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INTRODUCTION
Isopropyl alcohol (IPA) with its excellent properties is a growing-demand product worldwide.
Common names for it include IPA, rubbing alcohol, dimethyl carbinol, isopropanol, -propanol
and sec-propyl alcohol. IPA (C
!
"
#
$") is a flammable, colorless li%uid with a strong and slightly
pleasant odor. It is completely miscible with water, ethanol, acetone, chloroform, and ben&ene'
melting at -() C and boiling at ( C. It has an ad*antage of being soluble in non polar substances
and e*aporating %uic+ly. ,herefore, it is commonly used as either a sol*ent or a cleaning fluid. It
is *ery inexpensi*e and cost effecti*e which contributes to its widespread usage.-./-#/
In today0s society IPA has many practical uses from paint thinner to rubbing alcohol and has
extensi*e applications in pharmaceutical, pesticide, coatings, daily-use chemical and organic
synthesis sectors. ,he primary usage for IPA is as an industrial sol*ent for many oils, al+aloids,
gums and resins,but it has many more usages. In the stores, rubbing alcohol generally consisting
of #12 isopropanol is sold in order to be used for a *ariety of uses such as cleaning, sterili&ing
s+in or helping to get rid of swimmers ear. As a cleaning agents IPA is used on electronics
de*ices such as contact pins (li+e those on 3$4 cartridges), magnetic tape dec+ and floppy dis+
dri*e heads, the lenses of lasers in optical disc dri*es (e.g. C5, 565) and remo*ing thermal
paste from CP78s. It is also used to clean glass computer monitor screens, and is used by many
music shops to gi*e second-hand or worn records newer loo+ing sheens. It cleans dry-erase
boards *ery well and other unwanted in+ related mar+s. In biology isopropanol can be used in a
strong solution as a preser*ati*e to replace formaldehyde. Another common use for IPA is as an
additi*e in gasoline so that fuel lines don0t free&e in the winter. It is also used in manufacturing
acetone, glycerol and isopropyl acetate. -#/
$n the other side toxicology is a matter fact to be considered for human health. ,here is no ris+
of cancer, ris+ of malformation in an unborn fetus or ris+ of heritable genetic effects. 9ut, s+in
contact o*er a long period of time may cause dermatitis. ,herefore, body care products including
IPA are not ad*iced with respect to a clinical research.-(/-)/
,he total capacity of isopropyl alcohol is around .! million t:a in the world, !#2 in the 7nited
;tates, <2 in Canada, !2 in =atin America, !(2 in >est ?urope, (2 in @apan and A12 in the
Asian-Pacific 3egion. ,he 7nited ;tates, @apan and >est ?urope are also maBor consumers in
the world and the consumption accounts for #12 of the world total. In these countries and
regions isopropyl alcohol is mainly used as sol*ent and in acetone processing and the
consumption in these two fields0 accounts for .1 - #12 of the total. In terms of isopropyl alcohol
A
deri*ati*es, the demand in cleaning agents is ma+ing the most rapid growth and the consumption
in chemical intermediates is also ha*ing a rapid increase. ,he demand in pharmaceuticals,
surfactants and in+s has been stable in the recent years and the demand in coatings and pesticides
has presented a declining trend.-A1/
,here are three commercial routes to IPA are used. ,he indirect hydration of refinery-grade
propylene uses sulphuric acid to form isopropyl sulphate which is then hydrolysed with steam to
form sulphuric acid and IPA. ,hen, the crude IPA is distilled to the desired purity. ,he
disad*antage of this process is being corrosi*e and high energy demanding for acid
reconcentration and a%ueous waste treatment.,he direct hydration of chemical grade ()1-))2)
propylene is a more modern method which a*oids the need for sulphuric acid. ,his process uses
thermally stable polymeric catalyst. ,he third method uses acetone as the starting material unli+e
the first two methods. A *ery small amount of IPA is produced by the hydrogenation of acetone
in the li%uid phase. ,his process is only suitable where excess acetone is a*ailable. In 7;A
indirect hydration is commonly used' whereas in ?urope direct hydration process is more
common. -AA/-A/
,his proBect deals with direct li%uid phase hydration of propylene and water in the presence of a
strong acid solid catalyst for producing high %uality isopropyl alcohol. Cuality of the product,
low capital expenditures and sensiti*ity for en*ironment are ta+en in to consideration while
selecting this type of process. Isopropyl alcohol manufacturing plant is designed with a capacity
of <!,111 tons:year. ChemCA5 program is used to simulate the flow of the process and calculate
the inlet and outlet streams of the units.-AA/
Dirst EProcess ;election and 5escriptionF part of the report tells about fi*e different rele*ant
patents about this manufacturing process and describes them one by one. 9y comparing each of
them with respect to their properties, the patent which has better properties is selected. ,hen
grading of the processes are made according to their properties and units. ,his part lastly
describes the selected process in detail. ,hen, assumptions are implied at the beginning of the
calculation part. ,hen comes the E5iscussionF part which discusses the whole proBect. ,his part
contains the discussion of choice of the process, assumptions, calculations, chemcad and
discussion of the calculated design capacity. =astly the report ends with the EConclusionF part
which implies a general *iew of the proBect with technical information and %ualitati*e results.
P 1.((()
y P -<HH.!.!Hx
M A(!!.A#.HAx - A(<1A(.A(.).A
3
P 1.)(
1.?M11
<.?M1.
(.?M1.
A.?M1#
.?M1#
.?M1#
.?M1#
!.?M1#
!.?M1#
A))1 A)) A))< A)). A))( 111 11 11< 11. 11(
'ear
k
"
3andom ?xpon. (3andom) Poly. (3andom) =og. (3andom) =inear (3andom)
F!"$re 2.6 4odels fit to ! year mo*ing a*erage data
Pr#7e&te5 M#5e*
1.?M11
.?M1#
<.?M1#
..?M1#
(.?M1#
A.?M1(
A.?M1(
A))1 A))H 111 11H 1A1 1AH 11 1H
'ear
k
"
linear exp poly log consumption
F!"$re 2.8 4odels fit to ! year mo*ing a*erage data
(
( )
log
log A
i
Turkey
GDP
GDP
N
=
+
,he 3
*alues for polynomial, exponential, logarithmic and linear models are 1.)(1, 1.((), 1.)H1
and 1.)H1 respecti*ely. 9ecause the 3
<!H(A)1
!1#)).< H1!<H) A<.1)))1
1998 )<#!HH. HH).#(( H##<<.< (..H#
!<.H)HA
#
<<.)(#H
< A.H<)H! !#A(H1< A<1H#1H(
1997 A1.A)1H1 H.<.A<) H#1H)(< ))...
!<##!#
#
<!#H)1.
