Final GP2 Process Plantfor Aromatic Extraction

PROCESS PLANT
FOR
AROMATIC SEPARATION
United Arab Emirates University
College of Engineering
Training and Graduation Project Unit
Graduation Project 2
Shahnaz
Romia
Fatima
Ameri
Shaikha
Nader
Khawla
Kaabi
Conclusion
Safety & Environmental impact
Cost Analysis
Site Selection
HAZOP and Safety Studies
Materials of Construction
Detailed design
Summery of achievement in GP1 & GP2
Introduction
Acknowledgments
Outline
Acknowledgments
Supervisor, Dr. Marcelo Castier.
Project coordinator, Dr. Samir Emam.
Dr. Samir Abu-Eishah, Dr. Nayef Mohamed Ghasem,
Dr. Sulaiman Al-Zuhair, Dr. Mamdouh Ghannam, Dr.
Mohamed Nakou and Eng. Saad Al Omari.
Training and Graduation Projects Unit.

What are Aromatics ?
Hydrocarbons with distinctive perfumed smell
Hydrogen
Carbon
Benzene
Toluene
Xylenes
What is Aromatics Extraction?
Petroleum refining industry is the largest user of extraction.
Reformate
Rich in Benzene, Toluene and Xylenes (BTX).
Naphtha
Rich in aromatic hydrocarbons.
Recovered from reformate stream by catalytic
treatment of lower boiling distillates.
Aromatics
Catalytic reforming of Naphtha.
Extracted using suitable solvent.
From raw materials to daily life products,
discover the wonders of petro chemistry.
Summery of achievement in GP1
Designing a process plant for aromatics separation
using naphtha reformate as feed and Sulfolane as
solvent.

Achievements in GP1 :

Literature review
Selecting the best technology
Calculating mass and energy balances
Ethics and contemporary issues
Safety and HAZOP considerations
Economic evaluation.

Summery of achievement in GP2
Achievements in GP2:

Selecting the best types of pumps
Detailed design of major pieces like heat exchangers and
columns
Site selection for the aromatics extraction plant
Materials of construction of the equipments
HAZOP study was applied to each piece of equipment
Capital cost of the new aromatics extraction plant

Detailed Design
Distillation

Used to separate key components in a mixture based on the
difference in their boiling points.

Distillation is energy intensive; it can consume more than 50% of a
plants operating energy cost.

The importance of column internals is to provide better mass and
heat transfers between the liquid and vapor phases in the column.

Cont./Detailed Design
Stripper and Recovery Columns Using HYSYS
Number of trays 34
Column Diameter (m) 7.77
Column Height (m) 21
Top composition
n-heptane Toluene Sulfolane
0.99 0.011 0
Bottom composition
0.00162 0.17 0.83
Number of trays 34
Column Diameter (m) 3.9
Column Height (m) 21
Top composition
9.3*10
-3
0.99 0
Bottom composition
0 3.5*10
-5
0.99
ab
=

Using Antoine equation to calculate the vapor pressure:

vb
va
b
a
P
P
K
K
=
T C
B
A P
+
= ln
T C
B
A P
+
= log
L av
= (
(top)

(bottom)
)
0.5
= 1.385

Stripper column hand calculation
( )
( )
2 . 28
385 . 1 Log

0.1716
0.0016
0.0107
0.9893
Log
= Nmin

av Log

X
X
X
X
Log
= Nmin
LW
HW
HD
LD
=
(
|
.
|
\
|
|
.
|
\
|
(
|
|
.
|
\
|
|
|
.
|
\
|
o
( )
0562 . 0
D
Lmin
Rmin
18.044 Lmin
0.0141
1
*
X F
X D
X F
X D

=
F
Lmin

avg
FB
DB
FA
DA
= =
=
=
|
|
.
|
\
|
|
|
.
|
\
|
avg
o
o
Assume R = 1.2 Rmin
R = 0.0674

|
|
.
|
\
|
+
=
+
1 1
min
D
Dm D
R
R R
f
N
N N
0.01
1
=
+
D
Dm D
R
R R
58.63 N
0.51
1
min
=
=
+
N
N N
Using Gilliland correlation
32.5m 1.8 + 1.2 + 0.51 * ) 1 59 (
* ) 1 (
= =
+ =
H
s alloewance g Trayspacin N H
act
Recovery column hand calculation
L av
= (
(top)

