GAZI UNIVERSITY FACULTY OF ENGINEERING

2022-2023 FALL SEMESTER

CHE451 CHEMICAL ENGINEERING DESIGN I

F. D . ENA A E L

RES. ASST. HALE AKANSU

REACTOR DESIGN FOR ETHYLENE OXIDE

PRODUCTION FROM ETHYLENE

GROUP B:

191142003 - G l Z lal Al (Editor)

181142006 - A a A ala

191142014 - B e Bo do an (Leader)

181142015 - Na l Yonca B k

181142017 - Ze nep al

DUE DATE: 07.12.2022

TABLE OF CONTENTS

ABSTRACT .................................................................................................................................................. iv
1. INTRODUCTION ..................................................................................................................................... 1
2. METHOD OF ATTACK .......................................................................................................................... 3
3. LITERATURE SURVEY & DESIGN SELECTIONS.......................................................................... 4
3.1. Literature Research About The Reactions Procedure .......................................................................... 4
3.2. Raw Materials and Products of Reactions ........................................................................................... 4
3.3. Reaction Kinetics ................................................................................................................................. 6
3.4. Process Thermodynamics Specification .............................................................................................. 7
3.5. Catalyst Selection ................................................................................................................................. 7
3.6. Reactor Specification ........................................................................................................................... 8
3.6.1. Reactor Type Selection ..................................................................................................................... 8
3.6.2. Construction Material Selection.................................................................................................... 9
4. CALCULATIONS .................................................................................................................................. 12
4.1. Material and Energy Balances ........................................................................................................... 12
4.2. Specific Heat Capacity Calculations .................................................................................................. 16
4.3. Pressure Drop Calculations ................................................................................................................ 19
4.4. Cost Calculations ............................................................................................................................... 20
4.4.1. Cost of Reactor............................................................................................................................ 20
4.4.2. Cost of Catalyst ........................................................................................................................... 21
4.4.3. Insulation Cost ............................................................................................................................ 22
5. RISK ASSESSMENT ............................................................................................................................. 23
6. RESULTS AND DISCUSSION ............................................................................................................. 24
REFERENCES ............................................................................................................................................ 28
APPENDIX .................................................................................................................................................. 30

i
TABLE OF FIGURES

Figure. 1 Overall System .............................................................................................................................. 12

Figure. 2 Overall System .............................................................................................................................. 13
Figure. 3 Temperature Profile Graph For 1st Reactor .................................................................................. 26
Figure. 4 Pie char cost of reactor and catalyst .............................................................................................. 27
Figure. 5 Pie chart of whole system cost ...................................................................................................... 27

ii
TABLE OF TABLES

Table. 1 Method of Attack .............................................................................................................................. 3

Table. 2 Physical and chemical properties of ethylene ................................................................................... 4
Table. 3 Physical and chemical properties of oxygen ..................................................................................... 5
Table. 4 Physical and chemical properties of ethylene oxide ......................................................................... 5
Table. 5 Physical and chemical properties of carbon dioxide......................................................................... 6
Table. 6 Catalyst Properties ............................................................................................................................ 8
Table. 7 Reactor types (Albright,2008) .......................................................................................................... 9
Table. 8 Recommended materials for strength at high and low temperatures (Biegler et al.,1997) ............. 10
Table. 9 Reactor Specification Sheet ............................................................................................................ 11
Table. 10 Metal Properties (Towler&Sinnot,2013) ...................................................................................... 12
Table. 11 Flow Summary Table .................................................................................................................... 13
Table. 12 Gibb's and Formation Enthalpies at 298K .................................................................................... 17
Table. 13 Cost Indexes by Year .................................................................................................................... 20
Table. 14 Risk Assessment ........................................................................................................................... 23
Table. 15 Calculated values of DEQ variables For First Reactor ................................................................. 25

iii
ABSTRACT

In this project, it is aimed to design a reactor that produces ethylene oxide (50,000,000kg/year)
from ethylene at 25 bar an 240 C by an oxidation reaction with silver containing catalyst. The
reactor was designed in the most economical and reliable way, considering the operating
conditions of other side reactions that may occur during the ethylene oxidation reaction. For
the reaction, the most economical and reliable catalyst (Ag/Al2O3) is selected. Catalyst
selectivity chosen as 75% and conversion as 0.6. The kinetic expressions of this design, which
consists of 1 main and 2 side reactions, were found from the literature. The reactions are
irreversible and exothermic. While calculating with PFR approach in reactor design, fixed bed
reactor was chosen. Fort he desireble conversion three reactors were used. The operational type
of the system is adiabatic. The outlet temperature was calculated as 527.7508 for the first reactor
and 538.1148 K for the secon lastly 546.7267 K for the third reactor.
For conversion in the first reactor conversion found as 0.169602, for second it was 0.3042585
and for the last reactor it was 0.4740. The necessary calculations were made for the reactor
design, and the amount of catalyst used, and the reactor volume were calculated. The total
catalyst is 49.140 𝑘𝑔 and the reactor volumes are 30 m3, 30 m3 45 m3. According to this
calculated volume, the cost of the reactors were found to be $7.325.723,09. The cost of the
catalyst is $3.832.920.

