Beruflich Dokumente
Kultur Dokumente
Chemical
Engineering
(FChE)
SKKK 4153 PLANT DESIGN
2014/2015-SEM 1
FINAL REPORT
PROPYLENE PRODUCTION PLANT
LECTURER
ASSOC. PROF. IR. DR. SHARIFAH RAFIDAH WAN ALWI
DESIGN TEAM
EQUINOX
NO
.
1.
2.
3.
4.
5.
TEAM MEMBERS
EMAD MOHAMMED NOMAN AL-DHUBHANI
MUHAMMAD FAIRIS BIN HADIPORNAMA
KELVIN RAWING SEBASTIAN
NUR FADZLYANA BINTI HAMDAN
MIMI KHAIRIAH BINTI AWANG
MATRIC NO
AA103001
A11KK0022
A11KK0065
A11KK0035
A11KK0169
TABLE OF CONTENTS
Page
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
1.1
Background of Propylene
1.2
Uses of Propylene
1.3
Propylene Manufacturing
1.4
Market Survey
1.5
1.4.1 Introduction
11
12
12
Raw Materials
14
14
14
1.5
15
2.2
24
2.2.1
24
2.3
26
2.4
28
2.5
30
Material Balance
33
33
35
3.1.3
36
37
38
39
40
3.2
Energy Balances
40
3.3
60
3.3.1
Material Balance
60
3.3.2
Energy Balances
60
3.4
61
3.4.1
Mass Balances
61
3.4.2
Energy Balances
61
62
4.2
Algorithm Table
63
4.3
64
4.4
64
66
Introduction
69
6.2
Reactor
69
6.3
6.4
6.2.1
Sizing of reactor
69
6.2.2
Costing of reactor
70
Pump
70
6.3.1
Sizing of pump
70
6.3.2
Costing of pump
70
70
6.4.1
70
6.4.2
71
6.4.3
72
6.4.4
73
3
6.5
6.6
Compressor
74
6.5.1
Sizing of compressor
74
6.5.2
Costing of compressor
74
74
6.6.1
74
6.6.2
76
77
CONCLUSIONS
79
APPENDICES A
APPENDICES B
APPENDICES C
APPENDICES D
APPENDICES E
CHAPTER 1
INTRODUCTION
1.1
Background of Propylene
Propylene, also called propene is generally described as a volatile and a colorless gas
at room temperature. It has same empirical formula with cyclopropane 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, motor vehicle
exhaust, and tobacco smoke. Propylene is not expected to persist in the environment. Since
propylene is a gas, the exposure of propylene into the air is expected to be lower amount
when released into the environment. Because of its relatively short half-life in the atmosphere
and typically low environmental concentrations, propylenes contribution to potential global
warming is considered minor and its ozone depletion potential is negligible.
1.2
Uses of Propylene
Propylene is a major product of the petrochemical industry. It is one of the highest
volume chemicals produced globally. Propylene is primarily used as an intermediate for the
production of other chemical raw materials that are subsequently used to manufacture a large
variety of substances and products. Manufacture of polypropylene, a widely used plastic,
consumes more than half of the worlds production of propylene. Propylene is also used in
the manufacture of acrylonitrile, 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.
Polypropylene
Application Description
Propylene Oxide
Isopropanol
Cumene
Ethylene-Propylene
Elastomers
Polygas Chemicals
(nonene, dodecene,
heptenes)
1.3
Propylene Manufacturing
Lotte Chemical Titan Holding Sdn. Bhd. is one of the manufacturer and supplier of
propylene, located at Pasir Gudang, Johor Bahru. This company will be the benchmark of
Equinox Team to design a plant that can produce 100,000 lb/hr of propylene. The team will
propose a variety of production reactions of propylene and there are several production
processes such as catalytic dehydrogenation of propane, reformation of olefins reaction
(metathesis reaction), and the conversion of methanol to propylene. The most sustainable and
economically reaction processes will be chosen for the plant design. This includes the
comparison between the cost of raw materials, safety, environmental impacts, percentage
yield of conversion, energy consumption, and other factors that might affect the reaction
process.
1.4
Market Survey
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 discuss the
prices of propylene and its raw materials.
1.4.2
Production of Propylene
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 is currently about half that of ethylene. About 56% of the worldwide
production of propylene is obtained as a co-product of ethylene manufacture, and about 33%
is produced as a by-product of petroleum refining. About 7% of propylene produced
worldwide is on-purpose product from the dehydrogenation of propane and metathesis of
ethylene and butylenes; the remainder is from selected gas streams from coal-to-oil processes
and from deep catalytic cracking of vacuum gas oil (VGO). The supply of propylene remains
highly dependent on the health of the ethylene industry as well as on refinery plant
economics.
In 2010, production of polypropylene represented 65% of total world propylene
consumption, ranging from 53% in North America to more than 90% in Africa and the
Middle East.
Table 1.2: Annual Production of Propene (Propylene)
World
Europe
US
Figure 1.1 below shows how the production of propylene increased from 11 million
tons in 1994 to 16 million tons in 2007 but it had dropped since that time to 14.3 million tons
in 2013.
Figure 1.1: Wastern European Propylene Capacity, Production and Consumption 1994-2013
Top world companies are leading the production of propylene with LyondellBasell,
Netherlands on top of propylene producing companies by 2009. The top propylene-producing
companies are listed as bellow:
Sinopec, China
SABIC, KSA
3.8
4
4
4
5.8
6.1
15.8
1.4.3
Propylene Consumption
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% year-on-year. The
economic recession of 2008/2009 reflected both a reduction in pull-through demand for
polypropylene, as well as a supply-chain inventory rundown, reminiscent of the early 1980s
downturn. World petrochemical industries have historically witnessed very few upheavals
that combined the effects of both energy volatility and depressed downstream demand.
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, and PetroChina jumping from the seventh
spot to number four.
World consumption of propylene is forecast to grow slightly better than global gross
domestic product (GDP) rates over the next five years. Average growth will be 5% per year,
higher than GDP in general and higher than ethylene specifically, with growth for
polypropylene being much better than that for polyethylene. Growth will be led by the
Middle East, Asia, Central and Eastern Europe, and South America at 12.5%, 6.5%, 5%, and
4.5% per year, respectively. Asia is a mixed bag of growth rates with China and India at 8
10% annually and the mature economies of Japan, the Republic of Korea, and Taiwan at 1
2% per year. Near-term growth will be relatively slow in the mature economies of North
America and Western Europe.
11
Benelux; 6
China; 19
Germany; 6
Japan`; 7
Middle east ; 7 Rep. of korea ; 8
1.4.4
local downstream plastic processing activities. Malaysia is one of the largest plastics
producers in Asia, providing a steady supply of feedstock materials for the plastic processing
industry such as propylene.
