Petrochemical Industry Introduction To Chemical Engineering Assignment Engineering Essay

Petro chemical substance Industry Introduction To Chemical Engineering date Engineering EssayIntroductionPetrochemical persistence is organism chosen as our main topic for the introduction to Chemical Engineering assignment. Petrochemical is the second locate intersection bucks being derived from crude oil after several refining processes. These chemicals be typically extracted during the refining process ascrude oiland plash atomic number 18 di mumed or cracked, and they finish be utilized in a unsubtle variety of ways.Petrochemical dissolve be use to even off polyvinyl chloride ( polyvinyl chloride). premature ventricular contraction is one of the oldest synthetic materials with the longest history in industrial return.Its proterozoic history is of multiple and accidental disco really in different places at different times as salutary as unsuccessful quests for commercialised application. During the 1950s many more(prenominal) companies started to maturate premat ure ventricular contraction and volumes increased dramatically more or less the world. premature ventricular contraction merchandises rapidly became essential to the construction industry the plastics apology to light, chemicals and corrosion do it the best option for building applications. Improvement made to the materials resistance to extreme temperatures, allowed for polyvinyl chloride to be transporting water to thousands of homes and industries. polyvinyl chlorides low monetary value, smooth durability and process ability advance it the material of choice for slews of industries such as health c atomic number 18, IT, transport, textiles and construction.The chemical process for making polyvinyl chloride involves taking the simplest unit, called the monomer, and linking these monomer molecules together in the polymerisation process. Various additives including stabilizers and plasticizers read to be added to PVC resin to create a unite that meets the need of the subvert product and of the processing technology to be used.Importance of Petrochemical Industry in Our SocietyThe petrochemical industry is a colonial industry that affects all spheres of life. nigh items used in everyday life such as plastic products and soaps owe their existence to petrochemicals. The petrochemical industry connects refine rain cats and dogs sectors such as pharmaceuticals with the up pour oil and gas industry. The petrochemical industry deepens feed occupations such as naphtha and inhering gas components such as merelyane, ethane and propane by dint of steam shift or catalytic cracking into petrochemical building blocks such as olefins and aromatics. eyepatch olefins construct on ethyl radicalene, propylene, methanol and C4 stream such as butadiene, aromatics include benzene, methylbenzene and xylene. The petrochemicals of commercial importance in the petrochemical industry include ethylene, propylene, benzene and xylene. These petrochemical build ing blocks ar further processed to yield final exam products such as paints, polyester and plastics. Take ethylene for instance. It is processed into ethyl benzene, ethylene oxide, ethylene dichloride, ethyl alcohol, acetaldehyde and polyethylene. These undergo further trans dustation to yield a wide range of products such as tyres, detergents, agrochemicals and plastic products.Originally, most plastics were made from the resins of set up matter. But it wasnt long before plastics were developed from petrochemicals. The packaging industry, the leading substance abuser of plastics, accounts for nigh one-third of total U.S. per modelance. The building industry ranks second, which uses plastic to hold upinsulation, moulding, pipes, roofing, siding, and frames for doors and windows. otherwise industries, including automobile and truck manufacturing, too rely heavily on plastics. The United States was hardly alone in its rising use of crude oil products. Throughout the world, in creased industrialization and rapid population growth created sore and greater ingests for oil. By the late 1950s, petrochemicals became one of the largest industries, and control over the sources and transfer of oil became a major national and international political issue.The cater and DemandThe lancinating material used for the per holdance Poly vinyl Chloride (PVC) is Vinyl Chloride Monomer (VCM). Naphtha, which refers to a several different smooth-spoken pastiches of hydrocarbon, is the major feed stock used for the performance of VCM. The global VCM hand over capability in the course 2009 was 40.0 one one thousand thousand million million hemorrhoid which 50.8 % of it is based on Naphtha as feedstock. 27.2 % of the global condenser was based on Natural gas for feedstock followed by 17.2% by ember date only 4.7 % of the global capacity was based on an separate(prenominal) feed stocks. In terms of region oriented, Asia- Pacific had the largest production capacit y in 2009 with 18.1 million tons of production which stands 45.1% of the market sh are followed by Europe with a production capacity of 10.4 million tons and a share of 25.8%. The Middle East had the capacity of 2.0 million tons and a share of 5.2% while South and exchange America were closely ass with 1.6 million tons of production capacity with a share of 3.9%. found on the score Vinyl Chloride Monomer (VCM) Global Dynamics to 2020, global VCM look at in the stratum 2000 was 20.7 million tons and it grew at a compound annual growth rate (CAGR) of 3.8% from the year 2000 to 2009 in which the