Beruflich Dokumente
Kultur Dokumente
A PROJECT REPORT
ON
MONOETHANOLAMINE
Submitted to
The M.S. University of Baroda
in partial fulfilment for the Degree of Bachelor of Engineering in
Chemical Engineering
CERTIFICATE
ACKNOWLEDGEMENT
Presented By:
B.E. IV Chemical
4 Monoethanolamine
TABLE OF CONTENTS
CHAPTER TITLE PAGE NO.
nO 1. INTRODUCTION 8
2. LITERATURE REVIEW 9
2.1 HISTORY 9
3.1 CAPACITY 17
5 MECHANICAL DESIGN 63
6 COST ESTIMATION 70
9 PROCESS UTILITIES 81
10 BIBLIOGRAPHY 82-83
6 Monoethanolamine
LIST OF FIGURES
NO. TITLE PAGE NO.
2.1 FLOWSHEET OF DAVY KVAERNER PROCESS 13
3.2 REACTOR 19
3.3 MIXER 19
3.5 DEHYDRATOR 20
LIST OF TABLES
NO. TITLE PAGE NO.
2.1 PHYSICAL PROPERTIES OF MEA 10
CHAPTER 1: INTRODUCTION
Ethanolamines have been traditionally used in surfactants, detergents and personal care products.
But now-a-days, its use has dramatically increased due to its major role in the Gas Sweetening
Process where it is used to remove hydrogen sulphide and carbon dioxide from the sour natural
gas in order to obtain sweet natural gas.
My Project primarily deals with the Manufacture of Monoethanolamine (MEA), one of the many
chemicals from the ethanolamine family consisting of members like MDEA, MEA, DEA, DIPA,
DGA etc. The primary amine, MEA is a very effective, cheap, highly reactive and stable
chemical used for removal of sour gas. Hence I have selected MEA as a chemical for my Project.
The Chapter 2 of this report is titled Literature Review wherein I explore the History of this
chemical, its physical and chemical properties, its many applications, the multiple routes to
manufacture this product, the conventional process used for manufacture of MEA and an
overview and process condition of the major unit processes.
Chapter 3 has the Material and Energy balances. This also includes the relevant data about the
Production capacity of the various facilities producing MEA around the world. I have also
performed a basic DOF analysis of the process, taking the help of Felder.
In Chapter 4, I have designed a distillation column, a Heat Exchanger and taking the help of the
software CHEMCAD, designed a reactor.
Chapter 5 includes the Mechanical design of the equipments whose process design I performed
in the previous chapter.
Chapter 6 deals with the Cost Estimation wherein I found the fixed capital investment, total
product cost, Gross Profit, Net profit and the Rate of Return.
Chapter 7, 8 and 9 includes the Plant Location and the Layout, Environmental Pollution and
Safety and the various Process Utilities used in the manufacture of MEA. Based on the
guidelines, I have found out the ideal location in Gujarat to setup an MEA manufacturing plant,
while Chapter 10 is the Bibliography wherein I mention various references which have helped
me in making this project.
9 Monoethanolamine
This chapter deals with the History, Physical and Chemical properties, Applications, Various
Production technologies and the Overview of the Current Production technology used in the
manufacture of Monoethanolamine.
2.1 HISTORY
Amino alcohols have been prepared industrially since the 1930s. However large scale production
started only after 1945. In industries amino alcohols are usually designated as alkanolamines.
Ethanolamines are the important compounds in this group.
Ethanolamines were prepared in 1860 by Wurtz from ethylene chlorohydrin and aqueous
ammonia. It was only toward the end of the 19th century that an ethanolamine mixture was
separated into its mono, di and triethanolamine components. It was achieved by fractional
distillation.
Ethanol amines were not available commercially before 1930’s; they assumed steadily growing
commercial importance as intermediates only after 1945, because of the large scale production of
ethylene oxide. Since the mid-1970’s production of very pure, colorless ethanolamine in
industrial quantities has been possible. All the ethanol amine now is obtained economically in
very pure form (Ullman, 2001)2.
The versatile family of ethanolamines – including MEA, DEA and TEA – offers a broad
spectrum of application opportunities. Because ethanolamines combine the properties of amines
and alcohols, they exhibit the unique capability of undergoing reactions common to both groups.
As AMINES, they are mildly alkaline and react with acids to form salts or soaps. As
ALCOHOLS, they are hygroscopic (tendency to absorb moisture from atmosphere) and can be
esterified (Ullman, 2001)2.
A clear colorless liquid with an odor resembling that of ammonia. Flash point 185°F.
May attack copper, brass, and rubber. Corrosive to tissue.
Moderately toxic. Produces toxic oxides of nitrogen during combustion.
Ethanolamine is a base. Reacts with organic acids (acetic acid, acrylic acid), inorganic acids
(hydrochloric acid, hydrofluoric acid, nitric acid, sulfuric acid, chlorosulfonic acid),
acetic anhydride, acrolein, acrylonitrile, cellulose, epichlorohydrin, mesityl oxide,
beta-propiolactone, vinyl acetate.
