Ethylene Oxide-Ethylene Glycol - Info
Ethylene Oxide-Ethylene Glycol - Info
Ethylene Oxide-Ethylene Glycol - Info
Chemicals
Answers for industry.
Siemens AG 2009
The major production steps of the oxygen-based EO process are: Ethylene (acc. to IUPAC: Ethene) and oxygen are mixed with recycle gas and, after adding a moderating substance such as chloro-ethane, fed into a multi-tubular reactor. There, ethylene oxide (EO) is selectively produced utilizing a silver-based catalyst at 200 to 300 C and 10-20 bar. Along with ethylene oxide (80-85 %), CO2, H2O and heat are generated. Reaction heat is recovered by boiling water at elevated pressure on the reactors shellside. It is used at different locations of the plant. EO contained in the reactor productgas enters the EO absorber section where EO is scrubbed from the gas by water. The EO-containing water is concentrated by stripping producing crude EO which is suitable for feeding directly to a glycol producing plant. When pure EO is the desired final product, the crude EO is fed to a purification column. The cycle gas leaving the absorber is fed to the CO2 removal section, where CO2 (a by-product of the EO reaction) is recovered. Some of the CO2 remains in the cycle gas and returns to the EO reactor. Process constraints Various constraints exist regarding safe operation, product quality and plant efficiency in running and optimizing the EO production process : Oxygen is required as reactant to run the process and added to the cycle gas. However, at a certain concentration level (known as flammable limit) in the gas mixture, oxygen will cause the danger of a gas explosion. Therefore, the content of oxygen in the cycle gas must be monitored continuously with high accuracy and reliability. 2 Ethylene Oxide and Ethylene Glycols
Crude EO
Water 4
Reactor
+ O2 CH2 = CH2 + 3 O2
Cycle gas
Fig. 1: Ethylene oxide production process with measuring points (see details in table 1)
Methan is able to increase the flammable limit (which is treated as positive effect) and, hence, is added to the cycle gas in the form of natural gas. Natural gas, however, is commonly contaminated with gaseous sulfur compounds that are known as poison to the silver catalysts. Catalyst selectivity is an important parameter in EO production and should be as high as possible. Usually, during catalytic processes, other competing reactions can take place, and reactants are converted into undesired products. The ratio between desired products and the undesired products is called catalyst selectivity. Catalyst selectivity is optimized by adding moderating substances such as chloro-ethane. Control of cycle gas composition The desired product ethylene oxide represents only a relatively small percentage of the total effluent stream leaving the reactor. The remainder of the reactor effluent comprises several diluents and reaction by-products. The task of the diluents is to prevent the gas mixture to reach unwanted combustibility levels during the reaction. If the flam-
mability limit is reached or exceeded, the complete oxidation of ethylene to CO2 and water will occur explosively. Process operation is desired under conditions which will maximize the conversion of ethylene to ethylene oxide yet avoid safety problems. In order to find such an optimum, gases such as nitrogen and methane are fed to the cycle gas and mixed with the reaction byproduct carbon dioxide, and argon, which enters as an impurity in the oxygen feed. The goal is to find an optimum mixture which permits operation of the process at maximum concentrations of oxygen and ethylene thus increasing the selectivity of the ethylene present to ethylene oxide and, on the other side prevents from the danger of explosion. Process analyzer are used to find this optimum mixture and to keep the gas concentrations at the predetermined levels during the process. See table 1 for measuring details.
Siemens AG 2009
Ethylene glycol production The aqueous EO solution from the ethylene oxide production section is sent to the gylcol section. There, ethylene glycol (MEG, Monoethylene glycol) is produced from EO by reacting it with water at a 10 to 1 ratio of water to EO. This excess of water helps to reduce by-product formation. Some higher glycols are produced as co-products: diethylene glycol (DEG) and triethylene glycol (TEG). The reactor product is sent to a multi-effect evaporation train for removal of the water from the glycols in three successive stages. The glycols are then sent to the fractionation train where the MEG, DEG and TEG products are recovered and purified. Final product samples are collected from the overhead or side stream of the purification towers (fractionators). A variety of process analysis are performed, including water content, MEG, DEG or TEG (see table 2). Other measurements are color, acidity, aldehyde impurity content and TOC (fig. 2). The product must meet sales specifications prior to beeing released for shipment to customers. Otherwise the product is normally reprocessed.
