Design Project

Fall 2004

Acetone is typically produced in commercial quantities as a by-product during the formation of phenol.
However, acetone manufactured thus generally contains small amounts of the reactant benzene and the
desired product phenol. In the past, these impurities were deemed to be within allowable limits. However,
recent downward revisions of these limits by the US Food and Drug Administration has made alternative
processes (which do not involve benzene) more attractive. We wish to begin the design of one such alternative
process to produce 10,000 metric tons of acetone per year with a purity of 99.9%.

Part I

As part I of the project, you need to gather information about the process for acetone production and
develop a flow diagram. In particular, you need to do the following:

1. Describe the reactions that occur in the process where acetone is produced as a by-product during
the formation of phenol from benzene (process 1).

2. Describe the reactions that occur in the process where isopropyl alcohol is used as a reactant (process
2).

3. At what conditions (e.g. pressure, temperature) do the reactions for process 2 occur? What conver-
sions can be expected?

4. Utilize the Douglas Hierarchy and develop a flow diagram for process 2. Describe each step as well
as the rationale for each alternative. Find out the cost prices of the reactants and the selling price of
acetone and perform a preliminary economic analysis.

Part II

Consider the following reactions involved in making acetone.

(CH3 )2 CHOH −→ (CH3 )2 CHO + H2

The first reaction produces the desired product, acetone (AC) and hydrogen (H) while the second reaction
produces undesired product, di-isopropyl ether (DE) and water (WA). The reaction proceeds at 2 atm and
a temperature range of 300 o C to 360 o C.

As part II of the project, you need to do the following:

1. Utilize the Douglas Hierarcy to describe the rationale for using the BFD shown in Figure 1. Convert
this BFD into a skeleton PFD.

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 2. Assuming that there is no recycle, compute the mass balances necessary to get the desired product
specification. Use the following conversion information.
Team Temperature Conversion moles DE/moles AC
1 300 46.3 0.0100
2 310 55.4 0.0095
3 320 64.6 0.0090
4 330 73.4 0.0080
5 340 81.3 0.0070
6 350 87.8 0.0060
7 360 92.7 0.005

3. Now compute the mass balances with recycle.

This part of the project is done without using CHEMCAD. You are allowed to use a spread-sheet to do
calculations. Please note that many details have been left out in Figure 1 and some of the information in
the figure may not be correct.

Absorber
Feed
Reactor Flash

Acetone
Mixer
Recycled
Distillation

IPA
Distillation

DE, Water

Figure 1: Block Flow Diagram

Part III

As part III of the project, you need to do the following:

1. Utilize the BFD that you used in Part II and compute the molar flowrate of each stream in the
flowsheet using CHEMCAD.

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 2. Compute the energy balance using CHEMCAD and determine the heating/cooling requirements for
each unit.

3. Compare your CHEMCAD results with hand calculations done in Part II and comment on the differ-
ences (if any).

4. Specify which heuristics you used from TBWS to set pressure and/or temperature levels in the BFD.

Part IV

As part IV of the project, you need to do the following:

1. Determine the size of each equipment in your BFD. Specify which heuristic you used from TBWS for
sizing each unit.

2. Specify which type of equipment you are using and its material of construction.

3. Determine the total capital cost of your process by using CAPCOST.

4. Determine the total manufacturing cost of your process by using CAPCOST.

Final Design Project

Write a design report using the instructions given in TBWS that include all the questions asked in Parts
I-IV. You need to back up all your results and conclusions with appropriate calculations and/or references
to heuristics.