CHEMICAL ENGINEERING DESIGN II

KMM 4902E

DESIGN/GRADUATION PROJECT
FINAL REPORT

PROJECT TITLE: ETHANOLAMINES PRODUCTION

PROJECT ADVISOR: PROF. DR. AHMET SİRKECİOĞLU

TEAM NO: 14

Student No & Name Signature

Ezgi Ceren Yıldırım (060160148)

Gamze Keser (060160171)

Gökçe Tırnovalı (60150139)

ITU CHEMICAL ENGINEERING DEPARTMENT

Date: 11.06.2021
Cover Letter

Istanbul Technical University

Faculty of Chemical and Metallurgical Engineering

Department of Chemical Engineering

34469 MASLAK İSTANBUL

June 11, 2021

Dear Prof. Dr. Ahmet SİRKECİOĞLU, Prof. Dr. Hale GÜRBÜZ, Prof. Dr. Mehmet Ferhat
YARDIM, Assoc. Prof. Dr. Devrim Barış KAYMAK

The report of the “Production of Ethanolamines (mono-, di-, tri-ethanolamines) ” will be

presented in this document. It is proposed that Aliağa, İzmir is the location of the Ethanolamines
production plant.

The aim of this process is to produce high purity Ethanolamines using a low cost,
environmentally friendly process.

As a basis of design and by considering the consumption of the Ethanolamines in Turkey,

production capacity is recommended to be approximately 4400 tons per year. This report details
the discussion of alternative processes, selection of the process to be designed, mass and energy
balances of the selected process, the sizing of process equipment, process control of the
equipment, environment and waste management as well as economic analysis of the plant.
Sincerely,

Ezgi Ceren Yıldırım

Gamze Keser

Gökçe Tırnovalı

i
SUMMARY

Ethanolamines are raw materials widely used in industry. Carbon dioxide and hydrogen sulfide
absorption and the production of materials such as paint, rubber, adhesive, detergent, soap are
the areas where ethanolamines are frequently used. With the formation of new industrial areas,
the demand for ethanolamine is increasing every year.

Our design project aimed to produce mono-, di-, tri-ethanolamine of high purity and quality. In
aqueous environment, ethanolamines are obtained by the serial reactions carried out by feeding
ammonia and ethylene oxide into the plug flow reactor. This process runs on a continuous
model. Compared with other alternatives, the selected process has more sensitivity to the
environment. Production planning Turkey's industrial structure has been expected to establish
a complex system. For this reason, it was decided to establish the facility in İzmir, Aliağa
Industrial Zone. We take into account when determining the quality of our process is the most
important factor in Turkey's foreign trade deficit ethanolamine field. Accordingly, our annual
production capacity has been determined as 4440 tons.

Mass, energy and utility requirements values and some calculations were made using
Chemcad® simulation software. The process flow chart and block diagram were drawn using
Microsoft Visio 2013, and the process control charts of the equipment were drawn using
Draw.io. Capcost 2012 was used in the economic analysis. Other calculations were made by
manually.

ii
List of Tables

Table 2.1. Process Selection ...................................................................................................... 6

Table 3.1. Storage Conditions of the Raw Materials ................................................................. 8
Table 3.2. Pure Component Properties [13] .............................................................................. 9
Table 3.3. Optimized Arrhenius Parameters [15] .................................................................... 10
Table 4.1. Process Stream Table ............................................................................................. 14
Table 4.2. Overall Mass Balance ............................................................................................. 16
Table 4.3. Equipment Mass Balance ....................................................................................... 17
Table 4.4. Equipment Energy Balance .................................................................................... 18
Table 4.5. Overall Energy Balance .......................................................................................... 19
Table 5.1. Design of Storage Tanks ........................................................................................ 20
Table 5.2. Design of Reactor ................................................................................................... 20
Table 5. 3. Design of Mixer ..................................................................................................... 21
Table 5. 4. Design of Distillation Columns ............................................................................. 21
Table 5.5. Design of Pumps..................................................................................................... 22
Table 5.6. Design of Heat Exchangers .................................................................................... 22
Table 5.7. Design of Heat Exchangers (continued) ................................................................. 23
Table 6.1. Process Control Variables for Equipments............................................................. 29
Table 7.1. Safety of Process Materials .................................................................................... 32
Table 7.2. HAZOP Guide Word Meanings ............................................................................. 35
Table 7.3. HAZOP Analysis for R-101 ................................................................................... 35
Table 7.4. HAZOP analysis for T-101 .................................................................................... 37
Table 7.5. HAZOP analysis for T-102, T-103 & T-104 .......................................................... 38
Table 7.6. HAZOP analysis for E-101 & E-102 ...................................................................... 39
Table 7.7. HAZOP analysis for E-103, E-104, E-105 & E-106 .............................................. 40
Table 7.8. HAZOP analysis for P-101 ..................................................................................... 41
Table 7.9. HAZOP analysis for P-102, P-103 & P-104 .......................................................... 41
Table 7.10. HAZOP analysis for P-105 ................................................................................... 42
Table 7.11. Degree of Hazard for Fire & Explosion Index ..................................................... 42
Table 7. 12. Literature value for materials [20] ....................................................................... 43
Table 7.13. Dow's Fire and Explosion Index for R-101 .......................................................... 43
Table 7. 14. Process Control Credit Factor (C1) ..................................................................... 45

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Table 7.15. Material Isolation Credit Factor (C2) ................................................................... 45
Table 7. 16. Fire Protection Credit Factor (C3) ....................................................................... 46
Table 8.1. Overall Equipment Costs ........................................................................................ 48
Table 8.2. Storage Tank Costs ................................................................................................. 48
Table 8.3. Reactor Costs .......................................................................................................... 48
Table 8.4. Heat Exchanger Costs............................................................................................. 49
Table 8.5. Distillation Column Costs ...................................................................................... 50
Table 8.6. Pump Costs ............................................................................................................. 50
Table 8.7. Mixer Cost .............................................................................................................. 51
Table 8.8. Total Cost of Operating Labor ............................................................................... 52
Table 8.9. Utility Costs per Equipment ................................................................................... 53
Table 8.10. Raw Material Cost ................................................................................................ 53
Table 8.11. Revenue ................................................................................................................ 54
Table 8.12. Needed Information for the Cash Flow Diagram (CFD) ...................................... 55
Table 8.13. Discounted Profitability Criterion. ....................................................................... 56
Table 8.14. Non-discounted Profitability Criterion ................................................................. 57
Table 8.15. After Tax Cash Flow……………………………………………………..……...58
Table A2.1. Ammonia Storage Tank [27]…………………………………………………A2-2
Table A2.2. Ethylene Oxide Storage Tank..………………………………………………A2-4

iv
List of Figures

Figure 1.1. Ethanolamine market share by application as of 2019 [3] ...................................... 1

Figure 1.2. Formation of MEA, DEA and TEA [1] .................................................................. 2
Figure 3.1. Ethanolamine production reactions [14] ............................................................... 10
Figure 3.2. The Block Diagram of Ethanolamine Production ................................................. 11
Figure 4.1. Process Flow Diagram (PFD) ............................................................................... 12
Figure 6.1. Process Control for Reactor (R-101) .................................................................... 25
Figure 6. 2. Process Control for Distillation Columns ............................................................ 27
Figure 6.3. Process Control for Mixer (M-101) ...................................................................... 28
Figure 6.4. Process Control for Heat Exchangers ................................................................... 29
Figure 8.1. Cumulative Cash Flow Diagram for Discounted After–Tax Cash Flows ............ 56
Figure 8.2. Cumulative Cash Flow Diagram for Non-discounted After–Tax Cash Flows ..... 57
Figure A1.1. Overall ChemCAD Simulation ...................................................................... A1-2
Figure A2.1. R-101 ChemCAD Simulation ...................................................................... A2-11
Figure A2.2. T-101 ChemCAD Simulation ...................................................................... A2-12
Figure A2. 3. T-102, T-103 & T- 104 ChemCAD Simulation .......................................... A2-14

v
List of Symbols

EO Ethylene Oxide

MEA Monoethanolamine

DEA Diethanolamine

TEA Triethanolamine

SDC Serine Decarboxylase

vi
CONTENTS

SUMMARY ............................................................................................................................ ii
List of Tables .......................................................................................................................... iii
List of Figures ......................................................................................................................... v
List of Symbols ...................................................................................................................... vi
1. INTRODUCTION ............................................................................................................... 1
2. PROCESS OPTIONS AND SELECTION ......................................................................... 4
2.1. Anhydrous Process ...................................................................................................... 4
2.2. Aqueous Process .......................................................................................................... 4
2.3. Fermentation Process ................................................................................................... 5
2.4. Process Selection ......................................................................................................... 6
3. BASIS OF DESIGN ............................................................................................................ 7
3.1. Design Specifications .................................................................................................. 7
3.2. Feasible Process Conditions ........................................................................................ 9
3.2.1. Physical Properties and Thermodynamic Data of Components ........................ 9
3.2.2. Reaction Stoichiometry and Kinetics .............................................................. 10
3.3. Process Structure........................................................................................................ 11
4. PROCESS FLOW DIAGRAM (PFD) WITH MASS AND ENERGY BALANCES ...... 12
4.1. Process Flow Diagram ............................................................................................... 12
4.2. Process Description.................................................................................................... 13
4.3. Mass and Energy Balances ........................................................................................ 16
4.3.1. Mass Balance................................................................................................... 16
4.3.2. Energy Balance ............................................................................................... 18
5. EQUIPMENT DESIGN & SIZING .................................................................................. 20
5.1. Design of Storage Tanks ............................................................................................ 20
5.2. Design of Reactor ...................................................................................................... 20
5.3. Design of Mixer ......................................................................................................... 21
5.4. Design of Distillation Columns ................................................................................. 21
5.5. Design of Pumps ........................................................................................................ 22
5.6. Design of Heat Exchangers........................................................................................ 22
6. PROCESS CONTROL ...................................................................................................... 24
6.1. Process Control for Equipments ................................................................................ 25
6.1.1. Process Control for Reactor (R-101) ............................................................... 25

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 6.1.2. Process Control for Distillation Columns (T-101, T-102, T-103 & T-104).... 26
6.1.3. Process Control for Mixer (M-101) ................................................................ 27
6.1.4. Process Control for Heat Exchangers (E-101, E-102, E-103, E-104, E-105 &
E-106) ........................................................................................................................ 28
6.1.5. Process Control Summary ............................................................................... 29
7. WASTES ENVIRONMENT AND SAFETY ................................................................... 30
7.1. Safety ......................................................................................................................... 30
7.1.1. Occupational Health and Safety ...................................................................... 30
7.1.2. Safety of Process Materials ............................................................................. 32
7.1.3. Environmental Effects ..................................................................................... 32
7.1.4. Waste Treatment ............................................................................................. 34
7.2. Hazard and Operability Analysis (HAZOP) .............................................................. 34
7.3. Fire and Explosion Index ........................................................................................... 42
7.4. Loss Control Credit Factors ....................................................................................... 44
8. ECONOMICAL ANALYSIS ........................................................................................... 47
8.1. Estimation of Manufacturing Cost ............................................................................. 47
8.1.1. Fixed Capital Investment (FCIL) ..................................................................... 47
8.1.2. Equipment Cost ............................................................................................... 47
8.1.3. Operating Labor Cost ...................................................................................... 51
8.1.4. Utility Cost ...................................................................................................... 52
8.1.5. Raw Material Cost ........................................................................................... 53
8.1.6. Land Cost ........................................................................................................ 53
8.1.7. Waste Treatment Cost ..................................................................................... 54
8.1.8. Total Manufacturing Cost (COMd) ................................................................... 54
8.2. Profitability Analysis ................................................................................................. 54
8.2.1. Revenue ........................................................................................................... 54
8.2.2. Working Capital .............................................................................................. 55
8.2.3. Cash Flow Diagram of the Project .................................................................. 55
9. CONCLUSION AND RECOMMENDATION ................................................................ 59
REFERENCES ...................................................................................................................... 61
APPENDIX A1 ................................................................................................................. A1-2
A1.1. All Stream Report ............................................................................................... A1-2
A1.2. Overall Mass and Energy Balance Report .......................................................... A1-7
APPENDIX A2 ................................................................................................................. A2-2

viii
 A2.1. Manual Calculations ........................................................................................... A2-2
A2.1.1. Calculations of Storage Tanks (TK-101 & TK-102)................................ A2-2
A1.2. Calculations of Reactor (R-101) ......................................................................... A2-6
A1.3. Calculations of Mixer (M-101) ........................................................................... A2-8
A2.2. ChemCAD Simulation Calculations ................................................................. A2-11
A2.2.1. R-101 Equipment Reports ...................................................................... A2-11
A2.2.2. Distillation Columns Equipment Reports............................................... A2-12
A2.2.3. Heat Exchangers Equipment Reports ..................................................... A2-18
A2.2.4. Pumps Equipment Reports ..................................................................... A2-34
Appendix A3 ..................................................................................................................... A3-2
A3.1. Equipment Summary .......................................................................................... A3-2
A3.2. Utilities Summary ............................................................................................... A3-4
A3.3. COM Summary ................................................................................................... A3-4
A3.4. Cash Flow Analysis ............................................................................................ A3-6
A3.5. User Options ....................................................................................................... A3-8

ix
1. INTRODUCTION

Ethanolamine is a viscous hygroscopic organic compound which contains both amine and
alcohol groups. Ethanolamines are flammable, corrosive, colorless, viscous liquids that are
produced by the reaction between ammonia (NH3) and ethylene oxide (EO) [1]. All kinds of
ethanolamines can absorb water and carbon dioxide. They can form a solution with alcohol and
water.

Ethanolamines have many uses in industry. They are widely used as absorbents for acidic
components like carbon dioxide and hydrogen sulfide from air and petroleum-refinery gas
streams. Besides, ethanolamines involve reactions with long chain fatty acids to provide neutral
ethanolamine soaps. Converted ethanolamine compounds are used to produce soap, detergent,
polish, medical drugs, agricultural chemicals, glue, paint and rubber. Also Triethanolamine is
a corrosion inhibitor for automobile and airplane antifreeze solutions [2].

The global ethanolamine market share by application is given in Figure 1.1.

Figure 1.1. Ethanolamine market share by application as of 2019 [3]

The global ethanolamine market was recorded as 2.93 billion USD in 2017. This value is
expected to increase and reach 4.91 billion USD in 2026. China and USA are market leaders in
this industry. China, which follows America in second place with 767.3 million dollars, is
increasing its industrial volume year by year. Saudi Arabia and Brazil are the fastest growing

1
markets in this area. Especially in Saudi Arabia, with the capacity expansion of Saudi Kayan
Petrochemical Company, an increase in supply was witnessed [4].

The Ethanolamine sector is not monopolized in the world. It is very fragmented. Although
China, U.S Germany and Russia lead the race, countries such as Thailand, India, South Korea,
Brazil and Mexico have a very important share in production. With the development of new
agrochemical applications and the importance of gas treatment, there is an increase in the
demand for ethanolamine. Turkey does not meet this demand and is completely dependent on
external. Turkey has imported 2221 tons of monoethanolamine in 2019 and has exported only
23 tons of monoethanolamine [5].

Ethanolamine can be produced by biological or chemical means. In our design, it is

recommended to obtain ethanolamine by chemical method. Ethylene oxide reacts with
ammonia to form Monoethanolamine (MEA), Diethanolamine (DEA), and Triethanolamine
(TEA). The formation of MEA, DEA and TEA is given in Figure 1.2. The ratio of final products
depend on the amount of Ammonia molecules with which ethylene oxide reacts. It is known
that MEA has a larger market share than DEA and TEA. As a result, the MEA:DEA:TEA mass
ratio in our process is approximately (7.8):(3.6):(1).

Figure 1.2. Formation of MEA, DEA and

TEA [1]

Efficiency and economic gain are prioritized in our process. As a result, two reactors were used
to increase the reaction efficiency. Another reason for using two reactors is to reduce cost by
reducing reactor volumes. Different rates of ethanolamine may be requested in the future
depending on the future needs. In our design, unnecessary units are avoided, and a simple and

2
accessible process is preferred. So less expense will be required if the MEA:DEA:TEA ratio is
to be changed. Despite not using recycle system, the product efficiency is kept above 95% in
our design. To achieve this, the columns are designed to be integrated with each other.

Color change is observed in ethanolamine when exposed to high temperatures. Colored

ethanolamines are considered as spoiled. They have a lower market value than colorless
ethanolamines. In our design, the temperature was kept below 180 °C degrees throughout the
process. Thus, it is foreseen to produce ethanolamine with higher quality and higher economic
value.

3
2. PROCESS OPTIONS AND SELECTION

There are 3 different methods for the production of ethanolamines; in anhydrous conditions,
with aqueous ammonium and by fermentation. These methods have differences in terms of their
economic effects, safety and environmental effects.

2.1. Anhydrous Process

In the study, ethanolamine is synthesized by the reaction of ammonia and ethylene oxide using
acid activated clay catalysts. Ethanolamine synthesis is performed in a 100 cm3 tubular reactor
by using different zeolites or ion exchange resins as catalysts. It was aimed to obtain MEA with
high selectivity by using different NH3/EO ratios at different temperatures in the range of 110-
150 °C.

Acid-treated clays have certain properties that allow greatly increased reactor productivity
while maintaining high selectivity for MEA. The catalyst is obtained by transforming the
layered clay solid into a two-dimensional zeolite material that is more heat resistant through the
column forming process. The obtained catalyst provides a great advantage for the production
of MEAs that operate at very high gap speeds and still provide high selectivity and efficiency
with a lower percentage of by-products. The stability of the catalyst at higher temperatures
provides an advantage for the process [6].

A process is provided for selectively producing MEAs from ammonia and ethylene oxide using
acid activated clay catalysts. The process is economically profitable because high reactor
productivity rates are achieved with this catalyst. The catalyst also exhibits high selectivity for
MEA over DEA or TEA. An anhydrous reaction is simple and clean. However, the reaction
takes place in liquid phase and requires compression of ammonia into the liquid phase is a costly
process.

2.2. Aqueous Process

In the synthesis of ethanolamine in an aqueous environment, the reaction takes place by feeding
ammonia, ethylene oxide and water to the reactor. As a product, MEA, DEA, TEA are obtained.
From the reaction product, ammonia is removed with an ammonia stripper and water is removed
by evaporator. The concentrated reaction product is fed to a distillation plant to separate TEA
from MEA and DEA. Ammonia separated from the products in the stripper is captured by the
absorber in order to be fed back into the reactor. The ammonia absorber operates at a pressure

4
above 4 bar, preferably 4.8 bar or above, and the concentration of ammonia in the chamber of
the ammonia absorber should be at least 40%. The NH3/EO ratio entering the reactor is up to
or exceeds 6:1. The temperature in the reactor is lowered to lower the TEA concentration. The
concentrated reaction product has a maximum temperature of 180 °C before entering the
distillation facility [7].

If the water content used in ethanolamine production remains low, the reaction must be carried
out under high pressure and causes high investment costs. These reactions consume low levels
of energy. A high water content under low pressure can be used to reduce investment costs, but
the associated energy consumption will be higher as a result. With the reaction taking place in
the aqueous phase, the ammonia remains liquefied under lower pressures. This is a method of
reducing the reactivity of ethylene for safety purposes as ethylene oxide can be explosive. The
disadvantage of this process is that the water must be separated from the product stream after
the reaction, and also that if the temperature or pressure of the process stream is too high at any
time during the process, ethylene oxide reacts with water to form ethylene glycol.

2.3. Fermentation Process

Ethanolamine is synthesized by the bio-conversion of a fermentable carbon source by an

aerobically grown recombinant bacterium. The biological production of ethanolamine requires
the formation of serine as an intermediate product that can be converted into ethanolamine by
a plant serine decarboxylase encoded (SDC) in Arabidopsis thaliana. In this study, the problem
to be solved in the production of ethanolamine by fermentation is the biological production of
ethanolamine from an inexpensive carbon substrate such as glucose or other sugars. The number
of biochemical steps and the complexity of metabolic pathways requires the use of a
metabolically engineered whole cell catalyst for an industrially viable ethanolamine production
process. There are three stages in the ethanolamine method by fermentation [8]:

1. Fermentation of a bacteria that produces ethanolamine

2. Ethanolamine concentration in bacteria or environment and

3. Isolation of ethanolamine from the fermentation broth and remaining biomass,

optionally in portions or in total amount in the final product.

5
2.4. Process Selection

There are three possible methods to be used in the production of ethanolamines. The advantages
and the drawbacks are compared in the Table 2.1.

Table 2.1. Process Selection

Criterion Anhydrous Process Aqueous Ammonia Fermentation

Process Process

Economy + +++ +

Environmental ++ ++ +++

Safety + +++ ++

The method chosen in the proposed design project is the ethanolamine production by the
aqueous process. It significantly reduces the investment cost. The presence of water reduces
operating pressures, which positively affects process safety. If water and ammonia recycling is
added, energy savings can be achieved and it becomes an environmentally friendly process.

