Professional Documents
Culture Documents
SZ11
SZ11
iv
FIGURE INDEX
TABLE INDEX
v
ABSTRACT
The abstract summarizes the process of formaldehyde production using Aspen HYSYS. The
study explores the utilization of Aspen HYSYS, a process simulation software, to model and
optimize the formaldehyde production process. Key parameters such as reaction kinetics, feed
composition, and operating conditions are analyzed to enhance the efficiency and yield of
formaldehyde. The study aims to provide insights into the potential of Aspen HYSYS as a
tool for designing and optimizing formaldehyde production processes, contributing to the
advancement of chemical engineering and industrial applications.
vi
PROCESS DESIGNING AND OPTIMIZATION OF FORMALDEHYDE (HCHO) MANUFACTURING PROCESS BY
USING ‘ASPEN HYSYS’ SIMULATION SOFTWARE
CHAPTER-1
INTRODUCTION
1.1INTRODUCTION: -
A line list, on the other hand, is a tabulated document that outlines specific
details about individual process lines or pipelines in a system. This could
include information like line number, size, material, contents, and any other
relevant data pertaining to the piping or conduits within a project or facility.
Equipment List:
Reactor: Used for the reaction of methanol and air to produce formaldehyde.
Condenser: Condenses formaldehyde vapor into liquid form. Distillation Column:
Separates impurities and by-products from formaldehyde. 7Storage Tanks: For
storing raw materials, intermediates, and final product. Heat Exchanger: Manages
temperature during different stages of the process. Pumps and Valves: Control the
flow of liquids and gases in the system.
This work is a fully integrated and detailed report for the senior design project on the
PRODUCTION OF FORMALDEHYDE FROM METHANOL. The compilation of
this report was done gradually and chronologically over a period of four months
taking into account every aspect of design from a chemical engineering point of view.
The starting point of the design project was a background research for the process
literature. This research included a summary of the project, problem information and
kinetics, physical and chemical properties of the participating materials in the plant,
literature review of alternative production routes, safety precautions and
environmental preservation for the process. The second report was a quantitative
analysis for the mass and energy balances of the plant. Detailed calculations were
performed in this report for all equipment and streams in the plant, considering the
required process conditions to achieve a production capacity of 60000 ton/year of
formalin. The third task was to simulate the plants units and operations by utilizing
the chemical simulation software
The desired reaction is the first which is exothermic with a selectivity of 9, while the
second is an endothermic reaction. The projects target is to design a plat with a
capacity of 60,000 tons formalin/year. This plant is to include three major units: a
reactor, an absorber and a distillation column. Also, it includes pumps, compressors
and heat exchangers. All are to be designed and operated according to this production
capacity.
Methanol Oxidation: Methanol reacts with air in the reactor to produce formaldehyde.
Cooling: The formaldehyde vapor is cooled in the condenser, converting it into liquid
form. Separation: Impurities are removed in the distillation column, leaving purified
formaldehyde. Storage: The final product is stored in tanks, ready for distribution or
further processing. Line Sizing and Equipment Sizing
Line sizing calculation depends on various factors such as fluid properties, flowrate,
pressure drop, and pipe material. It is also important to known that how much amount
Quantity is transfer from one equipment to another equipment.
Equipment sizing calculations are specific to the type of equipment, such as pumps,
compressors, or heat exchangers. Each type has its own set of parameters to consider,
like flow rate, pressure, temperature, and efficiency.
Heat and Mass Balances: Ensuring efficient energy and material usage by balancing
the input and output of heat and mass throughout the production system.
Economic Optimization: Considering cost factors, such as raw materials, energy, and
catalysts, to achieve cost-effective formaldehyde production.
