DESIGN PROJECT 2 (NKB40303)

PRODUCTION OF ACRYLONITRILE FROM PROPYLENE AND

AMMONIA
Introduction
What is the Acrylonitrile?
What is the Acrylonitrile?

 Known as acrylic acid nitrile, propylene nitrile, vinyl

cyanide.
 The propylene, ammonia and Oxygen are the main raw
material consumed in this process of Ammoxidation of
Propylene known as SOHIO Process.

 Our plant is operated for 24 hours per day,340 day per year
and the production of the plant is 119000 tonnes per year.
 Piping and Instrumentation Design
10 2
27

V-9
Ammonium sulphate
TK-3
Water TK-5
9

2 V-8 Exhaust Gas

420 HE-4
High Steam HE-1 17 V-17
V-10 33
V-20 P-6 V-27
8 21 V-26
7
V-18 2 2 V-32 V-33
16 2 80 24 26
V-7 7 420 CD-1 25 2 2 CD-2
CM-2 Sulphuric 100 25
22
Acid V-16 Upper 2
85 18
RE-1 Section VT-3
2 15 14 V-21 Water 25
420 D-1
2 TK-4 18 V-19 20
150 TK-8 31
QC-1 V-14 V-15 TK-10
AC-1 24 RC-1 HD-1 39
V-11 ********** VT-2 2
2
50
2 V-6 100 VT-4 VM-1 2
150 6 TK-6 D-2 80 2
4 2 PH-1 Hydrogen 50
Lower 420
V-25
V-29 32 CD-3 V-40
VP-1 11 Section Water Cyanide
V-4 2
12 19
5 150 21
26
2 29
CM-1 2 37 TK-12
V-5 VT-1 80
V-36 2
PH-2 85 80 PR-1
1 V-22 V-39 2
V-12 V-28 28 2 50
2 27 80 V-34
V-1 VP-2 25 SC-1 TK-9 V-35 34 P-8
35
Acrylonitrile
P-1 W=
23
TK-7 V-24
TK-1 3 V-3 Acetonitrile
HE-2 2 V-23 P-5 2
25 HE-5 60
2 V-13 HE-3
13 Catalyst P-4
Propylene 1.8 Settling Pit 30 V-37 36
79 V-30
V-2 GT-1 2 TK-11
V-31 27
P-2 V-38

Oxygen Heavy Impurities

TK-2 P-3 P-7 HE-6 P-9

Ammonia
 DESIGN OF MAJOR EQUIPMENT

1. Fluidised Bed Reactor 4. Recover Column

2. Quench Column 5. Head Drying Column
3. Absorption Column 6. Product Column.
4. Stripper Column
 10 2
27

Fluidised Bed Reactor Water

TK-3
V-9

2 V-8
High Steam 420
HE-1
V-10
8
7

V-7 7
CM-2

RE-1
2
420
2
150

2 V-6
150 6
4
VP-1
2
V-4 5 150

V-5 CM-1
1

V-1 VP-2
P-1
TK-1 3 V-3

Propylene
V-2 GT-1
P-2
Oxygen
TK-2

Ammonia
Process Flow of Fluidised Bed Reactor

 Reactor is the heart of the entire process.  

1) Acrylonitrile (C3H6 + O2 + NH3 → CH2 = CH - CN + 3H2O)
 The production of acrylonitrile from
2) Acetonitrile formation (C3H6 + 3/2 O2+ NH3→ 3/2 CH2CN + 3H2O)
Propylene, Ammonia and Oxygen is
accomplished catalytically in a fluidized 3) Acrolein formation (C3H6 + O2 → CH2 = CHCHO + H2O)

bed reactor, forming some other by 4) Acrylic acid (C3H6 + O2 → CH2 = CHCOOH + H2O)
products.
5) Hydrocyanic acid (C3H6 + 3O2 + 3NH3 → 3HCN + 6H20)
 The reactions are highly exothermic.

 The catalyst used, bismuth molybdate base

6) Propylene burning to carbon dioxide (C3H6 + O2 → 3CO2 + 3H2O)
at 400-510°C and 50-200 kPa
 Assumptions: (fine particles)
Fluidised Bed Reactor a. It is the first order reaction

b. The reactor operates isothermally at constant

density and at a steady state.

c. The fluidizing (reactant) gas is in convective

flow through the bed only via the bubble gas
region (with associated clouds and wakes).

d. There is no convective flow of gas through

the emulsion region.

e. The bubble region is in PF (upward through

the bed).