6
3. BASIS OF DESIGN

3.1. Design Specifications

Turkey's needs in terms of ethanolamine is dependent on foreign countries. In order to meet

some of this need, our design project aims at the production of ethanolamine. PETKİM is one
of the establishments that produces ethylene oxide, one of the raw materials required for
production. For this reason, the location of the ethanolamine production facility close to this
establishment in İzmir Aliağa provides a great advantage in terms of logistics. In addition, since
Aliağa is an industrial zone, it is a location with high commercial activity. This facilitates the
delivery of the manufactured products to the international and domestic market. As a result, the
ethanolamine facility is expected to be established in İzmir Aliağa Organized Industrial Zone.

MEA, DEA and TEA production is targeted at the facility. MEA has a wider market volume
than other ethanolamines. Accordingly, it has been suggested that MEA selectivity should be
higher than other ethanolamines in our design. In determining the production capacity, speed
and production of large global firms in Turkey are taken into account demand for these
products. They are considering to meet a portion of ethanolamine demand in Turkey 4440
tons/year production was deemed appropriate. In this selection, the difficult supply of raw
materials, the abrasiveness of the materials used and the production cost has been effective. It
is foreseen that the facility will operate 24 hours a day and 300 days excluding holidays.

According to the American Institute of Chemical Engineers, on-stream factor is the fraction of
the time that a process unit is operating [9]. To calculate our on-stream factor, we assumed the
facility will operate 24 hours a day and 300 days per year. This assumption was made by
excluding holidays, planned and unplanned shutdowns.

𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝐷𝑎𝑦𝑠
𝑂𝑛 − 𝑆𝑡𝑟𝑒𝑎𝑚 𝐹𝑎𝑐𝑡𝑜𝑟 =
𝐷𝑎𝑦𝑠 𝑖𝑛 𝑎 𝑌𝑒𝑎𝑟

From the equation above, the on-stream factor of our proposed process is 0.822.

Raw materials to be used in the process are ammonia and ethylene oxide. The storage conditions
of these components should be considered in the design of the facility. Anhydrous ammonia is
the cooled or compressed liquid form of ammonia. Storing it under pressure prevents it for
vaporizing and makes it available for use in large volume. Ammonia storage tanks should be
kept in a cool, dry, temperature resistant environment, away from direct sunlight. The storage

7
area should be well ventilated and away from flammable materials. Anhydrous ammonia is a
very strong compound and has a capacity to corrode metals like zinc, copper, and alloys
containing these metals. Zinc is used to galvanize steel, and thus these containers are not
suitable to store anhydrous ammonia [10,11]. Ethylene oxide should also be stored in a cool,
fire-resistant area, away from other chemicals and in a well-ventilated place. The material of
the tank to be stored can be made of stainless steel, aluminum 3003, zinc, nickel, copper, teflon,
ceramic or glass. When long storage times are expected, a lower temperature range is
recommended to minimize polymerization. Long-term storage in small containers with a high
surface / volume ratio should be avoided because the polymerization rate increases with the
presence of any metal [12]. Depending on the storage conditions of the raw materials, the
material of the storage tanks is selected as stainless steel 316 (SS316). Storage conditions of
the raw materials are given in the Table 3.1.

Table 3.1. Storage Conditions of the Raw Materials

Storage Storage
Chemical
Component Temperature Pressure Phase
Formula
(°C) (bar)

Ammonia NH3 50 18 Liquid

Ethylene
C2H4O 10 2.3 Liquid
Oxide

MEA is the product with the most selectivity among ethanolamines. Accordingly, the
ethanolamies purity is aimed to be at least 99.6% pure. The decay temperature of the products
should be observed throughout the process. The process consists of two basic stages, reaction
and separation. Plug Flow Reactor (PFR) is used in the reaction stage. Since the aqueous
ammonia process was chosen; Ammonia and water are also available along with the desired
products in the output stream. In the separation part, firstly, water and ammonia are separated
by distillation column. The separated stream is returned to the process as a recycling stream.
Afterwards obtained by separating MEA, DEA and TEA with three distillation columns
connected in series, respectively.

8
 3.2. Feasible Process Conditions

3.2.1. Physical Properties and Thermodynamic Data of Components

The physical properties of the components used/obtained in the process are given in the Table
3.2.

Table 3.2. Pure Component Properties [13]

Component Pure Component Properties

Heat
Mole weight Boiling Density Melting
Name Formula Capacity
(g/mol) point (K) (kg/m3) Point (K)
(J/kgK)

Ammonia NH3 17.12 239.61 4.83 0.771 195.45

Ethylene Oxide C2H4O 44.05 468.15 2.008 870 160.55

Monoethanolamine C2H7NO 61.23 445.45 2.64 1020 283.45

Diethanolamine C4H11NO2 105.20 541.76 2.56 1060 301.05

Triethanolamine C6H15NO3 149.56 633.13 140.80 1125 294.15

Water H2O 18.02 373.15 19.72 998.08 273.15

Notes: 1. 101.3 kPa

2. 298.15 K

9
3.2.2. Reaction Stoichiometry and Kinetics
Chemical reactions of producing ethanolamines are shown in Figure 3.1.

Figure 3.1. Ethanolamine production reactions [14]

Reaction rate expressions are as follows [14],

𝑟1 = 𝑘1 𝐶𝑁𝐻3 𝐶𝐸𝑂

𝑟2 = 𝑘2 𝐶𝐸𝑂 𝐶𝑀𝐸𝐴

𝑟3 = 𝑘3 𝐶𝐸𝑂 𝐶𝐷𝐸𝐴

The production of ethanolamines occurs simultaneously in three reactions. All reactions are
exothermic. Optimized Arrhenius Parameters are shown in Table 3.3.

Table 3.3. Optimized Arrhenius Parameters [15]

Activation Energy (Ea) Frequency Factor

Reaction
(kcal/mol) (k0)
NH3 + EO 19660 1.581 x 107

MEA + EO 19660 4.92 x 108

DEA + EO 19660 5.2 x 108

10
3.3. Process Structure
Ammonia and the recycle stream that containing ammonia and water combine in the mixer.
Ethylene oxide is fed into the reactor with the stream coming out of the mixer, where the
reaction takes place under water catalyst. MEA, DEA and TEA are formed in the reactor. The
stream containing ethanolamines, ammonia and water enters the first distillation column to get
rid of ammonia and water. The distillate consisting of water and ammonia coming out of the
distillation column is sent to the mixer as a recycling stream. After the ammonia and water are
removed from the ethanolamines, MEA, DEA and TEA are fed to distillation columns and
obtained as liquid products. The described system arrangement is shown in Figure 3.2.

Figure 3.2. The Block Diagram of Ethanolamine Production

11
4. PROCESS FLOW DIAGRAM (PFD) WITH MASS AND ENERGY BALANCES

4.1. Process Flow Diagram

Figure 4.1. Process Flow Diagram (PFD)

12
4.2. Process Description

The process consists of two main sections; reaction and seperation. The raw materials required
for the reaction are stored under their own storage conditions. The liquid raw materials are kept
at the given temperature and pressure values in Table 3.1. Water, ammonia and ethylene oxide
are used as raw materials in the process. Water acts as a catalyst. After the feed water and
ammonia react, it is included in the process as a recycling stream. The ammonia:water ratio
used in the reaction is 30%. Liquid ammonia is supplemented in order to reduce the amount of
ammonia in the recycling stream. Liquid ammonia and the return current are combined in the
mixer (M-101) and come out at the reaction pressure 60 bar. M-101 outlet stream heated by a
heat exchanger (E-101) to 85 °C and fed to the reactor (R-101). Ethylene Oxide is also pumped
by P-102 to 60 bar and heated by E-102 to 85 °C. The reactor R-101 is assumed as isothermal
and it operates at 85 °C and 60 bar. MEA, DEA, TEA are produced by the exothermic reaction
in R-101 and ethylene oxide is completely consumed.

After R-101; the ethanolamines, unreacted raw materials and water fed distillation column
(T-101). T-101 separates ethanolamines from unreacted raw materials at 0.7 bar. The recycle
stream (8) containing water and ammonia comes out as the upper stream and is fed back to the
M-101. The bottom stream (9) which is purified of water and ammonia is pumped by P-102 to
the second distillation column (T-102). T-102 operates at 0.03 bar under vacuum conditions
and MEA as a distillate is obtained with 99.9% purity. Afterwards, MEA is cooled to a storage
temperature of 35°C by heat exchanger (E-103). The bottom stream containing DEA and TEA
is pumped by P-103 to the third distillation column (T-103). T-103 operates at 0.005 bar. 130
°C DEA is obtained with 99.6% purity from the top stream (15) and cooled to 50 °C, which is
the storage temperature, by the heat exchanger (E-104). The bottom stream (17) is pumped by
P-104 into the last distillation column (T-104) to obtain remaining DEA and pure TEA. T-104
operates at 0.001 bar and the remaining DEA is fully obtained from the top stream with 99.9%
purity. This stream is cooled by E-105 to 50 °C and then pumped by P-105 to obtain 0.01 bar
which is the pressure of DEA that obtained from T-103. DEA from T-103 and T-104 is
combined and stored. TEA of 99.9% purity is obtained from the bottom of T-104 at 165 °C and
cooled to 40 °C, which is the storage temperature, by the heat exchanger E-106.

All currents in the process are shown in Table 4.1.

13
Table 4.1. Process Stream Table

Stream No 1 2 3 4 5

Temperature (◦C) 20 10.2 85 50 52

Pressure (bar) 18 60 60 10 60

Molar Flow (kmol/h) 8.3 1346.7 1346.7 10.8 10.8

Mass Flow (kg/h) 141.05 23845.8 23845.8 476.85 476.85

Mass Flow (kg/h)

Ammonia 141.05 7153.3 7153.3 - -

Ethylene Oxide - - - 476.85 476.85

Monoethanolamine (MEA) - 1.46 1.46 - -

Diethanolamine (DEA) - - - - -

Triethanolamine (TEA) - - - - -

Water - 16691.03 16691.03 - -

Stream No 6 7 8 9 10

Temperature (◦C) 85 85 11.3 167.2 167.2

Pressure (bar) 60 60 0.7 0.7 1.05

Molar Flow (kmol/h) 10.8 1346.73 1338.45 8.3 8.3

Mass Flow (kg/h) 476.85 24322.65 23704.75 617.89 617.89

Mass Flow (kg/h)

Ammonia - 7012.26 7012.26 0 0

Ethylene Oxide 476.85 0 0 0 0

Monoethanolamine (MEA) - 377.45 1.46 375.98 375.98

Diethanolamine (DEA) - 179.75 0 179.75 179.75

Triethanolamine (TEA) - 62.16 0 62.16 62.16

Water - 16691.03 16691.03 0 0

Stream No 11 12 13 14 15

14
Temperature (◦C) 85.4 35 171 171 130

Pressure (bar) 0.03 0.03 0.03 0.45 0.005

Molar Flow (kmol/h) 6.2 6.2 2.1 2.1 1.7

Mass Flow (kg/h) 376.17 376.17 241.71 241.71 176.33

Mass Flow (kg/h)

Ammonia 0 0 0 0 0

Ethylene Oxide 0 0 0 0 0

Monoethanolamine (MEA) 375.64 375.64 0.34 0.34 0.34

Diethanolamine (DEA) 0.53 0.53 179.21 179.21 175.63

Triethanolamine (TEA) 0 0 62.16 62.16 0.36

Water 0 0 0 0 0

Stream No 16 17 18 19 20

Temperature (◦C) 50 176.3 176.3 106.9 50

Pressure (bar) 0.005 0.005 0.4 0.001 0.001

Molar Flow (kmol/h) 1.7 0.4 0.4 0.03 0.03

Mass Flow (kg/h) 176.33 65.38 65.38 3.58 3.58

Mass Flow (kg/h)

Ammonia 0 0 0 0 0

Ethylene Oxide 0 0 0 0 0

Monoethanolamine (MEA) 0.34 0 0 0 0

Diethanolamine (DEA) 175.63 3.58 3.58 3.58 3.58

Triethanolamine (TEA) 0.36 61.8 61.8 0 0

Water 0 0 0 0 0

15
 Stream No 21 22 23 24

Temperature (◦C) 50 50 165.5 40

Pressure (bar) 0.005 0.005 0.001 0.001

Molar Flow (kmol/h) 0.03 1.73 0.4 0.4

Mass Flow (kg/h) 3.58 179.93 61.8 61.8

Mass Flow (kg/h)

Ammonia 0 0 0 0

Ethylene Oxide 0 0 0 0

Monoethanolamine (MEA) 0 0.38 0 0

Diethanolamine (DEA) 3.58 179.21 0 0

Triethanolamine (TEA) 0 0.34 61.8 61.8

Water 0 0 0 0

4.3. Mass and Energy Balances

4.3.1. Mass Balance

Table 4.2. Overall Mass Balance

Mass Balance (kg/h) Mole Balance (kmol/h)

Overall
IN OUT IN OUT

Ammonia 7153.3 7012.3 420 411.7

Ethylene Oxide 476.9 0 10.8 0

MEA 1.4 377.4 0 6.2

DEA 0 179.7 0 1.7

TEA 0 62.2 0 0.4

Water 16691 16691 926.5 926.5

TOTAL 24322.6 24322.6 1357.3 1346.5

16
Table 4.3. Equipment Mass Balance

IN OUT
EQUIPMENT
IDENTIFY
Mass (kg/h) Stream No Stream No Mass (kg/h)
141 1
M-101 2 23845.8
23704.8 8
23845.8 2 E-101 3 23845.8

476.9 4 P-101 5 476.9

476.9 5 E-102 6 476.9

23845.8 3
R-101 7 24322.7
476.9 6
8 23704.8
24322.7 7 T-101
9 617.9
617.9 9 P-102 10 617.9
11 376.2
617.9 10 T-102
13 241.7
376.2 11 E-103 12 376.2

241.7 13 P-103 14 241.7

15 176.3
241.7 14 T-103
17 65.4
176.3 15 E-104 16 176.3

65.4 17 P-104 18 65.4

19 3.6
65.4 18 T-104
23 61.8
3.6 19 E-105 20 3.6

3.6 20 P-105 21 3.6

61.8 23 E-106 24 61.8

17
4.3.2. Energy Balance

Table 4.4. Equipment Energy Balance

IN OUT
EQUIPMENT
IDENTIFY
Energy (kW) Stream No Stream No Energy (kW)
-155.8 1
M-101 2 -81860.8
-81705 8
-81860.8 2 E-101 3 -79571

-238.8 4 P-101 5 -237.7

-237.7 5 E-102 6 -216.9

-79571 3
R-101 7 -80197.7
-216.9 6
8 -81705
-80197.7 7 T-101
9 -702.4
-702.4 9 P-102 10 -702.4
11 -433.1
-702.4 10 T-102
13 -292.4
-433.1 11 E-103 12 -446.5

-292.4 13 P-103 14 -292.4

15 -221.3
-292.4 14 T-103
17 -76.7
-221.3 15 E-104 16 -231.9

-76.7 17 P-104 18 -76.7

19 -4.6
-76.7 18 T-104
23 -72.8
-4.6 19 E-105 20 -4.7

-4.7 20 P-105 21 -4.7

-72.8 23 E-106 24 -78.6

18
 Table 4.5. Overall Energy Balance

Overall Energy
IN OUT
Balances (kW)
Feed Streams -82099.6 0
Product Streams 0 -82467
Total Heating 16645.2 0
Total Cooling -17024.6 0
Power Added 1.0259 0
Power Generated 0 0
TOTAL -82467 -82467

19
5. EQUIPMENT DESIGN & SIZING

5.1. Design of Storage Tanks

Table 5.1. Design of Storage Tanks

Storage Tanks TK-101 TK-102

Material of Choice Stainless Steel Stainless Steel 316
Temperature (°C) 50 10
Pressure (bar) 18 2.3
Volume per tank(m3) 19.68 15.2
Total Volume (m3) 49.72 91.1
Outside Diameter (m) 2.296 2.148
Inner Diameter (m) 2.256 2.068
Thickness (mm) 20 40
Height (m) 4.17 4
Cover Type Ellipsoidal Ellipsoidal
Bottom Type Ellipsoidal Ellipsoidal
Stored Material Liquid Ammonia Ethylene Oxide
Number of Tanks 3 6

5.2. Design of Reactor

Table 5.2. Design of Reactor

Reactors R-101
MOC Stainless Steel 316
b/a (major axis/minor axis) 2
Volume (m3) 7
Inner Diameter (m) 1.493
Outer Diameter (m) 1.58
Wall Thickness (mm) 42.3
Bottom Type Elipsoidal
Bottom Wall Thickness
42.3
(mm)
Cover Type Elipsoidal
Cover Wall Thickness (mm) 42.3

20
5.3. Design of Mixer

Table 5. 3. Design of Mixer

Mixer M-101
Material of Choice Stainless Steel 316
Temperature (°C) 10
Pressure (bar) 60
Volume (m3) 10.3
Outside Diameter (m) 2.076
Inner Diameter (m) 2.034
Thickness (mm) 44
Height (m) 2.5
Cover Type Ellipsoidal
Bottom Type Ellipsoidal
Mixed Material Liquid Ammonia & Water

5.4. Design of Distillation Columns

Table 5. 4. Design of Distillation Columns

Distillation T-101 T-102 T-103 T-104

Columns
MOC Stainless Steel Stainless Steel Carbon Steel Carbon Steel
316 316
Type Sieve Tray Sieve Tray Sieve Tray Sieve Tray

Tray Spacing (m) 0.61 0.61 0.61 0.61

Number of 16 11 12 10
Stages
Feed Stage 9 6 7 6

Reflux Ratio 0.12 0 0 1.79

Column 3.05 0.46 0.46 0.49

Diameter (m)
Height (m) 10 6.5 7 6

21
 5.5. Design of Pumps
Table 5.5. Design of Pumps

Pumps P-101 P-102 P-103 P-104 P-105

Type Centrifuge Centrifuge Centrifuge Centrifuge Centrifuge

MOC Carbon Steel Carbon Steel Carbon Steel Carbon Steel Carbon Steel

Efficiency 0.85 0.85 0.85 0.85 0.85

Electric (kW) 1 0.008 0.003 0.0008 0.0000004

Input Pressure 2.3 0.7 0.03 0.005 0.001

(bar)
Output Pressure
60 1.05 0.45 0.4 0.005
(bar)

5.6. Design of Heat Exchangers

Table 5.6. Design of Heat Exchangers

Heat Exchangers E-101 E-102 E-103

Type Shell & Tube Shell & Tube Shell & Tube

Stainless Steel/ Stainless Steel/ Stainless Steel/

MOC (Tube/Shell)
Carbon Steel Carbon Steel Carbon Steel
Power (kW) 2289.5 9.9 13.4
Number of Tubes 111/2 passes 348/4 passes 214/4 passes
Tube Inner Diameter (m) 0.019 0.019 0.019
Tube Outer Diameter (m) 0.016 0.016 0.016
Tube Wall Thickness (m) 0.003 0.003 0.003
Tube Length (m) 4.9 2.44 2.44
Shell Inner Diameter (m) 0.30 0.54 0.44
Shell Outer Diameter (m) 0.33 0.57 0.46
Shell Wall Thickness (m) 0.03 0.03 0.02
Heat Transfer Area (m2) 31.81 17.16 10.86
Fluid Inlet Temperature (°C) 10 10 85
Fluid Outlet Temperature (°C) 85 85 35

22
 Table 5.7. Design of Heat Exchangers (continued)

Heat Exchangers E-104 E-105 E-106

Type Shell & Tube Shell & Tube Shell & Tube
Stainless Steel/ Stainless Steel/ Stainless Steel/
MOC (Tube/Shell)
Carbon Steel Carbon Steel Carbon Steel
Power (kW) 10.6 0.2 5.8
Number of Tubes 277/4 passes 214/4 passes 214/4 passes
Tube Inner Diameter (m) 0.019 0.019 0.019
Tube Outer Diameter (m) 0.016 0.016 0.016
Tube Wall Thickness (m) 0.003 0.003 0.003
Tube Length (m) 2.44 2.44 2.44
Shell Inner Diameter (m) 0.49 0.44 0.44
Shell Outer Diameter (m) 0.51 0.46 0.46
Shell Wall Thickness (m) 0.02 0.02 0.02
Heat Transfer Area (m2) 14.05 10.86 10.86
Fluid Inlet Temperature (°C) 130 107 165
Fluid Outlet Temperature (°C) 50 50 40

23
6. PROCESS CONTROL

Process control is the combination of statistics and engineering disciplines that deal with
mechanisms, architectures, and algorithms to control a process. The role of process control in
industrial operations is to contribute to safety by keeping the process variable close to desired
values, minimizing environmental impact and optimizing processes.

Controlling or automating the process has benefits in a number of different areas in the
operation of a unit or chemical plant. The safety of workers and the community around a factory
are important elements in a process design. Chemical factories have the potential to cause
serious damage if something goes wrong. Therefore, it is one of the goals of the establishment
of process control to set limits on a particular unit in order not to injure or kill employees,
individuals in the community.

Most processes must operate in steady state conditions or a situation where they meet all the
benefits for a company, such as budget, return, security, and other quality objectives. In many
real-life situations, a process may not always remain static under these conditions and therefore
cause significant losses in the process. One of the reasons the process is moving away from
these conditions is that the system becomes unstable. When the system becomes unstable,
process variables are released from their physical boundaries in a limited period of time. The
departure from steady state conditions can result from various changes in environmental
conditions such as the composition of a feed, temperature conditions, or flow rate.

