1. The Production of Ethanol from Syngas
Mosleh Mohammed
Yousef bahbahani
Omar Ali
Kalid al-Sulaili
Eid Ali
Supervised by:
Prof. : Mohammed Fahim
Eng. : Yousif Ali

2. Agenda Introduction Hysys simulation program Process Description
The equipment we use
Mass balance
Conclusion

3. Introduction Ethanol is a 2-carbon alcohol,
volatile, flammable and colorless
Liquid which considered as renewable fuel which has received attention in recent years for its use in automobiles.
CH3CH2OH
Ethanol synthesis involves the reaction between CO and H2 ( syngas) under high pressure = psia and temperature = 617 F .

4. Hysys simulation program
HYSYS is powerful a software that was created by Hyprotech for simulation of chemical plants and oil refineries.
We use Hysys to simulate our plant.
Before entring the simulation environment we should put :
- The components, the fluid package and the reactions.

5. We choose UNIQUAC as a fluid package
Then We select the components

6. Selecting Reactions We make 2 set each for one reactor:
Set (1) include One main reaction : ( in the gas phase)
2CO(g) + 4H2(g) → C2H5OH(g) + H2O(g)
and 3 Side reactions:
C2h5OH  CH3CHO + H2
C2H5OH + H2O  CH3COOH + H2
C2h5OH + CH3COOH  CH3COOCH2CH3 + H2O
Set (2) include one side reaction:
CH3COOCH2CH3 + H2O  C2h5OH + CH3COOH

8. Plant by
Hysys

10. The equipments we use 2 Reactors 5 Distillation coloumn 1 Absorber
2 Air compressor
1 Heater
1 Cooler
1 Heat echanger
1 Valve

11. Process Description
A feed stream 1 of syngas which contain hydrogen and carbon monoxide at 100 F and 300 psia is fed to compressor K-100 to raise the pressure to 1038 psia in the outlet stream 1* and raise the temperature to 420 F.

12. Mass flow( Ib/hr )
Hydrogen
18743
Carbon monoxide
153280

13. The outlet stream 1* from compressor will enter the mixer and will mix with the recycled stream came from the absorber by MIX-100

14. The outlet stream 2 from mixer is fed to heat exchanger E-100 with the steam at 662 F and 2397 psia in which it heated stream 2 to 592 F
and a molar flow = kgmole/h.

15. The effluent stream 2* from heat exchanger is fed to heater E-101 which it heated the stream 2** to 617 F and 1640 psia which is the appropriate condition for the reaction in the reactor.

16. The stream 2** enter the first reactor with a temperature = 617 F and a pressure = 1640 psia and mass fraction of :

17. The main reaction :
2CO(g) + 4H2(g) → C2H5OH(g) + H2O(g)
The side reactions :
C2h5OH  CH3CHO + H2
C2H5OH + H2O  CH3COOH + H2
C2h5OH + CH3COOH  CH3COOCH2CH3 + H2O

18. Heat exchanger
Stream 3 is fed to a heat exchanger to be cooled by water stream with temperature 25c.
The stream will be cooled from 409 c to 60 c.

19. absorber
The outlet stream 3** from the heat exchanger will enter an absorber with water stream with 25 c.
Hydrogen and carbon monoxide will be absorbed then they will be recycled to mix with the feed for more efficiency.
The absorber has 10 stages with no specification.

21. Distillation column

22. Acetaldehyde column
The outlet stream from the valve will fed to a distillation column which called acetaldehyde column.
This column is used to separate acetaldehyde (as overhead product)from other compounds.
This column operates at 61 c and 68 bar.

23. We choose a full reflux condenser in this distillation because the boiling point of acetaldehyde is 68 F ,so it won’t come as a liquid if we choose total condenser.
This distillation has 10 number of stages with 200 reflux ratio of the condenser.
Also,we choose vent rate to recover acetaldehyde in stream 8 to be equal Ib/h.

24. Second Distillation (ethyl acetate column1)

27. Mass flow rate of Stream 10:

29. Reactor 2 :

30. The mass flow of stream 12 entring the reactor :

31. DISTILLATION #3

32. DISTALLATION INFORMATION
# of stages = 10
Type of condenser is total
Reflux ratio = 1
The water flow over head is = 20000(Ib/h)

33. Stream information Stream in is 14* T=36 F P=1.8 psia
Flow rate = 5.7*10^5 (Ib/h)

34. Stream information Stream down (16) go to the mixer to enter
Ethanol coloumn

35. DISTILLATION #4 # of stages = 10 Type of condenser is total
Reflux ratio = 2
The water flow down head is = 1.036*10^6(Ib/h)

36. Our main product ethanol
In stream 18
Mass flow = (Ib/h)

37. The Fifth Distillation(acetic acid coloumn)
The bottom stream 19 enter the fifth distillation to recover acetic acid in the upper stream and get rid of the waste in the bottom stream.
Number of stage =10
Pressure of the condenser
and the reboiler = 15 psia

38. The specifaction we add to get converged:
reflux ratio of the condenser = 2
Acetic acid recovery in the upper stream = 0.99

39. Mass flow rate of Stream 20:
We get acetic acid flow rate = 25349(Ib/h)

40. The bottom stream is waste , so we get rid of it

41. Mass balance The inlet streams are:
stream 1 + stream water1 + stream 14 = ( Ib/h )
The outlet streams are:
stream 8 + stream stream stream 21 = ( Ib/h )
Error = (inlet – outlet)/inlet *100 = 0.024%

43. -No additional equipment were added . - We get 694 million (Ib/yr)
Conclusion
-No additional equipment were added We get 694 million (Ib/yr)

44. Total energy consumption = 9.052*10^9(kJ/h)

45. Thank You
Thank You
Thank You