TERM PAPER

PROCESS CALCULATION (2CH405)

MANUFACTURING OF ETHYL METHYL KETONE

BY:
19BCH043- KUSHAL PATEL
19BCH049- PUNIT PATEL
 TABLE OF CONTENT
❖ PROCESS DESCRIPTION
❖ FLOW SHEET
❖ MATERIAL BALANCE
❖ ENERGY BALANCE
❖ REFERENCE
 PROCESS DESCRIPTION
➢ Methyl ethyl ketone (MEK) is manufactured by the dehydrogenation of 2-butanol. A
description of the processes listing the various units used is given below:
1. REACTOR :A reactor in which the butanol is dehydrated to produce MEK and
hydrogen, according to the reaction:

CH3CH(OH)CH2CH3 CH3COCH2CH3 + H2(g)

Here, the conversion of alcohol to MEK is 88% and the yield is taken as 99%.

2. Cooler-condenser : Two exchangers are used but they are modeled as one unit.
Of the MEK entering the unit 84% is condensed, together with 92% of the
alcohol. The hydrogen is non-condensable.
The MEK is cooled to a temperature of 32 °C. The water is fed to the cooler at a temperature of 24 °C.

3. Absorption column :In the absorption column the uncondensed MEK and alcohol are absorbed in
water. Around 98% of the MEK and alcohol can be considered to be absorbed in this unit, giving a
10%w/w solution of MEK.

4. Extraction column :In the extraction column the MEK and alcohol in the solution from the absorber
are extracted into trichloroethylene (TCE). The raffinate, water containing around 0.5 per cent w/w
MEK, is recycled to the absorption column. The extract, which contains around 20 per cent w/w
MEK.

5. Distillation column I :In the distillation column the unit separates the MEK and alcohol from the
solvent TCE. The solvent containing a trace of MEK and water is recycled to the extraction column.
The recovery is 99.99%.

6. Distillation column II :In the second distillation column, also known as the final the purification stage
which produces a 99.9% pure MEK product from the crude product from the first column. The
residue from this column, which contains the bulk of the unreacted 2-butanol, is recycled to the
reactor. The steam generated by the re-boiler in this unit is at a temperature of 140 °C.
 Crude product

Pure MEK (99.99%)

Water
0.5% w/w MEK

MEK and alcohol

gaseous
product

Uncondensed

MEK and alcohol

Reactor cooler- Absorptio Distillation Distillation
extractor
(dehydrog condens n column column-1 column-2
enation) er
Alcohol and
Unreacted

MEK
2-butanol

TCE
(trichloroethylene)
H2

Unreacted 2-butanol
 MATERIAL BALANCE
● MM of 2-butanol= 74 kg/kmol
Basis used: 1000 kg/hr ● Moles of 2-butanol= 1000/74= 13.35
kmol
(1) Reactor: ● Moles of the 2-butanol that reacted
= 0.88*13.35= 11.748 kmol
● From the equation:
CH3CH(OH)CH2CH3
ME CH3COCH2CH3 + H2(g
2-butanol (1000 kg) K ● Mole ratio for the reaction is 1:1
Reactor 2-butanol
● Hence moles of the MEK reacting is
11.748 kmol
H2 ● Mass of MEK then is 11.748*72=
Xr 845.856 kg
● Mass of 2-butanol is 0.12*1000=120 kg
● Mass of H2 is 11.748*2=23.496 kg
2. Cooler Condenser:

MEK = 845.856 kg Non-condensable

Cooler MEK = 135.33696 kg
2-Butanol = 120 kg
Condenser 2-Butanol = 9.6 kg
H2(g) = 23.496 kg
H2(g) = 23.496 kg

● Condensate comprises: (Condensate)

● 84% MEK= 0.84*845.856=710.51904 kg MEK = 710.51904 kg
● 92% 2-butanol= 0.92*120=110.4 kg 2-Butanol = 110.4 kg
● Incondensable stream comprises:
● H2=23.496 kg
● 2-butanol= 9.6 kg
● MEK = 135.33696 kg
 MEK =6.23296 kg
3. Absorption Column : K H2O =1240.36070 kg
MEK = 135.33696 kg MEK = 2.7067395 kg
2-Butanol = 9.6 kg Absorption 2-Butanol = 0.192 kg
H2(g) = 23.496 kg Column H2(g) = 23.496 kg
J

MEK = 138.8632 kg
● OVERALL BALANCE:
2-Butanol = 9.408 kg
(135.33696 + 9.6 + 23.496) + K = 1326.302208
H2O =1240.360703 kg
+ 0.05K + 2.767392 + 0.192 + 23.496
K = 1246.593671 kg
● RAFFINATE
MEK = 6.23296 kg
H2O = 1240.36070 kg
● STREAM J:
MEK = 138.8632 kg
H2O = 1240.360703 kg
2-butanol = 9.408 kg
4. EXTRACTION COLUMN : MEK =6.23296 kg
H2O =1240.36070 kg
B

MEK = 138.8632 kg Q X MEK = 132.63022 kg

2-Butanol = 9.408 kg EXTRACTOR 2-Butanol = 9.408 kg
H2O =1240.360703 kg TCE =521.11288 kg