Process controls are tools used to control a parameter such as temperature, level, and pressure.
The most common type of control used in the industry is a PID controller (proportional, integral,
derivative) that allows the operator to apply different control techniques that can be used to
achieve different settings in an experiment or process. A PID controller can be used in two main
control mechanisms that include feedback and feed forward. PID controllers are a type of
continuous controller as they continuously adjust the output to an on-off controller while
looking at feedforward or feedback conditions [16].

24
6.1. Process Control for Equipments

6.1.1. Process Control for Reactor (R-101)

R-101 is an ethanolamine production reactor. Ethanolamine production occurs through three
series of reactions. The reactions are exothermic and take place in liquid phase. Therefore, the
reactor operates in isothermal conditions. Temperature control is made in order to control the
isothermal environment. A jacket has been added to the outside of the tank for temperature
control inside the reactor. Coolant supplied to the jacket is manipulated to control the
temperature. The temperature controller (TC) receives the signal from the temperature
transmitter (TT) and sends this signal to the valve that adjusts the cooling water flow rate to
control it.

The reactor operates at a high pressure of 60 bar. Therefore, pressure control is necessary. By
measuring the pressure in the reactor, the inlet flow to the reactor is regulated by a valve
depending on this value. Depending on the pressure value, the pressure is kept at the desired
value by making gradual changes in the valve opening. Process control for the reactor is shown
in Figure 6.1.

Figure 6.1. Process Control for Reactor (R-101)

25
6.1.2. Process Control for Distillation Columns (T-101, T-102, T-103 & T-104)
There are five distillation columns in the process, T-101, T-102, T-103 and T-104. T-101
operates at 1 atm pressure and removes water and ammonia from the product. Other distillation
columns operate at low pressures and the products are obtained individually pure. Distillation
columns contain temperature, pressure, flow rate and level control. The vapor pressure in the
distillation column is measured to check the pressure. This measured value is sent to the valve
on the cooling water entering the condenser by using a pressure transmitter (PT) and pressure
controller (PC). The pressure is kept at desired values by manipulating the cooling water flow
rate. The pressure is reduced by increasing the cooling water flow rate.

The liquid level in the reflux drum is controlled by manipulating the flow rate of the distillate.
With the level control, excessive liquid loading in the reflux drum is prevented. In case of
exceeding a possible desired value, the distillate flow is discharged through the valve on it. In
addition, a flow transmitter is placed on the distillate and reflux flows to measure the flow rates
there. These signals are sent to the reflux controller and the flow rate of the reflux stream
entering the distillation column is manipulated by the valve. In this way, reflux rate control is
provided.

Temperature and level control is used at the bottom of the distillation column. The temperature
value of the lower side is the measured value and the steam flow rate entering the reboiler is
manipulated with this value. In addition, the liquid level in the column is signaled by the level
transmitter (LT) and the level controller (LC) and sent to the valve in the lower product outlet
flow. In this way, in case of overload, the bottom product is discharged and overloading is
prevented.

The same control systems are valid for all distillation columns in the process. The general
process control scheme for distillation columns is shown in Figure 6.2.

26
 Figure 6.2. Process Control for Distillation Columns

6.1.3. Process Control for Mixer (M-101)

The purpose of the mixer (M-101) is to ensure that the solution containing ammonia and water
entering the reactor contains 30% ammonia. One of the M-101 input streams is the recycle
stream containing a mixture of water and ammonia from T-101 and the other is ammonia. Flow
fraction controller (FFC) is used to achieve this ratio. It provides a fast rate control as it receives
the signals of the controlled feed, the ammonia current, as direct input with the recycle current
which is the wild feed. In addition, there is a discharge valve in the output stream in order to
control the overload in the mixer. By performing level control, overloading is prevented by
opening the relief valve when possible. The process control for the mixer is shown below as in
Figure 6.3.

27
 Figure 6.3. Process Control for Mixer (M-101)

6.1.4. Process Control for Heat Exchangers (E-101, E-102, E-103, E-104, E-105 & E-106)
E-101 and E-102 shell heat exchangers are used in the process to heat the raw material
to the reaction temperature. Other heat exchangers are shell and tube heat exchangers that cool
products to bring them to storage temperature. Gradual control is used in heat exchangers. In
cascade control, the output of the temperature controller (TC) is fed as a set point to the
feedback flow controller (FC), rather than directly feeding it to the control valve. This second
cycle is responsible for making sure that the utility flow rate does not change due to any factors
such as uncontrollable steam pressure or valve problems. The advantage of the Cascade control
system is that when there is a sudden pressure rise in the steam entering the heat exchanger, the
feedback flow control loop FC will immediately adjust the valve position when the steam flow
rate changes to bring the flow back to the value of the previous steady state condition. This
prevents a change in outlet temperature before it takes place. The flow control loop needs to be
adjusted to run much faster than the temperature control loop, so the process cancels out the
effect of the flow variance before affecting the fluid outlet temperature. The general process
control scheme of heat exchangers is shown in Figure 6.4.

28
 Figure 6.4. Process Control for Heat Exchangers

6.1.5. Process Control Summary

Process control variables and control types of the equipment are shown in Table 6.1.

Table 6.1. Process Control Variables for Equipments

Controlled Manipulated
Equipment Controlled Type
Variable Variable

Temperature Utility flow rate Feedback

R-101
Pressure Inlet flow rate Feedback
Ammonia feed flow
Flow fraction Feedforward
M-101 rate
Level Outlet Stream Feedback
Condenser utility
Pressure Feedback
flow rate
Level Distillate flow rate Feedback
T-101, T-102, T-103 Reflux Reflux flow rate Ratio Controller
& T-104
Reboiler utility flow
Temperature Feedback
rate
Bottom product flow
Level Feedback
rate
E-101, E-102, Temperature
E-103, E-104, Utility flow rate Cascade
E-105 & E-106 Flow rate

29
7. WASTES ENVIRONMENT AND SAFETY

7.1. Safety
It is very important to determine the dangers that may occur in chemical production facilities
in terms of waste management, environmental impacts, safety of process materials and
occupational health and safety. In order to provide a safe and conscious working environment
in the facility, the hazards that may occur should be analyzed and necessary measures should
be taken according to the degree of the hazards. In this project, the most optimum process was
selected, waste was minimized, a safe process environment was provided, and environmental
impacts were taken into account.

7.1.1. Occupational Health and Safety

According to the World Health Organization (WHO) and the International Labor Organization
(ILO) definition, Occupational Health and Safety (OHS) is “raising the physical, mental, social
health and welfare of all employees to the highest level and protecting this situation, eliminating
the unhealthy consequences of workplace conditions, the environment and the goods produced,
eliminating the risk factors that will expose employees to injuries and accidents, jobs suitable
for their specifications”. Depending on the industrialization in the world and in our country,
there is an increase in the rate of occupational accidents in workplaces. Occupational health and
safety measures should be taken to prevent these accidents and to provide a healthy and safe
environment for employees. The main targets of occupational health and safety are:

 To completely eliminate the risks in the workplaces or to minimize the damages,

 To protect and improve the health of employees in terms of physical, mental and
medical aspects,
 To protect employees from the negative effects of working conditions,
 To determine the health damages and occupational diseases and to provide their
treatment,
 To allow employees who suffered from work accidents or occupational diseases to work
in appropriate jobs,
 To determine and evaluate the degree of damages in objective, scientific and ethical
ways,
 To eliminate material and moral damages.
Various chemical substances are used in the production facilities and these substances can be
dangerous. Occupational Health and Safety (OHS) guidelines should be followed and

30
controlled regularly in order to prevent damages caused by these risky substances. The general
measures to be taken in order to prevent or minimize the health, safety and environmental risks
that may arise from chemical substances in production facilities are as follows;

 Appropriate arrangement and organization of work in the workplace,

 Taking into account technological developments, using appropriate and safe equipment,
 Adequate control and supervision in terms of the effectiveness and continuity of the
measures,
 Working with chemical substances with the least number of employees as possible,
 Not having more than the amount required for the work done in the production area,
 Keeping the workplace and its attachments tidy and clean at all times,
 Providing appropriate and sufficient conditions for personal cleaning of employees,
 Ensuring the most appropriate processing, use, transportation and storage of chemical
waste and residues,
 Prioritizing collective protection without departing from personal protection,
 Ensuring that appropriate personal protective equipment is used even if all kinds of
precautions are taken,
 Providing necessary occupational health and safety training to employees and carrying
out periodic health examinations,
 Making occupational health and safety risk assessment covering the whole workplace
[17].

31
7.1.2. Safety of Process Materials
The effects that may cause danger in this project are shown in Table 7.1 by making a hazard
analysis of raw materials and products.

Table 7.1. Safety of Process Materials

Environmental
Type Of Flammable /
Material and
Usage Combustible
Health Effect
Acute toxic
Ammonium
Corrosive Non-flammable
Hydroxide (%30 wt) Raw Material
Irritant

Acute toxic

Ethylene Oxide Corrosive Flammable

Raw Material
Irritant

Acute toxic

Ammonia Corrosive Flammable

Raw Material
Irritant

Water Raw Material - -

Acute toxic

Ethanolamine Corrosive Combustible

Product
Irritant

7.1.3. Environmental Effects

Ammonia is one of the raw materials used in the process. Ammonia, which is added to the
process during the feedback phase, is a toxic, corrosive, corrosive and explosive substance. It
can decompose at high temperatures, forming highly flammable hydrogen and toxic nitrogen
dioxide. May cause serious damage by inhalation or contact. In our project, ammonia does not
come out as waste, it is fed to the system without water and is included in the cycle as aqueous

32
ammonia. Unfortunately, there is no company that can supply ammonia in Turkey. Therefore,
it must be transferred from abroad. Ammonia transport equipment can be classified as fully
cooled, semi-cooled or pressurized. Temperature of -33 ° C is maintained in fully cooled tanks.
In semi-cooled tanks, a pressure of 3-4 atm and a temperature in the range of 0-5 °C are
provided. Pressurized tanks are designed for pressures up to 18 atm [18]. Problems that may
occur during the transfer are prevented by providing these conditions, and healthy
transportation conditions can be provided.

Ethylene oxide is another raw material used in the process. It polymerizes by iron rust, acids,
bases and by chlorides of iron and other metals. Polymerization is highly exothermic and may
result in explosion. So, this chemical highly reactive and explosive, also it can cause serious
damage if swallowed, inhaled or in contact with skin. Studies have shown that it is a
carcinogenic substance. It should be stored in grounded tanks to prevent a devastating explosion
caused by ethylene oxide. Considering this raw material, it was deemed appropriate to establish
the production facility in İzmir Aliağa Organized Industrial Zone. Production will be carried
out in a place close to Petkim, where this substance will be supplied, and thus, the dangers that
may occur during the transfer will be prevented. In addition, there should be no settlements near
this facility, which uses ethylene oxide in production. Because people living near the facility
may be exposed to industrial emissions, which can threaten people's health. Since our
production facility will be established in an organized industrial zone, this risk is eliminated. In
addition, ethylene oxide should be stored at least 15 m from the facility and should be covered
with a nitrogen blanket during storage. Nitrogen blanketing in ethylene oxide storage controls
the atmosphere above a flammable or combustible liquid, reducing the potential for ignition.
With this process, nitrogen, which is an inert gas, is given to the storage tank to counteract the
effects of ethylene oxide on the storage material. In order to prevent possible situations, relief
valve should be used. Ethylene oxide, which is included in the process as a raw material in our
project, is completely consumed as a result of the chemical reaction, and possible hazards are
prevented by taking necessary precautions.

Water is a raw material that acts as a catalyst in the process. All of the water fed is returned to
the system and since it is in this cycle, there is no waste of water. Besides, it is not a corrosive,
toxic or corrosive substance, so it does not contain any danger.

33
7.1.4. Waste Treatment
This project is environmentally friendly and has been designed with the “zero waste principle”
in mind. The water and ammonia used in the process are recycled and fed into the system
repeatedly. It is planned that the facility will undergo maintenance three times a year and that
the water in the system will be treated in the treatment facilities during these maintenances.
Thus, purified water is added to the process and returned to the system.

7.2. Hazard and Operability Analysis (HAZOP)

Production processes are a large system formed by the combination of many inputs such as
machinery, chemicals, processes, procedures, etc. Each process has a unique design and
component, and the dangers associated with the design of the process pose specific risks. When
designing a process, taking into account the prevention or reduction of the risk caused by this
process, risks are determined and measures are taken. The more complex the system, the more
difficult it will be to identify hazards, analyze and manage risks. To successfully control
hazards, it is necessary to understand the hazards and know how to identify them.

Hazard and Operability Analysis (HAZOP) is a systematic technique that includes system
review and risk management to identify potential hazards in a system. HAZOP is based on a
theory that assumes risk events are caused by deviations from design or operating intentions. It
has great advantages in detecting hazards and hazards that are difficult to analyze that may
result from human performance and behavior. It is recommended to use HAZOP as a hazard
identification method in the chemical industry in order not to overlook possible dangers. The
steps for applying the HAZOP technique are given below [19].

1. Selecting the unit of the working line (i.e. line, container, pump, operating instruction)
2. Defining the design conditions
3. Parameter selection
4. Use of guide words
5. Identifying possible causes of deviation
6. Evaluate consequences / problems
7. Consensus on changes
8. Tabulation of results
9. Repeating the procedure
The word meanings that are used in HAZOP analysis is given in Table 7.2.

34
 Table 7.2. HAZOP Guide Word Meanings

Guide Word Meaning

NO Negation of the Design Intent
LESS Quantitative Decrease
MORE Quantitative Increase
PART OF Qualitative Decrease
AS WELL AS Qualitative Increase
REVERSE Logical Opposite of the Intent
OTHER THAN Complete Substitution

Tables 7.3-7.10 consist of HAZOP analysis for reactor, distillation columns, heat exchangers
and pumps used in this plant design project.

Table 7.3. HAZOP Analysis for R-101

Equipment Name: Ethanolamine Production Plug Flow Reactor (PFR), R-101

Intention: Providing ethanolamine reaction efficiently.

Guide
Deviation Cause Consequence Action
Word
- Blockage in
pipes coming to - Cleaning and
the reactor maintenance of
pipelines and
- There may be a pumps of the
No flow entering - There will be
problem on storage tank
FLOW

reactor no reaction
equipments (heat - Control of inlet
NO exchanger, mixer flow
or pump) that - Maintain spare
comes before the pumps
reactor
- Blockage in the - There will be Cleaning and
No flow at the
pipeline leaving no stream to T- maintenance of
outlet of reactor
reactor 101 column pipeline

35
 - Cleaning and
- Partial blockage maintenance of
- Inefficient
Less than or leakage in the pipeline and
reaction
planned flow pipeline pump.
conditions
entering reactor - Problem in - Shut down
pump - Usage of
second pump
- Cleaning and
LESS maintenance of
- Level decrease
- Partial blockage pipeline and
in distillation
Less than or leakage in the pump
column
planned flow pipeline - Controlling
- Increased
leaving the - Changes in temperature and
temperature in
reactor reaction pressure
reactor
conditions - Install
temperature and
pressure alarm
- Flow control
valve must be
- Inefficient
closed manually
More than - Problem in reaction
MORE - Install pressure
planned flow pump or control conditions
relief valve
entering reactor equipment - High pressure
- Install pressure
and temperature
and temperature
alarm

- Problem in - Maintenance of
temperature heat exchanger
Temperature is
controller and - Decreased - Replacement of
LESS lower than
heat exchangers efficiency of heat exchanger
reaction
TEMPERATURE

that comes reaction - Install

temperature
before the temperature
reactor. alarm

- Problem in heat
exchanger and - Control the
Temperature is temperature - Fire in reactor temperature
MORE higher than controller - Decreased - Install
reaction - Blockage of the efficiency of temperature
temperature cooling water reaction alarm
line to the reactor -Shut down
jacket
- Control the
- Problem in pressure
More than pump
PRESSURE

- Undesired - Pressure relief

planned pressure - Blockage in the reaction valve
MORE
in reactor pipeline going to conditions - System shut
T-101 column - Explosion risk down
- Install pressure
alarm

36
 IMPURITIES
- Purification of
- Storage - Undesired
Increased the feed
MORE impurities product
impurities in - Cleaning or
- Contaminants - Lower
reactor replacement of
in the pipeline efficiency
storage tank

Table 7.4. HAZOP analysis for T-101

Equipment Name: Distillation Column T-101

Intention: Separating water and ammonia from ethanolamines.

Guide
Deviation Cause Consequence Action
Word
- Blockage in - Cleaning and
No flow entering pipes coming to - Column dry out maintenance of
NO column the column - Process cannot pipeline
FLOW

- Problem in be run - Schedule

reactor inspection
- Blockage in - Level decrease - Cleaning and
Less than pipes coming to in column maintenance of
LESS planned flow the column - Inefficient pipeline
entering column - Problem in separating - Schedule
reactor conditions inspection
- Problem in
Less than - Inefficient - Install
LESS temperature
TEMPERATURE

planned separating temperature

controller and
temperature conditions alarm
reboiler
- Problem in - Control the
More than temperature - Purity of the temperature
MORE planned controller products is - Install
temperature - Increase in the decreased temperature
amount of steam - Explosion risk alarm
in the column -Shut down
- Failure of - Control the
valves pressure
PRESSURE

- High amount of - Pressure relief

- Inefficient
MORE More than steam passing valve
separation
planned pressure from the reboiler - System shut
- Explosion risk
to the column down
- Install pressure
alarm

37
 Table 7.5. HAZOP analysis for T-102, T-103 & T-104

Equipment Name: Distillation Columns T-102, T-103 & T-104

Intention: Provide to separate MEA, DEA, TEA and obtain high purity products.
Guide
Deviation Cause Consequence Action
Word
- Cleaning and
- Blockage in maintenance of
pipes coming to - Column dry out pipeline
NO No flow entering
the column - Process cannot - Schedule
column
- Problem in be run inspection
pumps - Maintain spare
pumps
- Cleaning and
FLOW

- Blockage in - Level decrease maintenance of

Less than pipes coming to in column pipeline
LESS planned flow the column - Inefficient - Schedule
entering column - Problem in separating inspection
pumps conditions - Usage of
second pump
- Level increase - Install level
More than - Problem in in column alarm
MORE planned flow - Inefficient - Flow control
pump
entering column separating valve must be
conditions closed manually

- Problem in
Less than - Inefficient - Install
LESS temperature
TEMPERATURE

planned separating temperature

controller and
temperature conditions alarm
reboiler
- Problem in - Control the
temperature - Purity of the temperature
More than
MORE controller products is - Install
planned
- Increase in the decreased temperature
temperature
amount of steam - Explosion risk alarm
in the column -Shut down
- Failure of - Control the
valves pressure
- High amount of
PRESSURE

- Pressure relief
steam passing - Inefficient
MORE More than valve
from the reboiler separation
planned pressure - System shut
to the column - Explosion risk
down
- Problem in - Install pressure
pumps alarm

38
 Table 7.6. HAZOP analysis for E-101 & E-102

Equipment Name: Heat Exchangers E-101 & E-102

Intention: Increasing the temperature of raw materials to reaction temperature

Guide
Deviation Cause Consequence Action
Word

- Cleaning and
- Blockage in -Inefficient maintenance of
NO No flow entering pipes going to the conditions for pipeline
heat exchanger reactor reactor - Schedule
inspection

- Cleaning and
- Failure of the maintenance of
No heating steam inlet steam valve - Inefficient pipeline
NO flow in the heat conditions for - Schedule
-Blockage in
exchanger reactor inspection
FLOW

pipeline
-Check valve
-Manually open

- Partial - Cleaning and

Less heating blockages in - Inefficient maintenance of
LESS steam flow in the pipeline conditions for pipeline
heat exchanger - Leakage in the reactor - Schedule
pipeline inspection

- Undesired by
products - Install
More heating - Failure of
MORE - Inefficient temperature
steam in the heating steam
reaction alarm
Heat exchanger valve
conditions - Shut down
- Explosion risk

39
 Table 7.7. HAZOP analysis for E-103, E-104, E-105 & E-106

Equipment Name: Heat Exchangers E-103, E-104, E-105 & E-106

Intention: Decreasing the temperature of products to storage temperatures

Guide
Deviation Cause Consequence Action
Word

- Cleaning and
No flow entering - Blockage in -Inefficient maintenance of
NO heat exchanger pipes going to the conditions for pipeline
reactor storage - Schedule
inspection
- Cleaning and
- Failure of the maintenance of
No cooling water cooling water - Inefficient pipeline
NO flow in the heat valve conditions for - Schedule
FLOW

exchanger -Blockage in storage inspection

pipeline -Check valve
-Manually open
- Partial - Cleaning and
Less cooling blockages in - Inefficient maintenance of
LESS water flow in the pipeline conditions for pipeline
heat exchanger - Leakage in the storage - Schedule
pipeline inspection

More cooling - Failure of the - Inefficient -Check valve

MORE water in the cooling water conditions for - Schedule
heat exchanger valve storage inspection

40
 Table 7.8. HAZOP analysis for P-101

Equipment Name: Pump, P-101

Intention: Increase the pressure of ethylene oxide to reaction pressure

Guide
Deviation Cause Consequence Action
Word

- Cleaning and
- Blockage in maintenance of
NO No flow entering - No reaction in
pipeline pipeline
pump reactor
FLOW

- Schedule
inspection

- Inefficient - Cleaning and

Less flow - Partial conditions for maintenance of
LESS entering the blockages in reactor pipeline
pump pipeline - Cavitation is - Schedule
occur inspection

Table 7.9. HAZOP analysis for P-102, P-103 & P-104

Equipment Name: Pumps, P-102, P-103 & P-104

Intention: Providing flow to distillation columns

Guide
Deviation Cause Consequence Action
Word

- Cleaning and
- Blockage in maintenance of
NO No flow entering - No flow to
pipeline pipeline
pump distillation column
- Schedule
inspection
- Inefficient
FLOW

- Cleaning and
separation
Less flow - Partial maintenance of
LESS conditions for
entering the blockages in pipeline
distillation column
pump pipeline - Schedule
- Cavitation is
inspection
occur
- Problem in
- More flow
valve that in the
More flow entering
MORE bottom exit - Check valve
entering the distillation column
stream of - Shut down
pump that comes after
distillation
the pump
column

41
 Table 7.10. HAZOP analysis for P-105

Equipment Name: Pump, P-105

Intention: Increase the pressure of DEA to other DEA stream

Guide
Deviation Cause Consequence Action
Word
- Cleaning and
- Blockage in maintenance of
NO No flow entering - No flow to
pipeline pipeline
FLOW

pump DEA storage

- Schedule
inspection
- Inefficient - Cleaning and
Less flow - Partial conditions for maintenance of
LESS entering the blockages in storage pipeline
pump pipeline - Cavitation is - Schedule
occur inspection

7.3. Fire and Explosion Index

Fire and explosion incidents cause serious damage and financial losses. The Dow Fire and
Explosion Index (F&EI) is a ranking system that gives a relative index to the risk of individual
process units due to potential fires and explosions. Classification of hazard degree of F&EI
shown in Table 7.11.