12
1.4.5
Unit: KTPA
Production
Import
Export
Consumption
2007
839
33
78
765
2008
870
40
97
811
2009
867
25
95
797
2010
808
8
50
744
change
0.3%
0%
-2%
-5%
continue rising as the demand increases for the chemical material, Capacity and Prices for
Polypropylene - End-Use Sectors in Asia-Pacific to Drive Growth" 2014 market research
report says worldwide polypropylene capacity increased at a Compound Annual Growth Rate
(CAGR) of 5.2% from 2003, reaching 65 million tons per year (MMTY) in 2013, and is
expected to continue rising to 86 MMTY by 2018, at a slightly higher CAGR of 5.8%. It
forecasts China and Russia to be the leading contributors to future polypropylene capacity
increases, and will account for a combined 45% of global additions over the next five years.
As Malaysia is part of the global market it is normal for prices in Malaysia to be affected by
the global prices, following are prices of PP and its raw material (propane, ethylene, butene
and methanol) as achieved from ICIS.com.
Price
RM/Ib
1.962
0.79
2.158
1.118
1.635
RM/Kg
4.326
1.742
4.758
2.465
3.609
13
1.5
Raw Materials
1.5.1
petroleum gas (LPG) propane. The term LPG actually encompasses more
than one variety of gaseous fuel.
gases
the classification
of
LPG.
Their
common
It turns back into gas vapor when you release some of the
pressure in the gas bottle by turning on your appliance. Almost all of the
uses for LPG involve the use of the gas vapor, not the liquefied gas.
The gases that fall under the LPG label, including Propane, Butane,
Propylene, Butadiene, Butylene and Isobutylene, as well as mixtures of
these gases. The two most common are Propane and Butane.
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 Wesfarmers Limited, with origins dating back to 1914.
They have a long history in the Australian gas industry with over 55
years of experience retailing and distributing Liquefied Petroleum Gas
(LPG), over a decade of experience distributing Liquefied Natural Gas
(LNG) and advancing technology through their brand EVOL LNG, and most
recently retailing natural gas in Western Australia.
1.5.2 Raw Material Specifications
14
Propane
80
Butane
18
CHAPTER 2
2.0
SYNTHESIS STEPS
Process synthesis involves the selection of processing operations to convert raw
materials to products, given that the states of the raw material and product streams are
specified. The most widely accepted approach for process synthesis is introduced by Rudd,
Powers, and Siirola (1973) in a book entitled Process Synthesis. There are 5 key synthesis
steps which are:
1.
2.
3.
4.
5.
2.1
16
17
Table 2.1: Physical And Chemical Properties Of Reactant And Product For
Dehydrogenation Reaction
REACTION
PROPANE
PROPYLENE
HYDROGEN
Properties
Molecular formula
C3H8
C3H6
H2
Molar mass
44.10 g mol1
42.08 g mol1
2.016 g mol-1
Appearance
Colourless gas
Colourless gas
Colourless gas
Odor
Odourless
Gassy/ aromatic
Density
C, 101.3 kPa)
bar, 15 C)
101.325 kPa)
3
Boiling point
187.7 C; 305.8 F;
,185.2 C (301.4 F;
13.99 K (259.16 C,
85.5 K
88.0 K)
434.49 F)
42.25 to 42.04 C;
47.6 C (54 F;
20.271 K (252.879 C,
44.05 to 43.67 F;
226 K)
423.182 F)
230.90 to 231.11 K
Solubility in water
40 mg L1 (at 0 C)
0.61 g/m3
Vapor pressure
144.06 psia
100kPa (at 20 C)
Thermochemistry
105.2104.2 kJ mol1
+20.41 kJ/mol
Std enthalpy of
2.21972.2187 MJ
-2058.4 kJ/mol
-285.84 kJ/mol
combustion cHo298
mol1
Std enthalpy of
o
formation fH 298
To screen out whether this reaction will bring profit or not, the gross profit is calculated as
shown below:
C3H8 C3H6 + H2
18
C3H8
C3H6
H2
Molecular weight
44.09
42.08
2.016
lb
44.09
42.08
2.016
1.0478
0.048
0.79
1.96
11.30
lbmol
lb/lb of propylene
RM/lb
Gross profit for reaction path 1 = 1.96(1) + 11.30(0.048) 1.0478(0.79) = RM 1.67 /lb
propylene
B. Propylene from Ethylene and Butenes via Metathesis
Metathesis is a general term for a reversible reaction between two olefins, in
which the double bonds are broken and then reformed to form new olefin products. In
order to produce propylene by metathesis, a molecule of 2-butene and a molecule of
ethylene are combined to form two molecules of propylene. Some of the
thermophysical property data is shown on table 2.
Metathesis Reaction
19
20
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 C 2 tower bottom is processed in
the C3 tower to produce propylene product and a C 4 recycle stream. Purge streams
containing non-reactive light material, C4s and heavier are also produced. Ultra-high
purity propylene exceeding polymer grade specification is produced without a
propylene fractionation system, since the only source of propane is that contained in
the C4 and ethylene feeds.
Table 2.2: Physical And Chemical Properties Of Reactant And Product For Metathesis
Reaction
REACTION
BUTENE
ETHYLENE
PROPYLENE
Properties
Molecular formula
C2H4
C4H8
C3H6
Molar mass
28.05 g/mol
56.10 g/mol
42.08 g mol1
Appearance
Colorless gas
colorless
Colorless gas
Odor
Odorless
odorless
Gassy/ aromatic
Density
0.62 g/cm3
Melting point
Boiling point
Solubility in water
169.2 C (104.0 K,
185.3 C (301.5 F;
,185.2 C (301.4 F;
-272.6 F)
87.8 K)
88.0 K)
103.7 C (169.5 K,
6.47 C (20.35 F;
-154.7 F)
266.68
0.61 g/m3
Thermochemistry
Std enthalpy of
52.28 kJ mol1
1.17 kJ/mol
+20.41 kJ/mol
-1410.99 kJ mol1
-2718.6 kJ/mol
-2058.4 kJ/mol
formation fH 298
Std enthalpy of
combustion cHo298
21
To screen out whether this reaction will bring profit or not and whether it is better from
reaction A, the gross profit is calculated as shown below:
C2H4 + C4H8 2C3H6
C2H4
C4H8
C3H6
Molecular weight
28.05
56.10
42.08
lb
28.05
56.10
84.16
lb/lb of propylene
0.33
0.667
RM/lb
2.16
1.18
1.96
lbmol
Gross profit for reaction path 2 = 1.96(1) 2.16(0.33) 1.18(0.667) = RM 0.46 /lb
propylene
22
RM 1.67 / lb propylene
RM 0.46/lb propylene
Continuous process
Continuous process
Butane and ethylene is
Safety
Propane is flammable.
