ℎ𝐿 =
𝐷2
𝜋 4
𝑄 = 𝐴 × 𝑉𝑝𝑜𝑜𝑙
ṁ 𝜋 2
= 𝐷 × 𝑉𝑝𝑜𝑜𝑙
𝜌𝐿 4
𝑚3 𝜋 𝑚
2724.11011 = × (4′′ × 0.0254𝑚 ) 2 × 𝑉𝑝𝑜𝑜𝑙
ℎ𝑟 4 ℎ𝑟
𝑚3 𝑚
2724.11011 = 8.107 × 10−3 𝑚 2 × 𝑉𝑝𝑜𝑜𝑙
ℎ𝑟 ℎ𝑟
𝑚3
2724.11011 −3 2
ℎ𝑟 = 8.107 × 10 𝑚 × 𝑉 𝑚
−3 2 −3 2 𝑝𝑜𝑜𝑙
8.107 × 10 𝑚 8.107 × 10 𝑚 ℎ𝑟
𝑚 𝑚
411.324 = 𝑉𝑝𝑜𝑜𝑙
ℎ𝑟 ℎ𝑟
𝑉𝑝𝑜𝑜𝑙
ℎ𝐿 =
𝐷2
𝜋 4
𝑚
411.324
ℎ𝐿 = ℎ𝑟
(1.09 𝑚)2 1 60 𝑚𝑖𝑛
𝜋 × 2 𝑚𝑖𝑛 × ℎ𝑟
4
𝑚
411.324
ℎ𝐿 = ℎ𝑟 =
𝑚 2
27.993 ℎ𝑟
ℎ𝐿 = 14.69 𝑚−1
But the unit does not achieve the desired and is not equal to the unit of the unknown
L = ℎ𝑣 + ℎ𝑓 + ℎ 𝐿
L = 0.9652𝑚 + 0.35𝑚 + 14.69 𝑚
𝐿 = 16.025𝑚
38
Table 9:separetor sammary table.
Separator Design
Orientation vertical
Fluid Phases Two-Phase
Permitted Velocity 36.261m/s
Constant k 0.35m/s
Diameter 1.09 m
hv 0.9652m
hf 0.35m
Diameter of Feedline 4"
V pool 411.324 m/(hr )
hl 14.69 m
Length 16.025m
39
• Scrubber design
sample of calculations:
Table 10: input streams.
component Molar flowrate (Mmol/month) Molar flowrate (Kg/hr)

𝐻2 21.477 29606.74043
Water 2.386 58843.56338
IPA 71.0465 5845271.237
Acetone 21.477 1707606.241
Total 116.3865 7641327.781
Total liquid 94.9095
Table 11: output streams.
component Molar flowrate (Mmol/month) Molar flowrate (Kg/hr)

𝐻2 55.63 76687.7576
Water 3.3928 83673.2782
IPA 0.00056 46.073337
Acetone 0.0183 1455.007413
Total 59.04166 161862.1166
Selection of packing:
We've decided on a ceramic Intralox saddle.
Because ceramic intalox saddles are the most efficient, we chose them.
We chose ceramic packing material since acetone, IPA, and water are present in our
system and can cause corrosion, which ceramic material will prevent.
40
Number of transfer units (𝑵𝑶𝑮 ):
Assume the number of transfer units equal 10 .
Column diameter (D) :
L : flowrate of liquid mixture = 7641327.781 kg/hr
G: flowrate of gas = 29606.74043 kg/hr
Density of 𝐻2 gas (𝜌𝑣 ) = 0.0761 kg/𝑚3
Density of liquid (𝜌𝐿 ) :
𝜌𝐿 of mixture = 𝑥 𝐼 𝜌𝐼 + 𝑥𝐴 𝜌𝐴 + 𝑥 𝑊 𝜌𝑊
𝜌𝐿 = (0.0879 × 775) + (0.792 × 762) +( 0.12× 988 )= 790.1865 kg/𝑚3
Viscosity of liquid mixture at 45°𝐶 (𝜇) = 𝑥 𝐼 𝜇𝐼 + 𝑥𝐴 𝜇𝐴 + 𝑥 𝑊 𝜇𝑊
𝜇 (cp) = (0.0879)(1.3) + (0.792)(0.26) + (0.12)(0.63) = 0.3842
For our absorber we will design for 42mm water in packing.
Thus,
For 42mm of water / m of packing height
𝐾4 = 1.4, 𝐹𝑝 = 22.3
𝐾4 𝜌𝑣 (𝜌𝐿 − 𝜌𝑣 ) 0.5
G* = [ 𝜇 ]
13.1 𝐹𝑝 ( )
𝜌𝐿
G*= 24.344 kg.m2 /sec
Thus,
𝐺
A = area of cross section =
𝐺∗
A = 0.3378 m2
4
Diameter = D = [ × 𝐴]0.5
𝜋
41
D = 0.656 m
Height of packing (Z) :
For ceramic Intralox saddle :
𝐺𝑚 0.316
𝐻𝑂𝐺 = 1.14( ) , where :
𝐿𝑚 0.315
𝐻𝑂𝐺 : height of a transfer unit.
Where
𝐺𝑚 = gas flow rate, lbmoles/hr. ft 2
𝐿 𝑚 = liquid flow rate, lbmol/hr.ft 2
We have,
𝐺𝑚 = 29.401 Kgmol/hr m2
Since cross-section area = A = 0.3378 m2
𝐺𝑚
𝐺𝑚 (kgmole/m2 .sec) = = 0.02417
𝐴 ×3600 𝑠
Similarly,
𝐿 𝑚 = 0.1068 kgmole/m2 .sec
𝐻𝑂𝐺 = 0.711
Z = 𝐻𝑂𝐺 × 𝐻𝑂𝐺
Z = 7.112
Where Z is the height of packing.
Allowance for liquid distribution = 1.00 m
Allowance for liquid redistribution = 1.00 m
Total height of column = 1.0 + 1.0 + 7.112
Total height of column = 9.112 m

42
Table 12: parameters of the scrubber
Absorber
Area 0.3378 m2
Diameter 0.656 m
Total height 9.112 m
43
• Distillation design
At first, we need to find the temperature of the three streams (feed, top, bottom) to find it
we use a solver between the temperature and pressure that the pressure equal to
1050.9mmhg (1.4 bar) depending on it the temperature of the streams was:
𝐹𝑒𝑒𝑑 = 382.218 𝐾.
𝑇𝑜𝑝 = 338.046 𝐾.
𝐵𝑜𝑡𝑡𝑜𝑚 = 480.27 𝐾.
To find the number of stages we need to find the reflux ratio that we assume is 1.2 of the
minimum reflux ratios to find them we need to calculate the relative volatility of each
component we have and it is:
The equations below (11 – 20) from(sinnott,2005)[14]
𝐾𝐴
𝛼𝐴/𝐻𝐾 = (1)
𝐾𝐻𝐾
Where:
𝐾𝐴 = 𝐾 − 𝑣𝑎𝑙𝑢𝑒 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝐴 (𝑐𝑎𝑛 𝑏𝑒 𝑎𝑛𝑦 𝑐𝑜𝑚𝑝𝑒𝑛𝑒𝑛𝑡).
𝐾𝐻𝐾 = 𝐾 − 𝑣𝑎𝑙𝑢𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 ℎ𝑒𝑎𝑣𝑦 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 (𝐼𝑃𝐴).
We chose the IPA to be the heavy key and Acetone the light key.
44
• In our case to find the k value we use
𝑃𝐴𝑠𝑎𝑡
𝐾𝐴 = (2)
𝑝
Where:
𝑃𝐴𝑠𝑎𝑡 : 𝑠𝑎𝑡𝑢𝑟𝑎𝑡𝑖𝑜𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑓𝑜𝑟 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝐴 ( 𝑓𝑜𝑢𝑛𝑑 𝑏𝑦 𝐴𝑛𝑡𝑜𝑖𝑛𝑒 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛).
𝑃: 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑓 𝑝𝑟𝑜𝑐𝑒𝑠𝑠 𝑤ℎ𝑖𝑐ℎ 𝑒𝑞𝑢𝑎𝑙 1.4 𝑏𝑎𝑟 (1050.9 𝑚𝑚ℎ𝑔).
• For the conversion and total flow of each stream, we found it by material balance
And the result for the three components in the three streams will be:
• For the feed:
Table 13:feed stream data
T
A B C feed(bubble) l psat x p k volatility
IPA(HK) 17.664 3109.3 -73.546 7.5908509 1979.9975 0.026 1.88555 1
Acetone (LK) 16.763 2975.9 -34.523 382.2180903 8.2040641 3655.7775 0.2346 1050.09 3.481394 1.846355
water 8.14019 1810.94 244.485 5.2505611 190.67322 0.7393 0.181578 0.0963
• For top stream:
Table 14:Top stream data
A B C T top(dew) l psat y p k volatility

