PRODUCTION OF 2-ETHYLHEXANOL FROM
PROPYLENE AND SYNTHESIS GAS
PROCESS INSTRUMENTATION DESCRIPTION
ALBERO Apple Joy, DIAMANTE Ma. Heresa C., EDQUIBAL Kristelle H., GUEVARRA Mark Carlo A., MENDOZA Kinski R., RAMIREZ Charlyn Joy F.
Storage Tank 1
Synthesis gas is stored in ST1. Pressure is controlled by PIC 101 through RV 1 based on the transmission of PT 101. Pressure control is installed to ensure the safety condition inside the gas tank.
Compressor 1
Synthesis gas is compressed to achieve high pressure of the gas to control the flow of the gas. Computer programmable FIC 101 is installed before the compressor to maintain to proper flow rate of the feed. The system elements can be controlled manually via M1 if the programmable controller fails to operate. Pressure is also controlled by PIC 102 to achieve and maintain proper operating condition inside the compressor.
Heat Exchanger 1
After compressor, the gas will be subjected to water cooling in the heat exchanger. Based on the transmission of TI 101, temperature of the cooling water is controlled by TIC 101 through valve V3. Proper flow rate of the gas is controlled by FIC 102 before entering H1 through V2. M2 is installed as a substitute if the programmable controller fails to operate.
Storage Tank 2
Liquid Propylene is stored in ST2.
Pump 1
Flow of propylene to pump is controlled by FIC 111 through V5. Proper action will be taken after transmission of FT 111. M4 is installed as a substitute if the programmable controller fails to operate.
Boiler 1
Before entering the boiler, flow rate and liquid level inside the tank is maintained by V6 with the help of FIC 112 and LIC 112 based on the transmitted data of FT 112 AND LT 112. Also M5 is installed to manually control the system if the programmable controller fails to operate.
Compressor 2
Computer programmable FIC 113 is installed before the compressor to maintain to proper flow rate of the feed through V7. Temperature and pressure is also controlled by installing TIC 111 and PIC 111 to achieve and maintain proper operating condition inside the compressor. The system elements can be controlled manually via M6 if the programmable controller fails to operate.
Heat Exchanger 2
After compressor, propylene will be subjected to water cooling in HE 2. Based on the transmission of TI 112, temperature of the cooling water is controlled by TIC 112 through valve V9. Proper flow rate of the gas is controlled by FIC 114 before entering H1 through V8. M7 is installed as a substitute the other control valves failed to operate.
Storage Tank 3
Carbonyl Cobalt, catalyst in the Reactor 1, is stored in the storage Tank 3.
Conveyer 1
Conveyer is used to transport the catalyst to the reactor. Flow is controlled by FC 151 through the use of FI 121 and FT 121.
Compressor 3
The recycled product, Isobutyraldehyde is subjected to Compressor 3. Pressure inside the CM 3 is controlled by PIC 131. Before entering the R1, the flow of Isobutyraldehyde is controlled by FIC 131 through valve 38. M 23.1 is installed as a safety valve in case of emergency.
Reactor R1
In the reactor, hydroformylation ( oxo) reaction takes place to produce n-butyraldehyde. To achieve the desired conversion efficiency of the product, the temperature, pressure, quality as well as the level in the reactor should be maintained. FC100 will control the flow through V4 of
the reactants entering the reactor. The action will depend on the reading transmitted by the flow meter. The quality will be checked by the quality sensor installed in the reactor. The reading will then be transmitted by QT 151 to QIC151. Temperature and pressure are also maintained in the reactor. Temperature and pressure transmitter will transmit the reading on the respective control valves. A relief valve RV2 control the pressure in the reactor. Manual valve M3 is installed in case the programmable control valves don’t function correctly.
Gas – Liquid Separator I (SR1)
The products from the reactor then proceed to the Turbine 1 (T1) to adjust the pressure. The pressure on the outlet stream of the turbine 1 will be controlled. The fluid from the turbine 1 will pass through the Heat Exchanger 3 to lower the temperature. Inlet of the cold water will be controlled by valve 12 (V12) to regulate the temperature of the fluid exiting the heat exchanger. After the heat exchanger, it will be pumped by Pump 2 (P2). From the pump, the fluid will enter the liquid-gas separator 1 (SR1). In the separator 1, the level of the fluid inside will be controlled by valve 13 (V13) and manual valve 11 (M11). Also, the pressure inside the separator 1 will be controlled. The pressure inside will be regulated by the Relief Valve 3 (RV3). The temperature of the fluid exiting the separator 1 will also be regulated by controlling the inlet of the hot water entering the separator through Valve 17.1 (V17.1). The product of the separator will be of two streams, one will go to the turbine 2 and the other one will proceed to the filter press 1.
