CPB30004 Process Dynamics and Control Mini Project: Production of acetic acid

CPB30004-Process Dynamics and Control M in i Pr o j e c t - Fu l l R ep o r t ( Pr o g r e s s Re p o r t 3)

Malaysian Institute of Chemical and Bioengineering Technology

PROCESS DYNMICS ! CONTRO" CPB #$$$% MINI PRO&ECT

PROD'CTION O( CETIC CID

"ecture)s Name* +ulhafi, -rou. "ecture* "O/0T$1 Student)s Name

ID Num2er

Syed Syed miru mirull Shah Shaha2 a2 23 Syed Syed M3(i M3(i4r 4ry y

551/# 551/#// //5%5 5%56 6

Siti 7a8ar Mohamed

551/#//%115

Na2ilah 2inti Nordin

551/#//%$/9

nis I,,ati 2inti Mohd :elana

551/#//%$11

TB"E O( CONTENT

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CPB30004-Process Dynamics and Control M in i Pr o j e c t - Fu l l R ep o r t ( Pr o g r e s s Re p o r t 3) Contents

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Front Page#############################i $a%le $a%le o& Content##########################'ii Capter ! *+ecuti,e ummary####################''! Capter " .ntroduction########################" "'0 Project Description#####################" "'! Properties and /ses####################''3 Capter 3 Progress Report !#####################' 3'0 1,er,ie2######################### 3'! Control 1%jecti,es#####################' Capter 4 Progress Report "#################### 4'0 1,er,ie2 4'! P.D Diagram 4'" Process Description (2it process measurement and &eed%ac control) Capter  Progress Report 3#################### '0 1,er,ie2 '! Control trategies Re&erences###########################















CPB30004-Process Dynamics and Control Mini Project- Full Report (Progress Report 3)

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C7PTER / E;EC'TI
Production o& acetic acid is one o& te major demanding in te 2orld2ide' $o produce acetic acid se,eral &actors need to %e consider during te selection o& te process suc as demand o& te acetic acid5 te cost5 te 6uality o& acetic acid5 and sa&ety consideration' $e target production annually is a%out 400 000 tonnes (M$) per year o& acetic acid' $ere are %asically se,eral process to produce acetic acid' 7&ter considering te &actors and and oter oter cons consid ider erat atio ion5 n5 te te sele select cted ed proce process ss is met metano anoll car% car%ony onyla lati tion' on' $ $ee met metano anoll car%onylation uses metanol to produce acetic acid' $us5 te ra2 material in tis process is metanol and car%on dio+ide' $e cost &or te %ot ra2 material8 metanol and car%on dio+ide are RM "99'0:metric ton and RM "99;'!:metric ton respecti,ely' 7cetic acid is 2idely used in te 2orld' Basically5 acetic acid is used as a sol,ent to man y industrial process especially producing acetate ester' enerally5 *urope is te main pioneer in demands o& acetic acid 2it te top tree country are Belgium5 Belgium5 >ermany >ermany and ?eterlands ?eterlands'' $e second demanding continent is 7sia8 .ndia5 $ailand and Malaysia' $e tird in place &alls to te ?ort 7merica &ollo2ed %y out 7merica5 7&rica and last continent is 1ceania (@4'=M)' Roug estimation annual pro&it &or 400 000 tonnes per annum pro&it per year &or ra2 materials cost and production o& acetic acid is RM ! "4 00 ;='99'
















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C7PTER 1 INTROD'CTION

"'! Pro8ect Descri2tion .t is %elie,ed tat acetic acid 2as &irst &ound %y Aa%ir .%n ermany cemist in !=94 using clorination o& car%on disul&ide'
"'" Pro.erties nd 'ses
















7ppearance

Colourless or crystal

mell

Pungent smell

$aste

our

Pase

olid5 li6uid

Density

!'04;g:cm35li6uid

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!'" g:cm35 solid olu%ility

olu%le in 2ater

Boiling Point

!!='!GC

Melting Point

!' GC

Flas Point

43GC

Hiscosity

!'"" mPaIs at "GC

7cidity (pa)

