A Project report on

DESIGNING A PLANT FOR THE PRODUCTION

OF 200 TPA OF ISOPROPYL ALCOHOL
A Report submitted in partial
Fulfillment of the Requirements for the Award of the Degree of

BACHELOR OF TECHNOLOGY
IN
CHEMICAL ENGINEERING

By

P. Santosh Kumar (20331A0833) N. Dhanaraju (21335A0810)

K. Sai Kumar (20331A0819) K.Narayana (20331A0821)

Under the Esteemed Guidance of

Mr. G. Ravi Kishor (M. Tech, MS)

Assistant Professor

DEPARTMENT OF CHEMICAL ENGINEERING

MAHARAJ VIJAYARAM GAJAPATHI RAJ COLLEGE OF

ENGINEERING (A), VIZIANAGARAM
2020-2024
 MAHARAJ VIJAYARAM GAJAPATHI RAJ COLLEGE OF
ENGINEERING (A), VIZIANAGARAM

DEPARTMENT OF CHEMICAL ENGINEERING

CERTIFICATE

This is to certify that the dissertation thesis entitled "DESIGNING A PLANT FOR THE
PRODUCTION OF 200TPA OF ISOPROPYL ALCOHOL" being submitted by P.Santosh
Kumar (20331A0833), K.Saikumar (20331A0819), N.Dhanaraju (21335A0810), K.Narayana
(20331A0821), in the partial fulfillment of the requirement for the award of the degree of
"Bachelor of Technology" in Chemical Engineering from M.V.G.R College of Engineering(A),
Vizianagaram affiliated to JNTUGV in a record of bonafide work carried out by them under my
supervision and guidance during the academic year 2020-2024.

Place: Vizianagaram
Date:

Mr. G. Ravi Kishor Prof. B. Sarva Rao

Assistant Professor Professor
Project Supervisor Head of the Department
 ACKNOWLEDGEMENT

We would like to take this opportunity to respectfully acknowledge the encouragement and
guidance given by our project guide Mr. G. Ravi Kishor, Assistant Professor, Department
of Chemical Engineering for his/her whole hearted co-operation and valuable guidance
throughout the project work.

We consider it our privilege to express our sincere thanks to Dr. B.Sarva Rao, Professor,
Head of the Department, for his valuable suggestions and constant motivation that greatly
helped our project to get successfully completed.

We also thank Dr. R.Ramesh, Principal, MVGR College of Engineering (A) for extending
his utmost support and cooperation in providing all the provision for the successful
completion of project.

We sincerely thank all the faculty members of our department for their sustained help and
guidance throughout our Project.

We thank all those who contributed directly or indirectly in successful completion of this
work.

Place: Vizianagaram
Date:
P.Santosh Kumar (20331A0833)
K.Sai kumar (20331A0819)
N.Dhanaraju (21335A0810)
K.Narayana (20331A0821)
 DECLARATION

We, P.Santosh Kumar (20331A0833), K.Sai kumar (20331A0819), N.Dhanaraju (21335A0810),

K.Narayana (20331A0821) do hereby declare that this work entitled " Designing a Plant for the
Production of 200TPA of Isopropyl Alcohol" has been originally carried out by us under the
esteemed guidance of Mr. G. Ravi Kishor, Assistant Professor, Department of Chemical
Engineering, in the partial fulfillment of the requirement for the award of the degree of Bachelor
of Technology in Chemical Engineering from M.V.G.R College of Engineering, Vizianagaram.
We also declare that we have not submitted this dissertation to any other university for the award
of any other degree.

Place: Vizianagaram Signature:

Date: 1.
2.
3.
4.
 ABSTRACT

Designing a Plant for the Production of 200TPA of Isopropyl Alcohol

The project titled "Designing a Plant for the Production of 200TPA of Isopropyl Alcohol"is
primarily focused on addressing the material balance and energy balances of the various unit
operations involved in the process, as well as delving into the design aspects of two pivotal pieces
of equipment, namely the high-pressure separator and distillation column. Furthermore,
comprehensive discussions encompassing cost estimation, detailed plant layout, instrumentation,
process control, and safety aspects have been thoroughly incorporated into the project's scope.

Keywords: Material balance, Energy balance, Unit operations, Design, Key equipment, Plant
layout, Instrumentation, Process control, Safety aspect
 DEPARTMENT OF CHEMICAL ENGINEERING
PROGRAM OUTCOMES
PO 1: Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
PO 2: Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
PO 3: Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
PO 4: Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
PO 5: Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex engineering
activities with an understanding of the limitations.
PO 6: The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice.
PO 7: Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the knowledge
of, and need for sustainable development.
PO 8: Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
PO 9: Individual and team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
PO 10: Communication: Communicate effectively on complex engineering activities with
the engineering community and with society at large, such as, being able to comprehend and
write effective reports and design documentation, make effective presentations, and give and
receive clear instructions.
PO 11: Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a memberand
leader in a team, to manage projects and in multidisciplinary environments.
PO 12: Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological change.

PROGRAM SPECIFIC OUTCOMES

PSO1: An ability to solve chemical engineering problems using analytical methods and
modern tools and techniques
PSO2: An ability to design, operate, maintain and troubleshoot chemical process equipment.
 CONTENTS
Page no
CERTIFICATE 2

ACKNOWLEDGEMENT 3

DECLARATION 4

ABSTRACT 5

PROGRAM OUTCOMES 6

CHAPTER – 1: INTRODUCTION 10-16

1.1 Introduction 11
1.2 Indian Scenario 11
1.3 Synonyms 12
1.4 Properties 13
4.1 Chemical Properties 14
1.5 Applications 15-16

CHAPTER -2 LITERATURE REVIEW 17-19

2.1 Methods of production 18
2.1.1 Hydration of propylene via Sulphation and hydrolysis 18
2.1.2 Isopropanol is prepared by the hydration of propylene 18-19

CHAPTER-3 PROCESS DESCRIPTION 20-23

3.1 Process description 21-23

CHAPTER-4 MATERIAL AND ENERGY BALANCE 24-41

4.1 MATERIAL BALANCE 24
4.1.1 Reactor 25-27
4.1.2 High pressure separator 28-29
4.1.3 Low pressure separator 30-31
4.1.4 Light end distillation column 32-33

Page | 7
 4.1.5 Dehydration column 34-36
4.1.6 Azeotropic column 37-40
4.1.7 Benzene recovery column 41-42

4.2 ENERGY BALANCE 43-52

4.2.1 Reactor 43-44

4.2.2 High pressure separator 45-46

4.2.3 Low pressure separator 47-48
4.2.4 Energy balance for distillation column 49
4.2.5 Azeotropic distillation unit 50-52

CHAPTER-5 EQUIPMENT DESIGN 53-60

5.1 Design of high-pressure separator 53-54
5.2 Design of light end distillation column 55-61

CHAPTER-6 COST ESTIMATION 62-65

CHAPTER-7 PLANT LAYOUT AND
INSTRUMENTATION CONTROL 65-75
7.1 Plantlayout 66-68
7.2 Instrumentation 69-72
7.3 Industrial safety 73-75

CHAPTER-8 CONCLUSION AND REFERNCES 76-78

8.1 Conclusion 76-77
8.2 References 78

CHAPTER-8 APPENDIX 79-84

8.1 Appendix A 80
8.2 Appendix B 81
8.3 Appendix C 82
8.4 Appendix D 83-84

Page | 8
 List of figures and tables

Figure Name of the figure page no

1 flow sheet for production of isopropyl 23

Table Name of the table

6.1 Equipment name and cost 63
6.2 Factors dependent on direct costs 63
6.3 Factors dependent on indirect costs 63
6.4 Direct production costs 64
6.5 Fixed charges 64
6.6 General expense 64

Page | 9
 CHAPTER – 1
INTRODUCTION

Page | 10
 1.INTRODUCTION
1.1 INTRODUCTION

Isopropyl alcohol is a chemical compound with the molecular formula C3H8O or

C3H7OH. It is a colorless, flammable chemical compound with a strong odor. It is the
simplest example of a secondary alcohol, where the alcohol carbon atom is attachedto
two other carbon atoms sometimes shown as (CH3)2CHOH. It is a structural
isomer of propanol.In 1994, 1.5 million tons of isopropyl alcohol were produced in the
United States, Europe, and Japan. This compound is primarily produced by combining
water and propene in a hydration reaction. It is also produced by hydrogenating acetone.

There are two routes for the hydration process: indirect hydration via the
sulphuric acid process, and direct hydration. The former process, which can use low-
quality propene, predominates in the USA while the latter process, which requires high-
purity propene, is more commonly used in Europe. These processes give predominantly
isopropyl alcohol rather than 1-propanol because the addition of water or sulphuric acid
to propene follows Markovnikov's rule.

1.2 Indian Scenario

Deepak Fertilizers & Chemicals

Deepak Fertilizers and Petrochemicals Corporation Limited has set up India's

largest plant for producing Isopropyl Alcohol with an installed capacity of 70,000
MT per year at Taloja near Mumbai.

International Quality

Isopropyl Alcohol is manufactured using the direct hydration process, which

is an extremely efficient and environmental-friendly process. It produces a sparkling
colorless product of high purity with no undesirable odor or by-product formation. The
product meets International Standards for use in pharmaceuticals, agrochemicals,
specialty chemicals and other critical applications.