By-product
Operating
condition
Hydrogen
Temperature: 560 650 C
Pressure : slightly below atmospheric
pressure
No by-product
Temperature: 90-100C
Pressure: 100 110 bar
Conversion
Flammability
Flammable
Flammable
From the table above, it shows that the dehydrogenation of propane reaction is a better
process compared to the metathesis reaction.
2.2
2.2.1
m1C3H8
F lb/hr C3H8
m2C3H6
m3H2
gd
R lb/hr C3H8
C3H6 + H2
C3H8
C3H6
H2
stoichiometry
m1
m2=100,000.00
m3
MW (lb/lbmol)
44.10
42.08
2.01
n, (lbmole/hr)
2376.43
2376.43
2376.43
Assume 100% conversion, the mass flow rate of feed, m1 = 2376.43 x 44.1
= 104800.56 lb/hr
for 86% conversion, the mass flow rate of recycle, R = (1-0.86)/0.86 x 104800.56
R = 17060.53 lb/hr
24
Mass flowrate of H2 , m3
= (no. of mole) X (molecular weight)
= (2376.43) x (2.01)
= 4776.62 lb/hr
F = m1 + R
= 104800.56 + 17060.53 = 121861.09lb/h
25
2.3
0.99 C3H8
0.009
C4H10
0.001
C5H12
52.C
Pt-Sn
Reactor
600C, 1.0
bar
H2
C3H8
C3H6
C4H8
C4H10
C5H12
H2
-137.1c
C3H6
C3H8
40C
10 bar
17.5 bar
S2
S1 15 bar
LPG:
C3 H 8
C4H10
C5H12
110.7
C
C4H10
C5H12
137.1
C
C3H6
33C
S3
S4 15 bar
42C
-137.1C
C3H8
C3H6
C4H8
C4H10
C5H12
108.4
C
C4 H 8
C4H10
C5H12
42C
C3 H 8
In order to enable all chemicals involved to be supplied to their sinks, separation operations are
needed. Figure 2.5 shows the separation units that are needed 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 from butane and pentane. However, the separation is not perfect.
There will still have some butane and pentane that will 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
mixtures at the bottom product is 110.7C.
When the separation between propane, butane and pentane is done, propane as a reactant will enter the
reactor which will be operate at 600C and 1 bar. These pressure and temperature is selected because the
dehydrogenation process of propylene only will occur at these conditions.
After the reaction occurs, there have a lot of products produced. In order to separate the products, 3
separation units will be used. The first product that will be 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
26
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 product mixture.
Next, after separate hydrogen gas, we will separate propane and propene from the side product. From
Table 2.4 at 1 atm, the boiling point of C 3 is very low, - 48C, and hence if C 3 were recovered at 1 atm as the
distillate of the S3, very costly refrigeration would be necessary to condense the reflux stream. At 18 bar , the
bubble point of propane and propylene mixture is at 40C and much less cost refrigeration could be used. The
bottom products which are consists butane, butene and pentane has a dew point 108.4C at 17.5 bar.
After separation unit S3 is inserted into the process design, S4 follows naturally. The distillate from S3
is separated into nearly pure species in the S4, which is 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
available at 25C. However, S4 need special separation unit due to small difference of boiling point between
propane and propylene.
Chemical
H2
C3H8
C3H6
Normal
boiling
point
(1atm,
C)
-252.78
-42.11
-47.62
Critical constant
17.5 bar
20 bar
Tc (C)
PC (bar)
41.00
33.00
45.00
35.85
53.55
42.65
-240.01
96.74
91.06
12.96
42.51
45.55
27
2.4
Figure 2.6: Flowsheet with temperature-, pressure-, and phase-change operations in the propylene production process.
28
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, only 99% of LPG is converted to propane gas where another 1% is butane gas and pentane
gas.
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. The mixing of upper products from S1 and recycle
propane undergoes the following operations:
1. The product mixture is preheated before it is introduced to the reactor. The reaction occurs at around
600oC and 1 bar.
2. The products mixture is then cooled to its dew point -137.1oC at 10 bar.
3. Then, the product mixture is introduced into a condenser (S2) that separates the hydrogen gas from
other liquid products.
In addition, the liquid mixture that condensed at -137.1 oC at 10 bar from the condenser is operated upon as
follows:
1. Its pressure is increased to 17.5 bar.
2. The temperature is then raised to a liquid at its bubble point, 42oC at 17.5 bar.
3. Then, the liquid mixture is introduced into a separation column (S3) that separates the propane gas and
propylene gas from other liquid products.
Next, the upper products (propane gas and propylene gas) from separation column (S3) are then entered
into separation column (S4) at 40 oC. The propylene gas with a boiling point of 33 oC at 15 bar is come out as
an upper product from separation column (S4).
Finally, the propane liquid from the recycle stream (at 42 oC and 15 bar) undergoes the operation where its
temperature is raised to the mixing temperature at 47 oC at 15 bar.
29
2.5
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 flowsheet is sufficiently promising to undertake the preparation of a base case design. Below are the
descriptions of unit process shown in Figure 2.7:
1. Heat exchanger
Heat exchanger is needed to increase or decrease the temperature of the stream. A heat exchanger is a
piece of equipment built for efficient heat transfer from one medium to another. The media may be
separated by a solid wall to prevent mixing or they may be in direct contact.
2. Depropanizer
A propane rich liquefied petroleum gas (LPG) feedstock is sent to a depropanizer to reject butanes and
heavier hydrocarbons.
3. Furnace
Since the outlet temperature from the mixer is 47C and we need to increase the temperature to 600C,
the furnace is used to heat up the stream. This follows heuristics 26 which explained near-optimal
minimum temperature approaches in heat exchangers depend on the temperature level. For 250 to
350F, the 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 as reactor which provides heats of reaction. Furnace designs vary as to its function,
heating duty, type of fuel and method of introducing combustion air.
4. Oleflex Reactor
The UOP Oleflex process is a catalytic dehydrogenation technology for the production of light olefins
from their corresponding paraffins. One specific application of this technology produces propylene
from propane. The Olexflex process uses a platinum catalyst to promote the dehydrogenation reaction
5. Pump
Since the pressure change operation involves a liquid, it is accomplished by a pump, which requires
only 66 Bhp, assuming an 80% efficiency. The enthalpy change in the pump is very small and the
temperature does not change by more than 1C
6. Distillation Column
To separate the mixture of C3 and butane, butane and pentane, distillation column is selected as the best
separation unit. Distillation is based on the fact that 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
30
condensate will contain more volatile components. At the same time, the original mixture will contain
more of the less volatile material.
7. Propane-Propylene Splitter
C3 splitters are frequently designed with vapor-recompression heat pumps when sufficient low-energy
heat sources are not available. The heat of vaporization of propylene and propane at 100psia are nearly
identical. The only energy needed for a C 3 splitter heat pump is the compressor duty, which is typically
only 11-12% of the total reboiler duty. Therefore, the energy savings are significant. In addition, C 3
splitter heat pump system operates at much lower pressure than conventional columns without heat
pumping. The high-pressure compressor discharge stream is the same as the conventional towers top
pressure.
