DESIGN OF ETHYLENE GLYCOL PLANT

BY

HIMANI AGRAWAL 180103017

AAYUSH GUPTA 180103001
JATIN SINGH 180103020
SHREYA SINGH BHADAURIYA 180103038
VIVEK SURYAPRAKASH SINGH 180103048

DEPARTMENT OF CHEMICAL ENGINEERING,

SCHOOL OF CHEMICAL TECHNOLOGY
HARCOURT BUTLER TECHNICAL UNIVERSITY,
KANPUR-208002
2022

1
 A
PROJECT REPORT

ON

DESIGN OF ETHYLENE GLYCOL PLANT

Submitted for the partial fulfilment of requirement of

BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING

By

HIMANI AGRAWAL 180103017

AAYUSH GUPTA 180103001
JATIN SINGH 180103020
SHREYA SINGH BHADAURIYA 180103038
VIVEK SURYAPRAKASH SINGH 180103048

Under the supervision of

Dr. S.K. Gupta

DEPARTMENT OF CHEMICAL ENGINEERING
HARCOURT BUTLER TECHNICAL UNIVERSITY KANPUR-208002
2022

2
PROBLEM STATEMENT
To design an Ethylene Glycol plant of capacity 1,20,000Tonnes per year or 400
TPD from first principle approach including material balance and energy balance
per equipment as well as for the whole plant, cost analysis along with designing
and safety analysis. This report includes the design details for the process, an
economic analysis, and recommendations and predictions for the extent of its
success.

3
CERTIFICATE
This is to certify that HIMANI AGRAWAL (Roll no. 180103017), AAYUSH
GUPTA (Roll no.180103001), JATIN SINGH (Roll no.180103020), SHREYA
SINGH BHADAURIYA (Roll no. 18013038) and VIVEK SINGH
SURYAPRAKASH (Roll no.180103048), students of Department of Chemical
Engineering, Harcourt Butler Technical University, Kanpur have completed their
project report under my guidance. They have a desire for learning & I wish success
in their future endeavours.

Project Guided by
DR. S.K. GUPTA
(Department of Chemical Engineering)

4
DECLARATION
We hereby declare that the project entitled
“DESIGN OF ETHYLENE GLYCOL PLANT”
submitted to the Department of Chemical Engineering, School of Chemical
Technology, HBTU Kanpur is a record of an original work done by us under the
supervision of Dr. S.K. GUPTA, Department of Chemical Engineering, School of
Chemical Technology, HBTU Kanpur.
We further, declare that work done in this project has not been submitted and will
not be submitted either in part or full for the award of any degree or diploma to any
other University or Institute.

HIMANI AGRAWAL (180103017)

AAYUSH GUPTA (180103001)

JATIN SINGH (180103020)

SHREYA SINGH (180103038)

VIVEK SINGH (180103048)

(Final B.Tech. Chemical Engineering, H.B.T.U. Kanpur)

5
ACKNOWLEDGEMENT
We would like to take this opportunity to thank all those who helped us to
complete this project.
Firstly, we would like to extend our heartfelt gratitude towards our mentor, Dr.
S.K. Gupta, for his constant support and guidance throughout the span of this
project.
Also, we would like to thank Dr. Rajesh Katiyar, Head of Department, Chemical
Engineering, and the members of Chemical Engineering Department of Harcourt
Butler Technical University, Kanpur for constantly helping us and providing us the
resources needed to complete this project.

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ABSTRACT
Ethylene Glycol is a dihydroxy alcohol with a chemical formula C2H6O2. It is a
clear, sweet, slightly viscous liquid which is highly toxic. It is an incredibly
versatile compound that is used in a number of industrial applications that range
from transportation and construction to food and pharmaceutical production.

Ethylene glycol underpins almost every aspect of everyday life and is particularly
associated with energy, chemicals, automotive, textiles, transportation, and
manufacturing technologies. It is widely used as an antifreeze and a raw material in
the plastic industry.

In this project we first compared multiple production methods for Ethylene Glycol
processes and then design a plant of capacity of producing 1,20,000 tons per
annum on the basis of best process, that is non-catalytic hydrolysis of Ethylene
Oxide. Based on the aforementioned analysis, this process is found to be a viable
and profitable alternative to current methods of Ethylene Glycol production.
Furthermore, the process is environmentally friendly. And then do the cost analysis
of the ethylene glycol production plant.

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CONTENTS
Title Page 1

Problem Statement 3
Certificate 4
Declaration 5
Acknowledgement 6
Abstract 7
Contents 8
List Of Tables 9
List Of Figures 10

Title No. Description Page No.

Chapter 1 Introduction 14-23
1.1 Physical Properties 15
1.2 Chemical Properties 16
1.3 Applications 20
1.3.1 Antifreeze 20
1.3.2 Explosives 21
1.3.3 Polyester Fibres 21
1.3.4 Resins 21
1.3.5 Hydraulic Fluids 22
1.3.6 Capacitors 22
1.3.7 Other Uses 22
Chapter 2 Literature Survey 24-36
2.1 Environmental Protection And Ecology 24

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 2.2 Product Safety 26
2.3 Storage And Transportation 27
2.4 Economic Aspects 28
2.5 Leading Producers In World 29
2.6 Leading Producers In India 29
2.7 Quality specification 30
2.8 Manufacturing Processes 32
Chapter 3 Process Selection And Description 37-43
3.1 Process Description 38
Chapter 4 Material Balance 44-53
4.1 Reaction 45
4.2 Triple Effect Evaporator 46
4.3 Drying 48
4.4 Refining Column 49
4.5 Recovery Unit 51
Chapter 5 Energy Balance 54-65
5.1 Reactor 54
5.2 Triple Effect Evaporator 56
5.3 Drying Unit 60
5.4 Refining Column 61
5.5 Recovery Column 63
Chapter 6 Major Equipment Design 66-72
6.1 Reactor 66
6.2 Distillation Column 68
Chapter 7 Instrumentation And Process Control 73-76
7.1 Reactor 73

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 7.2 Evaporator 74
7.3 Drier 75
Chapter 8 Plant Utility 77-78
8.1 Steam Generation 77
8.2 Cooler Water 77
8.3 Water 78
8.4 Electricity 78
8.5 Compressed Air 78
Chapter 9 Plant Location And Layout 79-82
9.1 Raw Material Supply 79
9.2 Markets 79
9.3 Energy Availability 79
9.4 Water Supply 80
9.5 Climate 80
9.6 Transportation 80
9.7 Labour Supply 80
9.8 Waste Disposal 80
9.9 Taxes And Legal Phases 81
9.10 Site Characterization 81
9.11 Plant Layout 81
9.12 Storage Layout 82
9.13 Equipment Layout 82
Chapter 10 Safety And Pollution Control 83-87
10.1 Safe Operations 83
10.2 Fire Prevention And Protections 83
10.3 Environmental Considerations 84

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 10.4 Environmental Auditing 86
Chapter 11 Cost Estimation 88-96
11.1 Cost Estimation 88
11.1.1 Purchased Equipment Cost 89
11.1.2 Direct Costs 90
11.1.3 Indirect Costs 91
11.2 Estimation Of Total Cost 92
11.3 Profitability Analysis 94
Conclusion 97
References 98

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LIST OF TABLES
S.NO. TABLES PAGE NO.
1.1 Physical Properties 15

1.2 Applications of Various Properties of Ethylene Glycol 20

2.1 Product Specification of Fibre Grade Ethylene Glycol 31

2.2 Product Specification of Industrial Grade Ethylene Glycol 32

3.1 Comparison Of Different Processes 37

4.1 Material Balance on Reactor 46

4.2 Material Balance on Triple Effect Evaporator 48

4.3 Material Balance on Drying Unit 49

4.4 Material Balance on Refining Column 50

4.5 Material Balance on Recovery Unit 53

5.1 Heat Capacity and Enthalpy Data 55

5.2 Latent Heat Data 58

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LIST OF FIGURES
S.NO. FIGURES PAGE
NO.
1.1 Structure of Ethylene Glycol 14

2.1 Material Safety Data Sheet Of Ethylene Glycol 27

2.2 Global Consumption of Ethylene Glycol 28

2.3 Production Of Ethylene Glycol in India 30

3.1 Process Flow Diagram 39

3.2 Process Flow Diagram 40

7.1 Instrumentation Diagram Of Reactor 73

7.2 Instrumentation Diagram Of Evaporators 74

7.3 Instrumentation Diagram Of Drier 75

13
CHAPTER 1:
Introduction

Ethylene glycol (IUPAC name: ethane-1,2-diol) is an organic compound with the formula (CH2OH)2.
It is the simplest member of the glycol family of organic compounds. A glycol is an alcohol with two
hydroxyl groups on adjacent carbon atoms (a 1,2-diol). The common name ethylene glycol literally
means “the glycol derived from ethylene.”

Ethylene Glycol was first developed in 1859 by a French chemist—Charles-Adolphe Wurtz—via

saponification of ethylene glycol diacetate with potassium hydroxide.1,2 In the early stages, though
EG was produced on a very small scale, its development created a considerable revolution in coolant
and explosives industries during World War I. As the state-of-the-art invention by the Carbide
Company of vapor-phase oxidation of ethylene to ethylene oxide (EO)—a precursor for EG synthesis
via hydration—became cheaply available, the industrial production of EG has been widespread since
1953.

The global production and consumption of ethylene glycol were about 30.2 million metric tons in
2021 with an estimated increase of 40.6 million metric tonnes by 2029. EG underpins almost every
aspect of everyday life, particularly associated with energy, chemicals, automotive, textiles,
transportation, and manufacturing technologies. Hence, it has attracted intense research interest across
interdisciplinary fields.

Figure-1.1 Structure of Ethylene Glycol

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1.1 PHYSICAL PROPERTIES:

 Mono ethylene glycol and its lower polyglycols are clear, odourless, colourless, syrupy liquid
with a sweet taste. It is a hygroscopic liquid completely miscible with many polar solvents,
such as water, alcohols, glycol ethers, and acetone.

 Its solubility is low however in non-polar solvents, such as benzene, toluene, dichloroethane,
and chloroform. It is miscible in ethanol in all proportion but insoluble in ether, completely
miscible with many polar solvents, water, alcohols, glycol ethers and acetone.

 It is a toxic as methyl alcohol when taken orally. Ethylene glycol is difficult to crystallize,
when cooled; it forms a highly viscous, super-cooled mass that finally solidifies to produce a
glasslike substance.

 The widespread use of ethylene glycol as an antifreeze is based on its ability to lower
freezing point when mixed with water.

Table 1.1 Physical Properties

Physical Properties

1. Molecular formula C2H6O2

2. Molecular weight 62
3. Specific gravity at 20/20 oC 1.1135
4. Boiling point oC at 101.3 KPa 197.60
5. Freezing point oC -13
6. Heat of vaporization at 101.3 KPa; KJ/mol 52.24
7. Heat of combustion (25 oC) MJ/mol 19.07
8. Critical Temp. oC 372
9. Critical pressure, KPa 6513.73
10. Critical volume, L/mol 0.1861
11. Refractive index, ŋ 1.4318

15
 12. Cubic expansion coefficient at 20 oC, K-1 0.00062
13. Viscosity at 20oC; mPa S 19.83
14. Liquid density (20 oC) gm/cm3 1.1135
15. Flash point, oC 111
16. Auto-ignition temp in air oC 410
17. Flammability limits in air; vol%
Upper 53
Lower 3.2

1.2 CHEMICAL PROPERTIES:

Ethylene Glycol contains two primaries –OH groups. Its chemical reactions are therefore, those of
primary alcohols twice over. Generally, one –OH group is attacked completely before other reacts.

1) Dehydration
a) With Zinc chloride, it gives Acetaldehyde

HOCH2CH2OH CH3CHO + H2O

(Ethylene Glycol) (Acetaldehydes)

b) On heating alone at 500 oC, it gives Ethylene oxide.

c) With H2SO4 it gives dioxane which is important industrial solvent.
2) Oxidation

Ethylene glycol is easily oxidized to form a number of aldehydes and carboxylic acids by oxygen,
Nitric acid and other oxidizing agents. The typical products derived from alcoholic functions are
Glycolaldehyde (HOCH2CHO), Glycolic acid (HOCH2COOH), Glyoxylic acid (HCO-COOH),
Oxalic Acid (HOOCCOOH), formaldehyde & formic acid.

With HNO3 oxidation it yields nos. of substance as one or both primary –OH groups may be
oxidized to aldehydes and these carboxylic groups.
HNO3 [O] [O]

HOCH2CH2OH HOCH2CHO HOCH2CH2COOH CHOCOOH

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 (Ethylene Glycol) (Glycol aldehydes) (Glycolic acid) (Glyoxylic acid)

[O]

HOOC-COOH

(Oxalic acid)

[O]

HNO3 [O] [O]

HOCH2CH2OH HOCH2CHO CHOCHO CHOCOOH

(Ethylene Glycol) (Glycol aldehydes) (Glyoxal) (Glyoxylic acid)

3) Polyesters of Polybasic Acids- Polybasic acids or their derivatives will react with the glycols to
form polyesters. Depending on whether an excess of acid or glycol is used, the polymer may be
terminated with either alcohol or acid groups.