Vapor irritates eyes and nose. Liquid causes local injury to mouth, throat, digestive tract,
skin and eyes.
2.4 APPLICATIONS
When combined with fatty acids, ethanolamines yields soap used extensively as detergents and
emulsifiers. Other uses include solvents, plasticizing agents, corrosion inhibitors (hygroscopic)
and conditioning agents. They are also used in various chemical synthesis processes. MEA is
widely used to purify refinery and natural gases and for the production of ethanoldiamines and
ethylenemine (Dutia P, 2004)5.
12 Monoethanolamine
GAS TREATING
It is used for the treatment of natural, refinery and synthesis gas. Aqueous solution of MEA
and DEA are used on the industrial scale for the absorption of Carbon Dioxide and Hydrogen
Sulphide as the main contaminants. The choice of appropriate ethanolamine depends upon
the required efficiency of the removal of contaminants.
SURFACTANTS
It is used as a surface active agents for detergents and personal care products. It is mainly
used in shampoos, bubble baths and face and body gel-type cleansers impacting especially
the foaming properties, volatility, skin irritation and detergent properties of these products.
There are two processes used for the manufacture of Monoethanolamine (Dutia P, 2004)5:
While the anhydrous reaction would be simple and clean, high operating pressures are necessary
in order to liquefy ammonia so that the reaction can occur in liquid phase in this case, so that the
reactivity of ethylene oxide (highly explosive) can be controlled and capital and operating costs
can be reduced (Fassler P, 2008)6.
Hence for all practical purposes, the conventional Davy Kvaerner Process (liquid phase) process
is used.
In all the conventional processes, reaction takes place in the liquid phase, and the reaction
pressure must be sufficiently large to prevent the vaporization of ammonia at the reaction
temperature. The pressure in the reactor is 160 atmposphere and the reaction is carried out at 150
0
C. This would also be a good method of reducing the reactivity of ethylene, for safety purposes
(ethylene oxide can be explosive).
The flow sheet for the production of MEA is as shown in the diagram. Raw materials used are
ammonia and ethylene oxide. Aqueous solution of Ammonia is mixed with the recycle stream of
ammonia to get a concentration of 85% ammonia in water, which is mixed with ethylene oxide
14 Monoethanolamine
and sent to the reactor (plug flow reactor). The pressure of 160 atmosphere is maintained in the
reactor so as to avoid the evaporation of ammonia and keep the ammonia in liquid solution to
carry out the reaction in liquid phase (Ruehl C, 1997)7.
The disadvantage of this process is that the water would have to be separated later from the
product stream, and also the fact that if anytime during the process the temperature or pressure of
the process stream is too high, the ethylene oxide will react with the water to form ethylene
glycol.
But the reaction temperature in this case would never rise above 200 0C and the ethylene glycol
formation takes place only above 430 0C. It was decided to carry out the reaction in the aqueous
phase because the safety gained with aqueous ethylene oxide and money saved by putting
ammonia into solution would outweigh the cost of a separator.
2.6.1 REACTOR:
Next we had to consider the temperature, feed rate, and reactor size and type for the reaction.
Since the reaction is not auto-catalytic, we selected a plug flow reactor type to give the most
efficient reaction for the space in the reactor. The reactor is made of Stainless Steel (SS-316).
Temperature is best around 120-160 degrees. Anywhere below around 120 C seriously hinders
the rate of the reactions. In our present case we take around 150 degrees (Ruehl C, 1997)7.
The reactions that take place are all exothermic and very fast. Thus, the reactor size does not
need to be very big. In simulation, it was found that the theoretical reactor size was actually
smaller than the feed pipe to the reactor, so the reactor was made to be a size accompanying the
approximate diameter of the ammonia feed pipe plus a little extra to account for the amount
injected of ethylene oxide in the reactor. The dimensions were 3 meters long and about 30 cm in
diameter (internal volume .2120715 m3, residence time about 30 sec.). The extra length was to
ensure that all of the ethylene oxide reacted.
Reaction between ethylene oxide and ammonia is exothermic process with the release of 125
KJ/mole of ethylene oxide. Hence in order to maintain the reaction temperature heat has to be
removed by passing the cooling water in the jacket covering the reactor. Hence in the reactor, all
15 Monoethanolamine
the amines are produced i.e. MEA, DEA and TEA. In order to enhance the production of MEA,
we need to control the ammonia: ethylene oxide ratio.
High ratios of NH3 to EO lead to high ratios of MEA in the product stream, which is desirable
because it is generally the most profitable of the three products. However, high NH3 levels mean
a larger recycle stream, which increase compression costs and separation costs of water. It is
indicated that a 10:1 ratio of NH3 / EO was sufficient to produce virtually all MEA and that
roughly a 1:1 ratio can lead to a more even distribution of the products (Ruehl C, 1997)7.