31
Figure 2.7:
P-P Splitter
32
CHAPTER 3
3.1
MATERIAL BALANCES
3.1.1
m1C3H8
F lb/hr C3H8
m2C3H6
m3H2
gd
R lb/hr C3H8
C3H6 + H2
C3H8
C3H6
H2
stoichiometry
m1
m2=100,000.00
m3
33
MW (lb/lbmol)
44.10
42.08
2.01
n, (lbmole/hr)
2376.43
2376.43
2376.43
34
3.1.2
D1 lb/hr
C3H8
C4H10
0.001 C5H12
0.990
0.009
F1 lb/hr
S-1
C3H8
0.18 C4H10
0.02 C5H12
0.80
B1 lb/hr
0.90 C4H10
0.10 C5H12
Stream 1
Stream 2
Stream 3
No
.
Component
Mole
Fraction
Propane
0.80
104800.56
0.990
104800.56
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
Mass
Flowrate,
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
35
3.1.3
D1 = 106263.1 lb/hr
C3H8
0.009 C4H10
0.001 C5H12
0.990
F = 123323.6 lb/hr
M-1
a1 C3H8
a2 C4H10
a3 C5H12
10
R = 17060.53 lb/hr
1.0
Stream 3
C3H8
Stream 4
Stream 10
No
.
Component
Mole
Fraction
Propane
0.990
104800.56
0.991
121861.09
1.0
17060.53
Butane
0.009
1116.11
0.007
1116.11
Pentane
0.001
346.38
0.002
346.38
Mass
Flowrate,
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
36
3.1.4
123299.61 lb/hr
R-1
C3H8
C4H10
C5H12
C3H6
C4H8
H2
The percentage of conversion for propane and butane are 86% and 90% respectively and since the weight
percent of pentane is too small, we assume that pentane is remain unreacted.
Stream 4
Stream 5
No.
Component
Mole
Fraction
Mass Flowrate,
(lb/hr)
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
Mole
Fraction
Mass Flowrate,
(lb/hr)
H2 4811.36 lb/hr
123299.61 lb/hr
3.1.5
6
5
C3H8
C4H10
C5H12
Mass Balance
for Separation Unit 2
C3H6
C4H8
H2
S-2
7
C3H8
C4H10
C5H12
C3H6
C4H8
118488.25 lb/hr
37
Stream 5
Stream 6
Stream 7
No.
Component
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)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
38
3.1.6
118488.25 lb/hr
C3H8
C4H10
C5H12
C3H6
C4H8
C3H8
C3H6
S-3
1427.57 lb/hr
C4H10
C5H12
C4H8
Stream 7
Stream 8
Stream 9
No.
Component
Mass
Mole
Flowrate,
Fraction
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
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
Mole
Fraction
Mass
Flowrate,
(lb/hr)
39
3.1.7
11
100000 lb/hr
C3H6
117060.68 lb/hr
S-4
C3H8
C3H6
17060.53 lb/hr
10
Stream 8
C3H8
Stream 1
Stream 11
No.
Component
Mole
Fraction
Mass
Flowrate,
(lb/hr)
Mole
Fraction
Mass
Flowrate,
(lb/hr)
Propane
0.140
17060.53
17060.56
Propene
0.860
100000
100000
Mole
Fraction
Mass
Flowrate,
(lb/hr)
40
3.2
ENERGY BALANCES
Table 3.1: Table of Data for Heat of Capacities
Cp=A+B*T+C*T^-2+D*T^-3
Compound
Molecula
r Weight
Cp=A+B*T+C*T^-2+D*T^-3
H f
H v
Kj/mol
A*10^
3
B*10^
5
C*10^
8
D*10^1
2
Average
Cp for
liquid
KJ/
(mol.K)
Propane
44.09
103.
8
Propene
42.08
20.4
1
18.4
2
59.58
17.71
-10.17
24.6
0.1199
Butane
58.12
124.
7
22.3
06
92.3
27.88
-15.47
34.98
0.13367
Butene
56.1
1.17
21.9
16
82.88
25.64
-17.27
50.50
0.09396
Pentane
72.15
146.
4
25.7
7
114.8
34.09
-18.99
42.26
0.167
Hydroge
n
2.016
0.90
4
28.84
0.007
65
0.3288
0.8698
18.7
7
68.02
3
22.59
-13.11
31.71
0.10584
Energy Balance
41
T1
(Vapor)
k
QL n xk [ C po.k (T )dT H f , k (T2 ) H vap
(T1 )]
T2
Where,
T1
(Liquid)
For streams with composition or component change (i.e. reactor), heat of formation
must be included.
D1 lb/hr
C3H8
C4H10
0.001 C5H12
0.990
0.009
F1 lb/hr
S-1
C3H8
0.18 C4H10
0.02 C5H12
0.80
For Stream 1
B1 lb/hr
0.90 C4H10
0.10 C5H12
Liquid phase
Stream temperature, T = 325.13 K and consider datum at 298.13 K
42
Component
Flow rate
Ibmole/hr
Flow rate
mole/hr
Cp
H
KJ/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
4077274.484 KJ/hr
For Stream 2
Liquid phase
Stream temperature, T = 320.13 K and consider datum at 298.13 K
Componen
t
Flow rate
Ibmole/hr
Flow rate
mole/hr
Cp
liquid
Propane
2376.43
1077924.
