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ETHANOL
L/O/G/O
CONTENTS
INTRODUCTION
• Ethanol or ethyl alcohol, CH3CH2OH,
– is one of the most versatile oxygen-containing organic
chemicals because of its unique combination of properties
as a solvent, a germicide, a beverage, an antifreeze, a
fuel, a depressant, and especially as a chemical
intermediate for other organic chemicals.
• The name alcohol is a generic name derived from two
Arabic words, al and kohl.
Physical Properties
• volatile, flammable, clear, colorless
liquid
• when it is mixed with water ,the volume shrinkage ,when
it is mixed with gasoline, the volume expansion that.
• The physical and chemical properties of ethyl alcohol are
primarily dependent upon the hydroxyl group.
• This group imparts polarity to the molecule and
gives rise to intermolecular hydrogen
bonding.
•
Physical Properties
• Its low freezing point (-114.1°c) has made
it useful as the fluid in thermometers for
temperatures below –40°C, the freezing
point of mercury, and for other low-
temperature purposes, such as for
antifreeze in automobile radiators.
• Ethanol is a versatile solvent, miscible
with water and with many organic
solvents
Chemical properties
• All chemical properties of ethanol are
basically dependent on the hydroxyl
group
• Ethanol could go into several reactions
like dehydrogenation, dehydration,
oxidation, and esterification.
• Also replacement for hydrogen atom of
hydroxyl group could be attained.
Reactions related to hydrogen
atom
• Replacement of hydrogen atom by an
active metal
•
• Addition reaction of ethylene oxide and
ethanol to produce hydroxy ethers
•
• Addition of acetylene to ethyl alcohol to
produce ethyl vinyl ether.
•
•
• Addition of aldehydes or ketones to
alcohols to produce acetals.
•
Reactions related to hydroxyl
group
• The hydroxyl group can be replaced by
halogens from inorganic acid halides or
phosphorus halides to give two different
products, ethyl esters of the acid and
ethyl halide .
• Esterification reaction that occur between
alcohols and acids.
•
•
•
• Dehydration reaction that gives ethylene
or ethyl ether
•
•
• Dehydrogenation reaction that gives
acetaldehyde.
•
• Ethanol reacts with sodium hypochlorite to
produce chloroform “chloroform
reaction”.
•
•
Types of ethanol
Uses
Production methods
Fermentation Ethanol
FERMETATION ETHANOL
• Ethanol can be derived by fermentation
processes from any material that contains
sugar or compounds that can be converted
to sugar .
• The use of fermentation ethanol in the industrial
market depends on:
1)The availability and cost of the
carbohydrate relative to that of
ethylene.
2)The economics and government policies
relating to the fuel ethanol market.
–
sugar cane, molasses
sugar converted to ethanol directly.
grains, potatoes
Fermenataion starch more complex (must first be converted
to sugar )
wood, agricultural residues

cellusous much more difficult to hydrolyze
almost two-thirds of the mass would
disappear during the sequence
Fermentation Ethanol
• Benefits
1) Added in small amounts to gasoline, it reduces greenhouse
emissions like carbon monoxide and nitrogen oxides
because ethanol contains a lot of oxygen, thus is
burns pretty cleanly
2) Ethanol reduces dangerous and expensive dependence on
imported oil .
3) The ethanol industry creates jobs and investment across
especially in rural areas.
4) Ethanol increases fuel supply helping keep gas prices
down.
5) Ethanol adds value the agriculture crop by reducing the
amount available.
Ethanol – Not As good As We
Think
Ethanol – Not As Clean As We
Think
• The cost of Reformulated Gasoline with ethanol will increase 3-6
cents per gallons compared to RFG with MTBE.
• Ethanol cannot be shipped by pipeline because of its high affinity
for water posing significant distribution costs and hurdles for
gasoline blenders.
• For every gallon of ethanol produced, 1.4 gallons of energy is
consumed in the process, compared to 0.15 gallons used in the
manufacture of gasoline.
• It takes 1.5 gallons of ethanol (E-85) to drive as many miles as one
gallon of gasoline.
• Ethanol increases the vapor pressure of gasoline by 1 psi. resulting
in higher evaporative emissions of Volatile Organic Compounds,
while tailpipe emissions of Acetaldehyde increase 150%.
•
•
INDUSTRIAL ETHANOL
• Ethanol is manufactured by hydration of
ethylene:
– Indirect hydration process
– Direct hydration process
• Raw Materials for ethylene
– Ethane
– Naphthas
– Gas oils
Indirect hydration process
1) Absorption of ethylene in concentrated sulfuric acid to
form monoethyl sulfate (ethyl hydrogen sulfate) and
diethyl sulfate

