Tuesday 29 November 2016

HYDROGEN PEROXIDE PLANT - FLUIDIZED BED TECHNOLOGY

HYDROGEN PEROXIDE PLANT - FLUIDIZED BED TECHNOLOGY

SUMMARY

Hydrogen peroxide is produced by cyclic reduction and oxidation of a mixture of 2-ethylanthraquinone (EAQ) and 2-ethyltetrahydroanthraquinone (H4EAQ). These anthraquinones are dissolved in organic solvents (The mixture is called as Working Solution (WS)). The anthraquinones are catalytically hydrogenated to form 2-ethyltetrahydroanthrahydroquinone (H4EAQH2). Catalyst is separated from the working solution and returned back to the hydrogenator. Hydrogenated working solution combines with air (oxygen) in the oxidizer to form hydrogen peroxide. Hydrogen peroxide dissolved in working solution is extracted by demineralised water in the extractor. The working solution is dried by evaporation in the WS drier before it is returned to the hydrogenator feed tank. The aqueous phase from the extractor can contain up to 40 wt-% hydrogen peroxide but for efficiency reasons, normally max. 35 wt-% is produced. The final product concentrations (50 and 70 wt-%) are reached by vaporization and distillation of the crude hydrogen peroxide solution in the concentration unit (see doc 2.5.3-02). In the product day tanks stabilizer is added to the hydrogen peroxide solution to prevent decomposition.

PROCESS DESCRIPTION

The design of this hydrogen peroxide plant is based on the anthraquinone process (AO-process). It is based on cyclic reduction and oxidation of a mixture of 2-ethylanthraquinone (EAQ) and 2-ethyltetrahydroanthraquinone (H4EAQ), the so-called “All-tetra system”. This system got its name since the only hydrogenated quinone is 2-ethyltetrahydroanthrahydroquinone (H4EAQH2).
The anthraquinones are dissolved in a mixture of organic solvents, the so-called working solution (WS). The main components apart from anthraquinones are an aromatic solvent (non-polar solvent for dissolving H4EAQ), tetrabutyl urea (polar solvent for dissolving hydrogenated anthraquinone H4EAQH2) and trioctyl phosphate (polar solvent and corrosion inhibitor). The main equipments in the working solution loop are the hydrogenator (R1031), oxidizer (R2061), extractor (C3011) and WS dryer (S3202).

1             Hydrogenation

Working solution from the hydrogenator feed tank (T1021) is pumped by the
hydrogenator feed pump (P1022) to the bottom of the hydrogenator (R1031)
via the WS cooler (E1025) and the eductor (P1026). Recycled catalyst and
working solution from the primary filters (F1101-F1105) are injected into the
working solution through the eductor (P1026). The main working solution
stream works as motive flow for the eductor and provides the driving force for
the recycle stream. Hydrogen enters the hydrogenator (R1031) at the bottom
through spray nozzles. Working solution, catalyst and hydrogen are intimately
mixed so that the main hydrogenation reaction, conversion of anthraquinone
(H4EAQ) to anthrahydroquinone (H4EAQH2), takes place in the hydrogenator
(R1031). The conversion ratio is primarily controlled by the amount and activity
of the catalyst present, temperature, agitation intensity, and hydrogen pressure.
The temperature is controlled by a cylindrical cooling element inside the
hydrogenator (R1031), which also provides the necessary agitation.

                                               cat
             (H4EAQ) +3H2      -----------›    (H4EAQH2)
                               Main hydrogenation reaction

