ProductionofAcetonebyDehydrogenationofIsopropylalcohol (1)

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Production of Acetone by Dehydrogenation of Isopropyl alcohol
Thesis · May 2022

DOI: 10.13140/RG.2.2.30413.51685
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Onel Israel Badro

Salahaddin University - Erbil
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Kurdistan region
Salahaddin University-Erbil
College of Engineering
Chemical & Petrochemical Department
Production of Acetone by Dehydrogenation of

Isopropyl alcohol
A project submitted to the Chemical & Petrochemical Engineering Department
University of Saladin-Erbil
In the partial fulfillment of the requirement for the degree of bachelor of science in
Chemical and Petrochemical Engineering Department
Prepared By:
1. Lilian Hasan Raheem
2. Onel Israel Badro
3. Helen Mohammednazif Ibrahim
4. Pawan Kaka Ahmad Jameel
Supervised By:
Prof. Dr. Hazim Aljewaree

2021-2022
Acknowledgement
I would like to convey my sincere gratitude to the project supervisor Prof. Dr. Hazim
Aljewaree for his invaluable suggestions, constructive criticism, motivation and
guidance for carrying out related experiments and for preparing the associated reports and
presentations. His encouragement towards the current topic helped a lot in this project work
which also created an area of interest for professional career ahead.
We are also grateful to the head of department Assist Prof. Dr. Mohammed Barznjy for his
profound gratitude and super guidance in connection with the project.
A special thanks to our beloved parents from the core of heart, for their support, encouragement
and their belief on us that today we have achieved remarkable success in our life. Their
support and affection are the most precious gift for us in our life.
Last but not least, I would to appreciate the guidance given by other supervisor as well as the
panels especially in our project presentation that has improved our presentation skills by their
comment and tips.
ii
Abstract
Acetone is used as a polar, aprotic solvent in a variety of organic reactions. One
important property for which it is used as laboratory solvent is because does not
form an azeotrope with water. Acetone is also used in various medical and
cosmetic applications. It also forms an important component in food additives
and food packaging. So, the main purpose of this project was production of
acetone by Dehydrogenation of Isopropanol. This Project includes some
properties, manufacturing process, and methods for production. In the
manufacturing process, feed drum, vaporizer, heater, reactor, furnace, cooler,
condenser, flash unit, scrubber, acetone and IPA columns are used. Keeping
these points in mind, we work & we are feeling great to present our work on
“Production of Acetone from Isopropyl Alcohol by Dehydrogenation of
Isopropanol”.
The objective of this project is to design plant to produce acetone from

Isopropyl Alcohol, with the rate of 200 tons per year. This process is chosen
because of the importance of acetone in daily life applications. This project is
divided in different chapters. First of all, the introduction of acetone is given,
with its importance. Next are detailed description of the production process.
Afterwards material and energy balance is presented. In preceding chapter’s
introduction to different equipment’s of the plant along with their designing
procedure and specification sheets is presented. Instrumentation & control,
as well as equipment design, economy of the project, safety and plant layout.
iii
Supervisor’s Certificate
I certify that the Engineering project titled " Production of Acetone by
"
Dehydrogenation of Isopropyl alcohol the was done under my supervision at
Chemical & Petrochemical Engineering Department, College of Engineering -
Salahaddin University–Erbil. In the partial fulfillment of the requirement for the degree of
Bachelor of Science in Chemical & Petrochemical
Engineering.
Supervisor
Signature:
Name:
Date: / /
iv
TABLE OF CONTENTS
Title Page
Acknowledgement ii
Abstract iii
Supervisor’s Certificate iv
Table of Contents in
List of Figures ix
List of Tables x
List of Symbols
Chapter 1: Introduction 1.1 1
History 1.2 4
Physical and chemical properties 1.3 8
Acetone Production methods: 11
1.4 Uses & applications of Acetone Chapter 2: 15
Material balance 2.1 Detail process 18
description 22
2.2 Material balance around the reactor 25
2.3 Material balance around phase separator 27
2.4 Material balance around the scrubber 32
2.5 Material balance around the Acetone column 34
2.6 Material balance around the IPA column 36
2.7 Material balance around feed drum 38
Chapter 3: Energy Balance 40
3.1 Energy balance around the feed drum 41
3.2 Vaporizer 42
3.3 Reactor 45
3.4 Cooler 48
3.5 Condenser 49
3.6 Scrubber 51
3.7 Acetone Column 53
3.8 IPA Column 57
Chapter 4: Equipment Design 4.1 Process 60
description 61
4.2 Design of Heat Exchanger 62
in
4.3Description of the process in the reactor 73
4.4Design of Distillation column (Acetone column) 84
4.5 Design of Pump 92
Chapter 5: Economy 5.1 94
Introduction 95
5.2 Costing and Project Evaluation 95
5.3 Accuracy and Purpose of Capital Cost Estimates 95
5.4 Coast of Heat Exchanger 96
5.5 Cost of Acetone column 97
Chapter 6: Safety 6.1 98
Flammability 99
6.2 Acetone peroxide 6.3 99
Toxicity 6.4 99
Health Hazard 6.5 99
Handling and storage 6.6 99
NFPA Hazard Classification 6.7 GHS 100
Classification 101
Chapter 7: Conclusion 103
References
104
we
List of Figures
Figure 1.1 Jean Beguin Figure 1.2 5
Antoine Bussy Figure 1.3 Clostridium 5
Acetobutylicum Figure 1.4 Chaim Weizmann Figure 1.5 Acetone in 6
colorless liquid state Figure 1.6 Co-production in 6
hock phenol methods Figure 1.7 Catalytic cycle for the Wacker process 8
Figure 1.8 Wacket-Hechst direct oxidation of propene Figure 1.9 Dehydrogenation of 11
isopropanol flow chart Figure 2.1 Dehydrogenation of isopropanol flow chart Figure 12
4.1 Overall process plant Figure 4.2 Continues Tubular Reactor Figure 4.3 Variation of 13
inverse of rate law with conversion Figure 4.4 Allowable stress for the steel Figure 4.5 13
Correlation of flooding velocities for sieve trays Figure 5.1: Shell and tube heat exchangers. 19
61
73
76
82
88
96
Figure 5.2: Vertical pressure vessels. Time base mid-2004 Figure 5.3: Column plates. Time base 97
mid-2004 Figure 6.1: GHS Acetone labels 98
102
vii
List of Tables
Table 1.1 Physical properties of Acetone Table 2.1 9
Process stream table Table 2.2 Material 20

balance sheet 39
Table 2.2 Heat capacity coefficients Table 3.2 42
Heat capacity coefficients Table 3.3 Component 45

enthalpies Table 3.4 Component enthalpies 46
Table 4.1 Variation of inverse of rate law 47
with conversion Table 6.1 Conditions for safe storage Table 6.2 NFPA 76
Acetone Hazards label 101
102
viii
NOMENCLATURE
MW = Molecular weight [kg/kmol]

N = Mole [mol/h]
Y = Mol or mass fraction of gas stream
X = Mol or mass fraction of liquid stream
PT = Total pressure [bar]
Pv* = Vapor pressure [bar]
F = Feed flow rate [kmol/h]
V = Flow rate of vapor [kmol/h]
L = Flow rate of liquid [kmol/h]
T = Temperature [°C]
ÿH vap = Latent heat of vaporization [kJ/kg]
TC = Critical temperature [°C]
PC = Critical pressure [bar]
Tb = Normal boiling point [°C]
Q = Heat [kJ]
M = Mass flow rate [kg/h]
K = Activity coefficient A, heat transfer area (ft2 )
Aa = Active area (ft2 )
Ad = Down comer area (ft2 )
Ah = Area of hole
AT =Tower area (ft2 )
B = Baffle spacing (ft)
Cp = Specific heat (Btu/lb-°F)
Do = Outside diameter of tube (inch)
Db = Bundle diameter (mm)
De = Equivalent diameter (inch)
Di = Inside diameter of tube (inch)
Ds = Shell diameter (inch)
F = Feed flow rate (lb-mol/h)
G = Mass flow rate (lb-mol/h)
GS: Mass velocity (lb/hr-ft2)
Ho = Outside fluid film coefficient (Btu/ft2 -°F)
Hi = Inside fluid film coefficient (Btu/ft2 -°F) hT
= Total plate pressure drop (ft) k =
Thermal conductivity (Btu/h-ft-°F)
L = Liquid flow rate (lb-mol/h)
LMTD = Log mean temperature difference (°F)
MMSCFD = Million standard cubic feet per day. ÿ
= Density (lb/ft3 )
Psig = Gauge pressure (psig
ix
PT = Tube pitch (ft)

Q = Heat flow rate (Btu/h)
R = Heat of reaction (Btu/h)
T = Temperature (°F)
T1 = Inlet Temperature (°F)
T2 = Outlet Temperature (°F)
U = Overall heat transfer coefficient (Btu/h-ft-°F)
V = Vapor flow rate (lb-mol/h) ÿ
= Absorption efficiency factor
ÿPT = Total plate pressure drop (N/m2 )
ÿT = Temperature gradient (°F)
x
Chapter 1
Introduction
Chapter 1: Introduction
Acetone is the organic compound with the formula (CH3)2CO. Acetone consists of three carbon, six
hydrogens and one oxygen atom. Acetone comes under the categories of ketones, which are
organic compounds with a carbonyl group bonded to two hydrocarbon groups. Acetone is a
manufactured chemical produced by industries that is also found naturally in the environment.
It is also called dimethyl ketone, 2-propanone, and beta-ketopropane. Acetone is the simplest and
most important of the ketones. It is a colorless, volatile, flammable liquid, somewhat aromatic
odor, melting at -95.4 °C and boiling at 56.53 °C. It has a specific gravity of 0.819 (at 0
°C).and is miscible with water in all proportion and most organic solvents. People begin to smell
acetone in air at 100 to 140 parts of acetone in a million parts of air (ppm), though some can smell it
at much lower levels. Most people begin to detect the presence of acetone in water at 20 ppm.
Acetone evaporates readily into the air and mixes well with water.
Acetone occurs naturally in plants, trees, forest fires, vehicle exhaust and as a breakdown product
of animal fat metabolism. Acetone is a general building block in organic chemistry. In the human
body, it is normally present in very small quantities in urine and blood; larger amounts may be
found in the urine and blood of diabetics. Acetone is toxic in high doses. Formulation and production
of other chemicals can account for up to 75 percent of all uses of acetone. Acetone is a
volatile organic compound (VOC) that is considered to have low toxicity, though improper use of
it can cause serious problems. There are a number of uses for acetone, including in chemicals,
solvents and nail polish remover. The most common use of acetone is to formulate other chemicals.
Beyond chemicals and solvents, other uses for acetone exist in the production of cosmetics
and household and personal care products.
Acetone is classified as a low-toxicity VOC. It easily evaporates in the air, dissolves in water
and is highly flammable. Acetone is an excellent solvent for a wide range of gums, waxes, resins,
fats, greases, oils, dyestuffs, and cellulosic.
It is used as a carrier for acetylene, in the manufacture of a variety of coatings and plastics, and as
a raw material for the chemical synthesis of a wide range of products such as ketone, methyl
methacrylate, bisphenol A, diacetone alcohol, methyl isobutyl ketone, hexylene glycol (2-
methyl-2,4-pentanediol), and isophorone.
2
World production of acetone in 1990 was about 3 million metric tons per year, of
which about 1 million are made in the United States. In 2010, the worldwide
production capacity for acetone was estimated at 6.7 million tons per year in
which the United States had the highest production capacity with 1.56 million tons
per year and the second largest production is in Taiwan and followed by China
(2010).
Most of the world's manufactured acetone is obtained as a co-product in the

process for phenol from cumene and most of the remainder from the
dehydrogenation of isopropyl alcohol. Numerous natural sources of acetone
make it a normal constituent of the environment. It is readily biodegradable.
Chemical manufacturers can produce acetone, although it also can be found in the
environment as a naturally occurring substance. However, by the late 1950s,
routes to produce solvents from petroleum were made cost-competitive
with fermentation. In addition, the major feedstock at the time was molasses,
which spiked in price because of animal feed demand. Acetone is typically
produced in commercial quantities as a by-product during the formation of
phenol. However, acetone manufactured thus generally contains small amounts of
the reactant benzene and the desired product phenol. In the past, these impurities
were deemed to be within allowable limits. However, recent downward revisions
of these limits by the US Food and Drug Administration have made
alternative processes (which do not involve benzene) more attractive.
3
1.1 History
Acetone, (CH3)2CO, is a common solvent, first discovered by alchemists during the Middle Ages,
where it was known as spirit of Saturn. n 1833 or 1836 its chemical structure was determined
by chemists who was French chemist Jean Baptiste Dumas and German chemist Justus von
Liebig, who determined acetone chemical formula. French chemist in 1833, named
acetone, by adding one- suffix to the stem of the corresponding acetic acid. By 1852, Alexander
William Williamson, an English chemist concluded that acetone is a methyl acetate and in
the same year it was agreed/concurred by a French chemist Charles Frederic Gerhardt.
Chaim Weizmann, during World War 1, introduced the process for industrial production
of acetone known as Weizmann Process.
In previous eras it was made from the distillation of starches. A key component in explosive
manufacture during the First World War, acetone was so critical to the war effort that the British
government paid schoolboys to find horse chestnuts to distill into acetone. Acetone is
usually derived from fossil fuels in the modern era, by the petrochemical industry.
The name acetone derives from the Latin root acetum for acetic acid by adding “one” meaning
“daughter of” because it was obtained from the acid. Up to the First World War most of the
calcium acetate required to make acetone was produced in Germany where the Black
Forest provided ample supplies for the destructive distillation of wood. In those days the main
use of acetone was in the production of cordite, the propellant used in the standard British
rifle cartridge. Cordite was made by extruding a mixture of nitrocellulose and nitroglycerin
dissolved in acetone through small holes. Evaporation of the acetone resulted in a
spaghetti-like cord, hence the name “cordite”.
1595: In 1595 Acetone was observed as a product of the distillation of sugar of lead (lead
acetate). In the nineteenth century it was obtained by the destructive distillation of metal
acetates, wood, and carbohydrates with lime, and pyrolysis of citric acid.
4
1610: In 1610 Possibly the most vivid description of the preparation of acetone
is given by Jean Beguin, who established a school of pharmacy in Paris a few
years after the turn of seventeenth century. To save time in dictating notes, he
wrote a textbook in Latin, Tyrocinium Chymicum, published privately in 1610.
he cautions that it is necessary that the lead acetate must be distilled into
a receiver of sufficient capacity.
Figure 1.1: Jean Beguin
1832: In 1832, French chemist (Jean-Baptiste Dumas) and German chemist