IPA(HK) 17.664 3109.3 -73.546 5.9086292 368.20109 0.001 0.350638 1
Acetone (LK) 16.763 2975.9 -34.523 338.0463768 6.9584834 1052.0368 0.999 1050.09 1.001854 2.857234
water 8.14019 1810.94 244.485 5.0314486 153.15471 0 0.14585 0.415955
45
• For bottom stream:
Table 15:bottom stream data
T
A B C bottom(bubble) l psat x p k volatility
IPA(HK) 17.664 3109.3 -73.546 10.019239 22454.331 0.033 21.38324 1
Acetone (LK) 16.763 2975.9 -34.523 480.2689721 10.086776 24023.214 0.0015 1050.09 22.87729 1.06987
water 8.14019 1810.94 244.485 5.6414948 281.88376 0.9647 0.268438 0.012554
After finding the relative volatility value for each component in all streams we find the
initial value of the number of stages which is equal to 0.6 of the minimum number of
stages by:
𝑥𝐿𝐾 𝑥 (3)
𝑙𝑜𝑔 ( ( ) + ( 𝐻𝐾 )𝐵 )
𝑥𝐻𝐾 𝐷 𝑥 𝐿𝐾
𝑁𝑚 =
𝑙𝑜𝑔 𝛼𝐿𝐾
Where:
N m: minimum number of stages at the total reflux
α LK: average relative volatility of the light key with respect to the heavy key
x LK: light key concentration
x HK: heavy key concentration
𝛼𝐿𝐾 = 3√( 𝛼𝐿𝐾𝐷 𝛼𝐿𝐾𝐵 𝛼𝐿𝐾𝐹 (4)
Where:
α LKD: relative volatility for light key on top stream.
α LKB: relative volatility for light key on bottom stream.
46
α LKF: relative volatility for light key on feed stream.
3
𝛼𝐿𝐾 = √1.84 × 1.07 × 2.86 = 1.78
0.999 0.033
𝑙𝑜𝑔 ( (0.001)𝐷 + (0.0015)𝐵 )
𝑁𝑚 = = 17
𝑙𝑜𝑔 1.78
𝑁𝑚
𝑁 = (5)
0.6
17
𝑁 = = 28
0.6
• calculate the minimum reflux ratio using these equations
𝛼𝑖 𝑥 𝑖,𝑑 (6)
∑ = 𝑅𝑚 + 1
𝛼𝑖 − 𝛳
Where:
xi, d: concentration of component i in the top at minimum reflux.
Rm: the minimum reflux ratio.
ϴ: is the root found from equation 7 below.
𝛼𝑖 𝑥 𝑖,𝑓 (7)
∑ = 1– 𝑞
𝛼𝑖 − 𝛳
xi, f: concentration of component i in the feed at minimum reflux.
q: defined as the heat required to vaporize 1 mole of feed divided by the molar latent heat
of vaporization of feed which equals 1 in our case.
We calculate them by excel solver and the result was:
47
Table 16:calculate minimum reflux ratio
Ꝋ 1.30427
relative
ϴ * Xi, f αi - ϴ ϴ * Xi, f / αi - ϴ Xi, d ϴ * Xi, d ϴ * Xi, d / αi - ϴ Rm
component volatility Xi, f
IPA ( HK) 1 0.026 0.026 -0.304268652 -0.085450801 0.999 1.303 -4.282282697
Acetone (LK) 2.85723431 0.2346 0.67031 1.552965658 0.431630388 0.001 0.0013 0.000839857 5.281443
water 0.415955402 0.7393 0.30752 -0.88831325 -0.346179491 0 0 0
• calculate the number of stages using the equations:
( 1 + 54.4𝑋)(𝑋 − 1 ) (8)
𝑌 = 1 − 𝑒𝑥𝑝(
( 11 + 117.2𝑋)( 𝑋 0.5 )
Where:
Y: (N – N m) / (N +1).
X: (R – Rm) / (R + 1).
N: Number of stages.
R : reflux ratio.
And the result was:
Table 17:calculate the number of stages
N- N (with
Rm R R-Rmin/R+1 N
Nmin/N+1 condenser)
5.2814 6.338 0.1440 0.5108 36.3591 37
• determine feed location using these equations:
48
𝑁𝑅 𝑥𝐹,𝐻𝐾 𝑥 𝐵,𝐿𝐾 2 𝐵 0.206 (9)
= (( )( ) )
𝑁𝑆 𝑥𝐹,𝐿𝐾 𝑥 𝐷,𝐻𝐾 𝐷
Where:
N S: number of stages below the feed, including the reboiler.
N R: number of stages above the feed, including any partial condenser.
B: molar flow bottom product (Kmol/hr).
D: molar flow top product (Kmol/hr).
x f, HK: concentration of the heavy key in the feed.
x f, LK: concentration of the light key in the feed.
x d, HK: concentration of the heavy key in the top product.
x b, LK: concentration of the light key in the bottom product.
𝑁𝑅 + 𝑁𝑆 = 𝑁 (10)
Where:
N: total number of stages.
By using equation 9&10 the result was:
NR/NS NR+NS=N NS NR
0.9715 37 18.76770085 18.2322992 Feed Enters at Stages 19
The equations below ( 11 – 20 ) from [9]
49
• calculate the other streams flowrate and their component compositions using these
equations:
𝐿𝑛 = 𝑅 × 𝐷 (11)
Where:
Ln : the reflux liquid stream forms the top (Kmol/hr).
R: reflux ratio.
D: top product stream (Kmol/hr).
𝑉𝑛 = 𝐿 𝑛 – 𝐷 (12)
Where:
V n : The vapor stream that enters the condenser in the top (Kmol/hr)
𝐿𝑚 = 𝐹 + 𝐿 𝑛 (13)
Where:
Lm: the liquid stream enters the reboiler from the bottom (Kmol/hr)
F: the feed stream (Kmol/hr)
𝑉𝑚 = 𝐿 𝑚 − 𝐵 (14)
Where:
50
V m: the vapor stream returns the column (Kmol/hr).
B: the bottom product stream (Kmol/hr).
The result was:
Table 18:calculate the other streams flow rate and their component compositions.
R 6.338
component flow D flow Ln flow Vn feed flow B flow Lm flow Vm
IPA (HK) 0.032076 0.20329 0.235365 3.55485 3.471237 3.758139 0.286902
water 0 0 0 101.081 101.4758 101.0808 0.395036
Acetone (LK) 32.043924 203.086 235.1297 32.0757 0.162727 235.1615 234.9987
SUM 203.289 235.3651 SUM 340.0004 235.6807
• For the plate spacing, we assume it is 18 inches (0.46 m).
• determine the top column diameter using these equations
𝐹𝐿𝑉 = ( 𝐿 𝑛 / 𝑉𝑛 )(𝜌𝑣 /𝜌𝐿 )0.5 (15)
Where:
FLV: The flow parameter
ρL: the density for Ln stream (kg/m3 ).
ρV: the density for V n stream (kg/m3 ).
Ln : the reflux liquid stream(kg/s).
• For Ln and Vn we need to convert it to kg/s by multiplying it by molecular weight

and dividing by 3600 and for molar mass, we need to find its average:
51
Table 19: to determine the average molecular weight for each stream
component Mw X, F Y, T X, B M w, avg(feed) M w, avg(top) M w, avg(bottom)

IPA (HK) 60.1 0.026 0.001 0.033 1.5626 0.0601 1.9833
Acetone (LK) 58.08 0.2346 0.999 0.001547 13.625568 58.02192 0.08984976
water 18 0.7393 0 0.9647 13.3074 0 17.3646
SUM 28.495568 58.08202 19.43774976
• To determine the densities, we use Aspen plus V11 software:
Table 20:the densities in the top and bottom.
density kg/m3
D 749.258058
Ln Top 749.258058
Vn 2.904101
B 909.6866888
Lm bottom 909.6866888
Vm 19.63212726
𝑈𝑛𝑓 = 𝐶𝑠𝑏 ((𝜌𝐿 − 𝜌𝑣 )/𝜌𝑣 )0.5 (16)
Where:
Csb : is the vapor capacity (m/s).
U nf: flooding vapor velocity(m/s).
𝑈𝑛∗ = 𝐹 ∗ × 𝑈𝑛𝑓 (17)
52
Where:
U n * : the ideal downcomer design velocity(m/s).
F* : percentage flooding (assumed 80%).
𝐴∗𝑡 = 𝑄 /0.88 𝑈𝑛∗ (18)
Where:
A * t: tower area (m2 )
Q: volumetric flowrate of vapor (m3 /s)= 𝑉𝑛 /𝜌𝑣
4 × 𝐴∗𝑡 0.5 (19)

