ECH3117 UNIT OPERATION DESIGN GROUP 1

1|IDEAQO SDN BHD

ECH 3117 UNIT OPERATION SEMESTER 2 2019/2020 DESIGN PROJECT PRODUCTION OF ETHYLENE FROM FEED OF 100 TON PER MONTH METHANOL GROUP 1 – IDEAQO SDN.BHD Lecturer’s Name: Prof. Zurina Binti Zainal Abidin Group members: Matrics No. 195980 Name 198514 Mathesh Rao A/L Gunarayu 198742 Farah Raihana Binti Shafiee 198743 Nazeera Binti Zukernain Nur Ariena Hanis Binti Mohd Nor 2|IDEAQO SDN BHD

Prof. Zurina Binti Zainal Abidin, Lecturer of Unit Operation (ECH3117), Department of Chemical Engineering, Universiti Putra Malaysia. Dear Prof. Zurina, This is our project report based on the task given throughout this semester. The topic for the task given is the ‘Production of Ethylene’ from Methanol as our raw materials. As requested, this report need to be submitted to you as part of our assignment for Unit Operation’s subject for semester 2 2019/2020. This report contains executive summary which include the objective of our project, introduction of the project, process description for the production, process flow diagram, material balance, energy balance, unit operation detailed design and mechanical design and drawing. We also include the feasibility of the design, conclusions and recommendations for our project, acknowledgement, bibliography, and references. Thank you. Best Regards, IDEAQO SDN.BHD Group Members. 3|IDEAQO SDN BHD

Table of Contents EXECUTIVE SUMMARY .................................................................................................... 5 INTRODUCTION.................................................................................................................... 6 1.1 Project Background.......................................................................................................... 6 1.2 Process Description ......................................................................................................... 8 MATERIAL BALANCE, ENERGY BALANCE AND ASSUMPTONS ......................... 11 2.1 Excel Calculation ........................................................................................................... 12 2.2 Excel Explanation .......................................................................................................... 28 UNIT OPERATION DETAILED DESIGN AND JUSTIFICATION .............................. 32 3.1 Fractionating Column Detailed Design ......................................................................... 32 MECHANICAL DESIGN AND MECHANICAL DRAWING OF UNIT OPERATION .................................................................................................................................................. 36 DISCUSSION AND CONCLUSION ON FEASIBILITY OF DESIGN........................... 38 CONCLUSION AND RECOMMENDATIONS................................................................. 40 ACKNOWLEDGMENT ....................................................................................................... 41 BIBILOGRAPHY AND REFERENCES ............................................................................ 42 APPENDICES ........................................................................................................................ 43 4|IDEAQO SDN BHD

EXECUTIVE SUMMARY This report basically is about the result production of ethylene with 99.99% purity. Our raw material is methanol with the feed rate given is 100 tons/month. We use methanol in bulk since the pure methanol is expensive and can lower the profit. The methanol with purity of 97%, ethanol and water are required to go to the process selection. In consequence production of ethylene, we choose to undergo MTO process. First, we provide a brief description of MTO process. It consists of 2 main sections: (1) methanol to olefin reaction; and (2) product purification and separation. Since we use pure methanol, production of methanol will not be needed. The first section is omitted if methanol is to be purchased and to be the feedstock to the plant. The reaction for MTO can be shown in two steps. The first step is the conversion of methanol to dimethyl ether (DME) and water. This process involve pump (to maintain the pressure), reactor (to produce DME), cooler (to decrease temperature), distillation column (to separate the gas liquid product beside to increase purity), and heater (to increase temperature). Next, DME is converted to both ethylene and propylene. The ratio between ethylene and propylene production depends on the catalyst, reaction parameters and the technology. This conversion involve reactor, cooler, dryer, condenser, deethanizer and fractionation column. The MTO process converts crude methanol to olefins, which results in savings for a methanol purification section. Some units produce heat energy and some used heat energy. Separable table value of energy is required to manage the costing. Reactor, distillation column, deethanizer, fractionation are all producing heat energy while cooler, condenser, heater, dryer and pump are all use an electricity to function. The production price of ethylene from feedstock of methanol produce RM718,837.21 per ton ethylene per year. The purity of ethylene 99.99% is produced. From the calculation of costing, we found that the total income that we will obtain is RM3,379,090.12 in a year. By considering the overall cost of our plant which is RM100,077,674.01, eventually we will get maximum profit of -RM98,286,186.81 annually. 5|IDEAQO SDN BHD

1. Introduction 1.1 Project Background The conversion of methanol to olefins (MTO) is a means to produce ethylene from feedstock derived from sources other than crude oil or condensates. Methanol is widely produced from natural gas or coal at locations with abundant reserves. By utilizing methanol derived from these costs advantaged raw materials, MTO enables low costs of production for ethylene in a world with high oil prices. Ethylene is the largest of the olefin markets and is also one of the most important petrochemical derived monomers that are used as a feedstock to produce various commercially useful chemical products for example polyethylene, polymers, The aim of this plant design is to provide a comprehensive overview about olefins particularly ethylene production with high purity which is 99.99% and its commercial significance in the world market. This design plant consists of pump, heater, reactor, distillation column, cooler, dryer, condenser, deethanizer and fractionation column. This plant design aims to achieve its purity of ethylene through methanol to olefins (MTO) process. The conversion of MTO process means to produce ethylene from feedstock derived from sources other than crude oil or condensates. 100 ton/month of methanol that is equivalent to 4.2568 kilo moles per hour of methanol is the feedstock of this process. To produce ethylene, DME needs to be created from the feedstock first. Through the reactor, DME was produced from the fresh feed stock with 80% conversion. Then, it is passed to the cooler to decrease its temperature to get it ready for the next unit, distillation column. First, the outlet from the cooler is passed to the distillation column and DME is separated as the distillate product, the purity of DME increased in this column, with 85.9% of purity. The bottom product will be recycled back to the first reactor. From the distillation column, the distillate products were sent to the heater, and then to the second reactor to produce light olefins such as ethylene, propylene with 99.8% conversion of DME and ratio of ethylene to propylene 2.2. Next, the components were sent to cooler to decrease the temperature and after that, the components were sent to the dryer. Dryer is used to remove water from the components. Condenser is needed as to convert the components from vapour phase to liquid phase. In addition, deethanizer is added after the condenser to separate light olefins from the bulk components and sent to the fractionation column. In fractionation, ethylene is with high purity which is 99.4% is produced as the desired product. 6|IDEAQO SDN BHD

