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Process for the Production of Methyl Acetate from
Methanol and Acetic Acid
Team 1Ezgi KAYAHAN
Zeynep ÖĞRETMENGizem KUŞOĞLUErcan GÖKÇALYetkin DEMİR
1
IntroductionBasis of Design
Process Structure
Process Flow Diagram
Equipment Design
Process Control
Waste, Environment, Safety
Economy
Conclusion
CONTENT
2
INTRODUCTION
o Scope of the Project
Methyl Acetate Production in Turkey
Methyl Acetate
Imported from SpainNo production in Turkey
3
INTRODUCTIONo Main Applications of Methyl Acetate
Solvent
Coating
Printing Inks4
INTRODUCTIONo Market Situation
180,000
tonnes/ year (***)
1,300,000 tonnes/Year (**)
10,000tonnes/year (*)
(*) Azot Nevinnomyssk(**) Universitat de Barcelona(***) Eastman Chemical Company 5
INTRODUCTION
Many
equipments requirement
Extra seperation unit requirement
Low operation and investment
cost
High purity of the production
Low energy requirement
High operation and investment cost
Purity of the process can be
adjusted
Liquid-Liquid
Extraction
Reactive Distillation
Conventional Process
o Process Alternatives
6
BASIS OF DESIGNo Reactive Distillation
o Conventional Process
511 kg/h 629 kg/h
Methanol Methyl acetate
273 kg/h 155 kg/h
Acetic acid Water
344 kg/h 629 kg/h
Methanol Methyl acetate
408 kg/h 124 kg/h
Acedic acid Water7
PLANT PLANT
BASIS OF DESIGNProduction Capacity: 5000 tonnes/year (*)
Supplied from AKKİM Chemical Company Continuous Process:
- Fast Reaction
- High Capacity
(*) Based on the report taken from Aktaş Chemical Company
Raw Materials
Methanol(96 % w/w)
Acetic Acid(99.5 %
w/w)
8
BASIS OF DESIGNo Reaction kinetics
O O
CH3 – C – OH + HO – CH3 CH3 – C – O – CH3 + H2O
Acetic Acid Methanol Methyl Acetate Water
Reversible reaction• Reaction conditions
• Heat of reaction: -27.9 kJ/mol
High Temperature
Low Temperature
High Pressure
Reaction Temperature
Reaction Pressure
Side products
occur
30-120 ° C 1 atm
9
BASIS OF DESIGN Minimum Azeotropes
Catalyst
Component Temperature Weight Fraction
Methyl Acetate + Water
56.5 ° C 3.5 % Water
Methyl Acetate + Methanol
54.0° C 19 % Methanol
Heterogeneous
Catalyst
Amberlyst 1510
PROCESS STRUCTUREo Block Diagram for Reactive
Distillation
11
PROCESS STRUCTUREo Block Diagram for Conventional
Process
12
PROCESS FLOW DIAGRAM
Reactive Distillation
Heater E-101 E-102
Type Shell&Tube Shell&Tube
Area (m2) 1.68 1.17
Duty (kW) 7.72 5.23
MOC SS/CS CS/CS
T-101
Internal Diameter
(m)
0.46
Height (m) 25
Tray Number 38
Feed Tray 3 / 26
Pressure (bar)
1
MOC SS
Cooler E-105 E-106
Type Shell&Tube Shell&Tube
Area (m2) 2.10 17.29
Duty(kW) -11.2 -16
MOC CS/CS SS/CS 13
PROCESS FLOW DIAGRAM
Conventional Process
E-101 (heater)
Type Shell&Tube
Area (m2) 5.14
Duty (kW) 11.37
MOC SS/CS
R-101
Type CSTR-Jacketed
Diameter (m) 2.20
Height (m) 2.63
Volume (m3) 10
Pressure (bar)
1
Temperature (°C)
50
Duty 65
MOC SS
T-101 T-102 T-103
Internal Diameter (m)
0.46 0.31 0.61
Height (m) 2.37 2.26 2.09
Tray Number
18 25 32
Feed Tray 4 11 16
Pressure (bar)
1 1 1
MOC SS SS SS14
PROCESS CONTROLReactive Distillation
Controlled Variable
1. Column Pressure
2. Reflux rate
3. Bottom liquid level
4. Reboiler Reflux Drum Level
5. Distillate and bottom compositions