𝐷 = ( )
𝛱
Where:
D: the tower diameter (m)
𝐷𝑠𝑡𝑑 = 𝐷 + 6 𝑖𝑛 (20)
D std : the standard tower diameter (m).
❖ In the top:
203.289 × 58.082 2.9 0.5
𝐹𝐿𝑉 = ( )( ) = 0.0537
235.365 × 58.082 749.25
53
749.25 − 2.9 0.5
𝑈𝑛𝑓 = 0.08 ( ) = 1.282𝑚/𝑠
2.9 .
𝑈𝑛∗ = 0.8 × 1.282 = 1.025𝑚/𝑠
3.797
( )
2.9
𝐴∗𝑡 = = 1.45𝑚2
0.88 × 1.025
4 × 1.45 0.5
𝐷 = ( ) = 1.358𝑚
𝛱
𝐷𝑠𝑡𝑑 = 1.358 + 6 𝑖𝑛 = 1.51𝑚

It’s same calculation for the bottom and the value of diameter =0.69m
Table 21:Top diameter calculations value.
plate spacing(in) 18
plate spacing(m) 0.46
Top diameter Ln Vn
(kmol/hr) 203.2890727 235.3650727
(kg/s) 3.27984444 3.797355238
R 6.338
Flv 0.05377274
C sb m/s 0.08
Unf m/s 1.282497563
Assumed F 0.8
U*n(m/s) 1.025998051
Qv(m3/s) 1.307583737
At 2 1.448239214
m
D (m) 1.358267543
D, standred(m) 1.510667543
54
Table 22:bottom diameter calculations value.
plate spacing(in) 18
plate spacing(m) 0.46
bottom diameter Lm Vm
(kmol/hr) 340.0004002 235.6806791
(kg/s) 1.835789638 1.272528351
R 0.000
Flv 0.211930376
Csb m/s 0.06
Unf m/s 0.403994902
Assumed F 0.8
U*n m/s) 0.323195922
Qv(m3/s) 0.064818669
At 2 0.227903798
m
D (m) 0.538816582
D,standred(m) 0.691216582
Table 23:distillation summary table.
Value
Diameter(m) Top =1.5
Bottom= 0.7
Total colum 1.5
Hight(m) 21
Plate spacing(m) 0.46
Number of trays 37
55
Table 24: data for equipment’s
Equipment High T Low T High Low P Non- comp Exch. Htr. valve mix
P stoich.
feed
E-401 - - - - X Integrate
heat
better
within
process
R-401 350>250 - -
H-401 X No
special
concern
E-402 - - - - -
V-401 - 0.569<
1𝑏𝑎𝑟
T-401 X
T-402 X
E-403 - - - - -
E-404 - - - - Integrate
heat
better
within
process
56
Economic study
• Purchased cost
To find the purchased cost for each piece of equipment we use the following equation
𝐶𝑒 = 𝑎 + 𝑏𝑆 𝑛
Where:
Ce: purchased equipment cost on a U.S. Gulf Coast basis, January 2006.
a, b: cost constants from figure 1.
S: size parameter, units are given in figure 1.
n: exponent for that type of equipment.
And use figure 1 to take the parameter (a, b, and n)
Figure 15:the parameter to find the purchased cost.
57
• IPA feed vaporizer E-401
To choose the type of the heat exchanger we find the area (S) that is found in the
equipment design part, and the type well be in depending on the range given in figure 1
𝑆 = 𝐴𝑟𝑒𝑎 ≅ 7𝑚2
From figure 1, the Double pipe was the one because the range of the area between
1-80 m2 , for Double pipe heat exchanger a=500, b=1100, and n=1 so the purchased cost
will be:
𝐶𝑒 = 500 + 1100 × 71 = 8375$
• Reactor effluent color E-402

The same for all the heat exchangers for E-402 the area was ≅ 24𝑚2 so we choose the
shell and tube where a=11000, b=115, and n=1, the cost will be:
𝐶𝑒 = 11000 + 115 × 241 = 13750$
• Acetone column condenser E-403

E-403 the area was ≅ 26𝑚2 so we choose the shell and tube where a=11000, b=115, and
n=1, the cost will be:
𝐶𝑒 = 11000 + 115 × 261 = 14000$
• Acetone column reboiler E-404

E-404 the area was ≅ 2𝑚2 so we choose the shell and tube where a=500, b=1100, and
n=1, the cost will be:
𝐶𝑒 = 500 + 1100 × 21 = 2700$
• Reactor furnace H-401

For the furnace from figure 1 we need to find the duty in megawatt which we found in the
energy balance part to be equal to 0.546MW, depend on the rand the type of the furnace
is cylindrical the value of a=53000, b=69000, and n=0.8, the cost will be:
𝐶𝑒 = 53000 + 69000 × 0.5460.8 = 95500$
58
• IPA Reactor R-401
For the reactor we choose shell and tube reactor to calculate the cost we calculate each
part the shell as a pressure vessel (horizontal carbon steel) and the tube as a heat
exchanger, for the tube, the area was approximately 14m2 so a=11000, b=115, and n=1,
the cost of the tube will be:
𝐶𝑒1 = 11000 + 115 × 141 = 12650$
shell we need to calculate the mass of it, to find the mass at first, we calculate the
volume which for the shell is equal to the volume with the outside diameter subtracted
from it the volume with the inside diameter
𝑉𝑆ℎ𝑒𝑙𝑙 = 𝑉𝑤𝑖𝑡ℎ 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 − 𝑉𝑤𝑖𝑡ℎ 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 0.105𝑚3
The mass will be the volume multiplied by the density of carbon steel which equals
7850 kg/m3 [16]
𝑚𝑎𝑠𝑠 = 𝑣𝑜𝑙𝑢𝑚𝑒 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 ≅ 830𝑘𝑔
For this case a=-2500, b=200, and n=0.6 so the cost of the shell will be:
𝐶𝑒2 = −2500 + 200 × 8300.6 = 8800$
The total purchased cost for the reactor will be:
𝐶𝑒 = 𝐶𝑒1 + 𝐶𝑒2 = 21000$
• Phase Separator V-401