demand in the latter year had reached 29 million tons. The report has also indicates that at that place leave alone be increase in demand of VCM with growth of are a CAGR of 5.4% from 2009 to 2020. This means if the reports expectation is correct, the demand of VCM this year allow for be 32 million tones and by the year 2020, the demand will be reaching 50 million tones. Out of the 29 m illion tons of VCM demand in the year 2009, Asia-Pacific has the highest demand in the industry with 16.4 million tons with a major share of 56.4%. The North America had a demand of 5.9 million tons and its share was 20.3% while Europe had a VCM demand of 4.8 million tons, followed by South and Central America with demand of 1.2 million tons. The demand share owned by Europe was 16.5% while 4.1% of demand market share is occupied by South and Central America. The Middle East had a demand of only mere 0.8 million tons along with demand share of only 2.7%.In conclusion, we bathroom see that the major demand of VCM is in Asia Pacific and this is also where the production capacity of VCM is highest in a region around the world. Hence, we can intermit that the production capacity is usually closely related to the demand of the region. first moment of the industryThe production of PVC is a chemical industry. To be more specific, it is a synthetic material industry. It is considered a se gment of overall chemical industry with fictionalizationrs representing 20% of chemical industry. The plastic industry, which manufacturing of PVC is, stands around 70% of the whole synthetic material industry which also includes rubber and manmade fibres.The production of PVC requires a lot of process which in turn will require a big plant for the manufacturing as intimately as storing. The manufacturing process is complex which requires an expertise in the field. Hence, the industry requires the skill and association of a chemical direct to maintain the plant as well as solving problem that exists within the manufacturing process. Besides, transportation of raw materials is also needed to be coordinated by the manufacturer to lower to cost to yield more service.From the supply and demand perspectives, both of it is growing from year to year basis which is thoroughly discussed at Supply and Demand section. The fence to the increase in demand is due to the usage of this PVC ma terial, in the main in piping but also diversify to other utilities resembling plastic for manufacturing of table lamp. On the other hand , the supply of raw material increases due to the demand.The industry plays an distinguished role to the consumer in providing them the product as well as to the economy in making profit and providing jobs opportunity.Impact on the EnvironmentDuring the manufacturing of PVC process, take ins such as production residue sand ins portentousation waste which give impact on the environment will be released out. vinyl chloride monomer is used to allege thepolymerpolyvinyl chloride(PVC).VCM can be a carcinogen, can cause a rare form of cancer which known as angiosarcoma. Excluding its flammability potential at release, VCM quickly dissipates pose slight threat to human health in form of thin out form and quickly degenerates when exposed to normal daylight as in the open atmosphere. During the polymerisation process, basically all of the VCM is ch anged into the inert polymer chains that form the PVC plastic. The possibility of eternal rest unpolymerised VCM to stay on in the polymer and eventually transfer into food from PVC packaging is high.Some of the liquid fossil oilhydrocarbonwill be released into the environment like theoceanorcoastal waters due to human activity, and is a form ofpollution. In role the balance of ecosystem will be affected.In the process, the combustion of fossil fuels claims glasshouse gases and other air pollutants as by-products. In Addition, oil spill is a release of a petroleum hydrocarbon into the environment due to manufacturing PVC process.In other to reduce the impact on the environment, an capable waste wariness system will reduce the not being re-used and make the most of the use of economicalally and environmentally rational recovery schemes.Step of Incineration with efficacy Recovery can be taken. Oil that used in PVC production can be utilised as a nominal twice, Incorporating P VC consumer products can be under controlled and reduces the amount of PVC divergence to landfill and reduces the pollutions. The modern incinerators are equipped with pollution control equipment and run to the highest standards on that pointfrom it can help to minimise the release of emissions to the environment. In addition, machinelike and feedstock cycle can implementedMoreover, anything of the PVC recovery process, residual fraction of waste is contained which not recyclable. Controlled landfill still remains a disposal option in the restrain fraction. The consumer product which containing PVC presence in landfill does not even off a major risk to the environment is confirmed by determination of indep arrestent studies..Processeshow PVC is manufactured(Electrolysis, Chlorination VCM Cracker)1 Electrolysis Electrolysis, is a method of use electric current to drive a non-spontaneous chemical reaction. In the production of the PVC, centilitre is produced by separating th e chlorine and sodium ions of a salt dowse using the method of electrolysis. The electrolysis of salt brine will produce hydrogen gas and chlorine gas.2 Chlorination Chlorination is the process of adding chlorine into ethene to produce ethylene chloride also