DEPARTMENT OF CHEMICAL ENGINEERING: BEng Tech

CHEMICAL ENGINEERING DESIGN 2A

TECHNICAL REPORT x OR SUMMARY REPORT

Surname, Initials Student Percentage Student Signature

Number/s contribution

Ntshingila, S. P 21828003 33%

Manqele, M 21912912 33%

Baijnath, S 22038271 33%

PROJECT TITLE Technical and feasibility study for the production of 2-

ethylhexanol

GROUP NUMBER 14
ISSUE DATE

SUBMISSION DATE 31 March 2022

LECTURER Peterson Thokozani Ngema

Preface
This project has been written and submitted in partial fulfillment of the requirements made by
the department of Chemical engineering for chemical process design 2A, in Durban University
of Technology. This work was done in Rosean Sheerwood Residence in RS45 as well as inS6
level 03, under the supervision of Peterson Thokozani Ngema and Felicia Afolabi
Declaration
I declare that this assignment is my own work and I know plagiarism is a serious offence, which
is stealing someone else’s work or ideas without proper acknowledgement or reference.

S. P Ntshingila

M. Manqele

S. Baijnath
Table of content
Exclusive summary…………………………………………………5
Introduction………………………………………………………….5
Background…………………………………………………………..5
Technical Components……………………………………………….6
The composition of raw material and product………………………..6
General properties:……………………………………………………7
Description:…………………………………………………………...7
Status of 2-ethylehexanol …………………………………………….8
Advantages of 2-ethylehexanol ………………………………………9
Production of 2-ethylehexanol………………………………………..9
Other products and by-products………………………………………9
Calculations …………………………………………………………..11
Identification and governing on the variables ………………………...15
Financial feasibility……………………………………………………16
Environmental considerations…………………………………………16

Conclusion………………………………………………………………18
References………………………………………………………………19
Appendices………………………………………………………………20
Executive summary
The design objectives of the process plant are assessed with a critical approach for this project.
When simulating a design project, it is imperative to take note of all the desired requirements of
the process plant including design specifications, input and output streams, and all the process
routes. The main objective of this project is to design a 95000 tons/year capacity of 2-
ethylhexanol (C8H180) process plant, that will be built in Cato Ridge in KwaZulu-Natal, South
Africa. There are various processes used for producing 2-ethylhexanol, for instance
Acetaldehyde process route and e.t.c, but for this project we will specifically use the Oxo process
route which utilizes propylene and synthesis gas as feed components. Furthermore, recycle
processes were implemented in this process in order to improve the conversion efficiencies for
process equipment. In conclusion the procedures for safe operation and start-up of the 95000
tons/year of 2-EH production plant were documented.

Introduction
Background
2-ethylhexanol is a fatty alcohol and colorless liquid that has eight carbon branches. 2-EH is
moderately soluble in water but is more soluble in organic solvents. It is also used as a feedstock
for the production of lubricants and plasticizers, and since it is a fatty alcohol its esters have
emollient properties. This compound occurs as a vapor in the atmosphere and is combustible,
hence it will react violently with oxidizing materials and strong acids. 2-ethylhexanol is a
valuable resource in the petrochemical industry and is manufactured by petrochemical synthesis.
2-EH is ranked behind the lighter oils such as methanol and butanol, as the most valuable
synthetic alcohol. The compound has two main outlets, the first one is the production of
phthalate plasticizers, such as DOP which is used for the production of PVC. The second outlet
is for the manufacture of acrylate esters.
Industrially 2-ethylhexanol is produced at a large scale of 2,000,000,000 kg/year. There is an
increasing demand for phthalates plasticizers such as Dioctyl Phthalate which is a phlthalate
ester that has the largest volume, and hence the future of 2-EH depends on it. It was reported that
2-EH is produced by a three step process, involving aldol condensation on butyraldehyde,
followed by hydrogenation and dehydration. This process produces 2,500,000 tons yearly. Upon
conducting research, it was revealed that there are new methods of producing 2-EH that are
being studied. As mentioned previously that it’s crucial to take note of the design requirements
and specifications, therefore the unit operations for this process plant must be designed I such a
way that the production of 2-EH will be in excess to meet the current demand of world’s
increasing population as of 2022.
The plant design for the production of 95000 tons per year of 2-EH from propylene and synthesis
gas is prepared to generate its excess to today’s population demand. According to research
conducted it was found that 2,000,000,000 kg/year was produced but now this rate of production
accommodated the population at that time. In conclusion there is inadequate supply and
production of 2-EH to the world’s population. This has obviously led to finding new methods
and solutions on how to increase the rate of production, hence this project has been of great
interest as we will design a plant that will meet the demand of the current population.

