PRESENTATION ON THE DESIGN OF A PLANT FOR

THE PRODUCTION OF 48,000 kg/day OF METHYL

ETHYL KETONE BY VAPOUR PHASE CATALYTIC
DEHYDROGENATION OF 2-BUTANOL

BY

AGBANA TARE JEREMIAH

11CF011899
MEMBER OF TEAM HEBRON
SUPERVISOR: ENGR. S. SANNI
31st MARCH, 2015
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OUTLINE

INTRODUCTION

PROCESS DESCRIPTION

PROCESS FLOW DIAGRAM

WORKDONE

CONTRIBUTIONS

CONCLUSION

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INTRODUCTION

The production of methyl ethyl ketone (MEK) by vapour phase catalytic

dehydrogenation of 2-butanol involves the addition of heat at temperatures between
400-500 0C to 2-butanol using zinc oxide-brass catalyst to produce MEK and a by-
product, hydrogen.

CH3CH2CHOHCH3 CH3CH2COCH3 + H2
(2- Butanol) (Methyl ethyl ketone) (Hydrogen)

The plant was designed to produce 48,000 kg/day of MEK of 99.9% purity using 2-
butanol of 100% purity as raw material..

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PROCESS DESCRIPTION

Pre-heating of cold feed of 2-butanol to the reactor entry temperature.

Dissociation reaction of 2-butanol in the presence of zinc oxide-brass catalyst.

Partial condensation of reaction products.

Absorption of remaining uncondensed MEK and alcohol using water as absorbent.

Extraction of MEK and 2-butanol from the aqueous phase (water) using
tricholoroethane as solvent.

Extraction of tricholoroethane based on difference in volatility.

Separation of MEK and 2-butanol based on difference in volatility.

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PROCESS FLOW DIAGRAM

1 Cold feed preheater, 2 Thermo-syphon vaporizer, 3 Knockout drum, 4 First

superheater, 5 Compressor, 6 Second superheater, 7 Reactor, 8a Partial condenser, 8b
Condenser, 9 Absorber, 10 Solvent extraction column, 11 Solvent recovery column, 12
Distillation column, 13 Cooler, 14 MEK storage tank, 15 Reboiler 5
WORKDONE

Material balance (previous works)

Energy balance (previous works)

Process flow diagram design (previous works)

Chemical Engineering design of items of equipment.

Mechanical design of process equipment.

Design of the plant P&ID.

Costing and project evaluation.

Safety considerations for process equipment.

HAZOP analyses of process equipment.

MEK plant location and site selection.

Process simulation on Aspen HYSYS. 6

CONTRIBUTIONS

Design of the process control for the reactor.

HAZOP analyses on the reactor.

Preparation of P&ID using AutoCAD.

Coordination of team Hebron.

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CONTRIBUTIONS
PROCESS CONTROL FOR THE REACTOR

Where;
FT Flowmeter with visual display
FC Flow controller INSTRUMENTATION
FV Flow control valve OBJECTIVES
TT Thermocouple with visual display To maintain;
TC Temperature controller Reactor feed flowrate,
TV Temperature control valve
Reaction product temperature,
PIT Gauge pressure sensor
Reactor pressure at desired levels.
PC Pressure controller
PV Pressure control valve
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CONTRIBUTIONS
HAZOP ANALYSES ON THE REACTOR

HAZOP (Hazard and Operability studies) is a structured and systematic examination of a planned or existing

process or operation in order to identify and evaluate problems that may represent risks to personnel or

equipment or prevent efficient operation.

The 3 basic guide words that were used for HAZOP study: NO, MORE and LESS.

7 steps of HAZOP analyses:

STEP 1 General intention of operation.

STEP 2 Select line. 2

STEP 3 Intention of line.

STEP 4 Apply guide word.

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STEP 5 Possible causes.

STEP 6 Consequences.

STEP 7 Hazard.
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CONTRIBUTIONS
HAZOP ANALYSES ON THE REACTOR
GENERAL INTENTION: To supply 55034.5kg/day of MEK and hydrogen to the vaporizer.

LINE 1: REACTANT INLET

INTENTION: To supply the reactant, 2 butanol to the reactor.

APPLY THE GUIDE WORD: NO APPLY THE GUIDE WORD: MORE

Possible deviation: No 2 butanol flow. Possible deviation: More 2 butanol flow.

Possible causes: (i) Blockage in the feed pipe, (ii) valve
failure (mechanical or power.
Consequences: (i) No hot fluid flow to the vaporizer, (ii) No
formation of MEK and hydrogen, (iii) Pressure build-up
around the blockage.
Possible causes: Inlet valve stuck open.
Consequences: (i) The temperature of the hotter fluid in the
vaporizer will be lower than required, (ii) High liquid
content in the knockout drum, (iii) Leakage around the
reactor inlet/outlet pipe.

Hazard: (i) Eruption of the pipe resulting in death or injury Hazard: (i) Skin contact with leaking 2 butanol from the
of workers and other living organisms around the burst pipe reactor can cause skin irritation and permeation, (ii) Eye
at the point of rupture and afterwards until steam flow is contact also causes irritation.
stopped, (ii) Loss of productivity

SOLUTION : Safety has to be engineered into the reactor line 1 by application of process control
and instrumentation.
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CHALLENGES ENCOUNTERED

Lack of basic AutoCAD knowledge.

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CONCLUSION

The HAZOP studies and process control and instrumentation go together since the
HAZOP study gives the designer insight of possible faults or deviation from operating
conditions. Thus, the HAZOP study serves as a guide to a designer during the process of
safety engineering.

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THANK YOU

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