A

PROJECT REPORT ON

PLANT DESIGN FOR MANUFACTURE OF ETHYLENE

GLYCOL FROM ETHYLENE
SUBMITTED BY,

AMAR CHOUDHARI (B150027109)

SAURABH WALSE (B150027149)

AJAY SAPKALE (B150027136)

In partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING IN

PETROCHEMICAL ENGINEERING

GUIDED BY

Dr. DINESH BHUTADA

ASST. PROFESSOR

DEPARTMENT OF PETROCHEMICAL ENGINEERING

MAEER’S MAHARASHTRA INSTITUTE OF TECHNOLOGY

UNIVERSITY OF PUNE

2018-2019

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 UNIVERSITY OF PUNE

CERTIFICATE

This is to certify that the project report entitled “Plant Design For Manufacture Of

Ethylene Glycol From Ethylene” submitted by Mr. AMAR CHOUDHARI

(B150027112) , Mr. SAURABH WALSE (B150027149) & Mr. AJAY SAPKALE

(B150027136) is a record of the bonafide work carried out by them, under our guidance

in partial fulfilment for the requirement of the degree “Bachelor of Engineering in

Petrochemical Engineering” of the University of Pune for the academic year 2018-

2019.

Date:

Place: Pune -38

Dr. Dinesh Bhutada Prof. D. B. Dandge

(Internal Guide) Head,

Petrochemical Engineering Petrochemical Engineering

M.I.T. Pune. M.I.T. Pune.

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 ACKNOWLEDGEMENTS

We are sincerely thankful to all the great people who had helped us bring out the best flash into
our mind;

We are greatly indebted to Dr. Dinesh Bhutada for giving us guidance throughout the project
work. Who steered us clear of the fog of technical difficulties and hassles and led us where we
are.

We are thankful to our faculty members Prof. Vikrant Gaikwad whose inspiration, motivation
and discipline, played anvil shaping our mind and attitude just for this Project. We are also
thankful to Prof. Anand Kulkarni, co-ordinator of B.E. project for blessing us with this
opportunity.

We take this opportunity to convey our gratitude to Head of Department Prof. D. B. Dandge for
his valuable advice and suggestion.

We extend our heartful thanks to the entire teaching and nonteaching faculty members for their
timely help and co-operation. We are greatful to our colleagues for their constant support and
assistance that led to successful completion of our project work.

Last but not the least, we attribute success of our project work to our parents and friends whose
blessing cleared off the hurdles in our path

Sagar Zanzujade Sagar Suryawanshi

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 Plant Design For Manufacture Of Ethylene Glycol From Ethylene

TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

CERTIFICATE

ACKNOWLEDGMENT

LIST OF FIGURES AND TABLES

ABSTRACT

1 Introduction

1.1 History of Ethylene Glycol 11

1.2 Chemistry of Ethylene Glycol 11

1. 3 Uses 12

1.3.1 Antifreeze 13

1.3.2 Polyester Fibers 14

1.3.3 Resins 14

1.3.4 Hydraulic Fluids 14

1.3.5 Capacitors 15

1.3.6 Other uses 15

2 Literature Survey 16

2.1 Derivatives of Mono-Ethylene Glycol 16

2.1.1 Dithylene Glycol 16

2.1.2 Tri-ethylene Glycol 17

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 2.2 Storage and Transportation 18

2.3 Product Safety 19

3 Physical & Chemical Properties Of EG 21

3.1 Physical Property 22

3.2 Chemical Property 23

3.2.1 Dehydration 23

3.2.2 Oxidation 24

4 Market Survey 24

4.1 Economic Aspect 24

4.2 Leading Producers of EG In World 24

4.3 Leading Producers of EG In India 25

4.4 Current Indian Status Of Ethylene Glycol 25

5 Process Selection and Description 29

5.1 Industrial Process 29

5.2 Shell-Omega Process 31

5.3 Comparision Between Processes 32

6 Material balance 33

6.1 Basis for material balance 35

6.2 Material balance of individual equipment 36

6.2.1 Reactor 36

6.2.2 Evaporator 40

7 Energy balance 43

7.1 Overall Energy balance 43

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 7.2 Enthalpy of formation of reaction 44

8 Reaction Kinetics & Thermodynamics 47

9 Plant Utility 50

9.1 Steam Generation 50

9.2 Cooling Water 50

9.2.1 Natural Type 51

9.2.2 Mechanical Type 51

9.3 Water 51

9.4 Electricity 52

9.5 Compressed Air 52

10 Plant Location & Layout 53

10.1 Plant Location 53

10.1.1 Raw Material Supply 53

10.1.2 Markets 54

10.1.3 Energy Availability 54

10.1.4 Water Supply 54

10.1.5 Climate 55

10.1.6 Transportation 55

10.1.7 Labour Supply 55

10.1.8 Waste Disposal 55

10.1.9 Taxes & Regal Phases 55

10.1.10 Site Characterization 56

10.1.11 Fire & Explosion Protection 56

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 10.2 Plant Layout 57

10.2.1 Storage Layout 57

10.2.2 Equipment Layout 59

11. Instrumentation & Control 59

11.1 Why Required ? 59

11.1.1 Safe Plant Operation 59

11.1.2 Production Rate & Quality 59

11.1.3 Cost 59

11.2 Typical Monitoring Systems 60

11.2.1 Flow Measurnment 60

11.2.2 Temprature Measuring Devices 61

11.2.3 Pressure Measuring Devices 61

11.2.4 Liquid Level 62

12 Cost Estimation 63

12.1 Estimation Of Capital Cost 64

12.2 Total Indirect Cost 64

12.3 Total Direct Cost 65

12.4 Fixed Cost 66

12.5 Estimation Of Total Production Cost 67

12.6 General Expenses 68

13 Safety Health and Pollution Control 69

13.1 Safe Operations 69

13.2 MSDS For Ethylene Oxide 69

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 13.3 General Information 70

13.4 Handling & Storage 72

13.5 MSDS For Ethylene Glycol 73

13.6 Environmental Auditing 77

14 Reference 78

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 Plant Design For Manufacture Of Ethylene Glycol From Ethylene

LIST OF FIGURES

Figure No. Figure Name Page No.

1.1 Structure of EG 12

6.1 Block Diagram 0f Production of EG 34

6.2 PFD For Production of EG 35

6.3 P & ID For Production of EG 37

10.1 Plant Layout 58

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 Plant Design For Manufacture Of Ethylene Glycol From Ethylene

LIST OF TABLES

Table No. Table Name Page No.