We take the separator as a pressure vessel (vertical carbon steel) so we need to find the
mass, to find it we need to find the volume which is equal to the volume with the outside
diameter subtracted from it the volume with the inside diameter
𝑉𝑆ℎ𝑒𝑙𝑙 = 𝑉𝑤𝑖𝑡ℎ 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 − 𝑉𝑤𝑖𝑡ℎ 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
To find the inside diameter we need to find the thickness:
59
Vessel Thickness
𝑃𝑖 𝐷𝑖
𝑒=
2𝐽𝑓 − 𝑃𝑖
Where:
e = minimum thickness of the plate required
Pi = internal pressure, N/mm2
Di = internal diameter, mm
f = design stress, N/mm2
J = joint factor
internal pressure:
Operating pressure = 0.57 (the same pressure of previous heater)
Take as 10% of operating pressure:
10
𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = × 0.57
100
= 0.057 𝑏𝑎𝑟
= 0.0057𝑁/𝑚𝑚2
internal diameter:
equal the outside diameter -thickness where the outside diameter = 1.09m
60
design stress:
Figure 16:Typical design stress for a plate.
On boiling point for the mixture (43.675 °C) (carbon steel) design stress =135 N/mm2
[10]
joint factor:
Figure 17:Sample vessel illustrating full radiography of all seams
So, we take J = 1 [18]
61
____________________________________________________________________
𝑃𝑖 𝐷𝑖
𝑒=
2𝐽𝑓 − 𝑃𝑖
0.0057 × (1.09 − 𝑒)
=
2 × 1 × 135 − 0.0057
0.006213 − 0.0057𝑒
=
270 − 0.0057
𝑒 = 0.000023𝑚 = 0.023 𝑚𝑚
Corrosion allowance describes an extra measurement added to the thickness of the wall.
This helps estimate the expected metal loss throughout the lifespan of certain equipment.
Since the depth of penetration may vary from case to case, corrosion allowance has a safety
factor equivalent to 2. [19]
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 + 2 × 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
= 0.023 + 2 × 2
= 4.023𝑚𝑚
so, the inside diameter =outside diameter-thickness =1.085m
1.09 2 1.085 2
𝑉𝑆ℎ𝑒𝑙𝑙 = 𝜋 × ( ) × 16 − 𝜋 × ( ) × 16
2 2
= 14.9301 − 14.82073 = 0.10937𝑚3
𝑚𝑎𝑠𝑠 = 𝑣𝑜𝑙𝑢𝑚𝑒 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 0.10937 × 7850 = 858𝑘𝑔
For vertical carbon steel a=-400, b=230, and n=0.6, the purchased cost for the separator
will be:
𝐶𝑒 = −400 + 230 × 8580.6 = 12800$
62
• Acetone Scrubber T-401
We take the scrubber as two-part the first is a pressure vessel (vertical carbon steel) so we
need to find the mass, to find it we need to find the volume which is equal to the volume
with the outside diameter subtracted from it the volume with the inside diameter [13]
To find the inside diameter we need to find the thickness, we use the same law that we
use in the separator then the thickness equals 4.014mm
The outside diameter =0.656m so the outside will be =0.652 with height =9m
0.656 2 0.652 2
𝑉𝑆ℎ𝑒𝑙𝑙 = 𝜋 × ( ) ×9−𝜋×( ) ×9
2 2
= 3.04187 − 3.00488 = 0.03707𝑚3
𝑚𝑎𝑠𝑠 = 𝑣𝑜𝑙𝑢𝑚𝑒 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 0.03707 × 7850 = 290 𝑘𝑔
will be:
𝐶𝑒1 = −400 + 230 × 2900.6 = 6500$
The second part is the packing for packing we need to find the volume of it which equals
the volume of scrubber – void spacing, assuming that the void spacing =60% of the total
volume or 40%from scrubber volume
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑝𝑎𝑐𝑘𝑖𝑛𝑔 = 3.0403 − 1.824 = 1.232𝑚3
We chose Ceramic Intralox saddles packing where a=0, b=930, n=1 :
𝐶𝑒2 = 0 + 930 × 1.2321 = 1145$
The total purchased cost for the scrubber:
𝐶𝑒 = 𝐶𝑒1 + 𝐶𝑒2 = 7650$
63
• Acetone column T-402
For the distillation as two-part, the first is a pressure vessel (vertical carbon steel) so we
need to find the mass, to find it we need to find the volume which is equal to the volume
with the outside diameter subtracted from it the volume with the inside diameter
To find the inside diameter we need to find the thickness, we use the same law that we
use in the separator then the thickness equals 5.047mm
The outside diameter =1.51m so the outside will be =1.506 with height =number of
stages multiplied by the plate spacing which equals 18 inches to be the height equal 17m
1.51 2 1.506 2
𝑉𝑆ℎ𝑒𝑙𝑙 = 𝜋 × ( ) × 17 − 𝜋 × ( ) × 17
2 2
= 30.44337 − 30.28229 = 0.16108𝑚3
𝑚𝑎𝑠𝑠 = 𝑣𝑜𝑙𝑢𝑚𝑒 × 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 = 0.16108 × 7850 = 1264 𝑘𝑔
will be:
𝐶𝑒1 = −400 + 230 × 12640.6 = 16300$
The second part is the trays we chose sieve trays and we need the diameter of it assuming
it’s equal to the inside diameter which is 1.506m, and from figure 1 a=100, b=120, and
n=2 so the cost of the one tray will be :
𝐶𝑒2 = 100 + 120 × 1.5062 = 370$
We have 37 trays so the purchased cost of all trays equals:
𝐶𝑒2 𝑡𝑜𝑡𝑎𝑙 = 370 × 37 = 13770$
𝐶𝑒 = 𝐶𝑒1 + 𝐶𝑒2 𝑡𝑜𝑡𝑎𝑙 = 30000$
64
All of the previous costs are in 2006 and we need them in 2022 so we take the cost
inflation index in 2022 and we found it to be 317, and for 2006 =122.[14]
To measure the cost in 2022 we use the equation below:
𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2022
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 𝑐𝑜𝑠𝑡 𝑖𝑛 2006
𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2006
For E-401:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 8375 = 21700$
122
For E-402:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 13750 = 35700$
122
For E-403:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 14000 = 36400$
122
For E-404:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 2700 = 7000$
122
For H-401:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 95500 = 248000$
122
For R-401:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 21000 = 55000$
122
For V-401:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 12800 = 33300$
122
For T-401:
65
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 7650 = 19890$
122
For T-402:
317
𝑐𝑜𝑠𝑡 𝑖𝑛 2022 = × 30000 = 42000$
122
Table 25:summary of the purchased cost for all pieces of equipment.
Equipment Purchased cost in Purchased cost in

2006($) 2022($)
IPA feed vaporizer(E-401) 8375 21700
Reactor effluent color(E-402) 13750 35700
Acetone column condenser(E-403) 14000 36400
Acetone column reboiler(E-404) 2700 7000
Reactor furnace (H-401) 95500 248000
IPA reactor(R-401) 21000 55000
Phase separator(V-401) 12800 33300
Acetone scrubber (T-401) 7650 19890
Acetone column(T-402) 30000 42000
Delivered equipment cost (DEC) 205775 500600
66
• Total Fixed Capital investment
To find Total Fixed Capital investment (T.F.C.I) we follow the Chilton method
𝑇. 𝐹. 𝐶. 𝐼 = 𝑇𝑜𝑡𝑎𝑙 𝑓𝑖𝑥𝑒𝑑 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡 + 𝑂𝑓𝑓𝑠𝑖𝑡𝑒 𝐶𝑎𝑝𝑖𝑡𝑎𝑙, 𝐺𝑟𝑜𝑠𝑠 𝑟𝑜𝑜𝑡𝑠 𝑝𝑙𝑎𝑛𝑡𝑠

+ 𝑆𝑡𝑎𝑟𝑡𝑈𝑝 𝐸𝑥𝑝𝑒𝑛𝑠𝑒𝑠 + 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙
➢ First, calculate the total fixed plant cost
we need to find the Total physical plant costs (TPPC) as the first step which equals the
sum of the following:
• Installed equipment cost (IEC) which equals 1.43 multiplied by the

delivered equipment cost (DEC) that we found in the purchased cost part
𝐼𝐸𝐶 = 1.43 × 𝐷𝐸𝐶 = 1.43 × 500600 = 715900$
• Process piping, the fluid which equals 45% of the IEC
= 0.45 × 715900 = 320000$
• Instrumentation, Extensive which equals 16% of the IEC
= 0.16 × 715900 = 114500$
• Buildings and site development, Type of Plant Outdoor which equals 20%
of the IEC
= 0.2 × 715900 = 143000$
• Auxiliaries, Extent Minor addition which equals 2.5% of the IEC
= 0.025 × 715900 = 17897$
• Outside lines, the Average length Long which equals 20% of the IEC
= 0.2 × 715900 = 143000$
67
𝑇ℎ𝑒 𝑇𝑜𝑡𝑎𝑙 𝑝ℎ𝑦𝑠𝑖𝑐𝑎𝑙 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡𝑠 (𝑇𝑃𝑃𝐶 ) =
𝐹𝐶𝐼 + 𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑝𝑖𝑝𝑖𝑛𝑔, 𝑓𝑙𝑢𝑖𝑑 + 𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛, 𝐸𝑥𝑡𝑒𝑛𝑠𝑖𝑣𝑒 +

𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 𝑎𝑛𝑑 𝑠𝑖𝑡𝑒 𝑑𝑒𝑣𝑒𝑙𝑜𝑝𝑚𝑒𝑛𝑡 + 𝐴𝑢𝑥𝑖𝑙𝑖𝑎𝑟𝑖𝑒𝑠, 𝐸𝑥𝑡𝑒𝑛𝑡 𝑀𝑖𝑛𝑜𝑟 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛 +
𝑂𝑢𝑡𝑠𝑖𝑑𝑒 𝑙𝑖𝑛𝑒𝑠, 𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 𝐿𝑜𝑛𝑔 = 715900 + 320000 + 114500 + 143000 +
17897 + 143000 = 1450000$
Then we calculate the Total fixed plant cost as the second step which equals the sum of
the following:
• Engineering and construction, Difficult which equals 47.5% of the TPPC

= 0.475 × 1450000 = 690000$
• Contingencies, process firm which equals 15% of the TPPC
= 0.15 × 1450000 = 218000$
• Size factor, Small commercial unit which equals 10% of the TPPC
= 0.1 × 1450000 = 145000$
So, the total fixed plant will equal:
𝑇𝑜𝑡𝑎𝑙 𝑓𝑖𝑥𝑒𝑑 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡

= 𝐸𝑛𝑔𝑖𝑛𝑒𝑒𝑟𝑖𝑛𝑔 𝑎𝑛𝑑 𝑐𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛, 𝐷𝑖𝑓𝑓𝑖𝑐𝑢𝑙𝑡
+ 𝐶ontingencies, process firm + Size factor, Small commercial unit
+ TPPC = 690000 + 218000 + 145000 + 1450000 = 2500000$
➢ Second, we calculate the offsite capital, gross roots plant which equals 1.6 multiplied
by the TPPC
= 1.6 × 1450000 = 2320000$
➢ Third, we calculate the startup expenses which equals 10% of the DEC
= 0.1 × 500600 = 50060$
➢ Lastly, we calculate the working capital which equals
𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙
= 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡(𝑇. 𝐶. 𝐼) − (𝑜𝑓𝑓𝑠𝑖𝑡𝑒 + 𝑠𝑡𝑎𝑟𝑡𝑢𝑝 + 𝐷𝐸𝐶 )
68
𝑜𝑓𝑓𝑠𝑖𝑡𝑒 + 𝑠𝑡𝑎𝑟𝑡𝑢𝑝 + 𝐷𝐸𝐶 2320000 + 50060 + 500600
𝑇. 𝐶. 𝐼 = = = 3390000$
0.850 0.85
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 = 3390000 − (2320000 + 50060 + 500600) ≅ 500000$
After all of the previous calculations, we can find the total fixed capital investment
𝑇. 𝐹. 𝐶. 𝐼 = 𝑇𝑜𝑡𝑎𝑙 𝑓𝑖𝑥𝑒𝑑 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡 + 𝑂𝑓𝑓𝑠𝑖𝑡𝑒 𝐶𝑎𝑝𝑖𝑡𝑎𝑙, 𝐺𝑟𝑜𝑠𝑠 𝑟𝑜𝑜𝑡𝑠 𝑝𝑙𝑎𝑛𝑡𝑠