Other reactions
The hydroxyl groups on glycols undergo the usual alcohol chemistry giving a wide variety of possible
derivatives. Hydroxyls can be converted to aldehydes, alkyl halides, amides, amines, azides,

17
carboxylic acids, ethers, mercaptans, nitrate esters, nitriles, nitrite esters, organic esters, peroxides,
phosphate esters, and sulphate esters.

Reaction with Sodium- At 50 oC to form monoalkoxide and dialkoxide when temperature is

raised.

Na at 50 oC Na at 160 oC
HOCH2CH2OH HOCH2CH2ONa NaOCH2CH2ONa

(Ethylene Glycol) (Mono Alkoxide) (Di Alkoxide)

Reaction with Phosphorus Pentahalide (PCl5) - It first gives Ethylene chlorohydrin and
then 1, 2 dichloroethane. PBr5 reacts in same way.

PCl5 PCl5
HOCH2CH2OH HOCH2CH2Cl ClCH2CH2Cl

(Ethylene Glycol) (Ethylene chlorohydrin) (1, 2-Dicholorochlorohydrins)

With Phosphorus Trihalide (PBr3)- To form responding dihalide

PBr3 PBr3
HOCH2CH2OH HOCH2CH2Br BrCH2CH2Br

(Ethylene Glycol) (Ethylene Bromohydrins) (1, 2-Dibromohydrins)

With HCl- In two step reactions, form ethylene chlorohydrin at 160oC and second forms 1,
2 dichloroethane at 200oC.

160 oC 200 oC
HOCH2CH2OH HOCH2CH2Cl ClCH2CH2Cl

(Ethylene Glycol) (Ethylene chlorohydrin) (1, 2-Dicholorochlorohydrins)

 Ethylene glycol also produces 1, 4-dioxane by acid-catalysed dehydration to Diethylene

glycol followed by cyclization. Cleavage of Triethylene and higher glycols with strong
acids also produces 1, 4-dioxane by catalysed ether hydrolysis with subsequent cyclization
of the Diethylene of the Diethylene glycol fragment. Diethylene glycol condenses with
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 primary amines of form cyclic structures, e.g., methylamine reacts with Diethylene glycol
to produce N-methylmorpholine.

HOCH2CH2OCH2CH2OH + CH3NH2 O N CH3 + 2H2O

 Ketones and aldehydes react with ethylene glycol under acidic conditions to Form 1, 3-
dioxolanes cyclic ketals and acetals.
O
+ R'
H
HOCH2CH2OH +RCOR+ + H2O
R
O

 Ethylene glycol reacts with ethylene oxide to form di, tri, tetra and polyethylene glycols.

 Ethylene glycols is stable compound, but special care is required when ethylene glycol is
heated at a higher temperature in presence of NaOH, which is exothermic reaction at
temperature above 250 oC of evolution of H2 (-90 to -160 KJ/Kg).

Other Chemical Properties

Ethylene glycol is a colourless, practically odourless, low-volatility, low-viscosity, hygroscopic liquid.

It is completely miscible with water and many organic liquids. The hydroxyl groups on glycols
undergo the usual alcohol chemistry, giving a wide variety of possible derivatives. Hydroxyls can be
converted to aldehydes, alkyl halides, amines, azides, carboxylic acids, ethers, mercaptans, nitrate
esters, nitriles, nitrite esters, organic esters, peroxides, phosphate esters and sulphate esters. This
chemistry permits ethylene glycol to act as an intermediate in a wide range of reactions. Especially
significant is resin formation, including the condensation with dimethyl terephthalate or terephthalic
acid resulting in a polyester resin. The reactivity and solubility of ethylene glycol provide the basis
for many applications. The widespread use of ethylene glycol as an antifreeze is based on its ability to
lower the freezing point when mixed with water. The physical properties of ethylene glycol-water
mixtures are therefore extremely important. The end uses for ethylene glycol are numerous.
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 Table 1.2 Applications of various properties of ethylene glycol

Properties/Characteristics Applications/Uses
 Polyester resins (fibers, containers and films)
 Resin esters as plasticizers (adhesives, lacquers and
Chemical Intermediate for Resins enamels)
 Alky-type resins (synthetic rubbers, adhesives,
surface coatings)
 Deicing fluids (aircraft, runway)
 Heat transfer fluids (gas compressors, heating,
ventilating, air conditioning, process chillers, ice
Freezing Point Depression rinks)
 All-weather automotive antifreeze and coolants
 Water-based formulations (adhesives, latex paints,
asphalt emulsions
 Medium for suspending conductive salt in
Solvent
electrolytic capacitors
 Textile fibers
 Paper
Humectant  Leather
 Adhesives
 Glue

Chemical Intermediate  Solvents

Solvent Coupler  Stabilizer against gel formation

1.3 APPLICATIONS:

The following is a summary of the major uses of ethylene glycol:

a) Antifreeze
 A major use of ethylene glycol is as antifreeze for internal combustion engines. Solutions
containing ethylene glycol have excellent heat transfer properties and higher boiling points

20
 than pure water. Accordingly, there is an increasing tendency to use glycol solutions as a year-
round coolant. Ethylene glycol solutions are also used as industrial heat transfer agents.
 Mixtures of ethylene glycol and propylene glycol are used for defrosting and de-icing aircraft
and preventing the formation of frost and ice on wings and fuselages of aircraft while on the
ground. Ethylene glycol-based formulations are also used to de-ice airport runways and
taxiways as de-icing agent.
 Asphalt-emulsion paints are protected by the addition of ethylene glycol against freezing,
which would break the emulsion. Carbon dioxide pressurized fire extinguishers and sprinkler
systems often contain ethylene glycol to prevent freezing.

b) Explosives
 Ordinary dynamite will freeze at low temperatures and cannot then be detonated. Ethylene
glycol dinitrate, which is an explosive itself, is mixed with dynamite to depress its freezing
point and make it safer to handle in cold weather.
 Mixtures of glycerol and ethylene glycol are nitrated in the presence of sulfuric acid to form
solutions of nitro-glycerine in ethylene glycol dinitrate, which are a fed to dynamite in
amounts ranging from 25 to 50%.

c) Polyester Fibres
 The use of ethylene glycol for fibres is becoming the most important consumer of glycol
worldwide. These fibres, marketed commercially under various trade names like Dacron,
Fortel, Kodel, Terylene etc. are made by the polymerization of ethylene glycol with
BisHydroxyEthyl Terephthalate (BHET).
 These Polyester fibres are used for recyclable bottles.
d) Resins
 Polyester resins made from maleic and phthalic anhydrides, ethylene glycol, and vinyl-type
monomers have important applications in the low-pressure lamination of glass fibres, asbestos,
cloth and paper.
 Polyester-fiberglass laminates are used in the manufacture of furniture, automobile bodies,
boat hulls, suitcases and aircraft parts. Alkyd-type resins are produced by the reaction of
ethylene glycol with a dibasic acid such as o-phthalic, maleic or fumaric acid. These resins are
used to modify synthetic rubbers, in adhesives, and for other applications.

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  Alkyds made from ethylene glycol and phthalic anhydride is used with similar resins based on
other polyhydric alcohols, such as glycerol or pentaerythritol in the manufacture of surface
coatings. Resin esters made with ethylene glycol are used as plasticizers in adhesives, lacquers
and enamels.

e) Hydraulic Fluids
 Ethylene glycol is used in hydraulic, brake and shock absorber fluids to help dissolve
inhibitors, prevent swelling of rubber, and inhibit foam formation.
 Hydro lubes, which are water-based mixtures of polyalkylene glycols and presses and die
casting machines, and in airplane hydraulic systems because of their relatively low viscosity
at high pressure. An added advantage of primary importance is that these hydro lubes are
inflammable.

f) Capacitors
 Ethylene glycol is used as a solvent and suspending medium for ammonium perborate, which
is the conductor in almost all electrolytic capacitors.
 Ethylene glycol, which is of high purity (iron and chloride free), is used because it has a low
vapor pressure, is non-corrosive to aluminium and has excellent electrical properties.

g) Other uses
 Ethylene glycol is used to stabilize water dispersions of urea-formaldehyde and melamine-
formaldehyde from gel formation and viscosity changes. It is used as humectants (moisture
retaining agent) for textile fibres, paper, leather and adhesives and helps make the products
softer, more pliable and durable.
 An important use for ethylene glycol is as the intermediate for the manufacture of Glyoxal,
the corresponding dialdehyde. Glyoxal is used to treat polyester fabrics to make them
“permanent press.”
 Ethylene glycol derivatives mainly ether and ester are used as absorption fluids, Diethylene
Glycol is used as a softener (Cork, adhesives, and paper) dye additive (Printing and stamping),
de-icing agent for runway & air craft, drying agent for gases (natural gas).
 Tri ethylene glycol is used for same purpose as Di ethylene glycol. Poly (ethylene glycol)
with varying molecular masses and numerous uses in Pharmaceutical industry (Ointments,

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Liquids and tabletting) and cosmetic industry (cream lotion, pastes, cosmetic sticks, soaps).
They are also used in textile industry (Cleaning and dyeing agents), in Rubber industry
(lubricating & Mould parting agents), in ceramics (bonding agents and plasticizers).

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CHAPTER-2:

Literature Survey

The literature survey has been done with an aim to obtain information concerning Ethylene Glycol
and its production from number of sources. Such information sources include chemical abstracts,
periodicals and books on chemical technology, handbooks, encyclopaedias and internet websites. The
literature survey yielded a lot of information on Ethylene Glycol. A brief review of information
obtained from the literature survey is presented hereafter.

SHIPPING DATA FOR ETHYLENE GLYCOL [4]:

• Weight per Gallon at 20°C 9.29 lb

• Coefficient of Expansion at 55°C 0.00065

• Flash Point, Tag Closed Cup 260°F

Net Contents and Type of Container

• 1–Gallon Tin Can 9.0 lb

• 5–Gallon DOT 17E, Pail 47 lb

• 55–Gallon DOT 17E, Drum 519 lb

2.1 ENVIRONMENTAL PROTECTION AND ECOLOGY:

Ethylene glycol is readily biodegradable, thus disposal of waste water containing this compound can
proceed without major problems. The high LC50 value of over 10000 mg/lit account for its low
water toxicity.

Ethylene glycol released to the atmosphere will be degraded by reaction with hydroxyl radicals; the
half-life for this reaction has been estimated at between 0.3 and 3.5 days. No hydrolysis of ethylene
glycol is expected in surface waters. The compound has little or no capacity to bind to particulates

24
and will be mobile in soil. The low octanol/water partition coefficient and measured bioconcentration
factors in a few organisms indicate low capacity for bioaccumulation.

Ethylene glycol is readily biodegradable in standard tests using sewage sludge. Many studies show
biodegradation under both aerobic and anaerobic conditions. Some studies suggest a lag phase before
degradation, but many do not. Degradation occurs in both adapted and unadapted sludge. Rapid
degradation has been reported in surface waters (less in salt water than in fresh water), groundwater,
and soil inoculate. Several strains of microorganisms capable of utilizing ethylene glycol as a carbon
source have been identified [7].

Limited data are available on measured concentrations of ethylene glycol in environmental

compartments. Levels measured in surface waters have been generally low, at a few micrograms per
litre. Concentrations in wastewater from production plants, prior to treatment, have averaged up to
1300 mg/litre. By far the highest reported concentrations relate to runoff water from airports, with
levels up to 19 000 mg/litre.

Ethylene glycol has generally low toxicity to aquatic organisms. Toxic thresholds for microorganisms
are above 1000 mg/litre. EC50s for growth in microalgae are 6500 mg/litre or higher. Acute toxicity
tests with aquatic invertebrates where a value could be determined show LC50s above 20 000
mg/litre, and those with fish show LC50s above 17 800 mg/litre. The only valid acute toxicity value
for amphibians is 17 000 mg/litre for Rana brevipoda tadpoles. A NOEC for chronic tests on
daphnids of 8590 mg/litre (for reproductive end-points) has been reported. A NOEC following short-
term exposure of fish has been reported at 15 380 mg/litre for growth. Tests using de-icer containing
ethylene glycol generally showed greater toxicity to aquatic organisms than the pure compound,
indicating other toxic components of the formulations. Laboratory tests exposing aquatic organisms
to stream water receiving runoff from airports have demonstrated toxic effects and death.

Field studies in the vicinity of an airport have reported toxic signs consistent with ethylene glycol
poisoning (oxalate crystal formation), fish kills, and reduced biodiversity. These effects cannot
definitively be ascribed to ethylene glycol. Terrestrial organisms are much less likely to be exposed to
ethylene glycol and generally show low sensitivity to the compound. Concentrations above 100 000
mg/litre were needed to produce toxic effects on yeasts and fungi from soil. Very high concentrations
and soaking of seeds produced inhibition of germination in some experiments; these are not
considered of environmental significance. A NOEL for orally dosed ducks at 1221 mg/kg body

25
weight and reported lethal doses for poultry at around 8000 mg/kg body weight indicate low toxicity
to birds.