Technical Components
Propylene and synthesis gas as raw material
The composition of raw material and product:
The process includes the primary response which produces n-butyraldehyde, accompanied
through a gas-liquid separation that yields a liquid segment that handed via the distillation to
reap a flow-rich in n-butyraldehyde. This is then handled with sodium hydroxide and undergoes
a condensation to provide 2-ethylhexanal and decreased 2-ethylhexanol
The primary level is hydroformylation (oxo) reaction with the primary fabricated from n-
butyraldehyde which is used for the conversion of 2-ethylheanol. The feedstock that are used to
the reactor is CO/H2 aggregate in the synthesis gas and propylene within side the molar ratio of
2:1 and the catalyst that is applied is cobalt carbonyl. The synthesis gas is acquired from heavy
fuel after the elimination of sulfur compounds and CO2. The compositions of the mixture are
48.6% H2, 49.5% CO, 0.4% CH4, and 1.5% N2. The propylene feed has compositions of 93%
propylene and 7% propane respectively. The solution of n-butyraldehyde and isobutyraldehyde
in the ratio of 4:1 are produced from the solution. The reaction is carried out at operating
conditions of 130°C and 350 bar. Of the propylene feed, 3% is transformed to propane a few do
now no longer react. In the reactor, 6% of the n-butyraldehyde is minimized to n-butanol,
similarly 4% of isobutyraldehyde is minimized to isobutanol at the side of different reactions that
occur and yield excessive molecular weight compounds of 1% through weight of the
butyraldehyde-butanol combination at the exit of the reactor.
We then have the second stage where we have a gas-liquid separator (GLS) which operates at 30
bar and heats the liquid segment with steam in order to restore the cobalt carbonyl catalyst
through filtration by decomposing it. We then have a second gas-liquid separator in the third
stage that operates at atmospheric conditions that yields a liquid segment of aldehydes, water,
free from hydrogen, carbon monoxide, propylene and propane.
There are two distillation columns at the fourth and fifth stages. Distillation column 1 gives a
distillate product of mixed butyraldehydes which are then passed to distillation column 2 and
from there they are separated into an isobutyraldehyde stream (distillate product) which contains
1.3 mol% n-butyraldehyde and an n-butyraldehyde stream (bottoms product) which contains 1.2
mol% isobutyraldehyde.
Followed by a cracking unit with operating conditions of 275°C and 1 bar. The cracker converts
the isobutyraldehyde (from distillate 2) to propylene, CO, and hydrogen at a yield of 80%
conversion using catalyst and a dry saturated steam at 35 bar. Propylene, CO and hydrogen are
then recycled back to the oxo-reactor (hydroformylation), isobutyraldehyde is also recycled to
the cracking unit for more conversion, while the unreacted isobutyraldehyde and water are
separated in the separator unit.
The final stage is the production of 2-ethylhexanal in the aldol condensation reactor, this is
produced by treating n-butraldehyde with 2% w/w aqueous sodium hydroxide at a conversion
efficiency of 90%. 2-ethylhexanal and unreacted n-butyraldehyde is then separated. The 2-
ethylhexanal is the reduced by hydrogen gas of 98.8% H2 and 1.2% CH4 composition
respectively, and with the use of a catalyst with 99% conversion rate. The final product of this
stage is a recovered 99.8% 2-ethylhexanol at a purity of 99 wt%.
General properties:
Physical and chemical properties of propylene:
A colorless gas, with taste and with a faint color
Aggregate state at 20°C and atmospheric pressure of 1 atm – gas
Density (at 20°C and atmospheric pressure at a 1 atm) kg/m3 – 1,184
Density (at 0°C and atmospheric pressure at a 1 atm) kg/m3 – 1,9149
Melting point, °C -185,25
Boiling point, °C -47,6
Flash point, °C- 107,8
Molar mass, g/mol – 42,08
General properties of 2-ethylhexanol:
Description:
2-ethylhexanol is described as a colorless compound with a characteristic odor is insoluble in
water and has low density than water. Its esters have emollient properties since it is a fatty
alcohol. 2-EH basis of application is in the production of plasticizers and lubricants.
Molecular weight- 130.23 g/mol
Boiling point 183.5°C
Melting point -76°C
Specific gravity (air=1) 4.49
Vapour pressure 0.05 mmHg at 20°C
Solubility soluble in organic solvents, solubility in water 880 mg/l at 25°C
Henry’s law constant 2.65 × 10 atm-m/mol
Refractive index 1.431
Status of 2-ethylehexanol
As of this day, 2-ethylehexanol has a diverse use in a variety of industries often dealing with
chemicals, thus increasing its overall demand. Its usage in the manufacturing of emulsion paints
and surface coatings as well as manufacturing of plasticizers and lubricants have been
established to be its core driving values for its high demand.
Due to such high demand, the production of 2-ethylehexanol has been steadily increasing, and
according to Persistence market research (sept 2019) the market for it is growing at a
breathtaking rate with the pacific Asia and north America currently holding a large share in the
global 2-ethhylhexanol market. According to Markets and markets A country level segmentation
is done for both 2-Ethylhexanol and its applications for regions segmented as Asia-Pacific, North
America, Europe, and ROW, and further for key countries in each region that include U.S.,
Canada, Mexico, Germany, France, U.K., Italy, Poland, China, Japan, South Korea, Taiwan,
India, Saudi Arabia, and Brazil. 2-EH: 4,434.0 kilotons market by 2018, signifying a firm
annualized growth rate of over 5.2%
According to Mordor Intelligence (2021), Currently the production and usage of 2-ethylehexanol
is considerably low in south Africa as well as most African countries, however this opportunity
leaves a lot of un-pioneered ground to build upon with very little to zero competition. ‘
Advantages of 2-ethylehexanol

