CUMENE

PRODUCTION PROCESS
Presented by

Jidapa Cheksaengthong 61070700103

Tanatat Pisitamornchai 61070700110
Sivakorn Kozueavanich 61070700008
Nichakan Phetsinthopchai 61070700108

Technical Advisor : Dr. Hong-ming Ku

 OUTLINE
METHODOLOGY

THEORY SIZING AND COSTING

ECONOMIC
EVALUATION
INTRODUCTION

2
 INTRODUCTION
BACKGROUND OF CUMENE

CUMENE ISOPROPYLBENZENE

Phenol

CUMENE , C9H12 Cumene

( Isopropylbenzene ) hydroperoxide
(Intermediate) Acetone
3
 INTRODUCTION
CUMENE’S APPLICATIONS

Others

Acetone
Phenol

 Phenol
 Acetone
 Others

4
 INTRODUCTION
CUMENE’S APPLICATIONS

USA

>3,000

2017

5
 INTRODUCTION
OBJECTIVES

To compare the installation and operating cost of CD-Tech

and 3-DDM cumene process and select the most profitable
process.

To meet the required cumene purity of 99.97%wt with a

capacity of 9.616x108 lb/yr

6
 INTRODUCTION
SCOPE OF WORK

Aspen plus version 8.8 Capacity of cumene = Purity  99.97% of cumene

9.616 𝑥 108 lb/yr

Sizing and Costing Economic evaluation 1997 AIChE student design

competition problem
7
 THEORY
CUMENE’S REACTION
MAIN REACTION CH3 — CH — CH3

Acid
+ CH2 = CH — CH3

Benzene Propylene Cumene

ALKYLATION
SIDE REACTION
REACTION
CH3 — CH — CH3 CH3 — CH — CH3

Acid CH3
+ CH2 = CH — CH3
CH
CH3
Cumene Propylene DIPB

CH3 — CH — CH3 CH3 — CH — CH3

Strong Acid
CH3
+ 2 TRANS-ALKYLATION
CH
CH3 REACTION
DIPB Benzene Cumene

8
 METHODOLOGY

BASE CASE SIMULATION EQUIPMENT SIZING ECONOMIC

SIMULATION IMPROVEMENT AND COSTING EVALUATION
Preliminary process Minimize the utilities. Size and type of Investment cost
flow chart equipment.

9
 SIMULATION RESULTS
BASE CASE SIMULATION

Base case : 3DDM

4 Distillation columns 2 reactors

Case 2
IMPROVED CASE SIMULATION

Case 3 : CD-Tech 10
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Overall (3DDM)
Thermodynamic method : NRTL

Depropanizer Column

PSRK
11
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Overall (Flash revamp)
Thermodynamic method : NRTL

Depropanizer Column Flash Vessel

Depropanizer flash

12
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Case 3 : CD-TECH (Overall)
Thermodynamic method : NRTL

13
 SIMULATION RESULTS
SUMMARY
Case 1 Case 2 Case 3
Propylene feed flowrate
64,189 70,736 63,250
(lb/h)
Benzene feed flowrate
87,925 109,753 80,845
(lb/h)
*Number of distillation 3
4 3
units (1 Reactive distillation)
Number of reactor 2 2 1
Number of heat
5 5 5
exchanger
Number of flash vessel - 1 1

*Not include reboilers and condensers at columns 14

 SIZING AND COSTING
Main Equipment of 3 cases
Unit Base case Case 2 Case 3

Heat Exchanger 13 11 11

Reactor 2 2 1
Tower 4 3 2+1
Vessel - 1 2
Compressor - - 1
Pump 2 2 4
TOTAL 21 19 22

15
 SIZING AND COSTING
Alkylation and Trans- alkylation section
Unit R – 101
Length (ft) 26
Diameter (ft) 7
Type PFR
MOC CS
Cost ($) 817,600

Unit R – 301
Length (ft) 16.5
Diameter (ft) 4
Type PFR
MOC CS
Cost ($) 406,500

16
 SIZING AND COSTING
Fractionation section (Base Case)

Unit T -201 T-202 T -203 T-204

Diameter (ft) 13 13 11.5 11.5
Height (ft) 40 66 92 40
Number of stages 20 33 46 20
Type of trays Sieve tray Sieve tray Sieve tray Sieve tray
MOC CS CS CS CS
Cost ($) 1,806,000 1,926,000 2,191,000 892,700 17
 SIZING AND COSTING
Fractionation section (Case 2)

Unit D-201 (Flash)

Diameter (ft) 8
Height (ft) 23.5
MOC CS
Cost ($) 255,000

Unit T -201 T-202 T -203

Diameter (ft) 13.5 9.5 10.0
Height (ft) 60 64 36
Number of stages 30 32 18
Type of trays Sieve tray Sieve tray Sieve tray
MOC CS CS CS
18
Cost ($) 1,887,500 1,290,000 950,000
 SIZING AND COSTING
Alkylation section (Case 3)