2.2 PRODUCT SAFETY:

When considering the use of ethylene glycol in any particular application, review and understand
our current Material Safety Data Sheet for the necessary safety and environmental health
information. Before handling any products, you should obtain the available product safety
information from the suppliers of those products and take the necessary steps to comply with all
precautions regarding the use of ethylene glycol. No chemical should be used as or in a food, drug,
medical device, or cosmetic, or in a product process in which it may come in contact with a food,
drug, medical device, or cosmetic until the user has determined the suitability of the use. Because
use conditions and applicable laws may differ from one location to another and may change with
time, Customer is responsible for determining whether products and the information are
appropriate for Customer’s use [4].

26
 Figure- 2.1 Material Safety Data Sheet of Ethylene Glycol

2.3 STORAGE AND TRANSPORTATION:

Pure anhydrous ethylene glycol is not aggressive toward most metals and plastics. Since ethylene
glycol also has a low vapor pressure and is non caustic. It can be handled without any problems: it
is transported in railroad tank cars, tank trucks, and tank ships. Tanks are usually made of steel:

27
 high grade materials are only required for special quality requirements. Nitrogen blanketing can
protect ethylene glycol against oxidation.

At ambient temperature, aluminium is resistant to pure glycol. Corrosion occurs, however, above
100oC and hydrogen is evolved. Water air and acid producing impurities (aldehydes) accelerate this
reaction. Great care should be taken when phenolic resins are involved, since they are not
resistance to ethylene glycol.

2.4 ECONOMIC ASPECTS:

Ethylene glycol is one of the major products of the chemical industry. Its economic importance is
founded on its two major commercial uses as antifreeze and for fibre production. Since Ethylene
glycol is currently produced exclusively from ethylene oxide production plant are always located
close to plant that produce ethylene oxide. The proportion of ethylene oxide that is converted to
Ethylene glycol depends on local condition, such as market situation and transport facilities. About
60% of total world production is converted to ethylene glycol [2].

About 50% of the ethylene glycol that is used as antifreeze. Another 40% is used in fibre industry.
Consequently, the ethylene glycol demand is closely connected to the development of these two
sectors In view of the increasing price of crude oil, alternative production method based on
synthesis gas is likely to become more important and increasing competitive.

Figure 2.2 Global consumption of ethylene glycol

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2.5 LEADING PRODUCERS IN WORLD:
 BASF, Geismer, La. (America).

 DOW, Plaquemine, La .(America)

 OXYPETROCHEMICALS, Bayport, Tex .(America)

 SHELL, Geismer,La. (America)

 TEXACO ,Port Neches, Tex.(America)

 UNION CARBIDE, Taft,La.(America)

 BP Chemicals, Belgium, (West Europe).

 IMPERIAL Chemicals Ind. United Kingdom, (West Europe)

 BPC (NAPTHACHIMIE),France , (West Europe)

 STATE COMPLEXES ,USSR, (West Europe)

 PAZINKA, Yugoslavia, (West Europe)

 EASTERN PETROCHEMICAL CO. Saudi Arabia, (Middle East)

 National Organic Chemical, India, (Asia).
 Mitsubishis Petrochemicals, (Japan)

2.6 LEADING PRODUCER IN INDIA:

 India Glycol, Uttaranchal (North India).

 Reliance Industries Ltd. Hazira (Gujarat).

 Indian Petrochemical Corporation Ltd, Baroda (Gujarat).

 NOCIL, Thane.

 SM Dye chem. Pune.

29
 Figure 2.3 Production of Ethylene Glycol in India

2.7 QUALITY SPECIFICATION:

Since ethylene glycol is produce in relatively high purity difference in quality are not accepted. The
directly synthesized product meets high quality demands (fibre grade). The ethylene glycol produce
in the wash water that is use during ethylene oxide production is normally of a somewhat inferior
quality (antifreeze grade). The quality specifications for mono ethylene glycol are compiling in
table below. Since ethylene glycol is produced in relatively high purity, differences in quality are
not expected. The directly synthesized product meets the high-quality demands (polyester grade
glycol). The quality specifications are given in the table below. The UV absorption of fiber-grade
ethylene glycol is often used as an additional parameter in quality control [7].

30
 Table 2.1 Product Specifications of Fiber-Grade Ethylene Glycol

DESCRIPTION FIBER GRADE

Color, Pt-Co, max 5

Suspended matter Free

Diethylene Glycol, wt.% max 0.08

Acidity, as acetic acid, wt.% max 0.005

Ash, wt.% max 0.005

Water, wt.% max 0.08

Iron, ppm wt. max 0.07

Chlorides, ppm wt. max <0.2

Distillation Range, ASTM at 760mm Hg, °C, max 200

Odor Mild

UV Transmittance, %min at:

220 nm 70

250 nm 90

275 nm 95

350 nm 99

Specific Gravity, 20/20 °C 1.1151-1.1156

Water solubility Complete

Industrial grade ethylene glycol has a less stringent specification than fiber-grade, with a slightly
larger boiling range, higher allowable iron content and no UV transmittance test.
31
 Table- 2.2 Quality Specification OF Ethylene Glycol (Industrial Grade)

DESCRIPTION INDUSTRIAL GRADE

Color, Pt-Co, max 10
Suspended matter Substantially free
Diethylene glycol,.% max 0.6
Acidity, as acetic acid, wt.% max 0.02

Ash, wt.% max 0.005

Water, wt.% max 0.3
Iron, ppm wt. wt max 0.05
Distillation range, ASTM at 760mm Hg:
IBP, 0C min 196
DP, 0C max 199

UV transmittance, % min at:

220 nm 70
250 nm 90

275 nm 95

350 nm 99

Specific gravity, 20/20 oC 1.1151-1.1156

2.8 MANUFACTURING PROCESSES

Manufacturing processes for ethylene glycol involves laboratory methods and industrial

Methods [8]

2.1 Laboratory Methods

 An early source of glycols was from hydrogenation of sugars obtained from formaldehyde
condensation. Selectivity to ethylene glycol was low with a number of other glycols and
polyols produced. Biomass continues to be evaluated as a feedstock for glycol production.

32
  Using Potassium Permanganate- The most convenient and inexpensive method of preparing a
glycol in the laboratory is to react an alkene with cold dilute potassium permanganate,
KMnO4. Yields from this reaction are often poor and better yields are obtained using osmium
tetroxide, OsO4. However, this reagent is both expensive and toxic.
 By Hydrolysis Of Ethylene Bromide- The hydrolysis of ethylene bromide is done by boiling
under reflux with aqueous sodium carbonate solution. This reaction mixture is refluxed till an
oily globule of ethylene bromide disappears. The resulting solution is evaporated on a water
bath and semi-solid residue is extracted with ether-alcohol mixture. Glycol is recovered from
solution by distillation. The best yield of glycol (83-84%) can be obtained by heating ethylene
bromide with potassium acetate in Glacial acetic acid.

2..2 Industrial Methods

1) Hydrolysis of Ethylene- At present, the industrial approach to produce ethylene glycol is

hydration of ethylene oxide. Ethylene glycol is produced from ethylene (ethene), via the
intermediate ethylene oxide. Ethylene oxide reacts with water to produce ethylene glycol
according to the chemical equation:
C2H4O + H2O HO−CH2CH2−OH

This reaction can be catalyzed by either acids or bases, or can occur at neutral pH under elevated
temperatures. The highest yields of ethylene glycol occur at acidic or neutral pH with a large
excess of water. Under these conditions, ethylene glycol yields of 90% can be achieved. The
major by-products are the oligomers diethylene glycol, triethylene glycol, and tetraethylene glycol.
The separation of these oligomers and water is energy-intensive. About 6.7 million tonnes are
produced annually.

A higher selectivity is achieved by use of Shell's OMEGA process. In the OMEGA process, the
ethylene oxide is first converted with carbon dioxide to ethylene carbonate. This ring is then
hydrolysed with a base catalyst in a second step to produce mono-ethylene glycol in 98%
selectivity. The carbon dioxide is released in this step again and can be fed back into the process
circuit. The carbon dioxide comes in part from the ethylene oxide production, where a part of the
ethylene is completely oxidized.

33
2) Ethylene Carbonate Process- In this method, ethylene oxide is converted to an intermediate,
ethylene carbonate, by reaction with carbon dioxide, which is then hydrolysed by water to
give ethylene glycol. The carbonation process provides a saving in production cost. This is
largely because of a much lower steam requirement, owing to there being less excess water to
remove from the glycol. The carbonate process produces smaller amounts of di- and triglycol
coproducts, but the smaller requirement of ethylene oxide largely counterbalances the loss in
credits. This process was in use in the 1970s, but this process was replaced later by combined
ethylene oxide-glycol plants.

3) Halcon Acetoxylatin Process- This technology (Halcon license) was practiced by Oxirane in
1978 and 1979 but was discontinued due to corrosion problems. It is a two-step process.
In the first, ethylene glycol diacetate was obtained by the oxidation of ethylene in an acetic
acid solution, catalysed by tellurium and a bromine compound. The reaction complex, which
is quite complicated, is believed to proceed via a tellurium-bromoethylene complex. The
oxidation, which is carried out at 90-200 °C and 20-30 atm pressure, results in a mixture of
34
 acetates due to partial hydrolysis of the diacetate. The reaction liquid effluent is withdrawn
and processed to recover glycol acetates and glycol and provide the recycle streams back to
oxidation. In the second step of the process, the glycol acetates are hydrolysed to ethylene
glycol and acetic acid. The process however is not popular due to operating difficulties. A
plant started at Channelview to produce 800 million lb/yr of ethylene glycol was shut down
after difficulties in start-up. The catalysts and acetic acid are highly corrosive, requiring
expensive construction materials. Trace amounts of ethylene glycol mono-and diacetates are
difficult to separate from ethylene glycol limiting the glycol’s value for polyester
manufacturing.

4) From Ethylene Chlorohydrin- Ethylene glycol was commercially produced in the United
States from ethylene chlorohydrin which was manufactured from ethylene and hypochlorous
acid. Chlorohydrin can be converted directly to ethylene glycol by hydrolysis with a base,
generally caustic or caustic/bicarbonate mix. An alternative production method is converting
chlorohydrin to ethylene oxide with subsequent hydrolysis.

5) Union Carbide Syngas Process- The process was developed by Union Carbide, Inc. and uses
synthesis gas for the production of ethylene glycol. Glycerol and propylene oxide are the
major by-products. Methanol, methyl formate and water are also produced. An expensive
rhodium-based catalyst catalyses the reaction. The process is yet to be commercialized. Union
Carbide has already started work on a modified process in association with Ube Industries. It
plans to set up a commercial scale plant soon.

35
6) Teijin Oxychlorination Process- The Teijin process, which has not been commercialized yet,
produces ethylene glycol by the reaction of ethylene with thallium salts in the presence of
water and chloride or bromide ions. A redox metal compound (such as copper) oxidizable
with molecular oxygen is added to the reaction medium to permit the regeneration of the
thallium salt.

36
CHAPTER 3:
Process Selection and Description

The process selection is based on different advantages and parameters of the industrial methods.

Table 3.1 Comparison of Different Processes

1. Hydrolysis of Non- catalytic: Non-Catalytic:  Use large excess water to

Ethylene Oxide Yield: 98% increase the yield which
Selectivity: 98% leads to high energy
Temp:10℃ consumption
Pressure :1.5MPa

Catalytic: Catalytic:  Use less excess water which

Yield: 95% Sulfonic acids, leads to low energy
Selectivity: 90% Carboxylic acids consumption
Temp:200℃ and salts, Ion-  High yield & selectivity
Pressure :1-30 bar exchange resins,  Permit use of low temp &
Acidic zeolites, pressure
halides, Metal  Acid catalyst makes the
oxide and Metal reaction solution highly
salts. corrosive.
2. Ethylene Glycol Yield :50% Non-Catalytic  Very low yield selectivity
from Ethylene Selectivity: 75%  Very costly
chlorohydrin
3. Ethylene glycol Yield : 90-95% Chromate  High pressure process
From CO, H2, CH3OH & Temp: 200℃ Catalyst  Discontinued now a day
Formaldehyde Pressure:100atm  Low selectivity

4. Ethylene glycol Yield :98% Alkali halide  Give high yield and
from ethylene Selectivity: 95% or ammonium selectivity
carbonate Temp:180℃ salt.  Utility saving
Pressure:13bar  Extra purification cost
5. Esterification of Yield : 70% Copper  High conversion but catalyst
Oxalic acid and Selectivity: 90% Catalyst removal is very difficult
Reduction with
H2

37
6. Direct one stage Selectivity: 65% Rhodium  As crude prices increase this
synthesis of Temp:190-230℃ catalyst process will become more
Ethylene glycol Pressure:3400atm (Homogeneous economic
from syn gas ( Union catalyst route.)  Use of very high pressure
Carbide Process )  Not prove to be indirect
route maybe viable or not.
 Catalyst is very sensitive
and expensive.

