017 FinalReport PDF

Senior Design Final Report
Professor J.A. Sykes

May 12, 2006
By Team #7:
Larae Baker
Maxine Bent
Jonathan Bush
Mike Heslinga
Adam Jones
Abstract: A new process to produce styrene monomer is under development by Dow

Chemical and Snamprogetti. Team #7 has designed and simulated an industrial plant to
produce two billion pounds of styrene monomer per year. An advantage to the new
process is that it starts with a less expensive raw material, ethane, instead of ethylene.
The process has three key stages: 1.) A distillation reactor alkylates benzene and
ethylene to make ethylbenzene. 2.) A dehydrogenation reactor where ethylbenzene and
ethane are converted into styrene and ethylene respectively. 3.) A distillation train where
a purity of 99.93% styrene is achieved. Styrene can be produced at an estimated market
price of $0.99/lb with this process.
Table of Contents
1
INTRODUCTION..................................................................................................... 4
THE CHEMISTRY .................................................................................................. 4

2.1
2.2
2.3
ALKYLATION ....................................................................................................... 4
DEHYDROGENATION ............................................................................................ 6
POLYMERIZATION ................................................................................................ 7
OBJECTIVES ........................................................................................................... 8
PROCESS DESCRIPTION ..................................................................................... 9

4.1
DESIGN ALTERNATIVES ....................................................................................... 9
4.1.1 Styrene from Ethylene and Benzene.............................................................. 10
4.1.2 Co-Production of Styrene and Propylene Oxide .......................................... 10
4.2
AREA 100 ALKYLATION .................................................................................. 10
4.2.1 Equipment Design......................................................................................... 11
4.2.2 Catalyst Design............................................................................................. 13
4.3
AREA 200 DEHYDROGENATION ...................................................................... 13
4.3.1 Equipment Design......................................................................................... 14
4.3.2 Catalyst Design............................................................................................. 16
4.4
AREA 300 SEPARATIONS OF AROMATIC PRODUCTS ........................................ 17
4.4.1 Separations Train and Column Design......................................................... 17
4.4.2 Separations Inhibitors................................................................................... 20
4.5
AREA 400 LIGHT GAS SEPARATION ................................................................ 21
4.6
HEAT EXCHANGER DESIGN ................................................................................ 22
4.7
PUMP, COMPRESSOR AND TURBINE DESIGN ...................................................... 23
4.8
MATERIALS OF CONSTRUCTION ......................................................................... 24
ENVIRONMENTAL, HEALTH AND SAFETY ISSUES.................................. 25

5.1
5.2
5.3
ENVIRONMENTAL CONCERNS ............................................................................ 25

CHEMICAL HAZARDS ......................................................................................... 26
SAFETY HAZARDS .............................................................................................. 27
CONTROL DESIGN .............................................................................................. 28

6.1
6.2
6.3
6.4
CONTROL DESIGN ON AREA 100........................................................................ 28

ECONOMIC ANALYSIS ...................................................................................... 32
UNCERTAINTIES AND ASSUMPTIONS.......................................................... 34
FUTURE WORK .................................................................................................... 34
1 Introduction
Styrene is a precursor to many polymer products such as polystyrene, acrylonitile
butadiene styrene (ABS), styrene-acrylonitrile, and various styrene-butadiene
products. These materials are used around the world in a variety of ways including
food storage, packaging, and automobile parts.1 The market for styrenics has seen
overall growth in the previous decade despite a recent down year. The market is
expected to recover and see large gains in the near future. Therefore, now is an
excellent time to join the market, particularly if current styrene production cannot
meet future demand.2
The process of producing styrene is well established. It was first produced in the
1930s by I. G. Farben in Germay and Dow Chemical in the United States. Styrene
is a clear liquid at room temperature with an aromatic odor. It is currently sold with
a minimum purity of 99.8% but is more commonly produced at 99.93%. The price
of styrene remains largely dependant on the cost of its raw materials.3
2 The Chemistry
Production of styrene requires two reactions, an alkylation and a dehydrogenation.
2.1 Alkylation
The alkylation is a basic Friedl-Crafts alkylation, where ethylene reacts with benzene
to form ethylbenzene by Reaction 1a:3
(Rxn 1a)
This reaction is exothermic and takes place in a distillation reactor system that is
partially packed with catalyst. The benzene is in vapor-liquid equilibrium and it is
alkylated as it passes through the catalyst.4 This alkylated product has a lower
boiling point than benzene and will therefore become the distillate product in the
column. The catalyst is a molecular sieve known as EBZ-500S available through
UOP, LLC. EBZ-500S minimizes the amount of byproduct, such as polyaklylated
and oligomerized products.5 The polyalkylated products that are formed come off in
the bottoms of the distillation. They are sent to a transalkylation reactor to be
converted back to ethylbenzene by Reaction 1b:
(Rxn 1b)
The catalyst in this reaction is EBZ-100, also available through UOP, LLC.
Oligomerization products are caused by the partial polymerization of ethylene.
These may either come off the top of the column or aklylate with benzene to form
byproducts that include cumene, n-propylbenzene, butylbenzenes as well as other
heavy alkybenzenes. Other byproducts come from the raw materials; for example,
toluene and C6 non-aromatics can be present in the benzene feedstock, up to
1000ppm and 2000ppm respectively. These can also be alkylated, and leave as a
bottoms product.3
2.2 Dehydrogenation
The dehydrogenation occurs in a fluidized catalyst cracking reactor, or FCC.6 An
FCC was chosen over other reactor systems because it has the advantage of
continuous catalyst regeneration. The catalyst is comprised of gallium oxide
(Ga2O3), platinum, iron oxide (Fe2O3), potassium oxide (K2O) and silica suspended
on alumina.7 It is unique in that is used to simultaneously dehydrogenate ethane and
ethylbenzene via reactions 2a and 2b:
H2
(Rxn 2a)
H2
(Rxn 2b)
These reactions are highly endothermic. The energy for the reaction is provided by
the catalyst in the regeneration reactor, where it is heated to 660C upon decoking.
The catalyst needs to be decoked continuously because two side reactions occur that
form toluene, benzene and coke, as shown in Reactions 2c and 2d:
Coke
(Rxn 2c)
Coke
(Rxn 2d)
The coke deposits on the catalyst, reducing the number of active sites, and thus
lowering the conversion of the desired reactions, 2a and 2b.8 Toluene can also lose
another carbon to become benzene. These reactions account for total of 3% loss in
conversion.3 Reactions 2a and 2b are also highly selective with 90-94% and 90-93%
selectivities respectively.9
Other byproducts in the dehydrogenation form from byproducts in the alkylation.

For example, dehydrogenated cumene becomes -methylstyrene and npropylbenzene becomes allylbenzene. Other byproducts include vinlytoluenes,
xylenes, ethyltoluenes, phenylacetylene, unconverted alkylation byproducts and
heavy aromatics. These byproducts are insignificant in terms of yield loss, but
greatly affect the cost of purification and quality of the product.3
2.3 Polymerization
Under the right conditions styrene can polymerize violently. This is an exothermic
reaction; therefore, once polymerization begins it can escalate out of control.3
Polymerization is most likely to occur in the purification and storage phases of
production. Inhibitors are necessary to prevent this. For the storage tanks 4-tert-
Butylcatechol, or 4-TBC, is used in a concentration of 15 ppm. The tank is held

below 75F and oxygen is bubbled through the tank to increase the lifetime of the
styrene product. In the distillation columns 2,4-Dinitrophenol is fed continuously.10
These steps allow the final product to be sold at a purity of 99.93% styrene
monomer, this is equal to the industry standard.
3 Objectives
The following objectives were satisfied in the design:
1.) To design a plant with the capacity to produce styrene monomer at a rate of 2.2
billion lbs/yr with a purity at or above the industrial standard of 99.93 wt%
2.) To analyze the design to determine whether it is economically competitive at the
average market price over the past three years
3.) To develop the design with the following design norms in mind:
a. Justice and caring Design decisions were made that consider the rights
and needs of all stakeholders, even those seemingly unaffected by the
plant. If styrene products can be made available to more people at a
lower cost, people of a wider economic range might be able to benefit
more from this product.
b. Trustworthy People living around this plant need to trust that they will
be safe, even in the case of an accident. Customers need to be able to
trust the operators of the plant to have the amount of styrene promised at
the specification needed. Customers rely on knowing that the process
will not only run continuously, but also at the required purity.
c. Stewardship Caring for the earth and all that is in it was a key motivator
in designing a chemical processing plant. Making sure that the plant is
optimized to not have more adverse affects on the environment than is
necessary and also being sure that none of our starting materials go to
waste, but are used to their fullest potential. Additionally, optimized
equipment allows the plant to operate using the less energy than nonoptimized.
4.) To simulate the design using HYSYS
5.) To choose a suitable location for the plant to be built
6.) To determine the design specifications on the following pieces of process
equipment: compressors, turbines, pumps, heat exchangers, distillation columns
and reactors.
4 Process Description
The process to synthesize styrene monomer from ethane and benzene can be
simplified to four stages: alkylation, dehydrogenation, light gas separations, and
separations of aromatic products. However, starting with different raw materials
would lead to different designs.
4.1 Design Alternatives

There are two major design alternatives prevalent in industry today. The first is the
production of styrene from ethylene and benzene via an ethylbenzene intermediate.
The second is the co-production of styrene and propylene oxide from ethylene,
benzene and propylene.
4.1.1 Styrene from Ethylene and Benzene

The production of styrene from ethylene and benzene is the most common industrial
process to produce styrene. A basic Friedl-Crafts Alkylation occurs between
ethylene and benzene forming ethylbenzene. The ethylbenzene is then
dehydrogenated to form styrene.11 These are the same as reactions 1a and 2a,
respectively. Therefore, the impurities, catalysts, and separations of aromatic
products are the same as with the designed process.
4.1.2 Co-Production of Styrene and Propylene Oxide

Styrene is produced via the oxidation of ethylbenzene (formed from ethylene and
benzene) to ethylbenzene hydroperoxide. The ethylbenzene is epoxidized with
propylene, forming propylene oxide and -phenylethanol, the later of which is
dehydrated to form styrene. The amount of styrene produced is very dependant on
the market for propylene oxide because this process is a co-production. This process
also requires very complex and costly separations due to the aldehydes that form and
hinder the polymerization of styrene, a major concern for the customer.3
4.2 Area 100 Alkylation

The distillation reactor system requires four distillation reactors (R-100) run in
parallel, one distillation column (T-100), and four packed bed reactors (R-101) run in
parallel. The process begins with benzene and ethylene reacting to form
ethylbenzene, the precursor to styrene.
4.2.1 Equipment Design

A Friedl-Crafts alkylation occurs in a distillation reactor system. Benzene and
ethylene (recycled from the ethylene and ethane separations process) enter a
distillation reactor. The distillation reactor contains twenty-five trays, but is packed
with catalyst in the upper 30 vol% of the reactor.4 It is 6.5m tall and has a 1.9m
diameter. Two streams enter the reactor system; one is rich in benzene and the other
is rich in ethane with 9.01 mol% ethylene. The ethane exits as the distillate of R100, thus removing a distillation column from the Area-300 design. The inlet stream
with ethylene can operate at concentrations up to 95% ethane, with the remainder
ethylene. The boiling point of ethylbenzene is greater than ethane or benzene, so
once the ethylbenzene is formed it falls down the reactor as the bottoms product.
This reactor design has several advantages over the more industrially common
packed bed reactor:4
1.) High conversion of ethylene is controlled by having a 10:1 ratio of benzene to
ethylene and sufficiently large height of packed catalyst. This minimization of
unreacted ethylene reduces separation and recovery problems.
2.) The benzene that comes off the reactor as the distillate is recycled back to the
reactor feed. A purge is added so that very light gasses do not accumulate. Only
the benzene that has reacted leaves the distillation reactor.
3.) The continued removal of the alkylated and polyakylated products forces the
chemistry in Reaction 1a to favor the products. This also minimizes both the
polysubstitution and decomposition of the product.
4.) Because the compounds in the distillation reactor are boiling, the temperature at
which the reaction takes place is controlled by the boiling point of the mixture.
This has the further advantage that as the exothermic alkylation takes place the
reaction enthalpy increases the boil-up.
5.) The rate of reaction and distribution can be well controlled by regulating the
system pressure. Thus, upon piloting this process, the distillation reactor
efficiency can be increased significantly.
6.) Two stages are condensed into one; the first stage would consist of the reaction
of benzene and ethylene to ethylbenzene. The second would be the separation of
benzene from ethylbenzene. These two processes occur in one distillation
reactor.
The bottom products from the distillation reactor are then sent to a distillation
column, where the polyalkylated benzenes (mostly di- and tri- ethylbenzene) are
separated from ethylbenzene. This design achieves a purity of 99.78 mol%
ethylbenzene in the distillate. The bottoms product is entirely byproducts. The
polyalkylated benzenes, along with the heavier impurities, are sent to a
transalkylation reactor where reaction 1b occurs. The transalkylation unit is a
packed bed reactor. In the presence of more benzene, the formation of ethylbenzene
from the polyalkylated benzenes is favored.3 The unconverted polyalkylbenzenes
are then recycled to distillation column T-100. The 99.78 mol% pure ethylbenzene
is sent on to the dehydrogenation.
4.2.2 Catalyst Design

There are two catalysts used in Area-100. EBZ-500S is available from UOP and is
used in the distillation reactor. Its a zeolite catalyst in the solid -phase. It has a
spherical shape with a nominal diameter of 2.2mm and is absent of precious metals.
Unwanted side-reactions are minimized and it more resistant to poisons like water,
oxygenates, olefins, chlorides and sulfur. EBZ-500S has a life time of five years
without regeneration and can be regenerated up to three times, thus allowing the
catalyst to be used for 20 years before replacement.5 It is available from UOP for
approximately $105 per pound.12 When used in conjunction with EBZ-100 in the
transalkyation, a purity of 99.97% ethylbenzene can be achieved. EBZ-100 is
another catalyst also available through UOP. It is specifically designed to operate in
the transalkylation. It is also a solid zeolite catalyst with no precious metals and has
a nominal diameter of 1.6mm with an extrudated shape. Its life time is five years
without regeneration and it can be regenerated three times, and needs to be replaced
every 20 years.13 Its cost is $40 per pound.12 Together these solid catalysts will
provide the desired conversion for the distillation reaction system.
4.3 Area 200 Dehydrogenation

The fresh ethane feed and the ethylbenzene formed in Area-100 enter the
dehydrogenation . Four reaction vessels designed to the specifications of R-200 and
R-201 are used in parallel, allowing for temporary shutdown of one reactor. Here
Reactions 2a and 2b form the main product, styrene, along with ethylene. Side
reactions occur to form toluene, benzene, and coke.
4.3.1 Equipment Design

The fluidized catalyst cracking reactor (FCC) has two reaction vessels, RV-200 and
R-201. Ethane and ethylbenzene enter R-200 and form the dehydrogenated products
ethylene and styrene respectively. At the inlet of R-200 the ethane to ethylbenzene
volumetric feed ratio is 4.08:1. At this feed ratio, the product of conversion and
selectivity for Reaction 2a is 48% and for Reaction 2b is 9.7%.7 R-200 uses the
Optimix LSi FCC feed distribution system available through UOP LLC. The
ethane and ethylbenzene carry the solid catalyst to the top of the reactor, where it
exits through special disengaging arms which generate a centrifugal flow pattern.14,15
This is designed to disperse the catalyst uniformly in the riser of the reaction vessel.
The catalyst remains fluidized by the reagent mixture in the gaseous phase. The
dynamics of the reaction vessel cause the catalyst to move downward (due to
gravity) and components in the gaseous phase to move counter-current to the
catalyst. This causes thorough mixing between the catalyst and reaction
components. Ethane, ethylene, ethylbenzene, styrene, toluene, and benzene are the
major compounds leaving the FCC chamber, along with the dehydrogenated form of
the Area-100 byproducts. A solid side product, coke, is produced via Reactions 2c
and 2d, and deposits onto the catalyst.3 The gaseous products leave the reactor
through a solid filtering technique, known as cyclones. The cyclones extend towards
the bottom of the riser, but stop before the catalytic stripping part of R-200. This
design is common in VSS reactor systems available through UOP LLC. It contains
the hydrocarbons to the riser of the reactor and pre-strips the catalyst.15 The catalyst
falls further to an AF spent catalyst stripper, also available through UOP LLC. In
the catalyst stripper, absorbed hydrocarbons leave the catalyst particles. The catalyst
falls to the bottom of the stripping trays and is sent to regenerator R-201.16
In the regenerator the coke deposited on the catalyst is burned off via air at 560C,
producing carbon-dioxide. Hydrogen, recycled from Area-400, also enters R-201
and is combusted to produce water. By this process, the catalyst is heated to 680C
and transported back to R-200. The high temperature of the catalyst provides the
heat of reaction for Reaction 2a and 2b to occur. There are several reasons to use a
reactor-regenerator system:7
1.) The catalyst is continually regenerated. By continually removing coke the
catalyst will not degrade over time. This means the operating parameters and
catalyst performance will be constant for the lifetime of the plant.
2.) The heat for Reactions 2a and 2b are provided by the catalyst, thus super-heating
ovens are not needed.
3.) The re-mixing of the fluidized bed prevents hot spots from forming, which would
lower selectivity.
4.) The hydrogen can be recycled to R-201, where it is burned.
5.) The process can be made continuous without changing the operating parameters
of the plant over its lifetime.
6.) R-200 and R-201 are physically separate. This disallows mixing between the
hydrocarbons and any oxygen, an inherent process danger.
7.) Less inert gas needs to be used in the feeding to the reactor, thus higher
concentrations of the reactants can be used, which lead to higher reaction
selectivites.
4.3.2 Catalyst Design

This process is very catalyst-specific. Therefore, the design and development of the
catalyst is crucial. The catalyst in Area-200 is comprised of less than 10 wt% Ga2O3,
20 wt% Fe2O3, 100 ppm platinum, and the remainder alumina. The catalyst is
synthesized in a four-step process. The promoters are added to the carrier via an
aliquot. The sample dried at 150C and calcinated at 900C. The iron oxide and
remaining promoters are added to the carrier. The catalyst is dried and calcinated
again, as described previously.7 In order to determine the amount of catalyst needed
for a given feed composition, data from Figure 1 was taken from US patents
#6,031,143:
Weight of Catalyst vs. Ethane to EB Volumetric Ratio
300
Styrene
Ethane
250
200
g/h/kgcat
y = 498.18x-0.6678
R 2 = 0.9967
150
100
50
y = 17.28x0.5396
R 2 = 0.9996
0
0
10
Ethane/EB vol
Figure 1: Weight of Catalyst vs. Ethane and Ethylbenzene Volumetric Ratio
12
The catalyst for the selective combustion of hydrogen is available through UOP and
is OC-5. It is a solid sphere with a nominal diameter of 3.8mm and a density of
750 kg/m3.17 OC-5 uses platinum as a promoter and is available at $115 per
pound.12
4.4 Area 300 Separations of Aromatic Products

The separations system is set up to recover styrene at a purity of 99.93%, toluene at a
purity of 99.75%, benzene at a purity of 99.85%, and ethylbenzene at a purity of
98%. This system uses seven distillation columns of which three are for the
purification of styrene. The inhibitor 2,4-dinitrophenol is used in this system to
prevent the polymerization of styrene. The components that enter Area-300 can be
simplified into six categories: Light gases, C6 non-aromatics (modeled as n-hexane),
benzene, toluene, ethylbenzene, styrene, and heavy aromatics.
4.4.1 Separations Train and Column Design

In column T-300, light gases such as ethane and ethylene are vented to the light
gases area. Toluene and benzene are separated from ethylbenzene and styrene. To
ensure minimal styrene polymerization product the temperatures should stay low. T300 is a packed column which uses Flexipac HC structured packing, available
through Koch-Glitsch. The advantage to using structured packing is that there is a
small pressure drop across each stage of approximately 0.05 psi. This minimizes the
temperature difference across the column and therefore the temperature necessary in
the reboiler, which is crucial in preventing polymerization of the styrene product.
The column operates at vacuum conditions with a pressure of 26.7 kPa. It contains
66 stages, with the feed entering in the 50th stage. The diameter is 2.04m and its
height is 40.23m. The reflux ratio is optimized at 12:1. The distillate product is rich
in toluene (49.6 mol%) and benzene (49.1 mol%), with some n-hexane (1.2 mol%)
and the remainder ethylbenzene (0.1 mol%). These products are sent to column T301.
In T-301, a column of 23 trays, toluene is purified and leaves as the bottoms product.
It has a purity of 99.8% toluene, which is then to spot sold as high-grade toluene. T301 is a sieve-tray column with a diameter of 2.04m (6.7ft) and a height of 14.02m
(46ft). Sieve trays are used because polymerization in not a concern, and is less
expensive. The operating pressure is 26.7 kPa. The reflux ratio is optimized at 3.4:1
and the optimum feed inlet is tray ten. The distillate is mainly benzene, with some
non-aromatic impurities. It is then sent to column T-302 for further separation.
Column T-302 separates benzene from non-aromatic C6 hydrocarbons in 40 sieve

trays. This process is economically viable because the recovered benzene can be
recycled to Area-100. Like column T-302, sieve trays are used because costs can be
reduced without sacrificing product purity. The optimum feed inlet is in tray 28, and
optimum reflux ratio is 15:1. The diameter is 2.1m (6.9ft) with a height of 14.63m
(48ft). The operating pressure is 26.7 kPa. The benzene is purified to 99.85 mol%.
The bottoms product from column T-300 contains ethylbenzene (49.4 mol%),
styrene (50.4 mol%), the toluene (0.17 mol%) and the remainder heavy aromatic
byproducts. These are sent to column T-303, where the ethylbenzene is separated off
the top to be recycled to Area-200. Like T-300, this column uses Flexipac HC to
reduce pressure drop across the column. T-303 is 72 stages, with an optimum feed
inlet at stage 48 and optimum reflux ratio of 10:1. To further reduce operating
temperatures, and thus the possibility of polymerization, the pressure is decreased to
7.99 kPa. The diameter of T-303 is 5.33m and the height is 43.89m.
The remainder of the styrene product is then sent to T-304, where it is then purified.
Column T-304 incorporates the same packing as previously mentioned above the
feed inlet, and trays in the stages below the feed inlet. The advantage to designing a
hybrid column like this is due to some of the styrene monomer beginning to
polymerize. If any styrene polymerizes enough to form a solid within the column
then it will deposit onto the tray. Occasionally the column will need to be opened
and the trays cleaned to remove any solid polymer residue. This is easy to do with a
sieve tray and very difficult with packing. Since the highest temperatures are in the
reboiler, the polymers are most likely to form at the bottom of the column, on the
sieve trays. T-304 operates at a lower pressure (5.33 kPa) than column T-303. It has
a height of 27.4m and a diameter of 5.2m. The optimum reflux ratio is 0.75:1. The
total number of trays is 45 and the feed enters on the 24th tray. The bottoms product
is then further purified in T-305. The distillate is purified styrene and is sent to
storage or to the customer.
Column T-305 has a similar design to T-304. It is another hybrid column with
structured packing from stages one to fifteen and sieve trays from sixteen to the last
tray, thirty. It operates at 5.33 kPa, with a height of 18.3m and a diameter of 3.3m
(10.9ft). The optimum reflux ratio is 1.29:1. The bottoms product is sent to column
T-306. The distillate joins with the distillate from T-304 and goes to storage and for
sale.
The final column in Area-300 is T-306. It has the same dimensions as T-305 and
same tray design. The only difference is that it operates with a reflux ratio of 15:1.
The distillate product in columns T-304, T-305 and T-306 are mixed to produce the
final styrene product available at a purity of 99.93 wt% styrene. The bottom
products of T-306 are the heavy side-products. They are mixed with the heavy
byproducts from the alkylation and sent to be incinerated.
4.4.2 Separations Inhibitors

