PROPYLENE PRODUCTION PLANT

TABLEOFCONTENTS

Page
TABLEOFCONTENTS

2
2


CHAPTER1INTRODUCTION

1.1

BackgroundofPropylene

1.2

UsesofPropylene

1.3

PropyleneManufacturing

1.4

MarketSurvey

1.5

1.4.1 Introduction

1.4.2 ProductionofPropylene

1.4.3 PropyleneConsumption

11

1.4.4 OutlookforProductionofPropyleneinMalaysia

12

1.4.5 MarketPricesofPolypropylene

12

1.5

RawMaterials

14

1.5.1 SourceofRawMaterials

14

1.5.2 RawMaterialSpecifications

14

CHAPTER2PROCESSSYNTHESISSTEP
2.1

Step1EliminateDifferencesinMolecularType

15

2.2

Step2DistributetheChemicals

24

2.2.1
2.3

BasicMaterialBalances

Step3EliminateDifferencesinCompositions

24
26

2.4Step4EliminateDifferencesinTemperature,PressureandPhase

28

2.5Step5TaskIntegration

30

CHAPTER3MATERIAL,ENERGYBALANCESANDPROCESSSIMULATION
3.1

MaterialBalance

33

3.1.1 OverallMassBalances

33

3.1.2 MassBalancesforSeparationUnit1

35

3.1.3 MassBalanceforMixer

36

3.1.4 MassBalanceforReactor

37

3.1.5 MassBalanceforSeparationUnit2

38

3.1.6 MassBalanceForSeparationUnit3

39

3.1.7 MassBalanceForSeparationUnit4

40

3.2

EnergyBalances

40

3.3

SimulationResultfromASPENHYSYS

60

3.3.1

MaterialBalance

60

3.3.2

EnergyBalances

60

3.4

PercentageDifferencesbetweenManualCalculationandHYSYS

61
4

3.4.1

MassBalances

61

3.4.2

EnergyBalances

61

CHAPTER4:HEATINTEGRATION
4.1

ProcessEnergyIntegration

4.2

AlgorithmTable

62

63

4.3HeatExchangerNetwork

64

4.4ProcessFlowDiagramHeatExchangerNetwork64

CHAPTER5:PROCESSOPTIMIZATION

66

CHAPTER6:EQUIPMENTSIZINGANDCOSTING
6.1

Introduction

6.2

Reactor

69

69

6.2.1Sizingofreactor

69

6.2.2Costingofreactor

70

6.3Pump

70

6.3.1Sizingofpump

70

6.3.2Costingofpump

70
5

6.4Distillationcolumns(S1)

70

6.4.1Sizingandcostingofthemainvessel

70

6.4.2Sizingandcostingoftherefluxdrum

71

6.4.3Sizingandcostingofthecondenser

72

6.4.4Sizingandcostingofthereboiler

73

6.5Compressor

74

6.5.1Sizingofcompressor

74

6.5.2Costingofcompressor

74

6.6Heatexchanger(HE2)

74

6.6.1SizingofHeatexchanger(HE2)

74

6.6.2CostingofHeatExchanger(HE2)

CHAPTER7:TOTALCAPITALINVESTMENTS

CONCLUSIONS

76
77
79

APPENDICESA
APPENDICESB
APPENDICESC
APPENDICESD
APPENDICESE

CHAPTER1

INTRODUCTION

1.1

BackgroundofPropylene
8


Propylene, also called propene is generally described as a volatile and a colorless gas at room temperature. It has sameempiricalformulawithcyclopropane
but different ways of atom connected. Propylene is categorized as a alkene hydrocarbon compound with a molecular formula of C3H6. The presences of the double
bond make it slightly lower boiling point than propane and thus more volatile. The existences of natural propylene are in the environment from sources such as
vegetation and combustion such as fires, motorvehicleexhaust,andtobaccosmoke.Propyleneisnotexpectedtopersistintheenvironment.Sincepropyleneisagas,
the exposure of propylene into the air is expected to be lower amount when released into the environment. Because of itsrelativelyshorthalflifeintheatmosphere
and typically low environmental concentrations, propylenes contribution to potential global warming is considered minor and its ozone depletion potential is
negligible.

Figure1:StructuralformulaofPropylene.

Propylene reacts violently with oxide of nitrogen and also a number ofothersubstancesandcondition.Essentiallyallofthepropyleneproducedforchemical
purposes is consumed as a chemical intermediate in other chemical manufacturing processes. This hydrocarbon iswidelyusedinthemanufactureofcumene,resins,
fibres, elastomers and other chemicals which enable the manufacture of many chemicals and plastics. In addition to its use as a chemical intermediate,propyleneis
producedandconsumedinrefineryoperationsfortheproductionofgasolinecomponents.

1.2

UsesofPropylene
Propylene is a major product of the petrochemical industry. It is one of the highest volume chemicals produced globally. Propylene is primarilyusedasan

intermediate for the production of other chemical raw materials that aresubsequentlyusedtomanufacturealargevarietyofsubstancesandproducts.Manufactureof
polypropylene, a widelyusedplastic,consumesmorethanhalfoftheworldsproductionofpropylene. Propyleneis alsousedinthemanufactureofacrylonitrile,oxo
process chemicals, cumene, isopropanol, polygas chemicals, and propylene oxide. Table 1.1 below highlights several of the main applications of propylene and its
derivatives.

10

Table1.1:SelectedPropyleneApplication

ProductApplication

ApplicationDescription

Polypropylene

PropyleneOxide

Polypropylene is used to make many wellknown plastic

products.
Polypropylene resins can beinjection moldedand extruded
(intofibers,film,andsheets)tomakeavarietyofproducts.
Polypropylene may also be blowmolded or thermoformed,
buttheseprocessesarelessoftenused.
Polypropylene is extremelycorrosion resistant,lightweight,
flexible,andformedorwelded.

Used mainlyasa chemicalintermediateintheproductionof

polyurethanepolyolsandpropyleneglycols.
Used in the manufactureofpropyleneglycol,whichhelps to
make antifreeze, resins for reinforced plastics,
pharmaceuticals, packaging materials, dyes, and hydraulic
fluids, and humectants for foods, drugs, cosmetics,and pet
foods.
Derivatives of propylene oxide include polyether polyols
propylene glycol di and tripropylene glycol poly
(propylene glycol)s surfactants glycol ethers and
isopropanolamines.

11

Isopropanol

Cumene

EthylenePropylene
Elastomers

A variety of solvent applications, such as in printing inks,

surface coatings, and as a solvent for resins, shellacs, and
gums.
As a component of personal care products, such as
aftershaves and as an antiseptic and disinfectant, such as
rubbingalcohol.
Used in the production of acetone, methyl isobutyl ketone
(MIBK),isopropylaminesandisopropylacetate.

Alkylationofbenzenewithpropyleneyieldscumene.
Consuming in phenol production for the manufacture
phenolicresins,caprolactamandbisphenolA.

About half of the worldwide production of EP elastomer

goes into the manufacture of automobile body and chassis
parts,hoses,weatherstripping,andtires.
Also used to make thermoplastic polyolefin elastomers,
polymer modifiers, and other products used in automobile
componentsbesideusedinsingleplyroofing.

12


OxoProcessChemicals

PolygasChemicals
(nonene,dodecene,
heptenes)

PropyleneisusedtomanufactureIsobutyraldehyde,whichis
convertedtoisobutanolsolventforsurfacecoatings.
Propylene is also used to make nButyraldehyde, which is
converted to nbutanol or 2EH. nButanol is a solvent for
lacquers and coatings, and is an intermediate for several
chemicals.

Refinery productionofpolymergasolinealsoyieldsnonene,
dodecene and heptene and propylene is consumed to yield
thesepolygaschemicals.
Noneneis used innonylphenolandisodecylalcoholthatact
as an intermediate for surfactants, lubricating oil additives,
andphosphiteantioxidants.
Heptenes are consumed to make isooctyl alcohol, whichis
usedinthemanufactureofanotherphthalateester.

1.3

PropyleneManufacturing

Lotte ChemicalTitanHoldingSdn.Bhd.isoneofthe manufacturerandsupplierofpropylene,locatedat Pasir Gudang,JohorBahru.Thiscompanywillbethe

benchmark of Equinox Team to design a plant that can produce100,000lb/hrofpropylene.The teamwillproposeavarietyofproductionreactionsofpropyleneand
there are several production processes such as catalytic dehydrogenation of propane, reformation of olefins reaction (metathesis reaction), and the conversion of
13

methanol to propylene. The most sustainable and economically reaction processes will bechosenfortheplantdesign.Thisincludesthecomparisonbetweenthecost
ofrawmaterials,safety,environmentalimpacts,percentageyieldofconversion,energyconsumption,andotherfactorsthatmightaffectthereactionprocess.

1.4

MarketSurvey

1.4.1

Introduction
Market survey or market outlook will cover a review on the production and consumption of propylene in addition to that there will be another section to

discussthepricesofpropyleneanditsrawmaterials.
1.4.2

ProductionofPropylene

14

Propene production increased in(Europe and North America only) from 2000 to 2008, it has been increasing also in East Asia, most notably Singapore and
China.Total world production of propene iscurrentlyabouthalfthatofethylene.About56%of theworldwide productionofpropyleneisobtainedasacoproductof
ethylene manufacture, and about 33% is producedasabyproductofpetroleumrefining.About7%ofpropyleneproducedworldwideisonpurposeproductfromthe
dehydrogenation of propane and metathesis of ethylene and butylenes the remainder is from selected gasstreamsfromcoaltooilprocessesandfromdeepcatalytic
crackingofvacuumgasoil(VGO).Thesupplyofpropyleneremainshighlydependentonthehealthoftheethyleneindustryaswellasonrefineryplanteconomics.
In2010,productionofpolypropylenerepresented65%oftotalworldpropyleneconsumption,rangingfrom53% inNorthAmericatomorethan90%inAfrica
andtheMiddleEast.
Table1.2:AnnualProductionofPropene(Propylene)
World

80.0milliontones

Europe

14.3milliontons

US

14.3milliontones

Figure1.1belowshowshowtheproductionofpropyleneincreasedfrom11milliontonsin1994to16milliontonsin2007butithaddroppedsincethattime
to14.3milliontonsin2013.