3.1 PROCESS DESCRIPTION

The commercial route to ethylene glycols in use today involves the non-catalyzed thermal
hydrolysis of ethylene oxide. Ethylene oxide reacts with water to form glycol, and then further reacts
with ethylene glycol and higher homologues in a series of consecutive reactions giving oligomers as
byproducts.

The raw materials to a free standing glycol plant are refined ethylene oxide and pure water. These are
mixed with recycle waters and pumped into the hydration reactor after being preheated by the exit
product stream. The operating pressure of the reaction is controlled at a level, which limits or avoids
the vaporization of the ethylene oxide from the aqueous solution. Literature shows that commercial
reactors operating at 190-200℃ will be at pressures 14-22 atm depending on the initial concentration
of the oxide.

The water-glycol mixture from the reactor is fed to the first stage of the multiple stage of the
evaporator, which is reboiled with steam. The remaining stages operate at successively lower
pressures, with the final stage normally under vacuum. The evaporated water is recovered as
condensate and recycled back to the glycol reaction fed mixing tank. The water free glycol solutions
is sent to the series of vacuum distillation towers to produce purified monoethylene glycol and by-
product di- and triethylene glycol.

38
Figure 3.1- Process Flow Diagram

39
Figure 3.2- Process Flow Diagram

40
EO REACTION, EO AND CO SCRUBBING SECTION: Ethylene, oxygen, and
methane/nitrogen ballast gas enter from battery limits and are mixed with lean cycle gas before
entering a preheating unit (the Gas-Gas Exchanger). The gas mixture flows from the Gas-Gas
Exchangers to the EO Reactor/Gas Coolers where about 9.6% of the ethylene is converted per pass.
The ethylene to ethylene oxide selectivity is 83.4% at start-of-run (SOR). The reactors produce
ethylene oxide. The ethylene oxide is scrubbed from the EO Reactor/Gas Coolers exit gas using lean
cycle water and the rich cycle water is sent to the EO Stripping Section. The (scrubbed) cycle gas is
sent through the CO2 Contactor Section of the Wash Tower to remove carbon dioxide made in the
EO Reactor /Gas Coolers. The CO2 -lean gas is then recompressed back to the EO reactor/Gas
Coolers. Boiling water on the shell side of the multi-tubular reactors removes the heat of reaction.
Water circulation through the shell side of the reactors is by thermo syphon action. The steam-water
mixture from the reactors shell-side is sent to steam drums where make-up boiler feed water is
preheated and steam is separated from water and sent to the 21 kg/cm g steam header.

CO2 REMOVAL SYSTEM SECTION: The rich carbonate solution from the Carbonate Solution
Exchanger (EO and CO2 Scrubbing Section) is regenerated at essentially atmospheric pressure using
stripping steam. The regenerated lean carbonate solution is returned to the CO2 Contactor Section of
the Wash Tower (EO and CO2 Scrubbing Section) for CO2 absorption.

EO STRIPPING AND EO REABSORPTION SECTION: Rich cycle water containing ethylene

oxide in solution is preheated before entering the Stripping Column where ethylene oxide is stripped
out. The lean cycle water is then pumped through a series of heat exchangers where the water is
cooled prior to being returned to the Scrubber Section of the Wash Tower (EO and CO2 Scrubbing
Section). A bleed stream is taken and sent to the glycol unit to purge the glycol made in the cycle
water loop. The ethylene oxide in the overhead vapor from the Stripping Column is reabsorbed by
contact with cooled process water in the Re-absorber. The overhead from the Re-absorber is
compressed back into the cycle gas system by the Reclaim Compressor while the bottoms are sent to
the Glycol Feed Stripper (Glycol Reaction Section).

MEG reaction unit: Ethylene oxides mixed with recycle water and pumped to glycol reactor
where it is reacted with water at 1050C &1.5 MPa in the presence of catalyst. The Reactor is
Catalytic Plug flow Fixed bed type. The reaction volume consists of two phase, the liquid phase and
ionite (catalyst) phase. The liquid streams through catalyst bed in a plug flow regime. The catalytic
and non-catalytic ethylene oxide hydration takes place in the ionite phase, and only non-catalytic
41
reaction takes place in the liquid phase. The distribution of the components of the reaction mixture
between liquid and ionite phases is result of the rapid equilibrium. The glycol reactor operate at
approximately 1.5MPa pressure which is supplied by the reactor feed pump. The reactor effluent goes
to the evaporation unit for the evaporation of excess water.

MEG evaporation unit: The glycol evaporation system consists of multiple effect evaporation
system (three effects). The reactor effluent flows by difference in pressure from one evaporator to the
next the water content of glycol is reduced to about 15% in the evaporators. The remaining water is
removed in drying column, the pressure of the system is such that the reactor effluent is maintained as
a liquid and is fed as such in to the vapor portion of the first effect evaporator. Evaporation in the first
effect is accomplished by 12Kg/cm2 (g) pressure steam. The overhead vapor from the first effect is
used as heating media in the second effect. The steam condensate from the first effect is goes to the
medium pressure condensate header. The overhead vapour from the second effect is used as heating
media in the third effect. The third effect operated under vacuum. The vacuum is maintained by using
steam jet ejector. The bottom of the third effect containing 15% water is fed to crude glycol tank via
glycol pump, which is then fed to the drying unit. The condensate from first two effects and the vapor
from third effect containing water and some amount of glycol are fed to the glycol recovery unit.

MEG drying unit: The concentrated glycol from the third effect is containing approximately 15%
water. Essentially all the water is removed from the aqueous ethylene glycol solution in the drying
column. Normally the drying column is fed from the crude glycol tank. The drying column operated
under vacuum which is maintained by steam jet ejector. Drying column bottom which are free from
water are transferred by column bottom pump to MEG refining column. Where the MEG is separated
from the higher glycol, Water vapors leaving the top of the drying column are fed to MEG recovery
unit for glycol recovery. (An inert gas line is provided at the base of the drying column for breaking
the vacuum).

MEG refining unit: Drying column bottoms essentially free of water are fed to the MEG refining
column (PACKED COLUMN). About 15% of the feed to the MEG column enters as vapour due to
flashing. MEG product is withdrawn from the top of the column. Some MEG is purged in the
overhead to the vacuum jets to reduce the aldehydes in the product. The MEG column bottoms
primarily di-ethylene glycols are pumped from the column bottom to the storage tank. The MEG

42
column operates at a pressure of 10mmHg (A).The vacuum is maintained by MEG column ejector
system. The MEG column condenser is mounted directly on the top of the MEG column.

MEG recovery unit: The MEG leaving along with water from the Top of the multiple effect
evaporator & drying column are recovered in the MEG Recovery Column (PLATE COLUMN).The
column is operated under atmospheric pressure. MEG leaving from the bottom of the column and the
water leaving from the top of the column are Recycle to reactor.

Catalyst: Catalysts for the catalytic hydration of EO to EG primarily include anions of salts (such as
bicarbonate, bisulfide, and formate) immobilized on an ion-exchange resins (IER), quaternary
phosphonium halides, polymeric, supported metal oxides, and zeolites.

A cross-linked styrene–divinylbenzene anion exchange resin (SBR) in the HC �− −

3 /C �3 form,

activated by anion exchanging with sodium bicarbonate solution used as catalysts. (Dow Chemical
produced anion-exchange resins: DOWEX SBR). The ethylene oxide hydration process in a catalytic
fixed-bed tube reactor was studied .The properties of initial resins are summarized below:

Functional group: -[PhN(��3 )3 ]+

Particle size (mm): 0.3-1.2

43
CHAPTER 4:
Material Balance

Material balances are the basis of process design. A material balance taken over complete
process will determine the quantities of raw materials required and products produced. Balances
over Individual process until set the process stream flows and compositions. The general
conservation equation for any process can be written as

Material out = Material in + Accumulation

For a steady state process the accumulation term is zero. If a chemical reaction is taking place a
particular chemical species may be formed or consumed. But if there is no chemical reaction, the
steady state balance reduces to:

Material out = Material in

A balance equation can be written for each separately identifiable species present, elements,
compounds and for total material.

Basis
Production per annum = 1.2 Lakhs Tonnes

Working days per year = 300 days

So Capacity of plant per day = 400 TPD = 16666.67 kg/hr

Molecular weight of Ethylene Glycol (EG) = 62

So capacity = 16666.67 / 62 = 268.8 kmol/hr

This is the total amount of EG obtained from distillation/refining column.

Assumption:

44
  99% of EG in the feed to the column is obtained in distillate.
 93% of EG in feed to recovery column is recovered from recovery column.
 Suppose selectivity for Mono Ethylene Glycol is 95% in the reactor.
 Water content is reduced to 15% in the every evaporator.
 All the water is removed in the dryer.

Kmol of MEG fed to distillation column = 274 kmol/hr

4.1 Reactor

REACTOR
1 Temp. = 100℃ 2
Ethylene Oxide (EO) Ethylene Glycol
Conversion = 90% EG =274 kmol/hr
Water
Pressure = 1.5-2MPa Higher Glycol HG

Reactions taking place are-

C2H4O + H2O HOCH2CH2OH (1)

C2H4O + OHCH2CH2OH (HOCH2CH2)2OH (2)

Suppose selectivity for Mono Ethylene Glycol = 95%

Moles of undesired i.e. Higher Glycols HG = 274 / (0.95*100) = 2.88 kmol/ hr
From Reaction (2) Ethylene Oxide EO reacted = 3.2 kmol/hr

Hence from Reaction (1)

Total EG formed = 274 + 2.88 = 276.88 kmol/hr = 17166.56 kg/hr

Moles of EO reacted in reaction (1) = 307.64 kmol/hr

45
Hence total EO fed = 307.64 + 3.2 = 310.84 kmol/hr = 13676.96 kg/hr
By literature survey we know that EO: Water in feed = 1:10
So Water fed = 310.84 x 10 = 3108.4 kmol/hr = 55951.2 kg/hr
Water reacted in reaction (1) = 307.64 kmol/hr
Water unreacted = 3108.4 – 307.64 = 2800.76 kmol/hr = 50413.68 kg/hr
Moles of HG formed = 2.88 kmol/hr
HG formed = 106 * 2.88 = 305.28 kg/hr

Table 4.1 Material Balance on Reactor

Component In(kg/hr) (Stream 1) Out(kg/hr) (Stream 2)

Ethylene Oxide EO 13676.96 -
Water 55951.2 50413.68
Ethylene Glycol EG - 16988
Higher Glycols HG - 305.28

4.2 TRIPLE EFFECT EVAPORATOR

EG = 10 kmol/hr
Water = 2380.646 kmol/hr

Water=2800.76 kmol/hr. EVAPORATOR EG=264 kmol/hr

EG=274 kmol/hr HG = 2.88 kmol/hr
HGG = 2.88 kmol/hr. Water = 420.114 kmol/hr

Consider water content is reduced to 15% i.e. 85% of water is to be removed

Amount of water removed i.e. water in top product = 0.85 * 2800.76 = 2380.646 kmol/hr
= 42851.628 kg/hr

46
So total quantity of water in the bottom product = 2800.76 – 2380.646 = 420.114 kmol/hr
= 7562.052 kg/hr
There must be some carryover of EG with water in the top

Let the total amount of EG carried over along with water = 10 kmol/hr = 620 kg/hr
Total quantity of (Water + EG) leaving from top of the last effect = 10 + 2142.62
=2152.62 kmol/hr
Total EG in the bottom = 16988 - 620 = 16368kg/hr
Assume EG carryover in the first effect = 215kg/hr and water removed= 12453.6 kg/hr

EG = 215kg/hr
Water =12453.6kg/hr

1st Effect

FEED Pressure = 7 kg/cm2 MEG = 16773 kg/hr

Temp = 159 oC Water = 37960.08 kg/hr

Assume MEG carryover with water in 2nd effect = 205 kg/hr and water removed =13483.3 kg/hr

MEG=205kg/hr
Water=13483.3kg/hr

2nd Effect
Feed from 1st effect Y. MEG=16568kg/hr
Pressure = 3.5 kg/cm 2
Water=24476.78 kg/hr
Temp = 141 oC

Assume MEG carryover with water in 3rd effect =200 kg/hr and water removed=16914.728 kg/hr

47
 MEG = 200kg/hr
Water = 16914.728 kg/hr

3rd effect
4 MEG=16368 kg/hr
3
Pressure = 0.25 kg/cm 2
Feed from 2nd effect Water=7562.052kg/hr
Temp = 118 oC

Table 4.2 Material Balance on Triple Effect Evaporator

Component In(kg/hr) (stream 3) Out

Liq. Vapour
(stream 4) (stream 5)
EG 16988 16368 620
HG 305.28 305.28 -
Water 50413.68 7562.052 42851.628

4.3 DRYING
8 Water=420.114 Kmol/hr
EG=7 Kmol/hr
EG=264 Kmol/hr Drying Column
6
HG=2.88 Kmol/hr Pressure = 0.21 kg/cm2
Temp = 87 oC
Water=420.114 Kmol/hr
7 EG = 257 Kmol/hr
HG = 2.88 Kmol/hr
Feed F = 264 + 2.88 + 420.114 = 686.994 kmol/hr
48
Consider all water is removed

