CHE4170 - Week 1, Lecture 1

CHE4170 Final Year Design Project

Department of Chemical Engineering

1.PROJECT OVERVIEW (11-12pm)

2.Scope of work Submission A
(12-12.30pm)
3. Allocation of project conditions
4. Inherent Safety (1-2pm)
24 July 2017
www.monash.edu

2017 Project - Ethylene Glycol(s)

Mono ethylene glycol (MEG) = Ethane Diol

Di ethylene glycol (DEG)

Tri ethylene glycol (TEG)

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2017 Project - EG

Key uses of MEG:

1. Antifreeze agent

2. Dehydrating agent

3. Fibre manufacturing (polyesters: Dacron, Rayon )

4. PET films and bottles

n C6H4(CO2H)2 + n HOCH2CH2OH [(CO)C6H4(CO2CH2CH2O)]n + 2n H2O
(Terephthalic acid)

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Growth in MEG market

www.fibre2fashion.com/industry-article/7424/global-overview-market-trend-and-forecast-for-meg

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Growth is dominated by polymer-

grade MEG

www.fibre2fashion.com/textile-market-watch/analyst-corner/Rising-demand--PET-resin-polyester-fibres-antifreeze-global-MEG-Market/68

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MEG Consumption dominated by Asia

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Why do we need MEG production in

Australia / NZ?

What really happens to PET bottles in Australia?

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CHE4170 - Week 1, Lecture 1

Australian Plastics
PET has the highest recycling rate

BUT
Domestic
Recycling
<15% !!

OFarrell, K, 2011, National Plastics Recycling Survey, publ. PACIA

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70% of collected PET is exported

from Australia to China

Producing virgin PET in Australia will help

with recycling of PET in Australia.

To make PET we need MEG

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CHE4170 - Week 1, Lecture 1

Plant Processing Objective

Design a MEG plant with a capacity of between

50 200 kta
Plant will operate 24/7 with 4 week s/d (every 2yrs)
Plant Availability 95% (excl. s/d)

1. Must meet the Polymer Grade Specification

2. Minimise the cost of production
3. Minimise the carbon footprint

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Polymer Grade Specification

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CHE4170 - Week 1, Lecture 1

How do we make MEG?

Traditional route starts with Ethylene (which comes from steam cracking of ethane)

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Two processes dominate EO route - A

DOW Meteor Process (similar to conventional)

Dow Sinopec Plant
in Tianjin China

Meteor Most
Effective Technology
for Ethylene Oxide
Reactions

600 KTA ethylene

oxide/ethylene glycol
(EO/EG) Kuwait

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Two processes dominate EO route - B

Shell Omega Process

The advantage of Shell Omega is that it only produces MEG (no DEG or TEG)

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Best technology for Australia/NZ

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CHE4170 - Week 1, Lecture 1

Sustainability Considerations

1. Market size

2. Feedstock availability

3. Inherent Safety

4. Process Economics

5. Environmental factors

6. Community acceptance

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2. Ethane Availability ???

East coast NG resources

fast being depleted
( < 40% remaining)

Coal seam gas does not

contain ethane

West coast NG LNG

(without extracting
ethane)

Extraction from LNG

import terminals

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CHE4170 - Week 1, Lecture 1

Ethylene Price (tracks oil & NG price)

Careful consideration of feedstock price will be critical to economic viability

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Alternatives to Ethylene Processes

Synthesis gas (based on biomass)

Oxygen CH3OH

NO
CO 2. Reaction/Sepn 3. Nitrous acid
of DMO ester regeneration
Syngas 1. Syngas
separation DMO

H2 4. 5-6 Refining and

Hydrogenation purification

MEG

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CHE4170 - Week 1, Lecture 1

Production of Synthesis Gas

(Outside of scope of design)
Dual bed gasification

Syngas
Biomass (wet)
Biomass Char Pyrolysis CO2
Dryer Combustor Reactor separator

CO2
Flue gas Air

Advantages
1. No production of ethylene oxide intermediate
2. Potentially very low cost feedstock Municipal
greenwaste cost Nil
Cost $/t (db)
3. Low carbon footprint, due to carbon neutral
feedstock Green waste Nil
Straw pellets 100
Bagasse 100
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Co-product Process (Redox)

This process was developed by analogy with the

co-product process to convert C3H6 to C3H6O
Iso-butane

Oxygen/UV 1-2 Per-oxide

synthesis

Weak DtBP
formaldehyde
CH3OH 3-4 Redox 5-6 Refining and
Reactor/Sepns purification

t-butanol MEG

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CHE4170 - Week 1, Lecture 1

Cost of methanol & formaldehyde

Methanol price is strongly
correlated with the natural gas price

Cost of formaldehyde / tonne FA is

about 1.1 x cost of methanol

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Redox Process

Advantages
1. Relatively simple process

Disadvantages
Depends also on market for co-product
Best suited to an oil refinery integration

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CHE4170 - Week 1, Lecture 1

Singapore (9)
Raon Thailand (10) Locations
Dilli (8)

Darwin (7)

Burrup (6)
Brisbane
(13/14)

Botany (11)
Kwinana (5)

New Zealand
Melbourne (1) New Plymouth (3)
SA (15/16) Geelong (2) & Marsden Pt. (4)
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Restrictions on Ethylene Processes