Ref :- 1. Chemical engineering, J kingsauduniv,

Figure 1 Equipment Diagram of Reactor
Vol 4, Eng.sci.(2),page. 127-142
 Mechanical design of reactor
Fluidised Bed Reactor No Description Specification Unit
Process design of reactor 1 Material of constructions SS321L  
  Process design of the     2 Inside diameter 9.8446 M

FBR 3 Shell thickness 12 mm

No 4 Outside diameter 9.8686 M

Description Specification Unit
5 Insulation Red Mud  
1 Design model K-L model  
2 Type Fluidized bed - 6 Insulation thickness 50 Mm

3 Shape Vertical cylinder - 7 No of heads 2  

4 Height 7.983 M 8 Thickness of heads 12 mm

5 Diameter 9.8446 M 9 Height of head 1.355 m
6 Catalyst Bismuth   10 Reactor height including 7.983 m
molybdate heads
7 Temperature 420 ˚C 11 Type of support Bracket  
8 Pressure 2 Bar 12 Feed location Bottom through  
9 Weight of catalyst 3203.791 Kg spurgers
10 Residence time 30.342 sec
13 No of brackets 8  
11 Flow rate of feed 10.841 m3/sec
14 Tube diameter 50 mm
12 No of cyclones 13  
15 Tube length 8 m
13 No of cooling tubes 1018  
 Ammonium sulphate

Quench Column TK-5

17 V-17

2
V-18
16 420 CD-1
Sulphuric
Acid Upper 2
V-16 85
15 Section 14
TK-4
QC-1 V-14
V-15
V-11 **********
TK-6
Lower 2
420
11 Section Water
12

V-12 Catalyst
Settling Pit

TK-7
HE-2
13 V-13
1.8
79

P-3
Process Flow of Quench Column

 The Quench Tower was built with two sections which is upper and lower.
 The lower stage spray will trap the catalyst fines and polymers and remove it
from the bottom of quench column.
 At the quench upper stage, unreacted ammonia is neutralized by sulphuric
acid distributed by spray spargers.
 Ammonium sulphate solution will be obtained.
 The gaseous stream later enters coolers and will be cooled from 850C to
about 350C using cooling water.
 Process design of Quench Column

Quench Column Parameter

Material
Value
Stainless steel 304
Design pressure, kPa 202.650
Process design of Quench Column
Design temperature,
Design temperature, °C
°C 420
420
Parameter Value Vessel
Vessel thickness,
thickness, mm
mm 10
10
Longitudinal
Longitudinal stress,
stress, N/mm
2
4.63
The superficial gas velocity, m/s 4.795 N/mm2 4.63
Circumferential stress, 9.26
The diameter of the column, m 6.25 Circumferential stress, 9.26
N/mm2 2
N/mm
The dry-gas-pressure drop, Pa/m 167.25 Dead weight stress, N/mm22 5.03
Dead weight stress, N/mm 5.03
The liquid holdup in the column 0.44 Dead weight, N
Dead weight, N
The actual pressure drop when the bed Total longitudinal stresses, 14.23
Total 2 longitudinal stresses, 14.23
is irrigated, Pa/m 311.085 N/mm
N/mm2
Skirt support thickness, mm 20
Number of transfer units 5 Skirt support thickness, mm 20
Wind Loading, N/m 1088.64
The overall height of a gas-phase Wind Loading, N/m intensity, 1088.64
Maximum stress 0.39
transfer unit, m 8.66 Maximum
N/mm2 stress intensity, 0.39
The packed column height, m 43.76 N/mm2
Quench Column
Absorption Column
Exhaust Gas

V-20 21

2
25
22
18
V-21 Water
20
TK-8
AC-1 24
VT-2
PH-1 V-25

19
21

VT-1
PH-2
V-22
2
25

23
V-24
2 V-23
25
HE-3 P-4
Absorption column
 Used to recover the Acrylonitrile and other organic reaction products.

 CO, CO2, N2, unreacted oxygen, unreacted propylene and hydrocarbons, which
are not absorbed come out from the top and sent to the incinerator.

 The unabsorbed gas molecules were vented out at the top of absorber.

 Recover 99% of Acrylonitrile in the feed gases.

 Bottom stream is cooled then passes through the propylene vaporizer.