1.1 IUPAC Name 11
3.1 Physical Properties 22
4.1 Current Indian Status Of EG 25
4.2 Import Status Of EG 26
4.3 Production of EG in INDIA 27
5.1 Comparision between Processess 32
6.1 Molecular Weight 36
6.2 Material balance over reactor 39
6.3 Material balance over Evaporator 41
6.4 Overall material balances 42
7.1 Heat Capacity & Enthalpy Data 44

11.1 List Of Thermometers With Temp Range 61

12.1 Total Estimation Cost 63

12.2 Total Indirect Cost 64

12.3 Total Direct Cost 65

CHAPTER
I

INTRODUCTION

1.1 HISTORY OF EG :

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  Ethylene glycol (EG)—the simplest diol—was first developed in 1859 by a
French chemist—Charles-Adolphe Wurtz—via saponification of ethylene
glycol diacetate with potassium hydroxide.

 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.

 Currently, the global production of ethylene glycol are about 43 million

metric ton per year.

 Ethylene glycol (EG) is an important organic compound and chemical

intermediate used in a large number of industrial processes (e.g. energy,
plastics, automobiles, and chemicals). Indeed, owing to its unique properties
and versatile commercial applications, a variety of chemical systems (e.g.,
catalytic and non-catalytic) have been explored for the synthesis of EG,
particularly via reaction processes derived from fossil fuels (e.g., petroleum,
natural gas, and coal) and biomass-based resources.
 This project report describes a broad spectrum of properties of EG and
significant advances in the prevalent synthesis and applications of EG, with
emphases on the catalytic reactivity and reaction mechanisms of the main
synthetic methodologies and applied strategies. [1]

1.2 CHEMISTRYOF EG :

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  Compound contains more than one –oly group is called Polyhydric Alcohol
(Diols). Diols are commonly known as Glycols, since they have a sweet
taste.
 Dihydric alcohols because compounds contain two –OH groups on one
carbon are seldom encountered.
 This is because they are unstable and undergo spontaneous decomposition
to give corresponding carbonyl compound and water.
 Compounds containing two hydroxyl groups attached to separate carbon in
an aliphatic chain.Although glycols may contain heteroatom can be
represented by the formula C2nH4nOn-1(OH)2. [2]

Figure-1.1- Structure of EG [2]

Table- 1.1- IUPAC Name [2]

Formula Common name IUPAC name

CH2OHCH2OH Ethylene Glycol Ethane-1, 2-Diol

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

1.3.1 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 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.

1.3.2 Polyester Fibers

 The use of ethylene glycol for fibers is becoming the most important
consumer of glycol worldwide. These fibers, marketed commercially under
various trade names like Dacron, Fortel, Kodel, Terylene etc are made by the
polymerization of ethylene glycol with Bis-Hydroxy-Ethyl Terephthalate
(BHET).
 These Polyester fibers are used for recyclable bottles.

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 1.3.3 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 fibers, 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
ophthalmic maleic or fumaric acid. These resins are used to modify synthetic
rubbers, in adhesives, and for other applications.
 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.

1.3.4 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.

1.3.5 Capacitors

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  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 aluminum and has
excellent electrical properties.

1.3.6 Other uses

 Ethylene glycol is used to stabilize water dispersions of urea-formaldehyde
and melamine-formaldehyde from gel formation and viscosity changes. It
used as humectants (moisture retaining agent) for textile fibers,
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), deicing agent for runway & air craft,
drying agent for gases (natural gas).[1][2][3]

CHAPTER II

LITERATURE SURVEY

2.1 DERIVATIVES OF MONO ETHYLENE GLYCOL:

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 2.1.1 Diethylene Glycol:
 Diethylene glycol is similar in many respects to ethylene glycol, but contains
an ether group. It was originally synthesized at about the same time by both
Lourenco and Wurtz in 1859, and was first marketed, by Union Carbide in
1928.
 It is a co product (9 - 10%) of ethylene glycol produced by ethylene oxide
hydrolysis.
 It can be made directly by the reaction of ethylene glycol with ethylene
oxide, but this route is rarely used because more than an adequate supply is
available from the hydrolysis reaction.
 Manufacture of unsaturated polyester resins and polyols for polyurethanes
consumes 45% of the Diethylene glycol. Approximately 14% is blended into
antifreeze.
 Triethylene glycol from the ethylene oxide hydrolysis does not meet market
requirements, which leads to 12% of the Diethylene glycol being converted
with ethylene oxide to meet this market need. About 10% of Diethylene
glycol is converted to morpholine.
 Another significant use is natural gas dehydration, which uses 6%. The
remaining 13% is used in such applications as plasticizers for paper, fiber
finishes, and compatiblizers for dye and printing ink components, latex
paint, antifreeze, and lubricants in a number of applications.[4]

2.1.2 Triethylene Glycol:

 Triethylene glycol is a colorless, water-soluble liquid with chemical
properties essentially identical to those of Diethylene glycol. It is a co

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 product of ethylene glycol produced via ethylene oxide hydrolysis.
Significant commercial quantities are also produced directly by the reaction
of ethylene oxide with the lower glycols.
 Triethylene glycol is an efficient hygroscopicity agent with low volatility,
and about 45% is used as a liquid drying agent for natural gas. Its use in
small packaged plants located at the gas wellhead eliminates the need for
line heaters in field gathering systems as a solvent (11 %) Triethylene glycol
is used in resin impregnants and other additives, steam-set printing inks,
aromatic and paraffinic hydrocarbon separations,cleaning compounds, and
cleaning poly (ethylene Terephthalate) production equipment.
 The freezing point depression property of Triethylene glycol is the basis for
its use in heat-transfer fluids. Approximately 13% Triethylene glycol is used
in some form as a vinyl plasticizer.
 Triethylene glycol esters are important plasticizers for poly (vinyl butyral)
resins, Nitrocellulose lacquers, vinyl and poly (vinyl chloride) resins, poly
(vinyl acetate) and synthetic rubber compounds and cellulose esters. The
fatty acid derivatives of Triethylene glycol are used as emulsifiers,
emulsifiers, and lubricants.
 Polyesters derived from Triethylene glycol are useful as low pressure
laminates for glass fibers, asbestos, cloth, or paper. Triethylene glycol is
used in the manufacture of alkyd resins used as laminating agents and
adhesives.[4]

2.2 STORAGE AND TRANSPORTATION:

 Pure anhydrous ethylene glycol is not aggressive toward most metals and
plastics.

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  Monoethylene glycol (MEG), diethylene glycol (DEG) and triethylene
glycol (TEG) are transported in commerce via bulk delivery in 20 m3 (5,300
gallons) tank trucks, 75 m3 (19,840 gallons) railroad tank cars and 1,200 m3
-1,600 m3 (7,560-10,000 bbl) river barges.
 Some shipments are also made via ocean-going tankers, which vary in size.
MEG, DEG, and TEG are considered stable and noncorrosive materials with
high flash points. Under ordinary storage conditions, these glycols can be
stored in mild steel tanks.
 If traces of iron contamination and color changes are objectionable, use of
stainless steel, aluminum, or resin-lined tanks are recommended. Glycols are
hygroscopic and readily absorb atmospheric moisture.
 If low water content is to be maintained in storage, tank contents should be
kept under dry N2 pressure (circa 1.5 psig or 0.1 kg/ cm2 ga). For remote
offsite storage situations, desiccant units on glycol storage tank vent lines
are commonplace and preferred over the installation of lengthy nitrogen
piping from battery limits.
 Glycols become very viscous at low temperatures. Hence, for long term
storage in cold climates, heated or insulated tanks may be required to guard
against problems connected with pumping highly viscous material.
 If internal heating is required, use of tempered water or low-pressure steam
circulated through stainless steel coils is recommended. However, product
degradation can result from careless storage tank heating practices. These
glycols are not readily ignited, but glycols can burn when exposed to heat
and flames.