iv
5
1. INTRODUCTION

In this report, as given in Appendix 1 our complex problem was Producing Ethylene Oxide by
oxidation of Ethylene with a flow rate of 50,000,000 kg/year at 25 bar and 240 C by using Ag
containing catalyst. & Designing a reactor system for the production of Ethylene Oxide with
taking into account safety precautions and economical evaluation. The reactor is the heart of a
chemical process. It is the only place in the process where raw materials are converted into
products, and reactor design is a vital step in the overall design of the process. There are many
types of chemical reactors that operate under various conditions such as batch, flow,
homogeneous, heterogeneous, and steady-state. Thus, one general mathematical description
that would apply to all types of reactors would be extremely complex. The general approach for
reactor design, therefore, is to develop the appropriate mathematical model that will describe
the specific reaction system for the type of reactor under consideration. the main and auxiliary
reactor design and their cost outcome are assessed for the reactor oxidation of ethylene to
ethylene oxide process. With the world's growing population, through demand on health and
well-being, it is important to use in the sterilization of medical equipment. Ethylene oxide is
one of the largest chemical products in the world and one of the most important raw materials
in the ethylene glycol industry.[1]
The process involving the design and selection of chemical reactors and reactor systems
commences in the following manner. First, the reactor type or types to be evaluated must be
established. Then the reaction mixture or the catalyst volume is determined by solving the
appropriate design equation(s), utilizing kinetic and thermodynamic data. The volume
establishment step of the design process can present problems because the required kinetic data
may not be available and may require experimental determination. From the reaction mixture
or catalyst volume, plus ullage or void volume, the dimensions of the reactor are established.
This is followed by a determination of the heating and cooling requirements established from
reactor/reaction mass and energy balances for the ethylene to ethylene oxide production,
industrially common catalysts were searched and found to be Ag-based Al2O3-supported
catalysts. the most type of reactor working conditions were selected according to the safety
regulations of ethylene oxide and chosen catalyst s working conditions. Catalyst specification,
kinetic research, and reactor-type selection studies are mentioned. Overall, around-reactor mass
balances are conducted, leading to compositions and outlet and inlet flow rates. In size and
sizing sections, catalyst and reactor values are mentioned, respectively. Existing outlet flow
constraints, such as compositions and flow rate, lead to catalyst conditions, design temperature,
and material of construction. In reactor unit design, thermophysical properties were given and
1
key components like Gibbs and Enthalpies were determined. After that Kf,298 values were found
and irreversibility of the reaction proved. Mass balance determines the composition and flow
rates of distillate and bottom stream compositions. Size and sizing calculations are done. Design
pressure is considered for air and ethylene oxide ratio and checked. Hazard and operability
evaluations are presented as tables to assess the hazards in our process and determine whether
the process is operable for the reactor. The cost of each main piece of equipment is attained. In
auxiliary equipment design, purchase equipment and utility costs are presented.

Before this design was completed, risk assesment was made and necessary safety precautions
were taken into account. In this design, which was made by considering all the safety details
and standards required for the dehydrogenation of ethylbenzene and the production of styrene,
the most appropriate cost was found and the total cost was reached.

2
2. METHOD OF ATTACK

In this part of the report, the steps to be followed during the design of a reactor to produce
ethylene oxide from ethylene, are given in Table. 1 as the method of attack and the points to be
considered in reactor design such as physical-chemical properties of the raw materials and
products, the main and side reactions, the kinetics of the reactions, the choice of catalyst, and
the reactor type have also been given. Then, detailed calculations were made for the reactor and
the cost of the reactor was calculated considering the safety precautions and economical.

Table. 1 Method of Attack

Step 1 Make a literature survey for the reaction procedure (conversion, selectivity, yield, etc.)

Step 2 Define all raw materials and products and collect chemical and physical properties.

Step 3 Decide the reaction kinetics and decide the reactor type. (Concentration, catalysts, T, P,
thermodynamic limitations, etc.)
Step 4 Develop the process and make necessary material balances.

Step 5 Energy balance calculations.

Step 6 Safety precautions.

Step 7 Economic evaluation.

3
3. LITERATURE SURVEY & DESIGN SELECTIONS

3.1. Literature Research About The Reactions Procedure

The production of ethylene oxide involves the oxidation of ethylene in a high-temperature gasphase
adiabatic reactor. The reaction is irreversible and exothermic.[3]
Main reaction: C2H4 + O2 C2H4O

There are several other side reactions given below that consume ethylene and produce
undesirable by-products [2].

Side reaction 1: C2H4 + 3 O2 2CO2 + 2H2O

Side reaction 2: C2H4O + 5/2 O2 2CO2 + 2H2O (Side reaction 2 does not happen and
it is explained in more detail in 3.5. Catalyst Selection)

At the same time, dry air steam is used in the reaction. Dry air is used to provide the oxygen needed
for the reaction.

3.2. Raw Materials and Products of Reactions

Table. 2 Physical and chemical properties of ethylene

Property Information
Colour Colourless

Odor Characteristic
Melting Point -169,15 C (-272,5 F)

Boiling Point at 1 atm 103,77 C (-154,8 F)

Flash Point -135,85 C (-212,5 F)
Upper Flammability Limit %36

Lower Flammability Limit %2,7

Vapor Pressure 70 F (21,1 C)
Auto-Ignition Temperature 450 C (842 F)
Molecular Weight 28.06 g/mole
Gas Density 0,07246

4
Table. 3 Physical and chemical properties of oxygen

Property Information
Colour Colourless

Odor Characteristic
Melting Point -218,4 C (-361,1 F)
Boiling Point at 1 atm -183 C (-297,4 F)

Flash Point -

Upper Flammability Limit Not available

Lower Flammability Limit Not available

Vapor Pressure Not available
Auto-Ignition Temperature Not available

Molecular Weight 32 g/mole

Gas Density 0,083

Table. 4 Physical and chemical properties of ethylene oxide

Property Information

Colour Colourless
Odor Characteristic
Melting Point -111,7 C (-169,1 F)

Boiling Point at 1 atm 10,7 C (51,3 F)

Flash Point -29 C

Upper Flammability Limit %100

Lower Flammability Limit %3

Vapor Pressure 22 (Asia)

Auto-Ignition Temperature 429 C (804,2 F)
Molecular Weight 44,06 g/mole
Gas Density 0,114

5
Table. 5 Physical and chemical properties of carbon dioxide

Property Information
Colour Colourless

Odor Odorless
Melting Point -79 C (-110,2 F)

Boiling Point at 1 atm Not available

Flash Point -
Upper Flammability Limit Not available

Lower Flammability Limit Not available

Vapor Pressure 830 (psig)
Auto-Ignition Temperature 429 C (804,2 F)
Molecular Weight 44,01 g/mole
Gas Density 0,114

The specific heat capacity coefficients of the components in the main reaction are given in
Appendix 4. Specific heat capacity calculation was made using the data in Appendix 4.

3.3. Reaction Kinetics

The kinetic expressions are, respectively,

rA1 = mol / m3.s [3]

rA2 = mol / m3.s [3]

. ∗ / ∗ ∗
rA3 = mol / m3.s [3]
. ∗ / ∗

6
3.4. Process Thermodynamics Specification

In thermodynamics, an adiabatic process is a type of thermodynamic process that occurs without

transferring heat or mass between the thermodynamic system and its environment. (Q=0). It
can be considered an ideal process in which there is no heat transfer and the change in internal
energy would be equal to the work done. [4]

3.5. Catalyst Selection

Industrially, ethylene oxide is produced from gas phase ethylene oxidation, and ethylene
epoxidation, this is typically performed in fixed bed reactors with selected catalysts at
200 300 and 1-3 MPa. Two side reactions accompanied this process under working
conditions of this reaction;

(R.1)

(R.2)

(R.3)

According to a literature survey, Ag-containing catalysts are the industry's most common
catalyst used for ethylene oxide production. The support material was chosen as Al2O3 because
researchers indicates that alumina minimizes the further conversion of ethylene oxide to
nondesired products. Alumina-supported Ag is also commercially available for this reactor
project. [2]

This process requires high pressure to activate the ethylene oxide production by oxidizing the
silver surface of the catalyst.