884
0.10584
2509926.5
34
Butane
19.203
8710.288
0.13367
25614.69
Pentane
4.8
2177.23
0.167
7999.14
2543540.36 KJ/hr
43
For Stream 3
/Stream temperature, T = 377.13 K and consider datum at 298.13 K
Component
Flow rate
Ibmole/hr
Flow rate
mole/hr
Cp
liquid
Butane
8.86
4018.8
0.13367
42438.24
Pentane
0.756
342.91
0.167
4524.011
46962.25 KJ/hr
3.2.2
Heat exchanger 1
44
Component
Flow rate
Ibmole/hr
Propane
2376.96
Butane
534.7
Pentane
59.41
Flow rate
mole/hr
1077948.6
4
Cp
0.10584
3650882.69
242535.38
0.13367
1037430.53
26948.37
0.167
144012.08
4832325.3 KJ/hr
45
3.2.3
Furnace
Component
Flow rate
Ibmole/hr
Flow rate
mole/hr
CpdT
H
KJ/hr
Propane
2376.43
1077948.6
4
69.62
75046784.32
Butane
534.69
242535.38
90.91
22048891.4
Pentane
59.41
26948.37
112.17
3022798.66
3.2.4
100118475 KJ/hr
Stream outlet
1C
(Mixture
phase)
Stream
inlet
600C
(Gas
Stream inlet at 600C datum at 25C
Compound
H2
C 3 H8
C 3 H6
C4H10
C 4 H8
C5H12
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
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
47
3.2.5
Stream 5
1C
Flash separator
Stream 7
1C
Stream 5 (Feed Stream) at 1C datum at 25C
Compound
H2
C 3 H8
C 3 H6
C4H10
C 4 H8
C5H12
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
Flowrate
(mol/hr)
2393.7
CpdT
(kJ/mol)
nH
-0.6922
-1656.91914
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
Flowrate
(mol/hr)
386.86
2376.4
1.9203
17.283
4.8009
2787.2642
Q= H=0
48
Q = nHout - nHin
=(-7885.019431+ (-1656.91914)) (-9541.938571)
= 0 kJ/hr
3.2.6
Stream
inlet
1C
Stream
outlet
42C
49
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
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
Flowrate
(mol/hr)
386.86
2376.4
1.9203
17.283
4.8009
2787.2642
Q = nHout - nHin
= 3178.642106 (-7885.019431)
= 63273.40588 kJ/hr
3.2.7
STREAM INLET
1 bar
600C
STREAM
OUTLET
10 bar
600C
Inlet (stream 2)
Phase
Component
Vapor
Mixture
50
Pressure (bar)
Temperature (oC)
600
2349.64
Outlet (stream 3)
Phase
Vapor
Component
Mixture
Pressure (bar)
10
Temperature (oC)
600
2349.64
T 2 =T 1
P2
P1
( 1 )
( )
T 2 =600
10
1
(1 .31 .31 )
( )
1020.75 C
For energy balance,
Q= H = ni ^
H i ni ^
Hi
out
ni
out
298.15
C p dT ni
C p dT
298. 15
1293.9
Q= H =ni
298.15
1293.9
298.15
51
175.44+144.36+227 +197.87+278.61+30.52
)
2349.64
= 2476050.63 kJ/hr
3.2.8
117060.68 lb/hr
8
118488.25 lb/hr
C3H8
C4H10
C5H12
C3H6
C4H8
C3H8
C3H6
S-3
1427.58 lb/hr
9
For Stream 7
Liquid stream
C4H10
C5H12
C4H8
Flow rate
(lbmol/hr)
Flow rate
(mol/hr)
Cp
CpdT
(kJ/mol)
nH
kJ/hr
52
Propane
386.86
1.75447 105
0.10584
1.7993
315681.79
Butane
1.92
870.748
0.13367
2.2724
1978.69
Pentane
4.80
2176.871
0.167
2.8390
6180.14
Propene
2376.43
10.777 x 105
0.1199
2.0383
2196675.91
Butene
17.28
7836.735
0.09396
1.5973
12517.62
2533034.15
For Stream 8
Gas stream
Stream temperature, T = 317.15 K and consider datum at 298.15 K
Component
Flow rate
(lbmol/hr)
Flow rate
(mol/hr)
Cp
CpdT
(kJ/mol)
nH
kJ/hr
Propane
386.86
1.75447 105
0.10584
2.0110
352823.92
Propene
2376.4
1077732.426
0.1199
2.2781
2.45518 106
2.8080 x 106
For Stream 9
Liquid stream
Stream temperature, T = 381.55 K and consider datum at 298.15 K
Component
Flow rate
(lbmol/hr)
Flow rate
(mol/hr)
Cp
CpdT
(kJ/mol)
nH
kJ/hr
53
Butane
1.9203
870.884
0.13367
11.1481
9708.70
Butene
17.283
7838.095
0.09396
7.8363
61421.66
Pentane
4.80
2176.871
0.1670
13.9278
30319.02
101449.38
3.2.9
D1 lb/hr
C3H6
F1 lb/hr
8
S4
C3H8
C3H6
12
B1 lb/hr
C3H8
For Stream 8
Liquid stream
Stream temperature, T = 318.15 K and consider datum at 273.15 K
Component
Flow rate
(lbmol/hr)
Flow rate
(mol/hr)
Cp
CpdT
(kJ/mol)
nH
kJ/hr
54
Propane
386.95
1.75517 105
0.10584
4.7628
8.35952 105
Propene
2376.43
10.77929 105
0.1199
5.3955
58.15965 105
66.51917 105
For Stream 11
Gas stream
Stream temperature, T = 309.15 K and consider datum at 273.15 K
Component
Flow rate
lbmol/hr
Flow rate
(mol/hr)
CpdT
(kJ/mol)
nH
(kJ/hr)
Propene
2376.43
10.77929 105
2.258
24.33963 105
24.33963 105
For Stream 12
Liquid stream
Stream temperature, T = 320.15 K and consider datum at 273.15 K
Component
Flow rate
(lbmole/hr)
Flow rate
(mol/hr)
Cp
CpdT
(kJ/mol)
nH
(kJ/hr)
Propane
386.95
1.75517 105
0.10584
4.97448
8.73105 105
8.73105 105
55
3.2.10
Pump (P1)
outlet
inlet
Component
Molar volume,v(kmol/m3)
Fv
21.9375
23.2486
0.09667
0.09048
0.11452
3849.50
25055.81
0.08410
0.70918
0.24942
Inlet Stream
Phase
Pressure (bar)
Temperature (oC)
Liquid
1
-47
Outlet Stream
Phase
Pressure (bar)
Temperature (oC)
Liquid
18
-47
Q = Fv ( P)
Q = 28906.35 (18 -1) = 4.91408 105 kJ/hr
56
4
121861.09 lb/hr C3H8
+
1116.11 lb/hr C4H10
346.38 lb/hr C5H12
R-1
0.991 C3H8
0.007 C4H10
0.002 C5H12
C3H6 + H2
^
Hr1
2. C4H10
C4H8 + H2
^
Hr2
>
1. C3H8
C3H8
C4H10
C5H12
C3H6
C4H8
H2
>
>
C3H8 (g), 298K (25C), 1 bar
^ R 1+ n ^
Q1=n H = n H
H p 1+ ^
H r 1
(for Propane)
^ R 2 +n ^
Q2=n H =n n H
H p 2+ ^
H r 2
(for Butane)
Q=Q 1 +Q 2
57
^
H p1
^
Hr1
1253192.74
2330911.57
-91.8
184.72
-115043093.5
430565985.2
140.21
Component
Flow rate
(mol/hr)
Specific
^
Enthalpy, H
(kJ/mol)
H
(kJ/hr)
315523031.9
^
H p2
^
Hr2
8708.84
16547.07
-119.0
240.61
-1036351.96
3981390.5
125.87
Component
Flow rate
(mol/hr)
Specific
^
Enthalpy, H
(kJ/mol)
H
(kJ/hr)
1945164.41
Q=Q 1 +Q 2
Q=315523031.9
kJ
kJ
+1945164.41
hr
hr
59
3.3
3.3.2
3.4
Material Balance
Stream no.
