Design of an Ethylene Production Plant via Ethanol Dehydration

Team 06 The Minions - Vedant Didwania, Luke Harris, Alia Khan, and Sarah Leung

Agenda
Executive Summary
Abstract Project Background

Optimum Design
Financial Analysis Sustainability Final Recommendations

Reaction Scheme Separation Scheme Optimization Projected Costs of Project Market Pricing Feasibility Simulation

Environmental, Health, Safety Concerns Potential

Conclusion

Design of an Ethylene Production Plant via Ethanol Dehydration

BACKGROUND

Abstract
Assess the feasibility and sustainability of developing an ethylene production facility capable of producing 25,000 pounds per hour of 99.5% by weight ethylene To be used in plastic production facility in the Champaign-Urbana area 15-year project scope 350 production days per year Currently: Plant is purchasing ethylene

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

Relevance of Ethylene
Most highly produced organic compound globally 141M tons of ethylene was produced last year, Up by 3M from the previous year Slated to increase by around 6M Ethylene itself has no final use Building block for a large array of chemical products

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

Innovation Map
ABC Chemicals Value Environmentally Friendly Reliable production from non-fossil fuel source

Product

Polymer Grade Ethylene

Project Differences

Renewable

Lower Capital Cost

Simple Unit Operations

Produces Large quantities of Product per cracker

Technology

Dehydration Reaction

Cracking

In Brazil

In USA

Ethanol from Sugar Cane Raw Material

Ethanol from Corn

Activated Alumina Catalyst

Silica Catalyst

Sulfuric Acid

Naphthalene or other Fossil Fuel sources

Ethanol Dehydration
Strengths: Simplicity Environmentally friendly Ethanol accessibility Safer Lower FCI than steam cracking Weaknesses: Higher raw material cost Smaller profit margin

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

Design of an Ethylene Production Plant via Ethanol Dehydration

REACTOR SCHEME

Reaction Scheme

Consists of feed pump, process heater, steam-injected reactor with catalyst regenerator, two heat exchangers Feed of 49473 lb/h of 95% ethanol and 4000 lb/h hps
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

Feed Pump P-101

Centrifugal carbon steel 0.242 hp pump Feeds storage ethanol into process heater Provides pressure gradient for entire downstream process

Flow (lbmol/h) Discharge Pressure (psig) Temperature (F) Driver Type Shaft Power (hp) Material of Construction Number of spares

P-101 1157 2 77 Centrifugal 0.242 Carbon Steel 1

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

10

Process Heater H-101

Stainless steel natural gas fed fired heater Heats ethanol feed to 720F because reactor cannot heat reactants Simulated by a electric heater in ChemCAD

H-101 Type Tube Pressure (psig) Tube Temperature Duty (MJ/hr) Fuel Type Fired Heater 2 720 37300 Natural Gas

Material of Construction Stainless Steel

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

11

Recycle/Feed Mixing Valve

Three way valve to combine feed ethanol with recycle stream Recycle stream has higher pressure therefore flow is driven without need of pump Improves safety and costs less Recycle placement determined on heat duty If placed before H-101 would increase duty by 9% or $300,000/yr

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

12

Reactor R-101
Catalyzed PFR coupled with catalyst regenerator Operated isothermally by steam injection Activated alumina as catalyst Simulated in ChemCAD as isothermal Kinetic Reactor Jacketed Agitated Isothermal PFR in CAPCOST

R-101 Type Jacketed Agitated (Isothermal PFR) 1630 720 23 4 Steam Injected

Volume (ft3)
Operating Temperature (F) Operating Pressure (psia) Pressure Drop (psi) Specifications

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

13

R-101 Optimization
Sensitivity studies from Volume, Pressure, and Temperature versus product flow rates to maximum ethylene production with optimizing ethylene selectivity 81% ethylene selectivity 1630 ft2 Reactor operating at 23 psia and 720F Catalyst options Replacement every 90 days 4 reactors operating in series at 25% 50% 75% and 100% catalyst purities Catalyst regenerator Catalyst regenerator the cheapest option

