FINAL YEAR PROJECT PROPOSAL REPORT A PLANT DESIGN REPORT ON PRODUCTION OF 100,000 MTPY OF STYRENE
SUPERVISOR: DR. FAHAD REHMAN
BY:
ABUBAKAR SALEEM
SP15-CHE-059
MUHAMMAD HUMZA
SP15-CHE-053
IRFAN RIAZ
SP15-CHE-061
UMAIR SHOAIB
SP15-CHE-041
M.NOMAN SAEED
SP15-CHE-017
DEPARTMENT OF CHEMICAL ENGINEERING
COMSATS INSTITUTE OF INFORMATION AND TECHNOLOGY, LAHORE Contents
HISTORY
……………………………………
INTRODUCTION PHYSICAL PROPERTIES APPLICATIONS MANUFACTURING PROCESS
Catalytic Dehydrogenation of ethyl benzene Side-chain chlorination dechlorination
of
ethyl
benzene
followed
by
Side-chain chlorination of ethyl benzene hydrolysis to the corresponding alcohols followed by dehydration
Pyrolysis of petroleum recovery from various petroleum processes
Oxidation of ethyl benzene to ethyl benzene hydroperoxide which reacts with propylene oxide after which the alcohol is dehydrated to styrene
PROCESS SELECTION PEOCSS FLOW DIAGRAM PROCESS DISCRIPTION MARKET ANALYSIS HAZARDS ASSOCIATED SCOPE REFERENCE
ONE PAGE PROJECT DISCRIPTION Styrene, also known as ethenylbenzene, vinylbenzene, and phenylethene, is an organic compound with the chemical formula C6H5CH=CH2. Styrene is derivative of benzene and is a colorless oily liquid that evaporates easily and has a sweet smell, although high concentrations have a less pleasant odor. Styrene is the precursor to polystyrene and several copo lymers. Styrene is a chemical used to make latex, synthetic rubber, and polystyrene resins. These resins are used to make plastic packaging, disposable cups and containers, insulation, and other products. Styrene is also produced naturally in some plants. This project is to design a plant that is capable of producing 100,000 tons per year of styrene. There are many methods in producing Styrene which are: Catalytic Dehydrogenation of ethyl benzene. Oxidation of ethyl benzene to ethyl benzene hydroperoxide which reacts with propylene oxide after which the alcohol is dehydrated to styrene.
Side-chain chlorination of ethyl benzene followed by dechlorination. Side-chain chlorination of ethyl benzene hydrolysis to the corresponding alcohols followed by dehydration.
Pyrolysis of petroleum recovery from various petroleum processes. Selected method is Catalytic Dehydrogenation of ethyl benzene because process reaction is equilibrium limited and with the addition of steam the process can be controlled moreover steam (used to vaporize ethyl benzene) is recycled. So, this process is economical. Other processes such as Side-chain chlorination of ethyl benzene followed by dechlorination & Side-chain chlorination of ethyl benzene hydrolysis to the corresponding alcohols followed by dehydration generally suffers from high cost of raw materials and from the chlorinated contaminants in the monomer. Pyrolysis of petroleum recovery from various petroleum processes is not used due to unavailability of raw material and carbon also poisons catalyst.
The reaction is carried out at 600 to 650 C with a contact time of about 1 second between the feedstock and the catalyst (usually iron oxide o r cadmium oxide). The main aim of this project is to conduct conceptual design for100,000 MTPY styrene production to reduce/eliminate the importing costs. It will involve: Selection of an existing commercial process Material and energy balances. Design of major equipments. Proposing process instrumentation diagram for the selected equipments. Economic feasibility Hazard and operability study (HAZOP)
HISTORY In 1839, the German apothecary Eduard Simon isolated a volatile oil from the resin (called storax or styrax) of the American sweetgum tree (Liquidambar styraciflua). He called the oil "Styrol" (now: "styrene"). He also noticed that when Styrol was exposed to air, light, or heat, it gradually transformed into a hard, rubber-like substance, which he called "Styroloxyd" (styrol oxide, now: "polystyrene"). By 1845, the German chemist August Hofmann and his student John Blyth (1814 – 1871) had determined Styrol's empirical formula: C8H8. They had also determined that Simon's "Styroloxyd" which they renamed "Metastyrol" had the same empirical formula as Styrol. The modern method for production of styrene by dehydrogenation of ethylbenzene was first achieved in the 1930s. The pro duction of styrene increased dramatically during the 1940s, when it was used as a feedstock for synthetic rubber. Because styrene is produced on such a large scale, ethylbenzene is in turn prepared on a prodigious scale.