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  Since ethylene glycol also has a low vapor pressure and is non caustic. It can
be handled with out any problems: it is transported in railroad tank cars, tank
trucks, and tank ships.
 Tanks are usually made of steel: high grade materials are only required for
special quality requirements.
 Nitrogen blanketing can protect ethylene glycol against oxidation.
 At ambient temperature, aluminum 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.[5][6]

2.3 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.
 Due to the relatively high flash points, viz., 115 oC (240 oF), 143 oC (290 oF)
and 165 oC (330 oF), for mono-, di- and triethylene glycols, respectively,
these glycols are not readily ignited but can burn when exposed to heat and
flames. In the case of an accidental release, protective measures include
1) eliminate potential sources of ignition (no smoking, flares, sparks or
flames in the immediate area);
2) prevent all bodily contact with all spilled material; and
3) wear appropriate personal protective equipment when responding to spills.

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  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.
 Personal protective equipment selections vary based on potential exposure
conditions such as handling practices, concentration and ventilation.
 Chemical goggles should be worn for eye protection.
 Protective clothing which is chemically resistant to the material should be
worn.
 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.[6]

CHAPTER
III

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 PHYSICAL AND CHEMICAL PROPERTIES
OF EG

3.1 PHYSICAL PROPERTIES:

 Monoethylene glycol and its lower polyglycols are clear, odorless,
colorless, 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.
 Its solubility is low, however in nonpolar solvents, such as benzene, toluene,
dichloromethane and chloroform.
 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 glass line
substance.
 The widespread use of ethylene glycol as an antifreeze is based on its ability
to lower freezing point when mixed with water.[1]

Table 3.1 Physical Properties. [1]

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 Sr. Physical Properties
no.
1. Auto-ignition temperature 427.0 0C
2. Boiling point at 101.3 kPa 197.6 0C
3. Critical temperature 446.9 0C
4. Critical specific volume 19.1* 102 gmol
5. Cubic expansion coefficient at 20 0C 6.2 104 K-1
6. Density at 20 0C 1113.5 g m3
7. Flash point, closed cup ( Pensky-Martens closed cup) 126.7 0C
8. Flash point, open cup (Cleveland Open Cup) 137.8 0C
9. Heat of combustion at 25 0C -1053 kJ g1mol
10. Heat of vaporization at 1 atm 53.2 kJ g1mol
11. Lower explosive limit 3.2 Vol%
12. Molecular weight 62.1 g mol-1
13. Normal freezing point -13 0C
14. Onset of initial decomposition 240 0C
15. Refractive index at 25 0C 143.0 * 102
16. Solubility in water at 20 0C 100 %

3.2 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.

3.2.1 Dehydration
 With Zinc chloride, it gives Acetaldehyde
HOCH2CH2OH CH3CHO + H2O

(Ethylene Glycol) (Acetaldehydes)

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

 With H2SO4 it gives di-oxane which is important industrial solvent

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 3.2.2 Oxidation
 Ethylene glycol; the oxidation of ethylene glycol by various methods yields
acetaldehyde, formaldehyde, glycolic acid, oxalic acid and glyoxal. Glyoxal
is the most important oxidation product. The course of the reaction is
dependent on the reaction condition.[6]
HOCH2CH2OH + O2 CHO + 2 H2 O
(Ethylene Glycol) (Oxygen) CH-O (Water)
(Glyoxal)

CHAPTER IV

MARKET SURVEY

4.1 ECONOMIC ASPECTS:

 During the 1980’s through early 1990’s, ethylene glycol prices have varied
widely, a divergence believed to have been due largely to capacity variations
and supply imbalances.
 In August 2000, a market report gave a price essentially unchanged at 44
c/kg (20 c/lb) for both fiber grade and antifreeze grade ethylene glycol.
 North American ethylene glycol capacity estimate of 5.31×106 metric tons

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  (m.t.)/yr. (11.70×109 lb/yr) and a worldwide ethylene glycol capacity
estimate of 12.45×106 m.t./yr (27.44×109 lb/yr).
 It is economic importance is founded on its two major commercial uses as
antifreeze and for fiber production.
 Since Ethylene glycol is currently produced exclusively from ethylene oxide
production plant are always located close to plant that produce ethylene
oxide.
 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.[6]

4.2 LEADING PRODUCERS IN WORLD:

 BASF, Geismer, La. (America).
 DOW, Plaquemine, La .(America)
 OXYPETROCHEMICALS, Bayport, Tex .(America)
 PD Glycol ,Beaumont, 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)

4.3 LEADING PRODUCER IN INDIA:

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  India Glycol, Uttaranchal (North India).
 Reliance Industries Ltd. Hazira (Gujarat).
 Indian Petrochemical Corporation Ltd, Baroda (Gujarat).
 NOCIL, Thane.
 SM Dye chem. Pune. [9]

4.4 CURRENT INDIAN STATUS OF EG ( METRIC TON/YEAR)

Table no 4.1 - CURRENT INDIAN STATUS OF EG

YEAR IMPORT EXPORT NET IMPORT

2010 682182 5577 676605
2011 771189 39959 731230
2012 634589 66483 568106
2013 654831 71796 583035
2014 820724 67032 753692
2015 100350 73216 27134
2016 95324 71564 23760
2017 91457 67458 23999

Table no 4.2 – IMPORT STATUS OF EG

YEAR NET IMPORT

2010 676605
2011 731230
2012 568106
2013 583035
2014 753692
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2016 23760
2017 23999
 NET IMPORT
800000
700000
600000
500000 NET IMPORT
400000
300000
200000
100000
0
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

So, the graph is showing that Indias net import is going to zero in 2020.So we
have considered that the basis of our plant should be production of EG in India.

Table no 4.3 – PRODUCTION OF EG IN INDIA

YEAR PRODUCTION
2010 738.292
2011 746.322
2012 996.572
2013 1064.221
2014 1069.277
2015 1001.139
BY
1 T 2016
1000 kg 1158.97
INTERPOLATION
1 Yr 2017
330 Days 1110.5
FORMULA -
1 Day 24 Hrs
2011 746.322
2014 1069.277
Production 2020 1383.185 =BASIS
300
Capacity YEAR PRODUCTION t/yr
20% 2010 0.909090909
738.292 t/day
2011 909.0909091
746.322 kg/day
2012 37.87878788
996.572 kg/hr
2013 1064.221
2014 1069.277
26 | P a g e 2015 1001.139
2016 1158.97
2017 1110.5
2020 1383.185
SO, The Production of the plant should be 33.8787 Kg/Hr.