2-ethylehexanol is used in production of a wide variety of chemical products, which are often
unique and distinct from one another. Its s common usage can be found in production of
emollients and plasticizers. It has also been noted to be used in production of fragrances, flavors
as well as solvents.
According to Pub Chem (2010), 2-ethylehexanol has a boiling point of 180 to 186 °C, making it
safe to work with a room temperature and it can be capable of handling high temperatures
without autoigniting as it ignites at 231 °C, however it can be flammable when contacted upon
with a direct flame.
2-ethylehexanol being a low volatile substance is also an advantage as it does not evaporate
easily, thus working with it is made easy, making it easy to store it in its liquid phase without
needing extra work such as controlling its pressure and temperature as a gas would do

Production of 2-ethylehexanol
In project we aim to design a plant that will be capable of producing 95000 tons of 2-thylhexanol
over a period of one year, however the production is restricted to operate for 330 days and must
operate over a day shift, which is 9 hours per day. As a result, the plant will be in production for
2970 hrs. per year while producing 31 986.53 kg/hr. feed stream will contain synthesis gas and
propylene, which will undergo a series of reactions until a desired product is formed. Which are
hydroformylation of propylene to form n-butyraldehyde, separation of the catalytic solution,
condensation to release the needed aldehydes, a distillation column to extract by-products with
are n-butanol and iso-butanol, the aldolization which will form 2-thylhex-2-enal which will
then go into another separator to form 2-ethylhexanol. There will then be the last stage called
hydrogenator that will help reach the desired 99% conversion rate.