Reliance Industries Limited

Reliance Industries Limited also manufactures isopropyl alcohol with a plant

capacity of 30,000 Tons/Annum.

The total production in India is 100,000 Tons per annum

Page | 11
1.3 Synonyms of isopropyl alcohol

Isopropyl Alcohol, Isopropanol, 2-Propanol, IPA, Propyl Alcohol, 2-Propyl

alcohol, Propan-2-ol, Dimethyl carbinol, 1-Methulethanol, 2-Hydroxy propane, 2-
Hydroxy propane. In this report, the synonyms of Isopropyl alcohol, IPA and 2-
Propanol are used.

Page | 12
1.4 PROPERTIES

Physical Properties:

IUPAC Name Propan-2-ol

Molecular Formula C3H8O

Molar mass 60.10 g mol−1

Appearance Colorless liquid

Density 0.786 g/cm3 (20 °C)

Melting point −89 °C (−128 °F; 184 K)

Boiling point 82.6 °C (180.7 °F; 355.8 K)

Solubility in water miscible

Solubility miscible in benzene, chloroform, ethanol, ether,

glycerinsoluble in acetone
insoluble in salt solutions

Flash Point Open Cup: 11.7oCClosed

Cup: 13oC

Refractive index(nD) 1.3776

Viscosity 2.86 cp at 15 °C
1.96 cp at 25 °C
1.77 cp at 30 °C

Page | 13
1.4.1 Chemical Properties:

1. Reaction with Halogen Acids: Alcohols react with halides to form the
corresponding halo alkanes. The reaction occurs at a slower rate compared to
its primary alcohol counterpart due to the electron pulling effect of secondary
alkyl group.

CH3CH(OH)CH3 + HBr CH3CH(Br)CH3 + H2O

(Isopropyl alcohol) (Hydrogen Bromide) (2-Bromopropane)

2. Reactions with metals:

2CH3CH(OH)CH3 + 2M 2CH3CH(OM)CH3 + H2O

(Propan-2-ol) (Metal isopropoxide)

3. Formation of ketones: The alpha hydrogen can removed 2o carbon of

isopropylalcohol to form corresponding ketones (acetone).

K2Cr2O7
2CH3CH(OH)CH3 CH3COCH3
(Propan-2-ol) (acetone)

Page | 14
1.5 APPLICATIONS

The vast majority of isopropyl alcohol was used as a solvent for coatings or for
industrial processes. Isopropyl alcohol in particular is popular for pharmaceutical
applications, and is also used as a chemical intermediate. It is also used as a gasoline
additive.

Solvent
Isopropyl alcohol dissolves a wide range of non-polar compounds. It also
evaporates quickly and is relatively non-toxic, compared to alternative solvents. Thus,
it is used widely as a solvent and as a cleaning fluid, especially for dissolving oils.
Together with ethanol, n-butanol, and methanol, it belongs to the group of alcohol-
based solvents, about 6.4 million tonnes of which utilized worldwide in 2011.

Examples of this application include cleaning electronic devices such as contact

pins (like those on ROM cartridges), magnetic tape and disk heads (such as those in
audio and video tape recorders and floppy disk drives), the lenses of lasers in optical
disc drives (e.g., CD, DVD) and removing thermal paste from heat sinks
and IC packages (such as CPUs).

Isopropyl alcohol is used in keyboard, LCD and laptop cleaning, is sold

commercially as a whiteboard cleaner, and is a strong but safer alternative to common
household cleaning products. It is commonly used to clean prepared optical fibres just
before splicing. It is used to clean LCD and glass computer monitor screens (at some
risk to the anti-reflection coating on some screen), and used to give second-hand or
worn non-vinyl phonograph records newer-looking sheen. It is effective at removing
Hot-Melt Adhesive from a large variety of surfaces, residual glue from some sticky
labels. It can also be used to remove stains from most fabrics, wood, cotton, etc.In
addition, it can also be used to clean paint or other oil-based products so that they may
be reused. It is used as a wetting agent in the fountain solution used in lithographic
printing, and often used as a solvent for French polishing shellac used in cabinet
making.

Page | 15
Intermediate
Isopropyl alcohol is esterified to give isopropyl acetate, another solvent. It reacts
with carbon disulfide and sodium hydroxide to give sodium isopropylxanthate,a
herbicide and an flotation reagent. Isopropyl alcohol reacts with titanium tetrachloride
and aluminium metal to give titanium and aluminium isopropoxides, respectively, the
former a catalyst, and the latter a chemical reagent. This compound may serve as a
chemical reagent in itself, by acting as a dihydrogen donor in transfer hydrogenation.

Medical
Disinfecting pads typically contain a 60–70% solution of isopropyl alcohol
in water. A 75% v/v solution in water may be used as a hand sanitizer. Isopropyl alcohol
is used as a water-drying aid for the prevention of otitis external, better known as
swimmer's ear.

Automotive
Isopropyl alcohol is a major ingredient in "gas dryer" fuel additives. In
significant quantities, water is a problem in fuel tanks, as it separates from the gasoline,
and can freeze in the supply lines at cold temperatures. It does not remove water from
gasoline; rather, the alcohol solubilizes water in gasoline. Once soluble, water does not
pose the same risk as insoluble water, as it will no longer accumulate in the supply lines
and freeze. Isopropyl alcohol is often sold in aerosol cans as a windshield de-icer.
Isopropyl alcohol is also used to remove brake fluid traces from hydraulic braking
systems, so that the brake fluid (usually DOT 3, DOT 4, or mineral oil) does not
contaminate the brake pads, which would result in poor braking.

Laboratory
As a biological specimen preservative, isopropyl alcohol provides a
comparatively non-toxic alternative to formaldehyde and other synthetic preservatives.
Isopropyl alcohol solutions of 70–99% are used to preserve specimens.

Isopropyl alcohol is often used in DNA extraction. It is added to a DNA solution

in order to precipitate the DNA into a 'pellet' after centrifuging the DNA. This is
possible because DNA is insoluble in isopropyl alcohol.

Page | 16
 CHAPTER -2
LITERATURE REVIEW

Page | 17
 2.LITERATURE REVIEW

2.1 METHODS OF PRODUCTION

2.1.1 Hydration of propylene via Sulphation and hydrolysis:

Propylene mixed with C2-C3 hydrocarbon is absorbed in 70-75% H2SO4 at 20-
25 atm. The reaction is exothermic sulphation which is kept at 20-300C by refrigerated
brine circulation. The solution is hydrolysed in steam stripper which removes the
organic phase as a vapour. Weak acid is sent from the bottom to a concentrator. The
product vapour is fractionally condensed with the non condensable olefin fractions
returned to the sulphation step. The solution containing alcohol and ether is sent to the
ether column and isopropyl alcohol column. The distillate is sent to Azeotrope column
where it separates 87% isopropanol and 99% isopropanol.

CH3CH=CH2 + H2SO4 CH3CH(OSO3H)CH3

(Propylene) (Isopropyl-acid sulphate)

CH3CH(OSO3H)CH3 + H2O CH3CH(OH)CH3 + H2SO4

(Isopropyl-acid sulphate) (Isopropyl alcohol)

2.1.2 Isopropanol is prepared by the hydration of propylene:

It is a process for producing Isopropyl alcohol by direct liquid phase hydration
of propylene and water in the presence of a strong acid solid catalyst at a high
temperature and a high pressure. The reaction is carried out at a temperature ranging
between 100° and 250°C and a pressure ranging between 60 and 200 atm.
Water/Propylene molar ratio is maintained in a ratio of around 1:12. Overall Conversion
is 90% wt. of propylene to isopropanol where 3.5% wt. of isopropyl alcohol is
converted to diisopropylether. In the reactor single pass there is a 75% conversion by
weight of propylene content of the feedstock. Unreacted propylene is separated from
the reactor product stream in a series of two flash separators. The second separator is
operated at a pressure lower than the first. Unreacted propylene is recycled back to the
reactor. The aqueous product stream containing isopropyl alcohol, DIPE, water are
further separated in series of 4 distillation columns to produce 98% anhydrous alcohol.
The isopropyl alcohol-water azeotropic mixture after separation of light ends and water
Page | 18
in two distillation columns goes to azeotropic distillation column where benzene is used
as entrainer for separation of isopropyl alcohol.
Main reaction:
C3H6 + H2 O CH3CH(OH)CH3
(Propene) (Water) (Isopropanol)

By-product reaction:
2CH3CH(OH)CH3 (C3H7)2O + H2 O
(Isopropanol) (DIPE) (Water)

Page | 19
 CHAPTER-3
PROCESS DESCRIPTION

Page | 20
 3.PROCESS DESCRIPTION

3.1 PROCESS DESCRIPTION

This method of production of isopropyl alcohol requires gaseous propylene and water
as the raw material.

The raw material is fed to a trickle bed reactor in a 1:12 molar ratio of propylene and
water respectively.

The reactor consists of beds where the solidcatalyst like strong acid cation exchange
resins is used.

The reaction takes place at an operating temperature of around 1400C and pressure 100
MPa.

The reaction of propylene and water gives isopropyl alcohol which further undergoes a
side reaction togive some amount of water, Di isopropyl ether.