# AH1#.AH1 <<.!< AH!1#AH!
1996 )!H!1H H<()H< H#)#.)1< <.#<1(
!#!11
H
<#H
) A.#(.1. <#AH..< AA(H1!)(
1995 )1(1.1< <!H.(1#( (A!<((< HA!<
!#(<A
!(<!)<#
. AHAA.<A. .<AA<A. AA!)!<.
1994 )#!A#(1 <.<)(1 !(.1)HA. A#A!AH#
!!)!)(1
#
!HA.<
A<)#!#.! A)(.1A (#H.A<A
1993 <#<)!#. A#)..H
!1#<)!!
) A<11A#1 .H(## (!AHAH)
1992 H1H#!#A A#<(.!)
1A!1<A
< AH)A. .!1(1H
Drom the annual growth of ,ur+ey and J5P *alues of countries (,able A.!), it is calculated how
many years are the economy of each specific country at specific years ahead from ,ur+ey *ia the
e%uationO
)
-A/
LO years a country ahead from ,ur+ey
RO annual growth of ,ur+ey
J5PO Jross 5omestic Product
Drom now on, Jermany is chosen as the sample country and all of the calculations will be shown
according to the data of Jermany.
Dor year 11. for Jermany,
J5P ,ur+eyO )1#! S
J5P JermanyO !A#<< S (,able A.!)
Jrowth rate of ,ur+ey at 11.,R O ..A2 (,able A.)
( )
!A#<<
log
)1#!
A.AHA
log A 1.1.A
N
= =
+
year difference between 11. Jermany and ,ur+ey
,he same calculation is done for each year and each country
Ta)*e 2.- Near difference between de*eloped countries and ,ur+ey
Year 5!22eren&e )et;een 5eve*#%e5 &#$ntr!e an5 T$rke'
Year A$tr!a Fran&e Ger(an' Gree&e Ita*' S%a!n
S;!t<er*an
5
UK
2,,6 !.1.( .1A< A.AHA A#.A.) 1.H.A A).!.! <.AH! .#)
2,,4 A).!#) A(..( A#.(1( A<.!< A#.<<< A..!< 1.!!1 A).A1
2,,3 A..#(H A..H# AH.<## A.!1 AH.!(A A<.1#H A#.H. A...!<
2,,- ..<(. H..) <.HA) A)..A <..H< .<!) #.#< ..1)A
2,,2 1.1<) A).H.( A(.#<( A<.H A(.)A. A#.11H A.( A)..A)
2,,, 1.#H( 1.A!. A).!.# A!.H## A).<!1 A#.A<! .A<H A).#!H
1++= <..A!. <<..H. <!.)< ).1(( <!.!1( !#.1) H1.A.< <<.A!(
1++8 A).A(# A(.H)) A(.A.) A.1#A A(..! AH.<( A.1A! A(.!).
1++6 A.1H) 1.<AA A).))< A!.#. 1.1. A..H(. !.1A) 1.1<
1++4 1.(H< 1.<.H 1.1#! A!.!)# 1.A!. A..H< !.A1< A).(H<
1++- A#.)(! A#.#A) A#.!A) AA.<#! A#.<. A<.1<A 1.H.( A..#<(
1++2 H.1A) <...H <.A) A..H)A !.)<H A).#(1 (.!.H .#H
1++1
A.<.A
H
A.!.!1
!
AH)..H(
AA...
#
AH).)
1
A!.!
1
A)1.1A. AH.!A#
A1
Drom these *alues, the corresponding years of ,ur+ey is calculated with respect to the de*eloped
countries.
Ta)*e 2.3 Corresponding years of ,ur+ey to de*eloped countries
C#rre%#n5!n" 'ear #2 T$rke' t# 5eve*#%e5 &#$ntr!e
Year A$tr!a Fran&e Ger(an' Gree&e Ita*' S%a!n S;!t<er*an5 UK
2,,6 1) 1( 1# 1! 1# 1H 1!1 1)
2,,4 1< 1< 1! 1A) 1 1A 1H 1<
2,,3 1A 11 1A) 1A. 1A) 1A( 1 1A
2,,- 1) 1) 1( 1 1( 1H 1!A 1)
2,,2 1 1 1A 1A. 1A 1A) 1! 1
2,,, 1A 11 1A) 1A< 1A) 1A# 1 11
1++= 1<< 1<! 1<A 1# 1<A 1!H 1<( 1<
1++8 1A. 1A. 1AH 11) 1AH 1A 1A( 1AH
1++6 1A# 1A. 1A. 11) 1A. 1A! 1A) 1A.
1++4 1A. 1AH 1AH 11( 1AH 1A 1A( 1AH
1++- 1AA 1AA 1A1 11< 1A1 11# 1A< 1A1
1++2 1A# 1A# 1A. 11) 1A. 1A 11 1AH
,his result means that ,ur+ish economy is supposed to reach to the le*el of 11. Jerman
economy at 1#.
Low the population and IPA consumption per capita of each countries should be ta+en into
consideration.
In order to calculate 1# population of ,ur+ey , 11H year is ta+en as basis.
Population of ,ur+ey at 11H O #!)111
Population growth of ,ur+ey at 11HO A.!2 -A./
( ) 1# 11H
#!)111 (A 1.1A!) )(<1#(1.
+ =
In order to calculate 1# J5P of ,ur+ey , 11H year is ta+en as basis.