CHAPTER V

PROCESS SELECTION AND

DESCRIPTION

5.1 INDUSTRIAL PROCESS

 First of all Ethylene Oxide Production by Nippon Shokubai Process is
done in which oxidizing high-purity ethylene gas with oxygen in the
presence of an inert gas (methane); other gases like nitrogen, argon, carbon

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 dioxide and ethane are generally also present in the process system.
Oxidation conditions are: 446–518°F (230–270°C) at 15–25 atm is done.
 Ethylene Oxide stream is first contacted with Water in a gas absorber at an
Ethylene Oxide (EO) to Water ratio of about 1:20 (to reduce the formation of
higher homologues).
 The Ethylene Oxide solution is preheated to a temperature of about 200 oC
and fed to a Continuous Stirred Tank reactor (CSTR) where it is thermally
hydrolyzed to Ethylene Glycol at an operating temperature of about 190 –
200oC and pressure of about 14 – 22 atm.
 Ethylene Oxide reacts further with Mono-ethylene Glycol (MEG) and higher
homologues in a series – parallel reaction to form di-ethylene and tri-
ethylene glycol.
 The Water – Ethylene Glycol mixture from the reactor is fed to the first
stage of a multi-stage evaporator, where it is reboiled using high-pressure
steam then sent to a sequence of columns where the ethylene glycol is
separated to mono, di, and tri ethylene glycol respectively.
 Ethylene Oxide reacts faster with Ethylene Glycol than it does with Water
(Melhem, et al., 2001), hence without control, reaction proceeds normally
with the successive formation of higher homologues of glycol (di, tri, tetra
ethylene glycol) through the continuous reaction of ethylene oxide with the
ethylene glycol homologue formed – by addition polymerization to form
higher ethylene glycols.
 The most important process variable affecting the glycols (mono, di or tri
ethylene glycol) distribution is the water to ethylene oxide ratio in the
starting material and only marginally on the reaction pH and temperature
(Rebsdat & Mayer, 2005)

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  Hence an excess of water is usually used in commercial plants (almost 20
times more) for high selectivity and to achieve at least a 90% conversion of
Ethylene Oxide to mono ethylene glycol (MEG) (Arrieta, 2001).
 Therefore, to stop the continuous reaction, ensure selectivity and maximum
mono ethylene production (maximum volume for MEG), it is expedient that
some form of control mechanism be implemented to maintain the required
Ethylene Oxide to Water ratio of the feed entering the reactor.
 That is – maintain maximum volume of the mono ethylene glycol (MEG)
measured by the MEG/liquid level in the reactor (output variable) as changes
in the disturbance - inlet flowrate of the reactants occurs by manipulating the
ethylene oxide to water ratio – the manipulated variable.
 This involves the installation of appropriate controller which returns the
output variable back to its set point value whenever there is a disturbance
(changes in the inlet flowrate) in the process.
 Hence this work studied the behavior of the continuous stirred tank reactor
(CSTR) used for the hydrolysis of ethylene oxide to ethylene glycol
particularly to fluctuations in the feed flowrate and develop appropriate
closed loop models with Proportional-Integral-Derivative Controller capable
of bringing the system back/close to its original set point value and ensure
stability of the process.[7]

C2H4O + H2O → HO−CH2CH2−OH

5.2 SHELL OMEGA

29 | P a g e
  Producing EO over a catalyst is the first step in the overall EO/EG
manufacturing process. In the reaction section, EO is produced by catalysed,
direct partial oxidation of ethylene.

 Additionally, a portion of the ethylene fully oxidises to form CO2 and water.

 These reactions take place in an isothermal (tubular) reactor at temperatures

of 230–270°C.

 The reaction is moderated/optimised using an organic chloride.

 EO is recovered from the reactor product gas by absorption in water. Co-

produced CO2 and water are removed, and, after the addition of fresh
ethylene and oxygen, the gas mixture is returned to the EO reactor as feed.

 The EO–water mixture can be routed to a purification section for recovery of

high-purity EO and/or to a reaction section where EO and water are
converted into glycols.

 In the standard thermal glycol reaction process, EO and water are reacted at
an elevated temperature (about 200°C) and pressure without catalyst.

 This process typically yields about 90–92% monoethylene glycol (MEG)

and 8–10% heavier glycol products, mainly diethylene glycol (DEG) and
triethylene glycol (TEG).

 The resultant water–glycol mixture from the reactor is then fed to multiple
evaporators where the excess water is recovered and largely recycled.
Finally, the water-free glycol mixture is separated by distillation into MEG
and the higher glycols.[8]

C2H4O + CO2 → C3H4O3

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 C3H4O3 + H2O → HOC2H4OH + CO2

5.3 COMPARISION BETWEEN PROCESSES -

Table No 5.1 – COMPARISION BETWEEN PROCESSES

SR. NO PROCESSES PARAMETER CATALYST
1 HYDROLYSIS OF NON NON
ETHYLENE CATALYTIC CATALYTIC
OXIDE REACTION REACTION
(INDUSTRIAL TEMP-190-200OC
PROCESS) PRESS 14-22 Atm
SELECTIVITY-
90%
CONVERSION-
90%
2 SHELL OMEGA TEMP 230-270OC NON
SELECTIVITY- CATALYTIC
86% REACTION
CONVERSION-
88%
CHAPTER VI

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.

31 | P a g e
  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.

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 Fig No – 6.1 Block Diagram 0f Production of EG

33 | P a g e
 Fig No- 6.2 – PFD For Production Of EG

6.1 BASIS:
Basis: 37.87878788 Kg/Hr

 The process is planned and developed as a continuous process. A plant is

operated for 24 Hours per day and 345 per year.

No of working days = 345days

34 | P a g e
 Capacity = 37.87878788 Kg/Hr

Table No. 6.1 : MOLECULAR WEIGHT (KG / KMOL):

COMPOUND MOLECULAR WEIGHT

Ethylene Glycol : 62
Water 18
Ethylene Oxide 44.01
Water [H2O] 18
Diethylene Glycol 106

6.2 MATERIAL BALANCE OF INDIVIDUAL EQUIPMENT:

6.2.1 Reactor:

 Ethylene oxides mixed with recycle water and pumped to glycol reactor
where it is reacted with water at 190-2000C & 14-22 Atm Pressure.
 The Reactor is Continuous Stirred Tank reactor (CSTR).
 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 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.

35 | P a g e
  The glycol reactor operate at approximately 14- 22 Atm pressure which is
supplied by the reactor feed pump.
 The reactor effluent goes to the evaporation unit for the evaporation of
excess water.