Without inhibitors the distillation design in Area-300 would not work.
Polymerization would occur often, causing the columns to need to be shut down
frequently for cleaning. Therefore, the inhibitors that are used, and where they enter
the process, are important. There are two different types of inhibitors: retarders
(which slow polymerization) and true inhibitors (which stop polymerization in the
free radical stage).
The inhibitor which retards the polymerization process is 2,4-dinitrophenol. It is

added in the liquid stream coming from the condenser on column T-303, the first
column where the styrene product is purified. It will then fall through column T303, where the concentration of styrene increases as the inhibitor moves down the
column. It is carried through T-306 and removed before the styrene is sent to storage
tanks.
After removal of the 2,4-dinitrophenol, but before storage, the inhibitor 4-TBC is
mixed into the styrene product stream. It stops polymerization by interacting with
the free radicals formed in the initiation step of the polymerization mechanism. In
the storage tanks, oxygen is bubbled through the tank to activate the 4-TBC. The
styrene product is sent to customers with the 4-TBC present. Customers remove it
by adsorption when polymerization is desired.
4.5 Area 400 Light Gas Separation

The products from Area-200 are cooled to -50C and then separated in V-202 so that
the vapor products are rich in ethane, ethylene, nitrogen, and hydrogen and the liquid
products contain the aromatic products from the dehydrogenation. The vapor
products are then sent to Area-400, the light gas separations. Here the ethane and
ethylene are separated from the hydrogen and nitrogen via a series of compression,
cooling, expanding and two-phase separations. The necessary equipment includes
33 compressors in eleven compression stages, 30 heat exchangers, ten turbines, and
ten two-phase separators. Under ideal circumstances, ten throttling valves would be
used instead of turbines that operate at 85% efficiency. However, HYSYS could not
correctly model an isoentropic expansion for this case. If throttling valves were used
a cost reduction could be seen in both the equipment savings and in the compressor
duty. Because the turbine is not 100% efficient, some of the enthalpy of expanding
the gas goes to entropy, which must be made up by the compressors. The two-phase
separators operate at a range of temperatures from -68.5C in the first stage to
-168.2C in the last stage. The temperatures after compression get as high as 42C.
Three streams leave Area-400. The first is the bottoms product of the first two phase
separator and consists of mostly styrene, ethylbenzene, and other aromatics. The
second is the distillate recovered after ten two-phase separators. At -159.4C, it is
comprised of 64.9 mol% nitrogen, 34.9% hydrogen, and the remainder ethane and
ethylene. This stream is sent to Area-200 and is burned in R-201 to provide heat for
the reaction. The third stream is the mixture of the bottoms of each two-phase
separator, and is rich in ethane and ethylene at 90.0 mol% and 9.98 mol%
respectively. This stream is fed to Area-100 and supplies the ethylene feed for
Reaction 1a. Area-400 is the most expensive area in the process.
4.6 Heat Exchanger Design

Sixty-six heat exchangers have been designed in the process. The fundamental
design equation is:17
q = UATlm
Equation 1
where q is the total heat transferred, U the overall heat transfer coefficient, Tlm is
the log-mean temperature difference, and A is the area used for exchanger design.
The overall heat transfer coefficient is estimated from design tables provided by
Peters, Timmerhaus and West.18 Water is the coolant for streams needing to be
cooled down to 15C. It is used in the condensers in Area-300 and on exchanger E202.1. The coolant, R-22, is available to -60C and is primarily used in Area-400.19
The reboilers in Area-300 use exhaust steam available at 150 kPa and 109.95C for
heating the product streams. However, one exchanger uses saturated steam at 3550
kPa and 243.38C. Area-300 accounts for a total of sixteen exchangers. Area-400
uses thirty exchangers for interstage cooling after compression. Eleven exchangers
are used in Area-100 and ten exchangers are used in Area-200. The pressure drop
across the tube and shell side of each exchanger can be calculated. An example
calculation can be seen in Appendix E.1. The pressure drops were also increased to
account for losses due to piping and to ensure that estimates are on the conservative
side. The specifications on each exchanger can be seen in Appendix A.2. The cost
is a function of exchanger area and duty of the coolant or steam.
4.7 Pump, Compressor and Turbine Design

There are fifteen places in the plant design where vapor compression is necessary.
At each point the compressor arrangement is optimized. Forty-one compressors
operating at 75% efficiency are used in the process. The optimum arrangement
requires anywhere from one to six compressors with interstage cooling. Area-400
requires thirty-two of these compressors in order to separate ethane and ethylene
from nitrogen and hydrogen. The optimum arrangement was determined by
specifying that the duty on each compressor in one chain is equal, and a cost analysis
done for each case. This required over eighty various arrangements to be evaluated
and the optimum fifteen to be taken from this. The cost of each compressor was
determined from the material of construction, size and duty required. The cost of
each compression chain was the sum of the compressor and heat exchanger costs
annualized over twenty years.
There are ten turbines in the process; all of which are used in Area-400. Each
turbine is 85% efficient and used to cool the vapor into the two phase region. The
cost on each turbine is determined from the material of construction, size and duty.
There are four pumps needed in the process. They are on the benzene feed to Area100, benzene recycle from Area-400 to Area-100, and the toluene and styrene
products from Area 300. The cost of each pump is determined from its material of
construction, capacity, duty and pressure. Calculations and specifications for each
compressor, turbine and pump can be seen in Appendices A.1, A.6 and A.3,
respectively.
4.8 Materials of Construction

Carbon or stainless steel is used in all areas of the plant. Carbon steel is generally
less expensive than stainless steel, but has two problems. First, it degrades at
temperatures above 455C. Carbon will segregate from the piping, putting graphitelike deposits into the process.19 Therefore, in all areas operating above 455C
stainless steel is used. This is most prominent in Area 200. Reactors T-200 and T201 reach temperatures above 600C. The product stream is cooled below 400C
after exchanger E-200. However, the product stream contains hydrogen gas. The
second problem with carbon steel is that hydrogen gas can imbed itself within the
material, degrading the steel over time.18 Therefore, carbon steel cannot be used
again until Area-300 and cannot be used at all in Area-400. The materials of
construction greatly effect equipment cost. Therefore, whenever possible carbon
steel is used instead of stainless steel.
5 Environmental, Health and Safety Issues

Christian engineers are called not only to design for profit, but to design in a manner
that glorifies Gods creation and respects His people. Therefore, the design of this
plant includes taking consideration of environmental issues, as well as concerns for
the well-being of all people that might be impacted by the plant or its products. This
concern for the stakeholders in the plant guides this design.
5.1 Environmental Concerns

One of the design objectives is to show stewardship and therefore minimize the
impact on the environment. The importance of this objective cannot be overstated.
The environment consists of the land, water, air, animals and people near the plant.
One major byproduct is carbon dioxide. This is created from the incineration of
gaseous hydrocarbon side products and the burning of coke on the catalyst. Streams
306 and 311 are to be combusted to carbon dioxide and water. Purge stream 227
also contains carbon dioxide. All products are to be sent though scrubbers to reduce
the carbon monoxide content from side combustion reactions and bring the limits
within the National Ambient Air Quality standards of 9ppm per 8 hour nonoverlapping average.20 Unfortunately, the modeling of the incineration process and
estimations of the side combustion reactions are beyond the scope of the design. As
of 2004, the average American produced 5.76 metric tons of carbon dioxide per
year.21 The designed process produces the equivalent amount of 5750 Americans in
one production year. This is a weakness of the design, and would need to be reduced
before implementation.
The other byproducts consist of heavy hydrocarbons. These are incinerated when
possible and treated when they cannot be incinerated. The modeling of this process,
and the reactions that govern it, is also beyond the scope of the design. Water
generated from the combustion of hydrogen in T-202 is sent for treatment as well.
The significant benefit to the process is that the dehydrogenation reactions (2a and
2b) occur simultaneously. Thus the designs for ethane to ethylene and ethylbenzene
to styrene plants are incorporated into one design. This is evidenced by the need for
two separations process, Area-300 and Area-400. A possible pollution reduction can
be accomplished by incorporating two plants into one. An in depth analysis of this
hypothesis is beyond the scope of the design.
5.2 Chemical Hazards

Caution should be taken when dealing with several compounds in the process.
Styrene monomer should not have contact with skin. If it does, the skin should be
washed with water for at least fifteen minutes. Styrene is extremely flammable and
can travel a considerable distance to an ignition source and should be put out using a
dry chemical, alcohol foam or carbon dioxide. Pure styrene has a penetrating odor.
The flammability limits lie from 1.1 wt% to 6.1 wt%. Styrene waste should be
mixed with a more flammable solvent and then be atomized into an incinerator.22
The precursor to styrene, ethylbenzene, is also dangerous. It should never be inhaled

and CPR may be needed after doing so. It is labeled as a severe fire hazard and the
same method of fire fighting used for styrene should be applied to ethylbenzene.23
Benzene is an eye irritant and causes nausea, unconsciousness, and a change in blood
composition when breathed in. It is also a fire hazard, and should be put out with the
same method as styrene and ethylbenzene. The flammability limits are from 1.3
vol% to 7.9 vol%. A self contained breathing apparatus should always be used when
around benzene that could enter the surrounding air.24 Ethane is non-toxic but can
cause asphyxiation. It is also a fire hazard. If a cylinder is exposed to fire it may
rupture. The flammability limits are from 3.0 vol% to 12.5 vol%.25 Ethylene can
cause dizziness, asphyxiation, drowsiness, unconsciousness and muscular weakness
from overexposure. It is flammable, with limits from 3.1 vol% to 32.0 vol%. Fires
for both ethane and ethylene are best treated by removing or shutting off the
source.26
5.3 Safety Hazards

Safety is a primary concern in all areas of the process. There are three major
variables that affect equipment safety. They are the operating pressures,
temperatures, and the chemicals present. Choosing the appropriate materials of
construction (see sect 4.8) reduces the dangers associated with temperature and
certain chemicals. For example, carbon steel cannot be used above 455C or with
hydrogen gas, thus stainless steel is the appropriate material in streams which carbon
steel cannot be used. For equipment operating at high pressures, the thickness of
equipment must be increased. This is taken into account as a pressure factor used
when costing equipment. The flammability of each stream is also taken into
consideration. The only streams with oxygen present enter regenerator R-201. The
oxygen is consumed in the reaction. All other streams operate well above the upper
flammability limits. Using pressure, temperature, level, and flow controllers the
streams can be kept within the designated safety ranges.
6 Control Design
Whatever can be controlled in the process should be controlled.27 Controls are vital
to the safety of a process and are, therefore, incorporated in the design to converge
the real-world variables to the design variables. They are designed to check for
unsteady states, minimize the occurrence of unsteady states, and then correct the
problem. As such, the time lag between the occurrence of a problem and the
correction needs to be minimized. This is done by placing controls where they can
have the fastest impact.
6.1 Control Design on Area 100

The fresh benzene feed is to be controlled via a flow controller, which measures the
flow rate of incoming benzene. This controller disallows backflow to benzene
storage tanks and adjust the feed so that the benzene to ethylene ratio is 10:1 in R100. A temperature controller is used to verify this specification and is on the
reboiler, so that it will have a direct impact on space time and reaction temperature
inside R-100. Since there are actually four R-100 reactors in parallel, the feed
controller needs to be on each incoming stream. This would allow for temporary
shutdown or production rate decrease. However, the process is designed to operate
under constant production conditions and not vary with market demand or equipment
failure. R-100 has a flow controller on the condenser, which affects the ethane going
to Area-200. Column T-100 has two level controls; one on the reboiler and
condenser each. The bottoms of T-100 are sent to R-101, but with a flow control on
the purge stream. Like the benzene inlet control on R-100, this control varies the
polyalkylated benzene feed to keep its ratio with benzene constant.

The ethylbenzene and ethane from Area-100 is mixed with ethylbenzene from Area300 and fresh ethane feed. There is a feed controller on the ethane feed, controlled
based on the product from Area-100. The mixed stream is sent though exchanger E200, where a temperature control is used to stabilize temperature fluctuations. The
ethylbenzene is sent though a series of compressions and then mixed with inert gas.
This stream is sent though E-201, where the temperature entering the reaction needs
to be consistent and is controlled by a temperature controller. The product from T200 is sent through a flow control, which is modified based on the temperature after
E-202. After filtration, another temperature is used for exchanger E-204, so that the
temperature into the two-phase separator, V-200, is consistent and will cause the
aromatic products to be sent to Area-300 and the light gases to Area-400. Because
this controller determines the split in V-200 it will affect the entire process.
The air feed to Area-200 has a flow controller across a gate valve and then a pressure
controller on compressor K-201. This stream is heated by the product from T-201,
thus a flow controlled bypass is used to control the temperature of this stream. Its
temperature is vital because it causes the combustion in T-201 to occur, which

provides the energy for the reactions in T-200. The product stream from T-201 is
also heat exchanged with the hydrogen and nitrogen inlet from Area-400. A flow
controlled bypass is again used to control the temperature of both streams. The
product stream is filtered and another temperature controller used across the heat
exchanger before V-201. After a series of compression, where a pressure controller
is used, E-202 has a temperature control. When separated in V-200, the gaseous
nitrogen and carbon dioxide are sent across a flow control. This control varies how
much is purged and how much is sent to R-200 to fluidize the reactor bed.

There are three parameters that need to be controlled in Area-300. They are: the exit
composition of each column, the column pressure, and the reflux ratio on each
condenser. The first controller is a flow controller used directly before T-300. The
column then has six controllers. Because this column operates under vacuum
pressure, the pressure control is crucial. Depending on the column pressure, the
temperature, reflux and flows will all change. Therefore, it is essential that the
pressure meets the specs by which the column was designed. The pressure control
can open a gate valve used to vent off gases in case the pressure is too high. The
temperature control is on the column. The equilibrium within the column dictates
that a specific composition resides at a specific temperature. Thus a flow control is
connected to the reboiler exhaust steam. A level control varies what leaves T-300
through the bottoms and another level control is used on the condenser. On the
condenser, the level control operates a gate valve on the product stream. Its function
is to set the reflux ratio, which should be converged to the designed optimum reflux
ratio. Lastly, a flow controller controls how much reflux is sent back to T-300.
Since this is the first column in the distillation chain, it may be tempting to put two
temperature controllers on the column, each one to specify the composition on either
end. However, studies have shown that this creates many problems because the two
controllers are not mutually exclusive. One controller can interfere with the other
based on how much it tries to control the exchanger duty. Using only one
temperature controller is easier and still does a good job.
Columns T-301, T-302, and T-303 are designed in a similar manner, with six
controllers per column used to control the composition, pressure and reflux ratio.
For each of these columns, the reflux ratio is greater than one, and so the gate valve
for the level control on the condenser is positioned on the product stream. When the
reflux ratio is less than one, then the level control is on the condenser coolant, as
with T-304 and T-305. The flow control is on the product stream, and another flow
control manages the reboiler steam. A level control operates a gate valve on the
bottoms product. T-306 has a reflux ratio above 1, so there is a level control on the
distillate, and flow control on the reflux. However, the bottoms are designed with
the level control on the product stream, and the flow control on the reboiler steam.
The mixed styrene product stream is then sent to storage. There is a flow control on
this final stream.

Even though Area-400 has eighty two pieces of equipment, the control design is
simple. Every compressor has a pressure control. Every heat exchanger has a
temperature control and a flow control on the coolant. Every turbine has a pressure
control as well. Therefore, there are 102 controls used in Area-400 total.
7 Economic Analysis
Capital, utility and raw material costs along with revenue from the products
determine the profitability of the design. The purchase and installation of
equipment, land and piping affect the capital cost. Of these, the largest contributor to
the capital cost is from the equipment. This is priced according the cost spreadsheets
available from Peters, Timmerhaus and West. Direct costs, indirect costs, and
working capital affect the total capital investment. A few direct costs are the
purchased equipment, delivery, installation, piping and instrumentation costs.
Indirect costs are things like construction and legal expenses, engineering and
supervision, contractor fees, and contingency costs. Working capital is the cash on
hand needed to start the plant. The total capital investment is 2,508.7 million dollars.
Raw material costs are from ethane, benzene, air, OC-5, EBZ-100, EBZ-500S, TBC,
and DNP. The annual cost of all raw materials is 731.5 million dollars. Electricity,
refrigeration, steam, water treatment, and cooling water usage determine utility costs.
The total is 197.8 million dollars per year. The revenue generated from the products
styrene and toluene is 1,976.2 million dollars per year. The selling price for styrene
is $0.99 per pound. The variable costs consist of raw material costs, utilities and
general expenses; projected at 1,084 million dollars per year. The fixed costs include
fixed charges, plant overhead and general expenses; and are 297.7 million dollars per
year.18
The price for the styrene is chosen by varying the Investors Rate of Return (IRR). If
the IRR is set to 15.0%, the price of styrene is $0.99 per pound as shown in Figure 1:
IRR Analysis - Product Price Fluctuation
35.0%
30.0%
25.0%
IRR
20.0%
15.0%
10.0%
5.0%
0.0%
$0.70
$0.80
$0.90
$1.00
$1.10
$1.20
$1.30
-5.0%
Styrene Monomer Product Price ($/lb)
Figure 2: IRR Analysis Product Price Fluctuation
15.0% IRR is a common value and a good starting point.28 The Net Present Value
for this IRR is 1.99 million dollars, which is basically zero when compared to the
high capital costs. Equation 2 can be used to solve for the IRR:
0=
i=0
CFi
(1 + IRR) i
(Equation 2)
$1.40
The return on investment (ROI) stabilizes after the sixth production year, where it is
15.4% for the lifetime of the plant.
8 Uncertainties and Assumptions