J5P of ,ur+ey at 11H O (<1( S
J5P growth of ,ur+ey at 11HO #.<2
( ) 1# 11H
(1<( (A 1.1#<) <1(#.
+ = S
,he consumption per capita for Jermany'
H.#<1A11
1..()
()!111
=
S
AA
,he consumption per capita for ,ur+ey at 1#'
( ) ( )
,1#
,11.
: :
Turkey
Turkey Germany
Germany
GDP
consumption capita consumption capita
GDP
=
<1(#.
1..() 1.(((
!A#<<
=
S
In order to find the capacity of ,ur+ey at 1# consumption per capita is multiplied by predicted
population of ,ur+ey at 1#'
1.((( )(<1#(1. (#!#A!)A.A# =
Gg:year
Power purchasing parity (ppp) has to be ta+en into consideration in order to reach reasonable
data.
PPP
,ur+ey, 11H
P 1.(1 -A./
PPP
Jermany, 11H
P 1.)A
,he capacity of ,ur+ey at 1# considering power purchasing parity'
1.(
(#!#A!)A.A# ( ) #.((.(<.#A
1.)A
=
Gg:year
Ta)*e 2.4 Calculation of capacity with respect to Jermany
GER
P#%>T$r>2$t$r
e
GDP>T$r>2$t$re &#n?&a%!ta>GR &#n?&a%!ta>TR Ca%a&!t'>e/&>%%% Ca%a&!t'
2,,6 )(<1#(1H <1(#..H< 1..() 1.((( (#!#A!)A.A# #.((.(<.#A
2,,4 )!1!))( ))(1.111 1..!. 1..!. H)A(.(H.A). H1(1#..)#!
2,,3 ()AA#< !.!<.A.H 1..AH 1.H1H <<)#1!HH.<() !)H#!)A.(!1
2,,- )((#.<.H <A).<.A(. 1.#!( A.A AA1)#(.(.!#( )#.A.H<.A#
2,,2 )1H)..A1 H(#)... 1...H 1..!< H#<..)#).A( H1H#1)<A.#A
2,,, (())<)A! !<<).H<< 1..)H 1..! H.<1.!A.(H <)<)A#H..11.
1++= AA(A!1)1< AAA).)! 1..)( !.!1( !)1#))A.<) !<!)1!#.#!(
1++8 (<)#).H A#!##.< 1..)H 1.H. <<!.)H))..H! !)1<H<#..)H
1++6 (H11!!< A(<!1.H(H 1.#1# 1.H(# <))(AH!.11. <!)(!#<1.<H
1++4 (<A))#! A#H#.)!. 1.!<< 1.#< !1#.<AA.!HH 1!1#<A.))!
1++- #)A#(#AA A)A.A(( 1.H(! 1.!H) (!)(H.##< <)(H.(...(A
1++2 (H!<).) A(.1).!.< 1..H 1.H(. H11!<H..1H <<1!1<A<..1H
A
,his calculation is done for each year and each country.(,able A.#, A.(, A.), A.A1, A.AA, A.A,
A.A!).,hen they are plotted together.
1.?M11
H.?M1#
A.?M1(
.?M1(
.?M1(
!.?M1(
!.?M1(
A))1 A))H 111 11H 1A1 1AH 11 1H 1!1 1!H 1<1
'ear
k"?'ear
expo model
linear
poly
log
Austria
Drance
Jermany
Jreece
Italy
;pain
;wit&erland
?ngland
,ur+ey
;eriesA!
F!"$re 2.= Consumption ProBections of IPA 3esins in ,ur+ey Including ?uropean Countries
1.?M11
H.?M1#
A.?M1(
.?M1(
A))1 A))H 111 11H 1A1 1AH 11 1H 1!1 1!H 1<1
'ear
k"?'ear
expo model
linear
poly
log
Austria
Drance
Jermany
Jreece
Italy
;pain
;wit&erland
?ngland
,ur+ey
;eriesA!
F!"$re 2.+ Consumption ProBections of IPA 3esins in ,ur+ey Including ?uropean Countries
A!
Dinal consumption data for ,ur+ey are plotted in Digure .). As can be seen in the figure, ,he
logarithmic model fits best as a consumption proBection of IPA in ,ur+ey. Drom this model, the
capacity for the IPA production process in 1H was determined as <!,111 tons:year.
-. PROCESS SELECTION AND DESCRIPTION
-.1. Re*evant (et@#5 an5 %r#&ee
Isopropyl alcohol (IPA) is produced by combining water and propylene. ,here are three
processes in order to obtain it. ,wo of them use propylene as the starting material. ,hese are'
indirect hydration which is +nown as sulfuric acid process and direct hydration with a
heterogeneous polymeric acid catalyst. In the third process acetone is used as the starting
material. =ow %uality propylene is used during indirect hydration and it is commonly used in
7.;.A.' whereas direct hydration re%uires high %uality propylene and is commonly used in
?urope. -A/
Indirect hydration is used in order to produce IPA by using sulfuric acid. $lefins are hydrated to
alcohols by a two stage process. In the first step, olefins are esterified with sulfuric acid to al+yl
sulfates. In the second step these al+yl sulfates are hydroly&ed. ,he whole reaction ta+es place at
low temperature. ;ince this process is corrosi*e and demands high energy for acid
reconcentration and a%ueous waste treatment, it is not preferred in this proBect as the production
process.
5irect hydration process uses thermally stable polymeric catalyst. ;ince its product %uality
impro*ement is high, its capital expenditures are low and it is less en*ironmentally sensiti*e' it is
chosen as the production process.-A(/ ;imple reaction mechanism of direct hydration process is
shown below and it is an exothermic reactionO
propylene water isopropanol +
! . !
