{
  "authors": [],
  "basis": {
    "capacity": "16 kt/a hydrazine hydrate, 64 wt% N2H4 (10.2 kt/a N2H4) (ASSUMED)",
    "location": "generic (not chosen)",
    "operating_hours_per_year": 8000
  },
  "benchmarks": [],
  "chemistry": {
    "inputs": [
      {
        "chemical": "hydrogen-peroxide",
        "grade": null,
        "note": "feed:H2O2: hydrogen peroxide 70 wt% (e.g. hydrogen-peroxide-1), counted by mass of the solution",
        "role": "feedstock"
      },
      {
        "chemical": "ammonia",
        "grade": null,
        "note": "feed:NH3F: liquid ammonia (e.g. ammonia-1), 0.724 kg/kg hydrate",
        "role": "feedstock"
      },
      {
        "chemical": "butanone",
        "grade": null,
        "note": "feed:MEKF: MEK make-up",
        "role": "feedstock"
      },
      {
        "chemical": "acetic-acid",
        "grade": null,
        "note": "feed:ACOHF: acetic acid make-up",
        "role": "feedstock"
      },
      {
        "chemical": "disodium-hydrogen-phosphate",
        "grade": null,
        "note": "feed:PHOSF: disodium phosphate make-up",
        "role": "feedstock"
      },
      {
        "chemical": "water",
        "grade": null,
        "inventory_key": "feed:DW",
        "note": "Demineralised make-up water to the azine hydrolysis, 1.45 kg per kg hydrate",
        "role": "feedstock"
      }
    ],
    "outputs": [
      {
        "chemical": "hydrazine",
        "grade": null,
        "inventory_key": "product:HH",
        "note": "Hydrazine hydrate, 64 wt% N2H4, counted by mass of the hydrate",
        "role": "main-product"
      },
      {
        "chemical": "wastewater",
        "grade": null,
        "inventory_key": "product:WW",
        "note": "Reaction and peroxide water after ammonia recovery, 2.2 kg per kg hydrate",
        "role": "waste"
      },
      {
        "chemical": "oxygen",
        "grade": null,
        "inventory_key": "product:VENT",
        "note": "Reactor off-gas: O2 from peroxide decomposition and N2 from the 2-butanol side reaction, with traces of NH3 and MEK",
        "role": "emission"
      }
    ],
    "utilities": [
      {
        "chemical": "electricity",
        "grade": null,
        "inventory_key": "feed:POWER",
        "note": "0.05 kWh per kg hydrate, ASSUMED hand estimate (pumps, agitators)",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:MPS",
        "note": "MP steam 2000 kPa(a), 6.2 kWh per kg hydrate: working-solution regeneration (US 6,605,265 Ex. 1, scaled), azine and hydrolysis columns",
        "role": "utility"
      },
      {
        "chemical": "steam",
        "grade": null,
        "inventory_key": "feed:LPS",
        "note": "LP steam 500 kPa(a), 2.0 kWh per kg hydrate: ammonia recovery and hydrate concentration",
        "role": "utility"
      },
      {
        "chemical": "nitrogen",
        "grade": "gan-8barg-10ppm",
        "inventory_key": "feed:N2F",
        "note": "Headspace inerting sweep of the azine reactors and decanter, 0.32 kg per kg hydrate (O2 at most 8 mol% in the vent, ASSUMED, D-015); gaseous site/pipeline nitrogen, so the Atlas links the GAN market, not liquid nitrogen",
        "role": "utility"
      },
      {
        "chemical": "cooling-water",
        "grade": null,
        "inventory_key": "product:CW",
        "note": "25/35 C (ASSUMED), 9.4 kWh rejected per kg hydrate",
        "role": "utility"
      }
    ]
  },