So amount of water removed which is in the top product = 420.114 Kmol/hr

= 420.114 x 18 kg/hr = 7562.052 Kg/hr
Assume amount of EG carried over with water = 7 Kmol/hr
So Amount of EG in the top product stream = 434 kg/hr
Total quantity leaving in top product stream D = 420.114 + 7 = 427.114 kmol/hr

So from overall material balance,

F=D+W
686.994 = 427.114 + W
W= 259.88 kmol/hr
Amount of EG in bottom stream = 264 – 7 = 257 kmol/hr = 15934 kg/hr

Table 4.3 Material Balance on Drying Unit

Output (Kg/hr)
Components Input (Kg/hr) Bottom Top
(stream 6) (stream 7) (stream 8)
Water 7562.052 _ 7562.052
EG 16368 15934 434
HG 305.28 305.28 _

4.4 REFINING COLUMN

11 D = 254.68 kmol/hr
EG = 254.43 kmol/hr
Feed = 259.88 kmol/hr HG= 0.25 kmol/hr
Refining Column
EG=257Kmol/hr Pressure = 10 mmHg
9
Temp = 93.2 oC
HG=2.88Kol/hr

10 W = 5.2 kmol/hr

49 EG = 2.57 kmol/hr
HG = 2.63 kmol/hr
Assuming 99% recovery of EG

Amount of EG in distillate = 257 * 0.99

= 254.4 kmol/hr
= 15774.66 kg/hr
Suppose 99.9% of distillate is EG

0.999D = 254.43
D = 254.68 kmol/hr
HG in distillate = 254.68 - 254.43
= 0.25 kmol/hr
= 26.5 kg/hr

Also from Overall Material Balance,

W=F-D
W = 259.88 - 254.68 = 5.2 kmol/hr
HG in W = 2.88 – 0.25 = 2.63 kmol/hr
= 278.78 kg/hr
EG in W = 5.2 - 2.63 = 2.57 kmol/hr
=159.34Kg/hr

Table 4.4 Material Balance on Refining Column

Output (Kg/hr)
Components Inputs(Kg/hr) Liq. Vap.
(stream 9) (stream 10) (stream 11)
EG 15934 159.34 15774.66
HG 305.28 278.78 26.5

50
4.5 RECOVERY UNIT

Total EG in feed for recovery unit = EG carried over in Evaporator + EG carried over in Drying
= 10 + 7 = 17 kmol/hr
= 1054 kg/hr
Total water in feed = Water from Evaporator + Water from Drying unit
= 2380.646 + 420.114 = 2800.76 Kmol/hr
= 50413.68 kg/hr

Top D = 2799.14 kmol/hr

14
EG = 1.19 kmol/hr
Water = 99.9 % of water fed
= 2797.95 kmol/hr
Recovery Unit
Feed = 2817.76 kmol/hr
Pressure = 10 mmHg
EG=17 Kmol/hr Temp = 93.2 oC

Water =2800.76 Kmol/hr

Bottom W = 18.62 kmol/hr
13 MEG = 15.81 kmol/hr

Water = 2.81 kmol/hr

We had assumed 93 % recovery of EG

So EG recovered = 0.93 * 17 = 15.81 kmol/hr
= 897.76 kg/hr

EG in distillate = 17 - 15.81 = 1.19 kmol/hr

= 73.78 Kg/hr
Water in Distillate = 0.999 * 2800.76 = 2797.95 Kmol/hr
= 50363.266 kg/hr
Hence kmol of distillate D = 2797.95 + 1.19

51
 = 2799.14 kmol/hr
From Overall Material Balance,
F=D+W
2817.76 = 2799.14 + W
W = 18.62 kmol/hr
Water in W = 2800.76 - 2797.95 = 2.81 kmol/hr = 50.58 kg/hr

Table 4.5 Material Balance on Recovery Unit

Outputs kg/hr
Components Inputs kg/hr Liq. Vap.
(Stream 12) (Stream 13) (Stream 14)
Water 50413.68 50.58 50363.266
EG 1054 980.22 73.78

52
Components units Stream

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Ethylene 13676.
Kg/batch - - - - - - - - - - - - -
Oxide 9

55951. 50413. 50413. 7562.0 4285 7562.0 7562.0 50413. 50363.

Water Kg/batch - - - - 50.58
2 68 68 52 1 52 5 6 26

Ethylene 159.3 15774. 980.2

Kg/batch - 16988 16988 16368 620 16368 15934 434 15934 1054 73.78
Glycol 4 6 2

Higher 278.7
Kg/batch - 305.28 305.28 305.28 - 305.28 305.28 - 305.28 26.5 - - -
Glycols 8

67706. 67706. 24235. 4347 24235. 16239. 7996.0 16239. 438.1 15801. 51467. 1030. 50437.
Total Kg/batch 69628
9 9 33 1 33 2 5 2 2 1 6 8 04

Table4.6 showing Total Material Balance

53
CHAPTER 5:
Energy Balance

The first law of thermodynamics demands that energy be neither created nor destroyed. The
following is a systematic energy balance performed for each unit of the process. The datum
temperature for calculation is taken as 0 C. The different properties like specific heat, heat of reaction,
heat of vaporization, etc. are taken to be constant over the temperature range.

5.1 REACTOR

REACTOR
Temp. = 100℃
EO = 310.84 kmol/hr HG = 2.88Kmols/hr
Conversion = 90%
Water = 3108.4 kmols/hr EG= 274 Kmol/hr
Pressure = 1.5-2MPa
Water= 2800.76Kmols/hr

In the reactor following reaction takes place

�2 �4 O + �2 O HOC�2 C�2 OH --------- (1)

(Ethylene oxide) (Water) (Mono Ethylene Glycol)

�2 �4O + HOC�2C�2 �� HOC�2 C�2 OH ----------- (2)

(Ethylene oxide) (Mono Ethylene Glycol) (Higher Glycol)

54
 Table 5.1 Heat capacity and Enthalpy data

∆�° (kJ/kmol)
COMPONENT CP (kJ/kmol)
At temp. 298 K

Ethylene oxide -52640 47.9

Water -285830 75.28

MonoEthyleneGlycol -454800 149.5

Di-EthyleneGlycol -562570 441.602

Assume reference temp. = 25℃

 Enthalpy of formation of reaction

For first reaction

∆�0� = ∆ �0�� − ∆ �0��

= -454800 – (- 52640 – 285830)

= -116330 kJ/kmol of EO reacted
= -116330 x 282.4
= - 3.285 x 107 kJ/hr
For second reaction

∆�0� = ∆�0�� − ∆�0��

= -562579 – (- 52640 - 454800

= - 55130 kJ/kmol of EO reacted
= - 55130 x 282.4
= - 1.55 x 107 kJ/hr
Total enthalpy of formation = (- 3.285 x 107) + (- 1.55 x 107)

55
 = - 48.42 x 107 kJ/hr
 Enthalpy of reactants
As reactants are added at 25℃, so, its Enthalpy becomes 0.

 Enthalpy of products
∆�� = [( ���)��� + (��� )����� + ��� ��]∆�
= {(276.28 x 149.5) + (2800.76 x 75.28) + (2.88 x 441.602)} (100-25)
= 1.743 x 107 kJ/hr
 Enthalpy of reaction

∆�0� = ∆�� + ∆�0� − ∆��

= 1.743 x 107 + (- 48.42 x 107) - 0

= - 47.317 x 107 kJ/hr
So, it indicates that it is an exothermic reaction.

5.2 TRIPLE EFFECT EVAPORATOR:

Water to be evaporated = 42851.628 kg/hr
Total feed �� = 67401.68 kg/hr
The balances applying to this problem are:
FIRST EFFECT: �� �� + �� �� − �1 �� = �1 �1

MEG = 215 kg/hr

�2 � = 12453.6 kg/hr

Feed = 67401.68 kg/hr 1st Effect Evaporator

MEG = 16988 kg/hr MEG = 16773 kg/hr
Pressure = 7 kg/cm2
SECOND EFFECT: � Water = 37960.08
Water = 50413.68 kg/hr Temp. = 159 C
kg/hr

�1 �1 + �� − �1 �1 − �1 �� = �2 �2

56
 Water = 13483.3 kg/hr

MEG = 205 kg/hr

From 2nd effect evaporator MEG = 16568 kg/hr

Pressure = 3.5 kg/cm2
Water = 24476.78 kg/hr
Temp. = 141 oC

THIRD EFFECT: �2 �2 + �� − �1 − �2 �2 − �3 �� = �3�3

MEG = 200 kg/hr

�2 � = 16914.728 kg/hr

3RD Effect Evaporator

From 3rd effect MEG = 16368 kg/hr
Pressure = 0.25 kg/cm2
evaporator Water = 7562.052 kg/hr
Temp. = 118 oC

To MEG recovery column

Material balance: �1 + �2 + �3 = �1−3

�� = 100 o C
Consider steam is entered at 12 kg/cm2 so Ts = 190.825 o C
(After finding boiling point of solution)
Also last effect operates at a vacuum of 0.25 kg/cm2
So �3 = 106.15 o C

57
Consider for forward feed multiple effect evaporator pressure differences between effects will be
nearly equal.
So average pressure difference = 385.056 KPa /effect

Table 5.2 Latent Heat data

Pressure, KPa Steam or vapour λ, λ , kJ/kg (MEG)

temp. C kJ/kg (steam)
Steam chest, 1st effect 1179.69 TS= 190.82 λ S = 2210.8
Steam chest, 2nd effect 794.63 t1=175.17 λ 1 = 2244.1 λ 1 = 982.935
Steam chest, 3rd effect 409.57 t2=152.585 λ 2 = 2284.0 λ 2 = 1001.15
Vapor to condenser 24.53 t3= 106.155 λ 3 = 2379.1 λ 3 =1022.317

 FIRST EFFECT :

Cp avg. = �1 ��1
= 4.196 kJ/kg K
λ avg = 2016.38 KJ/Kg
�� �� + �� �� − �1 �� = �1 �1
�� X 1973.62 + 67401.68 x (100 – 175.17) x 4.196 = W1 x 2016.38
W1 = - 10273.928 + 0.9787 Ws

 SECOND EFFECT:

Cp avg = �� ���
= 4.105 KJ/Kg K
λ avg = 2088.28 KJ/K
�1�1 + (�� + �1 ) �1 − �2 �� = �2�2
W1 x 2016.38 + {(67401.68 – W1) x (175.17 – 152.585) x 4.105} = W2 x 2088.28
Put value of �1 from equation (1) and finally
�2 = 0.9010 Ws – 6702.47

58
  THIRD EFFECT
Cp avg = �� ���
= 3.873 KJ/Kg o K
Λ avg = 2207.35 KJ/Kg

�2 �2 + (�� − �1 − �2 ) �2 − �3 �� = �3 �3
W2 x 2088.28 + (67401.68 – W1 – W2) x (152.585 – 106.115) x 3.873 = W3 x 2207.35
Put value of �2 from equation 2 and finally we get
�3 = 0.7 Ws + 117.524
Taking overall Material balances:
�1 + �2 + �3 = �1−3 = 38567.016 + 620 (Amount of glycol carryover with water)
�� = 21725.739 kg/hr (Amount of Steam Required)
From above equations we calculated,
�1 = 10989.05 kg/hr
�2 = 12872.42 kg/hr
�3 = 15325.54 kg/hr
Now, Enthalpy out from the bottom of the last effect,
������� = 122 oC ���������� = 25 oC
∆� = 97 oC
Enthalpy out from Bottom = (mCp∆T) MEG + (mCp∆T) WATER + (mCp∆T) HG
= {(16368 x 3.077) + (7562.052 x 4.378) + (305.28 x 4.1032)}
= 7.897 x 106 kg/hr

59
 Top = 7996.052 kg/hr
5.3 Drying Unit MEG = 434 kg/hr

Water = 7562.052kg/hr

Feed = 24235.332 kg/hr DRYING COLUMN

686.994 kmol/hr Pressure = 0.25 kg/cm2
MEG = 16368 kg/hr Temperature = 87 oC
HG = 305.28 kg/hr

Water = 7562.052kg/hr
Bottom = 259.88 kmol/hr = 16239.28 kg/hr

MEG = 15934 kg/hr = 257 kmol/hr

HG = 305.28 kg/hr = 2.88 kmol/hr

Toperating = 87 oC Treference = 25 oC

o
Hence ΔT = 87 – 25 C = 62oC.