(Justus von Liebig) determined the empirical formula for acetone. In 1833, the
French chemist, Antoine Bussy named acetone by adding the suffix -one to the
stem of the corresponding acid. In 1852, English chemist, Alexander William
Williamson realized that acetone was methyl acetyl.
Figure 1.2: Antoine Bussy
5
During World War 1: acetone was developed the process for industrial
production of acetone by Chaim Weizmann. Weizmann needed something to
help him create the method of Bacterial Fermentation, so he made acetone using
the bacterium Clostridium Acetobutylicum. But the way it was abandoned due
to the low acetone of butanol produced.
Figure 1.3: Clostridium Acetobutylicum
Clostridium Acetobutylicum is a commercially valuable bacterium sometimes

called the "Weizmann Organism”. He is a senior lecturer at the University of
Manchester, England.
Figure 1.4: Chaim Weizmann
6
1916: in this year He used them as a bio-chemical tool to produce at the same time, acetone,
ethanol, and butanol from starch. The method has been described since as the ABE process,
(Acetone Butanol Ethanol fermentation process), yielding 3 parts of acetone, 6 of butanol,
and 1 of ethanol. Acetone was used in the important wartime task of casting cordite. The alcohols
were used to produce vehicle fuels and synthetic rubber. Unlike yeast, which can digest
sugar only into alcohol and carbon dioxide, clostridium acetobutylicum and other Clostridia can
digest sugar, starch, cellulose and perhaps certain types of lignin, yielding butanol, propionic
acid, ether, and glycerin.
1920: in the early 1920s Production of acetone by dehydrogenation of isopropyl alcohol began and
remained the dominant production method through the 1960s.
1960: In the mid-1960s virtually all United States acetone was produced from propylene. A
process for direct oxidation of propylene to acetone was developed by Wacker Chemie,
but is not believed to have been used in the United States. However, by the mid-1970s 60%
of United States acetone capacity was based on cumene hydroperoxide, which accounted
for about 65% of the acetone produced.
Acetone dehydrogenation history :
Production of acetone by dehydrogenation of isopropyl alcohol began in the early 1920s and
remained the dominant production method through the 1960s.
In the mid-1960s virtually all United State's acetone was produced from propylene.
7
1.2 Physical and Chemical properties of Acetone

1.2.1 Physical Properties of Acetone
Acetone (CH3)2CO consists of three carbon, six hydrogens and one oxygen
atom. Acetone comes under the categories of ketones, which are organic
compounds with a carbonyl group bonded to two hydrocarbon groups.
It is colorless, volatile, flammable liquid and somewhat aromatic odor. It is

miscible in all proportions with water and with organic solvents such as ether,
methanol, ethyl alcohol, and esters. Acetone is used as a solvent for cellulose
acetate and nitrocellulose, as a such ketone, hexylene glycol(2-methyl-2,4-
pentanediol), and isophorone carrier for acetylene and as raw material for the
chemical synthesis of a wide range of products as ketene, methyl methacrylate,
bisphenol A, diacetone alcohol, mesityl oxide, methyl isobutyl
Figure 1.5: Acetone in colorless liquid state
8
Property Value
Formula C3H6O
Melting point, -94.6
Appearance Colorless liquid

1
Molar mass, g.mol 58.08
Density, gcm 0.791
Viscosity at 10 , mPa.s 0.36
Flash point -18
Boiling point at 1 atm, 56.29
Specific heat of liquid, J/g.k 2.6
Electrical conductivity at 25 , S/Cm 5.5*10^-8
Heat of Vaporization, kJ/mol 29.1
Specific heat of vapor, J/(mol.k) 92.1
Heat of combustion of liquid, kJ/mol 1787
Heat of formation gas at 25 , kJ/mol -216.5
Heat of formation liquid at 25 , kJ/mol -248
Entropy of liquid at 298.15k, J/k 200.1
Acidity 19.2
Basicity -5.2
Flammability limits 2.6-12.8%
Molar entropy, j/mol.K 200.4
Refractive index 1.359
Dipole moment 2.91D
Material Safety Data Sheet of Acetone
Table 1.1: Physical properties of Acetone
9
1.2.2 Chemical Properties of Acetone
Acetone has closed-cup flash point of -18 and an autoignition temperature of 538 . The
explosive limits of acetone-air mixtures lie between 2.15 and 13.0 vol % acetone in air at
25 Acetone shows the typical reactions of saturated aliphatic ketones.
It forms crystalline compounds with alkali bisulfites; e.g., with sodium bisulphate, the
compound (CH3)2C(OH)SO3Na is obtained. Reducing agents converts convert acetone to
isopropyl alcohol and pinacol. Propane is the product of the Clemmensen reduction:
(CH3)2C=O+4HCl + 2Zn(Hg) ÿ CH3CH2CH3+ 2ZnCL2+2Hg+H2O
Isopropyl amine is produced by reductive ammonolysis of acetone:
catalyst
(CH3 )2 C=O+NH3+H2 (CH3)2 CHNH2 + H2O
100-500 Kpa
Acetone undergoes much condensation reaction. For example, condensation with amines
will yield Schiff bases. Orthoformic esters condense with acetone to form acetals. With
hydrogen sulfide, acetone reacts to form thioketone; with mercaptans, it yields thioketals. In the
presence of an amine, or ammonia, various esters condense readily with acetone. In the
presence of sodium alkoxides and sodium amide, ÿ-diketones are formed. It is also
possible to produce ÿ-diketones by reaction of acetone with carboxylic anhydrides in the
presence of boron tri-fluoride.
Acetone is stable to many of the usual oxidants, such as Fehling’s solution, silver nitrate,
cold nitric acid, and neutral potassium permanganate, but it can be oxidized with some of the
stronger oxidants such as alkaline potassium permanganate, chromic acid, hot nitric
acid. Acetone can also be oxidized by an alkali metal hypohalite or by halogen in the presence of
a base, to a halo-form and alkali metal acetate.
10
1.3 Acetone Production methods:
1.3.1 Co-production in hock phenol methods:
The Hock process to produce phenol and acetone from low cost reagents,
oxygen, and sulfuric acid was discovered by Hock and Lang in 1944. The
phenol produced by the Hock process approaches 99.99 % wt with total
impurities of only 60 ppm. The process starts with cumene being oxidized to
form an intermediate compound called cumene hydroperoxide (CHP) The
cumene hydroperoxide then goes through a cleavage reaction to form phenol
and acetone. Cumene (isopropyl benzene) is an aromatic hydrocarbon that can
be easily synthesized from benzene and is found in crude oil and refined fuels.
Phenol can be used in aspirin, billiard balls, dyes, deodorant, while acetone
finds in plastics and solvents.
The process steps are: first, cumene are reacted with oxygen in air to form an
intermediate compound (CPH). Second, the CPH is decomposed with sulfuric
acid to form the phenol and acetone co-products. Monitoring the process for CHP
concentration is very important since CHP is the critical intermediate as a product
of the oxidation step and as a reactant in the cleavage reaction. The oxidation
reaction is accomplished in a series of towers with each successive tower
producing a higher % of CHP. These steps are illustrated in figure 1.6.
Figure 1.6: Co-production in hock phenol methods
11
Figure 1.7: Co-production in hock phenol process flow diagram
1.3.2 The Wacker-Hoechst process direct oxidation of propene:
The most important source of acetone is the Hock process for phenol
production. In this process acetone is obtained as stoichiometric coupling
product. It can be obtained by a Wacker-Hoechst oxidation of propylene.
Acetone is used industrially as solvent. Moreover, the aldol condensate products of
acetone (diacetone alcohol) are used as solvents. Acetone is also converted in an
add catalyzed reactions with two moles of phenol for the synthesis of
bisphenol A. Bisphenol A is an important feedstock for the production of epoxy
resins and polycarbonates. The Wacker-Hoechst process has been practiced
commercially since 1964. In this liquid phase process propylene is oxidized to
acetone with air at 110-120°C and 10-14 bar in the presence of a catalyst system
containing PdCl2. As in the oxidation of ethylene, Pd (II) oxidizes propylene to
acetone and is reduced to Pd (0) in a stoichiometric reaction, and is then
reoxidized with the CuCl2 / CuCl redox system. The selectivity to acetone is
92% propionaldehyde is also formed with a selectivity of 2-4%. The conversion of
propylene is more than 99%. These steps are illustrated in figure 1.7.
catalyst
CH3CH = CH2 + 1/ 2O2 ÿ
CH3COCH3
12
Figure 1.8: Wacket-Hechst direct oxidation of propene flow diagram
13
1.3.3 Older methods:
Previously, acetone was produced by the dry distillation of acetates, for

example calcium acetate in ketonic decarboxylation. After that time, during World
War I, acetone was produced using acetone-butanol-ethanol fermentation with
Clostridium acetobutylicum bacteria, which was developed by Chaim Weizmann
(later the first president of Israel) in order to help the British war effort in the
preparation of Cordite. This acetone-butanol-ethanol fermentation was eventually
abandoned when newer methods with better yields were found.
1.3.4 Dehydrogenation of isopropanol:
Acetone is produced by several alternative processes, one of which is the

dehydrogenation of isopropanol (IPA). The endothermic gas-phase reaction
converts IPA to acetone and hydrogen. The process consists of a vaporizer,
heated tubular reactor, flash tank, absorber, and two distillation columns. The
liquid fresh feed is a mixture of IPA and water. It is combined with a small IPA/
water recycle stream, vaporized, and fed into the vapor- phase reactor, which is
heated by high- temperature molten salt. Reactor effluent is cooled and fed to a flash
tank. The gas from the tank contains most of the hydrogen but also some acetone.
This gas is fed to an absorber in which a water stream is used to recover acetone.
The liquid streams from the base of the absorber and the flash tank are fed to the
first distillation column, which produces high-purity acetone out of the top. There is
also a vapor vent stream leaving the reflux drum of this column to remove the small
amount of hydrogen dissolved in the feed which is shown in figure 1.8. The reactions
are:
• CH3 – CHOH – CH3 ÿ CH3 – CO – CH3 + H2
• 2CH3 – CHOH – CH3 ÿ (CH3)2 CH – O– CH(CH3)2 +H2O
• CH3 – CHOH – CH3 ÿ CH2=CH–CH3 +H2O
14
The equilibrium of the dehydrogenation reaction is shifted to acetone by

increasing temperature. At 325°C (97%) conversion is theoretically possible.
A large number of catalysts for the reaction have been investigated these
include: copper, silver, platinum, and palladium metal as well as sulfides of
transition metals of the groups IV, V, and VI of the periodic table. These
catalysts are made with inert supports and are used at 400°C – 600 °C lower
temperature reactions (315°C – 482°C) have been successfully conducted using
zinc oxide –zirconium oxide combinations, copper. Chromium oxide
combinations and combinations of copper and silicon dioxide. In one
commercial version the catalyst is zinc oxide (7-8%) on pumice carried.
Figure 1.9: Dehydrogenation of isopropanol flow chart.
15
1.4 Uses & applications of acetone:
1.4.1 Solvent:
Because acetone's dual polarity, and versatility, it is that solvent that can be used
in a multitude of different industries. One of the uses of acetone that is so common is as an
addition in gasoline. Acetone is a good solvent to be used to thin gasoline, allowing it to diffuse
easily in the engine improving fuel efficiency. Acetone can be solvent and dissolve many plastics
including those used in Nalgene bottles made of polystyrene polycarbonate and some types of
polypropylenes. And in the manufacture of smokeless powder.
1.4.2 Cosmetic:
Acetone denatures certain alcohol and it can be used as an additive in makeup and
creams. One of the basic ingredients of nail paint remover is acetone. By using a
cotton swab or cloth nail paint can be removed easily from nails and leaves it dry.
Sometimes it can cause eye irritation or skin irritation.
1.4.3 Laboratory:
It is an important solvent in the laboratory. It is used to rinse the glass apparatus

and makes the drying process faster. Its freezing point is near -80 degree Celsius
and it is used to conduct chemical reactions at low temperatures in a wide range.
The vapors of acetone can be used as tracers because it appears fluorescent under
UV light.
1.4.4 Electronics:
It is used in cleaning electronic devices. Many electronic gadgets and appliances

cleaners use acetone as a solvent Therefore, is used in the cleaning of electronic
gadgets and devices.
1.4.5 Medicine and pharmaceutical:
Acetone is an organic solvent which is most commonly used in pharmaceuticals.