The reactor outlet consisting of water, Di isopropyl ether and unreacted propylene
undergoes high pressure separation using a flash drum or a high-pressure separator. The
high-pressure separator separates most of the unreacted propylene from the mixture and
this separation process is followed by a low-pressure separation process which removes
all the unreacted propylene.

The unreacted propylene is recycled back to the reactor to maintain high efficiency of
the process and reduce wastage of the raw material.

The process has high overall conversion of 95-99% which can be achieved by
controlling by production of Di isopropyl ether during the reaction and recycling high
amounts of unreacted propylene.

Di isopropyl ether is removed from the mixture as distillate, by using a light end
separation column. Isopropyl alcohol and water is removed as bottom product.

Since, a typical process require at least ten times in mole as water as that of raw material
propylene to be supplied into inlet of the reactor, the resultant aqueous solution of crude
isopropyl alcohol has a concentration of around 10-30% by weight.2
Page | 21
On the other hand, since most of the isopropyl alcohol produced by theprocess is in
anhydrous form, therefore the concentration of isopropyl alcohol in the aqueous phase
has to be increased.

This is done in a Prehydration column which separates out most of the water content.
Water is then sent for waste water treatment and recycled to the process.

Now, the concentration of isopropyl alcohol goes up to 87-88% by wt. which is an

azeotropicmixture of isopropyl alcohol and water.

Therefore, in the industrial field, to the crude isopropyl alcohol of about 98% purity or
more, Azeotropic distillation is performed using an adequate entrainer like benzene.

The benzene forms a ternary azeotrope with isopropyl alcohol and water which is
send to a settler where it separates into two insoluble liquid layer ,the benzene rich
layer is refluxed into the distillation column, while the water rich layer is sent for
benzene recovery 98% anhydrous isopropyl alcohol is collected as bottom product from
the Azeotropic distillation column.

Page | 22
Figure 1: flow sheet for the production of isopropyl alcohol

Page | 23
 CHAPTER-4
MATERIAL AND ENERGY BALANCES

Page | 24
 4.MATERIAL AND ENERGY BALANCES
4.1 MATERIAL BALANCE
4.1.1 REACTOR

Reactions taking place inside the reactor:

C3H6 + H2O CH3CH(OH)CH3
Propylene(g) Water(l) Isopropyl alcohol(l)

2CH3CH(OH)CH3 (C3H7)2O + H2O

Isopropyl alcohol(l) Diisopropyl Ether(l) Water(l)

Basis: 100 Tons per annum of Isopropyl alcohol. (Continuous process)

Reactants

Quantity
Stream number Reactant Name
kmoles/h kg/h
S01 Fresh Propylene 0.694 28.91

R01 Recycle Propylene 0.184 7.66

S02 Water 8.328 149.90
Total in: 186.47

Note: The amount of water added in excess. Molar ratio of 1:12 with respect to fresh
propylene.
Single pass conversion through the reactor is 75%, whereas the overall
conversion is 95%. This data is necessary when calculating the amount of
propylene recycle.
Also, 3.5% (by wt) of Isopropyl alcohol formed in the reactor is converted to
Diisopropyl ether, the essential by product of the whole production process.
To calculate the extent of reaction (ξ):
−(𝑢𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒 )𝜉
𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑓𝑟𝑒𝑠ℎ 𝑓𝑒𝑒𝑑

Where, 𝑢𝑖 = 𝑠𝑡𝑜𝑖𝑐ℎ𝑖𝑜𝑚𝑒𝑡𝑟𝑖𝑐 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖

Therefor,
(0.95) * (0.694)
𝜉= = 0.660 𝑘𝑚𝑜𝑙𝑒𝑠
−(−1)
Page | 25
To calculate amount of recycle:
−(𝑢𝑝𝑟𝑜𝑝𝑦𝑙𝑒𝑛𝑒)𝜉
𝑆𝑖𝑛𝑔𝑙𝑒 𝑝𝑎𝑠𝑠 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 = Amount of fresh feed propylene + recycle(R)

Therefore,

-(-1)(0.660)
𝑅= − 0.694 = 0.186 𝑘𝑚𝑜𝑙𝑒𝑠
(0.75)

Species balance has been performed using the following equation:

𝑛 =𝑛 +𝑢 ξ
Hence,
Amount of IPA formed: 𝑛 = 0 + (1)(0.660)
= 0.660 𝑘𝑚𝑜𝑙𝑒𝑠/ℎ

Amount of IPA reacted to form DIPE:

3.5 wt % of IPA reacts to form diisopropyl ether.
Molecular weight of isopropyl alcohol = 60.98 kg/kmol
0.660 moles of IPA = 0.660 *60.98 = 40.25 kg/h
3.5 % of 40.25 kg/h = 1.409 kg/h
According to stoichiometry, amount of diisopropyl ether formed = 1.409/2
= 0.705 kg/h
Molar mass Diisopropyl Ether =102.18*0.705
=0.006 kmol/hr
Molar mass Isopropyl Alcohol = 60.1

Amount of unreacted propylene:

nout
Propylene = 0.694 + (-1)(0.660)

= 0.0347 𝑘𝑚𝑜𝑙/ℎ

Page | 26
Products:

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.660 39.66

Water 7.92 142.56

S05
Diisopropyl Ether 0.006 0.70
Unreacted Propylene 0.034 1.41
Total out: 186.47

Page | 27
4.1.2 HIGH PRESSURE SEPARATOR

The high-pressure separator is a horizontal flash vessel, which is used to

separate the unreacted propylene gas from the product mixture leaving the
reactor.

S06 F : 1.13kg/h
Propylene : 1.13kg/h
Temp. : 1400C

:184.33kg/h
IPA : 39.66kg/h
Water : 142.56kg/h
: 0.70 kg/h
Propylene: 1.41 kg/h

F : 183.2 kg/h
IPA : 39.66 kg/h
Water : 142.56 kg/h
DIPE :0.70 kg/h
Propylene : 0.28 kg/h
Temp. : 1400C

Input:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.660 39.66
Water 7.92 142.56
S05
Diisopropyl Ether 0.006 0.70
Unreacted Propylene 0.034 1.41

Total in: 184.33

Page | 28
Assuming 80% removal of Unreacted propylene(g)
Amount of Propylene in output stream S06 = 0.034–(0.034*80%) = 0.0272
kmoles/h Amount of Propylene in output stream S07 = 0.034–(0.034*20%)
=0.0068 kmoles/h

Output:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
S06 Unreacted Propylene 0.0272 1.13
Isopropyl Alcohol 0.660 39.66
Water 7.92 142.56
S07
Diisopropyl Ether 0.006 0.70
Unreacted Propylene 0.0068 0.28
Total out: 184.33

Page | 29
4.1.3 LOW PRESSURE SEPARATOR

The low-pressure separator is a horizontal flash vessel, which is used to separate

the remaining unreacted propylene gas from the product mixture leaving the high
pressure separator.

S08 F : 0.28 kg/h

Propylene :0.28 kg/h
Temp :1400C

: 183.2 kg/h
: 39.66 kg/h
:142.56kg/h

Propylene :0.28 kg/h

F : 182.92 kg/h
IPA : 39.66 kg/h
Water : 142.56 kg/h
DIPE : 0.70 kg/h
Temp. : 1400C

Input:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.660 39.66
Water 7.92 142.56
S07
Di isopropyl Ether 0.006 0.70
Unreacted Propylene 0.0068 0.28
Total in: 183.20

Page | 30
Assuming 100% removal of Unreacted propylene(g)
Amount of Propylene in output stream S08 = 0.022 – (0.022*100%) = 0.91 kg/h

Output
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
S08 Unreacted Propylene 0.0068 0.28
Isopropyl Alcohol 0.660 39.66

S09 Water 7.92 142.56

Diisopropyl Ether 0.006 0.70

Total out: 183.20

Page | 31
4.1.4 LIGHT END DISTILLATION COLUMN

The light end distillation column is used to separate the essential by-product
Diisopropyl ether (DIPE) from the product mixture.
About 99.9% of DIPE removal takes place in this
column. Material balance equation for distillation
column:
𝐹 = 𝐷+𝐵
F = Feed, kg/h
B = Bottoms or Residue, kg/h
D = Distillate or Overhead, kg/h

LIGHT END
COLUMN

D : 0.72 kg/h
IPA : 0.01 kg/h
Water : 0.02 kg/h
DIPE : 0.699 kg/h
Temp. : 68.20C
Pressure: 1 atm

B : 182.20 kg/h
IPA : 39.65 kg/h
Water :142.54 kg/h
DIPE :0.001 kg/h
Temp. :98.10C
Pressure: 1 atm
Page | 32
Feed:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.660 39.66

S09 Water 7.92 142.56

Diisopropyl Ether 0.006 0.70

Total Feed: 182.92

Distillate:
Assuming 99.99% removal of DIPE.
Amount of DIPE in distillate = 99.99%*0.70 = 0.699 kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.000166 0.01
SD10 Water 0.001 0.02

Diisopropyl Ether 0.0068 0.699

Total Distillate: 0.72

Bottoms:
Amount of DIPE in bottoms = 0.01%*0.70 = 0.001 kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.659 39.65