These approaches help in improving yield, reducing waste, and enhancing the overall
efficiency of formaldehyde manufacturing processes. Advanced simulation tools, such
as Aspen Plus
CHAPTER-2
2. LITERATURE SURVEY: -
metal oxide catalyst filled tubes where heat is removed from the exothermic reaction
to the outside of the tubes. Short tubes (1-1.5 m) and a shell diameter 2.5 m is the
expected design of typical reactors. The bottom product leaving the reactors is cooled
and passed to the absorber. The composition of formaldehyde in the absorber outlet is
controlled by the amount of water addition. An almost methanol-free product can be
achieved on this process design. The advantage of this process over the silver-based
catalyst is the absence of the distillation column to separate unreacted methanol and
formaldehyde product. It also has a life span of 12 to 18 months, larger than the silver
catalyst. However, the disadvantage of this process design is the need for significantly
large equipment to accommodate the increased flow of gases (3 times
larger)compared to the original silver catalyst process design. This increase in
equipment sizing clashes with economic prospect behind the design costs.
2.2 OBJECTIVE:
Aspen HYSYS Model: Create an accurate Aspen HYSYS simulation model that
represents the entire formaldehyde production process, considering reaction kinetics
and thermodynamics.
Reactor Design Optimize the design of the reactors used in the process to maximize
formaldehyde yield and selectivity while minimizing energy consumption.
Catalyst Selection Investigate different catalyst options and select the most suitable
one for the formaldehyde synthesis process.
Each of these components plays a specific and essential role in the Aspen Plus
simulation, enabling detailed and accurate modelling of the integrated PAFC-ORC
system.
CHAPTER-3
3.EXPERIMENTATION
3.1Problem Formulation
The project focused on some reasons are as follows: 1)Improved Efficiency Aspen
HYSYS allows for detailed process simulations, enabling the Identification and
elimination of Inefficiencies in the formaldehyde production process. This can lead to
increased production efficiency and reduced resource consumption.
2)Cost Reduction: Optimization using simulation software can help reduce operating
costs by optimizing the use of raw materials, energy, and other resources, ultimately
increasing profitability.
5)Product Quality Aspen HYSYS can help in maintaining and improving product
quality by fine: tuning the process parameters, ensuring that the formaldehyde
produced meets the desired specifications
6)Research and Development Projects like this often led to advancements in process
engineering and chemical manufacturing, contributing to the broader body of
knowledge in the field.
Open Aspen HYSYS and start a new case. Build a process flowsheet with reactors,
separators, and other necessary unit operations.
Catalyst Modelling:
If a catalyst is used, incorporate catalyst models and parameters into the simulation.
Simulation Run:
Run the simulation to obtain results such as conversion, yield, and selectivity.
Sensitivity Analysis:
Troubleshooting:
Address any issues that arise during the simulation, considering reactor fouling, heat
exchanger performance, etc.
Data Analysis: Analyse simulation results to understand the behaviour of the system
under different conditions.
Generate Reports: Generate reports summarizing the simulation setup, results, and
key findings.
3.4 ANALYSIS:
Clearly outline the goals of your formaldehyde production project. Specify key
parameters such as production capacity, efficiency targets, and any specific
requirements.
Develop a PFD to illustrate the major equipment and process steps involved in
formaldehyde production. Use Aspen HYSYS to create a preliminary simulation
model based on this diagram.
Use Aspen HYSYS to perform material and energy balances to ensure that the
process is optimized for efficiency. This involves determining feedstock
requirements, identifying reaction pathways, and evaluating energy consumption.
Model the formaldehyde synthesis reaction kinetics within Aspen HYSYS. Choose
appropriate reactor types and configurations based on reaction kinetics and desired
production rates.
Optimize the heat exchanger network to recover and reuse heat efficiently. Consider
utility requirements such as cooling water and heating sources.
Economic Analysis:
Sensitivity Analysis:
Perform sensitivity analyses within Aspen HYSYS to assess the impact of variations
in key parameters (e.g., feedstock prices, utility costs) on the project's economic
viability.
Incorporate safety features and assess environmental impacts. Use Aspen HYSYS
model emergency scenarios and ensure compliance with safety standards.
Optimization:
Iteratively optimize the Aspen HYSYS model to improve efficiency, reduce costs,
and meet specified project objectives.
Documentation:
Thoroughly document the Aspen HYSYS model, assumptions, and results. This
documentation is crucial for future reference, troubleshooting, and potential project
modifications.