Unit T-101
Diameter (ft) 9.68
Height (ft) 34
Number of stages 17
Type of trays Sieve tray
Reaction area 8 to 16
MOC CS
Feed stage (Propylene) 2
Feed stage (Benzene) 16
Equipment Cost ($) 8,410,000
Catalyst cost per 1.5 years 14,600
($/yrs)

Zeolite Y 19
 SIZING AND COSTING
Fractionation section (Case 3)

Unit T -201 T-202

Diameter (ft) 10 13.5
Height (ft) 20 52
Number of stages 10 26
Type of trays Sieve tray Sieve tray
MOC CS CS
Cost ($) 1,190,000 1,584,000

20
 SIZING AND COSTING
Heat exchanger network (Base case) Before HEN

Column 8
Number of heat exchangers 12
Others 4

21
 SIZING AND COSTING
Heat exchanger network (Base case) After HEN

Column 8
Number of heat exchangers 13
Others 5 22
 SIZING AND COSTING
Heat exchanger network (Base case)

Before HEN After HEN

Equipment cost ($) 14,176,000 14,387,200

Utility cost($/ 10 yrs.) 125,477,070 124,839,970

Total cost ($/ 10 yrs.) 139,653,070 139,227,165

Save energy 18.3 %

23
 SIZING AND COSTING
Heat exchanger network (Case 2) Before HEN

Column 6
Number of heat exchangers 10
Others 4

24
 SIZING AND COSTING
Heat exchanger network (Case 2) After HEN

Column 6
Number of heat exchangers 11
Others 5
25
 SIZING AND COSTING
Heat exchanger network (Case 2)

Before HEN After HEN

Equipment cost ($) 10,826,900 10,955,000

Utility cost($/ 10 yrs.) 110,985,590 106,795,130

Total cost ($/ 10 yrs.) 121,812,490 117,750,130

Save energy 30.97%

26
 SIZING AND COSTING

Heat exchanger E-105 (case 3 )

Heat duty 269,679,660 BTU/hr

Type BEM

Number of Tube 1

Number of shell 1

Tube length 13.28 ft

Dia. of shell 2.94 ft

27
 SUMMARY
CASE 1 CASE 2 CASE 3

Equipment cost ($) 14,387,200 10,955,000 18,144,869

Utility cost($/ 10 yrs.) 124,839,970 106,795,130 36,216,060

Total cost ($/ 10 yrs.) 139,227,165 117,750,130 54,360,929

28
 ECONOMIC EVALUATION
FIXED CAPITAL INVESTMENT (FCI)

n n
CGR =1.18 ෍ CBM,i + 0.5 ෍ C0 BM,i
i=1 i=1

Fixed Capital Investment 80 % 20,154,711

Work Capital 15 % 3,779,008.32
Land 5% 1,259,669.44

Total capital cost = 25,193,389

29
 ECONOMIC EVALUATION

COM = 1.23(CRM + CWT + CUT )+ 2.73COL + 0.280FCI

FCI CUT
FIXED CAPITAL INVESTMENT UTILTY COST

CRM COL
RAW MATERIAL COST OF OPERATING LABOR
CWT
WASTE TREATMENT 30
 ECONOMIC EVALUATION

RAW MATERIAL COST (CRM)

Component M $/ Year
Propylene 136.73
Benzene 199.75
Catalyst 0.0181
Total 336.49

COST OF OPERATING LABOR(COL)

Number of labors = 14
Salary of each person = 600 $ /month
Total cost of labor (COL) = 100,800 $/Yr.

31
 ECONOMIC EVALUATION

UTILITY COST (CUT)

Utility $ / Year
Cooling water 1,141,980
High pressure stream 756,980
Low pressure stream 244,186
Hot oil 1,244,855
Electricity 233,605
Total 3,621,606

WASTE TREATMENT COST (CWT)

Waste $/Yr.
Waste water 10,354

32
 ECONOMIC EVALUATION
PAYBACK PERIOD
Plant lifetime (n) = 10 yrs.

100 NPV = 65.72 M $

48.27
Cumulative Discount

Salvage
Cash flow ($M/yr)

50 54.22
33.38
41.42
3,046,387
23.93
0.22 13.06
0
0 1 2 3 4 5 6 7 8 9 10 11 12

-21.61 -15.22
$ 7.6 M For Working capital and Land
-32.26
-50
Time (yr)

Payback period = 3 Yrs. and 7 month

33
 ECONOMIC EVALUATION
NET CASH FLOW DIAGRAM

Plant life = 10 yrs.

100.00

65.72
59.40
54.22
Cash flow ($M)

48.27
50.00 41.42
33.38
23.93
13.06
0.22
0.00
0 1 2 3 4 5Time(year)
6 7 8 9 10 11 12
-5.71
-15.22
-21.61
-32.26
-50.00

Interest rate return (IRR) = 47 % > MARR = 15% 34

 ECONOMIC EVALUATION
SUMMARY

323.16 M$

EAOC = -(Product value – COM – Cost annuity)

299.07 M$ 4.63 M$
-19.45 M$

35
 CONCLUSION
SIMULATION RESULTS SIZING & COSTING ECONOMIC EVALUATE

3DDM Plant life time 10 yrs.