Measuring components C2H2 S compounds CO2 CH4 C2H4 C2H6 C2H4O N2 Ar/O2 H2O C2H4 CO2
Meas. range %
0 ... 5 0 ... 80 0 ... 40 0 ... 2 0 ... 3 0 ... 20 0 ... 25 0 ... 3 0 ... 40 0 ... 5 0 ... 12 0 ... 12 0 ... 12
MAXUM II
ULTRAMAT 6
O2 O2 O2 Cl-HCs CI-Hcs CO2 CH4 C2H4 C2H6 C2H4O N2 Ar/O2 H2O O2 O2 O2 C2H4 C2H6 C2H4O Ar/O2 CO2 H2O Formaldehyde Acetaldehyde C2H4, CO2, H2O C2H4 C2H6 CvH4O Ar/O2 CO2 H2O Aldehyde
Process control
0 ... 5 0 ... 80 0 ... 40 0 ... 2 0 ... 3 0 ... 20 0 ... 25 0 ... 3 0 ... 12 0 ... 12 0 ... 12 0 ... 40 0 ... 2 0 ... 0,05 0 ... 30 0 ... 30 0 ... 10
MAXUM II
EO absorber overhead
EO product
Product quality
MAXUM II
MAXUM II
Aldehyde content
TPA
MAXUM II TPA
Table1: Ethylene oxide process, measuring points (TPA: Third Party Analyzer)
Siemens AG 2009
Process Gas Chromatography Der Prozess-Gaschromatograph The MAXUM gas chromatograph fullfills the requirements for glycols quality control perfectly: Accurate analysis by optimized injection: Injection module with best evaporization characteristics for high boiling samples (MEG, boiling point 194-205C, DEG: 242-247C, TEG: 278C) avoid discrimination effect or hydration to water. Repeatable analysis by interferencefree separation. Safe separation of trace components is performed by elimination of main components by heart-cut. Used analyitcal tools: Siemens live switching in combination with capillary columns. Verification of the results by additional control parameter: cut-rest of main component, GC oven and ambient temperature. The excellent measuring stability, caused by the outstanding maxum hardware, is evident from fig. 4. Extended calibration cycles (typically > 6 weeks) by on-line calibration using closed cylinders. No enrichment with atmospheric moisture occurs in comparison to laboratory calibration principle. Inert capillary column systems to analyze traces of formalehydes and other highly reactive components High-precision O2/Ar measurement through combined data processing with OXYMAT analysis results; see next page.
Aqueous ethylene oxide Water 3 Recycle water Steam Water MEG DEG TEG
Fractionator
Fractionator
Fig. 3: Ethylene glycols production process Sampling point Sampling stream 1 2 3 4 MEG fractionator bottom DEG fractionator bottom TEG fractionator overhead Plant area Measuring purpose Quality control MEG Quality control DEG Quality control TEG Waste water and condensate monitoring Measuring components DEG, TEG Water in MEG MEG, TEG Water in DEG DEG, TEG Water in TEG TOC in water Measuring ranges Medium ppm level Medium ppm level Medium to high ppm level Siemens Analyzer MAXUM (Oven 1) MAXUM (Oven 2) MAXUM TPA
Table 2: Ethylene glycols process, measuring points MEG = Monoethylene glycol DEG = Diethylene glycol TEG = Triethylene glycol TEEG = Tetraethylene glycol TOC = Total Organic Carbon TPA = Third Party Analyzer
Fractionator
Fractionator
Siemens AG 2009
Composition of the reaction gas The EO reaction gas is a mixture of combustible, oxidizing and inert gases and made of O2 and C2H4 along with various diluent ingredients. Due to the flammable nature of oxygen, the ethylene production process relies on precise and accurate control of oxygen, and particularly, the "Limiting Oxygen Value" (LOV) or "Maximum Allowable Oxygen Concentration" (MAOC). The LOV is the oxygen concentration at which a combustion reaction will propagate through the ethylene oxide process gas. Hence, using too much oxygen can result in a catastrophic ignition, while using too little will result in poor yield. To control this critical situation Independent reactor inlet and outlet oxygen analyzers are used for oxygen monitoring and automatic safety shutdown and isolation of oxygen feeds. Typically, a certain offset from the LOV is defined (fig. 6) as safety margin. If the inlet oxygen concentration exceeds this LOV offset, the reactor must be shut down immediately to ensure that the safety margin is maintained. The size of the offset depends on the system geometry and other parameters. For example, the shut down could be triggered as the oxygen concentration exceeds LOV-2 vol%. Therefore it is crucial to monitor
and control oxygen concentration at the reactor with highest degrees of accuracy and reliability. Gain in allowable O2 concentration The danger of a gas explosion arises as the oxygen concentration comes closer to the LOV value. Considering the standard deviation values of available oxygen analyzers (fig. 6), the analyzer with a lower standard deviation (shown in blue) will allow a higher oxygen concentration and thus a higher process yield than an analyzer with a higher standard deviation (shown in brown). OXYMAT 6 OXYMAT 6 is well known for its outstanding features in reliability and stability with a very low standard deviation. It is specified by many chemical companies as preferred analyzer for this demanding application. OXYMAT 6 reliably ensures process safety and, at the same time, allows for best possible process yield and cost reduction. The measuring principle uses two gases: a reference gas, typically nitrogen or air, and the sample gas. The reference gas (shown in green, fig. 7) is introduced into the sample cell through two channels. The reference gas stream on the
Flammable limit
Gas mixtures consisting of combustible, oxidizing, and inert gases are only flammable under certain conditions. Flammable limits define the proportion of combustible components in a gas mixture, between which limits this mixture is flammable. The lower flammable limit (LFL) describes the leanest mixture that is still flammable, while the upper flammable limit (UFL) gives the richest flammable mixture. Increasing the fraction of inert gases in a mixture raises the LFL and decreases UFL. Temperature and pressure also influences flammability limits. Higher temperature results in lower LFL and higher UFL, while greater pressure increases both values. The effect of pressure is very small.