  "description": "Hydrogen peroxide (70 wt%), anhydrous ammonia and methyl ethyl ketone (MEK, fresh and\nrecycled) react at about 50 C in an aqueous working solution activated by acetamide/ammonium\nacetate with disodium phosphate. The methyl ethyl ketazine is insoluble in the working\nsolution and is decanted; the off-gas (oxygen from peroxide decomposition, nitrogen) is\nvented after a condenser/scrubber. The spent working solution is heated above 130 C in a\nregeneration column that removes the reaction and peroxide water and the excess ammonia; the\nammonia is recovered and returned, and the activator is made up with acetic acid. The azine\nphase is distilled: excess MEK returns overhead and a side draw bleeds the 2-butanol formed\nby a side reaction. The azine is hydrolysed with water by reactive distillation at about\n9 bar(a): MEK leaves overhead to the reactors, pyrazolines are purged from the column, and a\ndilute hydrazine hydrate (30 wt%) leaves the bottom and is concentrated to 64 wt% N2H4\n(100 % hydrazine hydrate) in a further column whose water is returned to hydrolysis.\n\nAll values are concept estimates: yields, ratios and the working-solution figures are\nASSUMED inside the ranges and examples of the cited patents; the regeneration steam is a\npatent example scaled to this design, the other duties hand estimates. See DESIGN.md for\nevery assumption and gated step.\n",
  "design_basis": {
    "assumptions": [
      "ASSUMED azine synthesis at 323 K, about 150 kPa(a), in the activated working solution; inlet MEK/H2O2 2.2 and NH3/H2O2 2.5 mol/mol (patent ranges 0.2-5 and 0.1-10, preferred 1.5-4) (D-003).",
      "ASSUMED H2O2 fully converted; per kmol H2O2: 0.85 kmol azine, 0.03 kmol 2-butanol (0.06 kmol H2O2), the rest (0.09 kmol) decomposed to O2 and water. Azine yield inside the 81-82 % (US 6,562,311 Ex. 4-5) to 'up to 90 %' (US 6,562,311, US 6,605,265) range; a sourced range check, not kinetics (D-004).",
      "ASSUMED working solution circulation 11 kg per kg H2O2, make-up 60 kg acetic acid and 3 kg Na2HPO4 per t H2O2 (US 6,605,265 Ex. 1) (D-005).",
      "Working-solution regeneration steam 10.5 t of 18 bar(a) steam per t H2O2, scaled from US 6,605,265 Ex. 1 (D-010).",
      "ASSUMED hydrolysis by reactive distillation at about 900 kPa(a), bottoms 30 wt% hydrazine hydrate, 0.5 % of the azine lost to pyrazolines (US 6,562,311 stage (f); US 12,134,558) (D-007).",
      "ASSUMED other column duties, reactor cooling and power: hand estimates (D-010).",
      "Accuracy: concept estimate; no property method qualified for the mixture (D-011)."
    ],
    "source": "process/design-basis.yaml"
  },
  "engineering": {
    "description": "",
    "name": "Hydrazine (peroxide process)",
    "requires": "cheme-as-code>=0.8",
    "stage": "concept",
    "stages": [
      {
        "id": "concept",
        "title": "Concept and feasibility"
      },
      {
        "id": "basic",
        "title": "Basic engineering"
      },
      {
        "id": "detail",
        "title": "Detail engineering"
      }
    ],
    "tool": "plantcode"
  },
  "facets": {
    "feedstock_basis": [
      "fossil"
    ],
    "product_classes": [
      "chemicals"
    ],
    "region": "generic",
    "unit_operations": [
      "reaction",
      "decantation",
      "distillation",
      "reactive-distillation",
      "evaporation"
    ]
  },
  "families": [
    "inorganic-chemicals"
  ],
  "gap_count": 6,
  "gates": null,
  "id": "hydrazine-1",
  "issues": {
    "closed_count": 0,
    "list_url": "https://github.com/ChemE-as-Code/process-library/issues?q=is%3Aissue%20label%3A%22process%3Ahydrazine-1%22",
    "new": {
      "action": "https://github.com/ChemE-as-Code/process-library/issues/new?template=1-action-item.yml&labels=process%3Ahydrazine-1&process=hydrazine-1",
