United Arab Emirates University College Of Engineering Chemical Engineering Department Graduation Project I

Group Members:
Alia Al-Mansoori Jameilah Ali 200002356 200002314

Khawla Al-Shehhi
Manar Mohammad Noha Ali

200002125
200002419 200002153

Supervisors: Advisor: Dr. Samir I. Abu-Eisha

Presentation Layout
Project Description

Drying Oil background

Process selection Process description Preliminary Safety and Environmental Impact

Material and Energy Balances Preliminary Cost Estimation

Project Description
The primary objective of this project is to design a chemical plant that uses palmitic acid (C15H31COOH) as a raw material to produce drying oil that is used as an additive to paints and varnishes to aid the drying process when these products are coated on a surface. It become one of the most important industrial chemicals in the world due to its low cost and variety of Sources. The acetylated castor oil is thermally cracked to the drying oil (C14H28) and a ceticacid (CH3COOH). It is desired to asses the design from economical, environmental and safety perspectives.

Drying Oil background

Definition History Physical and chemical characteristics Uses and Application
Availability And Market

Definition
Drying oil that is used as an additive to paints and varnishes to aid the drying process when these products are coated on a surface.

History
The addition of pigments is a more recent invention and oil paints as a medium of artistic expression have a history of over 1000 years. The original artist's paints were simple mixtures of oil and pigment which could be applied to wood or canvas and allowed to dry. Over time artists made many changes in how the paint was prepared to increase control of the texture, appearance and drying time of the paint.

Physical and chemical characteristics

Name:1-Tetradecene Formula: CH2=CH(CH2)11CH3 It is colorless liquid. It reacts with strong oxidants. It attacks rubber, paints and lining materials. A harmful contamination of the air will not or will only very slowly be reached on evaporation of this substance at 20C.

Uses and Applications

Alcohols for detergents surfactants, linear plasticizers flavors and fragrances lube oil additive paint and varnish

Process Selection for Design

Process Criteria
Drying oils are additives to products like paint and varnish

Purpose of this project

To determine the feasibility of constructing a chemical plant to to manufacture 50,000 tonne/y of drying oil

Process Selection for Design

Chemical Reactions
Acetylated Castor Oil (ACO), (C16H32O2) Drying Oil (DO), (C14H28) Acetic Acid (AA), (CH3COOH) Gum, (C28H56)

Process Selection for Design

Process Description
1. Feed Preparation Section
(mixing heating)

2. The Reaction Section

Both reactions proceed

Process Selection for Design

Reactor conversions and selectivity
X conversion to AA space time 10 min 0.130 0.245 0.513 0.559 0.597 0.635 selectivity moles DO/moles gum space time 10 min 6.43 x 107 9.18 x 105 8.55 x 103 3.38 x 103 1.43 x 103 5.58 x 102

T (oC) 310 330 370 380 390 400

Process Selection for Design

3. Purification Section
Gum Filtration (Filter) Distillation Column 1:
all (AA) goes to stream 10 all (ACO) goes to stream 9 99.5% (DO) goes to stream 10

Condenser 1:
Dew Point = 266C (P=2.5 bar)

Reboiler 1:
Bubble Point = 333C

Process Selection for Design

3. Purification Section (continue)
Distillation Column 2:
99.5% of AA goes to stream 11 99.5% of DO goes to stream 12

Condenser 2:
Dew Point = 153C (P=1.8 bar)

Reboiler 2:
Bubble Point = 280.5C

Material Balance
The Importance of material balance
Objectives - Quantities of raw materials required and products produced.
- process flow rates and compositions

Drying oil plant Process flow diagram

Vessel Reacto r Distilla tion Colum n

Distilla tion Colum n

Filter

Material Balance 0

Accumulation= Input Output + generation Consumption Data Given:

Basis product of DO Mwt of ACO Mwt of AA Mwt of DO Mwt of gum 50000 256 60 196 392 ton/year kg/kmol Kg/kmol kg/kmol kg/kmol

Material balance
C16 H 32 O 2 (l ) CH 3 COOH(g) C14 H 28 (l ) 2C14 H 28 (l ) C28 H 56 (s)

Production rate of drying oil=50000 ton/yr

Conversion=99.97%

49985 ton/yr 8556.12 ton/yr 65306.1 ton/yr

AA

ACO

Overall mass balance

DO

Gum

14.79 ton/yr

65306.1ton/yr

Reactor
ACO

28800ton/yr

T= 380oC X= 0.559 AA

Selectivity (mol DO/ mol

Gum)=3.38X103

DO
ACO

8556.12ton/yr

Gum
16.53ton/yr 27933.5ton/yr

Component ACO Acetic Acid

Input (ton/yr)
36506.1 0

Xi 1 0

Output (ton/yr)
28800 8556.12

Xo 0.44 0.13

Drying oil
Gum Total

0
0 36506.1

0
0 1

27933.5
16.53 653096.15

0.43
0.00025 3 1

Input = 65306.12ton/yr

Filter

Output = 65289.59ton/yr

AA
DO ACO

gum

16.53ton/yr

Mass balance on filter

Component ACO
Acetic Acid Input (ton/yr) 28800 8556.12 27933.5 16.5 65306.15 Output (ton/yr) 28800 8556.12 27933.5 0 65289.62