right-hand side (intensive green) meets the sample gas within the area of a magnetic field. The oxygen molecules (shown as blue beats) are drawn to the right, generating a pressure to the right reference gas channel. Because the two channels are connected, the pressure difference, which is proportional to the oxygen concentration, causes a cross flow, which is converted into an electric signal by a microflow sensor. Through suitable selection of the reference gas the zero point can be elevated physically with elevated oxygen concentration, e.g. 98-100% oxygen for purity monitoring.
O2 concentration of the process gas Gain in allowable O2 concentration by using OXYMAT 6 OXYMAT 6 Other O2 analyzer
Sample cell
Magnetic field
Siemens AG 2009
Siemens AG 2009
Product scope
Siemens Continuous Gas Analyzers and Process Gas Chromatographs
Extractive Continuous Gas Analyzers (CGA) ULTRAMAT 23 The ULTRAMAT 23 is a cost-effective multicomponent analyser for the measurement of up to 3 infrared sensitive gases (NDIR principle) plus oxygen (electrochemical cell). The ULTRAMAT 23 is suitable for a wide range of standard applications. Calibration using ambient air eliminates the need of expensive calibration gases. CALOMAT 6/62 The CALOMAT 6 uses the thermal conductivity detection (TCD) method to measure the concentration of certain process gases, preferably hydrogen.The CALOMAT 62 applies the TCD method as well and is specially designed for use in application with corrosive gases such as chlorine. OXYMAT 6/61/64 The OXYMAT 6 uses the paramagnetic measuring method and can be used in applications for process control, emission monitoring and quality assurance. Due to its ultrafast response, the OXYMAT 6 is perfect for monitoring safety-relevant plants. The corrosionproof design allows analysis in the presence of highly corrosive gases. The OXYMAT 61 is a low-cost oxygen analyser for standard applications. The OXYMAT 64 is a gas analyzer based on ZrO2 technology to measure smallest oxygen concentrations in pure gas applications. FIDAMAT 6 The FIDAMAT 6 measures the total hydrocarbon content in air or even in highboiling gas mixtures. It covers nearly all requirements, from trace hydrocarbon detection in pure gases to measurement of high hydrocarbon concentrations, even in the presence of corrosive gases. ULTRAMAT 6 The ULTRAMAT 6 uses the NDIR measuring principle and can be used in all applications from emission monitoring to process control even in the presence of highly corrosive gases. ULTRAMAT 6 is able to measure up to 4 infrared sensitive components in a single unit. ULTRAMAT 6 / OXYMAT 6 Both analyzer benches can be combined in one housing to form a multi-component device for measuring up to two IR components and oxygen. Process Gas Chromatographs (Process GC) MAXUM edition II MAXUM edition II is very well suited to be used in rough industrial environments and performs a wide range of duties in the chemical and petrochemical industries and refineries. MAXUM II features e. g. a flexible, energy saving single or dual oven concept, valveless sampling and column switching, and parallel chromatography using multiple single trains as well as a wide range of detectors such as TCD, FID, FPD, PDHID, PDECD and PDPID. MicroSAM MicroSAM is a very compact explosionproof micro process chromatograph. Using silicon-based micromechanical components it combines miniaturization with increased performance at the same time. MicroSAM is easy to use and its rugged and small design allows mounting right at the sampling point. MicroSAM features drastically reduced cycle times, provides valveless sample injection and column switching and saves installation, maintenance, and service costs. SITRANS CV SITRANS CV is a micro process gas chromatograph especially designed for reliable, exact and fast analysis of natural gas. The rugged and compact design makes SITRANS CV suitable for extreme areas of use, e.g. off-shore exploration or direct mounting on a pipeline. The special software "CV Control" meets the requirements of the natural gas market, e.g. custody transfer.