REACTOR
EG = 37.87 Kg/hr
EO = 29.86 Kg/hr o
Temp. = 190-200 C

36 | P a g e Selectivity = 90%

Pressure =14-22 Atm

 WATER = 219.94 WATER = 211.93 Kg/hr

 In the reactor following reaction take place

C2H4O + H2O HOCH2CH2OH --------- (1)

(Ethylene (Water) (Mono Ethylene Glycol)

Oxide)

 C2H4O + HOCH2CH2OH HOCH2CH2OH -------- (2)

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

 Moles of EG to be produced from reactor =37.87 Kg/hr

 Moles of ethylene oxide reacted by reaction –I

37 | P a g e
 = 37.87 Kg/hr

 Total Moles of ethylene oxide reacted = 29.868 Kg/hr

 Moles of ethylene oxide charged = 29.868 Kg/hr

 From the literature we know that the ratio of WATER TO ETHYLENE
OXIDE = 20 [10]
 Amount of water fed to reactor = 219.94 (Including excess)
 From the reaction moles of water reacted = 219.94 Kg/hr

 M.B.ON WATER:
 Moles of water fed = water reacted + water unreacted
219.94 = 8.01 + Moles of water unreacted
 Moles of water unreacted = 211.93 kg/hr
Table 6.2 Material balance over reactor

Component In, kg/hr Out, kg/hr

Ethylene oxide 29.86 -
Water 219.94 211.93
MEG - 37.87
Higher Glycol - 1.28

6.2.2 Evaporator:
 The glycol evaporation system consists of multiple effect evaporation
system.

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  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 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.

 Consider the water content of glycol is reduced to 15% i.e. 85% of water is
to be removed.
 Consider evaporator as single unit.
 Amount of water removed = 0.85 × 219.94
= 186.949 Kg/hr
 Total quantity of water at the top = 32.991 Kg/hr
 Remaining 15% water are still in the bottom along with the MEG and
Higher glycol.
 Amount of water in the bottom = 186.949 - 32.991
= 153.958 kg/hr

There is some quantity of glycol carry over along with water from the top of
Evaporator

MEG = 34.97
H2O = 153.958

evaporator
Pressure = 7
39 | P a g e kg/cm2
Temp = 159 oC
 M.E.G = 37.87 To Column

Water =208.44

Amount of glycol carry over along with water from evaporator = 36.59

Table 6.3 Material balance over evaporator

Component In, Kg/Hr Out, Kg/Hr

Liquid phase Vapor phase
Water 208.944 153.958 54.986
MEG 36.59 30.3 7.574
HG 1.28 1.28 -

Table 6.4 : Overall material balances

Equipment Component In, kg/hr Out, kg/hr

Liquid phase Vapor phase

Reactor Ethylene oxide 29.868 - -

Water 219.94 211.98 -

40 | P a g e
 MEG - 37.87 -

HG - 1.28 -

Evaporator Water 208.94 153.958 54.986

MEG 36.59 30.3 7.574

HG 1.28 1.28 -

CHAPTER VII

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 25 0C.
 The different properties like specific heat, heat of reaction, heat of
vaporization, etc. are taken to be constant over the temperature.

41 | P a g e
 7.1 Overall energy balance

REACTOR MEG =219.94 kg/hr

EO = 29.86 kg/hr
Temp. = 190-200 oC
HG = 1.28 moles

WATER = 219.94 Selectivity = 90% WATER = 11.93

Pressure =14-22 Atm

 In the reactor following reaction take place

C2H4O + H2O HOCH2CH2OH ------------- (1)

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

 C2H4O + HOCH2CH2OH HOCH2CH2OH -----(2)

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

Table 7.1 Heat capacity and Enthalpy data [11][12]

COMPONENT ∆ H 0f298 ( C p( Kj/kmol k)

Kj/kmol )
IN
Ethylene oxide -77704 99.106
Water -285830 189.39
OUT
Mono EthyleneGlyocol 454800 75.673

42 | P a g e
 Di-EthyleneGlyocol 285830 189.39
Water 562570 441.602

Assume reference temp. = 25 0C

7.2 Enthalpy of formation of reaction

For first reaction

∆ H0f = ∆ H0fp - ∆ H0 f R

= [- 454800] - [ - (77704) + (- 285830)]

= - 91266 KJ/ Kmol of EO Reacted
= - 91266 x 171.95
= - 15.693 x 106 KJ / hr

For second reaction -

∆ H0f = ∆ H0fp - ∆ H0 f R

= [- 562570] – [(- 77704) + (- 454800)]

= -30066 KJ/ Kmol of EO Reacted
= -30066 x 17.195
= -5.1 x 105 KJ / hr
Total enthalpy of formation = - 15.693 x 106 KJ / hr + -5.1 x 105 KJ / hr
= - 16.203 x 10 6 KJ / hr

 Enthalpy of reactants :
As reactants are added at 25 0C, so, its Enthalpy becomes 0.

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  Enthalpy of products :

∆ Hp = [ (m Cp ) MEG x (m Cp ) WATER x m Cp HG] / ∆T

= [ ( 154.76 x 75.693) + ( 3267.5 x 441.602 ) + ( 17.19 x 189.39) ] / ( 100

– 25 )
= 8575.90818 KJ / hr

 Enthalpy of reaction

∆ H0R= ∆ Hp + ∆ H 0f - ∆ HR

= ( 8575.90818 ) + ( - 16.203 x 10 6 ) - 0
= - 16.2115 x 106 KJ / hr
 So, it indicates that it is an exothermic reaction.
So, to control temp. Inside the reactor, cooling water is passed on side
to remove the reactor.

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CHAPTER VIII

REACTIONS KINETICS &

THERMODYNAMICS

EO + Water EG
Excess

COMPONENT Mol Wt
EO 44
WATER 18
EG 62

COMPONEN ΔG°f 298 K

T (kJ/mole)
45 | P a g e
EO -13
WATER -228.6
EG -448.68
 COMPONEN ΔH°f 298 K
T (kJ/mole)
EO -52.6
WATER -241.8
EG -455.2

ΔG°f 298 K = -207.08

K298= 2.5894

ΔG°f = -RT LnK

Componen Chem. Std. Std. Delta Cp
t Formula Delta H Heat Delta H of
Formatio capacity reac. at
n at Cp operating
298K temp 303K
KJ/mol J/mol K J/mol K J

EO C2H4O -52.64 47
75.4828
Water H2O -285.8 5
EG C2H6O2 -455 149.5
102.5
Delta H of
Reaction
at 298K -116.56 -99647.5
Delta H
(Prod-
Reactants) -116560 J/mol -99.6475 KJ

46 | P a g e

ΔG°f 298 K = Σ ΔG°f (product) - Σ ΔG°f (reactant)

 Operating
temp 463 K
Std temp 298 K
Delta T 165 K
Heat of
reaction
Delta H
at Delta H
operatin = at std. + (Delta
g temp. temp. Cp)*(Delt
303 K 298 K a T)
-99647.5 -116560 16912.5
-99.6475 KJ

This Proves That The Reaction is Exothermic and Energy Comes out From That is
-99.6475 KJ

Assuming cooling water entered at 25 ⁰C and leaving at 190 ⁰C

ΔT = 150 ⁰C

-99647.5 = M * 75.48285 * 150

M = 8.80011 Kg/Hr ( Cooling Rate)

47 | P a g e
 CHAPTER IX
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.

