MANUFACTURE OF CHEMICALS FROM DEHYDRATION

OF GLYCEROL
A Project Report submitted in partial fulfilment for the award of Degree of
BACHELOR OF TECHNOLOGY IN PETROCHEMICAL ENGINEERING

By
K.Niranjan
(13021A2506)

Under the Supervision of

Ms. J.A.Suhasini
Assistant Professor(C)
Department Of Petroleum Engineering And Petrochemical Engineering

DEPARTMENT OF PETROLEUM ENGINEERING AND PETROCHEMICAL

ENGINEERING
UNIVERSITY COLLEGE OF ENGINEERING KAKINADA (A),
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KAKINADA
KAKINADA – 533003
2017
 DECLARATION
I, K.Niranjan, hereby declare that this project entitled
“MANUFACTURE OF CHEMICALS FROM DEHYDRATION OF
GLYCEROL” is original and has not previously formed the basis for the award
of any degree of similar title.

Place: Kakinada
Date: (K.Niranjan)
 CERTIFICATE

This is to certify that the project work entitled “MANUFACTURE OF

CHEMICALS FROM DEHYDRATION OF GLYCEROL” submitted by K.Niranjan
(13021A2506) in partial fulfillment of the requirements for the award of Bachelor of
Technology in Petro Chemical Engineering is a bonafide work carried out by him.

Prof. K. V. Rao Ms.J.A.Suhasini M.Tech

Program Director Project Guide & Lecture

UCEK (A), JNTUK Dept. of PE&PCE.

UCEK (A), JNTUK

Dr. K. Meera Saheb

Head of the Department

Dept. of Petroleum Engineering &
Petrochemical Engineering
UCEK (A), JNTUK
 ACKNOWLEDGEMENTS

I take this opportunity to express my gratefulness and deep sense of

gratitude to Prof. K. V. Rao, Programme Director, Jawaharlal Nehru Technological University,
Kakinada for his valuable guidance and for being the inspiring source throughout the
fulfilment of this course. I feel privileged for pursuing this course under his supervision.

I would like to express our profound sense of gratitude to guide Ms. J.A. Suhasini,
Lecturer, Department of Petroleum and Petrochemical Engineering, for his skilful guidance,
timely suggestions and encouragement in completing this project.

I would like to express our sincere thanks to Dr. K. Meera Saheb, Head of the
Department, Department of Petroleum and Petrochemical Engineering for providing the
necessary facilities for the successful completion of this work.

I would like acknowledge our gratitude to Prof. G. V. R. Prasad Raju, principal

university college of engineering JNTUK, for providing good infrastructure.

I was also very thankful to all other faculty members of our department for their
valuable suggestions. Finally we thank our parents for their enduring love and encouragement
throughout the course.