Poperating = 0.25 kg /cm 2

Enthalpy of Feed = 7.897 x 106 kJ / hr

Enthalpy out from Top = (mλ )water + ( mλ )MEG +( mCpΔT )

= [(7562.052 x 2366.1) + (434 x 1109 .75)] + [378.8 x 75.2 x 62]
= 18.35 x 106 kJ / hr

Enthalpy out from Bottom = (mCpΔT )MEG + ( mCpΔT )HG

= [(257 x 187.90) + (2.88 x 432.72)] x 62
= 3.07 x 106 kJ / hr

Total Enthalpy out = Enthalpy out from (Top + Bottom)

= 18.35 x106 + 3.07 x 106
= 21.42 x106 kJ / hr

Enthalpy of feed = 7.897 x 106 kJ / hr

Q = Total Enthalpy out - Enthalpy of feed

60
 = 21.42 x10 6 - 7.897 x 106
= 13.52 x 106 kJ/hr (Amount of Steam Required)

Consider the steam enter at 2 kg/cm2 & 118.719oC

λsteam = 2205.82 kJ/kg

Q = m λsteam

21.42 x 106 = m x 2205.82

m = 6130.6 kg / hr (Rate of Steam)

5.4 Refining Column Top D = 254.68 kmol/hr

MEG = 15774.66 kg/hr = 254.43 kmol/hr
HG = 26.5 kg/hr = 0.25 kmol/hr
Feed = 16239.28 kg/hr MEG REFINING
654.988 kmol/hr COLUMN
MEG = 15934 kg/hr Pressure = 10 mmHg
HG = 305.28 kg/hr Temperature = 93.2 oC

Bottom W = 5.2 kmol/hr = 16239.28 kg/hr

MEG = 159.34 kg/hr = 2.57 kmol/hr
HG = 278.78 kg/hr = 2.63 kmol/hr

For top:
Assume Ttop = 91.8 oC Treference = 25 oC
ΔT = 66.8 oC
Poperating = 10 mmHg
Cpmean of MEG = 149.70 kJ / kmol oK
Cpmean of HG = 441.6 kJ / kmol oK
Total Enthalpy out with Distillate = (mCpΔT) MEG + (mCpΔT )DEG
QD = [(254.43 x 149.70) + (0.25 x 441.6)] x 66.8
QD = 2.55 x 106 kJ / hr
61
Assume Reflux Ratio = 0.71
i.e. L/D = 0.71
L = 0.71D
Vapor formed at the top
V = L + D = 0.71D + D = 0.71 x 254.68
V = 435.5 kmol / hr
Reflux L = 0.71D
= 0.71 x 254.68
L = 180.83 kmol / hr

 Enthalpy out with vapor:

QV = latent heat + sensible heat associated with that vapor
= mλ + (V Cp ΔT)
λEG = 68.578 x 103 kJ / kmol
λHG = 72.067 x 103 kJ / kmol
λAVEG = 68.58 x 103 kJ / kmol
QV = [(435.5 x 68.58 x 103) + (435.5 x 188.298 x 66.8)]
= 34.22 x 106 kJ / hr

 Enthalpy out with Reflux:

QReflux = (L CpΔT)Reflux
= [180.83 x 188.551 x 66.8]
= 2.27 x10 6 kJ / hr

 Condenser load:
QC = QV – ( QReflux + QD )
= [(34.22 x 106 ) – (2.27 x 106 + 2.55 x 106 )]
= 29.4 x 106 kJ / hr

For Bottom
Assume Tbottom = 94.6 oC ΔT= 69.6 °C
Cpmean of MEG = 188.531 kJ / kmol K
Cpmean of DEG = 443.2 kJ / kmol K
Enthalpy out with Residue, QW = ( mCpΔT )liq
= [(2.57 x 188.531) MEG + (2.63 x 443.2) DEG] x 69.6
= 0.12 x 106 kJ / hr

62
  Reboiler Load:
Reboiler heat load is determined from a balance over complete system

QB + QFeed = QD + QW + QC
QFeed = 3.07 x 106 kJ / hr

QB = (2.55 x 106 + 0.12 x 106 + 29.4 x 106 – 3.07 x 106)

=29 x 106 kJ / hr Amount of steam required
Consider the steam enter at 2 kg/cm2 & 118.719oC
λsteam = 2205.82 kJ / kg
QB = m λ steam
29 x 106 = m x 2205.82 kJ/kg
m = 13147.04 kg/hr

5.5 Recovery Column

Top D = 2799.14 kmol/hr
MEG = 156.24 kg/hr = 2.52 kmol/hr
Feed = 46428.95 kg/hr Water = 45327.4 kg/hr = 2797.95 kmol/hr
= 2817.76 kmol/hr
MEG = 1054 kg/hr MEG RECOVERY
=17 kmol/hr COLUMN
Water = 45372.95 kg/hr
= 2800.76 kmol/hr
Bottom W = 18.62 kmol/hr = 943.12 kg/hr
MEG = 897.76 kg/hr = 14.48 kmol/hr
Water = 45.36 kg/hr = 2.81 kmol/hr

For Top
Assume Ttop = 194 oC Trefrence = 25 oC
So ΔT = 169 oC
Poperating = 760 mmHg
Cp mean of MEG = 197.24 kJ / kmol K
Cp mean of H2O = 76.55 kJ / kmol K

Total Enthalpy out with Distillate = (mCpΔT )MEG + (mCpΔT )WATER

= [(2518.19 x 76.55) + (2.81 x 197.24)] x 169
63
 QD = 32.66 x 106 kJ / hr
Reflux Ratio = 0.51
i.e. L/D = 0.51 or L = 0.51D
Vapor formed at the top, V = L + D
= 0.51D + D
= 1.51 x 2520.71
V = 3806.27 kmol / hr
Reflux L = 0.51D
= 0.51 x 2520.71
L = 1285.56 kmol / hr
 Enthalpy out with vapor:
QV = latent heat + sensible heat associated with that vapor
= mλ + (mCpΔT)

λMEG = 68.578 x 103 kJ / Kg λH2O = 40.65 x 103 kJ / Kg

λAVEG = 40.67 x 103 kJ / kmol

QV = [(3806.27 x 40.67 x 103) + (3806.27 x 197.24x 169)]

= 281.7 x 106 kJ / hr

 Enthalpy out with Reflux:

QReflux = (mCpΔT)Reflux
= 1285.56 x 76.67 x 169
= 16.65 x106 kJ / hr
 Condenser load
QC = QV – ( QReflux + QD )
= (281.7 x 106 ) – (16.65 x 106 + 32.66 x106 )
= 232.39 x 106 kJ / hr
Assuming cooling water enter the condenser at 25oC & leaves at 45oC
QC = (mCpΔT )cooling water
232.39 x 106 = m x 75.7962 x 20
m = 113.63 x 103 kg / hr (Rate of cooling water)
For bottom

Tbottom = 198 oC Treference = 25oC

ΔT = 173 oC
64
 Cpmean of MEG = 197.6285 kJ / kmol K
Cpmean of Water = 76.607 kJ / kmol 0K
 Enthalpy out with Residue:

QResidue = (mCpΔT)liquid
= [(14.48 x 197.6285) MEG + (2.81 x 76.607)water ] x 173
= 584.46 x 103 kJ / hr
 Reboiler Load:
Reboiler heat load is determined from a balance over complete system
QB + QFeed = QD + QW + QC
QFeed = (mCpΔT )feed
= [(17 x 187.97) MEG + (2520.71 x 74.51) WATER] x 80
= 15.28x 106 kJ / hr
Reboiler load
QB = [(32.66 x 106 + 584.46 x 103 + 232.39 x 106 ) – (15.28x 106) ]
= 250.354 x 106 kJ / hrAmount of steam required,
Consider the steam enter at 2 kg/cm2 & 118.719oC
λsteam =2037.51 kJ / kg
QB = mλ steam
250.354 x106 = m x 2037.51
m = 122.87 x 10 3 kg / hr (Rate of steam)

65
CHAPTER 6:
Major Equipment Design

6.1 Reactor
PRODUCT= 3077.64
REACTOR kmol/hr= 67706.96 kg/hr
FEED = 3419.24
kmol/hr= 16857.36 kg/hr Ethylene Glycol EG = 274
Temp. = 100℃ kmol/hr= 16988 kg/hr
EO= 310.84
kmol/hr=13676.96 kg/hr Conversion = 90% Higher Glycol HG= 2.88
Pressure = 1.5-2MPa kmol/hr= 305.28 kg/hr
Water= 3180.4 kmol/hr=
Water= 2800.76 kmol/hr=
50413.68 kg/hr

The plug flow reactor has been selected according to:-

1) Mostly used for EG production.

2) High conversion.
3) No back mixing.
4) Less volume than CSTR.
5) Economical.

C 2H 4O + H 2O HOCH 2CH 2OH (1)

(Ethylene oxide) (Water) (Mono Ethylene Glycol)

The reaction is second order which obey the following equation:

-rEO = K *CE0* Cw

Where:

-rEO = rate of reaction.

66
k = constant of reaction.

CEO = concentration of ethylene oxide.

Cw = concentration of water.*

Mole fraction of EO= XEO= 0.091 Mole fraction of water= Xw= 0.909

Hence, ρmix = ∑ Xi * ρi = 0.091*882 + 0.909 * 1000

= 989.262 kmol/m3

Vmix = Mmix / ρmix = 3.456 m3

Ci = Mi / Vmix

By substituting in equation

CEO = 89.94 kmol/m3

Cw = 862.1 kmol/m3

As the concentration of water is large enough to be considered as constant so the reaction order will
become pseudo first order, as following :

-rEO = K * CEO

From Arhennius Equation, K= 0.305 hr-1

For plug flow reactor,

��
� ��
=
��� − ��
0

Here FA0 = 310.84 kmol/hr and XA = 0.9

On solving the equation, we get V= 30.76 m3

Mechanical Design
Stainless steel is used here because the reaction is at high pressure.

Generally the ratio of length to diameter (L/D) for reactors has range 1 to 3. Here it has been selected
as 1.5.
67
V= π D2 * L /4

By substituting:

D = 3.56 m L = 5.34 m

For a cylindrical shell, the minimum thickness required to resist internal pressure can be determined
by equation

t = Pi * Di / (2f – Pi)

t = thickness of cylindrical shell

Pi = Pressure of reactor = 2 MPa

On solving, t = 26.567 mm

6.2 Distillation column

Top D = 2799.14 kmol/hr

MEG = 156.24 kg/hr = 2.52 kmol/hr
Feed = 46428.95 kg/hr Water = 45327.4 kg/hr = 2797.95 kmol/hr
= 2817.76 kmol/hr
MEG = 1054 kg/hr MEG RECOVERY
=17 kmol/hr COLUMN
Water = 45372.95 kg/hr
=2800.76 kmol/hr
Bottom W = 18.62 kmol/hr = 943.12 kg/hr
MEG = 897.76 kg/hr = 14.48 kmol/hr
Water = 45.36 kg/hr = 2.81 kmol/hr

Let,

Mole fraction of MEG XF= 0.9889

XD = 0.999

XW = 0.4918

Numbers of theoretically stages:

Use McCabe Thiele method for determining the theoretical stages.

68
Assumption:
Binary mixture separation between MEG & DEG.

P= total pressure of the system = 10 mmHg

So at top, Psat MEG = 1.334 KPa

Psat DEG = 0.1331 KPa

So, top = Psat MEG / Psat DEG

= 1.334 / 0.1333

= 10.077

Now at bottom, Psat MEG = 1.4757 KPa

Psat DEG = 0.1673 KPa

So, bottom = Psat MEG / Psat DEG

= 1.4757 / 0.1673

= 8.8174

Thus, average = {top x bottom } 0.5

= {10.007 x 8.8174}0.5

average = 9.3933

Now we have the equation

Y = X / {1+ (-1)}

From the above eqn we can generate the vapor- liquid equilibrium data given as follow:

X 1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Y 0 0.5106 0.70134 0.80102 0.8623 0.9037 0.9337 0.9563 0.9740 1

69
Now plotting x-y diagram & Using McCabe Thiele method for determining the theoretical stages.
No. of theoretical stages = 18

Packed Column Diameter and Column Height:

The necessary data required is as follows:

Reflux Ratio = 0.71

Feed = saturated liquid (assume)

Kmol of Feed F = 188.306 kmol

Kmol of Distillate D = 184.54 kmol

Kmol of Bottom W = 184.54 kmol

Liquid density, L = 954 Kg/m3

Vapor Density, G = 2.099Kg/m3

Liquid Viscosity, = 2.2 x 10-3 Kg/m s

No. of theoretical stages = 18 ( from vapor liquid Equilibrium diagram). Owing to its low pressure
drop per theoretical stage metal Pall Ring is often preferred to other packing for vacuum distillation.

Here, L/D =0.71

L = 131.0234 Kmol / hr

Vapor rate = V = L+D

= 184.54 + 131.0234

= 375.5634 Kmol / hr.

Mass flow rate of vapor = (375.5634 x 62.044)/ 3600

Mg = 6.4726 Kg /s

Mass flow rate of liquid= (131.0234 x 62.044)/ 3600

70
 Ml = 2.2581 Kg /s

Flow parameter:

X = (Ml/Mg)*(G / L- G)0.5 ………. (1)

Where, X = flow parameter

Ml = Mass flow rate of liquid = 2.2581 Kg/s

Mg = Mass flow rate of vapor = 6.4726 Kg/s

G = Density of vapor=2.099Kg/m3

L = Density of liquid =954 Kg/m3

From equation (1)

2.2581 2.099
6.4726
(954  2.099)

X = 0.01638

By using plot of flooding and Pressure drop.