Hence we optimize and take the ration of NH3 to EO around 2:1. Hence the product distribution
would be 70% MEA, 20% DEA and 5% TEA.
For the safety reasons, ethylene oxide must be metered into the ammonia stream; in the reverse
procedure, ammonia or amine may cause ethylene oxide to undergo an explosive polymerization
reaction.
The product coming out of the reactor is sent to the flash unit to remove excess ammonia used
which is recycled. Reactor outlet stream will have a temperature of 150 degrees and 160 atm. In
the flash unit, pressure is lowered to about 1 atm. So in this manner, the ammonia is completely
removed from the top stream, from the bottom stream, we obtain the remaining product which is
sent as a feed to the DEHYDRATION TOWER.
16 Monoethanolamine
In this, almost all the water entering in the feed is removed as the top product. Only a negligible
amount of MEA will be lost due to the large temperature difference in the boiling point of water
and MEA. The boiling point of DEA and TEA are very high, hence they are removed as
Bottoms. Hence the seperation occurs only between MEA and water.
The bottoms of the DEHYDRATION TOWER is taken as a feed in the MEA tower. MEA is
obtained as a distillate (top product), both DEA and TEA are obtained as bottom product, which
are further sent for the vacuum column for their seperation. MEA of 99% purity is obtained, only
a small fraction od DEA is obtained along with it.
The bottoms of the MEA TOWER is taken as a feed in the DEA tower. DEA is obtained as a
distillate (top product), both TEA and other heavy products are obtained as bottom products.
There are two grades of DEA obtained, Grade A (98% DEA) and Grade B (55% DEA). In our
present case, we obtain Grade A type DEA.
17 Monoethanolamine
This chapter contains the Production Capacity of various facilities around the world along with
the assumed Capacity for the Project under consideration, DOF analysis and the Material and
Energy Balances.
3.1 CAPACITY
The consumption of ethanolamines in Asia has been 560,000 tons in 2011. Out of that China
consumed about 366,000 tons (Zhang B, 2012)11. Taiwan’s OUCC Company produces 40,000
tons/year of Ethanolamines whereas Akzo Nobel in China produces about 80,000 tons/year.
Sabic produces about 100,000tons/year of Ethanolamines. In India, Amines and Plasticizers Ltd.
(APL) produces about 10,000 tons per year.
Hence, we assume in our case, that if we want to setup an Ethanolamine Plant, we assume the
average production 30,000 tons/year with 300 working days in a year.
18 Monoethanolamine
x14 :total
0.99x14: MEA
0.01x14: DEA
0.99x10 = 0.99x14
x4 NH3 recycle
MEA Tower x18 :total
0.99x18: DEA
0.01x18: TEA
Dehydrator
Ammonia DEA Tower
Mixer Reactor
flash
a ammonia x1 NH3
MEA x5 MEA
solution DEA x6 DEA
0.7x1 NH3 TEA x7 TEA
0.3x1 water x3 water x8 water
x4 NH3 x10 MEA
x19 DEA
x11 DEA x15 DEA
x20 TEA
x12 TEA x16 TEA
x21 water
x13 water x17 water
Hence on solving for the reactor first, we might be able to calculate Material Balance for the
entire plant.
Ammonia solution x1
0.3 x1: ammonia
a ammonia 0.7x1: water
MEA x5 MEA
DEA x6 DEA
TEA x7 TEA
x3 water x8 water
x4 ammonia
x9 : total
0.99x9: water
0.01x9: MEA
0.98x8 = 0.99x9
x5 MEA
x6 DEA
x7 TEA
x8 water x10: MEA
x11: DEA
x12: TEA
x13: water
x14 : total
0.99x14: MEA
0.01x14: DEA
0.99x10 = 0.99x14
x10 MEA
x11 DEA
x12 TEA
x13 water
x15: DEA
x16: TEA
FIGURE 3.6: MEA TOWER x17: water
x18 : total
0.99x18: DEA
0.01x18: TEA
0.99x15 = 0.99x18
x15 DEA
x16 TEA
x17 water
x19: DEA
x20: TEA
x21: water
3.3.1 REACTOR
Basic reaction:
BASIS:
Approx tons/day of ethanol amines produced (30000/300): 100.0
Now 70% MEA is produced (tons/day): 70
20% DEA is produced (tons/day) 20.0
5% TEA is produced (tons/day) 5.0
Molecular weight of Ammonia (gm/mol) 17
Molecular weight of MEA (gm/mol) 61
Molecular weight of DEA (gm/mol) 105
Molecular weight of TEA (gm/mol) 149
Molecular weight of ethylene oxide (gm/mol) 44
23 Monoethanolamine
ammonia recovery
Flash
ammonia+water Column
Excess ammonia is vaporized. The product mixture then contains MEA, DEA,TEA and water.
98% water is removed in top fraction giving 99% wt. water and 1% wt. MEA.