K.Niranjan
13021A2506
 CONTENTS
CHAPTE CHAPTER NAME Page No.
NO.
ABSTRACT
LIST OF FIGURES
LIST OF TABLES
NOMENCLATURE
1 INTRODUCTION 1-2
1.1History 1
1.2Occurence 2
2 PHYSICAL, CHEMICAL PROPERTIES AND 3-9
USES
2.1 physical properties of Glycerol and acrolein 3
2.2 chemical properties of Glycerol 3
2.2 chemical properties of acrolein 4
2.3 uses of Glycerol 5
2.4 uses of acrolein 8
3 DIFFERENT MANUFACTURING PROCESSES 10-11
3.1 fluidized bed reactor 10
3.2 catalytic dehydration of glycerol 10
3.3 gas phase dehydration of glycerol 11
4 PROCESS SELECTION 12
5 PROCESS DESCRIPTION 13-15
6 MATERIAL AND ENERGY BALANCE 16-33
6.1 Mass Blance 16
6.1.1 Mass balance for mixer 16
6.1.2 Mass balance for reactor 18
 6.1.3 Mass balance for flash distillation column 19
6.1.4 Mass balance for heat exchanger 20
6.1.5 Mass balance for distillation column 21
6.2 Energy Balance 23
6.2.1 Equations used for calculation 23
6.2.2 Energy balance for condenser 24
6.2.3 Energy balance for reboiler 27
6.2.4 Energy balance for heat exchanger 28
6.2.4.1 Energy around tube side inlet 28
6.2.4.2 Energy around shell side inlet 29
6.2.4.3 Energy around tube side outlet 30
6.2.4.4 Energy around side side outlet 31
6.2.5 Energy balance for reactor 32
6.2.5.1 Energy around reactor inlet 32
6.2.5.2 Energy around reactor outlet 33
7 SIMULATION OF GLYCEROL 34-36
DEHYDRATION PLANT USING UNISIM
8 SPECIFIC EQUIPMENT DESIGN 37-41
8.1 Design of distillation column 37
8.1.1 Minimum number of stages 37
8.1.2 Minimum reflux ratio 37
8.1.3 Number of stages 38
8.1.4 Feed location 38
8.1.5 Liquid split and vapour split 38
8.1.6 Feed stream specifications 39
8.1.7 Distillate stream specifications 40
9 MATERIALS OF CONSTRUCTION 42-45
9.1 Important materials available 42
9.2 Recommended materials of construction 43
10 SAFETY, HEALTH AND ENVIRONMENTAL 46-54
ASPECTS
10.1 Hazard identification 46
10.1.1 Political acute health effects 46
10.1.2 Potential chronic health effects 46
10.2 Fire and explosion data 46
10.3 Accidental release measures 47
10.4 Handling and storage 48
10.5 Exposure control/personal protection 48
10.6 first aid measures 49
10.7 Toxilogical information 50
10.8 Ecological information 52
10.9 Disposal considerations 52
10.10 Transportation information 52
10.11 Other regulatory information 52
11 plant location and plant layout 55-61
11.1 Plant location 55
11.1.1 Marketing area 55
11.1.2 Raw materials 55
11.1.3 Transport 56
11.1.4 Availability of labor 56
11.1.5 Utilities 56
11.1.6 Environmental impact and effluent disposal 57
11.1.7 Local community considerations 57
 11.1.8 Climate 57
11.1.9 political and strategic considerations 57
11.2 Plant layout 58
11.2.1 Costs 58
11.2.2 Process requirements 58
11.2.3 Operations 58
11.2.4 Maintenance 59
11.2.5 Safety 59
11.2.6 Plant expansion 59
11.2.7 Modular construction 59
11.3 Desired plant location 60
12 INSTRUMENTATION AND PROCESS CONTROL 62-65
12.1 Instrumentation & control objectives 62
12.2 Components of the control system 62
12.3 Alarms and safety trips 63
12.4 Distillation column control 64
12.5 Flow controllers 64
12.6 Temperature controller 65
12.7 Pressure controller 65
12.8 Level controller 65
12.9 Control valves 65
13 COST ESTIMATION 66-71
13.1 Estimation of plant cost 66
13.2 Detailed cost analysis 66
13.2.1 Direct costs 66
13.2.2 Indirect costs 67
13.2.3 Fixed capital investment 69
13.2.4 Working capital 69
 13.2.5 Total capital investment 69
13.3 Estimation of total product cost 69
13.3.1 Estimation of direct production cost 69
13.3.2 Fixed costs 70
13.3.3 Plant overhead costs 70
13.3.4 General expenses 70
13.4 Total product costs 70
13.4.1 Current selling price 70
13.4.2 Gross earnings 70
13.4.3 Tax 71
13.4.4 Net profit 71
13.4.5 Pay-out time 71
13.4.6 Rate of return 71
14 BIBILIOGRAPHY 72
 ABSTRACT
This project discusses a Manufacture of chemicals from dehydration of
glycerol. A 800TPA Acrolein is synthesized from dehydration of glycerol and using a Gas
phase dehydration of glycerol. The process is elaborately described along with the overall
material and energy balances. Glycerol is taken as limiting reagent. A purity of 99.9 wt. %
of acrolein is obtained. Further, Distillation column is designed using a short-cut Fenske
Underwood Gilliland (FUG) method.
The Gas phase dehydration of glycerol is simulated in UNISIMR450. The
detailed procedure for simulation is described and the results are presented. Materials of
construction for the production of acrolein, health and safety factors including handling and
storage measures are included in this report. A preliminary cost estimation is done to produce
800TPA acrolein and the rate of return is calculated.
 LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
Figure 1.1 structure of glycerol 1

Figure 1.2 structure of acrolein 2

Figure 5.1 process flow diagram for dehydration of 15

glycerol
Figure 6.1 mass balance at mixer 17

Figure 6.2 Mass balance at reactor 18

Figure 6.3 Mass balance at flash distillation column 19

Figure 6.6 Mass balance at heat exchanger 20

Figure 6.7 Mass balance at distillation column 21

Figure 12.1 Glycerol dehydration plant-layout 61

 LIST OF TABLES
TABLE NO. TITLE PAGE NO.
Table 2.1 Physical properties 3
Table 4.1 Comparison of different processes 12
Table 6.1 Mass balance at mixer 17
Table 6.2 Mass balance at reactor 18
Table 6.3 Mass balance at flash distillation column 19
Table 6.4 Mass balance at heat exchanger 20
Table 6.5 Mass flow rates of distillation column 21
Table 6.6 Mass balance at distillation column 22
Table 6.7 Cp data for components 24
Table 6.8 Cp data for distillate streams 25
Table 6.9 Cp data for feed streams 26
Table 6.10 Cp data for bottom streams 27
Table 6.11 Energy values of streams of distillation 28
Table 6.12 Cp data for tube side inlet 28
Table 6.13 Cp data for shell side inlet 29
Table 6.14 Cp data for tube side outlet 30
Table 6.15 Cp data for shell side outlet 31
Table 6.16 Cp data for reactor inlet 32
Table 6.17 Cp data for reactor outlet 33
Table 9.1 Feed specifications 39
Table 9.2 Distillate specifications 40
Table 10.1 Composition of stainless steel of various grades 45
Table 14.1 Various Direct Costs 67
Table 14.2 Various Indirect Costs 68
 NOMENCLATURE
B Bottom rate
∆H Change in enthalry
Ws Shaft work
∆Ek Change in kinetic energy
∆Ep Change in potential energy

∆T Change in temperature
Hi Enthalpy in inlet
Hf Enthalpy in outlet
m Mass flow rate
Cp Specific heat
ƛ Latent heat of vaporization
MOl.Wt Molecular weight
V Vapor flow rate
D Distillate rate
Q Heat
L Reflux rate
F Feed rate
 STATEMENT OF THE PROJECT
The Design and Simulation of Gas phase dehydration of Glycerol for the
Synthesis of Glycerol, is carried out for the capacity 800TPA .