In-situ Continuous Gas Analyzers (CGA) LDS 6 LDS 6 is a high-performance in-situ process gas analyser. The measurement (through the sensor) occurs directly in the process stream, no extractive sample line is required. The central unit is separated from the sensor by using fiber optics. Measurements are carried out in realtime. This enables a pro-active control of dynamic processes and allows fast, cost-saving corrections. SITRANS SL SITRANS SL is a compact transmitterlike designed gas analyzer for fast in-situ measurements of oxygen concentration in process gases. The measuring principle is based on the diode laser technology and almost free of cross-interferences. The analyzer consists of a transmitter and receiver unit which are mounted directly at the process.
Product scope
Siemens AG 2009
Industrial Ethernet
Gas Chromatographs
Process Control DCS Integration: Modbus PROFIBUS Industrial Ethernet OPC via Ethernet
Maintenance
Serial Link
4-20 mA
Single Device
System
Analyzer networking for data communication Engineering and manufacturing of process analytical solutions increasingly comprises "networking". It is getting a standard requirement in the process industry to connect analyzers and analyzer systems to a communication network to provide for continuous and direct data transfer from and to the analysers. The two objectives are (fig. 16) To integrate the analyzer and analyzer systems seamless into the PCS / DCS system of the plant and To allow direct access to the analyzers or systems from a maintenance station to ensure correct and reliable operation including preventive or predictive maintenance (fig. 17). Siemens Process Analytics provides networking solutions to meet the demands of both objectives.
Decentralized
Centralized
Process GC
Field Installation
Shelter, CEMS
Analytical solutions are always driven by the customers requirements. We offer an integrated design covering all steps from sampling point and sample preparation up to complete analyser cabinets or for installation in analyser shelters (fig. 15). This includes also signal processing and communications to the control room and process control system.
We rely on many years of world-wide experience in process automation and engineering and a collection of specialized knowledge in key industries and industrial sectors. We provide Siemens quality from a single source with a function warranty for the entire system. Read more in chapter "Our services.
Siemens AG 2009
Modernization
FEED for Process Analytics Front End Engineering and Design (FEED for PA) is part of the planning and engineering phase of a plant construction or modification project and is done after conceptual business planning and prior to detail design. During the FEED phase, best opportunities exist for costs and time savings for the project, as during this phase most of the entire costs are defined and changes have least impact to the project. Siemens Process Analytics holds a unique blend of expertise in analytical technologies, applications and in providing complete analytical solutions to many industries. Based on its expertise in analytical technology, application and engineering , Siemens Process Analytics offer a wide scope of FEED services focused on analysing principles, sampling technologies, application solutions as well as communication system and given standards (all related to analytics) to support our clients in maximizing performance and efficiency of their projects.
Whether you are plant operators or belong to an EPC Contractor you will benefit in various ways from FEED for Process Analytics by Siemens: Analytics and industry know how available, right from the beginning of the project Superior analyzer system performance with high availability Established studies, that lead to realistic investment decisions Fast and clear design of the analyzer system specifications, drawings and documentation Little project management and coordination effort, due to one responsible contact person and less time involvement Additional expertise on demand, without having the costs, the effort and the risks of building up the capacities Lowest possible Total Costs of Ownership (TCO) along the lifecycle regarding investment costs, consumptions, utilities supply and maintenance.
Siemens AG 2009
If you have any questions, please contact your local sales representative or any of the contact addresses below:
Siemens AG I IA SC PA, Process Analytics stliche Rheinbrckenstr. 50 76187 Karlsruhe Siemens Energy & Automation Inc. 7101 Hollister Road Houston, TX 77040 USA Phone: +1 713 939 7400 Fax: +1 713 939 9050 E-mail: [email protected] www.siemens.com/processanalytics Siemens LLC I IA 2B. PO Box 2154, Dubai, U.A.E. Siemens Pte. Limited I IA SC PS/PA CoC 60 MacPherson Road Singapore 348615 Phone: +65 6490 8728 Fax: +65 6490 8729 E-mail: [email protected] www.siemens.com/processanalytics
Germany
Phone: +49 721 595 8631 Fax: +49 721 595 5211 E-mail: [email protected] www.siemens.com/processanalytics Siemens Ltd., China I IA SC, Process Analytics 7F, China Marine Tower No.1 Pu Dong Avenue Shanghai, 200120 P.R.China Phone: +86 21 3889 3602 Fax: +86 21 3889 3264 E-mail: [email protected] www.ad.siemens.com.cn
Phone: +971 4 366 0159 Fax: +971 4 3660019 E-mail: [email protected] www.siemens.com/processanalytics
Siemens AG Industry Sector Sensors and Communication Industry Marketing Food & Beverage 76181 KARLSRUHE GERMANY www.siemens.com/processanalytics
The information provided in this brochure contains descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Availability and technical specifications are subject to change without notice. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.