Production process Equipment cost ($)
18 M. NPV 65.72 $
Flash revamp Utility cost ($)
Production process IRR 47 %
36 M.
Total cost ($) PBP 3 yrs. 7 m.
CD – TECH 54 M.
Production process EAOC -19.45 M$

36
THANK YOU
 EQUIPMENT COST

Equipment Base case Case 2 Case 3

Reactor 4,257,920 4,461,504 395,876
Distillation column 25,997,600 19,399,000 11,326,029
Vessel 0 285,000 0
Heat exchanger 2,314,000 2,248,000 376,000
Pump 423,327 770,540 179,938
Compressor 0 0 1,110,000
Total cost ($) 32,992,847 27,164,044 13,387,843

38
 SIZING AND COSTING
Reactive distillation

Benzene

Reactor cost = 52,920𝐷𝑅1.066 𝐿0.802

𝑅

Column cost = 17,640𝐷𝐶1.066 𝐿0.802

𝐶

Tray cost = 229𝐷𝑅1.55 𝑁𝑇

Where, 𝐷𝑅 is diameter of reactor

𝐷𝐶 is diameter of column
𝐿𝑅 is reactor length
𝐿𝐶 is column length
Propylene 𝑁𝑇 is number of tray

39
THEORY
 THEORY
CUMENE REACTIONS

ALKYLATION REACTION
Produce cumene from benzene and propylene
CH3 — CH — CH3 CH3 — CH — CH3
CH3 — CH — CH3 CH3 — CH — CH3
Acid CH3
+ CH2 = CH — CH3 Acid CH3
+ CH2 = CH — CH3 CH
CH
CH3
Cumene DIPB CH3
Propylene
Product By-product
Cumene Propylene DIPB

TRANS-ALKYLATION REACTION

Convert by-product to cumene

CH3 — CH — CH3 CH3 — CH — CH3

Acid CH3
+ CH2 = CH — CH3
CH
CH3
Product
Cumene Propylene DIPB 42
 INTRODUCTION
ALKYLATION BENZENE’S BACKGROUND

Charles Friedel James Crafts

Friedel-Crafts alkylation of benzene with propylene

43
 THEORY
PROCESS DESCRIPTION 3-DDM DOW PROCESS

Recycled Benzene
Recycled DIPB
Propane Cumene
Trans-
Alkylation
alkylation
reactor

Depropanizer column
reactor

Cumene column
Recycle column

DIPB column
Propylene

Benzene

Heavies

44
 THEORY
PROCESS DESCRIPTION MOBIL BADGER PROCESS

Fresh benzene
Cumene
Propylene Recycled benzene Propane
Recycled PIPB

Benzene recycle column

Propane column

Cumene column
Trans-alkylation

PIPB column
Alkylation

Residue

45
 THEORY
PROCESS DESCRIPTION ENICHEM PROCESS

Propylene Recycled benzene Cumene

Propane Recycled PIPB

Benzene recycle column

Cumene column
Trans-alkylation

DIPB column
Alkylation

Drag

Fresh benzene
Heavies

46
 THEORY
PROCESS DESCRIPTION CD’s TECH PROCESS

Fresh benzene
Cumene
Propane

Reactive
distillation

Cumene column
Propylene

DIPB column
Trans-alkylation

Heavies

47
 THEORY
PROCESS DESCRIPTION
ALKYLATION

FRACTIONAL SECTION
TRANS-ALKYLATION

3-DDM DOW PROCESS

CD’s TECH PROCESS
ENICHEM PROCESS

MOBIL PROCESS

48
 LITERATURE REVIEW
Benefits of using CD-Tech process

High selectivity ,
Higher product yield
Lower by - product
and conversion
formation

Lower equipment Lower maintenance

Longer catalyst life
and operating cost cost

Lower energy
Lower utility cost
requirement

49
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Overall (3DDM)

Depropanizer Column
PSRK

BASED CASE : 3DDM

Thermodynamic method : NRTL 50

 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Alkylation section (3DDM)

51
 SIMULATION RESULTS
Alkylation section (3DDM)

Steam : S1 Mass flow : %wt T(°F),P(psia)

lb/hr
Ethane 140.26 0.218
Propylene 43,503 67.67
100,64.7
Propane 20,623.24 32.08
3
Total Flow 64,289.76

Steam : S3 Mass flow : %wt T(°F),P(psia)

lb/hr
1
Methyl – C5 24.04 0.025
Benzene 93981.72 99.81 100,64.7
Total Flow 94,159.06