S11 Water 7.90 142.54

Diisopropyl Ether 0.000009786 0.001
Total Bottoms: 182.20

Page | 33
4.1.5 DEHYDRATION COLUMN

The dehydration column separates the excess water from the bottom stream
leaving the light end separation column. The distillate leaves at a composition just
below the azeotropic composition for IPA+Water system
Azeotropic composition = Isopropyl alcohol: 87.9% (by wt.)
Water :12.1% (by wt.) Material balance
equation for distillation column:
𝐹 = 𝐷+𝐵
F = Feed, kg/h
B = Bottoms or Residue, kg/h
D = Distillate or Overhead, kg/h

DEHYDRATION
COLUMN

D : 45.09 kg/h
IPA :39.64 kg/h
Water : 5.45 kg/h
DIPE : 0.0008 kg/h
Temp : 860C
Pressure: 1 atm

F :185.50kg/h

B : 140.60 kg/h
IPA : 0.0039 kg/h
Water : 140.6 kg/h
DIPE : 0.0002 kg/h
Temp : 83.10C
Pressure: 1 atm

Page | 34
Feed:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.659 39.65

S11 Water 7.90 142.54

Diisopropyl Ether 0.000009786 0.001

S18 Water 0.195 3.518

Total Feed: 185.70

Distillate:

Assuming 99.99% recovery of IPA as distillate

Amount of IPA in distillate = 99.99%*39.65 = 39.64
kg/h Also, amount of IPA in distillate = 87.9% of D
0.879D = 39.64 kg/h
So, D = 45.09 kg/h
Therefore, Amount of water = 12.1% of D = 5.45 kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)

Isopropyl Alcohol 0.659 39.64

SD12 Water 0.302
5.45

Diisopropyl Ether 0.00000782 0.0008

Total Distillate: 45.09
*The amount of DIPE present in the distillate stream is negligible

Page | 35
Bottoms:
Amount of IPA in bottoms = 0.01%*39.65= 0.0039 kg/h
Amount of water in bottoms = (142.54+3.51) – (5.45) =140.6
kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.0000648 0.0039
Water 7.61 137.09
S13
Di isopropyl Ether 0.00000195 0.0002

Water 0.195 3.51

Total Bottoms: 140.60
*The amount of DIPE present in the bottoms stream is negligible

Page | 36
4.1.6 AZEOTROPIC DISTILLATION UNIT

To get 98% pure IPA, azeotropic distillation is used. Benzene is used as an

entertainer which breaks the azeotropic composition between IPA+Water.
Material balance equation for distillation column:
𝐹 =𝐷+𝐵
F = Feed, kg/h
B = Bottoms or Residue,
kg/h D = Overhead, kg/h

AZEOTROPE
COLUMN

S15
V : 40.54 kg/h
IPA : 12.42kg/h
Water : 4.90 kg/h
Benzene :41.90 kg/h
Temp. : 860C
Pressure: 1 atm

DECANTER

SR15 SD15

SD12 + S14

F : 87.07 kg/h
IPA : 39.64 kg/h
Water : 5.45 kg/h
Benzene :41.98 kg/h
Temp. : 850C
Pressure: 1 atm

S16 B : 27.77 kg/h

IPA : 27.22 kg/h
Water : 0.55 kg/h
Impurities :0.006 kg/h
Temp. : 83.10C
Pressure: 1 atm
Page | 37
Feed:

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.659
39.64
SD12 Water 0.302 5.45
Diisopropyl Ether 0.00000782 0.0008

S14 Benzene 0.410 41.98

Total Feed: 87.07

Bottoms:

The bottoms contain 27.77 kg/h of 98% IPA. Which gives us 200 TPA, based on
300 days of operation @ 24hrs each day.
Amount of IPA in bottoms = 98%*27.77 = 27.22 kg/h
Amount of Water in bottoms = 1.98*27.77 = 0.55 kg/h
Amount of Impurities (DIPE, C6 compounds) = 0.02%*27.77 = 0.006
kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.452 27.22

S16 Water 0.036 0.55

Impurities 0.006

Total Bottoms: 27.77

This stream is the final product stream for manufacture of 98%IPA.

For 300 days of continuous operation @ 24 hours each day

Total production = 27.77(kg/hr)*7200(hrs)

= 200 Tons per annum
Page | 38
Overhead Vapour:
Amount of Overhead = D = F – B = 87.07 – 27.77 = 59.3
kg/h Amount of IPA = 19.8% of 59.3 = 11.7 kg/h
Amount of water = 8.2% of 59.3 = 4.86 kg/h
Amount of benzene = 72% of 59.3 = 42.69 kg/h
*Percentage compositions based on Ternary Azeotrope, (See,Appendix D)

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.194 11.7

S15 Water 0.27 4.86

Benzene 0.546
42.69

Total Overhead: 59.3

Reflux:
𝑅𝑒𝑓𝑙𝑢𝑥 𝑖𝑠 𝑡ℎ𝑒 𝑏𝑒𝑛𝑧𝑒𝑛𝑒 𝑟𝑖𝑐ℎ 𝑝ℎ𝑎𝑠𝑒 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑒𝑡𝑒𝑟𝑜𝑎𝑧𝑒𝑜𝑡𝑟𝑜𝑝𝑒.
Amount of IPA=20.2% ×54.14=10.93 kg/h
Amount of water =2.3% ×54.14 = 1.24 kg/h
Amount of benzene =77.5% ×54.14 = 41.95 kg/h
*Percentage compositions based on Heterozeotrope uppper layer, (See,Appendix D)

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.182 10.95

SR15 Water 0.068 1.24

Benzene 0.537 41.95

Total Reflux: 54.14

Page | 39
Distillate:
Reflux is the benzene rich phase of the heteroazeotrope.
Amount of IPA=14.4% ×4.134= 0.595 kg/h
Amount of water =85.1% ×4.134 = 3.518 kg/h
Amount of benzene =0.5% ×4.134 = 0.020 kg/h
*Percentage compositions based on Heterozeotrope lower layer, (See, Appendix D)

Quantity
Stream Number Product Name
(kmol/h) (kg/h)

Isopropyl Alcohol 0.009 0.595

SD15 Water 0.195
3.518

Benzene 0.0002560 0.020

Total Distillate: 4.134

Page | 40
4.1.7 BENZENE RECOVERY COLUMN

Material balance equation for distillation column:

𝐹 = 𝐷+𝐵
F = Feed, kg/h
B = Bottoms or Residue,
kg/h D = Overhead, kg/h

BENZENE
RECOVERY

D : 0.615 kg/h
IPA : 0.595 kg/h
Benzene :0.020 kg/h
Temp. : 860C
Pressure: 1 atm

Benzene :0.020 kg/h

B :3.518 kg/h
Water :3.518 kg/h
Temp. : 83.10C
Pressure : 1 atm

Page | 41
Feed:
Quantity
Stream Number Product Name
(kmol/h) (kg/h)
Isopropyl Alcohol 0.009
0.595
SD15 Water 0.195 3.518
Benzene 0.0002560
0.020

Total Distillate: 4.134

Distillate:
Assuming 100% recovery of IPA and Benzene
Amount of IPA =100%×0.595 = 0.595kg/h
Amount of Benzene= 100%×0.020= 0.020 kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)

Isopropyl Alcohol 0.009 0.595

S17
Benzene 0.0002560 0.020
Total Distillate: 0.615

Bottoms:
Assuming 100% removal of water. No IPA and Benzene.
Amount of water in bottoms = 100%×3.518 = 3.518 kg/h

Quantity
Stream Number Product Name
(kmol/h) (kg/h)
S18 Water 0.195
3.518

Total Bottoms: 3.518

Page | 42
4.2 ENERGY BALANCE
STANDARD HEAT OF REACTION

Standard heat of reaction :

∆𝐻 (25 𝐶) = ∑ 𝑣 ∆𝐻 , − ∑ 𝑣 ∆𝐻 ,

Reactions ∆𝐇𝟎 (𝐤𝐉⁄𝐤𝐦𝐨𝐥)

𝐟

H20 (l) H2 + ½ O2 +285.9629 x 10-3

C3H6 (g) 3C + 3H2 -20.2 x 10-3

3C + 4H2 + ½ O2 i-C3H7OH (l) +311.088 x 10-3

C3H6(g) + H2O(l) i-C3H7OH(l) ∆𝐇𝟎 (𝟐𝟓 ℃) = -45.3251 x 10-3

𝐫𝐱𝐧

The heat of reaction at 1400C is calculated by adding the heat required to raise
products and reactants from 250C to 1400C

Formula used:

∆𝐻 = [H (T) − H (25 ℃)] − [H (T) − H (25 ℃)] + ∆𝐻 (25 𝐶)

Where, 𝐻𝑖(𝑇) − 𝐻𝑖(25 ℃) = 𝑛𝑖𝐶𝑝𝑚,𝑖∆𝑇 + 𝑛𝑖∆𝐻𝑖,𝑝ℎ𝑎𝑠𝑒 𝑐ℎ𝑎𝑛𝑔𝑒

Page | 43
4.2.1 REACTOR

To calculate heat of reaction at 1400C

C3H6 + H2O CH3CH(OH)CH3

(Propene) (Water) (Isopropanol)

Reactants:
Temperature: 1400C
Mean Specific
n nCpmΔT
Component Heat Capacity,
(kmoles/h) Cpm (kJ/kmol) (kJ/h)
Propylene(g) 4.8896 3.393
0.694