1 ( ) C H H CH OH OH +
A<
-.2. C#(%ar!#n #2 t@e %r#&ee )ae5 #n env!r#n(enta*A te&@n!&a* an5 e&#n#(!&a* a%e&t
-.2.1 D!!#%r#%'* Et@er Rever!#n !n I#%r#%an#* Pr#5$&t!#n
Patent n#B US 3A-42A+34
Date #2 %atentB O&t. 4A 1+=2
F!"$re -.1 5iisopropyl ?ther 3e*ersions in Isopropanol Production
,he aim of this in*ention is to produce isopropyl alcohol and blending into gasoline by hydration
of propylene. Digure !.A represents the flow diagram of this process. In this diagram some
amount of produced 5IP? is recycled' it is good to reuse some components, not to discharge
them. And there are no en*ironmental effects of the byproducts and units used.
In this patent, there is sufficient information about hydration reaction type, which is a down
flow, tric+le bed configuration using ion exchange catalyst in acid form, and dimensions used in
AH
production of water, IPA and 5IP?. In the hydration stage, the percent propylene con*ersion is
preferably maintained about .#2 which is a high number but below #H2 that is stated in the
selected patent. ,he temperature for the hydration reactor is A<!-A#)
1
C , which is reasonable.
Also high production of 5IP? as a byproduct results in an extra unit called re*ersion and so a
larger scale of plant is needed that increases the cost. After re*ersion unit, propylene, IPA and
water are separated and propylene is recycled into the hydration unit.
Dor the separation part, the flow sheet and the description are not clear and well defined. It is
stated that after hydration part a distillation tower, to separate IPA and water from 5IP?, and a
second one to separate water from IPA which is an a&eotropic distillation. >hile in the selected
patent, an a&eotropic distillation is not needed. In addition there exists limited information about
the distillation column in this patent, but in the selected one the reflux ratio, number of plates and
dimensions of the column are gi*en.
Additionally, it can be obser*ed that the data as molar flow rates and compositions at the inlet
and outlet streams of all the units are missing in this patent, while clearly well defined in the
selected one.
All in all, since this patent is lac+ of a lot of necessary information and re%uires more units, it is
not satisfactory to design an efficient plant using it.
-.2.2 Pr#&e 2#r Pr#5$&t!#n #2 A*&#@#*
Patent n#B US 6A=--A3=-
Date #2 %atentB De&. 21A 2,,3
A.
F!"$re -.2 A ;chematic 5iagram of a Catalytic 5istillation Column "a*ing two Catalyst 9eds
for the Catalytic 5istillation Process
,his process is related to production of alcohols *ia catalytic hydration of an olefin to the
corresponding alcohol and dehydration of an a&eotropic mixture including a first alcohol and
water to produce the first alcohol in a substantially anhydrous state. ,here is more than one flow
diagram in this patent, so one of them was chosen as a representati*e.
,his in*ention was formed as an alternati*e to older con*entional ones because of their
complexity and loss of efficiency. 4olar flow rates of all streams are a*ailable generally and
there are a temperature range between #1C K A(1C and a pressure range between 1.H4Pa K
.H4Pa, which are not so high, but suitable for such a process. Purity of products is nearly
A112.
And there are no en*ironmental effects of end-products and units used.
7p to now, there is no problem with this patent, but there are also some disad*antages of it
which can not be ignored during a process design. Dirst, a catalytic distillation column is used in
the flow diagram for both cataly&ing reactions and distillation process. ,his column operates as a
reactor and as a distillation column, so operating conditions of this unit should be chosen
specifically from a narrow range in order to obtain high con*ersion and design of this unit can
A#
not be performed in Chemcad simulation, which is the maBor reason for not choosing it. ;ince a
reactor and a distillation column can not be designed as a single unit in this simulation program,
this in*ention was not chosen. As another disad*antage, although the purity of end-products is
nearly A112 pure, con*ersion of main reactions ta+ing place in catalytic distillation column
changes between H-!H2, which can be accepted as a low con*ersion range.
In *arious flow diagrams of the patent, generally, fixed bed reactor was used as reactor type and
an acidic cation exchange resin catalyst was used as catalyst type. 9ut different feed streams
were used such as propene, isobutene and -methyl--butene in different flow diagrams. ?nd
products are not isopropyl alcohol in all processes. ,his patent is used for description of general
production of alcohols, not for a specific alcohol production such as isopropyl alcohol which will
be the desired product of the plant.
>hen ta+ing these reasons into considerations, this process is not the most rational one. ,hese
disad*antages are enough not to choose this process.
-.2.- Pr#&e 2#r t@e %r#5$&t!#n #2 !#%r#%'* a*&#@#*
Patent n#B US 3A86,A2,-
Date #2 %atentB A$". 1=A 1+=8
A(
F!"$re -.- Dlow ;heet of the ;ump Process of the In*ention
>ith the help of this patent, isopropyl alcohol can be produced by reacting a propene-containing
hydrocarbon stream with water in the presence of a strongly acidic, solid hydration catalyst.
As it can be seen in Digure !.A, !. and !.!, there are many reactors which are interconnected.
,hroughout these reactors, the total con*ersion le*el reaches up to ))2. $n the other hand, the
same con*ersion le*el can be reached with a single reactor in the selected patent.
,he temperature and pressure range during the process is between A1
1
C - 11
1
C and (1bar K
A1 bar respecti*ely. ,he range is close to the selected patent' howe*er there are more data in the
description of the selected patent.
,here is not any information about dimensions of the units. Although there are many data
corresponding to each example, it does not seem enough for the whole design of the
plant.,hrough the reactor &ones, water and olefin flows counter currently instead of parallel
flow. ,he main ad*antages of this fact are that high olefin concentration in the feed is not
necessary, olefin con*ersion is *ery high and selecti*ity of IPA is *ery high.
Drom these facts, one may conclude that, the patent <,#.1,1! is a useful one but it does not
include all of the data set re%uired for a plant design. Durthermore, the writing style of the patent
is *ery hard to understand. It is a handicap to select it.