Manipulated Variable
1. Condenser Coolant Flowrate
2. Reflux flow rate
3. Bottom outlet flow rate
4. Distillate flow rate
5. Tray Temperature
Controlled Variable
Manipulated Variable
Feed Drum Level Feed flow rate
Reactor Feed Temperature
Exchanger utility flow rate 15
WASTE, SAFETY & ENVIRONMENTOutlet waste stream of reactive
distillation column
Based on properties of 18%
acetic acid solution
%18 acetic acid solution lowThe steam has to be sent
İZAYDAŞ inceniration plant
18%(w/w) Acetic Acid (35.8 kg/h)
Dangerous Waste
High Recovery Cost
16
WASTE,SAFETY & ENVIRONMENT
F & EI Index Range Degree of Hazards
1-60 Light61-96 Moderate
97-127 Inremediates128-158 Heavy159-up Severe
F & EI: 60
Degree of Hazard for F&EI
17
RESULT OF HAZOP ANALYSIS FOR RDGuide Word
Deviation Cause Consequence
Action
No No flow of feed streams
Valve malfunction
No reaction or
distillation
Repairment
More of More flow rate of
methanol
Failure of valve to
close
Harder to break
azeotropes
Install high methanol
concentration alarm
More of More flow rate of
acetic acid
Failure of valve to
close
More acetic acid
unreacted than favored
Install high acetic acid concentraio
n alarmLess of Less flow
rate of acetic acid
Pipe blockage
Azeotrope aoccurs
Install low acetic acid
concentration alarm
18
ECONOMYConventional Process
Heat Exchangers ($662.6)
Pumps ($98.4)
Reactor ($97.1)
Storage Tanks ($307.1)
Towers ($357.4)
Vessels ($77.6)
Control Equipments ($5.5)
19%
41%
(x103)oPurchase Cost of Equipment
19
ECONOMY
Material Name Classification
Price ($/kg)
Flowrate (kg/h)
Annual Cost ($)
Acetic acid Raw Material 0.37 408.36 1,257,398
Methanol Raw Material 0.52 344.45 1,490,587 Methyl Acetate Product 1.30 629.00 6,804,899
o Material Analysis
20
ECONOMYo COM Share
FCICRMCUTCOL
Taxation Rate: 20%
MARCS Depreciation
Plant start-up at the
end of year 2
10 years project life
Land cost:$273,000
COM:$4,417,361
Interest rate (i): 10%
Revenue:$4,450,000/year 21
ECONOMYReactive Distillationo Purchase Cost of Equipments
Heat Exchangers ($578,600)
Pumps ($116,600)
Storage Tanks ($316,100)
Reactive Distillation Column ($460,000)
Others ($96,000)
29%
22
ECONOMY
Material Name
Classification
Price ($/kg)
Flowrate (kg/h)
Annual Cost ($)
Acetic acid
Raw Material
0.37 545.28
1,678,99
3
Methanol
Raw Material
0.52 282.15
1,220,98
7
Methyl acetate Product
(1.10) 625.00
(5,721,37
5)
o Material Analysis
23
ECONOMYoCOM Share
FCI ($2,340,000)
CRM ($2,900,000)
CUT ($74,000)
COL ($92,000)
54%43%
Taxation Rate: 20%
MARCS Depreciation
Plant start-up at the end of
year 2
10 years project life
Land cost:$227,000
Interest rate (i): 10%
Revenue:$5,201,250/year 24
ECONOMY
Cost of Reactive Cost of Conventional
Distillation Process
FCIL COMdRevenu
e0
($ 140,000 )
($ 83,500 )
($ 751,900)
25
ECONOMIC ANALYSIS
Net Present Value:$1,350,000
Discounted Payback Period: 3.9 years
26
RESULTS & RECOMMENDATIONSo Methyl Acetate Production via Reactive
Distillation
Objective: Producing Methyl Acetate in Turkey
High purity Methyl Acetate (99.5 %)
Environment friendly Low utility need
Profitable
Waste water cannot be recovered
Demand of Turkey provided
27
THANKS FOR YOUR
ATTENTION...
Special thanks to Prof. Dr. Hale GÜRBÜZ
28