14

Heat Exchanger E-101

Passes recycle stream with reactor exit stream Optimized by HEN Savings of $560,000/yr in operating by using heat integration
E-101
Type Duty (MMBtu/hr) Area (ft2) Temperature of Shell/Tube (F) LMTD End Points (F) Pressure of Shell/Tube (psig) Number of passes Floating Head 3.9 599 700/600 130.83 4.3/6.3 1-shell/2-tube

Material of Construction Stainless Steel/Stainless Shell/Tube Steel

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

15

Heat Exchanger E-102

Cools reactor exit stream further to separation 600F to 185F Uses cooling water Cheap and easy way to cool Optimized via HEN methodology
E-102
Type Duty (MMBtu/hr) Area (ft2) Temperature of Shell/Tube (F) LMTD End Points (F) Pressure of Shell/Tube (psig) Number of passes Floating Head 25.2 1150 105/185 242.39 5/5 1-shell/2-tube

Material of Construction Carbon Steel/Carbon Shell/Tube Steel

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

16

Design of an Ethylene Production Plant via Ethanol Dehydration

SEPARATION SCHEME

17

Process Flow Diagram

Ethanol Recycle

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

18

Flash Tanks
Removes excess water from process Two tanks with interstage cooling to reduce utilities usage and unit sizes Sensitivity study on ChemCAD utilized to determine operating temperature
V-101 Height (ft) Diameter (ft) Orientation Pressure (psig) 6.6 2.2 Vertical 4 V-102 6.6 2.2 Vertical 4

Temperature (F)
Material of Construction CBM

185
Carbon Steel $16,700

110
Carbon Steel $16,700

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

19

Distillation Towers
T-101 Function Ethylene Recovery T-102 Ethanol Recycle T-103 -Butylene

Purity
Production CBM

99.5% wt. fraction

25,527 lb/h Ethylene $379,600

4,121 lb/h Ethanol $264,300

99.8% wt. fraction

1,457 lb/h Butylene $301,400

3 Towers ChemCAD used to simulate tower design CAPCOST used to determine bare module unit costs CBM includes vessel, pump, partial condenser, and kettle reboiler
Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

Background

20

T-101 Optimization
T-101 Height (ft) Diameter (ft) Pressure (psig) Temperature (F) Number of Trays Feed Location Reflux Rate 34 1.8 5 Top: -128 Bottom: 61 6 3 325

Type of Trays
Material of Construction

Stainless Steel Sieve

Stainless Steel

Vary feed tray location to minimize condenser/reboiler duties Feed location of 3 out of 6 trays optimal
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

21

T-102 Optimization
T-102 Height (ft) Diameter (ft) Pressure (psig) Temperature (F) Number of Trays Feed Location Reflux Rate Type of Trays Material of Construction 38 2 5 Top: 83 Bottom: 182 8 4 62 Carbon Steel Sieve Carbon Steel

Feed location of 4 out of 8 trays optimal Large reduction in duties can be seen in figure above
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

22

T-103 Optimization
T-103 Height (ft) Diameter (ft) Pressure (psig) Temperature (F) Number of Trays Feed Location Reflux Rate Type of Trays Material of Construction 42 2.3 6.5 Top: 35 Bottom: 92 10 8 42 Carbon Steel Sieve Carbon Steel

Feed location of 8 out of 10 trays optimal Not middle tray for the -Butylene tower
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

23

Other Tower Equipment

Heat Exchangers:
Type E-105 Floating Head, partial condenser -4.4 141 -128 5/5 E-106 Floating Head, partial condenser -0.63 190 83 4/4 E-107 Floating Head, partial condenser -0.80 113 35 5.3/5.3 E-108 Kettle Reboiler E-109 Kettle Reboiler E-110 Kettle Reboiler

Duty (MMBtu/hr) Area (ft2) Temperature Pressure of Shell/Tube (psig) Number of passes MOC Shell/Tube

0.45 118 61 6.3/6.3

1.8 74.8 182 5.5/5.5

0.04 180 92 6.3/6.3

1-shell/2-tube Stainless Steel/Stainless Steel

1-shell/2-tube Carbon Steel/Carbon Steel P-102 930 4.3 -128 Centrifugal 0.5 Stainless Steel 1 Separation Scheme