9.1 STEAM GENERATION:

48 | P a g e
  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.

9.2 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.

9.2.1 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.

9.2.2 Mechanical Type:

They are classified in three types:
 Induced draft
 Forced draft
 Balanced draft
In induced draft a fan is rotating at the bottom while in balanced draft fan is
rotating at
the centre. In forced draft a fan rotating at top.
 Cooling by sensible heat transfer

49 | P a g e
  Cooling by evaporation

9.3 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.
9.4 ELECTRICITY:
 It is required for motor drives , lighting and general use. It may be generated
on site or purchase from GEB & G.I.P.C.L. Transformers will be to step-
down the supply voltage to the voltage used on the site.
 A three-phase 415-volt system is used in general industrial purposes and
240-volt single phase for lighting and other low power requirements.
 For large motors, high voltage 600 to 1100 is used.

50 | P a g e
9.5 COMPRESSED AIR:
 Compressed air is used during the chocking of pipes and for cleaning
purpose.
 Compressed air can be obtained from air compressor.

CHAPTER X
PLANT LOCATION AND LAY OUT

10.1 PLANT LOCATION:

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.
10.1.1 Raw material supply
The source of raw material is one of the most important factors influencing the

51 | P a g e
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.
The major raw material used in this plant is Ethylene oxide. This can be easily
available in the places nearer to Baroda (because of the huge plants at IPCL ,
Baroda itself) & hence any industrial area near by Baroda can be a suitable place
for the plant location.
Therefore, the industrial area around Baroda can be comfortably chosen as an ideal
place for our plant.

10.1.2 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.

10.1.3 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 the plant site. The local cost of power can help in determining whether
power should be purchased or self generated. As far as our plant is concerned, both

52 | P a g e
electricity power & fuel (gaseous, liquid or solid) as well as heating oil can be
made available easily in Baroda or from nearby sources.

10.1.4 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.
Baroda has plenty of such source like Ajwa lake, Mahi river & so. So, the
situation favors Baroda.

10.1.5 Climate
Weather can have serious effect on the economic operating of the plant.
Temperature
& humidity of weather should be favorable.
10.1.6 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.
Luckily Baroda has all of these facilities.
53 | P a g e
10.1.7 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.
10.1.8 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.
10.1.9 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.
10.1.10 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.
10.1.11 Fire & explosion protection
The site should be such that it should have the best possible & quickest fire
protection facility available during the emergency. If possible (means if the
company can afford) the plant should be having its own fire station, fully equipped
latest fire fighting equipments & skilled firemen team. So, in case of emergencies
it won’t have to rely totally on the external sources.

10.2 PLANT LAYOUT:

54 | P a g e
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.
 Maximum advantages of gravity flow are taken to reduce the operational
cost in the piping & flow design
10.2.1 Storage Layout :
Adequate storage of raw materials, intermediate products, final products, recycle
materials & fuel are essential to the operating of process plants. Storage of
intermediate products may be necessary during plant shutdown for emergency
repairs,
while storage of final products makes it possible to supply customer even during a

55 | P a g e
plant difficulty of unforeseen shutdown. An additional use of adequate storage is
often encountered when it is necessary to meet seasonal demands from steady
production.
10.2.2 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 achieved.

56 | P a g e
FIG NO – 10.1- PLANT LAYOUT

CHAPTER XI

INSTRUMENTATION AND CONTROL

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11.1 WHY REQUIRED?

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.
The primary objectives of the designer when specifying instrumentation and
control
schemes are:

11.1.1 Safe Plant Operation:

 To keep process variables within known safe operating limits.

 To detect dangerous situations as they develop and to provide alarms and
 Automatic shutdown systems.
 To provide interlocks and alarms to prevent dangerous operating
procedures.

11.1.2 Production Rate and Quality:

 To achieve the designed product output.

 To maintain the product composition within the specified quality standards.

11.1.3 Cost:

 To operate at the lowest production cost and to compensate with other

objectives.
 Process instrumentation is thus brain and nerves of a process plant.

58 | P a g e
  The instrumentation can be pneumatic, hydraulic or electric. The recent
trend is to go for electronic instrumentation, but pneumatic instrumentation
is still in use.
 The instrumentation is required to measure temperature, pressure, flowrate,
level, physical properties as density, pH, humidity, chemical composition
etc.

11.2 TYPICAL MONITORING SYSTEMS:

11.2.1 Flow Measurement:

 Due to nature of flow it is necessary to provide effective flow measuring

devices in each supply lines.
 The various types of flow meters available are orifice meter,venturi meter,
pitot tube etc.
 In spite of these the various types of area flow meters can also be used.
 Depending on temperature and velocity condition the suitable meter is
selected for measurement of flow rates and velocity.

11.2.2 Temperature Measuring Devices:

 Many devices are used to measure the temperature variations in the process
such as mercury in glass thermometer, bimetallic thermometer, pressure
spring thermometer, thermocouples, resistance thermocouples, radiation
pyrometers and optical pyrometers are used.
 Out of all these the industrial thermocouples are competitively good as they
provide large measuring range, without introducing error. Automatic control
is also possible with such devices.

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 Table-11.1 List of Thermometers with temperature Range
Measuring Instrument Temp. Range ºC

Mercury in glass – thermometer -27 to 400

Mercury in pressure thermometer -40 to 540
Vapor pressure thermometer -85 to 425
Resistance -200 to 1700
Thermocouple -250 to 1700
Thermister Up to 300
Pyrometer 1300 to 2500

11.2.3 Pressure Measuring Devices:

 Equipments, in which the important monitoring parameter is pressure,

pressure measuring devices like pressure gauges are widely used. Safety of
chemical plants
 depends up on the timely measurement of pressure and its control at a
specified level.
 Any excess pressure development than the design pressure may damage the
equipment in addition to the fire and other explosion hazard.
 Mainly in filter pressures where the pressure is an important criterion, this
device is used.
Various pressure measuring devices are:
·U – Tube Manometer
·Differential Manometer
· Inclined Manometer
· Bourdon Tube
· Bellows
· Diaphragm valve
· Mc Leod gauge
60 | P a g e
· Pirani gauge

In addition to all measuring devices described above various measurements like

density, viscosity, pH measurements etc. are installed.
For measuring quality standards in laboratory various laboratory instruments are
also necessary.

11.2.4. Liquid Level:

 Liquid level detectors measure either the position of a free liquid surface
above a datum level or the hydrostatic head developed by the liquid is
measured.
 The liquid level is measured both by direct and indirect means.
 Direct methods involve direct measurement of the distance from the liquid
level to a datum level.
 Indirect method follows changing liquid surface position on bubble tube
method, resistance method, radiation method, etc.

CHAPTER XII
COST ESTIMATION

A plant design obviously must present a process that is capable of operating under

61 | P a g e
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.

