A

PROJECT REPORT
ON
“PROCESS DESIGNING AND OPTIMIZATION
OF FORMALDEHYDE (HCHO)
MANUFACTURING PROCESS BY USING
‘ASPEN HYSYS’ SIMULATION SOFTWARE”
In Partial Fulfillment of the requirement for the Degree in Bachelor
of Engineering in the Chemical Engineering

Submitted To
SavitribaiPhule Pune University, Pune

By
Mahangare Saurabh Santosh B190115931
Bhelke Martand Shamkant B190115906
Gawade Kunal Manohar B190115919
Zagade Suraj Chagan B190115956
Under the Guidance of

Dr.S.A. MISAL

DEPARTMENT OF CHEMICAL ENGINEERING

PRAVARA RURAL ENGINEERING COLLEGE, LONI–
(AY 2023-24 SEM-II)
i
 Chemical Engineering Department

Certificate
This is to certify that,
Mr. Mahangare Saurabh Santosh
Mr. Bhelke Martand Shamkant
Mr. Gawade Kunal Manohar
Mr. Zagade Suraj Chagan

Student of B.E. Chemical Engineering have satisfactorily completed the

Project on “PROCESS DESIGNING AND OPTIMIZATION OF
FORMALDEHYDE (HCHO) PLANT MANUFACTURING PROCESS
BY USING ‘ASPEN HYSYS’ SIMULATION SOFTWARE”during the
academic year 2023-24.
This report embodies the work carried out by the candidate, towards
fulfillment of B.E. Degree course in Chemical Engineering conferred by
the SavitribaiPhule Pune University, Pune.

Date:

Place:

(Dr.S. A. MISAL) (Dr. S.A. Misal)

Guide HOD, Chemical Engineering

Examiner (Dr. S.M. Gulhane)

Principal

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 ACKNOWLEDEMENT

Every organization work has imprint of many people and this work is no different.
This work is gives me an opportunity to express deep gratitude for the same.

While preparing Project Stage II received endless help from number of people. This
report would be incomplete if I don’t convey my sincere thanks to all those who were
involved.

I would like to thank Dr.S.A.MISAL our project guide and Dr.B.L.Pangarkar, Project
Coordinator, Department of Chemical Engineering for giving me an opportunity to
present our Project report and his indispensable support, priceless suggestions and
valuable time.

Every work is an outcome of full proof planning, continuous and organized effort.
This work is combination of all the through put together sincerely.

Mr. Mahangare Saurabh Santosh

Mr. Bhelke Martand Shamkant
Mr. Gawade Kunal Manohar
Mr.Zagade Suraj Chagan

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 INDEX

Chapter No. Chapter Name Pg. No.

Certificate ii
Acknowledgement iii
Index iv
Abstract vi
1 Introduction 1
1.1 Significance and Historical Context 1
1.2 Process Overview
2 Literature survey
2.1 Historical Development and Research Milestones
2.2 Objective
3 Experimentation
3.1 Problem Formulation
3.2 Materials Selection
3.3 Experimental setup
3.4 Analysis
4 Simulation
4.1 Simulation Execution
4.2 Process validation
4.3 Flowrate Spreadsheet
4.4 Discussion Of Mass & Energy Balance
4.5 Equipment & Lining list
4.6 Process Calculation for Line Sizing
4.7 Process Calculation for Pump
5 Project Scenario
5.1 Expected Outcomes & Benefits of Project
5.2 Industry & Society Benefits
5.3 Advantages & Disadvantages
6 Result
6.1 Result & Discussion
6.2 Graphical Representation
6.3 Raferance

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 FIGURE INDEX

Figure Figure Name Pg. No.

No.
1.1 Experimental setup
1.2 Simulation setup

TABLE INDEX

Table Table Name Pg. No.

No.
1.1 Flowrate Spreadsheet
1.2 Equipment list

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 ABSTRACT

This project focuses on the process design and optimization of formaldehyde

(HCHO)production through the application of Aspen HYSYS simulation software. The study
aims to enhance the efficiency and yield of HCHO production by analyzing various process
parameters. Through rigorous simulation and optimization techniques, this research explores
optimal conditions, reactor configurations, and catalyst selection to maximize the production
of high-quality formaldehyde while minimizing energy consumption and environmental
impact. The findings highlight the potential for improved process designs to meet industrial
demands for HCHO withincreased efficiency and sustainability.