It is used in producing pills and liquid medicines to have proper density. It is
mandatory for the efficacy of medicine. It is also used as an antiseptic.
Dermatologists use acetone with alcohol for acne treatments to peel dry skin.
16
1.4.5 Domestic purpose:
It is used to remove oil stains from the walls. Also, there is stubborn ink that can
be removed by using acetone. It can be used to clean any brush or equipment
that is used during painting. It is used as paint thinner for oil paints and resins.
1.4.6 Bisphenol A:
One mole of acetone condenses with two moles of phenol to form bisphenol A.
bisphenol is mainly used in the production of polycarbonate and epoxy resins.
Polycarbonats are high strength plastics that are widely used in automotive
applications and appliances, multilayer containers, and housing applications.
17
Chapter 2
Material Balance
18
Figure 2.1: Process flow sheet Production of Acetone from Isopropyl Alcohol (IPA).
19
Table 2.1: Process stream table
Stream no. 1 2 3 4 5 6 7 8 10 11 12 14 15
Pressure 2 2 1.8 1.8 1.5 1.5 1.5 1.7 1.3 1.3 1.6 1.1 1.4
(bar)
Temperature 25 109.5 350.0 94.7 81.0 28.1 70.0 25.0 45.0 102.3 105.0 111.5 111.5
and (°C)
Acetone (kg/ - -
5336 5336 1218 1216. 1.218 -
5334. 5329.4 5.33 - -
hr) 782 782 46
Hydrogen (kg/
- -
184 184 184 -
184 - - - - - -
hr)
Water (kg/ 833.2 895.5 895.5 895.5 67 1085 -

1079 1168 -
11685. 62.298 11623.
hr) 02 7.6 1 5.42 42 122
Unreacted 5578. 6000 480 480 30 30 - -

477.4 55.68 421.74 421.74 -
IPA (kg/hr) 26 2
Mass flow (kg/ 6411. 6895.5 6895.5 6895. 1498 1210 185.2 1079 1749 5385.1 12112. 484.02 11623.
hr) 462 5 4.382 18 1 7.622 26 49 9 122
20
Chapter 2: Material balance
Material balances are the basis of process design. A material balance taken over complete
process will determine the quantities of raw materials required and products produced.
Balances over Individual process until set the process stream flows and compositions. The
general conservation equation for any process can be written as:
Material out = material in + accumulation
For a steady state process the accumulation term is zero. If a chemical reaction is taking place a
particular chemical species may be formed or consumed. But if there is no chemical reaction, the
steady state balance reduces to:
Material out = Material in
A balance equation can be written for each separately identifiable species present, elements,
compounds and for total material.
21
• Process description:
At the beginning of the process, feed including iso-propyl alcohol (IPA) and water,
and recycle stream are mixed in feed drum. From here, this mixture is send to
vaporizer to change stream’s phase as vapor. After vaporizer, mixture is heated to
reaction temperature in the heater. Reactor used is a fixed bed tubular reactor.
Acetone, hydrogen gas (H2) are produced and water and IPA are discharged. After
condenser the mixture is sent to flash unit. Hydrogen, acetone, IPA and water are
obtained as top product. This top product is sent to scrubber to remove hydrogen.
The bottom product of flash unit which is formed by acetone, water, and IPA are
mixed with the bottom product of scrubber before acetone column. In acetone
column, acetone is obtained from top product with 99 wt. %. IPA and water and
also 0.1% of acetone is sent to IPA column from bottom product. The top product
of this column is sent to feed drum and bottom product is thrown away as waste water.
2.1 Detail process description:

Feed drum: Feed drum is a kind of tank used for the mixing of the recycle stream
and feed stream. Recycle stream concentration is assumed to be same with the
feed stream. Feed stream is at room temperature (25°C) and at a pressure of 2
bars, which is assumed to be constant. The temperature of recycle stream
calculated as 111.50 °C from the energy balance around the IPA distillation
column. The temperature of the leaving stream from the feed drum calculated as
32.890 °C, by the energy balance around feed drum.
Vaporizer: In the vaporizer molten salt is used for heating. The temperature at the
entrance of the unit is the temperature of the mixture leaving the feed drum, which
is 32.890 °C. And the leaving temperature is the bubble point temperature of the
mixture, which is 109.50 °C. The pressure is 2 bars, and assumed to be constant.
22
Pre-heater: Since the temperature leaving the vaporizer is not enough for the reaction to carry
out. Due to which a pre-heater is used to maintain the temperature of the feed stream to the
reaction temperature of 350 °C which is the reaction temperature. The unit is working at 2 bars
and assumed to be constant. The entrance and leaving temperatures are 109.50°C and 350°C.
This unit heats the molten salt that provides heat to the reactor. Energy is supplied by
combustion of natural gas, which may be assumed to be pure methane. The heat capacity of
molten salt is 1.56 J/g K.
Reactor: The reactor is the starting point for the calculations. The temperature values for the
entering and leaving streams is 350 °C,m(i.e the process is isothermal).
The reaction takes place inside is endothermic, for this reason the reactor has to be heated.
For heating, molten salt is used from the furnace and the conversion at 350 °C temperature is
90%. The reactor exit pressure is 1.8 bar. Only the following reaction take occurs;
Catalyst
CH3-CHOH-CH3 (V)
ÿ
CH3-CO-CH3 (V) + H2 (g)

Catalyst
Acetone + hydrogen
ÿ
VIOLENCE
Cooler: The entrance temperature of the cooler is 350 °C and leaving temperature is 94.70°C
(temperature is calculated by using energy balance). For cooling purpose water is used. By
using refrigerant better results may be obtained. But since it costs too much, due to which it
isn’t chosen as the cooling material. From the temperature values it’s easily seen that the load
is on the cooler not on the condenser, for this process. But in reality the unit cannot cool that
much, and the load is mostly on the condenser. In this process, the mixture cooled down to its
dew point. The pressure is 1.5 bars, and assumed to be constant.
Condenser: The temperature of the entering stream is the dew point and the leaving
temperature is the bubble point of the mixture. In the condenser water is used as cooling
material.
Separation vessel: This unit disengages the vapor and liquid effluent from E-402.
In this separator, all hydrogen in the feed enters the vapor phase. All other components
distribute according to Raoult’s Law at the temperature and pressure of E-402. The combination
ofE-402 and V-401 is often called a flash operation.
23
Flash unit: Flash unit is operating isothermally, for this reason temperature is not changed. It is 81 °C
in the entrance and exit. From trial and error method, (V/F) value is found to be 0.2. The entrance
temperature of the unit is the bubble point of the mixture, but if it is its dew point the (V/F) value should
be much higher. In the flash unit the hydrogen is flashed out from the mixture of IPA, water and
acetone.
Along with hydrogen some amount of acetone and isopropyl alcohol is also flashed out. In order to
recover these, a scrubber unit is used.
Scrubber: Scrubber operated adiabatically. Water entering the unit is at room temperature (i.e
25°C). The temperature of the off gas, including hydrogen and a very little amount of acetone, is
between 40-50°C. The temperature of the leaving stream (containing water, acetone and isopropyl
alcohol) is found to be 28.10 °C from the energy balance around the scrubber. The streams leaving
the scrubber and flash unit are mixed together before entering the acetone column. The temperature
leaving the flash unit and scrubber are 81°C and 28.10 °C respectively. The temperature of the
mixture is found to be 45.0 °C. This result is obtained by using energy balance around the
mixing point.
Acetone distillation column: The acetone column is used to separate the acetone from the
mixture. The entrance temperature is 45 °C. The leaving temperatures for the top and bottom
product are 102.3 °C and 105 °C, respectively, which are the bubble and dew points. Top product of
the unit includes acetone (99wt% of acetone which is desired). From the bottom IPA, water and
a very little amount of 0.1 %, acetone is discharged.
IPA column: In this distillation column, IPA and water are separated. The entrance
temperature is 105°C. The leaving temperatures of the top and bottom products are both 111.50
°C. The top product is recycled to the feed drum. For this reason it’s assumed to have the same
concentration with the feed stream. The bottom product is pure water and it’s thrown away.
Since its temperature is very high it cannot be recycled to the scrubber. But if a cooler is used, a
recycle can be used.
24
Material Balance
2.2 Material balance around the reactor:
Basis Operating days/year = 365
Production Rate: 200 ton/day = 8.33 kg/h = 73000 ton/year of acetone (99% purity) the feed
consist of 67% of IPA and 33% water:
100 kgmol/hr of isopropyl alcohol (IPA) are entering the reactor.
From literature: conversion is 92%
Since the solution used for the preparation of acetone is 87%. So the number of moles of water
entering in the reactor is calculated as:
Weight of solute
Weight % = ×100%
Total weight of solution
Weight of IPA
0.87 =
(Weight of IPA+Weight of water)
100 kgmol 60kg

×
hr kgmol
0.87 =
100 kgmol 60kg
( ×
hr kgmol+weight of water)
Weight of water = 896.5 kg/hr

1
Moles of water entering in reactor (n water, in) = 896.5 kg/hr × 18kg/kgmol
n water, in =49.75 gmol/hr
Acetone=92kgmol/hr
IPA = 100 kgmol/hr 2 3 H2=92kgmol/hr

Reactor
Water = 49.75 kgmol/hr water=49.75kgmol/hr
Total feed = 149.75 IPA=8kmol/hr
Product =241.75 kgmol/hr
25
cuckoo
Reaction: CH3-CHOH-CH3 (V) ÿ CH3-CO-CH3 (V) + H2 (g)
n acetone 3 =0.92×100 kgmol/hr
n acetone 3 = 92 kgmol/hr
n hydrogen 3 = 0.92 × 100 kgmol/hr
n hydrogen 3 =92 kgmol/hr
n IPA 3 = 0.08 × 100kgmol/hr
3 = 8 kgmol/hr n IPA
n water 3 = 49.75 kgmol/hr
n T 3 = n acetone 3 + n hydrogen 3 + n IPA 3 + n water 3
n T 3 = 241.75 kgmol/hr
The concentration of streams ( 2&3) is given in table below
in
Yi =
ntotal
Table (2.A) the concentration of stream 2
VIOLENCE 0.67
water 0.33
Table (2.B) the concentration of stream 3
Acetone 0.3805
Hydrogen 0.3805
VIOLENCE 0.033
Water 0.2057
26
Overall material balance around reactor:
Mass in (stream 2) = Mass out (stream3)
(100kgmol/hr× 60kg/kgmol) + (49.75× 18kg/kgmol) = (92kgmol/hr× 58kg/kgmol) + (92kgmol/hr×

2kg/kgmol) + (8kgmol/hr× 60kg/kgmol) + (49.75kgmol/hr× 18/kgmol)
6895.5kg/hr = 6895.5kg/hr
2.3 Material balance around phase separator:
Acetone =21kgmol/hr
Hydrogen=92kgmol/hr
Water= 3.7kgmol/hr
Acetone=92kgmol/hr 3 Phase IPA=0.5kgmol/hr
H2=92kgmol/hr separator vapor=117.2kgmol/hr
Water =49.75kgmol/hr
IPA=8kmol/hr
9
Feed =241.75 kgmol/hr
Acetone= 71kgmol/hr
Water=45.99kgmol/hr
IPA=7.457kgmol/hr
Liquid = 124.447kgmo/hr
27
It is assumed that there is no change at temperature and pressure.
Bubble point ÿyi = ki × xi =1
do =1
Dew point ÿxi =
to =
do = pi/pT = pi
ÿ
xi pee
ÿ
Where ki is distribution coefficient and pi = vapor pressure of component i
The vapor pressure can be calculated by using Antoine equation
B
log p* = A –
T+C
*
p =vapor pressure, mmHg
A, B, C = the Antoine coefficients
T= temperature, °C
Component Antoine coefficients

A b C
Acetone 7.02447 1161 244
Isopropyl -alcohol 8.37895 1788.02 227.438

Water 7.96681 16681.21 2281
Ambrose, D., & Townsend, R, (1963). Thermodynamic Properties of Organic Oxygen Compounds. Part
9. J. Chem. Soc.
At bubble point T= 81°C & pressure = 1.5 bar
ÿ For acetone:
* 1161
log pi = 7.02447 –
81+224
*
log pi = 3.2179
pi = 1651.58 mmHg
k = 1651.58 mmHg
acetone
1.5bar× 760mmHg
1.013 bar
k acetone
= 1.4676
28
ÿ For IPA
* 1788.02
log pi = 8.37895 –
81+227.438
*
log pi = 2.5819
*
pi = 381.856 mmHg
= 381.856 mmHg
k VIOLENCE
760mmHg
1.5bar× 1.013 bar
k VIOLENCE
= 0.3393
ÿ For water
* 16681.21
log pi = 7.96681 –
81+228
*
log pi = 2.5681
*
pi = 369.913 mmHg
= 369.913 mmHg
k water 760mmHg
1.5bar× 1.013 bar
k water = 0.3287
From literature (V/F) =0.17
The presence of H2 does not affect the process, so we neglect n hydrogen
n acetone 3 3 + n water 3 n feed 3 = = 149.75kgmol/hr + n IPA
V = 0.17 × 149 75 kgmol/hr
V = 25.46kgmol/hr
F=V+L
L= 149.75 –25.46 = 124.29
yv = ki xL
29
For acetone
yv = 1.4676xL
n acetone 3 = n acetone 5 + n acetone 9
92 = 25.46 yv + 124 .29 xL
92= 25.56 (1.4676 xL) + 124.29xL
xL= 0.57 & yv = 0.84
For IPA:
yv = 0.3393 xL
n IPA 3 = n IPA 5 + n IPA 9
92 = 25.46 yv + 124 .29 xL
92= 25.56 (0.3393 xL) + 124.29xL
xL= 0.06 & yv = 0.02
For water:
yv = 0.3287 xL
n water 3 = n water 5 + n water 9
92 = 25.46 yv + 124 .29 xL
92= 25.56 (0.3287 xL) + 124.29xL
xL= 0.37 & yv = 0.15
At stream 5:
n acetone 5 = 24.46 × 0.84 = 21 kgmol/hr
n IPA 5 = 24.46 × 0.02 = 0.5 kgmol/hr
n water 5 = 24.46 × 0.15 = 3.7 kgmol/hr
30
At stream 9:
n acetone 9 = 124.29 × 0.57 = 71 kgmol/hr
n IPA 9 = 124.29 × 0.06 = 7.457 kgmol/hr
n water 9 = 124.29 × 0.37 = 45.99 kgmol/hr
Table (2.C) the concentration of stream 5
Acetone 0.18
Hydrogen 0.78
VIOLENCE 4×10-3
Water 0.03
Table (2.D) the concentration of stream 9
Acetone 0.57
VIOLENCE 0.06
Water 0.37
Overall material balance around phase separator:
Mass in (stream 3) = Mass out (stream5 + stream 9)
6895.5kg/hr = (92kgmol/hr × 58kg/kgmol) + (92kgmol/hr × 2kg/kgmol) + (49.7kgmol/hr × 18kg/

kgmol) + (8kgmol/hr × 60kg/kgmol)
6895.5kg/hr = 6894.6kg/hr
31
2.4 Material balance around the scrubber:
7
Hydrogen=92kgmol/hr
Water = 599.5kgmol/hr acetone=0.021kgmol/hr