2% of the feed water is in the bottoms as 1.29% wt. of the bottoms
DEHYDRATION
water+MEA+DEA+ TOWER
TEA
WATER BALANCE
Feed (F) (tons/day): 164.68
weight fraction of feed xf 0.39
Distillate (D) (tons/day): 64.02
weight fraction of distillate xd 0.99
Bottoms (W) (tons/day): 100.653
weight fraction of bottoms xw: 0.0129
Amount of MEA lost in distillate (tons/day): 0.64
Amount of MEA remaining in the bottoms (tons/day): 69.36
26 Monoethanolamine
99%MEA + 1% DEA
MEA
MEA+DEA+ TOWER
TEA
2% MEA + DEA+
TEA
MEA BALANCE
Feed (F) (tons/day): 100.65
weight fraction of feed xf : 0.69
Distillate (D) (tons/day): 69.36
weight fraction of distillate xd: 0.99
Bottoms (W) (tons/day): 31.29
weight fraction of bottoms xw: 0.02
Amount of MEA produced in a day (tons/day) containing 1% DEA 69.36
Amount of MEA produced in a day (tons/year) 20807.93
27 Monoethanolamine
99%DEA + 1% TEA
DEA BALANCE
3.3.6 RESULTS
Vn = 4263.3 kmol/day
D = 3531.78 kmol/day
Hence in the dehydrator, following components are to be considered: MEA, DEA, TEA and water
Hence in this case, the boiling point of DEA and TEA is too high. Hence it would do straight to the
bottom.
We consider the separation between water and MEA in this case. We design a distillation column based
on that.
F= 164676.6 kg/day
xf (weight fraction) = 0.39
xf (molar fraction) = 0.724
D (weight fraction) = 64023.31 kg/day
xd (weight fraction) = 0.99
xd (molar fraction) = 0.997
W= 100653.299 kg/day
xw (weight fraction) = 0.013
xw (molar fraction) = 0.050
F D W
kg/day 164676.61 64023.31 100653.299
kmol/day 4964.72 3531.78 1432.94
xf xd xw
weight fraction 0.39 0.99 0.013
molar fraction 0.724 0.997 0.050
38 Monoethanolamine
Now in order to further calculate the number of trays, we must first find Rmin. For that we use x-y plot.
TABLE 4.1: T-x-y DATA FOR MEA-WATER SOLUTION (Park SB, 1997)13
T (0K) T (0C) x y
443.3 170.15 0 0
440.1 166.95 0.02 0.11
437.4 164.25 0.04 0.21
435.1 161.95 0.05 0.26
433 159.85 0.06 0.31
430 156.85 0.09 0.41
420.6 147.45 0.16 0.59
418.5 145.35 0.18 0.64
415.2 142.05 0.21 0.69
408.5 135.35 0.28 0.77
404.4 131.25 0.32 0.83
397.3 124.15 0.42 0.88
392.8 119.65 0.49 0.92
385.5 112.35 0.65 0.96
382 108.85 0.75 0.97
378.5 105.35 0.84 0.98
374.3 101.15 0.97 1.00
373.1 99.95 1 1
At top:
Mass Flow rate Vwd of vapor (kg/s) = 0.90
Volumetric Rate of vapor (m3/sec) = 1.558
Mass Flow rate Lwd of liquid (kg/s) = 0.15
Volumetric Rate of liquid (m3/sec) = 0.0001569
40 Monoethanolamine
For designing, 80-85% of flooding velocity is used. Column diameter is determined from flooding
velocities. Flooding Velocities Uf is determined by Fair’s Correlation,
L V
U f K1
V
To determine K1 from plot we require FLV
LW V
FLV
VW L
FLV = 0.0041
Tray spacing = 18 inches normally = 0.5 metre
From the Fair’s chart of FLV versus K1 with tray spacing given:
value of K1 from the graph = 0.086 m/sec
Uf = 3.68 m/sec
Designing for 80% flooding velocity, U* = 0.8 * Uf = 2.95 m/sec
Net area required An = Vol. Rate for Vapor / U* = 0.53 m2
Net Area (An) = Column C/S area (Ac) - downcomer area (Ad)
if downcomer area is taken as 12% of Ac, An = (1-12/100)* Ac
Ac = ∏/4 * Dc2 = 0.601 m2
Hence, column diameter = 0.87 m
Approx. column diameter Dc = 0.9 m
therefore, Ac = 0.64 m2
From the graph of volumetric flow rate versus column diameter, we find that
the path is single path cross flow.