Other products and by-products

Iso-butanol and n-butanol are by products formed during the hydroformylation. They are
characterized as colorless, flammable, volatile liquids. They are 4 carbon molecules with a
chemical formula C4H9OH, they have a molecular weight of 74.1 and a boiling point of 118°C,
as well as melting point of -89°C. Their Specific gravity is 0.81.
“1-Butanol is used in cosmetics, flavorings, brake fluids, degreasers, repellants, and as a solvent
for many processes; it is used as an extractant in the manufacture of antibiotics, hormones, hop,
vegetable oils, and vitamins (WHO, 1987; Lington and Bevan, 1994).
Since these alcohols also occur naturally, they can be found in a variety of things such as cheese,
fruits, alcoholic beverages because of carbohydrate fermentation.
Calculations
R = (Synthesis reactor + Unreacted Propylene) per K-mole of Propylene feed.
x= mole fraction of Propylene in the Stripped gas.
Propylene feed = (100 + 100 Rx) =100(1+Rx) K- moles
Amount of Unreacted Propylene = 100(1+Rx) x 0.02 = 2(1+Rx) K -moles
Synthesis gas = 100 R (1 –x) K –moles
Assume: 100% of Unreacted Propylene is stripped in the striper.
Propylene: Synthesis gas = 1: 2
100(𝑅)(1−𝑥)
=2 …………... (1)
100(1+𝑅𝑋)

𝑅(1+𝑥)
=2
1+𝑅𝑋

R-Rx = 2+2Rx
3Rx = R – 2
(𝑅−2)
1 =x
3𝑅
2(1+𝑅𝑋)
X= …… (2)
2(1+𝑅𝑋)+100𝑅(1−𝑥)

(1+𝑅𝑋) 1+𝑅𝑋 1+𝑅𝑋

X= (1+𝑅𝑋)+50𝑅(1+𝑅𝑋) = =
1+𝑅𝑋+50𝑅−50𝑅𝑋 1+5𝑅−49𝑅𝑋

x(1+ 50R – 49 Rx) = 1+ Rx

x+50 Rx – 49 Rx2 = 1+Rx
x + 49Rx – 49 Rx2 = 1
x {1 + 49R – 49 Rx} = 1
(𝑅−2) 49𝑅(𝑅−2)
1 +49R-
3𝑅 3𝑅
(R – 2) (98R + 101) = 9R
98R2 +101R – 196R – 202 = 9R
98R2 -104R – 202 = 0
a = 98, b = -104, c = -202
(104)±√(104)2 −4(98)(−202)
R
2(98)

R=2.061
(𝑅−2) (2.061−2.0) 0.061
X= = = = 0.0099
3𝑅 3(2.061) 6.183
Synthesis gas = 100 R(1-x) = 100 x 2.061(1-0.0099) = 204.6 Kmoles
Propylene = 100(1+Rx) = 100 {1+2.061(0.0099)} = 102.03 Kmoles
Off- gas (Unreacted synthesis gas) = 204.06 – 102.03
= 102.03 Kmoles
98% of Propylene is converted.
∴Kmoles of Butyraldehyde = 0.98 x 102.03 = 99.99 Kmoles
n-Butyraldehyde: iso-Butyraldehyde = 4: 1
∴Kmoles of n- butyraldehyde = 99.99 x 0.8 = 79.992 K – moles
6% n- butyraldehyde of is converted to n-butanol
∴Kmoles of n-butanol = 0.06 x 79.992
= 4.800 Kmoles
Kmoles of iso- butyraldehyde = 99.99 – 79.992 = 19.998 Kmoles
4% of iso- butyraldehyde is converted to iso-butanol
∴Kmoles of iso-butanol = 0.04 x 19.998
= 0.800 Kmoles
Distillation column (I): Aldehydes/Alcohol separator
Assume: all Aldehydes (both n & iso- butyraldehydes leave as the top product) and all
alcohols (both n and iso-butanol leave as bottom product).
Distillation column (II):
Feed: n-Butyraldehyde = 79.992 – 4.800 = 75.192 Kmoles
iso-butyraldehyde = 19.998 – 0.800 = 19.198 Kmoles
More volatile component -------------------------- iso- butyraldehyde
(Mass balance on the basis of more volatile component)
19.198
ZF = =0.203; XD =0.987; XW = 0.012
94.39