(bottom)
)
0.5
= 316.79

( )
5 N
2 * N
2.55 = N
ln
X - 1
X
X - 1
X
ln
N
l theoritica
min l theoritica
min
B
B
D
D
min
=
=
(
(
(
(
|
|
.
|
\
|
|
|
.
|
\
|
=
N
avg
o
37 1 . 1 *
15 . 0
5
1 . 1 * = = =
q
th
act
N
N
m 21.2 1.8 + 1.2 + 0.51 * ) 1 7 . 36 (
* ) 1 (
= =
+ =
H
s alloewance g Trayspacin N H
act
( )
( )
0183 . 0
1 79 . 316
437
2523
1
min
min
=
|
.
|
\
|
=
|
.
|
\
|
=
RR
D
F
RR
o
( )
027 . 0 022 . 0
5 . 1 2 . 1
min
=
=
RR
RR RR
3 3 3
) 5 (
237 . 1 5 . 1236
336 *
.
.
10 * 2057 . 8
14 . 92 * 37 . 0
m
kg
m
g
K
K mole
m atm
mole
g
atm
RT
PMwt
v
= = = =
Gas velocity in the tower (u) = (1.2 -1.5)/ (1.237)

0.5
= 1.08 -1.35 m/s

Vapor flow rate = 46182.4 kg/h

Volumetric flow rare, V
.
= (46182.4 kg/h/3600 s/h)/ (1.237 kg/m
3
) =
10.371m
3
/s
Comparison between HYSYS results and hand calculation
For stripper column For recovery column
HYSYS results
Hand
calculation
N
min
34 59
Height (m) 21 32.5
Diameter
(m)
7.7 7.7
( )
m
V
D 13 . 3 49 . 3
1.35 - 1.08 *
3 . 153 * 4 4
.
= = =
t tu
HYSYS results
Hand
calculation
N
min
34 37
Height (m) 21 21.2
Diameter
(m)
3.9 3.49 3.13
Vessels

Vessels

Vessel Diameter(m) Height(m)
Raffinate wash column (V-101) 0.9368 2.811
Stripper Receiver (V-102) 1.695 5.085
Recovery Column Receiver (V-
103)
1.447 4.341
Extraction Column (T-101)

LLE

LLE

Mass balance of sulfolane (input streams)
Pumps

Type of pump Maximum head (m)
Centrifugal pump 152
Axial pump 12
Rotary pump 15200
Reciprocating pump 300000
According to the value of the head, the pump type will be selected.
The expected maximum head for each type of pump

g
P
H h g P
A
= = A
To calculate the head of the pump, the following equation is used:

Pumps

For example, pump P101 A/B
P1=1 bar to P2= 8.83 bar.
The density of the mixture is 848.5 kg/m
3

value of the head does not exceed 125m

068 . 94
81 . 9 5 . 848
10 ) 1 83 . 8 (
2 3
5
m
s
m
m
kg
Pa
H =

=
Pumps

To find the power of the pump this equation was used:

Where:
F is the head in feet
G is the flow rate in gallon per minutes (gpm)

| | | | / (bar) Pr )
min
( 67 . 1
3
Effeciency drop essure
m
Flow kW =
10 4 10 6.39 -
10 5.39 10 38 . 2 10 78 . 3 2855 . 0 80
2 2 10 2 4
2 4 2 7 4
G F G F
F FG FG F Effeciency
+
+ + =
Pumps

The molecular weight of benzene is 78.11 kg/mol and for octane is 114.23 kg/mol

1
min 60
) (
)
hr
kg
(
3
hr
m
kg
m
v
=
-
-

27 . 31389 77 . 81 89 . 383
hr
kg
kmol
kg
hr
kmol
Mw n m
avg
= = =
- -
kmol kg Mw
avg
/ 77 . 81 114.23) 0.101 ( ) 11 . 78 0.899 ( = + =

min
617 . 0
1
min 60
5 . 848
27 . 31389
3
3
m
hr
m
kg
hr
kg
v =
=
-
| | | | 69 . 15 5137 . 0 / 1)(bar) - (8.83 )
min
( .617 0 67 . 1
3
kW
m
Power = =
min
10 32 . 6
17 . 264
1
min
167 . 0
4
3
3
gallon
gallon
m
m

=
feet 308.62
m 1
feet 3.28084
068 . 94 = m
% 37 . 51 = Effeciency
Pumps P
in
(bar) P
out
(bar) Head (m)

Volumetric Flow rate
(m
3
/min)
Efficiency % Power (kW)

P101 A/B 1 8.83 94.07 0.6166 51.37 15.69
P102 A/B 1 6.1 41.43 0.00091 51.17 0.01514
P103 A/B 0.59 6.1 48.05 1.5736 61.79 23.43
P104 A/B 0.48 8.83 72.07 0.2147 45.56 6.57
P105 A/B 0.37 5.08 48.12 0.0470 48.90 0.7554
P106 A/B 1.41 8.83 110.65 0.9060 58.14 19.301
P107 A/B 0.48 2.05 16.98 4.8593 70.45 18.08
P108 A/B 0.65 6.1 47.44 0.01653 48.81 0.3081
For our plant, shell and tube heat exchanger was chosen to transfer heat between
fluids.
The reasons are:
It provides large ratio of heat transfer area to volume and weight.
Its shape allows easy construction in a wide range of sizes that can withstand
shop fabrication stresses, shipping and field erection stresses and normal
operation conditions.
It can be easily cleaned and if failure occurs, elements such as tubes and
gaskets can be easily replaced.
Heat exchangers