To produce ethylene, raw material is needed. In our project design, we used 97% purity of methanol and the rest are ethanol and water. Based on research on 2016, the global world consumption of ethylene, United States is the highest region followed by Middle East, China, and Western Europe. Our market target of production ethylene is Asia Pacific. Among these, Asia Pacific holds the major share of the market due to the growing adoption of lightweight metal in packaging, automotive, construction, and others. The packaging segment holds the major portion and is anticipated to continue its dominance in the market due to unique features offered by alkenes such as compatible, corrosion resistance, and other characteristics. Therefore, countries such as China, Japan, South Korea, and India are the major players in this market. We buy the raw material from China since the price cheaper there. The methanol feedstock increasing year by year. 7|IDEAQO SDN BHD

1.2 Process Description 1.2.1 Pump A pump is a machine that carries or supercharges fluid. It transfers the mechanical energy or other external energy of the prime mover to the liquid to increase the liquid energy. Pump is mainly used to transport water, oil, acid alkali, emulsion, suspended emulsion and liquid metal and other liquids, also can transport liquid, gas mixture and liquid containing suspended solids. In the production of chemical and petroleum sectors, raw materials, semi-finished products and finished products are mostly liquid, and the raw materials into semi-finished products and finished products, need to go through a complex process, pump in these processes played a role in transporting liquid and providing chemical reaction pressure flow. 1.2.2 The heater In metallurgical industry, the heater is the equipment (industrial furnace) that heats the material or work piece (generally metal) to the rolling forging temperature. The heating section is the main heating section, and the temperature of the furnace is high, so that the rapid heating can be realized. The soaking zone is located at the discharging end, and the temperature difference between the furnace and the metal material is very small to ensure that the product is heated evenly. 1.2.3 Reactor Reactor is a kind of equipment to realize the reaction process. It is used to realize the single- phase reaction process of liquid phase and the multi-phase reaction process of liquid liquid, gas liquid, liquid solid, gas liquid solid and so on. The device is equipped with stirring (mechanical stirring, airflow stirring, etc.) device. In the high diameter is relatively large, you can use a multilayer paddle. When the material needs to be heated or cooled in the reaction process, the jacket can be set at the wall of the reactor, or the heat exchange surface can be set inside the reactor, or heat exchange can be conducted through external circulation. Methanol vapour is dehydrated through solid catalyst to form dimethyl ether. The reaction equation for the preparation of methyl ether from methanol dehydration is as follows: CH3OH = CH3OCH3 + 2H2O The whole production process includes heating methanol, dehydration of methanol, and further cooling of methyl ether. Because the catalyst is not suitable to work at high temperature, we 8|IDEAQO SDN BHD

choose 250 degree Celsius to ensure the optimal activity of the catalyst to ensure a relatively high reaction rate. Therefore, the production efficiency will be greatly improved. 1.2.4 Cooler/Condenser Dimethyl ether, as we all know, is a flammable gas. Mixing with air can form an explosive mixture. Contact with heat, Mars, flame, or oxidizer easy to burn explosion. Contact with air or under light conditions can generate potentially explosive peroxide, density than air, can spread to a relatively far place at a lower level, in case of fire source will catch fire and reignite. If encounter high heat, pressure inside container increases, have craze and explosion danger. Therefore, the DME coming from the reflection part needs to go into the cooling room quickly to cool down and prevent the danger. Cooler and condenser are usually to decrease the temperature of the components or to convert the phase the components from vapour to liquid. 1.2.5 Distillation Column / Deethanizer Distillation column utilities in a way such that a mixture is separated into its component by heating the mixture to a temperature in which one or more of its components will evaporate and then is condensed and collected. Fractional distillation column is where it is like the simple distillation, however it is packed with a material that has high surface area packing to make separation more efficient that is caused by the repeated condensation and evaporation. Therefore, only the vapours that has enough amount of energy to stay in the vapour phase and reach the condenser. In result, the component that is condensed can approximately have pure composition. The distillation columns we used are distillation column followed by fractionation. The amount of feed being added is always equals the total amount of product as no reaction occurred. 1.2.6 DTO reactor Fixed bed reactor is chosen because high conversion rate per catalyst. To get high conversion of DME, the catalyst, SAPO-34 need to operate in high temperature in range 300◦C-450◦C. The inputs, which are DME, methanol, ethanol and water entering the reactor in gaseous form. In this process, we assume that methanol, ethanol, and water do not react because this reactor specifically for conversion of DME. This reactor undergoes DTO (dimethyl ether to olefins) reaction, which is basically an intermediate reaction to produce olefins. The ethylene did not produce directly from methanol but produce from DME. Furthermore, we also assume that this reactor is in isothermal condition so that the inlet and outlet temperature is the same. The power 9|IDEAQO SDN BHD

can be calculated from heat of reaction. This reactor is an exothermic because energy produce by products are higher than energy input. The enthalpy changes of every compounds can get from the calculated enthalpy and heat of formation. Heat of formation for the input should be in negative because it is consumed while heat of formation for the output should be in positive value because it is generated. 1.2.7 Fractionation Column Fractional Distillation (fractionation) is a physical process used to separate a fluid mixture of two (binary) or more (multi-component) substances into its component parts. In most cases, the components to be separated are miscible liquids with different volatilities and boiling points. This separation process is a thermal unit operation that utilizes the differences of vapour pressure to produce the separation. In this process, the vapour or liquid mixture is heated whereby the more volatile components are evaporated, condensed, and allowed to drip. In effect, fractionation is equivalent to a series of distillations, where the separation is achieved by successive distillations or repeated vaporization-condensation cycles. Each vaporization- condensation cycle makes for an equilibrium stage, commonly known as a theoretical stage. Fractionation towers may have several outlets at intervals up the column allowing for the withdrawal of different products having different boiling points or boiling ranges. This equilibrium is continuously disturbed by the mixing of the colder descending liquid and the hotter rising vapour, where the more volatile components of the descending liquid are vaporized and the less volatile components of the rising vapour are condensed and the driving force for the separation process is thereby maintained. According to the volatilities and boiling points, ethylene will fractionate out as a overhead product since it has very low boiling point which is -103°C followed by propylene(-47°C). Fractionation can separate ethylene with high purity. Fractionation is carried out in isolated, vertical, cylindrical fractionation columns or towers using different types of contacting devices, with condensers at the top for cooling and partially condensing the top products and reboilers at the bottom for heating and partial evaporation of the bottom products. So, the ethylene from the top product will be in liquid form with the help of condenser in fractionation column which condense the gas ethylene to liquid ethylene. By this process 99.99% purity of liquid ethylene produced. 10 | I D E A Q O S D N B H D

2. Material Balance, Energy Balance and Assumptions Figure 1. Overall BFD for MTO process in ethylene production Figure 1. Overall PFD for MTO process in ethylene production 11 | I D E A Q O S D N B H D