8 Off gases=92.021kgmol/hr
Scrubber
Acetone=21kgmol/hr
Hydrogen=92kgmol/hr Acetone=20.979kgmol/hr
Water=3.7kgmol/hr 5 IPA=0.5kgmol/hr
IPA=0.5kgmol/hr water=603.2kgmol/hr
6
Vapor feed= 117.2kgmol/hr
Liquid=624.679kgmol/hr
Assume 1/1000 of inlet acetone is in off-gas.
At stream 7:
n acetone 7 = 21 kgmol/hr × 1/1000 = 0.021 kgmol/hr
hydrogen = 92 kgmol/hr n
nT7 = 92.021kgmol/hr
Table (2.E) the concentration of stream 7
Acetone 2.3×10-4
Hydrogen 0.9997
32
At stream 6:
n acetone 6 = 21 –0.021 = 20.979kgmol/hr
n IPA 6 = 0.5 kgmol/hr
n water 6 = n water 8 + n water 5
n water 6 = n water 8 + 3.67
Mass of solvent:
1ÿA
yAcetone 7 =
1 ÿ An+1
yAcetone 5
1ÿA
yAcetone 7 =
1 ÿ A6
yAcetone 5
nT 8
A=
m × nT 5
3598
10.92ÿ
354.15
m=
p
Where A is scrubber factor & n is number of trays theoretically is equal to 5 trays & m is equilibrium absorption
constant.
3598
10.92ÿ
354.15
m= = 1.445
1.48
2.2 × 10ÿ4 1ÿA

=
0.17 1 ÿ A6
By try and error methods A= 3.54
nT 8
3.54 =
1.445 × 117.2
nT 8 = 599.5 kgmol/hr
n water 6 = 599.5kgmol/hr + 3.67 = 603.2kgmol/hr
n6= n water 6 + n acetone 6 + n IPA 6 = 624.679kgmol/hr
33
Table (2.F) the concentration of stream 6
Acetone 0.034
VIOLENCE 8×10-4
Water 0.96
Overall material balance around scrubber:
Mass in (stream 5 & 8) = Mass out (stream6 + stream 7)
(21/hr × 58kg/kgmol) + (0.5kgmol/hr × 60kg/kgmol) + (92kgmol/hr × 2kg/kgmol) +(603.2kgmol/hr × 58kg/

kgmol) = (21kgmol/hr × 58kg/kgmol) + (92kgmol/hr × 2kg/kgmol) + (603.2kgmol/hr × 18kg/kgmol) + (0.5kgmol/
hr × 60kg/kgmol)
12289.6kg/hr = 12289.6kg/hr
2.5 Material balance around the Acetone column:
11 Acetone= 91.887 kmol/hr
IPA=0.928kgmol/hr
Acetone=91.979kgmol/hr D=92.815kgmol/hr
Acetone
IPA=7.957kgmol/hr
Water =649.19kgmol/hr Column
F=749.126kgmol/hr
10
Acetone=0.091979kgmol/hr
IPA=7.029kgmol/hr
Water=649.19kgmol/hr
12
B= 656.3kgmol/hr
34
At stream (10) :
n acetone 10 = n acetone 6 + n acetone 9 = 20.979kgmol/hr + 71kgmol/hr
n acetone 10 = 91.979 kgmol/hr
n IPA 10 = n IPA 6 = 0.5kgmol/hr + 7.457 + n IPA 9
n IPA 10 = 7.957kgmol/hr
n water 10 = n water 6 + n water 9 = 603.2 kgmol/hr + 45.99kgmol/hr
n water 10 = 649.19kgmol/hr
T 10 = n acetone 10 + n IPA 10 + n water 10 n =749.126 kgmol/hr
Assume that 1/1000 of acetone is in bottom product.
n acetone 12 = 91.979 kgmol/hr × 1/1000 = 0.091979kgmol/hr
n acetone 11 = n acetone 10 – n acetone 12 = 91.979kgmol/hr – 0.091979kgmol/hr
n acetone 11 = 91.887kgmol/hr
Since acetone purity is 99%
n T 11 = 91.887kgmol/hr × 100/99 = 92.815kgmol/hr
11 = n T 11 – n acetone 11 = 0.928kgmol/hr n IPA
n IPA 12 = n IPA 10 – n IPA 11 = 7.957kgmol/hr – 0.928kgmol/hr
n IPA 12 = 7.029 kgmol/hr
n water 12 = n water 10 = 659.19kgmol/hr
T 12 = n acetone 12 + n IPA 12 + n water 12 n = 656.3kgmol/hr
Table (2.G) the concentration of stream 10
Acetone 0.12
VIOLENCE 0.01
Water 0.87
35
Table (2.H) the concentration of stream 11
Acetone 0.99
VIOLENCE 0.001
Table (2.I) the concentration of stream 12
Acetone 1.4×10-4
VIOLENCE 0.01
Water 0.989
Overall material balance around acetone column:
(91.979/hr × 58kg/kgmol) + (7.957kgmol/hr × 60kg/kgmol) + (649.19kgmol/hr × 18kg/kgmol) = (91.979kgmol/

hr × 58kg/kgmol) + (649.19 kgmol/hr × 18kg/kgmol) + (7.9547kgmol/hr × 60kg/kgmol)
17497.622kg/hr = 17497.622kg/hr
2.6 Material balance around the IPA column:

13
Acetone=0.091979kgmol/hr
IPA= 7.029kgmol/hr
Water= 3.461kgmol/hr
12
IPA column
D=10.49kgmol/hr
Acetone =0.091979kgmol/hr
IPA= 7.029kgmol.hr
Water = 649.19kgmol/hr
F=656.3kgmoll/hr
15 Water= 645.729kgmol/hr
36
Since all the i-propyl-alcohol is at the top product.
n IPA 13 = n IPA 12 = 7.029kgmol/hr
n acetone 13= n acetone 12 = 0.091979kgmol/hr
By neglecting n acetone in Stream 13 and assuming the composition of the recycle stream is as feed
stream so that:
7.029
0.67 =
nT13
n T 13 = 10.49kgmol/hr
n water 13 = n T 13– n IPA 13 = 3.461 kgmol/hr
n water 15 = n water 12 – n water 13 = 645.729kgmol/hr
Table (2.J) the concentration of stream 13
VIOLENCE 0.67
Water 0.33
Overall material balance around acetone column:
(0.091979/hr × 58kg/kgmol) + (7.029kgmol/hr × 60kg/kgmol) + (649.19kgmol/hr × 18kg/kgmol) = (0.091979kgmol/

hr × 58kg/kgmol) + (649.19kgmol/hr × 18kg/kgmol) + (7.029kgmol/hr × 60kg/kgmol)
12112.49kg/hr = 12112.49kg/hr
37
2.7 Material balance around feed drum:
IPA=92.971kgmol/hr IPA=100 kgmol/hr
Water = 46.289kgmol/hr Water = 49.75kgmol/hr

Feed Drum 2
Product=149.75kgmol/hr
Feed=139.26kgmol/hr
14 IPA=7.029 kgmol/hr
Water = 3.461kgmol/hr
Recycle=10.49kgmol/hr
Over all material balance

n IPA 2 = n IPA 14 + n IPA1
n IPA 1 = 100kgmol/hr + 7.029kgmol/hr
n water 2 = n water 14 + n water1
n water 1 = 49.75kgmol/hr + 3.461kgmol/hr
Table (2.K) the concentration of stream 1
VIOLENCE 0.67
Water 0.33
Overall material balance around feed drum:
Mass in (stream 1+ stream 14) = Mass out (stream2)
(100kgmol/hr × 60kg/kgmol) + (49.75kgmol/hr × 60kg/kgmol) = (49.75kgmol/hr × 18kg/kgmol) + (100kgmol/

hr × 60kg/kgmol)
6895.5kg/hr = 6895.5kg/hr
38
Acetone production:
kgmol kg hr dya 1ton
acetone 11 = 91.887 n × 58 × 24 × 365 ×
hr kgmol you year 1000kg
n acetone 11 = 46685.95ton/year
Since 73000 tons/year acetone is wanted to produce, all of these calculations should be correlated as this amount.
73000
Scale factor = = 1.6
46685.95
To allow for loses round off to 1.6
Table 2.2: Material balance sheet.
Stream 1 2 3 4 5 6 7 8 10 11 12 14 15
no.
Pressure (bar) 2 2 1.8 1.8 1.5 1.5 1.5 1.7 1.3 1.3 1.6 1.1 1.4
Tempera 25 109. 350. 94. 81. 28. 70. 25. 45. 102. 105. 111. 111.
ture (°C) 5 0 7 0 1 0 0 0 3 0 5 5
Acetone - -
92 92 21 20. 0.0 -
91. 92.8 0.09 - -
(kgmol/h 979 21 979 87 1979
r)
Hydroge
- -
92 92 92 -
92 - - - - - -
(kgmol/h
r)
Water 46. 49.7 49.7 49. 3.7 603 - 599 649 -
649. 3.46 149.
(kgmol/h 286 5 5 75 .2 .5 .19 19 1 75
r)
Unreacte 92. 100 8 8 0.5 0.5 - -
7.9 0.92 7.02 7.02 -
d IPA 971 57 8 9 9
(kgmol/h
r)
Mole 139 149. 241. 241 117 624 92. 599 749 92.8 656. 10.4 149.
flow .26 75 75 .75 .2 .19 021 .5 .12 15 3 9 75
(kgmol/h 6
r)
39
Chapter 3
Energy Balance
40
3.1 Energy balance around the feed drum

T inlet = 25 ÿ
I IPA = 5578.26 kg/hr T out let =?ÿ
m water = 833.202 kg/hr 2* I IPA = 6000kg/hr
Feed Drum m water = 895.5 kg/hr
mT= 6411.462 kg/hr

mT = 6895.5 kg/hr
14 T inlet = 111.5ÿ
m water= 62.298 kg/hr

m water =
I IPA = 421.74 kg/hr
833.202 kg/hr
mT = 484.083 kg/hr
Reference temperature = 25 ÿ
The feed drum is adiabatic =

CP IPA 2.497 kJ/kg.K
CP H2O= 4.178 kJ/kg.K
ig
CP Mixture = ÿ xiCP
CP mixture = (2.497 ×0.87) + (4.178 × 0.13 )
CP mixture= 2.7155 kJ/kg.K
mF = 6411.462 kg/h
mR = 484.083 kg/hr kg/h
mp = 6895.5 kg/hr kg/h
ÿÿHR = ÿÿHP
(mF × CPmix × ÿT) + ( mR × CPmix × ÿT)= (mP × CPmix ×ÿT)
[6411.462 kg/h ×2.7155 kJ/kg.K × (298 – 298)k] + [484.083 ( kg/hr kg)/h ×2.7155 kJ/kg.K ×
(384.5 ÿ 298)k] = [6895.5 ( kg/hr kg)/h × 2.7155 kJ/kg.K × (T ÿ 298)k]
T =304.07k = 31.07 ÿ
41
3.2 Vaporizer
T = 31.07 ÿ 2 T = 109.5 ÿ
2*
I IPA = 6000kg/hr Vaporizer I IPA = 6000kg/hr
m water = 895.5 kg/hr m water = 895.5 kg/hr
mT = 6895.5 kg/hr mT = 6895.5 kg/hr
Yaws, C.L. Chemical Properties Handbook 1995.

m water = 833.202 m water = 833,202 DE
Component A kg/hr B C
kg/hr
Acetone g IPA
IPA
35.918 9.3896×10-2 1.873×10-4 -2.1643×10-7 6.3174×10-11
g L 88.08 4.0224×10-1 -1.3032×10-3 1.9677×10-6
31.507 2.3082×10-1 -7.8983×10-5 6.3696×10-9 8.6908×10-13
H2O L 92.053 -3.9953×10-2 -2.1103×10-4 5.3469×10-7
H2O g
33.933 -8.4186×10-3 2.9906×10-5 -1.7825×10-8 3.6934×10-12
H2 g
25.399 2.0178×10-2 -3.8549×10-5 3.188×10-8 -8.7585×10-12
Table 3.1: Heat capacity coefficients.
(Yaws, C.L. Chemical Properties Handbook 1995)
Cp = A + BT + CT2 + DT3
For liquid When Cp= J/mol.k T in kelvin & (A ,B ,C ,D ) are constant.
Cp = A + BT + CT2 + DT3 + ET4
For gas
At temperature T= 31.07
Cp IPA = 1.5 kJ/kg.K
Cp H2O = 5.1 kJ/kg.K

ig
CP Mixture = 1.97 KJ/kg.K
Temperature = 109.5 °C
42
ig
Cp H2O = 1.86 kJ/kg.KCP Mixture = ÿ xiCP
CP Mixture= 0.97 KJ/kg.K
For water:
TC = 647.3 K
Tb =394 at 2 bar
ÿHf = 40683 kJ/kmol