The catalyst operating conditions were examined as 210 -290 and 1.5-3.0 Mpa. [5]
Selectivity is the most important parameter of a catalyst. Selectivity and conversion values were
selected from the literature because these performance parameters of the catalyst were not given
by the manufacturer. Selectivity was determined as %75 and conversion was assumed as %60.

7
Table. 6 Catalyst Properties

Type Ag/@-Al2O3
Outside diameter, (mm) 6~9
Service Life (year) 3 years
High, (mm) 7~9
Bulk density, (kg/m3) 780
Ag content, (wt%) 16~18
3.6. Reactor Specification

The design of a chemical reactor deals with multiple aspects of chemical engineering. Chemical
reactions, chemical energetics, and equations/laws of thermodynamics play an important role
in the selection and design of chemical reactors. [6]

3.6.1. Reactor Type Selection

According to the given properties for each reactor fixed bed (packed bed) reactor is selected
because of the advantages that you can see in the Table. 7.

Packed bed reactors can be used in chemical reactions in chemical industries. These reactors
are tubular and are filled with solid catalyst particles, most often used to catalyze gas
reactions.[7] The chemical reaction takes place on the surface of the catalyst. The performance
of a packed bed is highly dependent on the flow of material through it, which in turn is
dependent on the packing and how the flow is managed. Electrical tomography may be used to
observe the distribution of liquids at different cross-sections of the vessel, or indeed the flow
pattern throughout the packed column. Depending on the nature of the materials, capacitance
or resistance tomography may be used. [8]

Calculations were made by the PFR design approach. It is an adiabatic system, heat insulation
is used. These reactors are solid-catalyst-containing vessels. Their design can lead to high
pressure drops. These units are generally used in heterogeneous catalysis, where the catalyst
and reacting species are of different phases. The major advantage of such units is their simplicity
and ease of catalyst access for maintenance and regeneration. The use of multiple fixed beds
can improve both heat transport and control, resulting in improved performance while
maintaining the relative simplicity of this reactor arrangement. Flow through fixed beds tends
to approach plug flow. [9]

8
Table. 7 Reactor types (Albright,2008)

Catalytic Reactors Phase Advantages Disadvantages

-High Conversion per -Poor temperature

unit mass of catalyst control
Plug Flow Reactor
-Low operating cost -Difficulty in
-Continuous reaction cleaning

-Effective at high
temperatures and
pressures
-Higher conversion per
unit mass of catalyst -Poor temperature
comparing other control
Fixed (Packed) Bed catalytic reactors -Difficulty in
Gas-Solid
Reactor -Low operating cost cleaning
-Continuous reaction -Difficult to replace
-No moving parts to the catalyst
wear out
-Easy reaction
mixturecatalyst
separation
-Increased reactor
vessel size
-Uniform particle -Pumping
Fluidized Bed requirements and
Gas-Liquid-Solid mixing
Reactor pressure drop
-Continuous reaction
-Erosion of internal
components

-Tubes are easy to clean -Poor temperature

-Low-pressure drops control
-High conversion rate -Difficult to control
Tubular Reactor
per reactor due to temperature
-Good for large-scale and composition
processes variables

3.6.2. Construction Material Selection

Selected materials have to resist high temperatures. Materials for proper at high and low
temperatures are given below Table. 8. Since our process temperature is 270 C which is 518
Fahrenheit all the materials can be used. Butr temperature is not the only criteria for the
material selection. Corrosion and tensile strength are also important.

9
Table. 8 Recommended materials for strength at high and low temperatures (Biegler et al.,1997)

High-Temperature Service Low-Temperature Service

Tmax (F) Steel Tmin(F) Steel
950 Carbon Steel -50 Nickel Steel (A203)
1300 330 Stainless Steel -75 Nickel Steel (A325)
1500 Stainless Steels (304, 321,347, 316) -320 Steel
2000 Cast Stainless, HC -425 Steel

Corrosion: For internal corrosivity protection, materials can be lined with stainless steel.
Because, stainless steel has a resistance to corrosion due to its chromium content. (Turton et al.
2012)

Tensile Strength: Since our reactor operates at 25 bar, it s important to have a high tensile
strength to withstand the load.

In light of this information, it can be seen that stainless steel is the most suitable material because
of its resistance to corrosivity, high tensile strength, and max allowable stress according to Table
10. Although it s more expensive than carbon steel, we concluded that the properties of carbon
steel is not enough. Also from Appendix 3 resistance chart can be seen. After all that a reactor
specification sheet were prepared for reactor one. Other specification sheets for 2nd and 3rd
reactors can be found in Appendix 5.

10
Table. 9 Reactor Specification Sheet

REACTOR SPECIFICATION SHEET

Equipment Name R-1

Reactor Type Fixed Bed

Operational Type Adiabatic

Capacity,kg/year 18.839.304

Feed Flow Rate,mol/s 88,46

Conversion,xa 0,17

Selectivity 0,75

Type Ag/ -Al₂O₃

Diameter,mm 2

Bulk
780
Density,kg/m
Catalyst

Operational 200-290
range 15-30bar

Total
Amount,kg 14000

Cost,$ 1.092.000

Material of
Construction Stainless Steel

Inlet Pressure ,bar 25

Outlet Pressure,bar 25

Pressure Drop,atm 0,098

Inlet Temperature, 240

Outlet Temperature, 254

Reactor Volume,m 30

L/D 3,3

Diameter,m 3

Lenght,m 10

200-300
Operability Limits
10-30 bar

Purchased Cost,$ 527.477

11
Table. 10 Metal Properties (Towler&Sinnot,2013)

Max Allowable
Tensile Strength
Material Stress Price $/kg
(N/mm2)
(N/mm2)

Carbon Steel 430 0,02 0,82

Stainless Steel >540 0,14 2,55-3,79

Copper 200 0,046 8,44

Nickel 500 0,069 21,74

4. CALCULATIONS

4.1. Material and Energy Balances

Figure. 1 Overall System

RA1- C2H4 + O2 C2H4O (Main rxn) ∆𝐻 105,1𝑘𝑗/𝑚 𝑙𝑒

RA2- C2H4 + 3 O2 2CO2 + 2H2O (Side rxn) ∆𝐻 1327𝑘𝑗/𝑚 𝑙𝑒 RA3-
C2H4O + 5/2 O2 2CO2 + 2H2O (neglect) (Side rxn.)