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.

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CHAPTER-1
INTRODUCTION

1.1 INTRODUCTION: -

 PFD AND P&ID

A Process Flow Diagram (PFD) illustrates the general flow of a process,

showing major equipment and key control points. A Piping and
Instrumentation Diagram(P&ID) provides more detail, indicating piping,
valves, instrumentation, and other components.

For formaldehyde production, a PFD might outline the steps for

methanoloxidation to formaldehyde synthesis. Meanwhile, a P&ID would
show specific equipment like reactors, pumps, valves, and instruments, along
with details on piping connections and control loops. Detailed PFDs and
P&IDs for formaldehyde plants would be proprietary to the specific
engineering design of each facility, considering factors like reaction
conditions, safety features, and process optimization.

 Equipment List and Line List

An equipment list typically refers to a detailed inventory of the physical assets

or machinery used in a particular context, such as a project, facility, or
organization. It provides information about each piece of equipment, including
its name, description, specifications, and often its status or location.

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.

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 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.

1.2 SIGNIFICANCE AND HISTORICAL CONTEXT:-

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

Aspen Hysys to gain an optimized view of the process conditions. Design

and sizing for all units and equipment in the plant were performed in the fourth task.
The designed units included the reactor, the absorber, the distillation column, the
compressor, heat exchangers and pumps. A piping sizing of the plants layout and
connections is presented at the end of end of the design chapter. Operability,
efficiency and economic feasibility were the basis of the design and sizing of these
units. The final task of this project covered the estimation of the capital costs of the

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production process and its profitability. Cumulative cash flow diagrams were the
introduced in the analysis to demonstrate these costs in relation to the production
revenues and returns.

The main purpose of this project is to conduct a comprehensive study that

would lead ultimately to an integrated design, in a chemical engineering point of
view, of a plant that produces formaldehyde with a production capacity specified in
advance. This study will take unit design, process flow diagrams, cost estimations,
operation parameters, equipment sizing, construction materials and
environment/safety precautions. This project requires the theoretical and practical
application of mass transfer, heat transfer, fluid dynamics, unit operations, reaction
kinetics and process control. There are several tasks that are crucial to the completion
of the project outlines including mass and energy balances, Hysys simulation of the
Process Flow Diagrams, design of the reactor, design of heat exchangers, design of
the absorber and distillation column, energy optimization, economic analysis and
hazard analysis. Formaldehyde (CH2O), the target product of the projects plant, is an
organic compound representing the simplest form of the aldehydes. It acts as a
synthesis baseline for many other chemical compounds including phenol
formaldehyde, urea formaldehyde and melamine resin. The most widely produced
grade is formalin (37 wt. % formaldehyde in water) aqueous solution. IŶ this projects
study, formaldehyde is to be produced through a catalytic vapor-phase oxidation
reaction involving methanol and oxygen according to the following reactions:

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

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and heat exchangers. All are to be designed and operated according to this production
capacity.

1.3 PROCESS OVERVIEW:

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.

Optimization of Process & Simulation

Optimization and simulation of formaldehyde production typically involve

mathematical modelling and computational techniques to improve processes and
resource utilization. Key aspects include:

Reaction Kinetics: Modelling the chemical reactions involved in formaldehyde

production to understand reaction rates and optimal conditions.

Process Simulation: Using software tools to simulate the entire formaldehyde

production process, considering variables like temperature, pressure, and catalyst
Concentration.

Heat and Mass Balances: Ensuring efficient energy and material usage by balancing
the input and output of heat and mass throughout the production system.

Catalyst Selection: Optimizing the choice and concentration of catalysts to enhance

reaction efficiency and selectivity.

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Energy Integration: Identifying opportunities to integrate and optimize energy usage

within the formaldehyde production process.

