MANUFACTURE OF ETHANOL

Project members:
sravanthi.G
Raju.M
Sudheer. Ch

Under the guidance of:

N.Lavanya ,M.Tech
Contents:

 Introduction
 Physical properties
 Selection of the process
 Process description
 Flowsheet
 Material balance
 Energy balabce
 Design of shell&tube heat exchanger
 Design of Distillaton column
 cost estimation
 plant layout
 Bibliography
Introduction:

 Generic name derived from two arabi words al and kohol.

 replacement for MTBE
PHYSICAL PROPERTIES

Property value
Freezing point(0c) -114.1

Normal boiling point(0c) 78.32

Critical volume L/mole 0.167

Density gm/cc
0.7857
Surface tension at 298k dyne/cm 23.1

Viscosity at 293k cp 1.17

Heat of vapourisation at normal 200.6

Boiling point cal/gm
Physical properties:

 colourless mobile liquid with pleasant smell.

 excellent solvent for fats,resins and other organic substances .
 dissolves in KOH,NaoH and sulphur.
Chemical Names:

Other names Ethyl alcohol; grain alcohol; pure alcohol;

hydroxyethane; drinking alcohol; ethyl hydrate;
absolute alcohol
Various types of processes:
1. Ethylene hydration
2. Fermentation process
3. cellulosic ethanol
4. Indirect hydration

Selection of the process:

 Petroleum wastes are increasing

 To convert this to useful this is the best.

 a fuel additive without enhancement of properties.

Process description:

 Raw materials: ethylene , water

 Reactor operating conditions: Temperature and
pressures are 229°C and 4975kpa.
MATERIAL BALANCE

Basis: 200tonns/day of ethanol

Reactor

COMPONENTS INNS (kg) OUTS (kg)

Ethylene 14266.31 9701.09

Ethane 133.92 133.92

water 53280.85 50346.07

Ethanol 7500

Total 67681.08 67681.08

Flash1:
Components Feed (kg) Vapor (kg) Liquid (kg)

Ethylene 9701.09 9679.524 21.56516

Ethane 133.92 133.9172 0.00276

Water 50346.07 142.3659 0.00276

Ethanol 7500 225.5789 7274.422

Flash 2: components Feed(kg) Vapor(kg) Liquid(kg)

Etylene 21.56516 11.7979 9.7674

Ethane 0.00276 0.00273 0.000021

Water 50203.71 0.3669 50203.35

Ethanol 7274.422 0.5823 7273.839

Distillation column:
considering the Ethylene and Ethane are nearly equal to
zero

Compon Feed Distillate Residue

ents (Kg) (kg) (kg)
Ethylene 7273.83 6911.94 363.54

Water 50203.3 767.94 49435.7

5 1
ENERGY BALANCE

MIXER:
M4H4= M1H1+M2H2+M3H3
Water H1 = 3723.882 cal/gm
feedC2H4 H2 =436.7135 cal/gm
mix strm H3= 2492.519cal/gm
Enthalpy out = 4573.5cal/gm
HEATER :
Enthalpy in = 4573.5cal/gm
Enthalpy out = 2271.409cal/gm
Temperature = 502.15K
Amount of Energy Requrired for heater = m*(H2-H1)
=2.06*108cal/hr
Reactor :
Mass flow = 7944.53kg
Temperature = 502.15K
Enthalpy in =2271.409cal/gm
Enthalpy out =2083.421 cal/gm
∆ H0std = -46cal/gm
Hr = H2-H1 +(∆ H0std)=141cal/gm
Cooler :
Temperature = 323.15k
Enthalpy out =2083.421 cal/gm
Enthalpy in = 2566.833Cal/gm
Amount of energy required for cooler
= m*(H2-H1) = 1.494*107cal/hr
Flash 1 :
Temperature = 321.4722K
Enthalpy of vapor = -358.77Cal/gm
Enthalpy of Liquid = 3079.09Cal/gm
MfHf = MlHl + MvHv
Flash 2 :
Temperature = 320.3833K
Enthalpy of feed = 3079.09 Cal/gm
Enthalpy of vapor = -261.0714 Cal/gm
Enthaply of Liquid = -3231.112 Cal/gm
MfHf = MlHl + MvHv
Distillation Column :
Feed Temperature = 320.3823K
Enthalpy = 3231.112Cal/gm
Enthalpy of C2H4 Vapor = -46.36 Cal/gm
Temperature = 327.7553K
Enthalpy of Ethanol = 1593.819 Cal/gm
Temperature = 327.753K
Enthalpy of Waste Water = 3602.323 Cal/gm
Temperature = 393.04K
Condenser Load = 4.5388kw
Reboiler Load = 1.8479kw
Splitter :
Temperature = 327.7553K
Enthalpy = -46.3659 Cal/gm
Vapor of Flash2 = -261.0715 Cal/gm
Vapor of Flash1 = -308.7978 Cal/gm
Enthalpy of Split Fraction = -295.7032 Cal/gm
Enthalpy of Purge = -295.707 Cal/gm
Temperature = 322.22K
Compressor :
Temperature = 576.359K
Enthalpy =-420.1819 Cal/gm
DESIGN OF SHELL&TUBE HEAT
EXCHANGER
 Ft = 0.6911
 ∆Tlm = ft *∆Tln =69.0050
 U = 400 -600w/m2 0c choosen U=450w/m2 0c
 A = Q/U∆Tlm = 529m2
 Area of one tube = 0.4049m2
DB  do  
 K1 
1
 Nt  n1