In the top of hydrogenator (R1301) working solution and catalyst are separated from excess hydrogen. Working solution and catalyst flow through the primary filters (F1101-F1105) which have sintered stainless steel filter elements. The filtrate flows through the filter elements into the oxidiser feed tank (T2001). Catalyst particles are retained on the elements and recycled to the eductor (P1026).
Much of the catalyst falls off the filter elements due to the turbulent flow in the filter. However, the filter elements can become coated with excessive quantities of catalyst, and for this reason a periodic back-flush, where the flow direction through the filters is reversed, is required. The back-flush is generated with working solution from the oxidiser feed tank (T2001) pumped by the primary filter backwash pump (P2005), if required it may be passed through the backwash cooler (E2007).
Hydrogen gas, separated from working solution and catalyst, is discharged from the top of the hydrogenator (R1301). Excess hydrogen gas is recycled back to the hydrogenator (R1301) via the H2 recycle compressor unit (B1011). Make-up hydrogen combines with recycled hydrogen and is fed to the hydrogenator (R1301).
Make-up hydrogen flow is the determining factor in controlling the pressure in the hydrogenator (R1301). When the pressure is below the set-point the make-up hydrogen control valve (PV1039A) opens and make-up hydrogen is added to maintain the desired system pressure.
A small amount of hydrogen is bled off from the system to control the concentration of inerts. This purge is taken from the discharge of the H2 recycle compressor unit (B1011). The organic content of the purge is condensed in the H2 vent cooler (E1015). The condensed solvent is returned to the seal liquid tank (S1012). The purge gas is further purified in the hydrogen vent adsorbers (C1050A/B) before being discharged to the atmosphere.

PROCESS PARAMETERS

Hydrogenator (R1301) 
Inlet temperature (WS)                44 °C
Outlet temperature                      52-59 °C
Operating pressure              0.8-1.2 kg/cm2g

SAFETY OF THE HYDROGENATION

As hydrogen has an extremely wide explosive range with oxygen, it is important to keep control of the oxygen content. The start-up phase is more critical than the normal operation, which will be explained below.
To ensure the safety of the plant two redundant oxygen meters (instrument AI 1002 and AI 1041) are installed in the hydrogen loop. When hydrogen is fed at least one of the analysers must be in operation (by pass is only allowed for calibration of one analyzer at the time). During the venting before hydrogen cut in, both analysers are bypassed (to avoid emergency shut down due to high oxygen content). When the oxygen content is below a safe limit the analyzer alarms and interlocks are activated. Hydrogen feed can not start until at least one analyzer is active.
As soon as the hydrogenation has started the H4EAQH2 concentration starts to build up. Any oxygen entering the system will be consumed by oxidation of the H4EAQH2, forming hydrogen peroxide and H4EAQ. The H2O2 will decompose due to the presence of catalyst, forming ½ hydrogen and water. Note that the oxygen amount has been halved. These two reactions continue, and ultimately the oxygen ends up as water. Hence, the system has an inherent safety against oxygen during operation, although the reactions represent as loss of overall yield.

2             OXIDATION

Working solution from the oxidizer feed tank (T2001) is pumped by the oxidizer feed pump (P2002) through secondary filters (F2011-F2013) and safety filters (F2021-F2022). The safety filters (F2021-F2022) provides appositive safeguard against trace quantities of catalyst entering the oxidizer (R2061) in event of failure of the secondary filter system. After the safety filters (F2021-F2022) the working solution is passed through the oxidizer cooler (E2042). It is necessary to cool the solution prior to oxidation, since oxidation is an exothermic reaction.
Oil-free compressed air is supplied to the oxidizer (R2061). The air intake shall be isolated as much as possible from sources of atmospheric contamination such as power plant stack gases, etc. Process air from process air compressor (B2051/B2052) is passed through the process air buffer vessel, the oxidizer air filter (F2055A/B) and fed to the oxidizer (R2061). The feed line is supplied with a loop that diminishes the possibility of working solution flowing back into the air supply system in case of compressor failure.
Air is supplied in the bottom of the oxidizer (R2061) through spray pipes. The organic flow enters the oxidizer (R2061) at the top of the vessel and flow counter-currently down through the reactor. The oxidizer (R2061) is supplied with eight sieve trays (to ensure good dispersion of air bubbles, required for mass transfer).
In the oxidation step hydrogen peroxide is produced. Anthrahydroquinone (H4EAQH2) is oxidised to anthraquinone (H4EAQ) and the oxygen is reduced to hydrogen peroxide. At this point hydrogen peroxide is dispersed in the working solution.

                  (H4EAQH2) +O2  -----------› (H4EAQ) + H2O2
                                         Oxidiser reaction

The oxidiser off gas exits at the top of oxidizer (R2061) and is passed through the oxidiser off gas chiller (E2071) and the oxidizer off gas demister (S2072) into the solvent recovery unit (X2501). In the solvent recovery unit the remaining organic solvent in the off gas is recovered before the off gas is released to the atmosphere. The working solution is discharged from the bottom of the oxidizer (R2061) through the oxidiser outlet cooler (E2062) into the oxidiser degasser (S2063). The purpose of the oxidiser degasser (S2063) is to maintain the amount of dissolved air entering with working solution into the extractor (C3011). Release of air in the extractor (C3011) will disturb the extractor.

