1. ChE 308 - Chemical Process Analysis Sessional
WELCOME
ChE Chemical Process Analysis Sessional

2. HYSYS SIMULATION PROJECT 100 MTPD HYDROGEN PEROXIDE (50%) PLANT

3. DEFINITION OF THE PLANT
A hydrogen peroxide plant is to be set-up at Gazaria, Munshiganj having a capacity of 100 metric ton of hydrogen per oxide (50 % w/w) per stream day, corresponding to 33,000 metric ton of hydrogen peroxide(50% w/w) per year, including all off sites, auxiliaries, utilities and supporting facilities using natural gas as feedstock and fuel.

4. SPECIFICATION OF RAW MATERIALS
NG from TITAS Gas
Methane > 96 % (V/V)
Calorific Value > 1000 Btu
Pressure > 240 kPa
Temperature about oC
Air
Water

6. SPECIFICATION OF PRODUCT
H2O2 specification:
H2O2 content 50%
Free acid (as H2SO4) % max.
Non-volatile matter % max.
Stability % min.
Freezing point °C
Boiling point °C
Density kg/m3

7. PROCESS SELECTION By Auto-oxidation of alkylanthraquinones
By Electrolysis from Ammonium Bisulfate.
From Barium Peroxide
By oxidization of isopropanol
Auto-oxidation of 2-ethylalkylanthraquinone is selected for this project.

8. DESIGN BASIS Geological Data
Location
The site for the plant is selected on the bank of river Meghna at Baluakandi under Gazaria upzilla in Munshiganj district.
Load bearing capacity: The soil has a bearing capacity of 0.38 ton/ft required piling is used.
Corrosive tendency: Non Corrosive

9. DESIGN BASIS (Contd.) Climatic condition
Dry bulb temperature (maximum) oC (summer)
Dry bulb temperature (maximum) oC (winter)
Wet bulb temperature (maximum) oC (summer)
Wet bulb temperature (maximum) oC (winter)

10. DESIGN BASIS (Contd.) Meteorological condition
Average monthly Temperature 35oC (max.)
Average Temperature 30oC
Average annual rainfall mm
Wind flow
Direction = South to North
Velocity = 52 mile/h

11. DESIGN BASIS (Contd.) Utility Electric Power Voltage 380/220 V
Frequency 50 Hz
Phase 3 phases
Cooling Water
Inlet Outlet
Temperature < 30 oC 38 oC
Pressure 0.5 MPa 0.2 MPa
Turbidity ≤ 50 mg/l
Chlorine < 5 ppm
PH 6.5 – 8

12. PROCESS INVOLVED Four main stages involved:
Hydrogen Generation ( Reformer)
Hydrogenation
Oxidation
Extraction and Purification

13. REACTIONS INVOLVED Reformer: Hydrogenation And Oxidation tower:
CH4+H2O = CO+3H2 - Q
CO + H2O = CO2+H2 + Q
Hydrogenation And Oxidation tower:

14. PROCESS BLOCK DIAGRAM REFORMER OXYDATION TOWER EXTRACTION SEPARATOR
PRESSURE SWING
ADSORBER
HYDROGENATION TOWER
OXYDATION
TOWER
EXTRACTION
SEPARATOR
DSV
PURIFICATION
H2O2
STORAGE
TANK
Tail Gas NG
Steam
Tall Gas
Water WS
Make Up
DRYING TOWER
Air
WS STORAGE

15. PROCESS FLOW DIAGRAM

18. EQUIPMENT LIST Natural Gas Knock Out Drum Feed Gas Compressor
Desulfurization Vessel
Water Tank
BFW Pump
Stack
Heat Exchanger
Waste Heat Boiler
Reformed Gas Cooler
Raw Gas Separator
Pressure Swing Adsorber
Induced Draft Fan
Reformer

19. EQUIPMENT LIST (Contd.)
Static Mixer
Hydrogenation Tower
Working Solution Pump
Working Solution Storage Tank
Hydrogenated Solution Storage Tank
Hydrogenated Solution Pump
Hydrogenated Solution Cooler
Air Compressor
Oxidation Tower
Oxidation Solution Separator
Tail Gas Condenser
Oxidation Solution Cooler
Wet Gas Separator

20. EQUIPMENT LIST (Contd.)
Extraction Column
Working Solution Separator
Recycled Working Solution Pump
Extraction Water Pump
Recycled Working Solution Heater
Purification Column
Hydrogen Peroxide Storage Tank

21. THANK YOU