41 Monoethanolamine
K 2 0.9( 25.4 d h )
uh
v0.5
4.1.8 ENTRAINMENT
Actual Flooding Velocity for the design area = Vol. flow rate for Vapor/ net area An
0
Angle subtended at the plate edge by the unperforated strip 81
Total area available for the perforations Ap = Aa - (area of unperforated strip + area of calming zone)
Ap = 0.36
Ah/Ap = 0.132
47 Monoethanolamine
from the graph, lp/dh comes out to be 2.75 ( it should be between 2.5 and 4)
Fva = 2.46
Φ (froth) from the Fva curve 0.2
100q
uf
h f Dt
Velocity of the aerated mass uf = 5.50E-06 m/s
Reynold's No = Rh*uf*ρL/μL = 2.882
F= 0.075
10 4 fu 2f L f
Rh g
Where Lf = Lw
Δ 1.0E-10 cm
Δ is very small to be neglected.
49 Monoethanolamine
1/NOG = 0.99
NOG = 1.006
EOG = 0.634
Hence, Point Efficiency = 63.4 %
hL = hw + how = 52.81 mm
DE = 0.0353 m2/s
z L2
Pe
DE t L
Peclet Number Pe = 0.0520
m/(L/G)*EOG = λ * EOG = 0.69
EMV = 0.698
Hence Dry Murphee Plate Efficiency = 69.8 %
E’MV = 0.637
Wet Plate Murphee Efficiency = 63.70 %
log[ 1 Emv
'
( 1)]
EOC
log
SPECIFICATION SHEET
COLUMN ID 0.9 m
HOLE SIZE 5 mm
NUMBER OF HOLES 2500
WEIR LENGTH 0.684 m
WEIR HEIGHT 50 mm
FLOODING% 75.59 %
PLATE SPACING 0.5 m
THICKNESS 5 mm
PRESSURE DROP 0.1517 psi
Carbon
SHELL MATERIAL Steel
INSULATION MATERIAL asbestos
DENSITY OF INSULATION 2700 kg/m3
54 Monoethanolamine
For steam
Qc= mλ = m1λ1 + m2λ2
λ1 (MEA) = 848.1 KJ/kg
λ2 (water) = 2260.332 KJ/kg
m1 (MEA) = 0.640 tons/day
0.0074 Kg/sec
m2 (water) = 63.38 tons/day
0.734 kg/sec
Qc= mλ = m1λ1 + m2λ2 = 1664.46 KJ/sec
INLET OUTLET
TUBE SIDE TEMPERATURE (0C) = 30 (t1) 50 (t2)
SHELL SIDE TEMPERATURE (0C) = 102 (T1) 102 (T2)
TUBE SIDE PASS = 2
SHELL SIDE PASS = 1
m= 19.891 kg/sec
∆T1 = T1 – t1 = 72 0
C
∆T2 = T2 – t2 = 52 0
C
∆Tlmtd = 61.46 0
C
R= (T1-T2)/(t2-t1) = 0
S= (t2-t1)/(T1-t1) = 0.28
Ft (from 11.6 graph in Perry) = 1
∆Tlm = Ft * ∆Tlmtd
∆Tlm = 61.46
ASSUMPTIONS
o.d. = 20 mm
i.d. = 16 mm
length of the tube = 3.048 m
AREA OF SINGLE TUBE = ∏DL
AREA OF SINGLE TUBE = 0.19
No. of tubes = (Provisional Area/ Area of a single tube)
No. of tubes = 62.29
Approx. tubes (Nt) = 65
Prandtl No = Cp*μ/k
Prandtl No = 5.67
Now, as Reynold's No. is very high, it is in turbulent region
Hence we apply the Dittus Boelter Equation.
Nu = 0.023 * Nre 0.8 * Npr 0.3
Nu = 260.39
Nu = hi*di/k
hi = 9601.98 J/m2. sec. K
Reynold's No 182.283
58 Monoethanolamine
ho 8070.901
do
d o ln
1 1 1 di do 1 do 1
U ho hod 2K w d i hid d i hi
Kw = 50
dirt factor (1/hod + do/di *1/hid) = 0.00008805
1/Uo = 0.000386762
Design Uo = 2585.569
Assumed Uo = 2271.32
Design Uo > Assumed Uo
Hence our design is correct.
∆P length = 4*f*L*v2*density*g/(2*g*di)
∆P radial = 2.5*G2/(2*density)
Equip. No. 1
Name
Reactor type 1
Thermal mode 2
Pressure In atm 160.0000
Tout C 256.7071
Reactor volume m3 1.0759
Specify calc. mode 1
Conversion 0.9500
Key 2
No. of Reactions 3
Overall IG Ht of Rxn -5.1522e+007
(J/h)
Overall Liq H of Rxn -5.8430e+007
(J/h)
Reaction 1
RateConst = 5.0000e+000 Act.E = 1.0000e-020 Hrxn = 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.
3 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
4 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
Reaction 2
RateConst = 5.0000e+000 Act.E = 1.0000e-020 Hrxn = 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.
4 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
5 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
Reaction 3
RateConst = 5.0000e+000 Act.E = 1.0000e-020 Hrxn = 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.