+ 𝑆𝑡𝑎𝑟𝑡𝑈𝑝 𝐸𝑥𝑝𝑒𝑛𝑠𝑒𝑠 + 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙
= 2500000 + 2320000 + 50060 + 500000 ≅ 5400000$
Table 26:summary table for Chilton method result.
Parameter Price ($)

Delivered equipment cost 500600
Total fixed plant cost 2500000
Offsite capital 2320000
Startup expenses 50060
Working capital 500000
Total Fixed Capital Investment 5400000
69
• Operating expenses
➢ Raw materials
We have an IPA and water raw materials to find their cost we multiply the quantity we
need by the price of it
For IPA: we need 15521694.2 kg /year and the price of 1 kg of IPA =0.715 $ [1], so the
cost of IPA
= 15521694.2 × 0.715 = 11098011.4$/𝑦𝑒𝑎𝑟
For water: we need 18622603.31 kg /year and the price of 1 kg of water =0.004 $, so the
cost of water
= 18622603.31 × 0.004 = 7450.41$/𝑦𝑒𝑎𝑟
Then the Gross Raw Material Expense will be

= 11098011.4 + 7450.41 = 11105461.8$/𝑦𝑒𝑎𝑟
• Net material expenses
Since we don’t have any by-products the net material expenses will equal to the Gross
Raw Material Expense which is =11105461.8$/𝑦𝑒𝑎𝑟
➢ Direct expenses
• Utilities
We need in our process to Medium-Pressure Steam, Electricity, cooling Water, Fuel gas
or natural gas, Boiler feedwater
For Medium-Pressure Steam for equipment E-401, the cost of it
= 𝑚𝑎𝑠𝑠 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 ℎ𝑜𝑢𝑟 × 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑟 × 𝑝𝑟𝑖𝑐𝑒
782𝑘𝑔 1200ℎ𝑟 7.31

= × × = 6859.8$/𝑦𝑒𝑎𝑟
ℎ𝑟 𝑦𝑒𝑎𝑟 1000$
For Boiler feedwater for equipment E-404, the cost of it
70
= 𝑚𝑎𝑠𝑠 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 ℎ𝑜𝑢𝑟 × 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑟 × 𝑝𝑟𝑖𝑐𝑒
78.6𝑘𝑔 1200ℎ𝑟 2.54

= × × = 239.5$/𝑦𝑒𝑎𝑟
ℎ𝑟 𝑦𝑒𝑎𝑟 1000$
For cooling water, we need it in both equipment E-402 and E-403, the cost of it
= (ℎ𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 ℎ𝑜𝑢𝑟 × 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑟 × 𝑝𝑟𝑖𝑐𝑒)𝑓𝑜𝑟 𝑒𝑎𝑐ℎ 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡
2.28𝐺𝑗 1200ℎ𝑟 0.16$ 0.985𝐺𝑗 1200ℎ𝑟 0.16$

= × × + × × = 626.8$/𝑦𝑒𝑎𝑟
ℎ𝑟 𝑦𝑒𝑎𝑟 𝐺𝑗 ℎ𝑟 𝑦𝑒𝑎𝑟 𝐺𝑗
For Natural gas or fuel gas, we need it in the furnace, the cost of it
= (ℎ𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 ℎ𝑜𝑢𝑟 × 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑟 × 𝑝𝑟𝑖𝑐𝑒)
1.96𝐺𝑗 1200ℎ𝑟 3$
= × × = 7080.7$/𝑦𝑒𝑎𝑟
ℎ𝑟 𝑦𝑒𝑎𝑟 𝐺𝑗
For the electricity, we need it for the pumps so we have to calculate the power of the
pumps
Table 27:power needed for each pump
kg.m^2/s^3 KW
pump for feed IPA 190398.9157 5.28885877
pump for feedwater 7776.086406 0.2160024
pump for tubes of reactor 192415.6475 5.3448791
pump for the shell of the reactor 2215272.404 61.5353446
The pump of shell E-401 68700.6337 1.90835094
the pump of shell E-404 6913.390271 0.19203862
pump for acetone product 27453.35821 0.76259328
pump for water pumped to
scrubber 162001.8001 4.50005
pump after separator 192217.3707 5.33937141
total 134.653376
As an example, for the IPA pump the power equal

(𝑡ℎ𝑒 𝑓𝑙𝑜𝑤 𝑖𝑛𝑡𝑒𝑟 𝑡ℎ𝑒 𝑝𝑢𝑚𝑝 × 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑖𝑔ℎ𝑡 𝑜𝑓 𝐼𝑃𝐴) × 𝑔 × ℎ𝑖𝑔ℎ𝑡
𝑒𝑓𝑓𝑖𝑐𝑖𝑛𝑐𝑦
71
36.06 × 60.1 × 9.81 × 6 𝑚2
= = 190389.157𝑘𝑔. 3 = 5.2𝐾𝑊
0.67 𝑠
After calculating all the power needed take the total and substitute it with the electricity
𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 = 𝑝𝑟𝑖𝑐𝑒 𝑜𝑓 𝑜𝑛𝑒 𝐾𝑊 × 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑜𝑢𝑟𝑠 × 𝑡𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
= 0.05 × 1200 × 134.65 = 8079.2$/𝑦𝑒𝑎𝑟
𝑇𝑜𝑡𝑎𝑙 𝑢𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠
= 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 + 𝑀𝑒𝑑𝑖𝑢𝑚 − 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑆𝑡𝑒𝑎𝑚 + 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟
+ 𝐹𝑢𝑒𝑙 𝑔𝑎𝑠 𝑜𝑟 𝑛𝑎𝑡𝑢𝑟𝑎𝑙 𝑔𝑎𝑠 + 𝐵𝑜𝑖𝑙𝑒𝑟 𝑓𝑒𝑒𝑑𝑤𝑎𝑡𝑒𝑟
= 8079.2 + 7080.7 + 626.8 + 239.5 + 6859.8 = 22886$/𝑦𝑒𝑎𝑟
• Labor
To find the labor we need at first to find the working hours which are:
= 𝑦 × 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 × 𝑝𝑟𝑜𝑐𝑒𝑠𝑠𝑖𝑛𝑔 𝑠𝑡𝑒𝑝𝑠
log 𝑦 = −0.783 log 𝑥 + 1.252𝐵
Where:
Y: operating labor in man-hours per ton per processing step.
X: plant capacity, tons/day(15000 ton/year=45.4545 ton/day).
B: a constant depending upon the type of process and equal to -0.167 for a well-
instrumented continuous process.
log 𝑦 = −0.783 log (45.4545) + 1.252(−0.167)

𝑦 = 0.0311
Since we have four equipment (reactor, separator, scrubber, distillation) the processing
steps=4
So the working hours will be:
𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑜𝑢𝑟𝑠 = 0.0311 × 15000 × 4 ≈ 1867ℎ𝑟/𝑦𝑒𝑎𝑟
Then the labor
1867ℎ𝑟 5$ 9335$
𝑙𝑎𝑏𝑜𝑟 = × =
𝑦𝑒𝑎𝑟 ℎ𝑟 𝑦𝑒𝑎𝑟
72
• Supervision
= 30% 𝑜𝑓 𝑙𝑎𝑏𝑜𝑟 = 2800.5$/𝑦𝑒𝑎𝑟
• Payroll charges
= 40%(𝑙𝑎𝑏𝑜𝑟 + 𝑠𝑢𝑝𝑒𝑟𝑣𝑖𝑠𝑖𝑜𝑛) = 4854.2$/𝑦𝑒𝑎𝑟
• Maintenance
= 10% 𝑜𝑓 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 540267.22$/𝑦𝑒𝑎𝑟
• Supplies
7% 𝑜𝑓 𝑙𝑎𝑏𝑜𝑟 = 653.45$/𝑦𝑒𝑎𝑟
• Laboratory
= 20% 𝑜𝑓 𝑙𝑎𝑏𝑜𝑟 = 1867$/𝑦𝑒𝑎𝑟
• Clothing and laundry
= 20% 𝑜𝑓 𝑙𝑎𝑏𝑜𝑟 = 1867$/𝑦𝑒𝑎𝑟
• Environmental control
For the environmental control, we have wastewater that we can treat with
50$/106 kgthe amount of wastewater (out from stream 14) =102.233kmol/hr.
which equals 13249396.8 kg/year so the environmental control will be equal to
662.4$/year
• Royalties
= 5%𝑜𝑓 𝑠𝑎𝑙𝑒𝑠 = 2813739.669$/𝑦𝑒𝑎𝑟
Then the total direct expenses will equal all the utilities and from labor to royalties’ cost
= 3366711.44$/𝑦𝑒𝑎𝑟
And the total direct manufacturing expenses equal the sum of the total direct expenses
and the net material expenses
73
14472173.24$
=
𝑦𝑒𝑎𝑟
➢ Indirect expenses
• Depreciation
We assume that it’s a straight line for 10 years so it’s equal to the fixed capital
investment divided by 10
= 540267.22$/𝑦𝑒𝑎𝑟
• Plant-indirect expenses
= 5%𝑜𝑓 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = 270133.61$/𝑦𝑒𝑎𝑟
The total indirect expenses equal to the sum of the depreciation and the plant-indirect
expenses
= 810400.83$/𝑦𝑒𝑎𝑟
Then the total manufacturing expenses equal the sum of the direct and indirect expenses
= 4177112.27$/𝑦𝑒𝑎𝑟
• Packaging And Shipping Expense