Over balance:
F=D+W
D = F – W = 94.39 – W
Component balance:
F ZF = DxD + W.xw.
94.39(0.203) = (94.39 – W) (0.987) + W (0.012)
19.161 = 93.163 – 0.987W + 0.012W
0.975W = 93.163 –19.161 = 74.002
74.002
W= =79.9 kmoles
0.975

∴ D = 94.39 – 75.90 = 18.49 K-moles

n-Butyraldehyde in W = 0.988 x 75.9 = 74.989 K-moles
iso-Butyraldehyde in W = 75.9 - 74.989 = 0.911 K- moles
Aldol condensation: (90% conversion efficiency)
K-moles of 2-Ethyl hexanol = 0.90 x 74.989 = 33.745 K-moles
2
Side stream = water + Unreacted + iso-butyraldehyde
n-Butyraldehyde
= 33.745 + 0.1 (74.989) + 0.911
= 33.745 + 7.499 + 0.911
= 42.155 K- moles
29
Hydrogenation: (99% conversion)
K-moles of 2-Ethyl hexanol = 0.99 x 33.745 = 33.408 K-moles
H2 required (considering 100% excess) = 2 x (2 x 33.745) =134.98 K-moles
Propylene 2-ethyl hexanol
102.83 33.408

Production required:95,000 tons/year

Molecular weight of 2-Ethyl hexanol = 130.23
Operating period (per Anum) = 330 days*9(day shift working hours)
=2970 hrs.

95000∗1000
Production (kmoles/hr) = =245.62 kmoles
2970∗130.23
245.62∗102.03
Kmoles of propylene required= =758.31 kmoles
33.048

Synthesis gas required =2*758.31 =1516.62 kmoles

Unreacted propylene =0.2* 758.32= 151.662 kmoles
K-moles of butyraldehyde = 0.98 x 758.31 = 743.14 Kmoles
K-moles of n-butyraldehyde = 743.14 x 0.8 = 549.648 Kmoles
K -moles of n-butanol formed = 0.06 x 549.65= 35.68 Kmoles
K-moles of iso-butyraldehyde = 743.14 – 549.648= 193.49 Kmoles
K-moles of iso-butanol = 0.04 x 650.21 = 26.01 Kmoles
Distillation column:
Feed: n- butyraldehyde = 549.648 – 35.68 = 513.97 Kmoles
iso-butyraldehyde = 193.49 -26.01 = 767.48 Kmoles
F = 87.35 + 22.30 = 109.65 Kmoles
22.30
ZF= =0.2034 kmoles
109.65

Overall Balance:
F=D+W
D = F – W = 109.65 – W
Component balance:
FZF= DxD + Wxw
109.85 (0.2034) = (109.65 - W) (0.987) + W (0.012)
W = 88.169 Kmoles
n- butyraldehyde in W = 0.988 x 88.169 = 87.11 Kmoles
iso- butyraldehyde in W = 88.169 – 87.11 = 1.06 Kmoles
0.90∗87.11
K- moles of 2-Ethylhexanal = =39.2 kmoles
2

Side stream = 39.2 + 0.1 (87.11) + 1.06

= 48.971 KMoles
Kmoles of 2-ethyl hexanol = 0.99 x 39.2
= 38.81 Kmoles
H2 = 2 x (2 x 39.2) = 156.80 Kmoles.
Identification and governing on the variables
The major reaction produces n-butyraldehyde, which is preceded by a gas-liquid separation,
which produces a liquid phase that is carried through a distillation column to obtain a stream
high in n-butyraldehyde, which will then be reacted with sodium hydroxide and condensed to
produce 2-ethylhexanal, which would then be lowered to 2-ethylhexanol.

The first stage is the a hydroformylation Jessica Margalef(2021) described as a atom-economical

method to form aldehydes in a feedstock, which in this reaction will react with a main product of
n-butyraldehyde which is needed for the conversion to 2-ethylhexanol.The main feeds to the
primary reactor used are a CO and H2 which are a mixture forming synthesis gas and propylene
in the molar ratio of 2:1, and the catalyst being used is cobalt carbnyl. The synthesis gas is
composed of 48.6% H2,49.5% CO, 0.4% CH4 and 1.5% N2. The composition enterting the stream
found in the propylene feed is 7% propane as well as 93% propylene.