15


Figure1.1:WasternEuropeanPropyleneCapacity,ProductionandConsumption19942013
Top world companies are leading the production of propylene with LyondellBasell, Netherlands on top of propylene producing companies by 2009.Thetop
propyleneproducingcompaniesarelistedasbellow:

16


Figure1.2:Propylenetopproducers
1.4.3

PropyleneConsumption
After experiencing zero growth or declines in 2008 and 2009, global propylene consumption grew at a rate of almost 7.5% in 2010, led by Asia at 11%

yearonyear. The economic recession of 2008/2009 reflected both a reduction in pullthrough demand for polypropylene, as well as a supplychain inventory
17

rundown, reminiscent of the early 1980s downturn. World petrochemical industries have historically witnessed veryfewupheavalsthatcombinedtheeffectsofboth
energyvolatilityanddepresseddownstreamdemand.
The fifteen largest worldwide producers of propylene accounted for almost 51% of world capacity as of 2010, representing about the same level of
concentration as five years ago. The most significant changes in the last two years have been Sinopec taking over the top spot, a position long occupied by
ExxonMobil,andPetroChinajumpingfromtheseventhspottonumberfour.
World consumption of propylene is forecast to grow slightly better than global gross domestic product (GDP) rates overthenextfiveyears.Averagegrowth
will be 5% per year, higher than GDP in general and higher than ethylene specifically, with growth for polypropylene being much betterthanthatforpolyethylene.
Growth will be led by the Middle East, Asia, Central and Eastern Europe, and South America at 12.5%, 6.5%, 5%, and4.5%peryear,respectively.Asia isamixed
bag of growth rates with China and India at 810% annually and the mature economies of Japan, the Republic of Korea, and Taiwan at 12% per year. Nearterm
growthwillberelativelyslowinthematureeconomiesofNorthAmericaandWesternEurope.

18


Figure1.3:WorldConsumptionofPropylenein2010

1.4.4

OutlookforProductionofPropyleneinMalaysia

19

Malaysias petrochemical sector has contributed significantly to the development of local downstream plastic processing activities. Malaysia is one of the
largestplasticsproducersinAsia,providingasteadysupplyoffeedstockmaterialsfortheplasticprocessingindustrysuchaspropylene.
Table1.3:Production,Import,ExportandConsumptionofPPinMalaysia
Product

Unit:KTPA

2007

2008

2009

2010

change

Propylene

Production

839

870

867

808

0.3%

Import

33

40

25

0%

Export

78

97

95

50

2%

Consumptio

765

811

797

744

5%

1.4.5

MarketPricesofPolypropylene

20

Polypropylene prices are on the rise since the last decade and it is expected to continue rising as the demand increases for thechemicalmaterial,Capacity
and Prices for Polypropylene EndUse Sectors in AsiaPacific to Drive Growth" 2014marketresearchreportsaysworldwidepolypropylenecapacityincreasedata
Compound Annual Growth Rate (CAGR)of5.2%from2003,reaching65milliontonsperyear(MMTY)in2013,andisexpectedtocontinuerisingto86MMTYby
2018, at a slightly higher CAGR of 5.8%.ItforecastsChina andRussiatobetheleadingcontributorstofuturepolypropylenecapacityincreases,andwillaccount for
a combined 45% of global additions over the next five years. As Malaysia is part of the global marketitis normalforpricesinMalaysiatobeaffectedbytheglobal
prices,followingarepricesofPPanditsrawmaterial(propane,ethylene,buteneandmethanol)asachievedfromICIS.com.

Table1.4:Propyleneandrawproductsprices
Price
Product
RM/Ib

RM/Kg

Propylene

1.962

4.326

Propane

0.79

1.742

Ethylene

2.158

4.758

Butene

1.118

2.465

Methanol

1.635

3.609

21

1.5

RawMaterials

1.5.1

SourceofRawMaterials
The raw material that is utilized in this process is liquefied petroleum gas (LPG) propane. The term LPG actually encompassesmorethanone variety of

gaseous fuel. There are a number of hydrocarbon gasesthatfallinto the classification ofLPG. Theircommon distinguishingcharacteristic is thattheycanbe
compressedintoliquidatrelativelylow pressures. LPG is stored underpressure, as aliquid, in agas bottle. Itturnsbackintogasvaporwhenyoureleasesomeof
thepressureinthegasbottlebyturningonyourappliance.AlmostalloftheusesforLPGinvolvetheuseofthegasvapor,nottheliquefiedgas.

22

The gases that fall under theLPG label,includingPropane, Butane,Propylene,Butadiene, Butylene andIsobutylene,aswell as mixtures ofthesegases.
ThetwomostcommonarePropaneandButane.
The main supplier of LPG used in this process is Kleenheat Gas which is part of Wesfarmers Chemicals, Energy and Fertilizers, one of eight divisions of
WesfarmersLimited,withoriginsdatingbackto1914.
They have a long history in the Australian gas industry with over 55 years of experience retailing anddistributing LiquefiedPetroleumGas(LPG),overa
decade of experiencedistributingLiquefiedNaturalGas(LNG) andadvancingtechnologythroughtheirbrand EVOLLNG,and most recentlyretailingnaturalgasin
WesternAustralia.
1.5.2 RawMaterialSpecifications
Table1.5:LPGpropanesuppliedbyKleenheatGasAustralia
LPGspecification
CASNumber74986
Component

Molepercentage(%)

Propane

80

Butane

18

23

Butanes,pentanes,butadieneandheavier

CHAPTER2

PROCESSSYNTHESISSTEP

2.0

SYNTHESISSTEPS
Processsynthesisinvolvestheselectionofprocessingoperationstoconvertrawmaterialstoproducts,giventhatthestatesoftherawmaterialandproduct

streamsarespecified.ThemostwidelyacceptedapproachforprocesssynthesisisintroducedbyRudd,Powers,andSiirola(1973)inabookentitledProcess
Synthesis.Thereare5keysynthesisstepswhichare:
1. Eliminatedifferencesinmoleculartypes
2. Distributethechemicalsbymatchingsourcesandsinks

24

3. Eliminatedifferencesincomposition
4. Eliminatedifferencesintemperature,pressure,andphase
5. Taskintegrationcombinationofoperationsintounitprocessesanddecidebetweencontinuousandbatchprocessing

2.1

Step1EliminateDifferencesinMolecularType
A. PropylenefromPropaneviaDehydrogenation

Dehydrogenation is an endothermic equilibrium reaction it iscarriedoutinthepresenceofheavymetalcatalyst(chromium). Thefollowingequation

showsthepropanedehydrogenationreaction:

PropaneDehydrogenationReaction
About 86 wt% of propane is converted to propylene.To mitigate crackingreactions,dehydrogenationreactioninthistechnologyoccursinconditionssuchas
temperature ranges between 580 and 650 C, and pressures slightlybelowatmospheric.Forfurtherinformation,Table2.1showsthethermophysical property
dataforthisprocess.
25

Figure2.1:Commercialprocessflowdiagram(Dehydrogenation)

26


Figure2.2:Detailedprocessflowdiagram(Dehydrogenation)

ProcessDescriptionofPropyleneDehydrogenation

27

The propane dehydrogenation process is used to supplypolymergradepropylenefrompropanetomeetthegrowingpropylenemarket,independentof

a steam cracker or Fluid Catalytic Cracking (FCC) unit. It provides a dedicated, reliable source of propylene to give more control over propylene feedstock
costs.

From Figure 2.2, the process flow diagram consists of a reactor section, product recoverysectionandcatalystregenerationsection.Hydrocarbonfeed
is mixed with hydrogenrich recycle gas andisintroducedintotheheatertobe heatedintothedesiredtemperature(over540C)andthenenterthereactorsto
be converted at high monoolefin selectivity. Several interstage heaters are used to maintain the conversion through supplying heat continuously since the
reaction is endothermic. Catalyst activity is maintained by continuous catalyst regenerator (CCR) or shutting down reactors one by one and regeneratingthe
reactor by the regeneration air, the continuous catalyst regenerator is wherethecatalystiscontinuouslywithdrawnfromthereactor,thenregenerated,and fed
backtothereactorbed.

Reactor effluent is compressed, dried and sent to a cryogenic separator where net hydrogen is recovered. The olefin product is sent to a selective
hydrogenation process where dienes and acetylenes are removed. The propylene stream goes to a deethanizer where lightends are removed prior to the
propanepropylene splitter.Unconvertedfeedstockisrecycledbacktothedepropanizerwhereitcombineswith fresh feedbeforebeingsentbacktothereactor
section.

28

Table2.1:PhysicalAndChemicalPropertiesOfReactantAndProductForDehydrogenationReaction
REACTION

PROPANE

PROPYLENE

HYDROGEN

Properties
Molecularformula

C3H8

C3H6

H2

Molarmass

44.10gmol1

42.08gmol1

2.016gmol1

Appearance

Colourlessgas

Colourlessgas

Colourlessgas

Odor

Odourless

Gassy/aromatic

Density

2.0098mgmL1(at0
C,101.3kPa)

1.81kg/m3,gas(1.013
bar,15C)
613.9kg/m3,liquid

0.08988g/L(at0C,
101.325kPa)

Meltingpoint

187.7C305.8F
85.5K

,185.2C(301.4F
88.0K)

13.99K(259.16C,
434.49F)

Boilingpoint

42.25to42.04C
44.05to43.67F
230.90to231.11K

47.6C(54F
226K)

20.271K(252.879C,
423.182F)

Solubilityinwater

40mgL1(at0C)

0.61g/m3

Vaporpressure

853.16kPa(at21.1C)

144.06psia

100kPa(at20C)

Thermochemistry
Stdenthalpyof
formationfHo298

105.2104.2kJmol1 +20.41kJ/mol

29

Stdenthalpyof
combustioncHo298

2.21972.2187MJ
mol1

2058.4kJ/mol

285.84kJ/mol

Toscreenoutwhetherthisreactionwillbringprofitornot,thegrossprofitiscalculatedasshownbelow:
C3H
2
8
C3H
6+H

C3H8

C3H6

H2

Molecularweight

44.09

42.08

2.016

lb

44.09

42.08

2.016

lb/lbofpropylene

1.0478

0.048

0.79

1.96

11.30

lbmol

RM/lb

Grossprofitforreactionpath1=1.96(1)+11.30(0.048)1.0478(0.79)=RM1.67/lbpropylene
B. PropylenefromEthyleneandButenesviaMetathesis

30

Metathesis is a general term for a reversible reaction betweentwoolefins,inwhichthedoublebondsarebrokenandthenreformedtoformnewolefin

products. In order to produce propylene by metathesis, a molecule of 2butene and a moleculeofethylenearecombinedtoformtwomoleculesofpropylene.
Someofthethermophysicalpropertydataisshownontable2.