      "change": "https://github.com/ChemE-as-Code/process-library/issues/new?template=4-design-change.yml&labels=process%3Ahydrazine-1&process=hydrazine-1",
      "hold": "https://github.com/ChemE-as-Code/process-library/issues/new?template=2-engineering-hold.yml&labels=process%3Ahydrazine-1&process=hydrazine-1",
      "process": "https://github.com/ChemE-as-Code/process-library/issues/new?template=6-process-development.yml&labels=process%3Ahydrazine-1&process=hydrazine-1",
      "tq": "https://github.com/ChemE-as-Code/process-library/issues/new?template=3-technical-query.yml&labels=process%3Ahydrazine-1&process=hydrazine-1",
      "tracker": "https://github.com/ChemE-as-Code/process-library/issues/new?template=7-process-tracker.yml&labels=process%3Ahydrazine-1&process=hydrazine-1"
    },
    "open": [],
    "open_by_gate": {},
    "open_count": 0,
    "private": false,
    "repository": "ChemE-as-Code/process-library"
  },
  "keywords": [
    "hydrazine",
    "hydrazine hydrate",
    "peroxide process",
    "Pechiney-Ugine-Kuhlmann",
    "PCUK",
    "ketazine",
    "azine",
    "methyl ethyl ketone",
    "hydrogen peroxide",
    "ammonia",
    "reactive distillation"
  ],
  "lca": null,
  "lci_gaps": [
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "feed:H2O2",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "feed:MEKF",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "feed:PHOSF",
      "link": "technosphere",
      "type": "input"
    },
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "product:BUOHB",
      "link": "technosphere",
      "type": "output"
    },
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "product:HEAVY",
      "link": "technosphere",
      "type": "output"
    },
    {
      "dataset": "hydrazine-hydrate-by-the-peroxide-pcuk-methyl-ethyl-ketazine-process",
      "key": "product:WSP",
      "link": "technosphere",
      "type": "output"
    }
  ],
  "maintainers": [],
  "maturity": "concept",
  "preliminary": true,
  "provenance": {
    "library_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "previews": {
      "sheets": [
        "BFD",
        "PFD"
      ],
      "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
      "tool": "cheme 1.6.0 (pyDEXPI 2.1.0)"
    },
    "previews_stale": false,
    "source_commit": "c3ab3488c602bc797fdc98feffd4578375150dd0"
  },
  "publication": {
    "license": "CC-BY-4.0",
    "status": "public"
  },
  "references": [
    {
      "title": "US 6,562,311 B1 (2003) Method for preparing hydrazine hydrate (azine synthesis conditions and Examples 1-5, 2-butanol formation, hydrolysis stage (f))",
      "url": "https://patents.google.com/patent/US6562311"
    },
    {
      "title": "US 6,605,265 B1 (2003) Continuous production of azines/hydrazine hydrate (working-solution regeneration and Example 1 flows and steam)",
      "url": "https://patents.google.com/patent/US6605265B1/en"
    },
    {
      "title": "US 12,134,558 B2 (2024) Process for preparing hydrazine hydrate with pyrazoline recycling (hydrolysis column conditions, Example 1)",
      "url": "https://patents.google.com/patent/US12134558"
    },
    {
      "title": "US 4,724,133 A (1988) Preparation of concentrated aqueous solution of hydrazine hydrate (hydrolysis water/azine ratio and temperatures)",
      "url": "https://patents.google.com/patent/US4724133"
    },
    {
      "title": "US 4,725,421 A (1988) Process for the preparation of concentrated solutions of hydrazine hydrate (single hydrolysis column, water/azine 5-7.75, Examples 1-2)",
      "url": "https://patents.google.com/patent/US4725421"
    },
    {
      "doi": "10.1002/14356007.a13_177",