The operating conditions which this reaction occurs is at 130°C and at 35000 kpA. This reaction
produces a solution of n-butyraldehyde and isobutyraldehyde in the ratio of 4:1. Of the propylene
feed, 3% is converted to propane and some of it does not react. inside the reactor, 6% of the n-
butyraldehyde product is then later reduced to n-butanol and 4% of the isobutyraldehyde product
is reduced to isobutanol along with other reactions that occur that yields high molecular weight
compounds of about 1% by weight of the butyraldehyde-butanol mixture at the reactor exit.

The second stage which is a gas-liquid separator that operates at 3000 kpa, which burns the liquid
and helps to separate the cobalt carbonyl which acted as a catalyst for further usage. The third
stage is another gas-liquid separator that operates at atmospheric conditions that yields a liquid
phase of aldehydes, alcohols, heavy ends and water, free from propane, propylene, CO and H2.

This is preceded by the separate distillation columns with are the fifth and sixth stages. The initial
top column is of mixed butyraldehydes that are a by-product of the overall reaction which are then
passed through the second column which separates them into an isobutyraldehyde stream that
contains 1.3 mole % n-butyraldehyde and an n-butyraldehyde stream that contains 1.2 mole %
isobutyraldehyde.
The sixth and last stage is a reactor that treats the n-butyraldehyde with a 2% w/w aqueous sodium
hydroxide solution which must then undergoing an aldol condensation which converts 90% of it
into 2-ethylhexanal, which later change into 2-ethylhexanol by reacting with hydrogen gas, with
composition of 98.8% H2 and 1.2% CH4, in the presence of a Raney nickel catalyst which has a
99% conversion rate. This will in turn help to purify 99.8% of the 2-ethylhexanol to be recovered
at 99.0%.

Financial Feasibility
The feed stock is synthesis gas and propylene. The cost of 1516.62 kmoles of
synthesis gas is R150 000 and the cost of 151.662 kmoles of propylene is R20 000.
The cost of the production process could be estimated to R80 million
The estimated amount for the capital needed to start the plant would be R500
million. To pay workers to operate the plant, say there are 2000 workers and the
amounted needed to satisfy the salaries for the 2000 workers amounted to
R30000 for each worker, 2000×R30000=R60 million×12months=R720 million.
The cost of 1 ton of 2-ethylhexanol is R17 000 so since we are producing 95000
tons of it, 95000×R17 000=R1 615 000 000
Financial feasibility calculaution, thus the profit margin is calculated as
R1 615 000 000-R720 000 000-R80 000 000-R500 000 000=R315 million profit.

Environmental considerations
The legislation of South Africa for environmental protection for chemical industries have three
major environmental laws. The clean air act, the clean water act and the toxic substances control
act. All of these pertaining to the production of 2-ethylhexanol.

The production of the product requires disposal and emissions as biproducts. The product is a
solvent and must thus be contained in an enclosed container, also for transport. The biproduct air
emissions are harmful if inhaled so the plant should be situated away from urban areas. Solid waste
or waste water is not to be disposed of in any natural body of water as the biproducts are harmful
if ingested. Solid waste has to be contained and incinerated in accordance with the toxic substances
control act. Waste water is to be evaporated.