Most of the process specifications used in the HYSYS simulation came directly from
the patents. Generally, having some data is better than no data. This is true of the
data provided in the patents as well. However, the patents often provide one value
for one experiment. Without having multiple experiments run for each point, one
must trust the validity of that data point. In designing a pilot plant, this may not be a
big deal. When designing a plant to accumulate 14% of an already competitive
market more data would be better.
In HYSYS, the design was simulated using the General NRTL fluid package. The
NRTL is a local-composition thermodynamic model, and therefore, analyzes the
system according to its molecular interactions.
9 Future Work
Broadening the scope of the design would lead to the possibility to do a lot of further
work. Some of the most important work could be done to minimize pollutants. The
current design produces 33,098,000 kg/hr of carbon dioxide. This amount needs to
be reduced. Public opinion of processes that produce greenhouse gases is
continually becoming more negative. In order to be good stewards, the amount of
pollutants placed in the atmosphere must be reduced. To do this analysis, a
simulation of the combustion and side reactions should be done in HYSYS. A way
to model the formation of carbon monoxide would make the simulation more
realistic. This leads to stack scrubbing costs having an impact on the economic
analysis because the costs associated with the treatment of this gas can rise quickly.
Too much carbon monoxide production (or inadequate smokestack design) would
lead to fines from the EPA.
The fluidized catalyst cracking reactor could be designed with greater detail. If a
kinetic model could be developed and then used to design the various parameters of
the reactor, then the estimates on the reactor size could be improved. This would
help in pricing the reactor system. The reactor price is currently an educated
estimate. A more accurate price would improve the economic analysis as a whole.
FCC simulation software is also available. This would help because interpolated
values in the patents do not account for catalyst degradation. In fact, the values in
the patents are for a very specific system, using a specific catalyst and reactor set-up.
Any method for further modeling the FCC system that allows these parameters to
change would only improve the simulation.
The computer simulation software, HYSYS, can simulate processes which involve
solids. However, the HYSYS software used for this design does not have this
license available. A solid modeling license would allow the catalyst regeneration
step to be simulated, thus making the simulation more realistic. Filters that remove
solid catalyst particles from the regeneration product stream could also be simulated.
A better estimate of the pressure drop across a filter could be determined. Currently,
a valve simulates the pressure drop across a filter in HYSYS.
The HYSYS simulation also has another problem: it cannot model throttling valves.
Therefore, the designed process used expanders that were 85% efficient. Since this
caused a loss of energy and increased equipment costs, the turbines are far less
favorable than throttling valves.
There are sixty-six heat exchangers used in the process. The overall heat transfer
coefficients for each exchanger could be improved. Currently, all heat transfer
values are estimated using Peters, Timmerhaus and West, which gives a range of 250
to 600 W/m2K for medium organics cooled with water, and a range of 250 to 500
W/m2K for medium organics heated with steam.18 These temperature ranges can
vary the exchanger area significantly. Because the components are generalized and
the heat transfer coefficient given a broad range of possible values, it is likely that
the estimated heat transfer coefficients used for doing heat transfer area design are
wrong. A detailed analysis of all sixty-six exchangers would be ideal.
WORKS CITED
(1) SIRC: International Styrene Industry Forum. 9 Dec. 2005
http://www.styrene.org/international.html.
(2) Tullo, Alexander H. "Spotlight on Polymers." Chemical and Engineering News, 12
September 2005, 19-24.
(3) Kroschwitz, Jacqueline I., Raymond E. Kirk, Donald F. Othmer, and Mary HoweGrant. "Styrene." Encyclopedia of Chemical Technology. 4th ed. New York City:
Wiley, 1998.
(4) Smith, Jr., Lawrence A.; Arganbright, Robert P.; Hearn, Dennis. Process for the
preparation of ethyl benzene listed in US Patent #5,476,978; Nov 29, 1991.
(5) "EBZ 500S Catalyst." Ethylbenzene and Styrene. 2006. UOP. 20 Apr. 2006
<http://www.uop.com/objects/EBZ%20500S%20Catalyst.pdf>.
(6) Jones, Mark. "Ethane Plus Benzene." E-mail to the author. 18 Oct. 2005.
(7) Iezzi, Rodolfo; Buonomo, Franco, Sanfilippo, Domenico. Catalytic Composition
for the Dehydrogenation of C2-C5 Paraffins listed in US Patent # 5,143,886;
Sept 1, 1992.
(8) Buonomo, Franco; Sanfilippo, Domenico; Iezzi, Rodolfo; Micheli, Emilio. Catalytic
System and Proces for Dehydrogenating Ethylbenzene to Stryene listed in US
Patent # 6,242,660; June 5, 2001.
(9) Buonomo, Franco; Donati, Dianni; Micheli, Emilio; Tagliabue, Lorenzo. Process
for the Production of Styrene listed in US Patent #6,031,143; Feb 29, 2000.
(10) http://www.novachem.com/productservices/docs/StyMon_Safety_Guide.pdf
(11) Watson, Keith. Calvin College, Grand Rapids, MI. 5 Oct. 2005.
(12) Cooper, Geoff. "Catalyst Costs for a School Project." E-mail to the author. 1 May
2006
(13) "EBZ 100 Catalyst." Ethylbenzene and Styrene. 2006. UOP. 20 Apr. 2006
http://www.uop.com/objects/EBZ%20100%20Catalyst.pdf>.
(14) Optimix FCC Feed Distribuition Systsem
http://www.uop.com/objects/FCC%20Optimix.pdf
(15) FCC Vortex Separation Technology: The VDS Design and VSS Design
http://www.uop.com/objects/FCC%20Vortex.pdf
(16) AF FCC Spent Catalyst Stripper Technology
20%20AF%20Stripper%20Tech%20Sheet.pdf
http://www.uop.com/objects/
(17) "OC 5 Catalyst." Ethylbenzene and Styrene. 2006. UOP. 20 Apr. 2006
<http://www.uop.com/objects/OC%205%20Catalyst.pdf>.
(18) Peters, Max S.; Timmerhaus, Klaus D.; West, Ronald E.; Plant Design and
Economics for Chemical Engineers. 5th Ed. University of Colorado. 2003.
(19) Perry, Robert H.; Green, Don W.; Perrys Chemical Engineers Handbook. 7th Ed.
McGraw-Hill. New York. 1997.
(20) http://www.epa.gov/oar/oaqps/greenbk/o3co.html
(21) http://pages.ca.inter.net/~jhwalsh/wfsesr.html
(22) http://msds.ehs.cornell.edu/msds/msdsdod/a98/m48796.htm#Section5
(25) http://msds.ehs.cornell.edu/msds/msdsdod/a328/m163906.htm
(26) http://msds.ehs.cornell.edu/msds/msdsdod/a194/m96822.htm
(27) VanAntwerp, Jeremy. In Class Lecture. Engr. 342. May 8, 2006.
(28) Medema, Robert. Interview. Feb. 22, 2006.
Chen, Kaidong, Alexis T. Bell, and Enrique Iglesia. "Kinetics and Mechanism of
Oxidative Dehydrogenation of Propane on Vandium, Molybdenum, and Tungsten
Oxides." J. Phys. Chem 104 (2000): 1292-99.
Chemical Industry Intelligence - Chemical Pricing Reports. www.icislor.com.
Dessau, Ralph M. Dehydrogenation and Dehydrocyclization Using a Non-Acidic NU-87
Catalyst listed in US Patent # 5,254,787.
Diephouse, Dan, Scott Dykstra, and Derek Ferwerda. Hot for Hydrogen. Grand Rapids,
MI: Calvin College, 2004.
Dreise, Manuel, Randall Elenbaas, and Eric Smith. Bond...H-Bond. Grand Rapids, MI:
Calvin College, 2004.
Egloff, Gustav. Production of Styrene listed in US Patent # 2,376,532; May 22, 1945.
Frash, M V., and R A. Santen. "Activation of Small Alkanes in Ga-Exchanged Zeolites:
A Quantum Chemical Study of Ethane Dehydrogenation." J. Phys. Chem 104
(2000): 2468-75.
Iezzi, Rodolfo; Barolini, Andrea; Buonomo, Franco. Process for Activating Catalyst
Precursors for the Dehydrogenation of C2-C5 Paraffins, and a Catalytic
Composition Activated by the Process listed in US Patent # 5,308,822; May 3,
1994.
Iezzi, Rodolfo; Sanfilippo, Domenico. Process for the Dehydrogenation of
Ethylbenzene to Styrene listed in US Patent # 6,841,712; Jan 11, 2005.
Iezzi, Rodolfo; Bartolini, Andrea; Buonomo, Franco. Process for Activating Catalyst
Percursors for the Dehydrogenation of C2-C5 Paraffins, and a Catalytic
Composition Activated by the Process listed in US Patent # 5,414,182; May 9,
1995.
Polystyrene Packaging Council Homepage. http://www.polystyrene.org/.
Ogunnaike, Babatunde A., and Harmon W. Ray. Process Dynamics, Modeling, and
Control. New York: Oxford University Press, 1994.
Seider, Warren D., J D. Seader, and Daniel R. Lewin. Product & Process Design
Principles. 2nd ed. New York City: Wiley, 2004
Stichlmair, Johann G., and James R. Fair. Distillation Principles and Practices. New
York: Wiley-VCH, 1998.
Styrene Producers Price Capacity. http://www.the-innovationgroup.com/ChemProfiles/Styrene.htm.
Wankat, Phillip C. Equilibrium Stated Separations. Upper Saddle River, NJ: Prentice
Hall, 1988.
Wood, Andrew. "Dow Joins Snamprogetti to Develope Ethane-Based Styrene Process."
Chemical Week, 20 April 2005, 17.
Wood, Andrew. "Celanese, Dow Revisit Catalytic Route from Ethane to Ethylene."
Chemical Week, 15 June 2005, 25.
Zhou, Ying; Cavis, Stephen M. Dehydrogenation Catalysts and Process for Preparing
the Catalysts listed in US Patent # 5,219,816; June 15, 1993.
Appendix Table of Contents

Appendix A: Equipment Spec. Sheets
A.1 Compressor Specifications
A.2 Heat Exchanger Specifications
A.3 Pump Specifications
A.4 Tank Specifications
A.5 Two Phase Separator Specifications
A.6 Turbine Specifications
A.7 Distillation Specifications
Appendix B: PFD / PID / Layout
B.1 PFD: Alkylation Unit Area 100
B.2 PFD: Dehydrogenation Unit Area 200
B.3 PFD: Separations Unit Area 300a
B.4 PFD: Separations Unit Area 300b
B.5 PFD: Light Gas Separations Area 400
B.6 PFD: Compressor Chains
B.7 P&ID: Alkylation Unit Area 100
B.8 P&ID: Dehydrogenation Unit Area 200
B.9 P&ID: Separations Unit Area 300a
B.10 P&ID: Separations Unit Area 300b
B.11 P&ID: Light Gas Separations Area 400
B.12 P&ID: Compressor Chains
B.13 Plant Layout
B.14 Plant Layout, Front View
Appendix C: Separations
C.1 Separations Hand Calculations
C.2 Estimates of Column Height
C.3 Fenske Equation
C.4 Dimensioning of Packed Columns
C.5 MathCad Packed Column
C.6 Summary of All Columns
C.7 Optimization Reflux Ratio
Appendix D: Compressor Optimization
D.1 Compressor Optimization Analysis
D.2 K-404 Optimization Analysis Example
D.3 Compressor Hand Calculation Example
Appendix E: Heat Exchanger Design
E.1 Example Pressure Drop Calculation
E.2 Styrene Tank Heat Exchanger Size
Appendix F: Reactor Sizing
F.1 Dehydrogenation Reactor Size
Appendix G: Economic Optimization
G.1 Investment Summary
G.2 Economic Summary
G.3 Profitability Measures
G.4 IRR Analysis Product Price Fluctuation
Appendix A: Equipment Spec. Sheets
A.1: Compressor Specifications (1 of 41)

Compressor Specifications
K-200.1
Date: 5/8/2006
Dehydrogenation Feed Compressor Train
Prepared By:
ACJ
1
Checked By:
MJH
Fluid Properties
3
418300
Process Feed Flow Rate (m /hr)
0.8452
Ethane
0.0001
n-Hexane
0.0000
1 Meta 3 Ethyl Benzene
0.0003
Toluene
Benzene
0.0000
Ethyl Benzene
0.1542
Hydrogen
0.0000
Oxygen
0.0000
Vapor Composition (mol%)
Nitrogen
0.0000
Water
0.0000
Ethylene
0.0000
Styrene
0.0000
n-Butyl Benzene
0.0000
0.0001
Cumene
0.0000
n-Propyl Benzene
0.0000
Alpha Metal Styrene
0.0000
Meta Diethyl Benzene
Carbon Dioxide
0.0000
Inlet Temperature (C)
78.7
Outlet Temperature (C)
96.2
Inlet Pressure (kPa)
102.4
Outlet Pressure (kPa)
142.4
Design Specifications
Compressor Type
Centrifugal
Orientation
Horizontal
Material of Construction
Carbon Steel
Design Capacity (m3/hr)
461590
Max Design Pressure (kPa)
4000
Max Design Temperature (C)
480
Adiabatic Efficiency
75%
Design Power (Kw)
5872
Theoretical Power (Kw)
5321
ID Number:
Description:
No. Required

K-200.2
Date: 5/8/2006
Prepared By:
ACJ
1
Checked By:
MJH
Fluid Properties
3
315800
Ethane
0.8452
n-Hexane
0.0001
0.0000
Toluene
0.0003
Benzene
0.0000
Ethyl Benzene
0.1542
Hydrogen
0.0000
Oxygen
0.0000
Nitrogen
0.0000
Water
0.0000
Ethylene
0.0000
Styrene
0.0000
n-Butyl Benzene
0.0000
Cumene
0.0001
n-Propyl Benzene
0.0000
Alpha Metal Styrene
0.0000
0.0000
Carbon Dioxide
0.0000
96.2
113.0
142.4
194.9
Compressor Type
Centrifugal
Orientation
Horizontal
Carbon Steel
348500
4000
480
75%
Design Power (Kw)
5872
5321
ID Number:
Description:
No. Required

K-200.3
Date: 5/8/2006
Prepared By:
ACJ
1
Checked By:
MJH
Fluid Properties
3
241200
0.8452
Ethane
0.0001
n-Hexane
0.0000
0.0003
Toluene
Benzene
0.0000
Ethyl Benzene
0.1542
Hydrogen
0.0000
Oxygen
0.0000
Nitrogen
0.0000
Water
0.0000
Ethylene
0.0000
Styrene
0.0000
n-Butyl Benzene
0.0000
0.0001
Cumene
0.0000
n-Propyl Benzene
0.0000
Alpha Metal Styrene
0.0000
Carbon Dioxide
0.0000
113.0
129.2
194.9
263.3
Compressor Type
Centrifugal
Orientation
Horizontal
Carbon Steel
266100
4000
480
75%
Design Power (Kw)
5872
5321
ID Number:
Description:
No. Required

K-201
Air Feed Compressor
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
128680
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
25.0
59.5
101.3
135.8
Centrifugal
Horizontal
Carbon Steel
141760
4000
480
75%
1624
1471
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.2100
0.7900
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-202.1
Recycle Stream Compressor Train
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
163200
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
25.0
69.2
128.8
186.8
Centrifugal
Horizontal
Carbon Steel
180720
4000
480
75%
3388
3059
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9697
0.0246
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0057

K-202.2
Recycle Stream Compressor Train
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
116640
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
31.1
75.2
183.8
264.9
Centrifugal
Horizontal
Carbon Steel
129160
4000
480
75%
3388
3059
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9697
0.0246
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0057

K-300
Date: 5/8/2006
Ethyl Benzene Recycle Stream Compressor
Prepared By:
ACJ
1
Checked By:
MJH
Fluid Properties
3
380800
0.0000
Ethane
0.0000
n-Hexane
0.0000
0.0041
Toluene
Benzene
0.0000
Ethyl Benzene
0.9957
Hydrogen
0.0000
Oxygen
0.0000
Nitrogen
0.0000
Water
0.0000
Ethylene
0.0000
Styrene
0.0002
n-Butyl Benzene
0.0000
0.0000
Cumene
0.0000
n-Propyl Benzene
0.0000
Alpha Metal Styrene
0.0000
Carbon Dioxide
0.0000
61.7
137.4
8.0
105.0
Compressor Type
Centrifugal
Orientation
Horizontal
Carbon Steel
425190
4000
480
75%
Design Power (Kw)
3404
3049
ID Number:
Description:
No. Required

K-400
Light Gases Stream Compressor Train
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
285600
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-28.1
124.0
173.5
Centrifugal
Horizontal
Stainless Steel
315360
4000
900
75%
5050
4574
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
320300
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-68.6
-30.1
101.3
187.4
Centrifugal
Horizontal
Stainless Steel
353570
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
192030
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-12.6
184.4
325.2
Centrifugal
Horizontal
Stainless Steel
212010
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
109880
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-12.6
322.2
568.3
Centrifugal
Horizontal
Stainless Steel
121320
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.4
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
62628
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-12.6
565.3
997.2
Centrifugal
Horizontal
Stainless Steel
69151
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.5
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
35836
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-47.9
-10.6
997.2
1750.0
Centrifugal
Horizontal
Stainless Steel
39564
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-401.6
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
21318
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-38.4
-1.6
1747.0
3003.0
Centrifugal
Horizontal
Stainless Steel
23534
4000
900
75%
8730
7907
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-402.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
255200
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-99.6
-52.6
101.3
229.5
Centrifugal
Horizontal
Stainless Steel
281630
4000
900
75%
9509
8614
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-402.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
143200
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-52.6
-8.8
229.5
443.6
Centrifugal
Horizontal
Stainless Steel
158030
4000
900
75%
9509
8614
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-402.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
75477
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-6.3
440.6
845.5
Centrifugal
Horizontal
Stainless Steel
83311
4000
900
75%
9509
8614
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-402.4
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
39467
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
-6.3
842.5
1617.0
Centrifugal
Horizontal
Stainless Steel
43568
4000
900
75%
9509
8614
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-402.5
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
21763
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-37.0
5.8
1617.0
3003.0
Centrifugal
Horizontal
Stainless Steel
24020
4000
900
75%
9509
8614
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-403.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
124400
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-116.0
-26.7
101.3
396.8
Centrifugal
Horizontal
Stainless Steel
137710
4000
900
75%
8495
7671
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
0.0000
0.1215
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-403.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
45424
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
34.6
393.8
1088.0
Centrifugal
Horizontal
Stainless Steel
50302
4000
900
75%
8495
7671
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
0.0000
0.1215
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-403.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
16480
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
34.6
1085.0
3000.0
Centrifugal
Horizontal
Stainless Steel
18251
4000
900
75%
8495
7671
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
0.0000
0.1215
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-404.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
108700
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-123.1
-31.8
101.3
409.6
Centrifugal
Horizontal
Stainless Steel
120400
4000
900
75%
7683
6937
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
0.0000
0.1326
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-404.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
40301
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
37.1
406.6
1106.0
Centrifugal
Horizontal
Stainless Steel
44629
4000
900
75%
7683
6937
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
0.0000
0.1326
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-404.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
14856
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
37.1
1103.0
3000.0
Centrifugal
Horizontal
Stainless Steel
16453
4000
900
75%
7683
6937
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
0.0000
0.1326
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-405.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
95210
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-132.0
-39.8
101.3
427.2
Centrifugal
Horizontal
Stainless Steel
105410
4000
900
75%
7012
6331
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
0.0000
0.1296
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-405.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
35962
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
38.5
424.2
1129.6
Centrifugal
Horizontal
Stainless Steel
39824
4000
900
75%
7012
6331
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
0.0000
0.1296
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-405.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
13541
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
38.5
1127.0
3000.0
Centrifugal
Horizontal
Stainless Steel
15000
4000
900
75%
7012
6331
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
0.0000
0.1296
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-406.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
86480
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-136.2
-43.0
101.3
436.2
Centrifugal
Horizontal
Stainless Steel
95756
4000
900
75%
6508
5874
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
0.0000
0.0880
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-406.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
32965
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
40.1
433.2
1142.0
Centrifugal
Horizontal
Stainless Steel
36512
4000
900
75%
6508
5874
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
0.0000
0.0880
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-406.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
12544
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
40.1
1139.0
3000.0
Centrifugal
Horizontal
Stainless Steel
13898
4000
900
75%
6508
5874
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
0.0000
0.0880
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-407.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
78950
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-141.4
-47.9
101.3
448.1
Centrifugal
Horizontal
Stainless Steel
87432
4000
900
75%
6097
5501
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
0.0000
0.0525
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-407.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
30448
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
41.0
445.1
1157.0
Centrifugal
Horizontal
Stainless Steel
33731
4000
900
75%
6097
5501
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
0.0000
0.0525
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-407.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
11743
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
41.0
1154.0
3000.0
Centrifugal
Horizontal
Stainless Steel
13014
4000
900
75%
6097
5501
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
0.0000
0.0525
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-408.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
72360
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-147.9
-55.9
101.3
458.4
Centrifugal
Horizontal
Stainless Steel
80145
4000
900
75%
5707
5150
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
0.0000
0.0258
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-408.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
27739
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-55.9
34.3
458.4
1187.0
Centrifugal
Horizontal
Stainless Steel
30712
4000
900
75%
5707
5150
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
0.0000
0.0258
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-408.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
11029
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
40.0
1184.0
3000.0
Centrifugal
Horizontal
Stainless Steel
12223
4000
900
75%
5707
5150
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
0.0000
0.0258
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-409.1
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
66440
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-155.6
-66.6
101.3
470.8
Centrifugal
Horizontal
Stainless Steel
73585
4000
900
75%
5364
4840
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
0.0000
0.0097
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-409.2
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
25128
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-66.6
21.0
470.8
1228.0
Centrifugal
Horizontal
Stainless Steel
27820
4000
900
75%
5364
4840
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
0.0000
0.0097
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-409.3
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
10437
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-50.0
37.4
1225.0
3000.0
Centrifugal
Horizontal
Stainless Steel
11570
4000
900
75%
5364
4840
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
0.0000
0.0097
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

K-410
1
Fluid Properties
3
ID Number:
Description:
No. Required

Compressor Type
Orientation
Design Power (Kw)
Date: 5/8/2006
Prepared By:
ACJ
Checked By:
MJH
61520
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
-163.4
-151.1
101.3
138.0
Centrifugal
Horizontal
Stainless Steel
68172
4000
900
75%
730
659
0.0008
0.0000
0.0000
0.0000
0.0000
0.0000
0.3350
0.0000
0.6611
0.0000
0.0031
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
A.2: Heat Exchanger Specifications (1 of 61)

ID Number:
Description:
No. Required
Heat Exchanger Specifications

E-100
Ethane/Ethylene Return Heater
1
Unit Performance & Fluid Properties
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
366000
Flow Rate - Vapor (kg/hr)
Flow Rate - Liquid (kg/hr)
366000
0
-120
25
Temperature (C)
101
101
Pressure (kPa)
3
584
1.22
Density (kg/m )
0.0000
0.0095
Viscosity - Vapor (cP)
Viscosity - Liquid (cP)
0.2517
0.0000
72.03
51.96
Specific Heat (J/mol-K)
0.0000
0.0213
Thermal Conductivity - Vapor (W/m-K)
0.1840
0.0000
Thermal Conductivity - Liquid (W/m-K)
Total Heat Transfer Area (m2)
Duty (MJ/hr)
270680
391
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
121640
0
0
121640
111
111
150
147
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
Heat Flux (kJ/hr-m2-K)
4697
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-100C
Column T-100 Condenser
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
124100
124100
0
0
148
148
Temperature (C)
136
133
Pressure (kPa)
3
4.12
4.12
Density (kg/m )
0.0083
0.0083
0.0000
0.0000
178.70
178.70
0.0199
0.0199
0.0000
0.0000
Duty (MJ/hr)
122700
955
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
46639
46639
0
15
111
150
147
1015.00
0.85
0.0000
0.0125
1.1360
0.0000
75.44
39.87
0.0000
0.0254
0.5953
0.0000
966
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-100R
Column T-100 Reboiler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
37920
37920
194
194
Temperature (C)
136
133
Pressure (kPa)
3
714
714
Density (kg/m )
0.0000
0.0000
0.1863
0.1863
322.10
322.10
0.0000
0.0000
0.1052
0.1052
Duty (MJ/hr)
164800
1922
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
High Pressure Steam
93690
0
0
93690
243
243
3550
3547
14.89
804
0.0172
0.0000
0.0000
0.1099
74.72
86.22
0.0374
0.0000
0.0000
0.6242
1736
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

R-100C
Column R-100 Condenser
4
Tube Side
Inlet
Outlet
Fluid
Process Streams
31025
31025
0
0
148
148
Temperature (C)
136
133
Pressure (kPa)
3
4.12
4.12
Density (kg/m )
0.0083
0.0083
0.0000
0.0000
178.70
178.70
0.0199
0.0199
0.0000
0.0000
Duty (MJ/hr)
30675
239
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
46640
46640
0
15
111
150
147
1015.00
0.85
0.0000
0.0125
1.1360
0.0000
75.44
39.87
0.0000
0.0254
0.5953
0.0000
966
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

R-100R
Column R-100 Reboiler
4
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
9480
9480
194
194
Temperature (C)
136
133
Pressure (kPa)
3
714
714
Density (kg/m )
0.0000
0.0000
0.1863
0.1863
322.10
322.10
0.0000
0.0000
0.1052
0.1052
Duty (MJ/hr)
41200
480
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
High Pressure Steam
23423
0
0
23423
243
243
3550
3547
14.89
804
0.0172
0.0000
0.0000
0.1099
74.72
86.22
0.0374
0.0000
0.0000
0.6242
1736
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-200
Dehydrogenation Feed Vaporizer
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
481500
612700
131100
0
62
79
Temperature (C)
105
102
Pressure (kPa)
3
1.72
1.47
Density (kg/m )
0.0104
0.0107
0.3762
0.0000
75.15
73.49
0.0242
0.0246
0.1290
0.0000
Duty (MJ/hr)
66020
1059
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
29670
0
0
29670
111
111
150
147
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1546
Shell Side
1
Carbon Steel