Watson’s correlation:
0.38
ÿHvap H2O
= ÿHf × [ TCÿT
TCÿTb ]
0.38
647.3ÿ382.5
ÿHvap H2O
= 40639 kJ/kmol × [ 647.3ÿ394 ]
ÿHvap H2O = 41330.48 KJ/kgmol
ÿHvap H2O = 2296.14 KJ/kg

For IPA:
TC = 508.3 K
Tb =375 at 2 bar
ÿHf = 39858 kJ/kmol

Watson’s correlation:
0.38
ÿHvap IPA
= ÿHf × [ TCÿT
TCÿTb ]
0.38
ÿHvap IPA
= 39858 kJ/kmol × [ 508.3ÿ382.5
508.3ÿ394 ]
ÿHvap IPA = 38955.13 KJ/kgmol
ÿHvap IPA = 649.25 KJ/kg
ÿÿHR + q = ÿÿHP + ÿHvap
43
KJ KJ
× 1.97 × 0.97
[6895.5 kg
hr kg.K hr kg.K
× (304.07 ÿ 298)K] + q = [[6895.5 kg × (382.5 ÿ 298)K]] +
× 649.25 × 2296.14
[6000 kg
hr KJ kg] + [895.5 kg hr KJ kg]
q = 6,434,427.328 kJ/hr 4
Preheated:
T out let = 109.5 ÿ T out let = 325 ÿ
I IPA = 6000kg/hr I IPA = 6000kg/hr

Preheater
mP = 6895.5 kg/hr mP = 6895.5 kg/hr
m water = 833.202 kg/ m water = 833.202 kg/

hr hr
Temperature = 325 °C

ig
ÿÿHR + q = ÿÿHP + ÿHvap
KJ KJ
× 0.97 × 1.63
[6895.5 kg
hr kg.K hr kg.K
× (382.5 ÿ 298)K] + q = [[6895.5 kg × (598 ÿ 298)K]]
q = 2,806,709.8 KJ/hr
44
3.3 Reactor
T=325 °C T=350 °C
Reactor
CUCKOO
CH3 ÿ CHOH ÿ CH3 CH3 ÿ CO ÿ CH3 + H2
Component A BCD
Acetone g 71.96 20.2×10-2 -12.78 ×10-5 34.76×10-8
VIOLENCE L 32.427 1.886×10-1 6.405×10-5 -9.261×10-8
H2O L 33.46 0.688×10-2 0.764×10-5 -3.595×10-9
H2O g
33.933 -8.4186×10-3 2.9906×10-5 -1.7825×10-8
H2 g
28.84 0.00765×10-5 0.3288×10-8 -0.8698×10-12
(Yaws, C.L. Chemical Properties Handbook 1995)
Table 3.2: Heat capacity coefficient.
Reference temperature = 25 °C
Inlet temperature = 325 °C
Outlet temperature = 350 °C

T
2
+ DT 3
)dT
ÿHs = ÿ (A + BT + CT
T0
325
ÿHin IPA ÿ 9.261 × 10ÿ8T 3 )dT

= ÿ (32.427
25 + 1.886 × 10ÿ1T + 6.405 × 10ÿ5T 2
45
ÿHin IPA = 20.6 KJ/gmol

350
ÿHout IPA ÿ 9.261 × 10ÿ8T 3 )dT

= ÿ (32.427
25 + 1.886 × 10ÿ1T + 6.405 × 10ÿ5T 2
ÿHin IPA = 22.6 KJ/gmol

325
ÿHin H2O ÿ 3.595 × 10ÿ9T 3 )dT

= ÿ (33.46
25 + 0.688 × 10ÿ2T + 0.764 × 10ÿ5T 2
ÿHin H2O = 10.476 KJ/gmol
350
ÿHot H2O ÿ 3.595 × 10ÿ9T 3 )dT

= ÿ (33.46
25 + 0.688 × 10ÿ2T + 0.764 × 10ÿ5T 2
ÿHout H2O = 11,389 KJ/gmol

350
ÿHout Acetone + 34.76 × 10ÿ9T3 )dT

= ÿ (71.96
25 + 20.2 × 10ÿ2T ÿ 12.78 × 10ÿ5T 2
ÿHout Acetone= 33.940 KJ/gmol

350
ÿHout H2 ÿ 0.8698 × 10ÿ9T 3 )dT

= ÿ (28.84
25 + 0.00765 × 10ÿ5T + 0.3288 × 10ÿ8T 2
ÿHout H2 = 9.373 KJ/gmol
Components in Moles in Heat of Heat of phase Sensible heats

In formation ÿHf change ÿHfg ÿHs
KJ/gmol KJ/gmol KJ/gmol
VIOLENCE 100kmol/hr -272.290 39.858 20.6
Water 45.75kgmol/hr -241.826 40.65 10.476
Table 3.3: component enthalpies
ÿHi= In (ÿHf° + ÿHfg +ÿHs )
ÿHin IPA= - 2.11832 × 107 KJ/hr
ÿHin water= - 8.724525× 106 KJ/hr
ÿHin = ÿHin IPA + ÿHin water
ÿHin= 2.9907725 × 107 KJ/hr
46
Components in Moles in Heat of Heat of phase Sensible heats

In formation ÿHf change ÿHfg ÿHs
KJ/gmol KJ/gmol KJ/gmol
VIOLENCE 8kmol/hr -272.290 39.858 22.6
Water 45.75kgmol/hr -241.826 40.65 11.389
Acetone 92 kgmol/hr -216.69 92 kgmol/hr 30.2 33.940

hydrogen 0 Table 3.4: component 9.373
enthalpies.
ÿHi= In (ÿHf° + ÿHfg +ÿHs )
ÿHout IPA= - 1.678656 × 106 KJ/hr
ÿHout water= - 8.682755× 106 KJ/hr
ÿHout acetone= - 1.40346 × 107 KJ/hr
ÿHout H2= 8.62316 × 105 KJ/hr
ÿHout = ÿHoutIPA + ÿHout water + ÿHout acetone + ÿHout H2
ÿHout = -2.3533695 × 107 KJ/hr
Heat of reaction = ÿHr = ÿHout ÿ ÿHin
ÿHr = 6.37403 × 105 KJ/hr
Temperature = 350 °C
Cp Acetone = 1.37 kJ/kg.K
Cp H2 = 13.9 kJ/kg.K
ig
ÿÿHR + q = ÿÿHP + ÿHr
47
KJ KJ
1.63 1.85
[[6895.5 kg hr kg.K (598 ÿ 298)K]] +q = [6895,5 kg hr kg.K (623 ÿ 298)K] + (6.37403×105 KJ/hr)
q= 6,000,88.746 KJ/hr
3.4 Cooler:
T out let = 350 ÿ T out let = 94.7 ÿ
i drink = 480kg/hr I IPA = 480kg/hr
m water= 895.5 m water = 895.5 kg/hr
kg/hr
macetone = 5336kg/hr
Cooler
macetone = 5336kg/hr
mH2 = 184kg.hr
mH2 = 184kg.hr
mP = 6895.5 kg/hr mP = 6895.5 kg/hr
At temperature 94.7°C:
m water =
m water
Cp = kJ/kg.K
= 1.8
833.202 kg/hr
IPA 833.202 kg/hr
Cp H2 = 14 KJ/kg.K
ig
Q = mcpÿT
Q= (6895.5 Kg/hr × 1.9 KJ/Kg.k )×(467.7-623)K
Q= -2038585.6 KJ/hr
For water
Q= mH2O cpH2o ÿT
ÿT = 20ÿ Cp = 4.179 KJ/Kg.k
2038585.6= mH2O ×4.179 KJ/Kg.k ×20K mH2O = 24390.8 Kg/hr
48
3.5 Condenser:
T =out
94.7
let ÿ T =out
81letÿ
P= 1.5bar
I IPA = 480kg/hr I IPA = 480kg/hr
Condenser
macetone = 5336kg/hr macetone = 5336kg/hr
mH2 = 184kg.hr mH2 = 184kg.hr
mP = 6895.5 kg/hr mP = 6895.5 kg/hr
ÿÿHR
m + q ==ÿÿHP
water + ÿHr
833.202 m water =
For water at 81°C:
kg/hr 833.202 kg/hr
TC = 647.3 K Tb
= 385.186 K ÿHf =
40,683 kJ/kgmol
0.38
ÿHvap H2O
= ÿHf × [ TCÿT
TCÿTb ]
0.38
40,683 647.3ÿ354
=
ÿHvap H2O × [ 647.3ÿ385.186]
KJ
ÿHvap H2O = 2358
kg
For IPA:
TC = 508.3 K Tb
= 366.6 K ÿHf =
39,858 kJ/kgmol
0.38
ÿHvap IPA
= ÿHf × [ TCÿT
TCÿTb ]
0.38
39,858KJ 508.3ÿ354
=
ÿHvap IPA
kmol × [ 508.3ÿ366.6 ]
686.155KJ
ÿHvap IPA =
kg
49
For acetone:
TC = 508.1 K Tb
= 341.5 K ÿHf =
29,140 kJ/kmol
0.38
ÿHvap acetone= ÿHf × [ TCÿT

TCÿTb ]
0.38
508.1ÿ354
ÿHvap acetone= 29,140 × [ 508.1ÿ341.5 ]
487.741KJ
ÿHvap acetone=
Kg
At temperature 81°C:
CP IPA = 0.73 kJ/kg.K

CP H2 = 13.2 KJ/kg.K
ig
KJ KJ
× 1.9 × 1.25 hr
[6895.5 kg
hr kg.K kg.K
× (467.7 ÿ 298)K] + q = [[6895.5 kg × (354 ÿ 298)K]] +
× 686.155 × 2358 × 487.74
[480 kg
hr KJ kg] + [895.5 kg hr KJ kg] + ÿ5336 kg hr KJ kgÿ
q = 3,302,892.97 KJ/hr
50
3.6 Scrubber:
T=25°C T=70°C
H2 =184 Kg/hr
Water =10791Kg/hr
Acetone=1.218kg/hr
0ff gas =185.218Kg/hr
Scrubber
T=81°C
H2 =184 Kg/hr
Acetone=1218kg/hr Acetone=1216.782kg/hr
IPA= 30Kg/hr IPA= 30kg/hr
Water= 66.6kg/hr Water= 10857.6kg/hr
Water =1498.6Kg/hr Liquid =12104.38Kg/hr
Assumption: •
The scrubber is adiabatic
• The pressure of the unit is 1.5 bar and assumed to be constant

°
ÿÿHR + q = ÿÿHP + ÿHr
q= 0
°
ÿHr = 0
At temperature 70°C:
Cp H2 = 13.1 KJ/kg.K
CP Mixture= 12.8 KJ/kg.K
Assume that the liquid stream temperature is = 28.1 °C
At temperature 28.1°C:
Cp IPA = 1.5kJ/kg.K
51
Cp H2O = 5 kJ/kg.K
[1498.6 kg/h ×2.3 kJ/kg.K × (354 – 298)k] = [185.218 ( kg/hr kg)/h ×12.8 kJ/kg.K × (343 ÿ
298)k] +[12104.38 ( kg/hr kg)/h × 4.5kJ/kg.K × (T ÿ 298)k]
T =301k = 28 ÿ
4 Mixing point: T= 28.1°C
Acetone=1216.782kg/hr
IPA= 30kg/hr
Water= 10857.6kg/hr
T=81°C
Liquid =12104.38Kg/hr
ACETONE=4118kg/hr
T=45°C
WATER=827.82kg/hr
Acetone= 5334.782kg/hr
IPA=480kg/hr
IPA=477.42kg/hr
Water=11685.42kg/hr
Liquid =5425.82Kg/hr
F= 17497.622kg/hr
T= 318k = 45 °C
Cp IPA = 1.59 KJ/kg.K
= mf × CP×ÿT
= 17497.662 × 3.6 × (318-298)
Q= 20050095 KJ/hr
52
3.7Acetone column: T= 102.3 °C
T= 45°C IPA=55.68kg/hr
IPA=477.42kg/hr D=5385.146kg/hr
Water=11685.42kg/hr
Acetone column
F= 17497.622kg/hr
T=105 °C
IPA=421.74kg/hr
Water=11685.42kg/hr
The pressure in stream (D) is 1.3 bar

B=12112.4948kg/hr
Calculate the Tb by using this formula:
B ln P = A ÿ
T
• For acetone:
Pc = 47bar T c
= 508.1 k
P = 1.013 T = 329.2 k (normal boiling point)

B
ln 47bar = A ÿ
508.1k
B
ln 1.013 bar = A ÿ
329.2k
Then A= 10.91 B= 3587.3
Then at P= 1.3 bar
53
3587.3
ln 1.3bar = 10.91 ÿ
Tb
Tb = 336.9k
• For IPA:
Pc = 47.6 bar T c = 508.3 k

B
ln 47bar = A ÿ
508.3k
B
ln 1.013 bar = A ÿ
355.35k
Then A= 12.807 B= 4546.375
Then at P= 1.3 bar
4546.375
ln 1.3bar = 12.807 ÿ
Tb
Tb = 362.4k
0.38

TCÿTb ]
0.38
508.1ÿ375.3
ÿHvap acetone= 29,140 × [ 508.1ÿ336.9 ]
456.2KJ
ÿHvap acetone=
Kg
0.38
ÿHvap IPA
= ÿHf × [ TCÿT
TCÿTb ]
39,858KJ
0.38
= 508.3ÿ375.3
ÿHvap IPA
kmol × [ 508.3ÿ362.4 ]
=
641.3KJ
ÿHvap IPA
kg
ÿHvap mixture = (456.2× 0.99) + (641.3×0.01)
=
458,051KJ
ÿHvap mixture
kg
54
q= m × ÿHvap mixture
q= 5358.146 kg/hr × 458.051 KJ/kg
q= 2466671.51 KJ/hr
The pressure in stream (B) is 1.6 bar
Calculate the Tb by using this formula:

B
ln P = A ÿ
T
• For acetone:
Pc = 47bar T c = 508.1 k

B
ln 47bar = A ÿ
508.1k
B
ln 1.013 bar = A ÿ
329.2k
Then A= 10.91 B= 3587.3
Then at P= 1.6 bar
3587.3
ln 1.6bar = ÿ10.91
Tb
Tb = 343.6k
• For IPA:
Pc = 47.6 bar T c = 508.3 k

B
ln 47bar = A ÿ
508.3k
B
ln 1.013 bar = A ÿ
355.35k
Then A= 12.807 B= 4546.375
Then at P= 1.6 bar
55
4546.375
ln 1.6bar = 12.807 ÿ
Tb
Tb = 368.5k
• For water:
Pc = 220.5 bar T c = 647.3 k

B
ln 220.5bar = A ÿ
647.3k
B
ln 1.013 bar = A ÿ
373.15k
Then A= 12.72 B= 4743.39
Then at P= 1.6 bar

4743.39
ln 1.6bar = 12.72 ÿ
Tb
Tb = 387.8k
0.38

TCÿTb ]
0.38
508.1ÿ378
ÿHvap acetone= 29,140 × [ 508.1ÿ343.6 ]
459.5KJ
ÿHvap acetone=
Kg
0.38
ÿHvap IPA
= ÿHf × [ TCÿT
TCÿTb ]
39,858KJ 0.38
= 508.3ÿ378
ÿHvap IPA kmol × [ 508.3ÿ368.5 ]
619KJ
=
ÿHvap IPA
kg
0.38
ÿHvap H2O
= ÿHf × [ TCÿT
TCÿTb ]
56
0.38
647.3ÿ378
= 40,683
ÿHvap H2O
× [ 647.3ÿ387.8 ]
KJ
ÿHvap H2O = 2290.5
kg
ÿHvap mixture = (459.5× 0.0004) + (619×0.035) + (2290.5× 0.96)
= 2220.7KJ
ÿHvap mixture
kg
q= 12112.4948kg/hr × 2229.7 KJ/kg
q= 26898217 KJ/hr
3.8 IPA column

T=102 °C
IPA=421.74kg/hr
T=105 °C
Water=62.298kg/hr
IPA=421.74kg/hr
D=489.372782kg/hr
Water=11685.42kg/hr
IPA COLUMN
F=12112.4948kg/hr
water
T=115 °C
Water=11623.122kg/hr
water
• Since acetone was neglected in stream (D) so the y IPA= 0.87 & y water= 0.13
• The pressure in stream (D) is 1.1 bar
For IPA:
Pc = 47.6 bar T c = 508.3 k
water
57
B
ln 47bar = A ÿ
508.3k
B
ln 1.013 bar = A ÿ
355.35k
Then A= 12.807 B= 4546.375
Then at P= 1.3 bar
4546.375
ln 1.1bar = 12.807 ÿ
Tb
Tb = 357.65k
• For water:
Pc = 220.5 bar T c
= 647.3 k
B
ln 220.5bar = A ÿ
647.3k
B
ln 1.013 bar = A ÿ
373.15k
Then A= 12.72 B= 4743.39
Then at P= 1.6 bar
4743.39
ln 1.1bar = 12.72 ÿ
Tb
Tb = 375.72k
0.38
ÿHvap IPA = ÿHf × [ TCÿT

TCÿTb ]
0.38
= 39,858KJ 508.3ÿ375
ÿHvap IPA kmol × [ 508.3ÿ357.65]
= 634.1KJ
ÿHvap IPA kg
58
0.38
ÿHvap H2O
TCÿTb ]
= ÿHf × [ TCÿT
0.38
40,683
647.3ÿ375
=
ÿHvap H2O
× [ 647.3ÿ375.72]
KJ
ÿHvap H2O = 2262.4 kg
ÿHvap mixture = (643.1× 0.87) + (2262.4×0.13)

853.6KJ
ÿHvap mixture =
kg
q= 489.372782kg/hr × 853.6 KJ/kg
q= 417728.6 KJ/hr
The pressure in stream (B) is 1.1 bar
T c
= 647.3 k Tb = 375.72 k
0.38
ÿHvap H2O
TCÿTb ]
= ÿHf × [ TCÿT
0.38
40,683
647.3ÿ388
=
ÿHvap H2O
× [ 647.3ÿ375.72]
KJ
ÿHvap H2O = 2220.8 kg
q= m × ÿHwater
q= 11623.122kg /hr × 2220.8 KJ/kg
q= 25812629 KJ/hr
59
Chapter 4
Equipment Design
60
4.1 Process description:
At the beginning of the process, feed including iso-propyl alcohol and water, and
recycle stream are mixed in feed drum. From here, this mixture is sent to vaporizer
to change stream’s phase as vapor. After vaporizer, mixture is heated to reaction
temperature in the heater. Reactor used is a fixed bed tubular reactor. Acetone,
hydrogen gas (H2) is produced and water and iso-propyl-alcohol are discharged.
After condenser the mixture is sent to flash unit. Hydrogen, acetone, iso-propyl-
alcohol and water are obtained as top product. This top product is sent to scrubber
to remove hydrogen. The bottom product of flash unit which is formed by acetone,
water, and iso-propyl-alcohol are mixed with the bottom product of scrubber
before acetone column. In acetone column, acetone is obtained from top product
with 99 wt. %. ÿso-propyl alcohol and water and also 0.1% of acetone is sent to
iso-propyl-alcohol column from bottom product. The top product of this column is
sent to feed drum and bottom product is thrown away as waste water.
Figure 4.1: Overall process plant
61
4.2 Design of Heat Exchanger
TSteam=229.1ÿ
B1
TYPE=87.9ÿ TYPE=229.1ÿ
Tsteam=507.2ÿ
4.2.1 Calculation of caloric temperature
Hot fluid inlet temperature (T1) = 507.2°F Hot fluid

outlet temperature (T2) = 229.1°F Cold fluid inlet
temperature (t1) = 87.9°F Cold fluid outlet temperature
(t2) = 229.1°F
For the calculation of caloric temperature (D. Q. Kern, 1965:P.827)
2
ÿ
1
229.1 ÿ 87.9
== = = 0.508
1
ÿ
2
507.2 ÿ 229.1
Kc = 1; Fc = 0.5
Fc and Kc are in reference (D. Q. Kern, 1965:P.827).
Caloric temperature of the hot fluid, Thc = T2 + FC (T1 ÿT2 )
Thc=229.1+0.5×(507.2-229.1)
Thc=368.15°F
Caloric temperature of the cold fluid, Tcc = t1 + FC (t2 ÿ t1 )
Tcc=87.9+0.5×(229.1-87.9)
Tcc=158.5°F
62
4.2.2 Energy balance
From chapter 3
Q = 6,434,427.328 kJ/hr ÿ 6,098,660.38 Btu/hr

.
m IPA = 6000kg/hr ÿ 13227.74 Ib/hr
m water = 895.5 kg/hr ÿ 1974.23 Ib/hr
4.2.3 Calculation of heat transfer area and tube numbers
Assumptions: •
Fixed tube plate type • 1ÿÿ
OD tubes (14 BWG) on 1¼ÿÿ square pitch (PT) • Tube length
(Lt) = 24ÿ
• 1 shell pass-6 tube pass

• Tube ID=0.834ÿÿ
• Flow area per tube=0.546 inch2
Temperature correction factor (FT): 0.85 from literature
Tcc = t1 + FC (t2 ÿ t1 )
(507.2 ÿ 229.1) ÿ (229.1 ÿ 87.9)

LMTD =
507.2 ÿ 229.1
ln ( 229.1 ÿ 87.9 )
LMTD = 201.98ÿ
63
4.2.4 Determining the heat transfer area (A):
Q
A=
Uassm × × FT
6098660.38
A=
25 × 201.98 × 0.85
A=1425 ft2
4.2.5 Calculating no. of tubes (N):

A
N=
× × dÿ
1425
N=
1 × 24 ×
12
N=227 tubes
N= 240 is taken corresponding to the closest standard shell ID of 31 for fixed tube sheet, 1-
shell and 6-tube pass exchanger with 1 tube OD on 1¼ square pitch (D. Q. Kern,
1965:P.841:T.10).
4.2.6 Fluid Velocity
4m ( approx.)
Re= di ÿmix
4×15201.97( 6 240)
Re= 0.3
× ×1.938 12
64
Re=9987.48 > 104
in= Re ÿmix
ds ÿm
9987.48×1.938
in=
0.3
×55.31
12
u=10498.5 ft/hr
u=2.91 ft/s
u= 0.89 m/s
(So, the design velocity is within the acceptable range must be ÿ 1 / (D. Q.
Kern, 1965).
4.2.7 Determination of heat transfer co-efficient Tube side heat transfer co-efficient (hi):
ÿ mC 1 m
ÿ= ÿ0.14
ÿ
( ) 3( )
ÿw
jH=38 for the tube side fluid at Re=11571.4 (D. Q. Kern, 1965:P.834).
m
(Letÿs consider = 1, ÿ = viscosity of the tube side fluid; ÿw = viscosity of
ÿw
tube side fluid at wall temperature)
0.3
ÿ 1.938 × 0.035
12 1
38 = ÿ0.14
ÿ
( ) 3(1)
0.083 0.083
hi=118 btu h-1 ft-1 ÿ-1
65
4.2.8 Shell side heat transfer co-efficient (ho):
Assumptions:
• 25% cut segmental baffles
• Baffles spacing, B= 0.5DS=15.5ÿÿ (half of the shell ID is selected)
Equivalent diameter for the shell side for square pitch:
De=0.989 in
De=0.0824 ft
Shell side cross flow area

as=
PT
C= Tube clearance
C =PT - do
C =1¼ -1=0.25
0.25 15.5 31
12
)( 12
)( 12 )
( as= 1.25
( )
12
as=0.667 ft2
Mass velocity,
mh
Gs=
as
15201.97
Gs=
0.667
Gs=22791.55 Ib. h-1 .ft-2
66
Re=The Gs
m
Coordinates for isopropyl alcohol X=8.4, Y=13.4 (D. Q. Kern, 1965:P.831).

By these two coordinates from figure 10, ÿ=0.02 (D. Q. Kern, 1965:P.832).
Re=0.0824×22791.55
0.02
Re=81706.56
Now for the shell side,
h° De ÿ C jh = ( )
1 ÿ
ÿ0.14
ÿ
kk 3( ) ÿw
JH=140 for the shell side fluid at Re=81706.56 with 25% cut segmental baffles (D. Q. Kern,
1965:P.838).
0.0824 ( ) 0.57 × 0.028 ÿÿ 1

ÿ0.14
ÿ
140 = 0.3457 3(1)

0.345
ÿÿ=210 btu h-1 ft-1 ÿ-1
67
4.2.9 Overall heat transfer co-efficient (Uo, cal):
Fouling factor, Rdw=0.001 h ft2 °F Btu-1 for kerosene and Rdi= 0.00018 h ft2 °F
Btu-1 for Isopropyl alcohol is taken for this service.
ÿ1
A0 A0 A0
1 + Rdi +
Oo, cal=[h0 Ai ( d0ÿdi
2k0 ) + Ai ( 1
hi ) + Ai Rdw]
0.834 ÿ1
2 ÿ 2 2
ÿ(1) 12 12 ÿ(1) ÿ(1)
+ 0.00018 + ÿ(0.834)
2 ( 1 118) + ÿ(0.834)
Oo, cal=[210
1 2 ( 1 2×0.71 ) + ÿ(0.834) 2 0.001]
Uo, cal=30.7 btu h-1 ft-1 ÿ-1
Now,
=
Uo,calÿUo,assm
×100
Uo, assm
30.7ÿ25
= ×100
25
=22%
So, the design Overall heat transfer co-efficient is within the acceptable range must
be < 30% Therefore, the calculated overall heat transfer co-efficient is well within
the design criteria. (D. Q. Kern, 1965).
4.2.10 Pressure drop calculation
Friction factor f = 0.00025×144 = 0.0306 ft2 /ft2 for Re=9987.48 (D. Q. Kern,
1965:P.836).
×
at=
240×0.546
at=
6×144
at=0.151 ft2
68
Tube side mass velocity:
Gt=
15201.9
Gt=
0.151
Gt=13074.17 Ib.h-1 .ft-2
4.2.11 Frictional pressure drop
0.036×222752×24×6
ÿPt= 0.834
7.5×1012× ×0.78×1
12
ÿPt=2.273 psi
4.2.12 Return loss
ÿPR: (due to change in flow direction of the tube side fluid)
ÿPR=1.334×10ÿ13(2np-1.5)
ÿPR=1.334×10ÿ13(2×6-1.5)4222752
1
ÿPR=0.3 psi
69
4.2.13Total tube side drop neglecting nozzle loss:
ÿPT=ÿPR+ÿPt
ÿPT=0.3+2.273
ÿPT=2.573 psi
So, the Total tube side drop is within the acceptable range must be <10 psi Therefore,
the tube side pressure drop is within the maximum allowable pressure drop of 10 psi (D. Q. Kern,
1965).
4.2.14 Shell side pressure drop calculation
Tube clearance, C=0.25
Spacing, B=15.5
as = 0.667 ft2
-1
Mass velocity, Gs =22791.55 lb. h . ft-2
Re=81706.56
No of baffles,
ÿ
nb=
24
nb= 15.5
12
nb=18.6ÿ 19
70
Friction factor, f = 0.0017×144 = 0.2448 ft2 /ft2 with 25% cut segmental baffles (D.
Q. Kern, 1965:P.839).
Shell side frictional pressure drop ÿPs:
31
0.2448×22791.552×(19+1)× 12
ÿPt=
7.5×1012×0.082×0.78×1
ÿPt=0.25 psi < 7
ÿPrs = 0 (in case of single shell pass flow)
4.2.15 Total shell side drop neglecting nozzle loss:
ÿPS=ÿPs+ÿPrs
ÿPS=0.25 psi
So, the shell side pressure drop is within the acceptable range must be <7 psi
Therefore, the shell side pressure drop is within the maximum allowable pressure drop
of 7 psi (D. Q. Kern, 1965).
71
4.2.16 Over design
% Over design=
The design area of heat transfer in the exchanger (N =240):
A= ÿdÿLTNT
1
A=ÿ× ×24×240 12
A=1507.96 ft2
The required heat transfer area (where, nt =227):
A= ÿdÿLTNT
1
A=ÿ× ×24×227 12
A=1426.28 ft2
% Over design=1507.96ÿ1426.28
1507.96
% Over design= 5.2%
Over design 5.2% which is within the acceptable limit.
72
4.3 Description of the process in the reactor:

The reaction occurring in the reactor is in vapor phase. So, the Isopropyl alcohol is
first vaporized and then passed from the reactor. The process is continuous. Since
the dehydrogenation of the Isopropyl alcohol is the endothermic reaction, so heat
has been supplied to the reactor to maintain the temperature at 350 °C.
4.3.1 Reactor Design
B1
Figure 4.2: Continues Tubular Reactor
73
4.3.2 Design calculations

ÿ Performance equation for the reactor:
The performance equation for the Continues Tubular Reactor is:
Where W is the weight of the catalyst, is the flow rate of the isopropyl alcohol, is
the rate of the reaction. The weight of the catalyst is found from this performance
equation.
FAÿ = ÿ ÿ0
Since the rate equation of reaction is
-rIPA= K×CIPA
In the form of conversion, the rate equation becomes
1ÿ
-rA=K CAÿ( 1+ÿA XA
)
When A is limited reactant
E=Porosity
Tin = 325ÿ & 598K
All = 350ÿ & 623K
Pin = 2 bar or 1.81 atm
Pout = 1.8 bar or 1.78 atm\
74
YAÿ =0.67 Mole fraction IPA

P
CT =
RT
1.8
CT =
0.082×623
Total Volumetric flowrate is
CT=0.035 m3 /s
CAÿ=YAÿ × CT
Volumetric flowrate is
CAÿ=0.67×0.035
CAÿ=0.023 m3 /s
K=0.35 s-1
The void fractions (Porosity) for the spherical particles is between 0.4 to 0.41 (Stephen M. Hall
(2018), Rules of Thumb for Chemical Engineers; sixth edition)
ÿ = 0.41
1ÿ
-rA=K CAÿ( )
1+ÿA XA
1ÿ0.92
-rA=0.35 × 0.023( ) 1+(0.41)(0.92)
-rA=4.67×10-4
75
X -rA 1/-rA
0 8.05×10-3 124
0.12 6.75×10-3 148
0.22 5.75×10-3 174
0.32 4.83×10-3 207
0.42 3.98×10-3 251
0.52 3.18×10-3 314
0.62 2.43×10-3 412
0.72 1.74×10-3 575
0.82 1.08×10-3 926
0.92 4.67×10-4 2141
Table-4.1: Variation of inverse of rate law with conversion.
Variation of inverse of rate law with conversion

2500
2000
1500
1/-
rA
2141
1000
500
926
575
412
251 314
124 0 148 174 207
1 2 3 4 5 6 7 8 9 10
Figure 4.3: Variation of inverse of rate law with conversion
76
4.3.3 Volume of reactor
Simpson’s One-Third Rule is one

ÿ 1 4 1
V= FAÿÿÿ 0 =FAÿ [ ] + ÿ ( =0) ÿ ( 1) ÿ ( 2)
3
ÿX=0.92-0.52
ÿX=0.4
FAÿ=100kmol/hr ÿ 0.028 kmol/sec
V=0.028×0.4 [124 + (314 × 4) + 2141]

3
V=13.2 m3
4.3.4 Weight of the Catalyst
FAÿ = ÿ ÿ0
0.92
0.028 × 103 = ÿ 4.67 × 10ÿ4

0
W=55160.6 kg
77
4.3.5 Volume of the Catalyst
Density of copper particle = 8960 kg/m3
Weight of the catalyst = 55160.6 kg
Weight of catalyst
Volume of the catalyst =
Density
V=55160.6
8960
V=6.15 m3
4.3.6 Number of tubes
From TEMA standards,
Length of tube = L = 12 ft & 3.658 m

Diameter of tube = 70 m
Diameter of copper particles = 3 mm

2
Volume of one tube = 4 × Dtube × Ltube
Volume of one tube = × 0.072 × 3.658

4
Tube delay = 0.019 m3
Number of tubes = Volume of catalyst

Volume of one tube
6.15
Number of tubes =
0.019
Number of tubes = 324
78
4.3.7 Space time
Volume Reactor=13.2 m3
Volumetric flow rate (CAÿ) = 0.023 m3 /s

Volume of reactor
Space time =
Volumetric flow rate
13.2
Space time =
0.023
Space time = 573.91 sec
Space time = 9.56 min
4.3.8 Height of reactor (Shell)
Allowance of the reactor height is 20% - 50% of the shell height.

For our system assuming the allowance for shell is 20% of the tube height.
(Carl R. Branan (2002), Rules of Thumb for Chemical Engineers; third edition)
So,
High of Reactor = Ltube + [2×0.20×Ltube]
High of Reactor = 3.658 + [2×0.20×3.658]
High of Reactor = 5 m
79
4.3.9 Diameter of reactor (Shell)
Diameter of the shell is calculated by using the Harvey

equation. Harvey equation is:
(Dsÿk1) 2ÿPt (Dsÿk1)(nk1+k4)

NT =
1.23+P2
Where NT = Number of tubes = 324
K1 = 1.08, K3 = -0.9, K4 = -0.8
N = Number of passes = 1
PT = Pitch of tube
Tube Diameter = 70 mm & 2.8 inch
Ds = Diameter of Shell = ?
Pitch of tube = 1.25 × Tube Diameter
Pitch of tube = 1.25 × 2.8
Pitch of tube = 3.5 inch
(Dsÿ1.08) 2ÿ3.5(Dsÿ1.08)(1.08ÿ0.8) 324 =

1.23+3.5
2
DS = 68 inch & 1.8 m
• From Rule of Thumb Chemical Engineering Book,

if conversion is more than %80, must be in the range of [2.5m – 3m]
• Conversion is %92
5
ÿ = 2.77 (in range)
1.8
80
4.3.10 Vessel wall thickness
PR
t= + tc + td
SEÿ0.6P
t= vessel wall thickness, in.
P= design pressure difference between inside and outside of vessel, psig
R= inside radius of steel vessel, in.
S= maximum allowable stress for the steel.
E= joint efficiency
tc=corrosion allowance = 0.125 in.
Pin final = Pin + 10% Pin
Reactor conditions
Pin 2 bar
L= 5m
Pin final 2.2 bar & 31.9 psi

AND 0.9
tc= 0.125 in
td, P < 10 bar 1mm & 0.0394 in
R 0.9m & 35.43
S, from figure 810
Believe 350ÿ
Material of construction Stainless steel
81
When T is equal to 350ÿ maximum allowable stress is found by figure 4.4 below
which is S=810 (Jsbir S. Arora (2012), Introduction to Optimum Design, Third
Edition).
Figure 4.4: allowable stress for the steel
31..9×35.43
Thickness= + 0.125 + 0.0394
(810)(0.9)ÿ0.6(31.9)
Thickness =1.75 in
Thickness =45 mm
82
4.4 Design of Distillation column (Acetone column)

T= 102.3 °C
IPA=55.68kg/hr
T= 45°C
Q=2466671.51KJ/kg
IPA=477.42kg/hr D=5385.146kg/hr
Water=11685.42kg/hr
B2
F= 17497.622kg/hr
T=105 °C
IPA=421.74kg/hr
Water=11685.42kg/hr
Q=26898217KJ/kg
B=12112.4948kg/hr
Component Feed fraction (xf) Bottom fraction (xB) Top fraction (xD)
Acetone 0.3 0.0004 0.99

VIOLENCE 0.024 0.035 0.01
Water 0.67 0.96 0
Heavy Key Component HKC = IPA (isopropanol)
Light Key Component LKC = Acetone
83
4.4.1 Volatility calculations:
For volatility calculations, first step is to determine bubble point and dew point of feed, top product
and bottom product.
For bubble point and dew point calculations, we need K-values of all components.
To calculate K-values at given temperature, vapor pressure data of all feed components is
taken from Antoine equation and K-values are calculated using relation
B
log pi = A –
T+C
Which = Pi/ P
A, B, C = the Antoine coefficients (chapter 2)
T= temperature, °C
Where Pi = Vapor pressure of component i.

P = Operating pressure of column
Relative volatility (ÿ) of each component is calculated using K-value that component and
that of heavy key.
ÿ=Ki / Kj
Where
i=light key
j=heavy key
Adopting this procedure, relative volatility of each of components in feed, top product and
bottom product is computed at their respective temperatures.
Average volatility is calculated using top, feed and bottom volatilities using relation
1/3
avg = (ÿfeed*ÿtop*ÿbottom)
Feed (P=1.3 bar) D(P=1.3bar) B(P=1.6bar)

Pacetone= 1016.64mmHg Pacetone= 4697.7mmHg PIPA= Pacetone= 4986.8mmHg
65.45mmHg PIPA= 904.487mmHg Pwater= 6.42mmHg PIPA= 1001.02mmHg
Pwater= 9.28mmHg Table vapor pressure Pwater= 9.45mmHg
84
Feed (P=1.3 bar) D(P=1.3bar) B(P=1.6bar)

kacetone= 1.042 kacetone= 4.82 kacetone= 5
kIPA= 0.067 kIPA= 0.93 kIPA= 1.026
kwater= 0.0064 quarters= 0.0095 quarters= 0.008
Table K constant
Feed D B Average
ÿacetone = ÿacetone = ÿacetone = 4.8 ÿavg = 7
15 ÿIPA 5 ÿIPA = ÿIPA = 1 ÿavg = 1
= 1 ÿwater= 1 ÿwater= 0.01 ÿwater= 0.078 ÿavg = 0.02
0.096 Table relative volatility
ÿavg = 7
4.4.2 Calculation of Minimum no. of Plates:
XLK XHK
ln[( ÿXHK
)D×( ÿXLk
)B]
Nmin = ÿLK
ln( ÿ HK
)average
0.99
ln [ ÿ 0.01
×0.035 ÿ 0.0004 ]
Nmin =
ln (7)
Nmin = 5
4.4.3 Calculation of Minimum Reflux Ratio Rm:
1 1 ÿ xD
ÿ
Rm =
a ÿ 1 [ a ÿ xD 1 ÿ xF ]ÿ1
xF
ÿavg = 7
1 7 × 0.99 1 ÿ 0.99
ÿ
Rm =
7ÿ1[ 0.3 1 ÿ 0.3 ] ÿ 1
R m= 2.8
85
Actual reflux ratio: The

rule of thumb is: R= (1.2
------- 1.5) Rmin R = 1.2 Rmin
R= 3.4 4.4.4
Calculate the theoretical number of stages
ÿ
0.566
]
+1
= 0.75[1 ÿ ( ÿ +1 )
0.566
ÿ18
]
+1
= 0.75[1 ÿ ( 3.4ÿ2.8
3.4+1 )
= 12
4.4.5 Calculate the actual number of stages

Column Efficiency:
Average temperature of column = 85 °C
Feed viscosity at average temperature =ÿavg = 0.18 mPa.s
= 51 ÿ 32.5log ( )
= 49%
No. of actual trays = 12/0.49= 24

4.4.6 Calculate the Location of feed
log ( ) = 0.206 log [ ( )( ) ]
0.024 0.0004 2
log ( ) = 0.206 log [ 0.9954 ( 1 0.3 ) ( 0.01 ) ] = 0.2
86
+ = 24
= 20
=4
Vapor rate = D(1+R) = 5385.146(1+3.4) = 23694.64kmol/h

Liquid flow above the feed, L = R D = 3.4×5385.146 = 18309.5kmol/h
Liquid flow below the feed, Lo = (R×D) +F = (3.4×5385.146) + 17497.622
= 35807 kmol/h
= 2.1 = 165.8 /
3
0.5
=()()
35807 2.1 0.5
= 0.17
= ( 23694.64) ( 165.8 )
Capacity parameter:
Assumed tray spacing Hs = 18 in. = 0.45m
Fig (1) of value of parents-brown coefficient
,
Csb(20) = 0.06 m/
s (J.F. Richardson (2002), Particle Technology and Separation; Vol 2, Fifth edition)
87
Figure 4.5: Correlation of flooding velocities for sieve trays.

p 0.2 plÿpv 0.5
4.4.6 Vnf = csb( ) ( )
20 pv
165.8 ÿ 2.1
0.5
Vnf = 0.06( )
2.1
Vnf = 0.53m/s
Vn=0.9×Vnf
Vn = 0.477 m/s
vapor rate
Qv=
ÿv×3600
88
Qv = 3.13 m3 / s
L
QL=
ÿl×3600
QL = 0.06 m3 /s
4.4.7 Column diameter:
An=Qv/ Vn
An = 6.6m2
Pi
2
An = D
4
D=3m
And = An + Ad
Ac = An +0.15 Ac
Ac = 7.76 m2
Ad = 1.16 m2
Pi
And = 2d
4
89
dc= 3.14m = 10.362 ft
Aa = Ac ÿ 2Ad
Area = 5.44m2
Ah = 10% Aa
Ah = 0.544m2
Weir length = Ad/Ac
Weir length = 0.15m
Lw/dc = 0.8
Lw= 2.512m
hw= 50mm
ÿ = 10
Plate thickness = 10 mm
90
4.4.8 No. of holes