Filter Press (F1)
From the separator 1, the product will be pumped by Pump 3 (P3) to the filter press 1. The flow of the fluid will be regulated by Valve 14 (V14) and Manual Valve 12 (MV12). It will then pass through the Filter press 1 (FP1). The liquid product will be stored in the storage tank 4 (ST4) where the level of the fluid inside will be controlled by Valve 15 (V15) and Manual Valve 13 (V13). The filter cake from the Filter press 1 will then go to the Conveyor 2 (CV2)
Gas-Liquid Separator II (SR2)
Gas product from the Separator 1 (SR1) will pass through Turbine 2 (T2) to adjust the pressure. The flow of the gas exiting the Turbine 2 (T2) will be regulated by Valve 16 (V16) and Manual Valve 14 (MV14). The gas will then be pumped to the Separator 2 (SR2) by Pump 4 (PP4) where the exiting flow rate will be controlled by Valve 17 (V17) and Manual Valve 14 (MV14). The fluid will enter the Separator 2 (SR2). The level and the pressure inside the separator 2 (SR2) will be controlled by the Valve 17 (V17) and Manual Valve 15 (MV15) and Relief Valve 4 (RV4),
respectively. Two products will be produced from the Separator 2 (SR2). One product will be pumped into Storage Tank 5 (ST5) by Pump 5 (PP5), the pressure inside the tank will regulated by the Relief valve 5 (RV5). The other product will be pumped to the Distillation Column 1 (DC1) by Pump 6 (PP6).
Distillation Column I (DC1)
N-butylraldehyde, isobutyraldehyde, isobutanol, n-butanol, H20, 2-ethylhexanol, high molecular weights compound are being pumped by PP6 before going to the distillation column DC1. The flow is regulated by V18 and checked by FIC 401 in which if any deviation occurs; FT 401 will then transmit the changes then a corrective action is then taken through a controller installed. Manual valve M17 is installed to ensure that the flow of the fluid entering the column will be controlled in case the control valve malfunctioned.
Pressure in the column is regulated by RV6 and monitored by PIC 401 with reading being transmitted by PT 401.Temperature is monitored in the column through TT 401 and the corrective action will be acted by TIC 401. The deviation in the temperature in the column will be controlled via reboiler RB1 by regulating the heating fluid flow via valve V22.
Quality and the exit flow in the reboiler are regulated by valves V19 and V20. Likewise, it is monitored by comparing the flow in the boilup and bottom via FC 405 with their reading being transmitted by FT 401 and FT 403 respectively through FI 402 and FI 403.
Similarly, quality and the exit flow in the RF1 is monitored by comparing the flow in the reflux and distillate via FC 407 with the reading being transmitted by FT 404 and FT 405 respectively through FI 404 and FI 405. Regulation and corresponding actions is then acted upon by valves V25 and V26. In addition their temperature is monitored TT402 and TIC402 and is regulated by controlling the flow in the heating fluid via V24.
Distillation Column II (DC2)
The distillate product from Distillation Column 1 is being pumped by PP7 with their flow being regulated by V27 and checked by FIC 501 with reading being transmitted by FT 501 with corrective action to be taken through a controller installed. Manual valve M19 is installed to ensure that the flow of the fluid entering the column will be controlled in case the control valve malfunctioned.
Pressure in the column is regulated by RV6 and monitored by PIC 501 with reading being transmitted by PT 501.Temperature is monitored in the column through TT 501 and the corrective
action will be acted by TIC 501. The deviation in the temperature in the column will be controlled via reboiler RB2 by regulating the heating fluid flow via valve V28.
Quality and the exit flow in the reboiler are regulated by valves V29 and V30. Likewise, it is monitored by comparing the flow in the boilup and bottom via FC 506 with their reading being transmitted by FT 502 and FT 503 respectively through FI 502 and FI 503.
Similarly, quality and the exit flow in the RF2 is monitored by comparing the flow in the reflux and distillate via FC 507 with the reading being transmitted by FT 504 and FT 505 respectively through FI 504 and FI 505. Regulation and corresponding actions is then acted upon by valves V32 and V33. In addition their temperature is monitored TT 503 and TIC 503 and is regulated by controlling the flow in the cooling fluid via V34.