 ABSORPTION COLUMN DATA SHEET

Construction And Material

Type of material Carbon steel (SA-285, Grade C)
Type of tray Seive
No. of stages 30
Positions of feed tray 8
Column height, h (m) 16
Column diameter, Dc (m) 0.379
Area of column, A (m2) 20.24
Closure volume, Vh (m3) 0.396
Column volume, Vc (m3) 0.5
Total column volume, Vt (m3) 95.26
 16
m

0.4 m
Recovery Column HE-4

P-6 V-27
V-26
2
2 80 24 26
100

VT-3
25
D-1
31
RC-1
2
100 VT-4 VM-1
D-2
V-29

26
2 29
80

V-28 28 2
27 80
SC-1 TK-9

Acetonitrile
P-5

V-30 30

V-31

P-7
Recovery column
 Tray tower which separates the acrylonitrile from acrylonitrile by extractive distillation.

 The acetonitrile goes out at the bottom of the column in dilute water solution.

 Raw acetonitrile, namely a binary azeotrope with 20% water, separates in top.

 The bottom stream contains water with heavy impurities.

 Column operate at vacuum distillation at 0.5 bar is adequate to limit the bottom
temperature.
 RECOVERY COLUMN DATA SHEET

Process Data

Operating Conditions
Temperature (oC) 100
Pressure (atm) Atmospheric pressure
Relative Volatility, 5.89
Reflux Ratio 0.88

Construction And Material

Type of material Carbon steel (SA-285, Grade C)
Type of Tray Seive
Theoretical No. of Trays, Ntheory 12

Actual No. of Trays, Nactual 20

Column Height, h (m) 7.01
Column Diameter, Dc (m) 0.8
Plate thickness (mm) 5.0
Hole diameter (mm) 5.0
Plate Spacing, lt (m) 0.5
 (4)Stripper Column
 Absorption of gases into a liquid (to remove contaminants) and stripping of dissolved
gases from a liquid (to remove contaminants from a liquid stream) are usually
carried out in packed columns (or plate columns for large gas volume operations).
 The packing provides a large surface area per unit volume so that, when contacted,
it can provide a large area for mass transfer. In this experiment we will study the
stripping of dissolved Acrylonitrile in water using Hydrogen cyanide as the carrier
gas. (Strigle, 1994 & Billet, 1995).
 The diameter is determined by the gas velocity which must be small enough to
prevent entrainment and flooding of the column.
 The design of packed column using Intalox Saddles is covered in books by Strigle
(1994) and Billet (1995).
Figure: Packed Stripper Column
SPECIFICATION OF STRIPPER COLUMN
Stripper Column
Identification Item Stripper Column

Item No SC-1

Function To regenerate acrylonitrile

Operation Continuous

Design Data
Type Packed Column

Tower Material Stainless Steel

Number of 5 Stages
Stages
Column Height 3.0 m

Column 0.9 m
Diameter
Packing Type Intalox Saddles

Packing Size 2.0 in or 51 mm

 (5)Head Drying Column

 Separation is obtained in a flash operation by specifying the pressure and

temperature in the flash drum, so that the temperature is between the feed that
entering the equipment.

 Flash Separation Distillation column is one of the simpler separation processes to be

employed in a chemical plant.

 In flash separator column, component consists of Acrylonitrile, Acetonitrile, Water

(H2O), Acrylic acid, Hydrogen cyanide(HCN) and Acrolein.

 The vapor product that came out from the top stream is HCN due to its lowest
boiling point (25°C) and the remaining component leaves at bottom stream as liquid
product (LIU, HUO, MA, & QIAO, 2006).
 The feed enters at 80°C,the equipment which is Acrylonitrile, Acetonitrile,
Water (H2O), Acrylic acid, Hydrogen cyanide (HCN) and Acrolein.

 In between these products, HCN will enter as vapour while the remaining
composition enters the equipment as liquids.

 Vapor-liquid equilibrium principle will cause the vapor phase which is HCN and
the liquid phase which is Acrylonitrile, Acetonitrile, Water (H 2O), Acrylic acid
and Acrolein to have different compositions.