4'= at "GC

*ntalpy &ormation

J&<(l )K )K L4=3' A:mol

Hapour pressure

!' Pa at "0 GC

Based on ?ational .nstitute &or 1ccupational a&ety and















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acetate 2ere it can &orm poly,inyl acetate tat al2ays %eing used in late+ paints and paper or 2ood glues' Nastly5 it is also %eing applied in educational &or e+ample to understand te preparation o& %u&&er solution or p< 2ere %asic cemistry study &or ig scool and uni,ersity students in Malaysia' 7cetic acid actually colorless li6uid tat as smell lie pungent and taste lie ,inegar' $ere are so many used o& acetic acid in maing product' .t just lie in &or te+tile printing5 dyes and potograpic' $e acidic corrosi,e is te principle segment o& ,inegar yet at lo2 &i+ations tat are innocuous to people' 7cidic corrosi,e can go troug te eart &rom release and emanations &rom ,entures' $e smoldering o& plastics or elastic5 and &umes ,apor &rom ,eicles may lie2ise discarge acidic corrosi,e into nature' 7t te point 2en discarged into soil it dissipates into te air 2ere it is separated actually %y da yligt' $ese $ese cemica cemicals ls are te main main part part o& te li6ui li6uid d ,inegar ,inegar and armle armless ss %ecaus %ecausee its its concentration is ,ery lo2' .t can also %e piped into ri,ers or drainage related to te en,ironment i& not re6uired %y te industries' Besides5 acetic acid can %e generated troug te %urning o& ru%%er5 plastic and smoe &rom ,eicles' 7cetic acid 2ill also %rea do2n %y sunligt naturally 2en te sed to te ground' $us5 te en,ironmental conse6uences are not to %e dangerous to pu%lic' Breating steam 2it more 6uantity and also ig concentration o& acetic acid can cause irritation to te eyes and nose5 eadace and con&usion and are liely to e+perience ealt pro%lems as a result o& te ig e+posure o& acetic acid 2ile at 2orplace' Drin 2it a large num%er o& acetic acid 2ic can cause mout and troat come injured %y %urn5 a%dominal pain and diarrea' pill ig concentrations on te sin can cause %urns and e+posure to te eye may cause pain5 tears and increased sensiti,ity to ligt' Cildren e+posed to more concentrate o& acetic acid are e+pected to so2 same e&&ects on te adults and e,en cildren are easy to get te impression again and again 6uicly' $ere are &e2 data on te e&&ect o& acetic acid on te %a%y cild during pregnancy5 altoug no e&&ect on te cild or de,eloping &etus a,e %een reported' .t also can cause loss o& contents' ?o data eiter acetic acid to cause cancer in umans' 7cetic 7cetic acid tecnology tecnology is pro%a%l pro%a%ly y te mos mostt di,ers di,ersee in all major major indust industria riall organi organicc


















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production tecnology is dominant5 d ominant5 ten glo%al capacity capa city demand is accounting accoun ting &or o,er  and migt %e increase' $e main production process &or acetic acid is %asically etanol 2ill a,e an aero%ic &ermen &ermentat tation ion to produce produce tat tat acetic acetic acid' acid' *tano *tanoll is &rom &rom cataly catalytic ticall ally y deydro deydrogena genated ted and o+idied to acetaldeyde5 2ic is &urter o+idied to acetic acid' $ere are some types o& production process tat &ounded' Belo2 are te list o& te production process Metanol car%onylation Ni6uid pase o+idation o& %utane 1+idation o& acetaldeyde Manu&acturing acetic acid %y partial o+idation o& etane Manu&acturing acetic acid %y o+idation o& napta Manu&acturing acetic acid %y &ermentation o& ydrocar%ons  ydrocar%ons 7cet 7cetic ic acid acid prod produc uces es as %y produ product ct &rom &rom poly, poly,iny inyll alco alcoo oll and and cell cellul ulos osee acet acetat atee • • • • • • •

manu&acturing

C7PTER # PRO-RESS REPORT / #3$ O=er=ie>

.n tis capter5 te &i,e control o%jecti,es in terms o& production speci&ications5 economical regulations5 sa&ety5 operational constraint and economy are determined and related


















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Metyl iodide iodide &ormed ,ia te reaction o& metanol metanol and ydrogen iodide during te te process o& metanol car%onylation' Major rodium catalyst species present is OR(C1)"."-' Metyl .odide adds o+idati,ely to rodium species to &orm rodium-metyl comple+' $is rodium-metyl comple+ 2ill undergo rapid cange 2ic metyl 2ill %e si&ted to neig%oring car%onyl group and a&ter su%se6uent addition o& C15 te rodium comple+ 2ill %e loced into acyl &orm' Reducti,e elimination elimination o& acyl species and reaction 2it 2ater ten ten can occur to li%erate te original rodium dicar%onyl diiodide comple+ to &orm acetic acid and ydrogen iodide5 <.' Qen te 2ater content is ig (= 2t') te rate determining step in process is te o+idati,e addition o& metyl iodide to te rodium center' c enter'
ide reaction represent a loss o& selecti,ity respect to te te C1 ra2 material' $e gaseous %y product dilute C1 present in te reactor5 tus lo2ered te partial pressure' Propionic 7cid 7cid is te major li6uid %y-product tat &orm &rom te car%onylation o& etanol 2ic is present as impurity in metanol &eed' $e car%onylation car%onylation process is carried out in te te stirred stirred tan tan reactor on continuous %asis' Ni6uid


