CHAPTER- 4
SIMULATIOIN
This first section of the simulation is set to investigate results obtained from the
previous Mass & Energy balances section by means of validation of said results with
values obtained from the HYSYS simulation of the plant's processes. Percentages of
error are to be reported with these validations along with discussions and justifications
in the case of high errors. The error equation used to validate the results is as follows:
Errors of calculated values that were found to be 100% are in fact zero and relatively
close to the simulated values, for example:
Another example was calculating the overall mass balance across the reactor for both
the calculated and simulated which were 8439 kg/h and 8177 kg/h respectively with
error percent of 3.2%.
In this section of the validation, justifications are to be reported in the case of high
errors.
Streams 3. 4. 6 and 15: A high error for the flowrate of water is observed in these
streams due to the upstream mixing of the recycle stream with fresh methanol. This
recycle contains traces of water with recycled methanol. The error occurs because the
simulation percentage is much lower in relation to the amount of water recovered in
calculation which was 1% of water feed to the distillation column.Stream 9, 10, 13
and 14: Since the product was produced from one desired and one undesired
reactions, which were hand-calculated using the conversion given by the problem
statement. These conversions.were 78.66 and 8.74 for the desired and undesired
reactions respectively. However, the simulated version of the process has conversions
of 78.45 and 15.73 for the desired and undesired reactions respectively. As a result,
larger amount of methanol was consumed from the undesired reaction. And the
amount of methanol remaining became lesser in simulation. This makes high error in
the methanol amount.
Stream 12: As mentioned previously the conversion of the undesired reaction which
produces hydrogen is found from hand calculation and simulation software to be 8.74
and 15.73 respectively. Therefore, the amount of hydrogen leaving the reactor is
simulated to be 14.17 kmol/hr instead of the calculated amount (8.48 kmol/hr) which
lead to such high percentage error.
E-102: high percentage of error was found in
this heat exchanger because: The limit of the integration in the hand calculation of the
energy balance was from 37.3 C to 150°C, however, the inlet temperature of the heat
exchanger in the simulation software (HYSYS) is 168.9 °C and the outlet temperature
is 150 °C. So, the load found by hand calculation was higher which resulted to such a
higherror. In the hand calculation, the effect of pressure on the energy balance was not
considered. Variation of utility flows between the simulated process and the
calculated one contributed to the increase in error. F-103: A relatively high error was
observed in this unit's load due to:
The limit of the integration in the hand calculation of energy balance was from 25 °C
to 89.31-C, however, the inlet temperature of the heat exchanger in the simulation
software (HYSYS) is 199.8 °C and the outlet temperature is 102 °C. So, the load
found by hand calculation was higher. In the hand calculation, the effect of pressure
on the energy balance was not taken into accountE-106: Reasons of high percentage
of error in this heat exchanger are: The limit of the integration in the hand calculation
of energy balance was from 48.6 °C to 30°C, however, the inlet temperature.
∆P = f *v^2/g * le/D
=0.024*(0.66)^2/2*9.81*30/0.052
=0.30
By using hydrostatic law,
∆P =hpg
=0.30 *787 * 9.81
=2316.11
∆p = 2.3 kpa
∆P = f *v^2/g * le/D
=0.015*(15.56)^2/2*9.81*8/0.202
∆P = f *v^2/g * le/D
=0.0135*(17.33)^2/2*9.81*54.37/0.894
=13.15 m
By using hydrostatic law,
∆P =hpg
= 13.15 *1.07 * 9.81
= 0.138 kpa
CHAPTER-5
PROCESS SCENARIO
Cost Reduction: By simulating different scenarios, the software helps identify cost-
effective strategies, minimizing raw material usage and energy consumption.
Safety Analysis: The simulation can assess potential hazards and safety issues in the
production process, contributing to a safer working environment.
Real-Time Monitoring: The software can be utilized for real-time monitoring and
control of the production process, enhancing overall operational efficiency.
Training and Skill Development: Aspen HYSYS simulations serve as a valuable tool
for training operators and engineers, allowing them to familiarize themselves with the
formaldehyde production process in a virtual environment.
By leveraging Aspen HYSYS, industries can achieve a more robust and optimized
formaldehyde production process, leading to enhanced economic and environmental
sustainability.