A)
-.2.3 Pr#&e 2#r %r#5$&!n" !#%r#%'* a*&#@#* 0e*e&te5 %atent 2#r t@! 5e!"n %r#7e&t1
Patent n#B US 4A86-A6+-
Date #2 %atentB C$n. +A 1++=
F!"$re -.3 Dlow 5iagram of an Isopropyl Alcohol Production Process
,his patent relates to production of isopropyl alcohol by direct li%uid phase hydration of
propylene and water. ,he feed enters to a Bac+eted reactor with a strong acid cation exchange
solid catalyst. ,he reaction product discharged from the top of the reactor is sent to the
distillation column where the unreacted propylene is separated and recycled continuously to the
reactor as a feed. ,he li%uid phase drawn out from the upper portion of the reactor is fed to the
extractor where propane is fed to the system as an extractor agent. >hile the li%uid drawn out
from the bottom of the reactor is recycled to the reactor, the extract is drawn out from the top and
sent to the li%uid-li%uid separation column which results in the final desired product, isopropyl
alcohol.
In the process' the data a*ailability is *ery high. ,he dimensions of the reactor, the distillation
column and the extractor are gi*en details including the inner diameters and the heights. ,he
molar flow rates of the feed, inlet and outlet streams and the detailed stream compositions are
well defined. ,he temperature and pressure range of each stream is gi*en, so mass and energy
balances can be calculated. In addition, the features of distillation column such as reflux ratio,
1
plate number and the feed plate are gi*en which ma+es the distillation column easily designed.
,he ;:D ratio of the extraction is also gi*en in the patent.
$ne of the most important characteristic of a process is the purity of the product. In this process
the end product is ()2 by weight isopropyl alcohol, A12 water and about A2 di-isopropyl ether.
,his states that the desired product, isopropyl alcohol, has high purity and the unwanted by-
product di-isopropyl ether is produced at *ery low amounts. ,he high purity of the product
which is approximately )12 is highly acceptable. ,he high selecti*ity of isopropyl alcohol
which is approximately ))2, also ma+es this process ad*antageous. ,his can only be achie*ed
by controlling by-production of isopropyl ether during the reaction with the re%uirement of at
least ten times in moles as much water as that of the raw material propylene to be supplied into
an inlet of the reactor.
,he process of li%uid phase direct hydration of propylene using a solid catalyst results in a high
con*ersion rate of the reactor as #H2, if the reaction conditions are selected ade%uately. ,he
formation of the isopropyl alcohol is more fa*orable at low temperatures and high pressures. ,he
operation temperature and pressure gi*en in the patent are approximately AH1
o
C and (1 atm
respecti*ely. ,he temperature is stated according to the thermal resistance of the selected
catalyst. A %uite high pressure is re%uired to dissol*e raw material propylene into the li%uid
phase. ,herefore, the gi*en temperature and the pressure is preferable.
,he flow sheet, including the units and the streams is clear and well defined. =ow complexity of
the flow sheet ma+es this process fa*orable.
-.- Gra5!n" #2 t@e %r#&ee
A
Ta)*e -.1 ?*aluation of each process described in pre*ious section
COMPARED
PROPERTIES
Se&t!#n -.2.1
Patent n#B
US 3A-42A+34
Se&t!#n -.2.2
Patent n#B
US 6A=--A3=-
Se&t!#n -.2.-
Patent n#B
US 3A86,A2,-
Se&t!#n -.2.3
Patent n#B
US 4A86-A6+-
Ra; (ater!a*
propylene,
water
not clarified
propene,
water,
hydrocarbon
mixture
propylene,
propane,
water
En5 %r#5$&t
isopropyl
alcohol
different types
of alcohol
isopropyl
alcohol
isopropyl
alcohol
C#nver!#n D .#2 H-!H2 )(2 #H2
Rea&t#r T'%e tric+le bed fixed bed
sump or
tric+le Dixed bed
Cata*'t t'%e
Acidic ion
exchange
resin
acidic cation
exchange
resin
sulfanic acid
cation
exchange
acidic cation
exchange
resin
P$r!t' #2
%r#5$&t
not clarified ))2 ))2
()2
Env!r#n(enta*
E22e&t
no ha&ardous
effects
no ha&ardous
effects
no ha&ardous
effects
no ha&ardous
effects
O%erat!n"
C#n5!t!#n
a*ailable a*ailable a*ailable a*ailable
Data
Ava!*a)!*!t'D
moderate moderate low high
Ener"'
C#n$(%t!#n
not clarified not clarified not clarified low
C#(%*e/!t' #2
t@e %r#&e
moderate low complex low
E&#n#(!&
a%e&tD
expensi*e
no sufficient
data
expensi*e cost effecti*e
RESULT POOR VERY POOR
MODERAT
E
GOOD
Ta)*e -.2 Cualitati*e e*aluation of each process
COMPARED
PROPERTIES
Se&t!#n -.2.1
Patent n#B
US 3A-42A+34
Se&t!#n -.2.2
Patent n#B
US 6A=--A3=-
Se&t!#n -.2.-
Patent n#B
US 3A86,A2,-
Se&t!#n -.2.3
Patent n#B
US 4A86-A6+-
Ra; (ater!a*
M - M M
En5 %r#5$&t M - M M
C#nver!#n M - M M
Rea&t#r T'%e M M M M
Cata*'t t'%e M M M M
P$r!t' #2
%r#5$&t
- M M M
Env!r#n(enta*
E22e&t
M M M M
O%erat!n"
C#n5!t!#n
M M M M
Data
Ava!*a)!*!t'
- - - M
Ener"'
C#n$(%t!#n
- - - M
C#(%*e/!t' #2
t@e %r#&e
- M - M
E&#n#(!&
a%e&t
- - - M
Ta)*e -.- Cuantitati*e e*aluation of each process
!