) ( ) (
, , ,
.
, , ,
.
out water in water water P
water
out h in h h P
oil
T T C m T T C m q = =
C T
bulk
o
4 . 68
2
8 . 37 99
=
+
=
o
C kg
J
C C T At
h P
o
bulk
.
2393 4 . 68
,
= =
W
s
kg
T T C m q
h h h p
h
905 . 183267 ) 8 . 37 99 )( 2393 )( 25 . 1 ( ) (
2 1 ,
.
= = =
) (
2 1 ,
.
c c c P
c
T T C m q =
C
C kg
J
s
kg
m W
o
o
c ) 30 45 )(
.
4224 )( ( 905 . 183267 =

sec
89 . 2
kg
mc =
Heat exchangers

T
c2
=30
o
C
T
h2
=37.8
o
C
T
c1
=45
o
C
1
2
1 2
ln
T
T
T T
T
lm
A
A
A A
= A
T
h1
=99
o
C
AT
1
= 54
o
C
AT
2
= 7.8
o
C
C T
C T
o
o
8 . 7 30 8 . 37
54 45 99
2
1
= = A
= = A
C T
o
lm
88 . 23 = A
2
2
2
17.0562
.
450
28 . 7675
.
450 min
28 . 7675
88 . 23
905 . 183267
m
C m
W
C
W
U
UA
A
C m
W
U g assu
C
W
C
W
T
q
UA
T UA q
o
o
o
o
o
lm
lm
= = =
=
= =
A
=
A =
Heat exchangers

m
L
A
ndp
m L g assu
1.0858
5 *
17.0562
5 min
= = =
=
t t
From table A-11 (Holman, 2002) at nominal pipe size =1/8 in
tubes
dp
ndp
n
m in OD
m in ID
in tube
tube
tube
159 158.919
10 * 833 . 6
1.0858
,
010287 . 0 405 . 0
10 * 833 . 6 269 . 0
3
3
~ = = =
= =
= =
out shell
dp n D * >
in m dp n
out
5.1069 0.1297 010287 . 0 * 159 * = = =
Heat exchangers

m dp n m D
m in D
out shell
shell
1297 . 0 * 0.14633
0.14633 5.761
= ) =
= =
C T
o
b
4 . 68 at mixture the of Properties =
:
s
m
C m
W
k
m
kg
o
2
7
w
3
10 99 . 4
m.s
kg
0002528 . 0
m.s
kg
0003339 . 0
.
1155 . 0
918 . 6 Pr
1 . 669
=
=
=
=
=
=
v
Heat exchangers

low turbulentf
s
m
m
s
m
dp u
s
m
m
m
kg
s
kg
A
m
u
A u m
m m
ID n A
in
cross tubes
cross tubes
tube cross tubes
=
=
=
= =
=
=
= =
=
4392.66
10 99 . 4
10 * 833 . 6 * 320806 . 0
*
Re
0.320806
0058299 . 0 * 1 . 669
25 . 1
*
* *
0.0058299 ) 10 * 832 . 6 ( * 159 *
4
* *
4
2
7
3
2
3
,
.
,
.
2 2 3
2
,
v
t
t
14 . 0
3 / 1 8 . 0
Pr Re 027 . 0
|
|
.
|
\
|
=
w
d
Nu
Heat exchangers

14 . 0
3 / 1 8 . 0
sec .
0002528 . 0
sec .
0003339 . 0
) 918 . 6 ( ) 4392.66 ( 027 . 0
|
|
|
.
|
\
|
=
m
kg
m
kg
Nu
d
43.898 = Nu
C m
W
m
C m
W
ID
k Nu
h
o
o
tube
in
.
742.068
10 * 833 . 6
.
1155 . 0 * 43.898
*
2
3
= = =

Heat exchangers

559 . 4 Pr
sec
10 9097 . 6
.
6304 . 0
.
10 03 . 8
.
10 862 . 6
096 . 993
2
7
4
4
3
=
=
=
=
=
=
m
v
C m
W
k
s m
kg
s m
kg
m
kg
o
w
Shell calculation:
C T
b
0
5 . 37
2
45 30
=
+
=
C T
b
o
5 . 37 at water of Properties The =
Heat exchangers

out shell
2
3
.
.
2 2 2 2 2
2 2
dp n + d
4 4
0.80855
0.0036023 * 096 . 993
89 . 2
*
* *
0.0036023 010287 . 0 * 159 *
4
0.14633 *
4
* *
4
*
4
t t
t t
t t
shell shell
shell
shell
tube shell shell
A
P
A
HD
s
m
m
m
kg
s
kg
A
m
u
A u m
m m m
OD n D A
= =
= =
=
=
= =
=
Heat exchangers

m
m m
m
HD 0.0025739
010287 . 0 * 159 * 0.14633 *
0.0036023 * 4
2
=
+
=
t t
low turbulentf
s
m
m
s
m
HD u
HD
= = =

