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