 The reaction that occurs inside the flash separator, HD-1 equipment is the
Vapor-Liquid Separator.
 SPECIFICATION OF HEAD DRYING
MECHANICAL DESIGN SPECIFICATION DATASHEET
Type Vertical Flash Drum
Process description:
Feed temperature = 80°C Top temperature = 25°C
Operating pressure = 1.8 bar Bottom temperature = 84°C
Specification Data
Material construction Stainless steel, Alloy 625
Type of flash tower Vertical Flash Drum
Permissible velocity,Ut (m/s) 1.562
Diameter of vessel, DV (m) 0.275
Head Thickness, m 2.135 x10-3
(Hemispherical)
Vessel wall thickness (m) 2.27 x10-3
Height total (m) 339.885
Volume hold up, VH (m3) 13.38
Volume surge,VS (m3) 6.69
Height of hold up liquid, HH (m) 225.27
Height of surge, HS (m) 112.63
Height to inlet centerline, HLIN (m) 0.496
Height of disengagement, HD (m) 1.1056
Height of low liquid level, HLLL (m) 0.381
Nozzle diameter, DN (m) 0.0362
Product Column
39 2
50
2
50
CD-3 V-40

37 TK-12
PR-1
V-39 2
50

35
Acrylonitrile

2
60

V-37 36
2 TK-11
27
V-38
Heavy Impurities
HE-6 P-9
Process description

 Vacuum condition was applied in product column. The column

pressure is at 600 mm Hg with temperature feed at 50 °C
 Product at top temperature is at 55 °C while bottom temp is
at 60°C.
 The top product will be stored in Acrylonitrile storage before
being sold to the market.
 The bottom effluents of the column need to be further
treated because it contains heaviest product and by-products.
Product Column
Column Sizing
 Capacity/ hr = 3, 523, 098.04 m3
 Volume of cylinder = ∏r2 h
 Vc = 3, 523, 098.04 m3
 hc = 448.57 m
 Dc = 100.0 m
 Area of cylinder = 2 ∏rh + 2 ∏r2
 Area of hemisphere = 4/3 ∏r2
 Ac = 156839.82 m2
 If Dc >1m, plate spacing lt ,
 Height of the column = (no of plates + 2) x plate spacing
 lt = 7476.25 m
 Design pressure, P = 600mm Hg
 Design temperature = 60 °C
Sieve tray with hydraulic model
DESIGN OF AUXILARIES
EQUIPMENT
 (1)Centrifugal Pump

Parameter Value Tangential velocity of inlet vane edge, U1 56.2 ft/s

Diameter of suction flange, DSU 10 in Vane angle at inlet, 1 13o

Velocity in suction flange, VSU 11 ft/s Impeller outlet diameter, D2 13 ½ in

Shaft Diameter, Ds 2 1/8 in Radial component of outlet velocity, Vr2 11 ft/s

2 ½ in Vane angle at outlet, 2 20o

Impeller hub Diameter,DH
Total passage width at outlet, b2 1.98 in
Impeller eye Diameter, Do 7 5/16 in
Tangential velocity of outlet vane edge, 2 103.7 ft/s
Velocity through impeller eye,Vo 11 ft/s
Absolute velocity leaving impeller, V ' 52.5 ft/s
Diameter of inlet vane edge,D1 -7 5/16 in
Angle of water leaving impeller, V ' 13o
Velocity at inlet vane edge,V1 = Vr1 12 ft/s
Number of Impeller van,z 6
Passage width at inlet, b1 1.75 in per side
Centrifugal Pump
(2) Gas Holder Tank 27mm

600mm
1600 mm

13.552mm

5.62mm
Figure:Gas Holder Tank

Figure:Gas Holder Tank

Gas Holder Tank

Parameter Value
Design pressure p 1.765 N/mm2 (18 kg/cm2)
Design Temperature T 183°C
Design Code - ASME SEC.VIII Division 1
Design Height Vessel 1600mm
Inside radius of tank R 300 mm
Inside Diameter of vessel D 600mm
Joint Efficiency J 1
Safety Factor F.S 1.8
Corrosion Allowance C.A 3.0 mm
(3)Catalyst Settling Pit

Parameter Value
Type Rectangular basin
Width 2.285 ft
Length: 9.14 ft
Area 20.9 ft2
Volume 23.34 ft3
Depth 1.117 ft
The flow through velocity 0.12 ft/min
Where all the remaining Catalyst are undergoes The weir length 6.98 ft.
this Catalyst for Waste Treatment purposes.
Influent baffle to reduce flow momentum  
 (4)Decanter
 Product from top recovery column enter as feed

 Assuming separation of water and organic phase in the decanter about 97%.