E-201
Dehydrogenation Feed Heater/Product
Description:
Cooler
No. Required
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
612700
612700
0
0
129
420
Temperature (C)
263
260
Pressure (kPa)
3
3.29
1.91
Density (kg/m )
0.0123
0.0209
0.0000
0.0000
81.87
124.20
0.0308
0.0726
0.0000
0.0000
Duty (MJ/hr)
443300
3387
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
ID Number:
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Process Streams
738600
738600
0
0
600
388
133
130
0.63
0.81
0.0281
0.0230
0.0000
0.0000
104.30
89.24
0.1025
0.0738
0.0000
0.0000
800
Shell Side
1
Stainless Steel

ID Number:
Description:
No. Required

E-202.1
Nitrogen Recycle Stream Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
236100
236100
0
0
69
31
Temperature (C)
187
184
Pressure (kPa)
3
1.83
2.02
Density (kg/m )
0.0200
0.0183
0.0000
0.0000
29.54
29.34
0.0287
0.0261
0.0000
0.0000
Duty (MJ/hr)
9494
176
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
64290
64290
15
50
220
217
1015
988
0.0000
0.0000
1.1360
0.5442
75.44
79.03
0.0000
0.0000
0.5953
0.6432
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-202.2
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
236100
232400
0
3757
75
-50
Temperature (C)
265
262
Pressure (kPa)
2.55
0.14
Density (kg/m3)
0.0202
0.0146
0.0000
0.0000
29.57
29.92
0.0291
0.0203
0.0000
0.4680
Duty (MJ/hr)
40860
310
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
148200
148200
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1609
Shell Side
1
Carbon Steel

E-203
Dehydrogenation Startup/Control
Description:
Exchanger
No. Required
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
739200
739200
0
0
451
451
Temperature (C)
260
257
Pressure (kPa)
3
1.67
1.67
Density (kg/m )
0.0242
0.0242
0.0000
0.0000
105.00
105.00
0.0716
0.0716
0.0000
0.0000
Duty (MJ/hr)
0
803
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
ID Number:
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Used For Start Up
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-204
Separations Feed Stream Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
738600
738600
0
0
388
320
Temperature (C)
130
127
Pressure (kPa)
3
0.81
0.88
Density (kg/m )
0.0230
0.0221
0.0000
0.0000
89.24
83.14
0.0738
0.0645
0.0000
0.0000
Duty (MJ/hr)
125500
253
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Process Streams
126500
126500
0
0
-50
846
262
259
3.95
0.79
0.0146
0.0523
0.0000
0.0000
28.74
33.09
0.0204
0.0713
0.0000
0.0000
1032
Shell Side
1
Stainless Steel

ID Number:
Description:
No. Required

E-205
Separations Feed Stream Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
21490
490800
0
240700
320
-50
Temperature (C)
126
123
Pressure (kPa)
0.87
2.58
Density (kg/m3)
0.0212
0.0088
0.0000
1.9410
83.14
51.06
0.0645
0.0221
0.0000
0.1590
Duty (MJ/hr)
616400
2438
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
2236100
2236100
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-206
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
268300
236100
2122
34300
186
25
Temperature (C)
130
127
Pressure (kPa)
0.23
1.66
Density (kg/m3)
0.0661
0.0180
0.2882
0.8904
38.64
37.82
0.0918
0.0256
0.0382
0.6110
Duty (MJ/hr)
34360
676
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
84711
84711
15
111
220
217
1015
988
0.0000
0.0000
1.1360
0.5442
75.44
79.03
0.0000
0.0000
0.5953
0.6432
410
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-207
Nitrogen/Light Gases Exchanger
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
118700
118700
0
0
25
550
Temperature (C)
135
133
Pressure (kPa)
3
1.05
0.38
Density (kg/m )
0.0153
0.0348
0.0000
0.0000
28.96
31.39
0.0516
0.1099
0.0000
0.0000
Duty (MJ/hr)
97430
208
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Process Streams
270400
270400
0
0
580
186
132
130
0.55
0.89
0.0318
0.0223
0.0000
0.0000
32.91
31.02
0.0546
0.0355
0.0000
0.0000
1037
Shell Side
1
Stainless Steel

ID Number:
Description:
No. Required

E-208
Nitrogen/Air Exchanger
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
151700
151700
0
0
59
560
Temperature (C)
136
133
Pressure (kPa)
3
1.42
0.56
Density (kg/m )
0.0204
0.0411
0.0000
0.0000
29.36
32.29
0.0284
0.0582
0.0000
0.0000
Duty (MJ/hr)
81250
283
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Process Streams
268300
270400
2122
0
713
480
134
131
0.43
0.55
0.0393
0.0318
0.1910
0.0000
34.36
32.91
0.0684
0.0546
0.0382
0.0000
1052
Shell Side
1
Stainless Steel

ID Number:

E-300
Description:
Distillation Chain Feed Heater
No. Required
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
26
3657
240700
237100
-50
40
Temperature (C)
101
101
Pressure (kPa)
878
73.06
Density (kg/m3)
0.0081
0.0099
1.9440
0.5134
149.20
176.20
0.0174
0.0225
0.1590
0.1369
Duty (MJ/hr)
36680
584
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
20854
0
0
20854
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
569
Shell Side
1
Carbon Steel

ID Number:

E-301
Description:
Styrene Product Condenser
No. Required
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
112200
0
0
112200
61
44
Temperature (C)
5
5
Pressure (kPa)
3
0.20
885
Density (kg/m )
0.0063
0.0000
0.0000
0.5634
137.00
184.70
0.0120
0.0000
0.0000
0.1411
Duty (MJ/hr)
48142
5675
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
601200
601200
15
34
220
217
1015
1001
0.0000
0.0000
1.1360
0.7332
75.44
76.14
0.0000
0.0000
0.5953
0.6237
366
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-300C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
66800
66800
0
0
59
59
Temperature (C)
27
27
Pressure (kPa)
3
0.82
0.82
Density (kg/m )
0.0073
0.0073
0.0000
0.0000
105.30
105.30
0.0122
0.0122
0.0000
0.0000
Duty (MJ/hr)
39440
1697
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
374100
374100
15
40
220
217
1015
996
0.0000
0.0000
1.1360
0.6514
75.44
76.15
0.0000
0.0000
0.5953
0.6315
778
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-300R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
228500
228500
96
96
Temperature (C)
27
27
Pressure (kPa)
3
818
818
Density (kg/m )
0.0000
0.0000
0.3037
0.3037
205.00
205.00
0.0000
0.0000
0.1253
0.1253
Duty (MJ/hr)
66390
3903
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
29834
0
0
29834
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1073
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-301C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
3673
3673
0
0
42
42
Temperature (C)
27
27
Pressure (kPa)
3
0.80
0.80
Density (kg/m )
0.0073
0.0073
0.0000
0.0000
88.81
88.81
0.0109
0.0109
0.0000
0.0000
Duty (MJ/hr)
5194
370
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
82220
82220
15
30
220
217
1015
1004
0.0000
0.0000
1.1360
0.7972
75.44
76.09
0.0000
0.0000
0.5953
0.6182
780
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-301R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
4252
4252
70
70
Temperature (C)
27
27
Pressure (kPa)
3
822
822
Density (kg/m )
0.0000
0.0000
0.3448
0.3448
167.90
167.90
0.0000
0.0000
0.1249
0.1249
Duty (MJ/hr)
3552
79
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
1596
0
0
1596
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1076
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-302C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
103
103
0
0
33
33
Temperature (C)
27
27
Pressure (kPa)
3
0.90
0.90
Density (kg/m )
0.0060
0.0060
0.0000
0.0000
141.80
141.80
0.0130
0.0130
0.0000
0.0000
Duty (MJ/hr)
2768
453
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
52610
52610
15
28
220
217
1015
1005
0.0000
0.0000
1.1360
0.8418
75.44
76.03
0.0000
0.0000
0.5953
0.6147
612
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-302R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
3570
3570
42
42
Temperature (C)
27
27
Pressure (kPa)
3
854
854
Density (kg/m )
0.0000
0.0000
0.4838
0.4838
131.40
131.40
0.0000
0.0000
0.1266
0.1266
Duty (MJ/hr)
1284
17
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
577
0
0
577
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1080
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-303C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
116100
116100
0
0
62
62
Temperature (C)
8
8
Pressure (kPa)
3
0.30
0.30
Density (kg/m )
0.0064
0.0064
0.0000
0.0000
144.50
144.50
0.0124
0.0124
0.0000
0.0000
Duty (MJ/hr)
431700
11301
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
68340
68340
15
30
220
217
1015
1004
0.0000
0.0000
1.1360
0.7972
75.44
76.09
0.0000
0.0000
0.5953
0.6182
987
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-303R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
112400
112400
70
70
Temperature (C)
8
8
Pressure (kPa)
3
861
861
Density (kg/m )
0.0000
0.0000
0.4197
0.4197
192.10
192.10
0.0000
0.0000
0.1348
0.1348
Duty (MJ/hr)
461800
10431
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
11519
0
0
11519
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1063
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-304C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
78580
78580
0
0
61
61
Temperature (C)
5
5
Pressure (kPa)
3
0.20
0.20
Density (kg/m )
0.0063
0.0063
0.0000
0.0000
137.00
137.00
0.0120
0.0120
0.0000
0.0000
Duty (MJ/hr)
23770
1046
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
208700
208700
15
42
220
217
1015
995
0.0000
0.0000
1.1360
0.6274
75.44
76.14
0.0000
0.0000
0.5953
0.6340
755
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-304R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
33840
33840
61
61
Temperature (C)
5
5
Pressure (kPa)
3
869
869
Density (kg/m )
0.0000
0.0000
0.4635
0.4635
189.60
189.60
0.0000
0.0000
0.1370
0.1370
Duty (MJ/hr)
53210
977
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
23911
0
0
23911
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1073
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-305C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
26940
26940
0
0
61
61
Temperature (C)
5
5
Pressure (kPa)
3
0.20
0.20
Density (kg/m )
0.0063
0.0063
0.0000
0.0000
137.00
137.00
0.0120
0.0120
0.0000
0.0000
Duty (MJ/hr)
13900
611
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
122000
122000
15
42
220
217
1015
995
0.0000
0.0000
1.1360
0.6274
75.44
76.14
0.0000
0.0000
0.5953
0.6340
756
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-305R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
6893
6893
61
61
Temperature (C)
5
5
Pressure (kPa)
3
869
869
Density (kg/m )
0.0000
0.0000
0.4641
0.4641
190.20
190.20
0.0000
0.0000
0.1369
0.1369
Duty (MJ/hr)
24640
453
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
11073
0
0
11073
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
1075
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-306C
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
6715
6715
0
0
61
61
Temperature (C)
5
5
Pressure (kPa)
3
0.20
0.20
Density (kg/m )
0.0063
0.0063
0.0000
0.0000
137.00
137.00
0.0120
0.0120
0.0000
0.0000
Duty (MJ/hr)
40140
1781
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Cooling Water
0
0
352400
352400
15
42
220
217
1015
995
0.0000
0.0000
1.1360
0.6274
75.44
76.14
0.0000
0.0000
0.5953
0.6340
748
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

T-306R
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
0
0
178
178
73
73
Temperature (C)
5
5
Pressure (kPa)
3
838
838
Density (kg/m )
0.0000
0.0000
0.4730
0.4730
228.50
228.50
0.0000
0.0000
0.1324
0.1324
Duty (MJ/hr)
42820
239
Unit Construction
Tube Side
Number of Passes
2
Carbon Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
Exhaust Steam
19242
0
0
19242
111
111
220
217
0.85
52.08
0.0125
0.0000
0.0000
0.2490
39.87
75.92
0.0254
0.0000
0.0000
0.6847
4707
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-400
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
498000
498000
0
0
-28
-47
Temperature (C)
174
171
Pressure (kPa)
3
2.22
2.41
Density (kg/m )
0.0096
0.0089
0.0000
0.0000
40.06
38.83
0.0246
0.0225
0.0000
0.0000
Duty (MJ/hr)
14580
777
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
1378200
1378200
-60
-50
220
217
1465
1437
0.0000
0.0000
0.4134
0.3730
90.86
92.12
0.0000
0.0000
0.1273
0.1230
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-2
-25
Temperature (C)
3003
3000
Pressure (kPa)
3
34.71
38.00
Density (kg/m )
0.0115
0.0107
0.0000
0.0000
41.84
40.24
0.0301
0.0277
0.0000
0.0000
Duty (MJ/hr)
18600
1530
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
67721
67721
-60
-50
220
217
1465
1437
0.0000
0.0000
0.4134
0.3730
90.86
92.12
0.0000
0.0000
0.1273
0.1230
311
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-30
-50
Temperature (C)
187
184
Pressure (kPa)
3
2.42
2.59
Density (kg/m )
0.0096
0.0088
0.0000
0.0000
39.93
38.67
0.0244
0.0222
0.0000
0.0000
Duty (MJ/hr)
14920
429
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
559980
559980
-60
-35
220
217
1465
1394
0.0000
0.0000
0.4134
0.3231
90.86
94.28
0.0000
0.0000
0.1273
0.1163
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-13
-50
Temperature (C)
325
322
Pressure (kPa)
3
3.92
4.53
Density (kg/m )
0.0103
0.0089
0.0000
0.0000
41.09
38.67
0.0264
0.0223
0.0000
0.0000
Duty (MJ/hr)
28470
447
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
106200
106200
0
-60
-18
220
217
1465
8.95
0.0000
0.0107
0.4134
0.0000
90.86
51.52
0.0000
0.0088
0.1273
0.0000
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401.3
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-13
-50
Temperature (C)
568
565
Pressure (kPa)
3
6.85
7.95
Density (kg/m )
0.0104
0.0089
0.0000
0.0000
41.09
38.67
0.0267
0.0226
0.0000
0.0000
Duty (MJ/hr)
28470
447
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
106200
106200
0
-60
-18
220
217
1465
8.95
0.0000
0.0107
0.4134
0.0000
90.86
51.52
0.0000
0.0088
0.1273
0.0000
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401.4
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-13
-48
Temperature (C)
997
994
Pressure (kPa)
3
12.01
13.89
Density (kg/m )
0.0105
0.0092
0.0000
0.0000
41.09
38.80
0.0270
0.0233
0.0000
0.0000
Duty (MJ/hr)
26740
886
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
1528700
1528700
-60
-43
220
217
1465
1418
0.0000
0.0000
0.4134
0.3497
90.86
93.02
0.0000
0.0000
0.1273
0.1201
1656
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-401.4
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
497900
497900
0
0
-11
-38
Temperature (C)
1750
1747
Pressure (kPa)
3
20.92
23.36
Density (kg/m )
0.0108
0.0098
0.0000
0.0000
41.22
39.40
0.0280
0.0251
0.0000
0.0000
Duty (MJ/hr)
21340
385
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
79263
79263
0
-60
-16
220
217
1465
8.89
0.0000
0.0107
0.4134
0.0000
90.86
51.73
0.0000
0.0089
0.1273
0.0000
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-402
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
463100
463100
0
0
6
-14
Temperature (C)
3003
3000
Pressure (kPa)
3
33.45
36.02
Density (kg/m )
0.0119
0.0112
0.0000
0.0000
41.84
40.50
0.0315
0.0293
0.0000
0.0000
Duty (MJ/hr)
14840
323
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
53835
53835
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1588
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-402.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
463100
463100
0
0
-9
-50
Temperature (C)
444
441
Pressure (kPa)
3
5.21
6.14
Density (kg/m )
0.0106
0.0090
0.0000
0.0000
40.86
38.28
0.0276
0.0230
0.0000
0.0000
Duty (MJ/hr)
29230
418
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
108120
108120
0
-60
-14
220
217
1465
8.82
0.0000
0.0108
0.4134
0.0000
90.86
51.93
0.0000
0.0090
0.1273
0.0000
1616
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-402.3
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
463100
463100
0
0
-6
-50
Temperature (C)
846
843
Pressure (kPa)
3
9.85
11.73
Density (kg/m )
0.0108
0.0092
0.0000
0.0000
41.02
38.28
0.0282
0.0235
0.0000
0.0000
Duty (MJ/hr)
31010
420
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
114080
114080
0
-60
-11
220
217
1465
8.74
0.0000
0.0109
0.4134
0.0000
90.86
52.19
0.0000
0.0091
0.1273
0.0000
1615
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-402.4
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
463100
463100
0
0
-6
-37
Temperature (C)
1617
1614
Pressure (kPa)
3
18.83
21.28
Density (kg/m )
0.0110
0.0099
0.0000
0.0000
41.02
39.07
0.0289
0.0256
0.0000
0.0000
Duty (MJ/hr)
21990
359
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
80896
80896
0
-60
-11
220
217
1465
8.74
0.0000
0.0109
0.4134
0.0000
90.86
52.19
0.0000
0.0091
0.1273
0.0000
1612
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-403
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
214100
214100
0
0
35
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
26.03
35.86
Density (kg/m )
0.0149
0.0117
0.0000
0.0000
35.17
32.61
0.0442
0.0311
0.0000
0.0000
Duty (MJ/hr)
27610
256
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
100160
100160
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1617
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-403.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
214100
214100
0
0
-27
-50
Temperature (C)
397
394
Pressure (kPa)
3
4.30
4.71
Density (kg/m )
0.0120
0.0110
0.0000
0.0000
33.27
32.61
0.0349
0.0319
0.0000
0.0000
Duty (MJ/hr)
7408
183
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
154840
154840
-60
-32
220
217
1465
1384
0.0000
0.0000
0.4134
0.3130
90.86
94.85
0.0000
0.0000
0.1273
0.1147
1609
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-403.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
214100
214100
0
0
35
-50
Temperature (C)
1088
1085
Pressure (kPa)
3
9.44
12.99
Density (kg/m )
0.0146
0.0112
0.0000
0.0000
35.17
32.61
0.0431
0.0324
0.0000
0.0000
Duty (MJ/hr)
27610
257
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
100160
100160
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1609
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-404
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
189700
189700
0
0
37
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
24.98
34.70
Density (kg/m )
0.0153
0.0120
0.0000
0.0000
33.51
31.49
0.0466
0.0359
0.0000
0.0000
Duty (MJ/hr)
24970
229
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
90583
90583
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-404.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
189700
189700
0
0
-32
-50
Temperature (C)
410
407
Pressure (kPa)
3
4.38
4.71
Density (kg/m )
0.0122
0.0114
0.0000
0.0000
31.88
31.49
0.0363
0.0338
0.0000
0.0000
Duty (MJ/hr)
168
160
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
90583
90583
-60
-37
220
217
1465
16.18
0.0000
0.0000
0.4134
0.3282
90.86
94.02
0.0000
0.0000
0.1273
0.1171
53
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-404.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
189700
189700
0
0
37
-50
Temperature (C)
1106
1103
Pressure (kPa)
3
9.21
12.77
Density (kg/m )
0.0150
0.0116
0.0000
0.0000
33.51
31.49
0.0456
0.0344
0.0000
0.0000
Duty (MJ/hr)
24970
229
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
90583
90583
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-405
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
171600
171600
0
0
38
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
24.17
33.71
Density (kg/m )
0.0155
0.0123
0.0000
0.0000
32.12
30.58
0.0487
0.0375
0.0000
0.0000
Duty (MJ/hr)
22790
207
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
82675
82675
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-405.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
171600
171600
0
0
-39
-50
Temperature (C)
427
424
Pressure (kPa)
3
4.60
4.77
Density (kg/m )
0.0122
0.0117
0.0000
0.0000
30.74
30.58
0.0370
0.0356
0.0000
0.0000
Duty (MJ/hr)
2571
145
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
0
160040
160040
-60
-45
220
217
1465
1423
0.0000
0.0000
0.4134
0.3546
90.86
92.82
0.0000
0.0000
0.1273
0.1207
1570
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-405.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
171600
171600
0
0
38
-50
Temperature (C)
1130
1127
Pressure (kPa)
3
9.10
12.67
Density (kg/m )
0.0153
0.0119
0.0000
0.0000
32.12
30.58
0.0478
0.0361
0.0000
0.0000
Duty (MJ/hr)
22790
207
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
82675
82675
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-406
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
156600
156600
0
0
40
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
23.44
32.86
Density (kg/m )
0.0158
0.0125
0.0000
0.0000
31.10
29.92
0.0509
0.0392
0.0000
0.0000
Duty (MJ/hr)
21140
191
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
76689
76689
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1608
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-406.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
156600
156600
0
0
-43
-50
Temperature (C)
436
433
Pressure (kPa)
3
4.64
4.75
Density (kg/m )
0.0123
0.0120
0.0000
0.0000
30.00
29.92
0.0383
0.0373
0.0000
0.0000
Duty (MJ/hr)
1605
145
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
76689
76689
0
-60
-48
220
217
1465
1432
0.0000
0.0000
0.4134
0.3662
90.86
92.36
0.0000
0.0000
0.1273
0.1222
1627
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-406.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
156600
156600
0
0
40
-50
Temperature (C)
1142
1139
Pressure (kPa)
3
8.92
12.48
Density (kg/m )
0.0155
0.0121
0.0000
0.0000
31.10
29.92
0.0500
0.0378
0.0000
0.0000
Duty (MJ/hr)
21140
191
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
76689
76689
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1608
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-407
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
145400
145400
0
0
41
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
22.86
32.15
Density (kg/m )
0.0159
0.0126
0.0000
0.0000
30.23
29.36
0.0527
0.0406
0.0000
0.0000
Duty (MJ/hr)
19800
178
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
71828
71828
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1607
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-407.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
145400
145400
0
0
-48
-50
Temperature (C)
448
445
Pressure (kPa)
3
4.76
4.77
Density (kg/m )
0.0123
0.0122
0.0000
0.0000
29.38
29.36
0.0392
0.0389
0.0000
0.0000
Duty (MJ/hr)
448
10
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
1625
1625
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1735
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-408
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
137800
137800
0
0
40
-50
Temperature (C)
3000
2997
Pressure (kPa)
3
22.55
31.62
Density (kg/m )
0.0160
0.0127
0.0000
0.0000
29.57
31.62
0.0538
0.0416
0.0000
0.0000
Duty (MJ/hr)
18540
167
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
67257
67257
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1608
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-407.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
145400
145400
0
0
41
-50
Temperature (C)
448
445
Pressure (kPa)
3
8.82
12.38
Density (kg/m )
0.0157
0.0123
0.0000
0.0000
30.23
29.36
0.0518
0.0393
0.0000
0.0000
Duty (MJ/hr)
19800
178
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
71828
71828
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1607
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-408.1
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
137800
137800
0
0
34
-50
Temperature (C)
1187
1184
Pressure (kPa)
3
9.09
12.49
Density (kg/m )
0.0156
0.0124
0.0000
0.0000
29.53
28.96
0.0522
0.0405
0.0000
0.0000
Duty (MJ/hr)
17340
162
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
62904
62904
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1610
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-409
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
133500
133500
0
0
37
-50
Temperature (C)
3000.0
2997.0
Pressure (kPa)
3
22.52
31.31
Density (kg/m )
0.0160
0.0128
0.0000
0.0000
29.17
28.72
0.0543
0.0423
0.0000
0.0000
Duty (MJ/hr)
17420
127
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
63194
63194
0
-60
-5
220.0
217.0
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
2029
Shell Side
1
Carbon Steel

