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by Pınar Özbayby Pınar Özbay Nihal PayzaNihal Payza
Zeynep PekişenZeynep Pekişen Deniz Uğurlar Deniz Uğurlar
PRODUCTION OF ISOPROPYL ALCOHOL
(IPA)
Information about...Information about...
Isopropyl AlcoholManufacturing ProcessesProcess SelectionMarket ResearchCapacity DeterminationProcess Flow DiagramCalculation AlgorithmsResults & Conclusions
Isopopyl AlcoholIsopopyl Alcohol ??? ???
• Flammable , colorless liquid with a strong and pleasant odor
• Miscible with water , ethanol , acetone and benzene
• Used as a solvent and cleaning fluid
ApplicationsApplications • Pharmaceuticals ,pesticides ,coatings ,daily-use chemicals and organic
synthesis sectors
• As cleaning agents used on electronic devices such as contact pins, magnetic tape deck, lenses of lazers in opticak disk drivers
• Anti-freeze agent in fuel
• Preservative to replace formaldehyde in strong solutions
C3H7OH
IPAIPA Manufacturing Processes Manufacturing ProcessesDirect Hydration
combination of water and propylene with acidic cation exchange resin catalyst
Indirect Hydration Reaction of propylene with sulfuric acid with a heterogenous polymeric acid catalyst
Acetone Hydrogenation of acetone
Advantages of Direct Hydration
Thermally stable polymeric catalyst High product quality improvement Cost effective Environmental friendly High selectivity of IPA
Process SelectionProcess Selection
Process for producing isopropyl alcohol, US 5,763,693
Criteria for this selection
A final product with a composition of 90% IPA and 10% water High conversion of Direct Hydration Process High Selectivity of IPA Cost effectiveness No removal units High data availability Less complex process
Compressor and heat exchanger addition High pressure No recycle of propane
Market ResearchMarket ResearchLargest producers: Shell, ExxonMobil, Sasol and Dow (72%)
Design Capacity of IPADesign Capacity of IPA
IPA Consumption in Turkey
0.E+00
4.E+06
8.E+06
1.E+07
2.E+07
2.E+07
2.E+07
1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
years
kg Turkey
• TUIK DATATUIK DATA
• 5 year moving
• 3 year moving
• Projected Models
• Consumption Projections of IPA
5 Year Moving Data of IPA Consumption in Turkey
0.E+00
5.E+06
1.E+07
2.E+07
2.E+07
3.E+07
1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
years
kg5 yearsaverage
3 Year Moving Data of IPA Consumption in Turkey
0.E+00
4.E+06
8.E+06
1.E+07
2.E+07
2.E+07
2.E+07
1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
years
kg3 Yearmoving
Design Capacity of IPADesign Capacity of IPA
log
log 1
i
Turkey
GDP
GDPN
•Year difference calculation between countries
• Population, GDP, growth rates and consumption of countries
• Calculation of future population and GDP of Turkey )(
)(
)1(
)1(reffuture
reffuture
reffuturereffuture
populationpopulation
GDPGDP
• Calculation of consumption of Turkey per capita reference year: 2005
futureTurkeyTurkey populationcapitanconsumptionconsumptio )/(
• Final design capacity of Turkey
i
TurkeyTurkeyTurkey PPP
PPPnconsumptiocapacity
i
futureTurkeyiTurkey GDP
GDPcapitanconsumptiocapitanconsumptio ,)/()/(
GERMANY Pop_Tur_future GDP_Tur_future cons/capita_GR cons/capita_TR Capacity_exc_ppp Capacity
2006 98407805 40876.542 0.689 0.888 87371391.217 76886824.271
2005 93039928 29980.000 0.636 0.636 59182685.196 52080762.973
2004 89121274 23634.165 0.615 0.505 44970355.489 39573912.830
2003 98876465 41964.186 0.738 1.122 110927868.378 97616524.172
2002 90596610 25879.266 0.665 0.634 57466979.218 50570941.712
2000 88994913 23449.544 0.695 0.632 56240631.825 49491756.006
1998 118130904 112192.923 0.698 3.308 390799122.429 343903227.738
1997 84297965 17377.224 0.695 0.526 44369599.653 39045247.695
1996 85200334 18430.585 0.707 0.587 49981523.006 43983740.245
1995 84192973 17257.936 0.344 0.274 23076411.355 20307241.993
1993 79178711 12291.188 0.583 0.359 28392825.774 24985686.681
1992 85349269 18609.364 0.625 0.586 50034562.052 44030414.605
Sample Calculation of GermanySample Calculation of Germany
Design Capacity of IPADesign Capacity of IPA• TUIK DATATUIK DATA
• 5 year moving
• 3 year moving
• Projected Models
• Consumption Projections of IPA
0.E+00
5.E+07
1.E+08
2.E+08
2.E+08
3.E+08
3.E+08
1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040
years
kg/year
expo model
linear
poly
log
Austria
France
Germany
Greece
Italy
Spain
Switzerland
England
Turkey
Series130.E+00
5.E+07
1.E+08
2.E+08
1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040
years
kg/year
expo model
linear
poly
log
Austria
France
Germany
Greece
Italy
Spain
Switzerland
England
Turkey
Series13
The best fit Logaritmic model
Design capacity of IPA in 2025 43,000 tons/year
Process Flow DiagramProcess Flow Diagram96% propylene
4% propane
propane
propane
propane
90% IPA
10% water
water
Centrifugel Compressor & Pump
-Efficiency : 0.8
propane
propane
Mixer
Direct Hydration Unit (Packed Bed)
• No side reaction
•X = 0.75
• adiabatic rxn at 80atm
• T : 406 K 428 K
3 6 2 3 20 ( )C H H CH OH OH Component Separator(V101)
•Top: Propane, propylene
•Bottom: Water, propane, isopropanol
Distillation(V102)
•Propylene, propane recycle to mixer
•Bottom: propane
Mixer
Extraction
T: 403K
•Top: Isopraponal, water, propane
•Bottom: Water, propane recycle to
Gas-Liquid Separator(V102)
T: 353 K
•Top: Propane
•Bottom: IPAIPA
Calculation Algorithm Calculation Algorithm Heat Exchanger
Adiabatic Compressor
Component Seperator
∆H= Hinlet- Houtlet
*W
)/( moljWH
Adiabatic Reactor0
0[ ( )]i
i
Rxn R i P P R
i P P
X H T C T X C TT
C X C
As a summary . . .As a summary . . .düzeltçessdüzeltçessdata availability
˜ 75% conversion of IPA
cost effective
Direct Hydration Process
Isopropyl Alcohol
Are these reasons satisfactory to design a IPA production plant by using this process?
YES
90% IPA as end product
Less energy consumption
THANK
YOU
FOR YOUR
ATTENTION
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