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

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CHAPTER-2

2. LITERATURE SURVEY: -

\2.1 Historical Development And Research Milestone :-

Formaldehyde was discovered in 1859 by a Russian chemist named Aleksandr

Butlerov. Then in 1869, it was ultimately identified by the German chemist
August Hofmann. The manufacture of formaldehyde started in the beginnings of
the twentieth century. Between 1958 and 1968, the annual growth rate for
formaldehyde production averaged to 11.7%. In the mid-1970s, the production
was 54% of capacity. Annual growth. rate of formaldehyde was 2.7%peryear from
1988 to 1997. In 1992, formaldehyde ranked 22 among the top50chemicals
produced in the United States. The total annual formaldehyde capacityin1998 was
estimated by 11.3 billion pounds. Since then and the production capacity around
the globe is expanding exponentially reaching a world's production of 32.5million
metric tons by 2012. Due to its relatively low costs compared to other materials,
and its receptivity for reaching high purities, formaldehyde is considered one of
the most widely demanded and manufactured materials in the world. It is also the
center of many chemical research and alternative manufacture methods. This also
explains the vast number of applications of this material including a building
block for other organic compounds, photographing washing, woodworking,
cabinet-making industries, glues, adhesives, paints, explosives, disinfecting
agents, tissue preservation and drug testing.

As to be applied in this project, formaldehyde is most produced in industry through

the vapor phase oxidation reaction between methanol and air (Oxygen). However,
there are several methods of synthesizing formaldehyde that are notable and efficient
the production of formaldehyde (HCHO) and its optimization through process
designing has a rich history in chemical engineering. Formaldehyde is avital chemical
used in various industries, from plastics to textiles. The evolution of its production
methods has seen a significant shift toward optimization through simulation software
like Aspen HYSYS. Initially, formaldehyde was primarily 10produced using the

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catalytic oxidation of methanol, a process known as the Formox process. Over time,
advancements in technology and engineering led to the development of various other
methods, such as the silver catalyst process and the methanol-to-olefins (MTO) route.
The integration of simulation software like Aspen HYSYS revolutionized the
optimization of formaldehyde production processes. Aspen HYSYS allows engineers
to simulate chemical processes, model reaction kinetics, and optimize various
parameters to enhance efficiency, reduce costs, and minimize environmental impact.
By utilizing Aspen HYSYS, engineers can simulate different scenarios, assess the
impact of varying conditions, and design more efficient production processes for
formaldehyde. This software enables the modelling of intricate chemical reactions,
heat and mass transfer, and overall process dynamics, aiding in the design and
optimization of formaldehyde production plants. The simulation software allows for
the exploration of diverse operating conditions, catalyst choices, reactor
configurations, and feed compositions to attain the most efficient and cost-effective
production methods. The continual advancements in simulation technology have
contributed significantly to improving the efficiency, safety, and sustainability of
formaldehyde production processes. As a result, industries can meet the growing
demand for formaldehyde while minimizing environmental impact and maximizing
resource utilization.

Metal Oxide Catalyst Process: The Formax process developed by Reichhold

chemicals to produce formaldehyde through direct catalytic oxidation of methanol and
some other by-products such as carbon monoxide and dimethyl ether forms. In 1921,
the oxidation of methanol to formaldehyde with vanadium pentoxide catalyst was
introduced to and patented. Then in 1933, the iron- molybdenum oxide catalyst was
also patented and used till the early 1990's. Improvements to the metal oxide catalyst
were done through. the metal composition, inert carriers and preparation methods.
The first commercial plant for the production of formaldehyde using the iron-
molybdenum oxide catalyst was put into action in 1952. Unlike the silver-based
catalyst in this project, the iron-molybdenum oxide catalyst makes formaldehyde from
the exothermic reaction (1) entirely. Under atmospheric pressure and 300-
400oCmethanol conversion inside the reactor could reach 99% and a yield of
88%92%The process begins by mixing of vaporized methanol and air prior to

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entering the reactor. Inside the heat exchanger reactor, the feed is passed through the
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:

Process Design Develop a detailed process design to produce formaldehyde,

including equipment specifications material balances, and process flow diagrams.

Aspen HYSYS Model: Create an accurate Aspen HYSYS simulation model that
represents the entire formaldehyde production process, considering reaction kinetics
and thermodynamics.

Feedstock Selection: Optimize the selection of feedstocks (methanol and air) to

achieve the most efficient formaldehyde production with the least environmental
impact.

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.

Energy Efficiency: Improve energy efficiency in the production process by optimizing

heat integration and heat exchanger design.

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Environmental Impact. Assess and reduce the environmental impact of formaldehyde

production, including emissions and waste management.

