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Joanna Emerson, Andrew Wong, Phillip Zinsli 2-HYDROXYETHYL HYDRAZINE AND HYDRAZINE HYDRATE PLANT DESIGN Item Type text; Electronic Thesis Authors Hsu, Ivann Hong; Emerson, Joanna; Wong, Andrew; Zinsli, Phillip Publisher The University of Arizona. Rights Copyright © is held by the author. Digital access to this material is made possible by the University Libraries, University of Arizona. Further transmission, reproduction or presentation (such as public display or performance) of protected items is prohibited except with permission of the author. Download date 04/10/2021 01:26:45 Item License http://rightsstatements.org/vocab/InC/1.0/ Link to Item http://hdl.handle.net/10150/192492 2-HYDROXYETHYL HYDRAZINE AND HYDRAZINE HYDRATE PLANT DESIGN Ivann Hong Hsu Group Members: Joanna Emerson, Andrew Wong, Phillip Zinsli A Thesis Submitted to The Honors College In Partial Fulfillment of the Bachelor’s degree With Honors in Chemical Engineering THE UNIVERSITY OF ARIZONA MAY 2009 Approved by: _____________________________ Kimberly Ogden Chemical and Environmental Engineering STATEMENT BY ONE OF THE AUTHORS I hereby grant to the University of Arizona Library the nonexclusive worldwide right to reproduce and distribute my thesis and abstract (herein, the “licensed materials”), in whole or in part, in any and all media of distribution and in any format in existence now or developed in the future. I, and my group members, represent and warrant to the University of Arizona that the licensed materials are my original work that I am one of the owners of the rights in and to the licensed materials, and that none of the licensed materials infringe or violate the rights of my group members. I further represent that I have obtained all necessary rights to permit the University of Arizona Library to reproduce and distribute any nonpublic third party software necessary to access, display, run, or print my thesis. I acknowledge that University of Arizona Library may elect not to distribute my thesis in digital format if, in its reasonable judgment, it believes all such rights have not been secured. SIGNED: _____________________________ Abstract: The goal of this project is to design a manufacturing plant producing a military grade of 2-hydroxyethylhydrazine (HEH) as well as producing an excess of 48% hydrazine hydrate (HZH), 90% hydrazine hydrate and 95% hydrazine hydrate. HEH is synthesized through the reaction of ethylene oxide and hydrazine. Through a series of reactors and distillation columns, the product is produced. The purpose of producing this product is to replace the current propellant, anhydrous hydrazine, because anhydrous hydrazine is a very toxic compound. HEH is produced for markets such as the United States Air Force and the United States Department of Defense. After a 30 year cost analysis, the investment has a net present value of $960,000,00, and an investor’s rate of return of 43.34%. With a 20% interest rate, the pay back period is 2.83 years. Furthermore, a process hazard analysis was completed to determine the safety and environmental hazards of the process. Several actions must be taken to put the placed design into effect, but if these uncertainties are studied, it is recommended to build the plan as outlined in this document. The Roles of Group Members A chemical engineering group, all students represented by the honors college, developed a 2-hydroxyethylhydrazine (HEH) and hydrazine hydrate (HZH) plant. This project most exemplifies as an honors project by how in depth the project was and the amount of time placed in the project. All members of the group contributed an even amount of work. Phillip Zinsli was the team manager of the group. He organized group meetings, set deadlines for when things were due and planned meetings with our mentor, Dr. Greg Ogden. Furthermore, Phillip modeled the process of Unit 100, 400 and 500 on ASPEN Simulations. He did extensive research on reactions that could be used for the process and kept everyone focused on the goal at hand. Joanna Emerson modeled Unit 300, on ASPEN which contained many different chemical engineering processes. Furthermore, she determined the process safety hazards (PHAs) of the entire plant, edited the document and created the poster being presented at the Engineering Design Day. Andrew Wong , was the document organizer. He compiled everything that was placed and also edited the document. Furthermore, he determined the environmental concerts of the plant as well as calculated the amount of utilities needed. Other various activities were that he aided in were finding raw material costs, researching the storage and transportation and compiling the references used for the project. I, Ivann Hsu, calculated the economics for the plant. I calculated how much the equipment costs, called