 For a horizontal, cylindrical, decanter vessel, the interfacial area will depend
on the position of the interface.
Drain valve should be fitted at interface so that any tendency for an emulsion can
be checked; and the emulsion accumulating at the interface rained off
periodically as necessary.
(5)Heat Exchanger
 Shell and tube heat exchanger with the main function to increase or decrease the
temperature of the stream.

 2-shell 4-tube heat exchanger have been choose for this function.

 Deliver reliable heat transfer performance by utilizing a high turbulence and counter flow.
 Tube Side Shell Information Values
Cold Fluid Fluid Name Hot Fluid Tube OD 0.0238 m
30 Temp. in, °C 200
BWG 18
157.04 Temp. out, °C 90
Av. Density 180 r, Kg/m3 912.5 Tube Thickness 0.00124 m
Av. Viscosity 0.00164 m, Ns/m2 0.486
Tube ID, d 0.01975 m
Av. Heat 2.010 Cp, kJ/kg°C 4.18
Capacity Tube Length, L 3m

Heat 1,063.98 Q, kW 1,063.98 Tube type Stainless Steel

Exchanged
Tube thermal 16.8583 W/m.K
Av. Thermal 0.1450 k, W/m°C 0.1200
conductivity
Conductivity
Type of head split- ring floating head
Fouling 0.00088 R, m² °C/W 0.00018
Resistance Number of tubes 165

LMTD 89.7 °C
 Information Values
Pattern Square
Baffle Spacing 1.66 m

Area of Shell 0.01382 m²

Equivalent Diameter, de 0.013 m

Inner shell diameter 0.4546 m

Segmental baffle cut 25%

Heat coefficient in, hi W/m² K

Overall heat transfer coefficient W/m² K

(6)Condenser
 Tube Side Shell

Cold Fluid Fluid Name Hot Fluid

0 Temp. in, °C 55
30 Temp. out, °C 25
Av. Density 1000 r, Kg/m3 1596
Av. Viscosity 1.2 m, Ns/m2 2.816 x10-4
Av. Heat Capacity 2.010 Cp, kJ/kg°C 61.95
Heat Exchanged 11.91 Q, kW 119.1
Av. Thermal 0.1450 k, W/m°C 0.1200
Conductivity
Fouling Resistance 0.000325 R, m² °C/W 0.0002
LMTD 25.00 (Counter-current flow)

Table : Operating condition

 Information Values

Tube OD 0.014605 m

BWG 1

Tube Thickness 0.00762 m

Tube ID, d 0.11811 m

Tube Length, L 1074.43 m

Tube type Stainless Steel

Tube thermal 16.8583 W/m.K

conductivity
Type of head split- ring floating head

Number of tubes 16

Table 2: Tube Dimension

 Information Values
Pattern Square

Baffle Spacing 0.904 m

Area of Shell 0.01382 m²

Equivalent Diameter, de 0.013 m

Inner shell diameter 0.4546 m

Segmental baffle cut 25%

Heat coefficient in, hi W/m² K

Overall heat transfer W/m² K

coefficient
Table : Shell dimension
(7)Acrylonitrile Storage Tank

 Acrylonitrile and Acetonitrile storage tank (main production)

 Capacity/ day = 432.11 m3
 Volume of cylinder = ∏r2 h
 Vc = 2668.73 m3
 hc = 14.63 m (standard API tank size)
 Dc = 15.24m (standard API tank size)
 Area of cylinder = 2 ∏rh + 2 ∏r2
 Ac = 341.41 m2
 Design pressure, P = 101.325 kPa
 Design temperature = 25 °C
 Thickness of the wall => 0.305 m
 
Physical properties of Acrylonitrile

Characteristic Colourless liquid with a

pungent odour
Boiling point 77.3 °C
Burning velocity (in air) 0.47 m/s
Critical temperature 246 °C
Density (at 20°C) 806 kg/m3
Melting point - 83.5 °C
Molecular weight 53.1
Refractive index n25D = 1.3888
Solubility (20°C) 7.35 wt % ACN in water
3.1 wt % water in ACN
Critical pressure 3490 kPa
Heat of vaporization 615 kJ/kg
Specific heat 2.09 kJ/kg, °C
Surface tension (at 24 °C) 0.0273 J/m2
Vapour pressure (20 °C) 12kPa
Viscosity (20 °C) 0.4 mPa.s
 For the tank’s material, Stainless steel or carbons steel are the best for tank
that store Acrylonitrile solution

 Before initial use Carbon steel tanks are usually cleaned either by chemical or
physical in order to remove rust

 Copper materials is forbidden due to it can induce polymerization and also

discolor Acrylonitrile. (INEOS)
Safety
 located away from a potential source of ignition, including the
possibility of radiation from a fire in nearby area

 Dike wall around the tank- 110% of the tank size

 primary potential hazards of Acrylonitrile and Acetonitrile handling,

are polymerization and explosion or flammability.
 Both reactions are exothermic that release heat. This make the
heat of exothermic reactions is their primary hazard. The heat of
polymerization of Acrylonitrile is 17.3 kcal/gram-mole. The heat
of combustion of Acrylonitrile is 420.8 kcal/gram mole and
Acetonitrile is -300.3 kcal/mole.