PROCESS PARAMETERS

Oxidiser (R2061) 
Inlet temperature (WS)        42 °C, min. 37 °C
Inlet temperature (air)         40 °C
Outlet temperature              52 °C, max. 60°C
Operating pressure (top)      ~1.5 kg/cm2g
Oxidiser degasser (S2063) Operating Pressure Atmospheric

SAFETY IN THE OXIDATION

The most critical parameters to control in the oxidation system are the temperature and off gas oxygen content. During start up, the temperature shall be kept as low as possible to reduce the risk of explosions in the top of the oxidizer. During operation high temperature results in loss of product due to increased decomposition rate. Off gas oxygen content shall be kept below 10 vol-%, which ensures safe operation of the reactor and solvent recovery.
It is very important that no catalyst enters the oxidiser. To ensure this the WS is passed through secondary and safety filters. A catalyst detector is installed to indicate catalyst slipping through the secondary filters.
In the oxidiser feed tank (T2001) working solution is held as a buffer for the oxidiser. In case of hydrogen release the oxidiser feed tank (T2001) atmosphere is kept inert by nitrogen.

3             EXTRACTION

Working solution from the oxidiser degasser (S2063) is fed by the extractor feed pump (P3001) into the bottom of the extractor (C3011). Demineralised water is fed to the top of the extractor (C3011). Stabiliser, in the form of phosphoric acid, is added to the the extractor (C3011). In the column, water is the continuous phase and working solution is the discontinuous phase. Due to the difference in of the two phases (working solution being the lighter) the working solution rises and discharges from the top of the extractor (C3011) after being stripped of its hydrogen peroxide. The aqueous phase discharging from the bottom of the extractor (C3011) is controlled about 35 wt-% of hydrogen peroxide.
The extractor (C3011) consists of 32 sieve trays. The trays are specially designed in order to maintain the required residence time, good separation of hydrogen peroxide from the working solution and good re-dispersion of WS above the trays. Working solution passes through a coalescing polyethylene mesh before it is collected below the trays until it is forced through the holes, forming bubble droplets that rise through the water phase to the next tray.
In top of the column a coalescer pad is installed to improve the performance by reducing the overhead aqueous content. Working solution from the extractor (C3011) top passes the WS coalescer (S3015). The WS coalescer (S3015) is designed to coalesce and remove (by settling) the major part of the entrained water.

PROCESS PARAMETERS

Extractor (C3011)        
Operating temperature 37-45 °C
Operating pressure      Atmospheric

SAFETY IN EXTRACTION

It is important to ensure that the hydrogen peroxide content in the product does not exceed 41 wt-%, as the risk for reaction with working solution components increases with increased concentration. 40-41 wt-% is a well established safe concentration in the operating temperature range.
The temperature in the extraction must be carefully monitored for the same reason. In case of shutdowns that last more than one hour is very important to ensure that the working solution is well extracted, and that the hydrogen peroxide concentration in the bottom of the column is below 20 wt-% before working solution circulation is restarted. Failure to do this may result in so called reverse extraction, when hydrogen peroxide is transferred from the aqueous solution to the working solution. Then there is a risk that hydrogen peroxide is carried over to the hydrogenation, resulting in violent decomposition.

4             CRUDE PRODUCT PURIFICATION AND INTERMEDIATE STORAGE

Crude hydrogen peroxide from the extractor (C3011) is passed through the 
crude cooler (E3017) into the crude coalescer 1 (S3120) either by the crude
product pump (P3016) or by gravity (depending on product flow). The crude
coalescer 1 (S3120) and crude coalescer 2 (S3121) are connected in series and
are designed to coalesce and remove the majority of entrained solvent. The
removed liquid is decanted in the bleed decanter (S3122) and the removed
solvent is returned back to the oxidiser degasser (S2063). Hydrogen peroxide
from the crude coalescer 2 (S3121) and recovered hydrogen peroxide from the
bleed decanter (S3122), flows by gravity to the first product holding tank
(T3501).
The product holding tanks (T3501-T3504) are connected in series with a small
difference in height over the ground level, thus allowing the filling of T3504 via
T3503 and T3502 from T3501 by gravity flow. Over time, organic material (from
the crude hydrogen peroxide feed), may appear as a light organic phase in top
of the product holding tanks (T3501-T3504). These organics are batch-wise
recycled back to the AO-process by the solvent return pump (P3510).
The crude hydrogen peroxide from T3504 is pumped by the concentrator feed
pump (P3540A/B) to the hydrogen peroxide concentration unit.