= 7% 𝑜𝑓 𝑠𝑎𝑙𝑒𝑠 = 3939235.537$/𝑦𝑒𝑎𝑟
• Then the total product expenses equal to the sum of the Packaging And Shipping
Expenses and the total manufacturing expenses
= 8116347.8$/𝑦𝑒𝑎𝑟
• General Overhead Expense (SARE)
Equals 15% of the revenue, the revenue in our system equals the sales and the money
coming from selling the hydrogen that out from stream 11 where the amount of it
equals 32.4495 kmol/hr (64.899 kg/hr) and assume that the price of 1kg equals 1.5$
then the revenue will be
𝑡𝑜𝑡𝑎𝑙 𝑟𝑒𝑣𝑒𝑛𝑢𝑒 = 𝑠𝑎𝑙𝑒𝑠 𝑜𝑓 𝑎𝑐𝑒𝑡𝑜𝑛𝑒 + 𝐻2 𝑝𝑟𝑖𝑐𝑒 = 56274793.38$/𝑦𝑒𝑎𝑟
74
Then the General Overhead Expense will be
15% × 56274793.38 = 8441219.008$/𝑦𝑒𝑎𝑟
At last, the total operating expenses which equal the sum of the General Overhead
expenses and the total product expenses
= 16557566.819$/𝑦𝑒𝑎𝑟
TOTAL OPERATING EXPENSE SHEET

Product Acetone Total Annual Sales(kg/year) 15000000
Rated capacity(tons/year) 15000 Location
Fixed capital investment ($) 5402672.2 Operating hours per year 1200
Date 15/5/2022 By Group A
RAW MATERIALS Unit Quantity $/UNIT $/yr

IPA Kg 15521694.2 0.715 11098011.4
Water Kg 18622603.31 0.004 7450.41
Gross Raw Material Expense 11105461.8

BY-PRODUCT
By-Product Credit
NET MATERIAL EXPENSE 11105461.8
DIRECT EXPENSE
Utilities
Medium-Pressure Steam 6859.8
Electricity 8079.2
cooling Water 626.8
Fuel gas or natural gas 7080.7
Boiler Feed Water 239.5
Total Utilities 22886
Working hr *hour 9335
Labor
price
Supervision 30%of labor 2800.5
40% of the 4854.2
Payroll charges
labor+supervision
Maintenance 10%of FCI 540267.22
Supplies 7%of labor 653.45
Laboratory 20%of labor 1867
75
Clothing and laundry 20%of labor 1867
Wastewater 662.4
Environmental control
treatment
Royalties 5% of sales 2813739.669
Other
TOTAL DIRECT EXPENSE 3366711.44
TOTAL DIRECT MANUFACTURING EXPENSE 14472173.24
INDIRECT EXPENSE
Depreciation FCI/10 540267.22
Plant-Indirect expense 5%of FCI 270133.6
TOTAL INDIRECT EXPENSE 810400.83
TOTAL MANUFACTURING EXPENSE 4177112.27
Packaging And Shipping Expense 7%of sales 3939235.537
TOTAL PRODUCT EXPENSE 8116347.8
General Overhead Expense (SARE) 15% of revenue 8441219.008
TOTAL OPERATING EXPENSE 16557566.819
Table 28: calculation of cash profit at first year
name law Result

Gross income Total revenue-operating 35866124.3
expenses
Depreciation 0.1*TFCI 540267.22
maintenence 0.02*TFCI 108053.44
gross profit Gross income- 35217803.63
(Depreciation
+maintenance)
land&bulding Land rent *land area 45000
G&A Acetone sales*G&A 5550000
percent
EBIT gross profit-( land& 29622803.63
building+ G&A)
interest - 0
Taxes 0.3* EBIT 8886841.09
net income EBIT- (interest+ Taxes) 20735962.54
cash profit net income+ Depreciation 21276229.76
76
• Cash flow
The tables below explain the calculations and the mechanism of cash flow and cash
accumulated at 10 years from starting up. Known that t=0.7
Table 29: calculating the revenue
time Sales, Selling Sales, Selling Revenue

acetone Price, hydrogen Price, (R)
acetone $ hydrogen
-3
-2
-1
0 15000000 3.7 516795.8656 1.5 56275193.8
1 15000000 3.7 516795.8656 1.5 56275193.8
2 15000100 3.7 516799.3109 1.5 56275568.97
3 15000500 3.7 516813.0922 1.5 56277069.64
4 15001000 3.7 516830.3187 1.5 56278945.48
5 15001500 3.7 516847.5452 1.5 56280821.32
6 15002000 3.7 516864.7717 1.5 56282697.16
7 15002500 3.7 516881.9983 1.5 56284573
8 15003000 3.7 516899.2248 1.5 56286448.84
9 15003500 3.8 516916.4513 1.6 57840366.32
10 15004000 3.8 516933.6779 1.6 57842293.88
77
Table 30: calculating net operating income
time Total Cash Depreciation Operating Net Operating

Operating (D) Income R-C Income R-C-D
Expenses (C)
-3
-2
-1
0
1 20150404.62 540267.2219 36124789.18 35584521.95
2 20150538.66 540267.2219 36125030.31 35584763.09
3 20151074.8 540267.2219 36125994.83 35585727.61
4 20151744.99 540267.2219 36127200.49 35586933.27
5 20152415.17 540267.2219 36128406.15 35588138.93
6 20153085.35 540267.2219 36129611.81 35589344.58
7 20153755.53 540267.2219 36130817.46 35590550.24
8 20154425.71 540267.2219 36132023.12 35591755.9
9 20155095.9 540267.2219 37685270.43 37145003.2
10 20155766.08 37686527.81 37686527.81
Table 31: cash flow values
time Income Tax Net Income Cash Flow Accumulated

t*(R-C-D) Profit After [(1-t) *(R-C-D) Cash Flow
Tax (1-t) *(R- ]+D
C-D)
-3 0
-2 -5956204.01
-1 -5447672.219
0 -5402672.219
78
1 24909165.37 10675356.59 11215623.8 5812951.589
2 24909334.16 10675428.93 11215696.1 17028647.74
3 24910009.33 10675718.28 11215985.5 28244633.24
4 24910853.29 10676079.98 11216347.2 39460980.44
5 24911697.25 10676441.68 11216708.9 50677689.34
6 24912541.21 10676803.38 11217070.6 61894759.94
7 24913385.17 10677165.07 11217432.3 73112192.24
8 24914229.13 10677526.77 11217794 84329986.23
9 26001502.24 11143500.96 11683768.2 96013754.41
10 26380569.46 11305958.34 11305958.3 107319712.8
cash flow chart

120000000
100000000
cumulated cash flow ($MM)
80000000
60000000
40000000
20000000
0
-4 -2 0 2 4 6 8 10 12
-20000000
period
Figure 18: cumulated cash flow with time
79
Table 32:economic study summary.
parameter Value
Total purchased cost($) 500600
Total fixed capital investment($) 5402672
Total operating expenses($/year) 16557566.819
Payback period After 3 years
Hazard and Operability Analysis (HAZOP)

HAZOP is a risk management technique used to detect prospective hazards in present or
planned plants. The purpose of the programme is to decrease risk and guarantee the safety
of workers in plant environments. A HAZOP study is performed by an interdisciplinary
team of experts including engineers, chemists, and safety officers to determine risks,
process hazards, and design flaws. [15]
In this section HAZOP procedure was used to make a safety and losses study of the fixed
bed reactor and distillation column as shown in tables 1 and 2, respectively.
Where:
▪ No or Not: The complete negation of these intentions.
▪ More: Quantitative increases.
▪ Less: Quantitative decreases.
▪ Part of: A qualitative decrease.
Table 33: Hazop studied on reactor. [16]