commonly known as vinyl chloride. The chlorine is from the process of electrolysis of brine salt from previous process. In chlorination , chlorine is added to ethene to replace two H atom from the molecule without breaking the doubly seize in ethene to produce 1,2-dichloroethane. Iron (III) is used as catalyst in the process .CH2=CH2 + Cl2 ClCH2CH2Cl3 Thermal cracking(VCM Cracker)The main office of this process is to pose the chloroethene also known as VCM. This is done because VCM couldnt be obtained by simple chlorination of ethene. Hence, this process is carried out to removed one atom of chlorine from 1,2-dichloroethane as well as recovering the carbon-carbon double bond to obtain VCM. Basically the process is being c arried out with condition of ergocalciferol C with pressure ranging from 15 atm to 30 atm. Under that condition, 1,2-dichloroethane decomposes to produce chloroethene (VCM) and hydrogen chloride.ClCH2CH2ClCH2=CHCl+HCl(Prepared by Lim Chung Kin, 0902959)(4 Quenching,5 cooling water ,6 purification)Cracking furnace outgoing essential(prenominal) be quenched, or cooled rapidly, to keep coking at a minimum. in that respectfore, the hot effluent gases are typically quenched and take upially condensed by direct run into with cold EDC in a quench tower. Alternatively, the hot effluent can first be cooled by heat exchange with cold liquid EDC furnace feed or by vaporizing boiler feed water (BFW) to produce high pressure steam in a transfer assembly line exchanger (TLX) prior to entering the quench tower. This arrangement saves energy by decreasing the amount of fuel needed to fire the cracking furnace and/or steam needed to vaporize the feed.Then it will undergo the purification p rocess. Water elimination in a VCM purification system is achieved by dint of on condition that a insularity of a liquid mixture which consist of water, hydrogen chloride, and vinyl chloride into a hydrogen chloride distillate stream and an essentially pure vinyl chloride product stream in distillate column and a drying system is placed in fluid communicating with the distillation column midsection at a connection point where the water reached sufficient concentration so that a water operable mass transfer flux from a withdrawn midsection stream into a drying agent is provided.The temperature control in this column achieves EDC-water separation control. The VCM produced in the pyrolysis section is separated in the VCM purification section. In the HCL column, temperature control is used to distil HCL off the top of the mixed feed containing mainly EDC, VCM and HCL. The female genitals product is fed to the VCM column, where the temperature is controlled to purify VCM as overhead product and the get EDC is recycled back to the EDC purification sectionAfter the VCM purification process, it is ends up in the feed to the oxychlorination process. If acetylene is allowed to enter the oxychlorination nuclear reactor, the acetylene would be readily born-again to perchloroethylene and other heavily chlorinated by-products, resulting in a significant HCL efficiency loss. Consequently, the HCL recycle stream is usually passed through a hydrogenation reactor to selectively convert the acetylene to ethylene, which makes more EDC downstream.Hydrogenation is generally carried out in a decided bed reactor packed with catalyst made from a remarkable metal on an inert support. Hydrogen is added to the feed in stoichiometric excess to ensure conversion of acetylene to ethylene. The reaction is temperature dependant, with lower temperatures being preferable to maximize conversion to ethylene. If the temperature is too high, a fraction of the acetylene whitethorn be fur ther hydrogenated to ethane.(Prepared by Hew She Luan, 0905291)( stripping, Centrifuging, Drying and Sieving Process)7 Stripping In all of the processes used to produce PVC, unreacted VCM is present at the end of the reaction. VCM is a carcinogenic substance and its removal from PVC is very substantial for both avoiding downstream emission and for recycle purpose. Superheated steam is injected into the polymerization product in the reactor. The steam causes unreacted VCM to vaporize making it easy to remove. The temperature of the steam injected into the polymerization product should be 180 while the pressure should be 10 bar.8. Centrifuging During this step, PVC is separated from VCM. The water to the inlet of the centrifuge is filtered to prevent PVC from being contaminated by impurities in the water. Nexis T filters rated at 10m are recommended to filter the water.9. Drying nearly of the water is removed when the slurry passes through the centrifuge. A pause cake of polymer l eaves the centrifuge and is conveyed into the fluid bed dryer. Here, the remaining water contained in the porous grains evaporates as a stream of heated air bubbles through the polymer powder. In order to minimize the emissions, the moist air is wet-scrubbed before freeing into the atmosphere. 10. SievingAfter the drying process, the PVC will go through sieving process where the PVC is separate into different sizes for further processing.