Table 7.11. Degree of Hazard for Fire & Explosion Index

Table 7.11. Degree of Hazard for Fire & Explosion Index

Degree of Hazard F&EI INDEX RANGE

Light 1-60

Moderate 61-96

Intermediate 97-127

Heavy 128-158

Severe >159

According to The Dow's Fire and Explosion Index Hazard Classification Guide Appendix A,
literature values for R-101 reactor are taken as shown in Table 7.12.

42
 Table 7. 12. Literature value for materials [20]

Material MF HC NH NR NF

Ethylene
29 11.7 3 3 4
Oxide

For F&EI calculations the MF is taken as 29. In the light of these data and process conditions,
F&EI has been calculated as below Table 7.13.

Table 7.13. Dow's Fire and Explosion Index for R-101

FIRE & EXPLOSION INDEX SUMMARY SHEET

Area/Country: Process Unit: Location: Date:
İZMİR / TURKEY Plug Flow Reactor (PFR) ALİAĞA 01.06.2021
Site: Manufacturing Unit Process Unit: Plug Flow Reactor (PFR)

Reviewed by: Reviewed by:

Prepared by: Approved by:
(Technology (Safety & Loss
(Management) (Superintendent)
Center) Prevention)
Materials in Process Unit
Ammonia, Water, Ethylene Oxide, Monoethanolamine, Diethanolamine, Triethanolamine

State of Operation Basic Material(s) for Material Factor

( X ) Design ( ) Start up
( ) Normal Operation ( ) Shutdown Ethylene Oxide

Material Factor 29
Penalty
Penalty
1. General Process Hazards Factor
Factor Used
Range
Base Factor 1.00 1.00
A. Exothermic Chemical Reactions 0.30 to 1.25 1.00
B. Endothermic Processes 0.20 to 0.40
C. Material Handling and Transfer 0.25 to 1.05
D. Enclosed or Indoor Process Units 0.25 to 0.90
E. Access 0.20 to 0.35 0.35
F. Drainage and Spill Control 0.25 to 0.50 0.5
General Process Hazards Factor (F1) 2.85

43
 2. Special Process Hazards
Base Factor 1.00 1.00
A. Toxic Material(s) 0.20 to 0.80 0.6
B. Sub-Atmospheric Pressure (< 500 mm Hg) 0.50
C. Operation in or Near Flammable Range
1. Tank Farms Storage Flammable Liquids 0.50
2. Process Upset or Purge Failure 0.30 0.3
3. Always in Flammable Range 0.80
D. Dust Explosion 0.25 to 2.00
E. Pressure 0.86
F. Low Temperature 0.20 to 2.00
G. Quantity of Flammable/Unstable Material:
1. Liquids or Gases in Process 1
2. Liquids or Gases in Storage
3. Combustible Solids in Storage, Dust in Process
H. Corrosion and Erosion 0.10 to 0.75 0.2
I. Leakage - Joints and Packing 0.10 to 1.50 0.1
J. Use of Fired Equipment
K. Hot Oil Heat Exchange System 0.15 to 1.15
L. Rotating Equipment 0.50
Special Process Hazards Factor (F2) 4.06
Process Unit Hazards Factor (F1 x F2) = F3 11.57  8
Fire and Explosion Index (F3 x MF = F&EI) 232

The Dow Fire and Explosion Index of the reactor R-101 is found as greater than 159. In these
case, it is seen that the degree of danger for the process is severe from Table 7.11.

7.4. Loss Control Credit Factors

In addition to basic design requirements, certain loss control features based on experience have
proven beneficial both in preventing serious incidents and in reducing the probability and
magnitude of a particular incident. There are three categories of loss control features:

44
• C1: Process Control
• C2: Material Isolation
• C3: Fire Protection

The following Tables 7.14, 7.15 and 7.16. provide credit factors for calculating C1, C2 and C3.

Table 7. 14. Process Control Credit Factor (C1)

Process Control Credit Feature Credit Factor Range Credit Factor Used

A. Emergency Power 0.98 0.98

B. Cooling 0.97 to 0.99 0.97
C. Explosion Control 0.84 to 0.98 0.98
D. Emergency Shutdown 0.96 to 0.99 0.96
E. Computer Control 0.93 to 0.99 0.93
F. Inert Gas 0.94 to 0.96 0.96
G. Operating Instructions / Procedures 0.91 to 0.99 0.91
H. Reactive Chemical Review 0.91 to 0.98 0.91
I. Other Process Hazard Analysis 0.91 to 0.98 0.94
C1 Value 0.62

Table 7.15. Material Isolation Credit Factor (C2)

Process Control Credit Feature Credit Factor Range Credit Factor Used

A. Remote Control Valves 0.96 to 0.98 0.96

B. Dump / Blowdown 0.96 to 0.98 0.96
C. Drainage 0.91 to 0.97 0.91
D. Interlock 0.98 0.98
C2 Value 0.82

45
 Table 7. 16. Fire Protection Credit Factor (C3)

Process Control Credit Feature Credit Factor Range Credit Factor Used
A. Leak Detection 0.94 to 0.98 0.94
B. Structural Steel 0.95 to 0.98 0.98
C. Fire Water Supply 0.94 to 0.97 0.97
D. Special Systems 0.91 0.91
E. Sprinkler Systems 0.74 to 0.97 0.81
F. Water Curtains 0.97 to 0.98 0.97
G. Foam 0.92 to 0.97 0.94
H. Hand Extinguishers / Monitors 0.93 to 0.98 0.93
I. Cable Fire Protection 0.94 to 0.98 0.94
C3 Value 0.52

Loss Control Credit Factor = C1 x C2 x C3 = (0.62) (0.82) (0.52) = 0.26

46
8. ECONOMICAL ANALYSIS

The economical analysis of the mono-,di-,tri- ethanolamines production process is analyzed in

terms of manufacturing costs and profitability analysis.

Manufacturing costs are estimated by including all the costs related to the manufacturing of that
process. The costs used for the calculation of the total cost of manufacturing (COM) are fixed
capital investment (FCI), operating cost, utility cost, raw material cost, and land cost.

The profitability analysis is made by determining the revenue and working capital. For a general
idea, cash flow diagrams of the project are demonstrated.

Calculations are done with the CAPCOST_2012.xls program and by hand.

CAPCOST_2012.xls is altered with more accurate utility prices and tax rates. Hand calculations
are given in the Appendix A3.

8.1. Estimation of Manufacturing Cost

Manufacturing cost includes direct, fixed, and general costs.

Direct costs consist of equipment costs, operating labor costs, utility costs, raw material costs,
and waste costs. These costs vary with production rate.

Fixed costs do not vary with anything, they stay the same even when the facility is not working.
It consists of property taxes, insurance and depreciation.

General costs include management, sales, financing, and research functions and they often do
not vary with production rate. Some of these factors are discussed in further detail.

8.1.1. Fixed Capital Investment (FCIL)

Ethanolamines production capacity is chosen to be 4440 ton/year. Accordingly, with the use of
CAPCOST, FCIL is found as $ 3,980,000.

8.1.2. Equipment Cost

The equipment costs are calculated by the CAPCOST program and shown in Table 8.1.

47
 Table 8.1. Overall Equipment Costs

Equipment Bare Module Cost ($)

Storage Tank 846,000
Reactor 57,000
Distillation Column 1,040,100
Heat Exchanger 692,000
Pump 167,600
Mixer 14,800
∑ 2,817,500

8.1.2.1. Storage Tank Cost

The storage tank costs are calculated by the CAPCOST program and shown in Table 8.2.

Table 8.2. Storage Tank Costs

Length/ Purchased Bare

Equipment Diameter Pressure
Orientation Height MOC Equipment Module
No. (m) (barg)
(m) Cost ($) Cost ($)
Stainless
TK-101 Horizontal 4.17 2.54 19.8 25,500 702,000
Steel
Stainless
TK-102 Horizontal 4 2.17 2.3 20,600 144,000
Steel 316
Total Bare Module Cost ($) 846,000

8.1.2.2. Reactor Cost

The reactor costs are calculated by the CAPCOST program and shown in Table 8.3.

Table 8.3. Reactor Costs

Equipment Volume Purchased Bare Module Cost

Type 3
No. (m ) Equipment Cost ($) ($)

R-101 Jacketed Non-Agitated 7 14,300 57,000

Total Bare Module Cost ($) 57,000

48
 8.1.2.3. Heat Exchanger Cost

The heat exchanger costs are calculated by the CAPCOST program and shown in Table 8.4.

Table 8.4. Heat Exchanger Costs

Shell Tube Purchased Bare

Equipment Exchanger MOC Area
Pressure Pressure Equipment Module
No. Type (Tray/Tower) (m2)
(barg) (barg) Cost ($) Cost ($)
Fixed,
Stainless Steel
E-101 Sheet, or 4 60 31.8 26,900 130,000
/ Carbon Steel
U-Tube
Fixed,
Stainless Steel
E-102 Sheet, or 4 60 17.7 24,700 119,000
/ Carbon Steel
U-Tube
Fixed,
Stainless Steel
E-103 Sheet, or 1 0.03 10.9 23,800 111,000
/ Carbon Steel
U-Tube
Fixed,
Stainless Steel
E-104 Sheet, or 1 0.005 14.1 24,200 112,000
/ Carbon Steel
U-Tube
Fixed,
Stainless Steel
E-105 Sheet, or 1 0.001 10.9 23,800 110,000
/ Carbon Steel
U-Tube
Fixed,
Stainless Steel
E-106 Sheet, or 1 0.001 10.9 23,800 110,000
/ Carbon Steel
U-Tube
Total Bare Module Cost ($) 692,000

8.1.2.4. Distillation Column Cost

The distillation column costs are calculated by the CAPCOST program and shown in Table
8.5.

49
 Table 8.5. Distillation Column Costs

Purchased Bare
Equipment Tower Height Diameter Pressure
MOC Equipment Module
No. Description (m) (m) (barg)
Cost ($) Cost ($)
16 Stainless
Stainless
T-101 Steel Sieve 10 3.05 0.77 197,000 881,000
Steel
Trays
11 Stainless
Stainless
T-102 Steel Sieve 6.5 0.46 0.033 18,200 77,300
Steel
Trays
12 Carbon
Carbon
T-103 Steel Sieve 7 0.46 0.006 19,600 42,300
Steel
Trays
10 Carbon
Carbon
T-104 Steel Sieve 6 0.46 0.001 16,900 39,500
Steel
Trays
Total Bare Module Cost ($) 1,040,100

8.1.2.5. Pump Cost

The pump costs are calculated by the CAPCOST program and shown in Table 8.6.

Table 8.6. Pump Costs

Discharge Purchased Bare

Equipment Pump Power #
MOC Pressure Equipment Module
No. Type (kW) Spares
(barg) Cost ($) Cost ($)
Carbon
P-101 Centrifugal 1 1 60 7,610 46,400
Steel
Carbon
P-102 Centrifugal 0.01 1 1.05 7,610 30,300
Steel
Carbon
P-103 Centrifugal 0.003 1 0.45 7,610 30,300
Steel
Carbon
P-104 Centrifugal 0.001 1 0.4 7,610 30,300
Steel
Carbon
P-105 Centrifugal 0.001 1 0.005 7,610 30,300
Steel
Total Bare Module Cost ($) 167,600

50
8.1.2.6. Mixer Cost

The mixer costs are calculated by the CAPCOST program and shown in Table 8.7.

Table 8.7. Mixer Cost

Purchased
Equipment Bare Module
Type Power (kW) # Spares Equipment
No. Cost ($)
Cost ($)
M-101 Turbine 7.5 0 10,700 14,800
Total Bare Module Cost ($) 14,800

Total Bare Module Cost ($) is assumed as $2,817,500.

8.1.3. Operating Labor Cost

According to course textbook Chapter 24 (3rd ed.), considering the vacation time and sick leave
for each operator, an operator works 49 weeks per year in 8-hour shifts.

(49 weeks/year) (5 shifts/week) = 245 shifts/year per operator

The Ethanolamines Production Plant operates 24 h/day, meaning three 8-hour shifts per day.
The time required for repairs, periodical maintenance, and raw material supply is assumed as
65 days per year. Hence, there are 300 operating days per year.

(300 days/year) (24 h/day) = 7200 h/year

(300 days/year) (3 shifts/day) = 900 shifts/year

The required number of operators is calculated as,

900 shifts/year
= 3.67 operators
245 shifts/year

The operating labor for the plant is calculated by the formula correlated by Alkhayat and
Gerrard. According to this method, the operating labor requirement for chemical processing
plants is given as

NOL = [6.29 + (31.7) P2 + (0.23) Nnp] 0.5 (1)

51
NOL is the number of operators per shift, P is the number of processing steps involving the
handling of particulate solids—for example, transportation and distribution, particulate size
control, and particulate removal. In the process there is no particulate equipment used for the
process, so P=0 is assumed. Nnp is the number of nonparticulate processing steps and includes
compression, heating and cooling, mixing, and reaction. In the process, there is one reactor, six
heat exchangers, 1 mixer, five pumps, four distillation columns. So, Nnp=19 is assumed.

NOL = [6.29 + (31.7) (02) + (0.23) (17)] 0.5 = 3.19 operating labor

Operating labor = 3.67 3.19 = 11.7 ~ 12 operators

Since there are two main processes, reaction and separation, two engineers per shift is needed.
Total number of engineers: (2 engineers/shift) (3 shift/day) = 6 engineers/day

There is also a need for a manager for administerial purposes.

Monthly wages are assumed as, $1200 for the manager; $600 for engineers; $450 for operators.

Table 8.8. Total Cost of Operating Labor

Number of Annual Wage per Total Annual Cost

Employee Title
Employees Employee ($) ($)
Manager 1 14,400 14,400

Engineer 6 7,200 43,200

Operator 12 5,400 64,800

Total Cost of Operating Labor, COL ($) 122,400

8.1.4. Utility Cost

Utilities for this process are, low pressure steam and cooling water for heat exchangers and for
the reactor; and electricity for pumps.

According to CAPCOST program and the course textbook: Low pressure steam (5 barg, 160°C)
costs 2.03 $/GJ, cooling water costs 0.378 $/GJ and electricity costs 18.72 $/GJ.

In the Table 8.9, CUT value is rounded by 2 digits.

52
 Table 8.9. Utility Costs per Equipment

Utility Equipment Usage (MJ/h) Annual Cost ($)

Low Pressure Heat Exchangers

8275.6 120,920
Steam (E-101, E-102)
Heat Exchangers
(E-103, E-104, 107.845 293
E-105, E-106)
Cooling Water
Reactor (R-101) 1470 4,000

Pumps
Electricity (P-101, P-102, P- 0.3 581
103, P-104, P-105)
Total Utility Cost, CUT ($) 125,800

8.1.5. Raw Material Cost

In the ethanolamines production process liquid ammonia, ethylene oxide and water are raw
materials. The materials and their prices are shown in Table 8.10.

Table 8.10. Raw Material Cost

Flowrate Annual Cost

Material Name Price ($/kg) Flowrate (kg/h)
(kg/yr) ($)
Liquid
0.68 190.30 1,370,160 933,901
Ammonia
Ethylene Oxide 1.21 476.85 3,433,320 4,142,304
Water 0.86 9.27 66,744 57,418
Total Raw Material Cost, CRM ($) 5,133,623

Total raw material cost (CRM) is estimated as $5,133,623.

8.1.6. Land Cost

The plant is planned to be constructed in İzmir Aliağa Industrial Zone. The Mono-,di-,tri-
Ethanolamines production plant is decided as 10,000 m2.

A sale for 10,000 m2 of land in organized industrial zone is approximately $557,738 according
to a sale found [21].

53
8.1.7. Waste Treatment Cost
In the process there is a periodical maintenance and water impured by ammonia in recycle
stream will be sent to a treatment facility three times a year to dispose. The wastewater is
23704.75 kg per maintenance. Total working hours per year is 7200 h.

Total wastewater: (23704.75 kg) (3) = 71114.25 kg

Total wastewater flow per hour: 71114.25 kg / 7200 h = 9.88 kg/h

The annual waste treatment cost (CWT) is 14,227 $/year.

8.1.8. Total Manufacturing Cost (COMd)

Cost of Manufacturing without depreciation is calculated by Equation (X).

COMd = (0.18) FCIL + (2.76) COL + (1.23) (CUT + CWT + CRM) (2)

COMd = (0.18) (3,980,000) + (2.76) (122,400) + (1.23) (126,000 + 14,227 + 4,699,308)

= $ 7,006,852.05

Total Manufacturing Cost is also found as $ 7,006,853 by CAPCOST program.

8.2. Profitability Analysis

Once the manufacturing costs are determined, the cash flow diagrams are drawn in order to
analyze the profitability of process.

8.2.1. Revenue
To find the revenue of the project, the total capacity of the plant is multiplied by the respective
selling prices. It is shown in Table 8.11.

Table 8.11. Revenue

Products Price ($/kg) Flowrate (kg/h) Annual Revenue

Monoethanolamine (MEA) 2.36 375.64 6,382,843
Diethanolamine (DEA) 1.50 179.21 1,935,446
Triethanolamine (TEA) 3.00 61.80 1,334,794
Revenue ($) 9,653,083

54
8.2.2. Working Capital
Working capital of the process is calculated as a function of CRM, COL and FCIL from Equation
(3).

WC = (0.10) CRM + (0.10) FCIL + (0.10) COL (3)

WC = (0.10) (4699308) + (0.10) (3980000) + (0.10) (122400) = $ 880,170.8

From CAPCOST program, WC is found as $ 880,000.

8.2.3. Cash Flow Diagram of the Project

Processes generally have a limited lifespan and the value of the plant decreases every year due
to the depreciation rate. After two years of construction period, the factory starts its production
stage. At this stage, pieces of equipment may cause problems in the process and this can result
in buying new equipment or using back-up equipment. Once the plant completes the project
period and closes, the equipment is sold, and the total cost is considered as salvage.

Table 8.12. Needed Information for the Cash Flow Diagram (CFD)

Taxation Rate 22%

Annual Interest Rate 19%
Cost of Land $ 557,738
Salvage Value $ 398,000
Working Capital $ 880,000
FCIL $ 3,980,000
Construction Period 2 years
Project Life 10 years

There are various techniques that can be used to calculate depreciation. Due to its accuracy and
effectiveness, MACRS has been selected. Depreciation is calculated using the MACRS
depreciation method for five years and by considering multiple investments using CAPCOST
program in this project.

55
Discounted and Non-discounted Cash Flow Diagrams are shown in Figure 8.1. and Figure 8.2.
Profitability Criteria are given in Table 8.13. and 8.14., respectively.

Figure 8.1. Cumulative Cash Flow Diagram for Discounted After–Tax Cash Flows

Table 8.13. Discounted Profitability Criterion.