INTRODUCTION:
Styrene is a colorless oily liquid that evaporates easily and has a sweet smell, although high concentrations have a less pleasant odor ; melts at -30.6°C. Post-world war period witnessed a boom in styrene demand due to its application in the manufacture of synthetic rubber. This led to a d ramatic increase in styrene capacity. Styrene has wide application in producing plastic and synthetic rubber industry. It is mostly used in manufacturing of polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), styreneacrylonitrile (SAN), styrene-butadiene rubber (SBR) and lattices, unsaturated polyester resins (UP resins) and miscellaneous uses like textile auxiliaries, pigment binders polyester resin, aromatics and intermediate industries.
PHYSICAL PROPERTIES: Various physical properties of styrene are listed in Tables
Table 1
Physical Properties of styrene
Liquid
145°C
Form: Solubility
Density: Vapor density: Vapor pressure:
0.906 g/mL at 20 °C 3.6 (vs air) 12.4 mm Hg (37 °C)
Sensitive Color Stability
Storage temp: Flash Point:
2-8 °C 88 °F
Refractive index
Air sensitive Colorless Stable, but may polymerize upon exposure to light 1.5469
Melting point: Boiling point:
-33 °C to -30.6°C
0.24g/l
APPLICATIONS Applications of styrene are as:
Styrene is mainly used as raw material for polystyrene, synthetic rubber, plastics, ion exchange resins, etc. The most important use of styrene is as monomer for s ynthetic rubber and plastics, it is used to produce styrene-butadiene rubber, polystyrene, polystyrene foam; it is also used as other copolymerizable monomers to manufacture many different applications of engineering plastics. Styrene is used for the preparation of copper brightener, and has effect of leveling and bright. Styrene is used in table food, cake food, condiments, desserts, snacks, all kinds of canned food, candy. Variety of drinks, especially yogurt, lactic acid bacteria drin ks, carbonated drinks and other acidic beverages. Styrene is used for electron microscopic analysis, organic synthesis.
MANUFACTURING METHODS: Catalytic Dehydrogenation of ethyl benzene. Oxidation of ethyl benzene to ethyl benzene hydroperoxide which reacts with propylene oxide after which the alcohol is dehydrated to styrene.
Side-chain chlorination of ethyl benzene followed by dechlorination. Side-chain chlorination of ethyl benzene hydrolysis to the corresponding alcohols followed by dehydration.
Pyrolysis of petroleum recovery from various petroleum processes.
Pyrolysis of petroleum recovery from various petroleum processes:
In this process styrene is separated from thermally cracked petroleums. In the process of this invention thermally cracked petroleum is initially distilled to recover the fraction boiling between 120oC and 160oC. This fraction is then subjected to extractive distillation with an organic polar solvent containing a nitrite polymerization inhibitor in which the styrene is soluble. The solvent is removed and the styrene containing fraction is thereafter treated with nitric acid after which it is scrubbed with water or alkali. The resulting product is fractionated to recover styre ne o f high purity which is substantially colorless. This process is not favorable due to the unavailability of raw material . Due to carbon in petroleum catalyst can also be poisoned.
REGIOSELECTIVITY CARBOXYLATION OF PHENOL
Salicylic acid can be prepared by carboxylation of phenol with carbon dioxide in the prese nce of Lewis acid catalyst at normal temperatu re (20-80C). Aluminum bromide can also be used as a catalyst. To get better results the reaction condition can be changed This method is clean, mild, efficient, easy to use for the preparation of Salicylic Acid But it gives high regioselectivity into substitution of carboxyl group in Ortho situation KOLBE-SCHMITT PROCESS
The first suitable method was introduced by Kolbe in 1874. The process involves the reaction of sodium phenolate with carbon dioxide under high temperature and pressure. The drawback of Kolbe was the yield was not more than 50% and separation of by byproducts was difficult. Schmitt introduced the new temperature range from 120-140 C. Which increased the yield of process The reaction of carbon dioxide on the phenol which give an intermediate phenyl carbonate which rearrange itself to give O-sodium salicylate this method is known is Kolbe-Schmitt Process It is still the only industrial process that is available for manufacturing salicylic acid in bulk
Process Selection Today the production of salicylic acid is commercially done by Kolbe-Schmitt Process. The reason for the selection of this process is that it is the only process that can be done on industrial scale. Secondly the Kolbe-Schmitt process is a very efficient process that yields about 82-88% of the product.