Line Intention Guide Deviation Causes Consequences Actions
word
2 Transfers No Flow Plugged Loss cooling, Install filter with
the vapor cooling possible maintenance
mixture into coils, runaway. procedure. Install
the reactor Controller cooling water flow
fails and meter and low flow
closes alarm. Install high
valve. temperature alarm
alert operator, Place
controller on critical
instrumentation list.
80
Less Flow Partially Diminished Install filter with
plugged cooling, maintenance
cooling possible procedure. Install
line. runaway cooling water flow
meter and low flow
alarm. Install high
temperature alarm
alert.
More Flow Control Reactor cools, Instruct operator and
valve fails reactant update procedure.
open 2. concentration
Controller builds, possible
fails and runaway on
open valve heating.
Less IPA concentration Damage Minimizing the The use of
within the reaction rate temperature and
control and flow alarms plus
valve overheating controllers
More IPA concentration Damage Insufficient The use of

within the conversion and temperature and
control heating, low flow alarms plus
system quality product controllers
More Pressure Compressor Tank or reactor Trigger automatic
control will operate at emergency shut
failure very high down.
pressure
5 Transfer the Less Flow Partially Diminished Install filter with
reactor plugged cooling, maintenance
products cooling line possible procedure. Install
into runaway cooling water flow
following meter and low flow
units alarm. Install high
including temperature alarm
coolers and alert.
scrubber
open, concentration
open valve heating.
More Temperature High water Cooling system Install high flow
supply capacity alarm and/or cooling
limited, water high
temperature alarm.
81
temperature
increases
No Flow Plugged Production Fitting flow and
cooling amount temperature alarms
coils, shortage plus controllers,
Controller strainer use
fails and
closes
valve.
pressure
4 Transferring Less Flow Partially Minimizing the Install filter with
the heating plugged reaction rate, maintenance
material to cooling line conversion and procedure. Install
maintain a product cooling water flow
temperature quality, and meter and low flow
of 350 °C temperature alarm. Install high
within the which could temperature alarm
reactor. lead to side alert.
reactions and
by-products

open, concentration
open valve heating.
More Temperature Incorrect Side reactions, Minimizing the
settings improper heating steam flow
within the cooling which rate (flow
heating affects the controller)
system function of the
scrubber
No Flow Control It can cause Trigger automatic
valve bursting of emergency shut
closed pipe down and do
periodic check up
pressure
82
3 Transferring No Flow Control It can cause Trigger automatic
the heating valve bursting of emergency shut
median of closed pipe down and do
the reactor periodic check up
into the
furnace to
be heated
again.
Less Flow Partially Minimizing the Install filter with
plugged reaction rate, maintenance
cooling line conversion and procedure. Install
product cooling water flow
quality, and meter and low flow
temperature alarm. Install high
which could temperature alarm
lead to side alert.
reactions and
by-products

open, concentration
open valve heating.
pressure
Less Temperature Low water Controller Minimizing the

supply, handles ,Side heating water vapor
Incorrect reactions, flow rate (flow
settings improper controller)
within the cooling which
heating affects the
system function of the
scrubber
Part of Steam Leakage of Improper Adequate
other heating, side maintenance
substances reactions and
into the possible
storage or overheating or
transporting explosion of
pipes. flammable
materials
83
Table 34 : HAZOP studied on distillation column.
Line Intention Guide Deviation Causes Consequences Actions

word
12 Transferring No Flow • Pipe blockage • Column dry • Install low level
The feed to • Control valve shut out alarm
the • Valves fail • Possible • Check
distillation • Tube leakage and dangerous maintenance
from blocking concentration procedure and
scrubber • Pump failure • No operation schedule
and • Make bypass
separator • Emergency plant
shut down
Less Flow • Pipe blockage • Column dry • Install low level alarm
• Control valve shut out • Check maintenance
• Valves fail • Changes in procedure
• Tube leakage and product quality • Make bypass
blocking • Emergency plant
• Pump failure shut down
More Flow • Control valve is • Flooding in • Install high level

fully opened the alarm
• Increase pumping column • Check
capacity • Changes in maintenance
• Control valves product quality procedure and
failure • Temperature schedule
decrease • Install control
• Rise in bottom
More or Temperature • Instrumentation • Separation • Install temperature

high failure cannot be done indicator
• More steam flow • Changes in controller
• Exchanger tube product quality • Instruct operator
failure • Column on procedure
• High steam pressure flooding • Attention to heat
• Cooling water in • Film boiling in input and output
condenser failure. column and control
• Reboiler control reboiler
failure • Phase effect
• Heating medium • Pressure
leak into process changes
84
Less or Temperature • Instrumentation • Pressure • Install temperature
low failure change indicator
• Less steam flow • Product loss • Instruct operator
• Loss of heating • Changes in on procedure
(steam leakage) product quality • Upgrade isolation
• Low steam pressure • Ineffective • Attention to heat
and temperature separating input and out
• Ineffective isolation process control
• Phase effect
Less or Pressure Vapor line leakage • Low Install pressure

low efficiency indicator
of separation
• Loss of
products
High Level Output blockages • over pressure • install high level

reflux drum alarm
• Condensed • check maintenance
liquid flow back procedure and schedule
to distillation
Low level Pipe partial clogged • decrease in • install low level alarm
and leakage the level • check maintenance
• the valve procedure and schedule
closed • install valve
• back flow of
material
13 Acetone No Flow • Pipe blockage • Column dry • Install low level

production • Control valve shut out alarm
• Valves fail • Possible • Check
• Tube leakage and dangerous maintenance
blocking concentration procedure and
• Pump failure • No operation schedule
• Make bypass
• Emergency plant
shut down
85
• Rise in bottom

• Phase effect

of separation
• Loss of
products

reflux drum alarm
to distillation
• back flow of
material
14 Waste water No Flow • Pipe blockage • Column dry • Install low level
• Control valve shut out alarm
• Valves fail • Possible • Check
• Tube leakage and dangerous maintenance
blocking concentration procedure and
• Pump failure • No operation schedule
• Make bypass
86
• Emergency plant
shut down

• Rise in bottom

• Phase effect

of separation
• Loss of
products

reflux drum alarm
to distillation
87
• back flow of
material
More or pressure • Vapor pressure high • Low • Install high

high • Pressure indicator efficiency pressure alarm
controller fail of separation • Install pressure
• Rupture of relief valve
column or other
related
equipment
• Product loss
More or Temperature • Instrumentation • Separation • Install temperature