ID Number:
Description:
No. Required

E-409.2
Light Gases Cooler
1
Tube Side
Inlet
Outlet
Fluid
Process Streams
133500
133500
0
0
21
-50
Temperature (C)
1228
1225
Pressure (kPa)
3
9.73
12.80
Density (kg/m )
0.0152
0.0125
0.0000
0.0000
29.09
28.72
0.0512
0.0412
0.0000
0.0000
Duty (MJ/hr)
14140
143
Unit Construction
Tube Side
Number of Passes
2
Stainless Steel
Date:
Prepared By:
Checked By:
5/9/2006
ACJ
MJH
Shell Side
Inlet
Outlet
R-22
0
51295
51295
0
-60
-5
220
217
1465
8.53
0.0000
0.0112
0.4134
0.0000
90.86
52.86
0.0000
0.0094
0.1273
0.0000
1612
Shell Side
1
Carbon Steel
A.3: Pump Specifications (1 of 4)

Pump Specifications
P-100
Benzene Feed Pump
1
Fluid Properties
Process Fluid Mass Flow Rate (kg/hr)
ID Number:
Description:
No. Required
Process Fluid Compsition (mol%)

Pump Type
Orientation
Design Pressure (kPa)
Design Temperature (C)
Pump Efficiency (%)
Hydraulic Power (hp)
Brake Power (hp)
Date:
Prepared By:
Checked By:
88117
99.85% Benzene
0.1% n-Hexane
0.05% Toluene
25.0
25.0
101.3
135.8
Centrifugal
Horizontal
Cast Iron
97082
4000 (max)
300 (max)
75
1.9
2.5
5/8/2006
MJH
JRB

Pump Specifications
P-300
Benzene Recycle Pump
1
Fluid Properties
ID Number:
Description:
No. Required

Pump Type
Orientation
Pump Efficiency (%)
Brake Power (hp)
Date:
Prepared By:
Checked By:
3570
99.85% Benzene
0.14% n-Hexane
0.01% Toluene
41.8
41.9
26.7
135.8
Centrifugal
Horizontal
Cast Iron
3946
4000 (max)
300 (max)
75
0.25
0.33
5/8/2006
MJH
JRB

Pump Specifications
P-301
Toluene Product Pump
1
Fluid Properties
ID Number:
Description:
No. Required

Pump Type
Orientation
Pump Efficiency (%)
Brake Power (hp)
Date:
Prepared By:
Checked By:
4252
99.75% Toluene
0.24% Ethylbenzene
0.01% Benzene
69.5
69.6
26.7
101.3
Centrifugal
Horizontal
Cast Iron
4698
4000 (max)
300 (max)
75
0.21
0.28
5/8/2006
MJH
JRB

Pump Specifications
P-302
Styrene Product Pump
1
Fluid Properties
ID Number:
Description:
No. Required

Pump Type
Orientation
Pump Efficiency (%)
Brake Power (hp)
Date:
Prepared By:
Checked By:
112240
99.93% Styrene
0.04% Cumene
0.01% Toluene
Trace Heavies
43.7
43.8
2.3
105.0
Centrifugal
Horizontal
Cast Iron
124710
4000 (max)
300 (max)
75
7.2
9.6
5/8/2006
MJH
JRB
A.4: Tank Specifications (1 of 8)

Tank Specifications
Tank-100
Date: 5/8/2006
Styrene Monomer Product Tank
Prepared By:
MJH
3
Checked By:
MSB
Operating Conditions
Fluid Composition (by mass)
>99.93% Styrene Monomer
Operating Temperature (C)
23.9
Operating Pressure (kPa)
Atmospheric
Service Volume (m3)
10,010
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
NA
Power (hp)
Design Volume (m3)
11,310
Impeller Diameter (m)
NA
Tank Diameter (m)
20
Max Speed (rpm)
NA
Tank Height (m)
36
Heat Exchange?
Y
Residence Time (days)
10
Type
External Cooler
Liquid Level (%)
88.5
Media
H2O
Media Flowrate (kg/s)
16.2
Area (m2)
274
ID Number:
Description:
No. Required

Tank Specifications
Tank-101
Date: 5/8/2006
Styrene Monomer Off-Specification Tank
Prepared By:
MJH
1
Checked By:
MSB
<99.93% Styrene Monomer
23.9
Atmospheric
Service Volume (m3)
6,008
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
7,090
NA
Tank Diameter (m)
19
Max Speed (rpm)
NA
Tank Height (m)
25
Heat Exchange?
Y
2
Type
External Cooler
Liquid Level (%)
85
Media
H2O
Media Flowrate (kg/s)
11.2
189
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-103
Date: 5/8/2006
Benzene Feed Tank
Prepared By:
MJH
8
Checked By:
MSB
>99.8% Benzene
Atmospheric
Atmospheric
3
Service Volume (m )
9,026
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
10,681
NA
Tank Diameter (m)
20
Max Speed (rpm)
NA
Tank Height (m)
34
Heat Exchange?
N
30
Type
NA
Liquid Level (%)
85
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-104
Date: 5/8/2006
Benzene Off-Specification Tank
Prepared By:
MJH
1
Checked By:
MSB
<99.8% Benzene
Atmospheric
Atmospheric
3
Service Volume (m )
6,007
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
6,696
NA
Tank Diameter (m)
17
Max Speed (rpm)
NA
Tank Height (m)
29.5
Heat Exchange?
N
2
Type
NA
Liquid Level (%)
90
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-105
Date: 5/8/2006
Ethylbenzene Startup Tank
Prepared By:
MJH
1
Checked By:
MSB
~99.8% Ethylbenzene
Atmospheric
Atmospheric
3
Service Volume (m )
13,274
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
14,750
NA
Tank Diameter (m)
23
Max Speed (rpm)
NA
Tank Height (m)
35.5
Heat Exchange?
N
2
Type
NA
Liquid Level (%)
90
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-106
Date: 5/8/2006
Ethylbenzene Off-Specification Tank
Prepared By:
MJH
1
Checked By:
MSB
<99.8% Ethylbenzene
Atmospheric
Atmospheric
3
Service Volume (m )
13,274
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
14,750
NA
Tank Diameter (m)
23
Max Speed (rpm)
NA
Tank Height (m)
35.5
Heat Exchange?
N
2
Type
NA
Liquid Level (%)
90
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-107
Date: 5/8/2006
Toluene Product Storage Tank
Prepared By:
MJH
1
Checked By:
MSB
>99.7% Toluene
Atmospheric
Atmospheric
3
Service Volume (m )
1,177
Type
Cone Roof
Carbon Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
1,375
NA
Tank Diameter (m)
10
Max Speed (rpm)
NA
Tank Height (m)
16.5
Heat Exchange?
N
10
Type
NA
Liquid Level (%)
90
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required

Tank Specifications
Tank-108
Date: 5/8/2006
Toluene Off-Spec Storage Tank
Prepared By:
MJH
1
Checked By:
MSB
<99.7% Toluene
Atmospheric
Atmospheric
3
Service Volume (m )
236
Type
Cone Roof
Stainless Steel
Vessel Orientation
Vertical
480 (max)
Agitation Required?
N
4000 (max)
Power (hp)
NA
Design Volume (m3)
261
NA
Tank Diameter (m)
5.5
Max Speed (rpm)
NA
Tank Height (m)
11
Heat Exchange?
N
2
Type
NA
Liquid Level (%)
90
Media
NA
Media Flowrate
NA
NA
Area (m2)
ID Number:
Description:
No. Required
A.5: Two Phase Separator Specifications (1 of 13)

Two-Phase Separator Specifications
V-100
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Process Stream Conditions
Inlet Flows
Ethane (52.2%), Nitrogen (21.0%), Hydrogen (10.7%)
Vapor Feed
21490 kgmol/hr
Ethylene (5.6%), Ethylbenzene (5.1%), Styrene (5.0%)
Trace: n-Hexane, Toluene, Benzene
Outlet Flows
Ethane (58.0%), Nitrogen (23.7%), Hydrogen (12.0%)
Vapor Effluent
19080 kgmol/hr
Ethylene (6.30%)
ID Number:
Description:
No. Required
Ethylbenzene (45.2%), Styrene (44.7%), Ethane (5.6%),

Toluene (2.1%), Benzene (1.9%)
Trace: n-Hexane, Nitrogen, Heavies
Inlet
Exit
-50.0
Temperature (C)
Temperature (C)
-50.0
124.0
Pressure (kPa)
Pressure (kPa)
124.0
Design Data
Type
Two Phase Separator
Position
Vertical
Height (m)
9.07
Diameter (m)
2.59
Carbon Steel
47.79
Volume (m3)
Additional Equipment
Heat Exchange Required?
Agitation Required?
N
N
Liquid Effluent
2409 kgmol/hr

ID Number:
Description:
No. Required
Vapor Feed

V-101
Two-Phase Separator
1
Inlet Flows
Nitrogen (79.2%), Water (20.4%)
10380 kgmol/hr
Trace: Carbon Dioxide
Vapor Effluent
8477 kgmol/hr
Liquid Effluent
1904 kgmol/hr
Date: 5/11/2006
Prepared By:
LJB
Checked By:
MJH
Outlet Flows
Water (100%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
25.0
Temperature (C)
25.0
128.8
Pressure (kPa)
128.8
Design Data
Two Phase Separator
Vertical
6.93
1.98
Carbon Steel
21.34
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-102
Two-Phase Separator
1
Inlet Flows
8477 kgmol/hr
Vapor Effluent
8268 kgmol/hr
Outlet Flows
Nitrogen (99.4%)
Liquid Effluent
208.5 kgmol/hr
Water (100%)
Date: 5/11/2006
Prepared By:
LJB
Checked By:
MJH
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-50.0
Temperature (C)
-50.0
261.9
Pressure (kPa)
261.9
Design Data
Two Phase Separator
Vertical
4.27
1.22
Carbon Steel
4.99
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-400
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
Ethane (58.0 mol%), Nitrogen (23.7%), Hydrogen (12.0%),
19080 kgmol/hr
Ethylene (6.3%)
Vapor Effluent
19080 kgmol/hr
Liquid Effluent
0 kgmol/hr
Outlet Flows
Ethylene (6.3%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-68.6
Temperature (C)
-68.6
Pressure (kPa)
101.3
101.3
Design Data
Two Phase Separator
Vertical
9.60
2.74
Stainless Steel
56.61
N
Agitation Required?
N

ID Number:
Description:
No. Required
Vapor Feed

V-401
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
19080 kgmol/hr
Ethylene (6.3%)
Vapor Effluent
17920 kgmol/hr
Outlet Flows
Ethylene (6.5%)
Liquid Effluent
1161 kgmol/hr
Ethane (97.3%), Ethylene (2.7%)

Trace: Benzene, Nitrogen
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-115.3
Temperature (C)
-115.3
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
8.00
2.29
Stainless Steel
32.95
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-402
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
17920 kgmol/hr
Ethylene (6.5%)
Vapor Effluent
9642 kgmol/hr
Liquid Effluent
8281 kgmol/hr
Outlet Flows
Ethylene 12.2%)
Ethane (100%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-116.0
Temperature (C)
-116.0
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
9.60
2.74
Stainless Steel
56.61
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-403
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
9642 kgmol/hr
Ethylene 12.2%)
Vapor Effluent
8831 kgmol/hr
Liquid Effluent
810.2 kgmol/hr
Outlet Flows
Nitrogen (51.1%), Hydrogen (25.9%), Ethylene (13.3%)
Ethane (9.7 mol%)
Ethane (100%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-123.1
Temperature (C)
-123.1
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
5.87
1.68
Stainless Steel
13.01
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-404
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
8831 kgmol/hr
Ethane (9.7%)
Vapor Effluent
8222kgmol/hr
Liquid Effluent
609 kgmol/hr
Outlet Flows
Ethane (4.3%)
Ethane (82.6%), Ethylene (17.4%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-132.0
Temperature (C)
-132.0
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
5.30
1.52
Stainless Steel
9.62
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-405
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
8222kgmol/hr
Ethane (4.3%)
Vapor Effluent
7697 kgmol/hr
Liquid Effluent
524.9 kgmol/hr
Outlet Flows
Ethane (2.8%)
Ethylene (74.0%), Ethane (26.0%),
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-136.2
Temperature (C)
-136.2
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
5.33
1.52
Stainless Steel
9.67
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-406
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
7697 kgmol/hr
Ethane (2.8%)
Vapor Effluent
7304 kgmol/hr
Liquid Effluent
393.3 kgmol/hr
Outlet Flows
Ethane (1.6%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-141.4
Temperature (C)
-141.4
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
4.80
1.37
Stainless Steel
7.08
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-407
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
7304 kgmol/hr
Ethane (1.6%)
Vapor Effluent
7038 kgmol/hr
Liquid Effluent
393.3 kgmol/hr
Outlet Flows
Trace: Ethane
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-147.9
Temperature (C)
-147.9
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
4.80
1.37
Stainless Steel
7.08
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-408
Date: 5/11/2006
Two-Phase Separator
Prepared By:
LJB
1
Checked By:
MJH
Inlet Flows
7038 kgmol/hr
Trace: Ethane
Vapor Effluent
6890 kgmol/hr
Liquid Effluent
148.7 kgmol/hr
Outlet Flows
Nitrogen (65.6%), Hydrogen (33.2%)
Trace: Ethylene, Ethane
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-155.6
Temperature (C)
-155.6
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
4.80
1.37
Stainless Steel
7.08
Agitation Required?
N
N

ID Number:
Description:
No. Required
Vapor Feed

V-409
Two-Phase Separator
1
Inlet Flows
6890 kgmol/hr
Vapor Effluent
6832 kgmol/hr
Liquid Effluent
58.1 kgmol/hr
Date: 5/11/2006
Prepared By:
LJB
Checked By:
MJH
Outlet Flows
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Height (m)
Diameter (m)
Volume (m3)
Exit
-163.4
Temperature (C)
-163.4
101.3
Pressure (kPa)
101.3
Design Data
Two Phase Separator
Vertical
4.27
1.22
Stainless Steel
4.99
Agitation Required?
N
N
A.6: Turbine Specifications (1 of 10)

Turbine Specifications
ID Number:
Description:
No. Required
M-400
1st Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
Process Feed Flow Rate (kg/hr)
497960
58.04% Ethane
23.67% Nitrogen
11.99% Hydrogen
6.30% Ethylene
Trace Amounts Heavies
-47.5
-68.63
173.5
101.3

Expander Type
Orientation
Design Capacity (kg/hr)
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
549770
85
4739

ID Number:
Description:
No. Required
M-401
2nd Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
497920
58.04% Ethane
23.67% Nitrogen
11.99% Hydrogen
6.30% Ethylene
Trace Amounts Heavies
-25.4
-115.3
3000.0
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
549740
85
25280

ID Number:
Description:
No. Required
M-402
3rd Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
463070
55.50% Ethane
25.20% Nitrogen
12.77% Hydrogen
6.54% Ethylene
-15.7
-100.3
3000.0
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
511190
85
24900

ID Number:
Description:
No. Required
M-403
4th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
214070
17.27% Ethane
56.84% Nitrogen
23.74% Hydrogen
12.15% Ethylene
-50.0
-123.1
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
237330
85
10820

ID Number:
Description:
No. Required
M-404
5th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
189700
9.68% Ethane
51.14% Nitrogen
25.91% Hydrogen
13.26% Ethylene
-50.0
-132.0
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
210370
85
9811

ID Number:
Description:
No. Required
M-405
6th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
171600
4.28% Ethane
54.93% Nitrogen
27.83% Hydrogen
12.96% Ethylene
-50.0
-136.2
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
190400
85
8963

ID Number:
Description:
No. Required
M-406
7th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
156600
2.80% Ethane
58.67% Nitrogen
29.73% Hydrogen
8.80% Ethylene
-50.0
-141.4
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
173860
85
8209

ID Number:
Description:
No. Required
M-407
8th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
145370
1.59% Ethane
61.83% Nitrogen
31.33% Hydrogen
5.25% Ethylene
-50.0
-147.9
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
161500
85
7634

ID Number:
Description:
No. Required
M-408
9th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
137780
0.74% Ethane
64.17% Nitrogen
32.52% Hydrogen
2.58% Ethylene
-50.0
-155.6
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
153180
85
7276

ID Number:
Description:
No. Required
M-409
10th Turbine
1
Date: 5/8/2006
Prepared By:
MJH
Checked By:
LJB
Fluid Properties
133540
0.26% Ethane
65.55% Nitrogen
33.22% Hydrogen
0.97% Ethylene
-50.0
-163.4
3000
101.3

Expander Type
Orientation
Power Output (kW)
Centrifugal
Horizontal
Stainless Steel
148560
85
7136
A.7: Distillation Specifications (1 of 8)

Distillation Specifications
ID Number: T-300
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Composition (mol fraction)
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Pressure Drop (kPa)
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Toluene/Ethylbenzene Distillation Column

1
Feed
Distillate
236400
7924
0
1
0.0000
0.0000
0.0005
0.0002
0.0223
0.0202
0.4808
0.0000
0.0000
0.0000
0.0000
0.0000
0.4754
0.0000
0.0002
0.0000
0.0002
0.0001
0.0000
0.0000
0.0000
0.0000
0.0128
0.0000
0.4947
0.4913
0.0012
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
59.08
40
26.66
26.66
66
Flood Vapor Velocity (ft/s)
24
Design Vapor Vel. (ft/s)
50
12
Height of Packing (m)
3.3
0.95
Tower Construction
Carbon Steel
Flexipac HC
2.12
40.23
95.54
26.66
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ
Bottoms
228500
0
0.0000
0.0000
0.0000
0.0002
0.0020
0.0000
0.5014
0.0000
0.0000
0.0000
0.0000
0.0000
0.4958
0.0000
0.0003
0.0000
0.0003
0.0001
0.0000
0.0000
95.54
26.66
3.878
3.856
11.58

ID Number: T-301
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Pressure Drop (kPa)
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Benzene/Toluene Distillation Column

1
Feed
Distillate
7924
3673
1
1
0.0000
0.0000
0.0128
0.0000
0.4947
0.4913
0.0012
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0254
0.0000
0.0001
0.9745
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
59.08
41.54
26.66
26.66
23
24
10
3.41
1.15
0.85
Tower Construction
Carbon Steel
Sieve Tray
0.80
14.02
69.54
26.66
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ
Bottoms
4252
0
0.0000
0.0000
0.0000
0.0000
0.9975
0.0001
0.0024
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
69.54
26.66
13.033
13.033

ID Number: T-303
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Pressure Drop (kPa)
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Ethylbenzene/Styrene Distillation Column

1
Distillate
Feed
228500
116100
0
1
0.0000
0.0000
0.0000
0.0002
0.0020
0.0000
0.5014
0.0000
0.0000
0.0000
0.0000
0.0000
0.4958
0.0000
0.0003
0.0000
0.0003
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0041
0.0000
0.9957
0.0000
0.0000
0.0000
0.0000
0.0000
0.0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
95.54
61.68
26.66
8.00
72
24
48
10
3.6
0.95
Tower Construction
Carbon Steel
Flexipac HC
5.63
43.89
69.77
8.00
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ
Bottoms
112400
0
0.0000
0.0000
0.0000
0.0005
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.9982
0.0000
0.0005
0.0000
0.0005
0.0002
0.0000
0.0000
69.77
8.00
21.85
21.84
12.19

ID Number: T-304
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Pressure Drop (Psi.)
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ
Styrene/Heavies Distillation Column

1
Distillate
Feed
112400
78580
0
1
0.0000
0.0000
0.0000
0.0005
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.9982
0.0000
0.0005
0.0000
0.0005
0.0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0001
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.9994
0.0000
0.0003
0.0000
0.0000
0.0000
0.0000
0.0000
69.77
60.6
8.00
5.33
45
24
24
0.76
2.25
0.95
Tower Construction
Carbon Steel
Flexipac HC
5.61
27.43
60.65
5.33
Bottoms
33840
0
0.0000
0.0000
0.0000
0.0013
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9954
0.0000
0.0010
0.0000
0.0016
0.0007
0.0000
0.0000
60.65
5.33
22.575
22.573
19.51

ID Number: T-305
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ

1
Feed
Distillate
33840
26940
0
1
0.0000
0.0000
0.0000
0.0013
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9954
0.0000
0.0010
0.0000
0.0016
0.0007
0.0000
0.0000
0.0000
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9994
0.0000
0.0005
0.0000
0.0000
0.0000
0.0000
0.0000
60.65
60.61
5.33
5.33
30
24
16
1.29
1.5
0.95
Tower Construction
Carbon Steel
Flexipac HC
3.59
18.29
60.82
5.33
Bottoms
6893
0
0.0000
0.0000
0.0000
0.0058
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9798
0.0000
0.0028
0.0000
0.0078
0.0037
0.0000
0.0000
60.82
5.33
18.93
18.93
19.51

ID Number: T-306
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ

1
Feed
Distillate
6893
6715
0
1
0.0000
0.0000
0.0000
0.0058
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9798
0.0000
0.0028
0.0000
0.0078
0.0037
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9994
0.0000
0.0006
0.0000
0.0000
0.0000
0.0000
0.0000
60.82
60.6
5.33
5.33
30
24
16
15
1.5
0.95
Tower Construction
Carbon Steel
Flexipac HC
3.64
18.29
73.30
5.33
Bottoms
178
0
0.0000
0.0000
0.0000
0.2572
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1312
0.0004
0.1000
0.0000
0.3480
0.1632
0.0000
0.0000
73.3
5.33
4.614
4.571
17.07

ID Number: T-302
Description:
No. Required
Function
Feed Fluid
Flow Rate (kg/hr)