COMPARED
PROPERTIES
Se&t!#n -.2.1
Patent n#B
US 3A-42A+34
Se&t!#n -.2.2
Patent n#B
US 6A=--A3=-
Se&t!#n -.2.-
Patent n#B
US 3A86,A2,-
Se&t!#n -.2.3
Patent n#B
US 4A86-A6+-
Ra; (ater!a*
031 A1 ) A1 A1
En5 %r#5$&t
01,1 A1 # A1 A1
C#nver!#n
0=1 ) ! A1 )
Rea&t#r T'%e
041 A1 A1 A1 A1
Cata*'t t'%e
061 A1 A1 A1 A1
P$r!t' #2
%r#5$&t
081 H A1 A1 A1
Env!r#n(enta*
E22e&t
061 A1 A1 A1 A1
O%erat!n"
C#n5!t!#n
061 A1 A1 A1 A1
Data
Ava!*a)!*!t'
01,1 H H ! A1
Ener"'
C#n$(%t!#n
061 H H H (
C#(%*e/!t' #2
t@e %r#&e
0+1 H # ! (
E&#n#(!&
a%e&t
0=1 ! ! ! #
Total 626 537 571 728
-.3 De&r!%t!#n #2 t@e Pr#&e
<
101
107
108 109
110
114
115
116
118
119
117
121
K101
E101
E102
M101
M102
R101
V101
V102
E103
K103
M103
K104
V103
E104
V104
123
124
125
103
112
113
102
104
P101
120
122
K102
111
106
105
A101
F!"$re -.4 Dlow diagram of the selected process
-.3.1 Genera* De&r!%t!#n #2 t@e Pr#&e
,he aim of the process is to con*ert the mixture of propylene and water to isopropyl alcohol.
Digure !.# presents the flow sheet of this process. A1A is a propylene-propane mixture feed pipe
and A1 is water feed pipe. GA1A, GA1, GA1! and GA1< are compressors used to compress feed
streams before the reaction ta+es place. Additionally a pump and a *al*e are used to transport
li%uids. ?A1A, ?A1! and ?A1< are coolers and ?A1 is a heater. 4A1A, 4A1 and 4A1! are
mixers used in the process where mixing is re%uired. ;treams AA<-A1) are recycled propylene
circulation pipes. ;tream AA is recycled water circulation pipe. GA1 is the expander used in the
flow sheet. 3A1A is the reactor within reaction of isopropyl alcohol production ta+es place. 6A1A
is a component separator and it is used to separate output streams of the reactor. In
stoichiometric reactor model of Chemcad there is only one exit stream, so one stream is di*ided
into two different ones by using this unit. 6A1 is a distillation unit. 6A1! is an extraction
column with an extraction agent feed, namely stream AA#. 6A1< is a simple gas-li%uid
component separator.
-.3.2 Deta!*e5 De&r!%t!#n #2 t@e Pr#&e an5 Un!t
H
Deed A1A ha*ing a composition of ).2 propylene and <2 propane at a molar flow rate (H(H<
mol:h enters to the system at )(G and Aatm. Deed A1 as water enters to the system at a flow
rate )A<H! mol:h under the same conditions. 9oth feeds are compressed from A atm to (1 atm in
a compressor and a pump GA1A and PA1A, respecti*ely. ,hey operate with an efficiency of 1.(,
which is an ideal *alue for centrifugal compressors. ;tream A1! enters to cooler ?A1A at .A<G
and (1 atm and lea*es the cooler at <!G and (1 atm. ;tream A1< enters ?A1 at )(G and
(1atm and lea*es it at <!G and (1 atm, too. In 4A1A, both feed streams A1. and A1#, recycled
water stream AA - with a composition of A!#<#!mol:h water and AHH1Hmol:h propane - from
extraction column and recycled propylene stream A1) K with a composition of AAH#mol:h
propane and#<)(mol:h propylene - are mixed before they are sent through the reactor 3A1A.
?ntering pressures of these streams are set to (1 atm which is the re%uired pressure for the
reaction.
;tream AA1 enters reactor 3A1A with a composition of A<.!)Hmol:h water, 11AAmol:h
propane and A1)))!mol:h propylene at <1.G and (1 atm. 3A1A is a pac+ed bed reactor with a
catalyst type ha*ing a strong acid cation exchange resin in its tubes. ,he reaction which is ta+en
place in the reactor is named as direct hydration of propylene and its simple reaction mechanism
is shown belowO
propylene water isopropanol +
! . !
1 ( ) C H H CH OH OH +
;ince dissol*ing raw material propylene into the li%uid phase where hydration reaction is carried
out re%uires high pressure and low temperature, reaction pressure of 3A1A is +ept at (1atm and
approximately <1!G during the reaction. $*erall reaction is ta+en place with a con*ersion of
#H2. 3A1A operates adiabatically. ?xit stream AAA consists of both li%uid and gaseous phases in
it because of selection of stoichiometric reactor, and then they are di*ided into two streamsO AA
as gaseous phase and AAH as li%uid phase with the desired product. ;tream AAA enters separator
6A1A at <!1G and (1 atm with a composition of A!(A<!Amol:h water, 11mol:h propane,
(<)Hmol:h isopropanol and #<)(mol:h propylene.
7ncon*erted propylene and a little amount of propane are separated with stream AA with a
composition of #<)(mol:h propylene and #1HHmol:h propane at <(G and (1atm, it is sent to
distillation column 6A1. 9efore being sent to 6A1 its pressure is lowered from (1atm to !1atm
which is re%uired pressure for distillation by using *al*e AA1A. In 6A1 unreacted propylene is
.
collected by means of distillation and recycled to the reactor 3A1A as stream AA< at <!G and
!1atm. ;tream AA< has a composition of #<)(mol:h propylene and AAH#mol:h propane. It has a
composition which has a similar ratio to the feed stream ().2 propylene and <2 propane). It is
again compressed from !1atm to (1atm by using compressor GA1! before being mixed with feed
streams and the other recycled stream. ;tream AA< lea*es the compressor GA1! as stream A1) at
HA.G and (1atm with the same composition of stream AA<.
;tream AAH as the li%uid phase product of 3A1A is the reacted phase of the reaction and has a
composition of A!(A<!mol:h water, A).#mol:h propane and (<)Hmol:h isopropanol at <(G
and (1atm. 9efore it is sent to the extraction column 6A1!, it is cooled in the cooler ?A1! from
<(G to !!G and lea*es ?A1! as stream AA.. Actual desired temperature for the extraction is
<1!G, but it is satisfied after mixing with the extraction agent stream in 4A1!.