12
 C2H4 (ethylene) A
O2 (oxygen) B
C2H4O (ethylene oxide) C
2CO2 (carbon dioxide) D
2H2O (water) E

Figure. 2 Overall System

Table. 11 Flow Summary Table

Stream Number 1 2 3 4
Conditions
Reaction

Temperature (K) 513 527 538 546

Pressure (bar) 25 24,9902

Ethylene 88,46 73,17 50,48 26,12

Component flow rates

Oxygen 928,9 920,5 908 894,76

Nitrogen 3494,5 3494,5 3494,5 3494,5
(mol/s)

Ethylene oxide - 15,0 37,26 50,62

Carbon dioxide - 0,5 1,34 1,78

Water - 0,56 1,34 1,78

13
Material Balance for 1st reactor:

𝐹𝐴1 = 𝐹𝐴0 𝐹𝐴0 𝑋1 𝐹𝐴0 𝑋2) (1)

(2)
𝐹𝐶1 = 𝐹𝐶0 + (𝐹𝐴0 𝑋1) (3)
𝐹𝐷1 = 𝐹𝐷0 2 𝐹𝐴0 𝑋2) (4)
𝐹𝐸1 = 𝐹𝐸0 2 𝐹𝐴0 𝑋2) (5)
𝐹𝐼 = 𝐹𝐼0
𝐹𝑇 = 𝐹𝐴1 + 𝐹𝐵1 + 𝐹𝐶1 + 𝐹𝐷1 + 𝐹𝐸1 + 𝐹𝐼 (6)
𝐹𝐶0 = 0
𝐹𝐷0 = 0
𝐹𝐸0 = 0

Material Balance for 2nd reactor:

𝐹𝐴2 = 𝐹𝐴1 𝐹𝐴0(𝑋3 𝑋1) + 𝐹𝐴𝑂(𝑋4 𝑋2)) (7)

𝐹𝐴2 = 𝐹𝐴1 𝐹𝐴0 𝑋3) + (𝐹𝐴𝑂 𝑋1) + (𝐹𝐴0 𝑋4 𝐹𝐴𝑂 𝑋2) )

NOTE: FA1= FA0- FA0 x X1 – FA0 x X2

(8)
𝐹𝐶2 = 𝐹𝐶1 + (𝐹𝐴0 𝑋3) (9)
𝐹𝐷2 = 𝐹𝐷1 2 𝐹𝐴0 𝑋4) (10)
𝐹𝐸2 = 𝐹𝐸1 2 𝐹𝐴0 𝑋4) (11)
𝐹𝐼 = 𝐹𝐼0
𝐹𝑇 = 𝐹𝐴2 + 𝐹𝐵2 + 𝐹𝐶2 + 𝐹𝐷2 + 𝐹𝐸2 + 𝐹𝐼 (12)

Material Balance for 3rd reactor:

𝐹𝐴3 = 𝐹𝐴2 𝐹𝐴0(𝑋5 𝑋3) + 𝐹𝐴𝑂(𝑋6 𝑋4)) (13)

𝐹𝐴3 = 𝐹𝐴2 𝐹𝐴0 𝑋5) + (𝐹𝐴𝑂 𝑋3) + (𝐹𝐴0 𝑋6 𝐹𝐴𝑂 𝑋4))

(14)
𝐹𝐶3 = 𝐹𝐶2 + (𝐹𝐴0 𝑋5) (15)
𝐹𝐷3 = 𝐹𝐷2 2 𝐹𝐴0 𝑋6) (16)
14
𝐹𝐸3 = 𝐹𝐸2 2 𝐹𝐴0 𝑋6) (17)
𝐹𝐼 = 𝐹𝐼0
𝐹𝑇 = 𝐹𝐴3 + 𝐹𝐵3 + 𝐹𝐶3 + 𝐹𝐷3 + 𝐹𝐸3 + 𝐹𝐼 (18)

Adiabatic Line Equation;

(19)

Design equation for PFR:

(20)

(21)

Ergun equation for Pressure Drop:

(22)

𝑆 = %75 𝑓
𝑚 [2]
2
𝐹𝐶 𝐹𝐴0 𝑋1 𝐹𝐴𝑂 𝑋1 75
𝑆 (%) = = = =
𝐹𝐷 + 𝐹𝐸 (2 𝐹𝐴0 𝑋2) + (2 𝐹𝐴0 𝑋2) 4 𝐹𝐴0 𝑋2 100

𝑋1 3 𝑋2

𝑋𝑇 (%) = %60 𝑓 𝑚..

𝑋𝑇 = 𝑋1 + 𝑋2 = 0,6

From equation 8 and equation 9; 𝑋𝑇 = 4𝑋2 = 0,6

𝑋2 = 0,15

𝑋1 = 0,45
15
𝐹 𝑚𝑒 𝑎𝑖 4; 𝐹𝐷 (𝑐𝑎 𝑏 𝑑𝑖 𝑖𝑑𝑒 2 88,46 0,15 26,54 𝑚 𝑙/
𝐹 𝑚𝑒 𝑎𝑖 5; 𝐹𝐸 ( 𝑎 𝑒 2 88,46 0,15 = 26,54𝑚 𝑙/ Air
flow rate x %2 = FA0

Air flow rate = 4423 mol/s

Air contains 79% nitrogen and 21% oxygen. (From Appendix 1)

According to that; the Oxygen flow rate is 928.83 mol/s

The nitrogen flow rate is 3494.5 mol/s

4.2. Specific Heat Capacity Calculations

Table. 11 Specific Heat Capacities

Component a b c

C2H4 (ethylene)

O2 (oxygen)
C2H4O (ethylene
oxide)
CO2 (oxygen dioxide)

H2O (water)

N2 (nitrogen)

16
 (23)

(24)
(25)
(26)
(27)

(28)

(29)
(30)

Table. 12 Gibb's and Formation Enthalpies at 298K

Component

C2H4 (A) 52,5 68,5

O2 (B) 0 0

C2H4O (C) 52,6 13,0

CO2 (D) 393,5 394,4

H2O (E) 241,8 228,6

∆𝐻° ,298 ∆𝐻°𝑓, 𝑑 𝑐 ∆𝐻°𝑓, 𝑒𝑎𝑐 𝑎 (31)

(32)

(33)

(34)

17
∆𝐺° ,298 ∆𝐺°𝑓,𝐴 ∆𝐺°𝑓,𝐵 ∆𝐺°𝑓,𝐶) (35)

(36)

(𝐹𝐼 𝐶 𝐼 𝑑𝑇

Tf : 527 Kelvin
Same calculations with
adjustments for second and
third are done respectively again.