2.1 Excel Calculation 2.1.1 Pump Description Unit S1 S2 From To Liquid Heater 1 Phase Liquid Temperature K 318.15 318.15 Pressure 16 Average Molecular Weight Bar 1.15 32.182 Total Molar Flowrate 4.2568 Ethylene kg/kmol 32.182 0 Propylene 0 Methanol kmol/hr 4.2568 4.1291 Ethanol 0.0851 Water 0 0.0426 DME 0.0000 Total Mole Fraction 0 1 Ethylene 0 Propylene 4.1291 0 Methanol 0.9700 Ethanol 0.0851 0.0200 Water 0.0100 DME 0.0426 0.0000 Total Mass Flowrate 136.9863 Ethylene 0.0000 0 Propylene 0 Methanol kmol/kmol 1 132.2971 Ethanol 3.9222 Water 0 0.7669 DME 0.0000 Total Mass Fraction 0 1 0.9700 0.0200 0.0100 0.0000 kg/hr 136.9863 0 0 132.2971 3.9222 0.7669 0.0000 kg/kg 1 12 | I D E A Q O S D N B H D

Ethylene 0 0 Propylene 0 0 Methanol 0.9658 0.9658 Ethanol 0.0286 0.0286 Water 0.0056 0.0056 DME 0.0000 0.0000 Enthalpy Flow kJ/s 0.07128 2.1.2 Heater 1 Unit S2 S3 Pump Description Reactor 1 From Liquid Vapour To 523.15 Phase K 318.15 16 Temperature 4.2568 Pressure Bar 16 0 Total Molar Flowrate 0 Ethylene kmol/hr 4.2568 4.1291 Propylene 0.0851 Methanol 0 0.0426 Ethanol 0.0000 Water 0 1 DME 0 Total Mole Fraction 4.1291 0 Ethylene 0.9700 Propylene 0.0851 0.0200 Methanol 0.0100 Ethanol 0.0426 0.0000 Water 136.9863 DME 0.0000 0 Total Mass Flowrate Ethylene kmol/kmol 1 0 0 0.9700 0.0200 0.0100 0.0000 kg/hr 136.9863 0 13 | I D E A Q O S D N B H D

Propylene kg/kg 0 0 Methanol kJ/s 132.2971 132.2971 Ethanol 3.9222 3.9222 Water 0.7669 0.7669 DME 0.0000 0.0000 Total Mass Fraction 1 1 Ethylene 0 0 Propylene 0 0 Methanol 0.9658 0.9658 Ethanol 0.0286 0.0286 Water 0.0056 0.0056 DME 0.0000 0.0000 Enthalpy Flow 78.8593 2.1.3 Reactor 1 Description Unit S3 S5 S9 From Heater 2 Heater 2 To Cooler 1 Phase Vapour Vapour Vapour Temperature K 523.15 523.15 523.15 Pressure Bar 16 16 16 Total Molar Flowrate kmol/hr 4.2568 6.5700 4.6269 Ethylene 0 0 Propylene 0 0 0 Methanol 0 0.9049 0.7909 Ethanol 4.1291 0.1562 0.1425 Water 0.0851 3.5583 3.4120 DME 0.0426 1.9504 0.2816 Total Mole Fraction 0.0000 1 1 Ethylene kmol/kmol 1 0 0 Propylene 0 0 0 0 14 | I D E A Q O S D N B H D

Methanol 0.9700 0.1377 0.1709 Ethanol 0.0200 0.0237 0.0308 Water 0.0100 0.5416 0.7374 DME 0.0000 0.2969 0.0609 Total Mass Flowrate kg/hr 136.9863 190.145 106.3453 kg/kg Ethylene 0 0 0 Propylene 0 0 0 Methanol 132.2971 28.993 25.3391 Ethanol 3.9222 7.1990 6.5632 Water 0.7669 64.105 61.4698 DME 0.0000 89.857 12.9731 Total Mass Fraction 1 1 1 Ethylene 0 0 0 Propylene 0 0 0 Methanol 0.9658 0.1524 0.2383 Ethanol 0.0286 0.0378 0.0617 Water 0.0056 0.3371 0.5780 DME 0.0000 0.4725 0.1220 Enthalpy Flow kJ/s 92.8524 2.1.4 Cooler 1 Description Unit S5 S6 Reactor 1 From Distillation To Column Vapour Phase K Vapour 373.15 Temperature Bar 523.15 16 Pressure kmol/hr 16 6.5700 Total Molar Flowrate 6.5700 15 | I D E A Q O S D N B H D

Ethylene kmol/kmol 0 0 Propylene kg/hr 0 0 Methanol kg/kg 0.9049 0.9049 Ethanol kJ/s 0.1562 0.1562 Water 3.5583 3.5583 DME 1.9504 1.9504 Total Mole Fraction 1 1 Ethylene 0 0 Propylene 0 0 Methanol 0.1377 0.1377 Ethanol 0.0237 0.0237 Water 0.5416 0.5416 DME 0.2969 0.2969 190.145 190.145 Total Mass Flowrate 0 0 Ethylene 0 0 Propylene 28.993 28.993 Methanol 7.1990 7.1990 Ethanol 64.105 64.105 Water 89.857 89.857 DME 1 1 Total Mass Fraction 0 0 Ethylene 0 0 Propylene 0.1524 0.1524 Methanol 0.0378 0.0378 Ethanol 0.3371 0.3371 Water 0.4725 0.4725 DME -18.2961 Enthalpy Flow 2.1.5 Distillation Column Description Unit S6 S7 S10 16 | I D E A Q O S D N B H D

From Cooler 1 To Phase K Vapour Heater 3 Heater 2 Temperature Bar 373.15 Liquid Liquid Pressure kmol/hr 16 396.6 452.7 Total Molar Flowrate 6.5700 16 16 Ethylene 0 2.013821 4.556203 Propylene 0 0 0 Methanol 0.9049 0 0 Ethanol 0.1562 0.118214 0.39385 Water 3.5583 0.014304 0.08473 DME 1.9504 0.151756 3.85678 1.729547 0.22090 Total Mole Fraction kmol/kmol 1 Ethylene 1 1 Propylene 0 0 0 Methanol 0 0 Ethanol 0 0.05870 0.0864 Water 0.00710 0.0186 DME 0.1377 0.07536 0.8465 Total Mass Flowrate 0.85884 0.0485 0.0237 86.8607 96.1805 Ethylene Propylene 0.5416 0 0 Methanol 0 0 Ethanol 0.2969 3.7876 12.6191 Water 0.6580 3.9033 DME kg/hr 190.145 2.7340 69.4811 79.6802 10.1769 Total Mass Fraction kg/kg 0 0 1 1 28.993 7.1990 64.105 89.857 1 17 | I D E A Q O S D N B H D