MetathesisReaction

31

Figure2.3:Commercialprocessflowdiagram(Metathesis)

Figure2.4:Detailedprocessflowdiagram(Metathesis)

ProcessDescriptionofMetathesisofEthyleneandButene

32

Propylene is formed by the metathesis of ethylene and butene2, and butene1 is isomerised to butene2 as butene2 is consumed in the metathesis
reaction. In addition to the main reactions, numerous side reactions between olefins also occur. Ethylene feed can be polymer grade ethylene or a dilute
ethylenestream.Anysaturatedhydrocarbons,suchasethaneandmethane,donotreact.
From Figure 2.4, fresh C4s (plus C4 recycle) are mixed with ethylene feed (plus recycle ethylene) and sent through a guard bed to remove trace
impurities from the mixed feed. The feed is heated prior toenteringthevapourphasefixedbedmetathesisreactor wheretheequilibriumreactiontakesplace.
The reactor is regenerated insitu on a regular basis. The catalyst promotes the reaction of ethylene and butene2 to form propylene and simultaneously
isomerisesbutene1tobutene2.Theperpassconversionofbutyleneisgreaterthan60percent,withoverallselectivitytopropyleneexceeding90percent.
The product from the metathesis reactor is primarily propylene and unreacted feed. Reactor effluent is sent to the ethylene recovery tower where the
unreacted ethylene is recovered and recycled to the reactor. The C2 tower bottom is processed in the C3 tower toproducepropylene productandaC4recycle
stream. Purge streams containing nonreactive light material, C4s and heavier are also produced. Ultrahigh purity propylene exceeding polymer grade
specificationisproducedwithoutapropylenefractionationsystem,sincetheonlysourceofpropaneisthatcontainedintheC4andethylenefeeds.
Table2.2:PhysicalAndChemicalPropertiesOfReactantAndProductForMetathesisReaction
REACTION

ETHYLENE

BUTENE

PROPYLENE

Properties
Molecularformula

C2H4

C4H8

C3H6

Molarmass

28.05g/mol

56.10g/mol

42.08gmol1

Appearance

Colorlessgas

colorless

Colorlessgas

Odor

Odorless

odorless

Gassy/aromatic

33

Density

1.178kg/m3at15C,gas

0.62g/cm3

1.81kg/m3,gas(1.013
bar,15C)
613.9kg/m3,liquid

Meltingpoint

169.2C(104.0K,
272.6F)

185.3C(301.5F
87.8K)

,185.2C(301.4F
88.0K)

Boilingpoint

103.7C(169.5K,
154.7F)

6.47C(20.35F
266.68

47.6C(54F226K)

Solubilityinwater

3.5mg/100mL(17C)[

0.61g/m3

Thermochemistry
Stdenthalpyof
formationfHo298

52.28kJmol1

1.17kJ/mol

+20.41kJ/mol

Stdenthalpyof
combustioncHo298

1410.99kJmol1

2718.6kJ/mol

2058.4kJ/mol

ToscreenoutwhetherthisreactionwillbringprofitornotandwhetheritisbetterfromreactionA,thegrossprofitiscalculatedasshownbelow:

lbmol
Molecularweight

C2H4+C4H82C3H6

C2H
4

C4H
8

C3H
6

28.05

56.10

42.08

34

lb

28.05

56.10

84.16

lb/lbofpropylene

0.33

0.667

RM/lb

2.16

1.18

1.96

Grossprofitforreactionpath2=1.96(1)2.16(0.33)1.18(0.667)=RM0.46/lbpropylene

35

Table2.3:SummaryofReviewandScreeningofAlternativeProcesses
Dehydrogenationofpropane

C3H8C3H6+H2

Metathesisoffrom
Ethylene&Butenes
C2H4+C4H82C3H6

GrossProfit
RM1.67/lbpropylene

RM0.46/lbpropylene

Continuousprocess

Continuousprocess

(Appendix1)
Typeofprocess

Butaneandethyleneis
Safety

Propaneisflammable.

flammable,andethylenealso
maycausedizziness

36

Byproduct

Hydrogen
Temperature:560650C

Operating
condition

Pressure:slightlybelowatmospheric
pressure

Nobyproduct

Temperature:90100C
Pressure:100110bar

Conversion

86%percentofconversion

90%percentofconversion

Flammability

Flammable

Flammable

Fromthetableabove,itshowsthatthedehydrogenationofpropanereactionisabetterprocesscomparedtothemetathesisreaction.

37

2.2

Step2DistributetheChemicals

2.2.1

BasicMaterialBalance

OverallReactionEquation:
C3H8C3H6+H2

38


Basis:100000lb/hrofpropylene(C3H3)
86%ofconversion

C3H8

C3H6

H2

m1

m2=100,000.00

m3

MW(lb/lbmol)

44.10

42.08

2.01

n,(lbmole/hr)

2376.43

2376.43

2376.43

stoichiometry
Massflowrate(lb/hr)

Numberofmolesofpropyleneformed

=(100,000lb/hr)/42.08
=2376.43lbmole/hrC3H6

Assume100%conversion,themassflowrateoffeed,m1=2376.43x44.1
=104800.56lb/hr
39

for86%conversion,themassflowrateofrecycle,R=(10.86)/0.86x104800.56
R=17060.53lb/hr
MassflowrateofH2,m3
=(no.ofmole)X(molecularweight)
=(2376.43)x(2.01)
=4776.62lb/hr

Massflowratefeedtothereactor,

F=m1+R
=104800.56+17060.53=121861.09lb/h

2.3

Step3EliminateDifferencesinComposition

40

Figure2.5:Flowsheetwithseparationunitsofpropyleneproductionprocess

In order to enable all chemicals involved to be supplied to their sinks, separationoperationsareneeded.Figure2.5showstheseparationunitsthatareneeded

in a propylene production process. Since the raw material using in this process is from LPG that consists 80% propane, 18% butane and 2% pentane, so S1 as a
separating unit is needed to separate propane frombutaneandpentane.However,theseparationisnotperfect.Therewillstillhavesomebutaneandpentanethatwill
be distillate but in a small proportion. As referred to table 2.4, S1 will be operated at 15bar. The bubble point at distillate product is 47C and the dew point of
mixturesatthebottomproductis110.7C.
When the separation betweenpropane,butaneandpentaneis done,propaneasareactantwillenterthereactorwhichwillbeoperateat600Cand1bar.These
pressureandtemperatureisselectedbecausethedehydrogenationprocessofpropyleneonlywilloccurattheseconditions.

41

After the reaction occurs, there have alotofproductsproduced.Inordertoseparatetheproducts,3separationunitswillbeused. Thefirstproductthatwillbe

separated is hydrogen gas. The reason is, hydrogen gas has a low value of critical pressure and it will be difficult to separate the other products if the hydrogen
maintain in the product mixtures. S2 will be used as separation unit that will be operated at pressure 10 bar and temperature 137.1 at dew point of vapor of the
productmixture.
Next, after separate hydrogen gas, we will separate propane and propene fromthesideproduct.FromTable2.4at1atm,theboiling pointofC3isverylow,
48C, and hence if C3were
recovered at 1 atm as the distillate of the S3, very costly refrigeration would be necessary to condense the reflux stream. At18bar,the

bubble point of propane and propylene mixture is at 40C and muchlesscostrefrigerationcouldbeused.Thebottomproductswhichareconsistsbutane,buteneand

pentanehasadewpoint108.4Cat17.5bar.
After separation unit S3isinsertedinto theprocessdesign,S4followsnaturally.ThedistillatefromS3isseparatedintonearly purespeciesintheS4,whichis
specified at 15 bar. Under these conditions, the distillate (nearly pure propylene) boils at 33C and can be condensed with inexpensive cooling water, which is
availableat25C.However,S4needspecialseparationunitduetosmalldifferenceofboilingpointbetweenpropaneandpropylene.

Table2.4:Boilingpointsandcriticalconstant

Chemical

Normal
boiling
point
(1atm,C)

Criticalconstant
Boilingpoint(C)
15bar

17.5bar

20bar

Tc(C)

PC(bar)

42

H2

252.78

240.01

12.96

C3H
8

42.11

41.00

45.00

53.55

96.74

42.51

C3H
6

47.62

33.00

35.85

42.65

91.06

45.55

2.4

Step4EliminateDifferencesinTemperature,Pressure,andPhase

43

44

Figure2.6:Flowsheetwithtemperature,pressure,andphasechangeoperationsinthepropyleneproductionprocess.

Figure 2.6 shows the changes of the state of chemicals. Since the original state of the raw material (LPG) is at 20C and 18 bar, its temperature is raised to
52C at 15 bar. The LPG is then introduced into a separation column (S1) at 15 bar with 99% conversion that separates the propane gas from other LPG products.
Here,only99%ofLPGisconvertedtopropanegaswhereanother1%isbutanegasandpentanegas.
The process begins by mixing the upper products from S1 (propane gas, butane gas and pentane gas) with a stream of recycle propane gas at 47C and 15 bar.
ThemixingofupperproductsfromS1andrecyclepropaneundergoesthefollowingoperations:
1. Theproductmixtureispreheatedbeforeitisintroducedtothereactor.Thereactionoccursataround600oCand1bar.
2. Theproductsmixtureisthencooledtoitsdewpoint137.1oCat10bar.
3. Then,theproductmixtureisintroducedintoacondenser(S2)thatseparatesthehydrogengasfromotherliquidproducts.
Inaddition,theliquidmixturethatcondensedat137.1oCat10barfromthecondenserisoperateduponasfollows:
1. Itspressureisincreasedto17.5bar.
2. Thetemperatureisthenraisedtoaliquidatitsbubblepoint,42oCat17.5bar.
3. Then,theliquidmixtureisintroducedintoaseparationcolumn(S3)thatseparatesthepropanegasandpropylenegasfromotherliquidproducts.
Next, the upper products (propane gas and propylene gas) from separation column (S3) are then entered into separation column (S4)at40oC.Thepropylenegas
withaboilingpointof33oCat15bariscomeoutasanupperproductfromseparationcolumn(S4).