2) Hydrolysis of ethyl sulfates to ethanol:

3)
4)
5)
6) Reconcentrationof the dilute sulfuric acid
Direct hydration process
• Ethanol is manufactured by reacting
ethene with steam over phosphoric acid
on a charcoal support
Factor effecting the process
1)The proportions of ethene and steam
2)The temperature
3)The pressure
4)The catalyst & It’s concentration
5)Contact time
Temperature
Equilibrium Conversion
Degree
Temp 0 c 50 kg/cm2 80 kg/cm2 100 kg/cm2 150 kg/cm2
150 53 65 6.7 74
200 30.5 38.7 4.5 54
250 14.1 21.4 25 385
300 6.7 10.3 12.5 18.3

350 3.5 5.6 7 12.2
The proportions of ethene
and steam
Pressure
Contact time
Fermentation vs. Synthetic
Synthetic Fermentation
• Continuous process • Slow process

• Gas phase process • Batch process
• Depend on oil price Ethanol • Sold raw material (high cost of
transportation).
• Depend on agriculture crops prices.
Hazard and Operability Study
• Is a technique for identifying hazards without
waiting for an accident to occur.
• A HAZOP is a systematic procedure to analyze
the hazards associated with each process
pipeline, applying the following guide words:
NONE, MORE OF, LESS OF, REVERSE,
OTHER THAN, PART OF, MORE THAN with
other parameter.
Question Answers
What is HAZOP ? Systematic review by multidiscipline team
Identify potential hazards and
operability
Identify consequences
Any flow process or sequence procedure
What are HAZOP used Review of existing facility to uncover

for ? latent system and procedural shortcomings
Part of change control
Why HAZOP? Convention review techniques are

discipline restricted
No inter - discipline simultaneous checks
Verification without fixed structured
technique
Individual checks based on standards are
too specific .
GUIDE WORD HAZOP
TECHNIQUE
• Intention
• Guide Words
• Parameters
• Deviations
• Causes
• Consequences
•
Principle of Hazard
Guide
Parameter
Words
Possible INTENTION
Potential
Causes DEVIATIONS Consequences
Actio
ns
RISK RANKING
5 - Catastrophic
CONSEQUEN
CE(C)
4 - Major
3 - Moderate
2 - Minor
1 - Negligible
1 Improbable 2 3 4 5
Risk is Remote Occasional Probable Frequent
LxC
Likelihood of Occurrence (L)
SYSTEM : Spherical Tank
NO . GUIDE POSSIBLE CAUSES CONSEQUENCES EXISTING ACTION REQUIRED
1 HIGH PRESSURE Weather conditions Ethylene release SAFEGUARDS
Pressure control valve If ethylene must be
Increase in ethylene quantity Explosion(if the vent Vents released into the air, it is
External fire doesn't opened) done under a blanket of
Failed Open PCV steam
Inadequate Volume of Vents
Incorrect Vent Set Pressure for
Vents
2 LOW PRESSURE Undetected Leakage Failure in suction Pressure control valve Gas release detection
Gas Release process of ethylene Modify compressor criteria
Weather Conditions Reduce ethylene flow
Reduce ethanol yield
3 HIGH Ambient Conditions Explosion Temperature control External cooling