Ethylene 00 0 Propylene 0 Methanol 00 0.13120 Ethanol 0.04058 Water 0.1524 0.04361 0.07224 DME 0.10581 Energy 0.0378 0.00759 0.3371 0.03148 0.4725 0.91733 kJ/s 6.48496 2.1.6 Heater 2 Unit S8 S9 Distillation Description K Column Reactor 1 From Bar Vapour kmol/hr Liquid 523.15 To 452.7 16 Phase kmol/kmol 16 4.5562 Temperature 4.5562 0 Pressure kg/hr 0 0 Total Molar Flowrate 0 0.3939 Ethylene 0.3939 0.0847 Propylene 0.0847 3.8568 Methanol 3.8568 0.2209 Ethanol 0.2209 1 Water 0 DME 1 0 Total Mole Fraction 0 0.0864 Ethylene 0 0.0186 Propylene 0.0864 0.8465 Methanol 0.0186 0.0485 Ethanol 0.8465 96.1832 Water 0.0485 DME 96.1805 Total Mass Flowrate 18 | I D E A Q O S D N B H D

Ethylene kg/kg 0 0 Propylene kJ/s 0 0 Methanol 12.6191 12.6191 Ethanol 3.9033 3.9033 Water 69.4811 69.4838 DME 10.1769 10.1769 Total Mass Fraction Ethylene 1 1 Propylene 0 0 Methanol 0 0 Ethanol 0.1312 0.1312 Water 0.0406 0.0406 DME 0.7224 0.7224 Energy 0.1058 0.1058 62.3578 2.1.7 Heater 3 Unit S7 S11 Description Distillation From K Column Reactor 2 Bar Vapour To kmol/hr Liquid 723.00 Phase 396.57 16 Temperature kmol/kmol 16 2.0138 Pressure 2.0138 0 Total Molar Flowrate 0 0 Ethylene 0 0.1182 Propylene 0.1182 0.0143 Methanol 0.0143 0.1518 Ethanol 0.1518 1.7295 Water 1.7295 1 DME 1 Total Mole Fraction 19 | I D E A Q O S D N B H D

Ethylene kg/hr 0 0 Propylene kg/kg 0 0 Methanol kJ/s 0.0587 0.0587 Ethanol 0.0071 0.0071 Water 0.0754 0.0754 DME 0.8588 0.8588 Total Mass Flowrate 86.8607 86.8607 Ethylene 0 0 Propylene 0 0 Methanol 3.7876 3.7876 Ethanol 0.6590 0.6590 Water 2.7339 2.7339 DME 79.6802 79.6802 Total Mass Fraction Ethylene 1 1 Propylene 0 0 Methanol 0 0 Ethanol 0.0436 0.0436 Water 0.0076 0.0076 DME 0.0315 0.0315 Energy 0.9173 0.9173 2.1.8 Reactor 2 7.08328 Description Unit S11 S12 From Heater 3 To K Cooler 2 Phase Bar Vapour Vapour Temperature kmol/hr 723 723.00 Pressure 16 16 Total Molar Flowrate 2.0138 3.5067 20 | I D E A Q O S D N B H D

Ethylene kmol/kmol 0 1.0263 Propylene kg/hr 0 0.4665 Methanol kg/kg 0.1182 0.1182 Ethanol kJ/s 0.0143 0.0143 Water 0.1518 1.8778 DME 1.7295 0.0035 Total Mole Fraction Ethylene 1 1 Propylene 0 0.2927 Methanol 0 0.1330 Ethanol 0.0587 0.0337 Water 0.0071 0.0041 DME 0.0754 0.5355 Total Mass Flowrate 0.8588 0.0010 86.8607 86.8552 Ethylene Propylene 0 28.7884 Methanol 0 19.6308 Ethanol 3.7876 3.7876 Water 0.6590 0.6580 DME 2.7339 33.8312 Total Mass Fraction 79.6802 0.1594 Ethylene Propylene 1 1 Methanol 0 0.3404 Ethanol 0 0.2321 Water 0.0436 0.0398 DME 0.0076 0.0039 Energy 0.0315 0.3818 0.9173 0.0019 2.1.9 Cooler 2 -0.17586 Description Unit S12 S13 21 | I D E A Q O S D N B H D

From Reactor 2 To Phase K Vapour Dryer Temperature Bar 723.00 Vapour Pressure kmol/hr 16 323.00 Total Molar Flowrate 3.5067 16 Ethylene kmol/kmol 1.0263 3.5607 Propylene 0.4665 1.0263 Methanol kg/hr 0.1182 0.4665 Ethanol 0.0143 0.1182 Water kg/kg 1.8778 0.0143 DME 0.0035 1.8778 0.0035 Total Mole Fraction 1 Ethylene 0.2927 1 Propylene 0.1330 0.2927 Methanol 0.0337 0.1330 Ethanol 0.0041 0.0337 Water 0.5355 0.0041 DME 0.0010 0.5355 Total Mass Flowrate 86.8552 0.0010 86.8552 Ethylene 28.7884 Propylene 19.6308 28.7884 Methanol 3.7876 19.6308 Ethanol 0.6580 3.7876 Water 33.8312 0.6580 DME 0.1594 33.8312 0.1594 Total Mass Fraction 1 1 22 | I D E A Q O S D N B H D

Ethylene 0.3404 0.3404 Propylene Methanol 0.2321 0.2321 Ethanol Water 0.0398 0.0398 DME Energy 0.0039 0.0039 0.3818 0.3818 0.0019 0.0019 kJ/s -361.1206423 2.1.10 Dryer Description Unit S13 S14 S15 From Cooler 2 To K Condenser Liquid Phase Bar Vapour Vapour 293.00000 Temperature kmol/hr 323.00 363.00 16 Pressure 16 16 1.8778 Total Molar Flowrate 3.5067 1.6288 0 Ethylene 1.0263 1.0263 0 Propylene 0.4665 0.4665 0 Methanol 0.1182 0.1182 0 Ethanol 0.0143 0.0143 1.8778 Water 1.8778 0 0 DME 0.0035 0.0035 1 0 Total Mole Fraction kmol/kmol 1 1 0 Ethylene 0.6301 0 Propylene 0.2927 0.2864 0 Methanol 0.0726 1 Ethanol 0.1330 0.0088 0 Water 0 33.8312 DME 0.0337 0.0021 Total Mass Flowrate 53.0240 0.0041 0.5355 0.0010 kg/hr 86.8552 23 | I D E A Q O S D N B H D

Ethylene kg/kg 28.7884 28.7884 0 Propylene kJ/s 19.6308 19.6308 0 Methanol 3.7876 3.7876 0 Ethanol 0.6580 0.6580 0 Water 33.8312 0 33.8312 DME 0.1594 0.1594 0 Total Mass Fraction 1 1 1 Ethylene 0.3404 0.5429 0 Propylene 0.2321 0.3702 0 Methanol 0.0398 0.0714 0 Ethanol 0.0039 0.0124 0 Water 0.3818 0 1 DME 0.0019 0.0030 0 Energy 137944.2667 2.1.11 Condenser Unit S14 S16 Dryer Description Deethanizer From K Vapour Liquid To Bar 363.00 204.00 Phase kmol/hr 16 16 Temperature 1.6288 1.6288 Pressure kmol/kmol 1.0263 1.0263 Total Molar Flowrate 0.4665 0.4665 Ethylene 0.1182 0.1182 Propylene 0.0143 0.0143 Methanol 0 0 Ethanol 0.0035 0.0035 Water 1 DME 1 0.6301 Total Mole Fraction 0.6301 Ethylene 24 | I D E A Q O S D N B H D