Here, column is operated under vacuum, plot value at X = 0.01638

We get Y = 0.0125

Owing to its low-pressure drop, the metal pall ring is used as a packing for vacuum distillation:

Pall Ring: Metal

Size: 38 mm (1.499”)

Packing Factor fp (m-1) =131

Deigned H.E.T.P. (m) = 0.5425

Viscosity of liquids = 2.2 x 10-3 Kg/m s

Density of gas = 2.099 kg / m3

Density of liquid = 954kg / m3

71
G' in kg/m2.s is calculated as:

Y= (G’2 fp µ^0.1)/ (G* (l- G))

G'2 = [(0.0125 x 2.099 x (954 – 2.099)] / [131 x (2.2 x 10-3) 0.1]

G'2 = 0.3515 kg / m2 s

G’ = 0.5929 kg / m2 s

Taking vapor mass velocity as 60% if flooding velocity.

Hence, Area of tower

At = Mg/ (0.6* G’)

= 6.4726 / (0.6 x 0.5929)

= 18.19 m2

�
Diameter of tower, � = 4
∗D∗D

D = 4.81  5 m

Total height of packed be

Z = No.of theoretical stages x H.E.T.P.
HETP = height equivalent to one theoretical plate.
For pall ring metal (1.5”) H.E.T.P. = 0.5425
Z = No .of theoretical stages x H.E.T.P.

Z = 18 x 0.5425

Z = 9.765 m = 10 m

In packed tower, height of each bed is approximately ≥ its diameter.

Hence, 2 beds of 5 m heights are provided.

Spacing between each bed is = 2 m

Hence, total spacing = 0.5 x 3 = 1.5 m

Taking both disengaging space and distribution space = 2 m

Hence total height of tower =10 + 2 + 2
= 14 m
72
CHAPTER 7:
Instrumentation and process control
Instruments are provided to monitor the key process variables during plant operation. Instruments
monitoring critical process variables will be fitted with automatic alarms to alert the operators to
critical and hazardous situations.

1) REACTOR:

Figure 7.1 – INSTRUMENTATION DIAGRAM OF REACTOR

In the instrumentation diagram of Reactor we can note that:

73
 a) Thermocouple - In the diagram, thermocouples are used to measure and control the
temperature in case of emergency through control room. The temperature sensing instruments
are used to control the temperature so that selectivity of catalyst is set to optimum.
b) Flowmeter- One Flow controller is deployed at the entry of cooling water, to control flow rate
of cooling water. Drain is also provided for removal of extra cooling water.
c) One bypass valve is provided at the entry of feed to be used in case of emergency.
d) Motor and normal control valve are provided at each pipe to ensure the flow rate within
specified parameter.
e) Vent is provided for removal of non-toxic vapors from heat exchanger (reactor) and avoiding
the pressure buildup inside vessel.
f) Catalyst bed is regenerated using Ion exchange resin regeneration process.

2) EVAPORATOR:

Figure 7.2 – INSTRUMENTATION DIAGRAM OF EVAPORATORS

In the instrumentation diagram of Evaporator we can note that:

74
 a) Three digitally controlled gate valves are used at each entry of the evaporators for
the maintaining the inlet stream flow rate so that no overflow occurred in
evaporator.
b) Vents are provided for each evaporator to limit the internal pressure of vessels.
c) One pump is provided at the entry point of the multiple effect evaporators to
provide enough head to feed stream.
d) Evaporated water is passed through filter and reused in heat exchanger to provide
heat to feed.
e) For pressure measurement Bourdon tube is used as it can also be digitally operated
and provides less error.
3) DRIER:

Figure 7.3 – INSTRUMENTATION DIAGRAM OF DRIER

In the instrumentation diagram of Drier we can note that:

a) Two desiccant bed are used in alter operation using the two motor controlled
75
 valves. The operating time of a single drier is set to be 24 hours after that
another drier is opened by making the previous one closed.
b) A heater is provided for preheating of air to remove the water from the feed.
c) DCS is used to control the flow rate air from the blower.
d) Evaporated water is passed through filter and reused in heat exchanger to provide
heat to feed.
e) Pall rings packing is used in the packed bed of the driers. The pall rings are rested
on the mesh.

76
CHAPTER 8:
Plant Utility

The utilities such as water, air, steam, electricity etc. are required for most of the chemical
process industries. These utilities are located at a certain distance from processing area, from
processing area hazardous and storage area etc, where a separate utility department works to
fulfill the utilities requirements.

 Steam Generation
 Cooling water
 Water
 Electricity
 Compressed air

The utilities required for the plant are summarized as below .

1) STEAM GENERATION:

Steam is used in plants for heating purpose, where direct contact with substance is not
objectionable. The steam, for process heating, is usually generated in water tube boiler
using most economical fuel available i.e. coal, fuel oil on the site.
In reboiler of distillation column, drying column and evaporator steam is used at
different temperature depending on requirement.

2) COOLING WATER:

Cooling water is generally produced in plant by cooling towers. Cooling tower is used
to cool the water of high temperature coming from process. Cooling tower mainly
decreases temperature of water from process. There are two types of cooling tower.

77
 i. Natural Type: In this cooling tower the water from the process is allowed to fall in a tank.
From some height when falling it comes in contact with an air & gets cool.
ii. Mechanical Type: They are classified in three types:
Induced draft

Forced draft

Balanced draft

3) WATER:

A large reservoir has to be made which received water from nearby river. Storage also must
provide to such extent that turbidity is settling and then sent to raw water plant for further
treatment. Chlorine dose must be given to kill bacteria which prevent organic matter. Then this
water is sent to further treatment. To cooling tower, DM plant, service water system, drinking
water system, fire water system.

Cooling water is required for heat cooler, condenser etc. for cooling effect. Here in cooling tower
water is fall from high level and contacted with cross flow of air. Latent heat of water is high that
even a small amount of water evaporates produce large cooling effect. The temp of CW is up to 25
to 30 ˚C. DM water is use for process. DM water is produced by removing impurities salts, pass
through anion exchanger.

4) ELECTRICITY:

It is required for motor drives, lighting, and general use. It may be generated on site or purchased
from GEB and GIPCL. Transformers will be to step down the supply voltage to the voltage used
on site. A three phase 415V system is used in general for industrial purposes and 240V single
phase for lighting and other low power requirements. For large motors, high voltage 600-1100 is
used .

5) COMPRESSED AIR:

Compressed air is used during the chocking of pipes and for cleaning purpose. Compressed air can
be obtained from air compressor.
78
 CHAPTER 9:
Plant Location and Layout
Plant location means to discover an exact place where an industrial experience can be started
more profitable & a plant is a place where men, material, money, equipment, machinery etc.
are brought together for manufacturing products. Plant location involves two major activities.
Plant location plays a major role in the design or production as it determines the cost of:
 Getting suitable raw material.
 Processing raw material to finished products.
 Finished products distribution to customers.
The final selection of the plant location has a strong influence on the success of any industrial
venture. The following eighteen factors should be considered in choosing a plant side.

9.1 Raw material supply

The source of raw material is one of the most important factors influencing the selecting of the
plan. The raw material should be cheaply & regularly available at the plant site because this
permits considerable reduction in transportation & storage charges..

9.2 Markets
The location of markets or intermediates distribution centers can heavily affect the cost of
product distribution. Primarily to large market can be beneficial in the following three ways:
 The cost of transportation of the finished goods to the market is brought drastically down.
 The delay in supplying the goods to the market can be continently reduced & avoided.
 The market is studied properly & easily i.e. the future requirements can be easily &
accurately predicted.

9.3 Energy availability

Electricity power, steam supply & heating oil requirements are high in most of the
chemical plants. The power & fuel can be considered as one major factor in the choice of

79
the plant site. The local cost of power can help in determining whether power should be
purchased or self-generated.

9.4 Water supply

The chemical process industries use large quantities of water for cooling, heating, washing & as a
raw material. Therefore the plant site should be nearer to the source of water.

9.5 Climate
Weather can have serious effect on the economic operating of the plant. Temperature & humidity of
weather should be favorable.

9.6 Transportation
The everyday products are always needed to be transported from the plant site to the
marked or other plants & the raw materials necessary from the sources to the plant.
Hence transportation holds a great deal in the final product cost. A plant should have easy
access to transport facilities. Not only that, the transport facilities available to the plant should
also be sufficient, quick & available at reasonable rates.
Water, railway & national high-ways are the most common means of transportation.
These facilities are very much necessary for the transfer of raw material & product transportation.

9.7 Labor supply

Availability of skilled laborers with constant supply & reasonable pay rate should be
considered in the selection of the plant site. Labor problem should be minimum.

9.8 Waste disposal

The plant site should be such that it should have the best & adequate facilities for waste
disposal. The permissible tolerance levels for various methods of waste disposal should be
considered carefully & attention should be given to potential requirements for waste
treatment facilities.

80
 9.9 Taxes & legal phases
The state & local tax rates on property (such as plant machinery, building etc.), income, and
unemployment insurance & similar items have major influence on the plant site selection.

9.10 Site characterization

The characteristics of the land at the proposed plant site should be examined carefully. The
topography of the tract of the land & the soil structure must be considered, since either or both
have pronounced effect on construction costs

9.11 Plant Layout.

After the process flow diagrams are completed & before detailed piping, structural & electrical
design can begin, the layout of process units in the plant must be planned.
Plant layout means the allocation of space, arrangement of equipment & machinery in such a
manner so that maximum utilization of manpower, machines & material is done & minimum
material handling is required.
The following factors should be considered in selecting the plant layout.

 New site development or additions to previously developed site.

 Type & quantity of product to be produced.

 Possible future expansion.

 Economic distribution of utilities & services.

 Type of building & building code requirements.

 Health & safety considerations.

 Waste disposal problems.

 Sensible use of floor & elevation space.

 Operational convenience & accessibility.

 Type of process & product control.

 Space available & space required.

81
 Maximum advantages of gravity flow are taken to reduce the operational cost in the piping
& flow design

9.12 Storage Layout:

Adequate storage of raw materials, intermediate products, final products, recycle materials &
fuel are essential to the operating of process plants.

9.13 Equipment Layout:

In making plant layout, a due consideration should be given to that an ample space should be
assigned to each piece of equipment & their accessories. The relative levels of the several
pieces of equipment & their accessories determine their placement.
Gravity flow is preferable to reduce material handling cost during production, however it is
not altogether necessary because liquids can be transported by pumping & solids can be
moved by mechanical means. In making the equipment’s layout, the grouping should be done
so that the service of equipment’s performing similar function is grouped together & so the
better co-ordination of the operating is achieve

82
CHAPTER 10:
Safety and Pollution Control

1) SAFE OPERATIONS:

The goal of chemical plant is not only to produce the chemicals, but to produce
them safely. In the plant’s chain of processes and operations, loss of control
anywhere can lead to accidents and losses of life and property from hazards.
Attempts should be to prevent troubles from the inspection, while designing,
fabricating and operating.
Safety generally involves:

(1) Identification and assessments of the hazards

(2) Control of hazards
(3) Control of the process by provision of automatic control
system, interlocks, alarm trips, etc
(4) Limitation of the loss, by press relief, plant layout, etc.

2) FIRE PREVENTION AND PROTECTION:

1) Regulation for the prevention of Fire:

Ban on carrying of a potential source of ignition, Ban on lighting fires in battery

area. Ban on smoking. Ban on carrying lamps. Use of Sparks’s arrestors.

2) General Precautions:

Maintain good housekeeping. Follow the laid down procedure strictly. Sampling
and draining of hydrocarbon should be done under strict supervision. Do not
operate the equipment unauthorized. Use only approved type of tools. Anticipate
the hazards during vessel cleaning and take prevention steps in advance.
83
3) Fire emergency mock drill:

An emergency manual can be prepared to outline procedures and drills and detail
responsibilities of each individual involved .

 Training
 Valuable Check On The Adequacy and Condition of
exits and Alarm system
 Instills a Sense of Security Among The Occupiers if Careful Plans Are Made.
 Exits Drills
 Plant Drills (Mock drills in plant area)
 Mutual Aid Drills
 On-Site / Off site Drills etc.

3) ENVIORNMENTAL CONSIDERATIONS
The environmental considerations include:
 Control of all emission from the plant.
 Waste management.
 Smells.
 Noise pollution prevention.
 The visual impact.
 Liquid effluent specifications
 Environmental friendliness of the products.
3.1) WASTE MANAGEMENT:
Waste arises mainly as byproducts or unused reactants from the process, or as off-
specification product produced through mis-operation. In emergency situations, material
may be discharged to the atmosphere through vents normally protected by bursting discs and
relief valves.