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*n,ironmental e&&ects depend on te concentration and duration duration o& e+posure to to acetic acetic acid' .n ig concentrations it can %e arm&ul' Qen entering te en,ironment5 acetic acid can %e trans&erred as a ,apor and is solu%le in 2ater and degrades rapidly to armless su%stances in te en,ironment' Concentrated acetic acid is corrosi,e and attacs many metals &orming &lamma%le or e+plosi,e gases' .t can also attac some so me &orms o& plastic5 ru%%er and coatings' .t is a corrosi,e su%stance' ii3 Effluent Effluentss from from a .lant .lant ? >ithin >ithin the the limits limits

$e allo2a%le allo2a%le amount o& acetic acid concentration in te e&&luent sould %e %ased on speci&ic site &lo2 conditions5 as appro,ed ap pro,ed %y (*P75 "009)' $e ma+imum acetic acid discarge limit in te e&&luent is at ! ppm' 7ccording to te Protection o& ensiti,e 76uatic 1rganisms5 green algae is one o& te most sensiti,e a6uatic organisms to acetic acid5 2it dose at 0 o& te population pop ulation test (0'!= mg:N) and a no o%ser,a%le e&&ects concentration o& 0'!" mg:N5 %ased on la%oratory test' $o %e consistent 2it te / *P7 ris assessment policy &or acute e+posure5 a target ris 6uotient (or margin o& sa&ety) o& " is needed' $us5 te target acetic acid concentration o& 0'0; ppm 2as calculated to protect te most sensiti,e organisms organisms in te recei,ing 2ater %ody' $is ,alue5 coupled 2it te dilution &actor %ased on te recei,ing &lo25 determines te target residual acetic acid concentrations at te out&lo2' o ut&lo2'

Percentile Minimum

Dilution Factor

7cetic acid *&&luent Discarge Nimit (ppm)


















P a g e  =

0t



4 ';4

90t

!"

!!'3

9t

"04

!='4

=0t

349

3!'"

;0t

! ;"

! 43

;t

4 40

 =0

Limits Resulting in a Concentration of 0.09 ppm PAA in the Receiving ater !od". #Per the $igor%&  !

Higor1+ Higor1 + QQ$.. T Qaste2ater Qaste2at er Disin&ec Disin &ection tion $ecnolog $ecno logy y

p u%licly o2ned treatment 2ors (P1$Q) 2itin te Ta2le / indicates tat &i&ty percent o& te pu%licly /5 te allo2a%le acetic acid residual at te out&all in e+cess is "'3 mg:N or iger' $e study demonstrated %y te discarged o& acetic acid into in to te recei,ing 2ater %ody dissipates 2itin relati,ely sort distances5 2itin tens o& meters do2nstream o& te discarge point in all cases' $us5 due to decomposition and dilution o& acetic acid concentrations drop steeply once entering te recei,ing stream' .n conclusion5 setting a site-speci&ic5 dilution-&actor-2eigted acetic acid residual %alances te protection o& te most sensiti,e a6uatic species 2it te a%ility to meet target micro%ial patogen reduction' .n addition5 te rapid decomposition o& acetic acid leads to a lac o& persistence in te en,ironment5 in&luenced %y te acetic acid &ormation 2it non-arm&ul


















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as a distincti,e sour taste and pungent smell' 7ltoug 7ltoug it is classi&ied as a 2ea acid5 acid5 concentrated acetic acid is corrosi,e and can attac te sin' .n term o& o & sa&ety5 it it is including &or te e6uipment and personnel' .n term o& personnel /3 Safety Safety handl handling ing of cet cetic ic cid cid

Qen andling acetic acid5 ne,er add 2ater to tis cemical and al2ays eep acetic acid a2ay &rom sources o& eat5 spars or &lame' uita%le u ita%le respiratory e6uipment must %e 2ear i& andling acetic acid in an area tat isnUt 2ell-,entilated' .t is recommended to use glo,es5 splas goggles5 syntetic apron and ,apor , apor respirator (i& needed) (MDonline5 "0!4)'

/3 Pro.er Pro.er 7ealth 7ealth Care Care for cetic cetic cid cid [email protected] [email protected]