Xi 0.44 0.13 0.43 0.000253 1

Xo 0.28 0.36 0.358 0 1

Drying oil
Gum Total

Distillation column

Distillation column 1
Feed = 65289.62 ton/yr
AA DO

ACO

AA
DO

Top product = 36475.62 ton/yr

ACO

Bottom product= 28813.97 ton/yr

Component ACO Acetic Acid Drying oil Total

Fi

Xfi

Di

XDi

Wi

XWi

28800
8556.12 27933.5 65289.62

0.28
0.36 0.358 1

0
8556.12 27919.5 36475.62

0
0.5003 0.4997 1

28800
0 13.967 28813.97

0.9994
0 0.00063 1

Distillation column 2
Feed = 36475.65 ton/yr
AA

DO

Top product = 8652.966 ton/yr

AA

DO

Bottom product= 27822.68 ton/yr

Component Fi Drying oil 27919.5 Xfi 0.5003 Di 139.59 XDi 0.005 Wi 27779.9 XWi 0.9998

Acetic acid
8556.15 Total 36475.65 1 8652.966 1 27822.68 1 0.4997 8513.369 0.995 42.78 0.0002

Energy balance
Why do energy balance. Objectives: - Estimate the cooling water required for the process
- Find the fuel required for the process - Estimate the overall energy requirement for the process

Detailed flow diagram for drying oil producing process

Distillatio n Column Vess Vessel el React or Distillatio n Column

Furnac e

Filte r

Furnace

Q = 1.87X1011 kJ/yr

Air

Ng

mng = 3475.6 ton/yr

Heat Exchanger

Q = 2.7X1011 kJ/yr

CW
mcw=1.16X108 m3/yr

Condenser 1
At dew point Temperature = 265 C
P = 2.5 bar QC= 3.41X1012 kJ/yr

CW
mcw= 81,296,658 m3/yr

Reboiler 1
At bubble point Temperature = 332 C
P = 2.5 bar

Qr= -3.41X1012 kJ/yr

Reboiler

Condenser 2
At dew point Temperature = 153 C P = 1.8 bar

Qc=3.6X1012 kJ/yr

CW
mcw= 85,494,364 m3/yr

Reboiler 2
At bubble point Temperature = 280.5 C P = 1.8 bar

Qr=-2.13X1012 kJ/yr Reboiler

Safety and Environmental Impact

Safety and Environmental considerations are an important part of our daily lives. It is one of the most important issues that must be taken into consideration in designing any plant. It is the responsibility to everyone, from industries to families to save our provision earth.

Drying Oil (DO)

Acute Health Hazard

Eye: Not expected to cause prolonged or significant eye irritation Skin contact may cause drying or defatting of the skin. Inhalation: Not expected to be harmful if inhaled
Personal protection - Wear appropriate clothing and safety glasses - Eye washes and safety showers. Fire and explosive hazards

- Flash Point: > 107 C (> 224.6F) - Autoignition: 235 C (455F) - Lower Explosive Limit: 0.5 - Upper Explosive Limit: 5.4

 Acetic Acid (AA)

Acute Health Hazard Inhalation: Causes chemical burns to the respiratory tract. Eye: Causes severe eye irritation. Skin: Causes skin burns and blackening

Personal protection
Wear chemical goggles. Wear appropriate gloves to prevent skin exposure. Wear appropriate protective clothing to prevent skin exposure.

Fire and explosive hazards

- Flash point: 39 C - Autoignition temp.: 426 C - Flammable limit, %by volume: Lower: 4, Upper:19.9

 Castor Oil
Acute Health Hazard - Harmful if swallowed. -May cause irritation. -Avoid breathing vapors, or dusts Personal protection - Avoid breathing product vapour - use safety goggles. -Use chemically resistant gloves if required Fire and explosive hazards - Flash point: 229 C - Flammability limits (% by volume in air): Lower: N/A Upper: N/A

Plant Capital Cost

Estimating the detailed cost of a project cannot be done until finishing the design of all equipments and materials needed. But a primary cost estimation was done. The cost estimation is calculated using step counting method which is one of the Economic methods of cost estimation.

Step counting method

Capital Cost C = 130,000 N (Q/s) 0.30 Where: C: Capital cost in pound sterling Q: Plant capacity ton/yr N: Number of functional units s: Reactor conversion

 Feed: ACO Products: DO, AA Price of products = $ 59482150 + $ 15153039 = $ 74635189

$0.59 1 kg $590 / ton kg 0.001 ton $590 Cost of ACO feed 65306 .1 $38,530599 ton Cost of ACO

Gross profit estimation = $ 74635189 [$38,530,599 + $915,840 4152] /yr

= $39,446,439 /yr

Temperature Optimization
Optimization
5.00000E+07 3.00000E+07 1.00000E+07 -1.00000E+07 300 -3.00000E+07 -5.00000E+07 -7.00000E+07 -9.00000E+07 -1.10000E+08 -1.30000E+08 -1.50000E+08 Tem perature ( oC)

310

320

330

340

350

360

370

380

390

400

Profit

 S0 by optimization we found that ,s= 0.559 is the best C = 130,000 (5) (50,000/0.559)0.30 = 19.878 million pound = $868.867 million

2. Capital Cost in 2003 In order to calculate capital cost in year 2003, the process engineering index is used Cost in year A = Cost in year B * (Cost index in year A/ Cost index in year B) Value of index at 1998 = 390 Value of index at 2003 = 395 Cost in 2003 = 868.867x106 *(395/390) = $ 880*107

 Allowing for 3 % inflation from 2003 to 2007, Cost = 51.08*107* 1.03 = $52.61*107 So the total capital cost will be = $906.4*106 in 2005.