52
 SIMULATION RESULTS
Alkylation section (3DDM)

7
Steam : S7 Mass flow : %wt T(°F),P(psia)
lb/hr
8
Benzene 323026 76.46
Propylene 43,503 10.3
Cumeme 33,618 7.96 264.1, 375
Propane 20,626 0.05
Total Flow 422,476 Unit R-101
T,P 302, 375
Steam : S8 Mass flow : %wt T(°F),P(psia)
lb/hr
Benzene 249,821 59.13
Cumeme 134,910 31.93
302, 390
DIPB 15,271 3.61
Total Flow 422,476

53
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Fractional section (3DDM)

54
 SIMULATION RESULTS
Fractional section (3DDM)

Unit T-201
Reflux ratio 2.9
9
Number of stage 18
8
Feed stage 10
D/F ratio 0.1035 1
T,P 480, 300 0

S8 S9 (Overhead) S10 (Bottom)

Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia)
lb/hr lb/hr lb/hr
Benzene 249,811 59.13 2570 10.96 248,241 61.96
Propane 20,626 4.88 20,623 87.94 3.41 8.6x104
Cumene 137,904 31.93 302,390 0.01 2x1010 315,148 134,904 33.81 316,480
DIPB 15,270 3.61 0 4.2x105 15,270 3.83
Total Flow 422,476 23,452 399,025

55
 SIMULATION RESULTS
Fractional section (3DDM)

1
Unit T-202 5
Reflux ratio 0.66
Number of stage 35 1
1
Feed stage 17 3
D/F ratio 0.77 4
T,P 500, 100

S13 S14 (Bottom) S15 (Overhead)

Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia)
lb/hr lb/hr lb/hr
Benzene 276.516 59.68 0.04 2.4x105 276,516 86.75
Cumene 167,096 36.06 126,511 87.51 40,585 12.73
150,495 118,500 115,338
DIPB 17,548 0.038 17,548 12.13 0.01 2.6x108
Total Flow 463,323 144,573 318,751

56
 SIMULATION RESULTS
Fractional section (3DDM)

Unit T-203
Reflux ratio 3 2
Number of stage 48 6
Feed stage 24 1 2
D/F ratio 0.86 4 3
T,P 561, 100

S14 S21 (Overhead) S23 (Bottom)

Mass flow : %wt T(F),P(psia) Mass flow : %wt T(F),P(psia) Mass flow : %wt T(F),P(psia)
lb/hr lb/hr lb/hr
Cumene 126,511 87.51 120,275 99.97 6,235 25.69
DIPB 17,548 12.14 0.03 2.8x105 17,548 72.29
118,500 115,489 119,561
Heavies 305 0.211 0 0 305 1.255
Total Flow 144,573 120,300 24,242

57
 SIMULATION RESULTS
Fractional section (3DDM)

Unit T-204
Reflux ratio 0.99 2
Number of stage 30 6
Feed stage 14 2
D/F ratio 0.99 3 2
T,P 677, 100 4

S23 S26 (Overhead) S24 (Bottom)

Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia) Mass flow : %wt T(°F),P(psia)
lb/hr lb/hr lb/hr
Cumene 6,235 25.68 6,235 26.02 0 0
DIPB 17,548 72.29 17,503 73.05 44 14.20
119,561 115,555 118,667
Heavies 305 1.26 37 0.156 267 85.45
Total Flow 24,272 232,961 313

58
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Trans - alkylation section (3DDM)

59
 SIMULATION RESULTS
Trans - alkylation section (3DDM)

Steam : S29 Mass flow : %wt T(°F),P(psia)

2 lb/hr
9 Benzene 37,929 56.04
3 DIPB 17,503 25.86
220,320
0 Cumeme 11,802 17.44
Total Flow 67,683

Steam : S30 Mass flow : %wt T(°F),P(psia)

lb/hr
Cumeme 33,886 50.07
Benzene 30,816 45.53
Unit R-301 210,320
DIPB 2,397 3.54
T,P 302, 375 Total Flow 67,683

60
 SIMULATION RESULTS
MASS BALANCE *Mass flow rate unit : lb/hr
BASED CASE (3DDM)
Purge
11,000
Propane
23,452
Benzene
94,159
ALKYLATION
Propylene Cumene 99.97%wt
64,290 FRACTIONATION 120,300
Recycled benzene
= 9.624 x 108 lb/yr
DIPB
TRANS-
ALKYLATION Heavies
313

Purge
INPUT OUTPUT
3,384 158,449 158,449
61
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Overall (Flash Revamp) Depropanizer Column Flash Vessel

Depropanizer flash
PSRK

Thermodynamic method : NRTL

CASE 2

62
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Alkylation section (Flash Revamp)

63
 SIMULATION RESULTS
Alkylation section (Flash Revamp) Steam : S1 Mass flow : %wt T(°F),P(psia
lb/hr )
Unit R-101
Propylene 42,931 67.67
T,P 302, 375
Propane 20,352 32.08 100, 64.7
Total Flow 63,445