PROCESS PARAMETERS

Crude coalescer 1 (S3120) & crude coalescer 2 (S3121) 
Operating temperature                                          40 °C
Operating pressure                                                Atmospheric
Crude hydrogen peroxide concentration                  35 wt-%

SAFETY IN THE PRODUCT HOLDING TANKS

The temperature in the product holding tanks is the most critical parameter to
watch, both as an indicator of and to suppress decomposition. As a rule of
thumb the decomposition rate of hydrogen peroxide is doubled for every 10 °C
increase in temperature. Under normal conditions hydrogen peroxide is stable,
<1.0 % decomposition per year at 30 °C. Increased decomposition rate is
usually due to impurities. Organic substances or oxidisable metal ions will
drastically increase decomposition rate. Decomposition of hydrogen peroxide is
an exothermic reaction. Unexpected rise in temperature in a storage tank is
therefore an indication of decomposition.
All product holding tanks for hydrogen peroxide solution are equipped with
temperature indicators. In case of accelerated decomposition, water can be
pumped by the DMW pump (P3532A/B) from the DMW tank (T3531) to dilute
and cool the tank content. The DMW tank (T3531) is connected to all the
hydrogen peroxide product holding tanks (T3501-T3504).

5             WORKING SOLUTION DRIER

The working solution from the WS coalsescer (S3015) is heated in the WS
heater (E3201) before entering the WS drier (S3202). The pressure in the WS
drier (S3202) is reduced by the vacuum pump (B3221) to flash the water from
the working solution. The dried working solution from the WS drier (S3202) is
returned by gravity to the hydrogenator feed tank (T1021). The purpose of
drying the working solution is to optimize the catalyst behavior. Free water is
adsorbed onto the catalyst, resulting in loss of catalyst fluidization and activity.
The flashed water is condensed in the drier condenser (E3211) and in the
vacuum pump unit (B3221). The condensate is led to the solvent/water
separator (S3231) where entrained solvent is recovered. The water from the
solvent/water separator (S3231) is recycled to the DMW feed tank (T3535)
where it can be reused as extractor feed.

PROCESS PARAMETERS

WS drier (S3202)        
Operating temperature         50-55 °C
Operating pressure     0.06 kg/cm2a

6             REGENRATION OF WORKING SOLUTION

Due to the circulating working solution, undesirable compounds (principally
different quinones) can accumulate in the system. In order to keep the
concentration of the undesirable compounds in the working solution to a low
level, it is essential to convert them into active quinones. This is carried out in
columns with activated alumina, the process is known as regeneration.
A side stream of about 7 % of the main working solution flow is regenerated in
an activated alumina bed (regeneration column C2221 or C2222). The
regeneration stream is hydrogenated working solution taken from oxidiser feed
tank (T2001). The working solution is pumped through the regeneration system
by the regeneration system by the regeneration feed pump 1 (P2211). It is
heated to the required temperature in the regeneration economiser (E2213) and
the regeneration feed heater (E2215) and fed to the bottom of the activated
alumina packed regeneration column (C2221 or C2222). In this column the
undesirable quinones are converted to active quinones and the irreversibly
degraded quinones are removed by adsorption over the activated alumina bed.
Working solution from the regeneration column (C2221 and C2222) is passed
through the regeneration economiser (E2213) and through the regeneration
polishing filter 1 (F2225) on its way back to the oxidiser feed tank (T2001).
The optional regeneration stream is oxidized working solution from the
hydrogenator feed tank (T1021). The working solution is pumped through the
system by the regeneration feed pump 2 (P2228). This stream is not heated
before entering the regeneration column (C2221 and C2222). The regenerated
working solution is returned to the hydrogenator feed tank (T1021) via
regeneration polishing filter 2 (F2229). This path is used to make use of the
remaining adsorption capacity before discharging the spent alumina. If this path
is used with fresh alumina bed, the reversed hydrogenation of anthraquinones
will take place. An option that is used to control the EAQ/H4EAQ relation in the
working solution.   

