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DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

CPB30703 - DESIGN PROJECT 1


(DESIGN & FEASIBILITY STUDY OF PLANT)

Lecturer

MDM SALEHA BINTI ATAN

Member 1

AHMAD MUZAMMIL BIN IDRIS

Member 2

NOR SHAHIDA BINTI NORIZAN

Member 3

MUHAMAD FARIS BIN HAMIR

Member 4

AHMAD HAZIQ BIN MOHAMMAD RAZAK

Member 5

ABDUL HAKIM BIN MOHD YUSOF

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

Summary
This project deals with the manufacture of acrylic acid from propylene by oxidation of
propylene. Acrylic acid is a colorless liquid with an irritating acrid odor at room temperature
and pressure. Acrylic acid is used primarily as a starting material in the production of acrylic
esters; as a monomer for polyacrylic acid and salts, as a comonomer with acrylamide for
polymers used as flocculants, with ethylene for ion exchange resin polymers, with methyl ester
for polymers. Acrylic acid and its derivatives are primarily used in the preparation of solution
and emulsion polymers. The objective of this project is to design an acrylic acid plant that will
produce glacial acrylic acid, which is at 99.0% purity. Because acetic acid, a by-product, is
also a marketable commodity, purification of acetic acid to 95% purity is also desirable. Acrylic
acid is produced via the catalytic partial oxidation of propylene. The desired products must be
separated from the rest of the reactor product stream. This stream consists of acrylic acid,
acetic acid, water, oxygen, nitrogen, and carbon dioxide. Goal is to produce 150 000 Metric
tonnes per year of 99.0% acrylic acid utilizing 8000 hours a year. The one month of shut-down
time is most likely for catalyst regeneration and equipment maintenance.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.2

INTRODUCTION OF ACRYLIC ACID

This chapter will explain the background of acrylic acid, which covering the properties
and uses of acrylic acid, the production process and the chemical reaction of this acid.
Acrylic acid is unsaturated carboxylic acid which has double bond and carboxyl group
in C3 one molecule with the formula CH2=CHCOOH. The vinyl group is attached to the
carbonyl carbon directly. The systemic name is 2-propenoic acid. Acrylic acid is a colourless
liquid with a distinctive acrid odour. It is miscible with water, chloroform alcohols and ethers.
Acrylic acid is broadly utilized as a part of the coating formulation as well as in sheet
form because of the exceptional clarity and durability of the sheets. This type of acid is an
important chemical in the manufacturing of plastics and textiles industries. The uses of acrylic
acid, then are utilize in manufacturing of latex, in floor polish, in polymer solutions, emulsion
polymers, leather and finishing. Exposure to acrylic acid may occur basically in the working
environment through breathing and dermal contact. Acrylic acid is a strong irritant to the eyes
skin, and mucous membranes in humans. The liquid may cause blindness if it splashed into
eye. It is observed that acrylic acid may to produce lung haemorrhage and degenerative
changes in the liver and kidneys. Since acrylic acid is extremely reactive, special attention has
to be paid to its handling and use. The specified storage temperature range is between 59 and
77F at atmospheric pressure. Also, because of its flammability, only spark resistant tools
should be operated in its presence.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.3

PHYSICAL PROPERTIES

Chemical structure

CH2 = CH - COOH

Molecular weight

72.06 g.

Melting point

14 C

Boiling point

141 C

Water solubility

> 10 g/L

Critical temperature

342C

Specific gravity

1.05 (Water =1)

Density

1.051g/mL

Vapor density (air =1)

2.50g/mL

Appearance

clear, colourless liquid

Odor

acrid (strong)

Odor Threshold

0.092ppm

Vapor pressure

3.2mm Hg at 20C

Flash point

68C

Solubility

Soluble in cold water. Very slightly soluble in acetone.


Insoluble in diethyl ether.

Dispersion Properties

Partially dispersed in methanol, diethyl ether.

Water/Oil Distribution
Coefficient

The product is more soluble in oil. log (oil/water) = 0.4


Figure 1.0: Physical Properties of Acrylic Acid

Acrylic acid is a clear colourless liquid. The boiling point is 141.0C and
melting point 13.5C. It forms crystalline needles in the solid state. Acrylic acid is highly
miscible with water, alcohol, ester and many other organic solvents. The density of aques
solution is function as water content.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.4

CHEMICAL PROPERTIES

Figure 1.1: Chemical Properties of Acrylic Acid

Acrylic acid undergo reactions characteristics of both unsaturated acids and aliphatic
carbolic acids or esters. Moreover, the carbon-carbon double bond undergoes radical-initiated
addition reactions, Diels-Alder reactions with dienes, and polymerization reactions. The
carboxyl function is subject to the displacement reactions typical of aliphatic acids and esters,
such as esterification and transesterification. Joint reactions of the vinyl and carboxyl
functions, especially with bifunctional reagents, often constitute convenient route to polycyclic
and heterocyclic substances. Acrylic acids polymerise very easily. The polymerization is
catalysed by heat, light, and peroxides and inhibited by stabilizers, such as monomethyle ether
of hydroquinone or hydroquinone itself. These phenolic inhibiters are effective only in the
presence of oxygen. The highly exothermic, spontaneous polymerization of acrylic acid is
extremely violent.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.5