5 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
6 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
61 Monoethanolamine
Stream No. 1 2
Name feed product
- - Overall - -
Molar flow kmol/h 3.9373 3.4844
Mass flow kg/h 80.9200 80.9200
Temp C 25.0000 256.7071
Pres atm 1.0000 160.0000
Vapor mole fraction 0.6715 0.0000
Enth J/h -4.2894E+008 -4.4731E+008
Tc C 195.9296 269.7397
Pc atm 122.3345 208.7063
Std. sp gr. wtr = 1 0.738 0.795
Std. sp gr. air = 1 0.710 0.802
Degree API 60.2337 46.4681
Average mol wt 20.5524 23.2235
Actual dens lb/ft3 0.0788 24.3018
Actual vol m3/h 64.0768 0.2079
Std liq m3/h 0.1096 0.1018
Std vap 0 C m3/h 88.2484 78.0980
- - Vapor only - -
Molar flow kmol/h 2.6439
Mass flow kg/h 57.8405
Average mol wt 21.8772
Actual dens lb/ft3 0.0564
Actual vol m3/h 64.0497
Std liq m3/h 0.0829
Std vap 0 C m3/h 59.2587
Cp Btu/lbmol-F 9.0942
Z factor 0.9904
Visc cP 0.01006
Th cond Btu/hr-ft-F 0.0124
- - Liquid only - -
Molar flow kmol/h 1.2934 3.4844
Mass flow kg/h 23.0795 80.9200
Average mol wt 17.8441 23.2235
Actual dens kg/m3 851.2886 389.2775
Actual vol m3/h 0.0271 0.2079
Std liq m3/h 0.0268 0.1018
Std vap 0 C m3/h 28.9896 78.0980
Cp Btu/lbmol-F 18.9239 29.4702
Z factor 0.0011 0.4259
Visc cP 0.5418 0.08722
Th cond Btu/hr-ft-F 0.3181 0.1408
Surf. tens. dyne/cm 47.5582 0.1196
62 Monoethanolamine
Stream No. 1 2
Stream Name feed product
Temp C 25.0000* 256.7071
Pres atm 1.0000* 160.0000
Enth J/h -4.2894E+008 -4.4731E+008
Vapor mole frac. 0.67150 0.00000
Total kmol/h 3.9373 3.4844
Total kg/h 80.9200 80.9200
Total std L m3/h 0.1096 0.1018
Total std V m3/h 88.25 78.10
Flowrates in kg/h
Water 18.0000 18.0000
Ethylene Oxide 21.0000 1.0500
Ammonia 41.9200 35.3849
Monoethanolamine 0.0000 19.7850
Diethanolamine 0.0000 5.3088
Triethanolamine 0.0000 1.3913
63 Monoethanolamine
Necessary Specifications:
Shell:
Shell Material - IS: 2002- 1962 Grade 1 Plain Carbon Steel
Permissible tensile strength ft = 950 kg/cm2
Elastic Modulus E = 188000 MN/m2
Insulation Material : Asbestos
Insulation Thickness = 2 inch
50.8 mm
Density of Insulation = 575 kg/m3
Head: Torispherical Dished Head
Diameter = Di = 0.9 m
Operating Pressure = 1 atm
1.033 kg/cm2
Design Pressure = 1.1 * Operating Pressure = P = 1.1363 kg/cm2
PDi
Consider the vessel to be an internal pressure vessel ts C
2 fJ P
Corrosion Allowance ( C) = 2 mm
Joint Efficiency (J) = 0.85
and ft = f
Shell thickness = ts = 2.63 mm
Taking the thickness of the shell as ts = 6 mm as this is the lowest available thickness.
Therefore, thickness = 6 mm
64 Monoethanolamine
Skirt Support:
The cylindrical shell of skirt id designed for the combination of stresses due to vessel dead weight,
wind load and the seismic load. The thickness of the skirt is uniform and it is designed to withstand
maximum values of tensile or compressive stresses.
Available Data:
Diameter of column = 0.9 m
Height of column = 7 m
Density of the material = 7700 kg/m3
Thickness of the tray = 5 mm
Thickness of shell ts = 6 mm
Outer diameter of the skirt Dok = diameter of the column + 2 * ts = 91.2 cm
W
Stress due to dead weight = fd
Dok t sk
fd = stress
ΣW= dead weight of vessel contents and attachments = 1256.65 kg
Outer diameter of the skirt Dok = 91.2 cm
So, fd tsk = 4.39 kg/cm2
fd = 4.39/tsk kg/cm2
65 Monoethanolamine
The bending moment due to wind at the base of the vessel is given by
Mw= pw * H/2 = 574.24 kg m
fwb = Mw/Z = 4 * Mw/(π * (Do)2 * tsk)
Z = Modulus of section of skirt cross-section
(fwb tsk) = 9.031 kg/cm2
fwb = 9.031/tsk kg/cm2
Anchor Bolts:
Minimum weight of Vessel (Assumed Value) = Wmin = 2000 kg
fc,min = ( Wmin/A) - (Mw/Z)
where,
Wmin = 2000 kg
A= 5482.64 cm2
M w= 574.24 kg m
Z= 130856.001 cm4
hence, fc, min = -0.074 kg/cm2
Since, fc is negative, the vessel skirt must be anchored to the concrete foundation by anchor bolts.