*+posure to acetic acid can pose serious aards to ealt' $is cemical is dangerous 2en it comes in contact 2it eiter te sin or eyes' .n any instance o& acetic acid e+posure5 it is important to see elp &rom a medical pro&essional rigt a2ay to elp pre,ent damaging ealt e&&ects' 7s 7s e+ample5 i& contact 2it sin5 immediately &lus sin 2it 2ater &or at least ! minutes and remo,e contaminated cloting' Co,er te irritated sin 2it an emollient' .n case o& serious sin contact5 contac t5 2as using a disin&ectant soap' ee out medical attention as soon as possi%le' ?e+t5 2en contact 2it eyes5 e yes5 remo,e contact lenses rigt a2ay i& present' .mmediately &lus eyes 2it plenty o & 2ater &or no




















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.n term o& e6uipment /3 Safet Safety y handl handlin ing g >ith >ith rea react ctor or

.nstall and operate te e6uipment 2itin suita%le %arricade5 i& re6uired5 using appropriate sa&ety accessories and operating in &ull compliance 2it local sa&ety codes and rules' $e re6uirements &or %arricades di&&er so 2idely tat eac sould %e designed and %uilt in order to protect against te potential aards inerent in eac installation' 7ltoug tis pro%lem can arise 2en eating any &luid5 it is particularly dangerous 2en 2oring 2it 2ater &or acetic acid' 7t temperatures up to "00 0C5 it is passing te %oiling point o& acetic acid5 ence te %arrier cosen8 concrete5 %ric or steel5 must %ear te eat to a,oid e+plosion in reactor (P7RR5 (P7RR5 n'd)'

13 Ma@imu Ma@imum m Pressur Pressuree and Te Tem.eratur m.eraturee

$e ma+imum pressure and temperature at 2ic any reactor or pressure ,essel can %e used 2ill depend upon te design o& te ,essel and te materials used in its


















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#3/3% O.erational Constraints

Based on ?ational ?ational .nstitute .nstitute &or 1ccupational a&ety and

















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$ese cemicals are te te main main part o& te li6uid ,inegar and armless armless %ecause its its concentration is ,ery lo2' .t can also %e piped into ri,ers or drainage related to te en,ironment i& not re6uired %y te industries' Besides5 acetic acid can %e generated troug te %urning o& ru%%er5 plastic and smoe &rom ,eicles' 7cetic acid 2ill also %rea do2n %y sunligt naturally 2en te sed to te ground' Basically5 metanol car%onylation is one o& te process 2ic undergo se,eral upgradations' Firstly5 Firstly5 is te Mosanto process 2ic %egin 2en Mosanto Company introduced te rodium or iodine catalyst system &or tis process in !;90' $is process generally operates at lo2er pressure8 30 to 0 atmosperes and temperature8 !0GC to "00GC 2it te output o& acetic acid is appro+imately around 300 million pounds per year (Rot5 !;9)' Aones5 ("000) stated tat BP Cemicals &ound a ne2 tecnology &or metanol car%onylation and claimed it a,e lo2er production costs in !;;' $e ne2 &ound process is ten called Cati,a process 2ic uses an iridium as catalyst' $e iridium catalyst %asically produces !'" million tonnes per year and as iger acti,ity compared 2it te rodium process' >enerally5 >ene rally5 iridium catalyst can produce lesser %y product tan rodium catalyst' Ciyoda and /1P a,e impro,ed te metanol


















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precipitation and acie,e ig reaction rates5 lug 2ater concentrations in e+cess o& !0 2t' are desira%le' $ese restrictions place a limit on plant producti,ity and increase operating c osts since te distillation section o& te plant as to remo,e all te 2ater &rom te acetic acid product &or recycling to te reactor' $e num%er o& limiting conditions &or sa&e operation may %e large5 e,en &or a lo2 po2er researc reactor' For tis reason te limiting conditions sould %e grouped %y topic' 7n e+ample o& one suc grouping is as &ollo2s !' Fuel5 Fuel5 &uel &uel eleme elements nts and ass assem%l em%lies ies88 "' 1perating 1perating conditi conditions ons 2ic 2ic are tempera temperature ture and pressur pressuree 3' Fuel andl andling ing and and &eed &eed o& &res &res and and spent spent &uel &uel88 4' Reactor Reactor core core con&ig con&igurat uration ion88 ' Reacti, Reacti,ity ity and and reacti,i reacti,ity ty control control system systems8 s8


