vendors to price equipments we did not have equations for, determined 1 the cost of the raw materials, and utilities needed and the annual amount of sales of the hydrazine hydrate and 2-hydroxyehtyl hydrazine. I determined the cost of start up, land costs and other costs that would lead to the calculation of the total capital investment. Furthermore, I was able to calculate a pay back period, and investor’s rate of return through an excel spreadsheet and to apply a 30 year MACRS deprecation schedule to calculate the net present value. Besides economics, I was in charge of writing about the safety issues of the plant and how one should protect themselves from the chemicals in the system. I also estimated thermodynamic properties for methyl ethyl ketazine, a compound in which no literature was found. In addition, I determined where the plant could be built and contributed to the preliminary research conducted. 2 2-Hydroxyethylhydrazine (HEH) Plant Design Nedgo Engineering Design Team Nedgo Engineering, LLC Date Submitted: May 1 st , 2009 ___________________________ ___________________________ Phillip Zinsli Joanna Emerson Project Manager Senior Design Engineer ___________________________ ___________________________ Andrew Wong Ivann Hsu Senior Design Engineer Economics Analyst 3 Executive Summary The goal of the following project is to design a manufacturing plant with the capacity for producing 200 metric tons per year (MTPY) of military grade 2-hydroxyethylhydrazine (HEH). In addition to HEH, the proposed process also produces an excess 2,800 MTPY of 48 % hydrazine hydrate (HZH), 270 MTPY of 90 % HZH, and 9,700 MTPY of 95 % HZH, which will be sold as a product for use in non-military applications. The plant will be located in the panhandle area of Texas, just north of Amarillo. The close proximity to raw material suppliers and U. S. railways makes the area an ideal location. The product is intended to serve as a replacement for the current standard propellant, anhydrous hydrazine. The capacity represents about 6 % of the United State’s consumption of anhydrous hydrazine in rocket fuel applications in 1995. There exists a high demand for alternative rocket fuels with lower toxicity concerns, and there is a strong belief that HEH will be that future replacement. The production of HEH is intended primarily for use by the U. S. Government. The target markets are the United States Department of Defense, United States Air Force, and the Air Force Research Laboratory. HEH is synthesized from the reaction of HZH and ethylene oxide as outlined in U. S. Patent 2,660,607. Following the reaction, a series of distillation columns are used to concentrate and isolate the final product. The more environmentally friendly and economically efficient Produits Chimiques Ugine Kuhlmann Peroxide Method was chosen as the method of production of HZH. The Peroxide Method utilizes a series of distillation towers and a hydrolysis tower to synthesize 4 HZH. It is characterized for its internal recycle of catalyst and regeneration of the raw material, methyl ethyl ketone. Gel filtration and ion exchange columns are used to remove impurities from the final products. A complete process hazard analysis and a gate to gate life cycle assessment were performed on the proposed process to evaluate and minimize safety and environmental hazards. Combustion and explosion hazards from the contact of HZH with oxygen were identified as the most significant process hazard. The most significant environmental burdens of this process comes from the plant’s nearly 33 billion gallon annual water consumption and nearly 370 million kW·h annual energy requirement. A 30 year cost analysis was performed to evaluate any economical considerations. At 30 years, the investment has a net present value (NPV) of $ 960,000,000 and an investor’s rate of return of 43.34 %. At a 20 % interest rate, the payback period is 2.83 years. Sensitivity analyses were also performed to evaluate the economic effects of potential market fluctuations. Decreases in annual sales and increases in production costs were found to have the greatest negative impact on NPV. Several actions must be taken before the proposed design can be considered robust. Section 200 of the plant was not modeled and leaves several uncertainties about capital and economical costs, and raw material requirements. The exact grading requirement of HEH is assumed to be similar to military specification anhydrous hydrazine, but is ultimately unknown and should be determined. Thermodynamic data on HEH, methyl ethyl ketazine, and multi-phase mixtures of methyl ethyl ketazine, methyl ethyl ketone, hydrogen peroxide, and ammonia are needed to more 5 accurately model the process in simulation programs such as ASPEN. Gel filtration is used to
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