Production Of Methyl Ethyl

Ketone
Group 23
 Introduction
• The chemical compound chosen is Methyl
Ethyl Ketone

• There exists majorly only one method to

produce methyl ethyl ketone:
– Dehydrogenation of Secondary Butyl Alcohol
• The plant size was estimated as 35 ktpa.
• The flow sheet was developed in the Aspen
and completed with all the required utilities.
• The total flow rate of the reactant based on
the desired product output was found.
•Yearly Production of MEK 3.5*10^7 kg

Production per hour 3995.43 kg

Assume 85% Conversion in reactor SBA required 4831.07 kg/hr

Assume 5% loss in handling and purge 5072.63 kg/hr

Aspen Flowsheet with complete
utilities
• Similarly, Aspen was used to calculate the
utilities for reboiler, condenser separatly.
• Aspen was also used to determine the heat
duty required for total steam production. And
based on that cost of steam generator was
found.
 Sizing: Heat Exchangers
• Approach
– With the help of Aspen following things were
obtained
– U, Heat Exchanger Area, DelTlmtd
– Then, standard tubes with inner and outer
diameter were selected and standard length of 4
ft or 8 ft or 12 ft were chosen.
– Number of tubes were calculated.
– Shell diameter was calculated.
 Heat Exganger Number of tubes Shell Diameter
Cold feed Preheater 21 0.209
SBA vaporizer 195 0.44
Super heater 252 0.62
Partial condenser 975 1.15
Product heat exchanger 22 0.212
MEK Reboiler 478 0.83
MEK Condenser 168 0.51
TCE Reboiler 19 0.2
TCE Condenser 5 0.215
 Sizing: Reactor
• The reactor used is multi-tubular reactor
• The sizing of the reactor is based on the total
catalyst area that is required.
• The catalyst area was found by integrating the
rate equation.
• Using the adequate void fraction and tube
lengths, the reactor was designed.
 Sizing: Columns
• In order to design the diameter, standard
method given in the timmerhaus was
followed.
• With the help of the information obtained
from Aspen, the diameter was calculated.
• Efficiency was calculated with the help of the
formula and then, the height was calculated.
 Number of trays Height Diameter

MEK Distillation Columns 41 22.692 2.29

TCE Distillation Columns 27 15.96 0.79

Absorption Column 13 9.415 0.53

Liquid liquid Extraction Column 13 8.968 0.83

 Costing: Fixed Cost
• The purchase cost of the following items was
estimated using standard tables given in the
timmerhaus
– Heat Exchangers
– Pumps
– Mixers
– Distillation Columns, Absorber, Extractor
– Cooling Tower
• The total present cost was found by assuming
7 % inflation.
• Total equipment cost: INR 88728083.06
• Lang factor for MEK plant is about 4.8, hence
total fixed investment: INR 425894798.7
 Costing: Operating Cost
• Utility costs were determined using
appropriate correlations.
• It comes around INR 508607418.8
• The cost of electricity was determined by
assuming INR 8/unit
 Cost: Operating Cost
• Using guidelines given in the timmerhaus,
following costs were determined:
– Raw Material
– Labour Requirement
• Skilled
• Common
– Maintenance Cost
– Operating Supplies
– Local Taxes
– Insurance
– Depreciation
• Following costs were also found
– Plant Overheads
– Administration Cost
– Distribution and Marketing Cost
– RnD
• The summation of the total operating costs:
– INR 2,61,06,55,496
• MEK price: INR 73.2/kg
– Total Product sale in a year: INR 2,74,00,22,400
• Gross Profit = Total revenue - Total expenses
= 2,74,00,22,400 – 2,61,06,55,496
= INR 12,93,66,903.8
• Net Profit = Gross profit – Tax
= 129366903.8 - 38810071.14 /-
= INR 90556832.66 per year
• Payback period
= Total fixed capital Investment / net profit per year
= 425894798.7/90556832.66
= 4.7 years
• Thank you!