3.2) GASEOUS WASTES:

It is to be remembered that practice of relying on dispersion from tall stacks is seldom
entirely satisfactory. The gaseous pollutants can be very easily controlled by using
adsorption or absorption. Dispersed solids can be removed by scrubbing, or ESP. If the gas
84
is flammable it is to be burnt. As in the present case the gaseous waste being carbon dioxide.
But the gases should not be sent to vent or to atmosphere and hence the suitable scrubber
system requires to be installed downstream to minimize pollution.

3.3) LIQUID WASTE:

If the liquid effluent is flammable, it can be burnt in the incinerator. But as in this case if it
contains salts; acids and substantial amount of alkali it is to be subjected to effluent
treatment. Generally common effluent treatment plant (if the facility is situated in and
Industrial area with the CETP) serves the purpose. The level of effluent treatment up to
secondary treatment is sufficient for the effluent from the plant like one on the hard.

3.4) SOLID WASTE:

Solid wastes can be burnt in suitable incinerators or disposed by burial at licensed land fill
sites. Dumping of toxic solid waste should be avoided.

3.5) AQUEOUS WASTE:

The principle factors which determine the nature of an aqueous industrial effluent and on
which strict controls will be placed by responsible authority are:
 pH
 Suspended solids
 Toxicity
 Biological oxygen demand
For the present case pH of the effluent stream is expected to be alkaline and hence
addition of acids is recommended to neutralize the same. The suspended solids can
be removed by settling, using Chemical treatment may be given to remove some of
the chemicals.
Oxygen concentration in waste course must be maintained at a level sufficient to
support aquatic life. For this reason, the biological oxygen of an effluent is of
paramount importance. Standard BOD 5 tests can be applied for the determination
of the same. The test measures the quantity of oxygen which a given volume of
effluent will absorb in 5 days at constant temperature of 20 0C. It is a measure of
85
the organic matter present in the effluent. Ultimate oxygen demand test can be
performed if required.
Waste water should be discharged into sewers with the agreement of the local
water pollution control authorities or state pollution control boards.

3.6) NOISE

Noise can cause serious nuisance in the neighborhood of a process plant. Care
need to be taken when selecting and specifying equipments such as compressors,
air-cooler fans, induced and force draft fans for furnaces, and other noisy plant.
Excessive noise can also be generated when venting through steam and other relief
valves, and from flare stacks. Such equipments should be fitted with silencers.
Noisy equipment should be as far away from the site boundary.

3.7) VISUAL IMPACT:

The appearance of the plant should be considered at the design stage. Few people
object to fairyland appearance of a process plant illuminated at the night, but it is
different scene at daytime. There is little that can be done to change the appearance
of modern style plant, where most of the equipment and piping will be outside and
in full view but some steps should be taken to minimize the visual impact.

4) ENVIRONMENTAL AUDITING:

The company should go for a systematic examination of how a business operation affects
the environment. It will include all emissions to air, land and water and cover the legal
constraints the effect on the community the landscape and the ecology. Following are some
of the objectives of the environmental audit:

1) To identify environmental problems associated with the manufacturing process and

the use of the products before they become liabilities.
2) To develop standards for good working practices.
3) To ensure compliance with environmental legislation.

86
4) To satisfy requirements of insurers.
5) To be seen to be concerned with environmental questions: important for public
relation.
6) To minimize the production of waster: an economic factor .

87
CHAPTER 11:
Cost Estimation

A plant design obviously must present a process that is capable of operating under
conditions, which will yield a profit. Since net profit equals total income minus all
expenses, it is essential that the chemical engineer be aware of many different
types of costs involved in manufacturing processes.

The material used for storage tanks is SS-304.

11.1 Cost Estimation

1) Reactor
Poperating = 1500 kPa
Pstandard = 2070kPa > Poperating
Now, capacity of reactor = 30.76 m3
Standard cost of reactor of this capacity in January 2002 was = ₹ 4431675 (data is
taken from Timmerhaus)
From Cost Index method,
Present cost = Original cost * (Index value at present time) / (Index value at
Original time)
Now, we are using Chemical Engineering Plant Cost Index (CEPCI) Cost index in
2002 = 395.6
Average Present Cost index i.e. in 2021 = 616.5
Present Cost of Reactor = 4431675*(616.5 / 395.6) = ₹ 6906288.265

2) Triple Effect Evaporators

Cost of triple effect evaporator in 2002 = ₹ 3000000 * 3 (Cost is 3 times the

88
number of effect)
= ₹ 9000000
From cost index Method,
Present Cost of Evaporator = 9000000 *(616.5 / 395.6) = ₹ 14025530.8

3) Drying Column
Cost of Drying Column of surface area 5 m2 in 2002 = ₹ 3496800
From Cost Index method,
Present Cost of Drying Column = 3496800 * (616.5/395.6) = ₹ 5449386.25

4) Refining Column
Cost of Refining column having height of 3m and diameter of 3m in 2002 = ₹
16074213.76
Cost of our Refining column having height 3.5 and diameter of 5m in 2002 is,
Original cost = 160742
13.76*(3.5*5*5/3*3*3) ^ (0.6) (By six-tenths-factor Rule) = ₹ 22872993.45
So, Present cost of Refining Column = 22872993.45 *(616.5 / 395.6) = ₹
35645097.3

5) Storage Tank

The Storage tank of 500 m3 of storage is needed.

Cost of 500 m3 storage tank in 2002 = ₹ 8915076.06
Present Cost of Storage tank = ₹ 8915076.06 * (616.5 / 395.6) = ₹ 13893186.024

11.1.1 Purchased Equipment Cost

Cost per Unit Total Cost (in

S. NO. Equipment No. of Equipment
(in Lakhs) Lakhs)
1 MEG STORAGE TANK 2 138.93 277.86
2 HG STORAGE TANK 1 138.93 138.93

89
 ETHYLENE OXIDE STORAGE
2 138.93 277.86
3 TANK

PACKED BED
4 1 69.6 69.6
REACTOR
TRIPPLE EFFECT
5 1 140.25 140.25
EVAPORATOR
REFINING COLUMN
6 1 356.45 356.45
(PACKED COLUMN)
7 DRYING COLUMN 1 54.49 54.49

8 CENTRIFUGAL PUMP 6 2 12

9 HEAT EXCHANGER 7 7 49
10 BOILER 2 10 20

11 COOLING TOWER 2 22.5 45

TOTAL PURCHASE EQUIPMENT COST (PEC) = ₹ 1441.44 Lakh

11.1.2 Direct Costs

ITEM PERCENTAGE COST IN

S.NO.
OF PEC (%) LAKHS
Purchased Equipment
1 Cost 100 1441.44

Purchased Equipment
2 Installation cost 25 360.36

Instrumentation & Control cost

3 (Installed) 10 144.144

4 Piping cost (Installed) 50 720.72

5 Electrical Installation cost 10 144.144
6 Building cost 30 432.432
7 Yard improvement cost 10 144.144
8 Service facilities cost 40 576.576

90
 9 Land cost 5 72.072
TOTAL DIRECT COST = ₹ 4036.03 LAKH

11.1.3 Indirect Costs:

Sr. No. Item % of PEC Cost (Rs. Thousand)
1 Engineering & Design Cost 15 211.1625
2 Construction expenses 10 140.78
3 Contractors Fees 5 70.388
4 Contingencies 10 140.78

TOTAL INDIRECT COST = ₹ 563.11 LAKH

Fixed Capital Investment (FCI) = Total Direct Cost + Total Indirect Cost

= 4036.03 + 563.11

= ₹ 4599.14 Lakh

Working Capital Investment (WCI) = 20% of Fixed Capital Investment (FCI)

= 0.2 x 4599.14

= ₹ 919.828 Lakh

TOTAL CAPITAL INVESTMENT (TCI) = Fixed Capital Investment + Working Capital Investment

= ₹ 5518.968 Lakh

91
11.2 ESTIMATION OF TOTAL PRODUCTION COST:

11.2.1 Manufacturing Cost

 DIRECT PRODUCTION COST

1) Raw Material Cost

Working Days = 300

Raw Material Amount Cost Cost (Lakh Rs)

Ethylene oxide 98474112 (Kg/Year) 45(Rs / Kg) 44313.35

Styrene Di -vinylbenzeneanion
exchange Resin

(Catalyst) 0.69 m3 112500 (Rs/m 3) 0.7763

TOTAL COST OF RAW MATERIAL = ₹ 44313.6 Lakh

2) Utilities Cost = 20% of Raw Material Cost

= 0.2 x 44313.35 = ₹ 8862.67 Lakh

3) Maintenance and Repair Cost = 10 % of Fixed Capital Investment

= 0.1 x 4599.14 = ₹ 459.914 lakh

4) Operating Labour & Supervision Cost = 5% of Raw Material Cost

= 0.05 x 44313.35 = ₹ 2215.66 Lakh

5) Lab & Other Service Cost = 1% of Raw Material Cost

= 0.01 x 44313.35 = ₹ 443.13 Lakh

DIRECT PRODUCTION COSTS = Raw Material Cost + Utilities Cost + Maintenance and

Repair Cost + Operating Labour & Supervision Cost + Lab

& Other Service Cost

92
 = 44313.35 + 8862.67+ 459.914+ 2215.66 + 443.13

= ₹ 56294.724 Lakh

 FIXED COST:

1) Depreciation = 10 % of Fixed Capital Investment

= 0.1 x 4599.14 = ₹ 459.914 lakh

2) Local Taxes = 2 % of Fixed Capital Investment

= 0.02 x 4599.14 = ₹ 91.9828 lakh

3) Insurance Cost = 3 % of Fixed Capital Investment

= 0.03 x 4599.14 = ₹ 137.9742 lakh Rs.

TOTAL FIXED COST = Depreciation + Local Taxes + Insurance Cost

= ₹ 689.871 lakh

 PLANT OVERHEAD COST:

These costs are 100% of Labour cost, so, plant overhead cost is ₹ 1786.68 Lakh

TOTAL MANUFACTURING COST = Direct Production Costs + Total Fixed Cost + Plant
overhead cost

= 56294.724+ 689.871 + 1786.68

93
 = ₹ 58771.275 Lakh

11.2.2 General Expenses

1) Administrative Cost = 6% Of Manufacturing cost

= 0.06 x 58771.275 = ₹ 3526.2765 Lakh

2) Distribution & Marketing cost = 15% Of Manufacturing cost

= 0.15 x 58771.275 = ₹ 8815.69125 Lakh

Total General Expenses = ₹ 10341.967 Lakh

TOTAL PRODUCTION COST = Total Manufacturing Cost +Total General Expenses

= 58771.275 + 10341.967

= ₹ 69113.242 Lakh

11.3 PROFITABILITY ANALYSIS

Working days = 300

Product Amount kg/year Selling Price Rs./kg

MEG 120000000 60

Total Selling Cost (TSC) = ₹ 72000 Lakh

Gross Profit = Total Selling Cost – Total Production Cost

= 72000 – 69113.242
= ₹ 2886.758 Lakh
Tax Paid = 0.4 x Gross Profit = 0.4 x 2886.758
= ₹ 1154.7032 Lakh

94
NET PROFIT = Gross Profit – Tax Paid

= 2886.758 – 1154.7032

= ₹ 1732.0548 Lakh

PAYOUT PERIOD

����� ������� �������� ��� ����

�. �. � =
��� ������ + ������������

4599.14
�. �. � = 1732.0548 + 459.914

= 2.098 Years

RATE OF RETURN

��� ������
�. �. � = � 100
����� ������� ����������

1732.0548
�. �. � = � 100
5518.968

= 31.38 %

BREAK-EVEN POINT

Let N tonnes per annum be the Break-Even Production Rate

Fixed Cost = ₹ 689.871 lakhs/year

At break-even production,

Fixed charges + Direct Production Cost = Selling Cost

95
 (₹ 689.871 + ₹ 56294.724) Lakh = ₹ 60 * 1000 * N

N = 94974.325 TPA = 316.581 TPD

Hence, the break-even production rate is 316.581 TPD of the considered plant capacity.

96
CONCLUSION
Ethylene Glycol is a chemical has a vast usage in commercial and industrial applications. It
underpins almost every aspect of everyday life, particularly associated with energy, chemicals,
automotive, textiles, transportation, and manufacturing technologies.

There are various processes for the production of ethylene glycol but the process which is
employed mostly is the Hydration of Ethylene Oxide process. The same has been discussed in
this project in detail. This project helped us in developing the understanding of how a production
plant works and what necessary equipments are needed to set up the plant. The cost analysis
gives us the estimate of the total cost that is needed for the production.

The total production cost of the plant is found to be ₹ 691.13 Crores for producing 1,20,000 tons
of ethylene glycol per year.

97
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[12] Ethylene glycol: properties, synthesis, and applications, Hairong Yue, Yujun Zhao, Xinbin Ma
and Jinlong Gong* Chem. Soc. Rev., 2012, 41, 4218–4244
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1a7af4d9-5fc5-4cc1-8c3f-a33c6e2c0438
[16] https://www.chemengonline.com/2021-cepci-updates-january-prelim-and-december-2020-
final/#:~:text=The%20preliminary%20value%20for%20the,increase%20of%20over%205%20points.

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