3011.84
10 * 9097 . 9
0.0025739 * 0.80855
*
Re
2
7
v
14 . 0
3 / 1 8 . 0
Pr Re 027 . 0
|
|
.
|
\
|
=
w
d
Nu
14 . 0
4
4
3 / 1 8 . 0
sec .
10 03 . 8
sec .
10 862 . 6
) 559 . 4 ( ) 3011.84 ( * 027 . 0
|
|
|
.
|
\
|
m
kg
m
kg
Nu
d
26.576 =
d
Nu
Heat exchangers

C m
W
m
C m
W
HD
k Nu
h
o
o
out
.
6509.168
0.0025739
.
6304 . 0 * 26.576
*
2
= = =
C m
W
C m
W
C m
W
m
m
h h dp
dp
U
o
o o
out in in
out
.
458.185
.
6509.168
1
.
742.068 * 10 * 833 . 6
010287 . 0
1
1
*
1
2
2 2
3
=
+
=
+
=
2
2
16.751
.
458.185
28 . 7675
m
C m
W
C
W
U
UA
A
o
o
= = =
L dp n A
in tube
t =
m
m
m
dp n
A
L
in
908 . 4
10 833 . 6 * * 159
16.751
3
2
=
= =

t t
Heat exchangers

The properties of this shell-and-tube heat exchanger (E-101)
are:
s
kg
m
C T
C T
C T
C T
s
kg
m
water
o
out water
o
in water
o
h
o
h
h
89 . 2
45
30
8 . 37
99
25 . 1
.
,
,
2
1
.
=
=
=
=
=
=
m in OD
m in ID
tube
tube
010287 . 0 405 . 0
10 * 833 . 6 269 . 0
3
= =
= =

m in D
shell
0.14633 5.761 = =
C m
W
U
m A
tubes n
o
.
185 . 458
751 . 16
159
2
2
=
=
=
m Length 908 . 4 =
Heat exchangers

The properties of heat exchangers E-102 are as
follows:
C T
C T
C T
C T
s
kg
m
o
out water
o
in water
o
h
o
h
h
45
30
46
120
78 . 12
,
,
2
1
.
=
=
=
=
=
m in OD
m in ID
tube
tube
010287 . 0 405 . 0
10 * 833 . 6 269 . 0
3
= =
= =

m in D
shell
0.07366 900 . 2 = =
C m
W
U
m A
tubes n
o
.
298 . 21769
8657 . 2
27
2
2
=
=
=
m Length 944 . 4 =
Heat exchangers

The properties of heat exchangers E-103 are as follows:
s
kg
m
C T
C T
C T
C T
s
kg
m
water
o
out water
o
in water
o
h
o
h
h
4185 . 6
45
30
8 . 37
63
27 . 8
.
,
,
2
1
.
=
=
=
=
=
=
m in OD
m in ID
tube
tube
010287 . 0 405 . 0
10 * 833 . 6 269 . 0
3
= =
= =

m in D
shell
0.24765 9.75 = =
C m
W
U
m A
tubes n
o
.
1108.23
085 . 30
281
2
2
=
=
=
m Length 987 . 4 =
Heat exchangers

T-101
V-101
V-104
T-104
17
7
21
22
20
23
24
37
34
4
31
P-101 A/B
P-103 A/B
P-102 A/B
P-106 A/B
30
P-105 A/B
5
P-107 A/B
12
47
P-108 A/B
P-104 A/B
TT
TC
E-102
TC
TT
E-101
TT
TC
40
48
44
6
PT
15
13 E-103
26 10
27
V-102
E-107
E-105
E-104
T-103
T-102
14
25
LC
LC
V-103
LC
LT
LC
LT
Fc
FT
LC
42
38
LT
LC
45 46
1
2 3
35
39
32 33
36
11
PC
LC
LT
LT
LT
16
9
43
E-108
LT
LT
LC
41
P-107
E-106
Materials of construction (MOC)
The selection of materials of construction for equipment and facilities to produce
chemicals is a core subject of chemical engineering.
The desired products can not be manufactured without considering the selection
of optimum materials of construction used in the equipments of the process plant
for:

Safe.
Economical manufacture.
Required product quality.
The selection of materials of construction is guided by several important points
such as:
The corrosion of the materials by the chemicals used in the process.
The temperature.

All the equipments are operated below 400oC, carbon steel is selected because
it is cheap and strong.

Extraction
column
Stripping
column
Raffinate
water
wash
column
Solvent
recovery
column
Water
Stripper
Solvent
regenerato
r
Stripper
receiver
Recovery
column
receiver
Temperature
(
o
C)
Top
99 118 37.8 63 110 177 46 63
Bottom
85 168 37.8 169 121 - 46 63
Pressure
(atm)
Top
6.10 1.88 5.08 0.37 1.41 0.68 1.41 0.37
Bottom
8.83 2.22 5.08 0.59 1.48 - 1.41 0.37
Cont./ Materials of construction (MOC)
Solvent regenerator reboiler which is constructed from stainless steel.