Sizing of the Reactor Calculations

1st eac o ol me;

Bulk density = 780 kg/ m3

Amount of catalyst = 14.000 kg

Reactor cost = 527.477$
Catalyst cost = 1.092.000$
18
2nd eac o ol me;

Bulk density = 780 kg/ m3

Amount of catalyst = 14.000 kg

Reactor cost = 527.477$
Catalyst cost = 1.092.000$

3rd eac o ol me;

𝑉 𝑒𝑎𝑐 = 45𝑚3
Bulk density = 780 kg/ m3

Amount of catalyst = 21.060 kg

Reactor cost = 602.831$
Catalyst cost = 1.642.680$

Thickness
For the First Reactor

VReactor 10 ∙ 3 30m3

Material of Construction 304SS

Max allowable stress for 304SS at 250-300 C = 110000kPa

Cc=0,001m for dry hydrocarbons

Ej=weld quality factor = 0.85

4.3. Pressure Drop Calculations

From Eq.22

19
For the first reactor;

μ 1,7 ∙ 10 5Ns/m3

Dp = 2mm (particle diameter from provider)

ε 0,4 selected parameter ρ

1,16kg/m3

L= 10m

4.4. Cost Calculations

4.4.1. Cost of Reactor

Appendix 6 contains a graph of the purchased cost relative to the reactor's capacity. According
to that graph [13], the purchased cost of the first and second reactor of 30 m3 is read as 350.000$,
and the purchasing cost of the second reactor of 45 m3 is read as $ 400.000. Since the Appendix
5 graphic values belong to 2002, the current price in 2020 has been reached by applying the
CEPCI method.

Table. 13 Cost Indexes by Year

Year CEPCI

2002 395.6

2020 596.2

20
 𝑅𝑒𝑎𝑐 ′𝐶 = 527.477,25 + 527.477,25 + 602.831,14 = $1.657.785,64

4.4.2. Cost of Catalyst

To find the catalyst s volume we need to use the reactor s volume. By multplying it with the
void fraction result will give us the needed catalyst volume.

1st reactor = 𝑆 = 10 3 = 30𝑚3 𝑖𝑑 = 0,4 [3]

2nd reactor = 30 m3

𝑉𝑐𝑎 𝑎𝑙 = 18 𝑚3

3nd reactor = 45 m3

𝑉𝑐𝑎 𝑎𝑙 = 27 𝑚3

Bulk density = 780 kg/m3 [5]

21
𝐴𝑚 𝑓 𝑐𝑎 𝑎𝑙 𝑓 𝑒𝑐 𝑑 𝑒𝑎𝑐 = 14.040 𝑘𝑔

𝐴𝑚 𝑓 𝑐𝑎 𝑎𝑙 𝑓 ℎ𝑖 𝑑 𝑒𝑎𝑐 = 21.060 𝑘𝑔

𝑇𝑎 𝑙 𝑐𝑎 𝑎𝑙 = 49.140 𝑘𝑔

𝐶𝑎 𝑎𝑙 𝑐 𝑒 𝑘𝑔 = $78

𝑇 𝑎𝑙 𝑐𝑎 𝑎𝑙 𝑐 = 49.140 78 = $3.832.920

4.4.3. Insulation Cost

Surface area of the reactor = 2 𝐿+2 2

𝑆 𝑓𝑎𝑐𝑒 𝑎 𝑒𝑎 𝑓 𝑓𝑖 𝑒𝑎𝑐 = 150 𝑚2

𝑆 𝑓𝑎𝑐𝑒 𝑎 𝑒𝑎 𝑓 𝑒𝑐 𝑑 𝑒𝑎𝑐 = 150 𝑚2

𝑆 𝑓𝑎𝑐𝑒 𝑎 𝑒𝑎 𝑓 ℎ𝑖 𝑑 𝑒𝑎𝑐 = 213 𝑚2

𝑇 𝑎𝑙 𝑓𝑎𝑐𝑒 𝑎 𝑒𝑎 𝑓 ℎ𝑒 𝑒𝑎𝑐 = 513 𝑚2

𝐼 𝑙𝑎 𝑖 𝑐 𝑒 𝑚2 = $45

𝑇 𝑎𝑙 𝑖 𝑙𝑎 𝑖 𝑐 = $23.085

𝑃 𝑐ℎ𝑎 𝑒𝑑 𝐶 = $1.657.785,64 + $3.832.920 = $5.490.705,64

𝐼 𝑎𝑙𝑙𝑎 𝑖 𝐶 25% 𝑃 𝑐ℎ𝑎 𝑒𝑑 𝐸 𝑖 𝑚𝑒 𝐶 = $1.372.676,41

𝑆𝑎𝑓𝑒 𝑃 𝑒𝑐𝑎 𝑖 𝑎 𝑑𝐸 𝑖 𝑚𝑒 8% 𝑃 𝑐ℎ𝑎 𝑒𝑑 𝐸 𝑖 𝑚𝑒 𝐶

= $439.256,45

𝑇 𝑎𝑙 𝐶 𝑓 𝑅𝑒𝑎𝑐 = $7.325.723,09

22
 5. RISK ASSESSMENT

Risk assessment is the process of identifying potential hazards and analyzing what might
happen if a hazard occurs. Considering the possible risks for the reactor used in this design, the
precautions to be taken against these risks are given in below.[11]

Table. 14 Risk Assessment

RISK PRECAUTION

Extreme temperature rise; Designing a insulation.

To monitor all parameters such as

temperature and pressure in the reactor
instantly from computers and to allow the
Explosion
operator to intervene instantly in case of a
possible change.