Propylene kg/hr 0.2864 0.2864 Methanol kg/kg 0.0726 0.0726 Ethanol kJ/s 0.0088 0.0088 Water 0 0 DME 0.0021 0.0021 Total Mass Flowrate 53.0240 53.0240 Ethylene 28.7884 28.7884 Propylene 19.6308 19.6308 Methanol 3.7876 3.7876 Ethanol 0.6580 0.6580 Water 0 0 DME 0.1594 0.1594 Total Mass Fraction 1 1 Ethylene 0.5429 0.5429 Propylene 0.3702 0.3702 Methanol 0.0714 0.0714 Ethanol 0.0124 0.0124 Water 0 0 DME 0.0030 0.0030 Energy -458.6149 2.1.12 Deethanizer Description Unit S16 S17 S18 From Condenser To Fractionating Phase K Liquid Column Liquid Temperature 204.00 Liquid 360.0 196.1 16 Pressure Bar 1.6288 16 16 1.0837 0.5536 Total Molar Flowrate kmol/hr 25 | I D E A Q O S D N B H D

Ethylene kmol/kmol 1.0263 1.0263 0 Propylene kg/hr 0.4665 0.0489 0.4176 Methanol 0.1182 0 0.1182 Ethanol 0.0143 0 0.0143 Water 0 0 0 DME 0.0035 0 0.0035 Total Mole Fraction 1 1 1 Ethylene 0.6301 0.9470 0 Propylene 0.2864 0.0530 0.7544 Methanol 0.0726 0 0.2135 Ethanol 0.0088 0 0.0258 Water 0 0 0 DME 0.0021 0 0.0062 Total Mass Flowrate 53.0240 30.8455 22.1785 Ethylene kg/kg 28.7884 28.7884 0 Propylene kJ/s 19.6308 2.0572 17.5736 Methanol 3.7876 0 3.7876 Ethanol 0.6580 0 0.6580 Water 0 0 0 DME 0.1594 0 0.1594 Total Mass Fraction 1 1 1 Ethylene 0.5429 0.9333 0 Propylene 0.3702 6.67E-02 0.7924 Methanol 0.0714 0 0.1708 Ethanol 0.0124 0 0.0297 Water 0 0 0 DME 0.0030 0 0.0072 Energy 4.3874 2.1.13 Fractionation Column Description Unit S17 S19 S20 26 | I D E A Q O S D N B H D

From Deethanizer To Phase K Liquid Liquid Liquid Temperature 196.1 240.1 250.2 Pressure Bar 16 16 16 Total Molar Flowrate kmol/hr 1.0837 0.9193 0.1644 Ethylene 1.0263 0.9138 0.1125 Propylene 0.0489 0.0055 0.0517 Methanol 0 0 0 Ethanol 0 0 0 Water 0 0 0 DME 0 0 0 Total Mole Fraction kmol/kmol 1 1 1 Ethylene kg/hr 0.9470 0.9940 0.6843 Propylene 0.0530 0.0060 0.3143 Methanol 0 0 0 Ethanol 0 0 0 Water 0 0 0 DME 0 0 0 Total Mass Flowrate 30.8455 25.7981 4.7098 Ethylene kg/kg 28.7884 25.6326 3.1558 Propylene 2.0572 0.1655 1.5541 Methanol 0 0 0 Ethanol 0 0 0 Water 0 0 0 DME 0 0 0 Total Mass Fraction 1 1 1 27 | I D E A Q O S D N B H D

Ethylene 0.9333 0.9936 0.6700 Propylene 0.3300 Methanol 6.67E-02 0.0064 0 Ethanol 0 Water 00 0 DME 0 Energy 00 00 00 kJ/s 4.6570 2.2 Excel Explanation 2.2.1 Pump Firstly, pump is used to increase the pressure of the fresh feed from 1 bar to 16 bar with 4.2568 kmol/hr flowrate. The output flow and temperature of the pump are constant, but the pressure will be increased in the process. It produces the flow necessary for the development of pressure for the future unit which is reactor. In the whole process, energy is expressed by mechanical energy, so the mechanical energy is 0.0712755 kJ/s. 2.2.2 Heater 1 The output of the pump then is passed to the heater 1 with the flowrate of 4.2568 kmol/hour to increase its temperature from 318.15 K to 523.15 K. It is very important to heat up the components to that temperature as it is an optimum temperature for the next unit, reactor. So that, the chemical reaction that occur in the reactor will achieved the targeted fractional conversion. Pressure is not affected in this unit since both input and output pressure is same which is 16 bar. The compositions of the components are not changing in this unit as well because there is no reaction occurred. In the whole process, the heater absorbs 78.85928 KJ/s of energy. 2.2.3 Reactor 1 The outlet of the heater will then enter the isothermal reactor with the mol flowrate of 4.2568 kmol/hour and temperature of 523.15 K and pressure 16 bar. The presence of catalyst which is SAPO-34 will aid in the conversion of methanol to DME. The temperature for the reactor is high due to the activation of catalyst. The temperature must be maintained for the DME to produce and if the temperature exceeds the optimal temperature, the catalyst will be deactivated. The fractional conversion of methanol to DME is 0.8 making the composition of 28 | I D E A Q O S D N B H D

DME produced in the output is 0.2969. The output flowrate is 4.2568 kmol/hour. The equation below shows the chemical reaction occur in the reactor which is the dehydration of methanol. Ethanol is assumed to be inert in this process. 2CH3OH → CH3OCH3 + H2O Since the chemical reaction is highly exothermic, coolant which is molten salts is added to cool the components. The heat absorbed is calculated which is 92.8523 kJ/s. 2.2.4 Cooler 1 The output of the reactor then is passed to the cooler with the flowrate of 6.5700 kmol/hour to reduce its temperature from 523.15 K to 373.15 K. The components especially DME is very reactive and explosive, so the temperature must be reduced before it enters the distillation column. Besides, since the temperature is too high, if it enters the distillation column, the components will only evaporate instead of forming liquid and gas. Pressure was not affected in this unit since both input and output pressure is same which is 16 bar. The compositions of the components are not changing in this unit as well because there is no reaction occurred. The heat released to the surrounding is calculated to be 43.4788 kJ/mol of total heat energy. 2.2.5 Distillation Column The output of the cooler which is 6.5700 kmol/hour will be passed to the distillation column 1. The purpose of this distillation column is to separate DME and methanol to increase the purity of DME. DME is treated as the light key and the desired purity is 0.99 while methanol as the heavy key with desired purity of 0.01. DME is 0.99. The composition achieved for DME at the top is 0.858839 while methanol at the bottom is 0.082436. The temperature and pressure at the top are 396.57 K and 16 bar while the bottom are 433.83 K and 10 bar. This temperature and pressure used in this column is very important to make sure highest percent of DME is separated. This is because the overhead product including the DME separated will determine the purity of ethylene produced in this project. Based on the reference we have chosen, the total energy of this unit in kW is 5.775910317 which signs that heat is being absorbed during this process. 2.2.6 Heater 2 The stream of bottom product in distillation column enter the heater 2. The aim of heater is to increase the temperature before recycling to reactor 1. The inlet temperature if the stream 8 is 29 | I D E A Q O S D N B H D