The reason behind this is that sulfolane is a very stable extraction solvent, but
over time, and at high temperature in the presence of oxygen, it can form
acidic compounds.

The following four items are the main causes for corrosion/erosion
problems in the aromatics extraction unit using sulfolane:

Oxygen in the plant.
Chlorine in circulating solvent.
Accumulation of degradation and corrosion products in the plant.
High temperature in reboilers.

( )
( ) ( )
|
|
.
|
\
|

= A
cin hout
cout hin
cin hout cout hin
T T
T T
T T T T
T
ln
ln
Total module cost for different areas

( )
( )
ln
ln
T U
Q
A
T UA Q
A
=
A =
Optimization of process variables

Exchangers Type of
Exchanger
Tube
Pressure
(barg)
MOC Area
(square
meters)
Purchased
Equipment
Cost
Bare
Module
Cost
E-101 Multiple Pipe 6.18 Carbon Steel / Carbon Steel 15.8 $ 5,630 $ 18,500
Multiple Pipe 6.18 Carbon Steel / Carbon Steel 16.8 $ 5,940 $ 19,500
Total module cost for different areas
Total module cost for different types of pumps
Pumps
(with drives)
Pump Type Power
(kilowatts)
# Spares MOC Discharge
Pressure (barg)
Purchased
Equipment Cost
Bare Module Cost
P-101 Centrifugal 15.7 1 Carbon Steel 8.83 $ 6,280 $ 25,000
P-101 Positive Displacement 15.7 1 Carbon Steel 8.83 $ 14,000 $ 53,000
P-101 Reciprocating 15.7 1 Carbon Steel 8.83 $ 52,800 $204,000
P-102 Reciprocating 0.015 1 Carbon Steel 6.1 $ 9,470 $ 36,600
P-105 Reciprocating 0.755 1 Carbon Steel 5.08 $ 13,600 $ 52,500
Guide
Word
Deviation Possible Causes Consequences Actions Required
None No Flow - No feed material
being available.
- Outlet stream reduced
- The temperature increases
causing damage.
- Install low level alarm.
- Ensure good communication
with storage operator.
- Line Blockage,
Isolation valve
closed in error,
LCV fails shut
- Outlet stream reduced
causing damage.
- Check design of pump
strainers
- Pipes maintenance
- Installation for flow control.
- Line fracture - Outlet stream reduced
causing damage.
- Covered by a)
- Institute regular patrolling and
inspection of transfer line
HAZOP Study

Results of HAZOP of Pumps P-101A/B, P-102A/B, P-103A/B, P-104A/B, P-105A/B,
P-106A/B, P-107A/B and P-108A/B
More
of
Flow - LCV fails or LCV
bypass open in
error
- More Material
flow
- Low Outlet stream
- It may overload
motor.
- Install high flow alarm
(HFA) and check sizing of
relief opposite liquid over
filing.
- Repair FCV
Pressure - Isolation valve
closed in error or
LCV closed.
- Plug in pipe
Failure of MOC - Check lines and reduce
stroking speed of LCV id
necessary.
Temperature
- TCV Failure
- Loss of cooling
water due to
pump failure
- Higher
consumption for
cooling water in
other unit which
decrease the
cooling water.
- High Temperature
in transfer line.
- Affects tensile
strength of MOC
- Plant shut down
- Install a high Temperature
alarm
- Repair TCV
- Do a circulation for the feed
to avoid plant shutdown
and do the maintenance
mean while.
Less
of
Flow - FCV Failure

- Low material

flow
- Leaking
- Material Loss
- Low outlet stream
- Repair FCV
Cont./HAZOP Study

Cont./HAZOP Study

Pressure - Inlet valve or suction line may be
clogged
- Optimum condition not reached
- MOC failure if vacuum reached
- Causes cavitations which will damage
the component of the pump.
- Great deal of noise.
- Vibration and less of efficiency.
- Low pressure alarm
(LPA)
- Maintain inlet valves
Temperature - TCV Failure - Plant shut down - Low Temperature
Alarm (LTA)
- Decrease the
processing flow rate
to optimum rate
- Repair TCV
Maintenance - Equipment Failure - Line cannot be completely drained or
purged
- Install alarms.
Cont./HAZOP Study

Results of HAZOP for Extractor column T-101
Guide Word Deviation Possible Causes Consequences Actions
Required
None No Flow - No naphtha
feed available
- The column may be washed by solvent, leaving from
the bottom. (Quality and amount of product will
suffer)
- Install low
level alarm.
- No solvent flow - No separation of the naphtha feed - Install low
level alarm
- Line fracture - Accidental discharge to the environment (aromatics
are flammable material).
- Plant shut
down.
More of Flow - LCV fails open
in error
- Erosion.
- Overload the equipment.
- Overfills
- Material carry-over or inefficient separation.
- Further
evaluation of
additional cut-
off valve and
shutdown
system.