Mass
(lbmole/hr)
(Hysys)
stream 1
stream 2
stream 3
stream 4
stream 5
stream 6
stream 8
stream 9
stream 10
stream 11
stream 12
stream 13
stream 14
stream 15
stream 16
stream 17
stream 23
stream 24
stream 25
3179
3179
769.4
2410
2523
2523
4692
4692
4692
4692
2533
2159
2533
2533
156.3
2377
2263
113.4
113.2
Energy Balance
Equipment
Energy, kJ/h
(HYSYS)
Q-HE00
Q-HE01
Q-HE02
Q-Furnace
Q-Compressor
Q-Pump
5.76E+06
1.79E+08
1.65E+07
9.23E+07
6.78E+07
6.90E+04
Mass Balance
60
Stream no.
3.4.2
Energy
stream 1
stream 2
stream 3
stream 4
stream 5
stream 6
Equipment
stream 8
stream 9
stream 10
Q-HE00
stream 11
Q-HE01
stream 12
Q-HE02
stream 13
stream 14
Q-Furnace
stream 15
Q-Compressor
stream 16
Q-Pump
stream 17
stream 23
stream 24
stream 25
Mass
(lbmole/hr)
(manual)
2971
2971
721.5
2400.4
2787.3
2787.3
Energy,
kJ/h
5181
(manual)
5181
5181
4.83E+06
5181
1.80E+06
2787
6.33E+04
2393
2787
1.00E+08
2787
2.48E+06
165.4
4.91E+05
2663.5
2376.4
124.5
124.5
Mass
(lbmole/hr
)
(Hysys)
% Diff
3179
3179
769.4
2410
2523
2523
Energy, kJ/h
4692
(HYSYS)
4692
4692
5.76E+06
4692
1.79E+08
2533
1.65E+07
2159
2533
9.23E+07
2533
6.78E+07
156.3
6.90E+04
2377
2263
113.4
113.2
6.54
6.54
6.23
0.40
Balance
10.48
10.48
% Diff
10.42
10.42
10.42
10.4216.09
10.0399.00
10.8499.62
10.03 8.46
10.0396.35
5.82612.70
12.05
5.01
9.79
9.98
CHAPTER 4
HEAT INTEGRATION
4.1
Tmin = 10C
61
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
Cold
-136.8
30
0.028
T (C)
0.04
9
T (C)
865.70
H1
4.2
C3
Algorithm Table
FCpC -FCpH
(MW/K)
Hi (MW)
0
284.4
-0.049
13.94
526.22
-0.001
-0.52622
55.08
14.46
6.23
48.85
0.052
0.32396
C2
14.14
0.04
8
13.85
0.004
0.0554
35.00
14.08
10
0.032
0.3200
C1
13.76
0.05
3
-131.80
Pinch
-13.9356
581.30
25.00
1st Cascade
156.8
-0.021
-3.2928
C3
0.02
8
17.06
10.3
-0.049
-142.10
-0.5047
17.56
Qc
62
4.3
H (MW)
T pinch
FCp(MW/K)(870.7C)
1.5942
0.053
C1
50.08
25.5576
0.048
20
C2
576.3
4.6704
43.85
0.028
C3
30
-136.8
H1
49.3822
0.049
870.7
E11
25.5576
E22
E3
1.5942
C
4.6704
-137.1
17.56
TH,out(C)
TC,in (C)
TC,out (C)
E1
E2
870.7
349.12
349.12
316.59
43.85
20
576.3
50.08
E3
316.59
221.28
-136.8
30
221.28
-137.1
4.4
CHAPTER 5
OPTIMIZATION
Optimization is the tool to maximize our profit by minimizing the supply of raw material and
maximizing the product. In this case, our target that we want to maximize it the production of propene
(100000 Ib/hr) and our supply that we want to minimize it is the propane which is initially set to 104800
Ib/hr depending on the stoichiometric coefficient of (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
USD RM/Ib
0.79
1.96
11.3
Step 1:
Define decision variables:
P1= amount of product (Propene)
P2=amount of byproduct (Hydrogen)
R=amount of reactant (Propane)
Z=maximum profit
Step 2:
Define objective function
Maximum profit (Z) = (1.96*P1 +11.3*P2)-(0.79*R)
Step 3:
Propene production
b) Equality constraints
R= 1.048*P1
P2=0.0457*P1
c) Non-negativity constraint
R, P1, P2 0
Step 4
Optimization technique
We used solver add-in in Microsoft excel:
P1=100000 Ib/hr
P2=4789.36 Ib/hr
R=104800 Ib/hr
Z=167327.768 RM/hr
After optimization the maximum profit is close to the manually calculated one= RM 167327.768/hr.
CHAPTER 6
6.1
Introduction
In this chapter, the equipment sizing is done to all equipment that is involved in the proposed propylene production plant.
Equipment sizing is a very important aspect of process design as it enables the subsequent analysis that is involved in process design
such as mechanical design and economy analysis. The sizing involves the reactors, distillation column, compressor, pump, and heat
exchangers.