1-shell/2-tube Carbon Steel/Carbon Steel P-103 63 6.3 83 Centrifugal 0.7 Carbon Steel 1

Single Pass Carbon Steel/Carbon Steel

Single Pass Carbon Steel/Carbon Steel P-104 32 6.5 35 Centrifugal 0.7 Carbon Steel 1

Single Pass Carbon Steel/Carbon Steel

Pumps:

Flow (lbmol/h) Discharge Pressure (psig) Temperature (F) Driver Type Shaft Power (hp) Material of Construction Number of spares Reaction Scheme

Background

Economics

EHS

Sustainability

Conclusions

24

Design Decisions
Flash Tanks with interstage cooling Distillation tower use T-102 T-103 Partial Condenser Kettle Reboiler HEN Integration Side-product use
Reaction Scheme Separation Scheme

Background

Economics

EHS

Sustainability

Conclusions

25

Design of an Ethylene Production Plant via Ethanol Dehydration

ECONOMIC ANALYSIS

26

Financial Analysis
Quick Overview
Annual Cost of Ethanol: -$138 million Annual Revenue from Ethylene: $130 million

Bare Module Costs: -$5.6 million Annual Utility Costs: -$5.92 million
NPV: -200.58 million

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

27

Economic Feasibility
Production life of 15 years 2 years construction time 60% FCI Year 1, 40% FCI Year 2 Year 1 Start-up: 60% of full production capacity. 350 production days Land cost: $250,000 7-year Modified Accelerated Cost Recovery System (MACRS) Discount rate: 10% Tax rate of 40%
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

28

Cost Estimations
Fixed Capital Investment ($9.53 million)
Grassroots basis Bare Module Costs

Working Capital ($15.28 million)

Non-depreciable amount Raw Material, FCI, Operating Labor

Cost of Manufacturing Per Year - ($186.43 million)

Tertiary Wastewater system FCI, Catalyst Costs, Operating Labor Costs, Utility Costs, Raw Material Costs Catalyst Costs ($50k at $2.20/kg)

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

29

Cost Components - Equipment

Heat Exchanger Fired Heater Pumps Reactors

Towers
Flash Tank

Fired heater accounts for over 64% of total equipment costs & 66.7% of utility costs.
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

30

Profitability Analysis
NPV: -200.58 million
Discounted Cumulative Cash Flow, Current Position
-

10

12

14

16

(50,000,000.00)

Project Value, $

(100,000,000.00)

(150,000,000.00)

(200,000,000.00)

(250,000,000.00)

Project Life, Years

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

31

Profitability Analysis

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

32

Fluctuating Nature - Ethylene

Price of the product can vary from -50% to 20% in a typical analysis
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

33

Fluctuating Nature - Ethanol

Raw material availability and pricing can fluctuate from a dynamic range of -25% to 50%
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

34

Break Even Points: NPV

Price of Ethylene ($/lb) 0.670 Price of Ethanol ($/lb) 0.305 0.300 0.295 0.290 0.285 -63.16 -54.49 -45.82 -37.16 -28.49 0.680 0.690 0.700 0.710

Net Present Value ($, millions) -55.62 -46.95 -38.28 -29.62 -20.95 -48.08 -39.41 -30.74 -22.08 -13.41 -40.54 -31.87 -23.21 -14.54 -5.87 -33.01 -24.34 -15.67 -7.00 1.67

0.280

-19.82

-12.28

-4.74

2.80

10.34

Break even point: $0.283/lb ethanol and $0.695/lb ethylene

Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

35

Cash Flow Diagrams

CFD Scenarios

Ethylene ($/lb)
Current Market 0.61 Price Increase in Ethylene Price Decrease in Ethanol Price Increase in Ethylene and Decrease in Ethanol Prices 0.892

Ethanol ($/lb)
0.35 0.35

NPV
-200.58M +3.019M

Payback Period
N/A 2.9

0.61

0.237

+3.53M

2.8

0.710

0.280

+$2.84M

3.4

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

36

Design of an Ethylene Production Plant via Ethanol Dehydration

EH&S

37

Health and Safety Concerns

Importance of Safety Based on decisions made by administrators Legal and moral responsibility to employees and public EH&S Concerns Daily safety for plant operation Recommend tested pilot scale process Thermal impact jacket to prevent heat buildup from reactor T&P Transportation and storage of chemicals Endothermic reaction to avoid potential runaway

