CHE231

INTRODUCTION TO CHEMICAL ENGINEERING PLANT DESIGN

GROUP:
T4 EH1105B GROUP 6

PREPARED BY:

NAME STUDENT ID
NURUL ZETI NABIHAH BINTI ABDUL WAHIB 2020460578
NUR NILAM SARI BINTI AZINI 2020815912
MUHAMMAD HAFIZ FIRDAUS BIN SALNONJUNAIDI 2020
NUR ARIESYA TASNEEM BINTI AZMY 2020827514

PREPARED FOR:
MISS NORKAMRUZITA BINTI SAADON

CHEMICAL SELECTION:
PROPYLENE
HISTORY OF PROPYLENE
Propylene, also known as propene, is an unsaturated organic compound with the chemical formula
CH3CH=CH2. It has one double bond and is the second simplest member of the alkene class of
hydrocarbons. It is a colourless gas with a faint petroleum-like odour. Propene is the second most
important starting product in the petrochemical industry after ethylene. It is the raw material for a
wide variety of products. Polypropylene manufacturers consume nearly two thirds of global
production. Polypropylene end uses include films, containers, packaging, and caps and closures.
Propene is also used to produce important chemicals such as propylene oxide, acrylonitrile, cumene,
butyraldehyde, and acrylic acid. In the year 2013 about 85 million tonnes of propene were processed
worldwide. Propene and benzene are converted to acetone and phenol via the cumene process.
Propene is also used to produce isopropanol (propan-2-ol), acrylonitrile, propylene oxide, and
epichlorohydrin. The industrial production of acrylic acid involves the catalytic partial oxidation of
propene. Propene is also an intermediate in the one-step propane selective oxidation to acrylic acid.

PHYSICAL PROPERTIES OF PROPYLENE

Propylene is a colourless gas with a faint petroleum like odour. It is obtained by thermal cracking of
ethylene. At low concentration it forms an explosive and flammable mixture with air, while at high
concentrations it can cause asphyxiation and skin burns. It is used in the petrochemical industry as a
fuel and alkylate and in the chemical industry to produce polypropylene, isopropyl alcohol, propylene
oxide and other chemicals.

 Preferred IUPAC Name:

The preferred IUPAC Name of Propylene is Propene.
 Molar mass:
The molar mass of Propylene is 42.081g.mol-¹.
 Appearance:
Propylene is a colourless gas.
 Density:
The density of Propylene:
1.81kg/m³, gas
(1.013 bar, 15°C)
1.745kg/m³, gas
(1.013 bar, 25°C)
613.9kg/m³, liquid
 Melting
The melting point of Propylene is at -185.2°C (-301.4°F; 88.0K).
 Boiling Point:
The boiling point of Propylene is at -47.6°C (-53.7°F; 225.6K).
 Solubility in water:
It’s solubility in water is 0.61g/m³.
 Flashpoint:
-108°C (-162°F 165K)
COMMON APPLICATION OF PROPYLENE
1. IN PIPING (uses of PP-R, Polymer is more than 50% of the composition)
 Propylene is durable and chemically inert and will not react with water, or many
dissolved chemicals in water. PP-R is resistant to corrosion, scaling, and erosion.

2. IN PRODUCING PLASTIC BAG

 Propylene is made of long chains of propylene molecules, which provide flexibility to
the material but allow it to keep its strength. It is resistant to fatigue and does not
sustain damage from repeated use. Polypropylene has a low density, which makes it
lightweight and yet have a high strength to weight ratio.

3. CARPETS (made from polypropylene which is also known as olefin)

 Polypropylene is a synthetic material, meaning its man-made. It is (stain resistance),
soft, and value for money. It is also resistant to fading which are protected to sunlight.
If you spill something on a polypropylene carpet, it will sit on top of the rug until you
wipe it away. It is because polypropylene does not absorb any water, it is mildew
resistant. The biggest flex is polypropylene carpet are the cheapest among nylon,
polyester, and wool carpet.
METHOD OF PRODUCING PROPYLENE AND THE BEST METHOD

 Steam cracking units

The coke formation in the furnace tubes is the key problem and constraint to the working
lifespan of steam cracking systems. The reactions take place at high temperatures ranging
from 500 °C to 700 °C depending on the feed parameters. The combination of high
temperatures and short residence times is the key characteristic of the steam cracking process
for heavy feeds such as gas oil. A naphtha steam cracking unit's main focus is generally
generating ethylene, however the output of propylene in a typical naphtha steam cracking unit
can reach 15%.

 Propane dehydrogenation (the best method)

Propane Dehydrogenation (PDH) is a petrochemical process in the production of propylene
from propane which is the second most important starting product in the petrochemical
industry after ethylene. A PDH is a catalytic technology (CATOFIN: fixed-bed type of ABB
Lummus and OLEFLEX: moving-bed type of UOP) utilised for the conversion of propane
into propylene, and various catalysts have been developed to increase the propylene yield
over recent decades.
Propane Dehydrogenation (PDH) converts propane into propene and by-product hydrogen.
The propene from propane yield is about 85 m%. Reaction by-products (mainly hydrogen) are
usually used as fuel for the propane dehydrogenation reaction. As a result, propene tends to be
the only product, unless local demand exists for hydrogen.