6.2
Reactor
6.2.1
Sizing of Reactor
Parameter
6.2.2
SI
Volumetric Flowrate , Q
3517.02 ft3/hr
5 min
Reactor Volume, V
586.17 ft3
7.20 ft
Vessel Length, L
14.4 ft
Design Type
Vertical
Material of Contruction
Costing of Reactor
6.3
Pump
6.3.1
Sizing of Pump
6.3.2
P(2.31)
SG
= 356.82 ft
Costing of Pump
6.4
Distillation Column
6.4.1
Parameters
Domed head wall
S1
13.7 mm
thickness, a
Tray spacing, b
2ft
Column diameter, c
6.05 ft
Design type
Vertical
Material of Construction
Carbon steel
Material of insulation
Costing in $:
0.5 in
Mineral
wool,60mm
Column type
Plate column
Plate type
Sieve
Torispherical
6.4.2
S1
13.7 mm
thickness,
Vessel length,L
8.924 ft
vessel diameter, D
17.85 ft
0.562 in
Design type
Vertical
Material of Construction
Carbon steel
Material of insulation
Mineral
wool,60mm
After bare-model:
Cost= $ 223290
6.4.3
Parameters
Length of tube
S1
20 ft
Area of transfer,Ac
273.1 ft2
Material of Construction
Carbon steel
fixed head,
Type of HE
shell tube
exchanger
Cp= $ 21721
After bare-module,
Cost= $ 68857
6.4.4
Parameters
Length of tube
S1
20 ft
Area of transfer,AR
3.146 ft2
Material of Construction
Carbon steel
Type of HE
kettle reboiler
Vessel or Equipment
main vessel
Cost in $
484809
223290
the condenser
68857
the re-boiler
207080
Total
984036
CB= $ 65325
With bare-module
$ 3.17(65325) = $ 207080
6.5
Compresssor
6.5.1
Parameters
Compressor Type
Drive Type
Material of Construction
Inlet Volumetric Flow Rate, QI
Inlet Pressure, PI
Outlet Pressure, PO
Specific Heat Ratio, k
6.5.2
Costing in $:
6.6
Heat Exchanger
6.6.1
Compressor
Centrifugal
Steam turbine
Stainless steel
83283.83 ft3/min
14.5 psi
72.52 psi
1.10
Cold
Tin (C)
870.7
43.85
Tout (C)
349.12
576.3
LM
LM 314.74 o F
870.7 349.12
576.3 43.85
R 0.98
576.3 43.85
870.7 43.85
S 0.644
Ai 86.34 ft 2
Velocity of tube-side;
99.59m 3 144in 2 / ft 2 35.3145 ft 3
ui
x
x
hr
0.302in 2
m3
u i 1.68 x10 6 ft / hr
111244.12lb
ft 3
hr
x
x
hr
0.421lb 1.68 x10 6 ft
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;
0.302in 2
ft 2
x
tube
144in 2
Inside area/tube =
= 2.097x10-3 ft2/tube
Nt
0.157 ft 2 / pass
2.097 x10 3 ft 2 / tube
N t 75tubes / pass
Area per tube;
86.43 ft 2
4 passx 75tubes / pass
=
= 0.288 ft2/tube
0.288 ft 2 / tube
0.62in
x
12in / ft
L = 5.58 ft
6.6.2
Ai 86.34 ft 2
FBM = 3.17
F M =1.08+(
86.34 0.5
)
100
= 2.01
FL = 1.25 (Tube length = 5.58 ft2)
F P=0.9803+ 0.018
145.04
145.04 2
+0.0017 (
)
100
100
= 1.01
Fixed head:
C B=exp {11.05450.9228 [ ln ( 86.34 ) ] +0.09861 [ ln ( 86.34 ) ]
= $7,334.88
CHAPTER 7
7.1
By using method 3, which is based on the individual factors method of Guthrie, 1969, 1974 there are few steps to find the total
capital investments, CTCI.
Firstly, we need to prepare an equipment list, giving the equipment tittle, label, size, material of construction, design
temperature, and design pressure.
Equipment
Tittle
Labe
l
Size
Material of
Construction
Design
Temp.
(C)
Design
Pressure (bar)
Baremodule
Cost, CBM
Reactor
R1
Low- Alloy
Steel SA-387B
576
$ 243, 772
Pump
P1
V=586.17 ft3
Di = 7.20 ft
L= 14.4 ft
H =356.82 ft
Cast Steel
-137.1
$ 37,183
Distillation
Column
S1
D = 6.05 ft
t = 0.5 in
Carbon steel
50
Pinlet = 10
Poutlet = 17.5
15
Compressor
C1
Carbon Steel
526
Heat
Exchanger
HE2
Q = 83283.83
ft3/min
A = 86.34 ft2
Carbon Steel
870.7
Pinlet = 1
Poutlet = 10
10
CTBM
$ 984,036
$ 15,757,144
$ 59,003
$17,081,138
After we get the value of total bare module cost, CTBM, we need to find the site development cost, Csite, building cost, Cbuildings,
and offsite facilities cost, Coffsite facilities by assuming some factor. The calculation of total capital investment cost is shown below:
Assume it is grass-roots plant, the value fo CSITE is 10-20% of CTBM. Assume we take 15% of CTBM.
CSITE = 0.15 (17,081,138)
CSITE = $ 2,562,170.75
Thus,
CTCI = CTPI + CWC
CTCI = $ 39,969,863.01+ $ 7,034,695.89
CTCI = $ 47,004,558.90
7.2
Payback Period
Payback period is the time in which the initial cash outflow of an investment is expected to be recovered from the cash inflows
The formula to calculate payback period of a project depends on whether the cash flow per period from the project is even or
uneven. In case they are even, the formula to calculate payback period is:
Initial Investment
Cash Inflow per Period
Payback Period =
RM 152,764,816.40
RM 167,327.77 /hr
912.967 hr
1day 1 month
24 hr 30 days
= 1 month 9 days
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 subsequently used to manufacture a large variety of
substances and products. Example of such product is propylene, 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 shows that the production of propylene has its
demand in the global industry, hence a good marketability, especially in recent years where the price of propylene in the market is
expected to continue rising as 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, reaching 65 million tons per year (MMTY) in
2013, and is expected to continue rising to 86 MMTY by 2018, at a slightly higher CAGR of 5.8%. As Malaysia is a part of the global
market, it can be expected that prices in Malaysia to be affected by the global prices.
In terms of reaction pathways for this particular project, a screening process was done based on gross profit, economic
potential as well as other factors related 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 of
ethylene and butene. From the screening process, it was shown that dehydrogenation of propane reaction is a 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 plant design.
In addition to the reaction pathways and process screening, a process synthesis for the production of propylene from
dehydrogenation of propane was done by following the steps that was introduced by Rudd, Powers, and Siirola. From these steps, a
general overview of the whole process, starting from the raw materials into products is translated into a process flow diagram, as well
as the operating parameters were obtained. This is an important step in designing the production process of our desired product before
performing a further optimization of the processes and unit operations involved.
In a nutshell, after we had done a simulation, optimization and process integration, our total capital investment is $
47,004,558.90.
APPENDICES A
2. Separation Unit 1
Overall mass balance :
F 1 = D 1 + B1
From the overall mass balance, we know that the mass flowrate of propane at D1 is 104800.56 lb/hr and the composition is assume
0.990 of C3H8, so
0.990 D1 = mass flow rate of C3H8
D1 = mass flow rate of C3H8 / 0.990
= 104800.56 / 0.990
= 106263.1 lb/hr distillate
Propane balance :
0.8 F1 = 0.990 D1
F1 = (0.990 x 106263.1)/0.8
F1 = 140163.6 lb/hr feed
F 1 = D 1 + B1
B1 = 140163.6 106263.1
B1 = 33900.6 lb/hr of bottom product
3. Mixer
Overall mass balance :
F = D1 + R
from previous calculation, the value of D1 = 106263.1 lb/hr and R = 17060.53 lb/hr. Hence,
F = 106263.1 lb/hr + 17060.53 lb/hr = 123323.6 lb/hr
Propane balance :
Butane balance :
4. Reactor
For dehydrogenation of propane, 0.86% of propane is converted. The unreacted propane recycled.