7 Steam : S2 Mass flow : %wt T(°F),P(psia)

3 lb/hr

8 Benzene 93,558 99.81

100, 64.7
Total Flow 93,735

1
Steam : S8 Mass flow : %wt T(°F),P(psia)
Steam : S7 Mass flow : %wt T(°F),P(psia) lb/hr
lb/hr Benzene 246,519 62.41
Benzene 318,706 80.69 Cumene 103,263 26.14
Propylene 42,931 10.87 Propane 27,763 7.03 302, 389.7
280, 400
Propane 27,763 7.03 DIPB 15,074 3.82
Total Flow 394,977 Total Flow 394,977
64
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Fractional section (Case 2)

65
 Mole fraction of benzene (Overhead)

Mole fraction of benzene (Bottom)

Mole fraction of cumene (Overhead)

Mole fraction of cumene (Bottom)

PROCESS FLOW DIAGRAM
Sensitivity analysis of Case 2 (Temperature)
SIMULATION RESULTS

66
 Mole fraction of benzene (Overhead)

Mole fraction of benzene (Bottom)

Mole fraction of cumene (Overhead)

Mole fraction of cumene (Bottom) PROCESS FLOW DIAGRAM

Sensitivity analysis of Case 2 (Pressure)
SIMULATION RESULTS

67
 SIMULATION RESULTS
Fractional section (Case 2)

Unit D-201

9 T,P 52.5, 7

Steam : S9 Mass flow : %wt T(°F), P(psia)

lb/hr
1 Propane 20,001 82.22
0 Benzene 4,024 16.4 52.5, 7
Total Flow 24,327

Steam : S8 Mass flow : %wt T(°F),P(psia) Steam : S10 Mass flow : %wt T(°F), P(psia)
lb/hr lb/hr
Benzene 246,519 62.41 Benzene 242,496 65.42
Cumene 103,263 26.14 Cumene 103,197 27.84
Propane 27,763 7.03 302, 389.7 Propane 7,762 2.1 52.5, 7
DIPB 15,074 3.82 DIPB 15,073 4.07
Total Flow 394,977 Total Flow 370,650
68
 SIMULATION RESULTS
Fractional section (Case 2)

15
Steam : S13 Mass flow : %wt T(°F),P(psia)
lb/hr
Benzene 260,584 62.83 13
14
Cumene 126,648 30.54
85.2, 150
DIPB 16,389 3.95
Total Flow 414,738

Steam : S14 Mass flow : %wt T(°F), P(psia)

(Bottom) lb/hr Unit T-201

Cumene 122,738 87.98 Reflux ratio 0.84

DIPB 16,389 11.75 499.1, 117.2 Number of stage 26
Total Flow 139,514 Feed stage 9
D/F ratio 0.76
Steam : S15 Mass flow : %wt T(°F), P(psia)
(Overhead) lb/hr T,P 499.1, 114.7

Benzene 260,584 94.68

Cumene 3,909 1.42 266.6, 114.7
Total Flow 275,224 69
 SIMULATION RESULTS
Fractional section (Case 2)

22

23

Steam : S22 Mass flow : %wt T(°F),P(psia)

Unit T-202 (Overhead) lb/hr
Reflux ratio 2.9 Cumene 120,243 99.97
489.1, 114.7
Number of stage 36 Total Flow 120,288

Feed stage 12 Steam : S23 Mass flow : %wt T(°F), P(psia)

(Bottom) lb/hr
D/F ratio 0.89
DIPB 16,371 85.16
T,P 578.9, 114.7
Cumene 2,495 12.98 578.9, 118.2
Total Flow 19,225 70
 SIMULATION RESULTS
Fractional section (Case 2)
Unit T-203
Reflux ratio 4
Number of stage 36

26 Feed stage 28
D/F ratio 0.99
T,P 668.9, 114.7

25

Steam : S25 Mass flow : %wt T(°F),P(psia) Steam : S26 Mass flow : %wt T(°F), P(psia)
(Bottom) lb/hr (Overhead) lb/hr
TIPB 139 40.67 DIPB 16,297 86.30
N-OCT 127 37.38 Cumene 2,496 13.22 574, 114.7
668.9, 118.2
DIPB 75 21.93 Total Flow 18,885
Total Flow 341

71
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Trans - alkylation section (Case 2)

72
 SIMULATION RESULTS
Trans - alkylation section(Case 2)

29
Steam : S29 Mass flow : %wt T(°F),P(psia)
lb/hr
Benzene 26,058 56.15 30

DIPB 16,297 35.12

323.3, 210
Cumene 2,887 6.22
Total Flow 46,407

Steam : S30 Mass flow : %wt T(°F), P(psia)

lb/hr
Cumene 24,685 53.19
Unit R-301
Benzene 19,040 41.03 320, 210
T,P 320, 210
Total Flow 46,408

73
 SIMULATION RESULTS
MASS BALANCE *Mass flow rate unit : lb/hr
Case 2
Purge
3,138
Propane
25,811
Benzene
89,555
ALKYLATION
Propylene Cumene 99.97%wt
62,445 FRACTIONATION 120,229
Recycled benzene
= 9.618 x 108 lb/yr
DIPB
TRANS-
ALKYLATION Heavies
658