Vapor Fraction
Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Tray Efficiency
Tray Type
Tower Diameter (m)
Tower Height (m)
n-Hexane/Benzene Distillation Column

1
Feed
Distillate
3673
366.2
1
1
0.0000
0.0000
0.0254
0.0000
0.0001
0.9745
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.2480
0.0000
0.0000
0.7520
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
41.51
38.27
26.66
26.66
40
24
28
15
2
0.85
Tower Construction
Carbon Steel
Sieve Tray
0.34
24.38
41.82
26.66
Date: 5/11/2006
Prepared By:
MSB
Checked By:
ACJ
Bottoms
3307
0
0.0000
0.0000
0.0014
0.0000
0.0001
0.9985
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
41.82
26.66
3.449
7.976

ID Number: T-101
Description:
No. Required
Function
Feed Fluid
Date:
5/11/2006
Prepared By: MSB
Checked By: ACJ
Ethylbenzene Recovery
1
Flow Rate (kg/hr)

Vapor Fraction
Feed 1
111800
0
Feed 2
50190
0.0459
Distillate
124100
1
Bottoms
37920
0

Methane
Ethane
n-Hexane
1M3-EBenzene
Toluene
Benzene
E-Benzene
Hydrogen
Oxygen
Nitrogen
H2O
Ethylene
Styrene
n-Bbenzene
Cumene
n-Pbenzene
AMS
m-DiEBenzene
CO2
Carbon
0.0000
0.0000
0.0000
0.0005
0.0000
0.0000
0.8299
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0094
0.0011
0.0000
0.0000
0.1591
0.0000
0.0000
0.0000
0.0000
0.0004
0.0000
0.0002
0.0000
0.7444
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0207
0.0000
0.0000
0.0000
0.2343
0.0000
0.0000
0.0000
0.0000
0.0001
0.0004
0.0001
0.0000
0.9982
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0009
0.0000
0.0000
0.0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0660
0.0000
0.0000
0.0000
0.9340
0.0000
0.0000
152.50
135.9
155.6
135.8
147.5
135.8
193.9
135.8
49
24
12
3
4.9
0.85
Flood Vapor Vel. (ft/s)

4.793
4.793
Temperature (C)
Pressure (kPa)
Number of Trays
Tray Spacing (in.)
Feed Tray
Reflux Ratio
Pressure Drop (kPa)
Tray Efficiency
Tower Construction
Tray Type
Tower Diameter (m)
Tower Height (m)
Carbon Steel
Sieve Tray
3.55
29.87
69.54
26.66
A.8: Reactor Specifications (1 of 4)

Reactor Specifications
R-100
Date: 5/8/2006
Dehydrogenation Reactor
Prepared By:
MJH
4
Checked By:
Inlet Flows
Ethane (64.6 mol%), Nitrogen (23.6%), Ethylbenzene (11.8%)
Vapor Feed
19160 kgmol/hr
Trace: n-Hexane, Toluene, Styrene, Ethylene, Cumene
Diethylbenzene, Heavy Polyalkylates
Outlet Flows
Ethane (52.0 mol%), Nitrogen (21.0%), Ethylbenzene (5.1%)
Vapor Effluent
21540 kgmol/hr
Hydrogen (10.6%), Ethylene (5.6%), Styrene (5.0%)
Trace: Benzene, Toluene, Cumene, Carbon, Polyalkylates
Inlet
Exit
451.2
Temperature (C)
Temperature (C)
600.0
Pressure (kPa)
260.3
Pressure (kPa)
132.7
Design Data
Type
Fluidized Catyst Cracking
Position
Vertical
Stainless Steel
Volume (m3)
440.9
Tube Diameter (m)
3.8
Tube Length (m)
38.3
Agitation Required?
N
N
ID Number:
Description:
No. Required

ID Number:
Description:
No. Required
Vapor Feed
Vapor Effluent
R-10
Catalyst Regenerator
4
Date:
Prepared By:
Checked By:
5/8/2006
MJH
11408 kgmol/hr

Inlet Flows
Hydrogen (18.1 mol%), Oxygen (9.7%), Nitrogen (72.0%)
Trace: Ethane, Ethylene, Carbon
10380 kgmol/hr
Outlet Flows
Nitrogen (79.2 mol%), Water (20.4%)
Inlet
Temperature (C)
Pressure (kPa)
Type
Position
Volume (m3)
Tube Diameter (m)
Tube Length (m)
Exit
554.7
Temperature (C)
134.3
Pressure (kPa)
Design Data
Regenerator
Vertical
Stainless Steel
220.4
1.4
14.2
Agitation Required?
N
712.6
134.3

ID Number:
Description:
No. Required
Vapor Feed
Vapor Effluent
R-200
Alkylation Reactor
4
Date:
Prepared By:
Checked By:
31144 kgmol/hr

Inlet Flows
Ethane (83.5 mol%), Benzene (7.6%), Ethylene (8.9%)
Trace: n-Hexane, Toluene, Ethylbenzene, Nitrogen
11060 kgmol/hr
Outlet Flows
Ethane (99.99 mol%)
Trace: n-Hexane, Nitrogen, Ethylene
5/8/2006
MJH
Ethylbenzene (79.4 mol%), Diethylbenzene (19.3%)

n-Butylbenzene (1.1%)
Trace: Cumene, Polyalkylates, Styrene
Inlet
Exit
25.0
Temperature (C)
Temperature (C)
152.5
Pressure (kPa)
135.8
Pressure (kPa)
135.8
Design Data
Type
Distillation Reactor
Position
Vertical
Stainless Steel
Volume (m3)
124
3
Void Volume (m )
0.7
Packed Volume (m3)
0.3
Packed Diameter (m)
1.9
Packed Length (m)
6.5
Agitation Required?
N
N
Liquid Effluent
1008 kgmol/hr

ID Number:
Description:
No. Required
Liquid Feed
R-201
Transalkylator
4
441 kgmol/hr
Date:
Prepared By:
Checked By:
5/8/2006
MJH

Inlet Flows
Diethylbenzene (93.4 mol%), n-Butylbenzene (6.6%)
Trace: Cumene, Ethylbenzene, Toluene, Polyalkylates
Outlet Flows
Diethylbenzene (23.4 mol%), n-Butylbenzene (2.1%)
Liquid Effluent
441 kgmol/hr
Ethylbenzene (74.4%)
Trace: Cumene, Toluene, Polyalkylates
Inlet
Exit
121.4
Temperature (C)
Temperature (C)
155.6
Pressure (kPa)
135.8
Pressure (kPa)
135.8
Design Data
Type
Packed Bed
Position
Vertical
Stainless Steel
Volume (m3)
17
Void Volume (m3)
0.75
Packed Volume (m3)
0.25
Tube Diameter (m)
1.1
Tube Length (m)
19.1
N
Agitation Required?
N
Appendix B: PFD / PID / Layout
B.1 PFD: Alkylation Unit Area 100

108
114/
202
Ethylbenzene and Ethane

To Dehydrogenation
113/
324
Byproducts
To Separations
110
Ethylene and Ethane

From L.G. Separations
105/
452
119
E-100
118
106
116
12
112
49
T-100
R-100
111
R-101
109
Benzene
From Separations
117
104/
327
115
102
101
100
Benzene Feed
P-100
103
B.2 PFD: Dehydrogenation Unit Area 200

Hydrogen and Nitrogen
213/
455
216
217
E-207
208
209
E-208
Air Feed
K-201
230
215
218
210
R-200
214
E-206
R201
207
219
212
E-201
206
E-203
231
K-200
211
236/
401
K-200
Light Gas
To L.G.Separations
PFD pg. 6
205
232
233
V-202
234
E-204
E-205
E-200
235/
301
PFD pg. 6
Products
To Separations
204
K-202
Ethylbenzene
From Separations
203/
316

From Alkylation
114/
202
K-202
V-200
225
223
221
V-201
Water treatment
222
220
E-202
200
Ethane Feed
226
201
224
227
Purge
B.3 PFD: Separations Unit Area 300a
inerts
inerts
311
Incinerated
T-302
Steam
308
Light Gases
Vented
327
312
Benzene
To Alkylation
inerts
306
P-302
T-301
Steam
310
309
307
Toluene For
Sale
P-301
Products
From Dehydrogenation
235/
301
303
304
305
T-300
Steam
E-300
inerts
Products
453/
302
313
203/
316
314
Ethylbenzene
To Dehydrogenation
K-303
T-303
Steam
315
Styrene Finish
To Separations pg. 2
B.4 PFD: Separations Unit Area 300b
inerts
329
317
325
328
E-301
E-302
inerts
P-303
Styrene
to Customer
and Storage
P-1017
FC
319
inerts
321
Styrene Finish
From Separations pg. 1
315
T-304
P-1018
Steam
T-305
318
P-1019
Steam
320
T-306
Steam
322
Byproducts
From Alkylation
113/
324
323
Heavy Byproducts
To Treatment
B.5 PFD: Light Gas SeparationsArea 400
Light Gas
236/
401
402
K-400
403
404
V-400
405
M-400
E-400
406
K-401
407
408
V-401
409
M-401
E-401
411
K-402
PFD pg. 6
412
413
PFD pg. 6
410
415
416
K-403
417
418
V-403
420
M-403
E-403
421
K-404
PFD pg. 6
422
423
K-406
432
433
V-406
435
M-406
E-406
436
K-407
437
438
V-407
M-407
E-407
447
448
V-409
M-409
440
441
442
450
V-405
443
V-408
M-408
E-408
PFD pg. 6
439
451
K-410
PFD pg. 6
428
M-405
429
K-408
PFD pg. 6
E-409
427
E-405
PFD pg. 6
434
446
426
K-405
424
PFD pg. 6
K-409
425
PFD pg. 6
431
445
V-404
414
M-404
E-404
419
430
V-402
M-402
E-402
454
444

To Dehydrogenation
213/
455
E-410
456
To Treatment
449
105/
452
Ethylene and Ethane

To Alkylation
453/
302
Products
To Separations
B.6 PFD: PFD pg. 6 Compressor Chains

Dehydrogenation
K-200
L.G. Separations
K-403
205.
1
205
K-200.1
205.
2
K-200.2
205.
3
K-200.3
206
K-403.1
E-200.1
221.
1
K-202.1
221.
2
E-202.1
221.
3
K-202.2
222
415.
3
K-403.2
415.
4
E-403.2
416
K-403.3
K-404.1
420.
2
E-404.1
420.
3
K-404.2
420.
4
E-404.2
421
K-404.3
L.G. Separations
K-405
405.
1
K-401.1
405.
2
E-401.1
405.
5
K-401.3
405.
3
K-401.2
405.
6
E-401.3
405.
4
E-401.2
405.
7
K-401.4
425.
1
425
K-405.1
405.
8
405.
10
E-401.5
K-401.5
425.
2
E-405.1
425.
3
K-405.2
425.
4
E-405.2
426
K-405.3
L.G. Separations
K-406
E-401.4
430.
1
430
405.
9
406
K-406.1
430.
2
E-406.1
430.
3
K-406.2
430.
4
E-406.2
431
K-406.3
K-401.6
L.G. Separations
K-407
L.G. Separations
K-402
435.
1
435
409.
1
409
E-403.1
420.
1
420
E-202.2
L.G. Separations
K-401
405
415.
2
L.G. Separations
K-404
Dehydrogenation
K-202
221
415.
1
415
K-402.1
409.
2
E-402.1
409.
5
K-402.3
409.
3
K-402.2
409.
6
E-402.3
409.
4
435.
2
E-407.1
435.
3
K-407.2
435.
4
E-407.2
436
K-407.3
E-402.2
409.
7
K-402.4
K-407.1
409.
8
L.G. Separations
K-408
E-402.4
440.
1
440
K-408.1
440.
2
E-408.1
440.
3
K-408.2
440.
4
E-408.2
441
E-408.3
411
402.5
L.G. Separations
K-409
445.
1
445
K-409.1
445.
2
E-250
445.
3
E-251
445.
4
E-248
446
E-252
B.7 P&ID: Alkylation Unit Area 100

FC
108
114/
202

To Dehydrogenation
113/
324
Byproducts
To Separations
110
LC
V-93
Ethylene and Ethane

105/
452
119
E-100
118
106
116
12
112
FC
49
T-100
R-100
111
R-101
LC
109
Benzene
From Separations
117
104/
327
115
FC
102
101
103
100
Benzene Feed
P-100
FC
B.8 P&ID: Dehydrogenation Unit Area 200

213/
455
FC
TC
TC
PC
216
217
E-207
208
209
E-208
Air Feed
K-201
230
215
218
210
R-200
214
TC
E-206
R201
207
FC
219
212
E-201
E-203
TC
206
231
K-200
211
236/
401
K-200
TC
P&ID pg. 6
Light Gas
To L.G.Separations
TC
E-204
205
232
233
234
E-205
E-200
TC
226
235/
301
P&ID pg. 6
Products
To Separations
204
K-202
Ethylbenzene
From Separations
203/
316
FC
221
K-202
Water treatment
E-202
From Alkylation
114/
202
225
223
222
220
TC
FC
200
201
224
Ethane Feed
227
Purge
B.9 P&ID: Separations Unit Area 300a
inerts
LC
PC
inerts
311
Incinerated
FC
T-302
TC
FC
Steam
308
LC
LC
PC
Light Gases
Vented
327
312
inerts
Benzene
To Alkylation
FC
306
P-302
T-301
TC
FC
Steam
LC
LC
310
PC
309
307
Toluene For
Sale
FC
FC
Products
235/
301
303
304
305
P-301
T-300
TC
FC
E-300
Steam
inerts
Products
453/
302
LC
LC
313
PC
203/
316
314
Ethylbenzene
To Dehydrogenation
FC
K-303
T-303
TC
FC
Steam
LC
315
Styrene Finish
To Separations pg. 2
B.10 P&ID: Separations Unit Area 300b
inerts
FC
329
317
325
326
328
E-301
E-101
E-181
inerts
LC
FC
PC
319
inerts
321
Styrene Finish
From Separations pg. 1
315
T-304
TC
LC
FC
PC
Steam
LC
FC
T-305
318
LC
TC
FC
PC
Steam
FC
LC
T-306
320
TC
FC
Steam
LC
322
Byproducts
From Alkylation
113/
324
323
Heavy Byproducts
To Treatment
B.11 P&ID: Light Gas SeparationsArea 400
Light Gas
236/
401
402
K-400
403
404
405
M-400
E-400
406
K-401
407
408
411
K-402
P&ID pg. 6
V-400
409
M-401
E-401
V-401
412
413
M-402
E-402
V-402
P&ID pg. 6
410
415
416
K-403
417
418
420
M-403
E-403
421
K-404
P&ID pg. 6
422
423
431
K-406
432
433
E-406
435
436
K-407
437
438
P&ID pg. 6
447
E-409
448
E-407
K-408
V-407
451
K-410
V-409
441
442
443
M-408
E-408
P&ID pg. 6
V-408
439
450
M-409
V-405
429
440
M-407
P&ID pg. 6
V-406
446
K-409
428
M-405
P&ID pg. 6
V-404
434
445
427
E-405
424
M-406
P&ID pg. 6
426
K-405
419
430
425
M-404
E-404
P&ID pg. 6
V-403
414
454
444

To Dehydrogenation
213/
455
E-410
456
To Treatment
449
105/
452
Ethylene and Ethane

To Alkylation
453/
302
Products
To Separations
B.12 P&ID: P&ID pg. 6 Compressor Chains

Dehydrogenation
K-200
L.G. Separations
K-403
205.
1
205
K-200.1
205.
2
K-200.2
205.
3
K-200.3
206
Controls for each Compressor and

Heat Exchanger in the Process
415.
1
415
K-403.1
E-200.1
415.
2
E-403.1
415.
3
K-403.2
415.
4
E-403.2
416
PC
K-403.3
FC
TC
L.G. Separations
K-404
Dehydrogenation
K-202
221.
1
221
K-202.1
221.
2
E-202.1
221.
3
K-202.2
222
K-404.1
L.G. Separations
K-401
K-401.1
405.
2
E-401.1
405.
5
K-401.3
405.
3
K-401.2
405.
6
E-401.3
405.
4
E-401.2
405.
7
K-401.4
425.
1
425
K-405.1
405.
8
420.
3
K-404.2
420.
4
E-404.2
421
K-404.3
405.
10
E-401.5
K-401.5
425.
2
E-405.1
425.
3
K-405.2
425.
4
E-405.2
426
K-405.3
L.G. Separations
K-406
E-401.4
430.
1
430
405.
9
406
K-406.1
430.
2
E-406.1
430.
3
K-406.2
430.
4
E-406.2
431
K-406.3
K-401.6
L.G. Separations
K-407
L.G. Separations
K-402
435.
1
435
409.
1
409
420.
2
E-404.1
L.G. Separations
K-405
405.
1
405
420.
1
420
E-202.2
K-402.1
409.
2
E-402.1
409.
5
K-402.3
409.
3
K-402.2
409.
6
E-402.3
409.
4
435.
2
E-407.1
435.
3
K-407.2
435.
4
E-407.2
436
K-407.3
E-402.2
409.
7
K-402.4
K-407.1
409.
8
L.G. Separations
K-408
E-402.4
440.
1
440
K-408.1
440.
2
E-408.1
440.
3
K-408.2
440.
4
E-408.2
441
E-408.3
411
402.5
L.G. Separations
K-409
445.
1
445
K-409.1
445.
2
E-250
445.
3
E-251
445.
4
E-248
446
E-252
AREA 300 -SEPARATIONS
B.13: Plant Layout

5.63m.
3.80m.
3.80m.
Dehydro
Dehydrogenation
Dehydrogenation
3.59m.
T-303
T-305
2.12m.
T-300
0.80m.
T-301
3.80m.
3.80m.
Dehydrogenation
Dehydrogenation
0.34m.
3.64m.
T-306
5.61m.
T30
2
T-304
AREA 200 -DEHYDROGENATION
V-407
V-408
1.90m.
1.90m.
1.90m.
1.90m.
Alkylator
Alkylator
Alkylator
Alkylator
V-409
V-400
V-406
V-404
V-405
3.55m.
V-401
Alkylation Tower
V-403
V-402
AREA 400
LIGHT GASES SEPARATION
FRONT
AREA 100 -ALKYLATION
Trans
Akylator
Trans
Akylator
Trans
Akylator
Trans
Akylator
1.10m.
1.10m.
1.10m.
1.10m.
10.00m.
10.00m.
10.00m.
B.14: Plant Layout, Front View
T-300
Dehydro
Tr
a
n
s
Al
k
yl
at
or
T
3
0
2Alkyl
ator
Tr
Tr
a
a
n
n
s
s
Al Alkylation
Al
k Tower k
yl
yl
T-304
at
at
or
or
Alkyl
ator
Alkyl
ator
Tr
a
n
s
Al
k
yl
at
or
10.00m.
Dehydro
Alkyl
ator
V-400
V-401
V-402
V40
6
V- V- VV- V- V4040 403

40 40 40
7 5
8 4 9
10.00m.
T-306
T
3
0
1
Appendix C: Separations
C.1: Separations Hand Calculations (1 of 3)

Calculations for Column Diameter in Separations Unit : Tray Column T-300 Bottom of Column
atm ft
P := 0.2631
R := 1.314 lbmol K
atm
lb
MWv := 85.187
L := 4791
lbmol
lbmol
v := 5.1336 10
lb
Wl := L MWl
Wv := V MWv
Wl
= 28.833
Wl v
Flv :=

Wv l
Flv = 0.914
0.5
l := 51.077
T := 368.69 K
lb
MWl := 105.15
V := 205.1
hr
ft
Wv
lbmol
lbmol
hr
lb
ft
v := 7.3254 10
:= 21.913
dyne
cm
NumberOfTrays := 66
cP
From Wankat equation 12-10e for 24-in tray spacing

logCsb := .94506 0.70234 log( Flv) 0.22618 ( log ( Flv) )
Finding Csb:
logCsb
Csb := 10
Csb = 0.121
20
0.2
K := Csb
K = 0.123
v = 0.051
l = 51.077
l v
uflood := K
0.5
uflood = 3.878
fraction := 0.75
uop := ( fraction ) uflood
uop = 2.909
Finding the Diameter using equation 12-14 Wankat
:= 0.95
Dia :=
( 4 V MWv)
fraction
uflood
3600
Dia = 6.6
ft
Diameter := Dia
30.48
100
Diameter = 2.012
0.5

Calculations for Column Diameter in Separations Unit : Tray Column T-300 Middle of Column
atm ft
P := 0.2631
R := 1.314 lbmol K
atm
lb
MWv := 85.187
L := 4791
lbmol
lbmol
v := 5.1336 10
hr
lb
Wl := L MWl
Wv := V MWv
Wv
= 28.833
Flv :=
Wl v
Wv
l
Flv = 0.914
0.5
l := 51.077
T := 363.45 K
lb
MWl := 105.15
V := 205.1
ft
Wl
lbmol
lbmol
hr
lb
ft
v := 7.3254 10
:= 21.913
dyne
cm
NumberOfTrays := 66
cP

Finding Csb:
logCsb
Csb := 10
Csb = 0.121
20
0.2
K := Csb
K = 0.123
v = 0.051
l = 51.077
l v
0.5
uflood := K
uflood = 3.878
fraction := 0.75
uop = 2.909
:= 0.95
Dia :=
( 4 V MWv)
)
v fraction uflood 3600
Dia = 6.6
ft
Diameter := Dia
30.48
100
Diameter = 2.012
0.5

Calculations for Column Diameter in Separations Unit : Tray Column T-300 Top of Column
atm ft
P := 0.2631
R := 1.314 lbmol K
atm
lb
MWv := 85.187
L := 4791
lbmol
lbmol
v := 5.1336 10
lb
Wl := L MWl
Wv := V MWv
Wl
= 28.833
Wl v
Flv :=

Wv l
Flv = 0.914
0.5
l := 51.077
T := 332.23 K
lb
MWl := 105.15
V := 205.1
hr
ft
Wv
lbmol
lbmol
hr
lb
ft
v := 7.3254 10
:= 21.913
dyne
cm
NumberOfTrays := 66
cP

Finding Csb:
logCsb
Csb := 10
Csb = 0.121
20
0.2
K := Csb
K = 0.123
v = 0.051
l = 51.077
l v
0.5
uflood := K
uflood = 3.878
fraction := 0.75
uop = 2.909
:= 0.95
Dia :=
( 4 V MWv)
fraction
uflood
3600
Dia = 6.6
ft
Diameter := Dia
30.48
100
Diameter = 2.012
0.5
C.2: Estimates of Column Height (1 of 3)