Odd numbered locations:

1, 3, 5
Dow Meteor OR any syngas-based process

Even numbered locations:

2, 4, 6
Shell Omega OR any syngas-based process

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Conceptual Design Objectives

Determine economic viability
IBL CAPEX +/- 30%
Manufacturing costs & viable selling price
(based on discount rate 12%)
25 years of operation
Earliest start up date January 2022

Determine environmental viability

Preliminary EIA
LCA based on Cradle to Gate
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The role of Hoadley Enterprises

Some locations do not have some of the feedstock

Hoadley Enterprises will import and store the following in

atmospheric storage tanks if not currently available

1. Ethylene Liquid
2. Methanol Liquid
3. Formaldehyde Liquid (30wt% or 37wt%)
Iso-butane in pressurised storage bullet at average
ambient temperature
* CO2 streams leave the Regererator Column saturated in water
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Utilities (part of the OBL Plant)

Utilities*
Natural gas (as feedstock) $/GJ LHV (20oC, 300kPa(g))
ie Bass Strait NG: LHV=38.7 MJ/m3, sg=0.61, GHG=58.9kg CO2/MJ 7.0
Town water (mains pressure 7bar g) $/t 1
Demineralised water (7 bar g) $/m3 3
Desalinated Water (7 bar g) $/m3 7
Boiler feedwater (BFW) (105oC & P as required) $/t 3
Hot Water (60oC, 7 bar g) $/m3 2 + BFW
Steam (HP) 40 bara (saturated)1 $/t 14 + BFW
(IP) 20 bara (saturated)1 $/t 12 + BFW
(MP) 10 bara (saturated)1 $/t 10 + BFW
(LP) 5 bara (saturated)1 $/t 8 + BFW
Cooling water (mains pressure 7 bar g)2 $/m3 0.25
Recirculated chilled water (4 bar g @ 5oC) $/m3 5.0
Nitrogen (10 bar g) $/Nm3 0.3
Oxygen (95%, 2 bar a)
Trade waste sewage charge $/m3 $4.45 x 1.1 (LF)
Primary Waste water treatment costs $/m3 1.0
Electricity (11kV/3.3kV/415V 3Phase 50 Hz) $/MWh 150

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Bibliography
1. Rebstad, S, and Mayer, D., 2012, Ethylene Glycol, Ullmanns Chemical Encyclopedia, Wiley-
VCH Verlag GmbH.
2. Roy, S. 2016, Rising demand for PET resin, Polyester fibres, and Antifreeze to drive the
Global MEG Market, http://www.fibre2fashion.com/textile-market-watch/analyst-
corner/Rising-demand--PET-resin-polyester-fibres-antifreeze-global-MEG-Market/68/, sighted
20 July 2017.
3. HIS Markit, 2016, Chemical Economics Handbook, Ethylene Glycols,
https://www.ihs.com/products/ethylene-glycols-chemical-economics-handbook.html,
sighted 20 July 2017.
4. OFarrell, K, 2011, National Plastics Recycling Survey, publ. PACIA,
https://chemistryaustralia.org.au/mediacentre/media19012012, sighted 20 July 2017.
5. Kollar, J., 1984, Ethylene glycol from syngas, Chemical Technology, 504-511 and p578.
6. MEGlobal, http://www.meglobal.biz/monoethylene-glycol/sales-specs, sighted 20 July 2017.
7. CME Group, NYMEX Rulebook, https://www.cmegroup.com/rulebook/NYMEX/3/368.pdf,
sighted 20 July 2017.
8. R. Agrawal and R. M. Thorogood, 1991, Production of medium pressure nitrogen by
cryogenic air separation, Gas Separation & Purification, 5, (4), 203-209
9. C. Fu, T. Gunderse, 2011, Power reduction in air separation units for oxy-combustion
processes based on exergy analysis, Computer Aided Chemical Engineering, 29, 1794-1798.

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In-semester Assessment Tasks

Assessment Task Value Due Date

Interviews (3 total) 10% Weeks 4, 7, 9

Data gathering presentations 2.4% Weeks 2-6

Report submission A (Ch1-3) 19.2% Friday 1/9 5pm

Report submission B (Ch5-7) 21.6% 2 October 12pm

Final report 36.8% 25 October 5pm

Poster and Presentation 10% tbc 3rd exam

week

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Plan for weeks 1-2

Week 1
Decide on feedstock (Leader to inform Andrew by email by Monday
31/7)
Prepare Project Plan (based on advice on 26/7) Hand in Friday 28/7
Aspen Computer Tutorial Gibbs Reactor (3 of 6 team members)
Prepare Special Task (these will be issued on Tuesday 25/7) First
presentations 31/7
Week 2
Mass balances assuming reaction conversions and separation
Aspen Computer Tutorial Gibbs Reactor (3 of 6 team members)
Make list of issues to be resolved & search literature for answers

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Plan for weeks 3-4

Week 3
Start work on computer simulations (break into manageable
pieces)
Aspen Computer Tutorial - Distillation (3 of 6 team
members)
Week 4
Start to think about flowsheet optimisation
Aspen Computer Tutorial - Distillation (3 of 6 team
members)
Prepare data for heat integration studies
Start drawing PFDs
PFD Interviews (Thursday/Friday) CHE4170: 2016 33
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