PROCESS FLOW DIAGRAM
HEAT EXCHANGER MIXER
HEAT EXCHANGER
HEAT EXCHANGER
REACTOR
MIXER
HEAT EXCHANGER
HEAT EXCHANGER
CONDENSER
BOILER HEATEXCHANGER
CONDENSER
SEPARATOR
VALVE HEAT EXCHANGER
BOILER
FLASH TANK
CONDENSER
PUMP
HEAT EXCHANGER
PUMP
BOILER
PROCESS DISCRIPTION Salicylic acid is manufactured by the reaction of caustic soda with Phenol and from the treatment of sodium phenolate produced with CO2 and acidifying the end product with H2SO4.Phenol and caustic soda are feed to a mixer in an equimolar proportion. The mixed solution is then heated 130 C temperature and then evaporated to dryness in a stirred autoclave. Dry CO2 is absorbed and product of autoclave is dissolved in water in an equal amount and then filtered. Filtrate is precipitated and then dried. The pure product is obtained the crude
sodium salicylate solution decolorized with the activated carbon containing the zinc and then filtered. The filtrate is then acidified with excess of H 2 SO4 to precipitate the salicylic acid which is centrifuged and dried to give the high grade salicylic
MARKET ANALYSIS Salicylic aid is an organic white crystalline solid which is highly soluble in water. It is derived from the metabolism of salicin which is an anti-inflammatory agent extracted from willow bark. Salicylic acid is mainly used in manufacturing of aspirin and other personal care products consumption of aspirin is increasing in emerging economies of Asia which has resulted in growth of salicylic acid market at an annual growth rate of 8% in recent past The globe salicylic acid market is classified on the basis of the following segments
Pharmaceuticals Cosmetics Food and preservatives
HAZORDS ASSOCIATED The hazards problems related to Salicylic acid are given in the table below:
Types of Hazards
Acute Hazards
Prevention
Fire
Combustible
No open flame
Explosion
Finally dispersed particles explosion mixtures in air
Inhalation
Cough, Sore throat
Skin
Redness
Eyes
Redness and pain
Ingestion
Nausea. Vomiting, Ear ringing.
Exposure
from Prevent deposition of dust ; closed system ,dust explosion-proof electrical equipment and lighting Local exhaust or breathing protection Protected gloves Safety goggles or eye protection in combination with breathing protection Do not eat, drink, or smoke during work Prevent dispersion of dust
SCOPE: The global salicylic acid market is expected to reach USD 547.5 million by 2024, according to a new report by Grand View Research. Salicylic acid demand in food & preservative application was valued at over USD 90.0 million in 2015. Asia Pacific is expected to witness the highest growth as compared to other regions, growing at over 9.0% from 2016 to 2024.
REFERENCE:
i. ii. iii. iv. v. vi.
vii.
https://www.britannica.com/science/salicylic-acid https://www.ukessays.com/essays/biology/history-of-salicylic-acid-biologyessay.php https://www.thesisscientist.com/docs/EdwardCage/3e955573-2a08-4ff7-b9dc382502a5d76e.pdf http://www.chemicalbook.com/ChemicalProductProperty_EN_CB1680010.htm http://www.chemicalland21.com/specialtychem/finechem/SALICYLIC%20ACID.ht m ‘GEORGE H.ANDEREWS,PLANT REQUIREMENTS FOR MANUFACTURE OF SALICYLIC ACID,INTERNATIONAL COOPERATION ADMISTRATION WASHIGTON,D.C.,SEPTERBER 1961 E. Golub, D. Hanesian, H. Hsieh and A. J. Perna, The Siting and Design of a Manufacturing Facility, New Jersey Institute of Technology, 1997
