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2. Introduction Basis of Design Process Structure Process Flow Diagram Equipment Design Process Control Waste, Environment, Safety Economy Conclusion CONTENT 2

3. INTRODUCTION o Scope of the Project Methyl Acetate Production in Turkey Methyl Acetate Imported from Spain No production in Turkey 3

4. INTRODUCTION o Main Applications of Methyl Acetate SolventCoatingPrinting Inks 4

5. INTRODUCTION o Market Situation 180,000 tonnes/ year (***) 1,300,000 tonnes/ Year (**) 1,300,000 tonnes/ Year (**) 10,000 tonnes/ year (*) 10,000 tonnes/ year (*) (*) Azot Nevinnomyssk (**) Universitat de Barcelona (***) Eastman Chemical Company 5

6. INTRODUCTION Many equipments requirement Extra seperation unit requirement Low operation and investment cost High purity of the production Low energy requirement High operation and investment cost Purity of the process can be adjusted Liquid-Liquid Extraction Reactive Distillation Conventional Process o Process Alternatives 6

7. BASIS OF DESIGN o Reactive Distillation o Conventional Process 511 kg/h 629 kg/h Methanol Methyl acetate 273 kg/h 155 kg/h Acetic acid Water 511 kg/h 629 kg/h Methanol Methyl acetate 273 kg/h 155 kg/h Acetic acid Water 344 kg/h 629 kg/h Methanol Methyl acetate 408 kg/h 124 kg/h Acedic acid Water 344 kg/h 629 kg/h Methanol Methyl acetate 408 kg/h 124 kg/h Acedic acid Water 7 PLANT

8. BASIS OF DESIGN Production Capacity: 5000 tonnes/year (*) Supplied from AKKİM Chemical Company Continuous Process: - Fast Reaction - High Capacity (*) Based on the report taken from Aktaş Chemical Company Raw Materials Methanol (96 % w/w) Methanol (96 % w/w) Acetic Acid (99.5 % w/w) Acetic Acid (99.5 % w/w) 8

9. BASIS OF DESIGN o Reaction kinetics O O CH 3 – C – OH + HO – CH 3 CH 3 – C – O – CH 3 + H 2 O Acetic Acid Methanol Methyl Acetate Water Reversible reaction Reaction conditions Heat of reaction: -27.9 kJ/mol High Temperature Low Temperature High Pressure Reaction Temperature Reaction Pressure Side products occur 30-120 ° C1 atm 9

10. BASIS OF DESIGN Minimum Azeotropes Catalyst ComponentTemperatureWeight Fraction Methyl Acetate + Water 56.5 ° C3.5 % Water Methyl Acetate + Methanol 54.0° C19 % Methanol Heterogeneous Catalyst Amberlyst 15 10

11. PROCESS STRUCTURE o Block Diagram for Reactive Distillation 11

12. PROCESS STRUCTURE o Block Diagram for Conventional Process 12

13. PROCESS FLOW DIAGRAM Reactive Distillation HeaterE-101E-102 TypeShell&Tube Area (m 2 )1.681.17 Duty (kW)7.725.23 MOCSS/CSCS/CS T-101 Internal Diameter (m) 0.46 Height (m)25 Tray Number38 Feed Tray3 / 26 Pressure (bar) 1 MOCSS CoolerE-105E-106 TypeShell&Tube Area (m 2 )2.1017.29 Duty(kW)-11.2-16 MOCCS/CSSS/CS 13

14. PROCESS FLOW DIAGRAM Conventional Process E-101 (heater) TypeShell&Tube Area (m2)5.14 Duty (kW)11.37 MOCSS/CS R-101 TypeCSTR- Jacketed Diameter (m)2.20 Height (m)2.63 Volume (m 3 )10 Pressure (bar)1 Temperature (°C) 50 Duty65 MOCSS T-101T-102T-103 Internal Diameter (m) 0.460.310.61 Height (m)2.372.262.09 Tray Number 182532 Feed Tray41116 Pressure (bar) 111 MOCSS 14

15. PROCESS CONTROL Reactive Distillation Controlled Variable 1. Column Pressure 2. Reflux rate 3. Bottom liquid level 4. Reboiler Reflux Drum Level 5. Distillate and bottom compositions Manipulated Variable 1. Condenser Coolant Flowrate 2. Reflux flow rate 3. Bottom outlet flow rate 4. Distillate flow rate 5. Tray Temperature Controlled VariableManipulated Variable Feed Drum LevelFeed flow rate Reactor Feed Temperature Exchanger utility flow rate 15

16. WASTE, SAFETY & ENVIRONMENT Outlet waste stream of reactive distillation column Based on properties of 18% acetic acid solution %18 acetic acid solution low The steam has to be sent İZAYDAŞ inceniration plant 18%(w/w) Acetic Acid (35.8 kg/h) Dangerous Waste High Recovery Cost 16

17. WASTE,SAFETY & ENVIRONMENT F & EIIndex Range Degree of Hazards 1-60Light 61-96Moderate 97-127Inremediates 128-158Heavy 159-upSevere F & EI: 60 Degree of Hazard for F&EI 17

18. RESULT OF HAZOP ANALYSIS FOR RD Guide WordDeviationCauseConsequenceAction No No flow of feed streams Valve malfunction No reaction or distillation Repairment More of More flow rate of methanol Failure of valve to close Harder to break azeotropes Install high methanol concentration alarm More of More flow rate of acetic acid Failure of valve to close More acetic acid unreacted than favored Install high acetic acid concentraion alarm Less ofLess flow rate of acetic acid Pipe blockageAzeotrope aoccurs Install low acetic acid concentration alarm 18

19. ECONOMY Conventional Process o Purchase Cost of Equipment 19

20. ECONOMY Material NameClassification Price ($/kg) Flowrate (kg/h) Annual Cost ($) Acetic acidRaw Material 0.37408.36 1,257,398 MethanolRaw Material 0.52344.45 1,490,587 Methyl AcetateProduct 1.30629.00 6,804,899 o Material Analysis 20

21. ECONOMY o COM Share Taxation Rate: 20% MARCS Depreciation Plant start- up at the end of year 2 10 years project life Land cost: $273,000 COM: $4,417,361 Interest rate (i): 10% Revenue: $4,450,000/year 21

22. ECONOMY Reactive Distillation o Purchase Cost of Equipments 22

23. ECONOMY Material NameClassification Price ($/kg) Flowrate (kg/h) Annual Cost ($) Acetic acidRaw Material 0.37545.28 1,678,993 MethanolRaw Material 0.52282.15 1,220,987 Methyl acetateProduct (1.10)625.00 (5,721,375) o Material Analysis 23

24. ECONOMY o COM Share Taxation Rate: 20% MARCS Depreciation Plant start-up at the end of year 2 10 years project life Land cost: $227,000 Interest rate (i): 10% Revenue: $5,201,250/year 24

25. ECONOMY Cost of Reactive Cost of Conventional Distillation Process FCI L COM d Revenue 0 ($ 140,000 ) ($ 83,500 ) ($ 751,900) 25

26. ECONOMIC ANALYSIS Net Present Value: $1,350,000 Discounted Payback Period: 3.9 years 26

27. RESULTS & RECOMMENDATIONS o Methyl Acetate Production via Reactive Distillation Objective: Producing Methyl Acetate in Turkey High purity Methyl Acetate (99.5 %) Environment friendly Low utility need Profitable Waste water cannot be recovered Demand of Turkey provided 27

28. THANKS FOR YOUR ATTENTION... Special thanks to Prof. Dr. Hale GÜRBÜZ 28