45

Finally, the propane liquid from therecyclestream(at42oCand15bar)undergoestheoperationwhereitstemperatureisraisedtothemixingtemperatureat47oC

at15bar.

46

2.5

Step5TaskIntegration

Figure 2.7 shows task integration for the propylene production process. At this stage in process synthesis, it is common to make the most obvious combinations of
operations, leaving many possibilities to be considered when the flowsheetissufficientlypromisingtoundertakethe preparationofabasecasedesign. Belowarethe
descriptionsofunitprocessshowninFigure2.7:
1. Heatexchanger
Heat exchanger is needed to increase or decrease the temperature ofthestream.Aheatexchangerisapieceofequipmentbuiltforefficientheattransferfrom
onemediumtoanother.Themediamaybeseparatedbyasolidwalltopreventmixingortheymaybeindirectcontact.

2. Depropanizer
Apropanerichliquefiedpetroleumgas(LPG)feedstockissenttoadepropanizertorejectbutanesandheavierhydrocarbons.

3. Furnace
Since the outlet temperature from the mixer is 47C and we need to increase thetemperatureto600C,thefurnaceisusedtoheatupthestream.Thisfollows
heuristics 26 which explained nearoptimal minimum temperature approaches in heat exchangers depend on the temperature level. For 250 to 350F, the

47

stream must be heat up in a furnace for flue gas temperature above inlet process fluid temperature. An industrial furnace or direct fired heater is equipment
used to provide heat for a process or can serve asreactor which provides heats of reaction. Furnace designs vary as to its function,heatingduty,typeoffuel
andmethodofintroducingcombustionair.

4. OleflexReactor
The UOP Oleflex process is a catalytic dehydrogenation technology for the production of light olefins from their corresponding paraffins. One specific
applicationofthistechnologyproducespropylenefrompropane.TheOlexflexprocessusesaplatinumcatalysttopromotethedehydrogenationreaction
5. Pump
Since the pressure change operation involves a liquid, it is accomplished by a pump, which requires only 66Bhp,assumingan80% efficiency.Theenthalpy
changeinthepumpisverysmallandthetemperaturedoesnotchangebymorethan1C

6. DistillationColumn

48

To separate the mixture of C3 and butane, butane and pentane, distillation column is selected as the best separation unit. Distillation is based onthefactthat
the vapour of a boiling mixture will be richer in the components that have lower boiling points. Therefore, when this vapour is cooled and condensed, the
condensatewillcontainmorevolatilecomponents.Atthesametime,theoriginalmixturewillcontainmoreofthelessvolatilematerial.

7. PropanePropyleneSplitter
C3 splitters are frequently designed with vaporrecompression heat pumps whensufficientlowenergyheatsourcesarenotavailable.Theheatofvaporization
of propylene and propane at 100psia are nearly identical. The only energy needed for a C3 splitter heat pump is the compressor duty,whichistypicallyonly
1112% of the total reboiler duty.Therefore,theenergysavingsaresignificant.Inaddition,C3splitterheatpumpsystemoperatesatmuchlowerpressurethan
conventionalcolumnswithoutheatpumping.Thehighpressurecompressordischargestreamisthesameastheconventionaltowerstoppressure.

49

50

process

CHAPTER3

MATERIALANDENERGYBALANCESANDPROCESSSIMULATION

3.1

MATERIALBALANCES

3.1.1

OverallMassBalance

51

OverallReactionEquation:
C3H8C3H6+H2

Basis:100000lb/hrofpropylene(C3H3)
86%ofconversion

stoichiometry
Massflowrate(lb/hr)
MW(lb/lbmol)

C3H8

C3H6

H2

m1

m2=100,000.00

m3

44.10

42.08

2.01

52

n,(lbmole/hr)

2376.43

2376.43

2376.43

53

3.1.2

MassBalanceforSeparationUnit1

Stream1
No
.

Component

Mole
Fraction

Propane

0.80

Mass
Flowrate,
(lb/hr)
104800.56

Stream2
Mole
Fraction
0.990

Mass
Flowrate,
(lb/hr)
104800.56

Stream3
Mole
Fraction

Mass
Flowrate,
(lb/hr)

0
54

Butane

0.18

31076.58

0.009

1116.11

0.9

29960.47

Pentane

0.02

4286.49

0.001

346.38

0.1

3940.11

55

3.1.3

MassBalanceforMixer

Stream3

Stream4

No
.

Component

Mole
Fraction

Propane

0.990

104800.56

0.991

Butane

0.009

1116.11

Pentane

0.001

346.38

Mass
Flowrate,
(lb/hr)

Mass
Flowrate,
(lb/hr)

Stream10
Mole
Fraction

Mass
Flowrate,
(lb/hr)

121861.09

1.0

17060.53

0.007

1116.11

0.002

346.38

Mole
Fraction

56

3.1.4

MassBalanceforReactor

Thepercentageofconversionforpropaneandbutaneare86%and90%respectivelyandsincetheweightpercentofpentaneistoosmall,weassumethatpentaneis
remainunreacted.

Stream4
No.

Component

Mole
Fraction

Stream5
Mass
Flowrate,
(lb/hr)

Mole
Fraction

MassFlowrate,
(lb/hr)

57

Propane

0.991

121861.09

0.0747

17060.53

Butane

0.007

1116.11

0.0004

111.61

Pentane

0.002

346.38

0.0009

346.38

Propene

0.4587

100000

Butene

0.0033

969.58

Hydrogen

0.4620

4811.36

3.1.5

MassBalanceforSeparationUnit2

58

Stream5

Stream6

Stream7

No.

Component

Mass
Mole
Flowrate,
Fraction
(lb/hr)

Mole
Fraction

Mass
Flowrate,
(lb/hr)

Propane

0.0747

17060.53

0.1388

17060.53

Butane

0.0004

111.61

0.0007

111.61

Pentane

0.0009

346.38

0.0017

346.38

Propene

0.4587

100000

0.8526

100000

Butene

0.0033

969.58

0.0062

969.58

Hydrogen

0.4620

4811.36

4811.36

Mole
Fraction

Mass
Flowrate,
(lb/hr)

59

3.1.6

MassBalanceforSeparationUnit3

Stream7
No.

Component

Mole
Fractio
n

Stream8
Mass
Flowrate,
(lb/hr)

Mole
Fraction

Stream9
Mass
Flowrate,
(lb/hr)

Mole
Fraction

Mass
Flowrate,
(lb/hr)
60

Propane

0.1388

17060.53

0.1400

17060.53

Butane

0.0007

111.61

0.08

111.61

Pentane

0.0017

346.38

0.20

346.38

Propene

0.8526

100000

0.8600

100000

Butene

0.0062

969.58

0.720

969.58

61

3.1.7

MassBalanceforSeparationUnit4

Stream8

Stream1

Stream11

No.

Component

Mole
Fraction

Mass
Flowrate,
(lb/hr)

Mole
Fraction

Mass
Flowrate,
(lb/hr)

Mole
Fraction

Mass
Flowrate,
(lb/hr)

Propane

0.140

17060.53

17060.56

0
62

Propene

0.860

100000

100000

63

3.2

ENERGYBALANCES

Table3.1:TableofDataforHeatofCapacities

Cp=A+B*T+C*T^2+D*T^3
Cp=A+B*T+C*T^2+D*T^3
Compound

Molecular
Weight

Hf

Hv

Kj/mol

Average
Cpfor
liquid

A*10^3 B*10^5

C*10^8

D*10^1
2

KJ/(mol.K)

Propane

44.09

103.
8

18.77

68.023

22.59

13.11

31.71

0.10584

Propene

42.08

20.41

18.42

59.58

17.71

10.17

24.6

0.1199

Butane

58.12

124.
7

22.30
6

92.3

27.88

15.47

34.98

0.13367

Butene

56.1

1.17

21.91
6

82.88

25.64

17.27

50.50

0.09396

64

Pentane

72.15

146.
4

25.77

114.8

34.09

18.99

42.26

0.167

Hydrogen

2.016

0.904

28.84

0.0076
5

0.3288

0.8698

EnergyBalance
We useheat ofvaporization instead of liquidheatcapacities tocalculatethestream enthalpy andthevaluestatedinTable 3.1. Fora mixed stream,both
equationsareappliedbasedon the vapor/liquidfractioninvolved.Ifthereisnoreactionoccur inaunit(i.e.initialcomponent=finalcomponent),enthalpychange
fortheunitisexpressasbelow:

65

Where, nis

thetotalmolarflowrateofthatspecificstream

Forstreams

withcompositionorcomponentchange(i.e.reactor),heatofformationmustbeincluded.