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

38

R-101 P&ID

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

39

T-101 P&ID

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

40

Environmental Considerations
Environmental Compliance - EPA Regulation LDAR Leak Detection And Response MON Miscellaneous Organic chemical NESHAP HON Hazardous Organic chemical NESHAP NESHAP National Emission Standards for Hazardous Air Pollutants Waste facility auditing MSDS Reports Purging Storage

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

41

Design of an Ethylene Production Plant via Ethanol Dehydration

SUSTAINABILITY

42

Corporate Culture
Process Safety Management Plan Avenue for education and understanding of safety needs Comprehensive management and advisory board Emphasis on integrating safe technology and SOPs Monthly meetings to discuss various incidents and share ideas Safety awareness courses for all employees and administrators Preventative first-aid proficiency courses Industrial Recycling Growing global market for scrapping and industrial recycling Bureau of Industrial Recycling (BIR) Possible to attain a higher salvage value for equipment and side products
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

43

Sustainability
Factors to Consider Long term feasibility of operating the plant Role of materials and products Economic, societal and environmental impacts Value proposition for the future Price Sensitivity Selling price of 1 lb ethylene vs purchase price of 1.84 lb ethanol Operate when ethanol price is low, ethylene price high Current prices are not favorable Fluctuations in upstream product prices

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

44

Ethanol Price Trends

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

45

Ethylene Price Trends

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

46

Economic Considerations
Economic Considerations NPV target prices: $0.283/lb ethanol and $0.695/lb ethylene Current prices: $0.35/lb ethanol and $0.61/lb ethylene Decreasing fossil fuel supply leading to increased cracking prices Growing market for alternative fuel sources and more efficient production methods Realistic to expect these prices in the future

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

47

Accessibility
Location Factors Transportation infrastructure and plant accessibility Necessary to be able to access site to build and operate Personnel movement and access to nearby amenities Cost of transportation of raw materials and products Regional bioethanol and ethylene

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

48

Societal Considerations
Societal Considerations Quality of workforce and access to research and development Employee benefits with competitive wages, good morale Accelerated job creation and downstream growth of local economy Improved quality of life with strong community culture

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

49

Environmental Considerations
Environmental Considerations Renewable green bioethanol feedstock Lower carbon emissions Not a finite resource Important to maintain reserves of natural resources Rising crude prices for cracking lead to higher ethylene prices since this is the most common choice of technology Governmental tax and infrastructure benefits

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

50

Design of an Ethylene Production Plant via Ethanol Dehydration

CONCLUSION

51

Final Recommendations
Profitability controlled by volatile fluctuations in ethanol and ethylene prices Self-production of ethylene vs outright purchase Advantages Downstream societal and environmental effects of design Disadvantages High utility and heating costs in addition to changing prices Short term recommendation Not to pursue Long term recommendation Assess market dynamics
Background Reaction Scheme Separation Scheme Economics EHS Sustainability Conclusions

52

Design of an Ethylene Production Plant via Ethanol Dehydration

APPENDIX SLIDES

53

Reaction Data

Table 1: Kinetic Data with Activated Alumina Catalyst

Reaction C2H5OHC2H4 + H2O 2 C2H5OH(C2H5)2O + H2O (C2H5)2O 2C2H4 + H2O C2H5OH C2H4O + H2 2C2H4 C4H8

Aj (mole atm-1 kgcat-1 -1 s ) 5.41 x 106 9.55 x 107 2.79 x 1010 2.78 x 108 1.45 x 107

Ea (kJ mole1 ) 147.7 101.0 135.0 138.4 113.7

kj k1 k2 k3 k4 k5

Rate Law r1 = k1P C2H5OH r2 = k2P 2 C2H5OH r3 = k3P (C2H5)2O r4 = k4P C2H5OH r5 = k5P2 C2H4

54

EH&S
Reactor HAZOP

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

55

EH&S
Tower T-101 HAZOP

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

56

Reactor Summary Tables

Table 1: Process Heater Equipment Summary Table

Type Tube Pressure (psig) Tube Temperature Duty (MJ/hr) Fuel Type Material of Construction