 number of tubes = 1306 1

 Nt  n 1

 Bundle diameter = DB  do  K 
 1
=1292.5666mm
 Bundle diameter clearence= 80mm
 Shell diameter = Ds = 1372.5666mm
 0.14
Tube side coefficient = hi di 0.33   

 J h Re Pr  
k  w 

=810.09w/m2 0c
 shell side coefficient = hs=
k 1
xjh x Re x Pr 3
de

=16705.0455w/m2 0c
  do 
ln
do  
1 1 1  di  do 1 do 1
 overall coefficient =     *  *
 h0 hod 2k w di hid di hi

=387.4077w/m2 0c    
m
 P 42
 Tube side pressure drop= Pt  Np 8 j  L     2.5
f   w
  Di     2

=0.8112kpa 0.14
 Ds   L   us   
2
 Shell side pressure drop = Ps  8 j f      
D l
 e  B  2   w 
=37.6722psi
DESIGN OF DISTILLATION COLUMN
 Total number of stages = 20
 Tray Spacing (Lt) = lm
 Column height = 19 m
 Column diameter = 3.28208m
 Superficial velocity = 1.3534m/sec
 Area of the column = 8.4598m2
 Down comer area = 1.0152m/sec
 Net area (Ah) = 7.448m2
 Hole area (AL) = 0.7448m2
 Weir length (lw) = 2.4129 m
 Weir length (hw) = 50 mm
 Hole diameter (dh) = 5 mm
 Plate thickness ( Pt) = 5mm
 Chord length (Uh) = 0.5909mm
 Perforated area(Ar ) = 7.445m2
 Residual Drop(hr) = 14.1122mm
 Vapour velocity through holes(Uh) = 10.8668
 Plate total pressure drop (ht) = 116.08mm
 Residual drop = 14.1122mm
 Total pressure drop (Uh) =10.8668
 Flooding velocity (VA) = 3.904
 Liquid vapour flow factor = 0.0959
 Height of bottom edge of apron = 42 mm
 Clearance Area (Aap) = 0.1013m
 Head logs in down comer = 13.6602mm
 Residence time down comer (tr) = 7.656Sec.
COST ESTIMATION
EQUIPMENT NO. OF UNITS COST PER TOTAL COST (cr)
UNIT(cr)

Mixer 1 0.02647 0.02647

Splitter 1 0.02647 0.02647
Heat Exchanger 2 0.2814 0.5628

Reactor 1 2.45 2.45

Distillation column 1 0.7381 0.7381

Compressor 1 2.7232 2.7232

Valves 2 0.03 0.06
Flash 2 0.49 0.98
Total PEC=7.567
 DIRECT COST
TYPE OF COST RANGES ASSUMED TOTAL COST (cr)