Separations Unit at 100% Capacity
T-300
Toluene/EB Column
T-302
n-Hexane/Benzene Split
Pressure
0.2666
1.0133
0.2631
deg Celsius
59.08
90.3
95.54
81.64
24
66
1584
39.37
40.23
Pressure
0.267
1.013
0.263
deg Celsius
38.27
41.51
41.82
40.53
24
40
960
39.37
24.38
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
bar
bar/atm
atm
K
332.23
363.45
368.69
354.79
in.
in.
in./m
m
132 ft
Column Diameter
Top
2.12 m
6.96 ft
Based on Previous Models the Diameter of the
Total Column will be assumed to not change drastically
because changes in temperature are minimal
Diameter of Packing
1.31 m
4.29 ft
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
Column Diameter
Top
bar
bar/atm
atm
K
311.42
314.66
314.97
313.68
in.
in.
in./m
m
0.34 m
80.00 ft
1.10 ft
According to vendor information KOCH-GLITSCH

Column diameter range is from 3-9ft or 1.0-2.7m
T-301
Benzene/Toluene Column
T-303
EB/Styrene Column
Pressure
0.2666
1.0133
0.2631
deg Celsius
41.51
58.17
69.54
56.41
24
23
552
39.37
14.02
Pressure
0.080
1.013
0.079
deg Celsius
61.68
62.42
69.77
64.62
24
72
1728
39.37
43.89
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
Column Diameter
Top
bar
bar/atm
atm
K
314.66
331.32
342.69
329.56
in.
46.00 ft
in.
in./m
m
0.80 m
0.00 ft
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
bar
bar/atm
atm
K
334.83
335.57
342.92
337.77
in.
in.
in./m
m
144 ft
Column Diameter
Top
5.63 m
18.47 ft
Diameter of Packing
6.38 m
20.94 ft

Column diameter range is from 7.5-over 29ft or 2.3-~9m

Styrene Finish
T-304
Pressure
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
T-306
0.053
1.013
0.053
deg Celsius
60.6
60.61
60.65
60.62
24
45
1080
39.37
27.43
bar
bar/atm
atm
K
333.75
333.76
333.8
333.77
in.
in.
in./m
m
Pressure
90.00 ft
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
0.053
1.013
0.053
deg Celsius
60.6
60.69
73.3
64.86
24
30
720
39.37
18.29
bar
bar/atm
atm
K
333.75
333.84
346.45
338.01
in.
in.
in./m
m
60.00 ft
Column Diameter
Top
5.61 m
18.41 ft
Column Diameter
Top
3.64 m
11.96 ft
Diameter of Packing
5.88 m
19.27 ft
Diameter of Packing
1.72 m
5.63 ft

Column diameter range is from 7-17.5ft or 2.1-~5.3m

T-305
Pressure
Top
Middle
Bottom
Average
Tray Spacing
Number of Trays
Column Height
0.053
1.013
0.053
deg Celsius
60.61
60.63
60.82
60.69
24
30
720
39.37
18.29
bar
bar/atm
atm
K
333.76
333.78
333.97
333.84
in.
in.
in./m
m
60.00 ft
Column Diameter
Top
3.59 m
11.77 ft
Diameter of Packing
3.44 m
11.29 ft


Alkylation Unit
T-101
Pressure
1.358
1.013
1.340
deg Celsius
Top
147.5
Middle
193.8
Bottom
193.9
Average Temp
178.4
Tray Spacing
24
Number of Trays
49
Column Height
1176
39.37
29.87
Column Diameter
Top
bar
bar/atm
atm
K
420.65
466.95
467.05
451.55
in.
in.
in./m
m
3.55 m
98.00 ft
11.65 ft
C.3: Fenske Equation (1 of 3)

Hand Calculations for Minimum Reflux using Fenske's equation
Mix 3 going into separations
By Products
MW
Hydrogen
2.02
Nitrogen
28.01
Ethylene
28.05
Ethane
30.07
n-Hexane
86.18
Benzene
78.11
Toluene
92.14
Ethylbenzene
106.17
Styrene
104.15
cumene
120.19
n-p-benzene
120.19
1M3-EBenzene
120.19
-methylstyrene
118.18
m-DiEBenzene
134.22
n-Butyl-Benzene
134.22
Bp
-252.6
-195.8
-103.75
-88.6
68.73
80.09
110.65
136.2
145.16
152.41
159.24
161.33
165.5
181.14
183.3
K
8.72E+03
4.31E+03
3.11E+02
2.46E+02
1.18E+00
7.85E-01
2.70E-01
1.01E-01
6.86E-02
4.39E-02
8.49E-03
3.52E-02
2.70E-02
1.30E-02
9.95E-03
alpha
2.02
13.84
1.27
207.78
1.51
2.91
2.67
1.47
1.56
5.17
0.24
1.31
2.07
1.31
Mol fraction
0.0000
0.0000
0.0000
0.0000
0.0005
0.0200
0.0223
0.4821
0.4744
0.0002
0.0000
0.0002
0.0002
0.0001
0.0000
B-100 Ethylbenzene/Styrene Split

By Products
MW
Hydrogen
2.02
Nitrogen
28.01
Ethylene
28.05
Ethane
30.07
n-Hexane
86.18
Benzene
78.11
Toluene
92.14
Ethylbenzene
106.17
Styrene
104.15
cumene
120.19
n-p-benzene
120.19
1M3-EBenzene
120.19
-methylstyrene
118.18
m-DiEBenzene
134.22
n-Butyl-Benzene
134.22
Bp
-252.6
-195.8
-103.75
-88.6
68.73
80.09
110.65
136.2
145.16
152.41
159.24
161.33
165.5
181.14
183.3
K
8.72E+03
4.31E+03
3.11E+02
2.46E+02
1.18E+00
7.85E-01
2.70E-01
1.01E-01
6.86E-02
4.39E-02
8.49E-03
3.52E-02
2.70E-02
1.30E-02
9.95E-03
alpha
2.02
13.84
1.27
207.78
1.51
2.91
2.67
1.47
1.56
5.17
0.24
1.31
2.07
1.31
All taken from HYSYS

The closer to 1 the harder to separate
Vent Gas
Distillate
Distillate
T-300
Bottoms
Bottoms
T-303
BEB
7.79
TS
3.93
BT
2.91
TEB
2.67
TT
1.00
EBEB
1.00
EBT
0.37
SEB
0.68
zB
0.0200
zT
2.11E-03
zEB
0.4821
zS
0.49
zT
0.0223
zEB
0.50
FRA,dist
0.9999
FRA,dist
0.98
FRB,dist
0.9999
FRB,dist
0.98
Nmin
FRC,dist
19
0.9999
Nmin
FRC,dist
20
1.00
Mol fraction
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0021
0.5025
0.4945
0.0002
0.0000
0.0002
0.0002
0.0001
0.0000

Styrene/Cumene Split
By Products
MW
Hydrogen
2.02
Nitrogen
28.01
Ethylene
28.05
Ethane
30.07
n-Hexane
86.18
Benzene
78.11
Toluene
92.14
Ethylbenzene
106.17
Styrene
104.15
cumene
120.19
n-p-benzene
120.19
1M3-EBenzene
120.19
-methylstyrene
118.18
m-DiEBenzene
134.22
n-Butyl-Benzene
134.22
T-304
Bp
-252.6
-195.8
-103.75
-88.6
68.73
80.09
110.65
136.2
145.16
152.41
159.24
161.33
165.5
181.14
183.3
K
alpha
Mol fraction
8.72E+03
0.0000
4.31E+03
2.02
0.0000
3.11E+02
13.84
0.0000
2.46E+02
1.27
0.0000
1.18E+00
207.78
0.0000
7.85E-01
1.51
0.0000
2.70E-01
2.91
0.0000
1.01E-01
2.67
0.0001
6.86E-02
1.47
0.9982
4.39E-02
1.56
0.0005
8.49E-03
5.17
0.0000
3.52E-02
0.24
0.0005
2.70E-02
1.31
0.0005
1.30E-02
2.07
0.0002
9.95E-03 1.309709
0.0000
By Products
MW
Hydrogen
2.02
Nitrogen
28.01
Ethylene
28.05
Ethane
30.07
n-Hexane
86.18
Benzene
78.11
Toluene
92.14
Ethylbenzene
106.17
Styrene
104.15
cumene
120.19
n-p-benzene
120.19
1M3-EBenzene
120.19
-methylstyrene
118.18
m-DiEBenzene
134.22
n-Butyl-Benzene
134.22
Distillate
T-305
Bottoms
EBC
2.30
EBS
1.47
1.00
2.30
SS
EBS
1.47
CS
0.64
SS
1.00
zEB
0.000
CS
0.64
zC
0.001
zEB
0.000
zS
zC
0.001
FRA,dist
0.9993
1.00
FRB,dist
0.9993
FRA,dist
0.9993
Nmin
FRB,dist
0.9993
FRC,dist
Nmin
FRC,dist
32
1.00
K
alpha
8.72E+03
4.31E+03
2.02
3.11E+02
13.84
2.46E+02
1.27
1.18E+00
207.78
7.85E-01
1.51
2.70E-01
2.91
1.01E-01
2.67
6.86E-02
1.47
4.39E-02
1.56
8.49E-03
5.17
3.52E-02
0.24
2.70E-02
1.31
1.30E-02
2.07
9.95E-03 1.309709
Distillate
EBC
zS
Bp
-252.6
-195.8
-103.75
-88.6
68.73
80.09
110.65
136.2
145.16
152.41
159.24
161.33
165.5
181.14
183.3
1.00
32
1.00
Bottoms
Mol fraction
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9955
0.0010
0.0000
0.0013
0.0016
0.0007
0.0000

By Products
MW
Hydrogen
2.02
Nitrogen
28.01
Ethylene
28.05
Ethane
30.07
n-Hexane
86.18
Benzene
78.11
Toluene
92.14
Ethylbenzene
106.17
Styrene
104.15
cumene
120.19
n-p-benzene
120.19
1M3-EBenzene
120.19
-methylstyrene
118.18
m-DiEBenzene
134.22
n-Butyl-Benzene
134.22
Bp
-252.6
-195.8
-103.75
-88.6
68.73
80.09
110.65
136.2
145.16
152.41
159.24
161.33
165.5
181.14
183.3
K
alpha
Mol fraction
8.72E+03
0.0000
4.31E+03
2.02
0.0000
3.11E+02
13.84
0.0000
2.46E+02
1.27
0.0000
1.18E+00
207.78
0.0000
7.85E-01
1.51
0.0000
2.70E-01
2.91
0.0000
1.01E-01
2.67
0.0000
6.86E-02
1.47
0.9800
4.39E-02
1.56
0.0028
8.49E-03
5.17
0.0005
3.52E-02
0.24
0.0057
2.70E-02
1.31
0.0078
1.30E-02
2.07
0.0000
0.0099538 1.309709
0.0037
T-306
EBC
2.30
Distillate
EBS
1.47
Bottoms
SS
1.00
CS
0.64
zEB
0.000
zC
0.003
zS
0.98
FRA,dist
0.9983
FRB,dist
0.9983
Nmin
FRC,dist
28
1.00
C.4: Dimensioning of Packed Columns (1 of 2)

Values used in Calculation the Diameter of the Packed Column
At 100% Capacity
T-300
Molar Mass:
Liquid
Vapor
Molar Mass (kg/kgmole)
105.15
85.19
T-303
Molar Mass:
Liquid
Surface tension
dyne/cm
kg/s2
21.913
0.021913
Surface tension
dyne/cm
kg/s2
25.695
0.025695
0.30367 0.007325
3.04E-04 7.33E-06
Viscosity
cP
kg/m*s
0.41967 0.0063562
4.20E-04 6.3562E-06
Viscosity
cP
kg/m*s
Flows
kmol/h
kmol/s
104.18
Vapor
106.11
Flows
kmol/h
kmol/s
1199
0.3331
1222
0.3394
T-304
Molar Mass:
Liquid
Vapor
104.23
104.16
T-305
Molar Mass:
Liquid
104.51
Vapor
104.16
Surface tension
dyne/cm
kg/s2
Surface tension
dyne/cm
kg/s2
26.619
0.026619
0.46407
4.64E-04
0.0062951
6.30E-06
73.27
0.02035
287.4
0.07983
2421
0.6725
102.8
0.0286
26.67
0.02667
Viscosity
cP
kg/m*s
0.46345 0.006295
4.63E-04 6.30E-06
Viscosity
cP
kg/m*s
Flows
kmol/h
kmol/s
360.7
0.100194
Flows
kmol/h
kmol/s
838.3
0.23286
C.4: Dimensioning of Packed Columns (2 of 2)
T-306
Molar Mass:
Liquid
Vapor
119.68
104.16
Surface tension
dyne/cm
kg/s2
23.651
0.023651
Viscosity
cP
kg/m*s
0.47297 0.006295
4.73E-04 6.30E-06
Flows
kmol/h
kmol/s
1.634
0.000454
71.64
0.0199
C.5: Dimensioning a Packed Column

Taken from Fair, J. and Stichlmair, J. p. 457
Liquid Phase
Gas Phase
Molar Mass
kg
Ml := 105.15 kmol
Density
l := 818.17
kg
Mg := 85.19 kmol
kg
Surface Tension
:= 0.021913
kg
g := 0.82233
kg
2
kg
6 kg
g := 7.33 10
m s
m s
Liqflow := 0.6725 kmol
s
4
l := 3.04 10
Viscosity
kmol
s
Gasflow := 0.0286
Assumption of Operational gas flow rate:

0.5
Flow := 2.0 Pa
ug :=
Flow
(g0.5)
ug = 2.205
m
s
Vg := Gasflow
Mg
g
3
Vg = 2.963
m
s
Cross section Ac
Ac :=
Vg
ug
Ac = 1.343
0.5
Ac
Dc := 4
Dc = 1.308
C.6: Summary of All Columns in the Process

Separations Unit
Column Height (m) Column Diameter (m) Packing Height (m) Packing Diameter (m)
T-300
40.23
2.12
11.58
1.31
T-301
14.02
0.80
T-302
24.38
0.34
T-303
43.89
5.63
12.19
6.38
T-304
27.43
5.61
19.51
5.88
T-305
18.29
3.59
19.51
3.44
T-306
18.29
3.64
17.07
1.72
Alkylation Unit
Column Height (m) Column Diameter (m)
T-101
29.87
3.55
HETP assumed as 2 ft
C.7: Optimization Reflux Ratio (1 of 6)

The amount of EB recovered is not a specification in this optimization due to the degrees of freedom restriction on the distillation columns
Minimum Reflux From HYSYS Shortcut Calculation
Column 100
Column 100
Column 100
Pressure(kPa)
26.66
Condenser Temp (deg C)
86.23
Reboiler Temp (deg C)
97.09
Comp Recovery of Toluene
0.9999
Reflux Ratio
3
Total Trays w/o C & R
67
Tray Position
50
Composition of Exiting streams
Chemicals
Overhead exiting Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.0698
0.0000
n-Hexane
0.0022
0.0000
Ethyl Toluene(1M3-Ebenzene)
0.0000
0.0000
Toluene
0.1129
0.0000
Benzene
0.1118
0.0000
Ethyl Benzene
0.5757
0.3287
Hydrogen
0.0001
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0023
0.0000
Water
0.0000
0.0000
Ethylene
0.0046
0.0000
Styrene
0.1207
0.6640
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0023
n-P-Benzene
0.0000
0.0026
AMS
0.0000
0.0023
Pressure(kPa)
26.66
82.23
96.95
0.9999
Reflux Ratio
5
67
Tray Position
50
Chemicals
Methane
0.0000
0.0000
Ethane
0.0931
0.0000
n-Hexane
0.0030
0.0000
0.0000
0.0000
Toluene
0.1508
0.0000
Benzene
0.1492
0.0000
Ethyl Benzene
0.5909
0.3447
Hydrogen
0.0001
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0030
0.0000
Water
0.0000
0.0000
Ethylene
0.0061
0.0000
Styrene
0.0037
0.6486
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0021
n-P-Benzene
0.0000
0.0024
AMS
0.0000
0.0021
Pressure(kPa)
Reflux Ratio
Tray Position
26.66
73.20
96.48
0.9999
10
67
50
Chemicals
Overhead exiting
Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.1510
0.0000
n-Hexane
0.0049
0.0000
0.0000
0.0000
Toluene
0.2444
0.0000
Benzene
0.2419
0.0000
Ethyl Benzene
0.3429
0.3985
Hydrogen
0.0001
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0049
0.0000
Water
0.0000
0.0000
Ethylene
0.0099
0.0000
Styrene
0.0000
0.5954
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0022
AMS
0.0000
0.0019
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Vessel Parameters
Vessel
Diameter (m)
Height(m)
3
Volume(m )
Liq Vol. (%)
Level Calculator
Fraction Calculator
Vessel Delta P (kPa)
Fixed Vessel P Spec. (kPa)
Tray Section
Diameter (m)
Tray/Packed Space (m)
Tray/Packed Vol.(m3)
Hold up (m3)
6.36911E+07
1.04578E+08
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
Use levels and nozzles Use levels and nozzles
0.00
26.66
1.500
0.550
0.972
0.088
0.00
26.66
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
7.93204E+07
1.14809E+08
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
1.500
0.550
0.972
0.088
0.00
26.66
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
9.88086E+07
1.28452E+08
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
Use levels and nozzles
0.00
26.66
0.00
26.66
1.500
0.550
0.972
0.088
C.7: Optimization Reflux Ratio (2of 6)
Figure1C: Optimization of Reflux Ratio

Comp Recovery of Toluene =0.9999
Figure 1A: Optimization of Reflux Ratio

Comp Recovery of Toluene = 0.9999
Mole Fraction of Styrene in the overhead
1.2E+08
Condenser Duty (kJ/h)
1.0E+08
8.0E+07
6.0E+07
4.0E+07
2.0E+07
0.0E+00
3
10
0.1400
0.1200
0.1000
0.0800
0.0600
0.0400
0.0200
0.0000
15
Reflux Ratio
Figure 1B: Optimization of Reflux Ratio

10
12
14
16
Figure1D: Optimization of Reflux Ratio

0.6700
Mole Fraction of Styrene in the bottoms
1.6E+08
1.4E+08
Reboiler Duty (kJ/h)
8
Reflux Ratio
1.2E+08
1.0E+08
8.0E+07
6.0E+07
4.0E+07
2.0E+07
0.0E+00
3
10
Reflux Ratio
15
0.6600
0.6500
0.6400
0.6300
0.6200
0.6100
0.6000
0.5900
0.5800
0.5700
0
8
Reflux Ratio
10
12
14
16

The amount of toluene recovered is not a specification in this optimization due to the degrees of freedom restriction on the distillation columns
Minimum Reflux From HYSYS Shortcut Calculation
Column 100
Column 100
Column 100
Pressure(kPa)
26.66
43.59
95.48
Comp Recovery of Ethylbenzene
0.9999
Reflux Ratio
3
67
Tray Position
50
Chemicals
Methane
0.0000
0.0000
Ethane
0.2965
0.0000
n-Hexane
0.0095
0.0000
0.0000
0.0000
Toluene
0.1890
0.0186
Benzene
0.4750
0.0000
Ethyl Benzene
0.0007
0.4169
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0096
0.0000
Water
0.0000
0.0000
Ethylene
0.0195
0.0000
Styrene
0.0000
0.5587
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0018
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0018
Pressure(kPa)
26.66
49.96
96.02
0.9999
Reflux Ratio
5
67
Tray Position
50
Chemicals
Overhead exiting
Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.2472
0.0000
n-Hexane
0.0080
0.0000
0.0000
0.0000
Toluene
0.3238
0.0059
Benzene
0.3960
0.0000
Ethyl Benzene
0.0005
0.4223
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0080
0.0000
Water
0.0000
0.0000
Ethylene
0.0163
0.0000
Styrene
0.0000
0.5659
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0018
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0018
Pressure(kPa)
26.66
51.86
96.26
0.9999
Reflux Ratio
10
67
Tray Position
50
Chemicals
Overhead exiting
Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.2299
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3709
0.0001
Benzene
0.3684
0.0000
Ethyl Benzene
0.0005
0.4248
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5692
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Vessel Parameters
Vessel
Diameter (m)
Height(m)
3
Volume(m )
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
1.39669E+07
3.87203E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
1.500
0.550
0.972
0.088
0.00
26.66
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
2.79917E+07
5.37519E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
1.500
0.550
0.972
0.088
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
6.01163E+07
8.63321E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
1.500
0.550
0.972
0.088
Column 100
Optimal Reflux

Comp Recovery of Toluene = 0.9999
4.00E+07
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
2.50E+08
2.00E+08
1.50E+08
1.00E+08
5.00E+07
0.00E+00
0.00E+00
3
10
15
10
12
Reflux Ratio
15
20
30
40
50
Reflux Ratio
Figure 2C: Optimization of Reflux Ratio

Comp Recovery of EB =0.9999
Figure 2B: Optimization of Reflux Ratio

Comp Recovery of EB =0.9999
0.0000
60
50
40
30
20
10
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
3
1.500
0.550
0.972
0.088
6.00E+07
2.00E+07
7.21977E+07
9.84124E+07
Reboiler
1.193
1.789
2.000
50.000
8.00E+07
Mole Fraction of Styrene in the overhead
Vessel Parameters
Vessel
Diameter (m)
Height(m)
3
Volume(m )
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
3.00E+08
1.00E+08
Reboiler Duty (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
3.50E+08
1.20E+08
Pressure(kPa)
26.66
51.90
96.27
0.9999
Reflux Ratio
12
67
Tray Position
50
Chemicals
Overhead exiting
Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.2298
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3715
0.0000
Benzene
0.3681
0.0000
Ethyl Benzene
0.0005
0.4248
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5693
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019

Comp Recovery of EB = 0.9999
10
12
15
Reflux Ratio
20
30
40
50
10
20
30
Reflux Ratio
40
50
60

General Trends:
Reflux Ratio Solved by HYSYS
As the number of columns decreases the duty on the condenser and reboiler increases
As the number of columns decreases the mol fraction of ethyl benzene exiting in the distillate increases
As the number of columns decreases the purity of styrene increases because of the amount of ethyl benzene exiting in the distillate,
but there is a point where you start getting less purity of styrene.
Column 100
Column 100
Pressure(kPa)
Reflux Ratio
Tray Position
26.66
51.88
96.27
0.9999
12
67
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Vessel Parameters
Vessel
Diameter (m)
Height(m)
3
Volume(m )
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
Pressure(kPa)
Reflux Ratio
50