Cont./HAZOP Study

Pressure - Isolation valve close in
error
- Failure of a vessel or the
associated piping leading to
sequence events that result in a
disaster.
- Other streams may be diverted
leading to spillage.
- Pressure relief device.
- High pressure alarm (HPA)
- Back up pump
- Maintain pipe
More flow of
solvent
- Control valves fail open or
too far open or misdirected
when on manual (FCV
Failure).
- Action reversed or
controller.
- More material flow
Decrease selectivity of the
separation.
- Install high level alarm and
check sizing.
Temperature
- Higher pressure in transfer
line
- High miscibility.
- TCV Failure
- Uncontrolled mixing of water with
hydrocarbons which generate
high pressure conditions causing
damage.
- The components present in the
mixture will flash to steam and
then can rupture pipes and
vessels.
- Equip the system with pressure
relief device.
- High Temperature Alarm
(HTA).
- Repair TCV.
Cont./HAZOP Study

Less of Flow of solvent - Incorrect rate of process flows.

- FCV Failure.
- Low material

flow.
- Aromatic compounds
may well be lost to the
raffinate providing a
pure product but
achieving a less than
complete recovery.
- Isolate that
part of the
plant
- Repair FCV
Others Maintenance - Equipment Failure - Line cannot be
completely drained or
purged
- Install alarms.
Cont./HAZOP Study

Results of HAZOP for Water wash column V-101
Required
None Flow - No non-aromatic
compounds
- Water coming from stream 13
only pass through the
equipment
- low separation of non-aromatic
- Install low
level alarm
- Line fracture Accidental discharge to the
environment.
- Plant shut
down.
More of More flow of
water coming
from recovery
column receiver
- LCV fails open in error
- Overfills
- Water washes more material of
the non-aromatics
- Install high
level alarm
and check
sizing.
Cont./HAZOP Study

Results of HAZOP for Stripper column T-102

Required
None No Flow - No flow in stream
9 coming to the
column
- Quality and amount of product will suffer. - Install low level
alarm
- Line fracture - Accidental discharge to the environment
(aromatics are flammable material).
- Plant shut
down.
More of Flow - LCV fails open in
error
- Overfills
- Incomplete separation of non-aromatics from
solvent + aromatics
- Install high
level alarm and
check sizing.
Pressure - Isolation valve
close in error
- Full pump delivery - Isolation valve
close in error
Temperature - Higher pressure in
transfer line
- Degradation of the solvent quality will become
significant ms.
- High
Temperature
Alarm (HTA).
Cont./HAZOP Study

Less of Flow - Leaking flange of valve - Material discharge
to the environment
- Isolate that part of
the plant
Others Maintenance - Equipment Failure - Line cannot be
completely drained
or purged
- Install alarms.
Cont./HAZOP Study

Results of HAZOP for Recovery column T-103

Guide
Word
Deviatio
n
Possible Causes Consequences Actions Required
None No Flow - No flow in stream 11 - No aromatic separation - Install low level alarm
- Line fracture - Accidental discharge to the
environment
- Plant shut down.
More of More flow of
solvent rich
aromatics
- LCV fails open in error - Erosion.
- Leaks from other process.
- .
- Install high level alarm
and check sizing.
Pressure - Isolation valve close in
error
- Failure of a vessel or the associated
piping
- High pressure alarm
(HPA)
- Back up pump
Temperature - Higher pressure in
transfer line
- Degradation of the solvent which
leads to fouling and corrosion
problems.
- High Temperature Alarm
(HTA).
- Repair TCV.
Less of Flow - Leaking flange of valve
- Incorrect rate of process
flows.
- FCV Failure.
- Low material

flow.
- Material discharge to the
environment
- Isolate that part of the
plant
- Repair FCV
Cont./HAZOP Study

Results of HAZOP of Solvent regenerator V-104

Deviation Causes Consequences Action
More of Temperature
- TCV Failure
- Solvent degradation
causing corrosion to the
equipment.
- Equip the system with pressure relief
device.
- High Temperature Alarm (HTA).
- Repair TCV.
Pressure - Blockage in some of
the outlet streams.
- High flow in the inlet
streams.
- Failure of a vessel or the
associated piping leading to
sequence events that result
in a disaster.
- Pressure relief device.
- High pressure alarm (HPA)
- Back up pump
- Maintain pipe
Flow - Control valves fail
open or too far open
or misdirected when
on manual (FCV
Failure).
- Action reversed or
controller.
- More material flow
- Erosion.
- Leaks from other process
streams or the environment.
- Material carry-over or
inefficient separation.
- Further evaluation of additional cut-off
valve and shutdown system.
- Restriction orifice in line.
- High flow alarm (HFA)
- Repair FCV
Cont./HAZOP Study