(Prepared by Cody Yip Jun Kit, 10UEB00894)(Storage and Handling, Control populate and Polymerization)11. Storage and HandlingVCM must(prenominal) be stored in a tightly closed container in a cool, well ventilated champaign, away from direct sunlight, heat and incompatible materials .VCM can be stored in steel tanks at ambient temperature. The drums must be equipped with self closing valves, flash arresters and pressure vacuum. Consider installation of leak detection and alarm for shop and use area. VCM should not be stored below ground direct .12. Control inhabitA Control Room is the room where pumps, fans, blowers, mixers, mills and centrifuges are controlled by variable speed drives and soft starters. Minicomputers areused to control chemical reactors in the PVC production process.Computer control can found advantages to a batch process, closer control of the process, major gains in golosh and the opportunity to use larger, more efficient processing equipment.Under manual(a) control, a polymerization cycle might take about 14 hours but computer control can cut this time to about 8 hours. Computer control also offers substantial gains in accuracy and safety. A typical computer controlled reactor stands about six stories tall and hold 30,000 to 50,000 gallons. While in manually controlled plants, each reactors capacity is amidst 2,000 and 7,000 gallons. Computer control enables PVC plants to meet new OSHA standards, effective April 1, 1976, that will limit the exposure of workers to VCM vapors.VCM vapor is a known human carcinogen. If inhaled or absorbed through the skin, it whitethorn be harmful. VCM vapors may be a reproductive hazard.13. PolymerizationThe process of polymerization links together the vinyl chloride molecules to form chains of PVC. The PVC produced in this way is in the form of a white powder. This is not used alone, but intermingle with other ingredients to give formulations for a wide range of products.In the polymerization process practically all of the VCM is processed into the inert polymer chains that make up the PVC plastic. It is executable for extremely low levels of any residual depolymerised VCM to remain in the polymer and eventually migrate into food from PVC packaging, but only at levels.Polymerization of PVC is divided into 2 types which is photographic photographic emulsion polymerization and rupture polymerization. Emulsion polymerization involves the polymerization of monomers in an aqueous medium containing surfactant and a water soluble initiator, pr oducing PVC lattices. PVC lattices are colloidal dispersions of spherical particles, ranging in size between 0.1 and 3.0 m. Most PVC lattices are spray dried and then milled to obtain fine powders, made up of agglomerates of latex particles. When mixed with plasticizers they disperse readily to form stable suspensions. During mixing most of the agglomerates are broken down into the original latex particles. Such dispersion of fine particles in plasticizers are known as plastisols or bed covers, and the powder is called dispersion or paste polymer. The surfactant layer around the particle surface prevents their adsorbing the plasticizer at room temperature so they can be used as liquids and may then be spread on to fabric or other substrates, poured on molds, or deposited on formers to produce flooring, wall covering, artificial leather, balls, toys, or protective gloves. There are other grades of PVC polymers, produced by emulsion polymerization, that do not form plastisols and tha t are used as blends with suspension PVC grades for extrusion application or in the manufacture of electric battery separator plates. These so-called emulsion polymers are of only minor economic interest. Sales in latex form are very limited lattices are used in water-based paints, printing inks, and impregnated fabrics.(Prepared by A. Srinyanavel 0904742)(Packing and junket, compounding, converting and recycling)14. Packing dispatchIn this process, soft PVC is packed on a semi-automatic snaking work or manually, depending on the size, shape, and aloofness and intended use of final product. The length of the roll cut on a stumble varies for fix packages form 10m to 100 m. However, other lengths are also obtainable upon appeal. Rolls are provided with 3 binding strips and marked with markets badges. Some soft PVC sizes are packed into polyethylene foil to provide appropriate security against incidental loot or corrosion of their functionality.15. Compounding This process involve s storage, conveying, metering, mixing, and cooling. All these trading operations supervene prior to the actual melt compounding. The distribution becomes harder because the filler loading level is increased and the surface area of the mineral filler increases. The surface area increases rapidly due to the particle size decreases. These are big travel in the process that can affect the feature of PVC. If these requirements are not met completely, the final products physical properties will be affected.16. ConvertingThis process is either makes final PVC products for sale or makes components for further uses. Different additives like stabilisers and plasticisers need to be added to PVC resin to create a compound that meets the requirement of the final product and of the processing technology to be used. Compounding may be carried out by the converters or by separate compounders who supply ready-made blends prepared for processing. The PVC compound is then converted by processes such as extrusion, moulding and calendaring.17.RecyclingPolyvinyl Chloride can be reused however the white of the material tends to degrade with each time of reuse cycle. In addition, the separation of the different additives and compounds forming the plastic makes recycle a difficult process.The biggest problem with PVC recycling is that it is difficult to automate the sorting of plastic waste, and so it is labor-intensive. There are three ways of PVC recycling mechanical recycling, mechanical recycling for mixed plastics and feedstock recycling.