PROCESS PARAMETERS

Regeneration column   
Operating temperature
From T2001                71 °C
From T1021                52 °C
Operating pressure     3.5 kg/cm2g

7             PRODUCT STORAGE

This hydrogen peroxide plant has the following storage facility.
The product tank farm area consisting of five product day tanks (T5001-T5005) and five product storage tanks (T5006-T5010). The capacity of each the product day tanks are for T5001-T5004 60 m3 and for T5005 40 m3. The product storage tanks T5006 has a capacity of 20 m3, T5007-T5009 a capacity of 120 m3 each and T5010 80 m3.
The concentrated product from the hydrogen peroxide concentration unit is
taken to the product day tanks (T5001-T5005). The last product day tank
(T5005) and the last product storage tank (T5010) are separated from the other
tanks and are used for product with low concentration (35 wt-%) or high
concentration (70 wt-%). In the product day tanks (T5001-T5005) stabilizer
adjustments are made. The hydrogen peroxide shall be kept in the product day
tanks (T5001-T5005) until the correct concentration, purity and stability has
been verified by the laboratory. Then the final product is transferred by the
product transfer pump (P5021A/B) or the product storage pump 2 (P5027) to
the product storage tanks (T5006-T5009 or T5010). From the product storage
tanks (T5006-T5010) the product can be pumped to filling station for trucks or
(for T5006-T5009) pumped by the filling station feed pump (P6003/P6004) to
the filling station buffer tank (T6005). From there the product flows by gravity
to the different filling stations X6010, X6011 and X6012 for 30/50 kg carboys
and X6110 for 50 kg carboys/250 kg drums.
If necessary, unstabilised product in the product day tanks (T5001-T5005) can
be sent to the hydrogen peroxide concentration unit for further concentration.
For this purpose the concentration feed pump (P5035A/B) is used. It is very
important not to send stabilised product back to the concentration unit where
the stabiliser can cause severe corrosion damages.

PROCESS PARAMETERS

Operating temperature                          Ambient
Operating pressure of storage tanks       Atmospheric
Crude hydrogen peroxide concentration  35 wt-%
Hydrogen peroxide concentration   50 and 70 wt-% 

SAFETY IN THE PRODUCT STORAGE

The temperature in the storage tanks is the most critical parameter to watch,
both as an indicator of and to suppress decomposition. As a rule of thumb the
decomposition rate of hydrogen peroxide is doubled for every 10 °C increase in
temperature. Under normal conditions hydrogen peroxide is stable, <1.0 %
decomposition per year at 30 °C. Increased decomposition rate is usually due to
impurities. Organic substances or oxidisable metal ions will drastically increase
decomposition rate. Decomposition of hydrogen peroxide is an exothermic
reaction. Unexpected rise in temperature in a storage tank is therefore an
indication of decomposition.
All storage tanks for hydrogen peroxide solution are equipped with temperature
indicators. In case of accelerated decomposition, water can be pumped by the
DMW pump (P3532A/B) from the DMW tank (T3531) to dilute and cool the tank
content. The DMW tank (T3531) is connected to all the hydrogen peroxide
day/storage tanks (T5001-T5010).

8             STABILISER ADDITION

In order to improve the stability of hydrogen peroxide solution, stabilisers are
added to the extractor (C3011) and to the product day tanks (T5001-T5005).
For stabilisation in the extractor (C3011) phosphoric acid is used. Concentrated
phosphoric acid from barrels is pumped by the acid addition pump (P5191) to
the diluted acid (stabiliser) tank (T5171) where it is diluted with demineralised
water. The solution from the diluted acid (stabiliser) tank (T5171) is pumped by
the acid (stabiliser) dosing pump (P5172A/B) to the extractor (C3011).
For stabilising the end product in the product storage tanks (T5001-T5005)
many different stabilisers can be used. Stabiliser solution from barrels is
pumped by the stabilize addition pump (P5182) to the stabiliser tank (T5181)
where it can be diluted with demineralised water. From the stabiliser tank
(T5181) the stabiliser solution is pumped by the stabiliser dosing pump (P5182)
to any of the product day tanks (T5001-T5005). Controlled stabiliser addition is
done in stages after checking the stabiliser concentration of the hydrogen
peroxide in each stage.