Less of Temperature - TCV Failure - Low separation efficiency. - Low Temperature
alarm (LTA)
- Repair TCV
Flow - Incorrect rate of process flows.
- FCV Failure
- Low material

flow
- Less separation - Repair FCV
Pressure - Inlet valve or suction line may be
clogged
- Optimum condition not
reached
- Low pressure alarm
(LPA)
- Maintain inlet
valves
Level - Low flow in the feed stream. - Can result in gas entering
the heat exchanger surface.
- Low flow alarm
(LFA)
None Flow - Plug in pipe
- pipe ruptures
- No materials flow
- No separation - Low flow alarm
(LFA)
- Pipes maintenance
- Installation for flow
control and pumps
to increase the flow
upon loss.
Site Selection
The initial drive of this project is the interest of ENOC, a Dubai-based
company, to separate aromatics. The Dubai area was there for our first
choice.
Jebel Ali Free Zone was chosen as the best location to construct the plant.

Why JAFZA
Jafza is built over an area of 48
square kilometers, a few
kilometers from the city of
Dubai. It ranks among the
worlds largest and the fastest
growing free zones.

Free Zone Analysis
Demographic Analysis: All labor available with different educational
levels.
Trade Area Analysis: Feasibility of accessing the trade area.
Competitive Analysis: The nature, location, size and quality.
Traffic analysis: Logistics for transporting raw materials and products.
Site economics: Establishment and operational costs are fair as there is no
taxes.

Alternative Site, Ruwais Refinery

The Ruwais Refinery is to the west of Abu Dhabi about 240 kilometers. It
was built in the 1970s. It was officially opened in 1982. It started with
120,000 barrels per day (bpd) and, in June 1981, a 27,000 bpd were added
later.

HSE (Health, Safety & Environment) at Ruwais
Safety and operations comply with the ADNOC Environmental
Protection, Occupational Health and Safety policy.

Cost Analysis

Economics refers to evaluating the operating and capital costs that is
related with the operating and constructing of a new chemical plant.
Capital cost associated with the construction of a new plant. It is
concerned with design, constructions, equipment and their installation,
piping, control systems, buildings and structure, auxiliary
facilities(utilities and land).
Capital Cost

The CAPCOST program
will be used to calculate the
fixed capital cost.
It takes into account direct
and indirect cost, contingency,
fees, and auxiliaries.

Direct Indirect
Fixed
Capital
Investme
nt
Waste
Treatment
Raw
Material
s
Operating
Labor
Utilities
Maintenance
Manufacturing Cost

CAPCOST

The CAPCOST program is used to determine the capital cost of different
items of equipment in the process plant, which are heat exchangers, pumps,
vessels, extraction and distillation columns.
Pumps Power (KW)
Discharge Pressure
(barg)
Purchased
Equipment Cost
Bare Module
Cost
P-101 15.7 8.83 $ 6,280 $ 25,000
P-102 0.015 6.1 $ 3,270 $ 13,000
P-103 23.4 6.1 $ 7,510 $ 9,900
P-104 6.47 8.83 $ 4,560 $ 18,100
P-105 0.755 6.1 $ 3,270 $ 13,000
P-106 19.3 8.83 $ 13,700 $ 54,700
P-107 18.1 2.05 $ 6,670 $ 26,600
P-108 0.308 6.1 $ 6,530 $ 26,000
Heat Exchangers
Area (square
meters)
Purchased Equipment
Cost
Bare Module Cost
E-101 30.1 $ 13,700 $ 45,200
E-102 2.86 $ 4,970 $ 16,400
E-103 16.8 $ 7,920 $ 26,000
All pumps are centrifugal
All heat exchangers are multiple pipes and are centrifugal.
Cont./CAPCOST

All purchased towers are empty vertical vessel
Distillation
column
Height
(meters)
Diameter
(meters)
Pressure
(barg)
Purchased
Equipment Cost
Bare Module
Cost
T-101 45 9 1 $ 2,350,000 $ 10,400,000
T-102 39 7.7 2.22 $ 1,490,000 $ 7,870,000
T-103 21 3 0.59 $ 127,000 $ 515,000
Vessels Orientation
Length/Height
(meters)
Diameter
(meters)
Pressure
(barg)
Purchased
Equipment
Cost
Bare Module
Cost
V-101 Vertical 2.81 0.937 5.08 $ 5,750 $ 23,800
V-102 Horizontal 5.09 1.7 1.41 $ 15,200 $ 45,900
V-103 Horizontal 4.34 1.44 0.37 $ 11,700 $ 35,200
Total purchased cost = $ 4,078,030
Utilities cost

The costs of utilities are influenced by the cost of fuel affecting the
cost of electricity, steam, and thermal fluids.