USES OF ACRYLIC ACID


The worldwide production of acrylic acid in 1994 was estimated to be approximately 2

million tonnes. Acrylic acid is used primarily as a starting material in the production of acrylic
esters; as a monomer for polyacrylic acid and salts, as a comonomer with acrylamide for
polymers used as flocculants, with ethylene for ion exchange resin polymers, with methyl ester
for polymers. Acrylic acid is used in the field of application of
Plastics
Paper manufacture and coating
Exterior house paints for wood and masonry
Coatings for compressed board and related building materials
Flocculation of mineral ore fines and waste water, and treatment of sewage
Printing inks
Interior wall paints
Floor polishes floor and wall coverings
Industrial primers textile sizing, treatment and finishing
Leather impregnation and finishing
Masonry sealers
Lubricating and fuel oil additives
Lacquers for automotive, appliance and furniture finishes
Pharmaceutical binders
Hot metal coatings

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.6

The Production Processes


The earliest synthesis of acrylic acid occurred in 1843 via the oxidation of

acrolein. Since 1927, the commodity chemical has been commercially available
through many different production means, including the Ethylene cyanohydrins
process, the Reppe Process, the -Propiolactone Process, and the Acrylonitrile
hydrolysis. There is also ongoing research on microbe development to produce 3
hydroxypropionic acid by fermentation, followed by a dehydration reaction to form
acrylic acid.
The most common process for production of acrylic acid is the two stage oxidation of
propylene. This process employs highly active and very selective heterogeneous
catalysts consisting of metal oxides such as vanadium and molybdenum to oxidize
propylene to acrolein in the first stage,Acrylic acid, has been found within 1865 within
Europe. It had been resulting from acrylic acid and had been researched in 1877 while
Fittig and Paul, two German chemists, found the actual polymerisation method when
the substance turns into a polymers. It was not till 1933 which methacrylic acids uses
were discovered by simply The german

scientist, Otto Rohm, exactly who

trademarked the goods and also termed that Plexiglas a new well-known brand of
acrylic substances along with a lot of uses. They started advertising that within 1937,
and also hundreds of companies include their masterpiece version of the implemented
acrylic acid nowadays, they are still keep the manufacturing techniques identical.
Acrylic plastics place in history
Acrylic production is probably the most well-known materials which might be retail
generated these days, for example Plexiglas Industry is common material used.
During the manufacturing, it's been used in manufacturing of aeroplanes, bomber
planes, andmany other ordinary products.

Acrylic product however offers many

utilizes these days, which includes being manufactured of bulletproof materials for
automobiles or perhaps helmets, aquariums, and fibre optic products. Regardless of
it's existing numerous utilizes, U.S experts are still researching your materials
properties to learn more about it. This includes both business in addition to
professional medical utilizes, because it's a safe substance to help implant in the
surgical purpose.
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DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

1.7

CHEMICAL REACTIONS OF ACRYLIC ACID


There are several chemical pathways to produce Acrylic Acid, but the most common

one is via the partial oxidation of propylene. This is normally done as a standard process
involving two reactors in series. Each reaction step usually takes place over a separate
catalyst and at different operating conditions. The first reactor typically operates at a higher
temperature than the second unit. In this arrangement, the first reactor converts the propylene
to acrolein while the second reactor completes the conversion from acrolein to acrylic acid.
The reactions stoichiometric are as below:

1. Production of Acrolein:
C3H6 + O2

C3H4O + H2O

2. Production of Acrylic Acid:

C3H4O + O2

C3H4O2

During this process reaction, several side reactions may occur which resulting in the
oxidation of reactants and products. Some typical side reactions are given below:

C3H4 + O2

3CO2 + 2H2O

C3H4 + O2

3C2H4O2 + CO2

C3H6 + O2

3CO2 + 3 H2O

In industry, Acrylic acid is divided in two grades. First is 94% technical grade for
esterification. Secondly is 98-99.5% glacial grade with 0.3% water present by weight for
production of water-soluble resins. Acrylic acid polymerizes easily when exposed to heat, light
or metals, and so a polymerization inhibitor is added to commercial acrylic acid to prevent the
strong exothermic polymerization.
Acrylic acid undergoes the typical reactions of a carboxylic acid to forms the
corresponding ester if acrylic acid combines with alcohol. The esters and salts of acrylic acid
are collectively known as acrylates (or propenoates). The common alkyl esters of acrylic acid
are 2-ethylhexyl-acrylate, methyl-, butyl- and ethyl-.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

Furthermore, acrylic acid is ready to react with free radicals and nucleophilic or
electrophilic agents. It may polymerize in the presence of alkalis, amines, acids, iron salts,
elevated temperature, light, peroxides, and other compounds that form peroxides or free
radicals. Without inhibitor, peroxides are formed when oxygen is sparge into acrylic acid. The
vicinity of oxygen is required for the stabilizer to work adequately. Acrylic acid must never be
taken care of under an inert environment.

DESIGN AN ACRYLIC ACID PLANT WITH A CAPACITY OF 150 000 METRIC TONNES PER ANNUAL

REFERENCES
Encyclopedia of Chemical Technology , Vol 1, Kirkothmer (page 330 - 351)
Felder, R. M. and R. W. Rousseau, Elementary Principles of Chemical Processes (2nd ed.),
Wiley, New York, 1986.
Perrys Chemical Engineers Handbook , 6 th edition , Robert. H. Perry , Don Green , McGraw
Hill Publication
Ullmann,s Encyclopedia of Industrial Chemistry Vol A1 ( page 161 - 172 )

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