3.2.1 SeparationUnit1

66

ForStream1
Liquidphase
Streamtemperature,T=325.13Kandconsiderdatumat298.13K

Flowrate

Flowrate

Ibmole/hr

mole/hr

Propane

2376.43

1077948.64

0.10584

3080432.27

Butane

534.69

242535.38

0.13367

875332.014

Pentane

59.41

26948.37

0.167

121510.2

Component

Cp

KJ/hr

4077274.484KJ/hr

ForStream2
Liquidphase
Streamtemperature,T=320.13Kandconsiderdatumat298.13K

67

Flowrate

Flowrate

Cp

Ibmole/hr

mole/hr

liquid

Propane

2376.43

1077924.88
4

0.10584

Butane

19.203

8710.288

0.13367

25614.69

Pentane

4.8

2177.23

0.167

7999.14

Component

H
2509926.534

2543540.36KJ/hr

68

ForStream3
/Streamtemperature,T=377.13Kandconsiderdatumat298.13K
Flowrate

Flowrate

Cp

Ibmole/hr

mole/hr

liquid

Butane

8.86

4018.8

0.13367

42438.24

Pentane

0.756

342.91

0.167

4524.011

Component

46962.25KJ/hr

H=46962.25+2543540.364077274.484=1486771.86KJ/hr

69

3.2.2

Heatexchanger1

70

Flowrate

Flowrate

Ibmole/hr

mole/hr

Propane

2376.96

Butane
Pentane

Component

Cp

1077948.64

0.10584

3650882.69

534.7

242535.38

0.13367

1037430.53

59.41

26948.37

0.167

144012.08

4832325.3KJ/hr

71

3.2.3

Furnace

Streamtemperature,T=600Candconsiderdatumat47C

Flowrate

Flowrate

Ibmole/hr

mole/hr

Propane

2376.43

1077948.64

69.62

75046784.32

Butane

534.69

242535.38

90.91

22048891.4

Component

CpdT

KJ/hr

72

Pentane

59.41

26948.37

112.17

3022798.66

100118475KJ/hr

3.2.4

EnergybalanceforHeatExchanger2(HE2)

73

Streaminletat600Cdatumat25C
Compound
H2
C3 H8
C3 H6
C4 H1 0
C4 H8
C5 H1 2

Flowrate
(mol/hr)
2393.7
386.86
2376.4
1.9203
17.283
4.8009
5180.9642

CpdT
(kJ/mol)

nH

16.8053
71.2935
59.5563
93.1652
82.9306
114.9629
438.7138

40226.84661
27580.60341
141529.5913
178.9051336
1433.28956
551.9253866
211501.1614

Streamoutletat1Cdatumat25C
Compound
H2
C3 H8
C3 H6
C4 H1 0
C4 H8
C5 H1 2

Flowrate
(mol/hr)
2393.7
386.86
2376.4
1.9203
17.283
4.8009
5180.9642

CpdT
(kJ/mol)

nH

Hv

0.6922
2.5392
2.8776
3.2082
2.255
4.008
15.5802

1656.91914
982.314912
6838.32864
6.16070646
38.973165
19.2420072
9541.938571

18.77
18.42
22.306
21.916
25.77
107.182

Q=n(Hout
Hv))
Hin(

=5180.9642(15.5802438.7138(107.182))
=1798374.845kJ/hr
74

75

3.2.5

EnergyBalanceforFlashSeparator(S2)

Stream5(FeedStream)at1Cdatumat25C
Compound
H2
C3 H8
C3 H6
C4 H1 0
C4 H8
C5 H1 2

Flowrate
(mol/hr)
2393.7
386.86
2376.4
1.9203
17.283
4.8009
5180.9642

CpdT
(kJ/mol)

nH

0.6922
2.5392
2.8776
3.2082
2.255
4.008
15.5802

1656.91914
982.314912
6838.32864
6.16070646
38.973165
19.2420072
9541.938571

Stream6(Distillatestream)at1Cdatumat25C

76

Compound

H2

Flowrate
(mol/hr)
2393.7

CpdT
(kJ/mol)

nH

0.6922

1656.91914

Stream7(Bottomstream)at1Cdatumat25C
Compound
C3H8
C3 H6
C4 H1 0
C4 H8
C5 H1 2

Flowrate
(mol/hr)
386.86
2376.4
1.9203
17.283
4.8009
2787.2642

CpdT
(kJ/mol)

nH

2.5392
2.8776
3.2082
2.255
4.008
14.888

982.314912
6838.32864
6.16070646
38.973165
19.2420072
7885.019431

Theresnoheattransferfromtheflashcolumn:
Q = H = 0

Q=nHoutn
Hin

=(7885.019431+(1656.91914))(9541.938571)
=0kJ/hr

77

78

3.2.6

Energybalanceforheatexchanger3

Streaminletat1Cdatumat25C
Compound
C3H8
C3 H6
C4 H1 0
C4 H8

Flowrate
(mol/hr)
386.86
2376.4
1.9203
17.283

CpdT
(kJ/mol)

nH

2.5392
2.8776
3.2082
2.255

982.314912
6838.32864
6.16070646
38.973165
79

C5H12

4.8009
2787.2642

4.008
14.888

19.2420072
7885.019431

CpdT
(kJ/mol)

nH

1.2825
1.1118
1.7249
1.5516
2.1421
7.8129

496.14795
2642.08152
3.31232547
26.8163028
10.28400789
3178.642106

Streamoutletat42Cdatumat25C
Compound
C3H8
C3 H6
C4 H1 0
C4 H8
C5 H1 2

Flowrate
(mol/hr)
386.86
2376.4
1.9203
17.283
4.8009
2787.2642

Q=nHoutn
Hin

=3178.642106(7885.019431)
=63273.40588kJ/hr

3.2.7

EnergyBalanceforCompressor(C1)
80

Inlet(stream2)
Phase
Component
Pressure(bar)
Temperature(o C)
TotalMolarFlowRate(kmol/hr)

Vapor
Mixture
1
600
2349.64

Outlet(stream3)
Phase
Component

Vapor
Mixture

Pressure(bar)

10

Temperature(o C)

600

TotalMolarFlowRate(kmol/hr)

2349.64

81


Theoutlettemperatureofastreambyassumingtheprocessisanidealsystem.
(1
)

T 2 = T 1( P 2 )
1

Foridealsystem,=1.3.
Hence,
(1.31
1.3 )

T 2 = 600(10
1)

= 1020.75C

Forenergybalance,

out

in

Q = H = niH i niH i

= ni
out

298.15

C pdT ni
in

298.15

C pdT

Sincethereisnochangecomponentflowrate,
1293.9

Q = H = ni[

68.023103 + 22.59105T 13.11108T 2 + 31.711012T 3dT +

298.15

1293.9

298.15

59.58103 + 17.71105T 10.17108T 2 + 24.61012T 3dT +

1293.9

92.3103 + 27.88105T 1

298.15

= 2349.64(175.44 + 144.36 + 227 + 197.87 + 278.61 + 30.52 )

=2476050.63kJ/hr
82

3.2.8

SeparationUnit3(S3)

83

ForStream7
Liquidstream
Streamtemperature,T=315.15Kandconsiderdatumat298.15K
Flowrate

Flowrate

(lbmol/hr)

(mol/hr)

Propane

386.86

1.75447105

Butane

1.92

Pentane
Propene

Component

CpdT

nH

(kJ/mol)

kJ/hr

0.10584

1.7993

315681.79

870.748

0.13367

2.2724

1978.69

4.80

2176.871

0.167

2.8390

6180.14

2376.43

10.777x105

0.1199

2.0383

2196675.91

Cp

84

Butene

17.28

7836.735

0.09396

1.5973

12517.62

2533034.15

ForStream8
Gasstream
Streamtemperature,T=317.15Kandconsiderdatumat298.15K
Flowrate

Flowrate

(lbmol/hr)

(mol/hr)

Propane

386.86

1.75447105

Propene

2376.4

1077732.426

Component

CpdT

nH

(kJ/mol)

kJ/hr

0.10584

2.0110

352823.92

0.1199

2.2781

2.45518106

Cp

2.8080x106

ForStream9
85

Liquidstream
Streamtemperature,T=381.55Kandconsiderdatumat298.15K
Flowrate

Flowrate

(lbmol/hr)

(mol/hr)

Butane

1.9203

870.884

Butene

17.283

Pentane

4.80

Component

CpdT

nH

(kJ/mol)

kJ/hr

0.13367

11.1481

9708.70

7838.095

0.09396

7.8363

61421.66

2176.871

0.1670

13.9278

30319.02

Cp

101449.38

H=101449.38+2.8080x1062533034.15=376415.23kJ/hr

3.2.9

SeparationUnit4(S4)

86

ForStream8
Liquidstream
Streamtemperature,T=318.15Kandconsiderdatumat273.15K

Component

Flowrate

Flowrate

(lbmol/hr)

(mol/hr)

Cp

CpdT

nH

(kJ/mol)

kJ/hr

87

Propane

386.95

1.75517105

0.10584

4.7628

8.35952105

Propene

2376.43

10.77929105

0.1199

5.3955

58.15965105

66.51917105

ForStream11
Gasstream

Streamtemperature,T=309.15Kandconsiderdatumat273.15K

Component

Propene

Flowrate

Flowrate

CpdT

nH

lbmol/hr

(mol/hr)

(kJ/mol)

(kJ/hr)

2376.43

10.77929105

2.258

24.33963105

88

24.33963105

ForStream12
Liquidstream

Streamtemperature,T=320.15Kandconsiderdatumat273.15K
Component

Propane

Flowrate

Flowrate

(lbmole/hr)

(mol/hr)

386.95

1.75517105

Cp

0.10584

CpdT

nH

(kJ/mol)

(kJ/hr)

4.97448

8.73105105

8.73105105

Q=H=8.73105105+24.3396310566.51917105=33.44849105kJ/hr

89

3.2.10

Pump(P1)

Componen
t

MolarFlowRate
(lbmol/hr)

MolarFlowRate,F
(kmol/hr)

C3H8
C3H
6
C4H10
C4H
8
C5H
12

386.86
2376
1.92
17.28
4.801

1.75476102
10.77734102
0.00870102
0.07838102
0.02178102

Molar
volume,v(kmol/m3)
21.9375
23.2486
0.09667
0.09048
0.11452

Fv
3849.50
25055.8
1
0.08410
0.70918
0.24942

Fv=28906.35

90

InletStream
Phase
Pressure(bar)
Temperature(oC)

Liquid
1
47

OutletStream
Phase
Pressure(bar)
Temperature(oC)

Liquid
18
47

Q=Fv( P)

Q=28906.35(181)=4.91408105kJ/hr

3.2.11 EnergyBalanceforReactor

91

1.C3H8C3H6+H2

H r1

2.C4H10C4H8+H2

H r2

Q1 = nH = nH R1 + nH p1 + H r1 (forPropane)

92

Q2 = nH = n nH R2 + nH p2 + H r2 (forButane)

Q = Q1 + Q2

1.EnergybalanceforPropane
Component
Flowrate
(mol/hr)
Specific
Enthalpy, H
(kJ/mol)

H R1

H p1

H r1

1253192.74

2330911.57

91.8

184.72

93

H
(kJ/hr)

115043093.5

430565985.2

140.21

315523031.9

2.EnergybalanceforButane
Component
Flowrate
(mol/hr)
Specific
Enthalpy, H
(kJ/mol)
H
(kJ/hr)

H R2

H p2

H r2

8708.84

16547.07

119.0

240.61

1036351.96

3981390.5

125.87

1945164.41

Q = Q1 + Q2

94

kJ + 1945164.41 kJ
Q = 315523031.9 hr
hr

Q=317.468x106kJ/hr

95

3.3

SimulationResultfromASPENHYSYS
3.3.1 MaterialBalance
Streamno.