H-101 Fired Heater 2 700 37300 Natural Gas Stainless Steel

Table 2: Reactor Equipment Summary Table

Type Volume (ft3) Operating Temperature (F) Operating Pressure (psia) Pressure Drop (psi) Specifications

R-101 Jacketed Agitated (Isothermal PFR) 1630 720 23 4 Steam Injected

57

Heat Exchanger Summary Table

Table 1: Process Heat Exchangers Equipment Summary Table

Type Duty (MMBtu/hr) Area (ft2) Temperature of Shell/Tube (F) LMTD End Points (F) Pressure of Shell/Tube (psig) Number of passes Material of Construction Shell/Tube

E-101 Floating Head 3.9 599 700/600 130.83 4.3/6.3 1-shell/2-tube Stainless Steel/Stainless Steel

E-102 Floating Head 25.2 1150 105/185 242.39 5/5 1-shell/2-tube Carbon Steel/Carbon Steel

E-103 Floating Head 12.4 3030 110/115 45.21 5/5 1-shell/2-tube Carbon Steel/Carbon Steel

E-104 Floating Head 1.8 224 87/80 89.78 5/5 1-shell/2-tube Stainless Steel/Stainless Steel

58

Separation Equipment Table

Table 1: Flash Tank Equipment Summary Table

Height (ft) Diameter (ft) Orientation Pressure (psig) Temperature (F) Material of Construction

V-101 6.6 2.2 Vertical 4 185 Carbon Steel

V-102 6.6 2.2 Vertical 4 110 Carbon Steel

Table 2: Distillation Tower Equipment Summary Table

Height (ft) Diameter (ft) Pressure (psig) Temperature (F) Number of Trays Feed Location Reflux Rate Type of Trays Material of Construction

T-101 34 1.8 5 Top: -128 Bottom: 61 6 3 325 Stainless Steel Sieve Stainless Steel

T-102 38 2 5 Top: 83 Bottom: 182 8 4 62 Carbon Steel Sieve Carbon Steel

T-103 42 2.3 6.5 Top: 35 Bottom: 92 10 8 42 Carbon Steel Sieve Carbon Steel

59

Tower Summary Table

Table 1: Distillation Tower Heat Exchangers Equipment Summary Table

Type

E-105 Floating Head, partial condenser -4.4

Duty (MMBtu/hr ) Area (ft2) Temperatu re Pressure of Shell/Tube (psig) Number of passes Material of Constructi on Shell/Tube

E-106 Floating Head, partial condenser -0.63

E-107 Floating Head, partial condenser -0.80

E-108 Kettle Reboiler

E-109 Kettle Reboiler

E-110 Kettle Reboiler

0.45

1.8

0.04

141 -128 5/5

190 83 4/4

113 35 5.3/5.3

118 61 6.3/6.3

74.8 182 5.5/5.5

180 92 6.3/6.3

1-shell/2tube Stainless Steel/Stainle ss Steel

1-shell/2tube Carbon Steel/Carbo n Steel

1-shell/2tube Carbon Steel/Carbo n Steel

Single Pass Carbon Steel/Carb on Steel

Single Pass Carbon Steel/Carb on Steel

Single Pass Carbon Steel/Carb on Steel

Table 2: Pumps Equipment Summary Table

Flow (lbmol/h) Discharge Pressure (psig) Temperature (F) Driver Type Shaft Power (hp) Material of Construction Number of spares

P-101 1157 2 77 Centrifugal 0.242 Carbon Steel 1

P-102 930 4.3 -128 Centrifugal 0.5 Stainless Steel 1

P-103 63 6.3 83 Centrifugal 0.7 Carbon Steel 1

P-104 32 6.5 35 Centrifugal 0.7 Carbon Steel 1

60

Reaction Process Steam Table

61

Separation Process Stream Table

62

Distillation Process Stream Table

63

Appendix - CAPCOST

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

64

Appendix Utility Costs

Background

Reaction Scheme

Separation Scheme

Economics

EHS

Sustainability

Conclusions

65