Keeping coolant and fire extinguishing

Fire equipment around the reactor

23
 6. RESULTS AND DISCUSSION

The aim of this task is to design a reactor that will convert ethylene to ethylene oxide by
oxidation. For this task, first of all, the complex problem was discussed and a work plan was
prepared (Append ix 7-E) and the necessary division of labor was made among the group
members. According to the study plan, a literature search was conducted for all items for the
desired conditions at the beginning of the design. The thermodynamic information obtained as
a result of the literature review was used to determine the reactor type and operating conditions.
Considering all the findings obtained, the type of reactor was chosen an as adiabatic packed
bed (fixed bed). Ag-based Al203 supported Ag@- Al203 catalyst was chosen to be used in the
system. The inlet temperature of the reactor was given by Assignment 2 (Appendix 1) working
conditions were decided by taking into account the temperature operating range of the catalyst
used, and the operating conditions of the reactor were determined considering the operating
temperature range of the catalyst being 210-290 C. The flow sheet of the designed system is
given in Figure. 2 Flow summary table, Figure. 1 made from the flow sheet of design as Figure.
2. Necessary calculations were made considering the operating conditions of the reactor, side
reactions, the effect of the catalyst and operating conditions, and safety and cost parameters.

The calculations began by calculating the enthalpy of formation and the Gibbs free energy of
matter, and the Kf,298 were found as bigger than 1, which indicates that the reaction is
irreversible. After calculating the obtained Gibb s Free energies and reaction enthalpies were
found as 1327 kJ/mol at 298 K, and Gibbs energy was found as -1246 KJ/mol again at 298K.
Since the reaction is exothermic, the conversion value increases with decreasing temperature.
However, high temperatures to achieve high conversion levels are difficult and expensive to
use and also increase the incidence of side reactions. High conversions are usually desirable,
but for this particular process, it is more practical and cheaper to operate at lower temperatures
and therefore higher pressures. Studies have also shown that high pressures and high
concentrations of ethylene aid in the production of ethylene oxide. Keeping the temperature
low can reduce the formation of unwanted by-products that waste the ethylene reactant.
Therefore, there is an inverse relationship between conversion and selectivity. For this reason,
high conversion, and high selectivity were chosen for this report. High pressure also slows
down these unwanted reactions by activating the catalyst surface.

To produce ethylene oxide both suitable temperature both for the catalyst and reactor was
chosen to operate at 250 C and 25 bar. After material balance according to ethylene oxide air
ratio [11] values were tested with the help of POLYMATH. After the first calculations, XA1
24
value was found as 0.169602. This conversion value was not efficient so a need for a second
reactor was determined.

Table. 15 Calculated values of DEQ variables For First Reactor

Variable Initial value Minimal value Maximal value Final value

1 CpA 33.6955 33.6955 35.45368 35.45368
2 CpB 30.41983 30.41983 30.50784 30.50784
3 CpC 34.9984 34.9984 37.38232 37.38232
4 CpD 33.49764 33.49764 34.15122 34.15122
5 CpE 33.69113 33.69113 33.75644 33.75644
6 CpI 28.91895 28.91895 28.9488 28.9488
7 deltaHrxn1 -1.051E+05 -1.051E+05 -1.051E+05 -1.051E+05
8 deltaHrxn2 -1.327E+06 -1.327E+06 -1.327E+06 -1.327E+06
9 FA 88.46 73.17279 88.46 73.17279
10 FA0 88.46 88.46 88.46 88.46
11 FB 928.9 920.5459 928.9 920.5459
12 FB0 928.9 928.9 928.9 928.9
13 FC 0 0 15.00299 15.00299
14 FC0 0 0 0 0
15 FD 0 0 0.5684356 0.5684356
16 FD0 0 0 0 0
17 FE 0 0 0.5684356 0.5684356
18 FE0 0 0 0 0
19 FI 3494.5 3494.5 3494.5 3494.5
20 FI0 3494.5 3494.5 3494.5 3494.5
21 FT 4511.86 4504.359 4511.86 4504.359
22 P 0.4901526 0.4061222 0.4901526 0.4061222
23 R 8.314 8.314 8.314 8.314
24 rA1 0.5436669 0.4582982 0.5436669 0.4582982
25 rA2 0.0101637 0.0087953 0.0101637 0.0087953
26 S 3. 3. 3. 3.
27 T 513. 513. 527.7508 527.7508
28 XA1 0 0 0.169602 0.169602
29 XA2 0 0 0.003213 0.003213
30 z 0 0 10. 10.

Again using POLYMATH energy balances were made and outlet temperature was found as
527.7508 K.

25
Figure. 3 Temperature Profile Graph For 1st Reactor

Since our reaction is adiabatic and exothermic this temperature increase was expected. To
increase conversion taking the outlet values from the POLYMATH report second material and
energy balances were made. For the second reactor conversion value (XA3) found as 0.3042585
and temperature was 538.1148 K. Since the 0.3042585 was not enough another reactor was
selected and with using the same method conversion was found as (XA5) 0.474004 and
temperature was found as 546.7262 K.

Conversion Graph for the first reactor found. And the conversion of then main reaction was
bigger than the side reaction which is a good thing.

Calculated values of DEQ variables for the second and third reactor and XA-z graphs can be
found in the Appendix 7-A, Appendix 7-Band Appendix 7-C. Further graph equations can be
seen in Appendix 7-D.

The purchasing costs of the reactors were read from the graph and calculated to their present
values using the Cepci method. The total reactor cost was found to be $1.657.785. To find the
catalyst cost, first the volume of the catalyst was used from the void fraction formula using the
volume of the reactor. The mass of the catalyst was calculated from the volume of the catalyst
using the bulk density. The total price of the catalyst, which was $78 per kilogram, was found
to be $3.832.920.

The cost of safety precausions is expected to be 8 percent of the purchased cost, and the
installation cost is 25 percent. For the cost of reactor insulation, the surface area of all reactors

26
was calculated, and the price was based on the insulation material. As a result, the total cost
was found to be $7.325.723.

The ratio of catalysts and reactors in purchasing costs is given in the pie chart (Figure. 4).

Purchased Equipment Cost

Reactors
30%

Catalyst
70%

Reactors Catalyst

Figure. 4 Pie char cost of reactor and catalyst

The cost of the whole system is given in Figure. 5 as a pie chart. When the cost of the whole
system is examined, it is seen that the catalyst is the equipment with the highest cost.

Cost of Design
Safety Precautions,
Equipments,Insulation Reactors
6% 23%

Installation Cost
19%

Catalyst
52%

Reactors Catalyst Installation Cost Safety Precautions, Equipments,Insulation

Figure. 5 Pie chart of whole system cost

27
REFERENCES

[1] Gisela C.C. Mendes, Teresa R.S. Brandao, Cristina L.M. Silva, Ethylene oxide sterilization
of medical devices: A review, American Journal of Infection Control, Volume 35, Issue 9, 2007,
Pages 574-571, https:/ /doi.org/10.1016/j.ajic.2006.10.014.)