Mass
(lbmole/hr)
(Hysys)

stream1
stream2
stream3
stream4
stream5
stream6
stream8
stream9
stream10
stream11
stream12
stream13
stream14
stream15
stream16
stream17
stream23
stream24
stream25

3179
3179
769.4
2410
2523
2523
4692
4692
4692
4692
2533
2159
2533
2533
156.3
2377
2263
113.4
113.2

96

3.3.2

EnergyBalance

Equipment

Energy,kJ/h
(HYSYS)

QHE00
QHE01
QHE02

5.76E+06
1.79E+08
1.65E+07
97

QFurnace
QCompressor
QPump

9.23E+07
6.78E+07
6.90E+04

3.4

PercentageDifferencebetweenManualCalculationandHYSYSCalculation
3.4.1

MassBalance

Streamno.

Mass
(lbmole/hr)
(manual)

Mass
(lbmole/hr
)
(Hysys)

%Diff

stream1
stream2
stream3
stream4
stream5
stream6
stream8
stream9
stream10
stream11
stream12

2971
2971
721.5
2400.4
2787.3
2787.3
5181
5181
5181
5181
2787

3179
3179
769.4
2410
2523
2523
4692
4692
4692
4692
2533

6.54
6.54
6.23
0.40
10.48
10.48
10.42
10.42
10.42
10.42
10.03

98

stream13
stream14
stream15
stream16
stream17
stream23
stream24
stream25

2393
2787
2787
165.4
2663.5
2376.4
124.5
124.5

2159
2533
2533
156.3
2377
2263
113.4
113.2

10.84
10.03
10.03
5.82
12.05
5.01
9.79
9.98

3.4.2

EnergyBalance

Equipment

Energy,kJ/h
(manual)

Energy,kJ/h
(HYSYS)

%Diff

QHE00
QHE01
QHE02
QFurnace
QCompressor
QPump

4.83E+06
1.80E+06
6.33E+04
1.00E+08
2.48E+06
4.91E+05

5.76E+06
1.79E+08
1.65E+07
9.23E+07
6.78E+07
6.90E+04

16.09
99.00
99.62
8.46
96.35
612.70

99

CHAPTER4

HEATINTEGRATION

4.1

PROCESSENERGYINTEGRATION

Tmin=10C

Table4.1:SteamTableData

100

Stream

Type

Tsupply(C)

Ttarget(C)

FCp(MW/K)

C1

Cold

20

50.08

0.053

C2

Cold

43.85

576.30

0.048

H1

Hot

870.7

137.1

0.049

C3

Cold

136.8

30

0.028

T(C)

865.70

581.30

0.049
H1

T(C)

FCpCFCpH
(MW/K)

Hi(MW)

1stCascade

284.4

0.049

13.9356

13.94

526.22

0.001

0.52622

14.46

6.23

0.052

0.32396

14.14

55.08

48.85

C2

101

0.048

35.00

13.85

0.004

0.0554

14.08

10

0.032

0.3200

13.76

156.8

0.021

3.2928

25.00

C1

0.053

131.80

C3

17.06

0.028

10.3

0.049

0.5047

142.10

17.56

Figure4.1:AlgorithmTable
4.3

HeatExchangerNetwork

H(MW)

FCp(MW/K)

1.5942

0.053

50.08

25.5576

0.048

20

576.3

43.85

102

4.6704

0.028

30

49.3822

0.049

136.8

870.7

25.5576

1.5942 4.670417.56

Figure4.2:HeatExchangerNetwork

Table4.2:SummaryofTemperatureofHeatExchanger

TH,in(C)

TH,out(C)

TC,in(C)

TC,out(C)

E1

870.7

349.12

43.85

576.3

E2

349.12

316.59

20

50.08

E3

316.59

221.28

136.8

30

221.28

137.1

103

Figure4.3:ProcessFlow
DiagramHeatExchanger
Network
CHAPTER5

OPTIMIZATION

Optimizationisthetoolto
maximizeourprofitby
minimizingthesupplyof
rawmaterialand
maximizingtheproduct.In
thiscase,ourtargetthat
wewanttomaximizeit
theproductionofpropene
104

(100000Ib/hr)andoursupplythatwewanttominimizeitisthepropanewhichisinitiallysetto104800Ib/hrdependingonthestoichiometriccoefficientof
(propane/propene=1.048)and(Hydrogen/propene=0.0457).

Propane

Propene

Hydrogen

Ibmol

MW

44.1

42.08

2.16

Ib

44.1

42.08

2.16

Ib/Ib
propene

1.048

0.0457

USDRM/Ib

0.79

1.96

11.3

105

Step1:
Definedecisionvariables:
P1=amountofproduct(Propene)
P2=amountofbyproduct(Hydrogen)
R=amountofreactant(Propane)
Z=maximumprofit

Step2:
Defineobjectivefunction
Maximumprofit(Z)=(1.96*P1+11.3*P2)(0.79*R)

Step3:
Definingequalityandinequalityconstraints:
a) Inequalityconstraints
PropanesupplyR<<104800Ib/hr
PropeneproductionP1>>100000Ib/hr

106

b) Equalityconstraints
R=1.048*P1
P2=0.0457*P1

c) Nonnegativityconstraint
R,P1,P20

Step4
Optimizationtechnique
WeusedsolveraddininMicrosoftexcel:
P1=100000Ib/hr
P2=4789.36Ib/hr
R=104800Ib/hr

107

Z=167327.768RM/hr
Afteroptimizationthemaximumprofitisclosetothemanuallycalculatedone=RM167327.768/hr.

CHAPTER6

EQUIPMENTSIZINGANDCOSTING

6.1

Introduction

108

In thischapter,theequipmentsizingis donetoallequipmentthatisinvolvedintheproposedpropyleneproductionplant.Equipmentsizingisaveryimportant
aspect of process design as it enables thesubsequentanalysisthatisinvolvedinprocessdesignsuchasmechanicaldesignandeconomyanalysis.Thesizinginvolves
thereactors,distillationcolumn,compressor,pump,andheatexchangers.

6.2

Reactor

6.2.1

SizingofReactor
Parameter

SI

VolumetricFlowrate,Q

3517.02ft3/hr

Retentiontime(halffull),t

5min

ReactorVolume,V

586.17ft3

VesselInsideDiameter,Di

7.20ft

VesselLength,L

14.4ft

DesignType

Vertical

MaterialofContruction

LowAlloySteelSA387B

109

6.2.2

CostingofReactor

Costofvessel,Cv=$40,279
Costofladdersandnozzles,CPL=$10,264
CostofpurchaseCP=$58,599
Totalcostwithbaremodule=4.16(58,599)=$243,772

6.3

Pump

6.3.1

SizingofPump

Pressureinlet,P1=1000kPa=145.04psi
Pressureoutlet,P2=1750kPa=253.82psi
Pressuredrop,P=750kPa=108.78psi
Volumetricflowrate,Q=93.57m3/hr=413.09gpm
Pumphead,H=

= P
=356.82ft

P(2.31)

SG

110

6.3.2

CostingofPump

Costofpump,CP=$6577.78
Costofmotor,CP=$4689.90
Totalcostwithbaremodule=(6577.78+4689.90)(3.30)
=$37,183.34

6.4

DistillationColumn

6.4.1

Sizingandcostingofthemainvessel:

Parameters

Domedheadwall

S1
13.7mm

thickness,a
Trayspacing,b

2ft

Columndiameter,c

6.05ft

Columnwallthickness,
d

Designtype

0.5in
Vertical

111

MaterialofConstruction
Materialofinsulation

Carbonsteel
Mineral
wool,60mm

Columntype

Platecolumn

Platetype

Sieve

Domedheadtype

Torispherical

Costingin$:

Costofvessel.Cv=$67436
Costofladdersandnozzles,CPL=$21642
Costofplates,CT=$27462

Totalcostwithbaremodule
=4.16(67436+21642+27462)=$484809

112

6.4.2

Sizingandcostingoftherefluxdrum:

Parameters

Domedheadwall

S1
13.7mm

thickness,
Vessellength,L

8.924ft

vesseldiameter,D

17.85ft

Columnwallthickness,
d

0.562in

Designtype

Vertical

MaterialofConstruction

Carbonsteel

Materialofinsulation

Mineral
wool,60mm

Afterbaremodel:
Cost=$223290

113

6.4.3

Sizingandcostingofthecondenser:

Parameters

S1

Lengthoftube

20ft

Areaoftransfer,Ac

273.1ft2

MaterialofConstruction

Carbonsteel

fixedhead,
TypeofHE

shelltube
exchanger

Cp=$21721
Afterbaremodule,
Cost=$68857

114

6.4.4

Sizingandcostingofthereboiler:

Parameters

S1

Lengthoftube

20ft
115

Areaoftransfer,AR

3.146ft2

MaterialofConstruction

Carbonsteel

TypeofHE

kettlereboiler

CB=$65325
Withbaremodule
$3.17(65325)=$207080

TotalcostforS1:

VesselorEquipment

Costin$

mainvessel

484809

therefluxdrum

223290

thecondenser

68857

thereboiler

207080

Total

984036

116

6.5

Compresssor

6.5.1

MainSizingParameters

Parameters

Compressor

CompressorType

Centrifugal

DriveType

Steamturbine

MaterialofConstruction

Stainlesssteel

InletVolumetricFlowRate,QI

83283.83ft3 /min

117

InletPressure,PI

14.5psi

OutletPressure,PO

72.52psi

SpecificHeatRatio,k

1.10

6.5.2

Costingin$:

Purchasecostofcompressor=$7,328,904

6.6

HeatExchanger

6.6.1 SizingofHeatexchanger(HE2)

Heatexchangertype

2shelland4tubes
Designtype

FixedHead
Heatexchangerorientation
Horizontal
Tubeinletdirection

Horizontal
Heatduty(kJ/s)

1594.2
Heatduty(Btu/hr)

5.44x10^6

Hot
Cold
Tin(C)
Tout(C)

870.7
349.12

43.85
576.3
118

119

FromFigure18.15(a),FT=0.85and24exchangerisused.