Stripper (S) (Cracker)
The isobutyraldehyde top stream will undergo cracking to convert isobutyraldehyde to propylene, carbon monoxide, and hydrogen at a pass yield of 80% by passage over a catalyst with steam from the fired heater. The level inside the cracker is regulated by the flow controller 603 and its temperature will always operate at 275̊ C and 1 bar. The temperature will be controlled by manipulating Valve 39, and Pressure beind relieved at Relief Valve 8.
Gas Separator (SR3)
It separates propylene, CO and H2 from isobutyraldehyde. The isobutyraldehyde will be pumped by PP10 back to the cracker inlet and the cracked gas is compressed by CM3 and is recycled to the hydroformylation reactor. FIC 604 is responsible in regulating the inlet flow of the separator via valve 37.
Mixer
The liquid mixer consists of two mixing liquids – n-butyraldehyde and aqueous NaOH solution. Level sensor is installed in the mixer to maintain the level of the solution. Inlet/outlet valves with pumps for releasing mixing liquids before proceeding to the reactor is also installed in the pipe. The system elements can be controlled manually via M23 and M24 if the programmable controller fails to operate.
Reactor R2
In the reactor, aldol condensation takes place. To achieve the desired conversion efficiency of the product, the temperature, pressure, quality as well as the level in the reactor should be maintained.
FC802 will control the flow through V39 of the reactants entering the reactor. The action will depend on the reading transmitted by the flow meter. The quality will be checked by the quality sensor installed in the reactor. The reading will then be transmitted by Q801 to QIC801. Temperature and pressure are also maintained in the reactor. Temperature and pressure transmitter will transmit the reading on the respective control valves. A relief valve RV9 control the pressure in the reactor. Manual valve MN25 is installed in case the programmable control valves don’t function correctly.
Separator SR4
The products of the reaction which are 2-ethylhexanal and water will be separated by the separator SR4. 2-ethylhexanal will undergo hydrogenation to convert it to 2-ethylhexanol while the water will be stored in the storage tank ST8.
The flow of the products going out of the reactor is measured by the flow meter. FT901 will transmit the reading to V40 which will control the flow depending on the reading transmitted by FT901. Manual valve M26 will adjust the flow of the outgoing products in the reactor if the control valve malfunctioned. The level and the pressure of the separator will be controlled by sensors. The pressure and the level inside the separator will be automatically controlled by RV10 and V41 respectively. M27 will be used as a backup valve. The level inside ST8 will be monitored by a level sensor installed in it.
Reactor 3
The feeds to this reactor are 2-ethylhexanal and hydrogen gas. Pressure inside the storage tank of hydrogen will be regulated using RV12. Compressor will be used to deliver the hydrogen gas into the reactor. The flow before and after the compressor will be controlled using V44 and V45. Temperature, pressure, quality and the level in the reactor should be controlled to achieve maximum conversion.
FC774 will control the flow through V43 of the reactants entering the reactor. The corresponding action will depend on the reading transmitted by the flow meter. The quality will be checked by the quality sensor installed in the reactor. The reading will then be transmitted by Q771 to QIC771. Temperature and pressure transmitter TT773 and PT773 will transmit the
reading on the respective control valves. A relief valve RV9 control the pressure in the reactor. Manual valve MN29 is installed in case the programmable control valves don’t function correctly.
Separator SR5
Separator SR5 separates 2-ethylhexanol from 2-ethylhexanal (not all the product is converted to 2-ethylhexanol). The main product 2-ethylhexanol will be stored in tank ST10.
The flow of the products going out of the reactor is measured by the flow meter. FT661 will transmit the reading to V47 which will control the flow depending on the reading transmitted by FT661. Manual valve M32 will adjust the flow in case the control valve malfunctioned. The level and the pressure of the separator will be controlled by sensors. The pressure and the level inside the separator will be controlled using the valves RV1 and V48 respectively. M33 and M34 will be used as a backup valve. 2-ethylhexanol and the other products will be pumped by PP17 and PP18 respectively before going to the heat exchanger. Heat exchanger HE8 and HE9 is needed to cool down the product before storing it the tank. The temperature of the heat exchanger HE8 will be controlled by V49 while V50 will control the temperature of HE9. 2-ethylhexanol which is the main product will be stored in tank ST10 while the other products will be stored in tank ST11. A level sensor will detect the liquid level inside the tanks, it will transmit the reading to V51 for ST10 and V52 for ST11. The valves will indicate and will control the level depending on the reading transmitted. Manual valves M36 and M37 will be installed to ensure that the level of the liquid in the tanks will be controlled in case the control valves malfunctioned.
Fire Heater (FH)
It supplies steam to the whole process. The temperature is being regularly checked by the temperature indicator and controller. It also has a level indicator and controller to maintain the level of the water inside the heater.