[2] Tiancheng Pu, Huijie Tian, Michael E. Ford, Srinivas Rangarajan, and Israel E. Wachs ACS
Catalysis 2019 9 (12), 10727-10750

DOI: 10.1021/acscatal.9b03443

[3] Turton,R.C., Whiting, W.B., & Shaeiwitz. J. A. (2008). Analysis, synthesis and design of
chemical process, Pearson Education

[4] Bailyn, M. (1994). A Survey of Thermodynamics. New York, NY: American Institute of
Physics Press.p.21. ISBN 0-88318-797-3.

[5] EO catalyst EO/EG catalyst ethylene oxide catalyst. EO catalyst EO/EG catalyst Ethylene
Oxide Catalyst. (n.d.) Retrived December 7, 2022, from
http://www.eocatalyst.net/?gclid=Cj0KCQiA7bucBhCeARIsAIOwrzBXfk0brhRN49zQDSeP
H8FE%20qcJQzxqXOUiLTZ_4KPzEID9ht_QaAvTbEALw_wcB
http://nsdl.niscair.res.in/bitstream/123456789/757/1/Revised%20REACTORS%20AND%20
%20FUNDAMENTALS%20OF.pdf (December 2022)

[7] Fogler, H. Scott (2006). Elements of Chemical Reaction Engineering (4th ed.). Prentice
Hall. ISBN 0-13-047394-4.

[8] Perry, Robert H. & Green, Don W. (1984). Perry s Chemical Engineer s Handbook (6th
ed.) McGraw-Hill. ISBN 0-07-049479-7.

[9] Timmerhaus, Peter, West. Plant Design and Economics for Chemical Engineers. New Yprk:
McGraw Hill, 2002.

[10] Huazun high density XPS 10mm foam board styrofoam polystyrene XPS insulation
boards. Huazun High Density Xps 10mm Foam Board Styrofoam Polystyrene Xps Insulation
Boards - Buy High Density Compressed Styrofoam,Foam Backer Board,Xps 10mm Foam
Board Styrofoam Polystyrene Product on Alibaba.com. (n.d.). Retrieved December 7, 2022,
from https://www.alibaba.com/product-detail/HUAZUN-High-Density-XPS-10mm
Foam_1600501609081.html?spm=a2700.7724857.0.0.424c138fIISvEB

28
[11] Peters, M.S., & Timmerhaus, K.D. (1991). Plant design and economics for chemical
engineers. McGraw-Hill Science.

[12] Petrov, L., Eliyas, A., & Shopov, D. (1985). A kinetic model of steady state ethylene
epoxidation over a supported silver catalyst. Applied Catalysis, 18(1), 87-
103. https://doi.org/10.1016/s0166-9834(00)80301-2

[13] Peters, M. S., Timmerhaus, K. D., & West, R. E. (2002). Plant design and economics for
chemical engineers (5th ed.). McGraw-Hill Professional.

29
APPENDIX

APPENDIX 1

30
APPENDIX 2

31
APPENDIX 3

32
APPENDIX 4

33
34
35
APPENDIX 5

REACTOR SPECIFICATION SHEET

Equipment Name R-2

Reactor Type Fixed Bed

Operational Type Adiabatic

Capacity,kg/year 27.957.527

Feed Flow Rate,mol/s 73,17

Conversion,xa 0,3

Selectivity 0,75

Type Ag/ -Al O

Diameter,mm 2

Bulk
780
Density,kg/m
Catalyst

Operational 200-290
range 15-30bar

Total
Amount,kg 14000

Cost,$ 1.092.000

Material of
Construction Stainless Steel

Inlet Pressure ,bar 25

Outlet Pressure,bar 25

Inlet Temperature, 254

Outlet Temperature, 265

Reactor Volume,m 30

L/D 3,3

Diameter,m 3

Lenght,m 10

200-300
Operability Limits
10-30bar

Purchased Cost,$ 527.477

36
 REACTOR SPECIFICATION SHEET

Equipment Name R-3

Reactor Type Fixed Bed

Operational Type Adiabatic

Capacity,kg/year 16.779.540

Feed Flow Rate,mol/s 50,48

Conversion,xa 0,47

Selectivity 0,75

Type Ag/ -Al O

Diameter,mm 2

Bulk
780
Density,kg/m
Catalyst

Operational 200-290
range 15-30bar

Total
Amount,kg 21060

Cost,$ 1.642.680

Material of
Construction Stainless Steel

Inlet Pressure ,bar 25

Outlet Pressure,bar 25

Inlet Temperature, 265

Outlet Temperature, 273

Reactor Volume,m 45

L/D 5

Diameter,m 3

Lenght,m 15

200-300
Operability Limits
10-30bar

Purchased Cost,$ 602.831

37
APPENDIX 6

38
APPENDIX 7-A
Calculated values of DEQ variables For Second Reactor

Variable Initial value Minimal value Maximal value Final value

1 CpA 35.44769 35.44769 36.66728 36.66728
2 CpB 30.50754 30.50754 30.56948 30.56948
3 CpC 37.37418 37.37418 39.03125 39.03125
4 CpD 34.14899 34.14899 34.60132 34.60132
5 CpE 33.75622 33.75622 33.79959 33.79959
6 CpI 28.94869 28.94869 28.97187 28.97187
7 deltaHrxn1 -1.051E+05 -1.051E+05 -1.051E+05 -1.051E+05
8 deltaHrxn2 -1.327E+06 -1.327E+06 -1.327E+06 -1.327E+06
9 FA 61.24329 50.48353 61.24329 50.48353
10 FA0 73.17 73.17 73.17 73.17
11 FB 913.9879 908.0971 913.9879 908.0971
12 FB0 920.5 920.5 920.5 920.5
13 FC 26.7072 26.7072 37.2626 37.2626
14 FC0 15. 15. 15. 15.
15 FD 0.93902 0.93902 1.347743 1.347743
16 FD0 0.5 0.5 0.5 0.5
17 FE 0.93902 0.93902 1.347743 1.347743
18 FE0 0.5 0.5 0.5 0.5
19 FI 3494.5 3494.5 3494.5 3494.5
20 FI0 3494.5 3494.5 3494.5 3494.5
21 FT 4498.316 4493.039 4498.316 4493.039
22 P 0.3403678 0.2808986 0.3403678 0.2808986
23 R 8.314 8.314 8.314 8.314
24 rA1 0.384392 0.3209009 0.384392 0.3209009
25 rA2 0.0073763 0.0062676 0.0073763 0.0062676
26 S 3. 3. 3. 3.
27 T 527.7 527.7 538.1148 538.1148
28 XA1 0.16 0.16 0.3042585 0.3042585
29 XA2 0.003 0.003 0.005793 0.005793
30 z 0 0 10. 10.