Water(l) 8.328 8718.2820 72605.8525

Recycle Propylene(g) 4.8896 0.899
0.184

𝚺𝒏𝑪𝒑𝚫𝑻 = 72610.1445
±For calculation of mean specific heat capacity (See, Appendix B)

Product:
Temperature: 1400C
Mean Specific
n nCpmΔT
Component Heat Capacity,
(kmoles/h) (kJ/h)
Cpm (kJ/kmol)
Isopropyl Alcohol(l) 0.660 22907.8258 15119.165
Unreacted Propylene(g) 0.034 4.8896 0.16634
DIPE(l) 0.006 27650.5191 165.9031
Water(l) 7.92 8718.2820 69048.79344
𝚺𝒏𝑪𝒑𝚫𝑻 = 84334.0278

Therefore,

∆𝐻𝑟𝑥𝑛 = 84334.0278− 72610.1445+ (−45325.1) = −33601.2167 𝑘𝐽/ℎ

Page | 44
4.2.2 HIGH PRESSURE SEPARATOR

Input:

Stream temperature: 1400C

Model Calculation: To calculate enthalpy of IPA input

Molar flow rate (n) = 0.660 kmol/h

Temperature of stream = 1400C
Reference Temperature = 250C
Hence, ΔT = (140 – 25)0C
Mean specific heat capacity± (Cpm) = 22907.8258 kJ/kmol
Enthalpy of IPA = n*Cpm* ΔT
= 0.660*22907.8258*(140 – 25)
= 15119.165 kJ/h

All other calculations have been performed similarly

±
For calculation of mean specific heat capacity (See, Appendix B)

Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)

Isopropyl Alcohol(l) 0.660 22907.8258 15119.165

Unreacted Propylene(g) 0.034 4.8896 0.16634
S05
DIPE(l) 0.006 27650.5191 165.9031
Water(l) 7.92 8718.2820 69048.79344
𝚺𝒏𝑪𝒑𝚫𝑻 = 84334.0278

Page | 45
Output:

Stream temperature: 1400C

The operation is isothermal expansion, hence temperature remains the same.

Stream n Mean Specific

Heat Capacity, nCpmΔT
Number Component (kmoles/h)
Cpm (kJ/kmol) (kJ/h)

Isopropyl Alcohol(l) 0.660 22907.8258 15119.165

Unreacted Propylene(g) 4.8896 0.16634
0.068
S07
DIPE(l) 27650.5191 165.9031
0.006
Water(l) 8718.2820 69048.79344
7.92
S06 Propylene(g) 0.0272 4.8896 0.132

𝚺𝒏𝑪𝒑𝚫𝑻 = 84333.925

Page | 46
4.2.3 LOW PRESSURE SEPARATOR

Input:

Stream temperature: 1400C

Model Calculation: To calculate enthalpy of IPA input

Molar flow rate (n) = 0.660 kmol/h

Temperature of stream = 1400C
Reference Temperature = 250C
Hence, ΔT = (140 – 25)0C
Mean specific heat capacity± (Cpm) = 22907.8258 kJ/kmol
Enthalpy of IPA = n*Cpm* ΔT
= 0.660*22907.8258*(140-25)
= 15119.165 kJ/h
All other calculations have been performed similarly
±
For calculation of mean specific heat capacity (See, Appendix B)

Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)

Isopropyl Alcohol(l) 0.660 22907.8258 15119.165

Unreacted Propylene(g) 0.068 4.8896 0.16634
DIPE(l) 0.006 27650.5191 165.9031
Water(l) 7.92 8718.2820 69048.79344
𝚺𝒏𝑪𝒑𝚫𝑻 = 84333.793

Page | 47
Output:

Stream temperature: 1400C

The operation is isothermal expansion, hence temperature remains the same.

Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)

Isopropyl Alcohol(l) 0.660 22907.8258 15119.165

DIPE(l) 0.006 27650.5191 165.9031
Water(l) 7.92 8718.2820 69048.79344
Unreacted Propylene(g) 0.068 4.8896 0.16634
𝚺𝒏𝑪𝒑𝚫𝑻 = 84333.793

Page | 48
4.2.4 ENERGY BALANCE FOR DISTILLATION COLUMNS

Energy balance equations:

Fh + 𝑞 = 𝐵ℎ + 𝐷ℎ + 𝑞

𝑉𝐻 = 𝐿 ℎ + 𝐷ℎ + 𝑞

𝐹= Feed flow rate (kmoles/h) ℎ𝐹 = Enthalpy of feed (kJ/kmol)

𝐿0 = Reflux flow rate (kmoles/h) ℎ𝐿 = Enthalpy of Reflux (kJ/kmol)

𝐷= Distillate flow rate (kmoles/h) ℎ𝐷 = Enthalpy of Distillate(kJ/kmol)

𝐵= Bottoms flow rate (kmoles/h) ℎ𝐵 = Enthalpy of Bottoms (kJ/kmol)

𝑉= Vapor flow rate (kmoles/h) 𝐻𝑉 = Enthalpy of Vapor (Phase Change) (kJ/kmol)

𝑞𝑐 = Heat removed by condenser (kJ/h) 𝑞𝑅 = Heat added to reboiler (kJ/h)

Formula used for calculation:

ℎ𝐹,𝑖 (𝑜𝑟) ℎ𝐵,𝑖 (𝑜𝑟) ℎ𝐷,𝑖 (𝑜𝑟) ℎ𝐿,𝑖 = 𝐻𝑖(𝑇) − 𝐻𝑖(25 ℃) = 𝑛𝑖𝐶𝑝𝑚,𝑖∆T , (𝑘𝐽⁄ℎ)

𝐻𝑉 = 𝑛𝑖𝐶𝑝𝑚,𝑖 ∆T + ∆𝐻𝑖,𝑝ℎ𝑎𝑠𝑒 𝑐ℎ𝑎𝑛𝑔𝑒 = 𝑛𝑖𝐶𝑝𝑚,𝑖 ∆T + 𝑛𝑖𝜆 , (𝑘𝐽⁄ℎ)

Page | 49
4.2.5 AZEOTROPIC DISTILLATION UNIT

Feed:
Stream temperature: 850C

Model Calculation: To calculate enthalpy of IPA input

Molar flow rate (n) = 0.660 kmol/h
Temperature of stream = 850C
Reference Temperature = 250C
Hence, ΔT = (85 – 25)0C
Mean specific heat capacity± (Cpm) = 10780.0368 kJ/kmol
Enthalpy of IPA = n*Cpm* ΔT
= 0.660*10780.0368*(85 – 25)
= 7104.039 kJ/h

All other calculations have been performed similarly

±For calculation of mean specific heat capacity (See, Appendix B)

Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)
Isopropyl Alcohol(l) 0.660 10780.0368 7104.039

Water(l) 0.302 44519.1958 13444.79

Benzene(l) 0.410 8623.9400 3535.81
DIPE(l) 0.00000782
24084.69
𝚺𝒏𝑪𝒑𝚫𝑻 =
*DIPE in negligible amounts, data not shown

Bottoms:
Stream temperature: 83.10C
Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) (kJ/h)
Cpm (kJ/kmol)
Isopropyl Alcohol(l) 0.452 10780.0368 4872.57
Water(l) 0.036 4519.1958 162.690

DIPE(l)
𝚺𝒏𝑪𝒑𝚫𝑻 = 5035.26
*DIPE in negligible amounts, data not shown

Page | 50
Vapour:
Stream temperature: 860C
Model Calculation: To calculate Total enthalpy of IPA input
Molar flow rate (n) = 0.194 kmol/h
Temperature of stream = 860C
Reference Temperature = 250C
Hence, ΔT = (86 – 25)0C
Mean specific heat capacity± (Cpm) = 10780.0368 kJ/kmol
Latent heat capacity† (λ) = 39542.5538 kJ/kmol
Total Enthalpy of IPA = n*Cpm* ΔT + n*λ
= 0.194*10780.0368*(86 - 25)
+ 0.194*39542.5538
= 2091.32+ 7671.25 kJ/h

All other calculations have been performed similarly

±For calculation of mean specific heat capacity (See, Appendix B)
†
For calculation of latent heat capacity (See, Appendix C)

Mean Specific nCpmΔT

Stream n
Component Heat Capacity, (kJ/h)
Number (kmoles/h) Cpm (kJ/kmol)
For calculating sensible heat content
Isopropyl Alcohol(l) 0.194 10780.0368 2091.32
Water(l) 0.27 44519.1958 12020.18
Benzene(l) 0.546 8623.9400 4708.67

𝚺𝒏𝑪𝒑𝚫𝑻 = 18820.171
Stream n Latent Heat nλ
Component
Number (kmoles/h) λ, (kJ/kmol) (kJ/h)
For calculating Latent heat content
Isopropyl Alcohol(g)
0.194 39542.5538 7671.25
Water(g) 0.27 41443.3479 11189.69
Benzene(g)
0.205 30468.9556 6246.124
𝚺𝒏𝝀 =
25107.06
43927,231
Total Enthalpy of Vapor = 𝚺𝒏𝑪𝒑𝚫𝑻 + 𝚺𝒏𝝀 =

Page | 51
 Reflux:
Stream temperature: 860C
Mean Specific
Stream n
Heat Capacity, nCpmΔT
Component
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)
Isopropyl Alcohol(l) 0.182 10780.0368 1961.96