12.1 ESTIMATION CAPITAL COST:

Table No – 12.1 TOTAL ESTIMATION COST

SR.NO Equipment No. of Cost per Estimated
Equip- Unit (Rs. Cost
Ments Thusd) (Rs. Thusd)

1 MEG 1 50 50
STORAGE
TANK

2 HG STORAGE 1 50 50
TANK

3 EO STORAGE 1 50 50
TANK

4 CSTR 1 100 100

5 EVAPORATOR 1 165 495
6 DISTILLATION 3 300 900
7 CENTRIFUGAL 3 10 30

PUMP
8 MIXER 1 8 8
9 REBOILER 6 80 480
10 CONDENSOR 3 30 90
TOTAL ESTIMATION COST = 2273 Thusd Rs.
12.2 Indirect Costs:

Table No – 12.2 TOTAL INDIRECT COST

Sr. No. Item % of PEC Cost (Rs.

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 Thusd)

1 Engineering & 15 340

Design Cost

2 Construction 20 454
expenses

3 Contractors Fees 5 113

4 Contingencies 10 227

12.3 Direct Costs:

Table No – 12.3 TOTAL DIRECT COST
Sr. No. Item % of PEC Cost (Rs. Thusd)

1 Purchased 100 2273

Equipment
Delivered cost

2 Purchased 40 909
Equipment
Installation cost

3 Instrumentation & 15 340.9

Control cost
(Installed)

4 Piping cost 60 1363

(Installed)

5 Electrical 12 272.7
Installation cost

6 Building cost 18 409.1

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 7 Yard improvement 10 227
cost

8 Service facilities 70 1591

cost

9 Land purchase cost 10 227

TOTAL DIRECT COST = 7612.75 Thusd Rs.

Fixed Capital Investment (FCI) = Total Direct Cost + Total Indirect Cost
= 7612.75 + 2273
= 9885.75 Thusd Rs.

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

= 0.2 x 9885.75
= 1977.15 thusd Rs.

TOTAL CAPITAL INVESTMENT (TCI) = Fixed Capital Investment

+Working Capital Investment
= 9885.75 + 1977.15
= 11862.75 Thusd Rs.

12.4 Fixed Cost:

(1) Depreciation = 10 % of Fixed Capital Investment
= 0.1 x 9885.75
= 988.5 thusds Rs.

(2) Local Taxes = 2 % of Fixed Capital Investment

= 0.02 x 9885.75
= 197.715 thusds Rs.
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(3) Insurance Cost = 3 % of Fixed Capital Investment
= 0.03 x 9885.75
= 296.57 thusds Rs.
TOTAL FIXED COST = Depreciation + Local Taxes + Insurance Cost
= 1482.78 thusds Rs.

12.5 ESTIMATION OF TOTAL PRODUCTION COST:

Direct Production Cost

(1)Raw Material Cost

Working Days = 333

Total cost of material = 26953.115 thusd Rs.

(2) Utilities Cost = 20% of Raw Material Cost

= 0.2 x 26953.115
= 5390.623 thusd Rs.

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

= 0.1 x 9558.75
= 955.7875 thusd Rs.

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

= 0.05 x 26953.115
= 1347.665 thusd Rs

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

= 0.01 x 26953.115
= 269.531 Thuds Rs

DIRECT PRODUCTION COSTS

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 = Raw Material Cost + Utilities Cost + Maintenance and
Repair Cost + Operating Labour & Supervision Cost +
Lab & Other Service Cost
= 26953.115 +5390.623 + 955.7875 +1347.665 + 269.531
= 34916.735 thusd Rs.
Plant overhead Cost:

These costs are 100% of Labour cost,

So, plant overhead cost is 1347.655 thusds Rs.

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

= 34916.735 + 1482.78 + 1347.655

= 37347.041 thusds Rs.

12.6 General Expenses:

(1) Administrative Cost = 1% Of Manufacturing cost

= 0.01 x 37347.041
= 373.471 thusds Rs.

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

= 0.02 x 37347.041
= 754.94 thusds Rs.

TOTAL GENERAL EXPENSES = 1128.411 thusds Rs

TOTAL PRODUCTION COST = Total Manufacturing Cost +Total General

Expenses
= 37347.041 + 1128.411
= 38475.411 thusds Rs.

TOTAL PRODUCTION COST = 38475.411 thusds Rs

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 CHAPTER XIII

SAFETY, HEALTH AND POLLUTION

CONTROL

13.1 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.

13.2 MSDS FOR ETHYLENE OXIDE:

MATERIAL NAME: ETHYLENE OXIDE
USES: Chemical intermediate
SYNONYMS: Oxirane
HAZARDS IDENTIFICATION
Appearance and Odour:

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Clear liquid under pressure. Sweet Ethereal

Health hazards:
Toxic by inhalation. Irritating to respiratory system. Causes burns. May cause
cancer.

Environmental Hazards:
Harmful to aquatic organisms. May cause long-term adverse effects in the aquatic
environment.

Health Hazards Inhalation:

Toxic by inhalation. Vapours may cause drowsiness and dizziness.

Skin Contact:
Exposure to rapidly expanding gases may cause frost burns to eyes and/or skin.
Liquid solutions of ethylene oxide cause serious chemical
burns of the skin and eye lesions. Onset of effects may be delayed for several
hours.

Skin Protection: Wear protective gloves and clean body-covering clothing.

Eye Contact: Couses burns
Eye Protection:
Use chemical safety goggles. Maintain eye wash fountain and quickdrench
facilities in work area.

FIRST AID MEASURES:

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13.3 General Information:
Do not attempt to rescue the victim unless proper repiratory protection is worn.

Inhalation:
Remove to fresh air. Do not attempt to rescue the victim unless proper Expiratory
protection is worn
Skin Contact:
Remove contaminated clothing. Flush exposed area with water and follow by
washing with soap if available.
Eye Contact:
Immediately flush eyes with large amounts of water for at least 30 minutes while
holding eyelids open. Transport to the nearest medical facility for additional
treatment.
Advice to Physician:
Contact a Poison Control Center or toxicologist for guidance.

FIRE FIGHTING MEASURES:

(Clear fire area of all non-emergency personnel.)
Flash point -57oC / -71oF (PMCC / ASTM D93)
Explosion 2.6 – 99.99% (V)
Flammability limits in air Auto ignition: 428oC / 802oF
Specific Hazards:
The vapour is heavier than air, spreads along the ground and distant ignition is
possible. Sustained fire attack on vessels may result in a Boiling Liquid Expanding
Vapour Explosion (BLEVE)
Extinguishing Media:

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Shut off supply. If not possible and no risk to surroundings, let the fire burn itself
out..

Extinguishing Media Protective Equipment :

Wear full protective clothing and self-contained breathing apparatus.

Additional Advice:
If the fire cannot be extinguished the only course of action is to evacuate
immediately. Large fires should only be fought by properly trained fire fighters.
Evacuate the area of all non-essential personnel.