Product Purity: Optimize product separation and purification processes to achieved

desired formaldehyde purity.

systems and to ensure comprehensive simulation of all aspects of the PAFC-ORC

integration.

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.

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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.

3)Environmental impact: The project can also contribute to reducing the

environmental impact of formaldehyde production by minimizing waste and
emissions through better process control and resource utilization

4) Safety Enhancement. By simulating the production process: potential safety

hazards can be identified and mitigated, ensuring a safer working environment for
operators.

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.

7) Competitiveness: Efficient and optimized production processes can make a

company more competitive in the market potentially leading to increased market
share and profitability Overall this project has the potential to benefit the company’s

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bottom line, its environmental sustainability, and the overall competitiveness of the
formaldehyde production process.

8) Safety Enhancement. By simulating the production process: potential safety

hazards can be identified and mitigated, ensuring a safer working environment for
operators.

3.2 MATERIAL SELECTION:

Selecting materials for a formaldehyde manufacturing plant involves considering

factors like the process conditions, chemical compatibility, corrosion resistance, and
safety. Aspen HYSYS can help model the process conditions and simulate the
behaviour of different materials under those conditions to aid in material selection.
Common materials for such plants include stainless steels, nickel alloys, and certain
plastics that can withstand the harsh conditions of formaldehyde production. Material
selection for formaldehyde manufacturing process using Aspen hysis In Aspen
HYSYS, material selection for a formaldehyde manufacturing process involves
specifying the properties of equipment and piping materials based on their
compatibility with the process conditions. Here's a general approach: Define Process
Conditions: Set the temperature, pressure, flowrates, and other operating parameters
within Aspen HYSYS for the formaldehyde production process. Access Material
Databases: Aspen HYSYS has databases containing material properties. You can
access these to select appropriate materials for equipment and piping.

Evaluate Material Properties: Assess materials based on their resistance to corrosion,

temperature tolerance, pressure ratings, and chemical compatibility with
formaldehyde and any other chemicals involved in the process. Assign Materials to
Equipment: Within the simulation, assign selected materials to the various equipment
components (like reactors, heat exchangers) and piping to ensure accurate simulation
results. Simulation and Analysis: Run simulations in Aspen HYSYS to analyse how
the selected materials perform under the specified process conditions. Evaluate factors
like pressure drops, heat transfer, and material degradation. Remember, the accuracy
of simulation results heavily relies on the input data and the properties of the materials

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chosen. Detailed understanding of the process and the behaviour of materials under
operating conditions is crucial for reliable simulation.

3.3 EXPERIMENTAL SETUP :-

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1.1 Fig.Experimental Setup

3.4 SIMULATION PROCEDURE:

Define Reaction Kinetics:

Specify the chemical reaction for formaldehyde production.

Define reaction kinetics and thermodynamics.

Create Process Flowsheet:

Open Aspen HYSYS and start a new case. Build a process flowsheet with reactors,
separators, and other necessary unit operations.

Specify Reactor Conditions:

Set up reactor conditions, including temperature, pressure, and catalyst specifications.

Material and Energy Balances: Perform material and energy balances to ensure the
system is feasible and meets production targets.

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.

Optimization: Optimize the process parameters to maximize formaldehyde production

while considering economic factors.

Sensitivity Analysis:

Conduct sensitivity analyses to identify key parameters affecting the process.

Troubleshooting:

Address any issues that arise during the simulation, considering reactor fouling, heat
exchanger performance, etc.

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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:

Analysing a project to produce formaldehyde using Aspen HYSYS simulation

software involves several key steps. Here's a concise overview:

Define Project Objectives:

Clearly outline the goals of your formaldehyde production project. Specify key
parameters such as production capacity, efficiency targets, and any specific
requirements.

Process Flow Diagram (PFD):

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.

Material and Energy Balances:

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.

Reactors and Kinetics:

Model the formaldehyde synthesis reaction kinetics within Aspen HYSYS. Choose
appropriate reactor types and configurations based on reaction kinetics and desired
production rates.

Heat Exchangers and Utilities:

Optimize the heat exchanger network to recover and reuse heat efficiently. Consider
utility requirements such as cooling water and heating sources.

Economic Analysis:

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Utilize Aspen HYSYS to conduct an economic analysis, including capital and

operating costs. Evaluate the feasibility of the project based on financial metrics like
ROI and payback period.