;tream AA# is propane feed as the extraction agent at a molar flow rate of #)H.<<mol:h at )(G
and Aatm, and it is compressed from Aatm to (1atm in compressor GA1< in order to be reached
optimum pressure for the extraction. ,hen, stream AA. as the li%uid phase of the reacted mixture
and stream AA( as the extraction agent are mixed in 4A1! before being fed to the extraction
column. Actually, these streams enter the column separately, their entrance points are different,
but in stoichiometric units there is only one entrance for these type separators, so they are fed to
the column together in Chemcad simulation. ;tream AA) is the mixture of them and at <1!G and
(1atm. ,he lower the extraction temperature is, the more selecti*ely the alcohol can be extracted.
Pressure has also great influence on extracted amount and extraction selecti*ity. "igh pressures
are preferable for more efficient extractions. ,he extraction column 6A1! is a counter-current
multistage contact type extractor. =i%uid-li%uid extraction is carried out. In 6A1!, isopropanol is
exracted by using propane from the li%uid phase mixture or raffinate at <1!G and (1atm.
,he maBor amount of the raffinate mainly consisting of water is recycled from the bottom of
6A1! to the reactor3A1A along stream AA with a composition of A!#<#!mol:h water and
AHH1Hmol:h propane at <1!G and (1atm. ;tream A1 is the extracted phase' it contains propane
as the extraction agent, isopropyl alcohol as the desired product and a little amount of water with
molar flow rates of #)!A1.mol:h, (<)Hmol:h and ()H(mol:h, respecti*ely. Pressure of stream
A1 is reduced in AA1A from (1atm to !1 atm in order to separate a%ueous isopropyl alcohol
solution from the extracted phase. Low, stream A has a pressure of !1 atm which is suitable for
separation of product and extraction agent. It is cooled to !H!G from <1!G by using cooler ?A1<.
After stream A! lea*es the cooler, it is ready for separation and sent to the gas-li%uid separator
#
6A1<. ;ince the conditions for separation of propane from isopropyl alcohol a%ueous solution is
satisfied by reducing its temperature and pressure, in 6A1< they are separated from each other.
;tream A< contains propane as the only component with a molar flow rate of #)!A1.mol:h.
Dinally, stream AH contains isopropyl alcohol as the final desired product with a composition of
)12 isopropyl alcohol and A12 water at !H!G and !1atm. (,heir molar flow rates are
(<)Hmol:h and ()H(mol:h, respecti*ely.)
;tream A< as collected extraction agent is not recycled to the extraction column, because it is
needed to be re-compressed to the extraction pressure. In this process the solution is separated
from the extracted phase li%uefied by cooling, the pressure is still high. It is more ad*antageous
than recycling of extraction agent in terms of power re%uired.
3. CALCULATIONS
(
3.1 A$(%t!#n
Compressors, expanders and pump used in the process operate with an efficiency of 1.(.
,he reactor where direct hydration reaction ta+es place operates adiabatically.
,he reactor type is chosen as pac+ed bed reactor.
;ide reaction is ignored which results in a little amount of diisopropyl ether (5IP?) as
A2 of the final product.
,he main reaction ta+es place with a con*ersion of 1.#H in the reactor.
Composition of final product is ta+en as )12 IPA and A12 >ater instead of ()2 IPA,
2A1 >ater and 2A 5IP?.-/
3.2 Ener"' Ea*an&e ar#$n5 t@e @eat e/&@an"er
Dirst of all composition, pressure, temperature, and mole numbers of the inlet and outlet streams
of the heat exchangers should be made.
Drom the thermodynamic point of *iew, enthalpy can be calculated li+e that
-!/ (<.A)
;ince the process is at constant pressure
-!/ (<.)
Dor mechanically re*ersible, constant pressure, closed-system processes and for the transfer of
heat in steady-flow exchangers where T?
G
and T?
P
are negligible and >P1, ,hen
-!/ (<.!)
Dor ideal gas mixtures
)
-!/ (<.<)
;o then, A, 9, C, 5 constants for the mixture are found in order to use in e%uation shown below.
A for the mixture is obtained from the multiplication of the A *alues of each component with the
molar ratio. ,hen A, 9, C, 5 *alues are inserted to the e%uation below.
(<.H)
3.- Ener"' F C#(%#nent Ea*an&e ar#$n5 t@e C#(%#nent Se%arat#r
3.-.1 C#(%#nent Ea*an&e ar#$n5 t@e C#(%#nent Se%arat#r
;ince there is no reaction in the separator, mole numbers of the components in the inlet stream
and at the exit are conser*ed. ;o instead of mass balance, component balance is enough. Dor the
component balance the e%uation below is usedO
(<..)
3.-.2 Ener"' Ea*an&e ar#$n5 t@e C#(%#nent Se%arat#r
C
p
*alues of each component at the inlet and outlet streams at gi*en temperatures are found
according to the e%uation belowO
-!/ (<.#)
,hen the C
p
*alue of the mixtures at inlet and outlet streams is found according to the e%uation
belowO
-!/ (<.()
After that, for finding the enthalpy of the inlet and outlet streams, total number of moles, C
p
of
the mixture and temperature of the mixture multiplied and enthalpies of the streams are found.
!1
"PnUC
p
U, (<.))
Low, the e%uation below is used for the calculation of the enthalpy difference between the
streams.
T"P "
inlet
- "
outlet A
-"
outlet
(<.A1)
3.3 Ener"' Ea*an&e ar#$n5 C#(%re#r
3.3.1 P#;er Ca*&$*at!#n
Compressor is an adiabatic compressor with an efficiency of 1.(.
C
p
calculation of the inlet stream is done according to the e%uation belowO
-!/ (<.AA)
"eat capacity ratio becomes
-</ (<.A)
If VP1.(, for an adiabatic compression
-</ (<.A!)
Power is calculated by the rele*ant e%uationO
U> -</ (<.A<)
3.3.2 Te(%erat$re Ca*&$*at!#n at t@e &#(%re#r #$t*et
Around the compressor, the enthalpy difference is e%ual to the wor+ done on the system.
(<.AH)
!A
(<.A.)
>here (<.A#)
9y inserting e%uation <.. into e%uation <.H and ma+ing iterations, the outlet temperature can be
found.