Purge
INPUT OUTPUT
2,164 152,000 152,000
74
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Case 3 : CD-TECH (Overall)

Thermodynamic method : NRTL

CASE 3 : CD – TECH
75
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Alkylation section (Case 3)

76
 SIMULATION RESULTS
Alkylation section ( Case 3)

8
3

Steam : Mass flow : %wt T(°F),P(psia) 1

S1 lb/hr
Propylene 41,578 67.67
Propane 19,711 32.08 100, 64.7
Total Flow 61,445
Steam : Mass flow : %wt T(°F),P(psia)
S8 lb/hr
Steam : Mass flow : %wt T(°F),P(psia)
S3 lb/hr Benzene 301,438 99.17
Benzene 123,489 99.99 Cumene 2,231 0.73 249.7, 220
100, 64.7
Total Flow 123,503 Total Flow 303,948

77
 SIMULATION RESULTS
Alkylation section ( Case 3)
Unit T-101

Reflux ratio 2.0

9
Number of stage 19

Feed stage 2, 18

Distillate rate 1,000 lbmol/hr

T,P 423.7, 205.7 10

Steam : S9 Mass flow : %wt T(°F), P(psia) Steam : S10 Mass flow : %wt T(°F), P(psia)
lb/hr lb/hr
Benzene 42,764 68.22 Benzene 186,891 61.74
Propane 19,709 31.44 162.3, 205.7 Cumene 104,333 34.47
423.7, 205.7
Total Flow 62,690 DIPB 11,213 3.70
Total Flow 302,703
78
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Fractional section ( Case 3)

79
 SIMULATION RESULTS
Unit T-201

Fractional section ( Case 3) Reflux ratio 1.5

Number of stage 10
Feed stage 6
D/F ratio 0.7
13
T,P 235.1, 4.41

Steam : S12 Mass flow : %wt T(°F), P(psia)

lb/hr
Benzene 205,788 58.95
12 Cumene 129,989 37.24
410, 10
15 DIPB 12,938 37.06
Total Flow 349,067

Steam : S13 Mass flow : %wt T(°F), P(psia)

Steam : S15 Mass flow : %wt T(°F),P(psia) lb/hr
lb/hr

Cumene 127,461 90.75 Benzene 205,785 98.64

DIPB 12,862 9.16 235.1, 4.4 Cumene 2,528 1.21 98.1, 4.4

Total Flow 140,455 Total Flow 208,612

80
 SIMULATION RESULTS
Fractional section (Case 3)
Unit T-202
Reflux ratio 0.65
Number of stage 28
Feed stage 15
D/F ratio 0.875
16
T,P 265.1, 4.41

Steam : S16 Mass flow : %wt T(°F), P(psia)

lb/hr
Cumene 120,078 99.97
231.9, 4.4
Total Flow 120,114
17

Steam : S17 Mass flow : %wt T(°F), P(psia)

lb/hr
DIPB 12,858 62.77
Cumene 7,524 36.73 265.1, 4.4
Total Flow 20,483
81
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
TRANS-ALKYLATION (Case 3)

82
 SIMULATION RESULTS
Trans-alkylation (Case 3)

Steam : S21 Mass flow : %wt T(°F),P(psia)

lb/hr

21
Benzene 27,835 57.21
DIPB 12,858 26.43
320, 210
Cumene 7,822 16.08
Total Flow 48,651

22
Steam : S22 Mass flow : %wt T(°F), P(psia)
lb/hr

Cumene 26,920 55.33

Unit R-301
Benzene 19,830 40.76
T,P 320, 210 320, 210
DIPB 1,731 3.56
Total Flow 48,651

83
 SIMULATION RESULTS
MASS BALANCE *Mass flow rate unit : lb/hr
Case 3

Unreacted Benzene Cumene 55%wt

Propylene/Propane
63,250 Cumene
35%wt TRANS-
ALKYLATION FRACTIONATION
ALKYLATION
Benzene DIPB and
96,518 unreacted Benzene

Propane Cumene 99.97% Purge2

38,786 119,810 1,172

INPUT OUTPUT
159,768 159,768
84
 SIZING AND COSTING
Heat exchanger network (Case 2) SAVE 74.38 %

33.4 133.33 47.95 170.53 52.07 242.27

47.95 114.44 52.07 154.44 129.43 76.42

15 43.53 15 37.78 48.89 76.42 48.89 304.4

-18 32.48 -18 -8 32.22 37.78 32.22 37.78

Brine Brine Cooling Cooling 85

Water Water
* Temperature in Celsius
 SIZING AND COSTING
MPS at 178

Heat exchanger network (Case 3) 160

140.70

48.89 121.11

140.70
SAVE 37 %
32.22 76.67 158.8

Cooling
Water 121.11 111.11

48.89 105.69 121.11 111.11

32.22 38.28 105.69 53.6

Cooling
Water
* Temperature in Celsius 86
 SIZING AND COSTING
PROCESS FLOW DIAGRAM
Overall (3DDM)