Pumps Power

/year 7662.56 $ 0.95
year
day
365
day
hr
24
KW.hr
$
0.06 KW 15.34 cost
KW.hr
$
0.06 on substituti electric
KW 34 . 15
0.96
KW 15.69
power actual
A/B 101 - pump
= =
=
= =
P-101
A/B
P-102
A/B
P-103
A/B
P-104
A/B
P-105
A/B
P-106
A/B
P-107
A/B
P-108
A/B
Power (kW) 15.69 0.015 23.43 6.47 0.75 19.30 18.08 0.308
Power/ (kW) 15.34 0.0156 24.40 6.73 0.78 20.104 18.83 0.3208
Cost ($/yr) 7662.56 7.79 12183.41 3360.42 389.47 10038.33 9402.20 160.18
Cont./Utilities cost

Cooling water

Heat exchangers (GJ/hr) 10.7006
Stripper column(GJ/hr) 1.656*10
-8

Recovery column(GJ/hr) 1.51*10
-9

Heat Duties of equipments
$/year 31523.839 0.95
year
day
365
day
hr
24
GJ
$
0.354 hr 10.7006GJ/ Cost Total
0.354$/GJ water cooling of Cost
GJ/hr 10.7006 duty of amount Total
= =
=
=
Materials cost

Sulfolane cost

Sulfolane cost is equal to $4000/tones, where the total amount required in
the process is 6.228 tones/year.

Total cost of material = $4000/tones * 6.228 tones/year = 24,914.57
$/year
Mass of Sulfolane (Kg/hr) 0.068
Density of Sulfolane(Kg/m
3
) 1261
(hr) 0.25
mass/density 0.000053
V(m
3
) 0.000013
annual purchase ($/yr)
0.00243
Cost of labor

year 245shifts/ ek.labor 5shifts/we ar 49weeks/ye r.labor shift /yea of number
k.labor 5shift/wee k.labor shift /wee of number
49weeks /labor work week of number total
ar 52weeks/ye week/year of number total
= =
=
=
=
4.47
r yrear.labo 245shifts/
/year 1095shifts
any time at plant in the needed operator of number
/year 1095shifts y 3shifts/da r 365day/yea shift/year of number total
3shift/day
8hr/shift
24hr/day
r sheft /yea of number
= =
= =
= =
( )
( )
year
$
700,000
year
$
50,000 14 labor of cost
year
$
50,000
hour
$
25
shifts
hours
8
year
shifts
245 hour working
14labor 13.28 4.47 2.97 Nol
2.97 11 0.23 31.7(0) 6.29 Nol
equipment of number N
handling solid of number P
labor of number Nol
N 0.23 31.7P 6.29 Nol
2
np
2
np
2
= =
~ =
= = =
= + + =
=
=
=
+ + =
Profit Calculations

Total capital cost $ 4877512.59
COM $ 3,330,399
depreciation= 0.1 TCC 0.1
Tax rate 0.2
BTX selling price $/Ib 3.95
BTX density 0.8765
Total amount of BTX produced is 835,438.9425 tones/year
year
$
700.36 5,817,991, on depreciati after tax Profit Cash
$ 25 . 751 , 487 Cost Capital Total 0.1 on Depreciati
year
$
949.10 5,817,503, tax tax before Profit after tax Profit
year
$
27 . 987 , 375 , 454 , 1 2 . 0 936 , 879 , 271 , 7 rate tax income Net tax
year
$
936 , 879 , 271 , 7 income Net tax before Profit
year
$
936 , 879 , 271 , 7 COM - sale from Income income Net
year
$
7275210336 ) 62 . 2204 * 95 . 3 ( 94 . 835438
($/tones) price Selling (tones/yr) rate Production sale from Income
= + =
= =
= =
= = =
= =
= =
=
= =
Safety & Environmental impact

Hydrocarbon toxicity stands for toxic intake of either
petroleum or nonpetroleum-distillate hydrocarbons.

It has a considerable absorption through the human
digestive system causing:
Local toxicity (breathing problems, choking,
vomiting, cough, long term fever).
Systemic toxicity (depression, euphoria, headache,
dizziness and heart failure in severe cases).

Cont./Safety & Environmental impact

There is a large body of toxicity data related to
aromatic extract (hazardous products ).

Long-term exposure to high levels of benzene vapor
can cause serious health risks which has been
classified as a human carcinogen by the International
Agency for Research on Cancer (IARC).

Conclusion
The objective was to design of a process plant that handles approximately
37.89 m3/hr of an aromatic-rich blend of pyrolysis naphtha and coke oven
light oil to separate aromatics such as benzene, toluene and xylenes by using
an aromatic-selective solvent (sulfolane).

Following missions were done: Material and energy balance, Design of
every piece of equipment, Hazop study, safety and ethical considerations,
cost analysis and the site selection.

Final GP2 Process Plantfor Aromatic Extraction

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Final GP2 Process Plantfor Aromatic Extraction

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PROCESS PLANT

Gas velocity in the tower (u) = (1.2 -1.5)/ (1.237)

To calculate the head of the pump, the following equation is used:

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