Estimation of air emissions are high as this process generally gives of waste in the gas or liquid
phase. There are no combustion emmisions as the process can be done by means of esterification.
The solid waste is low as another means of disposing waste is via waste water, so liquid waste
water is high.
Conclusion
The production of 2-rthylhexanol is still in its early stages in south Africa, with the global market
being heavily controlled by North America, Europe, and Pacific Asia, however with the growing
demands and a multitude uses for 2-ethylhexanol, this promises a great profit margin for south
Africa as well as other African countries as this is still a growing market on a financial
standpoint.
The chosen location of the project is also advantageous as it is close to the N3 highway, as it
will minimize logistical and transportation issues. The Cato Ridge is less densely populated;
thus, the operation of the plant will not impose a great health risk.
The feedstock raw materials are also not difficult to obtain, as they are mostly natural occurring
or can be easily produced. This minimizes the hassle of getting them to start the operating and
them being available at low cost concludes to greater profits.
References
https://pubchem.ncbi.nlm.nih.gov/compound/2-Ethylhexanol
https://researchwap.com/chemical-engineering/prr6jb0vH6Fuap
https://en.wikipedia.org/wiki/2-Ethylhexanol
https://www.academia.edu/31749819/Ethylhexanol_from_propylene_and_synthesis_gas
https://saspublishers.com
https://www.persistencemarketresearch.com/market-research/2-ethylhexanol-market.asp
https://www.marketsandmarkets.com/Market-Reports/2-ethylhexanol-market-152484808.html
https://www.mordorintelligence.com/industry-reports/2-ethylhexanol-market
https://pubchem.ncbi.nlm.nih.gov/compound/2-Ethylhexanol#section=Autoignition-Temperature
Jèssica Margalef, ... Montserrat Diéguez, in Advances in Catalysis,
2021https://www.sciencedirect.com/topics/chemical-engineering/hydroformylation
APPENDIX
ETHYLHEXANOL FROM PROPYLENE AND SYNTHESIS GAS

Catalyst
Propylene feed Catalyst solution Filter cobalt Recycled to oxo-Reactor
93% propylene (Filtration) Propylene
7% propane CO
Hydrogen
Isobutyraldehyde stream Cracking Unit
Oxo Reactor Gas Liquid Gas Liquid (1.3mol% of n-butyraldehyde) (isobutyraldehyde
A
Cobalt carbonyl (Hydroformylation) n-butyraldehyde Separator 1 Separator 2 Cracking)
n - : iso = 4:1
(Catalyst) Isobutyraldehyde
Operating Conditions :
130 ˚C n-butanol( from 6% of n-butyraldehyde) Operating Conditions: Propylene
Isobutanol( from 4% isobutyraldehyde) Operating Conditions: Propane
350 bar 30 bar
1 atm Steam
1.0 wt% butyraldehyde/ butanol mixture Carbon
monoxide Separator
Propane( from 3% propylene)
Synthesis Gas Hydrogen
unreacted propane
(CO2/H2 mixture) Steam
48.6% H2 Water
49.5% CO Isobutyraldehyde stream
0.4% CH4 1.3 mol% n-butyraldehyde Unreacted isobutyraldehyde
1.5% N2 A
molar ratio
Synthesis Gas : Propylene 2-ethylhexanol
2:1 Reactor (99.8% recovery)
2-ethylhexanal (99% w/w purity)
(Reduction)
Distillation mixed butyraldehydes Aldehydes 2% w/w NaOH
Column 2 Heavy ends
Alcohols Conversion rate=99%
Water
Reactor
n-butyraldehyde (Aldol condensation)
B 2-ethylhexanal
Unreacted n-butyraldehyde Separator Catalyst Hydrogen
Distillation
B Conversion efficiency=90
n-butyraldehyde stream Column 1
1.2mol% isobutyraldehyde
Unreacted
n-butyraldehyde

Alcohols
 Chemical Engineering Design 2A- 2021
Assessment Sheet: Technical and Economic Feasibility Study
Student name: Student Numbers
S Ntshingila 21828003
M Manqele 21912912
S Baijnath 22038271
Final mark:

Required Sections and Criteria Mark

Title Page [1.5]
The following have been included:
 Title of project
 Full name of authors and student numbers
 A statement along the lines of 'Submitted in partial fulfilment of the
requirements for Chemical Process Design 2A in the Department of Chemical
Engineering, Durban University of Technology

Preface [1.5]
The following details have been included:
 where the work was carried out (e.g. S31evel 01, Steve Bike Campus, DUT)
 under whose supervision it was done, and over what period it was conducted

Declaration [1.5]
 A signed declaration by the students that the report represents their own work;
 Place and date of submission.