● MATERIAL BALANCE AROUND THE EXTRACTOR : R- RECYCLE FROM NEXT OPERATION

138.8632 = 6.23296 + 0.2X TCE
X = 663.1511 Kg

● OVERALL BALANCE :
Q+R=B+X
1388.631903 + R = 1246.59366 + 663.1511
R = 521.11288 Kg

● TCE = 663.1511 -132.63022 - 9.408

TCE = 521.11288 Kg
(5) DISTILLATION COLUMN 1 :

For this unit operation, the balances were obtained from the previous unit operation i.e. the
extraction column and are indicated in the block diagram below.
TCE = 521.11288 kg

MEK = 132.63022 kg
Distillation MEK = 132.63022 kg
2-butanol = 9.408 kg
column 1 2-butanol = 9.408 kg
TCE = 521.11288 kg
(6) DISTILLATION COLUMN 2 :

The material balance for the second distillation column is given as follows

MEK = ( 132.63022 +
710.51904 ) = 843.1493 kg MEK = 843.1493 kg
Distillation column 2
2-butanol = 9.408 + 110.4 = 2-butanol = 119.808 kg
119.808 kg

2-Butanol (recycled back to the

reactor)
 ENERGY BALANCE
(1) COOLER CONDENSER:
MEK = 845.856 kg Non-condensable
Cooler MEK = 135.33696 kg
2-Butanol = 120 kg
Condenser 2-Butanol = 9.6 kg
H2(g) = 23.496 kg
H2(g) = 23.496 kg

Qa
(Condensate)
MEK = 710.51904 kg
2-Butanol = 110.4 kg
ENERGY BALANCE FOR MEK:
Sensible heat to lower the temperature of the condensate MEK from 400
°C to 79.6 °C
= M Cp (T2 - T1) = 710.51904*1732*(400-79.6) = 394.2903 * 10^6 J
Sensible heat to lower the temperature of the incondensable MEK from 400 °C to 80 °C

= M*Cp*(T2-T1) = 135.33696*1732*(400-80) = 75.0091 * 10^6 J

Sensible heat to lower the temperature of the condensate MEK from 79.6 °C to 32 °C

=M*Cp*(T2-T1)= 710.5191*2084*(79.6-32) = 70.4823*10^6 J

No of moles of MEK condensed

= 710.5191 / 72 = 9.8683 kmol

Latent heat of vaporization of MEK

=9.8683*32.8*10^6 = 323.68024*10^6 J

Total energy required for MEK cooling and condensation

= ( 394.2903+75.0091+70.4823+323.68024)*10^6 = 863.46194 MJ/hr

 ● ENERGY BALANCE FOR 2-BUTANOL :
Sensible heat to be removed to lower the temperature of 2-butanol from 400 °C to 99 °C is
determined as follows,
Q = mCp(T2-T1)
Q = 120/74 * 197.1* (400 - 99) *1000 = 96.2061*10^6 J/h

To condense the 2-butanol,

Q = 5.95*10⁶ * 110.4

Q = 656.88 * 10⁶ J/h

Total heat to be removed from 2-butanol,

Q1+Q2 = (96.2061+656.88)*10⁶ = 753.0861*10⁶ J/h

Total heat to be removed from the cooler condenser,

Qr= (753.0891 + 863.4619 )*10⁶ = 1616.551 MJ/hr

Distillation column 2

F=1000 kg/h
Xf=0.88 D=843.1493 kg/h
Xd=0.9999

B=119.808 kg/h
Xb=0.0088
Taking reflux ratio (R.R)=1.94

Total energy balance equation is:

Hr+Qb=Qc+Hd+Hb

Qc is obtained by a balance around the condenser

An energy balance at steady state is:

Hv = Qc + Hr + Hd

Enthalpy of vapour:

Hv= latent heat + sensible heat

For methyl ethyl ketone, latent heat is given as:

Ln =4.56*10^5 J/kg

Latent heat of the vapor stream:

L=MnLn=2479.246942*4.56*10^5= 1130.5366*10^6 J/k

Sensible heat

=∑ ∫niCpidT

Boiling point of methyl ethyl ketone=352.6 k

Sensible heat of MEK,
=(moles of stream)(value of integral from 298k to 352.6k)
=34381.45808*5974.5263
=205.4129*10^6 J
Hv=latent heat + sensible heat
= 1130.5366*10^6 + 205.4129*10^6
=1335.9495*10^6 J
Hd=(moles of stream)(value of integral from 298k to 352.6k)
=11692.54334*5974.5263
=69.8574*10^6 J
Hr=(moles of stream)(value of integral from 298k to 352.6k)
=226835.53407*5974.5263
=135.5233*10^6 J
A balance around the condenser yields:

Qc=Hv-(Hr+Hd)

=1335.9495*10^6 - ( 135.5233*10^6 + 69.8574*10^6 )

=1130.5688*10^6 J

The quantity of heat that needs to be extracted from the condenser by the cooling
fluid is obtained as follows.

Qr is obtained by an overall energy balance around the column

Hf=962.9573*41800=40.2516*10^6 J

Hb=119.808*41800=5.0079*10^6 J
Qr=Qc+Hd+Hb-Hf

=1130.5688*10^6+69.8574*10^6+5.0079*10^6 - 40.2516*10^6

=1165.1825*10^6 J
THANK YOU