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.

Safety and Environmental Considerations:

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.

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CHAPTER- 4
SIMULATIOIN

4.1 SIMULATION EXCUTION:

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1.2 Fig. Simulation Setup

4.2 PROCESS VALIDATION :

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:

Error = calculated value - simulated value simulated value 100

Errors of calculated values that were found to be 100% are in fact zero and relatively
close to the simulated values, for example:

Stream 3- formaldehyde flowrate

Error = 10-0.14151 0.1415 100 = 100%

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%.

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4.3 FLOWRATE SPREADSHEET :

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1.1 Table of flowrate spreadsheet

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4.4 DISCUSSION OF MASS AND ENERGY BALANCE:

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
high error. 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.

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4.5 EQUIPMENT & LINING LIST :

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4.6 PROCESS CALCULATIONS FOR LINE SIZING

Line 1 Methanol storage tank to centrifugal pump

Pipe = 10m Elbow-1
Temperature = 25 c Tee-1
Q = 4000 kg/hr Strainer-1
Plug and valve-1

Density of methanol 787 kg/m^3

Q = 4000 Kg/hr = 4000/787 m^3/hr =5.082 m^3/hr
Consider velocity =1 m/s
Applying continuity equation,
Q=A*V
5.082/3600 = 1 * 3.142/4 * D^2
D = 0.0423 m
= 42.3 mm
Nominal pipe size = 2
Inner diameter = 52.48 mm
Actual velocity ,
Q=A*V
5.082/3600 =V * 3.142/4 8 * D^2
V = 0.66 m/s
Re = DVp/ u
P= 78.7 kg / m^3
U = 0.539 cp
Re = 50111.02
F = 0.024
Using Darcy-Weisbach equation ,

∆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

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Line 2 vapourizer to mixer

Pipe = 10m
Temperature = 78.3 c
Q = 4000 kg/hr
P = 103.42 kpa
=1.034 bar g
=2.034 bar a

Density of methanol 787 kg/m^3

Q = 4000 Kg/hr
P = PM/RT
= 2.034*32/0.08314 * ( 273 + 78.3 )
= 2.228 kg/hr
Q = 4000/2.228 =1795.33 kg / hr
Consider velocity =1 m/s
Applying continuity equation,
Q=A*V
1795.33/3600 = 20 * 3.142/4 * D^2
D = 0.1781 m
= 178.1 mm
Nominal pipe size = 2
Actual velocity ,
Q=A*V
1795.33/3600 =V * 3.142/4 8 * (0.202)^2
V = 15.6 m/s
Re = DVp/ u =0.202* 15.56 * 2.228/0.0114 *10 ^-3 =6.14 *10^5
F = 0.015
Using Darcy-Weisbach equation ,

∆P = f *v^2/g * le/D
=0.015*(15.56)^2/2*9.81*8/0.202

By using hydrostatic law,

∆P =hpg
=7.33 *2.228 * 9.81
=160 kpa

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Line 3 mixer to reactor

Pipe = 10m
Temperature = 281.1 c
Q = 43054.5 kg/hr
P = 70 Kpa
=0.70 bar g
=1.70 bar a
p = PM/RT
= 1.71/M * 0.08314*(273+281.1)
U = 2.743 * 10 ^-5 pa. s
(calculated from chemical properties hand book )
P =1.072 kg/m ^3
Velocity of gas 20 m/s
Consider velocity =1 m/s
Applying continuity equation,
Q=A*V
43054./1.074 * 3600 = 20 * 3.142/4 * D^2
D = 0.8417 m
= 841.7 mm
Nominal pipe size = 36
Actual velocity ,
Q=A*V
11.33 = V *3.142 * ( 0.894 )^/4
V = 17.73 m/s
Re = DVp/ u =0.894* 17.33 * 1.07/2.749 * 10^-5 = 616957.5 =6.1 *10^5
F = 0.0135
Using Darcy-Weisbach equation ,

∆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

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4.7PROCESS CALCULATIONS FOR METHANOL PUMP