Ui=235.5Btu/oF.ft2.hr

Velocityoftubeside

Crosssectionare/pass

120


Byusing0.75in.O.D.16BWGtubingwithI.D.of0.62in.

Insidearea/tube=
=2.097x103ft2/tube

Areapertube

=
=0.288ft2/tube

L=5.58ft

121

6.6.2

CostingofHeatExchanger(HE2)

FBM=3.17

0.5
F M = 1.08 + ( 86.34
100 )
=2.01

FL=1.25(Tubelength=5.58ft2)

145.04 2
F P = 0.9803 + 0.018( 145.04
100 ) + 0.0017( 100 )

=1.01

Fixedhead:

2
C B = exp{11.0545 0.9228[ln(86.34)] + 0.09861[ln(86.34)] }
=$7,334.88

C P = (2.01)(1.25)(1.01)(7, 334.88)
=$18,613.18

Baremodulecost=3.17(18,613.18)
122

=$59,003

CHAPTER7

TOTALCAPITALINVESTMENTANDPAYBACKPERIOD

7.1

TotalCapitalInvestment

Byusingmethod3,whichisbasedontheindividualfactorsmethodofGuthrie,1969,1974therearefewstepstofindthetotalcapitalinvestments,CTCI.

Firstly,weneedtoprepareanequipmentlist,givingtheequipmenttittle,label,size,materialofconstruction,designtemperature,anddesignpressure.

123

Equipment
Tittle

Label

Size

Materialof
Construction

Design
Temp.

Design
Pressure(bar)

Baremodule
Cost,CBM

(C)
Reactor

R1

V=586.17ft3
Di=7.20ft

LowAlloy
SteelSA387B

576

$243,772

CastSteel

137.1

Pinlet=10

$37,183

L=14.4ft
Pump

P1

H=356.82ft

Poutlet=17.5
Distillation
Column

S1

D=6.05ft

Carbonsteel

50

15

$984,036

Q=83283.83
ft3/min

CarbonSteel

526

Pinlet=1

$15,757,144

A=86.34ft2

CarbonSteel

t=0.5in

Compressor

Heat
Exchanger

C1

HE2

Poutlet=10
870.7

10
CTBM

$59,003
$17,081,138

124

After we get the value of total bare module cost, CTBM, we need to find the site development cost, Csite,buildingcost,Cbuildings,and
offsitefacilitiescost,Coffsite

facilitiesbyassumingsomefactor.Thecalculationoftotalcapitalinvestmentcostisshownbelow:

Assumeitisgrassrootsplant,thevaluefoCSITEis1020%ofCTBM.Assumewetake15%ofCTBM.
CSITE=0.15(17,081,138)
CSITE=$2,562,170.75

Assumeitisprocessbuildings,thevalueofCBUILDINGSis10%ofCTBM
CBUILDINGS=0.10(17,081,138)
CBUILDINGS=$1,708,113.80

ThevalueofCOFFSITEFACILITIESis5%ofCTBM
COFFSITEFACILITIES=0.05(17,081,138)
COFFSITEFACILITIES=$854,056.90

Usefactorof1.18tocoveracontingencyandacontractorfee
CTPI=1.18(CTBM+CSITE+CBUILDINGS+COFFSITEFACILITIES)
CTPI=1.18(17,081,138+2,562,170.75+1,708,113.80+854,056.90)
125

CTPI=$39,969863.01

ThevalueofCWCcanbeestimated17.6%ofCTPI
CWC=0.176(39,969863.01)
CWC=$7,034,695.89

Thus,
CTCI=CTPI+CWC
CTCI=$39,969,863.01+$7,034,695.89
CTCI=$47,004,558.90

7.2

PaybackPeriod

126

Payback period is the time inwhichtheinitialcashoutflowofaninvestmentisexpectedtoberecoveredfromthecashinflowsgeneratedbytheinvestment.It

isoneofthesimplestinvestmentappraisaltechniques.

The formula to calculate payback period of a project depends on whether the cash flow per period from the project is even or uneven.Incasetheyareeven,
theformulatocalculatepaybackperiodis:

PaybackPeriod=

InitialInvestment
CashInflowperPeriod

= RM152,764,816.40
RM167,327.77/hr
1month
= 912.967hr 1day
24hr 30days

=1month9days

127

CONCLUSION

Propylene is one of the highest volume of chemicals produced globally and primarily used as an intermediate for the production of other chemical raw
materials. These chemical raw materials are then subsequentlyusedtomanufacturealargevarietyofsubstancesandproducts.Exampleofsuchproductispropylene,
a widely used plastic where the manufacturing process consumes more than half of the worlds production of polypropylene. There are other uses as well, such as
manufacture of acrylonitrile, oxo process chemicals, cumene, isopropanol, polygas chemicals, and propylene oxide. This showsthattheproductionofpropylenehas
its demand in the global industry, hence a good marketability, especially in recent years where the price of propylene in the marketisexpectedtocontinuerisingas

128

the demand increases for the chemical material. Market research report says worldwide polypropylene capacity increased at a Compound Annual Growth Rate
(CAGR) of 5.2% from 2003, reaching65milliontonsperyear(MMTY)in2013,andisexpectedtocontinuerisingto86MMTYby2018,ataslightlyhigherCAGR
of5.8%.AsMalaysiaisapartoftheglobalmarket,itcanbeexpectedthatpricesinMalaysiatobeaffectedbytheglobalprices.

In terms of reactionpathwaysforthisparticularproject,ascreeningprocesswasdonebasedongrossprofit,economicpotentialaswellasotherfactorsrelated
such as energy consumption, toxicity, safety and environmental impacts. There are two reaction pathways suggested for the production of propylene, which are
dehydrogenation of propane, and metathesis reaction ofethyleneandbutene. From thescreeningprocess,itwasshownthatdehydrogenationofpropanereactionisa
better process compared to the metathesis reaction. Based on the gross profit calculation, a dehydrogenation process would bring in a gross profit of RM 1.67/lb
propylene with 86% conversion compared to only RM 0.46/lb propylene for metathesis reaction with a 90% conversion yield. Since the calculation was based on
gross profit, further analysis need to be done in order to optimize the production process of propylene via the dehydrogenation of propane process for a sustainable
plantdesign.

In addition to the reaction pathways and processscreening,aprocesssynthesisfor theproductionofpropylenefromdehydrogenationofpropanewasdoneby

following the steps that was introduced by Rudd, Powers, andSiirola.Fromthesesteps,ageneraloverviewofthewholeprocess,startingfromtherawmaterialsinto
products is translated into a process flow diagram, aswellastheoperatingparameterswereobtained.Thisisanimportantstepindesigningtheproductionprocessof
ourdesiredproductbeforeperformingafurtheroptimizationoftheprocessesandunitoperationsinvolved.

129

Inanutshell,afterwehaddoneasimulation,optimizationandprocessintegration,ourtotalcapitalinvestmentis$47,004,558.90.

130

APPENDICESA

CALCULATIONOFMATERIALBALANCES
SampleCalculationforMassBalance

1.Overallmassbalance
Numberofmolesofpropyleneformed

=(100,000lb/hr)/42.08
=2376.43lbmole/hrC3H6

Assume100%conversion,themassflowrateoffeed,m1=2376.43x44.1
131

=104800.56lb/hr

for86%conversion,themassflowrateofrecycle,R=(10.86)/0.86x104800.56
R=17060.53lb/hr
MassflowrateofH2,m3
=(no.ofmole)X(molecularweight)
=(2376.43)x(2.01)
=4776.62lb/hr

Massflowratefeedtothereactor,F=m1+R
=104800.56+17060.53=121861.09lb/hr

2.SeparationUnit1
Overallmassbalance:
F1=D1+B1

132

Fromtheoverallmassbalance,weknowthatthemassflowrateofpropaneatD1is104800.56lb/hrandthecompositionisassume0.990ofC3H8,so
0.990D1=massflowrateofC3H8
D1=massflowrateofC3H8/0.990
=104800.56/0.990
=106263.1lb/hrdistillate

Propanebalance:
0.8F1=0.990D1
F1=(0.990x106263.1)/0.8
F1=140163.6lb/hrfeed

F1=D1+B1
B1=140163.6106263.1
B1=33900.6lb/hrofbottomproduct

133

3.Mixer
Overallmassbalance:
F=D1+RwhereRistherecycleofpropane

frompreviouscalculation,thevalueofD1=106263.1lb/hrandR=17060.53lb/hr.Hence,
F=106263.1lb/hr+17060.53lb/hr=123323.6lb/hr
Propanebalance:0.990x(106263.1)+17060.53x(1.0)=123323.6x(a1)
a1=0.991
Butanebalance:0.009x(106263.1)=123323.6x(a2)
a2=0.007
andtheweightpercentofpentane
a3=10.9910.007=0.002

4.Reactor
Fordehydrogenationofpropane,0.86%ofpropaneisconverted.Theunreactedpropanerecycled.