39
Calculated values of DEQ variables For Third Reactor

Variable Initial value Minimal value Maximal value Final value

1 CpA 36.65394 36.65394 37.66209 37.66209
2 CpB 30.5688 30.5688 30.62058 30.62058
3 CpC 39.0131 39.0131 40.38509 40.38509
4 CpD 34.59638 34.59638 34.96961 34.96961
5 CpE 33.79912 33.79912 33.83371 33.83371
6 CpI 28.97161 28.97161 28.99237 28.99237
7 deltaHrxn1 -1.051E+05 -1.051E+05 -1.051E+05 -1.051E+05
8 deltaHrxn2 -1.327E+06 -1.327E+06 -1.327E+06 -1.327E+06
9 FA 35.0836 26.12712 35.0836 26.12712
10 FA0 50.48 50.48 50.48 50.48
11 FB 899.6708 894.7607 899.6708 894.7607
12 FB0 908. 908. 908. 908.
13 FC 41.844 41.844 50.62772 50.62772
14 FC0 26.7 26.7 26.7 26.7
15 FD 1.4348 1.4348 1.780319 1.780319
16 FD0 0.93 0.93 0.93 0.93
17 FE 1.4348 1.4348 1.780319 1.780319
18 FE0 0.93 0.93 0.93 0.93
19 FI 3494.5 3494.5 3494.5 3494.5
20 FI0 3494.5 3494.5 3494.5 3494.5
21 FT 4473.968 4469.576 4473.968 4469.576
22 P 0.196043 0.1461387 0.196043 0.1461387
23 R 8.314 8.314 8.314 8.314
24 rA1 0.2241623 0.1686495 0.2241623 0.1686495
25 rA2 0.0043773 0.0033406 0.0043773 0.0033406
26 S 3. 3. 3. 3.
27 T 538. 538. 546.7267 546.7267
28 XA1 0.3 0.3 0.474004 0.474004
29 XA2 0.005 0.005 0.0084223 0.0084223
30 z 0 0 15. 15.

40
APPENDIX 7-B

41
APPENDIX 7-C

42
 APPENDIX 7-D
Differential equations

1 d(XA1)/d(z) = S*(rA1)/FA0

2 d(XA2)/d(z) = S*(rA2)/FA0

d(T)/d(z) = (-
3 (deltaHrxn1*rA1+deltaHrxn2*rA2)*S)/(FA0*CpA+FB0*CpB+FC0*CpC+FD0*CpD+FE0*
CpE+FI0*CpI)

Explicit equations

1 FA0 = 73.17

2 FB0 = 920.5

3 FC0 = 15

4 FD0 = 0.5

5 FE0 = 0.5

6 FI0 = 3494.5

7 FI = FI0

inert

8 FA = FA0-(FA0*XA1)-(FA0*XA2)

ethylene

9 FB = FB0-(FA0*XA1*(1/2))-(FA0*XA2*3)

oxygen

10 FC = FC0+(FA0*XA1)

ethylene oxide

11 FD = FD0+(2*FA0*XA2)

carbon dioxide

12 FE = FE0+(2*FA0*XA2)

water

13 FT = FA+FB+FC+FD+FE+FI

14 deltaHrxn1 = -105100

15 deltaHrxn2 = -1327000

43
16 CpA = 3.95+(15.628*(10^-2)*(T-298))-(8.339*(10^-5)*((T-298)^2))

17 CpB = 29.10+(0.630*(10^-2)*(T-298))-(0.075*(10^-5)*((T-298)^2))

18 CpC = -4.686+(20.607*(10^-2)*(T-298))-(9.996*(10^-5)*((T-298)^2))

19 CpD = 22.243+(5.987*(10^-2)*(T-298))-(3.499*(10^-5)*((T-298)^2))

20 CpE = 32.218+(0.912*(10^-2)*(T-298))-(1.055*(10^-5)*((T-298)^2))

21 CpI = 28.883-(0.157*(10^-2)*(T-298))+(0.808*(10^-5)*((T-298)^2))

22 R = 8.314

pam3

23 P = 25*FA/FT

bar

24 rA1 = (1.96*exp(-2400/(R*T))*P)/(1+0.00098*exp(11200/(R*T))*P)

25 rA2 = (0.0936*exp(-6400/(R*T))*P)/(1+0.00098*exp(11200/(R*T))*P)

26 S=3

General

Total number of equations 29

Number of differential equations 3

Number of explicit equations 26

Elapsed time 1.157 sec

Solution method RKF_45

Step size guess. h 1

Truncation error tolerance. eps 1

Data file: c:\users\ lal al \downloads\react r second (1).pol

44
 3
Complex Problem: Producing EO by oxidation of ethylene with a flow rate of 50.000 m ton/yr at 25 bar 240 ˚C by using Ag-containing catalyst. By taking into account of safety and economical results.
Table. #1 Project Management and Risk Assessment

Assingment : 2

Group B
Duty Design reactor
APPENDIX 7-E
Gazi University

Editor G lsu Z lal ALI

Team Leader Buse BOZDO AN

Task # Description Time Interval Responsible Risk Assessment

P f. D . Se a Ya e li, Re . A

Major Task 1 Reaction Reasearch

2022-2023 Fall Semester, ING-01

Improper application of the

Department of Chemical Engineering

Minor Task 1 Collecting ethylene, EO and O2's physical and chemical properties. Nazl Yonca
information obtained in the
CHE 451 Chemical Engineering Design 1

4-5 days BIYIK Buse

literature research and not being
BOZDO AN
. Hale Aka

Minor Task 2 Investigating thermodynamics of the reaction. able to access some information.

45
Minor Task 3 Determination of main and side reactions & the catalyst kinetics, life, price etc.

Major Task 2 Reactor Design

Minor Task 1 Operating conditions. (Pressure, temperature, adiabatic/isothermal, etc.)

Minor Task 2 Selection of reactor type

Zeynep ÇALI Problems that may arise in the process due to the selection of inappropriate equipment and
1 week
G lsu Z lal ALI materials and the inability to place the process units correctly
Minor Task 3 Reaction kinetics

Minor Task 4 Material and energy balances

Minor Task 5 Safety Precautions

Major Task 3 Cost Estimation 2-3 days Ayça ATALAY Accessing outdated and incorrect data.
November 21, 2022