Net Present Value (millions) 2.58

Discounted Cash Flow Rate of Return 31.89%

Discounted Payback Period (years) 2.7

56
 Figure 8.2. Cumulative Cash Flow Diagram for Non-discounted After–Tax Cash Flows

Table 8.14. Non-discounted Profitability Criterion

Cumulative Cash Position (millions) 17.54

Rate of Return on Investment 44.06%

Payback Period (years) 1.7

Discounted Payback Period (DPBP) is found to be 2.7 years. It means that the project is highly
profitable. Net Present Value (NPV) is found as $2.58 million. Discounted Rate of Return is
also calculated as 31.89% which also shows the profitability is high.

57
 Table 8.15. After Tax Cash Flow

Cumulative Cash Flow

Cumulative Cash Flow

(R-COMd-dk)*(1-t)+dk

(Non-discounted)

(Non-discounted)
(discounted)

(discounted)
Investment

Cash Flow

Cash Flow
FCIL-Sdk

COMd
Year

dk

R
0 0.00 3.98 0.00 0.00 0.00 0.00
0 0.56 3.98 (0.56) (0.56) (0.56) (0.56)
1 2.39 3.98 (2.39) (2.01) (2.56) (2.95)
2 1.59 3.98 (1.59) (1.12) (3.69) (4.54)
2 0.88 3.98 (0.88) (0.62) (4.31) (5.42)
3 0.80 3.18 9.65 7.01 2.24 2.24 1.33 (2.98) (3.18)
4 1.27 1.91 9.65 7.01 2.34 2.34 1.17 (1.81) (0.83)
5 0.76 1.15 9.65 7.01 2.23 2.23 0.94 (0.88) 1.40
6 0.46 0.69 9.65 7.01 2.16 2.16 0.76 (0.11) 3.56
7 0.46 0.23 9.65 7.01 2.16 2.16 0.64 0.53 5.73
8 0.23 - 9.65 7.01 2.11 2.11 0.53 1.05 7.84
9 - 9.65 7.01 2.06 2.06 0.43 1.48 9.91
10 - 9.65 7.01 2.06 2.06 0.36 1.85 11.97
11 - 9.65 7.01 2.06 2.06 0.30 2.15 14.03
12 - 9.65 7.01 2.37 2.37 0.29 2.44 16.41
12 1.44 0.18 2.62 17.85

58
9. CONCLUSION AND RECOMMENDATION

Ethanolamines are used in many areas of industry nowadays and the demand for this chemical
is increasing day by day. Turkey cannot provide this demand adequately and is almost
completely dependent on foreign sources. The aim of this project is to provide the ethanolamine
need of Turkey and the plant capacity has been determined based on the most demanded
monoethanolamine. Based on Turkey's MEA need for 2021, the capacity has been specified as
4000 tons/year. As a result of the optimizations made during the design of the facility, an annual
production of 4440 tons of ethanolamine was achieved. Thus, with the presented project, it is
foreseen that Turkey's future imports will be reduced and the export of the product will be
increased, thus contributing to the country's economy. Our plant will be located in İzmir Aliağa
Organized Industrial Zone and will provide logistics advantages in terms of both raw material
supply and customer transportation.

In this project, among the alternatives as a production method; Aqueous Ammonia Process has
been chosen, which is economical, safe, environmentally friendly and easy to operate. The plant
is designed to operate in continuous mode. The design and optimization of the equipment was
done using the simulation program and with manual calculations. The equipment has been
designed with the potential hazards of chemicals in the process in mind. These potential hazards
were determined by performing HAZOP analysis for the equipment and calculating the F&EI.
The F&EI calculated for our facility was within the severe range. Considering possible dangers,
the facility was arranged with process control systems and accident risks were reduced.

CAPCOST simulation program is used for economic analysis. The economic analysis shows
that this proposed plant design for the production of Ethanolamines has a payback period of 1.7
years. The net present value found as a result of the calculations is $ 2.58 million, and the
project life is accepted as 10 years and the construction period as 2 years in the calculations.

Although the project promises to present a stimulating industrial opportunity, it can be further
developed in the future. For example; to treat the water recycled in the process, a treatment
system can be added to the facility. Thus, the transportation cost of treatment water is reduced
and waste management can be provided within the facility. In addition, a policy of continuous
improvement can be followed at the facility by keeping up with the developing technologies
and updating and improving the existing technologies.

59
As a result, it can be concluded that this facility is suitable to be built and operated with the
proposed equipment, operating conditions and working capacity.

60
REFERENCES

[1] Cost-efficient production of Ethanolamines (2008), Sulzer Technical Review 3, Sulzer

Chemtech (Retrieved December 22, 2020, from https://www.sulzer.com/-
/media/files/products/process-techology/processes-and-
applications/2008_3_12_faessler_e.ashx?la=en )

[2] Frauenkron, M., Melder, J.‐P., Ruider, G., Rossbacher, R. and Höke, H. (2001).
Ethanolamines and Propanolamines. In Ullmann's Encyclopedia of Industrial Chemistry, (Ed.).
https://doi.org/10.1002/14356007.a10_001

[3] “Ethanolamines Market Research Report: By Type (Monoethanolamine, Diethanolamine,

Triethanolamine), Application (Herbicides, Surfactants, Chemicals, Gas Treatment, Cement) -
Global Industry Analysis and Demand Forecast to 2030” (Retrieved January 23, 2021, from
www.psmarketresearch.com )

[4] Global Ethanolamines Market, Focus on Surfactants, Volume 2017, Issue 7, 2017, Page 2,
ISSN 1351-4210, https://doi.org/10.1016/j.fos.2017.07.007.

[6] ITC. (2021). Trade Map - Trade statistics for international business development . Retrieved
from: https://www.trademap.org/Index.aspx

[6] Grice, N. J., & Knifton, J. F. (1990). U.S. Patent No. 4,939,301. Washington, DC: U.S.
Patent and Trademark Office.

[7] Fässler, P. (2010). European Patent No. 2177501 A1. Munich, Germany. European Patent
Office.

[8] Soucaille, P., & Figge, R. (2009). U.S. Patent Application No. 12/302,726. Washington,
DC: U.S. Patent and Trademark Office.

[9] On-Stream Factor. (Retrieved January 23, 2021, from

https://www.aiche.org/ccps/resources/glossary/process-safety-glossary/on-stream-factor )

[10] Safety Tips for Storage & Handling of Anhydrous Ammonia - BEPeterson. (2018,
September 11). BEPeterson Inc. https://www.bepeterson.com/blog/safety-tips-for-storage-
handling-of-anhydrous-ammonia/

[11] Hydro Instruments. (2013). Ammonia Handling Manual. USA: Hydro Instruments

61
[12] Ethylene Oxide Health And Safety Guide (1998), IPCS International Programme On
Chemical Safety, Health And Safety Guide No. 16, World Health Organization, Geneva.
(Retrieved January 23, 2021, from http://www.inchem.org/documents/hsg/hsg/hsg016.htm)

[13] Basic Physical Properties of Chemical Compounds. (Retrieved January 23, 2021, from
https://app.knovel.com/hotlink/itble/rcid:kpKCTE000X/id:kt002VLXT1/knovel-critical-
tables/basic-physical-properties)

[14] Dan Liu, Zixin Lin, Weizhong An, Ran An, Haiyan Bie, Simulation and energy
consumption evaluation of reactive distillation process for ethanolamine production, Chemical
Engineering and Processing - Process Intensification, Volume 153, 2020, 107930, ISSN 0255-
2701, https://doi.org/10.1016/j.cep.2020.107930.

[15] Zahedi, G., Amraei, S. & Biglari, M. Simulation and optimization of ethanol amine
production plant. Korean J. Chem. Eng. 26, 1504–1511 (2009).
https://doi.org/10.1007/s11814-009-0254-z

[16] University of Michigan Chemical Engineering Department. (2006). Chemical Process

Dynamics and Controls,1(1-9).

[17] MEB. (2017). Mesleki Gelişim: İş Sağlığı ve Güvenliği. Ankara. Retrived from:
http://www.megep.meb.gov.tr/mte_program_modul/moduller_pdf/%C4%B0%C5%9F%20Sa
%C4%9Fl%C4%B1%C4%9F%C4%B1%20ve%20G%C3%BCvenli%C4%9Fi.pdf

[18] Hignett, T. (1985). Transportation and Storage of Ammonia. Fertilizer Manual, 73-82. doi:
10.1007/978-94-017-1538-6_7

[19] Akman, A. (2015). Kimya Sektöründe Tehlike Ve İşletilebilirlik (HAZOP) Analizi,

Çalışma Dünyası Dergisi, 3(2), 59-74

[20] American Institute of Chemical Engineers. (1994). Dow's Fire & Explosion Index Hazard
Classification Guide, Seventh Edition.

[21] Retrived from: https://www.sahibinden.com/ilan/emlak-arsa-satilik-aliaga-organize-

sanayi-de-satilik-arsa-904151146/detay

[22] Aleksandar Milovanović, Aleksandar Sedmak, Integrity assessment of ammonia spherical

storage tank, Procedia Structural Integrity, Volume 13, 2018, Pages 994-999, ISSN 2452-3216,
https://doi.org/10.1016/j.prostr.2018.12.185.

62
[23] Retrived from:
https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.111

[24] Retrived from: https://www.engineeringtoolbox.com/ammonia-pressure-temperature-

d_361.html

[25] Retrived from: https://www.tannerind.com/sto-anh-ammonia.html

[26] Retrived from: https://www.tannerind.com/sto-anh-ammonia.html]

[27] Retrived from: https://www.ntotank.com/ammonia-storage-tanks]

[28] American Chemistry Council. (2007). Ethylene Oxide Product Stewardship Guidance
Manual. USA.

63
APPENDIX A.1
Mass & Energy Balances
Calculations

A1-1
 Figure A1.1. Overall ChemCAD Simulation

APPENDIX A1

A1.1. All Stream Report

Simulation: EA’s Production Plant Final

STREAM PROPERTIES
Stream No. 1 2 3 4
Name
- - Overall - -
Molar flow kmol/h 8.2902 1346.5476 1346.5476 10.8245
Mass flow kg/h 141.0500 23845.7910 23845.7910 476.8504
Temp C 20.0000 10.2160 85.0000 10.0000
Pres bar 18.0000 60.0000 60.0000 2.3000
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -561.02 -2.9470E+005 -2.8646E+005 -238.76
Tc C 132.5000 291.7903 291.7903 196.0000
Pc bar 112.7848 170.4082 170.4082 71.9000
Std. sp gr. wtr = 1 0.619 0.844 0.844 0.878
Std. sp gr. air = 1 0.588 0.611 0.611 1.521
Degree API 97.1314 36.1377 36.1377 29.6364
Average mol wt 17.0310 17.7088 17.7088 44.0530
Actual dens kg/m3 609.1434 846.2119 752.2058 887.2420
Actual vol m3/h 0.2318 28.1795 31.7012 0.5743
Std liq m3/h 0.2281 28.2506 28.2506 0.5430
Std vap 0 C m3/h 185.8131 30181.0430 30181.0430 242.6159
- - Liquid only - -
Molar flow kmol/h 8.2902 1346.5476 1346.5476 10.8245
Mass flow kg/h 141.0500 23845.7930 23845.7930 476.8504
Average mol wt 17.0310 17.7088 17.7088 44.0530
Actual dens kg/m3 609.1434 846.2120 752.2058 887.2420
Actual vol m3/h 0.2318 28.1795 31.7012 0.5743
Std liq m3/h 0.2281 28.2506 28.2506 0.5430
Std vap 0 C m3/h 185.8131 30181.0430 30181.0430 242.6159
Cp kJ/kg-K 5.1347 4.4046 5.0639 1.9709
Z factor 0.0262 0.0664 0.0570 0.0234
Visc N-s/m2 0.0001384 0.0006784 0.0002115 0.0002098
Th cond W/m-K 0.4911 0.5542 0.4934 0.1568
Surf. tens. N/m 0.0222 0.0491 0.0281 0.0260

A1-2
Flow rates in kg/h
Ammonia 141.0500 7153.3003 7153.3003 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 476.8504
Monoethanolamine 0.0000 1.4630 1.4630 0.0000
Diethanolamine 0.0000 0.0000 0.0000 0.0000
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 0.0000 16691.0273 16691.0273 0.0000

Stream No. 5 6 7 8
Name
- - Overall - -
Molar flow kmol/h 10.8245 10.8245 1346.5476 1338.2662
Mass flow kg/h 476.8504 476.8504 24322.6426 23704.7500
Temp C 52.0657 85.0000 85.0000 11.3327
Pres bar 60.0000 60.0000 60.0000 0.7000
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -816.34 -780.79 -2.8871E+005 -2.9414E+005
Tc C 196.0000 196.0000 296.1451 292.8685
Pc bar 71.9000 71.9000 176.3615 170.9727
Std. sp gr. wtr = 1 0.878 0.878 0.850 0.846
Std. sp gr. air = 1 1.521 1.521 0.624 0.612
Degree API 29.6364 29.6364 34.9343 35.7747
Average mol wt 44.0530 44.0530 18.0630 17.7130
Actual dens kg/m3 827.2099 774.2017 759.2856 847.0817
Actual vol m3/h 0.5765 0.6159 32.0336 27.9840
Std liq m3/h 0.5430 0.5430 28.6087 28.0227
Std vap 0 C m3/h 242.6159 242.6159 30181.0430 29995.4277
- - Liquid only - -
Molar flow kmol/h 10.8245 10.8245 1346.5476 1338.2662
Mass flow kg/h 476.8504 476.8504 24322.6426 23704.7520
Average mol wt 44.0530 44.0530 18.0630 17.7130
Actual dens kg/m3 827.2099 774.2017 759.2857 847.0817
Actual vol m3/h 0.5765 0.6159 32.0336 27.9840
Std liq m3/h 0.5430 0.5430 28.6087 28.0227
Std vap 0 C m3/h 242.6159 242.6159 30181.0430 29995.4277
Cp kJ/kg-K 2.1578 2.3763 4.8552 4.4474
Z factor 0.1385 0.1349 0.0578 0.0008
Visc N-s/m2 0.0002136 0.0001737 0.0002170 0.0006605
Th cond W/m-K 0.1400 0.1269 0.4880 0.5544
Surf. tens. N/m 0.0194 0.0144 0.0286 0.0490

Flow rates in kg/h

Ammonia 0.0000 0.0000 7012.2568 7012.2568
Ethylene Oxide 476.8504 476.8504 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 377.4481 1.4630
Diethanolamine 0.0000 0.0000 179.7460 0.0000
Triethanolamine 0.0000 0.0000 62.1619 0.0001
Water 0.0000 0.0000 16691.0273 16691.0273

A1-3
Stream No. 9 10 11 12
Name
- - Overall - -
Molar flow kmol/h 8.2815 8.2815 6.1546 6.1546
Mass flow kg/h 617.8892 617.8892 376.1720 376.1720
Temp C 167.2018 167.1669 85.3627 35.0000
Pres bar 0.7000 1.0500 0.0300 0.0300
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -2528.6 -2528.6 -1559.2 -1607.5
Tc C 429.5247 429.5247 405.1247 405.1247
Pc bar 69.2491 69.2491 71.2388 71.2388
Std. sp gr. wtr = 1 1.054 1.054 1.022 1.022
Std. sp gr. air = 1 2.576 2.576 2.110 2.110
Degree API 2.6930 2.6930 6.9382 6.9382
Average mol wt 74.6112 74.6112 61.1203 61.1203
Actual dens kg/m3 931.6409 931.6726 964.9079 1004.8220
Actual vol m3/h 0.6632 0.6632 0.3899 0.3744
Std liq m3/h 0.5860 0.5860 0.3680 0.3680
Std vap 0 C m3/h 185.6175 185.6175 137.9473 137.9473
- - Liquid only - -
Molar flow kmol/h 8.2815 8.2815 6.1546 6.1546
Mass flow kg/h 617.8892 617.8892 376.1720 376.1720
Average mol wt 74.6112 74.6112 61.1203 61.1203
Actual dens kg/m3 931.6409 931.6726 964.9079 1004.8220
Actual vol m3/h 0.6632 0.6632 0.3899 0.3744
Std liq m3/h 0.5860 0.5860 0.3680 0.3680
Std vap 0 C m3/h 185.6175 185.6175 137.9473 137.9473
Cp kJ/kg-K 2.9137 2.9135 2.6228 2.4797
Z factor 0.0020 0.0030 0.0001 0.0001
Visc N-s/m2 0.0007630 0.0007634 0.002891 0.01367
Th cond W/m-K 0.2179 0.2179 0.2412 0.2384
Surf. tens. N/m 0.0332 0.0332 0.0416 0.0472

Flow rates in kg/h

Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 375.9814 375.9814 375.6380 375.6380
Diethanolamine 179.7460 179.7460 0.5340 0.5340
Triethanolamine 62.1618 62.1618 0.0000 0.0000
Water 0.0000 0.0000 0.0000 0.0000

Stream No. 13 14 15 16
Name
- - Overall - -
Molar flow kmol/h 2.1268 2.1268 1.6785 1.6785
Mass flow kg/h 241.7172 241.7172 176.3320 176.3320
Temp C 171.3292 171.2988 130.2835 50.0000
Pres bar 0.0300 0.4500 0.0050 0.0050
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -1052.5 -1052.5 -796.71 -834.93
Tc C 472.1628 472.1628 463.3930 463.3930
Pc bar 40.8913 40.8913 42.8270 42.8270
Std. sp gr. wtr = 1 1.109 1.109 1.103 1.103
Std. sp gr. air = 1 3.924 3.924 3.627 3.627
Degree API -3.9135 -3.9135 -3.2535 -3.2535
Average mol wt 113.6508 113.6508 105.0529 105.0529
Actual dens kg/m3 996.8162 996.8406 1019.2471 1077.4202
Actual vol m3/h 0.2425 0.2425 0.1730 0.1637
Std liq m3/h 0.2179 0.2179 0.1598 0.1598
Std vap 0 C m3/h 47.6702 47.6702 37.6215 37.6215
- - Liquid only - -

A1-4
Molar flow kmol/h 2.1268 2.1268 1.6785 1.6785
Mass flow kg/h 241.7172 241.7172 176.3320 176.3320
Average mol wt 113.6508 113.6508 105.0529 105.0529
Actual dens kg/m3 996.8162 996.8405 1019.2471 1077.4202
Actual vol m3/h 0.2425 0.2425 0.1730 0.1637
Std liq m3/h 0.2179 0.2179 0.1598 0.1598
Std vap 0 C m3/h 47.6702 47.6702 37.6215 37.6215
Cp kJ/kg-K 2.9121 2.9093 2.8041 2.6062
Z factor 0.0001 0.0019 0.0000 0.0000
Visc N-s/m2 0.001262 0.001263 0.003243 0.1043
Th cond W/m-K 0.2094 0.2094 0.2174 0.2137
Surf. tens. N/m 0.0333 0.0333 0.0378 0.0468

Flow rates in kg/h

Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.3434 0.3434 0.3434 0.3434
Diethanolamine 179.2121 179.2121 175.6280 175.6280
Triethanolamine 62.1618 62.1618 0.3607 0.3607
Water 0.0000 0.0000 0.0000 0.0000

Stream No. 17 18 19 20
Name
- - Overall - -
Molar flow kmol/h 0.4483 0.4483 0.0341 0.0341
Mass flow kg/h 65.3852 65.3852 3.5852 3.5852
Temp C 176.3141 176.2587 106.9349 50.0000
Pres bar 0.0050 0.4000 0.0010 0.0010
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -276.01 -276.00 -16.434 -16.980
Tc C 496.9138 496.9138 463.4984 463.4984
Pc bar 28.8871 28.8871 42.6923 42.6923
Std. sp gr. wtr = 1 1.125 1.125 1.104 1.104
Std. sp gr. air = 1 5.035 5.035 3.632 3.632
Degree API -5.6933 -5.6933 -3.2718 -3.2718
Average mol wt 145.8404 145.8404 105.1814 105.1814
Actual dens kg/m3 1022.0003 1022.0406 1037.0490 1077.5808
Actual vol m3/h 0.0640 0.0640 0.0035 0.0033
Std liq m3/h 0.0581 0.0581 0.0032 0.0032
Std vap 0 C m3/h 10.0488 10.0488 0.7640 0.7640
- - Liquid only - -
Molar flow kmol/h 0.4483 0.4483 0.0341 0.0341
Mass flow kg/h 65.3852 65.3852 3.5852 3.5852
Average mol wt 145.8404 145.8404 105.1814 105.1814
Actual dens kg/m3 1022.0004 1022.0407 1037.0490 1077.5808
Actual vol m3/h 0.0640 0.0640 0.0035 0.0033
Std liq m3/h 0.0581 0.0581 0.0032 0.0032
Std vap 0 C m3/h 10.0488 10.0488 0.7640 0.7640
Cp kJ/kg-K 2.8898 2.8872 2.7396 2.6065
Z factor 0.0000 0.0024 0.0000 0.0000
Visc N-s/m2 0.001904 0.001906 0.007154 0.1052
Th cond W/m-K 0.2002 0.2002 0.2181 0.2136
Surf. tens. N/m 0.0331 0.0332 0.0404 0.0468

Flow rates in kg/h

Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 0.0000
Diethanolamine 3.5841 3.5841 3.5800 3.5800
Triethanolamine 61.8011 61.8011 0.0051 0.0051
Water 0.0000 0.0000 0.0000 0.0000

A1-5
Stream No. 21 23 24 25
Name Recycle
- - Overall - -
Molar flow kmol/h 0.0341 0.4142 0.4142 1338.2576
Mass flow kg/h 3.5852 61.8000 61.8000 23704.7500
Temp C 50.0000 165.4624 40.0000 11.3317
Pres bar 0.0050 0.0010 0.0010 0.7000
Vapor mole fraction 0.0000 0.0000 0.0000 0.0000
Enth MJ/h -16.980 -262.24 -283.08 -2.9414E+005
Tc C 463.4984 498.9476 498.9476 292.8696
Pc bar 42.6923 27.4318 27.4318 170.9730
Std. sp gr. wtr = 1 1.104 1.126 1.126 0.846
Std. sp gr. air = 1 3.632 5.151 5.151 0.612
Degree API -3.2718 -5.8338 -5.8338 35.7744
Average mol wt 105.1814 149.1859 149.1859 17.7130
Actual dens kg/m3 1077.5808 1032.1481 1113.0146 847.0845
Actual vol m3/h 0.0033 0.0599 0.0555 27.9837
Std liq m3/h 0.0032 0.0549 0.0549 28.0225
Std vap 0 C m3/h 0.7640 9.2848 9.2848 29995.2324
- - Liquid only - -
Molar flow kmol/h 0.0341 0.4142 0.4142 1338.2576
Mass flow kg/h 3.5852 61.8000 61.8000 23704.7520
Average mol wt 105.1814 149.1859 149.1859 17.7130
Actual dens kg/m3 1077.5808 1032.1481 1113.0146 847.0845
Actual vol m3/h 0.0033 0.0599 0.0555 27.9837
Std liq m3/h 0.0032 0.0549 0.0549 28.0225
Std vap 0 C m3/h 0.7640 9.2848 9.2848 29995.2324
Cp kJ/kg-K 2.6066 2.8567 2.5311 4.4474
Z factor 0.0000 0.0000 0.0000 0.0008
Visc N-s/m2 0.1052 0.002363 0.2116 0.0006605
Th cond W/m-K 0.2136 0.2006 0.1986 0.5544
Surf. tens. N/m 0.0468 0.0342 0.0458 0.0490

Flow rates in kg/h

Ammonia 0.0000 0.0000 0.0000 7012.2568
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 1.4630
Diethanolamine 3.5800 0.0040 0.0040 0.0000
Triethanolamine 0.0051 61.7960 61.7960 0.0000
Water 0.0000 0.0000 0.0000 16691.0273

A1-6
A1.2. Overall Mass and Energy Balance Report

Simulation: EA’s Production Plant Final

Calculation mode : Sequential

Flash algorithm : Normal

Equipment Calculation Sequence

3 5 1 2 4 6 7 8 9 10 11 12 13 14 15 16 17

No recycle loops in the flowsheet.

