Catalytic Hydration

Method to Produce Ethanol

from Ethylene
Sam kk / April 2, 2012
A perfectly designed process for producing ethanol from ethylene would be the catalytic hydration method developed
based on direct hydration technology. This method has very less bottleneck factors when compared to other methods
like indirect hydration technology. Direct catalytic hydration method posses optimized energy consumption and
material balance. Equipments used in catalytic hydration are lesser than old process in practice.
Petrochemical industry that has high source of ethylene stock prefer to select this method. Ethylene with 95%
concentration is the best raw material quality that this process can handle. Designing a plant that
handles catalytichydration has high scope in modern continuous processes. Project of ethanol production has much
more important in most petrochemical industries due to its growing demand in the international market. Engineers
who can improve the existing process and bring out high performance by rectifying the problems are in demand for a
process industry.

Process description of catalytic hydration of ethylene:

Catalyst like diatomaceous earth will support the phosphoric acid. The surface of diatomaceous earth is coated with
phosphoric acid so that it acts as acid catalyst. The concentration of H3PO4 should be around 85-90%.
Water is vaporised and added to the vapours of ethylene at pressure 65-70 atm and then heated to the reaction
temperature 300 oC. The reactant mixture is fed to the reaction tower from top. Catalyst solution of H3PO4 is also fed
to the top of the tower as make up when required only. The concurrent flow pass through the packing material
of catalyst and following reaction take place.
H2O + CH2=CH2 H3PO4 CH3CH2OH
The impurity that is present in ethylene would be mainly acetylene (C2H2). This will also participate and react to
produce acetaldehyde by the reaction.
C2H2 + H2O CH3CHO (acetaldehyde)
The product mixture containing ethanol, unreacted ethylene, water and acetaldehyde are sent to
a separator. Ethanol and water are separated from bottom and unreacted ethylene removed from top and scrubbed
with caustic soda to remove the trace of acid. A high-pressure stripper separates acetaldehyde and sends it to a
hydrogenator to produce ethanol with the help of nickel catalyst. The reaction is.
CH3CHO + H2O N2 CH3CH2OH
Finally, ethanol (C2H5OH) is produced at different concentration as per the requirement in separators with a yield of
95-97% ethanol.
Other production methods:
Ethanol manufacturing by molasses fermentation