Depropanizer Column
PSRK

BASE CASE : 3DDM

Thermodynamic method : NRTL 87

 SIZING AND COSTING
Alkylation section (Case 2) Unit E-103

Unit E-102 Area (ft2) 1,736.52

Area (ft2) 8,811.65 MOC (shell side) CS

MOC (shell side) SS MOC (Tube side) SS

MOC (Tube side) CS Cost ($) 223,000

Cost ($) 747,000

Unit E-101

Area (ft2) 4,785.46

MOC (shell side) SS

MOC (Tube side) CS

Cost ($) 425,000

88
 SIZING AND COSTING
Unit R - 101
Alkylation section (Case 2) Length (ft) 95.95
Diameter (ft) 4
Type PFR
MOC CS
Cost ($) 3,865,800

Unit P-101 (Pump)

Type Centrifugal
Efficiency (%) 70
Work (BTU/h) 87.08
MOC CS
Cost ($) 364,421

89
 SIZING AND COSTING
Fractional section (Base Case)

Unit T -201 T-202 T -203 T-204

Diameter (ft) 12.99 12.71 12.70 3.42
Height (ft) 40 66 92 40
Number of stages 20 33 46 20
Type of trays Sieve tray Sieve tray Sieve tray Sieve tray
MOC CS CS CS CS
Cost ($) 2,690,000 2,140,000 2,950,000 96,800 90
 SIZING AND COSTING
Fractional section (Base Case)
Unit E -201
Area (ft2) 7,614.63

MOC (shell side) SS

MOC (Tube side) SS

Cost ($) 646,000

Unit E -202
Area (ft2) 5.39

MOC (shell side) SS

MOC (Tube side) SS

Cost ($) 130,000

91
 SIZING AND COSTING
Unit (condenser) E -204 E -206 E -208 E -210
Fractional section (Based
Area (ft ) Case)
9,190.2 2 3,371.5 7,774.3 567.8

MOC (shell side) CS CS CS CS

MOC (Tube side) CS CS CS CS

Cost ($) 3,930,000 1,620,000 3,280,00 352,000

Unit (reboiler) E -205 E -207 E -209 E -211

Area (ft2) 890.78 6,320.6 1,324.4 76.8

MOC (shell side) SS CS CS CS

MOC (Tube side) SS SS SS SS

Cost ($) 208,000 542,000 182,000 130,000

92
 SIZING AND COSTING
Trans - alkylation section (Base Case)

Unit P-301 (Pump)

Type Rotary
Efficiency (%) 70
Shaft work (hp) 34,170
MOC CS
Cost ($) 87,235

Unit E -301 Unit R - 301

Area (ft2) 99.03 Length (ft) 23.32
MOC( shell side) SS Diameter (ft) 3
MOC (Tube side) CS Type PFR
Cost ($) 130,000 MOC CS
Cost ($) 579,128
93
 SIZING AND COSTING
PROCESS FLOW DIAGRAM
Overall (Flash Revamp) Depropanizer Column Flash Vessel

Depropanizer flash
PSRK

Thermodynamic method : NRTL

CASE 2

94
 SIZING AND COSTING
Main Equipment (Case 2)
Unit Alkylation section
Trans – alkylation
Fractional section
section

Heat Exchanger 3 3 1

Reactor 1 - 1
Tower - 3 -
Vessel - 1 -
Compressor - - -
Pump 1 1 1
TOTAL 5 8 4
SUBTOTAL 17 units

95
 SIZING AND COSTING
Alkylation section (Case 2) Unit E-103

Unit E-102 Area (ft2) 1,736.52

Area (ft2) 8,811.65 MOC (shell side) CS

MOC (shell side) SS MOC (Tube side) SS

MOC (Tube side) SS Cost ($) 223,000

Cost ($) 747,000

Unit E-101

Area (ft2) 4,785.46

MOC (shell side) SS

MOC (Tube side) SS

Cost ($) 425,000

96
 SIZING AND COSTING
Unit R - 101
Alkylation section (Case 2) Length (ft) 95.95
Diameter (ft) 4
Type PFR
MOC CS
Cost ($) 3,865,800

Unit P-101 (Pump)

Type Centrifugal
Efficiency (%) 70
Shaft work (hp) 166,820
MOC CS
Cost ($) 364,421

97
 SIZING AND COSTING
Fractional section (Case 2)

Unit D-201 (Flash)

Diameter (ft) 10.48
Height (ft) 32.93
MOC CS
Cost ($) 285,000

2 units
Unit T -201 T-202 T -203
Diameter (ft) 12.52 9.60 10.27
Height (ft) 60 64 60
Number of stages 30 32 30
Type of trays Sieve tray Sieve tray Sieve tray
MOC Carbon steel Carbon steel Carbon steel
98
Cost ($) 3,760,000 1,050,000 1,160,000
 SIZING AND COSTING
Fractional section (Case 2)

Unit P-201 (Pump)