 Acrylonitrile is incompatible with which are Bromine, ammonia,

Amines, Copper and copper alloys, strong acids and bases
 Another important way of flammability preventation is the Nitrogen
blanketing. It also will help to reduce the potential for flammability of vapors
above the surface of liquid Acrylonitrile. The system will remove oxygen level
to below than 8 percent from the vapor space in the vessel or tank. (INEOS)
HYDROGEN CYANIDE
TANK
Designed by Nur Hanisah Binti Azizan
SPECIFICATION TANK

Specification Data

Mass flowrate (kg/hr) 741.268

Volume of tank(m3) 25.896

Diameter (m) 3.207

Length (m) 12.828

Area (m2) 41.14

 PROPERTIES OF HCN
Chemical formula HCN
Molar mass 27.0253 g/mol
Appearance Very pale, blue, transparent liquid or
colorless gas
Odor Oil of bitter almond
Density 0.687 g mL−1
Melting point −14 to −12 °C; 7 to 10 °F; 259 to 261 K
Boiling point 25.6 to 26.6 °C; 78.0 to 79.8 °F; 298.7
to 299.7 K
Solubility in water Miscible
Solubility in ethanol Miscible
Vapour pressure 630 mmHg (20 °C)
Henrey’s law constant kH) 75 μmol Pa−1 kg−1

Refractive index (nD) 1.2675 

Viscosity 201 μPa s
 SAFETY OF HCN TANK
1. Overview

 Exposures to hydrogen cyanide (HCN) can result in sudden collapse and death. HCN is very
unstable, and is sensitive to heat, light and moisture.

 HCN will rapidly or completely vaporize, or readily disperse in air and burn.

 The warning properties of HCN are very poor; 40-60% of the population is unable to smell the
characteristic odor of bitter almonds and there is a wide variation in the minimum odor
threshold.

 Those working with HCN or reactions that could result in HCN byproducts should have amyl
nitrite capsules on hand before work begins. (Michigan Department,2014)
2. Emergency Procedures

For all routes of entry, early symptoms include weakness, headache, dizziness, confusion, anxiety, nausea and
vomiting. In severe cases, breathing is rapid and deep and then becomes slow and gasping. The skin appears
bright red or pink.

 Skin Contact: The liquid is not irritating but can be absorbed through unbroken skin. Flush contaminated area with
water for at least 20 minutes. Remove and discard contaminated clothing. If the victim is having difficulty
breathing, provide antidote as described for inhalation exposure.

 Eye Contact: Immediately flush contaminated area with water for at least 20 minutes, separating eyelids to assure
complete rinsing. If the victim is having difficulty breathing, provide antidote as described for inhalation exposure.

 Inhalation: Administer amyl nitrite capsules. Crush one pearl of amyl nitrite onto a cloth and hold to the victim's
nose for 15-30 seconds of each minute. Use a new pearl every 3 to 5 minutes. Call Baylor DPS at 2222 and request
an ambulance immediately.

 Ingestion: Never give anything by mouth to a victim that is rapidly losing consciousness, or is unconscious or
convulsing. DO NOT INDUCE VOMITING. Have victim drink 8 to 10 oz. of water. If vomiting occurs naturally, rinse
mouth and repeat administration of water. If the victim is having difficulty breathing, provide antidote as
described for inhalation exposure. (Michigan Department,2014)
3. Handling

 Never work with HCN alone. Someone must be in view at all times and be equipped and trained to rescue.

 If HCN is released, immediately leave the area until the severity of the release is determined. Have
emergency equipment readily available.

 Use liquid HCN in a fume hood.

 Wear chemical splash goggles and impermeable gloves, such as Teflon, Siver Shield, 4H, or butyl rubber. Do
not use PVC or polyethylene. (Michigan Department,2014)

 Liquid hydrogen cyanide is highly flammable. Keep away from ignition sources. Do not use near welding
operations, flames or hot surfaces.