Given data
P =1.013 bar (a)
Fluid = methanol density =787 kg/m^3
Pipe length 11 m
Tank liquid level height = max =17.6 m
Working =16 m
Minimum =0.16 m
Pressure in terms of MLC
By using hydrostatic law ,
P =hpg
1.013 * 10 ^5 = h *787* 9.81
h=13.12 MLC (atmospheric pressure )
pressure drop in pipeline = 0.002 *11
=0.022 bar
Ie. 0.0222 *10^5 = h *787 *9.81
H =0.284 MLC
Vapour pressure = 204 mmhg
(by chemical properties handbook)
Vapour Pressure = 271 bar
NPSH(A)=Atmospheric Pressure + Liquid Height – Vapour Pressure –
Pressure Dropn in Pipe Line
=13.12+17.21-3.51-0.285
=26.926 MLC
Dicharge Head of Pump
=Vertical height + Pressure Drop In Pipe + Back Pressure
= 6m+9m+32.52 mlc
=47.52 MLC
Differential Head
=Dicharge Head – Suction Head
=47.52-25.32
=22.2 MLC
Hydraulic Power
=QHpg/3.6*10^6
=0.246 KW

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CHAPTER-5

PROCESS SCENARIO

5.1 EXPECTED OUTCOMES & BENEFITS OF PROJECT. :-

Process Optimization: Aspen HYSYS enables the optimization of process parameters,

leading to increased efficiency in formaldehyde production.

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.

Product Quality Improvement: Aspen HYSYS allows for fine-tuning of reaction

conditions, ensuring better control over the formaldehyde production process and
improving product quality.

Environmental Impact Assessment: The software facilitates the evaluation of

environmental impacts, aiding in the development of more sustainable and
ecofriendly production practices.

Scale-Up Insights: Aspen HYSYS simulations provide valuable insights into the
scalability of the formaldehyde production process, aiding in the design and
implementation of larger-scale manufacturing facilities.

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.

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By leveraging Aspen HYSYS, industries can achieve a more robust and optimized
formaldehyde production process, leading to enhanced economic and environmental
sustainability.

5.2 INDUSTRY & SOCIETY BENEFITS

Process Optimization: Aspen HYSYS allows for the optimization of formaldehyde

production processes, improving efficiency, reducing energy consumption, and
minimizing waste. This optimization contributes to cost-effectiveness in the industry.
Environmental Impact:. This aligns with sustainability goals and reduces the
environmental impact of formaldehyde production.

Safety Improvement: Aspen HYSYS can simulate different operating conditions,

aiding in the identification and mitigation of potential safety hazards. This contributes
to enhanced safety measures in the production of formaldehyde.

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.

Product Quality: Aspen HYSYS assists in ensuring consistent product quality by

optimizing process parameters. This is essential for meeting industry standards and
consumer expectations.

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.

Innovation and Research: The use of simulation software encourages ongoing

research and development in the industry, fostering innovation and the discovery of
new, more efficient production methods.

. 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.

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In summary, the application of Aspen HYSYS in formaldehyde production benefits

both industry and society by improving efficiency, reducing environmental impact,
enhancing safety, and contributing to sustainable and responsible production
practices.

5.3 ADVANTAGES & DISADVANTAGES: -

 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.

Process Optimization: Simulations allow engineers to optimize process parameters,

such as temperature, pressure, and catalyst composition, to maximize yield and
efficiency.

Cost Reduction: By simulating different operating conditions and scenarios, engineers

can identify opportunities to reduce costs, such as energy consumption or raw
material usage.

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:

Complexity: Aspen HYSYS is a complex software package that requires

significant training and expertise to use effectively, especially for modeling
intricate chemical processes like formaldehyde production.

Resource Intensive: Running simulations can be computationally intensive and may

require powerful hardware, especially for large-scale plants or detailed models.

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.

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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

6.1 RESULT AND DISCUSSION

Stream no. 1 2 3 4 5 6
Stream Methanol Air Mixed Reactor Absorber HCHO
feed exit outlet solution

Componant Mass % Mass% Mass % Mass % Mass % Mass %

Methanol 100 …. 9.29 0.09 …. 0.44
Oxygen …. 23.05 20.91 15.81 17.1 ….
Water …. 1.09 0.99 6.42 6.70 65.56
Formaldehyde …. …. …. 7.76 …. 37.00
Total 100

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6.2 GRAPHICAL REPRESENTATION :-

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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

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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.

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