Acknowledgements [1.5]
Contributions to the project by others have been acknowledged:
 the work of one's supervisor/mentor
 the support of any organization or institution which have provided assistance
or funding
 the active help of anyone directly involved with the project (colleagues,
assistants) .
Executive Summary [5]
 The problem has been defined.
 Brief details of the approach/procedure/methods have been described.
 The important results that were found have been stated.
 Appropriate conclusions and recommendations have been stated.

Table of Contents [5]

 Includes: main headings, sub headings, page numbers,
 List of tables,
 List of figures
 Table of Abbreviations / Nomenclature and
 Definitions of Terms / Glossary

Introduction [10]- (sub-minimum 5)

 Background information has been given.
 The problem has been defined.
 Reasons why the problem was worthy of being studied has been explained.
 Detailed objectives are described.
 The methodology used to compile this study is presented

Technical Component [134]- (sub-minimum 67)

Extensive and relevant presentation of the technical aspects related to the task. Shows
good understanding and integration of literature into the complete document.
1. 2-ethylhexanol in South Africa: [12] (sub-minimum 6)
Present an overview of the SA market, Sources of raw material, and Regulation
Policy that influence this project, Summary of major equipment for vinyl acetate
production and Processing Options.
2. Propylene and synthesis gas as a Raw Material: [12] (sub-minimum 6)
The composition of raw materials, product and general properties
3. Production process of 2-ethylhexanol: [40] (sub-minimum 20)
 Current status of 2-ethylhexanol:
 Some Advantages of 2-ethylhexanol,
 Production of 2-ethylhexanol
 Other products and by-product from 2-ethylhexanol: composition and
properties
 Establish flowrates, thermal and physical properties of all process streams.
 Identification and discussion on the Governing Variables in the Production of 2-
ethylhexanol Process: Temperature, Raw Material composition, Handling raw
material, Pressure, Heating Rate etc.
4. Financial Feasibility[40] (sub-minimum 20)
  : Cost of Feedstock, Production Process of vinyl acetate, Post treatment of
Products, etc.
 Estimation of capital and operating costs
 Income Projections,
 Financial Feasibility Analysis
 All calculations are formulated in Excel
5. Environmental Considerations: [30] (sub-minimum 10)
 Identification of Legal / Regulatory Environment legislation applicable
 Estimation of Air Emissions, Combustion emissions, Particulate Emissions, VOC
Emissions, liquid and solid waste
 Some comparative emission factors for heating and LPG

Conclusion and Recommendations [10]- (sub-minimum 5)

 All-important information learned from this work has been listed.
 The recommendations developed from the proposed design in terms of
requirements, resources and constraints have been listed.
 Implications of installing the pipeline are identified and described in
accordance with process requirements and environmental, economic, and
safety factors.

References [5]
 only one reference system used: Harvard Referencing System
 punctuation and elements standardized exactly (e.g.. order of elements,
punctuation, capitalization and publishing details)
Turnitin
Originality report from Turnitin
Appendices [10]
The appendix includes:
a. Excel spreadsheet must be prepared using formula auditing
b. Format and layout of spreadsheet is appropriate and easy to use.
c. Algorithms for the calculations are correct
d. Spreadsheet is functional
e. Electronic copy of the report and excel worksheets must uploaded on Moodle.
f. Include BFD and PFD diagrams
g. Include printed excel worksheets

Organisation and Presentation [15]

Clear, logical, easy to follow, starts & ends well, no unclear or weak points. Smooth
transitions between sections. The report says what it sets out to say. It addresses the
design scope.
 Presented computer-generated work neatly and professionally
 Punctuated, spelt and constructed sentences appropriately
 The needs of the readership have been addressed
 Computer graphics have been appropriately generated
 Diagrams have been accurately, neatly and legibly annotated
  Calculations in computer-generated spreadsheets have been presented
 Graphic material has been appropriately integrated
 Professional and technical vocabulary has been appropriately used
 Content has been critically and logically selected and arranged
 Page space has been effectively and efficiently used

TOTAL 200