452.68 K and the inlet pressure is 16 bar. The output pressure remains unchanged, but the outlet temperature is 523.15 K. The mole flowrate and the mass flowrate are constant since no reaction happens inside. The energy used in heater 1 is 62.358 kW. 2.2.7 Heater 3 From the distillate stream in distillation, the inlet temperature and pressure of the heater is 396.57K at 16 bar. the flowrate entering the heater is 2.0138 kmol per hour. The heater increases the temperature to 723K at 16 bar before the stream is passed to reactor 2. 723 K at 16 bar is the optimum temperature for the reactor 2 to operate well. The flowrate and the mole fraction inlet and outlet are same. The energy used by this heater 3 is 7.08328 kW. 2.2.8 Reactor 2 The reactor 2 is received input from the distillation column with the flow rate is 1.9432 kmol per hour at 723 K and 16 bar. This reactor 2 is assumed as isothermal reactor. The main objective of this reactor is to convert DME to light olefins such as ethylene and propylene. In this reactor, Sapo-34, a zeolite catalyst is used to increase the rate of reaction under optimum temperature which is at 723K and 16 bar. 2 mol of DME are converted to 1 mol of ethylene and 1 mol of water. Besides, the other reaction occurs as 3 mol of DME are converted to 2 mol of propylene and 3 mol of water. About 99.8 percent of DME is converted to light olefins with the ratio of ethylene/propylene is 2.2. The fractional conversion of DME at first reaction is 0.6861 and for the second reaction is 0.3119. The references use to calculate the energy are all components in vapour at 373.15K and 1 atm. The net energy is -0.1901 kW. Since the reactor is highly exothermic, a jacket cooling is added around the vessel to cool the internal substance. 2.2.9 Cooler 2 The output of the reactor 2 then is passed to the cooler 2 with the flowrate of 3.5992 kmol/hour to reduce its temperature from 723 K to 323 K. Pressure was not affected in this unit since both input and output pressure is same which is 16 bar. The compositions of the components are not changing in this unit as well because there is no reaction occurred. From the reference chosen, we obtained 370.64621 kJ/mol of total heat energy. 2.2.10 Dryer From cooler 2, the stream goes in the dryer with the mole flowrate is 3.5067 kmol per hour at 323K and 16 bar. The purpose of this dryer is to remove water component so that the mole 30 | I D E A Q O S D N B H D

composition of ethylene increases. We assumed 100% of water is being removed from the dryer. 1.8778 kmol per hour of water is removed at 363 K and the flowrate of the stream consists of the other components is 1.6288 kmol per hour at 293 K temperature. The outlet pressure for both streams are 16 bar. The net energy for the dryer is 137944.2667 kW. 2.2.11 Condenser The condenser is received the stream from the dryer that contain ethylene and the other products as the inlet. The inlet condition is 363 K temperature at 16 bar with the mole flowrate is 1.6288 kmol per hour. the function of the condenser is to condense the vapor stream to liquid. There are no changes in the mole flowrate and mass flowrate of the outlet stream. The stream goes out from the condenser at 204 K and 16 bar. Since the condenser is exothermic, so the total net energy is in negative value which is -458.6149 kW. 2.2.12 Deethanizer From the condenser, the stream enters the deethanizer with the mole flowrate is 1.6288 kmol per hour at 204 K and 16 bar. The main purposes of deethanizer is to separate the light olefins such ethylene and propylene from the bulk component as this can help to achieve the purity of 99.9% of ethylene at final stream. The stream 17 which is contain the components of ethylene and propylene, will go to the next unit with the mole flowrate 1.0837 kmol per hour at 196.1 K and 16 bar. The stream 18 that consist of the remaining propylene, DME, ethanol, methanol goes out of the condenser with the mole flowrate is 0.5536 at 360 K and 16 bar. The net energy is 4.3874 kW. 2.2.13 Fractionation Column From the deethanizer, the stream 17 enters the fractionation column with the mole flowrate is 1.0837 kmol per hour. the inlet temperature and pressure of the fractionation column are 196.1 K and 16 bar respectively. Fractionation column is needed as to increase the purity of the ethylene up to 99.9%. The components that enters fractionation column are binary mixture. To obtain the mole fraction of liquid and the mole fraction of water, Raoult’s law is applied in the calculation. The Tdp (dew point) and Tbp (boiling point) are calculated using Antoine equation. The distillate products are in liquid phase at 240.15 K temperature and 16 bar pressure. The bottom products are in liquid phase with the temperature and pressure at 250.15 K and 16 bar. The composition of 0.994 ethylene in distillate is the final product of this MTO process. The net energy of this unit is 4.6570 kW. 31 | I D E A Q O S D N B H D

3. Unit Operation Detailed Design and Justification (Fractionating column) Fractional Distillation (fractionation) is a physical process used to separate a fluid mixture of binary or multi-component substances into its component parts. In most cases, the components to be separated are miscible liquids with different volatilities and boiling points. This separation process is a thermal unit operation that utilizes the differences of vapour pressure to produce the separation. In this process, the vapour or liquid mixture is heated whereby the more volatile components are evaporated, condensed, and allowed to drip. In effect, fractionation is equivalent to a series of distillations, where the separation is achieved by successive distillations or repeated vaporization-condensation cycles. Each vaporization-condensation cycle makes for an equilibrium stage, commonly known as a theoretical stage. Fractionating tower have several outlets at intervals up the column allowing for the withdrawal of different products having different boiling points. This equilibrium is continuously disturbed by the mixing of the colder descending liquid and the hotter rising vapour, where the more volatile components of the descending liquid are vaporized and the less volatile components of the rising vapour are condensed and the driving force for the separation process is thereby maintained. According to the volatilities and boiling points, ethylene will fractionate out as overhead product with high purity since it has very low boiling point which is (-103°C) followed by propylene(-47°C). Fractionation is carried out in isolated, vertical, cylindrical fractionating columns or towers using different types of contacting devices, with condensers at the top for cooling and partially condensing the top products and reboilers at the bottom for heating and partial evaporation of the bottom products. So, the ethylene from the top product will be in liquid form with the help of condenser which condense the gas ethylene to liquid ethylene. By this process 99.4% purity of liquid ethylene produced. 3.1 Fractionating Column Detailed Design For the designing part, there are two factors which are looked upon very closely, a process design and mechanical design. Fractionating column considering as binary system since it has ethylene and propylene as inlet components. With the help of process design factors, McCabe- Thiele graphical method was used to determine the number of theoretical stages to achieve the desired product. Inlet of fractionating column are ethylene with purity 94.69% and propylene with purity 5.31% at temperature of 196.10 K and pressure of 16 bar. Since the inlet ethylene purity of the column is high, 2.3 stages including reboiler with a reflux ratio of 1.179 required 32 | I D E A Q O S D N B H D

