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ChE 308 - Chemical Process Analysis Sessional

HYSYS SIMULATION PROJECT

100 MTPD HYDROGEN PEROXIDE (50%) 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.

DEFINITION OF THE PLANT

NG from TITAS Gas◦ Methane > 96 % (V/V)◦ Calorific Value > 1000 Btu◦ Pressure > 240 kPa◦ Temperature about 5-15 oC

Air Water

SPECIFICATION OF RAW MATERIALS

H2O2 specification:

H2O2 content 50% Free acid (as H2SO4) 0.040% max. Non-volatile matter 0.080% max. Stability 97.0% min. Freezing point -52.2°C Boiling point 113.8°C Density 1191 kg/m3

SPECIFICATION OF PRODUCT

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.

PROCESS SELECTION

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/ft2

required piling is used. Corrosive tendency: Non Corrosive

DESIGN BASIS

Climatic condition

Dry bulb temperature (maximum) 35 oC (summer) Dry bulb temperature (maximum) 26 oC (winter)

Wet bulb temperature (maximum) 29 oC (summer) Wet bulb temperature (maximum) 22 oC (winter)

DESIGN BASIS (Contd.)

Meteorological condition

Average monthly Temperature 35oC (max.) Average Temperature 30oC Average annual rainfall 2850 mm Wind flow

Direction = South to NorthVelocity = 52 mile/h

DESIGN BASIS (Contd.)

Utility Electric Power

◦ Voltage 380/220 V◦ Frequency 50 Hz◦ Phase 3 phases

Cooling Water Inlet Outlet

Temperature < 30 oC 38 oCPressure 0.5 MPa 0.2 MPaTurbidity ≤ 50 mg/lChlorine < 5 ppm

PH 6.5 – 8

DESIGN BASIS (Contd.)

Four main stages involved:

1. Hydrogen Generation ( Reformer)

2. Hydrogenation

3. Oxidation

4. Extraction and Purification

PROCESS INVOLVED

A. Reformer: CH4+H2O = CO+3H2 - Q

CO + H2O = CO2+H2 + Q

B. Hydrogenation And Oxidation tower:

REACTIONS INVOLVED

PROCESS BLOCK DIAGRAM

REFORMERREFORMERPRESSURE

SWINGADSORBER

PRESSURE SWING

ADSORBERHYDROGENATION

TOWER

HYDROGENATION TOWER

OXYDATIONTOWER

OXYDATIONTOWER

EXTRACTIONTOWER

EXTRACTIONTOWER

SEPARATORSEPARATOR

DSVDSV

PURIFICATIONTOWER

PURIFICATIONTOWER

H2O2

STORAGETANK

H2O2

STORAGETANK

Tail Gas

SEPARATOR

SEPARATOR

NG

Steam Tall Gas

Water

WSMake

Up

DRYING TOWER

Air

Tail Gas

Water

WS STORAGE

TANK

PROCESS FLOW DIAGRAM

Natural Gas Knock Out Drum Feed Gas Compressor Desulfurization Vessel 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

EQUIPMENT LIST

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

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

EQUIPMENT LIST (Contd.)

THANK YOU