Flash Damping factor 0.50

Overall Mass Balance kmol/h kg/h

Input Output Input Output
Ammonia 420.016 411.735 7153.300 7012.257
Ethylene Oxide 10.824 0.000 476.850 0.000
Monoethanolamine 0.024 6.179 1.463 377.448
Diethanolamine 0.000 1.710 0.000 179.746
Triethanolamine 0.000 0.417 0.000 62.162
Water 926.507 926.507 16691.029 16691.029

Total 1357.372 1346.548 24322.643 24322.643

Overall Energy Balance MJ/h

Input Output
Feed Streams -295519
Product Streams -296882
Total Heating 59922.8
Total Cooling -61288.5
Power Added 3.42288
Power Generated 0

Total -296881 -296882

A1-7
APPENDİX A.2
Equipment Design
Calculations

A2-1
APPENDIX A2

A2.1. Manual Calculations

A2.1.1. Calculations of Storage Tanks (TK-101 & TK-102)
For TK-101: (Anhydrous Liquid Ammonia)

For this tank, instead of a new design and manual calculations, the storage tank was chosen in
the conditions and sizes specified in the article [22]

The minimum design pressure for containers shall be 250 psig = 17.24 bar [23].

It is accepted that 7156.5 kg/h of Ammonia will be fed to the reactor in the beginning and
sequentially 141.2 kg/h will be added. So,

The weekly consumption = Consumption in the 1st day + Consumption in remaining 6 days

7156.5 kg/h + [(23h/day) (141.2 kg/h)] + [(24h/day) (141.2 kg/h) (6 days)] = 30736.9 kg/week

 Weight of liquid ammonia is 2.34 kg/gal [24]

 Anhydrous Ammonia liquid weighs approximately 5 pounds per gallon, at 60°F
(15.6 °C) [25]

VNH3 = 30736.9 kg / (2.34 kg/gal) = 13135.4 gal

It is assumed that in the plant there are 3 storage tanks for Ammonia. In every tank there is
4378.5 gal of Ammonia.

A storage tank is usually considered to have an 85% usable capacity. (A 15% vapor space must
always be maintained when filling, to allow for expansion) [26].

VTank = 4378.5 gal * (100/85) = 5151.2 gal

So to compensate the weekly consumption of 13135.4 gal of Anhydrous Ammonia plus the
needed empty space, three 5200 gal storage tanks will be used.

It is given in Table A2.1 that,

Table A2.1. Ammonia Storage Tank [27]

Tank/Capacity Length Width Height Material

5200 Gallon Ammonia Stainless
2.54 m 2.54 m 4.17 m
Storage Tank Steel

A2-2
TK-101 is considered as a vessel operating under internal pressure.
P=18 bar
Pdesign = (18 bar)(1.1) = 19.8 bar = 20.19 kg/cm2
Since Pdesign > 15 kg/cm2; an elipsoidal top/bottom is needed.
VTank is proposed as 19.68 m3 and H = 4.17 m

In elipsoidal top & bottom if b:major axis, a:minor axis, we assume b/a=2. When b/a=2;

𝜋
𝑉𝑒𝑙𝑖𝑝𝑠 =
24
𝐷𝑖 3 (4)

can be used to calculate the volume of the elipsoidal part.

For the cylindirical part of the tank;

𝜋
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝐷𝑖 2 ℎ (5)
4

can be used.

𝑉𝑡𝑎𝑛𝑘 = (2)(𝑉𝑒𝑙𝑖𝑝𝑠 ) + 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (6)

Vtank is proposed as 19.68 m3

𝜋 3 𝜋 2
𝑉𝑡𝑎𝑛𝑘 = 2 𝐷𝑖 + 𝐷𝑖 ℎ = 19.68 𝑚3
24 4

Di = 2.256 m

𝑃 𝐷𝑖
𝑠0 = (7)
2𝜗 𝜎𝑒𝑚 −𝑃

For Stainless Steel 316: Considering Tmax=35 °C

σem=175 N/mm2 =1784.5 kg/cm2
υ=1 (Radiographic examination)

A2-3
Diameter Calculations:
 Cylindirical Part:
𝑃 𝐷𝑖 (20.19)(2.256)(1000)
𝑠0 = = = 12.83 𝑚𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(1)(1784.5) − 20.19

𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 12.8 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 15.7 𝑚𝑚

Since the liquid Ammonia is under high pressure, we choose 20 mm as the wall thickness.

𝐷𝑜 = 𝐷𝑖 + 2𝑠 = 2256 𝑚𝑚 + (2)20 𝑚𝑚 = 2296 𝑚𝑚 ≅ 2.3 𝑚

For TK-102: (Ethylene oxide)

Ethylene oxide is a colorless liquid. It is toxic, flammable, explosive, and corrosive. As the
material, Stainless Steel 316 must be used.

It is important to note that one popular stainless steel, SS304, is made cheaply by substituting
nickel and chromium for carbon. Nickel catalyzes a side reaction with ethylene oxide and MEA
to form acid aldehyde, an impurity which also causes discoloration in the ethylene oxides and
is a big problem if you sell TEA to cosmetics companies.

Table A2.2. Ethylene Oxide Storage Tank

Storage
Chemical Storage Pressure
Component Temperature Phase
Formula (bar)
(°C)

Ethylene Oxide C2H4O 10 2.3 Liquid

Between these parameters, at least 30 psia pressure is needed to keep the vapor-liquid
equilibrium and prevent decomposition in presence of diluent nitrogen blanket [28].

Using Pabs-Patm=Pgage and Patm=14.7 psia

30 psia-14.7 psia = 15.3 psig = 2.07 bar

Pdesign = (2.07 bar) (1.1) = 2.3 bar

A2-4
Ethylene oxide liquid density between 10-15 °C is obtained as 55 lbs/ft3 [28]. When converted,
the liquid density is 881.02 kg/m3.

Ethylene oxide will be stored weekly. Daily Ethylene oxide consumption is 476.85 kg/h. The
plant operates 24 h/day.

The weekly EO consumption: (476.85 kg/h) (24 h/day) (7 day/week) = 80110.8 kg/week

Using V=m/ρ VEO = 80111 kg / 881.02 kg/m3 = 91.1 m3

It is assumed that there are 6 storage tanks. So, every tank is 15.2 m3 of EO. No extra space will
be left empty since the pressure chosen maintains the VLE.

T-102 is considered as a vessel operating under internal pressure.

Pdesign = 2.3 bar = 2.35 kg/cm2
Since Pdesign < 15 kg/cm2; a klöpper (torispheric) top/bottom is needed.
VTank is proposed as 15.2 m3.
H= 4 m is assumed.
Vklöpper= (0.1) Di3
VTank=(2) (VKlöpper+Vcylindirical)= (2) [(0.1) (Di)3]+ (π/4)(Di)2 (h) = 15.2 m3

Di = 2.068 m

For Stainless Steel 316: Considering Tmax= 35 °C and using Table 4.5 [1st semester course book]
σem= 175 N/mm2 = 1784.5 kg/cm2
υ= 1 (Radiographic examination)

Diameter Calculations:
 Klöpper Part:
R= Di → R= 2.068 m and r = Di/10 → r = 0.2068 m

Cs: Stress Concentration Factor

1
Cs = (3 + √R + r) (8)
4
1
Cs = (3 + √2.068 + 0.2068) = 1.127
4

A2-5
 PRCS
s0 = (9)
2υσem

PRCS (2.35)(2.068)(1.127)
s0 = = = 1.5 mm
2υσem (2)(1)(1784.5)

s = s0 + c1 + c2 = 1.5 + 2 + 1 = 5.5 mm

According to the calculations, the wall thickness is less than 1 cm. Since Ethylene Oxide is very
corrosive and dangerous, we assume the wall thickness is 4 cm.

s = 4 cm = 40 mm

 Cylindirical Part:

(𝑃)(𝐷𝑖) (2.35)(2.068)(1000)
𝑠0 = = = 1.4 𝑚𝑚
(2𝜗)(𝜎𝑒𝑚 − 𝑃) (2)(0.95)(1784.5 − 2.35)

𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 1.4 𝑚𝑚 + 2 𝑚𝑚 + 1 𝑚𝑚 = 4.4 𝑚𝑚

According to the calculations, the wall thickness is less than 5 mm. According to the 1sk
semester design book, this is unacceptable. The storage tank is horizontal and the cylindirical
part needs to be thicker. So, we assume the wall thickness is 5 cm.

s = 5 cm = 50 mm

𝐷𝑜 = 𝐷𝑖 + 2𝑠 = 2068 𝑚𝑚 + 2 ∗ 50 𝑚𝑚 = 2168 𝑚𝑚 ≅ 2.17 𝑚

A1.2. Calculations of Reactor (R-101)

The reactor is considered as a vessel operating under internal pressure.

P= 60 bar = 61.2 kg/cm2

Pdesign=(61.2) (1.1)= 67.3 kg/cm2
Since Pdesign>15 kg/cm2 ; an elipsoidal top/bottom is needed.

A2-6
In elipsoidal top & bottom if b:major axis, a:minor axis, we assume b/a=2. When b/a=2 ;

𝜋 3
𝑉𝑒𝑙𝑖𝑝𝑠 = 𝐷𝑖
24

can be used to calculate the volume of the elipsoidal part.

For the cylindirical part of the reactor;

𝜋 2
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝐷𝑖 ℎ
4

can be used.
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 2𝑉𝑒𝑙𝑖𝑝𝑠 + 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟

Vreactor is proposed as 7 m3

𝜋 3 𝜋 2
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 2 𝐷𝑖 + 𝐷𝑖 ℎ = 7 𝑚3
24 4

Di=1.493 m

𝑃 𝐷𝑖
𝑠0 =
2𝜗 𝜎𝑒𝑚 − 𝑃

For Stainless Steel 316: Considering Tmax= 150 and using Table 4.5 [DK]

σem= 135 N/mm2 = 1376.662 kg/cm2

υ= 0.95 (Radiographic examination)

Diameter Calculations:
 Cylindirical Part:
𝑃 𝐷𝑖 (67.3)(1.493)(1000)
𝑠0 = = = 39.4 𝑚𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(0.95)(1376.662) − 67.3

A2-7
 𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 39.4 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 42.3 𝑚𝑚

𝐷𝑜 = 𝐷𝑖 + 2𝑠 = 1493 𝑚𝑚 + 242.3 𝑚𝑚 = 1577.6 ≅ 1.6 𝑚

 Elipsoidal Top:
𝑃 𝐷𝑖 (67.3)(1.493)(100)
𝑠0 = = = 3.94 𝑐𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(0.95)(1376.662) − 67.3

𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 39.4 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 42.3 𝑚𝑚

 Elipsoidal Bottom:
𝑃 𝐷𝑖 (67.3)(1.493)(100)
𝑠0 = = = 3.94 𝑐𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(0.95)(1376.662) − 67.3
𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 39.4 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 42.3 𝑚𝑚

A1.3. Calculations of Mixer (M-101)

Using Chemcad, we obtain that 7153.3 kg/h NH3 and 16691.03 kg/h water passes through the
mixer. For calculations, we will use the volume passing through per 2 seconds.

2 mins: 238 kg NH3 + 556 kg water

Using densities, we get 0.56 m3 water + 615.8 m3 NH3 = 616.36 m3

Converting the units, we get 5.14 m3/sec → 10.3 m3 per 2 seconds.

Tank is under 60 bar pressure. It is considered as a vessel operating under internal pressure.

P=60 bar
Pdesign = (60 bar) (1.1) = 66 bar = 67.3 kg/cm2
Since Pdesign > 15 kg/cm2; an elipsoidal top/bottom is needed.

In elipsoidal top & bottom if b:major axis, a:minor axis, we assume b/a=2. When b/a=2;

𝜋 3
𝑉𝑒𝑙𝑖𝑝𝑠 = 𝐷𝑖
24

A2-8
can be used to calculate the volume of the elipsoidal part.

For the cylindirical part of the mixer;

𝜋 2
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝐷𝑖 ℎ
4

can be used.
𝑉𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 2𝑉𝑒𝑙𝑖𝑝𝑠 + 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟

Vmixer is proposed as 10.3 m3 and h = 2.5 m.

𝜋 3 𝜋 2
𝑉𝑚𝑖𝑥𝑒𝑟 = 2 𝐷𝑖 + 𝐷𝑖 ℎ = 10.3 𝑚3
24 4

Di=2.032 m

For Stainless Steel 316: Considering Tmax=150

σem=175 N/mm2 =1784.5 kg/cm2

υ=0.95 (Radiographic examination)

Diameter Calculations:

 Cylindirical Part:
𝑃 𝐷𝑖 (67.3)(2.032)(1000)
𝑠0 = = = 41.2 𝑚𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(0.95)(1784.5) − 67.3

𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 41.2 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 44.1 𝑚𝑚

𝐷𝑜 = 𝐷𝑖 + 2𝑠 = 2032 𝑚𝑚 + (2)(44.1 𝑚𝑚) = 2120.2 𝑚𝑚 ≅ 2.1 𝑚

 Elipsoidal Top & Bottom:

A2-9
 𝑃 𝐷𝑖 (67.3)(2.032)(1000)
𝑠0 = = = 41.2 𝑐𝑚
2𝜗 𝜎𝑒𝑚 − 𝑃 (2)(0.95)(1784.5) − 67.3

𝑠 = 𝑠0 + 𝑐1 + 𝑐2 = 41.2 𝑚𝑚 + 2 𝑚𝑚 + 0.9 𝑚𝑚 = 44.1 𝑚𝑚

Turbine Calculations

Dt= 2.1 m and dk is the turbine diameter

𝑑𝑘 1
=
𝐷𝑡 3

dk = 2.1 m / 3 = 0.7 m

u= 0.15 m/s is assumed.

A=π (Dt)2/4 = π (2.1)2/4 = 3.464 m2/s

Q=u A = (0.15 m/s) (3.464 m2/s) = 0.52 m3/s

For dk/Dt=1/3 → NQ = 0.75

𝑄
𝑁𝑄 =
𝑛 𝑑3

3
0.52 𝑚 ⁄𝑠 𝑑 𝑑
0.75 = → 𝑛 = 2.02 = 121.2
𝑛 (0.73 ) 𝑠 𝑑

(2.02 )0.72 (0.85)

𝑅𝑒 = = 1237.25
6.8 × 10−4

From Re number → c=2 x 10-2 = 0.02 (for II/10)

w= 2πn= 2π (2.02) =12.7 d/s

𝑃 = 𝑐𝜌𝑤 3 𝑑5 = 0.02 × 846 × 12.73 × 0.75 = 5825.1

(5825.1) (1.15) = 6699 = 6700 watt

We choose the power as 7.5 kW.

A2-10
A2.2. ChemCAD Simulation Calculations

A2.2.1. R-101 Equipment Reports

Figure A2.1. R-101 ChemCAD Simulation

Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Kinetic Reactor Summary

Equip. No. 4

Name
Reactor type 2
Thermal mode 1
Pressure In bar 60.0000
Tout C 85.0000
Q MJ/h -1474.0143
Reactor volume m3 7.0000
No. of Reactions 3
Molar Flow Unit 1
Activ. E/H of Rxn Unit 4
Overall IG Ht of Rxn -1254.4943
(MJ/h)
Mass unit 1
Overall Liq H of Rxn -1399.2317
(MJ/h)
Partial P unit 5

Reaction Stoichiometrics and Parameters for unit no. 4

Reaction 1
RateConst: 1.5810e+007 Act.E: 1.9660e+004 Hrxn: 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.
1 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
3 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000

Reaction 2
RateConst: 4.9200e+008 Act.E: 1.9660e+004 Hrxn: 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.

A2-11
 3 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
4 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000

Reaction 3
RateConst: 5.2000e+008 Act.E: 1.9660e+004 Hrxn: 0.0000e+000
Comp Stoich. Exp.factor AdsorbFac. AdsorbE AdsorbExp.
4 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
2 -1.00e+000 1.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000
5 1.00e+000 0.0000e+000 0.0000e+000 0.0000e+000 0.0000e+000

A2.2.2. Distillation Columns Equipment Reports

Figure A2.2. T-101 ChemCAD Simulation

T-101
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

SCDS Rigorous Distillation Summary

Equip. No. 6

A2-12
Name
No. of stages 18
1st feed stage 9
Condenser mode 11
Condenser spec 1.0000e-004
Cond comp i pos. 5
Reboiler mode 11
Reboiler spec. 376.0000
Reboiler comp i 3
Est. dist. rate 1333.0822
(kmol/h)
Est. reflux rate 26.4790
(kmol/h)
Est. T top C 11.3313
Est. T bottom C 167.1991
Est. T 2 C 81.2069
Top pressure bar 0.7000
Calc cond duty kW -16450.9805
Calc rebr duty kW 14241.1143
Initial flag 6
Calc Reflux mole 143.9638
(kmol/h)
Calc Reflux ratio 0.1076
Calc Reflux mass kg/h 2550.0352
Tray type 3
Column diameter m 3.0480
Tray space m 0.6096
No of sections 1
No of passes (S1) 1
Weir side width m 0.5588
Weir height m 0.0508
System factor 1.0000
Optimization flag 1
Calc. tolerance 0.0106

Simulation: EA’s Production Plant Final

DISTILLATION PROFILE

Unit type : SCDS Unit name: Eqp # 6

* Net Flows *
Temp Pres Liquid Vapor Feeds Product Duties
Stg C bar kmol/h kmol/h kmol/h kmol/h kW
1 11.3 0.70 143.96 1338.27 -1.645E+004
2 81.2 0.70 139.52 1482.23
3 82.1 0.70 139.33 1477.79
4 82.2 0.70 138.89 1477.60
5 82.4 0.70 137.87 1477.16
6 83.0 0.70 135.62 1476.14
7 84.3 0.70 131.43 1473.89
8 86.6 0.70 125.49 1469.69
9 89.7 0.70 1140.56 1463.76 1346.55
10 127.9 0.70 1043.08 1132.28
11 152.8 0.70 1080.42 1034.80
12 157.8 0.70 1093.65 1072.14
13 158.4 0.70 1095.46 1085.37
14 158.5 0.70 1095.68 1087.18
15 158.5 0.70 1095.68 1087.40

A2-13
 16 158.5 0.70 1094.95 1087.40
17 158.8 0.70 1068.56 1086.67
18 167.2 0.70 1060.28 8.28 1.424E+004

Mole Reflux ratio 0.108

Total liquid entering stage 9 at 44.851 C, 1246.740 kmol/h.