to achieve 99.4% of ethylene purity at overhead product with the pressure of 240.15 K and pressure of 16 bar. Along that, diameter of the column and height of the tower were calculated which is 0.3 m and 2.5 m respectively. Column diameter is found based on the constraints imposed by flooding. The overall height of the column depends on the plate spacing. For column above 1 m diameter, plate spacing of 0.3 to 0.6 m will normally use. Since fractionating column diameter less than 1 m the plate spacing was determined to be 0.15 m with thickness of 5.0 mm and overall plate efficiency of 68.35%. It is technically possible to have 0.1 m space between trays since inlet ethylene purity is high and less time needed to achieve the desired outlet. The plate efficiency is low due to the low liquid flowrate which lead to weeping. Crossflow plates were used in fractionation where the flowing liquid is transferred from plate to plate through vertical channels called down comers. There are many types of tray used in industry like sieve plate, bubble-cap plate, and valve plates. Sieve trays are flat perforated plate in which vapor rises through small holes in tray floor, & bubbles through liquid in uniform manner. They have comparable capacity as valve trays. Sieve plate was chosen among others due to it has simple construction, low entrainment, low cost, low maintenance cost and low fouling tendency. The mechanical design of tower focuses on internal structure of the tower and arrangement of heat exchanging equipment. Stacked type of construction is used due to the column diameter being too small. From the calculation, the minimum operating rate was determined above weep point. Initially 100 mm was assumed to calculate the base pressure. From the calculation the total pressure drop was determined 72.76 mm. It is because, if there are small changes in physical properties, it will have little effect on the plate design. Thus, 72.76mm per plate is considered acceptable. The down comer area and plate spacing must be such that the level of the liquid and froth in the down comer is well below the top of the outlet weir on the plate above to avoid the column flood if the level rises above the outlet weir. From the calculation it was determined to be 0.3250 which is more than 0.22. So, the plate spacing is acceptable. Sufficient residence time was allowed in the down comer for entrained vapor to disengage from the liquid stream, to prevent heavily aerated liquid being carried under the down comer. For the trial layout, cartridge-type construction was used. 50 mm unperforated strip around the plate edge and 50 mm wide calming zones was designed. From the calculation, the active are was determined 0.0537 m². There are 274 holes with diameter of 5 mm. Larger holes 33 | I D E A Q O S D N B H D

occasionally used for fouling systems. The table below shows the summary of the specification of fractionating column. Detail excel calculation attached in Appendix. Parameters Value Feed specification Cold Liquid Composition Ethylene (94.69%) Propylene (5.31%) Flowrate 1.0837 kmol/hr Temperature 196.10 K Pressure 16 bar Distillate specification Vapor Composition Ethylene (99.4%) Propylene (0.6%) Flowrate 0.9193 kmol/hr Temperature 240.15 K Pressure 16 bar Bottoms specification Liquid Composition Ethylene (68.42%) Propylene (31.50%) Flowrate 0.1644 kmol/hr Temperature 250.15 K Pressure 16 bar Design parameters 1.179 Reflux ratio 2.3 (including reboiler) Number of theoretical plates 1 Feed plate number Column dimensions 34 | I D E A Q O S D N B H D

Column area 0.071 m² Column height 2.5 m Column diameter 0.3 m Plate parameters 68.35% Overall plate efficiency sieve Type of plate mild steel Plate dimensions 0.15 m Plate material 5.0 mm Plate spacing 0.228 m Plate thickness 50.0 mm Weir length 0.0085 m² Weir height 0.0537 m² Down comer area (12%) 5.0 mm Active area 1.964 x 10⁻⁵ m² Holes diameter 274 Holes area 1.25 x 10⁻² m Number of holes 72.758 mm liquid Hole pitch Plate pressure drop 35 | I D E A Q O S D N B H D

4. Mechanical Design and Mechanical Drawing of Unit Operation 3D Drawing of Fractionation Column TITLE : FRACTIONATION COLUMN ITEM NAME : BINARY SYSTEM DISTILLATION COLUMN FOR SEPERATION OF ETHYLENE AND PROPLENE GROUP : GROUP 1 COMPANY NAME : IDEAQO SDN BHD SUPERVISOR : PROF. DR. ZURINA BINTI ZAINAL ABIDIN SUPPORTING CALCULATION : APPENDIX SIDE VIEW OF SIEVE PLATE 3D VIEW OF DISTILLATION TOP VIEW OF DISTILLATION COLUMN COLUMN 36 | I D E A Q O S D N B H D

2D Drawing of Fractionation Column TOP VAPOUR OUTLET TITLE : FRACTIONATION COLUMN ITEM NAME : BINARY SYSTEM DISTILLATION COLUMN FOR SEPERATION OF ETHYLENE AND PROPLENE GROUP : GROUP 1 COMPANY NAME : IDEAQO SDN BHD SUPERVISOR : PROF. DR. ZURINA BINTI ZAINAL ABIDIN SUPPORTING CALCULATION : APPENDIX REFLUX COLUMN SHELL LIQUID RETURN WEIR FEED NOZZLE SIDE VIEW OF SIEVE PLATE WITH LIQUID FLOW DEMONSTRATION DOWNCOMER AREA REBOILER TOP VIEW OF SIEVE PLATE HOLE DETAILS RETURN SCALE 1:5 2D VIEW OF DISTILLATION COLUMN 37 | I D E A Q O S D N B H D