Protective measures:
Avoid contact with spilled or released material. Isolate hazard area and they deny
entry to unnecessary or unprotected personnel. Stay unwinds and keeps out of low
areas. Extinguish ant make flames.
Do not smoke.
Remove ignition sources. Avoid sparks.
Clean Up Methods:
Use water spray (fog) to reduce vapors or divert vapour cloud drift.
Do not use water in ajet. Alcohol foam applied to surface of liquid pools
may slow release of EO vapors into the atmosphere.

13.4 HANDLING AND STORAGE :

Handling:
Ventilate workplace in such a way that the Occupational Exposure Limit (OEL) is
not exceeded. The vapor is heavier than air spreads along the ground and distant
70 | P a g e
ignition is possible. Electrostatic charges may be generated during pumping.
Electrostatic discharge may cause fire.

Storage:
Ethylene oxide (EO), an extremely flammable and toxic gas, and other hazardous
vapours may evolve and collect in the headspace of storage tanks, transport vessels
and other enclosed containers Storage Temperature: 30oC / 86oF maximum.

Product Transfer:
Electrostatic charges may be generate during pumping. Electrostatic discharge may
cause fire. Lines should be purged with nitrogen before and after product transfer.
Refer to supplier for further product transfer instructions if required.

13.5 MSDS FOR MONO ETHYLENE GLYCOL (PRODUCT):

PRODUCT NAME : MONO ETHYLENE GLYCOL

SYNONYMS: 1,2 – ethanediol

HAZARDS IDENTIFICATION :
Color: Colorless
Physical State: Liquid
Odor: Sweet
Hazards of product: May cause eye irritation. Isolate area.

POTENTIAL HEALTH EFFECTS :

Eye Contact:

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May cause slight eye irritation. Corneal injury is unlikely. Vapor or mist may cause
eye irritation.
Skin Contact:
Brief contact is essentially nonirritating to skin.
Skin Absorption:
Prolonged skin contact is unlikely to result in absorption of harmful amounts.
Inhalation:
At room temperature, exposure to vapor is minimal due to low volatility. With
good ventilation, single exposure is not expected to
cause adverse effects.
Effects of Repeated Exposure:
Repeated excessive exposure may cause irritation of the upper respiratory tract. In
humans, effects have been reported on the following organs: Central nervous
system.
Birth Defects
Based on animal studies, ingestion of very large amounts of ethylene glycol
appears to be the major and possibly only route of exposure to produce birth
defects.

FIRST-AID MEASURES :

Eye Contact:
Flush eyes thoroughly with water for several minutes. Remove contact lenses after
the initial 1-2 minutes and continue flushing for several additional minutes.

Skin Contact:
Wash skin with plenty of water.
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Inhalation:
Move person to fresh air. If not breathing, give artificial respiration; ifby mouth to
mouth use rescuer protection (pocket mask, etc).

FIRE FIGHTING MEASURES :

Extinguishing Media:
Water fog or fine spray. Dry chemical fire extinguishers. Carbon dioxide fire
extinguishers. Foam. Do not use direct water stream. May spread fire.

Special Protective Equipment for Firefighters:

Wear positive-pressure self-contained breathing apparatus (SCBA) and
protective fire.

HANDLING ANDSTORAGE HANDLING:

Handling:
Do not swallow. Avoid contact with eyes. Wash thoroughly after handling. Spills of
these organic materials on hot fibrous insulations may lead to lowering of the
autoignition temperatures possibly. resulting in spontaneous combustion.
Storage:
Do not store near food, foodstuffs, drugs or potable water supplies.
Additional storage and handling information on this product may be obtained by
calling your sales or customer service contact. Ask for a product brochure.

PERSONAL PROTECTION :
Eye/Face Protection:

73 | P a g e
Use safety glasses. If exposure causes eye discomfort, use a full-face respirator.
Skin Protection:
Use protective clothing chemically resistant to this material. Selection of specific
items such as face shield, boots, apron, or full body suit will depend on the task.
Remove contaminated clothing immediately.
Hand protection:
If hands are cut or scratched, use gloves chemically resistant to this material even
for brief exposures. Use gloves with insulation for thermal protection, when
needed. Examples of preferred glove barriermaterials include: Butyl rubber.
Natural rubber

STABILITY AND REACTIVITY:

Stability/Instability:
Thermally stable at recommended temperatures and pressures.thermal
decomposition products depend upon temperature, air supply and the presence of
other materials.Decomposition products can include and are not limited to:
Aldehydes. Alcohols. Ethers.
TOXICOLOGICAL INFORMATION :
Acute Toxicity:
Ingestion
For ethylene glycol: Lethal Dose, Human, adult 3 Ounces LD50, Rat
6,000 - 13,000 mg/kg
Skin Absorption
LD50, Rabbit > 22,270 mg/kg
Inhalation
LC50, 7 h, Aerosol, Rat > 3.95 mg/l
ECOLOGICAL INFORMATION:
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Chemical Oxygen Demand:
1.19 mg/mg
Theoretical Oxygen Demand:
1.29 mg/mg

13.6 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:
 To identify environmental problems associated with the manufacturing
process and the use of the products before they become liabilities.
 To develop standards for good working practices.
 To ensure compliance with environmental legislation.
 To satisfy requirements of insurers.
 To be seen to be concerned with environmental questions: important for
public relation
 To minimize the production of waster: an economic factor

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REFERENCE

1. Hairong Yue, Yujun Zhao, Xinbin Ma and Jinlong Gong, Et.al (201 1), “
Ethylene glycol: properties, synthesis, and applications”.
2. https://pubchem.ncbi.nlm.nih.gov/compound/ethylene_glycol(13/09/2018).
3. Klaus Weissermel Hans ,Translated by Charlet R. Lindley, Et.al (2003)
“Industrial Organic Chemistry”, 153-154.
4. Case study “ ME GLOBAL” industry for properties of DEG and TEG.
5. https://ScienceLab.com MSDS(26/09/2018)
6. Robert Fulton Dye Et.al (2001), “Ethylene Glycols Technology”, TX 77478,
USA.

7. Akpa, Jackson Gunorubon, Onuorah, Paschal,Et.al (2018), “Simulation and

control of a reactor for the non-catalytic hydrolysis of ethylene oxide to ethylene
glycol”

8. Case study “Enhancements in ethylene oxide/ethylene glycol manufacturing

Technology”
9. https://www.businesswire.com/news/home/20171124005025/en/Top-5-Vendors-
Global-Glycol-Market-2017 (5/10/2018)
10. 34th Annual Report 2017-18 Statistics of EG production india glycol
limited,uttarakhand
11.https://aip.scitation.org/doi/10.1063/1.555876 #(heat capacities)(11/10/2016)

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12. https://sciencestruck.com/specific-heat-capacity-table (21/9/2016)
13. https://www.engineeringtoolbox.com/saturated-steam-properties-
d_101.html(18/10/2016)

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