Assuming there are 20 bolts .
Pbolt = ( fc /20) * (π/4 *(circle diameter2- skirt diameter2) 20.299 kg
SHELL SIDE
Material Carbon Steel
Fluid water vapor
Working Pressure 1 atmosphere
Design Pressure 0.1114 N/mm2
0
Temperature 102 C
Ds 316.92 mm
Permissible stress for carbon steel is 95 N/mm2
TUBE SIDE
Number of tubes 65
Number of passes 2
Inside Diameter 16 mm
Outside Diameter 20 mm
length of tube 3.048 m
Working and operating pressures are same as that of shell side.
0
Inlet Temperature 30 C
0
Outlet Temperature 50 C
ts = PD/(2fJ+P)
let J = 85% 0.85
ts 0.22 mm
Minimum thickness of shell including corrosion resistance is taken as 8 mm.
69 Monoethanolamine
material asbestos
Assume a gasket thickness of 0.6 mm
y (minimum design yield seating stress) 44.85 MN/m2
m (gasket factor) 3.5
do/di 1.001255 m
gasket inside diameter = shell outside diameter
di 0.31692 m
do 0.31731 m
Minimum Gasket Width (N) = (do-di)/2 0.00019889118 m
But take minimum width (10 mm) (new N) 0.01 m
new do 0.3369 m
Basic gasket seating width (b) 6 mm
Diameter at location of gasket load reaction G = di + N 0.3269 m
326.9156496 mm
5.2.3 TIE RODS AND SPACERS
These are provided to retain all cross baffles and tube support plates in position
For shell diameter 300-700 mm. Diameter of rod is 10mm and number of rods = 6
KP
5.2.4 Tube Sheet Thickness (Cylindrical Shell) :
Tts GC
f
Gc = mean gasket diameter for cover = 326.92 mm
P = design pressure = 0.1114 N/mm2
K-factor(when cover is bolted with full faced gasket) = 0.25
F = permissible stress at design temperature = 95 N/mm2
So, Tube sheet thickness = Tts = 5.597 mm
70 Monoethanolamine
TABLE 6.1: COST DATA OF VARIOUS EQUIPMENTS (FROM PERRY 6TH EDITION)
Marshal and Swift index : 1048 (Year 2002)
Now the available data with us :- Marshall and Swift Index : 1448.3 (Year 2010)
Number of Calculated
Equipment Size Unit equipment Cost ($)
Distillation tower 14 trays 2 31923.41
H.E. (Shell and Tube) 11.92 m2 5 44619.53
3
Jacketed Reactor 1.0759 m 1 120705.62
Centrifigal Pump 5 hp 4 71840.31
Pressure Vessel (Flash) 2.5 m3 1 67157.54
AC motor 5 hp 4 46119.60
Total Sum : 382366.02
where,
C1 is the Capitalized Cost of the Designed Plant.
C2 is the Capitalized Cost of the Existing Plant.
Q1 is the size of plant 1
Q2 is the size of plant 2
M1 is the Marshall and Swift index in 2002
M2 is the Marshall and Swift Index in 2010
71 Monoethanolamine
0.6405X +
DIRECT PRODUCTION COST = 6681031.43 Rupees
Consider the plant overhead cost as 60% of Operating Labor, Direct Supervisory & clerical labor,
Maintenance & Repair
74 Monoethanolamine
Manufacturing Cost = Direct Production cost + Fixed Charges + Plant Overhead cost
0.7405x +
MANUFACTURING COST 27901648.16 Rupees
C) Research and Development Cost (3% of Total Product Cost) 0.03X Rupees
0.9455X +
TOTAL PRODUCT COST (X) = 27901648.16 Rupees
Total income = selling price * quantity of product manufactured = S.P. * 70 tons/year *300
days/year
TOTAL INCOME 630000000 Rupees
RAW MATERIALS:
Location near the raw materials source permits considerable reduction in the
transportation and storage charge.
MARKETS:
This is one of the major deciding factors of the plant location and in this respect the plant
should be near a big city which should be a major trade center so that lots of money can
be saved on the transportation.
LABOR SUPPLY:
Consideration should be given to prevailing pay rates, restriction on number of hours
worked per week, high turnover rates among the workers and variation in the skill and
intelligence of the worker.
WATER SUPPLY:
Amount of water required for manufacture of MEA is high, hence the site near the river
will be quite feasible as water can be obtained from it.
78 Monoethanolamine
CLIMATE:
Excessive humidity or extremes of hot or cold weather can have a serious effect on the
economic operation of plant; and these factors must be examined while selecting the site.