Type rotary
Efficiency (%) 70
Shaft work (hp) 204,506
MOC CS
Cost ($) 335,614

Unit E -201 Unit E -202

Area (ft2) 6,959.95 Area (ft2) 107.86

MOC (shell side) SS MOC (shell side) SS

MOC (Tube side) SS MOC (Tube side) SS

Cost ($) 592,000 Cost ($) 130,000

99
 SIZING AND COSTING
Unit E -206 E -208 E -210
Fractional section (Case 2) (condenser)
Area (ft2) 2,821.6 2,800.7 447.2
MOC (shell side) CS CS CS
MOC (Tube side) SS SS SS
Cost ($) 284,000 182,000 127,000

Unit (reboiler) E -207 E -209 E -211

Area (ft2) 7,674.7 2,599.3 758.3

MOC (shell side) CS CS CS

MOC (Tube side) CS CS CS

Cost ($) 5,649,200 1,534,800 372,000

100
 SIZING AND COSTING
Trans - alkylation section (Case 2)
Unit R - 301
Length (ft) 24.83
Diameter (ft) 3
Type PFR
MOC CS
Cost ($) 595,704
Unit E -301
Area (ft2) 107.86
MOC (shell side) SS
MOC (Tube side) SS Unit P-301 (Pump)
Cost ($) 130,000 Type Centrifugal
Efficiency (%) 70
Shaft work (hp) 40,097
MOC CS
Cost ($) 70,505
101
 SIMULATION RESULTS
PROCESS FLOW DIAGRAM
Case 3 : CD-TECH (Overall)

Thermodynamic method : NRTL

CASE 3 : CD – TECH
102
 SIZING AND COSTING
Main Equipment (Case3)
Unit Alkylation section
Trans – alkylation
Fractional section
section

Heat Exchanger 1 1 1

Reactor - - 1
Tower 1(RD-column) 2 -
Vessel - - -
Compressor 1 - -
Pump 1 1 1
TOTAL 4 4 3
SUBTOTAL 11 units

103
 SIZING AND COSTING
Unit P-101 (Pump)
Alkylation section (Case 3) Type centrifugal
Efficiency (%) 70
Unit C-101 (Compressor)
Shaft work (hp) 71,975
Type Reciprocating
MOC CS
Efficiency (%) 70
Cost ($) 95,749
Shaft work (hp) 1,059,388
MOC CS
Cost ($) 1,100,000

Unit E -101 E -102 E -103

Area (ft2) 369.93 2,223.7 4,510.6

MOC (shell side) CS SS CS

MOC (Tube side) SS SS CS

Cost ($) 124,000 326,000 1,920,000

104
 SIZING AND COSTING
Alkylation section (Case 3)

Unit T-101
Diameter (ft) 9.68
Height (ft) 34
Number of stages 17
Type of trays Sieve tray
Reaction area 8-16
MOC CS
Feed stage (Top) 2
Feed stage (Bottom) 16
Equipment Cost ($) 8,188,011
Catalyst cost per year ($/yr) 21,891

105
 SIZING AND COSTING
Fractional section (Case 3)

Unit P-201 (Pump)

Type Centrifugal
Efficiency (%) 70
Work (BTU/h) 2.31
MOC CS
Cost ($) 29,651

Unit T -201 T-202

Diameter (ft) 3.82 3.73
Height (ft) 6.10 15.85
Number of stages 10 26
Type of trays Sieve tray Sieve tray
MOC Carbon steel Carbon steel
Cost ($) 405,000 911,000 106
 SIZING AND COSTING
Fractional section (Case 3)

Unit E-201
Area (ft2) 48.85

MOC (shell side) SS

MOC (Tube side) SS

Cost ($) 130,000

Unit (reboiler) E -203 E -205 Unit (condenser) E -202 E -204

Area (ft2) 7,312 288.1 Area (ft2) 1,274.86 1,858.5

MOC (shell side) CS CS MOC (shell side) CS CS

MOC (Tube side) CS CS MOC (Tube side) SS SS

Cost ($) 3,160,000 800,000 Cost ($) 179,000 218,000

107
 SIZING AND COSTING
Trans - alkylation section (Case 3)

Unit R-301
Length (ft) 10.06
Diameter (ft) 3
Type PFR
MOC CS
Cost ($) 395,876

Unit P-301 (Pump) Unit E-301

Type Centrifugal Area (ft2) 162.98
Efficiency (%) 70 MOC (shell side) CS
Shaft work (hp) 908.7 MOC (Tube side) SS
MOC CS
Cost ($) 122,000
Cost ($) 54,538

108
 SIZING AND COSTING
Heat exchanger network (Based case)

- 641,565.651 kJ/hr 56,638.80 kJ/hr

Transfer
56,638.80 kJ/hr

109
 WORK PLAN
SEP OCT NOV
WEEK 1 2 3 4 1 2 3 4 1 2

BASE CASE
SIMULATION

IMPROVE CASE
SIMULATION
EQUIPMENT
SIZING AND
COSTING
EVALUATING
ECONOMIC

OPTIMIZATION

110