T-102

Figure A2. 3. T-102, T-103 & T- 104 ChemCAD Simulation

Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

SCDS Rigorous Distillation Summary

Equip. No. 8

Name
No. of stages 13
1st feed stage 6
Condenser mode 11
Condenser spec 375.6380
Cond comp i pos. 3
Reboiler mode 11
Reboiler spec. 179.2120
Reboiler comp i 4
Est. dist. rate 6.1586
(kmol/h)

A2-14
Est. reflux rate 6.2122
(kmol/h)
Est. T top C 85.3566
Est. T bottom C 173.4548
Est. T 2 C 86.6565
Top pressure bar 0.0300
Calc cond duty kW -91.3195
Calc rebr duty kW 68.2301
Initial flag 1
Calc Reflux mole 0.1479
(kmol/h)
Calc Reflux ratio 0.0240
Calc Reflux mass kg/h 9.0370
Tray type 3
Column diameter m 0.4572
Tray space m 0.6096
No of sections 1
No of passes (S1) 1
Weir side width m 0.0825
Weir height m 0.0508
System factor 1.0000
Optimization flag 1
Calc. tolerance 1.5010e-007

Simulation: EA’s Production Plant Final

DISTILLATION PROFILE

Unit type : SCDS Unit name: Eqp # 8

* Net Flows *
Temp Pres Liquid Vapor Feeds Product Duties
Stg C bar kmol/h kmol/h kmol/h kmol/h kW
1 85.4 0.03 0.15 6.15 -91.32
2 87.3 0.03 0.11 6.30
3 90.3 0.03 0.08 6.26
4 92.3 0.03 0.07 6.23
5 92.9 0.03 0.06 6.22
6 93.8 0.03 5.88 6.21 8.28
7 93.8 0.03 5.88 3.76
8 93.8 0.03 5.88 3.76
9 93.8 0.03 5.88 3.76
10 94.1 0.03 5.82 3.76
11 101.1 0.03 5.16 3.69
12 144.0 0.03 4.84 3.04
13 171.3 0.03 2.71 2.13 68.23

Mole Reflux ratio 0.024

Total liquid entering stage 6 at 93.836 C, 5.884 kmol/h.

T-103

Simulation: EA’s Production Plant Final

Equip. No. 11

Name
No. of stages 14
1st feed stage 7

A2-15
Condenser mode 11
Condenser spec 175.6280
Cond comp i pos. 4
Reboiler mode 11
Reboiler spec. 61.8011
Reboiler comp i 5
Est. dist. rate 6.1586
(kmol/h)
Est. reflux rate 6.2122
(kmol/h)
Est. T top C 85.3566
Est. T bottom C 173.4548
Est. T 2 C 86.6565
Top pressure bar 0.0050
Calc cond duty kW -40.5182
Calc rebr duty kW 34.8921
Initial flag 1
Calc Reflux mole 0.0575
(kmol/h)
Calc Reflux ratio 0.0342
Calc Reflux mass kg/h 6.0393
Tray type 3
Column diameter m 0.4572
Tray space m 0.6096
No of sections 1
No of passes (S1) 1
Weir side width m 0.0825
Weir height m 0.0508
System factor 1.0000
Optimization flag 1
Calc. tolerance 1.1931e-008

Simulation: EA’s Production Plant Final

DISTILLATION PROFILE

Unit type : SCDS Unit name: Eqp # 11

* Net Flows *
Temp Pres Liquid Vapor Feeds Product Duties
Stg C bar kmol/h kmol/h kmol/h kmol/h kW
1 130.3 0.00 0.06 1.68 -40.52
2 134.4 0.00 0.05 1.74
3 135.5 0.00 0.05 1.73
4 136.6 0.00 0.05 1.73
5 137.2 0.00 0.04 1.72
6 137.6 0.00 0.04 1.72
7 137.8 0.00 1.89 1.72 2.13
8 137.9 0.00 1.89 1.44
9 137.9 0.00 1.89 1.44
10 137.9 0.00 1.89 1.44
11 137.9 0.00 1.89 1.44
12 138.3 0.00 1.86 1.44
13 146.3 0.00 1.69 1.41
14 176.3 0.00 1.24 0.45 34.89

Mole Reflux ratio 0.034

A2-16
Total liquid entering stage 7 at 137.554 C, 1.885 kmol/h.

T-104

Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

SCDS Rigorous Distillation Summary

Equip. No. 14

Name
No. of stages 12
1st feed stage 6
Condenser mode 11
Condenser spec 3.5800
Cond comp i pos. 4
Reboiler mode 10
Reboiler spec. 61.8000
Est. dist. rate 6.1586
(kmol/h)
Est. reflux rate 6.2122
(kmol/h)
Est. T top C 85.3566
Est. T bottom C 173.4548
Est. T 2 C 86.6565
Top pressure bar 0.0010
Calc cond duty kW -2.2871
Calc rebr duty kW 1.5462
Initial flag 1
Calc Reflux mole 0.0612
(kmol/h)
Calc Reflux ratio 1.7956
Calc Reflux mass kg/h 6.4376
Tray type 3
Column diameter m 0.5000
Tray space m 0.6096
No of sections 1
No of passes (S1) 1
Weir side width m 0.1040
Weir height m 0.0508
System factor 1.0000
Optimization flag 1
Calc. tolerance 1.0918e-010

Simulation: EA’s Production Plant Final

DISTILLATION PROFILE

Unit type : SCDS Unit name: Eqp # 14

* Net Flows *
Temp Pres Liquid Vapor Feeds Product Duties
Stg C bar kmol/h kmol/h kmol/h kmol/h kW
1 106.9 0.00 0.06 0.03 -2.287
2 108.1 0.00 0.06 0.10
3 128.1 0.00 0.05 0.09

A2-17
 4 153.6 0.00 0.05 0.08
5 157.1 0.00 0.05 0.08
6 157.4 0.00 0.46 0.08 0.45
7 160.6 0.00 0.46 0.04
8 163.1 0.00 0.46 0.05
9 164.5 0.00 0.47 0.05
10 165.1 0.00 0.47 0.05
11 165.4 0.00 0.47 0.05
12 165.5 0.00 0.05 0.41 1.546

Mole Reflux ratio 1.796

Total liquid entering stage 6 at 155.886 C, 0.454 kmol/h.

A2.2.3. Heat Exchangers Equipment Reports

E-101
Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 31.81
Shell I.D. 0.30 Area Required 25.01
Shell in Series/Parallel 1/1 COR LMTD 72.96
Number of Tubes 111 U (Calc/Service) 1254.97/986.68
Tube Length 4.88 Heat Calc 2912.07
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 2289.53
Excess % 27.19
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) 0.26/0.05
Number of Tube Passes 2 SS Film Coeff 11517.64
Number of Baffles 16 SS CS Vel 8.50
Baffle Spacing 0.28 TW Resist 0.000036
Baffle Cut, % Diameter 25 TS Film Coeff 4247.76
Baffle Type SSEG TS Vel 0.76
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2
Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

A2-18
 Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 2 26 3 27
Stream Name utility Utility out
Temp C 10.2163 150.0000 85.0000 90.0000
Pres bar 60.0000 4.0000 60.0000 3.6553
Enth kW -81861. -12749. -79571. -15038.
Vapor mole frac. 0.00000 1.0000 0.00000 0.00000
Total kmol/h 1346.5476 192.5821 1346.5476 192.5821
Total kg/h 23845.7930 3469.3657 23845.7930 3469.3657
Total std L m3/h 28.2506 3.4694 28.2506 3.4694
Total std V m3/h 30181.04 4316.47 30181.04 4316.47
Flow rates in kmol/h
Ammonia 420.0164 0.0000 420.0164 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0240 0.0000 0.0240 0.0000
Diethanolamine 0.0000 0.0000 0.0000 0.0000
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 926.5073 192.5821 926.5073 192.5821

Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:
Area Total m2 32.40 % Excess 27.19
Area Required m2 25.01 U Calc. W/m2-K 1254.97
Area Effective m2 31.81 U Service W/m2-K 986.68
Area Per Shell m2 31.81 Heat Duty kW 2.29E+003
Weight LMTD C 87.47 LMTD CORR Factor 0.8341 CORR LMTD C 72.96

Shellside Data:
Avg. SS Vel. m/sec 8.50
Film Coef. W/m2-K 11517.64
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.26
Inlet Nozzle Size m 0.13 Press. Drop/In Nozzle bar 0.03
Outlet Nozzle Size m 0.04 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 139.74
Rho V2 IN kg/m-sec2 2656.68 Press. Drop (Dirty) bar 0.44

Tubeside Data:
Film Coef. W/m2-K 4247.76
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.05
Inlet Nozzle Size m 0.09 Press. Drop/In Nozzle bar 0.01
Outlet Nozzle Size m 0.09 Press. Drop/Out Nozzle bar 0.00
Interm. Nozzle Size m 0.00 Mean Temperature C 48.41
Velocity m/sec 0.76 Mean Metal Temperature C 107.27

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.2898
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 16
Baffle Type Single Segmental

A2-19
 Baffle space def. Edge-Edge
Inlet Space m 0.282
Center Space m 0.282
Outlet Space m 0.282
Baffle Cut, % Diameter 25.000
Baffle Overlap m 0.038
Baffle Cut Direction Vertical
Number of Int. Baffles 0
Baffle Thickness m 0.003

Shell:
Shell O.D. m 0.33 Orientation H
Shell I.D. m 0.30 Shell in Series 1
Bonnet I.D. m 0.30 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:
Number 111 Tube Type
Bare
Length m 4.88 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 2
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:
Shellside Film m2-K/W 0.00009
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00024
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0054 Inlet Nozzle bar 0.0270
Tube Entrance bar 0.0018 Impingement bar 0.0173
Tube bar 0.0349 Bundle bar 0.2491
Tube Exit bar 0.0050 Outlet Nozzle bar 0.0022
End bar 0.0030 Total Fric. bar 0.2791
Outlet Nozzle bar 0.0028 Total Grav. bar -0.0034
Total Fric. bar 0.0529 Total Mome. bar -0.0162
Total Grav. bar 0.0000 Total bar 0.2595
Total Mome. bar 0.0016
Total bar 0.0545

E-102

Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 17.66

A2-20
 Shell I.D. 0.54 Area Required 0.77
Shell in Series/Parallel 1/1 COR LMTD 59.50
Number of Tubes 348 U (Calc/Service) 214.64/9.40
Tube Length 2.44 Heat Calc 225.47
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 9.88
Excess % 2183.20
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) -0.02/0.00
Number of Tube Passes 4 SS Film Coeff 10398.32
Number of Baffles 326 SS CS Vel 2.37
Baffle Spacing 0.00 TW Resist 0.000037
Baffle Cut, % Diameter 15 TS Film Coeff 292.41
Baffle Type SSEG TS Vel 0.01
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2
Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 5 6 26 27
Stream Name Utility out
Temp C 52.0657 85.0000 150.0000 90.0000
Pres bar 60.0000 60.0000 4.0000 3.6553
Enth kW -226.76 -216.89 -54.988 -64.863
Vapor mole frac. 0.00000 0.00000 1.0000 0.00000
Total kmol/h 10.8245 10.8245 0.8307 0.8307
Total kg/h 476.8504 476.8504 14.9642 14.9642
Total std L m3/h 0.5430 0.5430 0.0150 0.0150
Total std V m3/h 242.62 242.62 18.62 18.62
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 10.8245 10.8245 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 0.0000
Diethanolamine 0.0000 0.0000 0.0000 0.0000
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.8307 0.8307

Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:

A2-21
 Area Total m2 50.78 % Excess 2183.20
Area Required m2 0.77 U Calc. W/m2-K 214.64
Area Effective m2 17.66 U Service W/m2-K 9.40
Area Per Shell m2 17.66 Heat Duty kW 9.88E+000
Weight LMTD C 70.04 LMTD CORR Factor 0.8495 CORR LMTD C 59.50

Shellside Data:
Avg. SS Vel. m/sec 2.37
Film Coef. W/m2-K 10398.32
Allow Press. Drop bar 0.34 Calc. Press. Drop bar -0.02
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 139.74
Rho V2 IN kg/m-sec2 26.48 Press. Drop (Dirty) bar -0.04

Tubeside Data:
Film Coef. W/m2-K 292.41
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.00
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Interm. Nozzle Size m 0.00 Mean Temperature C 68.79
Velocity m/sec 0.01 Mean Metal Temperature C 135.00

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.5247
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 326
Baffle Type Single Segmental
Baffle space def. Edge-Edge
Inlet Space m 0.027
Center Space m 0.003
Outlet Space m 0.027
Baffle Cut, % Diameter 15.000
Baffle Overlap m 0.038
Baffle Cut Direction Vertical
Number of Int. Baffles 0
Baffle Thickness m 0.005

Shell:
Shell O.D. m 0.57 Orientation H
Shell I.D. m 0.54 Shell in Series 1
Bonnet I.D. m 0.54 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:
Number 348 Tube Type
Bare
Length m 2.44 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 4
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:

A2-22
 Shellside Film m2-K/W 0.00010
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00342
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0003 Inlet Nozzle bar 0.0002
Tube Entrance bar 0.0000 Impingement bar 0.0002
Tube bar 0.0000 Bundle bar 0.0083
Tube Exit bar 0.0000 Outlet Nozzle bar 0.0000
End bar 0.0000 Total Fric. bar 0.0083
Outlet Nozzle bar 0.0002 Total Grav. bar -0.0290
Total Fric. bar 0.0000 Total Mome. bar -0.0000
Total Grav. bar 0.0000 Total bar -0.0207
Total Mome. bar 0.0000
Total bar 0.0000

E-103

Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 10.86
Shell I.D. 0.44 Area Required 4.17
Shell in Series/Parallel 1/1 COR LMTD 25.36
Number of Tubes 214 U (Calc/Service) 126.85/48.72
Tube Length 2.44 Heat Calc 34.92
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 13.41
Excess % 160.36
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) -0.09/0.00
Number of Tube Passes 4 SS Film Coeff 449.13
Number of Baffles 326 SS CS Vel 0.00
Baffle Spacing 0.00 TW Resist 0.000035
Baffle Cut, % Diameter 15 TS Film Coeff 231.19
Baffle Type SSEG TS Vel 0.01
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2

A2-23
 Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 11 12 26 27
Stream Name Utility out
Temp C 85.3627 35.0000 20.0000 33.0000
Pres bar 0.0300 0.0300 1.0000 0.6553
Enth kW -433.12 -446.53 -3924.9 -3911.5
Vapor mole frac. 0.00000 0.00000 0.00000 0.00000
Total kmol/h 6.1546 6.1546 49.3367 49.3367
Total kg/h 376.1719 376.1719 888.8006 888.8006
Total std L m3/h 0.3680 0.3680 0.8888 0.8888
Total std V m3/h 137.95 137.95 1105.82 1105.82
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 6.1495 6.1495 0.0000 0.0000
Diethanolamine 0.0051 0.0051 0.0000 0.0000
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 0.0000 0.0000 49.3367 49.3367

Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:
Area Total m2 31.23 % Excess 160.36
Area Required m2 4.17 U Calc. W/m2-K 126.85
Area Effective m2 10.86 U Service W/m2-K 48.72
Area Per Shell m2 10.86 Heat Duty kW 1.34E+001
Weight LMTD C 29.89 LMTD CORR Factor 0.8485 CORR LMTD C 25.36

Shellside Data:
Crossflow Vel. m/sec 2.0E-015 EndZone Vel. 2.0E-015 Window Vel. 5.9E-
017
Film Coef. W/m2-K 449.13 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar -0.09
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 26.50
Rho V2 IN kg/m-sec2 196.48 Press. Drop (Dirty) bar -0.15

Stream Analysis:
SA Factors: A 49.87 B 0.00 C 0.00 E 50.13 F 0.00
Ideal Cross Vel. m/sec 0.92 Ideal Window Vel. m/sec 0.01

Tubeside Data:
Film Coef. W/m2-K 231.19 Reynolds No. 23
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.00
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00

A2-24
 Interm. Nozzle Size m 0.00 Mean Temperature C 60.18
Velocity m/sec 0.01 Mean Metal Temperature C 36.90

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.4232
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 326
Baffle Type Single Segmental
Baffle space def. Edge-Edge
Inlet Space m 0.027
Center Space m 0.003
Outlet Space m 0.027
Baffle Cut, % Diameter 15.000
Baffle Overlap m 0.038
Baffle Cut Direction Horizontal
Number of Int. Baffles 0
Baffle Thickness m 0.005

Shell:
Shell O.D. m 0.46 Orientation H
Shell I.D. m 0.44 Shell in Series 1
Bonnet I.D. m 0.44 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:
Number 214 Tube Type
Bare
Length m 2.44 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 4
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:
Shellside Film m2-K/W 0.00223
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00433
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0002 Inlet Nozzle bar 0.0016
Tube Entrance bar 0.0000 Impingement bar 0.0013
Tube bar 0.0009 Bundle bar 0.0155
Tube Exit bar 0.0000 Outlet Nozzle bar 0.0002
End bar 0.0000 Total Fric. bar 0.0155
Outlet Nozzle bar 0.0001 Total Grav. bar -0.1023
Total Fric. bar 0.0009 Total Mome. bar 0.0000
Total Grav. bar 0.0000 Total bar -0.0867
Total Mome. bar -0.0000

A2-25
 Total bar 0.0009

E-104

Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 14.05
Shell I.D. 0.49 Area Required 2.38
Shell in Series/Parallel 1/1 COR LMTD 42.95
Number of Tubes 277 U (Calc/Service) 103.83/17.59
Tube Length 2.44 Heat Calc 62.68
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 10.62
Excess % 490.42
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) -0.10/0.00
Number of Tube Passes 4 SS Film Coeff 328.79
Number of Baffles 326 SS CS Vel 0.00
Baffle Spacing 0.00 TW Resist 0.000035
Baffle Cut, % Diameter 15 TS Film Coeff 196.22
Baffle Type SSEG TS Vel 0.00
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2
Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 15 16 26 27
Stream Name Utility out
Temp C 130.2822 50.0000 20.0000 48.0000
Pres bar 0.0050 0.0050 1.0000 0.6553
Enth kW -221.31 -231.93 -1442.3 -1431.7
Vapor mole frac. 0.00000 0.00000 0.00000 0.00000
Total kmol/h 1.6785 1.6785 18.1299 18.1299
Total kg/h 176.3321 176.3321 326.6104 326.6104
Total std L m3/h 0.1598 0.1598 0.3266 0.3266
Total std V m3/h 37.62 37.62 406.36 406.36

A2-26
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0056 0.0056 0.0000 0.0000
Diethanolamine 1.6705 1.6705 0.0000 0.0000
Triethanolamine 0.0024 0.0024 0.0000 0.0000
Water 0.0000 0.0000 18.1299 18.1299

Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:
Area Total m2 40.42 % Excess 490.42
Area Required m2 2.38 U Calc. W/m2-K 103.83
Area Effective m2 14.05 U Service W/m2-K 17.59
Area Per Shell m2 14.05 Heat Duty kW 1.06E+001
Weight LMTD C 51.82 LMTD CORR Factor 0.8289 CORR LMTD C 42.95

Shellside Data:
Crossflow Vel. m/sec 4.8E-017 EndZone Vel. 4.8E-017 Window Vel. 1.2E-
018
Film Coef. W/m2-K 328.79 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar -0.10
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 34.00
Rho V2 IN kg/m-sec2 26.53 Press. Drop (Dirty) bar -0.18

Stream Analysis:
SA Factors: A 49.57 B 0.00 C 0.00 E 50.43 F 0.00
Ideal Cross Vel. m/sec 0.30 Ideal Window Vel. m/sec 0.00

Tubeside Data:
Film Coef. W/m2-K 196.22 Reynolds No. 2
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.00
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Interm. Nozzle Size m 0.00 Mean Temperature C 90.14
Velocity m/sec 0.00 Mean Metal Temperature C 53.01

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.4739
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 326
Baffle Type Single Segmental
Baffle space def. Edge-Edge
Inlet Space m 0.027
Center Space m 0.003
Outlet Space m 0.027
Baffle Cut, % Diameter 15.000
Baffle Overlap m 0.038
Baffle Cut Direction Horizontal
Number of Int. Baffles 0

A2-27
 Baffle Thickness m 0.005

Shell:
Shell O.D. m 0.51 Orientation H
Shell I.D. m 0.49 Shell in Series 1
Bonnet I.D. m 0.49 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:
Number 277 Tube Type
Bare
Length m 2.44 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 4
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:
Shellside Film m2-K/W 0.00304
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00510
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0000 Inlet Nozzle bar 0.0002
Tube Entrance bar 0.0000 Impingement bar 0.0002
Tube bar 0.0012 Bundle bar 0.0019
Tube Exit bar 0.0000 Outlet Nozzle bar 0.0000
End bar 0.0000 Total Fric. bar 0.0019
Outlet Nozzle bar 0.0001 Total Grav. bar -0.1068
Total Fric. bar 0.0012 Total Mome. bar 0.0000
Total Grav. bar 0.0000 Total bar -0.1049
Total Mome. bar -0.0000
Total bar 0.0012