(a) Mass flowrate of propane recycle
R = (1-0.86)/0.86 x 104800.56
R = 17060.53 lb/hr
(b) no of mol of propane recycle
= 17060.53/ 44.1 = 386.9 lbmole/hr
(c) no of mole of propene produce
= (121861.09 / 44.1) x 0.86 = 2376.64 lbmole/hr
(d) no of mole of butene produce
= 1116.106 / 58.12 x 0.9 = 17.28 lbmole/hr
(e) no of mole of hydrogen produce
= no of mole of hydrogen from propane + no of mole of hydrogen from propane
APPENDICES B
lbmol
1 kgmol
1000 mol
x
x
= 1253197.28mol/hr
hr
2.205 lbmol 1 kgmol
H R1=
C p(reactant) dt
873 K
298 K
H R1=
873 K
H R 1 =91.81kJ /mol
298 K
H R1=
873 K
C p( product ) dt
873 K
H p 1=
( 68.023 103 +22.59 105 T13.11 108 T 2 +31.71 1012 T 3 ) dt+ ( 59.58 103+17.71 105 T 10.17 108 T 2+24.6 1012 T 3 ) dt + ( 28
298 K
(119.8 ) kJ
20.41 kJ
+0
=140.21 kJ /mol
mol
mol
APPENDICES C
ASPEN HYSYS
APPENDICES D
Q=FCpCT
25.5576 = 0.048 (T 43.85)
T = 576.3
E2
Q=FCpHT
1.5942 = 0.049 (349.12-T)
T = 316.59C
Q=FCpCT
1.5942 = 0.053 (T-20)
T = 50.08C
E3
Q=FCpHT
4.6704 = 0.049 (316.59-T)
T = 221.28C
Q=FCpCT
4.6704 = 0.028 (T136.8)
T = 30C
APPENDICES E
REACTOR
Q = 3517.02 ft3/hr
Retention time =5 min at half full :
Volume, V = (3517.02 ft3/hr) (
5 min 1 hr
60 min
2 ) = 586.17 ft3
Assume L/ D = 2
V=
(D/2)2L = ( D3)/2
E = 1.0
tP =
21.48 7.2 12
2 ( 10993.86 ) ( 1.0 )1.2(21.48)
= 0.085 in
PUMP
Pressure inlet, P1 = 1000kPa = 145.04psi
Pressure outlet, P2 = 1750kPa = 253.82psi
Pressure drop, P = 750kPa = 108.78psi
Q = 93.57 m3/hr = 413.09 gpm
H=
P(2.31)
SG
= 108.78 psi x
H = 356.82 ft
1 lb / 2
1 psi
ft 3
43.9 lb
144 2
1 ft 2
PT =
QH
33000 = 413.09
= 26.16
gal
min
x 356.82 ft x
lb . ft
min
ln Q = 6.024
p = -0.316 +0.24015 (6.024) 0.01199(6.024)2
= 0.6956
PB =
PT
p
26.16
0.6956
= 37.61
lb . ft
min
ln PB = 3.627
m = 0.80 + 0.0319(3.627) 0.00182(3.627)2
= 0.892
43.9 lb
ft 3
0.1334 ft 3
1 gal
1
33000
PC =
PT
pm
26.16
(0.6956)(0.892)
= 42.16
lb . ft
min
ln Pc = 3.741
CB = exp [5.8259+0.13141(3.741)+ 0.053255 (3.741)2 + 0.028628 (3.741)3 0.0035549(3.741)4]
= $ 2605.50
FT = 1.8 (assume explosion-prof enclosure)
CP = FTCB = 1.8(2605.50) = $ 4689.9 for motor
FBM = 3.30
CPTotal (Pump + Motor) = (6577.78 + 4689.9) (3.30)
= $ 37,183.34
DISTILLATION COLUMN
Distillation column, S1
Main vessel sizing
Diameter, DT
FLG= 0.1345
CSB=0.34
FST=0.757
Assume:
FF=1,FHA=1
C=0.2574
Uf=2.758 ft/s
Ad/AT=0.10378
Assume 80% flooding
425100
)
3600
DT=
=6.05 ft=1.844 m
0.8(2.758)(3.14)(10.10378)(2.09)
4(
CT= $ 27462
tp =7/16=0.4375 in
ts =0.4375+0.125=0.562 in
W= (Di + ts)*(L+0.8*Di)*(ts)*
W=16150 Ib
Cv= $ 733210
After bare-model:
Cost= $ 223290
Condenser
Qc= -0.126* 10
Assume fixed head, shell tube exchanger and carbon steel, 20 feet long:
FL=1
FP=1
TM=2.732
CB= 7950
Cp= $ 21721
After bare-module,
Cost= $ 68857
Re-boiler costing
Heat flux 5000 Btu/hr.ft3
Q=16600 Kj/hr=15733.76 Btu/hr
AR=QR/ Flux
AR=3.146 ft2
Choose kettle reboiler with carbon steel, 20 ft long
FL=FM=FP=1
CB= $ 65325
With bare-module
$ 3.17(65325) = $ 207080
COMPRESSOR
(a)
= 14.5 psi
Outlet pressure, PO
= 72.52 psi
= 1.10
Mechanical efficiency, B
= 0.4952
PB =0.00436
(( )
1.10
83283.83 14.5
72.52
1.101
0.4952
14.5
1.101
1.10
1 =18430.94 BHp
(b)
Assumption:
Drive efficiency, C
= 0.75
Material factor, FM
PC =
18430.94
=24574.59 Hp
0.75
C P=$ 7,328,904
Tin (C)
Cold
870.7
43.85
Tout (C)
349.12
576.3
LM
LM 314.74 o F
870.7 349.12
576.3 43.85
R 0.98
576.3 43.85
870.7 43.85
S 0.644
Ui = 235.5 Btu/oF.ft2.hr
5.44 x10 6 Btu / hr
Ai
235.5 Btu / oF . ft 2 .hrx 0.85 x314.74 o F
Ai 86.34 ft 2
Velocity of tube-side;
ui
ui 1.68 x10 6 ft / hr
111244.12lb
ft 3
hr
x
x
hr
0.421lb 1.68 x10 6 ft
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;
0.302in 2
ft 2
x
tube
144in 2
Inside area/tube =
= 2.097x10-3 ft2/tube
Nt
0.157 ft 2 / pass
2.097 x10 3 ft 2 / tube
N t 75tubes / pass
Area per tube;
86.43 ft 2
4 passx 75tubes / pass
=
= 0.288 ft2/tube
0.288 ft 2 / tube
0.62in
x
12in / ft
L = 5.58 ft
Costing of Heat Exchanger (HE2)
Ai 86.34 ft 2
FBM = 3.17
0.5
F M =1.08+(
86.34
)
100
= 2.01
FL = 1.25 (Tube length = 5.58 ft2)
2
145.04
145.04
F P=0.9803+ 0.018
+0.0017 (
)
100
100
= 1.01
Fixed head:
C B=exp {11.05450.9228 [ 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
Bare-module cost = 3.17 ( 18,613.18)
= $59,003
PROCESS FLOW
DIAGRAM
(HEAT EXCHANGER
NETWORK)