134

(a)Massflowrateofpropanerecycle
R=(10.86)/0.86x104800.56
R=17060.53lb/hr
(b)noofmolofpropanerecycle
=17060.53/44.1=386.9lbmole/hr
(c)noofmoleofpropeneproduce
=(121861.09/44.1)x0.86=2376.64lbmole/hr
(d)noofmoleofbuteneproduce
=1116.106/58.12x0.9=17.28lbmole/hr
(e)noofmoleofhydrogenproduce
=noofmoleofhydrogenfrompropane+noofmoleofhydrogenfrompropane
=2376.4+17.28=2393.7lbmole/hr
(f)massflowrateofhydrogenproduce

135

=2393.7x2.01=4811.36lb/hr

136

APPENDICESB

CALCULATIONOFENERGYBALANCE
SampleCalculationforEnergyBalance
MolarFlowRateforPropane
1kgmol
1000mol
n = 2763.3 lbmol
hr x 2.205lbmol x 1kgmol = 1253197.28mol/hr

Forreactionofpropane

H R1 =
H R1 =

298K

C p(reactant)dt

873K
298K

(68.023103 + 22.59105T 13.11108T 2 + 31.711012T 3)dt

873K

H R1 = 91.81kJ/mol
H R1 =
H p1 =

298K

C p(product)dt

873K
873K

(68.023103 + 22.59105T 13.11108T 2 + 31.711012T 3)dt + (59.58103 + 17.71105T 10.17108T 2 + 24.61012T 3)dt + (28.84103 + 0.00765105T + 0.32881

298K

137

H p1 = 91.79kJ/mol + 75.75kJ/mol + 17.18kJ/mol

H p1 = 184.72kJ/mol

H r1 = viH f = (1)(H f )C3H6 + (1)(H f )H2 (1)(H f )C3H8

(119.8)kJ
H r1 = 20.41kJ
= 140.21kJ/mol
mol + 0 mol

138

APPENDICESC

ASPENHYSYS

139

140

APPENDICESD

CALCULATIONOFHEATINTEGRATION

Calculationfortemperatureofheatexchanger.
E1
Q=FCpHT
25.5576=0.049(870.7T)
T=349.12C

Q=FCpCT
25.5576=0.048(T43.85)
T=576.3

141

E2
Q=FCpHT
1.5942=0.049(349.12T)
T=316.59C

Q=FCpCT
1.5942=0.053(T20)
T=50.08C

E3
Q=FCpHT
4.6704=0.049(316.59T)
T=221.28C

142

Q=FCpCT
4.6704=0.028(T136.8)
T=30C

143

APPENDICESE

CALCULATIONOFSIZINGANDCOSTING

REACTOR
Q=3517.02ft3/hr
Retentiontime=5minathalffull:
3
Volume,V=(3517.02ft3/hr) ( 5min1hr
60min 2 )=586.17ft

AssumeL/D=2
V= (D/2)2L=( D3)/2
D=(2V/ )1/3=[2(586.17)/ ]1/3=7.20ft
L=2D=14.4ft

OperatingPressure=1bar=14.5psig:
Pd=exp{0.60608=0.91615[ln(14.5)]+0.0015655[ln(14.5)]2}=21.48psig(eqn.22.61)
S=10993.86psi(lowalloy)
144

E=1.0
21.487.212
tP= 2(10993.86)(1.0)1.2(21.48)
=0.085in

Minimumwallthickness,tP=0.375in
tS=tP+tC=0.375+0.125=0.5in
W=3.14[7.2+0.0417)(14.4+0.8(7.2)]0.0417(490)=9366.83lb
Cv=exp{7.0132+0.18255[ln(9366.83)]+0.02297[ln(9366.83)]2}=$40,279
CPL=361.8(7.2)0.73960(14.4)0.70684=$10,264
Cp=FMCv+CPL=1.2(40,279)+10,264=$58,599
BareModulecost
=4.16(58,599)=$243,772

PUMP
Pressureinlet,P1=1000kPa=145.04psi
Pressureoutlet,P2=1750kPa=253.82psi
Pressuredrop,P=750kPa=108.78psi
Q=93.57m3/hr=413.09gpm

145

ft3
1lb/in2
144in2
H= P(2.31)
= P

SG
=108.78psix
1psi x 43.9lb x 1ft2

H=356.82ft
S=Q(H)0.5=413.09(356.82)0.5=7803.14gallon.ft0.5/min
lnS=8.962
CB=exp[9.71710.6019(8.962)+0.0519(8.962)2]=$4872.43
FT=1,FM=1.35(Assumecaststeel)
CP=FTFMCB=(1)(1.35)(4872.43)=$6577.78forpump

QH
gal
1
PT= 33000
=413.09 min
x356.82ftx 43.9lb
0.1334ft3
ft3 x
1gal x 33000

=26.16 lb.ft
min
lnQ=6.024
p=0.316+0.24015(6.024)0.01199(6.024)2
=0.6956
lb.ft
26.16
PB= PT
p = 0.6956 =37.61 min

lnPB=3.627

146

m=0.80+0.0319(3.627)0.00182(3.627)2
=0.892
lb.ft

PT
26.16
PC= pm
= (0.6956)(0.892)
=42.16 min

lnPc=3.741
CB=exp[5.8259+0.13141(3.741)+0.053255(3.741)2+0.028628(3.741)30.0035549(3.741)4]
=$2605.50
FT=1.8(assumeexplosionprofenclosure)
CP=FTCB=1.8(2605.50)=$4689.9formotor
FBM=3.30
CPTotal(Pump+Motor)=(6577.78+4689.9)(3.30)
=$37,183.34

DISTILLATIONCOLUMN
Distillationcolumn,S1
Mainvesselsizing

Diameter,DT
FLG=0.1345
147

CSB=0.34
FST=0.757
Assume:
FF=1,FHA=1
C=0.2574
Uf=2.758ft/s
Ad/AT=0.10378
Assume80%flooding
4( 425100 )

3600
DT= 0.8(2.758)(3.14)(10.10378)(2.09)
=6.05ft=1.844m

Purchasecostsofthevessel

P0=1500Kpa=217.55psig
Pd=5.582psig
Di=6.05ft
L=50ft
(5.582)(6.05)(12)

tp= 2(15000)(0.85)(1.2*5.582) =0.0158 < tabulateddatathustp=0.375in

148

ts=0.375+0.125=0.5in
W=(Di+ts)(L+0.8Di)ts=21458Ib
Cv=$67436
CPL= 300.9 * 6.050.63316500.8016 =$21642
CT=$27462

Totalcostafterbaremodule=4.16(27462+21642+67436)=$484806

Costoftherefluxdrum

Dvolumetric=3350
Volumeflow=(1+3)*(3350)=13400ft3/hr
Assumeresidencetimeof5minsatfullcapacityandL/D=2
V=13400ft3/hr*(5min/(60min/hr))
V=116ft3
D=8.924ft3
L=17.85ft3

149


tp=7/16=0.4375in
ts=0.4375+0.125=0.562in
W=(Di+ts)*(L+0.8*Di)*(ts)*
W=16150Ib
Cv=$733210
Afterbaremodel:
Cost=$223290

Condenser

Qc=0.126* 10
Uf=4.402Btu/(ft2*hr*F)
TLM=10.48F
Ac=273.1ft2

Assumefixedhead,shelltubeexchangerandcarbonsteel,20feetlong:

150

FL=1
FP=1
TM=2.732
CB=7950

Cp=$21721
Afterbaremodule,
Cost=$68857

Reboilercosting

Heatflux5000Btu/hr.ft3
Q=16600Kj/hr=15733.76Btu/hr
AR=QR/Flux
AR=3.146ft2
Choosekettlereboilerwithcarbonsteel,20ftlong
FL=FM=FP=1

151

CB=$65325
Withbaremodule
$3.17(65325)=$207080

COMPRESSOR
(a)

Preliminaryestimateofbrakehorsepower,PB

Inletvolumetricflowrate,QI=83,283.83ft3/min
Inletpressure,PI

=14.5psi

Outletpressure,PO

=72.52psi

Specificheatratio,k

=1.10

Mechanicalefficiency,B

=0.4952

1.10
P B = 0.00436( 1.101
) 83283.8314.5
(( 72.52
0.4952
14.5 )

(b)

1.101
1.10

1) = 18430.94BHp

Purchasecostofcompressor

152

Assumption:
Driveefficiency,C =0.75
Materialfactor,FM

=1.00(carbonsteel)

Drivetypefactor,FD =1.15(steamturbine)

P C = 18430.94
0.75 = 24574.59Hp

Basepurchasecost,
C B = exp{7.5800 + 0.80[ln(P C)]}
C B = exp{7.5800 + 0.80[ln(24574.59)]}
C B = $6, 372, 960

Totalpurchasecost,
C P = F DF M C B
C P = 1.151.00$6, 372, 960
C P = $7, 328, 904

153

HEATEXCHANGER(HE2)
SizingofHeatexchanger(HE2)

Heatexchangertype

Designtype

Heatexchangerorientation
Tubeinletdirection

Heatduty(kJ/s)

Heatduty(Btu/hr)

2shelland4tubes
FixedHead
Horizontal
Horizontal
1594.2
5.44x10^6

Hot

Cold

Tin(C)

870.7

43.85
154

Tout(C)

349.12

576.3

155

FromFigure18.15(a),FT=0.85and24exchangerisused.

Ui=235.5Btu/oF.ft2.hr

Velocityoftubeside

Crosssectionare/pass

156


Byusing0.75in.O.D.16BWGtubingwithI.D.of0.62in.

Insidearea/tube=
=2.097x103ft2/tube

Areapertube

=
=0.288ft2/tube

L=5.58ft

CostingofHeatExchanger(HE2)

157

FBM=3.17

0.5
F M = 1.08 + ( 86.34
100 )
=2.01

FL=1.25(Tubelength=5.58ft2)

145.04 2
F P = 0.9803 + 0.018( 145.04
100 ) + 0.0017( 100 )

=1.01

Fixedhead:

2
C B = exp{11.0545 0.9228[ln(86.34)] + 0.09861[ln(86.34)] }
=$7,334.88

C P = (2.01)(1.25)(1.01)(7, 334.88)
=$18,613.18

Baremodulecost=3.17(18,613.18)
=$59,003

158

159


160

161


162

163


164

165


166

167


168