Water(l) 0.068 44519.1958 3027.30

Benzene(l) 0.537 8623.9400 4631.05
DIPE(l)
𝚺𝒏𝑪𝒑𝚫𝑻 = 9620.31
*DIPE in negligible amounts, data not shown

Distillate:
Stream temperature: 860C
Mean Specific
Stream n nCpmΔT
Component Heat Capacity,
Number (kmoles/h) Cpm (kJ/kmol) (kJ/h)
Isopropyl Alcohol(l) 0.009 10780.0368 97.02
Water(l) 0.195 44519.1958 8681.20

Benzene(l) 0.000256 8623.9400 2.207

DIPE(l)
8780.42
𝚺𝒏𝑪𝒑𝚫𝑻 =
*DIPE in negligible amounts, data not shown

To calculate condenser duty:

𝑉𝐻 = 𝐿 ℎ + 𝐷ℎ + 𝑞
Therefore, 𝑞𝑐 = 𝑉𝐻 − 𝐿 ℎ − 𝐷ℎ𝐷

= 43927.233 – 9620.31 – 8780.42

= 25526.5 kJ/h

To calculate reboiler duty:

Fh𝐹 + 𝑞𝑟 = 𝐵ℎ𝐵 + 𝐷ℎ𝐷 + 𝑞𝑐

Therefore, 𝑞𝑟 = 𝐵ℎ𝐵 + 𝐷ℎ𝐷 + 𝑞𝑐 − Fh𝐹

= 5035.26 + 8780.42+ 25526.5- 24084.64

= 15257.49 kJ/h

\
Page | 52
 CHAPTER-5
EQUIPMENT DESIGN

\
Page | 53
 5.1 DESIGN OF HIGH-PRESSURE SEPARATOR

Calculation of settling velocity:

𝜌 − 𝜌 /
𝑢 = 0.07[( )]
𝜌

𝑢 = settling velocity, m/s

𝜌 = liquid density, kg/m3
𝜌 = vapour density, kg/m3

The liquid is stream S07 and the vapor is stream S08.

Density of stream S07 = 995 kg/m3

Density of stream S08 = 854 kg/m3
Therefore,

Settling velocity = 0.07[(995-854)/(854)]1/2

= 0.028 m/s

To calculate diameter of the separator

𝟒𝑽𝒗
𝑫𝒗 = 𝛑 𝒖𝒔

𝐷𝑣 = minimum vessel diameter, m

𝑉𝑣 = gas, or vapor volumetric flow rate, m3/s
𝑢𝑠 = ut, if a demister pad is used, and 0.15 ut for a separator without a
demister pad
Therefore,
Diameter of vessel = [{4(5.91/854)}/{0.314(100.8)}]1/2
= 0.0525 m
*Demister pad not used
Assuming an L/D ratio of 3
Length of vessel = 3(0.0525)
= 0.157 m

\
Page | 54
 5.2 DESIGN OF LIGHT END SEPERATION COLUMN

The feed of the light end separation column is the diisopropyl ether, isopropyl alcohol
and water which undergoes multicomponent distillation.

The calculation of saturation pressure is done using the Antoine Equation:

𝑙𝑜𝑔 𝑃 =𝐴−[ ] , mm Hg
T(℃) + 𝐶

Where, A, B and C are the Antoine constants

T ℃ is the Bubble point temperature (or) Dew point temperature

Antoine Constants
Name
A B C
Isopropyl Alcohol 8.1182 1580.92 219.62
Water 7.96681 1668.21 228
DIPE 7.0971 1257.6 230.01

Model Calculation:

For calculating Psat of DIPE at feed bubble point temperature

Feed bubble point temperature = 98.10C

Antoine constants: A = 7.0971 B = 1257.6 C = 230.01

Therefore,

log Psat = 7.0971 – [(1257.6) / (98.1 + 230.01)]

Psat = 10^ (3.264) = 1837.550 mmHg

*All other calculations have been performed similarly

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 Calculations of bubble point temperature for feed:

Feed
Name kmoles/h xf

Isopropyl Alcohol 0.660 0.076

Water 7.92 0.922
DIPE 0.006 0.00069

Feed
Psat
Name BPT Pressure log Psat (mm Hg) Ki Kixf αi

Isopropyl Alcohol (0C) mm Hg 3.142 1387.945 1.826 0.138 1.955

Water 2.851 709.857 0.861 0.862 1.000
98.1 760
DIPE 3.264 1837.550 2.418 0.0016 2.589
Σkixf = 1.003474

Model Calculation:

For calculation of Kixf and αi for DIPE:

𝑃 1837.550
𝐾 = = = 2.418
Operating Pressure(P) 760

𝐾𝐷𝐼𝑃𝐸𝑥𝐷𝐼𝑃𝐸
𝑓 = (2.418) ∗ (0.00069) = 0.0016

𝐾𝐷𝐼𝑃𝐸 2.418
𝛼𝐷𝐼𝑃𝐸 = = = 2.589
𝐾𝑤𝑎𝑡𝑒𝑟 0.934

*All other calculations have been performed similarly

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 Calculations of dew point in the distillate:

Distillate
Name kmoles/h yd

Isopropyl Alcohol 0.000166 0.0208386

Water 0.001 0.1256
DIPE 0.0068 0.85363

Distillate
Psat
Name DPT Pressure log Psat (mm Hg) Ki yd/ki αi

Isopropyl Alcohol (0C) mm Hg 2.625 422.145 0.555 0.03754 1.953

Water 2.335 216.158 0.284 0.4422 1.000
68.2 760
DIPE 2.880 758.469 0.998 0.8553 3.509
Σkixf = 1.007246

Model Calculation:

For calculation of Kixf and αi for DIPE:

𝑃 758.469
𝐾 = = = 0.998
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑃) 760

𝑦𝐷𝐼𝑃𝐸 0.997
= = 0.8553
𝐾𝐷𝐼𝑃𝐸 0.998

𝐾𝐷𝐼𝑃𝐸 0.998
𝛼𝐷𝐼𝑃𝐸 = = = 3.509
𝐾𝑤𝑎𝑡𝑒𝑟 0.284

*All other calculations have been performed similarly

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 Calculations of bubble point in the bottoms:

Bottoms
Name kmoles/h xb

Isopropyl Alcohol 0.659 0.07699

Water 7.90 0.9230
DIPE 0.000009786 0.00000114

Bottoms
Psat
Name BPT Pressure log Psat (mm Hg) Ki Kixb αi

Isopropyl Alcohol (0C) mm Hg 3.144 1392.957 1.833 0.141 1.955

Water 2.853 712.425 0.937 0.864 1.000
98.2 760
DIPE 3.265 1842.497 2.424 0.000002 2.586
Σkixf = 1.005952

Model Calculation:

For calculation of Kixf and αi for DIPE:

𝑃 1842.479
𝐾 = = = 2.424
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒(𝑃) 760

𝐾𝐷𝐼𝑃𝐸𝑥𝐷𝐼𝑃𝐸
𝑓 = (2.424) ∗ (0.00000114) = 2.586

𝐾𝐷𝐼𝑃𝐸 2.424
𝛼𝐷𝐼𝑃𝐸 = = = 2.586
𝐾𝑤𝑎𝑡𝑒𝑟 0.937

*All other calculations have been performed similarly

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 Calculation of minimum reflux:
𝛂𝐢𝐱𝐢,𝒇
1−𝑞 =∑ …….(1)

Where, q = 1, for saturated feed

Calculation Of theta (θ)
Based On Feed
q= 1 (Feed as Saturated Liquid)
θ
Component xf αi αixi Eq. (1)
(Calculated)
Isopropyl Alcohol 0.076 1.955 0.14956 1.82 0.00
Water 0.923 1.000 0.92270
DIPE 0.001 2.588 0.00210
*The value for theta has been calculated using Microsoft Excel Solver 2013

𝛼𝑖𝑥𝑖,𝑑
𝑅𝑚 + 1 = ∑ … (2)
𝛼𝑖 − 𝜃

The value of ϴ is calculated from equation 1 to get the value of minimum reflux Rm .
Calculation Of Minimum Reflux
Based on Distillate
Component xd αi αixi αi - θ Eq (2)

Isopropyl Alcohol 0.001 1.953 0.0023 0.13 0.00

Water 0.002 1.000 0.0017 -0.82 -0.01
DIPE 0.997 3.509 3.4987 1.68 2.08
Rm + 1 = 2.07
Rm= 1.07

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 Calculation of minimum no of plates:

The Fenske Equation for calculation of minimum number oof plates is:

log [(𝑥𝐿𝐾 ⁄𝑥𝐻𝐾)𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 𝑋 (𝑥𝐻𝐾⁄𝑥𝐿𝐾)𝐵𝑜𝑡𝑡𝑜𝑚𝑠 ]

𝑁𝑚𝑖𝑛 =
log (𝛼𝐿𝐾 )𝑚𝑒𝑎𝑛

Where,

XLK = Mole fraction of light key component

XHK = Mole fraction of heavy key component

αLK = Relative volatility of light key component

After subsituting the values we get minimum no. of plates Nmin= 21.