      "title": "Schirmann, J.-P., Bourdauducq, P. Hydrazine. Ullmann's Encyclopedia of Industrial Chemistry, Wiley-VCH (issue #141 lead; not audited in this run)"
    },
    {
      "title": "NIST Chemistry WebBook, SRD 69: standard formation enthalpies of H2O2(l), H2O(l), NH3(g), N2H4(l)",
      "url": "https://webbook.nist.gov/chemistry/"
    }
  ],
  "repository": {
    "access": "public",
    "path": "processes/hydrazine-1",
    "url": "https://github.com/ChemE-as-Code/process-library"
  },
  "representations": [
    {
      "bytes": 47714,
      "id": "BFD",
      "kind": "bfd",
      "preview": "artifacts/hydrazine-1/BFD.svg",
      "source": "process/BFD.xml",
      "status": "preview",
      "title": "Block flow diagram"
    },
    {
      "bytes": 187080,
      "id": "PFD",
      "kind": "pfd",
      "preview": "artifacts/hydrazine-1/PFD.svg",
      "source": "process/PFD.xml",
      "status": "preview",
      "title": "Process flow diagram"
    },
    {
      "id": "process-model",
      "kind": "process-model",
      "source": "process/flowsheet.yaml",
      "status": "viewer",
      "title": "Flowsheet and stream table"
    },
    {
      "id": "equipment-list",
      "kind": "equipment-list",
      "source": "equipment/equipment-list.yaml",
      "status": "viewer",
      "title": "Equipment list"
    },
    {
      "id": "lca",
      "kind": "lca",
      "source": "lca/lca.yaml",
      "status": "viewer",
      "title": "Life cycle assessment"
    }
  ],
  "summary": "Ammonia is oxidised by hydrogen peroxide in the presence of methyl ethyl ketone to the ketazine, which separates as an organic phase, is distilled and hydrolysed under pressure to hydrazine hydrate; the ketone is recycled. Concept stage, assumed basis, preliminary gate-to-gate LCI per kg hydrazine hydrate (64 wt% N2H4), foreground only.",
  "title": "Hydrazine hydrate by the peroxide process (PCUK, methyl ethyl ketazine route, 16 kt/a)",
  "validation": {
    "notes": "Concept PFD (4 blocks, 11 steps, 3 recycle loops: MEK, working solution, ammonia; water loop in hydrolysis) with closed mass, component and element balances (cheme validate, cheme process streams: every block and step ok); reactor outlets calculated by cheme from selectivity/conversion specifications, every separator specified (scripts/balance.py). Consumptions per kg N2H4: H2O2 (100 %) 1.25 kg (85 % azine yield on H2O2, patent range 81 to about 90 %; 1.32 kg at 81 %, 1.12 kg at 95 %), NH3 1.13 kg, MEK make-up 0.12 kg. The reactor and decanter headspaces are inerted with 0.32 kg N2 per kg hydrate (O2 at most 8 mol% in the vent, ASSUMED). Steam 8.2 kWh per kg hydrate, of which the working-solution regeneration (a single patent example, scaled) is 55 %; the hydrolysis column steam is a lower bound (hydrolysis heat not counted), a high variant adds up to 1.1 kWh of MP steam per kg hydrate (+18 % MP steam). No energy balance: no property package covers the aqueous hydrazine/MEK/amide mixture (cheme process props --coverage). cheme maturity reaches no level. The LCI is foreground only, every background a gap (15 gaps plus 2 uncharacterised emissions): no impact result (lca.source none). Not reviewed. Main products and feeds are listed under chemistry with their chemicals registry entries (issue #251).",
    "status": "unreviewed"
  },
  "viewer": {
    "commit": "c3ab3488c602bc797fdc98feffd4578375150dd0",
    "dirty": false,
    "sheets": [
      "process/BFD.xml",
      "process/PFD.xml"
    ],
    "skipped": [],
    "snapshot": "snapshots/hydrazine-1/",
    "stale": false,
    "tool": "cheme-as-code 1.6.0",
    "views": [
      "checks",
      "streams"
    ]
  }
}