Purchased equipment cost 7.567

Insulation cost 10-15% 11% 0.8324

Piping of insulation cost 18-25% 18% 1.3621

Instrument and controlled 50-70% 55% 4.1619

cost
Building cost 10-70% 40% 3.0268

Installation cost 10-40% 20% 1.5134

Service facilities 30-80% 40% 3.0268

Yard improvement 10-20% 13% 0.9837

Land cost 20% 20% 1.5134

Technology and 20% 20% 1.5134

INDIRECT COST

TYPE OF COST RANGES ASSUMED TOTAL COST cr

Engineering 15-35% 20% 5.1

&supervision cost

Construction 35% 35% 8.925

expenses &
contractors fee

Contingency 8-20% 10% 2.55

Total IDC=16.575
 Fixed capital investment = DC+IDC =42.075 cr
 Working capital investment (WCIC):
10-20% of FCI . Assume 13%.
WCIC=5.4698cr
 Total capital investment = FCI+WCIC=47.5448
FIXED CHARGERS
Type of cost Ranges Assumed Total cost (cr)

Depriciation 10% 10% 4.2075

local taxes 3 -4% 3% 0.1262

Insurance 1% 1% 0.4208

Total FC=4.7545
 But fixed chargers= 15% of TPC
 TPC= fixed chargers* 0.15 = 31.6967 cr
 DIRECT PRODUCT COST
Type of cost Ranges Assumed Total cost(cr)

Raw materials 0.0591

Waste treatment 20% 20% 6.3393

utilities 10 -20% 12% 3.8035

Operating labour 15% 15% 4.7545

Direct superivisory 18% 18% 0.8558

&labour

Maitaince &Repairs 2 -10% 7% 2.9453

Operating supplies 0.09% 0.09% 0.0379

laboratory chargers 10 -20% 13% 0.6181

 Plant overhead cost = 50-70% 0f*(OLC+DSCLC+MRC)
=4.7056
 Total manufacturing cost = FC +DPC+ POC=28.876cr
GENERAL EXPENCES
Type of cost Ranges Assumed Total cost (cr)

Administrative cost 20 -30% 25% 0.0122

Distribution & selling cost 2 - 20% 19% 2.8876

Research & Development 3% 0.03% 0.5825

Total GE= 3.4823

 Total production cost = TMC + GE= 32.3583
 No. of operating days = 330
 Cost of ethanol per kg = 42
 Product annual sales =277.2 cr
 grss profit = Total income- TPC= 244.8417
 net profit = GP *( 1-tax)= 159.1471cr
 Rate of return = (NP*100)/ (TS)=57.4124cr
 Total variable cost = TDC+POC+GE= 33.6888cr
 At break even point FC+TVC= Net sales
 TPC= VC+FC
 VC= (TVC/PR)*Capacity
 Annual sales= capacity*cost per kg
capacity fixed cost variable cost TPC Annual sales

0 4.7545 0.0 4.7545 0

10000 4.7545 5.1 9,8545 42

20000 4.7545 10.2 14.9545 84

30000 4.7545 15.3 20.0545 126

40000 4.7545 20.04 25.1545 168

50000 4.7545 25.5 30.2445 210

60000 4.7545 30.6 35.3545 252

66000 4.7545 33.66 38.4145 277.2

Conclusion:

If the capacity is greater than 1500tonns/year profit will be

achieved.
PLANT LAYOUT
REFERENCES

 http://www.sciencedirect.com
 http://www.mde.stste.md.us
 http://
www.blepa.gov.otaq/consumer/fuels
/mtbe
 http://www.icis.com
 http://www.wikipedia.com
 http://che.cemr.wvu.edu
/publications
BIBILOGRAPHY:
 Analysis synthesis and design of chemical processes by
Richard Turton, Richard C. Bailie, Wallanc B. Whiting, Joseph
a. shaeiwitz
 Plant design and economics for chemical engineers, 4th
edition., by Max S.Peters, Klaus D. Timmerhause
 Coulson and richardson’s chemical engineering by R.K.
Sinnott, 6th volume, chemical engineering design
 The consolidated Perry’s chemical engineering hand book,
Robert H.Perry, Don W.Green
 Process heat transfer by Kern
THANK YOU