Resource Efficiency: The software enables the efficient use of raw materialsand
energy, leading to resource conservation. This is crucial for sustainability and aligned
with societal expectations for responsible industrial practices.
Cost Reduction: Through accurate simulation and optimization, Aspen HYSYS can
help identify opportunities to reduce production costs, making formaldehyde more
economically viable for both producers and consumers.
. Job Creation: As industries adopt advanced simulation tools like Aspen HYSYS,
there is a demand for skilled professionals in simulation and process engineering,
contributing to job creation in these specialized fields.
Advantages:
Accuracy: Aspen HYSYS is known for its robust thermodynamic models, which can
provide accurate predictions of the behavior of complex chemical processes like
formaldehyde production.
Safety: Simulations can help identify potential safety hazards and risks within the
plant, allowing for the implementation of safety measures to mitigate these risks.
Training and Education: Using Aspen HYSYS for simulation allows operators and
engineers to familiarize themselves with the operation of the formaldehyde plant in a
safe and controlled virtual environment.
Disadvantages:
Model Validity: The accuracy of simulation results depends on the validity of the
underlying thermodynamic and kinetic models, as well as the quality of the data used
to parameterize these models.
Cost: Acquiring and maintaining licenses for Aspen HYSYS can be expensive,
especially for smaller companies or academic institutions with limited budgets.
Modeling Limitations: Aspen HYSYS may not fully capture all aspects of the
formaldehyde production process, and users may need to make simplifying
assumptions or use additional software tools to address specific phenomena or
reactions.
CHAPTER-6
RESULT
Stream no. 1 2 3 4 5 6
Stream Methanol Air Mixed Reactor Absorber HCHO
feed exit outlet solution
6.3 CONCLUSION :-
Optimization Success:
Through rigorous simulation and analysis using Aspen HYSYS, we achieved notable
optimization in various aspects of the formaldehyde manufacturing process, including
raw material usage, energy consumption, and product yield.
Cost Reduction:
By fine-tuning process parameters and optimizing equipment configurations, we
successfully identified cost-saving opportunities, contributing to overall cost
reduction in the manufacturing process.
Efficiency Improvements:
The implementation of optimized process parameters resulted in significant
improvements in plant efficiency, leading to higher production rates and reduced
operational costs
6.4 REFERENCES: -
Book Reference:
Title: "Chemical Process Simulation and the Aspen HYSYS Software" Authors:
Michael E. Hanyak Jr., Mark A. Pelesko
General Reference:
Aspen Technology's official documentation for Aspen HYSYS. Check their guide and
tutorials for specific information on formaldehyde production simulations.
Paper Reference:
For academic papers, you may want to explore databases like IEEEXplore,
ScienceDirect, or the American Institute of Chemical Engineers (AIChE) Journal for
papers related to formaldehyde production using Aspen hysys.
1- Couper, James R. Chemical Process Equipment: Selection and Design.
Amsterdam: Elsevier, 2005. Print.
3- "Engineering ToolBox." Engineering ToolBox.N.p., n.d. Web. 19 Sept. 2012.
<http://www.engineeringtoolbox.com/>.
4- Fair, James R. Advanced Process Engineering. New York, NY: American Institute
of Chemical Engineers, 1980. Print.
5- Felder, Richard M., and Ronald W. Rousseau. Elementary Principles of Chemical
Processes. New York: Wiley, 2005. Print.
6- "Formaldehyde." Wikipedia. Wikimedia Foundation, 18 Sept. 2012. Web. 19 Sept.
2012. <http://en.wikipedia.org/wiki/Formaldehyde>.
7- "Formaldehyde Production from Methanol." McMaster University, 19 Dec. 2012.
Web. 19 Sept. 2012.
<http://www.scribd.com/doc/55043119/Formaldehyde-Production-From- Methanol>.
8-Grewal, S. Manufacturing Process Design and Costing: An Integrated Approach.
London: Springer, 2011. Print.188
9- Guidelines for Facility Siting and Layout. New York: Center for Chemical Process
Safety of the American Institute of Chemical Engineers, 2003. Print.
10- Holland, Charles Donald. Fundamentals of Multicomponent Distillation. New
York: McGraw-Hill, 1981. Print.