PROCESS PARAMETERS

Operating temperature                          Ambient
Operating pressure of stabiliser tanks     Atmospheric
Acid concentration to extractor (C3011)  10 wt-%   

9             WORKING SOLUTION MAKE-UP

The working solution is primarily composed of solvents and 2
ethylanthraquinone, which are continuously lost during production and must be
periodically compensated to maintain steady working solution composition and
inventory.
Working solution is prepared in batches in the WS make-up tank (T2201). The
WS make-up tank (T2201) is equipped with an agitator and steam half pipe
jacket. Required amount of the solvents (aromatic solvent, TBU and TOP) and 2
ethylanthraquinone are fed to the WS make-up tank (T2201) and heated to the
desired temperature during agitation (for uniform mixing). Periodic checking of
the mixed solution is done to see if there is undissolved anthraquinone. When
no undissolved anthraquinone is found, the working solution is pumped by WS
transfer pump (P2202) through WS make-up polishing filter (F2203) to the WS
coalesce (S3015).
Solvent evaporated during the working solution preparation is condensed by WS
make-up condenser (E2205) and returned to the WS make-up tank (T2201).

PROCESS PARAMETERS

Operating temperature                         50-85 °C
Operating pressure                              Atmospheric

SAFETY IN THE WORKING SOLUTION MAKE-UP

To avoid explosive mixtures or aromatic solvent and air in the WS make up tank
(T2201) the atmosphere is made inert with nitrogen gas when heated over 60
°C.

10         PRIMARY FILTER CLEANING

Periodically the filter elements in the primary filters (F1101-F1105) will have to
be cleaned from precipitated anthraquinones, catalyst etc. to maintain a low
pressure drop over the filters. While doing this the filter elements are taken out
of the production line and put into the filter cleaning system, i.e. filter cleaning
vessel (T1501). The filter elements are cleaned in the following sequence:
§     Pure solvent from solvent tank (T1531), 60 °C.
§     Low pressure steam.
§     Caustic soda (10%) from caustic tank (T1521), 50-70 °C.
§     Demineralised water.
§     Nitric Acid (30%) from nitric acid tank (T1541) at ambient temperature.
§     Demineralised water.
§     Low pressure steam.
§     Drying with N2.
Solvent, caustic and nitric acid need to be partly exchanged after a certain
amount of filter cleaning cycles. Solvent is returned to the WS make-up tank
(T2201) and used in the WS system after approval of quality, e.g., pH.
Caustic solution is depleted of solvent residues by absorption on activated
carbon in the NaOH carbon filter (F1551). The caustic is taken to the caustic
tank (T2303) for reuse in the and for neutralisation of the acidic effluent from
the rest of the plant in the neutralisation unit (X9600).
Spent nitric acid is taken to the NA tank (T2320).

11         DRAIN WATER TREATMENT

All drain water from the process containing solvents is collected as much as
possible of the solvent fraction is returned to the plant.
Condensates fractions containing solvents are collected in the regeneration
decanter (S2261). The light solvent phase will rise to the surface. It is returned
to the circulating working solution by the solvent transfer pump (P2262). The
water phase flow by gravity to the pump pit tank (T7001).
Other fluid overflow and waste streams from the process, containing water and
working solution, are collected in the pump pit tank (T7001) and the separator
tank (S7006). The content of the pump pit tank (T7001) is transferred to the
separator tank (S7006) by the pump pit pump (P7002). In the separator tank
(S7006) the water and solvent fraction are separated. The solvent fraction flow
to the separated solvent tank (T7016) from where it is returned to the
regeneration decanter (S2261) by the separated solvent pump (P7017). The
water fraction is taken via the separated water tank (T7011) to the
neutralisation system (X9600) for neutralisation or directly to the effluent
treatment plant for neutralisation there.

PROCESS PARAMETERS

Operating temperature                         Ambient
Operating pressure                              Atmospheric
pH treated waste water                        6-8

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