National University of Singapore

Department of Chemical and Biomolecular Engineering

CN4121
Design Project
Production of Drying Oil and Acetic Acid from Castor Oil
Interim Report
Team 03
Ong Zhi Yang
Thong Zhiwei
Chew San Lee
Gani Zhi Hao, Terry
Chew Jia Mei
He Songhua
Cai Jiashen

A0002815U
A0067339W
U083614X
A0004495H
A0070251W
A0072631M
A0071998J

Acetylation Reactor
Separation of Acetylation Reactor Products
Furnace
Drying Oil Reactor
Steam Generators
Separation of ACO from Acetic Acid & Drying Oil
Separation of Acetic Anhydride & Acetic Acid

Introduction
The team was tasked with the design of a plant that produces 15,000 tonnes/year of 97
wt% drying oil with 99.7 wt% acetic acid. The plant will acetylate pure castor oil with the use
of acetic anhydride, followed by a dehydration reaction to generate drying oil. Acetic acid
would be produced in both the acetylation and dehydration reactions.
Process Overview

CN4121: Design Project Interim Report

Team 03

As shown in the process flow diagram in Appendix A, castor oil and excess acetic
anhydride will be mixed and pre-heated before entering the acetylation reactor R-801. R-801,
an adiabatic plug-flow reactor, produces acetylated castor oil (ACO) and acetic acid. ACO is
separated from the reaction product mixture at the bottoms of distillation column C-801. The
light component of C-801is then fed into C-802, where acetic acid forms the light component
and acetic anhydride, the heavy component, is recycled back into the acetylation reactor.
ACO is fed into the drying oil reactor R-802, where a dehydration reaction takes
place. R-802 is housed within a furnace due to the high temperature required for reaction. The
reactor outlet contains unreacted ACO, products acetic acid and drying oil, as well as gum, a
side-product. Gum is extracted via a gum filter. Distillation column C-803 removes ACO as
the heavy component and recycles ACO back into the drying oil reactor. The remaining
products, acetic acid and drying oil, are separated in unit C-804, producing the drying oil
stream. The two acetic acid streams are then merged to produce the final acetic acid stream.
Team Milestones
Date
31/01/1
3

31/01/1
3

07/02/0
3

14/02/1
3

Milestones
Decision on general placement of units in plant
Placement of unit 7 (separation of acetic anhydride and acetic acid) was
discussed and 2 possible designs were evaluated.
Team placed unit 7 after the separation of acetylation reactor products.
Hypothetical component modeling in HYSYS completed
Methods of modeling castor oil, ACO and drying oil were explored
A vapor-liquid equilibrium estimation method was considered as it
enabled the modeling of the full triglyceride structure of castor oil.
Vapor-liquid model was eventually rejected in favor of single-stranded
modeling as suggested by department due to inconsistencies in HYSYS
modeling of vapor-liquid model.
Completion of HYSYS PFD
Convergence of parameters in HYSYS PFD was achieved.
Optimization of individual components commenced.
Preliminary cost estimations
Cost of raw materials (castor oil, acetic anhydride) and products (drying
oil, acetic acid) estimated based on recent market prices.
Cost of operating utilities in Singapore explored.
Capital cost of process units estimated

Section Milestones
Section
Acetylation reactor

Milestones
Optimized recycle ratio and sizing to achieve 100% acetylation via an
adiabatic PFR based on experimentally derived reaction kinetics.
1

CN4121: Design Project Interim Report

Separation of
acetylation reactor
products

Furnace

Drying oil reactor

Steam generators

Separation of ACO
from acetic acid and
drying oil
Separation of acetic
anhydride and acetic
acid

Team 03

Various separation processes were explored. Vacuum distillation

deemed necessary to meet target specifications. Preliminary
distillation column pressures, temperatures and reflux ratio
determined by shortcut calculations. Limiting temperatures for water
condenser (<49oC ) and HPS reboiler (<250 oC) were identified.
Identified plant sections that required heating from furnace: the feed
stream to the drying oil reactor, the drying oil reactor, which will be
integrated into the furnace, as well as the feed stream to acetylation
reactor. Furnace computations established for iterative purposes.
Optimized recycle ratio and PFR sizing to achieve target
specifications.
Identified kettle reboiler and horizontal thermosyphon reboiler as 2
possible steam generator configurations. Identified 2 possible
placements for steam generators and 4 possible heat recovery
scenarios. Gum separation methods have been explored.
Vacuum distillation deemed necessary to meet target specifications.
Preliminary distillation column pressures, temperatures and reflux
ratio determined by shortcut calculations.
Vacuum distillation identified as the primary option for separation,
due to the narrow boiling range of the components and the
degradation of acetic anhydride at 139 oC. Shortcut calculations were
performed to determine preliminary distillation column pressures and
reflux ratio.