TEMPERATURE Fire Situation valve
4 LOW TEMPERATURE Ambient Conditions Superheater overload Temperature control Modify superheater criteria
Reducing Pressure valve
SYSTEM : reactor
NO . GUIDE POSSIBLE CONSEQUENCES EXISTING ACTION REQUIRED
CAUSES SAFEGUARDS
1 HIGH Control Packing Flow control Regular
PRESSURE faults failure valve inspection check
Rupture valve
High
conversion
2 LOW Compressor Low Flow control Automatic start
PRESSURE failure conversion valve of standby
Control compressor
3 HIGH faults
Control High Temperature Regular
TEMPERATUR faults conversion control valve inspection check
E valve
4 LOW Control Low Temperature Regular

TEMPERATUR faults conversion control valve inspection check
E Superheater shutdown valve
failure
Material &Heat balance
Process simulation by hysys
Our hysys
The recycle gas ( R ) kg / hr 197245 . 9521
calculation 177300
Concentration of ethylene 85 87 . 5
T 2 of compressor1 182 0 f 205 0 f
BHP of compressor 1 324 hp 270 hp
T 2 of compressor2 196 0 f 148 0 f
BHP of compressor 2 1840 hp 2700 hp
Heat exchanger
Duty ( btu / hr ) 27 * 10^6 59 * 10^6
T out Stream to furnace 392 00 f 392 00 f
Stream for cooler 420 f 450 f
U ( btu / hr . ft2 . 0F ) 49 55
ΔTlm ( f ) 210 240
F correlation factor 0.9 0 . 97
Area ( ft 2 ) 3130 2240
Fired heater
Duty ( btu / hr ) 29 . 1 * 10^6 43 * 10^6
reactor
type Fixed bed Conversion
sizing VD (( mm )3 ) reactor
71 .. 74 reactor
71 .. 69
Distillation column H(m) 5 5 4
Reflux ratio 5 . 888
Ethanol fraction 0 . 945 0 . 9068
Design of process equipment
1st the spherical tank
• We will use 5 tanks
•
• Each tank has diameter of 12 m
•
• And thickness of 7.56 cm
2nd the first stage compressor
• We will use one individual horizontal

compressor that is characterized by:
• Cylinder (8x7) inch & PD= 180 CFM &
RPM=450
• BHP=324 HP
3rd the second stage
compressor
• We will use individual horizontal
compressor that is characterized by:
•
• cylinder(23*13)inch
•
• RPM=227&PD=1717CFM
•
• BHP=1840 HP
•
4th the heat exchanger
• Choose floating heat exchanger
• Shell side criteria
• We will use two shells and each one has a
diameter of 34”
• 1 pass &B=10” &P=1.25”&
• Pressure drop in shell side =1.83 psi
•
• Tube side criteria
• There will be 555 tubes in each shell
• O.D= 1'', 1.25'' Δ pitch,
I.D=0.834''=0.0695'
• B.W.G=14, De=0.072''=0.06'
• Tube length = 28 ft
• Pressure drop is negligible
5th fired heater
• We will use two furnaces for the two streams
exiting from each shell of heat exchanger
shells
• Each furnace “radiation zone”will be
characterized by:
• 6 tube/pass
• 42 tubes
• Choose 6" tube with criteria
• O.D=6.625 ", I.D=6.065 "
• TCD= 10 ft
• VTL=35 ft
• ΔP =0.0215 Psi
6th the reactor
• We will use fixed bed catalytic reactor that
has the following criteria:
•
• H= 5 M, D= 1.4 M ,
•
• V=7.7 M3
•
• Space velocity= 2000 hr-1
•
Distillation coloumn
• We will use that has the following criteria:
• Total number of trays =24 trays
•
•
Thank You!
L/O/G/O
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synthetic Fermentation
• Continuous process • Slow process

• Batch process
Ethanol
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PRODUCTION METHODS
FERMETATION
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ETHANOL

wood, agricultural residues

2) Hydrolysis of ethyl sulfates to ethanol:

300 6.7 10.3 12.5 18.3

• Continuous process • Slow process

What are HAZOP used Review of existing facility to uncover

Why HAZOP? Convention review techniques are

3 HIGH Ambient Conditions Explosion Temperature control External cooling

4 LOW Control Low Temperature Regular

• We will use one individual horizontal

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• How do I incorporate my logo to a slide

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the contents Click to add Text

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