 Olefins metathesis
The olefins metathesis process involves the combination of ethylene and butene to produce
propylene as presented in reaction above.

 H2C=CH2 + H3C-HC=CH-CH3 → 2 H2C=HC-CH3

The metathesis reactions of 2-butene can be performed in the presence of tungsten oxide

mesoporous silica catalyst. The reactions take place in gas phase and are slightly endothermic.
The reaction mechanism includes three reversible reactions: isomerization, cross-metathesis,
and self-metathesis and one irreversible reaction (cracking), in which propylene is produced
via two main alternative routes: cross-metathesis of 1-butene and 2-butene and cracking of 2-
butene.
PFD OF THE CHOSEN PROCESS

Propylene dehydrogenation is a continuous process with a regulated order of reaction and

reheat/regeneration that is carried out in cyclic-multiple reactors (four horizontal reactors connected in
parallel). The endothermic reaction initiates the process, followed by another evacuation, catalyst air-
regeneration, steam purging, and so forth. Specifically, by exchanging heat with hot process streams,
the fresh feed of high pure propane (98%), including the recycled feed from C3 splitter bottoms, is
preheated and vaporised. A charge heater is then used to further heat the hot feed so that it reaches the
reaction temperature of 540–760 °C. Gas is used to power electric heaters. The reactor section inlet
valves open when the requisite feed temperature is maintained, allowing propane to enter the cyclic
multiple fixed bed catalytic reactor where the subsequent dehydrogenation reaction takes place.
Within 7–15 minutes after entering the first reactor, propane is transformed to propylene. To raise the
weight percent of propylene and reach a propylene conversion of 45–50%, two parallel reactors
perform the conversion process (reaction). Heat exchangers that cool reactor effluent
(propane/propylene, or C3/C3") also raise the temperature of the feed. Before being compressed (7–20
atm), dried, and further chilled before entering a flash drum that separates light products (tail gas,
light gas, H2, C1) at the distillate and liquid products (C2 & C3/C3") at the bottom, the
propane/propylene product is further cooled in a trim cooler unit.

Distillate products are routed to a low-temperature recovery section for light end rejection, where light
gases are received and processed by a pressure swing adsorption (PSA) unit to provide a hydrogen-
rich gas (99.9%), fuel gas, and CO/CO2/C2 as by-products. The bottom-liquid streams from the flash
drum (C2 & C3/C3") and the low-temperature recovery section (C4 and oil) are pooled, fed via a
deoiler unit to remove heavy materials, and the remaining products are transferred to a deethanizer
unit to extract C2 as a fuel gas at the distillate. To produce the desired final product (propylene = C3"
at the distillate), deethanizer bottom-stream (C3/C3") flows through a two-column C3 splitter unit.
The C3 splitter bottom's unconverted propane/propylene mixture is recycled and heated to repeat the
conversion process.

PLANT LOCATION AND JUSTIFICATION

 LOTTE Chemical Titan(M) Sdn.Bhd

Industrial Estate, 312, Jalan Tembaga 4,

Kawasan Perindustrian Pasir Gudang, 81700

Pasir Gudang, Johor

ASPECTS THAT BEING USED TO DETERMINE THE PROPOSED SITE
LOCATION
Raw material

 The source and price of raw materials is one of the most important factors that determine the
location of a plant. Facilities that produce chemicals in bulk are usually located close to the source of
raw material if the costs of shipping the product is less than the costs of shipping the feed.

Environmental impact

 Depending on the location, it may be more difficult and costly to dispose of wastes

Transport facilities

 Facilities should be close to at least two major forms of transportation, whether that be road, rail,
waterway, or seaport.

Availability of suitable land

 The ideal land is flat, well-drained, with suitable load-bearing characteristics. Further
considerations have to be made if the land is reclaimed land near the ocean in earthquake zones.

LAYOUT OF THE PLANT

SIZE OF THE PLANT

78 ACRE
CONCLUSION
In conclusion, Superflex technology will continue to play a crucial strategic role in efficiently
fulfilling future propylene demand. The conversion of low-value or troublesome internal streams to
high-value light olefins will be profitable for refiners as well as for the owners of ethylene plants.
Superflex's sturdy and adaptable design will allow the company to transform a variety of inexpensive
feeds into propylene and ethylene with higher profit margins. Whether you are building a new plant or
retrofitting an existing plant or building, the main distinction is that while turning an old structure into
a new laundry always involves some degree of compromise, a new plant design can be specifically
tailored to the needs of the end-user. An existing structure might have lower than ideal ceilings, only
one side accessible for delivery vehicles, or columns spaced too closely in one or both directions. To
account for these current circumstances, you must alter the design, which could have an effect on the
project's productivity, capital cost, and efficiency.
APPENDICES

 https://matmatch.com/learn/material/polypropylene
 https://www.lottechem.my/products/prodguide-2-2.asp
 https://processdesign.mccormick.northwestern.edu/
 https://www.sciencedirect.com/topics/engineering/propylene
 https://en.wikipedia.org/wiki/Propylene
 https://americanlaundrynews.com/articles/plant-design-getting-back-basics-
conclusion