 It contains a stabilizer (usually phosphoric acid) that may decompose over time.

 Old samples may explode if the acid stabilizer is not maintained at a sufficient concentration. Do not
attempt to open a container if the age is unknown. (Michigan Department,2014)

 Close and check all valves before and after withdrawing HCN from the cylinder. Never trap HCN between
two valves. Use HCN gas in a fume hood or ventilated gas cabinet
4. Storage

 Empty containers may contain residues which are hazardous. Store in a cool, dry, well-ventilated area, out
of direct sunlight.

 Store away from heat and ignition sources; incompatible materials, or water or products containing water.

 Use grounded, non-sparking ventilation systems and electrical equipment that does not provide a source of
ignition.

 Use suitable, approved storage cabinets, tanks, rooms and buildings. If storing small quantities under
refrigeration, use an approved, explosion-proof refrigerator. Consider using leak detection and alarm
systems.

 Limit quantity of HCN in storage. Restrict access and keep storage area separate from work areas. Inspect
containers periodically for damage or leaks. Do not store containers more than 90 days or as recommended
by supplier.

 Store cylinders in a vertical position, adequately grounded and supported. Do not drop or damage cylinders.

 No part of the cylinder should be heated higher than 51ºC. Comply with all applicable regulations for
storage and handling of flammable materials. (Michigan Department,2014)
5. Disposal

 HCN cylinders should be returned to the compressed gas distributor when emptied
or no longer used. HCN compounds should be disposed as hazardous waste.
REFERENCES
 Joye, D. D. (1993). Maximum separation in binary and multicomponent flash operations. AIChE
Journal, 39(8), 1411–1414. https://doi.org/10.1002/aic.690390819

 LIU, Z., HUO, W., MA, H., & QIAO, K. (2006). Development and Commercial Application of Methyl-
ethyl-ketone Production Technology. Chinese Journal of Chemical Engineering, 14(5), 676–684.
https://doi.org/10.1016/S1004-9541(06)60134-1

 Mulyandasari, V., & Kolmetz, K. (2011). Separator Vessel Selection. KLM Technology Group, 1, 47.

 Sinnott, R., & Towler, G. (2013). Chemical Engineering Design - Principles, Practice and Economics
of Plant and Process Design Second Edition. Chemical Engineering Design.
https://doi.org/10.1016/B978-0-08-096659-5.00022-5.

 Svrcek, W. Y., & Monnery, W. D. (1993). Design two-phase separators within the right limits.
Chemical Engineering Progress.
REFERENCES
  Kister, Henry Z. (1992). Distillation Design (1st ed.). McGraw-Hill. ISBN 0-07-034909-6.

  Perry, R.H. and Green, D.W. (1997). Perry's Chemical Engineers' Handbook (7th ed.).
McGraw-Hill. ISBN 0-07-049841-5.

 Seader, J. D. & Henley, Ernest J. (1998). Separation Process Principles. New York: Wiley. 
ISBN 0-471-58626-9.
 Towler, G., & Sinnott, R. K. (2013). Chemical Engineering Design: Principles, Practice and
Economics of Plant and Process Design. Oxford: Academic Press.
 Green, D. W. (2008). Perrys chemical engineers handbook. New York: McGraw-Hill.
 Michigan Department of Licensing and Regulatory Affairs, Michigan Occupational Safety &
Health Administration and Consultation Education & Training Division (2014).
THANK YOU…..
CALCULATION (Head Drying Column)
 STEP 1: Find density for Top and Bottom Outlet
 For the top outlet (HCN Only),
The formula used : ρV = PMWave/RT (Sinnott & Towler,2013).
= 1.962 kg/m3
 For the bottom outlet (Acrylonitrile,H2O, Acetonitrile, Acrylic Acid, Acrolein),
The formula used : ρL = MWave/ Vliquid
= 978.92 kg/m3

 STEP 2: Find the settling Velocity, Ut

The formula used: Ut = 0.07 [(ρL – ρV)/ρv]^1/2
= 978.92 kg/m3
Separator w/out demister pad,Ua = 0.15(Ut)
= 0.234 m/s

 STEP 3: Find Vapor volumetric flowrate, VV = (Sinnott & Towler,2013).