Workplan
The general team workplan and the specific individual member workplans can be viewed
from the Gantt charts in Appendix C. Primary targets are outlined below:
Deadline
11/03/13
18/03/13
03/04/13
15/04/13

Task
Optimization of all individual plant units
Submission of individual reports and finalization of full plant design
Complete full cost analysis of plant
Complete HAZOP
Team report submission

Appendix A Process Flow Diagram

Fig.1 Process flow diagram of proposed drying oil plant

3

Appendix A Process Flow Diagram

Property
Mole Frac (Castor Oil)
Mole Frac (Drying Oil)
Mole Frac (Acetic Anhydride)
Mole Frac (Acetic Acid)
Mole Frac (ACO)
Mole Frac (Gum)
Vapour Fraction
Temperature
Pressure
Molar Flow
Mass Flow
Liquid Volume Flow
Heat Flow

Unit
C
kPa
kgmole/h
kg/h
m3/h
kJ/h

1
1.00
0.00
0.00
0.00
0.00
0.00
0.00
25.00
101.32
0.96
205.00
0.25
-5.37E+05

2
0.00
0.00
1.00
0.00
0.00
0.00
0.00
25.00
101.32
0.96
97.61
0.09
-6.00E+05

3
0.33
0.00
0.67
0.00
0.00
0.00
0.00
49.27
101.32
2.89
401.94
0.43
-1.73E+06

Property
Mole Frac (Castor Oil)
Mole Frac (Drying Oil)
Mole Frac (Acetic Anhydride)
Mole Frac (Acetic Acid)
Mole Frac (ACO)
Mole Frac (Gum)
Vapour Fraction
Temperature
Pressure
Molar Flow
Mass Flow
Liquid Volume Flow
Heat Flow

Unit
C
kPa
kgmole/h
kg/h
m3/h
kJ/h

8
0.00
0.00
0.00
1.00
0.00
0.00
0.00
96.34
50.00
0.96
57.64
0.05
-4.35E+05

9
0.00
0.00
0.00
1.00
0.00
0.00
0.00
96.38
101.32
0.96
57.64
0.05
-4.35E+05

10
0.00
0.00
0.99
0.01
0.00
0.00
0.00
123.23
64.00
0.97
98.68
0.09
-5.88E+05

Stream
4
0.33
0.00
0.67
0.00
0.00
0.00
0.00
50.00
101.32
2.89
401.94
0.43
-1.73E+06
Stream
11
0.00
0.00
0.99
0.01
0.00
0.00
0.00
123.26
101.32
0.97
98.68
0.09
-5.88E+05

5
0.00
0.00
0.33
0.33
0.33
0.00
0.00
136.57
101.32
2.89
401.95
0.44
-1.73E+06

6
0.00
0.00
0.50
0.50
0.00
0.00
0.00
48.99
4.99
1.93
156.32
0.15
-1.04E+06

7
0.00
0.00
0.50
0.50
0.00
0.00
0.00
49.02
50.00
1.93
156.32
0.15
-1.04E+06

12
0.00
0.00
0.00
0.00
1.00
0.00
0.00
217.96
15.72
0.96
245.63
0.29
-6.63E+05

13
0.00
0.00
0.00
0.00
1.00
0.00
0.00
218.03
101.32
0.96
245.63
0.29
-6.63E+05

14
0.16
0.00
0.00
0.00
0.84
0.00
0.00
259.25
101.32
2.67
666.71
0.79
-1.67E+06

Appendix A Process Flow Diagram

Property
Mole Frac (Castor Oil)
Mole Frac (Drying Oil)
Mole Frac (Acetic Anhydride)
Mole Frac (Acetic Acid)
Mole Frac (ACO)
Mole Frac (Gum)
Vapour Fraction
Temperature
Pressure
Molar Flow
Mass Flow
Liquid Volume Flow
Heat Flow

Unit
C
kPa
kgmole/h
kg/h
m3/h
kJ/h

Property
Mole Frac (Castor Oil)
Mole Frac (Drying Oil)
Mole Frac (Acetic Anhydride)
Mole Frac (Acetic Acid)
Mole Frac (ACO)
Mole Frac (Gum)
Vapour Fraction
Temperature
Pressure
Molar Flow
Mass Flow
Liquid Volume Flow
Heat Flow

Unit
C
kPa
kgmole/h
kg/h
m3/h
kJ/h

15
0.16
0.00
0.00
0.00
0.84
0.00
0.00
300.00
195.00
2.67
666.71
0.79
-1.59E+06
22
0.00
0.50
0.00
0.50
0.00
0.00
0.00
61.68
4.64
1.92
245.62
0.30
-6.89E+05

16
0.12
0.26
0.00
0.26
0.36
0.00
1.00
300.00
183.00
3.63
666.71
0.80
-1.39E+06
23
0.00
0.00
0.00
1.00
0.00
0.00
0.00
39.79
4.64
0.94
56.20
0.05
-4.30E+05

17
0.12
0.26
0.00
0.26
0.36
0.00
0.00
129.00
101.32
3.63
666.71
0.80
-1.83E+06

Stream
18
0.12
0.26
0.00
0.26
0.36
0.00
0.00
129.00
148.00
3.63
666.71
0.80
-1.83E+06
Stream

24
0.00
0.97
0.00
0.02
0.00
0.00
0.00
229.45
73.58
0.98
189.42
0.24
-1.79E+05

19
0.12
0.26
0.00
0.26
0.36
0.00
0.00
129.00
22.00
3.63
666.71
0.80
-1.83E+06

25
0.00
0.00
0.00
1.00
0.00
0.00
0.00
39.87
101.32
0.94
56.20
0.05
-4.30E+05

20
0.25
0.00
0.00
0.00
0.75
0.00
0.00
281.92
73.58
1.71
421.09
0.50
-1.01E+06
26
0.00
0.00
0.00
1.00
0.00
0.00
0.00
69.04
101.32
1.89
113.84
0.11
-8.65E+05

21
0.25
0.00
0.00
0.00
0.75
0.00
0.00
281.93
101.32
1.71
421.09
0.50
-1.01E+06
27
0.00
0.00
0.00
0.00
0.00
1.00
0.00
129.00
148.00
0.00
0.00
0.00
-2.62E+00

Appendix C Workplan
Team Gantt Chart

Fig. 2: Team Gantt chart

Appendix C Workplan
Sectional Gantt Chart

Fig. 3: Sectional Gantt chart