Pi
Area of 1hole = 2
ÿ
4
Area of 1hole = 7.85 × 10ÿ5 m2
N hole = Ah / area of one hole
N hole =6926
4.4.9 Height of distillation
= ( ÿ 1) + ÿ + ÿ
ÿ = 0.01 × 24 = 0.24
= (24 ÿ 1)0.45 + 1 + 0.24
= 11.6
91
4.5 Design of Pump

Pin = 2 bar
Pin = 1.1 bar
T= 115°C B1
T= 102°C
Acetone= 5.33 kg/hr
Acetone= 5.33 kg/hr
IPA= 421.74kg/hr
IPA= 421.74kg/hr
Water= 64.98
Water= 64.98
M in= 492.05 kg/hr M out= 492.05 kg/hr
Pump calculation:
Pin = 1.1 bar
Pout = 2 bar
Efficiency = 0.65
Pinlet = 1.1 bar = 111,000 Pa
Poutlet = 2 bar = 202,000 Pa
Densitymix = 812 kg/m3
Mass flow rate = 492.05 kg/hr (chapter 2)
M = 0.137 kg/s
Efficiency = 65%
××
=
×
=×ÿ
= 1.69 × 10ÿ4 × (202000 ÿ 111000)
P=15.4 watt
92
= 15.4 ÿ 23.69 watt

0.65
P=0.03 hp
0.137 × 9.81 ×
23.69 =
0.65
HT= 11.46 m
Net Positive Suction Head:
Pÿsolution= Pv = 185000 Pa [R. K. Sinnott, Coulson & Richardson’s Chemical Engineering:
Chemical Engineering Design (volume 6), fourth edition. (2005)]
NPSHR= ÿ ×HT
Assume ÿ=0.19 (maximum cavitation constant)
NPSHR=0.19×11.46
NPSHR=2.18 m
NPSHA=Hs - Hfs - ÿ + -
Hs= ÿ 5.73 m
2
Hfs = 0
ÿ=0
202000 185000
NPSHA=5.73 - 0 - 0 + -
9.81×812 9.81×812
NPSHA=7.87 m
NPSHA > NPSHR
93
Chapter 5
Economy
94
5.1 Introduction
The economic analysis cumene production chemical process will be discussed in this chapter.
The economic analysis's main goal is to find the profitability of a process, that will decide if this
process is economically favorable or not.
5.2 Costing and Project Evaluation
The design engineer needs to be able to make quick, rough, cost estimates to decide
between alternative designs and for project evaluation. Chemical plants are built to make a profit,
and an estimate of the investment required and the cost of production is needed before the
profitability of a project can be assessed.
The economic analysis cumene production chemical process will be discussed in this chapter.
The economic analysis's main goal is to find the profitability of a process, that will decide if this
process is economically favorable or not.
5.3 Accuracy and Purpose of Capital Cost Estimates
The accuracy of an estimate depends on the amount of design detail available. The accuracy of the
cost data available and the time spent on preparing the estimate.
Capital cost estimates can be broadly classified into three types according to their accuracy and
purpose:
1. Preliminary (approximate) estimates, accuracy typically ±30 %, which are used in initial feasibility
studies and to make coarse choices between design alternatives.
2. Authorization (Budgeting) estimates, accuracy typically ±10 - 15 % ,which is used for the
authorization of funds.
3. Detailed (Quotation) estimates, accuracy ±5 - 10 % ,which is used for project cost control and
estimates for fixed price contracts.
95
5.4 Coast of Heat Exchanger:

Material used Shell is Carbons steel & the Tubes are Stainless steel
A=1426.28 ft2 ÿ 132 m2
Pressure = 2 bar
Vertical Column, Cost from figure (5.1)
R. K. Sinnott, Coulson & Richardson’s Chemical Engineering: Chemical Engineering Design

(volume 6), fourth edition. (2005).
Figure 5.1: Shell and tube heat exchangers. Time base mid-2004
Purchased cost = (bare cost from figure) × Type factor × Pressure factor
Heat Exchanger
Bare cost (Figure 5.1) $100,000; type factor 0.8, pressure factor 1.0
Purchased cost = 100,000 × 0.8 × 1.0 = $80,000
96
5.5 Cost of Acetone column
Material used is Carbons steel & plates are molecular sieve.
An =6.6m2
Hc =11.47 m
P=1.6 bar

Figure 5.2: Vertical pressure vessels. Time base mid-2004.
Purchased cost = (bare cost from figure) × Material factor × Pressure factor
97
Bare vessel cost (Figure 5.2) $34,000; material factor 1.0, pressure factor 1.0
Vessel cost 34,000 × 1.0 × 1.0 = $34,000

Figure 5.3: Column plates. Time base mid-2004
Installed cost = (cost from figure) × Material factor
Cost of a plate (Figure 5.3), material factor 1 = 230 × 1= $230
Total cost of plates = 24 × 230 = $5520
Total cost of column = 34,000 + 5520 = $39,520 say $40,000
98
Total purchase cost of major equipment items
Acetone column $40,000

Heat Exchanger $80,000
Total $120,000
Total purchase cost of major equipment is $120,000 for Time base mid-2004
Total Cost of 2022 by using PEI (1.49) ÿ 1.49 × $120,000 = $176,400
Total Cost of 2022 by using CPEI (1.45) ÿ 1.45 × $120,000 = $174,000
Average = $175,200
99
Chapter 6
Safety
100
Chapter 6: Safety
6.1 Flammability:
The most hazardous property of acetone is its extreme flammability. At

temperatures greater than acetone's flash point of ÿ18 °C, air mixtures of between
2.6% and 12.8% acetone, by volume, may explode or cause a flash fire. Vapors can
flow along surfaces to distant ignition sources.
6.2 Acetone peroxide:
When oxidized, acetone forms acetone peroxide as a byproduct, which is a highly

unstable, primary high explosive compound. It may be formed accidentally, e.g.
when waste hydrogen peroxide is poured into waste solvent containing acetone.
Because its instability, it is rarely used, despite its simple chemical synthesis
6.3 Toxicity:
Acetone has been studied extensively and is believed to exhibit only slight toxicity
in normal use. There is no strong evidence of chronic health effects if basic
precautions are followed. It is generally recognized to have low acute and chronic
toxicity if ingested and/or inhaled. Acetone is not currently considered a
carcinogen or a source of concern for chronic neurotoxic effects.
6.4 Health Hazard:
INHALATION: vapor irritating to eyes and mucous membranes; acts as an

anesthetic in very high concentrations.
INGESTION: low order of toxicity but very irritating to mucous membranes.
SKIN: long contact causes defatting of the skin, possibly leading to dermatitis.
6.5 Handling and storage:
Avoid contact with skin and eyes. Avoid inhalation of vapor or mist. Keep away
from sources of ignition - No smoking. Take measures to prevent the buildup of
electrostatic charge. Store in cool place. Keep container tightly closed in a dry and
well-ventilated place. Containers which are opened must be carefully resealed and
kept upright to prevent leakage.
101
6.5.1 Conditions for safe storage, including any incompatibilities:
Storage conditions Keep only in the original container in a cool, well ventilated place away from: Heat
sources, Direct sunlight, incompatible materials. Keep container closed when not in use.
Heat-ignition Keep substance away from: heat sources, ignition sources.

Storage temperature 15 - 20 °C
Prohibitions on mixed Keep substance away from: oxidizing agents, reducing agents. strong acids,
storage (strong) bases, halogens, amines.
Storage area Store in a cool area. Keep out of direct sunlight. Store in a dry area. Store in a dark area.
Ventilation at floor level. Fireproof storeroom. Provide for an automatic sprinkler system.
Provide for a tub to collect spills. Provide the tank with earthing. Meet the legal
requirements.
Packaging materials SUITABLE MATERIAL: steel. stainless steel. carbon steel. aluminum. iron. copper. nickel. bronze.
glass. MATERIAL TO AVOID: synthetic material.
Table 6.1: Conditions for safe storage
6.6 NFPA Hazard Classification:
Diamond Hazard Value Description
Health 1
Can cause significant irritation.
Can be ignited under almost all

Flammability 3 ambient temperature conditions.
Normally stable, even under fire

Instability 0 conditions.
Special
Table 6.2: NFPA Acetone Hazards label
102
6.7 GHS Classification:
Oxidizing Harmful
Figure 6.1: GHS Acetone labels
103
Chapter 7
Conclusion
104
Conclusion
The following conclusion can be deduced from this project:
1-Study in deep the material and energy balance to the new capacity of production of Acetone.
2-We did design for some important equipment’s to be useful in the real establishment
of the plant of manufacturing the Acetone in the future.
3-Review all important study subjects like mass and heat transfer,
thermodynamics, fluid mechanics, organics ,reactor design and petrochemical process units.
4-We applying the engineering economy theory for getting the real estimation of this chemical plant.
5-Investigation all methods for manufacturing the Acetone depend on the raw materials.
105
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Edition (2001).
[2] R. K. Sinnott, Chemical Engineering Design, Volume 6, 4st ed (2005).
[3] M. Gopala Pao and Marshall Sitting, Outline of Chemical Technology,
third edition (2005).
[4] Dietrich von Engelhardt, Diabetes Its Medical and Cultural History,
(1989).
[5] Carl L. Yaws, Handbook of Antoine Coefficients for Vapor Pressure
(2015).
[6] D. Q. Kern, Process Heat Transfer, McGraw-Hill Book, 1st ed. (1965).
[7] Chemical Engineering (Fifth Edition) Volume 2: Particle Technology and
Separation Processes (2002).
[8] R. K. Sinnott, Chemical Engineering Design, Volume 6, 4st ed (2005).
[9] Carl R. Branan, Rules of Thumb for Chemical Engineers; third edition
(2002).
[10] Stephen M Hall, Rules of Thumb for Chemical Engineers; sixth edition
(2018).
[11] Jsbir S. Arora, Introduction to Optimum Design, Third Edition (2012),
106
[12] (J.F. Richardson, Particle Technology and Separation; Vol 2, 5th edition
(2002),
[13] R. K. Sinnott, Coulson & Richardson’s Chemical Engineering: Chemical
Engineering Design (volume 6), Butterworth-Heinemann, 3rd ed. (1999).
[14] R. K. Sinnott, Coulson & Richardson’s Chemical Engineering: Chemical
Engineering Design (volume 6), fourth edition. (2005).
107
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ProductionofAcetonebyDehydrogenationofIsopropylalcohol (1)

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Production of Acetone by Dehydrogenation of Isopropyl alcohol

Thesis · May 2022

Onel Israel Badro

The user has requested enhancement of the downloaded file.

Chemical & Petrochemical Department

Production of Acetone by Dehydrogenation of

A project submitted to the Chemical & Petrochemical Engineering Department

Prof. Dr. Hazim Aljewaree

The objective of this project is to design plant to produce acetone from

Chapter 1: Introduction 1.1 1

Physical and chemical properties 1.3 8

Acetone Production methods: 11

1.4 Uses & applications of Acetone Chapter 2: 15

Material balance 2.1 Detail process 18

2.2 Material balance around the reactor 25

2.3 Material balance around phase separator 27

2.4 Material balance around the scrubber 32

2.5 Material balance around the Acetone column 34

2.6 Material balance around the IPA column 36

2.7 Material balance around feed drum 38

Chapter 3: Energy Balance 40

3.1 Energy balance around the feed drum 41

3.7 Acetone Column 53

3.8 IPA Column 57

Chapter 4: Equipment Design 4.1 Process 60

4.2 Design of Heat Exchanger 62

4.3Description of the process in the reactor 73

4.4Design of Distillation column (Acetone column) 84

4.5 Design of Pump 92

Chapter 5: Economy 5.1 94

5.2 Costing and Project Evaluation 95

5.3 Accuracy and Purpose of Capital Cost Estimates 95

5.4 Coast of Heat Exchanger 96

5.5 Cost of Acetone column 97

Chapter 6: Safety 6.1 98

6.2 Acetone peroxide 6.3 99

Health Hazard 6.5 99

Handling and storage 6.6 99

NFPA Hazard Classification 6.7 GHS 100

Antoine Bussy Figure 1.3 Clostridium 5

Acetobutylicum Figure 1.4 Chaim Weizmann Figure 1.5 Acetone in 6

colorless liquid state Figure 1.6 Co-production in 6

Figure 1.8 Wacket-Hechst direct oxidation of propene Figure 1.9 Dehydrogenation of 11

mid-2004 Figure 6.1: GHS Acetone labels 98

Process stream table Table 2.2 Material 20

Heat capacity coefficients Table 3.3 Component 45

MW = Molecular weight [kg/kmol]

PT = Tube pitch (ft)

Most of the world's manufactured acetone is obtained as a co-product in the

Figure 1.1: Jean Beguin

1832: In 1832, French chemist (Jean-Baptiste Dumas) and German chemist

Figure 1.2: Antoine Bussy

Figure 1.3: Clostridium Acetobutylicum

Clostridium Acetobutylicum is a commercially valuable bacterium sometimes

Figure 1.4: Chaim Weizmann

Acetone dehydrogenation history :

1.2 Physical and Chemical properties of Acetone

It is colorless, volatile, flammable liquid and somewhat aromatic odor. It is

Figure 1.5: Acetone in colorless liquid state