CMEN 432 Alkylation Project Objective Produce 5,000 barrels per day of alkylate product.

Assume only 1% heavies (anything other than trimethylpentanes) can be in final product. Alkylate will have to be stored at atmospheric conditions so lights must be removed to be stable. HF is $0.08/lb Isobutane is $1.47/gallon Isobutene is $3.45/gallon Alkalyte product is worth $4.15/gallon Heavies (waste) valued at fuel cost (use book value for btu value). Assume fresh feeds are at 80F (atm pressure unless liquid , then use pressure to make vapor fraction zero). Reactor at 104F, 1:1 volumetric feed on HF assume a fresh makeup of HF of 0.2lb/bbl of alkylate product. For economics, use a 20% discount rate of return, 15 year project life (FCI year 0, operating year 1-15). Land does not need to be included, Working Capital is 20% of FCI, Depreciation is MACRS (7years, SV is 10% of FCI), Tax is 35%. 1. Isobutane + Isobutylene -> 2,2,4-trimethylpentane Frequency Factor=6.1 2. Isobutane + isobutylene -> 2,3,4 trimethylpentane Frequency Factor = 1.8 3. Isobutane + isobytylene -> 2,4 dimethylhexane Frequency Factor = 1.5 4. 2,2,4-trimethylpentane + isobutylene ->Duodecane Frequency Factor = 30 5. 2,3,4-trimethylpentane + isobutylene ->Duodecane Frequency Factor = 23 6. 2,4-dimethylhexane + isobutylene ->Duodecane Frequency Factor = 23 7. 2(2,2,4-trimethylpentane) -> heptane + nonane Frequency Factor = 0.41 8. 2(2,3,4-trimethylpentane) -> heptane + nonane

Frequency Factor = 0.47 9. 2,2,4-trimethylpentane + isobutane -> pentane + heptane Frequency Factor = 0.35 10. 2,3,4-trimethylpentane + isobutene -> pentane + heptane Frequency Factor = 0.35 11. 2(isobutylene) -> 2,4,4-trimethyl-1-pentene Frequency Factor = 2.2 Thermodynamics: Im not convinced SRK is the most appropriate (Im not sure it works with the electrolytic). Some items that we must consider: 1. We need to determine how much water is typically present in an industrial alkylation unit and use that as a target (some type of electrolytic model will be necessary if water is present). 2. Whatever simulation we choose, should predict the appropriate amount of HF in hydrocarbon (and hydrocarbon in HF). 3. Im finding literature that anyhydrous HF forms a hexamer (the manual states that SRK in ChemCAD is able to simulate HF as a vapor hexamer). The hexamer will behave as a heavier fluid than one would predict HF by molecular weight. 4. Some students have found an azeotrope between HF and some of the hydrocarbons (SRK simulated this). *Also Im uncertain if we need to simulate duodecane as a branched hydrocarbon (look at a VLE and see if the straight alkane separates differently than the branched C12H26