3.4 Ener"' Ea*an&e ar#$n5 t@e M!/er
3.4.1 Te(%erat$re &a*&$*at!#n at t@e (!/er #$t*et
Dor the ideal case enthalpy difference around the mixer is e%ual to 1.
(<.A()
A, 9, C, 5 *alues for e%uation abo*e are found from the multiplication of A, 9, C, 5 *alues of
each component with corresponding molar ratios. 4olar ratios for the inlet and outlet streams are
multiplied by (-) and (M), respecti*ely.
After inserting A, 9, C, 5, and 3 *alues in the e%uation abo*e, outlet temperature can be found
by trial and error.
3.6 Ener"' an5 C#(%#nent Ea*an&e ar#$n5 t@e Rea&t#r
3.6.1 C#(%#nent Ea*an&e ar#$n5 t@e Rea&t#r
$ne reaction occurs in the reactor with a con*ersion of 1.#H which is gi*en below. -AH/
C
!
"
.
M "
$ C
!
"
#
$"
!
,he sum of the feed rate to reactor and the change within reactor should be e%ual to the effluent
rate from reactor which can be expressed as the e%uation belowO
Ta)*e 3.1 Component balance around reactor
Fee5 rate t# rea&t#r C@an"e ;!t@!n Rea&t#r E22*$ent Rate 2r#( Rea&t#r
S%e&!e 0(#*?@1 0(#*?@1 0(#*?@1
C
-
H
6
D
1 " C
. !
(-)D
1 " C
. !
(1.#H) D
1 " C
. !
(A-1.#H)
H
2
O D
$1 "
(-)D
1 " C
. !
(1.#H) D
$1 "
- D
1 " C
. !
(1.#H)
C
-
H
8
OH 1 (M)D
1 " C
. !
(1.#H) D
1 " C
. !
(AM1.#H)
3.6.2 Ener"' Ea*an&e ar#$n5 t@e Rea&t#r
Dor adiabatic operation
1
1
- ( )/
i
i
Rxn R i P P R
i P P
X H T C T X C T
T
C X C
+ +
=
+
-H/ (<.A))
Dor the reactions occurring in the reactor, enthalpy at reference temperature ()( G) is
calculated. T" of reaction at )( G are calculated.
1 1 1
1 1 1
i i i
i
A A A
F C y
F C y
= = =
-H/ (<.1)
*alues for all components are found by di*iding their flow rates to limiting reactant.
b c d
A C
a a a
+ +
Dor the reaction abo*e, o*erall change in the heat capacity per mole of A reacted can be found
asO
!!
D C A
p P P P P
d c b
C C C C C
a a a
= + (<.AA)
1
i
i P
C T
,
P
X C T
r ,
i
i P
C
*alues are found and substituted into e%uation <.A) and , is found.
4. DISCUSSION
4.1 Pr#&e Se*e&t!#n
5irect hydration of propylene is chosen as the process in this proBect. 3easons of this choice are
impro*ement of its products %uality more than other two processes, its lower capital spending (it
means less acid resistant e%uipment is needed) and its en*ironmental sensiti*ity. >hereas direct
hydration has such ad*antages which are important when considering en*ironmental and
economic aspects' indirect hydration has some disad*antages. It is a corrosi*e process. ;ince
sulfuric acid is used, it is needed to reconcentrate the acid which demands high energy. A%ueous
waste treatment is another high energy demanding operation. All of these ma+e indirect
hydration more expensi*e and explain why it is not chosen. As a third process, production of
IPA from acetone is ta+en into account. 9ut this process method is not widely used and no
sufficient data was found about it. 9esides, IPA is used in production of acetone instead of usage
of acetone for production of IPA in most cases. As a result, it is decided that direct hydration of
propylene is the most suitable process in order to produce IPA among them.
4.2 Patent Se*e&t!#n F Gra5!n"
Dour different processes are e*aluated for the production of IPA. ,hese are diisopropyl ether
re*ersion in isopropanol production, process for production of alcohols, process for the
production of isopropyl alcohol and finally - the chosen one K process for producing isopropyl
alcohol. ,here are se*eral criteria which are determined by group members and important in
selection of a process. ,hese are con*ersion, data a*ailability, economic aspects as the most
important ones' and complexity of the process, raw materials, end products, reactor and catalyst
types, purity of products, en*ironmental effects, operating conditions and energy consumption.
!<
,hree different e*aluation methods are made. Dirst general characteristics of each process were
gi*en according to these criteria, and then they were e*aluated whether they affect the process
positi*ely or not. Dinally each criterion was ran+ed according to their importance' by multiplying
them their grade o*er A1, final total grades of them were found. In each e*aluation the selected
patent became the most suitable one. According to the results, the selected patent has higher data
a*ailability and is cost effecti*e. Its con*ersion is also high enough. =ow energy consumption in
this process has a positi*e influence on both its economy and en*ironmental effects. It is
important to ha*e a non-complex flow sheet. ,he selected one satisfies users with a lower
complex process when comparing with others. 9asing on these reasons, it can be easily
concluded that process for producing isopropyl alcohol is the most appropriate patent among
them.
4.- Pr#5$&t!#n Ca%a&!t'
,he design capacity is based on the data that is ta+en from 5I?, ,ur+ish Institute of ;tatistics,
7nited Lations 5ata and ,3 Prime 4inistry ;tate Planning $rgani&ation. IPA is not produced in
,ur+ey, so the consumption of this chemical is the difference between the imports and exports.
9ecause of the inconsistent data within the years from A))A to 11( as can be obser*ed in Digure
.!, it is approximated using both ! and H-year mo*ing a*erage in order to obtain a better fit.
>hen the ! year mo*ing a*erage data points, Digure .<, are compared with the H year mo*ing
ones, Digure .H, the points of latter figure seem more consistent with each other. "owe*er that
results in unsatisfactory data points to fit a model. ,hus, the ! year mo*ing a*erage data are
more suitable in order to estimate production capacity.
Polynomial, exponential, logarithmic and linear models are fit to the points and the models are
proBected to the future. ,he 3