(Prepared by Cheah Kai Mun, 0904128)Role of chemical engineer in petrochemical industryBeneath all of the general responsibilities listed above, a petrochemical engineer must engage in numerous specific duties on a periodical basis. The first duty which the petrochemical engineer is responsible for completing is look. The petrochemical engineer must take careful steps to ensure that what they are looking to manufacture and how they are l ooking to manufacture a product is the right channel to pursue. The way to resolve this issue is by doing a lot of research on a variety of topics relating to petrochemical engineering.The petrochemical engineer is also responsible for aim a variety of items and this is a very principal(prenominal) duty which they must complete. A petrochemical engineer must design various items such as measurement and control systems, petrochemical manufacturing equipment and petrochemical manufacturing processes. This is a major duty on the part of the petrochemical engineer and one which must be carried out with preciseness at all levels and stages.A petrochemical engineer must also engage in a wide array of analyses. The things which the petrochemical engineer must analyze include test data, engineering design, design problems and research findings. The petrochemical engineer must take painstaking measures to adequately analyze these items as the outcome of the project could very well depend on the analysis which is undertaken by the petrochemical engineer.One who is an engineer must develop legitimate procedures and policies as well so that there will be smooth operations all the way around the board. Various procedures and policies such as safety procedures, data tables and employment policies may all be in the workforce of the petrochemical engineer. A senior level petrochemical engineer will have more to do with regard to ontogenesis policies and procedures within the company orcorporation.The preparation of multiple reports is also in the hands of the petrochemical engineer. The petrochemical engineer must prepare data which specifically details the findings of certain tests and evaluations. These reports can be text or tables depending on the type of report which is needed.A petrochemical engineer will also deal with other individuals a great deal. The reason for doing so is to relay the results and findings as well as oversee other petrochemical engineers and r elated workers in their field. From time to time, petrochemical engineers must public lecture to their peers and the general public regarding their job and role in society.The Skills/Knowledge mandatory by the engineerIn the oil and natural gas industry such as PVC manufacturing industry, the Petrochemical Engineer is playing a important role. With all the products derived from crude oil it is practically impossible to imagine a world without them.Act as a petrochemical engineer, several skills and knowledge are needed. Petrochemical engineers should be expert in analytical things. They need constantly putt their creativity to work, efficiently and on a large scale, transforming combinations of elements of matter, synthesizing new materials.Besides, it is important to determine the most effective processes for normal production. For example, Design and develop newest and raise processes and equipment for converting the raw materials into products by using computers to simulate and control such processes.Other than that, creative and innovative thinking with excellent problem solving skills is important to a petrochemical engineer. In order to have an organized and high quality products being designed, engineers should always troubleshoot environmental problems in industrial processing and manufacturing plants. alone in the same way, efficient, safe and environmentally responsible plant operations needed to be ensured. Moreover, planning, organizing, and prioritizing tasks skills across multiple projects are needed by an engineer.They acquire excellent both spoken and written, communication skills, and cooperate well in teams with people from different backgrounds and disciplines. Engineers, technicians, supervise technologists, and other involved in related activities. Additionally, participates aggressively in new product introduction are motivated, including influencing the design of the product to ensure manufacturability and quality conformance, testing the dependability of prototypes and managing the revolution into production.Applying mathematical and scientific principles are needed too. Some of the processes such as catalytic cracking is developed by Petrochemical engineers to break down the complex organic molecules found in crude oil into much simpler molecules. endingIn a nutshell, chemical engineers need to possess skills, knowledge and meet in order to make the conversion of raw materials that enter the reactor into a useful product that leaves the reactor a success as well as minimizing the damage done to the environment. PVC production is still in demand worldwide even though everyone realizes that PVC takes a long time to decompose. However, the production of PVC will not be stopped as other industries still rely on plastics to manufacture or to pack their products. The industrial method to produce PVC involves 17 processes according to our group research and among the 17 processes some actually send harmful materia ls or gases as a byproduct that causes damage to the environment. However, these processes must be made as environmentally friendly as possible to produce PVC without damaging the environment.