high failure cannot be done indicator
• More steam flow • Changes in controller
• Exchanger tube product quality • Instruct operator
failure • Column on procedure
• High steam pressure flooding • Attention to heat
• Cooling water in • Film boiling in input and output
condenser failure. column and control
• Reboiler control reboiler
failure • Phase effect
• Heating medium • Pressure
leak into process changes
Plant location and Layout
For each plant design project, or for each business depend on building plant or factory,
there is a viral element must be studied, which is the plant location and layout. This point
has huge effect on succussing the project. Choosing bad layout or bad location could be
cause falling or losing a lot of money Unjustroachically.
88
There are some principles decides if this location is suitable or not. Therefore, the location
chosen must achieve most of these principles. The principles were; market, raw materials
availability, Transportation facilities, Labor supply, Utilities, Environmental Impact, and
Effluent Disposal, Community factors, Land, Climate conditions and Political and
Strategic Considerations.
In general, China considered the best choice for this plant. The market of acetone is good
in this country and it has efficient transportation methods. It considered one of the top
countries that export IPA in the world so there will be no problems in raw materials. The
workforce is available in abundance and their payrolls are not high. On the other hand,
there is no problems in all utilities needed because this country rich with water and energy
sources in addition to industry. Otherwise, in this project there is no Environmental Impact
and Effluent disposal (waste water can be treated and hydrogen gas can be collected and
sell). Community factors does not affect negatively. About the land, there is huge flat areas
far from Human gatherings which is suitable for building factory. China country is very
huge and have different climates Geographically. Finally, there is no political restriction
about this project because the China is one of the huge countries Politically, militarily,
industrially and economically (safe state).
But if the circle has been shrunken to the middle east only, Saudi Arabian and Iraq were
the best two choices for this project. Both have Abundant of raw materials (IPA and water).
The workforce is available in abundance and their payrolls are not high (Iraqis in Iraq and
Asians and Indians in Saudi Arabian). There are no problems in the utilities of the project
according to petrol and oil in these countries in addition to Abundant of water. Otherwise,
in this project there is no Environmental Impact and Effluent disposal (waste water can be
treated and hydrogen gas can be collected and sell). About the land, there is huge flat areas
far from Human gatherings which is suitable for building factory. However, the climate of
these two countries considered Desert climate but it is not a dilemma. There is no political
restriction internally or externally about building the plant. Finally, the condition that make
Saudi Arabian better than Iraq was the social situation of people and the safety of the state.
Saudi Arabian considered as a safe country, there is no war no political problems and there
is a social stability in it. However, there is a bloody war in the state according to the
89
sectarian nursing between society in addition to terrorism. Therefore, Saudi Arabian is the
best choice on the Arab countries level.
These pictures describe the distribution of acetone and IPA respectively in the world.
Figure 19: distribution of acetone in the world
Figure 20: distribution of IPA in the world
90
Inside the plant, known that the process area must approximately take 30% of the total area.
But about the equipment’s, optimization must be done for optimize each of cost, safety and
suitable area for maintenance. The below chart is a result of research about the suitable site
of equipment’s in the plant.
Figure 21: Intra-Unit Spacing Recommendations For Oil And Chemical Plants.
91
Figure 22: top view for the plant
92
Figure 23: layout of the plant process equipment’s
93
Conclusion
Determine the required number of raw materials in the manufacturing process to create
15000 metric tons of acetone per year, where the amount of isopropyl alcohol is roughly
14454 metric tons per year, based on the equipment design, and the plant was founded to
be economically achievable.
The factory machinery was designed and planned, which included a reactor, heater,
separation vessel, absorber (scrubber), distillation column and heat exchangers, and all of
this is presented in the equipment design section and layout, and various research was used
to estimate the site of the factory selection which is in China.
We utilized AutoCAD to measure the overall size of the factory, which is 1000 m 2 and
contains everything the plant requirements.
According to financial estimates and the Chilton method, the total capital investment for
this plant project is approximately 5402680 dollars, and total operating expenses are
estimated to be around 16557570 dollars, with 50060 dollars required for the plant's startup
and running per year. And the net profit of the plant project is 20735965 \dollars in the first
year, at this average this factory is expected to pay back its expenses in three years.
94
References
[1] R. and M. ltd, ‘Acetone Market - Growth, Trends, COVID-19 Impact, and Forecasts
(2022 - 2027)’. https://www.researchandmarkets.com/reports/5318478/acetone-
market-growth-trends-covid-19-impact (accessed May 15, 2022).
[2] ‘Acetone Market Size, Share, Revenue | 2022 - 27’.
https://www.mordorintelligence.com/industry-reports/acetone-market (accessed
May 15, 2022).
[3] Y. Tashiro, T. Yoshida, T. Noguchi, and K. Sonomoto, ‘Recent advances and future
prospects for increased butanol production by acetone‐butanol‐ethanol
fermentation’, Eng. Life Sci., vol. 13, no. 5, pp. 432–445, 2013.
[4] K. Kraemer, A. Harwardt, R. Bronneberg, and W. Marquardt, ‘Separation of
butanol from acetone–butanol–ethanol fermentation by a hybrid extraction–
distillation process’, Sel. Pap. ESCAPE-20 Eur. Symp. Comput. Aided Process Eng.
- 20 6-9 June 2010 Ischia Italy, vol. 35, no. 5, pp. 949–963, May 2011, doi:
10.1016/j.compchemeng.2011.01.028.
[5] E. R. C. Rivas and E. V. L. Choy, ‘Design of an acetone production plant via
catalytic dehydrogenation of isopropyl alcohol’, p. 86.
[6] J. F. Knifton, ‘PHENOL/ACETONE FROM CUMENE HYDROPEROXDE’, p. 8.
[7] A. I. Neamah, ‘Acetone Production’, p. 20.
[8] N. Sonawane, ‘Two-Phase Separator Design Basics (With PDF)’, What is Piping.
https://whatispiping.com/two-phase-separator-design-basics/ (accessed Apr. 05,
2022).
[9] J. R. Backhurst Harker, J. H. ,., Process plant design. New York: American Elsevier
Pub. Co, 1973.
[10] ‘Chegg.com’. https://www.chegg.com/homework-help/questions-and-
answers/material-typical-design-stress-plate-tensile-design-stress-temperature-c-n-
mm-strength-n-m-q86188197 (accessed May 06, 2022).
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[11] ‘Joint Efficiency – Pressure Vessel Engineering’. https://www.pveng.com/joint-
efficiency/ (accessed May 06, 2022).
[12] ‘What is a Corrosion Allowance? - Definition from Corrosionpedia’,
Corrosionpedia. http://www.corrosionpedia.com/definition/1260/corrosion-
allowance (accessed May 07, 2022).
[13] ‘Density of Steel’. https://amesweb.info/Materials/Density_of_Steel.aspx (accessed
May 16, 2022).
[14] ‘Cost Inflation Index FY 2021-22 (AY 2022-23) is 317’, TaxIndiaUpdates In, Jul.
05, 2021. https://taxindiaupdates.in/cost-inflation-index/ (accessed May 16, 2022).
[15] M. M. B. M. M. Mazri, ‘HAZOP for Distillation column Parameter Guideword
Deviation Possible Cause Consequence Action Flow NO No flow @BULLET Pipe
blockages’, Accessed: May 16, 2022. [Online]. Available:
https://www.academia.edu/33328920/HAZOP_for_Distillation_column_Parameter_
Guideword_Deviation_Possible_Cause_Consequence_Action_Flow_NO_No_flow_
at_BULLET_Pipe_blockages
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policy-and-standards/standards-and-specifications/gmp (accessed Apr. 28, 2022).
96

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An- Najah National University

Chemical plant design

May 15th ,2022

Figure 1: Acetone Market-Growth Rate by Region, 2022-2027 [1]

Figure 2: Acetone Market, Volume (%), by Application, Global,2021 [2]

1) Acetone–butanol–ethanol (ABE) fermentation

Because it’s not a common process we can’t find a flowsheet for it

2) Dehydrogenation of isopropyl alcohol (IPA)

The flowsheet of the process:

C6H6 + C3H6 + O2 → (CH3) 2CO + C6H6O

The flowsheet of the process:

4) Oxidation propylene to acetone.

A novel process for the preparation of acetone is reported by gas-phase oxidation of

Cumene IPA Oxidation of acetone-

weight Oxidation of IPA dehydration

𝑚𝑜𝑙𝑒 𝑜𝑓 𝐼𝑃𝐴 𝑖𝑛 = 0.88 × 100 = 88𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

Therefore, moles of IPA reacted equal 88-8.8=79.2 mole

To produce 15000ton/year → 1250 tons/month needed

To find the bubble pressure:

Using acetone equation to find 𝑃𝐴𝑠𝑎𝑡 and𝑃𝐼𝑠𝑎𝑡

𝑛𝐴𝐿 = 21.45528𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ , 𝑛𝐴𝑣 = 0.01834658𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

Figure 6:EES equation result for separator

P = 56.945 kpa = 0.562atm, T= 45 °C, 𝑆 7 =0.0193𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ,

IPA = 0.00039𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ, A = 0.018346𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

Suppose 𝑠9 = 2.5*𝑆1 =67.7925 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

Figure 7:equations of scrubber in EES

𝑆12 = 64.42 + 27.09 = 91.51 𝑀𝑚𝑜𝑙𝑒/𝑚𝑜𝑛𝑡ℎ

𝐴𝑐𝑒𝑡𝑜𝑛𝑒: 𝑛𝐴 = 𝑥𝐴𝑆10 + 𝑧𝐴 𝑆8 = 0.0002478 × 64.42 + 0.792 × 27.09

𝐼𝑃𝐴: 𝑛𝐼𝑃𝐴 = 𝑥1 𝑆10 + 𝑧1 𝑆8 = 0.000008731 × 64.42 + 0.08795 × 27.09

𝑊𝑎𝑡𝑒𝑟: 𝑛𝑊 = 𝑥 𝑤𝑆10 + 𝑧𝑤 𝑆8 = 0.9997 × 64.42 + 0.1201 × 27.09

Make total material balance

91.51 = 𝑆13 + 𝑆14

Figure 9:equations and result of distillation in EES

Results for heat exchangers were;

Table 1: results of energy balance on heat exchangers

E-401 E-402 E-403 E-404

However, for reactor;

Table 2: enthalpy of formation for each component

Enthalpy of Mass of Mass of

Table 3: enthalpy of products for each component

Specific heat Mass flowrate Enthalpy of

∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = ∆𝐻𝑝𝑟𝑜𝑑𝑢𝑐𝑡 + ∆𝐻𝑓𝑜𝑟𝑚𝑎𝑡𝑖𝑜𝑛 − ∆𝐻𝑟𝑒𝑎𝑐𝑡𝑒𝑛𝑡𝑠

∆𝐻𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 = 1206693.493 + 1382606.16 − 622426.8098 = 1966872.848 kj/hr

Table 5: enthalpy and mass needed from heater

Tin (deg.C) 360

The results have been shown below:

Table 6: designing heat exchangers

E-401 E-402 E-403 E-404

Total heat 490280.1906 633428.642 273726.8916 53881.47777

Cp for the 1.8723 4.186 4.186 1.996

Tout (deg.C) 374.15 80 55 270

Mass flowrate 7.159251434 10895.0937 9416.309696 78.69472445

for heat exchanger E-401;

boiling point of the mixture was equal 106.987℃

IPA: 1 , water : 2 , acetone : 3.

1.092𝑅𝑇𝑛 ln (𝑃𝑐 − 1.013)

Pc = 51.75 bar , Tc = 536.8 K , Tn = 355.65 K , T = 508.15 K

𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝐼𝑃𝐴 𝑎𝑡 25℃ (∆𝐻) = 47403.99802 𝑗/𝑚𝑜𝑙

𝑠𝑒𝑛𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 ∆𝐻 = 𝑚̇ 𝐶𝑝(𝑇2 − 𝑇1 )