Calculation of number of actual plates :

Number of actual plates is calculated by the “GILLAND CORRELATION”

Assuming RD = 2.3 RM,

Two euqations used are:

𝑅𝐷 − 𝑅𝑚
= 0.401
𝑅𝐷 + 1

From graph:

𝑁 − 𝑁𝑚𝑖𝑛
= 0.33
𝑁+1

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 Therfore,

(0.33)(N+1) = N-Nmin

0.33N + 0.33 = N – 21

0.67N = 21.33

Which gives, number of plates N = 31,

No of stages is equal to N-1 = 30

Assumed Plate spacing as 30 cm

Therefore,

𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝑪𝒐𝒍𝒖𝒎𝒏 = 𝑵𝒐. 𝒐𝒇 𝑺𝒕𝒂𝒈𝒆𝒔 𝒙 𝑷𝒍𝒂𝒕𝒆 𝑺𝒑𝒂𝒄𝒊𝒏𝒈 = 9 𝒎

Assuming L/D ratio of 3:1

Diameter of Column= = 3𝑚

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 CHAPTER-6
COST ESTIMATION

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6.1 COST ESTIMATION

cost index of the year 2020= 301

cost index of the year 2024= 348
present cost 1.15614617940199

Table 6.1 Equipment name and cost:

Cost (INR) IN Cost (INR)-in
Equipment name Quantity 2020 2024
Reactor 1 25287354 29232181.22
Heat exchanger 1 3226666.667 3730026.667
Separator 2 1352569 3127139.528
Distillation column 4 15357142.8 71011428.31
Condenser 4 715371.429 3307877.488
Reboilers 4 2730357 12625170.77
total=p 123033824

Table 6.2 Factors dependent on direct costs

Factors dependent on direct costs % cost (INR)
Installation cost 0.4*p 49213529.6
Instrumentation cost 0.3*p 36910147.2
Piping 0.4*p 49213529.6
Electrical 0.25*p 30758456
Building & site 0.4*p 49213529.6
Land 0.88*p 108269765
Direct costs(D) 323578957

Table 6.3 Factors dependent on indirect costs

Factors dependent on indirect costs
% Cost (INR)
Construction& expenses 0.2*D 64715791.41
Contingency (0.1/0.9) *(D+C) 43139546.56

Fixed capital investment(F)=(D+I) = 431434295 cost (INR)

Working capital (0.15/0.85) *F=76105009.65

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Total capital investment (TCI), T=(F+WC) = 507539304.7

Direct production costs

Table 6.4 direct production costs

COST(INR)
Raw material cost 2358331.2
operating labour(O)=(0.2*T) 101507860.9
Supervisor and labour(0.5 O) 50753930.47
utilities(0.1*T) 50753930.47
Patents and royalities(0.02T) 10150786.09
maintainance and repairs(0.02F) 8628685.901
Operating supplies(0.01F) 4314342.95
Laboratory(0.15 O) 15226179.14
Direct production costs = 243694047.2

fixed charges

Table 6.5 fixed charges

cost(INR)
Depreciation (0.15F) 64715144.3
Local tax (0.02F) 8628685.9
Insurance (0.08F) 34514743.6
Plant overhead costs(0.4 O) 40603144.4
Fixed charges 148461718

Manufacturing cost M=(DPC+FC+POC)

=432758909.7 (INR)

Total product cost(G+M) =TP

=508889805.4(INR)

General expenses

Table 6.6 general expenses

COST(INR)
Distribuition selling (0.05T) 25376965.2
Financing (0.1T) 50753930.5
General expenses(G) 76130895.7

Cost of IPA=130/KG
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Capacity=200TPA
Income=624000000

profit=(I-TP) = 115110194.623535

Payback period=(F/PROFIT)
=3.74 YEAR
% Profit based on sales=(profit/income)
=18.44714657 %

Return on investment=(profit/T) *100=22.68 %

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 PLANT LAYOUT

Plant layout may be defined as a floor plan for determining and arranging the desired
machinery and equipment of a plant, in the one best place, to permit the quickest flow of
material at the lowest cost and with the least amount of handling in processing the
product from the receipt of raw material to the shipment of finished products. The
material handling planned in the layout begins at the receiving point, where the material
arrives as raw material, then continuous progressively from storage through process,
moving in the form of worked material department to department, from machine to
machine, from operation to operation on each machine, and of particular importance,
between the worker and the machine flows in and out of temporary storage and is fed
through assembly lines for final assembly. Provision is made for inspection, packaging,
and storing the material as finished products and for finally loading the product on the
shipping platform for shipment to customers.

The laying out of a plant is still an art rather than a science. In involves the placing
equipment so that the following are minimized:
• Damage to persons and property in case of a fire, explosion, or toxic release
• Maintenance costs
• The number of people required to operate plant
• Other operating costs
• Construction costs
• The cost of the planned future revision or expansion
The first thing that should be done is to determine the direction of the prevailing wind.
This can be done by consulting Weather Bureau records

1. Process Site: Our process site is a group layout. This provides for ease of operation
and switching from one unit to another. This type of scheme is best for large plants.
The flow line layout uses the train or line system, which locates all the equipment in
the order in which it occurs on the flow sheet. This minimizes the length of transfer
lines and therefore reduces the energy needed to transport materials.

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 2. Since our raw material is in gaseous and liquid form, raw material storage and pump
house have been kept at neighboring points. Hence, they can be easily transported to the
process site through pipelines.

3. A separate area for further expansion has also been provided for future demands and
other endeavors.

4. As all the materials we are dealing with are highly flammable, certain guidelines, and
practices should be followed. Only approved containers and portable tanks shall be used
for storage and handling of flammable liquids. Approved safety cans or Department of
Transportation approved containers shall be used for the handling and use of flammable
liquids (Isopropyl Alcohol) in quantities of 5 gallons or less, except that this shall not
apply to those flammable liquid materials which are highly viscid (extremely hard to
pour), which may be used and handled in original shipping containers. For quantities
of one gallon or less, the original container may be used, for storage, use and handling
of flammable liquids.

5. Sufficient distance has been maintained between IPA and Propylene storage (NIOSH
guidelines) as both are highly flammable and in different phases. Adequate space has
been provided for personnel and carts to allow delivery and removal of cylinders. Floor
surfaces must be in good condition. Cylinders that are moved to allow access to other
cylinders must be secured to prevent accidental falling or damage.

6. Product storage and shipping are located right behind the railway line and the road.
This ensures an organized system of packaging, shipping and delivery.

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\
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 INSTRUMENTATION AND PROCESS CONTROL

Basic Instrumentation in process plants:

Temperature Measurement:

The temperature-measuring element in a control system for a jacketed tank is generally

thermocouple. The five most commonly used thermocouple are Copper-constantan,
iron-constantan, chromel-alumel, platinum-platinum 13% rhodium, and platinum-
platinum 10% rhodium.

Flow rate Measurement:

The industrial devices for flow rate estimation are Orifice meter, Venturimeter, Pittot
tube, and Rotameter. The piping system must be made of special corrosion resistant
material meant corrosive fluids are used.

Level Measurement:

The flow-shaft type is employed either in open vessels or in pressure vessels. This
method is suitable for a wide range of liquids and semi-liquids. Difficulties are
sometimes encountered when the liquid deposits on the floor and when the liquid level
is foaming or turbulent.

Process Control:
Feedback Control System: It uses direct measurement of control variables to adjust
the valves of the manipulated variables. The objective is to keep the controlled variables
at desired levels (set points). As the name suggests, variations in the control variable is
first measures and then necessary control action is taken.
Various controllers available for use include, Proportional control, Derivative control,
Integrative control, Proportional Derivative control and Proportional Integrative
Derivative control. Proportional Integrative Derivative (PID) controllers has been used
as it offers highest flexibility to achieve the desired control response by having three
adjustable parameters. It also increases the speed of closed loop response.

Process Instrumentation for Reactor: The catalytic reaction between propylene and
water is highly exothermic. Hence auctioneering control has been selected for our

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 trickle bed reactor. The point where the temperature is maximum is known as the hot
spot. The location of the hot spot moves along the length of the reactor depending on
the feed conditions and the catalyst activity. The primary objective is to keep the hot
spot temperature below the upper limit. Hence we need a control system that can
identify the location of the hot-spot and provide the proper control action. This can be
achieved through:
 Placement of several thermocouples along the length of reactor.
 Use of an auctioneering system to select the highest temperature which will be
used to control the flow rate of water.

Process Instrumentation for Separator: The most important control variable for the
separators is pressure. The outlet valve in each separator is controlled via pressure
control system. High pressure and low pressure alarm is provided in case of
emergencies.

Process Instrumentation for Distillation Column: In the first two columns,

temperature control is applied to condenser and reboiler in order to maintain the
required outlet flow rate and compositions. In case of the third column, a temperature
control is applied, along with the flow towards the settler.

Process Instrumentation for Decanter: The decanter separates two immiscible liquid
layers according to density. Hence, a level control is used which maintains the flow rate
of each layer.