P a g e  !4

#3/3%31 (eed Tan4 an4

Feed tan is su%ject to ,arious operational constraints tat mae it ard to &ill tans to te top' torage tans are commonly di,ided into &eed tans5 2ic recei,e te metanol acetic acid5 and carging tans5 2ic &eed metanol into te atmosperic distillation units Feed tans recei,e te acetic acid ,ia a pipeline or pumped in' Metanol must normally %e allo2ed to stay in te &eed tan &or a minimum o& "4 ours to allo2 any an y 2ater mi+ed 2it te acetic acid' .n general5 &eed tans cannot recei,e metanol &rom te pipeline and trans&er acetic acid to te carging tans at te same time' Most tans 2ill contain a mi+ o& di&&erent metanol &rom di&&erent sources and added to te tan at a t di&&erent times5 and trac te a,erage composition o& metanol in te tan' Qen a tan is discarged it cannot %e emptied completely5 co mpletely5 and te remaining acetic acid5 no2n as te eelE5 is mi+ed 2it te ne+t metanol parcel added'




















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o& '' $e *uropean and ?ort 7merican 7merican marets so2s a ealty gro2t 2it a demand %elo2 te a,erage maret gro2t (PR? ?e2s Qire5 Qire5 "0!9)' $e maret maret o& acetic acid 2as in&luenced in&luenced %y te application application o& acetic acid to produce ,inyl acetate monomer5 puri&ied tereptalic acid5 acetate ac etate esters5 acetic anydride5 an ydride5 and oters' Hinyl acetate monomer (H7M) (H7M) 2as te largest application segment &or te maret5 2ic taes a%out 3"'0 o& te glo%al acetic acid consumption in "0!' $o manu&acture H7M H7M as pro&ited o,er o, er /D "5000'0 million 2it consumption more tan  million ton in "0! %ecause H7M H7M is ,ery demanding in te adesi,e and sealant industry' 7cetic acid also can %e used to produce p roduce acetate esters' .t is one o& te strongest gro2t in te maret' $is is in&luenced %y te gro2ing demand


















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cooing as 2ell as ,inegar' Hinegar Hinegar consists o& 4 -!=  %y mass' .n te &uture5 tere 2ill al2ays ne2 tecnology created tat used acetic acid as te main component' $e use o& acetic acid 2ill increase and so does te demand' $e maret o& acetic acid as gro2n a lot since te past &e2 years and it is estimated to gro2 at a considera%le pace in te ne+t &i,e years' $is is dri,en %y te gro2ing demand o& te 2orld2ide as it is use to produce product tat consumer used on daily %asis' $o %e concluded5 acetic acid is one o& te most demanding product in te 2orld' Qit te gro2ing nations5 tey all 2anted to produce teir o2n product %ecause tey see o2 tey can


















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CPB30004-Process Dynamics and Control M i n i Pr o j e ct - Fu l l Re p o r t (P r o g r e s s Re po r t 3)

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%31 Process Descri.tion A>ith .rocess measurement and feed2ac4 control %313/ -eneral Process Descri.tion

$is process o& metanol car%onylation is te lo2 pressure metanol car%onylation trans&ormed te maret %ecause o& lo2er cost ra2 materials5 gentler5 lo2er cost operating conditions and iger yields' Reaction temperatures 2ere !0 T "00oC and te reaction 2as conducted at 3'3 T ' MPa (33 T  atm)' Metanol Car%onylation is te pre&erred route e,en or te industrial manu&acture o& acetic acid and old to te account o& 0 o& te 2orld capacity o& acetic acid' Metanol car%onylation can produce up to ; yield o& acetic acid' $e cost o& ra2



















CPB30004-Process Dynamics and Control Mini Project- Full Report (Progress Report 3) %3131 Process Descri.tion Descri.tion A>ith feed2ac4 control MET7NO" IN"ET <"
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&ET0STIRRED RECTOR

.n te jet-stirred reactor5 R!0!5 te reaction occurred 2ere te catalyst used is .ridium 2ic metanol is reacted 2it car%on mono+ide and is con,erted to unreacted metanol5


















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$e operating pressure is set to pressure controller5 PC3!! at te monitor' $en PC3!! recei,es te signals &rom &lo2 transducer5 F!3" ten it send te signals to &lo2 controller5 con troller5


















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temperature transducer5 $43! 2ere $43! do te split range o& current' $en5 te components are entering te reactor to %e reacted again in te main &eed stream 2it pure metanol inlet' Nastly5 at second outlet stream te product is acetic ac etic acid5 iridium and 2ater 2it mass &lo2 rate


















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%e &lo2 troug pump and ten troug te control ,al,e' During tis transition5 te &lo2 o& product cemical &rom R!0" 2ill %e controlled entirely %y electrical signal' $e $e mo,ement 2ill %e controlled %y present o& pressure controller (PC3!3)5 pressure transmitter transmitter (P$3"35 &lo2























































































































































CPB30004 Process Dynamics and Control Mini Project: Production of acetic acid

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