5. Discussion and Conclusion on Feasibility of Design First, the design plant is mainly targeted to produce ethylene with 99.99% purity. It consists of 12 units with 7 main units. In terms of technical feasibility, this design plant is technically feasible. This is because this design only requires 7 main units which is in its minimum range and uses reliable resources when it is being operated. The utilities used also consists of water, refrigerant and electricity. So that, the technical resources will easily be available to the organization. With that being said, the technical team can convert this design plant to a working system. In terms of economic feasibility, this design plant does not have its viability and it is not economically feasible as well. This is because, based on the economic analysis made to make the cash flow, our company is still operating at lost after 20 years being operated. Based on the market research on marketing of ethylene in China, the average price of ethylene is RM3,981.64/ton. Besides the main product, the by-products that we sell are also ethane, propylene, and propane. The maximum price of all our products is RM15,915.18 per ton, while the minimum price of it is RM7,895.73 per ton, giving the average price of RM11,905.45 per ton. Based on our cash flow, our maximum annual profit will be a negative of RM98,286,088.41 and the minimum is -RM99,639,977.75 at lost, giving the average profit of -RM98,963,033.08 annually. In 20 years, we calculated that our maximum net profit that we will get is a loss of RM1,964,323,937.82. This indicates that in 20 years, our company is still operating at a lost and it is not economically feasible. Furthermore, this design plant has its impact on society, environmental and sustainable development. The environmental impact of this design plant is it uses MTO (methanol-to-olefin) process which has less negative environmental impact to the environment. Some experts favour methanol-to-olefin (MTO) process since it is low investment and environmental impact. Regions such as China that lack domestic sources of crude oil have turned to MTO technology to take advantage of alternative feedstocks such as coal and natural gas. The environmental-friendly impact stated above also automatically gives positive impact to the society. Ethylene is a fundamental product to be sold as it has many usages in our industrial process thus contributing it to the society. For example, ethylene is the starting material for several industrial syntheses. It is employed as an intermediate in the chemical industry and to produce plastics. Not just that it is used in the production of specialty glass for the automotive 38 | I D E A Q O S D N B H D

industry (car glass and used as an anaesthetic in medical fields. This shows how the product of our design plant is very useful to the society and can help in catering the demand of this product. In terms of sustainable development, the two most widely used components to make plastics are ethylene and propylene, and both have traditionally been derived from crude oil. It also produces the highest yields of light olefins at the lowest cost of production, with the lowest catalyst consumption and the lowest operating cost. In terms of production, this MTO process is widely chosen as it is possible to efficiently adjust the ratio of propylene and ethylene produced so operators can most effectively meet demand for those products. Furthermore, comparing with the traditional way to produce olefins by steam cracking, this process offers benefits such as a more flexible range of ethylene‐to‐propylene ratio, higher selectivity toward light olefin, and mild reaction conditions. This shows the sustainability of this ethylene production is very high by using MTO process. 39 | I D E A Q O S D N B H D

6. Conclusions and Recommendations In conclusion, MTO process that our group has chosen to consist 2 stages. First the methanol converted into DME (dimethyl ether) and then from DME to olefins or we called that as DTO process. By feeding 100 tons per month of methanol, our company can produce 199.009-ton ethylene per year. From the process our final product should be ethylene, propylene, and all this product are selling in the market. SAPO-34, the catalyst that has been used in the reactor helps high conversion of DME in DTO reactor. The purity of ethylene produces is 99.4%. The number of theoretical stages in fractionating column s 2.3 including reboiler and the reflux ration is 1.179. From the calculation of costing of the maximum income calculated is RM 68,979,632.69 and the minimum is RM 51,786,775.12 for 20 years. These are several recommendations to be improved in next project: 1. We need to reduce the units to save the cost. 2. We did not consider the waste treatment, so waste treatment should be handled carefully for environments safety. 3. Use a distillation column with high temperature so higher purity ethylene can be achieved although this might insure higher maintenance and production costs. 4. Reactor with high efficiency should be used in order to produce more DME so that more ethylene can be produce. 5. Insulation required for distillation column, separator and fractionation for energy savings and prevent the column from being affected by swings in the weather, changing the heat transfer rate at the tower surface. 40 | I D E A Q O S D N B H D

Acknowledgement First, thanks to God because give me and my friends to complete this report for our design project just in time. Even we faced with a lot of difficulties along to complete this design project. Then, regarding to the design project that has been assigned to us entitled Production of Ethylene from Methanol, we would like to express deepest appreciation to our lecturers, Professor Zurina for giving us the opportunity to carry out this project and helped us a lot in finishing this project and being such a good guider for us while we are doing this design project. Thank you for continually and convincingly give us spirit to do the research and finish up the project. Without your guidance and persistent help, this design project would not have been possible. We would also like to express our heart full gratitude towards our group mates and classmates for their invaluable advice for the successful completion of our project and helped us a lot to carry out this design project. They patiently teach us a lot on how to use the Microsoft Excel to calculate our energy balance using formula, teaches us how to draw the process flow diagram and how to the design for the unit operation part. We also like to extend our sincere thanks to them for their invaluable help and always support us. They have given us guidance, suggestions, and motivation throughout the project. Finally, we take this opportunity to mention our sincere thanks to those who have helped us knowing or unknowingly for the completion of our project. 41 | I D E A Q O S D N B H D

Bibliography and References 1. Cho, W., Yu, H., Ahn, W. S., & Kim, S. S. (2015). Synthesis gas production process for natural gas conversion over Ni–La2O3 catalyst. Journal of Industrial and Engineering Chemistry, 28, 229-235. 2. Coulson and Richardson Volume 6, Chemical Engineering Design 3. Dughaither, A. S. (2014). Conversion of Dimethyl-Ether to olefins over HZSM-5: Reactivity and kinetic modeling. 4. Engineering ToolBox, (2008). Ethane - Thermophysical Properties. [online] Available at: https://www.engineeringtoolbox.com/ethane-d_1417.html 5. Gądek, M., Kubica, R., & Jędrysik, E. (2013). Production of Methanol and Dimethyl ether from biomass derived syngas–a comparison of the different synthesis pathways by means of flowsheet simulation. In Computer Aided Chemical Engineering (Vol. 32, pp. 55-60). Elsevier. 6. Iulianelli, A., Ribeirinha, P., Mendes, A., & Basile, A. (2014). Methanol steam reforming for hydrogen generation via conventional and membrane reactors: a review. Renewable and Sustainable Energy Reviews, 29, 355-368. 7. Iulianelli, A., Ribeirinha, P., Mendes, A., & Basile, A. (2014). Methanol steam reforming for hydrogen generation via conventional and membrane reactors: a review. Renewable and Sustainable Energy Reviews, 29, 355-368 8. Perry Chemical Engineering Handbook 9. Tang, H. Y., Erickson, P., Yoon, H. C., & Liao, C. H. (2009). Comparison of steam and autothermal reforming of methanol using a packed-bed low-cost copper catalyst. International Journal of Hydrogen Energy, 34(18), 7656-7665. 10. Transport Processes, Geankoplis 42 | I D E A Q O S D N B H D

Appendices Manual Excel Calculation 1. Pump 2. Heater 1 43 | I D E A Q O S D N B H D

3. Reactor 1 44 | I D E A Q O S D N B H D

4. Cooler 1 45 | I D E A Q O S D N B H D

46 | I D E A Q O S D N B H D

5. Distillation column 47 | I D E A Q O S D N B H D

48 | I D E A Q O S D N B H D

6. Heater 2 49 | I D E A Q O S D N B H D