TRANSPORTATION FACILITIES:
The kind and the amount of the raw material and product determine most suitable type of
transportation facility. Water rail road and highways are the common means of the
transportation. If possible plant site should have access to all three types of
transportation; at least two types should be available.
Reliance is the major manufacturer of Ethylene Oxide which is used as a raw material in the
manufacture of Ethanolamines. Reliance has India’s largest EO/EG Plant with the installed
capacity of 300 KTA and Pure EO Capacity of 56 KTA at its Hazira facility (Reliance) 8.
KRIBHCO is a major manufacturer of Ammonia which too is located in Hazira, which is used as
a raw material for the manufacturing of Ethanolamine. The installed capacity of ammonia plant
is 10.02 lakh MT per annum (KRIBHCO)9.
Hence there is an easy availability of raw materials. Also ONGC is the biggest costumer which
consumes Ethanolamines as it has a Gas Sweetening Unit, Hazira Gas Processing Plant, ONGC.
It is the largest gas processing plant in India, processing 42 Million Metric Standard Cubic Meter
(MMSCM) per day (Pandey M, 2005)12.
Also, there is an easy availability of labor in Hazira as it is one of the major manufacturing cities
in Gujarat. Plus, River Tapi flows nearby. Hence there is an easy availability of water.
8.2.1 TOXICITY:
Monoethanolamine: Prominent among the toxic effects of ethanolamines is irritating effect on
skin and mucous membranes. Based on toxicity testing on rats and rabbits it is found that, rats
survive 8-h inhalation of saturated vapor at 200C without any symptoms. Above 100 ppm
exposure to the ethylene oxide vapor is harmful to human beings.
Ethylene oxide is a reactant used for production of Monoethanolamine. Ethylene oxide is a
relatively toxic liquid and gas. Liquid causes eye injuries and the gas may cause eye irritation.
Ethylene oxide is a gas used primarily as a chemical intermediate in the production of
ethanolamines and other chemicals. A small percentage is also used as a fumigant for sterilizing
medical and dental equipment, and foods, such as spices and nuts. It is well established that
ethylene oxide can induce cancer, along with genetic, reproductive, developmental, and acute
health effects (SBIO) 14.
80 Monoethanolamine
A plant cannot operate without utilities. The various utilities that a plant may require:- AIR,
NITROGEN, STEAM, OXYGEN, COOLING WATER, HOT OIL, AND ELECTRICITY.
Now in the manufacturing of MEA, we require WATER, NITROGEN, HOT OIL AND
ELECTRICITY.
WATER: A huge quantity of water is required, not only for preparing Ammonia solution
but also as a coolant in the Condenser at the top for the Dehydrator.
NITROGEN: Ethanolamines readily react with CO2. Hence to prove an inert medium in
the storage tank of MEA, DEA and TEA, we need nitrogen.
HOT OIL: It is required as a heating fluid in the reboilers situated at the bottom of the
two separating towers. They are Multitherm heat transfer fluids, Dowtherm heat transfer
fluids, etc.
BIBLIOGRAPHY
Books, Magazines and Journals
1. Green D, Perry R. Perry’s Chemical Engineers’ Handbook-8th Edition. McGraw
Hill.2007
2. Frauenkron M, Melder JP et al. Ethanolamines and Propanolamines, in Ullmann’s
Encyclopedia of Industrial Chemistry. Wiley. 2001
3. Felder R, Rousseau R. Balances on Reactive Process, in Elementary Principles of
Chemical Processes. Wiley. 2000; 125-142
4. No author identified. Ethanolamines. Dow Chemical. 2003
5. Dutia P. Ethanolamines: A Techno-commercial Profile. Chemical Weekly. August 2004;
203-209
6. Fassler P. Cost-efficient Production of Ethanolamines. Suzler Technical Review. 2008;
12-15
Web References
7. Ruehl C, Hou C et al. Design Of A System Of Ethanolamine Reactors. Ceng 403.
October 7, 1997. http://www.owlnet.rice.edu/~ceng403/etham97.html
8. Ethylene Oxide. Reliance Industries.
http://www.ril.com/html/business/other_petrochemicals_eohome.html
9. Hazira Plant. KRIBHCO.
http://www.kribhco.net/index.php/en/operations/manufacturing/production-at-hazira
10. Lecture 17: Ethylene Oxide and Ethanol Amines.
http://nptel.ac.in/courses/103103029/module3/lec17/3.html
11. Zhang B. Asian ethanolamines demand to grow by 6-7% over next 3-5 years. ICIS. 2012.
http://www.icis.com/resources/news/2012/02/29/9536732/asian-ethanolamines-demand-
to-grow-by-6-7-over-next-3-5-years/
83 Monoethanolamine
13. Park SB, Lee H. Vapor-Liquid Equilibria for the binary Monoethanolamine + Water and
Monoethanolamine + Ethanol systems. 1997.
http://link.springer.com/article/10.1007/BF02706075