E-105
Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 10.86
Shell I.D. 0.44 Area Required 0.07
Shell in Series/Parallel 1/1 COR LMTD 35.48
Number of Tubes 214 U (Calc/Service) 63.01/0.39
Tube Length 2.44 Heat Calc 24.27
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 0.15
Excess % 15935.18
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) -0.10/0.00
Number of Tube Passes 4 SS Film Coeff 87.89
Number of Baffles 326 SS CS Vel 0.00

A2-28
 Baffle Spacing 0.00 TW Resist 0.000035
Baffle Cut, % Diameter 15 TS Film Coeff 297.39
Baffle Type SSEG TS Vel 0.00
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2
Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 19 20 26 27
Stream Name Utility out
Temp C 106.9362 50.0000 20.0000 48.0000
Pres bar 0.0010 0.0010 1.0000 0.6553
Enth kW -4.5651 -4.7165 -20.566 -20.415
Vapor mole frac. 0.00000 0.00000 0.00000 0.00000
Total kmol/h 0.0341 0.0341 0.2585 0.2585
Total kg/h 3.5851 3.5851 4.6572 4.6572
Total std L m3/h 0.0032 0.0032 0.0047 0.0047
Total std V m3/h 0.76 0.76 5.79 5.79
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 0.0000
Diethanolamine 0.0341 0.0341 0.0000 0.0000
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.2585 0.2585
Total std V m3/h 5.79 5.79 0.76 0.76
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 0.0000
Diethanolamine 0.0000 0.0000 0.0341 0.0341
Triethanolamine 0.0000 0.0000 0.0000 0.0000
Water 0.2585 0.2585 0.0000 0.0000

A2-29
 Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:
Area Total m2 31.23 % Excess
15935.18
Area Required m2 0.07 U Calc. W/m2-K 63.01
Area Effective m2 10.86 U Service W/m2-K 0.39
Area Per Shell m2 10.86 Heat Duty kW 1.51E-001
Weight LMTD C 42.85 LMTD CORR Factor 0.8280 CORR LMTD C 35.48

Shellside Data:
Crossflow Vel. m/sec 2.1E-017 EndZone Vel. 2.1E-017 Window Vel. 6.1E-
019
Film Coef. W/m2-K 87.89 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar -0.10
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 34.00
Rho V2 IN kg/m-sec2 0.01 Press. Drop (Dirty) bar -0.17

Stream Analysis:
SA Factors: A 36.43 B 0.00 C 0.00 E 63.57 F 0.00
Ideal Cross Vel. m/sec 0.00 Ideal Window Vel. m/sec 0.00

Tubeside Data:
Film Coef. W/m2-K 297.39 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.00
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Interm. Nozzle Size m 0.00 Mean Temperature C 78.47
Velocity m/sec 0.00 Mean Metal Temperature C 66.58

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.4232
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 326
Baffle Type Single Segmental
Baffle space def. Edge-Edge
Inlet Space m 0.027
Center Space m 0.003
Outlet Space m 0.027
Baffle Cut, % Diameter 15.000
Baffle Overlap m 0.038
Baffle Cut Direction Horizontal
Number of Int. Baffles 0
Baffle Thickness m 0.005

Shell:
Shell O.D. m 0.46 Orientation H
Shell I.D. m 0.44 Shell in Series 1
Bonnet I.D. m 0.44 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:

A2-30
 Number 214 Tube Type
Bare
Length m 2.44 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 4
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:
Shellside Film m2-K/W 0.01138
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00336
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0000 Inlet Nozzle bar 0.0000
Tube Entrance bar 0.0000 Impingement bar 0.0000
Tube bar 0.0000 Bundle bar 0.0000
Tube Exit bar 0.0000 Outlet Nozzle bar 0.0000
End bar 0.0000 Total Fric. bar 0.0000
Outlet Nozzle bar 0.0000 Total Grav. bar -0.1019
Total Fric. bar 0.0000 Total Mome. bar 0.0000
Total Grav. bar 0.0000 Total bar -0.1019
Total Mome. bar -0.0000
Total bar 0.0000

E-106

Simulation: EA’s Production Plant Final

SUMMARY REPORT
--------------
General Data: Heat Transfer Data:
Exch Class/Type R/AEL Effective Transfer Area 10.86
Shell I.D. 0.44 Area Required 1.09
Shell in Series/Parallel 1/1 COR LMTD 49.07
Number of Tubes 214 U (Calc/Service) 108.32/10.87
Tube Length 2.44 Heat Calc 57.71
Tube O.D./I.D. 0.0191/0.0157 Heat Spec 5.79
Excess % 896.92
Tube Pattern TRI60 Foul(S/T) 1.761E-004/1.761E-004
Tube Pitch 0.02 Del P(S/T) -0.10/0.00
Number of Tube Passes 4 SS Film Coeff 334.71
Number of Baffles 326 SS CS Vel 0.00
Baffle Spacing 0.00 TW Resist 0.000035
Baffle Cut, % Diameter 15 TS Film Coeff 207.86
Baffle Type SSEG TS Vel 0.00
Baffle space def. Edge-Edge

Thermodynamics:
K: Amine
H: Amine
D: Library

A2-31
 Number of Components: 6

Calculation Mode: Design

Engineering Units:
Temperature C
Flow/Hour (kg/h)/h
Pressure bar
Enthalpy kW-h
Diameter/Area m/m2
Length/Velocity m/(m/sec)
Film W/m2-K
Fouling m2-K/W

Simulation: EA’s Production Plant Final

FLOW SUMMARIES:

Stream No. 23 24 26 27
Stream Name Utility out
Temp C 165.4622 40.0000 20.0000 38.0000
Pres bar 0.0010 0.0010 1.0000 0.6553
Enth kW -72.843 -78.632 -1223.3 -1217.5
Vapor mole frac. 0.00000 0.00000 0.00000 0.00000
Total kmol/h 0.4142 0.4142 15.3774 15.3774
Total kg/h 61.8000 61.8000 277.0240 277.0240
Total std L m3/h 0.0549 0.0549 0.2770 0.2770
Total std V m3/h 9.28 9.28 344.66 344.66
Flow rates in kmol/h
Ammonia 0.0000 0.0000 0.0000 0.0000
Ethylene Oxide 0.0000 0.0000 0.0000 0.0000
Monoethanolamine 0.0000 0.0000 0.0000 0.0000
Diethanolamine 0.0000 0.0000 0.0000 0.0000
Triethanolamine 0.4142 0.4142 0.0000 0.0000
Water 0.0000 0.0000 15.3774 15.3774

Simulation: EA’s Production Plant Final

TABULATED ANALYSIS
------------------
Overall Data:
Area Total m2 31.23 % Excess 896.92
Area Required m2 1.09 U Calc. W/m2-K 108.32
Area Effective m2 10.86 U Service W/m2-K 10.87
Area Per Shell m2 10.86 Heat Duty kW 5.79E+000
Weight LMTD C 58.02 LMTD CORR Factor 0.8457 CORR LMTD C 49.07

Shellside Data:
Crossflow Vel. m/sec 7.2E-016 EndZone Vel. 7.2E-016 Window Vel. 2.1E-
017
Film Coef. W/m2-K 334.71 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar -0.10
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Mean Temperature C 29.00
Rho V2 IN kg/m-sec2 19.09 Press. Drop (Dirty) bar -0.17

Stream Analysis:
SA Factors: A 46.12 B 0.00 C 0.00 E 53.88 F 0.00
Ideal Cross Vel. m/sec 0.29 Ideal Window Vel. m/sec 0.00

A2-32
Tubeside Data:
Film Coef. W/m2-K 207.86 Reynolds No. 0
Allow Press. Drop bar 0.34 Calc. Press. Drop bar 0.00
Inlet Nozzle Size m 0.03 Press. Drop/In Nozzle bar 0.00
Outlet Nozzle Size m 0.03 Press. Drop/Out Nozzle bar 0.00
Interm. Nozzle Size m 0.00 Mean Temperature C 102.73
Velocity m/sec 0.00 Mean Metal Temperature C 54.81

Clearance Data:
Baffle m 0.0048 Outer Tube Limit m 0.4232
Tube Hole m 0.0008 Outer Tube Clear. m 0.0150
Bundle Top Space m 0.0000 Pass Part Clear. m 0.0000
Bundle Btm Space m 0.0000

Baffle Parameters:
Number of Baffles 326
Baffle Type Single Segmental
Baffle space def. Edge-Edge
Inlet Space m 0.027
Center Space m 0.003
Outlet Space m 0.027
Baffle Cut, % Diameter 15.000
Baffle Overlap m 0.038
Baffle Cut Direction Horizontal
Number of Int. Baffles 0
Baffle Thickness m 0.005

Shell:
Shell O.D. m 0.46 Orientation H
Shell I.D. m 0.44 Shell in Series 1
Bonnet I.D. m 0.44 Shell in Parallel 1
Type AEL Max. Heat Flux Btu/ft2-hr 0.00
Imping. Plate Impingement Plate Sealing Strip 5

Tubes:
Number 214 Tube Type
Bare
Length m 2.44 Free Int. Fl Area m2 0.00
Tube O.D. m 0.019 Fin Efficiency 0.000
Tube I.D. m 0.016 Tube Pattern TRI60
Tube Wall Thk. m 0.002 Tube Pitch m 0.024
No. Tube Pass 4
Inner Roughness m 0.0000016
Number of tubesheets 2 Tubesheet thickness, m 0.019

Resistances:
Shellside Film m2-K/W 0.00299
Shellside Fouling m2-K/W 0.00018
Tube Wall m2-K/W 0.00004
Tubeside Fouling m2-K/W 0.00018
Tubeside Film m2-K/W 0.00481
Reference Factor (Total outside area/inside area based on tube ID)
1.210

Pressure Drop Distribution:

Tube Side Shell Side
Inlet Nozzle bar 0.0000 Inlet Nozzle bar 0.0002
Tube Entrance bar 0.0000 Impingement bar 0.0001
Tube bar 0.0007 Bundle bar 0.0019
Tube Exit bar 0.0000 Outlet Nozzle bar 0.0000
End bar 0.0000 Total Fric. bar 0.0019

A2-33
 Outlet Nozzle bar 0.0001 Total Grav. bar -0.1022
Total Fric. bar 0.0007 Total Mome. bar 0.0000
Total Grav. bar 0.0000 Total bar -0.1002
Total Mome. bar -0.0000
Total bar 0.0007

A2.2.4. Pumps Equipment Reports

P-101
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Pump Summary

Equip. No. 3

Name
Output pressure bar 60.0000
Efficiency 0.8500
Calculated power kW 0.9391
Calculated Pout bar 60.0000
Head m 614.0405
Vol. flow rate m3/h 0.5743
Mass flow rate kg/h 476.8504

P-102
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Pump Summary

Equip. No. 7

Name
Output pressure bar 1.0500
Efficiency 0.8500
Calculated power kW 0.0076
Calculated Pout bar 1.0500
Head m 3.8309
Vol. flow rate m3/h 0.6632
Mass flow rate kg/h 617.8892

P-103
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES
Pump Summary

Equip. No. 10

Name
Output pressure bar 0.4500
Efficiency 0.7000
Calculated power MJ/h 0.0145
Calculated Pout bar 0.4500

A2-34
Head m 4.2958
Vol. flow rate m3/h 0.2422
Mass flow rate kg/h 241.4604

P-104
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Pump Summary

Equip. No. 10

Name
Output pressure bar 0.4500
Efficiency 0.8500
Calculated power kW 0.0033
Calculated Pout bar 0.4500
Head m 4.2965
Vol. flow rate m3/h 0.2425
Mass flow rate kg/h 241.7173

P-105
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Pump Summary

Equip. No. 13

Name
Output pressure bar 0.4000
Efficiency 0.8500
Calculated power kW 0.0008
Calculated Pout bar 0.4000
Head m 3.9412
Vol. flow rate m3/h 0.0640
Mass flow rate kg/h 65.3851

P-106
Simulation: EA’s Production Plant Final

EQUIPMENT SUMMARIES

Pump Summary

Equip. No. 17

Name
Output pressure bar 0.0050
Efficiency 0.8500
Calculated power kW 4.3521e-007
Calculated Pout bar 0.0050
Head m 0.0379
Vol. flow rate m3/h 0.0033
Mass flow rate kg/h 3.5851

A2-35
APPENDIX A.3
Economic Analysis
Calculations

A3-1
 Appendix A3

A3.1. Equipment Summary

Unit Number 100

CEPCI 616.5

User Added Equipment

Shell Tube Area Purchased

Exchanger Bare Module
Exchangers Pressure Pressure MOC (square Equipment
Type Cost
(barg) (barg) meters) Cost
Stainless
Fixed, Sheet, $
E-101 4 60 Steel / Carbon 31.8 $ 130,000
or U-Tube 26,900
Steel
Stainless
Fixed, Sheet, $
E-102 4 60 Steel / Carbon 17.7 $ 119,000
or U-Tube 24,700
Steel
Stainless
Fixed, Sheet, $
E-103 1 0.03 Steel / Carbon 10.9 $ 111,000
or U-Tube 23,800
Steel
Stainless
Fixed, Sheet, $
E-104 1 0.005 Steel / Carbon 14.1 $ 112,000
or U-Tube 24,200
Steel
Stainless
Fixed, Sheet, $
E-105 1 0.001 Steel / Carbon 10.9 $ 110,000
or U-Tube 23,800
Steel
Stainless
Fixed, Sheet, $
E-106 1 0.001 Steel / Carbon 10.9 $ 110,000
or U-Tube 23,800
Steel

Purchased
Power Bare Module
Mixers Type # Spares Equipment
(kilowatts) Cost
Cost
$
M-101 Turbine 7.5 0 $ 14,800
10,700

A3-2
Pumps Discharge Purchased Bare
Pump Power
(with # Spares MOC Pressure Equipment Module
Type (kilowatts)
drives) (barg) Cost Cost
Carbon $ $
P-101 Centrifugal 1 1 60
Steel 7,610 46,400
Carbon $ $
P-102 Centrifugal 0.01 1 1.05
Steel 7,610 30,300
Carbon $ $
P-103 Centrifugal 0.003 1 0.45
Steel 7,610 30,300
Carbon $ $
P-104 Centrifugal 0.001 1 0.4
Steel 7,610 30,300
Carbon $ $
P-105 Centrifugal 0.001 1 0.005
Steel 7,610 30,300

Volume Purchased
Bare Module
Reactors Type (cubic Equipment
Cost
meters) Cost
Jacketed Non- $
R-101 7 $ 57,000
Agitated 14,300

Tower Purchased Bare

Height Diameter Tower Pressure
Towers Descriptio Equipment Module
(meters) (meters) MOC (barg)
n Cost Cost
16
Stainless
Stainless $ $
T-101 Steel 10 3.05 0.77
Steel 197,000 881,000
Sieve
Trays
11
Stainless
Stainless $ $
T-102 Steel 6.5 0.46 0.033
Steel 18,200 77,300
Sieve
Trays
12 Carbon
Steel Carbon $ $
T-103 7 0.46 0.006
Sieve Steel 19,600 42,300
Trays
10 Carbon
Steel Carbon $ $
T-104 6 0.46 0.001
Sieve Steel 16,900 39,500
Trays

Length/Hei Purchased Bare

Storage ght Diameter Pressure Equipment Module
Tanks Orientation (meters) (meters) MOC (barg) Cost Cost
Stainles $ $
TK-101 Horizontal 4.17 2.54 Steel 19.8 25,500 702,000
Stainles $ $
TK-102 Horizontal 4 2.17 Steel 2.3 20,600 144,000

Total Bare
Module $
Cost 2,797,500

A3-3
A3.2. Utilities Summary

A3.3. COM Summary

Material Name Classification Price ($/kg) Flowrate (kg/h) Annual Cost

Liquid Ammonia Raw Material $ 0.68 190.30 $ 933,901
Ethylene Oxide Raw Material $ 1.08 476.85 $ 3,707,989
Water Raw Material $ 0.86 9.27 $ 57,418
Aqueous
Ammonia Hazardous Waste $ 0.20 9.88 $ 14,227
Monoethanolamin
e (MEA) Product $ (2.36) 375.64 $ (6,382,843)
Diethanolamine
(DEA) Product $ (1.50) 179.21 $ (1,935,446)
Triethanolamine
(TEA) Product $ (3.00) 61.80 $ (1,334,794)
endClassification endMaterial

Economic Options
Cost of Land $ 557,738
Taxation Rate 22%
Annual Interest Rate 19%
Salvage Value $ 398,000
Working Capital $ 880,000
FCIL $ 3,980,000
Total Module Factor 1.18
Grass Roots Factor 0.50

A3-4
 Economic Information Calculated From Given
Information
Revenue From Sales $ 9,653,083
CRM (Raw Materials Costs) $ 4,699,308
CUT (Cost of Utilities) $ 126,000
CWT (Waste Treatment Costs) $ 14,227
COL (Cost of Operating Labor) $ 122,400

Factors Used in Calculation of Cost of Manufacturing

(COMd)
Comd = 0.18*FCIL + 2.76*COL + 1.23*(CUT + CWT +
CRM)
Multiplying factor for FCIL 0.18
Multiplying factor for COL 2.76
Facotrs for CUT, CWT, and CRM 1.23

COMd $ 7,006,853

Factors Used in Calculation of Working Capital

Working Capital = A*CRM + B*FCIL + C*COL
A 0.10
B 0.10
C 0.10

Project Life (Years after Startup) 10

Construction period 2

Distribution of Fixed Capital Investment (must sum to

one)
End of year One 60%
End of year Two 40%
End of year Three
End of year Four
End of year Five

A3-5
A3.4. Cash Flow Analysis

Discounted Profitibility Criterion

Net Present Value (millions) 2.62

Discounted Cash Flow Rate of Return 31.98%

Discounted Payback Period (years) 2.7

A3-6
Non-Discounted Profitibility
Criteria
Cumulative Cash Position (millions) 17.85

Rate of Return on Investment 44.84%

Payback Period (years) 1.7

Year Investment dk FCIL-Sdk R COMd (R-COMd-dk)*(1-t)+dk

0 0.00 3.98
0 0.56 3.98
1 2.39 3.98
2 1.59 3.98
2 0.88 3.98
3 0.80 3.18 9.65 7.01 2.24
4 1.27 1.91 9.65 7.01 2.34
5 0.76 1.15 9.65 7.01 2.23
6 0.46 0.69 9.65 7.01 2.16
7 0.46 0.23 9.65 7.01 2.16
8 0.23 - 9.65 7.01 2.11
9 - 9.65 7.01 2.06
10 - 9.65 7.01 2.06
11 - 9.65 7.01 2.06
12 - 9.65 7.01 2.37
12

A3-7
 Cash Flow
Cash Flow Cumulative Cash Cumulative Cash Flow
(Non-
(discounted) Flow (discounted) (Non-discounted)
discounted)

0.00 0.00 0.00 0.00

(0.56) (0.56) (0.56) (0.56)
(2.39) (2.01) (2.56) (2.95)
(1.59) (1.12) (3.69) (4.54)
(0.88) (0.62) (4.31) (5.42)
2.24 1.33 (2.98) (3.18)
2.34 1.17 (1.81) (0.83)
2.23 0.94 (0.88) 1.40
2.16 0.76 (0.11) 3.56
2.16 0.64 0.53 5.73
2.11 0.53 1.05 7.84
2.06 0.43 1.48 9.91
2.06 0.36 1.85 11.97
2.06 0.30 2.15 14.03
2.37 0.29 2.44 16.41
1.44 0.18 2.62 17.85

A3.5. User Options

Hours per Operting Year 7200

Cost ($/GJ)
Common Utilities
Electricity (110V - 440V) 18.72
Cooling Water (30°C to 45°C) 0.378
Refrigerated Water (15°C to 25°C) 4.77

Steam from Boilers

Low Pressure (5 barg, 160°C) 2.03
Medium Pressure (10 barg, 184°C) 2.78
High Pressure (41 barg, 254°C) 5.66

Fuels
Fuel Oil (no. 2) 10.3
Natural Gas 3.16
Coal (FOB mine mouth) 2.04

Thermal Systems
Moderately High (up to 330°C) 3.95
High (up to 400°C) 3.95
Very High (up to 600°C) 3.95

Refrigeration
Moderately Low (5°C) 4.77
Low (-20°C) 8.49

A3-8
 Very low (-50°C) 14.12

Cost ($/tonne)
Waste Disposal (solid and liquid)
Non-Hazardous 36
Hazardous 200

Cost of Steam used in Steam Drives

Cost ($/GJ)
Steam used for steam-powered
drives $ 5.66

Equipment Effeciencies

Pump Efficiency 85%

Drive Efficiency 90%
Fan Efficiency 70%
Furnace Efficiency 90%
Turbine Efficiency 65%

Process Equipment

Operators per shift per

equipment

Cost of Labor (per operator/year) $ 66,910

Miscellaneous Numebrs

Solids Handling Coefficient 1.00

Power Preference
kilowatts

Pressure Preference
barg

Heat Duty Preference

MJ/h

Length Preference
meters

Area Preference
square meters

Volume Preference
cubic meters

Gas Flow Preference

cubic meters/s

A3-9
 Cost Preference
$/kg

Flowrate Preference
kg/h

Energy Price Preference

$/Gigajoule

A3-10