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 Reactor and Separator Control

\
Page | 71
 Distillation Unit Control

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 INDUSTRIAL SAFETY

The safe design and operation of facilities is of paramount importance to every

company that is involved in manufacture of fuels, chemicals and pharmaceutical
products. Certain manufacturing processes involved are hazardous to some extent,
hence important aspects like design of equipment’s, process conditions (temperature,
pressure etc.) should follow the safety norms and guidelines laid down by government
and documents like NIOSH, OSHA etc.
Considering our plant, safety hazards have been classified as:
a) Material Hazards
b) Process Hazards

Material Hazards:

a) Propylene: Since propene is volatile and flammable (at high temp and pressure),
precautions must be taken to avoid fire hazards in the handling of the gas. If propene is
loaded to any equipment capable of causing ignition, such equipment should be shut
down while loading, unloading, connecting or disconnecting.
b) Di isopropyl Ether (DIPE): Highly flammable. Slightly soluble in water. Form
explosive peroxide in storage. Inhalation causes anesthesia, nausea, headache,
dizziness, and irritation of the eyes and nose. Contact of liquid with eyes causes only
minor injury; repeated contact with skin will remove natural oils and may cause
dermatitis.
c) Isopropyl Alcohol: Permissible limits for airborne concentrations of IPA is 200ppm.
(By NIOSH).If they react with air or oxygen, they can form unstable peroxides which
can explode. Incompatibility: Heat, flame, strong oxidizers.

Process Hazards:

a) Pressure: If pressure exceeds maximum allowable working pressure of the

vessel by more than the safety margin allowed in the vessel design code, then
the failure of the vessel might occur usually a joint or flange. Hence pressure
relief devices like Directly Actuated Valves, indirectly actuated Valves and
Bursting Discs may be required.

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 b) Temperature: Excessively high temperature, over and above which the
equipment was designed, can cause a structural failure and initiate a disaster.
They can arise from loss of control of heaters and reactors, and externally may
be from open fires. This should be curbed by provisions of high temperature
alarms, emergency cooling systems and interlocks to shut down reactor feeds or
heating systems, if the temperature exceeds critical limits.
c) Explosions: An explosion is the sudden catastrophic release of energy causing
a pressure wave. It can occur without fire as well, such as by overpressure of a
steam boiler or an air receiver.
d) CVCE (Confined Vapor cloud Explosion): A relatively small amount of
flammable material can lead to an explosion when released into the confined
spaces. This is known as confined vapor cloud explosion. This happened in the
Praxair facility in Missouri, USA. Due to a high ambient temperature a leakage
took place in the propylene cylinder and formed a small CVCE. Due to the
occurrence of static charges in air, an explosion took place, which subsequently
combusted the neighboring cylinders.

Preventive Measures:

Basic Safety Practices that should be inculcated in all industries are:

 Face protection – face shields
 Safety hard hat (Head Gear)
 Heavy Protection Ear Muff & Ear Plug
 Eye Protection –Safety Goggles
 Body Protection- cotton vests,
 Foot Protection-Safety shoes, Boots
 Hand Protection- leather hand gloves, use of sanitizers
 Regular Medical Check-ups
 Employee Safety Inductions

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 With respect to handling of materials, the practices mentioned below should strictly be
followed:
 Cylinders should be kept in a well ventilated space.
 In case of leakage, personnel should be evacuated immediately and authorities
should be informed.
 Proper insulation cylinders to be used.

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 CHAPTER-7
CONCLUSION AND REFERENCES

\
Page | 76
 7.1 CONCLUSION
This report gives a pre-preliminary feasibility study for the manufacture of 100
TPA of Isopropyl Alcohol. After carrying out this exercise it was found that such a plant
it would be profitable and economically feasible. In terms of figures, the plant project
cost comes out to be 431434295(INR), giving an annual rate of return of 22.6%.The
payback period for the project turns out to be 3.74 years. Thus, the project on the basis
of the above analysis is definitely profitable and economically feasible.
At pre-preliminary level, the project looks attractive. So, it gives a green signal
for carrying out a detailed techno economic level feasibility for the given project.
However, this optimism may be premature since in this analysis several assumptions
were made. Some of these are the existence of an ideal market, stable raw material and
product prices and 100% product sale. Also, the cost estimate analysis methods are
based on certain rules of thumb and give only approximate estimate of all the costs
involved in the project.
This report demonstrates the significance of right choice of process selection
along with making a proper decision for the production of raw materials. Thus, this
preliminary study gives us more than enough reason to conduct a detailed analysis to
come up with more realistic figures.

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 7.2 REFERENCES

1. CRC Handbook of Chemistry and Physics. 44th. n.d.

2. David M.Himmelblau, James B.Riggs. Basic Principles and Calculations in
Chemical Engineering. Seventh. PHI Learning Pvt Ltd, 2010.
3. Don W.Green, Robert H.Perry. Perry's Chemical Engineers' Handbook. Seventh.
n.d.
4. Robert E.Treybal. Mass Transfer Operations. Mc-Graw Hill International Editions,
1981.
5. Ullman's. Chemical Engineering and Plant Design. Vol. II. Wiley-VCH, 2005.
6. R.K.Sinnot. Chemical Engineering Design. Fourth Edition. Elsevier, 2005.
7. S.Peters, Max, Klaus D. Timmerhaus and Ronald E.West. Plant Design and
Economics for Chemical Engineers. McGraw-Hill, 2004.
8. Hirata, Shigeru Yokohama-shi,Kangawa (JP) and Shinji, Yokohama-shi,Kanagawa
(JP) Ogawa. Process for producing isopropyl alcohol. European: Patent
EP0728721B1. 23 February 1996.
9. Hitara, Shingeru, Yokohama-shi, Kangawa (JP). Process for producing isopropyl
alcohol by hydrating propylene. European: Patent EP0717022B1. 15 December
1995.
10. Llyod Berg, Bozeman Mont, Zuyin Yang. Separation of the Propyl Alcohols from
Water by Azeotropic Distillation. United States: Patent 5085739. 4 February 1992.
11. Robert J.Schmidt, Rolling Medows I11. Process For Production of Isopropyl
Alcohol. United States: Patent 4469903. 4 September 1984.

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 CHAPTER-8
APPENDIX

\
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8.1 APPENDIX A
Miscellaneous properties of components involved in process

Normal Normal
Molecular Specific Melting Boiling
Component Formula CAS no.
Weight Gravity point point
(0C) (0C)

Isopropyl 60.096 0.789 -88.5 82.5

C3H8O 67630
Alcohol

Benzene C6H6 71432 78.11 0.879 5.5 80.1

Water H2O 7732185 18.015 1 0 100

Propylene C3H6 115071 42.081 0.854 -185.3 -47.8

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8.2 APPENDIX B
Calculation of mean specific heat

Heat Capacities of Inorganic and Organic liquids

Name Formula CAS No. C1 C2 C3 C4 C5

Isopropyl
C3H8O 67630 7.24E+05 -8.10E+03 3.67E+01 -6.64E-02 4.41E-05
Alcohol
Benzene C6H6 71432 1.29E+05 -1.70E+02 6.48E-01 0.00E+00 0.00E+00

Water H2O 7732185 2.76E+05 -2.09E+03 8.13E+00 -1.41E-02 9.37E-06

Propylene C3H6 115071 1.17E+05 -3.86E+02 1.23E+00 0.00E+00 0.00E+00

DIPE C6H14O 108203 1.63E+05 -4.50E+00 6.20E-01 0.00E+00 0.00E+00

Heat Capacities of Inorganic and Organic compounds in ideal gas state

Name Formula CAS No. C1 C2 C3 C4 C5

Propylene C3H6 115071 4.21E+01 4.39E-01 1.51E+00 1.40E+00 0.74754

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8.3 APPENDIX C
Calculation of Latent Heat Capacity

Constants for calculating latent heat capacity

Name Formula CAS no C1 C2 C3 C4
Propylene C3H6 115071 2.52E+07 0.33721 -0.18399 0.22377

Water H2O 7732185 5.21E+07 0.3199 -0.212 0.25795

Isopropyl Alcohol C3H8O 67630 7.25E+07 0.79137 -0.66092 0.34223

DIPE C6H14O 108203 4.61E+07 0.4 0 0
Benzene C6H6 71432 4.53E+07 0.39053 0 0

Formula for calculation:

Where,
Tr = Reduced Temperature
= (Component temp.)/(Critical temp. of respective component)

Tc, K
Name Formula CAS no
(Critical Temp.)
Propylene C3H6 115071 364.85
Water H2O 7732185 647.096
Isopropyl Alcohol C3H8O 67630 508.3
DIPE C6H14O 108203 500.05
Benzene C6H6 71432 562.05

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8.4 APPENDIX D
Azeotropic data

Azeotropic Composition:

Mole Percentage : Isopropyl Alcohol = 68.5%, Water = 31.5%

Weight percentage : Isopropyl Alcohol = 87.9%, Water = 12.1%

X = Mole fraction of IPA in liquid

Y = Mole fraction of IPA in Vapor

X Y X Y
0 0 0.5 0.5907
0.05 0.45529 0.55 0.61213
0.1 0.50838 0.6 0.63648
0.15 0.51966 0.65 0.66384
0.2 0.52354 0.7 0.69446
0.25 0.52771 0.75 0.72871
0.3 0.5343 0.8 0.76723
0.35 0.54388 0.85 0.81105
0.4 0.55652 0.9 0.86193
0.45 0.57215 0.95 0.92297
1 1

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 Ternary azeotrope data:

Weight percentages:

IPA = 19.8%
WATER = 8.2%
BENZENE = 72%

For the Heteroazeotrope formed inside the Decanter/Settler:

Upper layer, weight percentages:

IPA = 20.2%
WATER = 2.3%
BENZENE = 77.5%

Lower layer, weight percentages:

IPA = 14.4%
WATER = 85.1%
BENZENE = 0.5%

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