異丙醇脫氫反應製造丙酮之製程研究

本研究採用多管式熱交換型式之填充床觸媒反應器產製醫藥級丙酮，以年產量15,000公噸、99.9 mole%純度之丙酮為設計目標。製程中除異丙醇脫氫反應器外，還包括氣液分離單元、丙酮吸收及氣提單元、丙酮純化單元與異丙醇回流等單元。透過Aspen Plus軟體之敏感度分析可知，雖然異丙醇在450oC時有最高的轉化率，但是為了避免高溫造成觸媒燒結，本研究反應器溫度操作在350oC。另外值得一提的是，由於脫氫反應是吸熱反應，高壓蒸汽並無法提供足夠的反應溫度，故在反應器的殼側導入融鹽 (Molten Salt) 當作熱媒源，融鹽本身則需藉加熱爐供給熱能。在熱能整合及節能減碳部分，吾人利用Aspen Plus內之 “HeatX＂模組進行熱能整合，藉反應器出口物流預熱冷流進料，如此得以省去蒸汽之使用量，經計算得知此熱交換量為547.5 kW；另外的設計方式，吾人可利用反應器出口的高溫物流生產蒸汽以供製程使用，若生產高壓蒸汽，其量有1,453 kg/hr；若生產中壓蒸汽，其量有1,522 kg/hr；而若生產低壓蒸汽，則其量有1,477 kg/hr。在製程經濟評估方面，根據計算整廠之年製造成本為US$21,603,090/yr (不含折舊)，並由蒙地卡羅法模擬獲利及風險分析，在選擇MACRS折舊法的情況下，得知平均淨現值為US$10×106、平均投資報酬率為23%、平均回本期為2.2年。本論文之異丙醇脫氫反應製造丙酮的整廠設計，係使用化工程序軟體 “Aspen Plus”，主要進行其程序合成與設計，而程序流程圖則使用 “visio” 軟體繪製。

關鍵字

丙酮；異丙醇；脫氫反應；節能減碳；經濟評估；蒙地卡羅法

並列摘要

In this study, a multi-tube heat exchange, packed-bed catalytic reactor was used to produce pharmaceutical-grade acetone. The target was acetone with an annual yield of 15,000 metric tons and a purity of 99.9 mole%. In addition to isopropanol dehydrogenation reactor, gas-liquid separation unit, acetone absorption, stripping unit, acetone purification unit and isopropanol recovery unit are also included in the process. Sensitivity analysis of Aspen Plus software shows that isopropanol has the highest conversion at 450oC. To avoid sintering of catalysts, we will operate the reactor at 350oC. It is worth mentioning that since the dehydrogenation reaction is an endothermic reaction and the high-pressure steam does not provide sufficient reaction temperature, molten salt is introduced into the shell side of the reactor as a heat medium source. Note that molten salt itself is required by using a heating furnace as a supply of heat. In the thermal energy integration, energy-savings and carbon reduction section, we use the "HeatX" module in Aspen Plus. The strategy is to preheat the cold flow feed by the reactor exit stream, thus eliminating the need for steam usage. The heat exchange capacity is 547.5 kW. Another approach is that we can use the high-temperature reactor exit stream to produce various levels of the steam. High pressure steam can be produced with the amount of 1,453 kg/hr, medium pressure steam can be produced with the amount of 1,522 kg/hr, and low pressure steam can be produced with the amount of 1,477 kg/hr. In the aspect of process economic assessment, the annual manufacturing cost of the plant-wide IPA process was calculated (excluding depreciation) as US$21,603,090/yr. Monte-Carlo method was used to simulate the profit and risk analysis. In the case of the MACRS depreciation method, we found that the average net present value was US$10×106, the average return on investment was 22%, and the average return period was 2.2 years. It should be noted that, in this thesis, we used two kinds of software－Aspen Plus and “visio”. The first is applied to implement the process synthesis and design; the second is applied to draw the process flow diagram.

並列關鍵字

Acetone ； Isopropanol ； Dehydrogenative Reaction ； Energy-Savings ； Carbon Reduction ； Economic Assessment ； Monte-Carlo method

參考文獻

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【9】 Linnhoff, B., and J. R. Flower, “Synthesis of Heat Exchanger Networks-1: Systematic Generation of Energy Optimal Networks,” AIChE J., 24, 633-642 (1978).

【10】 Ahmad, S., B. Linnhoff, and R. Smith, “Cost Optimum Heat Exchanger Network-2: Targets and Design for Detailed Capital Cost Models,” Comput. Chem. Eng., 14, 751-767 (1990).

【13】唐寧慧，質傳速率基礎模型在焦爐氣水洗氨製程模擬的應用，碩士論文，國立清華大學，台灣(2012)。

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異丙醇脫氫反應製造丙酮之製程研究

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