= 0.0139 m3/s
 STEP 4: Find Diameter of vessel, Dv
The formula used : Dv = = 0.275m

 STEP 5: Find liquid hold up time

VL = = 0.0223 m3/s

Min allowable 10 min hol-up (Sinnott & Towler, 2013)

VH = 0.0223m3/s x (10x60) = 13.38 m3

Surge Volume, VS is 5 min allowed (Svrcek & Monnery, 1993)

Vs = 5 min x QL = (5x60) x 0.0223 m3/s = 6.69 m3

 STEP 6: Find the Height of hold up (HH) and surge (Hs)

HH = = 225.27 m

HS = = 112.63 m
 STEP 7: Find the Diameter of Nozzle, DN
VM = V L + V V
= 0.0362 m3/s
Mixture Fraction, λ:
λ= = 0.616
Mixture Density, ρM:
= ρL λ + ρυ (1- λ) = 603.77kg/m3
DN = ( )^1/2 (Joye, 1993)

= 0.3824 m
 STEP7: Find Height to HLIN, HD, HLLL, HME, T, Tv, ,HTOTAL
HLIN = 12inch + ½ DN
= 0.496 m
HD = 36inch + ½ DN = 1.1056 m
HLLL , 15inch = 0.381m
HME = 0 (due to no mist eliminator)

 
T= (Svrcek & Monnery,1993)
= 2.135 x10-3 m
Tv = = 2.27 x10-3 m (Outer Diameter)

HTOTAL = HLLL + HH + HS + HLIN + HD + HME + T

= 339.885m

 STEP 8: Find the volume of Cylinder Vessel

V = Π r 2h
= 20.188 m3
CALCULATION (Stripping column)
Component Feed, XF Distillate, XD Bottom, XW

Acrylonitrile 6.967x10-4 0 6.991x10-4

Acetonitrile 1.526x10-3 0.397 1.528x10-4

HCN 1.945x10-4 0.029 9.623x10-5

Acrylic acid 4.851x10-4 0 4.868x10-4

Acrolein 2.606x10-3 0 2.615x10-3

H2O 0.994 0.575 0.996

Heaviest Key Component = Water

Light Key Component = Acrylonitrile

 STEP 1: Find the Relative Volatility, α (Perry and Green, 1997)
Acrylonitrile = 2.85
Water = 1

 STEP 2: Minimun Reflux Ratio, RM

Using Underwood equation = + =1–q (Perry and Green, 1997)

As feed is entering as vapours so q = 0

By trial, θ = 1.88
+ = Rm + 1

Using eq. of min reflux ratio,

Putting all values Rm = 2.13

 STEP 4: Find the Actual Reflux ratio

Using the rule of thumb is: R = (1.2 ...................... 1.5) Rmin
R = 1.3 Rmin
R = 2.77
 STEP 5: Find the Minimun No.of Plates
The minimum no.of stages Nmin is obtained from Fenske relation which is,

(Kister & Henry, 1992)

Nmin = 3.29 4 stages

 STEP 6: Select the type and size of packing

 There are several types of packing such as raschig rings, pall rings, berl
saddle, intalox saddle, metal hypac, and super intalox.
 Raschig rings are cheaper per unit volume than pall rings or saddles, but are
less efficient and the total cost for the column will be higher.
 Usually for new column, the choices will normally be between pall rings and
berl or intalox saddles.
 For corrosive liquid, ceramic packing will be the first choice. The design data
for various packings can be seen at Table 2, (Seader, Henley &Ernest, 1998).
 Table 2 Data for various packing

Based on that table we select intalox saddles as our packing types and
2.0 inch or 51 mm as our packing size.
 STEP 7: Determine the height of the column
 To determine height of the column, we need to determine the tray efficiency
first.
 The distillation tray efficiency (Eo) is usually range between 0.5 to 0.7.
 So,to calculate the actual number of stages:  (Perry and Green, 1997)
Actual no.of stages =

A total ideal stage (without reboiler) is = 4-1 = 3

 The actual number of stages, Ns = = 4.286 5 stages

The usual HETP for 1.5 inch size of packing is 0.6 to 0.75 m.
 The height of column, H = 5 stages x 0.6 m/stages = 3.0 m

 STEP 8: Determine the diameter of the column

 By using the rule of thumb for packing distillation tower, we can determine the
diameter of the column.
 The recommended size ranges are: (Seader, Henley &Ernest, 1998).
Because of we are using 1.0 inch size of intalox saddles; the diameter
of the column is 0.9 m of 3 ft.