Chemicals
Overhead exiting
Methane
0.0000
Ethane
0.2298
n-Hexane
0.0074
0.0000
Toluene
0.3715
Benzene
0.3681
Ethyl Benzene
0.0005
Hydrogen
0.0002
Oxygen
0.0000
Nitrogen
0.0075
Water
0.0000
Ethylene
0.0151
Styrene
0.0000
n-B-Benzene
0.0000
Cumene
0.0000
n-P-Benzene
0.0000
AMS
0.0000
Tray Position
Bottoms Exiting
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.4248
0.0000
0.0000
0.0000
0.0000
0.0000
0.5693
0.0000
0.0019
0.0021
0.0019
7.21977E+07
9.84124E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
1.500
0.550
0.972
0.088
Column 100
26.66
51.88
96.27
0.9999
12
66
Pressure(kPa)
Reflux Ratio
50
Tray Position
26.66
51.88
96.26
0.9999
12
65
50

Chemicals
Methane
0.0000
0.0000
Ethane
0.2298
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3714
0.0000
Benzene
0.3682
0.0000
Ethyl Benzene
0.0005
0.4248
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5693
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019

Chemicals
Overhead exiting
Bottoms Exiting
Methane
0.0000
0.0000
Ethane
0.2298
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3712
0.0001
Benzene
0.3682
0.0000
Ethyl Benzene
0.0005
0.4248
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5693
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
7.21863E+07
9.84041E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
Use levels and nozzlesUse levels and nozzles
0.00
26.66
1.500
0.550
0.972
0.088
0.00
26.66
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
Tray Section
Diameter (m)
Hold up (m3)
7.21704E+07
9.83869E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
1.500
0.550
0.972
0.088

OPTIMAL STAGE FROM SHORT-CUT DIST. IN HYSYS
Column 100
Column 100
Column 100
Pressure(kPa)
26.66
51.88
96.27
0.9999
Reflux Ratio
12
66
Tray Position
50
Chemicals
Overhead exiting
Methane
0.0000
Ethane
0.2298
n-Hexane
0.0074
0.0000
Toluene
0.3714
Benzene
0.3682
Ethyl Benzene
0.0005
Hydrogen
0.0002
Oxygen
0.0000
Nitrogen
0.0075
Water
0.0000
Ethylene
0.0151
Styrene
0.0000
n-B-Benzene
0.0000
Cumene
0.0000
n-P-Benzene
0.0000
AMS
0.0000
Pressure(kPa)
26.66
51.90
96.27
Comp Recovery of Ethylbenzene 0.9999
Reflux Ratio
12
66
Tray Position
10
Chemicals
Methane
0.0000
0.0000
Ethane
0.2297
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3717
0.0000
Benzene
0.3679
0.0000
Ethyl Benzene
0.0005
0.4249
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5693
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019
Pressure(kPa)
26.66
51.90
96.27
0.9999
Reflux Ratio
12
66
Tray Position
20
Chemicals
Methane
0.0000
0.0000
Ethane
0.2297
0.0000
n-Hexane
0.0074
0.0000
0.0000
0.0000
Toluene
0.3717
0.0000
Benzene
0.3680
0.0000
Ethyl Benzene
0.0005
0.4249
Hydrogen
0.0002
0.0000
Oxygen
0.0000
0.0000
Nitrogen
0.0075
0.0000
Water
0.0000
0.0000
Ethylene
0.0151
0.0000
Styrene
0.0000
0.5693
n-B-Benzene
0.0000
0.0000
Cumene
0.0000
0.0019
n-P-Benzene
0.0000
0.0021
AMS
0.0000
0.0019
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Heating Duties
Condenser (kJ/h)
Reboiler (kJ/h)
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
7.21863E+07
9.84041E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
0.00
26.66
Tray Section
Diameter (m)
Hold up (m3)
Bottoms Exiting
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.4248
0.0000
0.0000
0.0000
0.0000
0.0000
0.5693
0.0000
0.0019
0.0021
0.0019
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
7.22308E+07
9.84525E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
Use levels and nozzlesUse levels and nozzles
0.00
26.66
Tray Section
1.500
0.550
0.972
0.088
Diameter (m)
Hold up (m3)
0.00
26.66
Vessel Parameters
Vessel
Diameter (m)
Height(m)
Volume(m3)
Liq Vol. (%)
Level Calculator
Fraction Calculator
7.22285E+07
9.84495E+07
Reboiler
1.193
1.789
2.000
50.000
Condenser
1.193
1.789
2.000
50.000
Horizontal cylinder
Horizontal cylinder
0.00
26.66
Tray Section
1.500
0.550
0.972
0.088
Diameter (m)
Hold up (m3)
1.500
0.550
0.972
0.088
0.00
26.66
Appendix D: Compressor Optimization
D.1: Compressor Optimization Analysis

Compressors
1
2
3
4
5
6
7
K-401
Total Cost/Year
$ 135,211,913.38
$ 46,301,845.84
$ 36,120,548.92
$ 34,700,489.93
$ 34,117,414.99
$ 34,019,360.00
$ 34,056,600.61
K-402
Compressors Total Cost/Year
1
$ 83,109,284.25
2
$ 36,885,784.77
3
$ 31,026,285.60
4
$ 30,567,660.67
5
$ 30,323,544.51
6
$ 30,344,373.78
7
$ 30,474,470.36
Compressors
1
2
3
4
5
6
7
K-403
Total Cost/Year
$ 16,723,672.81
$ 13,259,425.74
$ 12,954,054.50
$ 12,974,991.53
$ 13,112,584.04
$ 13,270,201.88
$ 13,343,714.61
Compressors
1
2
3
4
5
6
7
K-404
Total Cost/Year
$ 14,393,491.14
$ 11,988,687.07
$ 11,738,395.62
$ 11,816,536.09
$ 11,976,656.42
$ 12,141,798.15
$ 12,181,480.61
K-405
1
$ 11,799,344.63
2
$ 10,330,926.05
3
$ 10,156,880.73
4
$ 10,263,640.47
5
$ 10,423,114.77
6
$ 10,534,134.01
7
$ 10,598,345.00
Compressors
1
2
3
4
5
6
7
K-406
Total Cost/Year
$ 11,552,286.13
$ 10,271,294.13
$ 10,070,266.22
$ 10,211,462.87
$ 10,394,355.66
$ 10,482,010.82
$ 10,562,234.00
Compressors
1
2
3
4
5
6
7
K-407
Total Cost/Year
$ 9,993,175.16
$ 9,272,843.40
$ 9,079,644.47
$ 9,266,368.96
$ 9,465,635.45
$ 9,515,501.58
$ 9,613,541.49
K-408
1
$ 9,442,799.04
2
$ 9,054,784.68
3
$ 8,820,671.40
4
$ 9,072,796.99
5
$ 9,210,912.53
6
$ 9,321,584.03
7
$ 9,418,821.32
Compressors
1
2
3
4
5
6
7
K-409
Total Cost/Year
$ 8,645,010.91
$ 8,584,023.83
$ 8,343,378.82
$ 8,654,569.23
$ 8,748,205.56
$ 8,897,823.72
$ 8,968,179.58
Compressors
1
2
3
4
K-410
Total Cost/Year
$
442,471.46
$
453,857.44
$
454,264.96
$
471,742.91
K-400
1
$ 3,085,513.74
2
$ 3,284,760.49
3
$ 3,424,930.82
4
$ 3,742,178.44
Compressors
1
2
3
4
5
K-200
Total Cost/Year
$ 11,254,434.85
$ 10,294,761.84
$ 10,194,445.14
$ 10,546,200.01
$ 10,949,864.13
K-201
1
$
928,140.44
2
$
960,210.75
3
$
968,565.58
K-202
1
$ 4,124,658.09
2
$ 4,081,197.03
3
$ 4,144,069.67
4
$ 4,328,521.09
5
$ 4,486,006.45
K-300
1
$ 1,749,431.52
2
$ 3,673,363.34
D.2: K-404 Optimization Analysis

$15,000,000.00
$14,500,000.00
Cost Annually
$14,000,000.00
$13,500,000.00
$13,000,000.00
$12,500,000.00
$12,000,000.00
$11,500,000.00
1
4
# Compressors
D.3: Compressor Hand Calculation Example

Assume polytropic behavior that approaches adiabatic (Perry's page 10-37)
p
T2 = T1 2
p1
( k 1) / k
(10-67)
3 mol
M := 13841 10
hr
T2 := ( 273.15 + 122.03)K
3
p 2 := 263.38 10 Pa
G := 5.8282 10
5 kg
hr
T1 := ( 273.15 + 86.93)K
3
p 1 := 135.78 10 Pa
M W :=
G
M
R c := 8.314
k := 1.1204
( k 1)
k
k R c T1 p 2
Had :=

1
k1
p 1
(10-64a)
Had = 4.882 10 Sv
(10-65a)
Pad := G Had
6
Pad = 7.904 10 W
J 1
mol K M W
Appendix E: Heat Exchanger Design
E.1: Example Pressure Drop Calculation (1 of 2)

Tube Side Pressure Estimation of E-1000
From "Plant Design and Economics for Chemical Engineers" Pg. 667
Tube Diameter:
Mass Flow:
Visocity (At Bulk and Wall):
kg
Di := .15 m
M t := 519200
:= .00956 poise
hr
Number of Tubes:
w := .01241 poise
NP := 200
Temp. In and Out:
Cp at Bulk Temp.:
C p := 1.542 1000
Tin := ( 28.2 + 273.15) K
Tout := ( 47.5 + 273.15) K
kg C
Totherin := ( 60 + 273.15) K
Length:
Constants:
Length := 6 m
Density:
:= 2.224
n p := 2
kg
Kc := 0.3
S := 0.5
kg m
kconstant := 0.000163
4
s A
m
Equations:
Ac := Di
G :=
k := ( 1 S) + Kc +
Taverage :=
0.5 n p 1
np
Tin + Tout
2
T1 := Totherin Taverage
0.14
Mt
Ac NP
Di G
Re :=
Pr :=
Di
P = 80.234 Pa
kconstant
.2
f := 0.046 Re
0.28

0.51 k n p T1

B := 1 +
2
:= 1.02
2 B f G2 Length n
p
P :=
Cp
(Tout Tin) Pr
E.1: Example Pressure Drop Calculation (2 of 2)

Shell Side Pressure Drop Estimation E-100 Coolant
From "Plant Design and Economics for Chemical Engineers" Pg. 706-707
Known:
M t := 1435000
:= 1465
kg
:= .41330 poise
hr
kg
w := .4251 poise
Ds := 2.5 m
Pd := 0.1 m
Lb := 3 m
Ls := 6 m
Pt := 0.2 m
f := 0.025
t b := 0.1 m
Do := 0.1 m
Equations:
Sm :=
De :=
Re :=
Ds Pd Lb
Mt
Gs :=
Sm
Pt
4 0.86 Pt 0.25 Do
Do
De Gs
4 f G 2 D ( 1 + N )
s s
b
P :=
0.14

2 De
w
P = 5.542 Pa
Ls
Nb :=
1
Lb + t b
E.2: Styrene Tank Heat Exchanger Size

Twin := 283.15K
Two := 293.15K
Tsin := ( 273.15 + 23.88889)K
Tso := ( 273.15 + 18.3333 )K
Tair := ( 273.15 + 37.77778)K

W
h air := 20
h s := 1000
m K
ksteel := 45
m K
W m
2
m K
xsteel := 0.075m
Air and Styrene
1
Utank :=
1
h air
xsteel
ksteel
h := 36m
D := 20m
A := D h +
kg
Utank = 18.987
3
s K
1
hs
3 2
A = 2.576 10 m
T := Tair Tsin
T = 13.889 K
q := Utank A T
q = 6.794 10 W
Water and Styrene

Tlm :=
( Tsin Two ) ( Tso Twin)

( Tsin Two )
ln
( Tso Twin)
Uhe := 425
Tlm = 5.832 K
W
2
m K
A :=
q
Uhe Tlm
A = 274.11 m
Appendix F: Reactor Sizing
F.1: Dehydrogenation Reactor Size

GHSV := 225 hr
Time := 8000 hr
Molar_Flow := 19158000
mole
hr
Vol_Flow :=
Molar_Flow
48.281
mole
3
m
Vol :=
Vol_Flow
GHSV
3
Vol = 1.764 10 m
Numreactors := 4
Vol reactor :=
Vol
Numreactors
3
Vol reactor = 440.891 m
Vol_Flow = 110.223
m
s
Appendix G: Economic Optimization
G.1: Investment Summary

Styrene Monomer Production Process
TOTAL
Direct Costs
Purchased Equipment Costs:
Delivery Costs:
Installation Costs:
Instrumentation & Controls:
Piping:
Electrical Systems:
Buildings:
Yard Improvements:
Service Facilities:
Total Direct Costs:
$384.6
$38.5
$198.8
$152.3
$287.7
$46.5
$76.2
$42.3
$296.1
$1,523.0
Total Direct Costs:
$1,523.0
Total Indirect Costs:
$609.2
Indirect Costs
Engineering and Supervision:
Construction Expenses:
Legal Expenses:
Contractor's Fee:
Contingency:
Total Indirect Costs:
$139.6
$173.5
$16.9
$93.1
$186.1
$609.2
$2,132.2
FIXED CAPITAL INVESTMENT
Working Capital
Working Capital:
Total Working Capital:
TOTAL CAPITAL INVESTMENT
$376.5
$376.5
$2,508.7
G.2: Economic Summary (1 of 5)

Raw Material, Product, & Utility Summary
Raw Material
Ethane
Benzene
Air
Dehydrogenation Catalyst
Alkylation Catalyst
Transalkylation Catalyst
TBC (Inhibitor)
DNP (Inhibitor)
Total
Product
Styrene
Toluene
Total
Utility
Electricity
Refrigeration (to -50C)
Steam, Saturated
3550 kPa (243.38C)
150 kPa (109.95C)
Water Treatment
Cooling Water (15C)
Total
Price
($/kg)
0.34
0.83
0.45
115.00
105.00
40.00
63.80
260.00
Annual Amount
(million kg/yr)
317.07
704.93
9.43
0.24
0.02
0.01
0.02
0.02
Annual Cost of Raw Material

(million $)
108.1
581.8
4.2
27.8
1.7
0.3
1.4
6.2
731.5
Price
($/kg)
2.17
0.76
Annual Amount
(million kg/yr)
898.11
34.01
Annual Value of Product

(million $)
1950.3
25.9
1976.2
Price
Annual Amount
7.54 /kWh
14 $/GJ
1.16E+09
5.68E+06
Annual Cost of Utility

(million $)
87.7
79.5
8 $/1000kg
2 $/1000kg
36 $/1000kg
8 /m3
1.51E+06
3.88E+05
3.05E+05
8.51E+07
12.1
0.8
11.0
6.8
197.8

Purchased Equipment Cost Summary
Current Chemical Engineering Index (for 2006) = 493

Projected Chemical Engineering Index for 2007 = 519
Equipment Type
REACTOR VESSELS
DISTILLATION VESSELS
TRAY COSTS
HEAT EXCHANGERS
COMPRESSORS
PUMPS
TURBINES
STORAGE TANKS
TOTAL
Equipment Cost
(2007 MM$)
6.447
14.690
2.411
94.289
189.822
0.115
69.590
9.644
387.008

Variable Cost Summary
Styrene Production Process
Per lb Styrene
TOTAL
Raw Materials
Benzene
Ethane
Air
Dehydogenation Catalyst
Alkylation Catalyst
Transalkyation Catalyst
TBC (Inhibitor)
DNP (Inhibitor)
Total Raw Materials:
$0.294 per lb of Styrene

$581.8
$108.1
$4.2
$27.8
$1.7
$0.3
$1.4
$6.2
$731.5
$731.5

$12.1
$0.8
$6.8
$79.5
$87.7
$11.0
$197.8
$197.8

$2.7
$0.4
$131.4
$19.7
$0.4
$154.6
$154.6
$1,084.0
$1,084.0
Utilties
High Pressure Steam
Low Pressure Steam
Cooling Water
Refrigeration
Electricity
Waste Treatment
Total Utilities:
General Expenses
Operating Labor
Operating Supervision
Maintainance/Repairs
Operating Supplies
Laboratory Charges
Total Byproducts:
TOTAL

Fixed Cost Summary
TOTAL
Fixed Charges
Property Taxes
Insurance
Total Fixed Charges:
$43.8
$21.9
$65.7
$65.7
Total Plant Overhead:
$80.7
$80.7
$80.7
$26.9
$69.1
$55.3
Total General Expense: $151.3
$151.3
Plant Overhead
General Plant Overhead
General Expense
Administration
Distribution/Selling
Research & Development
TOTAL
$297.7

Cash Flow Summary
Year
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
Percentage
of Design
Capacity
Sales
Capital Costs
0.0%
Construction
-$319.8
0.0%
Construction
-$746.3
0.0%
Construction
-$1,066.1
45.0%
$988.1
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
90.0%
$1,976.2
**All numbers are in millions of dollars
Working Capital Variable Costs
Fixed Costs
Depreciation
Allowance
(MACRES)
Taxable Income
Income Tax
Costs
Net Earnings
-$376.5
$376.5
-$542.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$1,084.0
-$148.8
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-$297.7
-426.4
-682.3
-409.4
-245.2
-245.2
-123.7
$0.0
$0.0
$185.2
$349.3
$349.3
$470.9
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$594.6
$0.0
$0.0
-$64.8
-$122.3
-$122.3
-$164.8
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
-$208.1
$297.3
$594.6
$529.7
$472.3
$472.3
$429.7
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
Cumulative Net
Annual Cash
Present Value at
Flow
15.0%
-$319.8
-$746.3
-$1,442.6
$297.3
$594.6
$529.7
$472.3
$472.3
$429.7
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$386.5
$763.0
-$319.8
-$968.8
-$2,059.6
-$1,864.1
-$1,524.2
-$1,260.8
-$1,056.6
-$879.1
-$738.6
-$628.7
-$533.2
-$450.2
-$377.9
-$315.1
-$260.5
-$213.0
-$171.7
-$135.8
-$104.6
-$77.4
-$53.8
-$33.3
$2.0
G.3: Profitability Measures

**All numbers are in millions of dollars
The Investor's Rate of Return (IRR) for this Project is:
15.0%
The Net Present Value (NPV) at 15% for this Project is:
$1.99
ROI Analysis (Seventh Production Year)

Annual Sales:
Annual Costs:
Depreciation:
Income Tax:
Net Earnings:
Total Capital Investment:
ROI:
$1,976.2
-$1,381.7
$0.0
-$208.1
$386.5
$2,508.7
15.40%
G.4: IRR Analysis - Product Price Fluctuation

Product Prices
Product Prices ($/lb)
$0.75
$0.80
$0.85
$0.90
$0.95
$0.99
$1.05
$1.10
$1.15
$1.20
$1.25
$1.30
$1.35
Product Prices ($/kg)
$1.65
$1.76
$1.87
$1.98
$2.09
$2.17
$2.31
$2.43
$2.54
$2.65
$2.76
$2.87
$2.98
IRR
-0.8%
3.6%
7.2%
10.4%
13.2%
15.0%
18.2%
20.4%
22.4%
24.2%
26.1%
27.8%
29.5%
IRR Analysis - Product Price Fluctuation

35.0%
30.0%
25.0%
IRR
20.0%
15.0%
10.0%
5.0%
0.0%
$0.70
-5.0%
$0.80
$0.90
$1.00
$1.10
$1.20
Styrene Monomer Product Price ($/lb)
$1.30
$1.40

017 FinalReport PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

017 FinalReport PDF

Uploaded by

Copyright:

Available Formats

Senior Design Final Report

Professor J.A. Sykes

Abstract: A new process to produce styrene monomer is under development by Dow

THE CHEMISTRY .................................................................................................. 4

PROCESS DESCRIPTION ..................................................................................... 9

ENVIRONMENTAL, HEALTH AND SAFETY ISSUES.................................. 25

ENVIRONMENTAL CONCERNS ............................................................................ 25

CONTROL DESIGN .............................................................................................. 28

CONTROL DESIGN ON AREA 100........................................................................ 28

ECONOMIC ANALYSIS ...................................................................................... 32

UNCERTAINTIES AND ASSUMPTIONS.......................................................... 34

FUTURE WORK .................................................................................................... 34

Other byproducts in the dehydrogenation form from byproducts in the alkylation.

Butylcatechol, or 4-TBC, is used in a concentration of 15 ppm. The tank is held

4.1 Design Alternatives

4.1.1 Styrene from Ethylene and Benzene

4.1.2 Co-Production of Styrene and Propylene Oxide

4.2 Area 100 Alkylation

4.2.1 Equipment Design

4.2.2 Catalyst Design

4.3 Area 200 Dehydrogenation

4.3.1 Equipment Design

4.3.2 Catalyst Design

Figure 1: Weight of Catalyst vs. Ethane and Ethylbenzene Volumetric Ratio

4.4 Area 300 Separations of Aromatic Products

4.4.1 Separations Train and Column Design

Column T-302 separates benzene from non-aromatic C6 hydrocarbons in 40 sieve

4.4.2 Separations Inhibitors

The inhibitor which retards the polymerization process is 2,4-dinitrophenol. It is

4.5 Area 400 Light Gas Separation

4.6 Heat Exchanger Design

4.7 Pump, Compressor and Turbine Design

4.8 Materials of Construction

5 Environmental, Health and Safety Issues

5.1 Environmental Concerns

5.2 Chemical Hazards

The precursor to styrene, ethylbenzene, is also dangerous. It should never be inhaled

5.3 Safety Hazards

6.1 Control Design on Area 100

6.2 Control Design on Area 200

temperature is vital because it causes the combustion in T-201 to occur, which

6.3 Control Design on Area 300

6.4 Control Design on Area 400

Figure 2: IRR Analysis Product Price Fluctuation

8 Uncertainties and Assumptions

Appendix Table of Contents

Appendix A: Equipment Spec. Sheets

A.1: Compressor Specifications (1 of 41)

A.1: Compressor Specifications (2 of 41)

A.1: Compressor Specifications (3 of 41)

A.1: Compressor Specifications (4 of 41)

Vapor Composition (mol%)

Inlet Temperature (C)

A.1: Compressor Specifications (5 of 41)

Vapor Composition (mol%)

Inlet Temperature (C)

A.1: Compressor Specifications (6 of 41)

Vapor Composition (mol%)

Inlet Temperature (C)

A.1: Compressor Specifications (7 of 41)

A.1: Compressor Specifications (8 of 41)

Vapor Composition (mol%)

Inlet Temperature (C)